NHT Isom

OPERATING MANUAL FOR Doc No.
Draft
ISOMERISATION UNIT, Rev. A
VRCFP, HPCL VISAKH Page 1 of 231
OPERATING MANUAL
OF
ISOMERISATION UNIT
(UNIT NO.73)
VISAKH REFINERY CLEAN FUELS PROJECT
HINDUSTAN PETROLEUM CORPORATION LIMITED

VISAKH REFINERY
A Issued for comments NM

Rev No. Date Purpose Prepared by Checked by Approved by
Template No. 5-0000-0001-T2 Rev A Copyrights EIL- All rights reserved

OPERATING MANUAL FOR Doc No. Draft
PREFACE
This operating manual for Isomerization Unit of HPCL, VISAKH has been prepared by M/s
Engineers India Limited for M/s Hindustan Petroleum Corporation Limited.
This manual contains process description and operating guidelines for the unit and
is based on documents supplied by the Process Licensor (Axens). Hence the manual
must be reviewed /approved by the licensor before the start-up /operation of the
unit.
Operating procedures & conditions given in this manual are indicative. These should be
treated as general guide only for routine start-up and operation of the unit. The actual
operating parameters and procedures may require minor modifications/changes from those
contained in this manual as more experience is gained in operation of the Plant.
For detailed specifications and operating procedures of specific equipment, corresponding

Vendor's operating manuals/instructions need to be referred to.

Table of Contents
SECTION-1 ..................................................................................................................................................6
INTRODUCTION .......................................................................................................................................6
1.1 INTRODUCTION ...........................................................................................................................6
SECTION-2 ..................................................................................................................................................8
DESIGN BASIS ...........................................................................................................................................8
2.1 INTRODUCTION ...........................................................................................................................8
2.2 UNIT CAPACITY...........................................................................................................................8
2.3 ON-STREAM FACTOR .................................................................................................................8
2.4 TURNDOWN CAPABILITY .........................................................................................................8
2.5 FEED ...............................................................................................................................................8
2.6 PRODUCTS ..................................................................................................................................11
2.7 BATTERY LIMIT CONDITIONS................................................................................................17
2.8 UTILITY CONDITION ................................................................................................................17
SECTION-3 ................................................................................................................................................21
CHEMISTRY OF THE PROCESS .........................................................................................................21
3.1 INTRODUCTION .........................................................................................................................21
3.2 ISOMER REACTIONS.................................................................................................................21
3.3 ISOMAR CATALYST ..................................................................................................................25
3.4 CATALYST CONTAMINANTS .................................................................................................27
SECTION-4 ................................................................................................................................................30
PROCESS DESCRIPTION ......................................................................................................................30
4.1 ISOMERIZATION UNIT PROCESS SYSTEM: ..........................................................................30
4.2 PROCESS DESCRIPTION ...........................................................................................................34
4.3 CHLORIDE INJECTION FACILITIES .......................................................................................41
4.4 UTILITY SYSTEM.......................................................................................................................41
4.5 WASTE EFFLUENT FROM ISOMERIZATION SECTION ......................................................45
SECTION 5 .............................................................................................................................................47
PRE-COMMISSIONING PROCEDURE ...............................................................................................47
5.1 GENERAL ....................................................................................................................................47
5.2 PRE-COMMISSIONING ACTIVITIES .......................................................................................47
5.3 INSPECTION / CHECKING ........................................................................................................47
5.4 PREPARATION FOR PRE-COMMISSIONING .........................................................................49
5.5 PRE-COMMISSIONING OPERATION ......................................................................................50
SECTION 6 .............................................................................................................................................60
COMMISSIONING PROCEDURE ........................................................................................................60
6.1 FIRST START UP.........................................................................................................................60
6.2 STATUS OF THE UNIT ..............................................................................................................60
6.3 CHRONOLOGY ...........................................................................................................................60
6.4 COMPLETE INERTISING ..........................................................................................................61
6.5 HYDROCARBON CIRCULATION AND INITIAL DRY DOWN ............................................63

6.6 HYDROGEN SWEEP ..................................................................................................................64

6.7 OIL CIRCULATION, AND STABILIZER / DEISOHEXANIZER / LPG RECOVERY
SECTION START-UP ..................................................................................................................66
6.8 REACTION CIRCUIT OIL-IN.....................................................................................................71
6.9 ACIDIZING AND FINAL DRY-DOWN .....................................................................................75
6.10 HYDROGENATION AND ISOMERISATION CATALYST LOADING UNDER N2 .........81
6.11 HYDROGENATION REACTION SECTION START-UP.....................................................81
6.12 ISOMERIZATION REACTION SECTION START-UP ........................................................84
6.13 ISOMERIZATION UNIT LINE-OUT AT DESIGN CAPACITY ..........................................87
6.14 LPG RECOVERY SECTION LINE-OUT ...............................................................................88
6.15 UNIT RESTART ......................................................................................................................89
SECTION 7 ..............................................................................................................................................90
NORMAL OPERATING PROCEDURES..............................................................................................90
7.1 INTRODUCTION .........................................................................................................................90
7.2 CONTROL PHILOSOPHY ..........................................................................................................90
7.3 OPERATING PARAMETERS .....................................................................................................93
7.4 OPERATING PARAMETER .......................................................................................................95
7.5 SET POINTS OF ALARMS AND TRIPS ...................................................................................122
7.6 EQUIPMENT LIST.....................................................................................................................127
7.7 LIST OF INSTRUMENTS ..........................................................................................................136
7.8 PRESSURE SAFETY VALVES ................................................................................................143
7.9 ANALYZERS .............................................................................................................................145
SECTION - 8 ............................................................................................................................................147
SHUTDOWN PROCEDURES ...............................................................................................................147
8.1 GENERAL ..................................................................................................................................147
8.2 NORMAL SHUTDOWN PROCEDURE ...................................................................................147
8.3 SHORT DURATION SHUTDOWNS ........................................................................................148
8.4 LONG DURATION SHUTDOWNS ..........................................................................................149
8.5 SHUTDOWN FOR CATALYST REPLACEMENT ..................................................................151
8.6 EMERGENCY SHUTDOWN PROCEDURE ............................................................................152
8.7 AUTOMATIC SHUTDOWNS ...................................................................................................159
SECTION-9 ..............................................................................................................................................163
PROCESS VARIABLE ...........................................................................................................................163
9.1 BENZENE SATURATION ........................................................................................................163
9.2 ISOMERIZATION......................................................................................................................164
SECTION-10 ............................................................................................................................................170
TROUBLE SHOOTING .........................................................................................................................170
10.1 WATER BREAKTHROUGH FROM THE DRYERS ..........................................................170
10.2 SULPHUR BREAKTHROUGH: SULPHUR STRIPPING PROCEDURE ..........................172
10.3 LOSS OF C2CL4 INJECTION................................................................................................173
10.4 CHLORIDE BREAKTHROUGH ..........................................................................................174
10.5 PREVENTIVE MAINTENANCE: ........................................................................................174
SECTION -11 ...........................................................................................................................................175
SPECIAL PROCEDURES/INSTRUCTION/INFORMATION ..........................................................175

11.1 CATALYSTS LOADING UNDER N2 ..................................................................................175

11.2 SPENT CATALYST UNLOADING .....................................................................................183
11.3 SPECIFICATIONS OF CATALYSTS ..................................................................................184
11.4 CHEMICALS DURING NORMAL OPERATION ...............................................................187
11.5 CHEMICALS DURING TRANSIENT OPEARTION ..........................................................188
SECTION-12 ............................................................................................................................................189
UTILITY CONSUMPTION SUMMARY .............................................................................................189
12.1 INTERMITTENT CONSUMPTIONS FOR ISOMERIZATION SECTION ........................189
SECTION-13 ............................................................................................................................................191
SAMPLING PROCEDURE AND LABORATORY ANALYSIS REQUIREMENT ........................191
13.1 GENERAL .............................................................................................................................191
13.2 SAMPLING PROCEDURE ...................................................................................................191
13.3 LABORATORY TEST METHOD AND SCHEDULE .........................................................194
SECTION -14 ...........................................................................................................................................198
SAFETY PROCEDURE .........................................................................................................................198
14.1 INTRODUCTION ..................................................................................................................198
14.2 SAFETY OF PERSONNEL ...................................................................................................198
14.3 WORK PERMIT PROCEDURE ............................................................................................199
14.4 PREPARATION OF EQUIPMENT FOR MAINTENANCE.................................................201
14.5 PREPARATION FOR VESSEL ENTRY ...............................................................................203
14.6 HAZARDOUS CHEMICAL HANDLING ............................................................................209
14.7 FIRE FIGHTING SYSTEM ...................................................................................................218
14.8 USE OF LIFE SAVING DEVICE ..........................................................................................219
SECTION -15 ...........................................................................................................................................221
GENERAL OPERATING INSTRUCTIONS FOR EQUIPMENT ....................................................221
15.1 GENERAL .............................................................................................................................221
15.2 CENTRIFUGAL PUMPS ......................................................................................................221
15.3 POSITIVE DISPLACEMENT PUMPS .................................................................................224
15.4 CENTRIFUGAL COMPRESSOR .........................................................................................226
15.5 HEAT EXCHANGERS..........................................................................................................229

SECTION-1
INTRODUCTION
1.1 INTRODUCTION
Isomerization is the conversion of low octane straight chain compounds to their higher
octane branched isomers. The purpose of this process is to saturate benzene and to
isomerise normal paraffins to improve the research and motor octane number of the light
naphtha feed (predominantly C5/C6) before blending into the gasoline pool. The light
naphtha fraction is typically high in normal isomer content resulting in a low octane
number (typically < 68). The isomerization process converts an equilibrium proportion
of these low octane normal isomers into their higher octane branched isomers.
This process developed and licensed by Axens consists of three fixed bed adiabatic
reactors, with benzene saturation carried out in the first reactor, and C5/C6 isomerization
reactions completed in the following two reactors. The isomerization reactions are
carried over a fixed chlorinated platinum catalyst bed in a hydrogen environment.
Operating conditions are not severe as reflected by moderate operating pressure, low
temperature, low hydrogen partial pressure and high catalyst space velocity. These
operating conditions promote the isomerization reaction, minimize hydrocracking and
minimize equipment capital costs.
The feedstock of the Isomerization unit is light hydrotreated naphtha coming from
Naphtha Hydrotreating Unit. Naphtha is mixed with hydrogen. A small amount of
chlorinating agent is continuously injected in to the isomerization catalyst. The mixture
enters in first stage reactor where isomerization reaction occurs. The effluent is cooled
before entering the second stage reactor. Remaining isomerization reaction occurs in
third stage reactor. The effluent is then routed to stabilizer to reduce C4 rate in the
isomerization reactor effluent. The stabilizer overhead is partially cooled and vapor
phase is routed to LPG recovery section while liquid is used as reflux. Stabilizer bottom

is routed to deisohexaniser where low octane C6- n paraffin and methyl pentane is
recycled to the reactor circuit in order to obtain a high octane product.

SECTION-2
DESIGN BASIS
2.1 INTRODUCTION
The isomer unit is required to produce an Isomerate product which is suitable for gasoline
pool.
Important content of design basis is given below.
2.2 UNIT CAPACITY

Isomar Unit is designed for a capacity of 228641 T/yr.
2.3 ON-STREAM FACTOR

The facility is designed for 8000 operating hours per year.
2.4 TURNDOWN CAPABILITY

The facility is capable of operating at 50 percent of design feed capacity, while
maintaining the designated product specification.
2.5 FEED
The feedstock of the Isomerization unit is light hydrotreated naphtha coming from
Naphtha Hydrotreating Unit.
Three different feeds were considered for the design of the unit NIT CASE, AM CASE
(Arabian Mixed) and BH CASE (Bombay High).

2.5.1. Light Hydrotreated Naphtha
NIT case AM case BH case

Molecular weight 83.5 81.1 81.3
Sp Gravity @ 15C 0.689 0.6647 0.711
Composition, wt%
IBUTANE 0.00 0.00 0.01
NBUTANE 0.00 0.23 0.24
IPENTANE 8.48 10.89 11.41
NPENTANE 9.51 24.07 12.32
22DMB 0.44 0.30 0.52
23DMB 1.41 9.28 6.83
3METHYLPENTANE 7.98 9.93 5.36
NHEXANE 27.09 25.19 11.98
CYCLOPENTANE 1.15 1.39 1.62
METHYLCYCLOPENTANE 19.51 4.26 7.78
BENZENE 4.24 1.63 16.51
CYCLOHEXANE - 2.79 15.39
NHEPTANE 0.72 9.13 9.81
METHYLCYCLOHEXAN 1.67 0.46 0.20
Iso C7 8.41 0.00 0.00
TOLUENE 0.01 0.45 0.03
C8 0.14 0.00 0.00
Total 100 100 100
Impurities:
The Isomerization catalyst is an activated chloride, alumina based catalyst with a
platinum promoter. It is highly sensitive to impurities in the feedstock, in particular
water or other oxygenated compounds. Feed to this unit is hydrotreated and both feed
and make-up hydrogen are passed through dryers to remove any traces of water. Some
impurities are considered to be irreversible poisons such as water and nitrogen
compounds. Others are reversible such as sulfur.

It is critically important that the operating performances of both upstream hydrotreater

and dryers are such that the impurity levels in the isomerization reactor feed do not
exceed the levels shown hereafter. Discussions regarding feed poisons and their effects
will be presented in the Operating Instructions Section.
MAXIMUM ALLOWABLE IMPURITY LEVELS
IN THE FEED
Total Sulphur 0.5 ppm wt max. (1)

Total Nitrogen compounds 0.1 ppm wt max. (1)
Water + Oxygenates 0.1 ppm wt max. (1)
Metals 5 ppb wt max.
Chloride 1 ppm wt max. (1)
Olefins 1% wt max.
Arsenic 1 ppb wt max.
(1) At the outlet of the feed dryer.
2.5.2. Hydrogen
Hydrogen make-up to this unit is needed for isomerization unit for benzene
hydrogenation to cyclohexane and in order to satisfy the hydrogen partial pressure
requirement for the naphtha hydrotreatment and for the isomerization reactions.
Hydrogen is supplied from a new CCR unit. A gas compressor is required to satisfy the
process requirements of the different users.
Components (Mole %)
Origin CCR Unit

H2 93.0
C1 2.3
C2 2.2
C3 1.7
iC4 0.3
nC4 0.3
C5+ 0.2

Hydrogen quality
Impurities:
H2S
5 ppm vol max
HCl
0.5 ppm vol max
CO
6-10 ppm vol
COS
1 ppm vol max
CO + CO2
25 ppm vol max
H2O
50 vol ppm
Olefins
10 ppm wt max
N2 compounds
1 wt ppm max
MAXIMUM ALLOWABLE CONTAMINANT LEVELS

FOR HYDROGEN TO ISOMERIZATION UNIT
Total Sulphur 1.0 ppm wt max.

Total Nitrogen compounds 1.0 ppm wt max.
Water 0.5 ppm wt max.(1)
CO + CO2 10 ppm wt max.(1)
Olefins 10 ppm wt max.
Chloride 5 ppm wt max
(1) At the outlet of the hydrogen dryers.
2.6 PRODUCTS
There are four products. The primary product is light Isomerate i.e. deisohexaniser
distillate. The secondary product is heavy Isomerate, i.e. deisohexaniser bottom. The
third product Fuel gas comes from LPG separator drum. The fourth product is LPG
stream produced isomerization stabilizer overhead.

Light Isomerate product

The light isomerate product estimated flowrates and product characteristics are
presented hereafter:
SOR NIT CASE AM CASE BH CASE
Isomerate Product flowrate, kg/h 17859 21203 11961
Sp. Gravity @15C 0.6456 0.6414 0.6391
Estimated RON 88.9 89.4 88.5
Estimated MON 88.2 88.3 86.7
Estimated Yield, wt % (1) 65.7 78 44
Estimated RVP, kg/cm2 abs 13.56 14.9 16.7

Composition, wt %
PROPANE 0.01 0.02 0.01
IBUTANE 1.4 1.02 0.71
NBUTANE 0.53 0.43 0.39
IPENTANE 25.56 35.38 43.53
NPENTANE 8.28 10.82 16.47
22DMB 39.02 41.32 34.01
23DMB 7.25 3.6 0.75
NHEXANE 0.11 0.02 0
METHYCYCLOPENTANE 0.05 0.01 0
BENZENE 0 0 0
CYCLOHEXANE 0 0 0
NHEPATANE 0 0 0
METHYLCYCLOHEXANE 0 0 0
11DIMET-CYCLOHEXANE 0 0 0
Total 100 100 100
LightIsomerate flowrate (kg / h)

Yield = * 100
Freshfeed flowrate (kg / h)

EOR NIT CASE AM CASE BH CASE

Sp. Gravity @15C 0.6448 0.6401 0.6366
Estimated RON 89.0 89.4 88.5
Estimated MON 88.2 88.3 86.4
Estimated Yield, wt% (1) 64.3 78 44
Composition, wt %
PROPANE 0.02 0.03 0.02
IBUTANE 1.66 1.93 1.65
NBUTANE 0.44 0.66 0.69
IPENTANE 26.8 35.76 47.24
NPENTANE 8.76 10.99 17
22DMB 39.05 40.11 29.41
23DMB 6.87 3.45 0.33
NHEXANE 0.09 0.02 0
METHYCYCLOPENTANE 0.03 0 0
BENZENE 0 0 0
CYCLOHEXANE 0 0 0
NHEPATANE 0 0 0
METHYLCYCLOHEXANE 0 0 0
11DIMET-CYCLOHEXAN 0 0 0
Total 100 100 100
LightIsomerate flowrate (kg / h)

(1) Yield = * 100
Heavy Isomerate Product
Sp. Gravity @15C 0.7562 0.7243 0.7402
Estimated Yield, wt % (1) 26.3 13.9 50.7


Composition, wt %
IBUTANE 0.28 0.34 0.08
NBUTANE 0.1 0.23 0.1
IPENTANE 0.08 0.84 0.94
NPENTANE 0.01 0.07 0.09
22DMB 0 0.02 0.03
23DMB 0.02 0.31 0.62
NHEXANE 1.63 16.6 8.56
CYCLOPENTANE 0 0 0
METHYCYCLOPENTANE 7.61 8.05 22.18
BENZENE 0 0 0
CYCLOHEXANE 31.63 21.1 33.84
NHEPATANE 18.02 23.52 11.7
METHYLCYCLOHEXANE 23.24 12.27 7.56
11DIMET-CYCLOHEXAN 16.97 11.21 7.27
Total 100 100 100
HeavyIsomerate flowrate (kg / h)

Yield = *100 ]
EOR NIT CASE AM CASE BH CASE

Sp. Gravity @15C 0.7542 0.7252 0.7408
Estimated Yield, wt % (1) 26.8 13.5 49.8
Composition, wt %
IBUTANE 0.23 0.35 0.08
NBUTANE 0.15 0.2 0.08
IPENTANE 1.43 0.49 0.67
NPENTANE 0.12 0.04 0.06
22DMB 0.02 0.02 0.04
23DMB 0.02 0.31 0.61


NHEXANE 1.52 17.43 8.62
CYCLOPENTANE 0 0 0
METHYCYCLOPENTANE 6.26 7.34 21.48
BENZENE 0 0 0
CYCLOHEXANE 27.23 17.88 28.79
NHEPATANE 17.61 21.85 11.33
METHYLCYCLOHEXANE 26.9 15.014 11.63
11DIMET-CYCLOHEXAN 18.11 13.41 9.52
Total 100 100 100
LPG Product
LPG is recovered at LPG stripper 73-C-04 draw-off. Estimated flowrates and
compositions are presented hereafter.
SOR NIT Case AM case BH case
LPG normal flowrate kg/h 2427 2320 1930

Composition, wt%
H2 0 0.01 0.02
C1 0.03 0.58 0.95
C2 0.76 32.72 27.68
C3 28.53 59.75 61.38
iC4 65.33 6.68 9.72
nC4 5.11 0.24 0.25
C5+ 0.24 0 0
Total 100.00 100.00 100.00
Specific gravity @15C 0.5448 0.5432 0.5456
Yield estimated, wt % (1) 8.9 8.5 7.1
EOR NIT Case AM case BH Case

LPG normal flowrate kg/h 2794 2566 2283
Composition, wt%
H2 0 0 0
C1 0.02 0.01 0.02
C2 0.68 0.59 0.95
C3 27.31 33 27.46

EOR NIT Case AM case BH Case

iC4 65.71 60.38 62.69
nC4 6.03 5.77 8.63
iC5 0.25 0.25 0.24
Total 100 100 100
Specific gravity @15C 0.5459 0.5429 0.5455
Yield estimated, wt % (1) 9.8 9.0 8.0
LPG flowrate (kg / h)

(1) Yield = * 100
NHDT Feed flowrate (kg / h)
Note: LPG flowrates described here above take into account the LPG stream
coming from reforming unit.
Fuel gas
Fuel gas is recovered at caustic scrubber 73-V-11. Estimated flowrates and compositions
are presented hereafter:
SOR NIT Case AM Case BH Case

Off gas normal flowrate 285 261 590
(kg/h)
Composition, mol %
H2 83.49 86.33 69.06
C1 6.89 5.14 11.39
C2 5.22 3.88 9.78
C3 3.37 3.43 7.43
iC4 0.3 0.27 0.78
nC4 0.03 0.07 0.08
C5+ 0.7 0.88 1.48
H2O 0 0 0
Total 100 100 100
Molecular Weight 6.7 6.2 11.2
EOR NIT Case AM Case BH Case

Off gas normal flowrate 312 292 647
(kg/h)
Composition, mol %
H2 82.9 85.46 68.19
C1 6.97 5.27 11.49
C2 5.31 3.95 9.76
C3 3.65 4.03 8.03
iC4 0.32 0.33 0.98
nC4 0.05 0.06 0.07

C5+ 0.8 0.9 1.48

H2O 0 0 0
Total 100 100 100
Molecular Weight 6.9 6.5 11.6
2.7 BATTERY LIMIT CONDITIONS
Temperature Pressure
C Kg/cm2 g
Feedstock :
o Light Naphta feed 40 7.0
o H2 make-up 40 22.0
o H2 for start-up 45 20.0
o 10% caustic soda 40 3.0
Products :
o LPG 40 16.0
o Light Isomerate 40 7.0
o Heavy Isomerate 40 7.0
o Sweet Fuel gas 40 4.5
o Spent caustic soda 45 6.0
2.8 UTILITY CONDITION

UTILITY CONDITION AT UNIT BATTERY LIMIT
(All battery limit pressures are measured at grade)
Minimum (for Mech.
Sr. No. Parameter Normal Maximum
thermal design) Design
1 HIGH PRESSURE STEAM
Pressure, Kg/cm2g 33 35 38 40
Temperature, oC 340 360 380 400

Minimum (for Mech.

2 MEDIUM PRESSURE STEAM
Pressure, Kg/cm2g 9 10 11 12.5
Temperature, oC Satd 250 280 300
3 LOW PRESSURE STEAM
Pressure, Kg/cm2g 2.5 3.0 4.0 5.5
Temperature, oC Satd 150 170 190
4 STEAM CONDENSATE
Pressure, Kg/cm2g -- 5.5 -- 10
Temperature, oC -- 100 -- 185
5 COOLING WATER SUPPLY
Pressure, Kg/cm2g -- 5.3 -- 7.6
6 COOLING WATER RETURN
7 BOILER FEED WATER ( VHP )
Pressure, Kg/cm2g 47 50 -- 71
Temperature, oC 120 120 -- 120
8 BOILER FEED WATER ( MP )

Minimum (for Mech.

Pressure, Kg/cm2g 17.5 20.5 -- 29
Temperature, oC 120 120 -- 120
9 DEMINERALIZED WATER
Temperature, oC -- Ambient -- 65
10 PLANT AIR
Pressure, Kg/cm2g 3.0 4.0 5.0 9.0
11 INSTRUMENT AIR
Pressure, Kg/cm2g 4.0 5.0 6.0 9.0
12 NITROGEN
Pressure, Kg/cm2g 5.0 6.0 7.0 10.5
13 FUEL OIL SUPPLY
Pressure, Kg/cm2g 7 8 11 17
Temperature, oC 100 130 170 200
14 FUEL OIL RETURN
Pressure, Kg/cm2g 2.5 -- -- --

Minimum (for Mech.

Temperature, oC -- -- -- --
15 FUEL GAS
Pressure, Kg/cm2g 2.5 3.0 3.5 9.0
Temperature, 30 40-50 60 100
16 FLARE HEADER
Super imposed
back pressure at -- 0.1 -- --
B/L(kg/cm2g)
Built up
back pr. -- 1.5 -- --
(kg/cm2g)
Total back
pressure at PSV -- 1.7 -- --
outlet(kg/cm2g)

SECTION-3
CHEMISTRY OF THE PROCESS
3.1 INTRODUCTION
The main purpose of this process is to saturate benzene and to isomerise normal
paraffins to improve the research and motor octane number of the light naphtha feed
(predominantly C5/C6) before blending into gasoline pool. The light naphtha fraction is
typically high in normal isomer content resulting in a low octane number
(typically<68).The isomerization process converts an equilibrium proportion of these
low octane normal isomers into their higher octane branched isomers. In addition the
LPG recovery section allows separating light products (H2, C1, C2) from C3+ either from
isomerization or reformer stabiliser column.
This process consists of three fixed bed adiabatic reactors, with benzene saturation
carried out in the first reactor, and C5/C6 isomerization reactions completed in the
following two reactors. The isomerization reactions are carried over a fixed chlorinated
catalyst bed in a hydrogen environment. Operating conditions are not severe as reflected
by moderate operating pressure, low temperature, low hydrogen partial pressure and
high catalyst space velocity. These operating conditions promote the isomerization
reaction, minimize hydrocracking and minimize equipment capital costs.
General process variables will be presented and discussed first and process performance
will then be discussed with respect to these variables. Finally, the Isomar kinetic model
will be discussed. This model helps to define the operation of the unit and provides
insight into monitoring and adjusting plant operation.
3.2 ISOMER REACTIONS

The isomerization reactions are carried out in two steps:
1st step: Hydrogenation of benzene.
2nd step: Isomerization of normal paraffins

3.2.1 Hydrogenation of benzene:
This reaction is highly exothermic and occurs in a separate reactor, namely the
Benzene Saturation Reactor. This allows carrying out the isomerization reactions
separately at lower temperatures in the downstream isomerization reactors.
C6H6 + 3H2 C6H12
3.2.2 Isomerization:
Isomerization is the conversion or rearrangement of the structure of a compound
to its more branched, higher octane structure. These rearrangements are depicted
by the following formula:
CH3
CH3 - CH2 - CH2 - CH2 - CH3

CH3 - CH - CH2 - CH3
n-pentane isopentane
(RON = 62) (RON = 93)

CH 3 - CH 2 - CH 2 - CH 2 - CH 2 - CH 3 CH 3 - CH - CH 2 - CH 2 - CH 3
CH 3
n-hexane 2 methylpentane
(RON = 30) (RON = 74 )

CH 3 - CH 2 - CH - CH 2 - CH 3
CH 3
3 methylpentane
(RON = 75 )
CH 3
CH 3 - C - CH 2 - CH 3

CH 3
2,2 dimethylbutane
(RON = 92)
CH 3
CH 3 - CH - CH - CH 3

CH 3
2,3 dimethylbutane
(RON = 104)
These reactions, as shown, are reversible and the final distribution of the isomers is
based on the equilibrium composition which is dictated by the reactor process conditions
and kinetics.
In addition to the isomerization reactions, there are other side reactions taking place as
well, and some of them are not desirable.
3.2.3 Naphthene Ring Opening :

The three naphthene, which are typically, present in an isomerization feed are
cyclopentane (CP), methyl cyclopentane (MCP) and cyclohexane (CH). These
naphthenic rings break and hydrogenate to form paraffins. Ring opening reactions

increase with increasing temperature and again are governed by equilibrium

compositions at the reactor process conditions. At typical isomerization reactor
conditions the conversion of naphthene rings to paraffins will be approximately
20-30 percent.
+ H2 C 5 H 12
C 5 H 10
(cyclopentane)
+ H2 C 6 H 14
C 6 H 12
(cyclohexane)
CH 3
+ H2 C 6 H 14
C 6 H 12
(methyl cyclopentane)
Naphthenic or cyclic components tend to inhibit the isomerization reactions and are
therefore undesirable in large quantities. The cyclic components are absorbed on the
catalyst and reduce the active sites available for paraffin isomerization. They also
consume hydrogen, produce exothermic heat which is undesirable from the
isomerization equilibrium standpoint. However undesirable as they are, they are a
natural fraction of C5/C6 cut naphtha and are difficult to eliminate without also
eliminating other desirable components.

3.2.4 Hydrocracking
Operating at the low severity reactor conditions, very little C5/C6 hydrocracking occurs
in the isomerization reactors. C7 paraffins however hydrocrack readily to produce C3 and
C4 components. Much of the hydrocracking occurs in the first reactor which typically
operates at a higher temperature. Hydrocracking reactions consume hydrogen, and hence
it is recommended to restrict the C7+ content of the isomerization feedstock.
C7 H16 + H2 C3 H8 + C4 H10
3.3 ISOMAR CATALYST

There are several reaction mechanism theories presented based on the type of catalyst
used, i.e. whether it is a dual functional catalyst consisting of a metal and a support or if
its acidity is enhanced by a halogen. Whatever the type of catalyst used the intermediate
step is the same i.e., the formation of a carbonium -ion.
Isomerization on dual-function catalysts in a hydrogen atmosphere is generally
described by the following reaction scheme:
Pt

CH3 - CH2 - CH2 - CH2 - CH3 CH3 - CH2 - CH2 - CH = CH2 + H2
The metallic function of the catalyst, in this case platinum, catalyses the formation of an
olefin intermediate by dehydrogenation of the paraffin. The olefins are then converted
into carbonium ions by the addition of a proton during adsorption onto the acidic surface
of the catalyst.
+H+

CH3 - CH2 - CH2 - CH = CH2 CH3 - CH2 - CH2 - CH - CH3

Skeletal rearrangement then occurs:
C3

CH3 - CH2 - CH2 - CH - CH3 CH3 - CH2 - C - CH3

The rearranged carbonium ion is then desorbed as an iso-olefin which is then

hydrogenated by the catalyst metallic function to the iso-paraffin:
C3 C3
CH3 - CH2 - C - CH3 CH3 - CH2 - C = CH2 + H +

C3 C 3
Pt
CH3 - CH2 - C = CH2 + H2 CH3 - CH2 - CH - CH3
Dual-functional hydro-isomerization catalysts which operate at very low temperature

have stronger acid sites than those which require higher temperatures. In this case, the
theory postulates that the carbonium ion is formed by direct hydride ion abstraction from
the paraffin by the acid function of the catalyst.
+
CH3 - CH2 - CH2 - CH2 - CH3 + H A CH3 - CH - CH2 - CH2 - CH3 + H2 + A

After rearrangement, isopentane is formed and the chain is propagated by the generation
of a new acid site.
CH 3 CH 3
+
CH 3 - C - CH 2 - CH3 + A + H2 CH 3 - CH - CH 2 - CH 3 + H A

Another principal theory of initiation and propagation is that based on the Friedel-Crafts
theory. Friedel-Crafts isomerization is believed to require the presence of traces of

olefins or alkyl halides as carbonium ion initiators with the reaction thereafter
proceeding through chain propagation. The initiator ion, which needs to be present only
in small amounts, may be formed by the addition of HCl to an olefin which is present as
an impurity in the paraffin or is formed by paraffin hydrocracking.
RCH = CH2 + HCl R CH CH3 + Cl

The initiator then forms a carbonium ion with the paraffin to be isomerized.
R CH CH3 + CH3 - CH2 - CH2 - CH2 - CH3 R CH2 CH3 + CH3 - CH - CH2 - CH2 - CH3

After skeletal rearrangement, isopentane is formed and the chain is propagated by the
generation of a new normal carbonium ion.
C3 C3
CH3-C-CH2-CH3 + CH3-CH2-CH2-CH2-CH3 CH3-CH-CH2-CH3 + CH3-CH-CH2-CH2-CH3

3.4 CATALYST CONTAMINANTS

The contaminants and poisons for this catalyst are mainly sulfur, mercury and free
water. Table below shows the maximum allowable limit of impurities for feed and
hydrogen make-up gas.
The isomerization unit feed is dried and hydrotreated prior to contact with the
isomerization catalyst IS-614 A. These operations eliminate or reduce to an acceptable
level the contaminants naturally present in the feedstocks. However, it is possible that
upstream unit upsets or misoperation could lead to a contaminant breakthrough. The
following discusses their impact on the process.
a) Sulfur:
The presence of sulfur in the feed or make-up hydrogen will immediately decrease the
activity of the catalyst. Sulfur reacts with the platinum to form platinum sulfide, and this

reduces the metallic function of the catalyst affecting the hydrogen transfer mechanism.
This decrease in activity is temporary and recovery is normally rapid once the sulfur has
been removed. However, an increase in reactor temperature and a higher make-up
hydrogen rate will assist in purging the sulfur from the catalyst more rapidly. While
sulfur is present in the feed, an increase in temperature may help to partially compensate
for the reduced catalyst activity.
b) Water / Oxygenates:
The deactivation which results from water or other oxygenates breakthrough is
permanent. The oxygenated compounds react chemically with the active chloride on the
catalyst, which is chemically bound into the alumina structure during manufacture. The
water, once it reacts with the catalyst is chemically bound as hydroxyl to the alumina
and the chloride is removed as HCl. Approximately one kilogram of oxygen in any form
will deactivate 100 kg of catalyst. If breakthrough occurs, the catalyst deactivation will
occur in a piston-like fashion moving down the first catalyst bed. In addition to the loss
of product quality, a clear sign is the lack of reactor T in the top portion of bed and this
inactivity slowly moving down the bed. Once the catalyst is deactivated, it must be
removed for platinum recovery and replaced with fresh catalyst.
c) Nitrogen Compounds:
This refers to organic nitrogen or ammonia, not to molecular nitrogen N2. Nitrogen
compounds react to form ammonia which in turn reacts with the chloride in the catalyst
or the HCl to form ammonium chloride salt. This leads to a permanent deactivation of
the catalyst by a coating of the catalyst active sites, loss of chloride and possibly
inactivity due to maldistribution from salt deposits.
d) Fluoride Compounds:
This is also a permanent catalyst poison caused by the fluoride bonding to catalyst active
sites affecting the catalyst acidity. Again one kilogram of fluoride will deactivate
100 kilograms of catalyst.
Maximum Allowable Contaminant Levels in

a) Hydrogen Make-up :
Contaminants (by wt)

Total Sulfur 1 ppm wt. Max.
Water 0.5 ppm wt. Max. (1)
CO + CO2 10 ppm wt. Max.
Olefins 10 mol wt max.
Chloride 5 ppm wt. Max.
Total Nitrogen 1 wt ppm max.
(1) At hydrogen dryer outlet
Maximum Allowable Contaminant Levels in
b) Light Naphtha Feed:
Contaminants (by wt)

Total Sulfur 0.5 ppm max (1)
Water + oxygenates 0.1 ppm max. (1)
Metals 5 wt ppb max.
Olefins 1% wt max
Chloride 1 ppm wt max
Arsenic 1 ppb wt max
Total Nitrogen 0.1 ppm max (1)
(1) At the outlet of the feed dryer

SECTION-4
PROCESS DESCRIPTION
4.1 ISOMERIZATION UNIT PROCESS SYSTEM:

Isomerization of the light hydrotreated naphtha is carried out in a series of two fixed bed
reactors. As benzene content in feed is high and benzene hydrogenation reaction is
highly exothermic, benzene hydrogenation takes places in a separate fixed bed reactor,
installed upstream of the two isomerization reactors. In order to limit the temperature
increase across the hydrogenation reactor, part of the effluent is cooled and recycled to
dilute the reactor.
Isomerization is the conversion of hydrocarbons to their isomers, which have the same
molecular formula but a different arrangement of molecules. The C5 /C6 Isomerization
Section specifically converts the normal C5 / C6 paraffins to their isomers, i.e. to a
higher octane branched arrangement, over a proprietary platinum catalyst in the
presence of hydrogen. The conversion per pass of the normal paraffins to their isomers
is determined by the reaction equilibrium at the reactor operating conditions. The low
octane methyl-pentanes and the unconverted n-hexane are recycled back to the
isomerization reactors to achieve the objective to produce light isomerate stream with an
estimated minimum octane no. of 88.5 in order to meet gasoline pool constraints.
A stabilizer column is used for removing light ends from the reactor effluent. Stabilizer
bottom is routed to deisohexaniser column via chloride guard bed.
A Deisohexaniser tower is used for recovering stabilized isomerate product and
recycling the low octane methyl-pentanes and the unconverted n-hexane to the reactor.
The Deisohexaniser distillate goes as light isomerate to MS Pool via storage and
bottoms streams is pumped to LPG recovery section, where it is used as lean oil make-
up.
The stabilizer reflux drum off gas contains LPG, hydrogen and chloride which is sent to
the LPG recovery unit. The chloride is removed by scrubbing with caustic soda in
Caustic Scrubber.

The unit consists of the following sections:

- Dryer Section
- Hydrogenation Section
- Isomerisation Section
- Stabilizer Section
- Deisohexaniser
- Scrubber Section
- LPG Recovery Section
- Dryer Regeneration
- Chloride Injection Facility
Chemical reactions in Isomerization Section

There are principally two fundamental reactions occurring:-
- Benzene hydrogenation
- Isomerization
The first reaction is highly exothermic. In order to monitor the isomerization
temperature, the benzene hydrogenation takes place in the hydrogenation reactor 73-R-
01.
The second reaction is the isomerization reaction itself and it occurs in the two last
reactors 73-R-01 & 73-R-02.
Benzene hydrogenation:
Benzene and hydrogen react to form cyclohexane.
C6H6 + 3H2 C6H12
This reaction takes place in the superior part of the first reactor 73-R-01. Benzene
hydrogenation is an exothermic reaction (16660 kcal/kmole of consumed hydrogen).

Isomerization
Isomerization is the conversion of hydrocarbons to their isomers, which have the same
molecular formula but a different arrangement of molecules. C5 /C6 Isomerization
section specifically converts normal C5 / C6 paraffins to their isomers, i.e. to a higher
octane branched arrangement, over a proprietary platinum catalyst in presence of
hydrogen. The conversion of normal paraffins to their isomers is determined by the
reaction equilibrium at reactor operating conditions.
The term isomer refers to compound which have the same molecular formula but
different structural formula or a different arrangement of molecules. In general any
compounds that are linear or straight chain are termed normals, if they are in a
different arrangement, i.e. branched, they are termed isomers.
Examples:
n-pentane C5 H12:
H H H H H
H C C C C C H
H H H H H
Pentane has five carbon atoms. When in a straight chain as shown, this is called normal
pentane or n-pentane. The Research Octane Number (RON) of n-pentane is 62.
i-pentane C5 H12:
H H H H
H C C C C H
H H H
H C H

This is isopentane, one of the isomers of n-pentane; it has the same molecular formula
but a different arrangement or structure. Isopentane or i-pentane has a Research Octane
Number (RON) of approximately 93.
Isomerization is simply the conversion of compounds to their isomer, i.e., to a higher
octane branched arrangement.
Similarly with hexane:
n-hexane C6 H14:
H H H H H H
H C C C C C C H
H H H H H H
Hexane has six carbon atoms. When in a straight chain as shown, this is called normal
hexane or n-hexane. The Research Octane Number (RON) of n-hexane is 30.
i-hexane C6 H14:
H
H C H
H H H
H C C C C H
H H H
H C H
This is isohexane, one of the isomers of n-hexane; again it has the same molecular
formula but a different arrangement or structure. This is called 2,2 Dimethylbutane
(2,2,DMB) and has a Research Octane Number (RON) of approximately 92.
Not all n-pentane and n-hexane will convert to their isomer but a certain percentage or
equilibrium amount will exist at given operating conditions. This is then the measure of

the performance of an Isomerization unit, i.e. the percentage of the isomer in the reactor
effluent.
The conversion of n-pentane to isopentane and n-hexane to 2,2,DMB are only two of the
many reactions occurring simultaneously in the Isomerization process. These reactions
take place in the 73-R-02 and 73-R-03 reactors.
4.2 PROCESS DESCRIPTION

4.2.1. Dryer section
The hydrotreated naphtha is fed to the feed surge drum 73-V-01. Then it is pumped by
pumps 73-P-01 A/B under flow control to the two feed dryers 73-DR-01 A/B in series.
The feed dryers protect the isomerization catalyst from irreversible damage with water,
which is extremely poisonous to the reactor catalyst.
The make-up hydrogen gas from CCR unit also needs to be dried for the same reason.
Hydrogen from the CCR unit goes through make-up H2 K.O. drum 73-V-02. It is
compressed to the desired pressure level by compressors 73-K-01 A/B and cooled in
exchanger 73-E-01 A/B (one spare cooler is required due to frequent maintenance on
cooling water side). A part of the cooled gas is sent to the Prime G+: HDS section and
SHU section (unit 75). Hydrogen to Isomerization section is sent to dryers 73-DR-02
A/B in series, under flow control; excess hydrogen is routed to the flow control valve on
H2 compressor recycle (73-K-01 A/B). Set point of flow controller is reset by flow
controller on the feed to the isomerization reactor. Remaining dried hydrogen is mixed
with dried Naphtha under flow control and sent to the benzene hydrogenation section.
Set point of this flow controller is adjusted manually, according to the benzene
composition of the feed, as indicated by on line analyzer.
Remark: Isomerization section cannot be fed directly by hydrotreated naphtha from a
storage tank.

4.2.2. Hydrogenation Section

The combined two phase feed from the dryer section is preheated in Deisohexanizer
recycle/ Reactors feed exchanger 73-E-02 and in first stage reactor feed/effluent
exchanger 73-E-03. It is mixed with the diluent recycle from hydrogenation reactor and
further heated by HP Steam, if required, in hydrogenation reactor feed heater 73-E-04 to
the reaction temperature.
Feed enters the hydrogenation reactor 73-R-01, where benzene is hydrogenated to
cyclohexane. The hydrogenation reaction is highly exothermic.
The reactor effluent is routed to hydrogenation reactor flash drum 73-V-04. Operating
pressure leads to an almost liquid phase at the hydrogenation reactor effluent.
Thermodynamic model heat and material balances define reactor outlet as fully liquid,
but some vapor phase could be present.
The pressure of vessel 73-V-04 is controlled by split range controller, with an injection
of dry hydrogen to pressurize the drum and a vent line routed to the stabilizer.
A major part of the liquid from 73-V-04 is pumped via recycle pumps hydrogenation
reactor recycle pumps 73-P-03A/B under flow control and used as feed diluent. The
other part is pumped, under flow control; by isomerization reactor feed pumps 73-P-04
A/B to first stage isomerization reactor 73-R-02.
In case of high benzene content in feed, a part of diluent is cooled in reactor recycle air
cooler 73-A-01, while remaining goes through the air cooler by-pass line, in order to
allow the control of the isomerization reactor inlet temperature (and consequently of the
hydrogenation reactor). An additional pitch fan control is used for higher temperature
rise in benzene saturation reactor.
In case of low benzene content in feed, the temperature is controlled via HP steam of the
73-E-04 (air cooler is not required and is fully bypassed).
Diluent recycle is the key factor to control the temperature of the hydrogenation reactor.
Indeed, the rate of diluent recycle controls the reactor temperature gradient, while the
level of cooling on the diluent recycle controls the reactor inlet temperature.

The rate of diluent recycle must be adjusted by operator in order not to exceed 35C of
exothermicity in the hydrogenation reactor.
4.2.3. Isomerization Section

The isomerization reactors feed from flash drum is fed under flow control and mixed
with hydrogen under ratio flow control.
A small amount of chloriding agent is continuously injected into isomerization reactor
feed, by pump 73-P-02 A/B, in order to maintain the chloride balance on the
isomerization catalyst. This is a make-up for catalyst chloride, which is lost in reactor
effluent.
The mixture is routed to a static mixer 73-M-01 (homogenous mixing) before entering
the first stage isomerization reactor 73-R-02, where isomerization reactions occur. These
reactions are slightly exothermic. The reactor effluent, that leaves the first isomerization
reactor, has to be cooled before entering the second stage isomerization reactor 73-R-03.
Temperature of the second isomerization reactor inlet is controlled by first stage
isomerization reactor feed / effluent exchanger 73-E-03 bypass. In 73-R-03, remaining
isomerization reactions occur.
Both 1st and 2nd stage isomerization reactors are mixed phase, down-flow reactors, with
a single catalyst bed. The isomerization reactors are designed to operate in the lead/tail
position or in a single reactor configuration.
The reactor circuit inlet pressure is controlled using a back pressure controller located on
the reactor effluent stream, routed to the stabilizer 73-C-01. The temperature profile in
each of the reactors is monitored with multiple temperature indicators located across the
catalyst bed. The differential temperature between adjacent thermocouples is a measure
of the extent of reaction, while also indicating the reactive zone of the catalyst bed.
The effluent is then routed to the stabilizer 73-C-01 under pressure control.

4.2.4. Stabilizer Section

The raw isomerate is received in the stabilizer column 73-C-01 under pressure control.
The purpose of the stabilizer is to reduce C4- rate in the isomerization reactor effluent.
LPG, H2 and HCl are stripped and sent to LPG recovery section. The Stabilizer
operating pressure is optimized to strip out the C4 components from the reactor effluent,
while minimizing the C5 hydrocarbon vent losses and reducing the C4 content of the
Isomerate product.
The stabilizer overhead is partially cooled in stabilizer air condenser 73-A-02. It is
collected in the stabilizer reflux drum 73-V-05 where the vapor phase is routed under
pressure control to the scrubber while the liquid is pumped by pump 73-P-05 A/B under
flow control with level reset to the stabilizer as reflux.
Stabilizer bottoms are reboiled with high pressure steam in exchanger 73-E-05. Reboiler
duty is under temperature control at the sensitive tray of the column. The temperature
control is cascaded with the flow control on low pressure condensate.
Stabilizers bottom is routed to deisohexaniser column 73-C-02 under flow control
cascaded with the level control on the column bottom, via a chloride guard bed 73-V-06.
This guard bed prevents any chloride component in the deisohexaniser section during
upset.
4.2.5. Deisohexaniser
Deisohexaniser (called DIH) 73-C-02 is fed with stabilizer bottom which preheat the
DIH pump around through DIH feed/recycle exchanger 73-E-07. Deisohexaniser
recovers stabilized isomerate product and recycles low octane methyl-pentanes and n-
hexane to the reactors. This is done via the DIH recycle drum 73-V-07, which is fed on
level control. Recycle is pumped, by pump 73-P-07 A/B as a recycle to the reactor
section after being cooled successively in the deisohexaniser recycle/reactor feed
exchanger 73-E-02 and recycle trim cooler 73-E-08.

Remaining liquid from 73-P-07 A/B is fully vaporized by heat exchange with DIH feed
in 73-E-07, and is recycled to the DIH column, in order to reduce the heat load required
for reboiling of the column.
Overhead vapor of the column is totally condensed through deisohexaniser air condenser
73-A-03 and is routed to the deisohexaniser reflux drum 73-V-08. Reflux is pumped by
deisohexaniser reflux pump 73-P-06 A/B under flow control. Isomerate product is
pumped, under flow control reset by 73-V-08 level control, by pumps 73-P-09 A/B and
is further cooled in sea water cooler 73-E-09 and routed to storage.
The Deisohexaniser reflux drum pressure is controlled by split range pressure controller
at column overhead.
Deisohexaniser bottom is reboiled by medium pressure steam in exchanger 73-E-10.
Steam flow controller to the reboiler is reset by temperature control at the sensitive tray
of the column.
The bottom stream is concentrated in C7+ and C6 Naphthenes. It is pumped by
Deisohexaniser bottoms pumps 73-P-08 A/B to the LPG recovery section, where it is
used as lean oil make-up. The lean oil is under flow control cascaded by the column
level control.
4.2.6. LPG Recovery Section

The purpose of this section is to optimize LPG recovery from the stabilizer off gas, by
using of DIH bottom stream as lean oil.
The dry off gas is mixed with the recycle gas from LPG stripper reflux drum 73-V-12.
This stream is contacted with cold lean oil from LPG separator drum 73-V-11. The two
phase stream is further cooled LPG refrigeration system 73-E-13B exchanger and fed to
the LPG separator drum, in which gas phase and liquid phase are separated. The gas
phase is send to a packed zone, located in upper section of drum, for counter current
contacting with the cold lean oil, in order to maximize LPG recovery.
Off gas from this section is sent, under pressure control, to Fuel Gas.

The rich oil containing the absorbed LPG is pump from the cold separator drum through
73-P-14 A/B, underflow control cascaded with level control of separator drum 73-V-11,
to stripper 73-C-04. The stripper feed is preheated through heat exchangers 73-E-14 and
73-E-15, in order to optimize the recovery.
LPG stripper reboiler with HP steam as in 73-E-17 allows recovering the LPG product
which is produced as side stream liquid draw-off below pasteurization zone. Draw off is
cooled in LPG trim cooler 73-E-18 A/B and pumped by LPG product pumps 73-P-16
A/B to the battery limit. The LPG product is on flow control cascade by column top
temperature control.
Stripper overhead is partially condensed in LPG stripper condenser 73-E-19 A/B. The
stripper off gas is recycled and mixed with the dry scrubber off gas. The stripper
overhead is under pressure control.
The stripper bottoms stream is routed, under flow control cascade with the level control,
to feed/bottom heat exchangers of LPG stripper via 73-P-15 A/B. then lean oil is
combined with DIH bottom stream. The mixture is cooled down through LPG stripper
feed/bottom exchanger 73-E-15 and through water cooler 73-E-16 A/B. Part of this
stream is sent to export via storage. The other part is fresh lean oil (to be cooled down
before absorption of LPG) and is recycled to packed zone of the LPG separator drum.
Reboiler duty is under temperature control at the sensitivity tray of column.
In case LPG recovery is in shut down, facility is provided to by-pass completely this
section and route scrubber off gas directly to Fuel gas or to flare.
4.2.7. Scrubber Section

As the gas from stabilizer overhead contains HCl, it must be caustic treated and water
washed before released to LPG recovery section. Off gas enters the bottom of the caustic
scrubber 73-C-03 through hold-up and is first caustic washed, in a first packed bed.
Then off gas, saturated by caustic, is water washed in second packed bed before being
routed to scrubber off gas dryer. Caustic weight fraction varies from 10% wt to 2% wt as
it reacts with HCl to produce NaCl. The caustic is re-circulated by 73-P-11 A/B and is

maintained at the 55 oC through the caustic recycle heater 73-E-12, in order to keep the
caustic a few degrees warmer than the feed gas to avoid potential foaming problems due
to any hydrocarbon condensation.
Both the scrubber section are packed with raschig rings. The caustic inventory
requirement is stored in the tower bottom section and feed gas is bubbled through this
caustic inventory. A portion of the circulating caustic is sprayed on to the column walls
below the caustic wash packed section to avoid any wet hydrogen chloride corrosion in
this part of the scrubber.
When the concentration of circulating caustic has been decreased to about 2% wt, the
caustic inventory is drained through pump 73-P-11 A/B discharge and tower bottom is
filled up with 10% wt fresh caustic. Spent caustic is sent to the spent caustic system.
Fresh 10% wt is made up through pumps 73-P-10 A/B.
The gas leaving the caustic wash section is washed with water in the top packed section,
to remove any entrained caustic. Water is collected in the chimney tray below the water
wash packed section, and is circulated using the pumps 73-P-13 A/B. water loss to the
vent gas leaving the scrubber is made-up periodically by fresh de-mineralized water
addition (via pump 73-P-12 A/B and de-mineralized water drum 73-V-10), and once
every several days the water inventory is drained and replaced.
4.2.8. Dryers regeneration:

Naphtha feed, H2 make up and scrubber off gas flow through their respective dryers in
series. Molecular sieve becomes saturated after a certain period of time. Then they need
regeneration. The on line moisture analyzer is used to monitor the moisture content of
the streams leaving each dryer.
The feed dryers (73-DR-01 A/B), the Hydrogen dryers(73-DR-02 A/B) and the scrubber
off gas dryers are regenerated using vaporized deisohexaniser distillate product (from
73-P-09 A/B) as regenerant medium to remove down-flow the water trapped by the
molecular sieves. The concerned dryer is isolated from the other one which is still in
service.

This regenerant is completely vaporized by high pressure steam in dryers regenerant

vaporizer 73-E-20. Liquid level in the vaporizer is monitored closely to avoid liquid
carryover to dryers regeneration superheater 73-F-01 (electrical heater). The steam to the
vaporizer is under flow control and is cascaded to the level control of the vaporizer.
After passing through the dryers, the regenerant stream is cooled down by dryers
regenerant air condenser 73-A-04 and further by dryers regeneration trim cooler 73-E-
21. This stream is routed via dryers regenerant degasser 73-V-13 to isomerate storage.
The Regenerant Degasser is a liquid flooded drum, releasing the effluent regenerant
liquid on pressure control for mixing with the isomerate product. Any light components
which accumulate in the Regenerant Degasser are purged to flare as required through a
liquid level controller, which maintains a low liquid level at the very top of the drum.
Free water collected at the bottom of the Regenerant Degasser is periodically drained to
oily water sewer.
4.3 CHLORIDE INJECTION FACILITIES

Tetra-chloro-ethylene, C2Cl4 is the recommended chloriding agent which is injected
continuously from the chloride agent injection drum (73-V-03) to the Isomerization
reactors by pumps 73-P-02 A/B. This injection corresponds to the make-up for the
amount of chloride loss from the chlorinated platinum catalyst. C2Cl4 is fully converted
to HCl at reactor normal operating conditions. Hence chloride lost in the reactor effluent
is HCl form, which is finally converted into NaCl in the caustic scrubber.
4.4 UTILITY SYSTEM

The utility system consists of HP steam, MP steam, LP Steam, Condensate, Service Water,
Cooling Water, Bearing Cooling Water, Instrument Air, Plant Air, Nitrogen, Fuel Gas, etc.
Closed Blow Down (CBD), Flare is also provided within the unit.
4.4.1. HP Steam System

An 8 High pressure steam header has been provided for ISOM unit.

HP steam is distributed to the following equipment of the ISOM unit.

- Hydrogenation reactor feed heater 73-E-04
- Stabilizer reboiler 73-E-05
- LPG stripper reboiler 73-E-17
- Dryer regenerant vaporiser 73-E-20
4.4.2. MP Steam System

A 10 header supplies MP steam to the ISOM unit.
Use of MP steam in ISOM unit is mainly as follows:
- Deisohexaniser reboiler 73-E-10
- Start-up ejector 73-J-01
4.4.3. LP Steam System

A 4 header supplies LP steam to the ISOM unit. Mainly use of LP steam in ISOM unit is
as follows:
- Utility hose station
- Feed Surge drum 73-V-01
- Chloriding agent injection drum 73-V-03
- Compressor 73-K-01 A/B
- DIH Recycle drum 73-V-07
- Deisohexaniser 73-C-02
- Refrigeration package 73-LC-01
- LPG stripper 73-C-04
- LPG stripper reflux drum 73-V-12
4.4.4. Cooling Water System

The cooling water requirement for cooling purpose in the ISOM unit is met through sea
cooling water system. A 20 cooling water supply header supplies water to ISOM unit.
Cooling water from the supply header is taken to the following equipment in ISOM unit.

- Compressor 73-K-01 A/B

- LPG trim coolers 73-E-18 A/B
- Make up H2 trim cooler 73-E-01 A/B
- Lean oil trim coolers 73-E-16 A/B
- To sample points
- To analysers
- Isomerate trim coolers 73-E-09 A/B
- Recycle trim coolers 73-E-08 A/B
- Stabilizer trim cooler 73-E-06 A/B
- Dryers regeneration trim cooler 73-E-21 A/B
The return water is collected from all the equipments through cooling water return header
and sent to B/L.
Cooling water regularly PH, Chlorine, turbidity and conductivity to be monitored regularly.
In this PH and chlorine are most important parameters. Due to this, chances of exchanger
shell or tube damage increases.
4.4.5. Bearing Cooling Water System

Bearing cooling water is required for pump and compressor cooling purpose. A 4 bearing
cooling water supply header supplies water to ISOM unit. Bearing Cooling water from the
supply header is taken to the pumps and compressors.
The return bearing cooling water is collected in a 4 return header and sent to B/L.
4.4.6. Service Water System

The 3 common service water header supplies service water to the ISOM unit. The service
water header supplies water to various hose stations and chloriding agent injection pump
73-P-02 A/B, to prevent any spillage, in the units. Service water is required mainly for
cleaning and washing.

4.4.7. Instrument Air System

A 2 Instrument Air header supplies IA to ISOM unit. Apart from instrument air tapping
instrument air is supplied to the following facilities.
- Hydrogen Compressor 73-K-01 A/B
- Refrigeration package 73-LC-01
Instrument air Dew point (-400 C) is to be monitored regularly. If moisture is more then it
will create problems in control valves (mainly scaling).
4.4.8. Plant Air System

A 3 plant air header supplies plant air to the ISOM unit. Plant air is required for the hose
stations, Anhydrous HCL bottle, Refrigeration package etc.
4.4.9. Nitrogen
A 3 header supplies N2 to the ISOM unit. N2 is used for various purposes in equipment,
line etc. for inertisation, blanketing, purging etc. In addition to that following permanent
connections are provided for N2 in the ISOM unit.
- Hydrogen make up compressor (73-K-01 A/B)
- Isomerisation feed surge drum (73-V-01)
- Close Blow Down system (73-V-16)
- Stabiliser bottom chloride guard bed(73-V-06)
- Deisohexaniser reflux drum (73-V-08)
- Stabiliser (73-C-01)
- Stabiliser reflux drum( 73-V-05)
- Hydrogenation reactor flush drum (73-V-04)
- Isomerization reactors (73-R-02 / 03)
- Hydrogenation reactor (73-R-01)
- LPG separator drum (73-V-11)
- LPG stripper (73-C-04)
- ISOM feed dryers (73-DR-01 A/B)

- ISOM hydrogen dryers (73-DR-02 A/B)

- Scrubber offgas dryer (73-DR-03 A/B)
- Dryer regenerant vaporizer (73-E-20)
- Anhydrous HCL bottle etc.
Nitrogen purity is to be maintained by controlling oxygen ppm (<0.5). If nitrogen purity is
less then chances of damaging catalyst increases.
4.4.10. Fuel Gas System

FG supply header is of 2 size. Fuel Gas is mainly used for flare header purging and
maintaining the pressure of feed surge drum 73-V-01.
4.4.11. Flare System

Relief line from safety valves, Dry gas seal system of the compressor, Purge gases etc. are
collected in the common 28 common flare header.
4.4.12. Closed Blow-Down System

Drains from various equipments are collected in two nos of Closed Blow-down headers (4
size each) and combined to form 6 header leaving the battery limit.
4.5 WASTE EFFLUENT FROM ISOMERIZATION SECTION

4.5.1. Spent Caustic from Scrubber section:
Spent caustic is one of the effluents leaving the unit, and it is sent to the ETP unit. The
spent caustic is removed from the bottom of the Caustic Scrubber 73-C-03 on an
intermediate basis of estimated at 7 days.
Quantity, Tons/week 23
Temperature, oC 45-50
Water 87.3

Also, a small amount of spent water that is purged periodically from the scrubber water
wash section is combined with the spent caustic. This purge water contains entrained
caustic and dissolved light hydrocarbons.
4.5.2. Oily water:

Normally there is no sour water effluent leaving this unit, as the hydrocarbons and the
hydrogen feed streams contain only traces of water. However the maximum effluent
discharge from Regenerant Degasser is approximately 16 Kg/hr based on the maximum
effluent water content specified for the hydrocarbon feed, H2 make-up and scrubber off
gas streams.

SECTION 5
PRE-COMMISSIONING PROCEDURE
5.1 GENERAL
As the new unit nears completion, there is a large amount of preparatory work, which
should be performed by the operating crew. 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
exactly the operation of all equipments.
Some of the pre-commissioning works can be carried out simultaneously along with
construction. But, care in the organisation of this work is necessary so that it will not
interfere with construction work. It is most important to plan schedule and record with
checklists and test schedules all the preliminary operation and to co-ordinate the
construction programme.
5.2 PRE-COMMISSIONING ACTIVITIES

The material in this section gives general guidelines for preparing a unit for start-up.
Some sections need to be expanded to give specific directions (water flushing procedure,
inertising procedure for example); this shall be prepared by commissioning personnel
prior to start of the pre-commissioning/start-up.
5.3 INSPECTION / CHECKING

Sections of the unit should be checked out as soon as the contractor completes work in
those areas. Immediately following inspection of those areas, punch lists which indicate
the deviations from the design specifications should be written and distributed to the
contractor. In this manner mistakes in construction can be found and corrected early.
Inspection of the plant can be basically divided into the following areas:
- Vessels including reactor
- Piping
- Heaters

- Exchangers
- Pumps
- Compressors
- Instrumentation
- Catalyst/Chemical Inventory
Inspection of vessel, column, heaters etc.

Inspection of the interior of the vessels, columns, heaters and other equipments not
normally accessible during operation should be made to ensure that they are complete,
clean and correctly installed. Tray assemblies in columns should be checked with reference
to the engineering drawings to detect any defect in assembly or construction and to ensure
cleanliness. Packings, if any, are to be done after internal inspection and flushing. The
vessels are to be checked with reference to engineering drawings. The demisters are to be
fitted after internal cleaning and water washing.
In heaters, the burner assemblies should be checked for easy operation of air registers,
contour of the burner throat, debris material etc. The heater coils supports to be checked for
proper installation.
a) 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 direction and accessibility for operation and
maintenance. Spring supports, if any, to be checked for the cold setting and later for hot
settings while plant is in operation. Check for completion of welding work, especially on
small bore piping and socket weld valves.
b) Instruments
All instrument tapings for pressure, level and flow should be clear and thermo wells should
not foul with the internals. These should be checked prior to box up of the equipment.

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. Control
valves responses should be checked for controller outputs. The shutdown systems of the
equipments should be checked by simulating the various conditions in the control circuits.
c) 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.
d) Rotary Equipment
All rotary equipment such as pumps, compressors, turbines etc. are to be checked for
bearings, internals and free movement. The auxiliaries, control systems on this equipment
should be thoroughly inspected.
e) Drainage System
Check the OWS and blow down system against drawings. Check for free flow.
5.4 PREPARATION FOR PRE-COMMISSIONING

- Check the unit for completion of mechanical work against P&ID.
- Check list points are liquidated. Any pending point should not affect pre-
commissioning operation.
- 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, offsites and utilities are
complete and in working condition.
- Ensure that the required lube oil, grease and other consumable are available in
the unit.
5.5 PRE-COMMISSIONING OPERATION

Prior to the commissioning of the plant there are several pre-commissioning operations
that must be conducted to prepare the plant for the actual start-up; these are:
1. Commissioning of utilities
2. Final inspection of vessels
3. Flushing
4. Functional test of rotating equipment
5. Service and calibrate instruments
6. Vessel Loading
7. Tightness test
8. Purge and gas blanketing
9. Dry out of Reactor section
10. Reactor catalyst loading
It is important that these operations be carried out as thoroughly as possible to help

achieve a smooth and trouble-free start-up and later steady normal operation. A
discussion detailing the major items to monitor in each of these operations follows.
The above outline may be expanded somewhat as follows:
5.5.1. Commissioning of Utilities

The various utility lines should be tested and placed into service as soon as the
construction schedule allows. Pressure tests should be carried out on all steam
condensate, air, fuel gas, flare, and nitrogen lines as is done on all process lines.

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 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.
- To gauge the effectiveness of the steam blowing (and the amount of scale left in
the lines), target plates should be installed at the blow down points. The lines
should be repeatedly blown down until virtually unmarked target plates are
obtained. Condensate lines should be continually checked and traps removed
and cleaned if plugged.
Note: The following precautions to be taken while blowing / commissioning steam header:
- To drain the low points of the lines before and during heating period in order to
avoid water accumulation, this causes hammering.
- To open drain / vent during cooling period to prevent vacuum formation
- To isolate the instruments, remove orifice plates and control valves; to re-install
the orifice plates and control valves after 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 reconnected 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. 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 connections 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.
D. Fuel Gas Networks:

Networks shall be blown through from battery limit with a strong air flow in order to clean
the lines. During the operations, orifice plates and control valves shall be removed.
5.5.2. Final Inspection of Vessels

All vessels should be inspected before final closing and any loose scale, dirt, etc., should
be removed. Any line coming directly off of the bottom of a dirty vessel should be
removed.
It is very important that the internals of the hydrotreating reactor be inspected very
carefully. The hydrotreating reactor internals should be checked for holes and/or
damage and repaired as required. The catalyst support basket and unloading sleeve
should be checked to ensure correct fit in the nozzles.
The separator should be checked carefully to be sure the cement lining is installed well
and that the mesh blanket is securely fastened to the support ring. There should be no
gaps in the mesh blanket.

5.5.3. Flushing
After pressure test has been completed on any vessel with its connected piping,
receivers, exchangers, etc., required blanks are pulled and water is circulated for the
purpose of removing any dirt, scale, etc. Much of the dirt is picked up in the pump
screens where it is taken from the system by removing and cleaning the screen.
All possible lines and pumps should be used during the washing procedure for complete
cleanout of the system. Of course, no water circulation should be carried out in the gas
sections of the unit. 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.
- 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 starts coming 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 unit to 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.
Where low chloride test water is required to prevent the potential of chloride stress
corrosion cracking of austenitic stainless steel, it is especially important that all water
from low points is removed by being purged with nitrogen. Otherwise, as the remaining
water evaporates, the chloride concentration that started at lower concentration will
concentrate to levels that can (and will) crack or cause pitting of the austenitic stainless
steel. If pitting occurs, it may be discovered during a final equipment inspection (for
example, at the bottom of a fractionation column), allowing time for repairs. On the
other hand, if stress corrosion cracking occurs it will probably not be discovered until
the equipment temperature is increased for the first time, causing a delay in the start up
schedule.
5.5.4. Functional Test of Rotating Equipment

All rotary equipment (including dosing pumps) will undergo functional test to check their
performance.
i) 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 manufacturers 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.
ii) Pumps
Prior to unit start up, all centrifugal pumps should be thoroughly checked and run in
properly (after pressure testing and water flushing) as indicated in the following outline:
The pumps will be started and operated according to the manufacturers instructions.
CAUTION: Many high head pumps are not designed to pump water. To do so can
result in damage to the pump internals. Check the vendors specifications before
attempting to run in pumps with water.
iii) Compressors / Other Special Equipments

In the case of rotating equipment, such as the recycle gas compressor, net gas
compressor the separator pumps, and other special equipment, vendor representatives
(motor vendor also in some cases) normally directs rotation and alignment checkout and
all other activities required to prepare the equipment for service. Rotating equipment
specialists and operations representatives should monitor and participate in this activity
for verification purposes, as well as for the opportunity to learn valuable information
about the equipment. However the following measures before compressor
commissioning is suggested.
The compressors will be started and operated according to the manufacturers
instructions. Vendor representative should present for start-up of compressor.
5.5.5. Service and Calibrate Instruments

Normally, instrument lead lines will be tested hydrostatically up to block valves when
the balance of the unit is tested. Hydrostatic test pressure will not be made on
instruments which normally handle gas and no pressure-measuring element should be

subjected to test pressures above its range. Also, never pull a vacuum on a pressure
instrument or gauge unless it is specifically designed for it.
All instrument air piping should be tested at 7kg/cm2g (100 psig), with compressed air.
Soap solution should be used on all joints to check for leakage. Care should be taken to
ensure that this high air pressure is not put on any instruments or control valve
diaphragms. Likewise, when pressure testing of the unit is done, care must be taken that
the fuel gas pressure balance valves are blinded off to keep high pressure off the
diaphragm. Before starting up, all instruments should be serviced and calibrated. This
includes carefully measuring all orifice plate bores with a micrometer. The following
guidelines may be adopted for checking and calibration of all instruments.
i) Orifice Plates
Before each orifice plate is installed the orifice taps should be blown clear. The orifice
plate should be callipered to check, if the correct size orifice plate is installed. The plate
should then be installed after checking for the correct direction.
ii) 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
indicator.
iii) Pressure Transmitters and Receivers
These should be checked in place. The calibration of the receiver should be checked at
the same time.
iv) Alarms
All alarms, auto start and cut off systems should be checked by simulating the
conditions.
5.5.6. Vessel Loading

All vessels can be loaded except the reactor catalyst due to its extreme sensitivity to
moisture and air. In the design, the vessels to be loaded are:-
- Feed Dryers

- Hydrogen Dryers
- Scrubber off-gas dryers
- Reactor (support material)
- Caustic scrubber (Raschig Ring)
- Chloride guard bed (stabiliser bottom)
Before loading ensure that the vessels are clean and dry. They have previously been
pressure tested and water washed, ensure there are no water pockets in the piping loops
(not critical for the scrubber). Brush and vacuum the inside of the vessel if necessary and
ensure they are completely isolated and flanges or manways are open, top and bottom.
The inside must be thoroughly vented with air.
5.5.7. Tightness Test

The initial leak tests are to be performed according to the unit owner and engineering
contractor normal practices. These tests can be carried out using air or nitrogen
depending upon local facilities. As these utility pressures are much lower than the unit
design pressure, the test pressure should be the maximum available from either of these
facilities. The unit must be totally isolated from the fuel gas and flare headers and from
any adjacent units or sections which may contain hydrocarbons and also from other
utility systems where the design pressure is lower. This includes sewers which should
have already been tightened during previous start-up preparations.
Install a minimum of two pressure gauges in each section to monitor the unit pressure.
Pressure each section up to the air or nitrogen maximum operating pressure. Survey the
unit for leaks and carefully tighten. Their location should be recorded for further checks.
Continue this exercise, tightening each leakage point until the pressure loss in that
section is less than 0.05 kg/cm2/hour for four hours.
When the leak test is considered satisfactory for all sections, depressurize at all the low
points.
For the leak tests purpose, the following division into sections is recommended.
i) Dryers Section Including Regeneration Facilities :

Feed surge drum 73-V-01

Feed Dryers 73-DR-01 A/B
H2 Dryers 73-DR-02 A/B
H2 make-up cooler 73-E-01
H2 make-up K.O. Drum 73-V-02
Regenerant Vaporizer 73-E-20
Scrubber offgas dryers 73-DR-03
Dryers Regeneration Superheater 73-F-01
Dryers Regenerant Air Condenser 73-A-04
Dryers Regenerant Trim Condenser 73-E-21
Dryers Regenerant Degasser 73-V-13
Deisohexaniser recycle/reactor feed exchanger (tube side) 73-E-02
ii) Reactor Section :

Hydrogenation Reactor 73-R-01
Isomerization Reactors 73-R-02 & 73-R-03
Feed/effluent exchangers 73-E-03 A/B
Deisohexaniser recycle/reactor feed exchanger(shell side) 73-E-02
Hydrogenation reactor feed heater (shell side) 73-E-04
iii) Stabilizer Section:

Stabilizer 73-C-01
Stabilizer Air Condenser 73-A-02
Stabilizer Trim condensers 73-E-06 A/B
Stabilizer Reflux Drum 73-V-05
Stabilizer Reboiler 73-E-05
Stabilizer bottom chloride guard bed 73-V-06
Deisohexaniser feed/recycle exchanger (tube side) 73-E-07

iv) Deisohexaniser Section:

Deisohexaniser 73-C-02
Deisohexaniser Air Condenser 73-A-02
Deisohexaniser Reflux Drum 73-V-08
Deisohexaniser Reboiler 73-E-10
Deisohexaniser Recycle Drum 73-V-10
Deisohexaniser Feed/Recycle exchanger (shell side) 73-E-07
Off-spec Isomerate Trim Cooler 73-E-11
Isomerate Trim Coolers 73-E-09
v) Scrubber section:
Scrubber 73-C-03
Caustic Recycle Heater 73-E-12
vi) LPG recovery Section:

LPG refrigeration system (tube side) 73-E-13
LPG separator drum 73-V-11
Separator drum bottom/Lean oil exchanger 73-E-14
LPG stripper Feed/bottom exchanger 73-E-15
Lean oil Trim Cooler (shell side) 73-E-16
LPG stripper 73-C-04
LPG stripper Condenser 73-E-19
LPG stripper Reflux Drum 73-V-12
LPG stripper Reboiler 73-E-17
LPG Trim Cooler 73-E-18

SECTION 6
COMMISSIONING PROCEDURE
6.1 FIRST START UP

The following text describes the first start up of the new built unit. Any subsequent start
up of the same unit may or may not include all of the following steps depending upon
the status of the unit after shutdown.
6.2 STATUS OF THE UNIT

The unit prior to its first start up is as follows:
- Each section has been thoroughly drained free of water and lines have been blown
with air to remove ant pocket.
- All adsorbent have been loaded in the dryers.
- Pall and Raschig rings have been loaded, respectively, into the top of the LPG
separator drum and scrubber packed section.
- The bottom inert balls have been loaded into the reactor.
- The chloride guard bed has been loaded
- Each section has been satisfactorily leak tested.
- The unit has not been inerted but is isolated with blinds:-
On the feed and product lines
On the flare and fuel gas headers
On the sewer lines and utilities except cooling water, nitrogen and steam
ejector
On pressure relief valves to flare
On spent caustic and caustic make-up facilities
6.3 CHRONOLOGY
The first start up sequence is as follows:

- Complete inerting of
the dryer section, reactor section and regeneration section
the stabilizer, deisohexaniser, LPG recovery section
- Hydrogen sweep
- Oil circulation and stabilizer / deisohexaniser / LPG recovery section start-up.
- Reactor oil in
- Acidizing and final dry-out
- Hydrogenation / Isomerization catalyst loading
- Isomerisation unit start-up
- Lining out the isomerisation unit at design conditions
- LPG recovery start-up
- Lining out LPG recovery section at design conditions
6.4 COMPLETE INERTISING

The purpose is to reduce the O2 content in all of the sections below 0.2 volume % prior
to hydrogen or hydrocarbons introduction.
Evacuation using steam ejector followed by vacuum breaking with nitrogen is preferable
for the unit section where water is not desirable, like the dryer and reaction sections. The
inertising of these sections could also be carried out with repeated
pressurization/depressurization cycles using nitrogen. For the rest of the unit where
water is not a problem, the steam out procedure could be used.
Dryers, Dryers Regeneration Facilities and Reaction Sections

The inertising is assumed to be performed by evacuation using the start-up ejector. Steps
to be followed:
- Test the ejector to make sure that it is operational.
- Ensure the entire system is open, i.e., all pathways between pieces of equipment are
clear. Pumps should be isolated.

- Isolate the instruments not suitable for vacuum service.

- Install a minimum of two vacuum or compound gauges to monitor the vacuum level.
Locate as far as possible from the ejector.
- Pull a vacuum down to 0.2 bar absolute.
- Hold the vacuum for one hour to check for leaks, the pressure must not rise more
than 0.07 bar per hour.
- Break the vacuum by N2 pressurizing.
- Pressure up the unit to 1.0 bar with nitrogen.
- Depressurize through all low points, dead legs, vents, etc.
- Repeat until the oxygen content is less than 0.2% by volume. Check the system at
several points during depressurizing.
- Leave a residual nitrogen pressure of 0.1 bar g. Typically the required O2 content is
achieved with 3 cycles of pressurizing / evacuating.
Stabilizer, Deisohexaniser and LPG recovery Sections

These sections can be inerted with nitrogen or steam, as during the start-up any water
will be removed during oil circulation.
The chloride guard beds should be isolated and by-passed. Their inertising is
independently realized with nitrogen.
If inertising is performed with LP steam, the following brief procedure applies:
- Open high point vents and low point drains on the vessels to be steam purged.
- Start introducing steam into the bottom of all the columns using the steam-out
connection and steam out the reboiler and reflux drums separately. It may be
necessary to make-up additional steam connections to properly purge some
piping which may be dead ended.
- Thoroughly purge all equipments and associated piping, venting at all high
points and draining at all the low points.
- Continue steaming for one hour minimum after steam appears at all the vents.
- Remove the blinds on the :

safety valves to flare

flare header, fuel gas header
products to battery limits
Remaining blinds on utilities, sewers and caustic facilities.
- When steam purging is complete, start to close all the vents and drains.
Immediately start to introduce fuel gas or hydrogen to prevent the possibility of a
vacuum forming as the steam condenses.
- Cut back the steam flow until it is stopped. As the fuel gas or hydrogen is
admitted, the system will cool down and the condensate can be drained off.
- Pressure this section up to 1 bar g with either fuel gas or hydrogen. Check for
any leaks at flanges and gasketed points.
- This section is now ready to be charged with naphtha.
6.5 HYDROCARBON CIRCULATION AND INITIAL DRY DOWN

Before loading catalyst into the reactor, it is necessary to dry the piping and equipment
to remove any traces of water which might have remained from construction and
pressure testing. The unit is now considered oxygen free and leak tested. The following
procedure introduces hydrogen and then hydrocarbon circulation at design operating
pressure in order to begin dry out. During this period it will be necessary to change the
flow pattern through the reactors and associated piping to ensure that all lines are used.
In addition any dead lags such as control valve bypass should have flow established
through them for a short time and all instrument lead lines must be adequately purged.
This is to ensure that no water pockets remain in the system. These flow patterns are
repeated during the subsequent acidizing steps. Initially line up the isomerization
reactors for series flow operation. Then every six hours after hydrocarbon circulation
has been established switch the flow pattern as
a) Reactor 73-R-02 single operation.
b) Reactor 73-R-03 single operation.

c) Reactor 73-R-02 to Reactor 73-R-03 series operation.

d) Reactor 73-R-03 to Reactor 73-R-02 series operation.
6.6 HYDROGEN SWEEP

This step involves introducing hydrogen to the reaction section and pressuring up to
operating pressure.
- The hydrogen comes from the hydrogen unit. Check the hydrogen availability and
quality.
- With the Feed Dryers isolated and the distillation section blocked off from the
reaction section, line up the circuit before introducing hydrogen.
The LPG recovery section is isolated.
- Introduce hydrogen through the hydrogen dryers in series at a filling rate which will
not upset the other hydrogen users.
- Pressurize the reaction section up to operating pressure.
- Survey the unit for leaks and in particular the locations which were leaking during
the initial leak test.
- With the reactors holding at operating pressure, slowly open the H2 pressurization
line (to the stabilizer reflux drum) and pressurize the stabilizer column up to normal
operating pressure.
- Check that LPG recovery section is isolated.
- Crack open the bypass on the stabilizer overheads pressure control valve PV-2001
and pressure up the scrubber to design operating pressure. This must be carried out
very carefully so as not to bump or dislodge the packed sections. The DIH section is
not included in this system.
- Using LPG dedicated H2 pressurization line, pressurize the LPG stripper and the
LPG separator drum up to operating pressure
- Add sufficient hydrogen to the reaction section to maintain operating pressure and
close the H2 pressurization line.

- Set in service the pressure controllers on the stabilizer feed and overhead, the
scrubber, LPG stripper and the LPG separator drum. Route any excess gas first to
flare, then to fuel gas.
- Survey the unit for leaks. Set the hydrogen make-up flow at 40% of design rate.
- Switch the flow pattern around the dryers and ensure all possible dead legs are
adequately purged.
Hydrogen sweep:-
a) Reaction section :-
H2 from CCR 73-V-02 73-K-01 A/B 73-DR-02A/B
Start up line 73-R-01 73-E-04 / E-03 / E-02

(4-P-73-1606)
73-M-01 73-R-02 73-E-03 73-R-03
b) Stabiliser Section :-
Start up line
73-DR-02 A/B 73-V-05 73-E-06 A/B 73-A-02
(2-P-73-1514)
73-PV-2001 73-C-01
73-C-04

6.7 OIL CIRCULATION, AND STABILIZER / DEISOHEXANIZER / LPG

RECOVERY SECTION START-UP
This sequence allows the C5 / C6 feed introduction in the system through the Feed
Dryers, to the Stabilizer, the Deisohexaniser and the LPG recovery section by utilizing
the start-up line by-passing the Feed dryers and the reactors and the other one only by-
passing the reactors.
The dryers regeneration circuit is also flushed with oil and the oil is finally routed to
storage through the product lines. This performs a thorough flushing of foreign material
from the equipment and liquid lines.
- Check the C5/C6 feed availability and quality. It must be on-spec with regard to
contaminant content.
- Check that the Feed Dryers are blocked off from the reaction section.
- Check that the C5/C6 feed is by-passing the Feed Dryers. Line call start-up line
should be used.
Before establishing the complete loop it is necessary to draw off the C5/C6 to off-spec
storage to remove the equipment oil coating and not to contaminate the dryers molecular
sieves. A period of 8 hours is necessary before closing the loop. During this step, the
chloride guard bed will be by passed.
- Establish a level in the stabilizer bottoms 73-C-01.
- When the level in the stabilizer reaches 40%, route the bottoms to the
Deisohexaniser 73-C-02. The chloride guard bed 73-V-06 is still by-passed.
- Commission the Deisohexaniser air condenser 73-A-03A-H and then the reboiler 73-
E-10. Remove in a first step, route the isomerate product to off-spec storage (side-
draw control valve LV-2101 closed). In a second step, after all the equipment are
cleaned, commission the side-draw, and begin recycling the side-draw and keep
removing the isomerate to the off-spec storage. Set the pressure controller at the
deisohexaniser overhead.
After the 8 hour period, the complete loop including dryers can be established.

- Slowly fill each Feed Dryers separately using the globe valves and venting the
nitrogen to flare through the pressure safety valves bypass. Dryers filling and
nitrogen displacement is to be monitored through the level glasses on the PSV
bypasses.
- Once both dryers are full, the start-up line by passing the dryers is closed and the oil
circulation is continued to the stabilizer through the reactor bypass line.
- Commission the stabilizer overheads air condenser.
- As the level appears in the stabilizer, commission the reboiler.
- Slowly bring the stabilizer up to operating temperature. As the level appears in the
reflux drum 73-V-05 start the reflux pumps 73-P-05A/B and reflux back to the
column.
- Adjust the flow on the reactors by-pass line to reach a circulation rate of 60% of
design throughput.
- Once the circulation is steady, line up the regeneration circuit to by-pass the dryers.
- Crack open the flow controller on the regeneration loop and flush the loop free of
foreign material, back to rundown to storage.
- Adjust the flow to design rate, hold for 4 hours and then stop the circulation through
the regeneration loop. Close the by-pass line and re-establish the flow through the
dryers.
- Calibrate the moisture analyzers on the feed and hydrogen dryers. Commission them
to monitor dryer performance.
- During the circulation, switch the flow pattern around the dryers and ensure all
possible dead legs are adequately purged.

Oil Circulation and stabilizer / Deisohexaniser start-up
Treated Naphtha from 73-V-01 73-P-01 A/B

NHDT
6-P-73-1105
Start-up line
4-P-73-1321
Chloride Guard 73-C-01

Bed bypass
(4-P-73-1902)
8-P-73-1908
73-E-07 73-C-02 commission 73-E-10

73-A-03
(LV-2101 close)
1st step: - 73-P-08/B Start-up line

3-P-73-2212
Off-spec isomerate 73-E-11

to storage for min. 8 hrs.
Note: - Feed dryers blocked off from the reaction section:

NOTE: Enclosed start up circuits will be detailed by process licensor during Pre-
commissioning/Commissioning and shall be submitted accordingly by the licensor.

2nd Step:-
73-C-02 8-P-73-2206 73-V-07
4-P-73-1615)
73-E-08 A/B 73-E-02 73-P-07A/B
4-P-73-2101
73-V-01
After 8 hours: (Feed Dryers taken on line)
6-P-73-1105
From 73-V-01 73-DR-01 A/B
6-P-73-1303
73-C-01 (through reactor

bypass line
4-P-73-1513
Reflux
Commission 73-E-05 & A02
reboiler & condenser
after level appears
73-P-05 A/B 73-V-05 through

73-C-01 overhead
73-C-02 73-E-07 73-V-06
Similar to previous circulation
Note: Enclosed start up circuits will be detailed by process licensor during Pre-

LPG recovery section Start-up

Section status
- Leak test has been performed
- Raschig rings are installed on top of the scrubber and pall rings in the LPG separator
drum.
- Absorbent is loaded in the scrubber off-gas dryer.
- All utilities are available including chilling package
- Section is isolated as follows
Off gas from caustic scrubber : UV 2501 + block valves closed
Lean gas from LPG separator drum to fuel gas : PV 2801 + block valves closed
LPG : FV 3301 + block valves closed
Lean oil inlet from deisohexaniser bottoms : FV 2202 + block valves closed
Heavy product outlet : PV 2802 + block valves closed
LPG stripper bottom : FV 2803 close
LPG stripper reflux drum : PV 3001
Procedure
- Line-up the internal circuit between 73-V-11 (LPG separator drum) and 73-C-04
(LPG stripper).
- Slowly introduce heavy product from DIH bottom through FV-2202 at 73-P-08
discharge to 73-V11 upto 100 % at LG-2802 (LPG separator drum).
- Start the pump 73-P-04 and through FV 2801 introduce liquid to 73-C-04 (LPG
stripper)
- Commission VHP steam to 73-E-17 (LPG stripper reboiler) and bring 73-C-04 at
total reflux conditions. Make-up heavy product to 73-V-11 and restart 73-P-14 as
necessary to maintain LPG stripper levels.
- Commission the PIC-2801 at the LPG separator drum overhead. When PIC has
reached normal operating pressure set point, open UV 2501.

- Most of the rich off gas is still routed to fuel gas.

- Very slowly start to romp down PV 2501 (valve to close in approximately 20 mins)
- When PV 2501 is fully closed, then close UV 2503
- Commission chilling medium to 73-E-13 A/B
- Start recycling heavy product through FV 2804 , then restart 73-P-14 A/B
- PV 3001 (LPG stripper reflux drum), in auto mode, will start to open , to maintain
73-C-04 pressure, recycling the lean off gas to separator.
- When level reaches 50% at draw off tray level gauge (LG 2907), start 73-P-16 A/B
on minimum flow line, and then open FV 3301. The LPG product is ent to the off
spec storage during 8 hours.
- Commission PV 2802 and route LPG stripper bottoms to storage.
6.8 REACTION CIRCUIT OIL-IN

Status
Hydrogen is flowing at 40 % of design capacity through the H2 dryers 73-DR-02 A/B
and the reaction circuit at operating pressure, through the stabilizer 73-C-01, the
deisohexaniser 73-C-02, to the scrubber 73-C-03, the LPG recovery section, and out to
fuel gas.
C5/C6 feed is flowing through the Feed Dryers 73-DR-01 A/B bypassing the reactor
section to the stabilizer.
The Stabilizer, the Deisohexaniser and the LPG recovery section are operating under
total reflux at 60% capacity.
The dryer regeneration loop has been flushed and is full of liquid naphtha.
The pressure controllers of:
- stabilizer feed and overhead
- deisohexaniser overhead
- scrubber overhead
- LPG separator drum overhead
- LPG stripper overhead

are in service at their respective operating set-points

The caustic and water washes are not in service.
The isomerization reactors 73-R-02, 73-R-03 are loaded with bottom inert balls only and
are lined up for series flow.
- Establish normal hydrogen make-up flow.
- Commission the reactor feed heater 73-E-04 and slowly raise the hydrogenation
reactor inlet temperature to 110 C at 40 C/h. Place the reactor inlet temperature
controller in cascade service.
- Survey the unit for leaks.
- With all conditions steady, crack open the globe valve on the C5/C6 feed to allow
10% of the naphtha to flow through the reactors.
- Continue increasing the flow in 10% increments, maintaining system pressure,
closing the by-pass valve until all of the 60% design flow is flowing through the
reactors.
- Slowly increase the hydrogenation reactor inlet temperature to 160C at 20C/hr.
Test the reactor inter-coolers temperature control and alarms. Set in auto mode the
isomerization reactors TIC at 160C.
- The liquid flowing through the reaction section will remove the oil film on the vessel
inside walls and internals placed there after sandblasting. This oil will contaminate
the dryer adsorbent if regeneration is taking place.
During this period, it is also recommended that the deisohexaniser side-draw product
is not used to avoid contaminating the dryer adsorbent. The oil will flow out the
deisohexaniser bottoms and be routed to off-spec storage. The stabilizer chloride
guard bed is by-passed for the same reasons.
Dryer regeneration and/or cooling should be completed and discontinued before
reactor oil-in. Regeneration of either dryer must not take place until 8 hours after
reactor oil in,
- 8 hours after the reactor oil in, open the side-draw control valve, and increase slowly
the recycle flowrate to the reactors.

- During the hydrogen and hydrocarbons circulation, it will be necessary to switch the
flows through the different reactors circuits as discussed previously. It is imperative
that all piping sections are exposed to this dry out step. Also, line-up sulfur
stripping line.
- Continue drying until the water content is below 10 ppm at the reaction section
outlet. The water content in the heavy product to storage must also be lower than 10
ppm.
- Regenerate the dryers (feed and hydrogen and) on a regular basis.
- Commission the chloride absorber on stabilizer bottoms only when water content is
below 10 ppm.
Note 1: During this step all efforts should be made to get all moisture analyzers working
properly and most specially those down stream reactors, which will be used during
acidizing.
Note 2: The moisture analyzer installed downstream the reactor, which will be used
during acidizing should have its sampling system equipped with separator liquid / gas.
The liquid sample only will be send to the moisture analyzer cell.
The analyzer measure repeatability should be checked carefully at this stage as the
acidizing step follow-up will rely only on the good operation of this analyzer.

Reactor Circuit oil in:-
Naphtha 73-V-01 73-P-01 A/B 73-DR-01 A/B
73-E-02
73-E-03
73-E-04 (commission & rise

temp.upto 110C at
40C/h)
73-R-01 (at very slow rate,

10% of naphtha
should flow through
reactor)
73-R-02 Start-up line
4-P-73-1606
73-E-03 73-R-03 73-C-01

(through
8-P-73-1804)
73-V-06 bypass
(4-P-73-1902)
Off-spec 73-P-08 A/B 73-C-02 73-E-07

Isomerate
to storage

6.9 ACIDIZING AND FINAL DRY-DOWN

As previously mentioned iron oxide on contact with HCl will liberate H2O which is an
irreversible poison to the isomerization catalyst. In this step, the final dry down occurs
and anhydrous HCl is added to remove all traces of iron oxide in isomerization section
and LPG recovery section. These steps could take up to 3-4 weeks to satisfactorily
complete depending upon the equipment conditions, the sandblasting efficiency and the
previous initial dry down steps. The unit chemical cleaning during pre-commissioning
can significantly reduce the length of the dry out period.
Preparation:
- Make-up an inventory of 10% caustic solution in the scrubber bottom.
- Remove the blind on the spent caustic to safe disposal.
- Establish the water wash in the scrubber top section. Adjust the globe valve to
achieve design circulation.
- Establish the caustic circulation. Adjust the globe valves on the top and bottom
inlets to achieve design injection rates.
- Ph of the circulating water to be kept below 9/10
- Drain any liquid water which may have been accumulated in the stabilizer reflux
drum. During the acidizing period with HCl, it will be necessary to check and
drain these points on a frequent basis as highly acidic liquid could be present.
- Connect up the anhydrous HCl. The HCl cylinder should be mounted on an
accurate scale to determine and control the injection rate.
- Block in the reactor effluent moisture sample point to the dryer moisture
analyzer as the highly acidic effluent could damage the analyzer cells. After HCl
has been injected it is necessary to wait for at least one hour before reconnecting
the analyzer.
- Swing the blinds on the HCl injection facilities.
- Perform a leak test on the injection piping and the pressure controller.
- LPG section and DIH shall be isolated.

Acidizing Step :
With hydrogen flow at design rate, C5 / C6 feed at 60% of design, and the unit steady
with the reactors inlet temperature set at 160C.All hydrogenation reactor, recycle
section equipments, isomerization reactors and equipments are including in this
acidizing step.
Through out the HCl injection period, monitor the caustic strength in the scrubber
bottoms. Replenish as necessary. Do not allow NaOH concentrate decrease below 3%
wt. Check HCl content in the scrubber off gas with dragger tubes (HCl-1ppm vol)
1st Step:-
- Inject 5 kg of HCl into the hydrogen line going to hydrogenation reactor (1st
hydrogen make up line) at a steady rate over a 5 minute period.
Note: the first injection should take into account the volume of the injection line
(the quantity injected to be adjusted).
- Wait for one hour or until the reactor effluent sample pot vapour contains less
than 10 ppm HCl.
- Reconnect the moisture analyzer and obtain a reading on the sample pot liquid,
then disconnect. Record the moisture level, HCl addition and sample time (see
typical injection table data report attached).
- Continue HCl injecting in the same manner until the moisture level peaks start to
decline. During this period continue draining all low points, purging instrument
lead lines, flushing bypasses around control valves and switching the reactors
flow pattern.
- Continue HCl injection until no further response is noted by the moisture
analyzer.
- Check that the moisture analyzer is operating correctly and that the readings are
correct.
- Add another 10 kg of HCl over a 10 minute period. When the HCl content has
decreased below 10 ppm, recheck the moisture content. If a response is noted

return to regular injections of 5 kg of HCl over a 5 minute period. If no response

is noted, discontinue HCl injection.
- H2S stripping line and the superheater are lined up and acidified (160C at the
superheater). Crack closed the isolation block valve at the hydrogenation reactor
inlet.
- Continue unit circulation until the moisture content is 1 ppm at the reactor outlet.
2nd Step:-
- Swing the HCl line injection into the hydrogen line going to the isomerisation
section (2nd hydrogen make up line)
- Inject 5 kg of HCl at steady rate over a 5 minute period.
- Repeat same operation as 1st (regular HCl injections) until the moisture content is
1 ppm at the reactor outlet.
Remark : in case of vaporisation of all dissolved HCl in the separator drum, an
additional HCl injection point is foreseen at the separator outlet.
3rd Step:-
- Reduce the first isomerisation reactor inlet temperature to 100C over a one hour
period.
- When the reactors have cooled to 100C, slowly open the reaction section bypass
and route the naphtha around the reactors to the stabilizer.
- Reduce the steam flow to the Reactor Feed Heater until closed.
- The naphtha feed flow to the stabilizer can be stopped at this stage.
- Shut-off steam to the reboiler and shutdown the reflux pump.
- Reduce the stabilizer bottoms level to 30% and block in the stabilizer on standby
mode until ready for restart. The deisohexaniser and LPG recovery section
remain in standby mode.
- The stabilizer off gases are sent to the scrubber.

- Shutdown the caustic circulation and water wash pumps.

- Maintain stabilizer, LPG recovery section and scrubber pressure with hydrogen.
- Continue H2 make-up at design flowrate to cool and to sweep the reactor circuit
of liquid hydrocarbons to the stabilizer.
- Switch the reactor flow pattern to sweep out all liquid hydrocarbons.
- Cool the reactor circuit to 40C then shut-off the H2 make-up but maintain
pressure in the reaction section, stabilizer, LPG recovery section and scrubber by
switching normal hydrogen make-up line to dedicated start-up line.
- Block in and blind reactors.
- Depressurize and purge each reactor with nitrogen. Use only nitrogen containing
less than 1 ppm of water. If necessary route this nitrogen through a regenerated
H2 Dryer which has been properly purged.
- Pressure and depressurize with nitrogen until the hydrocarbon content is less
than 0.2 vol%.
- Maintain a slightly positive nitrogen pressure of 0.5 kg/cm2 g.
The hydrogenation and isomerization reactors are now ready for loading.

ACIDIZING INJECTION TABLE DATA REPORT 1

N Date Time Cylinder Weight Weight HCl Total
Number Before after Injected HCl
injection injection Kg/h. injected
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

ACIDIZING INJECTION TABLE DATA REPORT 2

No. Moisture Reactors Reactor A Reactor B Scrubber
Value Base line Arrangement Inlet T Inlet T NaOH Water
Wt ppm wt ppm AB BA % wt Ph
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

6.10 HYDROGENATION AND ISOMERISATION CATALYST LOADING

UNDER N2
Please refer section 11.1 for the detail procedure for catalyst loading of hydrogenation
and isomerization reactors.
6.11 HYDROGENATION REACTION SECTION START-UP

- Check the dryers operation, the moisture analyzer on the tail dryer must be reading
under 0.1 ppm wt H2O.
- Depressurize the hydrogenation reactor full of hydrogen and pressurize with
nitrogen. Use only nitrogen containing less than 1 ppm of water. If necessary route
this nitrogen through a regenerated make-up gas dryer which has been properly
purged.
- For start-up, feed will be introduced cold into the hydrogenation reactor 73-R-01. If
possible, it is recommended that this naphtha be as low as possible in benzene
content until the three reactors are up and running.
- Line-up the feed dryers and the hydrogenation reactor.
- Establish a level in the hydrogenation reactor flash drum.
- When the level in the hydrogenation reactor separator drum reaches 40%, start the
hydrogenation reactor recycle pumps 73-P-03 A/B. Establish a close loop from the
flash drum to the hydrogenation reactor passing through the recycle air cooler
73-A-01A/B/C/D and its by-pass.
- Stop the feed when the recycle is at design flowrate. Maintain the flowrate in the
recycle loop.
- Once a steady operation is reached, commission the reactor feed heater 73-E-04 and
slowly increase the hydrogenation reactor inlet temperature to 105C at a rate of
10C per hour.
- Using the 1st hydrogen make-up line going to the DIH recycle / reactor feed
exchanger 73-E-02, inject hydrogen in batch operation. There will be an immediate

exothermic reaction; this phenomenon will be short in duration, the magnitude of the
temperature increase will depend very much on the feed quality. Under no
circumstance the hydrogenation reactor should be above 200C. If it occurs, follow
the emergency procedure for high reactor temperature.
- Slowly pressurize with hydrogen the hydrogenation reactor flash drum.
- Repeat the hydrogen batch injection until there is no benzene in the recycle loop and
no temperature increase in the hydrogenation reactor.
- Start the isomerization reactor feed pump 73-P-04 A/B and line-up the
hydrogenation reaction section to the stabilizer 73-C-01, the isomerization reaction
section is still bypassed.
- With the stabilizer in normal operation, route the feed to the isomerization feed surge
drum 73-V-01. Close the loop from the feed surge drum 73-V-01, through the dryers
73-DR-01 A/B and the hydrogenation reaction section to the stabilizer 73-C-01 and
the chloride guard bed 73-V-06.
- Pressurize with hydrogen at design flowrate the isomerization section using the 2nd
hydrogen make-up line.
- Adjust the feed dryers inlet at 50% of design flowrate using fresh naphtha make-up.
- Adjust the hydrogen at the hydrogenation reactor inlet at 50% of the design flowrate.
- If necessary, rundown the excess of stabilizer product to off-spec storage.
- When there is no benzene in the recycle loop and no temperature increase in the
hydrogenation reactor 73-R-01, reduce the feed heater temperature down to 75C.
- Check the quality of the hydrogenation reactor outlet.

Hydrogenation reaction section start-up:-
H2 through 8-P-73-1503
6-P-73-1303
73-V-01 Hydro treated naphtha 73-DR-01A/B 73-E-02
6-P-73-1105
73-E-03
4-P-73-1322
73-E-04
73-A-01
73-R-01
73-V-08
73-P-03A/B 73-V-04
73-P-06A/B
6-P-73-1705
73-C-01 73-P-04A/B
73-C-02 73-V-06
73-P-08A/B 3-P-73-2212
Off-spec isomerate through 73-E-11
3-P-73-3306 / 3310
(through 73-E-11)

6.12 ISOMERIZATION REACTION SECTION START-UP

- On start up feed will be introduced into the benzene saturation reactor at a minimum
of 75% (FT-1101) of reactor design feed rate. Remark: reactor feed rate includes
recycle + unit fresh feed. 75% of the reactor design feed rate, corresponds to 50% of
unit design fresh feed (FT-1104). The reactors should never be operated less than
75% of design feed rate (FT-1101) and no part of reactor should be above 65 oC
- The 2nd isomerization reactor (73-R-03) in lag position is bypassed.
- Gently open the valve at the isomerization section inlet (downstream the static
mixer) and in the same time slowly choke the globe valve on the isomerization
reactors bypass line. Inject feed of isomerization reactor in about 5 minute.
- Survey the possible pressure surge to stabilizer 73-C-01 and scrubber 73-C-03.
- The temperature rise, although rapid, should not be a problem if the initial reactor
temperature is less than 65C.
- Adjust the flowrate at the hydrogenation reaction section inlet at 50% of design
flowrate with fresh naphtha feed in the feed surge drum.
- Once a steady operation is reached, commission the reactor feed heater and slowly
increase the isomerization reactor inlet temperature to 130C at a rate of 10C per
hour, while monitoring the exotherm and catalyst bed temperatures.
- When the temperature reaches 105C in the isomerization reactor, start C2Cl4
injection at 400 ppm wt based C5/C6 feed rate to the reactors.
- Monitor the chloride in the stabilizer off-gas. When the first isomerization reactor
stops consuming chloride, reduce the C2Cl4 injection to 150 ppm.
- Check the stabilizer bottoms quality, adjust the reactor temperature to achieve the
optimum product quality when operating on one reactor at 75% of design feed rate
(FT-1101). Slowly increase the fresh naphtha feed rate and decrease (and finally
close) the recycle from isomerate product (start-up line).
- Switch to isomerate rundown storage if desirable.
- Commission the scrubber off-gas H2 analyzer. Check the H2/HC ratio to be sure of
the procedure.

- Allow the operation to stabilize, adjust conditions where necessary, ensure all
instrumentation is working and in the proper range. The first isomerization reactor
should operate alone for at least two days in steady state operation before the second
isomerization reactor is brought on-line.
Isomerisation reaction section start-up

Feed
73-DR-01A/B 73-R-01 73-V-04
73-P-04A/B
6-P-73-1706
73-R-02
73-E-03
Offgas to scrubber
8-P-73-1805
73-C-01
73-C-02 73-V-06
73-P-08A/B Heavy isomerate to storage
73-V-08 73-P-09A/B Off-spec isomerate to

storage (4-P-73-3307)
Isomerate to storage
(4-P-73-3308)

Series Flow Operation:

When the second stage isomerization reactor is ready to be brought on-line, check the
reactor pressure versus the system pressure to ensure there is no significant differential.
If there is a pressure differential, depending on the magnitude, the Axens start-up
representative will advise on the best method to equilibrate the pressures before bringing
the second reactor on line. Naphtha feed rate should be at least 75% (FT 1101) of design
prior to this step.
- Reduce the first isomerization reactor outlet temperature to 110C and establish flow
through the Cold Feed / Effluent Exchanger (73-E-03) to cool the second reactor
inlet temperature as much as possible.
- Open the second reactor inlet and outlet block valves (inlet first) very slowly as to
maintain always flow to the stabilizer while filling the reactor.
- Establish flow through the second reactor by closing very slowly the single reactor
bypass line. The TIC should be on manual with all of the first reactor effluent
passing through the tube side of the Cold Feed / Effluent Exchanger.
- Increase the C2Cl4 injection back to 400 ppm to compensate for the chloride
consumption in the second reactor.
- Again monitor the stabilizer off-gas and reduce the chloride injection once the
consumption levels off.
- As before, there will be an increase of temperature in the second reactor, but this will
not be dramatic
- Allow the operation to stabilize. As the second reactor is brought on-line, there could
be some flow perturbation to the stabilizer.
- Commission the second reactor inlet temperature controller and slowly increase the
second reactor inlet temperature to 115C at 10C/hour.
- Adjust all operating conditions for optimum operation.

6.13 ISOMERIZATION UNIT LINE-OUT AT DESIGN CAPACITY

Status
- The unit is operating at 75% of reactor (FT 1101) design capacity (is equivalent to
50% unit design fresh feed) at design hydrogen make-up.
- Inlet temperatures to reactors have been adjusted for optimum isomerate quality.
- The Stabilizer 73-C-01 and the Deisohexaniser 73-C-02 are operating at design
reflux rates and the scrubber 73-C-03 is in operation with both water wash and
caustic circulation at design rates. Isomerate product is routed to rundown product
storage and scrubber off-gas to fuel gas.
- The dryer analyzers are in operation and the dryers have been recently regenerated.
- The stabilizer off-gases are sent to the scrubber (UV 2501 closed, UV 2503 open)
and LPG recovery section is bypassed.
Procedure:
- Slowly increase the C5/C6 isomerization unit feed rate to design in increments of
10% per hour. Monitor the catalyst bed temperatures for higher than normal
exotherms. Allow the unit to stabilize after each change.
- Record all operating data at each 10% increment, i.e., flows, temperatures,
conversion levels out of each reactor.
- At design capacity and steady temperatures, sample the isomerate product for
analysis.
- Adjust temperatures as necessary to improve the conversion ratios of the isomers.
The first reactor temperature should be adjusted to maximize isomerization in the
first reactor, and the second reactor temperature adjusted to take the advantage of the
higher equilibrium isomer content at lower temperatures. A sample point is located
at the first reactor outlet to allow an analysis of the conversion in the first reactor.
- Check the scrubber off-gas H2 analyzer to ensure that H2/HC ratio is above 0.06.

- Adjust the temperature and reflux on the stabilizer to meet the product RVP
requirements and to minimize the loss of C5+ in the overheads. Also, the stabilizer
should completely strip-out the HCl from the reactor effluent.
6.14 LPG RECOVERY SECTION LINE-OUT

The LPG recovery section operation is very sensitive to any upset in reflux or reboiling
duty at the LPG stripper, in which case chloride content in LPG product will not be
acceptable. For this reason, the gas feed to the LPG recovery section is only permitted
when LPG recovery has been lined up on lean oil side, LPG stripper being on total
reflux and lean oil at design flowrate.
For any upset in the stabilizer or in the LPG recovery section (loss of reboiler or reflux),
LPG recovery section will be bypassed on off-gas side (UV 2501 closed UV 2503
open).
The Isomerization unit is operating at design capacity. The stabilizer off-gases are sent
to the scrubber.
The LPG recovery section is isolated on isomerization off gas side (UV 2501 closed
UV 2503 open).
- Line-up the LPG recovery section on the lean oil side only, i.e. UV 2501 closed
UV 2503 open.
- Slowly increase the lean oil up to 60% of the design flowrate.
- Commission LPG refrigeration system, LPG separator drum and LPG stripper.
- LPG product is routed to isomerate off-spec product.
- Only when the design flowrate of lean oil is reached and LPG stripper operates at
design conditions (design reboiler duty and design reflux- PIC 2801 at design set
point), isomerization off gas feed to LPG recovery section is permitted. Open UV
2501, slowly ramp down PV 2501 (valve to close in approximately in20 minutes).
When PV 2501 is fully closed, then close UV 2503.
- Check the LPG separator off-gas H2 analyser to ensure that H2/HC ratio is above
0.06

- PC 2501 to be reset (PC 2501 and PV 2501 to remain in control mode in normal
operation of the unit.
6.15 UNIT RESTART

Any unit restart procedure derives from the first start-up procedure. The unit status after
the shutdown will dictate the point during restart where the general start-up procedure
can be resumed.
For example during the unit life, there will be instances when the lead isomerization
reactor will need to be taken out of service for catalyst replacement with other reactor
remaining in service. Restart procedure at this situation begins at the point for series
flow operation in the initial start-up procedure. Except in this case this reactor will be
under a low pressure nitrogen atmosphere.
As the freshly loaded catalyst will be cold, the reactor can be re-pressurized using the in-
service reactor feed through the bypass globe valve. As soon as the freshly loaded
reactor is up to operating pressure follow the series flow start-up procedure to align this
reactor in the tail position of the flow configuration.
A precautionary note for any restart or commission of the second reactor:

Maximize hydrogen make-up, set the naphtha feed at 75% of design and maximize
reactor temperature. Introduce the naphtha feed quickly to the fresh catalyst and
carefully monitor the catalyst bed temperature.

SECTION 7
NORMAL OPERATING PROCEDURES
7.1 INTRODUCTION
After the unit has been started up and lined out, the focus shifts to reaching and
maintaining a state of optimum operation. This state of optimum operation can be
achieved by establishing a few general operating rules and being aware of potential
problems which can occur. First, a means of judging performance must be defined.
Secondly, a list of operating variables is established. Using these operating variables, an
approach to operating the Isomar unit is outlined with respect to the performance
indicators. This procedure establishes a logical method for operating the plant,
increasing yields and ensuring longer catalyst cycles.
7.2 CONTROL PHILOSOPHY

The control philosophy for the C5 / C6 cut isomerization unit is simple and conventional.
Refer to P & IDS.
Reaction Section:
- The set point of hydrogen make-up going to the hydrogenation reactor is adjusted by
the operator according to the amount of benzene in the feed (on line analyzer).
- Hydrogen make-up gas going to the isomerization section is under flow ratio control
with the total liquid feed to the reactors.
- First isomerization reactor inlet temperature is controlled by steam flow to the
Reactor Feed Heater and by split range on the recycle air cooler and its by-pass.
- Second isomerization reactor inlet temperature is controlled through a by-pass of the
First stage reactor Feed / Effluent Exchanger.
- The reactor section pressure is controlled directly by a back-pressure controller on
the stabilizer feed.

Hydrogen / HC Mole Ratio

Measured by hydrogen analysis in the scrubber off-gas, this ratio must be maintained
close to 0.06. If there is a problem maintaining this ratio, reduce the feed rate
accordingly.
Stabilizer
- Stabilizer bottom is supplied to the Deisohexaniser on flow-control reset by level
control of the stabilizer tower.
- Reboiling is under steam condensate flow control reset by a sensitive tray
temperature.
- Pressure is controlled by a pressure controller on the stabilizer off gas.
- Reflux is under flow control reset by the Stabilizer Reflux Drum level.
Deisohexaniser
- Feed from the stabilizer bottoms is supplied on flow control reset by the stabilizer
bottoms level.
- Reflux to the Deisohexaniser is on flow control.
- Distillate product is withdrawn on flow control reset by level control of the reflux
drum.
- Side-draw is on level control of the Deisohexaniser Recycle Drum.
- Side-draw pump around is on flow control.
- Reboiling is under flow control reset by a sensitive tray temperature.
- Column pressure is controlled by a split range controller.
- Deisohexaniser bottom is supplied to the LPG recovery section on flow-control reset
by level control.
LPG recovery section

- Pressure of the LPG separator drum is controlled by a pressure controller on the
overhead gas.

- LPG separator drum bottom is routed to the LPG stripper on flow-control reset by
level control.
- Lean oil is on flow control.
- LPG stripper pressure is controlled by a pressure controller on the overhead gas.
- Reboiling is under flow control reset by sensitive tray temperature.
- LPG stripper bottom is routed to the storage on flow-control reset by level control.
- Side-draw is under flow control reset by sensitive tray temperature.
- LPG side stripper bottom is fed to storage on flow control reset by level control.
- LPG stripper reflux is on flow control reset by level control.
Neutralization
- The scrubbed off gas is withdrawn under pressure control.
- Temperature control of the caustic circulation is achieved through the Caustic
Recycle Heater.
Dryers
- The dryers will be in series flow for the feed, the make-up H2 services. Once the
moisture content in the lead dryer effluent, reaches 1 ppm wt, it must be taken out of
service for regeneration.
- The regeneration flow is flow controlled into the regeneration loop.
- A pressure controller maintains a backpressure in the loop prior to re-blending with
the isomerate product after the pressure control valve.
- A Degasser is required in the loop to purge off gas leakage from the dryers and to
separate water from the regenerant. Gas purging is under level control of the
Degasser which is maintained almost full of liquid.
- The regeneration temperature is controlled by electrical power of the Regenerant
Superheater.

7.3 OPERATING PARAMETERS

The process variables which according to the thermodynamics and kinetics have an
impact on the reactions of the isomerization process are listed below. This chapter
covers briefly these variables but does not present the variables from an operator
standpoint i.e. which variables can the operator actually adjust to improve or restore the
unit performance.
7.3.1 Temperature
As stated, the inlet temperature to the reactors is the most direct variable the operator
has available to control product quality. Typically during start-up when the unit is lined
out at design capacity and the stabilizer bottom product is on-spec. there are only a few
instances when the operator needs to adjust the reactor inlet temperature.
a) Coke accumulates on the catalyst surface:

During the cycle, coke will build up on the catalyst surface within the pores; reduce the
reaction surface and consequently the activity. An adjustment will be required on the
reactor inlet temperature to compensate for this activity loss. The difference between
start of run and end of run inlet temperatures could be as much as 30C. This change is
very gradual over typically a 2-3 year period.
b) Feed quality changes:

If the feed quality changes i.e. there are higher levels of benzene or C7+ in the feed, then
the operator must decrease the reactor inlet temperature to offset the increase in
exothermic heat.
c) For major changes in feed rate:

As catalyst activity is higher with the lower space velocity, and then the reactor inlet
temperature at 60% capacity should be different from that at 100% capacity. Typically
the temperature may be only a 5-8C difference. The operator can lower the reactor inlet

temperature at lower space velocity to control hydrocracking and preserve catalyst cycle
length.
7.3.2 Hydrogen make-up rate:

The design hydrogen to hydrocarbon ratio for this unit is 0.06 moles of hydrogen at the
reactor outlet per mole of naphtha feed. Operating below this ratio will increase coke
deposits or lead to a maldistribution of the flow in the reactors. Operating above this
ratio will preserve the cycle length but will not enhance the isomerization reactions by a
measurable degree. It is left to the operator discretion to reduce hydrogen make-up rate
as the naphtha feed rate is reduced to maintain a 0.06 ratio. This is mostly dependent on
the high pressure hydrogen and fuel gas balances.
7.3.3 Stabilizer / Scrubber / Deisohexaniser section operation:

a) Stabilizer
- Check the isomerate for HCl content. Periodic testing of the isomerate for chloride is
necessary to ensure no chloride is exiting with the isomerate. Upsets in stabilizer
operation will impact in chloride content in stabilizer bottom and shall be
recorded. Corresponding chloride will be absorbed on the chloride guard bed.
Record of the upset will enable the operator to predict the life length of the
chloride bed. As isomerate is used to regenerate the dryers, it must be free of HCl.
Otherwise damage to the molecular sieve will occur.
- Adjust the temperatures and reflux on the stabilizer to meet RVP requirements and
to minimize C5+ in the overheads.
b) Scrubber
- Check the scrubber operation for caustic losses and caustic strength in the circulating
caustic wash. The stabilizer off-gases are first scrubbed with 10% caustic solution
then water washed before routing to fuel gas. Check the exiting gas for HCl content
and caustic entrainment.

- The caustic inventory is replaced once the concentration drops to 2 to 3 wt. %, and
the caustic concentration should not be allowed to fall below 2 wt %. The circulating
caustic temperature should be maintained a few degrees above the off gas inlet
temperature in order to avoid condensation which can cause foaming and operating
problems in the scrubber.
c) Deisohexaniser:
- Deisohexaniser fractionates the isomerate product from the reactor recycle liquid,
and the octane number of the isomerate product is dependant on recycling the low
octane C6 components to the reactor.
- The recycle liquid also serves as a diluent for controlling the exotherm in the
benzene saturation reactor, especially when processing benzene rich feed streams
only.
- The recycle liquid in addition helps in diluting the C7+ components in the total
reactor feed to avoid excessive cracking of these heavy components in the
isomerization reactors.
d) LPG Recovery section

- Practically this section operates independently with feed from isomerisation unit.
7.4 OPERATING PARAMETER

Operating conditions are given in the table below.
ISOM UNIT PROCESS SYSTEM
Description Tag no. Unit Value
FEED SECTION
Feed to Dryers FI-1101 M3/hr 82.1
Feed to Dryers FIC-1101 M3/hr 82.1
73-P-01A/B discharge FIC-1102 M3/hr 29.0


Feed to Dryers FT-1103 M3/hr 82.1
Feed to surge drum FI-1104 M3/hr 44.5
o
Feed to surge drum TI-1101 C 40
NOR MIN MAX
Feed surge drum boot LI-1101 MM 300 900
Feed surge drum LI-1102 MM 600 2000
Feed surge drum LI-1103 MM 600 2000
Feed surge drum boot LT-1104 MM 300 900
Feed surge drum LG-1105 MM 600 2000
Feed surge drum LG-1106 MM 300 900
Feed surge drum PIC-1101 Kg/cm2 G 4.0
Feed surge drum PT-1101 Kg/cm2 G 4.0
73-P-01A/B discharge PT-1102 Kg/cm2 G 28.3
Feed to surge drum PI-1103 Kg/cm2 G 5.0
Feed surge drum PI-1104 Kg/cm2 G 4.0
73-P-01A discharge PI-1105 Kg/cm2 G 28.3
73-P-01B discharge PI-1106 Kg/cm2 G 28.3
CHLORIDE INJECTION SECTION
N2 to chloride
PI-1201 Kg/cm2 G 5.0
injection drum
Chloride injection
PI-1202 Kg/cm2 G 5.0
drum
Drum pump discharge PI-1209 Kg/cm2 G 5.0
N2 to drum PI-1207 Kg/cm2 G 6.0


Dry naphtha to 2 17.6
FO-1201 M3/HR
73-V-03 (min) (max)
10.6 35.8
73-P-02A/B discharge FO-1202 LIT/HR
(min) (max)
FEED DRYER SECTION
73-DR-01A bottom PI-1301A Kg/cm2 G 24.6
73-DR-01A top PI-1302A Kg/cm2 G 23.6
73-DR-01B top PI-1302B Kg/cm2 G 23.6
Dryer bottom
evacuation line to static PI-1303 Kg/cm2 G ATM to FV
mixer
73-DR-01B bottom PI-1301B Kg/cm2 G 24.6
Treated naphtha to TI-1301A C 40 DCS
dryer 73-DR-01A C 143-310 Dryer regeneration
Treated naphtha to TI-1301B C 40 DCS
dryer 73-DR-01B C 143-310 Dryer regeneration
HYDROGEN MAKE-UP COMPRESSOR
H2 to compressor
PI-1401 Kg/cm2 G 21.9
73-K-01A/B
H2 make up from CCR PI-1409 Kg/cm2 G 22.0
73-K-01 A discharge PI-1404 Kg/cm2 G 39.9
73-K-01 B discharge PI-1408 Kg/cm2 G 39.9
H2 to unit 74 PI-1406 Kg/cm2 G 39.0
73-K-01A suction PI-1403 Kg/cm2 G 21.8
73-K-01B suction PI-1407 Kg/cm2 G 21.8
H2 to unit 74 FQI-401 NM3/HR 7917 1333 (min)


H2 to dryers
FI-1402 NM3/HR 1000 max
( S stripping line)
3475
H2 make up to KOD FI-1403 NM3/HR 11698
(min)
H2 from CCR to KOD TI-1401 C 40
Make up compressor
TI-1404 C 93
A discharge
Make up compressor
TI-1407 C 93
B discharge
H2 to unit 74 &
TI-1404 C 40
dryers
CWR from 73-E-01A TI-1405 C 44 max
CWR from 73-E-01B TI-1406 C 44 max
H2 make up KOD LI-1401A MM 300 1050
H2 make up KOD LT-402 MM 300 1050
HYDROGEN DRYER SECTION
73-DR-02A inlet PI-1501A Kg/cm2 G 39.4
73-DR-02B inlet PI-1501B Kg/cm2 G 39.4
73-DR-02A outlet PI-1502A Kg/cm2 G 38.4
73-DR-02B outlet PI-1502B Kg/cm2 G 38.4
Dry H2 to 73-E-02 PT-1503 Kg/cm2 G 22.9
Evacuation line to
PI-1504 Kg/cm2 G ATM/ FV
static mixer
Hydrogen to flare PI-1505 Kg/cm2 G 39.4
73-DR-02A inlet TI-1501A C 40
73-DR-02B inlet TI-1501B C 40

73-DR-02A outlet TI-1502A C 40
73-DR-02B outlet TI-1502B C 40

NOR MIN MAX
Hydrogen from dryers FIC-1501 NM3/HR 4436 259 5381
H2 to 73-M-01 FIC-1504 NM3/HR --
Depressurization Line FO-1505 NM3/HR --
HYDROGENATION SECTION
Feed inlet to 73-R-01 PI-1601 Kg/cm2 G 21.6
73-R-01 outlet PI-1602 Kg/cm2 G 19.6
Feed inlet to
PI-1603 Kg/cm2 G 21.6
Hydrogenation reactor
Feed inlet to
PI-1605 Kg/cm2 G 21.6
PI-1606 Kg/cm2 G 19.6
outlet
HP steam to
PI-1607 Kg/cm2 G 29.0
73-E-04
DIH recycle to 73-E-02 PI-1609 Kg/cm2 G 8.6
DIH recycle from
73-E-02 to PI-1610 Kg/cm2 G 7.9
73-E-08
73-E-03 shell side outlet PI-1611 Kg/cm2 G 22.4
Reactor effluent from
PI-1612 Kg/cm2 G 32.5
73-E-03
73-E-02 outlet PI-1613 Kg/cm2 G 23.3


Dry feed from 73-
PI-1614 Kg/cm2 G 23.8
DR-01/02 A/B
Reactor feed inlet PI-1615 Kg/cm2 G 21.6
73-R-01 outlet PI-1616 Kg/cm2 G 16.1
Evacuation line to
PI-1608 Kg/cm2 G ATM/ FV
73-J-01
Hydrogenation reactor PDI/PDAH-
Kg/cm2 G PDAH = 2.0
diff. Pressure 1603
Dry feed from 73-DR-
TI-1601 C 40.0
01/02 A/B
73-E-02 shell side outlet TI-1602 C 60
73-E-04 temperature
TIC-1604 C 168
control
TI-1605 C 176
outlet
TI-1606 C 145
73-E-03
DIH recycle to 73-E-
TI-1607 C 105
02
DIH recycle from 73-E-
TI-1608 C 60
02
73-R-01 TI-1609 C 176 max
73-R-01 TI-1610 C 176 max
73-R-01 TI-1611 C 176 max
73-R-01 TI-1612 C 176 max


73-R-01 TI-1613 C 176 max
73-R-01 TI-1614 C 176 max
73-R-01 TI-1615 C 176 max
73-R-01 TI-1616 C 176 max
73-R-01 TI-1617 C 176 max
73-R-01 TI-1618 C 176 max
Reactor effluent to
TI-1619 C 182
73-E-03
Steam to 73-E-04 FIC-1601 KG/HR 3870
HYDROGENATION REACTOR SEPARATOR DRUM SECTION

Controller in H2
pressurization line of PIC-1701 Kg/cm2 G 19
73-V-04
73-V-04 depressurized
PKIC-1702 Kg/cm2 G --
line to flare
73-P-04A/B discharge to
PT-1702 Kg/cm2 G 40.1
static mixer
73-P-03A/B discharge PT-1703 Kg/cm2 G 28.1
73-V-04 PI-1709 Kg/cm2 G 19.2
73-P-03 A discharge PI-1705 Kg/cm2 G 28.1
73-P-03 B discharge PI-1706 Kg/cm2 G 28.1
73-P-04 A discharge
PI-1707 Kg/cm2 G 40.1
to static mixer
73-P-04 B discharge
PI-1708 Kg/cm2 G 40.1
to static mixer
73-P-04A/B suction PI-1704 Kg/cm2 G 19.2


73-P-04A/B discharge to
PI-1710 Kg/cm2 G 40.1
ISOM reactor bypass
73-A-01 downstream TIC-1702 C 137-176
73-P-04A/B suction TI-1703 C 137-176
73-P-04A/B discharge FIC-1701 M3/HR 105.4 70.1 121.2
73-P-03A/B discharge FIC-1702 M3/HR 265.1 117 318.1
73-P-04A/B discharge FT-1703 M3/HR 105.4 70.1 121.2
73-P-03A/B discharge FT-1704 M3/HR 265.1 117 318.1
FI-1705
73-V-04 purge gas out NM3/HR 6200
CASE I
73-V-04 H2 FI-1705
NM3/HR 6200
pressurization CASE II
73-P-03A/B discharge FO-1706 M3/HR 265.1 117 318.1
73-P-03 A/B minimum
FO-1707 M3/HR 70
flow circulation
73-P-04A/B discharge FO-1708 M3/HR 121.2
LI-1701 MM 400 2250
flush drum 73-V-04
LI-1702 MM 400 2250
flush drum 73-V-04
LG-1703A MM 400 2250
flush drum 73-V-04
LG-1703B MM 400 2250
flush drum 73-V-04
ISOM REACTION SECTION
Isomerate from reactor PT/PIC-
Kg/cm2 G 30
to stabilizer 1801


Reactor feed inlet to 73-
PI-1802 Kg/cm2 G 35
R-02
PI-1803 Kg/cm2 G 33
73-R-02
PI-1804 Kg/cm2 G 32
R-03
PI-1805 Kg/cm2 G 30
73-R-03
PI-1806 Kg/cm2 G 35
R-02
PI-1807 Kg/cm2 G 33
73-R-02
73-R-03 inlet PI-1808 Kg/cm2 G 32
Isomerate from 73-R-
PI-1809 Kg/cm2 G 30
03
Isomerate from 73-R-
PI-1810 Kg/cm2 G 30
03
Diff pressure across 73- PDI/PAHH-
Kg/cm2 G Software, PAHH=2
R-02 1812
Diff pressure across 73- PDI/PAHH-
Kg/cm2 G Software, PAHH=2
R-03 1813
Feed inlet to 73-R-02 PI-1814 Kg/cm2 G 35
PI-1815 Kg/cm2 G 33
73-R-02
Feed inlet to 73-R-03 PI-1816 Kg/cm2 G 32
TIC-1801 C 125-145
73-E-03


73-R-02 TI-1802 C 130-182
73-R-02 TI-1803 C 130-182
73-R-02 TI-1804 C 130-182
73-R-02 TI-1805 C 130-182
73-R-02 TI-1806 C 130-182
73-R-02 TI-1807 C 130-182
73-R-02 TI-1808 C 130-182
73-R-02 TI-1809 C 130-182
73-R-02 TI-1810 C 130-182
73-R-02 TI-1811 C 130-182
73-R-02 TI-1812 C 130-182
73-R-02 TI-1813 C 130-182
73-R-02 TI-1814 C 130-182
73-R-02 effluent TI-1815 C 130-153
73-R-03 TI-1816 C 125-153
73-R-03 TI-1817 C 125-153
73-R-03 TI-1818 C 125-153
73-R-03 TI-1819 C 125-153
73-R-03 TI-1820 C 125-153
73-R-03 TI-1821 C 125-153
73-R-03 TI-1822 C 125-153
73-R-03 TI-1823 C 125-153
73-R-03 TI-1824 C 125-153
73-R-03 TI-1825 C 125-153
73-R-03 TI-1826 C 125-153


73-R-03 TI-1827 C 125-153
73-R-03 TI-1828 C 125-153
73-R-03 effluent TI-1829 C 130-153
TI-1831 C 148-182
73-R-02
MP steam inlet to
FI-1801A M3/Hr -- -- --
ejector
ISOM stabilizer section
Stabilizer OVHD vapor PIC-1901 Kg/cm2 G 14.8
2
Stabilizer OVHD PT-1902 Kg/cm G 14.8
Stabilizer OVHD PT-1903 Kg/cm2 G 14.8
Stabilizer OVHD PT-1904 Kg/cm2 G 14.8
73-C-01 bottom PI-1905 Kg/cm2 G 15.1
Diff press across PDI/PDAH-
Kg/cm2 G PDAH=0.4
chloride guard bed 1906
VHP steam to
PI-1914 Kg/cm2 G 32.1
73-E-05
Feed inlet to 73-C-01 PI-1915 Kg/cm2 G 15.2
73-C-01 top PI-1910 Kg/cm2 G 14.8
73-C-01 bottom PI-1911 Kg/cm2 G 15.1
Chloride guard bed inlet PI-1912 Kg/cm2 G 15.1
73-E-05 inlet PI-1914 Kg/cm2 G 32.1
Feed inlet to 73-C-01 TI-1901 C 127-145
73-C-01 top TI-1902 C 74-84
73-C-01 TI-1903 C 170-181
73-C-01 top TI-1904 C 90


73-C-01 TIC-1905 C 138
73-C-01 inlet TI-1906 C 127-145
73-E-05 outlet to 73-C-
TI-1907 C 170-181
01
73-E-05 inlet shell side TI-1908 C 169-179
Chloride guard bed inlet TI-1909 C 170-181
NOR MIN MAX
VHP steam to 73-E-05 FIC-1901 KG/HR 7140 3026 7860
73-C-01 outlet to 73-C-
FIC-1902 M3/HR 107.4 49.5 118
02
Stabilizer
LIC-1901 MM 650 4150
73-C-01
Condensate pot 73-V-
LIC-1902 MM ** **
19
Stabilizer
LI-1903 MM 650 4150
73-C-01
73-V-19 LG-1904 MM ** **
73-C-01 LG-1905 MM 650 4150
ISOM STABILISER OVHD
73-V-05 PI-2001 Kg/cm2 G 14.3
Reflux to
PT-2002 Kg/cm2 G 19.4
73-C-01
73-V-05 PI-2003 Kg/cm2 G 14.3
2
73-P-05A discharge PI-2004 Kg/cm G 19.4
73-P-05A suction PI-2007 Kg/cm2 G 14.7


73-P-05B suction PI-2006 Kg/cm2 G 14.7
OVHD vapor inlet to
TIC-2001 C 65
73-E-06
OVHD vapor inlet to
TI-2002 C 43-49
73-V-05
OVHD vapor inlet to
TI-2003 C 43-49
73-V-05
Cooling water return
TI-2005 C 44 max
from 73-E-06A
TI-2004 C 44 max
from 73-E-06B
73-P-05A/B discharge FIC-2001 M3/HR 41.8 19.7 50.1
Offgas line from 73-V-
FI-2002 NM3/ HR 2232 971 2456
05
73-P-05A/B min flow
FO-2003 M3/HR 14
circ line
Stabilizer reflux drum LIC-2001 MM 150 1550

Stabilizer reflux drum LI-2002 MM 150 1550
Stabilizer reflux drum LG-2003 MM 150 1550
ISOM DIH RECYCLE DRUM SECTION
73-E-07 shell side inlet PI-2101 Kg/cm2 G 4.6
73-E-07 shell side outlet PI-2102 Kg/cm2 G 2.2
73-E-07 tube side inlet PI-2103 Kg/cm2 G 11.7
73-E-07 tube side outlet PI-2104 Kg/cm2 G 11.0
DIH recycle drum top PI-2105 Kg/cm2 G 2.0


DIH recycle to 73-V-
PI-2108 Kg/cm2 G 6.6
01
73-E-07 shell side inlet TI-2101 C 105
73-E-07 tube side inlet TI-2103 C 168
73-E-07 tube side outlet TI-2104 C 127
DIH recycle to 73-V-01 TI-2105 C 40
Cooling water outlet
from TI-2106 C 44 max
73-E-08A
Cooling water outlet
TI-2107 C 44 max
from 73-E-08A
73-P-07 discharge to
FIC-2101 M3/HR 39.3 18.3 47.1
73-C-02
73-P-07A/B discharge FIC-2102 M3/HR ** 30 97.9
DIH recycle to 73-V-
FIC-2103 M3/HR 38 17.5 45.6
01
DIH recycle from 73-E-
FI-2104 M3/HR 38 17.5 45.6
08A/B to storage
73-V-07 LIC-2101 MM 300 4300
73-V-07 LG-2102 MM 300 4300
ISOM DEISOHEXANISER SECTION:
73-C-02 top PT/PIC- Kg/cm2 G 1.7


2201
Deisohexaniser PT/PAHH-
Kg/cm2 G 1.7 PAHH=2.6
overhead 2202
overhead 2203
overhead 2204
73-C-02 top tray PI-2205 Kg/cm2 G 1.7
73-C-02 bottom PI-2206 Kg/cm2 G 2.3
MP steam to 73-E-10 PI-2208 Kg/cm2 G 8.3
73-C-02 PI-2209 Kg/cm2 G 2.3
Above tray 35 PI-2210 Kg/cm2 G 2.0
2
73-C-02 top PI-2211 Kg/cm G 1.7
Diff pressure across 73- PDT/PDAH
Kg/cm2 G PDAH=0.5
C-02 -2207
73-C-02 above feed tray PI-2215 Kg/cm2 G 1.9
73-C-02 feed from
TI-2201 C 96
73-E-07
73-C-02, above feed
TI-2202 C 95
tray
73-C-02 TI-2203 C 78
73-C-02 above tray 37 TI-2204 C 78


73-C-02 TI-2205 C 105
73-C-02 TI-2206 C 124
73-C-02 TI-2207 C 124
Deisohexaniser
TI-2208 C 78
overhead
73-C-02 TIC-2209 C 124
103-E-2008 shell side
TI-2210 C 122-136
inlet
73-P-08 A/B suction TI-2211 C 122-137
73-E-08 shell outlet TI-2212 C 120-137
NOR MIN MAX
Reflux to 73-C-02 FIC-2201 M3/HR 146.7 68 176.1
73-P-08 A/B discharge FIC-2202 M3/HR 22.1 3.0 24.3
MP steam to 73-E-08 FIC-2203 KG/HR 12500 5229 13920
73-P-08 discharge FI-2204 M3/HR 22.1 3.0 24.3
73-P-08 minimum flow
FO-2205 M3/HR 7.5 3.0 24.3
line
73-C-02 bottom LIC-2202 MM 300 1700
73-C-02 bottom LG-2203 MM 300 1700
ISOM DEISOHEXANISER OVHD SECTION
From 73-C-02 to PDT/PDIC-
Kg/cm2 G 1.7, PDIC=0.5
73-V-08 2301
73-V-08 PI-2302 Kg/cm2 G 1.2
PT/PALL-
73-P-06 discharge Kg/cm2 G 10
2303
73-P-06 A discharge PI-2304 Kg/cm2 G 10


73-P-06 B discharge PI-2305 Kg/cm2 G 10
OVHD vapor from 73-
C-02 to 73-V-08 (AFC PI-2308 Kg/cm2 G 1.3
2003 downstream)
Deisohexaniser reflux
PI-2309 Kg/cm2 G 1.2
drum 73-V-08
73-P-06 A suction PI-2310 Kg/cm2 G 1.3
73-P-06 B suction PI-2311 Kg/cm2 G 1.3
OVHD vapor from 73-
TIC/ TI-
C-02 to 73-V-08 (AFC C 55
2301
2003 downstream)
73-P-09 A/B discharge
FIC-2301 M3/HR 37.1 10.0 40.8
to 73-E-09
73-P-09 A/B discharge FIC-2302 M3/HR 36.1 10 39.7
73-P-06A/B minimum
FO-2303 M3/HR 53 6.7 **
flow
73-V-08 LIC-2301 MM 300 1600
73-V-08 LG-2302 MM 300 1600
ISOM SCRUBBER DM WATER PUMPS SECTION


73-P-13A/B discharge
PI-2407 Kg/cm2 G 17.0
to 73-C-03
73-V-10 drum level LG-2401 MM 300 3350
ISOM SCRUBBER SECTION
Off gas to fuel gas
PIC-2501 Kg/cm2 G 12.5
header
73-C-03 PI-2502 Kg/cm2 G 12.7
73-C-03 top PI-2503 Kg/cm2 G 12.6
73-C-03 PI-2504 Kg/cm2 G 12.8
73-C-03 PI-2505 Kg/cm2 G 12.9
2
73-P-11A discharge PI-2507 Kg/cm G 18.7
73-P-11A/B discharge PI-2508 Kg/cm2 G 18.7
LP steam to 73-E-12 PI-2511 Kg/cm2 G 1.8
Off gas to fuel gas
PI-2512 Kg/cm2 G 4.6
header
73-C-03 overhead vapor PI-2513 Kg/cm2 G 12.6
Differential pressure of
PDI-2514 Kg/cm2 G PDAH=0.9
73-C-03
o
73-E-12 shell outlet TIC-2501 C 55
o
73-C-03 overhead TI-2502 C 43-49
o
Off gas from 73-V-05 TI-2503 C 43-49


to 73-C-03
o
73-E-12 shell inlet TI-2504 C 45-55
Off gas to fuel gas o
TI-2505 C 43-49
header
Condensate from 73-
FIC-2501 Kg/HR 193 100 1143
E-12
DM water to 73-C-03 FI-2502 M3/HR 19.9 ** 24.0
Off gas to fuel gas
FI-2503 NM3/HR 2550 980 2476
header
Off gas to 73-DR-03
FI-2504 NM3/HR 2250 980 2476
A/B
73-E-12 shell outlet to
FI-2505 M3/HR 19.9 15.0 36.0
73-C-03
73-E-12 shell outlet to
FI-2506 M3/HR 10 15 36
73-C-03
73-C-03 chimney tray LI-2501 MM 100 1500
73-C-03 bottom LI-2502 MM 600 5950
73-C-03 bottom LG-2503 MM 600 5950
73-C-03 chimney tray LG-2504 100 1500
SCRUBBER OFF GAS DRYER SECTION
Off gas to 73-DR-03 A PI-2601A Kg/cm2 G 12.6
Off gas to 73-DR-03 B PI-2601B Kg/cm2 G 12.6
Off gas from
PI-2602A Kg/cm2 G 11.6
73-DR-03A
Off gas from
PI-2602B Kg/cm2 G 11.6
73-DR-03B
Off gas to 73-DR-03 A PI-2603A Kg/cm2 G 12.6


Off gas to 73-DR-03 B PI-2603B Kg/cm2 G 12.6
o
Off gas to 73-DR-03 A TI-2601A C 43-49
o
Off gas to 73-DR-03 B TI-2601B C 43-49
Off gas from o
TI-2602A C 43-49
73-DR-03A
Off gas from o
TI-2602B C 43-49
73-DR-03B
LPG REFREGERATION SECTION
Off gas to 73-E-13B PI-2701 Kg/cm2 G 11.6
Rich oil + gas to
TIC-2701 C 5
73-V-11
Lean oil from 73-E-14 TI-2702 C 16
Lean oil to 73-V-11 TIC-2703 C 5
Off gas to 73-E-13B TIC-2704 C 40
Lean oil to 73-V-11 TI-2706 C 5
Off gas to 73-E-13B TI-2707 C 40
LPG SEPARATOR DRUM SECTION
LPG separator drum 73-
PIC-2801 Kg/cm2 G 11 PAH=12 PAL=10.2
V-11 overhead
Heavy isomerate to
storage 73-E-16 A/B PIC-2802 Kg/cm2 G 16.0
shell outlet
73-V-11 differential PDI/PDAH-
Kg/cm2 G PDAH=0.1
pressure 2803
73-V-11 overhead PI-2804 Kg/cm2 G 11
73-V-11 PI-2805 Kg/cm2 G 11.1


73-V-11 top PI-2806 Kg/cm2 G 11.0
73-V-11 overhead to
PI-2807 Kg/cm2 G 4.5
fuel gas header
73-E-14 shell inlet PI-2812 Kg/cm2 G 16.8
73-E-14 shell outlet PI-2813 Kg/cm2 G 15.7
73-E-15 tube inlet PI-2814 Kg/cm2 G 17.0
73-E-15 tube outlet PI-2815 Kg/cm2 G 16.2
73-E-16 A/B shell
PI-2816 Kg/cm2 G 16.0
outlet
Heavy isomerate to
storage 73-E-16 A/B PI-2817 Kg/cm2 G 6.1
shell outlet
73-E-14 tube inlet PI-2818 Kg/cm2 G 14
73-E-14 tube outlet PI-2819 Kg/cm2 G 12.4
73-V-11 OVHD TI-2801 C 15.0
73-E-14 shell inlet TI-2802 C 5.0
73-E-14 shell outlet TI-2803 C 15.7
73-E-15 tube inlet TI-2804 C 124.0
73-E-15 tube outlet TI-2805 C 95.0
73-E-14 tube inlet TI-2807 C 40.0
Oil + gas to 73-V-11 TI-2808 C 5.0


Off gas to fuel gas
TI-2809 C 24.0
header
73-V-11 bottom to 73-
TI-2810 C 5.0
P-14 A/B suction
Heavy Isomerate to
TI-2811 C 40.0
storage
73-E-14 tube outlet TI-2812 C 16.0
TI-2813 C 44 max
from 73-E-16 B
TI-2814 C 44 max
from 73-E-16 A
73-P-14A/B discharge FIC-2801 M3/hr 10.6 3.8 11.7
73-P-14A/B min flow
FIC-2802 M3/hr ** 8.0 11.7
line
73-E-15 tube side inlet FIC-2803 M3/hr 6.2 1.95 6.8
73-E-14 tube side inlet FI-2804 M3/hr 4.4 1.4 4.8
Isomerate to storage FI-2805 M3/hr 19.8 2.7 21.8
Off gas from 73-V-11 FI-2806 NM3/hr 1250 477 1374
LPG separator drum
LIC-2801 MM Low=300 Max=2400
73-V-11
LPG separator drum
LG-2802 MM Low=300 Max=2400
73-V-11
LPG STRIPPER SECTION
LPG stripper OVHD PIC-2901 Kg/cm2 G 13.4
73-C-04 differential PDI/PDAH-
Kg/cm2 G PDAH=0.5
pressure 2902
73-C-04 bottom PI-2903 Kg/cm2 G 13.9


PT/PAHH
73-C-04 OVHD Kg/cm2 G 13.4
2904/05/06
LPG stripper feed PI-2907 Kg/cm2 G 13.8
73-C-04 bottom PI-2908 Kg/cm2 G 13.9
73-P-18 A/B shell inlet PI-2912 Kg/cm2 G 14.5
2
73-P-16B suction PI-2917 Kg/cm G 12.8
73-C-04 top PI-2918 Kg/cm2 G 13.4
VHP steam to 73-E-17 PI-2919 Kg/cm2 G 32.0
73-P-18 A/B shell inlet TI-2901 C 63.0
LPG stripper feed TI-2902 C 98.0
73-C-04 OVHD TI-2903 C 56.0
73-P-18 A/B shell outlet TI-2904 C 40.0
73-C-04 above 25th tray TIC-2905 C 98.0
73-C-04 below 28th tray TI-2906 C 98.0
73-C-04 above feed tray TI-2907 C 98.0
73-C-04 above feed tray TI-2908 C 98.0
73-C-04 above 9th tray TI-2909 C 212.0
73-C-04 above 17th tray TIC-2910 C 98.0
73-C-04 above 6th tray TI-2911 C 98.0


73-E-18A tube outlet TI-2914 C 44 max
73-E-18A shell inlet TI-2915 C 63.0
LPG stripper feed TI-2916 C 98.0
Stripper overhead TI-2917 C 56.0
73-P-16A/B suction TI-2918 C 40.0
73-E-18B tube outlet TI-2919 C 44 max
73-P-17A/B discharge
FIC-2901 M3/hr 11.1 3.8 13.3
to 73-C-04
73-P-15A/B discharge FIC-2902 M3/hr 4.5 ** 6.8
Condensate line from
FIC-2903 M3/hr 1.5 0.5 1.70
73-V-21
73-P-16A/B minimum
FIC-2904 M3/hr 4.5 1.9 6.0
circulation line
LPG stripper bottom LIC-2901 MM MIN=300 MAX=1500
73-C-04 side draw line LT-2902 MM MIN=150 MAX=1900
73-C-04 chimney tray LIC-2904 MM MIN=100 MAX=1000
LPG stripper bottom LG-2906 MM MIN=300 MAX=1500
LPG STRIPPER OVHD SECTION

73-V-12 inlet PI-3001 Kg/cm2 G 13.0
LPG stripper reflux
PI-3002 Kg/cm2 G 13.0
drum 73-V-12


Off gas from 73-V-12 PI-3004 Kg/cm2 G 13.0
PT/PALL-
73-P-17A/B discharge Kg/cm2 G 18.5
3005
73-V-12 inlet TI-3001 C 40.0
Offgas from 73-V-12 TI-3002 C 40.0
73-V-12 off gases FI-3001 NM3/HR 399 129 440
73-P-17A/B minimum
FO-3002 M3/hr 4.5 4.4 **
flow circulation
73-V-12 LIC-3001 MM Low=150,High=600
73-V-12 LG-3002 MM Low=150,High=600
ISOM DRYERS REGENERATION SECTION
VHP steam to 73-E-20 PI-3101 Kg/cm2 G 32.0
Regenerant to 73-F-
PI-3102 Kg/cm2 G 10.5
01
Hot vapor to 73-A-04 TI-3101 C 143-310
73-F-01 outlet TI-3102 C 143-310
Hydrogen to 73-F-01 TI-3103 C 143-153
73-F-01 outlet TIC-3104 C 143-310
Light isomerate to
TI-3108 C 40.0
73-E-20
VHP steam to 73-E-20 FIC-3101 Kg/Hr 6061 782 6667


HC feed to 73-E-20
FIC-3102 M3/Hr 15.0 5.0 16.5
(case-1)
HC feed to 73-E-20
FIC-3102 M3/HR 15.0 5.0 16.5
(case-II)
N2 to 73-E-20 FI-3103 NM3/ HR 240
Dryer regenerant
LT-3101 MM --
vaporizer 73-E-20
Dryer regenerant
LIC-3102 MM --
vaporizer 73-E-20
Dryer regenerant
LG-3103 MM --
vaporizer 73-E-20
Light isomerate to
PIC-3201 Kg/cm2 G 8.2
storage
73-E-21A/B shell inlet PI-3202 Kg/cm2 G 8.7
2
73-E-21A/B shell outlet PI-3203 Kg/cm G 8.4
73-V-13 PI-3204 Kg/cm2 G 8.2
73-E-21A/B shell inlet TI-3201 C 65.0
73-E-21A/B shell outlet TI-3202 C 40.0
Hot vapor to 73-A-04 TI-3203 C 290.0
73-V-13 LIC-3201 MM MIN=2450 MAX=4000
73-V-13 LI-3202 MM MIN=300 MAX=800
73-V-13 LG-3203 MM MIN=300 MAX=800
73-V-13 LG-3204 MM MIN=2450 MAX=4000
PRODUCT COOLING SECTION


LPG product to storage PI-3301 Kg/cm2 G 16.7
Off-spec isomerate to
PI-3302 Kg/cm2 G 7.1
slop
Light isomerate to
PI-3303 Kg/cm2 G 7.1
storage
73-E-11 tube outlet TI-3301 C 44 max
Light isomerate to
TI-3302 C 40.0
storage
Off spec isomerate to
TI-3304 C 40.0
storage
Light isomerate to
TI-3305 C 40.0
storage at B/L
LPG to storage TI-3306 C 40.0
Off spec isomerate to
TI-3307 C 40.0
storage at B/L
LPG to storage FIC-3301 M3/hr 5.4 1.9 6.0
LPG to off spec LPG
FO-3302 M3/hr 5.4 1.9 6.0
storage
Light isomerate to
FI-3303 M3/hr 36.1 10.0 39.7
storage
Off-spec isomerate to
FI-3304 M3/hr 22.1 3.0 24.3
slop

7.5 SET POINTS OF ALARMS AND TRIPS
Tag no. Description Unit Setting

PAH-1101 73-V-01 Kg/cm2 G 5.0
PAL-1101 73-V-01 Kg/cm2 G 3.7
PALL-1102 73-P-01 discharge Kg/cm2 G 27.4
FAH-1101 73-P-01 discharge M3/HR 94.4
FAL-1101 73-P-01 discharge M3/HR 55.7
FAL-1104 Feed to 73-V-01 M3/HR 19.5
FAH-1104 Feed to 73-V-01 M3/HR 53.4
LAL-1104 73-V-01 boot MM 450
LAH/LAL-1201 73-V-03 MM 1600/500
2
PAH/PAL-1201 73-V-03 Kg/cm G 7.0 / 4.7
H2 make up comp
TAH-1402 C 103
discharge
H2 make up comp
TAH-1403 C 50
discharge
LAH/LAL-1401 73-V-02 MM 700 / 400
LAHH-1402 73-V-02 MM 1050
PALL-1503 Dry H2 to 73-E-02 Kg/cm2 G 21.7
H2 from dryers
FAH/FAL-1501 NM3/HR 5381 / 259
73-DR-02A/B
Feed inlet to 103-R-
PAL-1603 Kg/cm2 G 20.8
2001
PAL-1604 Feed to 73-V-04 Kg/cm2 G 18.8
Set Point +5 Set Point
TAH/TAL-1604 Feed to 73-R-01 C
-5
TAH-1605 Feed to 73-V-04 C Set Point +10
TAH-1609 to 1618 73-R-01 C Set Point +5
TAHH-1609 to 1618 73-R-01 C Set Point +10
73-V-04 system
PAH/PAL-1701 Kg/cm2 G 20.0 / 18.2
pressure


Recycle to
Set Point +5 Set Point
TAH/TAL-1701 hydrogenation C
-5
reactor
Recycle to
TAH-1702 hydrogenation C Set Point +10
reactor
FAH/FAL-1701 73-P-04 discharge M3/HR 121.1 / 70.1
LAH/LAL-1701 73-V-04 MM 2000 / 650
LAH/LAL-1702 73-V-04 MM 2000 / 650
Isomerate to 73-C-
PAH/PAL-1801 Kg/cm2 G 31.0 / 29.2
01
Feed inlet to 73-R-
PAHH-1815 Kg/cm2 G **
02
Diff press across
PAHH-1812 Kg/cm2 G 2.0
73-R-02
Diff press across
PAHH-1813 Kg/cm2 G 2.0
73-R-03
Set Point +10 Set
TAH/TAL-1801 73-R-03 inlet C
Point -5
TAH-1802 to 1814 73-R-02 C Set Point +10
TAH-1815 73-R-03 outlet C Set Point +10
TAH-1816 to TAH-
73-R-03 C Set Point +10
1828
TAH-1829 73-R-03 outlet C Set Point +10
Reactor effluent
TAH-1831 C Set Point +10
from 73-R-02
PAH/PAL-1901 73-C-01 overhead Kg/cm2 G 15.8 / 14.0
PAHH-1902 73-C-01 overhead Kg/cm2 G 16.3


Condensate from
FAH-1901 Kg/hr 78060
103-D-2019
LAH/LAL-1901 Stabilizer MM 3800 / 1900
Condensate pot(
LAH/LAL-1902 MM ** / **
73-V-19)
LAH/LAL/ LALL-
Stabilizer (73-C-01) MM 3800/1900/650
1903
PAH/PAL-2001 73-V-05 Kg/cm2 G 15.3 / 13.5
2
PALL-2002 73-P-05 discharge Kg/cm G 17.9
OVHD vapor inlet Set Point +10 Set
TAH/TAL-2001 C
to 73-E-06 A/B Point -5
OVHD vapor inlet Set Point +10 Set
TAH/TAL-2002 C
to 73-V-05 Point -5
Off gas from 73-V-
FAH-2002 NM3/HR **
05
Stabilizer reflux
LAH/LAL-2001 MM 950 / 350
drum 73-V-05
LAHH/LAH/LAL- Stabilizer reflux
MM 1550/950/350
2002 drum 73-V-05
DIH recycle to 73-
TAH-2105 C 50
V-01
FAH/FAL-2101 73-E-07 inlet line M3/HR 47.1 / 18.3
73-P-07 min
FAL-2102 M3/HR 30.0
circulation line
DIH recycle drum
LAH/LAL-2101 MM 3800 / 800
(73-V-07)
PAH/PAL-2201 73-C-02 top Kg/cm2 G 2.2 / 1.3
PAHH-2202 73-C-02 OVHD Kg/cm2 G 2.6


TAH-2208 73-C-02 OVHD C Set Point +10
73-P-06A/B
FAL-2201 M3/HR 68.0
discharge
73-P-08A/B
FAH/FAL-2202 M3/HR 24.3 / 3.0
discharge
FAH-2203 73-E-10 steam inlet KG/HR 13920
LAH/LAL-2201 73-V-20 MM **
DIH column (73-C-
LAH/LAL-2202 MM 1550 / 450
02)
Set Point +10 Set
TAH/TAL-2301 73-V-08 inlet C
Point -5
73-P-09A/B
FAH/FAL-2301 C 40.8 / 10.0
discharge
LAH/LAL-2301 DIH reflux drum MM 1450 / 500
PAH-2501 73-C-03 OVHD Kg/cm2 G 13.5
PALL-2508 73-E-12 shell inlet Kg/cm2 G 17.2
Set Point +10 Set
TAH/TAL-2501 73-E-12 shell outlet C
Point -5
73-C-03 chimney
LAH/LAL-2502 MM 1500 / 100
tray
Water inlet to 73-C-
FAL-2502 M3/hr 19.0
03
FAH -2504 Off gas to dryer NM3/hr 2476.0
FAL-2505 Caustic circulation M3/Hr 19.0
73-E-13B tube
outlet
TAH-2703 73-E-13A tube inlet C Set Point +2
Offgas to fuel gas
PAH/PAL-2801 Kg/cm2 G 12.0 / 10.2
header


Offgas to fuel gas
header
73-E-16 A/B shell
outlet
73-P-14A/B
FAH/FAL-2801 M3/Hr 11.6 / 3.8
discharge
FAH/FAL-2804 73-E-15 tube inlet M3/Hr 6.8 / 2.0
LAH/LAL-2801 73-V-11 MM 2150 / 550
2
PAH/PAL-2901 73-C-04 overhead Kg/cm G 14.4 / **
2
PAHH-2904/05/06 73-C-04 overhead Kg/cm G 14.9
Feed to LPG Set Point +10 Set
TAH/TAL-2902 C
stripper Point -5
Set Point +10 Set
TAH/TAL-2903 73-C-04 overhead C
Point -5
Set Point +10 Set
TAH/TAL-2905 73-C-04 C
Point -5
Set Point +10 Set
TAH/TAL-2906 73-C-04 C
Point -5
Set Point +10 Set
TAH/TAL-2907 73-C-04 C
Point -5
Set Point +10 Set
TAH/TAL-2910 73-C-04 C
Point -5
Set Point +10 Set
TAH/TAL-2912 73-E-17 shell inlet C
Point -5
73-P-15A/B
FAL-2902 M3/Hr 4.5
discharge
LAH/LAL-2901 73-C-04 MM 1350 / 450
Off gas to 73-E-
PAH/PAL-3004 Kg/cm2 G 14.0 / 12.2
13B
73-P-17A/B
PALL-3005 Kg/cm2 G 17.0
discharge


Overhead vapor to Set Point +10 Set
TAH/TAL-3001 C
73-V-12 Point -5
Off gas to 73-E-
FAH/FAL-3001 NM3/hr 440 / 129
13B
LAH/LAL-3001 73-V-12 MM 500 / 250
TAH/TAL-3104 73-F-01 outlet C 320 / 305
VHP steam to 73-
FAH-3101 Kg/HR 6667.0
E-20
Light isomerate to
PAH/PAL-3201 Kg/cm2 G 9.2 / 7.9
storage
73-E-21A/B shell o
inlet
73-E-21A/B shell o
outlet
LAL-3201 73-V-13 MM 2550
LAH-3202 73-V-13 MM 750
3
FAH/FAL-3301 LPG to storage M /Hr 6.0 / 1.9
7.6 EQUIPMENT LIST

PUMPS
Design
Design Diff.
Discharge
Item No. Item Description Capacity Head
Pressure
(m/hr) (m)
(Kg/cmg)
AROMATIC
73-P-01 A/B HYDROGENATION 94.4 37.0 373.9
PUMP
CHLORIDING AGENT
73-P-02 A/B 10.6 lit/hr 46.0 255.8
INJECTION PUMP
73-P-03 A/B HYDROGENATION 318.2 33.0 174.3

Design
Design Diff.
Discharge
Pressure
(m/hr) (m)
(Kg/cmg)
REACTOR RECYCLE
PUMP
ISOMERIZATION
73-P-04 A/B REACTOR FEED 121.2 78.0 406.3
PUMP
STABILIZER REFLUX
73-P-05 A/B 50.2 23.5 95.4
PUMP
DEISOHEXANIZER
73-P-06 A/B 176.1 14.0 129.5
REFLUX PUMP
DEISOHEXANIZER
73-P-07 A/B 97.9 15.0 127.2
RECYCLE PUMP
DEISOHEXANIZER
73-P-08 A/B 24.3 28.0 290.0
BOTTOM PUMP
ISOMERATE
73-P-09 A/B 40.8 22.0 239.8
STORAGE PUMP
73-P-10 A/B CAUSTIC PUMP 30.9 21.0 159.1
CAUSTIC
73-P-11 A/B 36.0 23.0 46.3
CIRCULATION PUMP
DEMINIERALISED
73-P-12 A/B 100 lph 17.5 154.2
WATER PUMP
WATER
73-P-13 A/B 24.0 21.0 25.0
CIRCULATION PUMP
73-P-14 A/B SEPARATOR DRUM 11.7 27.0 138.9

Design
Design Diff.
Discharge
Pressure
(m/hr) (m)
(Kg/cmg)
BOTTOM PUMP
LPG STRIPPER
73-P-15 A/B 6.82 28.0 130.4
BOTTOM PUMP
73-P-16 A/B LPG PRODUCT PUMP 6.0 25.0 122.8
LPG STRIPPER
73-P-17 A/B 13.3 23.0 107.7
REFLUX PUMP
VESSELS
Internal Design Design
TL-TL
Tag No. Item Description Diameter Temp Pressure
(mm)
(mm) C Kg/cmg
ISOMERISATION
73-V-01 FEED SURGE 2500 6500 80 6.0+FV
DRUM
HYDROGEN
73-V-02 600 1800 80 26.0+FV
MAKE UP KOD
CHLORIDING
73-V-03 AGENT 1100 3300 80 10.5
INJECTION DRUM
HYDROGENATIO
73-V-04 N REACTOR 2800 7300 210 21.0
FLASH DRUM
STABILIZER 80
73-V-05 1900 5600 17.0
REFLUX DRUM (-)25


TL-TL
(mm)
(mm) C Kg/cmg
STABILIZER
BOTTOM
73-V-06 3120 2500 195 18.0
CHLORIDE
GUARD BED
DIH RECYCLE
73-V-07 1850 5350 120 5.0
DRUM
DIH REFLUX
73-V-08 2100 6100 80 4.0+FV
DRUM
Full of
73-V-09 CAUSTIC DRUM 3400 3700 80 Liquid +
250MM WC
DM WATER
73-V-10 1200 4000 80 3.5
DRUM
450(TOP)9
LPG SEPARATOR 80
73-V-11 50(BOTTO 14800 15.5
DRUM (-25)
M)
LPG STRIPPER 80
73-V-12 900 2600 15.5
REFLUX DRUM (-40)
DRYERS
73-V-13 REGENERANT 2550 850 310 12.5+FV
DEGASSER
CLOSED
73-V-16 BLOWDOWN 1900 5700 180 16.0
DRUM
73-V-18 CONDENSATE 450 3100 400 40.0+FV


TL-TL
(mm)
(mm) C Kg/cmg
POT
CONDENSATE
73-V-19 450 3200 400 40.0+FV
POT
CONDENSATE
73-V-20 450 3000 300 12.5+FV
POT
CONDENSATE
73-V-21 450 2900 400 40+FV
POT
COLUMNS
Tag No. Height
Item Description Diameter Temp. Pressure
(mm)
(mm) (C) (Kg/cm2g)
1400/ 2100/
3000 195
73-C-01 STABILIZER 31150 17.5
(top/mid/bot (-25)
tom)
DEISOHEXANISE
73-C-02 3400 45350 155 5+FV
R
1300/
CAUSTIC 2400
73-C-03 18850 80 16.0
SCRUBBER (top/
bottom)
650/ 1200
73-C-04 LPG stripper 27300 230 16.0
(top/bottom)

DRYER
Tag No. Item Height
Diameter Temp. Pressure
Description (mm)
(mm) (C) (Kg/cm2g)
80 /
73-DR-01 FEED
1800 6850 325 37.0+FV
A/B DRYERS
(REGEN)
135 /
73-DR-02 HYDROGEN
900 9250 325 46.0+FV
A/B DRYERS
(REGEN)
SCRUBBER 80 /
73-DR-03
OFFGAS 1100 10150 325 15.0
A/B
DRYER (REGEN)
COMPRESSOR
Design Design
Item DELTA P Design Press
Tag No. Capacity Temp
Description (Kg/cm2g) (Kg/cm2g)
(NM3/HR) (C)
73-K-01 H2 MAKE UP
14038 18.1 46.0 135
A/B COMPRESSOR
REACTOR
Internal Design
Tag No. Height Design
Item Description Diameter Pressure
(mm) Temp. (C)
(mm) (Kg/cm2g)
210
HYDROGENATIO
73-R-01 1450 4650 325 24+FV
N REACTOR
(regen)

Internal Design
Tag No. Height Design
Item Description Diameter Pressure
(mm) Temp. (C)
(mm) (Kg/cm2g)
1st STAGE
73-R-02 ISOMERIZATION 1400 21510 210 41+FV
REACTOR
2nd STAGE
73-R-03 ISOMERIZATION 1400 21510 210 41+FV
REACTOR
HEAT EXCHANGER (AIR COOLED)

Design
Tag No. Design Duty Design
Item Description Press.
(Mkcal/HR) Temp(C)
(Kg/cm2g)
HYDROGENATI
ON REACTOR
73-A-01 1.52 25+FV 210
RECYCLE AIR
COOLER
STABILIZER AIR 105/
73-A-02 A/B 1.47 17
CONDENSER (-25)
DIH AIR
73-A-03 A-H 9.87 4.0+FV 95
CONDENSER
DRYERS
REGENERANT
73-A-04 A/B 1.96 12.5+FV 325
AIR
CONDENSER

HEAT EXCHANGER
Design Press Design Temp
Tag No. Design Duty
Item Description Shell/Tube Shell/Tube
(Mkcal/HR)
(Kg/cm2g) (C)
73-E-01 H2 MAKE UP
2*0.28 46.0/36.5 150/65
A/B COOLER
DIH RECYCLE/
73-E-02 REACTOR FEED 0.65 37.0/29.0 135/120
EXCHANGER
FIRST REACTOR
73-E-03 FEED/ EFFLUENT 1.56 31/40 135/210
EXCHANGER
HYDROGENATIO
73-E-04 N REACTOR 4.89 31/40+FV 210/400
FEED HEATER
STABILIZER
73-E-05 3.32 40+FV /31.0 400/195
REBOILER
73-E-06 STABILIZER 80(-25)/
2*0.54 17.0/13.5
A/B TRIM OOLER 65
DIH FEED/ 14.0+FV/
73-E-07 2.02 140/195
RECYCLE 18.0+FV
73-E-08 DIH TRIM
2*0.16 15.0/11.5 120/65
A/B COOLER
73-E-09 ISOMERATE
2*0.114 22.0/17.0 80/65
A/B TRIM COOLERS
12.5+FV/
73-E-10 DIH REBOILER 6.66 300/155
10+FV


Tag No. Design Duty
(Mkcal/HR)
(Kg/cm2g) (C)
OFF SPEC
73-E-11 ISOMERATE 0.638 28.0/21.5 155/65
TRIM COOLER
CAUSTIC
73-E-12 RECYCLE 0.50 23.0/17.7 80/190
HEATER
LPG
73-E-13 -45,65/80/
REFRIGERATION 0.022/0.41 20.0/15.5
A/B -45,65/80, -40
SYSTEM
SEPARATOR
DRUM 80,(-25)/
73-E-14 0.04 19.0/17.5
BOTTOM/LEAN 100
OIL
LPG STRIPPER
73-E-15 FEED/BOTTOM 0.41 22.0/28.0 120/185
EXCHANGER
73-E-16 LEAN OIL TRIM
2*0.26 28.0/22.0 185/65
A/B COOLER
LPG STRIPPER 40.0+FV/
73-E-17 0.55 400/230
REBOILER 31.0
73-E-18 LPG TRIM 80,-25/
2*0.022 17/13.5
A/B COOLERS 65
73-E-19 LPG STRIPPER 80,-40/
2*0.252 15.5/12.0
A/B CONDENSER 65


Tag No. Design Duty
(Mkcal/HR)
(Kg/cm2g) (C)
DRYERS
31.0+FV/
73-E-20 REGENERANT 1.10 195/400
40.0+FV
VAPORIZER
DRYERS
73-E-21
REGENERATION 2*0.078 12.5+FV/ 10 310/65
A/B
TRIM COOLER
7.7 LIST OF INSTRUMENTS

In this section control valves, pressure safety valves, analyzers etc are listed.
Information regarding indicators & controllers (temperature, pressure, flow and level
instrument) are already given in previous section.
Control Valves:
Sr. No. Tag No. Description/Location
1 73-FV-1101 73-P-01A/B discharge
2 73-FV-1102 MCF of 73-P-01 A/B
3 73-LV-1101 Sour water from 73-V-01
4 73-PV-1101A Nitrogen blanketing of 73-V-01
5 73-PV-1101B 73-V-01 flare
6 73-PCV-1201 Nitrogen to 73-V-03
7 73-PV-1401 Hydrogen (73-K-01 A/B spillback line)
8 73-FV-1501 Hydrogen from dryer 73-DR-02A/B
9 73-FV-1502 Hydrogen from dryer 73-DR-02A/B
10 73-FV-1601 Steam inlet to 73-E-04
11 73-LV-1602 Condensate from 73-E-04


12 73-TV-1603A 73-E-03 shell side flow bypass line
13 73-TV-1603B 73-E-03 shell side inlet flow line
14 73-FV-1701 Isomerization feed from 73-P-04A/B
15 73-FV-1702 Reactor recycle (73-P-03 A/B discharge)
16 73-PV-1701A 73-V-04 Hydrogen pressurization
17 73-PV-1701B 73-V-04 purge gas
18 73-PV-1702 73-V-04 offgas to flare
19 73-TV-1701A 73-A-01 bypass line
20 73-TV-1701B 73-A-01 bypass line
21 73-TV-1801A Reactor effluent to 73-R-03
22 73-TV-1801B Reactor effluent 73-E-03 bypass
23 73-FV-1901 VHP condensate from 73-E-05
24 73-PV-1901 Reactor effluent from 73-R-03
25 73-PV-1901B Depressurization line
26 73-FV-2001 73-C-01 reflux
27 73-PV-2001 73-V-05 off gases to 73-C-03
28 73-PV-2002 Depressurization line to 73-C-03
29 73-FV-2101 DIH pump around 73-P-07 A/B
30 73-FV-2102 73-P-07A/B minimum circulation flow
31 73-FV-2103 DIH recycle from 103-E-08
32 73-FV-2201 DIH reflux (73-P-06A/B )
33 73-FV-2202 DIH bottom (73-P-08A/B discharge)
34 73-FV-2203 73-E-10 outlet condensate
35 73-FV-2205 73-P-08A/B minimum flow circulation
36 73-FV-1902 DIH feed from 73-E-07
37 73-LV-2101 DIH recycle to 73-V-07


38 73-FV-2302 73-P-09A/B minimum flow circulation
39 73-PV-2201A Liquid 73-A-03 outlet
40 73-PV-2201B 73-V-08 flare line
41 73-PDV-2301 73-V-08 Vapor equalizing line
42 73-FV-2302 73-P-09 A/B minimum flow circulation
43 73-PV-2201A Liquid 73-A-03 outlet
44 73-PV-2201B 73-V-08 flare line
45 73-FV-2501 LP condensate from 73-E-12
46 73-PV-2501 73-C-03 off gases to fuel gas header
47 73-FV-2801 73-P-14 A/B discharge
49 73-FV-2803 Fluid to 73-E-15
50 73-FV-2804 73-E-14 tube inlet liquid
51 73-PV-2801 Off gases from 73-V-11
52 73-PV-2802 Isomerate from 73-E-16A/B to storage
53 73-FV-2901 LPG stripper reflux
55 73-FV-2903 Condensate from 73-E-17
57 73-PV-3001 73-V-12 off gases
58 73-FV-3101 Steam to 73-E-20
59 73-FV-3102 Isomerate to 73-E-20 (Case-1)
60 73-FV-3102 Naphtha to 73-E-20 (Case-2)
61 73-LV-3201 Residual Vapor from 73-V-13
62 73-PV-3201 Light isomerate to storage
63 73-FV-3301 LPG from 73-P-16 A/B


64 73-FV-3302 Isomerate to storage
On/Off valves
1 73-UV-1101 73-P-01A/B suction line
2 73-UV-1102 Sour water from 73-V-01
3 73-UV-1201 73-P-02 A/B discharge line
4 73-KV-1301A 73-DR-01A regeneration line
5 73-KV-1301B 73-DR-01B regeneration line
6 73-KV-1302A 73-DR-01A inlet
7 73-KV-1302B 73-DR-01B inlet
10 73-KV-1304A 73-DR-01A inlet
11 73-KV-1304B 73-DR-01B inlet
12 73-KV-1305 73-DR-01A/B regeneration line
13 73-KV-1306 73-DR-01A/B inlet (regeneration line)
14 73-KV-1307 73-DR-01A/B outlet (regeneration line)
15 73-KV-1308 73-DR-01A/B inlet (Regeneration line)
16 73-KV-1309A 73-DR-01A inlet
17 73-KV-1309B 73-DR-01B inlet
18 73-KV-1310A 73-DR-01A inlet
19 73-KV-1310B 73-DR-01B inlet
20 73-KV-1311A 73-DR-01A outlet line
21 73-KV-1311B 73-DR-01B outlet line
22 73-KV-1312A 73-DR-01A (Regeneration line)
23 73-KV-1312B 73-DR-01B (Regeneration line)
24 73-KV-1313A 73-DR-01A (Regeneration line)


25 73-KV-1313B 73-DR-01B (Regeneration line)
26 73-KV-1314A 73-DR-01A outlet line (single reactor)
27 73-KV-1314B 73-DR-01B outlet line (single reactor)
28 73-KV-1315A 73-DR-01A outlet (analyzer loop line)
29 73-KV-1315B 73-DR-01B outlet(analyzer loop line)
30 73-UV-1401 73-K-01A/B suction line
31 73-UV-1402 73-K-01A/B discharge line
32 73-UV-1501 73-DR-02A/B outlet line
33 73-UV-1502 Dry naphtha to 73-E-02
34 73-UV-1503 73-DR-01A/B inlet line
35 73-UV-1504 73-DR-02A/B inlet line flare
36 73-KV-1501A 73-DR-02A (regeneration line)
37 73-KV-1501B 73-DR-02B (regeneration line)
38 73-KV-1502A 73-DR-02A outlet (single reactor)
39 73-KV-1502B 73-DR-02B outlet (single reactor)
40 73-KV-1503A 73-DR-02A inlet (regeneration)
41 73-KV-1503B 73-DR-02B inlet (regeneration)
44 73-KV-1505A 73-DR-02A inlet (tail period)
45 73-KV-1505B 73-DR-02B inlet (tail period)
46 73-KV-1506A 73-DR-02A outlet (single)
47 73-KV-1506B 73-DR-02B outlet (single)
48 73-KV-1507A 73-DR-02A inlet
49 73-KV-1507B 73-DR-02B inlet


56 73-KV-1511A 73-DR-02A/B outlet (analyzer lop)
57 73-KV-1511B 73-DR-02A/B outlet (analyzer lop)
60 73-UV-1601 73-E-04 steam inlet line
61 73-UV-1701 73-V-04 hydrogen pressurization line
62 73-UV-1702 73-V-04 purge gas
73-UV-1703 73-P-03 a/B discharge
63 73-UV-1704 73-P-04A/B discharge line
73-P-04A/B discharge line isomerization, reactor
64 73-UV-1705
bypass
65 73-UV-1706 73-P-04 & 73-P-04 suction line
66 73-UV-1801 H2 inlet line to 73-M-01
67 73-UV-1901 73-C-01 bottom outlet
69 73-UV-2001 73-P-05 A/B suction line
70 73-UV-2101 DIH recycle from 73-E-08 A/B
72 73-UV-2202 73-C-02 bottom outlet
73 73-UV-2301 73-P-06 & 09A/B suction line
74 73-UV-2501 73-C-03 gases to 73-DR-03 A/B
75 73-UV-2502 73-C-03 off gases to flare


76 73-UV-2503 73-C-03 off gases to fuel gas header
81 73-KV-2603A 73-DR-03A inlet
82 73-KV-2603B 73-DR-03B inlet
87 73-KV-2606A 73-DR-03A outlet (single)
88 73-KV-2606B 73-DR-03B outlet (single)
89 73-KV-2607A 73-DR-03A inlet
90 73-KV-2607B 73-DR-03B inlet
97 73-KV-2611A 73-DR-03A/B outlet (analyzer loop)
98 73-KV-2611B 73-DR-03A/B outlet (analyzer loop)

7.8 PRESSURE SAFETY VALVES

Sr. Description/Loc Set Pressure
Tag No. Base of selection
No. ation (Kg/cm2g)
Blocked liquid
1 73-PSV-1101 A/B 73-V-01 6.0
discharge, Fire case
Chloride agent
2 73-PSV-1202 A/B On hold
injection drum
Chloride injection
3 73-PSV-1202 A/B On hold
pump
73-DR-01 A/B
4 73-PSV-1301 A/B 36.5 Fire case
outlet
5 73-PSV-1401 73-V-02 26.0 Fire case
6 73-PSV-1402/1403 73-K-01A/B 46.0 Operational failure
7 73-PSV-1404/1405 Sea cooling water 7.6 Thermal expansion
8 73-PSV-1501A 73-DR-02 A 46.0 Fire case
9 73-PSV-1501B 73-DR-02 B 46.0 Fire case
10 73-PSV-1601 DIH recycle 15.0 Tube rupture
11 73-PSV-1602 73-V-18 40.0 Fire case
12 73-PSV-1603 73-R-01 24.0 Fire case
73-PSV-1701A / Operational failure,
13 73-V-04 21.0
1701B Fire case
73-P-04 A/B
14 73-PSV-1703/1704 21.0 Blocked outlet
discharge
15 73-PSV-1801 73-R-02 inlet 39.8 Fire case
16 73-PSV-1802 73-R-03 39.8 Fire case
17 73-PSV-1901 73-V-19 40.0 Fire case
18 73-PSV-1902 Stabilizer bottom 21.0 Fire case


No. ation (Kg/cm2g)
Fire case, Reflux,
cooling water, air
19 73-PSV-2001 A/B 73-V-05 17.0
cooler, electrical,
failure case
20 73-PSV-2002 A/B 73-E-06 A/B 7.6 Thermal relief
21 73-PSV-2101 A/B 73-E-08 A/B 7.6 Thermal Expansion
Fire case, Reflux,
73-PSV-2201 cooling water, air
22 73-C-02 4.0
A/B/C cooler, electrical,
failure case
23 73-PSV-2202 73-V-20 12.5 Fire case
24 73-PSV-2301 73-V-08 4.0 Fire case
25 73-PSV-2401/2402 73-P-12 A/B 17.5 Blocked discharge
Fire case,
26 73-PSV-2501 A/B 73-C-03 15.0 Operational failure,
Blocked outlet
27 73-PSV-2502 73-E-12 5.5 Tube rupture
Spent caustic to
28 73-PSV-2503 A/B 17.5 Blocked condition
ETP
73-DR-03 A
29 73-PSV-2601 A 15.0 Fire case
outlet
73-DR-03 A
30 73-PSV-2601 B 15.0 Fire case
outlet
73-E-13 B shell
31 73-PSV-2701 7.6 Thermal expansion
outlet
32 73-PSV-2801 A/B 73-V-11 15.0 Fire case, Blocked


No. ation (Kg/cm2g)
outlet,
33 73-PSV-2803/2804 73-E-16 A/B 7.6 Thermal expansion
Fire case/CW,
reflux, feed cutoff,
34 73-PSV-2901 A/B 73-C-04 15.5
power failure,
blocked outlet
35 73-PSV-2902 A/B 73-V-21 40.0 Fire case
36 73-PSV-2903/2904 73.-E-18 A/B 7.6 Thermal relief
37 73-PSV-3001/3002 73-E-19 A/B 7.6 Thermal expansion
Blocked outlet, fire
38 73-PSV-3101 73-F-01 outlet 18.0 (hold) case, thermal
expansion
Fire case, blocked
39 73-PSV-3102/3103 73-E-20 12.5
outlet
40 73-PSV-3201 A/B 73-V-13 12.5 Fire case
41 73-PSV-3203/3204 73-E-21 A 7.6 Thermal relief
42 73-PSV-3301 73-E-11 7.6 Thermal relief
42 73-PSV-3302/3303 73-E-09 A/B 7.6 Thermal relief
7.9 ANALYZERS
Sr.
Tag No. Type Location/Service
No.
1 73-AE-1101 Benzene On isom feed line to 73-DR-01 A/B
2 73-AE-1301 A/B Moisture 73-DR-01A/B outlet
3 73-AE-1501 A/B Moisture 73-DR-02 A/B outlet
4 73-AE-1901 Moisture Across 73-PV-1901

Sr.
Tag No. Type Location/Service
No.
5 73-AE-2601 Moisture 73-DR-03 A/B outlet

SECTION - 8
SHUTDOWN PROCEDURES
8.1 GENERAL
While shutting down the unit due to maintenance or emergency, care must be taken not to
admit air into the system until all hydrocarbon vapours have been removed. Operators
should be thoroughly familiar with shutdown procedures and understand the reasons for
each work. Good judgement must be exercised as no written procedure can completely
cover all details or problems that can arise in an emergency. Judgement is more likely to
be exact if prior thought and planning have been made.
In this section the activities related to the normal as well as emergency shutdown
procedures have been briefly outlined.
8.2 NORMAL SHUTDOWN PROCEDURE

Normal shutdown applies to a shutdown planned in advance for preventive maintenance
or to unexpected events which are not an emergency.
Before initiating any planned shutdown, review all records to determine what
inspections and repair works that must be accomplished during the shutdown. Prepare a
shutdown schedule, including plans for pre-arranging feed and product inventories
during turnaround time. Notify all services and other dependent operating units of the
schedule so that all activities can be properly coordinated. Arrange for all required parts,
tools and services in advance, in particular adequate nitrogen for purging.
When shutting down, steps should be taken to prevent catalyst or equipment damage
from expansion, contraction, thermal shock or unusual pressure or vacuum surges. Purge
with care all vessels, using steam for those that are not subject to condensation damage
and inert gas for the critical vessels until all equipment is hydrocarbon liquid and gas
free. Avoid a vacuum formation which could cause vessel collapse if insufficient inert
gas is admitted after flow ceases or as liquids are removed. Ventilate thoroughly and

check the atmosphere in the vessels before entering or starting repairs. Rigorously
observe all safety precautions.
The general procedure to be followed for a total shutdown is:
- To lower the severity
- To lower the capacity
- To switch the product to off-spec. or raw naphtha storage
- To shutdown the reaction section
- To drain all hydrocarbons
- To depressurize and purge.
Several shutdown cases are considered:

i) Short duration shutdowns (i.e. less than 24 hours)
ii) Long duration shutdowns for major repairs, equipment entry etc
iii) Partial shutdowns for catalyst replacement.
8.3 SHORT DURATION SHUTDOWNS

These shutdowns are typically less than 24 hours to make minor repairs without opening
any major equipment.
It is recommended to begin a shutdown after a dryer has completed a regeneration cycle
so as to have sufficient dryer cycle capacity on restart.
- Increase the make-up hydrogen flow to design
- Reduce the reactors inlet temperatures to 100C at a rate of 20C/hour. If necessary,
switch the stabilizer bottom and LPG product to off-spec storage.
- When the reactors beds temperatures have stabilized, decrease slowly the naphtha
feed rate to 50% of design fresh feed (correspond to 75% of the reactor design feed
rate FT 1101). Reduce the feed rate by steps of 10% per 30 minutes. It is important
to wait until the reactors temperatures have stabilized to avoid any increase in
reactors severity.
- As this is a short shut down, leave the Deisohexaniser in service.

- Reduce the reactors inlet temperatures to 90C over a one hour period and allow the
beds to cool. When isomerization reactors temperatures reach 105C approximately,
stop the chloride injection. Maintain these conditions for one hour (i.e. at 90C) to
sweep chloride from the feed circuit upstream of the reactors.
- Open the reactors bypass to bypass the C5/C6 feed directly to the stabilizer and close
the reactor feed valve. Cut the feed out as quickly as possible to minimize the low
liquid flow period over the catalyst.
- Continue sweeping the reactors with make-up hydrogen at design rate. Reduce the
reactors inlet temperatures at 20C/hour until the reactor feed heater is shutdown.
- When reactors have cooled below 60C, stop the hydrogen flow.
- Reduce the stabilizer temperature but as this is a short duration shutdown, leave the
stabilizer in operation at a low reflux rate.
- Maintain pressure in the reaction section, stabilizer and LPG stripper. If necessary
use the hydrogen make-up through the start-up line.
The unit is now considered to be on standby with C5/C6 feed bypassing the reactors, the
Deisohexaniser fed at 75% capacity with distillate and bottoms routed to off-spec
storage, the stabilizer on a low rate total reflux. The unit is under normal pressure with
hydrogen make-up as required. The reactors have cooled to below 60C.
8.4 LONG DURATION SHUTDOWNS

These are considered to be shutdowns for major repairs and for equipment entry or
inspection. Proceed as per the steps for a short duration shutdown, followed by the
additional steps summarized below:
- Stop fresh C5/C6 Feed.
- Close the reactor recycle liquid from the Deisohexaniser. Shut down gradually the
Deisohexaniser Reboiler and Reflux pumps.
- By pass the LPG recovery section, the off gas from the stabilizer overhead are sent
to the scrubber. Provide hydrogen from dryers by the start-up line to maintain the
pressure. Stop rundown the heavy product to the storage.

- Stabilizer circuit is also shutdown gradually. If the stabilizer needs to be opened for
inspection, a purge of make-up hydrogen should be sent to the tower to strip any HCl
in the overheads. This can be stopped after there is no measurable HCl in the gas
sample.
- Stop the LPG recovery section.
- Block in and isolate the reactors.
- With the unit still under pressure drain all the major vessels, first to storage then to
slop.
- Depressurize all sections to fuel gas first if desired then to flare. Avoid
depressurizing the stabilizer below the scrubber pressure as there is a risk of caustic
entrained gas backing up into the stabilizer.
- Depressurize all the reactors to flare through the hydrocarbon drain lines.
- Depressurize the LPG recovery section if required.
- Shutdown both the caustic and water washes in the scrubber.
- Shutdown all air coolers and water coolers.
- When the unit is considered totally depressurized and all the utilities e.g. water,
steam have been drained and isolated from their respective equipment, the reactors
can be blocked.
- Isolate the stabilizer section from the reaction section.
- Isolate with blinds the feed lines, hydrogen make-up, product lines and fuel gas
headers. Isolate all PSV's lines to flare and instruments not suitable for vacuum
service.
- Remove one of the blinds from the reactors to the ejector and pull a vacuum in the
reaction and dryer sections (the dryers can be evacuated separately if desired) down
to 0.2 bar abs.
- Break with dry nitrogen and pressure up 1.0 bar g.
- Depressurize through all low points, dead legs, vents etc
- Repeat the evacuation breaking with nitrogen steps until the hydrocarbon level has
decreased below 0.5 vol. %.

- Note the porous catalyst and adsorbent will require time to displace the
hydrocarbons inside the pores. Proceed with caution around the reactors and dryers
by allowing one hour before pulling the sample for testing.
- Leave a residual nitrogen pressure of 0.5 bar g.
- Purge scrubber with steam and if desired leave in it a positive nitrogen pressure.
- Purging the stabilizer and all items in LPG recovery section with steam is prohibited
(except for the initial start-up) as chloride traces in presence with water are
excessively corrosive.
- As a safety precaution block and blind reactors from the reaction circuit.
Depending upon the extent and reason for shutdown the various pieces of equipment can
be isolated and air purged for entry.
8.5 SHUTDOWN FOR CATALYST REPLACEMENT

For replacing the catalyst in any one of the isomerization reactors, it is recommended
that the unit be shutdown using only the short duration shutdown procedure. This would
enable immediate restarting of the unit with one isomerization reactor. The other
isomerization reactor, where the catalyst requires to be replaced, is isolated and purged
with N2 to flare using the hydrocarbon drain connections, prior to the beginning of
catalyst unloading operations.
Caution
For the benzene hydrogenation catalyst replacement, if the benzene hydrogenation
reactor bypass is used while isomerization reactors are still in operation, special
precaution shall be taken. This bypass should only be used for a limited time.
During that period monitoring of benzene (on line analyzer + frequent sampling) in
the fresh feed shall be closely followed. No unit feed with a benzene content higher
than 2.5 wt % is permitted.

8.6 EMERGENCY SHUTDOWN PROCEDURE

8.6.1. General
This unit is equipped with certain emergency shutdown controls which will
automatically place the unit in a non-hazardous status should a major failure occur. The
actions of the emergency shutdowns are responsible for protecting the personnel, the
catalyst and equipment from heavy coking or irreparable damage.
Personnel and equipment protection also results from:
- Personnel having a satisfactory knowledge of the safe operating and shutdown
procedures.
- A compliance with the safety rules in plant construction i.e. safety distances,
adequate orientation, etc.
- The installation of adequate fire and gas detection devices and fire fighting
equipment.
- Adequate operator safety awareness and procedures training.
The following special considerations are highlighted for operator awareness of the
isomerization process.
- The unit contains benzene and tetrachloroethylene which are known health hazards.
- The unit contains HCl downstream of the first isomerization reactor inlet. The
concentration is particularly high in the stabilizer overhead and in the LPG separator
drum. For this reason, operator shall bypass LPG recovery section, for any upstream
upsets, such as loss of H2, loss of feed, upset in stabilizer operation.
- The reactions are highly exothermic, mostly due to the benzene saturation and the
C7+ components hydrocracking. If the levels of these components in the feedstock
increase significantly, the hydrogenation reactor temperature could raise beyond a
controllable range.
- A reactor temperature excursion could occur if the flow of liquid through a hot
reactor is too low or if the reactor temperatures are too high. Reactor feed rate should
not decrease below 75% of design capacity (FT 1101).

- During an emergency situation in the stabilizer section, the stabilizer must not
depressurize below the pressure of the scrubber. There is a check valve in the
stabilizer overheads gas line to the scrubber and a static height to overcome but
despite this water and caustic could back up into the stabilizer causing a potential
corrosion problem.
- In the event a reactor temperature excursion occurs and the reactor temperatures
increase above 190C, the reactors must be depressurized to avoid excessive
hydrocracking reactions and to prevent mechanical damage. If for some reason the
reactors cannot be depressurized through the stabilizer, only as a last resort should
they be depressurized to the flare through the hydrocracking drain lines. It is
recommended to block the reactors in prior to depressurizing and to start a cold
nitrogen purge if necessary. Depressurization is started once the LPG recovery
section has been bypassed on off gas side (bypass is activated by I-101 emergency
shut down interlock).
Concerning the catalyst preservation, operators must avoid:

- An excessive catalyst grain temperature which can change the structure of the
alumina (> 700C). To avoid damaging the catalyst structure, bulk temperature must
never exceed 500C. Note that the reactor design temperature (under design
pressure) is much lower.
- The hydrocarbons presence without a sufficient hydrogen quantity which would lead
to a rapid coke deposit and the possible agglomeration of catalyst particles.
The following sections cover most of the emergencies that may have to face by the
operator. All operating personnel must study and fully understand the steps to be taken
in such situations prior to the unit start-up.
Some of these situations are handled by automatic shutdown trips. These trips must
always be operational, bypassing must be kept to a minimum e.g. during start-up,
transient periods etc

The following procedures include all the actions to be undertaken by the operator
assuming no action by the automatic shutdown devices.
8.6.2. Loss of Feed

Loss of feed to the isomerization reactors is an emergency situation. When feed flow
stops, the feed in the reactor circuit will pass slowly through the reactors swept by the
low flow of make-up gas. For a sudden decrease in feed flow, the temperature controller
on the inlet will not act fast enough and the unit pressure will decrease causing the back
pressure controller to close. The net effect is high severity in the reactors, over
conversion and soaring reactor bed temperatures.
Actions:
- Cut steam immediately from the reactor feed heater and close the bypass around
feed/effluent exchanger. Bypass LPG recovery section on off gas side.
- Increase the make-up hydrogen flow to maximum (2nd hydrogen make up line).
- Stop the isomerization feed pumps at hydrogenation reactor flash drum.
- Slowly depressurize the reaction section to stabilizer (via control valve PV 1901).
Depressurize at a rate which allows stable pressure control of the stabilizer.
- Stop the C2Cl4 injection when the lead reactor temperature reaches 105C.
- Monitor the reactor bed temperatures. If the hydrogenation reactor temperature is
below 190C and stable, continue cooling with make-up gas and cool down to 65C.
- If the reactor bed temperatures are still climbing, cut the hydrogen make-up, block in
the reactors and depressurize to flare through the stabilizer and the Scrubber. Purge
with dry nitrogen.
8.6.3. Loss of Make-up Hydrogen

When make-up hydrogen flow is lost, reactor pressure will decrease immediately, no
hydrogen will be available for hydrogenation or isomerization reactions. A
hydrocracking increase may occur, possibly causing a temperature excursion and a coke
deposits increase.

Actions:
- Cut steam immediately from the reactor feed heater.
- Cut the feed to unit.
- Increase ti maximum the recycle flowrate in the recycle air cooler. Close the recycle
air cooler bypass line. Start all fans at the air cooler.
- Bypass LPG recovery section on off gas side.
- Stop C2Cl4 injection when the isomerization lead reactor reaches 105C.
- Stop the isomerization reactor pump at the hydrogenation reactor flash drum.
- Slowly depressurize the hydrogenation reactor via the associated flash drum.
- Slowly depressurize the reaction section to the Stabilizer to keep the back pressure
control valve open and cold feed flowing through the reactors.
- Reduce the stabilizer pressure as necessary to maintain pressure control on the
column and flow of bottom to Deisohexaniser column.
- If the reactor temperatures cannot be controlled and increase above 190C during
this procedure, interlock I-101 must be activated (emergency shut down).
8.6.4. High Reactor Temperature

High isomerization reactor temperature could be the result of a high content of C7+ in the
feed or high catalyst severity due to low feed rates or poor temperature control of the
reactor inlet feeds. In order to avoid a reactor temperature excursion:
- Avoid liquid feed rates less than 75% of design (FT 1101)
- Avoid larger than design quantities of benzene or C7+ in the feed. It is also important
to be aware of changes in these contents due to crude changes or variations in the
upstream units.
- Avoid overheating the reactor charge.
Actions
- Increase the recycle flowrate to maximum.
- Cut steam immediately to the reactor feed heater.

- Increase to maximum the recycle flow rate in the recycle air cooler. Close the
recycle air cooler bypass line. Start all fans at air cooler.
- Maximum hydrogen make-up flow in the isomerization reaction section (2nd
hydrogen make up line)
- Stop C2Cl4 injection when the isomerization reactor reaches 105C.
- Hold the reactor inlet temperatures at 100C if conditions are stable.
- Modify the fractionation towers upstream of the unit to restore the design quantities
of benzene and C7+ in the feed.
- Or check out the controllers to determine the cause of the poor control.
- When the faults have been corrected, increase the reactor temperatures slowly back
to normal operating point.
- If any of the reactor temperatures exceeds 190C, cut the liquid feed and make-up
hydrogen. Activate I-102 / 103, emergency shut-down interlock in order to
depressurize the reaction section.
If the reactor temperature excursion is due to low liquid feed rate and this cannot be
corrected quickly, cut out the remaining feed and follow the procedures for loss of feed.
8.6.5. Steam Failure

If steam is lost in the unit, the Reactor Feed Heater, the Reboilers of the stabilizer, the
Deisohexaniser and the LPG stripper, the Caustic Recycle Heater and the Regenerant
Vaporizer will shut down.
Critical equipment is the reboiler of the stabilizer as unstabilized product containing HCl
could be sent through the downstream equipment to tankage, making the storage
equipment susceptible to corrosion.
Actions:
- Bypass the LPG recovery section on off gas side. The stabilizer off-gases are sent to
fuel gas via scrubber.
- Increase the hydrogen make-up flow to maximum rate in the isomerization reaction
section (2nd hydrogen make up line)

- Stop the C2Cl4 injection.

- When the reactors cool down to 100C, cut C5/C6 fresh feed to 50% of design rate by
steps of 10%.
- When 50% is reached, open the reactor bypass line and quickly remove the
remaining C5/C6 feed from the reactors.
- Continue the reactors cooling with hydrogen make-up gas, while maintaining
pressure profile in the reaction section and stabilization section.
- Cut the C5/C6 feed circulation and maintain the recycle flow rate around the
hydrogenation reactor.
- If at any time temperature begins to increase rapidly in any one of the reactors, begin
depressurizing through the stabilizer and scrubber.
- Stop the heavy product rundown as soon as possible.
8.6.6. Cooling Water Failure

This refers to cooling water failure or air cooler failure. If the recycle of the C5/C6 feed
fails, the dryers will be operating at a higher temperature significantly reducing the
dryers water retention capability. Any water breakthrough would be detrimental to the
isomerization catalyst.
Loss of cooling around the Deisohexaniser, stabilizer and LPG stripper will cause an
over pressuring of the column leading to possible relief through the PSV. There is also
the risk of sending hot isomerate or LPG product to tankage causing a fire hazard.
If cooling water or air cooling fails for an extended period of time, shutdown the unit
using the following procedure:
- Cut steam immediately from the Reactor Feed Heater.
- Bypass the LPG recovery section on off gas side. The stabilizer off-gases are sent to
the scrubber.
- Increase hydrogen make-up to maximum rate to the isomerization reactors.
- Increase to maximum the recycle flow rate in the recycle air cooler. Close the
recycle air cooler bypass line. Start all fans at air cooler.

- When the isomerization lead reactor reaches 105C, cut the C2Cl4 injection.
- Reduce steam to deisohexaniser reboiler, stabilizer reboiler and LPG stripper
Reboiler, but maintain the pressures.
- Follow the procedure as above for steam failure.
8.6.7. Power Failure

If a power failure occurs, all electrically driven equipment i.e. pumps; air coolers and
compressors (make-up hydrogen) will stop.
This is a severe condition as loss of flow through the reactors where exothermic
reactions occur will lead to a temperature runaway situation.
Actions:
- Immediately bypass LPG recovery on off gas side and simultaneously begin
depressurizing the reactors to flare (through the stabilizer and scrubber for the
isomerization section.
- When the pressure is low begin purging with cold dry nitrogen to cool the reaction
beds and displace the hydrocarbons.
- Shut off steam to the Reactor Feed Heater, the Reboilers of stabilizer, deisohexaniser
and LPG stripper.
8.6.8. Instrument Failure: Air or Power

It is too early to prepare a procedure on this type of failure without knowledge of the
system back-up and level of redundancy, etc, preferred by the unit owner. This section
will be fully defined during the detailed engineering stage based on the strategies
developed for other emergency situations.
8.6.9. Major Leak or Fire:

The following is only an overview of the steps to be taken during the discovery of a
major leak resulting in a fire. The following steps are from a process view mainly aimed
at avoiding runaway reactions and protecting the equipment and catalyst.

Incase of fire, depressurization of the reactors shall be actuated as per API 521
3.19. As the safety valves at the reactors have set pressure corresponding to
supercritical conditions, protection against fire exposure by safety valves is not
sufficient. It is mandatory to depressurize the corresponding vessels whenever a
fire is detected.
Actions:
- Shut off both C5/C6 feed and hydrogen make-up to the unit and block in the product
lines.
- Shut off steam to the Reactor Feed Heater, Stabilizer Reboiler, deisohexaniser
reboiler and LPG stripper reboiler.
- Immediately bypass LPG recovery on off gas side and simultaneously begin
depressurizing the reactors to flare, through the stabilizer and scrubber.
- If it is possible, isolate the problem area and block in the reactors and purge with
nitrogen to flare.
- The objectives of the following steps which should be developed by the
client/engineering contractor are to drain hydrocarbons from all the vessels, purge
the unit with inert gas in particular the reactors if they cannot be accessed. Leaving
the reactors with hydrocarbon inside and no flow will eventually lead to a
temperature excursion and mechanical failure, so all effort must be made to purge
these vessels.
8.7 AUTOMATIC SHUTDOWNS

There are several automatic shutdown process interlocks in the design of this unit to
protect the catalyst and the equipment during an incident or failure. Refer to the Process
Design Book for the shutdown and safety interlocks description and the P&ID'S.

8.7.1. Hydrogenation reaction section

If the naphtha feed flow rate to the hydrogenation reaction section or if the recycle flow
rate reduce the feed rate at the inlet of the reactor to 70% of design rate (or less), the low
flow switch will automatically stop:
- naphtha feed,
- hydrogen,
- steam of the hydrogenation reactor feed heater,
- stop the feed to the isomerization section,
- open the block valve of the recycle air cooler,
- close the bypass of the recycle air cooler.
This protects the catalyst from very low space velocity and potential hydrocracking
leading to a temperature runaway.
In case of high high temperature in the hydrogenation reactor, the same procedure is
followed.
8.7.2. Isomerization reaction section

If the naphtha feed flowrate to the isomerization reaction section reduces to 70% of
design rate (or less), the low flow switch will automatically stop the feed to the section.
If no problem is observed on the hydrogenation reaction section, the feed will bypass the
two reactors to the stabilizer.
This protects the catalyst from very low space velocity and potential hydrocracking
leading to a temperature runaway.
8.7.3. Stabilizer Reflux Drum High Liquid Level

The PSV protecting the stabilizer circuit is located on top of the Stabilizer Reflux Drum
discharging to the Caustic Scrubber. The release of hydrocarbon liquid to the caustic
scrubber causes foaming in the scrubber, and hence an HLL switch is added to the
Stabilizer Reflux Drum to shut down the unit.

8.7.4. Regenerant Superheater Shutdown

Activated by the following:
- a high liquid level in the Regenerant Vaporizer,
- a high coil skin temperature in the electrical Superheater,
- low regenerant feed flow.
8.7.5. Emergency Shutdown Hand Switch

This is not an automatic shutdown but a board mounted hand switch to be used at the
discretion of the operator. Should an emergency situation occur such as a temperature
runaway in the reactors or warning of a potential slug of water in the feed, the operator
can activate this switch which will:
- Shut off the fresh feed to the hydrogenation reactor.
- Shut off the recycle feed to the reactor.
- Stop the chloride injection pump.
- Shut off the hydrogen make-up.
- Shut off the isomerate to storage.
- Reroute scrubber off-gas to flare.
- Bypass LPG recovery section.
- Depressurize at a controlled rate the reaction section to the stabilizer.
- Depressurize at a controlled rate the stabilizer to the scrubber.
At no time should reactor be allowed to set with liquid hydrocarbon inside and no
flow. Under these conditions with no flow across, the thermocouples temperature
measurement would be false and the temperature runaway could be occurring with
no indication. Once depressurized reactor should be swept to remove any liquid
hydrocarbon using cold hydrogen make-up or nitrogen.

8.7.6. LPG Recovery section bypass hand switch

The operator, for a particular emergency situation, could decide to activate the hand
switch which will permit the bypass of the LPG recovery section on off gas side (UV
2501 closed and UV 2503 open).
It may occur during chloride breakthrough, water breakthrough, loss of make-up
hydrogen, high reactor temperature, steam failure, cooling failure, power failure and
major leak or fire.

SECTION-9
PROCESS VARIABLE
Process variables that affect the isomerization process are discussed below.
9.1 BENZENE SATURATION
There are six process variables which have an effect on the reactor performance:
- Reactor temperature.
- Reactor pressure
- Hydrogen make-up flow
- Liquid diluents recycle
- Space velocity.
- Feed composition
9.1.1 Reactor Temperature:

The high activity of the catalyst allows operation at moderate reactor inlet temperatures
(100 to 140C). Typical heat of reaction for the benzene hydrogenation reaction is
50,000 kcal/kmol.
9.1.2 Reactor Pressure:

A moderate pressure is sufficient to obtain the benzene hydrogenation. The pressure
recommended in the heat balance leads to an almost liquid phase at the reactor outlet.
9.1.3 Hydrogen make-up flow

Hydrogen in small excess (5 mole%) is mixed with dry feed under flow control.
Operator will adjust hydrogen flow set point according to amount of benzene measured
by on-line analyzer.

9.1.4 Liquid diluents recycle

The exothermicity in the reactor is linked to the benzene content in the feed. With 7.5%
wt of benzene, the reactor delta T is estimated to be about 75-80oC. The control of
exotherm in then reactor, in smooth and safe conditions, is realised with the recycled
hydrogenation reactor effluent, used as inert diluents recycle. The heat and material
balances show the recommended recycle flow for the maximum benzene content in the
reactor feed to maintain an acceptable delta T in the reactor. Temperature gradient
should always be limited to 30oC.
9.1.5 Space Velocity:

Liquid Hourly Space Velocity (LHSV) is defined as the ratio of the hourly flowrate of
liquid feed in m3 to the volume of catalyst in m3, i.e.
Hourly feed rate @15C (m 3 / h)

LHSV =
Total catalyst volume(m 3 )
9.1.6 Feed Composition:

Feed composition is an indirect variable, a variable the operator reacts to, rather than
adjusts for performance control. If the benzene content of the feedstock varies , the
operator will have to:
- Adjust the hydrogen makeup to ensure excess of 5% vol.
- Modify the recycle flowrate in order to have an acceptable gradient of temperature in the
hydrogenation reactor (no more than 30 oC elevation
9.2 ISOMERIZATION
There are six primary process variables which have a direct effect on the reactors
performances:
- Reactor temperature.

- Space velocity.
- Hydrogen / hydrocarbon ratio.
- Feed composition.
- Reactor outlet pressure
- Chloride Injection.
9.2.1 Reactor Temperature:

The high activity of the catalyst allows operating at moderate temperature (125-165 oC).
The inlet temperature to the reactors is the most direct variable the operator has
available to control product quality. Higher temperatures enhance catalyst activity and
approach to equilibrium, but it decreases the equilibrium amount of isomer in the reactor
effluent. Higher temperatures also increase hydrocracking reactions, and consequently
the coke deposits on the catalyst. An optimum temperature is determined which balances
the potential slight exotherm, the approach to equilibrium and the equilibrium level to
maximize the performance of the isomerization reactor. This optimum temperature
varies with feedstock variations, catalyst activity levels and space velocities without
forgetting that it must be adequate with the benzene saturation constraints.
9.2.2 Space Velocity:

Weight Hourly Space Velocity (WHSV) is defined as the ratio of the hourly flowrate of
liquid feed in kg/h to the weight of catalyst, i.e.
Hourly feed rate (kg/h)
WHSV = total catalyst weight (kg)
This parameter is fixed by the feed rate.

The quantity of catalyst being a constant, the space velocity can only be changed by
varying the liquid feed rate.

Decreasing the feed rate decreases the space velocity. At constant temperature this
increases activity and therefore the approach to equilibrium. The operator can therefore
reduce the reactor inlet temperature while maintaining catalyst optimum performance.
9.2.3 Hydrogen to Hydrocarbon Ratio:

This ratio is defined as the number of moles of hydrogen at the reactor outlet per mole of
C5+ liquid feed passing over the catalyst. The design ratio for this unit is 0.06, to supply
sufficient hydrogen at the active sites for the isomerization reactions to proceed and to
saturate the benzene. Also, it avoids carbon deposition on the catalyst with sufficient
hydrogen to saturate the hydrocracked components.
This ratio must at all times remain above 0.06. The operator should check this regularly
and pay particular attention during feed changes and end of life conditions in the
reformer. If necessary, reduce the reactor feed rate to maintain the ratio.
Hydrogen makeup is under ratio flow control according to the amount of the feed
coming from separator drum and going to the isomerization section.
9.2.4 Feed Composition:

Feed composition is an indirect variable, a variable the operator reacts to rather than
adjusts for performance control. As the feedstock compositions changes from processing
different crudes, the operator must make the necessary temperature adjustments to
maintain unit performance.
For example, when the cyclic content is high in the feed, the first stage isom reactor inlet
temperature is increased to increase the weight average bed temperature. This increases
ring opening in the first reactor and reduces the inhibition effect the cyclics have on the
isomerization reactions in the second stage reactor.
9.2.5 Reactor outlet pressure :

At the outlet of the second reactor, pressure shall be above the minimum of 30 kg/cm2

9.2.6 Chloride Injection:

The chlorinated platinum catalyst loses a small amount of chloride continuously to the
reactor effluent, and this is made-up by the continuous injection of a chloride agent to
the isomerization reactors. Tetrachloroethylene (C2Cl4) not stabilized is the
recommended Chloriding agent. The isomerization reactors should not be operated
for more than six hours without chloride injection, as the isomerization reactions
slow down significantly with chloride deficiency.

Figure 1
ISOPENTANE/ISO + NORMAL PENTANE EQUILIBRIUM PLOT
MOLE % ISOPENTANE/ISO + n-PENTANE
100
80
60
40
20
0
100 150 200 250 300
TEMPERATURE C
Figure 2
iC5/C5 Paraffin equilibrium ratio
85
83
81
79
77
IC5/C5P
75
73
71
69
67
65
60 80 100 120 140 160 180 200
TEMPERATURE C
Vapor phase equilibrium

Liquid phase equilibrium

Figure 3
C6 Fraction equilibrium Plot
100
MCP/MCP + CH
80
60
2-MP+3MP/ C6 PARAFFINS
40
n-HEXANE/ C6 PARAFFINS
20 2,2 DMB/ C6 PARAFFINS
2,3 DMB/ C6 PARAFFINS
0
100 150 200 250 300
TEMPERATURE C
Figure 4
2.2 DMB / C6 equilibrium ratio
52
50
48
46
44
42
22 DMB/C6P
40
38
36
34
32
30
28
26
24
22
60 80 100 120 140 160 180 200
TEMPERATURE C

SECTION-10
TROUBLE SHOOTING
The main concern for the isomerization unit operation is water breakthrough through a
malfunction of the dryers or major water upset in the upstream hydrotreater.
Two other concerns are:
- Sulfur poisoning which is reversible and poor de-nitrification in the upstream units
leading to chloride stripping off the catalyst.
- Chloride breakthrough in isomerate/LPG products.
The operator must be knowledgeable and experienced enough to make the proper
corrective actions immediately and to know if he should cut feed to the unit before any
catalyst activity loss occurs. The ultimate safe rule is to cut feed from the unit if a
breakthrough is suspected and follow carefully the necessary procedures for total unit
shutdown. Remember this unit produces a gasoline component for blending; it does not
produce any feedstock for other units and can therefore be shutdown with relatively little
disruption to the other refinery operations. The upset seriousness and the contaminant
breakthrough level will dictate the necessary course of action to take.
In this chapter we will highlight some of the potential problems which the operator may
have to face.
10.1 WATER BREAKTHROUGH FROM THE DRYERS

a. Feed and Hydrogen dryer
If water breaks through a dryer, as indicated by the moisture analyzers, immediate action
must be taken. Water entry into the reaction circuit will cause irreversible catalyst
damage as well as creating a highly corrosive environment.
Generally the dryers are taken off line and regenerated on a regular basis or when 1ppm
water content is registered in the lead dryer outlet analyzer. These analyzers are critical
to the performance and the unit condition and should be well maintained and calibrated
on a regular basis.

A sudden irregular indication of water breakthrough in the lead dryer analyzer indicates
either a malfunction of the analyzer or water upset upstream.
Operator action is to immediately cut out the feed indicating the high-water content i.e.
C5/C6 feed, make-up hydrogen.
After this, the corresponding emergency procedure for shutdown and purging can be
followed.
After the unit has been secured, the dryers which experienced the water breakthrough
should be regenerated and the dryer checked for water removal capability. The feed, the
make-up gas should be tested for moisture content and the source of the problem
corrected.
Then only a unit restart should be considered.
Remark: Water breakthrough from other sources
Chloride is not corrosive with dry hydrocarbons, but becomes very corrosive when
traces of water are present.
Stabilizer and equipment in LPG recovery section are made of carbon steel as reactor
effluent is water free.
However water ingress may occur with a leaking (cooling water exchanger or steam
reboiler). If water is detected in a stabilizer or LPG recovery section stream, unit shall be
shut down, for exchanger maintenance, in order to avoid extensive chloride corrosion.
b. Off-Gas Dryer
Water breakthrough will lead to purging of 73-E-13 (ice / LPG hydrates formation) and
ultimately to LPG recovery section bypass and shutdown. Incase of water breakthrough
Immediate action must be taken.
Also note that performance of the dryers is poor when process fluid temperature exceeds
50 oC. Therefore stabilizer overhead temperature and scrubber operating temperature
shall be closely monitored, in order to have a stable off-gas temperature at dryer inlet.

10.2 SULPHUR BREAKTHROUGH: SULPHUR STRIPPING PROCEDURE

If there is a disoperation in the upstream units leading to an increase in the level of
sulfur in the C5/C6 feed, then the isomerization unit must be immediately shutdown.
Sulfur breakthrough into the benzene saturation reactor and isomerization reactors is
indicated by a loss of benzene saturation and isomerization activity. If this occurs, the
temperature differential will shift down the benzene saturation reactor and possibly
across to the next reactor. H2S will also be detectable in the stabilizer off-gas.
If this occurs, discontinue naphtha feed to the unit immediately. It is possible after sulfur
poisoning to regain activity by stripping with hot hydrogen make-up gas. Good recovery
can be achieved, but complete recovery should not be expected.
The following outlines the sulfur stripping procedure when the lead isomerization
reactor has been sulfur poisoned:
- With light naphtha feed discontinued, maximize hydrogen make-up gas through the
reactors.
- For this operation, use hydrogen compressor bypass line. Hydrogen is routed via
hydrogen drier through normal circuit, with additional heating in the superheater.
Check that the blinds and block valves are lined out properly to use the electric super
heater. Hydrogen leaves the unit through the stabilizer and the caustic scrubber (LPG
recovery section must be bypassed).
- Increase the inlet temperature to about 260C, at 50C/hr rate based on the heater
limitations and mechanical design of the other equipment.
- Inject chloride into the first isomerization reactor inlet at a rate equivalent to
injecting 100 ppm chloride on a design throughput basis.
- Monitor the H2S content in the stabilizer off-gas. The H2S content will peak perhaps
as high as 1000 mol ppm depending upon the sulfur amount on the catalyst.
- Maintain the stripping operation for 24 hours or until the H2S content has decreased
to a low stable level.

- At this point the stripping operation is considered complete. Stop the chloride
injection, shutdown the reactor feed heater and the superheater and cool the reactor
catalyst beds to 65C.
- Follow the normal start-up procedures.
10.3 LOSS OF C2CL4 INJECTION

If C2Cl4 injection is lost, chloride will be stripped from the isomerization catalyst
resulting in an isomerization activity loss.
If chloride is lost for only a few hours, the catalyst activity can be regained by resuming
chloride injection at a higher rate (400ppm) until HCl in the Stabilizer off gas reaches
about 2000ppm.
If the chloride injection is lost for more than six hours, the ability for the catalyst to
regain activity is reduced leading to irreversible damage of the catalyst.
If chloride is lost the following actions should be taken:
- Reduce reactor inlet temperatures to 110C.
- If it appears that the chloride injection will not be available for more than six hours,
prepare the unit for shutdown.
- Reduce net naphtha feedrate to 50% of design capacity.
- When chloride becomes available, maintain the low severity conditions (110C inlet
temperature) inject into the reactor feed at 400 ppm wt until the stabilizer off-gas
chloride content increases back to 2000ppm.
- C2Cl4 injection rate: C2Cl4(Kg/h.) = Reactor feed flow (T/h.) /1000
Caution:
When a new load of C2Cl4 is required check that the purchase order indicates C2Cl4
unstabilized or catalytic grade. The stabilized C2Cl4 will not decompose in the reactors
and will end up with product in the Stabilizer leading to some problems with the
isomerate used to dryers regeneration.

10.4 CHLORIDE BREAKTHROUGH

Isomerate, heavy product and LPG product are regularly checked for HCl content.
Periodic testing is necessary to ensure no chloride exiting with the isomerate and LPG
product. As isomerate is used to regenerate the dryers, it must be free of HCl not to
damage the molecular sieves.
The isomerate unit and the LPG recovery section are very sensitive to any upset in
reflux or reboiling duty at the stabilizer and at the LPG stripper. Any upset will impact
in chloride content in isomerate, LPG product and heavy product shall be recorded.
Corresponding chloride will be absorbed on the chloride guard beds and the record of
the upset will enable the operator to predict the life length oh the chloride beds.
For any upset in the stabilizer or in the LPG recovery section (loss of reboiler or reflux),
the LPG recovery section will be bypassed on, off gas side. The stabilizer off gases are
sent to the scrubber and routed to fuel gas header. The lean oil still circulates in the LPG
recovery section.
10.5 PREVENTIVE MAINTENANCE:

To ensure a more trouble free operation of the isomerization unit, the mechanical unit
integrity should be adequately monitored and the equipment including instrumentation
inspected on a periodic basis. Items of particular importance are:
- The automatic valves around the naphtha feed, hydrogen make-up dryers. These
should be periodically checked for leakage.
- Spare automatic valves shall be provided in warehouse.
- The C2Cl4 injection pumps should be periodically checked for leakage and switched
to the standby.
- The water removal capability of the dryers should be monitored. Consider absorbent
replacement after 500 cycles.
- The moisture analyzers should be checked frequently for response and accuracy.
- Monitoring of the chloride absorbers life length.

SECTION -11
SPECIAL PROCEDURES/INSTRUCTION/INFORMATION
11.1 CATALYSTS LOADING UNDER N2

General:
The following procedure describes in detail the loading steps of catalyst. As the reaction
section has undergone a special drying procedure, care must be taken to ensure that no
air or moisture enters the reactors during the catalyst loading period. It is recommended
that the reactors be loaded using Axens' dense loading apparatus "CATAPAC".
The benzene hydrogenation catalyst LD-412 R and the isomerization catalyst IS-614 A
manufactured by Axens are shipped in sealed drums (120 kg for LD-412 R and 130 kg
for IS-614 A) that have a special protective lining (see Figure 5).
The catalyst is contained in a heavy plastic bag with an unloading neck. This bag is
inside another heat-sealed plastic bag. Care should be taken in the drums handling so as
not to break or puncture the plastic bags.
Before, during and after catalyst loading the catalyst must be protected from moisture at
all times.
Any contact with water or air will result in permanent deactivation of the catalyst.
The empty drums and bags should be kept to return the spent catalyst for platinum
recovery.
Preparation:
Prior to the loading, preliminary checking:
- The LD-412 R and the IS-614 A catalysts for loading, are stored by sealed plastic
bags in drums.
- The inert balls for top of the catalyst bed, it is recommended that these balls be oven
dried and stored in sealed plastic bags in drums similar to the catalyst.
- The CATAPAC dense loader device (see Figures 7, 8, 9 and 10).
- Special unloading lids with quick release retainer rings (4 required fitted at ground
level - see Figure 5).

- Sufficient dry nitrogen (less than 1 ppm wt H2O). If not available provide temporary
piping to route nitrogen through the hydrogen dryers.
- Provide emergency nitrogen storage in case of refinery nitrogen failure.
- Make available several nitrogen flexible hoses. They must be specified for nitrogen
service, must be new and perfectly dry.
- One telescopic crane capable of lifting a drum 3 m above the reactor upper flange
(see Figure 6).
- One standing hopper (see Figure 9).
- One forklift to handle the drum pallets.
- Tarpaulins should be available in case of rain or interruption during loading.
- One structure (scaffolding) disposed on the top of the reactor adapted to receive the
drums and to fill them into the reactor through the special device (see Figure 7).
- One safety harness, portable oxygen analyzer, air packs and dust masks.
- The oxygen analyzer will be used when reactors are open for catalyst loading to
make sure that no air is entering.
Catalyst Loading Procedure

The following instructions must be strictly followed throughout the entire catalyst
loading for the 3 reactors. It is imperative that no air or moisture enters the reactors or
comes in contact with the catalyst at any time.
- Connect the nitrogen flexible hoses from nitrogen header to drain point at reactor
bottom and to inlet pressure gauge tapping at reactor inlet line.
- Start a small purge of nitrogen into the reactor bottom and out the reactor inlet PI
connection.
- Unbolt and remove the reactor inlet elbow and top head. As the reactor is opened,
tightly cover the open flanges with plastic until the bottom inert balls entry.
- To install the dense loading device (CATAPAC) on the top distributor of the reactor,
attach the nitrogen connection and then attach the loading sock from the stationary
pipe above.

- Set down on the top man hole the stationary steel cover, the standing hopper and
pipe catalyst loading.
- At the same time, care must be taken to ensure that the sock penetrates in the center
of CATAPAC device. Look it through the little hole drilled on the steel cover
(figure 7).
- Then load, drum by drum the required quantity of catalyst.
- After the catalyst has been loaded install the top bed inert alumina balls layer
Note: At no time should a person enter a reactor having a nitrogen purge on it without
full instruction and experience with a fresh air mask, safety harness, safety clothes and
life line.
- Cover the manway again with plastic. Remove all the loading devices off the top
platform.
- Install the inlet distributor tray, reactor cover and inlet removable elbow as quickly
as possible after the loading is complete.
- Continue the nitrogen purge at the bottom of the reactor out through the inlet PI.
Check that the purge out through the PI is oxygen free.
- Pressure the reactor back up to 0.5 bar g. Check for flange leaks.
- Record all loading data, number of catalyst drums, inert balls, etc
- Repeat loading procedure for the second then third reactor.
Note: The opening, loading and closing procedure of the reactors should be a
continuous operation without break. During this operation a positive nitrogen
pressure should be maintained in the reactor at all times.

Figure 5
Preparation of the Drums

Figure 6
DRUM LIFTING CATALYST DENSE LOADING

Figure 7
Catalyst Handling with Catapac

Figure 8
Catalyst DENSE LOADING (part 1)

Figure 9
Catalyst DENSE LOADING (part 2)

11.2 SPENT CATALYST UNLOADING

When the catalyst is at end of life, it will be necessary to unload it. Spent catalyst can be
dumped from the reactors without previous coke combustion. This procedure must be
carried out with extreme caution under a nitrogen blanket at all times. The same
precautions used to keep air and moisture away from fresh catalyst must be used when
unloading spent catalyst. Specifically, the spent catalyst from isomerization reactors
contains a large chloride amount (3 to 4 %) and any moisture will make the material
very corrosive.
The reactor to be unloaded has to be depressurized, isolated with blinds, evacuated and
swept with cold dry nitrogen to a hydrocarbon level of less than 0.5 vol %. The reactor
is kept under a positive nitrogen pressure of 0.1 bar g with a nitrogen bleed entering at
the reactor bottom and exiting through the inlet PI.
- Close the nitrogen vent through the top PI and remove the blind flange on the
catalyst withdrawal nozzle.
- Attach the catalyst unloading sock. The bottom end of this sock must have a solid
metal section in order to clamp the catalyst bag.
- The spent catalyst can be loaded into the original catalyst drums and liners to protect
against corrosion during shipment.
- Place an empty drum on a scale, then put the inner plastic bag with the unloading
neck inside the outer heavy plastic bag. Purge the inner bag with nitrogen.
- Clamp the plastic unloading neck of the inner bag over the end of the unloading
sock.
- Partially detach the unloading spout, crimp the sock to stop any catalyst flow and
quickly remove the catalyst draw-off cover, reattaching the unloading spout.
- Uncrimp the loading sock and load into the drums. The first material will be inert
material followed by catalyst. If possible segregate the first few drums of inert
material for screening.
- The catalyst is dropped in the original catalyst drums.

- Load catalyst into each drum. Wire clamp the plastic unloading neck in two places
then wire clamp the outer heavy plastic bag.
- Close the drum tightly, record the weight and label the drum.
- A small amount of spent catalyst and inert material will be left in the bottom of the
reactor. This must be removed manually with a person inside the reactor to sweep
the catalyst toward the withdrawal spout.
- All the precautions previously listed for personnel entry during catalyst loading and
inspection should be followed here.
- With the reactor empty, an inspection can be carried out on the internals, and then
prepared for immediately catalyst reloading.
- Catalyst spillage should be minimized using the above procedure.
- However the concrete pad at the base of the reactors should be swept clean prior to
unloading. Any spillage during unloading can then be swept and placed in one of the
drums.
- The catalyst can then be shipped for platinum recovery including any catalyst
retrieved from screening of the initial drums of inert balls.
11.3 SPECIFICATIONS OF CATALYSTS

a) Benzene saturation catalyst:
73-R-01 LD-412 R (1)(2)
Supplier Axens
Shape Grey cylindrical extrudates
Nominal Particle Diameter 1.2 mm
Catalyst volume, m3 4.6 m3 (3)
Catalyst Cycle Length (estimated) 3 years (4)
Catalyst Life (estimated)
10 years
(1)Ready to use form

(2)Reduced and activated platinum on high purity alumina

(3)Dense catalyst loading method
(4)Ex-situ regeneration / reduction required at the end of cycle
The 73-R-01 was designed to have provision for future loading. Total future catalyst
amount will be 5.06m3
b) Isomerization catalyst:
73-R-02 & 73-R-03 IS 614 A (1)
Supplier Axens
Shape Cylindrical extrudates
Nominal Particle Diameter 1.6 mm
Catalyst volume, m3 56.22 m3 (28.11x2) (2) (4)
Catalyst Cycle First reactor : 4 years (3)
Length(estimated) Second reactor : 4 years (3)
Catalyst Life(estimated) 10 years
(1)Reduced and activated platinum on high purity alumina
(2)Dense catalyst loading method
(3)Ex-situ regeneration / reduction required at the end of cycle
(4)Total requirement for both reactors
The 73-R-02/03 were designed to have provision in the reactor for a future loading.
Total future catalyst amount will be 61.46m3 (30.73*2)
c) Dryers Adsorbents
Manufacturer AXENS
Type Molecular Sieve4A
Volume, m3 (1) (2) 37.56 m3
Estimated cycle length 30 hours (per bed)

Life period 3 years (estimated)

Notes: - (1) Total requirement for: 73-DR-01 A/B, 73-DR-02A/B, 73-DR-03A/B.
Manufacturer will advise on contingency to consider for this material.
(2) Sock catalyst loading method.
Manufacturer AXENS
Type Molecular Sieve 5A
3
Volume, m (1) (2) 13.7 (6.85x2) m3
Notes: (1) Total requirement for: 73-DR-01 A/B.
Manufacturer AXENS
Type Molecular sieve 13X
Volume, m3 (1) (2) 3.38 (1.69x2) m3
Notes: (1) Total requirement for: 73-DR-02 A/B.

d) Chloride guard bed Adsorbents

Manufacturer JOHNSON MATTHEY
Type Puraspec 6250 Puraspec 6255
Volume, m3 (1)(2) 2.44 9.56

Life Period 3 years (estimated)
Note: (1) Total requirement for: 73-V-06,

e) Alumina Balls
Manufacturer AXENS
Type Inert Ceramic Balls
Volume, m3 (1) 12.10
Type Inert Ceramic Balls
Volume, m3 (1) 10.81
Notes: (1) Total requirement for all vessels.

11.4 CHEMICALS DURING NORMAL OPERATION
11.4.1. Chloriding agent
Type C2Cl4
Quality Not stabilised (1)
Purity 99.9 wt%
Water Content < 25 wt ppm
Stabilizers < 10 wt ppm
Oxygen and Nitrogen compounds < 15 wt ppm
Halogens < 1 wt ppm
MW 165.8
Specific Gravity 1.623
Viscosity (15 oC) 0.95 cP
Estimated consumption 71 (Tons/year)
Notes: - (1) In order to have decomposition of C2Cl4 in HCl at reactor operating
conditions.

11.4.2. Neutralizing Solution

Type Aqueous Caustic
Quality NaOH 10 wt%
Estimated Consumption 1100 tons/year (1)
Notes: - (1) Based on spent caustic composition of 2 wt%
11.5 CHEMICALS DURING TRANSIENT OPEARTION

11.5.1. ACIDIZING GAS
Type HCl
Quality Anhydrous
Purity > 99.8 vol %
Cl2 + Br2 < 20 ppm
CCl4 < 150ppm
H2 + CO + CO2 + N2 < 1500 ppm
Estimated Consumption 2670 kg (1)
Notes:- (1) one time requirement , used during initial start-up of the reaction section,
removing water and oxide scales from reaction circuit.

SECTION-12
UTILITY CONSUMPTION SUMMARY
12.1 INTERMITTENT CONSUMPTIONS FOR ISOMERIZATION SECTION
Start up requirement
The estimated consumptions are based on a normal start-up sequence.
Intermittent operation can be assumed to occur once every 24 months.
Start-up instrument air

The instrument air is used for tightness test after catalyst loading.
Estimated consumption: Isomerization section: 900 Nm3.
Start-up nitrogen
Nitrogen gas is necessary to get the unit free of oxygen.
Start up hydrogen
At start-up, after 1st leak test, the reaction section is pressurized with hydrogen make-up.
Remark for Isomerization section: Hydrogen is needed during initial start-up to perform
acidizing at 60% of normal H2 flowrate. Moreover, in case of sulfur catalyst poisoning,
it is necessary to strip catalyst with hydrogen. In order to ensure a good hydrogen
distribution through the catalyst bed, it is recommended to process at a minimum
flowrate of 1000 Nm3/h.
Start-up hydrotreated naphtha:

For start-up, light hydrotreated naphtha is required to perform naphtha circulation in the
unit and to reach temperature in the unit.

Estimated required volume = 2 x estimated unit volume.
MP Steam
MP steam will be used as driving fluid of the start-up ejector 73-J-01 to inert reactor
section at the start-up.
LP Steam
LP steam will be used for steam purge out of the equipments and also as snuffing steam
on the flanges.

SECTION-13
SAMPLING PROCEDURE AND LABORATORY ANALYSIS REQUIREMENT
13.1 GENERAL
Control tests provide the information to the operating staff for making necessary
adjustments to get the maximum output and on-spec quality products. The control
tests are to be made at all steps to monitor the intermediate and final products whether or
not they are at the desired specification. Samples are taken and analyzed at regular
intervals such that the operation of the plant are monitored and any deviation (from
specification will indicate some maloperation / malfunction of the plant which can be
spotted and rectified in time without undue loss of time and product. Sometimes,
samples are taken to find out the effect of certain changes brought about in the operating
conditions. The samples are to be taken with great care so that the samples are
representative samples. The frequency of sampling, the type of analysis and points
where samples are to be taken are generally specified by t he process licensor. During
guarantee tests some additional samples can be taken at higher frequencies, which will
be specified, in the technical procedures prior to test run. The following guidelines
should be followed while collecting samples.
13.2 SAMPLING PROCEDURE

a) Liquid Sampling Procedure (Non-Flashing Type)
i) The person taking samples should wear proper or appropriate safety clothing like
face shields, aprons, rubber gloves etc. to protect face, hands and body.
ii) Whenever hot samples are taken, check cooling water flow in the sample cooler
is circulating properly.
iii) Sample points usually have two valves in series. One gate valve for isolation
(tight shutoff) and other globe valve for regulating the flow. Open gate valve
first and then slowly open the globe valve after properly placing the sample
containers. After the sampling is over, close the globe valve first and then the

gate. Then again open the globe valve and drain the hold up between the gate
and globe valve in case of congealing liquid.
iv) Sample valve should be slowly opened, first slightly to check for plugging. If the
plugging is released suddenly, the liquid will escape at a dangerously
uncontrolled rate. Never tap the line to release the plugging. Call the
maintenance gang to properly unplug the line. In case of congealing type
samples, sample point should be equipped with copper coil type steam tracer. It
should be ensured that steam-tracing line is functioning normally.
v) The operator taking the sample should be careful to stand in a position such that
the liquid does not splash on him and he has unobstructed way out from the
sample point in case of accident.
vi) While taking dangerous toxic material for sampling, it will act as an observer for
safety. Proper gas mask is to be used. It is advisable to stand opposite to wind
direction in case of volatile toxic liquid.
vii) Sample should be collected in clean, dry and stoppered bottle. In case of
congealing samples use clean dry ladle.
viii) Rinsing of the bottle should be thorough before actual collection.
ix) Before collecting, ensure that the line content has been drained and fresh sample
is coming.
x) Gradually warm up the sample bottle / metallic can by repeated rinsing before
collecting the sample.
xi) Stopper the bottle immediately after collection of sample.
xii) Attach a tag to the bottle indicating date, time, and name of the product and tests
to be carried out.
xiii) A few products suffer deterioration with time.
xiv) For example, the color of the heavier distillates slowly deteriorates with time. So
these samples should be sent to laboratory at the earliest after collection.

The samples after collection should be kept away from any source of ignition to
minimize fire hazard.
Volatile samples (e.g. naphtha) should be collected in bottles and kept in ice particularly
for some critical test like RVP.
b) High Pressure Hydrocarbon Liquid Samples (Flashing Type)

i) The person taking sample should use personal protection appliances like apron,
gas mask and hand gloves to protect himself.
ii) Ensure that sample bomb is empty, clean and dry.
iii) Connect the sample bomb inlet valve to the sample point with a flexible hose.
iv) Open the inlet and outlet valves of the sample bomb. Hold the sample bomb.
Hold the sample bomb outlet away from person. Keep face away from
hydrocarbon vapor and stand in such a way that prevalent wind should blow
hydrocarbon vapor away. Open the gate valve of sample point slowly till full
open. Then slowly cracks open the regulating valve. One should be careful at the
time of draining, because chance of icing is there. As a result, the formation of
solid hydrates is a continuing process, which leads to the plugging of valves.
v) When all the air in the hose and bomb are displaced as seen by the hydrocarbon
vapor rising from the outlet of sample bomb close the sample outlet valve. Allow
a little quantity of liquid to spill to make sure that the bomb is receiving liquid.
Frosting will be an indication of liquid spillage.
vi) Allow liquid hydrocarbon to fill the bomb. When the bomb is full up to the
specified level, close both the valves on sample point. Close inlet valve on the
sample point.
vii) Carefully disconnect the hose from the sample bomb. To allow for some vapor
space in the bomb for thermal expansion in case of overfilling, crack open the
outlet valve of bomb and discharge a small part of the liquid. Close outlet valve.

viii) Closed sampling facilities are provided at some locations where it is not
desirable to waste the costly product or if the material is toxic. For filling the
sampling bomb, pressure drop across a control valve is usually utilized or across
pump discharge & suction. Air is expelled from the bomb after it is connected to
upstream of control valve or pump discharge side. The sample is then collected
and bomb is detached after closing valves on both sides.
ix) Send sample bomb to laboratory for analysis. Protect the bomb from heat
exposure.
c) Gas Sample
For collection of gas sample, which are not under high pressure and temperature, rubber
bladders are used. For the operations under vacuum or low pressure, aspirator is used.
For representative sample, purge the bladder 3 to 4 times with the gas and then take t he
final sample. Use of 3 ways valve with bladder / aspirator will facilitate purging and
sampling.
Sample bombs are to be used for taking gas samples from high pressure and high
temperature source. Procedure mentioned under high-pressure liquid sampling (flashing
type) is to be used.
13.3 LABORATORY TEST METHOD AND SCHEDULE
Recommended Methods and Frequency

The frequencies given below are routine related to a normal operation. During start-up
and test runs more analysis will be required.
C5/C6 Feed
Property Method Frequency
Specific Gravity ASTM D 1298 1 per day
Distillation Curves ASTM D 86 2 per week

Chemical Composition IFP 9301 1 per day
Total Sulfur ASTM D 4045 1 per day
Water Content On line analyzer (also check

upstream of dryers with portable 1 per week
analyzer)**
Total Nitrogen ASTM D 4629 1 per week
Chlorine Content IFP 9316 As required
Bromine Index ASTM D 2710 As required
Arsenic Content IFP 9312 As required
Copper Content IFP 9507 As required
Lead Content IFP9406 As required
Nickel Content IFP 9507 As required
RON Clear ASTM D 2699 As required
MON Clear ASTM D 2700 As required
** PANAMETRICS is selling this kind of analyzer with the defined range of detection.
Hydrogen Make-up Gas

Composition IFP 9622 1 per week
Hydrogen Sulfide Dragger (tube CH 298) 1 per day
Water Content on-line analyzer -
Hydrogen Chloride Dragger (tube CH 295) As required

Ammonia Dragger (tube CH 205) As required
Isomerate Product
Specific Gravity ASTM D 1298 1 per day
Distillation Curve ASTM D 86 1 per day
Chemical Composition IFP 9301 1 per day
Chloride Content IFP 9316 1 per day
RVP ASTM D 323 1 per day
Bromine Index ASTM D 2710 As required
RON Clear ASTM D 2699 1 per day
MON Clear ASTM D 2700 1 per day
Isomerization Reactor Effluents (1st and 2nd stage)

Composition IFP 9301 1 per week
Stabilizer Off-Gas
Hydrogen Sulfide Dragger (tube CH 298) 1 per day
LPG product
Chemical Composition ISO 7941 1 per day
Chloride Content IFP 9316 1 per day
Specific Gravity @ 15C ASTM D 1298 1 per day

Scrubber Off -Gas

Hydrogen Chloride Drger ( tube CH 295) 1 per day
H2 On-line analyzer
HC On-line analyzer
Circulating Caustic
NaOH Wt % pH meter (lab) 1 per day
Caustic Make Up to Scrubber

NaOH Wt % pH meter (lab) As required
Catalyst
Carbon ASTM D 3178 As required
Specific surface Brunauer, Emmett and As required
Teller method
Metals content IFP 9315 As required
Stabilizer bottoms
Chloride content IFP 9316 1 per day
LPG stripper bottoms

LPG product

SECTION -14
SAFETY PROCEDURE
14.1 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, H2,
Naphtha and chemical like caustic, therefore adherence of safety rules should be given
uphill importance.
14.2 SAFETY OF PERSONNEL

General safety rules which shall be practised and enforces for all personnel who enter the
unit are summarized below:
a. 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.
b. Smoking shall be permitted only in specified areas which are clad as non-hazardous
and are pressurized through a ventilation system. Failure of the ventilation system
automatically cancels the smoking privilege until the system is repaired, inspected and
authorized operation.
c. Each employees assigned to work in the unit shall know where the safety and fire
suppression equipment is located and how to operate this equipment.
d. Safety glasses, goggles or face shields shall be worn while performing work which
could result in eye or face injury.

e. Operations personnel golden rule

Do not open or close any valve without first determining the effect.
Note:-Treat each piece of equipment or piping as if it is under pressure.
14.3 WORK PERMIT PROCEDURE

A work permit system must be issued by the appropriate operations group before
commencing any maintenance work affecting the operation of the unit. The work permit
is issued for Hot and Cold work. The Hot work permit must include as a
minimum, a precise description and mode of execution of Hot works, the equipment
to be used, the expected time which Hot works is scheduled to start and expected
completion, an exact location of the Hot works and precautions to be taken.
Unit areas are generally identified as hazardous areas as far as the threat of fire is
concerned. Therefore, in order to carryout works within these areas, a written work
permit is required. The work permit, when approved, indicates that a specific work can
be carried out in safe conditions provided that all safety precautions are observed.
a) Permit for Hot work

Permits of hot works are required for any work involving the use of or generation of heat
sufficient to ignite flammable substances.
Typical sources of ignition are:
- Electric and gas welding
- Any machine capable of producing a spark
- Not explosion-proof electrical equipment
- Internal combustion engines
- Ferrous tools, both hand operated and pneumatic or other type
b) Permits for Cold-Work

Permits for cold-work are required for any work not involving the use of a local ignition
source.

Typical examples of cold-work are:

- Disconnecting of lines for the insertion of blinds etc.
- Opening of any equipment such as vessels, filters, etc.
c) Entry permits
Entry permits are required for entering enclosed spaces such as vessels, sewer, pits,
trenches, etc.
The use of any tool or machinery, which could provide a source of ignition, is forbidden.
Also, prior to entry it should be ensured that area is well ventilated and the oxygen
content in air is about 21% by volume. Fresh air flow is to be ensured in the enclosed
space through out the duration of work. A gas test for H2S and flammable gases should
also be performed before entry. A person should also be on alert outside the enclosed
space for rescue in case of emergency. Procedure for carrying out work and rescue plan
shall be formulated before commencement of work.
d) Guidelines for release of permits

- The equipment item, on which works have to be carried out, shall be clearly
indicated. During the shutdown of any system, permits covering the whole section
with above mentioned item shall be issued, if possible. The type of work permitted
shall be clearly indicated.
- The date and the period of validity of the permit shall also be indicated. If the work
does not get over within the period of validity of the permit, the permit can be
extended provided that, at each start of the works the safety conditions are checked
again and signed by the operator in-charge and by safety officer. Beyond this
extended period, a next permit will have to be issued. The explosiveness test and the
check of toxic gases shall be performed always at the last moment before each start
of the work and subsequently every time the work is resumed or whenever doubts
arise.

- The validity of the permit can be cancelled at any moment by the operator or by
safety officer; in case they deem that the conditions are not safe.
- The conditions to be complied with shall include special precautions, such as the use
of protective clothing, breathing apparatus, safety equipment and the tools to be used
etc.
- No one shall be allowed to enter the vessel or other enclosed spaces without suitable
protective clothing and until the vessels or the enclosed spaces become safe for entry
by means of proper isolation, proper ventilation and suitable check of the
atmosphere inside and availability of rescue person outside the enclosed equipment.
If welding or hot work is to be done ensure that:-

- Fire fighting system is ready
- Close the neighbouring surface drains with wet gunny bags
- Keep water flowing in the neighbouring area to cool down any spark.
- Responsible operation supervisor should be present at the place of hot work till the first
torch is lighted.
14.4 PREPARATION OF EQUIPMENT FOR MAINTENANCE

a) 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 depressurisation.
- 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 of inside atmosphere with explosive meter.

- Complete opening if inside atmosphere is satisfactory.

- Analyse 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, pressurise the
vessel with N2 or gas and fill in the liquid and drain under pressure. This is to avoid
hydrocarbon going to atmosphere.
b) Precautions Before Handing Over Equipment

Following items should be checked by a responsible operating supervisor before the
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 O2 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:

- Keep fire fighting devices ready for use nearby.
- Close the neighbouring surface drains with wet gunny bags.
- Keep water flowing in the neighbouring area to cool down any spark bits etc.
- Keep stem lancers ready for use.

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 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. Detail procedure for preparation for vessel entry is given in next
sub-section.
14.5 PREPARATION FOR VESSEL ENTRY

The most common potential hazards in vessel entry are:
- Unit Checkout Prior to Start-up
- Turnaround Inspections
- Reactor Loading
- Reactor Unloading
The precautions apply equally to entry into all forms of vessels, including those enclosed
areas which might not normally be considered vessels.
Examples include:
Reactors, Columns, Separators, Receivers, Clay treater, Fired heaters, Sumps

Positive Vessel Isolation
Every line connecting to a nozzle on the vessel to be entered must be blinded at the
vessel. This includes drains connecting to a closed sewer, utility connections and all
process lines. The location of each blind should be marked on a master piping and
instrumentation diagram (P&ID), each blind should be tagged with a number and a list
of all blinds and their locations should be maintained. One person should be given
responsibility for the all blinds in the unit to avoid errors.

The area around the vessel manways should also be surveyed for possible sources of
dangerous gases which might enter the vessel while the person is inside. Examples
include acetylene cylinders for welding and process vent or drain connections in the
same or adjoining units. Any hazards found in the survey should be isolated or
removed.
Vessel Access
Safe access must be provided both to the exterior and interior of the vessel to be entered.
The exterior access should be a solid, permanent ladder and platform or scaffolding
strong enough to support the people and equipment who will be involved in the work to
be performed.
Access to the interior should also the strong and solid. Scaffolding is preferred when the
vessel is large enough. The scaffolding base should rest firmly on the bottom of the
vessel and be solidly anchored.
If the scaffolding is tall, the scaffolding should be supported in several places to prevent
sway. The platform boards should be sturdy and capable of supporting several people
and equipment at the same time and also be firmly fastened down. Rungs should be
provided on the scaffolding spaced at a comfortable distance for climbing on the
structure.
If scaffolding will not fit in the vessel a ladder can be used. A rigid ladder is always
preferred over a rope ladder and is essential to avoid fatigue during lengthy periods of
work inside a vessel. The bottom and top of the ladder should be solidly anchored. If
additional support is available, then the ladder should also be anchored at intermediate
locations. When possible, a solid support should pass through the ladder under a rung,
thereby providing support for the entire weight should the bottom support fail. Only one
person at a time should be allowed on the ladder.
When a rope ladder is used, the ropes should be thoroughly inspected prior to each new
job. All rungs should be tested for strength, whether they be made of metal or wood.
Each rope must be individually secured to an immovable support. If possible, a solid

support should pass through the ladder so that a rung can help support the weight and the
bottom of the ladder should be fastened to a support to prevent the ladder from
swinging. As with the rigid ladder, only one person should climb the ladder at a time.
Wearing of a Safety Harness

Any person entering a vessel should wear a safety harness with an attached safety line.
The harness is not complete without the safety line. The harness should be strong and
fastened in such a manner that it can prevent a fall in the event the man slips and so that it
can be used to extricate the man from the vessel in the event he encounters difficulty. A
parachute type harness is preferred over a belt because it allows an unconscious person to
be lifted from the shoulders, making it easier to remove him from a tight place such as an
internal manway.
A minimum of one harness for each person entering the vessel and at least one spare
harness for the people watching the manway should be provided at the vessel entry.
Providing a Manway Watch

Before a person enters a vessel, there should be a minimum of two people available
outside of the vessel, one of whom should be specifically assigned responsibility to
observe the activity of the people inside of the vessel. The other person must remain
available in close proximity to the person watching the man way so that he can assist the
or go for help, if necessary. He must also be alert for events outside of the vessel which
might require the people inside to come out of the vessel, for example, a nearby leak or
fire. These people should not leave their post until the people inside have safely
evacuated the vessel.
A communication system should be provided for the man way watch so that they can
quickly call for help in the event that the personnel inside of the vessel encounter
difficulty. A radio, telephone, or public address system is necessary for that purpose.

Providing Fresh Air

The vessel must be purged completely free of any noxious or poisonous gases and
inventoried with fresh air before permitting anyone to enter. The responsible
department, usually the safety department, must test the atmosphere within the vessel for
toxic gases, oxygen and explosive gases before entry. This must be repeated every 4
hours while there are people inside the vessel. Each point of entry and any dead areas
inside of the vessel, such as receiver boots or areas behind internal baffles, where there
is little air circulation should be checked.
Fresh air can be circulated through the vessel suing an air mover, a fan, or, for the cases
where moisture is ca concern, the vessel can be purged using dry certified instrument air
from a hose or hard piped connection. When an air mover is used, make certain that the
gas driver uses plant air, not nitrogen, and direct the exhaust of the driver out of the
vessel to guarantee that this gas does not enter the vessel. When instrument air is used,
it must be confirmed that a check of the supply header is made to ensure that it is
properly lined up and that there are no connections where nitrogen can enter the system
(nitrogen improperly used as a backup for instrument air by some refiners). The fresh
air purge should be continued throughout the time that people are inside of the vessel.
The responsible control room should be informed that instrument air is being used for
breathing so that if a change to nitrogen is required the people are removed from the
affected vessel.
A minimum of one fresh air mask for each person entering the vessel and at least one
spare mask for the hole watcher should be provided at the vessel entry. These masks
should completely cover the face, including the eyes, and have a second seal around the
mouth and nose. When use of the mask is required, it must first be donned outside of
the vessel where it is easy to render assistance in order to confirm that the air supply is
safe. Each mask must have a backup air supply that is completely independent of the
main supply. It must also be independent of electrical power. This supply is typically a
small, certified cylinder fastened to the safety harness and connected to the main supply
line via a special regulator that activates when the air pressure to the mask drops below

normal. The auxiliary supply should have an alarm which alerts the user that he is on
backup supply and it should be sufficiently large to give the user 5 minutes to escape
from danger.
Preparation of Vessel Entry Permit

Before entering the vessel a vessel entry permit must be obtained. A vessel entry permit
ensures that all responsible parties know that work is being conducted inside of a vessel
and establishes a safe preparation procedure to follow in order to prevent mistakes
which could result in an accident. The permit is typically issued by the safety engineer
or by the shift supervisor. The permit should be based on a safety checklist to be
completed before it is issued. The permit should also require the signatures of the safety
engineer, the shift supervisor, and the person that preformed the oxygen toxic and
explosive gas check on the vessel atmosphere. Four copies of the permit should be
provided. One copy goes to the safety engineer, one to the shift supervisor, one to the
control room, and one copy should be posted prominently on the man way through
which the personnel will enter the vessel. The permit should be renewed before each
shift and all copies of the permit should be returned to the safety engineer when the
work is complete. Additional requirements or procedures may be imposed by the
refiner, but the foregoing is considered the minimum acceptable for good safety practice.
Checkout Prior to New Unit Start-up

The risk of exposure to hydrocarbon, toxic or poisonous gases, and catalyst dust is low
during a new unit checkout; the primary danger is nitrogen. There will be pressure
testing, line flushing, hydrotesting, and possibly chemical cleaning being conducted in
the unit and nitrogen may be used during any of these activities. Some of the equipment
may have been inventoried with nitrogen to protect the internals from corrosion. An
additional hazard is posed by operations in other parts of the plant which may be beyond
the control of the people entering the vessel so that action taken at a remote location
could admit nitrogen, fuel gas, steam, or other dangerous material through a connecting

process line into the vessel which is being entered. For these reasons vessel entry
procedures must still be rigorously followed during the checkout of a new unit.
The oxygen content of the atmosphere inside of the vessel should be checked before
every entry and the vessel should be blinded. Independent blinds at each vessel nozzle
are preferred. However, in the event that many vessels are to be entered in a new unit
which is separate from the rest of the plant, the entire unit can be isolated by installing
blinds at the battery limits rather than by individually isolating every vessel nozzle.
Inspections During Turnarounds

In turnaround inspections, the possibility that vessels will contain dangerous gases is
much higher. Equipment which has been in service must be thoroughly purged before
entry. The vessel should have been steamed out unless steam presents a hazard o the
internals and then fresh air circulated through it until all traces of hydrocarbons are
gone. If liquid hydrocarbon remains or if odors persist afterwards, repeat the purging
procedure until the vessel is clean. The service history of the vessel must also be
investigated before entry so that appropriate precautions may be taken. The service may
require a neutralization step or a special cleaning step to make the vessel safe. Internal
scale can trap poisonous gases such as hydrogen sulfide or hydrogen fluoride which may
be released when the scale is disturbed. If this sort of danger is present, fresh air masks
and protective clothing may be required to be worn while working inside of the
equipment.
In a turnaround inspection, every vessel nozzle must be blinded at the vessel with
absolutely no exceptions. There will always be process material at the low and high
points in the lines connecting to the vessel because it is not possible to purge them
completely clean. The blinds must all be in place before the vessel is purge.
Another factor to be cautious of, especially if entering a vessel immediately after the
unit has been shut down, is heat stress. The internals of the vessels can still be very hot
from the steam-out procedure or from operations prior to the shutdown. If that is the

case, the period of time spent working inside of the vessel should be limited and
frequent breaks should be taken outside of the vessel.
14.6 HAZARDOUS CHEMICAL HANDLING

Hazardous properties of chemicals and their handling procedure are available in Material
Safety Datasheet. Hazards and handling procedure of some the material is discussed below.
14.6.1 HYDROGEN SULFIDE (H2S)

A hazard and handling procedures of H2S is as follows:
A) Potential For Exposure
The existence of H2S concentration with the fluids normally handled in this unit constitutes
an additional hazard to operating personnel that demands special attention. The properties
of H2S make exposure to even very low concentrations extremely dangerous. However,
many years of industry experience in handling the problems associated with H2S have
resulted in procedures which, if properly implemented, permit a reasonable level of safety
for unit personnel.
The danger of exposure of H2S cannot be lessened. The potential for exposure can only be
minimized.
The procedures and precautions contained within this section and elsewhere in this manual
constitute minimal requirements for dealing with H2S only. The implementation of
additional safety measures which can be found in various industry manuals is encouraged.
B) Properties of H2S (Hydrogen Sulphide)

The chemical formula H2S represents a compound which is made up of two hydrogen
atoms and one sulphur atom.
H2S (Hydrogen Sulphide) is a colourless (transparent), gas heavier than air.
Hydrogen sulphide is a poisonous gas that can paralyse the breathing system and kill a
person in minutes. In small amounts it is dangerous to health. This risk is increased by heat
or hot weather.

At low concentrations (small amounts) H2S has an offensive odour similar to rotten eggs.
At slightly higher concentrations (small amounts), H2S may have a sick-sweet odour. At
high concentrations no smell can be detected, because H2S rapidly deadens the sense of
smell by paralysis of the Olfactory-Nerve. Consequently the sense of smell cannot be
depended upon to detect H2S.
Characteristics of H2S
Hydrogen sulphide has the following characteristics:
- Deadly-extremely toxic gas.
- Colourless.
- Heavier than air tends to settle in low lying areas.
- Readily dispersed by wind movement of air currents.
- Burns with a blue flame, producing Sulphur Di-oxide (SO2), which is also a toxic gas.
- Odour of rotten eggs. Only in low concentrations rapidly deadens the sense of smell.
Do not depend on the sense of smell to detect H2S
- Highly corrosive to certain metals.
- More deadly than Carbon Monoxide (CO), and almost as toxic as Hydrogen Cyanide
(HCN) gas.
Property table OF H2S

- Auto ignition Temperature 500F(260C)
- Boiling Point @ 1 atm -76.6F(-60.33C)
- Critical Density 0.349 g/ml
- Critical Pressure 1309 psig (89.05 atm)
92 kg/cm2, absolute
- Critical Temperature 212.7F (100.4C)
- Density, gas @ 0C 1 atm 1.5392 g/l
- Density, Liquid @ b.p. 0.993 g/l
- Flammable Limits in Air 4.3-4.5% (by volume)

- Freezing Point @ 1 atm -121.9F (-85.49C)

- Latent Heat of Fusion @ m.p. 508cal/mole (16.7 cal/g)
- Latent Heat of Vaporization @ b.p. 4.463kcal/mole
(131 cal/g)
- Molecular Weight 34.08
- Solubility in Water @0C 1 atm 0.672 g/100 ml water
- Specific Heat, Gas @ 25C 1 atm
Cp = 0.240 cal/ (g) (C)
Cv = 0.181 cal/ (g) (C)
- Specific Gravity Gas 1.1895 15C, 1atm (Air = 1)
- Specific Heat Ratio, Gas 1.32@25C, 1 atm, Cp/Cv
- Thermal Conductivity @ 0C 0.305 cal/(Sec)(Cm2) (C/cm)
- Vapour Pressure @ 70F 252 psig (17.7 kg/cm2g)
- Specific Volume @ 70F, 1 atm 11.23 cu ft/lb (701 ml/g)
- Viscosity of Gas @ 0C 1 atm 0.01166 centipoise
- Explosive limits:
- Lower 4% volume in air upper 44% volume in air
C) Effects of H2S on Personnel

Itemized concentrations of Hydrogen Sulphide as prepared by American National
Standards Institute (ANSI Standard No. Z37.2-1972) are tabled below:
0.13 ppm Minimal perceptible odour

4.60 ppm Easily detectable, moderate odour
10 ppm Beginning eye irritation
27.0 ppm Strong, unpleasant odour, but not intolerable
100 ppm Coughing, eye irritation, loss of sense of smell after
2-15 minutes.

200-300 ppm Marked conjunctivitis (eye inflammation) and

respiratory tact irritation after one hour of exposure.
500-700 ppm Loss of consciousness, possible death in 30 minutes
to 1 hour.
700-1000 ppm Rapid unconsciousness, cessation (stopping or
pausing) of respiration and death.
1000-2000 ppm Unconsciousness at once, with early cessation of
respiration and death in few minutes. Death may
occur even if individual is removed to fresh air at
once.
ppm parts of gas per million part of air by volume.
D) H2S handling procedure

General Procedures:
Industry practice mandates that the following precautions procedures should be followed
by all personnel:
- When approaching the work area it is necessary to take the following precautions to
insure safe entry
1. Observe Condition signs and observe for audio/visual alarms.
2. Check for wind direction.
3. Look for personnel and their activity.
4. Enter work area slowly.
- Maintain mental image of two (at least) escape routes preferably cross wind.
- Continuous atmosphere monitoring or detecting equipment is required along with an
adequate audio/visual alarm warning system. Portable detectors and combustible gas
meters give an additional degree of safety.

- Gas ignition hazard must be eliminated and No Smoking regulations strictly

enforced.
- Continued observation of wind indicators, windsocks and streamers is a must. During
atmospheric contamination by H2S, move upwind/cross wind from source, not
downwind.
- Select a partner and use the Buddy System for mutual safety.
- Maintain and observe warning signs.
- Post emergency numbers in a conspicuous place. Maintain reliable communication
systems.
- Locate emergency stations a minimum of 250 feet or as far from the H2S source as
practical. During an emergency all personnel will assemble at the briefing stations for
instructions and for refilling air bottles.
- Hazardous concentrations of H2S can be disposed of by discharging through flare
stacks with automatic ignitions.
Note: Burning H2S produces Sulphur Dioxide (SO2), a deadly toxic gas that is heavier than
H2S. Because of the heat it rises and disperses into the upper atmosphere.
Maintenance Procedure:
There are two basic areas of maintenance operations which are inherently dangerous from
the standpoint of H2S exposure. These are venting / draining of piping and confined space
entry.
- Depressurisation of piping, valves, fittings, strainers, etc. in H2S service represents a
safety hazard in the unit, since the vent and drain valves are not hard-piped to a
closed vent or drain header.
Without exception, breathing air respirators are to be worn when opening piping, removing
valves or performing any operation which might permit vapours to enter the immediate
area. When valves are removed, install blind flanges.

- Confined space entry is entrance into areas such as tanks, vessels, etc. This is one of
the most dangerous activities of the unit and should be avoided whenever possible.
When it is absolutely necessary that a confined entry be made, entry should be made only
after the following safety conditions have been met.
- Entry permit form has been filled out and signed.
- Space contains at least 19.5% of oxygen by volume.
- Sample does not contain combustible vapours above L.E.L.
- Space does not contain toxic gas contaminants above the limit of appropriate threshold
values for the substance.
- Even if the above mentioned conditions are met, personnel entering such enclosed
spaces shall be equipped with self contained breathing apparatus (SCBA) pressure
demand type.
- Rescue equipment must be in close vicinity of the confined space.
- All personnel entering the confined space must wear safety harness and reflective tape.
- An adequate number of personnel must be stationed outside for emergency assistance.
- Communications must be clearly established and a system of safety signs and signals
understood by all.
- Any battery operated or electrical communications system such as hand-held walkie-
talkie or throat type microphone, if used in a hazardous environment must be
intrinsically safe.
- There are a number of other safety precautions and equipment to be considered when a
confined space entry must be made such as:
Resuscitation equipment, litter, safety lanterns or chemical lights, tripped for hoisting over
hatches, instrument calibration, mechanical ventilation, cascade systems, continuous
monitoring, houseline units, separate means of access where possible, emergency team and
plan and proper training.
Remember the fact that any entry into a confined space is inherently dangerous.

E) Emergency Procedures
If all the above procedures have been adhered to strictly, a catastrophic release of H2S
should never occur. In the unlikely event such a release does occur, the emergency
procedures detailed in this section should be followed.
a) Egress
H2S is a dangerous, deadly gas, however serious injury or death can be avoided by simply
evacuating the contaminated area and moving to a safe area upwind. Therefore, the most
important things to remember are to Stay Claim and Get Away.
Precise emergency escape procedures will be defined by the operations management of the
complex, however the following general procedures should be followed:
- Remain Calm-Do Not Panic
- Hold your breath
- Extinguish all fires
- Alert the rest of the crew
- Make a quick, cursory check of the area to see if the source of the gas is obvious.
- Do not spend time looking for a leak
- Observe windsock to determine wind direction. Move upwind or crosswind, not
downwind, until the safe breathing area is reached.
- Active alarms if not already done.
- Once assembled at the safe briefing area, the foreman will make a head count to
determine if all personnel have evacuated safely.
b) Rescue and First Aid

Although H2S is a dangerous, deadly gas, its effects are readily reversible provided the
appropriate action is taken in a timely manner. In the event of, a fellow worker is down or
overcome by H2S, the necessity of an immediate and effective rescue effort is or utmost

importance. A natural reaction is to unthinkingly rush to the side of the downed victim,
which could be a fatal action.
Instead, before proceeding into the hazardous area to rescue a downed victim, stop, think
and:
- Put on an appropriate safe breathing apparatus.
- Move quickly, but carefully to the victim, side. Move the victim to a safe area;
either upwind or crosswind from the hazardous area. Do not evacuate in a
downwind direction.
- Begin mouth-to-mouth artificial respiration if the victim has stopped breathing.
Check the victims pulse periodically to ensure that the victims heart is still
beating. If the victims heart stops beating, administer CPR. Artificial respiration or
CPR should be continued until:
- The victim begins to breathe and, if applicable, the heart begins to beat.
- He is pronounced dead by a doctor.
- He is dead beyond any doubt.
- Seek assistance at the first opportunity and make arrangements for transportation to a
medical facility to seek medical attention by a physician.
c) Abatement Procedure
Once the safety of all personnel has been determined, the next order or business is to
determine the source of H2S and stop it, if possible.
Control Room Personnel

- Control Room personnel Stay in the Control Room since it is equipped with a positive
ventilation system pulling suction from a higher elevation. Since H2S is heavier than
air, the Control Room should be safe.
- If leak can be located, activate the deluge system for that area.

Field Personnel
- Use breathing apparatus (Respirator).
- Establish communication with Control Room.
- Communicate with first personnel to sound alarm/notice of the H2S.
- To determine the general area of the source, slowly begin searching the source from the
upwind side.
14.6.2 HYDROGEN
Hydrogen is a colourless, tasteless, odourless and highly flammable gas and is the
lightest element. Since hydrogen is lighter than air, less danger exists of it collecting in
pockets in low areas. However, the potential danger from fire or explosion is high.
Gaseous fuels such as hydrogen can mix with air or oxygen in all proportions. However,
the proportions must be within certain limits before those mixtures will burn. The
limiting proportions are referred to as flammable limits or explosive limits and are
expressed as the percentage by volume of the fuel in the air-fuel mixture. Fuel-air
mixtures outside of the flammable range will not explode. Hydrogen has a very wide
range (4-75%) of flammability or explosive limits in air at atmospheric pressure. In
addition to, the flammability range becomes wider at higher pressure or if oxygen is
substituted for air. Thus, explosions can occur over a very wide range of hydrogen
concentrations in air. The safest approach to safeguard against possible fires or
explosions is to make sure that hydrogen leaks do not develop.
The auto ignition temperature of a substance is the lowest temperature required to
initiate or cause self-sustained combustion in the absence of a spark or flame. The auto
ignition temperature of hydrogen in air is 580C at atmospheric conditions. However,
other factors such as the nature, size, and shape of the igniting surface can affect this
temperature.
Unlike most gases, which cool when expanded or bled off, hydrogen heats up when
expanded and great care must be exercised when bleeding down lines or compressors to
the atmosphere. In its pure state, hydrogen burns with a bluish white flame (almost

invisible) that is extremely hot. Such a hot flame can weaken any support beams or lines
on which it may impinge. Any leaks should be put under a steam blanket immediately to
prevent the possibility of a fire. Be aware, however, that many leaks can auto ignite and
will be difficult to see. Replacing the source of the hydrogen with a nitrogen or steam
purge is the most effective way of combating a hydrogen fire.
Hydrogen, although a not a poisonous gas itself, is an asphyxiant (i.e. cuts off oxygen
supply to the body by displacing air in the lungs) and can cause unconsciousness and
even death if the victim falls and remains in a high hydrogen atmosphere.
Because of the small size of hydrogen molecules, a pressure check with air or nitrogen
or a hydrostatic test will not always show all leaks that will occur with hydrogen.
14.7 FIRE FIGHTING SYSTEM

The operating personnel should be fully conversant with Fire Fighting system provided in
the unit. All of them should have adequate fire fighting training and will serve as an
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.
Major Fire fighting facilities provided in the unit comprise the following:
i) Fire Water System
Water is most important fire fighting medium. Water is used for fire extinguishment,
control, equipment cooling & exposure protection of equipment/personnel from heat
radiation.
An elaborate fire water distribution network is provided around unit. Fire Water
Hydrants/Monitors are provided around unit, which give coverage to most of 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 the 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 power extinguishers; water and
foam should not be used. The used extinguishers should be checked and restored by fire
station personnel.
iv) Fire Signal
Break Glasses have been provided at strategic locations of unit to see fire alarm in fire
station. if a fire is sighted, glass of window should be smashed, causing fire alarm switch
to actuate. This is an emergency call & should be periodically tested for proper
functioning.
v) Steam Smothering
LP Steam hose connections have been provided at every convenient point inside unit.
Steam lances of standard 15M length can be fitted with these hose stations. Where ever
hydrocarbon leakage is detected which is likely to catch fire, Steam blanketing may be
done. Apart from diluting combustible hydrocarbons, steam prevents atmospheric oxygen
from taking part in combustion, thus help in extinguishing fire. However, steam should
never be applied on large pool of hydrocarbon fire. Direct application of steam on burning
oil may result in spillage of burning hydrocarbon & spread of fire. Similarly use of fire
water on hot oil surfaces may cause sputtering & spread of fire.
14.8 USE OF LIFE SAVING DEVICE

Safety of the personnel should the prime concern. Life saving device is to be used for
personnel protection. Important life saving devices which are required to be used are given
below:

Head protection:
Safety helmets shall be worn by all personnel at all times in the plant for protection of the
head. They may be removed when inside rooms or buildings which do not have overhead
or other hazards.
Eye and face protection

Safety glasses, goggles or face shields shall be worn while performing work, which could
result in eye or face injury.
Hand Protection
Proper hand protective gloves should be worn.
Foot protection
Safety shoes are to be worn for foot protection.
Ear protection
Whenever personnel are required to be work in noisy areas proper ear protection device
such as ear plug etc, is to be used.
Breathing apparatus
Whenever persons are required to work or enter an area of high
toxic/aromatic/hydrocarbon vapor concentration, wear appropriate respiratory
protection, such as self-contained breathing apparatus or an air mask with an external air
supply.

SECTION -15
GENERAL OPERATING INSTRUCTIONS FOR EQUIPMENT
15.1 GENERAL
This section covers the general procedure for operation and trouble shooting of commonly
used equipment like pumps, heat exchangers and furnace etc. For specific information and
more detail refer to vendor's manuals.
15.2 CENTRIFUGAL PUMPS

15.2.1. Start-up
- Inspect and see if all the mechanical jobs are completed.
- Establish cooling water flow where there is such provision. Also open steam for seal
quenching in pumps having such facilities.
- Check oil level in the bearing housing, flushing may be necessary if oil is dirty or
contains some foreign material.
- Rotate the shaft by hand to ensure that it is free and coupling is secure. Coupling guard
should be in position and secured properly.
- Open suction valve. Ensure that the casing is full of liquid. Bleed, if necessary, from
the bleeder valve.
- Energise the motor. Start the pump and check the direction of rotation. Rectify the
direction of rotation if it is not right.
- Check the discharge pressure. Bleed if necessary to avoid vapour locking.
- Open the discharge valve slowly. Keep watch on the current drawn by the motor, if
ammeter is provided. In other cases check at motor control centre.
In some pumps a by-pass has been provided across the check valve and discharge valve to
keep the idle pump hot. In such pumps, the by-pass valve should be closed before starting
the pump. It should be ensured that casing of these pumps are heated up sufficiently prior

to starting of the pump to guard against damage of the equipment and associated piping due
to thermal shock.
15.2.2. Shutdown
- Close discharge valve fully.
- Stop the pump
a) If pump is going to remain as standby and has provision for keeping the pump hot,
proceed as follows:
- Open the valve in the by-pass line across the discharge valve and check valve.
- The circulation rate should not be so high to cause reverse rotation of idle pump
and also overloading of the running pump.
b) If pump is to be prepared for maintenance, proceed as follows:

- Close suction and discharge valves.
- Close valve on check valve by-pass line, if provided.
- Close cooling water to bearing, if provided. Also shut off steam for seal quenching,
if provided.
- Slowly open pump bleeder and drain liquid from pump if the liquid is very hot
allow sufficient time before draining is started. Ensure that there is no pressure in
the pump. Also drain pump casing.
- Blind suction and discharge and check valve by-pass line and flare connection if any.
- Cut-off electrical supply to pump motor prior to handling over for maintenance.
15.2.3. Trouble Shooting

i. Pump not developing pressure
- Bleed to expel vapour/air
- Check the lining up in the suction side.
- Check the suction strainer.

- Check the liquid level from where the pump is taking suction.
- Check pump coupling and rotation.
- Get the pump checked by a technician.
ii. Unusual Noise

- Check the coupling guard if it is touching.
- Check for proper fixing of fan and fan cover.,
- Check for pump cavitation.
- Get the pump checked by a technician.
iii. Rise of Bearing Temperature

Generally the bearing oil temperature upto 80C or 50C above ambient whichever is
lower, can be tolerated.
- Arrange lubrication if bearing is running dry or oil level is low.
- Adjust cooling water to the bearing housing, if there is such provision.
- Stop the pump, if temperature is too high, call the pump technician.
iv. Hot Gland

- Adjust cooling water if facility exists.
- Slightly loosen the gland nut, if possible.
- Stop the pump and hand over to maintenance.
- Arrange external cooling if pump has to be run for sometime.
v. Unusual Vibration
- Check the foundation bolts.
- Check the fan cover for looseness.

vi. Leaky Gland

- Check the pump discharge pressure.
- Tighten the gland nut slowly, if possible.
- Prepare the pump for gland packing or adjustment/replacement of mechanical seal
as the case may be.
vii. Mechanical Seal Leak

- Stop and isolate the pump and hand over to maintenance.
15.3 POSITIVE DISPLACEMENT PUMPS

15.3.1. Start-up
i. Check if all mechanical jobs are completed.
ii. Flush and renew oil in pump gear box.
iii. Check whether suction strainer is installed.
iv. Check for proper lining up including the pressure safety valve in the discharge.
Open suction valve fully.
v. Check that the motor shaft is reasonably free and coupling secured. Coupling guard
should be in position.
vi. Energise motor. Open discharge valve. Start the motor and check direction of
rotation. Stop and rectify if direction of rotation is wrong.
vii. 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 calibration pot. In case the pumps is provided with a pressure controller
adjust it to obtain the required discharge pressure.
viii. Care should be taken to avoid dry running of pump and back flow of liquid. Bleed
if necessary to expel vapour/air.
ix. Check for unusual noise, vibrations, rise of temperature of both motor and gears.

15.3.2. Shutdown
- Stop the pump.
- Close the suction and discharge valves.
- Drain the liquid if maintenance jobs are to be carried out on the pump.

i. Insufficient Discharge Pressure
- Check the lining up in the suction side.
- Check the functioning of the safety valve and pressure control valve on discharge to
suction.
- Check the strainer on the suction side.
- Check for insufficient liquid level in the tank.
- Check pump coupling and rotation.
- Get the pump checked by pump technician.
ii. High Discharge Pressure

- Check the line up on the discharge side.
- Check pressure control valve opening.
iii. Leak Gland

- Check for normal pump discharge pressure.
- Tighten the gland nut slowly if possible.
- Hand over the pump for replacing gland packing.
iv. Unusual Vibrations

- Check the foundation bolts.
- Check motor fan cover for looseness.

15.4 CENTRIFUGAL COMPRESSOR

The pre-commissioning of the centrifugal compressor should follow the equipment
manufacturers recommended procedures. The following general procedures shall not be
construed as a replacement for the manufacturer procedures.
Verify that the lubrication, seal gas, and coolant systems are clean and free of
contamination and that all control systems function properly. The pre-commissioning of
these package units should follow the manufacturers recommended procedures.
Verify that the shutdown system on the compressor function according to design. The
temporary strainers on the suction should be removed prior to full-time operation.
Verify that the compressor rotate freely.
15.4.1. Start-up
i. Ensure all mechanical jobs have been completed on the compressor that is to be
started including suction line passivation.
ii. No load run of the motor to be completed before the compressor is coupled.
After no load run, de-energize the electrical supply. Couple the motor and
compressor. Check the rotating element of the compressor for free rotation
turning slowly by hand. If the rotor rubs, rotation should be stopped immediately
and the difficulty located and repaired.
iii. Check oil level in lube oil tank and refill as required bringing the oil level to the
high mark on the sight glass. Do not overfill.
iv. Line-up and start seal and lube oil circulation to make certain that bearings of the
compressor and driver are well lubricated.
v. Establish the pressure of lubricating oil in bearings and seal oil to seal.
Note: Seal system is to be in operation whenever any pressure is in the compressor, even
though the machine is idle.
vi. Bar the unit over once to be sure all moving parts are clear.

vii. Make sure that water cooler and air coolers coming in compressor circuit are in
operation.
viii. Ensure that compressor casing has also been purged with inert gas. Pressurise the
compressor with nitrogen and leak test.
ix. Open suction valve/discharge valve and line up to the system. Remove any
accumulated liquid from the casing by opening casing drain.
x. Start the drive as per the vendors recommendations and run the compressor.
xi. Allow the oil to warm up to 40o C. Watch compressor motor amperage. Listen
for unusual noise or vibration during the warm up period.
xii. Auxiliary motor driven lube oil pump will be stopped when shaft-driven pump
develops normal oil pressure and kept ready for auto start.
xiii. When the unit is warmed up and determined to be operating satisfactorily,
gradually start throttling the valve beyond surge requirements of the compressor.
xiv. Load the compressor to the required capacity in the above mentioned manner.
Note: The compressor before trial run on the actual medium may be tried on air with
suction and discharge open to atmosphere. While attempting to run the
Compressor on air, Vendor's instructions and recommendations are to be
followed. It is to be noted that scaling arrangement may be required to be
changed to suit the machine running on air.
15.4.2. Shutdown
i. Stop the drive.
ii. Start the oil pump to lubricate the bearing till required.
iii. Close the discharge valve.
iv. Close the suction valve.
v. Turn off cooling water to oil cooler as applicable.
vi. If the compressor is to be given for maintenance, isolate, depressurise and purge
with inert gas to make the compressor free of hydrocarbons.

15.4.3. Normal Operation

i. Check oil level in lube oil tank and add oil as required to maintain the proper
level as indicated on sight glass. Periodically check level in emergency
lubricating oil overhead tank.
ii. Log all temperatures, pressures, levels, flows.
iii. Adjust cooling water flows to compensate for changes in inlet water temperature
or ambient temperature.
iv. Listen for any unusual noise while the machine is operating. These should be
investigated immediately.
v. Periodically drain from suction pot etc.
vi. Watch differential pressure across oil filter to check cleanliness; change over
filter, if necessary and arrange cleaning of choked filter.
vii. Keep the exterior of the compressor and the compressor room floor clean.

Follow vendor's recommendations. However, some general guide lines are given below:
i. SURGING
- Restricted flow due to plant operating at partial load or throttling at discharge.
- Blocked suction due to strainer choking or line choking if a permanent strainer
is not provided.
- Liquid carry over from suction K.O. drum.
ii. HEAVY VIBRATIONS IN MACHINE

- Misalignment
- Bent rotor
- Damaged rotor
- Imbalance
- Weak foundation
- Mechanical Loosening etc.

- Bearing damage
15.5 HEAT EXCHANGERS

GENERAL
The unit has a number of heat exchangers, air coolers. Suitable valve arrangement for
bypassing and isolation is provided wherever necessary to offer the required operational
flexibility.
The exchangers have been provided with draining and flushing connections. The coolers
and condensers have been provided with TSV's on the cooling water side to guard against
possible rise of pressure due to faulty operations with the safety release to atmosphere.
Temperature gauges or 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.
AIR COOLERS
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 speed rotors in which the fan speeds are adjusted during
rotation. This allows variation in air flow as per the cooling requirements. A high
vibration switch is provided with alarm to indicate any mechanical damage.
EXCHANGERS
Shell and Tube type heat exchangers can be broadly classified into following types: -
- Water Coolers/condensers
- Steam heaters (reboiler)
- Exchangers

Start-up /shut down procedures for each unit shall vary slightly from case to case.
However, general start-up /shut-down procedures are discussed in the following
paragraphs.
15.5.1. Start-Up
After the heat exchanger has been pressure tested and all blinds removed, proceed as
follows:
i. Open cooling medium vent valve to displace non-condensable (air, fuel gas, inert
gas etc.) from the system. Ensure the drain valves are capped. For high pressure
system, drain valves should be flanged. This activity is not required if gas is the
medium.
ii. Open cooling medium inlet valve. Close vent valve when liquid starts coming
out through it, then open cold medium outlet valve and fully open the inlet valve
also. Where cold medium is also hot, warming up of cold medium side gradually
is also essential.
iii. Open hot medium side vent valve to displace non condensable (air, fuel inert gas
etc.). Check that the drain is closed and capped. This activity is not required if
gas is the medium.
iv. Crack open hot medium inlet valve. When liquid starts coming out from the vent
valve, close it. Open hot medium inlet valve and then open the outlet valve
fully. In case of steam heaters, initially the condensate shall be drained to sewer
till pressure in the system builds up to a level where it can be lined up to the
return condensate header.
v. In case by passes are provided across shells and tube side, gradually close the
bypass on the cold medium side and then the bypass across the hot medium side.
vi. Check for normal inlet and outlet temperatures. Check that TSVs are not
popping.
vii. The operation of inlet and outlet valves should be done carefully ensuring that
the exchangers are not subjected to thermal shock.

viii. In case of coolers/condensers, adjust the water flow to maintain the required
temperatures at the outlet.
ix. For avoiding fouling, velocity of water should be at least 1 m/sec in a
cooler/condenser.
15.5.2. Shutdown
Shut down of an exchanger, coolers, condenser is considered when the equipment is to be
isolated for handling over to maintenance while the main plant is in operation. The
following is the suggested procedure for isolation of the piece of equipment
i. Isolate the hot medium first. In case both hot and cold medium are from process
streams, exchanger shall remain in service till the hot stream has cooled down
enough.
ii. In case of a cooler, adjust cooling water flow to the cooler which is in line so that
product temperature is within allowable unit.
iii. Isolate the cold medium next.
iv. Drain out the shell and tube sides to OWS/Sewer/Closed blow down system as
applicable. In case flushing oil connection is given flush the exchanger to CBD.
Ensure that the CBD drum has sufficient level to receive the flushing of the
exchanger
v. Depressurize the system to atmosphere/flare/blow down system as applicable.
vi. Purge/flush if required. This is particularly important in congealing services.
vii. Blind inlet and outlet lines before handing over the equipment for maintenance.

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OPERATING MANUAL FOR Doc No.

VISAKH REFINERY CLEAN FUELS PROJECT

HINDUSTAN PETROLEUM CORPORATION LIMITED

A Issued for comments NM

Template No. 5-0000-0001-T2 Rev A Copyrights EIL- All rights reserved

For detailed specifications and operating procedures of specific equipment, corresponding

Template No. 5-0000-0001-T2 Rev A Copyrights EIL- All rights reserved

Template No. 5-0000-0001-T2 Rev A Copyrights EIL- All rights reserved

6.6 HYDROGEN SWEEP ..................................................................................................................64

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11.1 CATALYSTS LOADING UNDER N2 ..................................................................................175

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Template No. 5-0000-0001-T2 Rev A Copyrights EIL- All rights reserved

Template No. 5-0000-0001-T2 Rev A Copyrights EIL- All rights reserved

2.2 UNIT CAPACITY

2.3 ON-STREAM FACTOR

2.4 TURNDOWN CAPABILITY

Template No. 5-0000-0001-T2 Rev A Copyrights EIL- All rights reserved

2.5.1. Light Hydrotreated Naphtha

NIT case AM case BH case

Template No. 5-0000-0001-T2 Rev A Copyrights EIL- All rights reserved

It is critically important that the operating performances of both upstream hydrotreater

Total Sulphur 0.5 ppm wt max. (1)

Origin CCR Unit

Template No. 5-0000-0001-T2 Rev A Copyrights EIL- All rights reserved

MAXIMUM ALLOWABLE CONTAMINANT LEVELS

Total Sulphur 1.0 ppm wt max.

(1) At the outlet of the hydrogen dryers.

Template No. 5-0000-0001-T2 Rev A Copyrights EIL- All rights reserved

Light Isomerate product

Isomerate Product flowrate, kg/h 17859 21203 11961

Sp. Gravity @15C 0.6456 0.6414 0.6391

Estimated RON 88.9 89.4 88.5

Estimated MON 88.2 88.3 86.7

Estimated Yield, wt % (1) 65.7 78 44

Estimated RVP, kg/cm2 abs 13.56 14.9 16.7

PROPANE 0.01 0.02 0.01

IBUTANE 1.4 1.02 0.71

NBUTANE 0.53 0.43 0.39

IPENTANE 25.56 35.38 43.53

NPENTANE 8.28 10.82 16.47

22DMB 39.02 41.32 34.01

23DMB 7.25 3.6 0.75

2METHYLPENTANE 13.73 5.22 0.71

3METHYLPENTANE 2.51 0.71 0.07

NHEXANE 0.11 0.02 0

CYCLOPENTANE 1.55 1.45 3.35

METHYCYCLOPENTANE 0.05 0.01 0

Total 100 100 100

LightIsomerate flowrate (kg / h)

Template No. 5-0000-0001-T2 Rev A Copyrights EIL- All rights reserved

EOR NIT CASE AM CASE BH CASE

LightIsomerate flowrate (kg / h)

Heavy Isomerate Product

SOR NIT CASE AM CASE BH CASE

Isomerate Product flowrate, kg/h 7148 3791 13788

Sp. Gravity @15C 0.7562 0.7243 0.7402

Estimated Yield, wt % (1) 26.3 13.9 50.7

Estimated RVP, kg/cm2 abs 3.31 4.3 4.4

Template No. 5-0000-0001-T2 Rev A Copyrights EIL- All rights reserved

SOR NIT CASE AM CASE BH CASE

IBUTANE 0.28 0.34 0.08

NBUTANE 0.1 0.23 0.1