CONFIDENTIAL

CHT - RPIP

CDU / VDU Operation

October 2011
CONFIDENTIAL

Copyright of Shell Global Solutions Malaysia 10/14/2011 1

CONTENTS
• DOs

Maximise FOT

Minimise column pressure

Optimise LR stripping steam

Optimise HGO under reflux

Optimise desalter operation

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CONTENTS
• DOs

Monitor wetting rate

Optimise coil steam to vac furnace and

stripping steam vacuum column

Maintain steady vacuum conditions

Copyright of Shell Global Solutions Malaysia 10/14/2011 3

CONTENTS
• DONTs

X Exceed furnace constraints

X Operate below water dew point limit at

the column top

X Overload Circulating Reflux sections

X Inject stripping steam during high

column / stripper level conditions

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DOS

Maximise FOT
? Incaresing FOT results in higher middle
distillate yield at constant quality
 Increase furnace coil outlet temperature
upto maximum allowable operating
temperature .
Monitor furnace constraints SRF load, skin,
flue gas temperatures, BWT, heat fluxes

Copyright of Shell Global Solutions Malaysia 10/14/2011 5

DOS

Minimise column pressure
? Crude column pressure should be set as low
as possible to enhance recovery and minimise
energy consumption
 Operate at lower pressures by gradually
decreasing pressure set point .
Adjust temperature controller set points if
automatic temperature compensation is not
available
Be aware of air ingress risks below very low
pressure operations
Low pressure means low temperatures – May
affect LMTD – To be checked for units with
furnace constraints

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3
DOS

Optimise LR stripping steam

? Stripping steam injection reduces the partial
pressure at the flash zone and enhances distillate
recovery
 Check the impact of increased stripping
steam on the column top dew point – review
corrosion concerns.
Review the impact on O/H condensers, if
constrained
Increase gradually and monitor HGO colour

Copyright of Shell Global Solutions Malaysia 10/14/2011 7

DOS

Optimise HGO under reflux

? Amount of HGO under-reflux determines the
quality of HGO / LR
 Adjust HGO under reflux based on the HGO
and LR yields.
Do not operate HGO under reflux below the
minimum recommended for wetting
Monitor HGO colour while optimising HGO
under reflux

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4
DOS

Optimise desalter operation

? Well operating desalters are essential for salt
removal and corrosion control
 Try to maintain temperature: 125 – 145 o C.
Maintain Oil / Water mixing efficiency –
Follow vendors recommendations for
maximum ∆P across mix valves
Wash water injection @ 0.5 – 1% upstream of
crude preheat AND 4 – 8% upstream of mixing
valve

Copyright of Shell Global Solutions Malaysia 10/14/2011 9

DOS

Monitor wetting rate

? It is very important to ensure desired wetting rate
at the bottom of wash oil bed
 Check wash oil spray nozzle ∆P is within the
recommended range
Ensure correct functioning of filters in the
wash oil reflux circuits
Ensure correct metering of wash oil flow to
the bed
Provide for emergency wash oil flow, in case
of pump trips

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DOS

Optimise coil steam to vac furnace and

stripping steam vacuum column
? Coil and stripping steam steam help in sustaining
run length and improved distillate recovery
 Maintain coil steam close to around
recommended
Maintain minimum stripping steam all the
time to avoid weeping conditions in the bottom
section
Optimise stripping steam subject ejector
capacity and vapour velocity on wash oil bed

Copyright of Shell Global Solutions Malaysia 10/14/2011 11

DOS

Maintain steady vacuum conditions

? Steady vacuum conditions are important for
stable operation and steady distillate yield /
quality
 maintain column top pressure by keeping
pressure controller in operation
Do not commission / decommission ejector
sets while operating at lower thruputs
While optimising column pressure, proceed
in small steps

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DONTS

X Exceed furnace constraints

? Exceeding furnace constraints like furnace load,
skin, flu gas temperature might result in
excessive coke formation and reduced run length
 Monitor critical furnace parameters like duty,
skin temperatures, BWT and heat fluxes
Do not fire fuel more than the designed duty
of individual burners
Maintain flame pattern to avoid flame
impingement on tubes

Copyright of Shell Global Solutions Malaysia 10/14/2011 13

DONTS
X Operate below water dew point limit at
the column top
? Operating CDU column top below the dew point
conditions can result in water condensation on
the top trays. This could result in excessive
corrosion in the top sections / flooding due to
presence of 2 liquid phases
 Monitor water dew point at the column top
conditions
Maintain at least 10 o C ∆T between TCR
return and dew point
Minimise water carry over from desalters

Copyright of Shell Global Solutions Malaysia 10/14/2011 14

7
DONTS
X Overload Circulating Reflux sections
? Separation sharpness can be improved by
shifting duty from one CR to the next. If the
adjustment is excessive, the load of the higher
CR might exceed its capacity. In this case,
column operation becomes unstable
 Monitor duties while adjusting
Make gradual adjustments and allow 4 – 8
hrs for stabilisation
Monitor the impact on furnace inlet
temperature

Copyright of Shell Global Solutions Malaysia 10/14/2011 15

DONTS
X Inject stripping steam during high
column / stripper level conditions
? Typically stripping steam enters the column
below the bottom tray. When the liquid level is
high, steam inlet could get submerged in liquid.
 Monitor column / stripper bottom levels
during startup / shutdowns
Consider automatic stripping steam shut off
during column high levels
Ensure that the stripping steam is dry before
introduction during start up

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 Q&A

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