CDU-VDU Operating Manual

TECNICAS REUNIDASTR Jubail Refinery

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DOCUMENT No.:SA-JER-DS011 -TRJR-400100

REV: 01Date: 16-MAY-2013

TR Project No.: 02020Page 1 of 244

OPERATING AND SAFETY MANUAL

CRUDE DISTILLATION UNIT TRAIN 1

(UNIT 011)

REV.0100

DATE16-MAY-201322-FEB-2012

DESCRIPTIONAPPROVED FOR CONSTRUCTION

ISSUED FOR REVIEW

DISCIPLINE CODE DOCUMENT TYPE UNIT SYSTEM

PRO MAN 011

CHECKED BY

Jose Manuel pr~VED BY

echuga

DOCUMENT No.: SA-JER-DS011-TRJR-400100

REV: 01 Date: 16-MAY-2013

TR Project No.: 02020 Page 2 of 244

INDEX

I. INTRODUCTION 5II. BASIS OF DESIGN 7

II.1. Duty of the unit 7II.1.1. On stream factor 7II.1.2. Annual throughput 7II.1.3. Turndown 7

II.2. Environmental Conditions 8II.3. Feedstock and Product Specification and Integration Inside Refinery

Scheme 8II.3.1. Feedstocks 8II.3.2. Products 8

II.4. Battery Limit Conditions 12II.5. Specifications and Consumptions of Utilities 12II.6. Specification and Consumptions of Chemical and Catalysts 13

II.6.1. Chemicals 13II.6.2. Catalyst 14

III. PROCESS DESCRIPTION 15III.1. Process Theory 15III.2. Description of Flows 16

III.2.1. Crude Preheat Train 17III.2.2. Desalter Train 22III.2.3. Preflash Column 26III.2.4. Crude Heater 31III.2.5. Crude Distillation 40III.2.6. Vacuum Heater 49III.2.7. Vacuum distillation 58III.2.8. Sour Water 67III.2.9. Compressor / Amine Absorber 68III.2.10. Utilities Section 72

III.3. Process Variables 76III.3.1. Desalter 76III.3.2. Preflash Column 77III.3.3. Atmospheric Column 78III.3.4. Vacuum Column 81

IV. PREPARATION FOR INITIAL START-UP 83IV.1. General 84

IV.1.1. Check Lists 87IV.1.2. Test Sheets 88IV.1.3. Piping Test (Test Pack) 88

IV.2. Inspection Program 88IV.2.1. Check List Sheets 102




IV.3. Cleaning of Piping and Equipment 126

IV.3.1. Water Flushing 126IV.3.2. Steam Blowing 129IV.3.3. Air blowing 132IV.3.4. Oil Flushing 134IV.3.5. Chemical Cleaning 136

IV.4. Specific Pre-Start-up Operations 141IV.4.1. Instrument Loop Test 143IV.4.2. Electrical Motor Run 149IV.4.3. Tightness Test 153IV.4.4. Drying of Piping And Equipment 157IV.4.5. Purging with nitrogen 163IV.4.6. Operational Tests 164IV.4.7. Inter-Departmental Coordination 169IV.4.8. Utility headers Commissioning 169IV.4.9. Unit Gas In 171

V. START-UP PROCEDURES 172VI. NORMAL OPERATION 173

VI.1. Operation of CDU/VDU 173VI.1.1. Operating Flexibility 173

VI.2. Alternative Operating Modes 174VI.2.1. VDU Bypass 174VI.2.2. Light Arabian Crude Case 174

VI.3. Special Checks 175VI.3.1. Desalter Interface Level 175VI.3.2. Chemical Injection Systems 176VI.3.3. PZV Mechanical Interlocks 178

VI.4. Problem during Normal Operation 178VI.4.1. Off-Spec VGO 178VI.4.2. Tempered Water 179VI.4.3. Failure of Boiler Feed Water Valves Associated to Desuperheaters 179VI.4.4. Heat Exchanger Leakage Control 179VI.4.5. Hydrocarbon in Sour Water Recovery Drum 180

VI.5. Maintenance 180VI.5.1. Thermal Relief Valves 181VI.5.2. Control Valves 181VI.5.3. Cooling Water System 181VI.5.4. Steam-out 181VI.5.5. Blind Position 182VI.5.6. Drainage of Residue to Closed Drain 182

VI.6. Corrosion 183VI.6.1. Corrosion Mechanism 183VI.6.2. Inspection 183VI.6.3. Corrosion Probes and Injection Points 183

VII. NORMAL SHUTDOWN PROCEDURE 185




VIII.EMERGENCY SHUTDOWN PROCEDURES 186IX. UPSETS SCENARIOS 187X. ANALYTICAL REQUIREMENTS 188

X.1. Sample Schedule 188X.2. Analyzers 201X.3. Sample Connections for Monitoring 204

XI. PLANT SAFETY AND ENVIRONMENTAL PROTECTION 205XI.1. Toxic Hazards 205XI.2. Fire Hazards 207

XI.2.1. General Information about Flammable Theory 207XI.2.2. List of Flammable Limits, Self Ignition Temperature and Flash

Point streams and Chemicals present in the Unit 218XI.2.3. General HSE Precautions to avoid the Flammable Conditions 220XI.2.4. List of Fire Scenarios 222XI.2.5. List of Specific Flame, Leak, Heat or Gas Detectors and Relative

Control Systems or Fire Fighting Systems Provided, If Any. 222XI.2.6. Number & Design of Fire Water Monitors, Lances and Hydrants.

Plot plan and Coverage Area and List. Idem for Steam Lances 226XI.2.7. Localization and Capacity and Purpose (Electricity, Hydrocarbons,

Multi Purpose) of Extinguishers (Plot plan and List) 228XI.2.8. Localization and Coverage Area of Flashing Light and Sirens (for

Gas, H2S or Fire Detection) 230XI.3. Personal Protective Equipment 230XI.4. Emergency 232XI.5. Health & Environment 232XI.6. Flare 233

XII. ATTACHMENTS 234




I. INTRODUCTION

This Operation and Safety Manual, prepared by TR JUBAIL REFINERY intends to capacitate and assist operators for the start-up, operation, shutdown and maintenance of the Crude and Vacuum Distillation Unit (CDU/VDU) included in the Jubail Export Refinery located at Al-Jubail on the east coast of the Kingdom of Saudi Arabia. This document will allow personnel to operate the plant in an efficient and safe way as long as a smooth and stable operation is being carried out. Severe or modified guarantee conditions may lead to lack of accuracy or of applicability in correlations and guidelines stated in this operation manual. This Manual describes the procedures that are required to start, operate and stop the Crude and Vacuum Distillation Unit. The instructions contained herein are presented as a general guide to aid in safe start-up and operation of the unit. Operating experience will indicate where a procedure should be modified to improve the performance of the unit. All the operating personnel must be familiarized with the operation details as well as with the characteristics, function and location of all equipment and instrumentation, to assure the proper unit operation in a safe and efficient way. The Crude Distillation Unit processes the Arabian Heavy Crude from storage and the Wild Naphtha produced by the Low and High pressure HDS Units. The crude is processed into two parallel and identical trains (011 & 012) of integrated atmospheric and vacuum distillation units. Each train is designed to process a net throughput of 200000 BPSD of crude. The required turn-down of each of the CDU/VDU train will be 60%. The Crude Distillation Unit produces and provides the feeds to the following units:

Straight run Naphtha as feed of the Naphtha Hydrotreating Unit (NHDT). Straight run kerosene, as feed of one of the two Low Pressure HDS units for

either jet A1 or diesel production.

Light Atmospheric Gas Oil (LAGO) as feed of one of the two Low Pressure HDS units for diesel production.




Heavy Atmospheric and Light Vacuum Gas Oil (HAGO+LVGO) as feed of High

Pressure HDS units for diesel production

Vacuum Gas Oil (MVGO+HVGO) as feed of the DHC and the MHC units. Vacuum residue as feed of the Coker unit.

Each Crude and Vacuum Distillation Unit comprises mainly the following sections:

Crude Preheat Train, increases the crude feed temperature using the heat from pumparounds, distillated products, overheads and vacuum residue

Desalters, remove salt content from crude by mixing with wash water and a demulsifier

Preflash Column, separates the excess of the light components from the crude Crude distillation, including crude heater and atmospheric column with

fractionation and pumparound sections to produce Naphtha, Kerosene, LAGO, HAGO and Atmospheric Residue.

Vacuum Distillation, consisting of a heater and wet vacuum distillation column, equipped with pre-condenser + ejectors driven by superheated MP steam, to produce LVGO, MVGO+HVGO and Vacuum Residue.

Sour Water System, collects process water from the atmospheric and vacuum overheads is sent to SWS Unit (OSBL) before being used as desalting water. The salted water is then sent to WWT unit.

Compressor and Amine Absorber, compress and remove H2S of sour gas from ejector system to feed the vacuum heater.




II. BASIS OF DESIGN

II.1. Duty of the unit

The Crude Distillation unit is designed to process 400000 BPSD of Arabian Heavy crude from storage and produce:

Straight run Naphtha Straight run Kerosene Light Atmospheric Gas Oil Blend of Heavy Atmospheric Gas Oil and Light Vacuum Gas Oil Vacuum Gas Oil (VGO) Vacuum residue

The crude is processed into two parallel and identical trains of Atmospheric and Vacuum Distillation Units. As such each train is designed to process a net throughput of 200000 BSPD of crude. These design basis are applicable to each one of the two identical units.

II.1.1. On stream factor

The unit shall be designed for an on-stream factor of 8400 hours per year (96% on stream factor).

II.1.2. Annual throughput

The unit is designed to process an average of 9.9 Million Tonnes per Annum (MTA) of either of design feedstock defined later under feedstock characteristics on section II.3.1.

II.1.3. Turndown

The required turn-down of each of the CDU/VDU train will be 60%.




II.2. Environmental Conditions

The climatic conditions basic data is derived from:

JERES-A-112 RC meteorological & hydro design information May 2002 (Attachment A)

For more details, refer to JERES-C-101 Basic Design Data.

II.3. Feedstock and Product Specification and Integration Inside Refinery Scheme

II.3.1. Feedstocks

The definition of the crude quality is as provided by TOTAL Research Center of Gonfreville (CReG) from the standard analysis of the crude. A document generated by TOTAL SOG department (i.e quality of short cuts) from the crude analysis has been used as input of the PRO-II simulations to characterize crude quality. See Attachment 11. Pure components shall also been used for the definition of the PI-145 crude cut (See Attachment 11), in order to provide the components breakdown of the SR Naphtha cut PI-145 sent to the NHDT unit (breakdown required for NHDT/CCR units design). Wild Naphtha from HDS has been defined following data received from Licensors. Total wild naphtha flow rate is equally split between the two CDU/VDU units. For Wild Naphtha flow and composition see Attachment 11.

II.3.2. Products

The following cuts from atmospheric and vacuum distillation are to be produced:




Unstabilized Whole Naphtha (combined overhead of the preflash and

atmospheric distillation columns) as feed of the Naphtha Hydrotreating Unit (NHDT).

Kerosene, as feed of one of the two Low Pressure HDS units for either jet A1 or diesel production

Light Atmospheric Gas Oil (LAGO), as feed of one of the two Low Pressure HDS units for diesel production.

Heavy Atmospheric Gas Oil (HAGO) and Light Vacuum Gas Oil (LVGO), as feed of one of the two High Pressure HDS units for diesel production

Medium Vacuum Gas Oil (MVGO) and Heavy Vacuum Gas Oil (HVGO) as feed of the DHC and the MHC units.

Vacuum residue as feed of the Coker unit.

II.3.2.1. Cut Points and Flexibility Cases Following optimization studies carried out during the Conceptual study, the Base Case cutpoints are as follows (TBP cut points in C).

Unstabilized Whole Naphtha IBP 145 Kerosene (KERO) 145 230 Light Atmospheric. Gas Oil (LAGO) 230 300 Heavy Atmospheric Gas Oil (HAGO) 300 360 Light Vacuum Gas Oil (LVGO) 360 379 Medium Vacuum Gas Oil (MVGO) 379 442 Heavy Vacuum Gas Oil (HVGO) 442 550 Vacuum residue 550+

Additionally, three flexibility cases have be considered for the design:

1. Max Kero: Naphtha / KERO TBP cut point is decreased to 140C, to saturate the flash point specification of the Kero (ABEL Flash Point 38C).




2. Max Naphtha: Naphtha / KERO TBP cut point is increased to 160C, as a result

of the optimisation study on gasoline pool (PI-160C pure components breakdown will be also provided for CCR / NHDT design).

3. Kerosene in diesel pool : LVGO/MVGO cut point will be maximized in respect with both following specifications:

Combined Kero, Light and Heavy Atmospheric Gas Oil, and Light Vacuum Gas Oil cuts

ASTM D86 95%vol. 360C Flash Point Pensky Martens > 55C

II.3.2.2. Fractionation Efficiency Requirements

The table below summarizes the target values, following optimization studies carried out during the Conceptual phase:

Specification Units Target value

Naphtha / Kerosene gap C 20 min

Kero / LAGO overlap C 10 max

LAGO / HAGO overlap C 18 max

II.3.2.3. Product Specifications The product specifications are as follows:

Kerosene: o Flash point ABEL 38C (ASTM D3828) o Freezing point: -47C (ASTM D2386) o Distillation FBP : 300C (ASTM D86) o Other jet A1 specifications (with the exception of bright/clear/water and

sulfur specifications which will be handled in the LP HDS unit).

Diesel straight run pool: o Combined Light, Heavy Atmospheric Gas Oil, and Light Vacuum Gas Oil

cuts




ASTM D86 95%vol. 360C Light Atmospheric Gasoil: Flash point Pensky Martens > 55C

o In case Kerosene is incorporated to Diesel pool, LVGO / MVGO TBP cut point will be maximized in respect with both following specifications:

Combined Kero, Light and Heavy Atm Gas Oil, and Light Vacuum Gas Oil cuts

ASTM D86 95%vol. 360C Flash Point Pensky Martens > 55C

Straight run MVGO+HVGO: (target values) o Metals content (Nickel, Vanadium) < 2 ppm wt o Conradson Carbon Residue < 1wt% o Asphaltens C7 < 500 ppm wt o ASTM D1160 5%vol. MVGO 370C

II.3.2.4. Input Data for Product Properties Calculation The following product properties shall be calculated from the mini-cuts properties (SOG files) and correlations provided by Company (see CDU/VDU - Conceptual study Final report).

Thermodynamic properties (boiling point, density, molecular weight), Transport properties (kinematic viscosity@50C and @100C), Petroleum properties (flash point ABEL, smoke point, cloud point, pour point,

freezing point, Conradson Carbon)

Component distribution (PNA, Sulfur, Vanadium, Nickel, total and basic Nitrogen)

II.3.2.5. Expected Product Properties The expected product properties are provided for the following streams:




Unstabilized Naphtha Kerosene Light atmospheric gasoil Heavy atmospheric gasoil Light vacuum gasoil Medium vacuum gasoil Heavy vacuum gasoil Vacuum residue Light atmospheric gasoil + Heavy atmospheric gasoil + Light vacuum gasoil Medium vacuum gasoil + Heavy vacuum gasoil

Required properties for each cut are provided using the tables provided in Attachment 11. Expected product properties can be found on FEED document: CDU/VDU Expected product Properties, 2271-011-CN-0001-02, included in Attachment 11

II.4. Battery Limit Conditions

For process battery limit conditions, refer to Attachment 9 - Process Battery Limit Conditions For utility battery limit conditions, refer to Attachment 10 - Utilities Battery Limit Conditions

II.5. Specifications and Consumptions of Utilities

Refer to the Attachment 7 Utilities Material Balance




II.6. Specification and Consumptions of Chemical and Catalysts

II.6.1. Chemicals

The following chemicals are required in the daily operation of CDU/VDU. Permanent facilities for the injection of the following chemicals are provided

Chemical Commercial Reference Supplier

Demulsifier CHIMEC 2820 CHIMEC (SAUDI FAL)

Neutralizing Agent CHIMEC 1738 CHIMEC (SAUDI FAL)

Corrosion inhibitor CHIMEC 1054M CHIMEC (SAUDI FAL)

Phosphate CHIMEC 3665 CHIMEC (SAUDI FAL)

DEA DIETHANOLAMINE NASSAQ (U.I.C) II.6-1: List of Chemicals for CDU/VDU

De-emulsifying Agent Type: CHIMEC 2820 or equivalent. Chemical description: Alkoxylated resin in a high boiling hydrocarbon solvent mixture. It is injected at the Crude Charge Pumps suction and Desalter inlets in order to aid separation of any oil/water emulsions that cannot be resolved by electrostatic action alone.

Rate of Consumption at Charge Pump 011-G-0001 suction: 0.045 m3/h. Rate of Consumption at upstream 1st and 2nd Stage Desalters: 0.030 m3/h.

Neutralizing Agent Type: Chimec 1738 or equivalent. Chemical description: Blend of aminic derivates in water solution. It is injected into the preflash overhead line, topping overhead line and vacuum column overhead line in order to neutralize acid gases and assist in the protection of the main column overhead system against corrosion and fouling.




Rate of consumption at preflash overhead line: 0.001 m3/h. Rate of consumption at topping overhead line: 0.004 m3/h. Rate of consumption at vacuum column overhead line: 0.001 m3/h.

Corrosion inhibitor Type: CHIMEC 1054 M or equivalent. Chemical description: condensation products between poliamines and carboxylic acids in diesel oil. It is injected into the preflash overhead line and topping overhead line in order to protect the preflash and atmospheric column overheads systems against corrosion by both chlorides and hydrogen sulphide.

Rate of consumption at preflash overhead line: 0.001 m3/h. Rate of consumption at topping overhead line: 0.003 m3/h.

Phosphate Type: CHIMEC 3665 or equivalent. Chemical description: Blend of phospho-organic compounds in water solution. It is injected into the boiler feed water to the Steam Generator in order to remove the calcium hardness and maintains the alkalinity of boiler feed water at the desired level.

Rate of consumption at BFW inlet to D-0011: 0.0012 m3/h max. For further information of the chemical consumptions and characteristics refer to Attachment 31 Chemical Summary and Attachment 19 Material Safety Data Sheet, respectively.

II.6.2. Catalyst

No catalysts or inert balls are used in CDU/ VDU.




III. PROCESS DESCRIPTION

III.1. Process Theory

The distillation is a separation process in which a mixture is heated up and separated in several components or fractions by selective boiling and condensation. Each fraction may contain one or more components of similar volatility and other properties. In refinery distillation, a crude oil mixture is heated up in a fired furnace and then fed into a fractionation column. On entering the column, the feed is a partially vaporized. The liquid starts flowing down but the vapor with lower boiling point components separates and rises. As they rise as vapor, they cool with the liquid falling down from top and part of them enriched in the less volatile components begins to condensate and descend again. The lightest products those of lower boiling point or higher volatility exit from the top of the column. The heaviest products those with the highest boiling point collect and exit from the bottom of the column. In this process, there is no any kind of chemical reactions. The stage at the bottom of the column has the highest pressure and temperature, progressing upwards in the tower, the pressure and temperature decreases for each succeeding stage. The vapour-liquid equilibrium for each feed component in the column reacts in its unique way to the different pressure and temperature conditions at each of the stages. That means that each component establishes a different concentration in the vapour and liquid phases at each of the stages, and this result in the separation of the components. To improve separation, the distillation column is provided with internal contact elements: trays or packing. The trays basic principle is to bubble vapor through a liquid retained by a damming effect on the liquid phase. The packing consists of a metal latticework dispersing the two phases and providing a good exchange area between the fluids circulating in counterflow. Because physical trays or packing are not 100% efficient, a distillation column needs more trays or packing height than the required number of theoretical vapour-liquid equilibrium stages.




The part located below the feed inlet is called the stripping zone and its objective is to lower the light product content in the residue. The top of the column or rectifying zone is designed to eliminate heavy products from the distillate. The purity of top product can be improved by recycling some of the externally condensed top product liquid as reflux. In a continuous distillation, the system is kept in a steady state. The process variables are controlled by the automatic control system. An atmospheric distillation column operates at a pressure slightly above atmosphere. It produces an overhead fraction which is totally condensed as total naphtha; a kerosene cut; a light atmospheric gasoil cut; a heavy atmospheric gasoil cut and finally the bottoms product (atmospheric residue). All these cuts are processed further in subsequent refining processes. The distillation column produces fractions having boiling ranges. The boiling ranges between any cut and the next cut overlap because the distillation separations are not perfectly sharp. The atmospheric residue is heated and fed to a vacuum distillation column for additional separation of vacuum gas oil. A very small amount of residue will be thermally cracked in the heater. Dilution steam is injected to limit the temperature and reduce coking.

III.2. Description of Flows

Refer to the Process Flow Diagrams (PFD) for Base Case: Crude Preheat/Preflash (SA-JER-DS011-TRJR-450001, SA-JER-DS011-TRJR-450020), Crude Distillation (SA-JER-DS011-TRJR-450002), Vacuum Distillation (SA-JER-DS011-TRJR-450003, SA-JER-DS011-TRJR-450021) when reading the following descriptions. Refer to the Attachment 2. The CDU/VDU unit will process crude from storage and will provide feeds to the following units:

Straight run Naphtha as feed of the Naphtha Hydrotreating Unit, NHDT (Unit 111).

Straight run Kerosene, as feed of one of the two Low Pressure HDS units for either jet A1 or diesel production (Unit 101/102).

Light Atmospheric Gas Oil as feed of one of the two Low Pressure HDS units for diesel production (Unit 101/102).




Blend of Heavy Atmospheric Gas Oil and Light Vacuum Gas Oil as feed of one

of the two High Pressure HDS units for diesel production (Unit 091/092).

Vacuum Gas Oil (VGO) as feed of the DHC (Unit 041) and the MHC (Unit 051) units.

Vacuum residue as feed of the Coker unit (Unit 021).

DESALTERTRAIN

PREFLASHCOLUMN

CRUDE OIL

CDU

VDU

NHDT (UNIT 111)

LP HDS (UNIT 101/102)

LP HDS (UNIT 101/102)Gasoil Mode

HP HDS (UNIT 091/092)

DHC (UNIT 041)

MHC (UNIT 051)

DCU (UNIT 021)

SLOPS

SR NAPHTHA

KEROSENE

LAGO

HAGO

LVGO

MVGO

VACUUM RESIDUE

HVGO

Distillation Scheme

Each Crude and Vacuum Distillation Unit comprises mainly the following sections:

III.2.1. Crude Preheat Train

PFDs: SA-JER-DS011-TRJR-450001 and SA-JER-DS011-TRJR-450020 (Base Case). The Crude Distillation Unit has three trains of heat exchangers to recover the energy available in the system, from pumparounds, distillated products, overheads and vacuum residue, and raise the temperature of the crude oil from BL.




The crude oil from storage Unit 561 is pumped by the Crude Charge Pumps G-0001 A/B (33.8 barg), through the crude cold preheat train (from BL to the desalter inlet), which comprises the following heat exchangers in series: E-0001, E-0002, E-0003 A-D, E-0004 A/B, E-0005, E-0006, E-0007 A-B/C-D, E-0008 and E-0009 A/B. In this train the temperature of the crude is raised from the BL inlet temperature (range 30 50 C) up to 150 C maximum. Additionally, the CDU/VDU Unit can reprocess up to 5% of the feed rate of slop oil from storage Unit 681. The slops flow rate is controlled by FC-0175 and then, the stream is mixed with crude feed line upstream G-0001 A/B suction line. The unit crude feed rate is normally controlled at Preflash Column C-0001 inlet by FC-0006 which acts on FV-0006 in the same line. However, the operator can select, using HS-0009A/B, to control flow rate at G-0001A/B discharge by means of FC-0001 and valve PV-0007. The temperature upstream the Desalter D-0001/ D-0002 is controlled by action of TC-0031 on the HAGO bypass valve (TV-0031) of E-0012A/B. The objective temperature is 145 C. If the desalter operating temperature is very high the operator can partially bypass the E-0003 A-D crude feed by adjusting valve HV-0001. The purpose of E-0003 A-D crude feed bypass is to reduce the temperature at E-0004A/B inlet for increasing the duty transferred in this preflash condenser. The HV-0001 valve shall operate closed during normal operation and when the crude oil temperature coming from storage is below of 40 C, to maintain the temperature at E-0004A/B inlet around of 80 C. The hand control valve HV-0003 is provided at E-0003A-D inlet to ensure the adequate flow distribution when heat exchanger is bypassed. In normal operation HC-0001 is closed and HC-0003 is open. Minimum stop on HC-0003 has been implemented to allow feed flow rate. Downstream the Desalter D-0001/ D-0002, the crude is pumped by the Desalted Crude Pumps G-0002 A/B to the crude intermediate preheat train, consisting of the following heat exchangers: E-0010A/B, E-0011A/B, E-0012A/B, E-0013, E-0014A-F. This section raises the temperature of the crude oil from 145C up to 200 C at Preflash Column inlet.




Heat exchangers E-0011 and E-0012 are arranged in parallel. A ZIC system is used to control flow through each branch, with the objective of splitting and balance the flow to both exchangers. The flow in each stream is regulated by controllers FC-0111A and FC-0111B. The temperature upstream the Preflash Column C-0001 is controlled by action of the TC-0057 on the Vacuum Residue bypass of the E-0018A-D. The target operating temperature is 200 C. If the temperature upstream the C-0001 is very high the operator will be able to partially bypass the E-0014A-F Vacuum Residue side by action on HC-0008. To protect the pumps in case of very low flow rate, a dedicated flow controller (FC-0002 for G-0001A/B and FC-0061 for G-0002 A/B) opens the spill back control valves of each pump, recirculating the flow to the suction. Reference P&IDs SA-JER-DS011-TRJR-480001 through 480010 SA-JER-DS011-TRJR-480015 through 480019

TAG NUMBER SERVICE P&ID UNITS SET POINT

FC-0175 SLOPS FROM STORAGE SA-JER-DS011-TRJR-480001 t/h 59.0

FC-0001 E-0001 CRUDE INLET SA-JER-DS011-TRJR-480002 t/h 1179.3

FC-0002-A G-0001A/B CRUDE MINIMUM FLOW SA-JER-DS011-TRJR-

480002 t/h 563.5

FC-0139 E-0001 KERO INLET SA-JER-DS011-TRJR-480003 t/h 133.5

HC-0001 E-0003A-D CRUDE BYPASS SA-JER-DS011-TRJR-480004 t/h 179.2

HC-0003 E-0003A-D CRUDE INLET SA-JER-DS011-TRJR-480004 t/h 1000.1

TC-0016 E-0004A/B CRUDE BYPASS SA-JER-DS011-TRJR-480005 C 110

FC-0003 C-0002 KERO PA FLOW RATE SA-JER-DS011-TRJR-

480008 t/h 580.6

PDC-0449 E-0007A-D KERO PA INLET SA-JER-DS011-TRJR-480008 bar 1.5

TC-0024 E-0007A-D KERO PA BYPASS SA-JER-DS011-TRJR-

480008 C 122

TC-0031 E-00012A/B HAGO PA BYPASS SA-JER-DS011-TRJR-

480010 C 148

FC-0061-A G-0002A/B CRUDE MINIMUM FLOW SA-JER-DS011-TRJR-

480015 t/h 664.5

PC-0007 G-0002A/B CRUDE SUCTION SA-JER-DS011-TRJR- bar 12




TAG NUMBER SERVICE P&ID UNITS SET POINT480015

FC-0111-A E-0011A/B DESALTED CRUDE BALANCE SA-JER-DS011-TRJR-

480017 t/h 594.6

FC-0111-B E-0012A/B DESALTED CRUDE BALANCE SA-JER-DS011-TRJR-

480017 t/h 594.6

FZC-0111 E-0011/12 DESALTED CRUDE BALANCE SA-JER-DS011-TRJR-

480017 % 50

PDC-0110 E-0012A/B HAGO INLET SA-JER-DS011-TRJR-480017 bar 0.6

PDC-0111 E-0013 LAGO INLET SA-JER-DS011-TRJR-480018 bar 1.0

TC-0112 E-0013 LAGO PA BYPASS SA-JER-DS011-TRJR-480018 t/h 374

FC-0006 C-0001 DESALTED CRUDE FEED SA-JER-DS011-TRJR-

480019 t/h 1189.1

HC-0008 E-0014A-D VAC RES BYPASS SA-JER-DS011-TRJR-

480019 t/h 80

TC-0057 C-0001 FEED TEMPERATURE SA-JER-DS011-TRJR-

480019 C 200

Table III.2-1: Controllers of Preheat Train Section

TAG NUMBER SERVICE P&ID UNITS LL L H HH

PT-0001 G-0001A/B SUCTION SA-JER-DS011-TRJR-480001 Barg 0.9

PT-0140 G-0001-A/B SUCTION SA-JER-DS011-TRJR-480001 Barg 0.5

FT-0002-A G-0001-A/B CRUDE MIN FLOW SA-JER-DS011-TRJR-480002 t/h 482.82

FT-0002-B G-0001A/B CRUDE MIN FLOW SA-JER-DS011-TRJR-480002 t/h 460.3

PT-0002 G-0001-A/B CRUDE DISCHARGE SA-JER-DS011-TRJR-480002 Barg 39

TT-0001 G-0001-A/B CRUDE SUCTION SA-JER-DS011-TRJR-480002 C 55

TT-0170 G-0001-A/B CRUDE SUCTION SA-JER-DS011-TRJR-480002 C 70

TT-0003 E-0001 KERO OUTLET SA-JER-DS011-TRJR-480003 C 75

TT-0030 E-0009A/B HAGO OUTLET SA-JER-DS011-TRJR-480010 C 165

TT-0045 E-0009A/B CRUDE OUTLET SA-JER-DS011-TRJR-480010 C 143 153

TT-0388 E-0009-A/B HAGO OUTLET SA-JER-DS011-TRJR-480010 C 170

FT-0061-A G-0002A/B CRUDE MIN FLOW SA-JER-DS011-TRJR-480015 t/h 663.82

FT-0061-B G-0002A/B CRUDE DISCHARGE SA-JER-DS011-TRJR-480015 t/h 597.4

PT-0010 G-0002A/B DESALTED SA-JER-DS011- barg 32




TAG

NUMBER SERVICE P&ID UNITS LL L H HH

CRUDE DISCHARGE TRJR-480015

PDT-0122 G-0002A STRAINER SA-JER-DS011-TRJR-480015 mbar 100

PDT-0127 G-0002B STRAINER SA-JER-DS011-TRJR-480015 mbar 100

TT-0446 G-0002A/B DESALTED CRUDE SUCTION SA-JER-DS011-TRJR-480015 C 150

TT-0193 E-0014A-D VAC RES AFTER BYPASS SA-JER-DS011-TRJR-480019 C 210

TT-0289 E-0014A-D DESALTED CRUDE OUTLET SA-JER-DS011-TRJR-480019 C 190 205

Table III.2-2: Alarms of Preheat Train Section

TAG NUMBER SERVICE P&ID

FV-0175 SLOPS FROM STORAGE SA-JER-DS011-TRJR-480001

FV-0002 G-0001A/B MINIMUM FLOW CONTROL SA-JER-DS011-TRJR-480002

PV-0007 G-0001A/B CRUDE TO DESALTER SA-JER-DS011-TRJR-480002

HV-0001 E-0003A-D CRUDE BYPASS SA-JER-DS011-TRJR-480004

HV-0003 E-0003A-D CRUDE INLET SA-JER-DS011-TRJR-480004

TV-0016 E-0004A/B CRUDE BYPASS SA-JER-DS011-TRJR-480005

FV-0003 C-0002 KERO PA FLOW RATE SA-JER-DS011-TRJR-480008

PDV-0449 E-0007A-D KERO PA INLET SA-JER-DS011-TRJR-480008

TV-0024 E-0007A-D KERO PA BYPASS SA-JER-DS011-TRJR-480008

FV-0061 G-0002A/B CRU MIN FLOW SA-JER-DS011-TRJR-480015

FV-0109 E-0012A/B DESALTED CRUDE BALANCE SA-JER-DS011-TRJR-480017

FV-0110 E-0011A/B DESALTED CRUDE BALANCE SA-JER-DS011-TRJR-480017

PDV-0110 E-0012A/B HAGO INLET SA-JER-DS011-TRJR-480017

TV-0031 E-00012A/B HAGO PA BYPASS SA-JER-DS011-TRJR-480017

PDV-0111 E-0013 LAGO PA INLET SA-JER-DS011-TRJR-480018

TV-0112 E-0013 LAGO PA BYPASS SA-JER-DS011-TRJR-480018

FV-0006 C-0001 DESALTED CRUDE FEED SA-JER-DS011-TRJR-480019

HV-0008 011-E-0014A-D VAC RES BYPASS SA-JER-DS011-TRJR-480019

Table III.2-3: Control Valve of Preheat Train Section





PZV-0078-A SLOPS FROM STORAGE SA-JER-DS011-TRJR-480001

PZV-0078-B SLOPS FROM STORAGE SA-JER-DS011-TRJR-480001

TZV-0013 CRUDE COLD PREHEAT TRAIN SA-JER-DS011-TRJR-480010

TZV-0017 CRUDE INTERMEDIATE PREHEAT TRAIN SA-JER-DS011-TRJR-480019

Table III.2-4: Relief Valves of Preheat Train Section

III.2.2. Desalter Train

PFD: SA-JER-DS011-TRJR-450001 (Base Case). The crude oil contents inorganic salts that can cause severe corrosion and fouling problems. These salts are removed by emulsifying crude oil with wash water and separating them in the desalter train. The desalter train comprises two stage electrostatic desalting units (1st Stage Desalter D-0001 and 2nd Stage Desalter D-0002 -13.5/12.5 barg and 145C) operating in series. Normally, both stage desalters are operated in series, but the 1st stage and the 2nd stage desalter may be operated as a single unit if the other desalter is shut down for maintenance. The crude oil feed is injected with wash water and treated with a demulsifier chemical upstream the cold preheat train, to promote desalting through contact of oil and water phases. After heating up the crude oil, this emulsion enters the 1st stage Desalter through an inlet distribution header, where it is resolved by coalescence in a high voltage electrical field and subsequently separated into two phases, crude oil and water. The cleaned oil floats and exits the 1st stage desalter vessel via the outlet tray at the top of the desalter and passes on to the 2nd stage desalter vessel. The water containing the dissolved/wetted impurities (or brine) drops under gravity to the bottom of the desalter where it is removed via the effluent water outlet header. Afterwards, the stream is cooled down to 42 C through the E-0032A/B, air cooler A-0006 and E-0033, and finally released to the Waste Water Treatment (Unit 651). The brine flow rate is regulated by valve LDV-0089 which controls the crude/water interface level in the desalter (LDC-0089). Before entering the 2nd stage desalter vessel, wash water and demulsifying chemical are injected into the crude oil stream. Then it is fed to the D-0002 through an inlet




distribution header, where it is resolved by coalescence in a high voltage electrical field and subsequently separated again. The water drops under gravity to the bottom of the vessel where it is removed and recycled to the 1st stage via the level control valve LDV-0092 and Desalter Recirculation Pumps G-0024A/B. The mixing efficiency and hence salt content of the crude product is controlled by mixing valves provided upstream of each desalter, PDV-0005 for the 1st stage and PDV-0006 for the 2nd stage. They operate at constant differential pressure and help to disperse water uniformly in the crude increasing contact between both phases. Operating pressure at desalter outlet is controlled by PC-0007 which acts in a split range on the PV-0007 located upstream of the E-0001, and FV-0006 in the Preflash Column feed. It is essential to maintain the pressure in the desalter to prevent any vaporization of the crude. In case of low pressure in the desalter (pump trip) the PC-0007 will override FC-0006, via a low signal selector, and close the control valve FV-0006. The operating pressure measure to the pressure controller is manually selected by operator via hand switch HS-0007, pressure is measured from PT-0007 located downstream D-0002, or from D-0001 by the midpoint of PT-0373A/B/C in case D-0002 is out of service. An alternative control for the desalter pressure is given by means of manual selectors HS-0009A and HS-0009B, which will allow operator to control crude flow rate at unit inlet by PV-0007 and control pressure in the crude desalter on FV-0006. The desalting or wash water is made of phenolic and non-phenolic stripped sour water, and boiler feed water as back up. These streams feed the Desalting Water Surge Drum D-0007 (50C, 1.0 barg). Phenolic stripped water feeds D-0007 (1 barg and 50C) under flow control with controller FC-0171. Non-phenolic and Boiler Feed Water streams feed D-0007 under flow control (FC-0059B and FC-0059A respectively), reset by drum level control LC-0067 under split range mode. If level is decreasing, the non-phenolic water is fed to D-0007. In case level continues decreasing in the drum, the split range will allows the BFW to feed it. The desalting water is pumped by the Desalting Water Pumps G-0021A/B. The desalting water is preheated in two exchangers, the E-0024 and E-0032A/B until 115 C and sent under flow control to the crude oil feed (upstream the cold preheat train) and to the 2nd stage Desalter inlet by action respectively on the flow control valves FV-0005 and FV-0060. In case of 2nd stage Desalter maintenance the fresh desalting water can be sent to the 1st stage Desalter under flow control by FC-0004.




The demulsifier chemical is pumped from Demulsifier Drum D-0031 by the Demulsifier Pumps G-0030A/B (to G-0001A/B suction) and G-0031A/B (to E-0009 outlet). The purpose of demulsifier is to help the desalter dehydration and salt removal efficiency, and minimize the oil content in the water effluent. The dosing rate is controlled manually by operator adjusting the pump stroke. Reference P&IDs SA-JER-DS011-TRJR-480010 through 480014 SA-JER-DS011-TRJR-480107 through 480112


PDC-0005 D-0001 MIXING VALVE SA-JER-DS011-TRJR-480010 bar 0.5

LDC-0089 D-0001 INTERFACE LEVEL SA-JER-DS011-TRJR-480011 % 50

PDC-0006 D-0002 MIXING VALVE SA-JER-DS011-TRJR-480013 bar 0.5

LDC-0092 D-0002 INTERFACE LEVEL SA-JER-DS011-TRJR-480012 % 50

FC-0004 DESALTING WATER TO D-0001 SA-JER-DS011-TRJR-

480107 t/h 73.5

FC-0005 DESALTING WATER TO E-0001 SA-JER-DS011-TRJR-

480107 t/h 31.5

FC-0060 DESALTING WATER TO D-0002 SA-JER-DS011-TRJR-

480107 t/h 73.5

FC-0059-A D-0007 BFW FEED SA-JER-DS011-TRJR-480112 t/h 0

FC-0059-B D-0007 NON-PHENOLIC WATER FEED SA-JER-DS011-TRJR-

480112 t/h 0

FC-0171 D-0007 PHENOLIC STRIPPED WATER FEED SA-JER-DS011-TRJR-

480112 t/h 105.0

LC-0067 D-0007 DESALTING WATER SURGE DRUM SA-JER-DS011-TRJR-

480112 % 50

PC-0311 D-0007 DESALTING WATER SURGE DRUM SA-JER-DS011-TRJR-

480112 barg 1.0

Table III.2-5: Controllers of Desalter Train Section TAG NUMBER SERVICE P&ID UNITS LL L H HH

LDT-0089 D-0001 DESALTER INTERFACE LEVEL SA-JER-DS011-TRJR-480011 % 27.8 72.2


LT-0113 D-0001 DESALTER LIQUID LEVEL SA-JER-DS011-TRJR-480011 % 35

PT-0373-A D-0001 1ST STG DESALTER SA-JER-DS011-TRJR-480011 barg 6.5 9.0 14.5 15.0





PT-0373-B D-0001 1ST STG DESALTER SA-JER-DS011-TRJR-480011 barg 6.5 9.0 14.5 15.0

PT-0373-C D-0001 1ST STG DESALTER SA-JER-DS011-TRJR-480011 barg 6.5 9.0 14.5 15.0



LT-0114 D-0002 DESALTER LIQUID LEVEL SA-JER-DS011-TRJR-480012 % 35

PT-0450-A D-0002 2ND STG DESALTER SA-JER-DS011-TRJR-480012 barg 6.5 9 14.5 15.0

PT-0450-B D-0002 2ND STG DESALTER SA-JER-DS011-TRJR-480012 barg 6.5 9 14.5 15.0

PT-0450-C D-0002 2ND STG DESALTER SA-JER-DS011-TRJR-480012 barg 6.5 9 14.5 15.0

FT-0142-A G-0024A/B DISCHARGE SA-JER-DS011-TRJR-480013 t/h 27.75

FT-0142-B G-0024A/B DISCHARGE SA-JER-DS011-TRJR-480013 t/h 24.98

PDT-0200 D-0001 CRUDE MIXING VALVE SA-JER-DS011-TRJR-480010 barg 0.1

PDT-0201 D-0002 CRUDE MIXING VALVE SA-JER-DS011-TRJR-480013 barg 0.1

TT-0185 E-0033 BRINE OUTLET TO BL SA-JER-DS011-TRJR-480109 C 47

AT-0018 DESALTING WATER pH SA-JER-DS011-TRJR-480111 - 5.0 7.5

FT-0180-A G-0021-A/B PRW DISCHARGE SA-JER-DS011-TRJR-480111 t/h 42.57

FT-0180-B G-0021-A/B PRW DISCHARGE SA-JER-DS011-TRJR-480111 t/h 38.31

LT-0069 D-0007 DESALTING WATER SURGE DRUMSA-JER-DS011-TRJR-480112 % 12.42 87.58

PT-0231 D-0007 DESALTING WATER SURGE DRUMSA-JER-DS011-TRJR-480112 barg 0.5

Table III.2-6: Alarms of Desalter Train Section


LDV-0089 D-0001 DESALTER INTERFACE SA-JER-DS011-TRJR-480010

PDV-0005 D-0001 CRUDE MIXING VALVE SA-JER-DS011-TRJR-480010

LDV-0092 D-0002 DESALTER INTERFACE SA-JER-DS011-TRJR-480013

PDV-0006 D-0002 CRUDE MIXING VALVE SA-JER-DS011-TRJR-480013

FV-0004 DESALTING WATER TO D-0001 SA-JER-DS011-TRJR-480107

FV-0005 DESALTING WATER TO E- SA-JER-DS011-TRJR-480107




TAG NUMBER SERVICE P&ID 0001

FV-0060 DESALTING WATER TO D-0002 SA-JER-DS011-TRJR-480107

FV-0059-A D-0007 BFW FEED SA-JER-DS011-TRJR-480112

FV-0059-B D-0007 NON-PHENOLIC WATER FEED SA-JER-DS011-TRJR-480112

FV-0171 D-0007 PHENOLIC STRIPPED WATER FEED SA-JER-DS011-TRJR-480112

PV-0311-A D-0007 BLANKETING SA-JER-DS011-TRJR-480112

PV-0311-B D-0007 VENT SA-JER-DS011-TRJR-480112

Table III.2-7: Control Valve of Desalter Train Section


PZV-0001 D-0001 DESALTER SA-JER-DS011-TRJR-480011




TZV-0006 E-0033 CWR SHELL SIDE SA-JER-DS011-TRJR-480109

PZV-0049 D-0007 DESALTING WATER SURGE DRUM SA-JER-DS011-TRJR-480112

PZV-0050 D-0007 DESALTING WATER SURGE DRUM SA-JER-DS011-TRJR-480112

Table III.2-8: Relief Valves of Desalter Train Section

III.2.3. Preflash Column PFD: SA-JER-DS011-TRJR-450020 and SA-JER-DS011-TRJR-450002 (Base Case). After heating up the desalted crude through the intermediate preheat train, this is fed to the Preflash Column C-0001 (3.7/3.9 barg and 137/188 C) under flow control by FC-0006 which acts on FV-0006. Alternatively, the operator can select to control the crude flow rate by means of FC-0001 with PV-0007, and control pressure in the desalter train by PC-0007 acting on FV-0006. There is the alternative to feed Wild naphtha from HDS Unit into the C-0001 instead of the Atmospheric Column C-0002.




The Preflash Column C-0001 recovers the light-ends from crude oil to reduce the energy requirements and traffic in the distillation column. The total height of C-0001 is 26710 mm. The bottom section diameter is 7500 mm, and the main section diameter is 4200 mm. It has 19 trays with a stripping and a fractionation zone. The column operating pressure varies from 3.9 barg (bottom) to 3.7 barg (top), and the operating temperature from 188 C (bottom) to 137 C (top). Medium pressure steam is used as stripping steam in the column. This is injected continuously into the bottom of the column under flow control FC-0007. The normal flow rate is 4.5 t/h. The overhead vapor leaves the top at 137C; it is partially condensed through the E-0004A/B and directed to the Preflash Reflux Drum D-0003 (at 110 C and 3.0 barg). In the D-0003, the naphtha vapor and liquid are separated. The vapor leaving from the D-0003 is partially condensed in two steps by the A-0002A-F (air cooler) firstly, and then, it is totally condensed by the E-0021 (cooling water). The liquid Naphtha recovered is mixed with the naphtha from the Atmospheric Column C-0002, upstream E-0021, and sent to the Total Naphtha Drum D-0005. The D-0005 operates at 1.8 barg and 43C. The preflash and atmospheric naphtha produces the total Straight Run (SR) Naphtha which it is routed to the NHDT Unit by the Naphtha to NHDT Pumps G-0007A/B, under flow control FC-0062, reset by the D-0005 level controller LC-0030. The PC-0021 controls the pressure of the Preflash Reflux Drum D-0003, and therefore the cut point of preflash naphtha; by opening and closing in split range the valves PV-0038A/B in the Total Naphtha Drum D-0005. The controller vents non-condensable/gas to the flare or enters fuel gas to maintain the pressure in D-0005 and D-0003. The D-0003 pressure will be equals to D-0005 pressure plus the pressure drop of A-0002A-F/ E-0021 coolers and interconnecting pipes. The Total Naphtha Drum D-0005 is provided with the pressure controller PC-0038. This is an override control (with low signal selector) to ensure pressure in D-0005 does not fall below vaporization pressure thus preventing flashing of the naphtha in the drum. Under normal conditions, the lower signal selector selects the pressure from D-0003 for controlling PV-0038A/B valves. But, as the pressure in D-0005 drops the set value (1.4 barg), the selector switches to signal from controller PC-0038. When pressure in D-0005 is restored, the control returns to PC-0021 in D-0003.




The temperature of the Preflash Reflux Drum D-0003 is controlled by TC-0016 bypassing the crude side of E-0004A/B, via TV-0016. If a lower temperature needs to be achieved, the HV-0001 in the E-0003 crude bypass could be manually opened. The liquid naphtha is sent back as reflux to the column C-0001 by the Preflash Reflux Pumps G-0003A/B. The reflux flow rate is under flow control FC-0009, reset by the D-0003 level controller LC-0004. The water condensed in the D-0003 is collected in a boot, and then it is routed to Sour Water Recovery Drum D-0006 by gravity flow under interface level control LDC-0008. The topped crude is collected in the bottom of Preflash Column C-0001. Then, it is pumped by the Preflash Bottom Pumps G-0004A/B and preheated through the hot preheat train, which comprises six heat exchangers: E-0015A/B, E-0016A/B, E-0017 A/B, E-0018 A-D, E-0019 A-F and E-0020 A-F. Last, the topped crude is fed to Crude Heater F-0001. The bottom liquid level is controlled by LC-0003, which resets the flow master controllers FC-0014A/ FC-0014B of the Crude heater F-0001. These control the total flow of all the passes through the heater. To protect the pumps G-0004 A/B in the event of very low flow rate, an independent flow controller FC-0008 opens the recirculation valve for returning the crude to the column. Reference P&IDs SA-JER-DS011-TRJR-480020 through 480029 SA-JER-DS011-TRJR-480048 through 480051 SA-JER-DS011-TRJR-480142


LC-0003 C-0001 PREFLASH COLUMN SA-JER-DS011-TRJR-480020 % 50

FC-0008-A G-0004A/B MINIMUM FLOW SA-JER-DS011-TRJR-480021 t/h 471.2

FC-0009-A G-0003A/B REFLUX DISCHARGE SA-JER-DS011-TRJR-

480022 t/h 54.7

AC-0021 D-0003 AWS OUTLET SA-JER-DS011-TRJR-480023 6

LC-0004 D-0003 PREFLASH REFLUX DRUM SA-JER-DS011-TRJR-

480023 % 50

LDC-0008 D-0003 INTERFACE BOOT SA-JER-DS011-TRJR-480023 % 70

PC-0021 D-0003 PREFLASH REFLUX DRUM SA-JER-DS011-TRJR-

480023 barg 3.0





LC-0030 D-0005 TOTAL NAPHTHA DRUM SA-JER-DS011-TRJR-

480050 % 84


PC-0038 D-0005 TOTAL NAPHTHA DRUM SA-JER-DS011-TRJR-

480050 barg 1.4

FC-0062 G-0007A/B NAPHTHA TO NHDT SA-JER-DS011-TRJR-

480051 t/h 152.1

FC-0049 E-0015A/B HVGO INLET SA-JER-DS011-TRJR-480024 t/h 181.5

FC-0013 C-0002 HAGO PA RETURN SA-JER-DS011-TRJR-480026 t/h 664.6

PDC-0146 E-0017A/B HAGO PA INLET SA-JER-DS011-TRJR-480026 bar 0.52

TC-0079 E-0017A/B HAGO PA BYPASS SA-JER-DS011-TRJR-

480026 C 262

FC-0063-A C-0003 C-0003 VACUUM RESIDUE QUENCH SA-JER-DS011-TRJR-

480027 t/h 112.2

FC-0007 STRIPPING STEAM TO C-0001 SA-JER-DS011-TRJR-

480142 t/h 4.5

Table III.2-9: Controllers of Preflash Column Section TAG NUMBER SERVICE P&ID UNITS LL L H HH

PT-0A C-0001 TOP NAPHTHA OUTLET SA-JER-DS011-TRJR-480020 Barg 4.1 4.5

PT-0B C-0001 TOP NAPHTHA OUTLET SA-JER-DS011-TRJR-480020 Barg 4.1 4.5

PT-0C C-0001 TOP NAPHTHA OUTLET SA-JER-DS011-TRJR-480020 Barg 4.1 4.5

TT-0058 C-0001 TOP NAPHTHA OUTLET SA-JER-DS011-TRJR-480020 C 142

FT-0008-A G-0004A/B MINIMUM FLOW SA-JER-DS011-TRJR-480021 t/h

473.13

FT-0008-B G-0004A/B TOPPED CRUDE SA-JER-DS011-TRJR-480021 t/h

426.29

PT-0451 G-0004A/B CRUDE DISCHARGE SA-JER-DS011-TRJR-480021 barg 34.4

FT-0009-B G-0003A/B REFLUX DISCHARGE SA-JER-DS011-TRJR-480022 t/h 15.61

LT-0004 D-0003 PREFLASH REFLUX DRUM SA-JER-DS011-TRJR-480023 % 38.89

83.33

LT-0006 D-0003 PREFLASH REFLUX DRUM SA-JER-DS011-TRJR-480023 % 11.11

TT-0118 E-0021 NAPHTHA OUTLET SA-JER-DS011-TRJR-480049 C 48

FT-0026 D-0005 VAPOR TO FLARE SA-JER-DS011-TRJR-480050 t/h

LT-0028 D-0005 TOTAL NAPHTHA DRUM SA-JER-DS011-TRJR-480050 % 6.0

LT-0030 D-0005 TOTAL SA-JER-DS011- % 76 92





NAPHTHA DRUM TRJR-480050

PT-0100 D-0005 TOTAL NAPHTHA DRUM SA-JER-DS011-TRJR-480050 barg 0.8 2.9

LDT-0032 D-0005 INTERFACE BOOT SA-JER-DS011-TRJR-480050 %

LDT-0033 D-0005 INTERFACE BOOT SA-JER-DS011-TRJR-480050 %

AT-0013 NAPHTHA TO NHDT ASTM D86 95% SA-JER-DS011-TRJR-480051 C 140

TT-0195 E-0015A/B HVGO +MVGO INLET SA-JER-DS011-TRJR-480024 C 265

TT-0389 E-0015A/B HVGO +MVGO INLET SA-JER-DS011-TRJR-480024 C 275

FT-0063-B C-0003 VACUUM RESIDUE QUENCH SA-JER-DS011-TRJR-480027 t/h 67.8

TT-0194 STRIPPING STEAM TO C-0001 SA-JER-DS011-TRJR-480142 C 245 300

TT-0356 STRIPPING STEAM TO C-0001 SA-JER-DS011-TRJR-480142 C 205

Table III.2-10: Alarms of Preflash Column Section

TAG NUMBER SERVICE P&ID FV-0008 G-0004A/B MINIMUM FLOW SA-JER-DS011-TRJR-480021

FV-0009 G-0003A/B REFLUX FLOW RATE SA-JER-DS011-TRJR-480022

LDV-0008 D-0003 BOOT INTERFACE SA-JER-DS011-TRJR-480023

LDV-0032 D-0005 BOOT INTERFACE SA-JER-DS011-TRJR-480050

PV-0038-A D-0005 BLANKETING SA-JER-DS011-TRJR-480050

PV-0038-B D-0005 VENT SA-JER-DS011-TRJR-480050

FV-0062 G-0007A/B NAPHTHA TO NHDT SA-JER-DS011-TRJR-480051

FV-0049 E-0015A/B HVGO INLET SA-JER-DS011-TRJR-480024

FV-0013 C-0002 HAGO PA RETURN SA-JER-DS011-TRJR-480026

PDV-0146 E-0017A/B HAGO PA INLET SA-JER-DS011-TRJR-480026

TV-0079 E-0017A/B HAGO PA BYPASS SA-JER-DS011-TRJR-480026

FV-0063 C-0003 VACUUM RESIDUE QUENCH SA-JER-DS011-TRJR-480027

TV-0057 E-0018A-D VACUUM RESIDUE BYPASS SA-JER-DS011-TRJR-480027

FV-0007 STRIPPING STEAM TO C-0001 SA-JER-DS011-TRJR-480142

Table III.2-11: Control Valve of Preflash Column Section





PZV-0005-A C-0001 PREFLASH COLUMN SA-JER-DS011-TRJR-480020

PZV-0005-B C-0001 PREFLASH COLUMN SA-JER-DS011-TRJR-480020

PZV-0006 C-0001 PREFLASH COLUMN SA-JER-DS011-TRJR-480020

PZV-0007 D-0003 PREFLASH REFLUX DRUM SA-JER-DS011-TRJR-480023

PZV-0008 D-0003 PREFLASH REFLUX DRUM SA-JER-DS011-TRJR-480023

TZV-0001 E-0021 CWR TUBE SIDE SA-JER-DS011-TRJR-480049

PZV-0014 D-0005 TOTAL NAPHTHA DRUM SA-JER-DS011-TRJR-480050

PZV-0015 D-0005 TOTAL NAPHTHA DRUM SA-JER-DS011-TRJR-480050

Table III.2-12: Relief Valves of Preflash Column Section

III.2.4. Crude Heater

PFD: SA-JER-DS011-TRJR-450002 (Base Case). The topped crude enters into the Crude Heater F-0001, where is heated up to 366 C and partially vaporized until 33%wt for the atmospheric distillation. The F-0001 consists of two radiant cells and a common convection section above the arch. It is equipped with 20 hearth burners in total, 10 burners in line per cell. Low NOx burners are used. The heater is fired with fuel gas and is designed to reach a minimum fuel efficiency of 92%. No steam/air decoking system is required, only pigging facilities are provided. The crude is routed to two cells and divided into eight passes (four passes per cell). The flow control on each pass, FC-00015 A-H, is designed to maintain a variable distribution of mass flow into each pass with two objectives: achieve an overall fired heater flow set point and achieve equal pass outlet temperature. The software signal from each FC (dedicated to each pass) is sent in case of passes from A to D to one summing device and for passes E to H to another summing device to totalize and average the total flow. The two generated total average flow software signal (FC-0014A/FC-0014B) are reset by the level controller signal of the Preflash Column (LC-0003).




At the heater outlet the four passes are routed as individual branches to the transfer line. The average temperature of the four process outlets of each cell is controlled by temperature controllers (TC-0097AA/TC-0097BA) which set the setpoint of the demand controller FC-0069/FC-0076 for cell A and cell B respectively and the air /fuel ratio system control. In order to prevent the fuel gas pressure lower than the safety level, the signal from heat demand controller FC-0069/0076 is overridden by the minimum pressure controller PC-0136B/0196B via the high selector PY-0136/0196 which manipulate the control valve FV-0069/0076. During start-up operation, the fuel gas pressure is controlled by PC-0136A/0196A which manipulate the small control valve PV-0136/0196 for cell A and cell B respectively. A correct air/fuel ratio (or excess O2) is essential for energy efficient operation. In the crude heater, the O2 concentration is measured and controlled by AC-0001 and AC-0002 which regulates the air/fuel ratio for cell A and cell B respectively. The low air/fuel ratio alarm will alert the operator to correct in order to avoid sub-stoichiometric firing. Furthermore, the low-low air/fuel ratio will activate the minimum firing trip on the heater. The air flow controller FC-0074/0070 is the main tool to control the desired air/fuel ratio. Heat demand controllers 011-FC-0069/0076 manipulate the FVs. To prevent the main fuel pressure dropping below the minimum pressure, one pressure controller per cell PC-0136B/0196B will override the heat demand controller output in case the pressure is lower than the setpoint. The dampers PV-0395A/B in the two takeoffs to the stack operate as one; they are used to control a slight negative arch pressure by PC-0395, regulating the pass of the flue gases. The flue gases from the Crude and Vacuum Heaters (F-0001/ F-0002) are joined together and routed to an air preheat system. To recover heat from the flue gas, the air preheat system is provided with three Combustion Air Forced fan (K-0002 A/B/C), one Flue Gas Induced Fan (K-0003), a Steam/Air Preheater (011-E-0041), and an Air Preheater (E-0040) to transfer the heat from the flue gas to the combustion air. The air enters K-0002 A/B/C (two operating and one spare); through the Air Filter S-0013A-D, passes through the air preheating system, and it is divided into four streams for cell A and B of the crude and vacuum heaters. These streams are controlled by the Fuel/Air Ratio System using the flow venturis and dampers en each line. Therefore, the combustion air flow will maintain ratio to the fuel gas flow.




The temperature at Steam/Air Preheater outlet is controlled by TC-0223 which manipulates the control valve TV-0223 in the steam side. The skin metal temperature of the Air Preheater E-0040 is measured by TI-0032A/B/C in three different locations. The lowest of the three temperatures is controlled by TC-0032 which manipulates the bypass control valve of air preheater. At the air preheater outlet header the air pressure is measured and controlled by PC-0160 which sets and equal opening to the suction throttle dampers PV-0160A/B/C of running forced draft fans (K-0002 A/B/C). The flue gas from both cells is routed to a common stack located on top of F-0001, usually operating on balanced draft. A damper in the stack allows flue gas bypass around the Air Preheater E-0040 and K-0003, with the objective of keeping the heaters running in case K-0003 or E-0040 failure, operating then in forced draft. Normally the Flue Gas Induced Fan (K-0003) is used to create a draft at the base of stack. The stack damper HV-0015 is normally closed. Stack base draft is controlled by PC-0159 throttling the K-0003 suction valve PV-0159. In case of failure of the ID fan, the UC-0332 will switch balanced draft to forced draft mode. Part of the F-0001 convection section is used also to superheat Low Pressure Steam from LPS header. This is used as stripping steam in the Atmospheric Column (C-0002), HAGO Stripper (C-0006) and LAGO Stripper (C-0005). The Desuperheater DS-0001 has been provided to maintain stripping steam temperature from F-0001 to column C-0002, C-0005 and C-0006 at 350C. The temperature downstream of the desuperheater is controlled by action of the controller TC-0043 which acting on BFW control valve TV-0043. Reference P&IDs SA-JER-DS011-TRJR-480030 through 480042 SA-JER-DS011-TRJR-480115 through 480117 SA-JER-DS011-TRJR-480121 SA-JER-DS011-TRJR-480169 and 480270 SA-JER-DS011-TRJR-480311 and 480312





FC-0015-A F-0001 CRUDE PASS 1 INLET SA-JER-DS011-TRJR-

480030 t/h 138.4

FC-0015-B F-0001 CRUDE PASS 2 INLET SA-JER-DS011-TRJR-

480030 t/h 138.4

FC-0015-C F-0001 CRUDE PASS 3 INLET SA-JER-DS011-TRJR-

480031 t/h 138.4

FC-0015-D F-0001 CRUDE PASS 4 INLET SA-JER-DS011-TRJR-

480031 t/h 138.4

FC-0015-E F-0001 CRUDE PASS 5 INLET SA-JER-DS011-TRJR-

480032 t/h 138.4

FC-0015-F F-0001 CRUDE PASS 6 INLET SA-JER-DS011-TRJR-

480032 t/h 138.4

FC-0015-G F-0001 CRUDE PASS 7 INLET SA-JER-DS011-TRJR-

480033 t/h 138.4

FC-0015-H F-0001 CRUDE PASS 8 INLET SA-JER-DS011-TRJR-

480033 t/h 138.4

TC-0097-AA F-0001 CRUDE OUTLET CELL WEST SA-JER-DS011-TRJR-

480034 C 367

TC-0097-A F-0001 CRUDE PASS 1 OUTLET SA-JER-DS011-TRJR-

480034 C 366.5

TC-0097-B F-0001 CRUDE PASS 2 OUTLET SA-JER-DS011-TRJR-

480035 C 366.5

TC-0097-C F-0001 CRUDE PASS 3 OUTLET SA-JER-DS011-TRJR-

480036 C 366.5

TC-0097-D F-0001 CRUDE PASS 4 OUTLET SA-JER-DS011-TRJR-

480037 C 366.5

TC-0097-BA F-0001 CRUDE OUTLET CELL EAST SA-JER-DS011-TRJR-

480038 C 367

TC-0097-E F-0001 CRUDE PASS 5 OUTLET SA-JER-DS011-TRJR-

480038 C 366.5

TC-0097-F F-0001 CRUDE PASS 6 OUTLET SA-JER-DS011-TRJR-

480039 C 366.5

TC-0097-G F-0001 CRUDE PASS 7 OUTLET SA-JER-DS011-TRJR-

480040 C 366.5

TC-0097-H F-0001 CRUDE PASS 8 OUTLET SA-JER-DS011-TRJR-

480041 C 366.5

FC-0021 F-0001 STRIPPING STEAM TO C-0002 SA-JER-DS011-TRJR-

480042 t/h 20.2

TC-0043 DS-0001 BFW (STEAM TEMPERATURE) SA-JER-DS011-TRJR-

480042 C 350

FC-0069 F-0001 FUEL GAS FEED WEST SA-JER-DS011-TRJR-

480115 t/h 3.302

PC-0136-A F-0001 FUEL GAS FEED WEST SA-JER-DS011-TRJR-

480115 barg 0.12

PC-0136-B F-0001 FUEL GAS FEED WEST SA-JER-DS011-TRJR-

480115 barg 2.2

FC-0076 F-0001 FUEL GAS FEED EAST SA-JER-DS011-TRJR-

480116 t/h 3.302

PC-0196-A F-0001 FUEL GAS FEED EAST SA-JER-DS011-TRJR-

480116 barg 0.12

PC-0196-B F-0001 FUEL GAS FEED SA-JER-DS011-TRJR- barg 2.2




TAG NUMBER SERVICE P&ID UNITS SET POINTEAST 480116

AC-0001 F-0001 FLUE GAS O2% SA-JER-DS011-TRJR-480117 % 3

AC-0002 F-0001 FLUE GAS O2% SA-JER-DS011-TRJR-480117 % 3

PC-0395 F-0001 STACK SA-JER-DS011-TRJR-480117 mmH2O -2.5

FC-0070 COMBUSTION AIR TO F-0001 SA-JER-DS011-TRJR-

480121 t/h

FC-0074 COMBUSTION AIR TO F-0001 SA-JER-DS011-TRJR-

480121 t/h

HC-0015 F-0001/F-0002 HEATERS DRAFT SA-JER-DS011-TRJR-

480121

PC-0159 F-0001/0002 HEATERS DRAFT SA-JER-DS011-TRJR-

480121 mmH2O -13

PC-0160 E-0040 AIR OUTLET SA-JER-DS011-TRJR-480121 mmH2O

TC-0032 E-0040 FLUE GAS SA-JER-DS011-TRJR-480121 C 175

TC-0223 E-0041 COMB AIR OUTLET SA-JER-DS011-TRJR-480121 C 75

FC-0014-A F-0001 CRU INLET CELL WEST SA-JER-DS011-TRJR-

480311 t/h 138.4

FC-0014-B F-0001 CRU INLET CELL EAST SA-JER-DS011-TRJR-

480311 t/h 138.4

FC-0033-A F-0002 ATM RESIDUE CELL WEST SA-JER-DS011-TRJR-

480312 t/h 83.9

FC-0033-B F-0002 ATM RESIDUE CELL EAST SA-JER-DS011-TRJR-

480312 t/h 83.9

Table III.2-13: Controllers of Crude Heater Section


FT-0015-AA F-0001 CRUDE PASS 1 INLET SA-JER-DS011-TRJR-480030 t/h 55.64 82.96

FT-0015-AB F-0001 CRUDE PASS 1 INLET SA-JER-DS011-TRJR-480030 t/h 55.64 82.96

FT-0015-AC F-0001 CRUDE PASS 1 INLET SA-JER-DS011-TRJR-480030 t/h 55.64 82.96

FT-0015-BA F-0001 CRUDE PASS 2 INLET SA-JER-DS011-TRJR-480030 t/h 55.64 82.96

FT-0015-BB F-0001 CRUDE PASS 2 INLET SA-JER-DS011-TRJR-480030 t/h 55.64 82.96

FT-0015-BC F-0001 CRUDE PASS 2 INLET SA-JER-DS011-TRJR-480030 t/h 55.64 82.96

FT-0015-CA F-0001 CRUDE PASS 3 INLET SA-JER-DS011-TRJR-480031 t/h 55.64 82.96

FT-0015-CB F-0001 CRUDE PASS 3 INLET SA-JER-DS011-TRJR-480031 t/h 55.64 82.96

FT-0015-CC F-0001 CRUDE PASS 3 INLET SA-JER-DS011-TRJR-480031 t/h 55.64 82.96





FT-0015-DA F-0001 CRUDE PASS 4 INLET SA-JER-DS011-TRJR-480031 /h 55.64 82.96

FT-0015-DB F-0001 CRUDE PASS 4 INLET SA-JER-DS011-TRJR-480031 t/h 55.64 82.96

FT-0015-DC F-0001 CRU PASS 4 INLET SA-JER-DS011-TRJR-480031 t/h 55.64 82.96

FT-0015-EA F-0001 CRUDE PASS 5 INLET SA-JER-DS011-TRJR-480032 t/h 55.64 82.96

FT-0015-EB F-0001 CRUDE PASS 5 INLET SA-JER-DS011-TRJR-480032 t/h 55.64 82.96

FT-0015-EC F-0001 CRUDE PASS 5 INLET SA-JER-DS011-TRJR-480032 t/h 55.64 82.96

FT-0015-FA F-0001 CRUDE PASS 6 INLET SA-JER-DS011-TRJR-480032 t/h 55.64 82.96

FT-0015-FB F-0001 CRUDE PASS 6 INLET SA-JER-DS011-TRJR-480032 t/h 55.64 82.96

FT-0015-FC F-0001 CRUDE PASS 6 INLET SA-JER-DS011-TRJR-480032 t/h 55.64 82.96

FT-0015-GA F-0001 CRUDE PASS 7 INLET SA-JER-DS011-TRJR-480033 t/h 55.64 82.96

FT-0015-GB F-0001 CRUDE PASS 7 INLET SA-JER-DS011-TRJR-480033 t/h 55.64 82.96

FT-0015-GC F-0001 CRUDE PASS 7 INLET SA-JER-DS011-TRJR-480033 t/h 55.64 82.96

FT-0015-HA F-0001 CRUDE PASS 8 INLET SA-JER-DS011-TRJR-480033 t/h 55.64 82.96

FT-0015-HB F-0001 CRUDE PASS 8 INLET SA-JER-DS011-TRJR-480033 t/h 55.64 82.96

FT-0015-HC F-0001 CRUDE PASS 8 INLET SA-JER-DS011-TRJR-480033 t/h 55.64 82.96

TT-0097-A F-0001 CRUDE PASS 1 OUTLET SA-JER-DS011-TRJR-480034 C 372

TT-0100-A F-0001 CRUDE PASS 1 OUTLET SA-JER-DS011-TRJR-480034 C 390

TT-0097-B F-0001 CRUDE PASS 2 OUTLET SA-JER-DS011-TRJR-480035 C 372

TT-0100-B F-0001 CRUDE PASS 2 OUTLET SA-JER-DS011-TRJR-480035 C 390

TT-0097-C F-0001 CRUDE PASS 3 OUTLET SA-JER-DS011-TRJR-480036 C 372

TT-0100-C F-0001 CRU PASS 3 OUTLET SA-JER-DS011-TRJR-480036 C 390

TT-0097-D F-0001 CRU PASS 4 OUTLET SA-JER-DS011-TRJR-480037 C 372

TT-0100-D F-0001 CRU PASS 4 OUTLET SA-JER-DS011-TRJR-480037 C 390

TT-0097-E F-0001 CRU PASS 5 OUTLET SA-JER-DS011-TRJR-480038 C 372

TT-0100-E F-0001 CRU PASS 5 OUTLET SA-JER-DS011-TRJR-480038 C 390

TT-0097-F F-0001 CRU PASS 6 OUTLET SA-JER-DS011-TRJR-480039 C 372





TT-0100-F F-0001 CRU PASS 6 OUTLET SA-JER-DS011-TRJR-480039 C 390

TT-0097-G F-0001 CRU PASS 7 OUTLET SA-JER-DS011-TRJR-480040 C 372

TT-0100-G F-0001 CRU PASS 7 OUTLET SA-JER-DS011-TRJR-480040 C 390

TT-0097-H F-0001 CRUDE PASS 8 OUTLET SA-JER-DS011-TRJR-480041 C 372

TT-0098 F-0001 CRUDE PASS 1 TO 8 CONNECTION SA-JER-DS011-TRJR-480041 C 361 371

TT-0100-H F-0001 CRUDE PASS 8 OUTLET SA-JER-DS011-TRJR-480041 C 390

TT-0043 DS-0001 BFW SA-JER-DS011-TRJR-480042 C 360

TT-0091 F-0001 STRIPPING STEAM OUTLET SA-JER-DS011-TRJR-480042 C 403

TT-0359 F-0001 STRIPPING STEAM TO C-0002 SA-JER-DS011-TRJR-480042 C 345

TT-0360 F-0001 STRIPPING STEAM TO C-0002 SA-JER-DS011-TRJR-480042 C 155

PT-0131 F-0001 FUEL GAS FEED SA-JER-DS011-TRJR-480115 barg 0.05 2.2

PT-0132 F-0001 PILOT GAS FEED SA-JER-DS011-TRJR-480115 barg 0.4 1.4



PDT-0142 F-0001 PILOT GAS FEED SA-JER-DS011-TRJR-480115 bar 0.15

PDT-0143 F-0001 FUEL GAS FEED SA-JER-DS011-TRJR-480115 bar 0.15







PDT-0197 F-0001 PILOT GAS FEED SA-JER-DS011-TRJR-480116 bar 0.15

PDT-0198 F-0001 FUEL GAS FEED SA-JER-DS011-TRJR-480116 bar 0.15







PT-0150-A F-0001 CRU HTR

RADIANT HEADER BOX

SA-JER-DS011-TRJR-480117 mmH2O -11 -1

PT-0150-B F-0001 CRU HTR

RADIANT HEADER BOX


PT-0150-C F-0001 CRU HTR

RADIANT HEADER BOX


PT-0396 F-0001 CRUDE HEATER SA-JER-DS011-TRJR-480117 mmH2O -10 0

PT-0397-A F-0001 RADIANT HEADER BOX SA-JER-DS011-TRJR-480117 mmH2O -11 -1

PT-0397-B F-0001 RADIANT HEADER BOX SA-JER-DS011-TRJR-480117 mmH2O -11 -1

PT-0397-C F-0001 RADIANT HEADER BOX SA-JER-DS011-TRJR-480117 mmH2O -11 -1

FT-0070-A COMB AIR TO F-0001 SA-JER-DS011-TRJR-480121 t/h 17.13 24.47

FT-0070-B COMB AIR TO F-0001 SA-JER-DS011-TRJR-480121 t/h 17.13 24.47

FT-0070-C COMB AIR TO F-0001 SA-JER-DS011-TRJR-480121 t/h 17.13 24.47

FT-0074-A COMB AIR TO F-0001 SA-JER-DS011-TRJR-480121 t/h 17.13 24.47

FT-0074-B COMB AIR TO F-0001 SA-JER-DS011-TRJR-480121 t/h 17.13 24.47

FT-0074-C COMB AIR TO F-0001 SA-JER-DS011-TRJR-480121 t/h 17.13 24.47

PDT-0156 K-0003 FLUE GAS INDUCED FAN SA-JER-DS011-TRJR-480121 mmH2O 10

PT-0158 F-0001/ F-0002 HEATERS STACK SA-JER-DS011-TRJR-480121 mmH2O -30 0

PT-0161 E-0040 COMBUSTION AIR OUTLET SA-JER-DS011-TRJR-480121 mmH2O 20

TT-0032-A E-0040 FLUE GAS (SKIN) SA-JER-DS011-TRJR-480121 C 123

TT-0032-B E-0040 FLUE GAS (SKIN) SA-JER-DS011-TRJR-480121 C 123

TT-0032-C E-0040 FLUE GAS (SKIN) SA-JER-DS011-TRJR-480121 C 123

TT-0225 COMB AIR DUCT TO F-0001/0002 SA-JER-DS011-TRJR-480121 C 170 230

AT-0040 HEATER AIR FILTER SA-JER-DS011-TRJR-480270 95

AT-0045-A F-0001/ 0002 INTAKE AIR SA-JER-DS011-TRJR-480270 1 10

AT-0045-B F-0001/ 0002 INTAKE AIR SA-JER-DS011-TRJR-480270 1 10

PDT-0394 HEATER AIR FILTER SA-JER-DS011-TRJR-480270 bar 0.013

Table III.2-14: Alarms of Crude Heater Section





FV-0015-A F-0001 CRUDE PASS 1 INLET SA-JER-DS011-TRJR-480030

FV-0015-B F-0001 CRUDE PASS 2 INLET SA-JER-DS011-TRJR-480030

FV-0015-C F-0001 CRUDE PASS 3 INLET SA-JER-DS011-TRJR-480031

FV-0015-D F-0001 CRUDE PASS 4 INLET SA-JER-DS011-TRJR-480031

FV-0015-E F-0001 CRUDE PASS 5 INLET SA-JER-DS011-TRJR-480032

FV-0015-F F-0001 CRUDE PASS 6 INLET SA-JER-DS011-TRJR-480032

FV-0015-G F-0001 CRUDE PASS 7 INLET SA-JER-DS011-TRJR-480033

FV-0015-H F-0001 CRUDE PASS 8 INLET SA-JER-DS011-TRJR-480033

FV-0021 F-0001 STRIPPING STEAM TO C-0002 SA-JER-DS011-TRJR-480042

TV-0043 DS-0001 BFW SA-JER-DS011-TRJR-480042

FV-0069 F-0001 FUEL GAS FEED SA-JER-DS011-TRJR-480115

PV-0136 F-0001 FUEL GAS FEED SA-JER-DS011-TRJR-480115

FV-0076 F-0001 FUEL GAS FEED SA-JER-DS011-TRJR-480116

PV-0196 F-0001 FUEL GAS FEED SA-JER-DS011-TRJR-480116

PV-0395-A F-0001 STACK DAMPER SA-JER-DS011-TRJR-480117

PV-0395-B F-0001 STACK DAMPER SA-JER-DS011-TRJR-480117

FV-0070 COMBUSTION AIR TO F-0001 SA-JER-DS011-TRJR-480121

FV-0074 COMBUSTION AIR TO F-0001 SA-JER-DS011-TRJR-480121

HV-0015 F-0001/F-0002 DRAFT SA-JER-DS011-TRJR-480121

PV-0159 K-0003 FLUE GAS SUCTION SA-JER-DS011-TRJR-480121

TV-0032 E-0040/E-0041 AIR BYPASS SA-JER-DS011-TRJR-480121

TV-0223 LP STEAM TO E-0041 SA-JER-DS011-TRJR-480121

PV-0160-B E-0040 AIR DUCT TO F-0001 SA-JER-DS011-TRJR-480269

PV-0160-A E-0040 AIR DUCT TO F-0001 SA-JER-DS011-TRJR-480269

PV-0160-C E-0040 AIR DUCT TO F-0001 SA-JER-DS011-TRJR-480269

Table III.2-15: Control Valve of Vacuum Heater Section





PZV-0009 F-0001 STRIPPING STEAM OUTLET SA-JER-DS011-TRJR-480042

PZV-0010 F-0001 STRIPPING STEAM OUTLET SA-JER-DS011-TRJR-480042

Table III.2-16: Relief Valves of Crude Heater Section

III.2.5. Crude Distillation

PFD: SA-JER-DS011-TRJR-450002 (Base Case). The partially vaporized crude enters the Atmospheric Column C-0002 at the flash zone. Column total height is 60950 mm and has 57 trays. From tray #1 to #48 column diameter is 7800 mm and from tray #49 to tray #57 diameter is 5400 mm. Bottom internal stripping section diameter is 4800 mm. The feed inlet nozzle is located between trays #6 and #7. It includes a tangential distributor to correctly distribute vapor and adequately de-entrain heaviest components. Atmospheric column operating pressure varies from 1.6 barg (bottom) to 1.0 barg (top), and operating temperature from 354 C (bottom) to 119 C (top). In addition, the wild naphtha from the LP & HP HDS is processed in the Atmospheric Column. As the quality of these products is similar to a combined cut Naphtha + KERO, the wild naphtha is routed to the LAGO pumparound return line. Alternatively, the wild naptha could be sent to the inlet of Preflash Column C-0001. The crude distillation column is equipped with fractionation sections and pumparound sections with conventional trays to obtain the different crude cuts. These correspond to the following section arrangement, from top to bottom:

Naphtha / Kerosene fractionation zone Kerosene pumparound zone Kerosene / LAGO fractionation zone LAGO pumparound zone LAGO / HAGO fractionation zone




HAGO pumparound zone HAGO / FEED fractionation zone Bottom Stripping zone

III.2.5.1. Overhead The overhead vapor leaves the top at 119 C and condenses partially through the E-0003A-D. Then, it is totally condensed and cooled down in the A-0001A-H to 65C and directed to the CDU Reflux Drum D-0004 (at 03 barg and 65C). In the D-0004, the water is separated from the naphtha. The produced naphtha is pumped by the CDU Reflux Pumps 011-G-0005 A/B to be mixed with the Naphtha from Preflash Column C-0001 and directed through the E-0021 to the Total Naphtha Drum D-0005. Finally, the naphtha is pumped to the Naphtha Hydrotreating unit (NHDT) by Pumps G-0007 A/B, under flow control FC-0062, reset by the level controller LC-0030. Part of the naphtha flow is sent back as reflux to the column C-0002 under flow control FC-0019. The naphtha cut point is controlled by overhead temperature control TC-0101, which reset the reflux flow (FC-0019). The separated water is collected in the D-0004 boot. Then, it is directed to the Sour Water Recovery Drum D-0006 by gravity flow under interface level control LDC-0026. Each lateral product cut is sent to a side stripper (C-0004 Kerosene Stripper, C-0005 LAGO Stripper, and C-0006 HAGO Stripper). They are either stripped with superheated LP steam (for LAGO and HAGO) or reboiled (for KERO) to strip out the light ends. The stripping steam is feeding to the LAGO and HAGO Stripper under flow control by FC-0027 and FC-0028, respectively. Likewise, striping steam is injected continuously at the bottom of the column C-0002 under flow control by FC-0021. The LP steam is supplied form LPS header and superheated through the convection zone of the Crude Heater F-0001. The liquid level on the C-0004 Kerosene Stripper, C-0005 LAGO Stripper, and C-0006 HAGO Stripper is maintained by LC-0034, LC-0038 and LC-0040, respectively. These controllers act on the valves in the product stream from the column C-0002.




KERO and LAGO cuts are then sent to LP HDS Unit/ Storage by Kerosene product Pumps G-0009A/B and LAGO Product Pumps G-0011A/B respectively, and HAGO to the HP HDS Unit/ Storage by HAGO Product Pumps G-0013A/B. Because these units have reboiled (KERO) or steam stripping section of the effluents, there is no need to dry KERO, LAGO and HAGO products out of the distillation column before being sent to storage. The KERO, LAGO and HAGO products are under flow control FC-0039, FC-0140 and FC-0120 respectively. The column has 3 pumparound (KERO, LAGO and HAGO) allowing to extract heat at several thermal levels for crude preheat trains, and to provide heat for column reboiling in the fractionation section of NHDT (Unit 111), as well as for the Kerosene Stripper. Considering the required duty/temperature level the following heating media are used:

Naphtha Splitter Reboiler 111-E-0009: LAGO pumparound Naphtha Stripper Reboiler 111-E-0007 & Kerosene Stripper Reboiler 011-E-

0022: HAGO pumparound

III.2.5.2. Kerosene The Kerosene pumparound (KERO PA) is drawn off at tray #44. Kerosene Pumparound Pump, G-0008 A/B, circulates it through the exchangers E-0007A-D in the crude feed preheat train and returns to tray # 48. The KERO PA flow is maintained under flow control by FC-0003. The level of the KERO draw-off tray is controlled by LC-0010 which acts on flow control FC-0018 in the pumback reflux line of the G-0008A/B. A part of the draw-off is cascaded to the Kerosene Stripper, C-0004 (1.1 barg and 187C). This side stripper is equipped with ten two-pass trays and reboiler section to re-vaporization of light ends increasing the Naphtha recovery rate. Liquid from bottom tray is falling to reboiler sump area, and vapor from E-0022 reboiler return is entering from the opposite side of the C-0004 side stripper. The reboiling duty of C-0004 is controlled thanks to a temperature-flow cascade controller on E-0022. Temperature in the KERO stripper is controlled by TC-0121 acting on FC-0125. The KERO PA system condenses the Kerosene fraction; the duty removal in this section determines the Naphtha/KERO separation. A hot bypass across E-0007A-D is available to control the required KERO PA return temperature through controller TC-0024.




The stripped Kerosene from the C-0004 bottom is pumped by the Kerosene Product Pump G-0009A/B though the heat exchangers E-0008 and E-0001 of the crude preheat train, and cooler E-0023, to reduce the temperature before sending to BL.

III.2.5.3. LAGO LAGO pumparound (LAGO PA) is drawn off at tray #30. LAGO Pumparound Pump, G-0010 A/B, circulates it through the exchanger E-0013 in the crude feed preheat train and the NHDT Naphtha Splitter Reboiler 111-E-0009 (Unit 111), and returns to the column at tray #34. A part of the draw-off is cascaded to the LAGO Stripper, C-0005 (1.3/1.2 barg and 243/234C). This side stripper is equipped with six two-pass trays and steam stripped to enhance the Kerosene recovery rate. The LAGO PA system condenses the LAGO fraction; the duty removal in this section determines the KERO/LAGO separation. A hot bypass across E-0013 is available to control the required LAGO PA return temperature through controller TC-0112. The reboiling duty of Naphtha Splitter, 111-C-0002, is controlled thanks to a temperature-flow cascade controller on 11-E-0009. Temperature in the NHDT Splitter is controlled by 111-TC-0109 acting on 111-FV-0028. LAGO PA control loop in Unit 111 is always in operative conditions and 111-E-0009 is used during normal operation as it is designed to give the duty required for the 100% capacity (12.5 Gcal/h). The LAGO PA flow rate going to the NHDT Naphtha Splitter Reboiler should be maintained at around of 385 t/h by adjusting the set point of flow controller 111-FC-0028 and the bypass flow through PDV-0385 that bypass circulation through 111-E-0009 is 316 t/h. The total LAGO PA flow rate is maintained under flow control by FC-0023. The level of the LAGO draw-off tray is controlled by LC-0013 which acts on flow control FC-0024 in the pumback reflux line of the G-0010A/B. The stripped LAGO from the C-0005 bottom is pumped by the LAGO Product Pump G-0011A/B though the heat exchangers E-0011A/B, E-0006 and E-0024 of the crude preheat train and coolers A-0003A/B and E-0034, in order to reduce the temperature before sending to BL.




III.2.5.4. HAGO HAGO pumparound (HAGO PA) is drawn off at tray #15. HAGO Pumparound Pump, G-0012 A/B, circulates it through the NHDT Naphtha Stripper Reboiler 111-E-0007 (Unit 111) and return to CDU/VDU unit going to exchangers: E-0022 (KERO Stripper Reboiler); E-0017 A/B in the crude feed preheat train and finally returns to the column at tray #19. A part of the draw-off is cascaded to the HAGO Stripper, C-0006 (1.3 barg and 305 C). During normal operation, the HAGO pumparound flow to the Naphtha Stripper Reboiler 111-E-0007 is made by adjusting the flow controller 111-FC-0021 which is setting at 598 t/h and the bypass flow through PDV-0384 that bypass circulation through 111-E-0007 is 67 t/h. The total HAGO PA flow rate is maintained under flow control by FC-0013. The level of the HAGO draw-off tray is controlled by LC-0016 which acts on flow control FC-0022 in the pumback reflux line of the G-0012A/B. To avoid interferences between the flow controllers of CDU/VDU unit and NHDT unit in the HAGO pumparound line, it could be required to adjust 111-FC-0021 set point to 598.1 t/h, being the HAGO outlet temperature in this case 287 C in order to maintain the same duty. The HAGO PA system condenses the HAGO fraction; the duty removal in this section determines the LAGO/HAGO separation. A hot bypass across E-0017 A/B is available to control the required HAGO PA return temperature through controller TC-0079. The stripped HAGO from the C-0006 bottom is pumped by the HAGO Product Pump G-0013A/B though the heat exchangers E-0012A/B, E-0009A/B and E-0002 of the crude preheat train and coolers A-0004 and E-0035, in order to reduce the temperature before sending to BL.

III.2.5.5. Atmospheric Residue The Atmospheric residue is collected in the bottom of the C-0002. Then, it is pumped by the Atmospheric Residue Pumps G-0014 A/B to the Vacuum Heater F-0002. The bottom liquid level is controlled by LC-0020, which resets the vacuum heater flow master controller FC-0033A/B. These control the total flow of all the passes through the heater. To protect the pumps in the event of very low flow rate, an independent flow




controller FC-0032 opens the recirculation valve FV-0032 for returning the Atmospheric Residue to the column. An external overflash draw-off is implemented to measure the overflash flow rate. With this measurement it is possible to verify the fractionation between HAGO and Atmospheric Residue. Reference P&IDs SA-JER-DS011-TRJR-480043 through 480047 SA-JER-DS011-TRJR-480052 through 480066


FC-0018 C-0002 KERO REFLUX SA-JER-DS011-TRJR-480043 t/h 133.4

FC-0019 C-0002 NAPHTHA REFLUX SA-JER-DS011-TRJR-480043 t/h 97.2

FC-0023 C-0002 LAGO PA RETURN SA-JER-DS011-TRJR-480043 t/h 700.8

LC-0010 C-0002 ATMOSPHERIC COLUMN TRAY 44 SA-JER-DS011-TRJR-

480043 % 50

TC-0101 C-0002 NAPHTHA TOP OUTLET SA-JER-DS011-TRJR-

480043 C 119

FC-0022 C-0002 HAGO REFLUX SA-JER-DS011-TRJR-480044 t/h 228.8

FC-0024 C-0002 LAGO REFLUX SA-JER-DS011-TRJR-480044 t/h 194.7


480044 % 50


480044 % 50

LC-0020 C-0002 ATMOSPHERIC COLUMN BOTTOM SA-JER-DS011-TRJR-

480044 % 50

AC-0019 D-0004 SOUR WATER pH SA-JER-DS011-TRJR-480046 6

LC-0024 D-0004 CDU REFLUX DRUM SA-JER-DS011-TRJR-480046 % 83


PC-0033 D-0004 CDU REFLUX DRUM SA-JER-DS011-TRJR-480046 barg 0.3

FC-0025 G-0005-A/B NAPHTHA DISCHARGE SA-JER-DS011-TRJR-

480047 t/h 74.4

FC-0125 E-0022 HAGO PA INLET SA-JER-DS011-TRJR-480052 t/h 214.6

LC-0034 C-0004 KERO STRIPPER SA-JER-DS011-TRJR-480052 % 50

PDC-0046 E-0022 HAGO PA BYPASS SA-JER-DS011-TRJR-480052 bar 1.0

TC-0121 E-0022 KERO OUTLET SA-JER-DS011-TRJR- C 214





480052

FC-0027 C-0005 STRIPPING STEAM SA-JER-DS011-TRJR-480054 t/h 2.4

LC-0038 C-0005 LAGO STPR SA-JER-DS011-TRJR-480054 % 50

FC-0028 C-0006 STRIPPING STEAM SA-JER-DS011-TRJR-480056 t/h 2.2

LC-0040 C-0006 HAGO STPR SA-JER-DS011-TRJR-480056 % 50

FC-0029 E-0023 KERO OUTLET TO STORAGE SA-JER-DS011-TRJR-

480058 t/h 13.4

FC-0118 KERO TO LP HDS SA-JER-DS011-TRJR-480058 t/h 120.1

FC-0030 E-0034 LAGO OUTLET TO STORAGE SA-JER-DS011-TRJR-

480060 t/h 12

FC-0119 LAGO TO LP HDS SA-JER-DS011-TRJR-480060 t/h 108.3

FC-0140 E-0034 LAGO OUTLET SA-JER-DS011-TRJR-480060 t/h 120.3

FC-0120 E-0035 HAGO OUTLET SA-JER-DS011-TRJR-480062 t/h 108.9

FC-0032-A G-0014-A/B C-0002 ATM RES REC SA-JER-DS011-TRJR-

480066 t/h 240

HC-0020 VAC RESIDUE FROM 011-G-0018-A/B SA-JER-DS011-TRJR-

480066 t/h 559.7

PC-0446 HAGO+LVGO TO BL SA-JER-DS011-TRJR-480132 barg 7.0

PDC-0384 HAGO PA FROM/TO NHDT UNIT 111 SA-JER-DS011-TRJR-

480134 bar 2.3

PDC-0385 LAGO PA FROM/TO NHDT UNIT 111 SA-JER-DS011-TRJR-

480140 bar 2.5

Table III.2-17: Controllers of Crude Distillation Section TAG NUMBER SERVICE P&ID UNITS LL L H HH

LT-0010 C-0002

ATMOSPHERIC COLUMN TRAY 44

SA-JER-DS011-TRJR-480043 % 26.5 70

LT-0012 C-0002


SA-JER-DS011-TRJR-480043 % 5.5

PT-0029-A C-0002 NAPHTHA TOP OUTLET SA-JER-DS011-TRJR-480043 barg 0.6 0.8 1.6 2.1

PT-0029-B C-0002 NAPHTHA TOP OUTLET SA-JER-DS011-TRJR-480043 barg 0.6 0.8 1.6 2.1

PT-0029-C C-0002 NAPHTHA TOP OUTLET SA-JER-DS011-TRJR-480043 barg 0.6 0.8 1.6 2.1

TT-0245 C-0002 NAPHTHA TOP OUTLET SA-JER-DS011-TRJR-480043 C 142

LT-0013 C-0002


SA-JER-DS011-TRJR-480044 % 28.8 87.5





LT-0015 C-0002


SA-JER-DS011-TRJR-480044 % 5.63

LT-0016 C-0002


SA-JER-DS011-TRJR-480044 % 28.5 86.8

LT-0018 C-0002


SA-JER-DS011-TRJR-480044 % 5.3

LT-0020 C-0002

ATMOSPHERIC COLUMN BOTTOM

SA-JER-DS011-TRJR-480044 % 20 80

LT-0021 C-0002

ATMOSPHERIC COLUMN BOTTOM

SA-JER-DS011-TRJR-480044 % 5 95

FT-0114 D-0004 VAPOR TO FLARE SA-JER-DS011-TRJR-480046 t/h 5.4

LT-0022 D-0004 CDU REFLUX DRUM SA-JER-DS011-TRJR-480046 % 5

LT-0024 D-0004 CDU REFLUX DRUM SA-JER-DS011-TRJR-480046 % 72.5 92.5

TT-0120 C-0004 KERO TO C-0002 SA-JER-DS011-TRJR-480052 C 200

TT-0363 C-0005 STRIPPING STEAM SA-JER-DS011-TRJR-480054 C 345

TT-0366 C-0006 S

CDU-VDU Operating Manual

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