Uop NAPHTHA HYDROTREATING PROCESS (LIGHT NAPHTHA SYSTEM) GENERAL OPERATING MANUAL - LIMITED DISTRIBUTION - ‘This material is UOP LLC teshncal information of « coydewtal natwe for use nly by Pervonne! thin your organization requiring the information. ‘The material shall not be reproduced in any Tmunncr or diatbuted for an} purpose whatsoever excep by writen permission of UOP LLC and ‘except as authorized under agreements with UOP LLC. May 2001 Rev.2NAPHTHA HYDROTREATING PROCESS (LIGHT NAPHTHA SYSTEM) The information and suggestions presented in this manual are believed to be accurate and are based on our experience and the experience of others. However, the customer should determine the suitability of this material before adopting it in this unit. No part of this manual is to be deemed under any circumstances as a warranty, express or implied, by UOP to anyone, and UOP accepts no liability for any error, inaccuracy or omission. Moreover, the suggestions contained in this manual are not be construed as a license to operate under, or a recommendation to infringe, any existing patents, nor should they be confused with state, municipal or insurance requirements, or with national safety codes. The operating conditions mentioned within do not necessarily represent exact operating conditions or guarantees.UOP Naanhe Hycroreaing Process (ight Naphine System)~ Genet Operating Manuel Tobie of Coments UOP NAPHTHA HYDROTREATING PROCESS (Light Naphtha System) TABLE OF CONTENTS INTRODUCTION PROCESS PRINCIPLES A. Reaction Mechanisms B. Reaction Rates and Heats of Reaction C. Catalyst Properties PROCESS VARIABLES Reactor Pressure Reactor Temperature Feed Quality Hydrogen to Hydrocarbon Ratio Liquid Hourly Space Velocity Catalyst Protection, Aging, and Poisons ™moOD> PROCESS FLOW AND CONTROL Feed System Reactor Section Wash Water System Product Separator and Recycle Gas Compressor Section Stripper Column Section moop> PROCESS EQUIPMENT uop wanna Pee This intorotn fe contoontal Donat dstse fi eer. copy of use fe ay purpose unless you nave UO wien permission]{VOP Nephine Hycrotecing Process (Light Napa System) ~ Generel Operating Nora! ‘Tobie of Contents VI. COMMISSIONING ning Activities Clean and Service Utility System Check Unit Against Piping and Instrument Diagrams Inspection of Vessels Hydrostatic Testing Flushing of Lines Initial Run-in of Pumps and Drivers Instrument Checking Dry Out Fired Heaters Hot Oil System Running in Compressors Fin-Fan Heat Exchangers Initial cedures A. Preliminary ALT ITOMmMoOm> Vil. NORMAL STARTUP: Vil, NORMAL OPERATIONS A. Reactor Operations B. Product Separator C. Stripper D. —_Naphtha Splitter = Process Calculations A. B. Closed Flow Through Sampling (Liquid or Gas) C. Closed Flow Through to Flare Sampling Gas or LPG D. Samples for UOP Analysis E. _NHT Laboratory Test Schedule X. TROUBLESHOOTING XI. © NORMAL SHUTDOWN uop arte Pogez This iran fs conde Do rel ciclo Ko he Copy Ko we fay purpose ules you Fave UOP § wen ports,LUOP Naphina Myarresnng Process (Ligh Napa System) Ganerat Operating Nana ‘Table of Contents Xil. EMERGENCY PROCEDURES Cooling Failure (Water, Air, etc.) Loss of Recycle Gas A. Explosion, Fire or Line Rupture B. _ Leaking Valves or Vessels Cc. Power Failure D. Instrument Air Failure E. Heating Failure F. G. xi. rae PROCEDURES NHT Reactor Loading . Unloading of Unregenerated Catalyst Containing Iron Pyrites C. —_Hydrotreating Catalyst Regeneration D. Protection of Austenitic Stainless Stee! E. _Descaling of Hydrotreating Process Heater Tubes XIV. SAFETY A. Written Hazard Communications Program B, Training and Information C. Labels and Other Forms of Warning D. Material Safety Data Sheet (MSDS) XV. EQUIPMENT EVALUATION uop arin? Pages [Tis tomar confer Oo nt csciose We whore copy kr use Kia any purpose unless you ave UOP's ton pernien._]UOP Nanna Hyeraeating Process (ight Nephtha System) - General Operating Marual Introduction I. INTRODUCTION The UOP Naphtha Hydrotreating Process is a catalytic refining process employing a UOP hydrotreating catalyst and a hydrogen-rich gas stream to decompose ‘organic sulfur, oxygen and nitrogen compounds contained in the naphtha fraction. In addition, hydrotreating removes organo-metallic compounds and saturates olefinic compounds. ‘The Naphtha Hydrotreating Process is used to remove Penex catalyst poisons from light naphthas prior to charging to the Penex Process Unit. Typical hydrotreating catalysts used in the Naphtha Hydrotreating Process is composed of an alumina base impregnated with compounds of cobalt and molybdenum. The catalyst is insensitive to most poisons that affect dehydrogenatiorvisomerization reactions. A relatively high percentage of carbon on the catalyst does not materially affect its sensitivity or selectivity. Volumetric recoveries of products depend on the sulfur and olefin contents, but usually are 100% +2%. Commonly found organo-metallic compounds, such as arsenic, lead and silicon compounds, are known to be permanent poisons to platinum containing catalysts. The complete removal of these materials by hydrotreating processing gives longer catalyst life in the Penex Unit. Organic nitrogen and oxygenated compounds are permanent Penex catalyst poisons. Sulfur compounds are temporary poisons to the Penex catalyst; however, severe and frequent upsets may permanently deactivate the Penex catalyst. Sulfur is also used as a tracer compound as it is the easiest to remove and measure. Large amounts of olefins can polymerize at Penex operating conditions that can result in adsorbent bed, exchanger and reactor fouling. The Naphtha Hydrotreating Process makes a major contribution to the ease of operation and economy of Penex. Much greater flexibility is afforded in choice of allowable charge stocks to the Penex Unit. Because this unit protects the Penex catalyst, it is important to maintain consistently good operation in the Naphtha Hydrotreating Process Unit. op sartiee a Tis feat is conker Donat dios Ie ethers, copy i tee fray purpose wns you have UOPT wl peaseLVOP tops tcetreting Process (igh Nahtha System) Generel Operating Menu Invedection It can be seen that the primary function of the UOP Naphtha Hydrotreating Process can be characterized as a feed pretreatment operation. As such, the unit is critical to down stream unit operation. Figure |-1 presents a simplified flow scheme for the UOP Naphtha Hydrotreating Unit (for light naphtha). op seria 2 “This information is canfdenial. Do ot disclose ft others, copy or use It for eny purpose unless you have UOP's writen permission. |S) eset wop2atuy ome 2g z 2 oO 3 arise T ‘waBoupcH dnayey wDsABOUY MO}y 8s9201 payyduns dup, Burgwasgouphiry oyzydoNn JON Jor14RL T-1 ean g This efor is content Do rat dsciose Fe others copy ruse Tray purpose unas you have UOP switen parrisio [VOR Napnina Hyctareating Process (Light Napa System) ~ Genera! Overating Mensa!UOP Naphihe Hyeteaing Process (Ligh NaphiheSystam) - General Operating Manu! Process Principles Il. PROCESS PRINCIPLES A REACTION MECHANISMS: The main purpose of the Naphtha Hydrotreating Process Unit is to "clean-up" the light naphtha so that it is suitable as charge to the Penex Unit. The six basic types of reactions that occur in the Naphtha Hydrotreating Process Unit are as follows: Saturation of olefins Conversion of organic sulfur compounds to hydrogen sulfide Conversion of organic nitrogen compounds to ammonia Conversion of organic oxygen compounds to water Conversion of organic halides to hydrogen halides eee ene Removal of organo-metallic compounds. 1. Olefin Saturation Olefin saturation is almost as rapid as desulfurization and is highly exothermic. Most straight run naphthas contain only trace amounts of olefins, but cracked naphthas usually have high olefin concentrations. Processing high concentrations of olefins in a Naphtha Hydrotreating Unit must be approached with care because of the high exothermic heat of reaction associated with the saturation reaction. a. (Linear olefin) C-C-C-C=C-C + Hg ———* C-C-C-C-C-C C. oc b. (Cyclic olefin) { § + Hy ——> i Ne “¢ ¢ So uop sare o (is tent alte nt ioe io hr, nyo so ny Dns obs ohare UOPs we parison]LVOP Hephina Hyctresting Process (Light Naphita System) ~ General Operating Manuel Process Principles 2. ‘Sulfur Removal In general, sulfur removal in the hydrotreating process is relatively easy, and for the best operation of a Penex Process Unit, the hydrotreated light naphtha sulfur content should be maintained below 0.1 weight ppm. Minimizing sulfur in the stripper bottoms will increase the life of the Sulfur Guard Bed. Commercial operation at 0.1 weight ppm sulfur or less in the light hydrotreated naphtha is common. Typical sulfur removal reactions are shown below. a. (Mercaptan) C-C-C-C-C-C-SH +Hy ——> C-C-C-C-C-C-C+ HyS b. Gulfide) C-C-C-$.0-C-C+ 2H, ——> 2C-C-C+H,S c @isulfide) C-C-C-S-S-C-C-C + 3Hz ———> 20-C-C + 2H2S i c— ¢-c oa [g + 2g —> COE-CC+ HS Ng 7 e. (Thiophenic) gfe + at, copcos Hs Ng é It is possible, however, to operate at too high a temperature for maximum sulfur femoval. Recombination of hydrogen sulfide with small amounts of olefins or olefin intermediates can then result, producing mercaptans in the product. C-C-C-C=C-C + HgS ——* C-C-C-C-C-C-SH (Mercaptans) if this reaction is occurring, the reactor temperature must be lowered. Generally, operation at 315-340°C (600-644°F) reactor inlet temperature will give acceptable rates of the desired hydrogenation reactions and will not result in a significant vop sane wa |i iteration i content: Be not close i eter, copy house BTR any purpose ures you have UOPs writen periasion |'UOP NaphtaFycroteting Process (Light Nephtha Syston) Ganer! Operating Manual ‘Process Principles amount of olefin/hydrogen sulfide recombination. This temperature is dependent upon feedstock composition, operating pressure and LHSV. As the catalyst deactivates, it will be necessary to increase the reactor inlet temperature to achieve the same degree of sulfur removal The hydrogen sulfide generated through any of the above reactions is subsequently removed in Stripper Column as overhead offgas. Any remaining sulfur not removed by the hydrotreating reactors and stripper column will be removed by the sulfur guard bed prior to entering the Penex feed driers. 3. Nitrogen Removal Nitrogen removal is considerably more difficult than sulfur removal in naphtha hydrotreating. The rate of denitrification is only about one-fifth the rate of desulfurization. Most straight run naphthas contain much less nitrogen than sulfur, but attention must be given to ensure that the feed naphtha to a Penex catalyst contains a maximum of 0.1 weight ppm nitrogen. Cracked naphthas are expected to contain higher nitrogen levels. Any organic nitrogen that does enter the Penex will cause permanent catalyst poisoning and will decompose to ammonia and react with the chloride to form ammonium chloride. The ammonium chloride then deposits in the cold sections of the Penex Unit. These problems can be avoided or minimized by maximizing nitrogen removal in the Naphtha Hydrotreating Process Unit. The ammonia formed in the denitrification reactions, detailed below, is subsequently removed in the hydrotreater reactor effluent wash water. LN, a. (Pyridine) ¢ fi + 5Hy ——* C-C-C-C-C+ NH sy Ps Ss, ae co <¢ % Quinotiog a + 4H, —— op saris a This ifort 1 conde Do nt ecoee ie Gers, copy i use fray purpose urea you have UOP Ewen prison, JLUOP apna hyoreting Process (pt Naphve Sten Gael Operating Maral Proce Princes ee t c. (Pyrrole) i i + 4H, ——* C-C-C-C-C+ NHg Nye OC I NT c H HoH ra 4. Methylamine) H-G-N +Hp ——» CHy + NHg HOH 4. Oxygen Removal Organically combined oxygen, such as phenols, is removed in the Naphtha Hydrotreating Process Unit by hydrogenation of the carbon-hydroxyl bond, forming water and the corresponding aromatic molecule. The reaction is detailed below. t c-So Cy I I +H, ——> | I Keetay oe (Phenols) 5. Halide Removal Organic halides can be decomposed in the Naphtha Hydrotreating Process Unit to the corresponding hydrogen halide, which is either absorbed in the reactor effluent water wash or removed with the stripper overhead gas. Decomposition of organic halides is much more difficult than desulfurization. Maximum organic halide removal is thought to be about 90 percent, but is much less at operating conditions set for sulfur and nitrogen removal only. For this reason, periodic analysis of the hydrotreated (product) naphtha for organic chloride content should be made. A typical organic chloride decomposition reaction is shown below. C-C-C-C-C-C-Cl+ Hz ——* HCl+C-C-C-C-C-C uop serine ne This information is confidentol. De net disclose it to others, copy i or vse it fr sny purpose unless you have UOP's writen permission.)LUOP Naphina Hyroresing Process (iat Naprie System) - Genet Operaing Marva! Process Prcites 6. Metal Removal Most metallic impurities occur at the part per billion (ppb) level in naphthas. However, UOP hydrotreating catalysts are capable of removing these materials at fairly high concentrations, up to 5 weight ppm or more, on an intermittent basis at normal operating conditions. Most metallic impurities are permanently deposited on the catalyst when removed from the naphtha. The catalyst loses activity for sulfur removal as higher metal loadings are reached. Some commonly detected components found on used hydrotreating catalysts are arsenic, iron, calcium, magnesium, phosphorous, lead, silicon, copper, and sodium. Removal of metals from the feed normally occurs in plug flow with respect to the catalyst bed. Iron is found concentrated at the top of catalyst beds as iron sulfides. Arsenic, even though it is rarely found in excess of 1 weight ppb in light naphthas, is. of major importance because it is a potent platinum poison. Arsenic levels of 3 weight percent and higher have been detected on used hydrotreating catalysts that retain their activity for sulfur removal. Contamination of storage facilities by leaded gasolines and reprocessing of leaded gasolines in crude towers are the common sources of lead on used hydrotreating catalysts. Sodium, calcium and magnesium are apparently due to contact of the feed with salt water or additives. Improper use of additives to protect upstream fractionator overhead systems from corrosion or to control foaming account for the presence of phosphorus and silicon. Removal of metals is essentially complete above temperatures of 315°C (600°F) up to a total metal loading of about 2-3 weight percent on the catalyst. Above this level, the catalyst begins approaching the equilibrium saturation level rapidly, and some types of metal breakthrough are likely to occur. In this regard, mechanical problems inside the reactor, such as channeling, are especially bad since this results in a substantial overioad on a smalll portion of the catalyst in the reactor. Since these metals permanently destroy the catalyst's sulfur and nitrogen removal abilities, it will be progressively harder to remove these compounds. uep artis us Tis interno scorer Bo ot sce fa ater, copy Bo we a any purpose lees you have UOPS wien pomiason.—]LVOP Wahine yerarestng Process (Ligh Naphthe System) ~ Generel Operating Mana Process Pincles B. REACTION RATES AND HEATS OF REACTION ‘The approximate relative reaction rates for the three major reaction types are: Desulfurization 100 Olefin Saturation 80 Denitrification 20 The approximate heats of reaction (in kJ per kg of feed per cubic meter of hydrogen consumed) and relative heats of reaction are: Relative Heat of Reaction Heat of Reaction Desulfurization 8.1 1 Olefin Saturation 40.6 5 Denitrification 08 a As can be seen from the above values, desulfurization is the most rapid reaction taking place, but it is the saturation of olefins which generates the greatest amount of heat. As the feed sulfur level increases, the heat of reaction also increases. Conversion of organic chlorides and oxygenated compounds are approximately as difficult as denitrification. Consequently, more severe operating conditions must be used when these compounds are present. uop satin we This tortor is Conte Dp rot clon ito hers, copy Bo ue ho oy purpose nkess yu have UOP's wren permission]‘UOP Nahiha Hycroeating Process (ght Naphiha Syston) ~ General Operating Maru! Process Prnailes C. CATALYST PROPERTIES The following summarizes the physical properties of a typical UOP hydrotreating catalyst, S-12. UOP S-12 CATALYST PROPERTIES. Designator S12 Base Alumina Form Extrudate Size: mm (inch) 1.59 (1/16") ABD: kg/m? (Ibift3) 720.9 (45) Kg (ibyDrum 136 (300) Active Metals: Mo Co UOP S-12 CATALYST REGENERATION “Naphtha Hydrotreating Reactor Regeneration Inert Gas * Most refiners find it cheaper and more time effective to skim the top of the catalyst bed periodically to remove metals poisoned catalyst, replacing it with new hydrotreating catalyst. op variin2 “7 (Tis intormoton ts content. De not disclose tt others, copy h oF use i Tor any purpose unless you have UOP's writer permissionLUOP Nephi Hyeroeating Process (Light Naphthe System) ~ Generel Operating Manual Process Voriables Ill. PROCESS VARIABLES A. REACTOR PRESSURE The unit pressure is dependent on catalyst life required and feedstock properties. At higher reactor pressures, the catalyst is generally effective for a longer time and reactions are brought to a greater degree of completion. For light naphtha desulfurization, 45 to 55 kg/cm? (650-800 psig) reactor pressure is normally used. Higher operating pressures are sometimes necessary to completely remove organic halides. Halide contamination of naphtha is usually sporadic in occurrence and is normally due to contamination by crude oil well operators. The selection of the operating pressure is influenced to a degree by the hydrogen to feed ratio set in the design, since both of these parameters determine the hydrogen partial pressure in the reactor. The hydrogen partial pressure can be increased by operation at a higher ratio of gas to feed at the reactor inlet. The extent of substitution is limited by economic considerations. Most units have been designed so that the desulfurization and denitrification reactions go substantially to completion well below the design reactor temperature, for the design feedstock, Small variations in pressure or hydrogen gas rate in the unit will not cause changes great enough to be reflected by significant differences in product quality. B. REACTOR TEMPERATURE ‘Temperature has a significant effect in promoting hydrotreating reactions. Its effect, however, is slightly different for each of the reactions that occur. Desulfurization increases as temperature is raised. The desulfurization reaction begins to take place at temperatures as low as 230°C (446°F) with the rate of reaction increasing markedly with temperature. Above 340°C (64°F), there are only slight increases in further removal of sulfur compounds due to temperature. op rarite ws This eforratin i cant De ral dose lve cher ooy i ruse fr ony pune unless you have UOP wien permis, ]UOP Wapttha Hyroreatng Process (Ligh Nophtha Syston) ~ Genera! Operating Menuet Process Variables The decomposition of chloride compounds in low concentrations (<10 weight ppm) will require about the same temperature as the sulfur compounds decomposition. Olefin saturation behaves somewhat similarly to the desulfurization reaction with respect to temperature, except that olefin removal may level off at a higher temperature. Because this reaction is very exothermic, the olefin content of the feed must be monitored and controlled to keep reactor peak temperature within an acceptable temperature range. At very high temperatures, an apparent equilibrium condition limits the degree of olefin saturation. This may even cause the residual olefins in the product to be greater at higher temperatures than would be the case at lower operating temperatures. When processing @ naphtha with a significant amount of light ends over fresh catalyst, HS can react with these olefins to form mercaptans. In such a case, lowering the reactor temperature can eliminate residual olefins and thus mercaptan formation. Decomposition of oxygen and nitrogen compounds requires a somewhat higher temperature than desulfurization or olefin saturation, and the removal of these compounds does not appear to level off in the same way at elevated temperatures. Units with significant levels of nitrogen or oxygen must be designed for higher pressure and lower LHSV to ensure complete conversion. The demetallization reactions are not very dependent on temperature. Above 315°C (600°F), metals removal is essentially complete. Below this temperature, there may be some cases where all the metals will not be removed. The recommended minimum reactor inlet temperature to ensure a properly prepared Penex feed is 315°C (600°F). There are two factors which are important in determining this minimum temperature: first, below the minimum temperature, reaction rates for contaminant removal may be too low, and second, the temperature must be maintained high enough to ensure that the combined feed (recycle gas plus naphtha charge) to the charge heater is all vapor. uop varia he Thi etre contra. De rl scone fo thers oo) ruse Tr any upese unless you ave UF's wen partesUOP Haptthe Hycrarwatig Process (Ligh Nophtna Syston) ~ Genel Operating Manca! Process Vorabies As the catalyst ages, the product quality may degenerate, which may be corrected by increasing reactor inlet temperature. If increasing the temperature does not improve the product quality, a regeneration or change of catalyst will be required, depending on the history of the operation and catalyst condition. In most cases, replacing the dead catalyst in the top portion of the bed with new catalyst is sufficient. C. FEED QUALITY For normal operation, daily changes in reactor inlet temperature to accommodate changes in feed quality should not be necessary. However, in some cases, such as processing crudes from widely different sources, the naphtha quality may change significantly, and adjustment of reactor inlet temperatures may be necessary. D. HYDROGEN TO HYDROCARBON RATIO. The minimum hydrogen to feed volume ratio is dependent on hydrogen consumption, feed characteristics, and desired product quality. For light naphthas of moderate sulfur content, hydrogen to feed ratios of 150-185 Nm#m3 (900-1100 SCFB) at 315-370°C (600-700°F) are typical. As feedstocks vary, the hydrogen to feed ratio is proportioned between the extremes. Ratios above 3000 SCFB do not contribute to the rate of reactions. The use of low purity hydrogen as makeup gas is limited by economical operation of the recycle compressor. Recycle gas with hydrogen sulfide contents up to 10% and with large quantities of carbon monoxide and nitrogen are not harmful to the catalyst when reasonable desulfurization is the only concem. For nitrogen removal or complete sulfur removal, high hydrogen purity (80% minimum) is necessary. The prevention of excessive carbon accumulation on the catalyst requires maintenance of a minimum hydrogen partial pressure, so impurities present in the makeup gas require higher operating pressures. vop nari ha “his rloatio scone. Dart dace to char, copy Wer we Kor by purpose vrless you have UOP's wren parmitinVOR nephina Hrcreveatig Process (Light Napa Syston) General Operating Manvo! Process Variables Lower hydrogen to hydrocarbon ratios can be compensated for by increasing the reactor inlet temperature. The approximate relation for these variables is 10°C (18°F) higher reactor inlet temperature requirement for a halving of the hydrogen to feed ratio. This rule assumes operation above the minimum values of 315°C (600°F) reactor inlet temperature and 40 Nm®/m? (240 SCFB) hydrogen ratio. This relation is approximate, and it should again be pointed out that the product quality ‘should dictate the actual reactor temperature utilized. E. LIQUID HOURLY SPACE VELOCITY The quantity of catalyst per unit of feed will depend upon feedstock properties, operating conditions, and product quality required. The liquid hourly space velocity (LHSV) is defined as follows: =Nolume of chargeperhour |, lid volume of catalyst" With most charge stocks and product objectives, a simplified kinetic expression based on sulfur and/or nitragen removal determines the initial liquid hourly space velocity. This initial value may be modified due to other considerations, such as size of unit, extended first cycle catalyst service, abnormal levels of feed metals and requirements of other processing units in the refinery flow scheme. Relative ease of conversion for hydrotreating catalysts indicate that sulfur compounds react most easily, olefins next, then nitrogen and oxygen compounds. There is considerable overlap with several reactions occurring simultaneously and to different degrees. Charge stock variability is so large that only approximate ranges of space velocities can be indicated for the various feed types. Light naphtha is processed at 4-12 LHSv, FL CATALYST PROTECTION, AGING, AND POISONS Catalyst deactivation is measured by the decrease in relative effectiveness of the catalyst at fixed processing conditions after a period of catalyst use. The primary op waren ma This ifort is content De rat dacone io Othe, apy fo uae 11S ony purpose unless you have JOP wie ]LVOP Naphiha Hyckeveating Process Ligh Nephihe System) General Operting Manual Process Variables causes of catalyst deactivation are: 1) chemical combination of contaminants from the feedstock with the catalyst components, 2) accumulation of coke on the active sites, and 3) olefin polymer accumulation on catalyst active sites. In normal operation, a carbon level above 5 wt-% may be tolerated without a significant decrease in desulfurization although nitrogen removal ability may be decreased. The process variables employed affect the catalyst life by their effect on the rate of carbon deposition on the catalyst. There is a moderate buildup of carbon on the catalyst during the initial days of operation, but the rate of increase in carbon level soon drops to a very low figure under normal processing conditions. Desirable control of the carbon-forming reactions is obtained by maintaining the proper hydrogen to hydrocarbon ratio and by keeping the catalyst temperature at the proper level. Normal catalyst temperature is a minor factor in respect to the hydrotreating catalyst life. A higher catalyst temperature increases the rate of the carbon-forming reactions somewhat, with other factors being equal. It must be remembered that a combination of high catalyst temperatures and inadequate hydrogen is very injurious to the catalyst activity. Permanent loss of activity requiring catalyst replacement is usually caused by the gradual accumulation of inorganic species picked up from the charge stock, makeup hydrogen or effluent wash water. Examples of such contaminants are arsenic, lead, calcium, sodium, silicon, and phosphorus. Low concentrations of these species, in ppm and/or ppb, will cause deactivation over a long period of service because buildup of deposits depends on the integrated effect of both temperature and time. This effect is important in light naphtha processing for Penex feed. S-12 catalyst exhibits a high tolerance for metals such as arsenic and lead. Total metals content as high as 2 to 3 wt-% of the catalyst have been observed with the catalyst still effective. However, if the calculated metals content of the catalyst is 0.5 wt-%, the frequency of product analyses should be increased to prevent metal breakthrough to the Penex catalyst. Organic lead compounds are decomposed by hydrotreating catalysts and for the most part deposit in the upper portion of the catalyst bed as lead sulfide. Metals are not removed from the catalyst during a uop rartite ms This nfometon confer, De nt aco lo ater, copy fo ws Ror ey purpose unless you have UP wll parraseo,LVOP Nephina Hyoresting Process (Light Nap System) ~ General Operating Manuel Process Variables regeneration. When the total metals content of the catalyst starts to approach 1 to 2 wt-%, consideration should be given to replacing the catalyst. The only certain method of minimizing the effect of trace metal contaminants on the catalyst is to limit their entry to the system. This is done by careful, conscientious feed analysis and correcting the source of, or conditions, causing the presence of the metal contaminant. An excellent example is excessive use of corrosion or antifoaming chemicals in upstream units. These could contain metal contaminants. Dissolved oxygen, though not a catalyst poison, should be eliminated from the feed. With oxygen in the feed, excessive fouling of equipment, particularly the feed- effluent exchangers, can occur. The same is true for water. The feed will be saturated with water that does not pose a problem. However, if free water enters the unit it could cause corrosion, leaks and fouling problems. Apparent catalyst deactivation may be caused by the accumulation of scale and polymer deposits on top of the catalyst bed. This results in increasing reactor pressure drop, the flow pattem through the balance of the bed is disturbed, and Product quality is diminished. This condition is remedied by hot hydrogen stripping, skimming a portion of the catalyst, screening and reloading, or replacing with fresh catalyst. This scale deposit is generally iron sulfide. uop arin me This hiorietn i contort De rol disses 110 eer. copy oF use Wa ay pupose ures you have UOP's wien permiasionLUOP tape Hytrreating Process (ight Nephina Syston) General Operating Menual Process Flow and Control . PROCESS FLOW AND CONTROL This section will present a description of each major piece of equipment, its function in the process and its place in the process flow. Details relating to operation will be discussed in another section. A FEED SYSTEM The first vessel in the Naphtha Hydrotreating Process Unit is the Feed Surge Drum. The Feed Surge Drum pressure is controlled by a split range controller. On a low pressure signal, fuel gas will be added to the drum by opening the upstream gas control valve. On a high pressure signal, the vent line control valve opens to vent ‘excess gas to the flare system. At steady state conditions both valves would normally be closed. Some units are designed for unsaturated feed coming from a blanketed storage tank or directly from other units. It is very important that the storage tank be properly nitrogen gas blanketed to prevent oxygen from being dissolved in the naphtha, Even trace quantities of oxygen and/or olefin in the feed can cause polymerization of olefins in the storage tank when stored for long periods, or in the combined feed exchangers. This results in fouling and a loss of heat transfer efficiency and polymer formation on the catalyst in the diene saturation reactor. In units that have a pre-fractionation section, light naphtha flow from the Feed Surge Drum enters the Naphtha Splitter Charge Pumps where feed is sent to the Naphtha Splitter Feed/Bottoms Exchanger on to the Naphtha Splitter. In units that do not have a pre-fractionation section, light naphtha flows directly from the Feed Surge Drum to the Charge Pumps through the Combined Feed Exchanger to the Charge Heater. op waren ms This infermation is confidential. Do nol Gisclose to others, Copy i. oF use h for any purpose unless you have UOP's nalten pemvesion.—__]LUOP Naphtna Hychotesing Process (Ugh Nephtha System) ~ General Operating Manual Process Flow and Conta! Naphtha Splitter Section The Naphtha Splitter column separates light naphtha from heavy naphtha, The bottoms are reboiled, usually with MP steam to provide the heat necessary for vaporization of naphtha so that sufficient reflux can be maintained. Bottoms product are sent to other parts of the refinery for further processing. The overhead product from the Naphtha Splitter Receiver enters the Charge Pumps. At the suction of the Charge Pumps, there is a connection for sulfide addition that is used to depress catalyst activity during initial startup or if the sulfur in the reactor feed is less than 15 wppm. There is a minimum flow spillback on the Charge Pump discharge to protect the pump from damage. The Charge Pump discharge flow is directed to the Combined Feed Exchanger. The flow to the reactor is set by a Flow Indicating Controller. Low flow will shut the feed inlet control valve to prevent depressuring of the unit. Recycle gas from the recycle compressor mixes with the naphtha and enters the Combined Feed Exchanger which uses the reactor effluent for heating the feed and hydrogen. The feed and hydrogen exit the Combined Feed Exchanger and enters the Charge Heater. An automatic temperature control system is used to maintain the reactor inlet temperature by adjusting the gas flow to the bumer to control the Charge Heater outlet temperature. B. REACTOR SECTION The recycle gas and feed enter the Combined Feed Exchanger which is heated using reactor effluent. For low temperature operation and for unit startup, the outlet temperature of the Combined Feed Exchanger is controlled by a hand instrument controller when operating the reactor at low temperature. The feed and hydrogen exit from the Combined Feed Exchanger and enter the Charge Heater where the stream temperature is raised to the desired reactor inlet temperature. A temperature instrument controller at the Charge Heater effluent controls the gas flow rate to the bumer. uop warine we [ ‘This font is confidante De ro tose Ye eer, copy 07s Re ay pupose wees you have UOP’s wien permizaon.LUOP naptina Hyrereatng Process Li Nephne Syste) ~ Generel Operating Manat Process Flow and Catrol The Charge Heater effluent enters the reactor and flows down through the catalyst bed. Typically, there is a temperature recorder at the reactor outlet to wam against high reactor outlet and delta temperatures. Differential pressure controllers are usually installed to monitor pressure drop as scale, polymerized material, and coke plug up the reactor. Recycle gas purge is used at both the low and high pressure points to prevent hot hydrocarbons and scale from moving into the transmitter impulse lines. Typically, the Naphtha Hydrotreating Reactor Charge Heater will shut down automatically when the recycle gas going to the reactor registers low flow, when the fresh feed flow rate is too low, when the pilot (fuel) gas pressure drops below the minimum setpoint, or when the emergency shutdown switch is activated. . WASH WATER SYSTEM Wash water injection points can be located in the reactor effluent line at three different locations. The first two are at the Combined Feed Exchanger inlet and outlet. The third point is just upstream of the Products Condenser fin-fan bundle. The wash water is used to wash away any ammonium chloride salts and to dilute any hydrogen chloride that might be present. The reactor effluent along with the injected water flows into the Reactor Product Condenser fin-fan and from there into the Product Separator. The Product Separator is provided with a water boot to collect the injected water. The wash water injection pumps inject enough fresh water to the system to prevent salt buildup. Excess water is pressured out of the Product Separator water boot into the sour water heater via interface level controller. The wash water injection pump receives its cold condensate from a wash water tank. Level control allows fresh makeup condensate to come into the tank and maintain the level. uop arin ws L Tis infornaon is confer, Do nel isco Kio wbvers copy I orate Ke wy Rapose ues you have UOP's water permission.)‘UOP Nata Hycroveating Proce (ph NaphihaSystom) ~ General Operating Menust Process Fow and Contd D. PRODUCT SEPARATOR AND RECYCLE GAS COMPRESSOR SECTION The Separator and the Recycle Gas Compressor section separates the reactor effluent into unstripped liquid product and hydrogen-rich recycle gas. The Separator pressure is controlled by regulating the makeup hydrogen flow rate. The equipment in this section are: the Reactor Product Condenser, the Product Separator, the Recycle Gas Compressor, and if required, the Makeup Gas Compressor. The reactor circuit pressure is controlled at the product separator by pressure indicating control. This controls the makeup flow of hydrogen gas into the unit allowing enough hydrogen to replenish that which was consumed by the reaction and to keep pressure constant. The makeup hydrogen is added to the unit upstream of the Product Condenser fin-fans. There is a hand-control valve on the gas effluent line from the Product Separator that is normally closed. It can be used for emergency unit depressuring to the flare. High Pressure NHT Unit (Makeup Gas and Recycle Gas Compressors) Reactor effluent exits the reactor section and is partially condensed in the Reactor Product Condenser. It cools the effluent to approximately 60°C (140°F). The cooled liquid and gas then proceed to the Product Separator where they can be separated, Hp leaves the top of the Product Separator and is routed to the Recycle Gas Compressor Suction Drum and on through to the Recycle Gas Compressor, where the gas is recycled back to the Reactor. The Makeup Gas Compressor Suction Drum PIC and the Product Separator PIC float on a low-signal selector (LSS) signal on the Makeup Gas Compressor spillback control valve. A lower signal on the Makeup Gas Compressor Suction Drum opens the spillback control valve, thereby sending more gas to the suction of the Makeup Gas Compressor. A lower signal on the Product Separator closes the spillback, thereby sending more makeup gas forward to the Product Separator (See Figure IV-1). uop varie vs "Tris formation is coder. Do net Ascse tocar. copy House lean purpone unless yay have UOP's writen parmaLUOP Naphina Hycoestng Process (oh Napa Systm) Genera! Overating Marval Procees Flow ard Cont! NHT Unit with Recycle Gas In this type of configuration, the Product Separator PIC is controlled by the amount of makeup He entering the unit. When the pressure increases above setpoint, the makeup H, control valve closes, not allowing fresh H2 to enter the unit. When the pressure decreases below setpoint, the makeup H2 control valve opens to allow fresh H; to enter the unit. This configuration is depicted in Figure IV-2. NHT Unit with Once-Through Gas Figure IV-3 represents the NHT Unit in once-through mode. The pressure in the unit is controlled by the amount of gas vented from the Separator. As the pressure increases (or decreases), the vent valve opens (or closes) accordingly to help maintain setpoint value. E. STRIPPER COLUMN SECTION The purpose of the Stripper is to remove hydrogen, light gases, water and contaminant by-products (such as hydrogen sulfide) from the naphtha before it is routed to the Penex Unit. The feed to this column is first preheated in the Stripper Feed/Bottoms Exchanger before entering the Stripper. The stripper reboiler exchanger is provided to supply the required heat input for generating vapors that accomplish the stripping of the naphtha hydrotreated liquid product. The naphtha in the bottom of the tower is sent to the reboller exchanger. Steam is used to heat the shell side of the reboiler exchanger and is controlled on the outlet of the exchanger by flow control. The steam flow is adjusted to obtain the required bottoms temperature on the Stripper Column. vop nama ns This iiornaion fe contort Da nt eacose Bo ahr copy ruse fe ay Buose ives you have UO writen pemisson.'UOP Nephths Hycrotaating Process (Light Noptihe System) — Genera! Operating Manus! Process Flow and Coir Stripper vapors pass overhead to the Stripper Overhead fin-fan condenser and then are routed to the overhead condenser trim cooler and then to the Stripper Column Overhead Receiver. The liquid from the overhead receiver is refluxed back into the column by pumps. The reflux is pumped to the top tray of the Stripper Column. To increase the amount of reflux, the reboiler heat input must be increased to provide more overhead material and reflux. The net overhead gas leaves the receiver on Pressure control to the gas concentration unit. The Stripper Column design pressure is typically 13 kg/cm? (185 psig). The Stripper Column bottom liquid is pressured on level control to the tube side of the Stripper/Feed Bottoms Exchanger and then flows either to storage or the 'somerization Unit. The level control valve for the Stripper Column bottom liquid flow is typically located on the outlet of the Stripper Bottoms/Feed Exchanger. Figure |V-4 depicts a typical NHT unit's stripping section. The Naphtha Hydrotreating Process Unit product must meet the following ‘specifications to be acceptable as Penex feed with the associated targets: Maximum Target Total Suttur, wt-ppm 05 <0.1 Total Nitrogen, wt-ppm 05 <0.4 “Total Oxygenates wt-ppb Nil Nil “Lead, weppb 10 Nil “Arsenic, wt-ppb 1 Nil “Copper, wt-ppb 20 Nil “Fluoride, wt-ppm <0.5 Nil Other Metals: Iron, Sodium Nit Nil “Lower limit of delectability for each species analyzed uop rata we This eforeton scant Do no icone Ghee iby fo use fr By Brpose ries you have UO witenperriesion, —]wazcoe HN wr Process Flow and Contra! sapray 24 woy ty dnayen saree PE peamas zasuapuioy }IAPOLA soyoeay worg Tis ilormaton is corbertal_ Do rot toe Ro ahers py Bo we Mfr ay purpose ules you have UP Rte permaen | LumsBOI MOpy 889904 Poygy dung aanssadg YOIH up Buywasjospiyy vygydon JON g FAL nb UOP Napha Hyrteating Process (Light Naphha System) - Gener Operating ManualVOP Naha Hydrorestng Process Ligh Nophna Syston) — General Operating Menval Process Flow and Con! FIGURE IV-2 TYPICAL NAPHTHA HYDROTREATING UNIT REACTOR SECTION WITH RECYCLE GAS RECYCLE GAS COMPRESSOR vop write we This toate coe Dot Asc eer, copy BF we HI any pupae wets you have UOP's wll parenLUOP Noni Hycrotreatng Process (Ligh Neptthe System) ~ Gener! Operating Marva! Process Flow and Contes FIGURE IV-3 TYPICAL NAPHTHA HYDROTREATING UNIT REACTOR SECTION WITH ONCE-THROUGH GAS ‘once TwmouaH VENT cas ‘ronoaee uop sariine ws This erin cei Do a be a PTE apy. ear any pups wits ya hove UGE wt porno]'VOP Napnina Hyerorestng Process (Ligh Nophtha System) General Operating Manus! ‘Process Fow and Conte FIGURE IV-4 TYPICAL NAPHTHA HYDROTREATING UNIT STRIPPING SECTION uop nani 10 C Tis inloratn ie conker Go nk oes Fis atbers: copy use Wfr any purpose wrlers you hove UOP's wren pornsLUOE viaprena My crareatng Process (lg Napa Systm) - Genel Operating Manual Process Equpmont V. PROCESS EQUIPMENT This section will present a short description of some of the major pieces of equipment in the Naphtha Hydrotreating Unit (Light Naphtha System). Details regarding the process flow and control were covered in Section IV. FEED SURGE DRUM The function of the Feed Surge Drum is to provide a surge capacity for the NHT Unit. This vessel is constructed of killed carbon steel. NAPHTHA SPLITTER The purpose of the Naphtha Splitter is to separate light naphtha from heavy naphtha. This vessel is constructed of killed carbon steel. The diameter of the tower is the same at the top and at the bottom. Feed enters the column through an inlet pipe distributor located approximately 1/3 of the way from the top. Reflux enters the column through a similar inlet pipe distributor directly above the first tray. REACTOR CHARGE HEATER The Reactor Charge Heater raises the temperature of the combined feed from approximately 290°C to 342°C. The process stream entering the Charge Heater must be in the vapor phase to avoid damage to the tubes. Typically, the heater is of the radiant-convective type with a firing zone. It is a cylindrical updraft type having vertical tubes in the radiant section and horizontal tubes in the convection section. uop warning va I This itoring conte. Do not actos Fo others copy i ruse For ay purpose unas you Nave UOP's wlan permiven |{UOP Nagitha Hycrreating Process (Light Naphtne System) — Generel Operating Marval Process Eouoment REACTOR The NHT Reactor contains the UOP hydrotreating catalyst. The Reactor vessel is constructed of Cr-Mo metallurgy. The internal is lined with A-240, Type 405 or 410 alloy lining. The process stream, which consists of a feed / Hz mixture, enters the reactor vessel top through inlet basket distributors and leaves at the bottom. The distributor baskets, consisting of cylindrical slotted tubes are arranged in concentric circular arrangement{s) directly on top of the catalyst bed. The bottom head of the Reactor has a screen basket that allows the process stream to pass through it, but prevents catalyst or ceramic support material from migrating into the unit. There are catalyst unloading nozzles located in the bottom head. The nozzles extend through the catalyst support material to allow catalyst removal without disturbing the support material. The nozzles are blind-flanged during normal operation. The bottom head of the Reactor is first filled with 19 mm (3/4") ceramic support material to a level 150 mm (6") above the top of the outlet basket. Next, a layer of 6 mm (1/4") and a layer of 3 mm (1/8") ceramic support balls are placed directly on top of the 19 mm (3/4") ceramic support material as shown in the UOP Project Specifications. After loading of the catalyst, ceramic support material are also placed as hold-down material directly on top of the catalyst. First, 100 mm (4") of 3 mm (1/8") ceramic support balls are placed on top of the catalyst bed. Next, a 100 mm (4") layer of 6 mm (1/4") ceramic support material were placed on top of the 3 mm (1/8") balls. Finally, a 100 mm (4") of 19 mm (3/4") ceramic balls are placed on top of the 6 mm (1/4”) ceramic balls. Refer to the loading diagram as depicted in the UOP Project Specifications. PRODUCT SEPARATOR The Product Separator is a horizontal vessel made of killed carbon steel. The bottom half is lined with a 3 mm layer of monel weld overtay. A vertical monel wire mesh blanket coalescer is provided in the Separator to ensure complete separation of gas, hydrocarbon liquid and HO. The mesh blanket is tied with monel wires to the support ring that is welded to the internal of the Separator. vop varie ve C This ornate ororial De not cose Ifo Ghar, Cony or v8 Ko ty BU Wess youhave UDP’ win perrissonLVOP Haptine Hydrtrecting Process (Ligh Net Syste) — General Operating Manual Process Eguloment STRIPPER COLUMN The purpose of the Stripper is to remove HzO, H2S, Hz and light hydrocarbons from the product stream. The bottoms stream contains normal and iso-paraffins and is sent to the Penex Unit for isomerization. The vessel is made of killed carbon steel with multiple trays. The top half of the Stripper column is narrower than the bottom half due to lower volumes of liquid and vapor in the top section of the column. Feed usually enters the column through a pipe distributor located at the bottom of the conical section of the column, Reflux enters the column through a similar inlet pipe distributor directly above the first tray. HEAT EXCHANGERS Combined Feed Exchanger Feed from the Feed Surge Drum and recycle Hz from the Recycle Gas Compressor(s) enter the Combined Feed Exchanger on the tube side. The combined feed is heated up with reactor effiuent on the tube side. This exchanger is of the shell and tube type and allows heat transfer from the hot reactor effluent to the incoming combined feed to the Reactor Charge Heater. ‘Stripper Feed/Bottoms Heat Exchanger Liquid from the Separator is pressured from the Separator to the shell side of the Stripper Feed/Bottoms Heat Exchanger. This exchanger is of the shell and tube type and allows heat transfer from the hot Stripper bottoms to the incoming feed to ‘the Stripper. Stripper Reboiler Stripper bottoms is usually reboiled with medium-pressure steam to generate vapors to strip the hydrotreated liquid naphtha product. Steam is used to heat the shell side of the reboiler exchanger. op sarin vs This information is confidential. Do not disclose io overs. copy hor use ifr any purpose iniess you have UOP's writen permusson |LUOP Nephi Hychareating Process (ight Necha System) ~ Gone! Operating Marui Process Equpment FIN-FAN HEAT EXCHANGERS An air fin-fan exchanger consists of a fan with one or more heat transfer sections mounted horizontally on a frame. The heat transfer sections consist of finned tubes fixed between header boxes. Allowance for thermal expansion of the tubes is accomplished by anchoring only one header box and permitting the other end to move. A fan that is mounted above the tubes is called an induced draft fan because air must be drawn (induced) past the tubes. A fan mounted below the fans is known as a forced draft fan because air must be blown (forced) past the tubes. PUMPS: Centrifugal pumps are used for several applications in the NHT Unit. They are used for the Charge Pumps and Reflux Pumps for the Stripper. Proportionating pumps are used for the wash water injection pumps, for the caustic injection pumps, for the regeneration water return pumps and for the sulfiding pumps. Pumps used in hydrocarbon service use pressurized dual seals with API 52 seal plans. In this application, the seal oil circulation is established by way of a siphon. The seal oil is contained in a reservoir where it can be pumped to and from the Pump seal. The oil is continuously pumped between the two seals. In the event of a seal failure, the hydrocarbon will leak into the oil system and cause a pressure increase in the reservoir. The seal oll reservoir is normally equipped with a pressure alarm and pressure gauge to alert the operator to a seal failure. The reservoir is usually vented to flare through an orifice plate. uop arte ve “This information is confidential. Do not disclose i others, copy for uve it for ery purpose onioess you have UOP's writen periasion. |‘UO NaphiaHyaeteating Process (Light Naohina Syiem) ~ Generel Operating Masa! Process Equipment COMPRESSOR SUCTION DRUMS. Compressor Suction Drums are vertical vessels made of killed carbon steel. The purpose of a compressor suction drum is to knock out any liquid entrained in the gas prior to entering the compressor. A monel wire mesh blanket in the top of the drum coalesces and removes any entrained liquid droplets before the gas enters the compressor. The Recycle Gas Compressor Suction Drum is equipped with two trays and connections for HO / caustic addition and pressure control. These features are to be used for CO, and SO; removal during catalyst regenerations. During normal operations, condensed liquid from this drum is routed to the Stripper on a batch basis, Condensed liquid in the Makeup Gas Compressor Suction Drum is routed to the Stripper Receiver offgas on a batch basis. RECYCLE GAS COMPRESSORS There are normally two Recycle Gas Compressors. These are typically single stage, lubricated, cylinder type reciprocating compressors, each capable of 50- 100% of the design recycle gas flow. The gas is routed from the discharge of the compressor back to the front end of the reactor circuit to mix with fresh feed going to the Combined Feed Exchanger. MAKEUP GAS COMPRESSORS There are normally two Makeup Gas Compressors. These are similar to the Recycle Gas Compressors. They are also typically single stage, lubricated, cylinder type reciprocating compressors, each capable of 50-100% of the design recycle gas flow. The gas is routed from the discharge of the compressor to mix with reactor effluent going to the Product Condenser. op varie vs This hiernater i contderial Do nt dectose fo hers Copy fo uae et ay purpose unless you have UGP's wien personLUOP Naphina Hycoteating Procots (Light Naghihs System) Goneral Operating Meruat Commissioning Vi. COMMISSIONING The following section will discuss the various aspects associated with the ‘commissioning of the NHT Unit. The section contains information about the precommissioning and initial startup of the unit. The precommissioning procedures ensure that the unit is safe, operable, and constructed as specified by thorough inspection and testing. The initial startup subsection includes guidelines for vessel loadings, unit dryout, and other procedures used for commissioning the unit. PREC\ ISSIONING ACTIVITHI During the final stages of construction and on completion of construction, there is a large amount of detailed preparatory work that should be done by operating personnel in cooperation with others at the job site. The primary purpose of this work is to acquaint the operators with the equipment, to inspect the equipment to make certain the construction was done exactly as shown on the piping and instrument diagrams, to insure the equipment is free of debris and construction trash, to “run in” pumps and drivers, and to commission all utilities and supporting facilities so these will be ready for the startup of the process equipment. This subsection covers the work required in preparing the unit for operation. This work (such as testing and cleaning), is generally carried out during final stages of construction and on the whole, is generally carried out only once; however, it may be necessary to repeat some procedures after major turnarounds. Careful and thorough preparation is a requisite for satisfactory performance and will eliminate much trouble and delays during the startup. An outline is presented for a general method of cleaning and flushing lines and equipment. The outline for checking pumps, after installation and prior to operation, is applicable on all startups. Much of the work noted in this section is performed by construction personnel. No attempt is made herein to designate the personnel performing this preparatory work. There are some phases of the preparation, such as run-in of pumps during water circulation for line cleaning, which are best completed by the refiners operating Personnel. Much valuable experience can be obtained in this manner. i) varies ver Thin infometon is confident, Do pl dase ito oer, copy 7 u8e Kk” ay purzose ues you have JOE wien permisscn.LUOP naphtha Hyctareaing Process (Light Naphtha Syste) - Ganerat Operating Manual Commssinng A. CLEAN AND SERVICE UTILITY SYSTEM For ease of operation the utility system should be put into service as soon as possible. The various lines must be tested for leakage and washed free of debris and constriction trash. Steam lines should be warmed up slowly to prevent damage by water hammer. All steam traps and control valves in the system are to be placed in service for purposes of testing. Likewise the control system for air, water and fuel gas should be tested for operability. B. CHECK UNIT AGAINST PIPING AND INSTRUMENT DIAGRAMS Following construction it is necessary that a careful inspection be made of the equipment to ascertain that the construction was performed exactly as indicated on the piping and instrument diagrams. This can best be accomplished by covering every line and every notation with print marking pencils as the check is made. Particular attention should be paid to the details where errors in construction are most likely to occur. Any deviations from design are to be brought to the attention of those concemed for special consideration. C. INSPECTION OF VESSELS Before all vessels are closed and final bolting of manways done, they should be inspected for completeness and cleanliness. A suggested general check list follows: 1, Make sure the tray installation is complete and that all inspection plates where used are in place. If perforated trays or sieve trays are used, verify that all openings are clear. If side-to-side draw type are used with trap trays, make sure these are clear and properly installed. Test where required. op wanite we C Ths worraton i covfdorial, Dot dsclose Ko thers, copy Kran fe ay purpobe unless you have OP's wit perroLVOP HapheneHydreateg Process (ight Nop Systm) General Operating Manual Canmssining D Make sure all internal distributors for all of the towers are installed as the design case specifies. Verify that the openings and the sizings of the distributors are as specified. Where internal drawoff piping is installed off the bottom of the towers or vessels, make sure that these installations are as specified. Verify the location and length of all the thermowells. Determine that the location and range of level instrument intemal floats, extemal type displacement tube cages or differential pressure type nozzles are as specified. Verify that all orifice plates are available to be installed in their proper locations and are properly sized. Prior to hydrostatic testing, make sure that all lead lines to and from orifice tap flanges are shut off. HYDROSTATIC TESTING Hydrostatic tests are made on new or repaired equipment to prove strength of materials and welds. This test is made by completely water filling the equipment to be tested and increasing the pressure to the specified pressure. Normally, a portable positive displacement pump will be used to raise the pressure. This test should not be confused with other less severe tests generally carried out before a startup to check tightness of connections. The hydrostatic testing is ordinarily done by construction personnel. if for any reason it should become necessary for the operators to carry out such a test, the specified hydrostatic test pressure is normally 1.5 times design operating pressure. Equipment to be tested is generally divided into groups of simitar test pressures and isolated from other sections by installing suitable blinds. Screens should be placed in the suction lines of all pumps before any liquid is allowed to pass through them from newly constructed lines. If this is not done, scale, weld metal or slag, stones, etc., may freeze or damage the impellers of uUop sarsnt ws Ths maton ts Conteris lo Oar op) ruse Hor ay purpase unless you have UOP's wit permissionLVOP Nophina Hydrresting Process (ight Naphiha System) ~ General Operating Menuet Commissioning the centrifugal pumps. The screens also act to trap such dirt in a location where it can be conveniently removed. Screens should be placed in a flange between the suction valve and the pump so that the screen may be removed without depressuring any vessels. The flow through the screen should preferably be downward or horizontal. Precautions should be taken to place screens in a location where the dirt particles will not drop into an inaccessible place in the line when the flow through the pump stops. If this should happen, it would not be possible to remove the dirt upon removal of its screen. An air pressure test can be placed on the sections of the unit prior to a water test so that any open lines or flanges discovered and taken care of before liquid is admitted. However, a water hydrostatic test is considered necessary for final testing and the location of all leaks. It should be remembered that in pressure testing all vessels and towers, the test gauge should be placed at the bottom of the vessel so that the liquid head will be taken into account. Before introducing water into a tower vessel, vents should be opened. After the test, reduce the pressure developed during the hydrostatic test very slowly. ‘Some further suggestions which should be followed prior to and during the hydrostatic test period are as follows: a. Relief valves or rupture discs must be removed, blinded or gagged. b. All items under test must be liquid filled and all air vented. c. Internals such as level ball floats, which are not designed for the test pressure, must be removed. d. Items, such as connecting piping to a vessel under test, which are capable of withstanding the test, may be subjected to the test. e. Items, such as vessels connected to piping under test, which are not capable of withstanding the test, must be isolated by blinding. uop sarin ves “Tis fomatn fs coniderital Bo nok decoe he ober. Copy Rous WP ey purpose unless you have UOP's wien pemmssicn. |LVOP Naphine Hydrreateg Process (igh Nophta Syston) — General Operating Monual Commissioning f. A water filled system must be vented while draining to avoid collapsing equipment not designed for vacuum. g. The minimum temperature at which hydrotesting can be conducted is 15.6°C (60°F). h. All relief valves (PSV's) must be bench tested and set before final installation. This testing and setting may be done while hydrostatic testing is in progress. —. FLUSHING OF LINES 1. All piping should be thoroughly cleaned of debris and scale. Generally, fluid handling lines are flushed with water and thoroughly drained. Where practical, clean water should be supplied to the vessels and the contiguous lines be flushed away from the vessel, Do not flush debris into equipment. 2. Water flushed lines which do not drain freely should be blown clear with air. 3. Gas-handling piping may be either water flushed or air blown. Water should be blown from the gas lines on completion of flushing. Gas piping to compressors must be free of water. 4. _ Instrument air lines should be thoroughly blown with clean dry air. 5. _ Inall cleaning by flushing, whether with water, steam or air, maximum volume and velocity should be used for thorough cleaning. 6. Care must be taken to avoid a vacuurn condition when draining any pieces of equipment. When flushing from a vessel or other equipment, adequate venting must be provided. vop rere ws C Thi ration i oer, De et ceciose Ro thers copy use or By pupose unoes you bave UOP's won permis.'UOP Nephina ycrotestng Process (Light Naphtna System) General Operating Manu! Comming ri Following is a guide for flushing: b. Orifice plates must not be installed prior to flushing. Control valves should be removed or rolied out. Flexitallic gaskets cannot be reused so they should not be put in until final installation. Temporary gaskets can be used for initial installation. Instrument lines should be closed off or disconnected. Flush pump intake and discharge ing while disconnected. Supply and exhaust steam lines to turbines are cleaned by blowing while disconnected. Flush through open end lines. Do not restrict flow. Regulate rate of flushing medium from source. For example, water from a tower, regulate at the tower; and steam, at the valve in the ‘supply to the line being blown. Flush through all drains and vents. Where possible, flush downward or horizontally. First, flush or blow each lateral header from the source to end. ‘Second, flush or blow each lateral header from the main to end. Third, flush or blow each lateral header from the main to end. Always flush through bypass to an open end before flushing through equipment. uop varmns2 ws This inforaton scent De not deen there py hor ue Hr ary puaposewnivesyou have UOP's wien permision, —_}VOP naphine Hyoreting Process (Light Naphiha Systm) General Operating Manuat Commissioning n. For steam systems flush well through dirt leg drains and steam trap bypasses before placing the trap in service. ©. Disconnect lines at exchangers and flush to open end lines. 8. Upon completion of fine flushing of any system, carefully check that all temporary breaks are reconnected, control valves replaced, and pump alignments are normal. F. INITIAL RUN-IN OF PUMPS AND DRIVERS During precommissioning the only equipment that may be run in on clean wash water are the caustic circulation pumps. if wash water circulation pumps, and the water addition pump are present, they too may be run in on clean wash water. The drivers on the reactor charge pumps and stabilizer reflux pumps should be checked uncoupled. All the finfans should have been checked for amperage load and vibrational problems. 1. Proper installation and operation of pumps and drivers is essential for trouble- free performance. The pumps and drivers should receive careful handling uring initial run-in. The initial run-in of pumps is generally done by circulating water through the new equipment. Temporary strainers are installed in the intake of the pumps. During run-in of pumps, the strainers may cause some Testriction of flow, as debris collects in the strainers, and the flow to the pump will fall off. In this event, it will be necessary to limit the flow of centrifugal pumps by throttling the discharge valve. Avoid restricting the discharge to the extent that it will cause intemal slippage and excessive heat generation. The pump must not be permitted to cavitate, i.e., “losing suction,” which may cause damage to the pump. In starting a centrifugal pump, the rotation should be brought up to speed as rapidly as possible. An operating speed is attained rapidly and automatically with motor drive pumps and the usual motor starting control. op varie wr Tis infomation is conker Dont sce Ko oor, copy Kruse Tr ay Burposeureas ya Fave UOPs writen pammasion ——]LUOP NophineHyeroteating Process (Ligh Nophehe Systm) ~ Generel Operating Manual Conmssioning 2. The development of discharge pressure is essential to flush and lubricate the wearing rings. Subsequently, it is advisable, where practical, to close the pump discharge immediately prior to shutting down a centrifugal pump, to maintain maximum flush through wearing rings. 3. The discharge valve, of an operating positive displacement type pump. rotating or reciprocating, should not be closed as this will cause overpressuring. 4. Pumps in hot service must be gradually warmed to near operating temperature before placing in service. Uneven expansion of the intemals and casing may cause seizure and damage when starting. 5. — Following is a check list for prior-to-run-in: a. The manufacturer's operating instructions should be reviewed for any specific precautions that should be observed. b. Check that the overall installation is complete. ¢. Verify that the pump and driver have been aligned for cold operation. There must be no undue strain on the pump or driver by the piping. d. Check the water piping. Verify that the water piping is connected, where required, to bearing jackets, pedestals, stuffing boxes, etc. e. Check the steam piping. Verify that the steam piping, where required, is complete. f. Check the seal or gland oil piping. Conventionally packed pumps in hot service are generally furnished with gland oil: verify that this installation is. correct and complete. When a pump is furnished with mechanical seals, verify that all of the components of the flushing system, such as strainers, separator, restriction orifices and coolers, when required, have been uop versie we Tis ifort fs condone Do not deco teeters copy use for ary purpose unless you have UOP's writen PaTnsaeR.‘UOP Naphta Hycrazeating Process (Light Naptiha Syston) ~ Generel Operting Marva! Commissioning correctly installed and are clean. It is very important that the flush system be clean since the loss of flush or dirty flush can cause the loss of seals. Verify that packing or seals are installed. Check that temporary strainers in suction piping, when required, have been installed. Verify that bearings and shafts have been cleaned prior to final lubrication. Check that the pump and driver are lubricated according to the vendor's lubrication instructions. Check the rotation of electric motor drivers uncoupled from the pump. Run-in uncoupled, verifying operability. Run-in, uncoupled from pump, the other non-electric drivers. During run- in of the driver, overspeed trip bearings, controls, vibration, etc., are all satisfactorily checked to confirm operability. Abnormal conditions must be corrected before coupling to the pump. The pumps are normally delivering a material of lighter weight than the water circulated during initial run-in. The pump driver is sized for the normal pumping fluid, consequently while pumping water, the electric motors are easily overloaded. To avoid overioading the motor driving a centrifugal pump, the flow must be limited by throttling the pump discharge valve. If possible, check the amp usage against the design. ‘The following list is for operating the pumps during run-in: a. b. Rotate pump and driver by hand, verifying that they roll freely. Check that the water supply and delivery circuits are property lined up. uvop waite ws ‘This informatie i ontario nal dcoae He hoe apy, use Toray burpose uns you have UOP's won permion J