Unit Overview Module
Transcript of Unit Overview Module
Hydrocracker Unit 2600
Operator Training
Revision r0, March 24, 2017
Unit Overview
Module
Hydrocracker Unit 2600
Operator Training
Date Developed: Mar. 24, 2017 Last Reviewed On:Revision Date:
File Name Document Contact
Date Rev Comments
Date Developed: Mar. 24, 2017 Last Reviewed On:Revision Date:
File Name Document Contact
Date Rev Comments
Table of Contents
Hydrocracker Unit Inputs & Outputs
Material Hazards
Safety Systems.
Safety Systems Plot Plan
Plant Equipment
Simplified Process Flow
Page 2
Page 3
Page 7
Page 8
Page 10
Page 11
Unit Overview
Module
Physical Hazards. Page 9
Objectives and Introduction Page 1
Module Objectives
1. List the inputs and outputs of the Hydrocracker Unit.
2. Describe the types of equipment used in the Hydrocracker Unit.
3. Describe the simplified flow through the Hydrocracker Unit.
4. Describe the material hazards present in the Hydrocracker Unit.
5. Describe the physical hazards present in the Hydrocracker Unit.
6. Describe the safety systems used and their locations in the Hydrocracker Unit.
Module Introduction
The PCR Refining Refinery is an 85,000 barrel per day facility located in Sinclair, Wyoming. The major products of the facility are propane, gasoline, jet fuel, diesel, and asphalt. Opened in 1924, it is one of the largest refineries in the Rocky Mountain Region.
The refinery is a complex operation that consists of a number of different process units, each designed to perform a specific function. The Hydrocracker Unit converts heavy, high boiling compounds produced elsewhere in the refinery into lighter, more valuable products.
The purpose of this Unit Overview Module is to provide a general, introductory overview of the Hydrocracker Unit, the types of equipment used, and the general flow through the unit. Additionally, the safety and health considerations associated with this unit are discussed.
Hydrocracker Unit 2600
Operator Training
Unit Overview
Module
1
Hydrocracking Unit Inputs & Outputs
Inputs to the HCU include:
• Atmospheric Gas Oil
• Light Vacuum Gas Oil
• Light Cycle Oil
• Light Coker Gas Oil
• Hydrogen
Outputs of the HCU Plant include:
• Light Naphtha
• Heavy Naphtha
• Jet Fuel
• Diesel
Utilities produced in the HCU Plant
include:
• Steam
• Condensate
The following Waste Streams are
produced in the HCU:
• Sour Water
Inputs and Outputs
The Hydrocracker Unit (HCU) consists of a number of related systems. Products from one system may end up as feed to another, or
leave as final products. To fully understand the interaction of the systems, it is important for you to recognize its inputs and outputs.
Chemicals used in the HCU
include:
• Lean Amine
• Anti-foulant
• Corrosion Inhibitor
• H2S Scavenger
• BFW
• Steam
• Condensate
• Nitrogen
• Glycol
The Utilities used to enable the
Hydrocracking facility to function as
intended include:
• BFW
• Steam
• Condensate
• Nitrogen
• Glycol
The Utilities used to enable the
Hydrocracking facility to function as
intended include:
• Cooling Water
• Instrument Air
• Plant Air
• Fuel Gas
• Electricity
Waste Streams
Utilities Used
Outputs
Chemicals Used
Utilities Produced
Lean Amine Hydrocracker Unit Systems
Cooling Water
Instrument Air
Glycol
Steam
Fuel Gas
Electricity
Nitrogen
Rich Amine
Light Naphtha
Heavy Naphtha
Jet Fuel
Diesel
Steam
Sour Water
Condensate
Chemicals Produced
Train 2 Cold
Separation &
Absorption
System
Main
Fractionation
System
Distillate
Fractionation
System
C-001
Compression
System
C-002
Compression
System
Feed Heating &
Reaction
System
Hot Separation&
Train 1 Cold
Separation
System
Anti-foulant
Corrosion Inhibitor
H2S Scavenger
Inputs
Atmospheric Gas Oil
Light Vac Gas Oil
Light Cycle Oil
Light Coker Gas Oil
Hydrogen
BFW
Condensate
Plant Air
2
Cen
trif
ug
al
Pu
mp
Po
sit
ive
Dis
pla
ce
me
nt
Pu
mp
Su
cti
on
an
d D
isch
arg
e P
uls
e B
ott
les
Rec
ipro
ca
tin
g C
om
pre
ss
or
Centrifugal Pump Positive Displacement Pump Reciprocating Compressor
Pumps are used to move process
streams throughout the facility. The
spinning impeller on a Centrifugal Pump
gives the liquid velocity energy. Velocity is
converted to pressure as the liquid leaves
the pump. This increased pressure drives
the liquid to flow to its lower pressure
destination. Centrifugal Pumps are useful
for moving liquids at high flow rates, with
a low to moderate pressure increase.
Positive Displacement Pumps rely on
mechanical energy, rather than kinetic
energy to move liquid. They displace a
known quantity of liquid with each
revolution of the pumping element. This is
done by trapping liquid between the
pumping elements and a stationary
casing. Pumping element designs include
gears, lobes, rotary pistons, diaphragms,
vanes, and screws.
A Compressor is a machine that
increases the pressure of a gas. The
purpose of compressors is to move air
and other gases from place to place by
increasing the gas pressure. A
Reciprocating Compressor is a positive-
displacement compressor that converts
rotational crankshaft motion into pumping
piston motion to deliver gas at a high
pressure.
Suction and Discharge Bottles are
intended to isolate the piping system from
the pulses generated by the compressor.
These bottles smooth out, or dampen,
pressure pulsations created by the act of
compression to prevent excessive
vibration that could damage piping and
equipment.
3Equipment
3Equipment
Suction and DischargePulse Bottles
Sh
ell
an
d T
ub
e E
xc
ha
ng
er
Kett
le T
yp
e S
team
Gen
era
tor
Hair
pin
Exc
ha
ng
er
Air
Co
ole
r
Shell & Tube Heat Exchanger Air Cooler Hairpin Exchanger
Shell and Tube Heat Exchangers consist
of a series of tubes. One set of these
tubes contains the fluid that must be
either heated or cooled. The second fluid
runs over the tubes that are being heated
or cooled so that it can either provide the
heat or absorb the heat as needed. A set
of tubes is called the tube bundle.
Steam Generators produce steam for use
throughout the plant using heat from
process streams. A Kettle Type Steam
Generator is a special type of Shell and
Tube Heat Exchanger. The hot fluid on
the tube side heats boiler feed water on
the shell side to the point that it vaporizes.
Above the bundle of tubes, there is a
large, open space that allows for
separation of vapor.
Air Coolers, also known as Fin Fan
Coolers, can be considered a special type
of shell and tube exchanger. A large fan is
used to blow air past the tubes. Most Fin
Fan Coolers are either induced-draft or
forced-draft, the more common
arrangement being forced draft. The air is
moved by rather large fans. The tubes are
surrounded with foil-type fins, typically
about 1 inch high, that increase the
surface area available for heat transfer.
A Hairpin Exchanger is a double pipe
shell and tube exchanger. They have
been described as single pass
exchangers that have been folded in half
to look like a hairpin.
4Equipment
4Equipment
Kettle TypeSteam Generator
Fu
el
Fir
ed
He
ate
r
Se
pa
rati
on
Ve
sse
l
Str
ipp
er
Fra
cti
on
ato
r
Fuel Fired Heater Fractionator Stripper
A Fuel Fired Heater is a piece of
equipment that burns fuel gas to generate
heat for the process stream. The process
streams flow through tubes within the
firebox. The burner is equipped with a
pilot to light the burner. Fuel for the heater
can be derived from off-gas, natural gas,
or fuel oil.
These vessels are pressure vessels that
provide a moving fluid with a small
amount of storage space. The storage
space is used to smooth out flow
fluctuation. Additionally, the fluid has
enough residence time in the vessel to
separate into phases. Gases are drawn
off the top, and liquids are drawn off the
bottom.
A Fractionator is a vertical vessel, or
column, that separates a feed stream into
two or more components according to the
boiling points of the components. It
contains trays or packing to aid in the
gas-liquid contact. The lower molecular
weight lighter compounds are driven to
the top of the column and removed at the
overhead draw. The higher molecular
weight heavier compounds are driven
to the bottom of the column and removed
at the bottom draw.
A Stripping Column, or Stripper, is a
distillation column where a gas is stripped
from a liquid solution. Stripping is the
removal of a component from a liquid
stream through vaporization and uptake
by an insoluble gas stream. Thus,
absorption and stripping are opposite
operations, often used together in a cycle.
5Equipment
5Equipment
Separation Vessel
Ab
so
rpti
on
Co
lum
n
Pre
tre
ate
r R
ea
cto
r
Hyd
rocra
ck
er
Re
ac
tor
Pretreater Reactor
A Reactor is a pressure vessel designed to
contain and ensure mixing of reactants at
the proper conditions so that the desired
chemical reaction will occur. The Pretreater
shown above is a catalytic reaction vessel
that is used to remove sulfur, nitrogen, and
oxygen compounds from the HCU feed.
The Hydrocracker is a catalytic reaction
vessel that converts higher molecular
weight components that make up the HCU
feed into more valuable, lighter products.
Gas absorption is a process in which one
or more soluble components of a stream
is dissolved in a liquid. An Absorption
Column is a specific type of column used
to separate components from a rising gas,
using a falling liquid to absorb the gas.
The operation may involve just physical
absorption, or may involve absorption of
the material into the liquid, followed by
reaction with one or more components of
the liquid solution.
Absorption Column Hydrocracker Reactor
6Equipment
6Equipment
6Simplified Process Flow
In the XXXXX System,
In the XXXXX System, the
7Simplified Process Flow
7Simplified Process Flow
In the Hot Separation & Train 1 Cold Separation System, the process
begins to separate reaction products from reaction byproducts and
recycle gas. This Hot HP Separator collects the heavier hydrocarbon
material that will be sent to the Main Fractionator via the Hot Flash
Drum. The process stream from the top of the Hot HP Separator is
cooled, then again splits into two trains for cold separation. In this
system, the Train 1 stream is cooled to condense water and hydrocarbon
liquid so that it can be separated from the hydrogen-rich recycle.
Recovered hydrocarbon liquid is cooled and routed to the Main
Fractionator.
In the Train 2 Cold Separation & Absorption System, the Train 2
stream from the cooled Hot HP Separator vapor is further cooled to
condense water and hydrocarbon liquid so that it can be separated from
the hydrogen rich recycle. It is separated in 2 stages. The recovered
hydrocarbon liquid is cooled, then mixes with the Train 1 flow to the Main
Fractionator. Hydrogen-rich vapors recovered from Train 1 and Train 2
are treated with amine to remove H2S and increase purity of the stream
so that it can be recycled to the Reactors.
In the C-001 and C-002 Compression Systems, various hydrogen
streams recovered within the unit are compressed so that hydrogen can
be returned to the high pressure reaction system. Each system includes
a six-cylinder reciprocating compressor. Cylinders 1A and 2A compress
sweet recycle hydrogen from the Recycle Absorber to provide hydrogen
feed and quench gas to the reactors. Cylinders 1C and 2C compress
Main Fractionator overhead vapor, which is sent to the FCC Unit. The D
cylinders compress makeup hydrogen from the #1 Reformer. Discharge
mixes with hydrogen feed from the HDS. The combined stream is
compressed in the E and F cylinders, and supplies hydrogen to both
reactor trains.
In the Feed Heating and Reaction System, feed is pumped to the high
pressure reaction circuit, mixed with hydrogen, then heated to the
temperature necessary for reactions to proceed. Due to the unit s high
capacity, two parallel reactor trains are used. The feed is first pretreated
for sulfur and nitrogen removal, as well as for olefin saturation. This is
done primarily to protect the downstream hydrocracking catalyst.
Pretreater effluent flows through the Hydrocracker to convert higher
molecular weight feed components to more valuable, lighter products.
Reactions in both the Pretreater and the Hydrocracker occur at a high
temperature and pressure in a hydrogen-rich atmosphere, and in the
presence of catalyst.
In the Main Fractionation System, feed recovered in the Hot Separator
and in the Low Pressure Separators is separated into valuable products
through the process of distillation. There are two side draws on the Main
Fractionator: heavy and light naphtha. Each naphtha draw is routed to a
stripper for light ends removal. Light and heavy naphtha are cooled in a
series of Heat Exchangers and flow to storage The Fractionator bottoms
is routed to the Distillate Fractionator for further fractionation. A portion of
the bottoms is recycled to the Feed Surge Drum for additional product
conversion.
In the Distillate Fractionation System, Main Fractionator Bottoms is
separated through distillation to yield more valuable products. The
Distillate Fractionator also has two draws: jet fuel and diesel. Each of
these draws is routed to a steam stripper for light ends removal.
Distillate product is routed to storage. Jet Fuel is sent to dryers to
remove water to reduce haze point. Overhead is condensed and
separated to recover heavy naphtha product. Distillate Fractionator
Bottoms is also recycled to the Feed Surge Drum for additional product
recovery.
Train 2 Cold
Separation
&
Absorption
SystemDistillate
Fractionation
System
Coker Naphtha
HCU Feed from
Tank Farm
Reactor Effluent
Ma
in F
ractio
nato
r B
ott
om
s
Recycle Hydrogen
Distillate Fractionator Bottoms
Heat Exchange
Wash Water
Sour Recycle Hydrogen
Fractionator Feed
Hot Flash Drum Bottoms
Heat
Exchange
Wash Water
Fractionator Bottoms to TK-401
Quench & Make-up Hydrogen
Recycle Hydrogen
Recovery Gas to FCC
Fractionator Overhead Sour Gas
to Tank Farm
Recycle Hydrogen
Sweet Recycle Gas
Hydrogen from Header
Hydrogen to FCC
Recycle Hydrogen
Hot Separator Overhead
Light Naphtha to Storage
Heavy Naphtha to Storage
Jet Fuel to PV-2049
Diesel Fuel to Storage
Heavy
Naphtha
Fractionator Feed
Wash Water
Feed Heating
&
Reaction
System
Hot Separation
&
Train 1 Cold
Separation
System
Main
Fractionation
System
C-001 & C002
Compression
Systems
Material Hazards
Flammability
Special
Hazards
Health Instability
Flammability
Special
Hazards
Health Instability
The NFPA diamond is broken into four colored
sections, each representing a specific hazard.
Health, Flammability, and Instability are rated
numerically, and Special Hazards are identified with
symbols or abbreviations.
Numbers in the three colored sections range from 0
to 4, with the following definitions:
0 = Minimal 1 = Slight 2 = Moderate 3 = Serious
4 = Severe
Oxidizer
4: Explosive at room temperature
3: May detonate if shocked, or heated under confinement, or mixed with water
2: Unstable, may react with water
1: May react if heated or mixed with water
0: Normally stable, does not react with water
4: Extremely flammable gas or liquid (Flash point below 73 °F)
3: Flammable (Flash point 73-100 °F)
2: Combustible, requires heating to ignite (Flash point above 200° F)
1: Slightly Combustible
0: Will not burn under normal conditions
4: Highly toxic, may be fatal on short term exposure
3: Toxic, full protective suit and breathing apparatus required
2: Breathing apparatus and face mask must be worn
1: Breathing apparatus may be worn
0: No precautions necessary
OXY
Acid ACID
Alkali ALK
Corrosive COR
Use No Water W
Radiation
HydrogenMSDS: #
CAS: 1333-74-0
Flammable gas that burns with an
almost invisible flame. Asphyxiant.
Primary route of exposure is inhalation.
Ventilate the area to keep concentrations of
hydrogen from building up. A supplied air
respirator should be worn when
concentrations are unknown. Spark-proof
tools should be used to control ignition
sources.
Multiple processes
MaterialMSDS Number
CAS Number(s)Major Hazards
NFPA
RatingsSpecial PPE/Controls Location
Nitrogen CAS: 7727-37-9 Simple asphyxiant
Maintain O2 levels above 19.5%. Use
positive pressure NIOSH approved air
supply.
4
0 0
4
0 0
0
0 0
0
0 0
Fuel GasCAS: 74-98-6
115-07-1
Extremely flammable gas. Vapors are
heavier than air. May explode violently.
Keep away from heat/sparks. Provide local
ventilation, where possible, to minimize
worker exposure and prevent explosive
concentrations.
4
1 0
4
1 0
Hydrocarbons C2 – C5 CAS: By Stream Highly Flammable
Chemical goggles are recommended.
Wear chemical resistant gloves when
handling. Wear approved respirators if
allowable limits are exceeded.
4
1 0
4
1 0
Hydrocarbons C6+ CAS: By Stream Flammable
Chemical goggles are recommended.
Wear chemical resistant gloves when
handling. Wear approved respirators if
allowable limits are exceeded.
3
1 0
3
1 0
Hydrogen Sulfide CAS: 7783-06-4Flammable gas. Toxic at high
concentrations.
If concentration is above allowable limits,
ventilate the area. A supplied air respirator
or SCBA should also be worn.
4
4 0
4
4 0
Ammonia CAS: 7764-41-7Strong alkali. Colorless gas or liquid
with a pungent odor.
Provide adequate ventilation. Wear
chemical goggles, face shield, rubber
gloves, and protective clothing when
handling. Avoid breathing mist or vapors.
1
3 0
1
3 0
Sour Water
Clear to yellow-brown liquid with a foul
odor of rotten eggs. Explosive
concentrations can build up in poorly
ventilated areas.
If the concentration is above allowable
limits, ventilate the area. Supplied air
respirator or SCBA should be worn.
8Material Hazards
8Material Hazards
SA
1
2 0
1
2 0
CAS: 7783-06-4
7732-18-5
7647-14-5
Physical Hazards
Overview:
A Physical Hazard is defined as A factor within the
environment that can harm the body without
necessarily touching it.
Physical hazards include but aren t limited to:
electricity, radiation, pressure, and heights, amongst
many others.
The PCR Refining Refinery contains multiple physical
hazards. They can cause harm to yourself or your
co-workers, if not controlled. The main, physical
hazards found are summarized in the table to the
right. Through awareness and attention to your
surroundings, you can apply the appropriate controls
to keep everyone safe.
Physical HazardsPhysical Hazards9
Physical Hazards9
High Pressure
Pressure is present whenever there is a
need to move a material, raise or lower a
boiling point, or affect the state of a
material (solid, liquid, or gas).
Exposure to pressure over 400 psig could cause
severe damage to the employee, depending on the
length of exposure. The results could be as simple
as causing the loss of balance, or as severe as the
amputation of a limb or injection of material under
the skin or into the blood stream. Overpressure of a
line or vessel could cause a catastrophic failure of
the system(s), release of hazardous material, fire,
explosion, etc.
Be aware that material being released from
piping could be under high pressure, and
approach with caution. Ensure that all
Pressure Relief Valves are in proper working
order, and if there is a block valve
underneath, that it remains locked or car
sealed open at all times. Open all valves
slowly to avoid a sudden release of pressure.
Hazard Explanation ControlAssociated Risks
Electricity
Electrical hazards exist when contact
occurs with exposed live parts due to
faults, which could cause fire or
explosions, or where an electrical fault is
the source of ignition.
Electrocution incidents can be fatal, while non-fatal
shocks can result in serious and permanent burn
injuries to skin, internal tissues, and damage to the
heart, depending on the length and severity of the
shock.
Ensure only appropriately licensed personnel
carries out electrical work. Switch off
electricity where possible before working on
equipment. Ensure electrical equipment is in
good working order. Ensure tag out and
isolation procedures are in place, and always
follow electrical safety standards.
High Temperature
High temperatures can cause instant
injury to personnel, ranging from
blistering (second degree burn) to
charring (third degree burn) of the
affected area. Hydrocracker feed must be
heated to a high temperature for cracking
reactions occur. In addition, the process
flow through the unit uses the transfer of
heat in exchangers to heat other
materials and/or generate steam to
reduce utility costs.
Exposure to piping and equipment in the
temperature range of 200°F to 400°F could cause
burns to the employee, resulting in immediate
blistering (second degree burn) to actual charring or
burning of the skin (third degree burn), depending
on the length and location of the exposure.
Exposure to material from equipment greater than
400°F could cause immediate second and/or third
degree burns, or even death, depending on the
length and location of exposure.
Ensure that all lines subject to high
temperatures are properly insulated or have
personal protective controls in place to
reduce the risk of exposure.
Elevated Platforms
Elevated platforms are in place to allow
access to all parts of the facility. These
platforms can present some unique
hazards as weather conditions change.
Elevated platforms may cause personnel to slip as
the surfaces become slick. Tripping may also cause
injury due to the height of the platform.
Check the surface for debris, oil, water, or
other substances. Ensure that any ladder
safety bar or chain is in place and the railing
is secured.
Rotating Equipment
Rotating equipment, such as centrifugal
pumps and compressors, can be deadly
because of their motion.
Rotating equipment or apparatus can trap clothing,
hair, or body parts.
Do not use a piece of equipment until you are
instructed on its proper use. Do not remove
guards or safety interlock devices. Use the
appropriate personal protective devices:
glasses, gloves, goggles, and/or face shield.
Use approved lock, tag, and try procedures
before working on equipment.
Sa
fety
Sh
ow
er/
Ey
ew
as
h S
tati
on
Bre
ath
ing
Ap
para
tus
Fir
efi
gh
tin
g E
qu
ipm
en
t
Em
erg
en
cy
Sto
p S
wit
ch
PP
E
An Emergency Stop Switch (ESD)
is a safety mechanism used to
shut off equipment in an
emergency situation when it
cannot be shut down in the usual
manner. Unlike a normal
shutdown switch/procedure, which
shuts down all systems in an
orderly fashion, an emergency
stop switch is designed to
completely and as quickly as
possible abort the operation.
Minimum Personal Protective
Equipment (PPE) requirements to
perform work in the plant include:
•Hard Hat
•Impact resistant safety glasses
with side shields attached
•Safety shoes with leather uppers,
safety toes, oil resistant soles, and
a defined heel
•Fire Retardant Clothing (FRC)
•Hearing Protection
•Personal H2S Monitor
There are Safety Showers and
Eye Wash Stations located
throughout the plant. Eye wash
stations should be used whenever
an individual s eye comes into
contact with a chemical hazard.
Safety showers will be used when
an individual is exposed to a
hazardous chemical. The
locations of Safety Showers and
Eyewash Stations switches, as
well as other safety systems, are
shown in the plot plan on page 13.
The Firefighting Equipment consists
of hoses and other equipment
located throughout the plant. All
firefighting equipment is painted red
for easy identification.
Breathing Apparatus Firefighting Equipment Emergency Stop Switch PPE
10Safety Systems
10Safety Systems
11Hydrocracker Safety Systems Plot Plan
11Hydrocracker Safety Systems Plot Plan