FCCU I Operating Manual Compressed

PLANT OPERATING MANUAL
Chapter No: 1 Plant No. 04

Plant Name: FCCU-I
Rev. No. 1 Rev. Date : 15.03.2018 Page 1 of 752
ADMINISTRATIVE REQUIREMENTS
SECTION - A
PREFACE
The principal objective of the operating manual is to describe relevant operating procedures,
instructions and process safety information in an orderly manner for use by operating personnel for
safe and efficient operation of the plant.
FCCU-I R was commissioned in August 2000 after capacity augmentation of FCCU-I to 0.95 MMTPA
under VREP-II. The process licensor for the plant was M/s Exxon Research and Engineering. RR
downstream facilities were designed by M/s EIL. The flexi cracking process design provides flexibility
to provide variety of feeds at different modes of operation. Gas Concentration Section of the unit was
de-bottlenecked during 2012 and the unit design capacity is increased to 1.2 MMTPA.
The present edition of the operating manual of FCCU-I is the revised version of earlier operating
manual prepared in March 2012. The operating procedures are updated basis the inputs available in
the Process Design Package, Equipment Vendor Manuals, Process Safety Information received from
other concerned departments, Plant Standing Instructions (PSI) issued and the past operating
experiences. However, detailed operating and maintenance instructions were issued by the licensor
and equipment vendors are available separately. These may be referred as and when required.
Primary purpose of this revised operating manual is to consolidate, improve and upgrade all the
operating procedures fulfilling the requirements of Process Safety Management (PSM) standard.
HPCL Visakh Refinery adopted OSHA (Occupational Safety & Health Administration) PSM Standard
29-CFR-1910.119 (PSM for highly hazardous chemicals) in 2013 and released the “PSM Procedure
for preparation of Operating Procedures” (PSM-PR-4) in the refinery. The present version of the
FCCU-I Plant operating manual is prepared as per PSM-PR-4 (rev.1) and PSM audit observations in
order to make the Operating Manual OSHA PSM Standard compliant.
Operating procedures & conditions given in this manual are indicative and general guide for routine
start-up and operation of the unit. Efforts have been made to include the relevant information in a
concise, step-by-step, easy-to-read format so that they are within the comprehension of the readers.
The users of this manual are encouraged to read the operating manual and provide suggestions for
further improvements of the manual.
FCCU-1 Operating Manual CHAPTER-1 Page 1 of 752

Plant Name: FCCU-I
SECTION - B
TABLE OF CONTENTS
CHAPTER PAGE
TITLE REMARKS
NO. NO.
Administrative Requirements of the Manual
• Section A : Preface
• Section B : Table of Contents
• Section C: Records of revision, validation and Plant
1 1
Standing Instructions.
• Section D : Document control & List of Copy Holders
• Section E : Procedure for revision of the Manual
• Section F : List of Abbreviations
2 Introduction 13
3 Design Operating Conditions 17
4 Feed and Product Characteristics 27
5 Process Principle and Process Chemistry 63
6 Process Description and Configuration 69
7 List of Plant Equipment 129
8 Description of critical control schemes 159
9 Description of Distributed Control System (DCS) 185
10 Description of Advanced Process control 197
11 Refractory Dry-out & Commissioning 205
12 Initial Start-up Procedure 227
Start-up Procedure after Short shutdown or, emergency
13 235
shutdown.
14 Start-up Procedure after T&I shutdown 239
15 Normal Operation of the Plant 267
16 Operating Limits & Consequences of Deviations 275
17 Major Equipment Operating procedure 285

Plant Name: FCCU-I
CHAPTER PAGE
TITLE REMARKS
NO. NO.
18 Process troubleshooting and Upset 377
19 Emergency Handling Procedures and Shutdowns 399
20 Normal Shutdown Procedures 415
21 Temporary Operations 429
Process Safety Information
List of PSI documents
22 Details of PSI documents 437
a. Information on Plant Holdups-(PSM-FR-2.5)
b. Information of Plant Relief System-(PSM-FR-2.7)
23 Sampling requirement and Sampling Procedures 447

Plant Chemicals and Catalysts
a. Withdrawal management
b. Max Storage allowable in the Plant
c. Storage precautions
24 d. Loading procedures 453
e. Empty container disposal
f. Handling Precautions
g. Chemical Spillage Handling
h. Description of Chemical dosing system.
Occupational Safety & Health
a. Chemical Hazards
b. Special or Unique Hazards
25 469
c. First aid Procedures
d. PPE requirements, type and Usage.
e. Fire Fighting System & equipment
26 Plant Drainage System Description 535
Environmental Management
a. Effluent Generation and Control
27 547
b. Plant Emissions
c. Solid Waste

Plant Name: FCCU-I
CHAPTER PAGE
TITLE REMARKS
NO. NO.
Safe Work Practices
a. Work Permit Procedures.
28 b. Confined Space Entry Procedure 555
c. SWP for Plant access/Entry control
d. Procedure for Opening Process equipment and Piping
Unit Blind’s Lists
29 a. Unit Master Blinds list 603
b. Individual Equipment blind list
30 Special and Unique Hazards 615
31 Chemical/HC Spillage Handling Procedure 621
32 Instrumentation Tag List 625
33 Utilities 705
List of Annexures :
a) Check lists for Plant Start-up & Shutdown
b) List of Vendor manuals
34 c) CO Boiler 725

Plant Name: FCCU-I
SECTION - C
RECORDS OF REVISION, VALIDATION AND PLANT STANDING INSTRUCTIONS
The Operating Procedures and Practices w.r.to unit start up, normal operation, non-routine operations,
normal shutdown and emergency shutdown are periodically reviewed for improvements based on
experiences, new requirements and better understanding of the process. Accordingly, operating manuals
are validated every year and revised once in 5 years.
The yearly validation and revision details of the manual are as below:
The present edition of unit operating manual is reviewed and validated for the current operation of
the plant as indicated in the Table-1 below.
A record of Plant Standing Instructions (PSI) issued in the intervening period is listed in Table-2.
The PSIs issued since last revision till the date of next revision (after 5 years) of the operating manual
is reviewed for its applicability in the current operation during yearly validation and the same is
indicated during validation. During revision of the manual after 5 years, all the applicable PSIs are
properly integrated in the revised manual.
Table-1: Records of Revision & Validation
Rev. Validation Validation Validated By Designation Sign Remarks

No. No. Date (Name)
1 15.03.18 B Ravi DGM-O Revised for FGD, Chiller,
GCU Debottlenecking
Table-2: Records of Plant Standing Instructions (PSIs) issued
Sl. PSI Ref. No. Title of Issued on Validity Remarks Comments by

PSI (Date) (Till date) (signature, date, name)
Note: The PSI is available in “Standing Instructions File” at Unit Field Room and office of Div. Head

Plant Name: FCCU-I
SECTION - D
DOCUMENT CONTROL
• The administrative sections (Chapter 1 of PSM/GL/4.1) are approved by Division Head-
Operations.
• The original operating manual in file and tab format is maintained with the Division Head.
• Hard Bound copies with stamping & numbering, “Controlled Copy No. …. ” are made and
issued as below for usage. Controlled Copy means that Div. Head will monitor it for its status,
requirement of revision, ensures its applicability and accessibility.
Sl. Identification no. Issued to Issued on (date)

0 Original Kept with Div. Head – Opns
(Production Block)
1 Controlled Copy No. 1 Plant Field Room
2 Controlled Copy No. 2 Plant DCS Panel
3 Controlled Copy No. 3 Section Head – Operations
(FCCU-II)
4 Controlled Copy No. 4 Office of HOD - Operations
• Uncontrolled hard copies with stamping, “Reference copy” are made and issued as below:
a) Plant Personnel: by issuing on returnable basis from a set of Manuals (like Library)
maintained by Section Head.
b) Office of RSM
c) Disaster Control Room (formerly “Central Control Centre”)
d) Refinery Engg. Documentation
e) Tech. Dept.
• In case of any doubt regarding the latest revision, the Original Copy is the reference document
for confirmation.
• After the revised version is made and new “Controlled Copies” and “Training Copies” are
issued, the obsolete copies are destroyed.

Plant Name: FCCU-I
SECTION - E
PROCEDURE FOR REVISION OF THE OPERATING MANUAL
1. This Operating Manual is revised for the following:
Change in Operating practice in any part of the Plant.

Implementation of changes in Hardware and/or software systems of the Plant which
have impact on procedure.
Change in Chemicals.
Changes in Safety systems.
2. The revision of the Operating Manual is done in two stages :
Managing changes (revisions) in the Operating Manual within 5 year cycle.

Validating Operating Manual annually.
3. The revisions are issued as “Plant Standing Instructions”. The list of Plant Standing Instructions
is maintained in Section-C of Chapter 1-Administrative Requirements of the Manual”.
4. The Plant Standing Instructions are backward integrated into the Operating Manual once in 5
years.
5. The chapters which get revised at the time of revising operating manual, the Revision number
of the Chapter which is revised is increased by “1”.

Plant Name: FCCU-I
SECTION - F
ABBREVIATIONS
ABBREVIATION EXPANSION
AAG Amine Acid Gas
APC Advanced Process Control
API American Petroleum Institute
APS Atmospheric Pipe Still
ASTM American Society for Testing and Materials
ATF Aviation Turbine Fuel
ATP Additional Tank age Project
BARC Bhabha Atomic Research Centre
BA Breathing Apparatus
BCW Bearing Cooling Water
BFW Boiler Feed Water
BTU British Thermal Unit
CAS Chemical Abstracts Service
CBD Closed Blow Down
CPP Captive Power Plant
CRN Cracked Run Naphtha
DCP Dry Chemical Powder
DOB Daily Order Book
DMP De-Mineralization Plant
DRN Disposal Requirement Notice
DCN Design Change Note
EPM Environmental Procedures Manual
ESA External Safety Audit
EHS Environment Health Safety
ETP Effluent Treatment Plant
ELCB Earth Leakage Circuit Breaker

Plant Name: FCCU-I
EMS Environmental Management System
EDMS Engineering Document Management System
E&P Economics & Planning
FCCU Fluid Catalytic Cracking Unit
HLPH High Lift Pump House
HSD High Speed Diesel
IA Instrument air
ISA Internal Safety Audit
IWL Inspection Work List
IFO Internal Fuel Oil
KOD Knock Out Drum
LLPH Low Lift Pump House
LSHS Low Sulfur Heavy Stock
MOC Management of Change
MSIHC Rules Manufacture, Storage, Import of Hazardous Chemical Rules
MSB Motor Spirit Block.
MSDS Material Safety Data Sheet
MEROX Mercaptan Oxidation
MES Mechanical Engineering Services
MS Motor Spirit
NDT Non-Destructive Test
NRV Non return Valve
OISD Oil Industry Safety Directorate
OCP Operational Control Procedure
OSTT Off Shore Tanker Terminal
PCOLT Plant Connected Offsite Lines Testing
PDI Plant Daily Instructions
P&ID Piping & Instrumentation Diagram
PFD Process Flow Diagram
PLC Programmable Logic Control

Plant Name: FCCU-I
PPM Parts Per Million
PSI Process Safety Information / Plant Standing Instruction
PS&E Process Safety & Environment
PSV Pressure Safety Valve
PHA Process Hazard Analysis
PAD Process Analysis & Design
PPE Personnel Protective Equipment
PMS Project Management System
PSM Process Safety Management
PA Public Announcement
PSSR Pre- Start Up Safety Review
PESO Petroleum & Explosives Safety Organization
PIR Project Initiation Request
QRA Quantitative Risk Analysis
RCA Root Cause Analysis
RCW Recirculating Cooling Water
RCR Ramsbottom Carbon Residue
ROV Remote Operated Valve
RED Refinery Engineering Documentation
RSM Refinery Shift Manager
STEL Short Term Exposure Limit
SSA Surprise Safety Audit
SRU Sulfur Recovery Unit
SWP Safe Work Practice
SMPV Static & Mobile Pressure Vessels
SKO Superior Kerosene Oil
SAC Strong Acidic Cations
SBA Strong Basic Anions
SRN Straight Run Naphtha
SR Short Residue

Plant Name: FCCU-I
T&I Turnaround & Inspection
TLV Threshold Lower Value
TSV Thermal Safety Valve
TC Turnaround Cycle
TOB Turnover Book
TBP True Boiling Point
UEL Upper Explosive Limit
VRCFP Visakh Refinery Clean Fuels Project
VGO Vacuum Gas Oil
VBU Visbreaker Unit
VREP Visakh Refinery Expansion Project
VD Vacuum Diesel

Plant Name: FCCU-I

Plant Name: FCCU-I
INTRODUCTION
CHAPTER-2
INTRODUCTION
Over the past 50 years, Fluid Catalytic Cracking has developed into a major upgrading process
in the oil refining industry. It converts vacuum gas oils into more valuable products ranging
from light olefins to naphtha and middle distillates. The FCCU occupies a very important place
in a refinery because of its low cost conversion of heavy oils to lighter more valuable products.
The attractiveness of the FCC process is because of its flexibility in converting a variety of
feed stocks and its favorable economics of operation.
2.1 DEVELOPMENT OF THE PROCESS
Cracking is a phenomenon by which large oil molecules are cracked into small lower boiling
molecules. The stable molecules leave the system as cracked gasoline and reactive ones
polymerize forming fuel oil and even coke. Although primary objective in development of
the cracking process had been to get more of gasoline, all other oils having boiling ranges
intermediate between fuel oil and gasoline are also produced.
The originally developed process of cracking was “Thermal cracking”. Use of catalyst for
cracking was first investigated by HOUNDRY in 1927. The first catalytic cracker built in
1936 in the USA by Houndry had fixed bed of catalyst pellets made from natural treated clays.
The process was batch wise, and a series of reactors were employed. The advantage of a
continuous process led to the development of the idea of “moving bed” of catalyst. The
“Thermofor” and “Houndry-flow” catalytic cracking processes followed, where in the pelleted
catalyst was continuously withdrawn from the reactor by means of a mechanical conveyor or
“gas pressure” carried to the regenerator and brought back to the reactor, by similar means after
burning off the coke.
Heat liberated in the regenerator from the coke burn-off was gainfully utilized in heating and
cracking the oil feed in the reactor, however, the mechanical means employed put limit on the
amount of catalyst that could be circulated limiting the process.

INTRODUCTION
Plant Name: FCCU-I
INTRODUCTION
2.2 FLUIDISED CATALYTIC CRACKING
A more radical development was made by shell. Standard Oil (N.J. And Indiana), Kellogg,
Texas Co and UOP in the early 1940’s devised a plant in which catalyst was used in the form
of finely divided powder. This type of catalyst can be fluidized and all the properties of a Fluid
can be attributed to it. The development of the fluid catalytic cracking unit has permitted much
higher rates of catalyst circulation, and thereby the use of heavier feed stocks of lower value.
2.2.1 ADVANTAGES OF FCC:
From the Operating point of view:
1) Heat evolved in the regeneration of the catalyst is efficiently used.

2) Reaction temperature is well controlled.
3) Catalyst regeneration temperature is well controlled.
The catalyst available today is strong and retains its activity on a high scale. The reactions are
usually uniform over a long period of time, and the product quality does not change with the
lengthy use of catalyst.
The reason for the wide use of catalytic cracking is the greater yield of high octane gasoline.
The yield is better than with any other thermal operation. Also, the gas produced consists
mainly of the preferred propane and Butane hydrocarbons with less methane and ethane. The
formation of heavier oils and tars is minimized. The gasoline and the uncracked cycle Oil are
more saturated than those encountered in other thermal process because of high aromatics
concentration.
2.3 FUNCTION OF THE PLANT
The Fluidized Catalytic Cracking Unit catalytically cracks the vacuum Gas oil (side streams)
of VDU to various high priced hydrocarbons. In this process, catalyst is used in the form of
very small spherical particles which behave as a fluid when aerated with vapor. The fluidized
catalyst is continuously circulated between reactor and regenerator
FCCU consists of three sections – Catalyst section, Fractionation section & Gas concentration
Unit which operate together in an integrated manner. The cracking section consisting of reactor
and regenerator together with J bends and close coupled riser form catalyst circulation circuit.

INTRODUCTION
Plant Name: FCCU-I
INTRODUCTION
Feed contacts with hot fluidized catalyst from regenerator and gets cracked in the riser. The
cracked products in the vapors phase go to fractionator through the reactor vapors line. Coke
is deposited on the circulating catalyst in the reaction zone. This coke is burnt off in regenerator
using air from Air blower.
In the fractionation section, the reactor vapors are fractionated into the products clarified oil,
Heavy cycle oil, Light cycle oil, unstabilized gasoline and wet gas. Unstabilized Gasoline and
Wet Gas after compression are sent to gas concentration unit for further separation.
In Gas concentration section Gasoline, LPG and Fuel gas are separated. Gasoline and LPG are
sent to Merox for further treatment. Fuel gas from GCU joins refinery fuel gas system.
Clarified oil/HCO is used as fuel oil component. Gasoline produced in FCCU is having high
octane number. LCO is used as HSD/LDO component.
FGD section treates the flue gas coming out from Regenerator/CO Boiler for removal of SO2
and SPM.

INTRODUCTION
Plant Name: FCCU-I
INTRODUCTION

INTRODUCTION
Plant Name: FCCU-I
DESIGM OPERATING CONDITIONS
CHAPTER - 3
BASIS OF DESIGN
DESIGN OPERATING CONDITIONS
3.1 REACTOR-REGENERATOR DESIGN OPERATING CONDITIONS
3.2 FRACTIONATOR AND GCU DESIGN OPERATING CONDITIONS

Plant Name: FCCU-I
3.1 REACTOR-REGENERATOR SECTION
TABLE 3.1
Case IN 5N 1D
132.5 Sm3/hr 165.5Sm3/hr 132.5Sm3/hr

Arab Mix Arab Mix Arab Mix
Operation Max Naphtha Max Naphtha Max Distillate
VGO feed Rate, Sm3/hr 132.5 165.6 132.5
Residue Rate. Sm3/hr 0.0 0.0 0.0
HCO Recycle Rate Sm3/hr 0.0 0.0 58.3
Bottoms Recycle, Sm3/hr 0.0 0.0 5.3
Total feed rate, Sm3/hr 132.5 165.6 196.1
Total feed Specific gravity 0.9273 0.9273 0.9289
221 0C- conversion, WT%FF 68.2 61.6 51.9

204 0C- conversion, WT%FF 68.5 61.6 50.4
Reactor Operating Conditions

Reactor Temperature, 0C 529 529 493
Reactor Pressure, kg/cm2 (g) (1) 1.27 1.27 1.27
Catalyst Circulation Rate, Me
Tons/min 14.0 13.9 10.2
Cat/Oil Ratio. Kg/kg on Total
Feed 6.8 5.4 3.4
Total Feed Preheat Temperature,
0
C 327 392 382
Feed Injection Steam, kg/hr (4) 2449 1860 1361
Stripping Steam kg/hr 3175 3175 3175
Fluffing Steam, kg/hr 680 680 680
Catalyst Type GracdXP-80LX, Engelhard Precision 70x of equivalent
Catalyst MAT Activity (2) 75 75 67

Plant Name: FCCU-I
1N 5N 1D
Regenerator Operating Conditions

Regen Dense Bed temperature.0C 677 680 680
Regenerator Pressure, kg/cm2 (g) (5) 1.12 1.12 1.12
Wet Air Rate, kNm3/hr 56.3 56.3 49.8
Moisture in Air, Vol % (6) 4.0 4.0 4.0
Wet flue gas rate, kNm3/hr 60.1 59.8 52.6
Dry flue gas rate, kNm3/hr 52.4 52.2 46.1
Flue Gas Composition (Vol %), dry basis

CO2 14.63 15.30 15.95
CO 4.00 3.00 2.00
O2 0.01 0.01 0.01
SO2 (3) 0.45 0.57 0.55
Notes:
(1) Reactor dilute phase pressure is that used for process basis development. The actual
reactor operating pressure determined during design is 1.34kg/cm2 (g). The difference has
no significant effect on other operating conditions or yields.
(2) Catalyst MAT activity is on a Grace Europe basis- activities vary between vendor
measurements.
(3) Maximum expected concentration
(4) Feed injection steam rare required to maintain approximately 2.8 kg/cm2 (g) feed nozzle
pressure drop For Case 1 N. Nozzle pressure drop for other cases will be higher.
(5) Regenerator dilute phase pressure
(6) Yearly average
(7) 221o C- conversion = 380C -2210 C+ liquids (wt% FF)
(8) 204 o C- conversion =380C- 2040 C+ liquids (LV% FF)
UNIT DESIGN
Based on the study carried out and yield data furnished by ERE(Exxon Research Engineering)
for various feed cases, the following cases were selected by HPCL for design of the
fractionation and gas concentrations section.

Plant Name: FCCU-I
CASE FEED TYPE OPERATING MODE REMARKS

ID AM Feed Diesel Max Design Case
2D BH Feed Diesel Max Design Case
IN AM Feed Naphtha Max Check Case
DESIGN BASIS:
While the design of Reactor- Regenerator section is for the 16 cases enumerated in the Design
basis specifications (DBS) of ER &E. The Fractionator /GCU section shall be designed for the
following cases of DBS.
A) 20 KBSD Arab mix VGO in max. Distillate mode (Case ID)

B) 20 KBSD Bombay high VGO in max distillate mode (Case 2D) with 20% over design
Margin.
The operation with 20 KBSD Arab Mix VGO in max. Naphtha mode (Case IN) shall be a check
case for sizing equipment
No of stream hours per year: 8000

Turn down (%of max capacity): 60%
Number of trains: One
3.2 FRACTIONATOR & GCU SECTION DESIGN OPERATING CONDITIONS.
HCO Slurry Total feed to Combined feed

Fresh Feed
Case Recycle Recycle Reactor To Fresh Feed
(kg/hr)
(kg/ hr) (kg/hr) (kg/hr) Ratio (Wt)
ID 123900 50030 9516 183446 1.48
2D 118600 40412 9040 168052 1.42
IN 124300 0 7316 131616 1.06

Plant Name: FCCU-I
HEATER
Feed Flow Normal ABS Inlet Outlet

Inlet/Outlet
Rate Duty* Temp. Temp.
Press.(kg/cm2g)
(kg/hr) (MMKCAL/HR) (0C) (0C)
ID 173930 6.6 332 385 17.8/9.8
2D 19012 13.8 307 423 17.8/9.8
IN 124300 6.4 248 326 17.8/9.8
*The duty & inlet. Temperature values reported above are for the cold feed cases, (i.e. feed
temperature at unit battery limit = 700C)
PUMP AROUND
Total Duty Total Flow Draw-Off Return

PA Name Case
(MMKCAL/HR) Rate (kg/hr) Temp.(0C) Temp.(0C)
LCO PA ID (-)4.0 116069 240 180
2D (-)6.0 167450 228 168
IN (-)3.0 95043 222 162
HCO PA ID (-)6.0 155691 321 260
2D (-)5.5 134760 320 260
IN (-)6.5 193105 307 247
Slurry PA ID (-)16.9 283286 360 270
2D (-)13.9 234192 360 270
IN (-)10.5 202166 365 275

Plant Name: FCCU-I
NORMAL OPERATING PARAMETERS
MEASURING
ITEM UNIT VALUE
INSTRUMENT
ID 2D
Main Column
0
Top temperature TE/TI-2004. C 138 132
TE/TIC-2003
Top pressure PT/PI-2001 Kg/cm2g 0.69 0.69
0
Bottom temperature TE/TI-2019. C 360 360
TE/TIC-2013
Draw off temp
0
LCO TE/TIC-2015 C 240 228
TI-2014
0
HCO TE/TI-2016 C 321 320
TI-2008
OVERHEAD TRIM CONDENSER
0
Outlet temperature TE/TI-2403 C 40 40
TI-2404
WET GAS COMPRESSOR
Suction pressure PT/PIC-2629 Kg/cm2g 0.1(min) 0.1(min)
Discharge pressure PT-PI-2608 Kg/cm2g 15 15
PRIMARY ABSORBER
0
Top temperature TE/TI-2818 C 45 44
0
Bottom temperature TE/TI-2812 C 51.5 50.4
Bottom pressure PI-2803 Kg/cm2g 14.6 14.6
STRIPPER COLUMN
0
Top pressure PT/TI-2808 Kg/cm2g 15.0 15.0
0
Bottom temperature TE/TI-2810 C 140 145
DEBUTANISER COLUMN
0
0
Plant Name: FCCU-I
MEASURING
ITEM UNIT VALUE
INSTRUMENT
SPONGE ABSORBER
0
0
COMPRESSOR:
Note: The flow rates and other properties reported above are for the fresh gas Feed to the
compressor without any recycle.
ID 2D IN
Flow Rate(kg/hr)
1st Stage 21391 23562 33500
2nd Stage 10547 8952 15840
Avg. MOL Wt.
1st Stage 40.2-42.8 44.0-46.6 42.9-43.4
2nd Stage 31.64 32.65 34.0
Suction Pressure(kg/cm2a)
1st Stage
1.05/1.1/1.6 1.05/1.1/1.6 1.05/1.1/1.6
(Min./ Nor./Max.)
2nd Stage
-/4.5/5.0 -/4.5/5.0 -/4.5/5.0
(Min./ Nor./Max.)
Suction Temperature(0C)
1st Stage
38/40/45 38/40/45 38/40/45
(Min./ Nor./ Max.)
2nd Stage 38/40/45
38/40/45 38/40/45
(Min./ Nor./Max.)

Plant Name: FCCU-I
FGD-I:
The design of the EDV® system is based on 3 sets of FCCU operating conditions( Rate of
Regen Flue gas):
Cases
Units Maximum Normal Minimum
o
Temperature C 200 200 200
Pressure mmH2O 300 max 300 max 300 max
Flue gas flow Kg/hr 132050 110042 66025
Flue Gas Composition Kg/hr
H20 9,556 7,963 4,778
C02 27,285 22,738 13,643
N2 91,997 76,665 45,999
02 2,160 1,800 1,080
SO2 1,002 835 501
SO3 0 0 0
Catalyst fines Kg/hr 49.9 41.6 25
Particulate size
0-1 microns 3 3 3
0-3 microns 10 10 10
0-10 microns 50 50 50
FGD Stack Emissions:
The EDV® system is provided to meet the following the air emission standard specified below,
i.e.:
Catalyst fines removal: 90% minimum
SO2 removal: 90% minimum
SO3 removal: 40-70%

Plant Name: FCCU-I
PTU Effluent:
The combined purge treatment unit is designed for the following liquid and solid effluent
discharge standards:
pH: between 6 and 8.5
Total suspended solids: less than 15 mg/liter
COD from sulfites (as O2): less than 100 mg/liter
Temperature/pressure:
The equipment will be designed to withstand the following continuous conditions:

Items Temperature Pressure
o
EDV® Vessels 200 C 1250 mmWC (0.125kg/cm2)
Tanks 100oC Hydrostatic pressure
o
Stack 200 C ASTM STS-1
Site Conditions:
Wind velocity: 150 km/hour maximum Snow loads: 0

Seismic classification: Zone II for Visakh Region per India Standard 1893
Electrical classification: Class 1, Group D, Division 2
Elevation: 4.82 m MSL
Ambient temperature: 45EC maximum, 15EC minimum
Caustic Consumption: 5.4 m³/hr (20° Be NaOH Solution) for scrubber area and 2.5 m³/hr (20°
Be NaOH Solution) for PTU area.
Makeup water Consumption: 24.1 m³/hr
Emergency Water Requirement: 120 m³ for 1 hour in case of FCC upset and 83.35 m3 for ½
hour in case of over temperature condition.

Plant Name: FCCU-I
Chiller Plant:

Plant Name: FCCU-I
FEED AND PRODUCT CHARACTRISTIC
CHAPTER 4
FEED AND PRODUCT CHARACTERSTICS
FCCU I takes Hot VGO as feed from CDU’s. Sometimes this feed can be taken along with
slop cut depending up on the unit limitations. Cold VGO is taken from either Tank 01Ex
or 01FX depending on the process regulations. As a measure of energy conservation hot
feed from CDU’s is to be maximized depending on the unit conditions.
4.1 FEED CHARACTERESTICS
CHARATERISTIC VGO ARAN MIX(I) VGO BOMBAY HIGH(2)

Gravity, API21.1 29
Specific gravity 0.9273 0.8816
Sulfur wt% 2.76 0.3
Nitrogen, wppm 695 345
Conradson carbon wt% 1.5 0.4
Refractive Index at 67 1.4994 -
Aniline point 81 102
Nickel wppm 0.2 0.04
Vanadium, wppm 0.2 0.06
Distillation 15/5 15/5

IBP 343 271
5% 353 327
10% 363 327
20% 383 393
30% 404 416
40% 426 431
50% 448 443
60% 471 457
70% 494 473
80% 517 497
90% 541 536
FEED AND PRODUCT CHARACTERISTIC
Plant Name: FCCU-I
95% 553 559

FBP 566 566
(1) Feed is 50/50 volumetric blend of Arab Light/Arab Heavy crudes
4.2 Product Characteristics
Design criteria:
The following gaps/overlaps are considered in the main fractionator design.
Naphtha and LCO : +15 0C
LCO and HCO : +10 0C
HCO and Slurry : 0 0C
LPG
C5 content shall not be more than 2 vol%. A 95%recovery of C3 +components is aimed at but
it shall not be less than 91%.
CR Naphtha
RVP of cracked naphtha from stabilizer shall be 7 psi (max.)
Cycle Oil (LCO)

The flash point shall be 660C min.
Clarified Oil (CLO)

The max. Catalyst content shall be 0.2 wt. % and the flash point shall be 660C min.
B) Product Quality
FUEL GAS FROM SPONGE ABSORBER
ID 2D IN
Rate(Kg/hr) 2997 2531 4800
Mol. Weight (Avg.) 16.7 17.0 16.7

Plant Name: FCCU-I
Composition (Wt %) ID 2D
H2O 0.5425 0.5147
H2 4.2247 3.5753
H2 S 6.0048 0.6603
C1 23.9207 29.9684
Ethylene 19.3457 23.5119
C2 19.4548 16.6048
Propylene 4.1406 2.9757
C3 0.5265 0.3231
1-Butylene 0.0208 0.0125
2-Butylene 0.0164 0.0137
iC4 0.0113 0.0102
nC4 0.0033 0.0021
N2 16.0305 16.4737
CO 1.3337 0.7849
CO2 3.6015 4.1203
COS 0.0011 0.0005
NH3 0.6954 0.2907
HCN 0 0
Propadiene 0.0001 0
Phenol 0.0001 0.0001
1.3 – Butadiene 0.0001 0
C5+ 0.1255 0.157
STABILISED NAPHTHA
ID 2D IN
Rate (Kg/hr) 42260 55373 54113
0
Sp. Gravity@15 C 0.760 0.7422 0.758
RVP (Max) (Psi) 7 7 7
ASTM D-86 (Vol%) TEMPERATURE(0c)
5% 63.0 57.7 56.8
10% 72.1 62.4 60.9
30% 94.8 84.5 84.5
Plant Name: FCCU-I
50% 113.8 101.8 102.9

70% 135.6 123.6 126.6
90% 170.1 163.0 165.6
95% 184.0 171.3 174.2
\
LIGHT CYCLE OIL (LCO)
ID 2D IN
Rate(Kg/hr) 52035 37981 27710
Sp. Gravity@ 0.921 0.872 0.952
Flash Point(min)0c 66 66 66
0
ASTM D-86 (Vol %) TEMPERATURE( C)
5% 239.6 237.2 228.0
10% 253.9 249.1 241.0
30% 288.7 272.4 265.6
50% 322.8 300.0 285.6
70% 374.7 327.8 312.3
90% 368.5 347.8 340.7
95% 378.9 353.9 352.0
Heavy cycle oil (HCO)
ID 2D IN
Rate(Kg/hr) - - 6504
Sp. Gravity @ 150C - - 1.045
0
AST, D -86 (Vol %) TEMPERATURE( C)
5% 344.6
10% 361.1
30% 382.4
50% 391.7
70% 404.4
90% 429.5
95% 439.3
NOTE: HCO is not withdrawn as a product for cases 1D & 2D

Plant Name: FCCU-I
Clarified oil (CLO)
ID 2D IN
Rate (kg/hr) 9614 5961 7316
Sp. Gravity @ 150C 0.957 0.96 1.088
Catalyst content
0.2 0.2 0.2
(Max) (%wt)
ASTM D -86(Vol %) TEMPERATURE (0C)
5% 354.5 356.5 373.2
10% 371.9 372.8 395.3
30% 396.5 396.8 417.7
50% 419.4 416.0 435.9
70% 449.4 439.9 463.1
90% 510.4 503.7 530.7
95% 539.7 529.4 562.0

Plant Name: FCCU-I
LPG
Components in Mole%
H2O 0.0047
H2S 7.92
Ethylene 0.0206
Ethane 1.05
Propylene 30.2
Propane 9.24
I-Butane 8.1
Trans 2-Butane 23.07
iC4 14.03
nC4 4.703
CO2 0.0106
COS 0.006
NH3 0.034
HCN 0.07
Propadiene 0.0343
CH4S 0.0652
ETSH 0.002
Phenol 0.0014
1-3 Butadiene 0.44
Others 0.9982
Total 100
Mol wt. 49
FEED AND PRODUCT BATTERRY LIMIT CONDITION
FEED
Pressure
Temp.0C Source
FEED Kg/cm2a
120(min.)
VGO (Hot) 4.0 VDU’S
165 (max.)
70 (min.)
VGO (Cold) 4.0 Storage
90 (max.)

Plant Name: FCCU-I
PRODUCTS
Product- Pressure Kg/cm2 a Temperature 0C Destination

Fuel Gas 6.1 40-50 SRU/FG System
LPG 19.0 40. Amine Treating Unit
CR Naphtha 13.0 38 Merox Treating Unit
LCO 5.0 40 HSD Storage
HCO 13.0 60. FO Storage
Clarified Oil 13.0 60 FO Storage
Sour Water 4.0 Max 38-40 SWSU
Slop 5.5 Slop Tanks
4.2 UTILITY SPECIFICATION
HP STEAM
Mech.
Min Nor Max
Characteristics Design
Press. Kg/cm2a 34.0 36.0 39.0 41.0
Temperature (oC) 340 360 380 400
Silica as SiO2 PPM 0.0 0.01
Total Solids ppm <1.0
M.P STEAM
Characteristics Min. Nor. Max. Mech. Design

Press/ Kg/cm2a 10.0 11.0 12.0 13.5
Temp. 0C Satd. 250 280 300
L.P STEAM

Press, Kg/cm2a 3.5 4.0 5.0 6.5
Temp.0C Satd. 150 170 190

Plant Name: FCCU-I
INSTRUMENT AIR

Press. Kg/cm2a 5.0 6.0 7.0 9.5
Temp.0C 30 40 45 65
Dew Point oC (-) 40OC at atmospheric pressure
Oil Content ppm Nil
PLANT AIR

Press. Kg/cm2a 4.0 5.0 6.0 9.5
Temp.0C 30 40 45 65
Dew Point oC Not free moisture
Oil Content ppm Nil
RAW SERVICE WATER
Characteristic Unit Normal Value

Turbidity ppm 15
M. Alkalinity as CaCO3 ppm 180
Ca Hardness as CaCO3 ppm 200
Total Hardness as
ppm 400
CaCO3
Silica as SIO2 ppm 50 (max)
Chlorides as cl ppm 212
Sulfates, as SO4 ppm 96
Iron as Fe ppm 0.25
TDS as CaCO3 ppm 700
Total Suspended Solids ppm 23
pH [H+]CONC 7.0-9.0
Conductivity at 250C Micro Mho/cm 500
Pressure Kg/cm2a 3.5(Mech. Design;7.0)
o
Temp C 32 (Mech. Design;65)
Plant Name: FCCU-I
Cooling Sea Water:
Type Circulating Sea Water

Supply Pressure, Kg/cm2a 5.6 (upstream of sea water booster pump)
Return Pressure, Kg/ cm2a 3.6
Supply temperature.0C 33
Return temperature, 0C 44
Mech. Design Pressure (Kg/ cm2a) 8.6/11.0*
Mech. Design temperature.0C 65
*Downstream of the sea water booster pump.
DM Water
Turbidity ppm nil

Hardness as CaCO3 ppm nil
Silica as SIO2 ppm 0.05
Chlorides as Nacl ppm nil
Iron as Fe ppm nil
Conductivity at 200C micro/cm 1.0 max
pH 6.5-8.0.
Pressure at grade kg/cm2a 3.0
0
Operating temperature C 30
Mechanical design pressure kg/cm2a 7.0
0
Mechanical design temperature C 65
BFW
Pressure, (kg/cm2a) Temperature, (0c)
MP BFW 16 (Operating) 30 (Mechanical) 120 (Operating) 155 (Mechanical)
HP BFW 56 (Normal) 72 (Design) 120 (Normal) 155 (Design)

Plant Name: FCCU-I
CONDENSATE
a) MP Condensate
Characteristic Min. Nor Max Mech. Design

Pressure Kg/cm2a 11.0 - 11.5 13.5
Temp.0C 220 - 280 300
%vapor - Saturated
Conductivity
- 1 max.
Micro mho/cm
b) LP Condensate
Characteristic Min. Nor Max Mech. Design

2
Pressure kg/cm a - - 4.5 6.5
Temp.0c Saturated - 147 170
%vapor - Satd.
Oil Content ppm - 1.5
Conductivity
- 1 max.
Micro mho/com

Plant Name: FCCU-I
4.3 FUELS SPECIFICATION
4.3.1 FUEL OIL
Min. Nor Max Mech. Design
Pressure kg/cm2a 8.0 9.0 10.0 18.0
Temp.0C (as reqd.to meet 25 CSt) 110 130 200 200

FO LSHS
0
Specific Gravity@ 15/15 c 0.959 0.9756
Viscosity CSt @ 820C 100 39.4
@1000C 45 23.6
Sulphur content (wt %) 4.5 0.7(max)

Sodium Content ppm 35 2.0
Vanadium content ppm 90 6.0
Water Content ppm -
Nickel content - -
Ash content wt% - 0.1 -
Sediment ppm - 0.25(max)
Flash Point @ 820C >93 >93
Pour Point0C +30 +51
Heating Value Kcal/kg

Gross
10,200 10.200
Net
9,480 9.480
H/C Ratio(by wt) 0.13 0.128

Plant Name: FCCU-I
4.3.2 FUEL GAS
Min, Nor Max Mech. Design

Pressure kg/cm 2a 3.5 4.0 4.5 7.0
Temp.0C 30 40-50 60 70
Sweet Gas Sour Gas
28.55 29.69
Molecular weight
Composition(% mole)
H2S 0.0091 6.4
CO2 1.282 3.4
H2 16.704 15.38
CI 13.7 12.76
C2 11.89 11.15
C2” 6.42 6.6
C3” 7.62 8.44
C3 15.64 14.3
C4” 0.272 0.27
nC4 5.33 4.91
iC4 3.26 2.95
C5 0.27 0.25
N2 13.4 12.1
H2O 3.2 0
Heating value Kcal/kg
Gross 11300
Net 10050

Plant Name: FCCU-I
4.3 Description of feed properties
Characterizing an FCC feedstock involves determining both its chemical and physical
properties. To have a qualitative measurement of the feed'
s composition, it’s required to carry
out these physical property tests on a routine basis.
The most widely used properties are:
°API Gravity
Distillation
Aniline Point
Refractive Index (RI)
Bromine Number (BN) and Bromine Index (BI)
Viscosity
Conradson, Ramsbottom, Micro carbon, and Heptane Insoluble.
°API Gravity
The °API gravity measures the density of a hydrocarbon liquid. Specific gravity (SG) is another
common measurement of density. The liquid SG is the relative weight of a volume of sample
to the weight of the same volume of water at 15.5°C.
Since °API gravity is inversely proportional to specific gravity, the higher the °API gravity,
the lighter the liquid sample. In petroleum refining, °API gravity is routinely measured for
every feed and product stream.
The °API gravity is always reported at 60°F (15.5°C). Daily monitoring of °API gravity
provides the operator with a tool to predict changes in unit operation. For the same distillation
range, the 26°API feed cracks more easily than the 24°API feed because the 26°API feed has
more long-chain paraffinic molecules.
Long straight-chain paraffins are important to the economics of an FCC unit. They crack easily
to gasoline and LPG, with minimal production of slurry and fuel gas.

Plant Name: FCCU-I
Distillation
Boiling point distillation data also provides information about the quality and composition of
a feed. Distillation indicates molecular weight and carbon number. It indicates whether the feed
contains any "clean" products that could be sold "as is." The feed to the FCCU is a blend of
gas oils from operating units as the crude and vacuum columns, In recent years, the trend has
been toward heavier gas oils and residue. Residue is most commonly defined as the fraction of
feed that boils above 1,050°F (565°C). Each FCC feed stream has different distillation
characteristics.
The fractional distillation test conducted in the laboratory involves measuring the temperature
of the distilled vapor at the initial boiling point (IBP), as volume percent fractions 5, 10, 20,
30, 40, 50, 60, 70, 80, 90, and 95 are collected, and at the end point (EP). Three ASTM methods
are currently used to measure boiling points: D-86, D-1160, and D-2887. D-86 is the most
common method used in refineries. The distillation is done at atmospheric pressure. It is used
for samples with an EP less than 750°F (400°C).
Distillation data provides information about the light fraction of feed boiling at less than 650°F
(343°C). Light virgin feed, the fraction that boils under 650°F (343°C), often results in a greater
LCO yield and lower unit conversion. Sources of these fractions come from atmospheric gas
oil, light vacuum gas oil, and light coker gas oil. Lower conversion of light virgin feed is caused
by:
Lower molecular weight means the oil is more difficult to crack,
Light coker stocks are very aromatic.
Light aromatics have fewer crackable side chains.
Economics and unit configuration dictate whether to include 650°F material in the FCC feed.
As a general rule, this fraction should be minimized. Minor improvements in the operation of
the upstream distillation columns can substantially reduce the amount of light gas oil in the
FCC feed. However, including light gas oil in FCC feed reduces the amount of coke laid on
the catalyst. Less coke means a lower regenerator temperature. Light gas oil can be used as a
"quench" to decrease the regenerator temperature and to increase the catalyst to-oil ratio. The
distillation also provides information about the fractions that boil over 900°F (482°C). These
fractions provide an indication of the coke-making tendency of a given feed. Associated with
this 900°F+ fraction is a higher level of contaminants such as metals and nitrogen.

Plant Name: FCCU-I
Typical Distillation of Feed VGO
CHARATERISTIC VGO ARAN MIX(I) VGO BOMBAY HIGH(2)

Distillation 15/5 15/5
IBP 343 271

5% 353 327
10% 363 327
20% 383 393
30% 404 416
40% 426 431
50% 448 443
60% 471 457
70% 494 473
80% 517 497
90% 541 536
95% 553 559
FBP 566 566
Aniline Point
Aniline is an aromatic amine (C6H5NH2). When used as a solvent, it is selective to aromatic

molecules at low temperatures, and paraffins and Naphthenes at higher temperature. Aniline is
used to determine aromaticity of oil products, including FCC feed stocks. Aniline point (AP)
is the minimum temperature for complete solubility of an oil sample in aniline. ASTM D-611
involves heating a 50/50 mixture of the feed sample and aniline until there is only one phase.
The mixture is then cooled and the temperature at which the mixture becomes suddenly cloudy
is the aniline point.
The test senses solubility via a light source that penetrates through the sample. The aniline
point increases with paraffinicity and decreases with aromaticity. It also increases with
molecular weight. Naphthenes and olefins show values that lie between those for paraffins and
aromatics. Typically, an aniline point higher than 200°F (93°C) indicates paraffinicity and an
aniline point lower than 150°F (65°C) indicates aromaticity.

Plant Name: FCCU-I
Refractive Index
Similar to aniline point, refractive index (RI) shows how refractive or aromatic a sample is.
The higher the RI, the more the aromatics and the less crackable is the sample. A feed having
an RI of 1.5105 is more difficult to crack than a feed with an RI of 1.4990.
Bromine Number and Bromine Index
Bromine number (ASTM D-1159) and bromine index (ASTM D-2710) are qualitative methods
to measure the reactive sites of a sample. Bromine reacts not only with olefin bonds, but also
with basic nitrogen molecules and with some aromatic sulfur derivatives. Nevertheless, olefins
are the most common reactive sites and the bromine number used to indicate olefinicity of the
feed. The bromine number is the number of grams of bromine that will react with 100 grams
of the sample. Typical bromine numbers are:
Less than 5 for hydro treated feeds
10 for heavy vacuum gas oil
50 for coker gas oil
A general rule-of-thumb is that the olefin fraction of the sample is one-half of its bromine
number. Alternatively, the bromine index is the number of milligrams of bromine that will
react with 100 grams of the sample, and is most often used by the chemical industry for stocks
that have very low olefin contents.
Viscosity
Viscosity indicates the chemical composition of an oil sample. As the viscosity of a sample
increases, paraffins increase, hydrogen content increases, and the aromatic fraction decreases.
Viscosity is normally measured at two different temperatures: typically 100°F (38°C) and
210°F (99°C). Say bolt viscosity (ASTM D-88) is the most popular method of measuring the
viscosity of oils such as FCC feed. This method covers two procedures:
Say bolt Universal Viscometer (SUV) for light oils
Say bolt Furol Viscometer (SFV) for heavy oils
Conradson, Rams bottom, Micro carbon, and Heptane Insolubles
One area of cat cracking not fully understood is the proper determination of carbon residue of
the feed and how it affects the unit'
s coke make. Carbon residue is defined as the carbonaceous
residue formed after thermal destruction of a sample. Cat crackers are generally limited in coke

Plant Name: FCCU-I
burn capacity, therefore, the inclusion of residue in the feed produces more coke and forces a
reduction in FCC throughput.
Conventional gas oil feeds generally have a carbon residue less than 0.5 wt%; for feeds
containing resids, the number can be as high as 15 wt%. Four popular tests are presently used
to measure carbon residue or concarbon of FCC feedstocks:
Conradson
Ramsbottom
Micro-method
Heptane insolubles
The object is to indicate the relative coke forming tendency of feedstocks. Each test has
advantages and disadvantages, but none of them provide a rigorous definition of carbon residue
or asphaltenes. The Conradson test (ASTM D-189) measures carbon residue by evaporative
and destructive distillation.
4.4 Feed impurities
Today' s FCC feed stocks are generally heavier and contains higher levels of impurities like
nitrogen, sulfur, and metals. These impurities have negative effects on unit performance.
Understanding the nature and effects of these contaminants is essential in feed and catalyst
selection as well as troubleshooting the unit. Most of the impurities in the FCC feed exists as
components of large organic molecules. The most common contaminants are:
Nitrogen
Sulfur
Nickel
Vanadium
Sodium
Except for sulfur, all these contaminants poison the FCC catalyst, causing it to lose its ability
to produce valuable products. Sulfur in the feed increases operating costs because additional
feed and product treatment facilities are required to meet product specifications and comply
with environmental regulations.
Nitrogen
Nitrogen in the FCC feed refers to organic nitrogen compounds. The nitrogen content of FCC
feed is often reported as basic and total nitrogen. Total nitrogen is the sum of basic and non-
basic nitrogen. Basic nitrogen is about one fourth to one half of total nitrogen. The word "basic"
Plant Name: FCCU-I
denotes molecules that react with acids. Basic nitrogen compounds will neutralize acid sites on
the catalyst. This causes a temporary loss of catalyst activity and a drop in unit conversion.
However, nitrogen is a temporary poison. The burning of nitrogen in the regenerator restores
the activity of the catalyst. In the regenerator, about 70% to 90% of the nitrogen in the coke is
converted to elemental nitrogen. The remaining nitrogen is converted to nitrogen oxides
(NOX). The NOx leaves the unit with the flue gas. Catalyst poisoning from the presence of
basic nitrogen in the FCC feedstock is significant. Virtually all the basic nitrogen ends up in
coke. To compensate for nitrogen poisoning, the reactor temperature is raised. A catalyst with
high zeolite content and an active matrix is also recommended.
Apart from catalyst poisoning, nitrogen is detrimental to the unit operation in several other
areas. In the riser, some of the nitrogen is converted to ammonia and cyanide (H-CN). Cyanide
accelerates the corrosion rate of the FCC gas plant equipment; it removes the protective sulfide
scale and exposes bare metal to further corrosion. This corrosion generates atomic hydrogen
that ultimately results in hydrogen blistering. Cyanide formation tends to increase with
cracking severity. In addition, some of the nitrogen compounds end up in light cycle oil (LCO)
as pyrolles and pyridines. These compounds are easily oxidized and will affect color stability.
The amount of nitrogen in the LCO depends on the conversion. An increase in conversion
decreases the percentage of nitrogen in the LCO and increases the percentage on the catalyst.
The source and gravity range of raw crude greatly influence the amount of nitrogen in the FCC
feed
Sulfur
FCC feedstocks contain sulfur in the form of organic-sulfur compounds such as mercaptan,
sulfide, and thiophenes. Frequently, as the residue content of crude oil increases, so does the
sulfur content. Total sulfur in FCC feed is determined by the wavelength dispersive x-ray
fluorescence spectrometry method (ASTM D-2622). The results are expressed as elemental
sulfur.
Although desulfurization is not the goal of cat cracking operations, approximately 50% of
sulfur in the feed is converted to H2S. In addition, the remaining sulfur compounds in the FCC
products are lighter and can be desulfurized by low-pressure hydrodesulfurization processing.
In the FCC, H2S is formed principally by the catalytic decomposition of non-Thiophenic (non-
ring) sulfur compounds.
As with H2S, the distribution of sulfur among the other FCC products depends on several
factors, which include feed, catalyst type, conversion, and operating conditions. Feed type and
residence time are the most significant variables.

Plant Name: FCCU-I
Metals
Metals, such as nickel, vanadium, and sodium, are present in crude oil. These metals are
concentrated in the heavy boiling range of atmospheric bottoms or vacuum residue, unless they
are carried over with the gas oil by entrainment. These metals are catalysts themselves and
promote undesirable reactions, such as dehydrogenation and condensation. Dehydrogenation
means the removal of hydrogen; and condensation means polymerization. Hydrogen and coke
yields are increased and gasoline yields are reduced. Metals reduce the catalyst' s ability to
produce the desired products. These metals permanently poison the FCC catalyst by lowering
the catalyst activity, thereby reducing its ability to produce the desired products. Virtually all
the rnetals in the FCC feed are deposited on the cracking catalyst. Paraffinic feeds tend to
contain more nickel than vanadium. Each metal has negative effects.
Nickel (Ni)
Any FCC catalyst has two parts. The non-framework structure called matrix and the crystalline
structure called zeolite. In contact with the catalyst, nickel deposits on the matrix. Nickel
promotes dehydrogenation reactions, removing hydrogen from stable compounds and making
unstable olefins, which can polymerize to heavy hydrocarbons. These reactions result in high
hydrogen and coke yields. The higher coke causes higher regenerator temperatures. This lowers
the catalyst-to-oil ratio and lowers conversion. High nickel levels are normally encountered
when processing heavy feed. Neither excess hydrogen nor excess regenerator temperature is
desirable. Excess hydrogen lowers the molecular weight of the wet gas. Since the compressor
is usually centrifugal, this limits the discharge pressure. Lower pressure means less capacity
and this can force a reduction in charge or operation at lower conversion.
Catalyst composition and feed chloride have a noticeable impact on hydrogen yield. Catalysts
with an active alumina matrix tend to increase the dehydrogenation reactions. Chlorides in the
feed reactivate aged nickel, resulting in high hydrogen yield. Two common indicators track the
effects of nickel on the catalyst. These are:
Hydrogen/methane ratio
Volume of hydrogen per barrel of feed
The H2/CH4 ratio is an indicator of dehydrogenation reactions. However, the ratio is sensitive
to the reactor temperature and the type of catalyst. A better indicator of nickel activity is the
volume of hydrogen per barrel of fresh feed. The typical H2/CH4 mole ratio for gas oil having
less than 0.5 ppm nickel is between 0.25 to 0.35, the equivalent H2 make is between 30 and 40
scf/bbl of feed.

Plant Name: FCCU-I
VANADIUM
Vanadium also promotes dehydrogenation reactions, but less than nickel. Vanadium' s
contribution to hydrogen yield is 20% to 50% of nickel' s contribution, but vanadium is a more
severe poison. Unlike nickel, vanadium does not stay on the surface of the catalyst. Instead, it
migrates to the inner (zeolite) part of the catalyst and destroys the zeolite crystal structure.
Catalyst surface area and activity are permanently lost. Vanadium occurs as part of organo-
metallic molecules of high molecular weight. When these heavy molecules are cracked, coke
residue containing vanadium is left on the catalyst. During regeneration, the coke is burned off
and vanadium is converted to vanadium oxides such as vanadium pentoxide (V2O5). V2O5 melts
at 690°C, which allows it to destroy zeolite under typical regenerator temperature conditions.
V2O5 is highly mobile and can go from one particle to another.
V2O5 converts to vanadic acid (H3VO4) under regenerator conditions. Vanadic acid, through
hydrolysis, extracts the tetrahedral alumina in the zeolite crystal structure, causing to collapse.
The severity of vanadium poisoning depends on the following factors:
Vanadium Concentration
In general, vanadium concentrations above 2,000 ppm on the E-Cat can justify passivation.
Regenerator Temperature
Higher regenerator temperatures (>1,250°F or 677°C) exceed the melting point of vanadium
oxides, increasing their mobility. This allows vanadium to find zeolite sites. This deactivation
is in addition to the hydrothermal deactivation caused by higher regenerator temperature alone.
Combustion Mode
Regenerators operating in full combustion and producing "clean" catalyst increase vanadium
pentoxide formation because of the excess oxygen.
Sodium
Sodium and vanadium react to form sodium vanadates. These mixtures have a low melting
point (<1,200°F or 649°C) and increase vanadium mobility.

Plant Name: FCCU-I
Steam
Steam reacts with V2O5 to form volatile vanadic acid. Vanadic acid, through hydrolysis,
causes collapse of the zeolite crystal.
Catalyst Type
The alumina content, the amount of rare-earth, and the type and amount of zeolite affect
catalyst tolerance to vanadium poisoning.
Catalyst Addition Rate
A higher catalyst addition rate dilutes the concentration of metals and allows less time for the
vanadium to get fully oxidized,
Alkaline Earth Metals
Alkaline earth metals in general, and sodium in particular, are detrimental to the FCC catalyst.
Sodium permanently deactivates the catalyst by neutralizing its acid sites. In the regenerator it
causes the zeolite to collapse, particularly in the presence of vanadium. Sodium comes from
two prime sources:
Sodium in the fresh catalyst
Sodium in the feed
Fresh catalyst contains sodium as part of the manufacturing process.
Other Metals
Iron is usually present in FCC feed as tramp iron and is not catalytically active. Tramp iron
refers to various corrosion by-products from upstream processing and handling.
Copper is as active as nickel, but the feed contains much less of it.
Empirical correlations have been developed by the industry to determine chemical properties
from these physical analyses.
Process modeling uses the feed properties to predict FCC yields and product qualities. The
process model should be used in daily unit monitoring, catalyst evaluations, optimization, and
process studies.

Plant Name: FCCU-I
The most widely published correlations in use today are:

K Factor
TOTAL
n-d-M Method
API Method
K Factor
The K factor is a very useful indication of feed crackability. The K factor relates to the
hydrogen content of the feed. It is normally calculated using feed distillation and gravity data,
and measures aromaticity relative to paraffinicity. Higher K values indicate increased
paraffinicity and more crackability.
A K value above 12.0 indicates a paraffinic feed; a K value below 11.0, aromatic. Like aniline
point, the K factor differentiates between the highly paraffinic and aromatic stocks. However,
within the narrow range (K = 11.5-12.0), the K factor does not correlate between aromatics and
Naphthenes. Instead, it relates fairly well to the paraffin content. The K factor does not provide
information as to the ratio of naphthenes and paraffin contents. The ratio of Naphthenes to
paraffins can vary considerably with the same K values.
K value is the ratio of the cube root of a boiling temperature to gravity. There are two widely
used methods to calculate the K factor, KW and KUOP.
WATSON CHARACTERIZATION (K) FACTOR:
Watson Characterization factor is determined by
K (Watson) = (MeABP)1/3
Sp gr 600F/600F
MeABP = (MABP R + CABP R)
2
MeABP = Mean average boiling point

Plant Name: FCCU-I
MABP = Molal average boiling point

CABP = Cubic average boiling point
R = degree Rankin
Watson K- factor for FCCU feed stocks are generally in the range of 11.0 to 13.0. Feed
stocks are generally in the range of 11.0 to 11.5 are aromatic, those between 11.5 and
11.8 are considered naphthenic and those above 11.8 paraffinic.
Another characterization factor that is widely used is the UOP characterization factor.
K = (TB/D) 1/3
TB = Molal boiling point
D = Specific gravity at 15.6/15.6 C
The feed stocks are designed as per the following K values:
A) Paraffinic K (UOP) = 12.15 to 12.9

B) Naphthenic or mixed base K (OUP) = 10.5 –11.45 of 11.5-12.1
C) Aromatic K (UOP) = 10.5
TOTAL
The TOTAL correlations calculate aromatic carbon content, hydrogen content, molecular
weight, and refractive index using routine laboratory tests. The TOTAL correlations are listed
below and are also in Appendix
Molecular Weight (MW)
MW = 0.0078312 x (SG) ^ (-0.0978) x (AP °C) ^ 0.1238 x (VABP °C) ^1.6971

Plant Name: FCCU-I
Refractive Index (RI) @ 20°C (68°F)

RI (20oC) = 1 + 0.8447 x (SG) ^ 1.2058 x (VABP °K) ^ (-0.0557) x (MW) ^ (-0.00444)
Refractive Index (RI) @ 60°C (140°F)

RI (60oC) = 1 + 0.8156 x (SG) ^ (1.2392) x (VABP °K) ^ (-0.0576) x (MW) ^ (-0.0007)
Hydrogen (H2) Content, wt%

H2 = 52.825 - 14.26 x RI (20) - 21.329 x (SG) - 0.0024 x (MW) - 0.052 x (S) + 0.757 x ln (v)
Aromatic (CA) Content, wt%

CA = -814.136 + (635.192 x RI (20)) - (129.266 x (SG)) + (0.013x (MW)) - (0.34 x (S)) + (6.872
x ln (v))
Where: SG = Specific gravity at 20°C
AP °C = Aniline Point, °C
VABP °C = Volumetric Average Boiling Point, °C
VABP °K = Volumetric Average Boiling Point, °K
S = Sulfur, wt%
V = Viscosity at 100°C
For FCC feeds, particularly the ones containing residue, the TOTAL correlation is more
accurate at predicting aromatic carbon content than the n-d-M correlation. One option is to
calculate MW, RI (20), CA, and H2 from the TOTAL correlation, and use either the n-d-M or
API method to calculate the wt% naphthenes (CN) and wt% paraffin (Cp).
n-d-M Method
The n-d-M correlation is an ASTM (D-3238) method that uses refractive index (n), density (d),
average molecular weight (MW), and sulfur (S) to estimate the percentage of total carbon
distribution in the aromatic ring structure (% CA), naphthenic ring structure (CN), and paraffin
chains (% Cp). Both refractive index and density are either measured or estimated at 20°C
(68°F). The n-d-M method calculates, the percent of carbon in the aromatic ring
It is important to characterize FCC feeds as to their molecular structure. Once the molecular
configuration is known, kinetic models can be developed to predict product yields. The
simplified correlations above do a reasonable job of defining hydrocarbon type and distribution
in FCC feeds. Each correlation provides satisfactory results within the range for which it was
developed. Whichever correlation is used, the results should be trended and compared with unit

Plant Name: FCCU-I
operation. A clear understanding of feed physical properties is essential to successful work in

the areas of troubleshooting, catalyst selection, unit optimization, and any planned revamp.
CATALYST PROPERTIES
4.4 INTRODUCTION
FCC catalysts in use today are primarily compose of oxides of silicon and aluminum. Other
elements often present include sodium, calcium, magnesium and members of the rare earth
family such as acid site which enables the catalyst to crack gas oil molecules selectively to
gasoline and lighter materials without forming excessive amounts of coke. The number of acid
sites along with the strength and accessibility of sites determines the cracking of the catalyst.
The first FCC catalyst were finely ground naturally occurring clays. The first major
improvement in FCC catalysts was the introduction of the all synthetic catalysts in 1946. These
new catalysts, containing approximately 12% alumina and 88% silica, were spray dried as the
final step in their manufacture. The catalyst particles were roughly spheroidal, especially after
a few trips around the Reactor-Regenerator of any small rough edges and thus decreased
erosion problems. These low alumina catalysts were more active than the ground clays and did
produce a higher octane gasoline.
The early 1950’s saw the next major improvement in FCC catalysts. Additional alumina was
used to bring the catalyst alumina content to 25% these catalysts showed a higher activity
because of a greater surface area.
Shortly after the development of the higher alumina catalyst, a silica-magnesia catalyst was
introduced. This catalyst was advertised to be selective for middle distillable (light cycle oil)

Plant Name: FCCU-I
production. Unfortunately, these catalysts did not regenerate sufficiently to be commercially

acceptable.
A major breakthrough in FCC catalysts technology occurred the mid 1960’s This was the
incorporation of molecular sieves called zeolites, into the catalyst. The chemical composition
is basically the same, but the structure is radically different. A zeolite is a crystalline alumina-
silica compound with a framework structure. This regular structure differentiates the zeolite
from the previous catalysts, which were amorphous, that is having sponge like structure. The
zeolite has regular activities which can be occupied by large ions or water. These ions may be
exchanged for others as long as electrical neutrality is maintained. An enormous advancement
was made in 1964 when Mobil produced and successfully used spray-dried zeolite catalyst
commercially. Another major occurrence in FCC catalyst development was the invention of
ultra-stable Y (USY) zeolite by Grace Davison in 1964. It was subsequently learned that USY
zeolite with no rare earths enhanced cat cracked gasoline octane and led to the first successful
octane and led to the first successful octane catalyst trial in 1975. Furthermore, USY and rare
earth- treated (REUSY) zeolites have been recognized low selectivity for coke. Fluid cracking
catalyst retention properties were substantially improved by Grace Davison’s silica-sol and
alumina-sol binding technology introduced in 1973 and 1981 respectively. Other technological
breakthrough made by Grace Davison that has had a substantial effect on fluid cracking
catalyst quality and performance is matrix and zeolite advances. In 1986, a catalyst containing
a coke selective deep bottoms cracking matrix was commercialized by Grace Davison,
incorporated a new gasoline selective USY zeolite in fluid cracking in 1975 and bismuth nickel
passivation by Chevron in 1987. In 1986 Mobil introduced a ZSM-5 octane additive that
provides flexibility not only in octane enhancement but also C3 and C4 yields, largely the un-
saturates and gasoline yield.

Plant Name: FCCU-I
4.4.1 TYPES OF ALUMINO SILICATE CATALYST
4.4.1.1 NATURAL CATALYSTS
Natural Catalysts is finely ground chemically treated clay and was the original catalyst used in
the process. The catalyst has fell into disuse in spite of some desirable features, the principal
one being its low cost compared with the low- alumina synthetic catalyst most commonly used.
Natural catalyst produces a slightly higher yield of lower octane gasoline. However, because
of its lower initial activity and stability, a higher make-up rate is required for regeneration.
Being composed of irregularly shaped ground particles, natural catalysts tend to erode
standpipes and slide valves more rapidly and to break up more easily producing fires which
are most through the stack. Natural catalysts are also observed to circulate less rapidly and the
maximum circulation rate of unit can often be increased by changing to a micro spheroidal
catalyst.
4.4.1.2 SEMISYNTHETIC CATALYST
Semi-synthetic catalyst is manufactured from natural clay and is an attempt to simultaneously

obtain the advantages of the low cost of natural catalyst and the high “performance of synthetic
catalysts. In practice it appears that the properties and performance of semi-synthetics are
intermediate, and that all the disadvantages of natural catalyst are encountered to a somewhat
lesser degree.
Both semi-synthetic and natural catalyst finds a use in those units handling charge stocks
which are heavily contaminated with metals. In general, however, the most economical
solution to this problem is the elimination of contamination by making changes in the feed
preparation unit.
4.4.1.3 SYNTHETIC CATALYST
Synthetic Catalysts are prepared chemically and in general are micro spheroidal catalysts with
desirable physical properties, high initial activity and good stability. Several types of synthetic
catalysts are available.
A) LOW-ALUMINA CATALYST
Low-alumina catalyst containing 12-14% alumina is the original synthetic catalyst. It possesses
well balanced properties which are the standard against which other catalysts are still
compared.
Plant Name: FCCU-I
B) HIGH ALUMINA CATALYST
High-alumina Catalyst, containing 25-28% alumina, is a catalyst with higher initial activity
and superior stability. Equilibrium activity is higher and hence operating severity can be
reduced to maintain the same conversion. High alumina catalysts usually result in a higher
regenerator temperature and the apparent bulk density is lower than other catalyst. Low and
high alumina catalysts are also known as amorphous alumina-silicate catalysts.
CATALYST COMPONENTS
FCC catalysts are in the form of fine powders with an average particle size in the range of 75
microns. A modern cat cracking catalyst has four major components:
Zeolite
Matrix
Binder
Filler
Zeolite
Zeolite, or more properly, faujasite, is the key ingredient of the FCC catalyst. It provides
product selectivity and much of the catalytic activity. The catalyst' s performance largely
depends on the nature and quality of the zeolite. Understanding the zeolite structure, type,
cracking mechanism and properties is essential in choosing the "right" catalyst to produce the
desired yields.
Zeolite Structure
Zeolite is sometimes called molecular sieve. It has a well-defined lattice structure. Its basic
building blocks are silica and alumina tetrahedral (pyramids). Each tetrahedron consists of a
silicon or aluminum atom at the center of the tetrahedron, with oxygen atoms at the four
corners. Zeolite lattices have a network of very small pores. The pore diameter of nearly all of
today's FCC zeolite is approximately 8.0 angstroms (°A).
4.4.2 ZEOLITE CATALYSTS
The primary source of activity of cracking catalyst is Zeolite. Zeolite actually refers to a large
mineral group of crystalline materials. Nevertheless the word “Zeolite” is

Plant Name: FCCU-I
Commonly used to indicate the crystalline component added to fluid cracking catalyst to
provide its activity and selectivity. Specifically, the zeolite used in cracking catalyst is
faujasite. Faujasite is a crystalline three-dimensional alumina-silicate of the zeolite mineral
group with ion exchange capacity has pore opening of 8-90 A. primary structural units of
faujasite are tetrahedral made up of one silicon and four oxygen truncated hexagonal prisms,
forming faujasite.
4.4.2.1 TYPES OF ZEOLITE
Performance of faujasite is influenced by its method of manufacture and treatment there are
two basic zeolites used in catalysts that have distinctive performances.
A) Standard-Y (HY,REY), B) Ultra stable-Y (USY-REUSY)S
Standard –Y is produced by crystallization of sodium aluminate and sodium silicate. USY is

by far the most widely used zeolite in fluid catalytic cracking catalysts. UYS is made by special
manufacturing techniques that increase the silicon/aluminum atomic ration of the parent
Standard-Y zeolite structure, a process called de-alumination. Zeolite de-alumination is
achieved by steam calcinations or chemical treatment. The de-alumination process extracts
aluminum from the framework and heals the site with silicon, without collapsing the
framework structure, the USY zeolite is more resistant to deactivation in the FCC unit (more
stable) than its parent standard Y for two basic (1) its expelling additional aluminum and
collapsing the structure at FCC regenerator conditions and 2) its sodium level is generally
lower due to additional processing.
The three most common parameters governing zeolite behavior are as follows:
Unit Cell Size
Rare Earth Level
Sodium Content
Unit Cell Size (UCS)
The UCS is a measure of aluminum sites or the total potential acidity per unit cell. The
negatively-charged aluminum atoms are sources of active sites in the zeolite. Silicon atoms do
not possess any activity
Rare Earth Level

Plant Name: FCCU-I
Rare earth (RE) elements serve as a "bridge" to stabilize aluminum atoms in the zeolite
structure. They prevent the aluminum atoms from separating from the zeolite lattice when the
catalyst is exposed to high temperature steam in the regenerator. The rare earth increases zeolite
activity. The octane loss is due to promotion of hydrogen transfer reactions The insertion of
rare earth maintains more and closer acid sites, which promotes hydrogen transfer reactions. In
addition, rare earth improves thermal and hydrothermal stability of the zeolite. To improve the
activity of a USY zeolite, the catalyst suppliers frequently add some rare earth to the zeolite.
Sodium Content
The sodium on the catalyst originates either from zeolite during its manufacture or from the
FCC feedstock. It is important for the fresh zeolite to contain very low amounts of sodium.
Sodium decreases the hydrothermal stability of the zeolite. It also reacts with the zeolite acid
sites to reduce catalyst activity. In the regenerator, sodium is mobile. Sodium ions tend to
neutralize the strongest acid sites.
UCS, rare earth, and sodium are just three of the parameters that are readily available to
characterize the zeolite properties. They provide valuable information about catalyst behavior
in the cat cracker. If required, additional tests can be conducted to examine other zeolite
properties.
Matrix
Matrix is a component of the catalyst aside from the zeolite. Alumina is the source for an active
matrix. Most active matrices used in FCC catalysts are amorphous. Active matrix contributes
significantly to the overall performance of the FCC catalyst. The zeolite pores are not suitable
for cracking of large hydrocarbon molecules generally having an end point greater than
482°C. They are too small to allow diffusion of the large molecules to the cracking sites. An
effective matrix must have a porous structure to allow diffusion of hydrocarbons into and out
of the catalyst. An active matrix provides the primary cracking sites. The acid sites located in
the catalyst matrix are not as selective as the zeolite sites, but are able to crack larger molecules
that are hindered from entering the small zeolite pores. The active matrix pre-cracks heavy feed
molecules for further cracking at the internal zeolite sites. The result is a synergistic interaction
between matrix and zeolite, in which the activity attained by their combined effects can be
greater than the sum of their individual effects. An active matrix can also serve as a trap to
catch some of the vanadium and basic nitrogen. The high boiling fraction of the FCC feed
usually contains metals and basic nitrogen that poison the zeolite. One of the advantages of an
active matrix is that it guards the zeolite from becoming deactivated prematurely by these
impurities.

Plant Name: FCCU-I
Filler and Binder
The filler is clay incorporated into the catalyst to dilute its activity. Kaoline [Al2 (OH)2 Si2O5]
is the most common clay used in the FCC catalyst. FCC catalyst manufacturers uses kaoline
clay as a skeleton to grow the zeolite in situ. The binder serves as a glue to hold the zeolite,
matrix, and filler together. Binder may or may not have catalytic activity. The importance of
the binder becomes more prominent with catalysts that contain high concentrations of zeolite.
The functions of the filler and the binder are to provide physical integrity (density, attrition
resistance, particle size distribution, etc.), heat transfer medium, and a fluidizing medium in
which the more important and expensive zeolite component is incorporated. In summary,
zeolite will effect activity, selectivity, and product quality. An active matrix can improve
bottoms cracking and resist vanadium and nitrogen attacks. But a matrix containing very small
pores can suppress strip ability of the spent catalyst and increase hydrogen yield in the presence
of nickel. Clay and binder provide physical integrity and mechanical strength.
4.4.2.2 PHYSICAL PROPERTIES
APPARENT BULK DENSITY (ABD)
The Apparent Bulk Density of a fluid cracking catalyst is its apparent density and is determined
by weighing the quantity of catalyst required to fill a 25 ml. cylinder Fresh catalysts have
ABD’s ranging from” (0.75 – 0.80 Grams/ml, while equilibrium catalysts vary from 0.85-0.90
grams/ml. The ABD depends upon the chemical composition, pore volume and particle size
distribution.
SURFACE AREA
The particles of fluid cracking catalyst are full of pores and, while the activity is due to the
chemical composition of the catalyst, the surface area is a measure of the availability of the
catalyst activity. A fresh catalyst will have a surface are around 2000 M2/gram, while
equilibrium catalyst will run about 800M2/gram. The surface are will correlate fairly well with
activity for catalysts of the same chemical composition.
PORE VOLUME AND DIAMETER
The volume of the pores in a catalyst and their average diameter can be determined by
laboratory techniques similar to those used to determine surface area. A catalyst with a high
pore volume and pore diameter will tend to regenerate more easily and exhibit higher stability

Plant Name: FCCU-I
and higher resistance to sintering. However, high pore volume implies lower physical strength
and increased susceptibility to attrition.
PARTICLE SIZE DISTRIBUTION
The fluid properties of the catalyst are largely a function of the range of sizes the catalyst
particles. Typical size distributions are.
Fresh Catalyst Equilibrium Cat.

Sl. No. Particle Size
Fine Medium Coarse Fine Coarse
Wt(%) (%) (%) Wt (%) (%)
1
1. Below 20 microns 3 1 1 -
15
2. Below 40 microns 25 10 10 2
50
3. Below 60 microns 60 45 50 40
85
4. Below 80 microns 90 70 80 70
90
5. Below 100 microns 95 90 90 90
The desirable particle size distribution for any given unit is the coarsest distribution at which
stable operation is obtained, since this coarse distribution will also result in minimum stack
losses.
Satisfactory fluidization demands a range of particle size and the percentage of particle below
40 microns and above 100 microns are good indicators of the performance to be expected from
the catalyst. A decrease in the percentage of catalyst below 40 microns will result in poor
fluidization which will become, apparent through an increase in the carbon content of the
regenerated catalyst, a decrease in slide valve differential pressure, and possibly by increase in
the reactor temperature necessary to maintain conversion. UOP’s units, which are designed
for relatively coarse catalyst, will normally operate quite satisfactorily with 15% or less, of
particles smaller than 40 microns.
Occasionally large particles will accumulate in a unit will be the result of an equilibrium
involving attrition, cyclone performance, charge rate, catalyst make up rate and type. If a unit
is maintaining a satisfactory particle size distribution, a reduction in stack losses can often be
Plant Name: FCCU-I
maintained by using a coarser make-up catalyst while on other occasions make up with a finer
catalyst may be desirable to improve fluidization.
Particle size distribution is measured by ‘Micro Mesh Screens.
SINTERING INDEX
The sintering index is an arbitrary measure of the percentage of catalyst particles having a
majority of the pores closed by sintering. It is determined by using floatation in a heave liquid
to separate those particles having a density different from the bulk of the catalyst.
ATTRITION RESISTANCE
The attrition resistance of catalyst is measured by the quantity of fines produced by blowing
air at high velocity through sample of catalyst for a number of hours. A number of different
test methods are used, the most informative of which are those which measure the quantity of
fines produced in the subsequent thirty hours. The fines produced in the initial period tend to
be those originally present in the catalyst, whereas those yielded in the second period are the
products of true attrition. Good catalyst will average an attrition rate of about 0.2 Wt% per
hour in the second period. It might be felt that a catalyst with a high resistance to attrition is
desirable. However, such a hard catalyst would probably erode equipment more rapidly and
would not produce the fines necessary to maintain the particle size distribution necessary
for smooth operation. In addition, if a mixture of hard and normal catalyst is used, the hard
catalyst could grind the normal catalyst and produce an excessive quantity of fines.
The particle size distribution (PSD), sodium (Na), rare earth (RE), and surface area (SA) are
some of the parameters in the inspection sheet that require close attention.
Particle Size Distribution (PSD)
The PSD is an indicator of the fluidization properties of the catalyst, In general, fluidization
improves as the fraction of the 0-40 micron particles is increased; however, a higher percentage
of 0-40 micron particles will also result in greater catalyst losses. The fluidization
characteristics of an FCC catalyst largely depend on the unit' s mechanical configuration. The
percentage of less than 40 microns in the circulating inventory is a function of cyclone
efficiency. In units with good catalyst circulation, it may be economical to minimize the
fraction of less than 40-micron particles. This is because after a few cycles, most of the 0-40
microns will escape the unit via the cyclones, The catalyst manufacturers control PSD of the
fresh catalyst, mainly through the spray-drying cycle. In the spray dryer, the catalyst slurry

Plant Name: FCCU-I
must be effectively atomized to achieve proper distribution. The average particle size (APS) is
not actually the average size of the catalyst particles, but rather the median value.
Surface Area (SA), M2/g
The reported surface area is the combined surface area of zeolite and matrix. In zeolite
manufacturing, the measurement of the zeolite surface area is one of the procedures used by
catalyst suppliers to control quality. The surface area is commonly determined by the amount
of nitrogen adsorbed by the catalyst. The surface area correlates fairly well with the fresh
catalyst activity. Zeolite surface area is proportional to the zeolite content of the catalyst.
Sodium (Na), wt%
Sodium plays an intrinsic part in the manufacturing of FCC catalysts. Its effects are well known
and, because it deactivates the zeolite and reduces the gasoline octane, every effort should be
made to minimize the amount of sodium in the fresh catalyst. The catalyst inspection sheet
expresses sodium or soda (Na2O) as the weight percent on the catalyst. When comparing
different grades of catalysts, it is more practical to express the sodium content on the zeolite.
Rare earth (RE) is a generic name for 14 metallic elements of the Lanthanide series. These
elements have similar chemical properties and are usually supplied as a mixture of oxides
extracted from ores such as bastnaesite or monazite. Rare earth improves the catalyst activity
and hydrothermal stability. The data sheet shows rare earth or rare earth oxide (RE2O3) as the
weight percent of the catalyst. Again, when comparing different catalysts, the concentration of
RE on the zeolite should be used.

Plant Name: FCCU-I
4.5 FGD-I Feed and product characteristics:
FGD I is designed to operate for the following feed cases:

Cases
Units Maximum Normal Minimum Case
Case Case
o
Temperature C 200 200 200
Flue Gas flow Kg/hr 132,050 110042 66025
Flue Gas composition Kg/hr
H2O 9556 7963 4778
CO2 27285 22738 13643
N2 91997 76665 45999
O2 2160 1800 1080
SO2 1002 835 501
SO3 0 0 0
Catalyst Fines Kg/hr 49.9 41.6 25
Particulate Size Dist.:
0-1 microns % Weight 3 3 3
4.6 Stack emissions
Catalyst Fines removal: 90% min.

SO2 removal : 90% min
SO3 removal : 40-70%

Plant Name: FCCU-I
4.7 Purge
Purge flow is set to maintain based on Scrubber liquid properties as listed below:
TSS: <0.5 wt%

Chlorides: < 750mg/l.
TDS: <10 wt %

Plant Name: FCCU-I
PROCESS PRINCIPLE AND CHEMISTRY
CHAPTER 5
PROCESS PRINCIPLE AND PROCESS CHEMISTRY
General Function of the Plant:
The Fluid catalytic Cracking Unit (FCCU) is one of the most important and widely used process
unit aimed at maximizing the yield of light/middle distillates by cracking of heavy oils in the
presence of catalyst. The unit may be divided broadly into three sections:
I) Reactor Regeneration Section (R-R section)

II) Fractionation Section
III) Gas Concentration Unit.
The heavy oils (mainly Vacuum Gas oils) are cracked in the presence of a catalyst in the reactor
section of the unit. This cracking reaction cracks down the long chain, high molecular weight
hydrocarbons into lighter hydrocarbons. In course of the cracking reaction, coke is also
produced which remains on the catalyst particles and rapidly reduces its activity. In order to
maintain the catalyst activity at useful level, it is therefore necessary to regenerate the catalyst
by burning off the deposited coke. To achieve this, the catalyst continuously flows from the
Reactor to the regenerator where the deposited coke is burnt off in the presence of Oxygen
(air). The regenerated catalyst is removed from the regenerator and is lifted back into the reactor
by reactor feed. The regeneration of the catalyst is an exothermic process and thus provides
necessary heat for the cracking reaction, which is endothermic. The flow of catalyst between
reactor and regenerator is achieved through fluidization.
The cracked product from the reactor is distilled and separated into different product streams
of desired TBP cut range in the fractionation section. The net gas stream from the main
fractionator overhead condenser system is further processed in the Gas Concentration unit to
recover valuable LPG and naphtha range components. The non-condensable gases are routed
to SRU for fuel gas network whereas LPG and stabilized naphtha are routed to storage after
treatment.
General Description of the Flexi cracking Process
The FLEXICRACKING process being utilized in the Visakh FCC Revamp is a catalytic
conversion process which converts vacuum gas oil feed to fuel gas, LPG, high Octane gasoline,
middle distillates, fuel blending stock and coke. These materials are withdrawn as products
except for coke, which is consumed internally in the process to produce heat for the cracking
reaction.
FCCU-1 Operating Manual CHAPTER-5 PROCESS PRINCIPLE AND CHEMISTRY Page 63 of 752
Plant Name: FCCU-I
The zeolite catalyst is typically a synthetic silica-alumina support matrix with added zeolite,
manufactured in the form of a fine powder with an average particle size of around 73 microns.
Cracking catalyst can also be synthetic silica – solid support matrix with added zeolite, or a
clay based support matrix with added zeolite. Although the catalyst is a solid, it is maintained
in suspension or “fluidized” by reaction products, steam, or air in the vessels and catalyst
transfer lines. In this fluidized state, the catalyst behaves as a fluid and flows between the
Reactor and Regenerator.
The Reactor is operated between about 490 to 5300C at approximately 1.3 kg/cm2g. Feed is
introduced into the bottom of the reactor riser through steam atomized injection nozzles. When
the oil feed contacts the hot catalyst in the riser, it vaporizes and cracks, providing the lifting
force to carry the catalyst up into the riser. It vaporizes and essentially all of the conversion
takes place in the feed riser [short Contact Time (SCT) technology used in FCCU-1]. Oil vapors
pass from Reactor overhead to the fractionation section, where the products are
separated .Catalyst with coke deposited on it from the cracking reaction, passes down through
a stripping section in the reactor vessel where it is stripped with steam. This removes both the
oil remaining on the surface and oil vapors entrained between the particles of catalyst. The
catalyst then flows through a transfer line to the Regenerator.
In the Regenerator, coke is burnt off the catalyst with air in High temperature Regeneration
(HTR), partial CO burn mode of operation. The Regenerators operates with dense bed
temperatures of 675 -7300C, and a dilute phase pressure of approximately 1.1 kg/cm2g. A CO
promoter can be used to assist the combustion of CO to CO2. The hot, regenerated catalyst
flows via an overflow well into the regenerated catalyst transfer line and is transferred back to
the reactor riser.
Flue gases pass up and out of the Regenerator through cyclones, which removes any entrained
catalyst. Combustion of residual CO is completed in a CO Boiler where steam is generated.
Fractionation Section
The reactor effluent comprising of cracked hydrocarbon vapors, steam and non-condensable
enter the fractionator at the bottom of the quench section. The main column is a vertical
cylindrical vessel consisting of two sections, top section is the regular fractionator part and the
lower one is the desuperheating or quench section. The cracked vapors from the reactor are
cooled by circulating slurry pump around and part of the vapors condense. The entrained
catalyst if any in the cracked vapor is scrubbed by the slurry pump around stream. The column
bottom liquid which serves as slurry pump around and net bottom product is withdrawn from
the fractionator and pumped using slurry pumps.
Plant Name: FCCU-I
Light cycle oil (LCO) is withdrawn from the chimney tray CT-1. This stream is split up into
two streams, LCO product and LCO PA. LCO PA stream is used as an internal reflux
whereas LCO PDT is stripped off using MP steam in a stripper and withdrawn as a product
which joins Diesel pool or cutter. Heavy cycle oil (HCO) is withdrawn from the chimney tray
CT-2. This stream is split up into two streams, HCO product and HCO PA. HCO PA stream
is used as an internal reflux whereas HCO PDT is stripped off using MP steam in a stripper
and withdrawn as a product which can be used as feed, dilutant to settler and also joins CLO
which joins the FO pool.
The main fractionator overhead vapor consists of naphtha and lighter hydrocarbons together
with steam and non-condensable. The overhead vapors from fractionator, along with wash
water and spill back stream from wet gas compressor are cooled in main fractionator air fin
cooler and finally in fractionator overhead trim condenser and the three-phase mixture of non-
condensable, hydrocarbon liquid and water from trim condensers is routed to main fractionator
O/H accumulator. A portion of the condensed hydrocarbon is returned to the top tray of the
fractionator as reflux and the remaining liquid is withdrawn as unstabilized naphtha/LPD.
Gas Concentration Section

The wet gas and unstabilized naphtha streams coming from the fractionator overhead
accumulator are the feed for gas concentration section. In this section, the wet gases
(consisting of light hydrocarbons and non-condensable), LPG and stabilized naphtha are
separated. The net gases are routed to SRU fuel gas network whereas LPG and stabilized
naphtha are routed to storage after treatment.
Process Chemistry
FCC brings together heavy hydrocarbon feed with fluidized circulating catalyst. During
cracking reactions, carbon and hydrogen (i.e., Coke) is deposited on catalyst which reduces the
catalyst activity. This coke is burnt in the regenerator, which generates the heat to sustain and
continue the reaction and the catalyst activity is also restored.
Gas oil is portion of crude oil that boils in 330-550oC range and contains a mixture of paraffins,
Naphthenes and Aromatics. About 50% of the feed consists of saturated molecules (Paraffins
and Naphthenes) and remaining molecules contain at least one aromatic ring. Aromatic
molecules have saturated side chains and/or naphthenes rings attached to them.
Paraffins, Naphthenes and side chains can crack to smaller molecules whereas aromatic rings
cannot be cracked.
Plant Name: FCCU-I
Type of molecules in cracked products

Naphtha ----- Paraffins, Naphthenes, Olefins & 1-Ring aromatics
Heating Oil ----- 2- and 3- Ring aromatics
Bottoms and Coke ----- 4+ Ring Aromatics
List of Main FCCU Reactions

Cracking reactions
Paraffins Olefins+ Paraffins
Naphthenes Olefins
Aromatics Un-substituted aromatics+ Olefins
Olefins Smaller LPG Olefins
Hydrogen Transfer
Olefins Paraffins
Branched olefins Branched Paraffins
Olefins and Naphthenes Paraffins+ Aromatics
Dehydrogenation
Naphthenes Cyclo-Olefins & aromatics
Aromatics Heavy Heterocyclic Aromatics (coke)
Olefins Coke (Net Reduction)
Isomerization
Olefins Branched Olefins
Cyclization
Olefins Naphthenes
Alkylation
Aromatics Heavy Heterocyclic Aromatics (coke)
Aromatics Different alkyl aromatics
Plant Name: FCCU-I
Mentioned above is a list of major reactions that take place in reactor apart from numerous
other side reactions which provides innumerable ways of combining FCC with downstream
units to produce valuable products. This is perhaps the charm of FCCU which enthuses the
researchers around the globe.
Plant Name: FCCU-I
Plant Name: FCCU-I
PROCESS DESCRIPTION AND CONFIGURATION
CHAPTER 6
6.0.1 Feed Preheat Section

6.0.2 Feed Heater
6.0.3 Process System
6.0.4 Fuel system
6.0.5 Steam Super heater Coils & Generation System
6.0.6 Steam Air Decoking System
6.0.7 Heater Interlocks
6.1 Reactor
6.1.1 Reactor Feed System
6.2 Reactor
6.2.1 Feed zone
6.2.2 Reaction zone
6.2.3 Catalyst Recovery
6.2.4 Spent catalyst stripper
6.2.5 Reactor temperature/Pressure control
6.3 Regenerator and Associated Facilities

6.3.1 After-burning
6.3.2 Catalyst recovery
6.3.3 Air supply
6.3.4 Torch oil system
6.3.5 Air preheater
6.3.6 Regenerator temperature/Pressure control
6.4 Catalyst Circulation

6.4.1 Catalyst circulation overview
6.4.2 Main parameters affecting Catalyst circulation
6.4.3 Aeration
6.4.4 Catalyst particle size
6.4.5 Blast and Emergency steam
FCCU-1 Operating Manual CHAPTER-6 PROCESS DESCRIPTION AND Page 69 of 752

CONFIGURATION
Plant Name: FCCU-I
6.5 Unit Process Control Strategies

6.5.1 Components of the Heat balance
6.5.2 Components of the Carbon balance
6.5.3 Heat balance indication
6.5.4 Carbon balance indication
6.5.5 CO-Combustion Promoter Activity indication
6.5.6 Heat balance control
6.5.7 Carbon balance
A. Partial CO burn
B. Full CO burn
6.5.8 Effect of Other parameters on Heat and Carbon balance
6.6 Catalyst Handling System
6.7 Fractionator
6.7.1 Heavy Cycle oil circuit
6.7.2 Light Cycle oil circuit
6.7.3 Main column Overhead system
6.8 Gas Concentration Section

6.8.1 WGC Control Scheme
6.8.2 Sour water
6.8.3 Primary Absorber
6.8.4 Sponge Absorber
6.8.5 Stripper
6.8.6 Debutanizer
6.8.7 GCU Debottlenecking Project
6.9 System Variables

6.9.1 Fractionator section
6.9.2 Main column bottom process control
6.9.3 Heavy cycle oil PA system
6.9.4 Light cycle oil PA system
6.9.5 HCO product
6.9.6 LCO product
6.9.7 M/C O/H system
6.9.8 Gas compressor
6.9.10 Sponge absorber

CONFIGURATION
Plant Name: FCCU-I
6.9.11 Stripper
6.9.12 Debutanizer
6.10 Routine Process Control

6.11 Process Flow Diagrams
6.12 FGD Process Description

CONFIGURATION
Plant Name: FCCU-I
This section of the FCCU-I Operating Guide contains a description of the feed, process flow
and control schemes for the Fluid-solids, Air Blower and Catalyst Handling Facilities sections,
fractionation and GCU sections.
6.0 Feed System

6.0.1 Feed Preheat Section
Surge Drum and Facilities:
Hot VGO from CDU’s and cold VGO from offsite tanks are received in the feed surge drum
4V051. The feed surge drum is a horizontal vessel provided with local pressure, temperature
and level indications. Two level transmitters are provided for the drum, one for DCS level
indication (LI1703) and another for control purposes (LC1705). An LP Steam connection
is provided for the drum for startup and shutdown requirements. The vessel is provided with
a boot wherein any water coming along with the feed gets collected. The water is drained
manually upon accumulation. Level indication IL1704 is given for monitoring the interphase
level. The surge drum floats with the main fractionator at LCO section through a 6” line for
pressure balancing and relieving purposes.
The hot feed to the surge drum is a wild flow indicated by 4FT1700 (i.e., as received from the
upstream unit), the flow of cold feed is regulated by the surge drum level controller LIC1705.
TI1707 and TI1708 indicate the temperatures of the incoming hot and cold feeds respectively.
A flushing oil line and a startup circulation line join this feed line to the surge drum for start–
up purposes. Fresh feed pumps P051 A/B take suction from 4V51 and pump VGO to the
preheat train and then to the furnace.
A 4” connection is taken from the discharge of these pumps for use of VGO as pump seal
flushing fluid. Provision also exists to route VGO as torch oil from the feed pump discharge
and as seal oil for slurry pump wear rings. TI1705 in the pump suction measures the combined
(hot and cold) feed temperature while the fresh feed flow is measured by FI1701 on the pump
discharge line. P051 A/B is provided with a spill back connection with RO-1701.
Preheat Train:
The preheat exchanger train consists of O4-E051 (Feed/LCO exchanger.) 4E052 A/B/C/D
(Feed/CLO exchanger) 4E053 (Feed/LCO PA exchanger) and 4E054 A/B (Feed/Slurry PA
exchanger). In E051 VGO on the shell side is heated to 1290C by LCO on the tube side. This
CONFIGURATION
Plant Name: FCCU-I
preheat exchanger is used only for cold feed case when the temperature of the feed is 900C
max. The feed VGO then enters the final preheat exchanger 4E54 A/B/C on the shell side and
gets heated up to 3400C by Slurry pump around on the tube side.
In slurry PA exchangers, 4E54A/B/C, 3-4 ft/sec to prevent catalyst deposition and coke fouling.
The maximum velocity is limited to 10-12 ft/sec to avoid erosion by catalyst suspended in the
Slurry stream.
In addition to local PG’s the preheat train is provided with adequate number of TIs to measure
the temperatures of both shell and tube side fluids at each stage. Also .TSV’s are provided for
each of the exchangers (or banks) on the cold (VGO) side with their outlets to OWS.
Exchanger Shell Tube Remarks

In Out In Out
4E51 VGO 129 LCO
4E52A/B/C/D VGO 180 CLO
4E53 LCO PA VGO 180 208/160 Hot/Cold Feed
cases
4E54A VGO 208/160 Slurry PA
4E54B VGO Slurry PA
4E54C VGO 340 Slurry PA
6.0.2 Feed Heater (4F-51)
Major equipment of this section are heater, steam drum and steam decoking pot.
Description of feed heater is divided in following sub sections:

i. Process System
ii. Fuel System
iii. Steam Generation System & Super Heater Coils
iv. Steam Air Decoking System
6.0.3 Process System
VGO enters at the top of the convection zone of the fired heater. From the bottom of the
convection zone, the coils are routed to the radiation zone. From radiation zone, VGO comes
out of the heater and enters Reactor. VGO is heated from 3070C to 3320C, 2480C to 3850C and
3260C to 4230C in ID, 2D &IN cases respectively before entering the Reactor.
CONFIGURATION
Plant Name: FCCU-I
Flow in each pass is regulated by individual pass flow controllers namely FC1901 and FC1902.
These controllers get input signal from respective flow transmitters (FT-1901 & FT-1902)
and set point signal from a ratio controller. Controller generate output signal and manipulates
respective flow valves (FV1901 & FV1902).
The pass balancer in APC functions such a way that the weighted average temperature at the
outlet of each pass is maintained almost the same. The pass balancer receives software input
signal from TI1908 & 1909 (Outlet temperature of individual passes) and FC1901 &1902
(Current values of heater pass flows.) The output from the pass balancer regulates individual
VGO flow through the individual passes by manipulating the Flow control valves (FV1901
&1902) located on the individual passes.
The distribution of VGO through each pass should be adjusted in such a way that the heat duties
and hence COT (Coil outlet temperature) of all the passes are more or less same.
Both the passes join together at the outlet of radiation zone. TAH is provided at each pass outlet
along with DCS indication of temperature. TI1908 & TI -1909, TI1903 &TI1907 shows the
intermediate heating of VGO in the convection zone.
To avoid repetitive description, features of only pass- I have been taken up. For other pass
identical arrangement exists.
FC1901 controls and indicates VGO flow through pass-1. One flow low low alarm FAL1901
has been provided in DCS. A local PI indicates Field pressure and DCS bound TI1901 indicates
temperature of VGO at radiation zone I/L.TI1906 indicates the temperature in DCS of VGO of
pass -1 at heater outlet. Hot VGO enters a common manifold of 8” size before entering Reactor.
A corrosion probe and indicator is also provided on this line.
TIC 1911 and TI1912 indicate combined Final COT of the VGO. This Final COT of common
transfer line is controlled by the TIC1911 which regulates quantity of fuel to the furnace.
Typical values are 3850C (ID). 4230C (2D) and 3260C (IN)
Emergency coil MP steam connection are given in each pass on downstream of pass flow
control valves to displace VGO from the coil to the column during any emergency or after
normal shut down operation.
Soot blowers, using MP steam are provided in convection zone of the heater.

CONFIGURATION
Plant Name: FCCU-I
Emergency steam, soot blower steam, and decoking steam connections are taken from 6” MP
steam header. FI1905 and FI1906 indicate decoking steam flow to individual passes.
LP steam/Snuffing steam (furnace purging steam) is connected to convection zone and heater
box in order to extinguish Fire by steam blanketing in case of emergency. LP steam is used for
this purpose. At a safe distance of at least 15 meters from heater, Take off valves are provided..
6.0.4 Fuel System
4F-051 is natural draft furnace. Both the convection and radiation sections are used for heating
VGO. The combustion chamber houses the radiation section of the tubes. The convection
section provided at the top of radiation section serves to increase the thermal efficiency of the
furnace by utilizing further heat from the flue gas.
04F-51 is a dual fired furnace i.e, either fuel oil or fuel gas or both can be used.
a) Fuel Gas System
Fuel gas from fuel Gas KOD is supplied by a 10” header. This FG line is steam traced to avoid
condensation of heavier components. To arrest carryover of foreign particles like rust etc., a
40 mesh strainer is provided on the FG header. A shut down valve SDV1903 is provided on
FG to heater. This SDV is connected to interlock logic. FI1911 indicates FG flow in DCS. A
local PI and a TI are provided to indicate pressure and temperature at field.
PI1923 indicates FG pressure. If fuel gas tip pressure falls below the set valve of PALL1926
chances of flame failure and subsequent accumulation of unburnt hydrocarbons in the fire box
is possible. Low pressure alarm PALL1926 is connected to interlock and trips the furnace by
cutting off FG firing to the, heater. This can lead to the possibility of explosion or back fire in
the heater. Actuation of PSLL1926 shuts SDV1903.
Fuel gas pressure and hence flow to burners is controlled by PIC1901. PIC1901 regulates
PV1901 on FG line. PIC can be cascaded to COT TIC1911 through a selector switch SS-1904.
Minimum stop limit to PV1901 has been considered to avoid full closure of the valve due to
signal from TIC1911.
A 1” FG tapping upstream of SDV1903 has been branched off for pilot burners. This line has
a local PI that will aid in adjustment of fires. PI1920 is provided in DCS to monitor pilot gas
pressure.

CONFIGURATION
Plant Name: FCCU-I
b) Fuel Oil System
Fuel oil from battery limit is supplied by a 6” header. FO line is steam traced to maintain
temperature and avoid congealing.
Flow indicator FI1910 is provided on main FO supply line and FI1907 is provided on the main
FO return line from heater. Since this is a closed circuit through which FO circulation is
maintained, the net consumption of fuel oil is measured as the difference between the two by
FDI1910. FDI has the facility of recorder and totalizer. Fuel oil supply line has a 100 mesh
strainer. Shut down valve SDV1902 and SDV1901 are provided on supply and return header
respectively. Pressure is maintained by PV1902 on FO supply line. PV1902 has minimum limit
stop to avid full closure of the valve. A low pressure trip alarm PALL1913 has been provided
on supply line. Actuation of this alarm shuts SDV–1902 and cuts off fuel firing to the Furnace.
Since FO is normally a thick heavy liquid it needs to be always maintained in circulating state.
If it is left stagnant and unused in burners and piping, it can congeal despite the fact that tracing
steam of the FO circuit is on.
Circulation in heater area (FO piping forming a closed circuit across all passes called fuel oil
ring) is maintained even when no fuel oil burner is in use. A ratio of 2:1 FO consumption to
return is normally maintained to obtain a good control on firing and prevent congealing of FO
system. FO is drawn by individual burners through 3/4” lines from header and balance quantity
is sent to return line. When there is no need of FO firing in the heater, the circulation can be
maintained outside the furnace, through a 2” bypass line called Ring bypass.
Purge steam connections are provided on each oil burner. Pressure gauges are provided on FO
and atomizing steam line of each burner. FO burners are to be kept steam purged when idle.
When FO is fired, it is atomized or sprayed as a fine mist for realizing complete combustion.
The spraying of FO is done by de-superheated MP steam in FO burners. Atomizing steam is
supplied to heater through a 3” header. Atomizing steam pressure is controlled by differential
pressure controller DP IC1901 taking pressure signal from FO supply and MP steam
simultaneously. Atomizing steam pressure is maintained about 1.0-1.5kg/cm2 above FO
pressure. Atomizing steam pressure/flow-is measured by PL1918/ FI1913. Local PT and TI
also provided in this line. To arrest carryover of foreign particles a 100 mesh strainer is
provided on the line.

CONFIGURATION
Plant Name: FCCU-I
1 1/2” flushing oil connection is provided on FO supply line upstream and CBD/OWS drain is
provided on FO return line to flush the line within Battery Limit after heater shutdown.
6.0.5 Steam Superheater Coils & Generation System
The heat carried out by flue gas is used to super heat MP steam.
MP steam from 4E057 & 4E056 is carried through 10” header. 8” line with double block has
been provided for bypassing if necessary. Local PI & TI provided for monitoring pressure &
temperature in field at the inlet of heater coil. Steam generated from steam drum 4V063 also
joins at the heater inlet coil.
Inside the heater 2 banks of coils are provided to superheat. At the outlet of heater PI1906 &
TI1910 are provided to monitor pressure and temperature in DCS. PSV1901/1902 are provided
on the heater coil.
In case steam has to be vented to atmosphere steam silencer (4X-061) is provided. For further
recovery of heat from flue gas, steam generation system is provided.
BFW supply is controlled by FV1951. BFW can be preheated by two ways. This can be
directly routed through the economizer coils (2”) by which it will preheat & enter into the steam
drum (4V63). TSV1951 is provided on this line. PI1962 & TI1963 will indicate pressure &
temperature at heater outlet. BFW can also be routed through the coil, steam drum & then
through the economizer coil. Steam drum heater coil outlet is provided with TSV1952. PI1965
& TI1964 will indicate the pressure & temperature of BFW at drum outlet.
This preheated BFW will inter the steam drum from bottom. BFW is heated by down comer &
riser assembly. Two circulation lines (4” & 3”) are provided for better heat recovery. 4” line is
provided at lower elevation for higher heat recovery from higher temperature of flue gas. 3”
line is at upper elevation than 4”. Both the circulation lines are branched into 14 tubes of 2”
size inside the heater.
Steam generated from steam drum passes through the demister pad in the steam drum to catch
the water entrainment in the steam. Steam drum pressure will be controlled by PC1951. PT-
1951 is provided with High & low pressure alarm. Steam flow is measured by FT-1953.
Drum is provided with PSV1951/1952 to protect from overpressure. TI1965 gives the drum
temperature High & low of drum temperature is provided. Silencer 4X-059 is provided on
steam vent line.

CONFIGURATION
Plant Name: FCCU-I
2” blow down line provided with FT-1953 to maintain blow down of steam drum.
6.0.6 Steam Air Decoking System
STEAM AIR DECOKING (SAD) of feed heater tubes is done to remove coke deposit from
inside heater tubes with the help of steam and air. Removal of coke results in clean heater tube
internals and improves heater performance by better heat transfer to process fluid. SAD also
achieved\s low pressure drop through heater tubes and reduces chances of hot spot on heater
tubes.
Need for SAD of heater tubes is indicated by increased pressure drop and harder firing.
This dedicated (SAD) arrangement comprises of decoking drum (04V058). Piping and
instrumentation for plant air, Service water and MP steam. MP steam, connection to each pass
flow is provided to dislodge carbon deposit from inside the heater tubes. Plant air is required
to ignite the remaining coke film deposit clinging inner wall of tubes and achieve final cleaning.
Local and DCS mounted flow indication FI1909 are provided on main 3” plant air header.
FI1909 indicates total plant air consumption during decoking operation.
Service water quench provision is give on 4V058 to quench the contents before letting out to
atmosphere.
To carry out SAD, pass flow inlet and outlet of the furnace 4F-051 are isolated from process
network and connected by means of swing elbows with the decoking network. Heater pass flow
outlets are connected to the decoking pot 4V058. While MP steam is introduced in the tubes it
is fired from outside. Thermal shock caused by the flame cracks the coke scales inside the tubes
and flowing steam dislodge them. These are carried to 4V058 after being quenched in the
decoking pot by service water. When no more coke is removable as indicated by relatively
clear color of effluent, air along with steam is introduced into pass flow to burn out the coke
inside tube while firing is on in the heater. Oxygen burns coke at high temperature. Burning of
the coke is indicated by increased tube metal temperature.
A relatively new technology, Pigging of heater tubes was done in last two T&Is.
6.0.7 Heater Interlocks
Following safety interlocks are provided to trip the furnace in case of any emergency.
1. At low FG pressure to heater, 4SDV1903 will close. Initiator: 4PLL1926. Trip Value:
0.3kgf/cm2.
CONFIGURATION
Plant Name: FCCU-I
2. At low FO pressure, 4SDV1902 and 4SDV1901 on supply and return header respectively
are closed: Initiator: PALL1913 Trip Value: 2.77 kg/cm2.
3. At less VGO flow through any of individual passes, Fuel to heater will be cut off.
4SDV1903 on FG to heater ,4SDV1902 and 4SDV1901 on supply and return header
respectively are closed
Initiators: 4FLL1903 on Pass 1 and 4FLL1904 on Pass 2. Trip Value: 50m3/hr..
4. Actuation of emergency push button shall stop FO/FG to heater.
5. Stack damper shall open in case draught inside the furnace becomes low i.e. high pressure
in furnace arch (PSH-1963).
However, during tripping of furnace pilot gas shall remain unaffected.
6.1 Reactor
6.1.1 Reactor Feed System
There are four potential sources of feed to the FCCU-I Reactor as follows:
Vacuum Gas Oil (VGO) from the vacuum distillation unit.
Vacuum Residue (VR) from the vacuum distillation unit.
Heavy Cycle Oil (HCO) Recycle from the FCCU-I primary fractionator.
Fractionator Bottoms Recycle from the FCCU-I fractionator slurry circuit.
The flow rate of the feed to the Reactor, is measured by FI501. Provision is made to either
manually or or automatically divert the total Reactor feed back to the FCCU-I Main fractionator
during startup or emergency conditions.
Fractionator Bottoms Recycle is fed normally through a dedicated Reactor feed nozzle with its
flow rate controlled via FC504. This dedicated nozzle reduces the potential for coking/fouling
of the main feed nozzles due to incompatibility between the bottoms recycle and the other feed
components. However, provision has been made to divert the bottoms recycle to the main feed
nozzles as a backup to the normal routing.
FCCU-I Reactor can actually be considered to consist of three sections:
The feed nozzles and feed riser section external to the Reactor vessel.
The upper section of the Reactor, 4D-2X, consists of the inner section of the feed riser
and three pairs of internal cyclones which are close coupled to the feed riser

CONFIGURATION
Plant Name: FCCU-I
termination. The external and internal feed riser sections comprise the actual
“Reactor” in which essentially all conversion takes place.
The bottom section of the Reactor vessel contains the spent catalyst stripper. The
stripper contains 15 shed rows to promote contact between the catalyst and the
stripping steam. Steam enters via spargers located under the shed rows.
The various Reactor sections function to provide the following:
Contact of the oil feed with the regenerated catalyst.

Sufficient contact time with the catalyst in the external and internal sections of the
riser to yield the desired products.
Separation of the converted oil from the spent catalyst via two stage cyclones
contained within the Reactor vessel.
Steam stripping to remove oil vapor and oil from spent cat surface.
6.2.1 Feed Zone
In the Reactor feed zone the total feed (VGO and VR) is injected into the external riser via six
M/S KBR proprietary feed nozzles. Feed distribution to the individual feed nozzles depends
upon the symmetrical layout specified as part of the design. Flow will distribute to balance the
pressure drop through each parallel feed nozzle circuit, although provision was made for some
balancing via the feed globe valves.
Steam is injected into the feed upstream of each nozzle to atomize of the feed within the nozzle.
The total feed injection steam is controlled via FC13X. Feed injection steam is distributed to
the individual feed nozzles by the restriction orifices provided. If a nozzle is removed from
service, steam flow is maintained through the steam purge restriction orifice to prevent
plugging.
A dedicated feed nozzle is provided for the Fractionators Bottoms Recycle feed which is
controlled via FC504. Similar to the total feed nozzles described above, steam (controlled via
FC508) is injected upstream of the nozzle to promote atomization within the nozzle.
Feed contacts hot regenerated catalyst in the riser. To ensure an even distribution of catalyst to
the feed zone and to minimize catalyst back- mixing, Fluffing Steam is injected into the riser a
short distance below the feed zone (at the top of the regenerated catalyst angle riser). Fluffing
steam is injected via the same nozzle that is used to route emergency steam to the riser. The
Fluffing Steam is injected at a constant rate controlled by the restriction orifice in the by the
CONFIGURATION
Plant Name: FCCU-I
restriction orifice in the bypass around the emergency steam valve, HCV504. The Fluffing
Steam flow also functions to purge the emergency steam nozzle to keep the attached piping
cool and to avoid plugging.
Provision exist to inject naphtha or other quench stock into the feed zone to control riser
temperature during start-up or other situations as needed. Quench flow is controlled by FC503
and the quench has been provided to two of the total feed nozzles. When required, one or both
of these nozzles can be dedicated to quench service. Injection steam is maintained as in normal
feed service.
6.2.2 Reaction Zone
As the feed contacts the hot regenerated catalyst, it vaporizes and cracks. The vaporized oil,
feed injection steam and cracked products provide the lift to carry the catalyst up the feed riser.
The first section of the riser is a shallow angle cone connecting the feed zone and the increased
diameter required in the upper riser section to handle the higher vapor rate resulting from
cracking the feed. The shallow angle cone provides a smooth transition that avoids areas of
deceleration that can result in back mixing and lead to a loss of conversion selectivity. The
cracking reactions are completed as the feed/catalyst mixture moves up the external and
internal sections of the feed riser.
SCT technology minimizes the thermal and non-selective cracking reactions in the reactor
dilute phase by separating the catalyst from vapors in close coupled cyclones. Three parallel
close coupled sets of two stage cyclones are used for catalyst separation from hydrocarbon
vapors in Reactor.
6.2.3 Catalyst Recovery
Spent catalyst is separated from the reactor effluent in the two stage cyclones. Vapor enters the
cyclones from riser via a transfer tunnel and catalyst is rapidly separated to prevent undesirable
thermal and non-selective cracking reactions. The vapor enters the primary cyclones
tangentially in a horizontal direction. This separates dense catalyst from hydrocarbon vapors.
The vapor to the secondary cyclone still contains some catalyst of smaller particle size. Most
of the remaining catalyst is removed here. The relatively catalyst-free vapor then exits into
plenum chamber and from there to fractionator via the Reactor overhead line.
Catalyst separated in both cyclone stages falls through cyclone dip legs to Reactor stripping
section. The cyclone dip legs allow a column of catalyst to build–up, which provides the
necessary static head for the catalyst to enter the stripping zone. The trickle valves at the bottom

CONFIGURATION
Plant Name: FCCU-I
of the dip legs prevent bypassing of the cyclones during an upset by sealing the cyclone dip
legs so that vapor cannot flow up the dip legs which would result in increased catalyst losses.
The section of the Reactor above the primary cyclone inlets is sealed off by an anti-coking
baffle. The purpose of the baffle is to prevent coke formation in the area between the primary
cyclone inlet and the plenum chamber. The zone above the anti-coking baffle is purged by
steam which is first superheated in the Reactor as it flows through its supply line within the
vessel. The purge steam rate is constant and is set by a restriction orifice. It discharges above
the anti-coking baffle and purges the dead space, eventually flowing out and into the reactor
products via the gaps which exist in the baffle. The area between the anti-coking baffle and top
of the feed riser is another stagnant area in which coking could occur. A similar purge steam
connection is provided for this area.
6.2.4 Spent catalyst Stripper
Coke is deposited on the surface of the catalyst during cracking operation. The catalyst is
regenerated in Regenerator where the coke is burned off. Before spent cat enters regenerator,
valuable strippable hydrocarbons (which consist of liquid adsorbed on the surface and vapor
trapped within the catalyst pores/void spaces between particles) be removed from the spent
catalyst and recovered as product. Both forms are removed by stripping with steam in the
Reactor Stripping section.
Spent catalyst flows downward over 8 layers of MODGRIDs (shed rows were replaced with
MODGRIDS during T&I in 2016) which promote contacting between the catalyst and stripping
steam. Steam enters through steam distributor from the bottom. Stripping steam rate is set via
FC 505 with even distribution via the restriction orifices in the individual supply lines. As the
steam flows counter-current to the catalyst, strippable hydrocarbons are removed.
Stripper level is not directly controlled and depends upon the catalyst inventory within
the Reactor/Regenerator system. Regenerator inventory changes due to air rate adjustment
will be reflected in the stripper level. It is generally desirable to operate the stripper with both
dilute phase and dense phase stripping zones. The unit is designed for maintaining stripper
level at 75% full. The top dilute phase zone promotes rapid removal of hydrocarbon vapor from
the space surrounding the catalyst. This maximizes the steam partial pressure in the lower dense
phase stripping zone, promoting desorption of the liquid hydrocarbon adsorbed on the catalyst
surface.

CONFIGURATION
Plant Name: FCCU-I
6.2.5 Reactor Temperature and Pressure Control
Depending upon the Regenerator operation (partial or full burn), reactor temperature is
controlled by adjusting either the feed temperature for partial burn regeneration or the catalyst
circulation rate for full burn regeneration. Feed temperature is normally controlled by adjusting
firing in the preheat furnace. Catalyst circulation is controlled by the Reactor/Regenerator
pressure differential controller, PDC501.
Reactor pressure is not directly controlled. It will be set by the pressure controller at the suction
of the gas compressor. It can be varied by adjusting the set point of the compressor suction
pressure controller.
6.3 Regenerator And Associated Facilities
The function of the Regenerator, 4D -1X, is to restore catalyst activity lost during the cracking
reactions. It provides the heat required for feed vaporization, initiating and sustaining the
endothermic cracking reaction in the feed riser. Restoration of catalyst activity is accomplished
by burning off the coke and any un strippable hydrocarbon.
Complete removal of the coke from the catalyst is not possible because some is deposited deep
in the catalyst pores, and coke burning is never 100% efficient in commercial units. The trapped
coke on catalyst pores cannot be removed because of inefficiency in combustion. The
combustible coke should be kept as low as possible. Most of the heat released during
regeneration is absorbed by the catalyst and is then transferred to the Reactor to supply heat for
feed vaporization and the cracking reactions.
Catalyst enters the Regenerator via the spent cat riser which projects into the dense catalyst bed
a short distance above the grid. A flat circular plate located above the termination of the spent
catalyst riser acts to deflect and distribute the spent catalyst in the dense bed. The catalyst
leaves the Regenerator through an overflow well located diametrically opposite the spent cat
riser. Hence Regenerator level is not controlled and remains constant at the top of the overflow
well. The inventory of catalyst in the Regenerator can change with changes in air flow to 4D-
1X. The change in Regenerator inventory will affect the reactor stripping section level, since
the Regenerator bed level is maintained by the overflow well. The overflow well is tapered to
promote vapor disengaging from the regenerated catalyst, and extends downward to join the
RCSP before passing through the grid.
There are a number of factors which affect Regenerator performance as measured by the
percent carbon remaining on the regenerated catalyst. This residual Carbon on Regenerated

CONFIGURATION
Plant Name: FCCU-I
Catalyst (RCC) level will influence reactor conversion and coke yield. Low RCC is desirable
and attainable with efficient Regenerator performance. Many of the factors influencing
regeneration efficiency are not controllable variables. These include dense bed holdup,
operating pressure, and contacting efficiency.
The FCCU-1 Regenerator is designed to operate in a High Temperature Regeneration (HTR)

mode. Although Regenerator temperature is not directly controlled as discussed later, unit
operations should be adjusted to maintain temperatures in the range of 675 to 7300C. (Note
that although the design temperature of the Regenerator internals is 7600C, the operating
temperature should be limited 7300C to prevent deactivation of the catalyst).
This HTR Operating regime minimizes RCC, thus helps to maintain catalyst activity and avoid
carbon buildup. It promotes CO combustion within the bed, avoiding “afterburning” or CO
combustion in the dilute phase, which can lead to very high temperature causing mechanical
damage. The lower end of the range is set by CO combustion kinetics, while the upper limit is
set by catalyst deactivating considerations. RCC levels of 0.05 to 0.20 wt% can be expected
over the HTR operating temperature(high to low end) range, depending on the mode of HTR
regeneration (that is, full or partial burn).
With High Temperature Regeneration, the Regenerator may be operated in either a “partial
burn” or “full burn” mode. In a full burn operation, sufficient oxygen is available to completely
combust the coke to carbon dioxide. The Regenerator typically operates with a minimum of 1
vol. % excess oxygen in the full burn mode, and the carbon monoxide concentration is less
than 500 ppm. In a partial burn mode operation, insufficient oxygen is available to burn all of
the coke to carbon dioxide and the flue gas carbon monoxide content can be in the range of 2
to 12 vol. %
FCCU-1 was designed to normally operate in a partial burn operating mode. In this mode,
regenerator bed temperatures are in the range 675 to 7300C. The use of CO combustion
promoter is required in the range 675 to 7000C during afterburning. CO combustion promoter
is a catalyst additive that increases the rate of CO to CO2 combustion within the regenerator
dense bed. COP enhances the combustion of CO at reduced temperatures. All excess oxygen
is consumed within the dense bed, and CO concentration in the flue gas can range from about
1-2% (just short of complete CO-combustion) to levels as high as 10-20%. Typical RCC for
the partial burn mode is 0.10 to 0.20 wt% slightly higher than for full burn due to the depletion
of available 02 within the dense bed. Other features of the partial burn are:
Oxygen is used more efficiently. It is used where coke production is a primary limitation
like processing more feed at an air constraint or processing heavier feed.
CONFIGURATION
Plant Name: FCCU-I
Some heat can be “exported” in the form of CO for combustion in the CO Furnace.
CO content can vary over a wide range, 1-2% min, to 10-12% max. permitting a wide
range of heat balance.
RCC will be slightly higher than in a full burn operation. Higher coke production
compared to full burn.
FCCU-1 can also operate in a full burn operating mode if CO boiler is shut down. As
mentioned, in the full burn regeneration mode, sufficient air is supplied to achieve complete
combustion of carbon to CO2. Regeneration temperatures must be above 675 to 7300C so that
complete combustion occurs in the regenerator bed. As in partial burn regeneration, CO
combustion promoters may be required if the regenerator temperature drops below
7000C.Typical RCC level for full burn operation is 0.05wt%. Other features full burn is:
The total heat of complete combustion of coke must be absorbed in the process. Coke
yield must be relatively low to avoid problems absorbing all the heat produced.
The regeneration process is essentially insensitive to changes in excess oxygen
CO concentration in the flue gas will be extremely low.
Full burn is less air efficient. RCC levels are very low (0.05wt %), since excess 02 has
an efficiency effect on burning carbon off the catalyst.
6.3.1Afterburning
Afterburning in the Regenerator dilute phase can be identified by a temperature rise between
the bed and the primary cyclone inlets, or between the bed and the secondary cyclone outlets.
After burning does not normally occur above 7000C. However, if the temperature drops
below 7000C without promoter or below 6750C with promoter, CO combustion can move
from the dense to the dilute phase resulting in afterburning. If promoter is not being used and
temperature is high enough, addition of CO combustion promoter may eliminate the
afterburning. If promoter is being used and afterburning is present, operating changes to
increase the dense bed temperature are needed.
6.3.2Catalyst Recovery
The flue gas in regenerator carries entrained catalyst out of the dense bed. This catalyst must
be removed before the flue gas exits the Regenerator vessel. Catalyst is recovered in six parallel
pairs of two stage cyclones.
The flue gas rises through the Regenerator dilute phase and enters the primary cyclones
tangentially in a horizontal direction. The entrained catalyst is separated from the flue gas in
CONFIGURATION
Plant Name: FCCU-I
the two stages cyclones. The catalyst falls on the dense bed through the cyclone dip legs and
trickle valves and the flue gas passes through a plenum through the Regen overhead line to the
CO boiler or atmosphere.
6.3.3 Air Supply
Air is first used as control air in the spent cat riser to promote catalyst circulation from the
Reactor stripping section to the Regenerator. This control air is then utilized for carbon burning
in the Regenerator.
The Main Air Bower, 4K-1X,is a steam turbine driven centrifugal compressor and the Control
Air Blower, 4K-2X, is motor driven. The control air rate is set by FC2X and will be determined
by catalyst circulation considerations as discussed later in this section.
Total air rate to the Regenerator is set by FC516. This will control the speed of MAB turbine.
During normal operation, entire air can be supplied to the Regenerator through secondary air
header. Normally both the primary and secondary lines to APH can be used. Air flow is
balanced between the primary and secondary air lines by the manually operated butterfly
valves.
Note that during the firing of the Air Preheater, primary air flow rate must be adjusted
to achieve 100% excess air firing to prevent excessive temperatures which would damage
the combustion zone.
Air sent directly to the Regenerator flows through the Air Preheater and is then distributed to
the dense bed by a flat grid with a multitude of holes. A shroud (velocity reducer) is provided
for the exit of each grid hole to reduce the velocity of the air so as to avoid erosion and catalyst
attrition.
6.3.4 Torch Oil System
Additional heat may be required to keep the unit in heat balance than that is provided by feed
preheat and carbon burning during startup, shutdown or normal operation. This heat is supplied
by torch oil injected into the Regenerator dense bed through two retractable flat pattern spray
nozzles.
The torch oil sprays extend a short distance into the dense bed about 600 mm above the grid,
and are located 1800C apart. The oil is ignited by the hot catalyst in the presence of the
combustion air.

CONFIGURATION
Plant Name: FCCU-I
Torch oil rate is set by FC4X which is a split range controller. When the torch oil flow rate set
point is increased from zero, the split range controller first fully opens FC4XB, which provides
atomizing steam to the torch oil nozzles. When the controller output reaches 50% of its full
range, FC4XA begins to open and torch oil flow starts. The atomizing steam helps to convert
the torch oil into small droplets to ensure efficient burning. When the torch oil nozzles are not
in service, both the spray tip and the annular space around the tip are purged with steam for
cooling and to avoid plugging with catalyst. A TI point is provided above each torch oil nozzle
to help detect ignition.
6.3.5 Air Preheater
The Air Preheater, 4F-1, is integrally attached to the bottom of the Regenerator vessel. The
preheater is used to heat the Regenerator prior to catalyst addition, and to raise the dense bed
temperature during catalyst loading prior to using torch oil combustion to supply heat. It is used
in refractory dry out of RR during the initial startup of the revamped unit or after subsequent
turnarounds. Air from the Main Air Blower enters the Air Preheater through the primary and
secondary air connections. The preheated air then exits the preheater past a deflector cap before
entering the dense bed via the grid. The deflector cap helps to prevent catalyst from dropping
into the preheater and helps to distribute the air uniformly under the grid. It also helps to avoid
local overheating of the grid.
6.3.6 Regenerator Temperature/Pressure Control
Regenerator temperature is not directly controlled, but will equilibrate at a level set by the unit
heat and carbon balance. However, unit conditions must be set or adjusted to ensure that the
Regenerator operates in the High Temperature Regeneration (HTR) mode with dense bed
temperature between 675 and 7300C. Maintaining the Regenerator temperature within this
range ensures CO combustion within the limits of the combustion air rate. This temperature
range also minimizes afterburning in the dilute phase. The use of COP will enhance the
combustion of CO within the Regenerator bed at reduced temperatures.
Regenerator pressure is also not directly controlled. The Regenerator will operate at a fixed
differential from the Reactor as determined by the set point of Reactor/Regenerator pressure
differential controller, PDC501. The set point of this controller will manipulate the catalyst

CONFIGURATION
Plant Name: FCCU-I
circulation rate between the Reactor and Regenerator. See the discussion of catalyst circulation
which follows.
6.4 Catalyst Circulation
Operation of the fluid catalytic cracking process takes advantage of the properties of fluid.
Catalyst in a fluidized state behaves much like a liquid, and builds up a static head proportional
to its density and height. The density of the fluidized catalyst depends upon the relative
proportion of gas and solid at any particular point.
The basic principle of circulation control is that pressure buildup in dense beds and standpipes
provides the driving force for catalyst flow, while density reduction in up flow lines reduces
the resistance to that flow. In the standpipes, very little aeration is provided to offset the
compression effect and maintain an essentially constant density. A high density results in
pressure buildup. In the reactor riser and the spent catalyst riser, there is much more aeration
from the reaction products and control air resulting in a low density and low static head, though
velocity and frictional head can be substantial. Other changes such as in elevation of beds and
in pressure drop across slide valves can be used to more finely to ‘adjust the basic pressure
balance. FCCU-1 does not utilize slide valves for pressure balance control and relies solely on
pressure and density differences to control catalyst circulation.
6.4.1 Catalyst Circulation Overview
There are two catalyst circulation circuits in the unit:

Regenerated Catalyst And
Spent Catalyst Circuit.
The spent catalyst circulation rate is directly controlled and the unit is designed such that
regenerated catalyst circulation rate equals the spent catalyst circulation rate.
The fluidized catalyst in the stripper is relatively dense and pressure increases from the top to
bottom of the stripper. Stripper bottom connects to the spent catalyst transfer line. Below the
stripper is a short vertical section of line called the spent catalyst standpipe. A small amount of
aeration steam is added to the catalyst within the standpipe to maintain it in a fluidized state.
This aeration steam offsets the compression of the gas volume between particles as the pressure
increases over the vertical height from the top of the stripper.
If aeration steam is inadequate, catalyst can become de-fluidized and bridge the standpipe,
resulting in stoppage of catalyst flow. If the standpipe is over-aerated, several results are

CONFIGURATION
Plant Name: FCCU-I
possible. The first is potential loss of pressure buildup because catalyst density is too low. The
second is bubble growth as the catalyst flows downward in the standpipe, culminating in the
formation of a large “stable” bubble in the line. This bubble presents a restriction to catalyst
flow. Therefore, it is important that the proper amount of aeration gas be added.
Spent catalyst standpipe aeration steam injection rates are controlled by a restriction orifice in
the line supplying each aeration point. The steam supply is controlled by PC505. The pressure
must be maintained high enough so that critical flow is maintained over all of the orifices,
making the flow insensitive to the vertical elevation of the aeration point or to pressure changes
in the transfer line.
As with the spent catalyst standpipe control of the angle riser aeration steam rate is important,
and restriction orifices are provided in the line to each aeration point and the steam is pressure
controlled via PC507.
The top of the spent catalyst angle riser connects to the vertical riser. Control air is injected at
the bottom of the spent cat riser via a torroidal header with five individual injection points. The
control air rate is set via FC2X. The amount of control air determines the density in the spent
catalyst vertical riser: increasing the air rate decreases the density of the circulating catalyst
stream and vice versa. Control air rate is generally set and is not used to change the catalyst
circulation rate. With the control Air rate set, the primary control of catalyst circulation will be
the differential pressure between the Reactor and Regenerator.
Spent catalyst regenerated by burning off the coke in regenerator. The combustion air also acts
to maintain the catalyst in a fluidized liquid–like state. An overflow well is provided in the
Regenerator into which the regenerated catalyst flows. This overflow well maintains a constant
holdup volume of catalyst in the Regenerator. This requires that regenerated catalyst flow out
of the Regenerator is equal to the spent catalyst flows in. Therefore Spent catalyst circulation
rate establishes the overall catalyst circulation rate in the unit.
The overflow well is tapered to permit disengaging any entrained gas and connects to the RCSP
before passing through the Regenerator grid. The RCSP serves the same function as the spent
catalyst standpipe in allowing pressure to increase in the vertical down flow leg. Instrument air
is used to aerate the standpipe above the slide valve in order to avoid the possibility of steam
condensation and “mud” formation during startup when catalyst is stagnant in the standpipe
before establishing circulation. Aeration air is controlled by restriction orifices and PC508.
Steam aeration is used below the slide valve.

CONFIGURATION
Plant Name: FCCU-I
The horizontal connection between the RCSP and the vertical feed riser is provided by another
J-bend and angle riser. Aeration steam is added to the bottom of the angle riser through
restriction orifices and PC506. The feed riser connects to the top of the regenerated catalyst
angle riser. Feed injection and vaporization /cracking provides the vapor which decreases the
density in the feed riser. Thus, Catalyst is circulated from the dense leg in the RCSP to the
lower density riser.
The level in the RCSP will settle at a point which satisfies the pressure balance between the
two vessels. It will rise with increases in catalyst circulation rare and vice versa. The level must
be below the top of the overflow well to ensure aerated catalyst flow rates are equal. If the
overflow well is full, the unit will not respond as normal to changes in the Reactor/ Regenerator
differential pressure. It must also be sufficiently high (protection is provided by a low level
cutout, LL (CO) 503, to avoid loss of the catalyst seal between the Reactor and Regenerator).
A typical overflow well operating range is 60 to 75 %.
6.4.2 Main Parameters Affecting Catalyst Circulation
Although catalyst circulation rate is a very significant variable affecting FCCU-1 performance,
there is no direct means of measuring the rate. The catalyst circulation rate is calculated based
on a Regenerator heat balance. A key input to the heat balance is the flue gas analysis. Having
a calculated value of catalyst circulation rate, will be valuable for confirmation of the effect of
changes made in unit controls. Also, Reactor riser pressure drop is a good indicator of changes
in circulation rate. If feed, and steam rates (feed injection and aeration) are constant, an
increase in the pressure differential over the feed riser indicates an increase in circulation rate.
Spent catalyst circulation rate is affected by changes in the pressure balance which adjust the
driving force on the spent catalyst standpipe (SCSP). As RR DP increases, catalyst circulation
rate increases and vice versa. Regenerated catalyst circulation rate follows, with the level in
the RCSP rising or falling to accommodate the change in circulation rate.
There are three main parameters which can be manipulated to adjust catalyst circulation rate in
FCCU-1. These, are differential pressure, control air and Reactor stripper holdup. Each is
discussed below.
Differential pressure: The primary means of controlling catalyst circulation rate in FCCU-1
is to change the pressure difference between the Reactor and Regenerator dilute phases by
adjusting PDC501. For any given operation, Reactor pressure will be relatively constant as set
by the pressure controller on the suction of fractionator overhead gas compressor and the
pressure drop back to the Reactor. Therefore, differential pressure is changed by increasing or

CONFIGURATION
Plant Name: FCCU-I
decreasing Regenerator pressure via adjustments to the position of the slide valve in the
Regenerator overhead line.
Control Air Rate: The control air rate is normally set (via FC2X) and maintained constant
for any particular operation However, control air rate may require adjustment to keep the
regenerated catalyst overflow well level in a safe and operable range (typically 50 to75%).
Increase in circulation rate can be achieved by increasing the control air rate (which reduces
resistance to catalyst flow in the spent cat riser) and decreasing the unit differential pressure to
lower the overflow well level.
Reactor Stripper Bed holdup: An increase in Reactor stripper bed holdup has the same effect
as increasing the Reactor/Regenerator differential pressure. It increases the driving force on the
spent catalyst stand pipe, thereby increasing spent catalyst circulation. Since the Regenerator
dense bed volume is constant, the stripper bed will reflect changes in unit inventory. Catalyst
inventory can change via catalyst addition or withdrawal or due to changes in air rate to the
Regenerator which affects the density of the Regenerator bed. Also, as mentioned in Section
6.2.4 above, the desired stripper bed level should reflect the need to optimize stripping
efficiency by maintaining both dilute and dense phase stripping zones. With the other issues
influencing stripper bed level it can be inferred that it is a variable that is not readily available
for catalyst circulation control. However .its influence on the circulation rate should be
understood and the level maintained to balance all of the above considerations.
6.4.3 Aeration
Circulation control and stability also depends on the densities in the stand pipes, J-bends and
angle riser in both the spent and regenerated catalyst circuits. If these densities are unstable,
catalyst circulation will be unstable. Aeration rates are controlled and adjusted primarily to
ensure stable catalyst circulation, not to control circulation rate.
Aeration rates are changed only when gross changes in circulation are required. Once a stable
operating region is found they are kept relatively constant. Aeration rates are adjusted by
changing the set point of the corresponding aeration header pressure controller. A lower header
pressure gives less aeration and vice versa. The header pressure should be above the critical
pressure drop across the restriction orifices so as to keep a good, steady flow to all the orifices.
6.4.4 Catalyst Particle Size
Another factor affecting catalyst circulation is catalyst particle size distribution. Increases in
the proportion of small particles (40 microns and less) relative to larger particles (80 microns
and greater) will make the catalyst easier to circulate. An increase in heavier particles results

CONFIGURATION
Plant Name: FCCU-I
in a coarser catalyst which is more difficult to fluidize and may cause unstable circulation.
Changes in particle size may require changes to aeration rates, with larger, coarser catalyst
requiring more aeration.
6.4.5 Blast and Emergency Steam
Blast steam connections are provided at the bottom of both the spent and regenerated catalyst
J-bends and at the top of the spent catalyst angle riser. Blast steam is not required in normal
operation and its use is discouraged as it may upset catalyst circulation and promote erosion
and catalyst attrition. However, its use may be justified during startup to initiate circulation and
during special circumstances to address short term catalyst circulation problems.
An emergency steam connection is provided at the bottom of the feed riser. It will be
automatically cut-in during activation of any emergency system when feed is removed to clear
the riser of catalyst. It will be utilized during startup or feed reintroduction by adjusting
HCV504 to provide “lift” to initiate catalyst circulation. Emergency steam is not needed during
normal operation and its use is discouraged.
6.5 Unit Process Control Strategies
The Reactor and Regenerator must be simultaneously heat and carbon balanced for the unit to
operate in a stable manner. The following subsections briefly describe how heat balance and
carbon balance are monitored and controlled. The description will include both HTR operations
for the Regenerator: partial CO combustion and full bum. Note that the FCCU-1 controls have
been designed basing upon partial burn operation as the normal operating mode. For the
backup full burn mode either operator intervention or reconfiguration of some control loops
will be required to implement the control schemes discussed below.
6.5.1 Components of Heat Balance
Heat required for the cracking reactions must be supplied by heat from burning coke in the
Regenerator, plus sensible heat in the feed from preheat. Heat is required in the unit for the
following:
Preheating and vaporizing the feed.
Providing the heat to crack the feed.
Heating reaction products and any un-cracked feed to reactor temperature.
Heating regenerator air/flue gas up to the flue gas exit temperature.
CONFIGURATION
Plant Name: FCCU-I
Supplying heat losses due to radiation and to any other external sources of heat removal
from the unit.
Heat is supplied by the following:
Combustion: Burning coke produced in the cracking process in the Regenerator. This
provides the majority of the total heat supplied.
Preheat: Provided by external facilities, such as heat exchangers and feed preheat
furnace. This represents a minor part of the total heat supplied.
Occasional burning of torch oil in the Regenerator to correct a temporary heat
imbalance.
Heat produced from burning coke in the Regenerator is transferred to the Reactor with the
catalyst circulating between the two vessels.
6.5.2 Components of Carbon Balance
The coke produced is generated during cracking of feed molecules in the process. It is inherent
to the feedstock quality (especially Conradson Carbon) or associated with high matrix activity
catalysts; it results from reactions promoted by metallic poisons (such as nickel and vanadium)
on the catalyst: and it results from unstripped hydrocarbons transferred from the Reactor to the
Regenerator with the catalyst.
For a stable unit, it is necessary that the total amount of coke produced in the cracking reactions
be almost exactly enough to provide the heat required to maintain those reactions. The
remaining heat must be provided by the feed preheat.
6.5.3 Heat Balance Indication
Theoretically, either reactor or regenerator temperature may be used as an indicator of heat

balance. However, Reactor temperature, is a better choice as it has a significant impact on
product yield pattern. It should be the primary heat balance control variable for both partial and
full burn HTR operations. Close control of reactor temperature will also result in steadier
operation of the fractionator and light ends units, and good economic performance of the
process. Regenerator temperature need not be a controlled variable, since it does not
substantially affect the product yield pattern.
6.5.4 Carbon Balance Indication

CONFIGURATION
Plant Name: FCCU-I
The objective of the carbon balance is to match carbon production in the Reactor with carbon
consumption in the Regenerator. Maintaining this balance avoids a serious buildup (greater
than 0.5 wt %) of carbon on regenerated catalyst.
The choice of optimum indicator for carbon balance depends upon the mode of regenerator
operation: partial or full CO burn. In partial CO burn mode of operation, carbon balance
changes are best indicated by changes in measured CO concentration in the flue gas. An
increase in carbon production, at a fixed air rate, will result in an increase in CO.
In full burn regeneration, all the carbon produced in the reactor is burned essentially
completely to CO2, with relatively high levels of oxygen remaining in the flue gas. Therefore,
excess oxygen should be used as the indicator of carbon balance in the full burn mode. At a
constant air rate, a decrease in excess oxygen will indicate an increase in carbon burning and
vice-versa.
Since continues CO analyzers may sometimes have questionable reliability, a secondary carbon
balance indicator is regenerator temperature. In partial CO burn mode of operation, an increase
in regenerator temperature will indicate a lower carbon production. Since the heat released by
burning carbon completely to CO2 is much greater than that produced by burning carbon to
CO, the regenerator temperature will rise.
In full burn mode, regenerator temperature varies directly with carbon production provided that
all other variables remain constant. Thus, an increase in regenerator temperature indicates that
more carbon has been produced and is being totally burned, with some of the excess oxygen
being consumed.
6.5.5 CO Combustion Promoter Activity Indication
In full burn operation the desired CO concentration in the flue gas is set by emissions
requirements (typically less than 500 vppm.) This level is generally achieved by using a CO
combustion promoter (which catalyzes the combustion of CO to CO2). During operation with
CO combustion promoter, the regenerator dilute phase temperature difference, i.e. the DT
between the dilute phase and the dense bed, can be used as an indicator of promoter activity.
At the normal level of promoter activity, dilute phase DT will typically be 10 to 550C, but will
remain stable, due to after burning in the dilute phase. Decrease in promoter activity is indicated
by an increase in dilute phase DT. The quantity and/ or frequency of CO combustion promoter
addition should be based on a periodic check of this variable. Catalyst vendors provide

CONFIGURATION
Plant Name: FCCU-I
information on the initial and maintenance doses required to promote CO combustion in the
regenerator bed.
Note that CO combustion promoter can cause increased NOx concentration in the flue gas,
particularly with higher excess O2 levels and at higher temperatures. CO combustion promoter
addition must be carefully monitored during shutdown of the CO boiler because of the impact
on NOx concentration. More frequent addition of smaller amounts of promoter will minimize
NOx formation.
6.5.6 Heat Balance Control
Reactor temperature is the primary control variable for balance. Input to the reactor
Temperature controller, TIC512, is via a selector switch which allows control to be based on
the TI in the Reactor overhead line (TI -36X), or one of two TI’s at the outlet of the Reactor
secondary cyclones (TI510 or TI 511).
In partial CO burn regenerator operation, heat balance should be controlled by manipulating

the heat input from the feed stream and should not be controlled by catalyst circulation rate as
is done in a full burn mode. Catalyst circulation rate affects the carbon balance as well as the
heat balance. Unless the Regenerator is operating in full burn, increasing the catalyst circulation
rate can only heat the Reactor at the expense of cooling the Regenerator. Increased catalyst
circulation produces additional coke, and with air in the Regenerator being limited, this results
in more CO being produced at the expense of CO2. Since the combustion of coke to CO
produces significantly less heat than combustion of CO to CO2, the net result is that regenerator
temperature decreases in a partial bum mode as more coke is produced.
In a full CO burn regenerator operation, heat balance (reactor temperature) should be controlled
by manipulating catalyst circulation rate.
6.5.7 Carbon Balance Control
For either partial or full CO burn operation, regenerator temperature need not be closely
controlled, and should equilibrate between 6750 to 7300C with CO combustion promoter and
between 7000 to7300C without promoter. Catalyst deactivation proceeds more rapidly at
regenerator dense bed temperatures above 7300C, depending upon catalyst contaminant level.
At these elevated temperatures, catalyst deactivation will lead to an overall shift to poorer
product selectivity. At very low temperatures, poor product selectivity can result because of
the higher carbon on catalyst level. In addition, there is the possibility of “flame out”, when
CO ceases to be completely burnt in the dense bed. Flame out can result in severe afterburning.

CONFIGURATION
Plant Name: FCCU-I
Regenerator dense bed temperature is generally allowed to float over a 10 to 200C range but
should be corrected if outside of this range. It can be restored by changing some reactor side
operating parameters to alter the amount of carbon production.
(a) Partial CO Burn Carbon Balance Control
In partial CO burn operation, carbon balance should be controlled by manipulating the catalyst
circulation rate. The following sequence will occur:
The increased coke production will result in a higher CO-concentration in the flue
gas and lower CO2.
The regenerator temperature will drop because of the reduced heat release as more
CO and less CO2 is produced.
At constant catalyst circulation rate, less heat will be transferred to the Reactor
and reactor temperature will tend to fall.
The reactor temperature controller will increase heat input to the process by
raising feed preheat temperature.
The net results of the initial increase in coke production are:

Higher feed preheat temperature and/or lower feed rate
Lower regenerator temperature
Higher CO and lower CO2 in the regenerator flue gas.
(b) Full CO Burn Carbon Balance Control
Carbon balance should be controlled by manipulating feed temperature and/or feed rate. The
primary carbon balance indictor is flue gas O2 concentration. The following sequence will
occur:
Since there is excess oxygen available, the increased coke production will be
burned in the Regenerator, raising regenerator temperature and lowering excess
oxygen in the flue gas.
The hotter catalyst entering the Reactor will tend to increase reactor temperature,
so catalyst circulation rate will be reduced to control the heat balance.

CONFIGURATION
Plant Name: FCCU-I
The lower catalyst circulation rate results in a lower catalyst- oil ratio, resulting
in lower coke production, thus partially compensating for the initial increase in
coke production.
The net results of the initial increase in coke production are:

Slightly higher regenerator temperature
Slightly lower oxygen in flue gas
Lower catalyst circulation rate
6.5.8 Effect of Other Operating Parameters on Heat and Carbon Balance
The manipulated variables for heat and carbon balance control will be catalyst circulation rate
and feed preheat and/or feed rate. There are many other operating parameters such as air rate,
recycle rate, recycle cut point, stripping steam, etc. which can be used to keep the primary heat
and carbon balance manipulated variables and other dependent variables, such as flue gas
excess oxygen or CO within an acceptable control range. Note that although stripping steam
rate can be used to adjust the amount of coke carryover to the regenerator, this technique is not
recommended since it utilizes valuable hydrocarbons as fuel. These may also be used for “fine
tuning” the operation of the unit.
6.6 Catalyst Handling System
Fresh catalyst must be loaded on a continuous basis during normal operation to maintain
catalyst activity and fluidity. A proprietary packaged continuous fresh catalyst addition system
has been specified for the FCCU-1.
Combustion promoter BCA and ZSM-5 catalyst additives may be added with the fresh catalyst
through a lock hopper system in the normal fresh catalyst addition line. The additive is charged
to the 6” NPS by 1000 mm hopper via a funnel. The hopper is then pressured with plant air to
push the catalyst into the 11/2” line which is used for normal catalyst addition, and is carried
to the Regenerator by the transport air.

CONFIGURATION
Plant Name: FCCU-I
Equilibrium catalyst addition is controlled by a 1” gate valve and a sight glass is available for
confirming catalyst flow. Existing facilities permit adding large amounts of fresh catalyst
directly to the Regenerator during normal operation via the 4” line with hand control valve
from the bottom of the Fresh Catalyst Hopper. This is not normally required, however, and is
actually undesirable because the unit operation cannot normally tolerate the resulting increase
in catalyst activity.
Routine catalyst withdrawal from the regenerator is required to maintain catalyst activity
particle size distribution for fluidity. 2” continuous catalyst withdrawal with Instrument air as
carrying air also exist to minimize major changes in operation during unloading. The rate of
withdrawal is controlled by introducing air at the inlet of the small bore section to vary the
catalyst density. The piping is 5 Cr and a 6 mm thick 405 (or 410 S) stainless steel thermal
sleeve is provided upstream of the reduced bore, refractory lined section, to protect against the
high catalyst temperatures. Downstream of the catalyst pickup with carrier air, after a suitable
length to allow mixing and temperature reduction with the air, a high temperature alarm (TAH-
530) is provided. This alarm warns of excessive temperature to the used Catalyst Hopper. A
catalyst withdrawal rate should be controlled to stay below the 4270C design temperature
of the hopper. A panel mounted alarm (THA-534H set at 4150C) is also provided just upstream
of the hopper to warm of exceeding the hopper DT.
Catalyst unloading for unit shutdown is through the 6” line just above the regenerator gird, a
3” line below the grid, and a 3” line from each J-bend. These lines are intended for use during
shutdown only at catalyst temperature below 5350C. Unloading rate during shutdown is
controlled by throttling with the valves provided. Catalyst withdrawal rate should be controlled
to stay below the 4270C design temperature of the hopper. A panel mounted alarm (THA 534H
set at 4150C) is provided just upstream of the hopper to warn of exceeding the hopper DT.
Vacuum clean out lines are provided at all major vessel man ways for vessel clean out at
shutdown.
Routine laboratory inspections are conducted weekly to monitor the quality of the equilibrium
catalyst in the unit. Samples should be sent to the catalyst vendor on a weekly basis to obtain
a detailed analysis. More frequent analysis of the equilibrium catalyst may be required if unit
operating problems develop. These tests will determine how much catalyst must be added and
withdrawn from the unit to keep the catalyst at the desired activity level and fluidity. Activity
is increased, of course, by increasing fresh catalyst addition rate. At the same time fresh catalyst
addition adds a higher percentage of fine catalyst particles than is typically found in the
equilibrium catalyst. Properly sized particles are necessary for efficient fluidization of the

CONFIGURATION
Plant Name: FCCU-I
catalyst within the unit. A “Coarseness index” (ratio of 80+ to 0-40 micron particles) lower
than 3.0 is generally necessary for good circulation.
6.7 Fractionator
The reactor effluent comprising of cracked hydrocarbon vapors, steam and non-condensable
enter the fractionator 04C51 at the bottom of the quench section. The main column is a vertical
cylindrical vessel with 4.25m inside diameter & 44.1m height. The column consists of two
sections. Top section is the regular fractionator part and the lower one is the desuperheating or
quench section.
The quench zone has six disc and doughnut trays. Above them there are 36 valve trays (SS 410
S make). The column shell is clad with 1 ¼ Cr ½ Mo from bottom up to tray # 23 including the
head. The column has different design temperatures at different sections.
Trays Design Temp, oC

36 to 24 300
24 to 3 350
Below 3 550
The column design & operating pressure at top & bottom section are:
Section Pressure kg/cm2 Temperature oC

Design Operating Operating
Top 4.5 1.69 137
Bottom 5.0 2.05 360
The cracked vapors from the reactor are cooled by circulating slurry pump around and part of
the vapors condense. The entrained catalyst in the cracked vapor is scrubbed by the slurry pump
around stream. The fractionator bottom has a high coking tendency. Coking is further promoted
by higher liquid temperature and long residence time. To maintain the fractionator bottom
temperature below 3600C, cold quench stream of slurry pump around from 4E56 is directly
mixed with the fractionator bottom liquid under column bottom temperature control TIC2013.
Further LP steam is injected into the bottom liquid through a steam ring to counteract coke
formation and to maintain catalyst & coke particles in suspension. To ensure that large coke
particles in the bottom stream do not hamper the operation of the slurry pumps, a coke trap is
put around the bottom nozzle. The coke trap is made of SS-410S having 132 slots on it. The
main column is provided with LT-2005 with DCS high & low alarm facility and LT-2003 with
DCS low & high alarm facility & local indication: LSHH-2009 provides alarm in DCS in case
CONFIGURATION
Plant Name: FCCU-I
of high-high level. The LTs are provided with FLO connections to clean out lines in case of
choking. Sample coolers SC2001 to 2003 are provided at column bottom to collect samples.
Slurry pump around and net bottom product is withdrawn from the fractionator and pumped
using slurry pumps (4P052 A/B). One pump is motor driven and the other (standby) is
extraction type steam driven turbine. The slurry from 4P52 goes to feed/slurry PA exchanger
4E054A/B/C where it is cooled to 2860C/3030C/2700C in three different cases ID (CF)/1D
(HF)/2D, then it goes to slurry PA/MP steam generator 4E56 where MP steam is generated
from BFW. Slurry then enters main fractionator as quench under flow and temperature controls.
The slurry return temperature can be varied by bypassing 4E56 as required but too much
bypassing will reduce slurry velocity through exchanger and will result in choking. The slurry
stream can enter the column at three locations:
1) On top of desuperheating trays (D#6) under total flow control, FC2004.

2) In the middle of desuperheating section (D#4) under flow control, FC2005.
3) At the column bottom as quench stock under temperature control, TC2003.
Besides the quench stream most of the slurry will be returned on top of desuperheating trays
and the other flexibility has been kept to reduce localized hot spots to control vapor temp. Part
of Slurry can be rerouted as slip stream to maintain carbon balance. Temp and pressure
indication is available on this line in DCS as TI2201/PI2202, respectively. Provision exists to
inject HCO to the slurry as dilutant. Part of slurry is withdrawn as CLO and is cooled in 4E052
A/B/C/D consisting of two parallel banks of exchangers each having two shells connected in
series. CLO is then pumped by CLO Booster pumps 4P057A/B (at 14.3kg/cm2g pressure) and
is sent to fuel oil pool through FC3302. One start up connection has also been provided from
this line to facilitate cutter circulation during start-up/shut down.
A spill back of 4C051 bottom slurry from 4P052 discharge is sent back to column through RO-
2001.
It is important that a minimum flow should always be maintained in all the CLO lines at all
times of operation else CLO being of high pour point, may cause congealing problems in cold
lines. Under low flow condition, adjust the cooler duty to avoid excessive cooling of the
stream. After every unit shutdown, Steam out all the piping up to rundown lines. PI2012
measures the column bottom pressure.
Fractionator has been provided with PIs & TIs at different elevation to monitor the pressure &
temperature profile of column. TI2019.PT-2012 is provided at bottom section. TI2009 will
show the temperature above D#4. TI2010/2011&2012 in the vapor space equally spaced
around the circumference to measure the vapor temperature leaving desuperheating section.
CONFIGURATION
Plant Name: FCCU-I
TI2018/2007/2006/2005/2003 will indicate the temperature of tray #2, #6, #16, #23,
#34respectively. PT-2003/2002/2001 will show the pressure of the vapor space of Chimney
tray #2, chimney tray # 1 & tray #36 respectively. TI2004 is provided to show the fractionator
OVHD temperature.
6.7.1 Heavy Cycle Oil Circuit

Heavy Cycle Oil (HCO) is withdrawn from the column chimney tray CT-2 at a temperature of
320oC sent to the HCO stripper 04C53. A part of the HCO directly withdrawn from the column
is sent to the Gas Concentration Unit Debutanizer reboiler by HCO PA pump 4P60A/B. The
HCO PA from 4E68 at a temp of 273oC enters 4E57, HCO PA/MP Steam Generator, where it
generates MP steam whose pressure is controlled by 4PC3201 with High and Low Pressure
alarms at DCS.
Provision has been made to route a part of HCO PA to the top of desuperheating trays to get
additional wash liquid through HC2001.
The other part of HCO is stripped with MP steam in HCO stripper 4C53 containing 6 Valve
trays. Stripper is provided with LC2104 for monitoring the level. Stripping steam is injected
through 4FC2102. Stripped lighters along with steam returns to main column through 12”
vapor return line at tray#5. Stripped HCO from bottom of the 4C53 is pumped by HCO Product/
recycle pump 4P56A/B.
Two line ups are given for stripped HCO from discharge of 4P56A/B. One is a 6” recycle line
which joins fresh feed upstream of furnace under flow control 4FC2202. The other one is a 2”
product line joining the CLO product line upstream of 4E52 through flow control 4FC1801.
When the unit is operating on maximum distillate mode, stripped HCO is recycled back to
reactor. However when operating on maximum Naphtha mode, a small portion of HCO will be
available as product(apart from the recycle) which is routed to FO pool along with CLO
product. A portion of the HCO from recycle line is injected to the Slurry line to avoid choking
in that line. The total flow of this dilutant stream is measured by 4FI2203; All instruments in
this HCO circuit are provided with blow back connections with flushing oil.
6.7.2 Light Cycle Oil Circuit

Light cycle oil (LCO) is withdrawn from the chimney tray CT-1 above tray 23 at 242oC as
indicated by TI2015 through a 14” line. This stream is split up into two streams, LCO product
and LCO PA. LCO PA stream is pumped by 04P59A/B to the feed/LCO PA exchanger 4E053
whose outlet temperature is controlled by TIC1806 with a three –way control valve TV1806.
LCO PA stream then gets further cooled to 1800C in 4E66A, striper reboiler thereby heating
the stripper bottom liquid. TI2814 with low & high alarm facility indicates LCO PA temp ex
CONFIGURATION
Plant Name: FCCU-I
E66A it then returns to 4C051 on 26th tray through a duty controller JV2001 which gets signals
from FI2001 & TI2005/2015 The other stream of LCO draw off is sent to the LCO stripper
4C52 where the light ends are stripped off by medium pressure steam injected at the bottom of
the stripper through FC2101. LCO stripper contains 6 valve trays of SS-410 material. LC2103
with low/ high alarm controls stripper bottom level actuating the level control valve LV2103
on the stripper inlet line. A 2” fuel gas connection with control valve manifold is given to the
stripper vapor line for startup purposes. The stripper vapor return line enters the column 4C051
at tray # 26.Stripped LCO from 4C052 bottom at 2400C is pumped by LCO product + lean oil
pump 4P55 A/B to 4E65,Rich oil/LCO exchanger and then to 4E51 feed /LCO exchanger
where it is cooled, to1750C it is further cooled in 4E055 A/B. LCO/BFW exchanger, 4E060
A/B. LCO air cooler (to 650C) and finally in 4E061 A/B by circulating sea water before being
sent to storage Under flow control FC3303. A portion of LCO can be routed to offsite cutter
header FT-3305 will show the flow of LCO to cutter header. TI3302/3315/3317/3318 gives
temperatures at different points of LCO circuit in DCS. A LCO stream from 4E061 A/B outlet
is pumped by lean sponge oil pumps 4P058 A/B and is sent as absorbent to sponge absorber
routing cutter stock as quench to reactor during startup by taking suction from the unit flushing
oil header. BFW& seawater o/L lines from 4E55 A/B&4E061 A/B are having TSVs to save in
case of thermal pressure build up.
Piping provision has been given to route LCO to RFO or HFO or VB tar through CLO rundown
line. From cooler (4E61 A/B), a 6” line has been taken for booster pump suction(4P72
A/B) As CLO B/L pressure is 13 kg/cm2 this booster pump is required to boost LCO into
CLO header. FT7302 will indicate the flow of LCO in CLO rundown header.
6.7.3 Main Column Overhead System

The main fractionator overhead vapor consists of naphtha and lighter hydrocarbons together
with steam and non-condensable. Overhead vapors are withdrawn at temp. 138/132/1320C for
ID/2D/1N cases respectively and at 1.69 kg/cm2 a pressure through 30” overhead pipe. The
overhead vapors from fractionator, along with wash water and spill back stream from wet gas
compressor are cooled to 650C in main fractionator air cooler (4E58A-H) and finally in
fractionator overhead trim condenser (4E059 A-F) to 400C.
Stop switches (Push Button) are provided at grade level for each air cooler fan motor. The trim
condenser consists of three parallel banks each having two shell connected in series. Facilities
exist for isolating any one bank for cleaning/maintenance. The three phase mixture of non-
condensable, hydrocarbon liquid and water from trim condensers outlet are routed to main
fractionator O/H accumulator (4V053). A portion of the condensed hydrocarbon is returned to
CONFIGURATION
Plant Name: FCCU-I
the top tray of the fractionator as reflux through main fractionator reflux pumps 4P053A/B on
flow control FC2003 cascaded with TC2003 to control fractionator tray # 34 temp.
The remaining liquid from accumulator is pumped through unstabilized naphtha pumps (4P054
A/B) to WGC inter cooler on flow control FC2401 cascaded with accumulator level control
LC2402. For unit start-up, piping provision has been made to draw naphtha from offsite into
the accumulator drum. Piping flexibility is also given to take this offsite naphtha to the suction
of stabilized naphtha pumps and use it as quench naphtha stream during start-up. The sour
water from the accumulator boot is pumped by fractionator sour water pumps (4P063A/B) on
interface level control (LC2404).
The sour water is normally routed to the inlet of compressor after cooler (4E064 A/B) as wash
water. The water after separation in the HP receiver is routed to the inlet of compressor inter
cooler. The net water separated in the inter-stage knockout drum is sent out to SWS unit for
treatment. Provision to route the accumulator sour water directly to the inlet of inter cooler
overhead air cooler is provided. DM water is used as make up water at 4E063 suction for
meeting the wash water requirement during start up.
While the makeup water rate is regulated by FC2402 (total wash water flow), and interlock is
provided to prevent make up rate higher than required by closing the make up control valve
(FV2402) through interphase level switch high-high (LSHH-2405) on the accumulator drum
boot.
The gas from main column overhead accumulator contains various contaminants like ammonia,
ammonia salts, chlorides which cause corrosion, plugging & fouling problems in GCU. A wash
water stream is provided to dissolve these contaminants. Service water is injected as wash water
at the shell of 04E59A/B/C/D/E/F. Injected water after dissolving the contaminants collects in
the water boot of the accumulator.
The net gas from the accumulator flows to the WGC through suction KOD (4V054). The main
fractionator OVHD pressure is controlled by two independent pressure controllers (PC2407 &
PC2411). If pressure decreases, PC2407 actuates the compressor spill back control valve
PC2407 and recycle the gas from WGC II stage discharge. If pressure increases, then PV2407
will close fully to allow maximum gas evacuation from the system. If the pressure continues
to rise the flare valve PV2411 opens and the excess gas is flared to keep the pressure within
allowable limits. PSV2401 A/B is provided on this vessel. 2” depressurization line is provided
in case of depressurizing the vessel during shutdown.
CONFIGURATION
Plant Name: FCCU-I
6.8 Gas Concentration Section

The wet gas and un-stabilized naphtha streams from the fractionator overhead accumulator are
fed to gas concentration section. In this section, the wet gases (consisting of light hydrocarbons
and non-condensable), LPG and stabilized naphtha are separated. The net gases are routed to
SRU fuel gas network whereas LPG and stabilized naphtha are routed to storage after
treatment.
The wet gas from accumulator is first flashed in compressor suction KOD to remove any
condensate. The condensate from this drum is pumped back to 4V53 through pumps (4P064
A/B). Since the quantity of condensate generated is low. These pumps operate only
intermittently through drum level switches. The pump starts at high level in the drum and stops
when the low level is sensed in the drums The flashed gases from the drum are compressed in
a two stage centrifugal compressor (4K-051) to 16 kg/cm2a. The compressor suction line is
steam traced downstream of suction KOD to avoid any condensation due to ambient cooling.
The uncondensed vapors are routed to the primary absorber (4C54) for C3&C4’ recovery. The
condensed liquid is pumped by stripper feed pumps (4P062A/B) to the stripper (4C055) top
tray on flow control FC2701 cascaded with LC2703 (HP receiver level controller). In order to
avoid compressor surge during periods of low flow such as start–up / shutdown operation,
multifunction antisurge control is provided for each compression stage of compressor, since
the cracked gas handled by compressor has appreciable quantity olefins and di-olefins, it may
lead to formation of gummy material on the impeller. To wash off this material from impeller
surface, stabilized naphtha injection facility is provided.
6.8.1 WGC Control Scheme
Unstabilized naphtha and sour water from 4V053 are cooled in compressor inter-stage cooler
(4E063 A/B) is routed to the compressor inter-stage KOD (4V055) which is a horizontal vessel
with boot. The sour water drawn from the boot is routed on its own pressure SWSU. The
hydrocarbon liquid from the drum is pumped by inter-stage pump level controller (LC2504) to
the inlet of compressor after cooler. The uncondensed vapors are compressed in compressor II
stage to the final pressure.
Primary absorber (4C054) bottoms liquid and the top vapors from the stripper (4C055) enter
compressor after cooler (4E064 A/B). The mixture of cooled gases, condensed liquid and water
are separated in the high pressure receiver (4V056). The two-phase HP receiver is a horizontal
vessel with boot.
CONFIGURATION
Plant Name: FCCU-I
PV2629 controls the compressor I stage suction pressure. This control valve is provided with
limit stop so that this control valve will not close fully and there will minimum flow through
the control valve. FT-2601 measures the flow at compressor I stage suction. PT – 2601
&TE2601 will provide the pressure & temperature at I stage suction. These pressure &
temperature valves will be used for correction factor for the actual flow-calculation at I stage
suction.
Differential pressure between I stage suction & discharge is measured by DPI2620. This
differential value is used in the surge flow calculation in surge controller. DPSHH-2620 will
actuate on high-high differential pressure. On actuation of this WGC will trip.
Compressor suction is provided with high& low pressure switches. On actuation of PSHH-
2612 compressor motor will not start. PSLL2610 will trip the compressor on low low suction
pressure. Before actuation of PSLL2610, PSL2611 will actuate on low suction pressure.
2” vent line with, double block blind is provided in case of venting the 1st stage suction on
shutdown. 1 ½”inert gas line has been provided at both suctions for purging purpose on
shutdown.
I stage discharge temperature will be measured by TI2603 .TSH-2603 will give the high
discharge temperature and PT-2603 will indicate the discharge pressure. This has been
provided with high & low pressure alarm. Another high pressure switch PSH-2614 is provided
at compressor I stage discharge.
I stage discharge is routed to 4E063 A/B (inter stage cooler). 2” vent line through MOV2605
is connected to flare. On compressor trip MOV2605 will open to depressurizing the compressor
discharge line to flare. Limit switch is provided for open & close signal in DCS.
Surge controller will maintain the 1st stage suction flow by manipulating the FV2601.in case
of low flow it will open the control valve and vice versa.
II stage suction gas from the uncondensed gases separated in 4V055 (compressor inter-stage
K.OD) PV2632 will control the II stage suction pressure. This will get the signal from surge
controller. PT-2605 & TI2611 will indicate the pressure & temperature at compressor suction.
High pressure alarm has been provided. DPI2621 will measure the differential pressure
between II stage suction & discharge. This differential pressure is used in the surge controller
calculation. DPSHH-2621 will actuate on high differential pressure. On actuation of this
compressor will trip. Local PI & TI also provided at II stage suction.
CONFIGURATION
Plant Name: FCCU-I
On II stage discharge TE2606 & TE2609 will give the temperature. Both have been provided
with high temperature alarm. On actuation of TSHH-2604 compressor will trip. PE 2608 with
high & low pressure alarm will indicate the pressure at 2nd discharge. PSH-2615 will indicate
the high pressure at discharge & PSHH-2613 will actuate on high-high pressure of discharge.
On PSHH-2613 actuation, compressor will trip.
In case of II stage suction low flow FV2602 will open to increase the flow to the suction,
FV2602 will be controlled by the same surge controller which operates PV2632. II stage
discharge flow will be measured by FT-2602 which will be corrected on pressure &
temperature indication of PT-2609 & TI2601.
MOV2606 with limit switch of open & close signal will open in case of compressor trip to
depressurize the 2” discharge line to flare. In shutdown to vent of the compressor, discharge
line to atmosphere, a 2” vent line with double block blind is provided.
Compressor final discharge is routed of 4E64 A/B for cooling.
Compressor interstate cooler 4E63 A/B & after cooler 4E64 A/B is provided with wash water
from 4V53 boot water through pump 4P63A/B. This wash water will dissolve the salt
contamination deposited on the exchangers.
Both the exchangers are provided with 2” vent connection to flare to depressurize the system.
In order to prevent the compressor second stage discharge pressure from exceeding the normal
pressure of 16.0 ATA (due to increase in gas MW or decrease in gas temperature), the pressure
controller 4PC2712 at compressor discharge will take following actions in the order.
a. First stage spill back to open through first stage surge controller.
b. Second stage throttle valve to close through second stage surge controller
c. Second stage spillback to open through second stage surge controller. In the event
of decrease in second stage discharge pressure, the above actions are taken in
reverse order i.e.
a. Second stage spill back to close
b. Second stage throttle valve to open
c. First stage spill back to close.
CONFIGURATION
Plant Name: FCCU-I
6.8.2 Sour Water

Sour water is accumulated in different boots. This is used as wash water in the condensers and
sent to SWSU for treatment. Sour water from V53 boot is pumped by P63 A/B which can be
used as wash water in three exchangers E58 A-H. E63 A/B and E64 A/B. Boot level is
controlled by LV2404. DM water make up line is connected at the bottom of the boot to
maintain the level. FV2402 will control the flow of DM water. From 4V56, sour water can be
routed either to 04E63A/B or directly to SWSU for treatment. Boot level of 04V56 will be
controlled by LV2704. On low level switch (LSLL2705) activation, SDV2701 will close to
prevent hydrocarbon carryover to SWSU. From 4V55, sour water will be routed to SWS unit
on level control of LV2505. On low level of boot, LSLL2510 will activate to close SDV2510.
##
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CONFIGURATION
Plant Name: FCCU-I
Debutanizer OVHD accumulate boot water will be routed SWS unit through level control of
LV3103. On actuation of LSLL3105, SDV 3101 will close.
Uncondensed gas from HP receiver enters the primary absorber column 04C54 below the first
tray. The absorber consists of 36 valve trays and operates at a top pressure and temperature of
15.3 kg/cm2a & 450C and bottom pressure and temperature of 15.6 kg/cm2 a & 51.50CThe
valve trays are of SS 410S material and the column shell is of carbon steel. A portion of
stabilized naphtha from 04-P-65A/B is cooled in chiller 4-E-78 to around 18 deg C and is used
as absorbent controlled by FC2801. Stabilized naphtha is chosen for better recovery of LPG
components. The absorbent enters the column at a temp. of 180 and the feed also enters the
column at a temp. of 380C. The column is provided with LSH-2805 & LSL2806 with alarms
in DCS. LC2801 controls the column bottom level cascaded with FV2802 on absorber bottoms
pump 4P074 A/B discharge line. The Naphtha recycle rate is fixed in such a way so as to
achieve the desired recovery of C3 components. Low naphtha recycle rate will result in
insufficient absorption leading to loss of LPG components to fuel gas. Too high Naphtha
recycle rates will result in high absorption of LPG components but at the same time the
absorption of undesirable light components such as C1 and C2’ s will also increase. TI2803 &
TI2818 will indicate the tray # 19 & # 36 temperatures respectively. High & low alarm is
provided on TI2803. The gases from 04C54 flow to the sponge absorber column 04C57 for
separation of any light components. PE2801 & FI2804 are the pressure & flow indications of
this gas in DCS. The absorber bottom is pumped by 04P54A/B and joins the compressor 2nd
stage discharge stream at 04E064 A/B inlet. The bottoms pump is provided with methanol seal
pot with high pressure & low level alarm indication in DCS for its mechanical seal flushing.
TI2812 shows the column bottom temperature. Inter-stage Naphtha stream is withdrawn from
Chimney tray provided between tray 24 and 26. Inter-stage Naphtha pumps, 4-P-75A/B helps
in improving absorption further by cooling the liquid to less than 20 Deg C in 4-E-79. The
outlet from 4-E-79 is routed to Coalescer 4-V-70, before going back to column. Sour water
collected in the boot of 4-V-70 is routed to sour water system under level control. Liquid
Propane is used as Refrigerant in both 4-E-78 and 4-E-79. One LP steam connection is
provided to 04-C-54 for start-up / shut down purposes.
Sponge Absorber 04C57, operates at a top pressure and temperature of 15.0 kg/cm2a and
40.20C and bottom pressure and temperature of 15.2 kg/cm2a and 45.50C The trays are of
CONFIGURATION
Plant Name: FCCU-I
SS410S material and column shell is of CS. It has got 20 valve trays. Feed enters below tray
No. #1. Unabsorbed heavier components from 4C54 are removed here, which otherwise will
condense in the fuel gas system. LCO (Lean Oil) is used as the absorbent in the column. It
absorbs the heavy components at a temp of 400C. The lean oil is pumped by lean sponge oil
pumps. 04P58A/B and enters the column above tray # 20 under flow control FC2901. TI2901
shows the feed temperature. 4C057 is provided with PSV 2901 A/B of set pressure18.4
kg/cm2g discharging to flare. 4C057 has LSH-2903 and LSL2904 with DCS alarm facilities.
The overhead gas from sponge absorber is acidic containing H2S which is sent to sulfur
recovery Unit (SRU). PC 2901 with low & high alarm facility controls 04C57 top pressure.
TI2902 & FI2903 show temp & flow of the overheads gas flowing to SRU. The sponge
absorber bottoms (Rich oil) flow under column pressure to 4E065, Rich oil/LCO exchanger
where it is heated to 1990C by LCO. This Rich oil flows under bottom level control LC2902 to
C051 top (tray no # 27) for recovery of absorber Naphtha components. One CBD & OWS
connection is provided at column bottom to drain the column during shut down. To monitor
the column temperatures, TI2904, TI2903, TI2908 on trays # 6, #5 and overhead vapor line are
provided respectively.
6.8.5 Stripper
The stripper, 04C55 is a column operating at a top pressure and temperature of 16.0 kg/cm2 a
& 490C and bottom pressure and temperature of 16.3 kg/cm2a &1400C, the column is having
36 valve trays of SS-410S and the main column shell is of CS. The liquid from HP receiver,
04V56, is pumped to stripper via Stripper feed Coalescer (4-V-69). Sour water collected in the
boot of 4-V-70 is routed to sour water system under level control. The stripper feed enters the
column above the 36th tray at 380C the column is designed to remove the undesirable light
hydrocarbons from the liquefied C3+ hydrocarbon stream to control the vapor pressure of LPG
product. 04C55 is having LSH-2807 & LSL2808 with alarm facility in DCS. LC2802 cascaded
with FC2803 acting on FV2803 on stripper bottom line controls the bottom level of 4C55. The
stripper bottom flows under the column pressure to 4C56. Debutanizer column TI2810 gives
the temperature of this stream in DCS. The energy for separation in this column is provided
by reboiler 4E66 A/B. The temperature of the reboiler return stream (1400C) is given by TI2808
with low & high alarm facilities in DCS.
CONFIGURATION
Plant Name: FCCU-I
The amount of heat supplied through the Reboiler is such that it eliminates any absorbed C1
and C2 from the bottom product. The stripper reboiler is of once through horizontal thermo
siphon type having two shells connected in series and stacked. A forcing valve HC2801 is
provided at inlet of the reboiler in the circulating fluid stream. DPI2806 shows the pressure
drop across HC2801 in DCS. This HC is utilized to maintain a constant head to reboiler to
avoid reboiler flooding. Stabilized naphtha from debutanizer is used in E66A as heating
medium. Temperature of stabilized naphtha outlet is controlled by TC2801 (three-way control
valve).
LCO PA is used in E66A for heating. LCO PA outlet temperature is monitored by TI2814 with
high& low alarm.
C55 is having two PSVs PSV2801A/B. The overhead vapors from stripper join the compressor
2nd stage discharge stream upstream of 04E64A/B. Stripper is provided with TI2811 & TI2806
on tray #1 & 19 to monitor the column temperature PI2809 will show the pressure above the
chimney tray. High & low pressure alarm is provided.
6.8.6 Debutanizer
Debutanizer, 4-C-56 operates at a top pressure and temperature of 12.3/9.7/11.7 kg/cm2a and
65oC and bottom pressure and temperature of 12.7/10.1/12.1 kg/cm2a & 202/177/188 0C. The
column has 40 valve trays of SS410S and column shell is of CS. The feed from stripper bottom
enters the column in any one of the trays # 22,25 or 20 depending upon the feed quality.
For IN case lighter components will be higher. So tray #25 to be taken in line. The feed tray
will be mainly decided upon the sampling of the gas of compressor suction KOD. For light gas
top tray will be take in line. For heaviest gas bottom tray # 25 will be taken in line.
The column bottom is reboiled in 4E68 by HCO PA stream.TV3003 on HCO PA inlet to

reboiler controls the temperature of the bottom portion of the stabilizer. TI3004 on reboiler O/L
line with low & high alarm facility gives temperature indication in DCS.
Debutanizer is provided with different PIs & TIs to monitor the pressure & temperature of the
column. TI3009/3010/3011 are the feed tray temperatures TI3005 & TI3003 are provided on
CONFIGURATION
Plant Name: FCCU-I
the vapor space below tray#1. PI3006 indicates the pressure above tray#25. TC3001 is
controlled by the reflux flow from P66A/B cascaded with FC3001. The bottom portion of C56
has LSH3003 &LSL3004 with alarm facility in DCS. Naphtha from C56 bottom is first cooled
in stripper reboiler, 4E68B to 1300C. The temp is controlled by TC2801, a three way control
valve. It is further cooled in air cooler 4E69 and then in trim cooler 4E70 to 380C. TI3303/
3321/3314 indicate temperatures at different sections of this stream.
The cooled naphtha is pumped by stabilized naphtha product/recycle pumps 4P65A/B. A

portion of the pump discharge is recycled to the primary absorber as absorbent. A 3” take off
from this absorbent line serves as quench stream to reactor which goes under flow control
FC503. The naphtha quench to reactor is intermittent and used only when required. It is mixed
with the combined feed stream upstream of the riser feed injection nozzle. To handle this
quench requirement during start-up, when stabilized naphtha would not be available, provision
is given for this product pump 4P65 A/B to take suction directly from the fractionator overhead
accumulator 4V53. To protect the pump during such an operation, a minimum flow circulation
line is provided from the pump discharge to 4V53. The balance naphtha is routed as product to
Merox Unit for further treatment. The flow of this steam is regulated by FC3304 cascaded with
debutanizer bottom level controller LC3002. In addition to a slop connection, a start-up
circulation line to 4V53 is provided downstream of FV3304. A 2” connection for WGC wash
purposes is taken at downstream of trim cooler 4E70 A/B before the pump suction.
The overhead vapors from 4C56 is condensed in overhead condensers 4E67A/B. 2” equalizing
line is provided between the debutanizer top and accumulator to maintain pressure same as that
of debutanizer top. PC3001, a split range controller controls the column top pressure.
Debutanizer OVHD pressure controller PC3001 opens PV3001A allowing more flow through
condensers till MV of 50% and above 50%, PV3001B will open to release the excess pressure
to fuel gas header. 4V57 is having two PSVs PSV3101 A/B of set pressure15.0 kg/cm2.
The LPG product pumps, 4P67A/B, pump the condensed LPG. 4V57 is equipped with LSH-
3107 & LSL3106 with alarms in DCS. One part of the LPG is pumped as reflux to tary #35 of
C57 by 4P66A/B.
All the columns are provided with steam out and vent connections for startup purposes. All the
columns, pumps and vessels are provided with drain connection to OWS/CBD.
CONFIGURATION
Plant Name: FCCU-I
There is no alternative routing available for LPG. Naphtha is routed to storage/ NLU after
ensuring product quality.
6.8 System Variables
6.9.1 Fractionator Section

The Fractionation Section is equipped with circulating reflux streams and heat exchangers,
which can be used to adjust the tower heat balance. One is sometimes tempted to control tower
temperatures by varying the operation of these heat removal facilities without realizing that an
increase in the rate of heat removal from a tower does not necessarily result in a reduction in
tower temperature.
The temperature at any point in a fractionator can only be changed by changing the pressure,
or the composition of the material at that point. For example, increasing the LCO yield will
increase the LCO deck temperature, because a heavier product is being produced.
6.9.2 Main Column Bottom Process Control
The principal function of the slurry section of the main column is to scrub entrained catalyst
from the reactor vapors, de-superheat these vapors, and condense the clarified oil product. All
the catalyst will be effectively scrubbed from the vapors if the column is performing its heat
exchange functions.
6.9.4 Heavy Cycle Oil System
The heavy cycle oil system (HCO) is similar to the slurry system except that the rate is
determined by demands of the debutanizer reboiler located in the gas concentration section.
The system is designed such that under normal operating conditions, sufficient heat will be
removed from the circulating HCO and used as the internal reflux
If the circulating heavy cycle oil rate is reduced by the reboiler load, the material condensed in
the heavy cycle section decreases and the amount of internal reflux overflowing the draw off
deck in to the slurry section decreases, and the main column bottom level will fall. Upon a
CONFIGURATION
Plant Name: FCCU-I
decrease in main column level, an increase in the circulating slurry oil flow should compensate
for initial decrease in heavy cycle oil heat removal rate.
It is apparent that a reduction (or increase) in heat removal from one section of the column
must be compensated by an increase (or reduction) in heat removal from another section.
Within limits, this can be accomplished by manipulation of the slurry circulation rate and to a
lesser degree by control of heat removal from the HCO circulating stream. The main column
overhead reflux will then hold the column in balance under normal operating conditions,
compensating for slight fluctuations in the heat removal by other circulating streams.
6.9.5 Light Cycle Oil System (LCO)
The light cycle oil product from the main column is condensed by circulating reflux stream
which transfers heat to the stripper reboiler and the stripper feed preheater. The optimum rate
for this reflux is fixed by Stripper operation to recover maximum C3 and C4 consistent with
rejection of the non-condensable and light gases to the lean gas to avoid overload of the
compressor. In rare instances, the top decks of the main column may tend to overload or flood,
This section can be unloaded by reducing the LCO circulating rate which will be compensated
automatically by an increase in top reflux.
6.9.6 Heavy Cycle Oil Product
Heavy Cycle Oil drawn off from the main column is steam stripped in order to meet flash point
specifications. Depending upon the design rate and conversion, there are times when all the
HCO recycled to the reactor riser there by leaving no net HCO product for storage.
6.9.7 Light Cycle Oil Product
The light cycle oil drawn off also has to be steam stripped in order to meet flash point
specifications. A material improvement in the fractionation between the light cycle oil and the
gasoline can only he obtained by increasing the internal reflux in the tower above the LCO
draw off.
CONFIGURATION
Plant Name: FCCU-I
6.9.8 Main Column Overhead System
A substantial amount of the main column heat removal duty is handled by the top reflux. The
end point of the overhead gasoline product is determined by tower overhead vapour
temperature (and pressure) so that this temperature controller resets the top reflux flow rate.
The main column top temperature will be set to maintain a constant unstabilized gasoline
endpoint. The 90% recovery point of the distillation will vary with the quantity of light ends
lost in sampling. If it is essential to control the 90% point of the gasoline, the laboratory must
report the 90% evaporated point, which could then be used to reset the top temperature, or
report the 90% point on the de-butanized gasoline.
The main column top reflux and net overhead is condensed and run into the overhead receiver.
The water (from stripping steam and wash water injected for corrosion protection) separates in
the receiver boot and is drawn off on interface level control to safe disposal. The unstabilized
gasoline is discharged on level control to the Inter-stage condensers.
6.9.9 Gas Compressor

The gas from the main column overhead receiver is ‘compressed’ by the gas compressor 4K-
051. If the compressor trips, the pressure in the main column will quickly rise and PC2411
shall open and the gas shall go to the flare header through a 12” line. The main column overhead
pressure is controlled by 4PC2407. Before starting the WGC the I & II stage spill back should
be fully open.
Changes in stabilized Naphtha rate have a slight effect on the absorption efficiency. Increasing
Naphtha temperature will reduce the absorption efficiency of the oil and vice versa. Increasing
or decreasing the column pressure will also tend to slightly increase or decrease the efficiency
of operation, but this is not normally used as an operating variable.
CONFIGURATION
Plant Name: FCCU-I
The purpose of this column is to recover valuable components in the gas leaving the top of the
primary absorber by using a sponge oil stream of Light Cycle Oil from the main column.
Increasing the sponge oil flow rate tends to increase the absorption efficiency of the absorber.
Changes in sponge oil flow rates have only a slight effect on C3 recovery. But the effect is
more noticeable on the recovery of heavier components. Decreasing the lean sponge oil
temperature will also tend to increase the absorption efficiency.
Increasing the pressure on the sponge absorber will increase the absorption efficiency of the
sponge oil. But at the design pressure level, the change is so small that pressure is normally not
used as an operating variable.
6.9.12 Stripper
The main operating variable is the bottom temperature which is maintained by LCO PA &
stabilized naphtha flow through the reboiler. If the stripping rate is excessive, the stripper
vapors will be heavier than desired components which end up as a liquid in the high pressure
receiver. This will increase the feed rate to the stripper and increase the liquid loading and
consequently the pressure drop across the column. These conditions tend to increase liquid
entrainment back to the high-pressure receiver magnifying the problem. This may cause liquid
entrainment into the sponge absorber through primary absorber, where it will be returned to
the FCC main column with the rich sponge oil.
The above condition is called recycling. It is easily recognized by a reduction in the Stabilizer
feed and increase in HP receiver level. Also the stripper pressure and DP increases. The best
action to rectify the situation is to reduce the heat input to the bottom of the stripper unit until
the upset condition is corrected.
6.9.13 Debutanizer
The function of this column is to remove the majority of the C3 and C4 components present in
the rich FCC gasoline (stripper bottom).
The temperature controller, 4TC3001 sets the reflux flow as required to give the desired
composition of the over-head products. Sufficient heat should be introduced to the column by
adjusting the flow of heavy cycle oil to the reboiler.
CONFIGURATION
Plant Name: FCCU-I
The design composition of the overhead product is mainly C3 and C4 components with a small
amount of lighter material and a minimal quantity of the heavier i-pentane.
Pressure of the debutanizer column is maintained by a split-range controller. Total gases

coming from the column is totally condensed in this condenser and go to the debutanizer
receiver through the control valve.
C/V Position
4PC3001. OP 0 25 50 75 100
4PC3001A 0 50 100 100 100
4PC3001B 0 0 0 50 100
CONFIGURATION
Plant Name: FCCU-I
6.10 ROUTINE PROCESS CONTROL
This tabulation of process conditions is intended to assist the operator in selecting the optimum
operating conditions for different operations. It may be noted here that process units rarely
operate at their design conditions.
VARIABLE OPERATING CONDITION
MAIN COLUMN
Main column bottoms Adjust clarified oil yield and quench to hold low enough to
temperature prevent coking.
Circulating slurry rate As necessary to control fractionating column heat removal
requirements. To minimize top reflux to obtain minimum
gap (14-220C) on gasoline between 90% and E.P
Slurry return temperature Of little interest. Dependent on cleanliness of exchangers,
number in service and circulation rate.
Clarified slurry yield As necessary to control fractionating column bottoms
temperature and level.
Heavy cycle oil PA Rate set as desired to transfer heat to various reboiler
Heavy cycle Oil deck temp. Depends on distillation range of heavy cycle oil and on
tower pressure
Light cycle oil yield Depends on charge rate and conversion, and is varied to
maintain desired properties of light cycle oil. Also used to
control bottoms level.
Light cycle oil stripping Enough to meet flash point specifications.
steam
Light cycle oil deck temp. Depends on distillation range of light cycle oil and on tower
pressure.
Unstabilized gasoline top Is varied to control tower top temp. and depends on amount
reflux rate of heat removed in the lower section of the column.
CONFIGURATION
Plant Name: FCCU-I
VARIABLE OPERATING CONDITION
MAIN COLUMN
Fractionator column top Varied to control end point of unstabilized gasoline.

temp.
OVERHEAD SYSTEM
Overhead receive pressure Can be varied as discussed.
Overhead receiver Should always be as low possible.
temperature
Unstabilized gasoline yield. Depends on charge rate and conversion.
Wet gas molecular wt. Minor variations in density will be due to changes in
receiver conditions but major changes will be due to
increased tendency to surge.
Wet gas flow Dependent on compressor speed but must be adequate to
handle production plus spill back for control. Must be above
minimum to keep out of surge.
CONFIGURATION
Plant Name: FCCU-I
6.11 FGD PROCESS DESCIPTION (Brief)
Belco Technologies Corporation (BELCO®) has designed a gas cleaning system based on
LAB, SA (Lyon, France) technology known as EDV®. The system will treat the flue gases
from fluidized Catalytic Cracking Unit (FCCU-I) to remove Sulfur gases and Catalyst dust.
The following is a brief summary of the EDV® Scrubber system and its operation. The adopted
technology is EDV® 5000.
Particulate Removal
The particulate, contained within the flue gas, is mostly catalyst fines carried over by the gas
stream from the FCCU Unit. Particulate entrained in the flue gas stream will be removed in
the main EDV® Quench/Spray Tower (04-C-101) consisting of one (1) quench nozzle & seven
(7) G-400 spray nozzles. Additional fine particulate removal will be achieved in the Filtering
Modules (04-FM-101 A-H), located above the Cyclolabs, consisting of eight (8) F-130 nozzles.
SOx Removal
The EDV® Quench/Spray Tower (04-C-101) provides intensive gas/liquid contacting for the
absorption of SOx into the scrubbing liquid. The pH of the scrubbing liquid is controlled by
addition of caustic solution.
Mist Elimination
The 4 nos. CYCLOLAB droplet separators (04-CY-101 A-D), which are downstream of
filtering modules, will remove residual water droplets contained in the exiting gas.
Water Balance and Usage
Makeup water is added to compensate for water losses through purge to the Clarifier (at Purge
Treating Unit, PTU) and evaporation in the quench zone. A complete water balance includes
contributions from caustic addition, chemical reactions and seal water from pump mechanical
seals.
The water purge rate from the EDV® system is varied to maintain sulfite/sulfate and suspended
solids concentration in the scrubbing liquid, less than a defined value based on design
CONFIGURATION
Plant Name: FCCU-I
conditions. During upset conditions that produce excessive catalyst carry-over, the purge rate
to the Clarifier (at PTU) should be greatly increased to reduce concentration of suspended
solids.
Dilution Water Storage Tank
As existing service water system in the refinery does not have the required instantaneous water
rate for the quench/dilution water needed in case of an over temperature or FCC upset, an
Emergency Water Tank (04-T-109) is provided at higher elevation. In the case of an over
temperature situation, the Emergency Tank will provide the water at necessary pressure directly
to the quench nozzle so that the incoming hot gas can be cooled to below the design temperature
of the scrubber vessel. In the case of a FCC upset, i.e. excessive catalyst carry-over, the Tank
will provide the water at necessary pressure to reduce the concentration of solids in the recycle
loop to the desired operating concentration.
Future Sub Cooling
Provision for Future Sub-Cooling of the Quench/Spray Tower recirculation loop has been
provided. The sub-cooling essentially consists of a heat exchanger (04-E-101) which would
cool the recirculation loop so that water vapor in the saturated gas is condensed out and thereby
reduces the amount of make-up water used. A by-pass around the heat exchanger has been
provided for use till the exchanger is installed or for carrying out exchanger maintenance in
future.
Detailed Process Description (FGD)
Gas Side
Hot flue gas (under positive pressure), containing sulfur gases and laden with catalyst dust, is
transported via ducting to the EDV® System. The EDV® System cools the gas to its saturation
temperature in the quench section (quench nozzle located at scrubber inlet thimble) of the
Quench/Spray Tower (04-C-101). Sulfur gases and Catalyst dust are removed in the Spray
Tower and in the Filtering Modules (04-FM-101 A-H). The CYCLOLABS (04-CY-101 A-D)
remove the residual water droplets from the flue gas before its release into the atmosphere.
CONFIGURATION
Plant Name: FCCU-I
EDV® Quench/Spray Tower (04-C-101)
Flue gas from the FCCU enters the EDV® gas cleaning system horizontally at the Quench
section of the Spray Tower (04-C-101). The flue gas is quenched and saturated by means of
spraying liquor from one (1) LAB-G400 nozzle.
The SO2 absorption and coarse particulate removal takes place in the vertical up-flow portion
of the Quench/Spray Tower where seven (7) LAB-G400 nozzles (Spray nozzles) are arranged
on the centerline of the vessel, one nozzle at each of the seven levels. The gas passes through
the high density water curtains where atomized water droplets, moving in a cross-flow pattern,
CONFIGURATION
Plant Name: FCCU-I
cover the entire cross section of the gas stream and uniformly flushing the internal walls. The
intensive gas/liquid contacting provides effective removal of coarse particulate and
desulfurization. Scrub- bing liquid pH is
maintained at
pH = 7.0.
CONFIGURATION
Plant Name: FCCU-I
Filtering Modules (04-FM-101 (A~H))
Exiting the Scrubber/Quench Tower, the flue gas is distributed into eight (8) EDV®
Filtering Modules. The Filtering Modules (FM) with LAB-F130 spray nozzles treats
the flue gas exiting the scrubbing section. Within the divergent section of the venturi,
expansion of saturated gas causes a film of water to condense onto fine particulate and
agglomeration takes place. Also SO3 removal takes place in the Filtering module
section. In the spray box, at the bottom of the Filtering Modules, removal of the fine
particulates occurs by filtration through the unique high density water spray generated
by each LAB-F130 spray nozzle. One (1) LAB-F130 spray nozzle is provided for each
FM (8 total). Typical FM schematic is shown below.
CONFIGURATION
Plant Name: FCCU-I
CYCLOLABS (04-CY-101 A-D)
After exiting the Filtering Modules, the flue gas enters the CYCLOLAB Assembly. Four (4)
CYCLOLAB units are provided. CYCLOLAB separates the residual water droplets from the
flue gas by centrifugal force generated by the fixed vanes at the inlet of each CYCLOLAB.
The CYCLOLAB is self-cleaning as the separated water flushes the tube internal walls
uniformly and the water is drained at the bottom. The flue gas, free of water droplets, flows
through the CYCLOLAB outlet elbow (04-DX-102) to the stack (04-ST-101). Typical
CYCLOLAB schematic is shown below:
CONFIGURATION
Plant Name: FCCU-I
Liquid Side
EDV® System liquid side processes include the transport of Utilities into the system
(emergency water, service water, and caustic) or transport of process liquids within or away
from the system. The EDV® System includes the Quench/Spray Tower (04-C-101), Filtering
Modules (04-FM-101 A-H), CYCLOLABS (04-CY-101 A-D) and their associated liquid
collection tanks, pumps, valves, etc.
Make-Up Water
Make-up water to the EDV® System is required to replace the water lost through evaporation
and scrubber purge liquor. Service Water (SW) has been chosen as the primary make-up water
source.
Make-up water is introduced into the EDV® system at the FM Recycle Tank (04-T-102).
Make-up water flow rate is set by maintaining a constant level within the Wet Scrubber
Quench/Spray Tower (04-C-101). Based on maintaining a constant liquid level (04LIC8108)
within the Quench/Spray Tower (04-C-101), service water is introduced to the EDV® System,
via control valve (04FV8110) and controlled by (04FIC8110). The water level in the FM
Recycle Tank is maintained at a constant level by having a constant overflow by gravity into
the Quench/Spray Tower bottom carrying with it pollutants captured in the Filtering Modules
and CYCLOLABS.
EDV® System Caustic Make-Up
Note: The supply of caustic (20º Be NaOH solution) will be from the Centralized Caustic
System.
Due to absorption of SOx into the scrubbing liquor, an aqueous caustic solution (20º Be NaOH)
is added to the scrubbing liquor, at the Quench/Spray Tower (04-C-101) reservoir, to maintain
a constant pH value. A pH sampling station (04AT8101A/B) located on the suction piping of
pumps (04-P-101A/B/C), monitors scrubbing liquor pH and controls the flow of caustic into
the scrubber, via flow controller (04FIC8111) and control valve (04FV8111).
Caustic is also added at the Filtering Modules Recycle Tank to maintain pH and prevent
corrosion of material in the downstream Filtering Modules, Spray Box, CYCLOLABS and
Stack. A pH sampling station (04AT8102A/B) monitors pH of recycle water at the suction of
Filtering Module Recycle Pumps (04-P-104A/B) and controls the flow of caustic via flow
controller (04FIC8112) and control valve (04FV8112).
CONFIGURATION
Plant Name: FCCU-I
Emergency Water
An Emergency Water station is included to provide a quick, high volume water response to
events of either excessive temperature excursions within the Quench/Spray Tower (04-C-101)
or catalyst carry-overs to the EDV® System. The emergency water piping is connected directly
into the spray tower recirculation piping at the inlet quench section. When Spray Tower high
temperature (04TI8103A/B/C) activates the Emergency Water System, emergency water is
introduced into the Inlet Quench Section spray nozzle via control valves (04TV8103A/B).
During a catalyst upset (an excessive carry-over), the Emergency Water System should
preferably be manually activated from the DCS panel. If manual operation is not carried out,
the high amps alarm (04IAH8109A/B/C) from Recirculation Pumps will activate interlock
through Logic Note 10. The interlock will open valves (04TV8103 A&B) and the immediate
addition of dilution water to the EDV® System will dilute the excessive catalyst and flush it
from the system. The purge rate from the scrubber must also be increased at this time to prevent
flooding of the scrubber recycle tank by starting standby Purge Pump (04-P-102 A or B) and
placing purge control valves (04FV8104 & 04FV8105) in full open condition. Insufficient
purge flow may cause the Quench/Spray Tower’s (04-C-101) bottom reservoir’s level to rise
and the overflow from this reservoir is directed to the Scrubber Overflow Sump. The solids
will settle to the bottom of the Sump and the clear water may be pumped out and the solids are
manually removed as required.
Note: After the Emergency Dilution Water system has been activated, the control system must
always be manually reset to stop water flow into the EDV® System.
Quench/Spray Tower (04-C-101) Recycle Loop
The EDV® Quench/Spray Tower (04-C-101) operates with (3) 50% capacity pumps (04-P-
101A/B/C; 2W+1S). This arrangement allows the scrubber to continue in operation should a
pump require off-line maintenance. The recycle tank (reservoir) built in the bottom of the
Spray Tower serves as a supply tank for this recirculation loop.
The recirculation loop supplies scrubbing liquor to the LAB-G400 Spray nozzle at inlet Quench
Section and the seven (7) LAB-G400 spray nozzles of the Scrubber. This loop is continuously
monitored (at the DCS) for pH (04AIT8101), pressure (04PI8107) and pump current
(04II8109A/B/C).
During process upsets the scrubber bottom reservoir (04-C-101) may overfill and overflow to
the Scrubber Overflow Sump (04-S-101)
CONFIGURATION
Plant Name: FCCU-I
FM Recycle Loop
The Filtering Module Recycle Loop consists of one loop for the eight (8) Filtering Modules.
The Filtering Module spray nozzles inject liquid upward into the Filtering Modules. The loop
is equipped with two (2) 100% capacity pumps (04-P-104A/B). One (1) pump is operational
and the other is a standby spare. The Filtering Module Recycle Tank serves as a supply tank
for this recirculation loop.
The FM scrubbing liquors are collected in the FM Spray Box and drained (by gravity) to FM
Recycle Tank (04-T-102). All liquids, collected in the CYCLOLAB Inlet Plenum and
CYCLOLAB Droplet Separators (04-CY-101 A-D), are also drained by gravity to the FM
Recycle Tank (04-T-102).
Make-Up Water is introduced into the EDV® system at the FM Recycle Tank (04-T-102).
Clean water is being used in the removal of fine particulate to minimize potential carryover of
particulate in water droplets. From the FM Recycle Tank (04-T-102), water overflows (by
gravity) to the Scrubber/Quench Tower (04-C-101) bottom (reservoir). During process upsets,
which may cause the FM Recycle Tank (04-T-102) to overflow. The overflow from this tank
is directed to the Quench/Spray Tower bottom reservoir.
Scrubber area drains
Drains from the CYCLOLAB Outlet Elbow (04-DX-102) and Stack (04-ST-101) flow by
gravity to the Quench/Spray Tower bottom reservoir.
Scrubber Purge
Scrubber liquor is purged from the Quench/Spray Tower (04-C-101) recirculation loop to
remove dissolved sodium salts, chlorides, and suspended catalyst solids from the system. These
pollutants are transferred from the discharge of Scrubber Recirculation Pumps (04-P-
101A/B/C) to the Purge Pumps (04-P-102A/B), one operating, one standby. The Purge Pumps
are provided as the PTU is about 2 Km away from the Scrubber area. The Purge Pump (A or
B) transfers the purge to the Clarifier (85-TK-2001B) at PTU. In order to accommodate the
minimum and maximum purge flow rates and maintain an acceptable pressure drop over the 2
Km pipe run, two purge lines are provided. One line (2”) is used for the normal operating purge
rate range of 0 to 11 m3/hr and the other line (3”) is used for the maximum design purge rate
range of 11 to 22 m3/hr. During a FCC upset condition both control valves will set to full open
and both Purge Pumps may operate. The purge flow rate is manually set by the Operator at
CONFIGURATION
Plant Name: FCCU-I
either controller (04FIC8104 or 8105) for the process design conditions and controlled by a
control valve (04FV8104 or 8105). The discharge from both Purge Pumps are provided with a
spill back loop so that the pumps can operate more efficiently when the purge rates are much
lower than the pump’s rated capacity. The spill back loop has a restriction orifice (04FO8117)
and flows back to the Quench/Spray Tower bottom reservoir. However, the flow rate should
be monitored and recorded to optimize process operation.
In the scrubbing liquor, the suspended solids content should be maintained below 0.5% wt.,
or the chlorides content should be maintained below 750 mg/l, or the total dissolved solids,
TDS (measured sulfates, SO42-) should be maintained below 10% wt.
CONFIGURATION
Plant Name: FCCU-I
LIST OF PLANT EQUIPMENT
CHAPTER 7
S. NO EQUIPMENT NO EQUIPMENT DESCRIPTION
1. 04-K-1X Main Air Blower
2. 04-K-2X Control Air Blower
3. 04-K-051 Wet Gas Compressor
4. 04-K-81 A/B Chiller Compressors
5. 04-K-102A/B Seal Air Blowers
COLUMNS
6. 04-C-051 Main Fractionator
7. 04-C-52 LCO Stripper
8. 04-C-53 HCO Stripper
9. 04-C-054 Primary Absorber
10. 04-C-055 Stripper
11. 04-C-056 Debutanizer
12. 04-C-057 Sponge Absorber
13. 04-C-101 Quench/Spray Tower
HEATERS
14. 04-F-051 Heater
15. 04-F-01 Air Preheater
16. 04-F-052 CO Boiler Package
EXCHANGERS/COOLERS
17. 04-E-051 Feed/LCO Exchanger
18. 04-E-052A-D Feed/CLO Exchanger
19. 04-E-053 Feed/LCO PA Exchanger
20. 04-E-054A-C Feed/Slurry PA Exchanger
21. 04-E-055A-B LCO/BFW Exchanger
22. 04-E-056 Slurry/MP Steam Generator
23. 04-E-057 HCO PA/MP Steam Generator
24. 04-E-058A-D Main Fractionator Overhead Air Cooler
25. 04-E-059A/H Main Fractionator O/H Trim Condenser
26. 04-E-60 LCO Air Cooler

Plant Name: FCCU-I
27. 04-E-061A-B LCO Trim Cooler

28. 04-E-062A-D HCO/CLO Cooler
29. 04-E-063A-B Compressor Intercooler
30. 04-E-064A-B Compressor After Cooler
31. 04-E-065 Rich Oil/LCO Exchanger
32. 04-E-066A/B Stripper Reboiler 1&2
33. 04-E-067A/B Debutanizer O/H Condenser
34. 04-E-068 Debutanizer Reboiler
35. 04-E-69 A/B/C Stabilized Naphtha Air Fin Cooler
36. 04-E-70A/B Stabilized Naphtha Trim Cooler
37. 04-E-072 U-Tube Exchanger In 04-V-062
38. 04-E-075 MAB Turbine Surface Condenser
39. 04-E-076 MAB Inter Condenser
40. 04-E-077 MAB After Condenser
41. 04-E-94 A/B WGC LO Cooler
42. 04-E-94 A/B WGC SO Cooler
43. 04-E-81 Chiller Condenser
44. 04-E-78 Stabilized Naphtha Recycle Cooler
45. 04-E-79 Primary Absorber Inter Cooler
46. 04-E-83A/B 04-K-81 A/B Lube Oil Cooler
PUMPS
47. 04-P-051-A/B Fresh Feed Pumps
48. 04-P-052-A/B Slurry Pump Around Pumps
49. 04-P-053A/B Main Fractionator Reflux Pumps
50. 04-P-054-A/B Unstabilized Naphtha Pumps
51. 04-P-055A/B LCO + Lean Oil Pumps
52. 04-P-056A/B HCO Pdt/Recycle Pumps
53. 04-P-057A/B CLO Booster Pumps
54. 04-P-058A/B Lean Sponge Oil Pumps
55. 04-P-059A/B LCO PA Pumps
56. 04-P-60A/B HCO PA Pumps
57. 04-P-061A/B Compressor Inter-stage Pumps
58. 04-P-062A/B Stripper Feed Pumps

Plant Name: FCCU-I
59. 04-P-063A/B Main Fractionator Sour Water Pumps

60. 04-P-64A/B Compressor Suction KOD Pumps
61. 04-P-65A/B Stabilizer Naphtha Pdt/Recycle Pumps
62. 04-P-066A/B Debutanizer Reflux Pumps
63. 04-P-067A/B LPG Product Pumps
64. 04-P-068A/B Cooling Water Booster Pumps
65. 04-P-70A/B MAB Turbine Condensate Pumps
66. 04-P-071A/B CBD Pump
67. 04-P-72A/B LCO Booster Pumps
68. 04-P-073 Torch Oil Pump
69. 04-P-40A/B Ni passivators dosing pumps
70. 04-GM-35A/B/C Neutralizer Dosing Pumps
71. 04-GM-80A/B Anti-Oxidant Dosing Pump
72. 04-P-100A/B Hydraulic Oil Pump
73. 04-P-102A/B MAB LO Pump
74. 04-P-104A/B WGC LO Pump
75. 04-P-105A/B WGC SO Pump
76. 04-P-074A/B Absorber Bottom Pumps
77. 04-P-8101A/B/C Scrubber Bottom Pumps
78. 04-P-8102 A/B Purge Pumps
79. 04-P-8103 Sump Pump
80. 04-P-8104 A/B FM Recycle Pumps
81. 04-P-8105 Seal Water Booster Pump
82. 04-P-75A/B Primary Absorber Inter Cooler Pumps
83. 04-P-76 A/B New Salt Water Booster Pumps
84. 04-P-81A/B Chiller Comp A LO Pumps
85. 04-P-82 A/B Chiller Comp B LO Pumps
86. 04-P-83 Oil Reclaimer Pump
VESSELS
87. 04-V-051 Feed Surge Drum
88. 04-V-053 Main Fractionator Overhead
Accumulator
89. 04-V-054 Compressor Suction K.O. Drum

Plant Name: FCCU-I
90. 04-V-055 Compressor Interstage K.O. Drum

91. 04-V-056 HP Receiver
92. 04-V-057 Debutanizer O/H Accumulator
93. 04-V-058 Decoking Drum
94. 04-V-059 CBD Vessel
95. 04-V-060 Flare K.O. Drum
96. 04-V-061 Steam Generator Blow Down Drum
97. 04-V-062 LPG Vaporizer
98. 04-V-063 Heater Steam Drum
99. 04-V-064 Fuel Gas KOD
100. 04-V-065 Orifice Chamber
101. 04-V-066 HP Hydraulic Oil Accumulator
102. 04-V-067 LP Hydraulic Oil Accumulator
103. 04-D-1X Regenerator
104. 04-D-2X Reactor
105. 04-D-3 Fresh Catalyst Hopper
106. 04-D-03A Dosing Drum
107. 04-D-03B Combustion Promoter Addition Pot
108. 04-D-4X Used Catalyst Hopper
109. 04-D-051 Fresh Catalyst Addition System
110. 04-T-109 Emergency Water Tank
111. 04-T-102 FM Recycle Tank
112. 04-S-101 Scrubber O/H Sump
113. 04-V-69 Stripper Feed Coalescer
114. 04-V-70 Primary Absorber Inter Cooler Coalescer
115. 04-V-81 A/B Oil Tank Separators of 04K81 A/B
116. 04-V-82 Propane Receiver Drum
117. 04-V-83A/B Secondary Oil Separator Of 04K81 A/B
118. 04-V-84 04K81 A/B Suction KOD
119. 04-V-85 Oil Reclaimer
120. 04-V-86 A/B 04K81 A/B Seal Pot Drains
MISCELLANEOUS EQUIPMENT
121. 04-X-051 Silencer (On MAB Discharge Line)

Plant Name: FCCU-I
122. 04-X-052 Silencer(On MAB Turbine Inlet Line)

123. 04-X-053 Silencer(On CAB Discharge Line)
124. 04-X-054 MAB Ejector Silencer
125. 04-X-055 MAB Cond Pump Silencer
126. 04-X-056 MP Steam Silencer(On 04-E-056)
127. 04-X-057 MP Steam Silencer(On O4-E-057)
128. 04-X-058A/B VGO/FLO Filters
129. 04-X-59 MP Steam Silencer(MP Steam Drum)
130. 04-X-061 Steam Silencer(Heater Section)
131. 04-X-062 MP Steam Silencer(On Reactor O/H Line)
132. 04-J-051A/B/C/D Steam Jet Ejector(Part of MAB)
133. 04-JD-01 De-superheater (Heater Section)
134. 04-ST-7201 Steam Trap (On O4-E-072 Outlet Line)
135. 04-ST-7501 Steam Trap On CBD CW Inlet Line
136. HCV-1X Spent Catalyst Shutoff Slide Valve
137. HCV-2X Regen Cat Shutoff Slide V/V
138. STR-504A/B Torch Oil Strainer
139. STR-503 MAB Turbine Steam Strainer
140. 04-X-502A/B Torch Oil Spray Nozzles
141. 04-X-062 Silencer On Reactor Vent To Atmosphere
142. PDCV-501 Flue Gas Slide v/v
143. 4-H-1 Catalyst Conveying Ejector
144. 04-JD-01 MP Steam Super heater
145. 04-X-81A/B 04K81 A/B LO Filters
146. 04-FM-101 (A-H) Filtering Modules
147. 04-CY-101(A-D) Cyclo Labs
148. 04-ST-101 FGD Stack
149. 04-DX-101 Cyclo Lab Inlet Duct
150. 04-DX-102 Cyclo Lab Out Let Elbow

Plant Name: FCCU-I
EQUIPMENT DATA
Columns Data
Vessels Data
Heater Data
Catalyst hopper Data
Regen-Reactor, RCJB Circuit Data
Flue Gas Slide Valves
Regenerated and Spent Catalyst Slide Valves
Air Preheater
Torch Oil Spray Nozzles
Regenerator Cyclone Separators
Reactor Cyclone Separators
Regen & Reactor Particle Size Distribution
Flue Gas Analyzers
Heat Exchangers Data
Pump Data

Plant Name: FCCU-I
7.1.1 Columns Data (For Cases 1D/2D/IN)

COLUMNS
Operating Condition(CASE
Design condition
S. Equipm 1D/2D/1N)
Description
No. ent Tag Pressure Temperature Pressure Temperature
(Kg/cm²g) (°C) (kg/cm²g) (°C)
Top Bottom Top Bottom Top Bottom Top Bottom
0.69/ 1.05/ 138/ 360/

Main
1 4C51 3.5 4 300 - 550 0.69/ 1.05/ 132/ 360/
Fractionator
0.69 1.05 132 360
0.80/ 0.85/ 241/ 239/
2 4C52 LCO Stripper 3.5 3.75 265 0.80/ 0.85/ 228/ 226/
0.80 0.85 221 219
1.01/ 1.06/ 318/ 311/
3 4C53 HCO Stripper 3.5 3.75 340 1.01/ 1.06/ 318/ 311/
1.01 1.06 316 301
14.3/ 14.6/ 45/ 52/
Primary
4 4C54 19 19.2 100 14.3/ 14.6/ 44/ 50/
Absorber
14.3 14.6 46 52
15.0/ 15.3/ 48/ 140/
5 4C55 GCU Stripper 19 19.3 170 15.0/ 15.3/ 47/ 145/
15.0 15.3 47 133
11.3/ 11.7/ 64/ 202/
6 4C56 De-Butanizer 15 15.6 225 8.7/ 9.1/ 59/ 177/
10.7 11.1 64 188
14.0/ 14.2/ 40/ 46/
Sponge
7 4C57 19 19.4 100 14.0/ 14.2/ 40/ 44/
Absorber
14.0 14.2 40 45
FGD-I
8 4C101 Quench/Spray 0.125 200 150 mmWC 55 - 60
Tower

Plant Name: FCCU-I
7.1.2 Vessels Data

Design condition Operating Condition
S. Equipment
Description Pressure Temperature Pressure Temperature
No. Tag
1 4V51 Feed surge Drum 3.5 300 0.8 70 - 165
2 4V53 M/F O/H Condenser 3.5 65 0.35 40
3 4V54 WGC Suction KOD 3.5 65 0.35 40
4 4V55 Inter-stage KOD 10 65 7.64 38
5 4V56 HP Receiver 19 65 15 38
6 4V57 Debutanizer O/H 15 65 11 40

Accumulator
7 4V58 Decoking Drum Full of Liquid 150 1 atm 100
8 4V59 CBD Vessel 3.5 220 1 atm 40 - 150
9 4V60 Flare KOD 3.5 420 1.4 Amb - 399
10 4V61 Steam Generator Full of Liquid 125 1 atm 100

Blow Down Drum
11 4V62 LPG Vaporizer 16 170 11.5 75
12 4V63 Heater Steam Drum 11 180
13 4V64 Fuel Gas KOD 9 150 4 - 5 kg/cm²g 40 - 50
14 4D3 Fresh Cat Hopper Vacuum 3.05 66 Vacuum 1.7 32
15 4D4 Eq. Cat Hopper Vacuum 2.18 427 Vacuum 1.7 343
16 4T109 FGD-I Emergency ATM 65 ATM 40

Water Tank
FGD-I FM
17 4T102 0.125 100
circulation Tank
18 4S101 FGD-I Scrubber ATM 40 - 60
Overflow Sump
Stripper Feed
19 4V69 19 49
Coalescer
Primary Absorber
20 4V70
Intercooler Coalescer
Max: 100,
21 4V81A/B 17.5 15.77 60.79
Oil Tank Separator Min: -42.5
Max: 100,
22 4V82 17.5 15.27 44
Receiver Min: -42.5

Plant Name: FCCU-I

S. Equipment
No. Tag
Secondary Oil Max: 100,
23 4V83A/B 17.5 15.27 60.79
Separator Min: -42.5
Chiller Compressor Max: 100,
24 4V84 17.5 5.85/15.37 18/60.79
Suction KOD Min: -42.5
Max: 100,
25 4V85 17.5 5.95 13
Oil Reclaimer Min: -42.5
Max: 100,
26 4V86A/B 17.5 ATM ATM
Seal Drain Pot Min: -42.5
7.1.3 Heater Data (case 2D)
Heater type : Vertical cylindrical

Efficiency : 92% on LHV (min 90%)
Burner type : Low NOx, high intensity
Decoking facilities : Yes
Convection tubes : Only studded – No fins
Method of firing : Bottom fired. Each burner shall have a pilot burner
operating on fuel gas with a fixed igniter. Facility for manual ignition
with a portable igniter exists.
Heater section
Heat Absorbed (normal) : MM Kcal/hr 13.776 BY HMTD
HC (VGO + HCO recycle) MP steam

(superheating)
IN OUT IN OUT
Fluid Quantity
Total Vapor Kg/hr 159012 159012
Liquid Kg/hr 159012 159012
Plant Name: FCCU-I
Steam Kg/hr 2425 2425
Operating Temperature o C307.3 423.4 194250-280
Operating pressure Kg/cm2g17.8 9.8 11.5
Liquid properties:
Specific gravity at 15 oC 0.8936 0.8936
Specific gravity at T & P 0.7289 0.643
Viscosity at T & P 0.43 0.22 CP
Specific heat Kcal/kg C 0.7014 0.0485
o
Thermal conductivity Kcal/mhr C0.061 0.0485
Vapor properties
Molecular weight 18
Density at T & P Kg/m3 6.88
Viscosity at T & P CP 0.01
Specific heat Kcal/kg C 0.655
o
Thermal conductivity Kcal/mhr C 0.031
Allowable pressure drop Kg/cm28.00.5
Fouling resistance hr m2 oC/Kcal 0.001 0.002
2
Average heat flux (radiation) Kcal/hr m 12000
Over capacity factor
Flow % of normal 120
Duty % of normal
Turn down % of normal 60
Design and construction:

o
Design Temperature C By HMTD By HMTD
2
Design pressure Kg/cm g 29.5 15
Material of construction 9 Cr 1 Mo CS
Corrosion allowance mm 3.0 3.0
Headers Return bends
Soot Blowers: 16 Nos

Plant Name: FCCU-I
Desired thermal efficiency: 92% ON LHV
Fuel data:
Gaseous fuels: Fuel gas
Pressure at burner (min/max) 1.5/2.5
Temperature at burner oC 40-50
Molecular weight 28.55-29.69
Net Heating value: Kcal/kg 10050
Liquid fuel: Fuel oil / LSHS

2
Pressure at burner Kg/cm 4 -6
Temperature at burner 200/11/130
Specific gravity at OP T 0.86/0.87 at 200 C
Specific gravity at 15 C 0.959/0.975
Net heating value: Kcal/kg 9480
o
Pour point C +30/+51
Atomizing medium
Pressure at burner Kg/cm2g 9/10/8
o
Temp at burner C 250/280/satd
Utilities data: Min Normal Max Mech
Instrument air pressure kg/cm2g 3 4 5 8.5

Snuffing steam pressure kg/cm2g 1.5 2 3 5.5
Soot Blower pressure kg/cm2g 8 9 10 12.5
Note: The steam coil designed for alternate operating case 2D hot feed for which the
operating conditions are given below.
Steam flow (T/hr) 8.2

HC feed temp - In 331.8
- Out 423.1
Heater duty MM Kcal/hr : 11.03

Plant Name: FCCU-I
7.1.4 Regenerator (4D-1X)
Regenerator ID : 6.227/6.024 meters

TTL : 14.903 meters
Design Temperatures and pressures;
Location Temperature Pressure
Top head 343 C 2.96 Kg/cm2g
Bottom shell 343 C 3.95
Bottom cone and
Air preheater 343 C 4.37
Grid DP 343 0.18 (normal)
Grid DP 593 0.35 (startup)
Grid (down) 510 1.06
Plenum & cyclone DP 982 0.28
Material of Construction:
Refractory Lined surfaces: CS (SA516-70 normalized) 1.5 mm CA
Internals : Type 304 H + 0.5 mm CA
Grid : C-1/2 + 3.0 mm CA
7.1.5 Reactor (4D2X)
Reactor ID = 5.134/4.22 meters

TTL = 15.02 meters
Design Temperature Design pressure

Top head 343 C 3.38 kg/cm2g
Stripper bottom cone 343 C 5.71
Sheds 557 C +/-0.14 kg/cm2
Riser (inside Reactor) 557 C 0.4 kg/cm2
Plenum and cyclones 557 0.27 kg/cm2
Anti-Coking baffle 557 +/-0.035 kg/cm2
Material of Construction:
The reactor vessel and stripper: Carbon steel, SA516-70
Internal riser: C-1/2 Mo

Plant Name: FCCU-I
7.1.6 Slide Valves Data
S. No Descripti v/v type Body/ Internal Body/bonnet V/V DP Closure

on bonnet temp oC Pressure Normal/ time
temp oC short/Long 2
kg/cm (g) design Seconds
term .
1. DDSV Cold wall 343 760/982 2.11 0.52 / 2.1 10
2. HCV1X Cold wall 343 557 5.9 3.1 15
3. HCV2X Cold wall 343 760 5.9 3.1 15
7.1.7 Air Preheater (4F-1X)
Service Heating Regenerator Combustion Air

Location Attached to Bottom of Regenerator
Fuel Cutter Stock
Operating Conditions Firing Shutdown

Max. Total Air Rate, kNm3/h (wet) 39.8 59.7
Vol % Water in Air 5.8 5.8
Operating conditions Firing Shut down
o
Air Inlet Temperature, C 196 196
2
Air Inlet Pressure, kg/cm (g) 1.05 1.51
o
Maximum Air Outlet Temperature, C 593 196
2
Maximum Allowable Pressure Drop, Kg/cm 0.07
Heat Fired, M kcal/h (LHV) 5.7 0.0
Design Conditions
Temperature
Combustion Zone, oC 1649
Secondary Air Annulus, oC 343
Pressure
Shell (Long Time), kg/cm2(g) 4.37

Plant Name: FCCU-I
Combustion Zone (Collapsing), kg\cm2 0.14

Plant Name: FCCU-I
7.1.8 TORCH OIL SPRAY NOZZLES
Service Dense phase Torch Oil Sprays
Number Required 2
Type Retractable National Airoil Co.

Type F or equivalent
Spray Pattern Flat 90o angle
Fluid Sprayed Cutter Stock
Flow Rate (each nozzle) Sm3/hr 1.7
Atomizing Fluid MP STEAM
Allowable Pressure Drop kg/cm2 3.2
Design Pressure (internal), kg/cm2g 12.6
Design Temperature (internal), oC 343
Materials: Tip 18/8 Cr-Ni

Piping Note
Notes:
1. All piping from spray tip through stuffing gland shall be Type 304H extra
strong pipe

Plant Name: FCCU-I

Plant Name: FCCU-I
7.1.9 Regenerator Cyclone Separators
Design Requirements Primary Secondary
No. of Cyclones 6 6
Acceptable Type Emtrol Model 800 (or equivalent)
Voluted Inlet Yes No
Cyclone Lining ID, mm (+- 13 mm) 1143 1067
Minimum Inlet Area, m2 0.238 0.204
Outlet Area / Inlet Area 0.86 0.5
Length from Top of Cyclone to
Apex, mm (+- 150 mm) 5715 5334
Minimum Dipleg Diameter, (Nominal Pipe Size, in.) 18 10
Minimum Outlet Tube Penetration,
Percent of Inlet Height 80 80
Design Temperature, C o 760 760
Operating Conditions
Fluid Regenerator Overhead Gas

Normal Gas Rate, m3/hr 99,900 -
Inlet Temperature, oC 680 680
Inlet Pressure, kg/cm2(g) 1.13 -
Allowable Pressure Drop, kg/cm2
To Gas Outlet - 0.113
To Top of Dipleg - 0.053
Gas Characteristics
Density, kg/m3 (excluding dust) 0.775 -

Viscosity, cP 0.039 -
Normal Inlet Dust loading, kg/m3 8.47 -

Plant Name: FCCU-I
Dust Characteristics
Type Grace Spectra TM 447 or equivalent
Particle Density, kg/m3 1362
7.1.10 Reactor Cyclone Separators
Design Requirements Primary Secondary
No. of Cyclones 3 3
Acceptable Type Emtrol Model 800 Emtrol Model 800
(or equivalent) (or equivalent)
Volute Inlet Yes No
Cyclone Lining ID, mm (+- 13 mm) 1270 1143
Minimum Inlet Area, m2 0.291 0.238
Length from Top of Cyclone to
Apex, mm (+- 150 mm) 6350 5715
Outlet Area/Inlet Area 0.8 0.8
Minimum dipleg Diameter
Nominal Pipe Size, in 20 10
Minimum Outlet Tube Penetration,
Percent of Inlet Height 80 80
Design Temperature, oC 557 557
Operating Conditions
Fluid HC Vapor & Steam HC Vapor & Steam

Normal Gas Rate, m3/hr 50,960 -
Inlet Temperature, oC 529 529
Inlet Pressure, kg/cm2 (g) 1.34 -
Allowable Pressure Drop, kg/cm2
To Gas Outlet - 0.176
To Top of Dipleg - 0.211

Plant Name: FCCU-I
Gas Characteristics
Density, kg/m3 (excl dust) 3.04 -

Viscosity, cP 0.017 -
Normal Inlet Dust loading, kg/m3 16.4 -
Maximum Inlet Dust loading, kg/m3 19.6 -
Dust Characteristics
Type Grace Spectra TM 447 or equivalent

Particle Density, kg/m3 1362
7.1.11 Regenerator Catalyst Particle Size Distribution
Cumulative Weight Percent

Less Than Stated Particle Size Particle Size (micron)
@ Cyclone Inlet In Bed
0.1 15 15
0.5 19 20
1.0 22 23
5.0 32 34
20 45 47
40 54 57
80 74 82
95 90 107
99 102 133

Plant Name: FCCU-I
Reactor Catalyst Particle Size Distribution
Cumulative Weight Percent Particle Size

Less Than Stated Particle Size (micron)
0.1 15
0.5 20
1.0 23
5.0 34
20 47
40 57
80 82
95 107
99 133

Plant Name: FCCU-I
7.1.12 FCCU REGENERATOR FLUE GAS ANALYZERS
(AI501, 502 & AI 503)
The FCCU Regenerator Flue Gas Oxygen analyzer AI-501 shall be a Servomex Model 1100
or a Hartmann and Braun Magnos 7G oxygen analyzer. The ranges are provided:
0 – 1.0 Vol % Oxygen (Dry Basis)

0 – 5.0 Vol % Oxygen (Dry Basis)
0 - 25.0 Vol % Oxygen (Dry Basis)
The ranges shall be switched remotely from the DCS system in the control room. Three volt
free contacts will be provided, one for each range. The contacts shall be normally open,
closing to select the required range selection at the analyzer.
The FCCU Regenerator Flue Gas high range carbon monoxide and carbon dioxide analyzer
Al-502 shall be an ABB Process Analytics Vista Multi wave Photometer or a Hartmann and
Braun URAS 4 infrared analyzer. Two separate outputs are provided.
0 – 20 Vol % Carbon Dioxide (Dry Basis)

0 – 15 Vol % Carbon Monoxide (Dry Basis)
The FCCU Regenerator Flue Gas flow range carbon monoxide analyzer Al – 503 shall be an
ABB Process Analytics Vista Multi wave Photometer or Hartmann and Braun URAS 4
infrared analyzer. A single range is provided:
0 – 5000 VPPM Carbon Monoxide (Dry Basis)

Plant Name: FCCU-I
7.1.13 Exchanger Data

HEAT EXCHANGERS
S. Equipment
No. Tag
1 4E-51 Feed/ LCO 33.5 150 21.7 70 - 109
2 4E-52 Feed/ CLO 33.5 200 23 165 - 180
3 4E-53 Feed/ LCO PA 22.3 260 8.5 210 - 240
4 4E-54 A/B/C Feed/ Slurry PA 33.5 19.6 343
5 4E-55 A/B LCO/BFW 19.5 225 8.3 175 -205
6 4E-56 Slurry / MP Steam 15 /FV 225 13 194
7 4E-57 HCO PA / MP Steam 15 /FV 220 13 120 - 194
8 4E-58 A - D MF Air fin Cooler 3.5 /FV 160 0.69 65 - 137.5
9 4E-59 A - F MF O/H Trim cooler 6.7 100 0.69 40- 65
10 4E-60 LCO Air fin Cooler 2.37 205 7.6 65 - 175
11 4E-61 A/B LCO Trim Cooler 15 85 7 40 - 65
12 4E-62 A,B/C,D HCO/CLO Cooler 19 290 10 60 - 185
13 4E-63 A/B WGC Intercooler 10 150 7.64 38 - 72.2
14 4E-64 A/B WGC After cooler 19 150 15 38 - 52.3
Rich Sponge Oil/
15 4E-65 15 260 10 205 - 240
LCO
GCU Stripper' s 122.3 - 140,
16 4E-66 A/B
Reboiler 93.4 - 122.4
Debutanizer O/H
17 4E-67 A/B 15 100 11.3 40 - 64.4
Condenser
18 4E-68 Debutanizer Reboiler 15.6 235 11.7 202 - 215
Stabilized Naphtha
19 4E-69 15 150 11 65 - 130
AFC
Stabilized Naphtha
20 4E-70 A/B 15 85 10.3 38 - 65
Trim Cooler
U-Tube exchanger in
21 4E-72 16 170 11.5 40 - 75
4V62
MAB Turbine Vacuum Vacuum
22 4E-75 100 50 - 55
Surface Condenser 1.18 0.9
MAB Inter
23 4E-76
Condenser
Plant Name: FCCU-I
MAB After
24 4E-77
Condenser
Stabilized Naphtha Shell: 17.45 100/ -42.5 5.958 10.89 -->13.08
25 4E-78
Recycle Cooler Tube: 35.4 65 / -21 19.583 38 -->19.5
Primary Absorber Shell: 17.45 100/ -42.5 5.95 10.89 -->13.08
26 4E-79
Inter cooler Tube: 24.0 65 / -21 17.75 31.95 -->19.5
Chiller Unit Propane Max: 100, IN: 60.79
27 4E-81 17.45 15.29
Condenser Min: -42.5 Out: 44
Max: 100, IN: 69
28 4E-83A/B 4K81A/B LO cooler 23 20.77
Min: -42.5 Out: 50
7.1.14 Motor Data
No Load
Motor Power Volt/Hz/ DOR
Motor No. Service Manufacturer FLC Amps
Rpm (Kw) Phase
R/V/B
15/15/15
4P51A/B Fresh Feed Kirloskar 2977 290 3300/50/3 60 CW
14/13/13
Crompton
4P52A Slurry PA 1482 274 3300/50/3 59 22/22/22
Greaves
MF Reflux 10/11/10
4P53A/B NGEF 2960 37 415/50/3 63 CW
Pump 9.8/11/10
Unstabilized 415/50/3
4P54XA/B Naphtha
Kirloskar 2945 45 74 8 CW
38.9/37.8
LCO+Lean
4P55A/B Kirloskar 2973 45 415/50/3 75 /37.9 CW
Oil Pump
40/39/39
HCO Pdt+ 40/40/40
4P56A/B Kirloskar 2880 110 415/50/3 18.3 CW
Recycle 45/45/45
4/4.2/4.2
CLO
4P57A/B Kirloskar 2955 11 415/50/3 20 4.2/4.2/4. CW
Booster
2
10.5/11/1
Lean 2
4P58A/B Kirloskar 2970 30 415/50/3 51.53 CW
Sponge Oil 9.9/10/9.
8
126.0 28/28/28
4P59A/B LCO PA Kirloskar 2965 75 415/50/3 CW
2 28/30/30
4P60XA/B HCO PA Kirloskar 2960 90 415/50/3 148.2 33 CW
Plant Name: FCCU-I
Compresso
4P61XA/B r Kirloskar 2976 132 415/50/3 29 6.9 CW
Inter stage
Stripper
4P62A/B Kirloskar 2960 37 415/50/3 63.91 22/22/22 CW
feed
19.4/19.8
MF Sour
/18.6
4P63A/B water Kirloskar 2820 37 415/50/3 63.91 CW
20.5/20.6
Pump.
/18.6
No Load
RPM (Kw) Phase
R/V/B
1.2/1.3/1.
Compressor
2
4P64 A/B Suction Kirloskar 2975 15 415/50/3 31 CW
K.O.D. 1.3/1.4/1.
3
Stabilized
4P65X Naphtha
NGEF 2967 110 415/50/3 24 5.4 CW
A/B Product+
Recycle
9.5/9.5/8.
Debutanizer
4P66 A/B reflux
Kirloskar 2930 18.5 415/50/3 32 5 CW
8.5/9/9
LPG 20/20/20
4P67 A/B NGEF 2980 75 415/50/3 124 CW
Product 20/20/20
Cooling
77/80/79 Bidire
4P68 A/B water Kirloskar 987 125 415/50/3 218
80/82/82 ctional
Booster
MAB hot
Crompton 7.2/7.2/7.
4P70 A/B well 2920 15 415/50/3 26
Greaves 1
Condensate
Crompton 10.9/10.5
4P71 CBD 2955 37 415/50/3 63
Greaves 6/10.86
LCO Crompton 9.5/9/9.5
4P72A/B 2940 30 415/50/3 50 -
Booster Greaves 10/11/9.5
4P73 Torch Oil Kirloskar 2935 15 415/50/3 26 6.5/7/6.5 CW
6.5/6.5/6.
Primary
0
4P74 A/B Oils Kirloskar 2935 15 415/50/3 26 CW
6.5/6.5/6.
Bottom
0

Plant Name: FCCU-I
PA
4P75 A/B Intercooler 2920 9.3 15.8 3.9
Pump
New SCW
4P76 A/B Booster 1485 75
Pump
Bharat 21/21.4/
MAB.L.O. 1465 30 415/50/3 52 CW
Bijlee 21.4
04-KM- Bharat 7.5/7.8/8.
Seal Oil 1460 7.5 415/50/3 14.5 CW
P4-51 Bijlee 0
04-KM- Bharat 10.1/10/
WGC Oil 1460 15 415/50/3 27
P2-51 Bijlee 10.1
Hydraulic
PUMP1 & Reliance
Oil 1465 12HP 415/50/3 19.5
PUMP2 Electric
Pumps
Control Air 3.3KV/50
4K-2X BHEL 2967 160KW 33.5
Blower H2/3pt.
Wet Gas
3300/50H
4K-51 Compresso BHEL 1490 3300
2/3
r
DOR :( Facing Coupling End)
No Load
RPM (Kw) Phase
R/V/B
4EM58A1
O/H Air fin
A2,B1B2,
cooler BBL 1470 37KW 415V/50/3 65
C1C2,D1
Motor
D2
LCO Air
4 EM60
fin BBL 1460 18.5 415/50/3 32.5
A/B
Coolers
Naphtha
4 EM60
Air fin BBL 1450 11 415/50/3 21.5
A/B/C
Cooler
MAB,
WGC LO.
Exhaust Crompton
Sump 2800 0.37 415/50/3 0.95
fans Greaves
exhaust
fans

Plant Name: FCCU-I
No Load
RPM (Kw) Phase
R/V/B
LO LO ALFA 0.75K
69-75 415/50/3 2.0
centrifuge Centrifuge LAVAL W
Wet Gas
4K51 Compresso BHEL 1490 3300 3300/50/3 661 62.65
r
FGD-I
4PM8101 Scrubber
BHEL 200 6600/50/3 24 CW
A/B/C bottom
Pump
FGD-I
4PM8102
Purge 45 76 CW
A/B
Pump
FGD-I
4PM8013 Sump 1.1 2.5 CW
Pump
FGD-I FM
4PM8104
circulation 55 91 CW
A/B
Pump
FGD-I Seal
water
4PM8105 CW
Booster
Pump
4KM8102 FGD-I Seal Crompton
2910 10 14 CW
A/B air Blower Greaves
Chiller
4KM81A/
Compresso BHEL 2968 200 42 8.74 CW
B
r
LO Pump
4PM81A/
Motor for 1500 3.7 7.5 CW
B
4K81A
LO Pump
4PM82A/
Motor for 1500 3.7 7.5 CW
B
4K81A
Chiller
Plant Oil Crompton
4PM83 1500 1.1 2.4 CW
Reclaimer Greaves
Pump
7.1.15 PUMPS DATA

Plant Name: FCCU-I
No of Operatin Capacity Suction Pr Disch Pr

Description Stage g Temp Min/Rated/ (Kg/Cm²A (Kg/Cm²A RPM
s (°C) Nor (m³/hr) ) )
Fresh feed
2 70/165 158.7-168.4 1.8/9.6 25.7 2977
Pump
Slurry PA
1 360 422.5 2.4/4.65 12.6 1480
Pump
MF Reflux
1 40 94.3 1.6/4.2 7.9 2900
Pump
LPD Pump 1 40 41.3/120/99.76 2.08 9.78 2945
LCO+Lean oil
1 239.1 91.3 2.9/5.3 10.9 2950
Pump
HCO
Pdt/Recycle 1 310.5 65.6 2.3/4.7 22.5 2980
Pump
CLO Booster
1 40 10.4 9.1/20 ata 15.2 2900
Pump
Lean Sponge
1 40 22 5.6/16 19.4 2955
Oil Pump
LCO PA Pump 1 228.8 230.7 4.5/6.9 9.6 2970
HCO PA
1 319 118/340/283.4 3.36 9.34 2960
Pump
WGC Inter-
1 40 75/168/139.8 5.13 19.39 2976
stage Pump
Stripper feed 101.1/285/237.
1 40 15.71 20.88 1469
Pump 5
MF Sour
2 38.4 19 1.8/4.4 20 2960
Water Pump
WGC suction
1 40 5 1.5/4.74 3 2800
KOD Pump
Stabilized
Naphtha
1 38 65/155.78/187 7.6/16.6 20 2967
Pdt/Recycle
Pump
DB Reflux
1 42 90/81.5 10.8 13.43 2930
Pump
LPG Product
1 42 56.9/51.75 10.77 21.69 2900
Pump
Plant Name: FCCU-I

s (°C) Nor (m³/hr) ) )
SCW Booster
1 33 1600 5.2/7.2 6.7 987
Pump
MAB Hot
1 22.2 2900
Well Pump
CBD Pump 1 40 - 50 40 1/- 6 2950
LCO Booster
1 40 50 7.8/16 14.6 2950
Pump
Torch Oil
1 40 - 50 3.3 5.6/11 12.6 29
Pump
Primary
Absorber 1 41.5 69/57.45 15.43 18.43 2935
Bottom Pump
PA intercooler
1 32 23/60/50 16.26 18.75 2920
Pump
New SCW
1 33 485/1200/1000 5.03 6.7 1485
Booster Pump
Hydraulic Oil
1465
Pump
Hydraulic Oil
Conditioner
Pump
MAB LO
Motor Driven 1450
Pump
MAB LO
sump
Centrifuge
WGC LO
Motor Driven
Pump
WGC SO
Motor Driven
Pump
WGC SO
charging Pump

Plant Name: FCCU-I

s (°C) Nor (m³/hr) ) )
FGD-I
Scrubber 1 /690/
bottom Pump
FGD-I Purge
1 /28.8/
Pump
FGD-I Sump
1 /5/
Pump
FGD-I FM
circulation 1 /112/
Pump
FGD-I Seal
water Booster
Pump
LO Pump for
Screw 1500
4K81A
LO Pump for
Screw 1500
4K81B
Chiller Plant
Oil Reclaimer Screw 1500
Pump
7.1.17 Turbines Data

Plant Name: FCCU-I
Steam Full Load Sentin

Powe Pressure/Temp Trip
S. MFG Speed Steam el RV
TAG Description r (kg/cm²g / °C) Speed
No by (RPM) Rating Set Pr.
(KW) RPM
Inlet Outlet (kg/hr) (Psig)
1 4KT51 MAB Turbine
Dresser
2 4PT52B Slurry PA 1715 302 10/250 3 17890 1485 75
Rand
Hot well
3 4PT70A 10/250 3/150 1800 75
Condensate
Tothil
4 4PT102B MAB Lube Oil 1755 25 10/250 3/150 3000 1450 75
Corp
Tothil
5 4PT104B WGC Lube Oil 1755 12 10/250 3/150 1450
Corp
Tothil
6 4PT105B WGC Seal Oil 1755 6 10/250 3/150 1450
Corp

Plant Name: FCCU-I
DESCRIPTION OF CRITICAL CONTROL SCHEME
CHAPTER 8
DESCRIPTION OF CRITICAL CONTROL SCHEMES
In this chapter, the following important critical schemes are discussed as given below:
8.1 MAB antisurge Control system
The primary objective is to prevent MAB from surge.
8.1.2 Control system features: Output loop back test comparing actual output with
desired output determining output failure status.
Serial communication for data and alarm transfer to DCS.
8.1.3 Antisurge control system features Low select of its control response with the output
from local control panel based manual loader HIC509.
8.1.4 Emergency antisurge station (EAS) features Control of the antisurge v/v if the
companion antisurge controller falls or more than some configurable number of surges occurs/
Signal select to determine whether the EAS internal signal or the remote input signal
from the companion antisurge controller is connected to the antisurge v/v
Counting event surge cycles.
Counting total surge cycles.
Four stage progressive alarm system based on the number of event surge cycles.
8.1.5 Antisurge control loop description:
Compressor Controller Final control element

MAB FIC521 HCV509
Antisurge controller FIC521 uses transmitter FT521, PT512 and PT1382 to determine
the operating point of MAB relative to its surge control line. The controller modulates
antisurge blow off v/v HCV509.
The antisurge controller is configured to receive a remote low clamp analogue input
signal from the local control panel based manual loader HIC509. The antisurge
controller monitors its own antisurge control response signal and the HIC509 analogue
output signal (equivalent to a remote low clamp). A low selection between these two

Plant Name: FCCU-I
signals is made within the antisurge controller and the selected signal is sent as an
output to the antisurge blow off v/v HCV509.
8.1.6 EAS control loop description

MAB EAS 521 HCV509
Emergency antisurge station (EAS) EAS521 provides backup control to antisurge controller
FIC521 and will take control of antisurge blow off v/v HCV509 in the event that the main
controller fails or if the EAS detects a configurable rapid decline in flow rate from flow
transmitter FT521A. The EAS can also be used manual loading station for the antisurge blow
off v/v HCV509.
8.2 WGC Anti Surge Control System8.2.1 Primary objective:
The following is the primary control objective of the WGC antisurge control system:
Antisurge control for each section of compressor 04K51 and discharge pressure limiting
control for the compressor
8.2.2 Control system secondary objective
The following is the list of secondary control objectives of WGC antisurge control system
POC (Pressure override control) supplementary limiting control (of compressor
discharge pressure) by FIC2601 through 4FC2601.
Compressor discharge pressure limiting control also by FIC2602 through FV2602.
8.2.3 Control System options
The following is the list of control system options that are beneficial to process control.
ESD request.
Stop (Unload or normal stop)
Purge request
Antisurge control manual override (By shutting parameter mode AMOR to ON)
Compressor suction pressure low limiting through FIC2601

Plant Name: FCCU-I
8.2.4 Antisurge Control loop description

1st stage FIC2601 FV2601
2nd stage FIC2602 FV260
Antisurge Controller FIC 2601 uses transmitters FT2601, PT2601, PT2601A and TT2601 and
TT2601A
To determine the operating point of WGC 1st stage relative to its surge control line.
Section 1 Antisurge controller FIC2601 participates in a pressure override control

(POC) in coordination with performance controller PIC2712 to high limit compressor
discharge pressure by modulating antisurge v/v FC2601
Antisurge Controller FIC 2602 uses transmitters FT2602, PT2609, PT2609A and
TT2610 and TT2610A. To determine the operating point of WGC 1st stage relative to
its surge control line.
Section 2 Antisurge controller FIC2602 participates in high limiting the compressor
discharge pressure by modulating antisurge v/v FC2602
8.2.5 Performance Control Loop description:

WGC PIC2712 PV2632
WGC PIC2629 PV2629
For discharge pressure limiting control, performance (pressure) controller PIC2712

monitors PT2712 (Final discharge pressure) and modulates interstage suction control
v/v PV2632.
Pressure controller PIC2629 monitors transmitter PT2629 and modulates inlet 1st stage
suction control v/v PV2629
This prevents the compressor 2nd stage discharge pressure from exceeding its normal level of
16ATA.
The set point of pressure override control (POC) response of PIC2712 will be setup so that the
1st stage antisurge v/v FV2601 opens first on high discharge pressure. The PIC2712 own set
point will be slightly higher that its POC set point. Therefore, PV2632 will open after FV2601.
Plant Name: FCCU-I
8.3 Slide Valves
8.3.1 Introduction
The design of FCCU I provide shutoff slide valves in the regenerated and spent catalyst circuits
to provide positive isolation between the Reactor and Regenerator during an emergency, Stack
slide valves are for control of Reactor-Regenerator DP control and Diverter slide valve for
ON/Off control. Activation of the slide valves (RCJB, SCJB) protects against inadvertent flow
of hydrocarbon vapor into the Regenerator or air into the Reactor. To ensure the reliability of
these valves during an emergency, the design of the hydraulic systems has been specified to
include hydraulic reservoirs of sufficient capacity to allow two full cycles of all slide valves
under process conditions even after a hydraulic system failure. TAPCO hydraulic oil system is
provided in FCCU I for slide valve operation.
8.3.2 SYSTEM COMPONENTS – ELECTROHYDRAULIC
HYDRAULIC PUMP
These are variable displacement, pressure compensated, axial piston type pumps. During
periods of minimal fluid flow the pump automatically reduces displacement to match pressure
demand. It continues to run. But in an unloaded condition until flow/pressure is required. This
reduces wear and increases the life of the pump. There is less heat built-up as the pump is not
continuously loaded.
PUMP DRIVER(S) AND AUTO SWITCHOVER
The pump drivers are electric powered. At least one pump should be left “ON” at all times
during normal operating conditions. Normally the power for each electric motor comes from
two different sources to insure a more dependable backup system.
The dual backup pump circuit is for automatic switchover from one pump the other. Either
pump may be selected as primary while the opposite pump would be designated as the backup,
depending on motor control circuit. A time delay should be included to allow the primary pump
to build system pressure; this would prevent the second pump from starting until required. As
the primary pump pressure is lost or drops very low, a low pressure switch shall trip and cause
the backup motor/pump to start.

Plant Name: FCCU-I
PUMP / FILTER MANIFOLD
This manifold block includes two check valves, two shutoff valves and two system relief
valves. The check valves separate the two pumps. The shutoff valves are redundant and in-line
with the check valves. The relief valves are set 200 psi higher than the pump compensator
control. Connections are provided for pressure switches and gauges.
HYDRAULIC CONTROL MANIFOLD
This manifold contains the principal hydraulic circuit, the servo valve, check valves, flow
control valves, block and bleed valves, etc. They are cartridge design or mounted directly to
the manifold. Each significant valve or control component is labeled with an identification tag,
leaving readily identifiable components unmarked. The solenoid valves are remotely mounted.
ESD CONTROL MANIFOLD
This manifold includes the ESD circuit which will override auto control and act to close the
slide valve. The ESD solenoid is remotely powered and tripped from the control room. When
de-energized, two pilot operated check valves are opened which cause the slide valve to close.
Simultaneously, to isolate and block auto control, the fail in place solenoid valve is de-
energized.
ON-LINE TESTING OF ESD SOLENOID

Closing the lockable test valve will isolate operation of the overriding ESD circuit and allow
on-line testing of the ESD solenoid valve.
SERVO VALVE
The servo valve is the interface between the electronics and the hydraulics. This devise is
current-responsive and will direct fluid to the actuator cylinder in precise response to
commands from the servo amplifier. This valve is surface-mounted to the main control
manifold and contains two filters.
This valve is a jet-pipe type of design which is more tolerant to contaminants than other types
of servos.
NOTE: While the servo is in normal control mode, it has a continuous flow of 0.3 to 0.5 gpm
through the pilot to allow continuous control.

Plant Name: FCCU-I
FOUR-WAY PILOT OPERATED DIRECTIONAL VALVE
The directional valve is mounted to the Hydraulic Control Unit with an adapter. It is controlled
by solenoids “A” and “B” to shift hydraulic pressure to C1 or C2 to move the diverter valve.
TRANSDUCER FEEDBACK
The non-contacting linear displacement transducer (LDT) is located as an attachment to the

actuator cylinder. This device sends an interrogation pulse signal down the feedback probe,
monitors the signal feedback, and then sends a 4-20 mA signal, respective of actual valve
position, to the TAPCO servo amplifier circuit board.(SVA).
ACCUMULATORS
These devices are manufactured by Parker and ASME certified with code stamp. They are the
piston-separated type which contain a nitrogen pump flow, and stores enough pressurized
hydraulic fluid to stroke the slide valve actuator a minimum of three complete strokes.
The primary accumulator is dedicated to the normal control of the slide valve. The reserve
accumulator is isolated from the primary control circuit by either a manual valve or a solenoid
controlled, pilot operated check valve.
HYDRAULIC RESERVOIR
The fluid tank is stainless steel to help prevent fluid contamination. Visual gauges indicate fluid
level and temperature. Level and temperature switches are provided. Fluid level is originally
filled to within 1-2 inches; from the top of the tank. Normal fluid level (at normal operating
pressure) will be lower because the accumulators hold a certain amount of fluid when
pressurized.
All accumulators must be discharged to the tank before adding fluid.
Make certain accumulators are empty when checking fluid level. Otherwise there will be no
place in the reservoir to accept the fluid when the accumulator is drained and the reservoir will
overflow.

Plant Name: FCCU-I
YOKE ASSEMBLY
This is the mounting frame or structure for all components of the actuator. The lower yoke
flange is attached to the stuffing box/cover flange assembly. The valve stem is attached to the
stem coupling.
STEM COUPLING AND ANTI-ROTATION DEVICE
This is the connection between the actuator and the valve stem. Half of this coupling is a split
collar, while the other half is threaded and keyed. Both are held together by socket head cap
screws. This assembly includes an anti-rotation collar. This prevents the stem from turning as
rotational torque is created when using the mechanical gear.
MANUAL GEAR STEM
A 2 inch diameter stem with an acme thread engages the split-nuts of the mechanical gear. Both
ends are machined for adoption to the upper and lower couplings. The stem has a special
coating which includes high pressure lubricating solids for corrosion protection and to greatly
reduce the coefficient of friction.
ADJUSTABLE STOP
These split collars have threads matching the acme threads of the manual gear stem. They
clamp onto the stem in any position to mechanically limit travel.
HYDRAULIC CYLINDER
The hydraulic cylinder is a heavy duty single rod type with external tie rods. It has lip type
seals and cushions on both ends. The rod is hollow to accommodate the internal transducer.
The assembly is designated explosion proof.
MANUAL GEAR OPERATION
This TAPCO 20-T mechanical gear is a declutchable unit a three piece spilt nut. The unit may
be disengaged to allow linear movement of the stem of engaged for manual hand wheel
operation.

Plant Name: FCCU-I
8.3.3 Description of Operation of Slide Valves
8.3.3.1 Normal Operation
In normal operation: the “Command” knob must be in the “Remote” position. This gives
control of the slide valve position to the Control Room Operator. The “Function/Select” knob,
the “Set Point/Local Command “knob and the joystick (MDCV) in the control manifold are
not used. The “Deviation“ knob should normally be in the “Remote” position. The
“Function/Select” knob does not affect the function of the valve and should remain turned to
the “Position” LED for easy valve position reference.
For slide and diverter valves, the deviation indicated on the upper digital meter of the diagnostic
panel is the difference between the input command signal (%open) and the actual position
(%open) of the slide valve.
8.3.3.2 Transfer From Remote To Local
To transfer control of the slide valve position from the control room to the local control box,
the following steps must be followed:
On the electronic control panel, switch the “Deviation” knob to the “Local” position.
Use the “Set Point/Local Command” knob to drive the deviation, indicated in the LED,
to within 1% of zero (bump less transfer)
On the electronic control panel, switch the “Command” knob from “Remote” to “Local”
position.
The slide valve position is now controlled by the “Set Point/Local Command” knob on the
local control DIVERTER VALVE. To transfer control of the diverter valve position from the
control room to local hydraulic control, the following steps must be followed:
On the control manifold, switch the Mode Select Valve (MSV) to the “Manual” position.
This will close the pilot operated check valves and isolate the four-way pilot operated
directional control valve.
Use the Manual Directional Control Valve (MDCV) to move the diverter valve to the
desired position,

Plant Name: FCCU-I
8.3.3.3 Transfer from Local to Remote
To transfer control of the slide valve position from the local control box to the control room,
the following steps must be followed:
On the electronic control panel, switch the “Deviation” knob to the “Remote” position.
Have the control room adjust the command signal to the slide valve until the deviation
indicated on the local control box LCD display reads within 1% if zero (bump less
transfer).
On the electronic control panel, switch the “Command” knob from “Local” to “Remote”
position.
The slide valve position is now controlled by the signal coming from the Control Room
(Normal Operation).
To transfer control of the diverter valve position for the local box to the control room, the
following steps must be followed:
To avoid sudden changes in valve position, have the control room adjust the three
position switch in the DCS to the lock-in-place position.
On the control manifold, switch the mode select valve (MSV) to the “auto” position.
This will open the pilot operated check valves and return control to the four-way pilot
operated directional control valve.
The diverter valve is now controlled from DCS. The valve may be moved to the desired
position, open or closed.
8.3.3.4 Manual Hydraulic “Joystick” Operation
To operate the slide valve actuator with the manual hydraulic “joystick” valve, automatic
control of the servo valve must be isolated. Turn the Auto/Manual Mode Select Valve (MSV)
to its Manual position. This will close the pilot operated check valves and isolate the servo
valve. The system may now be operated with the manual directional control valve (MDCV).
For a bump less transfer back to automatic control, the command input signal, (either remote
or local), must be adjusted to the corresponding meter readout of deviation is less than 1%.

Plant Name: FCCU-I
Turn the Auto/Manual Mode Select Valve (MCV) to its AUTO position. This will open the
pilot operated check valves and allow automatic operation.
8.3.3.5 Hand-wheel Operation of The Slide Valve
To operate the slide valve actuator with the mechanical hand wheel, the automatic control to
the servo valve must be isolated.
On the control manifold, switch the mode select valve MSV-1 to the “Manual” position.
On the control manifold, open the two bypass / bleed valves (MV-11 and MV-12) which
allow hydraulic fluid, to bypass from one side of the cylinder to the other and also allow
excess fluid to bleed to the tank.
The de-clutchable manual gear may now be engaged and operated.
Caution is required during engagement to allow the gear teeth of the split-nut to align and
engage the stem.
Do not force the engagement lever. In order to do this safely, slight pressure must be maintained
on the engagement lever while the hand wheel is rotated several times. Once engagement is
felt, reverse the hand wheel rotation a half turn or so. Install the lock pin in the engagement
lever. The mechanical gear is now ready for operation.
To return control of the slide valve position to the control room, the following steps must be
followed:
On the electronic local control panel, switch the “Deviation” knob to the “Remote”
position (if necessary).
Have the control room adjust the command signal until the deviation indicated in the
local digital meter reads less than 1%
Switch the “Command” knob into the “Remote” position (if necessary).
Rotate the hand wheel while moving the engagement level to the disengaged position.
On the control manifold, close the two bypass / bleed valves (MV-11and MV-12).
Switch MSV-1 to the “Auto” position. This will allow automatic control through the
servo valve.
8.3.3.6 Analog Alarms during Normal Operation
During hand wheel or “joystick” operation of the valve, a loss of tracking alarm may occur.
This happens because, though the electronic circuit is isolated (overridden), it still senses a
deviation between command input and actual valve position. This is not a problem. The alarm

Plant Name: FCCU-I
will reset when the system is returned to electronic control or if the slide valve is manually
positioned to match the command input signal (zero deviation).
8.3.4 Electronic Control System – Assembly
8.3.4.1 Diagnostic Meter Descriptions
Deviation: This LCD (liquid crystal display) meter has two modes which correspond to a local
or remote command signal. It indicates the discrepancy (Error) in a percentage between the
actual side valve position and the selected remote or local command signal.
Function: This LCD (liquid crystal display) meter indicates the output value of the selected
function, indicated by a lighted LED. The Function Select Knob allows selection of the line
available functions of the Diagnostic Circuit.
8.3.4.2 Diagnostic Functions
Error%: Error is the difference between the actual slide valve position and the
command setting, and is expressed as percentage. Ranges from -100 to +100 can be seen.
Remote Command %: Indicates the 4-20 mA Remote Command Input Signal (from
control room) converted to a 0-100% scale.
Position %: Indicates the valve position in a 0-100% scale.
Remote Command (V): Remote command voltage is the 4-20 mA remote command
current converted to voltage. Readings range from 0 to 4 volts corresponding to a 4 to
20 mA input.
Error Bounded (V): Error Bound indicates the error signal used to drive the servo valve
output amplifier. The error bounded signal is equal to the error % signal but is clamped
to a maximum level to prevent over current driving the servo valve coils. Readings will
vary from 0 volts to 3.7 volts depending upon the error.
Servo Valve Voltage (V): This is the actual voltage driving the servo valve coil. This
signal can be used to roughly sense the current into or out of the coil.
Error Threshold (V): This function indicates the voltage level that is considered as an
error for tracking purposes. Adjustments from 0.5% to 5% relate to voltage readings of
0.05 to 0.5 volts. A hysteresis of 0.05 volts is used in this circuit. Consequently, low
level thresholds can be checked for the tendency to lock into the error state.
Dc Positive (V): Indicates DC power - Positive.

Plant Name: FCCU-I
8.3.4.3 CIRCUIT DISPLAY AND DIAGNOSTIC CIRCUIT
Power: This LED, when lit, signifies that AC power is applied.

Loss of Tracking: This LED indicates that the actuator did not follow the control signal
within a specified period of time.
Loss of Remote Command: This LED indicates when the input command signal falls
below 3.0 ma or has failed.
Loss of Feedback: This LED indicates that the signal from positive

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I
8.4 Reactor Temperature control:
Reactor Outlet temperature can be controlled in FCCU by controlling Circulation rate or by

controlling Heater coil O/l temp. In FCCU-I, heater O/L temperature by keeping the circulation
rate constant. Hence ROT is cascaded with COT which in turn is cascaded with Heater FO/FG.
Thus 4TC512 is cascaded to 4TC1911 which in turn can be cascaded with 4PC1902 (FO PCV)
or 4PC1901 (FG PCV).
8.5 MAB Air:
The total air input to heater is given by the tag 4FC516, but the total flow of the MAB
is governed by the Woodward Governor which in turn will control the steam input to
turbine.
MAB air rate is a summation of Primary, secondary and Control Air
4FC516=4FI6X+4FI7X+4FC2X.
Hence whenever any of the three is released for checking, care should be taken that
4FC516 to be taken on manual or control to be transferred to WWG.
8.5.1 Transferring of MAB air control from DCS to WWG and Vice Versa:
On DCS graphics(R-R) keep 4FC516 in manual with OP=0%. On wood ward

Governor, press F3 button, it appears “enable remote”. Yes/No? Press yes button. Now
MAB air rate control is transferred to DCS and from DCS by varying 4FC516 Set point
air rate can be regulated.
For reverting back to wood ward Governor Control, follow the same procedure in
reverse order. This is generally required for quick reduction of MAB air.
8.6 Other critical controls are as listed
S. No. Name of the Identific Control Importance of the control

Control Scheme ation Purpose
Tag No.
1 Catalyst 4PDC501 To maintain This is the most important control governing
Circulation RR DP catalyst circulation rate.
Control Air 4FC2X Control Air Controls control air to regen and also circulation
rate

Plant Name: FCCU-I
S. No. Name of the Identific Control Importance of the control

Control Scheme ation Purpose
Tag No.
MAB Air 4FC516 MAB air to The total air input to regen is given by the tag
Regen 4FC516, but the total flow of the MAB is
governed by the Woodward Governor which in
turn will control the steam input to turbine. MAB
air rate is a summation of Primary, secondary and
Control Air
4FC516=4FI6X+4FI7X+4FC2X.
WGC total Spill 4PC2407 Reactor Necessary for maintaining main column and
back Pressure reactor pressure without fluctuation and to
control maintain positive RR DP during S/D
WGC I stage 4PC2629 To control Maintains WGC I stage suction pressure and RR
suction control suction flow pressures.
of WGC
Sponge absorber 4PC2901 GCU pressure Necessary to maintain for better stabilization of
Pressure control Naphtha and separation of LPG and ATG.
Hot well level 4LC1302 Hot well level To maintain MAB surface condenser hot well
level
MAB LO header To maintain MAB LO header pressure
pressure
WGC LO header To maintain WGC Lo header pressure
WGC SO header To maintain WGC SO header pressure
WGC SO ovhd To maintain WGC SO Over head drum level
Level control
Chiller To protect chiller compressor from surge
compressor
Surge control
CAB antisurge
8.7 Interlocks
Automated Emergency Systems
The following sections describe the pre-alarms, initiators, and responses for all of the FCCU-I
automated emergency systems. Operator actions are also included.

Plant Name: FCCU-I
8.7.1 ES-1 Reactor Feed Failure
Pre-alarms:
1. FAL-501, Flow Alarm Low on Total Feed Line to Reactor Feed Riser. Set at 61 Sm3/Hr.
2. TAL-504, Temperature Low Alarm on Lower Reactor Feed Riser. Set at 480°C.
Initiators:
1. FL (CO)-502, Flow Low Cut-out on Total Feed Line to Reactor Feed Riser. Set at
40Sm3/Hr of design flow. Time delay set at 10 seconds.
2. TL(CO)-508, Temperature Low Cut-out on Lower Reactor Feed Riser (2 out of 3
voting). Set at 470°C. Time delay set at 2 seconds.
3. HS-501, ES-1 Emergency Pushbutton in Central Control Center.
4. ES-2, Main Air Failure Emergency system.
5. ES-4, Spent Catalyst Circulation Failure Emergency System.
6. ES-5, Regenerated Catalyst Circulation Failure Emergency system.
Responses:
1. Activate XA-501, Common ES-1 Tripped Alarm in the Central Control Center.
2. Close FCV-503 in Quench Naphtha Line to Reactor Feed Riser.
3. Close HCV-1X, Spent Catalyst Shutoff Slide Valve to stop spent catalyst, circulation.
4. Close HCV-2X, Regenerated Catalyst Shutoff slide Valve to stop regenerated catalyst
circulation.
5. Close HCV-501 in Oil Feed Line to the Reactor Feed Riser.
6. Open HCV-502 in Oil Feed Diversion Line to Fractionator.
7. Close FCV-504 in the Fractionator Bottoms Recycle Line to the Reactor Feed Riser.
8. Open HCV-504 in Emergency Steam Line to the Reactor Feed Riser.
9. Shutdown the Preheat Furnace.
10. TPSV will be diverted to stack and CO boiler inlet goggle v/v will be closed.
OPERATOR ACTION
Refer Page: ES-1 action

Plant Name: FCCU-I
8.7.2 ES-2 Main Air Failure
Pre-alarms
1. FAL – 516 Flow Low Alarm on Total Air to the Regenerator. Set at 33,000 Nm3/Hr.
Initiators:
1. FL (CO) 509, Flow Low Alarm on Total Air to the Regenerator. Set at 25,000Nm3/Hr.
Time delay relay set at 3 seconds.
2. HS-502, ES-2 Emergency Pushbutton in Central Control Center.
Responses:
1. Activate XA-502, Common ES-2 Tripped Alarm in the Central Control Center.
2. Open HCV-505 in Emergency Steam Line to Main Air Line.
3. Assist in closure of HCV-510, Check Valve in Main air Line.
4. Open HCV-507 in Emergency Steam Line to Regenerator Control Air Line.
5. Close FCV-2X, Flow Control Valve in Control Air Line.
6. Assist in closure of HCV-506, Check Valve in Control Air Line.
7. Close FCV-4XA in Torch Oil Line.
8. Close FCV-4XB in Torch Oil Atomizing Steam Line.
9. Close FCV-525, Flow Control Valve in Control Air Bypass Line.
10. Assist in closure of HCV-512, Check Valve in Control Air Bypass Line.
11. Activate ES-1, Reactor Feed Failure Emergency System.
12. Activate ES-8, Air Preheater Flame Failure Emergency System.
The Operator should verify that these automatic emergency actions have been taken. If they
have not occurred, then the operator must perform the actions manually.
The following summarizes the additional actions to be taken.
1. Main Air failure will result in the loss of fluidization in Regenerator and heat input to
the unit. Therefore, ES-2 activates steam to the air headers, cuts out feed and catalyst
circulation.
2. On Main Air Blower failure, the Regenerator pressure will drop rapidly. Maintain
Reactor pressure slightly higher than the Regenerator pressure (by 0.07 Kg/cm2). This
will prevent loss of the transfer line catalyst seals and Regen stack fire during start up.

Plant Name: FCCU-I
3. During MAB failure, fuel gas must not be injected into LCO stripper. The gas compressor
should be shut down immediately and Reactor pressure to be vented to flare.
4. Activation of ES-2 activates ES-1. For ES-1 steps Follow ES-1 procedure. Refer Page
The next course of action is determined on the blower outage - short or long term duration.
Each of these situations is covered separately below.
SHORT TERM BLOWER OUTAGE

If the loss of main air is short preparations can be made to restart the Main Air Blower and re-
introduce air to the Regenerator.
Check for catalyst back flow in the main air line and blower. Check the blower vent, suction
line, and drains for signs of catalyst. Before routing air to the Regenerator, the main air line
must be drained of any steam condensate in order to avoid damage to the grid.
Follow normal procedures when restarting the Main Air Blower.
Reintroducing Air:
Slowly introduce air below the grid. Gradually increase the air rate to sweep catalyst from
below the grid. Continue to increase air rate to the normal rate as limited by
Superficial velocity should not exceed the design velocity and must be limited to 0.9
m/sec
Normal operating (long term) grid DP should not cross 0.18Kg/cm2.
Short term pressure drop for the restart should not exceed 0.35Kg/cm2.
Minimum pressure drop for bed stability should be about 0.1 Kg/cm2.
Check for uniform fluidization after air introduction.

The following are signs improper fluidization.
Significant temperature variation (10 to 15°C) between bed thermocouples.
Variations exist in dilute phase of cyclone temperatures.
Grid pressure drop higher than expected at the unit operating conditions.
High bed density.
High catalyst loss

Plant Name: FCCU-I
If it is suspected that the Regenerator bed is not properly fluidized, Regen Bed fluffing can be
done. The detailed procedure for Regen grid fluffing is illustrated in Chapter#20.
Long Term Blower Outage
If the air outage is expected to be long term, preparations must be made to remove all
catalyst from the FCCU-1 fluid solids section.
Transfer catalyst from the Reactor and spent catalyst transfer line to the Regenerator.
Before unloading allow the catalyst to cool to below 425°C (design temperature of the
Used Catalyst Hopper). If this is not possible due to uneven cooling of the partially de-
fluidized bed, control the catalyst unloading rate.
Catalyst Samples should be taken to check for hydrocarbon contamination. This
information will be useful in determining any special precautions that may have to be
taken during subsequent startup operations.
8.7.3 ES-3 Control Air Failure

Pre – Alarms:
1. FAL-2X, flow Low Alarm on control Air to the Regenerator. Set at 3,800 NM3/Hr.
Timer delay set at 2 seconds.
Initiators
1. FL (CO) –510 flow Low Cut-out on Control Air to the Regenerator. Set at 2900 Nm3/Hr.
Time delay relay set at 2 seconds.
Responses:
1. Activates XA-503, Common ES-3 Tripped Alarm in the Central Control Center.
2. Opens HCV-507 in Emergency Steam Line to Regenerator Control Air Line.
3. Closes FCV-2X, Flow Control Valve in Control Air Line.
4. Assists in closure of HCV-506. Check Valve in control Air Line.
5. Closes FCV-525, Flow Control Valve in Control Air Bypass Line.
6. Assists in Closure of HCV-512, Check Valve in Control Air Bypass Line
Operator Action:
The following summarizes the additional actions to be taken:
1. Introduce SCJB lower blast steam.

2. Stabilize catalyst circulation as required by adjusting control air emergency steam flow.
Plant Name: FCCU-I
3. Check for afterburning in the dilute phase and / or cyclones. Afterburning can result
due to changes in the air distribution through the Regenerator bed. Serious afterburning
can be controlled with torch oil or the use of combustion promoter.
4. Maintain the minimum Reactor temperature of 4850C.If required reduce feed rate.
5. If the loss of Control Air was due to tripping of the blower, check for catalyst backflow
in the control air header and blower. Check the blower vent, suction line, and drains.
6. Operation with steam injection in the spent catalyst riser can be continued indefinitely.
7. Prior to a restart of the Control Air Blower, drain any steam condensate which may have
collected in the line.
8. Reintroduce Control Air. Stop steam flow to the spent catalyst riser and spent catalyst
J-bend (if in use).
9. Re-establish normal unit operating conditions.
8.7.4 ES-4 Spent Catalyst Circulation Failure
Pre-alarms:
1. LAL-2X, Level Low Alarm on Regeneration Overflow Well / Standpipe Catalyst Level.
Set at 0.21 Kg/cm2 static head above the lower instrument tap.
2. PDAL-501, Differential Pressure Low Alarm on Reactor / Regenerator. Set at –0.1
Kg/cm2.
3. TAH-527, temperature High Alarm on Spent Cat Angle Riser. Set at 550°C.
Initiators:
1. LL(CO)-503, Level Low cut out on Regenerator Overflow well/Standpipe catalyst
Level. Set at 0.14 Kg/cm2 static head above the lower instrument tap. Time delay set
at 2 seconds.
2. PDL(CO)-502A, Differential Pressure Low Cut-Out on Reactor/Regenerator. Set at -
0.13Kg/cm2. Time delay set at 2 seconds.
3. TH(CO)-528, Temperature High Cut-Out on Spent Cat angle riser. Set at 600° C. Time
delay set at 2 seconds.
Responses:
1. Activate ES-1, Reactor Feed Failure Emergency System.
Operator Action:
Plant Name: FCCU-I
1. Activation of ES-4 will trip ES-1 and result in the same automatic emergency actions
as Feed Failure:
(The operator actions to the taken are identical to those following activation of the Reactor Feed
Failure Emergency System. These are repeated below).
Operator Actions: Refer ES-1 actions
8.7.5 ES-5 REGENERATED CATALYST CIRCULATION FAILURE
Pre-alarms:
1. LAL – 3X, Level Low alarm on Reactor Stripper Catalyst Level. Set at 0.24 Kg/cm2
static head above the lower instrument tap.
2. PDAH-501, Differential Pressure High Alarm on Reactor/Regenerator. Set at
0.51Kg/cm2.
Indicators:
1. LL (CO)-502, Level Low Cut-Out Reactor Stripper. Catalyst Level. Set at 0.16 Kg/cm2
(15%) static head above the lower instrument tap. Time delay set at 2 seconds.
2. PDH(CO)-502B, Differential Pressure High Cut-out on Reactor/Regenerator. Set at 0.57
Kg/cm2. Time delay set at 2 seconds.
Responses:
1. Activate, ES-1 Reactor Feed Failure Emergency System.
Operator Action:
1. Activation of ES-5 will trip ES-1 and result in the same automatic emergency actions as
a Reactor Feed Failure
(The operator actions to be taken are identical to those following activation of the Reactor Feed
Failure emergency System. These are repeated below.)
Operator Action: Refer Page: ES-1 Actions

Plant Name: FCCU-I
8.7.6 ES – 6 MAIN AIR BLOWER MACHINERY FAILURE

Pre-alarms:
1. XS-503A/B Emergency push button in MOI and on local panel
Initiators:
1. L.O. header pr low (0.8 Kg/cm2.) PALL 1366A
2. Control Oil header pr. Very low (4.5 Kg/cm2.) PALL 1385 A
3. Trip Oil pr. Very low (2.0 Kg/cm2.) PALL 1385 A
4. Turbine steam exhaust pressure very high (-0.3 Kg/cm2.) PAHH 1372 A
5. Condensate Hot-well level very high (175mm) LAHH 1356 A
6. Turbine speed very high (7300 RPM) SAHH 1387
7. Turbine speed very high (WWG) 7230
8. Comp & Turbine vibration very high (VAHH 1350) (135µ)
9. Comp & Axial displacement ZAHH 1354 (0.7mm)
10. Comp & turbine thrust bearing temp very high TAHH 1361 (1200C.)
11. Comp & JB temp very high TAHH 1359 (110°C.)
12. Turbine JB Temp very high TAHH 1359 (120°C)
13. Emergency trip from LCP (HS503 A/B)-HSA 503BH
14. Emergency trip from DCS:HSA 503 AB
15. Manual trip lever on Governor Oil system.
Responses:
1. Active XA-504 A/B, Common ES-3 Tripped alarm DCS and on the local panel.
2. Active ES-7, Control Air Blower Machinery Failure Emergency System.
3. Shutdown turbine driver.
ES-6 will shut down the Main Air Blower. ES-7 will be activated by ES-6 to shut down
the Control Air Blower to protect it from damage due to loss of its normal suction
air flow. These actions will result in a loss of air flow to the Regenerator. This low flow
cutout will then activate ES-2, Main Air Failure Emergency System. All automatic
Plant Name: FCCU-I
emergency actions and operator actions are identical to those described previously for
activation of the Main Air Failure Emergency System.
8.7.7 ES-7 Control Air Blower Machinery Failure
Initiators:
1. HS-504 A, ES-7 Emergency Pushbuttons in Central Control Center and on the Local
Panel.
2. ES-6, Main Air Blower Machinery Emergency System.
3. Comp/ GBHS/ GBLS Relative Shaft vibration high (VAHH 1352) 100 µ / 100 µ / 135
µ.
4. Comp TB/ GB hi speed/ GBLS axial disp very high ZAHH 1351 +/-0.7mm.
5. Comp/ GBHS/ GBLS/ TB temp High – TAHH 1369 – (1200c.)
6. Comp/ GBHS/ GBLS/ LSJB temp very High – TAHH 1366: 90/110/1100c.
7. Emergency trip from LCP HS 504B – HSA 504 BHZ.
Responses:
1. Activate XA – 505 A/B, common ES – 7 Tripped Alarm DCS and on the Local Panel.
2. Shutdown motor driver.
ES-7 will shut down the Control Air Blower. These protective actions will result in a
loss of control air flow to the Regenerator activating FL (CO)-510, Flow Low Cutout on
Control Air to Regenerator. This low flow cutout will then activate ES-3.
8.7.8 ES-8 Air Preheater Flame Failure
Pre-alarms
1. FAL-6X Flow Low Alarm of Primary Air to Air Preheater.
Initiators:
1. FL(CO)-513, flow Low Cut-out on Primary Air to Auxiliary Burner.
2. BL(CO)-501, Air Preheater Flame Detector. Time delay is zero.
3. HS-505 A/B, ES-8 Emergency Pushbuttons in Central Control an on the Local Panel.
4. ES-2, Main Air Failure Emergency System.
Responses:

Plant Name: FCCU-I
1. Activate XA-506 A/B, Common ES-8 Alarm at DCS and on the Local Panel.
2. Close RCV-501 in fuel oil line to Air Preheater.
3. Close TCV-1 X in fuel oil line to Air Preheater
Operator Action:
1. During operation of the Air Preheater, an operator should always be at the local control
panel to monitor the burner flame and manually shut off the fuel in the event that the
emergency system fails to shut off fuel oil on loss of flame or primary air flow.
2. Following a trip of ES-8, the operator should verify that the automatic emergency actions
have taken place.
3. The flame failure detector should be checked for alignment or other possible problems.

Plant Name: FCCU-I
DESCRIPTION OF DISTRIBUTED CONTROL SYSTEM
CHAPTER-9
Introduction
The advancement of science and technology led to continuous development of instruments for
measurement and control. One could not have taken place without the other. The progress of
industry has always depended on precise, effective and diversified instruments. However the
principles of measurements and control do not vary whether the application is common place
or exciting. Improvement in the methods of measurement led to the development of equipment.
This improvement for measurement and control has become an essential feature of
manufacturing process operations.
The goal of control system is to achieve control of entire plant through a centralized computer.
One computer would receive a large number of inputs from field instruments, convert,
linearize, compensate, compensate, store their values and send appropriate commands to field
control devices. One great advantage of this centralized computer control is that operation is
through CRT based Video display unit(VDU). But the direct Digital control is not suitable for
large plants due to the following disadvantages.
If the centralized computer fails, the entire plant has to take a shutdown.
Termination of field wiring in one common area introduces the possibility of wiring
errors and reconfiguration of the entire system is difficult.
Limitations in the sophistication of application software.
With the advent of micro-processors, the above inadequacies are overcome in Distributed
Digital control system (DDCS) in which the computing power is distributed among many
microprocessor based controllers. Besides, the DDCS took the advantage of the CRT based
operator interface. The DDCS’s can be broadly into
Geographically and functionally distributed DCS
Geographically centralized and functionally distributed DCS.
The second one is generally preferred because this allows only one control room, air
conditioner, Uninterrupted power supply (UPS) etc.
Plant Name: FCCU-I
The second elements of DDCS are

Input/output (I/O) devices
Individual controllers
Computers for data manipulation
Engineering work station
Communication networks-for remote and local
Information exchange.
The concept of DCS is to divide a large application into multiple smaller sub-systems, each of
which carries out a portion of the application. The micro-processor based
controllers/processors receive analog signals from field transmitters as well as digital signals
from switches, relays, etc. The controllers condition these signals, perform control algorithms
and send outputs to control valve, solenoids etc. Besides, the controllers talk with each other
and with operator interface station (COPS) over a communication network called HF Bus or
DATA HIGHWAY. If a supervisory computer is also connected to DTA HIGHWAY, it has
access to all the data. The supervisory computer can be used for optimization, advanced
controls, Management information system, etc. The CRT displays provide the operator with
all the process information needed to understand and to make decisions regarding control
system. The advantages of DDCS are.
A) Flexibility
B) Better operator interface
Better monitoring and control
Easy operation with soft keys
CRT based display of all flow diagrams with existing conditions
C) Trend and Historical record facility
Eliminates need for recorders and stationery
Aid controller tuning and trouble shooting.
D) Provided scope for optimization, advanced control, MOS, etc.
E) High reliability at lower installed cost
F) Reduced maintenance.
Tata Honeywell Distributed Control System
TDC 3000 is Honeywell make Distributed Control System (DCS). Customer needs in process
industry resulted in advancements in Control and Instrumentation (C&I) technology. These
advancement and there advantages and disadvantages are shown below.

Plant Name: FCCU-I
Advancements in C&I Technology Advantage ×Disadvantage
× No Back Up
× Size of Control Panel increases
Single loop controller rarely fails
3 to 8 loops in one box

× No historisation possible
× No advance support
× No trending facility
Centralised control
Programmable configurations
× Main dependency on computer
Functions distributed
Redundancy possible
Failure of one element of the control system
may not effect the entire plant control
Development of C&I technology from Pneumatic to electronic equipment was itself a

very big change. In electronic C&I equipment various function blocks were used to function
under inter dependent circuits and control logic.

Plant Name: FCCU-I
At this stage these functions were interconnected by signals through multiple cables.
Application of microprocessors and Digital communication techniques made it possible to
distribute the elements of C&I equipment. Elements of C&I equipment distribute
geographically and functionally, reducing multiple cables inter connection into a single cable.
This interconnection of processing function blocks of a system is termed as a NETWORK.

The signal levels and states previously used through multiple cables are now digital information
packets, multiplexed in time, around the network, sent and received by connected functional
processors.
Further advancements allowed the distribution of C&I system on various types of functional
networks like
Process network

Plant Name: FCCU-I
Supervisory network
Plant information network
Plant wide C&I automation depended on these networks emerging as Distributed Control
system.
The important benefit of DCS which is making it popular is the fact that even Failure of
processor or a network will not result in failure of other processor or networks of the system
respectively.
Following are the function blocs in a DCS with their use:

Plant Name: FCCU-I
These are the main benefits of DCS over conventional C&I equipment.
Reduction in cabling in control room

Physically and functionally separate modules
More uniform management
Better integrations of plant controls
Considerable reduction over maintenance efforts (through built-in diagnostic)
TDC 3000 OPERATING SYSTEM
First DCS came in 1974 from Honeywell. It was named then TDC 2000 (Total Distributed
control 2000). The communication link in TDC 2000 is called DATA HIWAY.(DH)

Plant Name: FCCU-I
Further development introduced a new process network UNIVERSAL CONTROL

NETWORK (UNC) IN 1989. This new process network is connected LCN through Network
interface module (NIM). Capacity of NIM is higher that HG. This new TDC3000 system
architecture after inclusion of UNC and other process connected boxes is shown below.
ADVANCE PROCESS MANGERS (APM) AND LOGIC MANAGERS (LM) are the UNC
connected automatic process controllers. In various plant TDC3000 is practically implemented
with redundant communication medium (cables), Gate ways and process further advancements
resulted in release of TDC3000 in 1984. This new release of DCS from Honeywell contains
new supervisory LOCAL CONTROL NETWORK (LCN) and incremental capacity. A system
architecture of early TDC3000 is shown below.

Plant Name: FCCU-I
The LCN connected UNIVERSAL STATION (US) is used for man-machine interface and
HISTORY MODULE (HM) is used for storage of process and system related information.
Process connected controllers like BASIC CONTROLLERS (CB) and ADVANCD
MULTIFUNCTION CONTROLLERS (AMC) are linked to LNC through the process network
DG and an interface HIWAY GATE WAY (HG).
This means, monitoring and operating the process plan using Universal Station of TDC3000
system. This includes
Calling various displays
Monitoring status, values, trends, modes and events on displays
Manipulating Parameters
Responding to various alarms and messages
Taking various hard copies on printers
Storing important process related information.
Sensors and actuators of various kind from the process plant are connected to process
controllers. Through networks, process information (Values, Status, Modes, alarms etc) is
made available on the US displays. From US it is possible to manipulate direct actuator dive,
value and mode change of different parameter in automatic control functions. Also, various
commands to controllers and other network connected function blocks can be sent from US.

Plant Name: FCCU-I
Uninterrupted Power Supply (UPS)
The main function of any UPS is to maintain load and power backup. UPS protects the
equipment against power surges and spikes caused by rapid fluctuation in the amplitude of
alternating current and also ensures against low voltage and no power condition. The usage of
UPS for micro-processor based equipment is a must as these equipment are normally designed
to operate on very narrow voltage bands, are sensitive to large voltage variation.
The main elements of UPS are the Rectifier, Inverter, Static bypass switch and Service bypass.
The configuration completes with a battery for energy storage. Battery offers a no break
standby power supply. Rectifier gives DC voltage output from a given input power. This DC
voltage is converted by the inverter into AC which supplies the connected loads with constant
voltage and frequency.
In the Refineries UPS is normally provider for DCS and other important control stations. In
Visakh Refinery three different UPS have been provided. They are
1. 75KVA Cybrex (supplier) UPS for VREP-I requirements

2. 2x100 KVA Hirel (supplier) UPS for Old Refinery requirements
3. 10 KVA Keltron (supplier) UPS for power plant.
Plant Name: FCCU-I
VREP-II UPS SYSTEM
DESIGN BASIS:
This is a parallel redundant UPS with bypass facility. This capacity of each UPS is 100 KVA
(2x100KVA). This system is supplied by Gutor, Switzerland.
CDUIII and FCCI operating stations located in MOI building and control stations located in
CENTUM are fed from this system. TDC3000 US stations UPS supplied by Hire UPS.
INCOMER POWER DISTRIBUTION:
* In comer I&II (I/C-I/II) can be fed from SS 12A or SS40.

* Bypass is fed from SS40.
* Normally only one in comer will feed both UPS. If the one which is feeding fails then
one can be switched on. This operation is to be done manually by using bus coupler.
NORMAL CONDITIONS:
* Normally both UPS I and UPS II will be online with 50% load on each
* Bypass will be normally in ‘on’ position.
FAILURE CONDITIONS:
1. Normally both UPS fails (incomer or rectifier) the other one will take the full load.
2. If both the UPS fails battery backup will be available through inverter.
3. If both UPS and inverter-I & inverter-II fail, then bypass will take the entire load.
All the above actions are automatic through static switches and HSS. These can be done
manually also.
Inside UPS, 415V supply is stepped down to 240 V through a transformer and converted to
240 DC by a rectifier (fall control thyristorised converter). This DC bus is connected to 995AH
capacity battery backup with 170 cells and inverter. The inverter is of bipolar junction transistor
type which converts 240 DC to 110 V AC through a transformer. The batteries will be on
floating condition normally. Once in every 6 months each battery should be boost charged.
Plant Name: FCCU-I
Blocking diodes are provided after rectifier to prevent battery power flow to convert unit.
BYPASS
For bypass supply, 415V 3 Phase is stepped down to 110 V AC Single phase with help of 3
phase to 1 phase transformer along with servo voltage stabilizer.
Two static switches are available to change over to bypass supply at any time. This static switch
synchronizes output between UPS and bypass, thereby avoiding any fluctuations in 110V AC
output.

Plant Name: FCCU-I

Plant Name: FCCU-I
DESCRIPTION OF ADVANCED PROCESS CONTROLS
CHAPTER 10
10.0 ADVANCED PROCESS CONTROLLER (APC)

Phenomenal developments have taken place in the field of control, computing and
communications making it now possible to implement extremely complex control strategies
that would have been impossible to implement with analog hardware.
APC is a smart Controller which predicts the plant behavior controls and optimizes based on
its models in order to utilize total potential from the process plant”
Best Companion for plant operation

Predicts the immediate future of process
Strives for the most profitable combination
Reduces the Load of the most routine jobs
Earns the time for troubleshooting.
10.1.0 Overall Control Objectives

Throughput Maximization
Maintain Product Quality
Yield Maximization of Valuable Products Specific Energy & Utility Consumption
Minimization
Stable & safe operation
A technology called Robust Multivariable Predictive Control Technology (RMPCT) elegantly

combines traditional advanced control concepts into a single software application to achieve
throughput maximization, energy minimization and improved quality control of linear
multivariable processes in the presence of constraints. RMPCT is a Range Controller which
uses dynamic process model to predict MV moves, does economic optimization when there are
additional degrees of freedom and provides Good control even under model uncertainties
Honeywell’s Robust Multivariable Predictive Control Technology (RMPCT) is a multi-input

multi-output control application that controls and optimizes highly interactive industrial
processes Control and Optimization.
Honeywell’s Profit Controller (RMPCT) controls and optimizes processes that have significant
interaction between variables. The controller incorporates a model of the process dynamics.
Plant Name: FCCU-I
From this model, it predicts future behavior of the process and determines how to adjust the
controller’s out puts to bring all process variables to set points or within constraints. Then if
there are any degrees of freedom remaining, the controller adjusts the process to optimize
operations, for example by maximizing total product value.
10.1.2 Robustness
Robust refers to the unique ability of Profit Controller to maintain good control of a process with
highly interacting variables even though the process model might have large errors.
The Profit Controller (RMPCT) product consists of several components that we use for
collecting open-loop test data, identifying the model, and building, simulating, installing, and
operating a controller.
10.1.3 Data Collector -Collects specified CV, MV, and DV samples and stores the values to a
file. This tool is for LCN applications only.
10.1.4 Identifier - A Windows-based application that uses the files produced by the Data
Collector (or files in other sampled-data formats) to identify the process model.
10.1.5 Controller Builder- The hand-and -glove complement to the Identifier. This Windows-
based application uses the process model to build the controller.
10.1.6 Open Systems Simulator- An interactive, Windows-based tool that runs the controller
with a simulated process according to a scenario that you specify.
10.1.7 TDC 3000 Simulator

This simulator uses sub-process models in the form of x transfer functions that specify to mimic
an actual process. The simulated process can be hooked to a controller exactly as if it were a
real process. The Operator interface is the same whether a real or simulated process is being
controlled.
10.1.8 Online Controller The installed Profit Controller (RMPCT) runs the actual process or a
simulated process. It includes an Operator interface.

Plant Name: FCCU-I
10.1.9 Implementation of APC
Here is a summary of how a controller is implemented:
1. Identification of CVs, MVs, and DVs.
2. Open existing loops between CVs and MVs. Test input signals are applied to the MVs (the
simplest test signal is a series of steps made by the Operator). Test signals can be applied to the
DVs, if possible; otherwise, a period of time must be found when the DV value is undergoing
significant change.
3. CV, MV, and DV signals are recorded during the test. The variables’ values are sampled at
the interval (or a sub interval) at which the controller is expected to execute. The sampled values
are collected into one or more files.
4. Process model is identified using the collected data from the open-loop testing.
5. Controller is built from the model. Using the Honeywell Controller Builder, the result is two
files that define this particular controller application. These are read by the controller to define
its operation when it is first activated.
6. Controller is run in simulation to verify that the controller works as expected.
7. Controller is installed. Use WARM mode to test control before turning controller ON.
10.1.10 CVs
Controlled variables are the process conditions to be controlled (that is why they are also called
PVs, process variables). The temperature of an outflow stream can be a CV.
10.1.11 MVs
Manipulated variables are the control handles on the process. These are the variables whose
conditions are manipulated (changed) to control the CVs. The gas flow to a furnace can be an
MV.
10.1.12 DVs
Disturbance variables are measured disturbances (changes) in the process that influence the
CVs, but that are not DV.

Plant Name: FCCU-I
10.1.13 Benefits of APC

Reduce Variation of important variable (parameter)
Increase Throughput
Improve product yield
Reduce energy consumption
Minimize Quality Giveaway
Increase responsiveness
Improved process safety
Reduce environmental emissions
10.1.14 Computer System Configuration

It is very important to know the data flow for understanding RMPCT set up. The data
(Value) flows from DCS to APC server (FCCU-I APC server) through the interface
machine (APP Node). The APC server machine does all the control and tool kit
calculations and writes on the DCS tags through the APP node. This execution takes 30
seconds for RRS controller and 45 seconds each for MFR and GCU controllers. A
sketch of the computer system configuration is given below.

Plant Name: FCCU-I

Plant Name: FCCU-I
10.2 OPERATOR TRAINING SIMULATOR (OTS)
The Operator training Simulator is a simulation device used in training personnel before
operating the actual plant. FCCU-IR has got a custom model supplied by Honeywell. The
simulator uses Shadow Plant system. Shadow plant system is a new generation simulation tool
based on the Trainer process simulation system. Shadow plant application features are similar
to the original trainer features and functionality. The simulator is a collection of proprietary
programs that are used to build and run simulation models. These models represent the dynamic
process characteristics, controls information and logic configurations for a given process.
Shadow plant can be used for process design, operating strategy, development, process
troubleshooting and control strategy testing.
There are four types of shadow plant users:

Trainees
Instructors
Engineers and
System administrators
10.2.1 Instructors and trainees use the shadow plant to conduct both supervised and
unsupervised training sessions. During these sessions users may complete some or all of the
following tasks.
Create training exercises or scenarios.
Initialize the simulator to previously saved conditions
Operate and control the simulated process using the operator or instructor console
Monitor a trainee performance
Print or save trainee performance summary report
10.2.2 Engineers are responsible for creating and updating the simulation model to reflect
operating conditions.
10.2.3 System Manager is responsible for the following tasks.

Maintain hardware and simulation software.
Add, Delete and change Shadow plant accounts
Assigning space for source and operating files.
Manage disk storage space.
Back up of existing model files and
Manage system security.

Plant Name: FCCU-I
The system consists of a operating console which consists of normal Plant graphics, a FOD
(Field Operated Devices) station and a Simulator station where in emergencies and scenarios
are simulated. The operating console and FOD station are available to the trainee whereas the
Simulator station is made available to the Instructor.

Plant Name: FCCU-I

Plant Name: FCCU-I
REFRACTORY DRY-OUT & COMMISSIONING
CHAPTER 11
REFRACTORY DRY OUT
11.1 HEATER
11.1.1 Description
11.1.2 Heater Dry out Preparation
11.1.3 Heater Dry out Instructions
11.2 REGENERATOR - REACTOR
11.2.1 Dry out Pre-checks
11.2.2 Air Preheater Firing Procedure
a) Pre-checks
b) Heater Purge
c) Pilot Ignition
d) Burner Ignition
e) Burner Flame On
11.2.3 DRY OUT PROCEDURE
Fig 11.1 Heater Dry out chart
Fig 11.2 Excess air requirement chart
Fig 11.3 Calculated Grid DP
Fig 11.4 APH

Plant Name: FCCU-I
CHAPTER – 11
REFRACTORY DRY OUT
HEATER
11.1.1 DESCRIPTION
The FCCU furnace is single cell heater bottom fired furnace with radiation and convection
sections. It has an upright steel structure with an outer steel casing. The casing is lined with
refractory material on the inside and forms the combustion chamber.
The combustion chamber houses the radiant section tubes. In this section heat is transferred
primarily by radiation from the flame and hot combustion products. The casing convection
section provided at the top of the radiation section serves to increase thermal efficiency of the
furnace by recovering more heat from the flue gases leaving the radiant section. The convection
section houses preheat coils. The feed which is to be heated enter the convection section. From
the convection zone of the furnace it enters the radiant section. The flue gases from radiant
zone pass to the convection zone of the furnace.
The floor is elevated above grade so that the foundations are air cooled. This also helps in
burner operation and maintenance. Peep holes are provided in the floor as well as radiant
chamber side walls to facilitate inspection of the inside of the furnace. The furnace operates in
natural draft and the draft can be varied as required by the operation of the damper. The damper
can be operated from the grade or from DCS. Soot blowers are housed in the convection section
and these are to be operated once in a shift to keep the convection tubes clean.
Draft gauges and sample nozzles are provided in the heater to measure draft and to take flue
gas samples. Snuffing steam connections are given for fire box purging which can be operated
in emergency during fire on the floor box or purging the box.
11.1.2 HEATER DRYOUT PREPARATION:
1. Swing elbows to be lined up as follows. :
a) From steam / Air injection (decoking) to individual pass inlet at inlet of tubes.
b) From individual pass outlet to decoking heater decoking drum.

Plant Name: FCCU-I
2. All instruments on open loop and closed loops calibrated / stroke checked for MP steam, LP
steam, FG system. Heater (including dampers etc.) and temperature elements in individual
heater passes.
3. Heater trip logics to be checked including FG, FO PSL / PSLL

4. Heater inlet including tubes, studded tubes, burners etc. are clean.
5. Damper on stack to be operable locally through winch cables and from DCS
6. Heater peepholes should be free. Air registers should be in working order.
7. FG burners to be flushed with air and fixed / boxed up

8. Igniter rods and accessories should be tested and ready.
9. Heater explosion doors to be checked and ensured for freeness.
10. Heater M/H to be boxed up
11. Portable gas detectors and optical pyrometers to be made available.
11.1.3 HEATER DRY OUT INSTRUCTIONS
Heater dry out instructions, given below, should be followed for carrying out the dry out for
feed Preheat Furnace (04-F-051) of FCC unit.
(a) PURPOSE
Furnace dry-out procedures are utilized as a means of curing furnace refractory before initial
process operation. At the same time, the dry out period is also used as a means of checking the
operation of certain heater components such as burners and such control devices as may be
used during the dry-out period.
(b) DURATION
A 3-5 day dry-out cycle is generally required during which furnace temperature is gradually
increased to the point at which refractory is completely dry. If linings are excessively wet, then
only the pilots should be left alight for a day or to dry off this excess moisture. During the dry-
out cycle, moisture in the heater refractory close to the burners is evaporated within a very
short time, generally, over a three day cycle moisture inside the refractory is removed.
(c) TUBE PROTECTON
During the dry- out cycle, it is customary to circulate steam through all process tubes in order
to prevent over-heating. Steam is only introduced after warm up to prevent undue condensation

Plant Name: FCCU-I
and water hammer. The tube metal temperature should be measured by the monitoring the tags
TI1957, TI1958,TI1959, TI1960, TI1968, and TI 1969 regularly and limited to 5340C (Please
ensure that flue gas temperature at the entry of steam superheater should nor exceed
4100C). It is advisable to pass cooling steam even if the TMT is within the maximum allowable
figure specified in the datasheet.
(D) REFRACTORY DRY-OUT
For the initial phase of dry-out, only fuel gas should be used when available, to facilitate control
and easy changeover of burners.
This of course is an opportune moment for testing out stack damper mechanism, and any
rectification of faults of adjustment should be carried out before proceeding with the dry-out.
(E) PURGE FIRE BOX
Before even de-blinding fuel lines, the furnace firebox must be snuffed out with snuffing steam
and then tested for hydrocarbon gases, if negative, then proceed with the de-blanking of the
fuel gas lines and light off the pilot burner. If there is undue delay in removing fuel gas line
spades or any other delay which prevents the lighting of the burners. The fire box must be re-
purged with steam and retested for gas freeness.
Never de-blind the fuel lines, particularly fuel gas lines, and leave the heater overnight with
unlit burners i.e. a delayed or interrupted startup. If there is any leak. A serious buildup of fuel
gas in the furnaces can result in explosion.
(F) BURNER VENDOR INSTRUCTIONS
Vendor’s standing instructions on lighting burners and all directions concerned with heater
firing must be followed implicitly and Engineers India’s recommendations are complimentary
These instructions.
(G) LIGHTING BURNERS
It is recommended that drying out operation be done on fuel gas as control of firing will be
much easier. When the fire box has been certified “gas free” light all the pilot burners and raise
the temperature with lighting sufficient main burners to bring arch temperature upto 1200C at
a rate of 250 C/hr.

Plant Name: FCCU-I
(H) Dry Out
Hold the temperature at 1200C for 12 hours (minimum) by rotating the burners for heat
uniformity and then increase to 2000C after making sure that all the condensate has been
drained off. Check all burners, observe conditions inside the firebox and inspect areas of
expansion. Hold at 2000 C
Following this, increase the arch temperature to 4000C again at 250C/hr. Hold at this
temperature for 24 hours and repeat checks as above. Increase the flow of steam/N2/Air if the
tube metal temperature is found exceeding maximum temperature specified in the data sheet.
The heat duty requirement during dry out may not warrant firing of all the burners during dry
out. Sufficient number of burners, with good flames may be fired and the operation of burners
rotated every 2 hours to maintain uniformity. This shall not, however, be construed that only 1
or 2 burners may be fired as it may not be possible to maintain uniform firing.
Before proceeding to the final stage of drying out, check that ample supply of steam/N2/Air is
available to prevent over-heating the tubes. Increase the arch temperature at the rate of 250C/hr
to 5000C and hold for 24hours. Make a thorough check of the unit during this period and in
particular, expansion should be noted and damper movements checked.
During dry out, it is advisable to try all instruments and controllers on automatic control, and
see that all alarms, warning light, etc. are functioning properly.
At the end of the 5000C drying out period, reduce the arch temperature at a rate of 500 C per
hour and accordingly start reducing the steam/N2/Air flow through the tubes. Spade off the fuel
lines immediately.
When the firebox is cool enough and the inside entry permits available, inspect the refractory
for any signs of failure.
11.2 REGENERATOR – REACTOR REFRACTORY DRYOUT
This section covers the dry-out of the vessel refractory linings, which is carried out as part of
the preparation for initial startup after implementation of the revamp project. Before the initial
startup, or after major lining repairs (i.e. there is an area of replaced refractory larger than
2.8m2, or summed areas exceeding 20% of the total lining installation), the refractory linings
in the Reactor, Regenerator, Air Preheater, and transfer lines must be dried out at a controlled
rate to remove water in lining which could cause lining damage if rapidly heated. This involves

Plant Name: FCCU-I
heating the lining sections in a stepwise fashion with blower air and the Air Preheater up to
around 510 0C.The vessels may then be cooled down and the lining sections inspected for
damage, or the startup may be continued based in favorable outside shell metal temperatures.
11.2.1 PRECHECKS BEFORE REFRACTORY DRYOUT.
1. Check that all hydrocarbon blinds are installed, including the blind in the reactor
overhead line at the fractionator inlet. Commission required utility systems.
2. Open completely the reactor overhead vents, valves for diversion of the regenerator
overhead atmosphere, and the spent and regenerated catalyst shut-off slide valves.
3. Open all low point drains.
4. Commission all instrument purges.
5. Commission the reactor/regenerator differential pressure instruments, all temperature
instruments in the Reactor, Regenerator, and regenerator overhead, and all main air
blower instruments.
6. Confirm all blower auxiliary systems are operational. Commission the Main Air Blower
following procedures reflecting the vendor’s recommendations. Introduce air into the
unit with all vents, drains and slide valves fully open for unit blowout. Watch
regenerator grid pressure drop closely and do not exceed 0.35 kg/cm2.
7. Prepare the Air Preheater for firing. Confirm that a complete functional test of the
burner management system, including flame out, has been performed. Commission all
instrumentation and pull the blind on the fuel and pilot gas supply lines.
8. For each lining section requiring dry-out, select a representative TI to monitor air
temperature at that lining section. Consider using temporary or sacrificial TI’s for
critical area that normally would be without an available TI.
9. Control the blower outlet conditions to maintain an initial air temperature at the Air
Preheater outlet (based on a TI under the grid) between 65 and 1500C.
Adjust the spent and regen catalyst slide valves as necessary to achieve uniform temperature
in each transfer line. Maximize reactor side venting to achieve as uniform as possible
temperatures on the reactor and regenerator sides. Open additional vents or manways as
required, but avoid excessive noise. Drain water from all low points.

Plant Name: FCCU-I
11.2.2 AIR PREHEATER FIRING PROCEDURE
PRESTART –UP CHECK
1. Complete functionality test has been carried out in the BMS and associated Emergency
Shutdown Systems.
2. Ultraviolet flameout detector has been checked out and ready for use, but not
commissioned.
3. Igniter has been checked out to ensure it will operate.
4. Secondary air butterfly valve is wide open.
5. Fuel gas and plant air lines are drained of all condensate and clear of scale.
6. Steam tracing for the fuel oil supply has been commissioned.
7. Air flow is established to burner sight ports.
8. All instruments have been checked for operation.
9. Check that the oil gun is fitted.
10. Check that the burner manual isolating valves are closed.
11. Check that all the necessary services are available i.e. pilot gas, pilot air, atomizing
steam and fuel Oil.
12. Check the plant area for oil leaks.
13. Check that the fuel selector switch on the BMS panel is in the “oil selected” position.

Plant Name: FCCU-I
(A) HEATER PURGE
Before the heater can be purged, all the following interlocks must be healthy.
1. No Emergency Stop push buttons operated.

2. Primary air flow above the low limit.
3. Main air flow not failed.
4. No pilot flame detected.
5. No main flame detected.
6. Oil block valve RCV501 to be closed.
7. Igniter system not energized.
8. Heater purge not started.
When all the interlock are correct, the “heater ready to purge” lamp will be on. When the heater
purge button is pushed the “heater ready to purge” lamp will go out.
Before starting the purge the air – flow must be set manually to its maximum flow to ensure
that there is sufficient purge air.
When the purge time (5 minutes) is complete the “heater purged” lamp will go on and the fuel
control valve will go to its light up position.
The air fan must be manually set to its light up position (25%) and the primary air manual
damper set to a light up-position. (This is to be determined during commissioning)
(B) PILOT IGNITON
Ensure that the “heater purged” lamp is on.
Check that all the pilot air and pilot gas manual isolating valves are open.
Press the “pilot start” push button. The pilot ignition sequence is automatic and following a
period of time (approximately- 7-12 seconds), the “pilot flame on” lamp will come on.

Plant Name: FCCU-I
Note:-The pilot air and gas pressures should be set at 2kg/cm2 < 2 which is approximately 0.5
kg/cm2 < 2 above the furnace pressure.
(C) BURNER IGNITION
Check that all the manual oil and steam isolating valves are open.
Check that atomizing steam is flowing to the burner.
Check that the primary air flow is correct for light up.
Visually check for a satisfactory stable pilot flame.
Check that the “burner ready to start” lamp is on.
Press the “burner start” push button.
The oil flame must be detected by the main flame detector within 10 seconds. If a flame is not
detected by the end of this period the oil valves will close.
If the pilot burner is still a light it will be possible to try to light the oil burner again.
Note:-This should only be attempted three times before the heater is purged again.
(D) BURNER FLAME ON
Once the burner “flame on” lamp is on, the burner will stay alight until it is stopped either
manually or by an interlock failure. The burner combustion control will now-be in the control
of the plant operators.
11.2.3 REFRACTORY DRYOUT PROCEDURE FOR REGENERATOR-REACTOR

SECTION OF FCCU- 1 REVAMP UNIT
1. Monitor the temperatures throughout fluidized solids side of the Reactor and
regenerator during the dry-out period. A list of the TI’s to be monitored is attached.
2. Start – up the Air Blower and initially discharge the air flow to the atmosphere.

Plant Name: FCCU-I
3. Gradually route the air from the blower to the regenerator via the pre-heater. Adjust
the air blower –outlet conditions to achieve an initial air temperature at the air pre-
heater outlet to 120 Deg. C.
4. Continue to heat up at a rate of about 25 Deg. C per hour based on a TI under the
Regenerator grid (TI-4X) to a target temperature of 195 Deg. C. The maximum
temperature for this phase is 205 Deg. C.
The heat –up rate can be controlled by adjusting the air blower rate to the
Regenerator. If the target Regenerator temperature cannot be attained slowly with
the air blower, then the air pre-heater should be commissioned
Note:-The Air Preheater must always be run with a minimum of 100% Excess
primary air.
Hold within the temperature range of 120 to 205 Deg. C. for 1-1/2 hours per 25mm
refractory linings thickness. The maximum refractory thickness in the regenerator
vessel is about 125 mm requiring a hold period of about 8 hours
IMPORTANT: The maximum regenerator grid DP at any time during the refractory
dry-out and unit start – up is 0.35 kg/Cm2. Also, the maximum grid metal temperature
is 593 Deg. C
5. Commission the air pre heater, if not already commissioned during the below grid dry-
out phase.
Note:- The Air Preheater must always be run with a minimum of 100% primary excess
air. Minimum primary air requirements can be calculated as follows.
Minimum Primary air = FIIX * 0.0074 (T14X -107) Knm3 / hr
Safe minimum primary air = FIIX * 0.0074 ((T14X -107) + 2Knm3/hr
6. Increase the air preheater outlet temperature at a rate 25 Deg. C per hour as measured
below the grid until all refractory linings of the regenerator and reactor.
7. (Including the regen spent catalyst transfer lines) have been held between a minimum
of 120 Deg. C and a maximum of 205 Deg. C for 1-1/2 hour per 25mm linings thickness.

Plant Name: FCCU-I
The maximum refractory thickness in the reactor vessel is about 100mm, requiring a
hold period of about 6 hours.
Note: - Once the temperature exceed 120 Deg. C at any point in the reactor and
regenerator circuit, the holding period for refractory dry-out at that point begins.
The temperature exceeds in any section of refractory cannot exceed 205 Deg. C until it
has been held between 120 Deg. C and 205 Deg C for the specified time period. This
requirement may control the Air Pre-heater heat up-rate.
SUMMARIZING: All refractory linings of the Regenerator and Reactor (including

the regen spent catalyst transfer lines) must be held between a minimum of 120 Deg. C
and maximum of 205 Deg. C for 1-1/2 hours per 25mm of lining thickness.
7. Increase the Air Preheater outlet temperature at a rate of 25 Deg. C per hour, until
the regenerator outlet reaches 510 Deg. C and the Reactor outlet and Reactor Stripper
reach 435 Deg. C Hold all sections of the Regenerator at 510 Deg. C for 8 hours and
all section of the reactor at 435 Deg C for 6 hours to complete the dry-out process
Adjust the slide valve positions in the spent and regenerated catalyst circuits to achieve
uniform heat-up rate of the reactor outlet and reactor stripper sections.
Should the target reactor temperature of 435 Deg. C not be attainable, the lining is
considered dry when the outside shell metal temperature at that linings section location
has been held at or above 80 Deg. C for a minimum of 6 hours. Skin temperature should
be monitored using an optical pyrometer or skin thermometer.
REFRACTORY DRY OUT TEMPERATURES

TO BE MONITORED
Sl. No. Instrument Service
1. TI-X Regenerator Air Preheater
2. TI-9X Regenerator Upper Dense Phase
3. TI-11X Regenerator Primary Cyclone Inlet
4. TI-14X Regenerator Cyclone Outlet
5. TI-35X Regenerator Dilute Phase
6. TI-502 Lower Reactor Feed Riser
7. TI-509 Upper Reactor Feed Riser
8. TI-510 Reactor Plenum

Plant Name: FCCU-I
9. TIC-512 Reactor Overhead

10. TI-513 Reactor Stripper Bottom
11. TI-514 Regenerator mid Dense Bed
12. TI-517 Regenerator Lower Dense Bed
13. TI-519 Regenerator mid Dilute Phase
14. TI-521 Regenerator Grid Metal
15. TI-526 Spent Cat Riser
16. TAH-532 Main Air Blower Discharge
17. TAH-533 Control Air Blower discharge
18. TI-536 Regenerator Plenum
19. TI-538 Regenerator Overhead To Co-Boiler
20 TI-4X Regenerator below Grid

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I
11.3 COMMISSIONING ACTIVITIES
The steps required for the initial start-up of the FCC unit or start-up following turnaround:
Refractory within the Reactor and Regenerator should have been previously cured and the High
Temperature Field Test should have been completed.
Prior to introducing hydrocarbon to the FCC Complex, all lines and vessels (excluding
Regenerator and associated piping) must be air-freed by purging with steam or nitrogen; the
Wet Gas Compressor should be purged with nitrogen only. Purging allows hydrocarbon
introduction under an inert atmosphere.
11.4 PREREQUISITES
Commissioning and start-up procedures for WGC, MAB, APH.

The following utility systems must be fully commissioned:
Steam systems
Heat tracing
Condensate systems
Fire water
Utility water
Cooling water (ready for service subsequent to air purging)
Boiler feed water
Instrument air
Plant air
Nitrogen
Flare system
Oily water sewer
Closed blow down
Fuel and pilot gas systems
Required unit electrical systems
Sour water treatment
Main column chemical injection
Unit PRV‘s are installed and properly aligned
Spring hangers and supports properly set with stops removed
Expansion joint shipping bars removed and limit rods free

Plant Name: FCCU-I
Reamer available for unplugging aeration taps
MAB and WGC‘s available for operation, Unit pumps available for operation
APH available for operation; fuel gas system leak tested and air freed; fuel gas available
at battery limit
Spectacle blind in closed position at the following points:
2” start-up naphtha to feed distributor header

2” fuel gas line to APH
2” start-up naphtha to riser
Blind installed at the torch oil flow control valve
WGC‘s first and second stage suction, discharge, and spillback isolated
WGC‘s under N2 purge

Reactor vapour line vent to be kept open as Vapour line blind is IN position
Remove blinds and/or open vents/drains at the following points:

2 1½ drains at reactor wye
6” reactor vent
2” main column vent
2” main column overhead receiver vent
Compressor suction drum and Interstage suction drum vents
The unit must be completely flushed with all orifice plates installed and all hydrostatic
pressure testing completed.
Close the following valves:

Regenerated catalyst slide valve
Spent catalyst slide valve
6 nos. 4” globe valves on raw oil feed line to feed distributors
6 nos. 4” gate valves on raw oil feed line to feed distributors directly upstream f
secondary atomizing steam.
Confirm all other unit blinds set to correct positions for start-up as per the unit
blind list. Isolate cooling water supply and return valves and open vents/drains to
prevent excessive steam condensation.
Catalyst hopper logbooks must be available in control room and maintained up to date.
Plant Name: FCCU-I
Scaffolding has been erected for expansion joint monitoring.
TPSV is in divert position. CO Boiler should be bypass; Ensure TPSV should be towards
stack
Start Instrument air purge to the reactor and regenerator aeration points. Verify flow by
briefly closing individual root valves at the vessel and noting pressure increase, and then
reopening valves to verify taps are clear. Aeration flow should be stable with header
pressure greater than 4.0 kg/cm2 at all times.
Ensure 4HV502, feed diversion is open. This position closes oil feed to the riser shutoff
valve 4HC501 and opens feed bypass to the main column.
Ensure all 6 nos. 4” gate valves (shell valves) on the feed distributors are kept in close
position and provide temporary air hose connection at the Primary atomizing steam c/v
FV-13X d/s bleeder point and keep all the feed nozzles under air purge to prevent
plugging.
11.4.1 MAIN AIR BLOWER start-up and APH light up
Regenerator heating initially is conducted with heat generated from operating the main air
blower. After the discharge temperature has stabilized, the APH must be placed into
service to continue heating the regenerator.
Be sure all aeration points and all instruments on the reactor and regenerator structure are
in service.
Verify that the spent and regenerated catalyst slide valves are set to manual mode and are
closed. Commission the main air blower per detailed vendor instructions. Target a flow of
35000 Nm3/hr to maintain flow above the ES trip point of 25000Nm3/hr.
After the main air blower discharge temperature has stabilized, remove the 2 fuel gas
blind to the APH, and prepare the APH for service. Light the pilot flame per detailed
vendor instructions. Adjustment of the APH damper or air flow to regenerator may be
required to light the APH burners. An operator should be continuously stationed next to
the APH to monitor the flame during operation on a 24 hour basis. Operator rotation
should be planned accordingly.

Plant Name: FCCU-I
If the heater is shut down for any reason, allow a 10 minute purge before resetting the fuel
gas solenoid valves. During APH light up trial MAB air to regenerator need to reduce
below 25.5 KNM3/HR, hence MAB discharge flow LOW LOW trip need to be bypassed.
Heat from the pilots and main burner minimum firing will increase the APH outlet
temperature immediately. Maintain minimum firing and increase MAB flow to limit
temperature increase. Follow Refractory Dry out procedure.
Simultaneously open the slide valves and increase the reactor temperature. If the reactor
temperature has reached 180°C, introduce the following steams to the reactor.
11.4.2 STEAMING OF MAIN COLUM, LCO&HCO STRIPPER & GCU
Remove the blind from 4C51 main fractionator vent line and then keep the valve open a
couple of rounds. Open bottom drain blind to drain liquid /condensate.
Close the suction and discharge valves of the gas compressor. Start steam into the bottom
of the main column through SOP POINT. Start steam to HCO/LCO stripers, Steam out
these columns through the main column overhead condensers to main fractionator
overhead drum 4V51. Do not open cooling water to 4E59A/B/C/D during steaming and
steam purging.
Steam out all LCO, HCO, slurry, CLO circuits by opening steam at the pump SOP and
providing additional steam hoses in the circuit.
Ensure WGC suction and discharge valves are closed and compressor kept under
Nitrogen purge. Carry out pressure testing of compressor flanges with nitrogen at 1.5
Kg/cm2.During steam purging keep compressors positively isolated and make sure
steam doesn’t enter the compressor casing.
Introduce steam to 4V54 (WGC-I 1st stage KOD). Keep the vent and drain of this drum
open.
Introduce steam to 4V55 (WGC-I Inter stage KOD). Keep the vent and drain of this drum
open.
Simultaneously open the vent of the GCU columns 4C54, 4C55, 4C56, 4C57. Drain the
condensate and introduce steam through the column SOP. Steam out the connected line in
GCU by opening steam at the pump SOP/providing additional steam hoses in the circuit.

Plant Name: FCCU-I
Condensed steam will accumulate at the low points and will have to be drained off
frequently during the first few hours of steaming as the vessels and lines warm-up, less
steam will condensate but all low point drains should still be checked occasionally as
some condensate will accumulate.
When good amount of steam starts coming out from the top 4C54, 4C55, 4C56, 4C57 of
for a period of four hours, the system should be considered free of air.
Conduct a pressure test on the system by throttling all the vents and drains raise the
pressure on the system to 2.2kg/cm2and check form leaks.
Start taking fuel gas to the L.C.O Stripper vapour return line. Close all the vents and
continue draining condensate from all low points. Since gas is taken to system, stop
introducing steam. Slowly pressurize the main column up to 1.45kg/cm2. Keep 4PC2411
on main column receiver in service and maintain required pressure by releasing excess
pressure to flare. Fuel gas to L.C.O stripper should be kept open so that 4PC2411 will
open a little, releasing small quantity of gas to flare. This will ensure that any air that
might still remain in the system will be purged out. Send one sample of gas for knowing
the oxygen content in the system. Drain condensate from low points under gas pressure.
Set Rx-Reg differential pressure controller, PDC501 to 0.15 kg/cm2.
Once the regen temp has exceeded 260 C the spent cat SV should be placed in service. It
should read the same as the Rx-Reg DP. If not then there is condensate in the standpipe
which needs to be drained.
Fuel gas from 4-C-57 can be backed up into G.C.U side. Fuel gas to G.C.U can also be
taken by opening valve on 11/2 fuel gas line to 4-V-57 debutanizer receivers. After
taking fuel gas to G.C.U side, steam to all the towers should be closed. Isolate all the
vents and drain the condensate under fuel gas pressure sends one sample of gas from
G.C.U system in a balloon for knowing the oxygen content.
Drain free water from all low points on lines, exchangers, pumps, vessels and
instruments, under gas pressure.
After taking fuel gas, commission cooling water to all coolers. Ensure Circulating cooling
water is ready. Cooling water commissioning will help in condensing steam and build a
concentration of fuel gas in the overhead receiver.
This is done in preparation of starting the gas compressor blind all the vents headers of all
the vessels and towers.

Plant Name: FCCU-I
11.5 GENERAL COMMISSIONING ACTIVITES
11.5.1 Generalized Sequential Procedure:
Ensure that all components are fixed and check the readiness of the equipment for
commissioning.
Obtain equipment job completion report from maintenance job engineer.
Check the blinds position as per the blind register and remove the blinds which are
required to be removed for commissioning of the equipment.
Purge the equipment with steam or Nitrogen to displace air in the system.
Pressure test the equipment as per the testing pressure specified either with Steam or
Nitrogen for identifying and arresting leaks, if any.
For high temperature liquid hydrocarbons, cutter filling is necessary before taking high
temperature service in to the system.
Safety pressure relief devices (TSV/PSV) should be taken into service before closing the
bypass valve.
Keep a close watch on the system while commissioning the equipment with hot service,
there could be a sudden pressure rise in the system due to vaporization of cutter, if not
displaced properly.
All drain and vent points should be capped or plugged and CBD /Flare/ Flushing points
should be blinded as per the blind register.
After commissioning of equipment, frequent field rounds shall be initiated to monitor the
equipment for 8 hours.

Plant Name: FCCU-I
INITIAL START-UP PROCEDURE
CHAPTER 12
INITIAL STARTUP PROCEDURE
GENERAL
There is a large amount of preparatory work which should be performed by the operating crew
before starting of the unit after completion of mechanical jobs. A planned check of the unit will
not only set the foundation of a smooth start-up but will also provide a firm basis for
acquainting operators with the equipment. Start-up is a critical period and the operator must
know the operation of each of the equipment. Some of the pre-commissioning works can be
carried out simultaneously along with construction. But care in the organization of this work is
necessary so that it will not interfere with construction work. It is most important to plan
schedule and record with check-lists and test schedules all the preliminary operation and to co-
ordinate the construction program.
PRE-COMMISSIONING ACTIVITIES
12.1 Inspection
It is important for operating crew to participate in the inspection to the fullest extent since for
many of them this may be the only opportunity before start -up to examine the internals of
some of the equipment.
a. Inspection of Vessels and Columns

Inspection of the interior of the vessels, columns, heaters and other equipment that are not
normally accessible during operation will be made to ensure that they are completed clean and
correctly installed.
b. Piping and Accessories

Piping and accessories will be checked against drawings and specifications. Piping support and
hangers will be inspected to ensure that all anchorages are firm. Valves will be checked for
proper packing and mounting.
c. Instruments
Instruments will be checked. Starting from the controller and proceeding logically through the
control loop. Cascade control system will be checked from the impulse point of primary loop.
Operating crew should check proper mounting of control valves.

Plant Name: FCCU-I
d. Relief Valves
Relief valves will be set in the shop and mounted before the system pressure test. Block valves
ahead and after relief valves will be checked for lock open or lock close position as per P&ID.
Relief valves will be checked against specifications.
12.2 Preparation of Unit

• Check the unit for completion of mechanical work against P&ID.
• Remove all construction debris lying around in the unit and clean up the area.
• Install blinds as per master blind list.
• Safety valves should be kept blinded during flushing and re-installed afterwards. These
should be shop tested and set at the stipulated values.
• Ensure that underground sewerage system is in working condition. Clear plugging, if
any. Check by flushing with water.
• Check that communication between units, control room, Offsite and utilities are
complete and in working condition.
• Ensure that the required lube oil, grease and other consumable are available in the unit.
12.3 Commissioning of Utilities

Commissioning of various utilities in the unit is described below. Prior to commissioning of
each utility system, the utility section should be informed about it and the expected load.
a. Steam Network
Network shall be blown through completely from battery limit with a strong steam flow in
order to clean the lines. The following steps are recommended.
• Check network all equipment will be disconnected to avoid entry of flushed material.
• Drain at all the low points. If necessary open steam trap inlet flanges.
• Open slowly battery limit valve and let the temperature rise in the header, slowly and
steadily.
• Check support of fixed points and expansion loops.
• When line is hot, blow it through completely with a strong steam flow.
• Close battery limit valve and prepare another network. When the blowing is
satisfactory, reconnect all equipment and remount steam traps. Recharge header as
above.
Note: The following precautions are to be taken while blowing / commissioning steam header:
• To drain the low points of the lines before and during heating period. This is to avoid
water accumulation which may cause hammering.
Plant Name: FCCU-I
• To open drain / vent during cooling period to prevent vacuum formation.

• To isolate the instruments, remove orifice plates and control valves, to reinstall the
orifice plates and control valves blowing is over.
b. Cooling Water and Service Water

Network shall be cleaned from battery limit with a strong water flow. All equipment will be
disconnected at the inlet and reconnect when lines are cleaned. Control valves and orifice plates
will be removed and re-installed after the lines become clean. When system has been flushed
charge the lines to the operating pressure.
The following precautions to be taken:

• To open vents at high points in order to expel air from equipment and piping
• To open the battery limit valve, slowly and steadily.
c. Boiler Feed Water:

Flanges are to be opened at the inlet of the connected equipment and at any convenient low
point. Network shall be first cleaned with raw water from battery limit with a strong water
flow. The network shall then be drained and rinsed with boiler feed water. Open flanges will
be made up and header charged after the network is clean. Usual precautions for instruments
like isolation, removal etc. are to be taken as mentioned above in case of steam network.
d. Instrument and Plant Air

Network shall be blown through completely from battery limit with strong flow of air in order
to clean and dry the lines. All joints and connection shall be checked for tightness with soap
solution. Header and branch lines will be blown through with a high flow rate of air. During
all tests, the instruments and control valve shall be carefully isolated from the system.
e. Fuel Gas and Fuel Oil Networks

Networks shall be blown through from battery limit with a strong steam flow for fuel oil and a
strong air flow for fuel gas in order to clean the lines. During this operation, orifice plates and
control valves shall be removed. Special care shall be taken to prevent water from entering the
furnace. The fuel gas headers will be commissioned before firing the cocker furnace.
12.4 Water Flushing of Process Lines

To clean scales and foreign matters etc. from inside, lines and equipment are flushed with water
wherever possible. Temporary water connections should be provided at convenient locations
in the system for carrying out water flushing. The following points should be remembered
during water flushing.

Plant Name: FCCU-I
Low point drains and high point vents should be purged.
All instrument connection should be isolated, orifice plates removed. Control valves isolated
and by - passed. In case there is no bypass, remove control valve and flush the line. The valve
will be installed after clean water comes out and further flushing may be continued.
• If there is any heat exchanger in the line flushing should be done up to and around the
exchanger using by-pass line. It should be ensured that dirty water from initial flushing
does not get into the exchanger. Wherever by-passes are not available, the flanged joints
at the inlet of heat exchanger should be first opened and the line flushed till clear water
starts coming out. Then reconnect flange and flush through the exchanger.
• At each opening of the flanged joints, a thin metallic sheet should be inserted to prevent
dirty water from entering the equipment or piping.
• The flow of water should preferably be from top to bottom for flushing of heat
exchanger coolers. The bottom flange of the equipment should be opened to permit
proper flushing.
• The flushing should be carried out with maximum possible flow of water till clear water
starts coming out
• Vertical lines which are long and rather big (say over 100 mm dia) should preferably
be flushed from top to bottom. This will ensure better flushing. Filling the lines and
releasing from bottom is also helpful. The rundown lines can also be flushed
conveniently from the respective tanks.
• It should be ensured in all flushing operation that design pressure of lines and
equipment are never exceeded. After flushing of lines and equipment, water should be
thoroughly drained from all low points. Lines and equipment containing pockets of
water should not be left idle for a long time. it is preferable to dry these lines and
equipment with air after water flushing.
12.5 Functional Test

• All rotary equipment (including dosing pumps) will undergo functional test to check
their performance
A. Motors
Each motor should be checked and started to ensure that it has the correct direction of rotation.
The motor speed should be checked with tachometer to ensure that RPM is correct. The
manufacturer’s lubrication schedule should be used to ensure that all lubrication points have
been serviced. After a short run each bearing should be felt to ensure that it is free and not
overheated.

Plant Name: FCCU-I
B. Pumps
Generally the pump casing is opened and checked to ensure that it contains no foreign material.
Pump casing need not be opened up in case the pump had been stored carefully and the blinds
covering suction and discharge nozzles were not removed in storage or in transit. Cleanliness
of suction line and installation of line mesh strainer should be ensured. Pumps and motor will
be aligned and then tried on water. Temporary connections may have to made, if required.
When running a pump designed for hydrocarbons on water the discharge valve may have to be
throttled so that the rated amperage is not exceeded. Ensure that the vents and drains of the
pumps are clear pressure gauge tapping will be flushed and filled with sealing fluid wherever
necessary.
12.6 Calibration of Instrument

The following guidelines may be adopted for checking and calibration of all instruments.
Orifice Plates: Before each orifice plate is installed the orifice taps should be blown clear. The
orifice plate should be crosschecked to check, if the correct size orifice plate is installed. The
plate should then be installed after checking for the correct direction.
Differential pressure Transmitters and Receivers

Ordinarily these should be calibrated locally against a manometer. The calibration should be
checked at the receiver which may be board or locally mounted recorder or indictor.
Pressure Transmitters and Receivers

This should be checked in place. The calibration of the receiver should be checked at the same
time.
Alarms, trips and Logics

All alarms auto start and cut off systems should be checked by simulating the conditions. All
trips and interlocks of RR to be checked. All logics like pump auto cut in, cut off to be checked.
Wherever checking is not possible actually, logics and trips to be simulated and actions to be
noted.
12.7 Furnace Drying

The furnace refractory must be thoroughly drained out so that it does not crack when the Heater
is brought into operation. The drying should be done by gradual heating of the refractory so
that no spalling or cracking takes place due to sudden vaporization of moisture from the
refractory. The drying procedure for heater refractory is given separately.
Tightness Test
Plant Name: FCCU-I
The purpose of this test is to check the tightness of flanges, joints, manholes etc. (except pumps
and control instruments). This operation can be integrated with steam purging activity aimed
at expelling air prior to introducing hydrocarbon into the unit.
• Drains at low points will be opened and after draining is over, these will be closed.
Vents will be opened: pressure gauges will be installed on each circuit.
• Steam is progressively admitted where connections are available. Circuits which do not
have direct admission of steam will be supplied through hoses.
• The temperature of the whole installation is increased slowly and free expansion of
lines is checked. The condensed water is drained while the temperature of the circuit
rises.
• When temperature is steady, vents are progressively closed in order to get the desired
pressure by keeping a vent slightly opened. A steam make-up is maintained. All joints
will be checked for leaks. If leaks are detected system will be depressurized, leaks will
be attended and the system retested.
For detailed procedures on Heater and Regen reactor Refractory Dry-out, refer
Chapter-11
12.8 Charging of Chemicals
Neutralizer addition system to be kept ready by time of starting cat circulation. During cat
circulation, Neutralizer injection to main column overhead system to be ensured to maintain
the pH of sour water to be maintained. This has to be continued till feed cut in time. After feed
cut in Filmer injection to main column overhead system to be started and neutralizer injection
to be discontinued. Also catalyst and additives systems to be kept ready and to be started after
the feed cut in.
12.9 Instrumentation checks
All the control valves to be stroke checked and their operation to be confirmed. All the
instruments to be checked for their response with proper coordination between field and DCS.
MAB,CAB, WGC antisurge control systems to be checked and kept ready All the Control
valves operation to be checked and tuning to be done as to suit the conditions.
Prior to introducing hydrocarbon to the FCC Complex, all lines and vessels (excluding
Regenerator and associated piping) must be air-freed by purging with steam or nitrogen; the
Wet Gas Compressor should be purged with nitrogen only. Purging allows hydrocarbon
introduction under an inert atmosphere.
Plant Name: FCCU-I
Following is a list of prerequisites before introducing oil to FCCU
PREREQUISITES
Vendor commissioning and startup procedures for WGC, MAB, CAB, APH.

• Steam systems
• Heat tracing
• Condensate systems
• Fire water
• Utility water
• Cooling water (ready for service subsequent to air purging)
• Boiler feed water
• Instrument air
• Plant air
• Nitrogen
• Flare system
• Oily water sewer
• Closed blow down
• Fuel and pilot gas systems
• Required unit electrical systems
• Sour water treatment
• Main column chemical injection
Unit PRV’s are installed and properly aligned
MAB and WGC’s available for operation
Unit pumps available for operation
APH available for operation; fuel gas system leak tested and air freed; fuel gas available at
battery limit

Plant Name: FCCU-I
Confirm all other unit blinds set to correct positions for startup as per the unit blind list. Isolate
cooling water supply and return valves and open vents/drains to prevent excessive steam
condensation.
Start instrument air purge to the regenerator and reactor Inst points. Verify flow by briefly
closing individual root valves at the vessel and noting pressure increase, and then reopening
valves to verify taps are clear.
Fuel gas from 4-C-57 can be backed up into G.C.U side. Fuel gas to G.C.U can also be taken
by opening valve on 2” fuel gas line 04-V-57 debutanizer receivers. After taking fuel gas to
G.C.U side, steam to all the towers should be closed. Isolate all the vents and drain the
condensate under fuel gas pressure sends one sample of gas from G.C.U system in a balloon
for knowing the oxygen content.
Drain free water from all low points on lines, exchangers, pumps, vessels and instruments,
under gas pressure.
This is done in preparation of starting the gas compressor blind all the vents headers of all the
vessels and towers. Apart from this step, unit can be lined up as per the start-up procedure after
T&I as laid out in chapter 13.

Plant Name: FCCU-I
START-UP PROCEDURE AFTER AN EMERGENCY
SHUTDOWN
CHAPTER 13
STARTUP PROCEDURE AFTER AN EMERGENCY SHUTDOWN
Usually normal startup of the unit is with Reactor vapor line blind in closed position. During
emergency shutdown like steam/MAB failure etc. when unit is crash shutdown and duration of
shutdown is short, then unit can be started with vapor line blind in open position in the following
way
STARTUP:
1. Start MAB as per procedure
2. Start CAB as per procedure
3. Introduce air to Regenerator and introduce torch oil (450-480oC). Maintain DP across
Reactor and Regenerator
4. Maintain Reactor pressure 0.14Kg/cm2 above Regenerator pressure. Increase riser

emergency steam.
5. Keep the feed pump running on spill back and circulation back to feed surge drum and
column
6. Keep column bottoms circulation
7. Main Regenerator bed temperature with torch oil.
8. After adjusting the Reactor/Regenerator differential pressure to ensure that there is a

positive differential across the Regenerated catalyst shutoff slide valve (Reactor side
higher pressure), slowly open the valve. Make sure a level is being maintained in the
over flow well. As the stripper level rises, slowly crack open the spent catalyst shutoff
valve to return catalyst to the Regenerator. The pressure in the Regenerator can be
increased as the stripper fills and Regenerator bed level drops.
9. Increase the catalyst circulation rate by continuing opening the regen cat slide
valve/spend cat slide valve. Watch the Regenerator bed level. If it falls too low, throttle

SHUTDOWN
Plant Name: FCCU-I
SHUTDOWN
the regenerated catalyst shutoff slide valve or reduce emergency steam. Adjust aeration
rates to get smooth temperature and about 570 C regenerator temperature.
10. Once circulation established open fuel gas to LCO stripper and 4V-53 and start WGC
on spill back.
11. Heater all pilots should be ready
12. Light up one/two fires to bring up feed temperature.
13. Feed pump discharge spill back should be in open position, divert feed to 4C-51 and
close heater O/L to feed surge drum v/v. Do not cross surge drum temperature more
than150 C.
14. Condition prior to feed cut in
A) Overhead circuits lined up

B) Regenerator temperature about 570 C
C) Regenerator pressure around 0.91Kg/cm2
D) Reactor temperature 540 C
E) Reactor pressure 1.12 Kg/cm2
F) Stable catalyst circulation
G) Fractionator tower circuits lined up

H) Reactor feed circuits lined up
I) Bottoms temperature below 316 C
J) Slurry pump around on.
K) Fuel gas through Wet gas compressor to flare via light ends section.
15. Inform MP/SMP/YSF/ Slop/PP/CPP/TPH/FCCU-II Proceed for feed cut in by opening

HC501 and throttle valve HC502 diversion valve to get about 9.0 Kg/cm2 at feed header.
16. Slowly crack open one feed injector, throttle HCV502 as necessary to maintain the feed
header at 9.0Kg/cm2g. Add feed in increments. Do not allow the riser temperature to
SHUTDOWN
Plant Name: FCCU-I
SHUTDOWN
fall below 485oC. Increase catalyst circulation rate and feed preheat by adjusting heater
firing as necessary to maintain temperature.
17. As gas production starts, slowly decrease fuel gas injection to the overhead. Establish
a level in the fractionator overhead drum and start the overhead pump to provide reflux
back to the fractionator. Route excess liquid form the overhead drum to the light ends
section.
18. Regenerator temperature will increase as coke yield increases. Adjust air rate.
19. After two feed nozzles are in service, begin start reducing riser emergency steam.
20. Increase feed rate by slowly opening injector on the opposite side of the riser. Alternate
between these two injectors opening each to increase feed rate. After each increase,
wait for the temperature to return back to 530oC before making the next increase. When
the first two injectors are wide open, repeat with another pair, keeping a symmetrical
distribution around the feed zone. Maintain 9.0 Kg/cm2g at the header by throttling
HC502. After target feed rate is met adjust globe valves such that uniform flow to each
injector is achieved as indicated by local PI at each injector.
21. Close FG to LCO stripper subject to unit conditions.
22. Commission the fractionator pump around as required to control fractionator

temperatures when adequate liquid is available. Watch the level in the fractionator pool
and pump out as necessary to ensure the level is under control. Route the off spec
products to slop.
23. Commission Steam Gen 4E56 and 4E57 and adjust the conditions according to Column
Flash Zone and Bottom temperatures.
24. Adjust conditions in the GCU section to line out the operation. Ensure fuel gas is
routed to system.
25. Change Chemical Injection system from Neutralizer to Filmer
26. Start Fresh cat, DESOX and GSR additions Catalyst addition.
27. Commission Heater steam drum.

SHUTDOWN
Plant Name: FCCU-I
SHUTDOWN
28. Keep all the trips online
29. Stabilize the unit and route the products to rundown tanks.

SHUTDOWN
Plant Name: FCCU-I
START-UP PROCEDURE AFTER T&I
CHAPTER 14
STARTUP PROCEDURE AFTER T&I

14.1.1 Introduction
14.1.2 Pre startup Checks
14.1.3 General Preparation for normal startup
Table 14.1 General Outline for Normal startup

Table 14.2 Tightness testing
Table 14.3 Heating Rx/Rg and filling fractionator /light ends
Table 14.4 Catalyst loading/fractionator and drying
Table 14.5 Cat Circulation/fractionator and light ends circulation
Table 14.6 Starting oil feed / lining out unit.
Table 14.7 Procedures for catalyst loading.
Fig. 14.1 Standard bar chart for start up

Plant Name: FCCU-I
Introduction
Prior to startup of the unit, some of the activities which must be completed before the startup
of the FCCUI fluids solids section. The order in which the various tasks are accomplished will
depend upon the sequence of availability of the sections after the turnaround maintenance.
Many of the activities can be carried out in parallel to minimize the time required for
completion.
Prerequisites
Vendor commissioning and startup procedures for WGC, MAB, CAB, APH.

Steam systems
Heat tracing
Condensate systems
Fire water
Utility water
Cooling water (ready for service subsequent to air purging)
Boiler feed water
Instrument air
Plant air
Nitrogen
Flare system
Oily water sewer
Closed blow down
Fuel and pilot gas systems
Required unit electrical systems
Sour water treatment
Main column chemical injection
Unit PRV’s are installed and properly aligned
MAB and WGC’s available for operation
Unit pumps available for operation

Plant Name: FCCU-I
APH available for operation; fuel gas system leak tested and air freed; fuel gas available at
battery limit
Confirm all other unit blinds set to correct positions for startup as per the unit blind list. Isolate
cooling water supply and return valves and open vents/drains to prevent excessive steam
condensation.
Start instrument air purge to the regenerator and reactor Inst points. Verify flow by briefly
closing individual root valves at the vessel and noting pressure increase, and then reopening
valves to verify taps are clear.
Fuel gas from 4-C-57 can be backed up into G.C.U side. Fuel gas to G.C.U can also be taken
by opening valve on 2” fuel gas line 04-V-57 debutanizer receivers. After taking fuel gas to
G.C.U side, steam to all the towers should be closed. Isolate all the vents and drain the
condensate under fuel gas pressure sends one sample of gas from G.C.U system in a balloon
for knowing the oxygen content.
Drain free water from all low points on lines, exchangers, pumps, vessels and instruments,
under gas pressure.
This is done in preparation of starting the gas compressor blind all the vents headers of all the
vessels and towers
Pre-startup check
1. Check the installation of all blinds for correct positioning at battery limits and within
the unit. Gasket and blind registers to be updated.
2. Confirm that utilities are available to unit battery limits.
3. Inspect all vessels for completion of jobs, cleanliness.
4. Before box up of equipment, all connected nozzles to be proved clear and check lists to
be updated.
5. Before closing the Reactor and Regenerator check that all cyclone dip legs are clear.

Plant Name: FCCU-I
6. Confirm that mechanical work was complete. Confirm correct routing, installation,
rating and orientation of all valves, proper gasketing, flow orifice installation and
other related piping items.
7. Check that all onsite fire protection equipment has been installed and ready for use.
8. Confirm that the sewer systems have been commissioned.
9. Shop test all pressure relief valves to confirm settings as per refinery testing
requirements and reinstall the valves.
10. Blow out all instrument purge lines and aeration connections.
11. All required restriction orifices on steam lines and process lines to be cross checked
and updated
12. Inspect and prepare all instruments for commissioning.
13. Ensure that all sample transport tubing is clean and dry.
14. Prepare, inspect, run-in and test the Main Air Blower and Control Air Blowers in
accordance with the manufacturer’s recommended procedures. Check all associated
instrumentation and protective systems. Remove any temporary strainers or equipment
installed for run.
15. Carry out Mock up operation of MAB.
16. Remove Air Preheater igniter assembly and check ignition. Test the functionality of
the Air Preheater burner managements system. Burner barrel should be free of
refractory, catalyst and Pilot to be completely charged. Spark should be checked out
outside before inserting inside.
17. APH site glass should be clean.
18. Install the Reactor startup relief valve and atmospheric vent with silencer.
19. Confirm that steam tracing is operational.
20. Check that all catalyst loading and unloading systems are clear.
21. Confirm that there is sufficient inventory of equilibrium and fresh catalyst for unit
startup. Also confirm that a sufficient quantity of CO combustion promoter is available.
22. Confirm that feed is available and stable for unit startup. Confirm that sufficient
inventory is available in slop and product tankage.
23. Remove process line blinds at battery limits and prepare for the startup.
24. Refractory dry out of RR and Heater to be carried out as per the procedure.
25. During refractory dry-out all flanges to be checked for leaks and equipment to be
checked for free expansion.
General Preparation for Normal Startup
The following is the summary of the circuits in the fluid solids section which should be
maintained in a blinded off condition until the unit is air free and the service is required for
startup.

Plant Name: FCCU-I
a. Reactor vapor line blind.

b. Vacuum gas oil feed to the feed header
c. Fractionator bottoms recycle
d. Feed header Warm up line to the fractionator.
e. Naphtha quench from tankage and the fractionator to the feed header
f. Air purge to Reactor side instrument taps.
g. Torch oil to the Regenerator
h. Pilot gas and fuel oil to the Air Preheater.
Regenerator-Reactor tightness testing, refractory dry out, catalyst loading and sequence of
startup events are tabulated in previous chapters. As catalyst is loaded into the regenerator,
steps must be taken to avoid catalyst and/or air leakage across the spent and regen catalyst shut
off slide valves. Maintain control air flow and a differential pressure of 0.07Kgf/Cm2 higher
than the regenerator side. To prevent catalyst and air leakage through the regen cat slide valve
prior to initiating catalyst circulation, one of the two following methods should be used.
Method A: All aeration nozzles and instrument purge taps on the RCSP remain in service.
Increase reactor pressure to maintain a nominal 0.07 Kg/cm2 differential pressure across the
RCSV by maintaining a higher pressure on the reactor side.
Method B: Except for the two uppermost row aeration taps, close the valve closest to the
standpipe for all aeration nozzles and instrument taps on the regenerated catalyst standpipe
above the RCSV to obtain a “seal” of de-fluidized catalyst in the standpipe..
The main points of the procedure to initiate catalyst circulation are as follows:
The maximum reactor riser heat up rate is 1.5 to 2°C per minute based on the riser temperature
in the feed zone. This heat up rate is limited to protect the refractory linings on the reactor
side.
1. Reactor riser emergency steam rate is the primary variable for controlling the
riser heat up rate.
2. Monitor the unit for a higher than normal catalyst carryover to the fractionator.
TABLE 14.1 GENERAL OUTLINE FOR NORMAL STARTUP

Plant Name: FCCU-I
REGENERATOR/REGEN
REACTOR FRACTIONATOR LIGHT ENDS
OVERHEAD
1. Blinds in place 1. Blinds in place. 1. Blinds in place. 1. Blinds in place.
2. Check equipment and 2. Check equipment and 2. Check equipment and 2. Check equipment
controls. Confirm that all controls. Confirm controls. Confirm that and controls.
preparations for startup that all preparations all preparations for Confirm that all
have been completed. for startup have been startup have been preparations for
3. Start CO Boiler and completed. completed. startup have been
generate HP superheated 3. Tightness check with 3. Air free and tightness completed.
steam as necessary to air. check. 3. Air free and
meet steam demands. 4. Reactor heating with 4. Bring in gas oil to tightness check.
4. Start Main Air Blower and air. Use refractory dry unit, fill fractionator 4. If available bring in
tightness check with air. out procedure as circuit and circulate startup naphtha to
5. Fire Air Preheater and required. oil. Pressure with fuel fill the light ends
heat Regenerator to 5. Reactor isolated from gas. circuits and
0
538 C. Use refractory dry Regenerator and air- 5. Heat up and dry out circulate. Pressurize
out procedure as required. purging with steam. fractionator circuits. light ends with fuel
6. Load catalyst to the 6. Start catalyst 6. Keep fractionator dry, gas.
regenerator. Start torch circulation, heating removing any 5. Start gas compressor
oil, shutdown Air Reactor to 482 °C condensate. and light ends
Preheater. Catalyst 7. Introduce feed and 7. Adjust pump around, towers.
temperature must be bring to desired rate. start side streams and 6. Line out light ends
above 3700C to ensure 8. Line out Reactor. products to slop. towers and products
torch oil Ignition. 8. Line out fractionators to tankage when on-
7. Start catalyst circulation. and route products to spec.
8. Adjust Regenerator to tankage when on-
high temperature spec.
regeneration conditions.

Plant Name: FCCU-I
TABLE 14.2 TIGHTNESS TESTING
REGENERATOR/REGEN LIGHT
REACTOR FRACTIONATOR
OVERHEAD END
1. Fully open flue gas slide valve. 1. Fully open reactor Steam test Steam test
2. Commission all instruments and overhead vent and all fractionator GCU,
steam/air blow back. Make sure each low point drains. Columns,
tap is clear. Rod if necessary. 2. Commission all vessels and
3. Prepare the CO Boiler for startup. instruments and Systems.
4. Commission CO Boiler as required to steam/air blow back.
supply steam for startup operations Make sure each tap is
5. Open Main Air Blower atmospheric clear, rod if necessary.
vent valve. Start air compressor 3. Open regen and spent
following the vendor’s procedures shutoff slide valves.
and introduce air to the Regenerator.
Slowly increase air rate to the
Regenerator by opening the manual
butterfly valves in the primary and
secondary air connections to the Air
Primary Do not exceed grid design
pressure drop (0.35 kg/cm2). Blow
6. Shut vents to atmosphere
out all vents, drains and aeration
and increase Reactor
connections.
pressure to
6. Slowly close the flue gas slide valve
approximately 2.0
and pressure the Regenerator and
kg/cm2 (g) with the
overhead system to approximately
Regenerator.
2.0 kg/cm2 (g). If refractory dry out
is to proceed after tightness test, air
compressor discharge temperature
must be consistent with dry out 7. Drain condensate from
procedures. all low points. Blow out
all vents, drains and
7. Drain condensate from all low points.
aeration connections.
Blow out all vents, drains and
9. Tightness check. Tape or
aeration connections.
soap all flanges and
9. Tightness check. Tape or soap all
connections and check
flanges and connections and check
for leaks.
for leaks.
Plant Name: FCCU-I
10. Reduce pressure to 1.0 kg/cm2 (g).

STATUS AFTER THE ABOVE IS 10 Reduce pressure to 1.0
COMPLETED: kg/cm2 (g) with
Regenerator and overhead system Regenerator
tightness tested and blowing with air Reactor tightness tested
and blowing with air.
TABLE14.3 - HEATING REACTOR/REGENERATOR AND FILLING FRACTIONATOR/LIGHT ENDS
REGENERATOR/ REGEN
OVERHEAD
1.Commission Air Preheater 1. Commission all 1.Line up vent to 1. Close all vents
instrumentation and all TI’S in the TI’S on the flare from and drains. Line
Regenerator and overhead Reactor. overhead drum. up
system. Line up water/condensate
fractionator drains to
2. Pull blinds on Air Preheater pilot condensate to disposal.
gas and fuel oil. Commission Air disposal.
Preheater Burner Management
System and ES-8 (Air preheater 2.Start cooling water
Flame Failure), light pilot and to overhead
main burner following light off condensers and
procedures. slowly drain any
An Operator must be stationed at accumulated
the Air Preheater control panel at water from
all times when lit to observe the distillate drum.
flame. 4. To promote air Condensers and
flow through the line. Steam
Reactor, vent air fractionator from
Plant Name: FCCU-I
4.Control heat up according to the to the atmosphere the bottom and

refractory dry out procedure as via the startup maintain
required or use the following heat vent and silencer overhead
up procedure: on the Reactor pressure positive
Increase aux. burner outlet overhead line. by fuel gas
temperature at not more than 50oC Occasionally injection.
/hr. adjust fuel rates as required. stroke the slide
Always keep at least 100% excess valves one at a 3.Fill any steam
primary air Do not exceed time during heat- generators with
0
593 C to the grid or 0.35kg/cm2 up to ensure they boiler feed water
pressure drop through the grid. are not sticking. and commission
Control heat up all
5.Monitor TI’S and adjust the flue according to instrumentation.
gas slide valve to get an even refractory dry-out Close vents on all
heat-up. Continue to raise procedure as steam generators.
temperatures until Regenerator required or follow
reaches 5400C. Regenerator heat
6.Inspect the structure during heat up.
up. Check that:
A. Unit is free to expand and is not 5. Monitor TI’S and
Interfering with structural adjust slide valves
members to get uniform
B. Struts are free to move. heat-up.
C. Small piping is not under strain.
D. There are no hot spots on vessel
man ways.
OVERHEAD ENDS
7.Hot bolt all flanges that 6. Inspect the structure during
operate above 3160C. If a heat up. Check that:
separate dry out procedure is A. Unit is free to expand and
required, then hot bolting can is not interfering with
be done during dry out. structural members.
B. Struts are free to move.

Plant Name: FCCU-I
8. Reduce Air Preheater firing C. Small piping is not under

and do not exceed 0.35kg/cm2 strain.
pressure drop through the grid. D. There are no hot spots on
vessel man ways.
9. Commission the Control Air 7. Hot bolt all flanges that
Blower to provide air flow operate above 3160C. it a
to maintain the temperature separate dry out procedure is
in the spent cat riser. required, then hot bolting
Control Regenerator can be done during dry out.
pressure to approximately 9. Close regenerated catalyst
0.14 kg/cm2 below Reactor and spent catalyst shutoff
pressure. slide valves.
10. Crack valves and admit

steam as follows:
A. Riser emergency
B. Stripper
C. Anti-coking chamber
D. Feed injectors
E. J-bend blasts
F. All aeration connections
which normally use
steam
11. Steam out for two hours,

checking O2 level in Reactor
overhead. If O2 exceeds 5 vol%
increase gas injection to the
overhead drum. Continue to
drain condensate from low
points.
REGENERATOR/REGEN
REACTIOR FRACTIONATOR LIGHT ENDS
OVERHEAD
12. As the Reactor pressure is 12. After steaming 12. Lower
lowered, reduce the Regenerator for two hours, lower fractionator

Plant Name: FCCU-I
pressure to keep regen pressure Reactor pressure by pressure so that

lower than reactor pressure (by reducing steam to a the blind can be
opening the flue gas slide valve and low rate so that the removed from
reducing air flow to the blind can be removed the Reactor
Regenerator by closing the from the Reactor overhead line
butterfly valves in the primary and overhead line at the fractionator inlet.
secondary air lines to the Air fractionator inlet. Stop fuel gas
Preheater and simultaneously injection and
opening the air compressor maintain a small
atmospheric vent valve).Adjust Air flow or steam to
Preheater firing while reducing air. avoid entry of air
The following steps should be into the
taken, sequentially, as required to fractionator while
maintain Regenerator pressure swinging the
below Reactor pressure: blind.
A. Shutdown Air Preheater
B. Shutdown control Air Blower
C. Close main air and spent catalyst
riser control air butterfly valves.
D. Shutdown air compressor
13. After removing the 13. After removing
fractionator inlet blind, increase the blind, remove the
13. Establish 13. Remove
Regenerator pressure to 0.91 spool pieces from the
pressure control blinds and line-
kg/cm2(g).Restart Main Air and Reactor overhead
in the fractionator up the gas
control Air Blowers and re-light the vent line and the
overhead system compressor for
Air preheater as necessary. Resume Reactor safety valve
using fuel gas service.
heat up of the Regenerator in inlet line and install
injection.
preparation for loading catalyst. nozzle plugs. Re-
Maintain a
Temperatures about 250-3000C are introduce steam to the
pressure of 1.05
required to load catalyst. Always Reactor. Control
kg/cm2(g). Route
maintain regenerator pressure at reactor pressure
condensate to
minimum of 0.14kg/cm2 below through fractionator
disposal as
reactor pressure or as required if overhead pressure
required.
using Method-A to prevent control facilities.
catalyst/ air leakage. Continue to drain
condensate from low
points.

Plant Name: FCCU-I
REGENERATOR/
REACTOR FRCTIONATOR LIGHT ENDS
REGEN OVERHEAD
14. Line up emergency 14. Line up the source of startup 14. if available line up
steam to the main air gas oil in preparation for filling the source of startup
line and spent cat riser the fractionator oil circuits for naphtha in preparation
air header and dry-out. for filling the facilities
commission ES-2 15. pump startup gas oil through for circulation if the
(Main Air Failure) the reactor feed system and then light ends has been
and ES-3 (Control Air via the feed diversion line to the under a nitrogen
Failure). bottom of the fractionator. As blanket displace with
possible use a once through flow fuel gas and establish
of oil to sweep water from the system pressures as
unit to slop tankage. Route flow required for circulation.
through control valve and 15. Fill the light ends
equipment bypasses to ensure that system through which
water is removed from stagnant circulation will be
lines. established with
16. Fill the fractionator pump- naphtha.
around systems with startup gas 16. Start cooling water
oil and establish circulation. As to all coolers and
possible, continue to use a once condensers.
through flow of oil to sweep 17. Establish cold
water and scale from the unit to internal circulation of
slop tankage naphtha within the light
17. After the Initial once through ends section. Run-in all
sweep of the unit has been pumps to demonstrate
completed, establish cold internal their operation and
circulation within the unit check all level, flow
through the feed system and and other instruments
fractionator pump-around for proper operation.
systems. Circulate through all 18. After circulating
control valve and equipment for a period of time stop
bypasses. Run –in all pumps to circulation and allow
demonstrate their operation and water to settle. Drain
check all level, flow and other water that accumulates
instruments for proper operation. at low points.
Plant Name: FCCU-I
18. After circulating for a period

of time stop circulation and allow
water to settle. Drain water that
accumulates at low points.
REGENERTOR/REGEN
OVERHEAD
19. Re-establish cold 19. Re-establish
internal circulation in cold internal
preparation for starting circulation.
fractionator dry-out.
Establish a small net
input of startup oil and
purge to slop to ensure
water accumulation
does not occur.
STATUS AFTER THE

ABOVE IS COMPLETED:
Main Air and Control Air Fractionator pressure
Pressure floating Under fuel gas
Blowers in service at 1.05kg/cm2(g)
on fractionator. air pressuring
CO Boiler generating steam as maintained by fuel
free and steaming. blanket and
required Regenerator gas injection. Fuel
circulating
temperature at 5400C, pressure gas for pressuring
naphtha.
at 0.14kg/cm2 below Reactor being vented to flare.
pressure/.Air Preheater firing, All circuits filled and
ready for catalyst loading. circulating. Draining
condensate and
purging some gas oil
to stop.

Plant Name: FCCU-I
TABLE 14.4 CATALYSTS LOADING /FRACTIONATOR DRYING
OVERHEAD ENDS
1. Close all aeration valves 1. Close alt 1. Maximize circulation rates and
closest to the catalyst transfer aeration valves commission the feed preheater to
lines. Commission aeration closest to the begin drying the fractionator circuits
and vent to atmosphere catalyst (the fractionator upper pump-around
through rod-out valves to transfer lines. should be circulated only if provision
ensure that aeration supply Commission has been made to provide heat during
lines are clear of water and aeration and drying by circulating from the tower
condensate (steam aeration vent to bottoms. If not the pump around will
connection). atmosphere only act to cool the tower: they should
through rod – be purged once through with dry gas
out valves to oil and then shut down.) A maximum
ensure that heating rate of 300C/hr should be
aeration supply observed to prevent rapid generation
lines are clear of steam and possible equipment
of water and damage.
condensate
(steam aeration 2. Commission purge to instruments,
connections). monitor the O2 content of the
2. Commission Reactor/ fractionator off gas and adjust the
Regenerator Differential 2. Commission air rate of fuel gas injection to maintain
pressure controller set at 0.14 purge to the O2 content at safe levels.
kg/cm2 (Reactor higher than instruments.
Regenerator).
3. As the fractionator bottom warms
up, all pump around should be
3. Line up catalyst loading line to circulating(bottom or slurry pump
Regenerator and pressure up around only unless it is possible to
the Used Catalyst Hopper for heat the upper pump around) at
catalyst addition. Start maximum rates to flush water out of
transport air. Drain loading line pocket and low points which might
until dry air exits have been overlooked. Spare pumps
should be run. Open bypasses around
all exchangers and valves. This
operation emulsifies the oil and any
Plant Name: FCCU-I
residual water so that no “steam

bump” which could damage
fractionator trays, will occur. Record
fractionator pressures and
temperatures and check piping for
thermal expansion.
REGENERATOR/REGEN
REACTOR FRACTIONTOR LIGHT ENDS
OVERHEAD
4. Reduce air rate to maintain a 4. Monitor the 4. The fractionator As possible,
superficial bed velocity of about pressure differential system is free of start heat to
0.5 to 0.6 m/sec. to minimize between the water when the reboiler which
catalyst losses during loading Fractionator and the temperature of the are supplied
check that: Reactor, making sure fractionator top is heat by the
A. Air Compressor is reactor pressure is about 300C above the fractionator
operating at a safe margin above greater than the water boiling point at Pump around
surge fractionator pressure. the tower pressure. If and place
B. Air rate is above trip point Increase steam to the the upper pump towers on total
for ES-2 (Main Air Failure) Reactor if necessary to rounds are reflux.
C. Gird pressure drop is 0.10 maintain pressure circulating they are
2
kg/cm (min)to 0.35 kg/cm 2 differential.(Although also considered dry
(max). it is preferable to when the return
5. Commission all aerations if minimize steam to temperature is about
0
using method A to prevent reduce the possibility 30 C above the water
catalyst/air leakage. If using of rapid reactor cool boiling point. Slowly
Method B, do not commission down.) Reactor raise the fractionator
all regenerated catalyst pressure is best bottoms temperature
standpipe instrument purges controlled by the to 200 to 2300C and
and aerations EXCEPT the top fractionator overhead hold at this
Plant Name: FCCU-I
two aeration connections to the pressure controller temperature until

overflow well. relieving fuel gas to feed in introduced to
6. Load catalyst to the flare. the Reactor.
Regenerator quickly while 5. Commission all
maintaining a regenerator bed aerations.
temperature greater than 2900C.
Do not exceed 0.35 kg/cm2 grid
pressure drop.
7. Check the flue gas exhaust
stack for excessive catalyst
losses.
8. Commission flue gas
analyzers.
9. Continue adding catalyst
until the level is at least 1.5 m
above the torch oil nozzles.
Raise bed temperature to 3700C
for torch oil ignition.
OVERHEAD ENDS
10. Remove the blind in the torch oil
line and start torch oil slowly,
watching for a temperature rise to
indicate ignition. If there is no
temperature rise within one minute.
Stop torch oil, raise bed temperature
150C and wait 15 minutes before
trying again.
Never use torch oil unless:

A. Bed level is at least 1.5m above
the torch oil nozzles
B. Bed temperature is at least
3700C
Plant Name: FCCU-I
11. Close all drains

11. Continue to load catalyst until in the Reactor,
the Regenerator holdup is about 100 Stripper, spent
metric tons and the overflow well is catalyst and
full. Increase air rate to maintain grid regenerated catalyst
pressure drop at 1/3 of bed pressure transfer lines. Check
drop. Do not exceed 0.35 kg/cm2 that all stripping
grid DP. Do not exceed superficial steam nozzles and
bed velocity of 0.6m/sec. increase feed injectors are
Regenerator temperature, using clear. Feed injection
torch oil, to 450 to 480 0C. steam, anti-coking
12. The Air Preheater can continue steam, spent
to fire if necessary to maintain a standpipe aeration
minimum grid pressure drop of 1/3 and regen angle riser
of the bed pressure drop. As the air aeration steam flows
rate increases, reduce air preheater should be at design
firing. Do not exceed 0.35kg/cm2 rates, stripping
pressure drop across the grid. Once steam flow should
stable torch oil operation is be adjusted to give a
established, shut down the Air stripper superficial
preheater and install blinds in pilot velocity of 0.15
gas and fuel oil lines. m/sec. Riser
emergency steam is
commissioned
through the fluffing
steam RO only.
STATUS AFTER THE

Bottom circuit at 200 to Light ends circuits
ABOVE IS
2300C. lined up and
COMPLETED:
Steaming Reactor. circulating naphtha
Pressure above Circuits oil filled and dry.
Overhead circuits lined
regenerator
up
pressure Circulating hot oil in Pressure
bottom(slurry)pump maintained with
Regenerator pressure
around fuel gas.
0.91 kg.cm2 (g)

Plant Name: FCCU-I
(And in upper pump around

Regenerator as possible).
temperature at 450to Oil purge to slop.
480 0C and being
maintained by torch oil Monitoring overhead gas
firing. for O2 content.
Catalyst loaded. Adjusting fuel gas injection

as required maintaining
Air rate consistent with required reactor pressure
torch oil burning. and O2 concentration.
Minimum to give
required grid DP
maximum to limit of
superficial bed
velocity.
Air preheater shut
down

Plant Name: FCCU-I
TABLE 14.5 - CATALYST CIRCULATION/FRACTIONATOR AND LIGHT ENDS

CIRCULATION
REACTOR FRACTIONTOR
OVERHEAD ENDS
1. When ready to start catalyst 1. Maintain reactor Stop circulating the
transfer to the Reactor if pressure 0.14kg/cm2upper fractionator
Regenerated Catalyst Standpipe above regenerator pump around if they
aeration has been shutoff open all pressure. Increase have been in service.
aeration taps on the standpipe. Start riser Close any startup jump-
emergency
at the top and work down. Open steam to achieve a over to these Pump-
purges to the instrument taps on the maximum reactor around from the lower
standpipe. primary bottoms (slurry) circuit
cyclone
2. Slowly open the lower blast to
inset velocity of 3.0 avoid catalyst
steam connection to the regen cat J- carryover to the top of
m/sec during initial
bend to clear the line. then close, catalyst transfer. the fractionator.
leaving just the purge steam Fraction or slurry
commissioned. (bottom) pump around
3. Bypass only the following 3. Commission all and grid wash must be
emergency shutdown initiators, remaining maintained during 4. prepare
allowing manual operation of the emergency systems. catalyst circulation. the gas
catalyst slide valves: compressor
FLCO502 : Feed low low 4. As soon as catalyst for startup:
TLCO502 : Riser low temperature 4. As catalyst transfer starts, check
LLCO502 : Stripper low level transfers, the level in the O2 content of the Confirm O2
the stripper will fractionator off gas and content of
4. After adjusting the slowly increase. The increase fuel gas fractionator
Reactor/regenerator differential reactor pressure can injection rate to the off gas is
pressure to ensure that there is a be slowly reduced or overhead if necessary less than 5%
positive differential across the regenerator pressure to maintain less than Check fuel
Regenerated catalyst shutoff slide slowly increased as 5% O2. The gas
valve (Regen side at higher this level is temperature of the molecular
pressure), slowly open he vale. established. Watch steam from the Reactor weight is
Make sure a level is being for high catalyst will increase when within
maintained in the overflow well. losses in the catalyst transfer starts. compressor
Monitor the temperature rise in the fractionator bottoms Watch the fractionator operating
feed riser on the TI just above the and reduce riser top temperature and envelope.
Plant Name: FCCU-I
feed injectors. Use riser emergency steam and pump increase cooling as
steam flow to control the rate of more fractionator necessary. Avoid
catalyst transfer to maintain bottoms to slop if excessive cooling in the
maximum temperature rise of necessary. Maintain upper section the
20C/minute. This is to protect the the O2 level in the fractionator to avoid
refractory in the Riser, Reactor, and fractionator off gas water condensation.
stripper. less than5%.
REGENERATOR/REGEN REACTOR FRACTIONTOR LIGHT ENDS

OVERHEAD
5. Maintain the regenerator bed 5. As the stripper level 5. Check the slurry 5. Prepare to start the
temperature at 450 to 480 0C riser, slowly crack open pump around for gas compressor by
with torch oil. the spent catalyst catalyst control and opening the
shutoff valve to return increase purge rate compressor suction
6. Increase the catalyst catalyst to the to stop if necessary. and discharge
circulation rate by continuing Regenerator. The The slurry pump isolation valves. Start
to open the regent cat slide pressure in the around typically the compressor at
valve. Watch the Regenerator Regenerator can be contains about minimum governor
bed level. If it falls too low, increased as the stripper 0.3wt% catalyst. speed. Establish
throttle the Regenerated fills and the Regenerator compressor recycle
Catalyst shutoff Slide valve or bed level drops (by operation through the
reduce emergency riser steam. lowering the anti-surge recycle
Adjust aeration rates to get Reactor/regenerator system.
smooth circulation. Add differential pressure). 6. Avoid high
catalyst to the Regenerator as 6. Continue to open the fractionator 6. If possible
necessary to maintain bed spent catalyst slide bottoms establish a flow of
level. valve while adjusting fuel gas from the gas
temperature until
the Reactor/regenerator compressor through
feed is introduced
differential pressure to the light ends section
Plant Name: FCCU-I
7. Continue opening both maintain a stable level and the bottoms and commission
shutoff slide valves to increase in the Stripper. residence time pressure controllers
catalyst circulation while Adjust emergency decreases. at their normal
maintaining stable regenerator riser steam to get good operating set point
bed and stripper levels. catalyst circulation 7. Line-up the
Increase circulation and torch while observing limits normal feed to the 7. Pull remaining
oil as necessary to achieve a on reactor heat-up rate. unit. blinds in the light
5400C reactor temperature and 7. Pull blinds ends system.
about a 5700C regenerator downstream of the feed
temperature. diversion valve and in
Reactor/Regenerator the naphtha quench line
differential pressure should be to feed injectors. Ensure
controlled close to the normal all feed injectors are
expected differential of 0.21 double blocked and
kg/cm2 if possible. warm up the feed header
by circulating through
8. Add CO combustion the 1-1/2 startup line to 8. Pull remaining
promoter to the catalyst if the fractionators. blinds on the
promoted catalyst is not being fractionator
used. circuits.
REGENERATOR/REGEN
OVERHEAD
9. Commission TL (CO) -502 9. Maintain FL 9. Bring in normal
Riser low temperature; Stripper (CO)-502. Reactor vacuum gas oil feed to
low level. low feed in bypass. the feed drum and
10. Line up the fresh catalyst Ensure all other isolate startup gas oil
loading line to the Regenerator. emergency systems from the unit.
Prepare the Fresh Catalyst are commissioned.
Addition System for operation.
Start transport air. Drain 10 Hot bolt flanges
loading line until dry air exits. as required.
11. Add or withdraw catalyst to 11. Line up naphtha

establish proper regenerator quench. Make sure
bed level and stripper level. naphtha is
Plant Name: FCCU-I
Allow for change in the available up to the

regenerator bed density as the feed injectors.
air rate is increased during oil-
in Fractionators lower Fuel gas
Reactor circuits lined up. through gas
temperature 5400C Reactor feed circuits compressor to
STATUS AFTER THE Pressure 1.12 kg/ established. flare via light
ABOVE IS COM;SETED cm2 (g). Bottoms temperature ends section.
Overhead circuits lined up. Stable catalyst below 3160C Naphtha
Regenerator temperature about circulation Pressure to maintain circulating.
5700C All emergency Reactor at desired Light ends
Pressure 0.91 kg/ cm2 (g). system Initiators pressure, towers which
CO promoter in unit. active except Slurry pump around and have heat input
All emergency systems active. FL(CO)-502 on oil grid wash circulating on total reflux.
feed line to
Reactor.

Plant Name: FCCU-I
TABLE - 14.6 STARTING OIL FEED/LINING OUT UNIT
REGENERATOR/REGEN
OVERHEAD
1. Take a catalyst sample 1. Made sure all oil feed 1. Maintain the slurry
before feed in. injector block valves are pump around pumps in
closed. operation to ensure the
2. Check regenerator flue 2. Op HCV-501 block valve in slurry circulates over
gas O2 content. feed line and throttle HCV- the sheds.
502 diversion valve to get
about 9.0 kg/ cm2 (g) at the 3. As gas production
3. Regenerator temperature feed header. starts, slowly decrease
will Increase as coke yield 3. Slowly crack open one feed fuel gas injection to the
increases. Add torch oil if injector. Throttle HCV-502 as overhead. Establish a
necessary to gradually necessary to maintain the feed level in the
increase
2
regenerator header at 9.0 kg/ cm (g). add fractionators overhead
temperature to about 700 to feed in increments. Do not drum and start the
725 0C allow the riser temperature to overhead. Pump to
0
fall below 485 C: increase provide reflux back to
catalyst circulation rate as the fractionators. Route
necessary to maintain excess liquid from the
temperature overhead drum to the
4. increase feed rare by slowly light ends section.
4. Take occasional samples cracking open another injector
of regenerated catalyst for on the opposite side of the 4. 4. Adjust
Commission the
visual Inspection. Increase riser. Alternate between those conditions in
fractionator pump
catalyst circulation to hold two injectors opening each to the light ends
around as required to
Reactor temperature as increase feed rate after each section to start
control fractionator
required. Check O2 analyzer increase, wait for the to line out the
temperatures and when
to insure a minimum of 2% temperature to return back to operation.
adequate liquid is
O2in the flue gas. Route off-spec
5300C before making the next available.
products to
increase. When the first two slop.
injectors are wide open, repeat Watch the level in the
with another pair, keeping a fractionators pool and
symmetrical distribution pump-out as necessary
around the feed zone. to ensure the level stays
Maintain 9.0 kg/ cm2 (g). at
Plant Name: FCCU-I
the header by throttling HCV- below the fractionator

502 after target feed rate is inlet nozzle.
met, adjust globe valves such
that uniform flow to each Route off-spec products
injector is achieved , as to stop.
indicted by local PI at each
injector.
REGENERATOR/REGEN LIGHT ENDS

OVERHEAD
5. Continue to allow 5. After two feed 5. Adjust operation of 5. Continue to
Regenerator temperature to nozzles are in service, the fractionators pump adjust conditions
increase steadily by using torch begin reducing riser around circuits to bring to bring products
oil as necessary, Reduce torch emergency steam.(at the lower temperatures to on –spec.
oil as carbon production rate of 450kg/hr for each normal operating levels.
increases. Maintain a minimum 6.6 m3/hr of feed.
of 2.0%vol% O2 in the flue gas 6. Adjust catalyst
by gradually increasing air. circulation rate as
Watch for possible afterburning required to hold Reactor
below 7000C particularly if no temperature by adjusting
CO promoter is used. the Reactor/ Regenerator
differential pressure.
7. Raise reactor
8. Hold regenerator temperature pressure to the normal
between 7000C and 7250C with operating level of 1.34 8. Line out the 8. Send products
kg/ cm2 (g). Fractionators at the to storage when on
torch oil and maintain at least 2%
desired conditions and –spec.
O2 in flue gas. Torch oil should 8. Line out at target
send products to tankage
be backed out as soon as possible feed rate (at least 65% of
when on –spec.
while simultaneously increasing design) and conditions
and maintain reactor
Plant Name: FCCU-I
other coke making variables, e.g. temperature with catalyst

catalyst circulation. circulation.
9. Commission
FL(CO)-502: low feed
10. Commission the Fresh flow.
Catalyst Addition System
according to the manufacturer’s
recommendations. Start fresh 10. Watch Reactor
catalyst addition to the stripper bed level to
Regenerator to make up for made sure addition rate is
losses and maintain activity correct.

Plant Name: FCCU-I
REGENERATOR/REGEN LIGHT ENDS

REACTOR FRACTIONTOR
OVERHEAD
11. Regenerator temperature can 11. As unit feed
float between 7000 and 7250C. rate is increased it
This temperature range can be will be necessary
maintained by changing the to change to a
carbon make. Adjust air rate to partial burn mode
line out at 1.5 vol% O2 in the of operation and to
flue gas adjust the
STATUS AFTER THE ABOVE Regenerator
IS COMPLETED: operating
All equipment lined out. temperature.
Regenerator temperature Procedures for the
between 7000 C to 7250C. transition from a
Regenerator pressure held at full burn to partial
about 1.13Kg/cm2g as burn mode of Tower temperatures at Equipment is
determined by the operation are normal operating levels. lined out.
Reactor/Regenerator setting contained in Distillate drum pressure All products on-
needed to achieve the required section 7 of this set to control to desired spec to storage.
catalyst circulation rate and a operating Guide. reactor pressure
controllable level in the All pump around and
overflow well. Temperate side streams operating
Regenerator operating in full 0
500 to 525 C0
and lined out.
burn mode. Pressure target Product is on-spec to
1.34 kg/cm2 (g) tankage.
at target vacuum
gas oil feed rate.

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I
NORMAL OPERATION OF THE PLANT
CHAPTER 15
The unit start up and Shut down activities are considered as very critical in a FCCU. Normal
operation of the plant is also important. Neglecting this important aspect calls for unwarranted
emergencies. Continuous and cautious attention and observation on the operating parameters
and alarms need to be followed sincerely. A few operating tips are given below for the steady
operation of the plant.
Feed System
While taking feed into surge drum ensure that it is free of cutter stock and water, by bleeding
from feed line. Frequently check and drain from 4V51 boot for water if any.
Always ensure sufficient level in 4V51 and pump minimum flow has to be maintained.
Maintain feed pump discharge pressure low enough so as to get the required feed rate at that
point of time, with the maximum opening of heater pass flow control valves and total feed
control valve. High discharge pressure may lead to leak from the line particularly during sudden
S/D of the unit.
Heater
Ensure maximum number of pilot burners availability
Always ensure equal feed flow through both passes (pass balance) and limit the COT
at 420oC (max). Design temp is 423oC.
Do not allow the heater arch pressure to become positive. Too much draft also to be
avoided to reduce excess air and stack loss. An optimum of -3 to -4 mmWC has to be
maintained. At positive arch pressure stack damper automatically opens to wide with
an alarm. This to be confirmed in field. Then reset the stack damper and reduce opening
to get sufficient arch pressure.

Plant Name: FCCU-I
Do not allow arch temp to cross 819oC(max).
Do not allow skin temp to cross 549oC(max) and always maintain stack temp greater
than 165oC(Min) to prevent corrosion. Sulphur condensation will take place below 1650
C and do not cross 1800 C to reduce environmental pollution.
Always maintain pass flow outlet temperature as close as possible.
Ensure heater fires are not impinging on the tubes.
Ensure fires are not having smoky flame/ fire flies or sparklers in the fire box/ lazy or
uncomfortable flame pattern. Oil fires should be brick red, which is representative of
clean burning.
Reactor- Regenerator
Closely monitor reactor temperature and bed level
Maintain regen dilute phase and dense bed temp difference around 30 to 40 oC.
Too many changes of any parameter is not desirable.
Fine adjustment of cat circulation can be done by adjusting CAB air rate, while major
changes can be achieved by varying RR DP (4PDC501).
Always ensure regenerator reactor pressure balance (PDC501 +ve) and maintain reactor
and regen pressure not less than 1.45 and 1.2 Kg/cm2.
Ensure sufficient reactor stripping steam and do not vary it much for carbon balance
Maintain a minimum of 230oC reslurry temperature always to avoid line plugging.
Always try to maintain uniform distribution of temperatures in Regen and Reactor

cyclone O/L temperatures.
Plant Name: FCCU-I
Do not cross regen cyclone O/L temp of 760oC.
While unloading catalyst do not cross 427oC i.e. D4 design temperature.
Do not cross APH O/L temp of 593oC.
Do not cross regen bed temperature of 730oC.
Maintain sufficient Feed Injection steam, Anti coking, RCJB and SCJB aeration steams
and Cone aeration steam.
Ensure Emergency steam to MAB and CAB lined up and available in case of
emergency.
Ensure SCJB upper and lower blasts are available in case of emergency.
Try to keep all aeration taps in service.
Ensure all control air nozzles in service.
Ensure all the trips are online and healthy.
Always ensure sufficient air purge on cat loading and unloading lines, so that plugging
of lines can be avoided.
Ensure cutter flushing after using Ni-passivator line.
MAB
Maintain vacuum of -0.9kg/cm2 minimum
Maintain hot-well temperature below 45oC
Do not cross wheel chamber pressure of 16.5kg/cm2.

Plant Name: FCCU-I
Fractionator
Do not allow the vapor line temp to drop below 110oC (to avoid steam condensation).
Monitor LCO stripper level. If C/V opens more than 30%, level may be lost and LCO
PA may lose suction.
Maintain Flash zone temperatures. Never increase flash zone temp TI2010 above
360oC, bottom D/O temp TC2013 of 363oC and Liquid pool temp TI2009 above 383oC.
Monitor column DP
Too low flash zone temp may lead to HCO PA failure.
Wet Gas Compressor

Always monitor WGC load, Antisurge controller deviation read out, I and II stage
suction discharge pressure, I and II stage flows.
In case of WGC high load, reduce load by reducing 1st stage suction c/v opening or set
pressure.
To reduce flaring, if any, from upstream (4V53), temporarily increase OPRV set valve,
reduce reactor temperature, or feed rate to reduce WGC high load.
Avoid WGC total recycle c/v opening (4PC2407) as recycling the lean gas leads to high
interstage drum pressure and low deviation readout for the 1st stage anti surge
controller.
In case of high WGC final discharge pressure, reduce sponge absorber pressure. Never
allow 2nd stage discharge pressure to cross 16.5 ATA. (trip value: 17.5 kg/cm2 absolute)
When antisurge controller deviation tends to very low or negative, ASVs will open
leading to upset or gas flaring. To increase deviations, temporarily, ASVs can be
Plant Name: FCCU-I
opened or feed more fresh or rich gas to WGC by stopping main column overhead fans,
loading fresh cat into regen, increasing reactor temperature.
Monitor interstage drum level and flow continuously.
Monitor all vibrations, axial displacements, compressor bearing temperatures, during

routine rounds and log them in compressor house TOB.
Monitor suction KOD level and pump out liquid at regular intervals. (minimum : twice
in a shift)
Do carryout PM checks of WGC suction flow and suction KOD HAZOP switches.
Carryout suction strainer cleaning of suction KOD pumps as per DRJs.
Gas Concentration Unit

Monitor all drums/columns level with Gauge glass and LT and be proactive before
facing too high /low level.
To control LPG C2 content and optimize GCU stripper reboiler load. Always monitor
Stripper column D/O and be proactive before facing recycling. Recycling is indicated
by increase in difference of Stripper feed to Stabilizer feed (>35M3/hr), high GCU
stripper DP (>0.25Kg/Cm2) and high stripper pressure.
In case of recycling, reduce GCU stripper reboiling/ increase sponge absorber pressure
suitably.
Be prepared to handle the high influx of stabilizer feed after these changes.
In the stabilizer column, presence of C2 s results in high pressure. Accordingly adjust

CRN to primary absorber and stripper reboiling. High top reflux in stabilizer results in

Plant Name: FCCU-I
high column pressure. Accordingly adjust stabilizer over reboiling and C2s carryover
if any.
Never allow Naphtha carryover from primary absorber to sponge absorber and sponge
oil carryover from sponge absorber to ATG. When ATG rate is very high, there are
chances of liquid entrainment. Accordingly reduce ATG generation from upstream
(reactor)
Frequently check the FG KOD (4V64) for liquid carryover if any. It becomes more
difficult to drain /unplug the drum/drain line, when already enough liquid/solid is
accumulated. Initially, liquid carryover is manifested by swings in Fuel Gas flow meter
readings in FG system.
Slurry pumps:
Considering the criticality of slurry pumps due to its impact on process and lower auto-ignition
temperatures, the following routine checks of these pumps are to be performed by operating
personnel
1. Periodically check the good working condition of the pump by reading its instruments
such as temperature/pressure gauges, ammeter, and flow meters etc.
2. Ensure that the pump is running without any abnormal vibrations or noises. If any such
problems are noticed, change-over to standby and stop the running pump and check for
causes and make necessary corrections. If no such process related issues are found, then
refer to Rotary maintenance for further action.
3. Ensure that bearing lubricating oil level in chicken-feeder is healthily holding. Refer to
Rotary maintenance, any deviations are observed.
4. Check the pump seal flushing oil flows and pressures closely on daily-basis and record
in log book. Ensure that seal flushing oil pressures/flows are as per design criteria.
Plant Name: FCCU-I
5. Follow for periodical cleaning of pump suction strainers irrespective of performance of

the pump.
6. Check the healthiness of slurry pumps ROVs during shutdown/outage opportunity to

ensure that these ROVs are efficiently functioning.
7. Release the pump/motor for periodical maintenance activities as per schedule without
fail.
Monitoring catalyst:
1. Ensure that FCC fresh catalyst and equilibrium catalyst samples are collected and sent
to laboratory for analysis as per schedule and Tech-PAD advice.
2. Closely monitor the condition of Regenerator catalyst sample (color) to understand the
Regenerator temperature profile (After-burn/behind-burn conditions) and to take the
necessary mitigate measures.
3. In the event of possible detrimental impact on process conditions (Viz., yields or other
process parameters), refer to Tech-PAD for further action plan.
Maintaining Product specifications

LPG
Weathering can be controlled by adjusting TC3001. Weathering temperature can be reduced
by reducing TC3001 set point and vice-verse.
H2S can be controlled by increasing reboiling in stripper.
CRN
End point can be increased by increasing M/C tray 34 temperature TC2003 set point and vice-
versa.
RVP can be decreased by increasing stabilizer reboiling temperature and vice-versa.
LCO
Plant Name: FCCU-I
Flash point can be increased by increasing LCO stripping steam and vice-versa.
End point can be reduced by reducing LCO draw off temperature, which can be achieved by
reducing LCO run down and vice-versa.
CLO
Flash point can be increased by increasing m/c bottom striping steam or HCO stripping steam
and vice-versa and flash zone.
Regen Cat carbon content is to be maintained in the range of 0.1 to 0.2
General follow ups
All salt water condenser outlets drain to be checked for any oil traces to confirm tube
leak.
Ensure all rotary equipment are running below their respective FLCs. Check bearing
temperatures and BCW supply and return. Check for any unusual noises or vibrations.
Ensure pump’s minimum flow through spill backs.
Unit’s housekeeping to be done on regular basis.
Check all the pumps for any seal leak.

Plant Name: FCCU-I
OPERATING LIMITS AND CONSEQUENCES OF
DEVIATIONS
CHAPTER 16
OPERATING LIMITS AND CONSEQUENCES OF DEVIATIONS
Given below are various important parameters and their normal operating ranges. This list has
been compiled basing on the experience of the plant operators. This was prepared to help the
new operators getting trained and to help the already operating personnel in their day to day
operations. However, in case of any discrepancy Process Design package is considered as final.
S. No TAG DESCRIPTION LOW HIGH REMARKS

1. 4TI1707 Hot feed temperature 80 120 Design criterion
2. 4FI1702B Cold feed flow 50 91 If flow is greater than 91, Second
booster has to be in service
3. 4LC1705 Feed Surge Drum Level 50 75 At lower values pump may lose
suction
4. 4FI1701C Total feed thruput 130 170 Will be adjusted as per unit
conditions and as per planning
requirement
5. 4PI1709 Feed pump discharge 12 18 Will be adjusted as per pass flow MVs
and Feed ring pressure
Heater
6. 4FC1901/ Heater pass flows 55 90 feed rate adjustment. At 50m3/hr,
4FC1902 heater will trip
7. 4TI1901/ Preheat temperature 150 300 Low values indicated poor heat
4TI1902 exchange and increases load on heater.
8. 4TI1908/ Pass flow O/L 318 423 Design high value is 423oC
4TI1909 temperature
9. 4TI1960A/ Skin Temp 549 Design limits
TI1958A
10. 4TI1964 Heater arch temp 819 design limits
11. 4PI1964 Heater Arch pressure positive Damper will wide open on its own,
reduces heater efficiency
DEVIATIONS
Plant Name: FCCU-I
DEVIATIONS
12. 4PI1909 Feed ring pressure 5.5 9.5 Low values indicate less velocity
across feed nozzles and may clog the
nozzles. High values lead to erosion of
nozzles Design DP across nozzles is
2.5 to 4.5 kg/cm2
Reactor-Regenerator
13. 4TI502/505/5 Feed Riser temperatures 480 561 Too low values lead to activation of
06/507 4TLCO508 and High values are design
limitations
14. 4FC505 Reactor stripping steam 2000 4000 Adjust this rate according to the
requirement. Do not decrease it too much
as the efficiency of the stripper comes
down and too high values will result in
hydrothermal reactions in regenerator
15. 4TI511 Reactor plenum 490 529 Low values reduce the conversion and
temperature Octane of CRN also reduces. High values
promote ATG generation
16. 4PDI503 DP across Rx V/L 0.05 0.15 Healthiness of V/L and cyclones can be
inferred
17. 4PDC501 R-R DP 0.18 0.38 The greater the DP, greater the circulation
and yields. Maximize subject to
conditions
18. 4TI517/ Regen Grid temp 660 730 Lower value indicates high or low carbon
4TI1X content depending upon the mode of
operation(Partial /Full respectively)
Higher values will affect the catalyst
properties
19. 4TI536 Regen Plenum temperature 690 760 Lower value indicates high or low carbon
content depending upon the mode of
operation (Partial /Full respectively)
Higher values is the design limitation of
the material
DEVIATIONS
Plant Name: FCCU-I
DEVIATIONS
20. 4ZI6X/ Slide V/V positioner 100 Slide v/v should be wide open during
4ZI5X normal operation.
21. 4FC516 MAB Air rate 50 60 Should be adjusted according to carbon
balance
22. 4FC2X CAB air rate 6 7.2 Should be used in fine tuning cat
circulation rate
23. 4PDT509 Regen Grid DP 0.1 0.2 Minimum 0.1 has to be maintained to
prevent plugging of grid holes.
24. 4TI14X-19X Cyclone O/L temperature 680 750 Lower values are better. Design limits
Higher values
25. 4ZI3X/ DDSV positioner 15 30 Will vary according to MAB air rate and
4ZI4X Reactor pressure. At Higher values, Cat
loss may take place.
26. 4F520 Reactor anti-coking steam 360 420 Used to prevent coking in Rx Anti-coking
chamber by maintaining agitation
27. 4LI3X Reactor Stripper Level 35 55 The greater the level, greater the cat
inventory and greater the cat to oil ratio.
Maximize subject to conditions.
28. 4PDI504 Riser DP 0.1 0.2 Indicative of Cat circulation rate. The
higher the better, subject to unit limitation
29. 4LI1X Regen Level 35 45 Generally constant irrespective of reactor
level during normal running conditions
30. 4LI2X Overflow Level 45 75 Indicative of Cat circulation rate. The
higher the better, subject to unit limitation
31. 4FC13X Feed Injection steam 1850 2500 Adjust feed injection steam rate subject to
feed rate and Mode of operation
32. 4PI2X Regenerator Pressure 1.12 1.4 Adjusted by adjusting reactor pressure
subject to Regen Superficial velocities
33. 4PI3X Reactor Pressure 1.32 1.7

DEVIATIONS
Plant Name: FCCU-I
DEVIATIONS
Main Fractionator
34. 4PI2001 Main Fractionator 0.8 1.1 Adjusted to maintain reactor pressure
pressure
35. 4TI2004 Main Fractionator Top 110 135 At Lower values, Dew point Gap is
temperature reduced. At Higher values AFC I/L
reaches design operating temperatures
36. 4TC2003 Main Column tray 34 140 165 Used to regulate CRN EP. Greater the
temp value, greater the EP
37. 4TI2010 Main Fractionator Flash 300 360 Minimum have to be maintained to
Zone temp maintain column profile and Higher
values are limited by design
limitations.
38. 4TI2019 Main Fractionator 340 383 Minimum have to be maintained to
Bottom Temperature maintain column profile, preheat
temperature of feed for efficient
exchange of heat and Higher values
are limited by design limitations.
39. 4TC2013 Main Fractionator 320 363 Minimum have to be maintained to
bottom D/O maintain column profile and Higher
values are limited by design
limitations.
40. 4FC2004 Slurry PA flow 420
41. 4TI2015 Main Fractionator LCO 200 230 For proper fractionation
D/O
42. 4TI2016 Main Fractionator HCO 280 325 For proper fractionation
D/O
43. 4TI2403 Main Fractionator 35 40
OVHD drum temp
44. 4PC2407 4V53 Pressure 0.2 0.5 Subject to unit feed rate and reactor
pressure, it is adjusted.

DEVIATIONS
Plant Name: FCCU-I
DEVIATIONS
WGC
45. 4PC2629 WGC I stage suction 0.8 1.8 Adjust according to WGC load, C/V
pressure opening and 4V53 pressure. At low
MVs (<30%) fluctuations observed in
C/V functioning
46. 4IA2601 WGC Load 550 620 WGC FLC is 661 amps, Maintain a
healthy margin
47. 4ASV2601 WGC I stage surge 0.1 Try to maintain it above 0.1 , if
deviation deviation is decreasing ASV can be
opened in steps
48. 4ASV2602 WGC II stage surge 0.1 Try to maintain it above 0.1 , if
deviation deviation is decreasing ASV can be
opened in steps
49. 4TI2605 WGC I stage Discharge 110 135 Try to maintain it below 135 as trip
temp exists at 143.1
50. 4PI2605 WGC II stage suction 2.7 4 WGC II stage suction low-low trip
pressure exist at 2.3 kg/cm2 and too high
pressure reduces I stage Anti surge
deviation.
51. 4LC2504 Interstage Drum Level 30 35 Maintain minimum level for suction
head and at higher levels liquid carry
over may take place.
52. 4LI2506 Suction KOD level 0 Any level as indicated by LT should
be immediately pumped out.
53. 4PI2608 WGC II stage discharge 13 15 WGC trips at HI Discharge pressure.
pressure While Higher pressures are required
for efficient separation.

DEVIATIONS
Plant Name: FCCU-I
DEVIATIONS
GAS CONCENTRATION UNIT

54. 4FC2701 GCU Stripper feed 110 145 At higher values recycling may take
place. Adjust to suit unit conditions
55. 4TI2808 GCU Stripper 110 125 Depending upon the feed type, adjust
reboiler temperature to suit unit conditions. At too low
values efficient stripping of C2s and
H2s may not take place. At higher
values LPG components land up in
ATG. Too high values may cause
Recycling
56. 4DPI2810 GCU Stripper DP 0.1 0.25 Indicative of Recycling in stripper. At
higher values tend to recycling
57. 4FC2803 Stabilizer Feed 80 120 It is generally cascaded with stripper
level. Along with GCU stripper feed,
recycling can be assessed.
58. 4PC3001 Stabilizer Pressure 8.8 9.3 Adjust to suit unit conditions.
59. 4TI3004 GCU Stripper 165 180 At too low values efficient separation
reboiler temperature of LPG components may not take
place. At higher values LPG
components land up in CRN. Adjust
according to conditions and planner
requirements.
60. 4PC2901 Sponge Absorber 13 13.7 Adjust to suit the conditions. Too high
pressure values may increase back pressure on
WGC leading to increase in WGC II
stage discharge pressure. Also C2s
concentration increases in LPG. At
lower values LPG components enter
into ATG.
61. 4FC2901 Lean oil flow 4 7 At too low or high values carryover of
oil to ATG may occur

DEVIATIONS
Plant Name: FCCU-I
DEVIATIONS
BLOWER
62. 4PI1371 Hot Well vacuum -0.97 -0.85 MAB trip exists at high pressure of -
0.3.
63. 4TI1358 Hot well temperature 35 45 At higher temp efficiency of surface
condenser decreases. HP steam
requirement increases for providing
the air rate Back flushing is necessary.
FGD
64. 4PI8101 Flue gas inlet Pr. 500mmWC Higher values are limited by design
limitations.
65. 4TI8101 Flue gas i/l Temp. 175 220 Higher values are limited by design
limitations.
66. 4LC8102 Scrubber bottom 30 75 To prevent the pump damage, Trip

level LALL8102 is set at 15 %. Which will
trip both scrubber pumps and purge
pumps.
67. 4LI8104 Over flow sump level 1000mm 3000mm At high sump level activation
(4LSH8104) sump pump to be started
and to be stopped once it touches
4LSL8104
68. 4TI8103ABC Scrubber Temp. 50 60 High temperature will leads to
activation of TAHH8103ABC (Set @
85) which will open emergency water
valves.

DEVIATIONS
Plant Name: FCCU-I
DEVIATIONS
69. 4LI8105 FM Tank level 34 69 To prevent the pump damage, Trip

LALL8105 is set at 12 %. This will
trip FM recycle pumps.
70. 4AI8208 SPM in flue gas stack 50mg/Nm3 Limited by design.
71. 4AC8101AB Scrubber 6 8 Too Low pH results in damaging the

recirculation metallurgy and too high will leads to
higher caustic consumption.
72. 4AC8102AB FM tank pH 6 8
73. II8109ABC Scrubber bottom 17 18 Higher amperage indicates excessive

pump amperage catalyst carry over to scrubber hence a
Trip is set @ 19.15.
74. 4LI8701 Emergency water 75 85 Level will be maintained always to

tank level safeguard the scrubber and bottom
pumps during emergency.
75. 4PI8107A Scrubber bottom 2.7 Low pressure indicates broken spray
pump discharge nozzle or spray pipe
76. 4PI8116 Purge pump 9.7 Lower value indicates no flow from
discharge scrubber pumps.
77. 4PI8122 FM pump discharge 4.8 Low pressure indicates broken spray
nozzle or spray pipe
78. 4PDI8204 DP across FM & 100mmWC Set by design value. Higher value
Cyclo lab indicates plugging of FM modules.
DEVIATIONS
Plant Name: FCCU-I
DEVIATIONS
CHILLER UNIT
CHILLER COMPRESSORS
79. 4LI2858 Suction KOD level 0 Liquid carry over in to compressor is
to avoid machine vibrations. Trip @
53 % exists on high level.
80. 4PI2852/2855 Suction Pressures of 5.4 5.8 Adjust according to load and
4K81 A/B discharge pressure. Trip exists on lo lo
@ 4.5 Kg/cm2 suction pressure.
81. 4PI2854/2858 Disch Pressures of 11 15.7 Higher Disc. Pressures above

4K81 A/B operating range may lead to flow
reversal and surge. Trip exists
@16.77on high dish. Pressure.
82. 4TI2852/2856 Disch Temps of 4K81 52 61 Trip exists on high dish. Temp.79
A/B
83. 4PDI2852 DP across LO filters 0.1 <=0.3 If DP >0.3 filter element is to be

cleaned/replaced.
84. 4PDI2855 DP across LO header 2 Trip exists on lower dp @ 0.7

and comp. dish line Kg/cm2.

DEVIATIONS
Plant Name: FCCU-I
DEVIATIONS
COALESCERS
85. 4DPI2811 DP across stripper <0.1 0.5 In case DP >0.5% Coalescer element
Kg/cm2
feed Coalescer is to be replaced. Higher DP gives
back pressure to the stripper feed
pump.
86. 4DPI2811 DP across PA <0.1 0.5 Kg/cm2 In case DP >0.5% Coalescer element
intercooler liquid is to be replaced
Coalescer

DEVIATIONS
Plant Name: FCCU-I
MAJOR EQUIPMENT OPERATING PROCEDURE
CHAPTER 17
MAIN AIR BLOWER
17.1 GENERAL DESCRIPTION
17.2 LUBE OIL SYSTEM

Main Reservoir, oil pumps, Lube oil rundown tank, coolers, Filters,
Lube oil lines Lube oil pressure control valves.
17.3 OPERATION
Process gas system, Antisurge control, Sealing system. Lube oil
system starting, MAB startup, routine checks, operating pressures
and temperatures, MAB shutdown.
17.4 STEAM AND CONDENSATE SYSTEM
17.5 GOVERNING SYSTEM

Technical Data MAB
MAB Steam Turbine Data
MAB trip settings
CAB trip settings
MAB instruments Tag list
MAB local panel indications
Fig. 17.1 Performance curves
Fig. 17.2 Main Air Blower

Plant Name: FCCU-I
WET GAS COMPRESSOR

17.6.1 GENERAL DESCRIPTION
17.7 LUBE OIL SYSTEM

Oil pumps. Main Reservoir, Coolers, Emergency lube oil system, Lube oil lines,
Filters, Lube oil pressure control valves
17.8 SEAL OIL SYSTEM

Main Reservoir, Coolers, filters. Seal oil supply to seals. Seal oil transfer barrier
accumulators. Seal oil instruments, seal oil return system
17.9 COMPRESSOR OPERATION

Process gas description. Oil system startup. Seal oil system startup,
Compressor startup, operating pressures and temperatures Compressor surge
17.10 COMPRESSOR SURGE
17.11 Wet Gas Compressor Technical data, WGC trip setting, WGC instruments tag list.
17.12 WGC local panel indications/push buttons/lamps WGC performance curves
Fig. 17.3 Lube Oil System

Fig. 17.4 Seal oil system
Fig. 17.5 Capacity Control Diagram
Fig. 17.6 WGC thrust balancing
Fig. 17.7 Seal oil system
Fig. 17.8 Compressors seals

Plant Name: FCCU-I
MAIN AIR BLOWER (4K-IX)
GENERAL DESCRIPTION:
The air required in the Regenerator for burning of the carbon formed on the catalyst particle
during the cracking reactions, is supplied by Air Blower (4K-1X). Main Air Blower
(MAB) is a centrifugal compressor manufactured by BHEL. It is driven by a steam turbine.
MAB, with casing in two halves horizontally split and containing a shaft with three
impellers of 100cm of nominal diameter is designated as MCL 1003.
The compressor consists essentially of a static part known as stator (casing, diaphragms,
seals, bearing and covers) and a rotating part (rotor formed by shaft, impellers and
balancing drum).
CASING
The casing of the MCL compressor consists of two halves rigidly bolted together on the
horizontal center plane. The two mating surfaces are carefully machined for a perfect seal.
Four lugs projecting from the center plane, and laid on special pillars, support the casing.
The feet at the coupling end (or main coupling end) are provided with feather keys to
position the machine in longitudinal direction.
The machine is positioned in the transverse direction by two feather keys that anchor the
vertical plane containing the rotation axis. The feather keys are fitted in special
corresponding guides welded to the base plate. The arrangement prevents any casing
displacement for the best lining up and it permits completely the thermal expansions.
The end seals prevent the gas leaking from the casing ends. This arrangement allows a
check of the bearings without disassembling the compressor.
DIAPHRAGMS
The diaphragms make up the separating wall between each compression stage. Each
diaphragm constitutes a diffuser which converts the kinetic energy of the gas at the outlet
of the impeller into pressure and the recovery passage which leads the gas to the suction
of the next impeller.

Plant Name: FCCU-I
A series of guide vanes insides the recovery passages axially pipe the gas flow and
distribute it evenly to the suction of the impeller.
The diaphragms are manufactured in high strength cast iron and they are split on the
horizontal center line.
The upper halves of the diaphragms are fixed to upper half of the casting by means of
screws. This permits lifting the upper half of the casing without the danger of diaphragms
falling.
ROTOR
It consists of a shaft on which impellers and spacers are assembled. The spaces are shrunk
of the shaft and they axially position the impellers and protect the shaft sections, between
the impellers, from contact with the gas.
The impeller is the part of the centrifugal compressor that adds velocity to the gas. The
impellers are of enclosed backward-bladed type and are shrunk and keyed onto the shaft.
Before being mounted on the shaft each impeller is dynamically balanced and tested at a
speed 15% higher than the maximum continuous speed.
During the compressor operation the rotor is subjected to on axial thrust in the direction of
the suction end generated by the pressure difference action on the cover and hub of the
impellers.
The majority of the thrust is balanced by the balance drum.
The resulting axial thrust is absorbed by the thrust bearing.
BALANCING DRUM
The centrifugal compressor rotor is subjected to an axial thrust towards the suction end
due to the differential pressure acting on the hubs and covers of the impellers. In these
types of compressors, the axial thrust is partially balanced by the balance drum fitted
between the discharge sides of the two stages. The sizes of the drum is such that the
reduced, the remaining thrust being absorbed by the thrust bearing. This ensures that the
rotor does not move in axial direction.

Plant Name: FCCU-I
JOURNAL BEARINGS
The journal bearings of lemon type are force feed lubricated. They are housed outside the
compressor casing and they may be inspected without disassembling the casing. The
bearings are made of steel lined with white metal and split in two halves on a horizontal
plane. The two half bearings are dowelled and secured together. A pin projecting from
the bearing upper half prevents it rotating within its housing. The forced oil arrives to the
bearings radially at parting plane and it comes out at the two sides of the bearing.
THRUST BEARING
The thrust bearing, at the shaft end, is KINGSBURY type and it is designed to support the
residual axial trust operating on the rotor that is not completely balanced by the opposite
suction and by the balance drum.
The bearing is of the double type, and it is installed at both sides of the thrust collar at the
compressor shaft end.
It is provided with an oil control ring to minimize the power loss due to churning of the oil
in the bearing cavity under high speed operation.
LABYRINTH SEAL (INTERNAL)
The internal labyrinth seals are used between rotating and stationary parts of the
compressor to reduce gas leakage between areas of different pressure.
The labyrinth seal consists of a ring, the periphery of which is shaped on a series of fins
having small clearance with the rotor.
The rings are manufactured in 2 halves and 4 fourths of a slot alloy resistance to corrosion
to avoid damage to the rotor in the event of an accidental contact.
The upper halves of the rings are fastened to relevant diaphragm. The lower halves of the
rings can be easily removed by rotating them in their grooved seat in the diaphragms.
The positions of the rotor which face the labyrinth seals are: the impeller disk, the shaft
sleeves between the impellers and the balancing drum.

Plant Name: FCCU-I
The same type of seals is located at the shaft end to limit the gas leakage out of the
compressor.
LUBE OIL SYSTEM:
MAIN RESERVOIR:
It has charge capacity of about 13.4m3.
The reservoir is equipped with the following control safety and instruments:
o Level sight gauge (LG)
o Low oil level alarm switch (LSL)
o Local thermometer (TG)
The reservoir is fitted with steam heater to give the oil viscosity for start-up.
The reservoir is provided with necessary connection for filling, draining, venting,
inspection and oil purification. An oil conditioner is provided for purification of the oil.
Oil vapors extraction fan is provided on the top of the tank to remove Oil vapors/fumes
form the tank.
OIL PUMPS:
Two identical pumps provide the oil circulation. The main pump is driven by Aux drive
turbine and standby pump by an electric motor.
Each pump is capable of supplying the capacity required by the whole system, therefore
each pump can operate as a stand-by for a continuous service.
The stand-by pump starts automatically by a pressure switch in the common discharge of
both pumps in case there is a drop in pressure.
The suction line of each pump is provided with strainer and isolation valve and pressure
gauge. Pump running indication is provided through the pressure switch high contacts
located on the discharge of each pump.
The two discharge lines are joined into a single connection line leading to the coolers.

Plant Name: FCCU-I

Plant Name: FCCU-I
EMERGENCY LUBE OIL SYSTEM
LUBE OIL RUNDOWN TANK:

In case of shut-down of both oil pumps, the main lube oil pressure switch PSLL 1366 A, B,C in
the lube oil header shuts down the main driver. A certain time period is required for the compressor
to stop completely owing to the high inertia of the rotation masses. Therefore sufficient oil quantity
should be supplied to the bearing unit comes to standstill.
An overhead rundown tank placed about 7.0 meters over the compressor centerline with a normal
level capacity of about 4000lts. is provided for this purpose. It caters required oil quantity to the
bearings (of both MAB & CAB trains) during coasting down in case all the pumps fail to supply
the oil.
The tank is filled with oil during the preparation of the lube oil system. While the main oil
pump is running the oil inlet valve to the overhead rundown tank is kept open until the oil circulates
through the flow glass placed in the overflow line to main reservoir. Then close the oil inlet valve.
A permissive to compressor driver start-up interlock level switch is assembled on the overhead
rundown tank.
The rundown tank is maintained full while the unit is running by continuous oil flow which reaches
it though a fixed orifice.
NOTE: The overhead lube oil tank has a capacity to supply oil to the turbine bearings for a period
of 15 minutes after shutdown. Since the cooling down period of turbine is much longer, it shall be
ensured that one of the lube oil pumps is put back in service within this period.
COOLERS:
The oil is cooled by two water coolers, one as stand-by to the other one. Each cooling element is
designed to cool the whole oil flow necessary for the plant.
The oil flow is directed to one of the coolers leaving the other free for cleaning. This is realized
by means of two three-way trans flow valves which are simultaneously controlled by the hand
level.
To equalize the oil pressure and facilitate the changeover operation the two coolers are connected
by a bypass pipe incorporating a needle valve.

Plant Name: FCCU-I
To clean a cooler and subsequently fill it without interrupting the plant operation, proceed as
follows:
Check that the by-pass valve is open. Slightly open the stand-by cooler vent and check that
the cooler is full.
Direct the oil flow to the stand-by cooler till the oil pressure is equal in both coolers.
Close the by-pass valve and open the drain valve and vent of cooler to be cleaned. Clean
and check the condition of the cooler and close the drain.
Open the by-pass valve to fill the cleaned cooler and close the vent as soon as the oil start
flowing in the pipe.
The clean cooler will then be full of oil at the working pressure, the by-pass valve being open.
Piping with Temperature Control Valve TV1357 is provided to bypass the oil from the cooler and
connection directly to the cooler outlet for maintaining the oil temperature at a constant value.
Follow guidelines provided as per SI 41 for preventing inadvertent entry of water into lube oil
systems in view of the safety of machine.
FILTERS:
The oil reaches the filters, consisting of two distinct elements, each as stand-by to the other
one.
One filter is in service at a time thus cleaning, inspection and maintenance of the second
filter can be performed without interrupting oil flow or shutting down the machine.
To equalize the oil pressure and facilitate the changeover operation, the two filters are
connected by a by-pass pipe incorporating valve and fixed orifice.
The pressure drop in the filter units is measured by means of differential pressure indicator.
Differential pressure switch for an excessive differential pressure is installed in the filter
units,
When the differential pressure exceeds 1.5 kg/cm2 (20 psig) change the filter and replace
the filter elements
The filter unit should be filled with oil immediately after cleaning so as to be ready for use.
Lube oil sample should be checked for flash, viscosity & water content prior to starting the
machine. The same to be ensured prior to starting WGC & CAB.
The transfer of operation from one filter to the other should be accomplished in the same
way as for the two coolers. After checking that the filter to be used is full of oil, the bypass
valve is open, transfer the oil flow by the proper valves (or valve). Then clean and fill the
other following the procedure described for the cooler. For detailed procedure, please refer
respective PSI for lube oil filters change-over (SI 55).
Plant Name: FCCU-I
LUBE OIL LINES:
The filtered oil is pumped to a header from which the lube oil bearing lines are tapped.
The oil pressure in the, lube oil header is maintained at a constant pressure of 2 to 2.5 bar
g (28 to 35 psig) the pressure reducing valve PCV3105.
Each bearing oil feed pipe is fitted with a flow regulator which reduces the oil pressure to
the required level. The pressure value is indicated by a local gauge.
Flow glasses and local thermometers are installed in the oil outlet lines leaving each of the
lubrication points.
The oil outlets are tapped into a single receiver from which the oil is carried to the main
reservoir.
The lube oil pressure to bearings is adjusted by means of the flow regulator provided in
each oil inlet line to bearings 0.9 to 1.3 Bar g (12 to 18 psig) to journal bearings and approx.
0.3 to 1.3 Bar g (6 to 18 psig) to thrust bearings should be maintained.
The regulator lube oil through the bearings can be checked by means of flow glasses.
LUBE OIL PRRESSURE CONTROL VALVES:
The lube oil pump discharge pressure control valve PVC 1351 maintains a constant
pressure of 9.0 kg/cm2 kg by bypassing the excess oil being pumped back to the reservoir.
BEARING LUBE OIL PRESSURE CONTROL VALVE PCV 1352
The lubricating oil pressure control valve maintains a constant pressure of 2.5 kg/cm2 in
the lubricating oil header.
VALVE SETTING:
The valve setting is accomplished with the oil pump in operating and with stop valves and
by-pass valve operating.
Watching the pressure gauge placed in line in which valve maintains the required pressure
slowly close the bypass valve and in the same time set the control valve as it reached the
required pressure in the header when the bypass valve is fully closed.
The control valves PCV 1351 & PCV 1352 can be out-off maintenance by closing the stop
valves, and pressure can be regulated manually by the valve installed in parallel.

Plant Name: FCCU-I
OPERATION
PROCESS GAS SYSTEM:
The air is sucked from atmosphere through suction filter and compressed to 3.15 kg/cm2 abs and
196.70C in centrifugal compressor of type MCL-1003 (4K-1X).
Instruments to measure air pressure and temperature are provided in the compressor discharge and
suction lines. High/low temperature and High/low pressure alarms are provided in DCS to
annunciate the condition of the air discharged from the compressor. Safety Valves PSV 502A,B,C
are provided in the compressor discharge piping.
Part of the air discharged is further compressed in control air blower (4K-1X).
An isolation valve is provided in the compressor discharge before being connected to 4D-1X. A
quick closing NRV is placed in downstream of this valve which prevents reversal of air flow into
compressor.
A silencer is provided in the upstream of intake air filter to reduce the sound levels.
ANFILCO FILTRATION SYSTEM:
ANTIURGE CONTROL:
The Quantity of air sucked by compressor must always be higher than the air quantity
corresponding to the operating pressure in the antisurge curve (indicated on the performance
curves). The alternated stress to which the compressor rotor is subjected during surging can
seriously damage bearings and seals of the compressor. The surging effect reveals itself when
capacity sucked by compressor is less than that required as per the surge curve at that pressure and
speed. To avoid the surging effect during the automatic control of load, compressors are provided
with an automatic antisurge control system. It consists of a controller UC 521 which controls the
opening valve HCV 509 through which the difference between the capacity at surge limit and that
utilized by the plant is exhausted to the atmosphere.
During startup conditions i.e., till the minimum governing speed the compressor antisurge is
controlled by the control valve HV 509 in manual mode. The excess gas is vented to atmosphere.

Plant Name: FCCU-I
Ensure that the manual isolation valve provided upstream of antisurge valve HCV 509 is positively
kept in full open position and locked. Closure Of This Valve During Operation Of Compressor
Can Cause Severe Damage To The Machine.
Sealing System:
To prevent the ingress of lube oil into the suction side of the compressor and prevent hot air entry
into the bearing chamber in the discharge end of compressor, sealing system with instrument air
as the sealing fluid is provided. Globes valves are provided in the sealing air lines of the suction
and discharge ends respectively. Pressure gauges PI 353A, PI1353B are also provided in these
lines to ensure maintenance of a positive differential between the sealing air and the air leaking
through compressor seals.
Lube Oil System Preparation:
1. Be sure that the lube oil main reservoir is filled with the recommended grade of oil. (XT-
46)
2. Check the oil level in the main reservoir.
3. Start the heater for oil heating so that the oil temperature in the reservoir reaches 400C.
The temperature should not be lower than 250C.
4. Check that the isolating valves of the oil pumps are open.
5. Check that all by-pass valves are closed and the isolating valves of the control valve PCV
1351 and PCV-1352 in the bearings lube oil system are open.
6. Check that drain valves of coolers, filters, level indicators and pipes are closed.
7. Check that isolating valves of pressure switches, pressure gauges, pressure transmitters,
level gauge, switches and valve actuators are open.
8. Check that the isolating valves of water to oil coolers are closed.
Lube Oil System Starting:
1. Start the main lube oil pump according to manufacturer’s instructions. Open the by-pass
valve of twin coolers and twin filters.
2. Open the vent valves of oil coolers and filter is service. Bleed off the air and close the
valves again.
3. Crack open the vent valve of oil cooler and oil filter not in service and close it again as
soon as they are full.
4. Check the oil pressure to the various points, bearing in mind that oil pressure should be:
a. Lube oil pressure after pumps: 9Kg/Cm2 (g)
Plant Name: FCCU-I
b. Lube oil header: 2 to 2.5 Kg/Cm2

c. Lube oil pressure to journal bearings: 0.9 to 1.3 Kg/Cm2
d.
Lube oil pressure to thrust bearings: 0.3 to 1.3 Kg/Cm2
5. Check the normal flow of the oil coming out from journal and thrust bearings by the flow
sight glass device. Check the oil pressure drop through filters.
6. Fill completely the lube oil overhead tank.
7. Check the nitrogen %pressure of hydro pneumatic accumulator.
8. Prearrange for starting the standby lube oil pump oil pump driver.
9. Stop the lube oil main pump driver and check the stand-by pump automatic start-up
10. Then stop manually the stand-by pump and check the pressure point at which the alarm
and trip switches installed in the lube oil header operate.
11. Re-start the main lube oil pump.
12. Turn the control of the stand-by pump in automatic position.
13. When the oil temperature exceeds 400C-500C cut of the heater in the oil reservoir. If it is
necessary open the isolating valves of water valves to oil coolers.
Preparation and Inspection of the Units Gas Circuit:
Inspect the following
Verify that the valves are in the following positions

a. Antisurge valve HCV 509 OPEN
b. Isolation valve in discharge line to CAB suction CLOSE
c. NRV in final discharge CLOSE
d. Isolation valve in the upstream of discharge NRV HV510 OPEN
e. Valve in the bypass of Antisurge valve HCV 509 CLOSE
f. Isolation valve upstream of HCV 509 OPEN
(Locked in open position)
g. Isolation valves upstream of safety valves PSV 502 A, B, C OPEN
2. Instrument air isolation valve to seals.
NOTE: For the first period of the compressor operation it is necessary to put a cone shaped filter
on the suction piping near the machine.
Plant Name: FCCU-I
The filter is to be removed after making sure that the piping is clean.
1. Check on the control panel that the turbine speed control device is in manual position.
2. Check that the isolating valves of the pressure gauges, pressure transmitters, switches etc.,
are open.
3. Keep turbine under warm-up. Take clearance from power plant, MP.DMP shift.
4. Stroke check MAB antisurge control valve and keep in wide open position.
5. Bypass trip oil pressure low-low switch.
6. Keep FLCO 509 in bypass position.
7. Ensure trip circuit healthy on local panes, press reset push button on Woodward governor
panel in control room.
8. MAB ready to start.
9. Close MAB discharge valve, CAB suction and discharge valves.
10. Buildup trip oil pressure and remove bypass on trip oil pressure low-low switch.
11. Open emergency stop valve with starting device.
12. Give clearance for starting the machine.
13. Start the machine from control room with Woodward Governor by giving command
“RUN”.
14. Initially give set point 1000 RPM and gradually go up from 3000 to 4000 upto 5000.
15. Maintain instrument air to Thrust balancing line DP 0.2 Kg/Cm2.
16. Ensure suction, reset MAB discharge check valve (HV510) and open MAB discharge
valve.
17. Open primary air to Regen butterfly valve and establish flow.
18. Open secondary air to Regen butterfly valve and establish the flow by closing suitably the
antisurge valve.
19. Keep FLCO509 trip in service. (Air to Regen flow Low Low).

Plant Name: FCCU-I
CAB Startup
1. Ensure MAB discharge pressure 1.7 Kg/Cm2

2. Ensure CAB antisurge valve block valve in wide open position.
3. Open CAB suction valve 50% only and discharge valve in wide open position.
4. Ensure CAB bypass valve (suction to discharge) in closed position.
5. Keep FL516BP CAB air flow low switch in by pass position and keep FLCO510 in by
pass position.
6. Ensure CAB anti surge control selection of HC511 with output 100%
7. Take clearance from CPP, process substation and inform RSM
8. Press reset push button located on local panel to get CAB ready to start.
9. Start CAB and open suction valve gradually.
10. Maintain instrument air to Thrust balancing line DP 0. 2 Kg/cm2.
11. Reset CAB discharge check valve HV506 and reset FV2X and open the control valve
suitably.
12. Suitably close the antisurge valve and route control air to spent catalyst riser.
13. Establish normal control air flow, then keep FL516BP bypass switch in normal mode, and
keep FLCO510 (Regan CAB flow Low Low) switch in normal mode.
14. Ensure all five control air nozzles are clear. The following checks should be carried out
during initial start-up after prolonged standstill for every speed rise.
a. Machine Vibrations
b. Bearing oil Pressure and temperatures
c. Bearing temperatures
d. Radial vibrations
e. Axial displacement
Routine Checks (during normal operation)
To be performed on a regular basis on the running machines.
a. Oil level in the main reservoir.

b. Oil level in the lube oil overhead tank.
c. Oil temperature in the main reservoir.
d. Oil temperature at the inlet and outlet of oil cooler.
e. Temperature in the bearings.
f. Oil temperature in the discharges from bearings.
Plant Name: FCCU-I
g. Oil pressure downstream of pumps.

h. Oil pressure in the lube oil header.
i. Oil pressure drop through filters.
j. Oil pressure in the journal and thrust bearings.
k. Pressure in the lube oil accumulator.
l. Oil flow in the discharge lines.
m. Rotor axial displacements.
n. Radial Vibrations.
o. Temperature and pressure of the gas at the suction and discharge.
p. Periodically take oil sample from main reservoir for analysis.
q. Moisture level in the separator.
r. Expansion of turbine and compressor casings.
Operating Pressures and Temperatures

Lube oil pump discharge pressure : 9 Kg/cm2
The oil header : 2 – 2.5 Kg/cm2g
Journal bearing : 0.9 – 1.3 Kg/cm2g
Trust bearing : 0.3 to 1.3 Kg/cm2g
Minimum bearing oil inlet temperature : 35 °C
Normal bearing oil inlet temperature : 50 °C
MAB SHUTDOWN:
Shutdown of the machines can be programmed, either manually actuated or automatically actuated
by devices installed to protect the unit.
1. Routine shutdown may be easily achieved by pressing the trip pushbutton on the local control
panel, or operating the turbine trip valve.
2. If it is preferred to minimize upset of the steam and gas system, shutdown may be carried out
reversing the startup procedure.
3. As soon as turbine speed has been reduced to the low speed setting of the governor, trip the
machine.
4. The action of the routine shutdown and that caused by malfunction will be as follows:
a. Steam turbine Stops.
b. Antisurge valve Opens by action of its solenoid valve.
c. Final discharge NRV Close by action of its solenoid valve.
Plant Name: FCCU-I
5. For the turbine driver and steam system, observe instruction outlined in the turbine manual.
6. Blow down compressor drains.
7. Close the discharge valve.
Steam and Condensate System
General:
The steam and drain system consists of Main Steam, condensing System, gland Steam and drain
systems.
Main Steam System:
Main steam from the VHP, steam header is drawn for the turbine. The parameters of main steam
at turbine nozzle are: 36 ata and 360°C.
A provision given on the main steam line for connecting steam washing system to wash internals
of turbine with wet steam in case the turbine internals are salted.
The pressure & temperature measurements at steam inlet are provided local pressure indication
in main control panel.
Condensing System:
The exhaust from turbine is connected to the surface condenser with expansion bellow. The
condensate at a discharge pressure of 10 ata normal is extracted from condenser Hot well by
vertical condensate pump and discharged to the power plant battery limit through the control valve
LV 1302 A.
The condensate system consists of following:

1. Surface condenser
2. Vertical condensate pumps
3. Ejector condenser
Surface Condenser:
1. The identical condensate pumps provide the condensate circulation. The main pump is
driven by Steam turbine and stand by pump is driven by electric motors.
Plant Name: FCCU-I
2. Each pump is capable of supplying the capacity 22 m3/hr rated capacity, therefore each
pump can operate as a standby for continuous service.
3. The standby pumps starts automatically by a level switch LSH 1355 on surface condenser.
4. The suction line of each pump is provided with non-return valve.

5. The discharge line of each pump is provided with non-return valve, isolation valve and
pressure gauge. Pump running indication and alarm for standby pump start are provided.
6. The two discharge lines are joined into a signal connection line leading to the Level Control
Station.
7. The control station consisting of control valve LV 1302 (A and B) each one operated
depending upon the level controller LIC 1302 and these are split range type signal working.
8. Prior to the start of MAB, suction strainers of condensate pump shall be cleaned so as to
prevent issues at later stages of start-up activity.
Ejector Condenser:
Two identical ejectors maintain the condenser pressure. Both are of 2 x 100% capacity. Starting
ejector is provided only for Startup.
Gland Steam:
The rear bearing side to turbine is to be sealed against entry of air into casing. This is done by
injecting steam during start up. The VHP steam at 36 ata is reduced to the required pressure by
control valve PV1369A.
During normal operation, the steam leaked at front bearing side is led to rear bearing for sealing
against air leakage and gland steam leakage will be passed to surface condenser through
PV1369B.The control valves PV1369A & PV1369B are controlled by the controller PC 1369 in
split range control.
Drain System:
The steam drains from turbine and various steam systems are joined to drain header in surface
condenser according to pressure gradient.

Plant Name: FCCU-I
Governing System
The turbo compressor set is provided with electro hydraulic governing system. The electronic
governor is Woodward 505 microprocessor based digital governor.
The governing system is designed to control the speed corresponding to speed reference signal
provided by process controller.
Additionally the system incorporates protective devices like emergency trip device, emergency
stop valve, remote trip solenoid valve, hand trip valve etc.
Oil Supply To The Governing System
The supply of oil to the governing system is at 8 bar from the oil pump which also supplies oil to
the lube oil system.
Electronic Governor:
The electro hydraulic speed control circuit comprised of speed transmitter (SE), controller 505,
electro hydraulic converter, control valve actuator and control valves. The speed controller in the
Woodward electronic governor feeds a signal based on the actual speed/load to electro hydraulic
converter.
I/H Convertor
The electro hydraulic converter converts the electrical signal into proportional hydraulic signal
called as secondary oil pressure.
Control Valve Actuator (Servomotor)
Control valve actuator positions the control valves corresponding to the secondary oil pressure
generated by electro hydraulic converter.
Control valve actuator (Servo meter) main consists of a pilot valve, a power cylinder and a
feedback system. Upon change in secondary oil pressure, pilot valve provides oil passages to and
from power cylinder. The movement of power piston is transmitted to the control valves through
levers. The feedback lever resets the pilot valve to its neutral position once the power piston
occupies new position corresponding to changed secondary oil pressure. The system is such that

Plant Name: FCCU-I
the increase in secondary oil pressure cause the control valves to open. Hence interruption of
secondary oil pressure causes valves to close.
Damping Device
Damping device damps out the quick oscillations in secondary oil pressure generated by electro
hydraulic converters. This helps in improving the stability of the governing system.
Emergency Stop Valve and Starting Device
The emergency stop valve is of quick closing type. The valve is actuated by means of a starting
device. The emergency stop valve consists of a spring loaded piston disc, which is connected to
the valve cone through a spindle. For opening the emergency stop valve, start-up oil from starting
device is admitted to the space above the spring loaded piston, by operating the starting device.
Due to start-up oil pressure, the piston moves towards the piston disc and they form a tight seal
against each other. Oil from trip oil circuit is then admitted to the space under the piston disc and
the space above the piston is connected oil drain. The trip oil now forces both the position disc
and piston to the outer position thereby opening the stop valve. As long as the trip oil pressure is
maintained to the piston and the piston disc, can’t be separated by spring force. The stop valve is
closed only when the trip oil pressure drops substantially.
Tester For Emergency Stop Valve
Testing device is provided to check the proper functioning of emergency stop valve during normal
operation of turbine. If the testing device is operated, it will admit the pressure oil to the space
behind the test piston of emergency stop valve, which will then the pushed against the piston and
move the piston and valve spindle towards the closed position (partial closing).
Hand Trip Valve
Whenever the turbine is to be tripped, the governing oil pressure (trip oil line after hand operated
valve) is drained by hand trip valve. Thus pressure in front of stop valve piston disc and secondary
oil pressure falls, resulting in closure of stop valve and control valves.
The hand trip valve is operated either manually or by loss of source oil pressure.

Plant Name: FCCU-I
Trip Solenoid Valves
Trip solenoid valve facilities the tripping of turbine from remote place such as control room
through push button. Whenever the solenoid valve is de-energized, it interrupts the oil supply to
trip oil circuit and simultaneously depressurizes trip oil circuit. Solenoid valve is also de-
energized by any one of the signals initiated by limited value monitor devices or upon compressor
faults.
Over speed Trip System
Over speed trip system is realized in two channels.
Channel – I consist of exclusive2 out of 3 electronic over speed trip system of M/S Bentley Nevada
of over speed protection.
In channel –II over speed trip signal is generated in Woodward ‘505’ controller which derives its
signal from 1 out of 2 logic system. Trip signal from either channel I or channel –II reenergizes
the trip solenoid valves simultaneously.
Mock Up Operation

Plant Name: FCCU-I
MAB Technical Data

Condition Data
Compressor type MCL 1003
Gas handled Wet air
Capacity (wet) 75485 kg/hr
Suction conditions
Pressure 1.0332 kg/cm2a
Temperature 45
Molecular weight ( dry ) 27.949
Cp/Cv 1.377
Inlet Volume 72792 m3/hr
Compressibility 1.0
Relative Humidity 95%
Discharge conditions:
Pressure 3.15 kg/cm2g
Temperature 196 C
Cp/Cv 1.381
Total Power at coupling 3426 kw
Normal Speed 6258
Maximum continuous speed 6571
Direction of rotation viewed from drive
end.

Plant Name: FCCU-I
MAB Steam Turbine Data
Output
Normal output (designed) 3426 kw
Maximum output 3769 kw
Speed
Normal speed 6258 rpm
Speed range 4386-6571
Pressure
Specified initial steam pressure 36 ata
Permissible deviation without limitation 39 ata
Permissible deviation at no load operation 39 ata
Permissible deviation instantaneously for a total duration of
12hrs per annum 46.8 ata
Pressure Inside The Turbine
The pressure in the HP wheel chamber of the turbine must not
exceed the following value at maximum load and with salt
deposits on the blades.
The pressure in the LP. Wheel chamber of the turbine 16.3 ata
must not exceed the following value
Extraction pressure: The extraction pressure may rise to and -
drop to pressure at the exhaust flange. -
Pressure at the exhaust flange may rise and drop to 0.11 ata
Temperatures
Specified initial Steam temperature 360oC
Permissible deviation without limitation 380oC
Permissible deviation for longer periods 388.3oC
Permissible deviation for 400hrs per annum 394oC
Permissible deviation for 80hrs per annum but no longer than
15 minutes at a time 408oC
Cooling water temperature (condenser) 33oC

Plant Name: FCCU-I
MAB Trip Settings

S. No. Service Alarm Set Pt. Trip Tag Set Pt.
LO Header Pressure very low 0.8kg/cm2.
1 PAL 1365 1.5kg/cm2 PALL 1366A
2/3 voting
Control Oil Header Pr Very Low 4.5kg/cm2.
2 PALL 1385A
2/3 voting
Trip Oil Pr Very Low 2.0kg/cm2.
3 PALL 1385A
2/3 voting
Turbine Steam Exhaust Pr Very High - -0.3kg/cm2.
4 PAH 1371 PALL 1372A
0.6kg/cm2 2/3 voting
Condensate Hot-well Level Very 165mm
5 LAHH 1356A
High 2/3 voting
Turbine Speed Very High (BNC) 7300
6 SAH 1386 6,899.5 SAHH 1387
2/3 voting
7 Turbine Speed Very High (WWG) SAH 1387 6,899.5 WWG 7230 RPM
Comp & Turbine Vibration Very VAH
8 100u VAHH1350 135u
High 1350
9 Comp & Axial Displacement ZAH 1354 0.5u ZAHH 1354 0.7mm
10 Comp & Turbine TB Temp very High TAH 1361 110 C TAHH 1361 120 C
11 Comp JB Temp Very High TAH 1359 85 C TAHH 1359 110 C
12 Turbine JB Temp Very High TAH 1359 85 C TAHH 1359 120 C
13 Emergency Trip From LCP(HS503B) HAS 503BH
14 Emergency Trip From DCS HAS 503AB
15 Manual Trip Lever On Go System

Plant Name: FCCU-I
CAB Trip Settings
S. No. Service Alarm Points Trip Points
(Tag No) (Setting) Tag No) (Setting)
Comp/GBHS/GB
LS Relative Shaft
1 VAH1352 75 /75 /100 VAHH1352 100 /100 /135
Vibration Very
High
Comp TB/GB Hi
Speed/ GB LS Axial
2 ZAH1351 +- 0.5mm ZAHH1351 +- 0.7mm
Displacement Very
High
Comp/GB HS/GB
3 TAH1369 110 C TAHH1369 120 C
LS/TB Temp High
Comp/GB HS/GB
4 LS JB Temp Very TAH1366 85/90/90 C TAHH1366 90/110/110 C
High
Emergency Trip
5 From HSA504BHZ Push buttons
LCP HS 504B
6 CAB disc flow low 4FI517 FL517 2.922KNM3/Hr

Plant Name: FCCU-I
Main Air Blower Tag List
TAG
S.NO TAG NO STATUS ALM TRIP UNITS REMARKS
DESCRIPTION
1 4F13X Steam inlet flow High 21.35 T/hr

to turbine Low 15.69
2 4LL1350 L.O. Main Oil Low 1,397 mm
tank level low
3 4LL1351 L.O. Overhead Low 165 mm
tank level low
4 4LH1352 L.O. Overhead High 165 mm Consent for
tank level high comp
startup
5 4LL1353 Condenser hot Low 165 mm Consent for
well level low standby
CEP
6 4LLL1354 Condenser hot Very low 165 CEP trip
well level very
low
7 4LLH1355 Condenser hot High 165 mm Standby
well level high CEP start
8 4LHH1356X Condenser hot Very 165 mm Comp trip
4LHH1356Y well level very high LAHH1356
4LHH1356Z high
9 4DPI511 DP across MAB High 0.4 Kg/cm2
inlet air filter
10 4PH1361 L.O.MOP pump High 8 Kg/cm2
discharge
pressure
11 4PH1362 L.O. AOP pump High 8 Kg/cm2
discharge
pressure
12 4PL1365 L.O. Header Low 1.5 Kg/cm2 Start s/b
pressure LOP
13 4PHH1372A Turbine exhaust Very -0.3 K/cm2 Common trip
4PHH1372B steam pressure high Alarm
4PHH1372C PHH1372
Plant Name: FCCU-I
14 4PH1373 CEP2 discharge High 4 Kg/cm2

pressure high
15 4PH1374 CEP1 discharge High 4 Kg/cm2
pressure
16 4PL1377 LO discharge to Low 6.8 Kg/cm2
tank pressure
16 4PLL1385A Control oil header Very 4.5 Kg/cm2 Comp trip.
4PLL1385B pressure low Common
4PLL1385C alarm
4PLL1385
18 4PLL1387A Trip oil pressure Very 2 Kg/cm2 Common
4PLL1387B low Trip
4PLL1387C 4PLL387
19 4PDI1351 Differential pressure 2.2 Kg/cm2
across L.O. filter
20 4PH1363 L.O. pump High 8.5 Kg/cm2
4PL1363 discharge pressure Low 6.0
21 4PL1366A LO header pressure Very 0.8 Kg/cm2 Common trip
4PL1366B low alarm
4PLL1366
4PL1366C
22 4PH1368 Inlet steam pressure High 40 Kg/cm2
4PL1368 to turbine Low 29
Inlet steam pressure
to turbine
23 4PH1369 Gland steam header High 0.2 Kg/cm2
pressure
24 4PH1371 Turbine exhaust High -0.6 Kg/cm2
steam pressure
25 4PH1385 Control oil header High 8 Kg/cm2
pressure
26 4PH1388 Trip oil pressure High 4 Kg/cm2
27 4PH1X MAB discharge High 2.47 Kg/cm2
4PL1X pressure Low 1.72
28 4TI1359A/B Compressor journal High 85 110 C Common Pre-
4TI1360A/B bearing temp alarm
4TH1359 Trip
alarm
4THH1359
Plant Name: FCCU-I
29 4TI1361A/B/ Compressor thrust High 110 120 C Common pre

C/D/E bearing temp High 110 alarm
4TI1362A/B/ Turbine thrust 4TH1361
C/D/E bearing temperature Common trip
alarm
4THH1361
30 4TI1363A/B Turbine FJB High 85 120 C Pre-alarm
4TI1364A/B temperature 4TH1359
Trip 4THH1359
31 4TI1368A GB high speed shaft High 90 110 C 4TH1366
JB 4THH1366
32 4TI1369A/B GB low speed thrust High 110 120 Pre-alarm
bearing temp 4TH1369
Trip 4THH1369
33 4TI1370 GB low speed shaft High 110 Pre-alarm
4TI1371 JB 4TH1366
Trip 4THH1366
34 4TI1372A/B GB high speed shaft High 110 C Pre-alarm
TB 4TH1369
4TI1373A GB high speed shaft High 90 Trip 4THH1369
JB
35 4TI1374A/B CAB journal bearing High 85 C Pre-alarm
4TI1375A/B temperature 4TH1366
Trip 4THH1366
36 4TI1376A/B/ CAB thrust bearing High 110 C Pre-alarm
C temp 4TH1369
Trip: 4THH1369
37 4SI1386A/B/ Turbine speed probe High 6,899.5 7,300 RPM Trip : SHH1387
C
38 4SI1387 Turbine speed probe High 6,899.5 7,230 RPM WWG
39 4TI1356 L.O temperature High 55 C
40 4TI1357 L.O. temperature High 55 C
after cooler Low 45
41 4TI1358 Exhaust steam High 85 C
temperature
42 4TI2X MAB discharge High 225 C
temperature

Plant Name: FCCU-I
43 4TI502 MAB discharge High 210 C

temperature Low 160
44 4VI1350A/B MAB relative shaft High 100 135 C Pre-alarm
vibration (OTB) VHH1350
4VI1351A/B MAB relative shaft Trip: VHH1350
vibration (TB)
45 4VI1352A/B GB High speed shaft High 75 100 µ Pre-alarm
R.S.V (OTB) 4VH1352
4VI1353A/B GB high speed shaft Trip:
R.S.V (TB) 4VHH1352
4VI1354A/B CAB relative shaft
Vib (OTB)
4VI1355A/B CAB relative shaft
vib (TB)
46 4VI1358A/B Turbine vibration High 100 135 µ Pre-alarm
(FJB) 4VH1350
4VI1359A/B Turbine Vibration Trip:4VHH1350
(RJB)
47 4VI1360A/B GB low speed shaft High 100 135 µ Pre-alarm
4VI1361A/B R.S.V. TB 4VH1352
GB low speed shaft Trip:
R.S.V OTB 4VHH1352
48 4ZI1350A/B MAB thrust bearing High 0.5 0.7 mm Pre-alarm
axial displacement 4ZH1354
Trip: 4ZHH1354
49 4ZI1351A GB low speed shaft High 0.5 0.7 mm Pre-alarm
axial displacement 4ZH1351
4ZI1352A GB high speed shaft Trip: 4ZHH1351
axial displacement
4ZZI1353A/B CAB thrust bearing
axial displacement
50 4ZI1354A/B Turbine axial High 0.5 0.7 mm Pre-alarm
displacement 4ZH1354
Trip: 4ZHH1354
51 4ZAL1385A ESV close position
4ZAH ESV open position

Plant Name: FCCU-I
MAB LOCAL PANEL INDICATIONS:
ZE1354A/B Turbine Axial displacement

ZE1350A/B Blower Axial displacement
VE1350A/B Turbine Vibrations
VE1359A/B
SE1386A/B Turbine speed
SE1387A/B
TE1361ABCDE Blower TB temperatures
TE1359A/B Blower TB temperatures
TE1360A/B
TE1362ABCDE Turbine TB temperatures
TE1364A/B Turbine JB temperatures
TE1363A/B
PI1363B LOP discharge pressure
PI1364B L.O. Header pressure
PI1368B Turbine I/L steam pressure
TI535B Turbine steam I/L temperature
PI1371B Turbine exhaust pressure
TI1358B Turbine exhaust temperature
PI1381B MAB suction pressure
TI1381B MAB suction temperature
PI1XB MAB discharge pressure
TI2XB MAB discharge temperature
SI1387A Turbine speed
L009A Trip oil pressure very low bypassed
RIL1 Purge bypassed
KS0018A Bypass for trip oil press very low
KS2 Bypass for purge press very low
SW1 110V AC power ON/OFF
SW2 Illumination ON/OFF
SW3 Canopy ON/OFF
PB1385 Turbine speed raise
PB1386 Turbine speed lower
PAH1361A LOP 1 running
L001B LOP 1 disabled
L001A LOP 1 stopped
PB0010C LOP 1 stop
Plant Name: FCCU-I
PAH1362A LOP II running

L002B LOP II tripped/disabled
L002A LOP II stopped
PB0011C LOP II stop
HS0011 LOP II Auto/Manual
L003E OVEF on L.O. Tank running

Plant Name: FCCU-I
L003B OVEF on LO tank tripped/disabled

L0003A OVEF on LO tank stopped
PB0012C OVEF on LO tank stop
L004E Barring gear ON
L004B Barring gear tripped/disabled
L004A Barring gear off
PB0013C Barring gear off
HSA503AH MAB emergency trip from DCS
HSA503BH MAB emergency trip from LCP
L0025 Common pre alarm for all M/C alarms
L0009B Common alarm for all M/C trips
L0026 Common pre-alarm for all process alarms
L009D Common alarm for all process trips
VAH1350 Turbine/MAB vibrations high
VAHH1350 Turbine/MAB vibrations very high
ZAH1354 MAB axial displacement high
ZAHH1354 MAB axial displacement very high
TAH1359 Turbine/MAB JB temperature high
TAHH1359 Turbine/MAB JB temperature very high
TAH1361 Turbine/MAB TB temperature high
TAHH1361 Turbine/MAB TB temperature very high
PALL1385A Control oil header pressure very low
LAHH1356A Hot-well level very high
PALL1387A Trip oil pressure very low
PAHH1372A Turbine exhaust pressure very high
PALL1362 LO header pressure very low
SAHH1386A Turbine speed very high
XA504B Common trip
SAHH1387A Turbine over speed
ZLH1385B ESV opened
ZLL1385A ESV closed
PAH1374A CEP 1 running
L0005B CEP 1 disabled
L0005A CEP 1 stopped
PB0014C CEP 1 stop
PAH1373A CEP II running
L006B CEP II tripped/disabled
L006A CEP II stopped
Plant Name: FCCU-I
HS0015 CEP II Auto/Manual

EPA Purge pressure OK
LPA Purge pressure low
VLPA Purge pressure very low

Plant Name: FCCU-I
TAHH1369 Comp/GB/motor TB temperature very high
TAHH1366 Comp/GB/motor JB temperature very high
TAHH1378 Motor winding temperature very high
L009C Trip circuit healthy
L009E CAB ready to reset
PUSH BUTTONS
PB0018C Trip reset
PB0020 Lamp test
RPB Horn reset
APB Horn acknowledgement
SW1 110V AC power ON/OFF
SW2 Illumination ON/OFF
SW3 Canopy ON/OFF
KS1 Purge bypassing
APB Horn acknowledge
RPB Horn reset
L009C Trip circuit healthy
HS503B Emergency trip
L0009E Compressor ready to reset
PB0018C Trip reset
PB0020 Lamp test
HIC508 Auto/Manual for WWG
HIC509 Manual loader for ASC

Plant Name: FCCU-I
S.NO. TAG NO DESCRIPTION
1 PI1351B CAB suction pressure
2 TI1382B CAB Suction temperature
3 PI1352B CAB discharge pressure
4 TI1-2 CAB discharge temperature
5 VE1354A/B CAB Relative shaft vibration maximum
VE1355A/B
6 ZE1353A/B CAB axial displacement maximum
7 VE1352A/B GB high speed shaft vibration max
8 VE1353A/B GB high speed shaft vibration maximum
9 ZE1352A/B GB low speed shaft axial displacement
10 VE1361A/B GB low speed shaft vibration maximum
VE1360A/B
11 ZE1351A GB low speed shaft vibration maximum
12 TE1376ABC CAB TB maximum temperature
13 TE1374A/B CAB JB maximum temperature
TE1375A/B
14 TE1372A/B CAB GB low speed shaft TB maximum
TE1369A/B temperature
15 TE1378A/B/C/ Motor winding maximum temperature
D/E/F
16 TE1368A/ GB low speed shaft JB maximum temperature
1370/1371/
1373A
LAMPS
17 RIL 1 Purge bypass
18 EPA Purge pressure OK
19 LPA Purge pressure low
20 VLPA Purge pressure very low
21 HSA504BHZ Main motor stopped from LCP
22 XA505B1 Main motor running
23 L001B Main motor tripped/disabled
24 L0025 Common pre-alarm for all M/C alarms
25 L0026 Common pre-alarm for all process alarms
26 VAH1352 Comp/GB/Motor vibration high
27 ZAH1351 Comp/GB/Axial displacement high
28 TAH1369 Comp/GB/Motor TB temperature
29 TAH1366 Comp/GB/Motor JB temp high

Plant Name: FCCU-I
30 TAH1378 Motor winding temperature high

31 L009B Common alarm for all M/C trips
32 L009D Common alarm for process trips
33 VAHH1352 Comp/GB/Motor vibration high
34 ZAHH1351 Comp/GB/motor vibration very high
35 ZAHH1351 Comp/GB/motor vibration very high

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I
Fig16.2 MAIN AIR BLOWER

Plant Name: FCCU-I
WET GAS COMPRESSOR
16.6 GENERAL DESCRIPTION :
The compressor type 2 MCL, though it consists of a single casing, is featured by two stages. In
fact the gas comes out and passes through a cooler it is again sucked and brought to the discharge
conditions by the remaining impellers.
Wet Gas Compressor is driven by 3.3MW motor. The main duty of the compressor is to compress
the uncondensed the gas from fractionator overhead vessel 4V-53 for recovery of C3, C4 and C5
components. The compressor contains two stages. Gas compressed during first stage, passes
through coolers and the uncondensed gases from first phase are further compressed to the final
discharge conditions by the remaining impellers in the second phase.
The compressor consists essentially of static unit (casing, diaphragms, seals, Bearings and covers)
and a moving unit (rotor formed by shaft, impellers and balance Drum).
ROTOR:
It consists of a shaft on which impellers and spacers are assembled. The spacers are shrunk on the
shaft and they axially position the impellers and protect the shaft sections, between the impellers,
from contact with the gas.
The impeller is the part of the centrifugal compressor that adds velocity to the gas. The impellers
are of enclosed backward-bladed type and are shrunk and keyed onto the shaft.
During the compressor operation the rotor is subjected to on axial thrust in the direction of the
suction end generated by the pressure difference acting on the cover and Hub of the impellers.
The majority of the thrust is balanced by the balance drum. The resulting axial thrust is absorbed
by the thrust bearing.
BALANCING DRUM:
The centrifugal compressor rotor is subjected to an axial thrust towards the suction end due to the
differential pressure acting on the hubs and covers of the impellers. In these types of compressors,
the axial thrust is partially balanced by the balance drum fitted between the discharge sides of the
two stages. The size of the Drum is such that the axial thrust, though not entirely balanced, is

Plant Name: FCCU-I
considerably reduced, the remaining thrust being absorbed by the thrust bearing. This ensures that
the rotor does not move in axial direction.
JOURNAL BEARINGS
The journal bearings are of the tilting pad type with forced lubrication. Oil under pressure reaches
the bearings radially, goes through holes to lubricate pads and blocks. It is then laterally
discharged. The pads can swing inside the shell both in the direction for maximum dampening of
radial vibrations of the rotor.
CASING
The casing of the MCL compressors consists of two halves stiffly bolted together on the horizontal
center plane. The two mating surfaces are carefully machined for a perfect seal.
The ends seals, which prevent the gas leaking from the casing, are housed on the two ends of the
casing.
The rotor bearings are housed on two supports assembled on the casing ends. This arrangement
allows a check of the bearings without disassembling the compressor.
DIAPHRAGMS
The diaphragms make up the separating wall between each compression stage. Each diaphragm
constitutes a diffuser which converts the kinetic energy of the gas at the outlet of the impeller into
pressure and the recovery passage which leads the gas to the suction of the next impeller.
A series of guide vanes insides the recovery passages axially pipe the gas flow and distribute it
evenly to the suction of the impeller.
The diaphragms are manufactured in high strength cast iron and they are split on the horizontal
centre line.
The upper halves of the diaphragms are fixed to upper half of the casing by means of screws. This
permits lifting the upper half casing without the danger of diaphragms falling.
THRUST BEARING
Plant Name: FCCU-I
The thrust bearing, at the shaft end, is KINGSBURY type and it is designed to support the residual
axial thrust operating suction and by the balanced drum. The bearing is of the double type, and it
is installed at both sides of the double type, and it is installed at both sides of the thrust collar at
the compressor shaft end.
It is provided with an oil control ring to minimize the power loss due to churning of the oil in the
bearing cavity under high speed operation.
LABYRINTH SEAL (INTERNAL)
The internal seals, used between rotating and stationary parts of the compressor to reduce gas
leakage between areas of different pressure, are labyrinth type. The labyrinth seal consist of a ring,
the periphery of which is shaped on a series, of fins having small clearance to corrosion to avoid
damage to the rotor in the event of an accidental contact. The upper halves of the rings are fostered
to relevant diaphragm. The lower halves of the rings can be easily removed by rotating them in
their grooved seat in the diaphragms. The positions of the rotor which face the labyrinths seals
are: the impeller disk, the shaft sleeves between the impellers and the balance drum. The same
type of seals is located at the shaft end to limit the gas leakage out of the compressor.
GENERAL
The system Supplies cooled and filtered oil compressor and turbine bearings as illustrated in the
diagram
OIL PUMPS:
Two identical pumps provide the oil circulation. The main pump is driven by Aux drive turbine
and stand by pump by motor. Either of two pumps can be main or stand-by. Each pumps is capable
of supplying the capacity required by the whole system, therefore each pumps can operate as a
stand –by for a continuous service. The stand-by-pump starts automatically by a pressure switch
in the common discharge switch in the common discharge of both pumps. The suction line of each
pump is provided with strainer and isolation valve and pressure gauge. Pump running indication
is provided through pressure switches mounted on the discharge of each pump. The two discharge
lines are joined into a single connection line leading to the coolers.

Plant Name: FCCU-I
MAIN RESERVOIR:
It has a charge capacity of about 8.37 m3.

The reservoir is equipped with the following control safety and instruments:
a. Level sight gauge (LG)
b.Low oil level alarm switch (LSL)
c. Local thermometer (TG)
The reservoir is fitted with a steam heater to give the oil right viscosity for start-up.
The reservoir is provided with necessary connections for filling, draining, venting, inspecting and
purification. An oil conditioner is provided for purification of the oil.

Plant Name: FCCU-I

Plant Name: FCCU-I
COOLERS:
The oil is cooled by two water coolers, one as standby to the other one. To equalize the oil pressure
and facilitate the changeover operation the two coolers are connected by a bypass pipe
incorporating a needle valve.
EMERGENCY LUBE OIL SYSTEM:
LUBE OIL RUNDOWN TANK:
In case of shut-down of both oil pumps, the main lube oil pressure switch PSLL 2660A, B, C in
the lube oil header shuts down the WGC motor. A certain time period is required to stop
completely owing to the high inertia of the rotating masses. Hence sufficient oil quantity should
be supplied to the bearings until the unit comes to standstill.
An overhead tank placed about 7.0 meter above the compressor centerline with a normal capacity
of 1650 liters is provided for this purpose.
The tank is filled with oil during the preparation of the lube oil system. The oil inlet valve to the
overhead rundown tank is kept open until the oil circulates through the flow glass placed in the
overflow line to the main reservoir. Once flow is established, close the oil inlet valve.
A permissive to compressor driver start-up interlock level switch is assembled on the overhead
rundown tank. The rundown tank is maintained full while the unit is running by continuous oil
flow which reaches it though a fixed office.
If the lube oil pressure drops, NRV opens, providing lubrication to bearings.
LUBE OIL LINES:
1. Oil at required temperature is pumped to a header into which the lube oil bearing lines are
tapped.
2. The oil pressure in the lube oil header is maintained at constant pressure of 2 to 2.5 BAR
G (28 to 35 psig) by the pressure reducing valve PCV 3105.
3. The lube oil pressure to bearings is adjusted by means of the flow regulator provided in
each oil inlet line to bearings.
4. Pressure of approx. 0.9 to 1.3 Bar g (12.3 to 18 psig) to journal bearings and approx. 0.3
to 1.3 Bar g (5 to 18 psig) to thrust bearing should be maintained.
Plant Name: FCCU-I
5. Check the regular lube oil flow through the bearings by means of flow glasses.
FILTERS:
1. The oil reaches the filters, consisting of two distinct elements, arranged side by side, each
as stand-by to the other.
2. The oil flows is directed to one of the filters by means of two three way trans-flow valves
simultaneously controlled.
3. To equalize the oil pressure and facilitate the changeover operation, the two filters are
connected by a by-pass pipe incorporating a needle valve.
4. When the DP exceeds 1.5 Kg/Cm2 (20 psig) route the oil flow into the cleaned unit.
5. The filter unit should be filled with oil immediately after cleaning.
LUBE OIL PRESSURE CONTROL VALVES:
Lube Oil pump discharge header pressure control valve 4PC2640. The lube oil pump discharge
pressure control valve PCV 2640 maintains a constant pressure of 8.5 Kg/cm2 (g) by bypassing
the excess oil being pumped back to the reservoir. The LO header pressure control valve
(4PC2641) maintains a constant pressure of 2.5 Kg/cm2 in the lubricating oil header.

Plant Name: FCCU-I
SEAL OIL SYSTEM: Seal Oil System is totally independent of lube oil system having a
separate reservoir, pumps, coolers and filters etc. seal oil system supplies cooled and filtered oil
to the seals of compressor

Plant Name: FCCU-I
MAIN RESERVOIR:
1. It has a capacity of about 2.2m3

2. The reservoir is equipped with following control and safety instruments:
a. Level sight gauge (LG – 2644)
b. Low oil level alarm switch (LSL – 2656)
c. Local thermometer (TI -2671)
3. The reservoir is fitted with steam heater to give oil right viscosity for start-up
4. The reservoir is provided with necessary connections for filing, draining, venting and
inspecting.
5. Oil reservoir exhaust fan is provided on the reservoir to remove the oil fumes/vapours from
the tank.
OIL PUMPS:
1. Two identical pumps provide the oil circulation. The main pump is driven by auxiliary
system turbine. The stand by pump is driven by electric motor.
2. The stand by pump starts .automatically due to a differential pressure switch PSLL 2645
between common discharge of pump and reference gas or due to low level switch LSL
2646 on seal overhead tank.
COOLERS:
1. The oil is cooled by two oil coolers, each one stand by to the other.
2. The bypass line is provided with a control valve TV 2674 to bypass some of the oil from
the cooler and in the process injecting hot oil downstream of cooler. This valve is
controlled by TC 2674 which maintains a constant oil temp downstream of cooler.
FILTERS:
1. The oil reaches the filters, consisting of two distinct elements, arranged side by side, each
stand-by to the other.
2. DP switch for an excessive differential pressure is installed in the filter units.
3. When the differential pressure exceeds 1.5 Kg/cm2 (20 psig) reverse the oil flow bringing
in the cleaned unit.
4. The filter unit should be filled with oil immediately after cleaning so as to ready for use.
Plant Name: FCCU-I
DIFFERENTIAL PRESSURE CONTROL VALVE:
The oil pressure in the S.O. Pump discharge line is maintained constantly higher than the
reference gas pressure of the compressor by the differential pressure control valve PDCV 2647.
SEAL OIL SUPPLY TO SEALS:
The oil supply to the seals is regulated by maintaining a constant head of about 0.5Kg/cm2 over
the reference gas pressure, in order to overcome the gas pressure to prevent gas leaking along the
shaft past the seals. The head is generated by the elevation difference of approximately 7.5mts
between the normal level of the seal oil overhead tanks and the reference gas line of the
compressor. The top of overhead tank is connected with the reference gas signal from the
compressor.
The supply of seal oil is regulated by a LCV on overhead tank level.
For any variation in the reference gas pressure (due to a variation in suction) there is an alteration
in the amount of oil flowing out of the outer rings and the oil level of the overhead tank.
To equalize the pressure due to change in level, the level transmitter signals the level variation to
the controller which operates the level control valve adjusting its opening. The differential
pressure (constant head) is restored and the oil in the overhead tank returns to the normal level.
The overhead tanks have sufficient capacity to ensure oil supply to the seals for 5 minutes after
shutdown.
SEAL OIL TRANSFER BARRIER ACCUMULATORS:
1. Transfer barrier accumulators are provided between seal oil over head tank and compressor
oil to prevent the reference gas(contains H2S) contact with seal oil. The top of bladder is
connected to seal oil overhead tank which contains fixed quantity of stagnant oil with
which the reference gas is in contact.
2. The active seal oil pumps which is used for sealing is connected to the outlet line of transfer
barrier accumulator.
3. During normal operation, the bladder is in collapsed condition and the oil from top of
bladder is transferred to the seal oil overhead tank.

Plant Name: FCCU-I
4. When there is inadequate supply of S.O. or failure of S.O pumps the oil from seal oil
overhead tank enters the transfer barrier accumulator causing the bladder to expand and
below the bladder to seals.
SEAL OIL RETURN SYSTEM:
1. Majority of the oil reaching the chamber between each set of seal rings flows across the
outer rings (LP Ring).
2. The remaining flows across the inner rings (H.P. Rings) downstream of which the pressure
is at reference gas pressure.
3. The outlet oil from the inner rings goes to drain via two seal oil drain traps one for each
seal. Each drain pot is standby to the other.
4. The drain of seal oil drain pots are connected to the degassing tank by float valves. These
valves maintain a constant level in the drain traps.
5. The level sight glass indicator is installed on the drain trap.
6. The oil is sent from the drain pot to a degassifier tank, for removal of entrapped gases.
7. Each degassifier is provided with
a. Steam heater to heat the oil.
b. Temperature alarm switch (TSH)
c. Temperature gauge (TI)
d. Level sight glass indicator (LG)
e. Connection for vents, drain and sample.
8. From the degassifier tanks, oil is sent to the main reservoir

9. The gas which leaks from the equalization gas chamber though labyrinths in to the
reference area, is called Reference Gas.
10. It then passes into the seal leakage drain line, and to the seal oil drain pot. The gas vented
from each drain pot to a common line via restriction orifice, provided with bypass valve.
The gas flow flowing across the labyrinth seals prevents oil vapors from entering into the
compressor.
11. This is sent through a separator filter (oil mist separator) to vent. The separator filter is
provided with differential pressure switch and level gauge.
12. A separator seal is provided in the compressor to prevent mixing of seal oil with lube oil
in the compressor. For this purpose instrument air at a pressure of 2000mm wc is to be

Plant Name: FCCU-I
injected at this seal. The required pressured can be achieved the needle valve in the
instrument lines to the separator seals.
COMPRESSOR OPERATION
GAS SYSTEM DESCRIPTION:
This Compressor (04-K-051) raises the pressure of the wet gas from the main fractionator O/H
vapor and discharges to the HP receiver (04-V-056). The compressor is a two phase machine and
takes the suction from compressor suction K.O drum (04-V-054).
Wet gas from main fractionator O/H vapour column enters the 1st suction of compressor after
passing through knock out drum 04-V-054 at a pressure of 1.3 ata and 380 C. The gas from 1st
discharge at a pressure of 7.78 ata and 1190C goes through coolers (04-E-063A/B) and compressor
inter stage K.O. drum (04-V-55) before entering the 2nd phase suction. The gas is further
compressed in the 2nd phase to a pressure of 16ata and discharged to the process through after-
coolers (04-E-064A/B) and H.P. Receiver (04-V-056).
Temporary suction strainers are provided in both suctions to the compressors. They are required
during the initial operations of the compressors till pipe lines are free from foreign particles.
Each phase of the compressor is protected by a separate antisurge control valve and control system.
To protect 1st phase of compressor from surge, gas from the 1st discharge after passing through
cooler 04-E-063A/B and interstage K.O. drum 04-V-55 is connected to 1st phase suction. The
quantity of gas flowing through into 1st phase is controlled by throttling of antisurge valve FV2601
located in this line. Antisurge controller FC 2601 controls the position of the valve to keep the
machine out of surge by ensuring that the duty point does not move to the left of the surge limit
even at lower loads.
Protection of the 2nd phase of compressor from surge is done by drawing required quantity of gas
downstream of HP receiver 04-V-056 (in the 2nd discharge line) for recycling in the 2nd phase of
compressor. The quantity of gas to be recycled is controlled by 2nd phase antisurge control valve
FV2602. Antisurge control valve FC2602 controls the position of this valve to keep the 2nd phase
out of surge for operation at lower loads.
Suction throttle valve PV 2629 provided in the 1st phase suction throttles the incoming gas
pressure to maintain a constant pressure at compressor suction. This control is achieved by means
of pressure controller PC 2629.
Plant Name: FCCU-I
Suction throttle valve PV2612 is provided in the 2nd phase suction to achieve the desired pressured
at the phase of compressor for different operating conditions. The throttle valve PV2629 and 2612
are provided with min open position mechanical stoppers.
For increase in 2nd phase discharge pressure, pressure controller PIC 2712 (Pressure signal taken
from piping downstream of HP receiver 04-V-056) ensure constant discharge pressure for
different MW of gas by taking the following actions in the order mentioned below:
1) First stage A.S. valve FV 2601 to open.
2) Second stage suction throttle PV 2632 to close to min flow stop.
3) Second stage A.S. valve FV 2602 to open.
For increase in 2nd phase discharge pressure, the action taken to restore the pressure is as follows:
1) First stage A.S. valve FV 2602 to close.
2) Second stage Suction throttle valve PV2632 to open.
3) First Stage A.S. valve FV2601 to close.
Control actions for the above are achieved by means of controllers FC 2601 and FC 2602.
OIL SYSTEM PREPARATION
1. Confirm that the oil reservoirs (LO & SO) are filled with the recommended grade of oil.
2. Check the oil level in the main reservoir.
3. Start the heaters for oil heating so that oil temperature in the reservoir reaches 400-500 C.
The temperature should not be lower than 250 C.
4. Start the oil Vapor extraction fans of the main oil system.
5. Check that the isolating valves of the oil pumps are open.
6. Check that all by-pass valves are closed and the isolating valves of the following control
valve are open.
i. PCV 2641 - Bearing lube oil pressure control valve.
ii. PCV 2640 - L.O. pump discharge pressure control valve.

Plant Name: FCCU-I
iii. PDCV2647 - Seal oil/reference gas differential pressure control valve
iv. TV 2648 - Lube oil temperature control valve.

v. TV 2674 - Seal Oil temperature control valve
vi. LV 2646 - Seal oil overhead tank level control valve.
7. Check that the by-pass valves of the restricted orifices on the vent lines from the seal oil
drainage units are closed.
8. Check that the inlet and outlet valves to seal oil/gas separator filter (oil mist separator) on
the vent gas header from drainage units are open.
9. Check that the valves between degassing tanks and main oil reservoir are closed.
10. Check that at oil drain valves of coolers, filters, level indicator and pipes are closed.
11. Check that the water inlet and outlet valves of oil coolers are closed.
12. Check that the isolating valves if pressure switches and valve actuators are open.
13. Check that the isolating valve in the make-up line to transfer barrier.
14. When the oil temperature exceeds 40-500 C after coolers cut-off heater in the oil reservoir
and if necessary open the cooling water valves to oil coolers.
SEAL OIL SYSTEM STARTING:
1. Start the seal oil pump

2. Open the bypass valves of twin coolers and twin filters.
3. Open the vent valves of cooler and filters in service. Bleed of the valves and again crack
open the vent valves of oil cooler and oil filter not in service and valves and close it as they
are full.
4. Check that the oil pressure in the seal oil pump discharge header is higher than reference
gas pressure by 10 Kg/cm2
5. Open the valve in the initial make up line to transfer barrier accumulator. Fill the bladder
of this accumulator till oil overflow from the vent valve. After ensuring this, close the
valve.
6. Open LV2646 and fill up the seal oil overhead tank till the normal operating level.
7. Check the normal flow of seal oil from LP seal oil drains through sight glass devices.
8. Put the level control valve LV 2646 in Auto.
9. Keep standby oil pump driver ready to startup.
10. Stop the main pump driver and check the standby pump automatic startup.

Plant Name: FCCU-I
11. Then stop manually the standby pump and check the pressure point at which the trip
switches installed in the oil header and restart the seal oil pump.
12. Turn the control of the standby pump in automatic position. When the oil temperature
exceeds 40-50oC, cutoff heater in the oil reservoir and if necessary open the cooling water
valves to oil coolers.
The lining up if the degassing tank requires the operations listed below
1. Let the oil reach the normal level in the tank.
2. Allow steam through steam heater and raise the oil temperature upto 80-900 C
approximately.

Plant Name: FCCU-I

Plant Name: FCCU-I
GAS COMPRESSOR STARTUP:
1. Ensure WGC I stage KOD, I stage suction, II stage suction & casing is free of liquid.
2. Stroke check I stage (PC2629) and II stage (PC2712) suction pressure control valves, Anti
surge valves (FC2601 & FC2602) and total spill back control valve (PC2407)
3. Line up wet gas compressor
4. Start LO and Seal oil circulation
5. Check WGC MOV’s are operating from control room and local panel.
6. Keep WGC I stage and II stage suction pressure low-low switches in bypass position.
7. Take clearance from CPP, Process substation and inform RSM
8. Open WGC I stage and II stage suction and discharge and vent MOV’s
9. Keep I stage antisurge valve output at 30%, II stage anti surge valve at 80%, I stage suction
pressure control valve at 1% and II stage suction pressure c/v at 10%
10. Open vent manual b/v on I stage suction line to maintain I stage suction pressure 0.15kg/cm2
11. Ensure trip circuit healthy on local panel.
12. Close I stage and II stage vent MOVs
13. Press reset push button on local panel.
14. Start wet gas compressor, Open fuel gas make up to I stage KOD and gradually close I stage
suction vent block valve.
15. Check WGC RPM. Once it normalizes, open I and II stage antisurge valve in wide open
position and I stage suction pressure control valve suitably to maintain suction pressure
0.15Kg/cm2. Do not load compressor until it reaches rpm 9600.
16. Maintain Main fractionator O/H drum pressure with Total spill back control valve. (PC2407)
Do not allow Regenerator pressure drop below 0.6Kg/cm2. A drop in Regenerator pressure
leads to severe catalyst loss.
17. Monitor Wet Gas compressor suction and discharge operating parameters including
compressor load.
18. Maintain instrument air to Thrust balancing line DP 0.2 Kg/cm2
19. Maintain buffer gas to Reference gas 0.5 Kg/cm2 on Auto mode.
20. Check WGC
Machine vibrations.
Bearing oil pressure and temperatures.
Bearing temperatures.
Plant Name: FCCU-I
Radial Vibration and

Axial displacements.
Periodically analyses a lube/oil/seal oil sample
N2 PURGING
1) Open the nitrogen purge valve and gradually raise the pressure in the compressor gas circuit
(For both the phases). Open and then close the compressor casing drains. Close the nitrogen
purge valve and then gradually reduce the pressure by means of vent valves which vents gas
to the atmosphere. Repeat this operation a few times until the amount of oxygen present in the
gas of the compressor circuit is below the prescribed level.
2) Open the nitrogen feed valves to bearing chambers of the machines.
3) When the compressor circuit is filled with nitrogen at approx., 0.2 bar and with nitrogen feed
and gas vent Valves closed, open suction isolation valve of both phases and bring the gas
pressure in the compressor circuit to about 2 bar. Close the suction isolation valve, as soon
as this pressure is reached and gradually reduce the gas pressure to about 0.2 bar by venting
through vent valves. Then close the vent valves. Repeat this. Operation a few times until the
composition of the gas in the circuit is the same as that of the gas in the system upstream.
4) As soon as the purging of the gas circuits is finished, start filling the circuit with gas through
the Suction Isolation valve.
5) Open the compressor casing drain and remove any liquid accumulation.
Routine Checks (During Normal Operation):
The following are to be performed on a regular basis on the running machines.

Oil level in the main reservoir.
Oil level in the seal overhead reservoir.
Oil temperature in the main reservoir.
Oil temperature at the inlet and outlet of oil cooler
Temperature in the bearings
Oil temperature in the discharges from bearings.
Oil pressure downstream pumps.
Oil pressure in the lube oil header.
Oil pressure drop through filters.
Plant Name: FCCU-I
Oil flow in the discharge lines

Rotor axial displacements
Radial vibrations
Instruct Oil pressure in the pressurization lines
Water temperature downstream each cooler
Temperature and pressure of the gas at the suction and discharge of each stage.
Periodically take oil sample from main reservoir for analysis
COMPRESSOR SURGE:
Surge can be defined as the capacity below which the centrifugal compressor performance
becomes unstable. The surging conditions occur when the inlet capacity is reduced below a
particular limit. At a given speed as the inlet capacity is reduced, the discharge pressure of the
machine goes on increasing. When surging occurs, the high pressure gas at the discharge of the
machine flows back through the compressor in a complete reversal of the normal direction of flow.
Once the discharge pressure is dissipated sufficiently, the conditions causing the collapse of
pressure no longer exist and the compressor resumes normal flow and discharge pressure. If the
discharge conditions on the machine have not changed, the collapse of pressure producing ability
will repeat and cycle through the same sequence. The percentage flow at which the surge occurs
in a centrifugal compressor depends upon the aerodynamic design, gas properties, stability of flow,
system characteristics, stage components design etc.
The compressor was putting up a differential pressure of 14 Kg/cm2 when handling a 34 (say)
molecular wt gas. The compressor discharge pressure was fixed by the operating pressure of the
gas plant absorber. The compressor suction pressure was automatically controlled by the pressure
control valve PC2629. Normal the flow to compressor suction was 34 tons/hr. When the 4V-53
drum pressure started to rise due to incompressible gas (dry gas) create the pressure control valve
on the drum PC2407 (total spill back) will close. Further increase in pressure has created opening
of PC2411 (to flare) and starvation of suction to compressor.
For a constant speed centrifugal compressor differential pressure developed by the compressor
due to change in molecular wt of the gas at constant suction pressure and temperature is calculated
by
DPf = (MWf/MWI) *DPi

DPf = Differential pressure developed by the compressor at Mol wt MWf
DPi: Differential pressure developed by the compressor at Mol wt MWi

Plant Name: FCCU-I
So a drop in molecular wt of the gas will lead to the rise in polytrophic head (feet of head for a
compressible gas). The lower molecular weight gas will still trying to push the compressor further
up on its curve. But the machine could not operate left of its surge point. Hence compressor begins
to stall or surge.
CONSEQUENCES OF COMPRESSOR SEVERE SURGE:
1. The flow of gas across the rotor stops and reverses.

2. The gas flowing backwards pushes the rotor backwards.
3. The rotor slides back across its radial support bearings and slams against its thrust bearing.
The purpose of the thrust bearing is to contain the axial movement of the rotor.
4. Compressor emits horrifying sound, characteristic of surge. Every surge corresponds to an
impact of rotor hitting the thrust bearing. Eventually, the thrust bearing is deformed and
axial movement of rotor increases.
5. The rotor’s wheels move closer and the stators (fixed top, the compressor case). When a
wheel first touches a stator, both the wheel and the stator tear up and the compressor is
wrecked.
STOPPING THE SURGE:
1. Raising the set point on the spillback PC2407. This will increase the compressor’s suction
pressure by spilling back more gas into the suction and allow the compressor to run on its
curve.
2. Lowering the absorber pressure.
3. Increasing the molecular weight of the gas. The denser the gas, the lower the HP
(polytrophic head = DP * density of gas at compressor suction) required to generate a given
differential pressure.
Compressor is protected from surge by an antisurge control system. The basic idea in the antisurge
control system is to provide a minimum flow through the compressor suction at all speeds which
is higher than the surge either by recirculating back certain quantity from the discharge of the
machine or by venting. In the above cases it is necessary to maintain the suction parameters as per
design by cooling the gas which is recycled before being fed in the suction. Normally, the control
is effected based on the modulation of pressure, temperature flow and combination of those
parameters.
Note: In variable speed compressors, an increase in compressor could either cause a compressor
to surge or stop surging . The shape of the surge curve, which is unique to each compressor, also
influences the tendency of a machine to surge at its speed is altered.

Plant Name: FCCU-I
CAPACITY CONTROL DIAGRAM
Schematic diagram of using a by-pass valve to avoid surge

Plant Name: FCCU-I
COMPRESSOR SUCTION GAS COMPOSITION

1 Operating Conditions
Gas analysis Normal Normal Normal
2 Gas Composition Mol Wt. (1D Case) (2D Case) (3D Case)
(Mol %)
3 Water 18.015 5.540 1.493 5.540 1.492 5.540 1.492
4 Hydrogen Sulfide 34.076 5.710 0.886 1.660 0.889 4.680 6.162
5 Hydrogen 2.016 11.900 18.820 8.670 16.300 8.250 13.465
6 C1 16.043 8.900 13.341 9.420 16.878 8.900 14.121
7 Ethylene 28.054 4.030 6.128 4.570 7.368 4.250 6.320
8 C2 30.07 4.640 5.846 3.370 5.162 5.120 7.394
9 Propylene 42.081 14.720 16.998 16.540 19.354 14.450 16.351
10 C3 44.097 4.180 4.696 4.520 5.022 4.260 4.929
11 I-Butylene 54.092 4.250 2.604 4.250 2.530 4.240 2.694
12 N-Butylene 56.108 8.180 5.641 9.890 5.984 9.130 6.357
13 I-C4 58.124 1.300 0.939 1.300 0.830 1.890 1.376
14 N-C4 58.124 1.300 0.939 1.300 0.830 1.890 1.376
15 Inerts 4.270 6.287 3.640 6.413 4.190 6.570
16 Cos 60.071 0.004 0.004 0.003 0.003 0.003 0.003
16 Ammonia 16.031 0.354 0.395 0.109 0.159 0.205 0.284
18 Hydrogen Cynide 28.026 0.038 0.027 0.012 0.008 0.027 0.020
19 Propadiene 40.065 0.016 0.016 0.016 0.016 0.015 0.016
20 CH4S 48.103 0.029 0.020 0.003 0.002 0.025 0.018
21 Ethyl Mercaptan 62.13 0.004 0.002 0.001 0.000 0.00 0.001
22 Phenol 94.144 0.045 0.015 0.037 0.012 0.034 0.011
23 L, 3- BUTADIENE 54.092 0.104 0.077 0.121 0.078 0.180 0.931
24 C5 & C5 + 15.486 5.071 20.167 6.395 18.751 6.389
Total 100.0 100.0 100.0 100.0 100.0 100.0
Plant Name: FCCU-I
WET GAS COMPRESSOR TECHNICAL DATA
OPERATING CONDITION I STAGE II STAGE

Gas Handled Hydrocarbon mixture Hydrocarbon mixture
Capacity 44280 kg/hr 29880 kg/hr
Suction Condition
Pressure 1.3 kg/cm2 A 6.22 kg/cm2A
Temperature 38 C 38
Molecular weight 45.6 34.28
Cp / Cv 1.12 1.164
Inlet volume 19331 m3/hr 0.953
Compressibility 0.981 3651 m3/hr
Relative Humidity - -
Discharge Condition
Pressure 8.22 18.8
Temperature 119.5 C 111.27
Cp / Cv 1.107 1.146
Total power at coupling 3057 kw
Speed 9610
Note: Operating conditions (motor rated conditions)

Plant Name: FCCU-I
WGC TRIP SETTINGS
S.NO SERVICE ALARM TRIP

TAG NO SETTING TAG NO SETTING
1 Lube Oil Pr Low PSL2659 1.5 kg/cm2 PSLL2660 1.0 kg/cm2
VE2646,4
2 Comp vibration High 75u P/P VE2646,47 100u P/P
7
VE2642,4
GB Vibration Hi (LSS) 3 50u P/P VE2642,43 75u P/P
3
(HSS) VE2644,4 90u P/P VE2644,45 136u P/P
5
VE2640,4
4 Motor Vibration High 230u P/P VE2640,41 34u P/P
1
5 Comp Axial High ZE2642 ±0.5mm ZE2642 ±0.7mm
6 GB Axial High ZE2640 ±0.4mm ZE2642 ±0.45mm
7 Comp 1 Suction Pr Low PAL2611 -0.1kg/cm2 PSLL2610 -0.3kg/cm2
8 Comp 2 Suction Pr Low PAL2682 2.6kg/cm2 PSLL2680 2.4kg/cm2
DPSHH262
9 Comp 1 Dp Very High PAH2620 7.51kg/cm2 7.8kg/cm2
0
DPSHH262
10 Comp 2 Dp Very High PAH2621 13.42kg/cm2 14.1kg/cm2
1
11 Comp 1 Disch Temp TAH2603 138.16o C TSHH2680 144.4oC
12 Comp 2 Disch Temp TAH2606 156.20oC TSHH2604 163.3o C
Seal Oil O/H Tank 165mmfrom
13 LSLL2650
bottom tapping
14 Motor Wind Temp TSH2663 115o C TSHH2683 120o C
15 Comp Gb Motor JB temp hi TSH2650 100,120,85oC TSHH2655 120,125,90 oC
16 Comp Gearbox, TB temp Hi TSH2655 110, 120oC TSHH2655 120,125 oC
17 Comp 2 Stage Disc Pr PSHH2613 18.7 kg/cm2
18 WGC Trip From DCS
19 WGC Trip From LCP

Plant Name: FCCU-I
WGC INSTRUMENTS TAG LIST
S.
TAG NO TAG DESCRIPTION STATUS ALARM TRIP UNITS REMARKS
NO
4LL2642 L.O. Overhead tank From bottom
1 low 1,725 mm
level low
4LH2643 L.O. Overhead tank From bottom
2 high 1,825 mm
level high
3 4LLL2650 Seal oil O/H tank level Very low 600 mm From bottom
4LL2652 L.O. Main oil tank From bottom

4 Low 1,250
level low
5 4LL2656 Seal oil tank level low Low 764 From bottom
4LH2646 S.O. Overhead tank High From bottom
4LL2646 level Low 1,215 10% of LT
6 1,325 mm
4LHH2646 SO overhead tank very Very high 1105 80% of LT
high
DPH2641 Differential pressure
7 high 1.5 kg/cm2
across L.O. filter
4PDAL Differential pressure
8 low 8 kg/cm2
across SO and gas
PDH2646 Differential pressure
9 high 1.5 kg/cm2
across SO filter
PDH2652 DP across oil mist
10 high 0.3 kg/cm2
separator
DPI2620 DP across I stage
11 high 7.51 kg/cm2
suction and disc
DPI2621 DP across II stage
12 high 13.42 kg/cm2
suction and disc
PDI2648 Diff pr across SO and
13 high 0.75 kg/cm2
Reference gas
DPI2650 Diff pressure across bal
14 0.8 kg/cm2
gas & Ref gas
4PLL2610 1 stage suction pressure
15 Very low -0.3 kg/cm2
after filter
4PL2611 I stage suction pressure
16 low -0.1 kg/cm2
after filter
4PHH2612 I stage suction 1.4 kg/cm2
17 Very high
pressure after filter
4PHH2613 II stage discharge 18.7 kg/cm2
18 Very high
pressure high
Plant Name: FCCU-I
I stage discharge high 8.72 kg/cm2

19 4PH2614
pressure
II stage discharge high 16.89 kg/cm2
20 4PH2615
pressure high
L.O.MOP pump high 6 kg/cm2
21 4PH2656 discharge pressure
L.O.AOP pump
22 4PH2657 high 6 kg/cm2
discharge pressure
L.O. Discharge to tank
23 4PL2658 low 6.8 kg/cm2
pressure
4PLL2659 1.5
24 4PLL2660A/B/C LO header pressure Very low 1.0 kg/cm2
1.0
25 4PL2661 LO header pressure low 1.5 kg/cm2
LO MOP exhaust
steam pressure
So MOP discharge
pressure
So AOP discharge
pressure
II stage suction
29 4PLL2680 Very low 2.4
pressure
SO MOP exhaust
steam pressure
II stage suction
31 4PL2682 low 2.6 kg/cm2
pressure low
I stage discharge
32 4PH2603 high 4.5 kg/cm2
pressure
II stage suction
33 4PH2605 high 4.5 kg/cm2
pressure
II stage discharge
34 4PH2608 high 16.89 kg/cm2
pressure
1 stage suction pr after
35 4PH2629 high 0.99 kg/cm2
filter
36 4PH2679 Buffer gas pressure high 3.5 kg/cm2
37 4TI2650A/B Motor JB temp high 85 90 C
4TI12651 GB HSS JB
38 4TI2652 high 120 125 C
4TI2653
Plant Name: FCCU-I
4TI2653
4TI2654
4TI2655 GB HSS TB
4TI2656
4TI2657
4TI2658
4TI2692

Plant Name: FCCU-I
39 4TI2659 GB low speed shaft JB 120 125 C

4TI2660
4TI2661
4TI2686
4TI2687-91 GB low speed shaft TB
40 4T12662-65 Compressor Journal high 100 120 C
bearing temp
41 4T12666-70 Compressor thrust bearing high 110 120 C
temperature
42 4T12683A/B/ Motor winding temperature high 115 120 C
C/D/E/F
43 4T12603 I stage discharge high 138.16 C
temperature
44 4T12604 II stage discharge Very 163.3
temperature very high high
45 4T12606 II stage discharge temp hi high 156.2
46 4T 12680 I stage discharge very 144.4 C
temperature high
47 4V12640A/B Motor relative shaft high 230 340 U
vibration RJB
48 4V12641A/B Motor relative shaft high 230 340 U
vibration FJB
49 4V12642A/B GB high speed shaft R.S.V high 50 75 U
50 4V12643A/B GB HSS RSV TB high 50 75 U
51 4V12644A/B GB LSS RSV OTB high 70 135 U
52 4V12645A/B GB LSS RSV high 90 135 U
53 4V12646A/B Compressor relative shaft high 75 100 U
vibration
54 4V12647A/B Compressor relative shaft high 75 100
vibration TB
4Z12640A/B GB HSS axial high 0.4 0.45 mm
55
displacement
4Z12641A/B GB LSS axial high 0.4 0.45 mm
56
displacement
4Z12642A/B Compressor thrust bearing high 0.5 0.7 mm
57
axial displacement
4DPHH2620 DP across I stage suction Very 7.8 Kg/cm2
58
and discharge high
Plant Name: FCCU-I
4DPHH2621 DP across II stage suction very 14.1 Kg/cm2

59
& discharge high
60 4ZSH2642 LO MOP I/L CV open
61 4ZSL2642 LO MOP I/L CV close.
62 4ZSH2648 SO MOP I/L CV open
63 4ZSL2648 SO MOP I/L CV close.

Plant Name: FCCU-I
WGC LOCAL PANEL INDICATIONS/PUSH BUTTONS
S.
TAG NO DESCRIPTION
NO
1 PI2681B Compressor 1st stage suction pressure
2 TI2612B Compressor 1st stage suction temperature
3 PI2603B Compressor 1st stage discharge pressure
4 TI2605B Compressor 1st stage discharge temperature
5 DPI2620B Compressor DP across 1st stage suction and discharge pr
6 PI2605B Compressor 2nd stage suction pressure
7 TI2611B Compressor 2nd stage suction temperature
8 PI2608B Compressor 2nd stage discharge pressure
9 TI2609B Compressor 2nd stage discharge temperature
10 DPI2621B DP across 2nd stage suction and discharge pressure
11 PI2655B L.O. Header pressure
12 PI2654B LOP discharge header pressure
13 PI2671B SOP discharge header pressure
14 PD12648B Differential pressure across SO/Reference gas
15 PI2679B Buffer gas I/L pressure
16 TE2655,2656, GB high speed shaft TB temperature
2657,2658,
2692
17 TE2687,2688, GB Low speed shaft TB temperature
2690,2691
18 TE2651,2652, GB high speed shaft JB temperature
2653,2654
19 TE2659,2660, GB high speed shaft JB temperature
2661,2686
20 VE2646A/B GB high speed shaft vibration maximum
VE2643A/B
21 VE2646A/B Compressor relative shaft vibration maximum
VE2647A/B
22 VE2644A/B GB low speed shaft vibration maximum
VE2645A/B
23 VE2640A/B Motor shaft maximum vibration
VE2641A/B
24 ZE2641A/B GB low speed shaft axial displacement
25 ZE2640A/B GB High speed shaft maximum axial displacement
26 ZE2642A/B Compressor axial displacement
Plant Name: FCCU-I
LAMPS
27 RIL1 Purge bypass
28 2nd stage suction pressure low bypass
29 1st stage suction pressure low bypass
30 EPA Purge pressure OK
31 LPA Purge pressure low
32 VLPA Purge pressure very low
33 PAH2656A LOPI running
34 L001B LOP1disabled
35 L001A LOP1 stopped
36 PAH2657A LOP II running
37 L002B LOP II tripped/disabled
38 L002A LOP II stopped
39 PAH2657A SOP I running
40 L0005B SOP I disabled
41 L005A SOP I stopped
42 PAH2673A SOP II running
43 L006B SOP tripped disabled
44 L006A SOP II stopped
45 APB Horn acknowledge
46 RRB Horn reset
47 KS1 Purge bypass
48 KS2 Horn reset
49 PB0010C LOP I stop push button
50 HS0011C LOP II auto/manual selector switch
51 PB0014C SOP I stop button
52 HS0015 SOP II Auto/manual selector switch
53 PB0015C SOP II stop button
54 SWI 110V AC power ON/OFF selector
55 SW2 Illumination ON/OFF selector
56 SW3 Canopy on/off selector
57 L0025 Common pre alarm for all m/c alarms

58 L0026 Common prealarm for all process alarms
59 VAH2646 Compressor/GB/Motor vibration high
60 ZAH2640 Compressor/GB/axial displacement high
61 TAH2655 Compressor/GB/Motor TB temperature high
62 TAH2650 Compressor/GB/Motor JB temperature high
Plant Name: FCCU-I
63 TAH2683 Motor winding temperature high

64 ZLH2601 1st ASV opened
65 ZLH2602 2ndASV opened

Plant Name: FCCU-I
66 L009B Common alarm for all M/C trips

67 L009D Common alarm for all process trips
68 VAHH2646 Compressor/GB/Motor vibration very high
69 ZAHH2640 Comp/GB/axial displacement very high
70 TAHH2650 Comp/GB/ Motor TB temperature very high
71 TAHH2650 Comp/GB/ Motor JB temperature very high
72 TAHH2683 Motor winding temperature very high
73 ZLL2601 1st ASV closed
74 ZLL2602 2nd stage ASV closed
75 L0003E Overhead fan on LO tank running
76 L0003B Overhead fan on LO tank tripped/disabled
77 L003A Overhead fan on LO tank stopped
78 L004E Overhead fan on SO tank running
79 L004B Overhead fan on SO tank tripped/disabled
80 L0004A Overhead fan on SO tank stopped
81 XL2601B Main motor running
82 XL2601D Main motor tripped/disabled
83 XL2601C Main motor stopped
84 L0009C Trip circuit healthy
85 L009E Compressor ready to reset
PUSH BUTTONS
86 PB0012C O/H fan on LO tank stop
87 PB00I3C O/H fan on SO tank stop
88 PB0019A Main motor start
89 PB0018A Emergency trip
90 PB0018C Trip reset
91 PB0020 Lamp test
92 MOV2601 Open push button
96 MOV2605 Close push button
97 MOV2606 Close push button
LAMPS
98 TAH2630 Compressor 1st stage discharge temperature high
99 TAH 2606B Compressor 2nd stage discharge temperature high
Plant Name: FCCU-I
100 PAL2611 Compressor 1st stage suction pressure low

101 PAL2682B Compressor 2nd suction pressure low
102 PAH2615B Compressor 2nd stage discharge pressure high
103 PAHH262B Compressor 1st suction pressure very high
104 TAHH2680B Compressor 1st discharge temp very high

Plant Name: FCCU-I
105 TAHH2604B Compressor 2nd stage discharge temp very high

106 PALL2601B Compressor 1st suction pressure very low
107 PALL2680B Compressor 2nd suction pressure very low
108 PAHH2613B Compressor 2nd stage discharge pressure very high
109 DPAHH2620B DP across 1st suction and discharge very high
110 DPAHH2621B DP across 2nd suction and discharge very high
111 L2601C MOV2601 opened
112 L2601D MOV2601closed
114 L2602D MOV2602 closed
122 L2606D MOV2606 closed.

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I
Fig. 16.4 THRUST BALANCING OF BACK TO BACK COMPRESSORS

Plant Name: FCCU-I

Plant Name: FCCU-I
General
This section covers the operation and trouble shooting of commonly used refinery equipment like
pumps, Heat exchangers, furnace etc. For details of specific equipment refer to vendor’s manuals.
Pumps-Operating Procedures
All pumps used in FCCU/GCU are centrifugal pumps driven by electrical motors except slurry
pump driven by steam turbine Most of the pumps are provided with mechanical seals. Mechanical
seals ensure complete prevention of leakage and require minimum attention. The sealing is
achieved by two mating faces, one rotating with the shaft and other stationary in the casing.
Depending on the type of product handled, the liquid called “Seal Flushing Liquid” is supplied
from the discharge of the same pump, or from external source.
Description / Operation of Centrifugal Pumps:
Centrifugal pumps move liquid by raising the pressure head. This pump in its simplest form is
comprised of an impeller, fitted to a bearing supported shaft rotating in a volute casing.
Liquid led into the center of the impeller through the suction line is picked up by vanes. By rotation
of the impeller the liquid is accelerated to a high velocity and is discharged by centrifugal force
into the volute casing of the pump and out the discharge line. As the liquid is forced away from
the center, vacuum is created and more liquid is admitted. Consequently there is a constant flow
from the pump.
The centrifugal pumps are the most widely used pumps in the Refinery due to their simplicity and
dependability operating under a wide variety of fluids at different conditions. A very important
feature of this pump is that the flow from the discharge does not pulsate and the discharge rate
may be throttled, or controlled, without building up excessive pressure or over loading the driving
unit.
There are many variations in the types of centrifugal pumps used in a Refinery. These are
commonly classified as a single stage or pumps having only one impeller, and multistage, or
pumps having two or more impellers operating in series.
Operating principles of the multistage pumps are identical with the single stage, the difference
being that in a multistage pump the discharge from the suction impeller of first stage is directed
into the suction of the eye of the second stage impeller, thereby giving an additional increase in
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pressure at the final stage. Centrifugal pumps may be driven by either electric motor or steam
turbine depending upon design conditions.
Centrifugal Pumps Start-Up and Shutdown:

Preparation: Before starting a centrifugal pump check the following:
a) Check for proper lubrication of all bearing on both the drive and the pump.
b) Open cooling water to all bearing and glands where cooling water lines are provided.
c) Adjust the inlet valve on the water line to give a flow about the size of your small finger.
d) Check direction of Rotation of motor before coupling.
e) See the coupling guards are in place and that the drive shaft is free of any foreign objects,
such as wrenches, rags etc.
f) Be sure that all valves are open in the line to the pump and that stock to be pumped is
available with a positive pressure on the suction line.
g) Centrifugal pumps are not self-priming and must have liquid at the impeller eye in order to
function properly.
h) Open the suction valve wide.
i) See that pump discharge valve is fully closed, (unless otherwise specially ordered)
Prime The Pump:

Open the bleeder on the top of pump casing and bleed off gas until liquid come through in full
bore.
Pump casing must be full of liquid before starting

This is very important as wear rings may seize and cause serious damage if any attempt is made
to start pump dry. If pump has two or more stages, see that gas is bleed off from each stage till
liquid appears.
Spare Pump
On motor driven pumps, if pump dose not start immediately cut off the switch and check pump
for free rotation.
Avoid holding starting switch in “on” position as this causes arcing and burning of switch parts.
a. Check discharge PG. Observe suction PG if available. If no discharge pressure increase is
noted, shutdown immediately and re-prime by opening casing bleeder.
b. Open discharge valve when pump is up to full speed, and discharge pressure indicates good
suction, open discharge valve slowly. Rapid opening of the discharge valve may cause
cavitation and loss of suction.

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c. Where casing bleeder lines tie-into a closed bleed-off system, Close them before starting
pump.
d. Check glands for excessive leakage or heating as soon as pump is started.
e. Check all bearing to see that they are lubricating properly and do not over heat.
Shutting down:
To shut down centrifugal pump:
a) Close discharge valve completely.
b) Stop pump drive.
Electrical motor pump drives
Electrical motors are very practical and efficient drive for most centrifugal pumps. Due to ever
present possibility of explosive vapors existing around any pump handling petroleum products all
motors operating in an area where explosive vapors may be present must be of the “explosion
proof” type. These motors have a rotor which is totally enclosed in a vapors proof casting to
preventing any possibility of igniting strong vapors.
Motor over loadings:

Under normal conditions electric motors should not be permitted to operate above designed of
rated amperage stamped on the motor case.
If motor is operated above raised amperage stamped on the motor case, specific approval must be
obtained from the Engineering Department.
Caution:
Never play a water hose on electrical motor. All motor in continuous operation must have proper
lubrication.
Steam turbine (pump drive)

Steam turbines are used in most cases as drivers for spare centrifugal pumps.
Mechanical type consists of single or multistage wheels with blades mounted on the periphery.
a. Steam chest is bolted to base and passes steam to the nozzle chamber which is
bolted to it.
b. Steam expands in nozzle, transferring heat energy to velocity.
c. From nozzle, steam impinges on the blades, causing rotor to revolve.
d. On single wheel, after steam passes through on to blades of next rotor and so on to
exhaust.
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e. Cylinder cover are usually split horizontally with steam connection on bottom half.
This enables easy removal of top half.
f. Shaft carries rotor and is supported by two bearings. Rotor is pressed and keyed on to
shaft.
Speed control:
All turbines are equipped with governor for controlling speeds at desired conditions.
Operating personnel are not authorized to alter the governor settings unless the turbine is equipped
with a built in speed control valve specifically designed for this purpose.
Over speed trip:

All turbines are equipped with over speed trip for purpose of releasing a steam cut-out valve for
shutting down the turbine in the event of the operating speed exceeding a safe maximum.
Causes of over speed mechanism to trip:

a) Manual release of trip
b) Sudden excessive speed due to loss of suction on pump end
c) Excessive speed due to a mechanical failure i.e broken shaft, loose impeller on pump end
d) Too rapid opening of live steam to bring speed will cause trip.
Start-up of steam turbine procedure:

a) Check all bearings for proper lubrication.
b) Open cooling water to bearing where provided. Adjust cooling water inlet valve to give a
stream of water.
c) Check over speed trip mechanism to be certain that over speed cut-out valve on the steam
inlet is open.
d) Check turbine casing bleeder is open and drain water from casing.
e) Open bleeders on both exhaust steam and live steam lines and bleed off any accumulated
condensate.
f) Open exhaust steam valve.
g) Crack open the live steam sufficient enough to allow case to warm up and blow any
condensate from the case.
h) When turbine case is warm close bleeder valve. Governor starts rolling at desired speed.
Then open live steam.

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Shutting down turbine:

(a) Stop the turbine by tripping the over speed trips (stopping by this method is to assure proper
operation of the mechanism)
(b) Close the live steam
(c) Close exhaust steam valve (not always required to close)
(d) Open the turbine case bleeder valve
(e) After shutting down, reset the over speed trip for normal operation.
Precautionary steps taken for starting a turbine drive:

a) Do not start a turbine until all water is drained from steam supply, exhaust lines and from
turbine case.
b) Warm up turbine by circulating a small quantity of steam through casing before starting.
c) Do not start a turbine with excessive Vibration.
d) Do not operate a turbine with dirty oil.
e) Check service and emergency governor at regular intervals.
f) Do not set governor for speeds above that listed on manufactures name plate.
g) Do not re-hatch an over speed governor immediately after trips out. Allow the turbine to
slow down to at least half speed.
h) Always use a tachometer when rate of speed is in question.
Lubrication of plant equipment:
Proper lubrication of all mechanically operated equipment in a plant is a very important function
from the stand point of dependability and the responsibility of the operator technician in charge of
the equipment.
Faulty lubrication- Causes: In general, some of the principal causes of faulty lubrication are:
1) Oil lines plugging (2) Contamination due to dirt, sludge water etc. (3) Wrong grade of oil
used (4) Decomposition of the oil, caused by overheating or contamination (5) Oil level
run dry and (6) leakage of hydrocarbon into the oil due to leaking seals or piston rings as
in gas compressors.
Checking lubrication:
Operator should check the lubrication of all equipment in his area at least twice a shift.
Check oil lines for plugging:

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Lubrication at bottles may be full but no oil flowing. Fill bearing to correct level at top hole.
Remove oil bottle and observe if oil flow the bottom of bearing through oil supply line.
Check for contamination:

Water causes emulsion and sludge, keep all lubricating equipment clean free from dirt. When
opening bearing cases, do not allow dirt to enter bearing, wipe before opening plug.
Use correct grade of oil (Check lubrication chart); using wrong grade oil, may cause bearing
failure. To detect overheating, touch bearing with back of fingers. If hotter, frequent checking to
be done than normal.
Maintain proper oil levels
Leakage of gas will thin down the oil and flash point go off. This can be very hazardous.
Sample checking:
Samples of lubricating oil shall be taken on any operating equipment where large quantities of oil
are maintained in reservoirs of high pressure turbines and compressors like gas compressor. Main
air blower is having integral lubrication system.
Samples to be taken when oil shown oil shows signs of deterioration. Take sample while
equipment is running.
Test:
API gravity
Flash point
Viscosity at 100oF and viscosity at 210oF s and w.
Positive displacement pumps
General
Check if all mechanical jobs are completed.

a. Flush and renew oil in pump gear box.
b. Check for proper lining up including the pressure safety valve in the discharge. Open
suction valve fully.
c. Check that the motor shaft is reasonably free and coupling secured. Coupling guard should
be in position.
d. Energize motor. Open discharge valve. Start the motor and check direction of rotation.
e. Adjust the pump stroke and run the pump at different settings. Watch discharge pressure
and check the rate of pumping using the flow meter or by taking suction from the
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calibration pot. If the pump is provided with a pressure controller adjust it to obtain the
required discharge pressure.
f. Care should be taken to avoid dry running of pump and back flow of liquid. Bleed if
necessary to expel vapors.
g. Check for unusual noise, vibrations, rise of temperature of both motor and gears.
Shut down
a. Stop the pump.
b. Close the suction and discharge valves.
c. Drain the liquid if maintenance jobs are to be carried out on the pump.
Trouble shooting
I) Insufficient discharge pressure
a. Check the lining up in the suction side.
b. Check the functioning of the safety valve and pressure control valve on discharge to
suction.
c. Check the strainer on the suction side.
d. Check for insufficient liquid level in the tank.
e. Check pump coupling and rotation.
f. Get the pump checked by pump technician.
II) High Discharge Pressure

a. Check the line up on the discharge side.
b. Check pressure control valve opening.
iii) Gland Leak

a. Check for normal pump discharge pressure.
b. Tighten the gland nut slowly if possible.
c. Hand over the pump for replacing gland packing.
iv) Unusual vibrations

a. Check the foundation bolts.
b. Check motor fan cover for looseness.
c. Stop the pump and hand over to maintenance.
Heat exchangers
FCCU-I has a number of heat exchangers, overhead condensers, product coolers and steam
generators. Bypassing and isolation facilities provided for operational flexibility.

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The exchangers were provided draining and flushing connections. The coolers and condensers
have been provided with TSV’s on the cooling water side. Temperature gauges or the thermo wells
have been provided at the inlet and outlet of exchangers. Where water is the cooling medium, no
temperature measurement is provided for water inlet temperature which is the same as cooling
water supply header temperature.
Start up
After the heat exchanger was pressure tested and all blinds removed, proceed as follows:
a. Ensure that the drains, vents. Flushing oil line valves are properly closed and isolated.
b. Commission the cold fluid first and then the hot fluid. While commissioning the streams
first open the outlet valves and then open the inlet valve.
c. However in case of heavy oil coolers, commission the hot fluid initially to avoid
congealing of the product.
d. Close the shell and tube side bypass valves if provided.
Shut down
e. Gradually open bypass valve of shell and tube side of the exchanger that is to be isolated.
f. In case of a cooler, adjust cooling water flow to the cooler which is in line so that product
temperature is within allowable unit.
g. Gradually close heating medium inlet valve and then the outlet valve.
h. Drain out shell and tube side when the material is sufficiently cool.
i. If flushing oil connections are given, flush the exchanger to CBD. Ensure that the CBD
drum has sufficient ullage to receive the material.
j. Suitably blind the exchanger prior to handling over to maintenance.
Heater
The FCCU furnaces is single cell heater bottom fired furnace with radiation and convection
sections. It has an upright steel structure with an outer steel casing. The casing is lined with
refractory material on the inside and forms the combustion chamber.
The combustion chamber houses the radiant section tubes. In this section heat is transferred
primarily by radiation from the flame and the hot combustion products. The convection section
provided at the top of the radiant section increases thermal efficiency of the furnace by recovering
more heat from the flue gases leaving the radiant section. The flue gases from the radiant zone
pass to the convection zone.
The floor is, elevated above grade so that the foundations are air cooled. This also helps in burner
operation and maintenance. Peep holes are provided on the floor as well as radiant chamber side
walls to facilitate inspection of the inside of the furnace. The furnace operates on induced draft

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and the draft can be varied as required by the operation of the damper. The damper can be operated
from the grade. Soot blowers are housed in the convection tubes to clean the soot from the tubes.
Draft gauges and sample nozzles are provided in the heater to measure draft and to take flue gas
Samples. Snuffing steam connections are given for the furnace box purging which can be operated
in emergency during fire on the floor box or purging the box.
Operating procedure
The FCCU furnace can be fired both on fuel oil and fuel gas. Each main burner is provided with
pilot gas burner. The furnace should be operated to provide fires which are as uniform in length
as can be obtained. It is normally desirable to fire all burners even at reduced operating capacities
for a uniform heat flux distribution.
Excess air for satisfactory combustion is 30% for fuel oil 20% for fuel gas. The amount of excess
air should be measured at the inlet to convection and the base of the stack. The excess air in the
furnace should be reduced till the flue gas analysis indicates traces of carbon monoxide exist. The
pass should not go beyond 10% (maximum) Skin. Box and intermediate pass temperature
indicators have been-provided.
a. Ensure cleanliness inside the heater.

b. Keep stack damper wide upon. Bypass shut down circuit and open fuel oil and fuel gas
suet down valves.
c. Establish fuel oil. The rate of circulation should be such that the fuel oil returned should
be equal to the fuel oil consumption in the furnace. Keep instruments on manual control
and ensure that the burner valves are not leaking.
d. Commission the fuel gas system and check and rectify any leaks in the system. Steam
purge the furnace chamber and ensure that the burner gaskets are not leaking.
e. Keep the primary air register completely closed and secondary air register open. Cut the
snuffing steam and light the pilot burner with and igniter. If the pilot burner does not light,
shut off fuel gas and steam the furnace again and light the pilot. While lighting the burner,
it is advisable not to stand under the burner.
f. For lighting oil burner, flush the fuel oil line by opening the cross over valve. Set the steam
differential pressure controller so that steam pressure is about 1.8-2.0kg/cm2 higher that
fuel oil pressure.
g. Crack open the atomizing steam to the burner of burners have been lighted, open the FO
and atomizing steam valve full and control the flames by adjusting the fuel oil pressure.
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h. Maintain furnace draft about minus 2 mm water gauge at the inlet to convection.
i. Check excess air in the furnace and adjust the damper, primary and secondary air registers
to get the required excess air.
j. For lighting the fuel gas burners operate the FG valves and maintain1.5kg/cm2g on fuel
gas header pressure and follow the same lighting procedure as in the case of an FO burner.
k. It is preferable to operate a burner either on fuel gas or fuel oil only at a time.
l. When the unit stabilizes, ensure Reactor temp control is cascaded with FO supply pressure.
m. Commission the shutdown circuit of the furnace.
Shut down
Fuel to the heater should not be cut off abruptly unless an emergency shutdown is called for. The
product pass outlet temperatures should be slowly reduced. As burners tend to become unstable
when fired at low rate, reduce the number of burners as required. Follow the procedure outlined
below for shutting off individual burners.
a. Close fuel oil valve and open steam purge valve on the fuel oil line to the burner. Purge
all oil into the firebox and continue steaming for about 5 minutes. Close atomizing steam
to the burner.
b. Pull out oil gun. In case the gun is not withdrawn, leave a little steam blowing through
the tip to cool it. This may be done when a burner is to be taken out of service during
normal operation.
c. For shutting down the furnace, cut the burners one by one till all oil fires and gas Fires
are cut off. Bypass the shutdown circuit of the furnace, so that fuel oil and fuel gas supply
- are not interrupted when the feed flow to the furnace is reduced.
d. Ensure oil and steam flow through the furnace coils during shut down till the temperature
of the box comes to below 2500C.
e. After all fires are put open snuffing steam to box and purge the box for 15 minutes.
f. Install blinds on fuel gas. Fuel oil and pilot gas line to furnace.
g. Open all air registers and all the peepholes. Sack dampers should be opened fully to
permit ingress of air into the furnace to cool it.

Plant Name: FCCU-I
Air coolers
The FCCU has the following air coolers and condensers.
04-E-58 A-H Fractionator OVHD air cooler

04-E-60A/B LCO – Lean Oil Cooler
04-E-69A/B/C Naphtha Air Cooler
The air coolers/condensers comprise of a fin tube assembly running parallel between the inlet and
outlet headers. These are of the forced draft type. The forced draft fans provided have auto
variable pitch rotors in which the fan-blades are adjustable in pitch during rotation. This allows
variation in air flow as per the cooling requirements. These coolers are also provided with
manually and/or automatically operating louvers for the control of the cooler outlet temperature.

Plant Name: FCCU-I

Plant Name: FCCU-I
PROCESS TROUBLESHOOTINGS AND UPSETS
CHAPTER 18
PROCESS TROUBLESHOOTING AND UPSETS
Introduction
Following are the critical operating activities with potential hazards which need to follow safe
and standard operating practices, details of which are available in this manual.
MAB Start up
CAB start up
APH burner light up
Feed introduction to reactor riser
WGC start up
Feed failure
MAB failure
CAB failure
Power Failure
All the above and various other emergencies were also discussed in detail in this manual. Apart
from the above mentioned critical activities various other routine activities which have the
potential to upset the plant are mentioned and detailed procedures were given.
Standby equipment changeovers are routine procedures. By following systematically, plant

upsets can be avoided.
MAB LO filter change over procedure
MAB lube oil filter will be changed when DP across filter increases to 0.8 -1.0 kg/cm2
(DESIGN: 1.5Kgf/Cm2). GCU/MAB /WGC operator will check the DP in routine rounds and
inform to MOI/Field officer immediately in case of increase in filter DP. Then proceed for
change over filter.
Steps for changeover of filter:
1. Note down Filter DP, LO pump discharge pressure.

2. Check which filter is in service, (normally handle indicates which is in service)
3. Clean filter vent view glass thoroughly for good vision.
4. This change over is not emergency operation thus take another operator for
assistance.
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5. One should be at pump discharge side for checking any variation while operating
stand by filter vent valve.
6. Inform DCS officer about changeover.
7. Open vent valve of stand by filter slowly to sump, without effecting pump discharge.
8. Slightly open filter equalization valve (which is behind the inlet valves of filters)
watching pump discharge pressure.
9. Observe vent sight glass and ensure flow of lube oil to sump, without any air bubbles.
10. Once steady flow is established through filter vent to sump, confirm pump discharge
pressure and close filter vent. This process is required to confirm the standby filter
is pressured up fully without air locks before changing the filter.
11. Then change over filter to stand by filter.
12. Close equalization valve.
13. Note down the filter DP and pump discharge pressure.
14. Inform rotary to change the filter element, isolate the filter, drain lube oil in to drums,
and hand over to rotary.
15. After rotary job is completed, follow sequence of item no: 7, 8, 9 and10 and close
the equalization valve after pressurizing the filter and keep it as standby.
WGC lube oil filters changeover procedure
WGC lube oil filters are to be changed when DP across filter increases to 0.8-1.0
kg/cm2(Design: 1.5Kgf/Cm2) GCU/MAB/WGC operator will check the DP in routine rounds
and inform to MOI/Field officer immediately in case of increase in filter DP. Then proceed
for change over filter.
Steps for changeover of filters:
1. Note down Filter DP, LO pump discharge pressure.

2. Check which filter is in service, (normally handle indicates which is in service)
3. After ensuring the above, clean filter vent view glass thoroughly for good vision.
assistance.
7. Open vent valve of stand by filter slowly to sump, without effecting pump
discharge.
8. Crack open equalization valve of filters, (which is behind the inlet valves of filters)
very slowly, without effecting pump discharge pressure.

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9. Observe vent sight glass and ensure flow of lube oil to sump, without any air
bubbles.
10. Once steady flow established through filter vent to sump, confirm pump discharge
pressure is good, then close filter vent, which was in open condition. This process
is required to confirm the standby filter is pressured up fully without air locks before
changing the filter.
14. Inform rotary to change the filter element, isolate the filter, drain lube oil in to
drums, and hand over to rotary.
15. After rotary job is completed, follow sequence of item no: 3,4,5,6.7,8,9 and10 and
close the equalization valve for pressurizing the filter and keep it as standby.
WGC SO Filter Change over procedure
WGC Seal oil filters will be changed when DP across filter increases to 0.8 -1.0 kg/cm2
(Design: 1.5Kgf/Cm2.) GCU/MAB/WGC operator will check the DP in routine rounds and
inform to MOI/Field officer immediately in case of increase in filter DP. Then proceed
for change over filter.
Steps for changeover of filters:
1. Note down filter DP, SO pump discharge pressure.

2. Check which filter is in service, ( normally handle indicates which is in service)
3. After ensuring the above, clean filter vent view glass thoroughly for good vision.
assistance.
7. Open vent valve of stand by filter slowly to sump, without effecting pump discharge.
8. Crack open equalization valve of filters, (which is behind the inlet valves of filters)
very slowly, without effecting pump discharge pressure.
9. Observe vent sight glass and ensure flow of seal oil to sump, without any air bubbles.
10. Once steady flow established through filter vent to sump, confirm pump discharge
pressure is good, then close filter vent, which was in open condition. This process is

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required to confirm the standby filter is pressured up fully without air locks before
changing the filter.
14. Inform rotary to change the filter element, isolate the filter, drain seal oil into drums,
and hand over to rotary.
15. After rotary job is completed, follow sequence of item no: 3,4,5,6.7,8,9 and10 and
close the equalization valve for pressurizing the filter and keep it as standby.
Slurry Pump Change over procedure
1. Check which pump is running.

2. Two operators should follow along with Field supervisor during normal changeover of
the pump.
3. Note down motor load and pump discharge pressure.
4. Ensure standby pump shaft is rotating freely.
5. Ensure stand by Suction is wide open and discharge is in closed condition.
6. Drain the pump casing completely free of water or lighter content.
7. Inform DCS officer about the pump changeover.
8. Start the pump and observe the load/ RPM. Then open the discharge (for turbine it
remains open) of the pump that was started and start decreasing the discharge/reduce
RPM (by reducing the steam valve) of the opening of the running pump.
9. Observe the motor load/ RPM. Observe seal oil and seal steam and adjust accordingly.
10. Once the discharge of the started pump is sufficiently opened, completely tight shut the
discharge of the running pump and stop the motor.
11. Take concurrence from the DCS officer.
13. Ensure sufficient opening of minimum flow line. Warm up line to be kept open.
Feed Pump Change over procedure
1. Check which pump is running.

2. Two operators should follow along with Field supervisor during normal changeover of
the pump.
4. Ensure standby shaft is rotating freely.

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5. Ensure stand by Suction is wide open and discharge is in closed condition and ensure
BCW in service.
6. Drain the pump casing completely free of water/ light liquid.
7. Inform DCS officer about the pump changeover.
8. DCS officer to note the flow and C/V opening and bypass pass flow low low trips and
total feed on DCS after concurrence from Manager/YSF, take clearance from CPP and
shift engineer.
9. Field officer should note the FT indication and discharge pressure
10. Use large spanner for closing/opening of discharge valves.
11. Start the pump and observe the load. Then open the discharge of the pump that was
started and start decreasing the discharge of the opening of the running pump.
12. Observe the motor load.
13. Once the discharge of the started pump is sufficiently opened, completely tight shut the
discharge of the running pump and stop it.
14. Take concurrence from the DCS officer.
15. DCS officer should check pump discharge pressure, feed flow, Pass flow C/V opening,
and feed ring pressure.
16. DCS officer should check the healthiness of pass flow low low trips and total feed and
take them into service
18. Ensure sufficient opening of minimum flow line.
19. Also ensure warm up is in open condition.
20. Check feed pre heat train.
Total Feed FT PM Checks
PM checks of total feed FT is carried out monthly once and after every shut down
1. Note down total feed rate on DCS and field transmitter FT readings.
2. Bypass Total feed low low trip,4FLCO502 on DCS after concurrence from unit
manager/YSF.
3. Handover the FT to instrumentation.
4. Area must be prepared in the field to drain the FT lead lines.
5. During checking, hardware annunciator alarm on DCS keeps repeating, do not panic.
6. Once checking is complete, check the FT with the previous value and log the
observations.
7. Observe the FT performance for six hours and if the performance was found satisfactory,
put the trip on line.

Plant Name: FCCU-I
WGC suction flow PM checks
PM checks of WGC FTs will be carried out monthly once. Since the suction flows are
considered in calculating the surge line, care must be exercised while releasing the FT
for PM checks
1. Note down the Suction flow values of WGC I stage and II stage FTs.
2. WGC I and II stage Antisurge valves to be taken on hand wheel mode and closed and
locked. Bypass suction pressure low-low trips.
3. DCS officer has to coordinate with the field supervisor and to ensure the lock by opening
the antisurge control valves from DCS.
4. Once he ensures that the control valves are not operating, FTs can be released.
5. While checking the FTs WGC antisurge deviations keep varying, do not panic.
6. Compare the FT readings after checking.
7. Release the hand wheel lock of antisurge control valves. Ensure hand wheel in auto
position so that it acts in emergency.
8. Confirm ASV opening once by coordinating with DCS.
The above mentioned activities are some of the crucial routines. Hence utmost care and
supervision to be there while carrying out these activities.
Avoiding deviations and plant upsets:
Upset conditions do occur in plant operation due to any unforeseen activity or emergency
occurrence either in the plant or outside the battery limits.
Avoiding the conditions for the upsets at the base level is important for smooth operation of
the unit. Some incidents and upsets can be avoided by timely action and precautions. Proper
checking in the field, following DRJs, Close monitoring of process parameters at DCS and
ensuring that all systems and procedures are followed is the only way to avoid upsets.
Monitoring of pumps and their auxiliary systems at regular intervals will help in taking
corrective action. This result in increased pump life and thus lesser upsets due to pump failures.
Gauge glasses need to be checked and tallied with LTs which helps in identification of LT
malfunction. Ensuring healthiness of steam tracings and EHTs will minimize the risk of
plugged hydrocarbon lines. PM checks of critical motors and instruments shall be taken up.

Plant Name: FCCU-I
Following are some of the upsets which can be avoided by taking necessary precautions.
Upset Conditions Deviations causing upset Actions to avoid the

conditions deviations
1. Main column 1. Failure of boot interface level 1. Ensure stand by reflux and
pressure fluctuation or malfunction of boot LT in PA pumps are free of
O/H drum. condensate
2. Failure of sponge absorber 2. Ensure Interface is steady
bottom level indication with in overhead receiver boot
g/g. 3. Ensure sponge absorber
bottom level indication is
matching with gauge glass
2. Stabilizer pressure 1. Excessive stabilizer 1. Avoid abnormal increase
fluctuation reboiling. This increases in reflux flow.
reflux flow. 2. Ensure steady reboiler
outlet temperature.
2. Failure of boot interface level 3. Avoid slippage of C1 and
or malfunction of boot LT in C2s into stabilizer feed by
O/H drum ensuring stripper reboiling.
3. GCU recycling 1. Failure of Stripper feed FT 1. Avoid excessive reboiling
which creates excessive of stripper bottoms
stripper o/h vapors and 2. Don’ t overload stripper.
stripper DP. Maintain Stripper DP
2. Excessive stripper reboiling <0.35
temperature >125 deg. for 3. Monitor difference of
lighter feeds. Stripper to stabilizer feeds.
4. Frequent failure of 1. Failure of boot interface level 1. Ensure boot interface level
Top reflux, stripper, or malfunction of boot LT in is always matching with
LPG R/D, stabilizer O/H drum which results in to g/g.
reflux and stabilizer water carryover in to FTs 2. Carry out boot HAZOP
feed FTs switches PM checks
5. Higher drum 1. Failure at cooling towers. 1. Monitor Salt water supply

(4V53, 4V56, 4V55 pressure and temperatures
Plant Name: FCCU-I
and 4V56) 2. Insufficient salt water flow, and take corrective actions
temperatures, off pressures and temperature. accordingly.
gas generation and 3. Poor performance of 2. Plan for cleaning of salt
WGC load. 4PM68AB and 76AB pumps. water booster pumps
4. Higher ambient suction strainers.
temperatures. 3. Plan for back flushing of
5. Poor performance of condensers.
condensers. 4. Take corrective action
w.r.t poor condenser
performance
6. Condensate entry 1. Failure of steam gen LTs and 1. Ensure steam gen LTs are
into filling of the steam gen. leads matching with g/g and
MP steam header. to carry over of the ensure 4TI1910 is always
causing swing in condensate in to MP header. more than 220.
Rx level and other 2. Not Closing BFW to steam
parameters gens B/V during
emergency’ s
7. Low Service water 1. Failure of service water 1. Immediately inform RSM
header (<2.5kg) in pumps at reservoir or any and cooling tower to take
FGD (Less service other reasons like excessive corrective action.
water flow leads to service water usage at other 2. Monitor Service water
low scrubber level units. header Pr 4PI9005
and it trips scrubber (>2.5kg)
pumps and leads to
CO diversion.
8. Bad weather 1. Excessive rain may cause 1. During heavy rain bypass
causing failure of failure of Total feed low-low total feed and heater pass
FTs. and pass flow FTs and trip flow low-low trips and
FTs. Due to failure of steam keep both heater pass flow
tracings. FT’ s in Manual mode.
9. Reslurry nozzle 1. Poor reslurry flow and poor 1. Monitor reslurry line
plugging atomization temperature and ensure
4TI2201 >200oC.

Plant Name: FCCU-I
10. MAB LO and 1. Plugging of LO and 1. Monitor MAB LO filters

Control oil header Governor oil filters. DP if it increases (0.8-1)
pressure reduction 2. Passing of LO pump disc proceeds for change over.
PSV. 2. Monitor MAB governor oil
filter indicator if it
activates proceeds for
change over.
Some of the common problems faced by FCCU, the probable causes for the problem, data
required to identify the problem and the corrective actions required are mentioned in the
following pages.
Troubleshooting Guide for Fresh Feed Quality Problems
Problem Symptoms Possible Causes Data Required Corrective Action
A. Metals in 1. High H2 make 1. Pitch entrainment 1. Feed Nickel 1. Lower metals in

feed 2. General Increase in at crude unit equivalent feed
light-ends towers 2. Feed CCR
production 2. Feed type change 3. H2 make, Sm3/m3 2. Feed
3. Excessive coke 3. Abnormal crude feed segregation
make unit operation 4. Actual vs.
4. Higher rector predicted yields 3. Catalyst
velocities 5. Crude unit replacement
5. Overloaded cat gas operating conditions program
compressor 6. Feed color
B. Feed 1. Excessive coke 1. Leak in feed 1. Feed CCR 1. Isolate leaking

contamination make preheat 2. Feed RI and API exchanger(s)
with heavy 2. Unexplained exchanger train gravity 2. Minimize
hydrocarbons increases in air 2. Partly open valves 3. HCO Recycle possibility of
requirements at 3. Fractionator stream leaks by pressure
same conversion bottoms inspections balance
3. Poor weight entrainment into 3. Block in HCO
balance HCO recycle recycle and
stream (if bottoms recycle
utilized) (if used)

Plant Name: FCCU-I
C. Feed 1. Unsteady preheat 1. Leak in feed 1. Feed API gravity 1. Isolate leaking
contamination header pressure preheat 2. Feed front-end exchanger (s)
with light and flows exchanger train distillation 2. Minimize
hydrocarbons 2. Poor weight 2. Partly open possibility of
balance valves leaks by pressure
3. shift in yield 3. Excessive balance
distribution SPA/CHO
recycle
D. Water on 1. Vibration in 1. Leaks from stem 1. Water in feed 1. Check for

feed preheat system out connections steam leaks on
2. Unsteady flows 2. Trapped water tank heaters
and temperatures from idle 2. Ensure idle
3. Severe upset if equipment equipment is well
large amounts of 3. Water in feed drained before
water in feed tankage (if fed being brought on
from tankage) stream
3. Swing to high
suction on feed
tank(s)
Trouble shooting Guide for Fresh Catalyst Quality Problems

A. Catalyst 1. See metals in 1. Low catalyst 1.Metals on 1. Consider
contamination feed (Table 17.1 replacement rate equilibrium catalyst lowering metals in
problem A) 2. See metals in 2.H2 make, Sm3/m3 feed by adjusting
feed Table17.1 feed crude tower
problem A) 3.Product yield operation
distribution
2. Catalyst replacement
program
B. Sodium on
3. Feed segregation
catalyst 1. See sintering of 1. Salt in feed 1. Historical Na
catalyst content of catalyst
1. Minimize sources
(Table 17.2 C)
of Na input to
C. Sintering of
system
catalyst 1. Apparent 1. High Na and 1. Total and burnable
decrease in V on catalyst carbon analysis
catalyst activity 2. Metals on catalyst

Plant Name: FCCU-I
2. Increase in 2. Excessive 3. Yield distribution 1. Catalyst replacement

Carbon on regenerator temp 4.Predicted and 2. Minimize Na input
regenerated 3. Low bed measured activity with sea water or
catalyst stability 5.Regenerator salt in feed .
3. Change in 4. Excessive or operating conditions 3. Consider lower V
product yield prolonged use content in feed
distribution of torch oil 4. Use high stability
5. Localized catalysts
high regenerator 5. Review regenerator
D. Coarse temperatures operation.
catalyst 1. Particle size
1. Poor circulation 1. Loss of fines distribution analysis
2.Poor 2. H/C ratio
regeneration 3. Yield distribution 1. Minimize catalyst
3. Change in yield 4. Operating losses by lowering
distribution conditions in regenerator velocity
E. Attrition 4. Poor stripping general 2. Change to finer
catalyst
1. High velocity 1. Check unit for high
1. Higher catalyst stream into dense velocity streams
losses with phase beds or exceeding 60m/sec. 1. Eliminate or reduce
increasing fines transfer lines. Into catalyst high velocity stream
content 2. Fragile 2. Check for missing injection
catalyst RO’ s on aeration or 2. Replace missing
blast steam or partly RO’ s or decommission
open valves, etc. aeration taps / blast
3. Check fresh catalyst stream connections, etc.
properties that are missing RO’ s
4. Study catalyst loss 3. Follow-up on fresh
pattern catalyst supplies with
vendor

Plant Name: FCCU-I
Troubleshooting Guide For Reactor Operating Problems
PROBLEM SYMPTOMS POSSIBLE CAUSES DATA CORRECTIVE

REQUIRED ACTION
A. Reactor 1. High catalyst in 1. Erosion and/or
cyclone fractionator corrosion 1. Catalyst 1. Minimize
failure bottoms 2. Pressure content in reactor velocity
2. Frequent surges fractionator
fractionator SPA bottoms 2. Review
pump loss of stream new methods in
suction 2. Cyclone cyclone design
3. Loss of catalyst pressure drop and repair
fines 3. Review
4. Catalyst losses operating
become procedures and
progressively history of past
higher occurrences
See: Water in feed (Problem D), regenerator grid hole erosion (Problem E), Surging
B. regenerator holdup (Problem J), unsteady pressure differential controller operation
Unsteady (Problem K), rough circulation (Problem M), Failure of regenerator overflow well
reactor seals (Problem C), Compressor surging.
temperature
and
pressure 1. Rise in DP 1. Condensation of 1. Pressure 1. Ensure overhead
between reactor outlet reactor products in survey of line insulation is
and fractionators the overhead line overhead line in good
C. Coking inlet 2 H/C ratios condition
in overhead 3. Stripper
line tests
1. Insufficient 1. Check stripping
1. Unexplained stripping steam - Do- steam rate
increase in cock 2. Poor catalyst/steam 2. Consider
2. High H/C ratio contacting increasing
D. Poor 3. Catalyst properties reactor
catalyst 4. Low reactor Temperature
stripping temperature 3. Consider lower
5. Inaccurate stripping circulation rate
steam flow 4. Check stripper
controller operation is
within design

Plant Name: FCCU-I
Troubleshooting Guide for Regenerator Operating Problems

A. cyclone 1. Increase in catalyst 1. Excessive 1. Pressure drop 1. Minimize cat feed rate
failure losses temperatures/ between dilute 2. Minimize regenerator
2. Catalyst losses allowable phase and velocity
become progressively stresses plenum 3. Review new methods in
higher exceeded 2. Catalyst losses cyclone design and repair
2. Erosion 3. Regenerator 4. Review operating
velocity procedures and history
B. Plenum 1. Increase in catalyst 1. Excessive As above As above

chamber losses above normal level temperature
failure and stress
cracking
C. Failure of 1. Uneven bed and 1. Erosion 1. Grid DP 1. Avoid pressure surges on
Internal seals cyclone inlet temp. Pressure bump 2. Catalyst startup
2. Uneven CO or O2 2. Stresses too appearance 2. Maximize air to grid
distribution in dilute high 3. CO or O2 (minimize control air)
phase 3. Abnormal analysis of 3. Lower regenerator
3. Salt and pepper conditions with
gas in dilute pressure/increases grid
catalyst auxiliary
4. Surging of catalyst burner at phase. velocity
bed startup 4. Historical 4. Review operating history
5. Drop in grid DP 4. High operating and seal design.
6. Increased catalyst loss temperature data.
and Afterburning excursion.
D. Hole in 1. Unstable regenerator 1. Abnormal 1. Overflow 1. Alter regenerated catalyst
overflow well overflow well level and pressure well level and standpipe aeration
catalyst circulation 2. Erosion densities 2. Adjust PDC-501 and
2. Unstable overflow 2. Historical circulation rate
well density regenerator 3. Maximize control
3. High regenerator operating air/minimize air to grid
holdup conditions, 4. Check operation is within
4. Uneven temperatures particularly design
5. UnevenO2 holdup and
distribution temperatures

Plant Name: FCCU-I
E. Grid hole 1. Uneven bed and 1. Areas of de- 1. Catalyst 1. Maintain grid DP
plugging cyclone temperatures fluidized sintering index above a minimum of
and/or 2. Uneven O2 catalyst 2. Bed 0.1 kg/cm2 and
erosion distribution 2. Low bed stability maintain bed stability
3. Increased catalyst stability 3. CO or (grid DP /bed DP)
losses O2 analysis of above 0.33 kg/cm2
4. Surging of catalyst dilute phase minimum
bed 2. Maximize air
5. Increased sintering 3. Check operation is within
grid design
4. Check condition of catalyst
hopper (s) to ensure debris
does not enter the regenerator

F. Stuck or 1. Constant, high 1. Binding of hinge 1. Careful 1. Revise or replace as
failed trickle catalyst losses rings due to: examination of required to meet
valves 2. Loss of catalyst a. Clearances not large trickle valves specifications
fines/ increase in enough on shutdown
coarseness index b. Oxidation scale or
pieces of lining
c. Non-uniform wear
of moving parts
2. Installation angles
not correct
3. Improper material
G. Plugged As above 1. Spalled refractory 1. Careful 1. Careful detailed

diplegs forming partial examination of check of the unit to
and eventually diplegs or use of prevent refractory
total plugging probes, light, spalling
2. Air out periods balls, etc. to
with a lot of ensure diplegs are
water/steam in free before
vessel startup

Plant Name: FCCU-I
H. Excessive 1. Higher level of 1.Missing or larger 1. Equipment 1. Careful detailed

input of catalyst losses than required survey to make check of unit for
steam or air 2. High cyclone restriction orifice sure all RO’ s correction of equipment
pressure drop plates are in place and conditions listed under
3. Attrition- higher 2.Partially open are correctly causes
catalyst fines content valves on steam, sized
despite higher losses water or air lines
3.Malfunctioning
steam traps
Flow meter errors
I. Bed 1. Increase in 1. Insufficient air 1.Grid pressure 1. Maintain grid DP

stability too temperature below through the grid to drop: actual vs. above a minimum
low the grid support the catalyst predicted of 0.1kg/cm2 and
bed 2.Historical bed stability (grid
Eroded grid holes records of DP/ bed DP) above
Too many grid temperature
0.33 minimum.
holes below the grid
Flow meter errors 2. Repair any badly
eroded grid holes
3. 3.If problem is
expected to persist,
re-design grid for
lower air rates

J. Surging of 1. Erratic holdup, 1. Grid hole erosion 1.Regenerated See action required
catalyst bed density or 2. Hole in overflow catalyst standpipe for seal failures ©
overflow well well/ seal failures pressure survey grid hole erosion
level 3. Poor bed stability 2.Operating (E), poor bed
2. Unsteady 4. Poor PdlC condition survey stability (l), poor
circulation and control 3.Bed stability PdlC Control (K)
heat balance calculation
3. Catalyst
sintering
4. Uneven catalyst
regeneration
Plant Name: FCCU-I
K. Unsteady 1. Fluctuating 1. Poor flue gas 1. Unit performance 1.Check out slide
differential regenerator slide valve records valves and
pressure control pressure performance: associated
2. Unsteady a) Sticky slide instrumentation
circulation and valves 2.Check adequacy
overflow well b) Poor slide valve of transfer line
level instrument aeration
3. Unsteady reactor performance 3.Check gas
temperature 2. Unsteady compressor
4. Catalyst shifts circulation control
between reactor 3. Poor fractionator instrumentation
and regenerator overhead gas
1. compressor
pressure control
L. Regenerator 1. High 1. Damaged 1. Surface 1.Cool spot (s) with
hot spots temperatures on refractory temperature steam or air,
vessel shells or measurements avoiding abrupt
transfer lines 2. Thermography/In thermal shocks
2. Change in paint fra-red
color inspections
3. Vessels or
transfer lines
glow at night
M. Rough 1. Unsteady RR 1. Improper aeration 1. Transfer line 1.Tune aeration
catalyst temperatures 2. Coarse catalyst aeration pattern pattern as required
circulation 2. Unsteady RR 3. Fluctuating PDC- and pressure 2.Check PDC-501
holdups 501 survey instrument loop
3. Unsteady control 4. Water in aeration 2. Standpipe and 3.Check causes of
air medium transfer line coarse catalyst
4. Fluctuating densities 4.Ensure aeration
overflow well 3. Circulation rate steam is dry
level and transfer 4. Catalyst particle 5.Consider finer
line densities size distribution grade of catalyst
5. Transfer line temporarily
vibration

Plant Name: FCCU-I

N. Low 1. Inability to 1. Partial blockage 1. As in (M) 1. Check operation is
catalyst control of either spent or above within unit design
circulation regenerator regenerated catalyst 2. Increase control air
rate temperature transfer lines rate
2. Control air too 3. Change PDC-501
2. Excessive low set point
feed preheat 3. PDC501 setting 4. Ensure adequate
temperature inadequate aeration
requirements 4. Improper aeration
5. Too much
stripping steam
O. After 1. Excessive 1. Insufficient coke 1. Carbon on regen 1. Selective

burning dilute phase production catalyst analysis marginal use of
and cyclone a) Decrease in unit 2. Fresh feed torch oil
temperatures cracking intensity quality 2. Increase
2. Trend to b) Changeover to 3. Recycle boiling operating intensity
lighter color better feed quality range and cat
3. If poor air
in regenerated c) Lighter recycle circulation rate
catalyst 2. Non-uniform air 4. Grid DP history distribution,
3. Increase in distribution through 5. Bed density consider changing
dilute phase grid profile (if grid hole distribution
temperature 3. Poor air available) to during next unit
relative to distribution in dense determine if bed shutdown
dense bed bed due to partial is de-fluidized 4. Increase CO
temperature bed defluidization 6. Temperature promoter additions
4. Regenerator bed profiles in bed, 5. If partial bed
temperature too low dilute phase, and fluidization, remove
5. Inadequate COP cyclones feed and “ fluff” bed.
addition rate 7. CO promoter
If unsuccessful,
addition records
unload catalyst and
then reload.

Plant Name: FCCU-I
p. High 1. Dark 1. Excessive coke 1. Carbon on regen 1. Decrease operating

carbon on regenerated from catalyst intensity.
catalyst/ catalyst. a. Increase in unit analysis. 2. Increase air to
carbon 2. Dilute phase cracking 2. Fresh feed regenerator
build up temperature intensity quality 3. Inject lighter feed
decreases b. Changeover to 3. Recycle boiling 4. Decrease recycle
relative to poorer feedstock range and cat rate or stop
dense bed c. Heavier recycle. circulation rate completely.
temperature. d. Leakage of 4. Check stripper 5. Improve catalyst
3. High CO fractionator performance stripping.
4. Apparent loss bottoms into 6. Check feed meter
in catalyst feed circuit. accuracy.
activity 2. High CO
Troubleshooting Guide for Fractionator Operating Problem

A. 1. High bottoms 1. Too much heat 1. Fractionator 1.Lower heat
Fractionator API gravity removal in bottoms removal from
bottoms too Excessive slurry pump inspections tower bottoms
light. bottoms yield around 2. Tower operating consistent with
2. Dark color of 2. Tower bottom conditions in the coking
HCO recycle too cold. Poor lower half considerations
stream. liquid/ vapor 3. Check cracking 2.Maximize HCGO
contacting in intensity. recycle
shed section. 4. Check recycle 3.Consider
3. Lower flow meter. equipment
operating changes.
intensity.
4. Leaks into SPA
system

Plant Name: FCCU-I
B. Coking in 1. Frequent 1. Excessive 1. History of 1. Review

SPA and plugging of temperatures in bottoms API and recommended
bottoms slurry lower bottom BS&W limitations of
circuits. exchangers and 2. Low bottoms 2. Tower bottom tower bottoms
pumps with API operating operating
coke 3. High liquid conditions conditions and
2. Poor heat residence time 3. Calculation of adjust accordingly
transfer in SPA in tower bottom bottoms liquid 2. Consider changing
exchangers 4. Leakage of fresh residence time the pump screen
3. High insolubles feed into SPA. 4. History of size
in bottoms equipment fouling 3. Check for leakage
4. Frequent 5. Equipment or injection of
cleaning of inspection to verify extraneous streams
slurry pump possible into tower bottom
around contamination of
strainers. SPA with feed via
startup or flushing
lines
C. Salt fouling 1. Higher pressure 1. Salts in fresh 1. Pressure and 1. Avoid/remove
of fractionator drop in top feed temperature sources of
top trays 2. TPA return too survey of top of chlorides
cold tower 2. Water wash top
2. Flooding in the 3. Tower top 2. TPA operating of tower
top section temperature conditions 3. Adjust tower
3. Poor split below water 3. Chlorides in temperatures
between dew-point fresh feed 4. Adjust TPA
overhead and 4. Chlorides in return temperature
first side- distillate drum 5. Return cold
stream water reflux with warmer
4. Salt In TPA 5. Split between TPA
pumps fractionator 6. Consider
5. Chlorides in overhead stream installing screens
overhead water and first side- in TAP pump
stream suctions

Plant Name: FCCU-I
Troubleshooting Guide for Fractionator Operating Problems

D. Excessive 1. Scale from 1.Inadequate wash 1. Inspection reports 1. Increase wash water
corrosion in sample outlet water 2. Ultrasonic rates
overhead 2. High corrosion 2.High measurements of
system rate measured contaminant pipe tube wall
by probes level in thickness
measured by overhead vapor 3. Fractionator wash
probes 3.High water,
3. Blistering in contaminant corrosion/hydrogen
overhead concentration in probe and sample
circuit sour water outlet data
equipment stripper bottoms
4. Thin walls as 4.Inadequate
measured by polysulfide
ultrasonic injection (if
used)
E. Poor 1. High overlap 1.Improper tray 1. Stream distillations 1. Ensure adequate

fractionation between loading in lower 2. Fractionator stripping steam
between side stream 2.Poor pressure survey rates in side stream
streams distillations performance of 3. Pump around heat strippers
2. Shift in yield side stream removal 2. Adjust pump
pattern stripper 4. Detailed analysis of around heat duties
fractionator and
3. Increase in one side stream stripper 3. Consider equipment
side stream operations changes
volume at 5. Consider
constant equipment gamma
operating scans to
conditions identify/confirm
problem

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I
EMERGENCY HANDLING PROCEDURES AND
SHUTDOWN
CHAPTER 19
EMERGENCY HANDLING PROCEDURES AND SHUTDOWNS
Introduction
General Emergency Procedures and Instrumentation
Manual Emergency Shutdown of Fluid Solids Section
Automatic Emergency Systems
Normal emergency procedures
1. Air preheater failure.

2. WGC trip.
3. Power failure
4. Instrument air failure
5. DCS failure
6. Failure of boosted Saltwater
7. MP BFW failure
8. HCO PA pumps failure
9. HCO product +Recycle pumps failure
10. Slurry pumps failure
11. LCO Pdt + Lean oil pumps failure
12. LCO PA pump failure
13. LPD pumps failure
14. 4C-51 Top reflux pump failure
15. Torch oil pump failure
16. Stack slide valves failure
17. HV502 (feed diversion) failure
18. Failure of SDV’ s on Sour water system
19. Failure of Debutanizer reflux pumps
20. Sponge absorber LT failure
21. Primary absorber LT failure
22. RCJB, SCJB slide valves failure
23. MP Steam failure
24. CO boiler trip
25. Heater trip
26. LEL detectors
27. Sprinkler system
28. Other Emergency equipment

SHUTDOWN
Plant Name: FCCU-I
SHUTDOWN
19.0 Introduction
This section contains the procedures to be followed in FCCU-1 in response to an emergency

condition caused by process upset, loss of a utility system, equipment malfunction, or other
abnormal condition. Both manual and automated emergency actions are described, as well as
the additional operator actions required to put the unit in a safe condition after an automated
shutdown.
19.1 General Comments on Emergency Procedures and Instrumentation
Emergency conditions in a fluid catalytic cracking unit are usually caused by loss of feed or
air, loss of one of the utilities, or equipment malfunction. Emergency conditions may also result
from mechanical failure which prevents normal operation, or results in a serious leak or fire.
Some of these emergencies may be tolerated for a short time if proper measures are taken. In
some cases, operations may be continued by bypassing malfunctioning equipment until repairs
can be made. In other instances, it will be necessary to shut down the unit without damaging
equipment or creating additional hazards.
Automatic protective system instrumentation has been provided as part of the FCCU-1 design
for the most common emergencies for which immediate action is essential to put the unit into
a safe condition.
The immediate automatic and operator actions have been listed under each of the emergencies
in the following subsections, along with general actions to be taken if the emergency is of short
or long duration.
However, during an emergency, there is nothing that can take the place of the judgment of the
operator. A particular emergency will probably differ from the specific situations described in
the following. As a result the actual course of action must depend upon the operator’ s
assessment of the specific situation.
Each manually or automatically initiated protective system has been specified to have the
capability of periodic on stream testing to ensure reliable action during an actual emergency.
Upon activation of the emergency system, all protective system actuators must be locally reset
before the unit can be restarted.

SHUTDOWN
Plant Name: FCCU-I
SHUTDOWN
19.2 Manual Emergency Shutdown of Fluid Solids Section
In the event of an emergency, such as fire or equipment failure which requires an immediate
shutdown of FCCU-I, the following steps are to be taken
Initiator
1. Manually trip ES-1, using the ES-1 hardware switch HS-501. This will initiate the
following automatic emergency actions:
Actions
1. Activate Common ES-1 Tripped Alarm in the DCS.
2. Close HCV-1X, Spent Catalyst Shutoff Slide Valve, to stop Spent Catalyst Circulation.
3. Close HCV-2X, Regenerated Catalyst Shutoff Slide Valve, to stop regenerated catalyst
circulation.
4. Close HCV-501 in Oil Feed Line to the Reactor Feed Riser.
5. Open HCV-502 in Oil Feed Diversion line to Fractionator.
6. Close FCV-504 in the Fractionator Bottoms Recycle Line to the Feed Riser.
7. Open HCV-504 in Emergency Steam Line to the Reactor Feed Riser.
8. Shutdown the Preheat Furnace.
9. TPSV will be diverted to stack and CO boiler inlet goggle v/v will be closed.
The following summarizes the additional actions to be taken.
The globe valves on the oil lines to all feed injectors should be closed immediately to
protect against oil ingress into the feed riser. Reslurry to Reactor should be closed.
Injection steam flow should be maintained to prevent plugging of the feed injectors.
Maintain Reactor pressure by injecting fuel gas into the fractionator overhead system.
Increase fractionator O/H drum (4V-53) PC 2407 set point to 1.3Kg/cm2 and OPRV
(4PC2411) SP to 1.4Kg/cm2. Once feed flow has been diverted to the fractionator,
Reactor pressure will drop due to the sudden reduction in vapor rate from the Reactor.
To avoid loss of catalyst seal in transfer lines, maintain Reactor pressure higher than
Regenerator pressure. Maintain minimum regen pressure of 0.91Kg/cm2.

SHUTDOWN
Plant Name: FCCU-I
SHUTDOWN
Reduce MAB air rate in steps to around 46 to 48KNM3/hr to maintain Regen Grid DP
above 0.1Kg/cm2. (To maintain regen grid DP and superficial velocity).
Check that Regenerator bed level is more than 2 meters above the torch oil nozzles
(above 20%) and start torch oil injection.
Maintain Regen dense bed temperature around 510-550oC
Reduce fresh feed to the fractionator as quickly as possible to protect the preheat furnace
coil from overheating due to low.
Increase CLO run down to maintain fractionator level. Always maintain Slurry flow
over the sheds with a small makeup and purge to slop until catalyst is removed from
the Reactor.
To sustain WGC, bypass WGC suction low-low pressures switches at LCP.
Take WGC Antisurge into manual and sustain ASV deviation >0.05 to avoid
fluctuations. Close Naphtha injection to WGC, if any.
Close Main column bottom steam, LCO and HCO stripping steams.
Close BFW to steam generators.
Divert Sour water to Merox directly from the pump or drain to OWS at battery limit.
Stop catalyst and additives addition.
Stop Filmer injection to main column overhead and start Neutralizer injection.
Pump out all levels in GCU and LCO and HCO strippers to slop and stop pumps.
Close all unit Run down battery limit double block valves
Heater FO circulation to be established.
Reslurry circuit cutter flushing to be done.
As Regen flue gas diverts to stack, FGD caustic addition, purge rates to be reduced to
suit NCO emissions.
Naphtha to PA, PA intercooler pumps and chiller compressors to be stopped.
Lean sponge oil to Sponge absorber and Rich sponge oil to Main fractionator to be kept
closed.
Bypass ATG to SRU by opening SRU bypass valve at FCCU-I battery limit and close
If the cause of the initial problem has been determined and corrected, preparations can
begin to re-establish feed to the unit. Otherwise, shut down the unit following normal
procedures as closely as possible.
SHUTDOWN
Plant Name: FCCU-I
SHUTDOWN
19.3 Automatic Emergency Systems
For the list of Automated emergency systems and Interlocks, refer Chapter 8
TABLE 19.1 NORMAL EMERGENCY PROCEDURES
Emergency Causes Effects Actions To Be Taken

1) Loss Of Tank booster Same as Coordinate with TPH .Decrease feed
Cold Feed failure/off above rate accordingly. Maximize Hot feed
site rate.
lineup/failure
of cold feed
c/v
2) Loss Of Hot Problem at Coordinate with CDUs. Increase cold
Feed CDUs feed to suit preheat condition. Increase
furnace firing to meet preheat
requirements.
Increase CO/reslurry to suit the
conditions.
3) Faulty Surge Instrument Same as In case of LT failure, take level control
Drum Level. problem above on manual and monitor gauge glass till
it gets rectified.
4) Power Failure Power problem Unit will go Carryout the jobs as per the feed failure.
to shut down Blower operator should ensure hot well
at CPP
mode. ESI turbine cut in.
(feed failure) Establish torch oil flow via flushing oil
and ES3
header. If required Merox
(CAB failure)
booster/CDUIII booster to be started.
will be
activated. Isolate LCO, CRN, and LPG R/Ds at
unit limit.
Gas plant header to be maintained with
LPG from Merox.
SHUTDOWN
Plant Name: FCCU-I
SHUTDOWN

Ensure slurry turbine cut in and pump
out the level.
5) WGC Trip 1. Due to power 1. 4C-51 First important action should be to
dip pressure will control 4V-53 pressure
2. High level in shoot up. Line up FG to LCO stripper
4V-54 2. Circulation Press ES-1 and take out feed.
(LSHH2509) upset may
result which Follow ES-1 Line up LPG from Merox
3. Low I & II to gas plant as warranted.
may active ES5
stage suction
(Regenerated Isolate sour water to 4E63/ A/B and
pressure
circulation 4E64/B and route sour water to Merox.
4. High I & II failure).
stage disch temp Monitor flare KOD drum level.
5.High DP of Stop 4P74A/B (Primary absorber
each stage bottoms), 4P 58/A/B (Lean sponge oil),
4P62A/B (Stripper feed pump)
7) Seal oil
failure
8) Machine trips
6) Instrument 1. Merox Air All Check for all emergency systems have
Air Failure Compressors instruments been activated. If any action does not
Tripped. will go to fail take place, operators have to perform
safe position the same manually. Trip feed motor.
and
Open PIC2411 bypass if required to
emergency bring down 4C-51 pressure. Once
systems will
compressor suction pressure start
be activated.
coming down then only shutdown the
compressor
Slurry turbine will trip due to low
instrument air failure. Pump out the
level with motor only.

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Plant Name: FCCU-I
SHUTDOWN

MAB and CAB antisurge control
valves should have opened and
emergency steams should cut in.
Close MAB butterfly valves and
control air nozzle shell valves.
Proceed for shutdown.
7) DCS Failure 1. Power and 1. DCS will Manually trip MAB and carry out
DCS UPS not have actions from field.
failure. control on Check immediately the following and
field. proceed for the shutdown.
1. RCJB & SCJB slide valves should be
closed.
2. Column pressure should not shoot up.
Control through PIC bypass.
3. Column level to be closely monitored
using gauge glass.
4. Feed to reactor should shut off.
5. Emergency steams should cut in.
5. Pump out levels.
8) Failure Of 1. 04-P-68/A/B 1. Reactor 1. Try to place the 04PM-68A/B
Boosted Salt pumps failure pressure saltwater booster if it trips.
Water 2. Leak in the shoots up. 2. Reduce feed rate and severity as
boosted salt required.
water header.
In case of failure at cooling tower.
ES-2 and ES-1 will activate and
proceed for shutdown.
9) MP BFW BFW pumps 1. The water 1. Reduce thruput and severity if
Failure failure at power level in 4E56, required.
plant. 2. Decrease heater firing.
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Plant Name: FCCU-I
SHUTDOWN

4E57 and 3. Inform power plant about MP BFW
04V63 drops. failure.
2. Column 4. Bypass 4E 56 and 57 steam
Temperature generators and 4V-63 steam drum
rises
5. Bypass 04E-55A/B LCO/BFW
3. 4F51 pre exchanger.
heater
6. Adjust slurry through feed preheat
convection exchangers HCOPA and LCO PA to
tubes will dry
maintain column heat balance.
run.
5. NO BFW to
4E-55A/B
LCO R/D
temperature
will increase.
10) HCO PA 1. 04P60A/B 1. Main 1. If pump has tripped place the
Pumps pump failure. fractionator standby in service.
Failure heat balance 2. Adjust slurry PA flow and LCO PA
2. No suction
will be upset 3. Reduce thruput to maintain column
due to light oil
to the pump 2. Loss of top temperature.
reboiling 4. Bypass 04E57 steam generator.
gland.
media to 5. As there is no reboiling media for
stabilizer. stabilizer, route stabilizer bottoms to
3. Loss of MP slop.
steam
generation in
4E-57
14) HCO 1. Loss of 4C53 1. Loss of 1. If pump has tripped, place the
Product Pumps level. HCO dilutant standby in service.
Failure
2. Failure of to Slurry. 2. If D/0 c/v LV2104 fails, take it on
4LV2104 manual control
Control valve.

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Plant Name: FCCU-I
SHUTDOWN

3. Pump failure. 3. Close stripping steam to HCO
stripper
4. To hold main fractionator
temperature, adjust slurry and LCO
PA.
15) Slurry 1. Loss of 1. Rapid 1. If motor failure and turbine auto cut
Pump Failure fractionator increase in in does not take place. * Check
level. fractionator SDV7401
2. Less suction bottoms 2. Check instrument air to turbine
to pumps due to temperature governor.
followed by 3. If turbine failure and motor auto cut
strainer
rise in in does not take place reset motor
plugging or
temperature and try again
cavitation
of the column 4. To hold fractionator Temperatures
3. Turbine and right up to the adjust HCO PA and LCO PA.
motor failure. vapor line. 5. Maximize top reflux, over flow LCO
4. Leakage of 2. Steep drop and HCO to hold the column
steam from in fractionator bottoms.
4E56 tubes level resultant 6. Increase furnace firing to
of increased compensate loss of preheat.
temp. 7. If pumps fail due to loss of suction,
prime standby pump and normalize
3. Loss of operation.
feed preheat 8. If the failure is prolonged, take out
in 04E-54 the feed as per procedure.
A/B/C CC: Take out reactor temperature
4. Loss of control from cascade and increase cat
reslurry to circulation rate with control air if drop
reactor in reactor temperature.
resulting in
Regen after
burn.
5.Loss of MP
steam
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Plant Name: FCCU-I
SHUTDOWN

generation in
04E-56
16) LCO 1. Loss of LCO 1. No LCO 1. If pump tripped place the stand by in
Product Pumps stripper level. rundown service.
Failure 2. Failure of 2. Drop in 2. If D/O c/v 4LV2103 fail, take it on
4LV2103 feed preheat. manual control.
control valve.
3. Loss of lean 3. Feed preheat adjust other preheat
3. 04P58A/B sponge oil exchangers/furnace
failure.
4. 4. Isolate sponge oil. Isolate rich
Overflowing sponge oil (c/v at structure platform)
of LCO to 5. Reduce feed rate, till the pump gets
HCO zone. started.
17) LCO PA 1. 04P59A/B 1. Main 1. If pump has tripped place the stand
Pumps Failure failure. fractionator by in service.
heat balance
2. No suction to 2. Reduce feed rate to suit conditions.
pumps due to will upset and
MF top temp 3. Adjust slurry flow through 04E-56
strainer
will increases. and HCO PA circulation to maintain
plugging or
column heat balance.
pump cavitation 2.LCO zone
due to lighter temperature 4. Try to maximize stripper reboiling
liquid. increases through stabilizer bottoms.
3. Loss of 5. Release excess pressure build up in
reboiling stabilizer through 04PV-3001B to fuel
media to gas system
stripper 6. As there is less reboiling media for
3. Loss of stripper, LPG H2S will shoot up.
preheat in
4E53
18) LPD Pumps 1. 4P54A/B 1. 4V53 level 1. Try to place the stand by pump in
Failure failure. will shoot up. service.

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Plant Name: FCCU-I
SHUTDOWN

2. 4V55 2. Reduce thruput to suit unit
interstage conditions.
drum level 3. Close the suction 8” valve of stand
will decrease. by 04P65A/B and line up 4V53
3. Stripper hydrocarbon liquid to standby
feed will pump
come down. 4. Run both 4P65A/B pumps
simultaneously and partially route
4. 4C54 CRN and route to slop
primary accordingly.
absorber tail 5. Do not allow 4V53 drum level to
gases will cross 70% as liquid will get
increases carried over into 4V54
resulting in 6. Closely observe 04V55 interstage
higher off gas drum level and open more spill
yields. back of 04P61XA/B pumps.
19) 4C-51 Top 1.Due to 1. Column top 1. Try to start the standby pump.
Reflux Pump mechanical / temperature 2. Increase slurry pump around. Drop
Failure electrical will shoot up. flash zone temperature.
problem 2. Column 3. Increase HCO and LCO pump
pressure will around.
come down
and affects 4. Reduce the feed rate.
regenerator 5. Maintain column pressure by
reactor DP increasing 4PC2407.
7. If the pump startup is prolonged,
take out feed.
20) Torch Oil 1. 4P73 pump 1. No torch 1. Open the pump bypass.
Pump Failure failure oil to 2. In case torch oil is not coming
Regenerator
through the flushing oil header, divert
feed to torch oil (manifold near west of
feed pump)

SHUTDOWN
Plant Name: FCCU-I
SHUTDOWN

21) Stack Slide 1. Hydraulic oil 1. No control 1. In case of one hydraulic oil pump
Valves Failure failure to slide on Reactor- failure, other pump should
valves. Regenerator immediately auto cut in. If it does not
DP. take place, keep the switch in manual
2. DCS remote
signal failure 2. ES-4/ES-5 and start the standby pump.
from DCS. may actuate 2. In case of remote signal failure
3. Slide valves due to DP
from DCS, reach stack slide valves
switch upset.
and operate the slide valves with
limit
joystick by observing DP.
(feedback
signal) failure. 3. In case of hydraulic oil failure is
prolonged; stack slide valves to be
operated manually by releasing lock
on the lever.
22) HV502 1. In case of 1. High tower 1. Check the unit conditions and check
(Feed Diversion) ES1 activation bottoms level whether the C/V got opened due to any
only, this and loss of upset.
should open. In feed to
2. If it is confirmed due to false
case by false reactor. activation, it is to be immediately
activation of 2. Bottoms closed from centum/or from field.
this control
level must not 3. Pump out bottom level. If required,
valve leads to be permitted
high tower run both CLO boosters.
to rise above
bottoms level. the Reactor 4. Reduce feed rate also to Control the
vapor inlet level.
line.
3. If feed falls
below
40m3/hr ES1
will be
activated.
23) Failure Of 1. Failure of 1. Failure of 1. Route sour water from 4P63A/B to
SDVs On Sour instrument individual SWSU directly.
Water System SDV will
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Plant Name: FCCU-I
SHUTDOWN

lead to 2. Close sour water to 4E63A/B and
corresponding 4E64A/B I/L valves
inter phase
level increase
/ decrease
leading to
water carry
over to the
downstream
Naphtha or
vice versa.
24) Failure Of 1. Mechanical / 1. Debutanizer 1. Try to start the stand by pump.
4P66A/B electrical top 2. In case both pumps fail, reduce
problem temperature reboiling to the stabilizer.
will shoot up
25) Sponge 1. 1. No level 1. Keep the sponge absorber level
Absorber Instrumentation indication located at column structure floor 3 on
LT Failure problem manual and control the level.
2. High level will lead to oil carry
over to the off gas and no level will
lead to pressure upset in Rg-Rx (ES5
Activation).
3. If it is becoming difficult to control
the level, isolate lean sponge and rich
sponge oil till the LT gets rectified.
26) Primary 1. Instrument 1. No level 1. 4LC2801 located at tech structure
Absorber problem indication 4E64A inlet platform.
LT Failure 2. Manually control the level by
physical checking of gauge glass and
coordinate the person at the control
v/v.

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Plant Name: FCCU-I
SHUTDOWN

3. At high level, naphtha carryover
will take place to 4C57.
4. Isolate recycle naphtha to 4C54 as
last resort.
27) RCJB, 1) Signal failure 1) 1) Close the slide valves manually.
SCJB slide Hydrocarbon
2) Interlock 2) In case closing is not compete/failed
valves failed to carry over to
failure to close slump the catalyst in RCJB
close during Regenerator and SCJB by closing steams.
emergency 3) Hydraulic oil
2) Air entry to
failure For RCJB: Standpipe aeration steams,
Reactor
J-bend aeration and angle riser aeration
steam, J-bend blast steam. Feed riser
emergency/fluffing steam and feed
injection steam.
For SCJB: Standpipe aeration steam.
Reactor stripping steam and cone
aeration steam, J-bend aeration steam.
28) MP Steam Boiler trip 1) MAB Follow shutdown procedure
Failure condenser
two stage
ejector
2) MAB
condensate
turbine driven
pump
3) Feed
injector
atomizing
steam,
4) Feed riser
emergency
steam

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Plant Name: FCCU-I
SHUTDOWN

5) Emergency
steam to
Reactor,
stripping
steam. Cone
aeration
steam J bends
and angle
riser steam.
6) Other
miscellaneous
purges. Loss
of above
steam will
lead to ES-
4 ,ES-5 to
activate and
loss of ejector
steam will
trip MAB and
ES-2 will be
activated
29) CO Boiler CO boiler trip 1) TPSV will 1) Check for diversion of CO boiler to
Trip due to activation be diverted to stack.
of their stack
interlocks/ 2) CO boiler
problem
inlet goggle
valve will be
closed.
30) Heater Trip 1) Due to fuel 1) Reactor 1) Isolate fuel oil and fuel gas
oil/fuel gas/pass temperature individual valves.
flows low trip will start
2)Know the reasons for trip and reset
dropping SDV’ s and start heater

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Plant Name: FCCU-I
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3) Reduce feed rate accordingly to hold
Reactor temperature
32) Sprinkler Sprinkler system provided to
System hydrocarbon pumps in the unit. In
case of emergency, they can be
operated by a common header v/v
located at north east corner

SHUTDOWN
Plant Name: FCCU-I
NORMAL SHUTDOWN PROCEDURES
CHAPTER 20
Introduction
General Preparation for normal shutdown
Feed out
Catalyst unloading
Unit steam out procedure
Table 20.1 General Outline for normal shutdown

Table 20.2 Procedures for feed out
Table 20.3 Procedure for Cat Unloading
Fig 20.1 Bar chart for FCCUI feed taking out and
handing over to maintenance

Plant Name: FCCU-I
Introduction
This section describes the procedures to be used for a planned total shutdown of FCCU-I
General Preparation for Normal Shutdown
Prior to a scheduled unit shutdown, notify all affected units and personnel that the unit will be
shut down. Fuel gas to be bypassed in coordination with Merox and DHDS SRU to avoid liquid
carry over. Check available space in the Used Catalyst Hopper and slop tanks prior to initiating
the shutdown procedures. Check for the availability of utilities like steam, service water and
ETP.
A general outline of the normal shutdown procedure is given in Table 20.1
Feed Out
Procedures for cutting feed from the unit are provided in Table 19.2 The procedure given here
involves gradually reducing feed rate with FL (CO)-502, the Feed Low cut-Out initiator feed
rate, the remaining feed is taken out by manually tripping ES-1. The benefit of using this
procedure is that all emergency system responses can be completely tested and Operators gain
experience in performing the required emergency procedure.
Catalyst Unloading
Procedures for unloading catalyst from the unit are presented in Table 19.9.
Unit Clean-Out
The Reactor and Regenerator vessels have been provided with vacuum clean out lines near
major man ways. These facilities should be used to remove catalyst “ dead” zones of these
vessels and associated piping.
Prior to personnel entering the unit, checks should be made of the air quality within the vessels.
Steam out Procedure
Steam out procedure for individual systems in FCCUI Revamp is given below.
Feed System
Plant Name: FCCU-I
Use SOP’ s on hot and cold feed lines at unit limits.

a) Connect steam hoses for hot and cold feed lines at U/L
b) Use feed pump discharge SOP’ S
c) Use heater pass flows emergency steam for steaming heater coils. Feed to startup
circulation loop, total feed c/v loop steaming to be done. Care to be taken to avoid
hammering in heater coils
d) All preheat exchangers CBD/OWS to be cleared.
e) Steam Feed pump discharge to VGO filters loop.
f) Steam out feed make up U-Loop
g) Steam out feed diversion loop
h) Steam out heater outlet RV‘s loop.
4V-51 4P-51 A/B pump suction

4P-51 A/B 4E-51, 52A/B/C/D, 53,54A/B/C 4F51 HC501
4F-51 Startup circulation loop.
4F-51 RV’ s loop to column.
Slurry System
i) Use slurry pump discharge SOP’ s

j) Connect steam hoses at 4E-54A/B/C and 4E-56 for thorough steaming of pump
around circuits.
k) Connect Steam hoses at FC2005, FC2004 & TV2013 c/v u/s bleeders
l) Introduce steam to slurry settler (SOP). Displace cutter and steam thoroughly.
m) Steam CLO circuit upto CLO booster.
n) Use CLO booster pump discharge SOP for CLO rundown loop, CLO to startup
circulation.
o) Reslurry loop to Riser dedicated nozzle and reslurry to feed.
p) Steam 4C51 to slurry pump suction lines.
4C-51 4P52 A/B
4P-52A/B 4E54A/B/C 4E56 FC2004, FC2005,

TV2013 4C-51
4P-52A/B Reslurry FC504
4P-56A/B CLO R/D, HFO, RFO,VB tar

Plant Name: FCCU-I
4C-51 4P-52A/B
4P52A/B Reslurry Riser dedicated nozzle.
Reslurry Total Feed line.
HCO Pump Around System
q) Use pump (P60A/B) discharge SOP’ s

r) Steam stabilizer reboiler (4E68)
s) Connect additional steam hose at 4E-57 inlet
t) Steam out PA circuit up to column
u) Steam HC2001 loop (HCO PA to shed rows)
v) 4C-51 4P-60 A/B suction
4P-60A/B 4E-68 4E-57
4E-57 4C-57
HCO Product System
a) Use 4E56A/B pump discharge SOP’ s

b) Steam HCO to slurry settler
c) Steam HCO recycle to feed loop (4FC2202) upto heater inlet.
d) Steam HCO spill back to stripper.
4C-51 4P-56A/B suction
FV2202
4P-56A/B HV2204 Reslurry
FV1801 CLO rundown
LCO Product System
a) Use pump discharge (55A/B) LP steam SOP’ s

b) Connect additional steam hoses at 4E65 inlet, 4E51/ 4E55A/B, 4E60 (Air fin
cooler inlet), 4E61A/B (trim coolers), 4PM72A/B discharge.
c) Steam LCO to DHDS loop
d) 4P72A/B pump discharge and suction loops.
e) Steam LCO to flushing oil at technological structure loop
f) Steam LCO to cutter line.
g) Steam LCO to Lean sponge oil

Plant Name: FCCU-I
4C-51 4P55A/B
4P-55A/B 4E65 4E51 4E55A/B
4E55A/B 4E60 A/B 4E61A/B
LCO to DHDS
Lean sponge oil
4E61A/B Rundown
Flushing oil
LCO Pump around System
a) Use 4P59A/B discharge SOP’ s

b) Connect additional hoses at 4E53 inlet and 4E-66 A(stripper reboiler inlet)
c) Steam out LCO circuit upto column.
4C-51 4P59A/B suction
4P59A/B 4E53
4E66A 4C51
Flushing Oil System
a) Connect steam hose on 6” flushing oil header and also use SOP’ s on flushing oil header.
b) Disconnect/spread flushing oil to exchanger’ s inlet / outlet (2” )
c) Steam individual flushing oil connections.
d) Connect steam hose at flushing oil to pump seals (PV7302) and FLOM header
e) Steam through all FLOM manifolds (48 connections) as per list.
f) Steam out flushing oil to CBD corner points.
GCU Columns and Vessels
a) Introduce individual column’ s SOP steams

b) Get connected steam connections to 4V-55, 4V-56 and 4V-57
c) Back up the steam from columns and vessels to individual circuits.
Stabilizer Circuit
a) Open stabilizer bottom SOP

Plant Name: FCCU-I
b) Connect additional steam hoses at 4E-69A/B inlet, 4E-70A/B, 4P-65A/B pump

discharge for CRN circuit.
c) Connect additional steam hose at Reflux loop
CRN System:
a) Connect additional steam hose at air fin cooler inlet 4E69A/B,, 4E70A/B and
Pump discharge.
b) Steam circuit from 4E-66B to air fin cooler inlet (back up steam from 4E69A/B)
c) Steam out 4E70A/B to stabilized Naphtha pumps
d) Steam out 4P-65A/B discharge loop to rundown
e) Steam out the PA recycle Naphtha, LCO/Naphtha quench to Reactor loops
f) Connect steam hose to bottoms to stabilizer. Steam the stabilizer feed loop.
4C-56 4E66 4E69A/B 4E70A/B 4P65A/B Rundown.
4P65A/B Primary absorber

Quench to Reactor
LPG System
a) Backup steam from 4V-57 to LPG rundown circuit and reflux circuit
b) Connect additional steam hose at Reflux loop. Steam reflux to column loop
c) Steam 4V-57 BPC to sweet fuel gas
4V-57 4P67A/B
4V-57 4P66A/B
4P-66A/B 4C-55
4P67A/B Rundown.
WGC Circuit
a) Isolate WGC and install blinds on Suction and discharge lines and provide
spreads for steaming purpose.
b) Back up steam from 4V-55, 4V-56 and 4V-53 and steam the circuits.
Primary Absorber Circuit
a) Open bottom SOP steam

b) Connect additional steam hose to PA bottom circuit and steam loop upto 4E64A/B

Plant Name: FCCU-I
c) Steam out compressor discharge to PA loop

d) Open column vents and RV bypass
4C-54 4P74A/B
4P74A/B 4E64A/B
4P65A/B Recycle Naphtha
Sponge Absorber Circuit
a) Open bottom SOP steam

b) Steam Lean sponge oil circuit
c) Steam out rich sponge oil circuit up to 4E-65 by connecting additional steam
hoses at 4E-65 inlet and outlet.
d) Steam fuel gas lineup to U/L
4C-57 4E65 A/B 4C-51

LCO rundown Lean sponge oil 4C-57
Stripper Circuit
a) Open stripper bottom SOP

b) Connect additional steam hose to stripper d/o control valve.
c) Steam out stabilizer feed circuit
d) Ensure stripper gas to 4E-64A/B inlet steamed.
e) Open column vent and RV bypass.
4C-55 4C-56
4V-56 4P62A/B 4C-55
4C-55 top gas 4E64A/B
Gas Plant
a) Connect steam hoses to 4V64 and 4V62

b) Steam out sweet fuel gas, sour fuel gas, Fuel gas to flare, Fuel gas from 4V-62
to 4V-64, 4V-62 & 4V-64 RV outlet to flare, Fuel gas to distribution and
internal distribution loops.
Flare Header

Plant Name: FCCU-I
a) Open RV bypasses of 4C-51, 4V-53, 4V-55, 4V-56, 4V-57, 4C-55, 4C-56, 4C-
57, 4V-64 & 4V-62
b) For thorough steaming of Flare header PC2407 bypass also can be opened.
c) Open vent on Flare KOD.
TABLE 20.1
General Outline For Normal Shutdown

Regenerator/Regen Reactor Fractionator
Light Ends
Overhead
1. Reduce feed and

switch to full burn
regeneration
operating mode.
2. Reduce air rates 2. Gradually remove 2. Divert products 2. Divert products to
while maintaining at feed, replace with to slop. Shut down stop. Shut down
least 2% excess emergency steam. pump around and product rundowns as
oxygen in flue gas. product rundowns pumps lose suction.
Maintain adequate as pumps lose Shut down the gas
grid pressure drop. suction compressor and
follow
depressurizing
procedures.
3. Unload catalyst to 3. Transfer catalyst to 3. Empty the
used Catalyst Regenerator for remaining liquid 3. Empty the
Hopper. unloading to the inventory from the remaining liquid
Used Catalyst fractionator, inventory from
Hopper. strippers and other towers and other
vessels vessels. Steam out
towers and other
4. Air-cool 4. Steam out vessels. Open
Regenerator. 4. Steam out Reactor fractionator, vessels.
strippers and other
vessels. 4. Steam out towers
and other vessels
5. Open Regenerator. 5. Open vessels.
5. Open Reactor.
5. Open vessels.
Plant Name: FCCU-I
TABLE 20.2
Procedure for Feed Out

Regenerator/Regen
Reactor Fractionator Light Ends
Overhead
1.Reduce Feed rate and
switch to a full burn
regeneration operating
mode. Refer to
procedures in section
No.7 covering the
change from partial to
full burn operation.
2.Decommission ES-1.
3. As heat input 3. As gas rate
3.Maintain at least 2% 3. Begin slowly to the Fractionators drops, check that gas
O2 in flue gas while reducing feed preheat decreases, adjust compressor starts to
reducing air. Slowly temperature and feed rate. pump around rates and recycle (holding
reduce the catalyst Control regenerator /or return temperatures fractionator pressure)
circulation rate as feed temperatures. As feed rate is to maintain
rate is reduced. reduced, cut out feed nozzles fractionators
Maintain 0.09 kg/cm2 and maintain 9.0 kg/cm2 (g)at temperature profile
(g) minimum grid DP. the nozzles. Do not let
reactor temperature fall
below 4700C. Allow pressure
to fall but keep Reactor
pressure about 0.21 kg/cm2
higher than regenerator 4. When gas
pressure. 4. Maintain compressor suction
4. When reactor feed fractionator products pressure falls,
rate reaches about 60% of on spec. as long as maintain fractionators
design begin to inject possible, then divert to overhead and shut
emergency steam to the feed slop. When down compressor.
riser at the rate of 450 kg/hr fractionator overhead Close suction and
for every 6.6m3/hr of feed gas rate starts discharge. Block
pulled. decreasing, begin valves and purge
adding fuel gas into compressor to flare.
the overhead. Follow compressor

Plant Name: FCCU-I
depressurizing
5. Allowing regenerator procedures.
temperature to fall to
about 5400C after feed 5. When reactor 5.Divert products to
is removed. Line up Air 5. When only one feed feed is diverted to the slop as they go off
preheater and fire to nozzle remains in service, fractionators, reduce spec. divert heat
maintain regenerator manually close feed block fresh feed as quickly as source from
temperature at 510-540 valve and divert flow to the possible in order to reboiler.
0
C with torch oil. fractionators. Increase maintain fractionator
emergency steam to bottoms level.
maximum and maintain Sufficient flow should
injector steam. Double block be maintained to
each feed nozzle. protect the tubes in the
feed preheat furnace.
Shutdown feed
preheater.
Procedures for Feed Out
Regenerator/Regen
Overhead
6. Continue catalyst 6. Continue 6. Shutdown the 6. Pump out the light
circulation for at least 30 stripping and pump around and ends section to slop to the
minutes after feed is out to feed injection side stream pumps maximum extent
eliminate hydrocarbon and steam flow to as they lose suction. possible. Shutdown
reduce carbon level on reactor side at Maintain the slurry pump as they lose
catalyst. normal rates. pump around over suction.
the sheds until the
catalyst is out of the
Reactor. Maintain
bottom level and a
small flow to slop.
7. As Regen flue gas is

directed to stack, reduce 7. As possible, remove
caustic addition in FGD and remaining hydrocarbon
maintain pH if NCO boiler liquid in towers and other
is there or maintain bottom vessels to closed disposal
system. De-pressure light
Plant Name: FCCU-I
circulation for 4 hrs before ends section to flare.

pumping out levels. Block cooling water to
all coolers and
condensers and open
vents. Steam lowers and
vessels to remove
residual hydrocarbon.
8. Check if towers are

hydrocarbon free and
water wash if necessary.
9. Open towers and allow

to cool.
Table 20.3
Procedure for Catalyst Unloading
Regenerator/Regen Light
Reactor Fractionator
Overhead Ends
1. Close the regenerated 1. Close the spent 1. Make sure no air is
catalyst slide valve. catalyst slide valve. leaking from the
Maintain Reactor Regenerator (slide valves
pressure above closed and catalyst seals in
Regenerator pressure transfer lines) and increase
(to transfer catalyst to fuel gas rate to the
the regenerator.) fractionator Overhead to
raise fractionator pressure if
necessary.
2. Lower Regenerator 2. Re-open the spent

pressure as necessary for catalyst slide v/v 2. Maintain a small
catalyst transfer from the transfer as much flow of gas oil from tankage
Reactor. At the same time, catalyst as possible to through the feed system to
reduce air to maintain the Regenerator. the Fractionator and then
approximately constant Inject blast steam to out to slop through the
superficial velocity. clear the J-bends. slurry system. Blow back
Plant Name: FCCU-I
pump around and side

stream lines to the
3. Stop torch oil 3. When the level in fractionator with steam.
Injection, blow nozzles clear the stripping section
and blind oil line. Fire Air approaches zero, close
Preheat to maintain the spent catalyst slide
Regenerator temperature at valve.
3700C minimum.
4. Withdraw catalyst
4. Line –up the Catalyst from the spent and
Conveying Jet Ejector to the regen catalyst J-bends
used catalyst Hopper and to used catalyst
commission as needed. When Hopper as soon as
the catalyst temperature is possible to avoid the
below 4250C, withdraw possibility of cool
catalyst from the Regenerator down and “ mud”
bed to the used Catalyst formation.
Hopper as rapidly as possible,
throttling with the lower valve
in the 6” shutdown unloading
line.
5. After all catalyst has 5. When all the catalyst has
5. When all catalyst has been unloaded been unloaded, stop the feed
been unloaded, reduce continue to steam pump and blow the feed
regenerator pressure and shut Reactor to lines to the fractionator,
down Air Preheater. Blind fractionators for 5-6 pump out the fractionator
pilot gas and fuel oil lines. hours. bottoms, then shut down the
pump(s). Blind all feed and
product lines.
Procedures for Catalyst Unloading
Regenerator/Regen
Overhead
6. Open reactor 6. Block cooling water to
overhead vent to the overhead condenser
atmosphere and and open vents. Block and
reduce steam rates to blind the fuel gas to the
permit installation of overhead. Steam all
Plant Name: FCCU-I
the blind on the vessels and lines to the

reactor overhead line. fractionator for 2 hours.
7. Check if vessels are

hydrocarbon free. When
free stop steam out and
introduce air. NOTE:
Coke deposits in the
fractionator may be
subject to auto-ignition
when exposed to air .It
may be necessary to water
wash the fractionator
before displacing steam
8. When the Regenerator 8. Continue to with air.
cools to Main Air Blower steam out to
discharge temperature, atmosphere for two
shutdown the blower hours.
9. Shut off steam and 9. Block off all

install blinds as required. steam supplies
9. Open towers and allow
10. Open vessel and allow 10. Shut off steam it to cool. 10. Install
it to cool. and install blinds as blinds as
required. 10. Install blinds as required
required.
11. Continue with vessel 11. Open vessel 11. Open
entry procedures. and allow it to cool. vessel and
allow it to
cool.
12. Continue with
vessel entry 12. Continue
procedures. 12. Continue with vessel with vessel
entry procedures. entry
procedures.

Plant Name: FCCU-I

Plant Name: FCCU-I
TEMPORARY OPERATIONS
CHAPTER 21
Temporary Operations
Below mentioned are the operations used sparingly and as necessary like startup, emergencies
etc. All these cases are very vital and of much help in FCCU operation.
i. APH light up, lighting pilot and lighting main fire (oil).
ii. Torch oil lighting up.
iii. Utilizing inactive RR aeration taps in pressure surveys.
iv. Regen grid fluffing.
v. CO routing to CO boiler in joy stick mode.
APH burning
Lightening of regen APH is often difficult and time consuming. Hence it is essential to follow
manufacturers recommended procedure for lighting APH. The typical operating procedure for
lighting APH with fuel gas is presented.
Following pre startup checks should be conducted for auxiliary burner.

1. Preparation of chart relating to auxiliary fuel and primary air flow, it required to
maintain 100% excess air. For operation of APH.
2. Percentage of excess primary air to be calculated on continuous basis.
3. Verify fuel gas and fuel blinds are installed.
4. Carryout PM checks of burner management system (BMS) and associated emergencies
shutdown systems.
5. Check flame out detector or prepare for use but do not commission.
6. Verify igniter operability.
7. Secondary air valve wide open.
8. Clear fuel and air line from scale and condensate.
9. Verify that lock and control valves to gas burner and pilot are closed.
10. Verify that the steam tracings of fuel gas line have been commissioned.
Plant Name: FCCU-I
11. Verify that MAB is running with above 25% of normal air rate through auxiliary burner
12. Establish air flow to auxiliary burner sight glasses.
Typical auxiliary burner firing procedure: Lighting up pilot.

1. Insert the spark igniter and lock into place.
2. Pull pilot gas blind and line up gas flow to burner. (Leave last v/v closed)
3. Set primary air v/v to achieve about 10% of total air flow.
4. Purge pilot gas line until gas comes out the bleed near APH.
5. Start / complete burner purge cycle (5 air changes of the combustion chamber volume
for not less than 5 minutes)
6. Use igniter start push button to start fuel gas flow and to supply power to igniter.
7. Verify that igniter is sparking and that pilot gas ignites.
8. If ignition does not occur :
a. Shut off pilot fuel supply.
b. Purge auxiliary burner for 5 minutes before retrying to ignite pilot gas.
c. Recheck igniter and verify that fuel gas is reaching pilot.
d. Adjust primary air as needed
9. Once pilot is lit, retract igniter to rare position and lock in place.
Typical auxiliary burner firing procedure: Lighting up Main Burner

1. Pull out blinding main oil line.
2. Purge main oil line until clear oil comes.
3. Ignite main burner following the APH vendor’ s recommended procedure.
a. If fuel gas does not ignite after 1 minute
i. Shut off fuel gas flow and allow air to purge APH for 5 minutes before
retrying to ignite main burner fuel gas.
ii. Open drain valves to remove any liquid from fuel system.
iii. Recheck the system.
iv. Try relighting main fuel gas, once BMS purge cycle has been completed.
4. Once main burner is lit, adjust fuel oil/air rates to get desired APH outlet temperature.
5. Adjust primary air/fuel ratio to maintain minimum 100% excess air in burner at all
times.
6. Commission flame detector to cut out fuel on loss of flame.

Plant Name: FCCU-I
APH operating guideline following light up:

1. Operator to be stationed at APH always to monitor flame and control burner firing.
a. If flame goes out and automatic flame sensor fails to act, then operator must
immediately shut off main and pilot fuel supply to APH.
2. Rate of increase in APH outlet temperature must be controlled to protect refractory
lining in the R-R and downstream equipment.
3. Primary air should not be set too high such that it can blow out flame.
a. However, minimum of 100% excess air must be maintained at all times to
prevent excessive temperature and damage to combustion zone.
b. Chart relating to fuel and primary air flows require to maintain 100% excess air
should be developed for operator guidance.
4. If primary air become limiting, throttle secondary air flow.
5. Maintain burner outlet temperature below maximum value of 595oC, to protect regen
grid.(Note down Regen grid skin thermocouples,4TI521 to 525)
i. If temperature approaches 595oC, fuel should be reduced.
6. Regen grid pressure drop should not exceed 0.35 kg/cm2.
a. May require reduction in secondary air rate, as auxiliary burner temperature
increases.
7. Heat up rate should be achieved by increasing fuel gas rate.
8. Flame sensing device should be available to cut off fuel on flame failure.
Torch oil light up during Catalyst loading
1. Caution should be exercised to inject torch oil in regenerator

a. If burning does not initiate in the bed, an explosive gaseous mixture can be
formed in vapor space above the bed.
b. Heat released by burning in dilute face may produce excessive temperatures and
exceed equipment design limitations.
2. VGO should be used for torch oil.

a. Oil vaporizes in bed and has good ignition characteristics.
b. Naphtha and cycle oils should not be used as they have poor ignition
characteristics.

Plant Name: FCCU-I
3. Torch oil should be injected into regen bed only if

a. Minimum Catalyst level of 1.5 meters above torch oil nozzles
b. Catalyst bed temperature is at a minimum of 370oC.
c. Nozzle atomization steam available and lined up.
4. During torch oil injection

a. Monitor regen bed thermocouples closely for indication of ignition
i. Ignition indicated by rapid increase in bed temperature.
ii. Temperature response observed first on thermocouples closest to torch
oil nozzles.
b. If ignition has not occurred after 1 minute
i. Cut out torch oil.
ii. Wait at least 15 minutes to purge regen.
iii. Raise bed temperature by 15oC by increasing APH firing
iv. Re-inject torch oil once again
v. Repeat the procedure until torch oil is ignited.
5. Suggested torch oil operations

a. Torch oil rate (bbl/hr) = air rate (kcfm/2)
b. Target flue gas oxygen to be about 1 to 1.5 %
c. Excessive torch oil
i. May simply vaporize causing unnecessary cooling of regen bed.
ii. Leads to eventual burning of excess torch oil in downstream equipment.
6. Torch oil should be cut out if at any time :

a. Bed temperature drops below 400oC OR
b. Bed level drops below 1.5 meters.

Plant Name: FCCU-I
Utilizing inactive aeration tap in pressure surveys

1. When catalyst circulation problems occur
a. Pressure survey on stand pipe is one of the most effective means of analyzing
operation.
b. Many standpipe aeration taps may be shut off, reflecting previous experience
that indicated they were not required.
i. Desirable to use as many pressure points (i.e. aeration taps) as possible,
to get more complete picture of standpipe
ii. However, opening a closed aeration tap can change pressure pattern
inside standpipe.
iii. Therefore, it is necessary to utilize taps without commissioning full
aeration flow in the standpipe.
2. Valve position prior to start up procedure.
a. Valve “ A” closed,
b. “ B” closed, and
c. “ C” closed,
Schematic of typical aeration piping

Plant Name: FCCU-I
3. Commissioning inactive aeration taps procedure.

a. Remove plug from valve “ B” and then open valve B to atmosphere.
b. Open valve C to bleed aeration at full restriction orifice capacity.
c. Throttle valve C until just a fraction of full aeration flow passes to atmosphere.
d. Close valve B and open valve A. (Small amount of aeration still flowing, should
be sufficient to keep tap open/clear of catalyst without effecting pressure pattern
in stand pipe)
e. Take pressure reading at re-commissioned pressure taps.
f. Once pressure reading is taken, return aeration taps to normal condition by
closing valves A and C. Install plug on B.
Regen Grid fluffing:
During MAB trip Regen bed gets de fluidized. Also emergency steam which cuts in during that
time is in sufficient to maintain bed uniformly fluidized and also to prevent catalyst from falling
below.
MAB air rerouting to regen may not re fluidize the bed uniformly. Two techniques are available
to re fluidize the bed.
1. Pressure / De-pressure technique (Fluffing)
2. Unloading the catalyst
Fluffing Operation:
Before starting the fluffing transfer maximum possible regen catalyst to Reactor.
Transfer catalyst till 4LI1X comes to around 8-10% and 4LI2X is around 50%.
Close slide valves and stop torch oil burning.
Maintain regen Pressure around 1.25 Kg/cm2, Regen dense bed above 650oC and
MAB air around 48 Knm3/hr.
Gradually increase regen pressure by closing DDSV till RR DP > 0.05kg/cm2 and
suddenly open DDSV and reduce regen pressure back to normal. Increase pressure
by 0.2 to 0.35 Kg/cm2. Repeat this exercise for 2-3 times.

Plant Name: FCCU-I
After completion of fluffing reestablish catalyst circulation. Once it has been assured that
Regen bed is properly fluidized, proceed for startup as per procedure.
If Regen bed is still de fluidized go for catalyst unloading and re loading to regen.
CO routing to CO boiler in joy stick mode:
Earlier CO is diverted to NCO boiler from DCS directly. It has been reported that after
commissioning of FGD-I, CO routing to NCO boiler from DCS is causing back pressure in
NCO boiler furnace. Hence to avoid furnace pressure build up in NCO boiler CO is being
routed gradually in joystick mode.
The steps followed are given below:
i. Take clearance from PP II & RSM.

ii. Start 2nd Hydraulic oil pump also.
iii. Press the “ CO boiler reset” knob (MHS501H) at DCS.
iv. Turn the hardware switch (at east of “ 4P51B stop “ knob) to CO- boiler mode at
DCS.
v. Confirm with CO boiler personnel that the goggle v/v has opened. See that on RR
graphics page “ Flue gas indication block” becomes green color with” CO to CO
boiler” caption at DCS.
vi. Take TPSV in joy stick mode in field.
vii. After informing NCO boiler personnel open TPSV towards CO boiler side in 5% -
5% steps till it gets full open in coordination with NCO and DCS in field.
viii. Once TPSV gets 100% open towards CO boiler side and CO boiler stabilizes then
Press the reset knob “ TPSV reset to CO boiler” ( at west of CAB low low trip
switch) at DCS.
ix. Finally put back TPSV in remote mode.
x. Stop the 2nd Hydraulic oil pump.
Note: As FGD I inlet SDV is in full open condition and HGV (co boiler o/l to stack) is stuck
at 10% open towards stack ,it’ s to be ensured that FGD circulations and caustic flow
establishing are to be in service before routing CO to NCO boiler.

Plant Name: FCCU-I
Diverting CO to stack:
i. Take clearance from PP II & RSM.

ii. Turn the hardware switch (at east of “ 4P51B stop “ knob) to “ Stack” mode at DCS.
Confirm in field.
Note: After taking out CO from NCO boiler FGD circulation to be continued for 4hrs (min.) to
purge catalyst.

Plant Name: FCCU-I
PROCESS SAFETY INFORMATION
CHAPTER 22
PSM/FR/2.5: INFORMATION ON PLANT HOLDUPS:

Plant Name: FCCU-I
PSM/FR/2.7: Information of Plant Relief System

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I
Standing Instructions on Operating Philosophy of Pressure Safety Valves (SI40):
1. OBJECTIVE:
1.1. To ensure that PSV’ s are lined up according to the philosophy specified in P&ID’ s as per
PSM/FR/2.7 and OISD-Standard-106 on Pressure Relief and Disposal system.
1.2. To install locks or car seals on the inlet and outlet isolation valves of PSV’ s according to the
scheme specified in P&ID’ s as per PSM/FR/2.7
2. BACKGROUND:
2.1. The pressure safety valve (PSV) is an automatic pressure-relieving device actuated by the static
pressure on upstream of the valve.
2.2. The pressure safety valve (PSV) is a type of valve used to limit the pressure in a system or
vessel which can build up by a process upset, instrument or equipment failure or fire.
2.3. Multiple relief valves are required for hydrocarbon processing services, if the total relieving
capacity required cannot be provided in a single valve. In FCCU-I Atmos column 4 PSV’ s
were provided, one being spare.
2.4. Spare PSV’ s are often installed to facilitate testing and maintenance of one safety valve while
the other is online.
2.5. Spare PSV’ s are also meant for use in case of any problem with PSV in service, like PSV in
service does not reset after popping or PSV passing problem.
2.6. Inadvertent isolation of a PSV will defeat its purpose, therefore periodic checks to be carried
out to ensure that the lined up PSVs are as per PSM/ FR /2.7.
2.7. Upstream and downstream isolation valves of PSV in service to be locked (car seal) in open
position to prevent inadvertent closure.
3. NEED FOR RELIEVING SYSTEM

The relieving of pressure from a process system arises from a number of reasons as below:
3.1. This is required so that a system is not allowed to pressurize beyond its maximum allowable
working pressure, in order to avoid possible failure of the weakest part of the system.
3.2. For precautionary relieving of pressure from the system called as depressurization. This is
applicable for high pressure and or high inventory systems which need to be depressurized
during an emergency.
3.3. In the case of a fire, the maximum allowable yield stress of the metal reduces significantly due
to increased temperature. Relieving pressure under these situations allows the actual stresses
to be reduced below the lowered maximum allowable stresses thereby preventing failure.
Plant Name: FCCU-I
3.4. To take care of thermal expansions when a pipeline or equipment containing a liquid is blocked
in and subsequently heated.
4. STANDING INSTRUCTIONS:
4.1. The PSV’ s to be lined up as specified in PSM/FR/2.7 (Annexure-1 &2) there should not be any
deviation with PSM/FR/2.7 specifications.
4.2. Locks or Car seals to be fixed on the PSV inlet and outlet valves as specified in P&ID’ s as per
PSM/FR/2.7.
4.3. P&ID definitions for PSV’ s :
a. LO : Lock open (This indicates lock or car seal to be fixed to the respective block valve in
open position as indicated in P&ID to avoid inadvertent isolation of PSV)
b. LC : Lock close (This indicated lock or car seal to be fixed to the respective block valve in
close position as indicated in P&ID to keep the PSV as stand by )
4.4. For PSV’ s in Service Upstream and downstream isolation valves are to be car sealed in open
position to prevent such inadvertent closure.
4.5. For Stand by PSV’ s Outlet valves are to be car sealed in open position and inlet valve to be car
sealed in closed position.
4.6. If any problem arises with PSV in service then car seals can be broken, stand by PSV to be
taken in to service and the PSV having problem to be isolated and the same to be communicated
to Shift In charge, unit manager & chief manager immediately and to be entered in car seal
register and in FIELD/DCS TOB.
4.7. Periodic checks to be carried out for status checking of PSV’ s in service/stand by and PSV
register to be updated regularly.
In case of any PSV to be released for maintenance activity then prior approval to be taken from
unit manager & chief manger and after approval, online work requisition for safety valves
(WRSV) to be raised

Plant Name: FCCU-I
SAMPLING REQUIREMENT AND PROCEDURE
CHAPTER 23
SAMPLING REQUIREMENT&PROCEDURE
OBJECTIVE
To ensure standardized and systematic procedure for product sampling and testing to
optimize the plant operation and elimination of off-specification product generation.
To create awareness in the plant operating personnel about the various product quality
specifications and their functional importance.
To ensure products are produced as per laid out specifications
To make any corrections in case of any abnormalities.
To analyze a particular feed/ situation which demand our attention.
SAMPLE COLLECTION
All regular samples should be collected as per the LAB sampling schedule in cleaned
bottles/ grabbers with the required quantities (normally 1000 ml).
These samples should be tagged correctly writing the origin of the sample, name of the
stream, tests to be performed and date / time.
The tagged bottles should be kept at the designated place 15 minutes ahead of sampling
schedule.
In case, sample is not collected in time due to any problem, the technician concerned should
highlight to supervisor.
The Plant Technician, during routine rounds, should observe that the samples are taken by
Laboratory and inform shift supervisor and Laboratory if samples are not collected in time.
If sample collection is further delayed then shift supervisor should remind laboratory once
again and inform shift Forman.
The overall responsibility of ensuring availability of the sample at the collection point rests
with unit shift supervisor.
Shift supervisor should ensure that sufficient number of cleaned bottles/grabber and sample
tags are available in the unit for sample collection.
Normally, the quantity required for the regular sample is 1000 ml, if any special sample
requires specific quantity then shift supervisor should inform technician quantity required
to be collected.

Plant Name: FCCU-I
COLLECTION PROCEDURE
The samples are to be collected in clean and dry bottles.
The line content is to be drained to ensure representative sample is collected. Bottles are to
be thoroughly rinsed with the product before sample collection.
The products, those which are prone to oxidation in contact with air, are to be filled to the
top of the bottle. The bottle is to be properly sealed with a cap.
Wastage of product during sample collection is to be minimized. After collection of sample,
ensure that sample points are tight shut and oil is not dripping.
Heavy oil sample points are to be cutter / steam flushed after sample collection, to avoid
plugging of sample point.
Tags are to be tied to the respective bottles indicating the sample and the tests to be carried
out.
Sample Collection Procedure
CRN
1. Open the sample collection valve.

2. The line content is to be drained to ensure representative sample is collected.
3. Bottles are to be thoroughly rinsed with the product before sample collection.
4. Collect the full bottle of naphtha.
5. Close the sample point valve.
6. Tag is to be tied to the bottle indicating the sample and the tests to be carried out.
Precautions:
1. Use PPE (Safety shoes, safety goggles, safety helmet, safety hand gloves).
2. The sample is to be collected in clean and dry bottles.
3. After collection of sample, ensure that sample points are tight shut and oil is not
dripping.
4. Wastage of product during sample collection is to be minimized.
5. Proper care should be taken to avoid the breakage of sample collection glass bottle.
LPG sample for H2S and weathering
1. Vent the sample point line content to flare.

2. Connect the sample collection bomb and purge it with LPG to flare.
3. Collect the sample and close the sample valve.
Plant Name: FCCU-I
4. Disconnect the bomb and vent the sample line content to flare.
Precautions:
2. Ensure the bomb is properly connected so that there is no leakage of LPG to
atmosphere.
3. Care should be taken in handling LPG to avoid cold burns.
Regen Flue gas sample
1. Close the blow back air valve.

2. Crack open the sample point valve and vent the line content.
3. Purge the gas bladder with flue gas and collect the sample.
4. Close the sample point valve and open the blow back air valve.
5. Observe PG on the sample point.
6. On a tag write the tests to be carried out along with the date and time and sent to lab.
Precautions:
1. Use PPE(Safety shoes, safety goggles, safety gloves, Helmet, mask)
2. Observe the wind direction while collecting the sample to avoid ingestion.
3. Proper care should be taken to avoid ingress of air into the sample bladder.
4. Care should be taken while collecting sample near the hot surfaces.
5. Ensure that the bladder is not damaged
6. Optimum sample to be collected to avoid damage of the bladder.
Regen/Spent cat samples for cat carbon
1. Keep the grabber in the sample point.

2. Throttle Sample point shell valve
3. Close the aeration steam valve.
4. Catalyst will be collected in the grabber.
5. Once sufficient quantity of sample is collected, close the shell valve.
6. Open sample point aeration steam and then commission shell valve.
7. Observe aeration point pressure.
Plant Name: FCCU-I
8. Collect the grabber. Care should be taken that no skin comes in contact with the
withdrawn sample as it will be very hot.
9. Allow the sample to cool, and then transfer it to a bottle.
Precautions
2. The sample is to be collected using a grabber with a long handle.
3. Care should be taken in collecting the sample as the sample will be at very high
temperature.
4. Observe wind direction.
Slurry Sample
1. Sample is to be collected in a grabber.

2. Open the sample collection valve.
3. The line content is to be drained to ensure representative sample is collected.
4. Grabber is to be thoroughly rinsed with the product before sample collection.
5. Collect the slurry sample in the grabber.
6. Close the sample point valve and flush the line with LP steam (Provision exists).
7. Tag is to be tied to the bottle indicating the sample and the tests to be carried out.
Precautions:
2. The sample is to be collected in a grabber.
3. After collection of sample, ensure that sample points are tight shut and oil is not
dripping.
4. Wastage of product during sample collection is to be minimized.
5. As sample is very hot, be cautious in handling it.
Cat sample for ABD
1. Keep the hopper from which sample has to be collected in agitation mode for thirty
minutes.
Plant Name: FCCU-I
2. Stop agitation and close sample point purging air.

3. Collect the sample from the sample point.
4. Purge sample point with purging air
5. Tag is to be tied to the bottle indicating the sample, date and time and the test to be
carried out.
Precautions
1. Use PPE(Safety shoes, safety goggles, safety gloves, Helmet, mask)
2. Observe the wind direction while collecting the sample to avoid ingestion.
3. Care should be taken while collecting sample.

Plant Name: FCCU-I

Plant Name: FCCU-I
PLANT CHEMICALS AND CATALYST
CHAPTER 24
PLANT CHEMICALS AND CATALYSTS
Plant Chemicals
24.1 Withdrawal management
24.2 Maximum storage allowable in the plant
24.3 Storage precautions
24.4 Loading procedures
24.5 Empty container disposal
24.6 Handling Precautions
24.7 Description of chemical dosing system.
24.1 NORMAL CATALYST WITHDRAWAL SYSTEM
The normal catalyst withdrawal system is provided for catalyst inventory quality control during
various modes of operation. The basic objective of the system is to withdraw equilibrium
catalyst from the Regenerator in a timely and controlled manner. This system is usually
manually operated in a “ batch” mode. However, when processing resid feeds, catalyst
withdrawal rates will be relatively high and the system may need to operate as a “ continuous”
withdrawal.
The withdrawal system consists of a special withdrawal nozzle from the Regenerator which
has a thermal sleeve, a wire basket “ Johnson” screen, a capillary withdrawal “ choke” tube, and
catalyst transport piping to the Used Catalyst Hopper.
Before commissioning the normal catalyst withdrawal system conditions should be as follows:
1. All required instrumentation operational.
2. The Used Catalyst Hopper is depressurized.
3. The withdrawal nozzle purge is proved clear. Any condensation has been drained from the
withdrawal nozzle via the purge tap.
4. Air purge connections for withdrawal nozzle gate valves are lined up and ready for use.
To commission the catalyst withdrawal system:

Plant Name: FCCU-I
1. Commission carrier / transport air to the withdrawal line. The withdrawal nozzle purge,
located at the bottom of the Johnson screen assembly, must also be in service. The
withdrawal nozzle purge flow rate is set by an RO. Note that the purge flow to the inlet of
the Johnson screen assembly should always be in service to keep it clear of catalysts and
debris.
2. Both of the four-inch gate valves, between the Regenerator and the choke are fully opened
to establish catalyst flow. DO NOT THROTTLE either of these valves, as this will greatly
diminish valve life. First gradually open the outer gate valve fully and then open the inner
gate valve.
3. Flow of catalyst to the Used Catalyst Hopper is regulated by instrument air flow through
the local variable area flow meter/controller FI-522, which adjusts the rate of withdrawal
control air rate through FI-522 will increase the DP across the choke tube, resulting in a
reduction in the flow of catalyst to the Used Catalyst Hopper. Control the catalyst
withdrawal to the desired rate and temperature by adjusting the rate of instrument air
through FI-522. If desired, some additional control of catalyst withdrawal rate can be
obtained by adjusting the pressure of the Used Catalyst Hopper (that is adjusting the
backpressure on the withdrawal system). However, normally this is not necessary.
4. Withdrawal control air also cools the withdrawal stream to stay within the design
temperature of the downstream piping and Used Catalyst Hopper. The minimum air rate(FI-
522), or the maximum catalyst withdrawal rate, is limited by the downstream piping design
temperature of 5930 C. Local TI-540 is provided to allow the operator to monitor the
temperature while manually setting FI-522. After the system is manually commissioned in
the field, the board operator can monitor the catalyst/air mix temperature via TI-529. TAH-
530 alarms if the temperature exceeds the allowable limit. Note that the catalyst transfer
line to the Used Catalyst Hopper is finned to allow for addition cooling. The Used Catalyst
Hopper has a design temperature of 4270 C which must not be exceeded. TI-534 allows
monitoring of the temperature at the inlet to the hopper and an associated panel mounted
high temperature alarm will warn if the temperature exceeds 4150 C. If necessary the
withdrawal rate will have to be adjusted to keep the hopper temperature below the limit.
Monitor the regenerator and reactor stripper inventory levels. When sufficient catalyst has been
withdrawn from the unit, the system is decommissioned as follows:
1. When the withdrawal is complete, the four-inch gate valves are blocked in using valve as
purge connections as required to obtain a tight shut off. First close the outer block valve

Plant Name: FCCU-I
and then the inner block valve. Use the temporary valve air purge connections as required
to obtain a tight shutoff.
2. Allow the line to the hopper to be purged clear of catalyst for several minutes. Then
shutoff instrument air flow via FI-522, but not the purge air. Then maintain the
carrier/transport air to keep the line to the hopper clear. Alternatively, the carrier /
transport air can be shut off.
The following summarizes the maintenance requirements for the normal catalyst withdrawal
system which should be carried out on a regular basis:
1. Periodically dismantle the section of the withdrawal system that contains the Johnson
screen and clear it of accumulated refractory and other debris. At the same time,
check and clear the Johnson screen of accumulated material.
2. Check and clear the inlet hole in the refractory packed choke tube.
3. When indications are that the refractory hole is excessively enlarged due to erosion,
remove and replace this section of the line with a pre-fabricated spare. An indication
of choke tube erosion is progressively increasing catalyst withdrawal rates at the same
system conditions.
24.1.1 CATALYST HOPPER GAUGING
The catalyst hoppers should be gauged periodically to calculate regenerator losses by weight
balance. They are also gauged before and after any non-routine transfer either between hoppers,
any transfer to/from the unit at startup or shutdown or any transfer to/ from a catalyst supplier
or customer. Gauging is done through a 6 inch gauge hatch located on the top head of each
catalyst hopper. The hopper must be fully depressured before opening the gauge hatch.
Temporarily shut off cone aeration and relieve hopper pressure to atmosphere. A local pressure
gauge should be installed to check for zero pressure after the vent valve to atmosphere has been
fully opened. After depressuring, allow the catalyst inventory to settle for 30 minutes before
gauging. The catalyst inventory must be allowed to cool before gauging.
When gauging the Fresh Catalyst Hopper, the fresh catalyst addition system must be shutdown.
The gauging equipment, which normally consists of a flat-bottomed cup and a retractable
measuring tape, should be conductive (metal) and conductively bonded to the hopper before
insertion through the gauge hatch. This is to prevent potential static charge ignition of particles

Plant Name: FCCU-I
suspended above the normal inventory level. Personal protective equipment should be used to
protect the operator when gauging a hopper that could possibly contain hot catalyst.
Gauge the outage of the hopper against a common reference mark on the hopper. Available
inventory should be calculated using normal average bulk density for fresh and spent catalyst.
Be sure to subtract the normal “ loss on ignition” percentage for fresh catalyst when calculating
inventory available for the unit.
24.1.2 CATALYST LOADING / UNLOADING TO / FROM THE UNIT
Catalyst is unloaded from the Regenerator to the Used Catalyst Hopper through a 6” nozzle
located above the grid and a 3” nozzle below the grid. The transfer lines are unloaded using 3”
connections from the bottom of the spent and regenerated catalyst J-bends. The Reactor is
unloaded by transferring catalyst to the Regenerator and via the connection from the spent
catalyst J-bend, The normal procedure to unload the unit is to depressured or evacuate the Used
Catalyst Hopper and, when regenerator bed temperature is below 4250 C, unload to the hopper.
Transport air for unloading is provided by a 4” line from the plant air system.
Before unloading the unit, check for a high CRC that could ignite in the Used Catalyst Hopper.
TI-534 and its associated high temperature alarm at the inlet to the Used Catalyst Hopper
should be monitored for any combustion. If combustion is detected, stop the unloading
transport air and any aeration air being supplied to the hopper. Blow the unloading line back
into the Regenerator. Catalyst in the Used Catalyst Hopper can be slowly cooled using aeration
air to the bottom cone after unloading from the Regenerator has stopped and the line is blown
clear. Resume unit unloading after cooling both the regenerator bed and the hopper inventory.
24.1.3 To load the normal unit inventory at start-up, pressure the Used Catalyst Hopper and
use the 4” connection to the 6” start-up/emergency catalyst addition line. Control the catalyst
loading rate via the hand operated control valve in the 4” line from the hopper. During startup
loading either plant air or control air can be used as the source of transport air.
Chemicals / Additive Withdrawal Management (From Ware house):

The monthly chemical requirement for FCCU-I for various chemicals/ additives is shown
below. An inventory corresponding to 30 days chemical consumption (buffer stock) is to be
always maintained in the field at any point of time. The details are as follows:

Plant Name: FCCU-I
Sr. Generic Name Approved Considered quantity for 30 days

No. Chemical Name withdrawal from Stores inventory
every month needs to be
maintained at
Kg/ Month No. of drums
field (Kg)
(approx.)
approx.
1 Ni passivator Betz 75-U-00, EC 540 3 540

9000A, BPR44620
2 Corrosion Philm-plus, 210 2 210
Inhibitor NALCO 5186
3 Neutralizer Morpholine Minimum stock of 600 lit to be maintained.
4 Diesel EC 5305A, To be added only when LCO is routed to sweet
antioxidant EC5329, EC 5300, diesel.
Thermosol B, Dorf
5091, FGDU-1012
5 DeSOx additive DeSOx additive 3300 4 bags 3300
6 GSR additive GSR additive 10500 12 bags 10500
7 ZSM-5 additive ZSM-5 additive 2100 11 drums 2100
8 CO promoter COP 20 ~ 30 1 drum 100

Plant Name: FCCU-I
24.1.4 CONTINUOUS FRESH CATALYST ADDITION SYSTEM
(KCAU-KETJEN CATALYST ADDITION UNIT)
A Continuous Fresh Catalyst Addition system has been provided for the Fresh Catalyst Hopper.
The system consists of a blow pot and all of the valves and control devices needed to provide
continuous addition of catalyst. The basic objective of the system is to continuously add fresh
catalyst to the Regenerator in a timely and controlled manner.
A catalyst addition cycle consists of the following steps:
1. Load a batch weight of catalyst from the Fresh Catalyst Hopper to the catalyst addition
blow pot.
2. Pressure the catalyst addition blow pot with air.
3. Open the catalyst addition blow pot back to the fresh catalyst addition line, emptying the
blow pot to the Regenerator.
4. Vent the catalyst addition blow pot back to the Fresh Catalyst Hopper.
Fresh catalyst additions are controlled by adjusting the frequency of the catalyst addition cycle
and by changing the batch weight added to the blow pot during each cycle. The required fresh
catalyst addition rate, in metric tons per day is entered by the Operator at the control house
panel. The fresh catalyst addition rate controller will automatically adjust the injection of
catalyst to meet its daily addition rate set point over the course of the day. At the blow pot
addition system local panel, the Operator can switch the system from remote to a local mode
of operation and set either the catalyst batch weight or the cycle frequency or both.
Normal fresh catalyst addition is through the 11/2” normal catalyst addition line to the
regenerator vessel. As a backup, fresh catalyst directly from the bottom of the hopper can be
routed to the regenerator vessel using the connection to the normal catalyst addition line. A
sight glass and hand operated control valve are available to monitor and control addition via
this route. It is also possible to add fresh catalyst via the 4” connection to the startup/emergency
catalyst addition line. A hand operated control valve is used to adjust the addition rate via this
route. However, since this route can add catalyst at a high rate its use is discouraged due to the
possibility of upsetting unit operation.
Spent catalyst can be added to the Regenerator on at “ emergency” basis through the 4”
connection to the 6” startup/emergency catalyst addition. Catalyst can be added at a high rate
through this connection.

Plant Name: FCCU-I
24.4.1.1 KCAU CYCLES PRINCIPAL OF OPERATION
DESCRIPTION OF THE UNITS CYCLE
After each start, the KCAU will execute a number of actions defined as ‘the cycle’ . The cycle
is devised in a number of stages that are described below. Value steering diagram shown in the
Fig 9.1
(A) FILLING STAGE
After the start signal has been send from the PLC or DCS (Automatic Mode), or the text display
(Manual Mode), the Fill (Al) and subsequently the isolation (A3) valves are opened to start the
filling stage. The catalyst will flow through the air slide (CP5) through the Fill valve and the
isolation valve into the vessel. At the time the Fill valve is opened, a small amount of air is
injected into the air slide, which will activate the flow of catalyst into the air slide.
It is of vital importance that the flow of catalyst is controlled accurate, to ensure the
performance and capacity of the KCAU. The maximum catalyst flow rate through the air slide
is 1 kg/sec. The maximum capacity of the unit (obtained with a minimum of cycle time) is
based on the flow rate of 1kg/sec. Several provisions have been made to the air slide to the inlet
of the air slide. This flow restriction can be removed and or replaced by a restriction with
smaller or larger diameter if necessary.
During filling, the air evacuated from the vessel is vented back to the hopper through the vent
valve (A6).
When the amount of catalyst in the vessel equals the pre-set desired weight the filling will be
stopped. First the Fill valve will close, followed by the isolation valve. The time period between
closing of these two valves is used to make sure that all catalyst that has passed the Fill valve
has flown into the vessel. Since the catalyst will flow into the vessel with a certain velocity,
there is a weight stabilize time build in into the PLC program. After the weight stabilize time
has passed, the ‘read catalyst weight’ contact will be send from the PLC to the Control System.
This ‘read’ contact will be the signal that the filled weight is stabilized and that fills amount
will be transported to the regenerator. This weight will be used by the main control system to
administer the total amount of catalyst. The same signal will be used by the PLC to calculate
the weight correction on the next batch.
(B) ACTIVATE STAGE

Plant Name: FCCU-I
After the filling stage has been finalized, and the desired amount of catalyst is loaded into the
vessel, all valves will be closed. The Activate valve (A7) will open after the weight stabilize
time has expired and the vessel and its contents will be pressurized. During the Activate stage,
the pressure in the vessel will rise from 0 to app. 5 bar. The Activated air will flow through the
porous bronze plate (PP) mounted in the bottom compartment of the vessel. The porous plate
will prevent catalyst to flow into the activate line, and will ensure a maximum fluidization of
the catalyst in the vessel.
(C) DISCHARGE STAGE
The pressure in the vessel rises until the ‘Discharge start vessel pressure’ is reached. When this
pressure is reached, the Discharge valve (A4) will open. Due to over-pressure in the vessel, the
air and catalyst will flow into the discharge line to the regenerator. To make sure that the vessel
is emptied completely, the
Purge valve (A5) is also opened during discharging. The Activate valve remains in open
position during discharging.
When the pressure in the vessel has dropped to the pre-set ‘Discharge end vessel pressure’ , the
Discharge, Purge and Activate valves will be closed. The “ Discharge end vessel pressure” has
to be set to a value that is 0.2 bar over the regenerator back pressure. This prevents catalyst to
flow back to the catalyst hopper. After the Discharge, Purge and Activate valves have been
closed, the Vent valve is opened, the pressure in the vessel will drop from ‘Discharge end vessel
pressure’ to atmospheric pressure.
(D) STANDSTILL STAGE
The unit remains in this condition until a next start signal is given. In Standstill position, the
Vent and Continuous purge valves are opened. All other valves are closed.
The continuous purge will ensure that no catalyst can flow back from the regenerator to the
KCAU. Using the manual valve A12 the amount of air blown through the continuous purge
valve into the discharge line to the regenerator can be regulated.
Transport air for the startup/emergency catalyst addition line can be taken from either the; plant
air system or the Control Air Blower. However, control air should not be used if the unit is in
normal operation in order to guard against upsetting catalyst circulation if too much control air
is diverted for catalyst transport.

Plant Name: FCCU-I

Plant Name: FCCU-I
24.4.2 CO COMBUSTION PROMOTOR ADDITION
CO combustion promoter is added through an addition pot is pressured into the normal fresh
catalyst addition line.
Purge the addition pot and associate piping with plant air through the bottom of the
pot to the connection with the normal catalyst addition line. Check that the addition pot
outlet line is clear by checking the PI on the pot. The pressure should be close to the
Regenerator pressure if the line is clear.
Close the valve (with provision for temporary air purge) below the addition pot and
then close the valve in the plant air line to the pot.
Vent the addition pot to atmosphere via the 1” vent line. Check the pressure gauge
below the 3” addition pot loading valve to confirm that the pot is fully depressured.
Remove the rain cover and slowly open the 3” addition pot loading valve, Care should
be exercised in the event that the pot has not been completely depressured. Close the
valve in the 1” vent line.
Load a charge of CO combustion promoter into the addition pot and close the loading
valve.
Pressure the addition pot using the plant air connection. Leave the plant air connection
open.
Check that the valve (with the provision for temporary air purge) closest to the normal
catalyst addition line is open. Open the valve below the addition pot, depressuring the
contents into the fresh catalyst addition line. Confirm the CO Promoter enters the fresh
catalyst addition line using the sight glass below the purged outlet valve.
Repeat this procedure until the required amount of CO combustion promoter has been
charged to the unit.
After ensuring that the addition system has been blown clear, shut the valves
downstream of the addition pot and also the plant air supply line. Vent the lines above
and below the addition pot. Leave the addition pot depressured but not open to the
atmosphere.

Plant Name: FCCU-I
24.4.5 DESOX ADDITION SYSTEM
The system consists of

1. A storage vessel for the additive.
2. Piping and equipment to load to the additive storage vessel.
3. An addition valve which meters material to the FCC unit.
4. Load cells for monitoring of the weight of additive in the vessel.
5. An Intelligent Electronic Timer (IET) Controller.
6. All control changes such as stopping and starting additions, or changing
The daily addition rate are made from the IET Controller which displays
The weight of material in the storage vessel.
The daily addition set point.
The weight of material added so far in the 24 hour period.
The time of day.
If Combined feed ‘S’ is < 1.1 wt%, DESOX addition rate is 42Kgs/day. If Combined feed ‘S’ is >
1.1 wt%, DESOX addition rate is 100 Kegs/day.
24.5 SAFE DISPOSAL OF EMPTY CONTAINERS OF HAZARDOUS CHEMICALS

Safe disposal of empty containers of hazardous chemicals should be done based on guidelines
given by the manufacturers.
24.5.1 SAFE DISPOSAL OF STOCK OF EXPIRED HAZARDOUS CHEMICALS

Safe disposal of hazardous chemicals, whose shelf life has expired, should be done based on
guidelines given by manufacturer. As a precaution First-in & First-out practice should be
adopted to ensure consumption of chemicals before reaching their expiry date.
24.6 HAZARDOUS CHEMICALS HANDLED IN OIL AND GAS INDUSTRY

This section includes safety data sheets of most of the hazardous chemicals being used in
Petroleum Industry. The data provided are compiled from various data sources as given in
Reference.
For MSDS of individual chemicals and their handling precautions refer to chapter 25,
Occupational safety and health
Further procedures followed in the refinery can be seen at ADM/OPRN / HOD/ GDL / 005
Rev0

Plant Name: FCCU-I
24.7 Chemical Dosing System
For details about the chemistry and mechanism of these chemicals, refer chapter 4
The details about the addition system are as mentioned below.
24.7.1 KONTOL ADDITION SYSTEM
The Kontol addition system is shown in the sketch. The Kontol addition pot is provided with
provision for diluting with Naphtha. The dilution ratio is for every 1 part of Kontol, 3 parts of
Naphtha is added. Kontol addition rate is 9Kgs/day presently. Three pumps 04GM35A/B/C are
provided to pump the Kontol solution. During S/D, Neutralizer chemical is injected using the same
pot and pumps to Main column top to prevent corrosion of main column overhead system by
maintaining the pH of the system.
24.7.2 Ni Passivator ADDITION SYSTEM
The Ni Passivator addition system provided is shown in the sketch .Present addition rate is 13
Kg/day and it varies on TSD advice. Two pumps 04PM40A/B are provided for pumping the Ni
passivator solution to feed. Ni passivator is added to the feed at upstream of Total feed control
valve just before entering to reactor riser. The line is flushed with cutter for one hour after
completion of Ni passivator dosing to prevent plugging of lines.
The details of Ni passivation and the effect of metals is dealt in chapter 4.
A brief schematic of KONTOL and Ni passivator system is given below.

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I
OCCUPATIONAL SAFETY AND HEALTH
CHAPTER 25
The HPCL' s Safety Health and Environment or Loss Control Management demonstrates a
visible commitment to protect the people, property, process, and environment. As same as
many world class petroleum companies, HPCL is implementing the International Safety Rating
System which is the best management tool available today to objectively evaluate and quantify
HPCL Visakh refinery' s efforts in safety and health programs. The following pages gives
detailed information on Chemical Hazards associated with various chemicals used in FCCU-I
along with probable obnoxious gaseous emissions along with the various first aid procedures
and chemical handling procedures. This section also covers the information relating to HPCL-
VR standard for Minimum PPE usage, their type and usage as laid down by the Safe Work
practices brought out by F&S wing of HPCL, VR, various firefighting system & equipment
and spillage handling procedures.
Material Safety Data Sheet of various chemicals along with first aid procedures
Material Safety Data Sheet
Chemical product Carbon Dioxide
STEL: 54000 mg/m3 15 minute(s). Form: All forms
STEL: 30000 ppm 15 minute(s). Form: All forms
TWA: 9000 mg/m 3 8 hour(s). Form: All forms
TWA: 5000 ppm 8 hour(s). Form: All forms
NIOSH REL (United States, 6/2001).
STEL: 54000 mg/m3 15 minute(s). Form: All forms
STEL: 30000 ppm 15 minute(s). Form: All forms
TWA: 9000 mg/m 3 10 hour(s). Form: All forms
TWA: 5000 ppm 10 hour(s). Form: All forms
Physical state Gas
Hazards identification
Routes of entry Inhalation, Dermal, Eyes
Potential acute health effects

Eyes Moderately irritating to the eyes.
Skin Moderately irritating to the skin.
Inhalation Moderately irritating to the respiratory system.
Ingestion Ingestion is not a normal route of exposure for gases

Plant Name: FCCU-I
Potential chronic health effects

CARCINOGENIC EFFECTS: Not available.
MUTAGENIC EFFECTS: Not available.
TERATOGENIC EFFECTS: Not available.
First aid measures
Eye contact In case of contact, immediately flush eyes with plenty of water for at least 15
minutes. Get medical attention immediately.
Skin contact In case of contact, immediately flush skin with plenty of water. Remove
contaminated clothing and shoes. Wash clothing before reuse. Thoroughly clean shoes before
reuse. Get medical attention.
Inhalation If inhaled, remove to fresh air. If not breathing, give artificial respiration. If
breathing is difficult, give oxygen. Get medical attention.
Ingestion Do NOT induce vomiting unless directed to do so by medical personnel. Never

give anything by mouth to an unconscious person. Get medical attention if symptoms appear.
No action shall be taken involving any personal risk or without suitable training. If fumes are
still suspected to be present, the rescuer should wear an appropriate mask or a self-contained
breathing apparatus. It may be dangerous to the person providing aid to give mouth-to-mouth
resuscitation.
Frostbite: Try to warm up the frozen tissues and seek medical attention. Use an extinguishing
agent suitable for surrounding fires.
Carbon monoxide is a deadly human poison primarily through inhalation. Skin or eye contact
with the liquid also presents some exposure risk (frostbite and burns) but absorption is not
likely since carbon monoxide is normally a gas. There are no reports of carcinogenic episodes
in humans or animals. It is an experimental teratogen and has the ability to cross the placenta
barrier. Inhalation of carbon monoxide gas will cause progressive chemical asphyxia with
symptoms of rapid, irregular breathing (tachypnea), feeling of air starvation or “ air hunger,”
headache, fatigue, mental confusion, nausea, vomiting, giddiness, poor judgment, weakness,
hallucinations, cyanosis, angina, syncope (sudden loss of strength and possible fainting),
exhaustion, collapse, loss of consciousness, coma, convulsions, myocardial infarction, and
Plant Name: FCCU-I
death. In non-fatal exposures, there may be serious damage or injury to the central nervous
system (CNS), and possible cerebral edema (fluid on the brain). Carbon monoxide has an
affinity for blood hemoglobin some 200 times greater than that of oxygen. This means that it
will bond much more quickly than oxygen and will form carboxyhemoglobin, thereby
preventing the normal distribution of oxygen throughout the body. The gas may also combine
with myoglobin to form carboxymyoglobin which may affect muscle metabolism and cause
muscular disturbances, especially in the heart.
CHEMICAL NAME: CARBON MONOXIDE
HAZARD WARNING INFORMATION
HEALTH FIRE REACTIV OTHER DEGREE OF COLOR CODING OTHER CODES

E HAZARD
3 4 0 0 = Minimum HEALTH = BLUE OX = Oxidizer
Hazard FIRE = RED ACID = Acid
1 = Slight OTHER = WHITE ALK = Alkali
Hazard REACTIVITY=YELL COR = Corrosive
2 = Moderate OW W = Use No Water
Hazard
3 = Serious
Hazard
4 = Severe
Hazard
GENERAL INFORMATION
Characterization Gas
RCRA Number None
EPA Class Not Applicable
DOT Proper Shipping Name Carbon monoxide
Chemical Abstract Service (CAS) Number 630-08-0
DOT Hazard Class and Label Requirements Flammable Gas
DOT Emergency Guide Code 18 (gas) 67 (cryogenic liquid)
DOT Identification Number UN 1016 (gas) NA9202 (cryogenic liquid)
Chemical Formula CO
Synonyms Carbon oxide; flue gas; monoxide; exhaust gas; carbonic oxide.
HAZARDOUS INGREDIENTS AND IDENTITY INFORMATION

Hazardous Components (specific identity)

Plant Name: FCCU-I
Carbon monoxide (derivation: When organic materials such as wood, coal, paper, oil, or
gasoline are burned in limited air or oxygen; when flame contacts a surface colder than ignition
temperature of its gaseous part; exhaust gas from internal combustion engines). 1 ppm = 1.16
mg/m3
OSHA Exposure NIOSH Exposure Immediately Dangerous ACGIH Exposure

Criteria Criteria to Life and Health Criteria
(IDLH)
PEL: REL(10-hour): 1200 ppm TLV:
50 ppm 35 ppm 50 ppm
55 mg/m3 41 mg/m3 57 mg/m3
CEILING: STEL:
CEILING: 200 ppm 400 ppm
200 ppm 229 mg/m3 458 mg/m3
229 mg/m3
PHYSICAL AND CHEMICAL CHARACTERISTICS
Boiling Point :-3130F (-192oC)

Specific Gravity (H2O = 1) :0.97
Vapor Pressure (atmospheres) : >760 at 69oF (20oC)
Molecular Weight : 28.0
Vapor Density (Air = 1) :0.97
Freezing Point :-337oF (-205oC)
Solubility : Slightly soluble (2%) in water. Soluble in alcohol and
benzene.
Appearance and Odor : Colorless gas, odorless gas. Shipped as a non-liquefied or liquefied
compressed gas.
FIRE AND EXPLOSION HAZARD DATA
Flash Point (method used) Not Applicable (gas)

Explosive Limits in Air % by Volume LEL: 12.5% UEL: 74%
NFPA Classification Flammable Gas
Auto ignition Temperature: 1292oF (700oC)
Extinguishing Media: Stop flow of gas before attempting to fight fire.
Use water spray, fog, or regular foam.
Plant Name: FCCU-I
Special Fire Fighting Procedures
Carbon monoxide is an extremely flammable gas and presents a serious explosion hazard when
exposed to flame or in fire. Fires can produce toxic fumes: wear full protective clothing and
self-contained breathing apparatus (SCBA). Heat will build pressure and may rupture closed
storage containers. Keep fire-exposed containers cool with water spray.
Unusual Fire and Explosion Hazards
For large fires, use monitor nozzles or unmanned equipment, if possible. Boiling liquid
expanding vapor explosion (BLEVE) is possible: immediately evacuate if rising sound is
heard from venting device or fire is causing a discoloration in tanks. Isolate area 1500 -2000
feet in all directions.
REACTIVITY DATA
Stability: Stable
Conditions to Avoid Carbon monoxide is stable under normal operating conditions. Avoid
contact with incompatible materials, heat, and sources of ignition.
Unstable Incompatibility (materials to avoid) Carbon monoxide is incompatible with strong

oxidizers, bromine trifluoride, chlorine trifluoride, and most other halogen compounds, and
lithium.
Hazardous Polymerization: Will not occur

Conditions to Avoid Under normal conditions of temperature and pressure, hazardous
polymerization of carbon monoxide cannot occur.
Hazardous Decomposition or By-products Thermal oxidative decomposition of carbon

monoxide can produce toxic and irritating fumes and gases, including carbon and carbon
dioxide.
HEALTH HAZARD DATA
INHALATION: Extremely toxic gas. Causes chemical asphyxia with symptoms of headache,
nausea, dizziness, loss of consciousness, convulsions, coma, infarction (heart attack), and
death. In the bloodstream, it combines with hemoglobin 200 times more readily than oxygen
creating carboxyhemoglobin and prevent oxygen distribution in the body.

Plant Name: FCCU-I
SKIN & EYES: Contact with the liquid or compressed gas may cause burns (frostbite) or
irritation.
INGESTION: Not likely.
Carcinogenicity No Evidence Human and animals
Target Organs: Cardiovascular system, blood, CNS, lungs.
Medical Conditions Generally Aggravated by Exposure

Blood disorders (anemia), heart diseases, and chronic respiratory ailments.
Emergency and First-aid Procedures

Eye contact: Immediately flush large amounts of water for 15 minutes (minimum), occasionally
lifting eyelids, seek medical attention.
Skin contact: Remove all contaminated clothing.
Frostbite: immediately wash area with large amounts of tepid water. Do NOT rub!
Inhalation: Remove the person from exposure. Provide respiratory assistance and CPR.
Transfer promptly to medical facility.
DOCTOR: Treat aggressively with 100% oxygen and non-breather mask.
Swallowed: Not likely.
PRECAUTIONS FOR SAFE HANDLING AND USE

Steps to be taken in Case Material is Released or Spilled.
Wear SCBA. Remove all ignition sources. Ventilate area. Stop flow of gas. If the source of
leak is a cylinder and cannot be stopped, remove to safe place in open air; repair leak or let
cylinder empty.
Preferred Waste Disposal Method

None specified in the references (incineration of a gas may be the only alternative). Precautions
to be taken in Handling and Storage Do not store with incompatible chemicals since violent
reactions can occur. Store in tightly closed containers in a cool, dark, well-ventilated area away

Plant Name: FCCU-I
heat. Keep away from ignition sources such as fire, sparks, and flame. Prevent damage to
cylinders. Install carbon monoxide monitors with alarms.
Other Precautions and Warnings

Check containers for leaks using a soapy water solution upon arrival, whenever filling, and at
least every three months if not used. Install Class I, Group C electrical equipment.
CONTROL MEASURES AND PERSONAL PROTECTIVE EQUIPMENT
Respiratory Protection (specify type) Gas is odorless and tasteless. Exposures can occur
without warning. Always use an MSHA/NIOSH approved full face piece gas mask or respirator
with a carbon monoxide gas cartridge. Greater protection is obtained from a supplied air
respirator or a self-contained breathing apparatus (SCBA) with full face piece and operated in
pressure demand or other positive pressure or continuous flow mode.
Ventilation: Local exhaust or general mechanical systems recommended.
Protective Gloves Butyl Rubber

Eye Protection Chemical Goggles and/or Face Mask
Other Protective Clothing Rubber Apron
Work/Hygiene Practices
Always wash hands thoroughly after using chemical; never bring food, drink, or smoking
materials into vicinity of chemicals.
HYDROGEN SULFIDE
Hydrogen sulfide is a colorless gas with an extremely irritating, characteristic odor resembling
that of rotten eggs. It occurs in natural gas and in sewer gas. It is formed by the reaction of a
metal sulfide with dilute mineral acid and in petroleum refining.
Hydrogen sulfide is a gas at room temperature and pressure and, therefore, presents a serious
(life threatening) hazard to human health through inhalation. Liquefied compressed gas can
also cause serious health hazard risks if it should contact the skin or eyes. Ingestion is not
considered a probable route of entry. There are no reports in the references regarding the
carcinogenic, mutagenic, or teratogenic effects of hydrogen sulfide on humans or animals.
Inhalation of hydrogen sulfide vapors causes irritation of the eyes, nose, throat, and mucous
membranes of the respiratory tract. Other symptoms include nausea, vomiting, diarrhea,
olfactory fatigue, and other indications of central nervous system effects. These include

Plant Name: FCCU-I
dizziness, convulsions, staggering gait, excitability, pale complexion, muscular weakness,

numbing in the extremities, headache, and fatigue. These effects can progress to
unconsciousness and death due to respiratory paralysis. It is also an allergen and an asphyxiant.
Higher exposures can lead to a dangerous buildup of fluid in the lungs in a condition known as
pulmonary edema. This is a medical emergency and can be fatal. Symptoms may be delayed
up to 48 hours thereby creating a false sense of security with regard to health exposure risk.
Other respiratory system effects include asphyxia, rhinitis, bronchitis, pharyngitis, and
pneumonia. Skin and eye contact with the compressed liquefied gas can result in serious tissue
destruction and burns from frostbite. There may be surface redness (erythema), blistering,
vesiculation, and painful swelling. There may also be permanent damage or loss to vision. The
eyes are susceptible to a condition known as gas eye (kerato conjunctivitis) with palpebral
edema, bulbar conjunctivitis, and mucous-puss secretions.
HAZARD WARNING INFORMATION
HEALTH FIRE REACTIVE OTHER DEGREE OF COLOR CODING OTHER CODES

HAZARD
3 4 0 0 = Minimum HEALTH = BLUE OX = Oxidizer
Hazard FIRE = RED ACID = Acid
1 = Slight Hazard OTHER = WHITE ALK = Alkali
2 = Moderate REACTIVITY=YEL COR = Corrosive
Hazard LOW W = Use No Water
3 = Serious
Hazard
4 = Severe Hazard
HAZARDOUS INGREDIENTS AND IDENTITY INFORMATION
Hydrogen sulfide (derivation: By action of dilute sulfuric acid on a sulfide, usually iron
sulfide; by direct union of hydrogen and sulfur vapor at a definite temperature and pressure; as
a byproduct of petroleum refining).
1 ppm = 1.42 mg/m3
OSHA Exposure NIOSH Exposure Immediately Dangerous ACGIH Exposure

Criteria Criteria to Life and Health Criteria
(IDLH)
PEL (ceiling): REL (ceiling): 100PPM TLV:
20 ppm 10 ppm 10 ppm
28 mg/m3 15 mg/m3 15 mg/m3
PEAK: (10-minute) STEL:

Plant Name: FCCU-I
50 ppm STEL: 15 ppm

(10-minute) Not 21 mg/m3
Applicable
PHYSICAL AND CHEMICAL CHARACTERISTICS

Boiling Point 76°F (-60°C)
Specific Gravity (H2O = 1) 1.19
Vapor Pressure (atmospheres) 18.5 at 68°F (20°C)
Molecular Weight 34.1
Vapor Density (Air = 1) 1.175
Melting Point -122°F (-86°C)
Solubility: Slightly soluble in water (0.4%), Soluble in ethyl alcohol, gasoline, kerosene, crude
oil, ethylene glycol.
Appearance and Odor Colorless gas with a characteristic odor similar to that of rotten eggs.
Normally shipped as a liquefied compressed gas.
FIRE AND EXPLOSION HAZARD DATA
Flash Point (method used) Not Determined

Explosive Limits in Air % by Volume LEL: 4.0% UEL: 44.0%
NFPA Classification Flammable Gas
Auto ignition Temperature 500°F (260°C)
Extinguishing Media Stop flow of gas before attempting to extinguish fire! Use water
spray to knock down vapors.
Special Fire Fighting Procedures Extremely flammable gas. Burns with a blue flame and
gives off sulfur dioxide and other poisonous gases. Wear full protective clothing and self-
contained breathing apparatus (SCBA). Move containers from fire area if it can be done without
risk. Use unmanned device if possible.
Unusual Fire and Explosion Hazards Hydrogen sulfide is denser than air and can travel low to
the ground and collect in low-lying areas to present a serious explosion hazard. It can also
travel to an ignition source and flashback to cause fire or explosion. Cool containers with water
spray long after fire is out.
REACTIVITY DATA
Risk Management for Hazardous Chemicals.
Plant Name: FCCU-I
Stability : Stable
Conditions to Avoid Hydrogen sulfide is normally stable under routine conditions of handling
and storage. Avoid contact with heat and incompatible materials.
Unstable Incompatibility (materials to avoid) Reacts in contact with strong oxidizers, such
as chlorine, fluorine, and bromine, strong nitric acid, and will attack most metals (forms
sulfides).
Hazardous Polymerization Will not occur
Conditions to Avoid Under normal conditions of temperature and pressure, hazardous

polymerization of hydrogen sulfide is not expected to occur.
Hazardous Decomposition or By-products

When heated to decomposition, hydrogen sulfide emits toxic fumes and gases, including highly
toxic sulfur dioxide.
HEALTH HAZARD DATA
INHALATION: Irritation of the eyes, nose, throat, and respiratory system. May cause nausea,
vomiting, cramps, dizziness, headache, diarrhea, sneezing, staggering, excitability, dry cough,
pale complexion, muscular weakness, drowsiness, rhinitis, bronchitis, pharyngitis, and other
lung effects such as pneumonia and pulmonary edema. Other effects include asphyxia, tremors,
fatigue, weakness and numbing in the extremities, convulsions, coma, death.
SKIN & EYES: The liquefied compressed gas can cause painful frostbite, burning, and
blistering to the eyes and skin. Absorption of the vapor is not likely to occur.
INGESTION: Not likely (hydrogen sulfide is a gas at room temperature and pressure)
Carcinogenicity Unknown Human and animals
Target Organs Respiratory system, skin, eyes, CNS.
Medical Conditions Generally Aggravated by Exposure Eye and nervous system disorders
may be aggravated by exposure to hydrogen sulfide.

Plant Name: FCCU-I
Emergency and First-aid Procedures

Eye contact: Flush immediately with warm water for 15 minutes (minimum); seek medical
attention.
Skin contact: Remove all contaminated clothing. Wash area with large amounts of warm
(tepid) water. Seek medical assistance.
Inhalation: Remove the person from exposure. Provide respiratory assistance and CPR.
Transfer to medical facility. Observe 48 hours for lung effects.
Swallowed: Not a likely exposure route.

DOCTOR: Administration of 100% oxygen and hyperbaric oxygen if possible.
PRECAUTIONS FOR SAFE HANDLING AND USE
Steps to be taken in Case Material is Released or Spilled

Stop flow of gas. Use water spray to knock down vapors and protect personnel. If leak is a
cylinder and it cannot be stopped, remove it to a safe location (outdoors) and allow to vent until
empty. Ventilate area and remove ignition sources. Neutralize runoff with crushed limestone
or slacked lime.
Preferred Waste Disposal Method No Citation.
Precautions to be taken in Handling and Storage

Do not store hydrogen sulfide in the presence of incompatible chemicals or materials. Store in
tightly closed steel cylinders in a cool, dark, well-ventilated area. Personnel working with
hydrogen sulfide should be trained on its proper handling and storage prior to being assigned
to such responsibilities.
Other Precautions and Warnings Prevent physical damage to containers. Use non-sparking
tools, especially when opening and closing cylinders. Use class 1, group C electrical equipment
in storage and use areas.
CONTROL MEASURES AND PERSONAL PROTECTIVE EQUIPMENT

Respiratory Protection (specify type) Recommend using a self-contained breathing
apparatus (SCBA) with full face piece operated in pressure demand or other positive pressure
mode, or use a supplied-air respirator operated in continuous flow mode. Air purifying
respirators do NOT provide protection in oxygen deficient atmospheres.

Plant Name: FCCU-I
Ventilation Local exhaust or general mechanical systems recommended.
Protective Gloves Impervious, Thermal Protective
Eye Protection Chemical Goggles or Face Mask
Other Protective Clothing Protective Apron (avoid skin contact)
Work/Hygiene Practices
Always wash hands thoroughly after using chemical; never bring food, drink, or smoking
materials into vicinity of chemicals.

Plant Name: FCCU-I
ELOGUARD

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I
Additional Information and comments: The chemical is alkaline in nature. All

precautions taken with alkali should be taken.
Neutralizer:

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I
CO COMBUSTION PROMOTERS

Plant Name: FCCU-I
Common Name : Carbon Monoxide (CO) Combustion promoters

Supplier : Engelhard Corporation
Product Use : Industrial Catalyst
Physical and Chemical Properties

Appearance : White Powder
Odor : Odor less
Boiling Point : Non- Volatile solid.
Specific gravity : 1.0 to 1.3 g/cc (bulk density)
Melting point : Not determined.
Vapor Pressure : Negligible.
Vapor density : Non-volatile solid
Evaporation Rate : Negligible.
Solubility in Water : Insoluble.
PH : Not determined
First Aid Measures
Eye Contact : Flush eyes with plenty of water.

Skin Contact : Procedures normally not needed. If skin contact
occurs flush with plenty of water.
Inhalation : Remove to fresh air. If breathing is difficult,
oxygen should be administered by qualified
personnel.
Ingestion : Procedures not needed. If large quantities are
ingested, seek medical advice
ZSM – 5
Trade Name : Olefins Plus

Chemical name & Family : Silica-Alumina, Synthetic Zeolite.
Synonyms : Sodium Silicoaluminate or Sodium Aluminosilicate,
Silica-Alumina Catalyst.
Chemical Notation or structure : Na20.yAL203.zSiO2.xH2o, proprietary additive.
Ingredients : Na2O SiO2 Al2O3 Quartz
Sodium oxide Silica Alumina

Plant Name: FCCU-I
PHYSICAL PROPERTIES
Appearance : Off white to tan power

pH in 5% slurry : 3-6
Odor : Odorless
Specific gravity : 2.1
Bulk density : 35-50 lbs. /ft3
Solubility in water : Insoluble
Approximate Analysis
wt%
Alumina A1203 : 25.37

Silica SiO2 : 45-65
Proprietary Additive : 5-15%
Sodium Oxide Na2O : 0-1.0
Sulfate SO4 : 0-1.5%
Quartz, SiO2 max : 1.0%
PRECAUTIONS IN USE:
Prolonged contact with this product may be corrosive to the skin and mucous membranes. The
drying action of this material can cause irritation of the mucous membranes of the nose and
throat and irritation of the skin. If its use requires manual handling, wear long sleeves and
close-weave cotton gloves with tight-fitting wristlets.
FIRST AID:
Eyes: Immediately wash from eyes with large amounts of water, occasionally lifting upper
and lower eyes lids. Get medical attention immediately.
Skin: Wash area with soap and water. Personnel should shower after handling this material
if frequent contact with duct is experienced.
Ingestion: If ingested, drink milk or milk of magnesia and consult a physician.
Inhalation: If inhalation causes irritation or discomfort, remove person from exposure and
seek medical help if symptoms do not disappear.
SPENT CATALYST
Appearance : off-White to gray fine powder (micro-spheroids)

Plant Name: FCCU-I
PH in 5% Slurry : 3-6
Odor : None
Specific gravity : Approximately 2.1
Bulk Density : 0.7g/cc to 1.1 g/cc
Solubility in Water : Nil
Approximately Analysis:
Wt%
Alumina A1203 20-75
Silica SiO2 25-80
Sodium Na 0.2-1.5
Iron Fe 0.2-2.0
Rare Earths RE203 0.1-10
Titania TiO2 0.1-3
Sulfate SO4 0.1-2.5
Coke C 0-2
Vanadium* V 45-70000
Nickel* Ni 45-70000
Copper* Cu 5-1000
Antimony* Sb 0-2500
Quartz SiO2 max 1.0
*expressed as metals but present in oxide form on catalyst.
First Aid:
Eyes: Immediately wash the eyes with large amounts of water, occasionally lifting
upper and lower lids. If irritation occurs and persists, seek medical attention
Skin: Wash area with soap and water. Personnel should shower after handling this
material if frequent contact with dust is experienced.
Inhalation: If inhalation causes irritation or discomfort, remove person from exposure and
seek medical help, if symptoms do not disappear.
Ingestion: If ingested, drink 2 glass of water and get medical attention immediately.
PPE REQUIREMENTS TYPE AND USAGE
For Minimum PPE requirement for various activities, refer F& S manual as per the
details below:
Plant Name: FCCU-I
Doc NO: SWP

Ref: F&S –Safety Manual
Fire Fighting System& Equipment
Despite the achievement of better safety management, greater reliability of equipment,

advanced process control and optimum application of fire prevention and fire protection
measures, statistics indicate that occasional fire incidents continue to occur. Many large fires
are the result of escalation of smaller fires, so prompt and effective control of fires at initial
stages itself, is of prime importance. Hence, it is of paramount to upkeep the first-aid
firefighting equipment provided in the plant to tackle fire emergencies till the required help is
received from Fire & Safety Department.
The various chemicals used in FCCU-I include

KONTOL/ Filmer -- Eloguard p86
NEUTRALIZER-- Morpholine
Ni Passivator
Caustic
Fresh catalyst, E-catalyst
COP
Bottom Cracking Additive

Plant Name: FCCU-I
HAZARDS AND SAFETY
INTRODUCTION
Safety of personnel and equipment is very important. Ignorance of the details of the unit or the
techniques of safe and efficient operation reduces the margin of safety of personnel and
subjects the equipment to more hazardous conditions. All the operating and maintenance crew
therefore must be fully familiar with the equipment and materials being handled in the unit and
recognize the hazards involved in handling them and the measures taken to ensure safe
operations.
OBJECTIVES OF SAFETY
Design, create and maintain facilities, provide training, establish procedures in all the fields
and ensure that these are rigidly followed by the employees, the contractors, and the visitors
inside the refinery premises.
Carryout operations in safe manner protecting people and property
Comply with the relevant statutory rules and device appropriate standards in other cases
wherever required.
Maintain highest standards of vigilance and preparedness to respond to emergencies

supplemented with mutual aid of neighboring facilities and Government agencies.
Create awareness in employees, dealers, contractors, customers and public on safe storage,
transportation and handling of products and materials associated with our activities.
Ensure awareness among all employees, contractors and others of their responsibility and
accountability for safety on and off the work premises.
FIRE FIGHTING AND EMERGENCY PROTECTIVE EQUIPMENT
FIRE FIGHTING SYSTEM
The operating personnel should be fully conversant with Fire-fighting system provided in the
unit. All of them should have adequate firefighting training and will serve as auxiliary Fire
Squad in the event of a fire breakout. It will be the primary responsibility of unit personnel to
fight the fire at the very initial stage and at the least, localize it.

Plant Name: FCCU-I
Major Fire-fighting facilities provided in the unit comprise the following.
Water is most important fire-fighting medium. Water is used for fire extinguishments, control,
equipment cooling and exposure protection of equipment/ personnel from heat radiation. An
elaborate fire water distribution network is provided around the unit. Fire water
hydrants/Monitors are provided around the unit, which give coverage to the equipment.
II) FOAM SYSTEM:
For containing large Hydrocarbon fires, foam systems are useful. They have inherent
blanketing ability, heat resistance and security against burn back. Low expansion foam is used
for hydrocarbon oil fire. Foam can be applied over burning oil pool with the help of foam
tenders/ foam delivery system.
III) PORTABLE FIRE EXTINGUISHERS:
Fire should be killed at the incipient stage. Portable fire extinguishers are very useful in
fighting small fires. All extinguishers in the unit must be located in specified places only. The
operating crew should be acquainted with exact location of extinguishers. They also must
know most suitable type, which, when and how to use an extinguisher. For example electrical
fires should be put out with CO2 or dry powder extinguishers, water and foam should not be
used. The used extinguishers should be checked and restored by fire station personnel.
FIRE FIGHTING:
1. In some cases, such as the ignition of a small oil spill, it is possible to immediately
extinguish the fire without bringing down the unit. However, except for very minor
fire emergencies, immediately notify designated personnel and start fire-fighting
procedures.
2. All personnel are responsible for observing the firefighting instructions in force at the
refinery.
3. All personnel must know the location and use of all fire extinguishers, fire hoses and
hydrants, fire blankets, gas masks and respirators and other protective equipment such
as hard hats, rubber gloves etc. This equipment must be kept in accessible locations,
ready for immediate use at all times.
Plant Name: FCCU-I
4. Foam type extinguisher and water from fire hydrants must not be used on fires around
electrical equipment because the water solution will conduct electricity and may
aggravate the difficulty or result in the electrocution of personnel.
5. Carbon dioxide dry powder or foam type extinguisher is suitable for all fires. For large
oil fires, steam hose equipment or fog nozzles on the end of a water hose are suitable.
6. Carbon dioxide or dry powder extinguishers may be used safely on electrical fires.
7. Gas masks must be worn whenever poisonous fumes, such as ammonia, hydrogen
sulfide or petroleum vapors are anticipated or encountered.
8. Safety hats must be worn by all personnel engaged in firefighting. There is a possibility
of falling equipment or materials striking personnel.
9. All fire-fighting equipment must be checked periodically. Steam hoses should be

checked daily and water hoses weekly. Fire extinguishers must be put back in place
after use. Access to such equipment must not be obstructed.. Gas masks must have
fresh cartridges installed after use.
10. When fighting fire always approach from the windward side of the blaze so that smoke
and flames blow away from personnel.
MAINTENANCE OF ONSTREAM EQUIPMENT AND HOUSE KEEPING.
1. Operating equipment should be checked frequently for signs of leakage over heating or
corrosion, so that unsafe conditions may be corrected before they result in serious
consequences. Unusual conditions should be reported immediately.
2. Guards around moving shafts, couplings belts etc. which have been removed for repairs
to the equipment must be replaced when repair work is completed.
3. Tools, pieces of pipe etc. should never be left lying on platforms or railings of operating
equipment where they can be knocked off and injure someone below.
4. Access to ladders and fire escapes must be kept clear. Waste material and refuses must
be put in proper locations where they will not offer fire or stumbling hazards.

Plant Name: FCCU-I
5. Liquid spills must be cleaned immediately. Blanket gas leaks with steam and
immediately report leaks for repair.
6. In the event that electrical equipment does not function properly, notify the electrical
department and stay clear of the equipment until the electrician arrives.
7. Gas cylinders should be stored so that they cannot spillover. Guard caps must remain
in place over the valves of cylinders which are not in use.
PREPARATION OF EQUIPMENT FOR MAINTENANCE:
PROCESS EQUIPMENT TOWERS, VESSELS ETC.
Before opening any equipment, it should be purged to render the internal atmosphere non
explosive and breathable. Operations to be carried out are:
- Isolation with valves and blinds

- Draining and de-pressurization
- Replacement of vapours or gas by steam, water or inert gas.
- Take care about instrument tapping.
- Washing of towers and vessels with water.
- Ventilation of equipment
- Opening of top manhole.
- Testing inside with explosive meter.
- Complete opening if inside atmosphere is satisfactory
- Analyze the atmosphere inside for O2, CO and H2S
REPAIR WORK
1. Mechanical work around an operating unit must be kept to a minimum and the
minimum number of men should be used.
2. No mechanical work on the equipment is to be done without a properly authorized work

permit.

Plant Name: FCCU-I
3. Safety elements, belts must be worn by all personnel in area where repair work is under
taken. There is a possibility of falling tools or materials striking personnel.
4. No burning, welding, open fires or other hot work shall be allowed in the area unless
authorized by a work permit. Catch basins, manholes and other sewer connections must
be properly sealed off to prevent the leakage of gases which may ignite upon contact
with an open flame.
5. No personnel shall enter a vessel for any purpose whatsoever until it has been
adequately purged, blanked of as required, then tested to ensure freedom for obnoxious
or inflammable gases.
6. When flushing equipment with a fire hose, the fire hose must be equipped with a check
valve.
7. Lines operating at a low temperature might fracture if unduly stressed, therefore do not
physically strike these lines and avoid operating conditions which would cause a water
hammer to start.
8. Do not use light distillates such as gasoline or naphtha to clean machinery or for any
other cleaning purpose.
9. When people have to enter a vessel for inspection or other work, one person should
stand outside near the manhole of the vessel for any help needed by the persons working
inside. The person entering the vessel should have tied on his waist, a rope to enable
pulling him out in case of emergency.
WORK PERMIT SYSTEM:
It is the policy of the company to ensure safety of the people, equipment and materials when
performing any work within the Refinery premises. Job shall be performed only after obtaining
the stipulated permits. Permits shall be issued/renewed and received only by personnel
designated for the same and are to be signed by both the issuing and receiving personnel. All
necessary checks and tests should be conducted to ensure safety of the jobs prior to issue of
permits. All precautionary measures required to be taken shall be clearly indicated in the permit
and their compliance ensured. If any of the conditions vary during the work which may affect
safety of human beings and equipment, the job is to be stopped, the permit to be withdrawn.

Plant Name: FCCU-I
SAFE HANDLING OF VOLATILE AND CORROSIVE MATERIALS
The safety rules given below are for the protection of life and the prevention of property loss.
It is expected that refinery people will exercise common sense, alertness and good judgment in
carrying them out. If ever there is any doubt as to the safety aspect of a particular operation,
consult the supervisor immediately.
1. Respiratory Protection:
Most refinery gases, other than air, are harmful to human beings if inhaled in sufficient
concentration. Toxic gases may be classified as either asphyxiating or irritating. Asphyxiating
gases may cause death by replacing the air in the lungs or by reacting with the Oxygen carried
in the blood; examples are hydrogen sulfide, carbon monoxide, and smoke. Irritating gases
may cause injury or death not only by asphyxiation but also burns internal and external;
examples are chlorine and sulfur dioxide.
To guard against the inhalation of harmful gases:
a) Secure a gas test certificate showing the gas condition of the vessel.
b) Stand on the windward side of an opening from which gases escape.
c) Provide proper ventilation.
d) All personnel should become familiar with the accepted method of artificial respiration
in order to render assistance to anyone overcome by gas, electric shock, or drowning.
e) If anyone is overcome by gas, his rescuer should:

1. Never attempt a rescue unless an assistant is standing by.
2. Protect himself before attempting a rescue.
3. Get the victim to fresh air at once.
4. Give artificial respiration and send his assistant to call for medical aid.
f) When using a gas mask, be sure that the mask fits the face properly. Test it by squeezing
the hose and inhaling. If the face piece collapses, the mask fits properly.
g) Wear the correct type of gas mask, if required.
5. Gas Masks:

Plant Name: FCCU-I
There are three types of gas masks in general refinery service. They are the canister type
mask, the fresh air mask, and the tank type mask. They and their uses are described below.
a) The canister type mask utilizes a filter element to absorb the poisonous gas from the
air. Different gases require different types of filters. Information about the filters may
be obtained from the safety Department.
1. Use this mask only in the open air or where the gas concentration is less than 2%,
not in a tank or other confined space, except in an extreme emergency. A canister
type mask does not protect the user against a deficiency of oxygen. A lifeline
should be used in questionable locations.
2. When a seal is removed from a canister, mask the date on the canister, and after one
year discard it regardless of how little it has been used.
3. A record of the amount of time the canister has been used must be kept on a tag
attached to the canisters. Do not exceed the permissible time limit for the particular
canister being used.
a) In the fresh air mask, a remote air supply is provided by a hand operated blower through
a length of hose. It is used mostly for rescue operations.
1. When a man must enter a tank, sewer, or other confined area where the atmosphere is
20% or more of the lower explosive limit, or contains evidence of hydrogen sulfide or
other toxic materials, a fresh air mask must be used.
2. The blower must be placed where only fresh air can enter it, but not more than 100 ft
of hose should be used.
3. A life belt and rope should always be used with the end fixed so that it will not fall back
into the tank or sewer.
4. Be sure that the harness is buckled close to the wearer’ s body so that it will not slip
over his shoulders if a rope rescue is necessary.
5. One man who knows artificial respiration must be present on the outside.
c) The tanks type mask has a self-contained air supply carried on the back of the user. It
is the only one of the three types that is completely independent of outside air.
Plant Name: FCCU-I
1. This mask is to be used only by specially instructed personnel where there is little or
no ventilation.
2. It is used principally in emergencies.
3. After use, always notify the Safety Department so that they can recharge the tanks.
3. CORROSIVE MATERIALS:
Whenever containers of corrosive chemicals such as ammonia, chlorine, caustic soda, sulfuric
acid, etc., are to be opened or emptied, always have a connected water hose handy to flush off
and help absorb spilled material and to reduce spread of toxic vapour.
4. MISCELLANEOUS:
a) The Safety Department or your foreman is always available for information concerning
use of masks.
b) Become familiar with the accepted method of artificial respiration in order that you may
render assistance to anyone overcome by gas, electric shock, or drowning.
CHEMICAL HAZARDS:
The following chemicals are normally present in some equipment items and offer certain
specific risks, as described below:
1. OXYGEN(O2)
Oxygen is contained in cylinders for use in welding principally. Oxygen is a strong oxidizing
agent and combustibles frequently explode or take fire in its presence, especially when
confined under pressure. Never apply grease or oil to any equipment which will be used in
Oxygen service.
FURNANCE FIRING INSTRUCTIONS

Plant Name: FCCU-I
PRELIMINARY
1. Establish circulation of fuel oil through furnace fuel headers.
2. Open stack damper wide.
3. Set fuel oil automatic fireman in manual position.
4. Purge firebox with steam through the burners for 15 min. before lighting any burners.
IGNITION
1. Light pilot burners individually using a igniter.
2. Safety helmets with goggles or face shields must be worn when lighting any furnace.
Do not light any burner from adjoining main burner or hot brick work.
3. Do not stand directly in front of the firebox openings when the burners are being
lighted.
4. Reduce secondary air door openings to a minimum.
5. Wait a few minutes for burner blocks to be heated from pilot.
6. Open steam valve on burner to the point where a slight jet is flowing.
7. Gradually open fuel oil valve on burner until a flame four to five feet long is obtained.
If the first burner does not light immediately, shut off the fuel oil and
8. Thoroughly steam purge the furnace for 15 min. before attempting to relight the burner.
9. After the burner and muffle blocks become heated increase steam to improve the
atomization.
10. Place as many of the remaining burners in service as possible restricting the secondary
air supply to a minimum.
Plant Name: FCCU-I
11. To increase the temperature, increase the fuel to the burners by manually adjusting the
fuel oil controller.
12. Adjust the atomization steam and secondary air doors to obtain hard clean yellow flame.
NOTE: It is extremely important that close attention be paid to the adjustment on oil firing.
Insufficient air and/or atomizing steam will produce a dirty, orange long flame. Flame
impingement will burn the roof tubes and hangers.
12. During operation if one or more burners go out, but others remain, the fuel oil should
immediately be shut off to all those that are out. They should be relit progressively.
13. Ensure all piping is in place and all fuel valves shut before starting fuel furnace
headers.
Shutting Down Fuel Oil Burners
1. Open burner bypass valve until flame begins to pulsate.

2. Close oil valve tight.
3. Open steam wide to burner, and open bypass wide to blow out oil gun.
THERMAL EXPANSION IN EXCHANGERS:
Because of serious accidents caused by thermal expansion of liquid trapped in exchangers, the
following procedure is outlined in an effort to eliminate this hazard.
1. When the cooler side of an exchanger is to be bypassed while hot material is passing
through the other side, the drain or vent should be tried before bypassing to see that it
is not plugged.
2. When the exchanger is bypassed, the bleeder or vent should be arranged so that the
pressure can be dissipated to a suitable place.
3. Warning signs as follows must be installed on all exchangers where it is possible to

block in the cold side of an exchanger with hot liquid going through the other side.

Plant Name: FCCU-I
CAUTION:
THERMAL EXPANSION OF A TRAPPED LIQUID CAN CAUSE AN XPLOSION
DO NOT CLOSE BOTH INLET AND OUTLET VALVES UNLES YOU OPEN THE
DRAIN OR SMALL BYPASS.
SAMPLE WITHDRAWAL:
1. Samples will be withdrawn from the unit only by authorized personnel.
2. When sampling materials hotter than 54o C or colder than 0 oC are, collected, gloves,
goggles or face shields are recommended.
3. A container must never be filled to the brim; allow for expansion of the liquid when it
solidifies.
4. Avoid inhalation of vapours released by the withdrawn samples as they may contain
toxic compounds such as H2S, mercaptan and carbon monoxide.
5. Sample of any gas should be taken only in approved sample bombs.
6. When metal cans are used for sampling, a ground wire must be connected from the can
to the sample valve, to prevent ignition of the vapours by static electricity. This applies
for 5 gallon or 1 barrel size containers.
7. A sample should be slowly and cautiously withdrawn. Particularly when the sample is
at a high temperature or pressure. Normally a cooling coil is provided for high
temperature sample collections.
8. A large wrench must never be used to open a frozen sample connection on a small line;
application of too much force may break off the sample connection.
9. Do not bleed propane to sewer at any time. When drawing water from vessels
containing propane, watch the valve constantly to minimize purging of propane, with
attendant danger of freezing the valve open. Double block valves should be provided
where propane can be withdrawn. Propane should be throttled across the valve furthest
downstream of the pressure source so that the upstream valve may be closed in the
event the downstream valve freezes open.

Plant Name: FCCU-I
CRACKING CATALYST:
Fluid cracking catalyst is a fine dust capable of causing eye and lung irritation. When unloading
catalyst drums, drawing samples, etc., goggles or a face shield should be worn and if the
circumstances are such that the working atmosphere could remain dusty, a dust mask should
also be worn.
When drawing hot regenerated catalyst samples, gloves and long sleeved clothing should
always be worn. In case of hot catalyst leaks, care must be exercised to avoid the impingement
of hot catalyst on unprotected skin.
Loose catalyst is a relatively poor conductor of heat so that while the surface of a pile of catalyst
may be cool, the interior may be very hot. Personnel should not walk over piles of catalyst.
IRON SULFIDE:
Iron Sulfide is a black or grey powder deposit found in vessels where sulfur corrosion has
occurred. It is easily mistaken for coke. The danger of iron sulfide lies in its “ Pyrophoric”
properties, that is to say, it will ignite spontaneously when exposed to air. Since this is most
likely to occur in recently opened refinery vessels, a severe fire can result.
A vessel suspected of containing iron sulfide must be thoroughly steamed out and washed with
water before air is permitted to enter. Any suspected deposits must be kept wet until they can
be removed and buried in a safe location.
HEAVY CRACKED HYDROCARBONS:

Heavy cracked oils are skin irritant and when drawing samples, draining equipment and
cleaning vessels or exchangers, suitable care should be exercised to avoid skin contact. In case
of actual contact, the skin should be washed with hot soapy water for at least a half hour, and
any oil saturated clothing should be removed.
Should any hydrocarbon enter the eye, the recommended- FIRST AID is to wash with a copious
amount of clean water and obtain trained medical assistance as quickly as possible.
LIGHT CRACKED HYDROCARBON LIQUIDS:
Hydrocarbons in the gasoline boiling range will remove the natural oil from the skin, leaving
it unprotected and subject to irritation or infection. Those gasoline streams which contain

Plant Name: FCCU-I
aromatics will be particularly dangerous since benzene is a poison and heavier aromatics are
narcotics.
In case of exposure, no time should be lost in removing any gasoline soaked clothing and
washing the skin with hot, soapy water. FIRST AID for eye injuries is discussed above under
“ Heavy Cracked Hydrocarbons” .
LIGHT HYDROCARBON VAPOURS:

The inhalation of any light hydrocarbon vapour should be avoided. Such vapors can be toxic,
since they may contain aromatics, H2S or other lethal substances. A person who has inhaled
quantities of hydrocarbon vapours should be removed form the area and kept warm and
quiet. If necessary, artificial respiration with or without the use of Oxygen should be
administered and medical aid summoned.
INHIBITORS:
A variety of corrosion, oxidation, and other inhibitors are used around refineries. Where such
materials are toxic, the shipping container will be suitably labeled and the manufacturer’ s
literature will recommend appropriate safety practices. In general, these substances are likely
to be skin irritants or to be dissolved in solvents which are irritants. In case of skin contact,
thorough washing with hot, soapy water and immediate removal of contaminated clothing is
indicated.
Should such materials enter the eye, the recommended FIRST AID is to wash with copious
quantities of clean water, and obtain trained medical attention without delay. (Boric acid eye
wash may be soothing in some cases).
HYDROGEN SULFIDE (H2S):
Hydrogen sulfide is present in the gases produced by cracking or hydrogenating any oil
containing sulfur. It will occur in unstabilized gasoline, separator gases, stabilizer and stripper
overheads, absorber off gas and sour water stripper overheads. Hydrogen sulfide is one of the
most poisonous gases known, and exposure to an atmosphere containing less than 0.1% may
be fatal in 30 minutes or less. At very low concentrations, hydrogen sulfide has the
characteristic odor of rotten eggs, but at higher concentrations, the sense of smell is paralyzed
so that personnel may be unaware of increasing danger.
Extreme care must be exercised when opening lines and equipment which have contained even
low concentrations of H2S and in all cases of doubt, H2S detector should be used. When
drawing samples, venting instruments, bleeding pumps, etc., precautions should be taken to
avoid breathing the vapours.

Plant Name: FCCU-I
A person exposed to H2S may become excited or dizzy, may stagger and will ultimately loose
consciousness. FIRST AID consists of artificial respiration with or without Oxygen. The
patient should be kept warm and medical aid summoned.
TOXICITY OF H2S AND EFFECTS:
10 ppm : Can smell, for 8hrs exposure
100 ppm : Kills the sense of smell if exposed for 3 to 15

Minutes. May sting eyes and throat.
200 ppm : Kills the sense of smell shortly
500 ppm : Loses sense of reasoning and balance.

Respiratory system paralyses in 30 to 40 minutes.
Needs prompt artificial respiration.
1000ppm : Unconsciousness at once. Permanent brain

Damage if not rescued promptly.
FLUE GAS:
Flue gas from furnaces and cracking catalyst regenerators contain little or no Oxygen, so
that asphyxiation can result if a person enters an improperly ventilated duct (or a pit or
similar low area where the high density of flue gas will cause it to accumulate).
Asphyxiation is preceded by dizziness, a headache or shortness of breath.
Catalytic cracking flue gas is doubly dangerous since it also contains carbon monoxide,
which is toxic. A concentration of 0.4% can be fatal in about one hour. It may be useful
to note that the skin of a person suffering from carbon monoxide poisoning often assumes
a bluish-red color.

Plant Name: FCCU-I
FIRST AID in case of flue gas asphyxiation or poisoning consists of the administration of
artificial respiration, with or without Oxygen, under warm conditions, until medical aid
arrives.
AMMONIA
Anhydrous ammonia in cylinders is frequently used to combat corrosion in refineries.
Ammonia gas is highly irritating to the nose and eyes so that severe accidental exposure is
rare, except in cases where a sudden leak occurs. The basic FIRST AID in cases of
exposure to ammonia consists of washing the exposed area with a copious quantity of
water, and the eyes, if necessary with 5% boric acid eye wash. In case of collapse, artificial
respiration with or without Oxygen should be administered, and in all such cases, the
patient should be kept warm.
SODIUM SULFITE:
Sodium sulfite solution is not poisonous, but if some should be swallowed, an emetic
should be administered. Sodium sulfite reacts with acids to liberate the highly irritant sulfur
dioxide gas, the pungent odor of which minimizes the danger of exposure.
SODIUM PHOSPHATE:
Sodium phosphate solution is not poisonous, but if some should be swallowed, an emetic
should be administered, since commercial boiler additives contain a variety of organic
additives.
OCTADECYLAMINE:
The amine used for steam treatment is not known to be poisonous, but if some should be
swallowed, an emetic should be administered. Some amino-compounds are irritants, so in
all cases, skin contact should be avoided, and in cases of accidental contact, thorough
washing with soap and water is necessary.

Plant Name: FCCU-I
All the hazards of using these chemicals can be summarized as follows:
S. Chemical Physical Flammability Possible Required Emergency Handling

No Properties Unique Precautions Procedure
Hazard
Eloguard Liquid, Flammable only Nil Avoid Wear SCBA and
P86 Ammonical if ignited. contact with protective clothing. Wear
fishy odor, SG: Use DCP, CO2 Eyes and rubber shoes, hand gloves
098, extinguisher Skin. and protective glass while
Completely and spray water Storage: handling. On contact wash
soluble in Explosion Maintain with plenty of water.
water. Freezing Power: Nil Adequate
point: -1oC. Ventilation
Stable upto
700oC
Corrosion Liquid, Highly May Avoid Heat Wear SCBA and
Inhibitor Hydrocarbon corrosive evolve and possible protective clothing. Wear
odor, SG:0.92, carcinogen CO2 and source of rubber shoes, hand gloves
Flash And flammable. NOx in ignition and protective glass while
point:70oC Use Alcohol case of including handling. On contact wash
foam, DCP and fire. static with plenty of water.
Composition: firefighting discharge
HAN, Fatty materials
acid amine suitable for
condensate, Class B fires.
Naphthalene Use water spray
and 1,2,4- tri and fog for big
methyl fires. Quench
benzene the containers
thoroughly
during fire.
Ni Liquid, No Will not burn NIL Avoid During fire, wear SCBA
passivator odor, SG:1.3 until water is contact with and protective clothing.
Completely boiled away. Eyes and Wear rubber shoes, hand
soluble in May evolve Skin. gloves and protective
water Cox and NOx Storage: glass while handling. On
under fire. Maintain contact, wash with plenty
Adequate of water.
Ventilation
Caustic Colorless When in contact Avoid Extremely Eyes: Do not allow victim
liquid. Soluble with moisture or Water corrosive to to keep eyes tightly shut.
in water, water, sodium contact tissues in Flush immediately with
alcohol, hydroxide can (produces respiratory water for 15
glycerol, and generate extreme system. minutes(minimum);
methanol. enough heat to heat), Causes Skin contact: Remove all
Insoluble in ignite Absorbs many small contaminated clothing.
acetone and surrounding moisture Immediately wash
Plant Name: FCCU-I
ether. Boiling combustible and burns, hair area with large amounts
Point materials. carbon loss in nasal of soap and water.
2534°F Sodium dioxide passages Inhalation: Remove the
(1390°C) hydroxide may from person from exposure.
melt and flow air. Provide respiratory
when heated in assistance and CPR.
fire. Transfer to medical
facility.
Carbon Dioxide
S Chemi Physical Exposure Possible Hazard Required Emergency
. cal Properties limits Unique identification Precauti Handling
N Hazard ons Procedure
CO2 Colorless & STEL: 54000 Nil Moderately Eye contact
odorless gas. mg/m3 15 irritating to Imm
Boiling Point minute(s). the eyes, skin ediately flush
(-192oC) TWA: 9000 and eyes with
SG:0.97 mg/m 3 8 respiratory plenty of
Freezing hour(s). system on water for at
Point :-(- Form: All exposure. least 15
205oC) forms minutes.
Solubility TWA: 5000 Skin contact
Slightly ppm 8 Imm
soluble (2%) hour(s). ediately flush
in water. Form: All skin with
Soluble in forms plenty of
alcohol and IDLH:40000 water.
benzene. Gas PPM Remove
contaminated
clothing and
shoes. Wash
clothing
before reuse.
Thoroughly
clean shoes
before reuse.
Inhalation
Rem
ove to fresh
air. If not
breathing,
give artificial
respiration. If
breathing is
difficult, give
oxygen.
Plant Name: FCCU-I

Get medical
attention.
CO Colorless & TLV: An extremely Extremely Stop flow Eye contact

odorless gas. 50 ppm flammable toxic gas. of gas Imm
Boiling Point 57 mg/m3 gas. Causes before ediately flush
(-78.55oC) STEL: BLEVE is chemical attemptin eyes with
SG:0.97 400 ppm possible: asphyxia with g to fight plenty of
Freezing 458 mg/m3 symptoms of fire. Use water for at
Point:- ( - IDLH: 1200 headache, water least 15
78.5oC) ppm nausea, spray, minutes.
Solubility dizziness, loss fog, or Skin contact
Slightly of regular Imm
soluble (2%) consciousness foam. ediately flush
in water. , convulsions, skin with
Soluble in coma, and plenty of
alcohol and death. In the water.
benzene. bloodstream, Remove
Auto ignition it combines contaminated
Temperature with clothing and
(700oC) hemoglobin shoes. Wash
200 times clothing
more readily before reuse.
than oxygen Thoroughly
creating clean shoes
carboxy- before reuse.
hemoglobin Inhalation
and prevent Rem
oxygen ove to fresh
distribution in air. If not
the body. breathing,
give artificial
respiration. If
breathing is
difficult, give
oxygen.
Get medical
attention.
Immediately
evacuate if
rising sound is
heard from
venting
device or fire
Plant Name: FCCU-I

is causing a
discoloration
in tanks.
Isolate area
1500 -2000
feet in all
directions.
Wear SCBA.
Remove all
ignition
sources.
Ventilate
area. Stop
flow of gas.
H2S Colorless gas REL LEL: 4.0% Irritation of Stop flow Wear SCBA.
with a (ceiling): UEL: 44.0% the eyes, nose, of gas Remove all
characteristic 10 Extremely throat, and before ignition
odor similar to ppm flammable respiratory attemptin sources.
that of rotten gas. Burns system. May g to fight Ventilate
eggs. 15 mg/m3 with a blue cause nausea, fire. Use area. Stop
Boiling Point (10-minute) flame and vomiting, water flow of gas.
(- IDLH:100pp gives off cramps, spray, Eye contact
60°C) m sulfur dioxide dizziness, fog, or Imm
SG :1.19 and other headache, regular ediately flush
Vapor poisonous diarrhea, foam. eyes with
Density : gases. sneezing, plenty of
1.17 H2S is denser staggering, water for at
5 than air and excitability, least 15
Solubility can travel low dry cough, minutes.
Slightly to the ground pale Skin contact
soluble water and collect in complexion, Imm
(0.4%). low-lying muscular ediately flush
Soluble in areas to weakness, skin with
ethyl alcohol, present a drowsiness, plenty of
gasoline, serious rhinitis, water.
kerosene, explosion bronchitis, Remove
crude oil, hazard. It can pharyngitis, contaminated
ethylene also travel to and other lung clothing and
glycol. an ignition effects such as shoes. Wash
Auto ignition source and pneumonia clothing
Temperature flashback to and before reuse.
cause fire or pulmonary Thoroughly
(260 explosion. edema. Other clean shoes
°C) effects include before reuse.
Plant Name: FCCU-I

asphyxia, Inhalation
tremors, Rem
fatigue, ove to fresh
weakness and air. If not
numbing in breathing,
the give artificial
extremities, respiration. If
convulsions, breathing is
coma and difficult, give
death. oxygen.
Get medical
attention.
LPG LPG is a LEL: 1.9% Conc in air Avoid Wear SCBA.
colorless and UEL: 9.5% greater than contact. Remove all
odorless gas. Extremely 10% causes If catches ignition
BP:>-40oC flammable dizziness in fire, allow sources.
Auto ignition gas. few minutes. it to burn Ventilate
Temperature On contact 1% conc gives under area. Stop
with skin same control flow of gas.
(466. causes Frost dizziness in 10 and use Eye contact
1°C) bite. minutes. High water Imm
vapors Highly conc causes spray to ediately flush
density :1.5 inflammable asphyxiation. cool the eyes with
Floats on material vessel. plenty of
water. water for at
least 15
minutes.
Skin contact
Imm
ediately flush
skin with
plenty of
water.
Remove
contaminated
clothing and
shoes. Wash
clothing
before reuse.
Thoroughly
clean shoes
before reuse.
Inhalation
Rem
Plant Name: FCCU-I

ove to fresh
air. If not
breathing,
give artificial
respiration. If
breathing is
difficult, give
oxygen.
Propa Colour less PEL LEL: 2.1% Burns with a Avoid Wear SCBA.
ne and 1000PPM UEL: 9.5% luminous contact. Remove all
odourless IDLH:2100 Extremely smoky flame If catches ignition
liquid PPM flammable An fire, allow sources.
BP: -42oC gas. asphyxiant it to burn Ventilate
Vapour On contact gas. Feeling under area. Stop
density: 1.56 with skin of Air control flow of gas.
Slightly causes Frost hunger., and use Eye contact
soluble in air. bite. diminished water Imm
Soluble in Burns with a mental spray to ediately flush
Ether and luminous alertness, cool the eyes with
alcohol. smoky flame headache, vessel. plenty of
SG:1.55 Reacts dullness,shor Monitor water for at
violently with tness of area long least 15
oxidizers breath and after fire minutes.
such as impairment is Skin contact
chlorides/chl in muscle extinguis Imm
orine dioxide. coordination. hed. ediately flush
Store away , depression, Even if skin with
from heat rapid fatigue fire is plenty of
and flame. and extinguis water.
unconsciousn hed, Remove
ess. Can escaping contaminated
cause frostbit gas can clothing and
eand burns. form shoes. Wash
explosise clothing
mixture before reuse.
with air Thoroughly
and can clean shoes
ignite before reuse.
without Inhalation
warning Rem
ove to fresh
air. If not
breathing,
Plant Name: FCCU-I

give artificial
respiration. If
breathing is
difficult, give
oxygen.
Catalysts
S. Chemical Physical Required Emergency
No Properties Precautions Handling
Procedure
Fresh White solid, White Powder Odorless : Odor Use the Eyes: Immediately
Catalyst less usual PPE in wash the eyes with
Non- Volatile solid. handling of large amounts of
SG:1 to 1.3g/cc : 1.0 to powders- water, occasionally
1.3 g/cc (bulk density) gloves, dust lifting upper and
pH in slurry: 3 to 6 mask, lower lids. If
protective irritation occurs and
clothing and persists, seek
goggles medical attention
Avoid Skin: Wash area
formation of with soap and water.
dust. Do not Personnel should
breath dust. shower after
Keep handling this
container material if frequent
closed and contact with dust is
dry experienced.
undercover. Inhalation: If
inhalation causes
irritation or
discomfort, remove
person from
exposure and seek
medical help, if
symptoms do not
disappear.
Ingestion: If
ingested, drink 2
glass of water and
get medical attention
immediately.
E catalyst Off-White to gray Use the Eyes:Immediately
(micro spheroids) usual PPE in wash the eyes with
Plant Name: FCCU-I
pH in slurry: 3 to 6 handling of large amounts of

SG:2.1g/cc : 1.0 to powders- water, occasionally
1.3 g/cc (bulk density) gloves, dust lifting upper and
Bulk Density: 0.7g/cc to 1.1 g/cc mask, lower lids. If
protective irritation occurs and
clothing and persists, seek
goggles medical attention
Avoid Skin: Wash area
formation of with soap and water.
dust. Do not Personnel should
breath dust. shower after
Keep handling this
container material if frequent
closed and contact with dust is
dry experienced.
undercover. Inhalation: If
inhalation causes
irritation or
discomfort, remove
person from
exposure and seek
medical help, if
symptoms do not
disappear.
Ingestion: If
ingested, drink 2
glass of water and
get medical attention
immediately.
BCA
COP White solid, White Powder Odorless : Odor Use the Eye Contact: Flush
less usual PPE in eyes with plenty of
Non- Volatile solid. handling of water.
SG:1 to 1.3g/cc : 1.0 to powders- Skin Contact:
1.3 g/cc (bulk density) gloves, dust Procedures normally
pH in slurry: 3 to 6 : Not mask, not needed. If skin
determined. protective contact occurs flush
: Non clothing and with plenty of water.
volatile solid goggles Inhalation: Remove
Avoid to fresh air. If not
formation of breathing, give
dust. Do not artificial respiration.
breath dust. If breathing is
Keep difficult, give
container oxygen.
closed and Ingestion:
Procedures not
Plant Name: FCCU-I
dry needed. If large

undercover. quantities are
ingested, seek
medical advice.
ZSM-5 White to tan color solid : Use the Eye Contact: Flush
White usual PPE in eyes with plenty of
Powder handling of water.
Odorless : Odor powders- Skin Contact:
less gloves, dust Procedures normally
Non- Volatile solid. mask, not needed. If skin
SG:2.1g/cc : 1.0 to protective contact occurs flush
1.3 g/cc (bulk density) clothing and with plenty of water.
pH in slurry: 3 to 6 goggles Inhalation: Remove
Avoid to fresh air. If not
formation of breathing, give
dust. Do not artificial respiration.
breath dust. If breathing is
Keep difficult, give
container oxygen.
closed and Ingestion:Procedures
dry not needed. If large
undercover. quantities are
ingested, seek
medical advice
Ingestion: If
ingested, drink milk
or milk of magnesia
and consult a
physician.
PPE Requirements-Type and Usage
SWP-1 specifies the standard for Personal Protective Equipment (PPE) to be used in the
Refinery premises.
In FCCU-I, the following PPE are used as per requirement.
Head Protection:
Safety Helmet (Basic PPE)
Color: Fire & Safety - Yellow; Other Employees : White; Contractors: Other colours
Welder'
s Helmet integrated with face shield fitted with filter glass

Plant Name: FCCU-I
Eye protection (For protection against flying particles & fragments, material and molten metal
splashes, harmful dust, gases or vapors and aerosols, harmful radiation) (Basic PPE)
Dust proof goggles (Clear — Plain goggles /Dark — Smoked goggles)

Chemical goggles (Panoramic view goggles)
Cover all goggles (Zero powered safety goggles)
Ear Protection
Ear Muffs/Ear Plugs (Basic PPE)
Face Protection
Face Shield
Helmet with face shield
Hand Protection
General purpose hand gloves (With leather inner)
Neoprene hand gloves for chemical handling CE marked
PVC hand gloves with inner cotton lining CE marked
Foot Protection
Safety Shoe with PVC sole (Basic PPE)
Safety shoe with PU sole (light weight)
PVC gum boots PVC gum boot,
white colour size 8" with steel toe having impact resistance of 200 Joules conforming to IS
15298.
Fall Protection
Full body harness (Double lanyard)
Body Protection
PVC hood Acid & Alkali proof Hood PVC with protected ventilator breathers and replicable
acrylic visor, acid and alkali proof.
PVC yellow color splash proof coat and pant PVC yellow color splash proof coat and pant
Full body apron with hood Full body apron with hood suitable for the person of height 173 to
178 cm
Respiratory Protection
Chemical cartridge respirator with half face mask for protection against H2S gas
Chemical cartridge respirator with half face mask for protection against CO gas

Plant Name: FCCU-I
Chemical cartridge respirator with half face mask for protection against NH3 gas
Jumbo chemical canister for protection against acidic gases with full white color body.
Jumbo chemical canister for protection against organic vapor with full black color body.
Jumbo chemical canister for protection against Ammonia with full green color body.
Surgical Cotton mask
Dust / Mist Respirator, with an electrostatic filter for a high filtering efficiency against 0.3
micron sized particulates.
PPE Usage guidelines
Minimum PPE required for an activity or operation is as given below. However MSDS and
JHA and JSA with a proper assessment of the job conditions provide all the minimum required
PPE for carrying out the job.
Basic Minimum PPE (BM - PPE): In the refinery for entering any Plant or carrying out any
activity in the field, three minimum PPE are required. These PPE are called BM - PPEs
1. Safety Helmet
2. Safety Shoes
3. Hand Gloves with inner leather lining.
Additional PPE (A - PPE): These are the PPEs which are to be used in addition to the BMPPE
based on the job, environment and circumstances.
Modified PPE (M - PPE): In activities where the BMPPE or APPE quality, material or shape
is to be of a different kind to suit the requirements of that activity. This normally is a
replacement of the corresponding PPE of either BM-PPE or A-PPE.
Operational Activities
Walk around in the Plant Area except and declared High Noise Areas
BM - PPE + Dust proof goggles (Clear — Plain goggles / Dark -Smoked goggles)
Walk around in the Plant Area including High Noise areas

BM - PPE + a. Dust proof goggles (Clear —Plain goggles /Dark – Smoked goggles) & b. Ear
Muffs / Ear Plugs
Operational activity in Plant except in declared High Noise Area.

BM - PPE + Dust proof goggles (Clear — Plain goggles / dark - Smoked goggles)
Plant Name: FCCU-I
Operational activity in declared High Noise Area.

BM – PPE+ a. Dust proof goggles (Clear – Plain goggles / Dark – Smoked goggles) & b. Ear
Muffs / Ear Plugs
Burners removal, installation in Furnaces (or in any Direct Fired Equipment)

BM – PPE+ Ear Muffs / Ear Plugs ,Helmet with face Shield & b. Kevlar Hand Gloves
Observing of Fire box flames (or any direct fired equipment)

BM - PPE Ear Muffs / Ear Plugs Helmet with face Shield
Hot Liquid Sampling: BM - PPE + a. Helmet with face Shield & b. Kevlar Hand Gloves
Draining of liquid, gas, unplugging of bleeders.: BM - PPE + Helmet with face Shield
Chemicals storage, dispensing, pumping and other handling operations

BM - PPE Additional PPE as per respective MSDS+ a. Neoprene hand Gloves & b. Helmet
With face Shield
Fresh caustic , spent caustic and other chemical vessels or equipment purging, steaming,
venting, raining operations
BM - PPE + Chemical cartridge respirator, Helmet with face Shield
Powder catalyst handling: BM – PPE+ a. Dust proof goggles (Clear — Plain goggles) b. Dust
Mask & c. Additional PPE as per respective MSDS
Maintenance Activities
Walk around in the Plant Area except and declared High Noise Areas: BM – PPE+ Dust proof
goggles (Clear – Plain goggles / Dark - Smoked goggles)
Walk around in the Plant Area including High Noise areas: BM – PPE+ a. Dust proof goggles
(Clear —Plain goggles /Dark – Smoked goggles) & b. Ear Muffs / Ear Plugs
Tightening of any joints on piping system, column, exchanger and vessel.

Declared high noise area. ( While equipment in service)
BM - PPE + a. Dust proof goggles (Clear — Plain goggles) b. Ear Muffs / Ear Plugs a. Helmet
With face Shield, b. In case of chemical service: Neoprene hand gloves, c. In case of service
above 50 degree C : Kevlar hand gloves

Plant Name: FCCU-I
Opening of joints for segregation blinding of any piping, column, exchanger or any other
equipment system
BM – PPE+ Helmet with face shield
Welding operations
BM – PPE+ a. Welders Helmet integrated with face shield fitted with filter glass, &b. Welder'
s
leather hand gloves
Gas cutting operations

BM-PPE+ Eye cup goggles Welder'
s leather gloves
Grinding operations :BM – PPE+ a. Helmet with face shield. & b. Welders leather hand Gloves
Positioning (working) at 2 meters above ground or a permanent platform.

BM – PPE+ Full body safety harness with double lanyard
Motor PM checks (High noise area)

BM - PPE + a. Dust proof goggles (Clear – Plain goggles).& b. Ear Muffs / Ear PlugsHy flex
hand gloves
IR testing BM - PPE + Electric Arc Flash protection Face shield
IR testing (High noise area) BM - PPE Ear Muffs / Ear Plugs Electric Arc Flash protection
Face shield
Excavations in cable presence: BM - PPE + Dust proof goggles (Clear – Plain goggles) & PVC
gum boot
Scrap area works: BM – PPE+ Dust proof goggles (Clear – Plain goggles)
P2 wrapping using blow lamp for heating purpose to carry out P2 Wrapping of pipelines
BM – PPE +Helmet with Faceshield.
Dry handling of bricks, mud, mortar etc.: BM – PPE+ PVC gum boots
Wet handling of bricks, mud, mortar etc.: BM — PPE+ a. PVC gum boots & b. PVC hand
gloves with inner cotton lining.
Excavation jobs: BM – PPE + PVC gum boots

Plant Name: FCCU-I
Concrete chipping jobs Manual: BM – PPE+ Helmet with face shield
Concrete chipping jobs (Pneumatic): BM – PPE+ Ear Muffs Helmet with face shield
Fixing of Aluminum sheets for insulation purpose

BM – PPE + a. Dust proof goggles (Clear – Plain goggles) & b. Dust mask
Insulation Mineral wool handling jobs

BM — PPE+ a.Dust proof goggles (Clear — Plain goggles) & b. Dust mask
Painting jobs at grade level

BM – PPE+ a. Dust proof goggles (Clear Plain goggles) and b. Dust mask
Painting jobs at height more than 2 meters.

BM — PPE+ a. Full body safety harness with double lanyard b. Dust proof goggles (Clear
Plain goggles) & c. Dust mask
Shot / Grit blasting BM — PPE Shot blasting hood and suit with airline supply connected to
vortex air cooler.
Confined Space Entry & works

BM — PPE+ Dust proof goggles (Clear Plain goggles), Respiratory Protection Air Line
Respirator / BA Set as per JSA & Dust mask
Confined Space Entry & works at height more than 2 meters

BM — PPE + Dust proof goggles (Clear Plain goggles) Respiratory Protection Air Line
Respirator / BA Set as per JSA b. Dust mask
c. Full body safety harness with double lanyard
Fire Fighting System& Equipment
Despite the achievement of better safety management, greater reliability of equipment,

advanced process control and optimum application of fire prevention and fire protection
measures, statistics indicate that occasional fire incidents continue to occur. Many large fires
are the result of escalation of smaller fires, so prompt and effective control of fires at initial
stages itself, is of prime importance. Hence, it is of paramount to upkeep the first-aid

Plant Name: FCCU-I
firefighting equipment provided in the plant to tackle fire emergencies till the required help is
received from Fire & Safety Department.
Fire Fighting Equipment Available In The Plant
Portable 10Kg, DCP Extinguishers

1" First-aid hose-reels
Hydrant, monitors inside the unit
Hoses, nozzles, etc., in Hose Boxes
Water spray system for pumps / vessels
Firefighting equipment and their respective location is as mentioned overleaf.
DCP EXTINGUISHERS
S. LOCATION S. No LOCATION
No
37 Stair case 8th landing
1 North of pump 4P52B 38 Stair case10th landing
2 South of 4P59 A (LCO PA 39 Stair case11th landing
pump)
3 Near heater soot blower control 40 Stair case12th landing
panel
4 Near east of heater (near stair 41 Stair case13th landing
case)
5 North east battery limit entrance 42/43 Stair case14th landing
6 East of catalyst hoppers COMPRESSOR HOUSE
7 South of 4P53B (MC top reflux 44 Compressor house south east stair case
pump)
8 South of4P67A/B (LPG product 45 Near compressor panels
pump)
9 East of 4C56 reboiler (HCO PA) 46 Compressor house west stair case entry
control valve
10 East of 4P72A (LCO booster TECH STRUCTURE 1ST FLOOR
pump)
Plant Name: FCCU-I
11 West of Fuel gas KOD 47 4V55 north west pillar

12 North east of 4P68 A (CSW 48 4V56 north east pillar
booster)
13 East of CBD 49 North west of slurry settler
14 East of 4E57 (surface condenser) 50 4V52 north (stairs between 1st/2nd
floor)
15 North east of WGC seal oil pump TECH STRUCTURE 2ND FLOOR
16 North of 4E51 51 North of 4E62A/B (CLO cooler)
17 North of 4E54 A 52 Slurry settler RV outlet
18 North east of 4E57 53 South of 4E63A (inter stage cooer)
19 North of 4P54A 54 North west of 4V57 (Debut. O/H drum)
20 North east of 4P67A/B TECH STRUCTURE 3RD FLOOR
21 WGC south west pillar (east of 55 North of 4E67A/B (Debutanizer O/H
FT2602) condensers)
22 South west corner of heater 56 East of 4E61 A/B (LCO trim cooler)
23 North east of J-bends 57 South of 4E59A/B/C/D (4C51 O/H
condensers)
24 East of 4C-52/4C53 TECH STRUCTURE 4TH FLOOR
25 Stair case1st landing 58 East of 4EM58A
26 Stair case1st landing 59 South west of 4EM58C2
27 Stair case 2nd landing 60 West of 4EM60A
28 Reactor feed nozzle area (1st HEATER
platform)
29 Reactor feed nozzle area (1st 61 Heater feed outlet (TPSV platform)
platform)
30 SCSV hydraulic panel 62 Heater feed outlet (TPSV platform)
31 Stair case 3rd landing 63 Heater feed inlet platform
32 Regenerator APH platform 64 Heater feed inlet platform
33 Stair case 4th landing 65 Stack slide valve south side
34 Stair case 6th landing Chiller
th
35 Reactor manway (stair case 6 66 West of 4P76A/B
landing)
36 Stair case 7th landing (south east 67 South of 4K81B
corner)

Plant Name: FCCU-I
CO2 EXTINGUISHERS:
1 Compressor panel
2 Elevator Motor room
3 Field room
TECH STRUCTURE
(CONNECTED TO SOUTH WEST
FIRE water riser)
South west corner B/L (near flare
1 14 Near compressor suction KOD
KOD)
2 North of Primary absorber 15 South of 4V57
3 West of 4P51B feed pump 16 West of 4E67A/B
Near snuffing steam to heater b/V
4 17 South west corner at fourth floor
assembly
TECH STRUCTURE
5 Near heater soot blower panel (CONNECTED TO NORTH EAST
FIRE water riser)
6 Heater north east corner 18 North east corner at 1st floor
7 South of 4P60A (HCO PA0 pump) 19 North east corner at 2nd floor
8 North of 4E57 20 North east corner at 3rd floor
9 North of 4P61B 21 North east corner at 4th floor
10 North of 4P67A/B Chiller
11 Near CBD drum 22 South of Chiller compressor,4K81B
South of WGC seal oil pump (near
12 23 North of Coalescer
stair case)
13 Regen III floor

Plant Name: FCCU-I
SAFETY SHOWERS:
1 North of CO boiler/Regen stack
2 West of heater soot blower panel
3 Bottom of slurry settler North
4 Near Anti-oxidant dosing station
5 Near Flare Knock out drum
6 North of Scrubber
7 West of FGD-I purge pump, 4P8104B
1 Box north of Flare KOD

2 Box near CBD drum
3 Box near Heater Soot blower panel
4 Box at Tech structure floor # 1
8 Box at south of field room.
1 Chemical cartridges
2 PVC PANT & coat
3 PVC gloves
4 Ear muffs
5 Face masks
6 Safety belts
7 Surgical cotton mask
8 Dust filters
9 Pan view Goggles
10 PVC hood
11 Original vapor canisters
13 Acid vapor canisters
14 Face shield

Plant Name: FCCU-I
Spill Handling Procedure

Please be guided by the onsite emergency manual Ref: http://10.6.0.131/f&s/onsite.pdf

Plant Name: FCCU-I
PLANT DRAINAGE SYSTEM
CHAPTER 26
PLANT DRAINAGE SYSTEM DESCRIPTION
Effluent System
All off specification hydrocarbon streams, hydrocarbon contaminated with water, water
contaminated with hydrocarbons or chemicals and such liquid streams that cannot be disposed
of directly are collected and treated either for recovery of hydrocarbons or to render them
harmless to receiving stream or for the purposes. For these purposes slop system, CBD system,
OWS systems are provided. These systems are described sequentially in the following
paragraphs.
Slop System
Slop oil system is one of the common systems in the Refinery, which connects all process units.
Slop system (lines and tanks) is provided to facilitate storage of Off-spec liquid products
generated from different units (due to process upsets) in a centralized common storage system
to enable subsequent reprocessing. Slop is also generated in refinery operation during start-up
/ shut down of units and commissioning / de-commissioning activities.
Off specification hydrocarbon streams are routed to a 6” slop header at unit B/L to slop tanks.
The slop generated within FCCU-I is primarily dry slop. This header is routed to the dry slop
tanks located at offsite. All product rundown lines are connected to slop header.
Management of Slop System
CBD system provided in unit should receive only liquid HC products at design
temperature
In no circumstances, gases (H2 / N2 / AAG / Fuel Gas / Propylene / LPG) shall be
routed to CBD or Slop line / Tank.
Off-spec heavy liquid products should not be routed to slop tanks. In case of
requirement as advised by Planner / RSM, it can be routed to slop tanks for short
duration. But the line should be immediately flushed with adequate quantity of cutter
and the same should be mentioned in TOB (duration of flushing, which product used).
Flushing water, salt water etc., from pipelines should not be routed to slop under normal
conditions. In exceptional situations, after taking concurrence from DGM-Operations,
this should be done.

Plant Name: FCCU-I
Responsibility of Unit Supervisor
Ensure that the temperature of any stream routed to slop header does not exceed design
limit (50oC)
To ensure that the information w.r.t product name, likely quantity, temperature, likely
duration, reason for routing to slop, is given to RSM, TPH Supervisor at DCS and ETP
Supervisors.
Log in unit TOB book about the time and reasons for routing off-spec liquid products
to slop tank and mention the slop tank number to which the product is routed.
Closed Blow Down System
Those hydrocarbon streams that are either free of water or only slightly contaminated with
water are received in closed blow down (CBD) vessel, 04V59. Such hydrocarbon streams are
generated especially during shut down periods.
The hydrocarbon in the CBD vessel should be received at a temperature well below flash point
of lightest component present inside.
Uncontaminated hydrocarbons from equipment draining is collected and routed to CBD vessel
through CBD headers, covering entire unit. Two 8” underground CBD headers run across
FCCU I. LP steam and flushing oil connections are provided at all dead ends of CBD headers
for line cleaning. The headers are finally routed 04V59. CBD drum is underground vessel,
placed horizontally. Drum is provided with a coil through which sea water or LP steam can be
passed.
LI7501 and TI7501 on 04V59 indicates level and temperature of CBD drum and are provided
with low and high level alarms (for LI-7501) and high temperature alarm for (TI-7501). CBD
pump (04-P-71) is interlocked with high/low alarms (LSL-7503 and LSH-7502) for auto start
and auto stop. Hydrocarbon is pumped out by CBD pumps to slop header in FCCU-1.
Under normal conditions CBD drum floats on atmospheric. A small purge or steam is provided
at the vent of the drum to guard against fire at the vent top due to lightening and static electricity
hazard. One service water connection is given to the drum for cleaning purpose.
Oily Water Sewer
This system also called OWS is mainly to collect water contaminated with hydrocarbon oil.
Such streams are generated during equipment draining and flushing during routine operation.

Plant Name: FCCU-I
Streams suitable for OWS also generated as a result of floor washing. Cleaning or spilled oil
etc. drained streams received through OWS funnels etc. are routed to ETP-I through a
combined header. Contaminated rainwater from the unit-paved area is also routed to OWS
system. All equipment having CBD connections are normally provided with OWS connection.
Care should be taken no spark reaches vapors space of OWS tunnels. This may result in
explosion immediately there or elsewhere in network wherever explosive mixture of air and
hydrocarbon vapors is present in appropriate concentration for explosion.
Surface Drain System
The peripheral surface Drain with double block valve arrangement to route it either to OWS or
to storm sewer system depending upon its oil content.
Guidelines for Draining Effluent into OWS
1. In case of de-pressuring requirement, all oil bearing equipment shall be drained to CBD
system only. In case the CBD system is not provided or not available, controlled draining
shall be done to the OWS system with prior intimation to ETP Supervisor and after
taking RSM concurrence.
2. Ensure temperature should not cross design limit (60oC) under any circumstances. In
case of emergency and it is required to drain urgently, suitable fresh water spray be
maintained to cool and dispose the vapors. Inform RSM and ETP-II.
3. Heavy oil sludge / slurry, (Congealing fluids) should not be drained to OWS, but has to
be collected in drums and follow "Disposal Request Notice" raised by Division Head.
4. During start up and shut-down, excess effluent may be routed to OWS. Necessary
information to be given to RSM and ETP-II.
5. Water used for KMnO4 wash should be routed to OWS only.
6. While draining to chemical sewer, care is to be exercised to prevent oil entry. Similarly,
caustic / chemical should not be drained / washed into OWS wherever applicable.
7. Lube oil from compressor / MAB L.O. sumps should only be routed to CBD.
8. Effluent draining to OWS shall be recorded per shift with estimated quantity.
9. During dry weather, the unit surround OWS channel shall be kept lined up to the OWS
system. The surround OWS channel valve to the surface drain shall be kept closed.
10. During wet weather, after 30 minutes of continuous rain, the surround OWS channel
shall be switched to the surface drain. Before switching, the surround OWS channel shall
be checked for the presence of oil.

Plant Name: FCCU-I
11. Under emergency circumstances, if fire water is to be used for any oil dispersal suddenly,
it shall be restricted to maximum 1/2 hr. from one first aid hose reel in a 24 hr. span.
12. Usage of first-aid fire water system for any purposes other than its original intent is in
any case not permissible. The above limits are in case their usage is done for emergency
usage of First aid hoses in any two areas shall not be simultaneous. The above limits are
valid for normal operations and are not applicable in case of emergencies such as fire
etc.
13. Operating Units house-keeping shall be maintained in a manner that all OWS channels
and entry points within the Unit shall not receive any debris, loose earth, sand etc.
14. All OWS channels within the Unit shall always be kept covered with standard gratings
and no gaps shall be allowed within two gratings.
15. Surround OWS cage screens are regularly monitored for debris. It shall be periodically
cleaned once the silt / debris level reaches 50% volume.
16. Car sealing system is provided in the process units and any deviation from the system to
be logged in unit TOB, informed to the RSM and concerned unit manager immediately.
17. Car seals are provided for the drain lines connected to OWS viz., caustic drain lines,
sour water lines and first aid hose reels to prevent unintended draining to OWS.
18. Avoid fire water entering into OWS system during routine checks on fire water system.
Wherever hose length is not sufficient to reach nearest storm water drain / surround
OWS, checking time shall be limited to maximum of 5 minutes.
Chemical Sewer System
1. While performing draining operations to the Chemical Sewer System, care should be
taken to minimize oil entry into the system.
2. All Chemical Sewer drain receiving ports shall be kept kerbed up to 6" and rain water
runoff will not be allowed to enter the Chemical sewer from these points.
3. Chemical sewer is designed only for spent caustic and only spent caustic should be
drained into it.
General (Common for all areas w.r.t OWS system)
1. No chemical like spent caustic, acid etc. shall be drained to OWS system.
2. Clean / uncontaminated water entry to the OWS / CBD system shall be avoided.

Plant Name: FCCU-I
3. Priority should be allocated for identifying and arresting un authorized entry into OWS
like condensate / service water draining, overflow, BCW draining, salt water usage for
cleaning etc.
4. No M.H. Box cover shall be left open except for the period any cleaning / maintenance
is in any progress. Even in case of maintenance / cleaning activity whenever there is
interruption in work or after closing hours, the Lid shall be placed back in position.
5. All M.H. boxes shall be monitored for unpaved area runoff entry and corrective action
shall be taken to prevent it.
6. All M.H. Boxes shall be visually monitored regularly for the Kerb wall / structure
integrity, numbering, lid in position, painting condition and corrective action to be
initiated accordingly.
7. No hardware changes on the OWS system shall be done except as per MOC procedure.

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I

Plant Name: FCCU-I
ENVIRONMENTAL MANAGEMENT
CHAPTER 27
Liquid effluents from FCCU-I which can significantly affect the environment are:
(i) Sour Water

(ii) Equipment/ Floor washings, contaminated with oil & chemicals,
(iii) Catalyst and additives,
(iv) Caustic in FGD-I
(v) Hydrocarbon draining from columns, vessels, heat exchangers etc.
(vi) Salt water
These pollutants are controlled with use of the following facilities:
Sour Water Stripping Units
During distillation of hydrocarbons in the column, sour water, containing hydrogen sulfide,
ammonia, phenols, etc. gets collected in the overhead accumulator drum. The sour water is
stripped off the pollutants in strippers with a steam reboiler. The off gases viz. hydrogen sulfide
and ammonia are routed to SRUs while the stripped water is reused partly as Desalter wash
water and the balance stripped water is routed to Effluent Treatment Plant (ETPs) prior to
discharge as refinery effluent to the sea. A dedicated sour water system is available in FCCU-
I to absorb sulfides, ammonia, phenols etc., in main column overhead, HP, interstage and
stabilizer condensers and options exist to route this water directly to SWSU from all the
condensers and also from main column overhead system.
OWS & Chemical Sewers
Segregated sewer systems of Oily Water Sewer (OWS) and Chemical sewers are provided for
better separation of oil from water and other spent chemicals. All the process units, product
treatment units and tank farm areas are provided with underground OWS network. Spent
chemicals like spent caustic (rich in sulfides) from Mercaptan Oxidation (Merox) units and
Diesel Hydro-de-sulfurization (DHDS) unit have dedicated underground sewer system for
routing the effluents separately to the ETP.
Closed Blow down System
All process and treatment units have Closed Blow down (CBD) system installed to facilitate
draining of hydrocarbons from equipment/ heat exchangers prior to giving for maintenance &
Plant Name: FCCU-I
repairs. This drain facility ensures that the hydrocarbon is recycled back to the process system
as slop oil and not let out to ETPs.
Effluent Treatment Plants
ETPs are equipped with physic-chemical, biological treatment and effluent polishing facilities
to remove free oil, emulsified oil and reduction of Biological Oxygen Demand (BOD). The
effluent quality is monitored regularly at the outlet. APPCB also monitors the liquid effluent
discharge from the refinery premises by collecting regular legal samples for checking
compliance with Minimal National Standards (MINAS).
Zero effluent discharge
To achieve zero liquid discharge from the Refinery by internally reusing and recycling the
waste water, the study was taken up with assistance of EIL. Refinery is taking up conversion
of FCCU-II to Recirculating cooling water system from once through cooling water.
Dedicated sour water collection and reprocessing: The study was taken up with assistance
of EIL to provide dedicated sour water collection system in the refinery to safeguard ETP from
shock loads during emergency or abnormal plant status.
Correction of excess oil ingress at ETP-I/II: The study was taken up with assistance of EIL
to reduce oil ingress into the ETP’ s. The study was completed and project is implemented in
ETP-I in August 2008. Implementation in ETP-II is also at an advanced stage.
Performance evaluation of Bio system at ETP-II: The study was taken up with assistance of
NEERI and the recommendations on improvement of plant performance are under
implementation.
Plant emissions
Emissions from Refinery operations which significantly affect the environment are
(i) Sulphur Dioxide (SO2),
(ii) Carbon Monoxide (CO),
(iii) Oxides of Nitrogen (NOx),
(iv) Suspended Particulate Matter (SPM),
(v) Hydrocarbon (HC), and
(vi) Noise.

Plant Name: FCCU-I
VR processes various types of low and high sulphur crudes. One of the objective of
processing high sulphur crudes is to maximize refining margin.
As high Sulphur crudes are processed, refinery SOx emissions also increase (i.e., from
FCCU regenerators).
The daily SOx emissions from the refinery is set at 11.5MT/day with DHDS in service.
Basing on this the maximum VGO sulphur at which upper limit of SOx emissions are
reached is 1.13%.
Also while processing VGO in FCCU, 10% of Sulphur gets deposited on coke which
leads to SOx emissions in regenerator.
Hence Regen Flue gas de-sulfurizer was installed to reduce SOx and SPM from NCO emissions
CO Boiler in FCCU
CO boiler is installed at downstream of Fluid Catalytic Cracking Unit (FCCU-I) regenerator to
convert highly harmful CO to CO2, and in turn generating HP steam as it is an exothermic
reaction.
Low NOx burners in Furnaces

Low NOx burners have been provided in furnaces and boilers installed after the year 1999 to
reduce NOx emissions.
High efficiency cyclones in FCCU

FCCUs utilize zeolite based catalyst in regenerator and reactor for catalytic cracking of heavy
molecular weight complex hydrocarbons to low molecular weight simple hydrocarbons. In this
process, part of the catalyst gets deformed and forms fines which tend to escape to the
atmosphere along with the flue gas from the regenerator. The installation of highly efficient
cyclones within regenerator and reactor enables retention of the fines within the process
system.
Low noise machines/ motors

At the time of equipment purchase itself it will be specified that noise level to be below the
statutory limit with required acoustic enclosures. All the pump drivers are flame proof and are
covered with hoods for noise reduction.
Tall Stacks
Process furnace, regenerator and FGD-I stacks are provided with tall stacks (about 60m) for
better dispersion of flue gases and to get ground level concentration within allowable ambient

Plant Name: FCCU-I
air quality limits. All the stacks are provided with monitoring facilities for SOx, NOx, SPM,
CO and HC.
Noise Monitoring
Exposure to noise at high levels and for long duration can have adverse physiological and
psychological effects. Periodic measurement of the noise pollution is carried out by Fire &
Safety Department.
Stack Monitoring System for FCCU-1
The stack monitoring system is designed for measurement of CO, SO2, and NOx and HC levels
in the flue gas. The entire system consists of a cabinet containing sample handling system and
the main analyzers which are located on the roof of Old CENTUM. Apart, from this SPM and
O2 monitoring system is fixed on top location of the stack area for measuring oxygen
percentage in the flue gas. The readings of all the analyzers are read on DCS station.
ANALYZER SYSTEMS
Rosemount Analytical, NGA (Next Generation Analyzers) 2000 Series:
Analyzers:
• CO & SO2: Range is 0-500 ppm
• NOx: Range is 0-250 ppm
• THC: Range is 0-500 ppm
SPM Analyzer System:
Analyzers:
• SPM: Durag D-R 300 opacity monitor.
Rosemount world class 3000 Oxygen Analyzer System:
Analyzers:
• O2: IFT (Intelligent Field Transmitter) 3000, O2 Analyzer
• Manufacturer: Emerson Process Management (India) Pvt Ltd
• Series: WC3000 (Without Keypad)
• Type: 1U05680G08
• Model: 3001 NFX-52-1-4-11-1-14-50-21
Plant Name: FCCU-I
• Range: 0-10% O2
Sampling Principle for CO&SO2, NOx & THC:
The sample is collected inside the system from the stack through the sampling probe by a pump
connected by a flexible hose. The sample reaches a SOV which can be used to route either
Instrument air for blowback of the probe or the sample gas to the cooler or rest of the sample
handling system. The sample cooler dries the gas to about Dew Point of 5.0 0C. A Condensate
sensor senses for the presence of condensate and if it is detected the pump is tripped thereby
isolating the whole system from a moist sample gas. After this the sample gas is divided so that
all the three analyzers receive the sample gas. A NO2/NO Converter is provided in the path of
the NOx analyzer. Spent gases are vented to the atmosphere. The respective analyzers give the
reading comparing with the calibrated reference gases.
Calibration Gases:
• Zero Gas: Zero grade N2 in 47 liters WC cylinder
• Span Gases:
(i) 500 ppm SO2 + 1000 ppm CO bal. N2 in 10 liters Al cylinder.
(ii) 1000 ppm NO bal. N2 in 10 litres Al cylinder.
(iii) 50 ppm CH4 bal. N2 in 10 litres Al cylinder.
• Other Gases:
(i) Zero grade H2 (fuel gas for THC) in 47 liters cylinder.
(ii) 21% O2 bal. N2 in 10 liters cylinder
Sampling Principle for SPM:
It utilizes the principle of light transmission. It consists of a measuring head and the reflector
head which are mounted on the stack top location opposite to each other. The light beam (from
Semi-conductor light source) traverses the distance to be measured (Diameter of the stack).
The light beam loses intensity during the two & fro motion which is proportional to the particle
concentration in the air.
Sampling Principle for Oxygen:
The Rosemount Analyzer system is designed to measure the net concentration of oxygen i.e.
the oxygen remaining after all fuels have been oxidized. It measure net O2 in the presence of
all the products of combustion, including water vapor. The probe is permanently positioned
within the stack and performs without the use of a sampling system. The equipment measures
the O2 % by reading the voltage developed across a heated electrochemical cell. It consists of
Plant Name: FCCU-I
a small stabilized Zirconia Disc, either sides of the disc is coated with porous metal electrodes.
When the cell is at operating temperature absolute & there are unequal O2 concentration across
the cell, oxygen ions will travel from the high partial pressure of O2 (measured gas side - P2)
to the low partial pressure side of the cell containing the O2 (reference gas side – P1) . The
resulting logarithmic
Output voltage is proportional to the logarithm of the inverse of the sample, O2 partial pressure.
Thus, the magnitude of the output is proportional to the negative logarithmic of the O2 partial
pressure in the measured gas.
EMF = KT log10 (P1/P2) + Constant; (K is an arithmetic constant)
SOLID WASTE
Under this plan, all hazardous wastes generated have been analyzed and categorized
with help of EPTRI, Hyderabad.
Spent catalyst is sold to authorized recyclers to the extent possible. Other wastes are
kept stored either in bins or packed in an earmarked area developed for this purpose.
Disposal of Coke, Empty chemical drums to authorized parties is under practice.
List of effluents, emissions and wastes generated in the unit
a. Liquid Effluent generation and control

S. Name of Quantity (approx.) Source of Controlling measures
No Effluent Generated per day. generation
1. Cutter 50 m3 Slurry pumps Change of Pump sealing
mechanism
2. Sour water 220m3 Stripping Steam Treated in SWSU

Plant Name: FCCU-I
b. Plant Emissions generation and control

S. Name of Quantity (approx.) Source of generation Controlling measures
No Effluent Generated per day.
1. SOx Heater, Regen Flue gas FGD-I
2. SPM Heater, Regen Flue gas FGD-I
3. NOx Heater, Regen Flue gas Modified burners. Regen
temp should not cross
750oC
4. CO Heater, Regen Flue gas CO boiler
5. HC Heater, Regen Flue gas, Maintain after burning
Sampling conditions in regenerator
and route sample point
drains to CBD
c. Solid Waste generation and control

S. Name of Quantity (approx.) Source of Controlling measures
No Effluent Generated per day. generation
1. E catalyst 400Kg/day Regenerator High efficiency of cyclones to be
maintained. Regen flue gases to
be routed to FGD-I to scrub of
catalyst fines and absorb SOx
emissions.
CPAR
To ensure that non-conformance to environmental regulations are reported and to take

corrective actions to mitigate its impact and to take actions to prevent its recurrence, CPAR or
Corrective and Preventive action report is raised to note this non-compliance.
Environmental nonconformities are sudden leakage/ spillage/ accidental or abnormal release

of products/ wastes/ episodic emissions/ deviations from established norms of operation &
practice causing significant impacts observed during routine operations.
Natural calamities such as cyclones, earthquake, floods, major fires, impacting regular
operations leading to environmental disturbances are also considered as nonconformance.
The custodian/ operational in charge of an area raises the CPAR form and routes it to HOD
Plant Name: FCCU-I
Depending on the type and nature of the corrective and preventive action, coordination for its
implementation is done.
CPAR should be closed only after the identified Corrective and preventive action is
implemented.

Plant Name: FCCU-I
SAFE WORK PRACTICES
CHAPTER 28
SAFE WORK PRACTICES
SAFE WORK PRACTICES
Set of best industrial practices, standards and statutory requirements grouped together and compiled
to act as a guide to the employees in for executing the assigned job in a safe way.
They act as guidelines helping the executors for the safe execution of the jobs in the refinery.
Safe work practices list out the essential requirements that are to be ensured for carrying out jobs safely
in the refinery.
So far total of 17 safe work practices were developed, and released for implementation.
Title of Safe Work Practices (SWP) Availability

1 SWP-01 Specification of Personal Protective Equipment 1.Soft copies
2 SWP-02 Minimum Personal Protective Equipment for various available in
activities Intranet.
3 SWP-03 Examination of Eyesight of Certain Employees
4 SWP-04 Requirement of PPE Availability in Plants and Other 2.Hard copy
Locations available with
5 SWP-05 Control of Loose Materials, Unfixed Tools & Equipment F&S dept.
in Plant 3.Copy of SWP
6 SWP-06 Contractor job equipment safety assurance No. …. are
7 SWP-07 Operations safety huddle attached in this
8 SWP-08 Control and Monitoring of Slippery Areas in Plants Operating
9 SWP-09 Procedure for effective management of near misses Manual.
10 SWP-10 Lock out and tag out system for electrical isolations
11 SWP-11 Management of Existing Early Warning and Response
Systems
12 SWP-12 Chemical hazard communication and Signage
13 SWP-13 Safety Monitoring of Enclosed Facilities
14 SWP-14 Readiness Assurance of Water Spray System
15 SWP-15 Authorization For Field Execution Works In Refinery
16 SWP-16 Management of Personnel Entry in DHDS - SRU
17 SWP-17 Electrical Safety Huddle

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
WORK PERMIT PROCEDURES:
Work permit system in the refinery is for carrying out various types of works after ensuring the
safety of people, equipment and material when performing any work within the refinery
premises. The issuer and the receiver of the permit have their responsibilities and roles before
issuing the permit. The details have been discussed it this chapter.
Based on the nature of hazards involved in the work to be carried out, the “ Work Permits” are
of following types:
Type No. Type of Work Permit Color of Permit
I Cold Work Permit Yellow

II Hot Work Permit Dark Pink
III Electrical Isolation / Energization permit Dark Blue
IV Excavation Permit Light Green
V Confined Space Entry Permit. Brown
VI Loading / Unloading of Hazardous Chemicals Light Blue
permit
Note: Only the employees undergone Training on “ Revised Work Permit System” and with
“ Authorization Card for Work Permit” are eligible for permit issuing or Receiving based on
their nature of job.
ASSET CUSTODIANS FOR ISSUE OF WORK PERMITS:
!
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SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
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SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
TYPES OF WORK PERMITS WITH DETAILS:

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
TYPE OF DEFINITION EXAMPLE SCOPE APPLICABI

WORK LITY
PERMIT
Cold Permit for an activity Opening process Blinding & All areas
Work which does not machinery. Deblinding. under
Permit produce sufficient heat Tightening of Hot bolting Refinery
or spark to ignite a flanges. control.
flammable air- Inspection. Painting.
hydrocarbon mixture Scaffolding. Grass Cutting.
or a flammable
substance.
Hot Work Permit for an activity Welding. Grinding. All areas
Permit that can produce a Gas Cutting. Shot Blasting. under
spark or flame or other Burning. Soldering. Refinery
source of ignition Chipping. Hammering control.
having sufficient (metal)
energy to cause Open Fire. Use of certain
ignition, where the non- explosion
potential for proof equipment.
flammable vapors, Use of Stress relieving,
gases, or dust exists. Diesel preheating and
Generator. induction heating.
Electric flash Concrete
unit/ flash bulb chipping
for taking
videography /
photography.
Fire Water Radiography.
usage,
Isolation of
Fire Water
network
Hot Road Closure.
tapping.
Stopping of Use of ultrasonic
steam leaks on instruments for
line using thickness
pneumatic drill. measurements.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
Electrical Permit to enable an Energizing & isolation of all electrical All areas
Isolation equipment / facility Equipment connections at sub-stations. under
& Energi electrically safe and Refinery
sation that the electrical control.
Permit power is isolated to the
extent necessary for
the safe conduct of the
authorized work.
Excavatio Permit for an activity i. Road Cutting. All areas
n Permit which involves under
breaking of any ii. Tank Dyke wall breaking. Refinery
ground surface by control.
person or machinery
for any purpose, iii. Digging for cable & pipeline
including penetrating laying
the ground surface to
drive steel or wooden
pickets. Core drilling,
drilling for fixings,
vertical boring into
decking, floor slabs
etc. (Taking out layers
of soil using any tool)
Confined Permit for an activity Process Vessels Boilers. All areas
Space within an enclosure (above ground under
Entry with known or & underground) Refinery
permit potential hazards and Furnaces Storage tanks. control.
restricted means of Large Diameter OWS
entrance and exit pipes. manholes.
which is not normally Effluent Switch Chemical storage
occupied by people pits. room / shed.
and is usually not well Chemical / Entering
ventilated. Process Pump Excavation more
Houses than 1.2 meter
deep

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
Loading Permit for an activity Unloading of HCL, H2SO4 , NaOH, All areas
/Unloadin of loading / unloading NH3, H2O2 and such other chemicals under
g of of chemicals having from a tank or other containers Refinery
hazardous potential of causing control
chemicals spillage / leak resulting
Permit into environmental /
health / property
damage.
Validity of Work Permit:
i) Permit shall be issued for single shift. Where the work has to be continued, the same permit may
be revalidated / extended shift wise for a period not exceeding Seven Calendar Days in the
succeeding shifts by authorized person after satisfying the permit conditions.
II) In instances like plant turn around, project jobs, Storage Tank T&I jobs work permit of extended
duration may be issued with the approval of Division Head for a period not exceeding Thirty
Calendar Days. In such cases Manager of Executing Department should receive the permit An
additional Extension of Work Permit sheet shall be used for this purpose.(attached as in Format
PSM-FR-9.17)
DSI on Generation of Work requests for Plant Maintenance (DSI-0-6):
Work request is fundamentally an instrument for requesting repairs and in kind replacement of
plant equipment through maintenance department.
Work request is also used for facilitating various plant shutdown and start-up operations like
steaming, blinding, other isolation and sanitizing methods, inert methods like hose connection,
drain & vent connection etc.
Types of jobs requiring work request: Job types for which Work Request is required to be
placed are as below:
No Job type
J-1 Requirement of Repair or in kind replacement of existing plant equipment and
facilities

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
J-2 Requirements of isolation, blinding, de-blinding, de-pressuring, testing,

inerting, system cleaning, steam-water-air hose connections for start-up shut
down operations.
J-3 Housekeeping, Cleaning, Dressing
J-4 Preventive, Predictive maintenance of existing plant equipment
J-5 Provision (part or full, modification) of external features like supports, access
structures, protective guards or covers, instrument steam tracing, external
firefighting systems, Civil works like kerb walls, routing channels, paving, fire
proofing, Insulation, painting, stenciling, new lighting, safety boards, external
safety features, Field room facilities, personnel communication systems.
Approvals for different types of jobs are authorized as below:
Job Type Approval by

J-1 Plant Shift In charge
J-4 Area Maintenance Manager
J-5 Plant Manager
In all the case Except J-4, The work requests are generated by the respective plant shift in
charge and they are routed to respective officials based on the job type and priority.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
Job Type approval:
Priority No Approval By
0 Division Head or above
1 Division Head or above
2 Plant Manager
3 Shift In charge
4 Plant Manager
5 Shift In charge
Quantitative limits for raising work requests:
Maximum work requests per shift
C-1 C-2 C-3 C-4 C-5

J-1 5 n.u.l n.u.l n.u.l n.u.l
J-2 n.u.l n.u.l n.u.l n.u.l n.u.l
J-4 n.u.l n.u.l n.u.l n.u.l n.u.l
SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
n.u.l : No upper limit
• The quantitative limits for raising work requests is to avoid bunching of work requests,
not intended that in every shift work request rising is necessary.
• In case of requirement crossing the quantitative limit, then work request should be
routed through division head.
• At the time of placing work request an assessment of the existing area of the work
environment to be carried out.
• Information on plant process conditions for non-routine work PSM-FR-9.7 is to be
attached to every work request.
• It is ensured that for all the recommendations of the OSI, IWL, work request is
compulsorily raised within 2 working days of its receipt.
GUIDELINE FOR EXPLANATORY NOTES TO WORK PERMIT FORMS

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
Sr. Checklist Explanatory notes

No points
1 Exact Location Exact location of the area or the unit in which the work is to be
(Area / Unit / carried out shall be written against it. For example: CDU-I, 2-F-01
Equip no) Tank farm of 20-D-4, Tank 501 etc.
2 Description of Precise description of the work to be performed shall be written.
work Sketches should be attached wherever possible to avoid
miscommunication.
3 Equipment / Equipment or area where work is to be conducted should be
Area inspected inspected to ensure that it is safe to carry out the work and assess
other safety requirements / stipulations. In case of equipment /
vessel box-up permit, it should be ensured that the work is complete,
all personnel are out, no maintenance gear is left behind and debris
removed.
4 Surrounding Unsafe conditions for performance of work may arise from
area checked / surrounding area. It should be cleaned up
cleaned to remove flammable material such as oil, rags, grass etc.
5 Sewers, Flammable gases may be released from nearby sewers. Hot un-
Manholes, insulated surfaces (equipment / pipelines) may provide a source of
Closed Blow ignition and therefore, these are to be properly covered to prevent
Down (CBD) fires.
etc. and Hot
Surfaces
covered.
6 Hazard from Other activities (routine / non-routine) being carried out near-by,
other routine / which can create conditions unsafe for performance of the permit
non-routine work, should be taken into consideration and the concerned persons
operations should be alerted accordingly.
considered and
persons
alerted:
7 Equipment Before issuing a permit, it shall be ensured that electrical isolation
electrically has been done, switches are locked-out and cautionary tags duly
isolated and signed with date and time are attached.
tagged

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
8 Running water Running water hose and portable fire extinguisher are required to
hose / Portable flush / dilute in case of release of any hazardous chemical or to
extinguisher quench sparks and to put out small fires immediately.
provided / Fire In order to meet any contingency, it should be ensured that the fire
water system water system including firewater pumps, storage, network etc. is
available checked and kept ready for immediate use.
9 Equipment Equipment, for which the work permit is being issued, should be
blinded / isolated from the rest of the plant in order to ensure that there is no
disconnected / change in the work environment with respect to presence of toxic /
closed / flammable gases, liquids, hazardous chemicals etc. in the course of
isolated / the work. Blinding is one of the most effective ways of isolation.
wedge opened Blinds should be installed as close to the equipment as possible. If
lines cannot be blinded, these should be disconnected and the open
ends should be made safe by installing pipe caps / plugs, blind
flanges etc.
10 Equipment Equipment under pressure should be depressurized after isolation.
properly This should be followed by draining / purging / water flushing etc.
drained / as the case may be.
depressurized Equipment containing liquid hydrocarbons should be drained
completely. There may be a possibility of overlooking of liquid
collected in pockets or inaccessible areas such as level gauges, small
nozzles / bleeders on vessels, laterals in pipe work etc. All low point
drains should be in unplugged condition.
11 Equipment Purging of equipment (tanks, vessels, pipelines etc.) is done to make
properly them free of flammable hydrocarbon and toxic gases. Steam / Inert
steamed / Gas is used for gas freeing of vessels and pipes in refineries and
purged other locations. Other means of purging is by displacement with
water and final traces of gas removed by properly earthed air
eductor. All high point vents should be unplugged while purging. It
should be done in a systematic manner to cover the entire equipment
/ plant and continued till the concentration of toxic / flammable gas
is lowered to allowable level.
12 Equipment Water flushing is an effective means of cooling, cleaning and even
water flushed gas freeing of equipment. It is also employed to remove traces of
acids / chemicals. Equipment metallurgy must be considered before
using sea / saline water. Sometimes, flushing with demineralized
water would be necessary depending upon the metallurgy of the
equipment.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
13 Gas / Oxygen Gas test includes measurement of:

deficiency test (i) Hydrocarbons, (ii) Oxygen Deficiency by Oxygen Meter, (iii)
done Toxic gases like Hydrogen Sulphide, Carbon Monoxide, Nickel
Carbonyl, and Chlorine etc. by techniques like Indicator Tube
method, Lead Acetate Paper etc.
Measurement of lead in air is required for entering tanks (which
stored leaded gasoline earlier) and personal protective equipment
shall be worn before entering the tank
14 Shield against Hot works like welding, grinding etc generates sparks which can
sparks provide source of ignition to the surroundings. In order to protect
provided operating area from the hazards of sparks generated, shields are to
be provided to contain the sparks generated. The shield material
should be non-flammable and should be kept wet with water.
15 Proper Where natural ventilation is not available, fans / air eductors are
ventilation and provided. These are also required for
lighting Speedy dispersal of fumes generated by welding job. Only approved
provided reduced voltage extension lights (not exceeding 24 volts) are to be
allowed for work inside vessels from consideration of personal
safety.
16 Proper means Proper means of exit is required in case of emergencies developed
of exit on account of the work or otherwise. Availability of an alternate
provided route of escape should be considered.
17 Area cordoned To prevent any unwarranted entry in the work area and also to
off and caution caution other personnel taking actions which may endanger people
boards working on the permit job, precautionary tags / boards are to be
provided provided to display like "No Entry" sign on roads or "Caution - Men
at Work Inside" on the manhole of a vessel, Danger - Radiography
in progress" etc.
18 Portable As a precaution against static electricity generation, portable
equipment / equipment / hose nozzles e.g. nozzle of a shot blasting gun, are to
Hose nozzles be grounded. Use of hydrocarbon lines for earthing should be
properly avoided. 30
grounded Mili-amp circuit breaker shall be installed on electrical circuits /
cables feeding power supply to portable equipment.
19 Standby person Whenever a person is entering in a confined space, minimum two
provided for designated persons shall be kept at the manhole or entry point. The
entry to designated person shall be in constant communication with the
confined space persons inside the confined space.
SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
20 Standby Depending on the criticality of the job, work permit issuer shall
personnel decide the type of standby to be provided i.e. from which
provided for department, of which level, how many and also additional
fire watch from firefighting support facilities etc.
Process /
Maintenance /
Contractor /
Fire
Department
21 Iron Sulphide Pyrophoric substances may be present in operating area / equipment
removed / kept handling hydrocarbon. Iron Sulphide scale is the most common
wet pyrophoric substance encountered. These should be either removed
to safe locations or kept wet all the time to prevent their auto-
ignition.
22 Clearance For any excavation work which may affect underground sewers /
obtained for telephone lines / cables / pipelines
excavation / etc., clearance shall be obtained from all the concerned sections.
Road cutting / Markers should be put around the area where excavation is to be
dyke cutting done and the depth to be indicated in the work permit.
etc Road cutting can hamper the movement of the fire vehicles; initial
clearance should be obtained from Fire Department and final
approval from the higher designated authorities.
When the dyke is cut, any mishap in the tank farm can lead to a free
flow of oil to outside the bund. A higher level authority should be
designated for authorizing dyke cutting. Further, it should be
ensured that dyke would be reconstructed in the shortest possible
time.
23 Checked spark No vehicle / engine without spark arrestor shall be permitted in
arrestor on operating areas.
mobile
equipment
24 Checked for oil Before undertaking hot jobs, a check should be done for oil / gas
/ gas trapped trapped behind lining in the equipment.
behind lining
in equipment

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
1. BASIC RULES OF WORK PERMIT SYSTEM:
1.1 It is the policy of the company to ensure the safety of people, equipment and materials
when performing any work within the Refinery premises.
1.2 Jobs shall be performed only after obtaining the stipulated permit.
1.3 Permit shall be issued / renewed and received only by personnel designated for the same
and are to be signed by the issuing / renewing and receiving personnel.
1.4 All necessary checks and tests shall be conducted to ensure safety of the jobs prior to issue
of permits. All precautionary measures required to be taken shall be clearly indicated on
the permit and their compliance ensured before handing over the permit to receiver
1.5 Permits shall be worded so as to limit the work to the designated areas / equipment /
facilities, agencies and time.
1.6 If any of the conditions vary during the work which may affect safety of human beings
and equipment, the job is to be stopped, the permit to be withdrawn and given back to the
issuer. Reason for withdrawing the permit to be mentioned on the permit
1.7 If a permit is withdrawn, the work should be restarted only after safe conditions are
established back and clearance obtained from the issuing / renewing authority and Fire &
Safety.
1.8 Work permits shall be made readily available at the work site for verification by concerned
personnel. The permit shall be put in a plastic folder and same will be displayed at work
site. Failure to present the permit on demand for verification shall result in stoppage of
work.
1.9 Work permits are valid only for the time period specified in the permit. Normally the
permits will be issued for the General Shift timings i.e. 08:00 Hrs to 16:30 Hrs.
1.10 If the job is to be continued beyond the time limit specified in the permit, it has to be
renewed at the beginning of the next shift.
1.11 Permits up to maximum of 30 days can be issued for major shutdown / project jobs.
However, this permit must be presented every day prior to starting of the work in each
shift by the concerned Executing person to issuing authority for renewal.
1.12 While renewing a work permit that has already been issued by another Issuing authority
of the concerned department, the renewing authority is no way relieved of the duties and
responsibilities specified by the original issuing authority.
1.13 At the time of renewal of a permit or when the job is in progress, if the issuing or renewing
authority as the case may be feel that some additional conditions or precautions are to be
stipulated or any of the conditions or precautions already stipulated are not necessary

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
based on the prevailing conditions, a new permit is to be issued incorporating the changes
and the previous permit should be withdrawn.
1.14 All work permits must be closed on completion of the job by the Supervisor of the
executing department / section and the permit duly signed for closure is to be returned to
the issuer. Work permits once closed cannot be renewed.
1.15 The work permit should be issued for one job one location only. Separate permits to be
issued for performing separate work on same equipment.
1.16 No hot work shall be allowed to be included in the hot work permit already Issued for
other jobs.
1.17 Whenever there is a job in pipe track which is in close vicinity (5 meters) of process unit
then prior to issuing of the permit the clearance from the concerned unit in - charge should
also be taken.
1.18 Each hot work permit shall have only a single job with scope written on it and the person
who is taking the gas test must sign on the permit.
1.19 Always "Receiver" has to sign the permit last, after taking all the necessary approvals and
understanding the necessary safety measures.
1.20 The job demarcation of each contractor shall be clearly defined on the permit beforehand,
incase more than one contractor working in the same area.
2. SPECIFIC RULES FOR WORK PERMIT ISSUING / RENEWING PERSONNEL:

The issuing/renewing authority is primarily responsible for the safe execution
of the job covered under the work permit and as such is to perform the
following duties:
2.1 Analyze and determine the condition of the facility and the area involved and Stipulate
necessary measures to be taken to ensure safe execution of the work.
2.2 Stipulate precautionary measures such as area preparation, blinding / isolation / tagging,
provision of safety and fire protection equipment, standby personnel etc. in the permits
and ensure the compliance.
2.3 Stipulate preparatory, preventive and precautionary measures to be carried out and ensure
their compliance.
2.4 Coordinate with other departments / sections wherever precautions are necessary to be
taken from their end also and counter signature to be obtained prior to issuing of the permit
2.5 Verify and certify installation and removal of blinds / isolation and their tagging.
SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
2.6 Perform necessary gas and other tests and the person performing the gas test to sign on the
permit.
2.7 Ensure that the facilities and the area at and around the place where permit is issued /
renewed are made safe prior to commencement and also during the progress of the job.
2.8 Check periodically the progress of the job permitted and stop the job if conditions become
unsafe.
2.9 Ensure that while hot work is in progress, no other work conducive to hazards is permitted
in the vicinity eg. repairs to Oil or Gas lines, bleeding or sampling of flammable materials
etc.
2.10 Ensure that all personal protective equipment / clothing stipulated in the work permit are
available at site before commencement of work and the same used by the personnel while
performing the work.
2.11 If a hot work permit is issued or if Hot Work Permit continues beyond the normal office
working hours (after 4.30 p.m.) then the permit is to be renewed as per permit renewal
procedure.
2.12 If the job is being done through contractor and in case more than one contractor is working
in the same area then the issuer shall clearly define beforehand the demarcation of each
job per contractor to avoid over lapping of different jobs.
2.13 The issuer shall give clearance to the Job Engineer for carrying out the hot jobs and not
directly to the contractor personnel.
2.14 In case of Hot Work Permit for cutting, welding, grinding etc. the issuer or his
representative and the receiver must be present for the first cut / first weld / first grinding.
2.15 For unit housekeeping, mopping (regular contract) Operations Supervisor will give cold
work permit to contractor Supervisor directly.
2.16 Ensure that "Receiver" returns back permit duly signed on completion of job and
"Housekeeping" is maintained. Scrap is shifted to designated area. Returned closed permit
are preserved for 30 days.
3. SPECIFIC RULES FOR WORK PERMIT RECEIVING / EXECUTING PERSONNEL:
Although a work permit has been issued for performing a certain job, no way it relieves
the supervisor of the executing department or the person executing the work of their
responsibility for safe execution and completion of the job. The receiving authority /

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
executing personnel is / are responsible for the compliance of the precautions / conditions
prescribed in the permit. Their duties and responsibilities include the following:
3.1 Carry out Job Hazard Analysis and ensure precautions as per that.
3.2 Secure necessary work permit from the concerned department before commencement of
the job.
3.3 Provide for and comply with all necessary precautionary measures stipulated in the permit.
3.4 Ensure basic safety precautions like usage of Safety belts, provision of ELCB (of 30mA),
Flash back arrestor to cutting torch, DCP extinguisher / charged fire hose are provided as
per the need of the job. Ensure that DCP and fire hoses are in good operable condition and
available at site prior to start of the permit
3.5 Take extra care when commencing the work, especially while breaking flange joints,
cutting through lines, striking an arc for the first time etc. Permit receiver to be present at
job site for first cut or first weld.
3.6 Ensure safe working practices throughout by continuous supervision (Either by executing
personnel or contractor personnel)
3.7 Ensure the availability of all the Personal Protective Equipment / Firefighting equipment
at site before commencement of work and also ensure that the same are used during the
work.
3.8 Stop the job if conditions become unsafe and report to the issuing / renewing authority.
3.9 Ensure that the work permit is duly put in a plastic folder and displayed at the work site
for verification.
3.10 Ensure that no blinds or other isolations specified for the work are removed or disturbed
during the work.
3.11 Ensure usage of grit blasting hood while Grit Blasting with air supply line connected with
vortex cooling system and job area is fully covered to contain dust particles.
3.12 Grit blasting hopper to be tested at 1.5 times of maximum working pressure. Contractor
should maintain test certificate.
3.13 Ensure that 24 V (Ac) hand lamps are used in the confined space.
3.14 Ensure that grade area is barricaded with red & white colour tape to cover excavated area
or in case of material handling at overhead.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
3.15 On completion of the job, measures and maintain normal conditions at the area of work.
Clear all scrap material and maintain good housekeeping.
3.16 On completion of job the receiver will sign for closure of the permit at space provided at
the back of the permit and return the permit to the issuer.
3.17 Receiver to ensure that registration number is entered in the permit before commencing
the job
3.18 Ensure that the Contractor has received a booklet on "Safety Regulations for Contractors".
31.1.1 Procedure for Cold Work Permit:
Issuing Authority:
Cold work permits can be issued/renewed by authorized personnel of the department to which
the equipment or area belongs.
31.1.2 Procedure for Hot work Permit:
Responsibilities of Renewing/Issuing Authority:
Hot will permits will be issued/ renewed by duly authorized supervisor of the owner
department of the equipment or the area.
Identify the hazards and note on the permit. Suggest additional safety measures to carry
out the job.
Permit is valid for one shift and may be extended for one subsequent shift if condition
permits. Issuer to note the extension of permit on his copy and in TOB.
Issuer and receiver of the permit should be company employees, will arrange to deposit
Fire House copy of the permit at box provided at MOI control room by 10:00 hrs, 18:00
hrs and 02:00 hrs.
After office hours the hot work to be carried out with a fire watch from Operations
department/ executing department/ F&S, as decided by the permit issuing authority.
If the permit is renewed, the issuer will inform fire house on telephone.
31.1.3 Procedure for Electrical Work Permit:
Duties of Permit Issuer:

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
The operations department personnel/owner of the equipment will raise the perm in the
prescribed format and fill the permit as required. On receipt of permit from electrical section
duly filled and signed then only issuer can take further action.
Explanatory Notes for Hot Work Permit Form:
Excavation/ road cutting/ fire water usage/crane operation/ radiography/ vehicle entry into
restricted areas:
Clearance obtained for excavation from Electrical departments and telephone in charge:
For any excavation which may affect underground electrical cables, electrical
maintenance should give clearance. Markers would be put around the area where
excavation can be done and depth should be indicated in the work permit. Clearance
from telephone in charge to be taken to ensure that no telephone cables get damaged
while excavation.
Shoring Provided: If the depth of excavation is mote than 2 meters, shoring is to be
provided to avoid the caving in of the earth.
Equipment/ Area Inspected: To be checked to ensure it is safe to carry out work and
access other safety requirements.
NRV provided on fire inlet line: In case of fire water usage for filling water in the tank
or flushing the pipelines, NRV is to be provided on fire water line to avoid the back up
of tank content/ line content into fire water network.
Overhead HT cables Isolated: In case of crane entry and movement, the issuer of the
permit will inform the electrical department to isolate the overhead electrical cables if
there is a chance of crane touching the cables.
Flame arrestor on exhaust checked: Every vehicle must have a flame arrestor on the
exhaust.
Area Cordoned off: In order to prevent unauthorized entry of personnel and to avoid
accidents due to excavated pits, work areas must be cordoned off by red and white tape.
Danger Sign Displayed: To prevent unwanted entry into the work area and to caution
the people, danger sign boards must be displayed.
Hydrocarbon Gas testing Reading: Hydrocarbon presence to be tested by explosive
meter to ensure that the area is free of hydrocarbon. The person carrying out the gas
test has to write to value and put his signature at the designated place.
Clearance from F&S: In case of crane movement and road closure, the issuer of the
permit will inform F&S department and take shift F&S officer’ s signature at the
prescribed place in the permit.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
Vessel Entry/ Vessel Box-up/ Hot work/ hot tapping:
Equipment/ Area Inspected: To be checked to ensure it is safe to carry out work and access
other safety requirements. In case of box-up permit, it should be ensured that the work is
complete, all personnel are out, no maintenance gear is left behind and debris removed.
Surrounding area checked/ cleaned: Areas should be clean and free of any oil, rags, grass,
etc.
Sewers, manholes, CBD etc and hot surfaces covered: The hydrocarbon vapors may be
present in these areas, which may be ignited during hot jobs. Therefore such areas should
be covered. Hot un-insulated lines/ surfaces may provide a source of ignition. Therefore
these are to be covered properly to prevent fires.
Consider hazard from routine/non-routine operations and concerned personnel alerted:
Other activities being carried out nearby areas, which can create conditions unsafe for
performance of the intended job. Therefore these activities should be taken into
consideration and the concerned personnel should be alerted accordingly.
Equipment electrically isolated and tagged: Before issuing the permit for starting
mechanical/electrical job, it has to be ensured that the equipment is electrically isolated and
switches are locked out, cautionary tags duly signed with date and time area attached.
Running water hose, portable extinguishers provided and fire water system checked for
readiness: They are used to flush/ dilute in case of release of any hazardous chemical or to
quench sparks and to put out small fires.
Equipment blinded/ isolated/ disconnected/ closed/ wedged open: Equipment on which
work permit is being issued should be completely isolated from the rest of the plant with
which it is connected during the normal operation, in order to ensure that there in no change
in the work environment with respect to toxic/ flammable gases, liquids, hazardous
chemicals, etc.
Equipment properly drained and de-pressured: Equipment under pressure should be de-
pressured after isolation. This will be followed by draining/purging, water flushing as the
case may be.
Equipment properly steam purged/ water flushed: It is done to make equipment free of
flammable hydrocarbons and toxic gases.
Gas/ oxygen deficiency test done and found ok: Area should be free of hydrocarbon and
same has to be tested by explosive meter. In case of confined space entry, in addition to
hydrocarbon, presence of oxygen and toxic gases to be checked. The results have to be as
follows, only then conditions are considered to be safe for working.
Hydrocarbon = 0.
Oxygen Content > 19.5%.
Hydrogen sulfide < 2 ppm.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
CO < 10 ppm.
Shield against spark provided: It is provided to protect the operating areas from the
source of ignition generated during welding.
Proper ventilation and lighting provided: Where natural ventilation is not available fan/
air educators are provided. Wherever sufficient light is not available, lighting has to be
arranged.
Proper means of exit provided: proper means of exit is required in case of emergencies
developed on account work or otherwise. Availability of an alternate route should be
considered.
Precautionary tags/boards provided: To prevent any unwarranted entry and also to
caution other personnel taking actions which may endanger people working on the
permit job.
Portable equipment/ hose nozzles properly grounded: As a precaution against static
electricity generation, portable equipment/ hose nozzle is to be grounded.
Check flame/spark arrestor on mobile equipment: No vehicle to be allowed without
them.
Welding machine checked for safe location: It should be in non-hazardous and
ventilated areas. It should have proper supervision while welding job is in progress. It
should be switched off immediately after completion of job.
Checked for earthing / return connection to the equipment being welded: All earthing
connections should be given as per welding codes.
Oxygen and acetylene cylinder kept outside the vessel/tank: While cutting/welding in
confined spaces, oxygen and acetylene cylinders should be outside and their hoses
should be in healthy condition.
Standby person provided for vessel entry: Standby person has to be present at the man
way or entry point holding the rope connected to safety belt of person working inside.
In case of emergency inside or outside the vessel, the standby person can pull the person
out.
Standby person provided for fire watch from Process/ Maintenance/contractor/ F&S:
Depending on the criticality of the job, the work permit issuer will decide the type of
standby to be provided that is from which department and of what level, how many and
also additional firefighting support facilities.
Iron sulphide removed and kept wet: Pyrophoric substances may be present in the
operating area/ equipment handling hydrocarbon. Iron sulfide scale is the most common
pyrophoric substance encountered. This should be either removed to safe location or
kept wet all the time to prevent auto ignition.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
Checked for oil/ gas trapped behind lining in the equipment: Many times oil/ gas
trapped behind linings depicts itself in the form of swelling and can be confirmed by
way of drilling holes.
Area cordoned off: In order to prevent un-authorized entry of people and to avoid
accidents during excavations work areas are to be cordoned off.
Clearance obtained for dyke cutting: Applicable to offsite tank dyke cutting.
Inspection Approval: While it is presumed that modification job will be undertaken
always with the approval of designated authority, it is further to be noted that hot
tapping should be undertaken after an approval from Inspection personnel. Continuous
flow in the line is to be ensured. Gas and airlines are not permitted for hot tapping work.
Exempted Areas:
The following areas do not require a work permit to carry out a job.
Project Building
Machine Shop
Fire House
Garage
Contractor Yard
Dispensary
Administration and Technical Service Building
South and main gate
CONFINED SPACE ENTRY PROCEDURE:
Any place is termed as confined space if it meets the following criteria:
a) It is large enough and configured such that an employee can bodily enter and perform the
assigned task.
b) And has limited or restricted means for entry or exit.
c) And is not designed for continuous employee occupancy.
d) And it may contain or produce dangerous contaminants.
The examples of confined space in refinery are vessels, tanks, furnaces, boilers, pits, manholes,
sewers, heat exchanger shells (open from one end), excavation deeper than 1.2 meters, entry
on floating roof tanks when roof is more than 3 meters below from the top of tank shell, AC
ducting systems, etc.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
Hazards Involved:
Oxygen Deficiency (less than 19.5% volume): This leads to asphyxiation.

Presence of toxic, corrosive, hazardous materials: Maximum allowable are H2S= 2ppm,
HC=20% LEL, CO= 10 ppm, NH3=25ppm.
Presence of flammable, combustible, explosive or pyrophoric materials: They lead to
incidents like fire, etc.
Restricted Access- Limited number of entry, exit points: This can lead to problem of
evacuating the entrants immediately in case of an emergency.
Restriction of freedom of movement inside confined space: This can cause unwanted
emergencies due to space constraint problem.
Falling/tripping hazard: Falling hazards can cause injuries, accidents, etc when any object
falls from higher elevations. Uneven flooring/obstructions in the walk way etc. Can cause
tripping hazard.
Inadequate Illumination/visibility/communication: this can cause unwanted incidents and
confusion in case of emergencies.
High temperature and humidity: Surfaces of high temperature can cause injuries
humidity/vapour can cause suffocation problems and breathing problems.
Electrical, static or radioactive hazards: This can cause electric shocks to human life and
may create sparks/fire, etc.
Mechanical Hazards: Mechanical hazards can cause accidents, incidents, injuries to human
life.
Preparatory work Before Issuing Confined Space entry Permit:
All personnel involved with confined space entry should be aware of hazards and no
person should enter the confined space unless entry permit has been obtained by the
concerned supervisor.
All the connected lines to the confined space have to blinded or disconnected by blind
flanges. No entry can be given without positive isolation.
Power driven internal equipment such as mixers shall be disconnected electrically by
an authorized person.
Mechanical ventilation equipment shall be properly grounded (earthed) to dissipate any
static charges. Pneumatic air movers (educators) and exhaust fans are recommended for
this purpose. Electrical powered fans if any shall be explosion proof types. Air intake
of forced ventilation equipment shall be from an uncontaminated location.
Utility or instrument air cannot be used as means of ventilation or as air supply to
breathing apparatus. All entrants shall wear personal monitors as required (H2S, CO,
O2).

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
Adequate illumination shall be provided using 24V or below explosion proof lamps.
Use of any electrical equipment above 24V shall have ‘earth leakage circuit breaker’
and also F&S department approval.
Wherever possible, the confined space shall be adequately ventilated to enable entry
without requirement of respiratory protection equipment. At least two manways should
be open in every chamber of vessel for proper ventilation.
Care should be taken when ventilating vessels containing ‘pyrophoric iron scales to
avoid spontaneous ignition. In such situation entry with required safety precautions or
handling pyrophoric iron in wet condition should be adopted.
The confined area shall be made safe for entry by such methods as depressurizing,
venting, draining, steaming, washing and ventilating. Radiation sources if any shall be
removed.
Shift in charge should be aware of possible behavioral effects of hazard exposure in
confined space area before issuing the work permit at confined space area.
Gas Testing Procedure:
Shift in charge has to ensure all the meters/instruments to be used for gas test are ready
to use.
Technicians have to ensure that the meter is in good condition and it has to be checked
and logged in TOB at the starting of the shift. If any problem is found with the
instruments, it has to be brought immediately to shift in charge’ s notice.
The gas tests have to be carried out and the testing result values have to be recorded in
the permit. F&S personnel can be called for entry into critical areas for witnessing gas
test and providing guidance as required.
First, the meter should be checked in fresh air (preferably in safe zone/field room).
Batteries should not be changed or charged in hazardous area. Testing immediately
after stopping the purge may give misleading results. Purge medium or air mover
should be stopped temporarily for 15 minute or more depending on the size of space
prior to measurement.
Initially the test has to be done from outside the confined space, using a long probe. If
the initial gas tests indicate a concentration above the permissible limits, further was
freeing should be done until the gas concentration is within permissible limits.
Test result should be representative of the entire confined space. Hence the need may
arise to enter for gas testing at different locations inside large tanks or towers and
complex vessels based upon number of man ways, toxic material handled, size of
vessel, etc to get a representative result. Operation shift supervisor should decide at
initial stage, the need for entering the confined space for gas testing.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
The job executing supervisor should witness or satisfy himself, that actual gas test has
been done before issuing and accepting the permit. Receiver can refuse the permit if
proper gas test was not done. For critical entries, the receiver should accompany the gas
tester up to the man way.
At least 13% oxygen is required to obtain an accurate LEL reading from a combustible
gas meter. Hence, these cannot give a proper reading in atmospheres such as vessel
purged with steam/nitrogen. Hence LEL and O2 shall be measured simultaneously.
Gas meters should be calibrated once in a month and certified by HPCL instrumentation
section. Record for each gas tester is maintained by instrumentation section. Next
calibration due date should be marked on the tester.
Confined Space Entry Permit:
The permit receiver should give “ safety pep-talk” to entrants about the hazards and
precautions prior to entry.
The receiver has to provide means for easy exit and entry of personnel into and out of the
confined space. Safety rope should be provided where required.
Hot work permit has to be issued in case of confined space entry and should be completely
filled. Non-relevant items should be struck off.
The issuer has to make the receiver aware of the hazards involved in confined space entry
and precautions to be taken.
Where atmosphere within confined space is initially safe, but there is a reason to believe
that it may become unsafe during the period for which entry is authorized (from emission
of fumes from sludge or deposits contained in the space or welding fumes), continuous gas
monitoring is required. The same has to be mentioned on the permit at the time of issuing.
Communication at Confined Area:
Shift in charge should make effective communication visually or by voice with the
entrants, effective means of communication should be available. Intrinsically safe
hands-free communication sets should be preferred.
In IDLH (immediately dangerous to life or health) atmosphere, a common
communication link system should be provided and used by personnel who are entering,
standby, and maintaining the life support system. IDLH values for toxic gases are H2S
=300 ppm and CO= 1500 ppm.
Shift in charge should ensure that all the entrants should be evacuated if the
communication is interrupted.
Shift in charge may enter a confined space to attempt a rescue with the help of F&S
personnel and co-ordinate for rescue operations.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
Shift in charge should monitor all the activities inside a confined space to determine if
it is safe for entrants to remain in the space and can order all the entrants to evacuate in
case he feels the presence of any prohibited condition.
F & S personnel have to be communicated as soon as the shift in charge determines that
authorized entrants may need assistance to escape from confined space hazards.
Requirements for Entry with Respiratory Protection:
Entrants should wear air supplied respirators in oxygen deficient atmospheres, when
toxics are beyond TLV and where atmosphere within confined space is initially made
safe, but there is a reason to believe that it may become unsafe during the period for
which entry has been authorized.
Under no circumstances chemical cartridge/canister type gas masks should be used for
confined space entry. Particular respirators have to be used if required.
Receivers have to ensure that air supplied respirators are in good condition, well
maintained and inspected according to manufacturer’ s specifications.
Breathing apparatus users should be medically certified and properly trained to use
breathing apparatus.
Entrants should wear harness attached to lifelines and be attended by an attendant who
should have breathing apparatus and clothing ready for use outside the confined space.
In IDLH atmospheres, entrants shall wear breathing apparatus or airline mask attached
with standby escape set. Rescue arrangements should be made ready with the help of
F&S.
Additional Requirements for Inert Entry:
Creating inert atmosphere is required where it is impossible to gas free below 20% LEL and/or
presence of pyrophoric material. Inert atmosphere are IDLH due to oxygen deficiency.
Oxygen concentration in the inert confined space should not exceed 5%. Hydrocarbon
should be below 100% LEL at the manway. LEL reading inside is not required.
Issuer has to ensure continuous oxygen monitoring and alerting the attendant to
evacuate entrants if oxygen level is exceeded. Audio-visual alarm is recommended.
The people not entering the confined area have to wear respiratory protection if the
effluent from the confined space contaminates the air.
Independent source of air for different people with low pressure alarm and escape
cylinder attached to waist shall be provided.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
PROCEDURE FOR OPENING PROCESS EQUIPMENT AND PIPING:
In the refinery any maintenance job needs a preparatory work prior to conducting the job. When
any jobs (cold or hot) has to be done in areas where flammable/hazardous mixtures are likely
to be present, the isolation of equipment involved in the job, has to be done in a proper and
scientific way for the safety of the equipment and personnel.
Purging/ Isolation of the Equipment:
Before any maintenance job is done in the plant, it is necessary to remove all flammable or
toxic gases from the system. Inert gas, nitrogen or steam may be used for purging. Water is
used for flushing after ensuring that the equipment can carry weight of water involved. The
part of the plant or the system to be purged is to be isolated either by closing appropriate valves
or by proper blinding. No valves should be considered leak proof and in any the cases of
maintenance jobs. Isolation of equipment is to be done by blinding. A blind list should be
prepared for isolation of equipment and check shall be done to comply with it.
If the line to be welded has contained flammable material it must be drained and section should
be disconnected at both ends. The whole section or the isolated portion should be then gas freed
and tested before welding commences. Where isolation and gas freeing are impracticable, the
line after draining should be washed thoroughly with water and welding/hot job while charged
with low-pressure steam or filled with water.
While opening any flange joint for installation of blind, the following procedure must be
followed:
Wear protective clothing and appropriate eye/face protection.

Ensure adequate working platform is provided.
Initially flange bolts to be slackened slowly by standing upwind direction and cross
check for presence of flammable or toxic gas, blots opening can be performed at a faster
rate.
Removing flange bolts leaving a minimum of two bolts, then loose last two bolts
without completely removing the nuts. Spread the flanges to install blinds. Always open
flange on the side away from the person so that any sudden release will be directed
away from the personnel.
The presence of concerned operation technician is a must for any emergency help, like
further isolation etc.
Hot cutting for flange nut bolts will be permitted only when presence of flammable of
toxic gases is ensured zero.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
Mud Packing:
Most common method used for plugging the end of pipeline for hot work is “ MUD
PACKING” . The main objective of mud packing is to block the hydrocarbon vapour, which
might be present in the pipeline.
Procedure for Mud Packing:
Cold cut the line on which the flange is to be welded.

Insert the plug into the pipe as shown in the sketch.
The plug must have a hollow 1” pipe connected at the centre and pipe will be extended
to a distance 5 feet away from the hot work area. The purpose of hollow pipe at the
centre is to prevent any pressure build-up on the upstream. At frequent intervals the
presence of toxic/flammable gases is to be checked and recorded so as to ensure that
there is no abnormal situation at the site. The gap between the pipe and plug shall be
nicely packed with clay mud as shown in the sketch.
The gas coming out from the vent point to be continuously monitored.
Once the welding is completed, the plug has to be taken out along with the mud by
pulling.
Typical sketch of mud packing:

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
Removal of Scaling:
After draining and isolation of the vessel is completed, the material left, such as sludge
has to be removed. A powerful jet of water applied through an open manhole can
remove sludge. If this is not possible, use reagent to dissolve the sludge/scale. The
liquid may be removed through the drain and the whole system may then be flushed
with water.
Where the scaling cannot be removed by liquid, it should be chipped away. Care in
this case has to be taken that non-sparking tools are used for chipping purposes and the
area is kept wet with water if there is even a possibility of generation of inflammable
vapour.
When process equipment is removed from a unit and must be sent elsewhere for repair,
it is operations supervisor’ s responsibility to see that it is thoroughly cleaned and/or
properly tagged if it has contained flammable, corrosive or toxic chemicals or iron
sulfide.
Equipment having contained ‘sour’ stock must be inspected by operation personnel for
iron sulphide deposits. Arrangements must be made to remove them after wetting till
such time such deposits should be kept wet to prevent spontaneous combustion.
Personnel entering tank which are not declared ‘free’ of hydrocarbon vapour should
wear breathing apparatus set. Personnel should enter with “ Entry Permit” and keeping
a person as standby.
Preparation for Hot work after cleaning the equipment:
All cold work cleaning rules must be observed in preparing equipment for hot work.
When normal cold work preparation has not satisfactorily removed rust, oil or lead
sludge from internal surfaces of vessels they must be hand scrapped or if practicable,
they must be sand blasted with the nozzle bonded to the equipment being sand blasted.
Sewers openings in the area of hot work are to be sealed to ensure prevention of
flammable atmosphere. The seal must be removed upon job completion. Sand should
not be used for sewer sealing because vapors may escape through the porous material.
Pit covers can be sealed by mud packing.
Lines, vessels, etc which have contained flammable, toxic or otherwise injurious
materials must be carefully checked and appropriate measures taken to ensure that
liquids or gases are not entrapped between lines and vessel shell.
Preparation of Equipment for return to service:

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
It should be ensured that all foreign materials/scales/rust etc are removed and
equipment is properly cleaned prior to giving box-up permit.
It has to be ensured that water or test liquid has been drained properly.
Carefully inspect all the equipment that has been repaired before returning it to service
in order to be sure that all the guards and safety devices are placed back and they are in
safe condition to operate.
PROCEDURES FOR CRITICAL EQUIPMENT HANDING OVER:
Pumps / Turbines seal repairs:

For Handing over to maintenance:
Isolate suction, discharge and warm up valves.

Allow the system to cool down and then flush it with cutter to CBD through casing after
removing blinds on cutter and CBD of the concerned.
After ensuring the stock becomes light depressurize it to CBD. Open pump vent point
value for proper depressurizing.
Blinding is to be done for proper isolation on suction, discharge, warm-up, flushing oil,
seal oil, seal steam and CBD lines and update blinds register.
Isolate power to the pump & tag.
Isolate steam to the turbine &depressurize and blind it on steam side.
Issue permit, decouple turbine /pump after ensuring the above.
Keep equipment under maintenance display board.
Note: disconnect instrument thermocouples as per rotary.
After the seal replacement on pump/ Turbine:
Check BCW, seal system, seal oil systems and remove any foreign materials in and
around pump/turbine basements
Remove blinds on suction, discharge and warm up, CBD, seal systems, seal oil and
flushing oil. Ensure proper gaskets are installed.
Close pump vent, open casing drain to CBD. Throttle pump discharge PG drain valve
to remove air.
Open flushing oil slightly to fill casing and to remove air from downstream PG point.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
Once oil is coming through downstream PG point, close it. Also close casing drain to
CBD and check pump blind flanges with FLO pressure (9 Kg\Cm2) for leaks.
De-pressure the cutter to CBD and open pump warm up valve slightly for warm up
condition (only for hot service pumps).
Allow rotary to do hot alignment.
Allow maintenance to do hot bolting on blind flanges.
After hot alignment and coupling fixing, check for free movement of shaft.
Check no load and direction of motor rotation before coupling as per rotary/Electrical
and isolate power.
After ensuring all the jobs are over power to motor is to be released. Steam blind to
turbine is to be removed.
When all the above factors are ok place the pump /Turbine and see the performance.
Keep casing drain to CBD\OWS blind.
Ensure updating of gaskets and blind registers.
Remove equipment under maintenance display board.
Pump \ Turbine suction strainers cleaning:
For Handing over to maintenance:
Isolate suction, discharge and warm up valves.

Allow the system to cool down and then flush it with cutter to CBD through casing after
removing blinds on cutter and CBD of the concerned.
After ensuring the stock becomes light depressurize it to CBD. Open pump vent point
value for proper depressurizing.
Blinding is to be done for proper isolation on suction, discharge, warm-up, flushing oil,
seal oil, seal steam and CBD lines and update blinds register.
Isolate power to the pump & tag.
Isolate steam to the turbine &depressurize and blind it on steam side.
Issue permit, decouple turbine /pump after ensuring the above.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
Check BCW, seal system, seal oil systems and remove any foreign materials in and
around pump/turbine basements
Close pump vent, open casing drain to CBD. Throttle pump discharge PG drain valve
to remove air.
Open flushing oil slightly to fill casing and to remove air from downstream PG point.
Once oil is coming through downstream PG point, close it. Also close casing drain to
CBD and check pump blind flanges with FLO pressure (9 Kg\Cm2) for leaks.
De-pressure the cutter to CBD and open pump warm up valve slightly for warm up
condition (only for hot service pumps).
After ensuring all the jobs are over power to motor is to be released. Steam blind to
turbine is to be removed.
When all the above factors are ok place the pump/Turbine and see the performance.
Keep casing drain to CBD\OWS blind.
Ensure updating of gaskets and blind registers.
LPG/ Naphtha pumps seal repairs:
Isolate suction, discharge and warm up valves

Isolate self-coolant lines.
Depressurize the content to flare through casing vent to flare.
Provide steam hose connection pump D\S PG point.
After ensuring gas is depressurized close casing vent to flare, Open casing drain to
OWS and check if any gas is coming.
Observe passing of valves during depress ring to flare through of lines.
Ensuring system is depressurized blind S\C, D\S ,and self-coolant, casing CBD\OWS
and flare systems, update blind register.
Isolate power to the pump and disconnect steam hose.
Issue permit to rotary to carry out the seal replacement job.
Note: Inform instrument people to check and repair seal pot pressure and low level switches if
any.
Provide steam hose at pump downstream PG point.

Check self-coolant systems.
Check and remove all foreign materials in and around pump basement area.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
Remove blinds on suction, downstream and self-coolant systems.

Open steam and pressure test the pump for blinding flange leaks.
Close vents and bleeders.
During slight steam purge open suction valve and casing vent to flare for some time,
and close steam completely.
Close casing vent to flare after some time.
Open casing drain to displace condensate if any.
Blind pump casing drain to OWS\CBD.
Check for no load test before fixing coupling as per rotary \ electrical.
When all jobs are over release power to motor and check direction of pump.
Place the pump online slowly and check the performance.
Ensure updation of blind and gasket registers.
Releasing and commissioning of coolers, condensers and exchangers for tube leaks:
Coolers/condensers:
Isolate inlet and outlet valves on shell and tube.

Depressurize the hydro carbon content to CBD after removing blind.
Cooling water is to be de-pressured to intermediate sewer.
Provide steam connection on shell side vent and start initial steaming.
After ensuring sweat steam and non-passing of isolation valves stop steaming and blind
both sides shell and tube inlet and outlet lines and update blind register.
Again carry out final steaming for 2 to 3 hrs then stop steam.
Again put blinds to CBD lines.
Allow maintenance to carry tube leak jobs.
Care should be taken while bundle is pulled out and when fixing and dropping of
components.
Air fin coolers:
Isolate inlet and outlet valves on shell and tube. .

Depressurize the hydro carbon content to CBD after removing blind.
For attending the tube leak of one AFC, both the common inlet and outlet are to be
isolated. Power to AFC fans is also to be isolated.
Provide steam connection on tube side and start initial steaming.
After ensuring sweat steam and non-passing of isolation valves stop steaming and
blind both sides shell and tube inlet and outlet lines and update blind register.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
Carry out final steaming for 2 to 3 hrs then stop steam.

Put blinds to CBD lines.
Allow maintenance to carry tube leak jobs.
Care should be taken while bundle is pulled out and when fixing and dropping of
components.
Other standby AFC can be placed on line as per procedure after properly isolating
& blinding the AFC handed over to maintenance.
For exchangers:
Isolate inlet, outlet, warm up valves, TSV’ s on shell and tube sides and open bypass.
Steam connections are to be given to vents and depressurize to CBD\OWS on both
sides.
Ensuring sweat steam and non-passing of isolation valves blind both shell and tube side
inlet and outlet. Also carry out hot bolting of component bolts for dropping during
steaming condition.
Release exchanger for dropping components after closing steam valve. Disconnect it
only after final steaming for 2 to 3 hours.
Blind CBD lines and update blind register.
Commissioning of cooler/condenser:
After the maintenance jobs are over connect steam hoses on shell side vents.
Deblind the shell and tube sides.
Carry out steam test for blinding flanges at 5 to 6 Kg\Cm2.
When there is no leak, deblind FLO and CBD blinds.
Cutter flush to CBD.
Remove all steam hoses and cap off vents.
Ensuring water/cutter is displaced open inlet and outlet valves slightly keeping bypass
in wide open condition. Slowly open inlet and outlet valves and slowly close bypass
valve.
Establish cooling water flow through cooler/condenser and close intermediate sewer
valve before establishing flow on shell side.
Observe pressure and temperature and slowly open valves on shell & tube.
Check for flange leaks if any.
Blind CBD\OWS and FLO lines.
Ensure blind and gasket registers are updated.
Commissioning of Air fin cooler:

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
After the maintenance jobs are over, connect steam hoses on tube side after isolating
the common inlet and outlet valves and power to fans.
Deblind the tube side.
Carry out steam test for blinding flanges at 5 to 6 Kg\cm2.
When there is no leak, deblind CBD blinds.
Flush to CBD.
Isolate all steam hoses and cap off vents.
After filling with product on tube during slight steam purge by opening slightly inlet
and outlet so as to displace water to CBD/OWS, remove all steam hoses.
After ensuring water is displaced, open inlet and outlet valves wide.
Restore power to the fans for starting.
Observe pressure and temperature and slowly open valves on tube.
Check for leaks for flanges if any.
Blind CBD\OWS lines.
Update gasket and blind register.
Commissioning of exchanger:
After the maintenance jobs are over connect steam hoses on shell and tube side vents.
When there is no leak deblind FLO and CBD blinds.
Cutter flush to CBD\OWS.
After filling with cutter to displace water/condensate to CBD\OWS through top of the
bundle on shell & tube, displace cutter. Open inlet and outlet valves slightly. Keep open
wide seeing the unit conditions then close bypass valve.
Ensuring water is displaced open warm-up valve on crude from top to displace cutter.
Slowly open inlet or outlet valves and slowly displace cutter to CBD on shell side.
Ensuring cutter is displaced to CBD on crude side open the inlet and outlet valves,
warm-up valves slightly to prevent vapour lock. This may lead to feed failure to
furnace, hence slowly open them wide after checking unit conditions. Afterwards open
inlet and outlet valves slightly. Ensuring the conditions keep valves wide open and close
bypass valve.
Observe pressure and temperature on both sides.
Slowly keep the exchanger fully in service. Check for leaks on flanges and update blind
register.
For steam generator:

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
Isolate inlet and outlet valves, TSV’ s on shell and tube sides and open bypass.
Isolate BFW. Depressurize 42V21 level at 42E19A/B drains and blow down valves. By
opening 2” vent depressurize the system after closing PSV and warm-up valves on MP
steam.
Steam connections are to be given to vents and depressurize to CBD\OWS on both
sides.
Ensuring sweat steam and non-passing of isolation valves blind both shell and tube side
inlet and outlet.
Release exchanger for dropping components after closing steam valve. Disconnect it
only after final steaming for 2 to 3 hours.
Blind CBD lines and update blind register.
Commissioning of steam generators:
After the maintenance jobs are over connect steam hoses on shell and tube side vents.
When there is no leak deblind FLO and CBD blinds.
Cutter flush to CBD.
Build up levels in steam generators and 42V21 up to 30 %.
Keep steam generator vents open.
After filling with cutter displace cutter to CBD with SR through top of the bundle.
Ensuring cutter is displaced open inlet and outlet valves slightly keeping bypass in wide
open condition. Slowly open inlet and outlet valves and slowly close bypass of one
steam generator.
Keep 42V21 warm up open.
Observe steam generator pressure and temperature and slowly open steam outlet valves.
Slowly close SR side bypass and keep steam generators one by one online.
Close local vent and keep the steam pressure control on system finally. Blind
CBD\OWS and FLO lines. Update gasket and blind register.
31.1.4 Process Equipment: Towers, Vessels etc.:
Before opening any equipment, it should be purged to render the internal atmosphere non-
explosive and breathable. Operations to be carried out are:-
Isolation with valves and blinds.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
Draining and depressurization.

Replacement of vapors or gas by steam, water or inert gas.
Take care about instrument tapping.
Washing of towers and vessels with water.
Ventilation of equipment.
Opening of top manhole.
Testing of inside atmosphere with explosive meter.
Complete opening if inside atmosphere is satisfactory.
Analyze the atmosphere inside for O2 content and any poisonous gas.
Note: Open a vent on the upper part of the vessel to allow gases to escape during filling and
to allow air inside the vessel during draining. Ensure proper ventilation inside the vessel by
opening all manholes. For hydrocarbon or other gases, pressurize the vessel with N2 or gas and
fill in the liquid and drain under pressure. This is to avoid hydrocarbon going to atmosphere.
Precautions before Handing Over Equipment:
Following items should be checked by a responsible operating supervisor before equipment is

handed over for maintenance after it has been purged.
Ascertain that equipment is isolated by proper valves and blinds.

Ascertain that there is no pressure of hydrocarbons in the lines, vessels and equipment.
Purge the system with N2 first and later by air and check for 02 content at vent and drain
to ensure that the vessel is full of air.
Check that steam injection lines and any inert line connections are disconnected or
isolated from the equipment.
Provide tags on the various blinds to avoid mistakes. Maintain a register for blinds.
Check for pyrophoric iron and if existing. Keep this wet with water.
Keep the surrounding area cleaned up.
Get explosive meter test done in vessels, lines, equipment and surrounding areas.
If welding or hot work is to be done also:
1. Keep firefighting devices nearby, ready for usage.

2. Close the neighboring surface drains with wet gunny bags,
3. Keep water flowing in the neighboring area to cool down any spark bits etc
4. Keep steam lancers ready for use.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
After the above operations have been made, a safety permit should be issued for carrying out
the work. A responsible operating supervisor should be personally present at the place of hot
work till the first torch is lighted. Hot work should be immediately suspended if instructed by
the supervisor or on detecting any unsafe condition.
When people have to enter a vessel for inspection or other work, one person should stand
outside near the manhole of the vessel of for any help needed by the persons working inside.
The person entering the vessel should have tied on his waist a rope to enable pulling him out
in case of urgency.
Procedure for dropping Fuel gas burners:
Inform to DCS supervisor before fuel gas raisers cleaning.

During dropping and placing Fuel-gas make sure stack damper is in wide position to prevent
excessive pressure developing in the furnace.
Remove Fuel-gas fire& oil and pilot fires. Also isolate air registers.
Purge oil gun with steam for some time to congealing fuel-oil flexible hose.
Atomizing steam and purge steam valves are to be closed.
Blind fuel gas line. One person to be stationed there till completion of blinding. While
slackening the blinding flange make sure fuel gas line plug cock valve is not passing for
which gas tester may be used while slackening blinding flange. If valve is not passing, fuel
gas line to be blinded. If valve is passing suspend the job.
Check burner in-side for oil accumulation through burner view ports
Use face shield and asbestos gloves during checking and dropping of Fuel-gas burner tips
Keep burner drain at assembly open to drain oil inside, if any. After removing all fires&
closing air registers allow the burner to cool for 2to3hrs.
After dropping Fuel-gas raisers with face shield and asbestos gloves soak it in the soaking pit
after cooling
Remove and replace damaged tips of the burners with new parts after checking condition if
any, before assembling after cleaning.
Fix Fuel-gas raisers.
De-blind Fuel-gas line.
Inform to DCS supervisor about completion of job and placing of fires.
Ignite pilot.
Adjust air registers.
Place gas fire and then oil fire slowly.
Check for any leaks with gas detector.
Advise maintenance to carry to house-keeping.
Finally, up-date burner spares register, blind registers.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
Procedure for burner’s assembly dropping:
Inform to DCS regarding the job and ensure stack damper is in wide open condition to
prevent excessive pressure developing in the furnace
Remove oil fire, gas fire and pilot fires and hot well off gas fire (if it is a hot well burner).
Purge oil gun with steam for some time to prevent plugging with fuel-oil
purge steam valves are to be closed
Close atomizing steam valves.
Disconnect oil& steam flexible hoses.
Drop oil gun, after cooling keep it sample trough for soaking and subsequently gun to be
cleaned as per procedure.
After removing all fires& closing air registers allow the burner to cool for 2 to 3hrs.
Disconnect pilot burner electrical power.
Check burner in-side for oil accumulation through burner view ports
Use face shield and asbestos gloves during checking and dropping of burner assembly
Keep burner drain at assembly open to drain oil inside, if any.
Drop Fuel-gas/pilot gas burners/tips as per the procedure mentioned in fuel gas burner
dropping; with face shield and asbestos gloves soak it in the soaking pit after cooling.
Drop the burner assembly for repairs and fix a dummy plate at the bottom.
Fix burner assembly after repairs and after removing plate at the bottom after taking
clearances from INSPECTION/TSD.
Fix Fuel-gas/Hot well off gas/pilot burners .connect oil burner flexible hoses and oil gun.
Restore power to pilot burner.
De-blind Fuel-gas/Hot well off gas lines and pilot gas lines.
Lit up pilot burner and then keep Fuel-gas/Hot well off gas fires (if it is a hot well burner)
as per procedure.
Check for any leaks at pilot gas line, fuel gas line and hot well gas line flanges with gas
detector.
Place oil fire as per procedure and check for leaks if any after placing oil fire
Finally, up-date burner spares register, blind registers.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
ELECTRICAL LOCKOUT/ TAGOUT PROCEDURES:
Multi-lock system is used to prevent injury by accidental energizing of any equipment while it
is attended by different sections/agencies:
The executing authority and the issuing authority will jointly decide the requirement.
The issuing authority issues the work permit to competent electrical person to isolate the
electrical equipment from sub-station.
The competent electrical person and the executing authorities install their locks in the multi-
lock pad as per color coding.
Electrical and other parties sign the isolation work permit.
Color coding of pad locks:
a) Electrical maintenance- Brass Yellow

b) Mechanical Maintenance- Black
c) Others- Blue
Each lock should be numbered and the key should be same number.
After locking, the person who installs the lock is the responsible custodian of the key. The
locks should be removed by individual craft after completion of their jobs.
If the custodian of the key has to leave the site, responsibility has to be transferred to the
next shift person.
Electrical maintenance division shall be the last party to remove the lock only after
receiving the necessary permit.
Use of “DANGER-DO NOT OPERATE” tag with isolation by local switch shall be limited
to minor electrical jobs carried out by Electrical Maintenance division, such as re-lamping.
Electrical Isolation Procedure:
Electrical isolation may be required before starting work on or near electrical equipment to
avoid electric shock and other hazards. The extent of isolation required will depend on the
nature of work.
Requirement of isolation and extent of isolation shall be jointly decided by the issuing
authority and executing authority by using electrical isolation permit.
When multiple sections/ agencies are involved, the multi-lock system shall be followed. If
only electrical maintenance is involved they may use single lock.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
Wherever the possibility of electric shock or injury is expected due to inadvertent staring,
lock of power circuit at substation is mandatory. Locking the control circuit at local switch
shall not be considered as adequate.
When an electrical circuit/equipment is fed from two different sources of power supply,
both the source of power to be switched off to avoid back feeding.
CONFINED SPACE ENTRY PROCEDURE:
Any place is termed as confined space if it meets the following criteria:
• It is large enough and configured such that an employee can bodily enter and perform the
assigned task.
• And has limited or restricted means for entry or exit.
• And is not designed for continuous employee occupancy.
• And it may contain or produce dangerous contaminants.
The examples of confined space in refinery includes vessels, tanks, furnaces, boilers, pits, manholes,
sewers, heat exchanger shells (open from one end), excavation deeper than 1.2 meters, entry on floating
roof tanks when roof is more than 3 meters below from the top of tank shell, AC ducting systems, etc.
Hazards Involved:
Oxygen Deficiency (less than 19.5% volume): This leads to asphyxiation.

Presence of toxic, corrosive, hazardous materials: Maximum allowable are H2S= 2ppm, HC=20%
LEL, CO= 10 ppm, NH3=25ppm.
Presence of flammable, combustible, explosive or pyrophoric materials: They lead to incidents
like fire, etc.
Restricted Access- Limited number of entry, exit points: This can lead to problem of evacuating
the entrants immediately in case of an emergency.
Restriction of freedom of movement inside confined space: This can cause unwanted emergencies
due to space constraint problem.
Falling/tripping hazard: Falling can cause injuries if it is from higher elevation (e.g. Reactor).
Obstructions like staging rods causes tripping hazard.
Inadequate Illumination/visibility/communication: this can cause unwanted incidents and
confusion in case of emergencies.
High temperature and humidity: Surfaces of high temperature can cause injuries humidity/vapors
can cause suffocation problems and breathing problems.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
Electrical, static or radioactive hazards: This can cause electric shocks to human life and may
create sparks/fire, etc.
Mechanical Hazards: Mechanical hazards can cause accidents, incidents, injuries to human life.
Preparatory work Before Issuing Confined Space entry Permit:
The confined area shall be made safe for entry by such methods as depressurizing, venting,
draining, steaming, washing and ventilating. Radiation sources if any shall be removed.
Entry cannot be given without positive isolation.
Shift in charge should be aware of possible behavioral effects of hazard exposure in confined
space area before issuing the work permit at confined space area.
Power driven internal equipment like mixers are to be disconnected electrically
Mechanical ventilation equipment shall be properly grounded (earthed) to dissipate any static
charges. Pneumatic air movers (educators) and exhaust fans are recommended for this purpose.
Air for Flame proof Electrical powered fans used for forced ventilation shall be from an
uncontaminated location.
A person should enter the confined space with entry permit only.
Utility or instrument air cannot be used as means of ventilation or as air supply to breathing
apparatus.
Adequate illumination shall be provided using 24V or below explosion proof lamps. Use of any
electrical equipment above 24V shall have ‘earth leakage circuit breaker’ and also F&S
department approval.
Wherever possible, the confined space shall be adequately ventilated to enable entry without
requirement of respiratory protection equipment. At least two man ways should be open in every
chamber of vessel for proper ventilation.
Care should be taken when ventilating vessels containing ‘pyrophoric iron scales or coke to avoid
spontaneous ignition. In such situation entry with required safety precautions or handling
pyrophoric iron in wet condition should be adopted.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
Gas Testing Procedure:
All the meters/instruments to be used for gas test are ready to use.
The gas tests have to be carried out and the testing result values have to be recorded in the permit.
F&S personnel can be called for entry into critical areas for witnessing gas test and providing
guidance as required.
First, the meter should be checked in fresh air (preferably in safe zone/field room). Batteries
should not be changed or charged in hazardous area. Testing immediately after stopping the
purge may give misleading results. Purge medium or air mover should be stopped temporarily for
15 minutes or more depending on the size of space prior to measurement.
Initially the test has to be done from outside the confined space, using a long probe. If the initial
gas tests indicate a concentration above the permissible limits, further purging should be done
until the gas concentration is within permissible limits.
Test result should be representative of the entire confined space. Hence the need may arise to enter
for gas testing at different locations inside large tanks or towers and complex vessels based upon
number of man ways, toxic material handled, size of vessel, etc to get a representative result.
Operation shift supervisor should decide at initial stage, the need for entering the confined space
for gas testing.
The job executing supervisor should witness or satisfy himself, that actual gas test has been done
before issuing and accepting the permit. Receiver can refuse the permit if proper gas test was not
done. For critical entries, the receiver should accompany the gas tester up to the man way.
At least 13% oxygen is required to obtain an accurate LEL reading from a combustible gas meter.
Hence, these cannot give a proper reading in atmospheres such as vessel purged with
steam/nitrogen. Hence LEL and O2 should be measured simultaneously.
Gas meters should be calibrated once in a month and certified by HPCL instrumentation section.
Record for each gas tester is maintained by instrumentation section. Next calibration due date
should be marked on the tester.
Confined Space Entry Permit:
The permit receiver should give “ safety pep-talk” to entrants about the hazards and precautions
prior to entry.
The receiver has to provide means for easy exit and entry of personnel into and out of the confined
space. Safety rope or staging should be provided where required.
The issuer has to make the receiver aware of the hazards involved in confined space entry and
precautions to be taken.
Where atmosphere within confined space is initially safe, but there is a reason to believe that it
may become unsafe during the period for which entry is authorized (from emission of fumes from

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
sludge or deposits contained in the space or welding fumes), continuous gas monitoring is
required. The same has to be mentioned on the permit at the time of issuing.
Entry exit register has to be maintained. At any point of time, one person should be at man way if
people are inside and all the names are to be listed and signed.
Communication at Confined Area:
Shift in charge should make effective communication visually or by voice with the entrants,
effective means of communication should be available. Intrinsically safe hands-free
communication sets should be preferred.
In IDLH (immediately dangerous to life or health) atmosphere, a common communication link
system should be provided and used by personnel who are entering, standby, and maintaining the
life support system. IDLH values for toxic gases are H2S =300 ppm and CO= 1500 ppm.
Shift in charge should ensure that all the entrants should be evacuated if the communication is
interrupted.
Shift in charge may enter a confined space to attempt a rescue with the help of F&S personnel
and co-ordinate for rescue operations.
Shift in charge should monitor all the activities inside a confined space to determine if it is safe
for entrants to remain in the space and can order all the entrants to evacuate in case he feels the
presence of any prohibited condition.
F & S personnel have to be communicated as soon as the shift in charge determines that authorized
entrants may need assistance to escape from confined space hazards.
Requirements for Entry with Respiratory Protection:
Entrants should wear air supplied respirators in oxygen deficient atmospheres, when toxics are
beyond TLV and where atmosphere within confined space is initially made safe, but there is a
reason to believe that it may become unsafe during the period for which entry has been authorized.
Under no circumstances chemical cartridge/canister type gas masks should be used for confined
space entry.
Receivers have to ensure that air supplied respirators are in good condition, well maintained and
inspected according to manufacturer’ s specifications.
Entrants should wear harness attached to lifelines and be attended by an attendant who should
have breathing apparatus and clothing ready for use outside the confined space.
In IDLH atmospheres, entrants shall wear breathing apparatus or airline mask attached with
standby escape set. Rescue arrangements should be made ready with the help of F&S.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
PROCEDURE FOR OPENING PROCESS EQUIPMENT AND PIPING:
Any maintenance job needs a preparatory work prior to conducting the job. Any jobs (cold or hot) in
flammable areas requires positive isolation of equipment.
Purging/ Isolation of the Equipment:
Before starting any maintenance job, it is necessary to remove all flammable or toxic gases from the
system. Inert gas, nitrogen or steam may be used for purging. Water is used for flushing.
The part of the plant or the system to be purged is to be isolated positively by blinding. A blind list
should be prepared for isolation of equipment and check list has to be prepared.
While opening any flange joint for installation of blind, the following procedure must be
followed:
Wear PPE as per SWP

Ensure adequate working platform is provided.
Initially flange bolts to be slackened slowly by standing upwind direction and cross check for
presence of flammable or toxic gas, blots opening can be performed at a faster rate.
Removing flange bolts leaving a minimum of two bolts, then loose last two bolts without
completely removing the nuts. Spread the flanges to install blinds. Always open flange on the side
away from the person so that any sudden release will be directed away from the personnel.
The presence of concerned operation technician is a must for any emergency help, like further
isolation etc.
Hot cutting for flange nut bolts will be permitted only when presence of flammable of toxic gases
is ensured zero.
Removal of Scaling:
After draining the vessel, the material left, such as sludge has to be removed. A powerful jet of
water applied through an open manhole can remove sludge. If this is not possible, use reagent to
dissolve the sludge/scale. The liquid may be removed through the drain and the whole system
may then be flushed with water.
Where the scaling cannot be removed by liquid, it should be chipped away. Care to be taken that
non-sparking tools are used for chipping purposes and the area is kept wet with water
When process equipment is removed from a unit and must be sent elsewhere for repair, it is
operations supervisor’ s responsibility to see that it is thoroughly cleaned and properly tagged if it
has contained flammable, corrosive or toxic chemicals or iron sulfide.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES
Equipment having contained ‘sour’ stock must be inspected by operation personnel for iron
sulfide deposits. Arrangements must be made to remove them after wetting till such time such
deposits should be kept wet to prevent spontaneous combustion.
Personnel entering vessels with hydrocarbon vapors should wear breathing apparatus set.
Personnel should enter with “ Entry Permit” and keep a person as standby.

SAFE WORK PRACTICES
Plant Name: FCCU-I
SAFE WORK PRACTICES

SAFE WORK PRACTICES
Plant Name: FCCU-I
UNIT BLIND LIST
CHAPTER 29
RR BLIND LIST
S. Description Blind Size Metallurgy Remarks
No. & rating
1 Reactor vapor line blind 34x300 B21D
2 Reactor Vapor line vent line 10x300 B21D
3 Emergency steam to MAB discharge line at 6x300 B2A
upstream of HC505 RO flange
4 Emergency steam to CAB discharge line to check 6x300 B2A
valve near HC507
5 Torch oil to regen ½ x 300 B1A
6 Torch oil to APH ½ x 300 B1A
7 Reactor Cone aeration 3x300 B1A
8 Pilot gas to APH plug cock v/v upstream near ¾ x 150
APH
9 Torch oil atomizing steam ½ x 300 B2A
10 Torch oil atomizing steam to APH, at PRV 2 x 300 B2A
downstream near APH
11 RCSP aeration air ½ x 150 B2A
12 RCJB blast steam 4x300 B2A
13 SCJB lower blast steam 4x 300 B2A
14 SCJB upper blast steam 4x300 B2A
15 Emergency steam to reactor 8x300 B2A
16 Feed injection steam to reactor 6x 300 B2A
17 RCJB aeration steam 3x 300 B2A
18 SCJB aeration steam 3x300 B2A
19 Reactor anti coking steam 2x300 B2A
20 Reactor stripping steam 6x300 B2A
21 Reslurry injection steam 3x300 B2A
22 Feed to reactor HC 501 Downstream manifold 8x300 B23F
23 Reslurry to reactor at upstream of nozzle block 3x300
valve at FC 504
24 Feed makeup “ U” loop to fractionator ½ x 300
25 6” fresh cat loading near regen shell upstream 6 x 150
26 2” cat unloading from regen in between double 2 x 150
block valve near shell
27 6” cat unloading from regen in between double 6 x 150
block valve near shell
28 2” fresh cat loading near regen shell upstream 2 x 150 B23F
flange
UNIT BLINDS LIST
Plant Name: FCCU-I
UNIT BLIND LIST
29 4” RCJB cat unloading line 4 x 150 Already

blinded
30 4” SCJB cat unloading line 4 x 150 Already
blinded
31 4” below grid cat unloading line 4 x 150 Already
blinded
UNIT BLIND LIST

WGC
Description Size Gasket
S.NO
1 WGC 1st stage suction v/v d/s flange 30”
WGC 1st stage discharge MOV 16”
2 2602 u/s flange
WGC 2nd stage suction v/v d/s 16”
3 flange
WGC 2nd stage discharge MOV 12”
4 2604 u/s flange
Naphtha injection to WGC 1st v/v 2”
5 d/s flange at MAB platform
Buffer gas to WGC v/v d/s flange, at 2”
6 MAB platform
7 WGC 1st stage MOV to flare 2”
8 WGC 2nd stage MOV to flare 2”
Nitrogen to WGC seals at MAB 2”
9 platform
4F51
S.NO Description Size Gasket
1 Fuel gas spectacle blind u/s of SDV 6”
2 Pilot gas to heater 1”
3 Fuel oil I/L (supply) 2”
4 Fuel oil O/L (Return) 2”
5 Flushing oil to fuel oil 1½”
6 Soot Blowing steam 6”
7 Snuffing steam 10”
8 Fire Box steam 10”
9 Atomizing steam 3”
UNIT BLINDS LIST
Plant Name: FCCU-I
UNIT BLIND LIST
BLIND LIST -MAIN COLUMN (4C51)

S. No Description Blind Metallurgy Remarks
Size &
rating
1. O/H vapors to AFC 30x150 A16A
2. Top vent shell flange 2x150 A16A
3. RV’ s O/L to Flare Header 12x150 A16A
4. Top reflux from 4P53A/B @ C/V 8x150 A19A
5. Top reflux C/V bypass 8x150 A19A
6. Rich sponge oil to main column c/v and 4x300 A19A
bypass
7. Rich sponge oil to main column c/v bypass 4x300 A19A
8. LCO PA return to M/C C/V and Bypass 10x150 A1A
9. LCO PA return to M/C C/V Bypass 10x150 A1A
10. LCO stripper vapors return 6x150 A1A
11. 4V51 pressure balancing line 10x150 A1A
12. LCO to stripper M/C shell flange 14x150 A1A
13. HCO PA return to M/C C/V 10x300 B4F
14. HCO PA return to M/C C/V Bypass 10x300 B4F
15. HCO stripper Vapor return 12x150 A1A
16. Slurry PA & 4E56 total bypass b/v d/s 10x300 B3F
17. Slurry PA @ 4E56 O/L II B/V D/S 12x300 B3F
18. Slurry Settler RVs bypass line 2x300 B3F
19. 4V52 Minm flow to M/C 4x300 B3F
20. Reactor V/L @M/C shell nozzle 36x300 B21D
21. Reactor Feed Diversion HC502 C/V B/V 6x300 B23F
D/S
22. Slurry pump spill back @ m/c shell nozzle 8x300 B3F
23. MP stripping steam to bottom 4x150 B2A
24. Slurry pump D/O 14x300 B3F
25. Slurry pump D/O 14x300 B3F
26. Slurry sample point b/v d/s 2x300 B3F
29. LT 2003,2005, lSHH2009 (6 No.s) 1/2x300 B3F
30. PT 2012, PG2004,2006(6 No.s) 1/2x300 B3F
31. Cutter to LCO PA 6x150 A1A
32. From 4V52 to CLO @FI2204 orifice 3x300 B3F
33. HCO PA @ 4P60A/B S/C v/v( 2No.s) 10x150 A4F
34. 11/2” Feed U loop 11/2x300 B23F
UNIT BLINDS LIST
Plant Name: FCCU-I
UNIT BLIND LIST
35. 4V52 R/V O/L (2 No.s) 10x300 B3F

36. HCO PA to DD trays 4x300 B4F
37. LCO PA @ 4P59A/B suction v/v(2 No.s) 12x150 A1A
38. Cutter to HCO PA 6x150 A1A
39. LCO R/D @4P55A/B S/C V/V (2 No.s) 8x150 A1A
40. HCO to stripper at LLC b/v 8x150 A4F
41. HCO to Stripper at LC bypass 8x150 A4F
42. Heater RV O/L(2 No.s) 8x300 B23F
43. Heater RV bypass 2x300 B23F
44. FG to LCO V/R 2x150 A1A
45. FLOM to FC2004, FC2005 1/2x300 B3F
@TC2013(3No.s)
46. FLOM to FI2004,2005(4Nos) 1/2x300 B3F
47. FLOM to HC2001 1/2x300 B4F
48. FLOM to FI2007 1/2x300 B4F
49. 4V53 service water connection 2x150 A3A
4C54
1 PA O/L to Sponge absorber 6” (2 Nos) B16A
2 Suction of 4P75A/B 6” (2 Nos) B19A
3 4V70 O/L to PA 6” B16A
4 Naphtha to PA @ PA shell 4” B16A
5 Suction of PA bottom pumps 6” (2 No.s) B19A
6 4P74A/B spill back 2” B19A
7 4C54 drain to CBD 2” B16A
8. SOP 2” B19A
4C55
Stripper feed c/v d/s and Bypass v/v 8” (2 Nos) B19A
1 D/S
2 Stripper bottom to reboiler shell I/L 10” (2 Nos) B19A
3 Stripper Reboiler shell O/L to C55 12” (2Nos) B16A
4 Stripper bottom to C56 Shell v/v u/s 10” B19A
5 Stripper O/H vapor line shell v/v u/s 6” B16A
Stripper PSV 2801A/B isolation b/v 4” B16A
6 u/s
UNIT BLINDS LIST
Plant Name: FCCU-I
UNIT BLIND LIST
Stripper PSV 2801A/B bypass, in 2” B16A

7 between b/v
4C56
C Description Size Gasket
1 Stabilizer feed c/v b/v d/s 10 B19A
2 Stabilizer feed c/v bypass v/v u/s 10 B19A
3 Stabilizer bottom to 4E68 shell I/L 10 (2 Nos) B19A
Stabilizer bottom 4E68 shell O/L to 14 (2 Nos) B19A
4 4C56
5 Stabilizer O/H vapor line 12 B16A
Stabilizer bottom draw off shell v/v 8 B19A
6 u/s
Stabilizer PSV 3001A/B isolation b/v 8 (2 Nos) B16A
7 u/s
Stabilizer PSV 3001A/B bypass v/v 2 B16A
8 u/s
9 Reflux from 4P66A/B c/v d/s b/v 6 B19A
Reflux from 4P66A/B c/v bypass d/s 6 B19A
10 b/v
4C57
1. PA O/L to Sponge absorber 6” B16A
2. LCO to Sponge absorber 3” B16A
3. ATG T/O at Sponge absorber 4” B16A
Rich oil to column at 4C57/ FT RO 4” B19A
4. flange
5. 4C57 drain to CBD 2” B16A
6. SOP 11/2” B19A
4E51
1 Feed I/L B/V D/S flange 8”
2 Feed O/L B/V U/S flange 8”
3 FLO to Feed I/L S/B 2”
4 Feed I/L drain to CBD S/B 2”
5 Feed O/L drain to CBD S/B 2”
6 LCO I/L B/V d/s flange S/B 6”
7 LCO O/L B/V U/S flange 6”
UNIT BLINDS LIST
Plant Name: FCCU-I
UNIT BLIND LIST
8 LCO O/L to CBD S/B 2”
4E52 A/B/C/D
3 FLO to Feed I/L 2”
6 CLO I/L B/V d/s flange 4”
7 CLO O/L B/V U/S flange 4”
8 CLO I/L drain to CBD 2”
9 CLO O/L drain to CBD 2”
4E53
6 LCO PA I/L B/V d/s flange 10”
7 LCO PA O/L B/V U/S flange 10”
8 LCO PA I/L drain to CBD S/B 2”
9 LCO PA O/L drain to CBD S/B 2”
4E54 A/B/C
6 Slurry I/L B/V d/s flange 12”
7 Slurry O/L B/V U/S flange 12”
8 Slurry I/L drain to CBD 2”
9 Slurry O/L drain to CBD 2”
4E55A
UNIT BLINDS LIST
Plant Name: FCCU-I
UNIT BLIND LIST

1 LCO I/L B/V d/s 6”
2 LCO O/L B/V u/s 6”
3 BFW I/L B/V d/s 3”
4 BFW O/L B/V u/s 3”
5 LCO O/L to CBD 2”
4E55B
1 LCO I/L B/V d/s 6”
2 LCO O/L B/V u/s 6”
3 BFW I/L B/V d/s 3”
4 BFW O/L B/V u/s 3”
4E56
1 Slurry I/L B/V D/S flange 12”
2 Slurry O/L B/V U/S flange 12”
3 FLO to slurry I/L S/B 2”
4 Slurry I/L drain to CBD 2”
5 Slurry O/L drain to CBD 2”
6 BFW line D/S B/V 3”
7 Blow down B/V north S/B 2”
8 Blow down B/V south S/B 2”
9 RV shell flange 4” (2 Nos)
10 Vent line flange 2”
11 Steam O/L v/v u/s flange 8”
12 South g/g bottom/top 2” (2 Nos)
13 North g/g bottom/top 2” (2 Nos)
4E57
1 HCO PA I/L B/V D/S flange 8”
2 HCO PA O/L B/V U/S flange 8”
3 FLO to HCO PA I/L S/B 2”
4 HCO PA I/L drain to CBD 2”
5 HCO PA O/L drain to CBD 2”
UNIT BLINDS LIST
Plant Name: FCCU-I
UNIT BLIND LIST
6 BFW line D/S B/V 2”

7 Blow down B/V north S/B 2”
8 Blow down B/V south S/B 2”
9 RV shell flange 3” (2 Nos)
10 Vent line flange 2”
11 Steam O/L v/v u/s flange 4”
12 South g/g bottom/top 2” (2 Nos)
13 North g/g bottom/top 2” (2 Nos)
4E59A/B
1. 4E59A/B HC I/L D/S 24” A16A
2. 4E59A/B HC O/L V/V U/S 24” A16A
3. Cooling water I/L V/V d/s 12” J5A
4. Cooling water O/L V/V U/S 12” J5A
5. 1” Depressurizing v/v 1” A16A
6. Service water to 4E59A/B 11/2” A16A
7. 4E59A/B HC O/L to CBD 2” A16A
4E59C/D
1. 4E59C/D HC I/L D/S 24” A16A
2. 4E59C/D HC O/L V/V U/S 24” A16A
6. Service water to 4E59C/D 11/2” A16A
7. 4E59C/D HC O/L to CBD 2” A16A
4E59E/F
1. 4E59E/F HC I/L D/S 20” A16A
2. 4E59E/F HC O/L V/V U/S 14” A16A
6. Service water to 4E59E/F 11/2” A16A
7. 4E59E/F HC O/L to CBD 2” A16A

UNIT BLINDS LIST
Plant Name: FCCU-I
UNIT BLIND LIST
4V63
1 BFW to coil I/L at shell flange 2”
BFW coil O/L to economizer at 2”
2 drum shell flange
Economizer O/L to drum at shell 2”
3 flange
Drum O/L to superheater coils 4”
4 (3” and 4” ) at shell flange
5 4” superheater coil O/L to drum 4”
6 6” superheater coil O/L to drum 6”
MP steam O/L to header at drum 4”
7 shell flange
8 North g/g top t/o v/v u/s flange 2”
North g/g bottom t/o line shell 2”
9 flange
10 South g/g top t/o v/v u/s flange 2”
South g/g bottom t/o line shell 2”
11 flange
12 LT top t/o b/v d/s flange 2”
13 LT bottom t/o b/v d/s flange 2”
South blow down in between both 2”
14 b/v
North blow down in between both 2”
15 b/v
16 2” vent 2”
17 South RV t/o v/v u/s steam 3”
18 North RV t/o v/v u/s steam 3”
19 South Manway 18”
20 North Manway 18”
21 2” utility stub 2”
4E63A
1. 4E63A HC I/L D/S 18” A16A
2. 4E63A HC O/L V/V U/S 18” A16A
UNIT BLINDS LIST
Plant Name: FCCU-I
UNIT BLIND LIST
6. Service water to 4E63A 11/2” A16A

7. 4E63A HC O/L to CBD 2” A16A
4E63B
8. 4E63B HC I/L D/S 18” A16A
9. 4E63B HC O/L V/V U/S 18” A16A
13. Service water to 4E63B 11/2” A16A
14. 4E63B HC O/L to CBD 2” A16A
4E64A
15. 4E64A HC I/L D/S 18” B16A
16. 4E64A HC O/L V/V U/S 18” B16A
19. 1” Depressurizing v/v 1” B16A
20. Service water to 4E64A 11/2” B16A
21. 4E64A HC O/L to CBD 2” B16A
4E64B
1. 4E64B HC I/L D/S 18” B16A
2. 4E64B HC O/L V/V U/S 18” B16A
5. 1” Depressurizing v/v 1” B16A
6. Service water to 4E64B 11/2” B16A
7. 4E64B HC O/L to CBD 2” B16A
4E65
8. Rich oil I/L V/V D/S 4” B19A
UNIT BLINDS LIST
Plant Name: FCCU-I
UNIT BLIND LIST
9. Rich Oil O/L V/V U/S 4” B19A

10. LCO to 4E65 I/L V/V d/s 6” B1A
11. LCO to 4E65 O/L V/V u/s 6” B1A
12. Rich oil I/L to CBD 2” B19A
13. LCO O/L to CBD 2” B1A
4E67A
1. 4E67A HC I/L D/S 12” B16A
2. 4E67A HC O/L V/V U/S 10” B16A
5. Depressurizing v/v 3/4” B16A
6. 4E67A HC O/L to CBD 2” B16A
4E67B
1. 4E67B HC I/L D/S 10” B16A
2. 4E67B HC O/L V/V U/S 10” B16A
5. 1” Depressurizing v/v 3/4” B16A
6. 4E67B HC O/L to CBD 2” B16A
4E66A
1. LCO PA I/L(from 4E53) v/v d/s 10” B1A
2. LCO O/L( to 4C51) V/V u/s 10” A1A
3. Shell side I/L 10” (2 Nos) B19A
4. Shell side O/L 10” (2 Nos) B16A
5. Shell Side I/L to CBD 2” B19A
6. LCO O/l to CBD 2” A1A
7. LCO I/L Stub 1” (B/M) B1A
8. LCO O/L stub 1” (B/M) A1A
9. Shell side I/L stub 1” (B/M) B19A
10. Shell side O/L stub 1” (B/M) B19A
4E66B
UNIT BLINDS LIST
Plant Name: FCCU-I
UNIT BLIND LIST

1. Stab Naphtha I/L(from 4E53) v/v d/s 8” B1A
2. Stab Naphtha O/L( to 4C51) V/V u/s 8” A1A
5. Shell Side I/L to CBD 2” B19A
6. Stab Naphtha O/l to CBD 2” A1A
7. Stab Naphtha I/L Stub 1” (B/M) B1A
8. Stab Naphtha O/L stub 1” (B/M) A1A
9. Shell side I/L stub 1” (B/M) B19A
10. Shell side O/L stub 1” (B/M) B19A
4E68
1. HCO I/L v/v d/s 8” B4F
2. HCO O/L V/V u/s 8” B4F
5. Shell Side I/l to CBD 2” B19A
6. HCO I/L to CBD 2 B4F
7. HCO O/L to CBD 2 B4F
8. FLO to HCO 2 B1A

UNIT BLINDS LIST
Plant Name: FCCU-I
SPECIAL AND UNIQUE HAZARDS
CHAPTER 30
Introduction
Safety of personnel and equipment is very important. Ignorance of the details of the unit or the
techniques of safe and efficient operation reduces the margin of safety of personnel and
subjects the equipment to more hazardous conditions. All the operating and maintenance crew
therefore must be fully familiar with the equipment and materials being handled in the unit and
recognize the hazards involved in handling them and the measures taken to ensure safe
operations. Since the unit handles with one of the most potential source of fire and explosion,
LPG and chemicals like caustic, adherence of safety rules should be given uphill importance.
30.1 Safety of Personnel

General safety rules, which shall be practiced and enforced for all personnel who enter the unit,
are summarized below:
i) Safety helmets and boots shall be worn by all personnel at all times in the plant. They may
be removed when inside rooms or buildings which do not have overhead or other hazards.
ii) Smoking is not permitted inside the refinery.
iii) Each employees assigned to work in the unit shall know where the safety and fire
suppression equipment is located and how to operate equipment.
iv) Safety goggles or face shields shall be worn while performing work, which could result in
eye or face injury.
v) Operations personnel golden rule

Do not open or close any valve without first determining the effect.
vii) Maintenance personnel golden rule:
Treat each piece of equipment or piping as if it is under pressure.
30.2 Presence of Flammable Hydrocarbons and Safety Precautions
30.2.1 Hazards Related to Handling of Liquefied Petroleum Gases Systems
In the design of the LPG handling area (absorber section) major consideration has to be given
to the Hazards of LPG which are listed in this subsection. Liquefied Petroleum Gas is a mixture
of commercial Butane and commercial propane both saturated and unsaturated hydrocarbon.

Plant Name: FCCU-I
LPG is inherently dangerous on account of fire, explosion and other hazards. This calls for
special attention on the manner in which it is stored, transported or used. These hazards can
have an impact on both the public. As a consequence of this special emphasis has been given
on the safety regulations while designing this system.
1) LPG at atmospheric pressure and temperature is a gas which is 1.5 to 2.0 times heavier than
air. It is readily liquefied under moderate pressure. The density of liquid is approximately half
that of water and ranges from 0.525 to 0.58 at 15 0 C. Since LPG vapor is heavier than air, it
would normally settle down at ground level / low lying places and accumulate in depressions.
Under still conditions the dissipation of accumulated vapor is slow. This accumulation of LPG
vapors gives rise to potential fire and explosion hazard.
2) LPG has an explosive limit range of 1.8% to 9.5% volume of gas in air. This is considerably
narrower and gives an indication of hazard of LPG vapors accumulated involving areas in the
eventuality of leakage or spillage.
3) The combustion reactions of LPG increase the volume of product in addition to the
generation of heat. LPG requires 24 to 30 times its own volume of air for complete combustion
and at the same time yield 3 or 4 times its own volume of carbon dioxide yielding
approximately 10,900 kCal of heat per kg. Leaking liquid phase LPG will rapidly expand
around 250 times its own volume therefore creating a greater risk than would occur with a
similar size vapor leakage. When the pressure is reduced, LPG vaporizes rapidly reducing the
surrounding temperature. This may lead to burns in contact of LPG with the skin.
4) LPG liquid released forms a vapor which travels long distance. This explains the hazardous
aspects of faster spreading of LPG fire. The vapors of LPG can give more violent conclusion
in explosion as in case of Hydrogen due to higher flame propagation
5) Liquid phase LPG expands considerably when it s temperature increases, exceeding most of
petroleum products. The coefficient of expansion is around 0.000237 per degree centigrade at
15oC. This high rate of expansion has been taken into account when specifying the maximum
quantity of LPG permitted to be filled into any pressure vessel.
6) LPG is colorless in both liquid and vapor phase.
7) The vaporization of liquid cools the atmosphere and condenses the water vapor contained in
them to form a whitish fog which makes it possible to see an escape of LPG.
8) LPG has only faint smell and consequently it is necessary to add some odorant so that any
escaping gas can easily be detected.

Plant Name: FCCU-I
9) LPG has low viscosity and can leak when other petroleum products normally cannot thus
demand a very high integrity in the pressurized system to avoid leakage. It is also poor lubricant
and leaks are therefore likely to occur at pump seals and glands. In view of this, special
attention has been given e.g. to the selection of mechanical seals etc.
10) The hazards associated with release of a boiling flammable liquid to atmosphere show
themselves disproportionately when large quantities are involve - they can give rise to two
phenomena which are highly hazardous the unconfined vapor cloud explosion and the boiling
liquid expanding vapor explosion. Vapor cloud can ignite and burn as fireballs causing lot of
damage by radiation starting secondary fires at some distance. Vapor cloud ignites and
explodes causing high overpressures and very heavy damage. The latter is termed as Percussive
unconfined Vapor Cloud Explosion'i.e. PVUCE in short. Even though large quantities of LPG
emission are necessary only a fraction of this contributes to percussive effect. The boiling liquid
expanding vapor explosion (BLEVE) is due to holding pressurized flammable liquid above its
boiling point. This may result from inadequate vapor space for temperature expansion of the
content or high temperature due to radiation heat from the adjacent vessel under fire or due to
a mechanical damage. BLEVE even though not as serious as PUVCE, the potential for
spreading fire over a wide area makes them significant in terms of both life and property posing
hazard to fire-fighters. Ejection of boiling liquid produces reaction rupturing the vessel causing
the rocket projecting of dish ends. The released liquid flashed and atomizes immediately often
resulting in large fire ball. Although the fire ball lasts only a few seconds, its effects can be
devastating due to flame contact and thermal radiation.
30.2.2 Safety Precautions while Handling Flammable Hydrocarbons
i) LEL Detectors: LEL detectors are provided at various locations in the unit at critical
locations. This will help in early identification of any hydrocarbon leaks so that immediate
responsive action can be taken. Activation of LEL detector raises alarm in DCS.
ii) The unit handles hydrocarbon liquids and gases which can cause fire and explosion if
conditions for the same are favorable. Direct contact of hydrocarbons with any source of
ignition of fire such as spark or open flame should be avoided. Sparks or open fire should not
be allowed in the operating area while the unit is operating or has potential of hydrocarbon
leakage. Even during shutdown. When an open flame work is absolutely essential, this should
be allowed with the permission of the authorized person after suitable precautions have been
taken. Approved safety & work permit systems should be strictly followed.
iii) Propane gas is highly explosive in air mixtures containing 2.4 to 9.5 % by volume of
Propane vapors. Its concentration in air should normally be not allowed to exceed 0.4%. It must
be stored in a cool, isolated and ventilated area free of acute fire hazard. A concentration in air
above 1% of Propane may have mild narcotic effect. Inhalation of excessive amounts causes

Plant Name: FCCU-I
progressive aesthesia. Liquid Propane in contact with skin will cause frostbite through rapid
evaporation.
iv) Improper earthlings of equipment may produce static charges. All equipment must be
provided earthing connections as per standards.
v) The drain / vent valves and sample points on hot and heavy products and steam lines are
likely to get plugged, if the lines are not in constant use. Such valves should be crack opened
for a few minutes under personal supervision and only after the liquid flow has started the
opening of the valves should be adjusted as required.
vi) Leakage of hydrocarbons from equipment and pipe joints are undesirable and must be
reported to the immediate supervisor without delay.
vii) The set pressure of relief valves should never be altered without prior permission of the
authorized persons in writing. Wherever block valves are provided for isolation of relief valves,
these valves should be kept opened all the times as per stipulations in P&ID’ s.
viii) The closure of block or control valves which isolate exchangers or piping from relief
protection devices can subject the equipment to possible overpressure due to thermal expansion
of the blocked fluid. The expansion may be caused by heat from the atmosphere or adjacent
hot equipment. In order to prevent such over pressurizing some suitable drains/vents or other
valves connected with some closed system in the network should be left opened, to take care
of such expansion.
ix) Poor house-keeping in the operating area is a potential cause of accidents. Spillage of oil
etc. is very dangerous. Maintain a high standard of house-keeping in the work area.
x) Releasing equipment for maintenance without properly preparing it e.g. blinding / isolating
& making it hydrocarbon free and electrical isolation etc. should be avoided as this can also
result in major accidents.

Plant Name: FCCU-I
30.3 Catalyst Handling
Catalyst handling is a unique hazard especially applicable to FCCU unit operations. Care
should be exercised while handling and disposing catalyst as it is carcinogenic.
FIRST AID MEASURES

Inhalation : Remove the victim from contaminated area. Apply necessary
first aid treatment, seek medical help immediate.
Eyes : Immediately flush eyes with plenty of running water for at least
15 minutes. Hold eyelids apart to ensure rinsing of water. Get
medical aid immediately
Skin : Wash with water followed by soap if available for several
minutes. Seek medical attention if irritation persists.
Ingestion : Drink 2 glasses of water and get medical aid.
HANDLING AND STORAGE

Suitable storage conditions : Avoid breakage of bagged material or spills of bulk
material. Use dustless systems for handling, storage and
clean up so that airborne dust does not exceed the PFL.
Use adequate ventilation and dust collection.
Conditions to avoid : Avoid breathing dust, contact with eyes, skin and
clothing. Use with adequate ventilation.
EXPOSURE CONTROLS / PERSONAL PROTECTION
Respiratory protection : Approved air purifying respirator, surgical cotton

masks
Hand protection : Suitable chemical gloves
Eye protection : Splash proof chemical goggles
Skin & body protection :
DISPOSAL CONSIDERATIONS
Disposal of chemical : Raw (unused) material may be disposed of in a sanitary
landfill and cover disposed material promptly to avoid
dusty conditions.

Plant Name: FCCU-I

Plant Name: FCCU-I
CHEMICAL /HC SPILLAGE HANDLING PROCEDURE
CHAPTER 31
31.0 CHEMICAL AND HYDROCARBON SPILLAGE HANDLING:
“ Spill” means an event of a liquid coming out of its container especially accidentally. In a
refinery, this will mean oil coming out of any of the equipment whether it is storage, transport,
pump, processing equipment, etc. Every time a spill occurs, it has a potential to lead to
secondary events like fire, environmental damage, personnel injuries or injury/effects on public
outside the refinery. The occurrence and extent of these events will depend on the size and type
of oil spills. Best strategy is to prevent an oil spill. In order to achieve this, the design of the
facilities needs to be in a manner that prevents oil spillage from entering any surface drain or a
water body and the mechanical integrity of the equipment will have to be ensured all this time.
This will also require proper management practices and day to day administration in a manner
that the activities are under close control. However, residual risk always exists and in spite of
all precautions and an emergency response plan is meant to tackle and manage the residual
risk.
31.1Chemical Spillage
Corrosion Inhibitor
Do not dispose in a sink, drain or in the immediate environment. Wear appropriate personal
protective equipment (Impervious clothing, gloves, apron, boots, Chemical safety goggles/ full
faced shields). Safety glasses, Protective gloves and Protective clothing should be worn before
venturing to arrest spillage/ during handling of this chemical. Rubber foot wear should be worn.
Spill area should be washed with plenty of water. The chemical is alkaline in nature. All
precautions taken with alkali should be taken.
Neutralizer:
Restrict access to area as appropriate until cleanup is conducted. Clean up should be done by
trained personnel only. Ventilate spill area if possible. Remove sources of ignition. Stop/
reduce leaks if it is safe to do so. Use Safety glasses, Protective gloves and Protective clothing
should be worn before venturing to arrest spillage/ during handling of this chemical. Rubber
foot wear should be worn. Spill area should be washed with plenty of water.
Small Spills: Soak up spills with absorbent material. Place residues in a properly labeled
container. Wash affected area.

CHEMICAL/HC SPEILLAGE HANDLING PROCEDURE
Plant Name: FCCU-I
Large Spills: Contain liquid by using absorbent material by digging trenches or by diking.
Reclaim into recovery drums for proper disposal. Wash affected area. Prevent material from
entering into sewers and water bodies.
Nickel Passivator
Restrict access to area as appropriate until cleanup is conducted. Clean up should be done by
trained personnel only. Ventilate spill area if possible. Use Safety glasses, Protective gloves
and Protective clothing should be worn before venturing to arrest spillage/ during handling of
this chemical. Rubber foot wear should be worn. Spill area should be washed with plenty of
water.
Small Spills: Soak up spills with absorbent material. Place residues in a properly labeled
container. Wash affected area.
Large Spills: Contain liquid by using absorbent material by digging trenches or by diking.
Reclaim into recovery drums for proper disposal. Wash affected area. Prevent material from
entering into sewers and water bodies.
31.2 Hydrocarbon Spillage:
31.2.1 VGO:
VGO is moderately combustible above its flash point. VGO will release flammable vapours
which on exposure to source of ignition can burn or also can be explosive in confined spaces.
Mists/ sprays are flammable below the flash point. DCP, CO2, Foam and water fog are effective
extinguishing media.
Remove all ignition sources and safely stop flow of spill. Spill may create tripping hazard.
Pads/Absorbent material can be used. As VGO floats on water, resulting run off may cause fire
Hazard. Contain spill by using flushing with plenty of water to OWS after notifying the ETPs.
Barricade the area for tripping hazard. Use absorbent media/ sand to clean the area thoroughly.
31.2.2 LPG:
It is a common air contaminant. It is flammable when exposed to heat or flame. Keep the valves
tightly shut. In case of spill, shut off leaks if it is without risk. Warn everybody that air mixture
is explosive. In case of fire, allow it to burn under control. Keep water spray on the vessel to
protect it from breaking under heat stress.
31.2.3 Naphtha:
Remove all ignition sources. Wear SCBA respiratory protection. Restrict those not wearing
protective equipment and who are not involved in clean-up from entering area. Avoid skin

Plant Name: FCCU-I
contact. Stop leak if it can be done without risk. Provide maximum explosion-proof ventilation.
Absorb with vermiculite or other similar material and deposit in sealed containers. Use non-
sparking tools during clean-up.
31.2.4 LCO and CLO/Main Column Bottoms:

Remove all ignition sources and safely stop flow of spill. Spill may create tripping hazard.
Pads/Absorbent material can be used. As oil floats on water, resulting run off may cause fire
Hazard. Contain spill by using flushing with plenty of water to OWS after notifying the ETPs.
Barricade the area for tripping hazard. Use absorbent media/ sand to clean the area thoroughly.
For Major Hydrocarbon leak or Chemical Spillage handling onsite emergency plan was
prepared by fire and safety in coordination with KLG-TNO, Delhi
A Quantitative Risk Analysis ( QRA) of HPCL, VR was conducted to assess the cumulative
risk to people outside the Refinery complex boundaries due to the total refinery facilities by
M/s KLG-TNO, Delhi (Appointed to carry out the Risk Analysis study), in 1999. The computed
risk is presented as:
Iso- Risk contours (individual risk)

F-N curves (Societal or Group risk)
Dominant Risk Contributors
QRA provides a quantitative technique for assessing the significance of impact of any facility
on its external environment and a means for highlighting key areas of greater attention. The
release sources (based on IPO methodology currently in use in the EC countries) with potential
offsite consequences were selected from process units, storage and transfer lines. Release
consequence
Computations were done for selected release sources. From the results of the release
consequences calculations and using the criterion that there must be offsite consequences
associated with a scenario to justify its inclusion in QRA (to determine public risk), 20
scenarios were listed for QRA.

Plant Name: FCCU-I
The inputs to the “ Onsite Emergency Plan” preparation are drawn from the Risk Analysis Study
and the 20 scenario listed for QRA where losses will be of catastrophic nature.
Please be guided by the onsite emergency manual.

Ref: http://10.6.0.131/f&s/onsite.pdf

Plant Name: FCCU-I

FCCU-1 INSTRUMENTATION TAG LIST
CHAPTER 32
FCCU-1 INSRUMENTATION TAG LIST
FCCU 1 REVAMP CONTROL VAVES DATA
S. TAG TAG SI TE DESI INL FLOW PR SHUT FA

N NO DESCRIP ZE MP GN ET RATE ES OFF IL
O TION “ TEM PR NOR/MIN/ DR PR CO
P MAX OP DROP N
1 DPV- ATOMISI 2” 200 300 8.6 600/250/750 0.4 12.5 FO
1901 NG
STEAM
TO
HEATER
2 FCV- ATOMISI 1 70- 185 8.9 2240/672/29 2.4 33.5 FO
4XA NG 165 12
STEAM
TO
TORCH
OIL
3 FCV- TORCH 1.5 250 300 10 31.5/105/115 - 12.5 FC
4XB OIL TO .5
REGEN
4 FV-1801 FEED 4 250 300 9.8 2450/735/24 1 12.5 FO
INJECTIO 50
N STEAM
TO RX
5 FV1901 HCO 2 301 335 20.7 7.6/3.0/9.1 10. 39 FC
PRODOUC 5
T
RUNDOW
N

Plant Name: FCCU-I

6 FV1902 HEATER 6 267 385 19.5 116/38/40 10 33.5 FO

PASS-1 -
FEED 344
FLOW C/V
7 FV1902 HEATER 6 267 385 19.5 116/38/140 10 33.5 FO
PASS-2 -
FEED 344
FLOW C/V
8 FV1951 BFW TO 2 186 220 16.5 2.5/1.0//4 0.7 29 FC
HEATER -
STEAM 193
DRUM
9 FV2003 MF TOP 8 40 65 5.3 56/94/170 0.8 11.7 FO
REFLUX
10 FV2004 SLURRY 12 270 360 3.4 106/352/422 0.7 19 FO
PA
RETURN
TO MF D6
11 FV2005 SLURRY 10 270 360 3.4 50/175/352 0.7 19 FO
PA
RETURN
TO MF D4
12 FV2101 LCO 2 250 300 8.7 300/-/1000 7 12.5 FC
STRIPPIN
G STEAM
13 FV2102 HCO 3 250 300 8.7 1600/-4500 7 12.5 FC
STRIPPIN
G STEAM
14 FV2401 UNSTABI 4 38 65 78 66.8/30.2/80 1.2 13 FO
LISED
NAPHTHA
TO 4E63
15 FV2402 DM 3 30 65 1.9 5.0/1.0/10.0 0.2 6 FC
WATER
MAKE UP

Plant Name: FCCU-I

TO 4V-53
SW
16 FV2201 CLO 1.5 360 380 11.3 13/4.8/15.6 8 19
FROM
SLURRY
SETTLER
TOP TO
MF D2
17 FV2202 HCO 6 311 335 21 66.2/18/83 2.5 29 FC
RECYCLE
TO FEED
18 FV2601 WGC 1ST 10 38- 9 FO
STAGE 45
SPILL
BACK
19 FV2602 WGC 2ND 8 15.5 20 FO
STAGE
SPILL
BACK
20 FV2701 STRIPPER 8 38 65 19.1 145/75/200 1.3 25.3 FC
FEED
21 FV2801 STABILIS 6 38 65 18.5 105/572/126. 1.1 32.6 FC
ED 3
NAPTHHA
TO
PRIMARY
ABSORBE
R TOP
22 FV2802 PRIMARY 4 50- 100 17.5 46/18/65 1 24 FO
ABS 52.5
BOTTOMS
TO
4E64AB
23 FV2803 ST3ABILI 8 145 170 15 159.6/84/225 4.3 19.3 FC
SER FEED

Plant Name: FCCU-I

24 FV2901 LEAN 3 40 65 18.1 20/12/36 1.2 32.3 FO

SPONLE
OIL TO
4C-57
25 FV-2X CONTROL 8 216 290 2.25 7048/4934/8 0.2 5 FO
AIR 458 8
26 FV3001 STABILIS 4 40 65 14.9 53.2/21.2/64 1.1 21.4 FO
ER TOP
REFLUX
27 FV3203 BFW TO 2 186 220 14.4 2.8/0.9/13.4 2.5 29 FC
4E-57 -
193
28 FV 3204 BFW TO 3 186 220 14.4 14.7/4.0/18.0 0.5 29 FC
4E-56 -
193
29 FV3301 LPG R/D 3 40 65 20 25/9.7/32.8 1.1 31.4 FC
C/V
30 FV3302 CLO R/D 3 60 150 14 10/5/18.0 1 27 FC
C/V
31 FV3303 LCO TO 6 40 65 5.7 58/20/70 4.5 15 FC
NORMAL
RD/C/V
32 FV3304 CRN 4 38 65 18.7 74/35/125 7 31.6 FC
RUNDOW
N
33 FV503 NAPTHA 3 40 80 10.1 18975/18975. 1.4 19 FC
QUENCH /56925
TO RX
34 FV504 RESLURR 2 360 400 9.8 19100/1910/ 2 19 FC
Y TORX 19100
35 FV505 REACTOR 4 250 300 9.8 3330/999/34 1.5 12.5 FO
STRIPPIN 96
G STEAM
36 FV508 RESLURR 2 250 300 9.8 136/454/454 1.3 12.5 FO
Y
Plant Name: FCCU-I

INJECTIO
N STEAM
37 FV525 CAB 6 216 290 2 3500/1050/3 0.2 5 FC
DISCHAR 500
GE TO
MAB
DISCHAR
GE
38 HCV- SCJB Fail
1X SLIDE in
VALVE pla
ce
39 HCV- RCJB Fail
2X SLIDE in
VALVR pla
ce
40 HCV- MAB FO
509 SURGE
CONTORL
V/V
41 HV1951 HEATER FO
STACK
DAMPER
42 HV2001 HCO PA 4 261 281 3.9 10/6/30 0.1 5 FC
RETURN
TO MF D6
43 HV2204 HCO 2 311 335 18.1 10/5/50 9 26 FC
DILUTAN
T TO
SLURRY
SETTLER
44 HV2801 STRIPPER 12 92- 150 15.3 229/109/275 0.2 19.3 FO
BOTTOMS 105 5
TO
NOTE: For liquids normally flow m3/hr and for gases kg/hr

Plant Name: FCCU-I

REBOILE
R O/L
45 HV501 TOTAL 8 384 450 9.8 181100/5434 - 33.5 FC
FEED TO - 0/245410
REACTOR 411
46 HV502 FEED 6
DIVERSO
N TO MF
47 HV504 EMERGE 8 250 300 9.8 785/785/687 - 12.5 FO
NCY 0
STEAM
TO RX
RISER
48 HV505 EMERGE 6 250 300 9.8 -/27/2840 - 12.5 FO
NCY
STEAM
TO MAIN
AIR
49 HV506 CAB
DISCHAR
GE
CHECK
VALVE
50 HV507 EMERGE 6 250 300 9.8 -/27/452 - 12.5 FO
NCY
STEAM
TO
CONTROL
AIR
51 HV510 MAB - - - - - - - FC
DISCHAR
GE
CHECK
VALVE

Plant Name: FCCU-I

52 HV511 CAB FO
SURGE
C/V
53 HV512 CAB TO - - - - - - - FC
MAB
DISCHAR
GE
CHECK
V/V
54 JV2001 LCO PA 10 169 205 4.7 217/156/260 2.4 12.7 FO
RETURN
55 JV2002 HCO PA 10 261 281 3.7 217/156/260 2.2 11 FO
RETURN
56 LV1302 MAB 3 45 6 22.26 5.8 9 FO
A SURFACE
COND TO
PP
57 LV1302 MAB 1.5 45 6 22.26 5.8 9 FC
B SURFACE
COND
MAKEUP
C/V
58 LV1705 COLD 8 70- 150 2.5 138/16/167.4 0.5 15.8 FC
FEED TO 90
SURGE
DRUM
59 LV2103 LCO 8 220 265 0.8 94/36/113 0.1 3.5 FC
STRIPPER -
LEVEL 241
C/V
60 LV2104 HCO 8 310 345 1 69/8.5/85 0.1 3.5 FC
STRIPPER -
LEVEL 321
C/V

Plant Name: FCCU-I

61 LV2404 V53 2 38 65 18.5 8/5/10 1.2 26.8 FC

INTERPH
ASE
LEVEL
C/V
62 LV2504 INTREST 6 38 65 18 90/40/108 0.7 27 FC
AGE KOD
LEVEL
C/V
63 LV2505 INTREST 2 40 65 3.8 8/5/10 0.3 9 FC
AGE KOD
INTERPH
ASE LVL
C/V
64 LV2646 WGC SO 1 40 100 8.5 0.72/1.08 4.5 18 FC
O/H TANK
LEVEL
C/V
65 LV2704 HP REC 2 38 65 14.7 8/5/10 10. 19.4 FC
INTERPH 5
ASE
LEVEL
C/V
66 LV2902 RICH 4 199 220 12.9 24.3/12/30 10. 19 FC
SPONGE 3
OIL C/V
67 LV3103 STAB O/H 1 40 65 8.5 2/-5.0 7.5 15 FC
DRUM
INTERPH
ASE
LEVEL CV
68 LV7201 LPG TO 2 40 65 17.6 5/10.15/12.2 5.8 31.4 FC
VAPORIS
ER

Plant Name: FCCU-I

69 PDCV5 RG FLUE FC
01 GAS
SLIDE
VALVES
70 PV1369 MAB 1 360 36 43.6 34. 59 FC
A GLAND 9
STEAM
C/V
71 PV1369 MAB 1 40 45 7.6 37.4 1 12 FO
B GLAND
STEAM
TO
SURFACE
COND
72 PV1901 HEATER 6 193 70 2.8 2160/520/26 0.3 - FC
FLEL GAS 00
CONTORL
V/V
73 PV1951 HEATER 3 220 13 2360/1180/2 0.5 - FO
STEAM 830
DRUM PR
C/V
74 PV2497 COMP 24 FO
TOTAL
SPILL
BACK C/V
75 PV1902 HEATER 1.5 110 250 6.5 2.3/1.0/3.0 0.5 17 FC
FUEL OIL -
C/V 200
76 PV2411 V53 12 38 65 1 23562/7000/ 0.1 - FC
OVERPRE 33500
SSURE
RELIEF
77 PV2629 WGC 1ST 24 38- - - - 2.7 - FC/
STAGE 45 FL

Plant Name: FCCU-I

SUCTION
PR
CONTROL
78 PV2632 WGC 2ND 10 38- - - - - 12 FC
STAGE 45
SUCTION
PR
CONTROL
79 PV2650 WGC 1 30 3.5 230 1.2 10 FO
BUFFER
GAS PR
C/V
80 PV2901 SPONGE 4 40 65 13.7 2997/1520/4 8.5 19 FC
ABSORBE 800
R OFF
GAS
81 PV3001 STAB O/H 6 40 65 8.5/ 78.2/34/95 0.2 15 FO
A DRUM PR 11
CONTROL
82 PV3001 STAB O/H 2 40 65 8.5/ -/500/5000 0.2 15 FC
B DRUM TO 11
FG
SYSTEM
83 PV3201 4E57 4 194 220 13 2425/705/29 2 15 FO
STEAM 10
PR
CONTROL
84 PV3202 4E56 8 194 220 13 12750/3500/ 0.5 15 FO
STEAM 15300
PR
CONTROL
VALVE
85 PV505 RX CONE 1.5 250 300 9.8 192/385/385 1.5 12.5 FO
AWRATIO
N PR C/V

Plant Name: FCCU-I

86 PV506 RCJB 2 250 300 9.8 633/316//664 1.5 12.5 FO

AERATIO
N PR C/V
87 PV507 SCJB 2 250 300 9.8 746/373/783 1.5 12.5 FO
ARETION
PR C/V
88 PV508 RCSP 1.5 40 65 4.8 147/73.5/147 0.3 8.5 FO
ARETION
AIR PR
C/V
89 PV7201 LP STEAM 4 140 190 2.2 97.6/976/118 0.7 5.5 FC
TO - 0 6
VAPPORI 170
SER
90 PV7202 LPG VAP 3 40- 170 11.5 5400/540/64 7.3 16 FC
GAS TO 75 80
FG KOD
91 PV7203 FG KOD 4 40- 100 5 4000/500/48 2.6 6 FC
PR C/V 45 00 2
92 PV7301 FLUSHIN 2 70- 185 23.3 12/5/15 4.6 33.5 FO
G OIL TO 165 4 4
PUMP
SEALS
93 RCV501 SDV ON 1.5 70- 185 9.4 630/189/819 - 33.5
TORCH 165
OIL TO
RG APH
94 SDV137 SDV ON 4 300 13.5 4,500 - 19 FC
0 STEAM
TO MAB
LO
TURBINE
95 SDV190 HEATER 2 110 200 6 - - 17
1 FUEL OIL -
130

Plant Name: FCCU-I

RETURN
SDV
96 SDV190 HEATER 2 110 200 6 - - 17 FC
2 FUEL OL -
SUPPLY 130
SDV
97 SDV190 HEATER 6 40- 70 3 - - 6 FC
3 FG INLET 50
SDV
98 SDV137 SDV ON 3 300 13.5 2,800 - 19 FO
1 STEAM
TO MAB
HW
TURBINE
99 SDV251 SDV ON 2 40 65 3.8 - - 10 FC
0 INTERST
AGE
SOURWA
TER LINE
10 SDV264 SDV ON 3 250 280 12 1,600 12 15 FO
0 2 STEAM
TO WGC
LO
TURBINE
10 SDV264 SDV ON 2 280 12 1,000 12 15 FO
1 8 STEAM
TO WGC
SO
TURBINE
10 SDV270 SDV ON 2 38 65 14.7 - - 19 FC
2 1 HP REC
SOUR
WATER
LINE

Plant Name: FCCU-I

10 SDV310 SDV ON 1.5 40 65 8/11 - - 15.6 FC

3 1 HP STAB .5
O/H
DRUM SW
LINE
10 SDV740 SLURRY
4 1 TURBINE
STEAM
C/V
10 TCV523 STEAM 3 306 2.46 939/0/1086 0.0 4
5 TO SOL 6
HEATER
OIL
10 TV1357 MAB LO 3 80 10 27.6/41.4 1 15 FC
6 TEMP C/V
10 TV1806 LCO PA 12 241. 265 8.3 150/34/276.9 0.3 12.7 FC
7 STRIPPER 12 4 265 8.3 147/78/271 0.5 12.7
REBOILE 210
R I/L
TEMP
10 TVIX//S TORCH FC
8 OVIX OIL TO
REGEN
APH
10 TV2013 SLURRY 10 270 360 3.4 175/50/352 0.7 19 FO
9 PA
RETURN
TO MF
BOTTOM
D/O
11 TV2648 WGC LO 2 40 80 7.5 30.6 1 20 FC
0 TEMP C/V
11 TV2674 WGC SO 1 40- 80 0.72/1.08 1 30 FC
1 TEMP C/V 45
(B) FLOW INDIDCATION
Plant Name: FCCU-I

11 TV2801 STAB 8 130 225 11 120/65/144 0.5 15.6 FC

2 NAPHTHA 8 177 225 11.5 75/25 0.3 15.6
TO STR -
PREHEAT 201
ER
11 TV3003 HCO PA- 8 321 350 7 210/126/251 0.5 11 FC
3 STAB 8 321 350 7 2 0.2 11
REBOILE 65/15/125
R TEMP
C/V
11 TV3201 HCO PA 10 - 293 6 200/110/240 0.5 11 FC
4 4E57 10 273 293 6 100/65/200 0.2 11
STEAM 273
GENRATO
R
11 TV3202 SLURRY 12 303 350 9.5 120/50/362 0.2 19 FC
5 PA TO 10 303 350 10.5 362/150/435 6.5 19
04E56
STEAM
GEN
11 TV7401 BFW TO FC
6 4F51
ATOMISI
NG
STEAM
11 FV7302 LCO 3 40 - 13 50/25/75 8.0 23.2 FC
7 BOOSTER
PUMP
SPILL
BACK
11 FV9503 LCO TO 3 40 - 13.3 50/25/75 6.3 23.2 FO
8 RFO/HFO/
VBTAR
11 FV3601 LCO FC
9 TODHDS

Plant Name: FCCU-I

12 MOV26 1STAGE 24 38- 65 0.05 - - 3.5

0 01 SUCTION 45 -0.6
MOV
12 MOV26 1STAGE 16 116 150 3.96 - - 10
1 02 DISCHAR - -
GE MOV 125 7.54
12 MOV26 II STAGE 12 38 65 3.86 - - 10
2 03 SUCTION -
WGC 7.54
MOV
12 MOV26 IISTAGE 12 107 150 15 - - 19
3 04 DISCHAR -
GE MOV 132
12 MOV26 1STAGE 2 116 150 3.96 - - 10
4 05 DISCHAR - -
GE TO 125 7.64
FLARE
12 MOV26 IISTAGE 2 107 150 15 - - 19
5 06 DISCHAR -
GE TO 132
FLARE
12 PV2640 SELF 2 80 7.5 9.36/29.7/49. 7.5 28
6 ACTUATE 3
D WGC
LO U/S PR
C/V
12 PV2641 SELF 2 45 3.5 30.6/20.4 0.5 14
7 ACTUATE
D WGC
LO D/S PR
C/V
12 PV1351 LIBE OIL 3 15/ 80 12 42/14.4/70.2 12 12
8 (MAB) 45
SELF

Plant Name: FCCU-I

ACTUATE
D U/S C/V
12 PV1352 LIBE OIL 15/ 5.5 41.1/27.6 1.7 -
9 (MAB) 45
SELF
ACTUATE
D D/S C/V

Plant Name: FCCU-I

10 4FI505 Stripping steam to

S.No TAG NUMBER TAG
Reactor
DFSCRIPTION
11 4FI512 SCJB aeration
1 4FI504 Slurry bottoms
steam
recycle to Reactor
12 4FI506 Cone
2 4FI507 RCJB aeration
aeration/SCJB aeration
steam
13 4FIIXB 2” catalyst
3 4FI520 Anti coking steam
blowback air
flow
14 4FIIXB 6” catalyst loading
4 4FI508 Bottoms recycle
fresh catalyst addition
injection steam
15 4FII519 Continuous
5 4FI3X Steam to MAB
catalyst addition instrument air
6 4FI525 Control air bypass
16 4A1501 Regenerator flue
to MAB discharge
gas O2 analyser
17 FC516 FI6X+FI7X+FI2X
7 4FI12X Feed injection
steam
gas High rangeCO2
8 4FI518 MAB atmospheric
vent flow
gas low rangeCO2
9 4FI517 Control air blower
20 4FI521 Air to MAB
discharge
(suction)
Plant Name: FCCU-I

21 4FI503 Naphtha quench to 31 4FI1908 Decoking steam

Reactor total flow
22 4FI18X 6” Catalyst 32 4FI1902 Pass 2 feed flow
loading carrying air D4 33 4FI1911 Fuel gas flow
23 4FI501 Total feed to 34 4FI1912 Pilot gas flow
Reactor 35 4FI1909 Decoking air flow
24 4FI522 Normal catalyst 36 4F11905 Decoking steam
with drawl air (1 ½” ) flow pass 1
25 4FI15X Feed riser fluffing 37 4F11901 Pass 1 feed flow
and emergency steam 38 4FI1952 4V63 blow down
26 4FI18 Control air to flow
catalyst hoppers 39 4FI1913 Atomizing steam
27 4FI6X Primary air to flow to heater
Regenerator 40 4FI1953 4V-63 blow down
28 4FI1702 Cold feed flow to flow local indication
surge drum 41 4FI1951 BFW to steam
29 4FI1801 HCD product from drum
4E56A/B 42 4A11951 Analyzer at stack
30 4FII906 Decoking steam (SPM)
flow to 4C-51 43 4FI1910 Fuel oil supply
flow
Plant Name: FCCU-I

44 4A11952 NOx, SOx, CO, 54 4FI2101 LCO stripping

HC analyzers at stack steam
45 4A11954 Analyzer at heater 55 4FI2102 HCO stripping
arch steam
46 4FI1907 Fuel oil return 56 4FI2202 CLO to main
flow fractionator
47 4FI2007 HCO PA above 57 4FI2203 HCO to slurry
D6 settler dilutant
48 4FI2002 HCO pump around 58 4FI2202 HCO from 4P56
return A/B
49 4FI2004 Slurry PA return 59 4FI2204 CLO to feed
above D4 preheat exchanger
50 4FI2001 LCO pump around 60 4FI2304 Compressor total
return spill back flow
51 4FI2003 4C-51 top reflux 61 4FI2402 Sour water pump
flow discharge flow
52 4FI2006 Stripping steam 62 4FI2402 Unstabilized
flow to 4C-51 Naphtha flow
53 4FI2005 Slurry PA return 63 4FI2403 Service water to
above D4 O/H condensers

Plant Name: FCCU-I

64 4F12401 Unstabilized
Naphtha flow
65 4FI2501 Service water to
4E-63A/B
66 4FI2601 WGC 1st stage
suction flow
67 4FI2602 WGC 2nd stage
discharge flow68
68 4FI2704 Sour water from
4V-53 to 4E-64A/B
69 4FI2701 Stripper feed flow
70 4FI2702 Sour water from
HP receiver
71 4FI2703 Compressor 2nd
discharge to primary absorber
72 4FI2705 Service water to
4E64A/B (startup)

Plant Name: FCCU-I

(C) PRESSURE INDICATIONS

Plant Name: FCCU-I

1 4PI506 RCJB aeration 11 4PDI2X Reactor

steam differential pressure
2 4PDI502 Rx-Rg differential 12 4PI508 RSCP aeration air
pressure to ES-4 and ES5 trip c/v d/s pressure
3 4PDI3X Regenerated 13 4PI505 Cone/SCSP
catalyst overflow DP aeration steam
4 4PDI30X Spent catalyst side 14 4PDI509 Regenerator Grid
valve DP DP
5 4PI30X Catalyst unloading 15 4PI3 2” carrying
carrying air pressure pressure
6 4PI507 SCJB aeration 16 4PDI503 Reactor vapor line
steam c/v d/s pressure DP
7 4PDI1X Regenerator 17 4PDI501 Rx-Rg differential
differential pressure pressure
8 4PI2X Regenerator 18 4PDI504 Reactor riser DP
pressure 19 4PI3X Reactor dilute
9 4PI20X Regenerator O/H phase pressure
line pressure 20 4PI512 MAB suction
10 4PI1X MAB discharge pressure to ASC
pressure 21 4PI31X Catalyst unloading
air
Plant Name: FCCU-I

22 4PI85 6” catalyst loading 33 4PI1909 Feed O/L from

to Regen pressure heater to Reactor
23 4PI241X Reactor overhead 34 4PI1918 Atomising steam
line pressure
24 4PI513 CAB discharge 35 4PI1918 Heater steam drum
temperature BFW O/L pressure
25 4PDI511 MAB air inlet 36 4PI1920 Pilot gas pressure
suction hood DP 37 4PI1901 Fuel gas c/v d/s
26 4PI240X Total feed to pressure
Reactor 38 4PI1902 Fuel oil supply
27 4PDI4X RCJB slide v/v DP pressure to heater burners
28 4PI1709 Feed pump 39 4PI1908 Superheated MP
discharge pressure steam header pressure
29 4PI1923 Fuel gas supply 40 4PI1917 Fuel oil supply
pressure pressure c/v u/s
30 4PI1963 BFW supply to 41 4PI1962 BFW O/L from
steam drum pressure convection section
31 4PI1964 Heater arch 42 4DPI1901 Atomising steam
pressure fuel oil DP
32 4PI1951 4V-63 drum 43 4PI2003 4C-51 pr at HCO
pressure chimney tray below 24
Plant Name: FCCU-I

44 4PI2002 4C-51 pressure at 54 4DPI2620 WGC 1st stage

LCO chimney tray below 24 discharge and suction DP
45 4PI2001 4C-51 top 55 4PI2629 WGC 1st stage
temperature suction pressure
46 4PI2012 4C-51 column 56 4PI2605 WGC 2nd stage
bottom pressure suction pressure
47 4PI2202 Slurry settler 57 4PI2601 WGC 1st stage
bottom to Reactor suction pressure
48 4PI2411 4V-53 drum 58 4PI2608 WGC 2nd stage
pressure to flare discharge pressure
49 4PI2407 4V-53 drum 59 4PI2712 4V-56 gas to
pressure primary absorber
50 4PI2502 4V-53 drum 60 4PI2707 4V-56 gas to
pressure primary absorber at 4V-56
51 4PI2609 WGC 2nd stage 61 4PI2801 Primary absorber
discharge pressure O/H pressure
52 4DPI2621 WGC 2nd stage 62 4DPI2806 Stripper bottom
discharge and suction DP reboiler c/v DP
53 4PI2603 WGC 1st stage 63 4PI2809 Stripper bottom
discharge pressure pressure

Plant Name: FCCU-I

64 4PI2809 Stripper O/H 76 4PI7301 Seal oil pressure

pressure 77 4DPI7301 VGO filters DP
65 4PI2909 Sponge absorber 78 4PI7405 Instrument air
off gas pressure pressure
66 4PI2902 Sponge absorber 79 4PI7403 LP steam pressure
off gas c/v d/s pressure 80 4PI7411 MP steam pressure
67 4PI3001 Stabiliser O/H 81 4PI7401 HP steam pressure
pressure at U/L
68 4PI3003 Stabiliser bottom
pressure
69 4PI3006 Stabiliser tray 25
temperature
70 4PI3201 4E57 steam O/I
pressure
71 4PI3202 4E56 steam O/L
pressure
72 4PI7211 Fuel gas to
distribution
73 4PI7201 4V-62 pressure
74 4PI7202 4V-64 pressure
75 4PDI7302 VGO filters DP
Plant Name: FCCU-I

(D) TEMPERATURE INDICATIONS

Plant Name: FCCU-I

1 4T1530/529 Normal catalyst 11 4TI519 Regenerator mid

with drawl temp dilute phase
2 4T1509 Reactor feed riser 12 4TI518 Regenerator
temp (inside) overflow well level
3 4T1533 Control air blower 13 4TI526 Spent catalyst riser
discharge temp 14 4TI1_2X CAB discharge
4 4TI542 Air preheater pump
mixing zone 15 4TI521 Regen grid metal
5 4TI540 Normal catalyst temp
with drawl 16 4TSH (THC0528) Spent cat
6 4TI524 Regen gird metal angle riser temp receiver switch
temp 17 4TI515/516 Regenerator mid
7 4TI532 MAB discharge dense bed
temp high 18 4TI84X Catalyst with
8 4TI528 Spent catalyst drawl to 4D4
angle riser temp 19 4TI534 Cat with drawl
9 4TI520 Regenerator mid from regenerator temp at hopper
dilute phase 20 4TI501 Feed diversion to
10 4TI523 Regen grid metal fractionator
temp 21 4TI510 Reactor plenum
chamber temp
Plant Name: FCCU-I

22 4TI514 Regenerator mid 32 4TI9X Regenerator upper

dense phase temp dilute phase
23 4TI2X MAB discharge 33 4TI507 Lower Reactor
temp feed riser temperature
24 4TI517 Regenerator lower 34 4TI1XA Regen aux burner
dense bed temp
25 4TI525 Regenerator metal 35 4TI3X Regen aux burner
grid temp dome
26 4TI536/537 Regenerator 36 4TI26X/527 Spent catalyst
plenum angle riser
27 4TI531 MAB discharge 37 4TI12x Regenerator
temp primary cyclone inlet
28 4TI538 Regenerator O/H 38 4TI1X Regen above grid
to CO boiler temp
29 4TI535 MAB steam inlet 39 4TI8X Regen above
temp phase temp
30 4TI522 Regenerator grid 40 4TI11X Regenerator
metal temp primary cyclone inlet
31 4TI17X Regenerator 41 4TIX Regenerator aux
primary cyclone outlet burner combustion temp

Plant Name: FCCU-I

42 4TI36X Reactor overhead 53 4TI506 Lower Reactor

vapor line temperature feed riser
43 4TI31X Reactor dense 54 4TI513 Reactor stripper
phase temp bottom temperature
44 4TI5X Regen bed temp 55 4TI18X Regen primary
45 4TI35X Reactor dilute cyclone outlet
phase 56 4TI15X Regen primary
46 4TI4X Regenerator below cyclone outlet
grid 57 4TI511 Reactor plenum
47 4TI502 Lower reactor feed 58 4TI16X Regen primary
riser cyclone outlet
48 4TI14X Regen Primary 59 4TI1707 Hot feed
cyclone outlet temperature
49 4TI13X Regen Primary 60 4TI1705 Feed pump suction
cyclone inlet temp
50 4TI19X Regen Primary 61 4TI1708 Cold feed
cyclone outlet temperature
51 4TI20X/516 Regenerator O/H 62 4TI1805 4E54C feed O/L
line temperature
52 4TI505 Lower Reactor 63 4TI1803 4E53 feed O/L
feed riser temp
Plant Name: FCCU-I

64 4TI1802 4E52ABCD O/L 76 4TI1953 Below super

temp heating coils convection section temp
65 4TI1813 Slurry O/L from 77 4TI1911 Heater feed o/l to
4E54C reactor
66 4TI1807 LCO inlet to 78 4TI1972 BFW to 4V-63
4E51A inlet temperature
67 4TI1806 LCO O/L from 79 4TI1915 Fuel oil supply
4E53 to 4E66A temp
68 4TI1808 CLO from slurry 80 4TI1912 Heater feed o/l to
settler to 4E52ABCD reactor
69 4TI1809 CLO O/L from 81 4TI1918 Fuel gas inlet temp
4E52ABCD 82 4TSH1966 Heater stack
70 4TI810 4E54B slurry o/l damper
71 4TI1811 4E54C slurry o/l 83 4TI1910 Heater superheated
72 4TI1812 LCO O/L from steam O/L
4E51 84 4TI1967 Heater convection
73 4TI1814 4E54B feed o/l zone above
74 4TI1801 4E54A feed O/L 85 4TI1903 Heater convection
temp feed o/l pass1
75 4TI1804 4E54A feed O/L 86 4T11963 BFW convection
temp O/L temperature
Plant Name: FCCU-I

87 4TI1952 Temp at BFW and 97 4TI1957A/B Skin

steam coil convection section temperatures at convection
88 4T11954 Heater arch 98 4TI1959A/B Skin
temperature temperatures at radiation
89 4TI1951 Steam coil heater 99 4TI1969A/B Feed convection
convection temp tubes temp
90 4TI1955 Above 100 4TI1968A/B Feed convection
superheating coils convection section tubes at skin 101 4TI1958A/B Skin
91 4T11962 Heater box temperature at convection
temperature 102 4TI1960A/B Heater skin
92 4TI1902 Heater pass 2 feed temperature at convection
inlet 103 4TI1961 Heater fire box
93 4T11964 BFW convection temp
I/L temperature 104 4TI1956 Feed convection
94 4TI1904 Heater pass 1 feed O/L to radiation zone
I/L 105 4T11909 Heater feed
95 4TI1907 Heater convection radiation o/l pass2
feed O/L pass2 106 4TI1908 Heater feed
96 4TI1965 4V63 drum radiation o/l pass1
temperature 107 4TI1966 Heater stack
temperature
Plant Name: FCCU-I

108 4TI2005 Tray 23 temp 120 4TI2019 4C-51 column

109 4TI2006 Below tray 17 bottom liquid temp
temperature 121 4TI2016 HCO d/o temp
110 4TI2002 HCO PA return 122 4TI2010 4C-51 above DD6
temp temperature (flash zone temp)
111 4TI2001 LCO pump around 123 4TI2018 4C-51 temp above
return temperature tray2
112 4TI2009 4C-51 above DD4 124 4TI2101 LCO vapor return
temperature temp
113 4TI2003 4C-51 tray34 temp 125 4TI2105 LCO stripper d/o
114 4TI2004 4C-51 vapor line temperature
temperature 126 4TI2101 HCO stripper d/o
115 4TI2011 4C-51 above DD6 temp
temperature 127 4TI2104 HCO stripper
116 4TI2015 LCO d/o temp vapor return
117 4TI2007 4C-51 above tray 6 128 4TI2201 Slurry settler
temp bottom to Reactor
118 4TI2013 4C-51 bottom d/o 129 4TI2305 MC O/H air fin
pump discharge 119 4TI2012 coolers o/l temp
4C-51 above DD6 temp 130 4TI2403 4E59ABCD H/C
O/L temp
Plant Name: FCCU-I

131 4TI2503 4E63A/B HC O/L 142 4TI2606 WGC 2nd stage

temperature discharge
132 4TI2506 4E63A/B HC O/L 143 4TI2611 WGC 2nd stage
133 4TSHH2604 WGC 2nd suction
discharge 144 4TI2701 4V56 gas O/L
134 4TI2604 WGC 2nd temp
discharge 145 4TI2702 4E64A/B HC O/L
135 4TSH2603 WGC 1st stage temp
discharge temperature high 146 4TI2704 4E64A HC O/L
136 4TI2605 WGC 1st stage temperature
discharge 147 4T12818 Primary absorber
137 4TSH2606 WGC 2nd stage tray 36
discharge temperature high 148 4T12806 Stripper tray 19
138 4TI2610 WGC 2nd stage temperature
discharge 149 4T12811 Stripper below
139 4TI2603 WGC 1st stage tray 4 temperature
discharge 150 4T12805 Stripper O/H gas
140 4TI2601 WGC 1st stage temperature
suction temp 151 4TI2808 Stripper reboiler
141 4TI2609 WGC 2nd stage O/L to stripper 1524T12814
discharge 4E66A reboiler LCO O/L temp
Plant Name: FCCU-I

153 4T12809 Stripper reboiler 163 4TI3006 Stabiliser reboiler

inlet temp inlet temp
154 4TI2801 Stabilised Naphtha 164 4TI3003 Stabiliser tray 3
to 4E69B temperature
155 4TI2810 Stripper bottom 165 4TI3001 Stabiliser tray 38
d/o temperature temperature
156 4TI2503 Primary absorber 166 4TI3010 Stabiliser tray 22
tray 9 temp temperature
157 4TI2904 Sponge absorber 167 4TI3012 Stabiliser tray 13
tray 6temp temperature
158 4TI2906 Sponge absorber 168 4TI3009 Stabiliser tray 25
bottom rich sponge oil temp temperature
159 4TI2905 4E65 rich sponge 169 4TI3004 Stabiliser reboiler
to column temp O/L temp
160 4TI2903 Sponge absorber 170 4TI3007 Stabiliser tray1
tray 15 temperature
161 4TI2902 Sponge absorber 171 4TIS3005 Stabiliser tray 7
off gas temperature
162 4TI2901 Lean sponge oil 172 4TI3011 Stabiliser tray 20
sponge absorber temperature

Plant Name: FCCU-I

173 4TI3008 Stabiliser O/H 185 4TI3318 LCO rundown c/v

vapor temperature d/s temperature
174 4TI3104 4E67A HC O/L 186 4TI3303 Stabilised Naphtha
temperature AFC outlet
175 4TI3103 4E67A/BHC O/L 187 4TI3315 LCO inlet to
temperature 4E55A/B
176 4TI3201 HCO PA 188 4TI3316 LCO 4E55A outlet
return from 4E57 to 4C51 temp
177 4TI3204 BFW temperature 189 4TI3321 Stabilized Naphtha
178 4TI3205 4E56 temp 4E70A outlet 190 4TI3322 CLO
179 4TI3206 MP steam from rundown temp
4E56 to 4C51 191 4TI3325 BFW outlet
180 4TI3203 4E57 temp temperature from 4E55A/B
181 4TI3202 Slurry PA return 192 4TI7207 4V-62 drum temp
from 4E57 to 4C51 193 4TI7405 HP BFW
182 4TI3320 LCO 4E55A/B temperature
outlet temperature 194 4TI7404 MP BFW
183 4TI3314 Stabilised Naphtha temperature
4E70A/B outlet 195 4TI7402 MP steam temp
184 4TI3317 LCO air fin cooler 196 4TI7403 LP steam
outlet temp temperature
Plant Name: FCCU-I

197 4TI7401 MP steam temp

198 4TI7501 CBD drum
temperature

Plant Name: FCCU-I

(E) LT’S LIST

Plant Name: FCCU-I

04-ILT-1704 Feed surge drum 04-LT -2402 4V-53

boot interphase level hydrocarbon level
04-ILT-2404 4V-53 boot level 04-LT -2504 4V-55 drum level
04-ILT-2505 4V-55 drum boot 04-LT -2506 4V-54 drum level
level 04-LT -2703 4V-56 H/C level
04-ILT-2704 4V-56 boot level 04-LT -2801 Primary absorber
04-ILT-3103 4V-57 boot level bottom level
04-LT -1703 Feed surge drum 04-LT -2802 Stripper LT
level 04-LT -2902 Sponge absorber
04-LT -1705 Feed surge drum bottom level
level (for LIC) 04-LT -2X Regen overflow
04-LT -1952 4V-63 steam drum well level
level 04-LT -3002 Stabiliser level
04-LT -1X Regenerator level 04-LT -3101 4V-57 level
04-LT-2005 4C-51 bottom 04-LT -3205 4E57 steam drum
LT2003 4C-51 bottom LT level
04-LT -2009 4C-51 high level 04-LT -3206 4E56 steam drum
switch level
04-LT -2102 HCO stripper LT 04-LT -501 Reactor level
04-LT -2103 LCO stripper LT 04-LT -502 Reactor stripper
04-LT -2104 HCO stripper LT level LL(CO)
Plant Name: FCCU-I

04-LT -503 Regen overflow

well es-4
04-LT -7201 4V-62 level
04-LT -7204 4v60 (flare kod)
level
04-LT -7501 CBD drum level

Plant Name: FCCU-I

(F) LOCAL INDICATING TRANSMITTERS

Plant Name: FCCU-I

1 4FI3X 2” catalyst 12 4PDI509 Regenerated grid

blowback air DP
2 4PDI3X Spent catalyst 13 4FI18X 6” catalyst loading
slide valve DP carrying air to D4
3 4PDI4X RCJB slide valve 14 4FI178 Control air to
DP indication catalyst hoppers
4 4FI2X Control to 15 4FI522 Normal catalyst
regenerator withdrawal air (1 1/2” )
5 4FI519 Continuous 16 4PI1920A pilot gas pressure
catalyst addition instrument air 17 4FI1907A Fuel oil return
6 4PDI1X Regenerator flow
differential pressure 18 4FI1906B Decoking steam
7 4PDI504 Reactor riser DP flow pass2
8 4PDI1X Regenerator 19 4FI1953 4V-63 blow down
differential pressure flow local indication
9 4PDI2X Reactor 20 4FI1905 Decoking steam
differential pressure flow pass1
10 4FI514 Torch oil to air 21 4FI1909B Decoking air flow
preheater 22 4FI2003B 4C-51 bottom LT
11 4PDI510 Regenerated 23 4FI2006B Stripping steam
catalysts overflow DP flow to 4C-51
Plant Name: FCCU-I

24 4LI2102B HCO stripper LT 35 4FI2603B WGC 1st stage

25 4FI2203B HCO to slurry discharge pressure
settler dilutant 36 4FI2704B Sour water from
26 4FI2404B DM water makeup 4V-53 to 4E-64A/B
to 4V-53 boot 37 4FI2705 Service water to
27 4FI2403 Service water to 4E64A/B (startup)
O/H condensers 38 4FI3003 Stabilizer tray 38
28 4FI2501 Service water to temperature
4E63A/B 39 4TI3001 Stabilizer tray 3
29 4TI2605A WGC 1st stage temperature
discharge temperature 40 4FI3205 4E56/57 blow
30 4DPI2620B WGC 1st stage down flow
discharge and suction DP 41 4FI3305 LCO to offsite
31 4TI2609B WGC 2nd stage cutter
discharge temperature
32 4PI2608B WGC 2nd stage
discharge pressure
33 4DPI2621 WGC 2nd stage
discharge and suction DP
34 4PI2605 WGC 2nd stage
suction pressure
Plant Name: FCCU-I

(G) LOCAL TEMPERATURE GAUGES LIST

Plant Name: FCCU-I

04-TI-3306 4E70A saltwater 04-TI-1916 Atomising steam

o/l temperature temp at heater
04-TI-1301 MAB steam inlet 04-TI-1920 Decoking o/l to
temp (I) decoking drum
04-TI-1702 Cold feed 04-TI-1913 Fuel oil return
temperature temperature
04-TI-1701 Hot feed 04-TI-1919 Steam to soot
temperature blowers temp
04-TI-1704 Feed pump suction 04-TI-1904 Steam I/L to
temperature convection zone temp
04-TI-1703 Feed surge drum 04-TI-2017 4P-52 A suction
04-TI-706 Cutter stock to 04-TI-2008 HCO d/o
feed surge drum temperature
04-TI-1816 LCO PA o/l from 04-TI-2014 LCO d/o
4E53 temperature
04-TI-1914 Fuel oil supply 04-TI-2020 4P-52A suction
temp temperature
04-TI-1917 Fuel gas 04-TI-2106 LCO stripper d/o
temperature at heater temperature

Plant Name: FCCU-I

04-TI-2103 HCO stripper d/o 04-TI-2502 4E63A/B sea

temperature water return temp
04-TI-2301 4EM58A/B H/C 04-TI-2504 4V-55 drum
o/l temperature temperature
04-TI-2304 4EM58G/H H/C 04-TI-2615 WGC 1st stage
o/l temperature discharge
04-TI-2302 4EM58C/D H/C 04-TI-2608 WGC 2nd stage
o/l temperature discharge
04-TI-2303 4EM58E/F H/C o/l 04-TI-2607 WGC 2nd stage
temperature suction
04-TI-2401 4V-53 drum 04-TI-2602 WGC 1st stage
temperature suction
04-TI-2404 4V-53 drum 04-TI-2703 4E64A/B salt
temperature water return
04-TI-2405 4E59C/D s/w o/l 04-TI-2705 4V-56drum
04-TI-2402 4E59A/B S/W O/L 04-TI-2813 LCO PA from
temp 4E53 to 4E66A
04-TI-2501 Sour water o/l 04-TI-2817 Stripper reboiler
from 4V-55 o/l inlet temperature

Plant Name: FCCU-I

04-TI-2816 Stripper reboiler 04-TI-3307 4E62A/B saltwater

o/l temp return
04-TI-2815 LCO PA from 04-TI-3309 CRN rundown
4E53 to 4E66A temperature
04-TI-2909 Sponger absorber 04-TI-3324 4E55B BFW O/L
bottom temp temperature
04-TI-2907 LCO O/L from 04-TI-3310 CLO rundown
4E65 to 4E51 temperature
04-TI-2908 Sponge absorber 04-TI-3305 LCO rundown
off gas line temp temperature
04-TI-3102 4E67A/B HC 04-TI-3311 SEA water return
temperature from 4E62 C/D
04-TI-3101 4E67A/B saltwater 04-TI-3313 4E67A salt water
return O/L temperature
04-TI-3312 4E61A/B saltwater 04-TI-3323 4E55A BFW O/L
I/L temperature
04-TI-3301 LPG rundown 04-TI-3302 4E70 B salt water
temperature O/L temperature
04-TI-3319 4E61A HC O/L 04-TI-7102 Salt water return

Plant Name: FCCU-I

04-TI-7101 Salt water supply

temperature
04-TI-7104 Bearing cooling
water return
04-TI-7103 Bearing cooling
water return
04-TI-7206 4V-60 drum
temperature
04-TI-7201 Fuel gas internal
distribution
04-TI-7204 Fuel oil supply
temperature
04-TI-7202 Sweet fuel gas
temperature
04-TI-7203 Fuel oil supply
temperature
04-TI-7205 LPG to vaporiser
temperature
04-TI-7301 FLO to pump seals
04-TI-7405 HP BFW water
temperature
Plant Name: FCCU-I

(H) LOCAL PRESSURE GAUGES LIST

Plant Name: FCCU-I

04-PI-1126 Stripper Cone 04-PI-1148 Rx Top Pr Pdt 503

Aeration Local Pr
04-PI-1143 RCJB Aeration 04-PI-1149 Pt3x Local
Stm Nozzle Pr pressure
04-PI-1128 Stripper Cone 04-PI-1115 Feed Nozzle Pr
Aeration (D/S Inj Steam)
04-PI-1144 RCJB Aeration 04-PI-1127 Stripper Cone
Stm Nozzle Pr Aeration
04-PI-1145 RCJB Lower Blast 04-PI-1142 RCJB Aeration
Stm Pr Stm Nozzle Pr
04-PI-1118 Anti Coking 04-PI-1125 Stripper Cone
Baffle Steam Pr Aeration
04-PI-1146 Reslurry C/V D/S 04-PI-1110 Feed Injection Stm
Pressure C/V D/S pressure
04-PI-1147 Reslurry Inj Stm 04-PI-1111 Naphtha Quench
C/V D/S Pr C/V D/S Pr
04-PI-1117 Feed Nozzle Pr 04-PI-1140 RCJB Aeration
Pdt503 Local Pr Stm Nozzle Pr
04-PI-1105 2” Rx Stripping 04-PI-1101 Rx Stripping C/V
Stm Nozzle Pr D/S Pressure

Plant Name: FCCU-I

04-PI-1123 Stripper Cone 04-PI-1104 3” Rx Stripping

Aeration Stm Nozzle Pr
04-PI-1114 Feed Nozzle Pr 04-PI-1106 2” Rx Stripping
(D/S Inj Steam) Stm Nozzle Pr
04-PI-1112 Feed Nozzle Pr 04-PI-1107 3” Rx Stripping
04-PI-1122 Stripper Cone 04-PI-1108 3” Rx Stripping
Aeration Stm Nozzle Pr
04-PI-1121 Stripper Cone 04-PI-1119 Riser Anti Coking
Aeration steam Pr
04-PI-1120 Cone/SCSP C/V 04-PI-1116 Feed Nozzle Pr
D/S Pressure (D/S Inj Steam)
04-PI-1102 3” Rx Stripping 04-PI-1129 Stripper Cone
Stm Nozzle Pr aeration
04-PI-1109 Total Feed C/V 04-PI-1130 SCSP Aeration
U/S Pr Stm Pr
04-PI-1103 3” Rx Stripping 04-PI-1136 RCJB Aeration
Stm Nozzle Pr Stm Nozzle Pr
04-PI-1113 Feed Nozzle Pr 04-PI-1131 SCSP Aeration

Plant Name: FCCU-I

04-PI-1139 RCJB Aeration 04-PI-1224 SCJB Aeration

Stm Nozzle Pr Tap Pr (L)
04-PI-1138 RCJB Aeration 04-PI-1206 RCSP Aeration
04-PI-1124 Stripper Cone 04-PI-1225 SCJB Aeration
Aeration Tap Pr (L)
04-PI-1133 Feed Riser 04-PI-1208 RCSP Aeration
Fluffing C/V U/S Pr Tap Pr (L)
04-PI-1134 RCJB Aeration 04-PI-1205 RCSP Aeration
C/V D/S Pr Tap Pr (L)
04-PI-1132 SCSP Aeration 04-PI-1218 SCJB Upper Blast
Stm Pr Ro d/S Pr (L)
04-PI-1135 RCJB Aeration 04-PI-1231 Torch Oil Purge
Stm Nozzle Pr Stm Nozzle (L)
04-PI-1227 SCJB Aeration 04-PI-1223 SCJB Aeration
Tap Pr (L) Tap Pr (L)

Plant Name: FCCU-I

04-PI-1212 RSSP Aeration 04-PI-1217 Emg Stm to MAB

Tap Pr (L) C/V D/S Pr (L)
04-PI-1222 SCJB Aeration 04-PI-1221 SCJB Aeration
Tap Pr Tap Pr (L)
(L) 04-PI-1234 Cont Cat With
drawl Purge Air (I)
04-PI-1209 RCSP Aeration 04-PI-1235 Regen O/H Line
Air Tap Pr (L) Pressure (L)
04-PI-1213 RCSP Aeration 04-PI-1220 SCJB Aeration
Air Tap Pr (L) Tap Pr (L)
04-PI-1215 RCSP Aeration 04-PI-1233 Torch Oil Atm
Air Tap Pr (L) Stm C/V D/S 04-oe230
04-PI-1232 Torch Oil Purge 04-PI-1216 MAB Second Air
Stm Nozzle Pressure
04-PI-1214 RCSP Aeration 04-PI-1236 Regen Stack S/V
Air Tap Pr (L) D/S Pr (L)
04-PI-1202 RCSP Aeration 04-PI-1204 RCSP Aeration
Air C/V D/S Pr (L) Air Tap Pr (L)
04-PI-1211 RCSP Aeration 04-PI-1237 Regen Flue Gas
Air Tap Pr (L) Ro 560 D/S Pr (L)

Plant Name: FCCU-I

04-PI-1201 6” Cat Unloading 04-PI-1409 Carrying Air to

Carrying Air Pr Zsm-5 Drum
04-PI-1207 RCSP Aeration 04-PI-1411 4D3 Hooper Cone
Air Tap Pr (L) Aeration Pr
04-PI-1210 RCSP Aeration 04-PI-1412 4D3 Hooper Cone
Air Tap Pr (L) Aeration Pr
04-PI-1203 RCSP Aeration 04-PI-1417 4D4 Cone
Air Tap Pr (L) Aeration Pressure
04-PI-1238 Regen Flue Gas 04-PI-1416 Cont Cat Add
Ro 561 D/S Pr (L) Pressure up Air
04-PI-1305 CAB Discharge 04-PI-1408 ZSM-5 Drum
pressure Pressure
04-PI-1307 Hotwell Motor 04-PI-1414 4D3 Ejector T/O
Discharge Line Pressure
04-PI-1308 Hotwell Turbine 04-PI-1418 4D4 Cone
Discharge Aeration Pressure
04-PI-1306 MP Steam to 04-PI-1419 4D4 Cone
Ejectors (L) Aeration Pressure
04-PI-1304 CAB Suction 04-PI-1415 Control Air to 4d4
Pressure (L) Hopper Pr

Plant Name: FCCU-I

04-PI-1410 4D3 Hopper Cone 04-PI-1702 Cold Feed from

Aeration Pr Offsite
04-PI-1413 4D3 Hopper 04-PI-1705 4P51 B Pump
Control Air Pr Discharge Pressure
04-PI-1407 6” Fresh Cat 04-PI-1706 Feed Pump
Addition Carr Air Pr Suction Pressure
04-PI-1406 Comb Promoter 04-PI-1704 4P51B Pump
Control Air Pr Discharge Pressure
04-PI-1401 RCJB Cat 04-PI-1808 4E54C Slurry O/L
Unloading Air (L) Pressure
04-PI-1402 RCJB Cat Unload 04-PI-1809 4E54B Feed O/L
Nozzle Purge (I) Pressure
04-PI-1404 SCJB Cat Unload 04-PI-1806 4E54B Slurry O/L
Nozzle Purge (I) Pressure
04-PI-1403 SCJB Cat 04-PI-1801 4E51 Feed Outlet
Unloading Air (L) Pressure
04-PI-1405 Combustion 04-PI-1805 4E54 feed O/L
Promoter Pot Pressure
04-PI-1703 Feed Surge Drum 04-PI-1803 4E53 Feed O/L
Pressure Pressure
04-PI-1701 Hot Feed At U/L
Plant Name: FCCU-I

04-PI-1804 4E54A Feed O/L 04-PI-1928 Fuel gas pressure

Pressure at burner
04-PI-1807 Slurry PA O/L 04-PI-1919 Atomising steam
from 4e56 pressure
04-PI-1802 4E52A/B/C/D 04-PI-1925 Fuel gas supply
Feed Outlet Pressure pressure
04-PI-1924 Pass 2 Control 04-PI-1906 Heater pass 2 feed
V/V D/S Pressure convection o/l
04-PI-1907 Superheated Mp 04-PI-1914 Fuel oil pressure at
Steam O/L Pressure heater
04-PI-1916 Fuel Oil Supply 04-PI-1912 Pass 1 C/V D/S
Pressure C/S U/S pressure
04-PI-1910 Heater O/L Feed 04-PI-1931 Snuffing steam
To Reactor pressure
04-PI-1929 Fuel Oil Pressure 04-PI-1933 Decoking steam
at burner pass 2 pressure
04-PI-1911 Fuel oil return 04-PI-1903 MP steam inlet to
pressure super heater inlet
04-PI-1932 Steam to soot 04-PI-1904 Decoking steam
blowers pass 1 pressure

Plant Name: FCCU-I

04-PI-1905 Heater feed pass 1 04-PI-2004 4C-51 pressure

convection O/L above DD6
04-PI-1930 Atomising steam 04-PI-2112 HCO stripping
to burners steam pressure
04-PI-1922 Pilot gas pressure 04-PI-2115 HCO stripper
04-PI-2006 4C-51 pressure at bottom pressure
DD1 04-PI-2106 4P60A pump
04-PI-2009 4P52B discharge discharge pressure
pr 04-PI-2104 4P55B pump
04-PI-2008 4P52A discharge discharge pressure
pr 04-PI-2105 4P60A pump
04-PI-201 4P57B discharge discharge pressure
04-PI-2001 4P57A discharge discharge pressure
pr 04-PI-2101 4P-59A pump
04-PI-2014 4C-51 bottom d/o discharge pressure
pressure to 4P52A 04-PI-2114 LCO stripper
04-PI-2007 4C-51 bottom d/o bottom pressure
suction to 4P52B 04-PI-2111 LCO stripping
04-PI-2005 4C-51 o/h vapor steam pressure
line pressure
Plant Name: FCCU-I

04-PI-2110 LCO stripper top 04-PI-2404 4P53B pump

pr discharge pressure
04-PI-2107 4P56A pump 04-PI-2405 4P54A pump
discharge pressure discharge pressure
04-PI-2102 4-59B pump 04-PI-2410 Sea water return pr
discharge pressure from 4E59A/B/CD
04-PI-2113 HCO stripper d/o 04-PI-2402 4P-63B pump
to pump pressure discharge pressure
04-PI-2109 HCO stripper top 04-PI-2401 4P53A pump
pr discharge pressure
04-PI-2108 4P56B pump 04-PI-2406 4P54B pump
04-PI-2201 Slurry settler 04-PI-2507 4P61B pump
pressure discharge pressure
04-PI-2403 4P53A pump 04-PI-2508 4V-55 boot sour
discharge pressure water
04-PI-2409 Sea water supply 04-PI-2504 4P64A pump
pr to 4E59A/B/CD discharge pressure
04-PI-2408 4V-53 drum 04-PI-2509 N2 cylinder O/L
pressure pressure

Plant Name: FCCU-I

04-PI-2510 4E63A/B salt 04-PI-2628 Naphtha injection

water o/l pressure to compressor
04-PI-2503 4V-55 drum 04-PI-2701 4P62A discharge
pressure pressure
04-PI-2506 4P61A pump 04-PI-2702 4P62B discharge
04-PI-2505 4P64B pump 04-PI-2706 4P64 A/B salt
discharge pressure water return pressure
04-PI-2501 4V-54 drum 04-PI-2705 4P62 A/B suction
pressure indication pressure
04-PI-2622 Buffer gas fuel gas 04-PI-2704 Sea water supply
header to 4E64A/B
04-PI-2602 WGC 1st stage 04-PI-2703 4V-56 pressure
suction pressure 04-PI-2810 4P74A discharge
04-PI-2607 WGC 2nd stage pressure
dis pressure 04-PI-2805 Striper bottom
04-PI-2606 WGC 2nd stage pressure
suction pressure 04-PI-2807 Stripper O/H
04-PI-2604 WGC 1st stage vapor line pressure
discharge pressure 04-PI-2804 Stripper top
pressure
Plant Name: FCCU-I

04-PI-2803 Primary absorber 04-PI-3005 Stabiliser bottom

bottom pressure pressure
04-PI-2802 Primary absorber 04-PI-3106 4E67A/B salt
bottom pressure water return pressure
04-PI-2811 4P47B discharge 04-PI-3101 4P66A discharge
pressure pressure
04-PI-2905 Sponger absorber 04-PI-3105 4V-57 pressure
top pressure 04-PI-3107 4E67 A/B salt
04-PI-2907 Rich sponge oil to water return pressure
fractionator 04-PI-3104 4P67B discharge
04-PI-2904 4P58B pump pressure
discharge pressure 04-PI-3102 4P66B discharge
04-PI-2903 4P58A discharge pressure
pressure 04-PI-3103 4P67A discharge
04-PI-2906 Sponge absorber pressure
bottom pressure 04-PI-3204 4E57 pressure
04-PI-2908 Sponge absorber 04-PI-3203 BFW pressure
off gas c/v d/s gauge
04-PI-3004 Stabiliser top 04-PI-3205 4E56 pressure
pressure 04-PI-3307 4P65B discharge
pressure
Plant Name: FCCU-I

04-PI-3303 LCO rundown 04-PI-7107 BCW return pressure

04-PI-3301 LPG rundown 04-PI-1930 Atomizing steam to
04-PI-3302 Naphtha air fin burners
cooler oil pressure 04-PI-1922 Pilot gas pressure
04-PI-3304 CLO rundown 04-PI-2006 4C-51 pressure at DD1
04-PI-3305 Stabilised Naphtha 04-PI-2009 4P-52B discharge pr
rundown 04-PI-2008 4P-52A discharge pr
04-PI-3306 4P65A discharge 04-PI-201 4P-57B discharge pr
pressure 04-PI-2001 4P-57A discharge pr
04-PI-3308 LCO to 4E55A/B 04-PI-2014 4C-51 bottom d/o
inlet pressure pressure to 4P52A
04-PI-7101 Salt water supply 04-PI-2007 4C-51 bottom d/o suction
header pressure to 4P52B
04-PI-7105 Salt water supply 04-PI-2005 4V-51 o/h vapor line
header pressure (24” ) pressure
04-PI-7103 BCW return pressure 04-PI-2004 4C-51 pressure above
04-PI-7104 Salt water return pressure DD6
(24” ) 04-PI-2112 HCO stripping steam
04-PI-7102 Salt water return pressure pressure
04-PI-7106 Salt water supply 04-PI-2115 HCO stripper bottom
pressure (24” ) pressure
Plant Name: FCCU-I

04-PI-2106 4P60A pump discharge 04-PI-2109 HCO stripper top

pressure pr
04-PI-2104 4P55B pump discharge 04-PI-2108 4P56B pump
04-PI-2105 4P60A pump 04-PI-2201 Slurry settler
04-PI-2103 4P55A pump 04-PI-2403 4P53A pump
04-PI-2101 4P-59A pump 04-PI-2409 Sea water supply
discharge pressure pr to 4E59A/B/C/D
04-PI-2114 LCO stripper 04-PI-2408 4v-53 drum
bottom pressure pressure
04-PI-2111 LCO stripper 04-PI-2404 4P53B pump
04-PI-2110 LCO stripper top discharge pressure
04-PI-2107 4P56A pump discharge pressure
discharge pressure 04-PI-2410 Sea water return pr
04-PI-2102 4P59B pump from 4E59A/B/C/D
discharge pressure 04-PI-2402 4P-63B pump
04-PI-2113 HCO stripper d/o discharge pressure
to pump pressure
Plant Name: FCCU-I

04-PI-2401 4P-63A pump 04-PI-2501 4V-54B drum

discharge pressure pressure indication
04-PI-2406 4P54B pump 04-PI-2622 Buffer gas from
discharge pressure fuel gas header
04-PI-2507 4P61B pump 04-PI-2602 WGC 1ST stage
discharge pressure suction pressure
04-PI-2508 4V-55 boot sour 04-PI-2607 WGC 2nd stage
water discharge pressure
04-PI-2504 4P64A pump 04-PI-2606 WGC 2nd stage
discharge pressure suction pressure
04-PI-2509 N2 cylinder o/l 04-PI-2604 WGC 1ST stage
04-PI-2510 4E63A/B salt 04-PI-2628 Naphtha injection
water o/l pressure discharge to compressor
04-PI-2503 4V-55 drum 04-PI-2701 4P62A discharge
pressure pressure
04-PI-2506 4P61A pump 04-PI-2702 4P62A discharge
04-PI-2505 4P64B pump 04-PI-2706 4E64A/B salt
discharge pressure water return pressure

Plant Name: FCCU-I

04-PI-2705 4P62A/B suction 04-PI-2907 Rich sponge oil to

pressure fractionator
04-PI-2704 Sea water supply 04-PI-2904 4P58B pump
to 4E64A/B discharge pressure
04-PI-2703 4V-56 pressure 04-PI-2903 4P58A discharge
04-PI-2810 4P74A discharge pressure
pressure 04-PI-2906 Sponge absorber
04-PI-2805 Stripper bottom bottom pressure
pressure 04-PI-2908 Sponge absorber
04-PI-2807 Stripper O/H off gas c/v d/s
vapor line pressure 04-PI-3004 Stabiliser top
04-PI-2804 Stripper top pressure
pressure 04-PI-3005 Stabiliser bottom
04-PI-2803 Primary absorber pressure
bottom pressure 04-PI-3106 4E67A/B saltwater
04-PI-2802 Primary absorber supply pressure
top pressure 04-PI-3101 4P67B discharge
04-PI-2811 4P74B discharge pressure
pressure 04-PI-3105 4V-57 pressure
04-PI-2905 Sponge absorber 04-PI-3107 4E67A/B saltwater
top pressure return pressure
Plant Name: FCCU-I

04-PI-3104 4P67B discharge 04-PI-3308 LCO to 4E55A/B

pressure inlet pressure
04-PI-3102 4P66B discharge 04-PI-7101 Salt water supply
pressure header pressure
04-PI-3103 4P67A discharge 04-PI-7105 Salt water supply
pressure pressure (24” )
04-PI-3204 4E57 pressure 04-PI-7103 BCW return
04-PI-3203 BFW pressure pressure
04-PI-3205 4E56 pressure 04-PI-7104 Salt water return
04-PI-3307 4P65B discharge pressure (24” )
pressure 04-PI-7102 Salt water return
04-PI-3303 LCO rundown header pressure
04-PI-3301 LPG rundown 04-PI-7106 Salt water supply
04-PI-3302 Naphtha air fin pressure (24” )
cooler oil pressure 04-PI-7107 BCW return
04-PI-3304 CLO rundown pressure
04-PI-3305 stabilised Naphtha 04-PI-7213 Fuel oil return
rundown pressure
04-PI-3306 4P65A discharge 04-PI-7205 LPG/UL
pressure 04-PI-7214 LP steam to
vaporizer pressure
Plant Name: FCCU-I

04-PI-7210 Fuel gas internal 04-PI-7302 Flushing oil

distribution pressure header
04-PI-7208 4V64 drum 04-PI-7410 HP steam pressure
pressure 04-PI-7406 Plant air pressure
04-PI-7204 Fuel oil supply 04-PI-7413 HP BFW pressure
pressure 04-PI-7409 DM water pressure
04-PI-7212 Sweet fuel gas 04-PI-7408 MP BFW pressure
pressure 04-PI-7412 LP steam pressure
04-PI-7206 4V50 drum 04-PI-7404 Instrument air
pressure pressure
04-PI-7207 4V62 drum 04-PI-7407 Service water
pressure pressure
04-PI-7303 VGO filters inlet 04-PI-7402 MP steam pressure
pressure 04-PI-7501 Slop unit limit pressure
04-PI-7304 4p-72A discharge 4DG-1961 Heater draft above 4V-63
pressure steam
04-PI-7306 4p-73 discharge 4DG-1959 Heater draft at 4V-63
pressure steam
04-PI-7305 4p-72B discharge 4DG-1958 Heater draft at 4V-63
pressure steam convection

Plant Name: FCCU-I

4DG-1956 Heater draft gauge at

steam superheating
below superheating
convection O/L
convection O/L
heater fire box
heater fire box
4DG-1960 Heater draft gauge above
superheated coils.

Plant Name: FCCU-I

LOCAL FLUSHING MEDIA PRESSURE GAUGES LIST

04-PI/LT-502A Reactor Stripper level low low
04-PI/PDT-501A RX-RG Differential Pressure
04-PI/LT-3XA Reactor level
04-PI/PDT-504A Reactor riser DP
04-PS/PDT-502A RX-RG Diff Pr to Es-4 & Es-5 Trip
04-PI/FT-501A Total Feed To Reactor
04-PI/FT-501B Total Feed To Reactor
04-PI/LT-501A Reactor Level
04-PI/PDT-4XA RCJB Slide V/V DP
04-PI/PDT-2XA Reactor pr. tr. local gauge
04-PI/PDT-4XB RCJB Slide V/V DP
04-PI/PDT-2XB Reactor diff. pr.tr.local gauge
04-PI/LT-3XB Reactor level
G4-PI/PDT-1XB Reactor diff.pr.tr.local gauge
04-PI/PDT— 503B Reactor Vapor line DP
04-PI/PT –3X Reactor Dilute Phase
04-FI/PDT-501B RX-RG Differential Pressure
04-PI/LT-502B Reactor stripper level low low
04-PI/PT-241X Reactor Overhead line Pressure
Plant Name: FCCU-I

04-PI/PDT-502B RX-RG Diff Pr to Es-4 & ES-5 Trip

04-PI/FT-504A Bottoms Recycle to Reactor
04-PI/PT-240X Total feed to Reactor
04-PI/PDT-504B Reactor Riser DP
04-PI/FT-504B Bottoms Recycle to Reactor
04-PI/PDT-503A Reactor Vapor Line DP
04-PI/PDT-IXE Regenerator Diff Pressure
04-PI/PDT-TXG Regenerator Diff Pressure
04-PI/PT-30X Cat Unloading Carrying Air Pr
04-PI/PDT-3XC Spent Cat slide V/V DP
04-PI/PDT-3XA Spent Cat slide V/V DP
04-PI/PT-2X Regenerator Pressure
04-PI/PT-20X Regents Overhead line Pressure
04-PI/PDT-510A Regenerated Cat Over Flow DP
04-PI/PDT-1xA Regenerator Diff Pressure
04-PI/PDT-1XD Regenerator Diff Pressure
04-PI/PDT-1XC Regenerator Diff Pressure
04-PI/LT-2XB- Regenerator Overflow well Level
04-PI/LT-1XA Regenerator Level
04-PI/LT-503A Regenerator Overflow Well Es-4
04-PS/PDT-1XB Regenerator Diff Pressure
Plant Name: FCCU-I

04-PI/PDT-510B Regenerator Cat Over flow DP

04-PI/PDT-3XB Spent Cat Slide V/V DP
04-PI/LT-1XB Regenerator level
04-PI/PDT-1XF Regenerator Diff Pressure
04-PI/LT-503B Regen Over flow Well Es-4
04-PI/LT-2XA Regen Over flow Well Level
04-PI/PT-35 6” Cat Loading to Regen pr
04-PI/PT-3 2” Carrying Air pr
04-PI/PT-31X Catalyst unloading carrying air
04-PI/FV-1801 HCO production from 4E56A/B
04-PI/FT-1801A HCO production from 4E56A/B
04-PI/PI-1807 Slurry PA O/L from 4E56
04-PI/PH1808 4E54C slurry O/L pressure
04-PI/PI1806 4E54B slurry O/L pressure
04-PI/FT-1801B HCO production from 4E56A/B
04-PI/LT-2009A 4C-51 high level switch
04-PI/LT-2009B 4C-51 high level switch
04-PI/PT-2012 4C-51 column bottom pressure
04-PI/TV-2013 4C-51 bottom D/O pump discharge temp
04-PI/FT-20U4A Slurry PA return above D4 and D6
04-PI/LT-2003A 4C-51 bottom LT
Plant Name: FCCU-I

04-PI/FT-20028 HCO pump around return

04-PI/LT-2002A HCO pump around return
04-PI/PI-2008 4P52 A discharge pr
04-PI/JV-2002 HCO pump around turn
04-PI/LI2005B 4C-51 bottom LT
04-PI/PI-2006 4C-51 pressure at DD1
04-PI/PI-2004 4C-51 pressure above DD6
04-PI/PSL-2013 Slurry pump discharge pr DD6
04-PI/FT2005B Slurry PA return above D4
04-PI/LT-2005A 4C-51 bottom LT
04-PI/FT-2005A Slurry PA return above D4
04-PI/FV-2005 Slurry PA return above D4
04-PI/PI-2007 4C-51 bottom D/O suction to 4P52B
04-PI/PI-2014 4C-51 bottom D/O pressure to 4P52A
04-PI/LT-2003B 4C-51 bottom LT
04-PI/FT-2007B HCO PA above D6
04-PI/FT-2007A HCO PA above D6
04-PI/HV-2001 HCO PA to above D6
04-PI/FT-2004B Slurry- PA return above D4 and D6
04-PI/PI2009 4P52B discharge pr
04-PI/FV-2004 Slurry PA return above D4 and D6
Plant Name: FCCU-I

04-PI/PI-2107 4P56A pump discharge pressure

04-PI/LT-2102B HCO stripper LT
04-PI/PI-2108 4P56B pump discharge pressure
04-PI/PI-2106 4P6OB pump discharge pressure
04-PI/LT-2102A HCO stripper
04-PI/PI-2105 4P60A pump discharge pressure
04-PI/PI-2113 HCO stripper discharge pressure
04-PI/LV-2104 HCO stripper LT
04-PS/LT-2104A HCO stripper LT
04-PI/LT-24104B HCO stripper LT
04-PI/HV-2204 Slurry dilutant control valve
04-PI/FT-2203B HCO to Slurry settler dilutant
04-PI/FT-2203A HCO to Slurry settler dilutant
04-PI/FT-2202A HCO from 4P56A/B
04-PI/FV-2202 HCO from 4P56A/B C/O
04-PI/FT-2202B HCO from 4P56A/B
04-PI/TV-3003 Stabiliser tray 3 temperature
04-PI/TV-3202 Slurry PA return from 4E56 to 4C-51
04-PI/TV-3201 HCO PA return from 4E57 to 4C-51
(I) SDV’S AND CONTROL VALVES LIMIT SWITCHES LIST

Plant Name: FCCU-I

TAG NO DESCRIPTION
4ZSH/ZSL503 Spent catalyst slide valve
4ZSH/ZSL503 Naphtha quench to Reactor c/v
4ZSH3XA/ZSL2XB Control air to Regenerator
4ZSH502BA/ZSL502B CAB atmospheric vent
4ZSH/ZSL503B Bottom recycler to Reactor
4ZSH19A/ZSL519B Control air bypass to MAB discharge
4ZS0520B CAB discharge to MAB check v/v
4ZSH/ZSL501 Feed diversion to fractionator
4ZSH10AZSL510B Torch oil to PAH SDV
4ZSH505A/ZSL505B MAB air line emergency steam control valve
4ZSH507A/ZSL507B Spent car riser emergency steam
4ZSH509A/509B MAB antisurge control valve
4ZSH/ZSL4XA Torch oil flow to Regenerator
4ZSH/ZSL4XB Torch oil atomizing steam
4ZSH506A/XSL506B Control air check valve
4ZSC514A/ZSO514B RCJB slide valve
4ZSH/ZSL504 Emergency steam to feed riser
4ZSH/ZSL IX Regenerator Auxiliary burner temp
4ZSC513A/ZS0513B MAB discharge check v/v
4ZSC520A/ZS0520B CAB discharge to MAB check V/V
Plant Name: FCCU-I

4ZSH/ZSL1951 Heater stack damper

4ZSH/ZSL1902 Fuel oil supply SDV
4ZSH/ZSL1903 Fuel gas supply SDV
4ZSH/ZSL1901 Fuel oil return SDV
4ZSH/ZSL2501 4V-55 boot level low low
4ZSH/ZSL2603 WGC 2nd stage suction MOV
4ZSH/ZSL2606 WGC 2nd stage discharge to flare MOV
4ZSH/ZSL2601 WGC 1st stage suction MOV
4ZSH/ZSL2605 WGC 1st stage discharge to flare MOV
4ZSH/ZSL2604 WGC 2nd stage discharge MOV
4ZSH/ZSL2602 WGC 1st stage discharge MOV
4ZSH/ZSL2701 4V-56 boot SDV
4ZSH/ZSL3101 4V-57 boot Level
(J) LEVEL SWITCHES LIST

4LSH3107/4LSL3106 4V-57HC level switches
4LSH2105/4LSL2106 LCO stripper level
4LSHH2405 4V-53 boot level high high
4LSH2406/4LSL2407 4V-53 HC level
4LSH2511/41 SL2.512 4V55 drum level high high
4LSH 2507/4LSL2508 4V54 level
Plant Name: FCCU-I

4LSLL2510 4V-55 boot level low low

4LSHH2509 4V-54 drum level high high
4LSL2/10 4P-62A seal pot level low
4LSll2705 4V-56 boot level low low
4LSH2706MSL2707 4V-56 H/C level switches
4LSL2711 4P62B seal pot level
4LSL2810 A97E A seal pot level
4LSL2809 4P74B seal pot level
4LSL2810 4P74B seal pot level low
4LAL2809 4P74A seal pot level low
4LSL2806/4LSH2805 Primary absorber bottom level
4LSL2808/LSH2807 Stripper bottom level
4LSh2903/3LSL2904 Sponger absorber level
4LSH3003/4LSL3004 Stabiliser level
4LSL3111 4P67A seal pot level low
4LSL3103 4P66A seal pot level low
4LSLL3105 4V-57A boot level low low
4LSL 3110 4P6/A seal pot level low
4LSL 3109 4P66B seal pot level low
4LSH7208 4V64 high level
4LSH7205/4LSL7206 4V-62 level
Plant Name: FCCU-I

4LSH7502/4LSL7503 CBD Drum level
(K) GAUGE GLASSES LIST

Plant Name: FCCU-I

04-LG-3202 4E57 gauge glass 04-LG-2401A 4V-53

04-LG-1302 MAB hot well hydrocarbon G/G level
level 04-LG-2501A 4V-55 gauge glass
04-LG-1301 Surface condenser 04-LG-2503 4V-54 gauge glass
G/G 04-LG-2502 4V-55 boot gauge
04-LG-1701A Feed surge drum glass
gauge glass 04-LG-2501B 4V-55 gauge glass
04-LG-1701C Feed surge drum 04-LG-2702B 4V-56 boot level
gauge glass gauge glass
04-LG-1701B Feed surge drum 04-LG-2701A 4V-56 H/C gauge
gauge glass glass level
04-LG-1702 Feed surge drum 04-LG-2701B 4V-56 H/C gauge
boot gauge glass glass level
04-LG-2101N LCO stripper G/G 04-LG-2702A 4V-56 boot level
04-LG-2101B LCO stripper G/G gauge glass
04-LG-2101A LCO stripper G/G 04-LG-2804A Primary absorber
04-LG-2401B 4V-53 gauge glass
hydrocarbon G/G level 04-LG-2803C Stripper gauge
04-LG-2403 4V-53 boot gauge glass
glass 04-LG-2804B Primary absorber
gauge glass
Plant Name: FCCU-I

04-LG-2803B Stripper gauge 04-LG-3203B 4E56 gauge glass

glass 04-LG-3204A 4E56 gauge glass
04-LG-2803A Stripper gauge 04-LG-7207C 4V64 gauge glass
glass 04-LG-7203 4V60 gauge glass
04-LG-2901B Sponge absorber 04-LG-7207A 4V64 gauge glass
gauge glass 04-LG-7202 4V62 gauge glass
04-LG-2901A Sponge absorber 04-LG-7207B 4V64 gauge glass
gauge glass 04-LG-1951 4V-63 gauge glass
04-LG-3001A Stabiliser gauge 04-LG-1953 4V-63 gauge glass.
glass
04-LG-3001B Stabiliser gauge
glass
04-LG-3001C Stabiliser gauge
glass
04-LG-3102B 4V-57 gauge glass
04-LG-3104 4V-57 boot gauge
glass
04-LG-3102A 4V-57 gauge glass
04-LG-3201 4A57 gauge glass
04-LG-3203A 4E.56 gauge glass
04-LG-3204B 4E56 gauge glass
Plant Name: FCCU-I

(C) PRESSURE SWITCHES LIST
4PAH2812 4P74A seal pot pressure

4PSH1963 Arch pressure high
4PSL1921 Pilot gas pressure low switch
4PSL1927 fuel gas pressure low
4PSL1915 Fuel oil pressure low switch
4PSLL1926 Fuel oil gas low low pressure switch
4PSLL1913 Fuel oil low low pressure switch
4PSL2013 Slurry pump discharge pressure high high
4PSL2611 WGC 1st suction pressure low
4PSHH2612 WGC 1st stage suction pressure high high
4PAL2611 WGC 1st stage suction pressure
4PAHH2612B WGC 1st stage suction pressure high high
4PAHH2613B WGC 2ND stage discharge pressure high high
4PSHH2613 WGC 2nd stage discharge pr high
4PSH2615 WGC 2nd stage discharge pr high
4PAH2615B WGC 2nd stage discharge pr high
4PSLL2610 WGC 1st stage suction pr low low
4PALL2610 WGC 1st stage suction pressure low low
4PASH2614 WGC 1st stage discharge pressure high
4PSHH2710 4P62A seal pot pressure high
4PSH2711 4P62B seal pot pressure high
Plant Name: FCCU-I

4PAH2813 4P74Bseal pot pressure

4PSH3110 4P57A seal pot pressure high
4PSH3108 4P66A seal pot pressure high

Plant Name: FCCU-I


Plant Name: FCCU-I
UTILITIES
CHAPTER 33
UTILITIES
33.1 INTRODUCTION
33.2 INSTRUMENT AIR SYSTEM
33.3 PLANT AIR SYSTEM
33.4 SEA WATER SYSTEM
33.5 BEARING COOLING WATER SYSTEM
33.6 SERVICE WATER SYSTEM
33.7 DM WATER SYSTEM
33.8 BOILER FEED WATER SYSTEM
33.9 LP STEAM SYSTEM
33.10 MP STEAM SYSTEM
33.11 HP STEAM SYSTEM
33.12 LP CONDENSATE
33.13 FUEL GAS SYSTEM
33.14 FUEL OIL SYSTEM
33.15 FLUSHING OIL SYSTEM
33.16 EFFLUENT SYSTEM
33.16.1 Slop system
33.16.2 Closed Blow down system
33.16.3 Oil water system
33.16.4 Surface drain system
35.16.5 Flare system
33.17 UTILITIES REQUIRMENT DATA
33.18 ELECTRICAL DISTRIBUTION
FIG.33.1 REFINERY POWER DISTRIBUTION
FIG.33.2 SS-40 POWER SUPPLY

UTILITIES
Plant Name: FCCU-I
UTILITIES
CHAPTER - 33
UTILITIES
33.1 INTRODUCTION
The utility system consists of Instrument Air (IA), Plant Air (PA), sea water, bearing
cooling water, Service Water (WS), DM Water (DM), Boiler Feed Water (BFW), HP
Steam, LP Steam, MP Steam, LP Condensate Distribution, Fuel Oil (FO), Fuel Gas (FG)
and Flushing Oil (FLO).
Closed blow down (CBD). Flare system. Oily water Sewer System (OWS) are also
provided within the unit.
33.2 INSTRUMENT AIR SYSTEM
The existing compressed air system installed at Merox plant is being revamped and to
augment VREP-II air requirement. A new air compressor is provided for this purpose and
plant air is integrated into the existing plant air pipe work from where a tapping was taken
for FCCU-I(R).
An independent Instrument air system with dedicated air receivers and driers are provided
with the new air compressor (150-K-02B). Instrument air header is routed to VREP-II units
from where a 3” tapping is taken for FCCU-I(R) unit.
A 6” Instrument Air header is supplied to the unit. The header is provided with isolation
valve and a spectacle blind. PI-7405 indicates pressure of instrument air at battery limit in
DCS. Various Instrument air tapings are taken from this header. A 2” Instrument air tapping
has taken from this header to cater CO Boiler requirement. IA is used as motive force for
pneumatically operated control valves. FI-7404 on the main instrument air header is
provided.
33.3 PLANT AIR SYSTEM
A 10” plant air header supplies plant air to FCCU-I(R). The header is provided with
isolation valve and a spectacle blind for positive isolation at the battery limit. A number of
utility points are provided from this header. For decoking of feed heater 3” tapping are
taken from main header. A 4” tapping is provided for CO boiler requirement. FI7405 is
provided on main header to monitor flow in DCS.
UTILITIES
Plant Name: FCCU-I
UTILITIES
33.4 SEA WATER SYsTEM
The cooling water requirement for cooling purpose in the existing unit is met through Once
through cooling water system in which seawater is used. The cooling water additional
requirement for VREP-II cannot be met by this system due to capacity limitation. Thus, for
the new units under VREP-II and some of the existing units undergoing revamp, a
circulating water system is considered with seawater as makeup. This system consists of 5
cooling tower cells and six recirculating seawater pumps.
Seawater is supplied from this system and a 36” tapping is taken from the sea water Supply
(SWS) header for FCCU-I(R) unit. The seawater Return header (SWR) joins the main 48”
SWR header which is routed back to the cooling tower as a 60” header.
Within the unit, the SWS & SWR bifurcate into 2 headers. One of 36” for MAB/CAB &
CO Boiler, other 26” line is routed through cooling water booster pump (04-P68 A/B). The
pump discharge is supplying seawater to all sea water coolers. A 24” pump bypass line
provided for bypassing the pump.
FI-7101 indicates in DCS sea water supply now to the various consumers (exchangers).
All the exchangers are provided with back flushing arrangement. This back flushing water
is routed through 8” header to the sewer via FCUU1 existing sewer.
33.5 BEARING COOLING WATER SYSTEM
Circulating bearing cooling water is used for pump gland and bearing cooling, turbine oil
coolers etc., where use of seawater is prohibited.
The existing system consists of two bearing cooling water systems:
BCW system at PP - 1 is serving BCW requirements of units in VR and BCW system in

IFO area is serving BCW requirement of units in VREP-I. BCW system for VREP-I
caters to requirement in CDU-II, PP-II, Merox, air compressors, offsite and PRU.

UTILITIES
Plant Name: FCCU-I
UTILITIES
To meet the additional bearing cooling water requirement of units in VREP-II. a bearing
cooling water system with 2 cooling tower cells has been constructed near the IFO system
of the refinery complex.
For catering to BCW requirement for FCCU-I(R), a 4” header is tapped off the main 12”
header from new BCW system.
With the FCCU B/L isolation valves with spectacle blinds are provided on BCW 4” supply
and BCW 4” return lines. FI-7104 in DCS at B/L indicates flow of BCW flow to various
consumers (bearing cooling for pumps). A 2” tapping has been taken for CO Boiler
requirement.
33.6 SERVICE WATER SYSTEM
In the existing system 170-P-01 A/B was used as VREP-I DM plant feed pumps. These
pumps are now shifted to power plant-1 area and are installed parallel to pump 24-G-
07/07A to meet VREP-II additional raw requirements (Viz. Service water, Drinking water
etc.)
Pump 170-P-01A/B located at PP-I will cater to the drinking water and service water to VR
and VREP-II units, while 24-G-07/07A will cater to old DM plant only.
A 4” tapping has been taken from this existing service water heater to meet FCCU-I
service water requirement.
The 4” common service water header supplies service water to the unit. It is provided with
an isolation valve with a spectacle blind at battery limit. Local PI-indicates supply pressure.
The service water header supplies water to various hose stations in the plant. Service water
connections have been provided to MAB/CAB, Decoking pot and closed blow down drum.
Service water is required mainly for cleaning and washing. FI-7406 at B/L in DCS indicates
consumption of Service water in the unit.
Service water is also provided for MP steam blow down in 04-V-61 for washing and to
other equipment within the unit. Service water has been used in start-up in 04-V-53, 04-V-
56, and 04-V-57. It has been used as wash water in 04-E-59 A-D & 04E-63A/B.
33.7 DM WATER SYSTEM

UTILITIES
Plant Name: FCCU-I
UTILITIES
In the raw water tank area, new pumps 170-P-08 A/B/C are provided for supplying DM
plant feed to VREP-I and VREP-II DM plants. From VREP-II DM water is routed to and
stored in DM water tanks (130-T-04 A/B). 4” DM water distribution line has been taken to
unit.
A 4” common DM water header supplies DM water to the unit from offsite. It is provided
with double block valve and a spectacle blind. FI-7406 indicates DM water consumption
in DCS with low flow alarm and flow recorder and a local Pressure gauge shows supply
pressure.
DM water is used in MAB/CAB and 04-V-53.
33.8 BOILER FEED WATER SYSTEM
In the existing system , two BFW systems are provided one for VR (supplying
HP/MP/BFW requirements of utility boilers in PP-1 and steam generators in CDU-
1/FCCU-I) and the other for VREP-I (catering to BFW requirements of CO boiler-I, Utility
boilers, FCCU-II and HRSGs in CPP). In addition, there are two MP BFW pumps (140-P-
02 A/B) catering to the BFW requirement of steam generations in CDU-II and FCCU-II.
To cater to the additional BFW requirements, an additional deaerator (140-X-08) of

capacity 120T/hr is provided parallel to the exiting deaerators 140-X-02 A/B in PP-II area
and the LP/MP BFW requirements in all the units including CDU-I/IIFCCU-I/II and FCCU
IR) block shall be supplied from PP-II. For this purpose, the existing MP BFW pumps 140-
P-02 A/B of 35 m3/hr capacity is replaced with two new pumps of 120m3/hr normal
capacity.
A tap off the discharge from these pumps is utilized as MP BFW to CDU-1. FCCUI and
VREP-II from where a 4” line is tapped off to FCCU-I(R) unit. Block valve and a spectacle
blind have been provided at the battery limit for positive isolation. A Local PI and TI are
provided at B/L. FI-7407 in DCS indicator consumption of BFW.
BFW is also used in 04-V-58 (Steam drum) for generation of MP steam. It is also used to
desuperheat MP steam for use as atomizing steam in-the atmospheric and vacuum heaters.
BFW is used in 04-E-56 & 04-E-57 for MP steam generation. This BFW is initially
preheated in 04-55 A/B by LCO and then routed to generators.

UTILITIES
Plant Name: FCCU-I
UTILITIES
One HP BFW stream is taken into the unit by a 6” header. This BFW is used in CO Boiler
to produce HP steam.
33.9 LP STEAM SYSTEM
LP steam requirement for FCCU-I(R) and FCCU-1 shall be met by revamping of steam
distribution system located at PP-II unit. Here a tap off is taken from 14” SH-140-301-
D2A-IH existing header and the steam pressure and temperature are reduced in two stages
of pressure reduction and desuperheating. LP steam is also generated by the BFW turbine
(new) which runs on MP steam. This LP steam is also augmented for use in FCCU-I(R)
and FCCU-I.
The LP steam generated is distributed to FCCU-IR, CDU/VDU-III, VBU, FCCU-I, Merox,

IFO block and to existing 16” SL-140-306-A2A-IH LP steam header.
Within the unit requirement of LP steam is met by 24” line taken from offsite.
Isolation valve and spectacle blind provided at FCCU-IR battery limit. TI-7403. FI-7403
(DCS) and PI-7403 (with PAL) in DCS are provided at the battery limit to indicate
temperature, flow and pressure. FI-7403 has flow recorder and flow totalizer in DCS. Local
PI-7412 is also provided at B/L.
USE OF LP STEAM IS MAINLY AS FOLLOWS:
Sample point purging

Heating medium for exchangers (for heating products with LP steam)
Sealing system for air blower
Body steam for steam out of columns.
Quench steam for pump mechanical seal
Snuffing steam of Fired heaters/furnace
Soot blowing of fan blades
Tracing of process lines
Dilution of vented hydrocarbons from vent systems
Steam smothering and utility.
Dead end of CBD headers.

UTILITIES
Plant Name: FCCU-I
UTILITIES
33.10 MP STEAM SYSTEM
A 14” common medium pressure steam headers has been provided for FCCU-I(R) with
double isolation valve and a spectacle blind at FCCU-I(R) battery limit. PI-7411. FL-7402
and TI-7402 indicates MP steam pressure and flow rate and temperature in DCS. PI-7411
is provided with PAL in DCS. FI-7402 is provided with flow recorder and flow totalizer
in DCS, A local PI-7402 is also provided at B/L. MP steam is also produced in 04E-56,
04-E-57, 04-V-63 and is hooked up to this MP steam header.
MP steam serves mainly following purposes:
a) Feed header (04-F-051)

Emergency Steam to coil
Soot blowing steam
Decoking steam
F.O. Atomizing Steam
b)Utility (Hose station for use in equipment in hot services under shutdown/maintenance).
c) Stripping steam for 04-C-51/52/53.
d) Steam out purpose for different pump discharge & 04-V-52.
33.11 HP STEAM SYSTEM
A 12” HP steam has been provided for FCCU with double block & blind at B/L. This HP
Steam header is floating with the refinery steam header. HP steam is produced in CO Boiler
to maintain the pressure in the header. PT-7401 with low pressure alarm is provided at B/L.
33.12 LP CONDENSATE
LP condensate produced in the MAB turbine is routed to the offsite through a 6” header.
33.13 FUEL GAS STSTEM
Fuel gas being produced in various units is routed to the Sulphur block (which has been
augmented for handling additional FG generated) for removal of H2S. The sweet gas is then
routed to CPP, FCCU-I( revamp), FCCU-II and VREP-II units.
For FCCU-IR 10” tapping taken from SRU sweet fuel gas header.

UTILITIES
Plant Name: FCCU-I
UTILITIES
The FG produced within the FCCU-I (R) unit (ex-sponge absorber) is routed to SRU as
sour gas. FG supply header is of 10” size at B/L and is provided with double block and
spectacle blind. FI-7202 at DCS is provided to indicate FG consumption within the unit.
PI-7212, TI-7202 are provided locally at B/L FG lines are steam traced to avoid
condensation in the lines.
Sweet fuel gas from B/L is routed to Fuel Gas KOD (04-V-64) to separate the condensate
carry over. 04-V-64 is provided with local LG& LSH-7206 is provided in DCS for high
level alarm. To drain the condensate CBD & OWS connection has been provided from the
bottom of the vessel.
KOD overhead gas is routed to the unit. PC-7202 will control the pressure of fuel Gas. This
is a split range controller. In case of high pressure of FG, PC7203 will open to vent the gas
to flare. In case of low pressure of FG, PV7202 will open to allow LPG vapor to go in the
FG header from LPG vaporizer (04V-62).
LPG vaporizer level is controlled by LC-7201. LPG is taken from the unit. Provision has
been given to route LPG from Merox to 04-V-62. LPG will be vaporized in the vessel with
the help of LP steam passing through the embedded coil. Pressure of the vessel is
maintained by PC-7201 controls the steam flow through the coil. Steam condensate will be
drained to SS through a steam trap. Bypass of the trap has been provided in case trap has
to be taken for maintenance.
PSV-7201 A/B has been provided to take care of over pressure of the vessel.
Fuel gas flow is measured by FI-7206 & PI-7211 indicates the pressure in DCS.
Fuel gas is supplied to various consumers through 10” header. FT-7201 will show the
consumption of FG in the unit. Piping provision has been given to route the FG to the offsite
header through double block blind at B/L.
FUEL GAS IS USED IN THE FOLLOWING POINTS:
Feed heater (04-F-051) as fuel.

For purging of Reactor
LCO stripper vapour return for start-up
In CO Boiler
Flare header dead end purge (FT-7207 in DCS indicates FG purge
“ quantity” )
UTILITIES
Plant Name: FCCU-I
UTILITIES
33.14 FUEL OIL SYSTEM (FO)
To meet the additional FO requirement due to VREP-II the existing FO system is modified
and the following additional facilities are incorporated for augmenting the existing FO
system.
A new FO tank (400-T-02)
The existing FO pumps 400-P-01 A/B/C are replaced by a new set of four
twin screw type pumps 400-P-02 A/B/C/D (each of 35m3/hr capacity), (three
turbine driven & one motor driven). Normally two turbine driven pumps will
be in service.
The two FO heaters 400-E-01 A/B are supplemented with an identical

additional FO heater 400-E-01-C provided in parallel to 400-E-01 A/B to meet
the desired viscosity (20-25 CST.)
The FO is pumped into existing 6” offsite header, which caters to the entire complex
requirement. During normal operation of the refinery the IFO requirements are met by
LSHS. In case of non-availability of LSHS due to non-processing of low sulphur crudes,
finished fuel oil will be used as fuel oil. A 6” tapping is taken from offsite header for
catering to FO requirements for FCCU_I (R). The FO return is through a 4” header from
the unit which joins the offsite header back to the FO offsite tanks.
Double isolation valves and spectacle blind is provided on FO supply and FO return headers
at B/L. A local TI and PI are also provided on headers. The FO headers are steam traced
to avoid congealing.
Within the FCCU unit, FO is supplied to the CO Boiler & Feed heaters through 3” &2”
headers respectively with circulating lines back to the return headers. Constant circulation
is necessary in the FO lines to prevent congealing in the headers which may occur during
idle conditions.
33.15 FLUSHING OIL SYSTEM (FLO)
Flushing oil (FLO) is normally with boiling range and properties comparing well with gas
oil. It is used as a flushing medium for displacing heavy congealing and viscous material
from equipment & piping during unit shut down or other maintenance jobs requiring

UTILITIES
Plant Name: FCCU-I
UTILITIES
clearing of equipment from such hydrocarbons. It is also used as pump seal flushing oil
and instrument impulse tubing flushing.
There are two types of FLO used in the unit area.

1) One is heavy diesel which is used for equipment flushing during shutdown and
is designated as FLOA 4” tapping from FCCU-I (R) HD run down line is provided
for HD flushing system during initial startup condition when HD is not available
from FCCU-IR. HD will be received from the Merox flushing oil system (cutter
stock).
2) The second FLO system considered is that with VGO and is designated as FLOM
is used for flushing of instruments impulse tubing and for flushing of pump
mechanical seal (single and double mechanical seals).
VGO is taken in the FLOM header is maintained by PV-7301. FLOM is used in different
instruments & pump seal. Pumps with VGO flushing are 04-P-60 A/B, 04-P-52 A/B & 04-
P-56 A/B.
The entire FLOM system is steam traced to prevent congealing of VGO. An alternative
provision has been made from flushing oil header to FLOM and pump seal.
33.16 EFFLUENT SYSTEM
All off specification hydrocarbon streams, hydrocarbon stream contaminated with water,
water contaminated with hydrocarbons or chemicals and such liquid streams that cannot be
disposed of directly are collected and treated either for recovery of hydrocarbons or to
render them harmless to receiving stream or for the purposes. For these purposes slop
system, CBD system, OWS system is provided. These systems are described sequentially
in the following paragraphs.
33.16.1 SLOP SYSTEM

UTILITIES
Plant Name: FCCU-I
UTILITIES
Off specification hydrocarbon streams are routed to a 6” slop header at unit B/L which is
then routed to slop tanks. The slop generated within FCCU-I(R) is primarily dry slop. This
header is routed to the dry slop tanks located in Offsites.
All product rundown lines have access to slop header, when Quality goes off spec, (Mainly
during start-up/shut down) product can be routed to slop tanks.
33.16.2 CIOSED BLOW DOWN SYSTEM
Those hydrocarbon streams that are either free of water or only slightly contaminated
with water are received in closed blow down (CBD) vessel (04-V-59). Such hydrocarbon
streams are generated especially during shut down periods when equipment and systems
are drained under gravity to clear hold up oil. The hydrocarbon in the CBD vessel should
be received at a temperature well below flash point of lightest component present inside.
CBD network helps reducing amount of hydrocarbon loss. Uncontaminated hydrocarbons

from equipment draining is collected and routed to CBD vessel via CBD headers, covering
entire unit.
Two 8” underground CBD headers run across FCCU IR. LP steam and flushing oil
connections are provided at all dead ends of CBD headers for line cleaning. The headers
are finally routed 04-V-59. CBD drum is underground vessel, placed horizontally. Drum
is provided with a coil through which sea water or LP steam can be passed.
LI-7501 and TI-7501 on 04-V-59 indicates level and temperature of CBD drum and are
provided with low and high level alarms (for LI-7501) and high temperature alarm for (TI-
7501). CBD pump (04-P-71) is interlocked with high/low alarms (LSL-7503 and LSH-
7502) for auto start and auto stop. Hydrocarbon is pumped out by CBD pumps to slop
header in FCCU-1(R) unit. Under normal conditions it is expected to remain at atmospheric
pressure. A small purge or steam is provided at the vent of the drum to guard against fire
at the vent top due to lightening and static electricity hazard. One service water connection
is given to the drum for cleaning purpose.
33.16.3 OILY WATER SEWER
This system also called OWS is mainly to collect water contaminated with hydrocarbon
oil. Such streams are generated during equipment draining and flushing during routine
operation. Streams suitable for OWS also generated as a result of floor washing. Cleaning
or spilled oil etc. drained streams received through OWS funnels etc. are routed to ETP-
I through a combined header.

UTILITIES
Plant Name: FCCU-I
UTILITIES
Contaminated rain water from the unit-paved area is also routed to OWS system. All
equipment having CBD connections are normally provided with OWS connection.
Care should be taken that at no time any spark reaches vapour space of OWS tunnels. This
may result in explosion immediately there or elsewhere in network wherever explosive
mixture of air and hydrocarbon vapours is present in appropriate concentration for
explosion.
33.16.4 SURFACE DRAIN SYSTEM
The peripheral surface Drain with double block valve arrangement to route it either to
OWS or to Storm Sewer System depending upon its oil content.
33.16.5 FLARE SYSTEM
In the event of abnormal operating conditions or emergencies, the hydrocarbon operating

system may get pressurized. In order to prevent this from shooting up and crossing design
limit of respective system/equipment and causing accident and/or equipment damage, it
may become necessary to relieve same amount of non-condensable hydrocarbon vapours
to a system that renders them harmless. For this purpose a network of flare header is
provided for collection of relieved vapours in unit to which all relevant equipments are
connected. PSV’ s of the vessels of hydrocarbon service are all connected to 24” flare
header. Flare lines are designed for a pressure of 3.5 kg/cm2g and temperature about 200oC.
Flare lines to be tested pneumatically because of line support considerations. Entry of
steam and condensate in flare header to be avoided as it may lead to extinguishing of main
flare flame.
The following from FCCU-I(R) are routed to flare header.
All unit PSV discharges, LPG product pump seal pot

Debutanizer reflux. Primary Absorber bottom & Stripper Feed pump seal pot
LPG pumps and Debutanizer reflux pump casing vents
Main Fractionator Overhead naphtha accumulator pressure control vent
04-E-59-A-D.04-E-63 A/B. WGC 1st & 2nd discharge vent.
04-E-64 A/B condenser shell vents.

UTILITIES
Plant Name: FCCU-I
UTILITIES
FG dead end purge is provided on Flare header to maintain a positive pressure.
The 24” flare header from FCCU-[(R) (after Spectacle blind and isolation valve) routed to
the Flare Knock out drum (04-V-60).
LI-7204 (with LAH and LAL) indicates level in DCS. A2” drain line is connected to CBD
and another 2” drain line routed to OWS. PI-7206 and TI-7206 are provided locally
on the KOD. A flare flow meter is also provided at the outlet of KOD and before the battery
limit.
24” flare header from top of KOD routed to flare in the Offsites. FI-7208 is provided on
the header in DCS. The 24” flare header is routed to the newly installed flare system.
Separate provision is given at Unit Limit for keeping only gas plant flare system in service
during shutdown of Revamp unit. (FCCU IR flare header and gas plant flare header
separated with isolation valves and blinding flanges).
33.17 UTILITY REQUIREMENTS FCCU I REVAMP :
Recirculating Cooling Water Requirement : 3300 Nm3/Hr

DM Water Requirement : ----------------
MP BFW Requirement : 15.92 Tons
Condensate Recovery : 19.1 Tons
HP Steam consumption : 19.1 Tons
MP steam consumption : 19.4 Tons
Reactor/Regenerator Steam : 10.8
MAB/WGC connected Drives : 2.6
Stripping steam/Agitating Steam : 4.4
Atomizing Steam : 0.6
Tracing Steam : 1
------------------
19.4 Tons
: ------------------
MP Steam Production : 15.92 Tons
Heater Steam Drum : 0.72 Tons
Exhaust Steam From
MAB/WGC/Drives : 2.6(LP Steam)
4E -56 Steam : 12.7
4E-57 (HCO PA) : 2.5
-----------------
15.92 Tons
UTILITIES
Plant Name: FCCU-I
UTILITIES
-----------------
LP Steam Consumption : 2 Tons
(LPG Vaporizer Steam 1 Ton+ Tracing Steam 1 ton)
Power Requirement : 5146 KW

Instrument Air Requirement : 685 Nm3/Hr
Plant Air Requirement (Intermittent) : 3261 Nm3/Hr
Fuel Oil Requirement : 1.85 T/hr
Fuel Gas Consumption :
UTILITY REQUIREMENTS
REACTOR / REGENERATOR STEAM
Medium Pressure Steam (SM)

Requirements, kg/h Normal Maximum Emergency
Regenerator
Torch oil Atomizing and Purge Steam 25 105* 25

Emergency Spray Purge and Cooling Reactor 263 263* 263
Feed Injection 2,450 2,450 2,450
Bottoms Recycle Injection 454 454* 454
Stripping 3,330 3,490* 3,330
Anti-Coking 335 335* 335*
Stripper Cone/Spent catalyst Standpipe 385 385* 385
Aeration
Spent Catalyst J-Bend Aeration 746 771* 746
Spent Catalyst Upper/Lower Blast purge 734 734* 734
Spent Catalyst Upper/Lower Blast 0 4,486 0
Spent Catalyst Riser emergency Steam 27 4,582 4,582
Regen. Cat J-Bend Aeration 636 661* 636
Regen. Catalyst Lower Blast Purge 346 346 346
Regen. Catalyst Lower Blast 0 1,775 0
Regen. Cat. Feed Riser Emergency Steam 0 6,870 6,870
Regen. Cat Feed Riser Fluffing and 785 785* 785
Emergency Steam Purge
Main Air Line Emergency Steam 0 2,840 2,840
Main Air Line Emergency Steam Purge 27 27* 27
Catalyst Conveying Jet Ejector
Turbine Condenser Startup Ejector
Turbine Condenser Two-Stage Ejector
Turbine condensate Pumps
UTILITIES
Plant Name: FCCU-I
UTILITIES
Total (Ex Rates by Contractor & As Existing ) 10,543 10,806* 24,808
AIR SYSTEMS
INSTRUMENT AIR (AI)

Requirements,Nm3/h for R-R section Normal Maximum
Normal Catalyst Withdrawal 85 117*
Regen. Catalyst Standpipe Aeration 114 114*
Fresh Catalyst Addition Pressurization/Transport 80 80*
Instruments (Estimated) 37 37
Instrument Blowback ( Estimated) 217 217*
Total 533 565*
Air Systems
Plant Air (A.P)
Requirements, Nm3/h R-R section Normal Maximum
Spent Catalyst J-Bend Catalyst Unloading Aeration 0 47

Regen. Catalyst J-Bend Catalyst Unloading Aeration 0 47
Spent Catalyst J-Bend Unloading Air 0 1,205
Regen Catalyst J-Bend Unloading Air 0 1,205
Catalyst Unloading Transport Air 0 1,205
Catalyst Unloading Transport Air to 0 1,205
Grid Withdrawal Line
Used Catalyst Hopper cone Aeration 0 48*
Fresh Catalyst Hopper Cone Aeration 0 48*
Combustion Promoter Addition 0 161
Fresh Catalyst Hopper Pressurization 0 331
Startup Catalyst Addition Purge to Fresh Cat Hopper 0 104
Startup Fresh Catalyst Addition Transport Air 0 2,041
Backup Fresh Catalyst Addition Transport Air 0 138
Backup Catalyst Addition Purge 0 104
Startup Used Catalyst Addition Transport Air 0 2,041
Startup Cat Addition Purge to Used Cat Hopper 0 104
Catalyst loading transport air 0 As existing
Catalyst loading hopper aeration 0 As existing
Vent line purge 0 As existing
TOTAL 0 2137*
CATALYST REQUIREMENT:
UTILITIES
Plant Name: FCCU-I
UTILITIES
TYPE GRACE XP-89LX, ENGELHARD PRECISION 70X,OR EQUIVALENT
Estimated Initial spent catalyst inventory, Me Tons : 99

Estimated Normal Fresh catalyst requirement Me T/day :
Normal operation : 1.4
Resid Operation : 10.4
Estimated Spent Catalyst Production, Me Tons/day
Normal operation : 0.5

Resid Operation : 9.5
CO Combustion Promoter
Characteristics : See Annextures

Initial Charge, Kgs : 11 to 23
Addition Rate, Kgs/day
@ 1.4Me Tons/Fresh Cat addition rate : 1 to 6
@ 10.4 Me Tons/day Fresh cat Addition rate : 5 to 42
33.18 ELECTRICAL DISTRIBUTION
THE ELECTRICLA POWER REQUIRMENT OF VISAKHA REFOMERY IS

CATERED BY
1) APSEB from Naval Dockyard 1 & 2 feeders

2) CPP with GTG’ s 1,2,3&4
The power requirements of Visakh Refinery were originally met entirely through import
from APSEB. The power drawn at 132 KV from APSEB is stepped down to 11 KV at
132/11 KV switch yard with in the refinery.
GTG 1 & 2 having capacity 9 MW installed in VREP 1 expansion project. GTG 3 & 4
having capacity each 25 MW was installed under VREP II expansion project. GTG 1 & 2
are having two matching Heat recovery steam generators (HRSG) are connected to both

UTILITIES
Plant Name: FCCU-I
UTILITIES
GTG’ s to recover heat from the turbine exhaust gases In unfired condition each HRSG 1&2
will generate steam at 29.4 T/hr, 15ATA and 256 C.
HRSG’ s are also installed for both GTG 3 & 4 to remove heat form turbine exhaust gases.
These HRSGs 3 & 4 will generate steam 60 T/hr at 14 Kg/cm2 and 280oC at turbine base
load.
Double bus bar system (Siemens make) rated for 11KV, 750MVA is installed at CPP
substation to receive power generated form the gas turbines 1,2,3,&4 as well as form
APSEB grids 1&2. The double bus bar feeds to substation 40, 50, HLPH, Auxiliary
transformers for internal load of CPP and 3.3 KV transformers for boiler feed water pumps.
The power distribution network is shown in the sketch.

UTILITIES
Plant Name: FCCU-I
UTILITIES

UTILITIES
Plant Name: FCCU-I
UTILITIES

UTILITIES
Plant Name: FCCU-I
UTILITIES

UTILITIES
Plant Name: FCCU-I
ANNEXURES
CHAPTER-34
PRESTARTUP CHECKLIST FCCU I
The checklist is prepared to have a better understanding over the responsibilities and to
avoid confusion among the operating personnel. These are only guide lines and based on
the experience, these are to be updated from time to time. However the responsibilities are
fixed, the actual job allocation will be done by the supervisor in the shift and he can assign
any section job depending on the situation prevailing in the field. The shift in-charges are
the final authority for allocation of the job.
Sl.
ACTIVITY RESPONSIBILITY
No.
Information given to P&U for consumption of BCW, steam Senior supervisor
1 (MP/LP), BFW,DMW, FO and Un-boosted cooling water
2 Information given to FCCU II for consumption of FG Senior supervisor
3 Information given to TPH for consumption of Flushing oil Senior supervisor
4 Information given to CPP for consumption of POWER Senior supervisor
Information given to TPH for readiness of SLOP TANK and Senior supervisor
5
feed booster
6 Good housekeeping done Senior supervisor
7 Availability of all critical pumps Senior supervisor
8 Availability of instrument air Senior supervisor
9 Readiness of FIRE WATER Structure A/B
10 Readiness of utilities (BCW,STEAM,DMW,BFW) Structure A/B
11 Check for readiness of FG and effective FO circulation Structure A/B
12 Readiness of CBD pump GCU A/B
13 Ensured CBD level is under control Structure A/B
14 Ensured U/L feed B/V in closed condition Structure A/B
15 Ensured O/H cooling fans are stopped Structure A/B
16 Ensured cooling water to O/H condensers closed. Structure A/B
17 Ensured feed nozzles all valves and HV501 b/v kept closed Structure A/B
Ensured reactor stripping steam nozzles. RCJB, SCJB Structure A/B
18 aeration nozzles, cone aeration nozzles shell valves closed and
header take off valves closed.
Ensuring the above are condensate free again during Structure A/B
19
commissioning
20 FG to heater blinded Structure A/B

ANNEXURES
Plant Name: FCCU-I
ANNEXURES
21 Ensured heater stack damper in open position Structure A/B

22 Ensured availability of all pilot flames. Structure A/B
23 Ensured 4C-51, stripper levels , 4V-53 level under control Structure A/B
24 GCU drums and columns levels are under control GCUA/B
25 Ensured column bottom stripping steam, LCO,HCO Structure A/B
strippers stripping steam condensate free before
commissioning
26 Regenerator-Reactor levels, overflow well levels Structure A/B
confirmation
27 Ensured BFW to steam generators closed. Structure A/B
28 Ensured PC2407, PC2411 stroke checked Structure A/B
29 RCJB,SCJB slide valves, stack slide valve operation Structure A/B panel
checking
30 Ensuring aeration taps, cone aeration taps are clear Structure A/B
31 Ensured lift is in working condition Structure A/B
32 PPE box checked and found OK GCUA/B
33 Gas tester checked and found OK GCUA/B
A) MAB STARTUP
S. NO ACTIVITY RESPONSIBILITY
A MAB AUXILIARIES STARTUP
a)
Fill MAB surface condenser up to 60%, start CEPI and keep Blower operator
1
DM water makeup v/v slightly open
2 Keep hot well level controller on AUTO Panel
3 Keep stand by CEP on AUTO mode Blower operator
4 Ensure gland sealing water to CEPI and CEP2 Blower operator
b) LUBE OIL SYSTEM
1 Fill lube oil in MAB LO sump up to required level Blower operator
2 Start main lube oil pump (turbine driven) Blower operator
3 Put standby pump on AUTO mode Blower operator
Ensure LO pressure to Journal bearing in between 1.25 to Blower operator
4
1.5 kg/cm2

ANNEXURES
Plant Name: FCCU-I
ANNEXURES
5 Ensure LO pressure to Thrust bearing in between 0.75 to 1.0 Blower operator

kg/cm2
6 Ensure LO O/H tank is overflowing Blower operator
7 Maintain LO head pressure 2.5kg/cm2 to 3.0kg/cm2 Blower operator

ANNEXURES
Plant Name: FCCU-I
ANNEXURES
8 Maintain LO temperature after cooler at 40C Blower operator

Maintain governor oil/control oil header pressure Blower operator
9
8.0kg/cm2 to 9.0kg/cm2
10 Ensure both pressure control valves are on line. Blower operator
C) VACUUM SYSTEM
Hogging Ejector lineup
1 Open steam v/v to the ejector Blower operator
2 Open air v/v from surface condenser Blower operator
3 Ensure seal steam at < 0.2kg/cm2 Blower operator
4 Ensure vacuum at -0.75 kg/cm2 to -0.85 kg/cm2 Blower operator
Main ejector line up
1 Ensure CEP circulation through main ejector Blower operator
2 Open steam and then air valve Blower operator
3 Open main ejector condenser HP and LP drains Blower operator
4 Open air vent valve Blower operator
5 Isolate air valve of hogging ejector condenser Blower operator
16 Ensure suction flow, reset MAB discharge check v/v Panel/Blower
(HV510) and open MAB discharge valve.
17 Open primary air to Regan butterfly valve and establish Structure A/B
flow
18 Open secondary air to Regen valve and establish the flow Structure A/B.
by closing suitably the antisurge valve. panel
19 Keep FLCO509 trip in service (Air to Regan flow low) Panel officer
B)CAB START UP
1 Ensure MAB discharge pressure 1.7kg/cm2 Panel officer
2 Ensure CAB antisurge v/v in wide open position and its Blower
block valve in wide open position operator
3 Open CAB suction valve 50% only and discharge valve in Blower
wide open position operator
4 Ensure CAB bypass v/v (suction to discharge) in closed Panel officer
position
5 Keep FL517BP CAB air flow low switch in bypass position Panel officer
and keep FLCO510 in bypass position
6 Ensure CAB antisurge control selection on HC511 with Blower
output 100% operator
7 Take clearance from CPP, process substation and inform Senior
DMP (shift) supervisor
8 Press reset push button located on local panel to get CAB Blower
ready to start operator

ANNEXURES
Plant Name: FCCU-I
ANNEXURES
9 Start CAB and open suction v/v gradually Blower operator

Maintain Instrument air to Thrust balancing line DP Blower operator
10
0.2kg/cm2
Reset CAB discharge check v/v HV506 and reset FV2X and Panel officer
11
open the control v/v suitably
Suitably close the antisurge valve and route control air to Panel officer/Structure
12
spent catalyst riser A/B
Establish normal control air flow, then keep FL517BP by Panel officer
13 pass switch in normal mode, and keep FLCO510 (Regen
CAB flow low low) LM switch in normal mode.
14 Ensure all five control air nozzles are clear Structure A/B
C)WGC START UP
a) LUBE OIL SYSTEM
Fill lube oil WGC LO pump and seal oil sump up to required Blower operator
1
level.
2 Start main on lube oil pump (turbine drive) Blower operator
3 Keep standby on Auto mode. Blower operator
Start seal oil main oil pump (turbine driven) and keep Blower operator
4
standby pump on Auto mode.
5 Keep seal oil O/H tank on Auto (60%). Panel officer
6 Ensure LO pressure to journal bearing in between 1.25 to Blower operator
1.5kg/cm2
7 Isolate steam valve of hogging ejector condenser Blower operator
8 Ensure vacuum at -0.85kg/cm2 to -0.95kg/cm2 Blower operator
9 Keep gland steam c/v on AUTO Panel officer
d)
BARRING GEAR OPERATION
1 Normalize LO system Blower operator
Ensure LO pressure to barring gear in between 1.25 Kg/Cm2 Blower operator
2
to 1.5Kg/cm2
3 Engage the barring gear lever and start form local panel Blower operator
e) WARMING UP PROCEDURE
1 Ensure barring is in operation Blower operator
2 Open all turbine casing drains Blower operator
3 Open compressor casing drains Blower operator
4 Open all drains of main steam line Blower operator

ANNEXURES
Plant Name: FCCU-I
ANNEXURES
Start warming up by opening main steam bypass valve (Rate Blower operator
5
of heating should be 10C/10minutes)
6 Open main steam v/v and ensure steam inlet temperature Blower operator
around min 320C
MAB STARTUP
1 Establish mockup operation as per data sheet Panel officer
2 Establish condensate circulation Blower operator
3 Pull vacuum Panel/Blower
4 Check preliminary checks and interlocks of MAB “
Keep turbine under warm up. Take clearance from power plant, Senior supervisor
5
MP/DMP shift
Stroke check MAB antisurge control valve and keep in wide open Panel/Blower
6
position operator
7 Bypass trip oil pressure low-low switch Blower operator
8 Keep FLCO 509 in bypass position Panel officer
Ensure trip circuit healthily on local panel, press reset push button on Panel/Blower
9
Woodward governor panel in control room
MAB ready to start. Close MAB discharge valve, CAB suction and Blower operator
10
discharge valves
Buildup trip oil pressure and remove bypass on trip oil pressure low low Blower operator
11
switch
Open emergency stop valve with starting device and give clearance for Blower operator
12
starting the machine.
Start the machine from control room with Woodward Governor by Panel officer
13
giving command “ RUN”
Initially give set point 1000RPM and gradually go up from 3000 to 4000 Panel officer
14
upto 5000.
15 Maintain Instrument air to Thrust balancing line DP 0.2kg/cm2 Blower operator
PROCEEDING FOR WGC STARTUP
Ensure Wet gas compressor 1st stage KOD, 1st stage suction, 2nd stage GCU A/B
1
suction and casing is free of liquid
Stroke check 1st stage (PC2629) and 2nd stage (PC2712) suction GCU A/B
2 pressure control valves, antisurge valves (FC2601 & FC2602) and total
spill back control v/v (PC2411)
GCU A/B
3
Check lineup of wet Gas compressor

ANNEXURES
Plant Name: FCCU-I
ANNEXURES
GCU A/B
4
Start LO and seal oil circulation
GCU A/B
5 Check preliminary checks and interlocks of Wet Gas compressor MOV’ s
are operating from control room and local panel
GCU A/B
6 Keep WGC 1st stage and 2nd stage suction pressure low low trips on
bypass.
Senior Sup
7 Take clearance from CPP, process substation and inform DMP/MP
(shift)
HEATER STARTUP
1 Ensure cleanliness inside the burner Structure/AB
2 Keep stack damper in wide open position. Close all peep holes and Structure/AB
explosion doors.
3 Keep all burner valves closed. Bypass shutdown circuit and open fuel oil Structure/AB
and fuel gas shutdown valves (SDVs)
4 Established fuel oil circulation in all headers of the furnace. The rate of Structure/AB
circulation should be such that fuel oil returned should be equal to the
fuel oil consumption in the furnace.
5 Keep instruments on Manual control, check and rectify any leaks in the Structure/AB
system.
6 Commission the fuel gas system and check and rectify any leaks in the Structure/AB
system.
7 Steam purge the furnace chamber and ensure that burner gaskets are not Structure/AB
leaking.
PILOT LIGHTUP
1 Make sure the individual gas valves to the pilots are closed. Structure/AB
2 Open the main pilot fuel supply valve making fuel gas available to all of Structure/AB
the individual pilot block valves.
3 Check for leaks (close main t/o v/v observe for loss of header pressure ) Structure/AB
4 Select first pilot to be lit Structure/AB
5 Slowly open the pilot fuel gas valve while depressuring the ignition Structure/AB
button on the transformer. The pilot should light instantly.

ANNEXURES
Plant Name: FCCU-I
ANNEXURES
6 Once pilot is lit stop depressing the ignition button. If not lighted up, Structure/AB
close the valve and drop pilot burner, clean, check fix back the same.
7 Light all heater pilots using procedure outlined above. Structure/AB
Making sure all pilot block valves are full open and all pilots are in
8 operation, adjust, pilot main b/v such that pilot supply header pressure is “
0.35 kg/ cm2g to 1.0 kg/cm2g.
GAS BURNER LIGHT UP
1 Adjust the stack damper Panel/structure
2 Make sure the individual burner fixing valves are closed Structure/AB
Slowly open the main fuel supply valve allowing gas to flow upto the Structure/AB
3
individual burner fixing valves which remains closed.
With the pilot flame and air flow established, slowly open the burner fuel Structure/AB
4
gas firing valves which remains closed.
5 Continue to light all burners required Structure/AB
Proper burner operation, with excess air control dictates that all operating Structure/AB
6
burners should be fixed without throttling of individual block valves.
OIL BURNER LIGHTUP
1 Adjust stack damper (50%) Panel/structure
Circulate oil until header is completely filled with fuel at the proper
2 Structure A/B
temperature.
Open the steam valve to the oil gun until both steam and steam purge Structure/AB
3
lines to each burner are completely flushed of any condensate.
Adjust steam valve to 2-3 kg/cm2g steam pressure. Set the steam Structure/AB
4 differential pressure controller so that steam pressure is about 1.8 to 2
kg/cm2 higher than the fuel oil pressure.
5 Slowly open. The oil should ignite. Structure/AB
After burner lights, adjust oil valve for capacity and adjust Steam valve Structure/AB
6
for clean and bright flame.
When required more number of burners lighted, open the FO atomizing Structure/AB
7
steam valve full and control the flames by adjusting the fuel oil pressure
Maintain the furnace draft about minus 1 to 2 mm water gauge at the
8 Panel officer
inlet to the convection
9 Check excess air in the furnace and adjust the damper, primary and Panel officer
secondary air registers to give the required excess air.
10 When the unit stabilizes, take all controls and commission the TRC Panel Officer
control cascading either on gas or Fuel oil depending on the number of
burners on FO or FG service.
11 Commission the shutdown circuit of the furnace. Panel Officer
UNIT STARTUP CHECKLIST

ANNEXURES
Plant Name: FCCU-I
ANNEXURES
RESPONSIBILIT
ACTIVITY
S.NO. Y
Confirm with the blind lists, physical status of the blinds Structure
1 (Rechecking should be carried out prior to startup of the unit) A/B
Check for proper installation of gaskets, undersize bolts etc. GCU A/B
2 Check that all onsite fire protection equipment is ready Senior supervisor
3 Confirm that the sewer systems have been commissioned “
4 Check all safety relief valves are fixed in position Respective sections
Inspect the equipment opened for maintenance, prove clear all
5 “
Nozzles
Regenerator-Reactor instrument blow back air lines should be
Structure
6 blown and instrument taps nozzles to be proved clear (as per the
A/B
list all taps to be cleared systematically)
Check all restriction orifices on Rx stripping steams, Feed
7 nozzles, Feed injection steam nozzles, Emergency and blast Structure A/B
steam nozzles and aeration steams.
8 Stroke check all control valves. Respective sections
9 Check all emergency systems for correct response Structure A/B
10 Make trial run on MAB and CAB GCU A/B
11 WGC no load test to be conducted. Senior supervisor
Ensure preheater igniter assembly and check ignition system,
12 Structure A/B
check functionality of BMS system.
13 Check catalyst loading and unloading lines are clean “
14 Check all drums, vessels, columns LT’ s response Respective sections
15 Ensure the following are in blinded position until the unit is air
free and service required for startup
• Reactor vapor line blind
• Vacuum gas oil feed to the feed header
• Fractionator bottoms recycle
Structure
• Feed header warm up line to the fractionator
A/B
• Naphtha quench from tankage and the fractionator to the
feed header
• Air purge to Reactor side instrument taps
• Torch oil to Regenerator
• Pilot gas and fuel gas to the Air preheater
TIGHTNESS TESTING
a) INTRODUCTING AIR TO REGEN
1 Start MAB on venting as per the procedure GUC A/B

ANNEXURES
Plant Name: FCCU-I
ANNEXURES
2 Introduce air to Regen by slowly opening butterfly valves and

Structure A/B
closing the vent v/v
3 Do not exceed Grid pressure drop 0.35 Kg/cm2 Panel officer
4 Ensure primary and secondary air lines are clear Structure A/B
5 Open RCJB and SCJB slide valves. Panel officer
6 Buildup Regenerator Reactor pressure 2.0 Kg/cm2 by closing
Structure A/B
Reactor vent.
7 Drain condensate from all low points “
8 Blowout all vents, drains and aeration connections “
9 Check all Rg-Rx all flanges as per the systematic list and update
“
the same.
10 Reduce pressure back to 1.0Kg/cm2 “
REGENERATIOR-REACTOR CURING
APH LIGHTUP
Carryout the following pre checks
1 Check that oil gun is fitted Structure A/B
2 Remove blinds on APH pilot gas and Fuel oil. Check that the
“
burner manual isolating valves are closed.
3 Pressure pilot gas, pilot air, atomizing steam and fuel oil. Check
“
for no leaks
4 Check that the fuel selector on the BMS panel is in the “ OIL
“
SELECTED” position
5 Check fuel oil and atomizing steam flexible hoses for leaks with
“
atomizing steam
6 Clean and fix back APH sight glasses “
Check the electrical igniter, pilot and main flame scanners and
7 “
fix them inside APH
8 Repack or add pack fuel oil gun gland to avoid gland leaks. “
Commission instrument air purges to pilot and main flame
9 “
sensors
HEATER PURGE
Before the heater can be purged, all the following interlocks
must by healthy.
• No emergency stop push buttons operated.
• Primary air flow above the low limit
• Main air flow not failed “
• No pilot flame detected
• Main oil control v/v (RCV501) to be closed

ANNEXURES
Plant Name: FCCU-I
ANNEXURES
• Igniter system not energized

• Heater purge not started.
When all interlocks are healthy the “ the heater ready to purge”
lamp will be ON. Push “ Heater purge” button, then “ HEATER
READY TO PURGE” lamp will go off. When the purge time 5
“
minutes is complete, the “ HEATER PURGED” lamp will be on.
Before starting the purge air flow must be set manually to its
maximum flow to ensure there is sufficient purge air.
PILOT IGNITION
1 Ensure that the “ HEATER PURGED” lamp is on “
Check that all the pilot air and pilot gas manual isolating valves
2 “
are open
3 Press the “ PILOT START” “
The “ PILOT FLAME ON” lamp will come on with 7 to 12
4
seconds (the pilot ignition sequence is automatic)
The pilot air and pilot gas pressures should be maintained equal
5 “
and 0.5 Kg/cm2g above the Regenerator pressure.
MAIN BURNER IGNITION
1 Check that all the manual oil and steam isolating valves are open “
2 Check that atomizing steam is flowing to the burner “
3 Check that the primary air flow is correct for light up “
4 Visually check for satisfactory stable pilot flame “
5 Check that the “ BURNER READY TO START” lamp is on “
6 Press the “ BURNER START” push button “
7 The “ MAIN FLAME ON” lamp will come on
8 Increase the primary air to the operating value (min 5 Knm3/hr) Panel/structure A/B
The oil flame must be detected by main flame detector within 10
9 seconds. If the flame is not detected by the end of this period,
the oil valves will close.
If pilot is still alight it will be possible to try to light the oil
10 burner again. This should only be attempted three times before Structure A/B
the heater is purged again.
Once burner is lighted, control combustion chamber temperature Panel officer/APH
11
with TC1X operator
Operator must be stationed at APH control panel at all times when
12
lit, to observe the flame.
DRYOUT PROCEDURE
Commission APH instrumentation and TI s in the Reactor, Panel
1 Regenerator and overhead systems officer/Structure
A/B

ANNEXURES
Plant Name: FCCU-I
ANNEXURES
2 Light up APH as per procedure Structure A/B

3 Always ensure at least 100% excess primary air
Min PA = FI 1X * 0.00074((TI4X)-107) Knm3/hr
4 Panel officer
Safe Min PA=FI1X*0.00074((TI4X)-107) +2 Knm3/hr
Primary air requirement chart also available.
Increase TI4X temperature up to 195 C @ 25 C/hr) limiting to 205
5 Panel officer
C
All refractory linings of the Regenerator and Reactor (including
the Regen/spent catalyst transfer line) must be held between a
6 Panel Officer
minimum of 120 C and a maximum of 205 C for 1/1/2 hours per
25mm of lining thickness.
Increase the air preheater temperature at a rate of 25 C until the
7 Regenerator outlet reaches 510 C and the Reactor outlet and Panel officer
Reactor stripper should reach 435 C
Hold all sections of the Regenerator at 510 C for 8 hours and all
8 sections of Reactor at 435 C for 6hrs to complete the dryout Panel/ Stru A/B
process (curing chart available.)
9 Do not exceed grid approach temp 593 C (4TI1X) during dry out Panel
10 Do not exceed grid pressure drop 0.35 Kg/cm2g (PDI509) Panel
Temperatures to be monitored during refractory dryout for
uniform heat up
11 4TI4X,TI9X,TI11X,TI14X,TI35X,TI502,TI509,TI510, Panel
TC512,TI513,TI514,TI517,TI519,TI521,TI520,
TI536,TI538,TI4X
Occasionally stroke the slide valves one at a time during heat up
12 Panel/Structure A/B
to ensure they are not sticking.
Pinch Regen flue gas slide valves to force more air up through
13 Panel
Reactor stripper
14 Hot bolt all flanges at 300 C and 500 C respectively Structure A/B
Inspect Reactor, Regenerator and O/H system, structure during
15 Structure A/B
heat up
Check that unit is free to expand and is not interfering with
16 structural members, struts are free to move, Small piping is not Structure A/B
under strain and there are no hotspots on vessel man ways.
Commission the CAB to provide air flow at 5000 Knm3/hr to the
17 Structure A/B
spent cat riser.
18 Close RCJB and SCJB shutoff slide valves. Panel
REACTOR VAPOR LINE BLIND REMOVAL

ANNEXURES
Plant Name: FCCU-I
ANNEXURES
Admit steam to Reactor as follows:

• Riser emergency steam (FI15X) 3500Kg/hr
• Stripping steam (FC505) 3300Kg/hr
1 • Feed injection steam (FC13X) 1500Kg/hr Structure A/B
• J bend blast steams (RO bypasses only)
• All aeration connection which normally steam will be
introduced.
2 Steam fractionator from bottom venting from 4C-51 O/H vent “
Steam out the Reactor for 2 hours, checking O2 level in Rx
3 “
overhead. If O2 exceeds 5 wt% continue steaming
Continue to drain condensate from low points (blast steam
4 “
connection from both J bends)
Reduce steam to minimum in Reactor and fractionator and
5 simultaneously reduce pressure in Regenerator and take out vapor “
line blind.
If above is not possible, the following steps should be taken
sequentially to maintain Regenerator pressure below Reactor
pressure
• Shutdown APH
6 “
• Close main air and Spent riser control air valves.
• Leave control air and main air blowers running with air
venting (vents should be wide open to minimize discharge
pressure)
7 Remove blind from Reactor O/H line at the fractionator inlet “
Maintain a min flow of steam to avoid entry of air into the
8 “
fractionator while swinging the blind.
Ensure that both Reactor and Regenerator pressures are below
9 Panel officer
0.03 Kg/cm2g before removing the blind.
After blind removal, remove the spool pieces from the Rx O/H
10 Structure A/B
vent line and Rx PSV inlet line and install the nozzle plugs.
Reintroduce steam to Reactor, fractionator and steam for 1 hour
(Emergency steam 800kgs, Rx stripping steam 3300Kgs, and
Feed injection steam 1500Kgs. Anti-coking steam to baffle
11 “
chamber and riser anti-coking steam thru Ro s, J bends blasts
steam through ROs). Simultaneously introduce main air and
control air to Regenerator.
Test fractionator O/H drum for O2, continue steam venting until
12 “
O2<5%
Open fuel gas to LCO stripper and control fractionator overhead
13 “
pressure with PC2411. Maintain a pressure of 1.05 Kg/cm2g

ANNEXURES
Plant Name: FCCU-I
ANNEXURES
Take cutter and circulate through fractionator bottom circuit via

14 “
surge drum. Drain condensate
15 Displace cutter with VGO after pumping out cutter to slop “
16 Heat up oil in the furnace. Bottom circuit at 200-230 C “
Do not exceed feed pump approach temp 150C. Bypass 4E51
17 Panel officer
(LCO/Feed exchanger)
18 Increase Regen pressure to 0.91 Kg/cm2 “
19 Relight APH and heat up Regenerator Structure A/B
20 Maintain Reactor Regenerator DP 0.14Kg/cm2g Panel officer
Commission ES2 and ES3 (Main air line emergency steam and
21 “
control air line emergency steam)
22 Ensure Emergency steams bypasses through RO commissioned Structure A/B
CATALYST LOADING
1 Heat up Regenerator Panel

Commission aeration and vent to atmosphere through rod out Structure
2
valves A/B
3 Commission blow back air to all instruments “
Set Reactor-Regenerator DP at 0.14 Kg/cm2. Increase steam to Panel officer
4
reactor riser
Pressure up used catalyst hopper Structure
5
A/B
6 Lineup catalyst loading line Structure A/B
7 Blow the line with transport air to make the line clear “
8 Start the hopper cone aeration “
9 Reduce the air rate to maintain superficial velocity of about 0.5 Panel officer
to 0.6m/sec to avoid catalyst loss during loading.
10 MAB should operate at a safe margin above surge. “
11 Air rate should be above trip set point 25Knm3/hr “
12 Grid pressure drop should be maintained between 0.1 to 0.35 “
Kg/cm2
13 Two methods of loading catalyst: Structure
Method A: * Increase Rx Pressure to maintain 0.07Kg/cm2 DP A/B
across RCJB
* All aeration nozzles and instrument purge points will be in
service
Method B: * Except two upper most aeration taps, close all
remaining aeration and instrument taps on RCJB standpipe

ANNEXURES
Plant Name: FCCU-I
ANNEXURES
14 Load catalyst to Regenerator maintaining Regenerator bed Panel

temperature above 290 C Officer/Structure
A/B
15 Remove torch oil blind, Keep cutter ready Structure A/B
16 Once Regenerator level brought up above 1.5m torch oil nozzles Panel officer
(25%) bring up Regenerator temperature > 370 C
17 Introduce torch oil. Do not introduce torch oil below 370C “
18 Continue catalyst loading till Regenerator holdup reaches Structure
100tons A/B
19 Bring up Regenerator temperature and shutdown APH “
20 Install blinds on Pilot gas and fuel oil to APH “
21 Maintain column bottoms circulation at 200-230 C “
CATALYST CIRCULATION
1 Commission all aeration taps and instrument taps. “
2 Bypass only the following emergency shutdown initiators to Panel officer
allow the manual operation of the catalyst slide v/v
• FLCO502 (Feed flow low low)
• TLCO502 (Riser temp low low)
• LLCO502 (Reactor stripper level low low)
3 Open slowly Regen cat slide v/v “
4 Monitor temperature rise in the feed riser (should be 2 C/min) “
Observe overflow well level. Make sure level is being
5 “
maintained in the overflow
6 Observe Reactor stripper level .It will tend to rise “
Confirm O2 content of fractionator is less than 5% Structure
7
A/B
8 Maintain Regenerator bed temp at 450-480C with torch oil Panel officer
As the stripper level rises open SCJB slide valve slowly to
9 Panel officer
transfer catalyst from Reactor to Regenerator
Adjust catalyst circulation rate by opening RCJB,SCJB, Structure
10
aeration steam rates and emergency steam to feed riser A/B
Increase circulation/torch oil such that Regenerator temperature
11 Panel officer
at 570 C and Reactor temperature at 540 C
Maintain Reactor-Regenerator pressure differential
12 “
0.21Kg/cm2
GCU STEAMING/STEAM TESTING/GAS PURGING

ANNEXURES
Plant Name: FCCU-I
ANNEXURES
1 Introduce steam to GCU columns and circuits GCU A/B

2 Pressure test the columns, vessels and drums Respective section
Minimize the vents, make ready to take gas to the GCU section
3 “
during steam purge
Prior to Gas taking in thoroughly check for any pending jobs
4 “
(hot jobs)
Carefully check each circuit wise and get attended if any hot
5 “
jobs pending.
Back up gas via fuel gas line to sponge absorber and backup into
6 GCU A/B
the system
Gas injection points available are
7
4V-54,LCO stripper v/r, 4V-57
8 Take Naphtha to 4V-53 GCU A/B
Take Naphtha to 4V-55 and 4V-56 from 4V-53 by using LPD
9 “
and Interstage pumps
Take level into GCU stripper from 4V-56 by starting stripper
10 “
feed pumps (4P-62 A/B)
11 Take level into primary absorber “
Transfer level into Stabilizer from GCU stripper dropping
12 “
Debutanizer pressure
13 Frequently drain water from the columns and also at pumps “
WGC STARTUP ON SPILL BACK
Start Wet Gas compressor as per procedure with fuel gas on spill
1 GCU A/B
back
FEED CUTIN
1 Maintain FLCO 502 Reactor low feed in bypass Panel officer
2 Lineup cold feed to surge drum and circulate the same Structure A/B
3 Maintain Regenerator bed temperature with torch oil Panel officer
4 Minimize feed flow through passes and divert to column “
5 Inform TPH for lining up product tanks and slop Senior officer
6 Inform YSF “
7 Close circulation v/v near heater to feed surge drum Structure A/B
8 Introduce fires in heater. All pilots should be ready “
9 Maintain heater O/L temperature around 350-400C. Panel
10 Cut in feed by feed injectors globe valves slowly. Reactor “

temperature should not fall below 500C during feed cutin

ANNEXURES
Plant Name: FCCU-I
ANNEXURES
11 After two nozzles are in service begin reducing riser Panel officer
emergency steam (at the rate of 450 kg/hr for each 6.6 m3/hr of
feed)
12 Control column level during feed cutin. Slowly close feed “
diversion valve.
13 Adjust feed rate. slowly load Wet Gas Compressor and close “
spillbacks.
14 Adjust catalyst circulation rate. “
15 After attaining 4V-53 level, start top reflux pump Structure

A/B
16 Start HCO and LCO pump around pump “
17 Once LPD routed to GCU section levels should be watched and GCU A/B
interstage and stripper feed pumps to be started
correspondingly.
18 Introduce GCU stripper and Stabilizer reboiling. Panel officer
19 Start LPG reflux and R/D pumps after achieving the level in GCU A/B
4V-57
20 Inform to Merox before routing CRN and LPG Panel officer
UNIT SHUTDOWN ACTIVITY LIST

S. NO. ACTIVITY RESPONSIBILITY
1 Finalize shutdown work lists Supervisors
2 Finalize master blind list “
3 Carryout pre shutdown jobs “
4 Tag the location of leaks etc. Respective sections
5 Prepare detailed shutdown procedure Supervisors
6 Procure gunny bags for covering open sewers “
7 Empty CBD for taking unit flushings and draining Blower operator
8 Get calibrated explosive gas tester, H2S tester Supervisors.

ANNEXURES
Plant Name: FCCU-I
ANNEXURES
Inform other units about the shutdown schedule for flushing oil,
9 Supervisors
slop tank ullage etc.
Keep additional firefighting equipment standby wherever
10 Operators
required.
11 Plan the manpower and material Supervisors
Check equilibrium hopper to ensure that sufficient free volume Structure
12 available to accommodate unit catalyst inventory. Operator
SHUTDOWN CHECKLIST
12 In form to other units DMP/MP (shift) Supervisors
13 Reduce feed rate. Bypass FLCO502 feed flow low low initiator Panel officer
14 Adjust air rate “
15 MAINTAIN 0.09 Kg/cm2 minimum grid DP “
Introduce emergency steam to Feed riser in order to maintain
16 “
catalyst circulation
As the feed rate is reduced cutout feed nozzles as necessary to Structure
17
hold 9kg/ cm2g at the nozzles. operator
18 Do not allow Reactor temperate to fall below 470 C Panel officer
Once feed is completely taken out and diverted to
19 “
4C-51 :
SHUT DOWN HEATER
Fuel oil to the heater should not be cutoff abruptly unless
an emergency shutdown is called for
During normal shutdown divert feed to 4C-51,cutdown pass
outlet temperature
As the burner tend to become unstable when fired at low
rate, reduce the number of burners
Close fuel oil valve and open purge steam valve on the fuel
oil line to the burner
Structure
Purge all oil into the fire box and continue
operator
Steaming for about five minutes.
Close atomizing steam to the burner
Pull out oil gun, in case the gun in not withdrawn. Leave a
little steam blowing through the tap to cool it. This may be
done when a burner is to be taken out of service during
normal operation.
Cut the burners one by one till all the oil fires and gas fires
are cutoff
Bypass shutdown circuit of the furnace

ANNEXURES
Plant Name: FCCU-I
ANNEXURES
Ensure oil and steak flow through the furnace coils during
shutdown till the temperature of the box comes to below
250C
Close all manual block valves to the burner
After all fires are put off open snuffing steam to box and
purge the box for 15 minutes.
Install blinds on fuel gas, oil and pilot gas line to furnace
Open all the air registers and all the peep holes. Stack
dampers should be opened fully to ingress of air into
furnace to cool it.
Isolate BFW to 4V-63
20 Start APH and maintain Regenerator bed temperatures 510-540C “

Other shutdown procedure is to reduce feed to about 60% and
21 Panel officer
activate ES-1 (feed failure)
Close all feed nozzles globe valves and isolate total feeds control Structure
22
valve. Operator
Pump out 4C-51,Strippers, vessels and GCU level Structure /GCU
22
Operator
Close stripping steams to column. Structure
23
Operator
When the Reactor feed is diverted to the fractionator, reduce feed
24 Panel officer
as quickly as possible. Otherwise 4C-51 level will shoot up
Continue catalyst circulation for at least 30 minutes after feed is out
25 Panel officer
to eliminate hydrocarbon and reduce carbon level on catalyst.
26 Continue Reactor steaming. “
When Gas compressor suction pressure begins falling, bring in fuel Structure
27
gas from fractionator overhead and shutdown wet gas compressor Operator
Remove remaining hydrocarbon liquid in towers and other vessels Structure /GCU
28
to closed disposal system Operator
Block cooling water to all coolers and open vents
29 Structure /GCU
Steam towers, vessels and hydrocarbon circuits for residual
30 “
hydrocarbon
31 Install blinds and final steam the systems “
CATALYST UNLOADING
1 Transfer catalyst from Reactor to Regenerator Panel officer
2 Stop catalyst circulation “
3 Stop torch oil injection, blow nozzles clear and blind on oil line. Structure Operator
4 Fire APH to maintain Regenerator temperature at 370 C “
ANNEXURES
Plant Name: FCCU-I
ANNEXURES
5 Line up catalyst unloading line “

When the catalyst temperature is below 425C, withdraw catalyst from
6 “
Regenerator be to used catalyst hopper as rapidly as possible.
When all catalyst has been unloaded reduce Regen pressure and
7 “
shutdown APH
8 Suggested catalyst unloading temperature 315-345 C Panel officer
9 Continue steam to Reactor to fractionator for 5-6 hours Structure Operator
Stop feed pump and blow the feed lines to the fractionator. Pump
10 “
out the fractionator bottoms, then shut down the pumps.
Blind all feed and product lines. Structure /GCU
11
Operator
Open Reactor overhead vent to atmosphere and reduce steam rates Structure
12
to permit installation of blind on the Reactor overhead line. Operator
When the Regenerator cools to Main air blower discharge
13 Blower operator
temperature, shutdown the blower
14 Continue Reactor steaming for 2 hours Structure Operator
Complete steaming of all individual hydrocarbon circuits and do Structure /GCU
15
not leave any oil pockets. Operator
Install blinds as per master list and make entries initialed by Structure /GCU
16
operator in charge Operator
17 Steam equipment vigorously with proper venting, till the system is
Structure/GCU A/B
completely sweet
OPENING OF EQUIPMENT
1 Make sure equipment is hydrocarbon free and positively isolated. Respective Operators
2 Open adequate man ways and fix eductors to supply clean and cool
“
air
3 Test for gases with H2S tester and explosive meter “
4 Test for oxygen minimum requirement 20% “
5 Inspect internals for safe entry “
6 Give entry permit if above conditions are met “
7 Collect wet pyrophoric iron sulphide and store in water filled
“
drums stacked away from the unit.

ANNEXURES
Plant Name: FCCU-I
ANNEXURES
List of Vendor Manual
1. Design Specification list No.1

2. Design Specification list No.1
3. Reactor System manufacturing data book
4. Reactor System manufacturing data book
5. RR plenum manufacturing data book
6. RCSV data manual
7. SCSV data manual
8. DDSV data manual
9. TPSV data manual
10. TPSV maintenance manual
11. TAPCO slide V/V supplier vendor documents (RCSV,SCSV)
12. Reactor final documents
13. Regenerator final documents
14. Reactor Overhead final documents
15. Reactor Overhead final documents
16. Regenerated catalyst transfer line final documents
17. Spent catalyst transfer line final documents
18. Refractory work final documents
19. Certification Dossier- APH and BMS
20. Process design package Vol-I
21. Process design package Vol-II
22. GAMBO KCAU user manual
23. Flexi cracking unit refresher course manual
24. MAB, CAB documents Vol-I
25. MAB, CAB documents Vol-II
26. Operating & Instructions manual for Steam Turbines Vol-I
27. Operating & Instructions manual for MAB Vol-II
28. Operating & Instructions manual for auxiliaries and Instrumentation Vol-III part 1
31. Operating & Maintenance manual (Surface Condenser and Steam Jet Ejector)
32. Operating & Instructions manual for CAB
33. MAB Compressor control system manual Part-1
34. MAB Compressor control system manual Part-2

ANNEXURES
Plant Name: FCCU-I
ANNEXURES
35. Bentley Nevada 3300 system

36. WGC documents Vol-I
37. WGC documents Vol-II
40. WGC control Engg manual Vol-I
41. WGC control Engg manual Vol-I
Pumps
42. Strainers final documents

43. Final Documents of the pumps 4P51A/B, 4P59A/B, 4P60A/B, 4P61A/B, 4P62A/B,
4P66A/B
44. Instructions manual for 4P52A/B book-I
45. Instructions manual for 4P52A/B book-I
46. Final Documents of the pumps 4P53A/B, 4P64A/B, 4P67A/B, 4P621/B, 4P65A/B
47. Final Documents of the pumps 4P55A/B, 4P56A/B, 4P64A/B
48. Final Documents of the pumps 4P68A/B
51. Instruction manual for the pump 4P71
52. Operating & Instruction manual for KIRLOSKAR EBARA model pumps
Heat Exchangers
53. Heater final Documents(John Zink)

54. Operating manual for heater
55. Final documents of 4E51, 4E52A/B/C/D, 4E53, 4E62A/B/C/D
56. Final documents of 4E54A/B/C & 4E56
57. Final documents of 4E57, 4E55A/B, 4E60A/B/C, 4E61A/B , 4E68, 4E70 & 4E65
58. Final documents of 4E58A-H, 4E60A/B/C, 4E69A/B/C
59. Final documents of 4E59A/B
60. Final documents of 4E59C/D
61. Final documents of 4E63A
62. Final documents of 4E63B
63. Final documents of 4E64A

ANNEXURES
Plant Name: FCCU-I
ANNEXURES
64. Final documents of 4E64B

65. Final documents of 4E67A/B
Vessels
66. Final documents of 4V51, 4V53, 4V54, 4V55, 4V57, 4V58, 4V59, 4V61, 4V62
67. Final documents of 4V52, 4V56, 4V60, 4V64
68. Final documents of 4V66
69. Final documents of 4C51
70. Torch oil spraying system manual

71. Modular gas detection and monitoring system- Instructions manual
72. Damper final documents

ANNEXURES
Plant Name: FCCU-I
ANNEXURES
CO BOILER
INTRODUCTION:
CO laden flue gas from FCCU I Regenerator, containing CO. CO2 SO2, N2, O2 H2O
vapour and catalyst fines enter the CO – furnace through pressure control slide valve,
orifice chamber and two port slide valve,. In CO – furnace, complete combustion of ‘CO
‘is ensured in the presence of a support burner firing fuel gas (preferably). The combustion
products from CO furnace directly enter the Boiler, where potential heat (i.e. heat of
reaction and sensible heat) is recovered by generating 40 TPH HP steam. Supplementary
auxiliary firing is also essential in Auxiliary combustion chamber to make up this steam
generation. The flue gas is finally cooled down to a temperature 280-850 C before venting
to atmosphere at 60m elevation through a ground mounted steel-stack.
The CO boiler is designed to generate 40 TPH of HP steam at supply pressure of 38 kg/cm2

g and temperature of 3710C with support fuel (i.e. preferably fuel gas) firing required for
complete combustion of CO and additional auxiliary fuel ( i.e.LSHS/Fuel oil/Fuel gas )
firing. The CO boiler is also capable of producing steam at same capacity, pressure and
temperature on full auxiliary fuel firing mode in the absence of any gas.
The ground mounted stack is also designed to handle hot CO-gas on bypass operation of
the CO-boiler by changing the gas passage in ‘Two Port Slide Valve’ . In case of bypassing
of the CO-gas, the guillotine dampers located downstream of TPSV and downstream of
Gilled Ring economizer are to be closed manually to ensure no leakage of CO-gas to the
Boiler. The guillotine dampers are designed for 100% of sealing and provided with sealing
air arrangement. Additionally, blinds are to be provided along with these guillotine
dampers, to ensure safety for maintenance of the Boiler.
A plan exists for installation of wet gas scrubber on flue gas circuit at downstream of the
CO-Boiler system (i.e. after gilled ring economizer) to remove the oxides of sulphur
(SO2+SO3) from flue gas before venting it to atmosphere through a separate stack.
DESCRIPTION OF CO BOILER SYSTEM:
The CO furnace is a cylindrical vessel of 4m ID (net) / 9.5 m length (TL-TL) attached

horizontally to the CO boiler such that the combustion products directly enter the boiler.
The furnace is internally lined with two – layers of refractories. The furnace is equipped
with three number of CO-burners and one number of support burner. CO burners are
provided on the circular shell of the CO furnace, firing tangentially to make a whirlpool,
thereby increasing the CO gas residence time in furnace. Support burner is provided along
the central axis of the furnace, firing refinery fuel gas to maintain steady combustion of CO
ANNEXURES
Plant Name: FCCU-I
ANNEXURES
gas. Support burner is also suitable for firing of LSHS & Fuel oil and provided with a pilot
burner firing fuel gas continuously at all cases of operation of the boiler. The maximum
temperature of the furnace is maintained around 10000C, by controlling the support burner
firing duty and combustion air flow to CO furnace.
The CO boiler is a vertical, water tube boiler with membrane wall type construction. It has
a rectangular cross section and operated on natural circulation principle. The membrane
wall evaporative shell houses the super heater and evaporator (Fahnen) tube bundles
Economizer tubes are provided above the Fahnen tubes in metallic shell casing. Flue gas
from the boiler 2450 C maximum is further cooled down to 180-1850C in a cast iron gilled
ring economizer, located downstream of the CO boiler. Flue gases from the gilled ring
economizer exit to atmosphere at 60m elevation through the grade mounted stack.
The boiler is provided with a combustion chamber for auxiliary fuel firing, which made by
water wall tubes. All the water walls of auxiliary combustion chamber and provided with
separate Risers and Distributors for water circulation and all the water circuit operate on
natural circulation principle.
The super heater tube bundles are located just on top of the radiation chamber and followed
by FAHNEN 1 and then by FAHNEN II (1ST and 2nd evaporative tube bundles )
respectively. The boiler system is provided with one number of steam drum, operating
pressure of 43 Kg.cm2g. Externally mounted boiler feed water preheater is provided to
preheat BFW to 1650C (coming out from gilled ring economizer) before entering onto
economizer to avoid acid dew point corrosion in the cold end of economizer tube bundle.
Saturated steam from steam drum is used as heating medium for BFW preheater & steam
condensate returns to the steam drum by gravity.
The boiler is provided with 12 numbers of retractable type soot blowers at different
elevation with 2nos of soot blowers at each plane. Additionally, two nos retractable type
soot blowers are provided in gilled economizer. The soot blowers are motor driven and
provided with automatic logic sequential control system.
CO BOILER INTERLOCKS:
1. CO gas cannot be admitted to CO furnace unless
A) CO furnace temperature is raised to 8500C

B) And guillotine damper on CO duct downstream of TPSV is on Open
position.
C) And guillotine damper on flue gas duct downstream of CO boiler is in Open
position.
ANNEXURES
Plant Name: FCCU-I
ANNEXURES
2. CO gas shall be bypassed on the following conditions:
A) Control power failure

B) Instrument air failure
C) CO furnace pressure very high i.e. at 600 mm WC (2 out of 3 redundancy)
D) Oxygen to CO furnace very low
E) Air for CO burners very low
F) ES 1 activation from FCCU I R
G) FD fans failure, with time delay of 15 seconds
H) Main flame failure of support burner
I) Manual trip push button
J) Emergency trip push button
K) BFW supply pressure very low
3. CO BOILER LOGIC RELATED TO FCCU I REVAMP
During FCCU I revamp shutdown on ES-1 activation CO boiler will not be tripped along
with FCCU I revamp.
TPSV opens to stack, inlet goggle valve will be closed along with TPSV diversion.
TPSV position indication is provided in the hardware annunciator panel either to CO to

stack or CO to CO boiler and also position indication provided in the PPII console.
DURING SWITCHING CO TO BOILER:
Inlet Goggle valve to be opened from Power Plant II panel. Once the inlet goggle valve
opened, then start permissive will come on the FCCU I R DCS for switching CO to CO
boiler
A reset push button is provided in MOI. It has to be reset before opening the CO to CO
boiler.
DESIGN BASIS AND OPERATING CASES OF CO-BOILER
CO-GAS PARAMETERS
Flue gas flow rate from regenerator:
Rated Maximum : 77673 Kgs/hr (design flow)

Normal : 64141 Kgs/hr
Minimum : 43725 Kgs/hr
ANNEXURES
Plant Name: FCCU-I
ANNEXURES
Composition (Vol.%)
(Wet Basis)
Range Design
CO2 12.75 -13.97 12.75

CO 1.75 – 8.00 3.49
N2 70.52 – 72.86 70.53
O2 0.01 – 0.05 0.01
H2O2 8.60 –12.3 12.83
SO2 0.39 – 0.48 0.39
Hydrocarbon in Flue gas from regenerator : Absent
Operating Pressure downstream : 1400 mm WC

Of regenerator stack slide valve
Temperature at exit of Regenerator : Minimum Flow = 5660 C

Normal flow = 6800 C
Maximum = 6770 C
Mechanical design = 9820 C
Catalyst Fines Carryover : 0.5 to 2.0 MT/day (average

particle Size below 20 microns)
GUARANTEE CONDITIONS
Design steam load (Gross) : 40000 Kgs/hr (On auxiliary firing

alone or on CO-combustion mode)
Steam outlet pressure from CO : 38.0 + 1.0 Kg/Sq.Cmg

Boiler at B/L : - 1.0 Kg/Sq.Cmg
Steam outlet temperature from : 3710C + 100C

CO-Boiler at B/L - 100C
CO content in CO-Boiler outlet : 200mg/Nm3 (maximum)

Flue gas
Efficiency of the boiler : Not less than 80% (on NCV basis)

ANNEXURES
Plant Name: FCCU-I
ANNEXURES

ANNEXURES

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PLANT OPERATING MANUAL

Chapter No: 1 Plant No. 04

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23 Sampling requirement and Sampling Procedures 447

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Rev. Validation Validation Validated By Designation Sign Remarks

Sl. PSI Ref. No. Title of Issued on Validity Remarks Comments by

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Sl. Identification no. Issued to Issued on (date)

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1. This Operating Manual is revised for the following:

Change in Operating practice in any part of the Plant.

2. The revision of the Operating Manual is done in two stages :

Managing changes (revisions) in the Operating Manual within 5 year cycle.

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2.1 DEVELOPMENT OF THE PROCESS

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2.2 FLUIDISED CATALYTIC CRACKING

2.2.1 ADVANTAGES OF FCC:

From the Operating point of view:

1) Heat evolved in the regeneration of the catalyst is efficiently used.

2.3 FUNCTION OF THE PLANT

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DESIGN OPERATING CONDITIONS

3.1 REACTOR-REGENERATOR DESIGN OPERATING CONDITIONS

3.2 FRACTIONATOR AND GCU DESIGN OPERATING CONDITIONS

FCCU-1 Operating Manual CHAPTER-3 Page 17 of 752

DESIGN OPERATING CONDITIONS

3.1 REACTOR-REGENERATOR SECTION

132.5 Sm3/hr 165.5Sm3/hr 132.5Sm3/hr

221 0C- conversion, WT%FF 68.2 61.6 51.9

Reactor Operating Conditions

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Regenerator Operating Conditions

Flue Gas Composition (Vol %), dry basis

FCCU-1 Operating Manual CHAPTER-3 Page 19 of 752

CASE FEED TYPE OPERATING MODE REMARKS

A) 20 KBSD Arab mix VGO in max. Distillate mode (Case ID)

No of stream hours per year: 8000

3.2 FRACTIONATOR & GCU SECTION DESIGN OPERATING CONDITIONS.

HCO Slurry Total feed to Combined feed

2D 118600 40412 9040 168052 1.42

IN 124300 0 7316 131616 1.06

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Feed Flow Normal ABS Inlet Outlet

Total Duty Total Flow Draw-Off Return

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NORMAL OPERATING PARAMETERS

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FGD Stack Emissions:

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The equipment will be designed to withstand the following continuous conditions:

Wind velocity: 150 km/hour maximum Snow loads: 0

Makeup water Consumption: 24.1 m³/hr

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