Operating Manual Rev. 0 Vol i of III

Doc. No.: 2317 OPERATING MANUAL FOR LLDPE/HDPE Rev. 0 SWING UNIT, IOCL PANIPAT of 623

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All Rights Reserved

PREFACE

This operating manual for LLDPE/HDPE SWING PLANT of INDIAN OIL CORPORATION LIMITED has been prepared by M/s Engineers India Limited.

The operating manual is written in accordance with documents provided by process licensors

(NOVA), project specifications. The manual includes Design basis, Feed & Product

specifications, Operating Conditions and control, description of facilities and critical equipment

and sequence of activates for normal operation, start-up, shutdown & emergency handlings.

For detailed specifications and operating procedures of specific equipment, corresponding

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



TABLE OF CONTENTS

SECTION DESCRIPTION PG. NO.

Preface 1

1.0 Introduction 12

2.0 Design Basis of Unit 15

2.1 Introduction 16

2.2 On-Stream Factor 16

2.3 Unit Capacity 16

2.4 Turndown Capability 17

2.5 Feed Stock Specifications 18

2.6 Raw Material Specifications 21

2.7 Battery Limit conditions of Process Lines 34

2.8 Utility Conditions at Battery Limit /At Tie-in Points 35

2.9 Utility Summary 37

3.0 Process Chemistry 38

3.1 Catalyst Theory 39

3.1.1 Introduction 39

3.1.2 Sclairtech Catalyst 39

3.1.3 Catalyst Chemistry 39

3.1.4 Role of the Catalyst in Reaction Kinetics 41

3.1.5 Economic Optimization 43

3.1.6 Standard Catalyst 44

3.1.7 Heat Treated Catalyst 56

3.1.8 Butene-1 in the Catalyst Diluent 62

4.0 Process Description 64

4.1 Reaction Area 65

4.1.1 Recycle Solvent Purification 66

4.1.2 SH Purifier Regeneration 68

4.1.3 SH Makeup Dryer system 70

4.1.4 Solvent Pumping and Catalyst/Deactivator Diluents Supply 70

4.1.5 Hydrogen (J) Telogen System 72

4.1.6 Reactor Feed Tempering 73

4.1.7 Reactor Modes 74

4.1.8 Catalyst System 75



TABLE OF CONTENTS


4.1.9 Deactivator System 78

4.1.10 Preheating and Adsorption 80

4.1.11 PA Charging and Spent PA Removal 83

4.1.12 Polymer Separation 85

4.2 Recycle Area 87

4.2.1 Vapour Recovery 87

4.2.2 Distillation 90

4.3 Finishing Area 107

4.3.1 General Finishing Area Overview 107

4.3.1.1 Process Description 107

4.3.1.2 RA Extrusion 111

4.3.1.3 Vent Device System 126

4.3.1.4 Underwater Pelletizer 127

4.3.1.5 Die Plate Heating and Cooling 131

4.3.1.6 Automatic Die Freezing 131

4.3.1.7 Satellite Extruder 133

4.3.1.8 Solid Additive & Satellite Extruder Feed System 135

4.3.1.9 Additives 139

4.3.1.10 RA Stripper & Associated Equipments 146

4.3.1.11 PCW/Slurry Water System 153

4.3.1.12 Equipment Associated with RA Stripper 161

4.3.1.13 Blender Sampling System 166

4.3.1.14 Resin Conveying & Associated System 168

4.3.1.15 Area Skim Sumps 187

4.4 ISBL Utilities and Storage 188

4.4.1 Plant Air 188

4.4.2 Instrument Air 188

4.4.3 Pulldown Valve Air Supply 188

4.4.4 Nitrogen 188

4.4.5 Service, Demineralised and Potable Water 188

4.4.6 Cooling Water and Emergency Cooling Water 188

4.4.7 Boiler Feed Water 189

4.4.8 Dowtherm System 189

4.4.9 Steam and Condensate System 190

4.4.10 Flare System 191

4.4.11 De-inventory Storage 191



TABLE OF CONTENTS


5.0 Pre-Start-up Checks 194

5.1 Check list for Columns, Reactors and Vessels 195

5.2 Check list for Heat Exchangers 196

5.3 Check list for Fans and Blowers 196

5.4 Check list for Heaters 197

5.5 Check list for Agitators and Mixers 198

5.6 Check list for Centrifuges 199

5.7 Check list for Pumps 200

5.8 Check list for Safety valves and Rupture Discs 201

5.9 Check list for Piping 202

5.10 Check list for Valves 203

5.11 Check list for Steam traps 204

5.12 Check list for Tanks(Fixed roof type for Hydrocarbons) 204

5.13 Check list for Floating roof tanks (Hydrocarbon) 206

5.14 Check list for Insulation 206

5.15 Check list for Turbines 207

5.16 Check list for Compressor 208

5.17 Check for Rotary Feeder 208

5.18 Check for Cartridge Filter 209

5.19 Check List for Screw Conveyor 209

6.0 Pre-commissioning Procedure 210

6.1 General 211

6.2 Pre-Commissioning Activities 212

6.2.1 Introduction 212

6.2.2 Inspection 212

6.2.3 Preparation of Unit 213

6.2.4 Pipe Cleaning and Flushing 214

6.2.5 Tightness Test 216

6.2.6 Functional Test 216

6.2.7 Refractory Drying 217

6.2.8 FILLING OF ALUMINA/SILICA GEL PURIFIERS/GUARDBEDS 218

6.2.9 Drying, Purging and Inerting 218

6.3 Equipment Operating Procedure 219

6.3.1 Centrifugal Pumps 219

6.3.2 Positive Displacement Pumps 221



TABLE OF CONTENTS


6.3.3 Centrifugal Compressors 223

6.3.4 Heat Exchangers 225

6.3.5 Fired Heaters 226

6.3.6 Agitators 226

6.3.7 Ejectors 227

7.0 Start-up Procedure 229

7.1 Overall Plant Start-up Block Diagram & Procedure 230


7.2.1 Polymerization Start-up 237

7.2.2 Start-up of SH Purification System 241

7.2.3 Taking Standby SH Purifier In-line 243

7.2.4 Start-up of SH Purifier Regeneration System 245

7.2.5 Start-up of FE Feed System 247

7.2.6 Taking Standby primary FE Guardbed In-line 249

7.2.7 FE Gaurdbed Regeneration Start-up 251

7.2.8 CAB System Start-up 253

7.2.9 CAB-2 System Start-up 255

7.2.10 CD System Start-up 257

7.2.11 CT System Start-up 259

7.2.12 CJ System Start-up 261

7.2.13 Catalyst Knock Out Drum (31-V-115) Start-up 263

7.2.14 Deactivator System Start-up 264

7.2.15 SH Make-up Dryer Start-up 266

7.2.16 SH Make-up Regeneration 267

7.2.17 Absorption System and Reactor Feed Pump Start-up 268

7.2.18 Taking Standby Adsorber In-line 269

7.2.19 “j” system start-up procedure 275

7.2.20 Hydrogen Buffer Storage Start-up Procedure 277

7.3 Recycle Area 278

7.3.1 LB Column System Start-up 278

7.3.2 HB Column System Start-up 286

7.3.3 RB Column System Start-up 291

7.3.4 FE Column System Start-up 294

7.3.5 CM Column System Start-up 298

7.4 Finishing Area Start-up 301

7.4.1 Low Pressure Separator Start-up 301



TABLE OF CONTENTS


7.4.2 LPS Knock Out Pot Start-up 303

7.4.3 Extruder Start-up 304

7.4.4 Hot Oil System Start-up 307

7.4.5 Satellite Extruder Start-up 308

7.4.6 Satellite Extruder Feed System Start-up 310

7.4.7 Fines Separator System Start-up 310

7.4.8 Water Circulation System Start-up 311

7.4.9 RA Stripper System Start-up 313

7.4.10 Additive Holding Tank Start-up 316

7.5 Utility Area Start-up 317

7.5.1 DTA System Start-up 317

8.0 Normal Operating Procedures 323

8.1 Operating Parameters 324

8.2 List of Instruments 339

8.2.1 Control Valves 339

8.2.2 Analysers 347

9.0 Shutdown Procedure 348

9.1 Normal Plant shutdown 349

9.2 Area wise Plant Shutdown 353

9.2.1 Reaction Area Shutdown 353

9.2.2 Recycle Area Shutdown 357

9.2.3 Finishing Area Shutdown 364

9.2.4 Utility Area Shutdown 368

10.0 Plant Troubleshooting Procedure 369

10.1 LB Feed Condenser 370

10.2 Distillation System 370

10.3 Hot Flush System 370

10.4 Catalyst System 371

10.5 Reaction Feed Tempering System 371

10.6 IPS/LPS Vessels 372

10.7 Main Extruder System 372

10.8 Satellite Extruder System 373

10.9 Underwater Pelletizer System 374



TABLE OF CONTENTS


10.10 Liquid Additive System 376

10.11 Blenders and Associated Equipments 377

10.12 Stripper System 380

10.13 Fines Separator 383

10.14 Packing Silos System 383

10.15 Wearhouse Bag Slitter System 383

10.16 Flare System 384

10.17 Delumper System 384

10.18 FE Guardbed System 384

10.19 DTA System 385

10.20 SH System 385

11.0 Alarms and Trips 386




11.4 Utility Area 401

12.0 Operating Condition For Different Operating Cases 407

13.0 Effect of Operating Variables 418

13.1 Introduction 419

13.2 Parameters 419

13.2.1 Basic Control Parameters 420

13.3 Common Control Elements 433

13.3.1 FE Conversion Determination 433

13.3.2 Conversion Control and Active Catalyst Formation 434

13.3.3 Density Control 434

13.3.4 Molecular Weight and Molecular Weight Distribution 435

13.3.5 Melt Index Control (MI) 436

13.3.6 Stress Exponent Control (SE) 437

13.4 #1 Reactor Control 438

13.4.1 System Description 438


13.4.3 Melt Index 443

13.4.4 Combined Melt Index (MI) and Density Control 446



TABLE OF CONTENTS


13.4.5 Stress Exponent 447

13.4.6 Theoretical Model of Mixing in No. 1 Reactor 448

13.5 3→1 Reactor Control 455

13.5.1 3→1 Conversion Control (Q and Q3) 455

13.5.2 Density 458

13.5.3 Melt Index 460

13.5.4 Stress Exponent 467

13.5.5 Other Parameters 469

13.6 Reactor #3 + #1 Control 475

13.6.1 System Description 475


13.6.3 Melt Index Control 476

13.6.4 Stress Exponent Control 476

14.0 Safe Shutdown System 479

14.1 SPI (Solution Pumping Interlock) 480

14.1.1 Cause of Activation of SPI 480

14.1.2 Effect of SPI Activation 480

14.2 LOS (Light Off Switch) 481

14.2.1 Description 481

14.3 “Z” Trip (Plant Wide Feed Forward Shutdown) 482

14.3.1 Description 482

14.3.2 Effect of “Z” tripping 482

14.3.3 “Z” Button Activation 482

14.3.4 “Z” Button Reset 487

15.0 List of Emergencies and Emergency Handling Procedure 489

15.1 Electrical Power Failure 490

15.1.1 Electrical Power Failure 490

15.1.2 Complete Main Electrical Power Failure 490

15.1.3 Electrical Power Failure (Monetary Duration) 490

15.1.4 Electrical Power Failure (Extended Duration) 491

15.1.5 Uninterruptible Power Supply 491

15.1.6 Emergency Building Lights 492

15.2 Instrument Air Failure 492



TABLE OF CONTENTS


15.3 Steam Failure 492

15.4 Refrigerant Failure 494

15.5 Cooling Water Failure 495

15.6 Reactor Feed Pump Failure 496

15.7 Emergency Valve 497

15.8 Boiler Feed Water Failure 498

15.9 DTA Failure 499

15.10 Exchanger Tube Failure 500

15.11 Reaction Feed Tempering System Failure 500

15.12 Nitrogen Failure 500

15.13 #1 Reactor Agitator Tripping 501

15.14 RA Stripper High Temperature 501

15.15 RA Stripper High Pressure 502

15.16 Loss of Stripping Steam to RA Stripper 502

15.17 High Temperature Spin Dryer or Hold-up Bin 503

16.0 Catalyst and Chemical Requirement 504

17.0 Equipment List 507

17.1 Pumps 508

17.2 Vessels 509

17.3 Columns 513

17.4 Heat Exchanger (Tubular) 513

17.5 Heat Exchanger (Air Cooled) 516

17.6 Heat Exchanger (Plate Type)

17.7 Compressors/Blowers 517

17.8 Heaters 517

17.9 Filters 517

17.10 Sumps 519

17.11 Agitators 519

17.12 HX Items 520

18.0 Relief Valve Summary 526




18.4 Utility Area 534



TABLE OF CONTENTS


19.0 Blind List 536

20.0 Special Procedure and Information 570

20.1 FE Column & LB Reflux Drum Boot leg Draining Procedure 571

20.2 Temporary Pump Strainer Cleaning Procedure 571

20.3 Draining Procedure of 31-V-205 572

20.4 LPS HUT/LB Reflux Drum Boot Draining Procedure 572

20.5 Heat Exchanger Backflushing (On Opportunity) 572

20.6 Procedure for Catalyst Cylinder Disconnection 573

20.7 Draining of Catalyst/Co-Catalyst Mix Tank Boot and Deactivation 574

20.8 Pelletizer Cutter Change Procedure 575

20.9 Vent Device Collection Pot Draining Procedure 578

20.10 Resolution of HAZOP points 579

21.0 Lubrication Schedule 583

22.0 Hydrocarbon Detector Summary 589

23.0 Fire and Safety System 593

23.1 Fire Water System 594

23.2 Deludge System 596

23.3 Foam System 599

23.4 Fire Extinguisher 599

24.0 Sampling Procedure and Schedule 601

24.1 Liquid Sampling Procedure 602

24.2 Gas Sampling Procedure 603

24.3 Solid Sampling Procedure 604

24.4 Sampling Schedule 605

25.0 Procedure for Preparation of Equipment Handover 610

25.1 Preparation of Equipment for Maintenance 611



TABLE OF CONTENTS


26.0 Work Permit Procedures 613

26.1 Work Permit System 614

26.2 Types of Work Permit 614

26.3 Guidelines for Release of Permits 614

26.4 Preparation for Vessel Entry 614

27.0 Chemical Solution Preparation Procedure 619

27.1 Catalyst Batch Make-up 620

27.2 Liquid Additive Make-up Procedure 621



SECTION-1.0 INTRODUCTION



1.1 BRIEF PROCESS DESCRIPTION

The plant is divided into four basic process areas:

1.1.1 Reaction Area (Area 100) 1.1.2 Recycle Area (Area 200) 1.1.3 Finishing Area (Area 300) 1.1.4 Utilities Area (Area 400)

The brief descriptions of the three basic processing sections are as under:

1.1 Reaction Area (Area 100): • The process solvents, Cyclohexane (SH), recycled from the recovery area and is combined with

comonomer, Butene-1 (FB-1) and or Octene-1 (FC-1) and pumped to the absorber cooler.

• High purity Ethylene (FE) is dissolved at the absorber cooler in the solvent/comonomer stream to

form the reactor feed solution. This solution is pumped under high pressure to the reactor. The feed

stream is tempered to achieve precise control of the reaction feed temperature. Then the solution

catalytically reacted to produce polyethylene in solution.

• Purification systems are provided at strategic points to remove trace impurities from all feeds to the

reaction and the catalyst preparation systems.

• The reaction area includes two main reactors: a pipe reactor (31-R-102, No. #3 Reactor, HX-121)

and a stirred autoclave reactor (31-R-101, No. #1 Reactor, DC-101) as well as a final trimmer

reactor. The product resin properties are manipulated by controlling the quantity, type and injection

points of catalyst and the quantity and injection points of hydrogen. The catalyst caused the

ethylene and comonomer to polymerise exothermically which raises the solution temperature.

Hydrogen is used as a Telogen (chain terminator) to control the molecular weight and the resultant

Melt index of the product resin.

• The liquid steam leaving the trimmer reactor contains Polyethylene (RA) dissolved in SH together

with unreacted FE and commoners. Deactivator is then added to terminate the reaction and the

solution is passed through the Adsorber Preheaters (31-E-105A/B) to provide the thermal energy

needed for catalyst removal and for subsequent solvent separation. Addition of deactivators as well

as heat at the solution preheater promotes efficient catalyst removal in the Solution Adsorbers (31-V-

104A/B) due to the formation of a chelate.

• The Solution is then depressurised in stages causing solvent, unreacted ethylene and comonomers

to flash off, leaving molten polymer (RA) containing residual amounts of hydrocarbons. The flashed

vapors are sent to the recycle area and the polymer steam is sent to the finishing area.

1.2.2 Recycle Area (Area 200): The vapors streams leaving the reaction area containing SH, FE, comonomers, by-products and inerts are

further separated in this area. The major streams leaving this area are as follows:

Recycle Solvent (SH): The solvent stream contains recovered unreacted FC-1 when FC or Terpolymer resins are being produced.



High Purity Solvent (SH): For diluting the catalyst and co-catalyst in the mix tanks, a secondary solvent feed is provided. This

secondary source of solvent provides a supply of impurity free solvent to be used in the catalyst preparation

systems.

Recycle FB-1 FB-2 (Butene-2) which is formed due to isomerisation of FB-1 in the reaction area and that present in the FB

make-up is routed to the OSBL (C4 Mix Tank). Recycle FC-1 Low molecular weight polyethylene (RB) otherwise known as “grease” is used as a liquid fuel for the DTA

vaporisers. During FC/Terpolymer runs this streams will also contain FC-2 (octene-2) formed from the

isomerisation of FC-1 as well as any FC-2 present in the FC make-up. Other impurities are purged to waste

or flare.

1.2.3 Finishing Area (Area 300):

The polymer separated from the solvent and other components in the reaction area is further purified and

processed into finished product.

The polymer, RA containing residual hydrocarbons is extruded and cut into pellets. Additives may be

injected in liquid form either into the phase separation area (solvent flash) or into the extruder barrel. Solid

additives or recycle polymer can be added to the main extruder via a satellite extruder.

The residual hydrocarbons in the RA pellets are removed in the resin stripper by countercurrent flow of

steam. A condenser is provided to recover these hydrocarbons for return to the process. RA is then sent to

the blenders for blending to make a homogeneous production lot. Once blended, the RA is ready for

packaging.

1.2.4 Utility Area (Area 400):

The Area includes DTA Vaporiser, Recovery and Regeneration System, Nitrogen Heating System, Flare K.

O. Drum System, SH De-inventory Tank, FB Makeup and De-inventory System, FC De-inventory and FC

purification System.



SECTION-2.0 DESIGN BASIS OF UNIT



2.1 INTRODUCTION

The LLDPE/HDPE swing unit is used to produce various grades of Resins by varying the configuration of the

reactor system, the feed rate, and type and injection point of catalyst.

2.2 ON-STREAM FACTOR

The facility is designed for 8000 operating hours per year.

2.3 UNIT CAPACITY

The LLDPE/HDPE swing unit is designed for a capacity of 350000 TPA of polyethylene.

Unit capacity is dependent on product mix produced, since the production rate varies according to the resin

being synthesised.

Unit capacity is defined as:

Licensed capacity (tones per year) = R x 8000

Where R is the weighted average production rate (tones/hr)

∑/

Where ni= % sales for resin

Where Ri= guaranteed rate for resin, I (tons/hr)

Annual Capacity : 350kTA

Total Solution Rate : 252 t/hr

NOTE: Values shown in shaded rows in table below are used in the material balance for the plant design.



2.4 TURNDOWN CAPABILITY

The facility is capable of operating at 50% of the designed feed capacity, while maintaining the designated

product specification.

Design Case

Type Resin Sale% MI Density SEx Design RA (t/hr)

Guar. RA(t/hr)

LLDPE

I Film 11Q4 10.1 0.72 0.92 1.33 45.46 43.19

Film 11U4 10.1 1.35 0.9225 1.33 46.10 43.79

Film 11K1 5.1 1.35 0.921 1.33 45.76 43.47

VI Film 11L2B 15.1 0.72 0.92 1.31 46.29 43.97

Film 11G1 0 0.72 0.92 1.31 46.29 43.97

Film 11J1 0 0.95 0.92 1.32 46.38 44.06

IM 2111 2.8 19.2 0.9245 - 48.04 45.64

IM 2114 2.8 52.0 0.9245 - 49.52 47.04

RM 8107 6.9 4.8 0.925 1.26 47.25 44.89

W&C 31E 3.8 11.5 0.9215 1.26 49.44 46.97

II Ext. Coat 61B 1.9 11.5 0.922 1.23 49.34 46.87

Drip Tube 11U4 1.9 1.35 0.9225 1.33 46.10 43.79

B/M 55A 1.3 1.8 0.939 1.29 47.16 44.80

Netting 94D 1.3 1.77 0.936 1.30 47.99 45.59

HDPE

Raffia 99A 11.1 0.72 0.961 1.80 40.21 38.20

Raffia 97C 3.7 31.5 0.951 - 52.53 49.90

III IM 2712 4.6 31.5 0.951 - 52.53 49.90

IM 2710 0 17.2 0.951 - 52.48 49.85

IM 2908 4.6 7.0 0.9605 1.28 51.52 48.94

Film 19A 3.7 0.72 0.9615 1.82 41.33 39.27

RM 8606 3.7 3.6 0.948 1.26 49.89 47.40

BM 58A 1.5 0.41 0.9565 1.91 41.44 39.36

V BM 59A 1.5 0.72 0.9615 1.82 40.6* 38.37

W&C 47B 0.7 0.62 0.953 1.95 42.26 40.14

Pipe 51-35B 0.7 0.32 0.942 1.69 39.97 37.97

Pipe coat 51-35BP 1.1 0.38 0.9409 1.70 40.03 38.03



2.5 FEED STOCK SPECIFICATIONS:

ETHYLENE:

CHARACTRISTICS UNITS OF MEASURE

TEST AIM LOWER UPPER

Ethylene vol% 99.95

Hydrogen vppm 2

Nitrogen vppm 100

Methane+ethane vppm 500

Ethane vppm 300

Acetylene vppm 1

Propylene+havier vppm 10

CO* vppm 0.03

CO2* vppm 5

O2* vppm 1

Water* vppm 1

Total Sulphur as H2S* vppm 1

Methanol* vppm 10

Phosphine* vppm 0.03

Ammonia* vppm 1

Other polar impurities* vppm 1

*combined total of all poisons not to exceed 10 wppm.

SPEC. NO. NAME CODE

STPA-01I ETHYLENE FE

STPA-02I BUTENE-1 FB-1

STPA-03I OCTENE-1 FC-1

STPA-14I HYDROGEN J



BUTENE – 1:



Butene-1 wt% 98.5 99.2

n-butane & butane-2 wt% 1.3

Isobutene wt% 0.2**

Isobutene wt% 0.11

Other alpha olefins (not ethylene) wt% 1.5

Butadiene wppm 1000

Acetylene wppm 10

Water wppm 25

Peroxide wppm 1

Hydrogen vppm 10

Methanol* wppm 10

CO* wppm 5

CO2* wppm 10

Ethers (as MTBE)* wppm 10

TBA* wppm 10

DMA* wppm

DMF* wppm

Carbonyls(as acetaldehyde)*

wppm 10

Sulphur wppm 5

Sulphur+oxygen wppm 10

chloride wppm 10

*Combined total of all poisons: <25 wppm

**Butene-1 consumption guarantees based on 0.1wt% (maximum) isobutene.



OCTENE-1:



C8 hydrocarbon wt% 100 99

Mono-olefins wt% 100 99

Linear alpha-olefins wt% 95

Water wppm 25

Peroxide wppm 2

Sulphur (as H2S) wppm 5

Chloride wppm 5

Carbonyls (as acetaldehyde) vppm 10

Methyl Alcohol wppm 10

Appearance clear

Note: Higher alpha olefins such as hexane and octane will form peroxides in the presence of oxygen. To

avoid oxygen contamination octene-1 can be shipped in LPG type containers. Bulk shipping of octene-1 will

increase the potential for peroxide formation and will require the installation of a purification system.

HYDROGEN:



Hydrogen purity vol% 99.9

Water vppm 5

O2 vppm 5

CO vppm 3

CO2 vppm 5

Carbonyls vppm 0.5

Total Sulphur (as H2S) vppm 1

NH3 and amines vppm <1 1

Mercury Micro g/ m3 1

Balance of material

Methane

Ethane

Nitrogen

Argon



2.6 Raw Material Specifications:

RAW MATERIAL SPECIFICATION NO.: STFA-03

RAW MATERIAL NAME: G84-25

Ingredients: Viton Freeflow 10.

Base Resin: Sclair 11E1

CHARACTRISTICS UNITS OF MEASURE TEST AIM LOWER UPPER

*Contamination Rating H0398 None

*Colour Rating Visual O.K.

Avg. Pellet Size gr/30pel H0001 0.8 0.6 1.0

Volatiles wt% H0064 0.00 0.00 0.15

(Fluro Polymer Level) % calculated 25 24 26

Note: There are no upper and lower limits to contamination and colour.


RAW MATERIAL NAME: Irganox 1330 FF or Ethanox 330

NOVA CODE: AO3


Color (10% w/v in Toluene) % T @ 425 nm AAM-5736 - - -

Color (10% w/v in Toluene) % T @ 500 nm AAM-5736 - - -

Melting Point difference °C AAM-5293 0.0 - -

Purity (Assay) wt % AAM-5738 100.0 - -

Volatiles @105°C wt % AAM-5739 0.0 - -

Clarity of solution AAM-5828 10% w/v in Toluene – clear

@ Room Temp

Appearance AAM-5828 White crystalline powder


RAW MATERIAL NAME: Kemamide E Ultra (Erucamide)



Color (Grad) Rating AOCsdd1a-64 1 0 2

Acid value Rating AOCste18-64 0 0 1

Moisture % AOCstb2a-64 0.00 0.00 0.25

Amide % AOCstf1b-64 100 98 100

Iodine value Ratinng AOCstg1a-64 73.5 71 76

Melt Point °C AOCscc1-25 82.5 80 85




RAW MATERIAL NAME: CYASORB UV-531 or CHIMASSORB 81 Light Absorber

NOVA CODE: UV1



Appearance Rating Visual Passes

Freezing Point °C Thermal

Analysis

47.2 47.0 47.7

Water (Moisture) % KF Moisture 0.02 0.00 0.05

Toluene Insolubles % Gravimetric 0.013 0.00 0.10

*Transmission-initial (10% in toluene) % UV VIS 97 91 -

*Transmission (stability test) % UV VIS 93 80 -

* There is no upper limit for these tests. RAW MATERIAL SPECIFICATION NO.: STFA-13

RAW MATERIAL NAME: CYASORB UV-3346 (PASTILLES)

NOVA CODE: UV2

CHARACTERISTICS UNITS OF

MEASURE


Color Rating UV-VIS 145 0 300

Loss on drying

%

Evaporation

0.22

0

0.50

Toluene insolubles

%

Gravimetric

0.02

0

0.25


RAW MATERIAL NAME: IRGANOX 1010 FF

NOVA CODE: AO8



Appearance Rating Visual White to off-white granules

Clarity of Solution Rating 10 gin 100 ml

toluene

clear

solution

Transmittance (425mm) % 10 gin 100 ml

toluene

100 93 100




RAW MATERIAL NAME: S3-40

NOVA CODE: S3-40

RAW MATERIAL SPECIFICATIONS: Ingredients: Super floss Di-atomaceous silica

Base Resin: HPLDPE resin with MI 4.5, density 0.922



Melt Index gm/10min K1a 1.1

0.6 1.6

Ashable content %wt K1g 40.00% 39.25% 40.75%

*Yellow index MAC ADAM K1b 15.0 - 25.0

*Grey index MAC ADAM K1c 35.0 - 45.0

Moisture (Volatiles) %wt K1f 0.0% 0.0% 0.05%

ASTM 01921-89

Sieve analysis

#5 screen % 0 0 5

#7 screen % 100 90 100

#9 screen % 0 0 3

* There is no lower limit for yellow or gray index. Any value under 25 for yellow index and any value under

45 for gray index is acceptable. RAW MATERIAL SPECIFICATION NO.: STFA-16

RAW MATERIAL NAME: IRGANOX 1076

NOVA CODE: AO6



Melting Point °C N/A N/A 50 °C 55°C

Sulfated Ash % N/A 0% N/A 0.1%

Volatiles

%

2hr/105°C

@atmospheric P

0%

N/A

0.5%

Clarity of Solution Visual 10% g/ml in toluene

clear

Transmission (425nm) % 10% g/ml in toluene

(1 cm)

- 93% -

Assay % UV 100 98% 102%

Aspect White crystalline powder




RAW MATERIAL NAME: Irgafos 168

NOVA CODE: AO9



*Appearance Visual White color powder

Volatiles Visual 2hr/105°C @

atmospheric P

0% 0 0.3

Clarity of Solution

% 10 g in 100 ml toluene Clear

Soln

Colour of Solution at: 425nm

500nm

% 10 g in 100 ml toluene

100

100

97

98

100

100

Content of 2, 4 di-tert butyl

phenol

% LC 0 0.3 -

Assay % LC

* Note: There are no upper and lower limits for Appearance and Clarity of Solution.


RAW MATERIAL NAME: Xylene (Nitration Grade)

NOVA CODE: SZ



Comp Benzene

Liq. Vol% D2360 0.00 0.00 0.03

Non-arom. 0.00 0.00 2.0

Specific Gravity 60°F/60°F Ratio D3505 0.872 0.865 0.877

Color Pt-Co Scale D1209 5 5 20

Distillation Range (IBP-DP) °C D850 137.0 143.0

Acid Wash Color Rating D848 0 0 2

*Acidity Rating D847 Neg -

*Sulfur Compounds (SO2, H2S) Rating D853 Neg

Copper Corrosion Rating D849 1 1 2

*Appearance @ 65-78°F Rating Visual CB

Water Content mg/kg 0 0 10

* These tests have no upper and lower limits; the only acceptable value is the aim.




RAW MATERIAL NAME: Tinuvin B-600 FF

NOVA CODE: B-600



% HPLC 7.7% 6.6% 8.6%

Irgafos 168 % HPLC 15.4% 13.8% 16.9%

Tinuvin 622ld % HPLC 73% 69% 77%

Irganox 1010 % HPLC 3.9% 3.3% 4.4%

Transmittance (425 nm) % UV 100% 94% N/A

Transmittance (500 nm) % UV 100% 97% N/A

Particle Size <212 microns % CAN-PSDO2 0 N/A 5.0

Resistance to friability % CAN-RF03 100 65 N/A


RAW MATERIAL NAME: CAST 626-25

NOVA CODE: CAST 626-25

RAW MATERIAL SPECIFICATIONS: Antioxidant: Ultranox 626 (AO3) - 8.3%

Process Aid: Calcium Stearate, food grade 5264 - 16.7%

Base Resin: Sclair 97B - 75%



Volatile wt% MP726-1 0.00 0.00 0.07

Ash wt% MP 722 25 23 27

Specks /10g MP 761 0 0 2

*Color Rating Comp. to Ref Lot OK 315 good

Pellets Gram Manual count 45 37 53

* Note: There are no upper and lower limits to colour.


RAW MATERIAL NAME: Atmer 129

NOVA CODE: DE3



α-monoglycerides % A.O.C.S. CD 11-57 (83) 100 90 100

Free Glycerine % KBC-16 CD 11-57 (83) 0 0 1.5




RAW MATERIAL NAME: Irganox MD 1024

NOVA CODE: MD 1024



*Appearance Rating Visual White to off-white powder

Melt Start °C KBC-16 - 221 232

Melt End °C KBC-16 - 221 232

Weight loss % KBC-16 0.0 0.0 0.5

Ash % KBC-16 0.0 0.0 0.1

UV Assay % KBC-16 100 98 102


RAW MATERIAL NAME: TINUVIN 622LD

NOVA CODE: UV7



Appearance Rating Visual Coarse, white to slightly yellow powder

Volatiles % 0 - 0.50

Clarity of Solution Rating 10 g in 100 ml

toluene

Clear Sol.

Transmittance (425mm) % 10 g in 100 ml

toluene

100 93

Molecular Weight 3550 310

0

4000

Note: Maximum recommended storage time under suitable conditions (dry and cool) beyond date of analysis is 60 days.

RAW MATERIAL SPECIFICATION NO.: STPA-04

RAW MATERIAL NAME: Cyclohexane

NOVA CODE: SH


Cyclohexane vol% 95*

Total Chlorides ppm wt. 1.0

Total Sulphur ppm 1.0

Phenols ppm 1.0

Benzene Wt% 0.1

Boiling Range °C 80 82

Density (SG)

Solid Point °C 6.2

Water ppm 300 * 99.15 Vol% preferred, remaining material to be saturated hydrocarbons with an average molecular weight similar to cyclohexane.




RAW MATERIAL NAME: VOCl3/TiCl4 (80:20)

NOVA CODE: CAB


V-5 Wt% 23.5 23.2 23.5

VOCl3 Wt% 80.0 79.0 81.0

TiCl4 Wt% 20.0 19.0 21.0


RAW MATERIAL NAME: VOCl3/TiCl4 (50:50)

NOVA CODE: CAB-2


V-5 wt% 14.7 14.4 15.0

VOCl3 wt% 50.0 49.0 51.0

TiCl4 wt% 50.0 49.0 51.0


RAW MATERIAL NAME: Triethylaluminium

NOVA CODE: CT



Triethylaluminium * wt% 94.0

Tri-n-bytylaluminium * wt% 6.0

Trisiobutylaluminium * wt% 0.1

Hydride, as AlH3 wt% 0.1

* calculated from the hydrolysis gas composition


RAW MATERIAL NAME: DiethylaluminIum Chloride (DEAC)

NOVA CODE: CD CHARACTRISTICS UNITS OF MEASURE TEST AIM LOWER UPPER

Ethane* mol% 99.9 99.3

n-butane* mol% 0.1 0.5

Isobutene* mol% 0 0.1

Hydrogen* mol% 0 0.1

Aluminium wt% 22.2 22.0

Cl Al (molar) wt% 1.01 1.0 1.03

* calculated from hydrolysis gas composition




RAW MATERIAL NAME: DiethylaluminIum Ethoxide

NOVA CODE: CJ


Ethane* mol% 96.0

Propane* mol%

n-butane* mol%

Isobutene* mol%

Methane* mol%

Hydrogen* mol%

Aluminium wt% 20.1 19.5 20.7

Ethoxide wt% 34.9 33.4 36.5

EtO/Al ratio calculated 1.00 1.05

* calculated from hydrolysis gas composition


RAW MATERIAL NAME: 2,4 Pentanedione

NOVA CODE: PD


2,4-Pentanedione wt% 99

2,4-Hexanedione wt% 0.2

Acetic Acid wt% 0.2

Water wt% 0.1

Colour Pt/Co 50

Sp. Gr. 0.972 0.978

RAW MATERIAL SPECIFICATION NO.: STPA-13-A

RAW MATERIAL NAME: Alumina - Low Sodium

NOVA CODE: PA



Loss on Ignition (LOI) wt % 7 5 9

bulk density kg/m3 830 760 870

surface area m2/gm 330 280 360

crush strength kgf 6 4.5

attrition resistance (abrasion loss)

<20 Tyler mesh (fines)

wt%

wt%

>99.8(<0.2)

<0.2

98.5

1.5)

0.5

nominal size Tyler mesh 6x10 7x14

.



RAW MATERIAL SPECIFICATION NO.: STPA-13-B

RAW MATERIAL NAME: Alumina - Medium Sodium

NOVA CODE: PA



Loss on Ignition (LOI) wt % 7 5.5 9

Na2O wt % 0.6 2.0

Bulk Density kg/m3 830 760 870

Surface Area m2/gm 320 280 360

Crush Strength kgf >5 4.5

Attrition Resistance (Abrasion

loss)


wt%

99.8(0.2)

<0.2

99.0(1.0)

0.5

Nominal size Tyler mesh 6x10 7x14

RAW MATERIAL SPECIFICATION NO.: STPA-13-C

RAW MATERIAL NAME: Alumina - High Sodium

NOVA CODE: PA



Loss on Ignition (LOI) wt % 7 4.5 7

Na2O wt % 2.0 3.0

Bulk Density kg/m3 830 810 910

Surface Area m2/gm 320 220 320

Crush Strength kgf >5 5

Attrition Resistance (Abrasion

loss)


wt%

wt%

99 (<1.0)

<0.2

98

(2.0)

0.5

nominal size Tyler mesh 6x10 7x14

RAW MATERIAL SPECIFICATION NO.: STPA-15I

RAW MATERIAL NAME: Nitrogen



Nitrogen vol% 99.99

Water ppb 50 *

Oxygen ppm 3

Carbon dioxide ppm 3

* Equivalent to approximately -100 °C dew point at atmospheric pressure




RAW MATERIAL NAME: Molecular sieve

NOVA CODE: PM



Nominal pore diameter Angstroms 3

Bulk density Lbs/cu ft 41

Particle Diameter Inch 0.115 0.135

Crush Strength Lbs 20

Heat of Adsorption Btu/lb water 1800

Equilibrium water capacity @ 17.5

mm Hg/25 °C

wt% 20

Water content as shipped wt % 15


RAW MATERIAL NAME: Silica gel

NOVA CODE: PS



Bulk Density lbs/cu ft 45 38 50

Surface Area m2g 750 720 820

Pore Volume ml/g 0.45 0.40 0.50

Total Volatiles wt % 10

SiO2 wt % 99.5

Nominal Size Tyler mesh 6 x 10 6 x 12

Particle Size

through 20 mesh

through 6 mesh on 14 mesh

wt %

wt %

0.5

60.0


RAW MATERIAL NAME: (White) Mineral Oil


Boiling Point (min) °C 210

Density (min) @ 20 °C kg/m3 830

Flash Point (min) oC 175

Pour Point (max) oC -6

Viscosity (max) @ 40 °C cSt 40




RAW MATERIAL NAME: Calcium Hydrate (Calcium Hydroxide)



Calcium Oxide (CaO) wt% 73.6

Magnesium Oxide (MgO) wt% 0.8

Silica wt% 0.4

Ferric Oxide (Fe2O3) wt% 0.08

Total Sulphur (S) wt% 0.0.

Loss on Ignition wt% 23.9

Available Lime as Calcium Hydroxide wt% 95.2

Carbon Dioxide (CO2) wt% 0.5

Free Moisture wt% 0.5

Free Lime (CaO) wt% 0.4

Particle size through 28 mesh wt% 100


RAW MATERIAL NAME: Dow Corning® 33 - Medium (replaces Molykote® 33)



Penetration ASTM D 217 280

NLGI Number 2

Bleed % After 24 hr @149°C 2.0

Evaporation % After 24 hr @149°C 2.0

Dropping Point °C 210

Dirt Count MIL-I-15719A pass

Temperature Range °C -73 to 204

Specific Gravity @ 25 oC 0.97

Bomb Oxidation Psid ASTM D942 2.0

Water Washout Resistance % % 0.5

Thermal Conductivity Cal/sec/cm2/°

C/cm

0.00028

Specific Heat Cal/g/°C 0.379

High Temperature Bearing Performance

Weibull Bss 320

Max. DN value Bore size

(mm)

200




RAW MATERIAL NAME: Isobutanol (or Isobutyl Alcohol)



Isobutanol wt% 99.5

n-butanol wt% 0.1

n-propanol wt% 0.1

Other C4 compounds wt% 0.2

Total C3 compounds wt% 0.1

water wt% 0.1

Specific Gravity 20/20°C 0.802 0.804

Distillation:IBP

Dry point

°C

°C

107

Suspended Matter 108.5


RAW MATERIAL NAME: Teresstic® SHP 46 (ISO Grade) (for Capillary Reactor Seal design only)


Viscosity@ 40 oC

@ 100 oC

cSt

cSt

45

7.6

Viscosity Index 139

Specific Gravity @ 15.6 oC 0.840

Colour <a

Flash Point oC 244

Pour Point oC -54

FZG Gear Test Min. Stages passed 11




RAW MATERIAL NAME: Ceramic Ball Support Media


Al2O3 wt% 99.0

SiO2 wt% 0.2

Leachable Iron wt% Nil

Operating Temperature °C 1500

Crush Strength for

¼ inch (6 mm) diameter

½ inch (13 mm) diameter

¾ inch (19 mm) diameter

lb (kg)

lb (kg)

lb (kg)

75 (165)

200 (440)

550 (1211)

RAW MATERIAL SPECIFICATION NO.: STPA-11-1

RAW MATERIAL NAME: Pelargonic Acid



Acid Value 345 35.5

Iodine Value 0.2 0.5

Moisture % <0.05 0.2

Colour Gardner 1.0

Pelargonic Acid % 94 90

Caprylic Acid % 4 6

Capric Acid % 2 4

RAW MATERIAL SPECIFICATION NO.: STPA-11-2

RAW MATERIAL NAME: C8-10 Fatty Acid

NOVA CODE: PG


Saponification Value mg KOH/gm 365 370

Acid Value mg KOH/gm 364 358 370

Iodine Value 0.2 0.5

Moisture wt% <0.04 0.2

Colour Yellow/red

Lovibon 51/4”

1.1/0.1 3/0.8

C6 (caproic) wt% 4 6

C8 (caprylic) wt% 55 53 60

C10 (capric) wt% 39 34 42

C12 (lauric) wt% 0.4 2



2.7 BATTERY LIMIT CONDITIONS OF PROCESS LINES

Condition for all incoming and outgoing process lines shall be as per Table below.

Sl. No.

Parameter Minimum Normal Maximum Mech. Design

1 HYDROGEN (J)

Pressure, kg/cm2g 17 - - 42.9

Temperature, oC - 25 45 65

2 CYCLOHEXANE (SH)

Pressure, kg/cm2g - 4.1 - 8

Temperature, oC - Amb - 65

3 BUTENE (FB-1)

Pressure, kg/cm2g - 8 - 17

Temperature, oC - Amb - 65

4 OCTENE (FC-1)

Pressure, kg/cm2g - 11.4 - 18.2

Temperature, oC - Amb. - 65

5 ETHYLENE (FE)

Pressure, kg/cm2g - 49 50 83/56*

Temperature, oC - 25 - 65

6 FLARE

Pressure, kg/cm2g - 0.1 1.5 3.5

Temperature, oC - - - -

7 ETHYLENE PURGE (FE) (to NCU)

Pressure, kg/cm2g 2.5 2.5 5 6

Temperature, oC -50 24 50 -60/150

8 EHTYLENE PURGE (FE0 TO FUEL GAS)

Pressure, kg/cm2g 4.5 4.5 5 6

Temperature, oC -50 24 50 -60/150

9 BUTENE PURGE (FB-2)

Pressure, kg/cm2g - 6 - 12




2.8 UTILITY CONDITIONS AT UNIT BATTERY LIMITS/AT TIE IN POINT (All battery limit pressures are measured at grade)

Sl. No.


1 HIGH PRESSURE (HP) STEAM

Pressure, kg/cm2g 40 42 44 50/FV

Temperature, oC 380 390 400 427

2 LOW PRESSURE (LP) STEAM

Pressure, kg/cm2g 3.6 4 4.5 6.5/FV


3 CONDENSATE RETURN

Pressure, kg/cm2g 2.5 3.0 - -

Temperature, oC - 40/90 100/100 150

4 SERVICE WATER

Pressure, kg/cm2g 3 5 6 10

Temperature, oC - Amb. - 65

5 COOLING WATER

Supply Pressure, kg/cm2g - 5.4 - 10

Return Pressure, kg/cm2g 2.6 - - 10

Supply Temperature, oC 28 33 - 65

Return Temperature, oC - 45 45 65

6 DEMINERALIZED WATER

Pressure, kg/cm2g 4 7.5 8 17


7 BOILER FEED WATER (HP/MP)



8 PLANT AIR


Temperature, oC - 40 50 65



Sl. No.


9 INSTRUMENT AIR (Dew Point - 40 oC)

Pressure, kg/cm2g 6.5 7 - 10

Temperature, oC - - - 65

10 FUEL GAS (SUPPLY CONDITIONS)

Pressure, kg/cm2g 2.0 3 4.5 6


11 REFINERY FUEL OIL

Supply Pressure, kg/cm2g - 10.0 - 15.5

Return Pressure, kg/cm2g 3.5 4.0 4.0 15.5

Supply Temperature, oC 125 160-220 240 260

12 NITROGEN (Dew Point- 100 oC at atm. Pressure)

Pressure, kg/cm2g 4 6 7 10.5


13 EMERGENCY COOLING WATER

Supply Pressure, kg/cm2g - 5 - 10

Return Pressure, kg/cm2g 2.2 - - 10

Supply Temperature, oC 28 33 - 65

Return Temperature, oC - 45 45 65



2.9 UTILITY SUMMARY:

S. No. Utility Flow Max (m3/hr)

1. Process (Service) Water 42.8

2. Instrument Air 806.07

3. DM (Treated Water) Water 17

4. Emergency DM Water 101

5. Emergency Cooling Water 387.8

6. Bearing Cooling Water 13.56

Steam Summary:

Case I

11Q4

Case II

61B

Case III

2712

Case IIILC

2712LC

Case V

59A

Case VI

C11L2B

Light Off

(kg/hr)

HP Steam Import from OSBL 44577 42993 41295 44311 31992 66141

LP Steam Import from OSBL 0 0 0 0 0 0

HP Steam Export to OSBL 14882 7522 14376 13607 25035 40530

BFW Import from OSBL 0 0 3145 0 8006 0

Condensate Export to OSBL 14406 19823 14301 14704 0 8416

Normal

(kg/hr)






Maximum

(kg/hr)






Cooling Water Summary:

Case I

11Q4

Case II

61B

Case III

2712

Case IIILC

2712LC

Case V

59A

Case VI

C11L2B

Normal

(kg/hr)

Supply 4808369 4764989 4652652 4783956 3803136 5172296

Return 4808369 4764989 4652652 4783956 3803136 5172296

Maximum

(kg/hr)

Supply 5449214 5369856 5275610 5431044 4283478 5707700

Return 5449214 5369856 5275610 5431044 4283478 5707700



SECTION-3.0 PROCESS CHEMISTRY



3.1 Catalyst Theory:

3.1.1 Introduction

The role of the catalyst is central in any Ziegler-Natta polymerization process. Two catalyst systems are

used in the SCLAIRTECH process, these are known as the standard catalyst and the heat treated

catalyst. These two systems will be examined in more detail in the following section.

3.1.2 Sclairtech Catalysts

In the SCLAIRTECH process the active catalyst is generated through the reaction of a transition metal

mixture with one or more reducing/activating co-catalysts. The transition metal components are:

CA - Titanium tetrachloride (TiCl4)

CB - Vanadium oxytrichloride, Vanadyl trichloride (VOCl3)

The codes CA and CB are assigned to the species as indicated above. These designations will be used

in the remainder of this text. These components are premixed in different defined ratios in the two

SCLAIRTECH catalyst systems. Each of these mixtures is assigned an additional code illustrated below:

CAB - 80 wt % CB and 20 wt % CA CAB-2 - 50 wt % CB and 50 wt % CA

The CAB mixture is used in the standard catalyst (STD) mode and the CAB-2 mixture in the so called

heat treated catalyst (HTC) mode. Aluminum alkyl co-catalysts are used in conjunction with the above

transition metal mixtures to generate the active catalyst.

The aluminum alkyls serve two functions: to reduce and to alkylate the metals.

The co-catalysts used in the SCLAIRTECH process are listed below along with their corresponding codes

and industry accepted abbreviations:

CT - Triethyl aluminum (TEAL)

CD - Diethyl aluminum chloride (DEAC)

CJ - Diethyl aluminum ethoxide (DEAL-E) Figure 3.1.1 illustrates the chemical formulae and molecular weights of the various catalyst components.

These are the current catalysts used in the SCLAIRTECH process. Other catalysts and co-catalysts continue

to be investigated as catalyst research is ongoing.

Code Name Formulae MW

CA Titanium Tetrachloride TiCl4 189.7

CB Vanadium Oxytrichloride VOCl3 173.3

CAB 80 wt% CB + 20 wt% CA

CAB-2 50 wt% CB + 50 wt% CA

CT Triethyl Aluminium Al(C2H5)3 114.2

CD Diethyl Aluminium Chloride Al(C2H5)2Cl 120.6

CJ Diethyl Aluminium Ethoxide Al(C2H5)2OC2H5 130.2

Figure 3.1.1: Catalyst Components



3.1.3 Catalyst Chemistry: 3.1.3.1 The Initial Reduction/Alkylation Reactions The addition of co-catalyst to the transition metal mixtures results in the reduction of the oxidation state of

the metal followed by alkylation. These reactions are illustrated in a simplified manner below using CT

(Figure 3.1.2).

Ti 4+ reduction to Ti3+ TiCl4 + Al(C2H5)3 TiCl3 + Al(C2H5)2 Cl + C2H5·

Ti 4+ reduction to Ti3+ TiCl3 + Al(C2H5)3 TiCl2 + Al(C2H5)2Cl + C2H5·

V5+ reduction to V4+/V3+ VOCl3 + Al(C2H5)3 VOCl2 + Al(C2H5)2Cl + C2H5·

VOCl2 + Al(C2H5)3 VOCl + Al(C2H5)2Cl + C2H5·

Alkylation of Titanium and Vanadium TiCl3 + Al(C2H5)3 TiCl2C2H5 + Al(C2H5)2Cl

VOCl2 + Al(C2H5)3 VOClC2H5 + Al(C2H5)2Cl

Figure 3.1.2: Reactions

The initial reduction of the transition metals generates aluminum alkyl chlorides in addition to the

reduced metal chlorides. These aluminum alkyl chlorides are themselves active co-catalysts and are

capable of reducing and alkylating the vanadium and titanium. These reduction reactions are quite facile

and occur over a period of approximately 10 seconds. This corresponds to the minimum hold-up time

present in the catalyst mixing section of the SCLAIRTECH process. Additional undesirable side

reactions can occur in the presence of excess co-catalyst which result in the over reduction of the

titanium and vanadium to a catalytically inactive state. Thus, there is an optimum co-catalyst (CT or CD)

level in the catalyst make-up. The reduction of VOCl3 results in the rapid formation of VOCl2 and VOCl

over approximately 2 seconds. All of the catalyst components are soluble in cyclohexane prior to mixing.

Once mixed, the reduced metal species form precipitates. These precipitates can be quite sticky and

have on occasion caused plugging problems in the mixer used in the HTC Catalyst System. 3.1.3.2 Catalyst Crystallization and Precipitation: Precipitated TiCl3 can form one of 4 crystalline types. When operating in standard catalyst mode β-TiCl3 is

produced giving needle like crystals. With the heat treated catalyst planar crystals of γ-TiCl3 are formed.

3.1.3.2 Polymer Chain Growth: Figure 3.1.3 schematically illustrates the process of polymer growth through coordination of ethylene to the

metal centre and subsequent insertion into the metal alkyl bond. Initially, ethylene coordinates at a

catalytically active metal site forming a metal alkyl/olefin complex. A four cantered intermediate is then

produced as the ethylene starts to insert into the metal carbon bond of the alkyl group. This

intermediate then goes on to produce a new metal alkyl in which the alkyl chain length has been extended

by a C2H4 group. In this process the vacant coordination site on the metal is regenerated allowing the



catalytic cycle to continue. Finally, the alkyl chain formed at the metal can be eliminated to give a free

polymer chain with an unsaturated end group and a metal-hydride complex, which is itself catalytically

active and can give rise to a new polymer chain.

Hydrogen is often used for polymer molecular weight control (as discussed in Basic Parameter Control).

The hydrogen provides an additional termination mechanism for the growing polymer chain, reducing the

average polymer molecular weight. Like ethylene, hydrogen is able to coordinate to the metal centres. A

similar four cantered intermediate is then formed. However, the final reaction product is not an extended

alkyl chain but is a free polymer molecule with a saturated end group and a metal-hydride complex

which is an active polymerization catalyst.

The above discussion is simplified for brevity and in reality the co-catalyst is also intimately involved in

the initiation-propagation and termination reactions. Consequently, the nature of the co-catalyst

and its concentration have an important effect on the rate of the polymerization reactions and upon

the resulting polymer.

Figure 3.1.3: Polymer Growth

3.1.4 The Role of the Catalyst in Reactor Kinetics: The rate of disappearance of ethylene (or formation of polymer) is given by:

-d[FE]/dt = kp [C*] [FEout] V

where: [FE] ethylene conc.

[C*] active catalyst concentration

kp average reaction rate

V reactor volume

It is assumed that the reactor is a perfect CSTR i.e. that the ethylene concentration leaving the reactor is the

same as the concentration n the reactor. Also,

-d[FE]/dt TSR ([FEin] – [FEout])

Where: TSR Total Solution Rate

Combining these two equations,

kp[C*] [FEin] = TSR ([FEin] – [FEout])



By substitution,

Q = [FEin] – [FEout]/[FEin]

Where: Q fractional conversion

And simplifying this equation becomes:

kp[C*]V/TSR = Q/(1-Q)

Since V/TSR is the reactor hold-up time (HUT), we now have,

kp [C*] = Q/{(1-Q) HUT}

Catalyst ‘killing’ impurities present in the system are reflected in the amount of active catalyst that is

available i.e.

[C*] = [Cin] – [Cpoison]

Where: [ Cin] = catalyst feed concentration

[Cpoison] = catalyst poisoned by impurities

If Q/(1-Q)HUT is plotted against [Cin] a straight line is obtained of slope kp and an intercept on the x axis of

[Cpoison] see Fig.3.1.4

Fig. 3.1.4: Conversion Kinetics No. 1 Reactor (Ideal)

A similar graph can be generated assuming that the reactor is non ideal and thus more representative

of an actual reactor. This relationship is shown in Figure 3.1.5. Note that this model assumes that there

is a difference between [FEout] and [FEav]. In the SCLAIRTECH process the non ideal mixing of the reactor

can be verified by the temperature gradient present across the reactor. Note also that the average

polymerization rate constant used in the last expression is now expressed as the ratio of the

instantaneous polymerization rate constant and the rate of catalyst decay. The decay rate, kp, increases

with increasing reactor temperature and high co-catalyst concentrations.



Fig. 3.1.5: Conversion Kinetics No. 1 Reactor (Non-Ideal)

The above kinetic data is based on a stirred reactor (No.1 mode). In the SCLAIRTECH process a tubular

reactor may also be used in 3→1 mode. A trimmer reactor used in all modes of operation is also a

tubular reactor. In the case of a tubular reactor the relationship becomes:

ln {[FEin]/[FEout]} = kp [C*] HUT

This relationship is illustrated in Figure 3.1.6

Figure 3.1.6: Conversion Kinetics - Tubular Reactor

3.1.5 Economic Optimization: As the ethylene conversion approaches 100% more and more catalyst is required. This relationship is not

linear, each additional percent of conversion requires more and more additional catalyst. In parallel to the

increase in catalyst cost is the associated cost of deactivation and removal of the catalyst residues.

Conversely, higher conversions bring down the raw material cost of materials such as ethylene and

comonomer. This is shown in Figure 3.1.7



Figure 3.1.7: Economic Optimization

There is therefore, a conversion that corresponds to a minimum overall operating cost. At SCRS this

optimum is at approximately 95% conversion. Since this optimum can vary depending on type of resin

being produced, raw material costs, impurity levels and the value of the waste FE, it is recommended that

a similar analysis be done by each licensee on their own facility. It should be noted that a lower than

100 % conversion does not negatively affect polymer quality or reactor stability. As conversion

approaches 100% small changes in available FE can be a significant percentage of the total available

ethylene and may effect reaction. These aspects will be covered under each reactor type.

3.1.6 Standard Catalyst: 3.1.6.1 Physical Setup

In the standard SCLAIRTECH catalyst system CAB is mixed with CT, for a hold-up time of 2-5 seconds

at ambient temperature which then forms the active species. Mixing is accomplished through a simple Tee

fitting. The stickiness of the active polymer (TiCl3 especially) does cause some pluggage in this

system, but these instances are very rare. Figure 3.1.8 shows this setup.

Figure 3.1.8: Physical Setup



3.1.6.2 Molecular Weight Distribution – Standard Catalyst: The components of the catalyst mixture, CA and CB each contribute different effects to the final polymer

produced. These differences are primarily in the areas of molecular weight distribution.

Figure 3.1.9 Molecular Weight Distribution - CA/CT (CSTR at 140°C)

Figure 3.1.9 shows under controlled conditions (CSTR @ 140°C) the molecular weight distribution that would

occur using CA only. It is apparent that the active titanium sites of the CA produce lower molecular weight

polymer. Figure 3.1.10 shows the molecular weight distribution that would occur using CB only. It appears

that the active vanadium sites in the CB is where the higher molecular weight polymer is produced.



Figure 3.1.10: Molecular Weight Distribution - CB/CT (CSTR at 140°C)

Figure 3.1.11 shows the molecular weight distribution using CAB (the combined CA and CB main

catalyst). Notice the molecular weight distribution obtained appears to be a combination of that achieved by

each of the two components.



Figure 3.1.11: Molecular Weight Distribution - CAB/CT (CSTR at 140°C) 3.1.6.3 Main Variables Affecting Catalyst Behaviour and Optimisation: A. CB/CAB Ratio:

As the percentage CB in the CAB mixture varies, the conversion achieved with polymerization also

varies. Figure 3.1.12 shows this relationship.

This particular test, which was done under controlled conditions, shows a definite optimum conversion

with higher percentages of CB. This optimum appears to vary depending on the temperature of the reaction

as shown in Figure 3.1.13.



Figure 3.1.12: CB/CAB Optimization

Figure 3.1.13: Effect of Temperature on CB/CAB Optimum

In addition, it was found that varying this ratio also affects the stress exponent. This effect is shown in

Figure 3.1.14. The chosen levels of CB in our CAB mixture take both conversion optimization and stress

exponent into account.



Figure 3.1.14: Effect of CB/CAB on SE and kp on No.1 Reactor B. CT/CAB Ratio:

The addition of the co-catalyst or alkylating agent to the main catalyst mixture also proceeds on an

optimal curve. As the CT level is increased the conversion achieved also increases up to the optimum.

After this point, it appears that the catalyst has been over alkylated and conversion begins to drop off,

although on a somewhat slower basis. This relationship is shown in Figure 3.1.15. Addition of an impurity

such as acetone pushes the curve down and to the right indicating lower conversion and higher CT ratio

requirement.



Figure 3.1.15: Effect of CT/CAB Ratio on Conversion

If the optimal level of CT/CAB is plotted with the conversion achievable at different levels of CAB,

an optimization plot such a shown in Figure 3.1.16 is produced. This plot is similar to a topographical map,

and is in three dimensions, with the conversion rising up out of the page. It should be noted that the optimal

CT/CAB ratio varies somewhat as CAB level changes. At low levels of CAB the CT/CAB ratio is higher

than it is at higher CAB levels. This is primarily a reflection of the effect of impurities on CT.



Figure 3.1.16: Effect of CAB and CT on Conversion

The effect of the CT/CAB ratios is different for varying hold- up times within the tubular reactor. This effect

is shown in Figure 3.1.17. It appears that a higher CT/CAB ratio results in a higher level of reactivity

initially. With a lower ratio the rise in conversion continues for a longer period of time, and will actually

surpass the results from the higher ratio. This pattern of reactivity Vs hold-up time at various ratios is useful

to control Q in specific parts of the reactor i.e. front, or end especially in the tubular reactor mode.

Figure 3.1.17: Effect of CT/CAB Ratio on Conversion

The trends observed in Figure 3.1.17 are a result of changing kp values with varying hold up times and

varying CT/CAB ratios. This relationship is shown in Figure 3.1.18. At high CT/CAB ratios the curve is

quite steep, with a high kp constant at low hold up times. As the time increases the kp drops off quickly.

At low CT/CAB ratio there is much less catalyst decay. Although the kp does not start out as high, its

reduced decay rate results in the kp being higher at longer hold-up times. In general it is most desirable to

run the CT/CAB ratio on the low side.



Figure 3.1.18: Adiabatic Tubular Reactor kp Data

C. Impurities: There are two main types of impurities; those that affect the co-catalyst (CT) preferentially (water,

acetone, alcohol) and those that affect the whole catalyst i.e. CO2.

With impurities such as acetone the CT/CAB ratio necessary to achieve optimal conversion is

increased. Testwork shows that although the maximum conversion achieved was reduced, the achievable

maximums in the presence of the acetone were still well into the 90-100% range. It appears that ketones

preferentially attack the CT, and can be compensated for, to some extent, by increasing the CT/CAB ratio.

The effect is the same for the other similar impurities such as water. For these impurities it appears that the

optimum CT/CAB ratio increases as shown in Figure 3.1.19.



Fig. 3.1.19: Effect of CT attacking Impurities

The degree to which the impurities affect the catalyst is a function of their relative molecular weights. As

a general rule, one mole of impurity will attack one mole of CT, but since an impurity such as water

has a molecular weight of only 18 compared to CT at approximately 100 the result is that approximately

1 ppm of water can "knock out" five or six ppm of CT.

Water can originate in ethylene feedstock (depending upon the storage facilities used), upsets, leaks or old

drier beds. Alcohol is usually found as a result of methyl alcohol being injected into an ethylene line to

combat hydrate formation. Ketones are formed during operation and are normally removed at the purifiers.

For impurities such as oxygen and CO, however, an increase in all catalyst levels is require. The effect on

the optimum CT/CAB levels is shown in Figure 3.1.20



Figure 3.1.20: Effect of Whole Catalyst Attacking Impurities

Of this type of impurity CO2 is the most common, usually originating in the ethylene supply. Other

impurities that are suspected to behave the same way are CO and sulphur. To date these have not been a

problem at SCRS, but as these impurities are dependent on the ethylene supply, each facility may

present unique impurity problems.

There are some impurities such as the saturated hydrocarbons (ethane, butane etc), isobutene and

butene-2 that do not have an effect on the catalyst but do affect the overall operation of the facility. These

impurities are inert, take up pumping capacity and may affect phase separation.

The type of action that proves to be effective in compensating for the impurities will help to determine

what those impurities are, and what actions should be taken to resolve the problem from the source.

For example, if the reaction begins to gradually drop off the operator's first move is to compensate for this

drop off by increasing catalyst flow. He usually increases the co-catalyst (CT) first. If this helps to restore

conversion, the impurity was likely ketones or water. Potential sources for these containments (i.e. purifier

bed breakthrough) are explored. If it does not help, the CAB is increased to restore reaction.

D. Hold-up Time: The general effect of kp dropping off with increased hold up time is present on both the 3→1 reactor mode

and the No.1 reactor mode. This effect has been plotted at SCRS over a period of time, and the resulting

decay is found to occur in a broad band for each reactor type. This is interesting because the decay is



noticed in the No.1 reactor which does not see the same temperature increase over time as the 3→1

reactor does. This effect is shown in Figure 3.1.21. From this curve one can also see the decay rate of the

catalyst. For example, within the 3→1 reactor, the catalyst appears to loose half of its reactivity (half life)

within a period of 30 seconds. The curve for the No.1 reactor was obtained by mixing fresh active catalyst

with old decayed catalyst.

Figure 3.1.21: Effect of Hold-Up Time on kp

Hold-up time also has an effect on the total amount of catalyst required, to complete the reaction.

Theoretically, if there was no catalyst decay, twice the hold up time should require half the catalyst. In

actual fact, however, this is not the case. Only slightly less catalyst is required for large increases in hold-

up time. This effect is shown in Figure 3.1.22. This figure also shows the effect, again, of varying the

CT/CAB ratio. It can be seen then that the effect of reducing the hold-up time can be compensated for

either by increasing the overall catalyst level or by adjusting the CT/CAB ratio.

Figure 3.1.22: Effect of Hold-Up Time on Catalyst Requirements



E. Temperature and % FB: The amount of catalyst required to obtain a given reaction is also determined by the amount of

comonomer in the reaction and the temperature at which the reaction takes place. This is shown in Figure

3.1.23. It shows that as the amount of comonomer goes up the amount of catalyst required goes up. An

increasing temperature of the reaction also causes the catalyst required to go up. An increase in

temperature of 50o or 60oC or an increase from zero to the highest content of comonomer generally

doubles the amount of catalyst required. This is thought to be the result of the increased

catalyst decay at higher temperatures and the reduced mobility/reactivity of the FB molecules

compared to the FE molecules.

Figure 3.1.23 Effect of Temperature and Comonomer on Catalyst Requirements

3.1.7 Heat Treatment Catalyst: 3.1.7.1 Introduction The Heat Treated Catalyst (HTC) system gets its name from the method which is used to accomplish

the reduction and alkylation reactions on the catalyst metals. In this method the reduced catalyst species is

heated to an elevated temperature to stabilize its structure and prepare it for alkylation. As mentioned

earlier, in case of STD catalyst, the reduction and alkylation reaction are carried out in a single step by

using CT as a co-catalyst. This single step reaction can result in increased consumption of the catalyst

caused by over reduction and hence inactivity of the catalyst metals. To truly optimize the activity of the

catalyst which goes to the reactor, it is necessary to ensure that all catalyst is reduced to the desired

oxidation state (III & IV) and then alkylated without reducing the metals further. In the HTC system this is

achieved by using a two step method for carrying out the reduction and the alkylation.



In the first step, a reducing agent, CD (Diethyl Aluminum Chloride), which is not as strong as CT, is used

to ensure proper reduction of the catalyst. CD has one less ethyl group than CT and is therefore only about

2/3 as strong a reducing agent. By carefully controlling the ratio of CD to the catalyst, a greater percentage

of the catalyst molecules which are reduced will remain in the III oxidation state to be alkylated without

being further reduced. The reduction step is followed by the heat treatment step. This heat treatment has

the effect of changing the crystal structure of the catalyst into a form that breaks up very easily and

consequently has more exposed surface area and a higher overall activity. The next step is the alkylation

step, which is carried out by using CJ (Diethyl Aluminum Ethoxide) as the co-catalyst.

Although, CJ is the currently preferred co-catalyst for alkylation, it is not necessarily the only one. In the

past many others such as CG (Tetra Isobutyl Aluminoxane), CS (Diethyl dimethyl-ethyl Siloxy Aluminum), CT

(Triethyl Aluminum), CC (Tri Isobutyl Aluminum), CE (Tri Isoprenyl Aluminum) have been used as

substitutes. Each one has its own advantages and disadvantages based on the type of product being

produced. For each one of these the optimum ratios are different and the selection is mostly based on a

balance of reactivity and economics.

Along with the increased activity, the HTC system also offers enhanced energy consumption advantage.

The HTC system has the ability to run at higher temperatures than the STD catalyst system, which

translates into increased ethylene concentration and consequently a higher throughput. Also, the

higher reactor exit temperatures reduce the preheater loading thus reducing the energy consumption.

Figure 3.1.24 compares the activity of STD and some different types of HTC catalyst system. An energy

comparison is also shown in the figure.

However, at very high temperatures, the advantages of activity of HTC Catalyst over the STD Catalyst

diminish and there is a crossover point after which STD Catalyst has relatively higher activity than the HTC

Catalyst. Another notable benefit of HTC Catalyst, while making film resins, is the higher butene

conversion achieved. As a result, less FB is required in case of HTC than STD. The butene conversion

with HTC Catalyst, for film resins, is almost 30 - 50% higher than STD Catalyst.

1. Catalyst Activity Catalyst Type Catalyst Activity STD (CAB, CT) 4.5 (CSTR @ 206°C) HTC (CAB-4*, CT) 3.5 (CSTR @ 240°C) HTC (CAB-2, CT) 6.0 (CSTR @ 240°C) HTC (CAB-2, CD, CG) 10.0 (CSTR @ 240°C)

2. Energy Efficiency (based on Film Resins) Catalyst Type FE Conc. Reactor Temp. HTC 16% 240°C STD 13% 206°C *CAB-4 = 15% CB, 85% CA

Fig. 3.1.24: Comparison of Catalyst Activity

As can be seen from the figure, the activity of HTC (CAB-2, CD, CG) is approximately double that of

STD (CAB, CT) and 1.7 times that of HTC (CAB-2, CT). The energy efficiency numbers which



indicate an advantage of 3% in FE concentration in HTC over STD are true for film resins where reactor

temperatures are low. However, as the temperature increases, this advantage is reduced or reversed (3→1

resins).

3.1.7.2 Physical Set-up In the heat treated catalyst system, the catalyst CAB-2 and the co-catalyst CD are first brought

together in a vertical mixer. This is known as the cold mix section of the catalyst system. A residence time

of 5-30 seconds is necessary in this section to achieve proper mixing and reduction of the catalyst. This

is then followed by the injection of hot SH in the catalyst stream.

This section of the system is called the hot mix section. The residence time in this section should be from

60 - 90 seconds. The temperature of hot SH should be controlled so as to achieve a temperature of 190-

220°C at the exit of the hot mix section. Finally, CJ is injected into the system just prior to the catalyst

stream entering into the reactor system. Figure 3.1.25 shows the physical setup.

The conditions for achieving the proper mixing are very crucial in the formation of the active catalyst.

Poor mixing can cause both under and over reduction of the catalyst metals, resulting in reduced

catalyst activity. The key to ensuring adequate mixing lies in controlling the relative velocities of the CAB-

2 and CD streams in the mixer (velocities of these two streams are controlled through varying high

pressure diluent flow to the catalyst pumps). The mixer, as shown in Figure 3.1.26 is annular type in

which CAB-2 is injected through a dip tube in the middle and CD flows on the outside walls. The reason

for injecting CAB-2 in the middle stems from the fact that it is the Ti component of the catalyst which

forms the sticky material and hence should be kept away from the walls to prevent plugging. The

CAB-2 molecules disperse from the centre of the tube toward the walls while reacting with CD which

surrounds the dip tube. The result of this reaction is a sticky mixture.

Therefore the velocity should be high enough to carry these sticky particles in the forward direction and

not let them settle towards the walls. On the other hand, too high a velocity also tends to push these

sticky particles towards the walls thus resulting in plugs being formed. The existing vertical mixer design

should be operated at the following conditions so as to achieve optimum mixing.

Jet Velocity (m/sec) H.P. Diluent Flow (kg/hr)

CAB-2 0.463 105

CD 0.10 130

The temperature in the hot mix section is also very important in activating the catalyst. The hot mix section

exit temperature has an effect on the molecular weight distribution of the polymer. A high temperature

tends to narrow the resin while a low temperature tends to broaden the distribution. One can optimise

in the given temperature range to achieve the desired results.

The heat treatment is followed by the alkylation reaction. This is achieved by addition of CJ to the catalyst

mixture. As the alkylation reaction is the final step in activating the polymerization catalyst, it is important

to inject this catalyst into the reactor as quickly as possible to minimize any decay in catalyst activity with



time. This injection happens either at the base of No.1 reactor or at the entrance of the No.3 reactor and

the hold up time before entry into the reactor is kept to 1-2 seconds. Since this hold up time is very

short, good mixing is required to ensure that catalyst and co-catalyst see each other during this time

period. This is achieved by controlling the flow rate of the high pressure diluent to the CJ point to obtain

the correct relative velocity ratios at the injection point. CJ can also be directly injected into the No.1

reactor without any process penalties.

Figure 3.1.25: Physical Set-up (HTC)

Figure 3.1.26: HTC Mixer Detail

3.1.7.3 Molecular Weight Distribution in HTC: The relationships between CA, CB and CAB-2 are not as clear cut in the HTC system as they are in the

STD system. As can be seen in Figure 3.1.27, the molecular weight distribution produced with the

HTC catalyst system is somewhat different than that produced by the STD catalyst. The high

molecular weight "hump" present in the CAB does not appear in the CAB-2 catalyst after heat treatment.

This is attributable to the fact that CB which contributes mostly to the high molecular weight end looses

its activity during heat treatment (Reduction of V4+ to V3+). This also results in the polymer being

narrower for HTC than STD. Due to this reason, a stress exponent of 1.8 is considered to be the upper

limit of the HTC catalyst.



Figure 3.1.27: MWD (STD Vs HTC)

3.1.7.4 Variable Optimisation – Heat Treated Catalyst Since there are more controllable variables in the HTC, there are more variables to be optimized. These

are the co-catalyst ratios, cold and hot mix times and hot mix temperatures. They are all shown in Figure

3.1.28.

A. CD Ratio: The purpose of CD is to carry out the reduction reaction. If the catalyst is under or over reduced, it will have

an impact on the conversion. Although the graph indicates the optimum ratio to be around 1.2, it is desirable

to run at about 1.5. This is because we are in a relatively flat part of the curve at the top and running a

higher than optimum provides a comfort zone. A drop below the optimum tends to impact the conversion

significantly more than a little above optimum. The CD ratio also has impact on the SE of the resin.

Therefore, while producing broad resins, the CD ratio can be dropped to get more leverage out of the

catalyst and to prevent over reduction of Vanadium species which help the high molecular weight end.

B. Cold Mix Time: The cold mix section carries out the mixing of the CAB-2 catalyst. It is essential that there is enough

time provided for the reduction reaction to take place. Our findings indicate that a minimum of 10

seconds is necessary to carry out the reaction. However, the residence times of as high as 30 seconds

have showed no ill effects.



C. CJ Ratio: The purpose of CJ is to carry out the alkylation reaction prior to the catalyst injection into the reactor. We

have found a CJ ratio of 1.5 to be the most optimal. Considering that the curve is fairly flat, CJ is very

expensive, an economic optimization may have to be undertaken by each licence to determine their own

requirement. Small changes in CJ do not have an impact similar to CD.

Figure 3.1.28: HTC Optimization

D. Hot Mix Temperature: The hot mix temperature plays an important role in getting the catalyst ready for alkylation. We

have experimented at temperatures ranging from 185°C to 250°C. Our investigation shows that 210°-

220°C is the ideal mix temperature. However, the variation in hot mix temperature also has some

impact on the SE of the resin produced. It has been observed that the lower end of the temperature

produces high SE (approx. 1.34) and the higher end produces low SE (approx 1.26). This is not

unexpected as low temperature keeps more Vanadium (V4+ sites) alive which contributes to high MW.



E. Hot Mix Time: The hot mix time is important for getting the catalyst ready. A minimum time of 60 seconds is essential in

line for this. Higher times up to 90 seconds do not seem to have any adverse effect.

In attempting to compare temperature, comonomer level and catalyst requirements for the HTC

mode, the pattern shown in Figure 3.1.29 is very apparent. More catalyst is required to compensate

for increased temperature or increased copolymer rate.

Figure 3.1.29: Effect of Temperature and Comonomer on HTC Catalyst

3.1.8 Butene-1 in the Catalyst Diluent Addition of butene-1 in the catalyst diluent has an effect on reactor conditions. Normally the butene-1

required for density control is added to the recycle solvent. Catalyst diluent that is used to dilute the catalyst

and provide a high volume carrier stream to maintain certain hold up times in the catalyst system is taken

from the recycle solvent after the solvent purifiers. The butene-1 in the catalyst diluent is only operated

during production of butene copolymer resins and may contain up to 10% butene-1 in the diluent depending

on the product density.

The effects on reaction conditions are increases in both the mean and trimmer outlet temperatures for the

same melt index and density. This provides the ability to operate at higher ethylene concentrations while

maintaining the same resin properties (i.e. melt index), which then allows for higher resin production at

a given total solution rate.

The mechanism of this phenomenon is not well understood, however it is believed that the molecular

structure of the catalyst is altered enabling higher molecular weight resin to be made. This is being

accomplished by a change in the transfer rate where a growing polymer molecule is detached from the

active site. If the reactor temperatures were not increased with the additional ethylene concentration a



product with a lower melt index would be produced in the reactor. Figure 3.1.30 illustrates the differences

in trimmer outlet temperatures for a film product (11U4) and an injection molding product (2111) while

operating with no butene-1 in the catalyst diluent versus butene-1 in the catalyst diluent.

Figure 3.1.30: Effect on Reactor Conditions with and without Butene in the Catalyst Diluent



SECTION-4.0 PROCESS DESCRIPTION



This process can produce many different grades of resin by varying the configuration of the reactor system,

the feed rate, type and injection point of catalysts, operating temperature as well as the feed rate and

injection point of hydrogen. Hydrogen (J) is used as the Telogen (Chain terminator) for controlling the melt

index and the molecular weight distribution of some of the product resins. The characteristics of the polymer

product are also influenced by the presence of comonomers. The resin grades can be categorised as

follows:

Homopolymer resins consisting of Ethylene (FE) only

Copolymer resins containing Butene-1 (FB-1) as comonomer

Copolymer resins containing Octene-1 (FC-1) as comonomer

Copolymer resins also known as terpolymers, containing both FB-1 and FC-1 as comonomers.

The process is based on a solution phase reaction system using cyclohexane as the solvent. The plant is

divided into four areas as defined below:

4.1 Reaction area (Area 100) where the reactants (i.e. FE, J, FB-1 and FC-1) are dissolved in recycled

solvent and catalytically polymerised. Catalyst residues in the solution are deactivated and then the resin is

separated from the solvent, unreacted monomers and comonomers and impurities.

4.2 Recycle area (Area 200) where the unreacted FE and impurities are separated from solvent and

comonomers which can then be recycled.

4.3 Finishing area (Area 300) where the polymer product is pelletized devolatilised and prepared for

packaging.

4.4 The ISBL utilities and storage area (Area 400) includes the flare knock-out drums, hot nitrogen

systems, steam systems, Dowtherm (DTA) systems as well as tankage for storing and de-inventorying

solvents and comonomers.

The plant also requires the support of OSBL storage and utility systems such as cooling water, nitrogen

supply, etc.

The detailed section wise process descriptions are as follows:

4.1 REACTION AREA (AREA 100): The process sequence in this area is to cool the recycle cyclohexane (SH), purify it, mix comonomer, absorb

FE into the SH-comonomer mixture, pump the solution to reaction pressure and then adjust the temperature

of the stream for the polymerisation reaction if necessary, the tempered solvent-monomer-comonomer

mixture is then fed to the reactors.

Reaction is initiated and controlled by injecting catalysts into the reactor feed at selected locations.

Chemicals are fed to the reactor effluent to deactivate the catalyst. Reactor effluent is also heated to

facilitate separation of solvent and both volatile components from the polymer. Finally, the pressure of the

stream is reduced so polymer can separate as a liquid phase. Solvent and unreacted FE and any

associated comonomers flash off as vapour.



This section is subdivided into various sub sections which are as under:

4.1.1 Recycle Solvent Purification (Ref. PFD 00101- AA-31-0101) Cyclohexane solvent (SH) fed to the reaction area is always cooled in the recycle SH coolers (31-EA-101

and 31-E-101 A/B) and then purified in the SH purifiers (31-V-125 A/B) to remove water and catalyst

breakdown compounds which would otherwise poison the catalysts in the reaction system.

The system consists of two SH Purifiers (31-V-125A/B), in-line Solvent Feed Filters (31-G-103), a

regeneration system shared with the FC Purifiers), two Solvent Feed Pumps (31-P-101/S) and two HP

Diluent Pumps (31-P-102/S).

The SH purifier beds contain silica gel (PS) and a small quantity of activated alumina (PA) on top of the

Silica Gel (PS) bed. The alumina bed protects the Silica Gel bed (PS) from free water. The SH purifier

system consists of two identical vessels connected in parallel. One vessel is “on line” while the other is in

regeneration or on standby Adsorption through the beds is in a downward direction.

FB-1 recycle, which also includes fresh FB-1 make-up, is normally mixed to the recycle solvent stream

downstream of the SH purifiers at the suction of the solvent feed pump (31-P-101/S). As described later, the

FB-1 recycle stream is purified in the Area 200 and contains no catalyst poisons. However, a provision has

been made for feeding FB-1 also upstream of the SH purifiers. This path may be used under special

circumstances such as difficulties with the Area 200 purifiers. Provisions for a third injection point is provided

downstream of both the SH purifiers and the take-off for the catalyst injection system. FC-1 make-up is fed

upstream of 31-EA-101 and will always pass through the SH purifiers.

4.1.1.1 SH Purifiers (31-V-125A/B):

Solvent returning from the Recycle Area (Area 200), sometimes combined with comonomer, flow through

one of two SH Purifier for final impurity removal. It passes through the in-line Solvent Feed Filter to remove

any entrained solids from the stream and then on to the Solvent Feed Pump.



Each SH Purifier is packed with silica gel and has a small layer of activated alumina balls on top to prevent

lifting of the silica gel during the regeneration cycle. The silica gel and alumina will adsorb approximately

1.0% of their weight of ketones at 37°C. Therefore, the SH Purifier outlet stream should be analysed for the amount of ketones daily, and totalled to

determine when a purifier is to be taken off line and regenerated . Silica gel will also adsorb PD,

(deactivator), and trace quantities of water and other impurities. Silica gel will crumble if subjected to high

levels of free water.

A purifier will be on line for approximately three or four days before requiring regeneration, under normal

operating conditions. A flow distribution ring on the process inlet disperses the solvent flow evenly over the

packing bed, and a top hat screen in the upper regeneration line prevents any packing carryover during the

regeneration cycle. A slotted plate at the bottom of the purifier supports the silica gel bed. There is an in-line

Solvent Feed Filter (31-G-103) downstream of the SH Purifiers.

Purifier Data Charge: • Approximately 32,400 kg of PS on the top

• 800 kg of PA on top of the PS

• 200 mm of ceramic balls on top of the PA

Bed Loading: Bed is sized for a minimum of 50 hours on lne.

• Swing beds if ketones in the

• Ketones in effluent is greater than 0.2 ppm

• PD in effluent is greater than 0.4 ppm

Regeneration: Maximum number of regenerations before repacking: 30

Purge cycle duration : Minimum of 5 hours

Maximum regeneration temperature: 300°C at bed inlet

Minimum temperature bed outlet during purge: 175°C

Maximum cooler outlet temperature during purge: 40°C

Approximate heatup time 8 hours

Approximate cool down time 8 hours

4.1.1.2 Solvent Feed Pumps (31-P-101/S): The Solvent Feed Pump feeds a solvent and sometimes butene and/or octene mixture to the head tank

where a controlled flow of ethylene is absorbed and further pumped as the main feed flow to the reactor.

4.1.1.3 HP Diluent Pumps (31-P-102/S): The HP Diluent Pumps are positive displacement pumps that are used to supply a controlled dilution flow to

the discharge of the catalyst pumps. This dilution flow increases the velocity of the catalyst flow, therefore



reducing the elapsed time to observe the effects of a changed catalyst flow in the reactor. The flow should

be as per the recommendation and it should be checked regularly, if flow is less then it will cause loss of

reaction or if supplied in excess the reaction may become sluggish. The HP Diluent Pumps provide a source

of heated solvent for heat tempering the catalyst in the Heat Treated Catalyst mode. The diluents pumps

also supply a very small and continuous flow into the hydrogen and off-line catalyst injection points at the

reactor to prevent them from plugging. Flow orifice is provided in the Hydrogen injection line to check the

flow.

4.1.2 SH Purifier Regeneration

(Ref. PFD 00101-AA-31-0101) When water analysis of the SH purifier outlet indicates a moisture or impurity breakthrough, or when a

breakthrough is anticipated, the exhausted purifier is taken out of service and drained to the LPS hold-up

tank (31-V-201) in the recycle area. Nitrogen is used to displace the liquid. Then the purifier is

depressurised prior to regeneration.

Regeneration is accomplished by circulating hot nitrogen through the SH Purifier bed in upward direction,

counter-current to normal process flow. The purifier regeneration blower (31-K-101) maintains the flow in the

regeneration loop. The regeneration gas entering the bottom of the bed is heated in the purifier regeneration

heater (31-E-109). The gas leaving the top of the bed contains a significant amount of hydrocarbon vapour

and some quantity of moisture desorbed from the bed. This stream is cooled in Purifier Regeneration Cooler

(31-E-110) to condense the hydrocarbons and water. From the cooler, the regeneration gas is returned to

the suction of 31-K-101 via the Purifier KO drum (31-V-101). Heating is continued until the temperature of

the purifier outlet approaches and is sustained between 280 and 300°C.

When initial heating is complete, the impurity laden gases contained in the regeneration loop are purged to

flare. Heating continues during this purge step Once the purge has been completed, heating is turned off,

circulation is stopped and the direction of flow is reversed so the bed can be cooled to 50-60°C by

regeneration gas flowing downward. The regeneration blower after cooler (31-E-108) removes the sensible

heat contained within the purifier as well as the heat of compression from the regeneration gas. Purified

solvent from the operating bed is then filled into the bottom of the vessel. The entering liquid displaces

nitrogen to the LPS hold-up tank. To ensure good performance, the freshly regenerated bed is cooled down to its

normal operating temperature prior to placing the bed in service. This is accomplished by feeding cold solvent

from 31-E-101 A/B through the bed. The exiting solvent stream is sent to LPS hold-up tank (31-V-201).

The SH purifier bed media is replaced whenever regeneration is no longer effective in restoring the

adsorptive properties. The spent bed is dumped from the vessel and removed for off-site disposal. New

desiccant is charged through the top of the vessels and regenerated prior to returning the purifier to service.

The system consists of Purifier Regeneration Cooler (31-E-110A/B), Regeneration KO Drum (31-V-101),

Regeneration Blower Suction Filter (31-G-101), SH Recovery Tank (31-V-102), Purifier Regeneration Blower

(31-K-101), Purifier Regeneration Heater (31-E-109), Regeneration Blower Aftercoolers (31-E-108), and

Regeneration Waste Transfer Pump (31-P-112).



Regeneration System Description: 4.1.2.1 Purifier Regeneration Cooler (31-E-110A/B): This is a water-cooled exchanger, which cools the circulating nitrogen from 300°C to 37°C and condenses

any condensable vapours for removal in the Regeneration KO Drum.

4.1.2.2 Regeneration KO Drum (31-V-101): The initial condensed solvent passes through the Regeneration KO Drum and is collected in the SH

Recovery Tank (31-V-102). When the SH Recovery Tank is full, it is isolated from the Regeneration KO

Drum and the recovered solvent is transferred to the LPS Hold-up Tank. The balance of solvent collected in

the Regeneration KO Drum, which is saturated with impurities, is transferred to the fuel system. 4.1.2.3 Regeneration Suction Blower Filter (31-G-101): The suction filter is designed to remove dirt, pipe scale and miscellaneous contaminants from the nitrogen,

which could damage the rotating elements of the Regeneration Blower.

4.1.2.4 SH Recovery Tank (31-V-102): The SH Recovery Tank provides a reservoir for recoverable solvent from the Regeneration KO Drum. The

recoverable cyclohexane is analysed, and, if the quantity of impurities is acceptable, slowly transferred to the

LPS Hold-up Tank by using nitrogen pressure.

4.1.2.5 Purifier Regeneration Blower (31-K-101): The Purifier Regeneration Blower circulates nitrogen through the purifier during the heating and cooling

cycles. Makeup nitrogen is supplied through a pressure regulator to the inlet of the Purifier Regeneration

Blower. High temperature at the blower discharge, low suction pressure, high level in the Regeneration KO

Drum, or high differential pressure across the blower are interlocked to stop the Purifier Regeneration

Blower.

4.1.2.6 Purifier Regeneration Heater (31-E-109): The Purifier Regeneration Heater is an exchanger using DTA on the tube side. Nitrogen, which is present on

the shell side, is heated to 300°C.

4.1.2.7 Regeneration Blower Aftercoolers (31-E-108): The Regeneration Blower After cooler is designed to remove the heat generated in the blower during the

cool down cycle. This results in a quicker and more efficient cool down cycle.

4.1.2.8 Regeneration Waste Transfer Pump (31-P-112): The regeneration Waste Transfers the impurity laden regeneration waste solvent to the waste fuel system. A

low-low level alarm switch on the SH Recovery Tank is interlocked to stop the Regeneration Waste Transfer

Pump.



4.1.3 SH Makeup Dryer system: 4.1.3.1 Process Description: The SH Makeup Dryer system consists of a feed cooler, a single dryer, a water analyser an in-line strainer

on the dryer outlet line. This strainer prevents silica gel from contaminating the contents in the mix tanks.

4.1.3.2 SH Make-up Dryer (31-V-126): The SH Makeup Dryer dries the solvent used for preparing catalyst/co-catalyst batches. The dryer system

consists of a single dryer with a midpoint sample valve, a high-pressure steam coil, and permanent nitrogen

and flare header connections. The dryer is packed with silica gel with a layer of activated alumina balls.

Solvent from the storage area is pumped through the dryer for water removal. SH Make-up Dryer Data: Charge:

• Silica Gel (PS) : 0.753 m3

• Ceramic Balls : 100 mm of 12 mm dia balls

50 mm of 6 mm dia balls

Bed Loading:

• The bed will retain approximately 25 kg of water and 1.3 kg of ketones or a combination of both.

• The bed will be regenerated after each catalyst batch makeup or when a water result at the ample point

midway through the bed exceeds two parts per million. There normally will not be any ketones in the pure

solvent used for catalyst makeup.

Regeneration:

• Purge time is 2 hours with the nitrogen temperature from the dryer exceeding 150°C.

4.1.3.3 SH Makeup Cooler (31-E-116): The SH Makeup Cooler is a water-cooled plate exchanger. Solvent is pumped from the storage area and passes

through the SH Makeup Cooler. The solvent is cooled to < 40°C before it is lined to the SH Makeup Dryer.

4.1.4 Solvent Pumping and Catalyst/Deactivator Diluents Supply (Ref. PFD 00101-AA-31-0101) 4.1.4.1 Homopolymer Resins:

The purified SH flows to the suction of the solvent feed pumps (31-P-101/S) which pump it to the absorber cooler

(31-E-102). A small portion of the flow to the pump suction is diverted to the catalyst and deactivator areas for use

as diluents.

Diluent is distributed at two pressure levels:

• LP (Low Pressure) diluents used for maintaining a constant suction pressure for the positive

displacement catalyst and deactivator pumps.

• HP (high pressure) Diluent is added to further dilute the catalyst feed streams on the discharge side

of the catalyst metering pumps. HP diluent is also the source of hot solvent required when operating

with heat treated catalyst (HTC). HP Diluent is obtained by boosting pressure of purified SH with

one or two HP diluents pump (31-P-102/S).



4.1.4.2 FB-1 Comonomer Resins: This methodology is the same as that described above for homopolymer except that FB-1 can be injected

into the upstream of the suction of the solvent feed pump (31-P-101/S) but it should always be lined up

through the SH Purifier.

NOTE: Before taking FB-1 in FB Surge Drum its must be analysed, as it should match with the Feed Specification.

4.1.4.3 FC-1 Comonomer and Terpolymer Resins: The methodology is the same as that described above for homopolymer except that the recycle SH stream

will contain FC. 4.1.4.4 Ethylene (FE) Supply and Purification: (Ref. PFD 00101-AA-31-0101) FE feed to the polyethylene unit is supplied from the gaseous ethylene storage or directly from the ethylene

cracker. Due to the presence of impurities, the gaseous FE is passed through two purification steps. In the

first step FE passes through the primary FE guard beds (31-V-127A/B) which are packed with activated

alumina. These beds are used to remove oxygenate hydrocarbons, water, H2S and ammonia.

These beds operate with one online and the other in a regeneration or standby mode. The beds can be

swung based on measured or anticipated breakthrough of water or other impurities. The primary FE guard

beds will share a regeneration system with the FE column feed dryers (31-V-209A/B). The flow direction

during normal operation and the regeneration cycle will be same as previously described for the SH purifiers

(31-V-125A/B). The nitrogen regeneration temperature should be 280°C and the cool down temperature

37°C. It is anticipated that the there will be a minimum of 10 days between required regenerations. The

second step in the FE purification process is the secondary FE guard bed (31-V-132) which is used to

remove Phosphine. This bed is packed with a specialised activated alumina that is non-regenerable

adsorbent. The expected bed life is five years. At that time, the adsorbent material will have to be changed

and disposed off.

Primary FE Guardbed Data: Charge: • 1/8” Selexsorb CD: 20700 kg (5100 mm)

• 1/8” Selexsorb COS: 11800 kg (2600 mm)

• ¼” Alumina on Top: 360 kg

• ¼” Alumina on Bottom: 360 kg

Regeneration: • Heatup time is approximately 8 hours

• Purge time is 5 hours after maximum temperature is reached.

• Cool down time is approximately 8 hours.



Secondary FE Guardbed Data: Charge: • 1/8” Selexsorb AS: 5440 kg (3200 mm)

• ¼” Alumina on Top: 180 kg

• ¼” Alumina on Bottom: 180 kg

4.1.4.5 Ethylene Absorption and Reactor Feed Pumping: (Ref. PFD 00101-AA-31-0101) The purified gaseous ethylene (FE) is fed under flow control into the solvent stream upstream of the

absorber cooler (31-E-102). A sparger/Mixing Nozzle (31-HX-108) is used to aid in the absorption of FE into

the solvent. As ethylene dissolves in the solvent the heat of absorption increases the temperature of the

solvent significantly. The function of Absorber Cooler is to remove this heat of absorption.

To effect good contacting of the FE gas with the solvent, the feed section of the absorber cooler is packed

with Pall Rings. In effect, this packed section acts as an adiabatic absorber. The heat of absorption is

removed in a U-tube water cooled heat exchanger mounted above the packed bed. This cooling step makes

it possible to fully absorb the FE into the liquid stream.

From Absorber Cooler, the solution enters the Head Tank (31-V-103) and from there it flows to the reactor

feed pump system (31-P-103/104). The reactor feed pump (31-P-104) provides the pressure required to

overcome the pressure drop of the reaction system and to maintain a single liquid phase polymer solution

through the reaction and catalyst removal sections. The function of the Reactor Feed Booster Pump (31-P-

103) is to proved sufficient suction pressure and to maintain single phase flow to the Reactor Feed Pump

(31-P-104). A variable frequency drive on 31-P-104 is used to control the discharge flow rate.

A bypass has been provided around 31-V-103. This makes it possible to operate the reactor feed pump

without an FE flow or in a non-production mode. Under such conditions the FE vapour pressure is used to

maintain the normal pressure in the head tank.

4.1.5 Hydrogen (J) Telogen System: (Ref. PFD 00101-BA-31-0102) Hydrogen (J) is a telogen (chain terminator) used for controlling the Molecular Weight Distribution (MWD),

Melt Index (MI) and Stress Exponent (SEx) of the product. It is compressed in the Hydrogen compressor

(31-K-102/S) and is injected both downstream of the reactor feed pump (31-P-104) discharge and/or at one

of the five injection points along and downstream of the Reactor No. 3 (31-R-102). HP Diluent is added as a

carrier to the line which feeds hydrogen to the reactor system. When pipe reactor no. #3 is in service.

Required quantity of Hydrogen should be used; otherwise it will affect the MFI of the resin being produced.

The Hydrogen compressor is a diaphragm compressor with spillback pressure control to maintain discharge

pressure above the operating pressure of the reactor. Two compressors are provided for process

requirement. Normally only one compressor is required to be running for process requirement and the other

is standby. Capacity of each compressor is 25.2 kg/hr and hydrogen is supplied at 206 kg/cm2g and 60°C.

A water cooler (31-EA-102A/B) is provided on the discharge of the compressors to ensure the cooling of the

outlet stream.



NOTE: For details of Hydrogen Compressor (31-K-102/S) refer vendor’s operating & maintenance manual. Hydrogen Buffer Storage (31-V-425): A Buffer Storage of hydrogen is provided to take of hydrogen requirement of polymer units in case of trip of

PSA unit in NCU. Net storage capacity, equivalent to 6 hrs of total consumption of all the three polymer units

at maximum rate is envisaged. The available time will be more depending on grade under production or if

the units are turned down.

The vessel is protected by pressure relief valve PSV-8001A/B set at pressure of 145 kg/cm2g.

Tapping is taken from individual discharge of each Hydrogen compressor and the combined line feeds

hydrogen to the bullets. This arrangement allows independent use of the two compressors for the two

purposes, i.e. for feeding to the unit and for hydrogen buffer storage pressurisation. After pressurisation of

the storage vessel for the first time, as such these compressors are not required to be run for buffer storage

pressurisation until stored hydrogen is consumed due to problem in PSA or otherwise.

4.1.6 Reactor Feed Tempering: (Ref. PFD 00101-BA-31-0102) The reactor feed solution is heated as required to maintain the desired reactor inlet temperature. Automatic

temperature control ensures that the appropriate synthesis temperature required for density and MI control is

maintained. For broad MWD resins made in the pipe reactor (Case V), it is necessary to heat the reactor

feed to avoid polymer precipitation. Consequently, the duty of the reactor feed heater (31-E-103) is relatively

high. For other resins heat input is required for temperature control purpose only and the required duty is

low.

During normal operation, the feed stream is heated in reactor feed heater (31-E-103) using LP steam. A

fast-response temperature controller splits the feed stream between the heater and the water cooled reactor

feed coolers (31-E-104 A/B) to maintain the preset reactor inlet temperature.

“Light-Off” is a term used to describe the initiation of the exothermic reaction in the reactor. During light-off

the entire reactor feed stream is passed through 31-E-103 until the exothermic reaction heats the contents of

the reactor to the desired synthesis temperature. Normally, the reactor is started with reduced flow, i.e., the

design basis being approximately 33% of the Total Solution Rate. Heating is also required during loss of

reaction or shutdown. In these cases, HP steam is used in 31-E-103.

At the reactor inlet, the catalyst/co-catalyst stream is mixed into the tempered feed stream. The monomer

and, if required, comonomer are polymerised in the reactors to form polymer (RA). The product RA is fully

dissolved in the hydrocarbon stream consisting mainly of solvent, unreacted monomer and comonomer. The

degree of monomer conversion is controlled primarily by catalyst concentrations. The polymerisation

reaction is highly exothermic and causes the solution temperature to rise.



4.1.7 Reactor Modes: (Ref. PFD 00101-EA-31-0105) The reactor system consists of the pipe Reactor #3 (31-R-102), the Reactor #1 (31-R-101) which is the main

stirred autoclave reactor and the trimmer which is a length of pipe downstream of 31-R-101. In addition, the

feed temperatures and the injection points and rates of catalyst and Hydrogen can also be varied. The

reactor modes are as follows:

4.1.7.1 No. 1 Reactor Operation: In this mode the reactor feed solution can be fed both to the bottom and to the side of Reactor No. 1. The

feed entering through the bottom nozzle passes through Reactor No. 3 but remains unaffected as no catalyst

is fed to the pipe reactor.

The tempered feed stream enters the bottom of the Reactor no. 1 where it contacts the injected catalyst.

The contents of the reactor are mixed with an agitator. The feed rate of catalyst is varied to achieve the

desired monomer conversion. A normal conversion (95%) results in a temperature rise ranging from 186 to

252°C and approximately 15 to 20% RA concentration in the total solution depending on the resin being

produced. The required quantity of Hydrogen, in the solvent comonomer carrier, can be injected into the No.

1 Rector inlet to control the molecular weight of certain resin grades.

A metered portion of the reactor feed stream may be fed to the Reactor No. 1 through two side feed

connections. This is done to both improve the mixing of the high viscosity solution and can be used to vary

resin properties. The polymer solution formed in Reactor No. 1 leaves the vessel and enters the Trimmer.

4.1.7.2 Series Operation: no. 3 Reactor through No. 1 Reactor (3→1) To manufacture polyethylene resins with a broad MWD, the pipe Reactor No. 3 (31-R-102) is operated in

series with Reactor No. 1 (31-R-101). Conversion begins in Reactor no. 3 and is completed in Reactor no.

1. Reactor No. 1 operates with the agitator off. Reaction differential temperature indicates the degree of

conversion achieved. Hydrogen and catalysts are injected into Reactor No. 3. There are two catalyst feed

nozzles on Reactor no. 3. In addition to selecting the J feed point, catalyst and Hydrogen feed rates can be

varied to control MWD and melt swell characteristics of the RA. To avoid precipitation of solid RA when

using the Reactor No. 3, the inlet temperature of the reactor must be elevated.

4.1.7.3 Parallel Operation: No. 3 Reactor Plus No. 1 reactor (3+1) To make resins of intermediate MWD, the solution is fed to the Reactor No. 1 both via the side feed nozzles

and the bottom nozzle. Hydrogen and catalysts are also injected into the Reactor No. 3. Catalyst flow is

split between both reactors. The fraction of total solution fed to each reactor is varied to control MWD.

Higher the fraction going through the No. 3 Reactor, the broader the MWD. Temperature of each feed

stream can be separately adjusted.

4.1.7.4 Trimmer Reactor: The downstream pipe connecting the Reactor No. 1 to the Adsorber preheater (31-E-105 A/B) is called the

trimmer reactor. It is a fixed length of pipe with a specific volume. The trimmer may be considered as a

reactor because polymerisation continues along its length. This improves catalyst efficiency and ethylene

conversion.



4.1.8 Catalyst System: (Ref. PFD 00101-BA-31-0102 & 00101-CA-31-0103) In this system, the catalysts and co-catalysts are diluted with SH, accurately metered and proportioned, and

then injected into the synthesis reactors. 4.1.8.1 Process Description The process requires catalyst in relatively small, precisely controlled quantities for the conversion of ethylene

and comonomer into polyethylene.

The catalyst CAB, CAB-2 and co-catalyst CT, CD and CJ are incapable of producing significant

polymerisation until they are mixed to form active catalyst sites.

The catalyst must be injected at a rate and ratio necessary to sustain the optimum ethylene conversion

(usually 93%-96%).

There are two catalyst/co-catalyst systems used in the process. Both are basic Ziegler-Natta co-ordination

type catalysts.

4.1.8.1.1 Standard Catalyst System (STD): This uses two catalyst components, a transition metal component and an activating metal alkyl, which are

mixed prior to injection into #3 Reactor or #1 Reactor, depending on the reactor system selected. A

residence time of 2 to 5 seconds at ambient temperature before entry into the reactor system is necessary to

form active catalyst sites. (CAB + CT) – In this system single co-catalyst material CT, is used to reduce and

alkylate the CAB.

Standard catalyst is generally used for the series operation of Reactor No. 3 and No. 1 (3→1) but may also

be fed directly to Reactor No. 1. The active catalyst is formed by mixing the diluted streams of CAB catalyst

and CT co-catalyst together just before injecting the mixture into the reactor. In the 3+1 reactors mode

(parallel operation), STD catalyst is injected into both Reactors No. 3 and No. 1 inlets.

4.1.8.1.2 Heat Treated Catalyst (HTC): This uses three components – a transition metal component and two different metal alkyl components which

are used to sequentially treat the transition metal component and create the active polymerisation sites. In

addition, temperature is also important in the preparation of the catalyst.

Heat treated catalyst is principally used for the no. 1 Reactor mode. As the first step, the diluted stream of

CAB-2 catalyst and CD co-catalyst are mixed together. This takes place in a special mixing device (“cold

mixer”) developed for this purpose. The temperature of the resulting stream is then raised to approximately

230°C by adding Hot HP diluents to the catalyst/co-catalyst stream. HP Diluent is heated by the HP diluents

heater (31-E-111).

The time the catalyst mixture is held at high temperature is critical for proper activation of the catalyst.

Therefore, a residence time of 60-90 seconds is provided downstream of the cold mixer before the CJ co-



catalyst is injected. After this point, a further 1 to 2 seconds is provided for the combined stream (CAB-2,

CD, CJ) before injecting it into the Reactor No. 1.

The HTC delivery system is prone to plugging and therefore requires flushing and cleaning. To maximise

the on-stream time, the HTC delivery system has been twinned so that one can be on-line while the other is

being cleaned.

CAB-2 + CD + CJ) – In this system two co-catalyst materials are used to carry out, first the reduction

reaction and then the alkylation reaction, by CD & CJ respectively.

First, the catalyst CAB-2 and the co-catalyst CD are mixed in a vertical mixer. This is known as the cold mix

section. A residence time of 5 to 30 seconds is necessary to achieve proper mixing and reduction of the

catalyst.

Second, high-pressure Diluent is heated by the HP Diluent Heater to approximately 240°C at the exit of the

hot mix section. The residence time of the hot mix section is between 60 to 90 seconds.

Third, the hot mix section is followed b the alkylation reaction. The co-catalyst CJ is added to the CAB-2/CD

stream to activate the polymerization catalyst mixture. The residence time before entry into the rector system

is 1 to 2 seconds. The short time minimizes the reduction in catalyst activity.

4.1.8.2 Catalyst/Co-Catalyst The catalysts and co-catalyst are received in cylinders or `ISO Containers’. The catalyst/co-catalysts are

transferred by nitrogen pressure to their respective mix tank.

The catalyst/co-catalyst are diluted with a specific volume of dry cyclohexane in the respective mix tank. The

volume of cyclohexane is dependent on the weight of catalyst/co-catalyst added to the mix tank and the final

catalyst/co-catalyst concentration required. After the components are in the mix tank and the transfer lines

have been flushed with cyclohexane, the batch is agitated for one hour. The agitator is then stopped, and the

batch is allowed to settle for one hour before being transferred to the surge tank and catalyst pump.

The surge tank provides a sufficient supply of catalyst/co-catalyst to allow enough running time to be able to

take the mix tank off line for batch makeup. The solution is metered from the mix and surge tank and further

diluted with low-pressure diluents cyclohexane at the suction of the catalyst/co-catalyst metering pump.

Additional high-pressure diluents cyclohexane is added at the discharge of the metering pump to reduce the

transport time to the Reactor. After every batch make-up keep close monitoring on reaction section.

4.1.8.3 CAB Catalyst CAB catalyst is received in cylinders. It is transferred by nitrogen pressure to mix tank where it is diluted with

dry cyclohexane, and agitated to form approximately a 25% solution (5.6% metals).

The catalyst solution is metered from the mix tank and low-pressure diluents cyclohexane is added at the

catalyst pump suction to maintain a positive suction pressure for the pump.

4.1.8.4 CAB-2 Catalyst



CAB-2 catalyst is received in cylinders. It is transferred by nitrogen pressure to a mix tank where it is diluted

with dry cyclohexane, and agitated to form approximately 25.0% solution (4% metals).

4.1.8.5 CT Co-Catalyst CT co-catalyst is received in cylinders. It is transferred by nitrogen pressure to a mix tank where it is diluted

with dry cyclohexane, and agitated to form approximately 25.0% solution (3% metals).

4.1.8.6 CD Co-Catalyst CD co-catalyst is received in cylinders. It is transferred by nitrogen pressure to a mix tank where it is diluted

with dry cyclohexane, and agitated, to form approximately 25% solution (3.4% metals).

4.1.8.7 CJ Co-Catalyst CJ co-catalyst is received in cylinders. The CJ cylinders are pre-diluted by the supplier with dry cyclohexane

to form approximately 30% (6% metals) solution. This solution is transferred by nitrogen pressure to a mix

tank and agitated.

4.1.8.8 Catalyst/Co-Catalyst Mix Tanks (31-V-105/107/109/111/113): Each mix tank is equipped with:

• A nitrogen supply line with a regulator to maintain a constant pressure while the tank is in operation.

• A pressure safety valves and a bypass for depressurising the tank, which relieves to the Catalyst

Knock Out Drum.

• A catalyst make-up line at the top of the tank that has a dip tube extending into the tank, which

prevents static build-up.

• A sludge collection sump at the bottom of the tank to collect any solids in the tank. The sludge has

to be drained on regular basis to avoid chocking in Catalyst/Co-catalyst pump suction line. An

agitator nitrogen seal-conditioning unit.

• An outlet line to the surge tank with a standpipe extending slightly above the sump flanges.

• A level indicator, which provides a read out on a local panel and in the DCS.

• An agitator to thoroughly mix each batch.

4.1.8.9 Catalyst/co-Catalyst Surge Tanks (31-V-106/108/110/112/114): Each catalyst/co-catalyst surge tank is equipped with:

• A nitrogen supply with a regulator to maintain a controlled pressure on the tank.

• A pressure safety valve.

• A line to allow the pressure to be balanced on the vapour side between the surge and mix tank.

• A liquid draw off line from the bottom of the tank to the metering system.

• A level indicator, which provides a read out on a local panel and in the DCS

4.1.8.10 Catalyst/Co-Catalyst Pumps Each pump is a variable stroke, diaphragm pump. The pump takes suction from the mix or surge tank via the

metering system. There is a low-pressure diluent tie in at the pump suction. This maintains a positive

suction pressure and a constant volume to the pump that prevents damage to the pump diaphragms.



The pump suction line is equipped with a pulsation dampener to absorb the pressure pulsations produced by

the pump. High-pressure Diluent is injected at the pump discharge to speed up the co-catalyst flow changes

to the Reactor. A pump from another system can be utilized as a spare.

4.1.8.11 Catalyst/Co-Catalyst Metering System (31-P-105/106/107/108/109): Each metering system consists of a flow transmitter and a flow control valve. The low-pressure diluents

supply is pressure controlled and maintains a constant supply to the pump regardless of the catalyst flow,

e.g., when the catalyst flow is increased, the low-pressure diluents flow will decrease by the same amount to

satisfy the constant volume demand of the pump.

4.1.8.12 Catalyst Knockout Drum (31-V-115): The Catalyst Knockout Drum is charged with a solution of isobutanol and mineral oil (20% isobutanol and

80% mineral oil) for deactivation of any catalyst entering the drum. Pressure safety valves and vents from

the catalyst and co-catalyst systems tie into this vessel through separate lines. The vessel is vented to an

underground water sump through a seal leg. A continuous water flow enters the sump to provide a water

seal. This prevents air entering the Catalyst Knockout Drum.

4.1.8.13 HP Diluent Heater (31-E-111):

The heater heats high-pressure diluents cyclohexane, in which the metered streams of mixed CAB-2 and CD

pumps are introduced prior to injection to the reactor system.

The heater is a DTA exchanger. It is capable of heating 3000 kg/hr of high-pressure diluents from 30°C to

300°C. A temperature indicator controls the process temperature at the exit of the heater and provides high

and low temperature alarms. A three-way valve adjusts the flow through the HP diluents Heater and the

heater bypass line to control the exit temperature. A flow controller located on the inlet of the heater controls

the HP diluents flow to the heater.

4.1.9 Deactivator System: (Ref. PFD 00101-FA-31-0106)

The polymerisation reaction is terminated by deactivating the catalyst. Two chemicals are used for this

purpose. One is injected upstream and the other is injected downstream of the Adsorber Preheaters (31-E-

105 A/B). Static mixers (31-M-106 & 31-M-107) downstream of each injection point ensures efficient mixing.

The deactivator injected upstream of the Adsorber Preheater is Pelargonic Acid (PG) which functions to

terminate polymerisation and also to solubilise the catalyst restudies to minimise fouling of the adsorber

preheater. The deactivator injected downstream of the adsorber preheater is Acetyl Acetone (PD) which is

used as a chelating agent to promote adsorption of catalyst residues on the activated alumina (PA) in the

Solution Adsorbers (31-V-104 A/B).

Two types of deactivators are required because:

• Reaction must be stopped before the Preheater. PD injection at this point will lead to Preheater tube

corrosion and fouling.



• PG or C-810 by itself will not result in maximum Solution Adsorber bed life.

• PD results in a very high level of ketone impurities in the system that must be removed.

• In summary, maximum color and bed life can be attained along with minimum ketone production and

preheater fouling by using predetermined deactivator ratios.

4.1.9.1 PG or C-810 Deactivator System PG is stored in a PG Storage Tank (31-V-140), and transferred into the PG Storage Tank (31-V-116) with the

PG transfer pump (31-P-118). The tank uses nitrogen pressure to transfer the deactivator to the metering

system. It is then metered, diluted with solvent, and pressurised with the metering pump. The PG is injected

into the process stream upstream of the Static Mixer (31-M-106) that is installed before the Adsorber

Preheater.

4.1.9.2 PG Storage Tank (31-V-116/140): The PG Storage Tank operates under nitrogen pressure. The storage tank pressure is controlled by a

pressure control valve that adds nitrogen or by another pressure control valve that vents nitrogen to

atmosphere when necessary. It is protected by a pressure safety valve. An external low-pressure steam coil

around the tank heats the contents of the tank to 30°C.

4.1.9.3 PG Metering System The PG metering system consists of a low transmitter, a flow control valve and a low-pressure diluents

pressure control valve. PG from the PG Storage Tank enters the heat-traced piping that increases the

temperature to reduce the viscosity for accurate measurement and maintains a constant temperature of

30°C for consistent measurement. It then goes through the flow transmitter and control valve where the flow

is controlled before it is diluted and enters the metering pump.

4.1.9.3.1 PG Metering Pump (31-P-110/S): The PG Metering Pump and its standby are identical variable stroke diaphragm duplex pumps. The pump

takes suction from the metering system and a low-pressure diluents tie-in on the pump suction maintains a

positive pump suction pressure. The suction line is also equipped with a pulsation dampener to absorb any

pressure pulsation produced by the pump. PG is pressurised and then injected at the inlet of the Static Mixer

ahead of the Adsorber Preheater.

4.1.9.4 PD Deactivator System: PD is received in the drums and unloaded into the storage tank with the drum pump. It is transferred using

nitrogen pressure to the metering system. It is then metered, diluted with solvent and pressurised with the

metering pump before being injected into the process stream downstream of the Adsorber Preheater. 4.1.9.4.1 PD Storage Tank (31-V-117): The PD storage Tank operates under nitrogen pressure. A pressure control valve that adds nitrogen when

necessary controls the storage tank pressure. Another pressure control valve vents nitrogen to atmosphere.

It is protected by a pressure safety valve.



4.1.9.4.2 PD Bulk Unloading PD is received in drums. The liquid is pumped from the drum to the storage tank. A high-level alarm will

sound in the central control room. 4.1.9.5 PD Metering System The PD metering system consists of a flow transmitter, a control valve and a low-pressure diluents pressure

control valve. PD from the PD Storage Tank goes through the flow transmitter and control valve where the

flow is controlled before being diluted at the metering pump.

4.1.9.5.1 PD Metering Pump (31-P-111): The PD Metering Pump and its standby are identical variable stroke diaphragm duplex pumps. The pump

takes suction from the metering system and a low-pressure diluents tie-in on the pump suction maintains

positive pump suction pressure. The suction line is also equipped with a suction pulsation dampener to

absorb any pressure pulsation produced by the pump. PD is pressurised and then injected at the outlet of

the Adsorber Preheater into the Static Mixer.

4.1.10 Preheating and Adsorption: (Ref. PFD 11010-BA-31-0102) The polymer solution which leaves the reactors is first heated to a predetermined temperature in the

Adsorber Preheaters (31-E-105 A/B) and then passed through the activated alumina bed of one of the

Solution Adsorbers (31-V-104A/B). The solution adsorber removes the residues of the deactivated catalyst

from the solution so that a color-free and non-corrosive polymer product is obtained. 4.1.10.1 Adsorber Preheater (31-E-105A/B): The RA solution stream is heated to 286- 310°C in the adsorber preheaters (31-E-105 A/B) using Dowtherm

“A” (DTA) vapour as the heating medium. Adsorber Preheaters (31-E-105A/B) are 1- 4 Shell & Tube Heat

Exchanger with process fluid flowing through the tube side.

The shell side of the heaters (31-E-105A/B) is protected by PSV-1603A/B respectively. These PSV’s are

balanced bellow type valve and after any relieving event, these PSVs must be service to ensure that the

corrugation of the bellows is clean and free of polymer.

Heating promotes chelation and adsorption of catalyst residues on the alumina in the solution adsorber.

Heating is also necessary for effective flash separation of volatile hydrocarbons from the molten polymer in

the intermediate pressure separator (IPS) and low pressure separators (LPS I & II) units downstream.

4.1.10.2 Adsorption: The system includes two solution adsorbers (31-V-104 A/B) each of which is filled with activated alumina

(PA). One vessel is in service, while the other is being refilled with fresh PA or is on standby. The Solution

Adsorbers are designed to reduce the catalyst residues in the polymer solution to trace quantities, and to

enhance the appearance of the finished product. The catalyst residues, which have been deactivated to

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the bottom and flowing forward to the Intermediate Pressure Separator. Flushing tie-ins to the process inlet

and outlet lines are used for solvent flushing, depressurising, and nitrogen purging the Adsorbers. The bleed

valves between the process inlet valves and the process outlet valves on the solution Adsorbers are

equipped with a vapour squelching apparatus.

This apparatus is about 500 mm long. It is constructed of 150 mm stainless steel conveying pipe (thin wall).

At one end it is tapered down and welded to a pipe nipple that will fit the bleed valve to which it will be

attached. The opposite end is partially shrouded so that vapours coming from it will be deflected at a slight

angle. Inside the pipe there is a piece of tubing running the length of it. This tubing is near the side of the

pipe. The tubing is sealed at one end and has small holes drilled in it. The other end extends through the

squelcher wall and is fitted with a valve.

When the apparatus is in place, low-pressure steam will be piped up to this valve. The holes are placed in

such a way that a steam spray will be directed across the squelcher, cooling the process flow from the bleed

valve. The apparatus is placed in such a way as to deflect vapours away from any ignition source and the

operator who is opening the bleed valve.

There is a small slide port on the side of the squelcher, which can be opened so a visual check may be

made of the bleed port. This is done after the dead leg is depressurised and before the bleed valve is closed.

The operator checks the bleed for signs of polymer. The squelching apparatus cools the solvent vapour

coming from the bleed valve and helps disperse the vapours that are emitted.

A solution adsorber is removed from service when product colour deteriorates to a value lower than the

control minimum. Before the exhausted bed can be isolated, the RA solution in the vessel must be flushed

out with hot solvent. Solvent for flushing is provided from the recycle area and is heated in the steam purge

heater (31-E-106) followed by the DTA purge heater (31-E-107). Solution Adsorber Data: Charge: • Alumina: 26000 kg

Beds should be changed when: • The resin color reaches the minimum standard.

• The pH of the water removed at the FE Feed Coalescer falls below 3.0. (Acid content exceeds

10,000 ppm)

• The acid content of the RB reflux stream exceeds 2,000 ppm.

• The PD content in the LB base stream exceeds 5 ppm.

4.1.10.3 Hot Flush System Solvent from the LPS Hold-up Tank is supplied to the Hot Flush Pump. The solvent is heated in two Purge Heaters

to hot solvent flush and fill the Solution Adsorbers or the reactor system. In the event of a power failure the Hot

Flush Pump, which is supplied with priority power, will be used to flush out the Reactor system.



The flow from the Hot Flush Pump is flow-controlled at the Purge Heater inlet. There is a flushing tie-in to #3

Reactor. A warm-up line back to the LB feed Condenser that avoids thermal shock to the Purge Heaters. The

Solution Adsorbers flushing outlet header goes to either the IPS or LPS overhead lines and is used for heating and

depressurising the Solution Adsorbers. There is also a tie-in to the Polymer Knockout Drum for nitrogen purging

the Solution Adsorbers. The Hot Flush Pumps, the flushing flow valve, and the pressure control valve are

equipped with “Z” Override switches for Reactor system flushing during a “Z” activation.

The process side of the Purge Heaters is protected by a pressure safety valve at the outlet of each Purge Heater.

The shell side is protected by a Pressure Safety Valve on the inlet line to each Purge Heater. The temperature at

the outlet of the DTA Purge Heater controls the three-way control valve on the outlet of the heater. This three-way

valve diverts the flow to the DTA Purge Heater or through the bypass line.

4.1.11 PA Charging and Spent PA Removal: The bed of Activated alumina (PA) in the solution adsorbers, in time will become saturated with catalyst and

deactivator residues and must be occasionally removed and replaced. The PA charging system provides the

facilities for preparing and loading a fresh PA charge and from removing a spent PA bed from the solution

adsorbers.

Fresh PA is delivered in one ton bags and transferred to the PA charge hopper (31-V-123). The bags are

lifted above the PA charge hopper with the PA bag hoist (31-ME-102). PA is loaded into the hopper by

gravity. The Charge Heater Blower (31-K-104) is then started to blow air into the bottom of the PA charge

hopper and through the PA. This air stream is heated in the PA charge heater (31-E-112). The purpose of

heating is to remove moisture from the fresh PA, heat it and precondition it prior to use. When the PA

charge is dry and hot, it is transferred into the empty solution adsorber.

The spent PA bed is removed from the solution adsorber vessel by vacuum. The PA blower (31-K-105)

circulates nitrogen in a loop which starts at the unloading probe (HX-113) which is used to vacuum the hot

PA out of the adsorber vessel. The removed PA is conveyed by the nitrogen stream into the PA fall-out

hopper (31-V-124). Here the spent PA separates from the nitrogen stream and is dumped into a portable

container where it is allowed to cool and is then disposed off.

Nitrogen gas which is separated from the spent PA in the PA fall-out hopper is first filtered in the receiver

(31-G-104). The filter receiver is a self-cleaning bag house sitting directly on top of the fall-out hopper. The

gas continues ton to the PA blower via the duplex PA blower suction filters #1 & #2 (31-G-105 A/B) and the

PA blower suction cooler (31-E-114). From the blower, the gas returns to the solution adsorber to complete

the loop. An intercooler (31-E-115) is provided to control the temperature of the blower discharge stream

going to Solution Adsorber.

As the top of the solution adsorber is open during PA removal, nitrogen is fed into the loop to minimise the

ingress of air. The exhaust fan (31-K-103) has been provided to draw off the excess nitrogen and noxious

gases from around the open manway of the solution adsorber. In spite of this nitrogen purge, some air will

inevitable enter the loop. Purge is controlled to maintain O2 concentration in the circulating gas below a level

found to prevent the ignition of any combustible materials contained in the spent PA.



The system used in:

• Dumping and elevating alumina to the charge hopper.

• Heating the alumina

• Charging Solution Adosrbers.

• Emptying spent Solution Adsorber.

The system consists of:

PA Charge Hopper (31-V-123), PA Blower (31-K-103), PA Blower Suction Cooler (31-E-114), PA Fallout

Hopper (31-V-124), Filter Receiver (31-G-104), PA Charge Heater (31-E-112), PA Charge Heater Blower

(31-K-104), Oxygen analyser, PA Disposal Vessel, PA Bag Hoist (31-ME-102), Exhaust Fan (31-K-103)

4.1.11.1 PA Charge Hopper (31-V-123): The hopper is a one-compartment vessel. Bags of alumina will be hoisted and emptied into the top of the PA

Charge Hopper. The charge hopper is equipped with:

• A vent for venting hot air during the heat-up of the alumina

• A drop line with a swing joint for charging the Solution Adsorber by gravity with fresh, hot PA.

• A temperature indictor for indicating the air temperature before it leaves the hopper through the top

vent. 4.1.11.2 PA Blower (31-K-105): A positive displacement blower provides the vacuum required for unloading the Solution Adsorbers. The

blower is equipped with two in-line suction filters, a suction cooler and suction and discharge mufflers. The

discharge line is protected by a pressure safety valve.

The motor is interlocked with:

• Low blower suction pressure

• High level in the PA Fallout Hopper (31-LAH-2637).

• High temperature in the PA Fallout Hopper

• High-high Oxygen in the blower discharge (31-AAHH-2634)

• High differential pressure (31-PDAH-2646).

• High-high temperature on the discharge of the blower (31-TAHH-2633).

• Low lube oil pressure. 4.1.11.3 PA Fallout Hopper (31-V-124):

The PA Fallout Hopper provides:

• Space for the disengagement of spent alumina particles from the nitrogen.

• Hold-up for spent alumina while emptying a Solution Adsorber.

• The drop line has a nitrogen tie-in between the two block valves for providing a positive nitrogen

blanket while emptying a spent bed. The nitrogen blanket prevents air leakage into the vessel.



4.1.11.4 Filter Receiver (31-G-104): The sock filter removes alumina fines that did not disengage from the nitrogen in the PA Fallout Hopper.

The filters should be cleaned regularly to avoid any disturbances in Nitrogen flow during spent PA unloading

from Adsorbers (31-V-104A/B).

4.1.11.5 PA Charge Heater (31-E-112): The heat exchanger is used in heating air, required for alumina charge preparation. The exchanger has high-

pressure steam on the tube side.

4.1.11.6 PA Charge Heater Blower (31-K-104) The blower is used in driving air through the PA Charge Heater and PA Charge Hopper. The blower is

equipped with a discharge muffler. The discharge is protected by a pressure safety valve.

4.1.11.7 Oxygen Analyser The oxygen analyser samples the circulating nitrogen stream after the blower but before the nitrogen make

up tie-in. It supplies a continuous indication in the field for the unit operator. There is a high oxygen content

alarm that sounds in the control room when the oxygen level reaches 8%.

4.1.11.8 PA Disposal Vessel The spent PA Disposal Trailer is located n such a way as to be readily movable from the unit. It has a

connection for hooking up a nitrogen hose to provide a nitrogen blanket in the vessel just prior to dropping

charge of waste PA. The connection from the waste receiver is adjustable to allow misalignment of the

disposal vessel. There is a vent port (HX-157) on the top with a return line to the PA Fallout Receiver. This is

to reduce the dust emissions to atmosphere while dropping the spent alumina to the vessel. 4.1.11.9 Exhaust Fan (31-K-103): The exhaust fan is a centrifugal blower. It takes suction from the ducts around the heads of the Solution

Adsorbers. Valving in the ductwork allows the off-line Solution Adsorber to be lined to the suction of the

Exhaust Fan. It vents to atmosphere away from the operators work area. It prevents fumes from the spent

alumina reaching the operator while unloading the bed. Start the Exhaust Fan before the head is removed

and stop it after the bed is replaced with fresh PA.

4.1.12 Polymer Separation: (Ref PFD 00101-DA-0104) The product polymer (RA) is separated from the solvent in a three-stage flash separation system. After

separation, the polymer is a molten liquid which is fed into the RA extruder for pelletizing and further

processing.

The solvent separated from the polymer contains unreacted monomer and comonomers as well as any

volatile by-products and light inerts. These vapour streams go to the recycle area for the recovery of the

solvent, monomers and comonomers.



4.1.12.1 Intermediate Pressure Separation (IPS): The RA solution stream from the adsorber is let down from the reaction pressure to 28-31 kg/cm2g through

pressure control valves (31-PV-1909A/B) which maintains the desired pressure in the reactor system. When

the pressure of the stream is reduced, it separates into a gaseous solvent phase and an RA-rich liquid

phase. The two phase mixture is then fed into the IPS (31-V-118) where the phases separate.

Approximately 60% of the SH solvent flashes off as vapour along with the unconverted FE and most of the

unconverted FB as well as 45% of the FC. Low molecular weight polymer, denoted as grease (RB), which is

formed in the reaction, is entrained and carried overhead with the flashed vapour. The vapour components

leave the top of the IPS and go to the LB feed condenser (31-E-202) in the recycle area.

The liquid phase contains 40-50% RA. Even though this liquid phase is clearly heavier than the vapour

phase, detection of a distinct vapour-liquid interface is difficult. Therefore radiation type level instrumentation

is used to measure the vapour-liquid interface for level control purposes.

Some liquid additive solutions (e.g. antioxidants) are injected into the RA stream leaving the bottom of the

IPS.

4.1.12.2 Low Pressure Separation (LPS) Hydrocarbons present in the liquid steam leaving the IPS are further separated in the two-stage LPS. The

LPS consists of two conical vessels stacked on top of each other. They are separated by a sieve plate

installed as a supported plant in the second stage. The upper vessel is called the 1st stage low pressure

separator or LPS No. 1 (31-V-119) and the lower one is called 2nd stage low pressure separator or LPS No. 2

(31-V-120).

The liquid from the IPS enters the LPS No. 1 through a special inlet nozzle which has been designed to

minimise entrainment of RA in the flash vapour. The flow rate of the feed is regulated by the IPS level

controller. Most of the SH and other hydrocarbons dissolved in the liquid polymer flash off and, after being

combined with the vapour from LPS No. 2, to the LPS condenser (31-E-201 A/B/C) in the recycle area. On

the way, the vapour stream flows through the LPS KO pot (31-V-121) which removes carry-over polymer.

The separated RA, which still contains about 10 wt% SH, forms a liquid level on the perforated sieve plate.

The level of molten RA on this plate is controlled by the pressure difference between LPS No. 1 and No. 2.

The sieve plate splits the flow of the molten polymer flow into numerous strands which fall into the LPS No.

2. The increased surface area of the RA strands enhances the separation of hydrocarbons from the

polymer.

The molten polymer exiting LPS No. 2 feeds the main extruder (31-ME-315). The main extruder is installed

directly below LPS No. 2. The speed of the extruder is controlled to maintain a preset level of molten RA in

the LPS No. 2. The polymer entering the extruder contains approximately 2.5 wt% of solvent.

The hydrocarbons vapour which flashes off in LPS No. 2 combine with the flow from the LPS No. 1

overhead, through the LPS KO pot (31-V-121) then to the LPS condensers (31-E-201 A/B).



4.2 RECYCLE AREA – AREA 200 4.2.1 Vapour Recovery 4.2.1.1 Intermediate Pressure (IPS) Vapour Recovery: (Ref. 00201-BA-31-0111) The vapour stream from the IPS contains SH, the unreacted FE, comonomer (FB and/or FC), RB and small

quantities of reaction by-products. This overhead vapour and the intermittent hot solvent flow used for

flushing the solution adsorbers are combined and sent to the recycle area for purification. The stream is

partially condensed in the LB Feed Condenser (31-E-202). LB feed condenser is used to generate MP

steam for the HB Reboilers. During FC or Terpolymer resins excess MP steam generated by LB feed

condenser is let down to LP steam Header. The effluent of the LB Feed Condenser (31-E-202) is fed to the

LB column (31-C-201). The temperature controller in this line resets the pressure controller on the steam

side of the LB feed condenser. This is done to maintain the feed temperature as required for optimum

operation of the LB column.

During start-up, FE can be fed from the supply heater directly to the LB feed condenser to stabilize the LB column. This is done when no FE is being fed to the reactor.

4.2.1.2 Low Pressure (LPS) Vapour Recovery (Ref. PFD 00201-AA-31-0110)

The SH solvent vapour from the two stages of the LPS passes through the LPS KO pot (31-V-121) and is

then condensed and subcooled in the LPS condensers (31-EA-201 A/B/C). This condensate is collected into

the LPS hold-up tank (31-V-201). Whenever a solution adsorber is depressurised, some of the solvent is

sent to the LPS condensers. The LPS condensers are vertical single-pass condensers with co-current

cooling water flow on the shell side. The process side outlet temperature is automatically controlled at 50°C.

SH recovered in the finishing area decanter (31-V-311) in the finishing area is also pumped into the LPS

hold-up tank. An exhausted SH purifier will also be drained to 31-V-201 during regeneration. The LPS hold-

up tank pressure is maintained by an automatically venting non-condensable vapour to the flare or by

introducing nitrogen.

From the LPS hold-up tank, the recovered hydrocarbon is pumped to the LB column (31-C-201) by the LPS

condensate pumps (31-P- 201/S). On its way, the stream is first heated in the LB feed heater (31-E-207

A/B) using condensed SH from the HB column. It is further heated near the bubble point in the LB feed

heater No. 2 (31-E-206) using HP steam. The LB feed heater recovers heat from recycle SH. 31-E-207 A/B

is a process to process exchanger. It recovers heat from the recycle SH stream, reducing the load on the

SH recycle coolers.

SH required for solution adsorber heating and flushing is also taken from the LPS hold-up tank. Normally,

solvent is circulated through the standby solution adsorber to keep the bed hot and ready for service. In this

case solvent flow is taken from the discharge of the LPS condensate pumps. When the solution adsorber

must be flushed, the hot flush pump (31-P-202 A/B) is also used. In either case, solvent is heated in the

steam purge heater (31-E-106) and in the DTA purge heater (31-E-107). The hot stream from the purge

heaters can also be diverted to the reactors for flushing.



The level in the LPS hold-up tank is not controlled. The tank has been sized to accommodate the shifts in

solvent inventory as well as the inventory of one solution adsorber and one SH purifier. The SH inventory in

the LPS hold-up tank is maintained by pumping fresh SH make-up from OSBL into the tank. Make-up is

intermittent. In the rare occasion the plant has too much solvent, the excess can be sent to SH de-inventory

tank (31-T-401) by the LPS condensate pump.

4.2.1.2.1 LPS Knockout Pot (31-V-121): Most of the solvent dissolved in the liquid polymer flashes off in the First and Second Stages of the LPS.

These combined vapour flows enter the LPS Knockout Pot, which removes carry-over polymer before it is

cooled in the LPS condenser.

The LPS Knockout Pot is equipped with a low pressure steam connection that is used for decontaminating

the vessel and a polymer drain line to a waste container. A high-pressure steam coil on the cone supplies

heat to the vessel to maintain a minimum temperature of 140°C. The LPS Knockout Pot can be bypassed

and taken off-line if necessary. Two pressure safety valves and manual vent to the polymer flare header

protect the vessel. A high-level alarm will sound in the control room.

NOTE: Drain the KOD on regular basis to avoid high level in LPS KO Pot. 4.2.1.2.2 LPS Condensers (31-E-201A/B/C): LPS condenser is a Vertical Shell & Tube heat exchanger with CW on shell side and Process Vapours on

the Tube side. The process vapour stream enters at the top of the Tube Side and exits to the LPS Hold-up

Tank from the bottom. The process outlet temperature is controlled by TIC-2814. TIC-2814 gives set point

to TV-2814 provided on the common CW Return line from E-210A/B/C. Separate CW supply line is also

provided for Emergency (Power Failure) for Reactor Flushing.

The Shell Side of the Condensers have a Design pressure rating of 11 kg/cm2g at 175°C and is provided

with a Relief Valve (PSV-2807/2811/2812) set pressure is 11 kg/cm2g. on the Cooling water inlet lines of 31-

E-201A/B/C resp.

The Tube side of the Condensers have a Design pressure rating of 14 kg/cm2g at 325°C and are protected

by Relief Valve (PSV-2801/2810/2813) set at 14 kg/cm2g provided on the Inlet line of E-201A/B/C resp.

The main process flow is from the LPS KO Pot. However tie-ins are provided upstream of the condenser for:

• Hot SH Flush Return from Solution Adsorber/Steam & DTA purge heaters

• RB/HB Reflux Drum Vent

• Vent return from Analysers (AI-T-3810-1/3634/3810-2/3436/1340/2757/2743

• From LB Column (31-C-201) bottom

• From CM Column Bottom Pump (31-P-415A/B) discharge.

4.2.1.2.3 LPS Hold-up Tank (31-V-201): The LPS Hold-up Tank serves as a low pressure hold-up vessel for the flows from LPS-1 and LPS-2 before

pumping to the LB Column vessel.



A positive pressure is maintained using a split range controller PIC-2817. PV-2817B maintains the pressure

of the tank while excess pressure is vented to the Flare header through a pressure control valve PV-2817A.

The bottom of the tank has one liquid outlet line and a sump with a level switch and drain valve. The sump

serves to collect any free water in the system. A high level alarm is provided on LPS HUT boot leg. The boot

leg should be drained routinely. The outlet line provides suction to the LPS condensate pumps through a

vortex breaker and duplex strainers. There is a separate suction line to the Hot Flush Pump from the suction

line to the condensate pumps that can be used in emergency situation.

The vessel is equipped with a Relief valve (PSV-2803/S) set at 10 kg/cm2g each, a Temperature Gauge

(TG-2802), Hi and low level alarm (LIT-2815).

LPS hold-up tank holds the streams coming from various sections of the unit as listed below:

• Recovered Hydrocarbon from Finishing Area Decanter (31-V-311)

• Recovered SH from Purifiers (31-V-125A/B)

• Recovered SH from Flare KOD (31-V-404)

• From HB column Reflux Drum vent

• SH makeup from Storage

• Drain and bypass of SH Purifier (intermittent)

• Vapour from LPS KO Pot (31-V-121)

• From LB Column bottom (31-C-201) (Used for start-up)

• Solvent from Solution Adsorber (Intermittent)

• From CM Column bottom (31-C-203)

4.2.1.2.4 LPS Condensate Pump (31-P-201/S): The pump takes the suction from the LPS hold-up Tank (31-V-201) and discharges the solvent to the Solvent

De-inventory Tank (31-T-401) or to the LB Feed heater No.2 through the LB Feed heater or to the suction of

Hot Flush Pump (31-P-202A/B). FALL-2924 is provided at the outlet of the pump for its protection. Also

PSV- 2907 is provided at the outlet line from LB Feed heater (31-E-207A) set at a pressure of 45 kg/cm2g.

LPS condensate pump suction filters and pump strainers are provided to ensure that no suspended material

get into the pump. The filters and strainers should be cleaned regularly. When the Emergency Shutdown or

I-2003/2004 activates the pump P-201/S will shutdown.

4.2.1.2.5 Hot Flush Pump (31-P-202A/B): The Pump has Pulsation Dampeners at the Suction and Discharge lines. The pump takes suction from LPS

hold up tank or from the LPS condensate pump (31-P-201/S) discharge. The Suction/discharge lines are

protected by the Relief valves (PSV-2918/2908 and PSV-2919/2910 respectively) set at 45/215 kg/cm2g

respectively. Solvent is pumped to the Flushing header through FV-1723, Steam purge heater (31-E-106),

DTA purge heater (31-E-107). The pressure control Valve PV-2930 is provided to relieve the excess

pressure to the LPS Hold-up Tank (31-V-201) or to the LB Feed Heater No. 2 (NNF).



When the Emergency Plant Shutdown Trip activates, the hot flush pumps will shutdown. Also when the

interlock I-2006/I-2007 (Solution Adsorber Nitrogen Return High Pressure) activates the pump P-202A and

P-202B will shutdown respectively.

4.2.2 Distillation: The distillation section of the recycle area separates all of the light and heavy components from the reaction

area. It consists of five distillation column systems:

• LB column

• HB column

• RB column

• FE column

• CM column

4.2.2.1 Low Boiler (LB) Removal: (Ref. PFD 00201-BA-31-0111) The LB column (31-C-201) is the first column in the distillation train. It has two feeds:

• A two-phase vapour liquid stream from the IPS (including hot flush from the solution adsorbers).

• Liquid or a two-phase flow (after the LB feed heater) originating from the LPS hold-up tank.

The first feed is partially condensed in the LB fed condenser (31-E-202). The resulting two phase mixture is

fed to the upper fed tray (Tray No 34). The second feed is, generally, a liquid feed rich in SH, but with little

or no FB. This feed can be heated to its bubble point or above it before it is fed to the lower feed point. This

flexibility provides a means to shift duty between DTA (at the LB column Reboiler) and HP steam (at the LB

fed heater No. 2). The full duty of 31-E-206 may be shifted to the LB Reboiler.

The LB column operates at 21-22 kg/cm2g (tower top) and separates butene and lighter components as

distillate while heavier components, including SH, goes to the bottom. The allowable FB-1 concentration in

the bottoms depends on the resin being produced and can be as high as 2 wt% for film (FB) resins. Certain

impurities, such as light ketones split between the distillate and the bottoms product.

The overhead stream containing FE, FB-1, FB-2 and J plus other light ends are condensed in the air cooled

LB condenser (31-EA-201) followed by the water cooled LB trim condenser (31-E-204). Condensate is

collected in the LB reflux drum (31-V-202). Tower pressure is controlled by adjusting the speed of the LB

condenser fans. The trim condenser always operates at full duty.

Under normal circumstances, condensation of the overhead vapour is total. This is accomplished by

maintaining a certain FB/FE ratio in the overhead vapour. However, FE conversion may fall as a result of an

upset in the reactor and, as a consequence, the flow of unreacted FE to the LB column will increase. In such

a situation it may not be possible to completely condense the overhead vapour and it then becomes

necessary to vent some FE out of the system. A pressure controller has been provided to vent non-

condensable gases from the LB reflux drum to the flare if tower pressure should increase above the normal

operating value.



The LB column distillate is sent to FE column (31-C-204) via the FE column feed dryers (31-V-209 A/B). The

FE column separates FE from FB. Feed to the FE column is controlled to maintain the outlet temperature of

the LB trim condenser at a preset value. Material balance in the overhead system is maintained by recycling

FB from the FB surge tank (31-V-415) to the reflux stream for the LB Column. Connections have been

provided to feed this recycle to three places: (1) to LB column reflux line upstream of the reflux control valve,

(2) to the reflux line but downstream of the reflux control valve and (3) to the LB reflux drum, normally,

destination (1) will be used.

Another recycle stream into the LB column overhead system comes from the FE column feed dryers (31-V-

209 A/B). This stream cools the dryer after regeneration. When this is done, extra liquid is drawn from the

LB reflux drum, pumped to the dryer system and through the fresh dryer. Because the warm bed may

vaporise a small portion of the liquid, the stream is returned to the LB reflux drum via the LB trim condenser.

The LB column distillate is essentially free of SH. Separation of SH is accomplished by controlling the

selected temperatures at trays 39, 43, 47. The selected temperature resets the reflux flow rate to maintain

the tray temperature. A residual amount of SH remains in the LB column distillate stream to the extent of

200 to 1000 ppmw, depending on resin type, it is purge out of the system together with the FB-2 by-product,

at the bottom of the CM column.

Under normal operating conditions very little free water is expected to enter the LB reflux drum. Any

accumulation of free water will separate and collect in the boot. Water collected in the boot is manually

drained on a regular basis.

LB column bottoms feed the HB column (31-C-202) under flow control. The flow is reset by the HB column

bottoms level controller. The bottoms steam is primarily SH with small amounts of RB and other

contaminants. The bottoms sump of the LB column is large and provides surge capacity for the HB column

feed.

Boil-up for the LB column is supplied by the LB Reboiler (31-E-203) which is a vertical thermosyphon design

and is heated by LP DTA vapour. The LB Column system consists of LB Feed heater (31-E-207A/B), LB

Feed Heater No. 2 (31-E-206), LB Feed Condenser (31-E-202), LB Column (31-C-201).

4.2.2.1.1 LB Feed Heaters (31-E-207A/B): LB Feed Heaters are Horizontal Shell & Tube type process to process heat exchanger arranged in series

having single passes both in Shell and Tube side each. A bypass line is also provided for 31-E-207A/B.

The Recycle SH from HB Reflux drums flows in the shell side of E-207A/B. The LPS Condensate pump

discharge flows through the Tube side of the Heaters E-207A/B. The flow of Solvent from the Exchanger is

controlled by FIC-2924 (FV-2924 provided on the outlet line from E-207A) which takes the set point from

LIC-3030 (LB Column bottom level controller).

The Shell side of the heaters have a Design pressure rating of 18 kg/cm2g at 250°C and is provided with a

PSV-2904, set pressure is 10 kg/cm2g.



The Tube side of the heaters have a Design pressure rating of 42 kg/cm2g at 250°C and are protected by

Relief Valve (PSV-2907) set at 45 kg/cm2g provided on the outlet line from E-207A. TG-2915 is provided on

the recovered hydrocarbon outlet line from E-207A.

4.2.2.1.2 LB Feed Heater no. 2 (31-E-206): The heater is a horizontal 1-2 Shell & Tube heat exchanger having HP Steam on the Shell Side and the

process fluid on the Tube side. A tie-in line is provided upstream of the heater which is coming from the Hot

Flush Pump discharge PV-2930 (Excess pressure relieving line from P-202A/B discharge line).

TIC-3025 is provided at the outlet line from LB Feed heater to control the outlet temperature of LB Column

Feed using FV-3025 provided on the HP steam inlet line.

The Shell side of the heater has a Design pressure rating of 42.2 kg/cm2g at 260°C and is protected with

Relief Valve (PSV-3012/S) set at 42.2 kg/cm2g, provided on the HP steam inlet line to 31-E-206.

The Tube side of the heater has a Design pressure rating of 42 kg/cm2g at 250°C and is protected by Relief

Valve (PSV-3016) set at 40 kg/cm2g, provided on the outlet line of 31-E-206.

4.2.2.1.3 LB Feed Condenser (31-E-202): The condenser is a Kettle type horizontal 1-2 Shell & Tube heat exchanger, with vapour stream on the tube

side and BFW on the shell side. The temperature controller TIC-3039 is provided on the Effluent outlet line

from the Condenser to reset the pressure controller (PIC-3019) provided on the steam side of the LB Feed

condenser. This is done to maintain the feed temperature as required for optimum operation of the LB

column.

During start-up, FE can be fed from the supply heater directly to the LB feed condenser to stabilize the LB

column. This is done when no FE is being fed to the reactor.

A tie-in line is provided upstream of the LB Feed Condenser for Flushing return from DTA purge heater

(Warm-up line).

The Shell side has a design pressure rating of 30 kg/cm2g at 260°C and is protected by relief valves PSV-

3003A/B set at 30 kg/cm2g. The flow of HP Condensate is controlled by level controller LIC-3018 (LV-3018)

on the shell side of the exchanger. The level of the HP Condensate in the shell side should always be kept at

60% to ensure the tubes are completely covered. A BFW supply line is provided for the start-up and its flow

is controlled manually. HP steam supply and bypass line of NRV (PIC-3019 downstream) is provided for

start-up.

The Tube side has a Design pressure rating of 35 kg/cm2g at 300°C and is protected by the PSV-3015 set at

35 kg/cm2g.

4.2.2.1.4 LB Column (31-C-201): The LB column (31-C-201) is the first column in the distillation train. It has 51 valves trays and two feeds

which are located above Trays 34 and 21.



The column is protected by PSV-3005/S set at 27.5 kg/cm2g, and is equipped with a vapour pull down valve

on the overheads line, and a liquid pull down valve at the Reflux drum.

To monitor the column it is equipped with thermowells across its height. Pressure transmitters (PIT-

3022A/B/C/D) are provided on the overhead line, a differential pressure indicator (PDIT-3024) across the

column and a level transmitter (LT-3046) with Level controller (LIC-3030) is provided at the column bottom.

4.2.2.1.5 LB Column Reboiler (31-E-203):

The LB Reboiler is a vertical heat exchanger with the process on the tube side and the heating medium, low

pressure DTA on the shell side. LP DTA enters at the top of the shell and the condensate exits at the bottom

through a level control valve. Condensate flows to the low pressure condensate header. The shell side is

protected by a pressure safety valve (PSV-3004) set at 10 kg/cm2g and has a manual vent. Process fluid

flows by natural convection from the column base to the bottom of the Reboiler, through the tubes and

returns to the column from the outlet nozzle at the top. 4.2.2.1.6 LB Column Condenser (31-EA-201): The LB Column condenser is an air-cooled exchanger. It is protected by the two pressure safety valves on

the LB column. Adjusting the speed and/or blade pitch of the LB condenser fans controls the column

pressure. Temperature, indicators on the column and at the condenser outlet monitor the performance of

the column and condensers.

4.2.2.1.7 LB Trim Condenser (31-E-204): The LB trim condenser is a water-cooled condenser that operates at full duty. The shell-side is protected by

pressure safety valve (PSV-3117) set at a pressure of 10 kg/cm2g.

4.2.2.1.8 LB Column Reflux Drum (31-V-202): The LB Reflux Drum is protected by a pressure safety valve (PSV-3138) set at a pressure of 27.5 kg/cm2g

and vapour pulldown valve as the LB column. A vapor pulldown valve HV-3139 is provided on Reflux Drum.

An additional liquid pulldown valve on the bottom outlet line may be used to de-inventory the drum.

The vessel is equipped with a vortex breaker and a standpipe on the liquid draw line, temperature, level and

pressure indicators. It has a water collection sump with a level switch and manual drain.

4.2.2.1.9 LB Reflux Pump (31-P-203/S): The LB Reflux pump takes suction from the LB reflux drum. The pump delivers reflux back into the LB

column and forward feed to the FE column. Butene from the FB Surge Tank can be fed to three places:

a) LB Column reflux line upstream of the reflux control valve. (normal destination)

b) Reflux line downstream of the reflux control valve

c) LB Reflux Drum

Main Function of LB Column: 1. Removal of light ends (J, FE, FB, etc.) from SH

2. Partial removal of ketones from SH

3. Removal of SH from FB



Column Variable Range Control By Dependent Variables

Analysis Samples Position

Column Pressure 19-21 kg/cm2 LB Condenser Column Temperature

Tray 8/10/12 Temp. 100-105°C Reflux Flow or Overhead Feed to

FE Column

SH in overhead FB

Condensate Temp. 50-70°C (Varies

with FB & J

conc.)

Reflux Drum Vapor Purge (J, N2,

etc) or FB Make-up

FE Column overheads

Composition

Liquid Feed Temp. 160-230°C HP Steam Flow to feed heater

DTA flow to Reboiler 0.3 - 0.6 Ratio control DTA/LB Col. Bottom

flow

FB & Ketones conc. in

base

LB Base or

HB verheads

Column Base Level 50% Feed Liquid flow from LPS HUT

FE Column Feed Either flow control or on

overhead temp. control

LB Reflux Flow 65-85% LB Col. Overhead temp.

4.2.2.1.10 MODE OF OPERATTIONS: Operation of the tower depends on the type of resin being produced. The different modes are described

below:

4.2.2.1.10.1 FB Resins The above method is generally valid for the production of FB resins. However, the rate of FB-1 recycle from

FB surge drum will be low and automatic control of the LB trim condenser outlet temperature by modulating

the FE column feed rate may not be stable. The cascade from the temperature controller to the FE column

feed flow control may have to broken and put on simple flow control.

Any FB-1 in the LB column bottoms product will go overhead in the HB column and will end up in the reactor.

When producing FB resins a significant amount of FB-1 is fed to the reactor, thus concentrations of up to 2

wt% FB are acceptable in the LB column bottoms. It is important, however, that the concentrations are

continuously analyzed by an on-line analyser (31-AT-3436). The FB-1 recycle flow from the CM column

must be adjusted to compensate for the total FB-1 in the recycle solvent. It is important that the

concentration is constant in order to effectively control the total butene flow to the reactor.

4.2.2.1.10.2 Homopolymer Resins: In homopolymer operation, the LB column operates as it does in FB operation. Since there is no FB in the

Reactor feed, there is no FB in the reactor effluent. Therefore, it is not possible to solubilise the unreacted

FE in the LB column overheads without feeding FB column from other sources. For this reason FB is

recycled to LB column overhead system from FB surge tank (31-V-415). The rate of recycle is high and the

LB condenser outlet temperature will be sensitive to changes in the FE column feed rate.



In homopolymer production, only a very low concentration of FB-1 can be allowed in the reactor feed and

therefore in the LB column bottoms. The maximum allowable concentration of FB in this case is only 200

ppmw.

4.2.2.1.10.3 Low FB Resins: As with homopolymers there is a need to recycle FB to the LB column. The sum of the FB being fed to the

reactor plus the recycle flow to the LB column must be enough to solubilise the total unreacted FE from the

reactor. If additional FB is required for FE solubility an increased recycle FB flow will be necessary.

When low FB-1 flows are required to the reactor, the maximum allowable concentration of FB in the LB

column bottoms is higher than in the homopolymer resins and lower than the regular FB resins. The limit

used for design is 200 ppmw even though up to 1000 ppmw is considered acceptable.

4.2.2.1.10.4 Terpolymer Resins: In terpolymer operation, the LB column functions similar to FB resin operation except that the bottoms product

contains all of the recycle FC-1 and FC-2. The octenes present in the bottoms results in a temperature that is

higher than in FB or homopolymer operation. With terpolymer resins some FB is fed to the reactor. The quantity

is not sufficient to solubilise the unreacted FE in the LB column overhead. As with low FB resins the sum of the

FB being fed to the reactor plus the recycle flow to the LB column must be enough to solubilise the total unreacted

FE from the reactor. If additional FB is required for FE solubility an increased recycle FB flow will be necessary.

In terpolymer production, some FB -1 can be acceptable in the LB column bottoms. The maximum allowable

concentration of FB in the solvent can be up to 1000 ppmw.

4.2.2.1.10.5 FC Resins: Operation with FC resins is quite similar to that with homopolymers. There is no FB feed to the reactor and all FB

required for FE solubilisation in the LB reflux drum must be recycle to the LB column overhead system from the FB

surge tank. In FC production only a very low concentration of FB-1 can be allowed in the LB column bottoms.

The maximum allowable concentration of FB in the solvent is 25 ppmw. The operating conditions are very similar

to those of the terpolymer mode.

4.2.2.2 High Boiler (HB) Removal (Ref. PFD 00201-CA-31-0112) HB column (31-C-202) has 35 valve trays and receives two feeds. The main feed is the LB column bottoms which

feeds tray 24. The second feed is a liquid recycle from the RB column which is fed to the bottom sump. The HB

column operates at pressure 9.3 kg/cm2g or less. This is well below the operating pressure of the LB column.

When the LB column bottoms product is let down to the HB column the stream flashes to give a two phase flow to

the column.

The function of the HB column is to separate SH and lighter components (e.g. FB) as distillate while heavy

impurities, including RB, are purged out from the bottoms to the RB column (31-C-203). Small amounts of

impurities, such as ketones, may go overhead with the solvent. These are removed in the SH purifier in the

reaction area.



HB column overhead vapour is condensed in the HB condensers (31-E-216A/B). The process stream is total

condensed and collected in the HB reflux drum (31-V-203). The tower pressure is controlled by adjusting the

steam side pressure of HB condensers. A manually operated control valve (HV-3456) has been provided so any

non-condensable gases can be vented from the HB reflux drum to the LPS HUT (31-V-201). This valve is also

useful during initial start up of the recycle area.

From the HB reflux drum, the clean solvent is partially refluxed back to the column by the HB reflux pump (31-P-

204/S). The remaining distillate is recycled to the reaction area after first cooling the stream in the LB feed heater

(31-E-207 A/B). Flow to the reaction area is driven by the HB column pressure. Since the flows of all reactants

are controlled, the flow rate of the solvent to reaction is dictated by the flow controller at the discharge of reactor

feed pump (31-P-104) which is set to the desired TSR.

The HB reflux drum has sufficient volume to ensure that uninterrupted solvent supply to the reaction area can be

always maintained. It also provides capacity for liquid required to fill one SH purifier after it has been regenerated.

HB column bottoms product contains all high-boilers and is fed to the RB column (31-C-203) under flow control.

The flow rate is set to keep HB column bottoms temperature within acceptable limits. The required purity of the

solvent is achieved by operating the tower at a predetermined reflux ratio. A ratio controller automatically adjusts

the reflux flow to maintain a constant reflux-to-feed ratio. The material balance of the column is maintained by the

level controller in the bottom sump. This controller brings in fresh feed from the LB column.

Boil-up is controlled to keep the level in the reflux drum constant. Boil-up is supplied by two vertical thermosyphon

reboilers (31-E-205 A/B) that are heated mainly by MP steam. HP steam make-up as required is used for FB and

homo resins while for FC resins only HP steam is used. HB Column System consists of HB Column (31-C-202),

HB Reboilers (31-E-205A/B), HB Condenser (31-E-216A/B), HB Reflux Drum (31-V-203), HB Reflux Pump (31-P-

204/S).

4.2.2.2.1 HB Column (31-C-202): The column is protected by pressure safety valves (PSV-3304A/B/C/S) set at pressure of 11 kg/cm2g each and is

equipped with a vapour pulldown valve (31-HV-3445) on the HB Reflux Drum.

To monitor temperature across the column there are temperature indicators on trays 11, 23, 26 and 34. The

column base level is controlled by the feed from the LB Column base.

4.2.2.2.2 HB Reflux Drum (31-V-203):

The HB Reflux drum is protected by a pressure safety valve (PSV-3426) set at a pressure of 11 kg/cm2g. The

vessel is equipped with a liquid pulldown (31-HV-3433) and a vapour pulldown valve (31-HV-3445). The vessel is

equipped with a manual vent to the LPS condenser to remove non-condensable. The suction line to the HB

Reflux pumps has a standpipe with a vortex breaker on it. 4.2.2.2.3 HB Reboiler (31-E-206A/B)/Condensate Pot (31-V-208A/B): The HB Reboilers are vertical thermosyphon Reboilers and are heated by medium or high pressure steam.

Condensate exits from the Reboilers to the HB Reboiler condensate pot. A level valve on the outlet of HB

Reboiler condensate pot controls the condensate level in the HB Reboiler.

The shell side is protected by a pressure safety valve (PSV-3305/3307 resp.) and equipped manual vent. Inters



will collect at the top of the shell and must be vented of to prevent corrosion in the shell side of the Reboiler.

The tube side is protected by the column and the reflux drum pressure safety valves. Process flows by convection

from the column base to the bottom of the exchanger, through the exchanger and returns to the column from the

outlet nozzle at the top of the Reboiler.

4.2.2.2.4 HB Reflux Pump (31-P-204/S): The HB Reflux Pump takes suction from the HB Reflux Drum and is used to provide reflux to the HB

Column. Hot nitrogen and flare tie-ins at the pump are provided for purging and venting. There is a spare

HB Reflux Pump on standby.

4.2.2.2.5 HB Condenser (31-E-216A/B): The HB condensers are kettle type exchangers with the process fluid on the tube side and the cooling

medium i.e. Low-pressure condensate/BFW on the shell side (for start-up only). The process vapour is

totally condensed and collected in the HB Reflux Drum. The shell side is protected by pressure safety valves

(PSV-3410A/B & PSV-3411A/B resp.). The shell side LP Condensate level is controlled by control valve 31-

LV-3444 & 31-LV-3438 resp.

Column pressure is controlled by adjusting the steam side pressure of the HB Condensers. A continuous

purge to the hot well prevents solids build-up in the shell side of the condensers. The tube side is protected

by the column pressure safety.

Main Function of HB Column: 1. Removal of low mw polymer and high boiling impurities from SH.

2. Control of FC/SH separation on FC resins, so density control can be maintained and FC-2 level

controlled.

Column Variable Range Control By Dependent Varialbes Analysis For

Col. Pressure ~9 kg/cm2 Steam flow from overhead

condenser (pressure)

Base & Overhead

Temperatures

Reflux Flow 0.4 x SH

Throughput

Feed flow x 0.4 (Ratio Control) Overhead Heavy

Impurities

HB Overhead Ketones

(Grease)

Ref. Drum Level HP steam to Reboiler On-line GC for butene

and octene analysis in

Solvent

HB Base ~50% LB Tails Flow

SH feed to Area

100

Head Tank level in Area 100

Feed to RB

Column

Flow Control to RB - (ratio to

SH circulation)

Acids (indicates Sol.

Adsorber Breakthrough)



4.2.2.2.6 MODE OF OPERATTIONS: Two operating modes are associated with this column as explained below:

4.2.2.2.6.1 Hommopolymer and FB Resins: When making FB resins or homopolymers, the HB column operates with an approximate overhead pressure

of 9.3 kg/cm2g. The function of the tower is to separate small amounts of high boiling impurities from the

solvent. The bottom temperature is approximately 185°C. To achieve acceptable condition for the steam

side of the Reboiler MP steam is used. 4.2.2.2.6.2 Terpolymer and FC Resins: On FC resins or terpolymers, the optimum operating pressure has been established as 8.3 kg/cm2g

(approx.). In this case the tower separates FC-2 and minor impurities from the FC-1 and solvent. In fact the

RB column (31-C-203) functions as an extension of the HB column in this relatively difficult separation. This

service sets the size of the HB column. The Column bottom temperature is approximately 230°C. For this

case, HP steam is used in the HB Reboilers. 4.2.2.3 RB Separation: (Ref. PFD 00201-CA-31-0112) The RB column (31-C-203) receives feed from the HB column bottom. From a fractionation point of view, the RB

column acts as an extended stripping section of the HB column. The RB column operates at 3.6 kg/cm2g pressure

(3.3 kg/cm2g in FC or terpolymer modes), which is quite a bit lower than the pressure of the HB column. When the

HB column bottom product is let down to the RB column the stream flashes. This flashing feed enters the column

at tray 34. The top tray is a wash tray which minimises entrainment of heavy impurities such as RB.

RB column overhead vapour is condensed in the RB condenser (31-EA-202). Vapour is totally condensed

and collected in the RB reflux drum (31-V-204). The tower pressure is controlled by adjusting the speed of

the air cooler fan and pitch of the Louvers. From the RB reflux drum, the condensate is pumped by the RB

reflux pump (31-P-205/S), it splits between the reflux to the top of the RB column and the return flow to the

HB column bottom sump.

Reflux is provided for washing purposes rather than for fractionation. Provided carryover does not become a

problem, it is possible to reduce the reflux flow and increase the purge rate from the HB column bottoms by

an equal amount without affecting the internal traffic or the separation performance of the RB column. The

reflux flow is controlled to maintain a fixed reflux-to-feed ratio.

RB column bottoms product contains all high-boilers and is purged to the DTA vaporiser area where it is

used as fuel. The bottom product contains organic acids and catalyst residues and is corrosive to carbon

steel. It is also slightly corrosive to stainless steel. For this reason, the bottom section of the RB column is

of SS316L construction. To minimise corrosion, the bottoms purge rate is set to maintain RB column

bottoms temperature at or below 210°C.

The RB column bottom temperature determines the bottom purge flow rate to the waste fuel drum (31-V-

411) for the DTA vaporisers. The steam supply for column boil-up is reset by the bottoms level controller.

Boil-up is provided by the RB Reboiler (31-E-208). The heating medium used is LP DTA vapour.



4.2.2.3.1 RB Column (31-C-203): The RB Column is protected by pressure safety valves (PSV-3511/S) and a vapour Pulldown valve (31-HV-

3544). Because of the high concentration of acids, the bottom half of the column, tray 22 and lower the tails

line are constricted of stainless steel.

The column has 35 trays with side downcomers. The LP DTA to the RB Reboiler controls the column base

level. High and low level alarms are provided on the column base. High boilers are concentrated and

purged off to DTA Vaporiser section.

4.2.2.3.2 RB Air Condenser (31-EA-202): The RB Condenser is a horizontal forced draft finned tube condenser. The condenser is equipped with hand

operated louvers. The process vapour is totally condensed and collected in the RB Reflux Drum. 4.2.2.3.3 RB Reflux Drum (31-V-204): The RB Reflux Drum is protected by a pressure safety valve (PSV-3543) set at a pressure of 7.5 kg/cm2g.

There is a vapour pulldown valve (31-HV-3534) and a liquid Pulldown valve 31-HV-3523 to allow quick liquid

removal from the vessel. The vessel is equipped with a vortex breaker on the suction line to the reflux pump.

There is a vent line from the reflux drum to the LPS Condenser for removal of non condensable.

4.2.2.3.4 RB Reflux Pump (31-P-205/S): The RB Reflux Pump supplies feed to the HB Column as well as reflux back to the column. The HB Reflux

Pump supplies seal flushing for the RB Reflux pump seal.

Main Function of RB Column: 1. Concentration of low MW polymer (Grease) and high boiling impurities for purge.

2. Separation of Octene-2 from Octene-1

Column Variable Range Control By Dependent Varialbes Analysis For

Col. Pressure ~3.6 kg/cm2 Air Condenser Base & Overhead Temperatures

Feed Flow Flow control from HB Column

Flow to HB Col. Reflux Drum Level

Reflux Flow 0.4 – 0.6* Ratio to Col. Feed Impurities in FC

Base Temp. 190-210°C Base Purge to fuel High boilers in SH to Area 100

Base Level Reboiler DTA Flow Grease & HB

(on demand)

* On FC copolymers

4.2.2.3.5 MODE OF OPERATTIONS: Two o operating modes associated with this column are as follow:

4.2.2.3.5.1 Homopolymer and FB Resins The function of the RB column in this case is to recover solvent. It separates SH as a distillate while high

boiling components, including RB, are purged out from the bottom.



If concentrated too much, RB becomes very viscous and may plug the purge line unless kept hot. For this

reason some solvent is purge with the RB to keep viscosity low. The purge line is also traced with dual HP

steam tracer to keep the RB flowing.

4.2.2.3.5.2 Terpolymer and FC Resins: When processing octene resins, the HB column and the RB column work together to separate FC-1 and FC-

2. Most of the FC-1 goes overhead while FC-2 plus high boiling components go to the bottom. The bottoms

product is essentially solvent free in this case. This is a relatively difficult separation and governs the sizing

of the column.

As with FB resins and homopolymers, RB must be diluted to keep its viscosity low. In this case RB is diluted

primarily with FC-2. Since the amount of FC-2 produced by isomerisation in the reaction area is fixed, and

therefore limited, some FC-1 also has to be purged with RB to achieve the desired level of dilution.

When changing from FB to FC operation the FB to the reactor is replaced by FC. FB make-up to the LB

column system continues. The FC to the reactor is brought in from either FC storage via the FC purifier or

from the FC de-inventory tank (31-V-414). When the plant is returned to FB operation, FC must be de-

inventoried back to 31-V-414 and FB inventory must be re-established.

When starting FC resin production, FC-1 is fed to the reaction area through a make-up line. To speed up the

inventory build-up FC can also be fed to the HB column from the FC de-inventory tank. This flow goes to the

bottoms of the HB column via the RB column distillate line. The system has been designed to reinventory

FC at a rate which is essentially the same as the rate of FC-1 in the HB column feed during normal

operation.

When operation is switched from FC resins back to FB resins or homopolymer resins, all of the FC in the

process must be de-inventoried. With proper planning, much of the FC-1 will be consumed in the reactor.

However, as the concentration of FC-1 declines there comes a point when the product goes off-specification.

To minimise off-specification production FC should be de-inventoried as fast as possible. FC will therefore

be de-inventoried from the RB column overhead to the FC de-inventory tank using the RB reflux pump. The

rate of de-inventory is limited by the capacity of the pump.

When FC is being de-inventoried, the concentration of FC in the HB column bottoms declines and is

replaced by SH. De-inventory of FC from the HB column can be continued until the solvent concentration in

the HB bottoms becomes so high that flow to the FC de-inventory tank must be stopped. Any FC remaining

in the process at this pint must be purged out with RB from the bottom of the RB column. 4.2.2.4 FE Column Feed Purification (Ref. PFD 00201-DA-31-0113) LB column distillate is fed to the FE column (31-C-204). Normally, the distillate contains dissolved water as

well as organic impurities such as ketones. Since water will freeze in the refrigerated overhead condenser of

the FE column and ketones would poison the catalyst in the reactor, these impurities must be removed. This

is the function of the FE Column Feed Dryer (31-V-209 A/B).



4.2.2.4.1 Process Description: A feed stream containing butene-1, butene-2, ethylene, solvent, ketones and water passes through a FE

Column Feed Cooler and an FE Column Feed Coalescer before entering the FE Column Feed Dryer. The

Feed stream is cooled to improve the water and ketone removal capabilities of the adsorbent in the dryer.

The FE Column Feed Dryer system consists of the FE Feed Cooler, FE Coalescer, and two FE Column

Feed Dryer.

The feed stream from the LB Reflux Pump passes through the FE Column Feed Cooler, where it is cooled to

a minimum value. It then goes through the FE Column Feed Coalescer for free water removal. As it

continues through the dryer, final water removal is accomplished in the bottom of the dryer, which consists of

a layer of molecular sieves. The stream continues through the layer of silica gel where ketones are removed

before going to the FE Column.

The FE Column Feed Dryers are in service one at a time, with the off-line dryer being regenerated for re-use

or on standby. The FE Column Feed Dryers use a regeneration system shared with the FE Guard Beds for

the heating and cooling of the regeneration cycle. Hot nitrogen flows down through the packing during the

heat-up cycle to remove the adsorbed impurities. During the cool down cycle cold nitrogen flows

downwards.

4.2.2.4.2 FE Column Feed Dryer Coolers (31-E-209A/B): The FE Column Feed Cooler is an exchanger with process flow through the tube side and cooling water

through the shell side. The waterside is protected with two pressure safety vales venting to the flare header

in the event of tube failure. Two pressure safety valves protect both the FE Column Feed Cooler and

Coalescer.

4.2.2.4.3 FE Column Feed Coalescer (31-V-207):

The FE Column Feed Coalescer removes free water that is separated from the saturated feed stream that

enters the coolers. The free water is separated by filtration in the coalescer drained manually a regular

intervals.

4.2.2.4.4 FE Column Feed Dryers (31-V-209A/B): Each FE Column Feed Dryer has 4 distinct layers of packing or media in it. The lower layer is 2400 mm

layer of molecular sieves (PM) then a 4800 mm layer of silica gel (PS). On the top there is a 50 mm layer of

Alumina (PA), a 100 mm layer of 10 mm inert ceramic balls and finally a 50 mm layer of 20 mm inert ceramic

balls. Approximately at the junction of the molecular sieve and silica gel layers here is a sample point to

continuous water analyser. The spent media is periodically removed through the manway just above the

slotted plate at the bottom of the dryer. The new layers of the packing material are added through the top

manway of the dryer.

The run length of the dryer is 2 to 4 days depending mainly on the moisture content of the LB column

distillate and the regeneration history of the desiccant. The system has been designed for 30 hour



regeneration cycle. Once the adsorption capacity of the bed has been exhausted, it must be regenerated.

Replacement of the desiccant beds will, normally, be required every six to nine months.

FE Feed Dryer Data Charge: Silica Gel (PS) : 15700 kg each

Molecular Sieve (PM) : 7850 kg each

Bed Loading: Water will displace ketones from the bed. Beds are swung on water breakthrough at analyser.

Regeneration: Purge cycle duration : Minimum of 1 hour after mix. Temp. is reached

Approximate heatup time 8 hours

Approximate cool down time 8 hours

4.2.2.5 FE Recovery: (Ref. PFD 00201-EA-31-0114) Unreacted FE is recovered in the FE column (31-C-204) and recycled to the ethylene unit for clean-up and

recovery. Feed for the FE Column comes from the LB Reflux Drum through the FE Feed Dryers and fed to

the 19 tray. This stream consists of ethylene, butene-1, butene-2, cyclohexane, impurities, carbon dioxide

and traces of inerts. The column is designed to take ethylene, carbon dioxide and hydrogen off the top and

butene-1, butene-2, cyclohexane and impurities from the bottom.

The overhead vapour is partially condensed in the FE Condenser directly attached to the top of the column.

The cooling is supplied by the liquid propylene refrigerant. The condensed liquid or reflux returns to the

column by gravity. The uncondensed vapour, which leaves the column, is heated in the FE Purge Heater

(part of the refrigeration package) to a temperature, which is high enough for carbon steel piping.

The base stream goes to the CM Column by means of pressure differential. The FE column bottoms product

is mostly FB but also contains FE in low concentration. Boil-up of the FE column is controlled by column

temperature to maintain the purity of the bottom product.

A connection has been provided to feed the FE column bottoms to the FB surge tank, This may be used to

de-inventory excess FB from the process and it also allows recycling FE column bottoms to the LB column if

the CM column is shutdown.

In case the C3 refrigeration system must be shut down while the polyethylene plant continues production,

the FE column can no longer separate FE and FB because the refrigerated condenser becomes ineffective.

In this situation the operator has two options:

• Vent the unreacted FE from the LB reflux drum and stop forward feed to the FE column.

• Keep the FE column in service and vent FE from the FE column. Boil-up must be continued to strip

FE from FB.

The FE Column system consists of the FE Purge Heater, FE Column Feed Heater, FE Column, FE Reboiler

and Condensate Pot, and the FE Condenser.



4.2.2.5.1 FE Purge Heater (31-E-217): The FE Purge Heater is a process to process exchanger. The Purge gas from the FE Column top exchange

heat with the propylene refrigerant.

4.2.2.5.2 FE Column (31-C-204): This is a trayed column with 29 trays. The column operates at approximately 20 kg/cm2g (tower top). The

bottom sump of the tower has a larger diameter than the trayed section mainly due to liquid hold-up

requirements. Since the top of the column will see low temperature, the material of construction of the

condenser as well as the tower shell below the feed point is low temperature carbon steel (LTCS).

The column overhead is protected by pressure safety valves (PSV-3205/S) set at pressure of 21 kg/cm2g

and the bottom portion of the column is protected by PSV-3203/S set at a pressure of 29 kg/cm2g each. The

column has a vapour pulldown valve (31-HV-3221).

4.2.2.5.3 FE Reboiler (31-E-212) /Condensate Pot (31-V-210): The FE Reboiler is a vertical thermosyphon exchanger with low-pressure steam on the shell side. The shell

side is protected with a pressure safety valve (PSV-3202) that vent to the flare header in the event of a tube

failure.

Steam to the FE Reboiler is regulated by 31-FV-3217, which controls the column temperature. Condensate

from the Reboiler is collected in the FE Reboiler Condensate Pot whose level is controlled with 31-LV-3220.

4.2.2.5.4 FE Condenser (31-E-213): Overhead vapour is condensed in the FE condenser (31-E-213) which is a vertical shell and tube exchanger

flanged directly to top of the FE column. In this dephlegmator, the vapour condenses on the tube side of the

condenser and the condensate is returned to the column by gravity as reflux. Cooling is provided by boiling

C3 refrigerant (propylene) on the shell side. Liquid refrigerant flow is controlled to maintain a constant

temperature in the top section of the FE column. The level in the condenser regulates refrigerant flow to the

condenser. A temperature indicator is downstream of the condenser on the process outlet for monitoring

performances.

Main Functions of FE Column: 1. Separation of FE from FB

2. Separation of light components such as J, N2, CO etc. from FB

3.

Column Variable Range Control By Dependent Varialbes

Analysis For

Col. Pressure 21 kg/cm2 Overhead FE Purge or (Refrigerant

Flow)*

Base Temp. 110°C LP Steam flow to Reboiler FE in FB FE in FB in Case II

500ppm

Overhead Temp. ~ (-)30°C Refrigerant level in the FE Cond.

Base Level Feed to CM Column




Analysis For

FE Side Purge* (~80% FE)* Column Temperature FB in Recycle

FE

H2, CO, CH4, N2,

FB, C2H5

Overhead Flow 100% un-reacted

FE (~20% FE)*

Col. Pressure

(Flow Control Purge)*

J, CO in

Recycle FE

*IF Recycle FE System is used.

4.2.2.6 Comonomer Recovery: (Ref. PFD 00201-FE-31-0115)

4.2.2.6.1 Process Description: The main purpose of the CM column is to concentrate FB-1 in the column overheads for recycle to the

reaction area. To maintain the required FB-1 purity, the column also concentrates FB-2 so it can be purged

from column bottoms with a minimum loss of FB-1. Since FB-2 is formed only when making FB resins or

terpolymer resins, it is not necessary to operate the CM column when making homopolymer or FC resins.

CM column overhead vapour is condensed in the CM condenser (31-E-315) which is a water cooled,

horizontal shell and tube exchanger. Normally, vapour is totally condensed and condensate is collected in

the CM reflux drum (31-V-206). The tower pressure is controlled by throttling the cooling water flow to 31-E-

315. The same controller operates a pressure control valve which will vent non-condensable from the CM

reflux drum to the flare if the system pressure begins to increase. A low temperature at the condenser outlet

indicates build-up of light gases (e.g. FE) and a temperature controller has been provided to take control of

the vent valve in case low condensate temperature is detected.

From the CM reflux drum, the condensed FB, pumped by the CM reflux pump (31-P-206/S), is split between

the CM column reflux and the recycle to the reaction area. Any excess liquid is sent to the FB surge tank to

maintain constant level in the reflux drum. In case the liquid level falls, fresh FB make-up can be brought in

from OSBL, but the make-up must be lined up and controlled manually. The temperature of the recycle to

the reaction area is approximately 52°C. The comonomer feed cooler (31-E-113) further cools the recycle

stream down to 36°C which is the operating temperature of the SH purifier in the reaction area.

The CM column bottoms product contains all the FB-2 that needs to be purged plus some FB-1. It also

contains essentially all of the SH which goes overhead in the LB column. The bottoms flow rate is set to

keep the CM column bottoms composition within acceptable limits. For this the operator will rely on the gas

chromatograph which analyses the composition of both the distillate and the bottom streams. At the pressure

stated above, bottom temperature is approximately 70°C but is not a good indicator of composition because

the boiling point of FB-2 is quite close to that of FB-1. At constant pressure, an increase over the usual

temperature value would mean an accumulation of SH rather than a shift in FB composition. The column

pressure drop that depends on Reboiler loading will also cause temperature variations beyond those due to

composition.

The purity of the distillate is achieved by controlling the reflux flow (i.e. reflux ratio). A ratio control

automatically maintains a constant reflux-to-feed flow ratio. Boil-up is controlled to

. The following two operating modes are applicable:



• Homopolymer Resins In homopolymer operation there is no need to concentrate FB-2 and therefore the CM column is somewhat

redundant. If homopolymer is produced for extended periods the column may be shutdown by feeding the

FE column bottoms directly to the FB surge tank. The column may also be kept in service so it is

immediately available when required. If the CM column is kept on standby for an extended period of time a

slow accumulation of SH in the column base will occur. This will have to be controlled by recycling a small

flow to the FB surge tank.

• FB or Terpolymer Resins When making FB or terpolymer resins, FB-1 is fed to the reactor and, consequently, some FB-2 is formed as

a result of isomerisation. Thus, the CM column must be kept on line. The target concentration of FB-1 in

the overhead product is approximately 95 wt%. FB-2 purge is controlled to keep FB-1 concentration in the

bottoms at or below 15 wt% (5 wt% FB-1 should be feasible and would reduce the loss of FB-1 accordingly).

4.2.2.6.2 CM Column (31-C-205): The column is equipped with 83 valve trays. The column is protected by two pressure safety valves (PSV-

3823/S) before the CM Condenser.

Feed to the column enters between trays 68 and 69. The feed is supplied from the FE Column base.

Butene from the storage area may be brought into the column through the CM Reflux Drum. The column

has temperature indicators located throughout its length. They are for monitoring column performance. The

column is equipped with a high-high pressure switch that will shut off the steam to the Reboiler.

Gas chromatograph sample points monitor product purity. There is one on the butene-2 base purge and one

on the reflux line to the column. This is for purging butene-2 from the column and controlling the

concentration of butene-2 in butene-1.

4.2.2.6.3 CM Reboiler/Condensate Pot (31-E-214): The CM Reboiler is a vertical thermosyphon and is heated with low-pressure steam. Steam enters at the

topside and exits from the bottom side to the CM Reboiler Condensate Pot through a level control valve to

low-pressure condensate header. The steam flow is regulated to maintain a constant base level in the

column.

The shell side is provided with a pressure safety valve (PSV-3802) set at a pressure of 10 kg/cm2g. Process

flows from the column base by natural convection into the bottom of the Reboiler, through the tubes and

back into the column through the outlet nozzle at the top of the Reboiler.

4.2.2.6.4 CM Condenser (31-E-215): The condenser is a shell and tube condenser with water on the tube side and process fluid on the shell. This

condenser is used for pressure control on the column by controlling the water flow to the condenser using

control valve 31-PV-3809B. The tube side is protected by a pressure relief valve PSV-3907.



4.2.2.6.5 CM Reflux Drum (31-V-206): The CM Reflux Drum is protected by a pressure safety valve (PSV-3923) set at a pressure of 10.5 kg/cm2g.

A vapour Pulldown valve (31-HV-3918) is provided on the reflux drum. The Drum is equipped with a vortex

breaker on the liquid line to the reflux pump.

4.2.2.6.6 CM Reflux Pump (31-P-206/S): The CM Reflux Pump supplies reflux to the column. It also supplies comonomer through the CM Feed

Cooler to the reaction area via the purifiers as well as feed o the FB Surge Tank through the FB De-inventory

Cooler.

4.2.2.6.7 CM Feed Cooler (31-E-113A/B): The CM Feed Cooler is a water-cooled exchanger that cools the recycle butene stream to 35°C which is the

operating temperature of the SH Purifiers. The butene flow then passes through split-range flow control

valves. This flow can be directed to the inlet of the SH Purifiers or through the bypass to the suction of the

Solvent Feed Pump.

The tube side is protected with a pressure safety valve (PSV-1116) set at a pressure of 18 kg/cm2g. Tube

side is protected by a pressure safety valve (PSV-1106) set at a pressure of 10 kg/cm2g.

Main Function of CM Column: 1. To separate butene-2 from Butene-1

2. To remove any residue SH


Analysis For

Col. Pressure ~ 6 kg/cm2 Condenser Col. Temp.

Reflux Flow ~ 3.5 – 4.0 Ratio to Feed FB-1/FB-2

Seaparation

Overhead Flow Flow Control

Ratio to FE (to control RA density)

FB-1, FB-2’s

FB-2 Purge Flow Control FB-2 in

Overhead FB-

1 required

FB-1, FB-2

Base Temp. ~ 70°C SH/FB-2

Ratio in Base

Base Level 50% LP steam flow to Reboiler FB-1, FB-2

Reflux Drum

Level

Flow to FB Surge Tank



4.3 FINISHING AREA (AREA 300) 4.3.1 General Finishing Area Overview: In normal operation (when producing polymer), the IPS and LPS are vessels in which the system pressure is

reduced in order to separate the polymer from the solvent, monomer and comonomers. Most of the

cyclohexane, unreacted ethylene, comonomer, and a small amount of grease leave the IPS by way to the

IPS overhead line as a vapour phase. Polymer containing cyclohexane leaves the bottom of the IPS as a

liquid phase and flows to a two stage LPS that operates between 3.5 kg/cm2g and 10 kg/cm2g. Liquid

additives are added to this incoming flow as per manufacturing guidelines for the production resin. Most of

the remaining cyclohexane is removed in the first stage as a vapour. The differential pressures between the

two vessel sections affect the polymer flow from the first stage of the LPS to the second stage. A multi-holed

“sieve” plate is located between the two stages of the LPS. The polymer then flows by gravity through the

sieve plate to the LPS second stage into the feed section of the Extruder.

Vapours from the IPS and LPS overhead lines go to the Recycle Area where the cyclohexane is purified, and

unconverted comonomers are separated and recycled. Waste products such as grease and inert some are

removed as deliberate purges.

Liquid and dry additives are added in different locations to the resin parameters making a multitude of unique

polyethylene resins with many different end uses. Resins are stripped of volatiles, blended for lot uniformity,

dried and packaged in 25 kgs bags. During the resin residency in the stripper, lots are tracked, adjusted in

size and parameters recorded. In the Blenders residual volatiles, moisture is removed and a homogeneous

lot is produced. During packaging the resin is classified and bagged and are marked with readily identifiable

production lot numbers and resin type for ease of storage, shipment and future reference. Resin samples

taken over the duration of these activities provides the client with resin quality specifications for repeatable

quality verification to operate their businesses. Resin not packaged in bags is sent to the storage silos for

later dispersal.

4.3.1.1 Process Description: The hot solution, near reaction pressure, passes through the system pressure control valves (31-PV-

1909A/B) that is located on the inlet of the IPS and enters the vessel. The IPS pressure is controlled at

approx. 28-31 kg/cm2g.

During resin production, the IPS and LPS is vessel in which the system pressure is reduced in order to

separate the polymer from the carrier solvent, monomer and comonomers. The polymer is gravity fed to the

Extruder for pelletization. The majority of the solvent, unreacted ethylene and comonomers move to the

Distillation area for recovery.

Most of the cyclohexane, unreacted ethylene, comonomer, and a small amount of grease (low molecular

weight material) leave the IPS by way of the IPS overhead line as a vapour phase. Polymer containing

cyclohexane leaves the bottom of the IPS as a liquid phase and flow to a two stage LPS that operates

between 35 kPa and 900 kPa. Most of the remaining cyclohexane is removed from the LPS as a vapour

overhead. The differential pressures between the two vessels affect the polymer flow from the first stage of

the LPS to the second stage. A level on a “sieve” plate located between the two stages of the LPS creates a

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through an opening in the tip centre of the vessel. This reduces the velocity of the vapour and allows any

entrained polymer to fall out and collect in the bottom of the vessel. The vessel and bottom outlet valve are

traced with High Pressure Steam to keep any polymer that may collect in a molten state. The vessel is

checked periodically to keep empty any polymer that is collected can be drained into a waste container.

The vessel is equipped with a high level alarm and a pressure gauge. It has nitrogen and low pressure

steam connections for purging. It has a manual tie in to the Flare System for venting the pot. The two

pressure relief valves (PSV-1907/S) are set for 10 kg/cm2g.

The vessel has a by-pass line so the vessel may be removed from service for cleaning while polymer

production is maintained.

NOTE: It is preferred NOT to bypass the LPS KO Pot while operating, but it can be done if necessary. 4.3.1.2 RA Extrusion (Ref. PFD 00101-DA-31-0104) 4.3.1.2.1 Process Description: Molten RA from the LPS flows into the main extruder (31-ME-315) which is driven by a variable speed motor.

The speed is adjusted to maintain a constant polymer level in the LPS No. 2. RA enters the feed section of

the rotating extruder twin screw. The screw forces the molten RA through the die plate of the underwater

pelletizer (31-ME-314). A melt cutter then cuts the extrudate into pellets of predetermined length, typically

3.5 mm. The diameter of the holes in the die plate is approximately 3.5 mm and the speed of the melt cutter

can be synchronized to the speed of the extruder screw to give the required pellet length.

The pressure drop in the feed section of the extruder will result in some entrained solvent separating from

the molten polymer. This gas can form pockets in the feed section and affects the screws ability to push the

resin into the extruder barrel. To maintain maximum throughput these vapours are vented from the edge of

the screw flights through three vent devices (31-ME-317,318 and 319) on the side of the extruder feed

section. Depending on the resin being produced, the barrel of the extruder may need heating or cooling. For

this reason the extruder has been divided into zones.

Liquid additives can be injected into the extruder barrel as required through a special spacer in the barrel.

Similarly, solid additives and/or recycle resin from the satellite extruder (31-ME-316) may be injected via the

spacer located between barrel sections of the extruder.

NOTE: For Extruder start-up, shut-down, Trouble shooting, Emergency Handling procedure please

also refer vendor’s operating manual. 4.3.1.2.2 Extruder Equipment 4.3.1.2.2.1 Expansion Joint and Feed Section Spacer: A 60-inch nominal diameter bellows type expansion joint (HX-301) installed on the bottom of the second

stage LPS with the spacer bolted onto its bottom flange. The bellows is made of Incoloy 825 and has an

internal 16 gauge Teflon coated removable. It’s designed for 5000 cycles with axial movement of 25.4

mm, lateral movement of 2.54 mm and angular movement of zero to accommodate thermal growth. The

gasket material is SS with ceramic filler of standard thickness – spiral wound. An MP steam tracer in two



sections is clamped around the expansion piece, which provides heat to this critical resin flow area.

Design pressure is 10 kg/cm2 and design temperature of 300°C. Operating pressure is 0.06 kg/cm2g and

temperature of 210°C.

Fig. : Extruder Expansion Joint & Spacer

The expansion bellows has tie bars on the outside flanges that will compress it to allow the bellows to

be removed when internal cleaning is required. These tie bars must be relaxed prior to any heat

expansion for start-up and normal operation. The 111” thick spacer is also Teflon coated and with the

same design and operating pressures and temperatures. Applying compression to the in place flange rods,

allows this spacer to be removed first to allow maintenance working access to the expansion joint and to

allow gasket assembly. The spacer and the expansion joint may be part of the cleanup of the LPS

and extruder depending on the implemented procedure.

4.3.1.2.2.2 Extruder Inlet Feed Barrel/Transition Piece

The Extruder Feed Transition piece adapts the round 60” flange of the expansion joint to the

rectangular (1492 X 740 mm) feed extruder barrel opening.

The LPS expansion joint directly above this connection also has capabilities for axial and vertical growth.

The Main Extruder is pinned at the thrust bearing near the motor end of the extruder so thermal

growth occurs toward the cutter end of the extruder. The expansion joint is designed to accommodate up



to 6 mm of thermal growth although only about 2 mm is expected.

Fig. : Extruder Inlet Transition Piece

The Inlet Feed Section has five 2.5” inside diameter nozzles which are extended to the inner side of the

extruder barrel. These openings will accommodate the vent devices – three of which will be installed for

initial start-up. A more complete description of the Vent Devices comes later.

In addition to the vent device openings, there is a 6” pad type connection drain located slightly above the

screw centerline on the opposite side of this section to the vents. A 6” drain valve will be fitted to the

connection. This drain valve will only be utilized if the extruder drive cannot function and the LPS cone must

be emptied of molten polymer to facilitate repairs.

4.3.1.2.2.3 Main Extruder Motor The 4800 kW (6436HP) motor controls the extruder speed through a VFD using a Speed Indicating

Controller. The motor type is an EEXP so that instrument air is needed for purging and pressurizing. In

addition, since this motor is TEWAC type cooling water is required and supplied through a 3” CWS line.

Jacking Oil System - The Main Extruder motor has sleeve bearings and will have a need periodically

to be rotated at less than 10% of maximum speed. At low speeds, the shaft needs to be lifted up by the

Jacking Oil System Pumps (31-P-319A/B) in order to provide adequate lubrication for the sleeve

bearings. The running status of the Jacking Pumps is one of the Main Extruder start conditions. SI 4153 will

provide an automatic start up of these jacking oil pumps if main motor speed is less than 15% of maximum.

The motor runs from 80-1225 rpm while driving the screw speed between 12-125 rpm. Normal screw

speed in operation will be 50-80 rpm or approximately 30-50 t/hr. Machine vibration monitoring of the

motor bearings system is an early warning system for required maintenance.



Other downstream extruder related equipment is interlocked with the extruder motor so that

unacceptable process or equipment conditions will shutdown the motor, or ramp down the motor speed,

depending on the criticality of the condition. The motor cannot be started unless all interlocked

operating conditions are acceptable.

4.3.1.2.2.4 Extruder Gear Reducer A planetary type gearbox with a ratio of 12:1 delivers an output speed of 12-125 rpm to the extruder screws.

The gear reducer has a Lube Oil System with alarms and interlocks that will protect the gear reducer from

high temperatures, low oil pressure or low oil flows. The system is pumped, temperature controlled and filtered

providing lubrication of the gears achieved through this lube oil unit placing oil over the thrust bearings

and internal gears to 23 locations. This lube oil system consists of pumps 31-P-309/S running only one at a

time and oil supplied from the gear reducer sump that has a LG and low level switch. A PSV on the pump

discharge set at 6.5 kg/cm2g protects the line. Oil passes through the shell side of the water cooled

exchanger 31-E-320 with a TCV bypass line. There are dual inline 100 mesh filters with one on line at a

time and a pressure differential indicator transmitter to view the filter condition. Temperature gauges on

the input shaft; TE on the thrust bearing; seven vibration monitoring locations also protects this

equipment. The gear reducer also has a top window to monitor operation which can be removed for the

addition of oil when needed. The oil sump has two winterization heaters 31-H-318A/B that can be utilized to

heat the oil prior to extruder start-up during cooler periods. Machine monitoring is in place for both the

gear reducer temperature and its vibration. Indication and alarms at both the DCS and field touch screen.

4.3.1.2.2.5 Extruder Barrel and Adapter Section 4.3.1.2.2.5.1 Equipment Descriptions 4.3.1.2.2.5.2 Extruder Barrel

In this section, the basic function and theory of the extrusion system is discussed. For detail, design

and operation, the manual provided by the vendor should be referenced.

The extrusion process utilizes two Twin Screw extruders: the Main Extruder for production and the

Satellite Extruder for additive delivery and resin upgrades.

The Main Extruder is melt fed from the bottom of the LPS and its function is to convey the molten material,

mix in the additives delivered from the liquid additive system and/or Satellite Extruder, pressurize the

polymer, and deliver it to the Pelletizer where it is cut into uniform polymer pellets. The Satellite Extruder is

fed recycle resin from a feed hopper and dry additives from weigh feeders. The function of the

Satellite Extruder is to melt the feed material, thoroughly mix the additives, and pressurize the polymer to

deliver a homogenized melt stream to the Main Extruder.

4.3.1.2.2.5.3 Main Extruder: The Main Extruder is a Twin Screw, Co-Rotating, Fully Intermeshing extruder. The screws and barrels are

modular in design, which allows relatively easy screw design changes to meet process requirements.

Because the extruder has a fully intermeshing screw design, it is considered self-wiping. The interaction of

the screws keeps the screw flights clean as well as the barrel walls, thereby minimizing the amount of

material that can cause quality issues due to cross contamination or degradation.



The screws are comprised of individual components that have specific functions. These elements are

stacked up on the screw shafts to provide a design tailored to the application required. Although extruder

vendors may have proprietary elements, they are generally variations of standard elements.

The function of the Main Extruder is to convey, mix, and pressurize the polymer melt to extrude it through a

dieplate into the Pelletizer. As such, it is primarily comprised of conveying elements and some mixing

elements.

Fig. : Main Extruder Typical Screw Configuration

The elements located upstream of the LPS feed are typically narrow pitched elements to minimize polymer

melt from migrating back to the shaft seal area. The elements located directly below the LPS feed are

typically larger pitch conveying elements. These elements will have the highest conveying capacity and

deepest flights, which are required to be able to handle the gas entrained polymer from the LPS. Although

the extruder is melt fed, this feed can contain a fairly high amount of gas resulting in a frothy foam entering

the screw. As the material is conveyed from the feed throat into the barrels, the screws pitch narrows,

resulting in a lower conveying capacity. This transition from large pitch elements to narrower pitched

elements squeeze the gas bubbles out of the melt, and force them back towards the LPS and the vent

devices. Thus, the melt is going from a two phase (liquid and gas) to one phase (liquid).

The polymer melt continues to be conveyed down the length of the extruder using conveying elements and

an additive laden polymer stream is injected in one of the downstream barrels. The combined mainstream

and additive stream are then mixed together in a section comprised of mixing elements.

The thoroughly mixed melt continues to be conveyed to the end of the extruder using conveying elements.

As the melt continues down the length of the extruder, the conveying elements may change to a narrower

pitch, or single flighted elements, to develop the necessary pressure to extrude the melt through an hot oil

heated dieplate into the Pelletizer, where the individual die hole strands are cut into pellets. The final

elements on the screws are typically slotted mixing elements to ensure a homogenized melt temperature is

delivered to the Pelletizer.

4.3.1.2.2.5.4 Satellite Extruder The Satellite Extruder is also a Twin Screw, Co-Rotating, Fully Intermeshing extruder. Similarly, the

screws and barrels are modular in design, which allows relatively easy screw design changes to

meet process requirements. As stated for the Main Extruder, the Satellite Extruder has a fully intermeshing

screw design, it is considered self-wiping. The interaction of the screws keeps the screw flights clean as

well as the barrel walls, thereby minimizing the amount of material that can cause quality issues due

to cross contamination or degradation.



The function of the Satellite Extruder is to convey, melt, mix, and pressurize the polymer melt to deliver

the additive laden melt to the Main Extruder. As such, the screw design is comprised of conveying

elements, kneading blocks (for melting and mixing) and some optional mixing elements for dispersive

and distributive mixing.

Fig. : Satellite Extruder Typical Screw Configuration

The elements located directly below the feed hopper are typically wider pitch conveying elements, which

are required due to the lower bulk density of the pellets. These elements convey the carrier resin and dry

additives pellets into the barrels. The pellets are then fed into a melting section, which consists of a

number of kneading blocks. The primary melting mechanism is through shear energy imparted by the

kneading blocks. HP steam barrel heating may also provide resin melting, however it is a minor

contributor and usually only results in a melt film on the barrel wall. A left-handed element may be used

at the end of the kneading blocks to increase the fill in the kneading blocks to improve the melting.

Molten polymer exits the kneading blocks and is conveyed down the length of the extruder twin screws

using conveying elements and additional mixing elements. As the melt continues down the length of the

extruder, the conveying elements may change to a narrower pitch, or single flighted elements, to

develop the necessary pressure to inject the melt into the Main Extruder. JSW has developed the screw

sections arrangement to provide the melting, mixing and capacity required.

4.3.1.2.2.5.5 Screw Elements The preceding was intended to be a general overview of the screw elements and their purpose. For a

completed description of the element designs and their purpose, see the vendors manuals and the

explanations in our process technology manual.

4.3.1.2.2.5.6 Throughput The throughput of a Co-Rotating Fully Intermeshing Twin Screw Extruder can be analyzed similar to

Single Screw Extruder. There are two main factors in determining the output of the extruder; drag flow and

pressure (or reverse) flow. The drag flow is the rate due to the geometry of the screw and the rotational

speed of the unit with no pressure gradient. In order for the scraping action of the screw to force the

polymer forward, there must be viscous polymer in contact with the wall.

The pressure or reverse direction flow is a result of geometry plus the difference in pressure between the

higher pressure outlet and the lower pressure inlet. For this situation, the geometry that the polymer

"sees" is a long rectangular tube as if the screws were "unwound". With the delta P and the square

channel there is a theoretical reverse flow. This reverse flow takes away from the drag, or forward flow.

It is proportional to the pressure drop per length of screw. The higher the pressure change the greater the

back flow.



Although there are two main factors affecting throughput, there is another factor that is often neglected as it

has a minor affect; referred to as leakage flow. The leakage flow is the amount of polymer that flows in a

reverse direction through the clearances between the screws and between the screw flights and barrels.

As the screw wear occurs, the clearances become larger and the leakage flow can become more significant.

Although the co-rotating extruder conveys material in a similar manner to a single screw extruder, they

have a more complex geometry. This results in equations that are more complex for Drag, Pressure and

Leakage Flow. As such, the vendor should be consulted for a more detailed analysis.

The screw condition relationship to viscosity is important to understand. As the viscosity decreases (i.e.

MI increases), the leakage rate will increase and the overall rate for a given screw speed will decrease.

Screw wear will magnify the leakage rate increase with viscosity decrease. As the screw speed is

increased for higher rates, there is additional shear heating that results in a decrease in viscosity. As

this occurs, there may be a small reduction in the specific screw rate (mass flow per rpm)

The throughput of the Main Extruder, which is flood fed with polymer melt, is controlled by the screw

speed. The screws are assumed full and the transport mechanism is melt conveying. For a given product,

the specific screw rate can be determined, which is equal to the rate divided by the screw speed (kg/hr/rpm).

This parameter can be used to condition monitor the extruder. For example, if the specific screw rate has

a continuous trend downwards, it may indicate of screw/barrel wear resulting in higher leakage rates.

The throughput of the Satellite Extruder, which is designed to be starve fed, is primarily controlled by the

feed rate. The maximum capacity of the Satellite Extruder is usually based on the maximum

acceptable torque applied to the screws. The screw speed can be adjusted to increase or decrease the

degree of fill, mixing, and/or melt temperature.

4.3.1.2.2.5.7 Mixing Mixing within the Twin Screw Extruder occurs with the use of specifically designed screw elements and

through the transfer of the melt stream from one screw to the next. The two types of mixing that occurs

within the extruder are dispersive mixing and distributive mixing.

Distributive mixing is typically achieved through flow splitting. This is done using gear-type or slotted

elements that cause the melt stream to split and rejoin.

Dispersive mixing is typically achieved by subjecting the melt stream to high shear forces, causing the

particles to elongate and break apart. This is typically done using kneading block elements.

4.3.1.2.2.5.8 Operation Starving of the Main Extruder screw is possible. This occurs as a result of a high volume of gas in the

melt. Theoretically, flow should continue to rise as the rpm increases. However, in practice the flow remains

constant after a point of speed no matter how high the screw speed is. Corresponding to this, the amps

follow the curve up initially but once the starve fed condition is reached, the amps start to fluctuate

erratically. As starve fed condition is reached, the pressure at the inlet to the metering section begins to

drop somewhat. Pressure prior to the die, at the extruder outlet, rises until starve fed condition is reached



and then produces erratic pressures after that point.

An example of the loss of output as starving occurs is shown in the following figure for three different resins

of different MI‟s. Although the starving phenomenon is predominantly with lower MI resins, as they have

more of a tendency to trap SH, higher MI materials can also be affected.

As starvation is primarily a problem of gas mixed with the polymer, the NOVA provided proprietary

venting devices will allow greatly increased extruder speeds (and throughput) before this phenomenon

occurs.

Fig. : Flood Fed Vs. Starve Fed for Different MI Material

4.3.1.2.2.5.9 Venting It has been determined that the starvation process is primarily a phenomenon of gas coming out of the

polymer where the pressure drops below vapour pressure in the screws. This gas then forms a large gas

bubble in the throat of the extruder blocking other polymer from entering the extruder. The vent screw

provides for the venting of the gas bubble allowing a higher output from the extruder.

Fig. : Conceptual view of Vent Screw Operation



The vent screw design has a screw detached from the shaft, producing a free floating helix which

continually forces the polymer back into the extruder and in addition continuously cleans the shaft. The

helix is rotated and the shaft remains stationary preventing polymer build-up on the shaft.

The above figure shows a CFD simulated view of the vapour pocket formed in the extruder with a vent

screw superimposed to demonstrate the venting. Note three vent devices located in the side of the feed

barrel will be operational for the extruder at start-up. Additional blanked vent ports are included in the

equipment that will allow for future optimization in the field. The optional blanked vent ports as shown

below are two at the top rear of the extruder and one prior and one after the side operation vents.

Fig. : Vent Device Locations

These vent devices virtually eliminate the ceiling imposed on output as a result of starving the extruder.

Operations will adjust vent device parameters as the MI of the resin varies. The starvation of the Main

Extruder twin screws will occur at different rates for different MI materials. High MI resins do not require the

use of the vent screws, as the bubbles can find their way out of the low viscosity liquid easily. In fact, for

MI‟s greater than 20, it is recommended to isolate the vent devices as the material is of such low viscosity

that it may travel up the vent device and enter the knock-out pots. Running low MI materials, a stable gas

pocket is formed and two or more vent screws are required to remove the quantity of gas accumulated. In

intermediate MI resins the vent screw is required but the gas pocket formed is unstable due to the lower

viscosity. In this less stable area two vent screws appear to handle the material better than a single

one as reduced operating speeds can be utilized.

4.3.1.2.2.5.10 Melt Cutter and Pelletizing Once the polymer leaves the extruder, it is forced through the holes of the die and pelletized with the melt

cutter. The die is heated with hot oil. As the melt is forced through the holes it is cooled with the cutter

water and cut by the blades of the cutter assembly.

The pellet shape, in terms of diameter and length is influenced by MI and flow rate. Flow rate in the

die assemblies is usually defined as kg/hr/hole. The diameter of the pellet is larger than the die hole due

to melt swell. The temperature of the cutter water will have an effect on the cut pellets. If the temperature

of the water is too high, the newly formed pellets will stick together. To avoid pellets sticking together it

is important to keep the water temperature low, and the PCW water flow high, preferably with a water to

pellet ratio of at least 10:1 or higher.

Monitoring the pellet size distribution, chips etc. is a useful way in determining whether or not the die is

freezing up or holes are being plugged. When holes are being plugged or frozen off, the melt preferentially

flows through the other holes making the pellet size in the other holes increase. The number of open die



holes can be determined by taking a pellet per gram sample over a set timeframe and comparing against the

theoretical pellets per gram. This is established by knowing the number of cutter blades on the hub,

the production rate and the number of holes in the dieplate. Using the following equation, the number of

frozen/slow die holes is established.

Fig. : Determination of Number of Die Holes Open

The cutter used in this application employs contact cutting. That is, the knives are in constant contact with

the dieplate. This allows the knives to be continuously sharpened. It is important to maintain constant

contact with the dieplate, but also to control the amount of contact to optimize the life of the cutter knives

and the dieplate hard surface. Therefore, an understanding of the forces at work on the cutter knives

should be understood. The figure below illustrates the forces on the Pelletizer.

Fig. : Forces on the Pelletizer

The relationship between cutter speed and differential pressure on the cutter shaft will be determined initially

by the JSW rep. A procedure for developing this relationship can be obtained from the vendor.

As can be seen in DP vs. Speed figure below, as the cutter speed is increased the hydrodynamic forces

increase, drawing the knives towards the dieplate. To offset this, the cutter shaft hydraulic forces should be

adjusted to prevent excess wear of the knives.

Fig. : Pelletizer Speed Vs. Differential Pressure



The extruder barrel consists of several sections supported by pedestals. Warping of the barrel through

temperature changes is protected against using fixators that allow for all the thermal growth forward towards

the cutter end. The extruder is pinned at the thrust bearing, in front of the feed area to control this

expansion movement.

The barrel consists of several sections C1 ->C5 with the Satellite entry between C2 and C3. Indications

are available in the field and the DCS for temperature and pressure of each barrel section.

This barrel temperature control is through the HP steam heating /mist water-cooling system with

appropriate temperature control instrumentation. The HP steam temperature brings the barrel up to 260°C

prior to extruder start-up. The water/mist part of the temperature control system takes over after that for final

temperature control. The extruder barrel sections C1 and C2 where the LPS polymer feed enters the

extruder screws are supplied heat from one air operated temperature valve while the rest of the HP steam

heat valving is manually control. This should allow heat to the extruder for running and once operational

minimal barrel heat is required. The control side of this system is temperature activated water/mist automatic

valving to each barrel section. There is a water or mist switch to allow mode selection for each barrel

zone. With the mist mode being selected – the composition of the mist is CCW (cylinder Cooling

Water) of 0.09 m3/h and IA (Instrument Air) of 11.9 Nm3/h per nozzle for each barrel zone. The system

has its own water supply tank 31-T-305 with TW filling; level gauge, temperature gauge, level switch and

CWS cooled exchanger 31-E-328. Two supply pumps 31-P-320/S provide the cooling water for the system

loops. These pumps and associate tank are all monitored from the field with the tank level indication in the

DCS.

The interior parts of the barrel that contact with the Extruder screw has a hardened liner that ensures barrel

life. The screw is partly coated with COLMONOY 56 treated for wear. The barrel is sized to handle the

screw L/D of 23:1.

Located at the drive end of the feed section is a seal area with lantern box for the egress of polymer

with controlled amounts of solvent vapours. The seal has a cooling water loop, nitrogen purged lantern

housing with vent required for stable operation. Temperature probes with high temperature alarms are

present to assist in temperature control.

The Satellite Extruder injection port is located in a Dutchman section approximately mid way down the

barrel length. The Satellite Extruder may be isolated from the Main Extruder by a three-port valve. This

valve can be opened from the Satellite to the floor for purging the Satellite Extruder, or from the Main

Extruder to the floor to purge the line to the Extruder or from the Satellite to the Main Extruder. In

normal operation, the Satellite Extruder is always running or is available to operate. This three-port valve is

hydraulically operated (has its own unit) and HP steam heated

Temperature and pressure indicators are also located on the spacer.

Nearer the barrel discharge end, a hydraulically operated dump valve is located to help on equipment start-

up and prevent water from the cutter from entering the barrel during production down periods. A chute with

water spray water is provided to cool and move any polymer discharges to grade. A rupture disk is also



located on the bottom of this section. This rupture disk is provided with an interlock that will shutdown the

Extruder and also alarm that the disk has failed. .

In the forged steel die holder section with chrome-plated interior surfaces, a blanked port is provided for a

future Melt Rheometer located on the top of the adapter. The adapter is High-Pressure Steam jacketed to

maintain the polymer temperature.

4.3.1.2.2.5.11 Extruder Rear Seal & Dust Box Assembly The rear seal section of the extruder has a tempered water cooled sleeve that cools to solidify polymer

making a cool seal as the polymer tries to exit the back of the extruder shafts. Some small amounts of

polymer exit into the dust box assembly attached to the rear of the extruder. The dust box also houses a

secondary seal that prevents any gases from the extruder from leaving this area. The dust box is purged

with nitrogen to a vent discharging to a safe location. The nitrogen purge also prevents oxygen from

entering the extruder that could cause degradation of the polymer. The approximately 60 liter dust box

collection area has a 1” gate drain valve to grade, a tempered glass view port, a top cover with gasket

and hold down and a ½” globe valve nitrogen connection.

Low-pressure alarms will notify operations of a seal failure.

Fig. : Extruder Rear Seal

Material from the dust box – liquids or solids can be drained or removed as required to maintain the seal.

4.3.1.2.2.5.12 Extruder Screws(s) The extruder 387 mm co-rotating, fully intermeshing twin screw is designed to pump polymer at 57,780

kg/hr from the feed hopper of the extruder through to the dieplate. Throughput is dependant on resin

viscosity, pressures and temperature. During this operation, the polymer is compressed, metered and

mixed before it exits the extruder barrel. The screw has a diameter of 387 mm with a Length/Diameter of

approximately 23:1.

The drive ends of the screws mate to the output side of the gearbox, and the power is transferred

by the connecting keyways.



The feed section of the screws is located under the outlet of the LPS. Screw channels that are wide and

deep characterize the feed section. This is necessary in order to move as much polymer as is possible

into the compression section. The compressed gases released from the polymer are in part removed

through the 3 Vent Devices. These Vent Devices are used to reduce volatile build-up in the barrel to

help provide a more stable operation. This volatile reduction is accomplished by vacuuming these gases

to an overhead recovery system. Operation of these Vents will be addressed later.

The overall screw design is as follows:

• The screws are co-rotating and self-wiping, which means they convey polymer with one screw wiping the

polymer off the other moving the polymer to the dieplate.

The amount of energy put into the polymer is dependent on the viscosity of the polymer, and the

rate of extrusion. Only about 30% of the indicated power of the motor is used to extrude the

polymer, and the remainder is lost in heating of the polymer and friction.

4.3.1.2.2.5.13 Dump/Divert Valve Directly downstream of the screw discharge is an extruder dump/divert valve. This valve is

hydraulically operated by its own unit. This diverter valve when opened is used to prevent PCW water from

migrating through the extruder barrel into the LPS feed area during shutdown periods. It will also be utilized

during the cutter blade sharpening. A third function of this DV is to purge the extruder of low melt index

resin during a process upset or degraded material after a stoppage. The valve diverts the polymer away

from the extruder to a sloped water cooled tray to grade placed beneath the valve. This valve can only be

energized to the dump position by a local hand switch located such that the operator is well clear of the

discharge.

The diverter valve’s hydraulic system consists of a hydraulic oil tank (reservoir) 31-T-303 with drain,

air breather/fill cap and level gauge LG-4129. A single circulation pump 31-P-321 (with run indication in the

DCS and the field touch screen) starts up and pulls oil from the tank as required for a position move. Limit

switches indicate valve position and will shutdown the Main Extruder if the valve is not in the through

position. This valve is HP steam heated and must be up to temperature to move. The valve has a melt

temperature transmitter and pressure transmitter. The dump valve drive is interlocked to stop the extruder

drive on high-high pressure as a protection from damage.

4.3.1.2.2.5.14 Die Holder The polymer is conveyed into a HP steam heated die body housing maintained at approximately 250°C. A

70°C maximum temperature differential between this die body housing and the dieplate minimizes

mechanical stress from thermal expansion on the dieplate. The die housing has channels that evenly

feed polymer into the dieplate. This area has a melt temperature indicator as well as a pressure

transmitter that will stop the Main Extruder on high-high pressure.

4.3.1.2.2.5.15 JSW Deiplate The polymer is extruded through the dieplate that contains approximately forty-eight hundred 3.2 mm holes.

The dieplate is heated with hot oil that circulates through channels between the die holes. A hot oil



manifold connects the hot oil supply to eight inlets that freely circulates through to the eight outlets heating

the dieplate holes as the polymer passes through to the cutter. A titanium carbide face provides good

heat transfer and a hard cutting surface for the knives to obtain a clean cut. A uniformly heated dieplate is

essential to ensure good pellet weight distribution of 42 ppg. Between the nibs (each die hole) is an

insulating material that provides isolation from the circulating water so that maximum heat is retained for

the efficient extrusion of the polymer. Too low a temperature causes melt fracture of the resin as well as

high melt pressure as well as increasing resin temperature.

4.3.1.2.2.5.16 Extruder Barrel Cylinder Heating/Cooling System for Extruders 1. STEAM HEATING & WATER COOLING REQUIREMENTS FOR CYLINDERS The following shows cylinder heating and cooling requirements for extruder start-up and operation.

Prior extruder start-up, cylinder heatup is completed by HP steam from ambient temperature to around the

HP steam temperature (~260 ). During this period of cylinder heating, the cylinder water cooling is not

required. Once extruder start-up commences, pumping the molten polymer increases cylinder

temperature and cylinder water cooling is required. The cylinder temperature controller must be set to the

desired operation temperatures.

Fig. : Steam Heating Water Cooling Requirements for Cylinders

2. CYLINDER STEAM HEATING Before extruder start-up, steam heating for all cylinders is required as per above descriptions. During

this cylinder steam heating period, all HP Steam supply valves are opened fully. Cylinder temperature is

increased as shown in figure below. Finally, cylinder temperature is considered satisfactory for start-up

around full HP steam temperature of 260 . After this cylinder temperature is reaches 260 the

extruder barrel cylinders are continuously heated soaked for a minimum of two hours to completely heat

saturate the cylinder metal.

Note: All expansion is linear towards the cutter end of the extruder.

Fig. : Relationship between Cylinder Temperature and Cylinder Heating Time



3. HEAT BALANCE OF MOLTEN POLYMER INSIDE EXTRUDER Below figure shows the heat balance of molten polymer inside extruder. Molten polymer at approximately

180 is fed into the extruder feed hopper cylinder (C1cylinder). Polymer is conveyed by the extruder twin

screws to downstream barrel cylinders. During barrel conveying of polymer, the polymer is mixed at

clearance areas between cylinders inside bore and screws. Polymer temperatures rise progressively

travelling downstream through screw’s shear force. In order to reduce and control polymer temperatures

from rising too far and keep below the maximum of 270 , cooling water must be used. Extruder barrel

cylinders C2-5 are cooled by direct water or mist water circulation. This results in a controlled polymer

temperature during operation. During extruder operation, cylinder heating for C3-5 cylinders is not required

because cylinders are always heated by polymer temperature. Cylinder C1 and C2 may require heating on

some resins.

Fig. : Heat Balance of Molten Polymer Inside Extruder

4. CYLINDER HEATING AND COOLING OPERATION Before extruder start-up, all cylinders must be heated up by steam.

a. Cylinder water cooling valves are closed using the start-up panel.

b. Open manual HP steam valves fully for cylinder heating.

c. Cylinder temperature will increase as shown in figure above.

d. Finally, cylinder temperature will reach the steam temperature of approximately 260°.

e. Heat soak cylinders continuously for a further 2 hours continuing to use the HP steam after cylinder

temperature reaches maximum.

f. Close manual HP steam supply valves to cylinder heating except C1 & C2 cylinders should

preparations for extruder start-up be completed.

After extruder start-up, cylinders C3 through C5 will not require steam heating.

a. If required, C1 & C2 cylinders are automatically heated by steam that is controlled based on C2

cylinder temperature.

b. Set target cylinder temperature individually for each C2-5 cylinders in start-up panel.

c. Cooling line is controlled for OPEN/CLOSE of solenoid valve in line by time proportioning

controllers for setting cylinder temperatures and provides actual cylinder temperatures.

d. When cooling line is closed (cylinder temperature is lower than set temperature), cylinder is an



adiabatic condition and cylinder is heated by process molten polymer.

e. When cooling line is opened (cylinder temperature is higher than set temperature), water goes

through the extruder barrel jacket of the cylinders to provide cooling.

f. During extruder operation, cylinder heating with the exception of C1 cylinder is not required.

g. To provide the cylinders set temperatures, the opening and closing of direct or mist cooling water

valve is controlled automatically and as required during extruder operation.

Steam heating for cylinders is required for cylinder heating before extruder start-up and basically

steam heating except C1 cylinders are not required during operation. C1 cylinder is always heated by

steam. Then, C1 & C2 cylinders are automatically heated by steam during operation that is controlled

based on C2 cylinder temperature and steam heating for other C3 through C5 cylinders are operated by

manually operating HP steam valves. The JSW extruder barrels have two modes of operation for cylinder

cooling. One is “water direct cooling” and another is “water mist cooling”. Water direct cooling is used for low

MI grade to provide large cooling capacity. Water mist cooling is used for high MI grade to provide more

even heat distribution. The mode of operation required is selected on the local panel.

4.3.1.3 Vent Device System: The vent devices are used to reduce the build-up of cyclohexane vapours in the feed section of the extruder.

The vapours “starve” the Extruder, which reduces the efficiency and the output of the extruder. These

vapours have a tendency to collect due to the CCW screw rotation and the exiting volatiles from the polymer

collect in a “bubble” that will impede the flow of polymer into the compression section. By venting this

bubble, the efficiency of extrusion is increased. The screws are not designed to “pump” a vapour so this

alternative method is used to reduce or eliminate this bubble.

The collecting vapour is vented through a Vent Device port located in the feed section of the extruder barrel.

Each of the ports has been positioned to maximise the venting operation. In order to keep polymer from

flowing out these ports, a reverse acting screw is used. These screws have a stationary centre rod with a

“helix” screw for maximum efficiency. The helix screw, which is detached from the centre shaft, continually

forces polymer back into the Extruder and in addition continuously cleans the shaft. The motors of these

screws are speed adjustable.

The vapours flow up the channels of the ribbon screw to the outlet piping located under the vent screw

barrel. A “Strahman” ram type valve is located on this outlet and is used to isolate the system. Since the

ram type valves are flush with the vent screw barrel, it can also be used to push any build-up of greases or

polymer back into the Extruder.

When the Strahman valve is open, the vapours flow into a collection pot. An internal baffle in the collection

pot forces the vapour flow down towards the bottom of the pot where entrained polymer or grease may

separate from the vapour stream, the collection pot can be drained of water and small amounts of solvent

from a bottom valve.

A vacuum is normally maintained on the collection pot by an eductor located on the outlet line. The vacuum

assists in drawing vapours out of the Extruder. Adjusting the amount of steam flow to the eductor regulated

the amount of vacuum in the collection pot. A vacuum/pressure gauge is located on the collection pot outlet



line to monitor the conditions of the system. The steam and vapours from the educator are sent to the inlet

of the solvent vapour condenser located on the stripper overhead stream. If a properly controlled system

vacuum cannot be pulled on the system, then the eductor itself must be opened and cleaned of any

polymer which could be plugging the small internal orifices. Each vent device has its own eductor so it

should be easy identifying the source of the plugging.

4.3.1.3.1 Vent Device Operation: The drives are placed in the PLC/extruder field office. Indications for the motor amperes and speed are in

the DCS. Extruder room field buttons for start/stop and speed control located together for the three vents

close to the units. All the greasing points have extended tubes with fittings in common location for ease of

operation.

On the initial start-up of the vent device screws, it is critical to maintain reduced operating speed to reduce

wear and provide adequate greasing of the vent screws to avoid “galling” and subsequent seizure of the

helix screw and the centre shaft.

When new production is being extruded and the Strahman valve is open, the gasses from the new polymer

will act as a lubricant reducing the need for routine greasing to once every shift (8-12 hours).

Indications for additional greasing are an erratic or elevated amperage fluctuation of the Vent screw

motor (from base line operation).

The vent devices are operated in vacuum mode at approximately -0.05 kg/cm2 until the polymer Melt Index

exceeds 20. From a 20 to 40 melt index the amount of vacuum is reduced, until at a value of ~40 Melt Index,

no vacuum is provided and the Strahman valve is closed. Vent device operation limits established from

experience provides some expected cut-off point for the operator. These above stated melt indexes are for

guidance during initial operation, it is expected that they will be adjusted by the operators as they acquire

experience.

The frequency of the fluctuation seen in the system combination pressure/vacuum gauges will match the

vent screw RPM. This gauge pulsation shows the passage of vapours through the helix vent screw

exiting via the open Strahman valve opening to the condensate pot and ultimately to the RA Stripper

overhead Solvent Vapour Condenser inlet piping.

Only one collection pot is drained at a time while the Main Extruder is in operation (a reduced extruder

speed may be required during this exercise) and other two vent devices are on line in order to avoid a

process upset. A process upset (starving the extruder) can cause agglomerates to form in the Melt

Cutter housing (water chamber). This could result in a shutdown to change out of the cutter hub assembly. 4.3.1.4 Underwater Pelletizer (Ref. PFD 00101-DA-31-0104 & 00301-AA-31-0120) 4.3.1.4.1 General Description: The Underwater Pelletizer is composed of a die holder, dieplate, water chamber and cutter unit. The

Extruder Underwater Pelletizer Melt Cutter is used to pelletize the strand polymer exiting the Dieplate.

These pellets are generally 3.2 mm in diameter and length. The exact diameter and length is dependent on



the polymer properties such as melt index, density and melt swell. Normally, 35 to 50 pellets per gram is

the pellet size range with 42 ppg being goal. The U/W Melt Cutter speed is increased or decreased to alter

the pellets per gram. Increasing or decreasing the Extruder while maintaining the same Melt Cutter,

speed will also affect the pellets per gram count.

As the polymer is forced through the Dieplate, it is cooled by the Circulating Water flow and cut by

the revolving blades of the Melt Cutter. The quality of the cut is determined by many factors. Volatile

content of the resin, the physical aspects of the Melt Cutter, temperature and volume of the circulating

water flow are all contributors.

Part of the physical aspects that will affect cut is the distance between the U/W Melt Cutter blades and

the Dieplate surface. The JSW cutter blades are meant to be in contact with the dieplate surface. The

condition of the cutter blades will also greatly affect pellet cut. The adjusting method and tension required

depends on the resin backpressure and the cutter assembly setup. Direct contact of the knives with the

die face with too much force could damage the dieplate. If any polymer is allowed to collect on the hub

between the blades and the die face, pellet quality will be severely compromised.

The Circulating Water flow to the Melt Cutter housing can also be adjusted for different resin types to

promote a better quality of cut. The adjustable aspects of the PCW circulating water are flow and

temperature.

4.3.1.4.2 Die Plate: The Stainless Steel and Titanium carbide Dieplate forces the polymer to flow through 4832 die holes, 3.5

mm in diameter (0.0137”). As the polymer exits these holes, it is cooled in the circulating water and cut by

the knives attached to the cutter hub assembly.

To prevent the polymer from solidifying and plugging the die holes, sufficient polymer pressure must

be maintained from the extruder side of the dieplate. The circulating water is temperature controlled. Hot

Oil circulated through the die channels beneath the dieplate surface provides enough heat to the metal to

allow the resin to pass the resin at high rate keeping the holes open.

The surface of the Dieplate has an insulating material behind the die surface to preserve dieplate heat and

the die is a full-face plate. The cutter blades are hardened to a value below that of the die face such that

the blades wear, not the dieface.

The Dieplate is susceptible to damage from expansion and contraction, and the number of heat “cycles”

it is subjected to will partly determine the life of the Dieplate. For this reason, heat cycles are kept to a

minimum, and the application of heating or cooling is performed gradually through circulation and

temperature control of the six hot oil unit heaters.

4.3.1.4.3 Melt Cutter Operation: The die is filled with polymer in readiness for the system operation. The operator must scrape clean the

dieplate in readiness of the cutter assembly movement. With the hanging button control switch in one

operators control and another on the other side for safety, the cutter/housing assembly is moved forward



to the dieplate. The assembly uses guide pins into a housing locking device that securely holds the cutter

housing in place. Once the signal that the locking device is made; the extruder start-up sequence can be

activated. The cutter motor starts also simultaneously starts the cutter motor cooling blower and a

separate hydraulic oil pump used for knife adjustment to the dieplate. The cutter motor automatically

ramps up to 150 rpm (will be preset by JSW rep) and a pressure controller (PC) on the knife adjustment

hydraulic system allows the knives to move forward to the dieplate to a preset pressure (total knife

movement about 5mm). Cutter speed control is done from the control room (SIC)(after initial trials) and

knife pressure adjustment is done from the local cutter panel (HIC).

The knife adjustment to the die is accomplished with 3 double acting hydraulic oil cylinders with a

higher pressure fluid that counters the pressure on the retract side of the cylinders. Optimum pressure

of the knives against the die needs to be set to keep the die face clean while the die is heated up and

during operation of the plant to ensure good, clean pellet cut. Too much knife pressure will cause

excessive wearing of the knives as well as poor cut due to deflection of the knife blades. Different

pressures will be required on different resins as the pressure of the resin against the knives is proportional

to the viscosity or MI of the polymer. A low MI resin will exert more force on the knives as it exits the

dieplate than a high MI resin and therefore will need a higher forward knife pressure to ensure the knives

are close to the cutting surface. Typical operating pressures will be 40 to 70 kg/cm2 dependent upon the

resin. The cutter knife adjustment hydraulic system runs continuously while the cutter motor is running,

unlike the carriage movement hydraulic system which only operates when the carriage is to be moved. A

small finned hydraulic air cooler cools the hydraulic oil as it returns to the oil reservoir that is shared

with the carriage hydraulic system.

The docking, locking and cutter start-up is done immediately following the purging and subsequent

scraping (cleaning) of the die face with brass scrapers. A clean die face and quick start-up are necessary

to prevent polymer drool from smearing the dieplate during start-up, which will result in cutting problems.

The cutter knives should last approximately one month depending on the types of polymer being cut.

Knife wear is monitored with a knife position indicator dial that measures the wear of the knives. Wear of

more than 1.5 mm is to be avoided as it reduces the water flow between the knives and the dieplate,

which can cause cavitation and pitting of the cutter and dieplate. When new knives are installed on the

knife holder the knives need to be ground on the dieplate to remove any imperfections in the knives so that

all knives scrape the surface of the dieplate evenly. The knife holder is designed to hold 24 or 36 knives

however 24 knives are typically used. The knife holder has pumping holes between the blades that move

water to the die that helps convey the water and pellets out of the housing.

The cutter shaft is supported in the housing with a bearing assembly and seals on the cutter shaft prevent

water from leaking out of the cutter housing and into the bearing housing. Three positioning bolts located

120 degrees apart are used to ensure the knives and cutter shaft are aligned to the dieplate. A mechanical

lock at the end of the bearing housing can lock the knife shaft in position regardless of knife pressure

and can be used during outages to prevent excessive wearing of the knives while the plant is shutdown

and the cutter is running on standby. Five adjustable supports that rest on a rubber type material allow for

thermal growth and support of the cutter and bearing housings. The cutter housing is designed for 6.2



kg/cm2 and is protected against overpressure with a PSV directed to a drain.

Typically the cutter system is running even when the extruder and plant are shutdown (except

extended outages). IOCL operation will develop their strategies as to lengths of time for each operation of

the cutter. A frozen dieplate and water circulating in cutter prevents polymer from drooling through the die

from the extruder and LPS so that a polymer seal is always present in the system. The cutter system will be

shutdown periodically for maintenance or possibly in the event of a process upset in which the cutter

may be filled with polymer lumps.

Once the Main Extruder has been shutdown, and the hot oil flow to the die is stopped to freeze the die, the

cutter motor will be shutdown. The cutter motor stop command will initiate the knife adjustment hydraulic

system to retract the knives from the dieplate and shutdown the hydraulic pump, as well as stop the cutter

motor cooling blower. A hand switch on the local cutter panel (HS) is actuated to bypass the PCW water

from the die housing isolating it so the cutter housing water can be drained manually. A level switch low

(LSL) and pressure alarm low (PAL) indicate when the cutter housing is empty of water and a light is

illuminated on the local cutter panel that indicates that the cutter is ready to open (XLO). The cutter motor

disconnect can be locked out in the operator room in the extruder building prior to retracting the cutter

carriage.

A key-switch and pushbutton on a control station at the rear of the cutter carriage need to be

actuated simultaneously for the unlocking and retracting of the carriage to be initiated. If the switch or

button is de-actuated then the carriage will stop movement. The simultaneous actuation of the pushbutton

and key-switch is a safety function of the system to prevent accidental movement of the carriage and to

allow the operator an unobstructed view of the area around where the carriage will be retracted. When

the switches are activated, a warning horn sounds to signal the impending movement and potentially

dangerous area. Following the horn signal, the hydraulic oil pump starts and solenoids on the hydraulic

system are energised to unlock the cutter housing. The cutter is fully unlocked when the unlocking

hydraulic oil pressure reaches at least 80 kg/cm2 (PT), the unlocking cylinders have reached their preset

limit switches (ZSOA/B/C/D) or the total oil flow set point value on the flow totalizers (FQT) has been

reached. Once unlocking has been achieved a “locked” light goes out on the retracting control panel (ZLO)

and solenoids on the hydraulic system are energised to allow the cutter carriage to retract using a two speed

setting. A limit switch (ZEA) stops the carriage in the fully retracted position by stopping the hydraulic pump

and de-energising solenoid valves. The hydraulic oil pump is protected from overpressure with a PSV back

to the oil reservoir and an interlock that will stop the pump on high-high pressure.

In the event of a power failure or hydraulic pump failure the cutter carriage can be unlocked and retracted

with a manual hydraulic pump. Car Sealed Closed valves can be opened to allow manual operation of the

system.

During plant operation, cutter motor trips will immediately shutdown the extruder drive and close the hot

oil flow to the die. The cutter motor is protected against over-temperature and over current with interlocks

to trip the motor. Normally the cutter system is started long before the plant is close to producing

polymer and the extruder cannot be started prior to the cutter. An exception to this is when the dieplate is

drooled prior to cutter start-up to fill the die holes and in this case the interlock can be bypassed.



Clarify The 447 kW (600HP) variable speed motor controls the cutter speed to a normal operating range

of 326-408 rpm (24 knives), which corresponds to an operating range of 35-50 t/hr assuming all die holes

are open. The normal pellet size is 3.2 - 4.5 mm diameter depending on the melt swell of the product and

normal pellet count is 42 pellets per gram (ppg). The speed is fine tuned for each particular polymer being

produced however the following formulas can be used in general, to predict pellet count (ppg) as well as

theoretical cutter speed.

4.3.1.5 Die plate Heating and Cooling: 4.3.1.5.1 Process Description: The heating chambers of the dieplate have a design pressure of 60 kg/cm2 and a operating

pressure of 5.6kg/cm2 with the plate holes at 3.5 mm diameter and 4800 holes. Hot oil is used to provide

the heat source required to operate at designed production rates.

The Dieplate is a complex piece of equipment and is subject to extreme thermal stresses during the heat

up and cool down procedure. The “life” of the die is subject to the number of cycles it is exposed to and the

severity of those cycles.

The Dieplate heat up and cool down procedures are designed to minimize the thermal stress of the

Dieplate by slowly applying heating or cooling.

The extruder moves the process polymer through the dieplate holes to produce a string type discharge

that is pelletized by the cutter hub with knives traveling at a control/adjustable speed. The material carried

by the PCW that moves the resin to the downstream process equipment.

Should a stoppage of the process be expected, the Extruder is shutdown, the Circulating Water flow is

reduced to minimum and the temperature lowered to ~35°C.

Hot Oil temperatures are also decreased with a set point of 250°C maintained for 15 minutes. After 15

minutes, the set point is reduced to 200°C and maintained for 15 minutes.

High-Pressure Steam to the die body can also be reduced as the Hot Oil set point is reduced to 150°C.

The High-Pressure Steam to the die body would be isolated for a cutter change when the Extruder is full of

high Melt Index material, or for a total shutdown of the Extruder. Maintain the Hot Oil temperature of 150°C for

15 minutes. After the 15 minutes, reduce the Hot Oil to 100°C and maintain for 15 minutes. Finally, place

the Hot Oil TIC in Manual mode with zero Output for no heat, and allow the Circulating Water to cool

the die for another 15 minutes.

4.3.1.6 Automatic Die Freeze: 4.3.1.6.1 Process Description: The Automatic Die Freeze system is designed to assist in quickly freezing the Dieplate in emergency

stoppage situations. The freezing of the die is intended to reduce the amount of polymer exiting the

Dieplate after a low speed alarm of the cutter motor, or in the event of a low-low Circulating Water flow to

the cutter housing. Both of these conditions are interlocked to shutdown the Extruder motor.

The Die Freeze System was implemented to reduce the severity of cutter housing plugs. The severity of



the cutter-housing pluggage is directly related to the Melt Index of the polymer being extruded at the time

of the incident. On very high Melt Index polymers, even though any of the above circumstances will

immediately shutdown the Main Extruder motor, the screw will continue rotating from the imparted energy

for a matter of seconds. This partial screw rotation means a relatively large quantity of material moving

through the dieplate.

When the Automatic Die Freeze system is initiated, the Hot Oil flow to the Dieplate is isolated and a valve

located on an emergency water line will open, allowing cool water into the inlet line to the cutter housing.

The Die Freeze System has two (2) hand switches or push buttons: one to initiate the Die Freeze

system manually, and the other to reset the system. Low-low Circulating Water flow alarms will be

indicated on the local panel as well as in the control room. On the Local Panel, indicating lights are

provided to show whether the Die Freeze System is “ON” or “NORMAL”.

4.3.1.6.2 Die Freeze Operation: The Die Freeze System use is for an emergency response. It should not be tripped for normal situations

since the immediate termination of Hot Oil to the Dieplate and the application of cooling water causes a

severe thermal shock to the Dieplate. The fewer of these rapid thermal changes there are, the longer the

life expectancy of the dieplate. This die freeze situation is set up to operate in automatic or manually

activated scenarios.

An operational die freeze requirement during a extruder start-up first entails the freezing polymer in the

dieplate holes. This allows cutter preparation like knife sharpening with the assembly in the forward ready

position and the PCW water in circulation. In this situation, the TW supply for further cooling of the PCW

circulation is not utilized.

HS-4045 is the die freeze on/reset selector switch tied in I-3003 (FALL-4029 low-low water flow to cutter).

HS-4045A is the reset while HS-4045B in the on selection both with indicating lights on the local panel. XV-

4030 with open/close position indication lights is the TW valve supply. Automatic Operation: During normal cutter operation, the die is on heat. On die freeze activation, the hot oil circulation supply

valve XV-4046 forward flow to the dieplate is closed removing this heat source. At the same time, in

addition to the Hot Oil valve closure, the 3” demineralised water supply line into the 12” PCW circulation

flow near the cutter housing is opened.

In the event of a power failure, or low-low circulating water flow (I 3003) to the cutter housing or

on interruption in the cutter circuit, the hot oil 3-way valve XV-4046 diverts hot oil flow back to the system to

stop heat transfer to the dieplate. This circulating oil is sent back to the system on line pump 31-P-

317/S for continued circulation in all events but a power outage. The emergency water valve XV-4030

opens, directing die freeze cooling water flow into the Pelletizer circulating water housing past the dieplate.

Manual Operation: Die freeze can be activated manually by the operator wish to by selecting "DIE FREEZE ON". This is



only done in emergency circumstances since the thermal shock to the dieplate will shorten the operational

life of the die.

Reset: Heat is restored to the die by selecting "DIE FREEZE NORMAL". This resets the die freeze circuit that

stops emergency water to the die housing. This reset also restores hot oil circulation as the divert valve

directs oil flow to the dieplate. Heat from this circulation loop should be applied slowly to bring up the

dieplate to operation temperature using HIC-4320 that controls the heaters temperature settings. The

following procedure for heating the die is designed to reduce the adverse effects of rapid cooling on the die.

Note: This pushbutton is only intended to be used when immediate evacuation of the area is necessary

or to save equipment damage.

Note: The Die Freeze reset pushbutton is not to be energized until the Hot Oil System temperature

controller HIC-4320 for the Dieplate has reduced in temperature settings When, the reset

pushbutton is pushed, the automatic valve that stopped the flow of Hot Oil will open and the TW

valve will close. The temperature controller can be placed in manual initially to more effectively

control the system heaters.

4.3.1.7 Satellite Extruder: The JSW TEX 77 Co-rotating (counter-clockwise viewed from gearbox) Twin Screw Satellite Extruder

converts pelletized material into a molten form through barrel heating and the heat of compression,

injecting this melt into the Main Extruder. These melt materials can be combinations of recycle resin and/or

additives.

The primary purpose is to inject additives required for a particular grade of resin.

Some additives can only be obtained in a dry pellet form due to their insolubility in solvents. These

additives are chemicals compounded into a polyethylene base resin and then injected into new

production. The two (2) standard additives injected this way are silica (Antiblock) and Viton A (PPA), which

are used in most film grade resins.

The secondary purpose is to upgrade resin previously produced for monetary reasons.

This recycle resin is polymer that has already been through the production process once, but was not first

grade. By recycling this resin through the Satellite Extruder and into new production polymer, the recycle

resin can be upgraded to first grade. To use any recycle resin, it must have been made with the same

reactor mode and be of adequate colour quality and other characteristics.

In addition to the above purposes, the Satellite Extruder is used on initial startup of the LPS and extruder to

form a polymer seal in the LPS cone between the process and the extruder. This seal is for the protection of

personnel and equipment by isolating the extruder from the solvent needed for circulation and LPS and sieve

plate heatup.



During normal plant production periods the Satellite Extruder is usually running. Speed is dependent on

the amount of recycle resin available and the additives requirements for the production resin grade. The

satellite should also always be available should the possibility of vapours from the LPS “blow through” due

to low polymer levels in the LPS cone affecting the Main Extruder run capabilities due to high volatiles.

For safety reasons (isolation between extruder and LPS solvent) we have the satellite on standby if resin

production density is .935 and above since the LPS Cone levels would normally be lower on these resins.

Since these higher MI resins have smaller volatile bubbles entrained, they do not migrate to the resin

surface easily. The lower LPS cone level can result in a vortex and thereby vapours can channel through

the middle. Experience, vigilance and good procedures will avoid losing this vapour seal.

The Satellite Extruder consists of a variable speed motor and gearbox, a gearbox lube system, a

steam/water mist temperature controlled barrel and a twin screw specially configured for “dry melt” operation.

The 400 kW motor can be started locally with speed control possible from the field startup panel screen as

well as the central control room. An indication of motor amperage is shown in the field and control room.

There is an interlock that will prevent the Satellite from running when the Main Extruder is not operating.

A by-pass switch is available to allow running of the satellite for startup preparations, cleaning up the

adapter feed piping or empting the balance of material from the satellite screw/barrel. There is also a

high temperature alarm and interlock to stop the satellite drive motor.

The Satellite Extruder has a lube oil system for the gear reducer. The lube oil system consisting of two (2),

run selectable - circulation pumps (31-P-310/S), a lube oil cooler (31-E-321) with bypass plus

TCV. This temperature controller on the cooler controls the oil temperature into the gearbox. A dual oil filter

assembly with bypass (31-G-311) and differential pressure alarms in the field and DCS are also part of the

package. The unit incorporates alarms and interlocks for high oil temperature and low oil pressure.

The satellite barrel is of sectional construction with a polymer temperature and pressure indicator located at

the end of the barrel. A process melt high-pressure interlock will shutdown the Satellite Extruder motor. A

pencil type rupture disk is located at the end of the barrel (with safety switch alarm and wired Satellite

Extruder shutdown) to protect the equipment by stopping the drive motor if blown. The feed zone of the

barrel has a cooling water supply that is necessary to prevent dry additives from melting prematurely in

this area which would restrict the feed to the twin screw. The barrel is constructed of N60S material

that is harder than the screw (LPS-2 material) so that the screws will wear before the barrel.

The Satellite Extruder is connected to the Main Extruder by a three (3) inch jacketed adapter pipe with

hydraulic three directional valve. This jacketed adapter pipe to the Main Extruder is multi sectional, high

pressure steam heated. The steam heated, hydraulically operated 3-ported valve located near the Main

Extruder can be used to (1) purge the Satellite Extruder to the floor, (2) to purge the Main Extruder to the

floor or (3) to inject material from the satellite into the Main Extruder.

The recycle resin feed for the Satellite Extruder is transferred from the manual Bag Slitter hopper situated in

the bagging warehouse to the Recycle Resin Storage Bin. This recycle resin is then gravity fed to the

feed hopper (HX-311) above the feed section of the Satellite Extruder. Interlocks protect the overfilling of

the recycle feed hopper via the high level trip of the Bag Slitter Rotary Feeder.



The additives for the Satellite Extruder are transferred to the two additive weight/loss feeders (31-

ME- 320&321) from the two (2) floor located dry additives bins. Boxes or bags from the additive

supplier are transferred into these bins so additives can be moved to their respective bins above the

weight loss feeders. Material will auto transfer via Whitlock conveyor systems using pressure line drop

which starts and stops resin flow keeping the feed hoppers full.

The Additive Feeders discharge feed using a traveling belt weight system and then by gravity into the

feed hopper of the Satellite Extruder. Only the G84 feed hopper has an auto-timed pulse of nitrogen to

cool this additive with the nitrogen venting from the weigh system feed hopper vent. This nitrogen purge

helps to keep the G84 pellets from sticking together during higher temperature periods. Interruptions to the

weigh feeder additive flows might occur without this protection.

This 304 SS feed hopper is located just above the Satellite Extruder throat to the screws. The Dry Additives

are fed into the screws at the drive end of the extruder. The recycle resin is fed to the hopper along side

of the additives. The recycle resin enters through an extended downcomer (76.2mm or 3”) into the hopper

that keeps the feed from affecting the level switch for the additives on the inlet side. Two 2” cleanout flush

mounted pads are available if needed. A 12.7mm (1/2”) nitrogen purge line with rotometer enters at 45%

from the wall on the feed portion of the hopper. Nitrogen injection is used to eliminate air contact with the

resin and is used on some film grade resins to improve the gloss of the finished product. The requirement

for nitrogen addition is noted on the resin manufacturing guidelines sheet. Below see a drawing of this

satellite feed hopper. 4.3.1.8 Solid Additive Handling and Satellite Extruder Feed System (Ref. PFD 00101-DA-31-0104) 4.3.1.8.1 Process Description: The majority of the Satellite Extruder feed is unfinished resin that is recycled into new production. In

addition to this resin, Dry Additives in pelletized form may be metered into the Satellite feed by one or

both the Dry Additive Feeders.

4.3.1.8.2 Equipment:

The Bag Slitter System has a capacity of 5,000 kg/hr and is used to:

a) Send material to the Recycle Resin Storage Bin,

b) Move material to Reslurry Tank to provide a RA Stripper seal for initial startup and

c) Return resin to the blenders.

The Bag Slitter System consists of:

1. A Conveying Blower (31-K-311)

2. Cooler with water loop (31-E-319)

3. A manual bag hopper (31-ME-324)

4. Rotary Feeder (31-ME-325)

5. Instrumentation



A diverter valve on the discharge of the Rotary Feeder is used to route the flow to either the Recycle

Resin Storage Bin, which splits to the blenders, or the RA Stripper resin fill line into the Reslurry Tank.

A high-pressure switch (interlocked with the Rotary Feeder for shutdown) and a high-temperature switch

protect the blower. The blower and Rotary Feeder can be started or stopped in the field or in the

control room. The temperature on the outlet of the cooler is indicated in the control room, as well as the

amperage of the motor. Controls for this equipment that may be used to operate the system are located in

the field by the Bag Slitter. Bags are brought from their warehouse locations and placed on the working

platform. The operators then manually cut the bags open filling the Bag Slitter hopper above the transfer

Rotary Feeder sending the material to the desired locations.

The Recycle Resin Storage Bin has high and low-level switches that will alarm in the control room and on

the Local Panel. The high level switch is interlocked with the Bag Slitter Rotary Feeder to stop resin transfer

should a high level in the recycle bin be reached. A local by-pass switch is available to inhibit the alarm

in order to empty the Bag Slitter Hopper of small remaining amounts of resin. The outlet of the Recycle

Resin Storage Bin has a slide gate that may be used to isolate the downcomer to the Satellite Extruder in

order to re-position the diverter valve. The diverter valve is used to direct the recycle resin either to the

Satellite Extruder or to a container. This container would be used to empty the bin in order to re-fill with a

more compatible recycle resin.

The Additive Feeders have small individual hoppers that are filled by an eductor system that conveys

the material from bins located at grade.

A timer that is set to meet the demands of the Additive Feeder controls the eductors. High-pressure

switches (with alarms) on the Additive Feeder supply line will shutdown the eductors. A slide gate is

provided on the outlet of the feed hopper that may be used to isolate the hopper, or to regulate the flow into

the feeder to change the required belt speed. The G84 feed hopper also has a nitrogen line into it that has a

timer controlled isolating valve. When G84 is being used, this timer is set to blanket the feed hopper with

nitrogen at regular intervals.

Each Additive Feeder can be set to provide material at a rate based on kilograms per hour in the

field/DCS control screens, or by cascading the set point to the DCS in the control room. The belt speed

and the weight setting are displayed in the control room. The Additive Feeders (interlocked in automatic)

are not allowed to run unless the Satellite Extruder is running. A bypass switch in the PLC will allow the

dry additive feeders to run and be emptied should the satellite be shutdown.

The Reslurry Tank resin inlet from the manual Bag Slitter hopper is to place a seal of volatile free resin in

the RA Stripper for start-up. The resin amount keeps the new resin production above the LP stripping steam

inlet so volatile stripping can take place. This resin addition is accomplished prior to production but would

need the circulating water system operating. An isolation blank is removed and a spool piece of conveying

line added to complete a conveying inlet from the Bag Splitter. This blank must be in place and the

spool piece removed prior to starting production.



4.3.1.8.3 Satellite Recycle Feed System Operation: All vessels and lines should be confirmed clean and free of contaminants before use. Recycle resin is

transferred to the Recycle Resin Storage Bin from the Bag Slitter system. If any foreign material is

inadvertently sent to either of the feed systems, the Satellite Extruder should not be operated until the

material has been removed. The Recycle Resin Storage Bin (approx.18000 kg) should be filled with

enough resin to provide feed for many hours of use, or enough to last until a new recycle resin is required.

NOTE: The Additive Feeders should be checked for calibration before every film campaign.

Especially in case of G84 Additive Feeder (31-ME-320) since Viton A is a rubbery substance that can plate out on the slides and equipment. If weight indication is erratic, it could mean the equipment

needs cleaning. Also confirm with Laboratory (know the ppm input by result) the rate of Silica addition on a regular basis during film grade.

A Reactor mode change will require that a different recycle resin be used. Recycle resin identifier

nomenclature and warehouse storage limits will need to be established. The previous contents of the

Recycle Resin Storage Bin may be emptied to a container when not further required. This can be

accomplished through a position change in the hopper outlet valve. Recycle resin type should be changed

for the different ranges of Melt Index within a Reactor mode. If the correct type of recycle resin is not

available, an alternate type (previously established in classification specifications) may be used at a lower

rate so as not to affect the final product.

When not in use, the Bag Slitter Hopper should be covered by closing the lid to keep out foreign materials

and dust.

4.3.1.8.4 Dry Additive: 4.3.1.8.4.1 Extrusion Aid (G84) Certain fluroelastomers have been found to improve processability of polyolefin’s, especially LLDPE,

without affecting other polymer properties. They function by coating the metal surface of dies via hydrogen

bonding to the metal surfaces. This coating has a very low coefficient of friction and lubricates the flow of

polymer through the die.

One such fluoroelastomer extrusion aid is Du Pont's VITON Free Flow processing additive. Normally used

in a master batch, the VITON Free Flow 10 is melt-blended with a film base resin by a processor. The

Viton is first dispersed in the melt blend to ensure particle size reduction and good dispersion. This blend is

incorporated into the polymer using the Satellite Extruder prior to pelletizing.

VITON Free Flow fluoroelastomer products are very incompatible with polyolefin’s and have a high affinity

for metal surfaces. At die temperatures, the PPA will rapidly migrate to the metal/polymer interface where it

plates out on the die surface. This coating has a very low coefficient of friction, and acts to lubricate the

flow of polymer through the die while filling the microscopic imperfections in the metal. Since the PPA

called G84, is dispersed throughout the resin feedstock, fresh material is always arriving to replace material

abraded from the die lips or holes in the normal course of processing.



After start-up, it usually takes about 20-40 minutes for the coating to become completely effective.

Once established, it might take several hours for the coating to be removed, once resin not containing

VITON Free Flow-free is reintroduced.

As always in additive addition, the benefits are seen as the customer’s equipment. G84 helps especially in

film production as it eliminates die marks on the film as it is extruded.

G84 extrusion aid is a blend that is fed to the Satellite Extruder through the dry additive weigh-loss system to

be melted by the Satellite Extruder and transferred at desired PPM into the process production at

the Main Extruder.

4.3.1.8.4.2 Metal Deactivator The oxidative gradation of polyolefin’s is catalyzed by certain metal ions, including copper. Metal

deactivators are added to protect the resin breakdowns for applications involving copper contact. The

metal deactivator specified for use in NOVA resins is IRGANOX MD 1024. This material has hindered

phenolic functionality and does act as an antioxidant as well as a metal deactivator. Its performance is

enhanced however by the presence of another primary antioxidant such as IRGANOX 1010.

IRGANOX MD 1024 is specified only in NOVA wire insulation resins 45B, 46C and 47B. Metal deactivators

commonly have significant food contact restrictions and therefore should only be used in industrial

applications.

4.3.1.8.4.3 Antiblock Agent (Silica): "Blocking" is defined as the tendency for two films to become inseparable after they have been

brought together. High gloss, high clarity film is most subject to blocking. Winding film at elevated

temperatures and with high winding tension will increase the blocking effect.

Antiblocking agents are commonly silica in various forms, either man-made or natural (diatomaceous

earth), talc and calcium carbonate. When added the resin, these evenly dispersed particles will protrude

from the film surface, preventing the two film layers from adhesion with one another by effectively holding

the surfaces apart. The additives are again normally added by the resin manufacturer, just prior to pelletizing.

Note: Antiblocking agents can cause some discolouration; this is most noticeable in the resin pellets or in

the film roll.

Used currently is Silica (S3) that again is made into a master batch with a film resin as a base ending up

with a concentration of 40%. The additive is transferred to the weigh loss system to be melted by the

Satellite Extruder and injected at desired PPM into the Main Extruder prior to pelletizing.

4.3.1.8.4.4 Dry Additive Summary: The dry additives area is handled by operations that bring the dry additives required to the extruder room

and depositing them into the local additive storage bins. From these bins, the additives are vacuum

transferred into the feed hopers for the weight loss feeders. These feeders are set to provide the desired

additive rate which drops into the chutes feeding the Satellite Extruder feed hopper (HX-311).



The extruder operators are responsible for controlling the addition rates.

The dry additives are normally Silica (S3) and Viton material (G84), additives mixed with base resins

to a certain percentage. There are some others used per resin production requirements such

as MD-1024 which is a metal deactivator. WIC 5412 (31-ME-320 and feeder JD-305) & WIC 5418 (31-

ME-321 and feeder JD 306) control the belt speeds to meet the resin specification guideline.

Recycle resin sometimes also can be required and added via the Recycle Resin Storage Bin (31-V-318)

supplied from the Bag Slitter (31-ME-324) located in the warehouse.

Dry Additive Codes & Contents:

AdditiveCode Chemical Name Content %

S3 Silica Silica & Base resin 40%

G84 Viton A Viton A & Base resin 25%

M84-15 Dynamar FX-5911X Masterbatch of M84 & LDPE 15%

MD-1026 Metal Deactivator Copper Stabilizer 20%

4.3.1.9 Additives (Ref. PFD 00301-DA-31-0123) The additives are diluted or dissolved in SH or Xylene (SZ) and then metered to the appropriate location.

Solid additives are always added to the molten RA in the extruder using the satellite extruder.

4.3.1.9.1 Liquid Additives Types and Purpose: Process Description: Additives enhance the quality and increase the range of applications for which polyethylene can be used.

Liquid Additives are generally received in a powder form, and then mixed with a solvent in order to pump into

the polymer. Liquid Additives may be injected into the outlet of the IPS if they have been approved for food

and drug applications.

Other Liquid Additives may be injected directly into the extruder barrel. Excessive addition rates to the

extruder barrel will reduce the efficiency of the Extruder, and cause starving. All barrel addition additives are

metered over as long a time period as is possible to avoid starving the extruder because of excessive

solvents. This procedure also improves additive distribution in the resin. All polymer produced must have an

Antioxidant additive.

All liquid Additives are solvent mixed at the highest concentration possible for solutions to maintain solubility

at the normal 70°C of vessels and lines maintained throughout the liquid additive system.

The following additives are commonly used.

• Antioxidant (AO)

• Ultra Violet Stabilizers (UVS)

• Slip Additive

• Antistatic Agent



• Antioxidant (AO): Polyethylene is susceptible to degradation, is part caused when polyethylene is exposed to one or more of

following conditions: heat, ultraviolet radiation (UV), and mechanical shear. Reactive impurities such as

catalyst residues can also promote and even accelerate the degradation process. Polyethylene degradation

can result in discolouration, gel and black speck formation, inconsistent flow characteristics and physical

property changes. Molecular weight can increase as a result of cross-linking reactions. Alternatively, the

molecular weight can decrease as a result of chain scission reactions. Depending upon the conditions (e.g.

temperature, catalyst residue type), either reaction can dominate or they can both occur simultaneously.

The most commonly used Antioxidant is Irganox 1010 (coded AO8). It is mixed at 15% concentration in

cyclohexane and normally injected at the IPS tails injection point. Concentrations above 15% are not

recommended since the Irganox will become insoluble and solids will precipitate and plug the additive lines.

Other Antioxidants are used in conjunction with other types of additives to provide a package of protection

for special resin types. These other Antioxidants perform differently to provide short (primary) and long-term

(Secondary) protection. Some of these other Antioxidants are Phosphite 168, Irganox 1076, Ethanox 330,

and Irganox 1 68.

• Ultra Violet Stabilizers (UVS): Polyethylene oxidative degradation is accelerated by light (solar radiation), particularly the UV portion of the

spectrum. Sunlight has an especially strong effect, but light accelerated degradation of polyethylene can

also occur from exposure to fluorescent lighting fixtures.

Light exposure is measured in langleys, defines as a unit of energy per unit of area, equal to 1 g-calorie/cm2.

Natural, unprotected polyethylene will become embrittled after exposure to about 50 kilolagnleys.

Polyethylene can also be protected against UV accelerated degradation by UV stabilizers, added at low

concentration to the polymer melt.

The standard UVS in use is (coded) called UV8 made at 45% solution of Tinuvin 622, Cyasorb 531,

Phosphite 168, Irganox 1076, and Irganox 1010 in Xylene solvent. These various additives, (three UVS

additives and two antioxidants) provide a package of resin protection that exceeds coverage provided by any

single UVS.

• Slip Additive: Slip agents are used in polyolefin films to decrease surface friction during manufacture and converting,

where the film must slide over various equipment surfaces at high speed, and without binding. Fatty amides

are commonly used as slip agents in polyolefin films. Some of these amides have antiblocking

characteristics as well, but not sufficient to permit their used without additional anti blocking agents.

After film extrusion, the amides rapidly migrate to the film surface, due to their incompatibility with the

polymer. On the film surface, they form a surface layer and modify surface properties, particularly friction

characteristics. The effect reaches a maximum when sufficient slip reaches the surface to form a

monomolecular layer.



The amount of amide reaching the surface is a function of temperature, time, concentration of amide in the

body of the film, and its compatibility with the particular polyolefin being used. Another factor is the surface-

to-volume ratio of the film. Thinner films have a very high ratio and therefore required a higher amide

concentration in the polymer to ensure surface coverage, compared to thick films.

The used of slip agents can cause problems:

• Slip agents can affect extruder performance, particularly at high levels because of their lubricating

action.

• Treatment of films produced for later printing are affected by the presence of amide on the surface.

• Oxidation is encouraged by long storage times at elevated storage temperature, and by extrusion at

high temperature.

• Excess lubricant can volatilize and plate-out on cold surfaces, for instance on downstream

production manufacturing equipment like the surfaces of Internal Bubble Cooling units.

• In laminations, fatty amides can interact with the adhesives used to join the materials, affecting the

quality of the seal.

Where required, film grades can be produced with no slip, and with low, medium and high levels, to permit

selection of the appropriate level. Slip is injected at the extruder barrel where high levels can cause

discoloration and screw slippage.

• Anti-Static Agent: Polyethylene has a tendency to hold a static charge. This causes cleaning problems in the final product that

attracts dust. Polyolefins has excellent electrical insulation properties, which causes electrostatic charge

build-up during handling and processing. Antistatic agents are used to reduce the static built-up on finished

products, to prevent dust and dirt attraction and build-up on a finished product.

In some cases, antistatic agents are sprayed onto the part after fabrication, but for the most part, the

antistatic agent is added to the polymer mass during production.

Antistatic agents are surface-active materials of low polarity. They function by migrating to the surface of the

produced item or part where they tend to attract moisture from the atmosphere, forming a layer of high

electrical conductivity, dissipating the static charge.

The migration of the antistatic agents to the surface takes some time. They are also not effective when

humidity levels are very low.

ATMER 129 (DE3), glycerol monostearate an antistatic agents. This material has a broad food contact

regulatory approval status, necessary for antistatic resin grades being used in food contact applications. To

reduce this static charge, ATMER 129 (DE3) is injected into the IPS tail injection point (HX-104).

4.3.1.9.2 Liquid Additive System 4.3.1.9.2.1 Liquid Additive Solvents: Most of the additives are received in drums or bags as a powder and must be dissolved in a solvent of

pumping. The solvent used for each additive has been chosen based on the highest solubility of that

additive for a temperature of 70°C.



Cyclohexane (SH) is used whenever possible since it is completely compatible with the process and will

eventually be returned to the Recycle Area for purifying and re-used. The additive room has a cyclohexane

supply that can be fed from the recycle cyclohexane line or from OSBL.

Xylene (SZ) is used as an alternative solvent for those additives that are not very soluble in cyclohexane.

The Xylene solvent is supplied from the Xylene Storage Tank (31-V-312) to a solvent manifold line to the

totalizer 31-FQI-4823 in the additive building. The Storage tank is provided with a local level indicator, as

well as a level indicator (31-LI-4938) with high and low alarms in the DCS.

4.3.1.9.2.2 Liquid Additive Equipment: 4.3.1.9.2.2.1 Process Description: The liquid Additive area is used to store, mix and pump a variety Liquid Additives for the production and

many resins having different parameters.

The additives that are received as a powder are placed in the Additive Mixing Tank (31-V-305) and the

correct amount of solvent is added to obtain proper pre-calculated solutions. The solution is then mixed and

heated to 70°C before being transferred to one of the Additive Holding Tank.

The Additive Holding Tank (31-V-301/302/303/304) also maintains the temperature of the solution at 70°C.

They have Agitators that run continuously to keep the additives in solution. Should the tank level drop below

the internal agitator paddle then the tank would either receive additional additive or the agitator would be

shutdown. The Solution is pumped from the additive Holding Tanks to either the IPS tails outlet or the

Extruder barrel. The flow rate is measured and can be controlled from the DCS.

Each of the Additive Mixing Tank and Additive Holding Tanks are equipped with:

1. A 10” opening for the vertically mounted agitator for mixing.

2. A 20” hinged manway cover for adding the additives

3. A pressure controlled nitrogen supply with globe valve bypass

4. Two 3” Pad type level indicators & DCS Transmitter

5. A solvent / process supply line with slotted dip tube

6. A 2” vent line for de-pressuring the tank

7. A rupture disc

8. A 3” pressure relief valve (part of Nitrogen inlet piping)

9. A pressure gauge

10. A welded tank bottom flush mounted ball valve

11. A dimple tank bottom LP Steam jacket with drain / vent and temperature controller

12. A 2” tank outlet line to the pumps

4.3.1.9.2.2.2 Additive Metering Pumps 31-P-301/304 (Low Cap. Pump) 31-P-302/303 (High Cap. Pump) Four positive displacement multi head pumps are used that have stroke adjustment varying output capacity.

These pumps move liquid additive solutions as received from the Additive Holding Tanks to the IPS

tails injection point or to the barrel Dutchman of the RA extruder. Piping runs from each Additive

Metering Pump to a manifold which accesses both injection locations to provide ease of operation. An

interlock switch for each pump is conveniently located near the additives manifold. This switch has



interlock positions that if selected to the IPS tails, shuts down the associated pump if “Z” is tripped and if

selected to the extruder shuts down the pump if the Main Extruder stops. These selector switches are HS-

4842, HS-4843, HS- 4934 and HS-4935.

These Additive Metering Pumps all receive solutions at a suction pressure of 0.7 kg/cm2g and

discharge @ 203.7 kg/cm2g for a system differential pressure of 203 kg/cm2g. All pumps have a RV setting

of 228 kg/cm2g which relieves back to the appropriate tank. From this point, the pumps are different.

The Low Capacity Pump (31-P-301/304) have a rated capacity of 0.45 m3/h using a 7.5 kW drive @ 111.9

rpm. The drive is connected via a KTR flexible coupling and has a 28 mm cylinder type plunger with

double ball check valves suction and discharge. The additive solutions enter the pump via a 1” side flange

and discharge through a side ¾’ swagelok fitting to process. Eight rings of carbon packing are located at

the plunger which has a stroke length of 55mm with a 0-100% stroke adjustment. The pump rated

capacity of 498.0 liters/hr (500 l/h at 100% stroke) provides the required capacity of 450 l/h. The tapered

roller thrust bearings are SUJZ. Pumps have a 90% efficiency rating. The pump head is LP steam traced but

designed for 70°C process temperature.

The High Capacity pump have a rated capacity of 1.23 m3/h with 0.045 minimum and 1.06m3/h normal at PT.

The true pump rated capacity is 1.65 m3/h. The pumps use a 30kw drive @ 1500 rpm. The pump has a 44.5

mm triplex plunger with a linear speed of 0.233 and a stoke length of 75mm and has a 90% efficiency.

The pump suction is from the bottom and discharges via a 2” top swagelok to process. The pumps use

Weir valves and controls. The gear reducer ratio is 15:1. The different liquid additives are delivered to

either the IPS Tails injection spacer or the extruder barrel spring- loaded valves. A diagram of the IPS Tails

spacer shows the three 3.5mm holes facing downstream at 30 degrees spacing to be fully distributed into

the process stream.

For the two extruder barrel injection valves, the springs of each valve is set to open at 31.5 kg/cm2g with

a normal injection pressure of ~40 kg/cm2g. Compression movement of the springs is ~10.9 mm.

Using the many block and bleed valves, various components in the system can be taken out of service

separately or as a group. Care must be taken to ensure that the valving arrangements are lined up

(positioned) correctly before operating these pumps or turning them over to maintenance.

A mass flow meter (mfm) (FQI-4823) is installed in the line downstream of the discharge side of the pump.

The purpose of this device is to give a continuous measurement of the additive being pumped to either

injection point and to communicate this information to the DCS.

Do not forget to position the additive selector switch when pumping to either location to apply “Z” should it

be required.

4.3.1.9.2.2.3 Additives SH Cooler (31-E-303): The Additives SH Cooler 31-E-303 located near the PCW Plate exchangers is used to cool recycle SH

from distillation down to a usable temperature (under 50°C) for liquid additive make-up. This is a shell

and tube exchanger with Hydrocarbon on the shell side having a capacity of 3,000 kg/h in/out temps of

160°C/45°C and the cooling water side capacity of 22,679 kg/h and in/out temps of 33°C/41°C.



The operation on the process side is intermittent as needed to makeup additive batches.

The discharge side of the exchanger piping has FO 4847 inline to restrict the flow to a maximum of 3000

kg/h, which is enough flow to effectively provide for batch makeup. Either SH through the Cooler or SZ from

its own storage tank are transferred into the Additive Mixing Tank or Holding Additive Tanks via the TV-

4822 and the Flow Totalizer FQI-4823 as part of the batch make up.

TV-4822 is a temperature activated isolation valve should fire occur in the room. A plastic air tube that

holds the valve open encircles the room over the additive tanks and when broken or burnt through, air loss

will close this valve. In this way the liquid additives room is protected from more solvent being added to

a room fire situation.

The Flow Totalizer FQI-4823 measures the liquid through it and is pre-set for the total solvent required for

the batch makeup in the DCS. As the solvent is added to the Mix Tank, it totals the solvent until it shuts off

once the preset number is reached. In this way, overfilling of the Additive Mixing Tank or Additive

Holding Tanks should not occur and the operator doesn’t have to be wait in the area for this transfer to

complete.

Care still must be taken during all solvent transfers to be sure they go to the correct location and quantities

meet additive batch requirements.

4.3.1.9.2.2.4 SZ Storage Tank (31-V-312): The 2500 ID carbon steel SZ Storage Tank designed for 65°C and 10.5 kg/cm2g outside the additive

building is used when certain types of liquid additives require Xylene in the make-up. This vessel is filled

from 45 gallon SZ drums using a drum pump to a vessel top inlet. Xylene is transferred by nitrogen

pressure to the additives mixing tank as additive batch makeup demands. The bottom discharge piping

also has a restricting orifice FO-4820 that limits the flow to 3000 kg/h into the liquid additive building.

The SZ tank is nitrogen blanketed (with PCV and bypass) through a top inlet with local PG and check

valve. The tank is operated at 1.0 kg/cm2g. The vessel is protected by PSV 4905 set at 10.5 kg/cm2g and

carsealed open to flare header. This PSV also has a bypass with globe valve. The side level LI-4838 taps

are placed 3500 mm apart with the taps indicating LLL and HHL on the tank and indicating in the DCS. A

side 20” manway and a side 2” utility connect complete the tank nozzles.

Operators must monitor and maintain tank level while knowing production requirements.

4.3.1.9.2.2.5 Additive Waste Drum (31-V-306A/B): The Waste Drums 31-V-306A/B are provided to receive small amounts of purge or waste additives when

the Additive Mixing Tank or holding additive tanks are de-inventoried or flushing is occurring. These CS

drums are 1200 mm in diameter by 2050 mm long with a volume of 2.55 m3. They are only used one at a

time outside the additives building while the other is normally at the DTA vaporizers where the waste is

burned.



The vent lines from the Additive Mixing Tank and Additive Holding Tanks all discharge into the same

process header that leads into the on-line Waste Drum. Any liquids are dropped into the waste tank while

the vapours are vented to atmosphere at a safe location.

There is a nitrogen supply with FO and pressure gauge for blanketing during normal operation and

pressurizing the Waste Drum during unloading.

There is an immersion type low-pressure steam heater in the bottom of the drum with a temperature control

loop for heating to liquefy the contents when emptying the drum. All the lines are quick disconnection with

flexible hoses so limited time is required to disconnect the drum for transfer to its unloading facility.

When the on-line drum is full, indicated through WI-4919, a high weight alarm is generated in the DCS.

The drum is then heated to 70°C, disconnected and relocated by fork truck or small crane to the

Vaporizer / DTA area to be burned as waste fuel. The other empty drum is located at the additive area

and connected up to the vent line and all the services.

The connections to the Waste Drums are:

1. A 2” process line to transfer solvents and additives from the additive building on top of drum.

2. A 2” nitrogen line via a flow gauge to blanket the Hydrocarbons in the drum entering on top.

3. A 2” attached vent, which goes to a safe location located on top of drum.

4. A PSV (4906A/B) attached to each drum.

5. A 2” LP steam connection (4kg @ 152°C) entering the top of the internal four run steam pipe

heater 2000mm long with short radius bends to tie all together. This heater sits on a sliding support.

6. A LP steam condensate drain from the steam heater bottom pipe run to a condensate header.

7. There is a 2” bottom drain placed 10 degrees tangential.

8. A ground or earthing cable is connected to the vessel itself for safety.

9. An instrument airline is connected to the LP steam temperature valve controlled from TIC-4932A/B

to maintain the drum at 70°C.

All these connections are meant to be easy quick hose couplers via HX items (Flexible Hoses) for fast

change out of these drums.

The Waste Drum sits on a weight scale (HX-353) that has dial field readout and a DCS indication with a

high weight alarm. A scale empty weight of ~1180 kg plus weight of contents ~2855 kgs gives a working

scale range of 0-4500 kgs.

4.3.1.9.2.3 Liquid Additive Vent System Process Description: There are two venting systems that each of the additive tanks is connected to. The Depressurising Line is

connected to the Waste Drum and relieves the pressure in the tank to almost zero. The other vent system is

located downstream of the Relief Valves for each of the additive tanks. This line will relieve the tank

pressures to the Polymer Flare Header and is only used when a tank is over-pressurised.



A Waste Drum is used for venting the Additive Mixing and Holding tanks when transferring solutions. Lines

may also be purged with solvent to this drum. The drum has a constant nitrogen purge line with a rotometer

to set the flow. A high flow alarm is located on the inlet line to the tank that is used to send an alarm to the

DCS when a liquid flow is detected. A weight indicator shows the drum contents in the DCS and a high

weight alarm is provided. The drum has a local TIC to control the steam heating of the vessel, normally just

prior to movement for unloading. When the drum is full, it can be easily removed for emptying with the use

of flexible quick-disconnecting piping.

An Additive tank could be over-pressurised by excessive heating of the contents. It could also be caused by

overfilling the tank from the solvent supply line. Another possible cause is using a non-adjacent pump to the

tank. The pump outlet line could become plugged, and the Relief Valve will direct the flow to the adjacent

tank.

The Relief Valves located on the tanks should be removed and cleaned any time they have had a flow of

additive solution through them. The rupture disk located upstream of the tank Relief Valve should be

checked daily to ensure there is no pressure between it and the Relief Valve. If a pressure is indicated on

the pressure gauge provided, the rupture disk should be replaced and the Relief Valve cleaned.

Liquid Additive Vent System Operation: The vent system to the Waste Drum should be purged with a small amount of solvent on a regular basis to

prevent any build-up of additives in the line. The solvent easily vaporises in the line, leaving additive powder

residues.

This vent line is also used to transfer unwanted solutions to the Waste Drum. These transfers should also

be followed by a flushing operation using solvent. The line is then purged with nitrogen. The nitrogen from

the Additive Mixing Tank should be used since it is the furthest from the Waste Drum and it will purge the

entire line.

When the Waste tank is full, the temperature in the drum is increased to 70°C in order to liquefy the

contents. This will assist in emptying the contents. The nitrogen to the drum is isolated and the valve on the

depressurisation and flush line is closed. The lines are disconnected and the drum is replaced with the

alternate drum. 4.3.1.10 RA Stripper & Associated Equipment: 4.3.1.10.1 RA Stripper (31-V-310): 4.3.1.10.1.1 General Description: The RA Stripper is designed to remove residual solvent from resin. The RA Stripper receives unstripped

resin (approximately 2.5% volatiles) from the Reslurry Tank (31-V-309) delivered by one of two Reslurry

Pumps.

The water/resin slurry is fed first to the Bulk Dewatering Hydrosieve (HX-351) on the top of the RA

Stripper. This unit is designed to remove 50% of the water prior to entering the top of the RA Stripper.

The balance of PCW circulation water carries the resin and enters the RA Stripper passing an adjustable

cantering funnel onto the product distributor cone with water passing through into the collection pan under



the screened cone. The water from these two dewatering devices has a controlled return to the Water

Reservoir (31-T-301) or to the Reslurry Water Heater (31-E-302). Some water splashes from the screens

into the RA Stripper or is carried via resin/water surface tension.

The resin is delivered over the screen edges of the product distributor in a circular donut shaped pile in the

RA Stripper. Desuperheated low-pressure steam flows into the RA Stripper from the internal bottom

diamond screens and eight cone openings fed by a steam distribution ring, upwards through the resin,

stripping off the solvent to the overhead line.

The overhead flow of steam and solvent vapours are condensed and recovered first through the Solvent

Vapour Condenser (31-EA-301) and then the Solvent Vapour Trim Condenser (31-E-301). Separation of

water and solvent continues through the Coalescer(31-V-319) and the Decanter (31-V-311) with the

hydrocarbon pumped to the LPS Hold-up Tank. The resin flows from the bottom of the RA Stripper through

a level control valve and is conveyed to the Spin Dryer package (31-M-306) using a second water loop

from the Water Circulation Pumps (31-P-306A/B). Resin from the Spin Dryer passes through the Spin

Dryer Hold-up Bin (31-V-317) and enters a pneumatic conveying system which transfers the resin to the

assigned blender.

4.3.1.10.1.2 Principle of Operation: The RA Stripper is filled to its operating level before unloading begins. During unloading, the operating level

is maintained to give the resin entering the RA Stripper sufficient residence time to be stripped of

almost all residual solvent. The resin residence time in the RA Stripper is a function of the production

rate and the operating level and is required to be a minimum of 7 hours. This minimum residence time is

required to strip the solvents in the resin to a value of less than 0.05% by weight, which is the safe packaging

specification.

The RA Stripping tank is constructed of 304 SS and all connecting lines are SS, as well. The tank has a

support ring approximately half way along the straight side and a steam inlet jacket in the cone section at the

bottom. The interior of the tank contains an inlet distributor at the top and a diamond shaped cone in the

cone section. There are several separate inlets and outlets on this tank.

4.3.1.10.2 RA Stripper Dewatering Hydrosieve (HX-351): The Stainless steel Hydrosieve is located above the RA Stripper and contains a static screen assembly.

This adjustable Internal dewatering screen only can be moved by opening the dewaterer. The pre-

dewatering unit is used to remove water from the pellet slurry. This water removal quantity should be at

least 50% of the flow but can vary, as some water is needed to carry the resin to the RA Stripper Product

Distributor Cone. Adjusting the degree of back flooding in the Hydrosieve will thereby ensure adequate flow

of water to carry the resin into the Stripper. This also controls water removal rate from the Hydrosieve.

Separated slurry water from the Hydrosieve will flow by gravity through a discharge valve (butterfly valve)

and 4-meter seal leg to return to the Water Reservoir or Reslurry Water Heater.

The feed rate for this unit is up to 110,000 kg/h water and 55,000 kg/h maximum resin in the inlet slurry.

The Hydrosieve is designed for slight (both) negative and positive pressures with a normal operating



pressure of 0.05 kg/cm2g. The unit shall have flush inside mounted sight ports above and below the

internal water separation screen. The screen openings shall not exceed 0.76 mm (0.0.30”) slotted “Johnson

Style” wedge wire. A hinged view port provides access to the underside of the screen. Victaulic couplings

at the water and pellet discharges are furnished for access to the removable spool piece on the process

inlet to 31-V-310.

Note: Shutting down the process flows first before opening the unit must be completed as high

temperatures of the slurry flows could injury the operator.

Internals This nozzle is used as a resin directional flow device to centre the incoming resin / water slurry directly over

the top of the cone. The adjustable flange inserted cone piece has a 351 mm (15”) inlet and a 254 mm (10”)

outlet so incoming process flow can be cantered over the Inlet Product Distributor to fully utilize the

dewatering screens and maximize water separation. As part of RA Stripper commissioning, the adjustable

nozzle visually cantered over the cone of the Inlet Product Distributor, the graduated marks on (4) tab

arms noted and then tightened down in the RA Stripper flanges so it doesn’t move.

Should irregularities be noticed in the internal mixing then this adjustable nozzle can be re-positioned.

The Hydrosieve outlet piping has a removable spool with victaulic couplings directly preceding this nozzle

placement.

Inlet product Distributor: This assembly consists of "304" stainless steel struts supporting a wedge-wire screen. This slotted screen

is placed in 12 pie shaped flat panels made of #63 wire, 10-rod centres with 76 (0.030”) average slots. The

wire is placed at 90° to the radii of each section. This screen is at a 30° angle and allows the water to

pass through while the resin falls off the outer edges of the cone screen and the inner distribution baffle

ring into the RA Stripping tank. This assembly is supported from the top of the stripping tank. This

assembly serves a second purpose as it deflects the resin in such a way that it forms a circular donut

shaped gathering of resin below the distributor cone in the stripping tank. This shape in the stripping tank

compensates for internal frictions as the resin migrates to the base of the RA Stripper thereby reducing

the cross mixing of sequential resin grades. A tray beneath this screen collects the water that passes

through the distributor and this water is combined with water from the Hydrosieve back flooding and

returned to the Reslurry Water Heater or Water Reservoir. This water return drain line is covered on the

top with SS angle piece to prevent resin hold=up on the piping. Some water carries with the resin into the

RA Stripper which helps in resin movement to the RA Stripper bottom.

Stripping Steam Manifold: Just below the bottom tan line of the vessel is placed a stripping steam manifold. This manifold encircles

the vessel cone and accepts four (4) equally spaced steam pipe connections 8” in size. Two drains are

also part of the manifold to drain steam condensate back to the Fines Separators. This stripping steam

passes into the vessel through eight (8) equally spaced Johnson screen openings made flush on the inside

of the vessel. The screens are #69 wire 0.30‟ slot openings.



Between the stripping steam entering at these points and the Inner Cone steam entrance below - the entire

bed of resin receives stripping steam.

Inner Cone This 33° top and bottom angled diamond shaped cone is made of 304 stainless steel and placed in

the RA Stripper cone area. It is supported by eight (8) stainless steel struts welded to both the inner and

vessel exterior cones. The top portion of the cone is made of stainless steel screen encircling the entire

cone and then capped. This screened area allows the exit of stripping steam from the cone while not

allowing resin to enter the cone.

In addition, there are (8) equally spaced screens lower down the cone assembly. The stripping steam is

supplied via four (4) stainless steel pipes entering the stripping tank at the sidewall then runs through wall

of the inner cone. The bottom of the inner cone is covered to stop resin egress while allowing condensate

draining.

RA Stripper Bottom Screened Drain: On the outside shell of the RA Stripper just below the inner cone, a 6” flanged opening where a screened

basket 3” condensate drain and 2” utility nozzle are placed. The nozzles have a basket screen behind it

flush with the inside angle of the cone. The parallel flow screen is a Johnson Style with 0.045” slot openings.

The condensate drain connects to the steam jacket (manifold) outlet piping which flows to the Fines

Separators. This opening can be used to drain condensate should levels become high where the

normal outlet flow is insufficient. The utility nozzle can be used for nitrogen or steam inlet as required by

operations.

Level Valve: The RA Stripper empties resin (and small amounts of water) out the 10” opening into a piece of transition

piping First containing a slider type isolation valve HV-4612 controlled from the DCS. The discharge flow

then passes through a V-ball level control valve LV 4615 controlled in automatic from the Radar LIC

4615 on the RA Stripper top. Associated Interlocks can close this level control valve automatically if

activated. The CV is also tied into a bypass switch HS-4617 to empty the vessel should that become

necessary. During normal operation, LSLL- 4717 protects the RA Stripper Level from dropping too low and

effecting the residence time of the Resin.

In the outlet transition piping there is a controlled water flow via FIC-4441 (part of the circulation water

loop) that forms a liquid seal on the RA Stripper bottom and conveys the resin into the Spin Dryer.

Level Controller The RA Stripper radar level transmitter gives a continuous indication of the RA Stripper level from 0 to 22

m. Only measuring the uppermost section of the vessel is important since normally the RA Stripper is

operated at near full.

TAH - 4614 High Temperature at the top

LAHH - 4616 High-High Level Stops Main Extruder



LALL - 4617 Low-Low level shuts outlet valve on RA Stripper (bypass available)

LAH - 4615 High level alarm

LAL - 4615 Low level alarm

FAL – 4647 Low flow stripping steam to RA Stripper opens atmospheric vent 31-HV-4630

PAH - 4632 High pressure RA Stripper vapor overheads outlet

PAL - 4632 Low pressure RA Stripper vapor overheads outlet

TAHH - 4635B High Temp. to RA Stripper opens nitrogen supply FV-4636 into stripping steam lines

4.3.1.10.3 Blender Swing: There are two vibrating fork type switches to give a high and a low level alarm on each side of the

operating level 2.7 meters apart. The normal operating level is from 50 to 70% of the distance between

the two level switches.

A blender swing is executed for one of the following reasons:

• Present on-line blender is full

• A new type of resin is expected

• To segregate off-specification resin

• To remove a transition of resin

The blender control sheet and the on-line blender weight determine the time of the blender swing. The

RA Stripper continuous samplers can be monitored to confirm some resin changes (example off-

specification, transition from non UVS resin to resin with UVS, etc.; read the Resin Manufacturing Guidelines

instructions for additional particulars).

Govoni has a section in their conveying program that covers the procedure for swinging blenders.

Operation: 1. Prepare another blender for filling. (See Blender Preparation Procedure Details following this blender

swing operation.)

Note: Allow enough time before the blender swing to bring the newly prepared blender to operating

temperature (85°C).

2. When the blender lot is completed and/or swing time is reached (blender level alarm setting), shut

down the Spin Dryer Hold-up Bin Rotary Feeder.

Note: This will also close the level control valve 31-LV-4615 to a 10% opening. If a high resin level in the

Hold-up Bin is reached, this will close the level control valve completely.

3. Allow the RA Stripper transfer conveying line to clear of resin as indicated by Spin Dryer

Conveying Blower amperes dropping to a no load value.

4. Swing (switch) the appropriate diverter valve to the prepared blender.

5. Confirm the routing, done visually on the DCS.

6. Start-up the Spin Dryer Hold-up Bin Rotary Feeder.

Note: This Rotary Feeder operates at a fixed speed of ~17.5 rpm’s (70 t/hr of resin) and therefore on

restart will deliver maximum resin transfer until the Product Hold up bin is empty.

7. Confirm resin is transferring to the new blender (indicated by blender weight readout).

8. Ensure the RA Stripper level control valve is re-opening.



Interlocks:

• The Spin Dryer Hold-up Bin Rotary Feeder shuts down on: (Interlock 3039X)

a) High Spin Dryer Conveying Blower discharge pressure

b) Spin Dryer Conveying Blower shut down

The level control valve 31-LV-4615 closes to 10% when the Spin Dryer Hold-up Bin Rotary Feeder shuts

down.

A high level in the Hold-Up Bin will close the RA Stripper level control valve.

Maximum time setting used of 90 seconds (bin capacity is good for 7 minutes) allows for Spin Dryer

Rotary Feeder to be shutdown to make the blender swing before the timer (adjustable) drives the RA

Stripper outlet level valve to closed. (Interlock 3014)

• The Spin Dryer Conveying Blower will shut down on: (Interlock 3039X)

a) High motor temperature

• The Solvent Condensate Pump will shut down on: (“Z” Interlock) "Z" trip.

Sr. No.

Steps Key Points

1 Place the blend/unload valve of an empty

/clean blender in the blend position.

Has an associated interlock on valve position to be able to swing

into this blender.

2 Start this blender’s associated Purge Air

Blower Purge air must be established before the filling diverter valve will

operate.

Instructions must be followed to this point at a minimum to have resin enter the blender.

3 Open the Purge Air Blower heater LP Steam

valve.

Set heater TIC @ 85°C

4 Start associated Blender Blend Air Blower. Set heater/cooler TIC @ 85°C

5 Start Blender Rotary Feeder. Start Feeder @ min. rpm & increase slowly to max.

Blender slide gates are fully open

Feeders @ maximum of ~21 rpm in fill/blend mode.

6 Set Blender Scale batch in weight set point,

normally 90% of expected lot quantity. Set weigh scale zero once hot air has provided lift to the vessel.

This set point will alarm to alert operator of pending blender swing as lot filling occurs.

7 Check Blender high temperature alarm Set at 110°C

8 Check Blender wash water controls are

closed. If valve is open or dripping - this will result in wet resin & delays in packaging.

9 Check Nitrogen HS to be sure it is closed. Only used in emergency purging situations where the Purge

Air Blower has failed.

10 This Blender is now ready to receive resin from the RA Stripper.

Heater temperatures and feeder rpm’s are to be kept at stated

conditions for maximum effect.



• The RA Stripper outlet valve 31-LV-4615 closes on:

a) Spin Dryer shut down. (Interlock 3011)

b) RA Stripper low level (By-pass switch 31-HS-4617 is used to empty the RA Stripper).

• High temperature in Spin Dryer or Hold-up Bin opens fire protection valve. (Interlock 3018)

• RA Stripper Exhaust Valve (vent) 31-HV-4630 opens: (Interlock 3010)

a) On stripping steam failure

b) On "Z" interlock trip.

• High-High RA Stripper level ramps down extruder. (Interlock 3013)

• High-high stripping steam temperature closes steam flow control valve 31-FV-4642. (Interlock 3038)

• "Z" trip, High Vibration & Interlocks 3040 & 3042 will stop both Solvent Vapour Condenser fans

should any one activate.

• Low-Low RA Stripper Level closes RA Stripper outlet level valve. (Interlock 3015)

• High-High level in Reslurry Tank closes valve ramps down Main Extruder and closes 31-FV

4651 (RA Stripper return water) and 31-FV-4437 (circ water to Reslurry Water Heater). (Interlock

3006)

4.3.1.10.4 RA Stripper Auxiliaries: 4.3.1.10.4.1 LP Steam Desuperheater (31-V-322): 4.3.1.10.4.1.1 Material: All wetted parts are stainless steel.

4.3.1.10.4.1.2 Location: The LP Steam Desuperheater is located on the stripping steam supply line; just after the stripping steam

flow control valve FV-4642.

4.3.1.10.4.1.3 Purpose: The LP Steam Desuperheater unit is used to cool down or desuperheat the LP steam flow to a

usable temperature sufficient to heat the resin in the RA Stripper but not have it stick together. The LP

steam supply temperature is too high to utilize directly and without desuperheating the steam flow, the

pellets would reach resin stick temperatures and melt together.

4.3.1.10.4.1.4 Description: The Schutte and Koerting type 6910 Size 1 Desuperheater is a static unit for mixing and heat reduction.

The Desuperheater has an approximate steam inlet temperature of ~146°C. The treated steam outlet

temperature needs to be 102-105°C maximum for process. The 40°C demineralised water supply entering

on top through flow control valve FV-4643 provides the cooling medium. An internal basket of reaction rings

providing a large wetted surface area and a drain off the bottom traps out excess water.

4.3.1.10.4.1.5 Operation: The operating principle is that water is injected onto an internal baffle plate, which distributes water across

the reaction rings. Reaction rings in the basket cavity provide a large surface area over which the hot

vapor is forced to pass. The hot gas (steam) is then cooled by absorption of the water when contacting the

reaction rings. The saturated vapor flows via the LP Steam Desuperheater outlet and excess water drains



through the bottom and is removed through a trap.

The near atmospheric pressure of the RA Stripper also determines the lowest possible temperature the

stripping steam can reach. For this reason, the RA Stripper pressure is kept as low as possible.

The type of resin in the RA Stripper, and the "cut" of the resin influences the differential pressure between

the bottom of the RA Stripper and the overhead pressure. Too high a differential pressure will adversely

affect the stripping steam temperature. The cut of the resin should always be maintained between 35 and

45 ppg with 42 ppg being the goal and with as little fines production as possible to keep the bulk density of

the resin as low as possible.

4.3.1.10.4.1.6 Condensate Flow Control: The amount of cooling provided by a LP Steam Desuperheater depends on the volume of condensate

being atomised. This volume is controlled by the RA Stripper LP Steam Desuperheater temperature

indicating controller (TIC-4634). The controller operates a temperature control valve FV-4643 located in

the LP Steam Desuperheater condensate inlet line maintains the stripping steam temperature after the LP

Steam Desuperheater at the controller set point.

4.3.1.10.4.1.7 Nitrogen Back-up System: In case of a stripping steam failure, nitrogen is provided up to 1300 kg/hr maximum and may be

applied manually to the RA Stripper via the Stripping Steam Line providing a safe (cool) atmosphere.

On high stripping steam temperatures, nitrogen is added using a temperature loop cascaded to a flow

control to reduce the temperature. If the temperature continues to the high-high temperature setting,

stripping steam flow is discontinued.

Note: Should the nitrogen flow be introduced into stripping steam line flow due to uncontrollable

high temperatures, the RA Stripper Exhaust vent valve HS-4630 must be opened to remove the nitrogen

from entering the overhead line to the Solvent Vapour Condenser Inert purge lines are available but normally

are not large enough to handle this larger flow.

4.3.1.11 PCW/Slurry Water System: 4.3.1.11.1 General Description: Polymer melt is processed through the Underwater Pelletizer producing a slurry of pellets and water.

A tempered, closed loop, water system transports the pellets from the Underwater Pelletizer through

to the continuous stripping operation. Water for the Pelletizer, the Reslurry Tank, and the RA Stripper

discharge to the Spin Dryer will be pumped from the Water Reservoir. The two plate exchanger Water

Coolers (31-E-318 and spare) provide the desired temperature at the Pelletizer and RA Stripper outlet.

The water temperature to the Reslurry Tank (31-V-309) is regulated by the Reslurry Water Heater (31-E-

302).

Water will be delivered to the Pelletizer at up to a 15:1 (normally 12:1) ratio (water/polymer) at 30 -50°C.

The water/pellet slurry will enter the AU/DU 4000 & D550 Dryer Units where the most of the water will

return to the Water Reservoir via the multiple online Fines Separators. The proper sized pellets will gravity



flow to the Reslurry Tank and any lumps produced will be diverted into a waste pellet tank. Return water

from the RA Stripper overhead will be used to carry resin through the Reslurry Tank entering the

circulation water flow ahead of the Reslurry Water Heater. This water flow passes into the Reslurry

Tank and is heated to a temperature sufficient to give a RA Stripper inlet temperature (TI-4613) of 78-

82°C. Approximately 50% of the Circ water flow is separated in the RA Stripper Inlet Hydrosieve while the

resin passes into the RA Stripper. Water is routed back to either the Water Reservoir via the many Fines

Separators or the Reslurry Water Heater. Resin and the balance of the water continues into the RA Stripper

where the internal dewatering screen removes more water. This water collects in a tray under the inlet

cone screen that is combined in the same water return line as the Hydrosieve.

The reslurry water flow will be controlled at 1-3 times the resin rate. It will enter tangentially into the

Reslurry Tank to produce a concentration of pellets in water of between 25 to 50%. The slurry will then

be pumped to the RA Stripper. Water, part of the circulation water loop, will be provided to reslurry the

pellets for continued movement upon leaving the RA Stripper level valve. This RA Stripper bottom seal loop

water will be separated from the pellets using screens at the Spin Dryer inlet. Water separated in the Spin

Dryer will flow back to the Water Reservoir via the Fines Separators. The fines will be collected off the

Fines Separators in manual waste buckets to be disposed off. Equipment making up the water

circulating system will all have nitrogen purges and be vented to the atmosphere through flame

arrestors.

4.3.1.11.2 Equipment: 4.3.1.11.2.1 Delumper Dewatering Classifier Package (31-G-301): The Delumper Dewatering Classification Package (31-G-301) is the Carter Day AU/DU 4000 Unit in

combination with the D550 Dryer. The AU/DU 4000 static dewatering delumper receives the slurry inlet

via a 6”pipe. Inlet and outlet piping have Victaulic couplings for ease of maintenance. The slurry inlet

water column passes two access openings 24” (610) x 16” (406mm) over a viewed entry to the interior

delumping screen. These two doors are interlocked if opened to shutdown the circulating PCW Pumps

(31-P-306/S).

This flow passes an inlet overflow sight window for viewing process. The incoming water flows are

sufficient to keep the internal screens flushed. A lower access door in the Delumper provides access to the

internal resin screen as required. Water and pellets pass through the 0.77” perforated delumping screen to a

second dewatering separator screen and water drops out the bottom. The first grade cut resin passes

through the dewatering tower to further separate resin from the water carrier. Resin passes out to the D550

dryer inlet connection. Water discharges via 16” pipe to the Fines Separators. Agglomerates present in the

unit pass from the inlet screen to the agglomerate chute out an 18” pipe to waste collection. In this

agglomerate area of the static delumper, a lower grid and barrier sight window is present. On the

agglomerate discharge chute a sight window allows operation to view any build-up in the discharge. The Static

Delumpe Dewatering Classifier is continuously purged by a ¾” N2 line via FG 4402 which discharges

through a 4” vent with flame arrester (HX-322) passing nitrogen and small amounts of hydrocarbon vapours

to a safe location.

The discharge flow of resin pellets and ~15% water pass into the dryer inlet. This water flow from the static



Delumper Dewatering Classifier should be kept as low as possible while carrying the resin to maintain

proper operation of the Spin Dryer. Extra water from the Spin Dryer will lower the circulation water

temperature we are trying to maintain for the RA Stripper inlet. The D550 dryer is driven by a top

mounted 55kW (75HP) turning @ 1500prm with aluminum guard and inspection port. Resin enters the

bottom to be lifted by internal frame attached metal liters moving resin outwards against the internal

screens by centrifugal force. Screens with flow disrupter bars randomly distribute the product in the annular

area between rotor and screens. This screen connect provides a tight screen closure so loss of resin at

the connection doesn’t‟t occur. Rotation of the dryer is clockwise when viewed for the top. Resin moves

upwards discharging at the top on the dryer to an 11.5 (292.1) x 17.5 (444.51) discharge chute that

deposits resin into the Reslurry Tank inlet. Water removed from this resin flow exits the bottom via a 12”

(323.9) pipe connecting with the static delumper exit water flow in a 24” pipe, with a minimum two meter

vertical run below the dryer sized to ensure self venting flow. There is a top covered air inlet with discharge

on the side of the unit also covered over. The unit has access door covers that have proximity switches

interlocked to shutdown the unit if these doors are opened. Proximity switches are also used to indicate

dryer rotation. An Acoustical Sound Enclosure – composite lined SS sound panels keeps the sound

below 85dB for the unit. The dryer also has a vertical internal firewater line that can be used for flushing

the screens. The two- inch water supply requires a flow of 21 m3/h at 2.8 kg/cm2g.

The isolated lower bearing assembly at the bottom of the dryer is bolted to the rotor bottom plate. The L10

life spherical roller thrust bearing is isolated in a sealed cavity of the bolt on stub shaft. Greasing of the

bearing is made easy with an extended lubrication line and double lip seal holding grease in place.

Should the V-ring water seal fail, water will be discharged through six 3/8” drain slots without coming into

contact with the bearing. Increased availability is provided as the bearing and stub shaft can be exchanged

with rotor in place.

4.3.1.11.2.1.1 Delumper/Dryer Discharge: There are two (2) resin samplers at on the discharge of the pellet discharge section of the Dryer. First in

line is an automatic sampler (S-301X) with a timer to collect small resin samples at predetermined intervals.

This resin is pneumatically transferred automatically to the lab by way of the connected conveying line

sample system where it is collected in a plastic film tube for visual inspection and resin parameter quality

testing.

A manual sampler (S-308X) is located on the pellet discharge of the Dryer just after the automatic

sampler. This sample point is provided for the use by the field operator to monitor the resin cut on start-up

and for quality monitoring during regular operation.

On start-up of the extruder or during quality cut problems, a field operated diverter valve HS-4425 after

the manual sampler is provided to route this poor cut to a waste pellet tank. The waste pellets are

gravity routed through a Seal Pot to maintain the safe environment in the Dryer/Delumper Dewatering

Classifier. A small water flow part of the circulating water loop with service water backup enters the line to

the Seal Pot to flush the waste materials through the Seal Pot to the waste pellet tank or waste container.

Resin at this point in the system still contains approx. 2.5% volatiles and must be cooled for safety. A



hydrocarbon detector is located external to the waste pellet tank to monitor any volatile build-up in the

area. When the waste pellet tank has been filled, it is replaced with an empty waste container. Attention

must be paid to this container so resin accumulation on the ground doesn’t’t happen and plug area floor

drains.

Note: The waste pellet collection system is only used when the pellet cut is completely

unacceptable (possibly on start-up) or when lumps of polymer are produced by the Underwater

Pelletizer.

4.3.1.11.2.2 Reslurry Tank (31-V-309): A 316 stainless steel tank 3200 mm T-T is provided on discharge of 31-G-301 into which the good product

falls By gravity thru a 16” entry into the vessel. There is another line tied into this main downcomer with a

break out spool and isolation blank. This line is for adding seal resin to the RA Stripper from the Bag Slitter

for initial start-up. Tempered water from the RA Stripper return line or from the PCW circulation loop is

introduced into this tank tangentially at a rate to produce slurry of water and pellets of 30-50%

concentration. The Reslurry Tank has an associated level control valve, LV-4426 located on the discharge

side of the Reslurry Pumps. This controls the tank level at a normal 50-60% operating level. On the vessel

top, besides the resin entry nozzle are two (2) viewing sight glasses and a vent line tied into the overhead of

the static Delumper Dewatering Classifier through flame arrester HX-322. Level indicators and a level

alarm high-high are on the side of the Reslurry Tank. On the 12” tank discharge, the line to 31-P-305/S,

there is a removable vortex breaker projecting 75mm upwards into the tank. This heated slurry flow of

resin and water is the main feed for the RA Stripper.

4.3.1.11.2.3 Reslurry Water Heater (31-E-302): This vertical LP steam heated exchanger is provided to heat the PCW water entering the Reslurry Tank.

The LP steam heated exchanger has the capacity to heat the PCW water to a temperature sufficient to give

the slurry at the RA Stripper inlet Hydrosieve a minimum temperature of 78-82°C (boiling point of

SH/water azeotrope). Higher temperatures, causes the volatiles or SH carried in slurry entering the RA

Stripper inlet to flash off into the overhead vapor collection system for reclaim, environmental emissions

reduction and monetary savings. This reduces the build-up of solvent through the RA Stripper and in the

PCW circulating water system making the system safer.

This vertical exchanger operates by adjusting the steam condensate (shell side–approx. 8,482

kg/h x 1.5) (151.8°C in/140.5°C out) level next to the process water (tube side – approx. 97,157 kg/h x

1.5) (54.7°C in/100°C out) 304 SS tubes providing different degrees of heat transfer to the tube side-

reslurry water. This of course is accomplished by back flooding the LP steam condensate in the exchanger

shell. There are two 2” level connections on the shell. The LP Level indicating controller LIC 4447 receives

signal from TIC 4438A (on the exit of the Reslurry Tank) and adjusts to set point input (changing the

condensate level – tubes exposed).

Source water supply to the Heater is via an 8” nozzle from the PCW circulation loop and/or the RA

Stripper upper return water. As much as possible of the heated RA Stripper return water flow is utilized

to cut steam costs to the heater. The normal circulation loop water can be utilized for total flow or just a



part to augment the return water.

Note: It is important to maintain slurry water temperature to the RA Stripper at a proper level as

cooler temperatures will stop the removal of entrained solvent driving it into the RA Stripper resin/water

flow. This causes higher levels of solvent build-up in the circulating Water Reservoir.

4.3.1.11.2.4 Reslurry Pumps (31-P-305/S): The two stage pumps (capacity of 194m3/hour each) can pump a 30-50% slurry concentration of pellets in

water. A single pump operates at one time to receive this flow of pellets and water from the Reslurry

Tank and transfers the slurry to the inlet of the RA Stripper Hydrosieve. Here, most of the slurry water is

separated and returned to the Reslurry Water Heater inlet or the Fines Separators.

These pumps have a differential head of 57.7 meters to provide sufficient lift for the transfer. Conveying

line configuration is critical to this successful transfer. As few bends as possible is required to keep drag or

friction low to achieve designed slurry flow to the top of the RA Stripper. The pump heads have a vent and

drain on the casing as well as a tempered, controlled seal flushing flow. The pump seal flushing is

provided from the main clean water PCW circulation loop. This flow is set using a globe valve, maintained

and monitored via an inline FG with check valve to the pump seals. These seal flushing systems are on

each pump and must run when its pump is operating.

4.3.1.11.2.5 Water Circulation Pumps (31-P-306A/B): Two centrifugal 2-stage pumps, capable of providing the total water flow including flushing flows, to

the Underwater Pelletizer and the Reslurry Water Tank and the RA Stripper outlet are provided. They

draw water up to 900 m3/h from the bottom of the Water Reservoir through vortex breakers with a

normal capacity of 791 m3/hr each. Pumps have a maximum suction pressure of 0.25 kg/cm2g and

discharge of 5.10 kg/cm2g differential head for the pump is 50.7 m water flows of up to 55°C move to many

small takeoffs flows as well as the Pelletizer, RA Stripper outlet and the Reslurry Water Heater with flow

control valves and controllers.

Normal production flows should not exceed the capacity of a single pump but a second Circulation Water

Pump can be run if required. The second pump may be required if running a film resin at high rates

where a high water to pellet ratio is required and/or the return water from the RA Stripper is all routed to the

Fines Separators. The second pump should be started prior to maximum flows being required to avoid

system upset.

4.3.1.11.2.6 Recirculating Water Filters (31-G-307):

The Recirculating Water Filters are situated in the water flow to the Plate Exchangers. They have dual

filters with 304 SS shell and heads. Each casing filter cavity has both a bottom drain and top head vent.

Filters have switching valves to direct process flow to either one of the two filters. The internal 316 SS

basket type is constructed of 30 mesh screen which is capable of collecting the polyethylene fines trapped in

the solvent/water process flow.



Filters have a rated flow of 1065 m3/hr with a filter inlet pressure/temperature of 4.5 kg/cm2g and

55°C. Maximum allowable pressure drop is 0.07 kg/cm2 (when clean) to 1.0 kg/cm2g 50% plugged. Only

one filter will be online at a time with the other cleaned and on standby. The following picture is an example

from another plant as to what this unit will look like.

4.3.1.11.2.7 Water Cooler (31-E-318/S): Two SS plate and frame water exchangers can operate in parallel (normally one required) providing

the circulating water temperature control. The cooling medium is through a 16” inlet water line passing on

the other side of the plates to process with upwards of 1,307,000 kg/h exiting through a butterfly outlet TV

common to both Water Coolers. Cooling water inlet temperature normal average is 33°C with an outlet of

45°C. The outlet temperature is not to exceed 45°C to obtain the process out temperatures required. The

frame can accommodate additional plates to provide a minimum of 33% additional surface area capacity

built into the exchanger design. These additional plates can be added anytime providing more process

medium cooling.

Circulation water temperature inlet to the Water Coolers is up to 54°C with an outlet of 37°C for the

888,000 kg/h maximum flow. Pressure and temperature indications are available for field visual indications.

Both the cooling and process water sides have PSV protection.

The main PCW circulating water flows are to the Underwater Pelletizer and the RA Stripper outlet. The

Water Coolers have an allowable pressure drop of 1.0 kg/cm2g and when reached the spare Water Cooler

is placed online. The off line Water Cooler must be cleaned and readied for the next changeover.

4.3.1.11.2.8 Fines Separator (31-G-302A/B/C/D/E): The five (5) identical Fines Separator Units are circular in design. Each will handle a portion of the

total return process water received from the overhead distribution piping header. The inlet process

water flow of 1050 m3/h flow impacts a velocity breaker to reduce impact on the screens. Only four

Fines Separators are running at any time with one of these units on standby and closed to process

water flows. This is accomplished by closing the TSO butterfly inlet and outlet water flow valves. Each unit

has a internal 2½ HP, 1500-rpm motion generator with top and bottom force wheels to provide adjustable

vibration to the screened units. The following drawing shows the units location of the motion generator and

the top and bottom weights.

This vibration is accomplished through these eccentric weights; the top weight vibrates on a horizontal

plane, which causes material (fines) to move across the screen cloth to the periphery. The lower weight acts

to tilt the machine causing vibration in the vertical and tangential planes. The lead setting of these force

weights determine screening pattern and efficiency of the unit.

The unit has an accelerometer or vibration sensor attached to the lower weldment. The screen assembly

consists of supertaut plus 94T/18T (80 mesh screens with openings of 0.178” made of 0.14 mm diameter

wire) with white nylon sliders and 10m support mesh (numbered S7261075-17-10) assisting in the screen

cleaning during the working operation.

These sliders are ~1” when new and do wear in time. The screen should be replaced as sliders wear down to



~0.85” and lose screen cleaning effectiveness.

The drawing above shows the screen assembly and installation cut-out. Refer to the SWECO maintenance

manual for tightening parameters for this is critical to screen long life.

The polyethylene fines separation from the incoming process water are moved to the 8” discharge chute

for collection while the process water passes through the screens to discharge. The screen is held in

place by the centre tie-down stud and the outer edge clamps.

Each unit will have a ¾” nitrogen purge stream inlet on the domed cover via a flow gauge (FG) through

the vapor space in the screened area exiting via a 4” line flame arrester to a safe area. Two 10” (254) view

ports or inspection openings with covers are provided on the domed cover assembly. The units have

flexible connections of white neoprene on the 14” process inlet, ¾” (9) Nitrogen purge line and the outlet

polyethylene waste line. The water outlet (also with flex connection) is a 14” line entering the circulation

Water Reservoir.

The units also have a 24” access door to the bottom motor weight and grease lines.

4.3.1.11.2.9 PCW Water Reservoir (31-T-301): Reservoir - A stainless steel Water Reservoir (width 3000 x 1500 mm vertical ht. x 9000 mm long) is

provided to supply the circulating pumps, provide separation for the polyethylene fines and skimmer

for accumulated solvent.

Slotted plate - An SS slotted internal screen using 1.75 mm wire with 1.0 mm slot openings placed at a 60°

angle keeps fines from entering the pump suctions. This screen is 150 mm up from the reservoir bottom

to prevent structural failure should the screen become plugged.

Flows serviced - The PCW circulation pumps draw water from the Water Reservoir bottom (2) 20”

outlets through vortex breakers (normally only one pump running at a time) to supply the Reslurry Water

Heater flow, Underwater Pelletizer flows, the RA Stripper outlet flows and Reslurry Pumps seal flushing

and some smaller flush lines.

Bypass, Weir and Covers - The Water Reservoir also has a 12” PCW circulation water bypass inlet on

the bottom and a tank bottom 4” drain line. On top, there are two openings with hinged covers to

inspect the solvent skimming weir and clean the internal screen of polyethylene fines.

Nitrogen blanket - A 2” Nitrogen blanket purge line to protect the vessel from hydrocarbon vapours passes

an estimated 20Nm3/hr out a 6” vent line to a flame arrester (HX-315) discharging to a safe location.

Sparger - A 2” LP process steam inlet feeding the internal bottom located 700mm long sparger is used to

heat the water for initial start-up. This sparger has (7) 3mm diameter holes equally placed on both sides.

A secure guide allows expansion and contraction but still holds the sparger 100mm of the bottom.

Demineralised water makeup - The top of the Water Reservoir also has a 2” demineralised water makeup

line for start-up of the tank. It is estimated the (6) hours will be needed to fill the Water Reservoir. During



normal operation, condensate from the stripping operation provides required makeup water.

Fines Build-up and Sight glass - A 3” water overflow line is provided via a dip tube while (2) 4” pellet drains

are used to drain any fines build-up on the surface of the water out to the area pellet sump. A 6” sight glass

mounted on the side of the Water Reservoir at the tank operating level provides visible monitoring for fines

build-up on the water surface. There is a high and low level alarm on the level transmitter.

More on the Water Reservoir - The reservoir has a top adjustable 40 mm deep V-notch weir at one end.

The weir movement is from 1300-1450 mm measured from the tank bottom. The ½ meter square

solvent/water collection sump that the weir volume passes into is level controlled through with LIT-4445

by starting and stopping the pumps. The sump high-level trips pumps on and low level stops pumps.

Water Reservoir General Operation: This vessel is a storage place for returned cleaned water and steam condensate from the system. It feeds

water required to circulation pumps, Reslurry Tank flows and RA Stripper transport water. The Water

Reservoir has approximately 2.3 minutes of hold-up time at maximum circulation. Fines are cleaned from this

tank water source on an ongoing basis through internal piping level control flushing to drains. Solvent

entrained with the return water migrates to the surface and is constantly skimmed off and sent to the

Decanter for separation and recovery.

Note: This reservoir and its pumps, lines, filter etc. all could contain water at high temperatures of 50°C

plus. This is a burn hazard to an individual touching these pieces of equipment while your skin is

unprotected. For safety, always use personal protective equipment (PPE) such as gloves as hot water can

cause serious burns.

4.3.1.11.2.10 Solvent Skimming Pumps (31-P-307/S): The Water Reservoir overflow Solvent Skimming Pumps, fed from a 2” line, have a capacity of 2.7 m3/h

each with a ∆P of 2.41kg/cm2. These pumps operate through H/O/A switches that when placed in auto will

control the Water Reservoir weir sump level by starting or stopping the pumps as required. The solvent

laden water is transferred to the Solvent Skimming Pump Discharge Filters then onto the Coalescer and

Decanter. Separation is mainly completed in the Decanter and the solvent is then sent to distillation for

reuse.

The Solvent Skimming Pumps are “Z” interlock system and will stop on this trip stopping forward flow of

hydrocarbons.

4.3.1.11.2.11 Solvent Skimming Pump Discharge Filters (31-G-308): The Solvent Skimming Pump dual filters have a CS shell and heads. LP Steam tracing is on the casing

and is designed to keep the internal solvent/water/fines process flow above 20°C. Each casing filter cavity

has both a bottom drain and top head vent.

Filters have valving to direct process flow to either one of the two filters. The internal 316 SS basket



type is constructed of 30 mesh screen which is capable of collecting the polyethylene fines trapped in the

solvent/water process flow.

Filters have a rated flow of 2.7 m3/hr with a filter inlet pressure of 2.53 kg/cm2g and temperature of 52°C.

Only one filter will be online at a time with the other cleaned and on standby.

4.3.1.12 Equipment Associated with the RA Stripper 4.3.1.12.1 Spin Dryer (31-M-305): The RA Stripper Spin Dryer is a Carter Day D850 style DHW2 type 304L SS centrifugal dryer designed for

the separation of polyethylene resin pellets from the PCW circulating water. The pellet/water slurry has a

maximum resin / water flow capacity of 60,410/70,000 kg/h inlet to the dryer. Water conveys the resin

from the RA Stripper outlet to the dryer bottom inlet screen. This inlet inclined screen separates the

majority of the water from the pellets feeding the driven rotor of the Spin Dryer. The rotor consists of a

series of lifters/paddles on a frame that propel the pellets upward and outward via centrifugal force against

the stationary screens of the dryer. Resin moves upward until reaching the outlet chute (with sight glass)

located at the top of the dryer. The pellets (now virtually water free) fall by gravity into the Spin Dryer Hold-

Up Bin.

The conveying water separated from the pellets by the inlet inclined screen and the stationary screens

around the rotor collects in the base of the Spin Dryer and returns by gravity to the fine separators.

Air is pulled from the Spin Dryer inlet air filters thought the Spin Dryer and out to atmosphere via ducting

(HX- 328) discharging to a safe location. To prevent resin contamination, this purge air is protected by

dryer inlet filters designed to remove 99% of particles larger that 40 microns. This air movement prevents

any possible build-up of volatiles in the unit and ductwork.

The Dryer Exhaust Fan 31-K-315 has a hinged cleanout door located near the dryer in the bottom of its

inlet ductwork where any polymer fines build-up can be removed. This cleanout can be open remotely from

1-meter away, protecting operator injury from hot water. Fines build-up in the ductwork can reduce the

volume of purge air making the system more susceptible to fire.

The Spin Dryer and the Hold-Up Bin are protected against fire by a common 2” demineralised fire water

supply through TV-4618. High temperature alarms TAH-4618 (Spin Dryer) and TAH-4623 (Hold up Bin) will

each trip on water to both locations automatically. The Spin Dryer Hold-up Bin firewater enters the bin top

through three roof mounted nozzles. The Spin Dryer has a vertical mounted pipe with the spray nozzles on it.

A low speed switch connected to interlock 3011 is provided to indicate a dryer failure, which will stop the

resin flow to the dryer (drive the RA Stripper outlet LV closed) and give an alarm at the DCS panel.

An ampere indicator II-4620 is provided to monitor the load on the dryer motor which is an indication of

resin flow and/or internal dewatering screen pluggage.

The Spin Dryer drive belt has a spark-proof guard with inspection port.

Spin Dryer access doors for inspection of the interior screens and cleaning of the spray nozzles are



gasketed to keep them leak free.

The ductworks to and from the Dryer Exhaust Fan have flexible connections.

A drain from the bottom of the exhaust fan allows water and fines to be removed.

Note: The Spin Dryer and all associated equipment have been designed with a noise level less than 85

dBA at 1m.

4.3.1.12.2 Spin Dryer Hold-up Bin (31-V-317): The Hold-Up Bin is a SS, 7.5 tonnes capacity vessel to provide a collection point for resin exiting the RA

Stripper Spin Dryer while the on-line blender is being changed.

The bin top has:

• A process inlet line

• A vent to atmosphere

• Three (3) fire water spray nozzles

• A TI and TAH that opens fire water to the vessel

• A LSH vibrating fork to an interlock 3011 that closes LV- 4615 on RA Stripper discharge.

The bottom has:

• A manual slide gate for Rotary Feeder isolation

• Resin outlet to Rotary Feeder 31-ME-303

• A purge Fan 31-K-323 provides air at 560 Nm3/h to purge any volatile buildup from the resin

retained during a blender swing process. The three equally spaced inlet nozzles around the

cone have Johnson screens (1.75mm wire with 0.076mm slots) flush with the inside of the vessel.

The screens have a grill type support.

• A backup nitrogen supply of ~25kg/h through FO-4604 is lined into the Purge Fan conveying

piping. This nitrogen supply is automatically initiated on Purge Fan failure to keep the accumulated

resin safe.

To change blenders the constant speed Rotary Feeder (31-ME-303) at the base of the Hold-up Bin is

shutdown. This engages interlock 3014 driving the level control valve (LV-4615) on the RA Stripper exit

to 10% open. This action reduces the amount of material that requires collection in the Hold-up Bin. Once

the Rotary Feeder is shutdown, the Spin Dryer Conveying Blower (31-K-302) will purge the transfer lines

of remaining resin to the on-line blender. When the transfer lines are cleared of resin as indicated by the

Spin Dryer Conveying Blower amperes decreasing to a no load value, the appropriate diverter valves are

positioned to direct the transfer lines to the next prepared blender.

Note: This action must take less than 90 seconds (adjustable timer) to perform or RA Stripper LV will

close completely.

The Hold-up Bin Rotary Feeder (a constant 70tonnes/hr) is then restarted and the material collected in the

Hold-up Bin is sent to the new on-line blender and the level valve on the RA Stripper resumes its normal

operation (if in Automatic mode).



• If the level in the Hold-up Bin becomes too great, a high level switch will initiate an interlock to

close the level valve on the RA Stripper.

• The purge fan supplies a continuous purge of air through the Hold-up Bin to a vent to atmosphere to

prevent any possible build-up of volatiles.

• Remember that resin will be transferred at the maximum Rotary Feeder capacity (70t/h) until the

hold-up bin is emptied.

4.3.1.12.3 Solvent Vapor Condenser (31-EA-301): The purpose of the Solvent Vapour Condenser is to condense vapor from the RA Stripper overhead

stream maintaining a low RA Stripper pressure. The vapor from the RA Stripper overhead is condensed by

this forced draft air-cooled heat exchanger. The steam and hydrocarbon mixture at up to 107°C passes

through the CS tubes while air is moved through the exchanger by fans. Field adjustable manual chain-

operated louvers with a first fixed speed 30 kW drive (1470 rpm) and a second 30 kW motor with a VFD

drive (1475 rpm) determine the amount of cooling air sent through the condenser. Both condenser fans are

started and stopped and the VFD fan is controlled from the DCS. The noise levels of the operating fans are

85 dB(A) @ 1 meter or below.

High vibration switches complete with manual resets and high motor temperature switches will shutdown

the fans. A “Z” trip will also stop the fans motors as “Z” is designed to control solvent movement. A

temperature indicator on the self-venting outlet line of the condenser is displayed in the DCS. The

headers have full plate removable covers.

Outlet sloped condensate flow temperature is approx. 65°C and is moved onward to the Solvent Vapour

Trim Cooler for more cooling. Outlet pressure at this point is 0.02 kg/cm2g.

Vents (2”) on the inlet and outlet of each condenser can be used to pass trapped nitrogen inerts out of the

system. Different venting configurations for normal running and shutdown conditions are available. No

winterization has been provided for the air condenser, as maximum ambient temperature is 46.6°C with

minimum being above freezing point of SH.

4.3.1.12.4 Solvent Vapor Trim Condenser (31-E-301): The vertical Solvent Vapour Trim Cooler is a single pass shell & tube carbon steel exchanger. The

process stream, a mixture of steam and hydrocarbon (6,236 kg/h) passes through the tube side and cooling

water (9,454 kg/h) passes through the shell side. It works in series with the Solvent Vapour Condenser to

control RA Stripper overhead pressure even in the hottest periods.

The process temperature into the Solvent Vapour Trim Cooler is 65°C while the outlet to the Coalescer is

designed for 45°C. The cooling water runs counter-current to the process, with design temperatures of 33°C

inlet and 45°C outlet. The outlet cooling water flow has a globe valve for flow control as well as a TG and

sample point provides the monitoring required.

Non-condensable such as nitrogen will be vented from the Solvent Vapour Trim Cooler head and lined

through the Flame arrester (HX-317) and the Dead Weight Vent (HX-317) of the top of the Decanter.



Protecting the Solvent Vapour Trim Cooler is a PSV-4705 set at 3.5 kg/cm2g.

The condensate stream from both RA Stripper overhead condensers exit via self-venting piping and is sent

to the Coalescer and Decanter downstream. To provide pressure control, for the RA Stripper, these two

condensers can be operated in different ways. The cooling water to the Solvent Vapour Trim Cooler will

be opened fully and the air condenser louvers, fan speed and number of fans operating are the

mechanisms to provide desired pressure. There is bypass pipe and valving to remove the Solvent

Vapour Trim Cooler from service for maintenance if required and still operate the plant.

4.3.1.12.5 Coalescer (31-V-319): This carbon steel vessel is designed to breakup or coalesce any emulsion of the water and hydrocarbon

mixture from the RA Stripper Solvent Vapour Condenser, Solvent Vapour Trim Cooler and Solvent Skimming

Pumps to assist in the separation of water and solvents in the Decanter. Pall Proprietary Polymeric

coalescer elements provide an emulsion break between the hydrocarbon and water droplets. The element

also will provide some addition fines removal should the filter 31-G-308 pass any but this will shorten the

operating life of the element.

The Coalescer inlet process flow pressure and temperature of 0.15 kg/cm2g/45°C pass into an internal

distributor, then through the element onwards into the Decanter inlet sparger.

A bypass from the Solvent Vapour Trim Cooler outlet joins this overhead line. PDG 4626 is provided to

indicate Coalescer element plugging.

PSV-4704 protects the Coalescer and discharges into the overhead outlet line.

Bypassing the Coalescer and opening the head to remove this internal screen is the only way to complete

the cleaning of the element.

4.3.1.12.6 Decanter (31-V-311): The Decanter is initially filled with water from a hose connection located on the vent line. The nitrogen

injected into the Stripper overhead line will blanket the Decanter along with inert removed from the end

manifold of the Solvent Condenser and the Trim Condenser which both vent through a Spark Arrestor

assembly (HX-317) and a Dead Weight (HX-310) Vent off the top of the Decanter itself.

Condensate from both Condensers flow from the Coalescer to the Decanter. The Decanter separates the

lighter cyclohexane solvent from the steam condensate. Most of the water is removed from the inlet side

bottom to drain via s standpipe through 31-LV-4723. Solvent is collected in the second stage side after

spilling over another internal weir. This solvent side of the Decanter is level controlled via 31-LV-4717, which

opens to discharge solvent to the LPS HUT. Only one pump is required for normal operations running a

minimum spillback flow keeping the pump ready to discharge solvent as required. The Solvent Condensate

Pumps are interlocked to shutdown on a “Z” trip.

The solvent section also has a boot showing the interface between the solvent and trace water amounts

carried to the solvent side with a high level switch that will indicate a water level in the solvent. This boot is



to be drained periodically to remove water. Do the routine sampling of the water so know the SH conc. in the

stream.

On the inlet side of the Decanter, there is also a solid drain via a Strahman type valve, which can be set for a

small continuous purge as required. A filter assembly is located on the discharge of the Solvent Condensate

pumps to remove any polyethylene dust from the solvent stream to distillation.Primer Epilux A/c FRX Primer.

The finish coating is 2*125 Microns Amin Aduct Xured Epilxu 78 HBTL Finish. It has (2) -24” manways

providing access to inlet sparger and vortex breaker over the Solvent Condensate Pumps. A spillback

line from the pumps enters the top of the Decanter through a dip tube. Off the top, a 4” line to the

conservation vent arrangement that also provides a venting location for the Solvent Vapour Condenser,

the Solvent Vapour Trim Cooler and the Coalescer. The process condensate from the RA Stripper and the

solvent skimmed from the Water Reservoir enter the Decanter through a common 6” sparger. This sparger

has (3) holes top and bottom along with 20x800 mm slots on both sides.

Level indication gauge is provided on one end and a level controller on the other giving level in both sides of

the Decanter. The Decanter solvent side LLL is 350 mm up from the bottom and the HLL (75% of

measurement range) is 650 mm up from the bottom.

A Temperature gauge is also on the Decanter inlet end.

A 4” water draw off from the bottom is provided from an internal standpipe discharging to the Finishing

area sump via level control valve LV-4723. A second water draw via a positive tight shutoff 2” Strahman

ram type bottom angle drain valve (HX-350) which protrudes 12mm into the bottom of the Decanter also

discharges to the FA Sump.

The solvent section also has a boot showing the interface between the solvent and the water carried

to the solvent side with a high-level interface switch that will indicate that the water will need to be

drained. The outlet solvent collected in the second stage after spilling over an internal weir, exits via a

vortex breaker to 31-P-308 (S) and is pumped through filter 31-G-309 to the LPS Hold-up Tank in distillation.

The Solvent Condensate Pump Discharge Filters remove any polymer fines prior to this transfer to

distillation.

The Decanter is initially filled with water from a utility hose connection located on the vent line. The

nitrogen injected into the RA Stripper overhead line will blanket the Decanter along with inerts removed

from the end manifold of the Solvent Vapour Condenser and the Solvent Vapour Trim Cooler which both

vent through a Spark Arrestor assembly (HX-317) and a Dead Weight Vent (HX-310) off the top of the

Decanter itself.

Only one Solvent Condensate Pump is required for normal operations running a spillback flow through FO-

4709 or FO-4710 to keep the pump above its minimum flow requirements. The Solvent Condensate

Pumps are interlocked to shutdown on a “Z” trip.

4.3.1.12.7 Solvent Condensate Pump (31-P-308/S): The centrifugal horizontal pump with rated capacity of 2.32 m3/h has a suction pressure of 0.56 kg/cm2g.



Pump differential head is 22.8 meters. The pumps also have a dual mechanical seal that uses a buffer fluid.

These pumps take their condensate supply from the Decanter for transfer to distillation. Only one pump

operates at a time, pumping spillback via a FO (one on each pump spillback) to the Decanter, as flows

require. As the Decanter level requires, LV-4717 opens for forward solvent movement.

4.3.1.12.8 Solvent Condensate Pump Discharge Filters (31-G-309): The Solvent Condensate Pump Duplex filters have a CS shell and heads. LP Steam tracing is on the

casing and designed to keep the internal solvent/water/fines process flow above 20°C. Each casing filter

cavity has both a bottom drain and top head vent.

Filters have valving to direct process flow to either one of the two filters. The

internal 316 SS basket type is constructed of 20mesh screen which is capable of collecting the polyethylene

fines trapped in the solvent/water process flow.

Filters have a rated flow of 2.32 m3/h with a filter inlet pressure/temperature of 2.25 kg/cm2g and 50°C.

Only one filter will be online at a time with the other cleaned and on standby.

Solvent Condensate Pump Discharge Filters Cleaning Operation: Using the single switching valve design, the process is routed through the clean standby filter to regain

process pressure.

The drain valve on the plugged filter is opened draining the fluid and dropping pressure to atmospheric.

Open the off line filter cavity vent and undo the cover to gain access to the inside plugged basket filter.

Remove the basket filter and clean screen or replace with new one. Once the 316 SS basket is

replaced, tighten the head cover and close the drain valve. Process fluid can then be slowly bled into the

offline cavity until it exits the vent. Close the vent valve and this filter is ready for process flows.

4.3.1.13 Blender Sampling System: 4.3.1.13.1 Sampling Process Description: The Continuous Sampling System is used to obtain small samples of resin at a high frequency rate to

observe and retain a continuous sample of the product.

The two (2) automatic samplers mentioned in this section are S309X located exiting the RA Stripper

and S-310X outlet of the Spin Dryer Hold-up Bin.

The Continuous Sampler at the bottom RA Stripper tangent line (cone sampler) can be used to

positively identify when a critical separation of resin types should take place. This is particularly useful

when there have been numerous start-ups and shutdowns of the extruder and production rate changes

where the resin tracking becomes exceptionally difficult.

The Laboratory personnel are normally responsible for collecting hourly samples of the product going into

the RA Stripper at the Reslurry Tank. From these samples the resin parameters are obtained and changes

are made to the process to ensure the current batch of resin will be on-specification. The resin lots in the RA



Stripper may be changed depending on the results obtained from these samples.

The Samplers collect a sample of a few resin pellets at pre-selected time intervals, one to several

minutes, to provide an overall sample. It can give an immediate indication of a short duration bad colour

excursion or gradual color changes over a period of time some of which may not be known to the

laboratory personnel or polymer area operators. Some changes or system pressure bumps to the Solution

Adsorber may not be expected to cause colour troubles but do and therefore are not expected at the RA

Stripper outlet. Missed resin lot cuts or blender swings can cause loss of first grade product.

When the Laboratory personnel collect the hourly sample from the manual sample point at the Delumper

outlet, the Continuous Sampler collection bag should be time marked for reference. From these markings,

analysis can determine exactly how long it will take resin at a specific rate to go through the RA Stripper.

From this data, more exact resin tracking and batch separation is possible.

The Spin Dryer exit sampler is used to monitor resin entering the Blenders. This sampler on the

pneumatic conveying line after the SD Hold-up Bin is mainly for volatiles and lot samples. It also can

show colour excursions, wet resin and fines in the resin stream to the current Blender.

Note: The resin sample conveying system must remain operational to provide a clean, reasonable dry,

representative sample to the lab to give quality results.

4.3.1.13.2 Operation of Retractable Tube Resin Sampler: The samplers are a retractable tube with covered end and pre-cut inlet and outlet openings. These

samplers are fully automatic using a timer from a centrally located panel. The collection tube is driven

pneumatically into the resin stream and withdrawn with the accumulated resin sample after a set period of

time.

Set the timer for the sample interval required and turn to the "ON" position.

A solenoid will operate energizing the air-operated piston and the sample tube will enter the stream of

material to be sampled. The dwell of the sample tube in the stream of material is governed by an

adjustable time delay relay. A suggested dwell time of two seconds is normally enough time for a sample.

After the sample tube has collected the sample it will retract from the conveying line. This action closes the

inlet opening and opens another in the bottom of the tube to discharge the resin pellet sample.

Resin is then sent automatically (normally) to the lab collection polyethylene tubes or containers. Lab

personnel collect the sample, perform their tests and report results to operations.

See the following Resin Sampling number listing and location for a complete list.

Resin Samplers

Number Location Type

S-301X Outlet of Classifier Unit (31-G-301) GF - Automatic

S-302X Outlet piping of Blender 1 (31-V-313) CRB 50 Automatic



Number Location Type

S-303X Outlet piping of Blender 2 (31-V314) CRB 50 Automatic



S-306X Outlet of Product Classifier (31-G-305) CRB 50 Automatic

S-307X Outlet of Product Classifier (31-G-306) CRB 50 Automatic

S-308X Outlet of Classifier (31-G-301) GF - Manual

S-309X RA Stripper Cone Area (31-V-310) GF - Automatic

S-3010X Spin Dryer Hold-up Bin Outlet (31-V-317) GF - Automatic

4.3.1.14 Resin Conveying & Associated Systems: 4.3.1.14.1 System Description: System A – Feed to Blenders Resin pellet transfer from the RA Stripper Spin Dryer HUT to the inlet of one of four blenders. System B – Blenders Resin pellet circulation from any of the 4 blenders to-blend line, transfer to another blender, to the Storage. Silos or to the classification facilities for packaging. System C – Storage Silos The system covers the Storage Silos area and the pneumatic conveying piping transfer back to the blenders

or to the classification facilities.

System D – Classification This system covers the classification facilities and bagging hoppers.

System E – Bag Slitter This system covers the Bag Slitting facilities and the resin return to the blenders; Recycle Resin Storage

Bin or the Reslurry Tank.

System F – Resin Samplers Resin samplers placed throughout the resin transfer areas, collect and transport pellet samples known as

dribbler or grab samples to a local collection spot or to the laboratory directly.

4.3.1.14.2 System A – Feed to Blenders:

Resin pellet transfer from the RA Stripper Spin Dryer Hold-up Bin to the inlet of one of four blenders.

Equipment List utilized in System A:

Equipment No. Description System No.

31-E-317 Spin Dryer Conveying Cooler A

31-V-317 Spin Dryer Hold-up Bin A

31-ME-303 Spin Dryer Rotary Feeder A

31-K-301 Spin Dryer Hold-up Bin Purge Fan A

31-K-302 Spin Dryer Conveying Blower A



4.3.1.14.2.1 General Description: The blenders are fed continuously from the Spin Dryer Hold-up Bin (31-V-317). The discharge is through a

fixed speed rotary feeder 31-ME-303 running continuously at 70,000 kg/h feeds resin into the discharge

line of the Spin Dryer Conveying Blower (31-K-302) which pneumatically transports the product to the

blenders in System B.

During the blender the change over process (blender swing), the Rotary Feeder is stopped when a blender has

been filled to the required level. During the change over of valving prior to feeding the next blender,

product will accumulate in the Hold-up Bin at a reduced rate. This is accomplished when the Rotary Feeder is

stopped, a logic interlock drives the RA Stripper outlet level valve 31-LV-4615 to 10% open. The original

valve position will be re-established once the Hold-up Bin Rotary Feeder is restarted. This feeder restart

shall be after the transfer line has been cleared of resin (seen by a drop in blower amperes), diverter

valves lined up to the next blender and appropriate interlocks satisfied. Once the accumulated resin in the

Hold-up Bin has been removed and transferred to the new blender, the Spin Dryer Hold-up Bin will operate

empty keeping up to the production rate.

During the blender change over period, the Spin Dryer Conveying Blower will remain running. The

maximum change over period shall be limited to 4.0 minutes maximum, based on the hold-up capacity of

the Spin Dryer Hold-up Bin (estimated at 7.5 tonnes) with the normal timeframe required being max of 90

seconds (adjustable timer).

A continuously running Hold-up Bin Purge Fan (31-K-301) is required to ensure no build-up of volatile gases.

The transfer airflow rate will be 560 m3/hour at the fan suction conditions and air passes out the Hold-up

Bin top atmospheric vent. If the purge fan is stopped then an alarm shall be given by a low flow switch in

the discharge piping and a nitrogen purge is activated by the same signal. This nitrogen flow provides the

same protection as the air purge until the air fan purge can be re-established.

Note: Blending Blower 31-K-306 shall be piped up, including all necessary valves and controls, to serve as

a back up for Spin Dryer Conveying Blower (31-K-302). Venting of excess volumetric capacity

shall be considered to permit appropriate pickup velocity at the exit of 31-ME-303 when 31-K-306 is

used as a spare for 31-K-302.

4.3.1.14.3 System B – Blenders: Resin pellet circulation from any of the 4 blenders to – blend line, transfer to another blender, to the

Storage Silos or to the classification facilities for packaging. Equipment List utilized in System B:


31-E-304 Blending Heater /Cooler #1 B



31-E-307 Blending Heater/Cooler #4 B

31-E-308 Purge Air Heater #1 B







31-V-313 Blender #1 B





31-ME-304 Blender #1 Rotary Feeder B




31-K-303 Blending Blower #1 B




31-K-307 Purge Air Blower #1 B



31-K-310 Purge Air Blower #4 B 4.3.1.14.3.1 Blender & Equipment Purpose: The purpose of blenders and their associated equipment is to blend accumulated resin into a

homogeneous lot, purge some remaining volatiles, and dry resin received from the RA Stripper. This is

completed with a high degree of safety, efficiency with the ability to unload this resin to storage or

classification for packaging at a reasonably high rate of transfer.

4.3.1.14.3.2 System Description: This system comprises four (4) 200 tonne capacity blenders, 31-V-313 to 31-V-316. It takes approximately

4 hours to fill the blender with an averaged maximum filling rate of 53,528 kg/h. On this basis there will be

approximately a 7 hour time period before the same blender, now just full, should be available for filling

again. During this time period, the contents of the blender must be blended, (defined as 1½ turnovers of

the blender contents after filling is completed) and the contents discharged to either the storage facilities

(System C) or the classification facilities (System D).

During filling and blending, the Blending Blowers 31-K-303 to 31-K306 and heat exchangers 31-E-304

to 31-E-307 shall be operating to provide air at 85°C for blending the resin. Prior to transfer of the resin

pellets, the exchanger shall be switched to the cooling mode to provide air at 50°C for pellet transfer.



The blenders must have sufficient cycle time to cool the resin to a temperature low enough to allow

bagging directly from the blender without excessive snakeskin generation during conveying or melt

through of packaging bags. The resin transfer and bagging temperature shall be 50°C or less.

During the blender filling operation and while blending, the purge blowers 31-K-307 to 31-K-310 and

heat exchangers 31-E- 308 to 31-E-311 will be operating to provide a constant flow of air at 85°C

through the blender. The airflow rate will be 5600 m3/hour at the blower inlet.

The purge air system shall continue to run after blending is completed and during unloading, but with

heat turned off to assist in cooling the resin.

4.3.1.14.3.3 Blender Vessel Description: There are four (4) Philips type blenders set in a row just outside the extruder building. These vessels are

alike with each having the following criteria.

4.3.1.14.3.4 Purpose: The Blender vessel retains and mixes resin from various sources to produce a uniform lot. The resin is

also simultaneously purged of remaining volatiles and dried while inside the vessel.

4.3.1.14.3.5 Component Description: 1. Vessel Material – Made of stainless steel.

2. Capacity is 200 tonnes each with 500 mm of freeboard between inlet and top of resin.

3. Design temperature of 125°C and a design pressure of 0.2 kg/cm2g.

4. General The blenders are supported on structural steel without connecting steel such that the blenders can

float independently without interference to the weigh cell system. A support ring supplies brackets for

the weigh cells. They have a roof suitably reinforced to carry pipe supports, pneumatic conveying

piping along with diverter valves.

5. Blend Tubes

The six blend tubes are equally spaced in the blending tank and run the entire length of the vessel.

They are made of extruded aluminum pipe with three pie shaped channels in each pipe. Holes are cut

in the different channels at different heights that allow resin from various areas/heights in the blending tank

to fall through the channels to a small collection chamber immediately above the rotary discharge valve.

The blend tubes have an accessible top blind flange for inspection that is also the entry point for the wash

water nozzle.

6. Inner Inverted Cone This cone receives air from the purge air blower via a line entering through the exterior blender wall into

the cone. There are two smaller cones atop the main cone with spaces between them that allow air to pass

through to purge and dry the resin.

7. Rotary Discharge Valve This vented valve is driven by a variable speed electric motor, which can be adjusted to give a recirculation

rate of 85,000 kg/hour and an emptying rate of 35,000-85,000 kg/hr.



8. Purge Air Blower The blower is a positive displacement blower, driven by an electric motor. The system is equipped with

the following accessories (inlet filter and silencer, discharge silencer, relief valves, and a check valve).

There is also a temperature switch in the blower discharge, pressure gauges, and a pressure switch.

These blowers are also equipped with an air heater box with Low Pressure steam coils (with condensate

returns and traps). Low Pressure steam is supplied through a control valve for temperature control by a

standard temperature control loop. There is also a manually operated nitrogen supply to the blower

discharge as a safety feature.

9. Blend/Unload Blower The blower is a positive displacement blower, driven by an electric motor. This system is equipped similarly

to the purge air blower in regard to its accessories and heater box. In addition, water can be turned on to the

heater box, with the steam shut off to cool the resin.

10. Inline Sampler The inline sampler is located in the blend line and when activated, a tube enters the resin flow, taking a

sample and deposits the resin in a line where it is blown to a cyclone in the sample room in the area control

laboratory.

Conveying Lines:

• All the conveying line used in this blender transfer/classification area have Internal treatment (i.e.,

shot peening) to minimize the creation of product smears, fluff and/or streamers. Flow direction

should be marked on the piping after shot peening.

• Joints at couplings have tie bolts to pull butting ends of pipe together to avoid separation during

operation.

• Internal projections in product piping are not acceptable. Internal diameter of mating parts are

tapered if necessary to achieve a matching diameter.

• All bends shall be anodized aluminum or stainless steel. At least 15 to 20 diameters of straight

pipe is to be provided between a pick-up point and the first bend, unless approved otherwise

for specific locations to facilitate layout.

• Routing of conveying lines is as direct as possible from pick-up to termination point, with

minimum number of bends and elevation changes.

• Insulation is only required for personnel protection or noise abatement.

• Diverter valves are grouped together for accessibility with service platforms as required.

• Diverter valves are Slide type (aluminum/stainless steel) air operator Plug type (cast aluminum

body and plug) air operator.

• All conveying lines and equipment shall be bonded and grounded to dissipate static electricity.

Any flexible connectors shall be provided with bonded conductor jumpers.

4.3.1.14.3.6 Blender Capacities: Equipment numbers 31-V-313 to 31-V-316

FE-301X to FE-304XCapacity 200 tonnes each



Resin temperature 85°C in blender (maximum)

Resin feed rates 70,000 kg/h (max) from System A at 70°C (max)/50°C (min)

85,000 kg/h (max) from System C at 50°C (max)

85,000 kg/h from other blenders at 85°C

Blending rate 85,000 kg/h at 85°C

Unloading rate 85,000 kg/h to Storage Silos, System C, or product

classification, System D

85,000 kg/h at 85°C, maximum, to other blenders

1. Each blender is mounted on load cells and has jacking bolts as required to replace defective load

cells. Each blender shall not be constrained by piping or platform installations so as to affect the

operation of the load cells.

2. Filtering of air to the units will be required on the blenders. The exhaust air outlet shall be designed

to prevent water and foreign material from entering the blender. The blender vent should be sized

50 percent larger than the design requirement.

3. Periodically the blenders will be internally washed. The Rotary Feeder and blending blower will be

left running so as to allow the water to pass out of the blender and be blown out to atmosphere

through a diverter valve in the discharge piping.

4. Blenders shall be provided with all necessary connections including:

• 600x900 mm roof manway with man catcher and gravity cover hinged to provide overpressure

relief

• Feed nozzles

• Outlet nozzle to suit selected size of connecting device

• Vent

• Flanged nozzles complete with removable sprays for fire water/wash water piping for blender

interior and wash water for the blending tubes. Vendor to advise the quantity required providing

coverage to wash all internal surfaces.

• Rotary Feeder vent line.

• Blending tube access blind flange (inspection and clean-out)

• Purge air for drying complete with internals.

• Temperature indicator (1½” flanged)

• Temperature switch high-high.

• Level switch high.

• Contoured plug type manway at minimum distance to cone

5. Blender material is stainless steel.

6. All internal surfaces and welds are ground smooth.

7. Internal structural supports are designed to eliminate flat surfaces where pellets may accumulate

or hang-up. Flat profiles shall be tapered 30 to 40° from vertical.

8. Internal blending tubes supports are designed at a minimum to hold an empty blend tube during

recirculation and have adequate differential thermal expansion.



9. Internal bolting where required shall preferably be secured with stainless steel lock washers or

aircraft type lock nuts. Conventional bolting if used shall be secured with cotter pins or stainless

steel wire. Use of internal bolting shall be minimized.

10. Vessel roofs are reinforced to support concentrated loads from pipe supports, platforms, etc.

with access platforms.

11. Purge air is required to remove surface moisture from the resin and remove any residual

hydrocarbon. The air will be introduced below the blender cone. The peripheral space in the cone

shall provide a free area of 0.40 m2 minimum.

12. Blenders will not be insulated except where required for personnel protection or noise protection.

13. The blender height shall include 500 mm of freeboard between the underside of the filling nozzle

and the top of the discharge resin profile when blender is full (200 metric tons of resin).

4.3.1.14.3.7 Alarms & Interlocks: Alarm Setting Interlock Service

TAH Yes High temperature stops Blower.

PI Yes High pressure in conveying line stops Rotary Feeder. Low

pressure alarm only. Yes Rotary Feeder cannot run if Blower is stopped.

II Operator Adjustable Yes Blending Blower amperes.

TIC Operator Adjustable High temperature, Blending Blower Heater /Cooler air

discharge.

SIC Operator Adjustable Rotary Feeder low speed.

TAH Yes High temperature stops Blower.

PI High and low pressure Purge Air Blower.

TIC Operator Adjustable High and low temperature Purge Air Heater, air discharge.

Yes Diverter valve cannot open to Blender unless purge

running. Yes With end Blender selected for filling the other Blender fill

diverter valves must be in through positions and Purge Air

Blower running before Transfer Blower will run. Yes Only one of the transfer diverter valves can be in the

unload position, at any one time. Yes Blender cannot be brought on line using filling diverter

valves from RA Stripper if this diverter valve is open to

TAH Yes High temperature (top of Blender).

Stops associated Blending and Purge Air Blowers.

WIC Operator Adjustable High-high, high and low settings for resin weight in

Blender.



4.3.1.14.3.8 Blender Management: Resin production is a continuous operation and efficient blender management is very important to keep

the utility of the whole polyethylene unit at its maximum. Poor blender utility can easily happen should

forward planning not be constantly reviewed. Use the RA Stripper tracking of lot production to plan for empty

blenders to receive these production lots. First through yield resin lots, lots with colour or other off

specification conditions along with continued high production rates could develop into an "empty

blender" shortage. This situation can require a rate reduction or worse a reaction termination because of

an "all full" blender status.

As mentioned, good blender planning begins at the RA Stripper that has a minimum of seven hours

hold-up time running at its maximum operation level. Good production lot planning at this stage of the

process will greatly enhance the efficiency and utility of the blender status in the period ahead.

4.3.1.14.3.8.1 Production Lot Planning: Some of the conditions that will influence your lot collection decisions are as flows:

• Level of production run volatiles entering the RA Stripper.

• High run volatile results entering the RA Stripper can determine the production rate.

• Higher volatiles requires longer residence time (e.g.) lower production rates.

• Monitoring the run volatile results.

• Optimizing LPS operating conditions to ensure lowest possible run volatiles.

• Calculating the optimum production rate to ensure RA Stripper exit volatiles of <0.05% (500ppm)

4.3.1.14.3.8.2 Resin Parameter Limits: • Ensuring each 200 tonne lot in the RA Stripper falls within the specification limits.

• Foreseeing a lot parameter that will require a split lot (blender) to bring it on specification which

could hinder fill times and affect empty blender availability.

• Planning what the blender status will have to be when the split lot is ready to exit the RA Stripper.

• Calculating the optimum production rate to ensure blender availability for the collection period.

4.3.1.14.3.8.3 Resin Type Changes: • Calculating production run time changes to ensure optimum blender utility (e.g.) no small or part

lots when possible.

• Optimizing quantities of transition materials or off standard production to ensure no cross

contamination with on specification lots and minimizing the amounts of undesirable production.

• Should IOCL opt for high pressure resin mixing in the future, RA Stripper planning with

respect to production requiring the addition of "high pressure resins" (e.g.) these lots to be 85% of

blender capacity for virgin production with the balance being made up of H.P. resin added to the

blender.



4.3.1.14.3.8.4 Blender Planning: • Blender preparation should be started 30 minutes in advance of resin collection in this blender. This

time is needed to heat up the blender enough to zero the scales as there is a significant weight

differential between hot and cold conditions. This will be more noticeable during nighttime

operations.

• Set blender scale batch alarm with respect to the lot size to be collected minus approximately 25-

30 tonnes to give an alarm in time to prepare the next blender.

• Reset blender scales batch after first alarm warning to complete full quantity of lot collection.

• Ensure the blender rotary feeder speed is at maximum rate to minimize the time required to

produce a homogeneous blended lot of resin.

• If the lot being collected in this blender is smaller than normal the blend cycle and composite

sampling times can be ratioed down from normal to expedite blender turn around time and

enhance blender efficiency. Remember that after the lot of material is collected, 1.5 turnovers of

the material is required to provide a blended lot.

• If the lot being collected is a small "off specification" lot or a small "transition lot" it can be unloaded

from the blenders as soon as the composite sample has been taken. The lot specification by

laboratory analysis need not be known to get the material out of the blender to a packaging silo thus

enhancing the blender turn around time.

The following example of normal blender turn around from the time the blender is full until it is empty is

as follows (based on 1.5 turnovers of the material after full):

Fill Time 3.6 hrs (estimate) Blend cycle 3.53 (4) hrs

Laboratory analysis 1.0 hrs (this time can be eliminated)

Unloading time 2.35 (2.75) hrs

Total (approximately) 10.5 hrs with 100% efficiency

• As one can see, three blenders full time are required to handle normal production. If the lot being

collected was split from the RA Stripper to bring some parameter on specification, a fourth blender

could be required as well.

• It is imperative to have a goal to optimize blender turn around to a short a time as possible to

avoid any shortage of empty blenders that could restrict production rate or worse require a

reaction termination because of a lack of available blenders to collect the resin.

4.3.1.14.4 System C – Storage Silos: The system covers the Storage Silos area and the pneumatic conveying piping transfer back to the blenders

or to the classification facilities.

Equipment List utilized in System C:


31-E-312A Silo Conveying Cooler #1 C

31-E-312B Silo Conveying Cooler #2 C

31-E-312C Silo Conveying Cooler #3 C




31-V-325A Storage Silo #1 C

31-V-325B Storage Silo #2 C

31-V-325C Storage Silo #3 C

31-V-325D Storage Silo #4 C

31-V-325E Storage Silo #5 C

31-V-325F Storage Silo #6 C

31-ME-326A Silo #1 Rotary Feeder C

31-ME-326B Silo #2 Rotary Feeder C

31-ME-326C Silo #3 Rotary Feeder C

31-ME-326D Silo #4 Rotary Feeder C

31-ME-326E Silo #5 Rotary Feeder C

31-ME-326F Silo #6 Rotary Feeder C

31-K-312A Silo Conveying Blower #1 C

31-K-312B Silo Conveying Blower #2 C

31-K-312C Silo Conveying Blower #3 C 4.3.1.14.4.1 Purpose:

The Storage Silos are to store resin from production prior to packaging or reprocessing.

4.3.1.14.4.2 General Description:

The six (6) storage silos 31-V-325A to 31-V-325F receive resin from the blenders to hold for storage or to

allow classification system or packaging scheduling.

The 200 tons capacity Storage Silos are arranged in two (2) rows of three (3) silos. Plot plan layout

provides for the addition of two (2) silos at a future date. Storage Silos unloading conveying systems allows

for the transfer of resin from two (2) of any of the six Storage Silos at the same time.

Resin sent to the Storage Silos should be at the lowest temperature possible as residual heat in the resin

stays present for a long time. Resin does have low quantities of volatiles still residing in the pellets and

this lower temperature stops continued emissions. This is very important to the management of the

Storage Silos because only a nitrogen line is available to fight fires or slowly cool resin.

Also important is that the resin being transferred is as free of degradation as possible. Resin lots with

poor colour are extra work to clean the Storage Silos because no wash water facilities exist. Lots with high

amounts of fines or snakeskins are only cleaned up as they are sent to the classification systems. One

must be aware of the cleanliness of the Storage Silo for the next resin lot it is to receive. See the following

table of the Storage Silos and other vessels in this section.



The following vessels requirements:

Service Bulk Storage Bagging Silos Recycle Resin

Equipment No. 31-V-325A to

31-V-325F

31-V-320 and

31-V-321

31-V-318

Quantity 6 2 1

Product capacity 200 tonne each 400 m3 16 to 18 tonne

Maximum resin temperature °C °C Ambient

Maximum resin feed rate 85,000 kg/h 85,000 kg/h 15,000 kg/h

Maximum resin discharge rate 85,000 kg/h 85,000 kg/h 1000 kg/h

4.3.1.14.4.3 Storage Silos Vessel Description: The Storage Silos shall be provided with all necessary connections including but not limited to:

1. 600x900 mm roof manway with man catcher and hinged gravity cover to provide overpressure

relief

2. Feed nozzle and target box

3. Outlet nozzle to suit selected size of connecting device

4. Equalization line from rotary feeder (except for Bagging Silos)

5. Level transmitter – 6” 150# RF

6. Level switch high-high for product Storage Silos.

7. Nitrogen inlet –1” 150# RF

8. Temperature indicator – 1½” 150# RF (product Storage Silos only)

4.3.1.14.5 System D – Classification: This system covers the classification facilities and bagging hoppers.

4.3.1.14.5.1 Purpose: To package resins from blenders and bulk storage system after removal of oversize pellets, dust,

fines, snakeskin‟s, etc., through Product Classifiers prior to bagging from bag silos 1 & 2.

4.3.1.14.5.2 Classification and Packaging: There are two (2) separate classification systems. Both will take resin from either the blenders (System B)

or any two Storage Silos (System C). A bypass around each classification system is available to package

off colour resin lots or permit maintenance without plant shutdown. Clean product from the classifiers is

conveyed to the two Bagging Silos. Fines, chips, and angel hair are removed from these streams and

sent to waste collection bins.

4.3.1.14.5.3 General Description: The resin is sent to the either one of the two classification systems D1 or D2 from the blenders or the

Storage Silos. Resin pellets are directed into the Elutriators 31-ME-301 and 31-ME-302 at the top of these

vessels.



The Air Fans (31-K-313C/D) direct air through the incoming resin flows to help separate smaller particles

like fines, snakeskin‟s and angel hair. The other air fans (31-K-303A/B) entering the Elutriators near the top

assist in conveying these unwanted light end particles into the Elutriator Bag Filters 31-G-303 and 304

(see drawing below). These collected waste particles drop to the bottom for removal through the bottom Iris

valves to waste bins. The air from both blowers passes out the Elutriator Bag Filter vents to atmosphere.

Before passing out the top vents the air is cleaned of any air borne particles by the multi bag filters.

The resin flows by gravity leaving the Elutriator into the Elutriator Rotary Feeder (31-ME-308/309) passing

an inline metal detector (HV-5350 and HV-5352). The metal detectors having detected metal in the resin flow

would automatically swing a diverter valve to reject those pellets to waste collection. The inlet/outlet and

reject lines are all 16 inch in size. The first grade resin flows into the Product Separator (31-G 305/306)

and out to its Rotary Feeder ( 31-ME-310/311) and is carried by the Bagging Line Feed Blower ( 31-K-

314A/B) into its appropriate 200 tones capacity Bagging Silo for packaging.

Each Bagging Silo is equipped with a vent, a level indicator and high level alarms. Each vessel has a slide

gate on the bottom outlet.

A bypass is available to route incoming resin from directly to the Bagging Silos should operations not wish

to utilize the classification systems.

4.3.1.14.5.4 Elutriator Bag Filter:

The Elutriator Bag Filters have

A – 28” Air Outlet to atmosphere

B – 28” Air Inlet from Elutriator (cone flange) C – 20” Waste Product Outlet

D – 2” PDI Nozzle

E – 2” Instrument Air Inlet for the bag filter purges.

F – 2” Blinded Nozzle for future use

In addition to the above listing, there is a davit for the removal of the cover and bag filters and an

explosion panel on the side to protect the vessel.

The type FC 85 Bag Filters themselves are 2000 mm in length, 120 mm in diameter, each has a filter

area of 140 m2 while covered with an antistatic polyester filter cloth. There are 120 filters in total for each

unit.

4.3.1.14.5.5 Elutriators: The drawing below shows

A – 12” Product Inlet from system B& C

B – 16” Product Outlet to Rotary Feeder

C – 10”x2 entry points – Air Aspiration Inlet (2760 Nm3/h) D – 28” Air Outlet to Bag Filters

E – 20” Elutriation Air Inlet from blowers (1214 Nm3/h)

F – 1 ½ “ Level Indicator



4.3.1.14.5.6 Product Classifier: The product inlet line from the Elutriator Rotary Feeder has a 254 mm removable section that allows the

top aluminum cover to be removed. After passing across the inclined internal screens the good resin (proper

sized material) is discharged out the bottom centre. The large size material continues to the classifier end

to drop out the outlet to waste collection. There is a beater blanket at this discharge end to dampen the

vibration and prevent loss of good resin to waste. It also have a vent. The two cover also has inspection

view ports to check the screen condition.

The drive motor mounted to the unit provides the vibration movement to the screen deck supported by cable

and eyebolts. Screens and the general condition of these units should be inspected after each of resin to

ensure no hold-up of resin from one lot to another. The visual inspection is especially required when lots

with different specifications are sequenced through the classifiers.

System equipment and descriptions for D1 and D2 are in the following tables.

4.3.1.14.5.7 Equipment Descritption: Equipment No. Description Equip. Capacity System No.

31-ME-301 Elutriator #1 D1 31-G-303 Elutriator #1 Bag Filter D1 31-K-313A Exhaust Fan #1 2760 Nm3/h D1 31-K-313D Air Purge Fan #1 1214 Nm3/h D1 31-ME-308 Elutriator Rotary Feeder D1 31-G-305 Product Classifier #1 D1 31-ME-310 Product Classifier #1 RF D1 31-K-330 K-314A Blower Purge D1 31-K-314A 31-K- 314A Trans Blwr 7455 Nm3/h D1 31-E-314A 31-K-314A Water Cooler D1 31-V-320 Bagging Silo #1 D1

Equipment No. Description Equip. Capacity System No.

31-ME-302 Elutriator #2 D2 31-G-304 Elutriator #2 Bag Filter D2 31-K-313B Exhaust Fan #2 2760 Nm3/h D2

31-K-313C Air Purge Fan #2 1214 Nm3/h D2 31-ME-309 Elutriator Rotary Feeder D2 31-G-306 Product Classifier #2 D2 31-ME-311 Product Classifier #2 RF D2 31-K-331 K-314A Blower Purge D2 31-K-314B 31-K- 314A Trans Blwr 7455 Nm3/h D2

31-E-314B 31-K-314A Water Cooler D2 31-V-321 Bagging Silo #2 D2 4.3.1.14.6 System E – Bag:

The “E” system covers the Bag Slitting facilities and resin destinations to the four blenders; Recycle

Resin Storage Bin or the Reslurry Tank.



4.3.1.14.6.1 Purpose: The Bag Slitter and its pneumatic transfer system provides a way to move packaged material to

required destinations like the Reslurry Tank to provide a RA Stripper seal for initial start-up of the

vessel. Provides rework resin from the storage warehouse to the Satellite Extruder recycle hopper to feed

the Main Extruder for upgrade. This system also can be used to send rework resin back to the blenders

for blending or mixing with other materials or new production.

4.3.1.14.6.2 General Description: The Bag Slitter is located in the warehouse area near the bagging lines. This system comprises of the Bag

Slitter bin (31-ME-324), which has an operation platform with removable hand railing. The water-cooled

conveying blower (31-K-311) with a capacity of 3832 Nm3/h and ∆P of 0.54 kg/cm2 is the moving force for

the transfers. It has inlet filter and inlet/outlet silencers for area sound control. An inline expansion piece

looks after any temperature rise between the blower and the discharge piping. The blower discharge has a

PSV set at 1 kg/cm2g and a check valve downstream of this PSV to stop any water from entering the blower.

The blower sound enclosure has a purge fan that can be operated from the field or the DCS via its H/O/A

switch. The blower discharge temperature is controlled by the Blower Cooler (31-E-319) that is water-

cooled and protected by PSV-5408 set at 10 kg/cm2g. A temperature transmitter at the cooler discharge

gives a DCS indication for continued monitoring and a filter just prior to the Bag Slitter RF pick-up point.

The Rotary Feeder (31-ME-325) has a discharge view glass and air vent plus a bypass/remote/local switch

tied through interlock 3039X to the DCS. Field indication for this bypass switch, high and low levels of

the recycle bin, transfer blower run light and discharge blower pressure are all located on local panel. The

destination target selector has six positions for the pneumatic conveying piping back in to the process area.

Selector Switch HS-E-2 position Resin Destination

1 Reslurry Tank 31-V-309 2 Recycle Resin Storage Bin 31-V-318 3 Blender one 31-V-313 4 Blender two 31-V-314 5 Blender three 31-V-315 6 Blender four 31-V- 316

This system also includes the Recycle Resin Storage Bin (31-V-318) and its associated manual slide

valve and diverter installed under the Recycle Resin Storage Bin.

As mentioned, the platform mezzanine has a removable safety railing section to accommodate placement

of a pallet of bagged resin using a fork truck. The platform can also accommodate up to three operations

people to cut open these bags for rework of some fashion. The Bag Slitter will hold 5 tones of resin. The

resin type and classification will depend on its use at destination.

Resin can be sent to the Satellite Extruder recycle hopper for upgrading; to the Reslurry Tank to form a

seal in the RA Stripper for start-up and finally to any of the blenders for blending. This material is sent

via the Bag Slitter‟s blower and Rotary Feeder at 5,000 kg/h. High-level alarm interlocks at the recycle

hopper and blenders will stop the Rotary Feeder if triggered. Only the Reslurry Tank inlet does not have

interlocks associated with it to stop the Bag Slitter Rotary Feeder. The Reslurry Tank has a removable spool

piece and blind at the vessel top inlet that must be attached to transfer resin into 31-V-309.



The Bag Slitter hopper when not in use should have its cover closed to protect against dust and foreign

material entering the hopper.

Equipment List utilized in System E:

Equipment No. Description System No. 31-E-319 Bag Slitter Blower Cooler E 31-V-318 Recycle Resin Storage Bin 18 tonnes capacity E 31-ME-325 Bag Slitter Rotary Feeder 5 t/h capacity E

31-K-311 Bag Slitter Conveying Blower 3832 Nm3/h capacity E

31-K-332 Bag Slitter Conveying Blower Enclosure Purge Fan E

31-ME-324 Bag Slitter Hopper 5 tone capacity E 4.3.1.14.7 System F – Resin Samplers: Process resin samples need to be collected at various locations for laboratory analysis. To do this job,

resin samplers placed throughout the resin transfers areas, collect and transport pellet samples known as

dribbler or grab samples to the laboratory directly.

There are two types of resin samplers:

• Automatic is an air operated tube device that extends into the resin flow to catch a small

sample from the passing resin stream at a pre-determined timed interval or as activated from the lab

panel.

• Manual a hand operated, tube device, which can be pushed into the resin stream, at any time to

collect a sample into a handheld container.

Conv

Line No. Sampler No. Location Location

Vessel No. Associated

Line HV

Sampler Type

Lab Sample

Cyclone

Conveying

System

Local S-308X Delumper Unit Exit 31-G-301 Manual

1 S-301X Delumper Unit Exit 31-G-301 Automatic 31-V-322 Main Blower

31-K-333

2 S-309X RA Stripper Outlet 31-V-310 HV-4661 Automatic 31-V323 Vent

Cyclone

31-V-328

3 S-310X PHUT Outlet 31-V-317 HV-4662 Automatic 31-V-324

4 S-302X Blender 1 outlet 31-V-313 HV-5071 Automatic

CRB 50

31-V-325


CRB 50

31-V-325


CRB 50 31-V-325


CRB 50

31-V-325

5 S-306X Product Classifier 1

discharge

31-G-306 HV-5390 Automatic 31-V-326

6 S-307X Product Classifier 2

discharge

31-G-307 HV-5391 Automatic 31-V-327



4.3.1.14.7.1 Sampler System Equipment Description: The sample resin pellet transfer is handled through a pneumatic conveying system. These small resin

samples are transported to a central collection location at the laboratory room. The resin sampling

collection can be accomplished through either continuous-dribble type, or batch-manual or automatic time

activated. Once the sample is collected, a remote or locally controlled diverter valve directs the resin pellet

sample either to the local collection "film tube sock" or to the pneumatic conveying system where the sample

is automatically conveyed to a central collection point. The blenders operate to collect and convey the

pellet sample from one blender at a time. One can temporarily override automatic sample sequence to

obtain a locally delivered grab sample.

The pellet sample pneumatic conveying system includes a separate conveying line for transporting

pellet samples from: the Delumper/Spin Dryer Unit, the RA Stripper discharge, the Spin Dryer Hold-up Bin

RF discharge, each blender RF discharge area (one line to the collection cyclone), and the two classification

systems product discharges.

Separate conveying lines (all but the blender transfer line) insure that cross contamination of samples is not

possible and that the system has the capacity to simultaneously deliver continuous samples from all of the

conveying systems.

4.3.1.14.7.2 Principle of Operation: The automatic sampler can be switched on or off should you not wish to collect resin. When turned on,

the sampler is controlled by an adjustable timer. The product sampling frequency is locally adjustable using

its timer, from continuous to once per hour.

When the timer reaches zero, a circuit is completed and a solenoid is energized on top of a 4-way valve

located by the sample point. The movement of the solenoid directs air into an air cylinder that then extends

the pick-up tube into the flow of resin. A time delay relay is preset to give a dwell time in the resin flow of

approximately (2) seconds. When the dwell interval has passed, the relay activates the solenoid again and

the pick-up tube is retracted. Once retracted the resin sampler has an outlet for the resin into the

conveying transfer system. The air from the air cylinder is vented into the sample line that has a vacuum to

convey the resin to the sample cyclone outside the laboratory building. The vacuum blower (31-V-333)

provides the force to pull/carry the resin to its destination.

At the sample collection area, the resin enters a cyclone where the vacuum system air is vented overhead

through a 4” line to an 8” collect header to dust collector 31-V-328. From the cyclone, the resin falls into the

sample collection bag inside the laboratory. Lab personal collect the sample, mark its content and

proceed with the required testing.

The manual sampler, activated locally, located on the delumper spin dryer outlet downcomer and

operated locally by the operator, collects resin in a plastic baggy attached to end of the sampler discharge

spout. This is operated by simply pulling the handle or if air operated – using the field switch – which inserts

the pick-up tube into the flow of resin. When the baggy is full, the handle is pushed back in to withdraw the

pick-up tube.



4.3.1.14.8 Pneumatic Conveying Program Scope: 4.3.1.14.8.1 Overview: First, it should be realized that fines and snakeskin generation could never be totally prevented. Newly

treated conveying piping will last for approximately 6-8 months after start of production before signs of resin

degradation start to appear. Using proper operating procedures and a well thought out inspection and

maintenance program, fines and snakeskin creation can be minimized to an acceptable level. This program

should be put in place at the start of plant production and base line evaluations of the conveying system

should be established.

The Pneumatic Conveying Package has many different areas to inspect, monitor and maintain to provide

the downstream customer with a quality resin product. In the following write-up, equipment, piping and

procedures are reviewed so IOCL can put corrective actions into place at production start.

The following is only the first step in a system that should provide customers with a consistent quality

product while the later will be a scheduled maintenance program to continually monitor the plant.

The following is broken into different areas for follow-up:

1. Production

2. Blenders

3. Blender associated equipment

4. Blender services - Wash Water System

5. Conveying piping

6. Storage Silos

7. Classification systems & their associated equipment.

4.3.1.14.8.2 Production: Production of fines, twins, and clusters at the melt cutter can add extra load to the classification system

and increase levels of waste polymer produced. Therefore as part of an overall product quality program,

close attention must be paid to proper procedures and practices to help minimize production of fines, and

clusters. Close attention in this area, while not directly related to snakeskin production, will help with the

overall efficiency of operation of your resin handling system, and ultimately improve the quality of your „as

packaged‟ product. Economically, this is time and effort well spent, as waste not produced does not have

to be removed, thereby helping to augment ultimate capacity of the pneumatic conveying system. The

underwater pelletizer cutter should be maintained such that you are producing a consistently similar sized

pellet (~42 ppg), free of chips and without agglomerates. Good LPS control (temperature, pressure, levels

and movement), steady extrusion rates (with vent devices optimized) and quick corrective action during

any upset conditions are also important, and will increase your ability to further minimize waste production.

4.3.1.14.8.3 Blenders (31-V-313, 31-V-314, 31-V-315, 31-V-316): Over time friction produced by pellets rubbing against the aluminum/stainless steel blender shells will result

in deposits of polymer on the internal vessel walls, blend tubes and support structure. These polymer

deposits must be washed off to minimize and control this build-up. To help minimize the rate at which



deposits occur, it is important that operating temperatures and airflows in the vessels be maintained within

design parameters. Periodic inspections are necessary and should be part of the operation and

maintenance procedures. Remember that continuous or long-term movement of resin against aluminum

will cause rubbed dark markings to appear on the resin.

Damage to the vessel such as bent inlet deflector plates or indents to the conveying lines; plugged

aspiration vents; excessive blending times; high conveying temperatures and increased conveying

system pressure (and therefore increased terminal velocities) are all contributors to the production of resin

degradation.

• Vents

These blender vents are by design 50 % larger than required but still should be kept clean, as part of a

regular maintenance program. Nothing should impede the flow of dust and other contaminants that might

be carried with the aspirated air out through these vents. It should be noted that if you don‟t make a pellet

chip initially at the cutter, then there will be a substantially reduced amount of dust generated and regular

maintenance will be easier to perform. Should visual inspection indicate larger amounts of dust or

snakeskin’s exiting from these vents, the inspection should increase at this end of the pellet handling

system.

4.3.1.14.8.4 Blender Associated Equipment 4.3.1.14.8.4.1 Blower • Blending Blowers (31-K-303, 31-K-304, 31-K-305, 31-K-306) • Purge Air Blowers (31-K-307, 31-K-308, 31-K-309, 31-K-310) All the blowers should be monitored for high bearing temperatures, which can add to the generated

temperature of compression and go undetected for some time. The proper pressure should also be

maintained as we get approximately 7°C rise for each 0.073 kg/cm2 or (1 PSI) of pressure increase.

The typical system design pressures on a 28 m/s system are about 0.32 kg/cm2, and roughly 0.44 kg/cm2

on a 30.5 m/s system. It should be remembered that this temperature is in addition to ambient

temperature, which often is very high. Product to air ratio on a mass flow basis should be approx. 8:1,

with an upper range dictated by avoidance of slugging in the lines, but typically not exceeding 12: 1.

Product temperature during blending and drying is set at 85°C; this temperature should be reduced

to a maximum of 50°C (preferably, less than 38°C) during unloading operations. Note that it is optimum to

have the resin temperature as low as possible prior to starting the unloading of the blender. A lower pellet

temperature helps to avoid softening of the pellet. If the resin is too hot and the pellet becomes softened,

the level of snakeskin generation is increased. If the pellet is soft and sticky it may also get held up

in the product classification system screens, increasing waste levels, and reducing the efficiency of the

waste removal system.

Make sure that the purge air heaters and blend blower heater/cooler LP steam temperature valves are

properly closed during the cool down cycle. Any steam passing from these valves directly result in

increased heat levels that you are trying to avoid.



4.3.1.14.8.5 Blender Services – Wash Water System: Inspection is a key to the quick correction of internal polymer build-up as well as any possible physical

damage to the blenders. Maintaining and using the wash water at design pressure for the required

blender wash time period will help to significantly reduce the possibility of resin cross contamination.

Remaining pellets, dust, streamers and snakeskin’s, left in the blender after unloading are flushed out of the

blender. Periodic washing of the uppermost regions of the blender should also be done (using a service

hose), as the wash nozzle spray does not reach all of this area.

These wash water streams are meant to clean the vessel internals, walls, portioned blend tubes and the

bottom cone. Water exiting the Rotary Feeder is directed to the blend leg so that it is also flushed prior to

empting all the water to grade / trench. Done regularly, washing will help to minimize the rate of build-up.

Remember that lower density resins are softer/ greasier than others and tend to leave larger deposits, and

therefore require more frequent attention.

4.3.1.14.8.6 Conveying Piping: The conveying lines are seamless aluminum lines or SS with stainless steel elbows. One of the key

contributors to the formation of snakeskin’s is a pellet rubbing against smooth walls and elbows. The most

effective way to combat this is to “shot peen” the conveying pipes on a regular schedule. Aluminum

pneumatic conveying lines without an internal treated wall will only last approximately 6 months before

signsof degradation or physical breakthroughs (holes in the conveying piping) occurs. The treated piping

lasts longer and this extended life could reach an additional 3-6 months. The direction of treatment should be

in the same direction as the travelling process flows as this will provide the best life of the piping. Installing in

the reverse direction will in fact reduce expected treatment life and induce resin degradation sooner. As the

shot peening process slightly erodes and abrades the internal pipe wall, the condition and thickness of the

line will require inspection. Based upon this inspection, it would be decided whether a section of line can

be re-shotpeened, or if conveying pipe replacement is necessary. It is normal that after a number of

years of wear, some pipe and fitting segments will require replacement.

4.3.1.14.8.7 Storage Silos (31-V-325A/B/C/D/E/F): These vessels don’t have water wash capabilities but still need to be inspected and cleaned periodically. If

washing is required then a utility hose can be used through the top manway. During inspection, don‟t

overlook the target boxes for build-up of resin, and clean as required.

To do this safely, the operator and/or maintenance person must use a safety lanyard and tie off while

cleaning.

If the resin entering the Storage Silos from the blenders is too hot, it will retain this elevated temperature

for a considerable period of time (several days to weeks) and will slowly degrade the resin. High ambient

temperature as well will add to the cool-down problem. Elevated resin temperatures will contribute to the

formation of snakeskin’s during transfers out of the Storage Silos.



4.3.1.14.8.8 Classification Systems & Their Associated Equipments:

This system uses air aspiration to remove dust, light steamers and snakeskin‟s so therefore the filters

throughout need to be cleaned. Clean or replace the filters on the system as required. Inspect the Elutriator

1&2 Bag Filter dust socks to ensure that the air purge is cleaning them and that all the socks are in

place (these do come apart sometimes and the cleaning efficiency will be reduced if this happens). The

Instrument air pressure to the socks should also be checked. The Product Classifiers should be cleaned

after each lot of resin. Product Classifier vibration adjustments will help complete the proper separation.

4.3.1.15 Area Skim Sumps 4.3.1.15.1 General Description Two of the plant collection/skimming facilities is available in the plant, 31-LZ-301 (the Finishing Area Skim

Sump) and 31-LZ-302 (the Storage and Warehouse Area Skim Sump).

31-LZ-301 (the Finishing Area Skim Sump) normally accumulates oil-free resin pellets that can be

reclaimed and sold as sub-grade resin.

31-LZ-302 (the Storage and Warehouse Area Skim Sump) this collected effluent is not treated in the

Waste Water Treatment Plant due to the large volumes possible from rain water (particularly large during

monsoon season)

4.3.1.15.2 Operation Description:

Both 31-LZ-301 and 31-LZ-302 are the same size and operate essentially the same. Source effluent

flows of rain, blender wash water, area cleaning flows and resin from area drains/spills or even plugged line

clearings are all directed to the area sump.

These flows enter at one end of the sump via an 18” pipe which empties into an inlet weir area. The

solids or floating material is held back while the liquids water / solvents pass the concrete weir. These

liquids (and whatever passes the weir) move towards the discharge end of the ~3000x7000 mm area sump.

The discharge end of the sump has 12”rotating Skimmer pipe with notches cut into one side. The skimmer

can be rotated (from operating platform) using handle fixed to the top to open / close opening area of

skim flow which discharges resin (collected from the surface) out the end of the piping into a skim sump. The

skimmer has a stationary end at this discharge. Effluent also flows under the skimmer to the underflow

baffle and then over an outlet weir to the 18” outlet piping. A 600x600mm pump pit is just inside of the

weir for removing heavier flows if required.

The skim sump has an 8” standpipe with foot valve assembly to drain excess water and adjust the level

in the sump. (This foot valve assembly is removable for any maintenance work). The standpipe foot valve

assembly allows water to exit this skim sump area flowing to the main 18” outlet piping. Solids / resin are

retained within the sump and are separately pumped out for reclaim and sale. A hand railing for safety should

enclose sump area.



4.4 ISBL Utilities and Storage 4.4.1 Plant Air: Plant air is supplied throughout the operating areas from a source OSBL. The supply line is equipped with a

pressure and temperature indicator, and a flow totalizer.

4.4.2 Instrument Air: Dried instrument air is supplied from OSBL for use on pneumatic instruments and equipment within the plant.

The supply line is equipped with temperature and pressure indicators, and a flow totalizer.

The supply line is routed to an instrument air holder to proved emergency air backup.

The instrument air line has an emergency instrument air backup system.

4.4.3 Pulldown Valve Air Supply:

The air supply to the pulldown valves is an Emergency Air Supply system to ensure that these emergency

valves can be operated when required. Instrument air tubing to the Pulldown valves is made of steel to

delay failure in case of a fire.

4.4.4 Nitrogen: Nitrogen is used throughout the areas for purging of equipment, pressure testing, emergency response and

pressurising of catalyst and additive tanks. The nitrogen header must be dry (less than 10 ppm water)

before being put in use, as water is a catalyst poison.

The nitrogen supply line from OSBL is equipped with a temperature and pressure indicator, and a flow

totalizer. There are 4 HP DTA heated Nitrogen Heaters that are used for hot purging of equipment. The

heated nitrogen is more efficient for purging solvent vapours. The nitrogen supply lines to the Liquid Additive

Tanks and the Catalyst Tanks are each equipped with Pressure Control Valves. The nitrogen supply lines to

each of the Flare headers are equipped with a rotometer. 4.4.5 Service, Demineralised and Potable Water: Service, Demineralised and Potable water are supplied from OSBL.

The Service water is used in applications where contaminants are not an issue. The supply line is equipped

with a flow totalizer. Potable water is used for addition to reservoirs or equipment systems where cleanliness

is important. Potable water is used for drinking water and emergency backup to critical equipment systems.

A flow totalizer is located on the supply line. 4.4.6 Cooling Water and Emergency Cooling Water: Cooling Water is used for heat exchanges. The supply line is equipped with a temperature indicator and a

flow totalizer. The cooling Water Return line to OSBL is also equipped with a temperature indicator.

Emergency Cooling Water is supplied for the LPS Condensers and the Reactor Agitator Cooler.



4.4.7 Boiler Feed Water: There are two type of Boiler Feed Water: High Pressure and Low Pressure.

Boiler Feed Water is supplied from OSBL and is used to desuperheat the High Pressure Steam. The supply

line from OSBL is equipped with a flow totalizer.

The HP Boiler Feed Water is supplied to the LB Column Feed Condenser and the HB column Condenser

from the Condensate Drum. These condensers provide Steam for distribution.

4.4.8 Dowtherm System (Ref. PFD 00401-DA-31-0133 and 00401-EA-31-0134) Dowtherm “A” is a eutectic mixture of two very stable compounds, diphenyl (C12H10) and diphenyl oxide

(C12H10O). These compounds have practically the same vapour pressure. Its vapour phase is used as the

high temperature heating medium in the plant. There are two Dowtherm Vaporisers (31-LM-401 A/B), each

at 60% of the required total capacity. They are used to supply HP DTA vapour at nominal pressure of 4

kg/cm2g to the high temperature uses, which includes the adsorber preheaters (31-E-105 A/B). The

condensate from the high pressure users is collected in the HP DTA condensate drum (31-V-406) and

returned to the DTA vaporisers. The vapours from HP DTA condensate drum is the LP DTA vapour and is

used for high temperature heating duties in the recycle area, namely the LB Reboiler (31-E-203) and the RB

Reboiler (31-E-208) where somewhat lower temperatures are required. The condensate from these users

goes to the LP DTA condensate drum (31-V-410). This drum operates at 0.1 kg/cm2g. Flash vapour from

the LP condensate is minimal due to subcooling in the LB and RB reboilers. The condensate is returned to

the vaporiser by the LP DTA condensate pump (31-P-407 A/B). Inerts are vented from the DTA vaporisers

under pressure control, to the DTA vent recovery system.

Intermittent vents from DTA using equipment throughout the plant together with DTA vapour from the DTA

regeneration vessel (31-V-408) pass under vacuum to the DTA vent condenser (31-EA-401). Condensed

DTA and uncondensed inerts flow to the DTA vent receiver (31-V-407). The temperature of the condensed

DTA in this vessel is raised with the tank heater (31-E-404). This thermally strips any dissolved lighter

components from the condensate. The condensate collected in this vessel is pumped back to the LP DTA

condensate drum (31-V-410) with the DTA transfer pump (31-P-406 /S).

The vapour stream from the DTA vent receiver is cooled in the DTA vent pot condenser (31-E-412) and sent

to the DTA vent pot (31-V-409) where condensed DTA and its degradation products are collected. The

vapour stream from this pot consists of lighter degradation products and inters such as nitrogen. This

stream is exhausted to atmosphere by the DTA vent vacuum ejector (31-J-401).

DTA storage capacity is supplied by the DTA storage vessel (31-V-413). DTA collected in the vent receiver

and the inventory in the DTA storage vessel can be transferred to the LP condensate tank or the HP DTA

condensate drum by the DTA transfer pump.

The DTA vaporisers are fired on fuel gas, fuel oil and by waste materials from the process. The principal

waste material is RB, which passes continuously from the base of the RB column directly to the vaporisers.

A significant proportion of the total DTA vaporiser energy requirements are met by these waste material

streams. By-products from the SH purifier (31-V-125 A/B) regeneration is received intermittently from the



plant into the waste fuel drum (31-V-411). This waste material is fed to the vaporisers by the waste fuel

pump (31-P-412/S). Waste from the additives area can also be fired via the waste drums (31-v-306 A/B).

Periodic high boiler removal from the DTA is carried out by purging liquid DTA from the vaporisers to the

DTA regeneration vessel (31-V-408). DTA vapours are used for heating, and the purified vapour passed to

the DTA vent condenser for recovery. As well, the hot DTA condensate from the DTA regeneration vessel

heater (31-E-403) is also sent to 31-E-401 for sub cooling and recovery.

NOTE: For details of Vaporiser, refer vendor’s Operating Manual.

4.4.9 Steam and Condensate System (Ref. PFD 00401-AA-31-0130)

High pressure (HP) steam from battery limit is desuperheated and let down to normal pressure of 42

kg/cm2g, and supplied to different sections of the plant.

The HP Steam is supplied to the following Equipment:

• Reactor Feed Heater (31-E-103)

• LB Feed Condenser (For Start-up) (31-E-202)

• HB Column ReboilerS (31-E-205A/B)

• LB Feed Heater No. 2 (31-E-206)

• Steam Purge Heater (31-E-106)

• SH Make-up Dryer tracing (31-V-126)

• Polymer Knockout Drum Tracing (31-V-405)

• Extruder Vent Device Tracing

• LPS KO Pot Tracing (31-V-119/120)

• Reactor #1 and #3 Tracing

Medium pressure (MP) steam is generated at 15-24 kg/cm2g, depending on process conditions in the LB

feed condenser (31-E-202) and is used within the plant for the HB Reboiler (31-E-205 A/B) during FB and

homopolymer resin runs. Any surplus MP steam is letdown into low pressure (LP) steam header.

The condensate from the HP steam users is sent to the HP steam condensate drum (31-V-402). The flash

steam generated in the drum is used as LP steam. The condensate is pumped to the LB feed condenser

(31-E-202) for ISBL MP Steam generation. A booster pump is provided to supply condensate to the battery

limit HP steam desuperheater.

Some MP steam at approximately 17 kg/cm2g is required mainly for tracing duties. This small quantity could

be obtained from letting down HP steam.

Low pressure steam at 4.6 kg/cm2g is generated in the plant by the HB condenser (31-E-216) and by letting

down MP steam. This steam is employed between various users in the plant and any shortfall is made up by

letting down HP steam. Excess LP steam will be exported. LP steam will be imported at 4 kg/cm2g only in

case of a cold start-up or an upset condition.

Part of LP steam is superheated in the DTA Vaporisers (31-MA-401A/B) Steam Coil and Exported to OSBL.



Low pressure condensate from the LP users is collected in the LP steam condensate drum (31-V-403).

Condensate from this vessel is pumped by the LP steam condensate pump (31-P-402/S) to meet feed water

requirements for the HB condenser (31-E-216). Any surplus will be exported.

4.4.10 Flare System (Ref. PFD 00401-BA-31-0131) The ISBL flare system includes two K. O. D.

Polymer KOD (31-V-405) and Flare KOD (31-V-404)

The polymer KOD received discharges from all pressure safety relief valve (PSV) connected to the polymer

flare header. These PSVs protect equipment and piping which contain polymer solution and could relieve

molten polymer into the flare system. To prevent the molten polymer from congealing in this system both the

polymer flare header and the polymer KOD are traced with HP steam to maintain pipe wall temperature

about 140°C.

Discharges from the PSVs of the additives system are also connected to the polymer flare because the

additives may precipitate if cooled significantly below 70°C.

The Polymer flare header will be built in sections so the header can be disassembled and cleaned in case

there is a massive release of polymer into the flare system. The header should be laid out so that the

sections can be easily removed from the pipe rack.

Vapour from polymer KOD, as well as all other hydrocarbon releases, is fed to the flare KOD. This drum

also receives a liquids drained into the “Liquid Pulldown” header. The purpose of this drum is to separate

liquid from relief vapour which goes to the OSBL flare stack. Liquid hydrocarbon collected in the drum is

recovered by pumping it to the LPS hold-up tank in the Recycle area using the flare KOD pump (31-P-404).

The primary design consideration is to minimise the elevation of the flare header and, thus, the elevation of

the flare KOD. The elevation of the drum does not provide sufficient NPSH to transfer boiling liquid during

relief.

The drum has a boot which makes it possible to separate and drain water before hydrocarbon transfer. The

flare KOD is equipped with heaters (31-E-405A/B), which prevents freezing of the contents in the winter but

may also be used for boiling off light hydrocarbons such as FB.

Nitrogen purge and a fuel gas purge are be provided to the end of all the headers and sub headers in the

flare system of the PE plant to maintain a gas sweep in the headers and prevent ingress of air. The system

will also have a vacuum breaker which lets in nitrogen in the event that the system pressure approaches

atmospheric pressure.

4.4.11 De-inventory Storage (Ref. PFD 00401-CA-31-0132) The inventory of SH, FB-1 and FC-1 in the PE process depends on the type of resin being made. When the

product grade is changed, it is sometimes necessary to adjust the inventories of these chemicals. The PE

plant has three de-inventory systems which allow such adjustments as well as for a total de-inventory for

maintenance shutdowns:



• SH de-inventory system

• FB de-inventory system

• FC de-inventory system

4.4.11.1 SH de-inventory System SH de-inventory tank (31-T-401) has been provided to accommodate all of the solvent inventory of the plant

assuming vessel levels in Reaction and Recycle area have been reduced to minimum operating levels prior

to a shutdowns. The remaining solvent can then be transferred to the SH de-inventory tank from the LPS

hold-up tank (31-V-201) using the LPS condensate pump (31-P-201/S). A high temperature interlock

prevents transfer of solvent if its temperature is too high.

The plant may be re-inventoried with solvent from the de-inventory tank by the SH de-inventory pump (31-P-

410) which pumps solvent back to the LPS hold-up tank. SH de-inventory pump is used intermittently and

therefore it does not have a spare.

The SH de-inventory tank can be operated at pressures up to 100 kPa (g). Because the tank is vented to

atmosphere, this design minimises atmospheric emissions. The tank is blanketed with nitrogen. It also has

external heating panels which prevents SH from freezing during winter months. Because SH may contain

water, facilities for draining settled water from the tank have been provided.

4.4.11.2 FB De-inventory System The inventory of FB can be adjusted by changing the level in the FB surge tank (31-V-415). This is a

horizontal bullet sized to accept the entire FB inventory from the plant assuming vessel levels in Reaction

and Recycle areas have been reduced to minimum operating levels prior to a shutdown. FB surge tank is an

active part of the process and inventory; adjustments can be made on the run.

Feed to the FB surge tank comes from four sources:

CM reflux drum (31-V-206); OSBL storage; FE column (31-C-204) bottoms (NNF);

CM column (31-C-205) bottoms (NNF)

These streams are combined upstream of the FB de-inventory cooler (31-E-401) which cools the mixture to

50°C or less. The liquid level in the tank is controlled by adjusting the fresh make-up from OSBL. Its level

should be monitored regularly to avoid the starvation of FB Feed pump and its spare (31-P-411/S). The level

is normally maintained low so that sufficient room for the inventory of the process is available. Normally, FB

from the surge tank is pumped to the LP column system by the FB feed pumps (31-P-411/S). This is done to

ensure that the FB-1 is purified before it is fed to the reaction area. Since the flow rate varies significantly,

the pump has been protected by a minimum flow bypass. The bypass flow also passes through the FB de-

inventory cooler.

Ensure/confirm (by taking sample of FB) that the fresh make-up from OSBL is of high quality and does not

need purification. Fresh make-up FB from OSBL may be fed directly from the FB surge tank to the CM reflux

drum thus bypassing the FE column feed dryers and the FE column. A line with manual controls has been

provided to support this option. The same line is used for start-up as well.



4.4.11.3 FC Storage and De-inventory System In order to permit the change-over from FB copolymer production to FC copolymer production, and back

again, the FC de-inventory tank (31-V-414) has been provided to accommodate the FC inventory. This is a

horizontal bullet maintained under nitrogen blanket. The FC de-inventory pump (31-P-409) is used for

transferring the material back to process when required. Both de-inventory and re-inventory is done via the

HB column.

FC-1 must be stored under nitrogen blanket. Oxygen reacts with FC-1 to form peroxide which is self-

catalyzing catalyst poisons. If FC-1 is not shipped in nitrogen blanketed containers a possibility exists that

FC-1 contains peroxides. In such a case, purifiers are provided to remove any peroxide or inhibitors that

may be present.



SECTION-5.0 PRE-START CHECK



BROAD GUIDELINES FOR CHECKING A UNIT FOR COMPLETENESS (CHECK- LISTING)

5.1 CHECK LIST FOR COLUMNS, REACTORS AND VESSELS

Sr. No. JOB DESCRIPTION

1. Check whether the hydraulic test is taken before erection.

2. Check internals like trays, baffles etc. are not damaged.

3. Check that the platforms for safe operations and maintenance are provided. Platform should have

toe-guard. Steps of the staircase should have proper risers and be sure there is no chance of

falling. All opening in the platform to have guard chain.

4. Check the safety valves and see that they are at proper settings.

5. Check for installation of all instruments.

6. Check the column/reactor/vessel against P & ID and data sheets, demister, vortex breaker, weep

hole, distributors etc.

7. Check column trays.

8. Check that the quantity of catalyst and packing is exactly what is required for packed columns and

reactors.

9. Check the catalyst is not damaged.

10. See that the expansion provision as per drawing.

11. See that sight glasses are properly fixed.

12. Check grounding of vessels/column.

13. Check completion of fire proofing as per drawing.

14. Check blinding of all spare nozzles with proper rated blinds.

15. Box up manholes after clearance that no internal shipping materials remain.

16. Check supports (e.g. spring) for cold and hot setting at appropriate time.

17. Check the insulation as per the specification.

18. Check that all valves. Specially instrument drain valves and root valves are approachable from

working platform.

19. Check all gauges are visible from the grade.



5.2 CHECK LIST FOR HEAT EXCHANGERS Sr. No.

JOB DESCRIPTION

1. Ensure gasket on the main flange joints and floating head joints are changed to the specified ones

for the process (as per datasheet).

2. Ensure from records whether hydraulic test has been conducted on each head exchangers.

(Medium of test, air blowing/draining).

3. Ensure the exchange is properly supported, sliding surface/slot be cleaned.

4. In case of high temperature service, ensure that there is provision of full expansion on shell side

e.g. expansion bellows or roller support etc.

5. Check the equipment is properly earthed.

6. Check there is a provision for draining and venting on the shell side/tube side, and drain valves

are blinded properly (rating: stud/bolt specification, gasket etc.)

7. Check for proper installation of necessary instruments and safety valves/TSV.

8. Check completion of fire proofing and insulation as per drawing and specification.

9. Check whether the exchanger lay out is proper from maintenance points of view.

10. Check equipment Tag no. and compare with relevant data sheet.

11. Ensure that strainers are mounted in the streams of cold box.

12. Ensure that blinds on nozzles of cold box are removed only after completion of flushing activities.

13. Ensure that PID indications across inlet stream strainer of cold box are mounted at grade.

5.3 CHECK LIST FOR FANS AND BLOWERS

Sr. No. JOB DESCRIPTION

1. See that fan/blower is free to rotate

2. See that the following bolts are not loose.

3. Check the bearings, grease/oil them properly

4. Before Fan/Blower is coupled to the driver, take trial of the Driver and check its direction of

rotation.

5. Check the alignment. See that levels are in position after final alignment work is over.

6. See that Dampers are in working order and are in correct position.

7. See that the ducts are supported.

8. Check that the expansion joints are leak-proof and are not made to carry the load of the ducts.

9. Check that the ducts are clear of any foreign material.

10. After carrying out the above activities and when the machine is clear for trial just start and stop the

fan/blower. See that there is no undue vibration.

11. Check equipment tag no and compare against date sheet.

12. Ensure that all fittings supplied by vendor are in proper condition, e.g.

Oil/grease cup, Damper operating handle, Coupling guard, Suction strainer/cage etc.

13. Check accessibility of ON/OFF push buttons/switches.



5.4 CHECK LIST FOR HEATERS Sr. No.

JOB DESCRIPTION

COILS

1. Check for any mechanical damage to the coil.

2. System should be hydraulically tested before putting into service.

3. External/Internal cleaning of the tubes/coils.

4. Check thickness measurements from records at reference points for future comparison.

5. Check whether the supports are proper.

6. Check the coil for fouling inside by blowing air or steam.

7. Check there is no product leakage from any joint.

8. Check location of Metal Temperature thermocouples and their installation.

REFRACTORY

9. Check the expansion joint.

10. Check for any damage to refractory.

11. Ensure proper drying out of refractory is carried out.

12. Ensure that floor bricks are loose and the gaps in between are not filled up.

13. Ensure cleanliness inside prior to box up.

GENERAL (HEATERS)

14. Check the dampers for freeness and correct positioning and confirm open/close position

indication.

15. Check provision of condensate drains/traps on purging steam and atomizing steam line.

16. Ensure correct burners are installed and burners/tips are of the correct size and type: Check that

air registers are operating freely.

17. Check that the purging system is working normal.

18. Check that the air path and gas path is clear.

19. Check that the blower is working vibration free and running normal.

20. Check that the explosion doors/windows are in order.

21. Check the instruments and the control valves are properly working. Safety valves installed after

testing and flushing.

22. Check that there is not steam leakage around the firing system.

23. Check installation of Soot Blowers and freeness of motion as per drawing. They should be kept in

retract position by hand operation; ensure lubrication prior to operation.

24. Check platform is provided for easy accessibility. There should be two escape routes normally

from an elevated operating platform.

25. Inspect the internals of the heater before boxing up.

26. Necessary drying out temporary connections to be done.

27. Check all nozzles, piping and instrument as per P&ID.

28. Ensure cleanliness of header boxes: header box cover to be removable type with asbestos-gasket

to prevent air leakage.

29. Check venturi nozzles of burners and pilots for choking and general cleanliness.



5.5 CHECK LIST FOR AGITATORS AND MIXERS

Sr. No.

JOB DESCRIPTION

AGITATOR/MIXER/VESSEL

1. Check the foundation bolts of the vessel.

2. Check that gasket below bearing mounting stool is provided.

3. Check that bolts of bearing mounting stool are firm.

4. Ensure that alignments (between gear reducer and vertical shaft) are checked and are correct.

5. Lubricate (as recommended) gear reducer and bearings fitted on bearing counting stool and check

leakage. This should be done prior to turning of shaft (alignment).

6. Check the alignment from records between gear reducer and main drive.

7. Check the mechanical seal (if used) and disconnect any piping made for flushing.

8. Check the guard on coupling and on `V’ Belts, if provided.

9. Fit impeller blades and tighten the bolts.

10. If right coupling is provided on shaft in the vessel ensure that there is no clearance between the

couplings.

11. Check that all the bolts on agitator blade rigid coupling, inside the vessel are fitted with lock

washers.

12. Ensure proper fixing of the bottom bearing, if any.

13. Check for proper accessibility for the removal of mechanical seal.

SEAL FLUSHING ARRANGEMENT

14. Clean the oil tank with water first, drain, dry and then flush with oil.

15. Rotate the pump by hand.

16. Plug the drain cock of the tank.

17. Clean the level gauge of the tank.

18. Put flushing liquid in the tank and cover the manhole.

19. Flush the connecting pipes prior to oil filling.

20. Commission the seal flushing oil cooler, if any.



5.6 CHECK LIST FOR CENTRIFUGES

Sr. No.

JOB DESCRIPTION

1. Check the centrifuge and connected lines, valves erected as per drawings/specified as per

supplier.

2. Check for proper fasting of foundation bolts of centrifuge and its drive motor. Also check the fixing

of foundation pads.

3. Check proper fixing of flexible line connections. Also check whether all connecting lines are

supported.

4. Check that the gaskets are in position and bolts properly tightened.

5. Check the lubrication system.

In case of lube oil system

i). Check the lube oil tank, its drain and event connections.

ii). Get it cleaned thoroughly.

iii). Check bearing oil inlet and return line connections flushed, cleaned and dried.

iv). Check the lube oil cooling water connections and test it for any leakage.

v). Check and clean the lube oil filter.

vi). Check the free rotation of lube oil pump and its drive motor.

vii). Check whether electrically connected.

viii). Fix up all instruments in position.

ix). Fill up the oil in oil tank upto mark.

x). Start the oil pump for trial run, control the lube oil press and check for any oil

leakage and check the return flow of oil, through sight glass.

6. Check the direction of centrifuge motor and correct it if necessary.

7. Check for free, manual rotation of centrifuge.

8. Couple the centrifuge with driver motor or fix-up `V’ belts (as per the arrangement).

9. Check the tightness of `V’ belts and its drives, sliding arrangement and put a guard on `V’ drive.

10. Open all inspection covers and fix it back after completing inspection with proper gaskets.

11. Check the fixing and operating of over-load protection system.

12. Check the safety trips device for low lube oil press, over-load torque etc.

13. Flush the fluid coupling with oil and fill up the oil as specified by supplier up to required quantity.

Also check the safety fusible plug in position.

14. Check any oil leakage from oil seals. If necessary, replace the oil seal.



5.7 CHECK LIST FOR PUMPS

Sr. No.

JOB DESCRIPTION

1. Check installed pump and motor are suitable and meets the operating requirements. Check the

test certificate if in doubt.

2. Check the earthing of motor.

3. Check the tightness of foundation bolts.

4. Check the no load current of the motor. Ensure the alignment of coupling is within tolerance.

Check for an alignment record.

5. Ensure lubrication of bearing prior to turning of shaft (alignment).

6. Check the coupling bushes and lubrication for Greased/oil bath couplings.

7. Check suction & discharge piping and ensure no piping strain is transmitted to pump nozzles.

This will be done by either visually observation of unconnected pipes for small pumps or by

checking alignment with and without piping connection for bigger pumps.

8. Insert suitable strainer in suction piping. Ensure that there is no gap between strainer and pipe

wall. Ensure that strainer cleaning would not be a problem.

9. Check all the accessories viz. pressure gauge, oil cup, safety valve, vent valve, non-return valve,

drain valve, foot valve etc. Ensure that drain and vents are properly plugged as per drawing.

10. Ensure the pump surroundings are cleared up and easy approach to the valves, start/stop push

buttons etc.

11. Ensure the availability of spares and consumables.

12. Ensure availability of lifting arrangements.

13. Check coupling guards and mark the direction of Rotation outside. (Coupling guard to be of non-

sparking type material whenever hydrocarbon or any other inflammable material is being used).

14. Read carefully the operating manual for any special instructions/precautions.

15. Check whether the piping layout is not fouling from pump maintenance point of view.

16. Check completion of cooling system/lube system/seal flushing system/seal quench system as per

Data Sheets specifications.



5.8 CHECK LIST FOR SAFETY VALVES AND RUPTURE DISCS

Sr. No.

JOB DESCRIPTION

PRESSURE SAFETY VALVES (PSV)

1. Ensure the safety valve has a Test Certificate issued by Competent Authority provided by the

vendor.

2. Check the right safety valve is mounted at the right place and tagged properly. Safety valve

should have sealing arrangement after setting at shop.

3. Individual safety valve must be pressure tested and set at a pressure certified. Pressure test has

to be carried out either pneumatically (Using Nitrogen) or hydraulically depending on the value of

set pressure of the PSV.

4. While mounting in position, ensure plastic and caps fixed at the flanges are removed.

5. Ensure the safety valve mounted in position is completely isolated by blinding while flushing the

line or carrying out the pressure test of the system.

6. Check the tag of the safety valve for the following details:

a) PSV No.

b) Test Pressure/Set Pressure

c) Date of Testing

7. In case there safety valves are on steam, water or condensate lines releasing to atmosphere 1/4"

weep hole on the exit pipe to drain out stagnant water is provided.

8. Ensure test gauges are removed from safety valve top.

9. Check main Back pressure shown with pressure seen in discharge line. (If PSV is conventional

type).

RUPTURE DISCS

10. Check the Data Sheet of the rupture disc.

11. The rupture disc must be protected well during storage and since it is a very delicate item, it

should be handled with great care.

12. Ensure the right rupture disc is mounted on the right place.

13. While installing/mounting rupture disc in position, Ensure it does not damage.

14. Ensure the direction of mounting the discs is correct. Rupture disc manufacturer instructions are to

be carefully studied.

15. Provision of main cover on the vent pipe should not allow rain water to collect on top of disc, but at

the same time should be enough to allow Rupture Disc to blow out.



5.9 CHECK LIST FOR PIPING

Sr. No.

JOB DESCRIPTION

GENERAL

1. Check provision of branch lines, vents and drains, supports anchors, guides, etc. as per P&IDs.

2. Steam traps/strainers/Valve/control valves/Blinds as per ISOs/P&IDs.

3. To obtain clearance from construction with regard to

- Mechanical completion with exception, if any

- Blinds/caps/welded plates provided for testing are removed

- Supports including spring supports

- Testing

- Correct installation of gasket, bolts etc.

- Position of blinds (if any)

- Instrumentation

4. Ensure all instruments are provided.

5. Ensure all Flange joints have gaskets and bolted tightly.

6. Sliding support is free to slide (Visual).

7. Ensure that Expansion joints/loops/spring supports are provided.

8. Ensure that proper vents are provided for pipes rising upwards.

9. Ensure that proper drains are provided on downwards loops.

10. Ensure that proper slope is given towards drain points.

11. Ensure that all bolts are of correct size and uniform length.

12. Access to vents/drains and isolation valves.

13. Support to safety valves and vent line and drain hole in the vent line, if open to atmosphere.

14. Vent line should be clear (No clogging).

15. Spectacle blinds for isolation are provided at right points.

16. Flush the lines with steam of proper pressure (never beyond design pressure of line), in case of

steam lines.

17 During flushing, no slip blind to be inserted without tail and no blind gaskets are left off.

18. While filling/draining/the lines, vents are opened first.

19. While flushing the system control valves and orifice plates, instruments are to be removed.

Control valves to be replaced by spool pieces.

20. Check the state of insulation, tracing etc. There should not be any gap between pipe and tracer.

21. Check all foundations of supports have been laid.

22. Check respective hydro test is complete before flushing of lines is done.



Sr. No.

JOB DESCRIPTION

FUEL OIL LINE

23. Check as per P&IDs.

24. Check for provision of steam tracing.

25. No larger gap between oil and tracing line for better heat transfer.

IN LINE FILTERS

26. Check proper filter is installed as per specifications.

27. Check whether it is at the required position as per P&ID.

28. Check filter for any checking and damage.

29. Check vents, drains and gaskets on filter chamber.

30. Check whether sufficient room is there for draining, removal of filter candle/cartridge etc.

5.10 CHECK LIST FOR VALVES

Sr. No.

JOB DESCRIPTION

1. Check whether Globe & NRVs are mounted in proper direction.

2. Check whether valves can be properly operated. Valve wheels should be in position properly

locked.

3. Check whether gland are properly packed and bolted.

4. Check whether valves are properly accessible. Turning of the valve may be necessary in few

cases.

5. Check whether proper arrow indication for valve operation is provided. If not provided this should

be done by paint/or by punch and torque.

6. Check whether limit switches, are properly working for motor operated valves.

7. Check whether spindle extension is provided where valves are to be operated towards mounted

place.

8. Ensure proper greasing of spindle, gear box etc.

9. Valves having locking arrangement should be properly checked for this facility.

10. Valves in flare line should be normally mounted horizontally to avoid inadvertent falling of gate.

Vertical mounting with steam below is not desirable as liquid is likely to drip on the gland.

11. Control valves are to be checked for proper mounting and direction. Control valves with handle

are to be installed in such a way that handles can be operated as properly.

12. Check the greasing of the valve. Vent/breather on the top of the valve diaphragm should be

checked.

13. For most of the valves before installing protective plastic valve caps are to be removed. It is to be

ensured.

14. Check location of mixing port of three way valves before installation.



5.11 CHECK LIST FOR STEAM TRAPS

Sr. No.

JOB DESCRIPTION

1. Check whether mounted in proper direction.

2. Check whether strainer is provided and the screen is in position and clean.

3. Check whether trap outlet line connected properly to the right condensate Return Header/Drain.

Ensure atmospheric bleeds are available with proper isolation in case of condensate recovery.

4. Check whether steam trap connection line is properly flushed by dropping traps.

5. Trap vent where provided should be checked for cleanliness.

6. Ensure that trap is mounted in such a way that its removal for maintenance is possible without

effecting the process operation.

7. Where a bank of steam traps is located at one place, e.g. condensate station, ensure that all

valves are operable and approachable, staggering or lowering of valves or raising of headers may

be necessary to achieve this.

5.12 CHECK LIST FOR TANKAGES (FIXED ROOF TYPE FOR HYDROCARBONS)

Sr. No.

JOB DESCRIPTION

1. Check the tank and connected piping installed as per data sheet & P&ID.

2. Ensure vents and drain lines are cleaned.

3. Open the manhole cover for internal inspection and fix it back after completion of inspection with

proper gasket.

4. Check for provision of fire-foam monitor connections with rupture disc (glass) connections.

5. Check for proper functioning of level indicator.

6. Check whether earthing connections and lightening arrestors are provided.

7. Ensure that calibration is done for all the instruments as well as check their mountings.

8. Check dyke and drainage system.

9. Check nozzle orientation/drain elevation, etc.

10. Check alignment of gauge hatch, gauge hatch reference for easy operation & dip pipe for

communication holes at regular intervals, etc. as per drawing.

11. Check for flame arrestor, breather arrangement and their cleanliness.

12. Ensure removal of blind plates and blind gaskets from nozzles wherever applicable.

13. Inspect PVRV for proper setting.

14. Check for fire water spray arrangement.

15. Check whether hydraulic test and external painting subsequently are over after site fabrication.

16. Check the platform for safe operation and maintenance.

17. Check that the connected pipelines/fittings are erected/supported as per the engineering. Pipeline

diagram and specifications as well as properly flushed and not clogged.

18. Check the foundation bolts for proper size and tight fixing.



19. Check the accessibility of the entire valve connected to the tank nozzles.

20. Ensure that the level float is properly fitted with wire or a pipe sleeve arrangement.

21. Check the datum plate arrangement and its position from tank bottom.

22. Ensure that the level indicator pipe nozzle is independent.

Check list of insulation Sr. No.

JOB DESCRIPTION

1. Check for damage.

2. Check whether insulation is properly protected against rain water.

3. Check whether wooden blocks are in proper position (for cold insulation).

4. Check whether valve gland covers are kept uninsulated.

5. Check from record if the tank has been tested hydraulically and later painted externally before

insulation.

Check List for Mixers

Sr. No.

JOB DESCRIPTION

1. Check for proper gasket/bolting arrangement between the base plate and tank face.

2. Check the alignment of drive/gear reducer/mixer shaft.

3. Check for proper lubrication at the appropriate points.

4. Ensure that the coupling guard is properly fixed.

5. Check that all the bolts on the impeller blade inside the vessel are fitted firmly with lock washers.

6. Check the mechanical equipment check list for mixers.



5.13 CHECK LIST FOR FLOATING ROOF TANKS (HYDROCARBON)

Sr. No.

JOB DESCRIPTION

1. Check for proper covering of rain water and raise water draining arrangement.

2. Check the moving of ladder/rails/wheels on the roof top as well as the swivel joints of the roof rain

water drain connection for greasing and easy movement.

3. Ensure that water seal is made in all the seal pots of the roof before charging the process fluid.

4. Keep the locking pins on the floating roof supports at the bottom. Once tank inside inspection &

maintenance etc. are over, check if the roof rests properly at the bottom.

5. The clearance between the foam and the floating roof edge must be as minimum as possible, but

not more than 4 mm to 5 mm. The gap for filling the foam should also be uniform throughout.

6. Additional checkpoints

1. Earthing connection between floating roof and ladder.

2. Dipping pipe configuration/its lid operation.

3. Level indicator pipe orientation.

4. Moving of ladder rails/wheels on the roof top.

5. Swivel joint of the roof rain drain connection pipe.

6. Emergency drain connection.

7. Uniform gap all around the tank to fill the foam.

8. Slope of the base plate.

9. Vent for the sealing device (with flame arrestor and its cleanliness).

10. Cleanliness of the pontoon.

11. Roof seal condition.

12. Shell, roof accessories are provided and internals are complete.

5.14 CHECK LIST FOR INSULATION

Sr. No.

JOB DESCRIPTION

1. Check for damage.

2. Check whether inspection windows are provided properly.

3. Check whether insulation is properly protected against rain water.

4. Check whether wooden blocks are in proper position (for cold insulation).

5. Check whether valve gland covers are kept uninsulated.

6. Check from record whether lines/vessels are tested hydraulically before insulation.

7. All flange joints including those of equipment will remain exposed till the plant is put on stream and

joints are tested for leaks during operation. Subsequent covering of these joints with insulation will

be decided as per customer’s requirement.



5.15 CHECK LIST FOR TURBINES

Sr. No.

JOB DESCRIPTION

1. Operating manual should be thoroughly reviewed and must be followed.

2. Check with P&ID and schematic diagram for all the accessories and instrument, control etc.

3. Check for expansion bellows, non-return valve, piping supports etc.

4. Check the foundation and levelling of turbine.

5. Provide strainer in steam inlet piping, blow steam for sufficient duration to have no black particles

on silver strip put at inlet. Check the quality of steam as per the turbine manufacturer and

functioning of steam traps and condensate return.

6. Commission the ejector, condensate pump and check the vacuum attained in the system.

7. Commission lube oil system after thorough cleaning and pickling. Check for pressure, free flow

and leaks.

8. Check governing system, operation sequence of steam chest valve. Check extraction system

interlock and also capacity control of the driven equipment.

9. Check the safety and panel, confirm, correct operation and settings of pressure, flow, temperature,

level and other alarm switches etc.

10. Keep essential spares available.

11. Ensure good internal condition by opening few components like steam nozzles, sealing chamber

etc.

12. Take and record necessary measurements of alignment clearances, axial and radial play.

13. Provision for target blowing for inlet steam line.



5.16 CHECK LIST FOR COMPRESSOR

Sr. No.

JOB DESCRIPTION

1. Operating manual should be thoroughly reviewed and must be followed.

2. Check with schematic diagram for all the accessories and instruments, control etc.

3. Check for expansion bellows, direction of non-return valves, piping supports etc

4. Check foundation and levelling of the compressor. Gas compressor piping should be pickled and

free from any rust and foreign particles.

5. Check for specification and enclosure of electrical motor and check direction of rotation.

6. Check the lube oil system, cooling water system and ensure adequate pressure, flow of

lubrication.

7. Lube oil tank, heat exchangers, filtering units, auxiliary pump should be thoroughly cleaned rinsed

with recommended lubricating oil.

8. Check for leakage of lubricant as well as cooling water.

9. Check the safety and control panel, confirm correct operation and settings, of pressure switches,

flow switches, temperature, level and alarm circuit interlocks.

10. Ascertain correct functioning of the safety devices. Check the functioning of capacity control

devices like governor, unloaders, clearance volume controller, suction throttling, guide vane

control discharge throttling by-pass, venting to atmosphere etc. as case may be.

11. Keep the essential spares available.

12. Check for necessary arrangement for chemical cleaning and passivation of suction lines.

13. Refer all points in pump.

14. Temporary/permanent suction strainer to be provided.

15. Ensure good internal condition by opening few components like valves, cylinder, head, bearing

cover etc., if required. Compressor vendors should be consulted.

16. Check the record of necessary measurements of alignment clearance, axial and radial play etc.

5.17 CHECK LIST FOR ROTARY FEEDER:

Sr. No.

JOB DESCRIPTION

1. Check that there is equipotentiality on the machine and this is correctly secured.

2. Check that there are no foreign bodies inside the machine.

3. Check the supply voltage of the electrical components.

4. Check that the lubricant in the gear motor or variable gear motor or anywhere else requiring it, is

filled.

5. Check the rotor for its correct rotation direction.



5.18 CHECK LIST FOR CARTRIDGE FILTER:

Sr. No.

JOB DESCRIPTION

1. Check that there is equipotentiality on the machine and this is correctly secured.

2. Check that there are no foreign bodies inside the filter and ensure that the filter elements are free

of any foreign bodies and kept with “hygroscopic salts” while storage.

3. Check the supply voltage of the electrical components.

4. Check the pneumatic component working pressure and their correct operation.

5. Check that all clamps are correctly locked.

5.19 CHECK LIST FOR SCREW CONVEYOR:

Sr. No.

JOB DESCRIPTION

1. Check for any damage to trough, flanges or flighting.

2. Check that conveyor troughs are in proper sequence.

3. Check that inlet and discharge spouts are installed properly.

4. Check the alignment of the trough bottom centre line.

5. Check the alignment of conveyor motor.

6. Check the alignment of motor.

7. Check that conveyor screw is properly coupled with the motor.

8. Check the direction of rotation of the conveyor screw.



SECTION – 6.0 PRE-COMMISSIONING PROCEDURE



6.1 GENERAL “Pre-commissioning activities are operational activities performed in order to make the plant/unit/system

ready for commissioning”.

Pre-commissioning activities are carried out after the completion of erection and other non-operational

activities mentioned under “Mechanical Completion”. These activities include, but not limited to, the

following:

a) Inspection of Tanks/Vessels/Columns etc. for cleanliness and any construction debris.

b) Isolation/removal of in-line components/instruments for flushing operation and re-install them on the

completion of these operations with assistance from construction.

c) Flushing & Cleaning of pipes/vessels/equipment by air blowing/water flushing/hydrojetting/steam

blowing/oil flushing/degreasing etc.

d) Cleaning and flushing of sewer systems and blowdown systems.

e) Carry out chemical cleaning for pipes/vessels as per guideline provided by specialist group.

f) Passivation of lines/vessel/equipment as required.

Note: Activities (e) and (f) are normally included in the Erection Contract in which case they will be

part of construction activities.

g) Revisioning of compressors, special pumps/rotating equipment as per manufacturer’s instructions

including preparation of lubrication system for these equipments.

h) Testing of safety valves and other safety devices.

i) Testing of heat exchangers for leaks.

j) Testing of plant communication system.

k) Functional test of rotating equipment with a suitable medium (nitrogen/air/water etc.) as the case

may be.

l) Checking out interlock systems and emergency shutdown systems.

m) Installation of temporary blinds/spools etc. to enable isolation of systems during pre-commissioning

stage.

n) Refractory drying for furnaces.

o) Removal of temporary blinds just prior to commissioning.

p) Loading of catalyst, molecular sieve, packing etc. unless it is specifically provided in the contract to

be carried out by CONTRACTOR (Construction).

q) Water run/dry run for process systems to check the functioning of control systems (both software

and hardware) including tuning of controllers.

r) Installation of permanent packing/gaskets, if permanent packing/gasket is not suitable for initial run

up purposes. Otherwise this activity will be part of construction activity.

s) Leak testing of vessels/piping/equipments etc.

t) Drying of columns/reactors/equipment with dry air/nitrogen as required.

u) De-airing of the systems by nitrogen purging/steaming as required.

v) Nitrogen padding/fuel gas backing of the piping/vessels/equipment as required.



6.2 Pre-commissioning Activities: 6.2.1 INTRODUCTION As the new unit is nearing 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 operations with the equipment and system. Start-up

is a critical period and the operators must know thoroughly their plant and the operation of each piece of

equipment.

Some of the preparatory works such as hydro-testing of vessels, lines etc. will be performed by the site

construction group. A great deal of additional preparatory work can be finished before erection is

completed, though some care in the organising of this work is necessary so that it will not interfere with

construction work. It is important to plan and schedule all the preparatory work required to be completed

before start-up. It is advisable to prepare a network for the pre-start-up activities which will be of great help in

monitoring work progress. Close co-ordination shall be required with construction group for execution of the

preparatory work. It should be ensured that appropriate action has been initiated for procurement of lubes,

chemicals, catalysts etc. & the same are available for start-up. It should be ensured that adequate number

and the right types of fire extinguishers are available along with other fire fighting assistance at the time of

commissioning. 6.2.2 INSPECTION Inspection of the items listed below is an important activity for operating crew to participate in the inspection

to the fullest extent; since, for many of them, this may be the only opportunity before start-up to examine

the internals of some of the equipment, vessels etc.

6.2.2.1 Inspection of Vessels, Columns, Heaters etc. Inspection of the interior of the vessels, columns, heaters and other equipment not normally accessible

during operation will be made to ensure that they are complete, clean, and correctly installed. Column

internals and packing filling will be done after inspection. Specialist engineers will be associated for

inspection and checking of critical equipment.

6.2.2.2 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, mounting

direction and accessibility for operation and maintenance. Spring supports are to be checked for the cold

settings and later for hot settings while plant is in operation. All piping should be marked clearly for service,

line size & flow direction.

6.2.2.3 Instruments Instruments will be checked, starting from the controller and proceeding logically through the control loop.

Cascade control system will be checked from the impulse point of primary loop. Operating crew should



check proper mounting of control valves. The shut down systems of the equipments should be checked by

simulating the various conditions in the control circuits, including the fail safe positions.

6.2.2.4 Special Equipment Special equipment such as compressors, turbine, multi-stage pumps & other vendor package items will be

generally inspected in the presence of owner’s representative together with vendor’s commissioning

engineer.

6.2.2.5 Relief Valves Relief valves will be checked against specifications. Relief valves will be set at site workshop and mounted

just before the system tightness test. Block valves before and after relief valves will be checked for lock

open position as per P&ID. Relief valve setting and sealing are to be carried out and jointly inspected by

instrumentation and operations. Set value is to be separately recorded and kept.

6.2.2.6 Rupture Discs Rupture discs will not be mounted during the flushing and cleaning activities. However, it should be installed

prior to tightness test. 6.2.3 PREPARATION OF UNIT i) Check the unit for completion and correctness against P&IDs.

ii) Remove all construction tools and materials lying around in the unit and clean up the area.

iii) Install blinds as per master blind list (A master blind list needs to be prepared for this purpose which

would reflect the position of the blinds at site and the position required at various stages of the start-

up of the unit).

iv) It is preferable to install safety valves after flushing. If safety valves could not be removed due to

bigger size, their inlet should be blinded during flush cleaning operation. These blinds can be

removed afterwards. Before installation, all safety valves are to be tested at site and set at stipulated

values as mentioned earlier.

v) Ensure that underground sewerage system (OWS, Chemical Sewer and CBD) is in working

condition. Clear plugging, if any. Check by flushing with water (For flushing of OWS, flushing water

can be taken from fire hydrant by means of fire hoses).

vi) Check that communication system between units, control room, offsite and utilities is complete and

in working condition.

vii) Illumination to be checked in the plant and offsite for proper functioning.

viii) Ensure that the required lube oil, grease and other consumable are available in the unit.

ix) Ensure that necessary temporary strainers are available.

x) Ensure all utilities like cooling water, service water, steam, air, Nitrogen etc. are available at the

battery limit.

xi) Ensure that instrument back up power supply is operative.

xii) Cleaning and flushing of pipelines is done as per the procedure. Procedure adopted is same for

lines from generation area to battery limit of the plant, as well as within the plant battery limit.



6.2.4 PIPE CLEANING AND FLUSHING

Considering the type of fluid handled, pipe material and internal wall conditions, pipe cleaning method shall

be selected from following alternatives:

1. Cleaning by water

2. Air Blowing

3. Steam Blowing

4. Chemical cleaning

5. Oil flushing

6.2.4.1 Cleaning By Water As a rule, water flushing shall be done for pipes in liquid service. If cleaning by water is unsuitable, other

methods will be used. Following procedure shall be adopted for water flushing.

i) Low point drains and high point vents should be opened.

ii) Low point flanges should be opened during initial flushing, wherever possible.

iii) All instrument connections should be isolated, orifice plates removed, control valves dropped or

isolated and bypassed. In case there is no bypass facility provided, remove control valves and flush

the line. The valve will be installed after clear water starts coming out and further flushing may be

continued. Orifice plate can be installed only after the total flushing of the loop is over.

v) If there is any heat exchanger in the line, flushing should be done up to inlet of heat exchanger and

around the exchanger using bypass 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 joint at the inlet

of heat exchanger should be first opened (the exchanger nozzle should be covered thereby isolating

the exchanger internals) and the line flushed till clear water starts coming out. Then reconnect

flange and flush through the exchanger.

v) At each opening of the flanged joint, a thin metallic sheet should be inserted to prevent dirty water

from entering the equipment or piping.

vi) The flow of water should preferably be from top to bottom for flushing of heat exchangers/coolers.

The bottom flange of the equipment should be opened to permit proper flushing.

vii) Flushing should be carried out with maximum possible flow of water till clear water starts coming out.

viii) 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. Temporary water connection at suitable points can be made to carry out flushing operation.

The run down lines should be flushed from the unit to the respective tanks or tanks to unit.

ix) It should be ensured in all flushing operations 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. During water flushing

wherever applicable for the equipment having demisters, the demisters are to be removed and shall

be reinstalled only after flushing and subsequent drying with air is completed.

x) For flushing of stainless steel lines and equipment, DM water shall be used.



xi) In case the piping which is used in gas service is being cleaned by water, temporary pipe supports

may have to be installed. Confirmation from engineering departments should be obtained regarding

weight carrying capability of these lines, prior to introducing water.

6.2.4.2 Air Blowing Air blowing is done for pipes in gas service or low temperature service. If sufficient air is not available, pipes

can be cleaned by pressurising and depressurising by bursting disc of cardboard or gasket material.

Pressure should not increase beyond design pressure. Larger diameter pipe-lines also which cannot be

water flushed properly, shall be air blown completely with strong flow of air to clean and dry the lines. The

instruments and control valves shall be isolated/removed from the system before flushing. Equipment shall

be disconnected to prevent entry of flushed material.

Safety valves and rupture discs are to be isolated or removed during the flushing. Strainer elements to be

kept removed during the flushing operation.

6.2.4.3 Steam Blowing Steam blowing shall be done mainly for steam lines. It is preferable that insulation should be complete;

otherwise when steam is opened lot of condensate formation will take place. Hot uninsulated pipes may

cause injury to personnel. When cleaning by steam is performed thermal expansion of pipe should be taken

into consideration. Following procedure should be adopted.

i) Remove orifice plates and control valves.

ii) Spool piece to be put in place of control valves, flow meters etc. In case the above instruments have

been provided with a bypass, isolate the instrument and open bypass.

iii) Disconnect equipment to avoid entry of flushed material.

iv) If necessary make temporary arrangement for steam blowing at open end of the pipe.

v) Open steam trap bypass valves, and isolate steam traps.

vi) Slowly allow steam to heat the pipe and then flush thoroughly with a strong flow of steam. Avoid

steam hammering by draining condensate properly. Repeat this operation after allowing the line to

cool for effective flushing.

vii) Check pipe line supports and loops for expansion.

viii) If the steam header supplies steam to steam driven turbine use of target plates should be made to

ascertain cleaning. Target blowing should be done intermittently allowing the line to cool in between.

Blowing is to be continued till target plate does not have more than one dot per square cm (This

criteria should be ascertained from the turbine vendor).

ix) After blowing is over, allow the pipe to cool, with vent open to prevent vacuum pulling. Open drip leg

flanges and remove accumulated muck. Then box up the line. Install the control valves and orifice

plates.



6.2.5 TIGHTNESS TEST 6.2.5.1 GENERAL

The purpose of this test is to check the tightness of flanges, joints, manholes etc. For systems that operate

under pressure. Testing is done with air using soap solution for leak detection. The following steps are

recommended:

i) Ensure that the system that is to be tested is isolated from the rest of the system.

ii) Take the system gradually to a pressure of 1-1.5 kg/cm2g or the operating pressure, whichever is

lower. Check all flanges, joints, manholes etc. for any leakage with soap solution.

iii) If the system operates under vacuum no further pressurisation of the system is necessary beyond

1.5 kg/cm2g.

iv) If the operating pressure of the system is more than 1.5 kg/cm2g, slowly raise the pressure of the

system in the stage of 1.0 Kg/cm2g at a time to 3.5-5.0 kg/cm2g. After each stage check for leaks

using soap solution. Attend the leaks if any.

v) Further testing for pressure higher than 7.0 Kg/cm2g for gas systems is done when feed gas is

taken into the system, keeping in mind that pressurisation is at a slow rate and in stages.

vi) For vacuum system perform vacuum test after tightness test is satisfactory.

vii) Pull maximum possible vacuum with the ejector or the vacuum pump.

viii) Isolate the system and observe the rate of drop in pressure.

NOTE: For liquid lines additional tightness test can be carried out when the pumps are tested with water.

Alternatively, LP steam can also be used for leak checking if design conditions of the system permit.

6.2.6 FUNCTIONAL TEST All rotary equipment (including dosing pumps) will undergo functional test to check their performance with

water/air (if possible). All instruments will be checked/ calibrated. (Refer equipment specific vendors’ manual) 6.2.6.1 Motors Manufacturer’s lubrication schedule should be used to ensure that all lubrication points have been serviced.

Each motor should be checked and started on no load. Ensure that it has the correct direction of rotation.

The motor speed should be checked with tachometer to ensure that RPM is correct. After a short run each

bearing should be felt to ensure that it is free and not overheated. 6.2.6.2 Pumps Generally the pump casing is opened and checked to ensure that it contains no foreign materials. Pump

casings need not be opened up in case the pump had been stored carefully and the blinds covering suction

and discharge nozzles were not removed in storage or in transit. Cleanliness of suction line and installation

of fine mesh strainer should be ensured. Pumps and motor will be aligned and then tried on water.

Temporary connections may have to be made if required. When running a pump designed for hydrocarbons

on water, the discharge valve may have to be throttled, so that the rated current is not exceeded. Ensure that

the vents and drains of the pump are clear. Pressure gauge tapping will be flushed and filled with sealing

fluid wherever necessary.



6.2.6.3 Compressors It is important to make sure that the inside of piping (especially suction piping) around the compressor has

been cleaned. The compressor cylinder should have no stress of piping. The lube oil lines and compressor

suction lines downstream of the suction filter should be acid cleaned and pickled. For acid pickling, refer the

compressor vendor’s instruction manual. A temporary fine mesh strainer (about 100 mesh) should be

inserted in the suction line. Lube oil should be used as per manufacturers' recommendation. The compressor

should be run for a few hours following the manufacturers’ instructions regarding media and mode of trial

operation of the machine. A close watch should be kept on critical readings like bearing temperature and

pressure etc. When the compressor is found to function satisfactorily it should be connected to the rest of

the system. Vendors’ instruction shall be followed as far as medium for pumps and compressor is

concerned. In general, casing design pressures and rated motor current shall not be exceeded.

6.2.6.4 Instruments The following procedure may be adopted for checking 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 being installed. The plate should then be installed after

checking for the correct direction. Particular attention should be given to weep holes of orifice, wherever

provided.

ii) Differential pressure transmitters and receivers: Generally these should be calibrated locally. The calibration should be checked at the receiver, which may

be a 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 system should be checked by simulating the conditions.

v) Start-up/shut down logic: Check the sequence of start up/shut down interlocks by simulation. 6.2.7 REFRACTORY DRYING The refractory of various heaters must be thoroughly dried out so that it does not crack when the heaters are

brought into operation. The drying should be done by gradual heating of the refractory so that no spilling or

cracking takes place due to sudden vaporization of moisture from the refractory.

Temporary low pressure steam connection shall be made to the heater coil to have steam flow through them

while drying. It is preferable to have flow of heat carrying medium even if tubes are designed for dry service.

NOTE: This activity is to be carried out only after the Mechanical completion of the system and safety clearance is obtained for charging the fuel.



6.2.8 FILLING OF ALUMINA/SILICA GEL PURIFIERS/GUARDBEDS Before filling packed vessels, internals should be checked for fittings like distributors, packing support etc.

and cleanliness. Vessel should be cleaned to remove grease, dirt etc. before charging. Care should be

taken so that no foreign material goes inside along with packing. Height of the packed bed should be

checked, and then hold down grating (if any) should be installed as per vessel internal drawings.

6.2.9 DRYING, PURGING AND INERTING 6.2.9.1 Drying

Systems that have been water flushed or steam blown may require complete drying before hydrocarbon can

be taken in. This operation becomes critical when the plant is dealing with refrigerated systems operating at

low temperatures (e.g. LPG, LNG, C2/C3 recovery etc.) or systems handling chemicals like SO2 which will

lead to profuse corrosion.

If slugs of water are to be removed, the system is initially blown hard with a strong flow of plant air.

Necessary temporary connections for air inlet and outlet are to be made. Since plant air can give rise to

about 7 Kg/cm2g pressure on blocked out conditions, care should be taken to ensure that line design

conditions are not exceeded. Ensure that there is no inadvertent closing of valves during air blowing &

adequate venting is available. When major portion of water has been removed, the air drying can be

continued with compressed utility air to make the system completely dry. For pre-specified critical services,

the plant air is to be heated up to 800C and blown through the system followed by instrument air or Nitrogen.

Alternatively the line can be blown through, by N2. Portable dew point instrument is to be used to measure

the dew point of exit air. Normal recommended value is (-)40°C at atm pressure.

It is advisable to take up small systems at a time for drying. After drying these are to be isolated and kept

sealed with Nitrogen. While blowing with hot air, precautions are to be taken to take care of thermal

expansion of pipes.

6.2.9.2 Purging and Inerting

Before feeding any hydrocarbon to the plant all piping and vessels are to be purged out free of air. If air is

allowed to remain it will form an explosive mixture with the hydrocarbon. It can become potential hazard for

explosion. Hence it is imperative to remove Air (oxygen) from the system. Normal criteria are to bring down

oxygen content to less than 1%. This can be achieved as follows:

a) Steam purging, followed by Natural gas backing up and hydrocarbon charging.

This method is generally practised in refineries or plants where Nitrogen or inert gas is generally not

available in required quantities. In such plants the system is purged with steam continuously taking care to

keep the vents and drains open for steam & condensate respectively. Steam flow is maintained in such a

way that there is a positive pressure attained in the system. After blowing for a period long enough to bring

down oxygen content within limits, the Natural gas is backed up immediately, steam is cut off, and vents and

drains closed. After the system is cooled the condensed water is drained off from the low point drains.

Hydrocarbon liquid/vapour is taken into the system under small positive fuel gas pressure.



b) Nitrogen purging followed by hydrocarbon feed.

The second method, where N2 or inert gas is available, is fairly simple and straight forward. The system is

purged continuously from one end to the other with unidirectional flow than can sweep off all the air in the

system. Normal requirement of N2 for flow purge is of the order of 3 to 5 times the system volume. If the

system is designed for higher pressure it can also be pressure purged by pressurising it with N2 and

releasing through a top vent that will establish a unidirectional flow.

If the system can operate under vacuum, it is advisable to pull vacuum and refill with N2. In this way N2

consumption can be reduced to a maximum of 3 times the system volume. H.C. is taken while the system is

still under slight positive N2 pressure.

6.3 EQUIPMENT OPERATING PROCEDURES 6.3.1 CENTRIFUGAL PUMPS

6.3.1.1 Introduction

General procedures for start-up/shutdown and trouble shooting of centrifugal pump are discussed in this

section. For detail operating procedure refer the respective vendors’ operating procedure.

6.3.1.2 Start-up

i) Inspect and see if all the mechanical jobs are completed.

ii) No load run of the motor to be completed before the pump is coupled. After no load run,

de-energize the electrical supply and couple the motor with pump.

iii) Establish cooling water flow where there is such provision. Open external seal flushing liquid to

mech. seal in pumps having such facility. During pump trial run with water, it is to be ensured that

pump motor is suitable for operation of increased load due to pumping of water. Also such operation

may need approval of pump vendor/specialist rotary group engineer in certain cases. However,

normally all pump's minimum continuous flow and motor ratings are checked with water as pumping

medium. Pump suction strainer during initial trial run should be finer (typically 40 mesh).This can be

replaced with a coarse strainer (typically 6 to 8 mesh) or as recommended by pump vendor during

normal duty. During trial run of the pump, seal flushing line can also be charged with pumping fluid,

only if approved by pump and mech. seal vendor.

iv) Check oil level in the bearing housing, flushing may be necessary if oil is dirty or contains some

foreign material.

v) Rotate the shaft by hand to ensure that it is free and coupling is secured. Coupling guard should be

in position and secured properly.

vi) Open suction valve. Ensure that the casing is full of liquid. Bleed, if necessary, from the bleeder

valve. Keep discharge valve closed.

vii) It should be ensured that casing of the pump is nearly at normal pumping temperature. The casing

should be heated up/cooled down sufficiently if required, prior to starting of the pump. This is to

guard against damage of the equipment and associated piping due to thermal shock/vapour locking.

viii) Energize the motor. Start the pump and check the direction of rotation. Rectify the direction of

rotation if not correct.



ix) Check the discharge pressure.

x) 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/MCC.

xi) Check temperature of the bearings and if necessary adjust the cooling water flow (if provided).

xii) Check the gland/seal and if necessary adjust gland tightness/flow of the coolant for the seal. 6.3.1.3 Shut Down i) Close discharge valve fully if pump is single stage. If pump is multi-stage, having high tension

electric motor, follow pump vendors instructions particularly regarding minimum continuous flow

requirements.

ii) Stop the pump.

If pump is going to remain as stand by and has provision for keeping the pump hot-cold proceed as

follows:

• Open the valve in the bypass line across the discharge valve and check valve.

• The circulation rate should not be so high as to cause reverse rotation of idle pump or overloading of

the running pump. Reverse rotation of pump may have adverse affect on thrust bearings as they are

not designed for the same.

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.

• Close external flushing liquid to mechanical seals, if provided.

• Slowly open pump bleeder and drain liquid from pump. If the liquid is very hot or cold, 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.

• Cut off electrical supply to pump motor prior to handing over for maintenance after Locking and

tagging of equipment and work permit is to be issued.

6.3.1.4 Trouble Shooting i) Pump not developing pressure • Bleed/ vent pump casing.

• Check the lining up in the suction side.

• Check the suction strainer.

• Check the liquid level from where the pump is taking suction (physical verification).

• Check pump coupling and rotation

• Check the foot valve (in case of vertical lift pumps).

• Check the temperature of liquid. If it is higher than for what the pump has been designed, available

NPSH may come down.

• Check for any air leakage in the pump suction line or pump casing.



ii) Unusual Noise

• Check if coupling guard is touching coupling.

• Check for proper fixing of fan and fan cover of the motor.

• Check for pump Cavitation.

• Get the pump checked by a technician.

iii) Rise in Pump bearing temperature

Generally the bearing oil temperature up to 80oC or 50oC above ambient whichever is lower can be

tolerated (Refer vendors’ instruction manual for maximum tolerable pump bearing temperature).

• 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) Gland Overheating

• 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 Vibrations

• Check the foundation bolts.

• Check the fan cover for looseness.

• Stop the pump and hand over to maintenance

• Check alignment.

vi) Leaky Gland

• Check the pump discharge pressure.

• Tighten the gland nut slowly, if possible.

• Prepare the pump for gland packing adjustment or replacement of mechanical seal as the case may

be.

vii) Mechanical Seal Leak

• Stop and isolate the pump and hand over for maintenance.

NOTE: Refer to vendor's instruction for more details on trouble shooting of pumps. 6.3.2 POSITIVE DISPLACEMENT PUMPS


General procedure for start-up/shutdown and trouble shooting of the positive displacement pumps are

discussed. Vendor's operating manual should be studied for further details, specific to pump under

reference:

6.3.2.2 Start-up i) Check if all mechanical jobs are completed.

ii) No load run of the motor to be carried out before coupling with the pump. De-energize electrical

supply. Couple the motor with the pump.

iii) Flush and renew oil in pump gear box.



iv) Check whether suction/discharge blinds are removed.

v) Check whether suction strainer is installed and is clean.

vi) Check for proper lining up including the pulsation dampener and pressure safety valve in the

discharge. Open suction valve fully.

vii) Check that the motor shaft is reasonably free and coupling secured. Coupling guard should be in

position.

viii) Energize motor. Open discharge valve. Start the motor and check direction of rotation. If wrong,

correct it. Never start the pump with discharge valve closed.

ix) Adjust the pump stroke in case of reciprocating pumps and run the pump at desired settings. Watch

discharge pressure and check the rate of pumping using the flow meter or by taking suction from the

calibration pot. The valve on the recirculation line (provided in case of gear pump, screw pump etc.)

shall be adjusted to obtain the required discharge pressure.

x) Care should be taken to avoid dry running of pump and back flow of liquid. Bleed if necessary to

expel vapour/air.

xi) Check for unusual noise, vibrations, rise of temperature of both motor and pump.

6.3.2.3 Shut-Down

i) Stop the pump.

ii) Close the suction and discharge valves.

iii) Drain the liquid if maintenance jobs are to be carried out on the pump. Flush pump casing.

6.3.2.4 Trouble Shooting

i) Insufficient discharge pressure:

• Check the line up in suction side.

• Check up suction pressure.

• 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 vessel from which pump is taking suction.

• 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) Leaky Gland

• Check for normal pump discharge pressure

• Tighten the gland nut slowly if possible.

• Handover the pump for replacing gland packing.

iv) Unusual Vibration

• Check the foundation bolts

• Check motor fan cover for looseness.

• Stop the pump and hand over to maintenance.

NOTE: Refer to vendor's instructions for more details on trouble shooting of pumps.



6.3.3 CENTRIFUGAL COMPRESSOR


General procedure for start-up, shut-down and troubleshooting are discussed in this section. For detail

operating procedure refer the vendor operating procedure.

6.3.3.2 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.

iii) Check oil level in lube oil tank and fill as required to bring the oil level to the high mark on the sight

glass. Do not overfill.

iv) Start the standby motor operated lube/seal oil pump keeping pressure regulator at a value given by

the Vendor. Establish the pressure of lubricating oil in bearings and seal oil to seal.

v) Bar the unit over once to be sure all moving parts are clear.

vi) Open cooling water and ensure it is operative. Commission cooling water to all water cooler via oil

cooler, gas cooler etc. as applicable.

vii) Ensure that compressor casing has also been purged with inert gas, if applicable.

viii) Line up the antisurge valves of the compressor.

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. Adjust the minimum

circulation valve, so that the drive does not consume excess power.

Allow the oil to warm up to 40°C. Watch compressor motor amperage. Listen for unusual noise

during the warm up period. Auxiliary motor driven lube oil pump will be stopped when shaft driven

pump develops normal oil pressure and kept ready for auto start.

xi) When the unit is warmed up and determined to be operating satisfactorily, gradually start throttling

the valve beyond surge requirements of the compressor.

xii) 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. 6.3.3.3 Shut-Down i) Stop the drive and close the antisurge valves.

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.



6.3.3.4 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.

ii) Log all temperatures, pressures, levels, flows and amperage.

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 KOD/inter cooler 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.

6.3.3.5 Trouble Shooting NOTE: Follow vendor's recommendations. However, some general guide lines are given: 1. 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.

2 HEAVY VIBRATIONS IN MACHINE • Misalignment

• Bent rotor

• Damaged rotor

• Imbalance

• Weak foundation

• Mechanical Loosening etc.

3. INCREASE IN GAS TEMPERATURE AT SUCTION ALONG WITH DROP IN COMPRESSION

RATIO Increased circulation of gas due to internal leakage as a result of 'O' ring of end cover/diaphragm

damage.

4. OIL CARRY OVER IN THE COMPRESSOR UNIT IN THE PRODUCT SIDE

• Faulty operation of seal oil level control system.

• Damaged oil seals.

• H.P. seal oil drain collector levels not being maintained properly.

• At stand still condition, check the seal oil level controls, and check the drain oil quantities from HP

seals near the compressor and compare with previous data.

• Check seal oil traps and drain collectors.

• Check for any damage to the membranes in differential pressure indicators, and differential pressure

control valves to avoid leakage of pressure oil into the reference gas chamber.



• Check that the balance gas pressure at the compressor is at least 200 mmWC higher than the

respective reference gas pressure.

• Check oil seals.

• Avoid flooding of oil through reference gas lines from seal oil overhead tanks.

6.3.4 HEAT EXCHANGERS

6.3.4.1 Introduction Heat Exchangers (Shell & Tube or Plate) can be broadly classified into following types:

• Water Coolers/condensers

• Steam heaters

• Chillers

• 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. For detail refer the

respective Vendor document.

6.3.4.2 Start-Up After the heater 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. The return water temperature should not exceed 45°C.

ix) For avoiding fouling, velocity of water should be at least 1 m/sec in a cooler/condenser.



SHUT DOWN: 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) Isolate the cold medium next.

iii) Drain out the shell and tube sides to OWS/Sewer/Closed blow down system as applicable.

iv) Depressurise the system to atmosphere/flare/blow down system as applicable.

v) Purge/flush if required. This is particularly important in congealing services.

vi) Blind inlet and outlet lines before handing over the equipment for maintenance.

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 pitch rotors in

which the fan blades are adjustable in pitch during rotation. This allows variation in air flow as per the cooling

requirements. These coolers are also provided with manually and/or automatically operating louvers for the

control of the cooler outlet temperature.

Refer to vendors instructions for the detailed procedure of start-up, shut down and normal operation. 6.3.5 FIRED HEATERS

Refer Thermax Document. 6.3.6 AGITATORS


General procedures for start-up, shut down and troubleshooting are discussed. Vendors’ operating manual

should be studied for further details.

6.3.6.2 Start-Up

i) Ensure that all mechanical & electrical jobs have been completed on the agitation assembly that is to

be started.

ii) Check lubrication of bearing housing, gear box etc. It is preferable to change to fresh lubrication

material before starting.

iii) Energize the motor. Start the motor & check the direction of rotation. Rectify the direction of rotation

if necessary. Check the no load current.

iv) Check cleanliness of the vessel.

v) Rotate the shaft by hand to ensure that it is free & coupling is secured. Coupling guard should be in

position & secured properly.

vi) Before filling liquid check whether the vessel outlet valve is closed or not. If not, close the valve.

vii) Fill liquid in the tank up to normal operating height. Generally water could be used for initial test.

Commission level instruments if any.

viii) Start the motor & check for any vibration/heating of gear box, any excessive vibration of the shaft

etc. measure current drawn by the motor.

ix) If any solid to be mixed, slowly open the solid charge. Hold & start mixing slowly.



xi) Check for unusual noise, vibration, rise of temperature of both motor & gear.

xii) If any heating arrangement is there slowly commission the system & ensure it is operative.

6.3.6.3 Shut-Down

i) Stop the motor.

ii) If any heating arrangement is there, stop it. If any hot oil heating is there, slowly change over to cold

oil from hot oil. But keep the circulation on.

iii) If the liquid is sticky type, drain it as early as possible (in hot condition) & flush the system.

iv) Motor to be de-energised.

6.3.6.4 Normal Operation

i) Check lubrication system of bearing housing & gear box.

ii) Log all temperatures, level & amperage.

iii) Listen for any unusual sounds while the m/c is operating. If any, it should be investigated

immediately.

6.3.6.5 Trouble Shooting Follow vendors' instructions. General guidelines are given below:

1. Unusual vibration: • Check for misalignment and improper facing of bracket.

2. Seal getting heated

• Adjust cooling water flow, if provided.

6.3.7 EJECTOR


General procedure for start up, Shut down & trouble shooting are discussed here in this section. Vendor's

operating manual should be studied for specific details.

6.3.7.2 Start-Up

i) Ensure all mechanical jobs have been completed on the ejector with all accessories.

ii) Check all the blinds have been removed or not.

iii) Check hot well is properly filled with water or not. If not, fill it up.

iv) Charge the steam header to the ejector. Drain condensate from low point drains. Ensure steam is

clean before it is charged to the ejector.

v) If there are pre-condensers, inter condensers & after condensers, open condensate drain valve

provided on the precondenser, intercondenser & aftercondenser.

vi) If there is an aftercondenser, be sure that the air vent on the hot well is open & free to discharge to

the atmosphere.

vii) If there is no aftercondenser, be sure that the ejector discharge is open & free to discharge to the

atmosphere or against a back pressure only equal to that for which it was designed.



viii) If there are precondensers, intercondensers & aftercondensers, start circulation of cooling water

through the tubes of inter, pre and after condensers. In case of barometric condensers, open water

to the spray nozzles.

ix) Open all isolating valves on the first & subsequent stages of the ejectors.

x) Open upstream & downstream isolating valves of the pressure controller for controlling vacuum.

xi) Before opening steam to the ejector, open the strainer bleeder and purge the strainer.

xii) Open steam valve slowly to the last stage (which discharges to the atmosphere or after condensers).

Next open steam valve on preceding stage & so on until all stages are in operation. The vacuum on

the vessel to be evacuated should then start to rise steadily. Observe maximum vacuum pulled.

Adjust vacuum to operating level.

xiii) When hot well level starts increasing, try to control level of the hot well. After level becomes steady

put it on auto level control, if provided.

xiv) In case of H/C service, once sufficient level is there on the H/C side, start H/C recovery pump, and

control the level. When steady, put it on auto, if provided. 6.3.7.3 Shut-Down 1. Close steam valve to first stage.

2. Close steam valve to second & subsequent stages (if any) in their respective order.

3. Close isolating valves on all stages.

4. Close circulating water valve.

5. Open water make up for hot well.

6.3.7.4 Trouble Shooting If vacuum starts falling, the reason may be:

1. Insufficient inlet steam pressure.

2. Inlet water temperature to the condensers higher than normal temperature.

3. Air leaks in the tail pipe of inter condensers.

4. Flooding of the inter condensers by excessive water flow (direct C.W. condensers).

5. Starving of any inter-condenser by insufficient cooling water flow.

6. Plugging of water distribution system in the condenser.

7. Plugging of the tail pipe.

8. Plugging of the steam nozzle ejector and jets due to pipe scale.

9. Steam leak at nozzles throat.

The defects mentioned above are to be ascertained & rectified for proper operation.



SECTION-7.0 START-UP PROCEDURE



7.1 Overall Plant Start-up Block Diagram & Procedure:

BLOCK DIAGRAM: BEFORE STARTUP PHASE 1 PHASE 2 PHASE 3 PHASE 4 PHASE 5 Main Start-up Flows Secondary start-up Flows 7.1.1 Nitrogen Pressure Testing and Purging

All equipment and piping that will contain process material and which does not normally contain water should

be pressure tested with nitrogen to 3.5 kg/cm2g. The testing should be accomplished in manageable

sections. A leak is more evident on a small section as opposed to a large section of equipment. All control

valves should be 100% open in Manual mode.

The test consists of isolating a section at 3.5 kg/cm2g pressure for I hour. If the pressure drops more than

10%, a leak is assumed. The leak must be found and corrected, and another pressure test completed to

prove that the leak has been repaired.

OSBL FB FB SURGE

TANK

SH DE-INVENTORY

LPS HUT LB COLUMN

HB COLUMN

CM COLUMN

SH PURIFIER

HEAD TANK

REACTORS

IPS LPS

SATELLITEXTRUDE

EXTRUDER

CATALYST TANKS

OSBL SH

ADDITIVE

FE FEED DRYERS

FE COLUMN

CM COLUMN

ST

AR

T R

EA

CT

ION



When a section has been proven to be leak free, it is pressurized to maximum nitrogen pressure and

depressurized three more times to reduce the oxygen content to a safe amount. A section may be partially

depressurized into a new section if nitrogen consumption is critical.

Five nitrogen cycles, pressurizing to 3.5 kg/cm2g and depressurizing, are as effective for oxygen removal as

three maximum pressure cycles, but will require less nitrogen. However, much more time is required.

Systems that are designed to operate at less than 3.5 kg/cm2g can be continuously purged with nitrogen until

they are oxygen free instead of undergoing the multiple pressure cycle purges. All new equipment should be

pressure tested to verify the integrity of the equipment before being used with hydrocarbons.

The Low-Pressure Vapour Recovery (LPVR) system and the flare system usually contain free water and can

be purged with either steam or nitrogen until they are oxygen free. No moisture should be introduced into any

part of the Distillation or Reaction Areas unless absolutely necessary, since it will result in extensive dry

down periods. Care must be taken to ensure that any equipment opened to the atmosphere is protected from

the weather and that water does not accumulate in the lines or vessels.

When a section has been pressure tested and purged, it is kept isolated and maintained with a low nitrogen

pressure (nitrogen blanketed) until it is ready to be used or put into service with adjacent or related sections.

Check all emergency pulldown valves during the nitrogen test for a tight shut off (no passing, or leaking of

nitrogen). They are then placed in service and the isolating valves are “carsealed” in the open position, and

any associated drain valves are “carsealed” in the closed position.

The “carseal” may be in the form of a chain, or lock, that will prohibit anyone from changing the valve position

inadvertently.

7.1.2 System Drydown: The reaction process is very sensitive to water. Concentrations exceeding 2 ppm in the feed streams to the

Reactor cannot be tolerated.

Water can enter the system in various ways. It can be introduced during steaming operations when preparing

equipment for maintenance and when it is used in the process itself. Upsets in operating conditions or

equipment malfunctions can result in water being fed to the Distillation Area. From there it can travel on to

the Reaction area through the Purifiers.

Water is also used in heat exchangers. If a tube failure were to occur, large amounts of water could enter

the SH stream. During a shutdown, some equipment cleaning is done with high-pressure water. It is possible

to leave free water in lines that cannot be drained.

Decontamination should be done with hot nitrogen wherever possible to reduce the possibility of leaving

water in the equipment from shutdown preparations.

Basic water removal is done in the LPS Hold-up Tank. The Distillation Area can remove water to a small

extent. Any large quantity of water causes the Distillation Area to become upset. The water will then travel

through the Distillation Area to the Reaction area. If the columns are upset because of water, circulation to



the purification area should be stopped until the Distillation Area is stabilized and the water content in the

stream to the SH Purifiers is verified to be less than 20-ppm.

Early in the start-up program an organized approach should be taken to remove excess water as efficiently

and quickly as possible. When equipment becomes operational, low point drains should be checked for free

water. If a piece of equipment is suspected of being wet it should be checked for water and dried down (if

possible) before routing a flow through it.

Dry down loops should be planned to accelerate the dry down process. If the Distillation Area is brought into

service as a unit, a flow can be set up from the LPS Hold-up Tank, to the LB Column, to the HB Column and

back to the LPS Hold-up Tank. Low point drains should be inspected frequently for free water. A water

sample point is located at the inlet to the SH Purifiers. When the water content is down to 20 ppm, a flow may

be routed through the SH Purifiers.

If the lines downstream of the Purifiers are wet they will have to be purged out. The SH from the Purifiers will

be dry, therefore maximum flows possible should be taken through the lines to be dried. Low point drains

should be checked for free water. If the Reaction System is available, set up a flow loop from the Distillation

Area, to the Purifiers, through the Reaction system, to the IPS, back to the Distillation Area.

Do not contaminate a known dry system by taking a flow from a wet line into it.

Set up sample points where necessary to verify that the system is dry. Use only approved sample

equipment. Pressure and temperature of the SH must be taken into account when installing a sample point.

7.1.3 System Charging and Drying Down Initially, all control valves should be in manual mode with 0% output (or closed position).

All instrumentation control loops in each of the subsequent sections of the plant that are started up must be

in operating condition.

A plan must be prepared for de-inventorying each system before any hydrocarbon is introduced. e.g., an

oxygen- free HB system is ready to receive SH from the LB Column system if there is a leak. De-inventorying

to the flare is possible, but much of the inventory will be burned.

The water collection pots on the LPS Hold-up Tank, the Decanter, the LB Reflux Drum and the FE Feed

Dryer Coalescer must be drained every hour during the initial starting of the plant.

7.1.4 SH De-inventory to LPS HUT The inventory and start-up of sections of the plant should be followed in a sequence. The start-up sequence

should begin by bringing SH from the SH De-inventory Storage Tank to the LPS Hold-up Tank for free water

removal (or “drying down”).

During the initial start-up of the plant, instrumentation control loops will be in use for the first time and their

performance should be monitored for deficiencies. The tuning parameters of the control loops are not



expected to be adequate for the initial start-up since the values that will be used eventually will be those

values best suited for much higher process conditions.

7.1.5 LPS HUT to LB Column: The SH is then pumped from the LPS Hold-up Tank to the LB Column. The SH can be heated using the LB

Feed Heater #2 to raise the temperature of the column slowly. This will prepare the LB Column Reboiler for

heatup, and will reduce thermal shock to the equipment.

The LB Column is filled from the LPS Hold-up Tank, and the column is heated slowly until the LB Reboiler is

required for further heating. During the filling and starting up of the LB Column, the Comonomer Column

System can be filled and heated up. FB can also be sent to the FB Surge Drum. FB can be transferred to the

LB Reflux Drum after the LB System has been proven to be free of leaks while distilling SH. The FB will

accelerate water removal from the LB Column system.

The base of the LB Column is recycled to the LPS Condensers until it tests less than 20 ppm water. This is

the initial SH dry down “loop”.

7.1.6 LB Column base to HB Column: When the LB Column base flow is less than 20 ppm water, it is routed to the HB Column for the next dry

down loop.

7.1.7 LB Column to FE Column/CM Column: While the LB Column is drying down, the FB dry down loop can be started. FB is sent from the LB Reflux

Drum to the FE Column Feed Cooler, FE Feed Coalescer, FE Feed Dryer and into the FE Column. The FB

from the FE Feed Dryer will be dry, and if the CM Column is operating, it can be sent there. If the CM Column

is not operational, the base of the FE Column will be routed to the FB Surge Tank, from where it will be sent

back to the LB Column.

When the CM Column is available, the FB from the FE Column will be routed to the CM Column. The CM

Column is started up, and the FB is returned to the FB Surge Tank from the CM Reflux flow, from where it

will be sent back to the LB Column.

7.1.8 HB Column to LPS HUT: When the HB Column is up to operating conditions, a flow is started from the Reflux Drum to the inlet of the

SH Purifiers. The bypass line is used to return the flow to the LPS Hold-up Tank.

7.1.9 HB Column to RB Column: When the HB System has been filled from the LB system and started up, a flow to the RB System can be

started. The excess SH from the RB Reflux Drum is sent to the LPS Hold-up Tank. The HB Reflux flow to the

LPS Hold-up Tank is recycled until it is has less than 20-ppm water. An SH loop is maintained during this dry

down sequence by pumping from the LPS Hold-up Tank to the LB Column, to the HB Column, to the inlet of

the SH Purifiers, then back to the LPS Hold-up Tank.



7.1.10 HB Column through SH Purifier:

When the SH at the inlet of the SH Purifiers is less than 20 ppm water, the flow can be lined through a newly

regenerated SH Purifier and then the SH can be used to inventory downstream systems. When the SH

Purifier outlet water PPM starts to rise, swing to the other SH Purifier and regenerate the original SH Purifier.

Purge lines back to the LPS Hold-up Tank are provided at the Absorber Cooler outlet and Reactor Feed

Pumps. Maintain these dry down loops until the water is less than 20 ppm.

The SH is also fed forward through the HP Diluent Pumps and the LP Diluent lines to the catalyst area. The

SH is returned from the catalyst area by using temporary “jumper” lines connected from the outlet of the

catalyst metering pumps to LPS Hold-up Tank and by pumping into the reactors as soon as they are ready

for SH.

7.1.11 Reaction Area: While the SH and FB dry down loops are being started and maintained, the Reaction Area should be

prepared for SH by nitrogen pressure testing and purging lines and equipment.

NOTE: No pressure is put on the reactor system until the Reactor Agitator Seal system is operating and a

minimum differential Seal Oil pressure of 10 kg/cm2g is maintained. This differential pressure must

be maintained at all times, regardless of Reactor system pressure.

A pressure test is to be conducted from the Reactor Feed Pumps to the IPS to ensure that all drain lines are

closed and blind flanges are installed. This check of the drain lines should be accomplished with the aid of a

P&ID, and should be followed with another check by another person to ensure all drain lines are properly

closed and blind flanges are installed.

Nitrogen pressure test the Reactor System from the Reactor Feed Pump to the IPS after the drain checks are

completed.

After the nitrogen pressure test of the Reaction System is declared satisfactory, cycle the pressure up and

down three times with nitrogen to reduce the oxygen content. Use various drain points to increase the

efficiency of the oxygen purge.

Open all steam tracing supply valves on the lines and equipment from the Reactor Feed Pumps to the IPS.

Allow more than five hours for the steam tracers to heat the Reactor Area equipment and piping.

Ensure that the IPS is isolated completely from the LPS using “blanks” until the LPS is ready to be started up.

The LB Column Feed Condenser is prepared for operation. It is heated up initially by an SH flow from the

LPS Condensate Pump, through the Steam Purge Heater to the LB Column Feed Condenser.

The SH flow from the LPS Condensate Pump is re-directed from the LB Feed Condenser to the inlet of the

reactor system, through the Reaction Area to the IPS. It is returned to the LB Feed Condenser and the LB

Column.



Open the 1 inch bypass line from the hot flush system into the Reactor Feed Heater and Cooler. Ensure the

tempering system is open to the reactor system.

The system pressure valve on the inlet to the IPS is used to control the Reaction Area pressure at 20

kg/cm2g initially. The IPS pressure control valve should be 100% open in manual mode.

Any leaks in the Reaction Area must be repaired at this time, before the high-pressure test.

The Hot Flush Pump is started and a flow is taken through the Steam Purge Heater and the DTA Purge

Heater to the inlet of #3 Reactor. The desired temperature is 250°C.

The Reaction System pressure is then slowly raised in steps of 35 kg/cm2g using the system pressure valve.

A complete leak check should be made during each step before continuing with the next step. The pressure

is increased until a value of 165 kg/cm2g has been reached.

The SH temperature is maintained at, or less than 250°C during this pressure test. This will keep the SH

below its auto-ignition temperature in the event of a leak.

When the pressure test is complete, the system pressure is reduced to 100 kg/cm2g. The SH temperature is

raised from 250°C to 300°C to prepare the Preheater for operation.

Raise the IPS pressure to 37 kg/cm2g and check for leaks. Reduce the pressure to 28 kg/cm2g.

The Solution Preheaters are started after they have been subjected to the hot SH for 3 hours. The

desuperheated DTA Condensate is opened first, then DTA vapor is opened very slowly using the small

diameter warm-up lines provided.

The Reactor Feed Pump is then started to establish a higher SH circulation rate, usually at the RFP minimum

flow value, or at a value that allows the Reactor Feed Heater to sustain a Reactor temperature of 200°C.

Take a flow through the Reactor Feed Cooler.

The Hot Flush Pump is shutdown when the RFP is running and the Reactor feed Cooler is dry.

7.1.12 Catalyst Area One catalyst and one co-catalyst mix tank can be filled with OSBL SH from the SH Makeup Dryer. Drain the

SH from the bottom of the tank and into another mix tank. Drain the last mix tank to the LPS Hold-up Tank.

Diluent systems can be filled with dry SH from the SH Purifier and started up to their respective injection

points. Circulation and dry down of the catalyst pumps and piping must commence as early as possible to

fully utilize the available time for dry down.

When moisture checks at the exit of the SH Purifier, the catalyst diluent header and at the suction of the RFP

have been less than 2 ppm for two or more successive readings, then preparations can be made for

polymerization start-up.



7.1.13 LPS Vessel: When the LPS, Extruder and associated equipment are ready for operation, a polymer seal is established in

the LPS. The Satellite Extruder is used to fill the main Extruder and to pump polymer back into the LPS cone

area. This liquid polymer seal must be maintained at all times when SH is in the LPS.

A flow of SH is routed from the IPS base to the LPS when the seal in the LPS second stage has been

established. Flows can then be taken from the LPS first and second stage overhead lines to the LPS

Condensers to the LPS Hold-up Tank.



7.2 REACTION AREA 7.2.1 Polymerization Start-up

Sr. No.

ACTIVITIES

#1 Reactor Mode Start-up

1. Establish a stable SH circulation loop through the Recycle and Reaction area at approximately

33% of the maximum Total Solution Rate (TSR). The Absorber Cooler will be by-passed. Set

controls for a Reactor inlet temperature of 200°C and a 300°C Preheater outlet temperature.

NOTE: Operate at the lowest circulation rate to save energy but above the Reactor Feed Pump

shutdown interlock

2. Place the IPS level control valve in Manual mode. Adjust it to give a flow rate out of the LPS first

stage of 20% of the TSR value. When polymerization is achieved this flow should be set to 1.5 or 2

times the anticipated RA production rate. The goal is not to allow a level to build in the IPS

until conditions in the IPS are stable.

3. Verify SH, FE and FB-1 or FC purity.

4. Select the RA type, the goal and initial polymerization start-up rates (normally about 50% of

maximum) (At 50% rate some delay in Extruder start-up can be accommodated. Distillation upsets

are less server at lower TSR)

5. Refer the Product Manufacturing Guidelines Manual for the resin type to be produced.

• Calculate the required FE, FB (or FC) and J rates for initial RA rate, and the catalyst and

deactivator rates for goal RA rates.

• Set up the required Reactor system valving, including catalyst injection points and any

J injection points.

• Set system pressure to the required value.

• Start the Reactor Agitator.

• Alert the FE supplier, services supplier, and extrusion area of polymerization start-up times.

6. Set flows to the Reactor in the following order:

• HP Diluent flows are normally left on but flow rates should be checked and adjusted.

• J flow(s) at initial polymerization start-up rate.

• Comonomer at initial polymerization start-up rate.

• Set Preheater outlet temperature at the standard temperature.

• For High Temperature Catalyst (HTC) set the HP Diluent Heater temperature and the diluent

flow at recommended amounts.

• Deactivator at goal rate. (Should be started before catalyst injection)

• Catalyst and Co-catalyst at goal rates (At last to minimize comonomer polymerisation).

7. Set FE flow to the Absorber Cooler at the initial polymerization start-up rate and as pressure

in the Head Tank rises, close the Head Tank bypass.



Sr. No.

ACTIVITIES

8. If the Reactor temperature rises sharply showing a successful polymerization start-up, ignore

Step 9 and go to Step 10. If there is little or no temperature increase, go to Step 9.

(Reaction of FE to RA is exothermic giving about 12.5°C temperature rise per 1% of RA formed.)

9. If the Reactor temperature is not rising sharply after 5 minutes.

• Turn off the FE and bypass the Head Tank. (To avoid upsetting the Distillation area with excess

FE)

• Verify the catalyst flows and re-check diluent flows (A low co-catalyst/catalyst ratio, for example

will prevent polymerisation)

• Increase catalyst 20% maintaining a constant co-catalyst/catalyst ratio. Attempt polymerization

start-up again (Step 6).

• If reaction fails to start; return to Step 1 and identify catalyst deficiency or impurity poisoning the

catalyst. Correct the problem before attempting a polymerization start-up again (Although even

higher catalyst may overcome the problem this would probably give poor RA color. It is better to

remove the impurity or correct the catalyst concentrations).

10. As the reactor temperature increases to about 230°C, turn off the Light-Off Switch (LOS) and

bring the Reactor mean temperature into control (Tmean). Adjust the inlet temperature (lower) to

achieve the desired mean temperature control. Switch to Automatic when stable.

11. Allow a level to build in the LPS second stage. Then establish a level in the IPS. When

the IPS level is steady, establish a sieve level in the LPS (Delays in making the levels will result in a

high percentage of SH in the polymer. The excess volatiles will cause Extruder and Stripper

problems. The extruder and Melt Cutter must be operating before starting this step).

12. Start increasing FE, FB (FC), J and SH to the desired goal rate (The Extruder may be started when

there is a sufficient level in the LPS -II).

13. When the Reactor mean temperature, SH, FE, J and FB (FC) rates are on goal.

• Adjust the total differential temperature to the temperature given in the Manufacturing Guidelines

using catalyst concentration. (Maintain a constant co-catalyst/catalyst ratio). This ensures

approximately the goal conversion (At constant %FE, total differential temperature varies as FE

conversion changes. Raising catalyst and co-catalyst = raising total differential temperature).

• Adjust #1 Reactor differential temperature using the Side Feed flow and/or Reactor Agitator

speed.

• Optimize co-catalyst/catalyst ratio. (Find the ratio which minimizes the catalyst for the goal

differential temperature for the total reaction system). This also sets the Trimmer Reactor

differential temperature.

14. As an accurate FE conversion becomes available, adjust the co-catalyst/catalyst flows to give the

conversion specified in the Guidelines.

15. Adjust the J flow or mean temperature if MI is not on specification or the FB flow if the density is not

on specification. Remember to account for the time lag from the Reactor to the run analysis sample

point (Extruder).



Sr. No.

ACTIVITIES

3→1 Reactor Mode Start-up

1. Establish a stable SH circulation loop through the Recycle and React ion area at approximately

33% of the maximum Total Solution Rate (TSR). The Absorber Cooler will be by-passed. Set

controls for a Maximum Reactor inlet temperature and a 300°C Preheater outlet temperature.

NOTE: Operate at the lowest circulation rate to save energy but above the Reactor Feed Pump

shutdown interlock.

The LOS may be used to direct all flow to the Reactor Feed Heater. 2. Place the IPS level control valve in Manual mode. Adjust it to give a flow rate out of the LPS first

stage of 20% of the TSR value. When polymerization is achieved this flow should be set to 1.5 or 2

times the anticipated RA production rate. The goal is not to allow a level to build in the IPS

until conditions in the IPS are stable.

3. Verify SH, FE and FB-1 or FC purity.

4. Select the RA type, the goal and initial polymerization start-up rates (normally about 50% of

maximum) (At 50% rate some delay in Extruder start-up can be accommodated. Distillation upsets

are less server at lower TSR).

5. Refer the Product Manufacturing Guidelines Manual for the resin type to be produced.

• Calculate the required FE, FB (or FC) and J rates for initial RA rate, and the catalyst and

deactivator rates for goal RA rates.

• Set up the required Reactor system valving, including catalyst injection points and any

J injection points.

• Set system pressure to the required value.

• Start the Reactor Agitator.

• Alert the FE supplier, services supplier, and extrusion area of polymerization start-up times.

6. Set flows to the Reactor in the following order:

• HP Diluent flows are normally left on but flow rates should be checked and adjusted.

• J flow(s) at initial polymerization start-up rate.

• Comonomer at initial polymerization start-up rate.

• Set Preheater outlet temperature at the standard temperature.

• For High Temperature Catalyst (HTC) set the HP Diluent Heater temperature and the diluent

flow at recommended amounts (STD Catalyst will normally be used for 3→1 Reactor mode).

• Deactivator at goal rate. (Should be started before catalyst injection)

• Catalyst and Co-catalyst at goal rates (At last to minimize comonomer polymerisation).

7. Set FE flow to the Absorber Cooler at the initial polymerization start-up rate and as pressure

in the Head Tank rises, close the Head Tank bypass.

8. If the Reactor temperature rises sharply showing a successful polymerization start-up, ignore

Step 9 and go to Step 10. If there is little or no temperature increase, go to Step 9.

(Reaction of FE to RA is exothermic giving about 12.5°C temperature rise per 1% of RA formed.)



Sr. No.

ACTIVITIES

9. If the Reactor temperature is not rising sharply after 5 minutes.

• Turn off the FE and bypass the Head Tank. (To avoid upsetting the Distillation area with excess

FE)

• Verify the catalyst flows and re-check diluent flows (A low co-catalyst/catalyst ratio, for example

will prevent polymerisation)

• Increase catalyst 20% maintaining a constant co-catalyst/catalyst ratio. Attempt polymerization

start-up again (Step 6).

• If reaction fails to start; return to Step 1 and identify catalyst deficiency or impurity poisoning the

catalyst. Correct the problem before attempting a polymerization start-up again (Although even

higher catalyst may overcome the problem this would probably give poor RA color. It is better to

remove the impurity or correct the catalyst concentrations).

10. When the Reactor outlet temperature rises to about 290°C, turn off the LOS and manually lower the

Reactor inlet temperature to the temperature specified in the Manufacturing Guidelines. Switch to Auto

mode when stable.

11. Allow a level to build in the LPS-II. Then establish a level in the IPS. When IPS level is steady, establish

a sieve level in the LPS (Delay in making the levels will result in a high percentage of SH in the polymer.

The excess volatiles will cause Extruder and Stripper problems).

12. Start increasing FE, FB-1 ()FC), J and SH to the desired rate (The Extruder and Melt Cutter must be

operating before starting this step)

13. When the Reactor inlet temperature, FE, FB-1 (FC), J and SH rates are at goal:

Adjust the total differential temperature to the temperature given in the Manufacturing Guidelines using

catalyst concentration (Maintain constant co-catalyst/catalyst ratio). This ensures approximately goal

conversion (At constant %FE, total differential temperature varies as FE conversion changes. Raising

catalyst = raising total differential temperature).

Adjust the co-catalyst/catalyst to control #3 Reactor conversion (Q3).

14. When an accurate FE conversion becomes available, re-adjust the catalyst flows to give the conversion

specified in the Manufacturing Guidelines (As catalyst and co-catalyst concentrations are used for S.E.

Control optimization of FE conversion should be done after MI, S.E. are on spec.)

15. As preliminary MI, density and S.E results arrive adjust FB or FC flow for density control, J and T in for MI

control, JN, Catalyst/co-catalyst ratios for S.E, HSV and Melt Swell control.

NOTE: Raising FB or raising FC = dropping density.

Raising J1 or T in = Rising MI.

Rising J, rising catalyst or dropping co-catalyst = Rising S.E.



7.2.2 Start-up of SH Purification System 1. PURPOSE Taking SH Purifier (31-V-125A/B) System in line. The Purification system start-up includes the SH Purifiers (31-V-125A/B), the Solvent Feed Pump (31-P-101/S), and the HP Diluent Pump (31-P-102/S). 2. REFERENCES P & ID No. 00150-AA-31-1111 & 00150-BA-31-1112

Sr. No.

ACTIVITIES

1. Check that all the SH system steam tracing is turned on (when required) and the traps are working

properly.

2. Line up the following instrument:

• SH Purifier differential pressure PDT-1145 (After the nitrogen pressure test)

• PI-1243 (Solvent Feed Pump Suction Pressure indication)

• PIC-1250 (HP Diluent Pump 31-P-102/S Discharge Line)

• All field gauges.

• Downstream line of FV-1144 (Solvent Purge to SH Purifier or Filling Line)

3. Close all bleed valves on the system and isolate at the following locations:

• The process inlet block valve on each of the Purifier.

• The Nitrogen tie-ins to the inlet of each Purifier.

• The vent lines to the flare header on the inlet line of each purifier.

• The regeneration line tie-ins at the inlet line of each Purifier.

• The drain lines to the LPS Hold-up Tank at the outlet line of the each purifier.

• The Regeneration line tie-ins at the outlet of each purifier.

• The drain line at the SH Filter to LPS HUT.

• The LP Diluent line at the following pressure control valves:

• The solvent feed pump discharge at FV-1314A/B (valves for bypassing the head tank)

• The High pressure Diluent pumps discharge at the relief valves.

• The high pressure diluents pumps discharge at PIC-1250.

• The high pressure diluents pumps discharge at the following flow control valves:

FV-2060/2061, FV-2152, FV-2242.

• The high pressure diluents pump discharge at the catalyst injection points flushing tie-ins.

• After the H.P. diluents heater at the block valve at the injection point into the CAB-2, CD line.

• All connections to the catalyst mixing area.

4. Line up and car seal the following relief valves:

• PSV-1103/1106 (SH Purifier 31-V-125A/B overhead resp)

• PSV-1214 (On Solvent Feed Filter 31-G-103)

• PSV-1216/1219 (On HP diluent pump discharge line)



Sr. No.

ACTIVITIES

NOTE: The HP Diluent Pump discharge PSVs’ will be put online after the recycle SH system is

ready and the nitrogen purge has been completed in the purification system.

5. Admit cold nitrogen to the purification system and pressurise to 350 kPag. With the nitrogen valve

off, allow the system to site for one half hour. If the pressure falls off, determine and eliminate the

cause.

NOTE: Open valves where necessary to pressurise the system to the isolating block valve.

6. When the pressure test is complete, depressurise then cycle the pressure up and down 3-4 times.

This will reduce the oxygen content to a safe level.

7. Line up the system through one purifier, leaving the other on standby. Close control valves which

were opened for nitrogen purging.



7.2.3 Taking Standby SH Purifier In-line 1. PURPOSE. Taking Standby SH Purifier (31-V-125 B) System in line. The Purification system start-up includes the SH Purifiers (31-V-125A/B), the Solvent Feed Pump (31-P-101/S), and the HP Diluent Pump (31-P-102/S).

2. REFERENCES P & ID No. 00150-AA-31-1111 & 00150-BA-31-1112

Sr. No.

ACTIVITIES

1. Ensure that the standby SH purifier to be taken in line is already regenerated and is under slight

positive nitrogen pressure.

2. Check that all the SH system steam tracing is turned on (when required) and the traps are working

properly.

3. Line-up the following instrument:

• PI-1243 (Solvent Feed Pump Suction Pressure indication)

• PIC-1250 (HP Diluent Pump 31-P-102/S Discharge Line)

• FIT-1144 (SH filling line)

• All field gauges

• TI-1161/1162/1163 (SH Silica bed temp)

• FG-1104 (SH Purifier Vent line)

• TI-1137 (On SH purifier vent line)

4. Ensure that the following instrument transmitters are in line:

• PDT-1145 (SH Purifier differential pressure)

• FG-1101 (Free Draining line)

• PG-1115 (On SH supply line to solvent feed pump)

5. Check and ensure that following valves are isolated (if not isolate the same):

• HV-1135/1136 (SH Purifier top inlet line)

• HV-1138/1139 (SH Purifier bottom outlet line)

• HV-1142/1143 (Reg. Nitrogen inlet line at the SH purifier bottom)

• HV-1140/1141 (Reg. Nitrogen outlet line from the SH purifier top)

• HV-1151 (On SH vent line to LPS Hold-up tank)

• Drain valve upstream of FV-1144

• Block valves and drain valve on SH Purifier vent line

• Block valves and drain valve on free draining line take off line from regeneration Nitrogen line.

• Drain valve between HV-1138/1139


• Block valve and drain valve on local nitrogen inlet tie-in line to the SH inlet line to purifier.

6. Check and ensure that FV-1144 is closed and is in manual mode with 0% output.

7. Line up and car seal the following relief valve:

• PSV-1106 (SH Purifier 31-V-125B overhead)



Sr. No.

ACTIVITIES

8. Line-up the SH vent line to the Flare by opening the block valves on this line.

9. Check the pressure in the SH Purifier in PG-1102

10. If pressure is less than 0.15kg/cm2g, close the vent line block valve going to flare.

11. Line-up the vent line to LPS Hold-up Tank by opening the block valves on the line.

12. Open HV-1151 from the DCS and vent the nitrogen to LPS HUT.

13. Line-up the SH filling line to SH purifier by opening the block valves on the line.

14. Start filling the Standby purifier with solvent by opening FV-1144 in a controlled manner.

15. Ensure that Standby purifier is full of solvent.

16. Continue the flow through the bed to LPS HUT till the temperature reaches to same as that of the

on-line SH Purifier inlet.

17. Close the vent to the LPS HUT.

18. Close and isolate the filling valve after the new bed has reached operating pressure.

19. Open the Standby SH Purifier HV-1139, 1136, 1135 from the field.

20. Open slowly HV-1138 from the DCS.

21. Check PDI-1145 to ensure flow through the purifier.

22. Slowly close the HV-1128 (31-V-125A) process outlet valve.

23. Close HV-1151.

24. NOTE: Downstream pressure to be watched very carefully as this is the only supply to the solvent

feed pump. Pump damage may happen, if nitrogen is allowed to gas-off the pump.

25. After complete isolation of HV-1128, close HV-1129 from the field.

26. Close process inlet HV-1126/1127 from the field.

27. Open the drain valve between the HV-1126 & HV-1127. After draining, close the block valve.

28. Close the block valves of 31-V-125B vent line.

29. Open the Spent SH Purifier bottom drain line block valves and line-up it to the LPS HUT by

opening the HV-1151.

30. Open the Nitrogen supply line block valve and line-up nitrogen to the spent purifier to drain the

hold-up solvent from the bed.

31. After the Purifier bed is drained allow it to sit for minimum one hour to allow SH draining from the

packing and redraining to the LPS HUT.

Ensure that the steam tracing is isolated to off lined SH purifier.

NOTE: If the bed is not drained well, it will require extended time for the heat-up cycle to remove

the solvent.

32. Now the off lined spent SH Purifier (31-V-125A) bed is ready for regeneration.



7.2.4 Start-up of SH Purifier Regeneration System 1 PURPOSE Regeneration of SH Purifier.

The purifier regeneration system consists of a Purifier Regeneration Blower (31-K-101), Regeneration Blower Aftercooler (31-E-108), Purifier Regeneration Blower Suction Filter (31-G-101), Regeneration KO Drum (31-V-101), SH Recovery Tank (31-V-102), Purifier Regeneration Heaters (31-E-109), Purifier Regeneration Coolers (31-E-110 A/B). 2 REFERENCES P & ID No. 00150-AA-31-1111 & 00150-BA-31-1112 Sr. No.

ACTIVITIES

1. Check that all steam tracing is turned on and all the traps are working properly.

2. Ensure that all instruments have been lined up.

• FI-1222 (Nitrogen inlet line to Blower suction u/s of Filter 31-G-103)

• FIC-1260 ( Reg. Blower discharge flow rate)

• TIC-1259 (Purifier Reg. Heater outlet temperature)

• LI-1240/1241 (On 31-V-101)

• LI-1242 (SH Recover Tank level)

• TI-1258 (On Purifier Reg. Cooler inlet line)

• TI-1236 (On Purifier Reg. Cooler outlet line)

3. Line up all Field Instrument Gauges of Purifier Reg. System.

4. Depressurise the SH purifier to less than 0.007 kg/cm2g.

5. Close all bleed valves in the system and isolate at the following locations:

• The regeneration lines in and out of the purifiers.

• Double block in the lines and open the bleed valves between the block valves.

• The vent line to the flare header from the regeneration knockout drum (31-V-101).

• The block valve on the outlet of the SH Recovery Tank (31-V-102) outlet to the LPS HUT.

• The block valve on the SH Recovery Tank outlet to the vaporisers.

• The low pressure nitrogen supply to the blower suction line.


• PSV-1206 (The regeneration blower discharge)

• PSV-1208 (The regeneration knock out drum)

• PSV-1210 (The SH Recovery Tank)

The system is now isolated for pressure testing. Care will have to be taken to ensure that all

systems are lined up to the point of nitrogen injection. Particular care will have to be taken

because of the three way valves in the system.

7. Ensure that the Regeneration KO Drum (31-V-101) and SH Recovery Tank (31-V-102) are

completely empty.

NOTE: Any liquid remaining in these vessels from the previous regeneration will be saturated with

impurities and must be transferred to the waste fuel system.

8. Line up the Regeneration Blower (31-K-101) through the Regeneration Heater (31-E-109) to the

bottom of the purifier. Line the regeneration system through the purifier (31-V-125A/B), the



Sr. No.

ACTIVITIES

Regeneration Co0oler (31-E-110A/B), Regeneration KO Drum (31-V101), Regeneration Suction

Filter (31-G-103), and back to the blower. (For line up of Reg. Heater, Reg. Cooler follow the

standard procedure. Also vent the Exchanger (31-E-109) to remove any inerts present)

9. Check a low point bleed downstream of the regeneration heater to verify that no DTA has leaked

into the regeneration line. Start the Purifier Regeneration Blower (31-G-101) as per the standard

procedure.

Liquid solvent will accumulate in the Regeneration KO Drum and the SH Recovery Tank as it is

vaporised from the bed and then condensed by the Regeneration Cooler.

10. Ensure that the regeneration nitrogen inlet temperature at the bed should not be exceeded.

NOTE: Temperature above 300°C may damage the Silica Gel Bed.

11. When the bed outlet temperature reaches approximately 80°C, the temperature will remain

constant until all of the solvent has been removed from the bed and then re-continue rising.

12. The first portion of solvent that is collected in the SH Recovery Tank can be transferred to the LPS

Hold-up Tank by opening the bottom block valve through FO-1226, if the impurity level is

acceptable. The remaining solvent that is condensed during the regeneration will be very high in

impurities and it should not be returned to the process. This solvent will be pumped to the waste

fuel system.

13. When the top temperature of the bed reaches approximately 175°C to 200°C, open the purge line

to the flare header from the upstream side of the Regeneration Blower Suction Filter (31-G-103).

Adjust the purge flow to have a nitrogen makeup of about 60 kg/hr (50 m3/hr, Monitor the flow

using FI-1222). (The Regeneration KO Drum and the SH Recovery Tank must be completely

empty of liquid before proceeding for the above step)

14. Continue the step 13 for 5 hours.

15. After the purge cycle has been completed, close the vent valves upstream of Filter.

16. Stop the Reg. Blower as per the standard operating procedure.

17. Isolate the steam tracing of the SH Purifier.

18. Change the 3 way valve (HX-140) position such that the Regeneration Blower discharge will flow

through the Regeneration Blower Aftercooler, SH Purifier Bed, the Regeneration Cooler and back

to Suction of Blower. (Keep DTA supply on to Regeneration Heater to avoid thermal shock. Also

analyse the dew point of Nitrogen to check the tube leakage in 31-E-108

19. Start the Reg. Blower as per the standard operating procedure. This will cool the SH Purifier bed.

20. After the bed has been cooled to less than 50°C, stop the blower.

21. Isolate the bed under a positive nitrogen pressure of approximately 0.35 kg/cm2g. Ensure that the

bleed valves between the regeneration inlet and outlet valve have been left open.



7.2.5 Start-up of FE Feed System 1 PURPOSE. Taking FE Feed System in line.

The FE System consist FE Primary Guard Bed (31-V-127A/B), the Primary FE Guard outlet Filer (31-G-106), Secondary Guard Bed (31-V-132), Secondary FE Guard Bed outlet Filter (31-G-112).

2 REFERENCES P & ID No. 00150-RA-31-1127 & 00427-AA-31-1167

Sr. No.

ACTIVITIES

1. Ensure that Primary FE Guardbed (31-V-127A/B) bed loading is completed and the bed is

regenerated and kept under positive nitrogen pressure.

2. Ensure that FE Supply line steam tracing Nr. B/L is ‘ON’ and traps are working normal.


Primary FE Guardbed (31-V-127A) • PIT-2734 (FE inlet line to FE Guardbed ‘A’)

• PG-2724 (FE Guardbed ‘A’ vent line to flare)

• TI-2761A/2761B/2755 (Guardbed ‘A’ Temperature)

• TG-2703 (Guardbed ‘A’ middle bed temperature)

• FG-2710 (Guardbed Vent line)

• FIT-2758 (On filling line)

• FO-2711 (On filling line)

• PDIT-2769 (Primary FE Guardbed Diff. pressure)

Secondary FE Guardbed (31-V-132) • PIT-2772 (FE inlet line to Secondary FE Guardbed )

• PG-2726 (Secondary FE Guardbed inlet line)

• TI-2771A/2771B/2754 (Secondary FE Guardbed Temperature)

• TG-2706/2707 (Secondary FE Guardbed middle & bottom bed temperature)

• FO-2716 (Secondary FE Guardbed Vent line)

Battery Limit • PIC-6731

• PIT-6713

• PG-6702

4. Close all the bleed valves on the system and isolate at the following locations:

• At the process inlet to the Guardbed.

• At the process out of the guardbed at FV-1318.

• At the regeneration lines in and out of the guardbed.

• At the vent line of flare from the top of the guardbed.

• At the analysers take off point on the guardbed.



Sr. No.

ACTIVITIES

5. Check and ensure that following valves and its manual isolation valves are closed:

• PV-6731 (FE Supply line at B/L)

• HV-6714/6723 (FE Supply line at B/L)

• HV-2732/2733 (31-V-127A inlet line)

• HV-2737/2738 (31-V-127B inlet line)

• HV-2735/2736 (31-V-127A outlet line)

• HV-2740/2741 (31-V-127B outlet line)

• HV-2744/2745 (31-V-127A Nitrogen Inlet line)

• HV-2748/2749 (31-V-127B Nitrogen Inlet line)

• HV-2746/2747 (31-V-127A Nitrogen outlet line)

• HV-2750/2751 (31-V-127B Nitrogen outlet line)

• HV-2764 (Secondary FE Guardbed process inlet line)

• HV-2770 (Secondary FE Guardbed process outlet line)

• HV-2742 (Secondary FE Guardbed Pulldown valve)

• PV-2766 (FE Supply to FE Column Feed Dryers)

• FV-2758 (Filling line)

6. Line up and car seal the relief valves:

• PSV-2719 (On FE Primary Guardbed A)

• PSV-6730/S (FE Supply line at B/L)

7. Line-up Initial Start-up line (3/4”-P-27022-D21A-N) to 31-V-127A.

8. Line-up Initial Start-up line (2”-P-27029-D21A-LP) to 31-V-132

9. Line-up FE Primary Guardbed Filling line valves to 31-V-127A. Keep FV-2758 in manual mode

with 0% output.

10. Line-up FE from B/L up HV-6714 up to upstream.

11. Line-up FE to Primary FE Guardbed and Secondary FE Guardbed through the 1” bypass line (HV-

6723) and pressurise the beds slowly.

NOTE: High Temperature may cause polymerisation leading to damage the beds.

12. Keep watch on the bed temperature indicators, if the temperature rises beyond 60-70 oC,

depressurise it to flare by pulldown valves (HV-2752/2742).

13. When the beds attained the normal operating pressure, line up Primary FE Guardbed process

outlet line HV-2735/2736 to Secondary FE Guardbed (Open HV-2764).

14. Line-up FE inlet line HV-2732/2733 to 31-V-127A.

15. Isolate both the initial start-up lines.

16. Line-up Secondary FE Guardbed outlet line HV-2770, if the downstream section is ready to take

the feed.



7.2.6 taking Standby Primary FE Guardbed In-line 1 PURPOSE. Taking Standby FE Guardbed (31-V-127B) in line. The FE Guard Bed System consist FE Primary Guard Bed (31-V-127A/B), the Primary FE Guard outlet Filer

(31-G-106).

2 REFERENCES P & ID No. 00105-RA-31-1127 & 00206-HB-31-1137

Sr. No.

ACTIVITIES


• PIT-2739 (FE inlet line to guardbed)

• PG-2725 (FE Guardbed vent line to flare)

• TI-2762A/2762B/2756 (Guardbed temperature)

• TG-2704 (Guardbed middle bed temperature)

• FG-2710 (Guardbed Vent line)

• FIT-2758 (On filling line)

2. Ensure that the following instrument transmitters are in line:

• PDT-2769 (FE Guardbed differential pressure)

3. Check and ensure that following valves are isolated (if not isolate the same):

• HV-2737/2738 (FE Guardbed top inlet line)

• HV-2740/2741 (FE Guardbed bottom outlet line)

• HV-2748/2749 (Reg. Nitrogen inlet line at the FE Guardbed bottom)

• HV-2750/2751 (Reg. Nitrogen outlet line from the FE Guardbed top)

• Drain valve upstream of FV-2758

• Block valves and drain valve on FE Guardbed vent line to flare



• Block valve and drain valve on local nitrogen inlet tie-in line to the FE Guardbed bottom filling

line

• Preloading line block valve and drain valve.


5. Line up and car seal the following relief valve:

• PSV-2720 (FE Guardbed 31-V-127B overhead)

6. Line-up the FE Guardbed vent line to the Flare by opening the block valves on this line.

7. Check the pressure in the Primary FE Guard bed in PG-2725.

8. Open the block valves upstream and downstream of FV-2758 and line-up to the standby FE

Guardbed bottom line.



Sr. No.

ACTIVITIES

9. Open the FV-2758 slowly from DCS. (Line no. 2”-P-27016-D21A-LP)

10. Watch the bed temperature using TI-2762A/B/2756.

11. Ensure that the bed has equalized in pressure with the online bed, then close the FV-2758.

12. Close the block valves upstream and downstream of FV-2758.

13. Isolate the vent valve.

14. Open the Standby FE Guardbed process outlet line HV-2741 from the field.

15. Open the FE inlet line HV-2737/2738.

16. Open slowly HV-2740 from the DCS.

17. Keep watch on downstream pressure in PDIT-2717 and PIT-2739.

18. Check PDI-2769 to ensure flow through the guardbed.

19. Slowly close the HV-2735 (31-V-127A) process outlet valve from DCS.

20. Close HV-2732/2733 (31-V-127A) and watch the downstream section pressure.

21. Close HV-2736.

22. Depressurise the header between HV-2732/2733.

23. Open the Spent FE Guardbed vent line block valve and line-up to OSBL until pressure equalises.

24. Open the Spent FE Guardbed vent line block valve and line-up to flare.

25. Open the nitrogen inlet line block valve to Spent FE Guardbed bottom and purge the bed with

nitrogen for one hour.

26. Isolate the purge nitrogen and isolate the vent line block valve.

27. Now the FE Guardbed is ready for regeneration.



7.2.7 FE Gaurdbed Regeneration Start-up 1 PURPOSE FE Primary Guard Bed (31-V-127A/B) Regeneration Start-up

The FE Guard Bed Regeneration System consists of FE Primary Guard Bed (31-V-127A/B), the FE Feed

Dryer Regeneration Blower (31-K-201), FE Feed Dryer Reg. Coolers (31-E-210A/B), FE Feed Dryer Reg.

Heater (31-E-217), FE Feed Dryer Blower Aftercoolers (31-E-211A/B), FE Feed Dryer Regeneration KO Pot

(31-V-205)

2 REFERENCES P & ID No. 00105-RA-31-1127 & 00105-HB-31-1137

Sr. No.

ACTIVITIES

1. Line up nitrogen to the blower suction through the regulator which should be set at 0.4 kg/cm2g.

Before opening the regeneration line valves to the guardbed, it should be depressurised to less

than 0.7 kg/cm2g. All process lines in and out of the guardbed should be double blocked with the

bleed valves between them open.

2. Line-up the regeneration blower through the regeneration heater to the bottom of the guardbed.

Ensure that the bleed valves between the regeneration valves are closed, than line the

regeneration system through the guardbed, the regeneration cooler, KO drum, filter, suction

snubber and back to the blower.

NOTE: Use proper PPE before starting the activity.

3. Ensure that water is lined up to and from the regeneration cooler.

4. Set TIC-1259 temperature control on the heater for 230-280°C.

5. Open the regeneration bypass line to reduce the volume of flow through the guardbed.

6. Start the blower, proceed with heat up and control the temperature at the inlet of the bed at a

maximum of 230-280°C.

7. When the outlet temperature reaches its maximum (approximately 7-12 hours will be required),

shutdown the regeneration blower.

8. Line up nitrogen to the discharge side of the blower so that it flows through the heater and purge

the bed to the flare for one hour at a purge rate of 50 m3/hr (FO-3703 provided).

9. Block in the nitrogen.

10. Allow the bed to depressurise to 0.35 kg/cm2g. Block in the vent valve to flare at the top of the

purifier.

11. Swing the three way valve (HX-229) before the aftercooler (31-E-211A/B) to the cooling mode.

12. Take FE Feed Dryer Regeneration Cooler (31-E-210A/B) in line.

13. Start the Regeneration Blower (31-K-201).

14. Continue cooling the bed until the outlet temperature is down to less then 40°C).



Sr. No.

ACTIVITIES

15. Line up a FE flow of approximately 62 kg/hr to mix in with the cold nitrogen flow going to

guardbed. Reduce the FE flow if the Guardbed temperature rises above 65oC.The temperature

rise is caused by a too rapid rate of FE absorption in the packing. Continue this until increasing

the FE flow does not cause a temperature rise in the Guardbed.

16. Block in FE, shutdown the blower and block in nitrogen to the blower suction.

17. Close all the regeneration block valves in and out of the guardbed and open the bleeds between

the double block valves.

18. Pressurise the FE guardbed to full nitrogen pressure.

The fresh guardbed will normally be filled from the outlet. The start-up line bypassing the

guardbed should be used to allow filling from the bottom only when there is no bed online.

19. Open the HV-2733/2735 or HV-2738/2740 closest to the bed on inlet and outlet of the bed to be

filled. Close the bleed valves between the process block valves.

20. Line up FV-2758 and slowly pressurise the bed.

21. Shut off the filling flow by closing a manual valve. Depressurise the bed to the flare from the top to

7 kg/cm2g. Re-pressurise to full pressure.

22. Isolate the block valve on the filling line.



7.2.8 CAB System Start-up 1 PURPOSE Taking CAB System in line.

CAB system consists of a CAB Mix Tank (31-V-107), CAB Surge Tank (31-V-108), and CAB Metering Pump

(31-P-106).

2 REFERENCES P & ID No. 00105-JA-31-1120, 00105-LA-31-1122 & 00206-AA-31-1128

Sr. No.

ACTIVITIES

1. Check and Ensure that leak check has been carried out and no leak observed.

2. Check and Ensure that the Mix Tank, Surge Tank and connecting piping are dried using

cyclohexane circulation.

3. Check and Ensure that Catalyst KO Drum is made ready to take the vent releases.

4. Check and ensure that SH Make-up Dryer is made ready to take the solvent.

5. Check and ensure that LPS HUT (31-V-201) is made ready to take the solvent.

6. Check and Ensure that CAB Mix Tank Agitator seal conditioning system working properly and is in

“STOP” condition.

7. Check and ensure that weight cell micromotion meter are calibrated and working properly.

8. Line up the following transmitters:

• LT-2053 CAB Mix tank level.

• LT-2059 CAB Surge Tank level.

• AT-2246 (On SH O/L from SH Make-up Dryer 31-V-126)

• FIT-2245 (On SH O/L from SH Make-up Dryer 31-V-126)

• All field instrument to be taken in line.


• PSV-2024 (On 31-V-107 CAB Mix Tank)

• PSV-2026 (On 31-V-108 CAB Surge Tank)

• PSV-2022 (On Nitrogen inlet line to Catalyst ISO Cylinder)

• PSV-2029 (On 31-G-102 CAB/CAB-2 Filter)

• PSV-2218 (On 31-V-126 SH Make up Dryer)

• PSV-2225 (On SH Feed line to 31-V-126 SH Make up Dryer)

10. Check the operation of all control and block valves.

11. Close bottom outlet block valve.

12. Set the nitrogen regulator (PCV-2057) with the restricting flow orifice to control the nitrogen

pressure at 10 kg/cm2g.



Sr. No.

ACTIVITIES

13. Line up the nitrogen flow through the orifice (FO-2009) into the mix tank.

14. Start venting the tank to the Catalyst K. O. Drum (31-V-115).

NOTE: Open the vent valve 10%. If vent opened fully fumes will not be totally deactivated and the

level in the KO Drum will start cycling, setting off the high level alarm.

15. Take SH Make-up dryer in line as per the normal operating procedure. Check and ensure that

Dryer outlet SH stream has moisture content less than 2 ppm.

16. Place the catalyst cylinder in position and verify the material contents. Connect the catalyst

cylinder fittings and hose connections. Purge all connections with nitrogen to remove air.

17. Set the solvent meter (31-FQV-2245) output at 60% of the estimated total required amount

needed for the batch and send it to the mix tank.

18. When the 60% of the total solvent needed for the catalyst batch has been transferred to the mix

tank, start the mix tank agitator.

19. Record the starting weight of the cylinder.

20. Line up the CAB/CAB-2 Filter (31-G-102) as per the standard operating procedure.

21. Set the nitrogen regulator (PCV-2043) to 3.5 kg/cm2g and line the nitrogen into the cylinder by

swinging the 3-way valve on the nitrogen makeup line, and transfer all of the contents of the

catalyst cylinder to the mix tank.

22. Record the weight of the catalyst cylinder.

23. Continuously monitor the solvent for water content at the dryer water analyser readout in the DCS.

24. When all the catalyst has been transferred to the mix tank, calculate the weight of the catalyst that

has been sent to the mix tank. Calculate the extra solvent required to bring the batch to the

required concentration and transfer the remainder of solvent to the mix tank. Use some of this

solvent to flush the catalyst piping connection at the cylinder outlet.

25. Record the total solvent used; the weight of catalyst transferred; and the final level of the mix tank.

26. Close the vent on the mix tank and let the pressure come up to 0.7 kg/cm2g. Allow the agitator to

run for 1 hour after the last of the solvent is sent to the mix tank.

27. Raise the pressure on the mix tank until it is exactly equal to the pressure in the surge tank. Slowly

open the pressure balance line in the vapour line between the mix and surge tanks. Open the

bottom outlet on the mix tank to allow catalyst to flow to the surge tank and to the metering

system.



7.2.9 CAB-2 System Start-up

1 PURPOSE Taking CAB-2 System in line.

CAB-2 system consists of a CAB-2 Mix Tank (31-V-105), CAB-2 Surge Tank (31-V-106), and CAB-2 Metering Pump (31-P-105).

2 REFERENCES

P & ID No. 00105-JA-31-1120, 00105-LA-31-1122 & 00206-AA-31-1128

Sr. No.

ACTIVITIES

1. Check that all steam tracing of the system is turned on and all the traps are working properly.

2. Ensure that leak check has been carried out and no leak observed.

3. Ensure that the Mix Tank, Surge Tank and connecting piping are dried using cyclohexane

circulation.

4. Ensure that Catalyst KO Drum is ready to take the vent releases.

5. Ensure that Agitator seal conditioning system working properly.


• LT-2045 CAB-2 Mix tank level.

• LT-2051 CAB-2 Surge Tank level.




• Ensure that Catalyst weight cell is working properly.


• PSV-2023 (On 31-V-105 CAB-2 Mix Tank)

• PSV-2025 (On 31-V-106 CAB-2 Surge Tank)


• PSV-2029 (On 31-G-102 CAB/CAB-2 Filter)





10. Set the nitrogen regulator (PCV-2049) with the restricting flow orifice (FO-2008) to control the

nitrogen pressure between 10 kg/cm2g.


12. Start venting the tank to the Catalyst KO Drum (31-V-115).

NOTE: Open the vent valve 10%. Id vent opened fully fumes will not be totally deactivated and

the level in the KO Drum will start cycling setting off the high level alarm.



Sr. No.

ACTIVITIES






needed for the batches and send it to the mix tank.




18. Line up the CAB/CAB-2 Filter (31-G-102) as per the standard operating procedure.
















system.



7.2.10 CD System Start-up

1 PURPOSE Taking CD System in line.

CD system consists of a CD Mix Tank (31-V-109), CD Surge Tank (31-V-110), and CD Metering Pump (31-

P-107).

2. REFERENCES P & ID No. 00105-KA-31-1121, 00105-LA-31-1122 & 00206-AA-31-1128

Sr. No.

ACTIVITIES


2. Ensure that leak check has been carried out and no leak observed/ or eliminated.


circulation.




• LT-2137 CD Mix tank level.

• LT-2143 CD Surge Tank level.

• AT-2246(On SH O/L from SH Make-up Dryer 31-V-126)



• Ensure that Catalyst weight cell is working properly.


• PSV-2115 (On 31-V-109 CD Mix Tank)

• PSV-2118 (On 31-V-110 CD Surge Tank)






10. Set the nitrogen regulator (PCV-2141) with the restricting flow orifice (FO-2103) to controlthe








Sr. No.

ACTIVITIES

























system.



7.2.11 CT System Start-up

1 PURPOSE Taking CT System in line.

CT system consists of a CT Mix Tank (31-V-111), CT Surge Tank (31-V-112), and CT Metering Pump (31-P-108).

2 REFERENCES P & ID No. 00105-KA-31-1121, 00105-LA-31-1122 & 00206-AA-31-1128 Sr. No.

ACTIVITIES




circulation.




• LT-2145 (On CT Mix tank)

• LT-2151 (On CT Surge Tank)



All field instrument to be taken in line.

Ensure that Catalyst weight cell is working properly.


• PSV-2117 (On 31-V-111 CT Mix Tank)

• PSV-2119 (On 31-V-112 CT Surge Tank)
















Sr. No.

ACTIVITIES























system.



7.2.12 CJ System Start-up

1 PURPOSE Taking CJ System in line.

CJ system consists of a CJ Mix Tank (31-V-113), CJ Surge Tank (31-V-114), and CJ Metering Pump (31-P-109).

2 REFERENCES P & ID No. 00105-LA-31-1122 & 00206-AA-31-1128 Sr. No.

ACTIVITIES





circulation.



• LT-2235 CJ Mix tank level.

• LT-2241 CJ Surge Tank level.



All field instrument to be taken in line.

Ensure that Catalyst weight cell is working properly.


• PSV-2220 (On 31-V-113 CJ Mix Tank)

• PSV-2222 (On 31-V-114 CJ Surge Tank)
















Sr. No.

ACTIVITIES























system.



7.2.13 Catalyst Knock Out Drum (31-V-115) Start-up

1 PURPOSE

Taking Catalyst Knock out drum in line.

2 REFERENCES P & ID No.: 00105-LA-31-1122 & 00206-AA-31-1128

Sr. No.

ACTIVITIES

1. Check and ensure that the Nitrogen purging and pressure test have been completed in the CAB,

CAB-2, CT, CD and CJ sections.


3. Line up the following instruments:

• LI-2244 (On 31-V-115)

• LG-2202 (On 31-V-115)

• TG-2211 (On 31-V-115)

• PG-2226 (On 31-V-115)

4. Line up service water to the seal leg and establish a seal in the sump.

5. Purge the system with nitrogen through PCV-2243 bypass valve. Or alternatively from

• The CT, CD and CJ tanks.

• The CAB and CAB-2 tanks.

• The vent line of the CAB Drum (make up)

• The vent line of the CT Drum (make up)

• The CAB filter.

NOTE: Do not pressure test as the drum is open to atmosphere and relies on a water seal.

6. Continue the purge until the system is free of oxygen.

7. Check the oxygen content, if satisfactorily low then shut off all the purges.

8. Line up nitrogen through the PCV-2243 on the drum to maintain a small continuous nitrogen flow

through the drum at all times.

9. Pump up the required amounts of isobutanol (20% = 350 litres) and mineral Oil (80% = 1300

litres).



7.2.14 Deactivator System start-up

1 PURPOSE. Taking Deactivator system in line.

System includes a PG storage tank (31-V-116 & 31-V-140), PG Unloading Pump (31-P-117), PG Transfer Pump (31-P-118) & PG Metering Pump (31-P-110/S).

2 REFERENCES P & ID No.: 00105-MA-31-1123 & 31-1191

Sr. No.

ACTIVITIES

1. Check and ensure that leak test and dry down of the system is completed and no leaks were

observed or if any were eliminated.

2. Check that the LP steam is line-up through TV-2329/TV-9107 to the 31-V-116/140 respectively

and the traps are working normal.

3. Line up the following level, temperature and pressure instruments transmitters:

• LI-9106 (On 31-V-140)

• LI-9107 (On 31-V-140)

• LI-2313 (On 31-V-116)

• TIC-2329 (On Tracing Steam I/L to 31-V-116)

• TIC-9107 (On Tracing Steam I/L to 31-V-140)

All the temperature and pressure gauges.

4. Close all bleed valves and isolate the system at the following locations:

• The outlet line of 31-V-116, 31-V-140

• 31-P-110/S, 31-P-117 and 31-P-118 suction/discharge line drain.

• The PG tie-in to the reaction area before the Adsorber Preheater.

• The PD tie-in line to the reaction area after the Adsorber Preheater.


• PSV-2304 (On 31-V-116

• PSV-2305

• PSV-9105

6. Line-up Nitrogen through PCV-9103 and vessel vent PCV-9104 to maintain the vessel normal

operating pressure.

Line-up Nitrogen through PCV-2314 and vessel vent PCV-2315 to maintain the vessel normal

operating pressure.

7. Ensure that all the piping is lined up properly.

8. Connect the ISO container outlet nozzle to the 31-P-117 suction line through a Flexible Hose

tightly.

9. Ensure that 31-V-116 has enough level, so that transfer from 31-V-140 can be stopped for PG

make in 31-V-140 (In case of batch make-up during normal running plant).

10. Isolate the PG Storage bottom outlet line HV-9109.



Sr. No.

ACTIVITIES

11. Transfer the PG to 31-V-140 using the PG Unloading pump 31-P-117.

12. Keep watch on the level of PG Storage Tank 31-V-140.

LAHH-9113 DCS alarm is provided for vessel high-high level.

13. Keep watch on 313-P-117 discharge pressure, PG-9110.

14. After transferring the PG from ISO container to PG Storage tank, stop the pump as per the

standard operating procedure.

15. Keep TIC-9107 on Auto mode so that it will maintain the normal operating temperature inside PG

Storage tank.

16. Line up the PG tank bottom O/L to 31-P-118 suction by opening HV-9109 and line-up the pump

discharge to 31-V-116 inlet line.

17. Start 31-P-118 as per the standard operating procedure and transfer PG from V-140 to V-116.

18. Keep watch on the level of PG Storage Tank 31-V-116.

LAH-2313 DCS alarm is provided for vessel high level.

19. Keep watch on 313-P-118 discharge pressure PG-9101.

20. After transferring PG and filling the vessel up to sufficient level stop the pump P-118 as per the


21. Keep TIC-2329 on Auto mode so that it will maintain the normal operating temperature inside PG

Storage tank.

22. When the reactor system is ready for solvent, allow the metering pump 31-P-110/S to operate on

LP Diluent.

23. Line-up the bottom outlet line to pump 31-P110/S suction.



7.2.15 SH Make-up Dryer start-up 1 PURPOSE Taking SH Make-up dryer in line. System includes SH Make-up Cooler (31-E-116), SH Make-up Dryer (31-V-126), SH Make-up Dryer outlet

Filter (31-G-107).

2 REFERENCES P & ID No.: 00105-LA-31-1122

Sr. No.

ACTIVITIES

1. Check and ensure that LPS HUT is made ready to take SH from OSBL.


3. Line up all field instrument gauges.

4. Line-up and car seal the following relief valves:

• PSV-2225 (On SH make-up dryer cooler outlet line)

• PSV-2218 (On 31-V-126)

5. Line up pure cyclohexane from the storage area, through the SH Make-up cooler (31-E-116) to the

LPS Hold-up Tank bypassing (Using 3-way valve HX-174) the SH Make-up dryer. Pump the

solvent through this line until it is cooler than 40°C.

6. Check the temperature, when it is less than 40°C line the flow through the SH Makeup Dryer to the

LPS Hold-up Tank.

7. Check the water content, using online analyser (31-AT-2248) at the mid-point in the dryer.



7.2.16 SH Make-up Regeneration 1 PURPOSE. Regeneration of SH Make-up dryer (31-V-128) 2 REFERENCES P & ID No.: 00105-CA-31-1113

Sr. No.

ACTIVITIES

1. Bypass the SH Make-up Dryer by changing the position of the 3-way valve (HX-174).

2. Stop the SH supply to SH Make-up cooler by closing the block valve upstream of the cooler. Keep

cooling water supply on in the Cooler.

3. Drain the Dryer to the LPS HUT using nitrogen. Check a bleed valve to verify the vessel is empty.

4. Close the drain line to the LPS HUT.

5. Isolate the Analyser tapping isolation valve.

6. Open the vent line to the flare.

7. Open the high-pressure steam to the tracing coil.

8. Check that steam traps are functioning normal.

9. Allow the dryer to heat up for four hours.

10. Isolate the dryer bottom outlet line by changing the position of 3-way valve (HX-159). Start the hot

nitrogen to the bottom of the dryer through a flow orifice (FO-2207).

11. Check the temperature (TG-2201) on the line to the main flare.

12. When the Temperature reaches 150°C (it will take approx. 2 hrs.) shut off the HP Steam supply to

tracing coil. Release the pressure.

13. Allow the bed to sit and cool. If the dryer is required immediately, it can be cooled quickly by

passing cold nitrogen through it.

14. Leave the dryer under a positive nitrogen pressure (50 kg/cm2) when not in use.



7.2.17 Absorption System and Reactor Feed Pump Start-up

1 PURPOSE. To take Absorption system in line.

The system includes the Absorber Cooler (31-E-102), the Head Tank (31-V-103), Reactor Feed Booster

Pump (31-P-103), Reactor Feed Pump (31-P-104) and the associated piping. 2 REFERENCES P & ID No.: 00105-CA-31-1113 & 00206-AA-31-1128

Sr. No.

ACTIVITIES

1. Check and Ensure that System pressure test is completed and no leak exists.

2. Check and ensure that the Absorber Cooler upstream section (i.e. SH Purifier, Recycle SH air

cooler, Recycle SH water coolers) Dry down is completed.

3. Check and ensure that the steam tracing of Absorber Cooler bottom side, Head Tank and

associated piping are turned on (whenever necessary) and all the traps are working normal.

4. Line-up the following instruments:

• LIT-1322/1323 (On Head Tank 31-V-103)

• LAL-1322/ LALL-1323 (Head Tank low and low-low level trip)

• PIT-1320 (Head Tank Overhead Pressure)

• TIC-1319

5. Line-up all the field instrument gauges.

6. Check the operation of all the control valves and stroke check each of them.

7. Check and ensure that all the bleed valves in the system are isolated.

8. Isolate the system at following locations:

• FV-1318 downstream block valve on FE Supply line.

• Head Tank bottom outlet line to Pulldown Flare header Globe valve.

• Reactor Feed Pump discharge line Block valve.


• PSV-1305 (On Absorber Cooler overhead)

• PSV-1306 (On Head Tank overhead)

10. Open the drydown line on the outlet of the Absorber Cooler to the LPS HUT.

11. Start a flow from the SH Purifier outlet.

12. Line-up the flow through the Reactor Booster pump and Reactor Feed Pump to LPS Hold up tank by

opening the vent on the Reactor Feed Pump discharge. Continue the flow until moisture content

goes below 2 ppm.

13. Take the SH flow through the system bypass line to by opening FV 1314B.

14. When the system is dry line-up the cooling water to the absorber cooler.

15. When the Reactor Feed Tempering system and Reactor system are ready to receive SH, start the

Reactor Feed System as per standard operating procedure.

16. Stop the SH circulation from the Absorber Cooler outlet to LPS Hold-up Tank.



7.2.18 Taking Standby Solution Adsorber inline 1 PURPOSE To take standby adsorber (31-V-104B) in line. 2 REFERENCES P & ID No.: 00105-FB-31-1117, 00105-GA-31-1118, 00206-AA-31-1128 & 00206-BA-31-1129

Sr. No.

ACTIVITIES

1. Check and ensure that the Adsorber swivel joint is boxed up and head cover is boxed up and

tightened.

2. Check and ensure that DTA vapour is turned on (normally 24 hours prior to start-up of vessel) in

the Adsorber tracing and traps are working normal.

3. Check and ensure that nitrogen pressure has completed and bed is purged up and down three

times to reduce the oxygen content to less than 0.5% in the vessel.

4. Line-up PIT-1826 (On Sol. Ads. 31-V-104B).

5. Ensure that Steam Purge Heater (31-E-106) and DTA Purge Heater (31-E-107) are in line and

working normal.

Check FIT-1723 is in line. (On SH I/L to 31-E-106)

TIC-1724 is in line (On SH O/L from DTA Purge Heater 31-E-107).


• PSV-1810 (On Solution Adsorber)

• PSV-1710 (On Hot flush return line to LPS Hold-up Tank)

Ensure that all vents are closed.

7. Isolate all respective bleed point at the following locations:

• PV-1725 u/s & d/s bleeds

• Hot Flush inlet line to Solution Adsorber.

• Hot flush return line.

• Hot flush line bleed points (2 nos.) going to Ads. RA sol outlet line.

• Hot flush return line downstream of PV-1725 going to LBFC.

8. Check and ensure that following control valves are in close position:

• HV-1818/1819 (On RA Sol. Inlet line to Sol. Adsorber)

• HV-1820/1821 (On RA Sol. outlet line to Sol. Adsorber)

9. Line-up Hot Flush inlet line to Solution Adsorber by opening the block valve.

10. Line-up and start the hot flush flow to solution adsorber and the Hot Flush return line to LPS Hold-

up Tank through the LPS Condensers by opening the block valves.

PV-1725 will be kept in manual mode with 0% output.

11. Route the flushing flow into the recharged Solution Adsorber.

NOTE: During normal operation the Hot Flush Pump will be stopped and a small flow from the LPS

Condensate Pump will flow through the Purge Heaters to the LB Feed Condenser.



Sr. No.

ACTIVITIES

12. Start the Hot Flush Pump (31-P-202A/B) and maintain a flow of 3 Tons/hr. Adjust the PV-1725

opening accordingly and start building pressure inside Solution Adsorber.

13. Line-up the hot flush return to LB Feed condenser when pressure reaches to 25 kg/cm2g by

opening the block valve and stop the flow to LPS Hold-up tank by isolating the block valve.

Increase the hot flush flow to 5 tons/hr to allow the temperature control on the Purge Heaters to

remain stable.

14. Increase the pressure on the Hot Flush Pump discharge to 35, 70, 100 and 150kg/cm2g, checking

for leaks at each stage.

15. Maintain the Hot flush Temperature around 300°C by adjusting the flow through TV-1724.

16. As the solution Adsorber pressure increases, check the head and the inlet line flange with an

explosive meter. Check at pressures of 35, 70, 100 and 150 kg/cm2g.

17. Slowly open 31-PV-1725 and allow the Solution Adsorber pressure to decrease to 20 kg/cm2g.

NOTE: Care should be taken so that there should not be any upset of the distillation section.

18. Continue to take solvent through the Solution Adsorber until the Adsorber temperature is maximum

for the solvent pressure.

NOTE: Minimum of 2 hours is required for heat-up. Minimum heat-up temperature is 290°C-300°C.

SWING OVER OF SOLUTION ADSORBER

19. Pressurise the Solution Adsorber to slightly higher (4-5 kg/cm2g) pressure than outlet pressure of

the on-line Solution Adsorber through Hot Flush Pump pressure control valve PV-2930. Put PIC-

2930 in auto mode with a set point more than 4-5 kg/cm2g than the on-line adsorber outlet

pressure.

NOTE: If the pressure is lower, the backward flow into the new Adsorber, as the pressure equalize,

could damage the slotted plates in the bottom of the Adsorber.

20. When the pressure in the new Solution Adsorber is slightly higher than the outlet pressure of the

on-line Solution Adsorber, slowly open the HV-1820/1821 so that the flushing flow will join the

stream from the on-line Adsorber to the IPS.

21. Inform DCS operator to open, and then re-close HV-1819. This verifies the valve has power turned

on and also back-flushes the valve seat of HV-1819.

22. Open the process inlet valve HV-1818. Inform the control room operator that the Solution Adsorber

is on standby.

23. The DCS operator should open HV-1819 slowly, so that sufficient time will be available to fill the

new Solution Adsorber with polymer before proceeding.

24. Check the IPS level. Warn the Extruder operator that the level in LPS-2 may drop as the Solution

Adsorber is filled.

25. When the new Solution Adsorber is full of polymer, very slowly open the inlet of the new bed to

50% stopping for a few seconds at approximate 5% intervals.

26. The DCS Operator may slowly close process inlet line HV-1813 to 15%. At the same time, he will

open HV-1819 to 100%.



Sr. No.

ACTIVITIES

27. Close HV-1813 slowly at approximately 3% intervals until it is 0%

28. When the process inlet line HV-1819 is approximately 50% open, and the process inlet line valve

HV-1813 on the spent Adsorber is 50% closed, swing the Hot flush flow from the new Solution

Adsorber (31-V-1004B) to the spent Solution Adsorber (31-V-104A).

29. Monitor the pressure control valves on the Hot Flush Pumps.

30. Continue closing of HV-1813 and opening of HV-1819 simultaneously.

31. When HV-1813 is fully closed, close HV-1812.

FLUSHING OF THE SPENT SOLUTION ADSORBER

32.. Flush the Spent Adsorber for 15 min. with 4-5 tons/hr rate.

33. Isolate the process outlet line HV-1815 and HV-1816 to pressurise the spent adsorber. When the pressure in

the spent Adsorber is slightly higher than the pressure at the inlet of the on-line Adsorber (Adsorber “B’)

34. Open HV-1813 approximately 15%.

35. Slowly open the block valve HV-1812 approximately 15%.

Note: Open this valve slowly to prevent a pressure bump

36. Flush the inlet dead leg and the valve seats for fifteen minutes at more than 5 t/hr.

37. Isolate spent adsorber process inlet valves HV-1812 and HV-1813 and lock the same (turn off

power).

38. Open the spent adsorber process outlet line valve HV-1815 and HV-1816, so that the hot flush will

now be lined up to IPS.

NOTE: Always open HV-1815 and HV-1816 initially in small steps, to avoid sudden pressure rise at

Reactor #3 inlet, leading to RFP stoppage.

39. Line-up steam to Process inlet line squelcher. Check and confirm that Process inlet line Squelcher

is free of polymer to ensure isolation and flushing of inlet dead leg. If polymer is observed repeat

the flushing steps till the Squelcher is clear.

40. Increase the flushing rate to maximum possible. Adjust Hot Flush pressure at 130 kg/cm2g through

PV-2930 to achieve the flow. For effective flushing, always maintain DTA Purge Heater outlet

temperature 300°C during flushing.

41. When correct amount (Aprrox. 210 tons) of solvent has been flushed through the Solution

Adsorber, slowly reduce the flushing flow to 3 t/h.

42. Isolate spent adsorber process outlet line valve HV-1815 & HV-1816.

43. Isolate Adsorber hot flush supply valves at DTA Purge Heater outlet and direct hot flush flow to LB

feed system through normal hot flush circulation route. During this operation control the hot flush

pump pressure through PV-1725.

44. Check for any presence of polymer by spent adsorber process outlet line Squelcher.

45. If the clear solvent is seen through the squelcher, depressurise between these outlet block valves.

46. Close in the flushing header at the Solution Adsorber inlet.



Sr. No.

ACTIVITIES

DEPRESSURISING AND NITROGEN PURGING

47. Check and ensure the following valve position:

Hot flush inlet line block valves are closed tightly.

Spent Adsorber (31-V-104A) process outlet line motor operated valves HV-1815 & HV-

1816 are closed tightly.

Spent adsorber 31-V-104A inlet and outlet squelcher is kept open with throttled steam

supply.

48. Open both hot flush return line block valves and line-up the flushing outlet to 31-PV-1725.

49. Line 31-PV-1725 to the LB Feed Condenser.

50. Depressurise the Solution Adsorber to 20 kg/cm2g slowly to prevent an upset in the LB Column.

51. Block in the flow to the LB Feed Condenser (31-E-202). Open 31-PV-1725 to the LPS Hold-up

Tank (31-V-201) through the LPS Condensers (31-E-201A/B/C) and depressurise the remaining

pressure.

52. When the pressure it he Solution Adsorber is less than 3.5 kg/cm2g, open the hot nitrogen line into

the flushing header and purge the remaining solvent in the Solution Adsorber to the LPS

Condenser.

53. Close the line to 31-PV-1725 and open the flushing outlet header to the Polymer Knockout Drum.

54. Pressurise and depressurise three times during the purging to the Polymer Knockout Drum. Open the inlet line

HV and purge the process inlet vent valve. Check with an explosive meter and when non-explosive close the

control valve. Also analyse sample from hot flush return bleed for hydrocarbon contamination in laboratory.

55. Depressurise the Solution Adsorber through the inlet and outlet vent valves and check with an

explosive meter.

56. Ensure that a nitrogen purge has been taken through all bleed valves. If the Solution Adsorber is

explosive, repeat the nitrogen pressurizing procedure.

57. When the Solution Adsorber is decontaminated, double block and vent the nitrogen tie-in.

58. Ensure that all process and hot flush inlet and outlet lines are double blocked and tagged.

UNLOADING OF SPENT ALUMINA BED

59. Connect the Adsorber Plenum (HX-136A) to Solution Adsorber (31-V-104A).

60. Ensure that the other end is connected to the suction of Exhaust Fan (31-K-103).

61. Ensure that PA Fallout Hopper (31-V-124) is empty before lining up the vacuum system to the

Solution Adsorber to be emptied.

62. Line-up Nitrogen to Filter Receiver (31-G-104).

63. Connect the Flexible connector (HX-145) assembly to process inlet line.

64. Line-up Nitrogen to PA Blower discharge line through the rotometer (FG-2606) and start purging at

the rate of 100-120kg/hr.



Sr. No.

ACTIVITIES

65. Line the Oxygen Analyser AT-2634 and ensure that the oxygen content is less than 8%.

66. Start the Exhaust Fan (31-K-103.)

67. Remove the Solution Adsorber top head. Maintain a nitrogen blanket in the Solution Adsorber with

a nitrogen hose (3/4” hose w/quick connection provided on nitrogen line).

68. Ensure that PA Fallout Hopper bottom outlet line HV-2639 and HV-2640 is closed and nitrogen is

ON through rotometer FG-2607 between them.

69. Remove the blind flange on the process inlet line and connect the unloading tube and hose

assembly (HX-113) to the Solution Adsorber.

70. Remove the nitrogen hose connected for blanketing purpose.

71. Line-up PA Blower Suction Filter (31-G-105A/B) and cooling water to PA Blower Suction Cooler

(31-E-114) as per the standard operating procedure.

72. Line-up cooling water to PA Blower Intercooler (31-E-115).

73. Line-up PA Blower discharge to Solution Adsorber (31-V-104A).

74. Purge the system with Nitrogen connection provided at the PA Blower suction line.

75. Start the PA Blower as per the standard operating procedure and remove the pent alumina.

76. Stop the PA Blower after complete transfer of spent alumina and isolate the blower discharge block

valve on the nitrogen return line.

77. Continue Nitrogen purging to filter for at least one hour after unloading operation is completed to

ensure cleaning of filter bags.

78. Remove the HX-113 assembly from the Solution Adsorber.

79. Allow the spent alumina to cool before transferring it to the Disposal Vessel.

80. Reduce nitrogen flow in line between HV-2639 & HV-2640

81. Open the nitrogen line into the Spent Alumina Disposal Trailer and connect the ground strap.

82. Check the Oxygen content (it should be <5%)

83. Connect HX-157, HX-158. Open HV-2639 and HV-2640 and transfer the spent alumina to Disposal

Trailer.

84. Close HV-2639/2640 after transferring all the material. Disconnect HX-157, HX-158.

CHARGING ALUMINA

85. Inspect the Solution Adsorber and grid for cleanliness before charging the fresh alumina.

86. Install PA Charge Funnel (HX-114) on Solution Adsorber.

87. Check and ensure that HV-2628 is closed.

88. Start Charge Heater Blower (31-K-104) to remove any fines generated during charging of Fresh

Alumina.



Sr. No.

ACTIVITIES

89. Charge the required quantity of Fresh Alumina in PA Charge Hopper with the help of PA Bag Hoist

(31-ME-102).

90. Line-up HP DTA vapour to PA Charge Heater as per normal operating procedure.

91. Continue to run PA Charge Blower to heat the fresh charged alumina till TI-2627 shows 200°C after

that stop the Blower.

92. Swing PA Loading Chute using Swivel Joint (HX-146) into loading position.

93. Check and ensure that Exhaust Fan (31-K-103) is running to remove alumina dust.

94. Open HV-2628 provided on the bottom outlet line of PA Charge Hopper and transfer the material to

Solution Adsorber.

95. Check and ensure that all the alumina Is transferred to adsorber and Hopper is empty.

96. Close HV-2628 and clean the head surface.

97. Remove the PA Charge Funnel and reinstall the end blind flange in the inlet line of solution

adsorber. Box up the Adsorber head cover.

98. Stop Exhaust Fan.



7.1.19 “J” System Start-up Procedure Sr. No.

Description

1. Ensure that all the pre-commissioning activities are completed and system leak check is cleared.

2. Check and ensure that all start-up permissive are satisfied.

3. Start nitrogen flow to the vent header through FG-2405.

4. Line-up all the instruments in the system.

5. Keep FV-2421A/B and FV-2422A/B in manual mode with 0% output. Keep its upstream and

downstream isolation valves in closed condition.

6. Line-up PDV-2417 upstream and downstream isolation valves.

7. Select HS-2417 towards PIC-2417.

8. Inertise the Compressor suction and discharge lines individually by Nitrogen connection provided at

the suction and discharge line.

9. Now fill the system with hydrogen and purge the lines to safe location from Reactor inlet and RFP

discharge points, so that hydrogen atmosphere will be there before starting the compressor.

10. Before starting the blower check and ensure the followings:

• Cooling water inlet and outlet valves are opened and water is available.

• Water temperature is about 33°C.

• Oil level is sufficient. If the compressor is stopped from a long period, or after a lube oil drain

(for maintenance operations), the operator must check the crankcase oil level and the oil plates

must be filled using manual lube oil pump.

• Compressor must is isolated and vented (The HV-2430, HV-2431 / HV-2432, HV-2433 valves

being closed, the manual offloading valves (suction and discharge line) are opened to unload the

compressor gas circuit and for inertising the system then it is manually closed by the operator

before start)

NOTE: To avoid excessive loads on compressor and drive system, unloading is recommended

when the unit is to be started and also after stop of the machine. Unloading the unit is simply

venting the process gas pressure from the isolation valves, respectively HV-2430, HV-2431 for

31-K-102 /HV-2432 and HV-2433 for 31-K-102S being in closed condition.

11. Open the HV-2430 and HV-2431 upstream isolation valves.

12. Reset the system

13. Push the START button and start the compressor drive motor and check direction of rotation.

14. HV-2430/2431 will get open automatically 5 seconds after compressor start up.



Sr. No.

Description

15. The following signals are overridden for approx 8 seconds

• Gas suction pressure transmitters PALL-2429A/B

• Lube oil pressure transmitter PALL-2480A/B

• Vibration transmitter VAHH-2488A/B

• HV limit switch ZSO-2430/2431 for 31-K-102 and ZSO-2432/2433 for 31-K-102S.

• The inter stage pressure transmitter PALL-2450A/B should be overridden till the inter stage

pressure reach the 54 kg/cm2g

16. Check oil pressure and gas pressure, temperatures, noises and vibrations.

17. Check condensate accumulation rate and drain the condensate to avoid filling condensate reservoir

and carrying over liquid.

18. When the downstream section is ready to take the feed, select HS-2417 towards PDIC-2417 then

line up FV-2421A/B and FV-2422A/B as per the requirement.



7.1.20 Hydrogen Buffer Storage Start-up Procedure: Sr. No.

Description

1. Ensure that all the pre-commissioning activities are completed and system leak check is cleared.

2. Line-up all the instruments in the system and ensure that all instruments are working normal.

3. Check and ensure that PSV-8001A/B and PSV-8002A/B are taken in line and car sealed.

4. Check and ensure that all the appropriate vent and drain points are closed.

5. Inertise and purge the system with nitrogen through the points provided at the Hydrogen

compressor discharge line and the buffer storage vent line.

6. Check the oxygen content it should be less than 1%.

7. Fill the system with hydrogen by opening PDV-2417 bypass valve to displace nitrogen from the

system and purge it to hydrogen flare before taking pressurised hydrogen gas in the storage.

8. Isolate the all the vents opened earlier and PDV-2417 bypass valve once hydrogen atmosphere is

established in the system.

9. Select Mode of Operation “STORAGE” through Selector switch HS-8005 (As 31-K-102S is

envisaged to be used for pressurising Hydrogen Bullet).

10. Check and ensure that HS-8004 is selected for “PROCESS” mode (To avoid tripping of blower due

to activation of any interlock related to Hydrogen Buffer Storage).

11. Line-up HV-2433 downstream isolation valves (02 nos.) to buffer storage.

12. Start the Compressor 31-K-102S as per standard operating procedure (Refer Vendors’ document

for the procedure)

13. Pressurise the vessel up to normal operating pressure.

14. Stop the compressor as per the standard operating procedure (Refer Vendors’ document for detail

shutdown procedure).

15. Close the isolation valves provided on line going to buffer storage.

16. Change the selector switch position to “PROCESS” mode.



7.3 RECYCLE AREA START –UP 7.3.1 LB Column System Start-up 1 PURPOSE

To take Low Boiler Removal System in line.

LPS Condensers (31-E-201A/B/C), LPS Hold-up Tank (31-V-201), LPS Condensate Pump (31-P-201/S), Hot

Flush Pump (31-P-202A/B), LB Feed Heaters (31-E-207A/B), LB Feed Heater No.2 (31-E-206), LB Feed

Condenser (31-E-202), LB Column (31-C-201), LB Column Reboiler (31-E-203), LB Condenser (31-EA-201),

LB Trim Condenser (31-E-204), LB Reflux Drum (31-V-204), LB Reflux Pump (31-P-203/S).

2 REFERENCES P & ID No.: 00206-AA-31-1128, 00206-BA-31-1129, 00206-CA-31-1130 & 00206-DA-31-1131.

Sr. No.

ACTIVITIES

1. Check and ensure that the LB Column System leak check is done and the system is made inert using hot/cold nitrogen as per the standard operating procedure and requirement. Also keep system under positive nitrogen pressure of 0.35 kg/cm2g.

TAKING SH IN THE SYSTEM

2. Check and ensure that LPS HUT and connected piping leak check is done and the system is

inertised using Cold nitrogen/Hot nitrogen, positive pressure (0.35 kg/cm2g) of Nitrogen is

maintained in the tank through PV-2817B.

3. Ensure that PV-2817A/B are in line.

4. Check and ensure that the LPS Condensate Pump (31-P-201/S) and Hot Flush Pump (31-P-

202A/B) suction and discharge line leak test is done and the system is made inertise using cold/hot

nitrogen.

5. Check and ensure that steam tracing is turned on and all the steam traps are working normal.


• LIT-2815 (On LPS Hold-up Tank)

• LIT-2816 (On LPS Hold-up Tank Boot leg)

• PIT-2817 (On LPS HUT)

• FIT-2812 (On SH Supply line from OSBL to LPS HUT)

• All field gauges

7. Line-up and car seal open PSV-2803 (On LPS HUT).



Sr. No.

ACTIVITIES

8. Check that the following drain valve is closed:

• SH Supply line to LPS HUT

9. Check that the following isolation valves are closed:

• LPS HUT Bootleg drain valve

• Block valve on line from SH Purifier

• Block valve on line from solvent condensate pump

• Block valve on line from Flare KO Drum

• Block valve on SH De-inventory line

• SH line to/from De-inventory tank

• Block valve on SH Supply line from OSBL

• Block valves on inlet lines to LPS Condensers

• Block valves on lines from LPS condensers outlet

• Block valve on line from CM Column

• Block valves on lines from various pump drain

• Block valve on the tie-in line from CM Column to LPS Condenser

• Block valve on the tie-in line from LB Column to LPS Condenser

• Block valve on SH line to additive Cooler

• Block valves on Analyser vent lines

10. Open the Block valve on OSBL SH Supply line and take the 60% SH level in LPS HUT. Also check

the working of low and high level alarm of LPS HUT.

11. Isolate the OSBL SH supply line block valve to LPS HUT.

TAKING LPS CONDENSATE PUMP IN LINE

12. Check that the following valves are isolate:

• Pump suction filter drains

• Pump discharge drain

• Block valve on back flush tie-in line from LB Column bottom

• LB Feed Heater upstream block valve

• Block valve on line going to Hot flush pump suction

• HV-2940 on line going to Hot Flush pumps suction

13. Check and ensure that the pump suction filters are cleaned.

14. Check oil level in bearing housing is normal. Top up if required.

15. Line-up the Pump discharge PG-2902/2905.

16. Confirm the level in LPS HUT is between 50-60% as indicated by LI-2815 in DCS.

17. Check and ensure that PIT-2817 is in line and normal operating pressure is maintained in LPS HUT

through PV-2817B.

18. Open the pump suction valve of both pumps.

19. Check for any leakage through the seal.



Sr. No.

ACTIVITIES

20. Line-up the pumps discharge to the LPS HUT by opening the discharge line block valves and HV-

2968.

21. Check and Ensure that seal pot is filled with SH and for the initial plant the pump integral seal

flushing is lined up.

22. Check and ensure that HV-2817A is fully open.

23. Check that “Z” trip in not active.

24. Start pump in manual mode by pressing start-up push button at local start switch. Check running

lamp indication is coming at control room. Take the pump in Auto mode.

25. Check for any leakages or any abnormal sound from the pump.

26. Check for any abnormal noise from pump/pump discharge line.

27. Continue the cold circulation of SH until downstream section is ready to take the feed.

LINE-UP OF LPS CONDENSERS (SHELL SIDE)

28. Check and ensure that Shell side pressure test (leak test) has done.

29. Check that cooling water heater is charged up and cooling water is available for the plant.

30. Line-up the field instrument gauges. Take FIT-2813 in line.

31. Check and ensure that the following valves are in isolated condition:

• Tube side inlet and outlet block valves

• Cooling water return line block

• Back flush line block valves (inlet/outlet)

• Emergency Cooling water supply line block valve

• Block valve Minimum bleed flow of Emergency cooling water line

32. Check and ensure that TV-2814 is closed and is in manual mode with 0% output.

33. Line-up the Cooling water supply line PSV-2907/2911/2912

34. Crack open the vent valve of the condenser to make it free from non-condensable.

35. Start opening the line block valve.

36. Open the vent valve fully.

37. Ensure that full bore flow is coming out from the condenser.

38. Line-up the return line to the header.

39. Open the TV-2814 in manual mode. Keep the opening such that continuous flow of cooling water

should always be there.

40. Line up the Emergency cooling water minimum bleed flow line block valve to Cooling water return

line.



Sr. No.

ACTIVITIES

LINE-UP OF PROCESS STREAM IN LPS CONDENSER (TUBE SIDE)

NOTE: This activity should be started simultaneously while Line-up of SH to LB Column.

41. Take TI-2813, TIT-2814 and PG-2809 in line.

42. Line-up and car seal open the PSV-2801/2810/2813.

43. Line-up all the condenser one by one by opening the inlet and outlet line block valves.

44. Take TV-2814 in cascade with TIC-2814.

TAKING SH IN LB COLUMN

45. Check and ensure that line after following valves are isolated:

• Block valve on Hot flush pump bypass line

• Drain valve on LB feed Heater inlet line

• HV-3032 on LB Column bottom

• Block valve on Hot nitrogen tie-in line to LB column bottom outlet line

• Block valve on Back flush take off line to LPS Condensate. Pump

• Block valve on LB Column bottom outlet line after HV-3032

• Drain valve on LB Column bottom outlet line downstream of HV-3032

• Block valve on HB Column Feed line

• Block valve on emergency RB column flushing line

• Block valve on LB Feed line from LBFC outlet


47. Check and ensure that FV-3031 is closed and in manual mode with 0% output.

48. Line-up the following instruments: • TG-2915 (LB Feed Heater Outlet line)

• TI-3042/3025B (Column bottom)

• TI-3025A (On LB Column feed line)

• TI-3027 (On Tray No.20)



• TI-3028C (On Tray No.39)

• TI-3028B (On Tray No.43)

• TI-3028A (On Tray No.47)


• TI-3021 (LB Column overhead)

• PIT-3022A/B/C/D ( LB Column overhead)

• PIT-3024 (LB Column Bottom section)

• LIT-3030/3046 (LB Column bottom level)

• FIT-3031 (LB Column bottom outlet flow meter)

• TG-3002 (LB Column bottom outlet temperature gauge)



Sr. No.

ACTIVITIES

49. Line-up the following relief valves:

• PSV-2907 on (31-E-207A/B) discharge line (Tube Side) and its discharge to LPS HUT

• PSV-3005 on LB Column overhead

• PSV-3016 on LB Feed line downstream of LB Feed Heater No.2

50. Ensure that LB Column reflux drum vent is lined-up to flare header for venting the nitrogen.

51. Line-up the LB Feed Heater tube side by opening the LPS Condensate Pump line block valve.

52. Open the LB Feed Heater outlet line block valve.

53. Open HV-2924 in manual mode.

54. Start taking level in LB Column bottom by taking feed through LB Feed Heater No.2 tube side.

55. Check the level of LB Column bottom when it reaches to 50-60%, open the column bottom HV-

3032.

56. Line-up the LB Column bottom to LPS HUT by opening FV-3031 in manual mode taking the flow

through LPS Condensers.

57. Take FV-3031 in Flow control mode.

58. Take FV-2924 in cascade with LIC-3030.

59. Continue the circulation of SH through this loop.

LINE-UP OF HP STEAM TO THE LPS FEED HEATER NO. 2

60. Ensure that the steam is available. Get necessary clearance.

61. Ensure that all control valve stroke check is done and the other instruments are functioning

properly.

62. Line-up and car seal open PSV-3012 on steam side.

63. Ensure that TV-3025 is closed and is in manual mode with 0% output.

64. Charge HP steam up to TV-3025 upstream by opening the bypass of the upstream isolation valve.

65. Open drain isolation valves located at upstream of TV-3025 and ensure that dry steam comes out

through it.

66. Open the main block valve upstream of TV-3025.

67. Ensure that heater shell side highest vent is opened.

68. Open TV-3025 10% from the Control room.

69. Ensure that there is continuous steam flow through heater shell side vent (This ensures that shell

side is free of air and hence the non condensable)

70. Keep watching the pressure of the shell by observing PG –3010.

71. Open the drain valve upstream of LV-3007.

72. Drain the condensate from the shell side of the exchanger.

73. Isolate the heater vent valve.



Sr. No.

ACTIVITIES

74. Isolate the condensate drain valve when the operating pressure is attended.

75. Take TV-3025 in Automatic control Mode.

76. Take LV-3007 in Automatic control Mode.

LINE-UP OF LB CONDENSER

77. Check TIT-3210 is in line

78. Get the clearance from Maintenance to start the fans of the condenser.

79. Get the motors of the fan energised.

80. Check that the fields start switches of the fans is locked in the stop position.

81. Get the clearance from control room for starting the fans.

82. Start the fan from the field by taking the switch in manual mode.

83. Check for any abnormal noise, vibrations, etc.

84. Inform control room and change the fan switches to auto mode. Now the control of the fans shifts to

the control room keeping the set point as per the normal operating condition.

LINE-UP OF COOLING WATER IN LB TRIM CONDENSER

85. Check and ensure that Shell side pressure test (leak test) has done.

86. Check that cooling water heater is charged up and cooling water is available for the plant.

87. Line-up the field instrument gauge TG-3116.



• Back flush line block valves (inlet)

89. Line-up the Cooling water return line PSV-3117.

90. Crack open the vent valve of the condenser to make it free from non-condensable.

91. Start opening the cooling water supply line block valve.

92. Open the vent valve fully.

93. Ensure that full bore flow of cooling water is coming out from the condenser. Isolate the vent valve.

94. Line-up the cooling water return line to the header.

TAKING FB-1 IN LB COLUMN REFLUX DRUM/ FE IN LBFC

NOTE: This activity should be started after taking reboiler in line and raising the column pressure to

approximately 10 kg/cm2g.


• PG-3106 (Reflux drum pressure gauge)

• FIT-3123A/B (Reflux drum overhead gas flow to flare)

• LIT-3121 (Reflux drum level)



Sr. No.

ACTIVITIES

• LIT-3122106 (Reflux drum boot leg level)

• TG-3104 (Reflux drum temperature gauge)

• FIT-3134A/B (FB-1 supply line)

96. Check and ensure that following instruments are in line:

• TIT-3120 (Receiver feed temperature)

• PIC-3022B (Receiver pressure controller)

97. Line-up and car seal PSV-3138.

98. Check that the following valves are closed:

• Reflux pump (31-P-203) suction valves

• Vent & drain valves of the level indicator

• Boot leg drain valve

• HV-3133

• Isolation valve upstream of HV-1324

• HV-3124

• HV-3139 and its upstream and downstream isolation valves

99. Ensure that FV-3134A is closed and is in manual mode with 0% output.

100. Ensure that PV-3022B is in line.

101. Open FV-3134A in the FB-1 line and block valve in the FE line to Reflux drum and take 25-30%

level in LB Reflux Drum.

LINE-UP OF LB COLUMN REBOILER

102. Ensure that DTA Package is in service and sufficient quantity of LP DTA is available.


• LIT-3035 (On Reboiler DTA side level)

• TG-3001 (On vapour outlet line from Reboiler)

• TI-3045 (on LP DTA cond. Return line)

• PIT-3034 (On LP DTA inlet line)

• FIT-3033 (On LP DTA inlet line)

104. Line-up and car seal open PSV-3004.

105. Check that the following instruments are in line.

• LT-3046 (LB Column bottom Level indicator)

106. Ensure that FV-3033 is closed and is in manual mode with 0% output.

107. Ensure that LV-3035 is closed and is in manual mode with 0% output.

108. Check that there is 40 to 60% level in the LB Column bottom as indicated by LI-3046. Confirm it

with the LIT-3030. Ensure that column internal circulation is on.

109. Confirm that the following valves are closed:

• Isolation valves of FV-3033 (LP DTA flow to 31-E-203)

• LV-3035 (LP DTA Cond. Return line)

• Vent / drain valves in the inlet/outlet side of the Reboiler



Sr. No.

ACTIVITIES

110. Line up traps at the upstream and downstream of the Reboiler LP DTA inlet line isolation valves.

111. Open the drain valve upstream of FV-3033, charge the LP DTA up to the FV-3033 upstream side.

112. Isolate the drain valve.

113. Ensure that FB-1/FE is taken in LB Reflux drum.

114. Ensure that LB condenser and LB Trim condenser are taken in line.

115. Take PV-3022B in auto mode.

116. Open the Reboiler shell side vent.

117. Line-up the LP DTA condensate to the Reboiler shell side by opening the by-pass of LV-3035.

Take a level of 90%.

118. Open the FV-3033 slowly so that LP DTA vapour will displace the condensate and pressurise the

Reboiler up to operating pressure.

119. Keep close watch on PIT-3034.

HOT SH CIRCULATION THROUGH THE LOOP

120. In order to get stable conditions in the LB Column start taking FB-1 from LB reflux drum by starting

the Reflux pump (31-P-203/S) as per standard operating procedure.

121. Operate the column on Total reflux.

122. As the column comes to normal operating pressure and temperature, the condensate level in the

Reboiler will have to be lowered to approx. 30%.

123. Take LV-3035 in cascade with PIC-3034.

124. Take FV-3033 in auto mode with FIC-3033.

125. Continue the hot circulation of SH for dry down through the loop.

126. Check the LPS HUT and LB Reflux Drum boot leg for presence of water.

127. Drain the water from the boot leg of LPS HUT and LB Reflux drum.

128. Check the water content in the circulating SH, it should be less than 10-15 ppm.

129. If the sample result is OK take the LB bottom to downstream section.



7.3.2 HB Column System Start-up 1 PURPOSE

To take High Boiler Removal System in line.

This system consists of HB Column (31-E-202), HB Column Reboilers (31-E-205A/B), HB Condensers (31-

E-216A/B), HB Reflux Drum (31-E-203), HB Reflux Pump (31-P-204/S).

2 REFERENCES P & ID No.: 00105-AA-1111, 00206-AA-31-1128, 00206-CA-31-1130, 00206-FA-31-1133 & 00206-FB-31-

1134

Sr. No.

ACTIVITIES

1. Check and ensure that the HB Column System leak check is done and the system is made inert using hot/cold nitrogen as per the standard operating procedure and requirement. Also that the system is kept under positive nitrogen pressure of 0.35 kg/cm2g.

LINE-UP OF LP BFW IN HB CONDENSER (SHELL SIDE)

2. Check and ensure that the all the utility headers are charged.

3. Check and ensure the availability for the LP BFW by checking the header pressure.


• LIT-3432/3450 (BFW level)

• PIT-3430 (Steam outlet line pressure)

• PG-3419 (On steam outlet line)

• TG-3413 (On steam outlet line)

• TG-3415 (BFW supply temperature gauge)

5. Line-up and car seal open PSV-3411A/B.

6. Stroke check PV-3439.

7. Ensure that PV-3439 is closed and is in manual mode with 0% output.

8. Ensure that LP Steam is charged up to 10” isolation valve on the steam outlet line of HB

Condenser.

9. Ensure that boiler blowdown system (i.e. Hot Well system 31-LZ-201) is made ready.

10. Ensure that Boiler feed water is lined up to upstream of the Globe valve on BFW Supply line.

11. Open PSV-3411A/B upstream vent valve and 1” vent valve provided on the LP steam outlet line.

12. Start Taking BFW the HB Condenser by opening the isolation valve.

13. Close the IBD valve and 11/2” gate valves on the IBD line of HB Condenser when clear boiler feed

water starts coming out.

14. Check level in LT-3432 and crosscheck with the LT-3450. (Take 50-60% level in the condenser)



Sr. No.

ACTIVITIES

15. Line-up the CBD valve to hot well.

16. After the HB Reboiler start up, the steam generation will start in the boiler. When dry steam starts

coming out from vents, start throttling the vent valves and raise the pressure up to slightly higher

than the LP steam header pressure.

17. Watch the pressure in the boiler in PG-3419.

18. Equalise the pressure upstream and downstream of Stop check valve.

19. Line-up the steam to LP stream header by opening PV-3439.

20. Take PV-3439 in Automatic control mode.

21. Maintain the BFW level of HB Condenser by manually.

22. Follow the same the same procedure as given above to take 2nd HB Condenser (31-E-216A) in line.

PREPARING HB COLUMN REFLUX DRUM

23. NOTE: This activity should be started simultaneously while taking Reboiler in line.

24. Line-up the following instruments: • PG-3409 (Reflux drum pressure gauge)

• TW-3407/3408 (Outlet from HB Condensers to Reflux drum)

• TI-3457 (Outlet from HB Condensers to Reflux drum)

• LIT-3432 (Reflux drum level)

• TG-3404 (Reflux drum temperature gauge)

• FIT-3134A/B (FB-1 supply line)


26. Check that the following valves are closed • HB Reflux pump (31-P-204) suction valves

• Vent & drain valves of the level indicator

• HV-3433

• HV-3446 (Pulldown valve)

• HV-3445 (Pulldown valve)

• Isolation valve upstream of HV-3445

• HV-3433 and its upstream and downstream isolation valves

PREPARING RECYCLE SH AIR COOLER

27. Line-up the following instruments: • TI-1150 (inlet line to Cooler)

• TI-1155 (Cooler outlet temperature)

• PIT-1124 (inlet line to Cooler)

• FIT-1121 (inlet line to Cooler)

• TG-1114


29. Get the clearance from electrical /Mech./Inst. to start the fans of the condenser.



Sr. No.

ACTIVITIES

30. Get the motors of the fans engergised.


32. Get the clearance from control for starting the fans



35. Stop the pump and start when required.

PREPARING RECYCLE SH WATER COOLER FOR START-UP

36. Check and ensure that Tube side pressure test (leak test) has done.

37. Check that cooling water header is charged up and cooling water is available for the plant.

38. Line-up the following instruments

• TG-1107

• FIT-1146



• Back flush line block valves (inlet)

40. Line-up the Cooling water return line PSV-1109.

41. Open the vent valve provided on the cooling water return line of the condenser to make it free from

non-condensable.

42. Start opening the cooling water supply line block valve.

43. Ensure that full bore flow of cooling water is coming out from the condenser.

44. Line-up the cooling water return line to the header and isolate the vent valve.

45. Ensure that FV-1146 stroke checking is done.

46. Check and ensure that FV-1146 is closed and is in manual mode with 0% output. Also its upstream

and downstream isolation valves are closed.

TAKING SH IN HB COLUMN


• Block valve on Hot nitrogen tie-in line to HB column bottom outlet line

• Block valve upstream of FV-3319

• Block valve on line coming from RB Reflux pump discharge

48. Check and ensure that FV-3319 is closed and in manual mode with 0% output.


• TIT-3311 (HB Column bottom)






Sr. No.

ACTIVITIES

• TI-3308C (On Tray No.34)

• TI-3313 (HB Column overhead)

• PIT-3314A/B/C (On HB column below 1 Tray)

• PIT-3331 ( HB Column overhead)

• PIT-3317 (HB Column Bottom section)

• LIT-3312/3328 (HB Column bottom level)

50. Line-up and car seal PSV-3304A/B/C (On LB Column overhead)

51. Put the column pressure control on automatic mode and set for 5 kg/cm2g.

52. Start opening the LB Column bottom block valve (on line going to HB Column) slowly and Start

taking level in HB Column.

53. Check the level of HB Column bottom when it reaches to 50-60%, line-up the HB Column

Reboilers.

LINE-UP OF HB COLUMN REBOILERS

54. Ensure that HB condensers are taken on-line.

55. Ensure that HP Steam is charged in the header and is available in sufficient quantity.

56. Line-up the following instruments: • LIT-3320A/3320B (On HB Reboilers condensate pot level)

• TG-3302A/B (On vapour outlet line from Reboiler)

• TIT-3329/3330 (On Steam inlet line)

• PIT-3321/3324 (On Steam inlet line)

• FIT-3318/3322 (On steam inlet line)

57. Line-up and car seal open PSV-3305/3307.

58. Check that the following instruments are in line.

• LT-3328 (HB Column bottom Level indicator)

59. Confirm that the following valves are closed

• FV-3320A/B (Condensate outlet line from Cond. Pot) are closed and are in manual mode with

0% output

• Vent / drain valves in the inlet / outlet side of the reboilers

• Main steam isolation valves (10”) to the reboilers

• Warm up valves(1”) to the main steam isolation (10”)

60. Line up traps at the upstream of both the Reboiler steam isolation valves and upstream of HV-

3314A/B. Open the drain valves upstream of FV-3318A/3322A.

61. Open the drain valves on the condensate return lines of the reboilers.

62. Slightly open the warm up valves at the by-pass of the main steam isolation valves of the reboilers.

Check that condensate is coming out of it.

63. Open the warm up valve fully. Close the drain valve on the condensate return line.

64. Take the control valves FV-3318A and FV-3322A in line after confirming that they are closed in

manual mode in the control room.



Sr. No.

ACTIVITIES

65. Slightly open the main steam inlet valves of the reboilers.

66. Open the flow control valves FV-3318A-3322A to the extent of 5% each. Check for some flow

indication shown by each of them in FIT-3318/3322.

67. Open completely the main steam inlet line isolation valves of the reboilers.

68. Slowly adjust the flow rates of steam to the Reboiler by varying FIC-3318/3322 output till the

desired flow rates are obtained.

69. As the level reaches 40-50% in Condensate pot put LV-3320A/B on Automatic level control.

70. Put FV-3318/3322 on Automatic temp. & pressure compensated flow mode.

HOT SH CIRCULATION THROUGH THE LOOP

71. Ensure that LB feed heater shell side is ready to take in service.

72. Ensure that Recycle SH Air Cooler and water cooler are ready to take in service.

73. Check the level of Reflux drum.

74. Open the HB Reflux drum vent line block valve and HV-3456 and line-up it to LPS Condenser.

NOTE: Ensure that RB Reflux drum vent line block valve is isolated.

75. When level reaches to 40-60%, line-up the reflux bottom outlet to the HB Reflux pump suction by

opening the HV-3446.

76. Put the FV-3318A/3322A in cascade with LIC-3432.

77. Maintain the BFW level in the HB condenser manually.

78. Start the HB Reflux pump as per the standard operating procedure and line-up the reflux back to

the HB Column.

79. Check the HB Column top and bottom temperature and pressure.

80. Line-up the reflux bottom outlet to LB Feed Heater shell side by opening the HV-2925 and taking

flow forward through the Recycle SH Air Cooler (31-EA-101) and Recycle SH Water Cooler (31-E-

101A/B) to the LPS Hold-up Tank.

81. Close the LB Column Bottom outlet line Block valve going to LPS Condenser.

82. Put FV-3031on level cascade with LIC-3312.

83. Put FV-3437 on ration control with FIC-3031.

84. Put FV-3033 on ration control with FIC-3031.


86. Drain the water from the boot leg of LPS HUT and LB Reflux drum.


88. If the sample result is OK take the HB bottom to downstream section.



7.3.3 RB Column System Start-up 1 PURPOSE This system consists of RB Column (31-E-203), RB Column Reboilers (31-E-208), RB Condensers (31-E-

202A), RB Reflux Drum (31-E-204), RB Reflux Pump (31-P-205/S).

2 REFERENCES P & ID No.: 00206-FA-31-1133 & 00206-GA-31-1135

Sr. No.

ACTIVITIES

PREPARING RB COLUMN OVERHEAD SECTION


• TW-3510 (Condenser outlet line)

• LIT-3522 (RB Reflux drum level)

• PG-3506 (RB Reflux Drum Vent line to LPS Cond.)

• TG-3503 (RB Reflux drum Temp.)

• FIT-3526 (On RB Reflux line)


3. Check and ensure that following valves are isolated:

• Block valve on RB Reflux Drum vent line to LPS condenser

• Block valve u/s of HV-3523

• HV-3539 (on Reflux drum bottom outlet line)

4. Get the clearance from maintenance to start the fans of the condenser.

5. Get the motors of the fans engergised.


7. Get the clearance from control room for starting the fans.



10. Stop the fan and start when required.

TAKING FEED IN RB COLUMN


• Block valve on Hot nitrogen tie-in line to RB column bottom outlet line

• Block valve on RB column bottom line to Waste Drums

• Drain valve on RB column bottom outlet line

• Block valve on Emergency flushing line from LB Column bottom


• TI-3528A/3542 (RB Column bottom)

• TIC-3541(RB Column bottom)



Sr. No.

ACTIVITIES

• TI-3519/3541 (On Tray No.1)



• TI-3528B (RB Column overhead)

• PIT-3527 (RB Column bottom)

• PIT-3521A/B/C/D (On RB Column overhead)

• LIT-3520/3545 (RB Column bottom level)

• FIT-3315 (On HB Column bottom line to RB Column)


• PSV-3511 (On RB Column overhead)


15. Ensure that HV-3544 is in closed position.

16. Open HV-3319.

17. Start taking the flow from HB Column bottom to RB Column by slowly opening FV-3315.

Start the overhead RB Condenser Fans.

18. Put VFD motor of the overhead condenser fan on auto mode with the RB column overhead

pressure controller PIC-3521D.

19. Line-up the RB Reflux Drum overhead vent line to LPS Condenser by opening the block valve.

20. Check the level of RB Column bottom when it reaches to 50-60% line-up the RB Reboiler.

21. Ensure that LP DTA Package is in service and Sufficient quantity of LP DTA is available.


• LIT-3531 (On Reboiler LP DTA side level)

• TI-3536 (On vapour outlet line from Reboiler)

• PIT-3535 (On LP DTA inlet line)

• FIT-3530 (On LP DTA inlet line)

23. Line-up and car seal open PSV-3510.

24. Check that the following instrument is in line.

• LT-3520 (LB Column bottom Level indicator)



27. Check that there is 40 to 60% level in the LB Column bottom as indicated by LI-3545. Confirm it

with the LIT-3520.

28. Confirm that the following valves are closed.

• Isolation valves downstream of FV-3530 (LP DTA flow to 31-E-203),

• Upstream block valve of LV-33530 (LP DTA Cond. Return line).




Sr. No.

ACTIVITIES

• Block valve on Reboiler Tube side drain line

• Drain valve on Reboiler tube side drain line

29. Line up traps at the on LP DTA inlet line to Reboiler.

30. Open the upstream of FV-3530, charge the LP DTA up to the FV-3530 upstream side.

31. Isolate the valve.

32. Set the column pressure in PIC-3521D to 3.5 kg/cm2g and ensure that RB condenser fan VFD

motor is on auto control with PIC-3521D.

33. Open the Reboiler shell side vent.

34. Line-up the LP DTA condensate to the Reboiler shell side by opening the by-pass of LV-3531.

Take a level of 90%.

35. Isolate the vent line.

36. Open the FV-3530 slowly so that LP DTA vapour will displace the condensate and pressurise the

Reboiler up to operating pressure.

37. As the operating conditions are reached lower the LP condensate level up to 20%.

38. Keep close watch on PIT-3535.

39. Check the temperature and pressure at top and bottom of the column.

40. Open the RB Reflux drum vent line block valve and HV-3456 and line-up it to LPS Condenser.

41. Check the level of Reflux drum.

42. When the drum level reaches 40-50%, line-up the reflux bottom outlet to the RB Reflux pump

suction by opening the HV-3539.

43. Start the RB Reflux pump as per the standard operating procedure and line-up the reflux back to

LPS Condenser by opening the FV-3525 in manual mode and the block valve on line joining RB

pump discharge line to Reflux drum vent line(Dry out line 2”-P-35033-B1B-LP). Close the vent from

the reflux drum.

44. Check the SH for moisture content when it is less than 10-15 ppm line-up the reflux back to the RB

column by opening FV-3526.

45. Put the FV-3530 in cascade with LIC-3520.

46. Put FV-3526 in cascade with FIC-3315.


48. Drain the water from the boot leg of LPS HUT and LB Reflux drum keeping closed watch on the

LIT’s provided.


50. Check the RB Column bottom for presence of any high boiler.

51. If the sample collected contains high boilers then take the purge flow to the waste drum.



7.3.4 FE Column System Start-up 1 PURPOSE To take FE Column System in line.

This system consists of FE Column (31-E-204), FE Column Reboilers (31-E-212), FE Condensers (31-E-

213).

2 REFERENCES P & ID No.: 00206-DA-31-1131, 00206-EA-31-1132 & 00206-HA-31-1136

Sr. No.

ACTIVITIES

1. Check and ensure that the FE Column System leak check is done and the system is made inert using hot/cold nitrogen as per the standard operating procedure and requirement. Also that the system is kept under positive nitrogen pressure of 0.35 kg/cm2g.

PREPARING FE COLUMN OVERHEAD SECTION


• TI-328 (On FE Condenser outlet line)

• PI-3243 (On FE Condenser outlet line

• FIT-3219 (On FE Condenser outlet line)

• TI-3237 (On Inlet line from FE Condenser to Refrigeration package)

• TI-3238 (On outlet line from Refrigeration package to Ethylene unit)

• FIT-3233 (On Refrigerant return line from Condenser Shell side)

• TI-3222 (On Refrigerant return line from Condenser Shell side)

• PIT-3228 (On Refrigerant return line from Condenser Shell side)

• LI-3227 (Condenser shell side level)

• LIC-3227 (Condenser shell side level Controller)

• TI-3240 (On Refrigerant inlet line to condenser)

• PIT-3229 (On Tray 29)

• TI-3225 (On Tray 29)

• TI-3230A/B/C (On Tray 28, 26 and 24 respectively)

3. Line-up and car seal PSV-3203/S and PSV-3205/S.

4. Take Refrigerant in the FE Condenser Shell side by starting the Refrigerant Package as per

standard operating procedure. For detail start-up procedure refer vendors’ (Kirloskar Pneumatic

Co. Ltd.) Operating and Maintenance Manual.

TAKING FE COLUMN FEED DRYER COOLER, COALSCER AND DRYER IN LINE

5. Ensure that the loop from FE Column Feed Cooler, coalescer and dryer leak and pressure test is

over and loop is under positive nitrogen pressure.

6. Ensure that dryer to be taken in line is regenerated and is under positive nitrogen pressure.

7. Check and ensure that all drain and vent valves are closed.



Sr. No.

ACTIVITIES


• PDI-3140 (Across the FE Column Feed Coalescer)

• LIC-3130 (On Coalescer bootleg)

• TIT-3626-3631 (On FE Feed Dryer 31-V-209A/B resp)

• TI-3629A/B (On FE Feed Dryer 31-V-209A/B resp)

• AI-3634A/B (On FE Feed Dryer)

9. Line-up and car seal the following PSV:

• PSV-3114 (On Feed line to FE Column Feed Dryer Cooler)

• PSV-3109 (On cooling water return line from 31-E-209A/B)

• PSV-3919 (On FE Column Feed Coalescer)

• PSV-3607/3608 (On FE column Feed Dryer A/B resp.)

10. Check and ensure that following valves are in closed position:

• HX-207B (On Coalescer bootleg drain line)

• Block valve on Coalescer bypass line

• Block valve on Cooler bypass line

• Block valve on line going to FE Column Feed Dryer

• Block valve on line going to flare from Coalescer bootleg drain line

11. Line-up the Cooling water to FE Feed Dryer Cooler and establish a continuous flow as per the


12. Open the upstream and downstream block valves of 31-E-209A/B and upstream block valve of

Coalescer.

13. Open HV-3132 and Slowly fill and pressurise the system from the LB reflux pump discharge to the

inlet of the FE Feed Dryer. USE A BLOCK VALVE

NOTE: This must be done slowly to prevent disloadging the FE Coalescer element.

14. When the forward flow can be established into the FE Feed Dryer, flush the coalescer and FE

Column Feed Dyer Cooler bypass line for 10 min. each.

NOTE: Once forward flow is continuous, drain water from coalescer bootleg at regular interval

15. When the FE Column is ready to take feed, unblock the feed line to the FE Column but keep FV-

3210 closed on manual mode.

16. Start filling the system from the FE Coalescer slowly. When the system is equal to the LB Reflux

pump, vent nitrogen from the top of on-line dryer until the system is full of FB.

TAKING FEED IN FE COLUMN


• HV-3216 on FE Column bottom outlet line

• Block valve on Hot nitrogen tie-in line to FE column bottom outlet line

• Drain valve on FE column bottom outlet line

• Block valve on line going to FB De-inventory Cooler



Sr. No.

ACTIVITIES


• FIT-3210 (On Feed line to FE Column))

• TI-3211A/B/C (On Tray No 14,10 and 6)

• TI-3232 (On Tray no. 1)

• PIT-3215 (FE Column bottom Pressure)

• TI-3212 (FE Column bottom temperature)

• LIT-3244 (FE Column bottom level)

• LIT-3213 (FE Column bottom level)

• LI-3244A (FE Column bottom level)

• LIC-3213 (FE Column bottom level controller)

• TI-3226 ( On FE Column bottom outlet line)

• FIT-3214 ( On FE Column bottom outlet line)


20. Ensure that HV-3216 is in closed position.

21. Ensure that FE Dryer system is filled with FB and ready (ref. Steps 5 to 16)

22. Start taking the feed by slowly opening FV-3210 on controlled manner

23. Check the level of FE Column bottom when it reaches to 50-60% line-up the FE Reboiler.

LINE-UP OF FE REBOILER

24. Ensure that FE Column overhead system is taken in line.

25 Ensure that LP Steam is charged in the header and is available in sufficient quantity.

26.. Check and ensure that steam traps are working normal.


• LIT-3220 (On Reboiler LP steam side level)

• TG-3201 (On vapour outlet line from Reboiler)

• PIT-3242 (On LP steam inlet line)

• FIT-3217 (On LP steam inlet line)




• Isolation valves downstream of FV-3217 (LP steam flow to 31-E-212),

• Upstream block valve of LV-3220 (LP Cond. Return line).




31. Line up traps at the on LP steam inlet line to Reboiler.

32. Open the drain valve upstream of FV-3217, charge the LP steam up to the FV-3217 upstream side.



Sr. No.

ACTIVITIES


34. LV-3220 upstream block valve and bleed valve. Now slowly open FV-3217 and warm up the

reboiler.

35. Check that condensate is coming out from drain point.

36. Open completely the main steam inlet line FV-3217 to the reboiler.

37. Slowly adjust the flow rates of steam to the Reboiler by varying FIC-3217 output till the desired flow

rates are obtained.

38. As the level reaches 40-50% in Condensate pot put LV-3220 on Automatic level control.

39. Continue the heating using reboiler to stabilise the column.

40. When the column temperature and pressure profile is maintained then FE Column can be lined up

to CM column.



7.3.5 CM Column System Start-up 1 PURPOSE To take CM Column System in line.

This system consists of CM Column (31-E-205), CM Column Reboilers (31-E-212), FE Condensers (31-E-

213), cm Reflux Drum (31-206), CM Reflux Pump (31-P-215/S).

2 REFERENCES P & ID No.: 00206-JA-31-1138, 00206-KA-31-1139, 00206-DA-31-1131 and 00425-BA-31-1165

Sr. No.

ACTIVITIES

1. Check and ensure that the CM Column System leak check is done and the system is made inert using hot/cold nitrogen as per the standard operating procedure and requirement. Also that the system is kept under positive nitrogen pressure of 0.35 kg/cm2g.

PREPARING CM COLUMN OVERHEAD SECTION


• TI-3807 (On CM Column overhead line)

• PIT-3809A/BC/D (On CM Column overhead line)

• TI-3817/3819/3820/3821 (On Tray no 83/45/23/3 resp.)

• TIT-3922 (On CM Condenser outlet line)

• LIT-3912 ( CM Reflux Drum Level)

• FIT-3925 (CM Reflux Drum vent line)

• PIT-3921 (CM Reflux Drum vent line)

3. Line-up and car seal following PSV:

• PSV-3823/S (On CM Column Overhead)

• PSV-3907 (On Cooling Water Return Line from CM Condenser)

• PSV-3923 (On CM Reflux Drum)

4. Ensure that following valves are kept close:

• HV-3812 (On CM Column bottom outlet line)

• Block valve on Inlet line to cooler

• All drain valve and vent valves

5. Line-up upstream and downstream isolation valves of TV-3922, but keep TV in manual mode with

0% output.

6. Take Cooling water in the CM Condenser as per the standard procedure.

7. Line-up the FB-1 to CM Reflux Drum from FB-1 Surge Drum and take level in Reflux Drum.

8. Start the Reflux Pump as per standard operating procedure and establish a base level in the

column.



Sr. No.

ACTIVITIES

LINE-UP OF CM REBOILER

9. Ensure that CM Column overhead system is taken in line.

10. Check and ensure that level is taken in Column (Cross check the level in LIT-3806 and LIT-3808.

11. Ensure that LP Steam is charged in the header and is available in sufficient quantity.

12. Check and ensure that steam traps are working normal.


• PIT-3813 (CM Column bottom pressure)

• LIT-3806 (CM Column bottom level)

• LIT-3808 (CM Column bottom level)

• TI-3804 (CM Column bottom temperature)

• LIT-3816 (On Reboiler Condensate pot level)

• FIT-3811 (On CM Column bottom outlet line)




• Isolation valves downstream of FV-3814 (LP steam flow to 31-E-214),

• Upstream block valve of LV-3816 (LP Cond. Return line).




• Block valve on Sample line going to AI-3810

• Block valve on line going to Fuel Gas KOD

• Block valve on line going to 31-E-415

17. Line up traps at the on LP steam inlet line to Reboiler.

18. Open the drain valve upstream of FV-3814 charge the LP steam up to the FV-3814 upstream side.


20. Open upstream bleed valve of LV-3816. Line-up the downstream isolation valve of FV-3816. Now

slowly open FV-3816 and check that the condensate is coming out.

21. Take the condensate level in condensate pot.

22. Check the level in LIT-3816.

23. Line-up FV-3814 and charge the LP Steam in the Reboiler

24. Slowly adjust the flow rates of steam to the Reboiler by varying FIC-3814 output till the desired flow

rates are obtained.

25. Continue the heating using reboiler to stabilise the column.

26. When the column temperature and pressure profile is maintained then the feed from FE Column

Bottom can be lined up to CM column.



Sr. No.

ACTIVITIES

27. When the column operation steadiness out start a flow loop from CM Reflux pump to the FB surge

drum, to the LB Column, to the LB Reflux Drum, to the FE Column and back to the CM Column.

28. Line-up AI-3810 and watch water content.

29. When the water content comes to 5-10 ppm the stream can be taken to the SH Purifiers.

Note: Add drying of FB lines bypassing SH Purifier.



7.4 Finishing Area Start-up 7.4.1 Low Pressure Separator start-up 1 PURPOSE.

To take Low Pressure Separator knock out pot in line.

2 REFERENCES P & ID No.: 00105-HA-31-1119 & 00206-AA-31-1128 Sr. No.

ACTIVITIES

1. Check and ensure that IPS and other upstream sections are made ready.

2. Check and ensure that LPS Hold-up Tank is in service.

3. Line-up the following instrument transmitters:

• LT-1918 (LPS-I Level)

• LT-1922 (LPS-II Level)

• FIT-1917 (LPS-I overhead outlet vapor flow rate)

• PIT-1916 (LPS-I overhead pressure)

• PIT-1926 (LPS-II overhead pressure)

• PIT-1927 (LPS-II overhead pressure)

• TI-1915 (LPS-I overhead temperature)

• TI-1920 (LPS-I bottom temperature)

• TI-1925 (LPS-I overhead temperature)


• PSV-1905 (On LPS 1st stage overhead)

• PSV-1906(On LPS 2nd stage overhead)

5. Line-up cold nitrogen into LPS 2nd stage through PCV-1928 and by opening the PV-1927 control

valve.

6. Purge to atmosphere (by opening the PSV-1905 upstream drain valve) until the LPS is oxygen free.

7. Ensure that both the stages have been purged (It will take approximately 1000m3 of nitrogen to do

the job).

8. Purge the lower feed section to the extruder by introducing nitrogen through the vent device

systems at the same time as nitrogen purging is started on the LPS.

NOTE: Even with the extruder building open-walls and doors, care must be taken to monitor the

possibility of a high nitrogen atmosphere build-up during the purging process. O2 content should

be checked during this process.

9. Check oxygen content, when vessel is oxygen free, Line-up HP steam in the tracing and ensure

that all the steam traps are working normal.

10. Keep a positive nitrogen pressure in the LPS using nitrogen PCV-1928.

11. Make a sealing of Polymer in the LPS 2nd stage. Use the Satellite Extruder to force polymer into

the barrel of the Main Extruder and screw flights. When the screw is full, polymer will flow up the

expansion joint into the LPS second stage cone



Sr. No.

ACTIVITIES

12. When the polymer level in the LPS cone is high enough to form a safe polymer seal between the

needed flushing solvent and the extruder, inform the extruder operator of the upcoming

nitrogen test. Pressure test the LPS to 3.5 kg/cm2g. During the nitrogen test, valve off the vent

device nitrogen sources but keep them available until the seal has been proven. If there is a

pressure drop, determine and eliminate the source of leakage. Repeat as required.

13. Do the pressure test as per the standard operating procedure.

14. Ensure that the bypass around the first stage relief valve and second stage relief valve are closed,

and the nitrogen PCV is taken offline.

15. When the nitrogen pressure test has been completed, depressurise LPS to 0.35 kg/cm2g. And

prepare for the hot SH Flush. Inform the extruder operator prior to admitting solvent to the vessel.

The Satellite Extruder must be running to keep fresh, molten polymer entering the LPS.

16. Line-up the LPS 1st and 2nd stages overhead lines to LPS KO Pot by opening the Block valves.

17. Line-up the hot flush flow through the IPS to LPS by opening the IPS bottom isolation valve and

opening LV-1914.

18. Increase the SH flow rate to approximately 10 tons/hr and take it through both the stages of LPS

then to LPS HUT through the LPS condensers.

Note: Do not exceed 50°C per hour heatup rate.

19. When the LPS reaches operating temperature (170°-190°C) check with the extruder operator to

see if the extruder is heated (220°C on the barrel) and ready for resin production.

20. When the extruder operator is ready for polymer, initiate reaction (polymerization start up) on a

medium density, medium melt index type resin for coating the LPS walls.

21. When the extruder operator is ready for polymer, initiate reaction (polymerization start up) on a

medium density, medium melt index type resin for coating the LPS walls.

22. The LPS is ready for continuous process feed.

23. Carefully watch all your instrumentation to ensure that they are in operation. Have the cone and

sieve levels Geiger checked in the field to verify levels.

24. The Main Extruder is started as required for polymer production, vent devices and additive levels

set to normal operation per resin type and Manufacturing Guidelines

25. Switch the LPS Cone level bypass switch HS-1922 back to normal after the level is above 50%

and production is running normally.



7.4.2 LPS Knock Out Pot Start-up 1 PURPOSE.

To take Low Pressure Separator Knock out pot in line.

2 REFERENCES P & ID No.: 00105-HA-31-1119 & 00206-AA-31-1128

Sr. No.

ACTIVITIES

1. Close the manways and the bottom drain valve. Line up and carseal the block valves

upstream and downstream of the relief valves.

2. Line-up the field instrument gauges.

3. Line-up PSV-1907.

4. When the pressure test is complete, depressurize the vessel to the flare system. Cycle the

nitrogen pressure 2-3 more times, then reduce pressure to 0.35 kg/cm2g.

5. Turn on the HP steam tracing to the vessel, cone area and outlet valve and piping tracing and

ensure the traps are operating.

6. Allow the vessel to heat up for four hours.

7. Equalize the pressure in the vessel with the flare header via the by-pass line around the PSV-1907.

8. Close the vent to the flare header and line up the process lines into and out of the vessel.

9. Inform DCS Operator about line-up of process lines into and out of the vessel.

10. Keep watch on the LPS Level.

11. Start closing the By-pass line.



7.4.3 Extruder Start-up 1 Purpose: Taking RA Extruder in line.

NOTE: The following extruder start-up and shut down procedures do not apply in every situation. For

example, the reason for an extruder shut down will determine how and what is to be shut down and in

turn will affect the start-up procedure. Therefore, the following procedure may be more detailed than

required for normal operation but will serve as a reference. (Refer JSW documents TMA-078101-11, TMA-

078101-12 & TMA-078101-13 for detail instructions)

Sr. No.

Description

1. The LPS prior to the extruder and its equipment is assumed to be properly heated using tracing

while the purging with nitrogen and subsequent flushing with solvent will be in conjunction with

the extruder readiness for this operation.

PUTTING EXTRUDER ON HEAT-UP

2. Turn on steam heating for the tracing of the expansion joint (polymer inlet to extruder).

3. Turn on extruder barrel heating at 80°C increasing temperatures (from ambient) evenly and slowly

over time to 260°C.

4. Turn on HP steam tracing to the three vent devices piping, exit piping from the collection pots

and the double wall piping of the Strahman valve downcomers.

5. Make sure lube oil systems, Main Extruder motor, Main Extruder gear reducer, Satellite Extruder

gear reducer are all ready for operation, start as ready and required.

6. Start water loop for the Rear Seal and the main motor cooling.

7. Start nitrogen purge to the Rear Seal lantern.

8. Start HP Steam to the dump valve area and make sure valve is in the divert position (to grade).

9. Turn on HP steam heating to the die holder.

10. Take time out to recheck the first steps to ensure that steam is on, traps are working and control

temperatures on the barrel.

HEAT-UP AND SOAKING

11. Take time out to recheck the first steps to ensure that steam is ON, traps are working normal

and temperatures on the barrel is controlled.

12. Soak both the main and Satellite Extruder for eight hours after a temperature of 260°C has been

reached depending on conditions at heatup start.

13. Start the die plate hot oil system heatup bringing oil to operating temperature of 280°C.

14. After soak time completed, divert drool valve to through position and drool seal resin through die to

seal die holes and assemble the Underwater Pelletizer. Hot oil system in circulation as needed.

15. Clean die plate and move cutter assembly to the die plate.

16. Start the Pelletizer circulating water system.



Sr. No.

Description

17. Divert the dump valve to grade.

18. Make sure the cooling water is on to the gearbox lube oil cooler.

19. Make sure one of the oil filters is clean and on line. Start the lube oil pump.

20. Check and identify the type of additives are to be used for the start-up resin.

21. Line up the tanks with the required additive solutions and set up the pumps for the

approximate injection rates desired.

22. Keep the control room operator informed on how the start-up is progressing.

23. Drain condensate from the vent device systems (the steam supply line and the vent device pots).

24. Start vent devices at minimum setting.

25. Strahman valve closed, put steam on to the vent pot and system with a small vacuum on the K.O.

Pot (-0.1 -0.2 kg/cm2g).

POST SOAKING

26. Inject silicone grease into the additive injection nozzles on the barrel to ensure they are not

plugged. After greasing, be sure to close all nozzle and additive block valves. This procedure

should be done even if barrel injection is not required on start-up.

27. Check flow and temperature of cutter circulating water. If the water temperature is below 25°C,

cut problems could occur on the initial start-up. To bring the circulating water temperature up to

temperature for start-up, steam can be injected into the Water Reservoir sparger.

28. Line up hot oil system and start circulation in intervals up to the start-up temperature for extruder

start of production. This method will eliminate some of the thermo shock to the die plate and

provide longer die plate life.

29. Prepare drive motor to start (cooling fan running, cooling water on).

JUST BEFORE START-UP

30. Start pumping antioxidant at increased level over normal to the IPS tails as soon as the central

control room has confirmed polymer production. Other additives for IPS tails injection may be put

on-line for anticipated on-specification production.

31. Check hot oil flow and pressure at the dieplate.

32. Make a final check of the barrel temperatures, that drive motor is ready to start, that lube oil is on

to the gearbox, and that the die is up to temperature.

START-UP

33. Monitor the LPS cone level. Do not allow the level to exceed 60% before starting the extruder.

34. Check on the field DCS screens to see that all downstream equipment is running, and ready to

receive polymer before starting the extruder.

35. Make a final check of the extruder temperatures.

36. Set the PCW circulation water flows and cutter speed.



Sr. No.

Description

37. Vent screws should be running with outlet to the RA Stripper Solvent Vapour Condenser inlet

piping. Adjust the steam flow to give a vacuum of about 0.1 to 0.2 kg/cm2g.

38. Switch HV-4425 to Seal Pot for initial extruder start- up. Switch Divert dump valve to the through

position and start up the extruder at minimum speed to establish a flow through the die before

taking the screw speed up. Watch the die body pressure closely. (If the die body pressure climbs

too rapidly shut down the extruder.

39. Increase the screw speed and check temperatures, pressure, amperes and cut . As soon as

cut is acceptable switch HV-4425 to through position into Reslurry Tank.

40. Put the additives on line to the barrel if required.

41. Adjust the screw speed in relationship to the production rate. Maintain a 60%-80% Low

Pressure Separator cone level.

42. Adjust the Pelletizer speed in relation to the screw speed and pellet size. There should be

approximately 35-50 pellets per gram.

43. Set the cooling set points on the hot oil system 20°C-30°C higher than the heating set points.

44. Check lantern at the rear seal.

45. Do not put the Satellite Extruder on line until it has been purged of black specks visually seen from

the purge extrudant.

46. Make another check of temperature, amperes and pressures from the extruder motor through

to the Pelletizer.



7.4.4 Hot Oil System Start-up: 1 Purpose: Taking Extruder Hot Oil System in-line.

Sr. No.

Description

1. Ensure that system leak check has been done and system is inertised using nitrogen and kept

under positive nitrogen pressure.

2. Ensure that the total system is free of moisture prior to the introduction of oil into the system.

3. Ensure that PSV-4301/4302 are in line and car sealed.

4. Line-up the all the level, temperature and pressure instruments and field gauges.

5. Fill the Oil Reservoir (31-V-324) via the top fill line with block and check valve from drums via drum

pump.

6. The initial level must be watched and filled as required to fill the entire system piping and

associated equipment.

NOTE: Care must be taken not to overfill the Oil Reservoir as the oil expands during the heatup

process. Once all loops have been charged, the Reservoir level should be low enough to provide

enough room for expansion running 50% level on the Reservoir hot.

7. Flood the Primary Hot Oil Pump (31-P-317/S) with oil.

8. Line-up the 3-way valve XV-4046 to 31-P-317/S suction.

9. Start pump 31-P-317/S (only one running normally) and establish a oil flow via the heaters and

returned to the pump suction.

NOTE: This will establish this portion of the loop without affecting the cutter manifold piping. This

should include all the associated piping i/e/ PSV, bypass line, PG, pressure switches, tank level

gauges, nitrogen blanket, etc.

10. Increase the Oil temperature to ≈100°C by HIC-4320.

11. Once the die plate is installed with its Hot Oil Manifold in place, XV-4046 can be directed to the die

plate for continued circulation.

12. Increase the hot oil temperature as per the vendors’ recommendation for start-up (normally in the

range of 125°-150°C).

NOTE: The Die plate Hot Oil System is only capable of heating the oil to the desired set point.

There is no provision for cooling this oil flow other than removing heat source and continued

circulation. Temperature gauges are located on the inlet and outlet lines to the Extruder and

Die plate. High temperature switches provide alarms and interlocks to protect the equipment from

damage. High-pressure alarms and interlocks are located on the heaters outlet.



7.4.5 Satellite Extruder Start-up: (Also Refer JSW Instruction documents TMA-078102-11, TMA-078102-12 & TMA-078102-13)

Sr. No.

Description

1. Check and ensure that the Satellite Extruder, adaptor and nozzle into the Main Extruder are

properly assembled.

2. Line-up all the instruments and gauges and thermocouples.

3. Check and ensure that the 3-ported block valve is directed/opened to the floor.

4. Make sure interlock that holds the Satellite shutdown if Main Extruder is shutdown is in proper

position to run. (Interlock 3027).

5. Check that the dry additive feed systems and Recycle Resin Storage Bin are clean and ready for

the new production run.

6. Turn on the ½” cooling service water to the feed section (C1) of the barrel. This water supply

line should always be open fully while operating the satellite.

7. Turn ON the several HP steam connections on the adaptor piping and 3-ported valve at least 8

hours before the satellite is to be started. Make sure steam traps are working properly.

8. Start the satellite barrel heating by opening the HP steam/water mist barrel temperature control

system. Heat up can be to 260°C or the HP steam normal temperature but must be

controlled for normal operation.

9. Set the satellite barrel zones TV‟s at 50°C to start heatup sequence. Heat barrel evenly in

80°C increments until operating temperature of 220°C. Finalize heatup procedures after JSW initial operation is established. Note: Temperatures should be watched carefully to make sure the barrel heats up evenly as

resin left from the last operation will degrade if heated too long.

10. After the satellite barrel zones (C1, C2, C3, C4, C5 and adapter) are up to operating temperature,

allow 6 hours minimum soak time before starting the screw, depending on shutdown conditions.

11. When the barrel and adaptor piping are at operating temperature, grease the adaptor pressure

gauge with silicone grease. The 3-ported valve also may have a grease point that can be greased

at this time. Do not inject an excessive quantity of grease.

12. Inspect the 3-ported hydraulic unit and that the oil tank (31-T-304) has a proper level indicated on

the LG-4164. Check hydraulic pump is ready (31-P-322) for use and no alarms are in.

13. Transfer proper material to the Recycle Resin Storage Bin and additive feeder hoppers.

14. Line diverter valve on Recycle Resin Storage Bin outlet to the Satellite Extruder feed hopper and

open dry additive and/or recycle bin slide gates allowing resin into screw feed section just prior to

running the Satellite Extruder. Recycle resin will establish operation and additives are expensive to

waste during this heatup cycle. However, the additives must be through to the dump valve floor

location prior to satellite being brought on line to Main Extruder.

15. With Lube Oil System running, start the Satellite Extruder motor at minimum RPM and slowly

increase the screw speed to 10%.

16. Start Recycle Resin Rotary Feeder at minimum rpm and adjust as required.



Sr. No.

Description

17. Turn on service water to the 3-ported valve chute to carry purge resin to grade.

18. Watch Satellite Extruder amperes and adaptor pressure (Rupture disc relieves at 150 kg/cm2g).

Once a polymer flow has been established at the 3-ported valve directed to the floor, increase

extruder speed to 25% purging the barrel and adaptor piping until the molten polymer is free of

visible particles and black specks. Start the additive feeders to purge these systems, and then

shut them down until additives are required. Note item 14.

19. When specks have cleared up, lower the screw speed and stop the Recycle Resin Rotary Feeder;

direct the 3-ported valve to back purge the Main Extruder until any specks clear up. (Main

Extruder must be running). This can be seal resin at initial start-up or resin from previous stoppage.

20. When the purge from the Main Extruder has cleared up, close the purge valve and set Satellite

Extruder screw speed and Recycle Resin Rotary Feeder to the desired speeds. Normally, the

satellite will run at calculated dry additive rates to provide product specification resin additive PPM

in the final product.

21. Be sure to log in the extruder/operations logbook the time the Satellite Extruder goes on line (this

allows for a trouble shooting timeline).

22. Start-up the additive feed systems at desired rates as required.



7.4.6 Satellite Extruder Feed System Start-up: 1 Purpose:

Sr. No.

Description

1. Check the Recycle Resin Storage Bin and additive hoppers to be sure they are empty and clean.

2. Check that the additive conveyor systems are clear and shutdown.

3. Recycle resin is transferred to the Recycle Resin Storage Bin from boxes or bags as required.

4. Dry additives are transferred to the additive feeders from boxes or bags as required. A slide gate

at the entrance to the belt conveyors should be closed when initially filling the hopper to prevent

a flood of material on the belt.

5. Start a nitrogen purge to Satellite Extruder feed hopper (check the manufacturing

guidelines for requirement) if dry additive G-84 is to be used.

6. Open the slide gate at the entrance of the weigh belts and notify the central control room that the

system is now ready to start to feed the Satellite Extruder.

7. The approximate operating rates and their correlating equipment settings can be worked out ahead

of the system going into operation and set or left to the DCS board operator.

7.4.7 Fines Separator System Start-up:

Sr. No.

Description

1. Take clearance from the Maintenance Department. Also physically check the system for

completion of job.

2. Line up the nitrogen purge to each separator via the flow regulator. Make sure the atmospheric

vents/ flare arrestors to safe location are correct.

3. Line up water to Fines Separators by opening inlet valve slowly and keeping outlet open. Check for

any water leak, also check Spin Dryer (31-M-305) load.

NOTE: Spin dryer load may increase due to water back up.

4. If system is leak free close the inlet valve. Start Fine Separators from local panel. After starting fine

separator, check for any abnormality. If any abnormality found, stop fine separators from local

button.

5. Once fine separator is started, slowly open the inlet valve. Check for performance, i.e. fines

removal, abnormal sound, excessive vibration, leakages, extent of water coming out from fines

chute, pellets coming from fines chute.



7.4.8 Water Circulation System Start-up: 1 Purpose: Taking Water Circulation system in line.

The system includes Water Reservoir (31-T-301), Water Circulation Pumps (31-P-306A/B), Water Cooler (31-E-

318/S), Reslurry Water Heater (31-E-302), Solvent Skimming Pump (31-P-307/S), Reslurry Tank (31-V-309),

Delumper Dewatering Classifier (31-G-301).

2 Reference: P & ID: 00307-DA-31-1144

Sr. No.

Description

1. Ensure that the drain valve on the Water Reservoir (31-T-301) is closed.

2. Ensure water level in Water Reservoir (31-T-301) is sufficient and Demineralised water make-up is

ON.

3. Open the nitrogen purge to the Water Reservoir (31-T-301). When the Water Reservoir is

blanketed, only a very small flow is required to sustain the nitrogen environment.

4. Open the LP Steam supply valve to the steam sparger and maintain the desired temperature in the

Reservoir.

5. Line-up LP steam to Reslurry Water Heater (31-E-302). Place TIC-4438A/B in manual mode with

0% output until a flow is established.

6. Take Water Cooler (31-E-318) in line as per standard operating procedure.

7. Return water is to be lined up through Fines Separator (31-G-302A/B/C/D/E) and fines separators

are running.

NOTE: Fines separator should not be bypassed in any case.

8. Line up Water circulation pump (31-P-306A/B) discharge to back to water reservoir (31-T-301)

through Underwater pelletizer bypass line. Check for leakages if any.

9. Check for Delumper Dewatering Classifier (31-G-301) screen as well. Open the Delumper water

removal valves are fully.

10. Check and ensure that cutter/water housing outlet valve is full open.

11. Start Water Circulation pump (31-P-306A/B) as per standard operating procedure and establish the

desired circulating water flow to pelletizer by adjusting FIC-4029 manually. Once the flow is steady

place FIC-4029 in auto mode.

12. Line up backflush line to fines separator. Keep close watch on pressure drop across plate

exchanger.

Line up water to pelletizer housing and isolate simultaneously bypass valve. Check for any leak at

pelletizer housing.

13. Line up water circulation pump discharge to Reslurry Tank (31-V-309) via Reslurry Water Heater

(31-E-302) and establish the reslurry water flow using controller FIC-4437.

14. Check that RA stripper (31-V-310) is ready to receive slurry water.



Sr. No.

Description

15. Line up water return from RA Stripper screen to Fines Separator.

16. Start Reslurry Pump (31-P-305) as per the standard operating procedure.

17. Stabilise flow to Reslurry Water Heater and level in Reslurry Tank (31-V-309) with controller LIC-

4426.

18. Now start heating Reslurry water and maintain 99 °C (outlet of reslurry heater). Reslurry heater

steam condensate to be drain before heating to avoid hammering.

19. Line up and stabilise water flow to spin dryer (outlet of RA stripper). Maintain Water flow depending

on spin drier performance.

20. Once water circulation system is started, then start spin dryer and delumper.

21. After the extruder has started, place the solvent skimming pump (31-P-307/S) on auto mode.



7.4.9 RA Stripper System Start-up: 1 Purpose: Taking RA Stripper system in line. The system includes RA Stripper (31-V-310), LP Steam Desuperheater (31-

V-322),

2 Reference: P & ID: 00307-EA-31-1146, 00307-EB-31-1147

Sr. No.

Description

RA STRIPPER START-UP

1. Ensure that Water circulation system is taken in line.

2. Line-up all the instruments and ensure all are working normal.

3. Keep PVSV-4605/B isolated while drawing vacuum in the stripper.

4. Line-up Emergency Demineralised Water to Spin Dryer (31-M-305) and Spin Dryer Hold-up Bin

(31-V-317).

5. Open nitrogen to RA Stripper overhead rotometer (FG-4601) and set it at desired rate (3 m3/hr).

6. Line-up Nitrogen to RA stripper overhead line going to Solvent Vapor Condenser. Keep PV-4632 in

manual mode with 0% output. Ensure that PV-4632 bypass valve is close.

NOTE: Excessive nitrogen flows will adversely affect Solvent Vapor Condenser and Solvent Vapor

Trim Cooler operation.

7. Open the HV-4630 provided on the RA Stripper Exhaust line.

8. Line-up the LP Steam Desuperheater demineralised water supply to FV-4642 and closed bypass

around valve. Open condensate valves off bottom of the LP Steam Desuperheater.

9. Line-up LP Steam to RA Stripper. Keep HV-4629 in close position. Carseal open the HV-4629

downstream isolation valve.

10. Start the stripping steam flow to the cone jacket and inner diamond shaped cone.

Heat-up the Stripper for at least one hour before introducing unstrapped resin.

Start building a layer of High Density Resin which is previously stripped of Cyclohexane up to a

level above the stripping stream purge screens, so that new unstrapped resin will directly subjected

to stripping steam as it enters the stripper.

NOTE: High Density Resin is to be used as this avoids the sticking in stripper, also it

provides the minimum back pressure to the stripping steam due to its pellet shape. Low density resin pellets have a tendency to “stick” to each other in a static resin bed, causing

Stripper outlet flow problems.

11. Start one fan motor HS-4715 on the Solvent Vapor condenser (31-EA-301). Line-up the Cooling

Water to Solvent Vapor Trim Cooler (31-E-301).

12. Set the RA Stripper pressure PIC-4632 on auto mode with the set point of 0.005 kg/cm2.

13. Close HV-4630. Watch the RA Stripper pressure and temperature. Operate the HV-4630

depending on the pressure in the RA stripper until the condenser is free of inerts.



Sr. No.

Description

14. Set LIC 4648A/B to control return RA Stripper dewater and RA Stripper inlet screen water to

desired location of Reslurry Water Heater or Fines Separators. On initial start-up it is advised to

have all the return water routed to the Fines Separators as PCW water heat will not yet be

established.

15. Start a Reslurry Pump 31-P-305 or the spare and open Reslurry Tank level control valve LV-

4426 located on pump discharge and set the water flow rate from 1 to 3 times expected resin rate. Note: The reslurry water temperature should be at minimum of 82°C (TI-4613) at the inlet to the RA

Stripper Hydrosieve and higher if possible to minimize SH absorption in the carrier reslurry water.

16. Establish a water flow from the Water Circulation pumps to the RA Stripper exit. Flow rate can be

set at a 1:1.5 ratio of expected outlet production resin rate.

17. The Spin Dryer and conveying system do not need to be started until the RA Stripper has been

filled to the operating level and unloading is ready to begin. The operation of the equipment

should be checked and started before there service is required remembering that water is

travelling to the Spin Dryer inlet screens.

STRIPPER FILLING

18. Check that RA Stripper conditions are met for steam stripping. Vessel steam purge, stripping

steam rates and vessel heat up of seal resin is complete. The stripped resin seal is material from

the bag splitter added via the reslurry spool prior to the Reslurry Tank for start-up conditions. All

instrumentation shall be working properly.

19. Start-up extruder. Record extruder start up time, rates etc. When the synthesis area have

reached optimum production rate, calculate the anticipated time that the RA Stripper will reach

operating level. Take into account the seal resin amount already in the RA Stripper.

20. Check RA Stripper operating conditions frequently during the fill cycle as resin is still stripping off

volatiles during this residence time. Open the bottom level valve and / or condensate drains to

ensure there is no water build-up in the RA Stripper. Flooding in the stripping steam manifold

causes high pressures and high temperatures.

21. A small resin outlet purge from the RA Stripper may be necessary to provide resin movement as

the vessel filling not only takes place but also serves to provide condensate control. Prove the

working operation of the LV prior to the RA Stripper reaching the operating level. This slow

resin movement proves out downstream equipment and instrument operations.

RA STRIPPER UNLOADING

22. Prepare a blender to receive resin and line up appropriate diverter valves. (See Govoni Auto

System Write-up for this process description)

• When level is approximately 1 hour below operating level, start-up downstream equipment

(Spin Dryer and exhaust fan, Hold-up Bin Purge Air Fan, RA Stripper Spin Dryer Conveying

Blower and Rotary Feeder).

23. Open the RA stripper isolation valve HV-4612 (if not already open) and open level control valve LV-

4615 on manual mode with minimum valve loading. This is done to confirm that the unloading

operation is functional and to clear any bad cut or fines from the initial start-up. When the



Sr. No.

Description

discharge of resin is confirmed, take a resin volatile sample and close LV-4615. Send the sample

to the laboratory for RA stripper exit volatile analysis.

Note: Please remember that the timing of the volatile sample depends on RA Stripper

conditions and whether the seal resin is in place; you left resin in the vessel; or you are starting

with an empty vessel.

24. When the RA Stripper level reaches operating level and volatiles results from the laboratory

are confirmed at less than 0.05%, establish a discharge resin flow, using LV-4615 sending

resin to the prepared blender. Record the time that the resin reached RA Stripper operating level.

25. Once the outlet resin rate is stable swing the RA Stripper level control valve LV-4615 to the

automatic position and monitor the unloading. Ensure that the lower seal leg slurry water flow is

sufficient to carry away the resin. (Fluctuating Spin Dryer amperes would indicate insufficient water

flow).

26. Swing the RA Stripper low-level interlock HS-4617 to the "ON" position.

• Calculate the estimated time of unloading to the on-line blender. On a start-up, there will

always be a certain amount of off-specification resin or seal resin that must be segregated.

Collect this resin in one blender, then switch to another blender to collect the on specification

resin when it appears at the RA Stripper discharge valve.

27. Adjust water flows by closing the butterfly valve in the condensate return line at the base of the

RA Stripper. This will retain condensate in the RA Stripper cone that will assist resin flow out of

the RA Stripper. This is done if the operation requires more water than appears to be flowing

down with the resin.

28. Ensure that LIC-4615 is maintaining the desired operating level in the RA Stripper.



7.4.10 Additive Holding Tank Start-up:

Sr. No.

Description

1. Check that the Additive Holding Tank to receive the additive is empty and clean and has been

flushed with solvent.

2. Transfer the required type of additive solution from the Additive Mixing Tank to the Additive

Holding Tank, or make-up new batch directly in the Additive Holding Tanks (Refer Additive Batch

Makeup Procedure). The receiving tank will have to be depressurized with vent left open for transfer

3. Once transfer is completed, close incoming process lines and close vent and open Nitrogen.

Check that the nitrogen pressure in the Additive Holding Tank is 0.9 kg/cm2g and the Additive

Holding Tank temperature is 70°C

4. Agitate the Additive Holding Tank and keep agitating while transferring once the liquid level is

high enough to cover the internal agitator paddles and only then. Damage to the agitator

paddles and seals can happen if this procedure is not followed. The agitator will remain running

while tank contains additives above the agitator run level.

5. The additive is ready for use and transfer to the Additive Metering Pumps once the prescribed

heatup time at 70°C has been obtained.

6. Continue to monitor that tracing is working and the tank and transfer lines are up to temperature,

70°C



7.5 Utility Area Start-up 7.5.1 DTA System Startup:

Sr. No.

Description

TAKING VACUUM SYSTEM IN LINE

1. Ensure that system leak check is completed and there is no leak in the system.

2. Ensure that all instruments and controllers are lined up for operation and have been calibrated.

3. Close all valves which supply rupture discs, interlocks, alarm switches, etc., which are not designed

to operate in a vacuum. They will be re-opened following vacuum system start-up.

4. Close all drains and atmospheric vents on the system which are open.

5. Close all vent tie-ins to the vacuum system.

6. Close all user inlet valves, inlet trap block valves, and bypass valves (Each user will be vacuumed

independently).

7. Close all user outlet valves, outlet trap block valves, and bypass valves.

8. Close all pump vent valves.

9. Close the header trap inlet valves and bypass valves.

10. Close the liquid supply valve to the vaporiser flash drum and the outlet valve to the main header.

Vaporiser and flash drum will be vacuumed together.

11. Close the inlet and outlet valves on the high and low pressure condensate tanks, the DTA storage

tank, the vent receiver, the regeneration vessel and the vent pot. Each vessel will be vacuumed

out independently.

12. Ensure the bypass around the vent pot is closed and the drains from vent pot and regeneration

vessel to the waste fuel tanks are closed.

13. Open the steam supply to the steam ejector. The valve should only be cracked open until the

ejector is being supplied by dry steam. It can then be opened fully.

14. Open the inlet and outlet valves to the vent pot and draw the vessel into vacuum. Re-isolate the

vessel following this, and open the bypass around it. The vent pot will not be used during the start

up as only water would collect in it and it is desired to remove this from the system.

15. Observe the operation of the vacuum header pressure controller (PIC-6241A). It should shut off

the steam supply to the ejector when pressure falls to -0.8 kg/cm2g.

16. Open the vent pot bypass valve and PV-6241B downstream isolation valve simultaneously open

PV-6241B in manual mode. Thus Vent Receiver and the vent header will be drawn into a vacuum.

Observe the vacuum header pressure controller (PIC-6241B) operation.

17. Open the vent valve from the vaporisers (31-LM-401A/B) and vent valve of Flash Tank (31-V-

420A/B) and draw them into vacuum.

18. Open the drain valve from the vaporiser to the Storage Tank (31-V-413) and draw the storage tank

into vacuum through this line. Close the drain valves when the storage tank is under vacuum.



Sr. No.

Description

19. Vent each of the DTA Transfer Pumps (31-P-406/S) to the vacuum header.

20. Open the flash drum outlet valves from the vaporiser and draw the main header into vacuum.

21. Start vent condenser fans. To provide cooling for condensing.

22. Open the inlet and outlet valves to the vent pot and close the bypass valve.

23. Turn cooling water on to the vent pot condenser. Open the vent receiver drum outlet to the

Transfer Pump (31-P-406/S) and the recirculating line from the transfer pump and draw the line into

vacuum. The DTA Vent Receiver (31-V-407) is now ready to be filled to its normal operating level

from the storage vessel using the DTA Transfer Pumps (31-P-06/S).

24. Close the inlet and outlet valves from the vaporisers and isolate the vents.

25. Open the vent valves on the high pressure DTA condensate tank (31-V-406) as well as the inlet

and outlet piping and draw it into vacuum.

26. Vacuum out the HP DTA Condensate Pumps (31-P-405/S), repeat the same process with the LP

DTA condensate tank (31-V-410) and for the LP DTA cond. Pumps (31-P-407/S).

27. Vacuum out each process user one at a time and then re-isolate them. The entire system should

now be under vacuum.

TAKING LEVEL IN DTA STORAGE VESSEL (31-V-413)

28. Ensure that all the instruments are taken in line.

29. Line-up Storage Tank (31-V-413) PSV-6214 and carseal.

30. Isolate the bottom outlet block valve to Transfer pumps (31-P-406/S).

31. Ensure that following isolation valves are closed:

• DTA drain line from Vaporisers

• DTA Flash Tank Level Gauge blowdown line

• DTA emergency vent inlet line

• DTA Pump discharge line to DTA Condensate tank

32. Ensure that isolation valves under storage tank PSV is opened and carseal.

33. Open upstream and downstream isolation valve of PV-6236 but keep PV in manual mode with 0%

output.

34. Turn N2 on to the Storage Tank. Observe the operation of tank pressure controller (PIC-6236).

35. Maximum pressure for operation is 1 kg/cm2g. Normal pressure is 0 kg/cm2g.

36. Draw a sample of material from DTA barrel and analyse it.

37. Connect the temporary hose from Barrel unloading station to Transfer Pump (31-P-406/S) suction

line. Ensure that there is no leakage in the lines.

38. Open the supply line valve and start the DTA Transfer pump as per the standard operating

procedure and take level in the DTA Storage Vessel (31-V-413).

39. When required quantity (70-80%) of DTA is transferred, close inlet valve on filling connection.



Sr. No.

Description

TAKING LEVEL IN SYSTEM

40. Open the supply valves from the storage tank to the DTA Transfer Pumps (31-P-406/S) and flood

the pumps.

41. Ensure the DTA Transfer pump discharge and suction valves are open.

42. Close the pump discharge line LV-6238 downstream isolation valve to the LP Condensate tank.

43. Line up all the instruments and PSV-6217 and carseal.

44. Open the inlet valve to the DTA Vent Receiver (31-V-407) from the DTA transfer pumps. This

vessel will be filled first.

45. Start the transfer pump and fill the DTA vent receiver to its normal operating level which normally

operates at 40-60% level. When the tank has reached the proper level stop the pump.

46. Line-up Vent Receiver bottom outlet valve to DTA Transfer pump.

47. Take Vent Receiver level controller in auto mode.

48. Ensure the outlet valves to the condensate system from the RB Reboiler (31-E-208), LB Reboiler

(31-E-203) and the desuperheater (31-V-133A/B) are closed.

49. Close he supply valves from the LP Condensate pumps (31-P-407/S) recirculating line to the LP

DTA condensate Drum (31-V-410).

50. Ensure the block valve under the LP Condensate Drum (31-V-410) PSV-6005 is lined up and

carsealed.

51. Ensure the block valves on the LP condensate Drum pressure control (PIC-6015) are open. Tank

normally operates at 0.1 kg/cm2g.

52. Open the discharge valve from the DTA transfer pumps (31-P-406/S) to the LP Condensate Drum

(31-V-410).

53. Start the transfer DTA Transfer pump. Fill the LP Condensate tank to 50% level.

54. Observe the level control on the DTA vent receiver for proper operation. Some venting of the

condensate tank may be required.

55. Closed the high pressure condensate pumps inlet valves. Tank will be filled first.

56. Line-up all the instruments and PSV-6107 and carseal HP DTA Condensate Drum.

57. Close the condensate return valve to the HP Condensate Drum (31-V-410). To prevent

condensate backing up into users.

58. Close the Adsorber preheater (31-E-105A/B) condensate return valves to the HP Condensate

Drum.

59. Fill the HP condensate tank to 50% level.

60. When the condensate tanks have been filled to the desired level, close the supply valves from the

DTA storage tank to the transfer pumps. Allow the transfer pump operating. A circulating loop

through the DTA vent receiver is now in operation.

61. Close a block valve on the supply line to the DTA Vaporiser Flash Tank (321-V-420A/B) from the

HP/LP DTA Condensate Pumps.



Sr. No.

Description

62. Open the LP condensate pumps recirculation line block valves to the LP condensate tank.

63. Open the supply valves from the LP Condensate Drum to the LP Condensate pumps (31-V-407/S).

64. Flood the pumps. Some venting may be necessary.

65. Start up each of the LP condensate pumps and open its outlet valve and establish flow through

recirculation line back to LP Cond. Drum. Check the operation and observe the working of flow

control valves. Keep one pump running to maintain the loop.

66. Open the supply valves to the HP Condensate pumps (31-P-405/S) from the tank.

67. Flood the pumps, some venting may be necessary.

68. Start each of the HP Condensate pump (31-P-405/S), open their discharge valves and establish

flow through recirculation line back to LP Cond. Drum. Check the operating. Observe working of

flow control valve. Leave one pump running to maintain the loop.

69. Place the HP condensate tank level control (LIC-6114) in operation and observe the operation.

70. Close the supply valves from the DTA Flash Tank (31-V-420A/B) to each of the DTA Circulation

Pumps (31-P-414A/B/S).

71. Close the drain valves from each of the vaporisers back to the storage tank.

72. Ensure the block valves under the flash drum relief valves are opened and carsealed.

73. Close the block valves from the flash tank to the DTA vapor header.

74. Open the block valves on the supply line to the DTA flash drum from the condensate pumps.

75. Open the supply valve from the DTA storage tank to the transfer pumps to supply necessary make-

up.

76. Fill the flash drum to 80%. Observe the operation of the flash drum level controller.

77. Close the supply valve from the storage tank to the transfer pumps.

78. Flood each of the DTA circulation pumps. Vent the pumps to remove any entrapped air.

79. Start each of the circulating pumps, one at a time and establish flow through the pump and then

start filling the vaporiser tubes.

80. Open the supply valve from the storage tank to the transfer pumps to supply the necessary make-up.

81. When the first vaporiser has been fixed, the process is repeated with the second.

82. With both vaporisers filled, close the supply valve from the storage tanks to the transfer pumps.

The Flash Tank should have a level of 10% with the vaporiser tubes flooded for start up.

VAPORISER STARTUP

83. Ensure that Refractory Dryout has been completed.

84. Start the vaporiser as per the standard operating procedure (Refer vendors’ Operating &

Maintenance Manual for detail procedure)



Sr. No.

Description

STARTUP OF THE VAPOR HEADER

85. Place the Vent Receiver Heater (31-E-404) and low boiler removal system in service when ready.

86. Ensure the supply and discharge valves to each of the DTA users are closed.

87. Open the trap bypass valves on all of the header traps.

88. Open the trap bypass on the inlet traps of any users so equipped. This will help to rid the header of

excess liquid during its warm up. The traps are returned to normal operation once the header is

hot.

89. Ensure the supply valve to the DTA Regeneration Heater (31-E-403) is closed.

90. Open the HP DTA Cond. Drum (31-V-406) vent valve and draw vacuum in the main header. When

DTA is admitted to the system a loop will be established; from DTA Vaporiser (31-LM-401A/B)

through header trap bypass to HP DTA Cond. Tank (31-V-406), from HP Cond. Drum through Vent

to Vent Receiver (31-V-407), from Vent Receiver via DTA Transfer Pumps (31-P-407/S) to LP DTA

cond. Drum (31-V-410); from LP DTA Cond. Drum via LP Cond. Pump (31-P-407/S) to Flash Tank

(31-V-420A/B).

91. Allow sufficient time for a full vacuum to be pulled on vapor header.

92. Start the cooling fans of Vent Condenser (31-E-401).

93. When the Flash Tank Pressure reaches to normal operating pressure (i.e. 4-4.5 kg/cm2g), open the

Flash Tank outlet valve slowly to avoid hammering in the header. Observe the fire rate and the

Flash Tank liquid level. It will be necessary to add liquid DTA to the system from the Storage

Vessel (31-V-413).

94. Ensure there is no leakage in the system and do hot bolting wherever necessary.

95. As the header gets hot, place the trap on normal operation.

96. When the level starts building in the HP condensate Drum (31-V-406), open LV-6114 on line going

to Flash Tank and put LV-6114 on auto mode. Check the operation of level controller LIC-6114.

97. Ensure that the LP DTA inlet line isolation valve and LP Cond. Outlet valve from LP DTA users are

closed.

98. Open the trap bypasses on the LP DTA users.

99. Close the HP DTA Cond. Drum vent valve and allow the pressure to rise to normal operating

pressure (i.e. 2 kg/cm2g).

100. Open vent valve on the LP DTA Cond. Drum (31-V-410) and draw vacuum in LP vapor header.

101. When hot vapours are being drawn through the LP Cond. Drum vent line, the vent can be closed

and close the trap bypasses on the LP DTA users.

102. The system is now in operation. Each user should have a vacuum drawn on it before DTA is

admitted, and there trap bypass until gets hot. Levels can be built up in the appropriate vessels

while drawing make up from the DTA Storage Vessel as required.



Sr. No.

Description

TAKING HIGH BOILER REMOVAL SYSTEM IN LINE

103. Ensure the drain valves from the DTA Regeneration Vessel (31-V-408) to Waste Drum (31-V-306B)

and Waste Fuel Drum (31-V-411) are closed.

104. Ensure all controllers and instrumentations are taken in line and ready for service.

105. Line-up PSV-6221 and carseal.

106. Open the block valves slowly from the DTA Vaporiser Flash Tank (31-V-420A/B) to the DTA

Regeneration Vessel to admit liquid DTA to the vessel.

107. Bypass the DTA Regeneration Heater (31-E-403) traps and admit DTA vapour to the heater coil.

Traps can be place in normal operation once the lines are heated up.

108. Observe the operation of the controllers. The pressure should be controlled at 0.2 kg/cm2g (PIC-

6246), the temperature at 265°C (TIC-6251) and the level at 50% (LIC-6245).

109. Periodically the material which has collected in the vessel should be drained to the waste drum or

Waste Fuel Drum. Shutoff the liquid feed while this is being done so that good DTA is not

disposed.

TAKING LOW BOILER SYSTEM IN LINE

110. Ensure the valve to DTA vaporisers.

111. Open the inlet and outlet valve to the vent pot condenser (31-E-412).

112. Open inlet and outlet valves for the vent pot cooling coils if necessary (e.g. usually in Summer

seasons).

113. Close the bypass valve of the vent pot (31-V-409).

114. Open the inlet and outlet valves to the vent pot condenser and Receiver.

115. Monitor the Vent Pot level.

116. Maintain the pressure in the Vent pot between -0.7 to -0.8 kg/cm2g and temperature around 180°C

to separate out the low boilers.



SECTION -8.0 NORMAL OPERATING PARAMETERS



8.1 Operating Parameters:

Description

Tag no. Unit Value

(Normal)

Recycle SH Air Cooler (31-EA-101)

Solvent Outlet Temperature TI-1155 oC 65

Solvent Feed to SH Air Cooler FI-1121 kg/hr. 210043.64

Solvent Feed Inlet Pressure PI-1124 kg/cm2g 8

Solvent Feed inlet Temperature TI-1150 oC 149

FC Make-up feed Temperature TI-1153 oC 37

FC Make-up feed Flow Rate FIT-1149 kg/hr. 5003.83

Recycle SH Water Cooler (31-E-101A/B)

Solvent Inlet Temperature TG-1157 oC 65

Solvent Outlet Temperature TG-1107 oC 36

Cooling Water Inlet Temperature TG-1105 oC 40

SH Purifier (31-V-125A/B)

Solvent Inlet temperature TI-1125 oC 36

Purifier Bed Temperature

Top TI-1158/1161 oC 36/300

Middle TI-1159/1162 oC 36/300

Bottom TI-1160/1163 oC 36/300

Solvent Inlet Pressure PG-1113 Kg/cm2g 5.1

Pressure Drop Across SH Purifier PDI-1145 Kg/cm2g 4.9

Solvent outlet pressure from Purifier PG-1115 Kg/cm2g 4.1

Regeneration Gas inlet temperature TI-1156 oC 300

Regeneration Gas outlet temperature TI-1147 oC 300

Purifier Vent outlet temperature TI-1137 oC 36/300

Nitrogen Flow Rate to Vent header FO-1111 kg/hr 962

Comonomer Feed Cooler (31-E-113A/B)

Comonomer Outlet Temperature TI-1123 oC 36

Comonomer flow rate FIT-1122 kg/hr. 26879.13

Cooling Water outlet temperature TG-1119 oC 39

Regeneration Blower Aftercooler (31-E-108)

Aftercooler outlet temperature TG-1254 oC 280

Cooling Water outlet temperature TG-1207 oC 38



Description

Tag no. Unit Value

(Normal)

Purifier Regeneration Heater (31-E-109)

Heater outlet temperature TG-1226 oC 300

Purifier Regeneration Cooler (31-E-110A/B)

Reg. Gas inlet temperature TI-1258 oC 280

Reg. Gas outlet temperature TI-1236 oC 37

Cooling Water Return Temperature TG-1224 oC 45

Regeneration KO Drum (31-V-101)

Nitrogen Flow Rate to KO Drum FI-1222 kg/hr. 250

Regeneration Blower (31-K-101)

Blower Inlet Gas Temperature TG-1223 oC 36

Blower Inlet Gas Pressure PG-1205 Kg/cm2g 0.85

Blower Inlet Gas Pressure PI-1237 Kg/cm2g 0.85

Blower Discharge Pressure PG-1202 Kg/cm2g 1.95

Solvent Feed Filter (31-G-103)

Pressure Drop Across Filter PDIT-1211 Kg/cm2g 5.7

Solvent Feed Pump (31-P-101/S)

Pump Suction Pressure PI-1243 kg/cm2g 4.1

Pump Flow Rate FI-1244 kg/hr. 207560

Pump Discharge Pressure PG-1213/1228 kg/cm2g 44/44

HP Diluent Pump Spillback Cooler (31-E-117)

Cooler Outlet Temperature TG-1255 oC 40


HP Diluent Pump (31-P-102/S)

Pump Discharge Pressure PG-1218/1220 kg/cm2g 187/187

Pump Discharge Pressure PIT-1250 Kg/cm2g 187

Pump Discharge Temperature TI-1248 oC 45

Absorber Cooler (31-E-102)

FE inlet Temperature TI-1317 oC -

Absorber Cooler outlet temperature TIC-1319 oC 38

Absorber Cooler outlet Pressure PG-1339 Kg/cm2g 28

Absorber Cooler Cooling Water outlet temperature TG-1303 oC 45



Description

Tag no. Unit Value

(Normal)

Head Tank (31-EV-103)

Head Tank Overhead Pressure PI-1321 Kg/cm2g 28

Reactor Feed Booster Pump (31-P-103)

Pressure Diff. Across Pump PDIT-1326 Kg/cm2g 35

Pump Discharge Pressure PI-1342 kg/cm2g 34

Reactor Feed Pump (31-P-104)

Reactor Feed Pump Discharge Pressure PG-1309 kg/cm2g 182

Flow through FO FO-1302 kg/hr 249200

Discharge Flow Rate FI-1329B kg/hr. 249170

Reactor Feed Heater (31-E-103)

Heater Inlet temperature TI-1404 oC 48

Heater outlet Temperature TI-1405 oC 120

Reactor Feed cooler (31-E-104A/B)

Cooler inlet temperature TI-1404 oC 48

Cooler outlet temperature TI-1418 oC 35

Cooling Water Return temperature TG-1411 oC 37

Reactor #1 (31-R-101)

Reactor Side Feed inlet temperature TI-1520 oC 35/120

RA Solution outlet temperature TI-1535 oC 220-305

Pipe Reactor #3 (31-R-102)

Pipe Reactor Inlet Temperature TI-1538 oC 240

Pipe Reactor Inlet Pressure PI-1537A kg/cm2g 182

Pipe Reactor Outlet Temperature TI-1548A oC 350

Catalyst System

Temp. downstream of CAB/CAB-2 injection point TI-1548A/1546B oC 350

HP Diluent Heater (31-E-111)

HP Diluent outlet temp. from E-111 TI-1514 oC 300

Static Mixer(31-M-106)

RA Solution Inter temp. to M-106 TI-1607 oC 300

RA Solution Inter pressure to M-106 PI-1608A kg/cm2g 156



Description

Tag no. Unit Value

(Normal)

Adsorber Preheater (31-E-105A/B)

RA Solution inlet temp. to Preheaters TI-1609 oC 300

RA Solution Outlet temp. from Preheaters TIT-1613/1620 oC 310/310

HP DTA inlet temp. after desuperheater TIT-1624/1623 oC 320/

HP DTA inlet pressure. after desuperheater PI-1622/1623 kg/cm2g 2.5/2.5

HP DTA outlet temp. from Preheater TG-1604/1605 oC 320/320

Static Mixer (31-M-107)

RA Solution inlet temp. to static mixer TI-1617 oC 310

RA Solution inlet pressure to static mixer PIT-1608B kg/cm2g 140

Purge Heater System

Solvent outlet from E-107 temp. TIT-1724 oC 310

Warm-up solvent flow rate to Standby Adsorber FO-1707 kg/hr 3000

Nitrogen Flow rate FO-1702 kg/hr 432

Solution Adsorbers (31-V-104A/B)

RA Solution inlet Pressure PI-1814A/B kg/cm2g 142/142

RA Solution Outlet Pressure PI-1814C kg/cm2g 121

Hot Flush inlet Pressure to adsorber PG-1807/1808 kg/cm2g 142/142

Hot Flush Return pressure from Adsorber PG-1705 kg/cm2g 142

Hot Flush Return temperature from Adsorber TI-1726 oC 310

SH pressure to LPS Condenser PIT-1725 kg/cm2g 35

Intermediate Pressure Separator (31-V-118)

RA Solution inlet pressure PI-1909B/1909A kg/cm2g 121/121

IPS Overhead temperature TI-1910 oC 275

RA Solution outlet temperature TI-1932 oC 275

Vapor outlet pressure from IPS PIT-1911 kg/cm2g 32

Low Pressure Separator 1st /2nd Stage (31-V-119/120)

Vapor outlet pressure from LPS -1 PIT-1916 kg/cm2g 6.1

Vapor outlet temperature from LPS-1 TI-1915 oC 230

RA temperature at the junction of LPS-1 & 2 TI-1920 oC 230

Vapor outlet pressure from LPS -2 PIT-1926/1927 kg/cm2g 0.6/0.6

LPS-2 top temperature TI-1925 oC 230



Description

Tag no. Unit Value

(Normal)

LPS KO Pot (31-V-121)

KO Pot overhead pressure PG-1901 kg/cm2g 6.0

CAB-2 Mix Tank (31-V-105)

Mix Tank top pressure PG-2014 kg/cm2g 0.7-3.5

Mix Tank Temperature TG-2040 oC 37

Nitrogen inlet Flow to Mix Tank FO-2008/2010 kg/hr 12.5/20

Nitrogen inlet pressure to Mix Tank PG-2033 kg/cm2g 3.5

P-105 Suction Pressure PG-2016 kg/cm2g 3.5

CAB-2 Surge Tank (31-V-106)

Surge Tank Temperature TG-2012 oC 37

LP Solvent inlet to 31-P-105 suction FI-2004 kg/hr 86.9

CAB Mix Tank (31-V-107)






CAB Surge Tank (31-V-108)


LP Solvent inlet to 31-P-105 suction FI-2005 kg/hr. 72.78

CD Mix Tank (31-V-109)






CD Surge Tank (31-V-110)





Description

Tag no. Unit Value

(Normal)

CT Mix Tank (31-V-111)








CJ Mix Tank (31-V-113)




Nitrogen inlet pressure to Mix Tank PG-2229 kg/cm2g 0.7-3.5





Catalyst KO Drum (31-V-115)

Temperature of KO Drum TG-2211 oC 45

Nitrogen Flow to Seal Sump FO-2215 kg/hr 10

SH Make-up Cooler (31-E-116)

SH Outlet temp. from Exchanger TG-2214 oC 37

Cooling water return Temp. TG-2203 oC 45

SH Make-up Dryer (31-V-126)

SH Inlet temp. to SH Make-up Dryer TG-2201 oC 37/300

SH Outlet temp. from V-126 TG-2213 oC 37/300

Pressure Drop Across outlet filter (31-G-107) PDI-2249 kg/cm2g 3.9



Description

Tag no. Unit Value

(Normal)

Hydrogen Compressor (31-K-102/S)

Hydrogen supply pressure PI-2428 kg/cm2g 17

Hydrogen suction pressure to compressor PG-2401/2402 kg/cm2g 205/205

Compressor Discharge Temp. TIT-2418A/2426A) oC 60

Compressed J temp. after Cooler TG-2407/2409 oC 60/60

Pressure of “J” Supply to Reactor Feed Pump discharge PG-2412 kg/cm2g 205

Pressure of “J” supply to Reactor Section PG-2411 kg/cm2g 205

“J” Flow rate to Reaction Section FIT-2422A/B kg/hr. 13.9

“J” Flow rate to Reactor Feed Pump FIT-24221B kg/hr. 0.5

PA Charge Hopper (31-V-123)

Hopper Temperature TG-

2609/2602/2601 oC 300/300/300

Charge Heater Blower (31-K-104)

Blower discharge pressure PG-2615 kg/cm2g 0.3

PA Blower (31-K-105)

Blower Discharge Pressure PG-2622 kg/cm2g 0.15

Blower Suction Pressure PG-2619 kg/cm2g -0.5

PA Fallout Hopper (31-V-124)

Hopper bottom conical portion temperature TI-2638 oC 280

FE Primary Guardbed (31-V-127A/B)

FE Supply temperature TI-2759 oC 25

FE Supply pressure PI-2760 kg/cm2g 50

FE Guardbed temp

Top TI-2755/2756

oC

150/300

Middle TI-2761A/2762A 150/325

Bottom TG-2702/2705 25/300

FE Secondary Guard Bed (31-V-132)

Bed Inlet pressure PIT-2772/PG-2726 kg/cm2g 50

Bed temperature

Top TI-2754

oC

25

Middle TG-2706 25

Bottom TG-2707 25

Guardbed bottom outlet pressure PI-2765 kg/cm2g 50



Description

Tag no. Unit Value

(Normal)

LPS Condensers (31-E-201A/B/C)

LPS Condenser Vapor inlet temperature TI-2813 oC 305

LPS Condenser Process fluid outlet temp. TG-

2808/2819/2822 oC 50/50/50

LPS Hold-up Tank (31-V-201)

LPS Hold-up tank temp. TG-2802 oC 50

LPS Hold-up tank pressure PIT-2817 kg/cm2g 0.12

Liq. Inlet temp. from LPS Cond. TIT-2814 oC 50

LPS Cond. Pump Suction Pressure PG-2917/2918 kg/cm2g 0.12

LPS Cond. Pump Discharge Pressure PG-2902/2905 kg/cm2g 30/30

Pressure Drop across LPS Cond. pump suction filter PDI-2923/2920 kg/cm2g 0.12/0.12

Hot Flush Pump Discharge pressure PG-2909/2911 kg/cm2g 195/195

LB Feed heater process fluid outlet temperature TG-2915 oC 170

LB Column (31-C-201)

LB Col. Feed Temp. TIT-3025A oC 235

Column Overhead temp. TI-3021 oC 100

Column Bottom temp. TI-3025B oC 244

Column’s temp. profile

Bottom TI-3042

oC

244

On tray 2 TI-3040 243

On Tray 20 TI-3027 240

On Tray 34 TI-3029 235

On Tray 36 TI-3026 232

On Tray 39 TI-3028C 220

On Tray43 TI-3028B 180

On Tray47 TI-3028A 118

On Tray 51 TI-3041 97

LB Feed Condenser (31-E-202)

LBFC Process fluid outlet temp. TIC-3039 oC 230

HP Cond. flow rate to LBFC FI-3020 kg/hr 24861

HP Cond. inlet temp to LBFC TG-3043 oC 159

LBFC Shell side pressure PI-3019 kg/cm2g 16

LBFC steam side temperature TG-3008 oC 204



Description

Tag no. Unit Value

(Normal)

LB Reboiler (31-E-203)

LP DTA inlet pressure PIT-3034 kg/cm2g 0.8

LP DTA condensate outlet temperature TI-3045 oC 260

Reboiler DTA level LI-3035 % 311

Reboiler vapor outlet temperature TG-3001 oC 240

LB Reflux Drum (31-V-202)

Drum Temperature TG-3104 oC 50-70

Reflux Drum overhead pressure PG-3106 kg/cm2g 20.6

LB Reflux pump discharge pressure PG-3105/3111 kg/cm2g 30/30

FE Col Feed Dryer Cooler (31-E-209A/B)

Cooler outlet temperature TG-3102 oC 36

Cooling water return temperature TG-3101 oC 40

Pressure Drop Across FE Col. Feed Coalescer PDI-3140 kg/cm2g 29/24

FE Column (31-C-204)

Column overhead temperature TI-3218 oC -28

Column overhead pressure PI-3243 kg/cm2g 20

Column bottom temperature TI-3212 oC 108

Column bottom pressure PI-3215 kg/cm2g 21.6

Column temperature profile

On Tray 1 TI-3232

oC

108

On Tray 6 TI-3211C 106

On Tray 10 TI-3211B 99

On Tray 14 TI-3211A 86

On Tray 19 TI-3223 62

On Tray 20 TI-3231 55

On Tray 24 TI-3230C 48

On Tray 26 TI-3230B 28

On Tray 28 TI-3230A -12

On Tray 29 TI-3225 -26

Pressure on tray 11 PI-3224A/B/C kg/cm2g 21/21/21

Pressure drop across col. Bottom and top PDI-3215 kg/cm2g



Description

Tag no. Unit Value

(Normal)

Refrigeration package

Refrigerant inlet temperature from Col. Overhead

condenser TI-3222 oC -34

Refrigerant inlet pressure from Col. Overhead condenser PI-3228 kg/cm2g 0.83

FE Column Reboiler (31-E-212)

LP Steam inlet pressure PIT-3242 kg/cm2g 2.6

LP steam inlet flow rate FIC-3217 kg/hr 3682

Vapor outlet temp. from reboiler TG-3201 oC 108

HB Column (31-C-203)

HB Column overhead pressure PIT-3331 kg/cm2g 9.3

HB Column overhead temperature TI-3313 oC 180

HB Column bottom pressure TI-3311 oC 230

HB Column bottom temperature PI-3317 kg/cm2g 10.6

Pressure drop across bottom and top PDI-3317 kg/cm2g -

Pressure on Tray 1 PI-3314A/B/C kg/cm2g 10.6/10.6/10.6

Temperature profile of Column

On Tray 11 TI-3310

oC

224

On Tray 23 TI-3325 198

On Tray 26 TI-3309 193

On Tray 34 TI-3306 188

Reflux inlet temperature TI-3316 oC 173

HB Reboilers (31-E-205A/B)

Vapor outlet temperature TG-3302A/B oC 250/250

HP Steam inlet temperature TI-3329/3330 oC 247/247

HP Steam inlet pressure PIT-3321/3324 kg/cm2g 37/37

HB Condensers (31-E-216A/B)

LP Steam outlet pressure PIT-3443/3439 kg/cm2g 5.2/5.2

LP condensate inlet flow rate FI-3447/3448 kg/hr 31311/31311

HB Reflux Drum (31-V-203)

HB column overhead Condensate inlet temperature TI-3457 oC 173

Reflux Drum Temperature TG-3404 oC 172-181

Reflux Drum pressure PG-3409 kg/cm2g 9

Reflux pump discharge pressure PG-3420/3421 kg/cm2g 12/12

Reflux flow rate to HB Column FIT-3437 kg/hr 101154.34



Description

Tag no. Unit Value

(Normal)

RB Column (31-C-203)

Col. Overhead pressure PI-3521A/B/C kg/cm2g 3.6/3.6/3.6

Col. Overhead temperature TI-3528B oC 185

Col. Bottom pressure PI-3527 kg/cm2g 4

Col. Bottom temperature TI-3542 oC 220

Col. Temp. Profile

Below tray 1 PIC-3545

kg/cm2g

-

On Tray 2 TI-3519 195

On Tray 18 TI-3518 188

On Tray 34 TI-3517 184

RB Reboiler (31-E-208)

Vapor outlet temp. TI-3536 oC 225

LP DTA inlet pressure to reboiler PIT-3535 kg/cm2g 0.8

LP DTA inlet flow rate to reboiler FIT-3530 kg/hr 99564

LP DTA Level in Reboiler LI-3531 % -

RB Reflux Drum (31-V-204)

Reflux Drum pressure PG-3506 kg/cm2g 3.4

Reflux Drum Temperature TG-3503 oC 137-178

Reflux pump discharge pressure PG-3507/3513 kg/cm2g 12/12

Reflux flow rate to HB Column FIT-3525A/B kg/hr 24773.72

Reflux flow rate to RB Column FIT-3526 kg/hr 9909.49

FE Column Feed Dryers (31-V-209A/B)

Feed inlet pressure PIT-3625/3630 kg/cm2g 1.6/2.4

FE Dryer Bed temp. Bottom TI-3626/3631

oC 150/325

Middle TI-3629A/3629B 36/300

FE Col. Dryer Reg. System

Reg. Blower Suction Pressure PI-3732 / PI-3731 / PG-3710 kg/cm2g 1.5/1.5/1.5

Reg. Blower Discharge Pressure PG-3709 kg/cm2g 2.6

Reg. Blower Discharge temperature TI-3724/TG-

3707 oC 75

FE Feed Dryer Reg. Heater outlet temp. TIT-3725 oC 300

FE Feed Dryer Reg. Heater outlet pressure PG-3708 kg/cm2g 2.4

FE Feed Dryer Reg. Coolers outlet temp. TG-3712 oC 166

FE Feed Dryer Reg. Coolers CWR temp. TG-3705 oC 45



Description

Tag no. Unit Value

(Normal)

Comonomer Column (31-C-205)

Column top pressure PI-3809A/B/C kg/cm2g 10.5/10.5/10.

5

Column top temperature TI-3807 oC 56

Column bottom pressure PI-3813 kg/cm2g 7.5

Column bottom temperature TI-3804 oC 72

Column temperature profile

On Tray 3 TI-3821

oC

65

On Tray 23 TI-3820 61

On Tray 45 TI-3819 58

On Tray 68 TI-3818 56

On Tray 83 TI-3817 56

CM Reboiler (31-E-214)

LP Steam inlet flow FIT-3814 11382

LP Steam inlet pressure to Reboiler PIT-3815 kg/cm2g 2.6

LP Steam inlet temperature TG-3805 oC 140

Reboiler outlet temperature to CM Column TG-3801 oC 70

CM Condenser (31-E-215)

CM Condenser outlet temperature TIT-3922 oC 52


Condenser overhead pressure PIT-3921 kg/cm2g 5.75

Reflux return flow rate to CM Column FI-3916 kg/hr 58652

FB-1 purge flow rate to Battery Limit FI-3911 kg/hr 1005

Reflux flow rate to FB Surge Tank FI-3919 kg/hr 23000

Reslurry Tank (31-V-309)

Reslurry Tank outlet Temp TIT-4438A 82

Reslurry Water Heater (31-E-302)

Reslurry Water heater circulation water inlet flow rate FIT-4437 kg/hr 97157

Reslurry Water heater circulation water outlet temp. TIT-4438B oC 100

Circulation water flow rate to RA stripper outlet FIT-4441 kg/hr 53830



Description

Tag no. Unit Value

(Normal)

Stripping & Drying Section

RA Stripper Feed In Temperature TI-4613 oC 82

RA Stripper Top Temperature TI-4614 oC 103

RA Stripper overhead line temperature TI-4631 oC 100

RA Stripper Overhead Pressure PIT-4632 kg/cm2g Atm

LP Steam inlet temperature to RA Stripper TIT-4611 oC 102

Steam inlet flow rate to internal distributor FI-4633 kg/hr 5252

RA Stripper pressure PI-4610 kg/cm2g 4

Desuperheated steam temp from Desuperheater TI4635B oC 102

Reslurry Water heater inlet flow rate from RA Stripper FI-4651 kg/hr 102317

DM water inlet flow rate to Desuperheater FIT-4643 kg/hr 186

LP Steam inlet flow rate to Desuperheater FI-4647 kg/hr 5086

Nitrogen inlet flow rate to RA Stripper FIT-4636 kg/hr 1000

Spin Dryer Hold-up Bin Temp. TI-4623 oC 70

Solvent vapor Condenser outlet temperature TI-4714 oC 65

Liquid Additive System

Recycle SH outlet temp. from 31-E-303 TI-4840 oC 149

Cooling Water Return temp. from 31-E-303 TG-4819 oC 65

Additive mix tank 31-V-305 overhead pressure PI-4821 kg/cm2g 1

Additive holding tank 31-V-301 overhead pressure PI-4825 kg/cm2g 1




Nitrogen Heating System

HP DTA inlet pressure to 31-E-406/407/408/409

PG-

5605/5606/5607/

5608

kg/cm2g 4/4/4/4

Nitrogen outlet temp. from 31-E-406/407/408/409

TG-

5611/5612/5613/

5614

oC 300/300/300/

300

Polymer KO Drum (31-V-405)

Drum overhead pressure PG-5707 kg/cm2g 1.05

Drum Bottom temperature TG-5710 oC 150



Description

Tag no. Unit Value

(Normal)

Flare KO Drum (31-V-404)

Drum temperature TG-5703 oC Amb

Flare Heater Pressure Nr. KO Drum PG-5709 kg/cm2g 1.6

HP Steam inlet temp. to KO Drum TI-5715 oC 30

KO Drum Overhead Pressure PI-5716/5717 kg/cm2g 1.6/1.6

KO Drum Bottom Temperature TG-5704 oC Amb

LP Steam inlet pressure to 31-E-405A/B PG-5706A/B kg/cm2g 4.5/4.5

Purge Nitrogen line Pressure to Flare heater PI-5719 kg/cm2g 1.6

LP DTA Condensate Drum (31-V-410)

Drum Overhead temperature TG-6002 oC 260

Drum overhead Pressure PIT-6015 kg/cm2g 0.1

LP DTA Cond. discharge flow rate from 31-P-407/S FIT-6012 121460

HP DTA Condensate Drum (31-V-406)

Drum Bottom temperature TI-6116 oC 313

Drum overhead Temperature TG-6103 313

Drum Overhead Pressure PIT-6112 kg/cm2g 2

HP DTA Cond. discharge flow rate from 31-P-405/S FIT-6113 kg/hr 80828

Dowtherm Make-up & Recovery System

DTA Storage Vessel bottom temperature TG-6219 oC 10-45

DTA Storage Vessel overhead Pressure PIT-6236/PG-

6231 kg/cm2g 0.1/0.1

DTA Storage Vessel overhead Temperature TIT-6252 oC 45-343

Min circulation inlet temp. to DTA Receiver TG-6226 oC 180

DTA Vent Receiver overhead temperature TI-6253/TG-

6222 oC 189/189

DTA Vent from user inlet temp to Receiver TG-6220 oC 150

DTA Vent from user inlet temp to 31-EA-401 TG-6232 oC 344

Ejector inlet line pressure PIT-6241 kg/cm2g -0.9

Cooling Water Return temp. from 31-E-412 TG-6224 oC 45

DTA Vent Pot overhead temp. TI-6254 oC 400

CW Return line temp. from 311-V-409 tracing TG-6255 oC 45

DTA Reg. overhead Temp. TG-6207 oC 265-280



Description

Tag no. Unit Value

(Normal)

DTA Reg. overhead Pressure PIT-6246 kg/cm2g 0.2

Nitrogen inlet pressure to DTA Reg. Vessel PG-6202 kg/cm2g 0.2

DTA Reg. vessel bottom temperature TIT-6251 oC 265-280

DTA Waste Fuel System

RB Purge inlet line flow to Waste Fuel Drum FIT-6323 1400

Waste Fuel Drum overhead Pressure PG-6306 kg/cm2g 2.5

Waste Fuel Drum bottom temperature TIT-6322 oC 220

SH De-inventory Tank (31-T-401)

Tank Temperature TG-6404 oC 10-50

Nitrogen inlet line pressure PI-6410 kg/cm2g 0.5

FB De-inventory Tank (31-V-415)

CW Return line temp from 31-E-401 TG-6516 oC 45

FB Surge Drum overhead Pressure PIT-6510/PG-

6503 kg/cm2g 0.5/4

Surge Drum bottom temperature TG-6504 oC 10-40

FB Feed Pump Discharge flow rate FIT-6515 kg/hr 5455

FB-1 Make-up from OSBL FIT-6514 kg/hr 23899.3

FC Purifiers (31-V-416A/B)

FC Purifier Bed temperature (31-V-416A) TI-6631/6632 oC 30/300

FC Purifier Bed temperature (31-V-416B) TI-6633/6634 oC 30/300

Flow rate through the filling line FIT-6657 1500

FC Purifiers outlet line pressure PG-6614 kg/cm2g 9

FC Purifier TI-6635 oC 37

Nitrogen in/out temp. TI-6636 oC 38/280

FC De-inventory Tank (31-V-414)

Tank overhead pressure PIT-6623 kg/cm2g 3.5

Tank Bottom temperature TG-6601 oC 50

FC Purifier outlet flow rate to FC De-inventory Tank FIT-6626 7000

FC De-inventory tank flare line pressure PG-6602 kg/cm2g 3.5



8.2 LIST OF INSTRUMENTS

In this section control valves, pressure safety valves, analysers etc are listed. Information regarding

indicators & controllers (temperature, pressure, flow and level instrument) are already given in previous

section).

8.2.1 Control Valves: 8.2.1.1 Reaction Area (Area 100):

Sr. No.

Tag No.

Description/Location

Size (Inch)

Flow Fail Safe Position

Min. Nor. Max.

1 31-FQV-2245 SH from SH dryer to CAB/CAB-2 Filter and

CT/CJ/CD Mix Tank 1.5 - 5000 6500 FC

2 31-FV-1122A

Comonomer from CM Reflux Pump through E-113

A/B to SH Purifier, Solvent Feed and HP Diluent

Pump

3 1400 23000 29521 FC

3 31-FV-1122B

Comonomer from CM Reflux Pump through E-113

A/B to SH Purifier, Solvent Feed and HP Diluent

Pump

2 1400 23000 29521 FC

4 31-FV-1144 SH Filling line to Regenerated Purifier 1.5 14000 14000 14000 FC

5 31-FV-1146 Inventory Adjustment line to LPS Hold-Up Tank 3 35000 75600 75600 FC

6 31-FV-1314A SH/Comonomer from Solvent Feed Pump to

Absorber Cooler 4 - - - FC

7 31-FV-1314B SH/Comonomer from Solvent Feed Pump to Reactor

Feed Booster Pump Suction 4 - - - FC

8 31-FV-1318 FE from Secondary FE Guard Bed to Absorber

Cooler 4 - - - FC

9 31-FV-1515 Connecting line between O/L from Reactor Cooler

(31-E-104) and Reactor Heater(31-E-103) 8 - - - FC

10 31-FV-1547 HP Diluent (as a carrier of CD, CAB, CAB-2) from

Pump to Reactor #1 through 31-E-111. 1 1400 2000 2400 FC

11 31-FV-1513 HP Diluent (As a carrier of Hydrogen) from Pump to

Reactors #1 and #2 1.5 - 482 578 FC

12 31-FV-1723 Solvent (Flushing SH) to Steam Purge Heater (31-E-

106) 3 3000 3000 25200 FC

13 31-FV-2047 CAB-2/CAB to CAB-2/CAB Metering Pump Suction 1/2 - - - FC

14 31-FV-2055 CAB/CAB-2 to CAB/CAB-2 Metering Pump Suction 1/2 - - - FC

15 31-FV-2060 HP Solvent from HP Diluent Pump to CAB-2

metering pump Discharge line 1 - - - FC

16 31-FV-2061 HP Solvent from HP Diluent Pump to CAB metering

pump discharge line 1 - - - FC

17 31-FV-2139 CD to Pump suction 1/2 - - - FC

18 31-FV-2147 CT to Pump Suction 1/2 - - - FC

19 31-FV-2153 HP Diluent to CT Metering Pump Discharge 1/2 - - - FO



Sr. No.

Tag No.


Size (Inch)


Min. Nor. Max.

20 31-FV-2152 HP Diluent to CD Metering Pump Discharge 1/2 - - - FO

21 31-FV-2237 CJ/CT line to CJ Metering Pump suction 1/2 - - - FC

22 31-FV-2242 HP Solvent from HP Diluent Pump to CJ Metering

pump Discharge line 1 - - - FC

23 31-FV-2317 PG From 31-V-116 to PG Metering Pump Suction 1/2 - - - FC

24 31-FV-2321 PD from 31-V-117 to PD Metering Pump Suction 1/2 - - - FC

25 31-FV-1149A Make-up FC from FC Purifier to Recycle SH Air

Cooler 3 6500 8000 35000 FC

26 31-FV-1149B Make-up FC from FC Purifier to Recycle SH Air

Cooler 2 2507 5004 8000 FC

27 31-FV-2421A Hydrogen from Compressor to Reactor Feed Pump

Discharge 1/2 - - - FC

28 31-FV-2421B Hydrogen from Compressor to Reactor Feed Pump

Discharge 1/2 - - - FC

29 31-FV-2422A Hydrogen from Compressor to Reactors #1 and #2 1/2 - - - FC

30 31-FV-2422B Hydrogen from Compressor to Reactors #1 and #2 1/2 - - - FC

31 31-FV-1615 HP DTA Vapor to Adsorber Preheater DTA

Desuperheater(31-V-113A) 8 5100 41000 49200 FC

32 31-FV-1616 HP DTA Vapor to Adsorber Preheater DTA

Desuperheater(31-V-113B) 8 5100 41000 49200 FC

33 31-FV-2758 Initial Start-Up line to FE Guard Bed 31-V-127 A/B 1 700 700 700 FC

34 31-LV-1611 Condensed DTA from Adsorber Preheater (31-E-

105A) to HP DTA Condensate Drum 6 7680 47500 57000 FC

35 31-LV-1619 Condensed DTA from Adsorber Preheater (31-E-

105B) to HP DTA Condensate Drum 6 7680 47500 57000 FC

36 31-LV-1914 RA Solution from IPS to LPS 1st Stage 8 - - - FC

37 31-LV-2045 SH+CAB-2 to CAB-2 Mix Tank 1.5 - - - FC

38 31-LV-2053 SH+CAB to CAB-Mix Tank 1.5 - - - FC

39 31-LV-2137 CD inlet line to CD Mix Tank 1.5 - - - FC

40 31-LV-2145 CT inlet line to CD Mix Tank 1.5 - - FC

41 31-LV-2235 CLJ Catalyst from Catalyst Drum to CJ Mix Tank 1.5 - - - FC

42 31-LV-1410 HP+LP Condensate Return from Reactor Feed

Heater Condensate Pot 2 15106 19060 - FC

43 31-LV-1721 HP Condensate Return from Steam Purge Heater

Condensate Pot 1.5 300 300 6220 FC

44 31-PV-1250 HP Diluent Pump discharge line to HP Diluent

Spillback Cooler 1 - 3802.23 - FO

45 31-PDV-2417 Compressor Discharge Common Header to

Compressors Suction Line 1 - 206 - FO

46 31-PV-1320 Head Tank Overhead Depressurising line to Flare 3 - - 3000 FC



Sr. No.

Tag No.


Size (Inch)


Min. Nor. Max.

47 31-PV-1725 SH/N2 Flush Return from Solution Adsorbers to

LPS/LB Condensers 2 - - - FC

48 31-PV-1909A RA from Solution Adsorber to IPS 4 - - - FC

49 31-PV-1909B RA from Solution Adsorber to IPS 4 - - - FC

50 31-PV-1911 IPS Overhead Flashed Vapor to LB Feed Condenser 6x8 - - - FC

51 31-PV-1916 LPS 1st Stage Flashed off SH+HC to LPS KO Pot 14 - - - FC

52 31-PV-1926 LPS 2ndStage Flashed off SH+HC to LPS KO Pot 8 - - - FC

53 31-PV-1927 Vacuum Breaker Cold N2 supply to LPS 2nd Stage 1 - - - FO

54 31-PV-2063 LP Solvent to CAB-2 Metering Pump suction line 1/2 30 90 140 FO

55 31-PV-2064 LP Solvent to CAB Metering Pump suction Line 1/2 30 90 140 FO

56 31-PV-2157 CD Metering pump suction line 1/2 - - - FO

57 31-PV-2158 CT Metering pump suction line 1/2 - - - FO

58 31-PV-2250 LP Solvent from SH Purifier to CJ Metering Pump

Suction 1/2 30 90 140 FO

59 31-PV-2330 LP Solvent to PG Metering Pump Suction 1/2 40 80 140 FO

60 31-PV-2331 LP Solvent to PD Metering Pump Suction 1/2 40 80 140 FO

61 31-PV-2766 FE to FE column Feed Dryers 1.5 1750 3500 3500 FC

62 31-TV-1259 HP DTA Vap. I/L to Purifier Regeneration Heater 8 5675 11350 19300 FC

63 31-TV-1319 CW Return line from Absorber Cooler 10 - - 400000 FO

64 31-TV-1405A LP Steam Supply to Reactor Feed Heater 8 7553 15106 - FC

65 31-TV-1405B HP Steam Supply to Reactor Feed Heater 6 9530 19060 - FC

66 31-TV-1405C HP/LP condensate Return from Reactor Feed Heater

Condensate Pot 3 - 19060 - FO

67 31-TV-1406A Reactor Feed+ Hydrogen O/L from Reactor Feed

Coolers 6 - - - FC

68 31-TV-1406B Reactor Feed+ Hydrogen O/L from Reactor Feed

Heater 6 - - - FO

69 31-TV-1548 HP Diluent from HP Diluent Pump to HP Diluent

Heater 1 - 1400 1800

(3 way

valve)

70 31-TV-1724 Solvent O/L from Steam Purge Heater to/bypass of

DTA Purge Heater 3 - - -

(3 way

valve)

71 31-TV-1624 HP DTA Cond. From HP DTA Cond. Pump to Adsorber

Preheater DTA Desuperheater (31-E-133A) I/L 1 1621 12929 15511 FC

72 31-TV-1625

HP DTA Cond. From HP DTA Cond. Pump to

Adsorber Preheater DTA Desuperheater (31-E-

133B) I/L

1 1621 12929 15511 FC

73 31-TV-2329 LP Steam Supply to PG Storage Tank 3/4 - 319 -



8.2.1.2 Recycle Area (Area 200):

Sr. No.

Tag No.


Size (Inch)

Flow Fail Safe PositionMin. Nor. Max.

1 31-FV-2812 SH Feed from OSBL to LPS Hold-Up Tank 1 25 160 8000 FC

2 31-FV-2924 From LB Feed Heaters to LB Feed Heater No.2 3 22107 83418 100703 FC

3 31-FV-3017 FE Make-Up line to Vap. From IPS line 1.5 1750 3500 3500 FC

4 31-FV-3126 Reflux Return to LB Column 6 25404 101448 155976 FO

5 31-FV-3031 LB Column Bottom to HB Column 8 105283 210565 252678 FC

6 31-FV-3033 LP DTA supply to LB Reboiler 16 43000 86300 119480 FC

7 31-FV-3210 Purified FE from FE column Feed Dryer to HB

Column 4 10116 26383 35864 FC

8 31-FV-3214 FE Column bottom to CM Column

3 9088 29322 32255 FC

9 31-FV-3217 LP Steam Supply to FE Reboiler 4 1117 3302 3797 FC

10 31-FV-3437 Reflux from HB Reflux pump discharge to HB

Column 6 35426 76616 121385 FO

11 31-FV-3315 HB Column Bottom to RB Column 4 12600 25209 30239 FC

12 31-FV-3318A HP Steam Supply to HB Reboiler (31-E-205A) 1.5 850 7780 8940 FC

13 31-FV-3318B HP Steam Supply to HB Reboiler (31-E-205A) 3 7250 14375 16550 FC

14 31-FV-3322A HP Steam Supply to HB Reboiler (31-E-205B) 1.5 850 7780 8940 FC

15 31-FV-3322B HP Steam Supply to HB Reboiler (31-E-205B) 3 7250 14375 16550 FC

16 31-FV-3525 SH from RB Column Reflux Pumps Discharge to HB

Column 4 18313 24774 77365 FC

17 31-FV-3526 Reflux from RB Reflux Pump to RB Column 2 7325 9909 11422 FO

18 31-FV-3911 FB-1 Purge from CM Reflux pump discharge to

Battery limit 1 48 627 1254 FC

19 31-FV-3916 Reflux from CM Reflux Pump to CM Column 4 20000 58604 73255 FO

20 31-FV-3811 CM Column Bottom Pump discharge to Butene

Purge Steam Cooler Inlet line 1 244 1284 2570 FC

21 31-FV-3919 CM Reflux Pump discharge to FB Surge Tank 1.5 9000 23000 26450 FC

22 31-FV-3814 LP Steam Supply to CM Column Reboiler 8 4642 11342 13045 FC

23 31-FV-3219 FE Condenser to Refrigeration Unit 1.5 586 2128 3542 FC

24 31-FV-3134 FB-1 from FB Feed Pump to LB Reflux Drum 2 3000 23000 27350 FC

25 31-FV-3736 Nitrogen from FE Feed Dryer Regeneration Blower

to FE Feed Dryer Regeneration Cooler Inlet 4 500 1500 3000

26 31-FV3530 LP DTA Vapor supply to RB Column Reboiler 8 10500 21100 24300

27 31-LV-3018 HP cond. Supply to LB Feed Condenser 1.5 5090 24862 29835 FO



Sr. No.

Tag No.


Size (Inch)

Flow Fail Safe PositionMin. Nor. Max.

28 31-LV-3035 DTA Return from LB Reboiler 8 42800 119500 119500 FC

29 31-LV-3438 LP Cond. Supply line to HB Condenser (31-E-216B) 2 15835 37311 42906 FO

30 31-LV-3444 LP Cond. Supply line to HB Condenser (31-E-216A) 2 15835 37311 42906 FO

31 31-LV-3531 LP DTA cond. From RB Reboiler to Cond. Receiver 4 7300 24200 24200 FC

32 31-LV-3816 LP Cond. Return from CM Col. Reboiler and

Reboiler Condensate pot 2.5 3000 11400 13200 FC

33 31-LV-3320A HP Steam Cond. Return from HB Reboiler Cond.

Receiver (31-V-208A) 3 6000 16600 16600 FC

34 31-LV-3320B HP Steam Cond. Return from HB Reboiler Cond.

Receiver (31-V-208B) 3 6000 16600 16600 FC

35 31-LV-3220 LP Steam Cond. Return from FE Reboiler Cond. Pot 1 1130 3680 4420 FC

36 31-LV-3227 Refrigerant (Propane) supply to FE Condenser (31-

E-213) 2 1905 3810 4572 FO

37 31-PV-2817A LPS Hold-Up Tank overhead line to Flare 2 40 150 300 FO

38 31-PV-2817B N2 Supply to LPS Hold-up Tank 1 38 150 180 FC

39 31-PV-2930 Hot Flush Pump Discharge line to LPS Hold up

Tank/LB Feed Heater No. 2 2 - - 25200 FO

40 31-PV-3019A HP Steam from LB Feed Cond. to HB Reboilers 8 5040 24363 29274 FC

41 31-PV-3019B LP Steam O/L from LB Feed cond. to LP steam

system 6 7208 14416 17366 FC

42 31-PV-3022B LB Reflux drum vent line to flare 1 - - - FO

43 31-PV-3234 FE from Refrigeration system to Flare 2 600 3500 4075 FC

44 31-PV-3439 LP Steam O/L from HB Condensers (31-E-216B) 10 15678 36942 42482 FO

45 31-PV-3443 LP Steam O/L from HB Condensers (31-E-216A) 10 15678 36942 42482 FO

46 31-PV-3809B CW Return from CM Condenser 8 288307 576614 663106 FO

47 31-TV-3922 CM Reflux drum overhead line to Flare 2 820 2160 2600 FC

48 31-TV-2814 CW Return from LPS condensers 10 350585 876460 1344300 FO

49 31-TV-3025 HP Steam supply to LB Feed Heater No.2 4 2700 5415 8704 FC

50 31-TV-3629 FE Column Feed Dryer’s FE filling Line 2 - - - FC

51 31-TV-3725A

Regeneration Hot gas line from FE Feed Dryer

Regeneration Heater to Fe Col. Dryer or FE Guard

Bed

10 9073 9917 10500 FC

52 31-TV-3725B Reg. Hot gas E-217 bypass line 8 584 584 1428 FO



8.2.1.3 Finishing Area (Area 300):

Tag No.


Size (Inch)

Flow Fail Safe Position Min. Nor. Max.

1 31-FQV-4823 Recycle SH to Additive mix tank/V-301/302 I/L 1.5 - 3000 - FC

2 31-FV-4029 Water I/L to Underwater Pelletizer 8 198745 619044 807449 FO

3 31-FV-4437 Water from Water Circulation Pump discharge to

Reslurry Water Heater I/L 6 41406 97157 145736 FC

4 31-FV-4441 Cooled Circulation water from Cooler to RA Stripper

Outlet 4 31054 53830 80745 FO

5 31-FV-4636 Nitrogen to RA Stripper 2 500 1000 2000 FC

6 31-FV-4642 LP Steam I/L to Desuperheater 8 3911 5086 7629 FC

7 31-FV-4643 DM Water I/L to Desuperheater 1 - - - FO

8 31-FV-4651 Water from RA Stripper to Reslurry Tank 4 50000 102317 134575 FC

9 31-LV-4426 Reslurry Pump discharge to RA Stripper 6 60547 157456 188947 FC

10 31-LV-4615 RA Pellets O/L from RA Stripper to Spin Dryer 10 - - - FC

11 31-LV-4717 LP Cond. O/L from Solvent Cond. Pump Discharge

Filters to LPS Hold-Up Tank 1.5 303 1576 1734 FC

12 31-LV-4447 LP Condensate O/L from Reslurry Water Heater 3 4241 8482 10178 FC

13 31-LV-4723 Oily Water O/L from Decanter to Skim Pump Suction 1.5 2060 4118 4530 FC

14 31-LV-4648 Water O/L from RA Stripper to Fines separator 4 50000 102317 134575 FO

15 31-PV-4632 Nitrogen Supply to RA Stripper Vent Line 1 - - 175 FO

16 31-TV-4439 CW Return from Water Cooler (31-E-318/S) 12 522935 1370338 1568810 FO

17 31-TV-4618 DM Water Supply to Spin Dryer and Spin Dryer Hold-

Up Tank 2 - - - FC

18 31-TV-4822 Recycle SH I/L to Additive mix Tank 1.5 - - - FC

19 31-TV-4826 LP Steam I/L to Additive Mix Tank Bottom Jacket 1.5 225 445 490 FC

20 31-TV-4827 LP Steam I/L to Additive Holding Tank (31-V-301)

Bottom Jacket 1.5 225 445 490 FC

21 31-TV-4833 LP Steam I/L to Additive Mix Tank (31-V-302) Bottom Jacket 1.5 225 445 490 FC



8.2.1.4 Utility & ISBL Area (Area 400):

Sr. No.

Tag No.


Size (Inch)


Min. Nor. Max.

1 31-FV-6626 FC from FC Purifier O/L to FC De-inventory cooler

O/L 2 5000 7000 10000 FC

2 31-FV-6113 HP DTA Pumps Discharge Back to HP DTA Cond.

drum line 2 - - 55760 FO

3 31-FV-6012 LP DTA Pumps Discharge Back to LP DTA Cond.

drum line 2 - - 52000 FO

4 31-FV-6323 RB Purge line to Waste Fuel Drum 1 425 1400 2810 FC

5 31-FV-6514 FB-1 Make-Up from OSBL to FB De-inventory

Cooler 1 450 5455 7500 FC

6 31-FV-6515 Recycled FB-1 from FE Feed Pump discharge to FB

de-inventory Cooler I/L 2 - - 10200 FO

7 31-FV-6657 FC Purifier FC filling line 1 750 1500 3000 FC

8 31-LV-6409 SH Recycle to SH De-inventory Tank from SH De-

inventory Pump 4 - - - FC

9 31-LV-6619 FC from FC de-inventory Cooler to FC De-inventory

Tank 4 - - - FC

10 31-LV-6114 DTA Cond. from HP DTA Cond. Tank to DTA Cond.

Vaporiser 6 61300 169188 272882 FC

11 31-LV-6238 DTA Transfer Pump discharge to HP/LP DTA cond.

Tank 1.5 - - 5580 FC

12 31-LV-6245 Liq. DTA from DTA Vaporisers to DTA Regeneration

Vessel (31-V-408) 1 100 518 518 FC

13 31-PV-6112A HP DTA Vap. From Header to HP DTA cond. Tank

bottom 10 39000 97500 116500 FC

14 31-PV-6112B HP DTA Vap. From Header to RB Reboiler line from

HP DTA Cond. Drum 4 7800 19500 23300 FC

15 31-PV-6015A HP DTA Vap. To HP DTA Cond. Drum I/L 2 1595 3185 3820 FC

16 31-PV-6015B LP DTA cond. Drum Vent to DTA Vent Receiver 1 340 725 860 FC

17 31-PV-6236 N2 Supply to DTA Storage Vessel 1 2 8 10 FC

18 31-PV-6241A HP Steam Supply to Ejector 1 - - - FC

19 31-PV-6241B DTA Vent from Vaporiser and Diff. Section to DTA

Vent Condenser 4 - - 2000 FO

20 31-PV-6241C Air to Ejector 3 - - - FC

21 31-PV-6246 DTA Regeneration Vent to DTA Vent condenser 1.5 100 400 518 FC

22 31-PV-5902B DTA Vap. From Vaporiser to DTA Storage Vessel - - - FC

23 31-PV-6419 N2 Supply to SH De-inventory Tank 1 50 100 120 FC

24 31-PV-6510A FB Surge Tank Vent line to flare 2 180 500 FC

25 31-PV-6510B N2 to FB Surge Tank vent Line 1 1200 330 480 FO

26 31-PV-6913 HP Steam line at battery limit 10 - - - FC



Sr. No.

Tag No.


Size (Inch)


Min. Nor. Max.

27 31-PV-5717 Fuel Gas Purge line to Flare KO Drum 2 - - - FO

28 31-PV-5719 Nitrogen Purge Line to Flare KO Drum 2 - - - FO

29 31-PV-6731 FE Supply from Storage to Primary FE Guard Bed 8 - - - FC

30 31-TV-4932B

31 31-TV-6240 HP DTA Cond. O/L from DTA Vent Receiver coil to

HP DTA Cond. Tank 1 200 830 1025 FC

32 31-TV-6322 LP Steam Supply to Waste Fuel Drum Heating coil 1 - 100 - FC

33 31-TV-6251 HP DTA Vap Supply to DTA Regeneration Tank

Heating Coil 1 100 200 200 FC

34 31-TV-6252 DTA Storage Vessel Vent to Atm 2 - - - FC

35 31-TV-6914 HP Steam line Nr. Battery Limit 12 - - - FC

36 31-TV-6916 Condensate from P-403/S 2 - - - FC

37 31-TV-6928 LP steam line at battery limit 18 - - - FC

38 31-TV-6929 Condensate from P-402/S 1 - - - FC



8.2.2 Analysers: 8.2.2.1 Reaction Area (Area 100):

Sl. No.

Tag No. Location/Service Component Measured Property

1 31-AT-1134 Solvent O/L from Recycle SH Water

Cooler - Water

2 31-AT-1164 - SH

3 31-AT-1340

A/B/C/D/E/F

Purified FE from Secondary FE Guard

Bed to Adsorber Cooler I/L -

Methane, Ethane,

CO2, Acetylene, CO,

Methanol

4 31-AT-2246 SH from SH Make-up dryer bottom O/L

to CAB/CAB-2 Filter - Water

5 31-AT-2634 PA Blower discharge line to 31-V-

104A/B Oxygen/Nitrogen Oxygen

6 31-AT-2743 Primary FE Guard Bed O/L Ethylene, CH3,C2H6, Propylene, C2H2

,H2, CO2, CO,CH3OH, (CH3)2O, NH3 Water

7 31-AT-2757 Primary FE Guard Bed O/L Ethylene, CH3,C2H6, Propylene, C2H2

,H2, CO2, CO,CH3OH, (CH3)2O, NH3 Oxygen

8.2.2.2 Recycle Area (Area 200):

Sl. No


1 31-AT-3436

A/B/C/D/E

HB Reflux Pump Discharge and SH

from Solvent Feed Pump Suction

FB-1, FB-2, FC-1, FC-2, SH,

Ketones, Xylene

FB-1, FB-2, FC-1, FC-

2, SH

2 31-AT-3634 FE Column. Feed Dryer H2O, Ethylene.FB-1, FB-2, SH,

Ketones, H2, C2H6 Water

3 31-AT-3810-1

A/B/C/D/E/F CM Col. Bottom outlet line

FB-1, FB-2(Cis, Trans),n & I Butene,

SH, Ethylene, Ketones, Butadiene,

C2H6, Propylene, i-Butane

FB-1, FB-2(cis), FB-2

(trans), n-Butane, i-

butene, SH

4 31-AT-3810-2

A/B/C/D/E/F CM Reflux Pumps common outlet line -

FB-1, FB-2(cis), FB-2

(trans), n-Butane, i-

butene

8.2.2.3 Utility Area (Area 400):

Sr. No.


1 31-AT-8601 LP Steam Cond. Pump Discharge - HC, PH, K



SECTION-9.0 SHUTDOWN PROCEDURE



9.1 Total Plant shutdown:

A total plant shutdown and de-inventory requires a systematic shutdown of the various areas. Nitrogen

purging must commence as soon as possible in order to use the residual heat of the equipment.

If a cleaning of the Low Pressure Separator is included in shutdown plans, then a suitable resin must be

produced four hours prior to the termination of reaction in order to ease the cleaning process. The following

timetable and sequence is suggested:

9.1.1 Pre-Shutdown 1. Ensure there is adequate storage room for all plant raw materials (e.g. SH, FB).

2. Two days before the shutdown remove the insulation from all flanges that will be blanked. Tie the

appropriate blanks and gaskets near flanges to be blanked.

3. Install all temporary jumper lines that are required.

4. Keep the inventories of SH and FB as low as possible (in the Distillation Area) for 48 hours before

the shutdown.

5. Schedule to have one SH Purifier out of service 24 hours before shutdown. Heat the Purifier to the

maximum regeneration temperature. This Purifier will be used to reheat nitrogen for decontamination

of the Reaction System

6. Ensure all process analyzer vents are opened to the flare system 12 hours before the shutdown.

7. Three weeks before the shutdown, pre-plan catalyst inventories to suit shut down work and to

ensure the proper catalyst is available for the startup.

8. Maintain low inventories in the Liquid Additive room since any hot work would require the room to be

de-inventoried and decontaminated.

9. Ensure that the standby FE Feed Dryer has been regenerated and is under nitrogen.

10. If applicable, schedule to have one of the Solution Adsorbers out of service, emptied, SH filled and

hot, ready for flushing at shutdown (allow at least 48 hours to perform this work).

11. Ensure SH Makeup Dryer and associated piping is de-contaminated and under nitrogen.

12. Develop blanking lists and diagrams for all vessels to be blanked for cleaning, repairing, or

inspecting before the shutdown.

13. Ensure all portable hydrocarbon detectors, oxygen analyzers and gas analyzers are in good working

condition.

14. If possible, increase finished resin inventories to satisfy sales for the term of the shutdown.

15. Review the Safety Procedures required for the shutdown work.

T = Symbol for Reaction Termination (in Hours) T-12 Increase the base purge on RB Column to remove all grease before shutdown.

T-4 Increase AO8 injection to the IPS outlet to a minimum of 1000 ppm to prevent resin

degradation in any equipment that will not be cleaned of polymer.

T-4 Change to a 0.935 density, 5 Melt Index, #1 Reactor resin with high antioxidant to provide

the LPS with a coating of high antioxidant resin that is easy to clean.



9.1.2 Reaction Termination (T+0) • Terminate reaction (start the Reactor Agitator if it is not running).

• Stop liquid additive injection and flush the systems with SH to the injection points.

• Maintain the highest flow through the Reactor Feed Pump permitted (RFH loading).

• Flush the system completely at maximum inlet temperature for 2 1/2 hours.

NOTE: The time between termination of reaction and the shut down of the Reactor Feed Pump should be

used for flushing while the system equipment is still hot. This will assist in the nitrogen purging of

lines that normally contain cold SH.

• Ensure an adequate polymer seal is left in the LPS cone when shutting down the Extruder. The

Satellite Extruder must remain operational (on standby) with a sufficient amount of recycle resin in

the Recycled Resin Storage Bin to re-establish a polymer seal if necessary. The die plate should be

frozen to reduce drooling during pressure cycles in the LPS.

• Control the outlet temperature of the Recycle SH Water Cooler at 65°-70°C.

• Lower the cooling to minimum on the LPS Condensers.

• Raise the pressure to maximum on the LB Feed Condenser.

• Raise the IPS pressure to 35 kg/cm2g

• Take a maximum flow from the IPS to LPS.

• Flush at least 20 tons of SH through the LPS sieve plate.

• Purge liquid additive lines with nitrogen to a grounded metal pail at injection points, then grease all

injection nozzles with silicone grease.

• Prepare a LP steam line to the shell side of the Absorber Cooler using a hose.

9.1.3 Time T + ½ Hours

• Close the catalyst and co-catalysts valves at the outlet of the mix and surge tanks and open low-

pressure diluent SH upstream of the flow meters. Establish a flow to each injection point (one at a

time) to flush.

• Close the deactivator lines from the storage tanks and open low-pressure diluent to the flow meters

and purge the deactivator pumps and lines.

• Flush out the Side Feed lines to #1 Reactor, one at a time.

• Depressurize the catalyst and co-catalyst mix and surge tanks to 0.7 kg/cm2g.

• Shut down the catalyst, co-catalyst and deactivator pumps after flushing for 20 minutes (the pumps

may gas-off with the hot SH from the Purifiers).

• Flush all J injection points, then shutdown the HP Diluent pumps.

9.1.4 Time T+1 Hour

• Flush the Solution Adsorber, if applicable. When complete, flush out the Solution Adsorber bypass

lines.

• After Solution Adsorber flushing is complete, line the flushing flow at maximum rate and 310°C into

#3 Reactor.



9.1.5 Time T+1 ½ Hours • Shut down the Solvent Feed Pump and allow the Reactor Feed Pump (RFP) to lower the level in the

Head Tank to minimum or to the low level RFP interlock trip. The RFP must be shut down before it

starves. (Ensure that before the RFP is shut down the LPS has been adequately flushed with a

minimum of 20 tons of SH through the sieve).

• Depressurize from the Solvent Feed Pump to the RFP to the LPS Hold-up Tank.

• Depressurize simultaneously from the RFP discharge to the IPS, including the tempering system, the

Reactor, Solution Preheater, Solution Adsorber and IPS to the LB Feed Condenser (caution: the IPS

PSV setting is 67 kg/cm2g).

• While depressurizing the Reaction Area, the Agitator Seal System pressure can be lowered but must

be maintained at 15 kg/cm2g above the Reactor pressure until the Reactor is completely de-

pressurized and open to atmosphere.

• Close the Seal Oil Accumulators when starting to depressurize the Seal Oil System.

9.1.6 Time T+2 ½ hours

• When the Reaction Area pressure equals the LB System pressure, continue flushing into the Reactor

with the Flushing Pump until the Reactor reaches maximum temperature. Shutdown the Flushing

Pump and allow the Purge Heaters and piping to depressurize along with the Reaction System, to

the first and second stage LPS systems.

• Open hot nitrogen through the Purge Heaters to the #3 Reactor. Open hot nitrogen into the RFP

discharge and purge the Reactor Feed Heater and Cooler.

• Stop the flow from the LPS Condensate Pumps to the LB Column and open the line from the LPS

Condensate Pumps to the SH De-inventory Storage Tank. Start to de-inventory the LPVR.

9.1.7 Time T+4 Hours • Start moving SH from the LB System to the HB System to the LPS Hold-up Tank, to the SH De-

inventory Storage Tank.

• The contents of the LB Reflux Drum (FB) can be sent to the FE System, then to the CM System.

• De-inventory the CM System to the FB Surge Tank.

• Stop the feed to the RB Column and de-inventory the overheads to storage and the base to the

waste fuel tank if there is still some grease (when the grease has been purged out, boil the base

contents overhead).

• When all SH has been removed from the Distillation Area (except the LPS Hold-up Tank), nitrogen

can be opened into the SH Purifiers and SH can be purged forward to the LPS Hold-up Tank through

the drain lines on the Solvent Feed Pump, Absorber Cooler and bypass, Head Tank and Reactor

Feed Pump.

• Nitrogen purge the low-pressure Diluent lines, catalyst and de-activator pumps, high pressure

Diluent pumps, piping and all high-pressure Diluent and catalyst lines to the Reactors. This purging

can start once the Reaction System is depressurized to less than 3 kg/cm2g.



• When SH has been displaced from all of the piping downstream of the Purifiers, isolate the old

Purifier and open nitrogen through the hot Purifier and commence purging of the piping. Vents and

valving can be opened to the flare system to allow purging of the piping, Absorber Cooler and the

Head Tank.

• Regenerate the old SH Purifier.

• Nitrogen purge the Reactors, Preheater, through the Solution Adsorbers and the IPS to the LPS and

to the flare system. When the line from the IPS to the LPS is hydrocarbon free, isolate the LPS and

proceed to prepare it for clean out. Open the IPS Pulldown Valve and continue to purge the Reactor

System to the flare system until it is decontaminated.

• When the LB Column is empty, begin a hot nitrogen purge to the flare system

• When the HB System is empty, begin a hot nitrogen purge to the flare system

• Similarly, when the FE Column, RB Column, and CM Column systems are empty, begin a hot

nitrogen purge to the flare system.

• Care must be taken to ensure that all inter-connecting lines, dead legs and low points are drained

and properly purged out.

• Purging of all vessels and piping should continue until explosimeter testing indicates safe levels of

residual hydrocarbons.

• When all other systems are SH free the LPS Condensate System can be drained to the SH De-

inventory Tank and then de-contaminated.

• Any inspection or repairs to the Resin Stripper will be delayed by the seven hours required to empty

the Stripper.

• When all process equipment and lines are hydrocarbon free, then the plant utilities can be shutdown.

• When all services that have relief valves going to the flare system are shutdown, and all process

equipment and lines with relief and pulldown valves are shutdown and decontaminated, then the flare

system can be shutdown.



9.2 Area wise Plant Shutdown: 9.2.1 Reaction Area Shutdown:

Sr. No.

Description

SYSTEM SHUTDOWN

1. Inform the FE supplier, service supplier, and extrusion area.

2. Increase MFI.

Delumper to be continuously monitored during MFI increase.

3. Reduce TSR to 120 t/hr.

4. Cut off FE flow to Absorber Cooler and bypass the Absorber Cooler. Isolate Ethylene block valve.

5. Isolate Ethylene supply from B/L.

6. Depressurise the header, online FE purifier, and purifier outlet header to Cracker.

7. Pressurise/Depressurise the following

• FE header from B/L to Guardbed inlet.

• FE header from Guardbed outlet to Head tank

8. Put the IPS level valve in Manual mode and increase the valve loading slightly.

9. When the Reactor differential temperature starts to fall, increase the reactor inlet temperature

rapidly to minimise the drop in the Reactor outlet temperature (HP Steam to Reactor Feed Heater

31-E-103 may be lined up by the use of LOS).

10. With reaction terminated, the Reactor inlet and outlet temperature should be about 190°C. Stop

the Catalyst flow. Start Catalyst flushing.

11. Continue the PG, PD dosing to Reactor System for 20 minutes after stopping catalyst and co-

catalyst. (To deactivate the remained traces of catalyst). Flush all lines into the reactor then stop

all cold flows to the reactors.

12. Adjust the IPS level control valve in Manual mode to give a base flow rate of approximately 40% of

the TSR. Do not exceed a maximum overhead flow from the LPS-I stage of 50 t/hr or polymer

may be entrained and carried over into the piping.

13. Stop and Isolate Butene, Hydrogen. Depressurise hydrogen manifolds.

14. Set LPS-II stage outlet valve about 25% open on manual mode. When the LPS sieve blows

through (sharp increase in second stage pressure) place the LPS-I stage pressure controller in

automatic mode and set it at approximately 100kPa.

15. Shutdown the Reactor Agitator.

16. Line up hot flush to #3 Reactor (31-R-102) at 310oC. Drain water from the Reactor Feed Cooler

and connect LP steam with a hose to the shell side. Leave a low point bleed open to drain

condensate.

17. Stop RFP after 3.0 hrs from FE cut-off (To ensure the proper flushing of reactor loop). Stop Fans

of Recycle SH Air Cooler (31-EA-101) and Cooling water in Recycle SH Water Cooler (31-E-

101A/B). Depressurise Reactor Feed Pump, Reactor Feed Heaters, Reactor Feed Cooler,



Sr. No.

Description

Reactors, Solution Adsorbers, IPS to LB Feed Condenser. When pressure is approximately 20

kg/cm2g, depressurise through LPS Condensers to LPS HUT. Stop hot flush at 20 kg/cm2g

pressure. Isolate FV-1723 upstream valve and warm up line valves.

18. Isolate the following valves:

• RFP discharge block valve

• Side feed valves after they have been individually flushed

19. Start Depressurisation and Decontamination of Solvent Feed Pump to Reactor Feed Pump

discharge. Drain inline SH Purifier (31-V-125A/B). Ensure SH Purifier inlet line is drained. Isolate

the steam tracing of SH line from B/L.

20. Isolate Solvent Feed Pump suction isolation, FV-1284 (on min. circulation line) upstream and

downstream.

21. Start Draining of Head tank (31-V-103), RFP (31-P-104) and Reactor Feed Pump discharge to

LPS HUT (31-V-201)

22. Drain Booster Pump (31-P-103) liquid to LPS HUT.

23. Isolate cooling water to Absorber cooler (31-E-102) and drain.

24. Isolate Booster discharge valve, Decontaminate Reactor Feed Pump.

25. Pressurise /Depressurise loop from Solvent Feed Pump (31-P-101) to Booster Pump (31-P-103)

discharge with hot Nitrogen.

26. Check LEL, if LEL is NIL release for Head tank Process side blinding (To prevent fire incident

during hot work)

27. Start decontamination of RFP (31-P-104) discharge to IPS Pulldown to flare.

Drain Utility side of Reactor Feed Heater, before depressurising of process side. Drain bypass

pipe to HUT

28. Start hot nitrogen from RFP discharge (To Ensure the complete decontamination).

29. Check LPDs provided between HV-1337 and FIT-1329A for SH.

30. Start decontamination of Recycle SH Air cooler (31-EA-101) to SH Purifier drain.

31. Isolate 31-EA-101 inlet valve.

32. Check LPDs of Recycle SH Air Cooler (31-EA-101) and Recycle SH Water Cooler (31-E-101A/B).

33. Isolate at the following locations:

• HP Diluent to Catalyst pump discharge

• HP Diluent to Heater

• HP Diluent to J injection points

• HP Diluent to short catalyst and HP Diluent to #3 Reactor (31-R-102)

• HP Diluent to FV-1513



Sr. No.

Description

34. Stop HP diluent Pump (31-P-102/S). Isolate suction, D/s and spill back lines of both pumps.

35. Depressurise the system to 0.2Kg/cm2g through LPS-1 & LPS-2 (31-V-19/120) overhead.

36. Line-up Hot Nitrogen to reactor loop at following points (Hot N2 has to be used for complete

decontamination of hydrocarbon):

• Steam Purge Heater (31-E-106)

• FV-1513

37. Isolate IPS (31-V-118) bottom and three times through IPS pull down. Decontaminate LPS-1 and

LPS-2 using standard procedure, including high additive flows.

38. Check LEL at all appropriate bleeds in the reactor system.

39. Isolate IPS (31-V-118) overhead PV-1911 downstream, LPS-I (31-V-119) overhead ,LPS-II (31-V-

120) overhead lines.

Isolate LPS KO pot (31-V-121).

DECONTAMINATION AND DEPRESSURISATION

For Decontamination and Depressurisation Reaction Area is divided into following Loops. Loop – 1 : Decontamination of Absorber cooler, Head tank to RFP discharge.

Loop – 2 : Decontamination of RFP discharge to IPS (31-V-118).

Loop – 3 : Decontamination of SH purifier regeneration system.

Loop - 1

40. Isolate FE B/L and depressurise header and FE Primary Guard Bed (31-V-127A/B) and FE

Secondary Guard Bed (31-V-132) to 5 kg/cm2g.

41. Close FV-1318 downstream isolation valve and put an Isolation tag.

42. Isolate FE Secondary Guard bed (31-V-132) outlet HV-2770 and depressurise header to flare from

tapping near Absorber cooler (through line 2”-NF-1306-LP).

43. Pressurise depressurise header 4-5 times to Flare.

44. Close suction isolation valves of both Solvent Feed Pump (31-P-101/S) and FV-1284 and put an

isolation tag.

45. Ensure both Solvent Feed Pump discharge isolation valves are in line and HV-1268 is in full open

position.

46. Open FV-1314A/B 100% in manual mode.

47. Start Hot N2 to Solvent Feed Pump and Booster Pump suction and Pressurise/Depressurise with

Nitrogen 2-3 times through the drain lines. Hold the Loop under N2 pressure positive pressure.

48. Ensure RFP draining is complete.

LOOP - 2

49. Close HV-1536 downstream isolation valve and put isolation tag.

50. Isolate RFP (31-P-104) discharge isolation and put isolation tag.



Sr. No.

Description

51. Isolate Cooling water from Recycle SH Water Cooler (31-E-101A/B) and drain the utility side.

52. Ensure HV-1337, HV-1536 and TV-1406B is open.

53. Pressurise & Depressurise 3-4 times.

51. Isolate to LPS HUT (31-V-201), depressurise the loop to atmosphere.

LOOP - 3

52. Ensure Purifier Regeneration Blower (31-K-101) is stopped and de-engergised

53. Ensure SH Recovery Tank (31-V-102) and Regeneration K.O. Drum (31-V-101) is empty.

54. Start N2 to blower suction.

55. Take 2.5 kg/cm2g pressure.

56. Pressurise and depressurise system 3-4 times.

57. Depressurise the system and check LEL.



9.2.2 Recycle Area Shutdown:

Sr. No.

Description

SYSTEM SHUTDOWN

1. Clean both Hot Flush Pump (13-P-202A/B) suction strainers.

2. Ensuring complete removal of grease.

3. Flush the lines with LP Steam (To avoid line chocking).

4. Minimise inventory of Butene in the System. Maintain LB reflux drum level around 50%. Maintain

CM reflux drum level 50 %.

5. Till RFP is running Maintain HB Reflux Drum (31-V-203) level at 50 %.

6. After RFP stoppage out LB column base to HB column and HB column base to RB column base

Line up HB Reflux, RB reflux to HUT. De-inventory SH from HUT to minimise level.

Line up Hot Flush Pump (31-P-202A/B) supply from HUT and stop LPS Condensate Pump (31-P-

201/S) if required.

7. After Area 100 Reactor Loop is depressurised and nitrogen purged twice, stop Feed, Heat source

and Reflux to LB,HB , FE and RB column.

8. De-inventory LB, HB, RB, FE & CM columns as per the procedure given below.

9. Ensuring complete decontamination

10. After Reactor loop is Decontaminated: To Prevent SH back up in Area 300

LPS-I & II overhead line common isolation valve to be isolated in Area 200. Isolate the LPS

Condensers (31-E-201A/B/C) process side.

11. After FE cut-off stop the Refrigerant system as per the procedure provided by the vendor.

CYCLOHEXANE DEINVENTORY

12. Line up LPS Condensate Pump (31-P-201/S) discharge to SH De-inventory Tank (31-T-401) by

isolating feed to LB Column (31-C-201) and diverting three way valve at SH make up line to SH De-

inventory tank.

13. Isolate LB column (31-C-201) base to HB column (31-C-202) after the LB Column is empty.

14. LPS HUT (31-V-201) to be emptied out to SH De-inventory Tank (31-T-401).

15. Isolate HB column (31-C-202) base to RB column (31-C-203) & RB Reflux to HB column base till

base level is minimum. Pump out HB Reflux Drum (31-V-203) to inlet of SH Purifier (31-V-125A/B)

through FV-1146 to LPS HUT (31-V-201) till HB Reflux Drum (31-V-203) level reaches to minimum.

Pressurise the drum with Nitrogen and drain remaining SH through HB Reflux Drum (31-V-203)

drain to LPS HUT through Reflux Pumps (31-P-204/S) casing drains.

16. Transfer the complete material left in HB column base to RB column (31-C-203) and isolate.

17. RB column (31-C-203) to be boiled off with minimum LP DTA to recover maximum cyclohexane

from base. Keep RB Reflux Drum (31-V-204) under Nitrogen pressure and transfer contents to

Reflux Pump (31-P-205/S) discharge to LPS HUT. Empty out Reflux Drum (31-V-204). Isolate LP

DTA to Reboiler (31-E-208).



Sr. No.

Description

BUTENE DEINVENTORY

18. The LB Reflux Drum (31-V-202) contents to be emptied out to FE column (31-C-204) base. FE

column base is drained to CM column (31-C-205), if CM column base level is high then drain it

directly to FB Surge Tank (31-V-415) through FB De-inventory Cooler (31-E-401). Ensure that de-

inventory valves on CM Reflux Pumps (31-P-206/S), CM column bottom to FB Surge Tank (31-V-

415) are closed.

19. FE Column Feed Cooler (31-E-209A/B), FE Column Feed Coalescer (31-V-207) & FE Feed Dryer

(31-V-209A/B) are also to be drained to FE column (31-C-204).

ISOLATION OF LPS CONDENSERS SHELL SIDE

20. Isolate PV-3019A/B downstream isolation valve.

21. Isolate start up steam line.

22. Isolate LV-3018 isolation valves and bypass isolation valve.

23. Isolate PV-3019A/B upstream drip leg traps.

24. Drain shell through blowdown line.

25. Isolate both blowdown valves.

DECOMMISSIONING AND DECONTAMINATION OF LB FEED CONDENSER

26. Ensure that IPS (31-V-118) overhead line is decontaminated.

27. As LB column is de-inventoried, column pressure will start going down. When column is completely

drained, check from bottom bleed point.


29. Isolate process flow from DTA Purge heater in to LB Feed Condenser (31-E-202).

30. Isolate vapor feed to LB Column.

31. Start Hot N2 on IPS overhead line (PV-1911 downstream).

32. Isolate Boiler Feed Water to LB Feed Condenser (31-E-202). Drain the Condenser, line up HP

steam to Shell side. Keep drain valve open. This will keep nitrogen hot which will expedite

decontamination.

33. When LB column is depressurised, start Nitrogen purging through each vapor and liquid feed point

in to LB column then isolate again.

34. Pressurise & depressurise 5 times using LB Column Overhead Pull down valve HV-3023 to

expedite decontamination.

35. When system is decontaminated, isolate & depressurise the nitrogen.

36. Isolate HP steam to condenser. Drain & depressurise shell side. Close isolation valves on LP

steam header and MP steam valves on HB column reboiler.



Sr. No.

Description

DECOMISSIONING AND DECONTAMINATION OF LB COLUMN AND LB CONDENSER SYSTEM

37. Ensure LP DTA is on to LB Reboiler (31-E-203). LP DTA shell side temperature not to exceed

270°C.

38. Stop the LB Condenser Fan (31-EA-201) and Trim Condenser (31-E-204) Cooling water.

39. Isolate both feed to HB column and Emergency Flush to RB Column bottoms.

40. FV-3919 downstream and upstream tapping.

41. Line-up Hot N2 to LB column through the following points:

• IPS overhead line

• LB Reflux Pump (31-P-203) suction

42. Take 5.5 kg/cm2g pressure.

43. Connect the temporary hose and drain the vertical leg at following points to LPS HUT:

• FV-3031 upstream bleed.

• Bleed on FE Column Feed Dryer Coolers (31-E-209A/B) outlet FE feed inlet line to

Coalescer (31-V-207).

• FV-3126 upstream bleed.

Use Dry Down Loop-1.

44. Depressurise LB Column through Reflux Drum Liquid Pulldown and Column Vapour Pulldown.

45. Pressurise Depressurise Column and Reflux Drum till LEL shows NIL.

46. Check LEL.

47. Isolate all Hot N2 to Column and Reflux Drum.

48. Depressurise Column and Reflux Drum

49. Isolate vapour And liquid feed to column

50. Isolate Reflux Pump (31-P-203/S) discharge to FE Column Feed Dryer Coolers (31-E-209A/B) and

bypass

51. Isolate the following Block Valves

• FV-3166 upstream

• FV-3126 downstream

52. Isolate vapour and liquid pull down valves

53. Isolate PSV

54. Isolate Drydown Loop-1 and connected hose for draining.

55. Isolate LP DTA vapour and LP DTA Condensate of LB Reboiler (31-E-203). Vacuum out shell side

LP DTA.

56. Release LB Column (31-C-201), LB Condenser (31-EA-201) and LB Trim condenser (31-E-204),

LB Reflux Drum (31-V-202) for blinding.



Sr. No.

Description

DECOMISSIONING AND DECONTAMINATION OF HB COLUMN AND HB CONDENSER SYSTEM

57. Ensure that LB Column (31-C-201) is decommissioned.

58. Ensure feed to HB column (31-C-202) is isolated.

59. Ensure Steam is on to HB Reboilers (31-E-205A/B).

60. Isolate bottom flow to RB column (31-C-203) near RB column

61. Isolate RB reflux to HB base line.

62. Isolate line to Hot Flush Pump (31-P-202/S) suction.

63. Isolate HB Reflux Drum flow to LB Feed Heaters (31-E-207A/B).

64. Isolate Reflux Drum vent to LPS Condensers (31-E-201A/B/C).

65. Line-up Hot N2 to HB Column (31-C-202) through Reflux Pump (31-P-204/S) suction Hot N2 tapping

and LB Column base. Isolate BFW to overhead HB condensers (31-E-216A/B). Isolate LP

condensate to HB Condensers and bypass of LV-3438/3444 Isolate steam pressure control valve

PV-3439/34443 Drain condensate through blowdown lines.

66. Take 5.5 Kg/cm2.

67. HB Reflux Drum (31-V-203) to be emptied through Reflux Pump Casing Drain lines to LPS HUT.

68. Drain vertical leg through temporary hose connected through the following points

• HB Reflux FV-3437 downstream bleed

• RB Feed FV-3315 downstream bleed

69. Pressurise and depressurise HB Column (31-C-202) through liquid and vapour pulldown valves 4-5

times.

70. Check LEL.

71. Isolate all Hose connected for draining

72. Isolate liquid draining line to LPS HUT.

73. Isolate all Hot N2 to HB column.

74. Isolate HB Reflux Pump suction and discharge block valves.

75. Isolate HB Reflux to column FV-3437.

76. Isolate vapour and liquid pulldown and process side’s PSV.

77. Isolate Steam to HB Reboilers (31-E-205A/B).

78. Depressurise HB column and Reflux Drum.

79. Isolate blowdown lines.

80. Release condenser for blinding as per blind list.

81. Release for Vessel entry after temp is < 40°C & LEL and hydrocarbon sample is checked.



Sr. No.

Description

RB COLUMN DRAINING, DEPRESSURISATION AND DECONTAMINATION

• Increase grease burning rate from 24 hrs before FE cut off, so as to bring RB Column DT ≈ 5°C

within 2 to 3 hrs of system flushing.

Note: Line up RB reboiler drain line to Grease line and close bottom HV-3529. This is to drain all

polymer from Reboiler.

82. Isolate forward feed to RB column.

83. Stop reflux to RB Column. Stop Reflux pump (31-P-205/S). Stop condenser (31-EA-202) fan & de-

energize.

84. Transfer Reflux Drum (31-V-204) contents through LPS Condensers (31-E-201A/B/C) to HUT using

drydown line (2”-P-335033-B1B-LP).

85. Continue LP DTA vapours to Reboiler (31-E-208) at minimum rate till all SH in RB base is boiled off

and column pressure starts falling. Pressurise Column up to 4 kg/cm2 with N2 from RB Reflux Pump

(31-P-205/S) and HB Column base.

86. Isolate LP DTA vapours to Reboiler (31-E-208) and block LP DTA Condensate outlet after

confirming no LP DTA level in reboiler shell side.

87. Let RB Column base get emptied out through Grease line to Fuel Drum.

88. Isolate RB Column base to Grease line.

89. Put Hot Nitrogen from RB base to column & pressurise to 5 kg/cm2.

90. Transfer RB Reflux Drum (31-V-204) contents under Nitrogen pressure LPS Condenser.

91. Pressurise the column with hot nitrogen & vent from RB column overhead to flare using vapor pull

down valveHV-3544. Repeat this for 4-5 times.

92. Provide blinds as per the blind list.

93. Release for Vessel entry after temp is < 40°C & LEL and hydrocarbon sample is checked.

SHUTDOWN OF FE FEED DRYER COOLER AND COALESCER

94. Once LB Reflux drum (31-V-202) is emptied out, isolate LB Reflux pump (31-P-203/S) discharge

valve.

95. Depressurise FE from the FE Column to the Cracker and then to flare.

96. Drain the beds to FE column. Drain all the liquid FB from FE column (31-C-204) to the FB Surge

Drum (31-V-415). Depressurisation of FE Column to be done after draining to avoid low

temperature.

97. When pressure is less than 4 kg/cm2 line up Hot N2 at LB reflux pump suction.

98. Pressurise & depressurise the system 4-5 times to expedite decontamination.

99. When system is decontaminated install blinds as per the blind list.



Sr. No.

Description

FE FEED DRYER AND FE COLUMN SYSTEM SHUTDOWN

After complete de-inventory of LB Reflux System, the online feed dryer is to be drained to FE column.

Keep the bed under 4 kg/cm2g nitrogen pressure and put the bed for regeneration, as per regular SOP.

The off line dryer must be drained, regenerated & kept under nitrogen pressure 3 days before shutdown.

Filling of the bed is not to be done so as to have minimum inventory. Accordingly bed change over is to be

planned. The regeneration heating sequence of the feed dryer is to be adjusted so that FE column hot

Nitrogen purging can be done with hot nitrogen from regeneration.

100. Transfer all remaining FB & SH in FE column (31-C-204) bottom & FE Reboiler (31-E-212) to CM

column (31-C-205) Line up FE Column overhead to Cracker till column top temperature is -10°C.

When FE Column top temperature increases, line up to flare and isolate valve to Cracker.

101. Increase steam to FE Reboiler (31-E-212) to maximum.

102. Shutdown Refrigerant flow to FE (31-E-213) condenser.

103. Transfer all remaining FB & SH in FE column bottom & Reboiler (31-E-212) to CM column (31-V-

205), if space is available in CM column. Isolate FE column bottom valve to CM column.

104. When FE column base is liquid free, depressurise column to flare at following points

• Column pull down valve, HV-2102 to flare

• Column overhead to flare

105. When FE column pressure is 1kg/cm2, Hot N2 from FE Feed Dryer (31-V-209A/B) at the end of heat

up cycle to be lined up to FE column. Put Hot N2 from FE Column bottom at suction of FE bottom

pump purge to flare.

106. The following lines are to be purged separately:

• FE Column bottom to CM column

• FE column bottom pump discharge to LB system

• Column PDIT and level transmitter taping

107. Pressurise and depressurise column to expedite decontamination.

108. Release feed dryer & column for blinding as per the blind list.

CM COLUMN DECONTAMINATION

107. Stop fresh FB-1 make up before planned shutdown. Keep a minimum level, approximately 25% in

all vessels.

110. Bring down level in LB Reflux Drum and FE column base 15 – 20 %.

111. After FE cut off transfer LB reflux drum contents to FE column base to CM column

115. Stop feed to CM column. Isolate the valve. Isolate fresh FB -1 make up valves.

116. Line up CM Reboiler (31-E-215) drain valve and transfer CM column base contents to FB Surge

Tank (31-V-415).

117. Start reducing steam to CM column Reboiler. Cut off steam once reboiler pressure increases.



Sr. No.

Description

118. Line up N2 through permanent points and hose connections from Column bottom.

119. Transfer the Liquid collected in CM Reflux drum to FB Surge Tank (31-V-415).

120. Transfer all the liquid FB in the lines connected to the column i.e. feed line, FB make up line ,

Reflux line to FB De-inventory Cooler (31-E-401) using hoses at the Low Drain points of each line.

121. Isolate Cooling Water to CM Condenser (31-E-215) and drain. This is to prevent Cooling Water

ingress in CM condenser and reflux drum, when column is de pressurised.

122. Pressurise and depressurise the column 4-5 times. Isolate CM Condenser (31-E-215)

123. Check LEL at vent point near condenser.

124. Open top manhole and provide blind as per drawing.

DECONTAMINATION OF HUT

125. LPS HUT (31-V-201) is the last vessel to be de-inventoried as solvent from all equipments is

diverted to LPS Hold up Tank.

126. All the tie-in lines to HUT must be blown free of SH before final de-inventory of LPS HUT. Isolate

the lines which are connected with LPS HUT

127. Once LB, HB & RB columns nitrogen purging is started, empty out LPS HUT through de-inventory

line & stop pump.

128. The remaining material must be drained through boot in drum and transfer it to de-inventory tank.

129. Isolate all incoming line towards LPS HUT.

130. Isolate all out going line from hut.

131. Put Hot Nitrogen through 2” utility connection point and purge to flare by pressurizing &

depressurising 5 times.

132. Open manhole.

133. Install blind at connected lines of HUT.

134. Put fire water to dilute sludge and drain.

135. Put steam hose and Start steam purging till vessel is free of hydrocarbon smell.

136. Cool the vessel by water spray.

137. Drain water.

138. Put plant air hose and Start air purging till vessel O2 content reaches to approx. 21-22 vol%.

139. Clean manually after putting air hose.

140. Blind the Vessel as per the blind list.



9.2.3 Finishing Area Shutdown:

The Finishing are shutdown is taken in following sequence:

1) Extruder stoppage.

2) LPS - II draining.

3) Die-freezing & Die-body removal.

4) RA Stripper empty out & inspection.

5) Main Extruder screw removal.

6) Hot oil system shutdown.

7) Water circulation system draining

8) Satellite Extruder Screw removal

9) Water reservoir cleaning

Sr. No.

Description

EXTRUDER SHUTDOWN

1. One hour before shut down increase antioxidant injection to 1000 parts per million. This allows

easier removal of polymer remaining on the sides of the LPS.

2. When reaction has been discontinued and resin flow has stopped, discontinue additive injection.

Flush the additive system with SH. Shut the pumping system down when it is empty. Purge

additive line to IPS tails with nitrogen to remove the last traces of solvent. Block in and tag isolating

valves.

3. Continue to extrude polymer until the LPS cone level reaches 60%. At this point, shut down

the extruder until the synthesis area has finished flushing and has a nitrogen purge established.

4. When the resin flow to the LPS has stopped, continue to extrude (purge) the remaining resin from

the LPS cone.

5. Position the Satellite Extruder diverter valve to the floor. Isolate the Satellite Extruder from the

Main Extruder and continue a slow satellite purge onto floor until the LPS is completely empty. This

is such that a polymer seal in the LPS can be re-established quickly if necessary.

6. Close the vent screw Strahman valves. Block in steam to the eductor and the eductor outlet to

the Solvent Vapour Condenser inlet line. Install a nitrogen tie-in to one of the vent screw collection

pots and line nitrogen into the extruder barrel with a slight pressure (0.1 kg/cm2g). This nitrogen

inlet works in conjunction with the LPS nitrogen purge to blanket the LPS and extruder system.

7. Once the low-pressure separator and extruder barrel have been cleared of volatiles as indicated

by Explosimeter checks, discontinue the nitrogen purging. Care must be taken that the oxygen level

in the extruder building is not depleted with this nitrogen purging going on.

8. With the last remnants of resin removed from the LPS by repeatedly purging at half hourly

intervals, until the barrel is completely empty, empty the satellite barrel and shut it down. Lower

both extruder barrel temperature set points to about 150°C. Block in the hot oil to the dieplate.

9. Retract the cutter housing and rotor.



Sr. No.

Description

10. Block in steam to the expansion joint and the vent screw tracing. The LPS vessel can now be cooled.

11. Maintain heat on the extruder barrel until maintenance have removed the screw and cleaned the

barrel.

12. Start the tagging procedure with the maintenance and electrical departments.

Note: If the dieplate is to be removed, the hot oil lines must be drained and vacuumed with

steam left onto the die holder until just prior to removal of the dieplate (to keep polymer molten for

flange face and dieplate separation).

Satellite Extruder Shutdown

13. Stop the feed to the Satellite Extruder. Close gates or swing recycle chute DV as required.

14. Direct the 3-ported purge valve to the floor blocking off the Main Extruder.

15. Extrude the remaining resin in the Satellite Extruder to the floor (there is no way to completely

empty the adapter piping of resin and it will solidify in the pipe when heating is removed). Stop ½”

service water to the feed section of the barrel as required.

16. Stop the hopper nitrogen purge if it is in use at shutdown time.

17. Shut down the Satellite Extruder motor and tag (for planned outage or maintenance work).

18. Set the barrel TV‟s to zero to stop the steam/mist barrel temperature control.

19. Block in the cooling water to the Satellite Extruder feed zone.

20. Shutdown the lube oil system as outage dictates.

21. Close HP steam supply to the adapter piping if a long term outage is expected. Should this piping is

to be removed, heat must only be removed just prior to maintenance being ready to remove it.

22. Isolate the 3-ported valve hydraulic unit as required.

Satellite Extruder Feed System Shutdown

23. Should a change in dry additives be forthcoming, shutdown the feed resin conveyor systems

(usually closing an air line will do or switch off the venturi transfer system) to additive feeders and

any Recycle Resin Storage Bin transfers from the Bag Slitter.

24. Forward planning will let the additive feeders clear themselves of material or reduce the amount to

be removed on the changeover.

25. Notify central control room to shut down the additive feeders when empty should the field operator

not be able to continue watching them.

26. Remove unwanted feed and replace with upcoming run materials as required.

RA Stripper Shutdown

27. When the resin flow to the RA Stripper has stopped and the RA Stripper is to be emptied

completely, switch the level control valve LV-4615 to manual and set the valve loading such that

the same unload rate prior to stoppage of production is maintained. This will satisfy the stripping

requirements (residence time) of the resin remaining in the RA Stripper. Nitrogen back up to the

steam supply should be in manual and closed.



Sr. No.

Description

28. When the low-level alarm sounds, swing the interlock switch HS-4617 to the by-pass position and

re- establish the previous unloading rate. (This interlock / alarm would have closed the RA Stripper

outlet level valve and therefore a resin flow must be re-established).

29. Take the stripping steam rate down to 2600 kg/hr 1/2 hour after the resin flow to the RA Stripper

has stopped. Full steaming is not required since resin is not being added to the RA Stripper.

(Maintain reslurry water temperature as some of this water does enter the RA Stripper and knock

down steam or bypass the cutter and stop Reslurry water flow to the RA Stripper).

30. Empty the RA Stripper. This will be confirmed when the Spin Dryer Hold-up Bin Conveying Blower

31-K-302 amperes drop off.

31. Shutdown the Spin Dryer 31-M-305 and its exhaust fan 31-K-315, the Spin Dryer Hold-up Bin

Rotary Feeder 31-ME-303, the Spin Dryer Hold-up Bin Purge Air Fan 31-K-323 and RA Stripper

Spin Dryer Conveying Blower 31-K-302.

32. Continue the stripping steam purge for 15 minutes. Keep condensate drain open sufficiently to drain

any steam condensate build-up.

33. Take the stripping steam purge off-line.

34. Open the RA Stripper exhaust vent valve 31-HV-4630, switch the RA Stripper pressure controller

PIC-4632 to manual and close.

35. Shut off the Solvent Vapour Condenser fans if required and lock if any shutdown work is

associated with this first condenser. Close the cooling water to the Solvent Vapour Trim Cooler

and open drain lines if required. The Coalescer can be isolated and bypasses closed and tagged

again depending on the jobs to be completed. The same for the Decanter - it also must be

emptied or isolated depending on scheduled work to be performed. Lines leading into and out

of this piece of equipment are to be drained, blocked and tagged with the maintenance work in

mind. Associated pumps must be tagged out.

36. Switch the reslurry water control valve LV-4426 (after Reslurry Pumps) to manual and close the

valve. Shut down reslurry water pump if this has not already been done.

37. Switch the Reslurry Water Heater TIC-4438A to manual and close the valve.

38. Switch the circulating water valve FV-4441 (to RA Stripper outlet) to manual and close the valve.

Note: For circulating water shut down.

39. Close the RA Stripper outlet isolation valve HV-4612 and then level control valve LV-4615.

40. Proceed with the lock, tag, clear and try procedure on those pieces of equipment required

with associated maintenance, inspection or cleaning. Record and tag the equipment disconnects.

Circulating Water Shutdown

41. Following the JSW procedure, when the dieplate has been frozen, stop the PCW flow to the

Pelletizer, close supply circulation water and drain housing. Drain and retract cutter vs. timing of

established procedure. Shutdown the running Water Circulation Pump.

Caution: Any time circulating water flow to the Pelletizer is discontinued, die heating must be lowered

or discontinued to prevent boiling of the water isolated in the cutter housing. Part of the normal



Sr. No.

Description

cooling process is to reduce the Hot Oil Circulation temperature to help in the dieplate cooling. The

demineralised emergency water line (Die Freeze water) is not used unless opened manually because

it would close the Hot Oil Circulation loop valve due to interlock.

42. Stop the water flow from the heater to the Reslurry Tank FV-4437.

43. Stop the flow via LV-4426 to the RA Stripper inlet Hydrosieve from the Reslurry Tank and shut down

the online Reslurry Pump.

44. Stop the water flow to the RA Stripper lower seal leg FV-4441.

45. Close the nitrogen purge line to the Water Reservoir only after solvent has been skimmed from the

water surface.

46. Shut off the CW water to the Water Cooler.

47. Block in the LP steam supply to the Reslurry Water Heater.

48. Close nitrogen purge line on Delumper Dewatering Classifier.

49. Stop the operational Fines Separators. Close all Fines Separator nitrogen purges should they in

any way pose a safety hazard to any maintenance work.

50. Stop the Solvent Skimming Pump.

51. Open the Water Reservoir bottom drain only after solvent has been removed if work is to be done

inside reservoir and the water must be removed.

Caution: The Water Reservoir is considered a confined space, should internal work be required,

vessel entry procedures must be followed.

Note: Timing required to complete proper nitrogen purges of vessels and equipment along with

system cool downs are to be determined through operation and then applied to these procedures.



9.2.4 Utility Area Shutdown

Sr. No.

Description

DTA SYSTEM SHUTDOWN

1. Take shutdown of DTA vaporiser as per the standard operating procedure (Refer vendor

document)

2. Allow the system to get Depressurised.

3. Open the vents on the vaporisers and Flash Tanks when pressure has fallen to zero.

4. Transfer all condensate from the HP DTA users to the HP DTA cond. Drum (31-V-406) and pump

this material to Flash Tank. Drain the Flash Tank to DTA Storage Vessel (31-V-413) as and when

required.

5. Transfer all condensate from the LP DTA users to the LP DTA cond. Drum (31-V-410) and pump

this material to Flash Tank. Drain the Flash Tank to DTA Storage Vessel (31-V-413) as and when

required.

6. Drain the DTA Vaporisers (31-LM-401A/B) and Flash Tank (31-V-420A/B) to the DTA Storage

Vessel (31-V-413).

7. Using the vent tie-ins, vacuum the remaining DTA from each vaporiser, exchanger, pump header,

etc. Vacuum each piece of equipment separately.



SECTION-10.0 PLANT TROUBLE SHOOTING PROCEDURE



10.1 LB Feed Condenser: Sr. No.

Problem Possible Cause Corrective Action

1. Lower temperature of

process outlet stream going

to LB Column

• TIC-3039 malfunctions to open

PV-3019B

• Readjust the side feed (Increase HP

Steam flow to LB Feed Heater No. 2 i.e.

increasing the load of the heater to

maintain the column overhead

temperature in the limit) so that column

temperature profile remains stable

2. High /low pressure in the

system • Malfunction of PIC-3019 to

close/open PV-3019A/B

• Readjust the side feed (Increase HP

Steam flow to LB Feed Heater No. 2 i.e.

increasing the load of the heater to

maintain the column overhead

temperature in the limit) so that column

temperature profile remains stable

3. Lower level in shell side • LIC-3018 malfunctions to close

LV-3018.

• Line-up the BFW to the condenser

10.2 Distillation System: Sr. No.


1. Low temperature in base of

FE Column or CM Column.

High pressure in FE

Column or CM column

Reboiler shells

• Loss of heat transfer due to

“surface boiling”

• Reduce steam flow to Reboiler until shell

side pressure starts to drop. Then slowly

increase the steam flow

• Raise column pressure if possible

2. Low temperature from

regeneration system DTA

heater

• Non-condensable gases in DTA

• Incorrect valve positions,

instrumentation error

• Process gasses in nitrogen

• Vent DTA side of heat exchanger

• Check valves and instruments and repair

if necessary

• Increase cooling water to coolers

10.3 Hot Flush System: Sr. No.


1. No flow of hot flush liquid to

reactor in emergency/start-

up

• Hot Flush pump trip • Remove the System Pressure Control

valve 31-PV-1909A/B from pressure

cascade and maintain the system

pressure under operating range by

adjusting it manually

• Line-up the standby hot flush pump.



10.4 Catalyst System: Sr. No.


1. Plugging in control valve or

micromotion • Catalyst build up

• Flush with solvent

• Remove and clean plugged equipment

2. CAB control valve is open

too much

• This position needed for the

desired flow

• Decrease the low pressure diluents

pressure or raise the Mix Tank pressure

3. CAB valve is nearly closed • This position needed for flow

• Increase the low pressure diluents

pressure or lower the Mix tank pressure

10.5 Reactor Feed Tempering System: Sr. No.


1. Plugging of the side feed

line with polymer • Side block valves left open while

side feed flow valve was closed

• During reaction shutdown flush reactor

system for one hour to remove all

polymers

• Slowly reduce the system pressure to

increase differential pressure across the

blockage and then cautiously divert the

reactor feed flow through side feed valves

• If blockage clears, flush the side feed

lines separately to ensure both lines are

clear. Do not exceed 50% valve loading

with RFP at minimum flow

• Verify steam tracing is turned on to Side

feed line. Stop the Reactor Feed Pump.

Start Hot Flush into Reactor Feed

Heater/Cooler using ¾ inch line. Take a

flow backward through HV-1536, FV-

1515 and one of the Side Feed valves.

Drop Reactor pressure to 25 kg/cm2g if

necessary. Raise Hot Flush pressure to

150 kg/cm2g

• If the blockage cannot be cleared, then a

complete Reactor system shutdown and

decontamination between the RFH/RFC

and Solution Adsorber will be required to

clean lines

2. Insufficient heat transfer

from the Reactor Feed

Heater

• Condensate pot level malfunction or

the flow from the condensate pot is

restricted, causing the Reactor Feed

Heater to fill with condensate

• Drain the condensate, repair the level

valve or clear the restricted line



10.6 IPS/LPS Vessels: Sr. No.


1. IPS Polymer carryover • A change of pressure or

temperature that caused a false

level indication

• Any carryover of polymer is serious which

could block pressure control piping, plug

the KO pot or cause a lengthy shutdown

for cleanout

2. Low temperature of IPS

solution • Low temperature out of the

Preheater

• Increase preheater temperature

• Expect false levels

• Avoid carryovers

• Put IPS level control valve or manual and

open. Flow from LPS-1 should be

minimum of 2.0 x RA rate for Homo-

Polymer and FB Copolymer resins

3. IPS high level • Temperature or pressure changes

in IPS

• Restriction in outlet flow

• Keep preheater temperature even

• Put level valve on manual open it

4. High/Low pressure in IPS • 31-PV-1911 malfunctions to

close/open

• Readjust the LB column feed,

5. High level on LPS sieve

plate • No enough pressure

• Change in resin parameters

• Sieve plate holds plugging due to

low temperature

• Increase pressure in first stage

• Monitor MI changes expected

• Increase temperature from IPS

6. High volatile content in

resin at cutter • High LPS second stage pressure

• Low exit preheater temperature

• Unsteady sieve plate levels

• Lower pressure – max of 0.25 kg/cm2g

• Raise incoming temperatures

• Keep steady levels

7. Gel formation • Degradation of polymer • Keep correct LPS tracing temperature

• Keep additive levels correct

• Keep air out of vessel.

10.7 Main Extruder System:

Sr. No.


1. Extruder motor will not run • Power is off

• Interlock preventing motor from

starting

• Turn on power

• Determine which interlock and correct

2. High barrel pressure. • Resin heat (low heat)

• Faulty pressure gauge

• Low barrel heat (hot oil system)

• Increase barrel heat

• Make sure adapter steam jacketing

steam is operating

• Grease to free gauge




Sr. No.


3. Extruder starving • Low LPS cone level

• Too high extruder rate

• High 1st and 2nd stage pressures

• No sieve level

• Vent Devices plugged

• Slow extrusion rate

• Slow extrusion rate

• Lower pressure to help release volatiles

• Establish level

• Add steam, clean collection pot or piping

4. Rear Seal Temperature

high • Rear seal drool plug.

• Faulty transmitter.

• Screw grooves damaged.

• Check drool pipe steam

• Repair transmitter

• Check for damage at earliest time

5. Gearbox noise • Damaged gears

• Low oil level

• Excessive heat build-up

• View ASAP

• Add oil as required

• Lube system cooler fouled or restricted

water supply

10.8 Satellite Extruder System: Sr. No.


1. High motor amperes • Low barrel heat • Increase barrel heat

• Ensure adapter HP steam jacketing is

operating properly.

2. High barrel pressure • Faulty pressure gauge

• Low barrel heat

• Adapter 3-way valve improperly

positioned

• Grease or replace


• Correct positioning

3. No resin flow • Out of recycle

• Gravimetric feeder stopped or out

of feed

• Feed hopper resin bridge formed

• Rupture disc blown

• Move resin from bag slitter

• Start feeder or re-establish additives to

feed hopper

• Must remove Sat feed hopper and

remove resin above screw

• Replace rupture disc

4. No barrel pressure • No resin feed

• Faulty gauge

• Polymer bridge

• Add resin

• Replace as required

• Remove feed hopper and remove resin

5. Dry additive feeders will not

operate • Disconnects open

• Lose weigh belts

• Slide gate closed

• G84 N2 not on and material not

flowing

• Whitlock conveyors turned off

• Feed hopper at Whitlock

conveyors- empty

• Re-establish pore

• Tighten belts

• Open slide gate

• Establish cooling N2 and break up G84

material

• Establish feed system

• Additives required



10.9 Underwater Pelletizer System: Sr. No.


1. Pellets with Small Tails • Dull or damaged knives (i.e.

chipped).

• Damaged die holes or uneven

cutting surface.

• Misaligned cutter.

• Contamination stuck in die holes.

• Grind knives to get sharp edge back.

• Increase cutter hydraulic ∆P by 0.5

kg/cm2 to grind knives. Repeat if

necessary.

• S/d and grind knives.

• Replace knives.

• Remove die plate and regrind and/or plug

hole.

• Correct alignment.

• Disassemble die plate and remove

foreign material from die holes.

2. Pellets with Larger Tails

and Twins or Chains • Dull or damaged knives (i.e.

chipped).

• Knife(s) don’t overlap all die holes

(ID and OD of cutting surface)

• Melt fracture

• Circ water flow is too low.

• Strong vibrations on Cutter.

• Damaged die holes or uneven

cutting surface.

• Throughput per die plate hole is

too low.

• Contamination stuck in die holes

• Grind knives to get sharp edge back.


kg/cm2 to grind knives. Repeat if

necessary.

• S/d and grind knives.

• Check cutter hub mounting for parallelism

at toe and heel of blades.

• Replace knives.

• Check knife alignment and adjust or

replace knives as necessary.

• Increase die plate temperature; increase

Circ Water temperature.

• Increase Circ Water flow.

• Temporarily increase cutter hydraulic ∆P;

try adjusting cutter speed +/- 10%. Notify

Maintenance to repair cutter.

• Remove die plate and regrind and/or plug

hole.

• Increase RA rate if possible.





Sr. No.


3. Pellets Stuck Together

but with no Tails • Circ water Temperature too high

• Product Temperature too high.

• Reduce Circ Water temperature by 10°C

and monitor for 2 hours. Repeat if

necessary. Minimum 35°C

• Reduce die plate temperature by 10°C

and monitor for 2 hours. Repeat if

necessary. Minimum 200°C.

4. Agglomerates and Chunks • Smear on die plate at start- up.

• Water enters cutter chamber too

quickly on start-up

• Cutter Alignment

• Hydrocarbon blow-through from

LPS.

• Water behind die plate.

• Excessive wear on pelletizer

knives.

• Knife contact pressure is not

correct (i.e. too high and toe lifts or

too low and heel lifts).

• Ensure die plate is clean prior to docking

cutter.

• Adjust s/u sequence timing if necessary.

• Check knife wear and die wear during

grinding to ensure even wear. If

necessary, have Maintenance correct

alignment.

• Ensure LPS level does not go too low and

vent devices are functioning.

• Ensure die plate is drooled and froze prior

to docking cutter and starting extruder.

• Change knives.

• Adjust hydraulic pressure up or down by

0.5 kg/cm2 and monitor. Repeat as

necessary

5.

Pellet Non-uniformity –

longs, shorts, irregular

shaped

• Die plate was not sufficiently

heated through - temperature is

too low.

• Pellet water arrives too early at the

die plate.

• Throughput per hole is too low at

pelletizer start or normal operation.

• Throughput is brought up to final

rate too slowly.

• Die plate has foreign material

partially plugging holes.

• Non-uniform heating of die plate.

• Cutter speed too high (on Hi Mi

material primarily).

• Ensure proper heat-up of die plate prior

to s/u. Increase die plate temperature as

necessary.

• Adjust s/u sequence timing if necessary.

• Start extruder at higher rate and increase

rates if possible.

• Increase ramp up of extruder rate.



• Increase hot oil temperature in

increments of 10°C and monitor. If

necessary, clean internal hot oil channels.

• Reduce cutter speed if possible; reduce

rates; switch to 36 knife cutter hub



Sr. No.


6. Cutter knives move back

while in normal operation • Die plate smeared.

• Cutter hydraulic ∆P too low.

• Cutter speed increased/decreased

too much/too fast.

• Plugged hydraulic filter.

• Temporarily Increase cutter speed and/or

cutter hydraulic ∆P. Shutdown if

necessary to clean.


kg/cm2 and monitor. Repeat if necessary.

• Ramp cutter speed changes by 5 to 10

rpm/min. If increasing speed, monitor dial

indicator and decrease hydraulic ∆P as

above to maintain knife contact. If

decreasing cutter speed, increase

hydraulics to maintain knife contact.

• Change filter within 12 hours of

observation.

10.10 Liquid Additive System: Sr. No.


1. High Additive results • High pumping rate

• Batch concentration incorrect

• RD blown and solvent vented

• Decrease and recalculate lot

• Sample – change DCS setting

• Replace RD and add solvent per

concentration check

2. Low Additive results • DCS setting incorrect

• Pumping rate low

• Pump relieving internally

• Lines or pump leaking

• Check and reset DCS setting

• Calculate and increase rate

• Check holding tank level for hourly rate.

• Repair any leaks

3. Plugging of solutions • Pump check valves not working

• Holding tank agitator shut off

• Tank, pump, room tracing low

• Electrical tracing tripped

• Holding tank steam temperature

control low

• Heat up/ clears checks

• Set agitator to run while additives are in

tank

• Increase tracing maintain 70°C

• Reset breaker, establish heat

• View set point – adjust

4. Material will not transfer • Nitrogen pressure not established

correctly

• Valves closed in transfer route

• Pump trip

• Adjust regulator

• Check valving working backwards from

destination

• Start other service pump

5. Contamination • Wrong powers left in tank prior to

new batch

• Valves left open

• Visual inspection of tank not made

• All valves are to be closed unless in use

for transfers or pumping



Sr. No.


• Wrong additive information on

record

• Additives pumped to wrong

injection point

• Records and DCS information wrong

imputed

6. Higher pressure in additive

holding tanks • Partial chocking in the discharge

of pump

• Flush the stagnant portion with

cyclohexane to keep these portions free

of additives

7. High Venting of Holding

Tank • More opening of vent valve • While venting communicate with the

control room

10.11 Blenders and Associated Equipments:

Sr. No.


1. Resin slow drying and

purging. • Purge air temperature set

incorrectly.

• Ruptured L.P. steam line in

Purge Air Heater.

• Leaking control valve in wash water

line.

• Plugged screens on RA Stripper

Spin Dryer and more water being

carried into blender.

• Increase steam flow to Purge Air Heater.

• Repair.

• Repair.

• Clean screens.

2. Purge air low pressure. • Purge Air Blower stopped.

• Broken drive belts

• Separation of air line between

Blower and Blender.

• Damaged Blower.

• PSV malfunction.

• Check power supply i.e. fuses.

• Replace belts.

• Repair line.

• Repair or replace.

• Repair.

3. Purge air high pressure • Conveying air line lugged

between Blower and Blender.

• "Check" valve stuck closed

• Clean conveying air line.

• Repair valve.

4. Blending Blower low

pressure. • Blending Blower stopped.

• Broken drive belts

• Separation of conveying air line

between Blower / resin

destination.

• Damaged Blower.

• PSV malfunction.

• Check power supply i.e. fuses.

• Replace belts.

• Repair line.

• Repair.

• Repair.



Sr. No.


5. Blending Blower high

pressure • Conveying air line plugged.

• "Check" valve stuck closed.

• Diverter valve in incorrect

position.

• Broken L.P. steam line or cooling

water line inside Heater/Cooler.

• Receiving vessel full.

• Transfer rate too high.

• Clean line.

• Repair valve.

• Check diverter valve alignment.

• Repair line.

• Choose another destination.

• Reduce rate.

6. Low purge air temperature • L.P. steam supply line plugged.

• L.P. steam supply block valves

closed.

• L.P. steam supply control valve

malfunction (I & E or mechanical).

• Condensate valves closed.

• Condensate line plugged.

• Low steam supply from L.P.

steam system.

• Clean line.

• Open valves.

• Repair.

• Open.

• Clean lines.

• Increase supply.

7. High purge air temperature • L.P. steam supply control valve


• Blower malfunction

• Repair.

• Repair.

8. Low Blending air

temperature • Low steam supply from L.P. team

system.

• Malfunction of cooling water

supply valve (open).


• Repair.

9. High Blending air

temperature • LP steam supply control valve


• Blower malfunction.

• Repairs.

• Repair.

10. Purge Air Blower will not

start • Power

• Blower seized.

• High temperature.

• Interlock.

• Check power supply, i.e. fuses disconnect

switch


11. Purge Air Blower will not

stop. • Power malfunction. • Check power supply, (I & E) Switch.

12. Blending Blower will not

start • No power.

• Blower seized.

• High temperature.

• Interlock.

• Check power supply i.e. fuses disconnect

switch.


13. Blending Blower will not stop • Power malfunction. • Check power supply, (I & E) Switch.



Sr. No.


14. Blender Rotary Feeder will

not start. • No power

• Rotary Feeder seized.

• Malfunction of variable speed

drive.

• Interlock.

• Check power supply i.e. Fuses

disconnect switch

• Repair.

• Repair.

• Correct interlock function, i.e. - start blend

Blower.

15. Blender Rotary Feeder will

not stop. • Power malfunction

• Malfunction of variable speed

drive.

• Check power supply, (I & E) switch

• Repair.

16. No Nitrogen • Closed block valves

• Control supply valve malfunction.

(I & E or mechanical).

• No supply.

• Plugged supply line.

• Open.

• Repair.


• Clean line.

17. No wash water supply. • Closed block valves.

• Control supply valve malfunction.

(I & E mechanical).

• No supply

• Plugged supply line

• Blender Wash Pump 31-P-408 not

running

• Open.

• Repair.


• Clean Line.

18. Diverter valves fail to

function • No air supply to solenoid valves.

• No power to solenoid valves.

• Diverter valve seized.

• Malfunction of switch mechanism.

• Check air supply.

• Check power supply.

• Repair.

• Repair.

19. Low Blending/unload rate. • Blending blower low pressure

• Rotary Feeder problems

• Plugged Blending tubes

• Plugged collection zone of

Blender

• Rotary Feeder equalisation line

plugged

• Repair or Correct

• Repair or Correct

• Clean

• Clean or repair

• Clean



10.12 Stripper System: Sr. No


1. Stripper High Temperature • High Vessel Pressure

• Fire in the vessel

• Faulty desuperheater

• Faulty instrumentation

• Steam control valve cycling

• Desuperheater flooded with

condensate

• Overhead condensers plugging up

• Open Blank

• Blanket Steam valve

• Check desuperheater condensate supply

• Look at desuperheater control

instruments

• Instrumentation to correct Top

temperature thermocouple

• Check drains and bottom trap

2. Stripper High Pressure • High stripping steam flow rate

• Faulty pressure transmitter

• Overhead condenser has high

inerts

• N2 overhead valve opening

• Low condensing

• Additives

• Cut too many fines causing

blockage

• High stepper level

• Reduce stripping steam flow rate

• Check /repair instrumentation

• Check dead weight working

• Manually vent the condenser inerts

• Visually inspect valve for opening

• Use block valves for quick operation

check

• Lap/replace valve should seat be

damaged

• Turn on more fans

• Adjust fan pitch control

• Adjust louvers open

• Some additives help to adhere water to

the pellets – check goal ppm

• Correct cut, eliminate fines and keep

resin bed moving to clear from stripper

• Lower stripper level to drop internal

pressure

3. Stripping Steam High Back

pressure • Plugged stripping steam bottom

inlet screens

• Poor pellet cut

• Faulty pressure gauge

• High condensate level in stripper

• Condensate outlet lines plugged

or valves closed

• Check/clean screens

• Inspect/ correct small cut quality.

• Inspect/replace instrument

• Remove condensate, open valves

• Ensure slurry inlet temperature is above

78°C

• Open valves/unplug lines

4. Stripper low temp. • Nitrogen valve passing/open • Inspect Nitrogen valve passing/high zero

setting- instrumentation.



Sr. No


5. High top collection water

flow • Inlet distributor cone screen

plugged

• Inlet dewatering screen plugged

• Valves on the dewatering screen

closed

• Clean Screen

• Clean screen

• Inspect position and correct

6. Low Stripper exit flow • Outlet valve not correctly set

• Product has lumps restricting

outlet

• Convey water to steam chest not

sufficient enough

• Outlet line water flow insufficient

• Interlocks have closed outlet

valve

• Outlet line restricted

• High water level

• Check opening percentage and correct

• Alter temperature, open level valve to

pass lumps, increase water flow. Rod

outlet opening to clears lumps

• Increase water flow to carry resin out exit

• Increase water flow to carry resin out exit

• Check out high-level interlock

• Check spin dryer inlet is free

• Open level valve and cut water flow to

steam chest

7. Pellets in reservoir • Stripper dewatering screen

broken

• Stripper inlet cone broken or

incorrectly assembled

• Bottom cone screens broken

• Steam inlet screen broken

• Spin dryer inlet incline screen

broken or misaligned

• Spin dryer screen broken

• Repair, replace screen or correct

connections/seems

• (Many of these repairs will need a

shutdown)

8 High Hydrocarbons in

Circulating water • Stripper inlet slurry temperature

too low-under 78°C

• Solvent skimming pumps not

running

• Solvent skimming pump filters

plugged

• Very high resin volatiles

• Low steam flows

• Increase slurry tank outlet temperature

• Switch onto Run, check fuses, and check

motor resets

• Clean filter to have solvent pass

• Correct IPS, LPS conditions

• Increase vent device speed, drain & clean

collection pots as required

• Increase vent device vacuum

• Increase steam to charted levels



Sr. No


9. Lot cross mixing • Low stripper level

• Faulty level indication

• Damaged bottom cone

• Improper timing of lot collection

• Inlet screens badly plugged on

one side

• Raise stripper-operating level

• Find and correct

• Inside stripping steam line broken, cone

moved to one side, stiffening bars

causing obstruction

• Miscalculation of lot amounts and cut time

• Johnson screen high-pressure water

cleaned

• Find out way resin is on one side –

misaligned feed

10. Contamination • Very high stripper level

• Process upset

• Areas of Hold-up internally

• Resin stuck to stripping screens

– degraded

• Spin dryer hold-up

• Sampler not closing, poor

sample water

• Over filling the stripper could fill water

outlet pipe/tray, cause hold up inside.

Check instrumentation

• Catalyst changes, high deactivator flows,

pressure upsets in IPS/LPS or additive

discoloration

• Vessel might have areas incorrectly

prepared

• Remove ring inspect and clean

• Resin degradation in bottoms of

dryer/long periods of shutdown and

sustained heat

11. Large Transitions • Low stripper levels. Slow

production rates.

• Improper tracking calculations.

• Trouble putting on additives.

• Slow lab results.

• Maintain proper operating level.

• Conditions will dictate.

• More diligent tracking methods.

• Lot to lot can dictate or systems faulty.

• Communications a must.

12. High exit volatiles • Low Spin Dryer temperature

• Incorrect IPS/LPS conditions

• Low Stripper level

• Resistance time too short

• Increase steam to heater

• Correct vessel operating conditions

• Increase level to normal operating point

• Slow exit rate to provide proper

resistance time

• Cut reactor rates



10.13 Fines Separator: Sr. No.


1. Chocking in Fine Separator • Accumulation of fines in the

separator

• Ensure that nitrogen is lined up to the

separator. Increase the Nitrogen flow

inside the Separator and inspect the clean

the screen on regular basis

2. Lower water level in 31-T-

301 • Chocking of internal reservoir

screens

• Take changeover of fine separator

10.14 Packing Silos System:

Sr. No.


1. High Blower amps/low

transfer rate • Classification bag filters plugged • Clean the filter

2. No blower ampere increase

when RF started • RF drive broken- belt, shear pin,

chain

• Variable speed drive damaged

• Inspect and repair

• Electrical to repair

3. Transfer system plugging • Blower drive belts slipping or

damaged

• Blower PSV relieving

• Inlet air filters plugged

• Tighten or replace

• Recalibrate PSV

• Clean or replace

4. High temperature • Faulty transmitter

• Fire after unstrapped resin

transfer

• Check and repair

• Use Nitrogen on bottom for vessel

protection and discontinue filling. Stop

blower directed into silo

10.15 Warehouse Bag Slitter System:

Sr. No.


1. Bag slitter blower will not

start • Open power disconnect

• High level recycle hopper

• Interlock faulty

• Close disconnect

• Bypass interlock or use resin in recycle

hopper

• Correct damaged or faulty interlock

2. Transfer blower PSV

relieving • Faulty PSV setting

• Line plug

• Discharge valving incorrect

• Repair

• Clear line plug

• Correct valving line up

3. Poor silo unload rate • RF equalisation line plugged

• Silo outlet restriction

• Clean the line

• Remove snakeskins or restriction



10.16 Flare System:

Sr. No.


1. Low temperature Flare KO

Drum • Excessive FB or FE venting • Find vent source and stop it

• Increase steam to internal heater to raise

temperature

2. High level in Flare KOD • Loss of absorber/cooler water

• Excessive venting

• Close water to absorber cooler and

replace

• Eliminate source flow through

investigation

3. Low Flare System

pressures • End of header purges stopped

• Loss of fuel gas

• Faulty pressure transmitters

• Flare stack drum seal lost

• Establish purges and find out why they

were eliminated

• Open nitrogen valve fully until fuel gas

flows re-established

• Replace transmitters

• Establish flare seal again

4. Passing pulldown valve • Recent use or dirt on slider • Rework to establish tight shutoff again.

• De-inventory and repair

10.17 Delumper System: Sr. No.


1. Partial chocking of

delumper drum holes • Spray nozzle chocking • Regular inspection of spray nozzle to be

done

2. Higher pressure in the

delumper • Chocking of flame arrestor • Increase the flow of Nitrogen to clean

flame arrestor and do the regular cleaning

10.18 FE Guardbed System: Sr. No.


1. High pressure during

Regeneration heat-up • Insufficient N2 purge prior to heat-

up

• High FE concentration in the

Regeneration system

• Open vent on the regeneration system

• FE Guardbed from the Regeneration

system and N2 purge to flare again.



10.19 DTA System: Sr. No.


1. SH in DTA • Tube leak in Heat Exchanger • By sampling each heat exchanger

determine the one with a tube leak and

take it off line for repairs.

2. Loss of Capacity of Heat

Exchanger • Build-up of inerts in heat

exchanger

• Vent top of heat exchanger to the vacuum

system to remove all low boilers and

inerts.

3. High pressure in

condensate Drum • Built-up of inerts in drums or a

process leak

• Vent top of drum, check for leaks in

process.

4. Difficulty in maintaining

levels in vaporisers. • Bumping of level is generally

caused by the high level of

contaminants in system

• Analyse for contaminants and increase

purge to HB system

5. Loss of vaporiser capacity • Dirty tubes, burners or improper

combustion

• Blow the tubes with soot blower. Adjust

or tune fuel air ratio.

6. Smoky Fire • Dirty burner or improper

atomisation

• Clean the burner and adjust the atomising

steam.

7. Vent System unable to

maintain vacuum • Leakage from user • Check all user’s vents and close or repair

leak (s).

10.20 SH System:

Sr. No.


1. Large pressure cycle in the

system • FB lined-up before the 31-EA-

101, causes FB to flash-off on

contact with hot SH

• Line-up FB after 31-EA-101

2. Large amount of SH during

Regeneration Cycle • Improperly drained purifier

• Passing block valves on process

lines

• Review the draining procedure for future

purifier.

• Ensure the process inlet and outlet valves

are double block and bleeds between are

open.

3. Abnormally slow

temperature rise during a

regeneration heat-up cycle

• Low N2 flow to the heater

because of the bypass valve on

line from blower discharge to the

regeneration cooler is open.

• Close bypass slowly.



SECTION-11.0 ALARMS AND TRIPS



11.1 Reaction Area (AREA 100): Sr. No.

Tag no. Description Unit Set Point

1 AI-1134(H) Solvent Purifier Moisture content ppm 2

2 AI-1134(HH) Solvent Purifier Moisture content ppm 4

3 TI-1137(L) Purifier Vent °C 40

4 TI-1137(H) Purifier Vent °C 60

5 PDI-1145A/B (H) SH Purifier DP kg/cm2g 0.4

6 TI-1155 (H) Solvent outlet from 31-EA-101 °C 80

7 PDI-1211 (H) DP across Solvent Feed Filter kg/cm2g 1

8 TAH-1236 Purifier Regeneration Cooler O/L °C 65

9 PAL-1237 Purifier Reg. Blower Suction kg/cm2g 0.7

10 TAHH-1239 Purifier Reg. Blower discharge °C -

11 LAH-1241 Reg. KOD % 80

12 LI-1242 (H) SH Recovery Tank Level % 52.4

13 LI-1242 (HH) SH Recovery Tank Level % 60.73

14 LAL-1242 SH Recovery Tank Level % 5

15 PAL-1243 Solvent Feed Pump Suction kg/cm2g 1.6

16 FIC-1244 (L) Solvent Feed pump Suction t/h Var

17 PDAHH-1251 Purification Reg. Blower kg/cm2g 1.44

18 TIC-1259 (H) Purifier Reg. heater outlet °C 305

19 PI-1270A/B/C/D (H) 31-P-101/S kg/cm2g 4/4/4/4

20 LI-1271 A/B/C/D (L) 31-P-101/S % 20/20/20/20

21 LI-1271 A/B/C/D (H) 31-P-101/S % 80/80/80/80

22 LI-1279 (L) 31-P-112 % 20

23 LI-1279 (H) 31-P-112 % 80

24 TIC-1319 (H) Absorber Cooler outlet °C 45

25 PIC-1320 (L) Head Tank kg/cm2g 22

26 PIC-1320 (H) Head Tank kg/cm2g 42

27 PAL-1321 Head Tank kg/cm2g 17.5

28 PALL-1321 Head Tank kg/cm2g 6.5

29 LIC-1322 (L) Head Tank % 37.5

30 LIC-1322 (H) Head Tank % 75

31 LALL-1323 Head Tank % 7.5

32 PDAL-1326 Reactor Feed Booster Pump kg/cm2g 5

33 FI-1329B (L) Reactor Feed Pump discharge Flow t/hr 95

34 FALL-1329B Reactor Feed Pump discharge Flow t/hr 90



Sr. No.


35 AI-1340 (H) CO2 CO2 in FE to Absorber Cooler ppm 5

36 PI-1342 (H) Reactor Feed Booster Pump Discharge kg/cm2g 48

37 PI-1347 (H) 31-P-103 kg/cm2g 4

38 LI-1348 (L) 31-P-103 % 20

39 PI-1354 A/B (H) 31-P-104 kg/cm2g 4/4

40 LI-1355 A/B (L) 31-P-104 % 20/20

41 LIC-1410 (L) Reactor Feed Htr. Condenser Pot (31-V-122) % 20

42 LIC-1410 (H) Reactor Feed Htr. Condenser Pot (31-V-122) % 90

43 TIC-1405(L) Reactor Feed Heater outlet to Reactors °C 102

44 FIC-1513 (L) HP Diluent from Pump kg/hr 300

45 TI-1514 (L) HP Diluent Heater outlet °C 200

46 TI-1514 (H) HP Diluent Heater outlet °C 290

47 FIC-1515 (L) Reactor #1 Side Feed t/h D5%

48 TALL-1526A Reactor #1 Mid °C 150

49 TALL-1528A Reactor #1 Mid °C 150

50 TI-1535 (H) Reactor Outlet temperature °C 315

51 TDI-1535A (L) Reactor #1 Inter alarm Delta Temp °C -

52 TDI-1535B (L) Reactor #1 Total Delta Temp °C -

53 TDI-1535B (H) Reactor #1 Total Delta Temp °C -

54 TI-1533A (L) Reactor #1 Base °C -

55 TI-1533A (L) Reactor #1 Base °C -

56 PI-1537A(L) Pipe Reactor #3 Inlet Pressure kg/cm2g 95

57 PI-1537A(H) Pipe Reactor #3 Inlet Pressure kg/cm2g 177

58 PAHH-1537B Pipe Reactor #3 Inlet Pressure kg/cm2g 187

59 PALL-1537B Pipe Reactor #3 Inlet Pressure kg/cm2g 90

60 TDI-1538 (L) Reactor #1 inter alarm Delta Temp °C Var

61 TDI-1538 (L) Reactor #1 inter alarm Delta Temp °C Var

62 TI-1538 (L) Pipe Reactor #1 inlet temperature °C 102

63 FIC-1547 (L) HP DTA Heater outlet flow kg/h 1000

64 II-1550 (H) Reactor #1 Agitator motor current Amps 480

65 SI-1556 (L) Reactor #1 Agitator rpm 200

66 SI-1556 (H) Reactor #1 Agitator rpm 290

67 FIC-1570 (L) HP Diluent flow to Reactor #1 Agitator Seal kg/hr 130.22

68 PI-1608A (H) Sol. Adsorber Inlet Pressure kg/cm2g 173

69 PDI-1608 (H) RA Sol To/From Sol Adsorber Preheater kg/cm2g 17



Sr. No.


70 PAHH-1608A Adsorber Preheaters Inlet Pressure kg/cm2g 180

71 TDI-1609 (L) Total Reactor Delta Temperature °C Var

72 TDI-1609 (H) Total Reactor Delta Temperature °C Var

73 PAH-1610 HP DTA Vap. To Adsorber Preheater kg/cm2g 7

74 LIC-1611 (H) Solution Adsorber Preheater 31-E-105A Condensate

Level % D10%

75 TIC-1613 (L) RA outlet from 31-E-105A °C 286

76 TIC-1613 (H) RA outlet from 31-E-105A °C 315

77 TI-1617 (L) SA Preheater outlet temperature °C 286

78 TI-1617 (H) SA Preheater outlet temperature °C 310

79 TALL-1617 Adsorber Preheaters Outlet Temperature °C 284

80 PAH-1618 HP DTA Vapour to SA Preheater 31-E-105B kg/cm2g 7

81 LIC-1619 (H) SA Preheater 31-E-105B Condensate Level % D10%

82 TIC-1620 (L) RA Solution from SA preheater 31-E-105B °C 286

83 TIC-1620 (H) RA Solution from SA preheater 31-E-105B °C 315

84 PI-1622 (L) HP DTA Vap. To 31-E-105A kg/cm2g 0.5

85 PI-1623 (L) HP DTA Vap. To 31-E-105B kg/cm2g 0.5

86 TIC-1624 (H) HP DTA to 31-E-105A after desuperheater °C 325

87 TIC-1625 (H) HP DTA to 31-E-105B after desuperheater °C 325

88 LIC-1721 (L) Steam Purge heater Condensate Pot % 20

89 LIC-1721 (H) Steam Purge heater Condensate Pot % 80

90 FIC-1723 (L) Solvent from Hot Flush Pump t/h Var

91 TI-1724B (L) Hot Flush O/L Temperature from 31-E-107 °C 250

92 TIC-1724 (L) Hot Flush O/L Temperature from 31-E-107 °C 250

93 TIC-1724 (H) Hot Flush O/L Temperature from 31-E-107 °C 315

94 FIC-1736 (L) Solvent from Hot Flush Pumps to Purge Htrs. t/hr 500

95 PDI-1814A/B PD across Sol. Adsorber 31-V-104A/B kg/cm2g 41

96 PDAH-1909 (L)/(H) RA Solution to IPS kg/cm2g -3/3

97 PIC-1909 (L) RA Solution to IPS kg/cm2g 93

98 PIC-1909 (H) RA Solution to IPS kg/cm2g 112

99 PIC-1911 (L) IPS Overhead pressure kg/cm2g 25

100 PIC-1911 (H) IPS Overhead pressure kg/cm2g 33

101 LIC-1914 (L) IPS level % 20

102 LIC-1914 (H) IPS level % 50

103 LAHH-1914 IPS Level Hi-Hi % -

104 PIC-1916 (H) 1st Stage LPS overhead pressure kg/cm2g 10



Sr. No.


105 LIC-1918 (L) 1st Stage LPS Level % 20

106 LIC-1918 (H) 1st Stage LPS Level % 80

107 LAHH-1919 1st Stage LPS Level % -

108 LAL-1922 2nd Stage LPS Cone % 40

109 LI-1922 (L) 2nd Stage LPS Cone Level % 50

110 LI-1923 (H) 2nd Stage LPS Level % 5

111 LI-1923 (HH) 2nd Stage LPS Level % 20

112 LAH-1924 2nd stage LPS side % -

113 PIC-1926 (L) 2nd stage LPS overhead pressure kg/cm2g 0.1

114 PIC-1926 (H) 2nd stage LPS overhead pressure kg/cm2g 0.8

115 PI-1927 (L) 2nd stage LPS N2 kg/cm2g 0.05

116 LAH-1929 LPS KO Pot 2nd Stage % -

117 LI-2045 CAB-2 Mix Tank level % 15

118 LAH-2045 CAB-2 Mix Tank level % 90

119 FIC-2047 (L) CAB-2 flow kg/h D10%

120 LI-2051 (L) CAB-2 Mix Tank level % 90

121 LI-2051 (LL) CAB-2 Mix Tank level % 25

122 LAH-2053 CAB Mix Tank Level % 90

123 LI-2053 (L) CAB Mix Tank Level % 15

124 FIC-2055 CAB flow kg/h D10%

125 LI-2059 (L) CAB Mix Tank Level % 90

126 LI-2059 (LL) CAB Mix Tank Level % 25

127 FIC-2060 CAB-2 HP Diluent kg/h D10%

128 FIC-2061 CAB HP Diluent kg/h D10%

129 LAH-2137 CD Mix Tank Level % 90

130 LI-2137 (L) CD Mix Tank Level % 15

131 FIC-2139 (L) CD Flow to CD Metering pump kg/h D10%

132 LI-2143 (L) CD Surge Tank % 90

133 LI-2143 (LL) CD Surge Tank % 25

134 LAH-2145 CT Mix Tank Level % 90

135 LI-2145 (L) CT Mix Tank Level % 15

136 FIC-2147 (L) CT flow to CT Metering Pump kg/h D10%

137 LI-2151 (L) CT Mix Tank Level % 90

138 LI-2151 (LL) CT Mix Tank Level % 25

139 FIC-2152 (L) HP Solvent to CD Pump kg/h D10%



Sr. No.


140 FIC-2153 (L) HP Solvent to CT Pump kg/h D10%

141 LI-2235 (L) CJ Mix Tank Level % 15

142 LAH-2235 CJ Mix Tank Level % 90

143 FIC-2237 (L) CJ Flow to Meter Pump kg/h D10%

144 LI-2241 (L) CJ Surge Tank level % 90

145 LI-2241 (LL) CJ Surge Tank level % 25

146 FIC-2242 (L) CJ HP Diluent kg/h D10%

147 LI-2244 (H) Catalyst KO Drum Level % 50

148 FQSH-2245 (H) SH Make-up Dryer 31-V-126 outlet flow Tones Var

149 AAH-2246 A/B SH Make-Up Dryer Moisture Content ppm 2

150 LI-2313 (H) PG Storage Tank % 90

151 FIC-2317 (L) PG Flow to PG Meter Pump kg/h D10%

152 LI-2320 (H) PD Storage Tank % 90

153 FIC-2321 (L) PD flow to PD meter Pump kg/h D10%

154 PIC-2417 (H) J Compressor Discharge Pressure kg/cm2g 220

155 PDIC-2417 (L) J Compressor Discharge Pressure kg/cm2g 30

156 TAH-2418 J Compressor discharge °C -

157 FIC-2421A (L) J to Reactor Feed Pump Hi Range kg/h Var+10%

158 FIC-2421A (LL) J to Reactor Feed Pump Hi Range kg/h Var

159 FIC-2421B (L) J to Reactor Feed Pump Low Range kg/h Var+10%

160 FIC-2421B (LL) J to Reactor Feed Pump Low Range kg/h Var

161 FIC-2422A (L) J to Reactor Hi Range kg/h Var+10%

162 FIC-2422A (LL) J to Reactor Hi Range kg/h Var

163 FIC-2422B (L) J to Reactor Hi Range kg/h Var+10%

164 FIC-2422B (LL) J to Reactor Hi Range kg/h Var

165 PI-2428 (L) J from OSBL kg/cm2g 17

166 TAHH-2631 Charge Heater Blower discharge °C -

167 TAHH-2633 PA Blower Discharge °C 142

168 AI-2634 (H) PA Blower Discharge O2 content %O2 10

169 AAHH-2634 PA Blower Discharge %O2 12

170 PAL-2635 PA Blower Suction kg/cm2g 0.9

171 TAH-2636 PA Blower Suction Filter Receiver °C 140

172 LAH-2637 PA Fallout Hopper % -

173 TAH-2638 PA Fallout Hopper (31-V-124) °C 280

174 LAH-2638 PA Fallout Hopper % -



Sr. No.


175 PAH-2643 Solution Adsorber kg/cm2g 1

176 PDAH-2646 PA Blower kg/cm2g 1

177 PDAH-2648A Filter Receiver G-104 kg/cm2g 0.02

178 PDI-2717 (H) Primary FE Guardbed Outlet Filter (31-G-106) kg/cm2g 1

179 PAHH-2734/2739 Primary FE Guardbed 31-V-127A/127B kg/cm2g 30/30

180 PAH-2734/2739 Primary FE Guardbed31-V-127A/127B kg/cm2g 12/12

181 AI-2743A/B/C (H) Primary FE Guardbed H2O ppmv 2

182 TI-2754 (H) Secondary Guardbed (31-V-132) °C 90

183 TI-2755/2756 (H) Primary FE Guardbed (31-V-127A/B) °C 90/90

184 AI-2757 (H) Primary FE Guardbed O2 ppmv 5

185 TI-2759 (H) FE from B/L °C 40

186 TAH-2761A V-127A °C 100

187 TAH-2761B V-127A °C 100

188 TAH-2762A V -127B °C 100

189 TAH-2762B V -127B °C 100

190 PI-2765 (L) FE to Absorber Cooler kg/cm2g 35

191 PAL-2765 FE to Absorber Cooler kg/cm2g 6.5

192 TI-2767 (H) N2 to/from Primary FE Guardbed Top °C 200

193 TI-2768 (H) N2 to/from Primary FE Guardbed Bottom °C 50

194 PDI-2769 (H) Primary FE Guardbed inlet/outlet kg/cm2g 1

195 TAH-2771A Secondary FE Guard bed °C 100

196 TAH-2771B Secondary FE Guard bed °C 100

197 PAHH-2772 FE to Secondary FE Guardbed kg/cm2g 30

11.2 Recycle Area (Area 200):

Sr. No


1 TIC-2814 (H) LPS HUT feed from LPS Condenser °C 55

2 LI-2815 (H) LPS HUT Level % 80

3 LI-2815 (L) LPS HUT Level % 20

4 LI-2815 (LL) LPS HUT Level % 10

5 LI-2816 (H) LPS HUT Boot interphase Level % 75

6 PIC-2817 (L) LPS HUT N2 Blanketing kg/cm2g 0.04

7 PIC-2817 (H) LPS HUT N2 Blanketing kg/cm2g 0.5

8 FIC-2924 (L) LPS Condensate Pumps Discharge to LB Feed Heater t/h 35

9 FIC-2924 (L) LPS Condensate Pumps Discharge to LB Feed Heater t/h 115



Sr. No


10 FALL-2924 LPS Condensate Pumps Discharge t/h 25

11 FI-2943 A/B/C/D (L) 31-P-201/S lpm 1/1/1/1

12 PI-2946 A/B/C/D (H) 31-P-201/S kg/cm2g 4/4/4/4

13 LI-2947 A/B/C/D (L) 31-P-201/S % 20/20/20/20

14 LI-2947 A/B/C/D (H) 31-P-201/S % 80/80/80/80

15 LIC-3007 (L) LB Feed Heater #2 Condensate Pot level % 20

16 LIC-3007 (H) LB Feed Heater #2 Condensate Pot level % 80

17 LIC-3018 (L) LB Feed Condenser (31-E-202) % 20

18 LIC-3018 (H) LB Feed Condenser (31-E-202) % 80

19 PIC-3019 (H) LB Feed Condenser kg/cm2g 27

20 FI-3020 (L) HP condensate to LBFC t/h 1

21 TI-3021 (L) LB Column Overhead °C 92

22 TI-3021 (H) LB Column Overhead °C 115

23 PDAH-3022 C-201 overhead kg/cm2g 0.5

24 PIC-3022A (L) LB Reflux Drum Vent to Flare kg/cm2g 18.5

25 PIC-3022A (H) LB Reflux Drum Vent to Flare kg/cm2g 22.4

26 PDI-3024 (H) LB Column overhead Diff. Pressure kg/cm2g 0.6

27 TIC-3025 (L) LB Column Feed Temperature °C 198

28 TIC-3025B (H) LB Column Bottom Temperature °C 240

29 Ti-3027 (L) LB Column Tray #20 °C 220

30 LIC-3030 (L) LB Column Bottom Level % 40

31 LIC-3030 (H) LB Column Bottom Level % 80

32 PIC-3034 (H) LP DTA to LB Column Reboiler kg/cm2g 1.5

33 PIC-3034 (HH) LP DTA to LB Column Reboiler kg/cm2g 2

34 LIC-3035 (L) LB Reboiler level % 5

35 LIC-3035 (H) LB Reboiler level % 80

36 TAL-3037 FE Make-Up to LB Feed Condenser °C -5

37 LI-3038 (L) LB Feed Condenser level % 10

38 LI-3038 (HH) LB Feed Condenser level % 90

39 TIC-3039 LBFC process fluid outlet temperature °C 175

40 TIC-3120 (L) 31-E-204 outlet to LB Reflux Drum °C 40

41 TIC-3120 (H) 31-E-204 outlet to LB Reflux Drum °C 75

42 LIC-3121 (H) LB Reflux Drum Level % 80

43 LIC-3121 (L) LB Reflux Drum Level % 20

44 LIC-3121 (LL) LB Reflux Drum Level % 10

45 LI-3122 (H) LB Reflux Drum Boot level % 75



Sr. No


46 FI-3123 (H) LB Reflux Drum Vent t/h 0.4

47 FIC-3126 (L) LB Reflux flow Return to LB Column t/h 40

48 FIC-3126 (H) LB Reflux flow Return to LB Column t/h 140

49 FAH-3129 FE col. Feed cooler CW Return to Flare -

50 LI-3130 (H) FE Feed Coalescer boot level % 75

51 PDI-3140 (H) FE Column Feed Coalescer kg/cm2g 4

52 FI-3148 A/B (L) 31-P-203/S lpm 1/1

53 PI-3151 A/B (H) 31-P-203/S lpm 4/4

54 LI-3152 A/B (L) 31-P-203/S % 20/20

55 TIC-3211 (L) Fe Column Bottom °C 107

56 TIC-3211 (H) Fe Column Bottom °C 115

57 TI-3212 (L) FE Column Base temperature °C 105

58 LIC-3213 (H) FE Column bottom level % 80

59 LIC-3213 (L) FE Column bottom level % 40

60 LIC-3213 (LL) FE Column bottom level % 10

61 PDI-3215 (H) FE Column Bottom/Condenser Pressure Diff. kg/cm2g 0.25

62 TI-3218 (L) FE Column Overhead O/L to Refrigeration °C -33

63 TI-3218 (H) FE Column Overhead O/L to Refrigeration °C -23

64 LIC-3220 (L) FE Reboiler Condenser Pot Level % 20

65 LIC-3220 (H) FE Reboiler Condenser Pot Level % 60

66 PSHH-3224 Fe Column 31-C-204 kg/cm2g 26

67 PDAH-3224 C-204 kg/cm2g 0.5

68 TI-3225 (L) FE column Tray #29 temp °C -33

69 LIC-3227 (L) FE Condenser Level % 10

70 LIC-3227 (H) FE Condenser Level % 80

71 PIC-3229 (L) FE Column Top Pressure kg/cm2g 18

72 PIC-3229 (H) FE Column Top Pressure kg/cm2g 23

73 FI-3233 (L) Propane to Refrigeration Package kg/hr 1000

74 PIC-3234 (H) FE Purge Heater to Flare kg/cm2g 5.5

75 TI-3238 (L) Refrigeration Package Outlet °C -5

76 TALL-3239 Refrigeration system O/L °C -29

77 TI-3240 (H) Propane Refrig. To FE Condenser (31-E-213) °C -30

78 PIC-3242 (H) LP Steam to FE Reboiler kg/cm2g 2

79 TI-3311 (H) HB Column Bottom Temperature °C 190

80 LIC-3312 (L) HB Column Bottom Level % 40

81 LIC-3312 (H) HB Column Bottom Level % 80



Sr. No


82 TIC-3313 (L) HB Overhead Temp °C Var

83 TIC-3313 (H) HB Overhead Temp °C Var

84 PDAH-3314 C-202 Overhead kg/cm2g 0.5

85 PDI-3317 (H) HB Column overhead diff. pressure kg/cm2g 0.6

86 FIC-3318/3322 (L) HP Steam to Reboiler (31-E-205A/B) t/h D10%/ D10%

87 FIC-3318/3322 (H) HP Steam to Reboiler (31-E-205A/B) t/h D10%/ D10%

88 LIC-3320A/B (L) HB Reboiler Condensate Pot level (31-E-208A/B) % 12/12

89 LIC-3320A/B (H) HB Reboiler Condensate Pot level % 80/80

90 PIC-3321/3324 (L) HP Steam to HB reboiler (31-E-205A/B) kg/cm2g 8.5/8.5

91 PIC-3321/3324 (H) HP Steam to HB reboiler (31-E-205A/B) kg/cm2g 30/30

92 PIC-3331 (L) HB Column Overhead pressure kg/cm2g 7.8

93 PIC-3331 (H) HB Column Overhead pressure kg/cm2g 10

94 LIC-3432 (H) HB Reflux Drum Level % 80

95 LIC-3432 (L) HB Reflux Drum Level % 20

96 LIC-3432 (LL) HB Reflux Drum Level % 10

97 FFIC-3437 (L) HB Reflux Flow Ratio 0.35

98 LIC-3438/3444 (L) HB Condenser Level(31-E-216B/A) % 20/20

99 LIC-3438/3444 (H) HB Condenser Level(31-E-216B/A) % 80/80

100 LI-3449//3450 (HH) HB Condenser (31-E-216A/B) Level % 90/90

101 TDI-3457 (H) HB Reflux Drum Inlet °C Var

102 PI-3468 A/B (H) 31-P-204/S kg/cm2g 4/4

103 LI-3469 A/B (L) 31-P-204/S % 20/20

104 LIC-3520 (L) RB Column bottom level % 40

105 LIC-3520 (H) RB Column bottom level % 80

106 PIC-3521 (L) RB Column Overhead Pressure kg/cm2g 3

107 PIC-3521 (H) RB Column Overhead Pressure kg/cm2g 5.5

108 LIC-3522 (H) RB Reflux Drum Level % 80

109 LIC-3522 (L) RB Reflux Drum Level % 20

110 LIC-3522 (LL) RB Reflux Drum Level % 10

111 FIC-3525 (H) RB Reflux to HB Column t/hr

112 FFIC-3526 (L) RB Column Reflux Flow 0.35

113 PDI-3527 (H) RB column overhead diff. pressure kg/cm2g 0.4

114 LIC-3531 (H) RB Reboiler Level % 80

115 LIC-3531 (L) RB Reboiler Level % 20

116 LIC-3531 (LL) RB Reboiler Level % 5

117 PDAH-3521 RB Column C-203 pressure kg/cm2g 0.5



Sr. No


118 PSH-3533 (H) 31-EA-202 Ambient Temp °C 200

119 PIC-3535 (H) LP DTA To RB Reboiler kg/cm2g 1.5

120 PIC-3535 (HH) LP DTA To RB Reboiler kg/cm2g 2.0

121 TIC-3541 (L) RB Column Tray #1 temp °C var

122 TIC-3541 (H) RB Column Tray #1 temp °C Var

123 FI-3553 A/B (L) 31-P-205/S lpm 1/1

124 PI-3556 A/B 31-P-205/S kg/cm2g 4/4

125 LI-3557 A/B (L) 31-P-205/S % 20/20

126 PAH-3625 FE Col. Feed Dryer V-209A feed inlet kg/cm2g 18

127 PAL-3625 FE Col. Feed Dryer V-209A Feed Inlet kg/cm2g 3

128 TAHH-3626 FE Feed V-209A Bottom °C 75

129 TI-3626/3631 (H) FE Feed Dryer 31-V-209A/B Bottom °C 65/65

130 TI-3629A/B (H) FE Column Fed Dryer 31-V-209A/B interbed °C 75/75

131 PAH-3630 FE Col. Feed Dryer V-209B Feed Inlet kg/cm2g 3

132 PAL-3630 FE Col. Feed Dryer V-209B Feed Inlet kg/cm2g 18

133 TAHH-3631 V-209B bottom °C 75

134 AI-3634 A/B(H) FE Feed Dryers 31-V-209A/B Moisture Content ppmw 10

135 TI-3644 (H) Regeneration Gas Supply header °C 300

136 TAHH-3722 FE Regeneration Blower Discharge °C 120

137 TI-3724 (H) FE Dryer Reg. Blower outlet °C 120

138 TIC-3725 (H) Reg. N2 to FE Column or Guardbed °C 325

139 LI-3726 (H) FE feed Dryer Reg. KO Pot % 45

140 LAHH-3726 FE feed Dryer Reg. KO Pot % 75

141 LI-3727 (H) FE feed Dryer Reg. KO Pot % 45

142 PDAHH-3730 FE Dryer Reg. Blower kg/cm2g 1.44

143 PI-3731 (L) FE Dryer Reg. Blower inlet kg/cm2g 1.235

144 PALL-3731 FE Dryer Reg. Blower inlet kg/cm2g 1.135

145 PI-3732 (L) FE Dryer Reg. Blower inlet kg/cm2g 1.3

146 PDAH-3780 FE Dryer Reg. Blower kg/cm2g 1.34

147 TI-3804 (L) CM Column Bottom Temperature °C 65

148 LIC-3806 (L) FE Column Bottom Level % 40

149 LIC-3806 (H) FE Column Bottom Level % 80

150 PI-3809A (H) CM Col. Overhead kg/cm2g 7

151 PIC-3809B (L) CM Col. Overhead/CM Condenser kg/cm2g 5..5

152 PIC-3809B (H) CM Col. Overhead/CM Condenser kg/cm2g 6.5

153 PDAH-3809 CM Col. Overhead kg/cm2g 0.5



Sr. No


154 FIC-3811 (L) CM Column Bottom outlet kg/h 300

155 PDI-3813 (H) CM Col. Overhead kg/cm2g 1

156 PIC-3815 (L) LP Steam to CM Reboiler kg/cm2g 0

157 PIC-3815 (H) LP Steam to CM Reboiler kg/cm2g 1

158 LIC-3816 (L) CM Reboiler cond. Pot level % 20

159 LIC-3816 (H) CM Reboiler cond. Pot level % 55

160 PI-3837 A/B (H) 31-P-415/S kg/cm2g 4/4

161 LI-3838 A/B (L) 31-P-415/S % 20/20

162 LIC-3912 (H) CM Reflux Drum Level % 80

163 LIC-3912 (L) CM Reflux Drum Level % 20

164 LIC-3912 (LL) CM Reflux Drum Level % 10

165 FIC-3916 (L) Reflux return to CM column t/h 0.025

166 FIC-3919 (L) FB to FB Surge Tank t/h 0.5

167 PI-3921 (H) CM Reflux drum vent kg/cm2g 6.5

168 TIC-3922 (H) CM Condenser outlet °C 3

169 PI-3932 A/B (H) 31-P-206/S kg/cm2g 4/4

170 LI-3933 A/B (L) 31-P-206/S % 20/20

11.3 Finishing Area (Area 300): Sr. No


1 FIC-4029 (L) Pelletizer Circulation Water Flow t/h 400

2 FI-4029 (L) Circulation Water to Pelletizer t/h 350

3 FI-4029 (H) Circulation Water to Pelletizer t/h 750

4 FALL-4029 Circulation Water to Pelletizer t/h 250

5 PDAH-4118 Main Extruder LO filter kg/cm2g -

6 PAL-4119 Main Extruder LO kg/cm2g -

7 FAL-4120 Main extruder LO Flow -

8 TAH-4121 Satellite Extruder Motor Temp. °C -

9 PDAL-4128 DC Motor Purge Air kg/cm2g -

10 PDAL-4129 Sat. Extruder Motor Purge Air kg/cm2g -

11 TI-4137 (H) Rear Seal Temp °C 325

12 II-4146/4149 (L) Satellite/Main Extruder - -

13 II-4146/4149 (H) Satellite/Main Extruder - -



Sr. No


14 SIC-4148 (L) Satellite Extruder - -

15 TI-4154 (H) Extruder Feed Hopper °C 295

16 TI-4156 (H) Extruder Barrel Spacer °C 295

17 TI-4158/4160 (H) Main Extruder Barrel spacer Zone 3/4 °C 295

18 TI-4162(H) Die Body °C 295

19 PSH-4163X Underwater Pelletizer kg/cm2g -

20 PI-4163 Underwater Pelletizer kg/cm2g -

21 II-4165 Pelletizer - -

22 PAH-4169X Main Extruder Adapter zone 4 kg/cm2g -

23 PSH-4169 Main Extruder Adapter zone 4 kg/cm2g 350

24 TAH-4174 Extruder Gear Box °C -

25 TAHH-4174 Extruder Gear Box °C -

26 PDAH-4175 Satellite Extruder Rupture Disk kg/cm2g -

27 PAL-4176 Sat. Extruder LO kg/cm2g -

28 FAL-4177 Sat. Extruder LO kg/cm2g -

29 TIC-4189 (HH) Satellite Extruder Zone 4 °C 295

30 TI-4193 (H) Satellite Extruder Head °C 295

31 PI-4194 (H) Satellite Extruder Head °C 295

32 LAH-4228X Extruder Hot Oil Reservoir V-323 % -

33 LAL-4228X Extruder Hot Oil Reservoir V-323 % -

34 TAH-4229X Extruder Oil heater H-306 Outlet temp. - -

35 LAH-4312X Extruder Hot oil Tank % 80

36 LAL-4312X Extruder Hot oil Tank % 20

37 PAH-4316X Primary Hot Oil Pump P-317/S Discharge kg/cm2g -

38 PAH-4317X Oil Heater H-307 outlet temperature kg/cm2g -

39 PAL-4318X Primary Hot oil Pump P-317/S Discharge kg/cm2g -

40 TAH-4319X Oil Heater H-307 Outlet °C -

41 LIC-4426 (L) Reslurry Tank level % 20

42 LIC-4426 (H) Reslurry Tank level % 80

43 LI-4433 (L) Water Reservoir % 85

44 LI-4433 (H) Water Reservoir % 95

45 FIC-4437 (L) Reslurry Water Heater Flow t/h 85

46 TIC-4438A (L) Reslurry Tank outlet temperature °C 88

47 TIC-4438A (H) Reslurry Tank outlet temperature °C 95

48 TIC-4438B (H) Reslurry Water Heater outlet to Reslurry Tank °C 98

49 TIC-4439 (L) Water Cooler Discharge Temperature °C Var



Sr. No


50 TIC-4439 (H) Water Cooler Discharge Temperature °C Var

51 TI-4439B (L) Water Circulation 31-E-318A/B Discharge Temp °C 60

52 FIC-4441(L) Circulation Water to Resin Stripper outlet t/h 20

53 LI-4445 (HH) 31-T-301 CW Skimming °C 90

54 LI-4445 (H) 31-T-301 CW Skimming °C 80

55 LI-4445 (L) 31-T-301 CW Skimming °C 20

56 LI-4445 (LL) 31-T-301 CW Skimming °C 10

57 LAHH-4453 Reslurry Tank V-309 - -

58 PI-4463 (L) 31-P-305/S Seal Flush kg/cm2g 4

59 PDI-4464 (H) Pressure Diff. across 31-G-307 kg/cm2g 1

60 LI-4477 A/B (L) 31-P-307/S % 20/20

61 LI-4477 A/B (H) 31-P-307/S % 80/80

62 FI-4484 A/B (L) 31-P-305/S lpm 1/1

63 PI-4610 (H) RA Stripper Steam Ring kg/cm2g 0.3

64 TI-4613 (L) RA Stripper Feed In Temperature °C 76

65 TI-4614 (H) RA Stripper Top Temperature °C 105

66 LIC-4615 (L) RA Stripper Level % -

67 LIC-4615 (H) RA Stripper Level % -

68 LAHH-4616 RA Stripper Level 3 sec. delay % -

69 LALL-4617 RA Stripper Level 3 sec. delay % -

70 TI-4618 (H) Spin Dryer Fire Emergency °C 105

71 TAHH-4618 Spin Dryer Fire Emergency °C 110

72 II-4620 Spin Dryer Motor amp 96

73 TI-4623 (H) Spin Dryer Hold-up Bin Fire Emergency °C 105

74 TAHH-4623 Spin Dryer Hold up bin Fire Emergency °C 110

75 FI-4628 (L) Spin Dryer hub Purge m3/h 520

76 TI-4631 (L) RA Stripper overhead Temp. °C 92

77 PIC-4632 (L) RA Stripper overhead N2 Pressure kg/cm2g 0.01

78 PIC-4632 (H) RA Stripper overhead N2 Pressure kg/cm2g 0.08

79 LAH-4624 Spin Dryer Holdup bin V-317 3 sec delay % -

80 TIC-4634 (H) LP Steam Desuperheater outlet temp °C Var

81 TAHH-4635B Strip steam to RA Stripper °C 108

82 TIC-4635 (H) Strip steam to RA Stripper °C Var

83 FIC-4636 (H) Strip N2 flow kg/h 1000

84 PAH-4637 Spin dryer Conv. Blower K-302 discharge kg/cm2g -

85 TI-4638 (H) Spin Dryer Conv. Blower Discharge °C 50



Sr. No


86 FIC-4642 (L) LP Steam Desuperheater LP Steam Flow kg/h 5000

87 FIC-4642 (H) LP Steam Desuperheater LP Steam Flow kg/h 7000

88 FIC-4643 (L) D. M. Water to LP Steam Desuperheater kg/h 100

89 FIC-4643 (H) D. M. Water to LP Steam Desuperheater kg/h 300

90 FALL-4647 LPS to LP Steam Desuperheater V-322 kg/h 4000

91 LIC-4648A (L) Stripper Conveying Water to Fine Separator % 85

92 LIC-4648A (H) Stripper Conveying Water to Fine Separator % 70

93 LI-4711 (H) Decanter Boot level % 70

94 TI-4714 (H) Solvent Vapor Condenser (31-EA-301) Vent °C 75

95 LIC-4717 (L) Decanter Level % 20

96 LIC-4717 (H) Decanter Level % 45

97 LIC-4723 (L) Decanter Drain % 25

98 LIC-4723 (H) Decanter Drain % 75

99 LI-4733 A/B (L) 31-P-308/S % 20

100 LI-4733 A/B (H) 31-P-308/S % 80

101 PI-4821 (H) Add Mix Tank Pressure kg/cm2g 3

102 FQI-4823 (H) Solvent to Additive System tones Var

103 PI-4825 (H) Add Holding Tank (31-V-301) Pressure kg/cm2g 3

104 PI-4831 (H) Add Holding Tank (31-V-302) Pressure kg/cm2g 3

105 LI-4836 (L) Add Mix Tank Level (31-V-305) % 20

106 LI-4836 (H) Add Mix Tank Level (31-V-305) % 85

107 LI-4837/4828 (L) Add Hold Tank Level (31-V-301/302) % 20/20

108 LI-4837/4838 (H) Add Hold Tank Level (31-V-301/302) % 90/90

109 TAHH- 4839 SH Add Cooler Outlet °C 70

110 TI-4840 (H) SH Additive Cooler (31-E-303) outlet °C 60

111 FIC-4844/4845 (L) Add meter pump

(31-P-301/302) flow kg/h Var

112 WI-4919 (H) Waste Drum (31-V-306A) kg 2665

113 PI-4921/4927 (H) Additive Holding Tank (31-V-303/304) Level % 3/3

114 LI-4928/4929 (L) Additive holding Tank (31-V-304/303) Level % 20/20

115 LI-4928/4929 (H) Additive holding Tank (31-V-304/303) Level % 85/85

116 FAH-4931 Mix/Hold Tank Depressurization Flush to Waste Drum - -

117 FIC-4936/4937 (L) Additive hold Tank (31-V-303/304) flow kg/h Var

118 LI-4938 (L) SZ Storage Tank Level % 20

119 LI-4938 (H) SZ Storage Tank Level % 90

120 PAHH-5017 Blending Blower #2 K-304 Outlet kg/cm2g -



Sr. No


121 TI-5022 (H) Blender #1 31-V-313 Top Temp °C 110

122 TI-5027 (H) Purge Air Blower #1 31-K-307 discharge °C -

123 TIC-5028 (H) Blender #1 31-V-313 Purge Air Temp °C 90

124 PI-5029 (L) Purge air to Blender #1 31-V-313 kg/cm2g 0.02

125 PI-5029 (H) Purge air to Blender #1 31-V-313 kg/cm2g 0.36

126 TI-5032/5134/5149 (H) Blending blower #1/#3/#4 31-K-303 Discharge °C -

127 TIC-5034/5151 (H) Blender #1/#3/#4 31-V-313/315/316 Air Conv. Temp °C 60/60/60

128 TI-5036/5123/5138 (H) Blender #2/#3/#4 31-V-314/315/316 Top Temp °C 110/110/110

129 TI-5041/5128/5143 (H) Purge air Blower #2/#3/#4 31-K-308/309/310 Discharge °C

130 TI-5042/5129/5144 (H) Blender #2/#3/#4 purge air temperature °C 90/90/90

131 PI-5043/5130 (L) Purge air to Blender #2/#3 kg/cm2g 0.02/0.02

132 PI-5043/5130 (H) Purge air to Blender #2/#3 kg/cm2g 0.36/0.36

133 FSL-5044/5059/5131/5146 Purge Air to Blender #2/#1/#3/#4 m3/h 5000/5000/50

00/5000

134 TI-5047 (H) Blending Blower #2 Discharge °C -

135 TIC-5049 (H) Blender #2 air conv. Temp °C 60

136 PSHH-5051 Blending Blower #1 31-K-303 outlet kg/cm2g -

137 TAHH-5054 Blender #1 V-313 °C 100

138 TAHH-5055 Blender #2 v-314 °C 100

139 LAH-5062 Blender #1 % -

140 LAH-5063 Blender #2 % -

141 PAHH-5117 Blending Blower #4 31-K-306 Discharge kg/cm2g -

142 PSHH-5161 Blender blower #3 Discharge kg/cm2g -

143 TSHH-5165/5166 Blender #3/#4 °C 100/100

144 TAHH-5165 Blending Blower #3 °C 100

145 TAHH-5166 Blending blower #4 °C 100

11.4 Utility Area (Area 400): Sr. No


1 LALL-5711 Flare KOD Level % 3

2 LI-5711 (HH) Flare KOD Level % 20

3 LI-5713 (H) Flare KOD Level % 10

4 LAH-5714 Polymer KOD Hi Level % -

5 TI-5715 (L) Flare from Flare Header to Flare KO Drum °C 15

6 TI-5715 (H) Flare from Flare Header to Flare KO Drum °C Var

7 PAL-5717 Flare KOD to Flare Stack kg/cm2g 0.04



Sr. No


8 PALL-5719 Vent from Flare KOD Outlet Pressure kg/cm2g 0.04

9 PI-5727 31-P-404 kg/cm2g 4

10 LI-5728 (L) 31-P-404 % 20

11 LI-5728 (H) 31-P-404 % 80

12 PIC-5902A (L) DTA Vaporiser Master Control kg/cm2g 3.5

13 PIC-5902A (H) DTA Vaporiser Master Control kg/cm2g 5.5

14 PIC-5902B (H) DTA Vaporiser Master Control kg/cm2g 7.5

15 LI-6013 (L) LP DTA Cond Drum Level % 20

16 LI-6013 (H) LP DTA Cond Drum Level % 80

17 PIC-6015 (L) LP DTA cond. Drum kg/cm2g 0

18 PIC-6015 (H) LP DTA cond. Drum kg/cm2g 0.5

19 TI-6016 (H) LP DTA Condensate Drum (31-V-410) °C 265

20 FI-6028 A/B (H) 31-P-407/S lpm 8/8

21 PIC-6112 (L) HP DTA Cond. Drum Pressure kg/cm2g 1.0

22 PIC-6112 (H) HP DTA Cond. Drum Pressure kg/cm2g 2.8

23 LIC-6114 (L) HP DTA Cond. Drum Level % 16

24 LIC-6114 (H) HP DTA Cond. Drum Level % 21

25 LI-6115(LL) HP DTA Cond. Drum level % 15

26 LI-6115(HH) HP DTA Cond. Drum level % 22

27 PI-6127 A/B 31-P-405 kg/cm2g 16/16

28 FI-6128 A/B (H) 31-P-405 lpm 8/8

29 LI-6234 (L) DTA Storage Vessel Level % 20

30 LI-6234 (H) DTA Storage Vessel Level % 70

31 LAHH-6235 DTA Storage Vessel % 85

32 PIC-6236 (L) DTA Storage Vessel Pressure kg/cm2g 0

33 PIC-6236 (H) DTA Storage Vessel Pressure kg/cm2g 1.5

34 LI-6237 (H) DTA Vent Pot Level % 80

35 LI-6238 (L) DTA Vent Receiver Level % 20

36 LI-6238 (H) DTA Vent Receiver Level % 80

37 PIC-6241A (L) DTA Vapour to DTA Vent Vacuum Ejector kg/cm2g -0.8

38 PIC-6241A (H) DTA Vapour to DTA Vent Vacuum Ejector kg/cm2g -0.7

39 PI-6242 (H) DTA Vent from users to DTA Vent Condenser kg/cm2g -0.6

40 LI-6245 (L) DTA Regn. Vessel Level % 20

41 LI-6245 (H) DTA Regn. Vessel Level % 60

42 PIC-6246 (L) DTA Regeneration Vessel Pressure % 0.1

43 PIC-6246 (H) DTA Regeneration Vessel Pressure % 0.5



Sr. No


44 TIC-6251 (L) DTA Regeneration Vessel Temp °C 265

45 TIC-6251 (H) DTA Regeneration Vessel Temp °C 295

46 TAH-6252 DTA Storage Vessel Vent °C 260

47 TI-6253 (L) DTA Vent Receiver Vent °C 50

48 TI-6253 (H) DTA Vent Receiver Vent °C 207

49 TI-6254 (H) DTA Vent Pot Vent °C 207

50 PI-6267 A/B (L) 31-P-406/S kg/cm2g 5/5

51 FI-6268 A/B (H) 31-P-406/S lpm 8/8

52 LI-6313 (L) Waste Fuel Drum Level % 15

53 LI-6313 (H) Waste Fuel Drum Level % 80

54 LAHH-6314 Waste Fuel Drum Level % 90

55 WI-6321 (L) Waste Drum (31-V-306B) kg Var

56 TIC-6322 (L) Waste Fuel Drum Temperature °C 180

57 FI-6333 A/B (L) 31-P-412/S lpm 1/1

58 PI-6337 A/B (L) 31-P-412/S kg/cm2g 1/1

59 LAHH-6409 SH De-inventory Tank % 90

60 TAH-6414 SH To/From Area 200 °C 50

61 LI-6415 (L) SH De-inventory Tank Level % 20

62 LI-6415 (H) SH De-inventory Tank Level % 80

63 LI-6429 (L) 31-P-410 % 20

64 LI-6429 (H) 31-P-410 % 80

65 LIC-6509 (L) FB Surge Tank Level % 20

66 LIC-6509 (H) FB Surge Tank Level % 80

67 PIC-6510 (L) N2 to FB Surge Tank Pressure kg/cm2g 3.8

68 PIC-6510 (H) N2 to FB Surge Tank Pressure kg/cm2g 5.2

69 TI-6517 (H) FB Surge Tank (31-V-415) Inlet °C 45

70 PI-6522 A/B/C/D (H) 31-P-411/S kg/cm2g 4/4/4/4

71 LI-6523 A/B/C/D (L) 31-P-411/S % 20/20/20/20

72 LI-6618 (L) FC De-inventory Tank Level % 20

73 LI-6618 (H) FC De-inventory Tank Level % 80

74 LI-6619 (H) FC De-inventory Tank Level % 85

75 LAHH-6619 FC De-inventory Tank % 90

76 PIC-6623 (L) FC De-inventory Tank Pressure kg/cm2g 3.8

77 PIC-6623 (H) FC De-inventory Tank Pressure kg/cm2g 5.2

78 TI-6635 (L) FC Purifier Vent °C 40

79 TI-6636 (H) N2 to/from FC Purifier Top °C 200



Sr. No


80 PDI-6667 (H) Pressure Drop across FC Purifiers kg/cm2g 305

81 LI-6669 (L) 31-P-409 % 20

82 LI-6669 (H) 31-P-409 % 80

83 PAL-6713 FE Supply from Offsite storage kg/cm2g 6.5

84 PI-6728 (L) FE Purge to Fuel Gas Blending kg/cm2g 2

85 PI-6728 (H) FE Purge to Fuel Gas Blending kg/cm2g 3

86 TI-6729 (L) FE Purge to Fuel Gas Blending kg/cm2g -5

87 TI-6729(H) FE Purge to Fuel Gas Blending kg/cm2g 45

88 PIC-6731 (L) FE from offsite Storage kg/cm2g 40

89 PIC-6731 (H) FE from offsite Storage kg/cm2g 50

90 PI-6809 (L) To Bearing cooling Water kg/cm2g 4.5

91 FI-6824 Cooling Water Supply from offsite t/hr Var

92 FI-6825 DM Water from Offsite kg/hr 3000

93 PI-6827 (L) D. M. Water supply from offsite kg/cm2g 5

94 TI-6828 (H) Cooling Water supply from offsite kg/cm2g 35

95 PI-6829 (L) Cooling Water supply from offsite kg/cm2g 5

96 PI-6830 (L) Fire Water supply from offsite kg/cm2g -

97 FI-6833 (H) Fuel Gas from offsite kg/hr 2800

98 TI-6834 (L) Fuel Gas from offsite °C 15

99 TI-6834 (H) Fuel Gas from offsite °C 55

100 PI-6835 (L) Fuel Gas from offsite kg/cm2g 2.5

101 PI-6835 (H) Fuel Gas from offsite kg/cm2g 5

102 TI-6837 (L) Fuel Oil from offsite °C 160

103 TI-6837 (H) Fuel Oil from offsite °C 220

104 PI-6838 (L) Fuel Oil from offsite kg/cm2g 7

105 PI-6838 (H) Fuel Oil from offsite kg/cm2g 12

106 PI-6840 (L) Service Water Supply from offsite kg/cm2g 2

107 PI-6844 (L) N2 Supply from offsite kg/cm2g 4.5

108 TI-6848 (H) Cooling Water Return to Offsite °C 45

109 PI-6849 (L) Instrument Air from offsite kg/cm2g 5.5

110 PI-6850 (L) Plant Air from offsite kg/cm2g 5

111 FI-6851 (L) Fuel Oil Return to Offsite kg/h 500

112 TI-6852 (L) Fuel Oil Return to Offsite °C 135

113 TI-6852 (H) Fuel Oil Return to Offsite °C 230

114 PI-6853 (L) Fuel Oil Return to Offsite kg/cm2g 3.6

115 PI-6853 (H) Fuel Oil Return to Offsite kg/cm2g 5



Sr. No


116 FI-6854 (L) Emergency CW Supply from Offsite kg/h 100

117 TI-6855 (H) Emergency CW Supply from Offsite °C 35

118 PI-6856 Emergency CW Supply from Offsite kg/cm2g 5

119 TI-6858 (H) Cooling Water Return to Offsite °C 45

120 PI-6869 (L) Emergency DM Water kg/cm2g 4.5

121 PIC-6913 (L) HP Steam from 31-V-417 Pressure kg/cm2g 35

122 PIC-6913 (H) HP Steam from 31-V-417 Pressure kg/cm2g 40

123 TDAH-6914 HP Steam Desuperheater outlet temp C 6

124 TAHH-6914 HP Steam Desuperheater Reset °C 265

125 TIC-6916 (H) HP Steam Desuperheater outlet °C 254

126 FI-6920 (H) LP Condensate return to offsite t/hr 11

127 PI-6923 (L) LP Steam at B/L kg/cm2g 3

128 PIC-6925 (L) LP Steam kg/cm2g 3.6

129 PIC-6925 (H) LP Steam kg/cm2g 5.5

130 FI-6927 (L) LP Steam to offsite t/hr 3

131 FI-6927 (H) LP Steam to offsite t/hr 35

132 TAHH-6928 LP Steam Desuperheater outlet temp °C 185

133 TDAH-6928 LP Steam Desuperheater outlet temp. °C 3

134 TIC-6929 (H) LP Steam Desuperheater outlet temp °C 165

135 PIC-6935 (H) LP Steam Vent kg/cm2g 4.8

136 TI-8001 (L) Hydrogen Buffer Storage (31-V-425) °C 5

137 TI-8001 (H) Hydrogen Buffer Storage (31-V-425) °C 60

138 PIC-8001 (L) Hydrogen to offsite kg/cm2g 20

139 PIC-8001 (H) Hydrogen to offsite kg/cm2g 30

140 PAHH-8002 Hydrogen to offsite kg/cm2g 35

141 PI-8003 (L) Hydrogen Buffer Storage (31-V-425) kg/cm2g 30

142 PI-8003 (H) Hydrogen Buffer Storage (31-V-425) kg/cm2g 120

143 PAHH-8005 Hydrogen to Buffer Storage kg/cm2g 135

144 PI-8006 (L) Hydrogen to Buffer Storage kg/cm2g 30

145 PI-8006 (H) Hydrogen to Buffer Storage kg/cm2g 120

146 LI-8201 (L) BCW Sump (31-LZ-402) Level % 12.5

147 LI-8201 (H) BCW Sump (31-LZ-402) Level % 87.5

148 LAL-8202 BCW Sump (31-LZ-402) Level % 12.5

149 LAH-8202 BCW Sump (31-LZ-402) Level % 87.5

150 PI-8201 (L) Blender Wash Pump (31-P-408) Discharge kg/cm2g 3.9

151 PI-8201 (H) Blender Wash Pump (31-P-408) Discharge kg/cm2g 5



Sr. No


152 PAL-8304 Nitrogen Amplifier (31-K-402/S) discharge kg/cm2g 11.5

153 PAL-8301 Nitrogen Cylinder discharge kg/cm2g 5

154 LI-8501 (L) Condensate Sump (31-LZ-401) % 12.5

155 LI-8501 (H) Condensate Sump (31-LZ-401) % 87.5

156 LAL-8502 Condensate Sump (31-LZ-401) % 12.5

157 LAH-8502 Condensate Sump (31-LZ-401) % 87.5

158 AI-8601 (H) HC Analyser ppmw 5

159 PIC-8601 (L) HP Steam condensate Drum Vent to LPS header kg/cm2g 4

160 PIC-8601 (H) HP Steam condensate Drum Vent to LPS header kg/cm2g 5.5

161 AI-8602 (H) Conductivity Analyser µmho/cm 1

162 LIC-8602 (L) HP Steam condensate Drum (31-V-402) % 12.5

163 LIC-8602 (H) HP Steam condensate Drum (31-V-402) % 87.5

164 AI-8603 (H) pH Analyser - 9.5

165 PIC-8603 (H) HP Steam booster/condensate pump dis. to 31-V-402 kg/cm2g 35

166 PIC-8604 (L) LP Steam condensate Drum (31-V-403) kg/cm2g 0.1

167 PIC-8604 (H) LP Steam condensate Drum (31-V-403) kg/cm2g 0.5

168 LIC-8605 (L) LP Steam condensate Drum (31-V-403) % 9.7

169 LIC-8605 (H) LP Steam condensate Drum (31-V-403) % 90.3

170 LALL-8610 HP Steam condensate Drum (31-V-402) % 0

171 LALL-8611 LP Steam condensate Drum (31-V-403) % 0

172 PIC-8701 (L) Nitrogen Cylinder discharge kg/cm2g 6.5

173 LI-9106 (L) PG Storage Tank (31-V-140) % 10

174 LI-9106 (H) PG Storage Tank (31-V-140) % 90

175 LI-9113 (LL) PG Storage Tank (31-V-140) % 5



SECTION-12.0 OPERATING CONDITION FOR DIFFERENT OPERATING CASES



Operating Conditions: Reaction Area:

Equipment Operating Conditions Comments

Absorber Cooler 22 to 35 kg/cm2

35°C to 55°C • The set point will be

approximately 45 kg/cm2.

Head Tank Optimum temperature and pressure for

FE absorption.

The reactor feed pump specifications

will determine the minimum operating

pressure.

• The FE concentration and the

Absorber Cooler outlet

temperature control pressure in

the head tank.

IPS Inlet (System

Pressure)

100 to 125 kPa System pressure will have to be

set to prevent phase separation

for different resins.

IPS 28 to 31 kg/cm2

260° to 275°C.

Level 25% to 49%.

• The IPS will be operated at 31

kg/cm2 while producing film

resins and 51-35B resin at

high rates.

• The IPS should operate at 28

kPa kg/cm2 while on all other

resins.

• Variation from normal

operating conditions will

require recalibration of level

transmitter.

LPS Level 30% to 70%

0 to 13 kg/cm2 1st stage

0.1 to 0.35 kg/cm2 2nd stage

• The first stage operating

pressure depends on the resin

melt index and the RA rate.

• The second stage pressure

should be as low as possible.



Recycle Area:


LB Feed Condenser 180° - 200°C process outlet

LB Feed Heater #2 210°- 225°C outlet

LB Column 21 kg/cm2

Tray 8,10,12 - 95° to 105°C

Reboiler – 0.03 to 0.06 DTA/SH

feed Ratio

• To keep the column stable

maintain a minimum reflux rate

of 30 tons/hr and the Reflux

Drum temperature above 40°C.

• If the ketones in the LB

bottoms outlet become

excessive, increase the boil up.

LB Trim Condenser 40°-50°C (Condensate

temperature)

Increase the FB circulation to help

control the FE content if the Reflux

Drum temperature starts to

decrease.

• Boil up to the column should be

increased four hours before a

homo-polymer run to ensure no

FB remains in the SH.

FE Column 20.4 kg/cm2

Feed temperature 35°C

Overhead temperature - 32°C

Base temperature > 107°C

Overhead flow 100% unreacted

FE

• A high differential pressure

indicates flooding of the

column or freezing in the top

end of the column or

condenser. Reduce the load

on the column, and boil out.

HB Column Pressure 8.3 kg/cm2

0.4 reflux ratio to feed in FB or

homopolymer mode

Base temperature 184°C

• If ketones get too high in the

reflux, increase LB column boil

up and the purge rate from the

RB Column base.

• Adjust bottoms flow to maintain

RB concentration for FB-1/FE

copolymer.

RB Column Pressure 3.6 kg/cm

Base temperature 190° to 210°C

0.4 to 0.6 reflux ratio to feed.

• The column purge rate from

the base is adjusted to

maintain the desired

temperature in the base.

• Increasing the purge rate will

lower the column base grease

concentration and temperature.

• Acid content can be controlled

by the purge rate.




CM Column Pressure 6 kg/cm2

Overhead condenser outlet ≈50°C

FB-2 purge – variable • Base FB-2 purge is taken as

necessary to maintain an FB-1

purity of 92 – 95% in the reflux.

• Gas chromatograph on reflux

line.

Base temperature - 70°C • FB-1 <15%

• Gas Chromatograph on base

outlet line.

3.5 to 4.0 reflux ratio to feed. • Reflux to feed ratio is adjusted

to achieve FB-1/FB-2

separation desired.

OPERATING MANUAL FOR LLDPE/HDPE SWING UNIT IOCL, PANIPAT


Doc. No.: 2317 Rev. 0 of 623

OPERATING CONDITIONS A100

11Q4 61B 2712 59A OCTE NE 2712(LC) 11L2B RECYCLE SH AIR COOLER

Recycle SH+FC stream in/out Temp. oC 140/65 149.39/65 153.17/65 159.6/65 136.03/65 153.16/65

Recycle SH+FC stream in/out Pressure kg/cm2g 6.12/5.62 6.12/5.62 6.12/5.62 6.12/5.62 6.12/5.62 6.12/5.62

RECYCLE SH WATER COOLER

Recycle SH+FC stream in/out Temp. oC 65/36 65/36 65/36 65/36 65/36 65/36

Recycle SH+FC stream in/out Pressure kg/cm2g 5.62/5.12 5.62/5.12 5.62/5.12 5.62/5.12 5.62/5.12 5.62/5.12

SH PURIFIER

Purifier stream in/out Temp oC 36/36 36/36 36/36 36/36 36/36 36/36 Purifier stream in/out Pressure kg/cm2g 5.12/4.1 5.12/4.1 5.12/4.1 5.12/4.1 5.12/4.1 5.12/4.1 Purifier Outlet Flow Rate MT/hr 188.227-207.05 177-194.72 191.4-210.6 210-231 207.19-227.9 191.54-210.7

PURIFIER REG. HEATER

Shell Side In/out Temperature oC 95.27/300 95.27/300 95.27/300 95.27/300 95.27/300 95.27/300 Shell Side In/Out Pressure kg/cm2g 1.95/1.81 1.95/1.81 1.95/1.81 1.95/1.81 1.95/1.81 1.95/1.81 Shell Side Flow Rate (intermittent) kg/hr 12800 12800 12800 12800 12800 12800

REG. BLOWER AFTERCOOLER

Shell Side In/out Temperature oC 95.27/37 95.27/37 95.27/37 95.27/37 95.27/37 95.27/37

Shell Side Flow Rate (Intermittent) kg/hr 12800 12800 12800 12800 12800 12800 PURIFIER REG. COOLER

Shell Side In/out Temperature oC 300/37 300/37 300/37 300/37 300/37 300/37

Shell Side Flow Rate (Intermittent) kg/hr 12800 12800 12800 12800 12800 12800

SOLVENT FEED PUMP

Suction/Discharge Pressure kg/cm2g 4.10/43.98 4.10/43.98 4.10/43.98 4.10/43.98 4.10/43.98 4.10/43.98 Flow Rate MT/hr 203 200 193.714 207.405 203.39 193.39

HP DILUENT PUMP

Suction/Discharge Pressure kg/cm2g 4.10/187 4.10/187 4.10/187 4.10/187 4.10/187 4.10/187 Flow Rate MT/hr 3.526-5.012 3.52-5.004 3.514-4.997 2.432-3.698 3.514-4.997 3.514-4.997

ABSORBER COOLER

Solution In/Out Temperature oC 51.72/38 51.95/38 53.31/38 51.65/38 50.99/38 53.3/38 Solution In/Out Pressure kg/cm2g 29.7/28.2 30.71/29.21 35.37/33.87 29.16/27.66 30.63/29.13 35.36/33.86 Solvent Flow Rate MT/hr 203 200 193.714 207.405 203.39 193.8-213.2 Ethylene Inlet Pressure kg/cm2g 29.7 30.7 25.4 29.16 3063 35.36 Ethylene Inlet Temperature oC -0.19 1.27 7.79 -0.98 1.15 7.77

Ethylene Flow Rate MT/hr 44.88-47.128 47.91-50.305 54.214-56.924 41.606-43.686 44.38-46.599 54.214-56.924

HEAD TANK

Pressure kg/cm2g 28.2 29.21 33.87 27.66 29.13 33.86 Level % 80 80 80 80 80 80

BOOSTER PUMP Suction/Discharge Pressure kg/cm2g 28.2/34.53 29.21/35.42 33.87/40.17 27.66/34.22 29.13/35.5 33.86/40.16

REACTOR FEED PUMP

Discharge Pressure kg/cm2g 179.13 165.02 142.57 182.02 173 142.56

Discharge Temperature oC 47.64 46.45 44.45 48.01 47.44 44.45

Discharge Flow Rate MT/hr 248-260 248-260 248-260 249-261 248-260 248-260



Doc. No.: 2317 Rev. 0 of 623


11Q4 61B 2712 59A OCTE NE 2712(LC) 11L2B

REACTOR #1

Side Stream inlet temperature oC 36.94 36.93 - - 36.95 - Side Feed Flow Rate MT/hr 86.7-186 74-186 - - 86-186 - Bottom stream inlet temperature oC 37 37 36.94 104.38 37.04 36.94 Solution Outlet Temperature oC 265 280 301 300 266 294

Catalyst + Solvent Inlet Temperature oC 190 190 190 123 189 125

CATALYST SYSTEM

CD Solution Flow Rate to 31-P-107 suction kg/hr 13.09-44 15.1-44 17.11-44 - 17.11-44 17.11-44 CAB sol. Flow Rate to 31-P-106/105 suction kg/hr - - - 27.22-44 - - CAB-2 sol. Flow Rate to 31-P-105/106 suction kg/hr 13.1-44 15.12-44 17.14-44 - 17.14-44 17.14-44 CJ Flow Rate to 31-P-109/108 suction kg/hr 14.13-47 16.3-47 18.48-47 - 18.48-47 18.48-47 CT Flow Rate to 31-P-108/109 suction kg/hr - - - 100-140 - -

PIPE REACTOR #3

Solution inlet temperature oC 37 37 37 105 37 37

Solution inlet temperature kg/cm2g 156 145 125 159 150 125

HYDROGEN SYSTEM

J Flow Rate to RFP Discharge kg/hr - - - 0.5-2.5 - - J Flow Rate to Reactor kg/hr - 2.27-2.5 7.82-8.6 13.87-25.2 - 7.82-8.6

TRIMMER REACTOR Trimmer Reactor Outlet Temperature oC 265 280 301 300 266 294 STATIC MIXER PG Flow Rate kg/hr 28.58-92 32.97-92 37.37-92 36.58-92 37.37-92 37.37-92

SOLUTION PREHEATERS Solution In/Out Temperature oC 264.9/290 279.9/290 300.8/305 299.9/310 265.9/290 293.8/305 STATIC MIXER PD Inlet Flow Rate kg/hr 18.09-58 20.87-58 23.65-58 23.15-58 23.65-58 23.65-58

IPS

System Pressure kg/cm2g 107.8 121.2 101.77 97.97 100 101.77 IPS Pressure kg/cm2g 31.6 31.6 30.6 30.6 31.6 30.6

Bottom Outlet Temperature oC 246 240 275 275 264 275

LPS

LPS-I Overhead outlet Pressure kg/cm2g 4.1 0.8 0.8 6.1 4.1 0.8 LPS-I Overhead outlet Temperature oC 210 210 230 230 230 230

LPS-II Overhead Outlet Pressure kg/cm2g 0.6 0.2 0.2 0.6 0.6 0.2



Doc. No.: 2317 Rev. 0 of 623


11Q4 61B 2712 59A OCTE NE

2712(LC) 11L2B LPS CONDENSER

Outlet Temp. 0C 50 50 50 50 50 50 Outlet Pressure kg/cm2g 0.13 0.1 0.1 0.09 0.16 0.11

HUT Temperature 0C 50 50 50 50 50 50 Pressure kg/cm2g 0.12 0.12 0.12 0.12 0.12 0.12 Level % 20-80 20-80 20-80 20-80 20-80 20-80

LPS CONDENSATE PUMP Flow MT/hr 68.79-82 45.8-55 53.2-63 44-52.8 86-103 53.2-63

LB FEED HEATER

LPS Cond to LB Feed Heater Tube Side out Temp.

0C 162.5 162.5 169.49 169.48 170.98 169.49

LPS Cond to LB Feed Heater Tube Side in kg/cm2g 28.52 28.52 28.52 28.52 28.52 28.52

HB Reflux to LB Feed Heater Shell side out Temp.

0C 140 149.49 153.27 159.76 138.52 153.27

HB Reflux to LB Feed Heater Shell side out Pressure kg/cm2g 8.18 8.18 8.18 8.18 8.18 8.18

HOT FLUSH PUMP Discharge Pressure kg/cm2g 195 195 195 195 195 195 STEAM PURGE HEATER Hot Flush (Tube Side) in/out Temp. 0C 52-162/225 52-162/225 52-162/225 52-162/225 52-162/225 52-162/225 DTA PURGE HEATER Hot Flush (Tube Side) Outlet temp. 0C 310 310 310 310 310 310

LB FEED HEATER NO. 2 Tube side outlet Temp. 0C 162 162.39 230.6 169.36 232.74 230.66 Condensate Pot (31-V-212) Level % 20-50 20-50 20-50 20-50 20-50 20-50

LB FEED CONDENSER

Vap. From IPS (Tube Side) Out Temp.

0C 216.9 211.87 224.97 227 225 225

Vap. From IPS (Tube Side) In Pressure kg/cm2g 24.5 24.5 24.5 24.5 24.5 24.5

Shell side Level % 75-80 75-80 75-80 75-80 75-80 75-80 Shell side Temp. 0C 201 201 201 201 201 201

Shell side Pressure kg/cm2g 15 15 15 15 15 15

LB COLUMN

Col. Top/Bottom Temperature 0C 97.5/227.6 100.3/227.7 99.5/233.4 102/233.4 96.8/242.5 96/233.4 COLUMN PRESSURE kg/cm2g 21.2 21.2 21.2 21.2 21.2 21.2 Reflux Flow Rate to Column 117.2-140.6 135.5-162.5 120.3-144.4 67.1-80.5 68.7-82.5 136-163 Base Flow Rate 189-226.8 178-213.8 192-230 210.5-252.6 203.7-244.4 192.3-230.8 Base Level % 20-60 20-60 20-60 20-60 20-60 20-60

LB REBOILER DTA Vap Flow MT/hr 96.5-115.8 99.5-119.5 93.5-112.2 93.1-111.7 80.5-102.6 85.5-102.7 DTA Vap flow to Base Flow Ratio 0.51-0.61 0.55-0.67 0.487-0.58 0.44-0.53 0.4-0.50 0.44-0.53

LB CONDENSSER Outlet Temperature 0C 65 69.7 65 65 65 65 LB RTRIM CONDENSER Outlet Temperature 0C 61.36 69.7 60.8 59.55 60.09 50.36



Doc. No.: 2317 Rev. 0 of 623

OPERATING CONDITIONS A200 11Q4 61B 2712 59A OCTE NE 2712(LC)

Outlet Pressure kg/cm2g 20.59 20.59 20.59 20.59 20.59 20.59

LB REFLUX DRUM Temperature 0C 61.36 69.7 60.8 59.5 60.1 50.3 Pressure kg/cm2g 20.59 20.59 20.59 20.59 20.59 20.59 Level % 30-80 30-80 30-80 30-80 30-80 30-80

FE COLUMN FEED DRYER COOLER

LB Reflux to Cooler in/out Temperature

0C 62.6/36 71.09/36 62.14/36 60.7/36 61.4/36 51.5/36

FE COLUMN

Col. Top/Bottom Temp. 0C -27.28/108.15 -27.65/108.13 -28.69/107.94 -31.5/107.77 -27.29/107.77 -27.99/107.97 COLUMN PRESSURE kg/cm2g 20.38 20.38 20.38 20.38 20.38 20.38 Feed Flow Rate MT/hr 21.7-24.7 30.4-33.4 26.36-29.36 23.34-25.34 20.2-23.2 32.8-35.8 Overhead Flow Rate MT/hr 2.1-2.4 2.2-2.258 2-2.34 1.1-1.3 2.02-3.33 3.5-4.0 Base Flow Rate MT/hr 19.6-22.6 28.1-31.1 24.3-27.3 21.1-24.1 18.1-21.1 29.3-32.3 29th Tray Temp. 0C -25.07 -25.07 -25.44 -26.1 -25.15 -25.44 Base Level % 40-80 40-80 40-80 40-80 40-80 40-80

FE REBOILER Steam Flow Rate MT/hr 2.4-2.9 3.3-4 2.8-3.4 2.3-2.8 2.2-2.7 3.68-4.4

Condensate Pot (31-V-210) Level % 20-50 20-50 20-50 20-50 20-50 20-50

CM COLUMN

Column Top/Bottom Temp. 0C 55.63/68.23 55.62/68.22 55.5/70.6 55.39/61.2 55.4/62.95 55.59/71.3 Column Pressure kg/cm2g 6 6 6 6 6 6 Feed Flow Rate MT/hr 19.62-23.5 28.12-33.8 24.32-29.2 21.12-25.4 18.12-21.2 29.32-33.2 Reflux Flow Rate MT/hr 41-49 58-70 24-29 26-31.4 27.7-33.3 21.7-26 Base Level % 20-50 20-50 20-50 20-50 20-50 20-50

CM REBOILER Condensate Pot (31-V-211) Level % 20-50 20-50 20-50 20-50 20-50 20-50

CM CONDENSER Cooling Water Flow Rate MT/hr 400-463.5 576-663 326-374 316-363 306-352 341-392 Condenser Outlet Temperature 0C 52.4 52.4 52.3 52.24 52.24 52.4

CM REFLUX DRUM Temperature 0C 52.4 52.4 52.3 52.24 52.24 52.4 Pressure kg/cm2g 5.75 5.75 5.75 5.75 5.75 5.75 Level % 30-100 30-100 30-100 30-100 30-100 30-100

HB COLUMN

Column Top/Bottom Temp 0C 180.52/184.25 180.52/184.33 182.24/184.22 182.24/183.99 188.86/228 182.24/184.2 COLUMN PRESSURE kg/cm2g 9.3 9.3 9.3 9.3 8.3 9.3 Feed Flow Rate MT/hr 189-226.8 178-213.8 192-230 210.5-252.6 203.7-244.4 192.3-230.8 Reflux Flow Rate MT/hr 75.33-90.4 70.85-85 76.6-92 84-100 101-121 76.6-92 Base Flow Rate MT/hr 25-29 25.2-29 25.2-29 25.2-29 25.2-29 25.2-29 Base Level % 20-80 20-80 20-80 20-80 20-80 20-80

HB REBOILER Steam flow rate Ratio 15.5-17.3 13.8-15.3 6.5-6.6 1.7 28.75-33 9.8-10.6 Condensate Pot (31-V-208A/B) Level % 20-50 20-50 20-50 20-50 20-50 20-50



Doc. No.: 2317 Rev. 0 of 623

OPERATING CONDITIONS A200 11Q4 61B 2712 59A OCTE NE 2712(LC)

HB CONDENSER

Shell side Level % 75-80 75-80 75-80 75-80 75-80 75-80 Shell side Temp. 0C 159 159 159 159 159 159 Shell side Pressure kg/cm2g 5.1 5.1 5.1 5.1 5.1 5.1

Condenser Outlet Temperature 0C 172.5 172.5 179.5 179.5 180.98 179.5

HB REFLUX DRUM

Temperature 0C 172.5 172.5 179.5 179.5 180.98 179.5

Pressure kg/cm2g 9 9 9 9 8 9

Level % 50-100 50-100 50-100 50-100 50-100 50-100

RB COLUMN

Column Top/Bottom Temp. 0C 140.3/210 140.3/210 140.3/210 140.3/210 183.96/211.8 140.3/210 COLUMN PRESSURE kg/cm2g 3.6 3.6 3.6 3.6 3.3 3.6 Feed Flow Rate MT/hr 25-29 25.2-29 25.2-29 25.2-29 25.2-29 25.2-29 Reflux Flow Rate MT/hr 9.8-11.8 9.8-11.8 9.8-11.8 9.8-11.8 9.5-11.4 9.8-11.8 Base Level % 20-80 20-80 20-80 20-80 20-80 20-80

RB REBOILER LP DTA Flow Rate MT/hr 20.7-23.8 20.65-23.7 20.7-23.8 20.9-24 14.6-16.8 14.6-16.8 RB CONDENSER Condenser Outlet Temperature 0C 137.2 137.2 137.2 137.2 179 137.2 RB REFLUX DRUM Level % 30-80 30-80 30-80 30-80 30-80 30-80



Doc. No.: 2317 Rev. 0 of 623

OPERATING CONDITIONS A300 11Q4 61B 2712 59A OCTE NE 11L2B

UNDERWATER PELLETIZER Water Circulation MT/hr 545-682 592-740 630-788 484-606 555-694

Water Circulation Temperature oC 37 37 37 37 37

Nitrogen To Cutter kg/hr 83-157 83-157 83-157 83-157 83-157

RESLURRY WATER HEATER Water In/out Temperature oC 54.72/98 54.72/98 54.72/98 54.72/98 54.72/98 Heater Cond. Level % 20-50 20-50 20-50 20-50 20-50

RESLURRY TANK Reslurry Tank Water Flow MT/hr 84-113 91-123 97-151 74-100 85-115

Reslurry Tank Water in/out Temperature oC 98/81.8 98/81.87 98/81.9 98/81.79 98/81.85

Reslurry Tank Level % 20-80 20-80 20-80 20-80 20-80

RESLURRY PUMP Discharge Pressure kg/cm2g 5.5 5.5 5.5 5.5 5.5 Flow Rate MT/hr 136-164 147-177 157-188 121-145 138-166

RA STRIPPER

Stripper Pressure kg/cm2g 0.003 0.003 0.003 0.003 0.003

Steam Temp. at Stripper Base oC 103.12 103.11 103.12 103.11 103.12

Steam Temp. at Stripper Cone oC 103.12 103.11 103.12 103.11 103.12

Steam Flow Rate at Striper Base MT/hr 2.273-3.9 2.468-4.2 2.68-4.4 2-3.5 2.3-4 Steam Flow Rate at Stripper Cone MT/hr 2.273-3.9 2.468-4.2 2.68-4.4 2-3.5 2.3-4

Stripper Top Temp. oC 98 98 98 98 98 Water Inlet Temp to Stripper oC 37 37 37 37 37

Water Flow Rate to Stripper Cone MT/hr 45-68 49-74 52-78 40-60 46-60 Stripper Level % 75-90 75-90 75-90 75-90 75-90

SOLVENT VAP. COND. (31-EA-301) In/Out Temp. oC 108.81/65 108.29/65 107.77/65 109.97/65 108.79/65

SOLVENT VAP TRIM COOLER outlet Temp. oC 45 45 45 45 45

WATER RESERVIOR Water Outlet Temp. oC 54.5 54.5 54.5 54.5 54.5

WATER COOLER (31-E-308A/S) Water Outlet Temp. oC 37 37 37 37 37



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11Q4 61B 2712 59A OCTE NE

2712(LC) 11L2B

DTA Regeneration Vessel Temperature oC 265-280 265-280 265-280 265-280 265-280 265-280 Pressure kg/cm2g 0.2 0.2 0.2 0.2 0.2 0.2

DTA Storage tank Temperature oC amb. amb. amb. amb. amb. amb. Pressure kg/cm2g 0.1 0.1 0.1 0.1 0.1 0.1

SH De-inventory Temperature oC 15-40 15-40 15-40 15-40 15-40 15-40 Pressure mmWC 70 70 70 70 70 70

Waste Drum Temperature oC 70 70 70 70 70 70 Pressure kg/cm2g 6.5 6.5 6.5 6.5 6.5 6.5

Waste Fuel Tank Temperature oC 220 220 220 220 220 220 Pressure kg/cm2g 2.5 2.5 2.5 2.5 2.5 2.5

DTA Vent Receiver Temperature oC 150-207 150-207 150-207 150-207 150-207 150-207

Pressure kg/cm2 (abs) 0.2-0.3 0.2-0.3 0.2-0.3 0.2-0.3 0.2-0.3 0.2-0.3

Xylene Storage tank Temperature oC amb. amb. amb. amb. amb. amb.


FB Surge Tank Temperature oC 40 40 40 40 40 40

Pressure kg/cm2g 4.47 4.47 4.47 4.47 4.47 4.47

FC De-inventory Tank Temperature oC 51.1 51.1 51.1 51.1 51.1 51.1 Pressure kg/cm2g 13 13 13 13 13 13

HP DTA COND. TANK Temperature oC 313 313 313 313 313 313


LP DTA COND. TANK Temperature oC 260 260 260 260 260 260 Pressure kg/cm2g 1 1 1 1 1 1

HP STEAM COND. DRUM Temperature oC 159 159 159 159 159 159

Pressure kg/cm2g 5.1 5.1 5.1 5.1 5.1 5.1

LP STEAM COND. DRUM Temperature oC 107 107 107 107 107 107

Pressure kg/cm2g 0.3 0.3 0.3 0.3 0.3 0.3

COND. RETURN COOLER Cooler Return Temperature oC 90 90 90 90 90 90

Cooler Return Pressure kg/cm2g 3 3 3 3 3 3



SECTION-13.0 EFFECT OF OPERATING VARIABLES



13. Effect of Operation Variable : 13.1 Introduction:

This section gives the guidelines on controlling both product and process parameters. Most of the

mechanism used to control a particular parameter also affects other parameters.

Parameter control ranges from Reactor condition through to resin property control, including colour and

pellet size, Guidelines for upgrading off standard production lots (or batches) of resin by blending are also

explained.

13.2 Parameters: Melt Index: Melt Flow Index defined in American Standard

Testing Methods D 1238 using 2160 g.

Stress Exponent: log 6/ 20.447 log

log

Where I2 is melt index flow with 2160 g

Where I6 is Melt Index flow with 6480 g

Density Density in gm/cc of solid RA

Specific Gravity

Molecular Weight General term for the variation for molecular weight about the mean

Distribution molecular weight

M. W. Molecular Weight

Mw Weight Average Molecular Weight

Mn Number average Molecular Weight

Mw/Mn ration Measure of breadth of MWD = 1.0 if MW is uniform

Shear Stress r x ∆P/2L for circular die radius r, length L and differential pressure

(∆P)

Shear Rate 4Q/r3 for circular die radius r, volumetric flow Q

Viscosity (apparent)

High Shear Viscosity

at 600 sec-1 shear rate

using 40:1 L/D die, 190°C

Melt Swell

X 100



13.2.1 Basic Control Parameters: 13.2.1.1 Density 13.2.1.1.1 Measurement Polymer density, like any other density, is weight per unit volume. The density of SCLAIRTECH resin

is measured by use of a densimeter which utilizes Archimedes' principle to evaluate density. In this

case the sample is weighed directly, and then the volume obtained by measuring the weight of the

displaced water. Other methods for obtaining density may be used such as a gradient tube. In this case a

tube is filled with liquid of varying density and calibrated. A sample is put into the tube and allowed to settle

at the level consistent with the density of the liquid. This is an accurate, but time consuming method. Both

of these methods are used for determining the density of the solid polymer.

It is important to remember that in doing density tests that the rate of cooling is important. A faster sample

cooling time will result in a lower calculated density. As well over time any polymer sample will increase

its level of crystallinity and thus its density. It is vital then, that the test method be adhered to in all cases. 13.2.1.1.2 Effect on Physical Properties: At different densities the customer sees changes in the physical properties of the resin. These are

outlined generally in Figure 12.2.1 and more specifically in Figure 12.2.2. As indicated, a low density

polymer is quite flexible, stretchy, clear and is very resistant to environmental stress crack. The higher

density polymer, on the other hand, is stiffer, stronger, hazier, less permeable to water and has a higher

softening point.

Fig. 13.2.1 Effect of Density on Process ability and Product Properties

13.2.1.1.3 Control of Solid Polymer Density 0.920 Density 0.960 DensityTensile Yield 1600 PSI 4400 PSI Elongation At Break 900% 50% Flexural Stiffness 35,000 150,000 Softening Point 100°C 130°C Permeability (H2O) 10 UNITS 1 UNIT Haze LOW HIGH Environmental Stress Crack Resistance 1,000 HRS, (1.0 MI) 15 HRS.

Dielectric Constant 2.28 2.36

Fig. 13.2.2 Effect of Density on Physical Properties



13.2.1.1.3.1 Branching: Density variations in the solid polymer are primarily controlled by the amount of comonomer present in

the resin. SCLAIRTECH process uses butene and octene as comonomers. The comonomer adds onto the

ethylene as branches or side chains. With a large amount of side chains or branches the density is lower. A

homopolymer has a high density. This phenomena is known as "short chain branching". The effect of

comonomer content in the polymer can be seen on Figure 13.2.3 and 13.2.4.

Note: That the line curves upwards in Figure 13.2.3, but can be straightened out by using a log-log

scale and an empirical constant of +0.01.

Fig.13.2.3: Effect of Comonomer on Content on Density (STD Catalyst)

The branching of the comonomers affects how well the molecules fit together on cooling, or their

crystallinity. Density tends to reflect the level of crystallinity in the solid polymer. A highly crystalline

structure has a high density. A structure of lower crystallinity has a lower density. The normal density range

for SCLAIRTECH polymer is 0.920-0.960. Densities beyond this range have been produced (i.e. up to

approximately 0.972, and down to 0.912) but they tend to be of limited usefulness. At 0.972 density the

polymer would be close to 90% crystalline. At 0.912 it would be approximately 40% crystalline.



Fig.13.2.4: Effect of Comonomer content on Density (Log Log Plot)

Since the amount of comonomer in the resin is the most important control mechanism for density it is

important to be able to estimate how much butene is required to produce a given density. To do this curve

Figure 13.2.5 is used.



Fig.13.2.5: Estimating Comonomer content

Figure 13.2.5 plots final FB in polymer to FB/FEavg. As a useful rule of thumb a 1:1 ratio of FB to FE in will

yield approximately 3% FB in the final resin. The reason that this amount is so low is that the FB molecule

is much larger than the FE molecule. The smaller FE molecule is more mobile and can access the

catalyst site more readily resulting in a higher reactivity for the FE molecules. This effect is even more

pronounced for the still larger FC molecules where a 1:1 ratio will only give about 2% FC in the resin.

Reactivity of the FE molecule is about 30 x higher than the FB molecule and about 50x higher than the FC

molecule.

13.2.1.1.3.2 Melt Index: There is also an effect of Melt Index on density. Melt Index is inversely related to molecular weight and will

be covered in more detail later. Figure 13.2.6 shows the effect of MI on density (with the stress

exponent and amount of comonomer held constant for each reactor type).

Short polymer chains (or high MI) tend to cool more evenly, and crystallize more effectively resulting in

a higher density. The longer chains (or lower MI) have more trouble packing tightly and cooling evenly with

the result that they are less dense. The very high density polymer at the top right of the graph is extremely

brittle.



Fig.13.2.6: Effect of Melt Index on Density

13.2.1.1.3.3 Stress Exponent: Stress Exponent, which is related to the width of the molecular weight distribution, also has an effect on

density (with all other things held equal). Control of Stress exponent will be covered later in this section.

Figure 13.2.7 shows the effect of stress exponent on density.

Fig.13.2.7: Effect of Stress Exponent on Density



From Figure 13.2.7, it can be seen that as the stress exponent goes up, the density of the resin goes up

also. In this figure the Y axis is shown as the delta density (or the density of the homopolymer less

the density of the copolymer) becoming more negative. This occurs because with the stress exponent

going up, a lot of short chains (grease or RB) are produced. These shorter chains tend to crystallize

more quickly, and pack more effectively.

13.2.1.1.4 Molten Polymer Density: In general all molten polymer has the same density (0.764 gm/cc at 190°C). There is a slight effect of

temperature on the melt density as is shown in Figure 13.2.8. This curve is useful for homopolymers or

any of the copolymers made with the SCLAIRTECH process. The range shown reflects testing done at

different times.

Fig. 13.2.8: Liquid Polyethylene Density

13.2.1.2 Melt Index: 13.2.1.2.1 Measurement: Melt Index is inversely related to the molecular weight of the polymer. Polymers made from long chains

have a low Melt Index or MI, and polymers made up of short chains have a high MI. Melt Index is

measured using a 2160 gram weight to force the melted polymer through a die. The amount of polymer that

flows through over a 10 minute period is considered the Melt Index. The die itself is quite short (3.8:1 L/D),

which makes it a poor representation of commercial dies. A longer die, as is found in normal commercial

applications has less effect from the entrance of the die itself and, as a result, will see less swelling of the

polymer on exit. Although the test is a poor representation of industrial use, it is still accepted as the

industry standard for this polymer property. The melt index test is essentially a measure of viscosity within

a specific shear rate range. Figure 13.2.9 shows this relationship.



Fig. 13.2.9: Melt Properties

Note the difference between the range of shear rate in the MI test Vs that used in commercial processing.

This high shear area is important for determining required extruder horsepower to push the melt

through a commercial die. The other area that is important is the very low shear range where melt

strength is measured. This is important to determine whether the melt will hold its shape until freezing. It

is especially important in applications such as bottles and pipe. At zero shear rates the viscosity

correlates quite well with molecular weight, and because of this the viscosity correlates well with MI

Figure 13.2.10 shows this relationship between viscosity at zero shear and molecular weight.

Fig. 13.2.10: Effect of Molecular Weight on Viscosity at Zero Shear Rate



As previously mentioned MI is inversely related to the chain length or molecular weight and because of this it

is also inversely related to viscosity. High MI resins have low viscosity, low MI resins have high viscosity. An

MI of 0.01 would correspond to a molecular weight of approximately 350,000 while an MI of 200

would correspond to a molecular weight of 28,000. The relationship between MI and molecular weight is

evaluated by use of a GPC (Gel Permeation Chromatography). Figure 13.2.11 shows the relationship

between MI and molecular weight for SCLAIRTECH resins.

Fig. 13.2.11: Correlation between MI and MW

Molecular weight itself is usually determined on either a number or weight basis. These two functions

are shown in Figure 13.2.12.

Fig. 13.2.12: Molecular Weight Definitions



The number average molecular weight of the polymer will normally be lower than the weight average

molecular weight. The only time that these two values are equal is when there is a perfectly uniform

polymer. The number average molecular weight is very sensitive to grease and other small molecules

which are high in number for a given weight. Figure 13.2.13 shows the differences in the molecular

weight values for some typical SCLAIRTECH resins.

Sample

Mw/MnMolecular Wts. (K) Cumulative Weight Percentages

Mn Mw Mz 1000K 700K 500K 300K 100K 10K 5K 2K

11D (11536) 4.12 34.7 143 578 1.8 3.2 5.2 10.8 35.8 94.9 98.3 100.0

14C (LAO#37) 4.1 26.3 108 394 0.9 1.7 3.1 7.2 28.9 92.9 97.3 99.5

2916 2.81 13.2 38.2 87 0 0 0 0.4 6.4 81.1 91.9 98.6

35B (8193A Bk) from 14084

9.3 19.4 180 1013 4.0 6.1 8.7 14.3 32.6 88.2 94.5 98.8

44H (81667) E417-01

16.7 12.6 210 1744 5.6 7.4 9.4 13.1 26.4 80.4 89.4 97.3

51-35B (03743) 11.0 17.9 197 1197 4.7 7.0 9.7 15.0 32.7 87.5 94.0 98.6

58A (00595) 13.9 13.6 189 1388 4.8 6.8 9.0 13.3 27.9 81.7 90.4 97.6

8507 (82327) 3.3 23.5 77 215 0.1 0.5 1.2 3.7 21.0 91.2 96.7 99.6

96A UVI (82517) 10.0 19.9 198 1261 4.8 7.1 9.5 14.5 31.3 88.2 94.7 99.0

99C UVI (20389) 11.8 14.8 174 1077 4.2 6.5 9.0 13.9 28.7 83.7 92.0 98.1

Fig. 13.2.13: Molecular Weight Distribution 13.2.1.2.2 Effect on Physical Properties: As in density, the customer will see a change in physical properties as the MI changes. These are

outlined in Figure 13.2.14 (a and b). Primarily as MI goes up (and the chains become shorter) the

strength properties go down, (namely tensile strength, impact strength, stress crack, etc). Thus there is

always compromise required between processability and the physical properties of strength and toughness.

As M.I. Elongation To Break Ultimate Tensile Strength Dart Impact (Film) Impact Strength Pipe (Hrs To Burst) E.S.C.R.

Fig. 13.2.14a: Effect of Melt Index on Physical Properties



Fig.13.2.14b: Effect of Melt Index on Polymer Properties

13.2.1.2.2 Control of Melt Index: Control of MI is done by controlling molecular weight. This is done by controlling the rate of polymer

growth Vs the chain transfer rate. The polymer growth rate is proportional to the concentration of FE.

The chain transfer rate is the rate at which the growing chains break off from the catalyst sites. Factors that

affect the rate at which the chains break off include temperature, hydrogen and comonomer. If the

temperature is higher there is more energy vibrating the molecules and they break away from the

catalyst sites more readily. Once the chains break loose another chain begins to grow at the same catalyst

site. Hydrogen will add on to the chain, on the final atom, and causes it to break off. The site remains active

and a new chain begins to grow. In this function of assisting the old chain to break away and the new

one to begin growing, the hydrogen is called a telemer, or a chain transfer agent. The smallness and

mobility of the hydrogen atom makes it very effective in this role.

The comonomer, if added in the chain, makes the chain somewhat weaker at that point and allows it to

break away more easily. Thus the addition of comonomer to control density also has some effect on

chain transfer causing the chains to break away more easily and the MI to go up. What this means is that to

control the density using FB or FC, while holding the MI constant will also require some adjustments

in temperature and/or hydrogen level to compensate for the FB or FC change. These effects are

summarized in Figure 13.2.15.

Fig. 13.2.15: Control of Molecular Weight



13.2.1.3 Stress Exponent: 13.2.1.3.1 Measurement: The stress exponent test is specific to the SCLAIRTECH process. The test is identical to the melt index test

but uses both the 2160 gm weight and a 6480 gm weight (3x heavier). The stress exponent is defined as:

This essentially provides some means to judge the non-Newtonian nature of the polymer. A stress exponent

of 1 would mean that if three times the weight were applied, three times the flow would result. Stress

exponent varies with the width of the molecular weight distribution. An example of a typical molecular

weight distribution is shown in Figure 13.2.16.

Fig. 13.2.16: Typical Molecular Weight Distribution

Differences in the molecular weight distribution at different stress exponents are shown in Figure 13.2.17.

As previously mentioned both number average and weight average molecular weights can be determined.

The ratio of weight average molecular weight to number average molecular weight is a good representation

of how broad the molecular weight distribution is. If the Mw/Mn ratio is 1 then the polymer is perfectly

uniform. Other expressions can be used that incorporate the same principles, and give increasing weight to

the long chains. Typical of this is the Mz value, shown in Figure 13.2.12. This value would be used to

correlate properties that depend on long chains, properties such as melt swell.



Fig. 13.2.17: Difference in Molecular Weight Distribution and Stress Exponent

13.2.1.3.2 Effect on Physical Properties: Differences in stress exponent are apparent to the customer in the processing of the resin (see Figure

13.2.18). A low stress exponent resin will maintain its viscosity over a wide range of shear rates. A higher

stress exponent resin will have higher melt strength (viscosity at low shear rates). Processing of products

such as bottles require easy processing at high shear rates but high melt strength as the product cools. The

actual slope of the viscosity Vs shear rate curve is related to the stress exponent. The combination of the

melt index, and the stress exponent help to identify this curve, with melt index fixing the middle section, and

stress exponent establishing the slope. This curve gives a good indication of how the polymer behaves

over a wide range of shear rates. Stress exponent also has an effect on physical properties of the

finished product. As stress exponent goes up qualities such as film gloss, impact strength and creep

resistance deteriorate. Warpage also gets worse because of the varying freezing times of small Vs long

molecules. Because of these effects, products such as film, where physical appearance and impact strength

is so important, require fairly narrow or low stress exponent resins. These properties are summarized in

Figure 13.2.19.

Fig. 13.2.18: Effect of Stress Exponent on Melt Properties



Fig. 13.2.19: Effect of Stress Exponent on Polymer Properties

The Mw/Mn ratio can be correlated to stress exponent using the slope of the viscosity/shear rate line.

Figure 13.2.20 show viscosity Vs shear rate for a typical SCLAIRTECH resin (58A). Since the slope of

this line is related to Stress Exponent (and because of this to Molecular Weight Distribution), the

slope should also correlate to the Mw/Mn ratio. Figure 13.2.21 shows this relationship. Note that it is a

positive correlation.

Fig.13.2.20: Correlation of Viscosity and Shear Rate

13.2.1.3.3 Control of Stress Exponent: Control of stress exponent primarily involves control of the molecular weight distribution. In general to make

a narrow molecular weight distribution resin (low stress exponent) a stirred autoclave is used which makes

a very uniform product. To make a broad resin a tubular reactor is used. The tubular reactor is



comparatively uneven, with high molecular weights being produced at the beginning (where there is a

high concentration of FE and quite low temperatures) and short chains being produced at the end (where

there is a lower concentration of FE and higher temperatures). Within the reactor type some variation can

be made by use of hydrogen (J) etc. These will be explored as we discuss control within each reactor type.

Fig.13.2.21: Correlation of Mw/Mn to Stress Exponent

13.3 Common Control Elements 13.3.1 FE Conversion Determination FE conversion measurement and control is essential to get the required RA rate and control of RA

parameters such as density and Melt Index. A low conversion may also cause phase separation in the

Solution Adosrbers and upset the Recycle Area, The symbol “Q” is used to denote FE conversion.

FE Conversion (Q%)= ((%FEin-%FEout))/(%FEin) x 100= (%RA x 100)/(%FEin) A fast measurement of Q is obtained from overall reactor differential temperature (Tout – Tin) which varies as

% RA.

Q% = (%RA*100)/(%FEin)=(Differential Temperature)/X x 1/(%FEin) x 100

X varies from 12 to 13.5 depending on the mean reactor temperature. This factor is based on experience.

The standard reactor conditions have been set to include this factor.

To quickly obtain the conversion specified in the standard reactor conditions, aim to establish the predicted

differential temperature. If %FE is accurate this should give conversion within 2% of the target.

NOTE: % RA should be adjusted downward by the comonomer component if present.



After conversion is on target, the operator should continue to watch total differential temperature for early

warning of conversion changes. A sharp drop in differential temperature (unless due to %FE dropping)

signal a conversions loss due to impurities or catalyst changes. The operator should check catalyst readings

and increase catalyst to correct the differential temperature.

A differential temperature variation of 2°C call for corrective action. A differential temperature loss of 10°C

may require termination of reaction unless quickly corrected.

13.3.2 Conversion Control and Active Catalyst Formation: FE conversion in the Reactor is controlled by varying the active catalyst concentration. Two different

methods of forming the active catalyst are used.

13.3.2.1 Regular Catalyst (CAB-CT) Mode: The active catalyst is formed by combining two catalyst components, CAB and CT, 2 to 5 seconds before

entering the reactor. CAB is a 80/20 mole% mixture of VOCl3 and TiCl4, pre-mixed in that ratio to give

maximum activity and the correct stress Exponent (narrow molecular weight distribution). CT is Tri-ethyl

Aluminium, an organic reducing agent. This reduces the of VOCl3+TiCl4 to lower valence states which,

unlike the soluble CAB, are micro-crystalline insoluble particles with alkylated active sites on the surface.

These active sites will combine FE molecules (also FB-1 or FC-1) to grow a linear polyethylene molecule,

which is attached to the active site. The polymer molecules will periodically break off, allowing new

molecules to grow on the site.

13.3.2.2 High Temperature Catalyst (HTC) Mode: The HTC system is an alternative method of alkylating the VOCl3+TiCl4 mixture to form a more efficient

catalyst. This catalyst makes similar resins to standard catalyst at higher reactor temperature, which saves

energy. CAB-2 is a 50/50 mole% mixture of VOCl3 and TiCl4. The CAB-2 is first mixed with CD (reducing

agent) for 30 seconds. After this 270°C solvent is added to control the catalyst temperature at 230°C for 60

seconds hold-up time. About 2 seconds before entering the #1 reactor, a second co-catalyst, CJ (alkylating

agent) is added to the heat-treated CAB-2/CD mixture. The CAB-2, CD, CJ product then enters the Reactor

where it controls conversion. Hot and cold High-pressure Diluent flows are used to control the hold-up time

in each catalyst section.

13.3.3 Density Control: The solid polymer density determines its stiffness and toughness. Lower density is less stiff by tougher.

Density depends on the %FB (or %FC) in the polymer molecules, and is controlled by varying the ratio of

FB-1 (or FC-1) to FE molecules present at the catalyst site. The FB molecule and FC molecules inserted in

the growing polymer molecule give short side branches to the linear polymer molecule. FB-1 molecules give

a 2-carbon atom side branch (Ethyl) and FC-1 gives a 6-carbon atom side branch (Hexyl).



A homopolymer containing only ethylene has a density of about 0.960 while a 0.920 density copolymer

needs about 7% FB or 9.5% FC. The FC copolymer is tougher than the FB copolymer for a given density,

Density can be controlled from about 0.915 to 0.960 in this process.

In controlling density, a 1:1 ratio of FB: FE in the reactor gives about 3.0% FB in RA while 2:1 gives 6% FB in

RA. FE is about 33 times more reactive than FB. FE is also 50 times more reactive than FC and 1:1 FC/FE

will give only 2% FC in RA. The ratio of FB-1/FE or (FC-1/FE) at the catalyst site is controlled by varying the

feed FB-1/FE or (FC-1/FE) ratio and the FE conversion.

[FE] reactor = % FEin (1-Q)

NOTE: Only those olefins higher than FE with terminal double bonds are reactive (FB-1, FC-1) so FB-2 and

FC-2, FC-3 etc. which have internal double-bonds, are unreactive. The unreactive FB-2 and FC-2 isomers

may be present in the feedstock or formed by isomerisation in the solution adsorbers and must be purged to

prevent accumulation. Gas chromatograph readings of the comonomer reactor feed give %FB-1 in total FB.

This allows the FB-1/FE ratio to be controlled. The same is true for FC.

13.3.4 Molecular Weight and Molecular Weight Distribution The molecular weight of the polyethylene governs how easily the molten polymer processes (the viscosity)

and along with density, determines the sold-state strength. High molecular weight polymer has improved

strength but is more viscous and difficult to process. Molecular weight and molecular weight distribution

(MWD) can be measured directly by size exclusion chromatography in an analytical laboratory. For plant

control, however convenient measurements are Melt Index (MI) and Stress Exponent (SE) which

approximately ensures average molecular weight (Mw) and Molecular Weight Distribution (MWD)

respectively.

NOTE: MI varies inversely as Mw.

The Melt Index is a measure of molten polymer flow under constant pressure. The Stress Exponent reflects

the ratio of melt flow increase at three times the pressure, a high MI indicates a low Mw and polymer which

will flow readily. A high SE indicates a broad MWD or high Mw/Mn polymer which will show sharply

decreasing viscosity at higher shear rate. An SE of 1.0 is an ideal (Newtonian) fluid (Mw/Mn=1.0) with

constant viscosity vs. Shear rate. Polyethylene MI can be controlled from 0.15 to 150 and SE from 1.15 to

2.2.



Corresponding Viscosity’s

MWD and Viscosity 13.3.5 Melt Index Control (MI)

Melt Index (approx. 1/ Mw) is controlled by varying the rate (called the transfer rate) polymer molecules

break away from the catalyst site (and a new molecule begins growing) divided by the growth rate.

However, the transfer rate depends mainly on Reactor temperature, hydrogen concentration and

comonomer (FB-1) concentration. Growth rate depends on FE concentration in the Reactor [=%FEin (1-Q)].

therefore:

MI (Transfer Rate)/(Growth Rate)=(K1 [Temp]+ K2[J]+ K3[FB])/(Kp[FE])

where: K1, K2, K3, Kp are rate constant.



MI in normal practice is controlled by Reactor temperature, J concentration to FE concentration and FB-1/FE

ratio with [FE] maintained constant for economic reasons (maximum % FEIN and optimum Q).

NOTE: FB-1/FE also determines density control so Melt Index and density control interact.

13.3.6 Stress Exponent Control (SE) SE which measures MWD, is controlled by varying the range of molecular weight made in the Reactor. A

perfectly stirred autoclave (#1) Reactor with constant temperature, FE, FB and J concentration makes a

uniform MW, (and narrow MWD). An unstirred adiabatic tubular reactor (#3→1 reactor) with a wide range of

temperature (100°C to 300°C) and FE concentration (17% to 1%) will make a broad range of molecular

weights. Stress Exponent ranges from 1.6 to 2.2 depending on how the J concentration profile throughout

the Reactor is manipulated.



13.4 #1 Reactor Control: 13.4.1 System Description: The No.1 Reactor set up is shown in Figure 13.4.1. The No.1 Reactor is a stirred autoclave, and is followed

by a tubular trimmer reactor, which could appropriately be considered an after burner. The feed

temperature is controlled by the mean reactor temperature which is measured at a point situated

approximately 2/3 down No.1 Reactor. The feedstock entering the reactor passes through a tempering

system which results in the appropriate feed temperature being delivered to the reactor. Another important

temperature for control is the total delta T. This is the difference between the temperature at the outlet of

the trimmer reactor less the inlet temperature. The delta T across the No.1 Reactor alone and the trimmer

reactor alone are also determined. These values are useful in setting up and optimizing process conditions.

There are three entrances for the feedstock to the reactor vessel. The first of these is at the reactor

base. The second and third are situated on opposite sides of the reactor, partways up, and are used for

resins requiring "split feed". The resins requiring this setup are primarily low MI resins, which because of

their high viscosity do not mix well. The catalyst and co-catalysts enter from the bottom of the reactor

close to tip of the bottom paddle of the agitator.

The agitator has five sets of blades, with 8 paddles per set. The paddles themselves angle downwards

at 45°. The agitator runs at range of 200 to 285rpm. This speed is important as it optimizes the deflection

that occurs because of the natural frequency of vibration for the agitator. The critical nature of this agitator is

also reflect ed in the high level of sophistication of the agitator seal.

The reactor [autoclave] volume, for a plant of 350 KTA size, is approximately 7.2 m3, and the trimmer

reactor volume is approximately 55% of the reactor volume. The material of construction for the reactor is

carbon steel.

The trimmer reactor is an adiabatic tube. It normally runs at approximately 10% of the overall conversion

and overall delta T. It allows the No.1 reactor to operate at lower levels of conversion, and with less

catalyst, while maintaining the same overall conversion over the system.



Fig. 13.4.1: No. 1 Reactor Physical Setup

13.4.2 Density Control: Density depends mainly on the %FB incorporated into the resin. There are also MI and MWD effects on

density. Compared to a 5 MI with the same % FB in RA, a 50 MI resin has about 0.008 higher density and a

0.5 MI resin has 0.008 lower density.

Control of density is primarily accomplished by control of the amount of comonomer present in the resin.

There is also a lesser effect from the melt index. These effects for FB are summarized in Figure 13.4.2

Fig. 13.4.2: Effect of Comonomer and MI on Density

Density goes down with increasing levels of comonomer, and goes up with higher melt index. Control of

the amount of comonomer in the resin is accomplished by controlling the ratio of comonomer to average

ethylene. This relationship, and how it can be used to determine the amount of comonomer needed for a

specific density and melt index is shown in Figure 13.4.3.



Fig. 13.4.3: Controlling Comonomer Content

For example, if a resin with a density of 0.935 and a melt index of 4.0 is required, and FB is the

comonomer, it is apparent that approximately 3% FB in the resin is required, and this will be achieved by

having a ratio of approximately 0.8 (FB/FE)av.

The desired ratio (FB/FE)av is then used to determine the FBin. This relationship is shown below:

where: %FE is calculated by the difference between %FEout of trimmer reactor (trimmer temperature) and

%FE at control point reactor mean temperature.

or

where: ∆T1 is the temperature gradient across the No.1 Reactor and not the temperature difference

between feed and reactor outlet. Reactor temperature.

∆Ttrim is the temperature gradient across the trimmer reactor.



The relationship that relates ethylene converted to polymer to the temperature change is developed and

shown in more detail in Figure 13.4.4.

Fig. 13.4.4: Heat Rise in Synthesis

To control density using this relationship, it is necessary that the ∆T in the No.1 Reactor and in the trimmer

reactor be controlled as well. Control of the ∆T in the No.1 Reactor is primarily accomplished by

manipulating the split feed. An increase in flow to the split feed yields a lower ∆T as the average

temperature in the reactor is reduced.

Other things that affect the ∆T in the No.1 Reactor are TSR, concentration of ethylene and viscosity or

Reynolds number. These are primarily related to the ability of the reactor to adequately mix the solution.

This is of primary importance at the base of the No.1 Reactor. The condition of poor mixing is more likely

to occur if solution viscosity is high (low base reactor temperature, low MI, high RA %) and the feed flow

to the base is high. If mixing becomes inadequate, the reactor base temperature drops, making still

lower MI and causing worse mixing. The condition is indicated by a steadily increasing ∆T within No.1

Reactor with erratic base temperature.

The main control of the mixing, and therefore of the polymerization or ∆T is the amount of split feed. If

more split feed does not improve the mixing, cutting FE concentrations slightly will probably be effective

as this lowers viscosity. These relationships, TSR, concentration and MI or viscosity are shown in Section

13.4.6. In addition, a more complete modelling of this relationship within the No 1 Reactor is developed

in Section 13.4.6.



A summary of the mechanisms to control ∆T1 is shown below:

∆T1 goes up when:

• Amount of side flow goes down

• TSR goes up

• % FE goes up

• MI goes down

There is little that can be done to control the ∆T in the trimmer reactor. In its function as an afterburner it

normally burns approximately half to two thirds of the FE that comes into it out of the No 1 Reactor. As

is typical in all tubular reactors it does correspond to the relationship:

With a set physical design regulating the HUT and a fairly steady FEin/FEout ratio the only parameter

that allows any control in the STD catalyst mode is CT/CAB ratio. Adjusting this downwards extends the life

of the catalyst and would allow more conversion in the trimmer reactor. In HTC, however, lowering

CJ/CAB-2 ratio has the opposite effect. Lowering this ratio leads to catalyst not being fully activated which

reduces the life of the catalyst.

To summarize, the density is controlled by the following relationship:

The variables within this relationship are controlled by the following means:

VARIABLE CONTROLLED BY

(% FB-1)av % FB-1in

(% FE)out CAB or CAB-2 at optimal catalyst, co-catalyst ratios (CT/CAB, CJ/CAB-2)

∆T1 Split Feed (increasing the side feed can narrow the delta T1)

∆Ttrim Difficult to control however some control via CT/CAB ratio and CJ/CAB-2 ratio

In normal operation this translates to:

FBav Main Control % FBin

FEav Should hold constant as it is controlled by:

% FE: Maximum as specified in Manufacturing Guidelines

Q: Optimum as specified in Manufacturing Guidelines

∆T1: approx 20°C max on less than 2.0 MI or reactor unstable (vary side flow to No. 1)

∆Ttrim: depends on FEout of No.1

NOTE: These are not to be used for purpose of primary reaction control and best maintained stable.



2

Guidelines for density control:

1.0 (FB/FE)av = 3.5% FB in RA

+ 10% (FB/FE)in = - 0.001 Density

- 10% (FB/FE)in = + 0.001 Density

MI x 10 = + 0.008 Density

MI / 10 = - 0.008 Density

13.4.3 Melt Index: Melt index is proportional to the rate of chain transfer over the rate of chain growth.

NOTE: k2[FE] is small and usually ignored.

Melt Index is mainly dependent on the Reactor mean temperature, J concentration to FE concentration

average, and (FB-1/FE)average. As (FB-1/FE)average is the main density control variable, it is not available for

MI control. J concentration to FE concentration average and the Reactor mean temperature remain as prime

MI controls for a given density. FE average elements are generally held constant so only J concentration

and mean temperature remain as useful variables on #1 Reactor. J variation is the preferred tool as mean

temperature is normally set as high as possible to maximise differential temperature and %RA. Its effect can

be seen in Figure 13.4.6. Changes of +1 ppm of J will increase MI by about 10%.

Figure 13.4.5 shows that the effect of FE alone is small especially when running at a constant conversion

rate. There is a small effect at higher temperatures but this is usually ignored as being of little practical

significance.

Fig. 13.4.5: Effect of Ethylene on MI (no J, FB)



Fig. 13.4.6: Control of MI with Hydrogen

The effect of FB on MI is a somewhat greater. FB and temperature interact, and affect both MI and

density. This relationship is shown in Figure 13.4.7.

Fig. 13.4.7: Effect on Butene on MI and Density

For example, to obtain a polymer of 0.940 density and an MI of 1, this figure shows that an (FB/FE)av ratio

of 0.5 and an average temperature of 200°C would be needed. Since the comonomer content is primarily

used for density control, it is not normally available for MI control. When little or no hydrogen is used

temperature is the most often used method to control MI.



Finally the catalyst type (HTC Vs STD) has an effect on the MI. The normal relationship between

temperature and hydrogen is altered when the catalyst is changed from STD to HTC. The use of HTC

appears to be the equivalent of adding up to 20 ppm J or increasing reactor temp by 32°C (see Figure

13.4.8).

Tmean

Fig. 13.4.8: Effect of Catalyst Type Because of the inter-relationships between the various control mechanisms, it is virtually impossible to

change a variable without compensating in another area. All of these effects have been summarized on

Figure 13.4.9.

Fig. 13.4.9:Control of MI and Density



An example using this figure shows that for HTC catalyst, if a polymer of 0.940 density and 0.5 MI is

required, an (FB/FE)in ratio of 0.09 is needed together with Tm + 1.8 J = 225. If 10 ppm of J is used, the

Tm becomes 207°C. To summarize, the MI controls in No 1 Reactor mode:

*J - main MI control

*Tav - use when J is minimum or 0

*(FB/FE)av - Mainly used for density control but also affects MI

- Set in Manufacturing Guidelines

Guidelines for MI Control:

J + 10 ppm = MI x 2

+ 1 ppm = MI up 10%

Tav +10°C = MI x 2

+1.5°C = MI up 10%

(FB/FE)av + 15% = MI up 10%

13.4.4 Combined Melt Index (MI) and Density Control: As stated above, the tools for changing MI and density are interactive. It is impossible to change one control

variable (FB flow, mean temperature or J flow) and change only the MI or only the density. There is always

a slight effect on the other product property, provided the FE average is constant (conversion is constant).

To co-ordinate the effect of the three control variables, FB-1/FE average (or FB flow at a constant FE

average), mean temperature and hydrogen concentration, please refer to Figure. shown below. The

combined effect of the three control variables on MI and density is shown. It can be used to fine-tune MI and

density after the standard Reactor conditions are established. The centre point on the chart represents the

initial or present MI, density, initial FB-/FE average, mean temperature and J concentration. Changes

needed in J or Tmean and the FB-1/FE average (normally FB concentration) to change from the present or

base MI and density to the goal MI or density are shown on the chart. Tmean

Examples:

Control Move MI Change Density Change

+4° Tmean +20% +0.0005

+4 ppm J +40% +0.001

+20% FB +15% -0.002

+3° Tmean + 5% FB +20% 0.0

+2 ppm J and 5% FB +20% 0.0

-20% FB-1/FE and +3° Tmean 0 +0.002

-20% FB-1/FE and 2 ppm J 0 +0.002

**If 1-5 ppm J is being used



Combined Effect of the Three Control Variables on MI and Density

13.4.5 Stress Exponent: Stress exponent is not normally controlled on the No 1 Reactor as this reactor mode is used primarily to

make narrow distribution (SE 1.2-1.36) resins. For fine-tuning within this range there are a few

mechanisms that have been discovered to have a slight effect on the SE within the No.1 Reactor. One

of these is hydrogen. Adding some hydrogen can reduce the SE slightly. Addition of very low quantities of J

(say 1 ppm) will drop SE approximately 0.08. Where a very low SE is required on #1 Reactor (Rotational

Moulding resins) a minimum J requirement is specified on the standard Reactor conditions. At minimum J,

use the mean temperature to reduce MI if necessary. Above 1.5 ppm J, the J effect on SE is smaller: also

SE is not normally specified on high J consuming resins (high MI).

The stress exponent with or without the use of the trimmer reactor is slightly different as well. The use of

the trimmer adds to the SE as the grease is added to the end of the molecular weight distribution. Split feed

also has an effect. More split feed makes the resulting polymer more uniform, narrowing the SE slightly.

There is also a slight effect of catalyst. If the amounts or ratios used are very far from normal, there will

be a slight stress exponent change noted. HTC also has a slight effect Vs standard catalyst. This

relationship is shown in Figure 13.4.10. Use of HTC brings the SE down approximately 0.03 and is

compensated for by using less split feed. As mixing is improved the molecular weight distribution narrows.

Conversely, with higher ∆T and worse mixing, the stress exponent becomes larger.



Another factor that has come to light recently is the temperature of the heat treatment loop in the HTC

catalyst mode. Running a lower temperature (185°-195°C) tend to increase the SE (up to 1.35)

while a higher temperature (230°-250°C) tends to decrease the SE (down to 1.25). This effect, however,

is still being further evaluated.

Fig. 13.4.10: Molecular Weight Distribution (HTC Vs STD Catalyst)

13.4.6 Theoretical Model of Mixing in No. 1 Reactor: Plant operating practice has shown that the delta T across the reactor changes with total solution rate

and the concentration of ethylene in the feed solution. Figure 13.4.11 shows a plot of delta T across the

reactor versus % ethylene in the feed solution and total solution rate. At low feed rates the delta T across

the reactor is only 4 to 8°C. The delta T across the reactor increases to 20°C at high feed rates. The

increase in delta T affects the melt index and the molecular weight distribution (MWD) of the resin. This

effect is to be related to mixing within the No.1 Reactor and consequently a theoretical model of the No.1

Reactor was developed.

The reactor is assumed to consist of a series of mixed vessels. Each agitator paddle represents a mixing

vessel.

Several Variables are known to influence ∆T and must be accommodated within the model:

• Solution Rate

• Reactor Volume

• Inlet Monomer Concentration

• Rate of Reaction

• Degree of Agitation



Fig. 13.4.11: Effect of Ethylene Concentration on Temperature Differential

The paddles in the No.1 Reactor point downwards at an angle of 45 degrees. Because of this the agitator

forces the flow down the reactor whereas the feed flow pushes the flow upwards.

This can be depicted as:

F is the flow into the first tank, and R is the recycle flow back from the second tank into the first tank. The

flow from first to second tank to (R+F). The mass balance equations can be solved analytically for up to

3 stirred tanks. The concentrations in the tanks can be calculated:



where:

C0 = inlet concentration

C1 = concentration in tank 1

CN = concentration in tank N X

=

Circulation flow through flow

[model was fitted to plant data by varying R]

= R

F

A = kt

t = hold-up time at each tank

k = rate constant of reaction (known) The model shows that increased agitation in the form of a higher R/F value will bring CN closer to CN-1.

Since delta C is proportional to delta T it follows that agitation is inversely proportional to ∆T - or in other

words poor mixing/agitation leads to high ∆T, or good mixing leads to low ∆T.

This is also shown in Figure 13.4.12, where a "mixing factor" has been defined as

This mixing factor has been plotted against temperature rise for a variety of mixing models.

In addition, this mixing factor has also been related to molecular weight distribution. This relationship is

shown in Figure 13.4.13.

Since increased viscosity will reduce circulation flow, and in doing so reduce the value of R/F higher viscosities lead to poorer mixing. Since poorer mixing leads to higher ∆T, it follows that higher

viscosities lead to higher ∆T.

Conversely, low viscosity resins (high MI) mix well and have lower ∆T.



Fig. 13.4.12: Temperature Rise Vs Mixing Reactor

Fig. 13.4.13: Molecular Weight Distribution Vs Mixing Reactor

The model also predicts that the overall delta T across the reactor increases with total solution rate.

This confirms the plant data. This is shown with Reynolds number identifying the increased TSR in Figure

13.4.14. Increasing the Reynolds number from 200 to 3400 reduces the delta T through improving mixing.

Reynold’s number is defined as NRE = (D2 x N x Density)/Viscosity

where D is the Dia. of paddle

N is the rpm of paddle



Fig. 12.4.14: Effect of Reynold’s number on ∆T

The agitator motor power consumption changes with NRE as shown in Figure 13.4.15.

The power increases gradually as NRE decreases. The power increases rapidly as NRE is reduced to less

than 2000. The ∆T across the reactor is 6°C at NRE = 3000. The reactor delta T increases to 40°C at NRE =

1700. The reactor becomes very unstable at NRE <1700. As the flow regime in the reactor changes from

turbulent to laminar the degree of mixing in the reactor is decreased.



Fig. 13.4.15: Agitator Current Vs Reynold’s Number

Fig. 13.4.16: Effect of Poor Mixing on Control



The temperature profile across the reactor changes as shown in Figure 13.4.16 as the mixing

decreases. The temperature difference increases from 10°C to 20°C. The system pressure and agitator

current increase. A larger ∆T across the reactor indicates that the ethylene concentration at the base of

the reactor has increased, resulting in a lower melt index resin at that point. The lower MI resin further

depresses the turbulence in the bottom of the reactor, thus increasing the ∆T and so forth. As a result,

the reactor becomes unstable. To combat this the operator increases the temperature of the reactor,

which results in producing a higher MI resin to regain stability and correct the problem. The affect on ∆T

across the reactor versus split feed is also illustrated in Figure 13.4.18

Following the example laid out on Figure 13.4.16 as the operator tries to reduce the reactor

temperatures, the reactor becomes unstable once more due to the higher viscosity at the bottom. The

higher ethylene concentrations and the lower reaction temperatures results in producing low melt index

resin which increase the delta T across the reactor.

To combat this mixing problem, feed can be injected into two different points up the side of the reactor.

This spreads the mixing load to different points along the agitator. The model fitted plant data covering

feed rates from 5.6 tons to 22.7 tons/hr. The model predicts that the delta T increases from 6° to 35° delta

T, as the rates are increased from 22.7 tons/hr to 90.9 tons/hr (see Figure 13.4.17). This was confirmed

by subsequent plant test. The molecular weight distribution (MWD) broadens with feed rate.

Run Flow Rate (tons/hr) ∆T (°C)

MWD

1 5.6 5.8 6.71 2 11.36 10.0 6.87 3 22.7 16.5 7.19 4 45.4 25.1 7.68 5 90.9 34.8 8.30

Fig. 13.4.17: Variation of Flow Rate About Base Condition

Fig. 13.4.18: Effect of Split Feed on ∆T



13.5 3→1 Reactor Control: 13.5.1 3→1 Conversion Control (Q and Q3):

Fig. 13.5.1 #3→1 Reactor (Tubular)

There is only a limited amount of conversion control available with the 3 1 Reactor. Catalyst levels and

ratios, useful in the No.1 Reactor for conversion are required for stress exponent control in this reactor

type. Stress exponent control will be covered later in this section. Luckily, the conversion does tend to come

out in the optimal economic range within this reactor mode.

The conversion in the 3→1 mode can be viewed as happening in two stages. The first stage is the

tubular reactor, where temperatures are low and high molecular weight producing catalyst species are

present. In the second stage, the No.1 Reactor, the temperatures are high and polymer produced is

narrower.

The conversion through the length of the tubular reactor results in a temperature rise through the

reactor as shown in Figure 13.5.2. The portion of the overall temperature rise that occurs up to the J

injection point in the No. 3 Reactor is proportional to the amount of conversion taking place up to the J

injection and is referred to as Q3. This J injection point is in the No.3 reactor and is a useful tool for

stress exponent control. It is very important to understand that Q3 refers to conversion up to the J point

in the No.3 Reactor and not to the total conversion in the No.3 Reactor.

Thus Q3 = (% Reaction up to Jn Injection Point)/(Total Reaction)



Fig. 13.5.2: Temperature Rise through Reactor

Hydrogen which is a tool for parameter control, is normally injected into the process at two points, a small

amount of hydrogen at the RFP discharge and a greater amount of hydrogen later in the reactor. The

second point of J injection can be carried based on the properties desired by the resin. The hydrogen itself

is used in the reaction, as is shown in Figure 13.5.3. By the end of the reactor, approximately half of the

hydrogen has been utilized in the reaction. The other half finds its way to the top of the FE column where it

stays with the recovered FE and is returned to the ethylene plant.

Fig.13.5.3: Effect of Hydrogen injection



The conversion and temperature profile through the Reactor is very dependent on the CT/CAB ratio. This is

shown in the fig. 13.5.4 below

Fig. 13.5.4: CT/CAB Ratio Effects on Q

As constant CAB concentration a high CT ratio moves the reaction to the front of the tube giving a fast initial

reaction, high Q3, but lower final conversion. (Excess CT appears to cause rapid catalyst decay at high

temperatures). However, at a lower CT/CAB ratio while the initial reaction is slower and Q3 is lower, the

overall conversion is higher.

Overall conversion can be raised by: a) Increasing the CAB concentration at constant CT/CAB ratio.

b) Decreasing the CT/CAB ratio to the point where maximum trimmer outlet temperature is obtained.

Beyond this optimum point further lowering of the CT/CAB ratio drops conversion.

Q3 or #3 Reactor conversion may be increased by:

a) Raising the CT/CAB ratio.

b) Increasing the CAB at a constant CT/CAB ratio.

c) Moving the J injecting point to give longer hold-up time (J3 to J4, J4 to J5 or J5 to J6).

The trimmer Reactor conversion is not controlled and is almost negligible on the #3→1 Reactor system.

In setting up the standard Reactor conditions at the start of the run, the J point is specified, but CAB should

be adjusted to give the specified overall conversions (Total differential temperature). The CAB concentration

suggested on the standard Reactor conditions is an average value and will vary from one production run to

another depending on the rates and impurities. Similarly, the CT/CAB should be increased or decreased to

raise or lower Q3 (differential temperature #3) if the suggested CT/CAB ratio does not give the desired Q3.

Once correct, overall conversion and Q3 are set, no changes should be made until MI and SE results are

available. After that, Q3 and CAB (hence Q overall) may need adjusting as discussed under MI and SE

control to obtain RA parameter control.

On resins where MI, SE and Melt swell are all specified, overall conversions tends to be uncontrolled as CAB

concentrations and CT concentrations are used to control the RA parameter. Provided conversion is in the

93-98% range it is not a prime concern provided resin parameters are on specification. On HTC 3→1 resins,

the CJ/CAB-2 ratio is used in place of CT/CAB to control Q3 and behaves similarly.



13.5.2 Density: 13.5.2.1 General Similar to the No.1 Reactor, the major variable in the control of density is the amount of comonomer in

the resin. However, density control using comonomer is different in the 3→1 Reactor than in the No.1

Reactor. In the No.1 mode the stirred autoclave results in a uniform mixture of comonomer to monomer

(FB-1/FE ratio, FC-1/FE ratio), throughout the reactor vessel. The tubular nature of the 3→1 Reactor

results in an uneven reaction. Polymer produced near the beginning of the reactor is quite different than

that produced near the end of the reactor. The passage of the polymer through the tubular reactor can be

expressed in terms of hold up time (HUT) or % FE conversion. Ethylene (FE) reacts continuously as it

travels along the reactor. As it reacts it is transformed from ethylene to polymer. This means that the level

of FE in the stream goes down with increasing conversion. The comonomer (i.e. FB or FC) also is reduced

as it too is converted to polymer through the length of the reactor. The reduced reactivity of the FB or FC

causes its conversion to polymer through the reactor to be slower than that of the FE with the result that

the FB/FE, or FC/FE ratio changes through the length of the reactor (or alternatively the FB/FE ratio

varies with HUT). This effect for FB/FE is shown in Figure 13.5.5 NOTE: In this figure, the mixture starts out with a very low FB/FE ratio at the beginning of the reactor and

exits the reactor with a very high FB/FE ratio.

Fig. 13.5.5: Changes in FB/FE ratio through Reactor in 3→1 mode

Because the amount of comonomer in a resin is one of the main variables in the control of density, the

varying levels of comonomer ratio throughout the reactor system result in polymer of different densities

being formed at differing points in the reactor system. This effect is shown in Figure 13.5.6. The very low

FB/FE ratios at the beginning of the reactor result in higher density polymer being produced at that point.

The high FB/FE ratios at the end of the reactor result in very low density polymer being produced in that

part of the reactor. The density of the polymer produced by the 3→1 Reactor appear as an average of the

densities produced at the various parts of the reactor.

Density control within the 3→1 Reactor mode is much more stable than with No. 1 Reactor. This has two

major reasons. First, the polymer densities throughout the reactor all blend to form the final density. This

blending effect smooth any control problems. Another reason is that while the FB/FE ratio, and



consequently the density, is very much dependent on the conversion in the No. 1 Reactor mode the

conversion’s impact on density in 3→1 mode, is mainly towards the end of the 3→1 Reactor.

Fig.13.5.6: Effect of FB/FE ration on Polymer Density in 3→1 Mode

13.5.2.1 Density Control: The main control mechanism for the density in the 3→1 mode is the comonomer ratio into the reactor

(Figure 13.5.7 shows this for butene). It is interesting to note that because of the blending effect, the

(FB/FE)in ratio required to produce a given density is higher in the 3→1 Reactor than in No 1

Reactor. To get very low polymer densities using the 3→1 Reactor requires very large amounts of

comonomer. Production of low density resins results in a significant quantity of short polymer (grease or

RB) being produced in the trimmer reactor where temperature is high or FB/FE ratio is very high. High

levels of grease in the polymer can result in processing difficulties for the customer and handling

problems in the finishing area. For this reason the SCLAIRTECH process does not generally produce

resin below 0.935 in the 3→1 Reactor mode.



Fig. 13.5.7: Effect of Reactor type and Comonomer content on Density

The high levels of FB needed to produce three low density resins also result in higher catalyst requirements.

As well, high FB levels tend to raise the MI. to compensate for this, the concentration must be lowered,

reducing the economics of the commercial process.

General Guideline: Adjust the FB-1 concentration: +10% for 0.001 density decrease

- 10% for 0.001 density rise.

13.5.3 Melt Index: 13.5.3.1 General: Melt Index is inversely proportional to molecular weight. Low melt index corresponds to high molecular

weight, and high millet index corresponds to low molecular weight. At the beginning of the 3→1 Reactor

there are low temperature, high amounts of FE and the catalyst has greater proportions of CB which is

responsible for high molecular weight. This combination results in the formation of long chains or low MI

near the front of the reactor. The low amount of J at the beginning of the reactor (put in at the RFP outlet)

tends to keep the MI low. As the temperature rises and the FE levels drop through the reactor, the chains

get shorter and shorter and as a result the MI of the polymer produced also rises. At the second hydrogen

addition point the MI takes a jump up. This effect is shown in Figure 13.5.8.



Fig. 13.5.8: Melt Index through Reactor

13.5.3.2 Melt Index Control: Control of Melt Index is done by a number of variables. The two most common means of MI control within

the 3→1 Reactor are the inlet temperature and the hydrogen supplied at the reactor feed pump. Other

factors with some effect are Q3, concentration, catalyst ratio and level and TSR.

13.5.3.2.1 Temperature: An increase of the inlet temperature will increase the entire MI Vs HUT curve as is shown in Figure

13.5.9. Conversely to lower Melt Index the inlet temperature would be reduced. This is due to the fact that

higher temperatures encourage chain termination which results in shorter chain and hence higher MI.



Fig. 13.5.9: Effect of inlet Temperature on MI

13.5.3.2.2 Hydrogen: The second control mechanism is the J supplied to the process at the RFP. Reduction of the J supplied

to the process at this point will reduce the melt index, while raising it will increase the melt index. Any

change in J at the RFP results in a change in J throughout the entire reactor.

This is explained by the fact that hydrogen acts as a chain transfer agent and as a result the chains

produced are shorter which contribute to increased MI.

In case of HTC, the hydrogen required is a lot more than in the case of STD catalyst. This is mainly due to

the fact that HTC makes a very narrow molecular weight distribution and lower MI resin. Addition of

hydrogen facilitates the increase of MI. 13.5.3.2.3 Q3: The Q3 or the proportion of the reaction taking place in the No.3 Reactor up to 2nd J point, also has an effect

on melt index. Since the polymer made in Q3 has a lower MI than does the polymer made later in the

reactor, increasing Q3 serves to lower overall MI and lowering Q3 serves to raise overall MI (see Figure

13.5.10). Change of Q3 is accomplished by altering the catalyst injection point, the J injection point,

changing the TSR (lower TSR raises the HUT), and by adjusting CT/CAB Ratio.



Fig. 13.5.10: Effect of Q3 on MI

13.5.3.2.4 Concentration: The melt index is also affected by the concentration (or % RA). Concentration and the resulting

conversion is related to temperature. As % RA goes up so does the temperature. Thus higher % RA results

in higher MI. This is because the higher amounts of polymer produced from higher concentration, resulting

in higher temperature, primarily produces short chains (grease) or high MI polymer.

13.5.3.2.5 Catalyst Ratio: The CT/CAB ratio is another factor used in the control of MI. Raising the CT/CAB ratio will raise polymer MI.

Lowering it will reduce MI. As the CT ratio is lowered there is a drop in Q3. This would appear to be

contrary to earlier discussion which stated that a lower Q3 would result in a generally higher level of MI.

However, the lowering of the CT/CAB ratio also has the effect of allowing increased activity of the vanadium

(CB) portion of the catalyst which creates the high molecular weight portion of the polymer. Thus

although you make less overall polymer in the No.3 Reactor, what is made is much higher in molecular

weight or lower in MI. It is low enough in MI to compensate for the reduced quantity of the low MI polymer

and thus the result is an overall reduction in MI. This unusual effect of lowering of the CT/CAB ratio

works only on standard catalyst, as the heat treatment of the HTC catalyst process has an adverse

effect on the high molecular weight producing species of the catalyst. The effect of lowering the CT/CAB

ratio is shown in Figure 13.5.11.

In case of HTC, the CD/CAB-2 and CJ/CAB-2 ratios do not have the same pronounced impact on MI as



the STD catalyst. It has been noted, however, that an increase in the CJ ratio tends to lower MI while

keeping the other parameters consistent. Increasing the CJ ratio has the result of increasing Q3 thus

making more high MW material and hence resulting in lower MI.

The shift in MI with increase of CJ ratio tends to be more drastic for high density resins in comparison to

low density resins. Lower CT/CAB ratios also increase the life of the catalyst as shown in Figure

13.5.12. With a longer catalyst life the reaction continues on into the trimmer reactor to a greater extent

increasing the quantity of very lower molecular weight (high MI) polymer produced there.

Fig. 13.5.11: Effect of Catalyst on MI

Fig. 13.5.12: Effect of Catalyst Ratio on Conversion



13.5.3.2.6 Catalyst Concentration: Changes in the overall concentration of catalyst also have an effect on the melt index of the polymer

produced. More catalyst increases the amount of vanadium sites available for polymerization when

evaluated with respect to the amount of ethylene present. This allows some very low MI material to be

produced at the beginning of the reaction. This has a similar effect to the lowering of the CT/CAB ratio, and

acts to lower the melt index.

13.5.3.2.7 TSR: Finally a variable that can affect MI, although not always in a beneficial or controllable way, is TSR. This

is primarily related to the mixing of the catalyst with the reacting stream. If the TSR is lowered, it may cause

poor mixing between the catalyst and the ethylene at the front end of the reactor. With poor mixing in this

area there will be a catalyst rich area and a catalyst poor area. The catalyst rich area would see a

much higher initial temperature rise than the catalyst poor area resulting in a hot section and a cold

section within the reactor (see Figure 13.5.13). This non-homogeneous flow eventually vanishes but while

it is present the high temperatures within the catalyst rich areas can lead to thermal damage of the high

molecular weight producing sites of the catalyst (the CB or vanadium sites). Recall from the discussion on

the catalyst that the vanadium sites are temperature sensitive and can be rendered inactive by high

temperature. Thus with poorer mixing, resulting from low TSR, there is less high molecular weight material

formed, and consequently the melt index is higher. The inability of the poorer mixed material to produce the

higher molecular weight polymer also has an effect on the ability to achieve high stress exponent at low

TSR. If low RA production rates are required (for example a capacity limitation in the finishing area), it is

possible to reduce the effect of poor mixing by reducing the concentration. This allows a higher TSR

while limiting the RA production. The higher TSR will increase the mixing, and control the temperature

variations allowing the MI to drop, and the S.E. to go back up.

Fig. 13.5.13: Effect of Mixing on MI



The apparent melt index of the polymer produced through the reactor will be the average melt index

produced in the various parts of the reactor and is proportional to the conversion in those parts.

Average Melt Index is proportional to Q3 MI3 + (1 - Q3) MI1

MI3 is primarily dependent on J at RFP and inlet temperature

MI1 is primarily dependent on J at both the RFP and the second J injection point, and also on the

temperature.

13.5.3.2.8 General Guidelines (Resin Groups 9, 10, 11, 12):

To lower the MI: a) Use J1 for MI control: about 1 ppm for 10% MI change.

b) ***If J1 is minimum (1 ppm) then decrease the CT/CAB ratio (this will raise SE).

c) ***If both of above moves still result in the MI being above goal:

Increase the CAB concentration in 5-10% sets, up to 35 ppm if necessary. (At higher CAB

concentration, costs increase and colour decrease). This move will raise SE.

d) If the MI is still too high:

1. Lower %FE decrease differential temperature and TMEAN (as TIN is constant). This lowers % RA but

is less cost-efficient.

2. Raise the solution rate. This increase the mixing efficiency of FE and catalyst at the catalyst

injection nozzle. If mixing is poor due to low rate or high viscosity, it is difficult to make very low MI

in the front of #3 Reactor and the MI will be high and these low. Both (d) 1 and (d) 2 assists in

correcting this problem.

13.5.3.2.9 On Resin Group 13 Control is different since J is supplied to the Reactor inlet. This resins are high SE resins (broad MWD)

requiring minimum initial MI.

General Guideline To lower MI: a) Decrease Reactor inlet temperature. About 2°C = 10% MI change. Do not go below 110°C** as low

MI material may for slurry,

b) ***If Tin is at minimum (110°C), decrease the CT/CAB concentration.

c) ***If the CT/CAB ratio is down to optimum, raise the CAB concentration.

d) IF the CAB concentration is up to maximum (35 PPM).

(i) Lower FE concentration.

(ii) Raise the Total Solution Rate.

*Resin Group 9,10,11,12 are #3→1 resins using J1. Group 13 is #3→1 resin using no J1.

** With zero J, the ultra high MW formed needs 110°C to ensure solubility.

*** These methods are not applicable to HTC resins. NOTE: b, c, d moves are common to all groups.



13.5.4 Stress Exponent: 13.5.4.1 General: The control of melt index and the control of stress exponent are very inter-related. Stress exponent reflects

the breadth of the molecular weight distribution, and is affected by fractions of high molecular weight

polymer and the low molecular weight polymer. Thus, variables that raise or lower MI by creating high

molecular weight polymer, or low molecular weight polymer also affect stress exponent.

13.5.4.2 Stress Exponent Control: 13.5.4.2.1 Hydrogen: The prime variable for stress exponent is the hydrogen added to the middle points in the reactor. Increasing

the J to these points serves to raise subsequent MI and in doing so, raises the stress exponent (See

Figure 13.5.14). Additionally, reducing the J added at the RFP outlet or reducing the inlet temperature serve

to increase the high molecular weight portion and in doing so, increases the stress exponent. Use of

these techniques together can increase stress exponent at both ends of the MWD while keeping MI

constant.

More hydrogen is required for operation in the HTC mode than in the STD mode. Also the J injection point in

the reactor is earlier in HTC than in STD due to the fact that HTC is more reactive at low temperature and in

order to control conversions and MI, more hydrogen is required at earlier J point.

Fig 13.5.14: Effect of Hydrogen on SE

13.5.4.2.2 Catalyst: A lower CT/CAB ratio has the effect of increasing stress exponent by increasing the amount of low

molecular weight material formed. This happens because with the lower ratio the catalyst remains active

longer, into the trimmer reactor where low molecular weight polymer or grease (RB) is formed. A low

CT/CAB ratio also serves to increase the activity of the vanadium sites which produce the high

molecular weight polymer thus increasing the stress exponent on both ends of the MWD. In a

similar way a higher overall catalyst concentration increases the vanadium sites for polymerization and

increases the high molecular weight material. The high levels of catalyst also increase the overall Q, which

allows more grease to be formed in the trimmer reactor. This effect is shown in Figure 13.5.15. Increase in

S.E. due to increased high molecular weight polymer production is generally the more important



phenomenon.

In case of HTC, however, the impact of catalyst is not so pronounced. Due to high temperature encountered

in the HTC loop, the vanadium species is partially destroyed thus reducing the ability to produce high MW

polymer. Therefore, the S.E of the resin, in case of HTC, is lower than the STD catalyst. Upper limit of SE

with HTC catalyst is 1.8. For production of resins beyond a 1.8 SE, the use of STD catalyst is

recommended.

Fig. 13.5.15: Effect of Catalyst on SE

13.5.4.2.3 TSR: As previously mentioned TSR affects the mixing. Poor mixing affects the vanadium species through

thermal degradation. Poor mixing also affects the ability of the ethylene to react well with the catalyst as a

result of the reduced contact. As a result of this, poor mixing will reduce the amount of high molecular

weight polymer (low MI) produced and in doing so will lower stress exponent.

13.5.4.3 Combined Effects of Hydrogen, Catalyst and Temperature on MI and SE: The preceding discussion has shown how a number of variables can affect both MI and S.E. The

combined effects of hydrogen, catalyst and temperature on both MI and S.E., is summarized on Figure

13.5.16. This figure is useful to determine the compensating actions required to adjust for MI and S.E. For

example to increase only the S.E., and not the MI, would require both an increase in the J to one of the

middle injection points and a compensating action of either reducing the CT/CAB ratio, increasing the

CAB concentration, decreasing the temperature in or decreasing the J to the RFP to readjust the MI back

to the original level. Use of this figure is similar to that of a standard vector diagram.

The behaviour of HTC catalyst is also similar to the one shown in Figure 13.5.16 for STD catalyst except for

the fact that the co-catalyst ratios do not have the same effect. The CD and CJ ratios do not impact the MI

and S.E. in the same way as CT ratio. However, it has been seen that increasing CJ ratio, which increases

the Q3 has had the result of lowing MI while maintaining the same S.E.



Fig. 13.5.16: MI/SE Control – Combined Effect (STD Catalyst)

13.5.5 Other Parameters: There are also several other parameters that can be controlled, at least to some extent, within the 3→1

reactor. Among these are zero shear viscosity, high shear viscosity and melt swell.

13.5.5.1 Zero Shear Viscosity: Zero shear viscosity or low shear viscosity reflects the melt strength. This property is measured by a test

known as a drop weight test. In this test the time for a given extruded amount of polymer to drop free of

the die is recorded. This test is repeated for a variety of polymer weights and the test result is determined

as the amount of polymer that would fall free in six minutes. This test is done using the melt index test

facilities.

The very high molecular weight polymer, produced in the No.3 Reactor, governs changes in zero

shear viscosity. From the preceding discussion it has been shown that the following variables affect this

area of the molecular weight distribution; J to RFP, overall temperature, CT/CAB ratio and catalyst

mixing. Larger quantities of high molecular weight polymer increase the low shear viscosity or melt

strength. Lower amounts of these high molecular weight molecules reduce the melt strength.



13.5.5.2 High Shear Viscosity (HSV): High shear viscosity reflects the actual processing range of the polymer. Ideally the polymer should have

high melt strength and a low level of high shear viscosity to hold shape on cooling well, yet take very little

power to extrude. Figure 13.5.17 shows this phenomenon. High shear viscosity is measured by

determining what force is required to extrude the molten polymer out of the die at a given speed.

Fig. 13.5.17: High and Low Shear Viscosity

High shear viscosity is primarily dependent on the lower molecular weight component. Large amounts of

this component lead to a resin that is easy to extrude.

The differing effects of the low molecular weight and high molecular weight polymers in processing can

be explained by a model which predicts polymer behaviour as similar to a two components mixture.

This two components mixture consists of pockets of high molecular weight material, floating in a

mixture of low molecular weight material.

At low shear rate, the long chains tangle together and govern the melt strength. At higher shear they ball up

and are swept along.



To control the high shear viscosity, J is added to the mid points increasing the MI of the final part of the

reactor (see Figure 13.5.18). Additionally, the No.1 Reactor can be stirred. Both of these techniques cause

the grease to get "greasier", and lower the molecular weight. More hydrogen produces lower MW, lower

amounts of hydrogen lead to higher MW.

Fig. 13.5.18: Effect of Hydrogen on High Shear Viscosity

13.5.5.2.1 General Guidelines (At Constant MI, SE) To lower the HSV increase J3 (J4 or J5) flow.

To raise the HSV decrease J3 (J4 or J5) flow.

NOTE: MI is an inverse viscosity at about 1 sec-1 shear rate. A given MI fixes one point on viscosity

versus the shear rate, while Stress Exponent fixes the slope. If the line was perfectly straight

then fixing MI and SE fixes the HSV. J injection along the tube will bend the line downwards.

13.5.5.3 Melt Swell: Melt Swell is one phenomenon that separates non-Newtonian fluids (like polymer) from Newtonian fluids

(like water). In the case of melt swell the non-Newtonian fluid, the polymer, begins to act in a similar

way to a rubber. With pressure pushing the polymer through a die, the energy is absorbed within the

polymer and then causes the resin to expand on the outlet of the die. Melt Swell is measured as the

diameter of the frozen strand coming out of a die divided by the diameter of the die itself. In this test the

polymer is pushed through the die in a set up shown in Figure 13.5.19.



Fig. 13.5.19: Melt Swell Test

One factor affecting the melt swell test is the pressure required to extrude the strand. The more pressure

needed to push it through the die, the higher the high shear viscosity component of the material and the

higher the melt swell. To lower swell, it is necessary to lower the high shear viscosity component. Putting

more J to the No.1 Reactor does this. This effect is shown in Figure 13.5.20. Melt swell is also

proportional to the elasticity of the polymer, the more elastic the polymer, the greater the swell. The stress

exponent governs the elasticity of the polymer. The higher the S.E, the more tendencies for swell. Since

the Mz/Mn ratio is proportional to S.E., melt swell is also proportional to the Mz/Mn ratio.

The rate of swell is also important because what actually matters is the amount of swell that will occur prior

to freezing. Apparent differences in melt swell between competing resins are sometimes the result of a

difference in swell rate. Competing resins achieve the same ultimate swell or even higher levels if the

freezing is delayed (i.e. by extruding the polymer into hot oil).

SCLAIRTECH resin appears to have a higher swell than some competitors due to its higher swell rate.

Thus, to the customers, more swell actually takes place prior to freezing. Melt swell is compensated for in

the customer's moulds and dies and therefore must be consistent. The lower MI resins with their longer

chains appear to resist swell. In these resins the zero shear component is very high. This shows up as

reduced melt swell due to a slower swell rate.



Fig. 13.5.20: Effect of SE on Melt Swell

Figure 13.5.21 shows the relationship of HSV and S.E. to swell for a given MI. Putting more J to the

autoclave, while increasing S.E. serves to reduce the HSV and in doing so reduces melt swell. This is

shown in the figure as a move from point A1 to B1. In addition if the J point is moved forward (i.e. J3 to J4)

with the same amount of J being injected the swell is reduced. This appears to be the result of changing

the size of Q3 and has very little effect on S.E.

In the figure this is shown as moving from the point C1 to D1. This does adjust the MI in this control

scheme. These are the 2 main methods of melt swell control. Other methods such as adjusting the inlet

temperature to No.3 Reactor, % FE and catalyst normality are also useful tools for controlling melt swell.



Fig. 13.5.21: Effect of HSV and SE on Melt Swell

The preferred method for control:

To lower Melt Swell:

1. Lower HSV by increasing J to the reactor (JN)

2. Move the J point later (3 to 4, etc.) in the Reactor, if necessary. Generally the optimal J point is

specified on the standard Reactor conditions sheet (Section 7).

3. Further moves which sometimes are helpful:

a) Raise CT/CAB ratio (also lowers SE).

b) Raise %FE (by causing initial mixing and final conversion to decrease this can lower MWD at the

extreme ends and tends to lower SE).

NOTE: Control of parameters such as Melt Swell and HSV become very difficult if high impurity levels are

present. These limit the use of CAB and CT/CAB use as parameter control tools since some impurities

prevent high MW formation. It may be necessary to shift to a less critical resin until impurities are reduced.



13.6 Reactor #3 + #1 Control: 13.6.1 System Description: The 3+1 Reactor setup is a hybrid of the 3→1 Reactor and the No.1 Reactor. In this case all three parts

of the Reactor set up are being used; the tubular Reactor, the stirred autoclave and the trimmer Reactor.

The Reactor system is fed at two points, the side of the No.1 Reactor and the entrance to the No.3

Reactor. There is a cold feed coming from the tempering system at approximately 30-40°C to the side

of the No.1 Reactor and a hot feed from the heater coming into the No.3 Reactor. The temperature of

these two streams is controlled independently. Controlling the heater outlet temperature sets the

temperature of the feed to No.3. The heater itself is steam heated and the control adjusts the steam flow

to this heater. The temperature of the No.1 Reactor controls the temperature of the inlet flow to the side

of this Reactor. Taking the cold stream and bleeding in some hot feed to achieve the desired temperature

achieve temperature control of this stream.

The amount of split feed going to this side feed point Vs to the No.3 Reactor is also a controlled

variable. Control is achieved by increasing the backpressure on the line to the No.3 Reactor (by closing

off a valve) forcing the flow through the side feed to No.1 Reactor.

Catalyst is injected at two points, the entrance to the No.3 Reactor and into the autoclave. Hydrogen can

be supplied either at the RFP, or in the Reactor itself, or both. This setup is shown in more detail in Figure

13.6.1.

Fig. 13.6.1: Physical Setup

The goal of this hybrid Reactor set up is to make a slightly broader No.1 Reactor resin by putting in

some higher molecular weight resin. Doing this improves the stress crack resistance while maintaining

the flow properties from the No.1 Reactor resin. There are, however, only a limited number of resins

where this combination of attributes is required. Resins made using the 3+1 Reactor set up tend to be

between 3 and 30 in MI and between 0.950 and 0.960 in density.

13.6.2 Density Control: As in all Reactor cases, adjusting the comonomer inlet ratio controls density. Conversion is kept steady

because it can affect the comonomer ratio which in turn will affect the density.



13.6.3 Melt Index Control: Melt Index control is also similar to other Reactor set ups. Temperature and hydrogen play major roles.

To raise the MI of the resin (lowering the molecular weight) the temperature is raised to the No.3 Reactor

inlet. The higher temperature reduces the activity of the high molecular weight producing sites on the

catalyst, with the result that the resin MI is raised.

Alternatively hydrogen to the RFP can be increased to increase MI. This hydrogen will go to both the

Reactors and increases the chain transfer rate. Hydrogen to No 1 Reactor is not normally used for the MI

control, but can be used in the control of S.E.

It is also possible to affect MI by increasing the mean temperature in No.1 Reactor. Of the two

temperature controls it is preferable to raise the inlet temperature to the No.3 Reactor as raising the No.1

mean can also have the side effect of reducing conversion. This is due to reduced levels of activity of

the catalyst at higher temperatures. The temperature of the No.1 Reactor is generally set in the

Operating Instructions usually at approximately 230 or 240°C which gives a trimmer outlet of approximately

270 or 280°C and then left constant.

Another variable affecting MI is the amount of split feed. Increased feed to No.3 Reactor lowers MI as a

greater portion of the resin is made in this Reactor, where the long chains are formed. Higher MI resin is

made in the autoclave.

13.6.4 Stress Exponent Control: The effect of the various Reactor components can be seen most clearly by plotting log MI and

temperature against conversion (Figure 13.6.2). MI and temperature rise through the No.3 Reactor and

then drop slightly and hold steady through the autoclave. They then rise again in the trimmer Reactor.

Very low MI is made at the front of No.3. By the end of No.3 the reaction is producing a fairly high MI.

This pattern also shows that if Q3 were reduced there is very little effect on the resulting polymer because

what is lost is the highest MI made in the No 3, which is very similar to that made in No 1.

Fig. 13.6.2: Temperature Rise through Reactor



This can also be seen by examining the molecular weight distributions made (Figure 13.6.3). The very

low MI resin made in the No.3 Reactor is the most important for providing unique properties compared to

resins made in the autoclave or tube. In addition, the lower the MI is on the material made in the No.3

Reactor, the greater the stress exponent.

Fig. 13.6.3: Molecular Weight Distribution The primary means for stress exponent control is the percentage of flow directed to the No.3 Reactor

Vs the No.1 Reactor. This governs how much of the low MI material is actually made. As the amount of

flow directed to the No.3 is increased more low melt index resin is made, which will lower the overall MI and

raise the stress exponent. This can be seen clearly by imagining a situation where the flow to No.3 Reactor

was cut way down. Eventually there would only be a stirred autoclave which is used to produce very narrow

distributions. The 3+1 Reactor setup fills in the gap between the narrow distribution made in the stirred

autoclave and the broad distribution made in the tubular Reactor.

Another major variable is temperature. If the inlet temperature to No.3 is lowered, then even higher

molecular weight material is made at this point which lowers the MI and increases the S.E.. Similarly,

lowering the CT/CAB ratio results in the production of more very high molecular weight material in the No.3

Reactor which increases the S.E. Alternatively, the use of hydrogen to the No.1 Reactor will affect the low

molecular weight portion of the resin. If the amount of J to the No 1 Reactor is raised then the S.E. will

rise by even shorter chains being formed in the trimmer Reactor. This has the effect of making the grease

"greasier".

The control mechanisms for 3+1 resins are summarized in Figure 13.6.4

Fig. 13.6.4: Effect of Control on MWD



Control Variable for Reactor #3+#1 Control:

To Raise Density • Lower Comonomer Ratio

To Raise Melt Index

• Raise Temperature at No.3 Inlet

• Increase J at RFP

• Increase Mean Temperature

• In No.1 Reactor

• Reduce Feed to No.3 Reactor

To Raise Stress Exponent

• Increase Flow to No.3 Reactor

• Lower Temperature at No.3 Inlet

• Lower CT/CAB Ratio in Std Mode

• Increase J to No.1 Reactor



SECTION – 14.0 SAFE SHUTDOWN SYSTEM



14.0 Introduction:

For Safety of the plant three types of Safe Shutdown system is provided in the plant. These are as under:

1.1 SPI (Solution Pumping Interlock)

1.2 LOS (Light Off Switch)

1.3 “Z” Trip (Plant Wide Shutdown & Solvent Isolation)

14.1 SPI (Solution Pumping Interlock): 14.1.1 Description:

The primary purpose of the Solution Pumping Interlock is to shutdown all of the flows in the Reaction Area

which are normally flushed through the system by the solution flow from the reactor feed pump. This

includes the catalyst and deactivator flows which will cause problems if pumped into the system without a

reactor feed flow.

In addition, the SPI is used to shutdown the Reactor Feed Pump on low reactor feed pump flow and high

solution adsorber pressure.

14.1.2 Cause of Activation of SPI: 1. DCS Switches (31-HS-1335A/B)

2. Low Reactor Feed Pump Flow Low-Low (31-FALL-1329B)

3. Reactor Feed Pump System Activated (31-HL-1332A)

4. Reactor Feed Pump not running (31-ML-1327)

5. Reactor pressure at Adsorber Preheaters (31-PAHH-1608A) or High pressure in the system

14.1.3 Effect of SPI Activation:

When SPI is activated the following valves will close:

Sr No Tag No. Location

1 31-HV-1337 Reactor Feed Pump discharge line to Tempering System

2 31-FV-1314 A SH to the Head Tank

3 31-FV-1314 B SH/CM from solvent feed pump to booster pump suction line

4 31-FV-1318 FE to the Absorber Cooler

5 31-FV-1122 A&B CM from 31-E-113A/B outlet tie in line to 31-E-101A/B outlet line

6 31-FV-1149 A/B FC Make-up line

7 31-TV-1405 A LP Steam to the Reactor Feed Heater

8 31-TV-1405 B HP Steam to the Reactor Feed Heater

9 31-FV-2421 A/B Hydrogen to the Reactor Feed Pump Discharge

10 31-FV-2422 A/B Hydrogen to the Reactor Section

11 31-FV-2047 CAB-2 to the CAB-2 Metering Pump

12 31-FV-2055 CAB to the CAB Metering pump

13 31-FV-2139 CD to the CD Metering Pump



14 31-FV-2147 CT to the CT Metering Pump

15 31-FV-2237 CJ to the CJ Metering Pump

16 31-FV-2317 PG to the PG Metering Pump

17 31-FV-2321 PD to the PD Metering Pump

18 31-LV-1611 Condensate from Adsorber Preheater (31-E-105A)

19 31-LV-1619 Condensate from Adsorber Preheater (31-E-105B)

20 31-FV-1615 HP DTA Vapour to Adsorber Preheater (31-E-105A)

21 31-FV-1616 HP DTA Vapour to Adsorber Preheater (31-E-105B)

22 31-TV-1624 HP DTA Condensate to Adsorber Preheater (31-E-105A)

23 31-TV-1625 HP DTA Condensate to Adsorber Preheater (31-E-105B)

The following Pumps will STOP:

Sr No. Tag No. Location

1 31-P-101/S Solvent Feed Pump and its standby

2 31-P-104 Reactor Feed Pump

14.2 LOS (Light Off Switch) 14.2.1 Description: The Light Off Switch is used to provide a rapid temperature increase in the reactor feed flows. A

temperature increase in the reactor prevents the production of high molecular weight polymer. High

molecular weight polymer can cause rapid pressure increases in the reactor system because of its greater

viscosity (which will cause a process shutdown).

LOS is activated by:

1. ‘LOS’ interlock Activation Switch from DCS (31-HS-1407E)

2. ‘LOS’ interlock Activation Switch from HWC (31-HS-1407B)

3. FB flow to unit low flow deviation alarm (31-FSLL-1122)

4. Reactor Agitator Speed (31-SSL-1552)

5. Hydrogen to Reactor Feed Pump Flow (31-FSLL-2421 A/B)

6. Hydrogen to Reactor Flow (31-FSLL-2422 A/B)

LOS to be activated in the following cases:

1. Sudden loss of reaction.

2. On activation of TAL-1514/TAL-1548A/B or TIC-1514 malfunction to bypass the flow through 31-E-

111.

The following valves and controllers will be affected by LOS:

Sr. No. Tag No. Location

1 31-TV-1405 B HB Steam to the Reactor Feed Heater will open.

2 31-FV-1405 A LP Steam to the Reactor Feed Heater will close.



3 31-TIC-1405 Reactor Feed Heater temperature controller will select a 200°C set point

4 31-TV-1405C Will swing to the High Pressure Cond. Header.

5 31-TV-1406B Reactor Feed Heater flow will open.

6 31-TV-1406 A Reactor Feed Cooler flow will close.

14.3 “Z” Trip (Plant Wide Feed Forward Shutdown & Solvent Isolation):

14.3.1 Description: In case of an emergency, the emergency shutdown switch, “Z” button, can be tripped. There are “Z” buttons

located throughout the units and in the central control room. A power failure will trip the “Z” system. The

purpose of the “Z” button is to stop all forward feeds and remove all heat sources from the process.

14.3.2 Effect of “Z” tripping: Heat sources are isolated from the following:

1. Solution Preheater (DTA)

2. Reboilers (LP/HP Steam and DTA)

3. Reactor Feed Heater (HP Steam)

The following pumps will stop:

All forward feed pumps

Catalyst and deactivator pumps

Feed pumps from OSBL

Solvent condensate Pump

Solvent Skimming Pump

Reflux pumps will continue operating to provide condensing and cooling to help reduce the pressure in the Distillation Columns.

The following valves will close:

• Feed supply valves

• Recycle flow isolating valves

• Purge valves

• Perimeter valves

• Forward feed valves

• The Stripper will vent to atmosphere

14.3.3 “Z” Button Activation The following will occur when the “Z” button is tripped:

The “Z” indicator lights in the control room and/or DCS will illuminate to indicate that the “Z” system has been

activated.

The following equipment will shut down:



Reaction Area: Sr. No Tag No. Location

1 31-P-101/S Solvent Feed Pump

2 31-P-102/S HP diluents Pump and Spare

3 31-P-103 Reactor Feed Booster Pump

4 31-P-104 Reactor Feed Pump

5 31-P-105 CAB-2 Metering Pump

6 31-P-106 CAB Metering Pump

7 31-P-107 CD Metering Pump

8 31-P-108 CT Metering Pump

9 31-P-109 CJ Metering Pump

10 31-P-110/S PG Metering Pump and Spare

11 31-P-111 PD Metering Pump and spare

12 31-P-112 Regeneration Waste Transfer Pump

13 31-P-117 Stop PG Unloading Pump

14 31-P-118 PG Transfer Pump

15 31-K-101 Purifier Regeneration Blower

16 31-K-102/S ‘J’ Compressor

17 31-M-108 Reactor Agitator

Recycle Area:

Sr. No Tag No. Location

1 31-P-201/S LPS Condensate Pump and Spare

2 31-P-202 A/B Hot Flush Pumps

3 31-K-201 FE Feed Regeneration Blower

Finishing Area:


1 31-P-301 Additive Metering Pump




5 31-P-307/S Solvent Skimming Pump and Spare

6 31-P-308/S Solvent Condensate Pump and Spare

7 31-EA-301 Solvent Vapour Condensers Fan 1 & 2

8 31-P-415A/B CM Column Bottom Pump

Utility Area:


1 31-P-410 SH De-inventory Pump

2 31-P-409 FC De-inventory Pump

3 31-P-404 Flare KOD Pump

4 31-P-411/S FB Feed Pump and Spare

5 31-P-412/S Waste Fuel Pump and Spare



The Following Control Valves will close:

Reaction Area:


1 31-FV-1122A Comonomer from CM Reflux Pump through E-113 A/B to SH Purifier, Solvent Feed and

HP Diluent Pump

2 31-FV-1122B Comonomer from CM Reflux Pump through E-113 A/B to SH Purifier, Solvent Feed and

HP Diluent Pump

3 31-FV-1144 SH Filling line to Regenerated Purifier

4 31-FV-1146 Inventory Adjustment line to LPS Hold-Up Tank

5 31-FV-1314A SH/Comonomer from Solvent Feed Pump to Absorber Cooler

6 31-FV-1314B SH/Comonomer from Solvent Feed Pump to Reactor Feed Booster Pump Suction

7 31-FV-1318 FE from Secondary FE Guard Bed to Absorber Cooler

8 31-FV-1547 HP Diluent (as a carrier of CD, CAB, CAB-2) from Pump to Reactor #1 through 31-E-111.

9 31-FV-1723 Solvent (Flushing SH) to Steam Purge Heater (31-E-106)

10 31-FV-2047 CAB-2/CAB to CAB-2/CAB Metering Pump Suction

11 31-FV-2055 CAB/CAB-2 to CAB/CAB-2 Metering Pump Suction

12 31-FV-2060 HP Solvent from HP Diluent Pump to CAB-2 metering pump Discharge line

13 31-FV-2061 HP Solvent from HP Diluent Pump to CAB metering pump discharge line

14 31-FV-2139 CD/CT to CD Metering Pump

15 31-FV-2147 CD/CT to CT Metering Pump

16 31-FV-2152 HP Diluent to CD Metering Pump Discharge

17 31-FV-2153 HP Solvent to CT Metering Pump Discharge

18 31-FV-2237 CJ line to CJ Metering Pump suction

19 31-FV-2242 HP Solvent from HP Diluent Pump to CJ Metering pump Discharge line

20 31-FV-2317 PG From 31-V-116 to PG Metering Pump Suction

21 31-FV-2321 PD from 31-V-117 to PD Metering Pump Suction

22 31-FV-1149A Make-up FC from FC Purifier to Recycle SH Air Cooler

23 31-FV-1149B Make-up FC from FC Purifier to Recycle SH Air Cooler

24 31-FV-2421A Hydrogen from Compressor to Reactor Feed Pump Discharge

25 31-FV-2421B Hydrogen from Compressor to Reactor Feed Pump Discharge

26 31-FV-2422A Hydrogen from Compressor to Reactors #1 and #2

27 31-FV-2422B Hydrogen from Compressor to Reactors #1 and #2

28 31-FV-1615 HP DTA Vapor to Adsorber Preheater DTA Desuperheater(31-V-113A)

29 31-HV-1128 Purified SH from 31-V-125A to Solvent Feed Pump Suction

30 31-HV-1138 Purified SH from 31-V-125B to Solvent Feed Pump Suction

31 31-HV-1337 Reactor Feed to Tempering System(31-E-103, 31-E104A)

32 31-LV-1611 Condensed DTA from Adsorber Preheater (31-E-105A) to HP DTA Condensate Drum




33 31-LV-1914 RA Solution from IPS to LPS 1st Stage

34 31-PV-1725 SH/ N2 Flush Return from Solution Adsorbers to LPS/LB Condensers

35 31-PV-1909A RA from Solution Adsorber to IPS

36 31-PV-1909B RA from Solution Adsorber to IPS

37 31-PV-1911 IPS Overhead Flashed Vapor to LB Feed Condenser

38 31-PV-1916 LPS 1st Stage Flashed off SH+HC to LPS KO Pot

39 31-PV-1926 LPS 2ndStage Flashed off SH+HC to LPS KO Pot

40 31-TV-1405A LP Steam Supply to Reactor Feed Heater

41 31-TV-1405B HP Steam Supply to Reactor Feed Heater

42 31-PV-2766 FE Supply to FE Column Feed Dryer

43 31-HV-2247 SH to SH Make-up Cooler (31-E-116)

44 31-TV-1624 Close HP DTA Condensate to Desuperheater (31-V-133A)

45 31-TV-1625 Close HP DTA Condensate to Desuperheater (31-V-133B)

46 31-LV-1619 Condensed DTA from Adsorber Preheater (31-E-105B) to HP DTA Condensate Drum

47 31-HV-1151 SH Purifier Vent

48 31-HV-2732 FE Supply to Primary FE Guard Bed (31-V-127A)

49 31-HV-2737 FE Supply to Primary FE Guard Bed (31-V-127B)

50 31-HV-2736 Primary FE Guardbed (31-V-127A) FE outlet

51 31-HV-2741 Primary FE Guardbed (31-V-127B) FE outlet

52 31-FV-2758 Primary FE Guardbed charging valve

53 31-FV-1513 HP Diluent from Pump

Recycle Area:


1 31-FV-2812 SH Feed from OSBL to LPS Hold-Up Tank

2 31-FV-2924 From LB Feed Heaters to LB Feed Heater No.2

3 31-FV-3017 FE Make-Up line to Vap. From IPS line

4 31-FV-3031 LB Column Bottom to HB Column

5 31-FV-3033 LP DTA supply to LB Reboiler

6 31-FV-3210 Purified FE from FE column Feed Dryer to HB Column

7 31-FV-3214 FE Column bottom to CM Column

8 31-FV-3217 LP Steam Supply to FE Reboiler

9 31-FV-3315 HB Column Bottom to RB Column

10 31-FV-3318A HP Steam Supply to HB Reboiler (31-E-205A)

11 31-FV-3318B HP Steam Supply to HB Reboiler (31-E-205A)

12 31-FV-3525 SH from RB Column Reflux Pumps Discharge to HB Column

13 31-FV-3814 LP Steam Supply to CM Column Reboiler

14 31-FV-3219 FE Condenser to Refrigeration Unit




15 31-FV3530 LP DTA Vapor supply to RB Column Reboiler

16 31-HV-2925 Recycle SH from LB Feed Heater to Recycle SH Air Cooler

17 31-HV-3529 RB Column bottom O/L to Waste Fuel Drum

18 31-HV-3132 HC from LB Reflux pump discharge to FE col. Feed Dryer Cooler Inlet line

19 31-PV-3019A/B MP Steam from LB Feed Condenser to LP Steam System

20 31-FV-3134A/B FB-1 from 31-P-411/S

21 31-FV-3811 CM Column Bottom outlet

22 31-FV-3911A/B FB-1 Purge to Battery Limit

23 31-FV-3919 FB to FB Surge Tank

24 31-TV-3025 HP Steam inlet to LB Feed Condenser (31-E-202)

25 31-HV-3314A HP Steam to HB Reboiler (31-E-205A)

26 31-HV-3314B HP Steam to HB Reboiler (31-E-205B)

27 31-FV-3322A HP Steam Supply to HB Reboiler (31-E-205B)

28 31-FV-3322B HP Steam Supply to HB Reboiler (31-E-205B)

29 31-HV-3645 FE Feed inlet to 31-V-209A

30 31-HV-3646 Purified FE outlet from 31-V-209A

31 31-HV-3647 FE Feed inlet to 31-V-209B

32 31-HV-3648 Purified FE outlet from 31-V-209B

33 31-HV-3635 Regeneration Gas supply to 31-V-209A

34 31-HV-3638 Regeneration Gas Return from 31-V-209A

35 31-HV-3639 Regeneration Gas supply to 31-V-209B

36 31-HV-3642 Regeneration Gas Return from 31-V-209B

37 31-TV-3629 FE Column Feed Dryer

Finishing Area:


1 31-LV-4717 LP Cond. O/L from Solvent Cond. Pump Discharge Filters to LPS Hold-Up Tank

Utility Area:


1 31-HV-6305 Waste Fuel drum 31-V-411 outlet

2 31-FV-6514 FB-1 Make UP From OSBL to FB Surge Tank 31-V-415

3 31-FV-6626 FC Purifier outlet to FC De-inventory Tank

4 31-FV-6657 FC Purge to FC Purifier Valve

5 31-HV-6638 FC Purifier vent/Drain to FC De-inventory Tank

6 31-HV-6642 FC from FC Purifier 31-V-416A

7 31-HV-6651 FC from FC Purifier 31-V-416B




8 31-HV-6711 SH Supply to SH Make-Up Cooler and LPS Hold-Up Tank

9 31-HV-6712 FC Supply from Offloading Facility to FC Cooler

10 31-HV-6714 FE Supply from Storage/NCU to Primary FE Guard Bed

11 31-HV-6719 FB-1 Supply to FB cooler

12 31-HV-6720 Hydrogen Supply to Compressor

13 31-HV-6723 FE Supply bypass at B/L

NOTE: 31-HV-4630 Stripper vent valve will open when the “Z” trip is activated. Upon activation of the “Z” system, all of the controllers for the above listed valves will switched to Manual

and the valve loading (Output) set to the “Fail Safe” position.

NOTE: Prior to resetting the “Z” circuit or flushing the system with the Hot Flush Pump, the following should

be put on automatic pressure control:

• LPS Second Stage pressure control 31-PV-1926

• LPS First Stage pressure control 31-PV-1916

• IPS pressure control 31-PV-1911

• Reactor System pressure control 31-PV-1909 A/B

The set points should be positioned so that the control valves remain closed when “Z” is reset. They should

then be adjusted to the correct operating pressure.

NOTE: 31-LV-1914 should be opened enough to ensure all the polymer is flushed out of the Reactor system

through the base of the IPS to the LPS.

14.3.4 “Z” Button Reset: All “Z” control stations are to be switched to Manual and set at the desired valve position before the “Z”

button is reset, if this has not already occurred.

Check the availability of steam.

Reset the “Z” button in the control room.

If the emergency is such that the plant can be started up, proceed as follows:

a) Warm the column Reboilers and start up the columns. Admit DTA to the Solution Preheater.

b) Line the Hot Flush Pump (31-P202) through the Purge heaters to the Reactor inlet and slowly

pressurise the system, if the pressure has dropped off. Proceed to flush the Reactor system into the

LPS.

“Z” over-ride switches are provided on the following valves so the system can be either depressurised or the

polymer flushed out, whichever is required in a situation, when the “Z” circuit cannot be reset.



• System pressure 31-PV-1909A/B

• IPS pressure 31-PV-1911

• Feed to the LPS 31-LV-1914

• LPS First Stage pressure 31-PV-1916

• LPS Second Stage pressure 31-PV-1926

• Flushing flow control 31-FV-1723

• Preheater A/B temperature controls 31-FV-1615/31-FV-1616

• Preheater level control 31-LV-1619

• SH Purifier bypass to LPS HUT 31-FV-1146

• Area 200/100 isolation 31-HIC-2925

If the Reactor system must be depressurised:

Depressurise the Reactor system through the IPS to the LPS. Allow the vapours to be condensed in the

LPS Condenser. This action will be limited by the remaining capacity of the LPS Hold up Tank. When this

tank is full, vent the LPS to the Flare header through the manual bypasses around PSV’s. (The advantage

of depressurising the system in this way is that the polymer is retained in the LPS).

If the system can be flushed, but the “Z” circuit cannot be reset:

Line a flushing flow from the LPS Hold-up Tank to the Hot Flush Pump, to the Purge heaters, to the inlet of

the Reactor, to the IPS, to the LPS. Allow the solvent to flush to the LPS Condenser (emergency cooling

water for the LPS Condenser may be required). Flush the system until “Z” can be reset or until inventories

dictate a halt.



SECTION-15.0 LIST OF EMERGENCIES AND EMERGENCY HANDLING PROCEDURE



15.1 Electrical Power Failure 15.1.1 Electrical Power Failure There are three different sources of electric power:

1. Main Power Supply 2. Priority Power Supply This is a back up electrical system. The pumps listed below will be supplied by the main power supply until it

fails, then priority power will supply the following:

1. Seal Oil Circulating Pumps

2. One of two Hot Flush Pumps

3. Power supply to the Uninterruptible Power System

3. Uninterruptible Power System The uninterruptible power system will supply power to:

1. Maintain control of all instruments. 2. The alarm panels. 3. The interlock systems (e.g. solution pumping interlock) 4. The “Z” circuit. 5. The “Z” circuit over-rides. 6. The control computer. 7. The communications circuit. 8. The fire alarm. 9. The Reactor Feed Pump sequencing circuit (Start-up/Shutdown). 10. The emergency lighting system. 11. The solenoid on the air supply to the pulldown valves.

15.1.2 Complete Main Electrical Power Failure

The following services should be available during a power failure:

1. Cooling water through a dedicated line to the LPS condenser and water to the die freeze on the

Extruder.

2. A supply of Nitrogen to blanket the LPS, the Stripper and the Additive Tanks.

3. Sufficient HP steam to supply the Purge Heater during the reactor system flushing operation.

4. Priority power for the Reactor Seal Oil Circulating Pumps.

5. An uninterruptible power supply for the services listed above.

“Z” button is activated on loss of main power. A time delay of approximately 5 seconds is allowed for power

dips before “Z” will trip.

15.1.3 Electrical Power Failure (Monetary Duration) 1. Check the availability of steam before resetting steam loads.

2. Proceed to start up the plant as described in the “Z” trip procedure.



15.1.4 Electrical Power Failure (Extended Duration): 1. Check the availability of steam. Do not increase steam loads until the supplier has given approval.

Conserve steam and water wherever possible.

2. a) Priority power will be supplied to the Reactor Seal Oil Circulating Pumps and the Hot Flush

Pumps.

b) The uninterruptible power supply is supported by the priority power supply. If the priority power

supply fails the uninterruptible power also fails in a period of time. Should this happen, it will be

necessary to start procedures for flushing out the reactor system immediately. “Z” over-rides

switches have been provided at the necessary valves for flushing the polymer out of the reactor

system and into the LPS. (The reactor system will have to be depressurised as soon as possible

after the polymer has been flushed out. The supply of seal oil in the Accumulators should last

approximately 1 hour).

3. Line up emergency cooling water to the LPS condenser and flush out the reactor system with the

Hot Flush Pumps. Take all the flow from the IPS to the LPS. Do not allow any vapour flow to go

overhead in the IPS.

The “Z” button circuit cannot be reset until the main power has been re-established.

NOTE: A positive pressure must be maintained on the LPS at all times. Nitrogen should be introduced to

maintain this positive pressure at 0.005 kg/cm2g.

15.1.5 Uninterruptible Power Supply:

The uninterruptible power supply is from a battery system through an inverter. It is maintained from the main

power supply. If that fails, the priority power comes on and feeds the system. If that also fails, then the

system is fed from the batteries.

A failure of the uninterruptible power occurs when the backup battery system has been depleted. Therefore,

no power is available to operate any of the control panels. Any control stations in the field will continue to

operate if they are pneumatically operated and air remains available.

15.1.5.1 Power is also lost to: 1. The alarm panels

2. The interlock systems

3. The “Z” circuit

4. The “Z” circuit bypasses

5. The control computer

6. The communications circuit

7. The fire alarm

8. The emergency lighting system

9. The solenoid on the air supply to the Pulldown valves



15.1.6 Emergency Building Lights:

Emergency lights are standard lamps that are fed from the uninterruptible power supply.

15.2 Instrument Air Failure 15.2.1 General: The instruments air header supplies air for all pneumatic instruments within the plant. Loss of the instrument

air system is automatically backed up by emergency instruments air into the instrument air system. Failure

of the nitrogen system as well necessitate an immediate shutdown of the entire plant, as all mode of control

would be lost until one of the systems could be restored.

15.2.2 Procedure:

Sr. No.

Description

1. Watch Instrument Air header pressure.

2. Activate 'Z' Switch.

3. Monitor Main Reactor seal oil pressure, adjust pressure manually. Maintain pressure difference of

30 kg/cm2g between seal oil pressure & #1 Reactor inlet pressure.

4. Start Hot Flush Pump (31-P-102/S) and maintain system pressure by throttling manual valves.

5. Stop flushing if pressure falls below 4.0 kg/cm2g and depressurise the system to IPS (31-V-118) &

LPS I & II (31-V-119/120).

6. Isolate all pull down valves in recycle area/Line-up N2 to satellite extruder panel.

7. ISOLATE THE FOLLOWING

• LB reflux vent

• LPS HUT vent

• N2 LPS HUT

• N2 to DTA storage

• Deluge valves

• Pull down valves

15.3 Steam Failure: 15.3.1 General Description of Steam System:

HP steam is supplied from OSBL. Vapour from the HP Condensate Drum, with additional makeup steam

from OSBL; supply all Low pressure steam users. Additional medium pressure and low-pressure steam is

generated in the LB Feed Condenser and the HB Condenser respectively. Low-pressure steam is imported

or exported to or from OSBL as required.

15.3.2 Operating Procedures: In the event of a total steam failure the following would be affected:

• Line and vessel tracing LP/MP/HP Steam

• Reactor Feed Heater HP Steam



• Purge Heaters HP Steam

• FE Column Reboiler LP Steam

• FE Column Feed Heater LP Steam

• HB Column Reboiler HP Steam

• CM Column Reboiler LP Steam

• Steam to rear seal purge jacket on Extruder LP steam

• Extruder vents tracing and jackets HP Steam

• Extruder vent gas educators LP steam

• Underwater Pelletizer Body HP steam

• Extruder transition piece to die body HP steam

• Additive Waste Drum heating coil LP steam

• Additive Mixing Tank heating LP steam

• Additive Holding Tank heating LP steam

• Reservoir heating LP Steam

• Reslurry Water heater LP Steam

• Stripper and blanket steam LP Steam

• Desuperheater LP Steam

• Purge Air Heaters LP Steam

• Blending Air Heaters LP Steam

• Flare KOD heating Coil LP Steam

15.3.3 Procedure in case of HP Steam Failure

Sr. No.

Description

1. If polymer is being produced and a HP steam failure occurs, immediately terminate reaction and

take shutdown of RFP.

2. Flush the reactor system using the Hot Flush Pump (31-P-102/S) through the DTA Purge Heater to

the reactors, IPS (31-V-118) to the LPS (31-V-119/120) and forward to the LPS Hold-up Tank (31-

V-201).

3. Flush the reactor system until all polymers has been flushed to the LPS.

4. Maintain the Adsorber Preheater (31-E-105A/B) temperature while flushing the reactor system.

5. Close the steam control valves on the HB Reboilers (31-E-205A/B). Reduce the reflux flow, stop

forward feed, then shutdown the Reflux pumps (31-P-204/S). Leave the LB and RB Columns on

Total Reflux.

6. Continue the flushing flow from the Hot Flush Pump to maintain the Reactor temperature and

pressure.



15.3.4 LP Steam Failure:

Sr. No.

Description

1. Flush the Reactor System using the RFP at minimum flow. Maintain the IPS (31-V-118) at

operating pressure.

2. Maintain Preheater temperature. When the reactor system has been flushed of all polymer,

shutdown the RFP.

3. Close the steam control valves on the FE and CM Column Reboilers. Reduce reflux flows

(refrigeration system), stop forward feed, then shutdown the Reflux pumps

15.4 Refrigerant Failure:

15.4.1 General A failure of the refrigerant system will affect the FE Column causing a loss of cooling at the top of the column

and resulting in butane losses.

While some loss of butene cannot be avoided, the following procedure should reduce this loss to a minimum.

15.4.2 Procedures:

Sr. No.

Description

1. Watch the FE Column (31-C-205) Pressure.

2. Reduce Feed to FE Column from LB Reflux Drum to minimum to control the LB Column Reflux

Drum level.

3. Watch LB column pressure. Vent LB Reflux drum if necessary. Keep FE column bottom temp. >

108°C.

NOTE: It may be necessary to vent from the LB Reflux Drum to purge excess ethylene if the LB

Column becomes unstable.

4. Reduce FE reboiler steam.

5. Increase FE overhead purge to cracker/fuel gas header & flare if required.

NOTE: Inform Cracker Unit about the line of FE.

6. Stop FE purge to cracker if FE column overhead temperature goes above 40°C. While isolating to

cracker line up to flare.

7. Do not let the base temperature of the FE Column drop below 108°C. This prevents ethylene,

hydrogen and other impurities from going to the CM Column.

NOTE: If ethylene collects in the CM Reflux Drum due to a low base temperature in the FE

Column, it may be vented to the Flare System.



15.5 Cooling Water Failure 15.5.1 Cooling Water Supply Cooling Water is supplied to the following:

• Recycle SH Water Cooler

• Regeneration Blower Aftercooler

• Purifier Regeneration Coolers

• Absorber Cooler

• Reactor Feed Pump Seal Quench

• Seal Oil Cooler

• Lube Oil Cooler

• Agitator Water Cooler

• SH Makeup Cooler

• Hydrogen Compressor

• PA Blower Suction Cooler

• PA Blower Intercooler

• LPS Condensate Pumps

• LB Trim Condenser

• LB Reflux Pump

• HB Reflux Pumps and Seal Quench

• RB Reflux Pumps

• FE Column Feed Cooler

• CM Condenser

• Comonomer Feed Cooler

• FB De-inventory Cooler

• LP Steam Vent Condenser

• Circulating Water Cooler

• Lube Oil Cooler (Main Extruder and Satellite extruder)

• SH Additive Cooler

• Extruder Assembly

• Extruder Purge Fan

• Satellite Extruder Assembly

• Pelletizer Shaft Cooling Water Cooler

• Blending Air Heaters/Coolers

• Silo Conveying Blower Coolers

• Bagging Line Feed Blower Coolers

• Bag Slitter Conveying Blower Cooler



15.5.2 Procedures:

Sr. No.

Description

1. In the event of a Cooing Water failure, terminate reaction (cut off Ethylene, Butene and Hydrogen)

by activating ‘LOS’

2. Stop solvent circulation by stopping Reactor Feed Pump, hold the system pressure.

3. Line up the Emergency Cooling Water supply line to LPS Condensers (31-E-201A/B/C).

4. Check Extruder. On cooling water failure, low-pressure interlocks will automatically shut down

extruders and associated equipment. Stop all other non-essential flows to conserve water.

5. Vent RA Stripper to atmosphere, freeze the die plate and vacuum out DTA system.

6. Columns with air condensers or steam generators can be left on total reflux. Columns with water-

cooled condensers will have to the steam to the Reboilers closed.

7. Using the Hot Flush Pump, flash the Reactor System through to the LPS.

15.6 Reactor Feed Pump Failure 15.6.1 Procedures:

Sr. No.

Description

1. To prevent phase separation, maintain system pressure at 100 to 110 kg/cm2g by closing system

pressure valves PIC-1909 A/B. Take Master controller PIC-1909 in manual and modulating the

output.

2. The low solution flow will activate interlocks (SPI, I-1053), which will close the following valves:

• Solvent feed pump discharge control valve (FV-1314 A/B)

• Hydrogen flow to Reactor Feed Pump (FV-2421A/B)

• Hydrogen flow to Reactor

• Reactor Feed Pump discharge valve (HV-1337)

3. Line-up hot flush to #3 Reactors and flush (Reactor side feed lines to be flushed with hot flush).

Adjust HP DTA flow to Preheater in order to maintain 286-3000C temperature. Maximise hot flush

flow to reactor keeping hot flush temperature @ 3000C.

4. Open FV-1036 and adjust flow to desired rate. Stop the Recycle SH Air Cooler (31-EA-101) fans if

air temperature is below 10oC.

5. Stop catalyst/co-catalyst.

6. Stop PG and PD.

7. Line-up LP diluent to catalyst/co-catalyst & deactivator pumps and flush the system (including

catalyst & co-catalyst control valves).

8. Stop additive injection and line-up SH to additive line.

9. After identifying the cause of failure and corrective action, fill-up RFP check-list. Flush the system

until temperatures have equalised, usually 20 – 30 minutes at maximum flushing rate.

Adequate flushing is required to prevent pressure jerk during RFP restart up



15.7 Emergency Valves: 15.7.1 General Description Remote operated valves are provided for isolating, dumping and depressurising equipment to the flare in the

event of an emergency.

15.7.2 Emergency Isolating Valves: Emergency isolating vales allow vessels containing large quantities of process materials to be separated

from each other quickly.

Isolating valves (which may be closed individually from the central control room) are located in the following

places:

• Head Tank outlet to Reactor Feed Pump 31-HV-1324

• J supply at Battery Limits 31-HV-6720

• SH supply at Battery Limits 31-HV-6711

• FB1 supply at Battery Limits 31-HV-6719

• FC supply at Battery Limits 31-HV-6712

• FE supply at Battery Limit 31-HV-6723

• LPS Condensate Tank outlet 31-HV-2818B

• LB Column outlet 31-HV-3032

• LB Reflux Drum outlet 31-HV-3133

• LB Reflux to FE Feed Dryers 31-HV-3132

• FE Column base 31-HV-3216

• CM Column base 31-HV-3812

• CM Reflux Drum outlet 31-HV-3920

• HB Column base 31-HV-3319

• HB Reflux Drum outlet 31-HV-3446

• RB Column outlet 31-HV-3529

• RB Column Reflux Drum outlet 31-HV-3539

The isolating valves are normally open. During an air failure, most of them will close and are inoperable until

air is restored.

31-HV-1812 and 31-HV-1818 (Solution Adsorber inlet valves) will retain their positions and can be operated

manually.

15.7.3 Emergency Pulldown Valves: The pulldown valves are normally operated by instrument air but have a backup supply of emergency air.

Activation controls are located on the emergency panel in the control room.



Pulldown valves in the field are at the following locations:

• LB Reflux Drum & LB Column Vapour 31-HV-3023

• LB Reflux Drum Liquid 31-HV-3124

• FE Column side Vapour & Liquid 31-HV-3221

• HB Reflux Drum Vapour 31-HV-3445

• HB Column Vapour 31-HV-3327

• HB Reflux Drum Liquid 31-HV-3433

• RB Reflux Drum Liquid 31-HV-3523

• RB Column Vapour 31-HV-3544

• RB Reflux Drum Liquid 31-HV-3534

• CM Column Vapour 31-HV-3824

• CM Reflux Drum Vapour 31-HV-3918

• CM Reflux Drum Liquid 31-HV-3913

• IPS Vapour 31-HV-1913

• FE Feed Dryers Liquid 31-HV-3633

• Stripper Vapour 31-HV-4630

15.7.4 Pressure Safety Valves (PSV) Pressure safety valves are sized and set to prevent damage to equipment from over-pressurisation. Valves,

which have the potential to release hydrocarbons, have the downstream side piped to the Flare System.

This is for the safe containment and disposal of any releases. A rupture disc precedes most Pressure Safety

Valves.

Pressure Safety Valves and Pulldown valves are meant to be in service and their respective isolating valves

open and car sealed. When isolating an emergency valve, the high-pressure side should always be closed

first. When placing the valve in service, the low-pressure side should be opened first.

15.8 Boiler Feed Water Failure 15.8.1 General Description: HP Boiler Feed Water is supplied to the HP Steam De-superheater at Battery Limits, LB Feed Condenser

and the HB Condenser. Failure of the HP Boiler Feed Water will affect the operation of this equipment when

it is in use. The HP Steam will be isolated by high temperature interlock for 31-TV-4532.

15.8.2 Procedures: 1. Shutdown the Reactor Feed Pump and proceed to flush out the system using the Hot Flush Pump

and the DTA purge Heater. Take most of the flow out the IPS base to the LPS then to the LPS

Condensate Tank.

2. Shut off the heat supply to the HB Column Reboiler. Place the LB column and the RB Column on

the total Reflux.



15.9 DTA Failure 15.9.1 General Description: The HP & LP DTA is supplied Reaction and Recycle area. Failure of DTA will affect the following users of

the unit:

HP DTA Users:

• HP Diluent Heaters (31-E-111)

• SH Purifier Regeneration Heater (31-E-109)

• DTA Purge Heater (31-E-107)

• PA Charge Heater (31-E-112)

• Solution Adsorber Preheaters (31-E- 104A/B)

• FE Feed Dryer Regeneration Heater (31-E-217)

• LP DTA condensate Drum (31-V-410)

• Nitrogen Heaters (31-E-406/407/408/409)

• HP DTA Condensate Drum (31-V-406)

LP DTA Users:

• LB Reboiler (31-E-203)

• RB Reboiler (31-E-208)

15.9.2 Procedures: Sr. No.

Description

1. Conserve DTA by Optimising DTA to LB, RB reboilers and secondary users. N2 heaters in all

areas, PA Charge heater, Purifier regeneration heater of Area 100 / 200.

2. Reduce TSR to minimum.

3. RFP to run till preheater outlet temp drops to 286 °C. or no build up of level in IPS (31-V-118). Stop

reaction, and then stop RFP.

4. If header pressure drops below acceptable limit, stop extruder if DTA pressure drops to 2.0 kg/cm2.

In case of LOW MFI (i.e.) < 3 MFI Observe adapter / die body pressure rise in case of low MFI grade.

5. Monitor adapter pressure if MEX is running with high MFI.

6. Run hot flush to flush polymer from system using Steam Purge heater.

7. Continue FE, CM, HB, columns on Total Reflux.

8. Shutdown RB column.

9. Warm-up DTA user at 50°C/hr when DTA is available.



15.10 Exchanger Tube Failure: 15.10.1 Procedure: CASE A: Minor Leak

Sr. No.

Description

1. If the chest pressure has increased gradually and if PAH-1610/1618 get activated, vacuumise the

shell side & check for SH ingress in the HP DTA condensate Drum (31-V-406). The

pressure/temperature profile will change throughout the DTA systems. Once PAH-1610/1618

interlock acts LV-1611/1619 will close automatically. HP DTA Condensate Drum level valve will

close.

2. It the leak is minor open the shell side vent & check for SH. IF SH IS FOUND DEPRESSURISE

THE REACTOR LOOP.

CASE B: Major Leak

Sr. No.

Description

1. Once PAH-1610/1618 interlock acts LV-1611/1619 and HP DTA Condensate Drum level valve will

close automatically.

2. Stop RFP & Depressurise the Reactor System.

15.11 Reactor Feed Tempering System Failure: 15.11.1 Procedure:

Sr. No.

Description

1. Terminate the Reaction. Activate ‘LOS’.

2. Reduce the TSR so that the desired temperature is maintained at the outlet of adsorber preheater.

3. Flush the system with solvent so that the pining gets free of polymer.

4. Restart the reaction as soon as possible.

15.12 Nitrogen Failure: 15.1.12.1 General Description: Priorities of critical systems/ parameters in the event of this emergency on which the sequence of actions is

based:

1. Nitrogen consumption reduction: Minimise usage to slowdown the drop in header pressure.

15.12.2 Operating Procedure:

Sr. No.

Description

1. Monitor Pelletizer current. Reduce Main Extruder speed if Pelletizer current increases.

2. Line-up plant air to cutter immediately.

3. Stop & Isolate purifier regenerations (SH/CM, FE feed dryer, FE purifier, SH makeup dryer, Octene purifier),

Adsorber unloading operations if in progress.



Sr. No.

Description

4. Close Storage tank PIC-6236.

Monitor Surge tank pressure to prevent pump cavitation.

5. All catalyst tanks N2 padding to be isolated and pressure to be held.

6. Isolate N2 padding to following tanks if Nitrogen pressure drops below 3.0 Kg/cm2g:

Additive tanks, LPS HUT, FB Surge Drum, Waste Fuel Drum.

15.13 #1 Reactor Agitator Tripping: 15.13.1 Operating Procedure: Sr. No.

Description

1. Ensure ‘LOS’ Activation. (If required activate manual).

2. Stop Reaction using normal procedure.

3. Flush the system with RFP for 15 minutes.

4. Start agitator only after Reactor is flushed, as shown by equal temperatures throughout the reactor system.

5. Agitator freeness to be checked

6. Restart reaction after Rectification. Otherwise: Stop CAT, J, PG, PD.

NOTE: Reactor agitator to be started only if reactor temperatures are >150° C.

‘LOS’ will activate if SAL-1552 alarm appears even agitator is running.

15.14 RA Stripper High Temperature: 15.14.1 Operating Procedure: Sr. No.

Description

1. Ensure the nitrogen TIC-4635 is responding to the condition by opening FV-4636. Monitor RA

Stripper pressure (nitrogen will affect the condenser).

2. Investigate cause of high temperature (e.g. high RA Stripper pressure, loss of condensate for

LP Steam Desuperheater, high steam flow, high back pressure at steam purge ring due to high

condensate levels or plugged screens.

3. If the temperature reaches the high-high alarm, the stripping steam valve 31-FV-4642

will close. Discontinue extrusion to stop resin flow into RA Stripper, apply blanket steam 31-HV-

4629 and ensure the RA Stripper exhaust valve 31-HV-4630 has opened.

4. Place RA Stripper bottom level valve 31-LV-4615 in manual and continue unloading at the same

rate before the high temperature condition.

Note: It is very critical to keep the resin bed in the RA Stripper in motion to avoid the resin "sticking"

and forming lumps inside the vessel. Monitor RA Stripper exit volatiles that they do not exceed

0.05% without corrective actions.



15.15 RA Stripper High Pressure: 15.15.1 Operating Procedure: Sr. No.

Description

1. Check stripping steam is in control.

2. Check nitrogen TIC-4635 is closed and FV bypass globe valve closed.

3. Check nitrogen to overhead line PV-4632 is closed and bypass not leaking.

4. Ensure cooling fans are running on the Solvent Vapour Condenser.

5. Ensure the cooling water is on full to the Solvent Vapour Trim Cooler and lines are opened properly.

6. Check Coalescer is working properly, lined up with bypass closed.

7. Check Decanter levels

8. Check vents and inert build-ups on Solvent Vapour Condenser, Solvent Vapour Trim Cooler,

Coalescer, Decanter and system vent is operating properly.

9. Check nitrogen rotometer to any RA Stripper instrument that may need them and could

contribute to internal inerts.

10. Open exhaust valve as required keeping internal pressure down.

11. Monitor stripping steam temperature.

15.16 Loss of Stripping Steam to RA Stripper: 15.16.1 Operating Procedure: Sr. No.

Description

1. Ensure RA Stripper exhaust vent valve has opened.

2. Discontinue extrusion.

3. Apply blanket steam – residual flow should be available for a short timeframe..

4. Place RA Stripper bottom level valve in manual and maintain a minimum resin flow out of the

vessel. Monitor exit volatiles, do not allow them to exceed 0.05%.

5. Establish nitrogen flow using FV-4636 to stripping steam line.

6. Determine cause of steam loss.

7. Establish steam flow as soon as possible.



15.17 High Temperature Spin Dryer or Hold-up Bin: 15.17.1 Operating Procedure: Sr. No.

Description

1. Discontinue pellet flow out of RA Stripper into the Spin Dryer and Spin Dryer Hold-up Bin.

2. Shutdown Spin Dryer Hold-up Bin Rotary Feeder.

3. Ensure fire protection TV-4618 has opened (in the field). There is a building external trip switch

for use to keep operators out of the Spin Dryer area for safety.

Note: Demineralised. water supplied is piped to both the Spin Dryer Hold-up Bin and the Spin

Dryer and operates at both locations whether both are involved or not. This is covered under

Interlock 3018.

4. Determine equipment damage after temperatures have returned to normal. If high temperature

alarm remains on, assume firewater nozzles in the equipment are plugged and proceed using

alternate methods. Nitrogen insertion, water hose for spot area and instrumentation verifications of

related instrument.

5. Ensure no polymer lumps have formed in Hold-up Bin from melted polymer that would affect rotary

feeder operation

6. Ensure Spin Dryer Hold-up Bin Purge Fan and Spin Dryer exhaust fan are operating

correctly. An inspection of the Exhaust fan duct cleanout might be required. Use the remote

opening mechanism for the ductwork cleanout port until operator safety is assured. Clean as

required, it is important that this ductwork does not accumulated dust and fines.



SECTION -16.0 CATALYST AND CHEMICAL REQUIREMENT



Six month’s requirements of catalyst and chemicals are as under:

Catalyst, Co-catalyst & De-activator

Name Code NOVA Spec. Purpose Unit

Quantity

Pure Mater Batch

%conc.

TiCl4 (20/80mix) CAB STPA-05 Catalyst MT 7.0

TiCl4 (50/50 mix) CAB-2 STPA-06 Catalyst MT 13.0

Triethyl Aluminium CT STPA-07 Co-catalyst MT 6.0

Diethyl Aluminum Chloride CD STPA-08 Co-catalyst MT 12.0

Diethyl Aluminum Ethoxide CJ STPA-10 Co-catalyst MT 13.0

Pelargonic Acid PG STPA-11-1 De-activator MT 140.0

2,4- Pentanedione

PD STPA-12 De-activator MT 89.0

Additives

50% AO6, 50% AO9 AO2 MT 19.0

Irganox 1076 or similar AO6 -

Irganox 1010 or similar AO8 MT 86.0

Irgofos 168 or similar AO9 -

Processing Aid G-84 MT 27.0 108.00 25

Anti-block Silica MT 146.0 363 40

Kemamide E Ultra Slip MT 31.0

Irganox MD- 1024 MD1 MT 3.0

Xylene SZ MT -

Auxiliary Materials

Name Code NOVA Spec. Purpose Unit

Quantity

Pure Mater Batch

%conc.

Mineral Oil STPA-20 m3 4.0

Isobutyl Alcohol STPA-24 m3 1.0

Extruder Oil (spec. by

extruder vendor)

HTF for

Extruder

Package

m3

Silicon Grease (Molykote 33’) kg 20.0

Sodium Hydroxide kg 140.0

Cyclohexane SH STPA-04 Solvent MT 2025

Butene-1 FB STPA-021 Co-monomer MT 7528

Octene-1 FC STPA-031 Co-monomer MT 3053

Dowtherm HTF MT 250



NOTE: l 1) The requirement of Catalyst, Co-catalyst & De-activator for Initial Start-up will depend on the Total

Solution Rate. The requirement of six month’s is given in the above table.

2) The Vessel bed packing requirement of initial startup is same as given in the Table below under the

subheading “Qty. Per Vessel” Column.

Vessel Bed Packing

Name NOVA Spec. Comments Equip. Tag Unit

Quantity

Qty. per Vessel

Total

Silica Gel STPA-17 Grace 40 or

Equivalent

SH Purifiers

(31-V-125A/B) kg 32400 97200

SH Make-up Drier

(31-V-126) kg 500 500

FE Col. Feed Drier

(31-V-209A/B) Kg 15700 47100

Activated Alumina STPA-13B Activated Alumina

Sol. Adsorber

(31-V-104A/B) MT 26 1657

SH Purifiers

(31-V-125A/B) kg 810 2430

Alumina

1/8” Selexsorb CD or

equivalent Primary FE Guard

Bed

(31-V-127A/B)

kg 20700 41400

1/8” Selexsorb COS

or equivalent kg 11800 23600

¼” Alumina Support kg 720 1440

1/8” Selexsorb AS or

equivalent Secondary FE

Guard Bed

(31-V-132)

kg 5440 5440

¼” Alumina Support kg 360 360

1/8” Selexsorb CD or

equivalent

FC Purifiers

(31-V-416A/B) kg 7500 15000

Ceramic Balls STPA-27

6 mm Balls

31-V-125A/B kg 540 1620

31-V-126 kg 10 20

31-V-209A/B kg 160 480

31-V-416A/B kg 80 160

10 mm Balls 31-V-209A/B kg 325 975

31-V-416A/B kg 160 320

12 mm Balls 31-V-125A/B kg 270 810

31-V-126 kg 20 40

20 mm Balls

31-V-125A/B kg 270 810

31-V-209A/B kg 160 480

31-V-416A/B kg 80 160



SECTIOIN –17.0 EQUIPMENT LIST



17.1 PUMPS:

Item No.

Item Description

Rated Cap. m³/hr (lpm)

Discharge Pressure kg/cm²g

Diff. Head

m

Motor Rated Power

kW

31-P-101/S Solvent Feed Pump 302 40.6 505 550

31-P-102/S HP diluents Pump and Spare 6.09 210 - 38

31-P-103 Reactor Feed Booster Pump 391.3 35.1 95 90.54

31-P-104 Reactor Feed Pump 391.3 179.7 2172 2000

31-P-105 CAB-2 Metering Pump 0.18 193 - 5.50

31-P-106 CAB Metering Pump 0.18 193 - 5.50

31-P-107 CD Metering Pump 0.18 193 - 5.50

31-P-108 CT Metering Pump 0.18 193 - 5.50

31-P-109 CJ Metering Pump 0.18 193 - 5.50

31-P-110/S PG Metering Pump and Spare 0.18 175 - 5.50

31-P-111 PD Metering Pump and spare 0.18 175 - 5.50

31-P-112 Regeneration Waste Transfer Pump 4.71 2.54 31.9 1.5

31-P-113/S Seal Oil Circulating Pump - - - 11.0

31-P-114/S Lube Oil Pump & Spare - - - 1.50

31-P-116/S Lube Oil Pump and Spare - - - -

31-P-117 PG unloading Pump 6.0 2.5 27.8

31-P-118 PG Transfer Pump 6.0 5.6 50

31-P-119/S Gear Type Lubrication Pump - - - -

31-P-120/S Reciprocating Lubrication Pump - - - -

31-P-201/S LPS Condensate Pump & Spare 147 28.55 389 177

31-P-202 A/B Hot Flush Pumps 19 190 - 115

31-P-203/S LB Reflux Pump and Spare 386 28.53 151 113.1

31-P-204/S HB Reflux Pump and Spare 201 11.47 51 28.1

31-P-205/S RB Reflux Pump and Spare 67.7 12.08 150 36.4

31-P-206/S CM Reflux Pump and Spare 188 10 71 29.1

31-P-221/S Lube Oil Pump and spare (204) - - 5.5

31-P-222 Oil Reclaimer Pump (20) - - 1.1

31-P-223 A/B Gear Type Lubricating Pumps - - - -

31-P-224 A/B Reciprocating Lub. Pumps - - - -

31-P-301 Additive Metering Pump 0.45 204.4 - 7.50




31-P-305/S Reslurry Pump and Spare 194.8 6.8 kg/cm2(a) 57.7 54

31-P-306/S Water Circulation Pump & Spare 900 5.1 50.7 151



Item No.

Item Description

Rated Cap. m³/hr (lpm)

Discharge Pressure kg/cm²g

Diff. Head

m

Motor Rated Power

kW

31-P-307/S Solvent Skimming Pump & Spare 2.7 2.53 33 2.34

31-P-308/S Solvent Condensate Pump & Spare 2.32 2.26 22.8 1.34

31-P-309/S L. O. Pump and Spare (Main Ext.G/R) - - - 15.0

31-P-310/S L. O. Pump and Spare (Sat. Ext. G/R) - - - 2.20

31-P-311/S Pelletizer L.O. Pump & Spare - - - -

31-P-312/S Primary Hot Oil Pump - - - -

31-P-313 Secondary Hot oil Pump - - - -




31-P-317/S Primary Hot oil Pump & Spare (Die

Plate) (1.9) - - -

31-P-318/S Main Extruder Motor Lube Pump &

Spare - - - -

31-P-319 Jacking oil Pump for Main Extruder

Motor - - - -

31-P-320/S Extruder Barrel Cooling Water Pump

and Spare - - - -

31-P-321 Hydraulic Pump for Main Extruder

Diverter Valve - - - -

31-P-322 Hydraulic Pump for Satellite Extruder

Diverter Valve - - - -

31-P-401/S HP Steam Cond. Pump and Spare 34 32.1 295 73

31-P-402/S LP Steam Cond. Pump and Spare 67.5 16.6 168 75.0

31-P-403/S HP Steam Cond. Booster Pump &

Spare

15.3(6.3+MC

F) 50.1 225.7 42.72

31-P-404 Flare KOD Pump 18 2.02 31.9 3.26

31-P-405/S HP DTA Cond. Pump and Spare 256.9 10.45 106 132.0

31-P-406/S DTA Transfer Pump and Spare 6.0 3.8 44.6 3.77

31-P-407/S LP DTA Cond. Pump and Spare 208.7 9.08 106 93.5

31-P-408 Blender Wash Pump 100 5.1 21 8.074

31-P-409 FC De-inventory Pump 79.94 12.99 137 36.06

31-P-410 SH De-inventory Pump 63.4 4.16 48.89 9.94

31-P-411/S FB Feed Pump and Spare 60 36.17 556 86.9

31-P-412/S Waste Fuel Pump and Spare 24.1 11.2 130.8 15.65

31-P-414 A/B/S DTA Vaporizer Circulating Pump 451 - 70 110.0

31-P-415 A/B CM Column bottom Pump 4.6 9.7 54.3 1.84

31-P-416 A/B Condensate Sump Pump 15 5.9 62 7.31

31-P-417 A/B Return BCW Pumps 55 5.9 60 16.44



17.2 VESSELS:

Tag No. Item Description ID(mm)

TL-TL(mm)

Design Temp (°C)

Operating Temp. (°C)

Design Pressure (kg/cm2g)

Operating Pressure (kg/cm2g)

31-V-101 Regeneration KOD 1800 4800 150 36 3.5/FV 0.85

31-V-102 SH Recovery Tank 1900 2700 150 36 10.5/FV 1.1

31-V-103 Head Tank 2700 4700 150 33-45 60/FV 27-40

31-V-104 A/B Solution Adsorbers 3800 2900 340/315 286-310 190/195/FV 110-145

31-V-105 CAB-2 Mix Tank 2300 3300 150 37 70/FV 0.7-3.5

31-V-106 CAB-2 Surge Tank 850 2000 150 37 7.0/FV 0.7-3.5

31-V-107 CAB Mix Tank 2300 3300 150 37 70/FV 0.7-3.5

31-V-108 CAB Surge Tank 850 2000 150 37 7.0/FV 0.7-3.5

31-V-109 CD Mix Tank 1900 3300 150 37 7.0/FV 0.7-3.5

31-V-110 CD Surge Tank 850 2000 150 37 7.0/FV 0.7-3.5

31-V-111 CT Mix Tank 1900 3300 150 37 7.0/FV 0.7-3.5

31-V-112 CT Surge Tank 850 2000 150 37 7.0/FV 0.7-3.5

31-V-113 CJ Mix Tank 1900 3300 150 37 7.0/FV 0.7-3.5

31-V-114 CJ Surge Tank 850 2000 150 37 7.0/FV 0.7-3.5

31-V-115 Catalyst KOD 1300 2500 330 45 3.5/FV ATM.

31-V-116 PG Storage Tank 2000 3000 150 30 7.0/FV 4.9

31-V-117 PD Storage Tank 1600 2400 150 30 7.0/FV 4.9

31-V-118 Int. Pressure Separator 2600 3900 343 245-275 67/FV 24-53

31-V-119 1st Stage Low Pressure

Separator 6200 6940 300 210-230 14/FV 0.5-9.2

31-V-120 2nd Stage Low Pressure

Separator 6200/ 3760 - 300 190-230 10/FV 0.36

31-V-121 LPS KO Pot 5250 5250 260 205-230 10/FV 0.2

31-V-122 Reactor Feed heater Cond.

Pot 520 2200 260 140/246 42.2/FV 2.6/36.8

31-V-123 PA Charge Hopper 3780 3780 350 300 0.02/-0.005 ATM.

31-V-124 PA Fall-out Hopper 3300 4300 350 280 max. 0.4/-0.6 -0.47

31-V-125 A/B SH Purifier 2800 9150 325 Max Norm 36

Reg. 300 18/FV

Max Norm

4.9

Reg. 1.2

31-V-126 SH Make-Up Dryer 600 3200 400 Norm 37

Reg. 300 10.5/FV 1.2-2.9

31-V-127 A/B Primary FE Guard Beds 2700 5400 150/325 25 56/3.5/FV 50

31-V-128 A/B LP Barrier Oil Accumulators - - - - - -

31-V-130 Water/Oil Reservoir - - - - - -

31-V-132 Secondary FE Guard Bed 1700 3900 150 25 56/FV

50




TL-TL(mm)

Design Temp (°C)




31-V-133 A/B Adsorber Preheater DTA

Desuperheater - - 400 10/FV

31-V-134 Steam Purge heater

Condensate Pot 450 700 260 246 42.2/FV 36.8

31-V-135 A/B Suction Volume Bottle

- - 65 45 43 16.8

31-V-136 A/B 1st Stage Volume Bottle - - 180 133 70 54.1

31-V-137 A/B 2nd Stage Volume Bottle - - 200 151 245 207

31-V-138 A/B H.P. Barrier Oil Accumulator - - - - - -

31-V-139 A/B Barrier Oil Leakage Pot - - - - - -

31-V-140 PG Storage Tank 3400 5100 150 30 7.0/FV 1.0

31-V-201 LPS Hold-Up Tank 3600 11200 240 50 10/FV 0.12

31-V-202 LB Reflux Drum 3200 9500 270 27.5/FV

31-V-203 HB Reflux Drum 3700 11300 250 172-181 11.0/FV 8-9

31-V-204 RB Reflux Drum 1600 4400 270 137-178 7.5/FV 3.1-3.4

31-V-205 FE Feed Dryer

Regeneration KO Pot 1400 2800 150 36 3.5/FV 1.47

31-V-206 CM Reflux Drum 2300 7400 150 52 10.5/FV 5.75

31-V-207 FE Column Feed Coalescer - - 150 36 40/FV 29.13

31-V-208 A/B HB Reboiler Cond. Pots 600 1700 260 195/240 42.2/FV 13/32

31-V-209 A/B FE Column Feed Dryers 2550 7900 150/325 36/300 40.0/3.5/FV 24.4/2.11

31-V-210 FE Reboiler Condensate

Pot 450 2900 185 140 10/FV 2.6

31-V-211 CM Reboiler Cond. Pot 450 3400 185 140 10/FV 2.6

31-V-212 LB Feed heater No. 2 Cond.

Pot 450 1300 260 246 42.2/FV 36.8

31-V-221 Oil Tank Separator 841 2100 120/-45 -71.3 21/FV 17.86

31-V-222 Secondary Oil Separator 321 1275 120/-45 71.3 21/FV 17.76

31-V-223 Receiver 1319 6080 -45/+65 44 21/FV 17.37

31-V-224 Knock Out Drum 1225 1800 -45/+65 -34 21/FV 0.82

31-V-225 Oil Reclaimer Drum 321 1240 -45/120 -34/+71.3 21/FV 0.82

31-V-226 Seal Drain Pot 201 801 -45/60 AMB 3.5/FV ATM

31-V-301 Additive Holding Tank 1900 2000 185 70 3.5/FV 0.92





31-V-306A Waste Drum 1200 2050 285 70 10.5/FV 0-6.5

31-V-306B Waste Drum 1200 2050 285 70 10.5/FV 0-6.5




TL-TL(mm)

Design Temp (°C)




31-V-307 Seal Pot - 1000 110 50 Full of

water ATM.

31-V-309 Reslurry Tank 1067 3200 110 85-90

1.0+Full of

water

1 m WC

ATM.

31-V-310 RA Stripper 6300 22480 121 103 0.35/-0.07 5

31-V-311 Decanter 1400 4200 121 50 3.5/FV ATM.

31-V-312 SZ Storage Tank 2500 4500 65 AMB. 10.5/FV 1

31-V-313 Blender #1 5500 16290 100 50-85 -0.01/+0.05 -

31-V-314 Blender #2 5500 16290 100 50-85 -0.01/+0.05 -

31-V-315 Blender #3 5500 16290 100 50-85 -0.01/+0.05 -

31-V-316 Blender #4 5500 16290 100 50-85 -0.01/+0.05 -

31-V-317 Spin Dryer Hold-Up Bin - - 100 70 0.35 ATM

31-V-318 Recycle Resin Storage Bin - - 60 ATM 0.04 ATM

31-V-319 Coalescer - - 121 50 3.5/FV 0.15

31-V-322 LP Steam Desuperheater - - 185 142 10/FV 0.095-0.1

31-V-324 Hot Oil Tank - - - - - -

31-V-325A Storage Silo #1 6000 13500 100 AMB-50 -0.01/ 0.05 -

31-V-325B Storage Silo #2 6000 13500 100 AMB-50 -0.01/+0.05 -

31-V-325C Storage Silo #3 6000 13500 100 AMB-50 -0.01/+0.05 -

31-V-325D Storage Silo #4 6000 13500 100 AMB-50 -0.01/+0.05 -

31-V-325E Storage Silo #5 6000 13500 100 AMB-50 -0.01/+0.05 -

31-V-325F Storage Silo #6 6000 13500 100 AMB-50 -0.01/+0.05 -

31-V-326 Cyclone #1 - - 80 AMB. -0.6 -0.31

31-V-327 Cyclone #2 - - 80 AMB. -0.6 -0.31

31-V-328 Cyclone #3 - - 80 AMB. -0.6 -0.31

31-V-329 Cyclone #4 - - 80 AMB. -0.6 -0.31

31-V-330 Cyclone #5 - - 80 AMB. -0.6 -0.31

31-V-331 Cyclone #6 - - 80 AMB. -0.6 -0.31

31-V-332 Cyclone #7 - - 80 AMB. -0.6 -0.31

31-V-402 HP Steam cond. Drum 3500 8400 260 159 10/FV 5.1

31-V-403 LP Steam Cond. Drum 2900 7150 185 107 10/FV 0.3

31-V-404 Flare KOD 5000 16500 315 AMB. 3.5/FV 1.6 MAX.

31-V-405 Polymer KOD 3700 4190 350 150 7.5/FV 1.05

31-V-406 HP DTA Cond. Drum 3400 12200 400 313 10/FV 2.0

31-V-407 DTA Vent Receiver 1500 2200 400 150-207 10/FV -0.8 to -0.7

31-V-408 DTA Regeneration Vessel 900 2000 400 265-280 10/FV 0.2




TL-TL(mm)

Design Temp (°C)




31-V-409 DTA Vent Pot 400 900 400 16-204 10/FV Int (-) 0.933

Top (-)0.833

31-V-410 LP DTA Cond. Drum 2900 9000 400 260 10/FV 0.1

31-V-411 Waste Fuel Drum 3300 8250 260 220 10/FV 2.5

31-V-412 Fuel Gas KOD - - - - - -

31-V-413 DTA Storage Vessel 3400 9350 400 10-45 10/FV 0.1

31-V-414 FC De-Inventory Tank 3900 11700 270 50 7.5/FV 3.5

31-V-415 FB Surge Tank 4000 12000 150 10-40 10.5/FV 6

31-V-416 A/B FC Purifier 1800 5400 Max 240

Reg. 325

Max 30

Reg. 300

Max. 20.5/

Reg. 3.5/Fv

Max 9.8

Reg. 1

31-V-417 HP Steam Desuperheater - - 427 400 50/FV 42

31-V-419 Import LP Steam

Desuperheater - -

185

288 -

10/FV

6.5/FV -

31-V-420 A/B DTA Vaporizer Flash Drum 2750 7000 400 350 12/FV 4.5

31-V-425 Hydrogen Buffer Storage 3000 15000 80/(-40) - 145 -

* FV= Full vacuum

17.3 COLUMNS:

Tag No. Item

Description

No. of Tray/Feed Location

ID (mm)

TL-TL (mm)

Operating Temp (°C)

Operating Press.(*kg/cm²g)

Top Bottom Top Bottom

31-C-201 LB Column 51 3500

4000 38800 110 237 21.2 21.8

31-C-202 HB Column 35 3800 24350 179-184 183-226 9.3 9.55

31-C-203 RB Column 35 1500 21500 185 210 3.6 3.9

31-C-204 FE Column 29

1100

1700

2500

21200 -28 108 20.4 20.54

31-C-205 CM Column 83 2700 42100 56 72 6.0 6.6



17.4 HEAT EXCHANGERS (TUBULAR):

Tag No. Item Description Heat Duty

106 kcal/hr

(kW)

Shell Side Tube Side

Fluid Operating Temp.

Op. Press.

kg/cm2g

(MPa/g)

Fluid

Operating Temp.

Op. Press.

kg/cm2g

(MPa/g) In Out In Out

31-E-101 A/B Recycle SH Water

Coolers 3.31 HC 65 36 6 CW 33 40 5

31-E-102 Absorber Cooler 3.93 CW 33 45 5 HC 62 38 38.8

31-EA-102A/B “J” Comp. Aftercoolers

31-E-103 Reactor Feed heater 7.741*1.25LP

Steam140 140 2.6 HC 47.6 120 143.2-183.3

31-E-104 A/B Reactor Feed coolers 1.497 CW 33 37 5 HC 47.4 35 143.2-183.3

31-E-105 A/B Adsorber Preheaters 6.035 DTA 320 320 2.46 HC 255 290 152

31-E-106 Steam Purge Heater 0.286 HP

Steam248 248 38 HC 50 225 145

31-E-107 DTA Purge Heater 1.665 DTA 344 344 4 HC 225 310 144

31-E-108 Regeneration Blower

Aftercooler 0.286 N2 127.7 38 1.84 CW 33 38 5

31-E-109 Purifier Regeneration

Heater 0.721 DTA 343.6 335.6 3.35 HC+N2 76.9 300 1.84

31-E-110 A/B

Purifier Regeneration

Cooler

1.99 HC+N2 68.1 37 1 CW 33 45 5

31-E-111 HP Diluent

Heater 0.304 DTA 344 339.4 4 HC 35 300 174

31-E-112 PA Charge Heater 0.648 Atm Air -0.7 300 0.23 DTA-A 344 344 4

31-E-113 Comonomer Feed Cooler 0.312 HC 53.7 36 8 CW 33 39 5

31-E-114 PA Blower Suction Cooler - - - - - - - - -

31-E-115 PA Blower Intercooler - - - - - - - - -

31-E-116 SH Make Up Cooler 0.028 HC 50 37 4.1 CW 33 45 5

31-E-117 HP Diluent Pump

Spillback Cooler 0.027189 HC 55 40 7.8 CW 33 38 5

31-E-118 Seal Oil Cooler - - - - - - - - -

31-E-119 Lube Oil cooler - - - - - - - - -

31-E-120 Water Cooler - - - - - - - - -

31-E-122A/B Inter Stage Gas Coolers - Water 33 37 4.5 H2 -133 -43 54.1

31-E-123 A/B Discharge Gas Coolers - Water 33 38 4.5 H2 -151 -45 207

31-E-124 A/B Lube Oil Coolers 0.03 Oil 58 50 5 Water - - 4.5

31-E-201 A/B/C LPS Condenser 13.67 CW 33 45 5 HC 205.3 50 0.22

31-E-202 LB Feed Condenser 15.122 Cond./L

P Steam159 204 16.3 HC 269.3 227 24.5

31-E-203 LB Reboiler 9.491 DTA 311.6 262 0.78 HC 244.3 246.6 22.3

31-E-204 LB Trim Condenser 2.302 CW 33 45 5 HC 65 50.4 20.9




106 kcal/hr

(kW)



Op. Press.

kg/cm2g

(MPa/g)

Fluid

Operating Temp.

Op. Press.

kg/cm2g


31-E-205 A/B HB Reboilers 14.083 MP

Steam198.4 198.4 14.3 HC 184 184.5 9.8

31-E-206 LB Feed Heater No. 2 4.333 HP

Steam246 246 36.8 HC 170.8 233 24

31-E-207 A/B LB Feed Heaters 6.742 HC 181 138.4 8 HC 53.2 171 34.2

31-E-208 RB Reboiler 2.221 DTA 311.6 262 0.78 HC 210 225 4.1

31-E-209 A/B FE Column Feed Dryer

Coolers 0.912 CW 33 40 4.5 HC 71.3 36 25.6

31-E-210 A/B FE Feed Dryer

Regeneration Coolers 0.649 N2 280 37 1.65 CW 33 45 5

31-E-211 A/B FE Feed Dryer Blower

Aftercoolers 0.248 N2 131.7 37 2.52 CW 33 45 5

31-E-212 FE Reboiler 2.267 LP

STEAM139.7 139.7 2.6 HC 108 108.3 20.7

31-E-213 FE Condenser 0.46 Refrig. -34 -34 0.81 HC -25.4 -28.1 20.4

31-E-214 CM Reboiler 6.73 LP

STEAM139.7 139.7 2.6 HC 68.3 68.6 6.9

31-E-215 CM Condenser 7.96 HC 55.6 52.4 6 CW 33 45 5

31-E-216 A/B HB Condensers 21.18 Cond./L

P Steam107 159.1 5.2 HC 180.5 172.5 9.3

31-E-217 FE Feed Dryer

Regeneration Heater 0.604 DTA 344 344 4 N2 75 300 2.52

31-E-221 Condenser 0.7125 Refrig. 71.3 44 17.47 CW 33 40 5

31-E-222 FE Heat Exchanger 104848 Refrig. 44 23.7 17.39 FE purge gas -60.8 10 2.5- 4.5

31-E-223 Economiser with Surge

Drum 0.7149

Refrig.-11.5 -11.5 3.12 propylene 44 -6.5 17.37

31-E-224 Lube Oil Cooler 0.1439 Lube oil 89 60 23.37 CW 33 40 5

31-E-225 A/B Lube Oil Cooler - - - - - - - - -

31-E-301 Solvent Vapour Trim

Cooler 0.113* 1.5 CW 33 45 5

H2O +

HC 65 45 0.02

31-E-302 Reslurry Water Heater 4.407*1.5 LP

Steam151.8 140.5 2.6 H2O 54.7 100 0.6

31-E-303 Additives SH Cooler 0.183 HC 160 45 8.18 CW 33 41 5

31-E-304 Blending air cooler #1 (3017) CW 33 45 0.54 AIR 146 45 0.076

Blending air heater #1 (1336) STEAM 150 149.6 0.46 AIR 40 85 0.043


Blending air heater #2 (1336) Steam 150 149.6 0.46 AIR 40 85 0.043







106 kcal/hr

(kW)



Op. Press.

kg/cm2g

(MPa/g)

Fluid

Operating Temp.

Op. Press.

kg/cm2g



31-E-308 Purge heater #1 (1087) AIR 30 85 (0.032) LP steam 150 149.6 (0.46)

31-E-309 Purge heater #2 (1087) AIR 30 85 (0.032) LP

Steam 150 149.6

(0.46)

31-E-310 Purge heater #3 (1087)

AIR 30 85 (0.032) LP

Steam 150 149.6

(0.46)

31-E-311 Purge heater #4 (1087) AIR 30 85 (0.032) LP

Steam 150 149.6

(0.46)

31-E-312 A/B/C Water Coolers (2889) CW 33 45 (0.54) AIR 139 45 (0.077)

31-E-314 A/B Water Coolers (1775) CW 33 45 (0.54) AIR 108 45 (0.047)

31-E-317 Water Cooler (222) CW 33 45 (0.54) AIR 119 50 (0.045)

31-E-319 Bag Slitter Blower Cooler (1015) CW 33 45 (0.54) AIR 115 45 (0.053)

31-E-320 L.O Cooler (Main Ext.

G/R) 0.0942 L. O. 56 40 5.0 CW 33 35.3 5.4

31-E-321 L.O Cooler (Sat. Ext.

G/R) 0.01204 L. O. 55 43.4 (0.5) CW 33 33.9 (0.54)

31-E-327 Lube Oil Ex. For Main

Extruder Motor - - - - - - - - -

31-E-401 FB De-inventory Cooler 0.291 HC 50.2 40 5.1 CW 33 40 5

31-E-403 DTA Regeneration Vessel

Heater 0.0129 DTA 265 265 0.2 DTA 344 335 3.35

31-E-404 DTA Vent Receiver

Heater 0.055 DTA 207 - -0.733 DTA 260 230 7.4

31-E-405A/B Flare KOD Heater 0.4675 HC -3.66 -3.45 0.1 LP

Steam 156 156 4.6

31-E-406 Nitrogen Heater #1 0.0668 N2 -0.7 300 6 DTA 344.5 344.5 4




31-E-410 FC De-inventory Cooler 1.576 HC 182 50 4.10 CW 33 45 5

31-E-412 DTA Vent Pot Condenser 0.5506 HC 152 152 -0.853 CW 40 52 4.5

31-E-415 Mixed Butene Cooler - - - - - - - - -



17.5 HEAT EXCHANGERS (AIR COOLED):


106 kcal/hr

Tube Side

Fluid Operating Temp. Op. Press.

kg/cm2g In Out

31-EA-101 Recycle SH Air Cooler 12.54 HC 159.7 65 6

31-EA-201 LB Condenser 14.995 HC 100.4 69.7 20.9

31-EA-202 RB Condenser 3.077 HC 140.3 137.2 3.5

31-EA-301 Solvent Vapour Condenser 2.724*1.5 LP Steam HC 107.9 65 0.02

31-EA-401 DTA Vent Condenser 0.328 DTA 344 150 -0.833

31-EA-402 Cond. Return Cooler 0.488 Condensate 108 90 3

31-EA-403 LP Steam Drum Vent Cond. 1.042*1.4 LP Steam 107.5 107.5 0.3

17.6 PLATE EXCHANGERS:


106 kcal/hr

(kW)

Hot Side Cold Side


Op. Press. kg/cm2g

Fluid

Operating Temp.

Op. Press.

kg/cm2g

In Out In Out

31-E-116 SH Make-Up Cooler 0.028610 HC 50 37 4.1 CW 33 45 5

31-E-318/S Water Cooler and

Spare 18.83

Cir.

water54.7 37 4 CW 33 45 5

31-E-328 CCW Cooler 0.66 CCW 70 60 1.5 CW 33 45 5.4

17.7 COMPRESSORS/BLOWERS:

Tag No. Item Description Type Capacity Nm3/hr (kg/hr)

Suction Press.

(kg/cm2g)

Discharge Pressure (kg/cm2g)

31-K-101 Purifier Regeneration Blower Rotary Lobe Type & Oil Free 10247 0.85 1.95

31-K-102/S “J” Compressor & Spare Diaphragm (Triple) (25.2) 17.82(A) 208(A)

31-K-103 Exhaust Fan Centrifugal (7505) 1(A) 1.05 (A)

31-K-104 Charge Heater Blower Rotary Lobe (8372) ATM. 1.27 (A)

31-K-105 PA Blower Rotary Lobe 2783 0.47(A) 1.18 (A)

31-K-201 FE Feed Dryer Regeneration

Blower Rotary Lobe Type & Oil Free (10500) 1.37 2.56

31-K-221 Refrigeration Compressor Flooded screw with separator (5560) 1.75(A) 18.9(A)

31-K-301 Purge Fan - 560 98 KPa (A) -

31-K-302 Spin Dryer Conveying Blower Three lobes/vertical 7402 0.978 (A) 0.85

31-K-303 Blending Blower #1 Three lobes/vertical 7875 0.978 (A) 1






31-K-307 Purge Air Blower #1 Three lobes/vertical 5250 0.978 (A) 0.38




31-K-311 Bag Slitter Conveying Blower Three lobes/vertical 3832 0.978 (A) 1

31-K-312

A/B/C

Silo Conveying Blower

#1/#2/#3 Three lobes/vertical 7990 0.978 (A) 1

31-K-313 A/B Air Aspiration Blower #1/#2 - 2760 98 KPa (A) -

31-K-313 C/D Air Aspiration Blower #3/#4 - 12147 98 KPa (A) -

31-K-314 A/B Bagging Line Feed Blower

#1/#2 Three lobes/vertical 7455 0.978 (A) 0.63

31-K-315 Exhaust Fan Centrifugal - - -

31-K-333 Root Blower Three lobes/vertical 1260 0.978 (A) -0.4

31-K-401 A/B DTA Vaporizer Combustion Air

Fans - - - -

31-K-402 Nitrogen Amplifier - 2.0 6 15

17.8 Heaters

Tag. No. Item Description

31-H-101/S P-101/S Elec. Sump Heater

31-H-201 A/B P-102/S Elec. Sump Heater

31-H-308 Hot Oil Unit Heater



31-H-311 Hot Oil Unit Heater (For Die Plate)






31-H-317 Electrical Heater for Lube Oil Tank

31-H-318 A/B Electrical Heater for Main Extruder

Notes: Two convection sections are provided. One is above Charge heater and No 1 interheater and the

other one is above No 2 Interheater and No 3 Interheater.



17.9 FILTERS:

Tag No. Item Description Type Flow Rate (kg/hr) m3/hr

Design Temp.

°C

Design Pressurekg/cm2g

31-G-101 Regeneration Blower Suction Filter Simplex 6381 150 3.5/FV

31-G-102 CAB/CAB-2 Filter Simplex 0.72 150 14.1

31-G-103 Solvent Feed Filters Duplex & Basket 305.2 100 18

31-G-104 Filter Receiver Bag (2783) 350 0.4/-0.6

31-G-105 A/B PA Blower suction Filters #1/#2 - - - -

31-G-106 Primary FE Guard Bed Outlet Filter Simplex 652 150 56/FV

31-G-107 SH Make-Up dryer Outlet Filter Simplex 6.5 185 10.5

31-G-108 A/B LP Barrier Oil Supply Filter - 1.2 - 140

31-G-109 A/B HP Barrier Oil Supply Filter - - - -

31-G-110 Seal Oil Filter - 1.2 - 240

31-G-111 Lube oil Filter - - - -

31-G-112 Secondary FE Guard Bed Outlet ‘Filter Simplex 652 150 56/FV

31-G-113 A/B K-102 Suction Filter - - - -

31-G-114 A/B K-102/S Lube oil Duplex Filter - - - -

31-G-115 LP Barrier Oil Return Filter - 1.2 - 10

31-G-116 HP Barrier Oil Return Filter - 1.2 - 10

31-G-117 Flushing fluid Filter - 1.2 - 240

31-G-118 Double Change Over Filter - - - -

31-G-119/S P-102/S Lube Oil Duplex Filter - - - -

31-G-202 A/B LPS Cond. Pump Suction Filters Duplex 147 250/

180

42 &

FV/

45&FV

31-G-203 FE Feed Dryer Regeneration Filter Simplex 3974

150 3.5+FV

31-G-204 A/B - - - -

31-G-221 Duplex Oil Filter - - - -

31-G-302

A/B/C/D/E Fines Separators #1/#2/#3/#4/#5

Flow thru separator

unit 275 110

Full of water

+ 1 m

water

31-G-303 Elutriator #1 Bag Filter Reverse Pulse Jet 21000 100 0.1

31-G-304 Elutriator #2 Bag Filter Reverse Pulse Jet 21000 100 0.1

31-G-305 Product Classifier #1 - (85000) 50 -

31-G-306 Product Classifier #2 - (85000) 50 -

31-G-307 Recirculating Water Filters Duplex 1065 110 6.8/FV

31-G-308 Solvent Skimming pump Discharge

Filters Duplex 2.7 110 4.6/FV



Tag No. Item Description Type Flow Rate (kg/hr) m3/hr

Design Temp.

°C

Design Pressurekg/cm2g

31-G-309 Solvent Cond. Pump Discharge Filters Duplex 2.32 110 10/FV

31-G-310 LO Filter for Man Ext. G/R - - - -

31-G-311 LO Filter for Sat Ext. G/R - - - -

31-G-314/S Lube Oil Filter for main Extruder Motor - - - -

31-G-401 A/B/C Side Stream Filter - - - -

17.10 SUMPS

Tag No. Item Description

31-LZ-101 Catalyst Seal Sump

31-LZ-201 Hot Well

31-LZ-202 Process Area Skim Sump

31-LZ-301 Finishing Area Skim sump

31-LZ-302 Storage and Warehouse Area Skim Sump

31-LZ-401 Condensate Sump

31-LZ-402 BCW Sump

17.11 AGITATORS:

Tag No. Item Description

31-M-101 CAB-2 Agitator

31-M-102 CAB Agitator

31-M-103 CD Agitator

31-M-104 CT Agitator

31-M-105 CJ Agitator

31-M-106 Static Mixer

31-M-107 Static mixer

31-M-108 Reactor Agitator

31-M-301 Additive Holding Tank Agitator




31-M-305 Spin Dryer package

31-M-306 Additive Mix Tank Agitator



17.12 HX ITEMS AREA – 100

Sr. No. Tag No. Item P & ID No.

1 HX-102A Vapour Squelcher 00105-GA-31-1118

2 HX-102B Vapour Squelcher 00105-GA-31-1118

3 HX-102C Vapour Squelcher 00105-GA-31-1118

4 HX-102D Vapour Squelcher 00105-GA-31-1118

5 HX-104 Injection Nozzle 00105-HA-31-1119

6 HX-105A Catalyst Drum hose 00105-JA-31-1120

7 HX-105B Catalyst Drum hose 00105-KA-31-1121

8 HX-106A Catalyst Drum hose 00105-JA-31-1120

9 HX-106B Catalyst Drum hose 00105-KA-31-1121

10 HX-108 Mixing Nozzle 00105-CA-31-1113

11 HX-109A PG Drum Pump 00105-MA-31-1123

12 HX-109B PD Drum Pump 00105-MA-31-1123

13 HX-112A Drum weight Scale 00105-JA-31-1120

14 HX-112B Drum weight Scale 00105-KA-31-1121

15 HX-113 Unloading Pipe & Hose 00105-QA-31-1126

16 HX-114 PA Charge Funnel 00105-QA-31-1126

17 HX-117 Injection Nozzle 00105-FA-31-1116

18 HX-118 Injection Nozzle 00105-FA-31-1116

19 HX-120A Catalyst line Purge Hose 00105-JA-31-1120

20 HX-120B Catalyst line Purge Hose 00105-KA-31-1121

21 HX-123A Mixing tee 00105-EA-31-1115

22 HX-123B Flow Orifice 00105-EA-31-1115

23 HX-125A Sparger – Type A 00105-EA-31-1115

24 HX-125B Sparger – Type A 00105-EA-31-1115

25 HX-126A Sparger – Type B 00105-EA-31-1115

26 HX-126B Sparger – Type B 00105-EA-31-1115

27 HX-126C Sparger – Type B 00105-EA-31-1115

28 HX-127 Sparger – Type C 00105-EA-31-1115

29 HX-132A Seal Quench Nozzle 00105-CA-31-1113

30 HX-132B Seal Quench Nozzle 00105-CA-31-1113

31 HX-136A Adsorber Plenum 00105-QA-31-1126

32 HX-136B Adsorber Plenum 00105-QA-31-1126

33 HX-139 3-Way Valve 00105-BA-31-1112

34 HX-140 3-Way Valve 00105-BA-31-1112

35 HX-141 3-Way Valve 00105-JA-31-1120




36 HX-142 3-Way Valve 00105-KA-31-1121

37 HX-144 Toroidal Ring 00105-NA-31-1124

38 HX-145 Flexible Connector 00105-QA-31-1126

39 HX-146 Swivel Joint – 8” 00105-QA-31-1126

40 HX-147 In-;line strainer 00105-CA-31-1113

41 HX-148A Hose 00105-MA-31-1123

42 HX-148B Hose 00105-MA-31-1123

43 HX-150A Hose 00105-MA-31-1123

44 HX-150B Hose 00105-MA-31-1123

45 HX-152A Catalyst Cylinder 00105-JA-31-1120

46 HX-152B Catalyst Cylinder 00105-KA-31-1121

47 HX-154A DTA Vapour/Liquid Separator 00105-FA-31-1116

48 HX-154B DTA Vapour/Liquid Separator 00105-FA-31-1116

49 HX-156 Adsorber Ducting 00105-QA-31-1126

50 HX-157 Hose- 4” 00105-QA-31-1126

51 HX-158 Hose – 8” 00105-QA-31-1126

52 HX-159 3- Way valve 00105-LA-31-1122

53 HX-160 Pilot Operated Check Valve 00105-CA-31-1113

54 HX-169 Loading Chute 00105-QA-31-1126

55 HX-172 Filter 00105-BA-31-1112

56 HX-174 3- Way valve 00105-LA-31-1122

AREA - 200


1 HX-206A Spool Piece for 31-V-202 00206-DA-31-1131

2 HX-206B Monel Valve 00206-DA-31-1131

3 HX-206C Monel Valve 00206-DA-31-1131

4 HX-206D Monel Valve 00206-DA-31-1131

5 HX-207A Spool Piece for 31-V-207 00206-DA-31-1131

6 HX-207B Monel Valve 00206-DA-31-1131

7 HX-207C Monel Valve 00206-DA-31-1131

8 HX-207D Monel Valve 00206-DA-31-1131

9 HX-208A Spool Piece for 31-V-201 00206-AA-31-1128

10 HX-208B Monel Valve 00206-AA-31-1128

11 HX-208C Monel Valve 00206-AA-31-1128

12 HX-208D Monel Valve 00206-AA-31-1128

13 HX-212A Strainer 00206-HA-31-1136



14 HX-212B Strainer 00206-HA-31-1136

15 HX-213A Strainer 00206-GA-31-1135

16 HX-213B Strainer 00206-GA-31-1135

17 HX-217 Hose 00206-GA-31-1135

18 HX-218 Hose 00206-GA-31-1135

19 HX-219 Hose 00206-GA-31-1135

20 HX-220 Hose 00206-GA-31-1135

21 HX-223 Hose 00206-HA-31-1136

22 HX-224 3 - Way Valve 00206-AA-31-1128

23 HX-225 Blowdown Valve 00206-CA-31-1130

24 HX-226 Blowdown Valve 00206-CA-31-1130

25 HX-227A Blowdown Valve 00206-FB-31-1134

26 HX-227B Blowdown Valve 00206-FB-31-1134

27 HX-228A Blowdown Valve 00206-FB-31-1134

28 HX-228B Blowdown Valve 00206-HB-31-1136

29 HX-229 3 - Way Valve 00206-HB-31-1136

30 HX-237 Valve 00206-HB-31-1136

31 HX-239 Valve 00206-HB-31-1136

32 HX-240 Valve 00206-HB-31-1136

33 HX-242 Valve 00206-HB-31-1136

34 HX-244 Valve 00206-HB-31-1136

35 HX-245 Valve 00206-HB-31-1136

36 HX-246 Valve 00206-HB-31-1136

37 HX-247 Valve 00206-HB-31-1136

38 HX-248 Monel Valve 00206-HB-31-1136

39 HX-252 Hose 00206-GA-31-1135

AREA – 300


1 HX-301 Extruder Expansion Joint 00307-AA-311140

2 HX-304A In-line Filter 00307-FA-311148, 00307-GA-31-1149

3 HX-304B In-line Filter 00307-FA-311148, 00307-GA-31-1149

4 HX-304C In-line Filter 00307-FA-311148, 00307-GA-31-1149

5 HX-304D In-line Filter 00307-FA-311148, 00307-GA-31-1149

6 HX-305A Flame Arrestor 00307-DB-31-1145

7 HX-305B Flame Arrestor 00307-DB-31-1145

8 HX-305C Flame Arrestor 00307-DB-31-1145

9 HX-305D Flame Arrestor 00307-DB-31-1145




10 HX-305E Flame Arrestor 00307-DB-31-1145

11 HX-306A Jet Ejector System 00307-AA-31-1140

12 HX-306B Jet Ejector System 00307-AA-31-1140

13 HX-306C Jet Ejector System 00307-AA-31-1140

14 HX-307A K.O. Pot 00307-AA-31-1140

15 HX-307B K.O. Pot 00307-AA-31-1140

16 HX-307C K.O. Pot 00307-AA-31-1140

17 HX-309A Pneumatic Conveyor 00307-MA-31-1154

18 HX-309B Pneumatic Conveyor 00307-MA-31-1154

19 HX-310 Dead Weight Vent 00307-EB-31-1147

20 HX-311 Feed Hopper- Satellite Extruder 00307-DA-31-114

21 HX-315 Flame Arrestor 00307-EB-31-1147

22 HX-317 Flame Arrestor 00307-DA-31-1144

23 HX-318 Spray nozzle 00307-EB-31-1147

24 HX-319 Hose 00307-DA-31-1144

25 HX-320 Hose 00307-GA-31-1149

26 HX-321 Hose 00307-GA-31-1149

27 HX-322 Flame Arrestor 00307-GA-31-1149

28 HX-326A Spray nozzle 00307-DA-31-1144

29 HX-326B Spray nozzle 00307-EA-31-1146

30 HX-326C Spray nozzle 00307-EA-31-1146

31 HX-328 D850 Spin Dryer Exhaust

Ducting 00307-EA-31-1146

32 HX-329 Hose 00307-EA-31-1146

33 HX-330 Tank Chute 00307-GA-31-1149

34 HX-332 Hose 00307-DA-31-1144

35 HX-333 Extruder Motor Purge Duct 00307-GA-31-1149

36 HX-336 Air Filter 00307-BA-31-1141

37 HX-341 Satellite Extruder Feed Chute 00307-AA-31-1140, 00307-MA-31-1154

38 HX-342 Satellite Extruder Feed Chute 00307-AA-31-1140, 00307-MA-31-1154

39 HX-345 Hose 00307-GA-31-1149

40 HX-346A Flexible Connector 00307-HA-31-11450

41 HX-346B Flexible Connector 00307-HA-31-11450

42 HX-346C Flexible Connector 00307-JA-31-11451

43 HX-346D Flexible Connector 00307-JA-31-11451

44 HX-346E Flexible Connector 00307-KA-31-11452

45 HX-347 Hose 00307-GA-31-1149

46 HX-348 Drum Pump 00307-GA-31-1149




47 HX-349 Hose 00307-GA-31-1149

48 HX-350 Angle Valve 00307-EB-31-1147

49 HX-351 Dewatering Screen 00307-EA-31-1146

50 HX-352 Additives Funnel 00307-FA-31-1148

51 HX-353A Waste Drum Weigh Scale 00307-GA-31-1149

52 HX-353B Waste Drum Weigh Scale 00307-EA-31-1163

AREA – 400


1 HX-402 In-line Filter 00421-AA-31-1157

2 HX-403 Hose 00424-EA-31-1163

3 HX-404 Hose 00424-EA-31-1163

4 HX-405 Hose 00424-EA-31-1163

5 HX-406 Silencer 00424-DA-31-1162

6 HX-408 Hose 00424-EA-31-1163

7 HX-410 Hose 00424-EA-31-1163

8 HX-422 In-line Filter 00424-BA-31-1160

9 HX-423 In-line Filter 00424-CA-31-1161

10 HX-424 3-Way valve 00425-CA-31-1166



SECTION-18.0 RELIEF VALVE SUMMARY



18.0 Pressure Safety Valves: 18.1 Reaction Area (Area 100):

SR. No.

Tag No. Description/Location Set

Pressure (kg/cm2g)

Capacity (kg/hr)

Capacity basis

1 PSV-1103 31-V-125A Overhead 18 26520 External Fire

2 PSV-1106 31-V-125B Overhead 18 26520 External Fire

3 PSV-1108 CW Return from Comonomer Feed Cooler 10 -

Thermal Relief

4 PSV-1109 CW Return line from Recycle SH Water Cooler 10 - Thermal Relief

5 PSV-1112 Solvent I/L to Recycle SH Water Coolers 18 External Fire

6 PSV-1116 Comonomer O/L from Comonomer Feed Cooler 18 External Fire

7 PSV-1204 CW Return from Regeneration Blower

Aftercooler 10 - Thermal Relief

8 PSV-1206 Purifier Regeneration Blower Discharge line 3.5 12800 Closed outlet valves at

vessel, pump or heater

9 PSV-1208 Regeneration KOD overhead 3.5 5851 External Fire

10 PSV-1210 SH Recovery Tank Overhead 10.5 7031

External Fire

11 PSV-1212 CW Return line from Purifier Regeneration

Cooler 10 - Thermal Relief

12 PSV-1214 Solvent Feed Filter 18 External Fire

13 PSV-1216 HP Diluent Pump 31-P-102 Discharge Line 216 3890 Closed outlet valve at


14 PSV-1219 HP Diluent Pump 31-P-102S Discharge Line 216 3890 Closed outlet valve at


15 PSV-1229 HP DTA Vap I/L to Purifier Reg. Heater (Shell

Side) 10 External Fire

16 PSV-1232/S Solvent Feed Pump Suction line 18 18681 Leakage through

Check valve

17 PSV-12556/S HP DTA Pump discharge line to HP Diluent

Spillback Cooler I/L (Shell Side) 18 315

Leakage through

Check Valve

18 PSV-1257 CW Return from HP Diluent Pump Spillback

Cooler 10 - Thermal Relief

19 PSV-1305 Absorber Cooler 8 - Thermal Relief

20 PSV-1306 Head Tank Overhead 60 12640 External Fire

21 PSV-1307 Reactor booster Pump Discharge Line 89 23550 Leakage through

Check Valve

22 PSV-1401/S Reactor Feed Heater/Cooler I/L 190 249158 Closed outlet valves at vessel,

pump or heater

23 PSV-1402/S HP Steam I/L to Reactor Feed Heater Cond. Pot 42.2 204185 Exchanger Tube Leak

24 PSV-1414 CW Return line from Reactor Feed cooler 8 - Thermal Relief

25 PSV-1504/S Reactor #2 Inlet Line 193 5272 External Fire



SR. No.


Pressure (kg/cm2g)

Capacity (kg/hr)

Capacity basis

26 PSV-1505 HP DTA I/L to HP Diluent heater (Shell Side) 10 234426 Heat Exchanger Tube

failure

27 PSV-1507/S HP Diluent heater O/L (Tube side) 195 - Thermal Relief/Closed

Outlet valve at heater

28 PSV-1512 RA+HC O/L from Reactor #1 195 - External Fire

29 PSV-1603A HP DTA Vap. I/L to Adsorber Preheater (31-E-

105A) 10 - Heat Exchanger Tue leak/

External Fire

30 PSV-1603B HP DTA Vap. I/L to Adsorber Preheater (31-E-

105B) 10 -

Heat Exchanger Tue

leak/ External Fire

31 PSV-1708 DTA Purge heater O/L (Tube side) 195 - Heat Exchanger Tube leak/

External Fire

32 PSV-1709 Steam Purge Heater O/L

(Tube Side) 195 27720 Closed outlet valves at vessel,

pump or heater

33 PSV-1710 SH to LPS Condenser (Hot Flush) 35 - Control Valve Fail

Open

34 PSV-1711/S HP Steam I/L to Steam Purge Heater (Shell

Side) 42.2 345462

Heat Exchanger Tube

Failure

35 PSV-1712 Solvent O/L from DTA Purge Heater (Tube

side) 195 25200 Closed outlet valve at vessel,

pump or heater

36 PSV-1809 Hot Flush & RA Solution I/L to Solution

Adsorber (31-V-104A) 195 - External Fire

37 PSV-1810 Hot Flush & RA Solution I/L to Solution

Adsorber (31-V-104A) 195 - External Fire

38 PSV-1904/S HC vap. O/L from IPS 67 167703/7327 Closed outlet valves at

vessel/External Fire

39 PSV-1905/S Flashed off Vap (RA) O/L from LPS 1st Stage 14 82673 Closed outlet valves at

vessel/External Fire

40 PSV-1906/S LPS 2nd Stage Overhead 10 5960/13932 Closed outlet valves at

vessel/External

Fire/External Fire

41 PSV-1907/S Vapour O/L from LPS KO Pot 10 20148 External Fire

42 PSV-2022 Catalyst O/L from Catalyst Cylinder 5 62.5 Control valve FO

43 PSV-2023 CAB-2 Mix Tank Overhead 7 4700 External Fire

44 PSV-2024 CAB Mix Tank Overhead 7 4700 External Fire

45 PSV-2025 CAB-2 Surge Tank Overhead 7 1300 External Fire

46 PSV-2026 CAB Surge Tank Overhead 7 1300 External Fire

47 PSV-2029 N2 I/L to CAB/CAB-2 Filer

14.1 - External Fire

48 PSV-2112 N2 Supply Line 5 62.5 Control Valve Fail

Open

49 PSV-2115 CD Mix Tank Overhead 7 3900 External Fire

50 PSV-2117 CT Mix Tank Overhead 7 3900 External Fire

51 PSV-2118 CD Surge Tank Overhead 7 1300 External Fire

52 PSV-2119 CT Surge Tank Overhead 7 1300 External Fire



SR. No.


Pressure (kg/cm2g)

Capacity (kg/hr)

Capacity basis

53 PSV-2218 SH Make-Up Dryer Overhead 10.5 3772 External Fire

54 PSV-2220 CJ Mix Tank Overhead 7 3900 External Fire

55 PSV-2222 CL Surge Tank Overhead 7 1300 External Fire

56 PSV-2225 SH O/L from SH Make-Up Cooler 10 - External Fire

57 PSV-2227 CW Return line from SH Make-Up Cooler 10 - External Fire

58 PSV-2304 PG Storage Tank Overhead 7 8075 External Fire

59 PSV-2305 PD Storage Tank Overhead 7 5085 External Fire

60 PSV-2413 CW Return from Hyd. Compressor (31-K-102) 10 - Thermal Expansion

61 PSV-2414 CW Return from Hyd. Compressor (31-K-102S) 10 - Thermal Expansion

62 PSV-2415 Hydrogen O/L to Compressor (31-K-102) 245 - Closed outlet of

Compressor

63 PSV-2416 Hydrogen O/L to Compressor (31-K-102S) 245 - Closed outlet of

Compressor

64 PSV-2612 Charge Heater Blower Discharge O/L 0.35 - -

65 PSV-2613 PA Blower Discharge O/L 0.2 - -

66 PSV-2614 CW Return line from PA Blower Suction Cooler 10 - Thermal Expansion

67 PSV-2623 PA Blower Suction Cooler O/L (Shell Side) 3.5 8203/540 Heat Exchanger Tube

Failure/Others

68 PSV-2625 HP DTA Vap. I/L to PA Charge Heater (Tube

Side) 10 - External Fire

69 PSV-2626 CW Return line from PA Blower Intercooler

(Tube Side) 10 - Thermal Expansion

70 PSV-2701 FE To FE Col. Feed Dryer Line 40 - Control Valve Fail

Open

71 PSV-2719 FE I/L to Primary FE Guard Bed (31-V-127A) 56 8169 External Fire

72 PSV-2720 FE I/L to Primary FE Guard Bed (31-V-127B) 56 8169 External Fire

73 PSV-2721 Secondary Fe Guard Bed Overhead 56 2340 External Fire



18.2 Recycle Area (Area 200):

Sr. No. Tag No. Description/Location Set

Pressure (kg/cm2g)

Capacity (kg/hr)

Capacity basis

1 PSV-2801 RA Vap/Hot Flush I/L to LPS cond. (31-E-201A)

(Tube Side) 14 - External Fire

2 PSV-2803/S LPS Hold-Up Tank Overhead 10 49300/3113 Loss of Cooling

Medium/ External Fire

3 PSV-2806 SH De-inventory from LPS Cond. Pump

discharge to LPS Hold up Tank Line 15 - Misvalving

4 PSV-2807 CW I/L to LPS Condenser (31-E-201A) (Shell

Side) 11 - Thermal Expansion

5 PSV-2810 RA Vap/Hot Flush I/L to LPS cond. (31-E-201B)


6 PSV-2811 CW I/L to LPS Condenser (31-E-201C) (Shell


7 PSV-2813 RA Vap/Hot Flush I/L to LPS cond. (31-E-201C)


8 PSV-2812 CW I/L to LPS Condenser (31-E-201B) (Shell


9 PSV-2904 Recycle SH I/L to LB Feed heater (31-E-207A)

(Shell side) 18 52345

Heat Exchanger Tube

Failure

10 PSV-2907 Recovered HC O/L from LB Feed Heater (Tube

Side) 45 2313/1425

Thermal

Expansion/Others

11 PSV-2908 Hot Flush Pump (31-P-202A) Discharge Line 215 14250 Closed outlet valve at


12 PSV-2910 Hot Flush Pump (31-P-202B) Discharge Line 215 14250 Closed outlet valve at


13 PSV-2914 LB Feed Heater O/L to Steam Purge Heater line 45 Others

14 PSV-2918 Recovered SH I/L to Hot Flush Pump (31-P-

202A) 45 1425 Backflow on pump

15 PSV-2919 Recovered SH I/L to Hot Flush Pump (31-P-

202B) 45 1425 Backflow on pump

16 PSV-3003A LB Feed Condenser (Shell Side) 30 -

Closed outlet of

Condenser/Control

Valve Fail

Open/External Fire

17 PSV-3003B LB Feed Condenser (Shell Side) 30 -

Closed outlet of

Condenser/Control

Valve Fail

Open/External Fire

18 PSV-3004 LP DTA I/L to LB Reboiler (Shell side) 10 22737 Heat Exchanger Tube

Failure

19 PSV-3005/S LB Column Overhead 27.5 196170 Air Cooled Cond. Failure/Heat

Exchanger Tube Leak/External

Fire

20 PSV-3012/S HP Steam I/L to LB Feed Heater No. 2 (Shell

Side) 42.2 - External fire

21 PSV-3015 Vap. From IPS line to LB Feed Condenser 35 - Control Valve Fail Open

22 PSV-3016 SH Rich Feed I/L(Tray 21) to LB Column 40 - External Fire




Pressure (kg/cm2g)

Capacity (kg/hr)

Capacity basis

23 PSV-3109 CW Return from FE Col. Feed Dryer cooler 8 - Thermal Expansion/Heat

Exchanger Tube leak

24 PSV-3114 Reflux Inlet line to 31-E-209A/B 40 - External Fire

25 PSV-3117 CW Return from LB Trim condenser 10 48956 Heat Exchanger Tube

Failure/Thermal Expansion

26 PSV-3119 FE Col. Feed coalesce Overhead 40 - External Fire

27 PSV-3138 LB Reflux Drum Overhead 27.5 28216 External Fire

28 PSV-3202 LP Steam I/L to FE Reboiler Shell Side) 10 13027 Heat Exchanger Tube

Failure/External Fire

29 PSV-3203/S FE Col. Middle Section 29 59584/59584 Loss of Reflux/Loss of Cooling

Medium/External fire

30 PSV-3205/S Refrigerant(Propane) O/L from FE condenser 21 -

Closed outlet of

condenser/Thermal

Expansion

31 PSV-3235/S FE O/L from Refrigeration System to FE Unit 6 - Control Valve Fail Open

32 PSV-

3304A/B/S HB Col. Overhead 11/11.55/11 490032 Power Failure/Heat Exchanger

Tube Leak/External fire

33 PSV-3305/S HP Steam I/L to HB Reboiler (31-E-205A) 42 - External Fire

34 PSV-3307/S HP Steam I/L to HB Reboiler (31-E-205B) 42 - External Fire

35 PSV-3410A/B HB Condenser (31-E-216A) (Shell Side) 11 - Closed outlet of Condenser/

Control valve Fail

Open/External fire

36 PSV-3411A/B HB Condenser (31-E-216B) (Shell Side) 11 - Closed outlet of Condenser/

Control valve Fail

Open/External fire

37 PSV-3423 CW Return from 31-P-204 10 - Thermal Expansion

38 PSV-3424 CW Return from 31-P-204S 10 - Thermal Expansion

39 PSV-3426 HB Reflux Drum Overhead 11 23344 External Fire

40 PSV-3510 LP DTA Vap I/L to RB Reboiler (Shell Side) 11 - External Fire

41 PSV-3511/S RB Col. Overhead 7.5 37600 Air Cooled cond. Failure/Heat

Exchanger Tube Leak/External

Fire

42 PSV-3543 RB Reflux Drum Overhead 7.5 6247 External fire

43 PSV-3607 FE Col. Feed Dryer (31-V-209A) 40 - External fire

44 PSV-3608 FE Col. Feed Dryer (31-V-209B) 40 - External fire

45 PSV-3713 CW Return from FE Dryer Regeneration Cooler s 10 - Vaporization in Exchanger/

Thermal Expansion

46 PSV-3714 CW Return from FE Feed Dryer Blower

Aftercooler(Tube Side) 10 - Thermal Expansion

47 PSV-3715 FE Feed Dryer Regeneration Blower Discharge

Line 3..5 10500

Closed valve at vessel,

pump or heater

48 PSV-3716 FE Feed Dryer Regeneration KO Pot Overhead 3.5 27214/1556//90

0

Heat Exchanger Tube

Failure/External Fire/PCV Fail

Open)

49 PSV-3717 N2 Supply to 31-V-205 3.5 - PCV Fail Open

50 PSV-3718 FE Feed Dryer Reg. Heater O/L (Tube Side) 3.5 1071 Heat Exchanger Tube





Pressure (kg/cm2g)

Capacity (kg/hr)

Capacity basis

51 PSV-3719 HP DTAI/L to FE Feed Dryer Reg. Heater 10 - External Fire

52 PSV-3720 CW Return from FE Feed dryer Reg. Blower 10 - Thermal Expansion

53 PSV-3802 LP Steam I/L to CM Reboiler 10 - External Fire

54 PSV-3823/S CM Col. Overhead 10.5 122823 Loss of Cooling Medium

55 PSV-3907 CW Return from CM Condenser 4.5 - Thermal Expansion

56 PSV-3923 CM Reflux Drum Overhead 10.5 9302 External Fire

18.3 Finishing Area (Area 300):

Sr. No.


Pressure (kg/cm2g)

Capacity (kg/hr)

Capacity basis

1 PSV-4049 CW Return from Satellite Extruder 10 - Vaporisation in Heat

Exchanger/Thermal Expansion

2 PSV-4101 CW Return from Lube Oil Cooler 10 - Thermal Expansion

3 PSV-4102 CW Return from Lube Oil Cooler 10 - Thermal Expansion

4 PSV-4103X Lube Oil I/L to DC Motor Purge Fan - Control Valve Fail Open

5 PSV-4415 Water Cooler O/L (Process Side) (31-E-318S) 6.8 - External Fire

6 PSV-4416 Water Cooler O/L (Process Side) (31-E-318S) 6.8 - External Fire

7 PSV-4417 CW Return line from Water Cooler (31-E-318S) 10 - Thermal Expansion

8 PSV-4418 CW Return line from Water Cooler (31-E-318) 10 - Thermal Expansion

9 PSV-4421 LP Steam I/L to Reslurry Water Heater (Shell


10 PSV-4606 LP Steam Desuperheater 10 - External Fire

11 PSV-4607 Spin Dryer conveying Blower Discharge Line 0.92 - Closed outlet/Heat

Exchanger Tube Fail

12 PSV-4609 CW Return line from Water Cooler 10 - Thermal Expansion

13 PSV-4703 CW Return from Solvent Vap. Trim Cooler

(Shell Side) 10 - Thermal Expansion

14 PSV-4704 Coalescer 3.5 2160 Closed outlet valve at


15 PSV-4705 Solvent Vap. Trim cooler O/L (Tube Side) 3.5 2160/8245

Closed outlet valve at

vessel, pump or

heater/Heat Exchanger

Tube Failure

16 PSV-4801 Recycle SH O/L from Additive SH Cooler (Shell

side) 18 - External Fire

17 PSV-4802 Additive Mixing Tank Overhead 3.5 16000/6847


vessel, pump or

heater/External Fire



Sr. No.


Pressure (kg/cm2g)

Capacity (kg/hr)

Capacity basis

18 PSV-4803 Additive Holding Tank (31-V-301) 3.5 16000/5742


vessel, pump or


19 PSV-4804 Additive Holding Tank (31-V-302) 3.5 16000/8317


vessel, pump or


20 PSV-4805 Additive Metering Pump Discharge (31-P-301) 228 - Closed outlet of pump

21 PSV-4806 Additive Metering Pump Discharge (31-P-302) 228 - Closed outlet of pump

22 PSV-4816 CW Return from Additive SH Cooler 10 - Thermal Expansion

23 PSV-4901 Additive Holding Tank (31-V-303) overhead 3.5 16000 Closed outlet

24 PSV-4904 Additive Holding Tank (31-V-304) overhead 3.5 16000/5742 Closed outlet /External

Fire

25 PSV-4905 SZ Storage Tank (31-V-312) Overhead 8 11054 External Fire/Closed

outlet

26 PSV-4906A Waste Drum (31-V-306A) Overhead 10.5 3358 External Fire

27 PSV-4907 Additive Metering Pump (31-P-303) discharge

line 228 - Closed outlet of Pump

PSV-4908 Additive Metering Pump (31-P-304) discharge

line 228 - Closed outlet of Pump

28 PSV-5007 Purge Air Blower #1 Discharge Line (31-K-307) 0.33 -

Closed outlet of

Blower/Heat Exchanger

Tube Leak

29 PSV-5008 Blending Blower #1 Discharge Line (31-K-303) 0.92 - Closed outlet of Blower/Heat

Exchanger Tube Leak


Closed outlet of


Tube Leak


Exchanger Tube Leak

32 PSV-5015 CW Return line from Blending Air Cooler (31-E-

304) 10 - Thermal Expansion



34 PSV-5107 Purge Air Blower #3 Discharge Line 0.33 - Closed outlet of Blower/Heat

Exchanger Tube Leak


Exchanger Tube Leak


Closed outlet of


Tube Leak


Exchanger Tube Leak





40 PSV-5207 Silo Conveying Blower #2 Discharge Line - - -



Sr. No.


Pressure (kg/cm2g)

Capacity (kg/hr)

Capacity basis



43 PSV-5211 CW Return from Water Cooler (31-E-312C) 10 - Thermal Expansion

44 PSV-5214 CW Return from Water Cooler (31-E-312A) 10 - Thermal Expansion

45 PSV-5215 CW Return from Water Cooler (31-E-312B) 10 - Thermal Expansion

46 PSV-5301 Bagging Line Feed blower #1 Discharge line - - Closed outlet of Blower/Heat

Exchanger Tube Leak

47 PSV-5302 Bagging line Feed Blower #2 Discharge Line - - Closed outlet of Blower/Heat

Exchanger Tube Leak

48 PSV-5309 CW Return line from Water Cooler (31-E-314A) 10 - Thermal Expansion

49 PSV-5310 CW Return line from Water Cooler (31-E-314B) 10 - Thermal Expansion

50 PSV-5406 Bag Slitter Conveying Dryer

51 PSV-5408 CW Return from Bag Slitter 10 - Thermal Expansion

18.4 Utility Area (Area 400):

Sr. No.


Pressure (kg/cm2g)

Capacity (kg/hr)

Capacity basis

1 PSV-5615 HP DTA Vap. I/L to Nitrogen Heater #1 (Shell








5 PSV-5619 N2 I/L to heater #1 10.5 - External Fire




9 PSV-5623/S Nitrogen Supply to Mix Tanks in Additive Area 3.5 - Control Valve Fail Open

10 PSV-5624/S Nitrogen Supply to Mix/Surge Tanks in Catalyst

and Deactivator Area 6.5 - Control Valve Fail Open

11 PSV-5706A LP Steam I/L to Flare KO Drum Heater 10 - External Fire

12 PSV-5706B LP Steam I/L to Flare KO Drum Heater 10 - External Fire

13 PSV-6005 LP DTA Cond. Drum 10 24789 External Fire

14 PSV-6107 HP DTA Cond. Drum 10 28851 External Fire

15 PSV-6211 CW return from Jacketed Pipe D/S of DTA

Regeneration Vessel bottom O/L 10 - Thermal Expansion



Sr. No.


Pressure (kg/cm2g)

Capacity (kg/hr)

Capacity basis

16 PSV-6214 DTA Storage Vessel Overhead 10 29405 External Fire

17 PSV-6217 DTA Vent Receiver Overhead 10 14302/8089 Heat Exchanger Tube


18 PSV-6218 CW Return line from DTA Vent pot condenser 10 - Thermal Expansion

19 PSV-6221 DTA Regeneration Vessel Overhead 10 3246 External Fire

20 PSV-6223 Nitrogen I/L to DTA Vent Pot 10 1737 External Fire

21 PSV-6228 CW Return from DTA Vent Pot 10 - Thermal Expansion

22 PSV-6229 HP DTA Vap. I/L to DTA Regeneration Vessel

Heater 10 - External Fire

23 PSV-6230 HP DTA Cond. I/L to DTA Vent Receiver Heater 23 - External Fire

24 PSV-6307 Waste Fuel Drum Overhead 10 30225/3600 External Fire/ Vessel

overfill

25 PSV-6401 SH De-inventory Tank Overhead 1 - External Fire

26 PSV-6502 FB Surge Tank Overhead 10 31584 External Fire

27 PSV-6507 CW Return from FB De-inventory Cooler 10 - Thermal Expansion

28 PSV-6603/S FC De-inventory Tank Overhead 7.5 1100/29099/450

00

Control valve fail

open/External

Fire/vessel overfill

29 PSV-6606 FC Purifier Overhead (31-V-416A) 20.5 52226 External Fire

30 PSV-6607 CW Return from FC De-inventory Cooler ( Tube

Side) 10 11208

Heat Exchanger Tube

Failure/Thermal

Expansion

31 PSV-6613 FC Purifier Overhead (31-V-416B) 20.5 52226 External Fire

32 PSV-6730/S FE Supply Line from Storage to B/L 56 - Closed outlet from

Storage

33 PSV-6908/S Piping D/S of 31-V-417 42.2 - Control Valve Fail Open



SECTION-19.0 BLIND LIST



REGENERATION KO DRUM (31-V-101)

Blind No. Blind Location Blind Size/Pres. Rating

1 Vapour outlet line nozzle 12”/ 150#

2 LIT-1241 LP tapping nozzle 2”/ 150#


4 LIT-1240 HP tapping nozzle 2”/ 150#

5 V-101 bottom outlet line nozzle 3”/ 150#


7 Feed inlet nozzle from 31-E-110 12”/ 150#

8 PSV-1208 line nozzle 4”/ 150#

SH RECOVERY TANK (31-V-102)


1 Feed Line from V-101 nozzle 3”/ 150#

2 Sample connection Nozzle 2”/ 150#

3 Utility Connection Nozzle 2”/ 150#

4 Safety Valve(PSV-1210) Nozzle 3”/ 150#

5 Nitrogen I/L Nozzle 2”/ 150#

6 LI-1242 LP tapping 2”/ 150#

7 LI-1242 HP tapping 2”/ 150#

8 Bottom Outlet line Nozzle 3”/ 150#

HEAD TANK (31-V-103)


1 Solution I/L to 31-V-103 at Nozzle 12”/ 600#

2 V-103 Bottom O/L Nozzle 12”/ 600#

3 V-103 Overhead line at Nozzle 6”/ 600#

4 Level Indicator (LIT1322) LP tapping 2”/ 600#

5 Level Indicator (LIT1322) HP tapping 2”/ 600#

6 Level Indicator (LIT1323) LP tapping 2”/ 600#

7 Level Indicator (LIT1323) HP tapping 2”/ 600#



SOLUTION ADSORBR (31-V-104A/B)


1 Feed inlet line nozzle from 31-M-107 10”/ 1500#

2 DTA Inlet line nozzle to tracing 1”/ 300#

3 Bottom outlet line nozzle 10”/ 1500#

4 DTA outlet line nozzle to tracing 1”/ 300#

5 Pressure Tapping connection nozzle special”/ 1500#


7 DTA outlet line nozzle to tracing 1”/ 300#


CAB-2 MIX TANK/CAB MIX TANK

(31-V-105/31-V-107)


1 Level Indicator (LI-2025) LP tapping nozzle 3”

2 Vent 3”

3 Agitator nozzle 10”

4 Nitrogen Inlet line nozzle 2”

5 Feed from Catalyst Cylinder 2”

6 Bottom O/L nozzle to V-106 2”

7 Level Indicator (LI-2025) HP tapping nozzle 3”

8 Temperature Gauge (TG-2040) nozzle 2”

CAB-2 SURGE TANK/CAB SURGE TANK

(31-V-106/31-V-108)


1 N2 inlet line nozzle 2”

2 Level Transmitter (LT-2045) nozzle 3”

3 Bottom O/L nozzle 2”

4 Temp Gauge (TG-2012) nozzle 2”

CD MIX TANK/CT MIX TANK (31-V-109/31-V-111)


1 Level Indicator (LI-2137) LP tapping nozzle 3”

2 Vent 3”

3 Nitrogen Inlet line nozzle 2”

4 Feed from Catalyst Cylinder 2”

5 Bottom O/L nozzle to V-110 2”

6 Level Indicator (LI-2137) HP tapping nozzle 3”

7 Temperature Gauge (TG-2130) nozzle 2”



CJ SURGE TANK/CT SURGE TANK (31-V-110/31-V-112/31-V-114)


1 N2 inlet line nozzle 2”

2 Level Transmitter (LT-2143) nozzle 3”

3 Bottom O/L nozzle 2”

4 Temp Gauge (TG-2107) nozzle 2”

CATALYST KO DRUM

(31-V-115)


1 Filling connection nozzle ¾”

2 Nitrogen inlet Nozzle 2”

3 Feed I/L nozzle 4”

4 Feed inlet line nozzle 4”

5 LG-2202 LP tapping 2”

6 LG-2202 HP tapping 2”

7 TG-2211 nozzle 2”

8 LI-2244 HP tapping 2”

9 LI-2244 LP tapping 2”

PG STORAGE TANK

(31-V-116)

Blind No. Blind Location Blind Size/Pres. Rating 1 Feed Inlet nozzle from Cat. Drum 1”

2 Vent Nozzle 3”



5 V-116 Bottom outlet nozzle 2”


PD STORAGE TANK

(31-V-117)


1 Feed Inlet nozzle from Cat. Drum 1”

2 Vent Nozzle 3”



5 V-116 Bottom outlet nozzle 2”




INTERMEDIATE PRESSURE SEPARATOR

(31-V-118)


1 RA I/L 12”/ 600#

2 Level Element LT-1914 Nozzle 6”/ 600#

3 Blanked Spare Nozzle 3”/ 600#

4 Vapour O/L nozzle 12”/ 600#

5 Temperature Well (TI-1910) 2”/ 600#

6 Tracing Steam I/L ¾”

7 Tracing Steam I/L ¾”

8 Tracing Steam O/L ¾”

9 Tracing Steam O/L ¾”

10 RA O/L from V-118 12”/ 600#

LOW PRESSURE SEPARATOR (1ST stage) (31-V-119)


1 Tracing Steam Coil steam i/l (top Portion) 1”

2 Vapour O/L from LPS 1st stage 20”/ 300#


4 Tracing Steam Coil steam o/l (top Portion) 1”

5 RA I/L to LPS 1st stage 16”/ 300#

6 TE-1920 Nozzle 2”/ 300#

7 Bottom Outlet of 31-V-119 Special Blind








LOW PRESSURE SEPARATOR (2nd stage) (31-V-120)


1 TE-1925 Nozzle 2”/ 150#

2 Safety valve (PSV-1906) line Nozzle 10”/ 150#

3 Vapour Outlet nozzle 8”/ 150#




7 RA inlet to LPS 2nd stage Special Blind

8 Spare Nozzle 8”/ 150#

9 Tracing steam coil steam inlet 1”

10 RA O/L from V-120 Nozzle 60”/ 150#

11 Tracing steam coil steam outlet 1”

12 Tracing steam coil steam inlet 1”

13 Tracing steam coil steam outlet 1”

14 Nitrogen Inlet line nozzle 2”/ 150#

LPS KO POT (31-V-121)


1

2 Nitrogen Inlet line Nozzle 2”/ 300#

3 Vapour O/L nozzle 30”/ 300#

4 Level Switch(LSH-1929) Nozzle 1”/ 300#

5 Jacket Steam Inlet 1”

6 Jacket Steam outlet 1”

7 Waste Waster o/L from V-121 4”/ 300#

8 Tracing Steam Outlet 1”

9 Vapour I/L from LPS Nozzle 30”/ 300#

10 Tracing steam inlet 1”

REACTOR FEED HEATER CONDENSATE POT

(31-V-122)


1 Cond. line from 31-E-103 6” / 300# (IBR)

2 Vent Line Nozzle 1.5” / 300# (IBR)

3 Cond. O/L from 31-V-122 Nozzle 6” / 300# (IBR)

4 LI-1440 HP tapping Nozzle 2” / 300# (IBR)



PA CHARGE HOPPER (31-V-123)


1 Vent 16”

2 Hot Gas inlet 14”

3 V-123 Bottom outlet 8”

4 Hot Gas inlet 14”

5 TG-2601 2”

6 TG-2602 2”

7 TG-2609 2”

PRIMARY FALLOUT HOPPER (31-V-124)


1 Feed Nozzle 10”

2 Vapour outlet To be confirmed

3 Disposal truck vent 4”

4 LSH-2637 nozzle 6”

5 V-123 bottom outlet to disposal truck 8”

6 TE-2638 nozzle 2”


SH PURIFIER (31-V-125A/B)


1 Regeneration N2 to/from line at V-125A/B Nozzle 12”/ 150#

2 PSV-1103 line at V125A/B Nozzle 4”/ 150#

3 At V-125A/B Bottom O/L Nozzle 12”/ 150#

4 TE-1158 2”/ 150#

5 TE-1159 2”/ 150#

6 TE-1160 2”/ 150#

7 Solvent I/L to V125A/B on line (10’-P-11012-A1B-LP/10’-

P-11012-A1B-LP) side 10”/ 150#



SH MAKE-UP DRYER

(31-V-125A/B)


1 Vapour outlet line nozzle 3” / 300#

2 Sample connection nozzle 3” / 300#

3 Bottom outlet line nozzle 2” / 300#

4 Tracing condensate outlet line nozzle 1” / 300#

5 TG-2212 tapping nozzle 2” / 300#

6 Tracing steam inlet line nozzle 1” / 300#

PRIMARY GE GUARD BEDS (31-V-V127A/B)


1 TE-2761A nozzle 2”

2 Analyser Connection nozzle 2”

3 TE-2761B nozzle 2”

4 V-127A/B Bottom outlet nozzle 10”




SECONDARY FE GUARD BED

(31-V-132)


1 TE-2762A nozzle 2”

2 TE-2762B nozzle 2”

3 V-132 bottom outlet nozzle 8”






LPS HOLD UP TANK (31-V-201)


1 Feed nozzle from E-201A/B/C 12” 150#

2 Feed nozzle from V-125A/B line 8”/ 150#

3 Vapour outlet nozzle from V-201 to flare 8”/ 150#

4 LI-2815 LP tapping nozzle 3”/ 150#

5 LI-2815 HP tapping nozzle 3”/ 150#

6 Bottom Outlet nozzle 10”/ 150#

7 Bootleg outlet drain 3”/ 150#

8 LI-2816 HP tapping 3”/ 150#

9 LI-2816 LP tapping 3”/ 150#

10 TG-2802 nozzle 2”/ 150#

LB REFLUX DRUM

(31-V-202)


1 Feed nozzle 16”/ 300#

2 PSV line nozzle 4”/ 300#

3 Vent line to flare 4”/ 300#

4 LIT-3121 LP tapping 3”/ 300#

5 LIT-3121 HP tapping 3”/ 300#

6 Condensate outlet nozzle 10”/ 300#

7

8 Bootleg Level alarm LIT-3122 HP tapping 3”/ 300#

9 Bootleg Level alarm LIT-3122 LP tapping 3”/ 300#

10 TG-3104 nozzle 2”/ 300#

HB REFLUX DRUM

(31-V-203)



2 PSV line nozzle 6”/ 150#



5 Bottom outlet nozzle 14”/ 150#

6 TE-3457 nozzle 2”/ 150#



RB REFLUX DRUM (31-V-204)




3 LIT-3522 LP tapping 3”/ 150#

4 LIT-3522 HP tapping 3”/ 150#

5 Bottom Outlet nozzle 6”/ 150#

6 TG-3503 nozzle 2”/ 150#

FE FEED DRYER REGERNERATION KO POT

(31-V-205)


1 Vapour outlet nozzle 12”/ 150#


3 LI-37xx HP tapping nozzle 2”/ 150#

4 LI-37xx HP tapping nozzle 2”/ 150#


6 LI-37xx LP tapping nozzle 2”/ 150#

7 LI-37xx PP tapping nozzle 2”/ 150#

8 PSV-3716 nozzle 4”/ 150#

LB FEED HEATER NO. 2

(31-E-206)


1 HC outlet line nozzle (Tube Side) 8”/300#

2 Steam inlet line nozzle (Shell side) 6”/300#

3 Condensate outlet line nozzle (shell Side) 6”/300#

4 HC inlet line nozzle (Tube side) 8”/300#

FE COLUMN FEED COALESCER

(31-V-207)


1 FE outlet line nozzle 6”/ 300#

2 PSv-3119 line nozzle ”/ 300#

3 Feed inlet line from 31-E-209A/B 6”/ 300#


5 Boot leg drain line nozzle 2”/ 300#



HB REBOILER CONDENSATE POT (31-V-208A/B)


1 Equalization line nozzle 2”/ 300#

2 Inlet line from 31-E-205A/B 6”/ 300#

3 Condensate outlet line nozzle 6”/ 300#

4 Drain line 2”/ 300#

5 LIT-3320a tapping nozzle 2”/ 300#

FE COLUMN FEED DRYER

(31-V-209A/B)



2 TW-3402 nozzle 2”/ 300#

3 TE-3629 nozzle 2”/ 300#

4 TE-3636 nozzle 2”/ 300#


6 Analyser AI-3634 nozzle 2”/ 300#

FE REBOILER CONDENSATE POT

(31-V-210)


1 Vent 2”/ 150#

2 Equalization line 3”/ 150#

3 LIT-3220 nozzle 2”/ 150#

CM REBOILER CONDENSATE POT (31-V-211)


1 Vent nozzle 2”/ 150#

2 Equalization line 6”/ 150#

3 LIC-3816 nozzle 2”/ 150#

LB FEED HEATER NO.2 CONDENSATE POT

(31-V-212)



2 Vent 2”/ 300#

3 Condensate Outlet 6”/ 300#

4 LIC-3007 nozzle 2”/ 300#



ADDITIVE HOLDING TANK (31-V-301)


1 Vent line nozzle 2”

2 PSV-4803 nozzle Note 3

3 LIT-4837 LP tapping 3”

4 Feed line nozzle from V-305 2”


6 LIT-4837 HP tapping 3”

7 Bottom outlet nozzle 2”

8 Jacket condensate outlet nozzle 2”

9 TIC-4826 nozzle 2”

10 Jacket steam inlet line nozzle 2”

ADDITIVE HOLDING TANK

(31-V-302)





4 Feed inlet line nozzle from V-301 2”







ADDITIVE HOLDING TANK

(31-V-303)

Blind No. Blind Location Blind Size/Pres. Rating 1 Vent line nozzle Note 6



4 Feed inlet line nozzle from Add. Mixing tank 2”









ADDITIVE HOLDING TANK (31-V-304)


1 Vent line nozzle Note 8



4 Feed inlet line nozzle from Add. Mixing tank 2”







ADDITIVE MIXING TANK

(31-V-305) Blind No. Blind Location Blind Size/Pres. Rating




4 SZ Feed inlet line nozzle 2”







WASTE DRUM (31-V-306A/B)


1 Nitrogen inlet line nozzle 2”/ 150#

2 Vent 2”/ 150#

3 PSV-4905A line nozzle 3”/150#

4 Vents from Additive mix/holding tanks 2”/ 150#

5 TIC-4932A tapping nozzle 2”/ 150#

6 Drain line nozzle 2”/ 150#

7 Condensate outlet line nozzle 3/4”/ 150#

8 Steam inlet line nozzle 3/4”/ 150#

SEAL POT (31-V-307)


1 Drain line nozzle 2”/ note 11



RESLURRY TANK (31-V-309)


1 Sight glass 4” Note 12

2 Vent nozzle 4”

3 Feed nozzle 16”

4 Sight glass 4”

5 LSHH-4427 2”

6 LSHH-4453 2”

7 Water inlet line nozzle 8”


9 LIT-4426 HP tapping nozzle 3”

10 LIT-4426 LP tapping nozzle 3”

RA STRIPPER

(31-V-310)



2 TI-4614 tapping nozzle 2”/ 150#

3 Vapour outlet line nozzle to 31-EA-301 14”/150#

4 Steam inlet line 3”/ 150#

5 PSV-4605 line nozzle ”/ 150#

6 Equalizing Valve 2”/ 150#

7 LIT- 4615 tapping nozzle 10”/ 150#

8 Steam inlet line nozzle 8”/ 150#




12 PIT-4610 nozzle 2”/150#

13 Utility Connection 2”/150#

14 Bottom outlet line nozzle 12”/150#

15 Process Steam inlet line nozzle 6”/150#




19 Drain 3”/150#

20 Drain 3”/150#

21 Sample Connection ”/150#

22 LSHH-4616 nozzle 4”/150#

23 LSLL-4617 nozzle 4”/150#

24 Water Outlet line nozzle 14”/150#



DECANTER (31-V-311)


1 Feed nozzle from 31-P-308/s 2”/ 150#

2 Vent 4/150#

3 LIT 4717 LP tapping nozzle 2”/ 150#

4 LIT 4717 HP tapping nozzle 3”/ 150#


6 Bootleg drain line nozzle 2”/ 150#

7 Boot leg level indicator LIT-4723 HP tapping nozzle 3”/ 150#

8 Boot leg level indicator LIT-4723 LP tapping nozzle 3”/ 150#

9 Vessel drain nozzle 2”/150#

10 Draw off to skim pump nozzle 4”/ 150#

11 LG-4707 HP tapping nozzle 4”/ 150#

12 TG-4719 tapping nozzle 2”/150#

SZ STORAGE TANK

(31-V-312)



2 PSV-4905 Note 10#

3 SZ Feed nozzle 2”/ 150#




DECANTER (31-V-319)

Blind No. Blind Location Blind Size/Pres. Rating 1 Outlet line nozzle 3”/ 150#

2 PSV-4704 nozzle /150#

3 Inlet line nozzle 3”/ 150#

4 Drain line nozzle 2”/ 150#



HP STEAM CONDENSATE DRUM (31-V-402)


1 Excess Steam feed nozzle 10”/#

2 HP Condensate Feed nozzle 14”/#

3 Vent 2”/#

4 31-P-401/S min flow return line 4”/#

5 TG-8601 nozzle 2”/#

6 PG-8607 nozzle 2”/#

7 PSV-8607 nozzle 8”


9 Steam outlet line to LP Steam header 18”

10 LG-8601 LP tapping nozzle 2”


12 LG-8601 HP tapping nozzle 2”


14 BFW feed line nozzle 2”

15 Drain 3”

LP STEAM CONDENSATE DRUM

(31-V-403)


1 Feed line nozzle from LB Cond. Header 12”/150#

2 HP Condensate Feed nozzle 10”/ 150#

3 PSV-8603 nozzle 4”/ 150#

4 Cond. Inlet line nozzle 2”/ 150#

5 TG-8602 nozzle 2”/ 150#

6 PG-8608 nozzle 2”/ 150#

7 Vent 2” / 150#

8 Vapour outlet line nozzle 8” / 150#

9 LG-8604 LP tapping nozzle 2” / 150#

10 LIT-8605 LP tapping nozzle 2” / 150#

11 LG-8604 HP tapping nozzle 2” / 150#

12 LIT-8605 HP tapping nozzle 2” / 150#

13 Bottom outlet line 6” / 150#

14 BFW feed line nozzle 2” / 150#

15 Drain 3” / 150#



FLARE KNOCK OUT DRUM (31-V-404)


1 Vapour outlet nozzle to flare stack 42”/ 150#

2 TG-5703 nozzle 2”/ 150#

3 Feed nozzle - from pull down flare header Note 13

4 Feed nozzle- from Flare header 36”/ 150#

5 Steam inlet to E-405B tube nozzle 3”/ 150#

6 Condensate outlet from E-405B nozzle 2”/ 150#

7 TG-5704 nozzle 2”/ 150#

8 Bottom outlet line nozzle Note 14


10 LG-5701 LP tapping nozzle 2”/ 150#



13 Condensate outlet nozzle from E-405A 2”/ 150#

14 Steam inlet nozzle to e-405A 3”/ 150#



POLYMER KNOCK OUT DRUM (31-V-405)



2 PG-5707 nozzle 1”/ 150#

3 Steam inlet nozzle in Coil 1”

4 Steam outlet nozzle from coil 1”

5 Feed line nozzle from Additive Area NOTE 15

6 Feed line nozzle from Solution Adsorbers 4”/ 150#

7 Steam inlet nozzle in coil 1”



10 TG-5710 nozzle 2”/ 150#

11 Steam inlet nozzle in coil 1”

12 Feed nozzle from Reaction Area NOTE 16



HP DTA CONDENSATE DRUM (31-V-406)


1 Feed line nozzle of HP DTA collection 12”/ 300#

2 Feed nozzle from P-406/S 4’/ 300#

3 TG-6103 nozzle 2”/ 300#

4 PIT-6112 nozzle 2”/ 300#

5 PSV-6107 nozzle NOTE 17

6 Vent nozzle 2”/ 300#




10 TE-6116 nozzle 2”/ 300#




14 Feed from Adsorber Preheaters 10”/ 300#

15 HP DTA vap. Inlet nozzle 16”/ 300#

DTA VENT RECEIVER (31-V-407)


1 PSV-6217 nozzle 3”/ 300#




5 Return line nozzle from DTA Transfer pump 2”/ 300#

6 TE-6240 nozzle 2”/ 300#




10 DTA liquid Outlet nozzle from E-404 2”/ 300#

11 DTA vap. Inlet line nozzle to E-404 2”/ 300#




DTA REGENERATION VESSEL (31-V-408)



2 PSV-6246 nozzle 2’/ 300#

3 Vap. Outlet nozzle 3”/ 300#

4 TG-6207 nozzle 2”/ 300#


6 HP DTA vap inlet line to E-403 2”/ 300#

7 Liq. Outlet nozzle from e-403 1.5”/ 300#


9 TE-6251 nozzle 2”/ 300#





DTA VENT POT (31-V-409)


1 PSV-6223 nozzle 2”/ 300#

2 Feed nozzle 3’/ 300#




6 CW outlet nozzle (Tracing coil) 1”/ 300#



9 CW inlet nozzle (Tracing coil) 1”/ 300#


11 TG-6209 nozzle 2”/ 300#



LP DTA CONDENSATE DRUM

(31-V-410)


1 Feed nozzle from LP DTA collection 4”/ 300#

2 DTA makeup Feed line nozzle from DTA transfer pump 4’/ 300#

3 PIT-6015 nozzle 3”/ 300#

4 TG-6002 nozzle 2”/ 300#


6 Vent line nozzle 3”/ 300#





11 TE-6016 nozzle 2”/ 300#


13 Feed line nozzle from RB Reboiler 6”/ 300#

14 Feed line nozzle from LB Reboiler 10”/ 300#

WASTE FUEL DRUM NOTE 21 (31-V-411)


1 Feed line nozzle (RB purge) from RB column 2”

2 Feed line nozzle from Reaction Area 2”

3 Vent 2”

4 Nitrogen inlet line nozzle 2”




8 LP steam inlet line nozzle 1”

9 LP condensate outlet line nozzle 1”





14 Feed line nozzle from P-412/S 4”



DTA STORAGE VESSEL

(31-V-413)


1 Nitrogen Inlet line nozzle


3 Feed from DTA emergency vent line nozzle NOTE 19

4 Feed line nozzle from Vaporiser drain 3”/ 300#





9 TG-6219 nozzle 2”/ 300#


FC DEINVENTORY TANK

(31-V-414)




3 PSV-6603 nozzle 6”/ 150#



6 LIT-6619HP tapping nozzle 2”/ 150#


8 Bottom outlet line nozzle 6”/3150#

9 TG-6601 nozzle 2”/ 150#

FB SURGE TANK

(31-V-415)


1 Feed line nozzle 6”/ 150#

2 PSV-6502 nozzle 6”/ 150#





7 TG-6504 nozzle 2”/ 150#



FC PURIFIER (31-V-416A/B)


1 At Feed line inlet on 10”-P-66027-B1B-P side 10”/ 300#

2 Reg. N2 line nozzle 4”/ 300#


4 TE-6632 nozzle 2”/ 300#

5 TE-6631 nozzle 2”/ 300#

LB COLUMN

(31-C-201)


1 Vapour outlet nozzle from Column 16”/300#

2 Reflux return nozzle 10”/300#

3 TE-3028A tapping nozzle 2”/300#

4 TE-3028B tapping nozzle 2”/300#

5 TE-3028C tapping nozzle 2”/300#

6 Reboiler return line nozzle 28”/300#

7 TE-3025B tapping nozzle 2“/300#

8 Col. O/L to Reboiler 24“/300#

9 Column bottom outlet line nozzle 18“/300#

10 TE-3042 tapping nozzle 2“/300#

11 LI-3046 HP tapping nozzle 3“/300#

12 LIT-3030 HP tapping nozzle 3“/300#

13 LI-3046 LP tapping nozzle 3“/300#

14 PIT-3024 tapping nozzle 2“/300#

15 LIT-3030 LP tapping nozzle 3“/300#



18 Feed nozzle from 31-E-206 6“/300#

19 Feed nozzle from 31-E-206 6“/300#


21 Feed line nozzle 8“/300#






HB COLUMN (31-C-202)

Blind No. Blind Location Blind Size/Pres. Rating 1 Vapour outlet nozzle from Column 24”/150# 2 Reflux return nozzle 10”/150#

3 TE-3309 tapping nozzle 2”/150#



6 Feed line nozzle from RB column bottom 6”/150#

7 Reboiler return line nozzle




11 Column O/L nozzle to Reboiler

12 Column bottom outlet line 6“/150#

13 Column O/L nozzle to Reboiler


15 LIT-3312 HP tapping nozzle 3“/150#


17 LIT-3312 LP tapping nozzle 3“/150#

18 Reboiler return line nozzle

19 Feed inlet line nozzle 12“/150#


RB COLUMN

(31-C-203) Blind No. Blind Location Blind Size/Pres. Rating

1 Vapour outlet nozzle from Column 12”/150# 2 Reflux return nozzle 4”/150#


4 TE-3518 tapping nozzle 2”

5 TE-3519 tapping nozzle 2”

6 PIT-3527 tapping 2”

7 Reboiler return line nozzle 16”

8 TE-3528A nozzle 2“

9 Column O/L nozzle to Reboiler 14“

10 Column bottom outlet line 2“


12 LI-3545 HP tapping nozzle 3“


14 LI-3545 LP tapping nozzle 3“

15 LIT-3520 LP tapping nozzle 3“

16 TIC-3541 tapping 2”“

17 Feed nozzle 8”/150#“



FE COLUMN (31-C-204)


1 Vapour outlet nozzle from Column Special

2 TE-3225 nozzle 2”/300#

3 PIT-3229 nozzle 2”/300#




7 TE-3231 nozzle 2”/300#





13 PIT-3215 tapping 2“/300#

14 Reboiler outlet to Column 14”/300#

15 Column outlet line nozzle to Reboiler 12“/300#


17 TE-3262 nozzle 2“/300#


19 LIT-3213 HP tapping nozzle 3”/300#


21 LIT-3213 LP tapping nozzle 3”/300#

22 TE-3232 nozzle 2”/300#

23 PSV-3203 nozzle

24 TE-3223 nozzle 2”/300#



CM COLUMN (31-C-205)

Blind No. Blind Location Blind Size/Pres. Rating 1 Vapour outlet nozzle from Column 16”/150#

2 TE-3817 nozzle 2”/150#

3 Feed line nozzle 8”/150#




7 Reboiler outlet to Column 20”/150#

8 LI-3808 LP tapping nozzle 3”/150#


10 LI-3808 HP tapping nozzle 3”/150#


12 Column outlet line nozzle to Reboiler 16”/150#


14 TE-3808 nozzle 2“/150#

15 PIT-3813 nozzle 2“/150#

16 TE-3818 nozzle 2“/150#

17 Reflux return line nozzle 8“/150#

RECYCLE SH WATER COOLER

(31-E-101A/B)

Blind No.

Blind Location Blind Size/Pres. Rating

1 Water outlet nozzle (Tube Side) 10”/150#

2 Hydrocarbon Inlet nozzle (shell Side) 10”/300#

3 Shell vent nozzle ¾”/300#

4 Hydrocarbon outlet nozzle (Shell side) 10”/300#

5 Water inlet nozzle (Tube side) 10”/300#

ABSORBER COOLER

(31-E-102)

Blind No.


1 Cooling water inlet line nozzle 10”/150#

2 Drain 2”/300#

3 Process liquid outlet line nozzle 12”/600#

4 Process liquid inlet line nozzle 12”/600#

5 Drain 2”/150#

6. Cooling Water outlet line nozzle 10”/150#

7 PSV-1305 nozzle 4”/150#



REACTOR FEED HEATER (31-E-103)

Blind No.


1 HC outlet line nozzle 10”/1500#

2 Steam inlet line nozzle 10”/300#

3 Vent 3/4”/300#

4 Condensate outlet nozzle 6”/300#

5 HC inlet line nozzle 10”/1500#

REACOTR FEED COOLERS

(31-E-104A/B)


1 Hydrocarbon outlet nozzle (Tube Side) 10#/1500#

2 Cooling water inlet nozzle(Shell Side) 10”/150#

3 Cooling water outlet nozzle (Shell Side) 10”/150#

4 Hydrocarbon outlet nozzle (Tube Side) 10”/150#

ABSORBER COOLER

(31-E-105A/B)

Blind No.


1 Process outlet line nozzle 8”/1500#

2 Dowtherm inlet line nozzle 14”/300#

3 Dowtherm condensate outlet line nozzle 8”/300#

4 Process inlet line nozzle 8”/1500#

STEAM PURGE HEATERS

(31-E-106)


1 HC outlet nozzle (Tube Side) 4”/1500#

2 Steam inlet nozzle (Shell side) 4”/300#

3 Shell side vent ¾”/300#

4 Condensate outlet nozzle (shell side) 4”/300#

5 HC inlet nozzle (Tube Side) 4”/1500#



DTA PURGE HEATER (31-E-107)


1 HC outlet nozzle (Tube Side) 4”/1500#

2 DTA inlet nozzle (Shell side) 3”/300#

3 Shell side vent 1.5”/300#

4 DTA outlet nozzle (shell side) 4”/300#

5 HC inlet nozzle (Tube Side) 4”/1500#

REGERNERATION BLOWER AFTERCOOLER

(31-E-108)


1 Cooling water outlet nozzle (Tube Side) 4”/150#

2 Nitrogen inlet nozzle (Shell Side) 12”/150#

3 Nitrogen outlet nozzle (Shell side) 12”/150#

4 Cooling water inlet nozzle (Tube side) 4”/150#

PURIFIER REGENERATION HEATER

(31-E-109)


1 Nitrogen outlet nozzle (Tube Side)

2 DTA inlet nozzle (Shell side)

3 DTA outlet nozzle (Shell Side)

4 Nitrogen inlet nozzle (Tube Side)

PURIFIER REGENERATION COOLER

(31-E-110)


1 Cooling water outlet nozzle (Tube Side) 6”/150#

2 HC+Nitrogen inlet nozzle (shell Side)

3 HC+Nitrogen outlet nozzle (shell Side)

4 Cooling water inlet nozzle (Tube side) 6”/150#

HP DILUENT HEATER

(31-E-111)


1 HC outlet nozzle (Tube Side) 1.5”/1500#

2 DTA inlet nozzle (Shell side) 4”/300#

3 Shell side vent 1.5”/300#

4 DTA outlet nozzle (shell side)SS 2”/300#

5 HC inlet nozzle (Tube Side) 1.5”/1500#



PA CHARGE HEATER (31-E-112)


1 DTA inlet nozzle (Tube Side)

2 Air outlet nozzle (Shell Side)

3 Air inlet nozzle (Shell Side)

4 DTA outlet nozzle (Tube Side)

COMONOMER FEED COOLER (31-E-113)


1 Water outlet nozzle (Tube Side) 4”/150#

2 HC liquid inlet nozzle (Shell Side) 4”/300#

3 HC liquid outlet nozzle (Shell Side) 4”/300#

4 Water inlet nozzle (Tube Side) 4”/150#

LPS CONDENSER (31-E-201A/B/C)


1 Water inlet nozzle (Shell Side) 14”/150#

2 Condensate outlet nozzle (Tube Side)

3 Water outlet nozzle (Shell Side) 14”/150#

4 Vapour Inlet nozzle (Tube Side)

LB FEED CONDENSER

(31-E-202)

Blind No. Blind Location Blind Size/Pres. Rating 1 Vapour inlet nozzle (Tube Side) 14”/300#

2 Steam outlet nozzle 12”/300#

3 LG-3044 LP tapping nozzle 2”/300#

4 PSV-3003A nozzle 4”/300#

5 PSV-3003B nozzle 4”/300#


7 LIC-3018 LP tapping nozzle 2”/300#


9 LIC-3018 HP tapping nozzle 2”/300#

10 CBD line nozzle 2”/300#

11 IBD line nozzle 2”/300#

12 LG-3044 HP tapping nozzle 2”/300#

13 Feed nozzle (Shell side) 4”/300#

14 Vapour outlet nozzle (tube Side) 8”/300#



LB REBOILER (31-E-203)


1 LB Reboiler outlet line nozzle

2 Shell side Vent 2”/300#

3 DTA condensate outlet line nozzle 10”/300#

4 Tube side drain nozzle 2”/300#

5 LB Reboiler inlet line nozzle 24”/300#



8 DTA vapour outlet line nozzle 24”/300#

LB TRIM CONDENSER

(31-E-204)


1 Tube side Vent 1.5”/300#


3 Water inlet line nozzle (shell side)

4 HC outlet line (Tube Side) 16”/300#

5 Water outlet line nozzle

HB REBOILER (31-E-205A/B)


1 HB Reboiler outlet line nozzle

2 Shell side vent 1”/300#

3 Condensate outlet line nozzle 6”/300#

4 Tube side drain 2”/300#

5 HB Reboiler inlet line nozzle (Tube side) 16”/150#

6 Steam inlet nozzle 10”/300#

LB FEED HEATER NO. 2

(31-E-206)




3 Condensate outlet line nozzle (shell Side) 6”/300#




LB FEED HEATER

(31-E-207A/B)



2 Recycle SH inlet nozzle (Shell side) 10”/300#

3 Recycle SH outlet line nozzle (shell Side) 10”/300#


RB REBOILER

(31-E-208)


1 RB Reboiler outlet line nozzle (Tube Side) 16”/300#

2 Shell side vent 1”/300#

3 DTA Condensate outlet line nozzle 6”/300#

4 Tube side drain 2”/300#

5 RB Reboiler inlet line nozzle (Tube side) 14”/150#



8 DTA vapour inlet line nozzle 12”/300#

FE COLUMN FEED DRYER COOLER

(31-E-209A/B)



2 Water inlet nozzle (Shell side) 6”/150#

3 Water outlet line nozzle (shell Side) 6”/150#


FE FEED DRYER REGENERATION COOLER

(31-E-210A/B)


1 Cooling water outlet line nozzle (Tube Side) 4”/150#

2 Nitrogen inlet nozzle (Shell side) 12”/150#

3 Shell side vent 3/4”/150#


5 Cooling water inlet line nozzle (Tube side) 4”/150#



FE FEED DRYER BLOWER AFTERCOOLERS (31-E-211 A/B)

Blind No. Blind Location Blind Size/Pres. Rating 1 Cooling water outlet line nozzle (Tube Side) 3”/150#

2 Nitrogen inlet nozzle (Shell side) 12”/150#


4 Cooling water inlet line nozzle (Tube Side) 3”/150#

FE REBOILER

(31-E-212)


1 FB Reboiler outlet nozzle (Tube Side)

2 Condensate outlet line nozzle (Shell side) 3”/150#

3 Drain nozzle (Tube side) 2”/300#

4 FB Reboiler inlet line nozzle (Tube side) 12”/300#


FE CONDENSER

(31-E-213)


1 Vent 2”/300#

2 HC Vapour outlet line nozzle 4”/300#

3 Vent 3/4”/300#

4 Blowdown 2”/300#





9 Drain 3/4”/300#

10 Refrigerant Liquid inlet line nozzle 2”/300#

11 Refrigerant vapour outlet nozzle 6”/300#

12 Special body flange

CM REBOILER

(31-E-214)


1 CM Reboiler outlet line nozzle (Tube side)

2 Condensate outlet line nozzle (Shell side) 6”/150#

3 Drain 12”/150#

4 CM Reboiler inlet line nozzle (tube Side) 16”/150#

5 Steam inlet line nozzle 10”/150#



CM CONDENSER

(31-E-215)


1 Cooling water outlet line nozzle

2 HC inlet line nozzle (Shell Side) 16”/150#

3 Vent 1.5”/150#

4 HC outlet line nozzle (Shell side) 14”/150#

5 Water inlet line nozzle (Tube side)

HB CONDENSER

(31-E-216A/B)


1 Steam outlet line nozzle (Shell side) 10”/150#

2 LG-3402 LP Tapping nozzle 2”/150#

3 PSV-3411A nozzle

4 PSV-3411B nozzle





9 CBD line nozzle 2”/150#

10 IBD line nozzle 2”/150#

11 LG-3402 HP tapping nozzle 2”/150#

12 Feed nozzle (Shell side) 4”/150#

13 Liq. HC outlet line nozzle 4”/150#

14 Vapour HC outlet nozzle 18”/150#

FE FEED DRYER REGENERATION HEATER

(31-E-217)


1 Nitrogen outlet line nozzle

2 DTA inlet line nozzle

3 DTA outlet line nozzle

4 Nitrogen inlet line nozzles



SOLVENT VAPOR TRIM COOLER

(31-E-301)


1 Tube side vent nozzle 2”/150#

2 Water +HC inlet line nozzle (Tube side) 3”/150#

3 Water Inlet line nozzle (Shell Side) 3”/150#

4 Water+HC outlet nozzle (Tube side) 6”/150#

5 Water outlet line nozzle (Shell Side) 6”/150#

RESLURRY WATER HEATER

(31-E-302)


1 Reslurry water inlet line nozzle (Tube side) 8”/150#

2 Steam inlet nozzle (shell side) 8”/150#



5 Condensate outlet line (Shell side) 3”/150#

6 Reslurry water outlet line nozzle (Tube side) 8”/150#

ADDITIVES SH COOLER

(31-E-303)


1 Water outlet line nozzle (Tube side) 3”/150#

2 HC inlet line nozzle (Shell side) 1.5”/300#

3 HC outlet line nozzle(Shell side) 1.5”/300#

4 Water inlet line nozzle (Tube side) 3”/150#

FB DEINVENTORY COOLER

(31-E-401)


1 Water outlet line nozzle (Tube side)

2 HC inlet line nozzle (Shell side) 6”/150#

3 HC outlet line nozzle(Shell side) 6”/150#

4 Water inlet line nozzle (Tube side)



NITROGEN HEATER #1 (31-E-406)


1 Nitrogen inlet line nozzle (Tube side) 3”/300#

2 DTA vent line nozzle (Shell side) 1.5”/300#

3 DTA inlet line nozzle (Shell side) 3”/300#

4 DTA outlet line nozzle (Shell side) 1.5”/300#

5 Nitrogen outlet line nozzle (Tube side) 3”/300#

NITROGEN HEATER #2

(31-E-407)



2 DTA vent line nozzle (Shell side) 1.5”/300#




NITROGEN HEATER #3

(31-E-408)



2 DTA vent line nozzle (Shell side) 3”/300#




NITROGEN HEATER #4

(31-E-409)



2 DTA vent line nozzle (Shell side) 3”/300#




FC DEINVENTORY COOLER

(31-E-410)


1 Cooling water outlet line nozzle (Tube Side) 6”/150#

2 HC inlet line nozzle (shell side) 4”/300#

3 HC outlet line nozzle (Shell Side) 4”/300#

4 Cooling water inlet line nozzle (Tube side) 6”/150#



SECTION-20.0

SPECIAL PROCEDURES/INFORMATION



20 Special Procedure:

20.1 FE Column Feed Coalescer (31-V-207) & LB Reflux Drum Boot leg draining procedure

Sr. No. Activities

1. Use mandatory PPE’s while draining.

2. When LT-3130 (interface level transmitter) high level alarm gets activated (as informed by panel

officer) Open drain valve HX-207B.

3. Now open the valve globe valve and its downstream deadman valve and start draining the boot

leg water.

4. Keep watch on boot leg level indicator.

5. When FE or FB vapor starts to vent from the drain, stop draining.

6. Isolate HX-207B.

20.2 Temporary Pump Strainer Cleaning Procedure:

Sr. No. Activities

1. Ensure that pump stopped and push button is kept in off mode position and confirm it with the

control room.

2. Isolate the pump discharge isolation valves. Isolate upstream of the strainer.

3. Depressurise the line by venting/draining depending upon the service of the pump. Do not blow

nitrogen through the strainer.

4. Use mandatory PPE’s and certified tools.

5. Ensure that valves are not passing.

6. Ensure that line is cooled down.

7. Open the flange and remove the strainer.

8. Clean the strainer.

9. Fix the strainer in position and box-up the line.



20.3 Draining procedure of 31-V-205:

Sr. No. Activities

1. Use mandatory PPE’s while draining.

2. Keep Portable Hydrocarbon detector while starting the activity.

3. During the purge cycle of each regeneration, Open drain valve HX-248.

4. Now open the gate valve and it’s downstream of HX-248 and start draining the waste.

5. Keep watch on level indicator.

6. When nitrogen at approximately 0.2 kg/cm2 comes out of the drain and all the water and ketones

are drained stop draining.

7. Isolate HX-248 and its downstream gate valve.

20.4 LPS HUT (31-V-201)/LB Reflux Drum Boot Draining Procedure: Hut LAH-2816/3122 will indicate water accumulation in the boot of LPS HUT or LB Reflux Drum.

Sr. No. Activities

1. Open HX-208B in case of LPS HUT.

2. Slowly open second isolation valve to drain out water from boot.

3. When solvent starts coming close the second isolation valve.

4. Ensure boot drain line isolation valve is not passing.

5. Isolate HX-208B.

20.5 Heat Exchanger Backflushing (On Opportunity):

Sr. No. Activities

1. Isolate the cooling water supply valve.

2. Open the bottom drain valve provided in the supply line.

3. Keep it open till clear water is physically seen in drain line.

4. Close the drain valve.

5. Open the cooling water supply isolation valve.

6. While back flushing chilled water controlled back flushing is done by monitoring the level in the

chilled water supply tank.



20.6 Procedure for Catalyst Cylinder Disconnecting:

Sr. No. Activities

1. Ensure that catalyst cylinder is fully emptied. Isolate #4/8 valve as shown in the above fig. and

open #5/6/7/9/10 valves.

2. Take flow of SH (remaining quantity to be fed to Mix Tank to achieve the required concentration)

through the line so that this line will get flushed.

3. After flushing the line with remaining SH isolate the valve #5/ #6.

4. Open valve #4/#7 and purge the line using Nitrogen through the Mix Tank.

5. After purging the line to Mix tank isolate valve #9/#10.

6. Swing the three-way valve (#1) and line-up to catalyst K. O. Drum.

7. Open valve #2/#3/#8.

8. Start nitrogen purging through the catalyst cylinder to Catalyst K. O. Drum.

10. After purging for sufficient duration isolate the nitrogen. Now the cylinder may be disconnected

for shifting. (Use mandatory PPE’s while performing the job).



20.7 DRAINING OF CATALYST, CO-CATALYST MIX TANK BOOT AND DEACTIVATION:

Sr. No. Activities

1. Wear aluminised suit and all other mandatory PPE’s before starting the activity.

2. Ensure that Fire Fighting equipments are kept ready for use in case of any emergency situation.

3. Ensure that a standby person (wearing aluminium suit) is available during the operation.

4. Ensure that Catalyst mix tank and surge tank is drained.

5. Make a solution of Isobutanol and Mineral Oil (20% Isobutanol + 80% Mineral Oil) in open

suitable drums (drums to be filled up to 50%) depending on the approximate quantity of catalyst

to be drained. Ground the drum.

6. Isolate desired Mix Tank and corresponding Surge Tank and depressurise them to Catalyst KO

Drum.

7. Close mix tank top/bottom HV.

8. Connect the appropriate draining arrangment to ¾” valve provided on the boot of mix tank and

dip the other end inside the drum.

10. Start N2 from the connection provided on the top of the tank.

11. Slowly open the drain valve.

12. Adjust the drain rate to control the fumes to drum. N2 purge to be kept on while draining.

13. Monitor the temperature of the drum. If it reaches beyond 70oC stop deactivation.

14. Once the drum reaches 65 to 70 % level close drain valve stop nitrogen supply and shift the as

arrangement made to the next drum.

15. Repeat the steps 8 to 13 till all the material is drained from the boot.



20.8 Pelletizer Cutter Change Procedure:

Sr. No. Activities

Knife Change

1. Shut down extruder and freeze the die using HIC-4320 to reduce Hot Oil temperature.

2. If drooling continues, close the HP steam to the die holder.

3. Use housing view port to establish die is polymer sealed.

4. Shutdown cutter drive.

5. On LOB, select HS-4147 to unlock the pelletizer housing 4 lock rings.

6. On the LOB, select carriage low / high speed switch HS-4139 and backward switch HS-4140 and

open cutter housing.

7. Lock and tag applicable equipment for knife change out.

8. Operations should make sure dieplate is free of polymer.

9. Maintenance can now safely install a new cutter hub with knives. Approximately 30-45 minutes to

complete this work.

Grinding Knives

1. While the cutter housing is undocked, set local blade wear dial gauge to read the same as the

DCS.

2. With clean dieplate. Die is heated using the hot oil system to 100°C at 40°C per hour. From 100°

to 150°C the rate of die heating would be 80-100°C per hour. At this point the die would be

~160°C. Hot oil die temperature is set at about 220°C and die temperature is increasing.

3. Once the die temperature is approximately 165°C, divert the dump/divert valve on the Main

Extruder to the floor to prevent water from migrating back to the LPS.

4. Remove knife cover and unlock drive while using appropriate safety measures dock and lock the

pelletizer. Start cutter.

5. Introduce PCW into the cutter housing, open the inlet valves and close the bypass valve. The

manual drain valve is closed.

6. Starting the cutter motor and knifes advance is sequenced, as cutter housing is being water

filled.

7. With dieplate at 220°C, run cutter at 300rpm for approximately 20 minutes at 5 kg/cm2. JSW will

determine the forward and reverse pressures and grind speed/duration during their initial

equipment setup.

8. Until the operation becomes routine and all operation people are comfortable with it, you might

need to go through the retract exercise a few times to gain comfort that the process is being

completed properly.

9. Cool die down to 160°C depending on the material in the dieplate. Retract the cutter. Inspect the



Sr. No. Activities

die face for indication of the knives contacting, the die face should be clean. Inspect the knifes,

we are looking for wear from toe to heel on each blade.

10. Scrape the die face clean and dock the cutter start it once more.

11. Once you are satisfied with the knife grind and start up is less than 4 hours, divert dump/divert

valve back to dieplate and drool the die (to ensure all the water has been pushed out of the

dieplate). Then dock the cutter to freeze die.

Die Change

1. Have the LPS second stage level down to 35% prior to reactor shutdown to provide more time for

knife sharpening. A sufficient level of low MI polymer in the LPS to provide a polymer seal is still

required.

2. Review procedures for die change out, and ensure gaskets, hoses, tools, rags, absorbent

matting, and spill pans are in place before proceeding.

3. Reduce hot oil control temperature to ~160°C or less depending on product.

4. Shut down Extruder and block in hot oil to dieplate and HP steam to die housing.

5. Restart hot oil pump and circulate on skid.

6. Freeze dieplate and retract pelletizer carriage.

7. Switch Main Extruder dump/divert DV to the floor using HS-4105 and lock out the diverter valve

hydraulic motor.

8. Block in the HP steam to die housing and Divert Valve.

9. If required, the HP steam on the last two extruder barrel zones can be blocked in and cooled to

100°C to minimize drool to floor.

10. Reduce barrel temperatures to 160°- 200°C to minimize drool.

11. Tag and isolate hydraulic system to Divert Valve.

12. Connect a N2 hose to the vent on the hot oil return line to the dieplate. Make sure you use a

check valve on the end of the hose.

13. Connect the steel braided hose to the drain on the die hot oil return line and the hot oil drain

header.

14. Open N2 supply to nitrogen hose slowly keeping pressure to minimum.

15. Open valving to the hot oil expansion tank.

16. View expansion tank level.

17. Blow back oil from the dieplate to the expansion tank.

18. Monitor PG and don’t allow the return pressure to exceed 2 kg/cm2g. Two operators will be

required to do this operation.

19. Close and reopen the N2 supply several times to allow oil to fall to the piping low point.



Sr. No. Activities

20. When all the oil has been returned, close all valving opened for this activity. Depressurize the die

loop.

21. Reset PCV-4310

22. Remove all hoses.

23. Lock out the cutter system for change out.

24. Reopen HP steam to die housing if required by maintenance when ready to remove bolts

25. Maintenance installs new dieplate.

26. To allow for hot torquing, HP steam should be opened to the die housing to heat both die and die

housing at the same time.

27. When 180°C on die housing has been met, soak for one hour.

28. Close cutter for maintenance alignment check on docking pins.

29. Maintenance returns equipment to Operations

30. O2 free piping and pressure check with nitrogen to 7 kg/cm2g.

31. Line up high point vent with tubing to pail at floor level, use second operator at level above die

and Crack open hot oil block valve to slowly fill piping and the die itself. XV-4046 will have to be

opened prior to the system filling.

32. Monitor the oil flow. Carefully monitor the hot oil pump when pushing the oil and any remaining

N2 back to the hot oil unit.

33. Increase hot oil skid temperature to at least 250°C

34. Bring temperature of extruder up to 210°C and soak for 4 hours.

35. De-tag and unlock Divert Valve.

36. Follow established procedure to bring system back to operational readiness.



20.9 Vent Device Collection Pot Draining Procedure:

Sr. No. Activities

1. Close Strahman valve (up position). The Vent drive stays operating at reduced speed.

2. Using appropriate PPE for this procedure, close valve between collection pot and eductor.

3. Close overhead process line valve while slowly closing the eductor steam supply to control

pressure.

4. Open collection pot drain valve.

5. Drain collection pot solvent / water condensate into an approved container equipped with

grounding cable and remove from the extruder building at end of draining process.

6. Close collection pot drain valve until only ¼ turn open then slowly open steam to eductor

purging air out the drain valve. Close drain valve completely.

7. Slowly open valving to purge the associated piping, which will put some steam into the extruder.

8 Avoid over pressurizing pot if drain line established as plugged. This could result in a sudden

release of the pressure with possible splash hazards. Clean drains or connections as required.

9. Close drain line and open valve to overhead line. Establish desired vacuum on collection pot

and open the Strahman valve.

10. Should a draining of liquids not fully restore a good vacuum then replace the pot using

one of the standby pots and inspect connecting piping for blockages. Clean as required.

11. Move to cleaning of the eductor should it be established as plugged.

Note: To reduce the impact of little or no venting while draining the collection pot while the extruder is

running, you may:

a) Reduce extruder RPM (this need can be established during change out as more than one vent

will still be in operation)

b) Drain only one vent system at a time.

c) Reduce vacuum slowly before closing Strahman valve d) Return to normal operation as soon as

possible.

d) Return to normal operation as soon as possible.



20.10 RESOLUTION OF HAZOP RECOMMENDATIONS:

Sr. No. HAZOP Rec. Ref.

Cause Resolution

1. 1 FIC-1244 malfunctions to close FV-1314A. Refer emergency procedure for RFP

tripping (Ref. Section 15.6.1)

2. 6 Tracing is on during block condition in SH

purifier

Ref. section 7.2.4

3. 7 Block heating case in SH line (2”-P-67005) Ref. Point 19 of Section 9.1.1

4. 12,14 Pump 31-P-102/S tripping Ref. Section 14.2.1

5. 16 31-FV-2152/2153 closes Ref. Section 14.2.1

6. 19 FIC-1513 malfunctions to close FV-1513

Chocking in hydrogen injection lines

Ref. Section 4.1.1.3

7. 20 More flow of HP diluents due to malfunction

of control valves.

Ref point 27 of section 4.1.1.3

8. 23 TIC-1548 malfunction to bypass the HP

diluents flow through 31-E-111

Ref Section 14.2.1

9 27 PV-6731 malfunctions to close. Ref. Section 14.2.3

10. 29 High temp. in the system due to Fast

pressurisation of system

Ref Sr. No. 11 of Section 7.2.5

11. 30 Reactor feed pump trip Ref. Section 14.1.2

12. 32 Lower temperature in the Reactor #3 due

to TIC-1406 malfunction to close TV-1460B

and open TV-1406A

Ref. Section 15.11.1

13. 33 Higher pressure in the system due to poor

reaction

Ref 14.1.2

14. 51 Impurities in FB-1 system Ref Sr. No. 53 of Section 25.4

15. 55 Impurities Ref Section 4.1.4.2

16. 56 Impurities Ref Section 4.1.4.2

17. 57 Lower level in Surge Drum due to

malfunction of FV-6514.

Ref Section 4.4.11.2

18. 64 Less flow of CAB-2 causing chocking in 31-

P-105

Ref Section 4.1.8.8

19. 68 Less flow of CAB causing chocking in 31-

P-106

Ref Section 4.1.8.8

20. 70 More SH in catalyst causing dilution of

catalyst

Ref Sr. No 7 of Section 7.2.8




Cause Resolution

21. 71 More SH in catalyst causing dilution of

catalyst Ref. Section 28.1

22. 72 Less SH in catalyst causing dilution of

catalyst

Ref. Section 7.2.8

23. 73 Less SH in catalyst causing dilution of

catalyst Ref. Section 28.1

24. 78 Lower temperature in the PG system due

to failure of stream tracing

Ref Sr. No. 2 of Section 7.2.14

25. 81 Fore flow of J to reactor due to malfunction

of FV-2422B/2421A

Ref Section 4.1.5

26. 95 No flow of IPS vapours to LBFC due to

malfunction of 31-PV-1911.

Ref. Sr. No. 4 of Section 10.6

27. 98 Low flow of IPS vapour to LBFC due to



28. 101 More flow of IPS vapour to LBFC due to



29. 102 Lower temperature of LB feed condenser

outlet due to malfunction of TIC-3039


30. 104 Higher pressure in the system due to

malfunction of PIC-3019


31. 106 Low pressure in the system due to

malfunction of PIC-3019


32. 108, 109 Lower level in 31-E-202 due to malfunction

of LIC-3018

Ref. Sr. 3 of Section 10.1

33. 112 Extruder tripping due to process or

machinery interlocks


34. 113, 114 Less flow of LPS condensate to LB column

due to suction filter and strainer chocking

Ref. Section 4.2.1.2.4

35. 116 Higher level in KOD due to no draining Ref. Section 4.2.1.2.1

36. 119 High level in LPS HUT due to tube leakage

in 31-E-201A/B/C

Ref Section 4.2.1.2.3

37. 124 Pressurisation of 31-E-203 shell side due

to tube leak

Ref Section 15.10

38. 125 Higher interface level in boot due to

malfunction of LT-3130.

Ref. Section 4.2.2.4.3

39. 127 Loss of Hydrocarbon due to Excessive

draining of boot

Refer Section 20.1

40. 153 Chocking in Pump Suction Strainer Refer Section 20.2




Cause Resolution

41. 156 31-E-215 tube rupture due to corrosion Refer Sr. No. 60 Section 25.4


43. 166, 170

171

Routine Sampling Refer Sr. No. 51 Section 25.4


45. 174 Routine Sampling Refer Sr. No. 52 Section 25.4

46. 177 Tube leakage in 31-E-208 due to corrosion

or material failure

Ref. 15.10

47. 180 Partial chocking of delumper drum holes

due to spray nozzle failure


48. 189 Higher pressure due to chocking of flame

arrestor


49. 195 Less flow from RA stripper bottom to fine

separation due to partial choking of

condensate drain line in screen


50. 196 Chocking in fine separator due to

accumulation of fines in the separator


51. 197 No nitrogen flow to fine separator due to

disturbance in header pressure


52. 213 No flow of hot flush liquid to reactor in

emergency/start-up due to tripping of hot

flush pump


53. 214 Less flow of hot flush liquid to adsorber due

to Chocking in upstream or downstream of

PV-1725.

Procedure deleted as per the NOVA

Comments in Rev A

54. 216 Less flow from adsorber to LB feed

condenser/LPS condenser due to chocking

in upstream or downstream of PV-1725


Comments in Rev A

55. 218 Higher pressure from adsorber to LB feed

condenser due to chocking in line (6”-P-

17023)

Ref. Section 7.2.18

56. 220 Higher pressure from adsorber to LPS

condenser due to chocking in PV-1725

downstream line (6”-P-18031)


Comments in Rev A

57. 225 Lower temperature of regeneration gas due

to accumulation of inert in the E-109

Ref. Sr. No. 8 of Section 7.2.4




Cause Resolution

58. 228 Tube leakage in E-108 due to corrosion. Ref. Sr. No. 18 of Section 7.2.4

59. 231 Higher pressure in regeneration gas loop

due to residual hydrocarbon in the bed.

Ref. Sr. No. 1 of Section 7.2.7

60. 233 Higher level in KOD 31-V-205 due to

improper draining

Ref. Section 20.3

61. 234 Lower level in KOD 31-V-205 due to

improper draining

Ref. Section 20.3

62. 236 Less flow of nitrogen during spent PA

unloading from adsorber due to chocking in

suction filter

Ref. Section 4.1.11.4

63. 238 Air ingress in the system due to vacuum

formation

Ref. Section 7.2.18

64. 244 Less flow of KO liquid from flare KOD to

LPS hold up tank

Ref. Section 20.2

65. 245 Higher level in polymer KOD (31-V-405) Ref Section 10.16

66. 249, 251 Now flow of additive from holding tank to

IPS inlet due to pump trip

Ref Section 10.10

67. 252, 254

255, 256

257

Less/more flow of additive from holding

tank to IPS inlet

Ref Section 10.10

68. 259 Higher pressure in additive from holding

tank to IPS inlet

Ref. Section 10.10

69. 261 High venting from holding tanks Ref. Section 10.10

70. 268 Less flow of water from reservoir to

pelletizer due to chocking of filter G-307 or

pump suction strainer

Ref. Section 20.2

71. 278 Lower level water reservoir due to chocking

of fines separator

Ref Section 10.13

72. 284 Tube leak in 31-E-301 due to corrosion Ref Section 4.3.1.12.4

73. 285 Coalescer element damage Ref Section 4.3.1.12.4

74. 292, 293

294

Less flow of HP/LP condensate to

exchangers due to chocking in pump

suction strainer

Refer Section 20.2

75. 298 Less flow of waste fuel to DTA vaporiser Refer Section 20.2



SECTION-21.0

LUBRICATION SCHEDULE



Doc. No.: 2317 Rev. 0 of 625

Equipment Tag No. Lubricant ISO Grade Supplier IOC Equivalent Quantity of Flushing oil

per item

Quantity of first fill per

item

Total Quantity of lubricant per item (required for six

months after commissioning)

Total quantity of lubricant for equipment

Remarks ( indicate replacement quantity, time interval for the first and subsequent running hours)

Compressor

31-K-102/S

OIL VG 68 Shell IOCL-IOC VG 68 NA 45 lts 80 lts 250 lts 1st drain after 50 hrs then drain every 3000hrs or every year

Grease

(Alvania RL3) Shell NA 410 gm 90 gm 1 kg Regreasing 35gm after 2800hrs

Lobe Blower 31-K-201 OIL VG 68 Oil jug IOCL-IOC VG 68 30 lts 30 lts 40 lts 100 lts 4 months

Lobe Blower 31-K-101 OIL VG 68 Oil jug IOCL-IOC VG 68 30 lts 30 lts 40 lts 100 lts 4 months

Lobe Blower 31-K-104 OIL IOCL servo system 320 50 lts 50 lts 100 lts 200 lts 1st oil change after 100 hrs then after 2000hrs or discoloration

31-K-105 OIL IOCL servo system 320 40 lts 40 lts 70 lts 150 lts 1st oil change after 100 hrs then after 2000hrs or discoloration

31-P-103 OIL VG 46 IOCL servo system 2 lt 2 lt 2 lt 6 lts 1st replacement after10-15hrs,subsequent replacement 8000hrs

31-P-104 OIL VG 32 IOCL servo system 1000 lts 1000 lts 1000 lts 3000 1 change during 6 months

31-P-203/S OIL VG 46 IOCL servo system NA 2.5 lts 2.5 lts 10 lts 100 first replacement, subsequently every 8000 hrs

31-P-403/S OIL VG 46 IOCL servo system NA 2 lts 2 lts 8 lts 100 first replacement, subsequently every 8000 hrs

31-P-411/S OIL(SAE

15W-40) 1 lts 1.5 lts 1.5 lts 8 lts 1st change after 10-15 hrs then after 12 months

31-P-412/S OIL VG 46 IOCL servo system NA 1.5 lts 1.5 lts 6 lts 100 first replacement, subsequently every 8000 hrs

31-P-408 Oil VG-46 IOCL servo system NA 2 lts 2 lts 4 lts 100 first replacement, subsequently every 8000 hrs

31-P-201/S OIL VG 68 IOCL IOCL-IOC VG 68 70 lts 70 lts 210 lts 700 lts 1st refill after 50 hrs , 2nd after 500hrs then after 3000 - 5000 hrs




31-P-112 OIL VG 32 IOCL servo system 2 lts 2 lts 4 lts 8 lts 1st change out 500hrs & relube interval 4000hrs

31-P-307/S OIL VG 32 IOCL servo system 2 lts 2 lts 4 lts 16 lts 1st change out 500hrs & relube interval 4000hrs






31-P-

415A/B OIL VG 32 IOCL servo system 2 lts 2 lts 4 lts 16 lts 1st change out 500hrs & relube interval 4000hrs

31-P-204/S OIL VG 46 IOCL servo system 20 lts 2 lts 8 lts 60 lts 1st replacement after 10-15 hrs, subsequently every 4000 hrs



Doc. No.: 2317 Rev. 0 of 625


per item


item





31-P-409 OIL VG 46 IOCL servo system 20 lts 2 lts 8 lts 30 lts 1st replacement after 10-15 hrs, subsequently every 4000 hrs

31-P-101/S OIL VG 46 IOCL servo system 5 lts 2 lts 4 lts 22 lts



31-P-

306A/B OIL VG 46 IOCL servo system 5 lts 2 lts 4 lts 22 lts

31-P-

100A/B OIL VG 46 IOCL servo system 5 lts 2 lts 4 lts 22 lts

Vert. Pump 31-P-

101A/B grease servogem-2 1 kg

Vert. Pump 31-P-


Vert. Pump 31-P-


31-P-117 OIL VG 46 IOCL servo system 5 lts 2 lts 4 lts 11 lts

31-P-118 OIL VG 46 IOCL servo system 5 lts 2 lts 4 lts 11 lts

31-P-305/S

Recip.

31-P-102/S

oil VG 150 IOCL 100 lt 150 lt 250 lt


grease UnirexN3 ESSO 0.5 kg

Recip. 31-P-

202A/B



grease UnirexN3 ESSO 0.5 kg

Recip. 31-P-302 Oil 6743-6 FUCHS 200 lit 200 lit 200 lit 600 lit

Recip. 31-P-303 Oil 6743-6 FUCHS 200 lit 200 lit 200 lit 600 lit

Recip. 31-P-105 Daphne super

gear oil 150 VG 150

IDE MITSU KOSAN

Comp. Ltd

33 lit 33 lit 66 lit



Doc. No.: 2317 Rev. 0 of 625


per item


item





Daphne super

hydro A 46 VG 46

IDE MITSU KOSAN

Comp. Ltd 18 lit 18 lit 36 lit

Recip. 31-P-106

Daphne super

gear oil 150 VG 150

IDE MITSU KOSAN


Daphne super

hydro A 46 VG 46

IDE MITSU KOSAN


Recip. 31-P-107

Daphne super

gear oil 150 VG 150

IDE MITSU KOSAN


Daphne super

hydro A 46 VG 46

IDE MITSU KOSAN


Recip. 31-P-108

Daphne super

gear oil 150 VG 150

IDE MITSU KOSAN


Daphne super

hydro A 46 VG 46

IDE MITSU KOSAN



gear oil 150 VG 150

IDE MITSU KOSAN




Doc. No.: 2317 Rev. 0 of 625


per item


item





Daphne super

hydro A 46 VG 46

IDE MITSU KOSAN


Recip. 31-P-110/S

Daphne super

gear oil 150 VG 150

IDE MITSU KOSAN


Daphne super

hydro A 46 VG 46

IDE MITSU KOSAN


Recip. 31-P-111

Daphne super

gear oil 150 VG 150

IDE MITSU KOSAN


Daphne super

hydro A 46 VG 46

IDE MITSU KOSAN


Recip. 31-P-301

Daphne super

gear oil 150 VG 150

IDE MITSU KOSAN


Daphne super

hydro A 46 VG 46

IDE MITSU KOSAN



gear oil 150 VG 150

IDE MITSU KOSAN




Doc. No.: 2317 Rev. 0 of 625


per item


item





Daphne

hydraulic fluid

32

VG 32 IDE MITSU KOSAN


Fan 31-K-103 Grease IOCL Servo 2 & 3 400 gm 500 gm 900 gm Freq. of regrease (20 gm) - 2500hrs, Freq. of change - 4500 hrs

EOT crane 31-ME-104

Servomesh 320 IOCL 320 120 150 270 lit

servogem 2 IOCL 2 20 20 40 kg

31-ME-105



31-ME-106



Drum pump HX-109A

OIL ISO 32 0.5 lt 90 lts 360 lts subsequent change every 24-30hrs HX-109B

HX-348

60-PA-102

N2 booster 31-K-402/S Not required



SECTION-22.0

HYDROCARBON DETECTOR SUMMARY



HC DETECTOR LOCATIONS:

Sr. No. Tag no. Equipment/Area Name Placement-Specific Location

1 AI-1001A/B HVAC System of SRR-04 Locate at the suction air intake lines

2 AI-1001C/D Control system in Extruder Building Locate inside the Extruder Operator

Room Housing

3 AI-1001E/F HVAC System of Extruder Located at the suction air intake lines

4 AI-1001G/H HVAC System of Extruder Located at the suction air intake lines

5 AI-1164 31-EA-101 Nr. Inlet line to 31-EA-101

6 AI-1165 Recycle SH Water Cooler (E-101A/B) Near Shell Gasket

7 AI-1166A SH Purifiers (31-V-125A/B) Between purifiers at Top Valve

8 AI-1166B SH Purifiers (31-V-125A/B) Between purifiers at Bottom Valve

9 AI-1265 Solvent Feed Pumps (31-P-101/S) At seal between pumps

10 AI-1266 HP Diluent Pumps (31-P-102/S) At seal between pumps

11 AI-1365 Reactor Booster Feed Pump (31-P-103) At seal Area

12 AI-1366 Reactor Feed Pumps (31-P-104) At seals

13 AI-1465 Reactor Feed Cooler (31-E-104 A/B) Near Shell Gasket

14 AI-1466 Reactor Feed Heater (31-E-103) Near Shell Gasket

15 AI-1565 Reactor #1 (31-R-101) At Grade

16 AI-1566 Reactor Agitator (31-ME-101) At reactor seal

17 AI-1567 Reactor Agitator Seal Locate between Reactor Agitator

Seal and Lube Oil Pump

18 AI-1665 Solution Preheaters (31-E-105 A/B) Between preheaters

19 AI-1865 Solution Adsorber A (31-V-104A) Near Top Flange

20 AI-1866 Solution Adsorber B (31-V-104B) Near Top Flange

21 AI-2075 Near Catalyst Unloading Building Locate close to Grade at dyke area

22 AI-2076 Near Catalyst Unloading Building Locate close to Grade at dyke area

23 AI-2077 Catalyst Unloading Room Near ISO Cylinders

24 AI-2078 Catalyst Unloading Room Near ISO Cylinders

25 AI-2265 Catalyst Seal Pump (31-LZ-101) Near Vent at Grade

26 AI-2775 Primary FE Guard Beds (31-v-127A/B) Between FE Guard Bed

27 AI-2776 Secondary FE Guard Bed (31-V-132) At Grade

28 AI-2865 LPS Hold-Up Tank (31-V-201) At Drain

29 AI-2866 LPS Condensers (31-E-201A/B) Between and below exchangers

30 AI-2965 LPS Condensate Pumps (31-P-201A/B) At seals between pumps

31 AI-2966 Hot Flush Pump (31-P-202A) At seals

32 AI-2967 Hot Flush Pump (31-P-202B) At seals

33 AI-3265 Near Process Exchanger (31-E-213)




34 AI-3165 LB Reflux Pumps (31-P-203/S) At seals between pumps

35 AI-3465 HB Reflux Pumps (31-P-204/S)

At seals between pumps

36 AI-3565 HB Reflux Drum (31-V-203) Between HB and RB Reflux drums at

floor

37 AI-3566 RB Reflux Pumps (31-P-205/S) At seals between pumps

38 AI-3567 Process Skimming Sump (LZ-202) Locate off Railing close to Sump

39 AI-3660 V-209A Locate between 31-V-209A and 31-

V-209B

40 AI-3965 CM Reflux pumps (31-P-206/S) At seal between pumps

41 AI-4065 Satellite Extruder Locate near satellite extruder motor

42 AI-4066 Extruder Locate Near Rear Seal Drool of

Extruder

43 AI-4067 Under Water Pelletizer Unit -

44 AI-4068 Extruder Locate near Main Extruder vent

device

45 AI-4165 Extruder Locate Near Extruder motor intake

46 AI-4166 Satellite Extruder Locate Near Satellite Extruder Motor

Air Intake

47 AI-4365 31-H-306 Centre of 31-H-306 skid

48 AI-4465 Waste Pellet Collection (outlet of HX-330) At Grade

49 AI-4466 Extruder Building Between cutter and water reservoir

50 AI-4765 Decanter Locate near Decanter Drain at Grade

51 AI-4865 Additive Building Locate at Grade

52 AI-4866 Near Additive Building Locate at Grade

53 AI-4965 Additive Building Between waste drum and SZ storage

tank

54 AI-4966 31-LZ-301 Locate near off railing of LZ-301

55 AI-5765 Polymer KOD (31-V-405) Near concrete pad outside vessel leg

56 AI-5766 Flare KOD (31-V-404) At boot end near transfer pump

57 AI-5965 31-V-404 Locate near V-404 boot end near

Transfer Pump

58 AI-6065 LP DTA Condensate Pumps (31-P-407/S) At seal

59 AI-6165 HP DTA Condensate Pumps (31-P-405/S) At seal

60 AI-6265 V-407 Located Between V-407 & V-408

61 AI-6340 DTA Vaporisers




62 AI-6365 Waste Fuel Drum (31-V-411) At Grade

63 AI-6465 SH De-inventory Tank (31-T-401) Inside dyke near tank drain

64 AI-6565 FB Surge Tank (31-V-415) Inside Dyke

65 AI-6566 FB Feed Pump (31-P-411/S) At seal Area

66 AI-6665 FC De-inventory Tank (31-V-414) Inside Dyke near tank drain

67 AI-6666 FC Purifiers (31-V-416A/B) One between the two purifiers near

ground level



SECTION-23.0 FIRE AND SAFETY SYSTEM



Introduction: Fire and gas detection facilities are necessary for personnel, asset and environment protection. The purpose

of the fire and gas detection system is to detect a fire or gas release as early as possible. The operating

personnel should be fully conversant with Fire Fighting system provided in the unit.

Major Fire fighting facilities provided in the unit comprise the following:

23.1 Fire Water System: 23.1.1 Hydrant System

• Double headed fire hydrants, Type A as per IS: 5290 shall be provided. Each hydrant post (with two

nos. of type-A hydrant valve) shall be provided with 4” jumper connection. Jumper connection shall

be fitted with stainless steel threaded cap. The cap shall have four SS lugs and chain attached to it.

Each hydrant post shall be provided with 4” isolation valve.

• Fire hydrant and monitor has been provided alternately for every 30 m of perimeter of battery limit

(by others). Any additional hydrants/ monitors/ long range monitors, if

• Required on the main header shall be provided by EPCC-3 to provide full coverage. Hydrants

protecting utilities and miscellaneous buildings in high hazard areas shall be spaced at 45 m

intervals. The horizontal range and coverage of hydrants with hose connections shall not exceed

more than 30 m.

• Fire hydrant shall be located at a minimum distance of 15 m and maximum distance of 22.5 m from

the surface of equipment to be protected. In case of building, the distance from hydrant to the face

of building under protection shall be minimum 2m and maximum 15 m. Hydrants/ monitors shall be

located to have easy accessibility.

• Vessels/ process columns, which are of height up to 10 m and are accessible by hydrant, shall be

covered by hydrant. Each vessel/ process column shall have coverage from at least two hydrants.

• Tall columns, structures, towers and equipments where it may not be possible to provide access

staircase with hydrants on landings, shall be protected by monitors and long range monitors.

• Elevated monitors/ long range monitors remotely operated from grade level shall be provided for

areas not covered by hydrants/ monitors based on actual requirement.

• Installation arrangement of hydrant post: Hydrants shall not be installed directly vertical to headers. It

shall be installed with ‘L’ branch shape piping. In addition, 1.5 to 2.0 m portion of headers shall be

taken above ground and entire branch pipe near hydrant shall be epoxy painted.

23.1.2 Double Headed Landing Valves

• On technological structures.

• Double headed landing valve assembly (each landing valve assembly consisting of two nos. of

Type-A hydrant valves as per IS: 5290) shall also be provided on each staircase landing of upper

floor of buildings, working platforms of technological structures at 1.2 m above floor level.



23.1.3 Hose Cabinets

Hose cabinet shall be provided near each fire hydrant and landing valve location. Hose cabinets shall be as

per EIL specification 6-66-47 type-II as the following:

• Hose cabinet made up of 18 SWG sheet and shall be suitable to accommodate 2 delivery hoses 63

mm (2½”), 15 m long with end couplings, hollow jet/ spray nozzles with branch pipes and 1 universal

branch pipe.

• Hose cabinet shall be of self supporting type suitable for outside installation.

• Hose cabinet shall be painted with 3 coats of anti-corrosive fire red paint from outside and white

paint from inside.

Specification of contents housed in each hose cabinet shall be the following:

1. Delivery hoses shall be of the size of 2 x 2 ½” (63 mm) size and 15 m length as per IS: 636, Type-

II

2. SS 304 end couplings, jet nozzle and branch pipe shall conform to IS: 903

3. SS 304 universal branch pipe shall conform to IS: 2871.

23.1.4 Monitors

• Fixed monitor (generally as per IS: 8442) shall be provided in the process area to supply large

capacity Water flows.

Monitor location shall be given special consideration for protection of cluster of towers, heaters,

columns and other high structures not fully covered by hydrant. Each monitor connection shall be

provided with independent isolation valves. The monitors should not be installed less than 15 m from

hazardous equipment. The location of monitors shall not exceed 45 m from the hazard to be

protected.

• Vessels/ process columns which are of height up to 25 m shall be covered by ordinary monitor.

(Horizontal throw = 45m, Vertical throw = 28 m). The range of monitor shall be taken as 45 m.

• For vessels/ process columns of height above 25 m, which are inaccessible due to height, remote

controlled elevated long range monitor shall be provided (Horizontal throw= =80 m, Vertical

throw=45 m). The horizontal and vertical throw shall be suitable to cover all high rise columns,

equipments.

• Where due to horizontal obstruction, a particular vessel/ process column is not approachable by

ordinary monitor or hydrant, long range monitors remotely operated from grade level shall be

provided to take care of such conditions.

• All monitors shall be non aspirating type water cum foam monitor with aqua fog foam nozzle.

23.1.5 Hose Reels

Fire hose reels shall be provided along with every landing valve and around/ within unit battery limit as first

aid fire contingency. These shall be floor/ wall mounted type and shall have water connection from hydrant

network.



• Each hose reel shall have 1” x 40 metre long collapsible hose with branch pipe with a jet/ spray/ off

nozzle, which could be reached for water spray over the affected fire area.

• Hose reels shall be located 40 m apart and should cover all process area in ground floor.

• Additional hose reels shall be provided with each landing valve on stair cases & around the unit and

at strategic locations to cover the complete unit as first aid fire contingency as per OISD

requirements on floor of process units. 23.2 Deludge system: The deluge sprinkler system is the first line of active fire protection. The main purpose of this system is to

keep vessels and structural steel cool by the application of water via sprinkler to the entire fire area. The

deluge systems are designed for automatic and manual activation.

The rationale for selection of the deluge sprinkler system is considered in the context of the NFPA

designation of water usage namely:

• Water extinguishing

• Control of burning

• Exposure protection

• Explosion protection

Water Extinguisher:

It is difficult to extinguish fires caused by flammable gases or liquids with flash points considerable below

ambient temperature. In the context of the polyethylene plant there is no major requirement for water

extinguishment e.g. ethylene and butene are gases at atmospheric pressure. Cyclohexane and octene are

liquids at atmospheric pressure with flash points usually below ambient temperature.

Control of Burning:

When a leak fire has occurred, water can be applied to reduce the rate of burning and cool the area

immediately surrounding the fire. Such action minimises the heat damage to adjacent equipment. Firewater

monitors can be effective for control of burning but they are generally ineffective against strong opposing or

cross winds. In some areas, there can be difficulties in achieving rangeablility and coverage with monitors.

For these reasons the Deluge system is provided for control of burning.

With equipment which is readily accessible and where one or more adjacent monitors can be brought to bear

then fixed monitor systems may be acceptable. With high capacity deluge sprinkler systems the burning

liquids (i.e. from a pool fire) must be effectively removed from the fire zone in a manner that will not lead to

fire propagation to adjacent equipment or systems. Deluge water from elevated floors is collected and

drained using dedicated piping to grade.



Exposure Protection:

To minimise the potential for vapour cloud formation, a high density fixed water spray is located above

critical equipment item (e.g. high pressure seals) to effect dispersion of the released hydrocarbon material to

below its lower flammability limit.

To effect vapour cloud dispersion high capacity water sprays are installed above the reactor feed pump

seals, the R-101 Reactor seal and above all pump seals handling light hydrocarbons (i.e. nearly all pumps in

the recovery area).

The water spray capacity suggested by NFPA 15 is used as a minimum.

The whole plant is divided into 8 zones (i.e. zone 1 to zone 8) plus two additional zones SS2/SS3.

Refer P & ID 6841-031-16-47-00043

The zone wide equipment provided with deluge system given in the table below:

Zone Equipment Tag No.

1 LB Column System

31-E-203

31-C-201

31-P-203/S

31-P201/S

31-E-202

31-V-201

31-V-202

31-E-206

31-E-204

31-E-201A/B/C/D

31-V-121

2 HB/RB/FE/CM Column System

31-ME-201

31-C-204

31-E-212

31-C-205

31-E-214

31-V-207

31-C-203

31-E-208

31-C-202

31-E-207A/B

31-E-205A/B

31-P-206/S




2 HB/RB/FE/CM Column System

31-P-205/S

31-P-204/S

31-P-202A/B

31-V-206

31-V-204

31-V-203

31-E-215

31-E-216A/B

31-V-406

31-V-410

31-P-405/S

31-P-407/S

3 SH/FC Purifier System/SH Recycle System

31-V-101

31-EA-101A/B/C/D

31-V-102

31-E-117

31-V-125A/B

31-E-101A/B

31-P-112

31-P102/S

31-P-101/S

31-E-102

31-E-217

31-V-205

31-V-416A/B

31-P-406/S

31-V-103

31-P-412/S

H2 Vessel 31-V-425

4 Reactor/Solution Preheater/Solution Adsorber

31-R-101

31-V-405

31-E-107

31-V-104A/B

31-E-103

31-E-104A/B

31-E-105A/B

5 Catalyst/Deactivator Pump Room

Catalyst/Deactivator Pump Room

Building

31-V-126




6 Catalyst Tanks

31-V-105

31-V-106

31-V-107

31-V-108

31-V-109

31-V-110

31-V-111

31-V-112

31-V-113

31-V-114

31-V-115

31-E-116

31-V-116

31-V-117

7 Liquid Additive Building Liquid Additive Building

31-V-312

8 IPS & LPS

31-V-118

31-V-119

31-V-120

SS2 RFP Seal Spray 31-P-103

31-P-104

SS3 Extruder Building Spray system

23.3 Foam System All the plant fixed water deluge spray system should be connected to the aqueous film forming foam (AFFF)

system. The system shall be designed so that foam concentrate can be injected into individual deluge headers.

The system shall be manually activated from the deluge house. Complete foam system including pumps and

tanks shall be designed and provided as per NFPA.

Major foam demand shall be when Zone-1 and Zone-2 are under fire simultaneously.

As per NFPA, minimum foam solution application rate required is 6.5 lpm/m2.

Since the foam is to be injected in deluge headers and deluge spray system is designed for 10.2 lpm/m2, hence

the foam shall also be designed for 10.2 lpm/m2.

Foam solution application rate provided is 10.2 lpm/m2

Foam solution demand for Zone-1 = 10933 lpm approx.

Foam solution demand for Zone-2 = 19482 lpm approx.

Hence, foam solution demand for Zone-1 & Zone-2 is 30415 lpm

Considering 3% foam, foam requirement is 912.5 lpm. (54.74 m3/hr)

Foam concentrate storage has been designed for 10 minutes duration.

Hence, storage required = 9125 litres say 9200 litres



A vertical atmospheric foam concentrate storage tank of 9200 litres shall be provided.

Foam pumps (1W + 1S) of capacity 55 m3/hr and head 110 m (approx.) shall be provided.

Actual pump discharge head shall be finalized by foam supplier.

23.4 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.

Fire extinguishers shall be located strategically throughout the plant in easily accessible places. Refer P & ID

6841-031-16-47-0024 for location of Fire Extinguishers in the unit.

Type Capacity (kg) No.

DCP

5 53

10 73

50 10

CO2 4.5 24



SECTION-24.0 SAMPLING PROCEDURE AND SCHEDULE



24.1 Liquid Sampling Procedure:

24.1.1 Liquid sampling in open bottle 1 Purpose Cyclohexane samples are taken from different process streams for ketones, impurities and polymer content.

Where necessary the sample points will be equipped with a water cooler to lower sample temperatures

below the boiling point.

DTA samples are sent for checking High boilers and Low boilers. It becomes necessary to sample this

material from time to time because it degrades on use and generates high boilers which reduce the

efficiency of the system.

FC-1 sample is collected in glass bottles for moisture.

2 Procedure.

Sr. No.

ACTION

1. Use the recommended PPE’s.

2. Line up water through sample cooler, if it is required.

3. Open process valve slowly and purge the line. (1-2 minutes).

4. Close the valve.

5. Keep a clean glass bottle approx 250 ml. below the sample point.

6 Open process valve slowly and fill sample bottle 3/4 of its level to prevent overflow and spillage.

7. Close the process side valve.

8. Close cooling water inlet and outlet valves.

9. Properly tag or label the bottle for identification.

Send the sample to the Laboratory.

24.1.2 Liquid sampling in closed end bottles 1. Purpose It is necessary to sample the cyclohexane (SH) stream at the outlet of SH make-up dryer and SH/CM purifier

and inlet of SH/CM purifier for water content. Any solvent added to a catalyst batch or in the reactor must

have less than 2 ppm water content.



2. Procedure

Sr. No.

ACTION

1. Use the recommended PPE’s

2. Slowly open the sample point valve and purge it for 1-2 minute.

3. Close the valve.

4. Insert the sample needle in the sampling point.

5. Purge the needle (½ - 1 minute).

6 Insert the sampling needle into the sealed bottle.

7. Collect the sample in the bottle and close the valve.

8. Remove the sample bottle and send it to Lab.

9. Remove the needle and cover it. Keep it at a safe place to prevent injury.

24.2 Gas Sampling Procedure: 1. Purpose.

• Sampling of FB-1, raw material coming into the process is analysed to determine FB-1 purity before

entering the process.

• Sampling of ethylene feed stream is done to determine the purity of the feed stock to maintain a

steady reaction.

• Sampling of Hydrogen is done to determine impurities like oxygen.

• Adsorber sample is taken for checking oxygen content in bladder.

2. Procedure.

Sr. No.

ACTION

1. Use the recommended PPE’s.

2. Slowly and carefully purge the sample point through purge valve to atmosphere. (1 - 2 minutes).

3. Close the sample point valve.

4. Connect bomb to sample point.

5. Open inlet and outlet valve of the sample bomb.

6 Open sample point valve and purge it for 2 - 3 minutes.

7. Close outlet valve of the sample bomb and allow the bomb to fill.

8. Close inlet valve of the bomb.

9. Close sample point valve.

10. Depressurise the deadleg between sample point valve and I/L valve of bomb and disconnect the

sample bomb.



Sr. No.

ACTION

11. Properly label the sample bomb.

12. Send it to Laboratory.

13. Inform junior analyst/analyst (Lab).

14. Sampling in a sampling bladder.

I. Follow steps 1 to 3

II. Open inlet bladder clip

III. Connect bladder to sample point

IV. Open sampling point valve and fill up the bladder

V. Remove the bladder and squeeze

VI. Repeat steps III, IV & V, 3-4 times

VII. Again fill up the bladder, pressurise it and put clip on inlet tube

VIII. Close sample point inlet valve

IX. Label the bladder

X. Send it to lab. And inform junior analyst/analyst (Lab)

24.3 Solid Sampling Procedure

1. Purpose Sampling of Master-Batch is done to analyse the percentage of additive in Base - Product. Also visual

inspection for colour and checking softness of pellets are done

Delumper sample is to be taken for visual inspection of colour and cut size.

2. Procedure.

Sr. No.

ACTION

1. Use recommended PPE’s

2. Small polyethylene bottles/bags are used to carry Polyethylene samples to Lab.

3. Ensure proper drum/ bag is available to collect the unwanted pellets.

4. Sampling for in process materials from Delumper and Spin drier is done (as per the schedule)

manually in the field. Collect approx. 0.2 kg sample in a plastic bottle and send it to laboratory at

scheduled time.

5. Approximately 2.5 kg retained/composite samples from Blenders/ Silos are collected in cans or

bags as required.

6. Ensure housekeeping to remove any spilled pellets.



24.4 Sampling Schedule:

Blow down water condition is one indication of whether the boil-out has achieved satisfactory results. The

only conclusive determination of boil-out effectiveness, however, is by a visual internal inspection of the

steam drum.

Sr. No. Sample

No. P&ID Ref. Location of Analysis Type of Analysis Frequency

1. S 00105-AA-31-1111 31-E-101A/B Recycle SH Water

Coolers CW Return Water Quality As condition require

2. S 00105-AA-31-1111 31-E-113 Comonomer Feed Cooler

CW Return Water Quality As condition require

3. AI-1134 00105-AA-31-1111 31-V-125A/B SH Purifiers inlet and

Solvent Pump Suction

Water content in a

Solvent stream Continuous – DCS

4. S-105 00105-AA-31-1111 Solvent after water cooler Impurities As required

5. S-115 00105-BA-31-1112 Solvent Outlet from 31-G-103 Ketones Daily

6. S 00105-BA-31-1112 31-E-108 Regeneration Blower

Aftercooler CW return Water Quality As condition require

7. S 00105-BA-31-1112 31-E-110A/B Purifiers

Regeneration Coolers CW return Water Quality As condition require

8. S 00105-BA-31-1112 31-E-117 HP Diluent Pump

Spillback Coolers CW return Water Quality As condition require

9. S 00105-BA-31-1112 31-K-101 BCW Return line Water Quality As condition require

10. S-101 00105-BA-31-1112 31-V-102 SH Recovery Tank Ketones Each SH purifier

regeneration

11. S-102 00105-CA-31-1113 FE from FE Guard Beds Impurities As required

12. AI-1340 00105-CA-31-1113 31-E-102 Absorber Cooler inlet Impurities Continuous – DCS

13. S 00105-CA-31-1113 31-E-102 Absorber Cooler CW

return Water Quality As condition require

14. S 00105-DA-31-1114 31-E-104A/B RTR Feed Heaters

CW return Water Quality As condition require

15. SC-117 00105-DA-31-1114 31-V-122 free vent line HC As condition require

16. SC-106 00105-FA-31-1116 31-E-105A HP DTA Condensate SH in DTA As required

17. SC-107 00105-FA-31-1116 31-E-105BHP DTA condensate SH in DTA As required

18. SC-118 00105-FB-31-1117 31-V-134 cond. Return line SH in Condensate As required

19. SC-104 00105-HA-31-1119 31-V-118 IPS Overheads Polymer As needed

20. S-110 00105-JA-31-1120 CAB-2 Mix 31-V-105 & Surge 31-V-

106 outlet

%concentration /

metals As required



Sr. No. Sample


21. S-111 00105-JA-31-1120 CAB Mix 31-V-107 & Surge 31-V-

108 outlet %concentration/metals As required

22. S-112 00105-KA-31-1121 CD Mix 31-V-109 & Surge 31-V-

110 outlet %concentration/metals As required

23. S-113 00105-KA-31-1121 CT Mix 31-V-111 & Surge 31-V-

112 outlet % concentration/metals As required

24. S-114 00105-LA-31-1122 CJ Mix 31-V-113 & Surge 31-V-114

outlet % concentration/metals As required

25. S 00105-LA-31-1122 31-E-116 SH makeup Cooler CW


26. S-103 00105-LA-31-1122 31-V-126 on outlet Water in SH (to LPS

HUT) As required

27. AI-

2246A/B 00105-LA-31-1122 31-V-126 probe in bed.

Water in SH to Cat

Makeup

Continuous & Closes

FQV- 1244

28. S 00105-NA-31-1124 31-K-102 Cooling Water Return

Line Water Quality As condition require

29. S 00105-NA-31-1124 31-K-102S Cooling Water Return

Line Water Quality As condition require

30. AI-2634 00105-QA-31-1126 31-K-105 PA Blower Discharge line O2 Continuous – DCS

31. S 00105-QA-31-1126 31-K-105 PA Blower Suction

Cooler CW return Water Quality As condition require

32. S 00105-QA-31-1126 31-K-105 PA Blower Inter Cooler


33. AI-2743 00105-RA-31-1127 31-V-127A/B Primary FE Guard

Bed Water Continuous – DCS

34. AI-2757 00105-RA-31-1127 31-V-127A/B Primary FE Guard

Bed outlet O2 Continuous – DCS

35. S-119 00105-RA-31-1127 31-V-127A/B vent line HC As condition require

36. S 00206-AA-31-1128 31-E-201A LPS Condenser CW

return Water Quality As conditions require

37. S 00206-AA-31-1128 31-E-201S LPS Condenser CW

return Water Quality As conditions require

38. S 00206-AA-31-1128 31-E-201C LPS Condenser CW


39. SC-203 00206-CA-31-1130 31-C-201 LB Column outlet Ketones Once per Shift

40. SC-204 00206-CA-31-1130 31-E-202 HP condensate

continuous purge

CO2 and water

hardness Once per Shift

41. SC-213 00206-CA-31-1130 31-E-202 MP Steam outlet line CO2 and water

hardness Once per Shift

42. S 00206-DA-31-1131 31-E-204 LB Trim condenser CW

Return Water Quality As condition require

43. S 00206-DA-31-1131 31-E-209 A/B FE Col. Feed dryer

Coolers CW return Water Quality As condition require



Sr. No. Sample


44. SC-206 00206-EA-31-1132 31-C-204 FE column outlet Upset conditions As required.

45. S-209 00206-EA-31-1132 31-ME-201 Refrigeration Package

FE to Cracker

FE impurities

N2/CO/FB-1 As required.

46. SC-207 00206-FA-31-1133 31-C-202 HB Column outlet Deactivator Acids &

Ketones Once Per Shift

47. SC-205A 00206-FB-31-1134 31-E-216A Continuous blowdown Water Hardness Once Per Shift

48. SC-205B 00206-FB-31-1134 31-E-216B Continuous blowdown Water Hardness Once Per Shift

49. SC-208 00206-FB-31-1134 31-P-204 & S discharge to HB

column

“FB-1, FB-2, FC-1, FC-

2, SH” As required.

50. AI-3436 00206-FB-31-1134 31-P-204 & S discharge to HB

column

“FB-1, FB-2, FC-1, FC-

2, SH Continuous - DCS

51. SC-210 0kl0206-GA-31-1135 31-V-204 RB Reflux Drum outlet “FC-1, FC-2” As required.

52. SC-212 00206-GA-31-1135 31-C-203 RB Column outlet %RB AS required.

53. AI-3634 00206-HA-31-1136 31-V-209A/B FE Column Feed

Dryers midpoint % Water in FE Continuous – DCS

54. S 00206-HB-31-1137 31-E-210 A/B CW return Water Quality As condition require

55. S 00206-HB-31-1137 31-E-211 A/B CW return Water Quality As condition require

56. S 00206-HB-31-1137 31-K-201 BCW Return line Water Quality As conditions require

57. AI-3810-1 00206-JA-31-1138 31-C-205 CM Column outlet

FB-1, FB-2 (CIS), FB-2

(TRANS), n-Butene, i-

Butene, SH

Continuous - DCS

58. SC-211 00206-JA-31-1138 31-C-205 CM Column outlet “FB-1, FB-2 (CIS), FB-2

(TRANS), n-Butene, i-Butene,

SH”

As required.

59. S 00206-JA-31-1138 31-E-415 CW Return line Water Quality As condition require

60. S 00206-KA-31-1139 31-E-215 CM Condenser CW


61. AT-3810-

2 00206-KA-31-1139

31-P-206/S CM Reflux Pumps

discharge

“FB-1, FB-2 (CIS), FB-2

(TRANS), n-Butene, i-

Butene, SH”

Continuous - DCS

62. S 00307-BA-31-1141 31-E-321 Sat Ext. Lube Oil Cooler

CW return Water Quality As conditions require

63. S 00307-BA-31-1141 31-E-320 Main Ext. Lube Oil Cooler


64. S 00307-BA-31-1141 31-E-322 Pelletizer Shaft Lube Oil


65. S 00307-CA-31-1142 31-E-323/4/5/6 Hot Oil Skid Cooler Water Quality As condition require.



Sr. No. Sample


66. S-301X 00307-DA-31-1144 31-G-301 Delumper outlet – Auto

“Pellets –MFI, MWD,

SE, HSV, Melt Swell,

Colour, Size, form of

pellets”

“Hourly, pellet cut

analysed as needed”.

67. S-308X 00307-DA-31-1144 31-G-301 Delumper outlet –

Manual

Pellets – check resin

cut on start-up and

random checks

As required.

68. S-301 00307-DA-31-1144 31-E-318 & S Plate water coolers


69. S-302 00307-DA-31-1144 31-E-318 & S Plate water coolers

Circulating Water Outlet line Water Quality As condition require

70. S-309X 00307-EA-31-1146 31-V-310 RA Stripper Cone – Auto

“Pellets – Continuous,

resin lots, colour, cross

mixing.”

Ongoing as

operations / lab

require.

71. S-310X 00307-EA-31-1146 31-V-317 Stripper HUB outlet Pellets – Stripper outlet

Volatiles As required.

72. S 00307-EA-31-1146 31-E-317 Stripper Conveying

Blower CW return Water Quality As condition require

73. S 00307-EB-31-1147 31-E-301 Solvent Vapour Trim

Condenser CW return Water Quality As condition require

74. S 00307-FA-31-1148 31-E-303 SH Additive Cooler CW


75. S-302X 00307-HA-31-1150 31-V-313 Blender #1 Bl/Unl line –

Auto Finished Lot – Colour

Each lots approx every 4

hrs.

76. S-303X 00307-HA-31-1150 31-V-314 Blender #2 Bl/Unl line –


Each lots approx.

every 4 hrs.

77. S 00307-HA-31-1150 31-V-313 Blender #1 Blending Air


78. S 00307-HA-31-1150 31-V-314 Blender #1 Bl/Unl Blower


79. S-304X 00307-JA-31-1151 31-V-315 Blender #3 Bl/Unl line –


Each lots approx.

every 4 hrs.

80. S-305X 00307-JA-31-1151 31-V-316 Blender #4 Bl/Unl line –


Each lots approx.

every 4 hrs.

81. S 00307-JA-31-1151 31-V-315 Blender #3 Blending Air

Cooler CW return Water Quality As conditions require

82. S 00307-JA-31-1151 31-V-316 Blender #4 Blending Air

Blower Cooler CW return Water Quality As condition require

83. S 00307-KA-31-1152 31-E-312A Silo Conveying Blower

Cooler 1 CW return Water Quality As condition require

84. S 00307-KA-31-1152 31-E-312B Silo Conveying Blower


85. S 00307-KA-31-1152 31-E-312C Silo Conveying Blower


86. S-306X 00307-LA-31-1153 31-ME-310 Product Classifier 1 RF

discharge

Pellet Quality prior to

packaging.

Per Lab Requests or

Business case

87. S-307X 00307-LA-31-1153 31-ME-311 Product Classifier 2 RF

discharge

Pellet Quality prior to

packaging.

Per Lab Requests or

Business case



Sr. No. Sample


88. S 00307-LA-31-1153 31-E-314A Class Transfer Blower


89. S 00307-LA-31-1153 31-E-314B Class Transfer Blower


90. S 00307-MA-31-1154 31-E-319 Bag Slitter Transfer

Blower Cooler CW return Water Quality As condition require

91. SC-407 00421-AA-31-1157 31-V-404 Flare K.O.D. outlet

SH quality prior to

pumping back to LPS

HUT

Each Transfer to the

LPS HUT

92. SC-403 00424-BA-31-1160 31-P-407 & S LP DTA Condensate

Pump (s) outlet DTA High Boilers Once Per Day

93. SC-401 00424-CA-31-1161 31-V-406 HP DTA Condensate

Drum outlet DTA High Boiler Once Per Day

94. SC-402 00424-DA-31-1162

31-LM-401 A/B returns to DTA

Regeneration Vessel from Vap.

1&2

DTA High Boiler Once Per Day or as

required.

95. S 00424-DA-31-1162 31-E-412 DTA Vent Pot CW return Water Quality AS condition requires

96. S 00424-DA-31-1162 31-V-408 Bottom Outlet line Cooler

CW Return line Water Quality AS condition requires

97. S 00424-DA-31-1162 31-V-409 Tracing CW Return line Water Quality AS condition requires

98. S 00425-BA-31-1165 31-E-401 FB De-inventory Cooler

CW return Water Quality AS condition requires

99. S 00425-CA-31-1166 31-E-410 FC Cooler CW return Water Quality AS condition requires

NOTE: Also refer NOVA’s Quality Control Information Manual



SECTION-25.0

PROCEDURE FOR PREPARATION OF EQUIPMENT HANDOVER



25.1 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 equipment is handed

over for maintenance after it has been purged.

a) Ascertain that equipment is isolated by proper valves and blinds.

b) Ascertain that there is no pressure of hydrocarbons in the lines, vessels and equipment.

c) 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.

d) Check that steam injection lines and any inert line connections are disconnected or isolated from the

equipment.

e) Provide tags on the various blinds to avoid mistakes. Maintain a register for blinds.

f) Check for pyrophoric iron and if existing, keep this wet with water.

g) Keep the surrounding area cleaned up.

h) Get explosive meter test done in vessels, lines, equipment and surrounding areas.

If welding or hot work is to be done, also:

a) Keep fire fighting devices ready for use nearby

b) Close the neighbouring surface drains with wet gunny bags

c) Keep water flowing in the neighbouring area to cool down any spark bits etc.

d) Keep steam 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.



SECTION-26.0 WORK PERMIT PROCEDURE



26.1 Work Permit System: NOTE: IOCL Work Permit Procedure is to be Followed.

General guidelines for carrying out the activities are as under:

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.

26.2 Types of Work Permit a) 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.

b) 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

a) 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. A fresh air flow

to be ensured in the enclosed space throughout 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.



26.3 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 feel that the conditions are not safe.

• The conditions to be complied which 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

a) Fire fighting system is ready

b) Close the neighbouring surface drains with wet gunny bags

c) Keep water flowing in the neighbouring area to cool down any spark.

d) Responsible operation supervisor should be present at the place of hot work till the first torch is

lighted.

26.4 Preparation for Vessel Entry Whenever a supervisor must enter a vessel a meeting should be arranged between personnel who will be

involved. The meeting should include review of the vessel entry procedures, the client’s safety requirements

and facilities, preparation of a vessel entry schedule, assignment of responsibility for the preparation of a

blind list, and assignment of responsibility for the vessel entry permits.

The most common tasks of a supervisor which could involve a potentially hazardous 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, Drums, 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 man ways 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 be strong and solid. Scaffolding is preferred when the vessel is large

enough to permit it to be used. 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. 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 are 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 man way.

A minimum of one harness for each person entering the vessel and at least one spare harness for the

people watching the man way should be provided at the vessel entry.

Providing a Man way 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 manway so

that he can assist them 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 using an air mover, a fan, or, for the cases where moisture is

a 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 exit gas does not enter the vessel. When

instrument air is used, the responsible personnel must check the supply header to ensure that it is properly

lined up and that there are no connections where nitrogen or a contained backup source can enter the

system. The fresh air purge should be continued throughout the time that people are inside of the vessel.

A minimum of one fresh air mask for each person entering the vessel and at least one spare mask for the

whole 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.



SECTION-27.0 CHEMICAL SOLUTION PREPARATION PROCEDURE



27.1 Catalyst Batch Make-up:

Following is the stepwise procedure of Catalyst batch preparation:

• Ensure that the person who is going to prepare the Catalyst batch and the standby person have

worn the approved PPE’s (Aluminised heat resistant coat and pant, hood and gloves)

NOTE: Refer respective MSDS for the HAZARD involved in handling the Catalyst.

• Line-up pure cyclohexane from the storage area, through the SH Make-up Cooler to the LPS HUT.

Pump the solvent through this line until it is cooler than 40°C.

• When it is less than 40°C line the flow through the SH Make-up Dryer to the LPS HUT.

• Place the catalyst cylinder in position and verify the material contents. Connect the catalyst cylinder

fittings and hose connections. Purge all connections with nitrogen to remove air.

• Check all the fittings of HX items for Leak with soap solution, attend the same if any.

• Check moisture content of Cyclohexane after SH Makeup Dryer.

• If moisture content is less then 2 ppm, line-up to Mix tank, otherwise continue to take through LPS.

• Reduce the Mix tank pressure to 0.7kg/cm2g, by venting to Catalyst KO Drum.

• Set the solvent meter (31-FQV-2245) output at 60% of the estimated total required amount needed

for the batch and send it to the mix tank.

• When the 60% of the total solvent needed for the catalyst batch has been transferred to the mix


• Record the starting weight of the cylinder.

• Line up the CAB/CAB-2 Filter (31-G-102) as per the standard operating procedure.

• Set the nitrogen regulator (PCV-2043) to 3.5 kg/cm2g and line the nitrogen into the cylinder using 3-

way valve, and transfer all of the contents of the cylinder to the mix tank.

• Record the weight of the catalyst cylinder.

• Continuously monitor the solvent for water content at the dryer water analyser readout in the DCS.

• When all the catalyst has been transferred to the mix tank, calculate the weight of the catalyst that

has been sent to the mix tank. Calculate the extra solvent required to bring the batch to the required

concentration and transfer the remainder of solvent to the mix tank. Use some of this solvent to

flush the cylinder to hose manifold before disconnecting it.

• Record the total solvent used; the weight of catalyst transferred; and the final level of the mix tank.

• Close the vent on the mix tank and let the pressure come up to 0.7 kg/cm2. Allow the agitator to run

for 1 hour after the last of the solvent is sent to the mix tank.

• Raise the pressure on the mix tank until it is exactly equal to the pressure in the surge tank. Slowly

open the pressure balance line in the vapour line between the mix and surge tanks. Open the bottom

outlet on the mix tank to allow catalyst to flow to the surge tank and to the metering system. Monitor

the Reaction section after every fresh catalyst batch line-up.

Precautions to be taken while making catalyst Batch:

Fumes given off by CAB and CAB-2 when exposed to moist air consist primarily of hydrochloric acid. These

fumes must not be allowed to contact human tissue. Fumes will be very irritating to the eyes and the



respiratory tract and immediate medical attention must be obtained after exposure. Other tissue exposed to

these vapours should be flushed with water.

When CT, CD and CJ are brought into contact with air, some fumes will be released. The addition of water

to CT, CD and CJ will cause violent eruptions over a wide area. Because of its reaction with water, CT, CD

and CJ will cause severe burns in contact with the skin. Immediately rinse the skin thoroughly with large

quantities of water and treat as for thermal burns. Water must not be used on a CT, CD or CJ spill.

Vermiculite to a depth of 5 cm will effectively reduce the fire potential. Should a fire start, dry chemical is the

best extinguishing agent.

27.2 Liquid Additive Make-up Procedure:

Following is the stepwise procedure of Liquid Additive batch preparation:

Sr. No.

Step Key Points

1. Prepare empty mix tank

• Check that the mix is empty.

• Close mix tank access valves, vent tank.

• Adjust tank temperature controller to zero.

• Ensure the agitator is in the switched off position.

2 Purge the mix tank

• Purge nitrogen through tank and vent system for 1

hour.

• Shut off nitrogen and allow tank to depressurise.

3 Open and inspect mix tank

• Loose the bolts on the hatch cover.

• Put ‘ON’ a small purge of Nitrogen (approx. ½ turn).

• Ground yourself by touching ground strap with bare

hand before opening hatch.

• Open top of mix tank standing on the opposite side to

the lid hinge and check vessel for residual powders.

NOTE: After the bolts to hatch have been removed, keep clear. Do not open hatch cover until a

small Nitrogen purge is established or Oxygen will enter the tank.

NOTE: If residue powder or solvent is found in the tank (Ensure that Hatch cover is closed), flush the mix to the waste tank. Then start back at step #2.

NOTE: Additive dust suspended in air is explosive. Maximum permissible oxygen concentration in the tank to prevent ignition is 9%.

4 Gas test the mix tank

• Use a gas tester with a flow proportioner for checking

nitrogen atmosphere.

• Check atmosphere in and around the tank opening to

ensure it is below LEL.

• If the reading is too high, then close the tank and

repeat nitrogen purging.



Sr. No.

Step Key Points

Note: Repeat Nitrogen purging if the LEL reading is too high on the tank.

5 Install the funnel

• Place the additive funnel HX-352 onto the tank

opening.

• Using the additive funnel requires a use of a ground

strap

• The funnel must be connected to the dust exhaust

plenum.

6 Start exhauster on Dust Plenum

• Ensure the exhaust duct slide gate is open only to the

tank being used.

• Start the exhaust blower.

7 Add powder to mix tank.

• Add all dry additives through top opening.

• Use a dust mask (cartridge or powered) during

handling of powders.

NOTE: Maintain a Nitrogen purge while dumping additives to prevent oxygen entering the tank.

NOTE: All powders are placed into mix tanks prior to solvent introduction. Never add powder tosolvent, this could cause a static spark.

8 Close Mix tank

• Check the gasket on the lid for cleanliness and

condition.

• Tighten the lid down evenly.

• Shut off nitrogen purge.

9 Line solvent to mix • Line up solvent from the transfer header.

10 Add solvent to mix tank • Start solvent flow to tank.

• When using Xylene the same meter will be utilized.

11 Confirm solvent flow

• Check meter for a flow.

• Check the mix tank level indication to verify movement

and correct tank is receiving the solvent.

12 Shutdown solvent

• Close off the solvent header when the transfer is

completed.

• The total litres of solvent should be recorded on the

batch make up sheet.

13 Start mixing the batch

• Close the vent on the mix tank.

• Open nitrogen to the mix tank.

• Increase mix tank temperature controller to 70°C.

• Start the mix tank agitator.

14 Record batch information

• Full out a batch make-up sheet.

• Use the next number in order of the Additive batch and

record the amount.

• Update the Additive room record book



Sr. No.

Step Key Points

15 Allow for proper mixing/heat up

• Allow appropriate time for tank to come to full

temperature.

• Tank temperature is maintained at 70°C that keeps

powders from dropping out of solution.

NOTE: If the steam TIC is not able to control the tank temperature to set point, the manual block

valve will have to be sued. Too low a temperature will cause additives to come out of solution and solidify. Too high a temperature will boil the batch solvent causing tank pressure to increase.

The increase in pressure will pop the relief valve and allow the solvent to boil off.

16 Follow additive heatup times

• All AO’s -1 hr. Minimum. If time is available, mix for

1.5 hrs.

• Kemamide E – 1 hr.

• Crodamide - 1.5 hrs.

• Xylene based UV’s – (e.g. UV 8) 2.5 hrs.

17 Field transfer additive

• When the material has been transferred, it must be

recorded in the logbook.

• State the date, additive type, location from which the

batch came from the destination, batch number and

operators initials.

Operating Manual Rev. 0 Vol i of III

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Transcript of Operating Manual Rev. 0 Vol i of III