97903378 Naptha Cracking Plant Operation

SECTION

MODULE NO. CKR-PR-P-001 RELIANCE INDUSTRIES LIMITED

PROCESS DESCRIPTION AND UTILITIES

CKR-PR-P-011

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

1 0 0 23/08/2015 BMK

SECTION

MODULE NO. CKR-PR-P-001 RELIANCE INDUSTRIES LIMITED

Preface This operating manual gives general guidelines for the understanding and operation of the Cracker Plant. It provides basic information on the process , utilities, effluent treatment and emergencies. This

shall be read with other Standard

Operating Procedures to understand precisely the operation and control methodology of the plant. It is recognised that several improvements can be made to this manual for more efficient operation of the plant. Any such changes shall be communicated to the Manager in charge for proper updating and revision.

Author B.M.Krishna

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

2 0 0 23/08/2015 BMK

SECTION

MODULE NO. CKR-PR-P-001 RELIANCE INDUSTRIES LIMITED

CONTENTS: 1

2

2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 2.09 2.10 2.11 2.12

NGL / NAPHTHA CRACKER PLANT AT RIL, HAZIRA Introduction Feed Stock Other Products Chemicals, Additives And Catalysts Products Specification Process Description Cracking Furnaces USC main furnace and recycle furnace quench fittings Quench Oil Tower HFO Stripper LFO Stripper Quench Water Tower Dilution Steam generation system Distillate stripper Quench Water Circulation Circuit Quench Oil Circulation Circuit Pan Oil Circulation Circuit Cracked gas compression ,Acid gas removal,

2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2.23 2.24 2.25 2.26 2.27 3

Dehydration Demethaniser system PSA Unit Deethaniser C2 Acetylene hydrogenation system Ethylene fractionation Depropaniser C3 MAPD hydrogenation system Secondary and tertiary deethanisers Propylene fractionation Debutaniser C4 hydrogenation and Aux. C4 hydrogenation Ethylene refrigeration system Propylene Refrigeration System Gasoline Hydrogenation Unit Spent Caustic Oxidation Unit Utilities

1.1 1.2 1.3 1.4 1.5

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

3 0 0 23/08/2015 BMK

SECTION

MODULE NO. CKR-PR-P-001 RELIANCE INDUSTRIES LIMITED

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 4.0 4.1 4.2 4.3 5 5.1 5.2 5.3 5.4 5.5 5.6 6 7 7.1 7.2 8.0

CW System Steam System Condensate and Boiler feed water system Fuel gas system Nitrogen, plant air, instrument air system Service Water system DM Water system Fire water system Electrical Power systems Plant Effluents and disposal Methods Liquid effluents Solid effluents Gaseous effluents Emergencies Power failure (ISBL ONLY) Steam failure IA failure CW failure QW failure QO failure Equipment List Relief and blowdown system Flare system at OSBL Fire and Gas Detection System

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

4 0 0 23/08/2015 BMK

SECTION

MODULE NO. CKR-PR-P-001

1

RELIANCE INDUSTRIES LIMITED

1.1 INTRODUCTION The NGL / Naphtha Cracker plant is designed to product 5,00,000 metric tonnes per annum of polymer grade ethylene from cracking Naphtha and NGL. Subsequently, the plant was engineered to increase the capacity from 5,00,000 MTA to 7,00,000 MTA. It is designed to crack Naphtha, NGL, AGO and C2/C3 recycle and fresh streams. However, the 7,00,000 MTA capacity of ethylene is produced by cracking of low aromatics naphtha only. Also, the recycle streams like C2,C3,C5, C6-C8 raffinate from aromatics plant and hydrogenated mix C4 are cocracked with Naphtha in the furnaces. The minimum propylene production capacity is 3,20,000 MTA for an optimum cracking severity of 3.11 KSFA for the designed on stream time of 8000 hours per year. The

plant

is

able

to

produce

HP

ethylene

vapour

at

58kg/cm2g ,LP vapour ethylene at 27 kg/cm2g. and ethylene as liquid at -980C for storage in atmospheric tank. The plant also includes two IFP units C4 hydrogenation unit for processing mixed C4 and GHU unit for the treatment of gasoline generated during cracking. For the production of high purity hydrogen, one PSA unit is installed supplied by UOP, USA.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

5 0 0 23/08/2015 BMK

SECTION

MODULE NO. CKR-PR-P-001

1

RELIANCE INDUSTRIES LIMITED

1.2 FEED STOCKS The cracker plant is designed on the basis of single light naphtha feed stock as defined below : SG

: 0.7

Distribution Curve

: 0C

1BP

: 45

10%

: 68

50%

: 100

90%

: 130

FBP

: 150

PONA :

WT

Paraffins

74% Min.

Naphthalenes

Balance

Aromatic

10%

Olefins Vol.

Max. 1.0%

Hydrogen, WT%

15.2

Sulphur PPM wt/wt

800 max.

RVP kg/cm2a

0.94 max.

However,

plant

is

capable

in

using

other

feed

stacks

NGL/AGO,C2/C3, recycle hydrogenated C4 mix, C5 from GHU and C6-C8 raffinates from aromatics.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

6 0 0 23/08/2015 BMK

SECTION

1

MODULE NO. CKR-PR-P-001 RELIANCE INDUSTRIES LIMITED

DESIGN SPECIFICATION OF NGL FEEDSTOCK: Particulars Specific Gravity ASTM distillation: IBP 50% FBP PONA analysis: Paraffins Naphthenes Aromatic Olefins Sulphur Reid Vapour pressure Lead Chloride Colour

Unit

Design

-

0.73

C C C

45 95 150

vol. % vol. % vol. vol. ppm wt/wt kg/cm2a

59 26 15 nil 800 0.5

ppm wt/wt ppm wt/wt Saybolt

0.075 2

Note : The i-Paraffins may be present up to 50% by wt. of total Paraffins

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

7 0 0 23/08/2015 BMK

SECTION

1

MODULE NO. CKR-PR-P-001 RELIANCE INDUSTRIES LIMITED

DESIGN SPECIFICATION OF C2/C3 FEEDSTOCK: Components Colour Methane Ethane Propane Butanes

Units % % % %

mol mol mol mol

Design 0.7 75.54 21.96 1.5

DESIGN SPECIFICATION OF C3/C4 FEEDSTOCK: Components Ethane Propane n-Butane i-Butane Pentane

Units % mol % mol % mol % mol % mol

Design 0.98% 49.02% 34.31% 14.71% 0.98%

1.3 Other Products: While main products form cracker plant are ethylene and propylene, there are a number of lesser products. These are listed below : Methane: The plant is able to produce 500 kg/hr of methane vapour at 27 kg/cm2g and ambient temperature. It is intended to be used as ballast gas MEG plants Hydrogen: The high purity hydrogen produced form PSA unit is intended for captive use for Acetylene, MAPD , C4 mix and gasoline CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

8 0 0 23/08/2015 BMK

SECTION

1

MODULE NO. CKR-PR-P-001 RELIANCE INDUSTRIES LIMITED

hydrogenations. The excess hydrogen is exported to OSBL for use in aromatics, PTA & PE Plants. Fuel Oil: The fuel oil component product during liquid feed stocks are rich in carbon index. This can be used as feestock for carbon block manufacture.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

9 0 0 23/08/2015 BMK

SECTION

1

MODULE NO. CKR-PR-P-001 RELIANCE INDUSTRIES LIMITED

Ethane & Propane: The ethane and propane produced form ethylene and propylene fractionation system is cracked in recycle furnaces or along with Naphtha in four main furnaces. Excess of ethane and propane after vaporisation can be dumped in to fuel gas. Also provision for export of ethane /propane mix is also provided. However, liquid propane from propylene fractionation system is preferentially exported to OSBL for storage to act as back up fuel during emergency (or) during start-up of the plant. C5 Mix.: C5 Mixture reported from gasoline in depentaniser unit after hydrogenation of diolefins impurities is recycled to furnace for cracking along with Naphtha. C6-C8 Cut : C6-C8 after treatment in gasoline hydrogenation unit for the improvement of stability, octane no. Bromine number and sulphur is

fed as feedstock for aromatics plant for the

separation of benzene, toluene and xylene. Fuel Gas :

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

10 0 0 23/08/2015 BMK

SECTION

MODULE NO. CKR-PR-P-001

1

RELIANCE INDUSTRIES LIMITED

Fuel Gas which is a mix of primarily methane and hydrogen is fed to furnaces for providing heat for cracking. The excess of the requirement is sent to OSBL for use in fuel in gas turbines, dowtherm heaters, VCM furnaces etc. Hydrogenated C4 Mix : Butadiene rich C4 mix from liquid cracking is hydrogenated in main and aux. C4 hydrogenation units to remove butadiene to extinction is sent to OSBL to the sold as industrial LPG (or) excess of the maker is cracked in main furnaces along with Naphtha. 1.4 Chemicals, Catalysts and additives: 1.4.1

Chemicals:

Many chemicals are used at different parts of the plant for the smooth and efficient of the plant. They are listed as below : 1)

2)

3) 4) 5)

Ammonia i) Deaerator (V900) ii) QW Tower O/H (C-220) Caustic (20%) i) Dilution steam stripper (not used) ii) Condensate polishing unit for regeneration iii) Caustic tower HCL (20%) i) Condensate polishing unit for regeneration ii) SCO effluent neutralisation DMDS i) USC main furnaces with Naphtha ii) USC recycle furnaces with Dilution steam Hydrazine i) Deaerator

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

11 0 0 23/08/2015 BMK

SECTION

CKR-PR-P-001

1 6)

MODULE NO. RELIANCE INDUSTRIES LIMITED

Trisodium Phosphate i) Main & Recycle furnace steam drums Methanol i) As required in cold sections Corrosion inhibitor DP 1800 i) Process water stripper - C260 Antifoulant DORF 94362 I) Depropaniser C-510 Emulsion Breaker DORF EB 4024 i) C-220 quench water tower Neutralising Amine DP 197 i) C-220 Quench water tower Antioxidant DORF 410 i) Raw pyrolysis gasoline feed ii) C5 product iii) C9 product iv) Raw C6-C8 cut Corrosion Inhibitor DORF 2002 CI i) GHU Stripper Antipolymerant (Trial on) i) Caustic tower

7) 8) 9) 10) 11) 12)

13) 14)

1.4.2

Catalysts and Desiccants:

Unit Cracked Gas Dehydrator

Item No. V 370 A/B

2

Secondary dehydrator

V 453 A/B

3

C2 Acetylene hydrogenation C3 MAPD Hydrogenation C4 Main and auxiliary hydrogenation FIRST stage C4 Main & Auxiliary

R-451 A/B/C R452 A/B R-531 A/B/C

1

4 5

6

CHECKED BY N.S.P APPROVED BY B. DAS

R-801, R-803

R-802, R-804

Type Molecular sieve EPG 118” and Alumina Balls Molecular sieve EPG 1/8 “ and Alumina Balls G 58 E Catalysts and Alumina Balls LD 273 catalyst and Alumina Balls LD 265 & Alumina Balls

Source UOP

LD 271 & Alumina Balls

Procatalyse

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

UOP SUD CHEMIE UCIL Procatalyse Procatalyse

12 0 0 23/08/2015 BMK

SECTION

1

7 8

hydrogenation II stage Gasoline hydrogenation I stage Gasoline hydrogenation II stage

MODULE NO. CKR-PR-P-001 RELIANCE INDUSTRIES LIMITED

R-710 A/B

LD 265 & Alumina Balls

Procatalyse

R-740

LD 145 for upper bed and ALUMINA balls 1+R 306C and alumina balls for lower bed

Procatalyse

1.5 Product specifications: SPECIFICATION OF POLYMER GRADE ETHYLENE PRODUCT: Components Ethylene Methane + Ethane C3 and Heavier Other Olefins Acetylene Propadiene Hydrogen CO CO2 Oxygen Nitrogen NO Ammonia Carbon Oxysulphide Sulphur Water Methanol Chlorides Acetone Methylacetylene Arsine Carbonyl

CHECKED BY N.S.P APPROVED BY B. DAS

Units % mol ppm mol/mol ppm mol/mol ppm mol/mol ppm mol/mol ppm mol/mol ppm mol/mol ppm mol/mol ppm mol/mol ppm mol/mol ppm mol/mol ppm mol/mol ppm mol/mol ppm mol/mol ppm wt/wt ppm wt/wt ppm mol/mol ppm mol/mol ppm mol/mol ppm mol/mol ppm wt/wt ppm mol/mol

99.95 500 10 10 5 5 10 0.2 5 5 50 5 5 0.02 1 1 5 2 2 5 0.03 5

Process description and Utilities

Guaranteed Values min max max max max max max max max max max max max max max max max max max max max max

PAGE REV ISSUE DATE AUTHOR

Expected 40 max

13 0 0 23/08/2015 BMK

SECTION

1

MODULE NO. CKR-PR-P-001 RELIANCE INDUSTRIES LIMITED

SPECIFICATION OF POLYMER GRADE PROPYLENE PRODUCT: Components Propylene Ethane Ethylene Propane C4 and Heavier Acetylene Butenes Butadiene Methyl acetylene plus Propadiene Hydrogen CO CO2 Oxygen Ammonia Carbon Oxysulphide Other Non condensibles Sulphur Water Methanol Green Oil Arsine Phosphine Isopropanol

CHECKED BY N.S.P APPROVED BY B. DAS

Units % mol ppm mol/mol ppm mol/mol ppm mol/mol ppm mol/mol ppm mol/mol ppm mol/mol ppm mol/mol ppm mol/mol ppm mol/mol ppm mol/mol ppm mol/mol ppm mol/mol ppm wt/wt ppm mol/mol ppm mol/mol ppm wt/wt ppm wt/wt ppm mol/mol ppm mol/mol ppm wt/wt ppm wt/wt ppm mol/mol

Process description and Utilities

99.8 30 10 Balance 2 1 2 2

Guaranteed Values min max max max (as C4s) max max max

10 20 0.05 5 2 5 0.02 300 1 2 5

max max max max max max max max max max max

0.03 0.03 35

max max max

PAGE REV ISSUE DATE AUTHOR

14 0 0 23/08/2015 BMK

SECTION

1

MODULE NO. CKR-PR-P-001 RELIANCE INDUSTRIES LIMITED

SPECIFICATION OF HYDROGEN PRODUCT:

Components Hydrogen CO CO2 Ammonia Mercury Oxygen Total Sulphur Water CH4s, C2H6s H2 Argon Acetylene

Units % mol ppm mol/mol ppm mol/mol ppm mol/mol mg/m3 ppm mol/mol ppm wt/wt mg/m3

Guaranteed Values 99.9 min 5 max 5 max 1 max 1 max 5 max 0.5 max 5 max Balance

ppm mol/mol

10

max

SPECIFICATION OF METHANE PRODUCT: Components Methane Ethylene Hydrogen Carbon Monoxide Acetylene

Units % mol % mol % mol % mol ppm

Guaranteed Values 95.0 min 1.0 max 3.0 max 1.0 max 50 (1) max

mol/mol

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

15 0 0 23/08/2015 BMK

SECTION

MODULE NO. CKR-PR-P-001

1

RELIANCE INDUSTRIES LIMITED

SPECIFICATION OF C4 STREAMS: A.

Mixed C4 Stream (before hydrogenation): Expected Value

B.

C3s and Ligher

0.15% wt max

C9s

0.4% wt max

1, 3-Butadiene

52% wt min and 56% wt max

Hydrogenated C4 Stream Butadiene

10 ppm wt max

Dimer (C8) content:

500 ppm max

Trimer (Green Oil) content: none SPECIFICATION

OF

C5

PRODUCT

(PARTIALLY

HYDROGENATED): Components Distillate Residue C9s and lighter C6s Benzene Diene value Copper Strip Corrosion Existing Gum

Units % wt % mol % mol % mol mg/100ml

Values 1.5 Balance 1.2% max 0.3% max 2 max 1B after 4 max

heptane wash SPECIFICATION OF HYDROGENATED C6/C8 CUT: Components

C9s C9s-2000C C6-C8 Total Sulphur CHECKED BY N.S.P APPROVED BY B. DAS

% mol % mol

Units

ppm wt Process description and Utilities

Values Balance 1.0 max PAGE REV ISSUE DATE AUTHOR

16 0 0 23/08/2015 BMK

SECTION

1

MODULE NO. CKR-PR-P-001 RELIANCE INDUSTRIES LIMITED

Bromine number Thiophene ‘S’ Copper Strip Corrosion Diene Valve Existing Gum

gr/100 gr ppm wt mg/100 ml after

0.1 0.5 max IA Nil

Distillate Residue

heptane wash %

1.5 max (ASTM D-

Oxidation Stability

Minutes

62) 960 min with 5 ppm antioxidant

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

17 0 0 23/08/2015 BMK

SECTION

1

MODULE NO. CKR-PR-P-001 RELIANCE INDUSTRIES LIMITED

SPECIFICATION OF PYROLYSIS FUEL OIL: PARTICULARS Asphaltene Ramsbottom Carbon Ash Sulfur Sodium BMCI Flash Pt Pour Pt

UNITS % wt % wt % wt % wt ppm wt deg C deg C

LFO <0.2 <0.5

HFO 30-50 20-50

PFO 15-20 10-15(1)

<0.05 <0.09 <10 125 90-100 <0.0

<0.05 <0.09 <10 >125 >100 >50.0

<0.05 <0.09 <10(2) >125 >100 >15.0

NOTES : 1. Typical values are quoted 2. Based on no sodium being present in the plant feeds.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

18 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

PROCESS DESCRIPTION

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

19 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

2.00 PROCESS DESCRIPTION: This section contains a description of the process flow during normal operation with the RIL “Expansion Case” FEEDSTOCK. The description should be read in conjunction with process flow diagrams 0320015-75D-01 to 10. 2.01 CRACKING FURNACES A total of 15 cracking furnaces are provided to achieve the required annual ethylene and propylene production. Twelve of these furnaces, H-110 t0 H-190 and H-192, 194 and 196, described as USC (ultra selective conversion) furnaces are utilised to crack liquid naphtha fresh feed and H-110 to H-190 for Naphtha and AGO both and the liquid recycle streams generated within the plant or from the aromatics unit i.e. hydrogenated C4s, hydrogenated C5s and C6-C8 raffinate. The remaining three furnaces, H-111, H-121 and H-131 described as USC recycle furnaces are installed to crack gaseous ethane and propane feedstocks which are recovered and recycled from the recovery section. Four of the USC furnaces H-110, 120,130 and 140, can be utilised for ethane / propane co-cracking with naphtha while one of the USC recycle furnaces is being decocked.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

20 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

The naphtha feedstock is stored in OSBL, tanks and pumped to the battery limit at 10.5 kg/cm2g. Hydrogenated C5’s and C6C8 raffinate for recycle cracking can also be supplied from OSBL storage as C5-C87 max naphtha fresh feed line. The total flow of C5-C8’s blended into the Naphtha is regulated. The naphtha liquid blend is preheated by exchange with circulating quench water in the Naphtha feed Heater, E-041. Hydrogenated C4’s for recycle cracking can be obtained from storage or directly from the hydrogenation units. A separate hydrogenated C4’s header is provided and the flow to each fresh feed furnace can be independently controlled. The hydrogenated C4’s are blended with the Naphtha upstream of the furnace convection section. The combined Naphtha liquid blend is fed through the USC furnace convection section and partly vaporised. Dilution steam is added downstream to the hydrocarbon feed stream to complete vaporisation. A weight ratio of 0.5 steam to hydrocarbon is utilised. The liquid hydrocarbon feed is divided equally into six streams before being fed to the USC furnace convection section. the hydrocarbon fed is preheated by the furnace flue gas in the fifth from bottom bank of the six-bank convection section. Slightly superheated dilution steam form the Dilution Steam Stripper, C-270, overhead and from the auxiliary dilution steam stripper, C-80 overhead is split into six streams and fed to the

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

21 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

dilution steam superheating coils located in the second from bottom bank of convection section. Three streams from each of the hydrocarbon and dilution steam coils are combined into one and mixed in a sparger to complete the vaporisation of hydrocarbon. There are two spargers per furnace. One outlet is taken from each sparger and split into three streams. The six streams of hydrocarbon and dilution steam mixture are further heated in the fourth and then first bank of the convection section. Three streams of

heated

hydrocarbon and dilution steam mixture at the outlet of the first bank are combined into one mixing fitting. There are tow mixing fittings per furnace. Four outlets are taken from each mixing fitting, and each outlet is split into eight radiant coils. Each radiant coil is fitted with a critical flow venturi nozzle. The boiler feed water from the Deaerator is preheated in the sixth (top) bank of the USC Furnace convection section and fed to the steam drums, V-110 to 190, 192, 194 and 196. The saturated steam generated in USX and TLX exchangers is superheated in the third bank of the convection section. The recycle ethane feed to the USC Recycle Furnaces is vaporised by heat exchange against demethanizer feed, in E461, and heated against propylene refrigerant, in E-411, while recycle propane feed is vaporised against circulating quench water in E-542. The ethane and propane is mixed and further CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

22 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

heated against circulating quench water, in E-011, before being fed to the USC recycle furnaces. Dilution steam is added in a weight ratio of 0.3 steam/hydrocarbon. The ethane and propane mixed feed is split into four streams before being fed to the USC Recycle Furnace Convection section. The mixed hydrocarbon feed is preheated by the furnace flue gas in the fourth (top) bank of the four-bank convection section. Slightly superheated steam from the dilution steam generator is injected into each hydrocarbon stream at the outlet of the fourth bank. The four mixed streams are further heated in the first (hottest) bank of the convection section. Two streams of the heated hydrocarbon and dilution steam mixture are combined at the outlet of the first bank into one mixing fitting. There are two mixing fittings per recycle furnace. Two outlets are taken from each mixing fitting, and each feeds a separate radiant coil. Each radiant coil is fitted with a critical flow venturi Nozzle. The boiler feedwater form the deaerator is preheated in the third bank of the USC Recycle Furnace convection section and fed to the steam Drums, V-111,121 and 131. The saturated steam generated in USX exchangers is superheated in the second bank of the convection section.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

23 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

Both types of furnaces are vertical radiant tube type; the USC Furnace employs 64 “U” coils with inlet and outlet at the top of the radiant box. The USC recycle furnace employs four “M” type radiant coils with inlet and outlet also at the top of the radiant box. The USC Furnaces each have 32 floor fired burners. The burners are designed for gas firing only. The USC Recycle Furnaces have both wall and floor burners. Both floor and wall burners are gas fired. There are 16 floor fired burners and 32 wall burners per furnace. The feedstocks are thermally cracked in the furnaces where dilution steam to feed ratios and furnace effluent temperature are carefully controlled to achieve the desired olefin distribution and yield. The furnace effluents are cooled rapidly by heat exchange against boiler feed water in steam generating USX exchangers, E-110 to 190, 192,194 and 196 A-H & J-Q, and E115/125/135 A-D, and TLX Exchangers, E-111 to 191, 193,195 and 197. Rapid quenching of the furnace effluent is necessary to prevent degradation of olefins into undesirable components. The high pressure steam generated in USX and TLX exchangers is superheated in the convection section before being used, mainly for compressor turbine drivers.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

24 0 0 23/08/2015 BMK

SECTION

MODULE NO.

2

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

2.02 USC Fresh feed and Recycle Furnace Quench Fittings The Quench Fittings, Z-110 to 190 and Z-192, 194 and 196, on the USC fresh feed furnaces and Z-111/121 on the USC Recycle Furnaces are provided to reduce the temperature of the furnace effluent before entering the quench oil tower, C-210 and Heavy Fuel Oil Stripper, C-230, respectively. H-131 effluent enters C210 board on material balm to requirement . The temperature reduction, or quenching, is achieved by contacting individual furnace effluent streams with quench oil in specially designed fittings. 2.03 Quench Oil Tower The

Quench

Oil

Tower,

C-210

condenses

the

fuel

oil

components and recovers higher level heat by cooling furnace effluent

from

the

discharge

of

the

quench

fittings

to

approximately 1030C. It is divided into the following three sections, each of which has a specific operating purpose  Quench Oil Circulating Section  Pan Oil Circulating Section  Rectifying Section

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

25 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

2.03.1 Quench Oil Circulating (Scrubbing Section) The effluents from the USC Furnace and USC Recycle Furnace Quench Fittings flow to the Quench Oil Tower. The effluent from all of the USC Quench Fittings and the new USC Recycle Furnace Quench Fitting, Z-131 are routed via the top section of the Heavy Fuel Oil Stripper C-230. The vapour and liquid portions of the effluent stream are separated in the bottom of the Quench Oil Tower and Heavy Fuel Oil Stripper. The combined vapours rise through the bottom section of the QO tower contains four trays and a distributor. The Quench oil distributor is positioned below the chimneys of the pan oil collection pan. The Quench Oil Circulating Pumps, P-210 A/B/C, discharge through the Quench Oil Filters, Z-210 A/B/C which remove any coke particles, before heat is recovered from the oil. A slip stream of hot quench oil is fed to the three USC recycle furnace Quench fittings to better control the outlet temperature from the three Quench fittings. Heat is recovered from the quench oil in the Dilution Steam Generator / Quench Oil Reboilers, E-271 A/H. The cooled quench oil then flows to the all of the USC Furnace Quench Fittings and the scrubbing section of the Quench oil tower.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

26 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

2.03.2 Pan Oil Circulation Section The pan oil (PO) circulating section of the Quench Oil Tower condenses a portion fuel oil together with any vaporised quench oil and also cools the cracked gas. The circulating section contains ten trays, the pan oil collector pan, and the pan oil distributor. Vapour, cracked gas, and steam enter the bottom of this section through the chimneys in the pan oil collector pan. The pan oil from the collector pan flows to the Pan Oil Circulating Pump, P-211 A/B from where it is pumped and circulated to obtain heat recovery. A portion of the uncooled pan oil is sent to the distributor spray in the Quench Oil Tower scrubbing section. Another uncooled portion of the pan oil is fed to the light fuel oil stripper, C-240 on flow control and the balance is cooled in the pan oil user exchangers. The cooled pan oil is reintroduced into the Quench Oil Tower pan oil circulating section via the pan oil distributor. 2.03.3 Rectifying Section Light Fuel Oil components contained in the vapours entering the rectifying section are condensed in this section to prevent their transfer to the QW tower and thereby maintain the end point of the raw PYROLYSIS gasoline. The required fractionation in this particular section is accomplished by using gasoline CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

27 0 0 23/08/2015 BMK

SECTION

MODULE NO.

2

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

reflux from the base of the Quench Water Tower, C-220 on a flow control. The light fuel oil components are collected on the draw - off tray and flow controlled to the light fuel oil stripper, C-240. Overhead vapour from the stripper returns to the rectifying

section.

The

Quench

Oil

Tower

overhead,

at

approximately 1030C, is sent to the Quench Water Tower, C220. 2.04 Heavy Fuel Oil Stripper The Heavy Fuel Oil Stripper, C-230 strips the light ends from the heavy Fuel Oil and returns to the Quench Oil Tower. The stripping effect is achieved by contacting quench oil with the USC recycle furnaces vapour effluent in the Quench Fittings, Z-111 and Z-121, and passing the combined mixture into the Heavy Fuel Oil Stripper, C-230, where separation into vapour and liquid is achieved. The separation of light and heavy ends in the Heavy Fuel Oil Stripper results in a return of light ends into the Quench Oil Tower and build-up of a large middle boiling range quench oil inventory as required for circulation and optimum heat recovery. The heavy fraction separated out in the Heavy Fuel Oil Stripper bottom contains all the asphaltenes and tar which are formed in the cracking operation.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

28 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

The heavy fuel oil stripper bottoms liquid is pumped by Heavy Fuel Oil Product Pumps, P-230 A/B to product blending, cooling and delivery to plant battery limits.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

29 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

2.05 Light Fuel Oil Stripper The Light Fuel Oil Stripper, C-240 regulates the quench oil quality and optimises the heat recovery in the Quench Oil Tower. The light Fuel Oil Stripper is fed from two sources. The main source is the draw off tray in the quench oil tower rectification section, the second source is the recycle stream form the pan oil circuit. Stripping of the light components is effected by dilution steam injection, which enters below the bottom tray. The stripped vapour returns to the rectification section of the Quench Oil Tower. The light fuel oil product passes from the bottoms to the Light Fuel Oil Product Pumps, P-240 A/B, which discharge it to the fuel oil blending, cooling and delivery system. 2.06 Quench Water Tower The cracked gas from the rectification section of the Quench Oil Tower passes into the Quench Water Tower, C-220. In this tower, the gas is further cooled to 40.60C, by direct contact with circulating quench water. Effective contact and cooling of the gas with quench water are attained by returning the circulating quench water through distributors in the tower middle and top sections. For this service, two packed beds are provided for contacting the gas and quench water. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

30 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

The flow and distribution of quench water into the middle and top sections is regulated by flow controllers reset by the temperature of middle section overhead and top section overhead, respectively, to attain cooling of the cracked gas and to provide a hot quench water supply for process reboiling and heating. In this tower, dilution steam and the gasoline fraction of the cracked gas are condensed. The condensed hydrocarbon and water are separated in the bottom section, which contains a series of chevron-type plate baffles for the settling out of the water and hydrocarbon phases. Part of the separated gasoline is used as reflux to the Quench Oil Tower and the balance feeds the distillate Stripper, C-250. Most of the hot water from the base of this tower is circulated through various process heaters and reboilers before returning to the quench water tower, while the balance is fed to the dilution steam generation system. 2.07 Dilution Steam Generation System Most of the dilution steam contained in the furnace effluent is condensed in the Quench Water Tower. The reuse of steam condensate collected form both the condensation of dilution steam in the Quench Water Tower and in the cracked gas CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

31 0 0 23/08/2015 BMK

SECTION

2 compression

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

system

minimises

the

demineralized

water

makeup requirements and reduces the load on the waste water effluent treatment system. Water is circulated by the Quench Water Circulating Pumps, P220 A/B/C, to the dilution steam generation system. The water is first delivered to the water stripper feed filter, Z-261 A/b, which removes trace solids such s pipe scale and coke that impair the effectiveness of the downstream coalescer. The filtered water enters the water stripper feed coalescer, V262 A/B, where free hydrocarbon droplets are separated from the water. These hydrocarbons are returned to the Quench Water Tower from the top of the coalescer. The water from the coalescer is heated by exchange against dilution steam blowdown in the Dilution Steam Stripper blowdown cooler / stripper feed heater, E-259. The water then passes through the water stripper feed heater, E-258, where it is heated against pan oil. It then enters the water stripper C260, where it is stripped of dissolved hydrocarbons, acid gases, and ammonia. Stripping steam is provided from the Dilution steam Stripper overhead. The overhead vapours flow to the quench water tower. The dilution steam stripper feed pumps, P-260 A/B, deliver the water stripper bottoms to the two dilution steam strippers. The CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

32 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

main portion of the process water is routed to the DSS tower, C270, and en-route is heated by exchange against 3.5 kg/cm2g level steam in E-269. The water then passes through the Dilution Steam Stripper Feed Heater No.1, E-268, where it is heated against pan oil. The preheated condensate enters the Dilution Steam Stripper, C-270, above the top tray. The DSS tower, C-270 bottoms are reboiled against quench oil in the Dilution Steam Stripper / Quench Oil Reboiler, E-271 A/H, and against 12 kg/cm2g level steam in Dilution Steam Stripper / Steam Reboiler, E-270 A/D. The remaining portion of the process water stream is routed to the auxiliary DSS tower, C-280 and en-route is preheated against steam condenste in the auxiliary dilution steam stripper feed heater, E-279. The preheated process water enters the auxiliary Dilution steam stripper C-280 above the top tray. C280, bottoms are reboiled against 12 kg/cm2g steam in the auxiliary dilution steam stripper reboiler, E-280 A/C. Most of the generated dilution steam flows to the cracking furnaces, where it is used for dilution of hydrocarbon feed, decoking of furnace

tubes, or operating a furnace on hot

standby without hydrocarbon feed. A small portion is used for stripping in the light fuel oil stripper and LP Water Stripper. Approximately 5 percent of the steam produced is returned to the Water Stripper for use as stripping steam. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

33 0 0 23/08/2015 BMK

SECTION

MODULE NO.

2

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

LMP steam injection into the dilution steam header maintains sufficient superheat to avoid condensation in the piping to the furnaces. LMP steam can also be used directly to supplement the dilution steam to the furnaces. The blowdown, the net bottoms

stream from C-270, is cooled first in the Dilution

Steam Generator Blowdown / Water Stripper Feed Heater, then against

cooling

water

in

the

Dilution

Steam

Generator

Blowdown Cooler, E-273, before being discharged to the oily water sewer. The blowdown from C-280 is cooled against cooling water before being discharged to the oily water sewer. 2.08 Distillate Stripper The

Distillate

Stripper,

C-250,

debutanizes

the

gasoline

collected in the bottom section of the Quench Water Tower and first three stages of cracked gas compression, before it is fed to the gasoline hydrotreating unit. Gasoline from the Quench Water Tower is fed to the stripper by a slip stream from the quench oil tower reflux pump, P-211 A/B while the feed from the cracked gas second stage suction drum is pumped by distillate stripper feed pump, P-230 A/B. C4’s and light ends from the Distillate stripper are returned to the cracked gas compressor via the Quench Water Tower.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

34 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

The Distillate Stripper is reboiled by pan oil in the Distillate Stripper Reboiler, E-250. The gasoline product from the bottom is pumped via the Distillate Stripper Bottoms Pump, P-250 A/B. Most of the gasoline from this pump goes to the GHU. A portion is recycled back to the Quench Oil Tower to provide additional reflux inventory. The stream is sent to the Quench Oil Tower Pan Oil section (rather than to the top of the tower) to ensure that any heavy components are fractionated out. 2.09 Quench Water and Pan Oil circuits Quench water is circulated to the following users from the Quench Water tower, C-220, via the quench water circulation pumps, P-220 A/C, at a temperature of approx. 820C : Exchanger No. :

Description

E-011

Ethane / Propane recycle heater

E-041

Naphtha feed heater

E-051 A/B

AGO feed heater no.1

E-210

Fuel oil cooler

E-215

Quench water steam heater

E-340

Weak caustic heater

E-359

Condensate stripper feed heater

E-360 A/B

Condensate stripper reboiler

E-410

Demethanizer prestripper reboiler

E-439

Demetahnizer prestripper bottoms heater

E-440 A/C CHECKED BY N.S.P APPROVED BY B. DAS

Deethanizer Reboiler Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

35 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

E-530

Secondary deethanizer reboiler

E-535

Tertiary deethaniser reboiler

E-540 A/D

Propylene tower auxiliary reboiler

E-542

Propane recycle vaporiser

E-731

Wash oil condenser

Two of the exchangers, E-731 and E-210, provide an additional heat input to the quench water and a third exchanger, E-215, utilises steam to adjust the quench water temperature. The remaining users accept the waster heat from the quench water system. After interchanging heat with the QW users, all of the quench water is cooled in the primary quench water cooler, E-220 A/g, down to a temperature of 54.40C. The bulk of this water is fed to the lower packed section of the QW tower. The remainder is further cooled in the secondary quench water cooler, E-230 A/H, down to a temperature of 37.80C before being fed to the upper packed section of the QW tower. Pan oil is circulated to the following users from the quench oil tower via pan oil circulation pumps, P-211 a/B :Exchanger No. Description E-268

Dilution Steam Stripper Feed Heater No.1

E-258

Water Stripper feed Heater

E-250

Distillate Stripper Reboiler

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

36 0 0 23/08/2015 BMK

SECTION

MODULE NO.

2

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

E-510

Depropanizer Reboiler

The final Pan Oil temperature of 1210C is controlled by diverting pan oil flow to the pan oil trim cooler, E-219, before the pan oil is recirculated back to the middle section of the quench oil tower. 2.10 Compression/Acid Gas Removal/Dehydration The water saturated hydrocarbon overhead form the quench water tower is fed to the cracked gas (C G) first stage suction drum, V-310. The C.G. first stage condensate Pump, P-310 A/B, discharges the liquid transferred from drum V-320 and any slugs of liquid carryover in the cracked gas back to the quench water tower. The vapour from this drum flows to the first stage of the cracked gas compressor, B-300. Wash oil is injected into the suction line of each compression stage by the wash oil Injection Pump, P-300 A/B. Wash oil is injected to keep the impeller blade tip wet, thus preventing polymer accumulation. The first three stages of compression are each followed by an aftercooler and a discharge drum used to separate water / hydrocarbon condensate from vapour. Heat is rejected to cooling water in each aftercooler. The first stage aftercooler,

E-310,

effluent

is

combined

with

gasoline

hydrogenation unit vents in the 2nd stage suction drum, V-320 before entering the 2nd stage of compression. The condensate

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

37 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

stripper overhead joins the second stage aftercooler, E-320, into the 3rd stage suction drum, V-330. The liquid form the C.G. Third stage Discharge Drum, V-335, is successively cascaded to the CG. Third stage suction drum and then to C.G. second stage suction drum, which is designed to separate the hydrocarbon condensate from the water. The hydrocarbon condensate from the CG second stage suction drum is sent to the Distillate stripper, while the water is routed to the CG 1st stage suction drum. The oily water is pumped via P-310 A/B to the quench Water Tower, C-220. To prevent C.G. compressor surging, two minimum flow bypasses are provided. The first bypass protects the first three stages of compression, and the second bypass protects the fourth stage. The first minimum flow bypass is provided form the third stage discharge drum to the first stage suction drum. The recycle automatically protects the compressor by keeping the flow above surge point during reduced capacity operation. The third stage discharge gas is passed through a caustic wash followed by a water wash in the caustic tower, C-340. The acid free tower effluent is combined with the vents from the ethylene rectifier and secondary demethaniser reflux drums and fed to the C G Fourth Stage Drum, V-340. The drum CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

38 0 0 23/08/2015 BMK

SECTION

MODULE NO.

2

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

overhead feeds the Fourth Compression Stage. The discharge effluent is cooled in the C G Fourth Stage Aftercooler, E-345, by cooling water and passed to the Cracked Gas Rectifier, C-350, which fractionates the heavy ends and reduces the gas flow to the demethaniser system. Reflux for the rectifier is provided by hydrocarbon

condensed

in

the

C

G

Rectifier

Overhead

Condenser, E-355, using propylene refrigerant. The C G Rectifier Reflux Drum, V-346, is designed to separate the hydrocarbon condensate from water. The water from the C G Fourth Stage Suction Drum and C G Rectifier Reflux Drum is sent to the Third Stage Suction Drum. Bottoms from the C G Rectifier are discharged to the Fourth Stage Suction Drum. The Fourth Stage Suction Drum condensate is routed to the Condensate Stripper Feed Coalescer, V-359, for the removal of free water. The water is collected in a boot and sent to the Third Stage Suction Drum. The hydrocarbon stream is heated against quench water in the Condensate Stripper Feed Heater, E-359, to prevent hydrate formation and then fed to the Condensate Stripper, C-360. In the Stripper, c2s and lighter are recovered overhead and sent to the C. G . Third Stage Suction Drum. The Condensate Stripper Bottoms Pump, P-360 A/B, delivers the remaining hydrocarbons to the Depropanizer, C-510. Stripping vapour is produced by quench water in the Condensate Stripper Reboiler, E-360 A/B. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

39 0 0 23/08/2015 BMK

SECTION

MODULE NO.

2

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

The second minimum flow bypass line, taken from the C.G. Rectifier overhead, is recycled to the C.G. Fourth Stage Suction Drum. A small stream taken from upstream of the C.G. Fourth Stage Aftercooler is used to heat this gas to avoid hydrate formation across the kick-back minimum flow control valve. In addition, a bypass stream to the third stage discharge is provided to ensure adequate vapour loading on the Ripple trays of the Caustic Tower during reduced capacity operation. 2.10.1

Acid Gas Removal

The caustic wash operation is installed to remove hydrogen sulphide and carbon dioxide from the cracked gas in order to meet product quality requirements on the ethylene and propylene products. Also, the removal of these acid gases protects downstream catalytic operations, since some acid gas components are known to be catalyst poisons. Acid gases are also removed to avoid corrosion and the possible formation of CO2 ice within the cold process systems. These acid gases, which are produced in the cracking furnaces, are removed by scrubbing the gas from the C. G. third Stage Discharge Drum with circulating caustic solutions in the Caustic Tower, C-340. The tower is divided into four sections. The three bottom sections provide for caustic scrubbing of the cracked gas. The bottom section uses weak caustic, the middle uses CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

40 0 0 23/08/2015 BMK

SECTION

MODULE NO.

2

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

medium caustic, and the top circulates strong caustic. The fourth section, at the top of the tower, is the water wash section, which prevents caustic carryover into the cracked gas Fourth Stage Suction Drum. The acidic cracked gas enters the caustic tower below the bottom section where it is contacted with weak caustic solution. The weak caustic is circulated by the weak caustic circulating pump, P-342 A/B, then heated against quench water in the weak caustic Heater, E-340, prior to making contact with the acidic cracked gas. This ensures that the cracked gas does not fall below its dew point, which would cause hydrocarbon condensation. The cracked gas flows upward, contacting the medium caustic, and then the strong caustic solution. These streams are recirculated A/B,

and

by the Medium Caustic Circulating Pump, P-343 strong

caustic

circulating

Pump,

P-344

A/B,

respectively. Spent caustic solution is contained in the caustic tower bottoms section, where by any hydrocarbon condensate / polymer oils are separated out via an overflow weir into a separate hold-up compartment. The spent caustic is mixed with aromatic gasoline from the discharge line of the Recirculating Gasoline Pump, _347 A/B, via the spent caustic /aromatic gasoline mixer, Z-343 and is then fed to the spent caustic deoiling drum, V-342. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

41 0 0 23/08/2015 BMK

SECTION

MODULE NO.

2

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

Separation of entrained oil from the spent caustic, and some hydrocarbon degassing, is achieved in the deoiling drum. The recovered liquid hydrocarbons are discharged on level control to quench water tower. The drum pressure floats on the CG 2nd stage suction Drum pressure. The deoiled spent caustic is then discharged to the spent caustic Degassing Drum, V-343, which operates

at

neat-atmospheric

pressure.

The

residual

hydrocarbon gas is flashed to the flare system, and the spent caustic is finally pumped to the steam stripper, C-1101 via the steam stripper feed preheater E-1101. In the steam stripper benzene and other entrained aromatics are stripped with live LP steam which is injected below the bottom tray. The overhead vapour from the tower is recycled back to the QW tower, via the water K.O. Drum, V-1102, which collects any slugs of water that may be carried over. The aromatics free spent caustic bottoms stream is pumped by the steam stripper bottoms pump, P-1104 A/B to the spent caustic oxidation unit for further treatment. In the event that the steam stripper is out of commission the raw spent caustic liquor can be sent to the spent caustic holding tank, T-1101 A/B, and subsequently recycled to the steam stripper utilising the spent caustic feed recycle pump, P1101 A/B.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

42 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

Fresh caustic is delivered from offsite as a 20 wt. percent solution to the concentrated caustic tank, T-340. Makeup caustic is drawn from the tank by the concentrated caustic pump, P-341 A/B, and charged to the caustic tower via the caustic diluent mixer, Z-341, where it is mixed with spent wash water to produce a 10 percent caustic solution. The wash water is supplied from the caustic tower wash water loop. The consumption of caustic depends on the quantity of CO2 and H2S in the feed to the tower and on the residual concentration of NaOH in the spent caustic solution. The Caustic Pump, P-341 A/B, supplies the required makeup caustic to the Caustic Tower and is used for pH control in the dilution steam generation system. The make-up caustic to the caustic tower is combined with the return circulating strong caustic, whereby the strong caustic circulating pump provides mixing of the two streams. Excess strong caustic overflows from the caustic strong section to the medium section via an external downflow pipe on the strong caustic chimney tray. In turn, the excess medium caustic solution overflows to the weak caustic section via an internal dowflow pipe on the medium caustic chimney tray. Means for aromatic gasoline (C6-C8 cut) injection is provided into the top of each of the caustic scrubbing sections. Injection of gasoline into the suction of the strong caustic circulating CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

43 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

pump is on a continuous basis. The aromatic gasoline acts as a solvent for any polymers being accumulated on the trays and passes down with the spent caustic to the Deoiling Drum, V-342 where it is separated and discharged to the Quench Water tower. The neutralised cracked gas passes to the wash water section where it is cooled by rejecting heat to the circulating wash water stream. Deaerated boiler feedwater is used as a makeup supply to the wash water section. The wash water is circulated by the wash water circulating pump, P-345 A/B, which directs the water through the wash water cooler, E-341, where it is cooled against cooling water. The cooled wash water flows to the top tray of the Caustic Tower. In the event of a cracked gas compressor shutdown, liquid in each section of the tower will fall from the Ripple trays towards the bottom of each section. For the top section, the excess wash water will accumulate in the wash water chimney tray. The strong caustic chimney tray is capable of holding the majority of the dumping liquid from the strong caustic section, following the provision of a control valve provided on the external downflow pipe to the medium caustic section which is to close when the cracked gas compressor trips. The bottoms compartment below the C G Feed nozzle provides excess liquid holding capacity for the excess strong caustic solution, and all of the liquid from the medium and weak caustic sections. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

44 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

2.10.2 C G Dehydration The cracked effluent from the overhead of the C G Rectifier Reflux Drum is fed to one of two cracked gas dehydrators, V370 A/B. These fixed-bed dehydrators are each composed of a main bed and a guard bed. Both beds are filled with molecular sieve. While one dehydrator is operating the second is either being reactivated or is in a standby position. The desiccant in the main bed is designed for a 24 hour operating cycle at the end of bed life. The desiccant in the guard section provides additional protection time before water breakthrough. At the end of each cycle, the standby dehydrator is put into service and the operating dehydrator is switched over to reactivation. Reactivation of the desiccant is accomplished with reactivation gas (a methane/hydrogen mixture) by upward flow through the beds. Fresh reactivation gas is supplied from the Demethanizer System. It is first heated against reactivation gas effluent in the Reactivation Gas Feed / Effluent Exchanger, E-371, and is then further heated by HP steam in the Reactivation Gas Heater, E372. The hot gas passes upward through the dehydrator, heating the bed and desorbing the water from the molecular CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

45 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

sieve. The effluent passes to the Reactivation Gas Feed/Effluent Exchanger where heat is released to cooling water. The cooled effluent enters the Reactivation Gas Separator, V-371, where water and hydrocarbon liquids, removed from the desiccant, are separated from the reactivation gas. The gas is then returned to the fuel gas system, and the oily water gas is then returned to the fuel gas system and the oily water is discharged to the Quench Water Tower. The hot reactivated is discharged to the Quench Water Tower. The hot reactivated desiccant is then cooled to the normal temperature with cold residue gas which is cooled and chilled in the Reactivation Gas Feed Cooler, E-373, and in the Reactivation Gas Feed Chiller, E-374, respectively. 2.11 Demethanizer System The Demethanizer system consists of two parallel feed chilling trains and three stages of fractionation : the Demethanizer Prestripper, C-410, the Demethanizer, C-420, and the Residue Gas Rectifier, C-430. There are two parallel sets of precoolers. Each set consists of three heat exchangers, through which the total cracked gas feed from the dehydrators is cooled and partially condensed prior to the first liquid fraction being separated in the Demethanizer

Prestripper

Feed

Drum,

V-410,

and

the

Demethanizer Prestripper Parallel Feed Drum, V-414. The first CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

46 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

parallel set of precoolers are the Demethanizer Precooler No.1, E-401, and Demethanizer Parallel Precooler No.1, E-407, which use-6.7 C propylene refrigerant as coolant. Further cooling of the cracked gas occurs in the Demethanizer Bottoms Reheater, E-438, and its parallel reheater, E-408, which utilise the Demethanizer net bottoms stream as coolant. In Demethanizer Precooler No.2, E-402, and its parallel precooler, E-409, the cracked gas mixture is cooled by -23.3 C propylene refrigerant. The liquid condensed at this point contains some methane and C2s and the major portion of the C3 and heavier components; it is separated from the vapour in the Demethanizer Prestripper feed drum, V-410, and its parallel drum, V-414. The liquid streams from these drums are combined and fed to the demethanizer Prestripper, C-410, as the bottom feed for removal of methane. The vapour from the Demethanizer Prestripper Feed Drum, V410 is cooled and partially condensed in the Ethane Recycle Vaporiser, E-461, where recycle ethane from the Ethylene Stripper bottoms is vaporised. The partially condensed stream is further cooled by using -40C propylene refrigerant in the Demethanizer precooler No.3, E-403. This partially condensed stream is fed to the Demethanizer feed drum no. 1, V-411, for separation of the vapour / liquid streams. The vapour from the Demethanizer Prestripper Parallel feed drum is also cooled by using-40C propylene refrigerant in the Demethanizer Parallel CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

47 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

Precooler no.3 This partially condensed stream is fed to the demethanizer parallel feed drum no.1, V-415 for separation of the vapour / liquid streams. The liquid streams from V-411 and V-415 contain methane and C2s, along with much of the remaining C3 and heavier components. They are combined and fed to the Demethanizer Prestripper as the top feed. The vapour phase from V-411 is divided into two parallel streams, after which it is cooled further and partially condensed. The larger portion of this vapour stream is cooled by using the -51.1C and -73.3 C levels of ethylene refrigerant in the reminder is cooled by heat exchange with residue gas in demethanizer core exchanger no.2, E-412. Both partially condensed streams are recombined and fed to the demethanizer feed drum no.2, V-412, where vapour and liquid streams Are separated. The vapour phase from V-415 is also cooled using two levels of ethylene refrigerant (-51.1 C and -73.3 C) in the Demethanizer parallel precooler no.4, E-422. The partially condensed stream is then fed to demethanizer parallel feed drum no.2, V-416, where vapour and liquid streams are separated. The liquid streams from V-412 and V-416 are combined and fed to the Demethaniser, C-420. The vapour streams from these drums (mainly hydrogen, methane, and ethylene) are further cooled and partially condensed in an exchanger arrangement identical to that of the previous stage, except for the use of CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

48 0 0 23/08/2015 BMK

SECTION

MODULE NO.

2

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

-100.6 C ethylene refrigerant in the Demethanizer Precooler No.6, E-406, and Demethanizer Parallel Precooler No.6, E-424, respectively. The split stream

from V-412 is cooled by heat

exchange with residue gas in Demethanizer Core Exchanger No.3, E-413. A vapour / liquid separation is repeated in the Demethanizer Feed Drum No.3, V-413, and Demethanizer Parallel Feed Drum No.3, V-417. The liquid streams, consisting of ethylene , ethane, and methane, are combined and fed to the Demethanizer, C-420. The vapour streams are combined and

cooled

further

and

partially

condensed

in

the

Demethanizer core exchanger No.4, E-414, prior to being fed into the Residue Gas Rectifier, C-430, where the ethylene loss to fuel is minimised. The liquid streams from the Demethanizer Prestripper Feed Drum and Demethanizer Prestripper Parallel Feed Drum, are combined and fed to the Demethanizer Prestripper, C-410. A second

feed

to

the

Prestripper

tower

comes

form

the

Demethanizer feed drum no.1 and the demethanizer parallel feed rum no.1 The prestripper is reboiled with quench water in the demethanizer prestripper reboiler, E-410. The stripper bottoms product is essentially methane free with roughly one third of the C2 components and goes

directly to the

deethanizer, C-440, bypassing the demethanizer, C-420. The prestripper overhead vapour is fed to the demethanizer.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

49 0 0 23/08/2015 BMK

SECTION

MODULE NO.

2

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

The purpose of the demethanizer is to make a sharp separation between methane and ethylene. Each feed enters the tower at different tray locations to gain the maximum benefit from the pre-fractionation produced by the fractional condensation. The heat input for the Demethanizer Reboiler, E-420, is supplied by condensing

7.2

C

propylene

refrigerant

vapour.

The

demethanizer condenser, E-425, is cooled by evaporating ethylene refrigerant at -100.6C. The overhead product vapour stream is heated as it passes through the Demethanizer core exchanger no.3 and is then directed to the Methane Expander, B-421. The Residue Gas Rectifier recovers the ethylene contained in Demethanizer Feed Drum No.3, and Demethanizer Parallel Feed Drum No.3. The liquid from the bottom of the Residue Gas Rectifier is returned to the top of the Demethanizer, C-420. The Residue

gas

overhead

is

partially

condensed

in

the

Demethanizer core exchanger no.5, E-415, by gas which has been chilled by expansion in the cryogenic expansion turbine. The residue gas from the Residue gas rectifier reflux drum, V436, is cooled an partially condensed through the Hydrogen core exchanger, E-419. The partially condensed stream is fed to the hydrogen drum V-431, where 95 percent hydrogen vapour is separated from the

liquid. The maximum amount of 95

percent hydrogen vapour is sent to the pressure swing Adsorption Unit, Z-400, for the production of extra high purity hydrogen.

The

CHECKED BY N.S.P APPROVED BY B. DAS

hydrogen

vapour

is

Process description and Utilities

heated PAGE REV ISSUE DATE AUTHOR

through

the

50 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

demethanizer core exchanger no.1 through 4 and through the hydrogen core exchanger. The remainder of the Hydrogen Drum vapour and the Hydrogen Drum Bottoms (fuel gas) are flashed down to 1.45 kg/cm 2g and are reheated in the following multi-pass exchangers. Hydrogen core exchanger, E-419, Demethanizer core exchangers Nos. 1 through 5. The fuel gas and the purge gas from the PSA unit are then directed to the Fuel Gas Compressor, B-900, at a temperature of about 320C. The Demethanizer net overhead vapour stream is heated through Demethanizer core exchanger no.3 and is then sent to the

Methane

Expander,

B-421.

The

expander

outlet

temperature is such that the required amount of cooling is supplied to the overhead rectifier condenser. The expander effluent, which is at low pressure, is reheated in demethanizer core exchangers nos. 1 through 5. The heated gas regn. goes to the Methane Recompressor, B-420. The compressor is driven by the expander, usually, an integral construction. The gas leaves the compressor at a pressure of 5.6 kg/cm 2g, sufficient for regeneration requirements. The Demethanizer bottoms product goes to the Deethanizer after being heated by exchanger with cracked gas from precooler no.1

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

51 0 0 23/08/2015 BMK

SECTION

MODULE NO.

2

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

The Methane produce stream is obtained by removing a portion of the liquid from the Demethanizer, Reflux Drum, V-426, and vaporising in an air vaporiser, E-427, to about 5 C. The vapour is then allowed to warm-up to ambient temperature by heat gain from the atmosphere in the pipeline before transfer to OSBL>

2.12 PSA Unit The

PSA

unit,

prefabricated

Z-400, provided

valve

and

piping

by UOP, skid,

consists

adsorber

of

a

vessels,

molecular sieve type adsorbent control panel, instrumentation, and a tail gas surge tank. The unit is designed to permit outdoor unattended operation. It employs a pressure swing adosrpiton (PSA) process to purify the 95 mol percent hydrogen stream supplied from the Demethanizer system. The PSA process uses a series of adsorbent beds to provide a continuous and constant hydrogen product flow. The adsorbers operate on an alternating cycle of adsorption and regeneration. One adsorber is always in operation while the remaining are in various stages of regeneration. The unit produces a high purity hydrogen stream which fulfils the export product stream requirement, as well as the C2, C3, CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

52 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

C4 and Gasoline hydrogenation unit needs. The hydrogen stream has a

minimum composition of 99.9 mol percent

hydrogen. The balance of the feed gas is purged to the fuel gas system. Constant hydrogen recovery can be maintained at flow rates as low as one-third of the design feed flow rate.

2.13 Deethanizer The dual feed deethanizer , C-440 separates the Demethanizer and Demethanizer Prestripper bottoms streams into a C2 stream and a C3 and heavier stream. The demethanizer net bottoms is heated in the Demethanizer bottoms reheater, E438, and its parallel reheater, E-408, before entering the tower as the top feed. The Demethanizer Prestripper Bottoms Reheater, E-439 A/B, and is the lower feed to the tower. The Deethanizer gross overhead, consisting primarily of C2’s, is partially condensed in the Deethanizer condenser, E-445, using -23.30C propylene refrigerant. The vapour-liquid mixture is separated in the Deethanizer reflux drum, V-446. The liquid is returned to the tower as reflux by the deethanizer reflux pump, P-445 A/B, and the net overhead vapour is directed to the c2 acetylene hydrogenation system.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

53 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

The reboil heat to the tower is supplied by the deethanizer reboiler, E-440 A/B, using quench water. The deethanizer net bottoms stream, which is composed of C3’s and heavier components, is fed to the Depropanizer.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

54 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

2.14 C2 Acetylene Hydrogenation System Acetylene (C2H2) is produced in the cracking operation and as an impurity must be removed from the deethanizer overhead stream by catalytic hydrogenation (Palladium based catalyst), so that the

ethylene product contains less than 2 ppm of

acetylene. Acetylene's are hydrogenated into ethylene and ethane, which are

subsequently separated in the ethylene

fractionation system. The acetylene is removed in a three step hydrogenation process. Three identical adiabatic reactors are employed working in series. The first step is performed by the primary C2 hydrogenation reactor, R-452 A/B which has its own spare. The second and third steps are performed by the C2 hydrogenation reactors, R-451 A/B/C, which share a common spare. The deethanizer net overhead vapour leaving the deethanizer reflux drum, V-446, is fed to the hydrogenation system on flow control. Hydrogen from the PSA unit is injected, on ratio flow control, before it enters the C2 hydrogenation feed / effluent exchanger,

E-452

A/D,

and

is

steam

heated

by

C2

hydrogenation feed heater, E-450, where the inlet temperature to the FIRST reactor is made in the first reactor. The reaction is controlled by adjusting the reaction temperature and by bleeding in raw hydrogen containing CO into the pure hydrogen stream from the PSA unit. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

55 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

The effluent from the first reactor passes through the C2 hydrogenation adiabatic reactor Intercooler No.1, E-458, where the inlet temperature to the second reactor is controlled. A split range flow control system is provided such that part of the flow may be by-passed across E-458 for better temperature control. Hydrogen is injected on ratio flow control, upstream of E-458. Approximately 35% of the conversion of the acetylene is made in the second reactor. The reaction is controlled by adjusting the reaction temperature and by bleeding in raw hydrogen containing CO into the pure hydrogen stream from the

PSA

unit. The effluent from the second reactor is cooled in the C2 Hydrogenation Adiabatic

Reactor

Intercooler

No.2,

E-455,

before passing to the third reactor. Hydrogen is again injected on ratio control. In this reactor, the remaining acetylene is removed so that the reactor effluent contains less than 1.7 ppm acetylene. The reaction is controlled by adjusting the reaction temperature and by bleeding in raw hydrogen containing CO into the pure hydrogen stream from the PSA unit. Effluent leaving the third reactor is water-cooled in C2 hydrogenation Adiabatic Reactor Afterooler, E-456 A/B, prior to preheating the feed to the first reactor in the C2 hydrogenation feed / effluent exchanger, E-452 A/D.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

56 0 0 23/08/2015 BMK

SECTION

MODULE NO.

2 The

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

reactor

beds

are

periodically

regenerated

using

regeneration gas supplied from the reactor treatment furnace, H-710, in the gasoline hydrogenation Unit. The three reactors, R-451 A/B/C are rotated such that the newly regenerated bed assumes the third reactor position. The effluent from E-452 A/D passes to the C2 hydrogenation effluent separator, V-455, where condensed polymers are knocked out prior to the effluent being dried in the secondary dehydrators, V-453 A/B. After drying, the effluent passes to the Ethylene rectifier, C-470. The secondary dehydrators are supplied for removal of any water formed in the acetylene hydrogenation reaction any polymers not removed in the C2 Hydrogenation effluent separator. While one dehydrator is operating, the second is either being reactivated or is in a standby

operation.

Reactivation

of

the

desiccant

is

accomplished by upward flow of reactivation gas through the beds. The reactivation gas is supplied from the same system employed by the cracked gas dehydrators, V-370 A/B. 2.15 Ethylene Fractionation The C2 acetylene hydrogenation system feeds the two-tower ethylene fractionation system. The feed stream consists essentially of ethylene and ethane with trace quantities of methane, hydrogen and propylene. This system fractionates the feed into an ethylene product stream and an ethane stream for recycle cracking in the furnaces. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

57 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

A pasteurising section is located at the top of the ethylene rectifier, C-470, above the ethylene product drawoff, to separate any lights from the gross

overhead

is

ethylene product. The rectifier

condensed

against

-400C

propylene

refrigeration in the ethylene rectifier condenser, E-475. The condensed liquid is collected in the ethylene Rectifier Reflux Drum, V-476, then pumped back to the top pasteurising tray by the ethylene rectifier reflux pump, P-475 A/B. A vent is recycled from the drum to the C. G. Fourth Stage Suction Drum. Below the pasteurising section, the ethylene product is withdrawn as liquid and fed under its own pressure to the intermediate storage spheres. The option also exists to either send the ethylene product to atmospheric storage via the ethylene product coolers no.1,2 & 3, E-480, E-481, E-482 respectively, or to vaporise the ethylene product and deliver it as a low pressure vapour to the battery limits via the ethylene product vaporiser, E-477, and ethylene product superheater, E-478 A/b. Normally, the ethylene liquid will be imported from the intermediate storage spheres after quality control and either fed as a low pressure liquid to the ethylene product vaporiser, E-477, and ethylene product superheater, E-478 A/B to produce a low pressure vapour for export or fed as a high pressure liquid to the HP ethylene product heater no.1, E-40, and HP ethylene CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

58 0 0 23/08/2015 BMK

SECTION

MODULE NO.

2

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

product no.2, E-491, to produce a high pressure vapour for export. Both ethylene fractionation towers are equipped with reboilers. Desuperheated ethylene refrigeration compressor discharge vapour is the reboiling medium for the ethylene rectifier reboiler, E-470. Propylene refrigerant vapour at 7.20C is the reboiling medium for the ethylene stripper reboiler, E-460. The ethylene stripper, C-460, net bottoms supplies the ethane recycle. The ethane recycle is routed to the ethane recycle vaporiser, E-461, superheated in the demethanizer core exchanger no.1, E-411, and then delivered to the USC recycle furnace as feed for cracking. 2.16 Depropaniser The dual-feed Depropanizer, C-510, is fed by the Deethanizer bottoms and condensate stripper bottoms. Propylene, propane, and any lighter components make up the tower overhead. This stream is totally condensed by vaporising 9.40C propylene refrigerant

in

the

Depropanizer

condenser,

E-515.

The

condensed liquid is collected in the Depropaniser Reflux Drum, V-516. The liquid is pumped to the tower as reflux by the Depropanizer Reflux pump, P-515 A/B. The net overhead stream is pumped by the C3 hydrogenation feed pump, P-516 A/b, to the C3 Hydrogenation system. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

59 0 0 23/08/2015 BMK

SECTION

MODULE NO.

2

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

The Depropanizer gross bottoms is reboiled against pan oil in the Depropanizer Reboiler, E-510 A/B. The net bottoms stream, composed mainly of C4’s and heavier components, is sent to the Debutanizer. 2.17

C3 Hydrogenation System

The C3 Hydrogenation system, designed by Institut Francais du Petrole (IFP) is a one stage, liquid-phase catalytic process. There are three installed reactors, R-531 A/B/C. Two are normally operated in parallel while the third is on stand-by. Methyl acetylene (MA and propadiene (PD) in the Depropanizer net overhead are selectively converted to propylene and propane in the reactors. The condensed Depropanizer net overhead is pumped into the system by the C3 Hydrogenation Feed Pump, P-516 A/B. This stream first flows through the C3 hydrogenation feed coalescer, V-519, which eliminates any free water. The coalescer outlet is split into two parallel passes, one for each operational reactor. Each pass is diluted with liquid C3 recycled from the C3 hydrogenation recycle pump, P-520 A/B, and then mixed with make-up hydrogen from the PSA unit. The purpose of the liquid recycle is to control inlet concentration of MA+PD in the reactor feed. This avoids excessive vaporisation in the reactors due to the highly exothermic reactions.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

60 0 0 23/08/2015 BMK

SECTION

MODULE NO.

2

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

In the reactors, MA and PD are selectively hydrogenated to propylene, propylene hydrogenation to propane is minimised. The heat of reaction induces partial vaporisation of the hydrocarbon stream. Purge to the C.G. Fourth Suction Drum). During normal operation, the effluent is sub-cooled and no off-gas is purged. The drum bottoms are pumped out by the C3 hydrogenation recycle pump, P-520 A/B, and divided into two streams : liquid recycle for reactor feed dilution and the product which feeds the secondary deethanizer, C-530. The spare reactor allows catalyst reduction, reactivation or regeneration operations with the C3 Hydrogenation unit running. For catalyst reduction or reactivation operations, hydrogen make-up gas is combined with fuel gas of the methane type to achieve

mixed

stream

hydrogen

content

of

25

mol%.

Alternately, nitrogen may be used instead of fuel gas. The mixed stream is then preheated to the required temperature in the C3 hydrogenation catalyst treatment exchanger, E-522. The off-gas, which is similar to the inlet gas, is sent to flare for disposal. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

61 0 0 23/08/2015 BMK

SECTION

MODULE NO.

2

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

The reactors are regenerated, as required, by regeneration gas supplied from the GHU first Stage Reactor Treatment Furnace, H-710. Spent regeneration gas is returned to the GHU decoking drum, V-713, for disposal. The composition of the spent gas is similar to the fresh regeneration gas except that it contains small amount of light hydrocarbons at the beginning of reactor sweeping and CO/CO2, during combustion steps. 2.18 Secondary and Tertiary Deethanizer Secondary and Tertiary Deethanizer,C 530 & C-535, towers in series are designed to remove water and C2 and lighter hydrocarbons from the propylene / propane stream prior to C3 fractionation. The liquid effluent from the C3 hydrogenation system is fed to the secondary deethanizer at tray number 22. The overhead vapour stream is condensed against cooling water in the secondary

Deethanizer

condenser,

E-535.

Following

the

separation of water in the secondary Deethanizer reflux drum, V-536, the total hydrocarbon condensate phase is pumped back to the top of the tower by the secondary deethanizer reflux pump,

P-535

A/B.

Noncondensables

in

the

secondary

deethanizer overhead are normally vented to the cracked gas fourth stage suction drum. Any condensed water is removed

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

62 0 0 23/08/2015 BMK

SECTION

MODULE NO.

2

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

from the boot of the reflux drum and is sent to the oily-water sewer. The secondary deethanizer reboiler, E-530, is heated by quench water.

The

tower

bottom

stream

flows

to

the

Tertiary

Deethanizer, C-535 via the secondary deethanizer bottoms pump, P-530 A/B. The Tertiary Deethanizer, C-535, tower has been added to the system

in

series

with

the

secondary

deethanizer

to

accommodate the increased expansion loads. It is designed to further remove water and C2 and lighter hydrocarbons from the propylene / propane stream prior to C3 fractionation to meet the required product specifications. The Secondary Deethanizer Bottoms Pump effluent is fed to the Tertiary Deethanizer, C-535, at tray number 22. The overhead vapour stream is condensed Tertiary

Deethanizer

against cooling water in the

Condenser,

E-537.

Following

the

separation of water in the Tertiary Deethanizer Reflux Drum, V537, the total hydrocarbon condensate phase is pumped back to the top of the tower by the Tertiary deethanizer reflux pump, P-537 A/B.

Noncondensables in

the Tertiary

Deethanizer

overhead are vented to the cracked gas Fourth Stage Suction Drum. Any condensed water is removed from the boot of the Reflux Drum and is sent to the oily-water sewer.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

63 0 0 23/08/2015 BMK

SECTION

MODULE NO.

2

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

The Tertiary Deethanizer Reboiler, E-536, is heated by quench water. The tower bottom stream flows to the Propylene Stripper, c-540, via the Tertiary Deethanizer Bottoms Pump, P536 A/B. 2.19 Propylene Fractionation The net bottoms stream from the secondary deethanizer, containing propylene, propane, plus trace amounts of ethane and C4’s , is fed to the propylene stripper, C-540. Because of the large number of trays required to make the separation, two towers are provided for the propylene / propane fractionation : the Propylene Stripper, C-540, and the Propylene Rectifier, C550. Reboil heat I supplied to the bottom of the stripper by circulating quench water in the Propylene Tower Reboilers, E540 A/D and if necessary by the Propylene Tower Auxiliary Reboilers, E-541 A/B. The Stripper bottoms stream consists of propane recycle which is vaporised in the Propane Recycle Vaporiser, E-542, and is sent to the USC Recycle Furnaces for cracking. Green oil formed in the C3 hydrogenation reactor is continuously drained from E-542 and is sent back to the 2nd stage suction drum V-320. Vapour from the top of the stripper flows to the bottom of the propylene rectifier. Liquid from the bottom of the rectifier is pumped back to the top of the stripper via the propylene transfer pump, P-550 A/B. Overhead vapour from the rectifier is condensed CHECKED BY N.S.P APPROVED BY B. DAS

using

cooling

water

in

Process description and Utilities

the

propylene

PAGE REV ISSUE DATE AUTHOR

tower

64 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

condenser, E-555 A/H, and passes to the Propylene tower reflux drum, V-556. Condensate from the reflux drum is pumped to the top of the rectifier as reflux and to offsite propylene storage and uses by the propylene tower reflux / product pump, P-555 A/B. A slip stream, located off the propylene product stream provides make up to the propylene refrigeration system, as needed. 2.20 Debutanizer The Depropanizer bottoms stream is fed to the debutanizer, C560. The tower gross overhead is condensed against cooling water in the debutanizer condenser, E-565. The mixed C4’s stream is pumped by the Debutanizer Reflux / Product Pump, P565 A/b, from the Debutanizer reflux drum V-566, to the C4 hydrogenation unit / intermediate storage and back to the tower as reflux. The Debutanizer bottoms stream is reboiled against LLP steam in the Debutanizer Reboiler, E-560 A/B. The tower net bottoms, consisting of C5s and heavier, are sent to the Gasoline Hydrogenation Unit. 2.21 C4 Hydrogenation System : The raw C4 cut is routed to the feed surge drum, V-801 and then pumped under flow control by the feed pump, P-801 A/B.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

65 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

The vessel pressure is regulated at 4.5 kg/cm 2g by a split range control which regulates the N2 make up and release to flare. The flow rate of hydrogen make up is regulated by flow ratio control with the C4 feed. This flow ratio set point is calculated in proportion to the butadiene content at reactor inlet (feed+recycle). The C4 cut feed is mixed with liquid recycle and hydrogen make up gas and flow to the top of the reactor R-801. The hydrogenation reaction is exothermic and a cooled recycle stream is required to be mixed with the C4 feed and hydrogen in order to prevent excessive temperatures within the catalyst bed and in order to ensure a good hydraulic distribution through the catalyst bed. As the mixture flows down through the catalyst bed of the reactor R-801, the temperature rises due to the exothermic reaction. The inlet temperature of the reactor R-801 is minimised (in order to prolong the active life of the catalyst) consistent with achieving the required conversion rate of diolefinic hydrocarbons. As the catalyst activity reduces, during the run life, the feed temperature is increased form about 43 0C at start of run (SOR), to about 600C at end of run (EOR). The reactor outlet temperature should not exceed 1000C in order to prevent excessive damage to the catalyst. Below 400C the

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

66 0 0 23/08/2015 BMK

SECTION

MODULE NO.

2 reaction

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

rate

is

not

sufficient

to

achieve

the

required

conversion, even with fresh catalyst. Steam preheating through the heater E-801 is necessary during start-up to reach the inlet R-801 temperature. The volume of the gaseous phase in the mixture reduces as hydrogen reacts with the diolefinic hydrocarbons but some of the C4 hydrocarbons are vaporised as the temperature rises. The two phase mixture leaving the reactor R-801 flows directly to the Hot Separator, V-802. Vapour from the Hot Separator V802 is cooled

in the post-condenser, E-803. The condensate

which is formed, is separated in the post-condenser drum, V803, and is recycled to the separator V-802 after mixing with reactor R-801 effluent. First reaction section pressure is controlled by purging V-803 gas to the cracked gas compressor suction. The liquid collected in the Hot Separator is pumped by the Recycle Pump, P-802 A/B and cooled in the Recycle Cooler, E802. Most of the cooled liquid represents the R-801 recycle and the other part represents the first stage effluent. A separate bypass control around the cooler E-802 enables the regulation of R-801 inlet temperature.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

67 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

A second separate E-802 by-pass control enables the regulation of the R-802 inlet temperature. This stream is sent under flow control to the second stage hydrogenation reactor R-802. The H2 make up to the finishing reactor R-802 is delivered under flow ratio control. the set point of this flow ratio is calculated in proportion to the butadiene content at R-802 inlet. R-802 effluent is cooled down to 430C through the product cooler, E-804, and flashed into the c4 product flash drum, V-804 at fuel gas network pressure to eliminate potential remains of hydrogen or other light components. the liquid product is pumped to battery limit under level control by the C4 product pump. An identical unit called as auxilary hydrogenation is installed to operate in parallel to main unit for additional loads . 2.22 Ethylene Refrigeration System The Ethylene Refrigerant Compressor, B-600, is a three stage single casing machine. The machine is designed to supply ethylene refrigerant at -100.60C, and -51.10C, respectively. The compressor is driven by a steam turbine. The compressor third stage discharge vapour is desuperheated by

using

cooling

water

in

the

Ethylene

Refrigerant

Desuperheater No.1, E-645, then by using 7.2 C and -6.7 C CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

68 0 0 23/08/2015 BMK

SECTION

2 propylene

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

refrigerant

in

the

Ethylene

Refrigerant

Desuperheaters No.2, E-646, and no.3, E-647, respectively. The refrigerant vapour then flows through the ethylene refrigerant oil filter, z-610 A/B, for removal of compressor lube or seal oil. The takeoff for the minimum flow bypass line is downstream of the filter. Normally, the desuperheated vapour is condensed in the ethylene rectifier reboiler, E-470 A/B. For start-up and upset conditions, the auxiliary ethylene refrigerant condenser, E-649 condensing the desuperheated ethylene vapour as required. The condensed ethylene refrigerant flows to the ethylene refrigerant surge drum, V-645. The liquid from the surge drum is sub cooled using -40.0 0C propylene refrigerant in a plate - fin exchanger, the ethylene refrigerant subcooler, E-650. The subcooled liquid flows into the ethylene refrigerant third stage suction drum, V-630, via a level control valve. A slip stream of the subcooled liquid flows to the ethylene product cooler no.1 refrigerant flash pot, V-480 and demethanizer parallel precooler no.4 flash pot A, V-422, which service ethylene product cooler no.1, E-480 (normally not in service) and demethanizer parallel precooler no.4, E-422A, respectively). The third stage suction drum pressure is maintained by the compressor, resulting in a refrigerant temperature of -51.10C. This drum serves as a thermossyphon drum for demethanizer

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

69 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

precooler no.4, E-404. The flash vapour generated in this drum flow to the third stage suction nozzle of the compressor. A portion of the -51.10C liquid flows into the ethylene product cooler no.2 refrigerant flash pot, V-481, servicing the ethylene product cooler no.2, E-481 and demethanizer parallel precooler no.4 flash pot B, V-423, servicing the demethanizer parallel precooler no.4, E-422B. The balance of the liquid from V-630, is fed into the ethylene refrigerant second stage suction drum, V620, via a level control valve. The second stage suction drum pressure is maintained at a corresponding liquid temperature of -73.30C. This drum serves as a thermosyphon drum for Demethanizer Precooler No.5, E405. The vapour generated in this drum flows to the second stage suction nozzle of the compressor. A majority of the -73.30C liquid satisfies four parallel process users: the Demethanizer Precooler No.6, E-406; Ethylene Product Cooler no.3, E-482; Demethanizer Condenser, E-425; and Demethanizer Parallel precooler No.6, E-424. The ethylene vapour out of the associated flash pots of these users is sent to the ethylene Refrigerant first stage suction drum, V-619, at -100.60C. The entire first stage suction drum vapour is sent to the ethylene refrigerant compressor. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

70 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

Any accumulation of oil or liquid in the first stage suction drum flows into the ethylene refrigerant drain drum, V-646. This drum is equipped with a propylene refrigerant heating coil, receiving propylene vapour upstream of propylene refrigerant condenser, E-699 A/H, J/K, and discharging condensed propylene liquid to the propylene refrigerant fourth stage flash drum, V-690. Any ethylene refrigerant liquid in the drain drum is evaporated, allowing the oil to accumulate and be periodically drained from the drum. Three

minimum

flow

bypasses

are

provided

into

the

compressor suction drums to maintain the compressor in a stable flow regime. 2.23 Propylene Refrigeration System The Propylene Refrigerant Compressor, B-650, is a four stage single - casing machine, which is designed to supply propylene refrigeration at -400C, -23.30C, -6.70C and 7.20C, respectively. The compressor is driven by an extraction condensing steam turbine. The compressor discharge vapour is desuperheated and condensed in the water cooled propylene refrigerant condenser , E-699 A/H, J/K.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

71 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

The minimum flow bypass is taken upstream of the propylene refrigerant condenser. As required , this vapour goes to the propylene refrigerant first stage suction, second stage suction, third stage flash, and fourth stage flash drums. The condensed propylene from E-699 A/H, J/K, flows into the propylene refrigerant surge drum, V-695. The drum pressure is maintained by saturated compressor discharge vapour. This is necessary to prevent “stonewall operation”. The liquid propylene at 40.60C flows from the surge drum and divides into three separate streams. The propylene is subcooled in all three streams, acting as the heating medium for process streams. These services are : Demethanizer core exchanger no.1, E-411. The subcooled propylene flows to propylene refrigerant second stage suction drum, V-670. Ethylene product superheater, E-478 A/B. The subcooled propylene flows to propylene refrigerant third stage flash drum, V-680. HP ethylene product heater no.2, E-491. The subcooled propylene is divided into three parallel process services. Reactivation gas feed chiller, E-374, Depropanizer condenser, E-515 and cracked gas rectifier overhead condenser, E-355. The CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

72 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

vapour generated in these services and the balance of liquid propylene refrigerant each flow to the propylene refrigerant fourth stage flash drum, V-690. The Fourth Stage flash drum vapour is used as the heat source in the ethylene stripper reboiler, E-460, and demethanizer reboiler, E-420. The condensed propylene flows through the respective seal pots and is flashed into the propylene refrigerant third stage flash drum, V-680. The fourth stage flash drum operates at 7.20C. This drum serves as a thermosyphon drum for ethylene refrigerant desuperheater no.2, E-646. Some of the liquid is vaporised in the demethanizer precooler no.1, E-401, and demethanizer parallel precooler no.1, E-407. The balance of the liquid is flashed directly to the third stage flash drum, V-680. The third stage flash drum vapour, is condensed in the ethylene product vaporiser, E-477, and the HP Ethylene product heater no.1, E-490. The propylene condensed in these exchanger is collected in the respective seal pot, V-477 and V-490, then flashed to the propylene refrigerant second stage suction drum, V-670. The third stage flash drum operates at -6.70C. This drum serves as

a

thermosyphon

drum

for

the

ethylene

refrigerant

desuperheater No.3, E-647. The liquid propylene from the drum CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

73 0 0 23/08/2015 BMK

SECTION

MODULE NO.

2 supplies

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

the

following

four

services:

Auxiliary

ethylene

refrigerant condenser, E-649 A/B; Deethanizer condenser, E445

A/D;

Demethanizer

precooler

No.2,

E-402,

and

Demethanizer Parallel precooler no.2, E-409. The vaporised propylene is sent to the

propylene refrigerant second stage

suction drum, V-670. Additionally, the third stage flash drum liquid is flashed into the second stage drum. All of the vapour from the second stage suction drum, at -23.30C, is routed to the compressor. Some of the liquid satisfied three parallel process users : Demethaniser parallel precooler no.3, E-421; Demethanizer Precooler no.3, E-403 and ethylene refrigerant subcooler, E-560. The propylene vapour out of these services is sent to the propylene refrigerant first stage suction drum, V-660. The balance of the liquid is flashed into the first stage suction drum to satisfy the ethylene rectifier condenser, E-475, requirement. The first stage suction drum serves as a thermosyphon drum for the ethylene rectifier condenser. The entire first stage suction drum vapour is sent to the refrigerant compressor. Any excess liquid in the first stage suction drum may be sent to the LLP steam-traced propylene refrigerant drain drum, V-696. The vapour from the drain drum is returned to the first stage suction drum. 2.24 Gasoline Hydrogenation Unit CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

74 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

The GHU consists of two stages. This process provided by Institut Francais du Petrole (IFP) produces a feedstock for downstream aromatic recovery by selectively hydrogenating the diolefins in the first stage and the olefins in the second stage. 2.24.1 First stage reaction section The raw pyrolysis gasoline, mixed with the recycled wash oil, is fed to the feed surge drum, V-701 under slight pressure, after being filtered through the Z-702 A/B package. The filtration facility is mostly useful when some of the feed comes from the storage tanks. Free water, if any, can be purged from V-701 boot. The first stage feed pump, P-701 A/B raises the feed pressure up to the reaction selection pressure. Part of the P-701 discharge can be routed to storage under V-701 level control. H2 make up supply is introduced at the First stage feed pump discharge under pressure control. The pressure of both reaction sections, HD1 and HD2, is controlled from the same point, at the top of the 2nd stage separator drum, C-740. The fresh feed and H2 make up are mixed with cooled reactor effluent to dilute the feed. The role of the dilution is to lower

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

75 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

the feed reactivity and thus obtain a smooth control of temperature elevation in R-710 A/B first catalyst bed. The mixed stream is charged to the reactor after heating through E-701, reactor feed effluent heat exchanger. R-710 A/B reactor inlet temperature is controlled by by-passing part of the reactor effluent around E-701. During start-up periods, the temperature is controlled by means of the steam preheater E702. The reactions (diolefins and alkenyl aromatics hydrogenation) occur in mixed phase (mainly liquid) in a fixed bed type reactor R-710 A/B. The catalyst is divided into two beds. The overall temperature profile through the reactor is controlled by dilution of feed, as mentioned above, and by the injection of quench under temperature flow control cascade (TC at the inlet of second bed). Reactor R-719 effluent, partly cooled through E-701, is flashed into the Hot Separator, V-710. Part of the liquids is recycled as quench and dilution via the First stage quench pump, P-710 A/B and First stage quench cooler, E-711. The remainder is sent under level flow control cascade etc. the depentanizer, C-720. V-710 vapour phase is cooled down through the hot Separator Vapour Condenser , E-712 and flashed into cold separator V711. V-711 liquid is fed to C-720 under level control. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

76 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

V-711 vapour feeds the second stage reaction section as hydrogen rich make-up. Decoking drum V-713 collects the regeneration effluents of first and second stage reaction section, as well as C3 and C4 hydrogenation units. Depentaniser: The first purpose of the depentanizer C-720 is to stabilise the first reactor product by eliminating the light components which have been dissolved under high pressure in V-710 and V-711. The second purpose is to split the C5 cut from the C6+ cut. Stabilisation is performed in the uppermost trays. The overhead vapours of C-720

are condensed in the depentanizer

condenser, E-725 and the liquid collected in reflux drum, V-726. Reflux drum V-726 vapour phase is purged to flare or to cracked gas compressor under pressure control. The V-726 liquid is pumped by the depentanizer reflux pump, P725 A/B, as external reflux under flow control reset by level control.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

77 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

The C5 cut is withdrawn in liquid phase under temperature flow cascade control, and sent to battery limit after being water cooled through the C5 product cooler, E-726. The depentanizer reboiling is performed by the thermosyphon reboiler E-720. C6 + Cut is fed to the deoctanizer, C-730, under flow control reset by C-720 bottom level control. Deoctoniser: The purpose of the Deoctanizer, C-730 is to split the C6+ cut into C6-C8 cut and C9+ cut, and also to withdraw a C9-200 0C wash oil cut. C-730 is operated under slight vacuum in order to limit the bottom temperature to 1750c and to allow the reboiling with saturated LMP steam. Vacuum is maintained by means of steam ejector Z-736. The pressure is controlled at the top of C730 by recycling MP steam at Z-736 outlet into the ejector together with the non condensable components issued from the column through post condenser, E-736. The overhead vapours of C-730 are condensed in the deoctanizer condenser, E-735, and the liquid is collected in reflux drum, V-736. The Deoctanizer Reflux Pump, P-735 A/B, sends the external reflux to the column under flow control. The distillate feeds the

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

78 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

second stage reaction section via the 2nd stage feed pump, P736 A/B, under flow control, reset by V-736 level control. The Deoctanizer reboiling is performed by the thermosyphon reboiler, E-730 A/B which is controlled by temperature control of the bottom section of the tower. C9+ cut is sent to battery limit via the deoctanizer feed pump, P-730 A/B and water cooler, E-732. The wash oil is withdrawn as a vapour phase 3 trays above the bottom of the column. It is condensed in water cooler, E-731, and collected in the wash oil holding drum, V-731. It is sent to the battery limit via the wash oil transfer pump, P-731 A/B and wash oil trim cooler, E-737, under flow control.

2.24.3 Second Stage Reaction Section The feed to second stage reaction section is pumped via the 2nd stage feed pump, P-736 A/B under flow control reset by V736 level control. Fluctuation in V-736 level can also be smoothed by the option of sending feed to storage.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

79 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

The feed is mixed with recycle and make up gas at the compressor B-740 A/B discharge, before being heated up through E-740 A/B/C/D/E feed effluent exchanger and feed heater H-740. The second stage reactor inlet temperature is controlled by the furnace H-740. The reactions (hydrogenation of olefins and desulfurization) occur in vapour phase on a fixed bed type reactor R-740 filled with two types of catalysts :  LD 145 : mainly hydrogenation  HR306C : mainly desulfurisation. The temperature profile through the reactor is kept under control by the injection of quench between the two catalyst beds regulated by temperature control of the second bed. The effluent of R-740 is flashed in the second stage separator, V-740, after consecutive cooling in E-740 A/B/C/D/E and E-741 water cooler. V-740 vapour phase is partly released to flare or to cracked gas compressor under flow control. The overall pressure control is ensured from V-740 by action on H2 make-up to the first reaction section. Both reaction section pressures are controlled through this pressure control.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

80 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

The remaining vapour phase is recycled to the 2nd stage K.O. drum, V-741, where it is mixed with first stage cold separator, V-711, vapour, which is the h2 rich make up to the second stage reaction section. Both gases are sent under flow control back to the 2nd stage reaction section via the recycle and make up compressor, B740 A/B. The V-740 net liquid phase is fed to stripper section under level flow cascade control, while some liquid is recycled as quench to the reaction section via the 2nd stage quench pump, P-740 A/B. 2.24.4 Stripper Section The purpose of the stripper, C-750, is to eliminate H2S and light components dissolved at high pressure in the C6-C8 cut. Before being fed to the stripper, the C6-C8 cut is heated up against stripper bottom product through the feed / effluent exchanger, E-749 A/B. The stripper overhead vapours are partially condensed in the stripper Condenser, E-755 and collected in reflux drum V-756. The reflux is returned to the column by the reflux pump, P-755 A/B, under flow control reset by V-756 level control. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

81 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

V-756 vapour phase is purged to flare or to the cracked gas compressor under column overhead pressure control. The stripper reboiling is performed by the thermosyphon reboiler, E-750, using LMP steam. The bottom product is pumped under level control to battery limit by the C6-C8 product pump, P-750 A/B through the feed / effluent exchanger, E-749 A/B and water cooler E-751. the pump, P-752 is provided for the injection of corrosion inhibitor into the stripper overhead. The First stage reactor treatment furnace, H-710 is provided to service the First stage reactor R-710 A/B, and the C2, C3 and C4 reactors during catalyst treatments. The purpose of the spent caustic oxidation unit is to oxidise the sodium sulphide in the spent caustic as completely as practicable to harmless sodium sulphate, to cool the resulting effluent, and sent it to the effluent treatment plant. Spent caustic is gasoline washed, de-oiled, stripped with steam, cooled and sent to the SCO feed surge drum, V-1121, which is nitrogen-blanketed and vented to the wet flare system.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

82 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

Alternatively, the spent caustic feed is pumped from holding tank T-1101 A/B by P-1101 A/B, and sent to V-1121. Spent caustic from V-1121 is pumped by reactor feed pump P1121 A/B on flow control through feed / vent gas exchanger E1122 A/B, where it is heated on temperature control. The heated spent caustic is sent to the bottom of R-1122A, the first reactor in a series of three. The three reactors are fed with air

from reactor feed air

compressor B-1121 A/B/C, by way of air surge drum V-1123. The air is sent under pressure control through feed air filter Z1121 A/B/C to two flow controllers on each reactor, supplying a special distributor at the bottom of each reaction zone. Each distributor is also fed with desuperheated steam on flow control. Each reactor operates nearly full of liquid at 1300C, and is divided into two zones by a valve tray. The spent caustic flows slowly upward in contact with a stream of fine air bubbles. The reactor pressures are individually controlled to allow the flow of spent caustic through each reactor, under level control. On the spent caustic stream from each reactor, a filter Z-1123 A/B/C is provided for removal of possible agglomerated polymer. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

83 0 0 23/08/2015 BMK

SECTION

2

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

The residence time in each reactor is approximately 4 hours at the maximum design rate. The high reactor temperatures required for good oxidation are maintained by adjustment of the steam injection rates. The sulphide content is highest in R-1122A, which therefore requires more air than the other reactors. Heat from the oxidation reactions is also highest in R-1122A, causing its steam injection rate to be the lowest. Oxidised spent caustic from R-1122C is filtered in Z-1123C, cooled in E-1121 A/B, and released on level control to effluent surge drum V-1122. The vent gases from the reactors are released by their pressure controls, and combined before flowing through feed / vent gas exchanger E-1122A/B and vent gas cooler E-1123A/B to V-1122. Vent gas from V-1122 is released on pressure control to atmosphere at 400C. It consists mainly of nitrogen and oxygen, with a small amount of water vapour. The oxidised spent caustic from V-1122 at 400C is pumped by the effluent transfer pump P-1122 A/b on level control to the T-1101 product tank. This spent caustic is further neutralised in CPU pit to pH of 7.0 and pumped to effluent treatment plant.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

84 0 0 23/08/2015 BMK

SECTION

3

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

UTILITIES

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

85 0 0 23/08/2015 BMK

SECTION

3

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

3.1 Cooling Water System The cooling water in supplied by a dedicated cooling water tower at OSBL. The cooling water quality supplied has the following specifications : pH :

7.2 to 7.8

Total Dissolved Solids Max. 2500 ppm as caco3. Chlorides

Max. 200 ppm as cl.

Silica

Max. 100 ppm as S1O2

Free chlorine

Max. 0.5 ppm

Turbidty

Max. 15 NTV

Total viable count

Max. 0.3 million colonies per ml.

Total hardness as Caco3

500 max.

0.P04

6.5-9.0 ppm

T-PO4

9-14

Total FC

3.0 max.

Zinc as Zn

2.0 max.

Corrosion monitoring system is provided at ISBL at the inlet of E-230 exchangers. Cooling water supply temperature is 340C. In order to keep the circumstances to an optimum low quantity. a two level system with some cooling services operating at an intermediate inlet temperature of 390C which is known as cooling water tempered CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

86 0 0 23/08/2015 BMK

SECTION

MODULE NO.

3

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

(CWT). The maximum temperature rise through the entire circuit is 90C. The typical return temperature will be 430C. The cooling water supply pressure is 5.0 kg/cm2g with a return pressure of 2.5 kg/cm2g The cooling tower contains 16 cells and 8 main pumps and two stand by pumps which supply into the common CWS header of 54”

size.

Also

one

more

20”

parallel

supply

header

complements the cooling water supply to tertiary deethanizer. Auxiliary

C4

hydrogenation

and

propylene

fractionation

overhead condensers. Total of 54000 m3/hr cooling water supply requirement is met by light pumps running continuously. The preselected three standby pumps cut in on auto In case of drop in header pressure to 4.6 kg / cm2g. There are jumpover from CW supply to CW tempered and CW supply to CW return to balance the header requirements. However, these jump over valves are used only during start-up and remained closed during normal plant running. Apart from cooling water supply is provided to decoke pot scrubbing , furnace decoke header injection and pump seal / hearing house cooling which are routed to OWS system. This is provided

to

CHECKED BY N.S.P APPROVED BY B. DAS

convert

water

by

reducing

Process description and Utilities

service

PAGE REV ISSUE DATE AUTHOR

water

87 0 0 23/08/2015 BMK

SECTION

3

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

requirement and accomplishing cooling tower blowdown which otherwise it essential at holding tower to maintain circulating water quality.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

88 0 0 23/08/2015 BMK

SECTION

MODULE NO.

3

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

Cooling Water Balance Cooling Water User E-320 A-C E-330 A-C E-345 A-D A-101 Note 1 B-420/421 BTG-900 E-900 E-990 A/B E-645 BTG-600 E-960 E-980 BTG-650 B-965 BTG-300 E-930 E-981 E-982 E-699 A-K E-555 A-H E-556 E-565 E-725 E-736 E-737 E-738 (Note 1) E-751 E-755 E-910 E-920 E-735 E-273 B-458 E-455 E-456 A/B E-521 E-535 E-566 E-711 E-712 E-726 E-732 E-741 E-742 E-802 E-803 E-804 E-230 A-K E-373 E-220 A-G E-375 G-1000 (NOTE 1) E-1102 A/B E-921 (NOTE 1) E-341 P-900 A-C

CWS Header Flow (kg/h)

1.153.334 1.119.791 1.213.325 159,120 22,599 102,060 167,907 25,957 169,180 61,690

CWT Header Flow (kg/h) In Out

1.153.334 1.119.791 1.213.325 159,120 22,599 102,060 167,907 25,957 169,180 61,690

102,060

102,060

92,988

92,988

11,562,225 8,662,000 10,500 986,800 864,500 4,000 82,500 63.648 154,333 63,167 228,000 436,926 1,987,400 46,000 1,033,600 1,090,600 1,120,200 449,783 650,000 513,400 507,667 13,000 30,667 66,500 420,333 5,000 1,022,824 6,600 94,964 4,198,000 122,960

11,562,225 8,662,000 10,500 986,800 864,500 4,000 82,500 63,648 154,333 63,167 228,000 436,926 1,987,400 46,000 1,033,600 1,090,600 1,120,200 449,783 650,000 513,400 507,667 13,000 30,667 66,500 420,333 5,000 1,022,824 6,600 94,964 4,198,000 122,960

355,212 672,000 177,000 263,543 355,212 33,654

355,212 672,000 177,000 263,543 355,212

CHECKED BY N.S.P APPROVED BY B. DAS

CWR Header Flow (kg/h)

3,790,129 147,654

3,790,129 147,654

10,633,802

10,633,802

10,633,802 125,528 35,456

10,633,802 125,528 35,456

8,436,750

8,436,750

33,654

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

89 0 0 23/08/2015 BMK

SECTION

MODULE NO.

3 P-901 A/B P-989 A/B E-310 A-F E-274 E-537 SUB TOTAL BYPASS TOTAL

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

716 716 1,693,763 37,700 747,500 45,225,124

37,700 747,500 39,850,705

45,225,124

39,850,705

CHECKED BY N.S.P APPROVED BY B. DAS

716 716 1,693,763

Process description and Utilities

33,803,121 6,047,584 39,850,705

39,177,540 6,047,584 45,225,124

PAGE REV ISSUE DATE AUTHOR

90 0 0 23/08/2015 BMK

SECTION

MODULE NO.

3

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

Cooling Water Balance For 700 KTA Expansion Case ALL FLOWS ARE FROM LATEST ISSUE OF PROCESS DATA SHEETS @ 31 AUG.94 (DESIGN FLOW i.e.NORMAL OPG+ DESIGN MARGIN) PLUS AVAILABLE VENDOR DATA Cooling Water User E-320 A-C E-330 A-C E-345 A-D A-101 Note 1 B-420/421 BTG-900 E-900 E-990 A/B E-645 BTG-600 E-960 E-980 BTG-650 B-965 BTG-300 E-930 E-981 E-982 E-699 A-K E-555 A-H E-556 E-565 E-725 E-736 E-737 E-738 (Note 1) E-751 E-755 E-910 E-920 E-735 E-273 E-458 E-455 E-456 A/B E-521 E-535 E-566 E-711 E-712 E-726 E-732 E-741 E-742 E-802 E-803 E-804 E-230 A-K E-373 E-220 A-G E-375 G-1000 (NOTE 1) E-1102 A/B

CWS Header Flow (kg/h)

1,291,387 1,219,203 1,334,067 159,120 22,599 102,060 167,907 25,374 203,934 61,690

CWT Header Flow (kg/h) In Out

1,291,387 1,219,203 1,334,067 159,120 22,599 102,060 167,907 25,374 203,934 61,690

102,060

102,060

92,988

92,988

13,273,629 9,961,300 11,550 1,085,480 1,037,400 4,400 90,750 63,648 169,766 75,334 228,000 480,619 2,225,888 831,266 1,136,960 1,199,660 1,232,220 494,761 747,500 564,740 609,200 14,300 33,734 73,150 487,586 5,000 1,278,530 13,200 132,000 4,198,000 147,552

13,273,629 9,961,300 11,550 1,085,480 1,037,400 4,400 90,750 63,648 169,766 75,334 228,000 480,619 2,225,888 831,266 1,136,960 1,199,660 1,232,220 494,761 747,500 564,740 609,200 14,300 33,734 73,150 487,586 5,000 1,278,530 13,200 132,000 4,198,000 147,552

586,100 672,000 177,000

586,100 672,000 177,000

CHECKED BY N.S.P APPROVED BY B. DAS

CWR Header Flow (kg/h)

Process description and Utilities

3,790,129 147,654

3,790,129 147,654

10,633,802

10,633,802

10,633,802 125,528 35,456

10,633,802 125,528 35,456

10,602,000

10,602,000

PAGE REV ISSUE DATE AUTHOR

91 0 0 23/08/2015 BMK

SECTION

MODULE NO.

3 E-921 (NOTE 1) E-341 P-900 A-C P-901 A/B P-989 A/B E-310 A-F E-274 E-537 SUB TOTAL BYPASS TOTAL

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

263,543 565,168 33,654 716 716 1,836,442 41,470 747,500 51,613,821

263,543 565,168

51,613,821

45,738,516

33,654 716 716 1,836,442 41,470 747,500 45,738,516

35,968,371 9,770,146 45,738,516

41,843,676 9,770,146 51,613,821

Notes : 1. Cooling Water flows for E-738, G-1000, A-101 & E-921 are based on Reliance data. 2. Deleted 3. Cooling Water flows to analysers, analyser house and pump pedestals are not included (minimal, typically 1-6 litres/min).

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

92 0 0 23/08/2015 BMK

SECTION

MODULE NO.

3

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

3.2 Steam System The steam system is based on well established principles developed by S&W. The following sections shall be read with reference to Utility flow diagram enclosed : 3.2.1

Steam Levels

Five steam levels are employed with the ISBL. Steam Level SHP Steam HP Steam MP Steam LMP Steam LLP Steam

Pressure kg/cm2g Norma Min Max. l 105 102 107 40 38 42 17 15 18 12 11.5 13 3.5 3.0 4.5

Temperature Norma Min. l 510 480 373 360 255 235 260 240 187 165

0

C Max.

5100C 400 28 270

SHP Steam (SH) SHP Steam is generated in the main and cracking recycle furnaces is utilised for driving CG Compressor and propylene refrigeration compressor, along with import steam from OSBL. SHP Header float with OSBL 105 kg level header. Normally, SHP to M P let down remains closed and opens only during trip of any one of the two machines to satisfy HP steam demand. The import header is sized for 235 TPH.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

93 0 0 23/08/2015 BMK

SECTION

MODULE NO.

3

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

HP Steam (SM) HP Steam is drawn as extraction from propylene refrigeration turbine for ISBL requirements. Normally, no import or export of HP steam taken place. However, the header that with OSBL header. The header is sized for 60 TPH. Also HP to

LMP

letdown closed and opens only during trip of propylene refrigeration compressor. MP Steam (SMP) MP Steam is generated as extractor from cracked gas compressor turbine. This extraction pressure is selected to float with OSBL. existing pressure./ the header flats with OSBL header. Normally, any excess of MP Steam letdown to LMP steam is exported to OSBL network. However, import of steam takes place In case of CG Compressor trip beyond the requirement of letdown from HP to LMP steam. The import export header is sized for 100 TPH. MP SteamL (SLM) LMP Steam steam generated from the letdown of MP steam during

normal

operation

(or)

from

HP

steam

during

emergencies / shutdown. There is nor LMP pressure level OSBL. There is import / export facility for this steam.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

94 0 0 23/08/2015 BMK

SECTION

MODULE NO.

3

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

LLP Steam (SL) This steam is imported by letdown of 5.5 kg/cm2g pressure level at OSBL. to extent of excess requirements of let down from LMP Level. The import header is sized for 50 TPH. However, during start-up turndown and upsets two scenario is different depending on furnaces cracking and running of major turbine drives. 3.3 Condensate and Boiler feed water system The cracker plant is self sufficient to handle and recycle all the steam condenste into the BFW system after treatment. The facility for condensate, export to OSBL is also provided. For the net quantity of steam that is reported as there are no facilities to import condensate, this loss is made up from the import of DM water. The Boiler feed water is generated in deaerator from recycling of

clean

condensate

and

by

polishing

of

contaminated

condensate in condensate polishing units. DM water imported form OSBL is used to make up the loss of steam due to net export or otherwise and loss of condensate. This steam is heated and treated to meet boiler feed water for the generation of steam in furnace steam drums. Condensate Pressures : HP Condensate : 37 kg/cm2 LMP Condensate : 10 kg/cm2 CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

95 0 0 23/08/2015 BMK

SECTION

MODULE NO.

3

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

LLP Condensate : 2.5 kg/cm2 Condensate system is divided into two subsystems as clean condensate and support condensate. All high pressure HP, LMP from user equipment is condensate, flashed in flash drums to generate steam and the condensate is returned to deaerator directly as clean condensate. LLP condensate from user equipments where process side pressure is higher than the steam pressure is routed to suspect condensate vessel and subsequently sent to CPU for polishing or to deaerator through activated carbon filter. All surface condensate from CGC,C2,C3R turbines are sent to deaerator after polishing in condensate polishing unit. During start-up and upset conditions, surface condensate can be exported to OSBL, before polishing core after polishing. After deaeration and pH adjustment using ammonia, this is termed as Boiler, feed water. This BFW is pumped to furnace steam drums for steam generation for make up in main and auxiliary

dilution

steam

generation

systems

and

for

desuperheating in SHP to HP letdown system. Two motor driven and a turbine driven high pressure BFW pumps ate provided out of which two will be running normally and one motor driven pump as stand by on auto. In case of pressure drop in HP BFW CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

96 0 0 23/08/2015 BMK

SECTION

3

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

header, stand by pump takes auto start to maintain header pressure. One LP boiler feed water pump is running to supply water to desuperheating stations and nominal quantity is exported to aromatics plant. 3.4 Fuel Gas System: Cracker Plant is self sufficient of in fuel requirements. All fuel gas majority methane from demethanise, residue gas from chilling train and purge gas from PSA unit is mixed in fuel gas mixing drum and is consumed in main, recycle and GHU furnaces at 3.5 kg/cm2g pressure. Excess fuel gas during normal plant operation is exported at 5.5 kg/cm2 g pressure level from the

discharge off expander

compressor. Provision of using C4 raffinate from main and aux. C4 hydrogenation units (or) form OSBL storage is provided as back up. Provision of using propane / off .spec propylene from OSBL storage sphere. propane directly from propylene fracitonator is also provided.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

97 0 0 23/08/2015 BMK

SECTION

MODULE NO.

3

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

LPG from OSBL LPG bullets can also be routed to fuel gas system through vaporisers in case of requirement. Due to various combination of full from methane during normal operation to C4 raffinate during emergencies, homogeniser system is provided at the down stream of mixing drum to adjust density of fuel to furnaces. Fuel gas is first superheated with LLP steam and LMP steam is injected superheated in the homogeniser based on the density of the fuel gas entering the homogeniser. For initial start-up high pressure of fuel gas form OSBL is provided as make up into the fuel gas mixing drum. Design specification of fuel gas Mole% C1

92.5%

C2

1.68%

C3

0.1%

CO2

5.7%

H2O

0.01%

H2S

4 PPM mol/mol

Operating pressure

: 27 kg/cm2g

Operating temperature Design MW CHECKED BY N.S.P APPROVED BY B. DAS

: 1300C

: 17.9 Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

98 0 0 23/08/2015 BMK

SECTION

3

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

3.5 Nitrogen Process Air, Instrument Air System 3.5.1 Nitrogen Nitrogen is supplied to cracker at two pressure levels as HP Nitrogen and LP Nitrogen. This is supplied from air separation unit. 3.5.1.1 HP Nitrogen HP Nitrogen is used during start-up as a sealing medium for compressor during start-up air run. During normal operations. HP Nitrogen is used in pump seals. Apart from OSBL import, battery of HP nitrogen cylinders (two sets) is provided to maintain ISBL header pressure to PMP seals as back up in case of any drop in OSBL header pressure. 3.5.1.2 LP Nitrogen LP Nitrogen is used for various services as tank blanketing, seal gas for ethylene refrigerator compressors and for hose stations with NRV to cannot to any equipment for purging etc. Both HP & LP Nitrogen shall be oil free, dew point of -1000C at atmospheric pressure and max. oxygen gas content of 10 ppm mol/mol. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

99 0 0 23/08/2015 BMK

SECTION

MODULE NO.

3

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

Pressure HP Nitrogen

Normal

Min.

Max.

30

27

-

LP Nitrogen 3.5.2

7

-

8

Instrument Air

Instrument air is supplied form OSBL by CPP which is compressed, dried and free of oil. Two parallel headers one at 102 N piperack and other at 105 N pipe rack maintain the requirement of IA throughout the plant. Pressure kg/cm2g Min. Norma Max.

Temperature (0C) Min. Norma Max

l 7.0

l 45

4.5

7.5

30

50

(0C)

-40

3.5.3 Plant Air Plant air is supplied from OSBL by CPP which is compressed, saturated to moisture at the supply pressure. The oil content shall be max. 0.5 ppm wt/wt supply propane. The air is fed from the hose points to equipments which required deinertisation etc.

Min. 6.0

Pressure Normal 7.0

CHECKED BY N.S.P APPROVED BY B. DAS

Max. 8.0

Temperature Min. Normal Max. 30 45 50

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

100 0 0 23/08/2015 BMK

SECTION

MODULE NO.

3

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

3.6 Service Water System Service water which is treated raw water is supplied by CPP to OSBL which is used as service water at hose stations for washing

etc.

and

an

drinking

water

at

control

room,

changerooms and yard toilet. Also this water is supplied to laboratory for cleaning, washing etc. Specifications for Service Water pH :

7.8

Thurbidity :

2 NTV

Chloride :

32 ppm as cl.

Sulphate :

35 ppm as SO4

P-Alkalinity :

Nil

M-Alkalinity :

187 as Ca CO3 ppm

Total Anions :

269 as Ca CO3 ppm

Total Hardness :

134 as Ca CO3 ppm

Magnesium Hardness :

62 as Ca CO3 ppm

Sodium :

135 as Ca CO3 ppm

Total Cations :

269 as Ca CO3 ppm

Total Silica :

10 as SiO2 ppm

Collected silica :

0.2 as S1O2 ppm

Total iron :

0.5 as FE ppm

Total Dissolved solids :

CHECKED BY N.S.P APPROVED BY B. DAS

170 ppm

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

101 0 0 23/08/2015 BMK

SECTION

3

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

3.7 DM Water system DM water is imported from CPP at a maximum peak flow rate of 250 m3/hr during start-up and upsets. DM water is received in DM water storage tank and pumped to deaerator as make-ups. Also provision is provided for make up into quench water tower for make up. during upsets / start-up, DM water consumption is minimised by recycling the condensate from various system. DM water from OSBL has the following specifications : pH :

6.5 to 7.0

Total dissolved solids :

0.5 ppm

Total hardness :

Nil

Chlorides :

Nil

Iron :

.005 ppm as FE

Electricity conductivity :

0.2 ms/cm

Total silica :

0.02 as SiO2 ppm

Sodium :

Nil

Colour :

Colourless

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

102 0 0 23/08/2015 BMK

SECTION

3

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

3.8 Fire water system Fire water is received from the hydrant header surrounding the plant ISBL from OSBL fire water system. Every area is provided with divide headed fire hydrant points with fire hose box adjacent to them. Each hydrant point has an isolation valve and hydrant points (single) on the structures has been provided with common isolation valve at grade. Apart from hydrant points, on line water monitors are provided at strategic locations. Quench fittings on main and recycle furnaces are provided with manual deluge system to be care of any fire emergency at this locations. Headers in each area of the plant can be isolated by closing slice valves provided at both the ends of the network. (Refer enclosed singe line sketch).

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

103 0 0 23/08/2015 BMK

SECTION

3

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

3.9 ELECTRIC POWER SYSTEM : Electrical power at 33 KV, 50 Hz for start-up and normal operations shall be available from the OSBL central electrical power handling facility at the battery limit. The electrical power system is characterised as follows :

Particulars A B

C D

Specification

Frequency of all AC power supply Electrical Power Generation : Emergency Generator : Type Voltage Level Primary Distribution in OSBL: Type Voltage Level DC Power supply system: Voltage Level a)

Suggested Users

50 HZ # 3% AC 3 phase 415 V # 6% AC, 3 phase 33 KV # 5% 220 V -20%

+

10%,

Critical lighting supply for breakers, annunciators.

control circuit alarm

110 V -20%

+

10%,

Shutdown system solenoid valves) existing plant area.

b) (all in

c) 24 V DC E a)

Other AC Power Supply System : Type Voltage Level Type Voltage Level

AC 3 phase 6.6 KV # 6% AC, 3 phase 415 V # 6%

c

Type Voltage Level

AC 1 phase 240 V # 6%

d

Type Voltage Level UPS based Non UPS CHECKED BY N.S.P

b

APPROVED BY B. DAS

AC, 1 phase 110 V # 2% 110 V # 5% Process description and Utilities

Relay logic, switches, solenoid valves in ISBL. Motor drives above 160 KW Motor drives (0.18 KW to 160 KW, lighting, welding machine, overhead crane. Motor drives below 0.18 KW & control supply for 415 V motor contactor, instrument cabinet lighting, hand lamp socket, portable tools, motor panel / space heater, plant communication, fire alarm, level gauge illumination. All instrument, DCS PAGE REV ISSUE DATE AUTHOR

104 0 0 23/08/2015 BMK

SECTION

MODULE NO.

3 e

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

Type Voltage Level

AC, 1 phase 24 V # 6%

For handheld / portable lighting

UTILITY CONDITIONS AT BATTERY LIMIT ALL STREAM PRESSURE SHALL BE CONSIDERED AS AT GRADE LEVEL : Sl.

Particulars

Unit

Operating Conditions Minimum Normal Maximu

Design

m A B C D E F G H I J K L M N

SHP Steam Pressure Temperature HP Steam : Pressure temperature HP Steam (Import): Pressure Temperature LMP Steam (Export): Pressure Temperature LP Steam (Import): Pressure Temperature LLP Steam (Export): Pressure Temperature Steam Condensate (Export): Pressure (note-3) Temperature Instrument Air : Pressure Temperature Plant Air Pressure Temperature LP Nitrogen Gas: Pressure Temperature HP Nitrogen Gas: Pressure Temperature Service Water Pressure Temperature Fire Water: Pressure Temperature Cooling Water Supply Pressure

CHECKED BY N.S.P APPROVED BY B. DAS

kg/cm2g C

102 485

105 500

107 510

112 (4) 510

kg/cm2g C

38 360

40 373

42 400

47 420

kg/cm2g C

15 235

17 245

18 280

22 350

kg/cm2g C

11.5 240

12 260

13 270

15 300

kg/cm2g C

4 160

4.5 170

5.5 200

8.1 270

kg/cm2g C

3.0 165

3.5 187

4.5 (4)

6.5 250

kg/cm2g C

3 AMB

4.5 AMB

kg/cm2g C

4 30

6.5 45

7.5 50

10.5 65

kg/cm2g C

4 30

7.0 45

7.5 50

10.5 65

kg/cm2g C

7 Ambient

8 Ambient

9

10.5 65

kg/cm2g C

30 Ambient

32 Ambient

33 Ambient

40 65

kg/cm2g C

4 Ambient

5.5 Ambient

7 Ambient

10 65

kg/cm2g C kg/cm2g

17.9 65

10 Ambient 4.0

Process description and Utilities

5

PAGE REV ISSUE DATE AUTHOR

12 65 6

105 0 0 23/08/2015 BMK

8.0

SECTION

3

MODULE NO.

Supply Temperature

O P Q

C

Return Pressure Return Temperature Demineralized (DM) Water: Pressure Temperature Drinking Water Pressure Temperature LP Boiler Feed Water: Pressure Temperature

CHECKED BY N.S.P APPROVED BY B. DAS

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

Ambient

34

34

65

kg/cm2g C

2.5 43

kg/cm2g C

5 Ambient

7.5 Ambient

10 65

1 Ambient

3.0

5.0 65

kg/cm2g C

0.5 Ambient

kg/cm2g C

Process description and Utilities

8.0 65

21.2 115

PAGE REV ISSUE DATE AUTHOR

33.5 17.0

106 0 0 23/08/2015 BMK

SECTION

4

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

EFFLUENTS

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

107 0 0 23/08/2015 BMK

SECTION

4

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

4.0 Plant effluents and Disposal Methods: Due to complex nature of operations, a variety of solid, gaseous and liquid effluents are obtained form the gas cracker plant. This is intended that all operating personnel shall take all necessary measures to minimise effluents generation. 4.1 Solid effluents: Coke: Coke is the solid waste product obtained during decoking operation from the decoke pots and during hydrojetting of USX and collection headers. This is being disposed off to OSBL as land fill. By the addition of DMDS to the feed of cracking main and recycle furnaces, this coke formation is minimised. 4.2Gaseous effluents : Flue Gases : There are produced in cracking furnaces and in GHU furnaces which are released to atmosphere continuous. The quality of this effluent from cracking furnace is continuously monitored by one line CO and O2 analysers. Also, complete emission constituents are analysed by central environmental monitoring cell to ensure adherence to local statutory requirements.

Gases Hydrocarbons

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

108 0 0 23/08/2015 BMK

SECTION

4

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

During normal operation, no gases effluents are produced as most all of the vent gases are recycled into the process system for recovery. Few discharges as GHU stripper vent and spent caustic oxidation stripper vents are routed into flare system where they are flared at 110 M high level. For the completion of combustion, steam is injected into the flare system. Also, hydrocarbon vent during unit upset is routed to flare stack for complete combustion and safe disposal. 4.3Liquid Effluents : Storm Water : Water during rains is collected in the ISBL by means of catch pits and are routed to two storm water walls, located at north and south side of the plants with slice gate to stop flow into the storm water channel. During normal season, the water collected into these walls from fire water drain, boiler drum CBD, decoke pot drain and steam condensate drains are pumped to effluent treatment plant for suitable treatment and disposal. During monsoon, water collected in these walls overflow into the storm water channel and are disposed into Tapi River entry.

Oily water sewer :

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

109 0 0 23/08/2015 BMK

SECTION

4

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

Water containing traces are hydrocarbon, seal cooling liquid form pump seals, dil. steam generation blowdown, suspect condensate drain, and other process aqueous plant drain are collected into OWS well via hubs connected to underground closed piping system. This

is pumped to effluent treatment

plant for suitable treatment and disposal. Spent Caustic Effluent : Spent Caustic from Caustic Tower after treatment with gasoline and additives is pumped to spent caustic oxidation unit where COD and sulfur content is reduced to the great extent. Also, stripper provided at the upstream of spent caustic oxidation unit removes aromatic components. Thus this effluent is neutralised with hydrochloric acid to pit of 7.0 and pumped to effluent treatment plant for disposal. CPU regeneration waste : Regeneration water effluent from condensate polishing unit is mixed along with SCO effluent and neutralised to pH 7.0 and sent to ETP for disposal. Quench oil sewer : All heavy oil drains in the prefractionation area is collected in a hubs which are connected to double pipe underground network to drain drum. From the drain drum it is recycle back into quench oil tower or can be sent to OSBL storage tanks. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

110 0 0 23/08/2015 BMK

SECTION

5

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

EMERGENCIES

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

111 0 0 23/08/2015 BMK

SECTION

5

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

5.0 Emergency Shutdown In all cases of emergency, the Operator in charge shall exercise his discretion regarding shutdown, bearing in mind : a) The safety of Personnel b) The safety of equipment Failure of an individual pumping unit, where a standby unit is available for immediate service; individual instrument, failure, where bypass or direct manual control (handjack) is available, and similar isolated or individual failures must not be treated as requiring emergency shutdown. Momentary failure of any utility should be treated as a temporary emergency and any tripped equipment or its standby unit must be commissioned, as quickly as possible. quench oil failure must not be treated as requiring emergency shutdown. Quenching of the furnace effluent is automatically continued by naphtha. Continue operation unit it is obvious that oil circulation can't be restored and a planned shutdown is then carried out. Shutdown of the furnaces should be undertaken if the base liquid level of the quench oil tower, C-210, approaches the transfer line inlet nozzle elevation and disposal of quench oil continues to be a problem. If quenching of the furnace effluent is insufficient for any reason, hydrocarbon feed should be taken out of the furnaces. If a compressor should trip due to CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

112 0 0 23/08/2015 BMK

SECTION

5

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

an in-built safety system, the fault should be cleared before restart; trips must not be overridden. The extent to which the furnaces are kept on line during such an emergency will depend upon individual circumstances but there should be normally no necessity to use an emergency trip on the furnaces. The trip of any system, and in particular the reactor systems, must be thoroughly investigated before attempting to bring them back into operation. Again no emergency trip of any other equipment should be necessary in this case. Emergency shutdowns will be carried out for the following events : 1. Total and sustained electric power failure 2. Total and sustained cooling water failure. 3. Total and sustained instrument air failure 4. Loss of steam pressure 5. Uncomfortable leakage of hydrocarbons 6. Serious and uncontrollable fire. The P&I diagrams show the major automatic alarm and shutdown systems included in the plant. SOP must be consulted as necessary for detailed operation.

Electric Power Failure CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

113 0 0 23/08/2015 BMK

SECTION

5

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

A sustained power failure is regarded as a remote possibility but would however result in the shutdown of : -furnaces, due to induced draft fan failure (SD-2 -pumps and normal plant lighting Motor driven compressors Actions to be taken if Power is not Immediately Restored: a) Block off all hydrogen supply to the C2 Hydrogenation Reactors,

depressurise the reactors

and nitrogen and

nitrogen purge. Block in regeneration air flow if any is being used. Refer to the IFP Operating Manuals for information on handling the C3,C4 Gasoline Hydrogenation units. b) Close cracking furnace burner cocks, block in hydrocarbon fuel supply, close dampers to reduce rate of refractory cooling. Close decoking air if any was used. Try to maintain dilution steam to furnaces as long as is necessary to purge coils. c) If available, continue cooling water flows to all units. Release excessive pressures in equipments to the flare, using safety valve bypass valves, or depressurization control valves, in preference to allowing the safety valves to lift and possibly not reset. d) Block in cracked gas dehydrators, take note of regeneration status when blocking in regeneration lines. e) Shut off heating medium to fractionation tower reboilers at control valves and / or block valves. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

114 0 0 23/08/2015 BMK

SECTION

MODULE NO.

5

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

f) Isolate the various refrigeration stages by block valves to prevent pressure migration, if it is decided to shutdown the compressors. g) Reduce liquid levels in towers and drums to near normal, by either pressuring to the next process sequence or to blowdown

drums,

circumstances.

In

the

choice

general,

being

where

a

dependent restart

upon

after

an

emergency shutdown is anticipated fairly soon, levels should be maintained at the optimum to facilitate the restart. h) Equipment should be shutdown and shut in as far as possible by means of control room instruments, particular attention being paid to equipment pressures. Cooling Water Failure Cooling Water failure will automatically trip all USC and Recycle furnaces to SD-2 -CG Compressor -C2 Hydrogenation unit on offspec. Actions to be taken at a Sustained Water Failure a) Block in furnaces as under 9.2.1(b) b) Stop electrically driven process compressors (B-740 A/B) and block in. c) Stop all heating media to reboilers. d) Remove hydrogen from reactors and block in as under 9.21. (a)

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

115 0 0 23/08/2015 BMK

SECTION

MODULE NO.

5

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

e) Stop charge pumps, stop reflux pumps as reflux drum levels drop. f) On a system by system basis release excessive pressures in equipment to the flare only when required, using safety valve bypass valves or drpressurization control valves, in preference to allowing the safety valves to lift and possibly not reset. Great care must be taken not to overload the flare relief system by dumping large relief loads simultaneously. g) Reduce liquid levels in towers and drums to near normal by either pressuring to the next process sequence or to blowdown

drums,

circumstances.

In

the

choice

general,

being

where

a

dependent restart

upon

after

an

emergency shutdown is anticipated fairly soon, levels should be maintained at the optimum, to facilitate the restart. h) Equipment should be shutdown and shut in as far as possible, by means of the control room instruments, particular attention being paid to equipment pressures. i) Stop the pumping of fresh caustic solution to the caustic wash tower. j) Stop the injection of DMDS to the Furnaces and shutdown all other process chemicals injection systems. k) Stop all product withdrawal Instrument Air Failure Air failure would be result in the failure of activating air to control valves. the instrument design of the plant is such that

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

116 0 0 23/08/2015 BMK

SECTION

5

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

the valves move to put the plant in the safest possible condition under the circumstances. Action to be taken on a General Instrument Air Failure All automatic valves will have gone to the fail-safe position, block valves on the following systems should also be closed to make doubly sure of safe conditions. a) Block off hydrogen to all reactors, proceed as under 9.2.1(a). b) Shutdown furnaces as under 9.2.1(b). c) block in compressors and refrigeration system. d) Block in cracked gas dehydrators as under 9.2.1(d). e) Isolate the various refrigeration stages to prevent pressure migration. f) Block off heating medium to reboilers, preheaters, etc. g) Reduce liquid levels in towers drums to normal working levels by use of control valve bypasses pressuring to the next process sequence or the blowdown drum, maintaining adequate levels to facilitate the starting operation. Loss of steam pressure Dependent upon the steam main involved various emergencies could occur and the senior operator will need to exercise his discretion upon the appropriate action to be taken. IN all cases every effort must be made to continue dilution steam flows to the cracking furnaces until all hydrocarbon materials are purged out.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

117 0 0 23/08/2015 BMK

SECTION

5

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

Action to be taken a) Conserve the dilution steam main pressure as long as possible, reducing higher pressure steam consumption wherever possible. b) Activate shutdown 1 on all furnaces. This will cut out furnace feed, add dilution steam to the hydrocarbon coils and cut 60% of the heat input to the furnaces. c) If dilution steam failure is imminent, activate shutdown 2 on all furnaces. In addition to the SD-1 trips, this will cut out all gas burners and after a short purge period, shut off the dilution steam flow. It is possible that furnaces which suffer dilution steam failure before the short purge period will require decoking before the next start-up. d) If the S-105 steam supply pressure falls, stop the cracked gas compressor to maintain the Refrigeration Compressors in service if required depending on the steam demand at low levels. NOTE : When intending to shutdown furnaces or any other equipment in an emergency situation, do not proceed by an indirect route, i.e. making a process alteration which will in normal sequence lead to the desired shutdown action.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

118 0 0 23/08/2015 BMK

SECTION

5

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

If shutdown 1 or 2 on the furnaces is called, for, activate the switches provided, checking that all furnace conditions proceed thereby to the desired safe condition.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

119 0 0 23/08/2015 BMK

SECTION

MODULE NO.

5

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

Uncontrollable Leakage and Fire Actions to be taken at the occurrence of a large leakage or fire will obviously depend upon the location of the fire, the proximity of other inflammable materials and numerous other variables. Company standard fire drill procedures should be followed while the plant is being shutdown in as orderly a manner as possible, extinguishing all furnace burners as quickly as possible, stopping fans and closing furnace stack dampers, isolating the burning equipment and cutting off supplies of inflammable material to the source of the fire. Motor operated isolation valves are installed on the common suction lines to all hydrocarbon pumps and are also installed on the first stage suction, third stage discharge, and the fourth stage suction and discharge of the cracked gas compressor, and the suction and discharge of all stages of the propylene and ethylene refrigerant compressors, and also major product streams. All these valves are operable from the field so that easier isolation can be achieved. In the case of pumps, the pump motor is tripped when the remote isolation switch is activated. Snuffing steam purges to pump seals are provided with remote field valves. During

any

containment

plant of

emergency

gaseous

and

or

normal

liquid

shutdown,

hydrocarbons

the with

controlled release to the flare and blowdown must be enforced. Inflammable liquids accidentally entering surface drainage CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

120 0 0 23/08/2015 BMK

SECTION

5

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

systems and hydrocarbon vapours can lead to hazardous conditions or an increase in an existing conflagration.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

121 0 0 23/08/2015 BMK

SECTION

6

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

EQUIPMENT LIST

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

122 0 0 23/08/2015 BMK

SECTION

MODULE NO.

6

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

6.0 Equipment List Section 1 2 3 4 5 6 7 8 9 10

Title BUILDINGS ROTATING EQUIPMENTS TOWERS EXCHANGERS GENERAL EQUIPMENT FURNACES PUMPS REACTORS TANKS DRUMS

BUILDINGS

A A A A A A A A A A A A A A

CHECKED BY N.S.P APPROVED BY B. DAS

ITEM NO.

DESCRIPTION

003 004 101 105 110 120 301 401 410 450 510 601 701 901

Mechanical Workshop/Dining Room HVAC Chilling Unit Compressor House MCC & Control house Gas Turbine Control House Furnace Analyser Shelter No.1 Furnace Analyser Shelter No.2 Cracker Gas Compressor Shelter Methane Compressor Shelter Cold Fractionation Analyser Shelter No.1 Cold Fractionation Analyser No.2 Warm Fractionation Analyser Shelter Refrigeration Compressor Shelter G.H.U. Compressor Shelter Fuel Gas Compressor Shelter

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

123 0 0 23/08/2015 BMK

SECTION

MODULE NO.

6

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

ROTATING EQUIPMENT ITEM NO. B 100 B 101 A/B B 102 B 103 B 110 B 111 B 120 B 121 B 130 B 131 B 140 B 150 B 160 B 170 B 180 B 190 B 192 B 194 B 196 B 300 B 420 B 421 B 600 B 650 B 710 A/B B 740 A/B B 900 B 915 B 1101 A/B B 1121 A/B/C BT 102 BT 300 BT 600 BT 650 BT 900

CHECKED BY N.S.P APPROVED BY B. DAS

QTY. 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 2 3 1 1 1 1 1

DESCRIPTION Gas Turbine FD Fan (Motor Driven) FD Fan (Motor Driven) GT Fuel gas Compressor ID Fan (USC Furnace) ID Fan (USC Recycle Furnace) ID Fan (USC Furnace) ID Fan (USC Recycle Furnace) ID Fan (USC Furnace) ID Fan (USC Recycle Furnace) ID Fan (USC Furnace) ID Fan (USC Furnace) ID Fan (USC Furnace) ID Fan (USC Furnace) ID Fan (USC Furnace) ID Fan (USC Furnace) ID Fan (USC Furnace) ID Fan (USC Furnace) ID Fan (USC Furnace) Cracked Gas Compressor Methane Recompressor Methane Expander Ethylene Refrigerant Compressor Propylene Refrigerant Compressor 1st Stage Make-up and Recycle Compressor 2nd Stage Make-up and Recycle Compressor Fuel Gas Compressor Polisher Air Blower High Pressure Air Compressors SCO Reactor Feed Air Compressor FD Fan Turbine Cracked Gas Compressor Turbine Ethylene Refrigerant Compressor Turbine Propylene Refrigerant Compressor Turbine Fuel Gas Compressor Turbine

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

124 0 0 23/08/2015 BMK

SECTION

MODULE NO.

6

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

TOWERS

C C C C C C C C C C C C C C C C C C C C C C C C C C C

ITEM NO. 210 220 230 240 250 260 270 280 340 350 360 410 420 430 440 460 470 510 530 535 540 550 560 720 730 750 1101

CHECKED BY N.S.P APPROVED BY B. DAS

QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

DESCRIPTION Quench Oil Tower Quench Water Tower Heavy Fuel Oil Stripper Light Fuel Oil Stripper Distillate Stripper LP Water Stripper Dilution Steam Stripper Auxiliary Dilution Steam Stripper Caustic Tower Cracked Gas Rectifier Condensate Stripper Demethanizer Prestripper Demethanizer Residue Gas Rectifier Deethanizer Ethylene Stripper Ethylene Rectifier Depropanizer Secondary Deethanizer Tertiary Deethanizer Propylene Stripper Propylene Rectifier Debutanizer Depentanizer Deoctanizer Stripper Steam Stripper

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

125 0 0 23/08/2015 BMK

SECTION

MODULE NO.

6

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

EXCHANGERS ITEM NO. E011 E 041 E 051 A/B E 052 E053 E 110 A/H, J/Q E 111 E 115 A/D E 120 A/H, J/Q E 121 E 125 A/D E 130 A/H, J/Q E 131 E 135 A/D E 140 A/H, J/Q E 141 E 150 A/H, J/Q E 151 E 160, A/H, J/Q E 161 E 170 A/H, J/Q E 171 E 180 A/H, J/Q E181 E 190 A/H, J/Q E 191 E 192 A/H, J/Q E 193 E 194 A/H, J/Q E 195 E 196 A/H, J/Q E 197 E 210 A/C E 215 A/B E 219 E 220 A/G E 230 A/H, J/K E 239

CHECKED BY N.S.P APPROVED BY B. DAS

QTY. 1 1 2 1 1 16 1 4 16 1 4 16 1 4 16 1 16 1 16 1 16 1 16 1 16 1 16 1 16 1 16 1 3 2 1 7 10 1

DESCRIPTION Ethane/Propane Recycle Heater Naphtha Feed Heater AGO Feed Heater AGO Feed Heater No.2 AGO Feed Heater No.3 USX Exchanger (USC Fresh Feed Furn.) TLX Exchanger (USC Fresh Feed Furn.) USX Exchanger (USC Fresh Feed Furn.) USX Exchanger (USC Fresh Feed Furn.) TLX Exchanger (USC Fresh Feed Furn.) USX Exchanger (USC Fresh Feed Furn.) USX Exchanger (USC Fresh Feed Furn.) TLX Exchanger (USC Fresh Feed Furn.) USX Exchanger (USC Fresh Feed Furn.) USX Exchanger (USC Fresh Feed Furn.) TLX Exchanger (USC Fresh Feed Furn.) USX Exchanger (USC Fresh Feed Furn.) TLX Exchanger (USC Fresh Feed Furn.) USX Exchanger (USC Fresh Feed Furn.) TLX Exchanger (USC Fresh Feed Furn.) USX Exchanger (USC Fresh Feed Furn.) TLX Exchanger (USC Fresh Feed Furn.) USX Exchanger (USC Fresh Feed Furn.) TLX Exchanger (USC Fresh Feed Furn.) USX Exchanger (USC Fresh Feed Furn.) TLX Exchanger (USC Fresh Feed Furn.) USX Exchanger (USC Fresh Feed Furn.) TLX Exchanger (USC Fresh Feed Furn.) USX Exchanger (USC Fresh Feed Furn.) TLX Exchanger (USC Fresh Feed Furn.) USX Exchanger (USC Fresh Feed Furn.) TLX Exchanger (USC Fresh Feed Furn.) Fuel Oil Product Cooler Quench Water Steam Heater Pan Oil Trim Cooler Primary quench water cooler Secondary quench water cooler LFO Stripping Steam Superheater

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

126 0 0 23/08/2015 BMK

SECTION

MODULE NO.

6

E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E

ITEM NO. 250 258 259 265 A/B 269 270 A/D 271 A/H 273 274 279 280 A/C 310 A/C 310 A/F 320 A/C 330 A/C 340 341 345 A/D 355 359 360 A/B 371 372 373 374 375 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 419 420 421 422

CHECKED BY N.S.P APPROVED BY B. DAS

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

QTY. 1 1 1 2 1 4 8 1 1 1 3 6 3 3 1 1 4 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

DESCRIPTION Distillate Stripper Reboiler Water Stripper Feed Heater DSS Bd./Water Stripper Feed Heater DSS Feed Heater No.1 DSS Feed Heater No.2 DSS Steam Reboiler DSS Q.O. Reboiler DSS Blowdown Cooler Auxiliary Dilution Steam Stripper Blowdown Cooler Aux. Dilution Steam Stripper Feed Heater Aux. Dilution Steam Stripper Reboiler C.G. First Stage Aftercooler C.G. Second Stage Aftercooler C,G. Third Stage Aftercooler Weak Caustic Heater Wash Water Cooler C.G. Fourth Stage Aftercooler C.G. Rectifier Overhead Condenser Condensate Stripper Feed Heater Condensate Stripper Reboiler Condensate Stripper Reboiler React. Gas Feed / Effluent Exchanger React. Gas Feed Heater Reactivation Gas Feed Cooler Reactivation Gas Feed Chiller Reactivation Gas Effluent Cooler Demethanizer Precooler No.1 Demethanizer Precooler No.2 Demethanizer Precooler No.3 Demethanizer Precooler No.4 Demethanizer Precooler No.5 Demethanizer Precooler No.6 Demethanizer Parallel Precooler No.1 Demethanizer Parallel BTMS Reheater Demethanizer Parallel Precooler No.2 Demethanizer Prestripper Reboiler Demethanizer Core Exchanger No.1 Demethanizer Core Exchanger No.2 Demethanizer Core Exchanger No.3 Demethanizer Core Exchanger No.4 Demethanizer Core Exchanger No.5 Hydrogen Core Exchanger Demethanizer Reboiler Demethanizer Parallel Precooler No.3 Demethanizer Parallel Precooler No.4

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

127 0 0 23/08/2015 BMK

SECTION

MODULE NO.

6

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

EXCHANGERS

E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E

ITEM NO. 424 425 426 427 438 439 A/B 440 A/C 445 A/D 450 452 A/D 455 456 A/B 458 460 461 470 A/B 475 A/D 477 478 480 481 482 490 491 A/B 510 A/B 515 A/B 521 522 530 535 536 537 540 A/D 541 A/B 542 555 A/H 556 560 A/B 565 566 645

CHECKED BY N.S.P APPROVED BY B. DAS

QTY. 1 1 1 1 1 2 3 4 1 4 1 2 1 1 1 2 4 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 4 2 1 8 1 2 1 1 1

DESCRIPTION Demethanizer Precooler No.6 Demethanizer Condenser Methane Product Heater Methane Product Heater Demethanizer Bottoms Reheater Demethanizer, Prestripper Btms Reheater Deethanizer Reboiler Deethanizer Condenser C2 Hydrog. Feed Heater C2 Hydrog. Feed / Effluent Exchanger C2 Hydrog. Adia. Rct. Intercooler No.2 C2 Hydrog. Adia. Rct. Aftercooler C2 Hydrog. Adia. Rct. Intercooler No.1 Ethylene Stripper Reboiler Ethylene Recycle Vaporiser Ethylene Rectifier Reboiler Ethylene Rectifier Condenser Ethylene Product Vaporiser Ethylene Product Superheater Ethylene Product Cooler No.1 Ethylene Product Cooler No.2 Ethylene Product Cooler No.3 HP Ethylene Product Heater No.1 HP Ethylene Product Heater No.2 Depropanizer Reboiler Depropanizer Condenser Interstage Cooler Catalyst Treatment Secondary Deethanizer Reboiler Secondary Deethanizer Condenser Tertiary Deethanizer Reboiler Tertiary Deethanizer Condenser Propylene Tower Reboiler Propylene Tower Aux. Reboiler Propane Recycle Vaporiser Propylene Tower Condenser Propylene Product Cooler Debutanizer Reboiler Debutanizer Condenser Pyrolysis Gasoline Product Cooler C2 Refrigerant Desuperheater No.1

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

128 0 0 23/08/2015 BMK

SECTION

MODULE NO.

6

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

EXCHANGERS

E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E

ITEM NO. 646 647 649 A/B 650 695 699 A/H, J/K 701 702 711 712 713 720 725 726 730 A/B 731 732 735 736 737 738 740 A/B 741 742 749 A/B 750 751 755 801 802 803 804 805 806 807 808 900 902 903 904 905 906 907 909

CHECKED BY N.S.P APPROVED BY B. DAS

QTY. 1 1 2 1 1 10 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 5 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

DESCRIPTION C2 Refrigerant Desuperheater No.2 C2 Refrigerant Desuperheater No.3 Aux. C2 Refrigerant Condenser C2 Refrigerant Subcooler C3 Refrigerant Desuperheater C3 Refrigerant Condenser 1t Stage Reactor Feed/Effl. Exchanger 1st Stage Reactor Start-up Heater 1st Stage Quench Cooler Hot Separator Vapour Condenser 1st Stage Compressor Bypass Cooler Depentanizer Condenser Depentanizer Condenser C5 Product Cooler Deoctanizer Reboiler Wash Oil Condenser Deoctanizer Bottoms Cooler Deoctanizer Condenser Decoct Post Condenser Cooler Wash Oil Trim Cooler Ejector Condenser 2nd stage Feed / Effluent Exchanger 2nd stage Reactor Effluent Cooler 2nd stage Compressor Bypass Cooler Stripper Feed / Effluent Exchanger Stripper Reboiler C6-C8 Product Trim Cooler Stripper Condenser Reactor start-up heater Recycle Cooler Post Condenser Product Cooler C4H Startup Heater (Unit-2) C4H Recycle Cooler (Unit-2) C4H Postcondensor (Unit-2) C4H Product Cooler (Unit-2) Fuel Gas Compressor Recycle Cooler Cold Blowdown Vaporiser C5 Fuel Vaporiser Suspect Cond. Drum vent Condenser C3/C4 Fuel Vaporiser Fuel gas Superheater Methanol Vaporiser Cold Flare Superheater

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

129 0 0 23/08/2015 BMK

SECTION

MODULE NO.

6

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

EXCHANGERS

E E E E E E E E E E E E E E E E E E E E E E

ITEM NO. 910 920 921 922 930 938 960 961 965 966 980 981 982 990 A/B 1101 1102 A/B 1103 1104 1105 1121 1122 1123

CHECKED BY N.S.P APPROVED BY B. DAS

QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1

DESCRIPTION Knock-out Drum Slops Cooler Contaminated Condensate Cooler Condensate Polisher Inlet Cooler CPU Effluent Heat Exchanger C.G. Comp. Steam Turbine Condenser Ejector Condenser C2 Refrig. Comp. Steam Turb Condenser Z-960 Ejector Condenser C3 Refrig. Comp. Steam Turb Condenser Z-965 Ejector Condenser C2/C3 Refrig. Compressor Lube/Seal Oil Cooler CG Compressor Lube Oil Cooler Cg Compressor Seal Oil Cooler Fuel Gas Compressor Lube / Seal Oil Cooler Steam Stripper Feed Pre-heater Steam Stripper Effluent Cooler Influent / Effluent Heat Exchanger Oxidation Reactor Effluent Cooler SCO Treated Effluent Cooler SCO Effluent Cooler SCO Feed / Vent Gas Exchanger SCO Vent Gas Cooler

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

130 0 0 23/08/2015 BMK

SECTION

MODULE NO.

6

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

GENERAL EQUIPMENT: ITEM NO. BG 300 BG 650 BL 300 BL 650 BL 900 BS 300 BTG 300 BTG 600 BTG 650 BTG 900 G 101 G 711

QTY. 1

Turning Gear Motor

1 1 1 1 1 1 1 1 1 1

CG Compressor Lube Oil Console E 650 & E 600 LO/SO Console FG Compressor LO/SO Console CG Compressor Seal Oil Console CG Compressor Gland Stm Ejector Pkg C2 Refrig. Comp. Gland Stm. Ejector Pkg C3 Refrig Comp Gland Stm. Ejector Pkg Fuel Gas Comp Gland Stm Ejector Pkg Main Control Room HVAC Package Polymerisation Inhibitor Package Including : T-711, Z-711, P-711 A-D Deoctanizer Ejector System DMDS Injection Package Including: P-742 Corrosion Inhibitor Injection Package Including : T-752, Z-752, P-752 Phosphate Injection Package Including : T-981, Z-981, P-981 A/C Hydazine Injection Package Including: T-982, Z-982, P-982 A/B DMDS Injection Package Including : T-986, P-986 A/B, P-995 A/D Corrosion Inhibitor Package Including: T-987. Z-987, P-987 A/B Defoaming : T-987, Z-987, P-987 A/B Including : T-988, Z-988, P-988 A/B Spent Caustic Oxidation Unit Quench Fitting (USC Furnace) Quench Fitting (USC Recycle Furnace) Quench Fitting (USC Furnace) Quench Fitting (USC Recycle Furnace) Quench Fitting (USC Recycle Furnace) Quench Fitting (USC Furnace) Quench Fitting (USC Furnace) Quench Fitting (USC Furnace) Quench Fitting (USC Furnace) Quench Fitting (USC Furnace) Quench Fitting (USC Furnace) Quench Fitting (USC Furnace) Quench Fitting (USC Furnace) Quench Fitting (USC Furnace) Quench Fitting (USC Furnace) Quench Oil Filters

G 736 G 742

1 1

G 752

1

G 981

1

G 982

1

G 986

1

G 987

1

G 988

1

G 1000 Z 110 Z 111 Z 120 Z 121 Z 130 Z 131 Z 140 Z 150 Z 160 Z 170 Z 180 Z 190 Z 192 Z 194 Z 196 Z 210 A/B

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

CHECKED BY N.S.P APPROVED BY B. DAS

DESCRIPTION

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

131 0 0 23/08/2015 BMK

SECTION

MODULE NO.

6

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

GENERAL EQUIPMENT

Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z

ITEM NO. 230 A/B 261 A/B 300 301 320 330 335 340 341 342 343 344 400 401 601 602 610 A/B 611 660 690 701 702 A/B 711 736 740 752 900 901 A/B 902 A/B 903 A/B 904 A/B 905 906 910 914 930 960 965 981 982 987 988 990

CHECKED BY N.S.P APPROVED BY B. DAS

QTY. 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1

DESCRIPTION Heavy Fuel Oil Filter Water Stripper feed Filters Oil Purifier Cracked Gas Compressor Service Crane Vane Separator for 2nd stage suction drum Vane Separator for 3rd stage Suction Drum Vane Separator for 3rd stage suction drum Vane separator for 4th Stage Suction Drum Caustic Diluent Mixer Week Caustic Circ. Pump Suction Strainer Spent Caustic / Aromatic Gasoline Mixer Caustic Area Sump Pressure Swing Adsorption Unit Methane Comp. Service Crane Main Compressor Service Crane Ethylene Compressor Service Crane Ethylene Refrigerant Oil Filters Vane Separator for C2R 1st Stage Suction Drum Vane Separator for C3R 1st Stage Suction Drum Vane Separator for C3R 4th Stage Flash Drum GHU Compressor Service Crane RPG Feed Filters Polymerisation Inhibitor Mixer Deoctanizer Ejector System 2nd stage ejector Corrosion Inhibitor Mixer Condensate Polisher S40 Desuperheater S12 Desuperheater S3.5 Desuperheater Suspect Condensate Filters GHU Reboiler Steam Desuperheater SMP Extraction Steam Desuperheater Flare System (outside Battery Limits of Cracker) Polisher Acid Tank Agitator CG Compressor Turbine Ejector Package C2 refrig Compressor Turbine Ejector Pkg C3 refrig compressor Turbine Ejector Pkg Phosphate tank Agitator Hydrazine Tank Agitator Corrosion Inhibitor Tank Agitator Defoaming Agent Tank Agitator Emergency Power generator

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

132 0 0 23/08/2015 BMK

SECTION

MODULE NO.

6

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

GENERAL EQUIPMENT

Z Z Z Z Z Z Z Z Z Z Z Z

ITEM NO. 995 A/B 996 1101 1103 1104 1121 1122 1123 A/B/C 1124 1125 1126 1127

QTY. 2 1 1 1 2 1 1 3 1 1 1 1

DESCRIPTION Storm Sewer Collection Sump OWS Collection Sump Vapour Scrubber SCO Steam Desuperheater Carbon Canisters SCO Feed Air Filter SCO Reactor Feed Filter SCO Reactor Effluent Filters SCO SLM Steam Desuperheater SCO Reactor Sparger Capsules (1 Lot) SCO Feed Steam Filter SCO Vent Gas Silencer

FURNACES

H H H H H H H H H H H H H H H H H

ITEM NO. 110 111 120 121 130 131 140 150 160 170 180 190 192 194 196 710 740

CHECKED BY N.S.P APPROVED BY B. DAS

QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

DESCRIPTION USC Fresh Feed Furnace USC Recycle Furnace USC Fresh Feed Furnace USC Recycle Furnace USC Fresh Feed Furnace USC Recycle Furnace USC Fresh Feed Furnace USC Fresh Feed Furnace USC Fresh Feed Furnace USC Fresh Feed Furnace USC Fresh Feed Furnace USC Fresh Feed Furnace USC Fresh Feed Furnace USC Fresh Feed Furnace USC Fresh Feed Furnace 1st Stage Reactor Treatment Furnace 2nd Stage Reactor Feed Heater / Regeneration Furnace

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

133 0 0 23/08/2015 BMK

SECTION

MODULE NO.

6

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

PUMPS

P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P

ITEM NO. 210 A/C 211 A/B 220 A/C 221 A/B 225 A/C 230 A/B 240 A/B 250 A/B 260 A/B 270 300 A/B 310 A/B 320 A/B 341 A/B 342 A/B 343 A/B 344 A/B 345 A/B 346 A/B 347 A/B 348 A/B 349 355 A/B 360 A/B 400 A/B 401 425 A/B 445 A/B 451 A/C 470 A/B 475 A/B 515 A/B 516 A/B 520 A/B 530 A/B 535 A/B 536 A/B 537 A/B 550 A/B 555 A/B 565 A/B 701 A/B 710 A/B

CHECKED BY N.S.P APPROVED BY B. DAS

QTY. 3 2 3 2 3 2 2 2 2 1 2 2 2 2 2 2 2 2 2 2 2 1 2 2 2 1 2 2 3 2 2 2 2 2 2 2 2 2 2 2 2 2 2

DESCRIPTION Q.O. Circulating Pump Pan Oil Circulating Pump Quench Water Circulating Pump Quench Oil Tower Reflux Pump Secondary Quench Water Circ. Pump Heavy Fuel Oil Product Pump Light Fuel Oil Product Pump Distillate Stripper Bottoms Pump Dilution Steam Stripper Feed Pump QO Drain Drum Pump Wash Oil Injection Pump C.G. 1st Stage Condensate Pump Distillate Stripper Feed Pump Concentrated Caustic Pump Weak Caustic Circulating Pump Medium Caustic Circulating Pump Strong Caustic Circulating Pump Wash Water Circulating Pump Caustic Area Sum[p Pump Aromatic Gasoline Circulating Pump Spent Caustic Discharge Pump Aromatic Gasoline Injection Pump Cracked Gas Rectifier Reflux Pump Condensate Stripper Bottoms Pump Methanol Pump Methanol Unloading Pump Demethanizer Reflux Pump Deethanizer Reflux Pump C4 Coolant Circ. Pump Ethylene Rectifier Bottoms Pump Ethylene Rectifier Reflux Pump Depropanizer Reflux Pump C3 Hydrogenation Feed Pump C3 Hydrogenation Recycle Pump Secondary Deethanizer Bottoms Pump Secondary Deethanizer Reflux Pump Tertiary Deethanizer Bottoms Pump Tertiary Deethanizer Reflux Pump Propylene Transfer Pump Propylene Tower Reflux/Product Pump Debutanizer Reflux/Product Pump 1st Stage Feed Pump 1st Stage Quench Pump

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

134 0 0 23/08/2015 BMK

SECTION

MODULE NO.

6

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

PUMPS

P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P

ITEM NO. 711 A/B 725 A/b 730 A/B 731 A/B 735 A/B 736 A/B 740 A/B 742 750 A/B 752 755 A/B 801 A/B 802 A/B 803 A/B 900 A/C 901 A/B 902 A/B 910 A/C 914 915 A/B 916 A/B 917 930 A/B 931 A/B 932 A/B 942 A/B 956 A/B 960 A/B 961 A/B 965 A/B 971 A/B 974 A/B 981 A/C 982 A/B 983 A/C 985 A/D 986 A/C 987 A/B 988 A/B 989 A/B 990 A/B 991 A/C

CHECKED BY N.S.P APPROVED BY B. DAS

QTY. 4 2 2 2 2 2 2 1 2 1 2 2 2 2 3 2 2 3 1 2 2 1 2 2 2 2 2 2 2 2 2 2 3 2 3 4 3 2 2 2 2 3

DESCRIPTION Polymerisation Inhibitor Pump Depent anizer Reflux Pump Deoctanizer Bottoms pump Wash Oil Transfer Pump Deoctanizer Reflux Pump 2nd Stage Feed Pump 2nd stage Quench Pump DMDS Injection Pump C6-C8 Product Pump Corrosion Inhibitor Pump Stripper Reflux Pump Feed Pump Recycle Pump C4 Product Pump Boiler Feed Water Pump LP Boiler Feed Water Pump knock-out Drum Slops Pump Boiler Feedwater Make-up Pump CPU Feed Pump Polisher Caustic Pump Polisher Acid Pump Polisher Effluent Pump CG Compressor Turbine Condensate Pump Cracked Gas Compressor Seal Oil Pump Cracked Gas Compressor Lube Oil Pump Methane Expander / Rcomp. Condensate Pump Debutanizer Reboiler Condensate Pump C2R Comp. Turbine Condensate Pump C2/C3 Refrig Comp. Lube / Seal Oil Pump C3R Comp. Turbine Condensate Pump S/E LO Pump B-710 A/B S/E LO Pump B-740 A/B Phosphate Injection Pump Hydrazine Injection Pump Polymerisation Inhibitor Injection Pump Fresh Feed Furnaces DMDS Injection Pumps DMDS Injection Pump Corrosion Inhibitor Injection Pump Defoaming Agent Injection Pump Suspect Condensate Pump Fuel Gas Compressor Lube / Seal Oil Pump Boiler Feedwater Lube Oil Pump

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

135 0 0 23/08/2015 BMK

SECTION

MODULE NO.

6

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

PUMPS

P P P P P P P P P P

ITEM NO. 992 A/B 995 A/D 996 A/B 997 A/B 1101 A/B 1102 A/B 1103 A/B 1104 A/B 1121 A/B 1122 A/B

CHECKED BY N.S.P APPROVED BY B. DAS

QTY. 2 4 2 2 2 2 2 2 2 2

DESCRIPTION Aux. Corrosion Inhibitor Injection Pumps Storm Sewer Transfer Pump OWS Transfer Pump Portable Dewatering Pump Spent Caustic Feed / Recycle Pump High Pressure Feed Pumps Effluent Transfer Pumps Steam Stripper Bottoms Pump SCO Reactor Feed Pump SCO Effluent Transfer Pump

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

136 0 0 23/08/2015 BMK

SECTION

MODULE NO.

6

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

REACTORS

R R R R R R R R R R R R R R

ITEM NO. 451 A/C 452 A/B 531 A 531 B 531 C 532 710 A/B 740 801 802 803 804 1101 1122 A/B/C

QTY. 3 2 1 1 1 1 2 1 1 1 1 1 1 3

DESCRIPTION C2 Hydrog. Adiabatic Reactor Prim. C2 Hydrog. Adiabatic Reactor C3 Hydrog. Reactor # 1 C3 Hydrog. Reactor # 2 C3 Hydrog. Reactor # 3 C3 Hydrog. Second Stage Reactor First Stage Reactor Second Stage Reactor Hydrogenation Reactor Final Hydrogenation Reactor C4H Reactor (Unit-2) C4H Final Hydrog. Reactor (Unit-2) Oxidation Reactor SCO Reactor

TANKS

T T T T T T T T T T T T T T T T T

ITEM NO. 300 340 400 711 752 900 910 914 915 916 981 982 983 986 987 988 1101 A/B

CHECKED BY N.S.P APPROVED BY B. DAS

QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

DESCRIPTION Wash Oil Tank Concentrated Caustic Tank Methanol Tank Polymerisation Inhibitor Tank Corrosion Inhibitor Tank CPU Feed Surge Drum BFW Make-up Storage Tank Polisher Acid Storage Tank Polisher Caustic Tank Polisher Acid Tank Phosphate Mixing Tank Hydrazine Mixing Tank Polymerisation Inhibitor Tank DMDS Tank Corrosion Inhibitor Mixing Tank Defoaming Agent Mixing Tank Spent Caustic Holding Tank

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

137 0 0 23/08/2015 BMK

SECTION

MODULE NO.

6

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

DRUMS

V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V

ITEM NO. 061 110 111 120 121 130 131 140 150 160 170 180 190 192 194 196 198 199 262 A/B 270 310 320 330 335 340 342 343 346 359 370 A/B 371 403 406 410 411 412 413 414 415 416 417

CHECKED BY N.S.P APPROVED BY B. DAS

QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1

DESCRIPTION LPG/C4 raffinate Vaporiser Feed Drum Steam Drum (USC Furnace) Steam Drum (USC Recycle Furnace) Steam Drum (USC Furnace) Steam Drum (USC Recycle Furnace) Steam Drum (USC Furnace) Steam Drum (USC Recycle Furnace) Steam Drum (USC Recycle Furnace) Steam Drum (USC Recycle Furnace) Steam Drum (USC Recycle Furnace) Steam Drum (USC Recycle Furnace) Steam Drum (USC Recycle Furnace) Steam Drum (USC Recycle Furnace) Steam Drum (USC Recycle Furnace) Steam Drum (USC Recycle Furnace) Steam Drum (USC Recycle Furnace) Decoke Drum Separator/Silencer Decoke Drum Separator/Silencer Water Stripper Feed Coalescer Quench Oil Drain Drum CG First Stage Suction Drum CG Second Stage Suction Drum CG Third Stage Suction Drum CG Third Stage Discharge Drum CG Fourth Stage Suction Drum Spent Caustic Deoiling Drum Spent Caustic Degassing Drum Cracked Gas Rectifier Reflux Drum Condensate Stripper Feed Coalescer Cracked Gas Dehydrators Reactivation Gas Separator Demethanizer Preclr. No.3 Refrig. Flash Pot Demethanizer Preclr. No.6 Flash Pot Demethanizer Prestripper Feed Drum Demethanizer Feed Drum No.1 Demethanizer Feed Drum No.2 Demethanizer Feed Drum No.3 Demethanizer Prestripper Parallel Feed Drum Demethanizer Parallel Feed Drum No.1 Demethanizer Parallel Feed Drum No.2 Demethanizer Parallel Feed Drum No.3

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

138 0 0 23/08/2015 BMK

SECTION

MODULE NO.

6

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

DRUMS

V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V

ITEM NO. 418 419 420 422 423 424 425 426 431 432 436 445 446 453 A/B 455 460 476 477 480 481 482 490 516 519 525 536 537 556 566 610 620 630 645 646 650 660 670 680 690 695 696 701 710

CHECKED BY N.S.P APPROVED BY B. DAS

QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

DESCRIPTION Methane Expander 2nd Stage Suction Drum E-419 Knockout Drum Demethanizer Reboiler Refrig. Seal Pot Demethanizer Parallel Precooler # 4 Flash Pot A Demethanizer Parallel Precooler # 4 Flash Pot B Demethanizer Parallel Precooler # 6 Flash Pot B Demethanizer Condenser Refrig Flash Pot Demethanizer Reflux Drum Hydrogen Drum PSA Unit Surge Drum Residue Gas Rect. Reflux Drum Deethanizer Condenser Refrig. Flash pot Deethanizer Reflux Drum Secondary Dehydrators C2 Hydrogenation Effluent Separator Ethylene Stripper Refrig. Seal Pot Ethylene Rectifier Reflux Drum Ethylene Prod. Vaporiser Refrig. Seal Pot Ethylene Product Cooler No.1 Refrig. Flash Pot Ethylene Product Cooler No.2 Refrig. Flash Pot Ethylene Product Cooler No.3 Refrig. Flash Pot HP Ethylene Product Heater No.1 Seal Pot Depropanizer Reflux Drum C3 Hydrogenation Feed Coalescer C3 Hydrogenation Separator Secondary Deethanizer Reflux Drum Tertiary Deethanizer Reflux Drum Propylene Rectifier Reflux Drum Debutanizer Reflux Drum Ethylene Refrig. 1st Stage Suction Drum Ethylene Refrig. 2nd Stage Suction Drum Ethylene Refrig. 3rd Stage Suction Drum Ethylene Refrigerant Surge drum Ethylene Refrigerant Drain Drum Ethylene Refrigerant Subcooler Flash pot Propylene Refrig. 1st Stage Suction Drum Propylene Refirg. 2nd Stage Suction Drum Propylene Refrig. 3rd Stage Suction Drum Propylene Refrig. 4th Stage Suction Drum Propylene Refrigerant Surge Drum Propylene Refrigerant Drain Drum Feed Surge Drum 1st Stage Hot Separator

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

139 0 0 23/08/2015 BMK

SECTION

MODULE NO.

6

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

DRUMS ITEM NO. V 711 V 712 V 713 V 726 V 731 V 736 V 737 V 740 V 741 V 756 V 801 V 802 V 803 V 804 V 805 V 606 V 807 V 808 V 900 V 901 V 902 V 904 V 905 V 906 V 907 V 908 V 915 A-C v 916 V 917 V 920 V 926 V 927 A/B V 928 V 930 V 931 V 932 V 937 V 940 V 945 V 946 V 954 V 956 V 961 V 972

CHECKED BY N.S.P APPROVED BY B. DAS

QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

DESCRIPTION 1st Stage Cold Separator 1st Stage Knock-out Drum Decoking Drum Depentanizer Reflux Drum Wash Oil Holding Drum Deoctanizer Reflux Drum Z-736 Oily Water Separator 2nd Stage Separator Drum 2nd Stage Knock-out Drum Stripper Reflux Drum Feed Surge Drum Hot Separator Cold Separator C4 Product Flash Drum C4H Feed Surge Drum (Unit-2) C4H Hot Separator (Unit-2) C4H Cold Separator (Unit-2) C4 Product Flash Drum (Unit-2) Deaerator Cold Flare Knock-out Drum Hot Flare Knock-out Drum S3.5 Suspect Condensate Drum AGO Feed Heater No.3 Condensate Pot AGO Feed Heater No.2 Condensate Pot Methanol Vaporiser No.1 Condensate Pot Cold Blowdown Vaporiser Condnesate Pot Polisher Mixed Beds Polisher Regn Vessel Polisher Effluent Vessel S40 Steam Condensate Flash Drum DSG Feed Heater No.2 Condensate Pot DSG Reboiler Condensate Pots Quench Water Steam Heater Condensate Pot S12 Steam Condensate Flash Drum Continuous Blowdown Drum Intermittent Blowdown Drum Reactivation Gas Heater Condensate Pot Fuel Gas Mixing Drum C2 Hydrog. Feed Water Condensate Pot C2 Hydrog. Adia Reactor Feed Htr Cond. Pot Propylene Tower Reboiler Condensate Pot Debutanizer Reboiler Condensate Pot LPG/C4 Raffinate Vaporiser Cond Pot Depentanizer Reboiler Condensate Pot

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

140 0 0 23/08/2015 BMK

SECTION

MODULE NO.

6

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

Table 1

V V V V V V V V V V

ITEM NO. 973 975 980 981 1101 1102 1103 1121 1122 1123

CHECKED BY N.S.P APPROVED BY B. DAS

QTY. 1 1 1 1 1 1 1 1 1 1

DESCRIPTION Deoctoniser Reboiler Condensate Pot Stripper Reboiler Condensate Pot C3/C4 Fuel Vaporiser Condensate Pot Fuel Gas Superheater Condensate Pot Steam Stripper Feed Preheater Condensate Pot Water K.O. Drum SCO Reactor Feed Surge Drum SCO Feed Surge Drum SCO Effluent Surge Drum SCO Air Surge Drum

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

141 0 0 23/08/2015 BMK

SECTION

7

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

FLARE SYSTEM

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

142 0 0 23/08/2015 BMK

SECTION

7

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

7.1 Pressure Relief, Blowdown and flare system 7.1.1 Pressure Relief Valve Header System Within Cracker Plant, a relief valve Header system is provided to collect hydrocarbon discharges : 1. The C2 & lighter effluents which below -450C are collected in the cold flare header made of autenitic

steel subjected to

gravity separation in the cold flare knockout drum and steam superheated prior to being discharged to the hot flare header. 2. Cold dry effluents (basically C3) at temperatures from 0C to -450C are collected in the intermediate flare header (IF) which is (LTCS) subjected to gravity separation in the same knock-out drum as the C2 and lights effluents. 3. Hot wet effluents above 0C are collected in a carbon steel header and subjected to gravity separation in the horflare knockout drum. The gases from this drum joined by the superheated effluent from the cold knockout drum and sent to OSBL flare stack. 4. Cold flare knock out drum vaporiser which vaporises any liquid lighters and the outlet superheater is provided, heated by steam via an intermediate methanol loop as a heating medium.

7.1.2 Blowdown System CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

143 0 0 23/08/2015 BMK

SECTION

7 Blowdown

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

Systems

are

provided

to

remove

residual

hydrocarbon only during unit shut down or fire emergency. The drains of all hydrocarbons that will vaporise when opened to atmosphere are routed to the blowdown system. Hot blowdown is having CS piping (above 0C) and cold blown is provided with SS headers. These drain are collected in a common headers and terminate in their corresponding relief valve header KW drums. Provision is made for vaporising any coalesced liquids. In cold flare knockout drum, a steam heated indirect exchanger is used while in hot flare knock out drum a steam coil is used. Any accumulated liquid from cold or hot flare knock out drum are pumped either to quench oil tower or to OSBL. 7.2 Flare system at OSBL Flare from cracker ISBL, Tank farm, MEG & Aromatics gaseous effluents are collected in the common header and are routed to OSBL flea stack system. Flare stack system, corrosion of knock out drum where any liquid is separated. Then gases are passed to liquid drum where these gases bubbled through water seal and reach the flea stack. Then there gases pass through molecular seal at the stack top and are burnt at the flare tip. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

144 0 0 23/08/2015 BMK

SECTION

7

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

4 No.s of burners continuously burn at the tip which is supplied by fuel gas separately. Flare front generator located at grade provides necessary ignition for putting pilots on these are designed remain on even during heavy wind with rain. Each pilot is provided with a thermocouple which sends any loss of flare and connected to alarm. System both out the local panel and in DCS. Also, one thermocouple provided at the centre of the tip gives warning incase of any burnback., Two stages of steam are provided one at the centre into the flare trip to cool the flea provides steam for complete combustion. Centre, steam is adjusted manually at controlled rate and the QS steam which is varied in accordance to the flow to obtain smokeless flare. Flare stack design parameters Flare Gas: Flow Rate : 1,050,689 kg/hr Mot. Wt. : 33.26 Temp.: 800C

Pilot Gas: Type : Fuel Gas CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

145 0 0 23/08/2015 BMK

SECTION

7

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

Pressure : 1002 kg/cm2g MW : 19.57 Steam : Pressure : 7.03 kg/cm2g @ flare trip. Flow max. : 32,659 kg/hr QS manifold @ 7.03 kg/cm2g Flow : 430 kg/hr. Cooling rate for QS manifold Flow Max. : 3855 kg/hr. through centre tip @ 7.03 kg/cm2g Flow : 225 kg/cm2g cooling rate for center tip @ 7.03 kg/cm2 OPERATING INSTRUCITONS : Pre-Start Up Check List Before starting up the flare, checks should be made for the following items : 1. Verify that all the flare components are installed in accordance with the reference drawings. 2. If chromel-alumel Type K thermocouples are used, the blue wire is negative (-) and the brown wire is positive (+). 3. All system lines should be dry and free of dirt and foreign material. 4. Check that all drain and vent valves are closed and that all drain and vent plugs are tightly secured. A drain plug or valve is required at each low point in each pilot ignition line. 5. All manual valves in the pilot gas and waste gas systems should be closed. 6. Check that all set points are properly adjusted.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

146 0 0 23/08/2015 BMK

SECTION

7

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

7. The pilot ignition lines must be dry and unobstructed so that the flame front is not quenched or blocked. Start-Up and Operation Procedures for Smokeless Flare System (QS-C): The EEF-QS-60/66C flare uses 4 Energy Efficient Pilots as an ignition source. The flare is equipped with a 8” QS Steam Manifold and steam injectors capable of providing 32,659 kg/hr of saturated steam @ 7.03 kg/cm2g. A 3” Centre Steam Sparger is included which is capable of providing 3,855 kg/hr of saturated steam @ 7.03kg/cm2g. A continuous steam flow of 375 kg/hr should be maintained to the QS Steam Manifold for cooling and to prevent cracking of the steam injectors and manifold. The centre steam sparger requires 225 kg/hr of cooling steam. 1. Start up and operation: Light the pilots: The method of lighting the 4 pilots should be carried out using the flame front generator panel. (refer to appendix “A” “Operating Instructions for Flame Front Generator” - Bulletin 5401E (2 pages). c) Introduce the cooling steam flow to the Centre Steam (225 kg/h). The Centre Steam rate should be set manually.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

147 0 0 23/08/2015 BMK

SECTION

7

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

d) Introduce the cooling steam flow to the upper QS Steam Ring (375 kg/hr). e) Start the waste gas flow at a nominal vent rate (500-1000 kg/hr) f) With the QS Steam set at the cooling rate of 375 kg/hr, adjust the Centre Steam until smokeless operation is achieved. It may be necessary to make this adjustment several times with the flea receiving gas at the nominal vent rate. When the required Centre Steam rate is achieved, it should be changed. It is suggested that the Centre Steam manual valve handle be removed. Since one of the purposes of the Centre Steam is to prevent burn-back inside the flare tip, it is advisable to observe the flare tip at night for a glow (excessive heat) below the flare tip exit. The above procedure should be followed for initial start-up. g) During a flaring event, the steam flow to the QS Steam Manifold should be adjusted to the point where smoke is not visible and the flame is a yellow orange colour. The amount of steam to achieve this is anticipated to be 0.4 kg steam per 1.00 kg. waste hydrocarbon. h) After cessation of a flaring event, the QS Steam Manifold rate should be returned to a rate of 375 kg/h for cooling. Do not readjust the centre steam rate as the flare will still be experiencing a nominal vent rate of waste gas. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

148 0 0 23/08/2015 BMK

SECTION

7

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

2. Shut down a) Close the steam supply valves to the QS Steam Manifold on the flare trip. Close the steam supply to the Centre Steam Sparger. c) Shut Down the purge gas flow : d) Extinguish the pilots by closing the pilot fuel gas block valve. e) Close all hand valves. f) Close all utility gas supply systems OPERA TING INSTRUCITIONS FOR FLAME FRONT GENERATOR

Important : A. All ignition lines must be one rich. B. All low spots in ignition lines must be drained Note : Sagging between supports is sufficient to cause low spots in the line which can hold liquids and quench ignition flame. C. Confirm that all utilities are connected and operating properly per the job drawing. Ignition : 1. Purge flare system with nitrogen or fuel gas until all oxygen has been replaced with purge gas. Blow down air and gas supply lines to flame front generator at blow down valves to remove condensate. Open all drains in the low spots of ignition lines. Blow down each ignition line, one at CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

149 0 0 23/08/2015 BMK

SECTION

7

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

a time, through valves A,E and C. Close all drains. Check each ignition line for blockage by opening valve D and at a time. When valve D is closed, pressure should fall off rapidly on the pressure gauges. If pressure does not fall off rapidly, investigate and correct the blockage in the ignition line. 3. Push switch ‘F” actuate Magiclite to check for spark at the sight port. 4. Open valve “A’. Close valve “B” and “C” to ignite pilot No.1 5. Open valve “H”. This is the fuel for pilots. 6. Open valve “E” and set pressure gauge at 10 psig. (gas). 7. Open valve “D” and set pressure gauge at 13 psig. (air). 8. Wait two to three minutes after opening valves E and D. 9. Push and release quickly, switch “F”. At the same time observe through the sight port to see if air/gas mixture was ignited. (If same is not observed, change either the air or gas slightly until flame is observed). If the system uses Magiclite ignitor, actuate as if you were using switch “F”. 10. If pilot does not light, repeat steps 8 and 9. 11. If repeating steps 8 and 9 two or three times does not ignite the pilot, change air or gas pressure slightly using valve “D” or valve “E”. Repeat steps 8 and 9 until pilot is ignited. 12. Close valve “A”. Open valve “B” to ignite Pilot No.3. Repeat steps 8 and 9 until the pilot is ignited. 14. When all pilots are ignited, close valves ‘D” and “E”.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

150 0 0 23/08/2015 BMK

SECTION

7

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

15. On light or sunny days, if is difficult to observe pilot flame to verify ignition. To observe pilot flame, close valve “D” and open valve “E” fully for two or three minutes. If ignited, pilot flame will become luminous. This can be repeated for each pilot by opening and closing valves A,B, and C. 16. After all pilots are ignited and verified, the flea is ready for operation. Waste gas can now be flared provided the remainder of each system is operational. 1. If no spark is observed, check the electrical circuit and the spark gap (1/16-1/8 inch). If a blue flash cannot be observed at the sight glass, check for gas and air delivery as follows : A. Disconnect the spark plug lead and remove sight glass. B. Check for air delivery by opening valve “D” and check for gas delivery by opening valve “E”. C. If a noticeable hiss does not occur, break the piping union and check orifices at “I” (air). and “J” (gas). 3. If the pilot will not light and the above have been confirmed. A. Check the piping between the flame front generator and the pilot to ensue no low points in the piping have filled with condensate. B. Ensure that pilot gas pressures is per job drawing. If a fuel gas other than that specified on the job drawing used, the orifices “I” and “J” must be resized. Please contact John Zink in Tulsa for specific recommendations.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

151 0 0 23/08/2015 BMK

SECTION

8

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

FIRE & GAS DETECTION SYSTEM

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

152 0 0 23/08/2015 BMK

SECTION

8

1.

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

INTRODUCTION

Industrial processes increasingly involve the use and manufacture of highly dangerous substances, particularly toxic and combustible gases. Inevitably, occasional escapes of gases occur creating a potential hazard to the industrial plant, its employees and people living nearby. In most industries, one of the key parts of any safety plan for reducing the risks to personnel and plant is the earlywarning device such as Gas Detectors. These can help to provide more time in which to take remedial or protective action. They can also be used as part of total, integrated monitoring and safety system for an industrial plant. This report is intended to offer an overview of the Fire and Gas Detection System in Naphtha Cracker plant in RIL, Hazira. It provides a brief explanation of the principles involved in such systems and the instrumentation needed for satisfactory protection of personnel and environment. Some of the topics related to the Fire and Gas Detection system are also discussed.

2.

COMBUSTIBLE GASES

Combustion is basically a simple chemical reaction, in which oxygen combines rapidly with another substance resulting in the release of energy. This energy appears mainly as heat - sometimes in the form of flames. The igniting substance is normally, but not always, an organic or hydrocarbon compounds and can be a solid, liquid, vapor or gas.

AIR

HEAT FIRE FUEL

The process of combustion can be represented by the well-known fire triangle. As can be seen, three factors are always needed i.e. a source of ignition, oxygen and fuel in the form of combustible gas or vapor. In any fire prevention system, therefore, the aim is always to remove at least one of these potentially hazardous items.

3.

TOXIC GASES

Though there is a large group of gases, which are both combustible and toxic, the hazards and the regulations involved and the types of sensor required are different for the two categories of the gases. With toxic substances, (apart from the obvious environmental problems) the main concern is the effect on workers of exposure to even very low concentrations, which could be inhaled, ingested or absorbed through the skin. It is important not only to measure the concentration of gas, but also the total time of exposure, since adverse effects can often result from additive, long-term exposure. Sometimes these substances can interact and produce a far worse effect when together than the separate effect of each on its own. Concern about concentrations of toxic substances in the workplace focus on both organic and inorganic compounds, including the effects they could have on the health and safety of employees, the CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

153 0 0 23/08/2015 BMK

SECTION

8

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

possible contamination of a manufactured end product (or equipment used in its manufacture) and also the subsequent disruption of normal working activities. Concentrations of gas in air are expressed as parts per million (ppm), which is a measure of gas concentration by its volume.

4.

EXPLOSIVE LIMITS

There is only a limited band of gas/air concentration, which will produce a combustible mixture. This band is specific for each gas and vapor and bounder by an upper level, known as the Upper Explosive Limit (UEL) and a lower level, called the Lower Explosive Limit (LEL). 100% gas 0% air TOO RICH UEL FLAMMABLE RANGE LEL TOO LEAN

100% air 0% gas

At levels below the LEL, there is insufficient gas to produce an explosion (i.e. the mixture is too lean), whilst above the UEL, the mixture has insufficient oxygen (i.e. the mixture is too rich). The flammable range therefore falls between the limits of the LEL and UEL for each individual gas are mixture of gases. Outside these limits, the mixture is not capable of combustion.

5.

HAZARD ZONES

Not all areas of an industrial plant or site are considered to be equally hazardous. For instance, an underground coal mine is considered at all times to be an area of maximum risk, because some methane gas can always be present. On the other hand, a factory where methane is occasionally kept on site in storage tanks, would only be considered potentially hazardous in the area surrounding the tanks or any connecting pipe work. In this case, it is only necessary to take precautions in those areas where leakage could reasonably be expected to occur. In order to bring some regulatory control into the industry, therefore, certain areas have been classified as follows : ZONE 0

in which an explosive gas/air mixture is continuously present, or present for long periods.

ZONE 1

in which an explosive mixture is likely to occur in the normal operation

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

154 0 0 23/08/2015 BMK

SECTION

8

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

of the plant. ZONE 2

6.

in which an explosive mixture is not likely to occur in normal operation.

GAS DETECTION SYSTEMS AND GDACS

For continuously monitoring an industrial plant for leakage of hazardous gases, a number of sensors are placed at strategic points around the plant at the places where any leaks are most likely to occur. These are then connected to a multi-channel controller located some distance away in a safe, gas free area having display and alarm facilities, recording devices, etc. This is known as Fixed point system. It is permanently located in the industrial plant (i.e. oil refinery, cold storage, etc.) and generally has a standard analogue electrical circuit design. The controllers used in the fixed systems are normally centrally located in a control panel. The control units normally have internal relays to control functions such as alarm, fault and shut down. The alarm can be set at either one or two levels, depending on statutory requirements or working practices within the industry. Alarm inhibit and reset, over-range indication and an analogue 4-20 mA output for a data logger or computer are some of the useful features of the control units. GDACS stands for Gas Data Acquisition and Control System. This system uses transmitters to convert the 4-20 mA signal of standard gas sensors into digitally coded pulses. It also allows the information from a number of other sources, temperature or pressure sensors, fire detectors, etc. to be interfaced to a two-wire, digital highway. Highway is a simple digital communication channel. Each input to the highway is allocated a unique address code and when a sensor is ‘interrogated’ by the highway control card, it transmits status information back to the control room. The use of the microprocessor technology enables the compensation of external environmental influences for greater accuracy. By two-way communication with the sensors, the system can provide operational status and diagnostic information. The system can accept ‘status switches’ on the highway in addition to analogue devices. By using addressable output actuators, it is possible to operate local alarms or shut down procedures from the highway itself, instead of wiring all functions back to the controller. The highway control cards give an output with detailed status information from the input devices and these can be passed via a serial port to a suitable host computer and visual display unit.

7.

LOCATION OF SENSORS

There are three methods of locating sensors: Point Detection, where sensors are located near the most likely sources of leakage, Perimeter Detection, where sensors completely surround the hazardous area (which could also be point detectors) and Open path detectors (uses IR beam for detection), in which the detectors can be connected covering a distance of several hundred meters. Some of the factors to be kept in mind while deciding the location of a sensor are given below : 1.

Any sensor which is to be used for detecting a gas with vapor density greater than 1 heavier than air), e.g. Butane, LPG and Xylem, etc. should be located near ground level.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

( i.e.

155 0 0 23/08/2015 BMK

SECTION

MODULE NO.

8

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

2. Conversely, for any lighter-than-air gases, such as hydrogen, methane, ammonia, etc. The sensor 3.

4. 5.

8.

is to be connected higher-up. In the open, environmental conditions get more importance. Sensors are to be located downstream of the prevailing winds and the weather shields are to be fitted to protect against rain and snow. Diffusion-type sensors will normally be mounted so that they face downwards, particularly for light gases. The location of IR sensors should be such that, there is no permanent blockade of the IR beam. Though normally sunlight does not cause any problem, it should not fall directly on the instrument window. The locations mostly requiring protection are around gas boilers, compressors, pressurized storage tanks, cylinders or pipelines. Valves, gauges, flanges, T-joints, filling or draining connections, etc. are most vulnerable. Sensors should be positioned a little way back from any high-pressure parts to allow gas clouds to form. Otherwise any leakage of gas is likely to pass by in a high-speed jet and not be detected by the sensor.

GENERAL OVERVIEW OF THE F&G SYSTEM IN NAPHTHA CRACKER PLANT

The Fire & Gas Detection System in the Cracker plant in RIL, Hazira has been supplied by Zellweger Analytics (Sieger) Ltd, UK. The system consists of two independent detection systems: Gas detection system and Fire detection system. The Gas Data Acquisition and Control System (GDACS) within the control cabinet provides four RS485 internal highways for gas, fire and fault condition data collection. It is an Analogue Addressable System. The different types of gas and fire detectors used in this plant are as follows: Gas detectors : 1. Combustible (hydrocarbon) 0-100% LEL detectors, 2. Toxic gas detectors : a) Hydrogen Sulphide detectors 0-50 ppm b) Carbon Monoxide detectors 0-500 ppm Fire detectors : 1. Smoke detectors :

a) Optical b) Ionization

2. Heat detectors 3. IR Flame detectors 4. Manual Alarm Callpoints.

The system comprises five dual bay cabinets namely : 1. 2. 3. 4. 5. CHECKED BY N.S.P APPROVED BY B. DAS

Gas control cabinet Fire control cabinet Marshalling cabinet Control room mimic cabinet Fire station mimic cabinet. Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

156 0 0 23/08/2015 BMK

SECTION

8

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

Both the Gas and Fire detection systems have two highways each. Highways one & two are used for gas detection system and Highways three & four are used for fire detection system. Individual gas sensor and fire loop status from the GDACS is given to a Data Concentrator. This data from the Data Concentrator goes to the DCS ( Distributed Control System) via a Protocol Converter. Gas and fire alarms on a fire area-grouping basis are annunciated via control room and fire station mimic panels and by siren/visual/internal audibles directly within the fire areas. All field detector loops are terminated within the marshalling cabinet, which houses the intrinsic safety (I.S.) MTL isolation units for these circuits. Gas detection transmitter 24V DC feeds are also terminated in this cabinet, each circuit having fuse/isolation terminals.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

157 0 0 23/08/2015 BMK

SECTION

MODULE NO.

8

FIG :

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

FIRE & GAS DETECTION SYSTEM BLOCK DIAGRAM

9.

DETECTORS

9.1

Gas Detectors :

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

158 0 0 23/08/2015 BMK

SECTION

8

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

The gas detectors comprise two main units - a transmitter and a sensor. All units use a weather protection assembly providing protection to the sensor-input sinter against rainwater splash and high air speeds.

9.1.1 Combustible Gas Detectors : Nearly all modern, low cost, combustible gas detection sensors are of the electro-catalytic type. They consist of a very small sensing element called a ‘bead’, a ‘Pellistor’ or a ‘Siegistor’. They are made of an electrically heated platinum wire coil. The coil is covered first with a ceramic base such as alumina and then with a final outer coating of palladium or rhodium catalyst dispersed in a substrate of thoria as shown in the figure below. When a combustible gas/air mixture passes over the hot catalyst surface, combustion occurs and the heat evolved increases the temperature of the ‘bead’. This in turn alters the resistance of the platinum coil and can be measured by using the coil as a temperature thermometer in a standard electrical bridge (Whetstones Bridge) circuit. The resistance change is then directly related to the gas concentration in the surrounding atmosphere and can be displayed on a meter or some similar indicating device. The change in resistance gets converted to a 4-20 mA signal (by amplifier) which corresponds to 0-100%

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

159 0 0 23/08/2015 BMK

SECTION

8

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

LEL.

FIG :

CHECKED BY N.S.P APPROVED BY B. DAS

A COMBUSTIBLE SENSOR

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

160 0 0 23/08/2015 BMK

SECTION

8

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

FIG :

DIMENSIONS OF A COMBUSTIBLE GAS DETECTOR

9.1.2 Toxic Gas Detectors : Toxic gases are generally needed to be detected and measured at very low concentrations. Therefore, although many toxic gases are also combustibles (e.g. ammonia, carbon monoxide or methanol), it is not possible to use combustible gas sensors for toxic gas measurements because the sensitivity needed is well below that which can be achieved with a flammable gas sensor. A toxic gas detector uses an electro-chemical sensor. It is an electrochemical cell, consisting of two electrodes immersed in a common electrolyte medium. This can be in the form of either a liquid, a gel-like fluid, or an impregnated, porous solid. The electrolyte is isolated from outside influences by means of a barrier, which may be in the form of either a gas permeable membrane, a diffusion medium, or a capillary. The cell is designed for maximum sensitivity combined with maximum interference from any other gases present. During operation, a polarizing voltage is applied between the electrodes and when gas permeates through the barrier into the sensor, an oxidation-reduction reaction generates an electrical current that is linearly proportional to the gas concentration.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

161 0 0 23/08/2015 BMK

SECTION

MODULE NO.

8

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

FIG :

FIG :

A TOXIC SENSOR

DIMENSIONS OF A TOXIC GAS DETECTOR

The Combustible and toxic gas detectors are identical in appearance accept that, the transmitter of a toxic gas detector is slightly smaller than that of a combustible gas detector as shown in the figures above. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

162 0 0 23/08/2015 BMK

SECTION

8

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

Total 180 combustible gas detectors are in the plant. Since the combustible gases have a tendency to go up, these detectors are placed mostly at the top. Each of 6 H2S & CO detectors are used in the top and ground floors of the HVAC Inlet area.

FIG : CONNECTION DIAGRAM OF A GD TO GAS CONTROL CABINET

9.2

Smoke Detectors :

Optical and Ionization Smoke Detectors are the two most common types of plug-in smoke detectors. Ionization detectors are excellent for detecting the smaller aerosols associated with clean fires, which result from fibrous materials, i.e. paper or wood. Therefore this detector is a good selection for office areas. The Optical detectors provide a better response for mid-range range to heavy or large aerosols such as those produced by many synthetic products. Therefore this detector is a better selection for protecting areas where this type of material is prominent, i.e. electrical switch rooms, cable spreader room, rack room, where overheated cables and electrical components are the main risk. Large smoke particles can also result from smaller aerosols combining together, which usually happens as smoke travels over longer distances, i.e. along corridors. That is why, in the control room building area, both the types of detectors have been connected side by side.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

163 0 0 23/08/2015 BMK

SECTION

8

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

FIG :

SENSITIVITY OF THE DETECTORS TOWARDS SMOKE PARTICLES OF DIFFERENT SIZES

9.2.1 Optical Smoke Detector : The inner chamber of an optical smoke detector consists of two main parts : an infrared LED and a photo-diode. The LED is positioned at an obtuse angle to the photo diode. The photo-diode has an integral daylight filter for protection against ambient light. The LED emits a burst of collimated light every 10 second. In clear air conditions the photo-diode does not receive light particles (photons) due to the collimation of the light and the angle at which the light travels relative to the photo diode. When smoke enters the chamber, it excites the photo-diode by scattering photons onto it. Then the LED emits two further bursts of light at an interval of two seconds. Due to the presence of smoke, light is scattered on both these pulses of the photo-diode causing the detector to go to the alarm state. At the alarm state, a silicon controlled rectifier on the printed circuit board is switched on and the current drawn by the detector is increased from an average of 40 mA to a maximum of 61mA. To ensure reliability, the LED emits light modulated at about 3 KHz and the photo-diode reacts only on receiving light at this frequency.

9.2.2 Ionization Smoke Detectors : An Ionization Smoke detector has an inner and an outer chamber. The inner & outer chambers are called ionization (inner reference chamber) and smoke chambers respectively. (The smoke chamber has smoke inlet apparatus fitted with an insect resistant mesh.) A radioactive source holder and the CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

164 0 0 23/08/2015 BMK

SECTION

8

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

smoke chamber acts as positive and negative electrodes respectively. The radioactive source is inside the ionization chamber. This radioactive source irradiates the air in both the chambers to produce positive and negative ions. On applying a voltage across the electrodes, an electric field is formed. The ions are attracted to the electrodes of opposite signs, some ions collide and recombine, but a small net electric current flows between the electrodes. A sensing electrode between the two chambers converts variations in the chamber currents into a voltage. When smoke particles enter the ionization chamber, ions become attached to them and reduce the current flowing through the ionization chamber. The current in the smoke chamber reduces far more than that of ionization. This imbalance causes the sensing electrode to go more positive. The sensor electronics monitors the voltage on the sensing electrode and produces a signal when a preset threshold level is reached and causes the detector to go to the alarm state. The total number of smoke detectors used in this plant is 155 and these have been supplied by Apollo Fire Detectors Limited. The detectors are used inside the control room building area. These are mounted on the ceiling, above ceiling and below false flooring. Remote indicators are also provided for giving indication of any actuation above ceiling. The Ionization & Optical Smoke detectors are identical in appearance. The difference is that, the color of the LEDs on the Ionization and Optical Smoke detectors are red and white respectively. But when they get actuated, both emit red light. The total number of smoke detectors used in the control room building area is 155.

9.3

Heat detectors :

Heat detectors are basically temperature-sensing devices. The main function of the heat detectors is to provide fire detection where speed of response is not so critical, or for the areas where unwanted triggering of smoke detectors is likely to occur, i.e. kitchen and workshop areas. Heat detectors are available in three basic forms --- Fixed Temperature, Rate of Rise sensors and Rate Compensated sensors. Fixed Temperature type detectors are used in this plant. These heat detectors may be of bi-metal switch design or of single fixed electronic thermal sensor design. These are designed with a pre-set fixed temperature trip point e.g. 60, 75 or 90 0C. If the preset temperature value is exceeded, contacts of the switch changes and generates alarm signal. The detector contact closes at operating temperature. The contact is self-resetting. The detector temperature setting is the sum of ambient temperature and 100 0F. Here, ambient temperature has been taken as 40 0F. Therefore the set point of the heat detectors is 140 0F or 600C. The detector will give a low-level alarm if the temperature increases to 25% of its preset value. In cracker plant only 13 Heat detectors are in use. Most of them are used in the transformer yard and Diesel Generator room.

9.4

IR Flame Detectors :

The IR Flame Detectors provide early warning of hydrocarbon flames. The detectors are used for the protection of high risk areas from fire (producing CO 2 ) caused by the accidental burning of materials, like flammable liquids & gases, paper, wood, plastics, etc. The detector uses infrared sensors, filters and microprocessor that provide immunity to ‘black body’ false alarm sources. The detectors have a very fast speed of response -- typically 2 to 3 seconds. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

165 0 0 23/08/2015 BMK

SECTION

8

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

Two signals (waveforms) are derived from the 4.3 µm wavelength, which corresponds to hot CO 2 emissions of a hydrocarbon fire. The microprocessor analyses this signal and another one taken from the 3.8µm wavelength by means of a parented correlation technique to determine the presence of fire. The detectors can see hydrocarbon flames through smoke and high densities of solvent vapors. These are blind towards sunrays. There are 16 IR Flame Detectors in the plant. These have been supplied by Thorn Security Limited. The detectors are used mostly in the Crack Gas Compressor (CGC) Building, Refrigeration Compressor, Methane Compressor Shelter, Recycle Compressor and Fuel Gas Compressor area.

9.5

Manual Call Points :

The MAC is the simplest of all the other detectors used in the Fire and Gas detection System. This is a manually operated device. The MAC used in this plant is of ‘Break-glass’ type. The unit is operated by applying thumb pressure to a pre-scored glass plate, releasing a micro-switch, which is normally held open, by the edge of the glass plate and alarm is generated. The glass is covered by a clear film to protect the operator from suffering glass cuts or splinters during operation. During operation, the LED in the front side also glows. The number of MACs used in the whole plant is 90.

FIG :

CONNECTION DIAGRAM OF MAC & SD FROM FIELD TO GAS PANEL

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

166 0 0 23/08/2015 BMK

SECTION

8

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

There are two level alarms for gas detection system :  For 0-100% LEL detectors, Ist (lower) level alarm is at 20% LEL and 2nd (higher) level alarm is at 60% LEL  For 0-500 ppm CO detectors, Ist level alarm is at 10% i.e. 50 ppm and 2nd level alarm is at 60% i.e. 300 ppm.  For 0-50 ppm H2S detectors, Ist level alarm is at 20% i.e. 10 ppm and 2nd level alarm is at 50% i.e. 25 ppm.

10. AUDIBLE AND VISUAL ALARMS For warning the persons working in the plant of gas leakage or fire, Electronic Sounders are used. The tone of the sounder is very piercing (500 - 1000 Hz). The sound generated can be modulated in a number of ways (pulse, warble, multi tone, etc.) which makes the sound stand out from other ambient noises. In areas where the ambient noise is particularly high to the point where the occupants are required to use ear defenders, ‘flashing light’ alarm devices are also used as a visual backup warning to the occupants.

11.

SYSTEM DESCRIPTION

11.1

Gas Control Cabinet :

The signals from all the gas detectors come to this cabinet via the Marshalling cabinet and are terminated in the four channel Safe Area Quad Input (SAQI) cards. These signals act as the input to the Highway Control Cards (HCC). The Gas Control Cabinet has four pairs of HCCs, functioning in a main and standby configuration. There are two Highways in each HCC : Primary and Secondary. The Primary Highway is normally active. The Secondary Highway is automatically used if failure of the Primary Highway is detected by the HCC. Communication takes place in one Highway at a time. Each pair of HCC’s has both a dual power supply card and a highway bus manager module. The bus manager module controls the switching from the main to standby HCC whenever the dual power supply card fails. Dual Highway Voting Cards (HVC) are interfaced to each of the four highways to provide voted alarms. HVC takes signals from the HCC and votes as per user logic, which is configured in HVC and generates output. These outputs are used to indicate alarms, sirens, etc. The voting of the Fire Area is explained with the help of the voting logic and the cause and effect diagrams in the next page.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

167 0 0 23/08/2015 BMK

SECTION

MODULE NO.

8

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

FIG : VOTING LOGIC FOR THE DETECTORS IN THE FA-3

FA - 3 D G ROOM CAUSE

VOTING EFFECTS

DETECTION

2 OUT OF 2

MAIN CONTROL PANEL

2 OUT OF 3

AUD. ALMS

VISUAL ALMS

AUD ALM(FS ONLY)

FIRE & GAS

FIRE/FLAME GAS

X

X

X

X

X

X

X

X

X

X

X

X

X

X

AUDIBLE ALM

VISUAL ALARM

FIRE

GAS

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

CCT

HEAT (POINT)

1ST

HEAT (POINT)

2ND

X

GAS-FLAM 20% GAS-FLAM 60%

1ST

GAS-FLAM 60%

2ND

MANUAL

GRAPHIC MIMIC PANELS

X

X

FIG : CAUSE & EFFECT DIAGRAM FOR THE FA-3 Highways one and two have twenty-eight SAQI cards each. Total sixteen no of 16 channel input cards are used in highways three and four. A SAQI card has four channels whilst a 16 channel I/P card has sixteen channels as the name suggests. The whole plant has been divided into different fire areas. All the gas, heat and IR flame detectors have unique addresses and they are connected individually to the highways. In some cases, MAC and smoke detectors of some fire areas have been connected in loops and these loops have been assigned unique addresses. The system being an Analogue Addressable System cannot check the status of each of the detectors in the loop. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

168 0 0 23/08/2015 BMK

SECTION

8

MODULE NO. RELIANCE INDUSTRIES LIMITED

CKR-PR-P-001

The incoming data of gas concentration and fault information is gathered on highways one and two and fire alarm/fault switch inputs are gathered on highways three and four. The 4-20 mA analogue loop signals from the gas detectors come to the SAQI cards, which convert them to digital format. The outputs of the SAQI cards are the inputs to highway one and two. The signals from smoke, heat, IR flame detectors and MAC come to 16 channel I/P cards (via 2 channel and 6 channel Fire cards). The output of these cards is given to highways three and four. The main function of HCC in polling mode is to request data from each address loop. The data collected is checked against the configuration data in the EPROM in the HCC. The configuration data contains alarm settings and relay driver channel allocations for each Highway device address. If any alarm level, fault or warning code is present in the received message from an addressed device, a transistor relay driver channel may be activated. In some specific areas, some but not all detectors are voted for final output, e.g. Two out of three detectors are voted i.e. if any two detectors out of the three get actuated then only an output will be generated. The Highways of all the four HCCs are connected to a Data Concentrator which acts as a multiplexer. The Data Concentrator can time division multiplex upto 8 HCCs. The Data Concentrator converts the RS 422 data from the HCC to RS 232 and gives it to the Protocol Converter. The Protocol Converter (based on Intel 80186 compatible single board computer) internally builds a table of GDACS gas readings, sensor statuses, types and ranges. It then communicates these values in a suitable format via a second serial port to the DCS system. The Protocol Converter converts GDACS protocol to MODBUS protocol, which is acceptable for ABB DCS.

11.2

Fire control cabinet :

The signals from the detectors used for fire detection come to this cabinet via the Marshalling cabinet and are terminated in the 16 channel I/P cards. The signals then go to the HCCs in the Gas control cabinet. Two types of cards are used for fire detection control. Twin Zone Fire card monitors the smoke detection loops and Six Channel Switch Input cards monitors the MAC loops. Below the Fire Cards, there is a sub panel for providing annunciation and operation functions. These are as follows : System healthy (Green LED) System faults (Amber LEDs) HVAC/Plant Status (Amber LEDs) Alarm reset Accept Lamp Test Audible alarm The System Healthy indicator in the panel goes off whenever there is any fault in the system. The Twin Zone Fire Module monitors the detector loop current for open and short circuits and also passes a nominal quiescent current of 4 mA through the loop for monitoring. Any HARDWARE error condition is annunciated by visual and audible alarms within the control room for initial attention seeking. The audible alarm has two tones, continuous to define fire or gas alarm and intermittent to define a fault condition. CHECKED BY PAGE 169 N.S.P Process description and Utilities REV 0 ISSUE 0 APPROVED BY DATE 23/08/2015 B. DAS AUTHOR BMK

SECTION

MODULE NO.

8

11.3

RELIANCE INDUSTRIES LIMITED

CKR-PR-P-001

Marshalling cabinet :

The dual bay marshalling cabinet provides the main termination facility between field and control electronics. The panel contains all intrinsic safety isolating modules for input and output loops.

Type/model and loop type: MTL 3041 MTL 3043

Gas Detection Fire Detection

4/20 mA loops 1/40 mA loops

Connections into the other system panels are being terminated in ELCO sockets.

11.4

Control room mimic cabinet :

The control room mimic panel is considered the master mimic. It houses LED display, graphically representing fire and gas zonal alarm status. LED colors:

Red Amber Blue

(fire detection) (combustible gas detection) (Toxic gas detection)

Master/function/indications:

Supply on System Alert (HVAC status change) System fault Lamp test (switch) At the normal condition, all the LEDs and the lamps on the mimic panel are off. The ‘System Alert’ and ‘System Fault’ glow only when there is any fault in the system. The ‘Lamp Test’ switch is used for checking the working condition of the LEDs on the panel. The LEDs on a Fire Area glow when any gas leakage or fire is detected in that particular area. A draft of the cabinet is given on the next page.

11.5

Fire station mimic cabinet :

The fire station mimic cabinet is similar to the control room in respect to the display.

12. SIEGER CALIBRATION & COMMUNICATION SOFTWARE PACKAGE, CALCOM The operation of the G.D.A.C.S. is fully monitored and controlled with the help of software, which is known as CALCOM. A PC having CALCOM can be connected to the RS 232C serial interface on a Bidicom. The Bidicom is a bi-directional communicator, which can convert both RS 422 & RS 485 into RS 232 communications suitable for connection into a serial port of a computer. CHECKED BY PAGE 170 N.S.P Process description and Utilities REV 0 ISSUE 0 APPROVED BY DATE 23/08/2015 B. DAS AUTHOR BMK

SECTION

MODULE NO.

8

CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

Whenever there is no visual indication defining any hardware failure, a software diagnosis can be done through CALCOM. The operator can interrogate a highway and its respective device address electronics asking for responses to the control commands. The responses contain more detailed data on occurrence of a fault. CALCOM is also used for calibrating the gas detectors.

13. CALIBRATION DETECTORS

PROCEDURE

OF

GAS

Small particles, corrosion, water may block the sinter of a combustible sensor thereby causing its failure. Exposure to certain ‘poisons’ can also degrade the performance of a sensor. Therefore it is essential that any gas monitoring system should be calibrated at the time of installation as well as checked regularly and re-calibrated as necessary. An accurately calibrated standard gas mixture should be used for checking, so that the ‘zero’ and ‘span’ levels can be set correctly on the transmitter. Here we are using 2.5% methane in air as the calibration gas. To calibrate, one has to expose the sensor to a flow of gas and the other to check the reading shown on the scale of its control unit (PC). Adjustments are then made to the ‘zero’ and ‘span’ potentiometers until the reading exactly matches that of the gas mixture concentration. The calibration procedure for both the combustible and toxic gas detectors is same. Calibration can be done in situ or remote from the transmitter. Sensors can be pre-calibrated and then plugged in. The transmitter is factory set and does not require calibration. If required, the transmitter can be calibrated using a Dummy Sensor. The sensors are calibrated remote from the transmitter using the Calibration unit as follows : 1. 2. 3. 4. 5. 6. 7.

Power is applied and waited for 5 minutes for stabilization. The calibration cover above the adjustment potentiometers are loosen and slided up. The display on the calibration unit will show ‘CAL’. Zero potentiometer (MZ) is adjusted to obtain zero reading on the display. Test gas at the rate of 1-2 liters/min is applied and waited for 5 minutes to stabilize. Span potentiometer is adjusted until display indicates 50% LEL of the test gas. Test gas is removed and zero is re-checked. The calibration cover is tightened (should not be over tightened). The display should read zero and the ‘CAL’ from the display should disappear.

The above procedure is repeated if necessary. The dummy sensor is used to inject either a Zero or a variable signal into the transmitter. The procedure is as follows : 1. The sensor is removed from the transmitter to be calibrated and the dummy sensor is fitted in its place. 2. The transmitter local display should show ‘Fault’ and no gas reading. 3. The transmitter should show zero reading when the switch on the dummy is in zero position. If not, it should be made zero by adjusting the signal level knob until zero is displayed. Zero calibration command is given from the CALCOM (through the PC) connected to the Data Concentrator of the system. 4. The switch of the dummy sensor is changed to the Span position. Then the signal level knob is turned to inject a simulated ‘gas signal’ into the transmitter. The display on the transmitter should show 50% LEL. 50% Span calibration command from CALCOM is given. 5. The transmitter should indicate zero when the switch on the dummy sensor is kept in zero position. The transmitter should also indicate the correct value when the switch is kept on the span position. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

171 0 0 23/08/2015 BMK

SECTION

8 6.

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

After completing the tests, the dummy sensor is removed and the correct sensor is refitted to the transmitter.

The procedure is repeated if required.

14. CHECKING PROCEDURE 14.1

Smoke Detectors :

Smoke or spray is applied to the detectors to check their actuation.

14.2

Heat Detectors :

Heat is applied to the detector with the help of Heat Blower to see the actuation.

14.3

IR Flame Detectors :

Spark or fire flame is generated in front of the detectors and checked their actuation.

14.4

MAC :

A special key to check its operation operates MAC. The LED in the front side does not glow when the MAC is in fault condition. All the checking procedures given above are done online.

15. GRAPHICS PACKAGE A Graphics computer having the Intellution FIX graphics software has been installed in the control room for quick and exact detection of the location of any fire or gas leakage. By the graphics interface, an operator gets an optimum presentation of site information. He can also view sensor and alarm data at any level of the hierarchical data structure. CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

172 0 0 23/08/2015 BMK

SECTION

8

MODULE NO. CKR-PR-P-001

RELIANCE INDUSTRIES LIMITED

An Overview screen provides the occurrence of alarm in any zone. It is indicated by the change of border color of that particular zone. The Menu bar at the bottom right corner in the overview screen has different function keys, e.g. Alarm, History, Engineer, etc. When Alarm screen is opened, a screen Menu appears at the right hand side of the Alarm Screen with options: Alarm Log Files & Log Files. The Alarm Log File enables the user to view the alarm log files listed in the date order. Log file option can be used to see the log on/off events and security violations. Alarm History gives the list of all the alarms in the buffer. The Engineering screen lists all the tags, their descriptions, current values, current status, and GDACS addresses for all the sensors in each zone. Normalization and Calibration of the gas sensors can be carried out from the Engineering screen Menu. The Fire area select Menu on the top right corner of the Overview screen enables the user to view any particular fire area. A red surrounding of a fire area button indicates the occurrence of an alarm. The detectors on the screen as well as the alarm message appearing in the Alarm Summary field at the bottom of the screen changes their color corresponding to the type of alarm, e.g. a gas detector, which has been shown as Green at normal state, will become Orange to indicate a High alarm, Red to indicate HiHi alarm and Yellow to indicate a fault. This helps the operator to check whether actual fire or gas leak has taken place or not. Two buttons -- ‘Accept’ and ‘Alarm Reset’ are used for accepting and resetting an alarm. A System screen can be viewed with the help of the ‘System’ button at the right side of the Overview screen. By double clicking at a sensor the user can view the Trend Graphs. The trend logs record 30 days of data at 1-minute intervals. The trend graphs of the gas detectors can be useful for relating or comparing the gas levels of the plant area at different times.

CHECKED BY N.S.P APPROVED BY B. DAS

Process description and Utilities

PAGE REV ISSUE DATE AUTHOR

173 0 0 23/08/2015 BMK