HAZOP STUDY REPORT

Client

Nagarjuna Oil
Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

3.Unit Description
The unit consists of the following sections:
Reaction
Recycle Gas Loop
Stripper and LP Absorber
- Reaction Section
The feed consists of SRHD, LVGO, LCGO, and LCO streams supplied from battery limits. The
gas oil blend flows to the back wash Feed Filter, 140-F-001, before entering the Feed Surge
Drum, 140-V-001. The feed drum is nitrogen blanketed and the drum pressure is under level
controlled using a split range control scheme. The oil feed is pumped to the reactor circuit on flow
control using the Gas Oil Feed Pump, 140-P-001 A/B. The feed drum level is controlled by
supplying excess DHU feed from storage. The level controller is sent to storage, Unit 2500,
outside battery limits.
Make-up hydrogen is supplied at 20 bar g, to the Make-up Gas Compressor K.O. Drum 140-V002, and then is compressed by the Hydrogen Make-up Compressor 140-K-001 A/B. The makeup compressor has two stages and the interstage gas cooling is done with cooling water in the
Make-Up Compressor Interstage Cooler, 140-EE-008 A/B. The make-up gas flowrate to the
reaction section is controlled by means of a compressor spillback to the Make-up Gas
Compressor K.O. Drum, 140-V-002. The spill back is cooled by the Hydrogen Make-Up Kick Back
Cooler, 140-EE-004. A line is provided on the Make-up Gas Compressor discharge to send
Hydrogen to bullet storage. Before being sent to storage outside battery limits the hydrogen is
cooled in the Hydrogen Cooler, 140-EE-009.
The make-up and recycle gas streams are combined with the feed, and the total feed mixture is
heated up against the reactor effluent in the Reactor Feed / Effluent Exchanger, 140-EE-001
A/B/C/D. A bypass of all the shells is provided on the gas oil feed line to facilitate the Hydrotreater
Reactor Feed Heater, 140-H-001, operation at minimum turndown. The preheated oil and
hydrogen mixture is heated to the reactor inlet temperature in the Hydrotreater Reactor Feed
Heater, 140-H-001.
The Hydrotreater Reactor, 140-R-001, contains five catalytic beds. Recycle hydrogen is used as
the quench gas, for maintaining the desired WABT in each of the catalytic bed. The top layer of
the first catalytic bed in the reactor operates at a lower temperature, and this bed saturates the
feed olefins and diolefins. The inlet temperature to the Reactor is adjusted so that the required
inlet temperature is obtained for the subsequent HDS catalyst in the same catalytic bed. The
effluent from the first catalytic bed is quenched to control the inlet temperature of the second
catalytic bed. In the remaining four catalytic beds, the targeted average WABT is about the same
to complete the remaining reactions. The quench gas is supplied on flow control, reset by the
catalytic bed inlet temperature.
The reactor effluent is cooled by preheating the stripper feed in the Stripper Feed Preheater, 140EE-002, then by preheating the oil/hydrogen feed in the Feed/Effluent Exchanger, 140-EE-001
A/B/C/D. Wash water is injected into the reactor effluent at the outlet of the final Feed/Effluent
Exchangers shell, in order to prevent any deposit of ammonium salts. The wash water is a

mixture of recycled water from the Stripper Reflux Drum, 140-V-008, and the Coalescer, 140-V009, plus make-up stripped sour water from battery limits. Additional water injection facilities are

HAZOP STUDY REPORT

Client

Nagarjuna Oil
Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

provided for the last two shells, tube side, of the Feed/Effluent Exchanger to wash out any salt
deposits. This injection is normally intermittent and usually not required. The wash water is
pumped by the Wash Water Pump, 140-P-002 A/B, from the Wash Water Drum, 140-V-004, on
flow control to the reactor effluent upstream of the Reactor Effluent Air Cooler, 140-EA-001, to
avoid ammonium salt deposit and the risk of corrosion. The Wash Water Drum, 140-V-004 is
nitrogen blanketed and the drum pressure is under level controlled using a split range control
scheme.
The Reactor Effluent then is cooled in the Reactor Effluent Air Cooler, 140-EA-001, and the
Reactor Effluent Trim Cooler, 140-EE-003. The reactor effluent is collected in the Separator
Drum, 140-V-006. The vapor phase out of the Separator Drum consists of the recycle and quench
gas circulated by the recycle compressor. The Separator Drum is equipped with a water boot, and
adequate residence time is provided for obtaining a good separation of the liquid and sour water
streams. Sour water is separated from the hydrocarbon liquid phase on HC/water interface level
control from the settling zone of the separator. Then the sour water is routed to the Sour Water
Flash Drum, 140-V-017, before being sent to FCC Sour Water Unit, Unit 550 outside battery
limits. The hydrocarbon liquid flows on level control to the stripping section. The separator also
contains a coalescing pad close to the feed inlet nozzle. In addition to coalescing the small water
droplets, the coalescing pad helps to streamline the HC/H 2O flow in the settling zone.

-Recycle Gas Section

The recycle hydrogen stream leaving the Separator Drum, 140-V-006, is routed to the HP Amine
Absorber, 140-C-001 for HsS removal, through the HP Amine Absorber KO Drum, 140-V-007. The
lean amine is a 40 wt% MDEA solution, supplied on flow control to the HP Amine Absorber using
the Lean Amine Booster Pump, 140-P-003 A/B. The rich amine from the HP absorber bottoms is
sent to the LP Amine Absorber, 140-C-003, on level control, for flashing off the dissolved light
ends.
The recycle gas leaving the HP Amine Absorber is routed to the Recycle Compressor, 140-K-002,
through the Recycle Compressor K.O. Drum, 140-V-005. There is a provision to remove a small
amount of the sweetened gas stream leaving the HP absorber on flow control as a high pressure
purge, to provide added flexibility during operation. However, the unit is designed based on no
purge gas flow, and hence normally there is no high pressure purge gas leaving the unit. The
recycle compressor is driven by a back-pressure type steam turbine, 140-KT-002.
The reactor circuit pressure is controlled at the Separator Drum, 140-V-006. The pressure is
controlled through a hand switch sending a signal adjusting either the make-up hydrogen supply
to the reactor circuit or/and the HP purge gas. 1
The Recycle Compressor discharge is split into recycle gas and quench gas streams. The recycle
gas is combined with the make-up hydrogen and the gas oil feed. Then, the total feed enters the
reaction circuit.

HAZOP STUDY REPORT

Client

Nagarjuna Oil
Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

-Stripper Section
The Stripper, 140-C-002, fractionates the diesel product and the wild naphtha from the reactor
effluent liquid stream supplied from the Separator Drum, 140-V-006. Liquid Feed from the
Separator is first preheated by heat exchange with the stripper bottoms in the Stripper
Feed/Bottoms Exchanger, 140-EE-006 A/B/C/D, followed by the final heating with the reactor
effluent in the Stripper Preheater, 140-EE-002. The stripper feed temperature is controlled by
varying the feed flow through the Stripper Feed Preheater and the exchanger bypass streams.
The hot feed enters the Stripper onto the 22nd tray (counting from the bottom). The feed is stripped
of H2S and light ends from the diesel product using MP steam, which is superheated to 237C.
The MP Steam comes from the Recycle Compressor Steam Turbine, 140-KT-002.
The Stripper overhead vapor is condensed in an air cooled condenser, 140-EA-002, and the trim
condenser, 140-EE-005. The sour off-gas product from the Stripper Reflux Drum, 140-V-008, is
sent to the LP Amine Absorber K.O. Drum, 140-V-010, where it is mixed with any Flash Gas
coming out of the Sour Water Flash Drum, 140-V-017. Then the sour off-gas is sent to the LP
Amine Absorber, 140-C-003, where it is contacted with lean amine from battery limits. In the LP
Absorber, H2S is removed from the offgas, which then flows to the Off Gas K.O Drum, 140-V-018
before being directed to battery limits.
The stripper circuit pressure is controlled by the pressure controller located on the LP Amine
Absorber overhead, downstream of the Off Gas K.O. Drum, 140-V-018. The LP Amine absorber is
operated at a high enough pressure to route the sweet off-gas product to either Unit 350 or to fuel
gas. High pressure rich amine from the HP Amine Absorber is let down to LP Amine Absorber,
and the combined rich amine is sent from the LP Amine Absorber under level control to the Amine
Regeneration Unit. The water condensate containing dissolved H 2S and traces of NH3 is removed
from the Stripper Reflux Drum waterboot on interface level control. This sour water is recycled to
the Wash Water Drum, 140-V-004, for water injection upstream of the Reactor Effluent Air cooler,
140-EA-001. The stripper reflux is returned to the tower on flow control, and the Wild Naphtha
overhead product is sent to the battery limits on flow control, reset by the reflux drum level. The
wild naphtha product is normally sent to Unit 200, with provisions for routing to Unit 160.
The stripped diesel product is pumped by the Stripper Bottoms Pump, 140-P-005 A/B, to the
battery limits on level control of the stripper bottoms. Heat is recovered from the diesel product by
preheating the stripper feed in the Stripper Feed/Bottom Exchanger, 140-EE-006 A/B/C/D, and
the Stripper Preheater, 140-EE-002. The diesel product is further cooled in the Gas Oil Air Cooler,
140-EA-003 and Gas Oil Trim Cooler, 140-EE-007. The dissolved water in the diesel product
settles out as free water as the product stream is cooled. The entrained water is first taken out in
the Product Coalescer, 140-V-009. The Product Coalescer, 140-V-009 water is recycled under
interface level control to the Wash Water Drum, 140-V-004 to be used as Wash Water. Water is
further removed from the diesel product to meet water specification in the Salt Dryer, 140-V-019
before being routed to the storage, Unit 2500, outside battery limits.