Loh 01 12

01 Aug 2002
Unit 14 Light Oil Hydrotreater
Section 1.0
Rev. 12
Process System Description

TABLE OF CONTENTS
1.0
PROCESS SYSTEM DESCRIPTION.............................................2
1.1
Process Design Basis...........................................................................................................2
1.2
Description of Flow...........................................................................................................23
1.3
Description of Process Controls.........................................................................................54
1.4
Description of Emergency Systems...................................................................................63
1.5
Chemicals and Materials....................................................................................................79
1.6
Environmental Protection..................................................................................................93
1.7
Utilities...............................................................................................................................97
1.8
Design Codes and Standards..............................................................................................98
Petrolera Ameriven, S.A.

/var/www/apps/conversion/tmp/scratch_5/316833739.doc
Hamaca Crude Upgrader
Page 1 of 100
01 Aug 2002
Section 1.0
Rev. 12

1.0
PROCESS SYSTEM DESCRIPTION

1.1
Process Design Basis

1.1.1 Introduction
The Light Oil Hydrotreater (Unit 14) is located in Hydrocracker Area 50. The
unit is designed to process a mixture of the following: straight run combined
distillates from the Crude Unit (Unit 10); light coker gas oil (LCGO), coker
naphtha, and coker light ends from the Gas Plant (Unit 18); and cold distillate
from intermediate tankage. The design capacity of the Light Oil Hydrotreater
is 60,000 BPSD.
Products leaving the Light Oil Hydrotreater are further processed in the
downstream Hydroprocessing Support Unit (Unit 15).
The objective of the Light Oil Hydrotreater is to maximize C5-680F (full
range naphtha, kerosene, and diesel) production. The unit minimizes fuel gas
production while meeting product specifications at SOR and EOR conditions.
The design is based on an expected 2-year catalyst cycle length.
The Light Oil Hydrotreater consists of a liquid hydrocarbon feed system, high
pressure reaction loop, and flash drum. Other facilities such as product
stripping, hydrogen makeup compression, high pressure lean amine supply,
wash water injection pumps, neutralization equipment, and flash gas scrubbing
are provided in the Hydroprocessing Support Unit (Unit 15).
1.1.2 Feedstock Characteristics
1.1.2.1 Unit Capacity
The Light Oil Hydrotreater (Unit 14) has 3 feed cases.

Feed Case 1 is based on 165,000 BPSD of Hamaca Crude feed

to the Crude Unit (Unit 10) and 1000+F vacuum resid feed to
the Delayed Coking Unit (Unit 12). The basis for Feed Case 1
is 35,540 BPSD of straight run combined distillates, 1,800
BPSD of coker light ends, 7,560 BPSD of coker naphtha, and
15,100 BPSD of LCGO for a total feed of 60,000 BPSD.
Feed Case 2 is based on 165,000 BPSD of Hamaca Crude feed

to the Crude Unit and 950+F vacuum resid feed to the
Delayed Coking Unit. The basis for Feed Case 2 is 29,310
BPSD of straight run combined distillates, 2,220 BPSD of
coker light ends, 8,920 BPSD of coker naphtha, and 18,000
BPSD of LCGO for a total feed of 58,450 BPSD.
Page 2 of 100
01 Aug 2002
Section 1.0
Rev. 12
Feed Case 3 is based upon 190,000 BPSD of Hamaca Crude

feed to the Crude Unit and 1000+F vacuum resid feed to the
Delayed Coking Unit. Case 3 has different cuts being made in
the vacuum tower, therefore, the feed to the Light Oil
Hydrotreater for Feed Case 3 is lighter, and has less nitrogen
and sulfur than in Feed Cases 1 and 2. The feed basis for Feed
Case 3 is 31,810 BPSD of straight run combined distillates,
1,970 BPSD of coker light ends, 8,789 BPSD of coker naphtha,
and 17,431 BPSD of light coker gas oil (LCGO) for a total feed
of 60,000 BPSD.
1.1.2.2 Feed Sources

The Light Oil Hydrotreater receives straight run combined
distillate feed from the Crude Unit (Unit 10) and light coker gas oil
(LCGO), coker naphtha, and coker light ends from the Gas Plant
(Unit 18). About 90% of the total feed is normally processed hot
directly from the Crude Unit and Gas Plant.
Normally, coker naphtha and LCGO are not diverted to
intermediate tankage due to its gumming characteristics. Only
straight run material is routed through tankage.
1.1.2.3 Feed Rates and Compositions
The feed properties and distillations of the straight run combined
distillates, coker naphtha, and LCGO for Feed Cases 1, 2, and 3 are
provided in Tables 1.1.2-1 through 1.1.2-6.
Table 1.1.2-1 Feed Properties - Case 1
(165,000 BPSD Hamaca Crude Feed & 1000+F Coker Feed)
Feed rate, BPSD

Volume Percent of Feed
Weight Percent of Feed
API Gravity
Specific Gravity (60/60)
Sulfur, wt%
Nitrogen, wppm
Water, vol. %
Cetane Index, ASTM D-976
Chloride, wppm
Combined
Distillate
35,540
59.23
62.06
25.0
0.9042
2.4
450
Saturated
32
2.6
Coker
Naphtha
7,5601
15.602
12.682
61.73
0.7323
1.0
80
Saturated
2.6
Light Coker
Gas Oil
15,100
25.17
25.26
31.9
0.8660
2.76
1190
Saturated
41
2.6
Page 3 of 100
01 Aug 2002
Section 1.0
Rev. 12

Flash Point, F
Pour Point, F
Aniline Point, F
Bromine No.
Acid No., mg KOH/g
Color, ASTM
Metals, Ni+V, wppm
Conradson carbon, wt%
C7 Insolubles, wppm
Composition, vol. %
Paraffins
Olefins
Naphthenes
Aromatics
Diene Value
Conj. Dienes, wt%
TBP Cut, F
Distillation, TBP,F
IBP (1%)
5%
10%
30%
50%
70%
90%
95%
EP (98%)
Combined
Distillate
111
-30
114
1.85
< 0.1
< 100
-
Coker
Naphtha
-65
75.0
0.0
-
Light Coker
Gas Oil
178
-3
123
19.66
0.0
0.01
4
26.5
19.9
21.7
31.9
350 740
38.4
33.7
13.5
14.4
5.43
2.37
C5 - 350
164
290
374
528
599
664
729
753
795
65
85
103
172
227
281
330
350
380
307
367
389
460
522
580
645
667
689
350 645
NOTES:
1. Total flow of Coker Naphtha is 9,360 BPSD, which is a combination of 7,560 BSPD (C5-350 TBP Cut
from Table 1.1.2-1) and 1,800 BPSD (light ends from Table 1.1.2-2).
2. Percentage is based on total Coker Naphtha feed of 9,360 BPSD.

Page 4 of 100
01 Aug 2002
Section 1.0
Rev. 12

Table 1.1.2-2 Coker Naphtha Light Ends
-Case 1
(165,000 BPSD Hamaca Crude Feed & 1000+F
Coker Feed)
Component
C3
C3=
iC4
NC4
C4=
1,3 Butadiene
Total, lb/hr
Total, BPSD
Rate, lb/hr
2,115
312
1,577
6,091
4,868
95
15,058
1,800

Combined
Distillate
Feed rate, BPSD
API Gravity
Sulfur, wt%
Nitrogen, wppm
Water, vol. %
Chloride, wppm
Flash Point, F
Pour Point, F
Aniline Point, F
Bromine No.
Acid No., mg KOH/g
Color, ASTM
Metals, Ni+V, wppm
29,310
50.15
52.96
26.2
0.8975
2.3
300
Saturated
32
2.6
107
-50
115
1.68
< 0.1
Coker
Naphtha
8,9201
19.052
15.732
61.54
0.7330
1.0
80
Saturated
2.6
-65
75.0
0.0
-
Light Coker
Gas Oil
18,000
30.80
31.31
32.2
0.8640
2.69
1170
Saturated
41
2.6
178
-2
124
20.02
0.0
0.00
Page 5 of 100
01 Aug 2002
Section 1.0
Rev. 12

Combined
Distillate
C7 Insolubles, wppm
Composition, vol. %
Paraffins
Olefins
Naphthenes
Aromatics
Diene Value
Conj. Dienes, wt%
TBP Cut, F
Distillation, TBP,F
IBP (1%)
5%
10%
30%
50%
70%
90%
95%
EP (98%)
Coker
Naphtha
Light Coker
Gas Oil
< 100
26.8
20.3
21.6
31.3
350 700
38.4
33.7
13.5
14.4
5.47
2.39
C5 - 350
176
286
352
510
573
631
699
726
770
65
85
103
174
231
282
331
350
380
307
367
389
460
522
580
645
667
689
350 - 645
NOTES:
1. Total flow of Coker Naphtha is 11,140 BPSD, which is a combination of 8,920 BPSD (C5-350 TBP Cut

Page 6 of 100
01 Aug 2002
Section 1.0
Rev. 12
Table 1.1.2-4 Coker Naphtha Light Ends - Case 2

(165,000 BPSD Hamaca Crude Feed & 950+F
Coker Feed)
Component
C3
C3=
iC4
NC4
C4=
1,3 Butadiene
Total, lb/hr
Total, BPSD
Rate, lb/hr
3,172
561
1,871
6,952
5,931
95
18,582
2,220

Feed rate, BPSD

API Gravity
Sulfur, wt%
Nitrogen, wppm
Water, vol. %
Chloride, wppm
Flash Point, F
Pour Point, F
Aniline Point, F
Bromine No.
Acid No., mg KOH/g
Color, ASTM
Metals, Ni+V, wppm
C7 Insolubles, wppm
Combined
Distillate
31,810
53.0
55.7
26.8
0.894
2.1
271
Saturated
32
2.6
99
-75
115
1.62
< 0.1
< 100
Coker
Naphtha
8,7891
17.92
14.72
63.1
0.727
1.0
80
Saturated
2.6
-65
75.0
0.0
-
Light Coker
Gas Oil
17,431
29.1
29.6
31.5
0.87
2.76
1190
Saturated
41
2.6
178
5
123
19.66
0.0
0.01
4
Page 7 of 100
01 Aug 2002
Section 1.0
Rev. 12

Composition, vol. %
Paraffins
Olefins
Naphthenes
Aromatics
Diene Value
Conj. Dienes, wt%
TBP Cut, F
Distillation, TBP,F
IBP (1%)
5%
10%
30%
50%
70%
90%
95%
EP (98%)
Combined
Distillate
Coker
Naphtha
Light Coker
Gas Oil
26
20
22
32
350-680
38.4
33.7
13.5
14.4
5.43
2.37
C5-350
169
263
344
497
562
621
698
727
778
82
87
98
158
218
285
346
369
420
291
357
386
463
527
585
651
673
697
NOTES:
1. Total flow of Coker Naphtha is 10,759 BPSD, which is a combination of 8,789 BPSD (C5-350 TBP Cut

Page 8 of 100
01 Aug 2002
Section 1.0
Rev. 12

Table 1.1.2-6 Coker Naphtha Light Ends Case 3
(190,000 BPSD Hamaca Crude Feed &
1000+F Coker Feed)
Component
Rate, lb/hr
C3
1,900
C3=
331
iC4
1,792
NC4
6,853
C4=
5,578
1,3 Butadiene
95
Total, lb/hr
16,549
Total, BPSD
1,970
1.1.2.4 Makeup Hydrogen

Makeup hydrogen for the Light Oil Hydrotreater is supplied from
the Hydroprocessing Support Unit (Unit 15).
1.1.2.5 Lean Amine Supply
Lean amine for the Light Oil Hydrotreater is supplied from the
Hydroprocessing Support Unit (Unit 15).
1.1.2.6 Wash Water Supply
Wash water for the Light Oil Hydrotreater is supplied from the
Hydroprocessing Support Unit (Unit 15).
1.1.3 Design Processing Parameters
1.1.3.1 Catalyst Description
Product yields, properties, and reactor conditions shown in this
operating manual for the Light Oil Hydrotreater are based upon the
catalysts specified in Table 1.1.3-1.

Page 9 of 100
01 Aug 2002
Section 1.0
Rev. 12

Table 1.1.3-1 Reactor Catalyst
Reactor
No. 1
Bed
Number
Bed 1
No. 1
Bed 2
N-204, HC-K
No. 1
Bed 3
HC-K
No. 2
Bed 4
HC-K
No. 2
Bed 5
HC-K
Catalyst Type
TK-10, TK-551, N-204
1.1.3.2 Reactor Conditions

The Light Oil Hydrotreater (Unit 14) is designed based on the
reactor conditions listed in Table 1.1.3-2.
Table 1.1.3-2 Reactor Conditions
Case 1
(165,000 BPSD
Hamaca Crude
Feed & 1000+F
Coker Feed)
Case 2
(165,000 BPSD
Hamaca Crude
Feed
& 950+F Coker
Feed)
Case 3
(190,000 BPSD
Hamaca Crude
Feed
& 1000+F Coker
Feed)
SOR
EOR
SOR
EOR
SOR
EOR
-1
26.3
26.3
25.6
25.6
26.3
26.3
LHSV, Catalyst 2, hr-1
3.51
3.51
3.42
3.42
3.51
3.51
-1
0.79
0.79
0.77
0.77
0.79
0.79
1600
1600
1600
1600
1600
1600
122
Reactor Inlet Temp, F
636
684
632
681
627
673
Reactor Outlet Temp, F
735
769
736
770
736
770
WABT, F
710
745
710
745
710
745
Cold Separator Temp, F
120
120
120
120
120
120
Makeup Gas, SCF/BBL FF
1157
1157
1170
1170
1162
1162
Reactor Treat Gas, SCF/BBL FF
4000
4000
4000
4000
4000
4000
Reactor quench, SCF/BBL FF
3400
3800
3600
4000
4730
4970
2.0
2.0
2.0
2.0
2.0
2.0
LHSV, Catalyst 1, hr
LHSV, Catalyst 3, hr
Reactor Outlet Pressure, psig

Design Reactor Pressure Drop,
psi
Purge Gas, SCF/BBL FF

Catalyst Life, years

Page 10 of 100
01 Aug 2002
Section 1.0
Rev. 12

1.1.3.3 Cold Feed
At startup, the Light Oil Hydrotreater (Unit 14) is designed to
process cold feed at a rate equivalent to 50% of the design hot feed
rate.
1.1.3.4 Unit Turndown
The Light Oil Hydrotreater is designed for a throughput of 50% of
the design feed rate while making on-specification product quality.
Unit turndown is expected to last for only a short time period (on
the order of one to three weeks).
1.1.3.5 Alternate Feed
The Light Oil Hydrotreater may have to process a portion of the
Gas Oil Hydrocracker (Unit 16) feed when the Gas Oil
Hydrocracker is shut down.
Although the Light Oil Hydrotreater is not specifically designed for
this condition, the expected capabilities of the catalyst loaded in
this unit to process the alternate feed is as follows:
a. The operation is feasible if the maximum feed rate used
is 50% of the design total feed rates for Units 14 and 16:
approximately 57,000 BPSD.
b. The limiting product specification is expected to be the
kerosene smoke point. The operating temperature of Unit
14 should not be increased more than 10F above the
operating temperature prior to the feed change. If the
smoke point cannot be met at that temperature limit, the
feed rate should be reduced until all product specifications
are met. Without the cracking catalyst in the system, yields
will shift from distillates to gas oil.
c. In order to maximize throughput and minimize catalyst
deactivation during this operation, it is recommended that
the HVGO and HCGO endpoints be reduced as much as
possible. A 50F reduction in these endpoints would
significantly improve the Unit 14 catalyst performance.
1.1.3.6 Design for Feed Case 3
In order to minimize the impact of Case 3 feedstock on the
Hydroprocessing Support Unit (Unit 15), the temperature of the
Page 11 of 100
01 Aug 2002
Section 1.0
Rev. 12

Flash Drum (14-V-004) liquid routed to Unit 15 must be reduced to
385 F (from 420F) for the Case 3 EOR.
1.1.3.7 Catalyst Cycle Length / Unit Service Factor
The Light Oil Hydrotreater (Unit 14) is designed for a 2 year
expected catalyst cycle length. The expected unit on-stream
service factor, including a turnaround once every 2 years for
catalyst replacement, is 93%.
1.1.3.8 Presulfiding
The Light Oil Hydrotreater is designed for catalyst presulfiding
operations using wet methods.
1.1.3.9 Regeneration
The Light Oil Hydrotreater is not designed for in-situ catalyst
regeneration.
1.1.3.10 High-Pressure Cold Separator Relief Setting
The pilot operated relief valve located at the high pressure cold
separator is set at 105% of the normal operating pressure.
1.1.3.11 Reactors
The maximum reactor size has been governed by a weight limit of
1100 short tons, an outer diameter of 20 ft, and a tangent-tangent
length of 120 ft.
1.1.3.12 Feed Filters
Cartridge type filters are provided for the combined feed to the
Light Oil Hydrotreater.
1.1.3.13 Injection Wash Water
Injection wash water requirements are met using up to 50%
stripped sour water from the Sour Water Stripper (Unit 26) plus
pumped steam condensate.
1.1.3.14 Startup/Shutdown Considerations
The Light Oil Hydrotreater design includes all required equipment
for startup and shutdown of the unit, including catalyst presulfiding and austenitic stainless steel equipment neutralization,
Page 12 of 100
01 Aug 2002
Section 1.0
Rev. 12

except for equipment provided in the Hydroprocessing Support
Unit (Unit 15) that is provided as common for both the Light Oil
Hydrotreater and the Gas Oil Hydrocracker (Unit 16).
Straight run distillate (diesel range material) is to be used as startup oil for the initial startup of the Light Oil Hydrotreater.
Combined distillate from the Crude Unit is to be used as start-up
oil for subsequent startups of the Light Oil Hydrotreater. Flushing
oil is to be used during shutdown of the Light Oil Hydrotreater.
1.1.3.15 Feed Control
During normal operation, cold feed at a rate equivalent to 10% of
the design feed rate supplements hot feed. This cold feed stream is
used as the primary means of level control in the feed surge drum.
Supplementary level control is provided to shut off the flow of feed
on high level in the Light Oil Hydrotreater feed surge drum.
1.1.3.16 Feed Surge Requirements
The feed surge drum is designed for a surge time of ten (10)
minutes from high to low liquid level.
1.1.3.17 Rich Amine
Rich amine from the Light Oil Hydrotreater is flashed in the Fuel
Gas Scrubber provided in the Hydroprocessing Support Unit (Unit
15) to protect amine regeneration equipment from high pressure
vapor.
1.1.3.18 Amine Sump
An amine sump servicing the Light Oil Hydrotreater is provided in
the Hydroprocessing Support Unit (Unit 15).
1.1.3.19 Feed from Tankage
During normal operation, 10% of the unit charge rate is cold
distillate feed from tankage. Coker naphtha and LCGO are not
normally to be diverted to tankage.
1.1.3.20 Feed Coalescer
A coalescer is required for the cold feed from tankage. The
coalescer is sized for 50% of the unit design feed rate.

Page 13 of 100
01 Aug 2002
Section 1.0
Rev. 12

1.1.3.21 Charge Pump Sparing Philosophy
The Gas Oil Hydrocracker spare charge pump is used as a common
spare charge pump for both the Light Oil Hydrotreater and the Gas
Oil Hydrocracker.
1.1.4 Product Rates and Qualities
1.1.4.1 Product Specifications
The Light Oil Hydrotreater (Unit 14) is designed to meet the
overall Hydroprocessing Area product specifications indicated in
Table 1.1.4-1. The specifications provided are met by the blended
product from the Light Oil Hydrotreater (Unit 14) and the Gas Oil
Hydrocracker (Unit 16) after processing in the Hydroprocessing
Support Unit (Unit 15).

Page 14 of 100
01 Aug 2002
Section 1.0
Rev. 12
Table 1.1.4-1 Overall Hydroprocessing Area Product Specifications

Case 1 and Case
2
Minimu
m
Case 3
Maximu
m
Minimu
m
Maximu
m
ASTM D86 (5%), F
236
236
ASTM D86 (95%), F
310
310
47.0
47.0
5.0
5.0
2,000
2,303
19
19
3.0
3.0
45
45
1500
1500
7.0
7.0
20
25
20
25
Flash Gas, Design H2S Concentration, ppmv
50
50
LPG, Design H2S Concentration, ppmv
50
50
Refinery Gas, Design H2S Concentration,

ppmv
100
100
Product Specification
Heavy Naphtha Diluent (TBP Range, 180F 345F)

Nitrogen ppmw
API Gravity
RVP, psia
Diluent Makeup Rate, BPSD
Kerosene (TBP Range, 345F 525F)
Smoke Point, mm
Naphthalenes, vol%
Diesel Product (TBP Range, 525F 680F)
Cetane Number, ASTM
Gas Oil (TBP Range, 680F+)
Nitrogen, ppmw
Commercial Crude
RVP, psia
Vacuum Residue Content, vol. %
1.1.4.2 Estimated Product Yields

Estimated volumetric and weight percent product yields and
chemical hydrogen consumption for Case 1 (165,000 BPSD of
Hamaca Crude Feed and 1000+F Coker Feed), Case 2 (165,000
BPSD of Hamaca Crude Feed and 950+F Coker Feed), and Case
Page 15 of 100
01 Aug 2002
Section 1.0
Rev. 12

3 (190,000 BPSD Hamaca Crude Feed and 1000+F Coker Feed)
are provided in Tables 1.1.4-2, 1.1.4-3, and 1.1.4-4.
Table 1.1.4-2 Estimated Product Yields - Case 1
Units: Vol% Fresh
Feed or (SCF/BBL)
Units: Wt%
Fresh Feed
SOR
EOR
SOR
EOR
Chemical Hydrogen Consumption
(1100)
(1100)
1.93
1.93
H2S
(81.8)
(81.8)
2.43
2.43
NH3
(4.8)
(4.8)
0.07
0.07
H2O
(4.2)
(4.2)
0.07
0.07
C1
(10.1)
(16.2)
0.14
0.23
C2
(6.1)
(10.1)
0.16
0.27
C3
(15.2)
(19.3)
0.58
0.74
IC4
0.7
0.8
0.46
0.53
NC4
2.3
2.4
1.58
1.65
Light Naphtha (C5 - 180F)
7.4
7.6
5.71
5.87
Heavy Naphtha (180F - 345F)
19.5
19.7
17.12
17.30
Kerosene (345F - 525F)
35.5
35.7
34.50
34.69
Diesel (525F 680F)
30.9
30.3
30.89
30.28
Gas Oil (680F+)
8.2
7.8
8.21
7.81

Units: Vol% Fresh
Feed or (SCF/BBL)
Units: Wt%
Fresh Feed
SOR
EOR
SOR
EOR
(1110)
(1110)
1.98
1.98
H2S
(77.1)
(77.1)
2.33
2.33
NH3
(4.3)
(4.3)
0.06
0.06
H2O
(3.8)
(3.8)
0.06
0.06
C1
(9.8)
(15.8)
0.14
0.22

Page 16 of 100
01 Aug 2002
Section 1.0
Rev. 12

Units: Vol% Fresh
Feed or (SCF/BBL)
Units: Wt%
Fresh Feed
C2
(5.9)
(9.8)
0.16
0.26
C3
(19.7)
(23.6)
0.77
0.92
IC4
0.8
0.9
0.55
0.61
NC4
2.7
2.8
1.83
1.90
8.2
8.4
6.42
6.58
Heavy Naphtha (180F 345F)
22.1
22.4
19.71
19.90
37.4
37.5
36.66
36.79
Diesel (525F - 680F)
28.5
27.9
28.74
28.07
Gas Oil (680F+)
4.5
4.2
4.56
4.25

Units: Vol% Fresh
Feed or (SCF/BBL)
Units: Wt%
Fresh Feed
SOR
EOR
SOR
EOR
(1110)
(1110)
1.96
1.96
H2S
(74.4)
(74.4)
2.24
2.24
NH3
(4.1)
(4.1)
0.06
0.06
H2O
(3.8)
(3.8)
0.06
0.06
C1
(9.8)
(16.0)
0.14
0.23
C2
(5.9)
(10.0)
0.16
0.27
C3
(14.0)
(18.0)
0.55
0.70
IC4
0.8
0.9
0.53
0.59
NC4
2.7
2.8
1.85
1.92
8.0
8.3
6.28
6.51
Heavy Naphtha (180F 345F)
22.6
22.8
20.09
20.27
37.5
37.5
36.70
36.71

Page 17 of 100
01 Aug 2002
Section 1.0
Rev. 12

Units: Vol% Fresh
Feed or (SCF/BBL)
Units: Wt%
Fresh Feed
SOR
EOR
SOR
EOR
Diesel (525F - 680F)
28.6
28.0
28.76
28.16
Gas Oil (680F+)
4.5
4.2
4.55
4.24
1.1.4.3 Estimated Product Properties

The estimated product properties for light and heavy naphtha,
kerosene, diesel, and unconverted oil are provided in Tables 1.1.45, 1.1.4-6, and 1.1.4-7.

Page 18 of 100
01 Aug 2002
Section 1.0
Rev. 12

Table 1.1.4-5 Estimated Light & Heavy Naphtha Properties
Case 1
(165,000 BPSD
Hamaca Crude
Feed
& 1000+F Coker
Feed)
C5-180F Light Naphtha
API Gravity
Sulfur, wppm
Nitrogen, wppm
Hydrocarbon Types, Vol%
Paraffins
Naphthenes
Aromatics
Mercaptan Sulfur, wppm
RVP, psia
RON Clear
Distillation, TBP, F
IBP (1%)
10
50
90
EP (98%)
Case 2
(165,000 BPSD
Hamaca Crude
Feed
& 950+F Coker
Feed)
Case 3
(190,000 BPSD
Hamaca Crude
Feed
& 1000+F Coker
Feed)
SOR
EOR
SOR
EOR
SOR
EOR
80.6
10
<1
80.6
10
<1
80.6
10
<1
80.6
10
<1
80.3
10
<1
80.5
10
<1
77
22
1
<5
65
77
22
1
<5
65
77
22
1
<5
65
77
22
1
<5
65
90
8
2
<5
65
90
8
2
<5
65
50
97
147
174
210
50
97
147
174
210
50
97
147
174
210
50
97
147
174
210
50
97
147
174
210
50
97
147
174
210
180 - 345
180 - 345
180 - 345
180 - 345
180 - 345
180 - 345
55.0
10
<1
55.0
10
<1
55.5
10
<1
55.5
10
<1
55.5
10
<1
55.5
10
<1
59
36
5
<5
49
NIL
-
59
36
5
<5
49
NIL
-
59
36
5
<5
49
NIL
-
59
36
5
<5
49
NIL
-
59
36
5
<5
49
NIL
-
59
36
5
<5
49
NIL
-
Heavy Naphtha
Nominal TBP Distillation
Range, F
API Gravity
Sulfur, wppm
Nitrogen, wppm
Hydrocarbon Types, Vol%
Paraffins
Naphthenes
Aromatics
RVP, psia
RON Clear
Benzene, Vol %
Toluene, Vol %
Page 19 of 100
01 Aug 2002
Section 1.0
Rev. 12

Table 1.1.4-5 Estimated Light & Heavy Naphtha Properties
Case 1
(165,000 BPSD
Hamaca Crude
Feed
& 1000+F Coker
Feed)
IBP (1%)
10
50
90
EP (98%)
Case 2
(165,000 BPSD
Hamaca Crude
Feed
& 950+F Coker
Feed)
Case 3
(190,000 BPSD
Hamaca Crude
Feed
& 1000+F Coker
Feed)
SOR
EOR
SOR
EOR
SOR
EOR
150
187
150
187
150
187
150
187
150
187
150
187
263
327
360
263
327
360
263
327
360
263
327
360
263
327
360
263
327
360
Table 1.1.4-6 Estimated Kerosene Properties

Case 1
(165,000 BPSD
Hamaca Crude
Feed
& 1000+F Coker
Feed)
Case 2
(165,000 BPSD
Hamaca Crude
Feed
& 950+F Coker
Feed)
Case 3
(190,000 BPSD
Hamaca Crude Feed
& 1000+F Coker
Feed)
SOR
EOR
SOR
EOR
SOR
EOR
345 525
345 - 525
345 - 525
345 - 525
345 525
345 - 525
API Gravity
37.2
37.2
38.3
38.3
38.3
38.3
Sulfur, wppm
10
10
10
10
10
10
Nitrogen, wppm
<1
<1
<1
<1
<1
<1
IBP (1%)
330
330
330
330
330
330
10
369
369
369
369
369
369
50
454
454
454
454
454
454
90
513
513
513
513
513
513
EP (98%)
535
535
535
535
535
535
Flash Point, F
22.0
22.0
23.0
23.0
23.0
23.0
Kerosene
Nominal TBP Distillation
Range, F
Smoke Point, mm

Page 20 of 100
01 Aug 2002
Section 1.0
Rev. 12

Table 1.1.4-6 Estimated Kerosene Properties
Case 1
(165,000 BPSD
Hamaca Crude
Feed
& 1000+F Coker
Feed)
Case 2
(165,000 BPSD
Hamaca Crude
Feed
& 950+F Coker
Feed)
Case 3
(190,000 BPSD
Hamaca Crude Feed
& 1000+F Coker
Feed)
SOR
EOR
SOR
EOR
SOR
EOR
Naphthalenes, vol%
<3
<3
<3
<3
<3
<3
Freeze Point, F
-63
-63
-63
-63
-63
-63
Aromatics, Vol%
11
11
11
11
11
11
<5
<5
<5
<5
<5
<5
Doctor Test
NEG
NEG
NEG
NEG
NEG
NEG
Silver Strip
7.1
7.1
7.1
7.1
7.1
7.1
Viscosity, cSt at 20C
Table 1.1.4-7 Estimated Diesel & Gas Oil Properties

Case 1
(165,000 BPSD
Hamaca Crude
Feed
& 1000+F Coker
Feed)
Case 2
(165,000 BPSD
Hamaca Crude
Feed
& 950+F Coker
Feed)
Case 3
(190,000 BPSD
Hamaca Crude
Feed
& 1000+F Coker
Feed)
SOR
EOR
SOR
EOR
SOR
EOR
525 - 680
525 - 680
525 - 680
525 - 680
525 680
525 - 680
API Gravity
32.7
32.7
33.8
33.8
33.8
33.8
Sulfur, wppm
10
10
10
10
10
10
Nitrogen, wppm
<1
<1
<1
<1
<1
<1
IBP (1%)
515
515
515
515
515
515
10
538
538
538
538
538
538
50
596
596
596
596
596
596
90
663
663
663
663
663
663
EP (98%)
710
710
710
710
710
710
Flash Point, F
Diesel
Nominal TBP Distillation Range, F

Page 21 of 100
01 Aug 2002
Section 1.0
Rev. 12

Table 1.1.4-7 Estimated Diesel & Gas Oil Properties
Case 1
(165,000 BPSD
Hamaca Crude
Feed
& 1000+F Coker
Feed)
Case 2
(165,000 BPSD
Hamaca Crude
Feed
& 950+F Coker
Feed)
Case 3
(190,000 BPSD
Hamaca Crude
Feed
& 1000+F Coker
Feed)
SOR
EOR
SOR
EOR
SOR
EOR
Pour Point, F
-7
-7
-7
-7
-7
-7
Cloud Point, F
-7
-7
-7
-7
-7
-7
Cetane Number
~53
~53
~54
~54
~54
~54
50
50
51
51
51
51
Aromatics, Vol%
12
12
12
12
12
12
<5
<5
<5
<5
<5
<5
Copper Strip
CFPP, F
6.9
6.9
6.9
6.9
6.9
6.9
Nominal TBP Distillation Range, F
680+
680+
680+
680+
680+
680+
API Gravity
32.2
32.2
33.0
33.0
33.0
33.0
Sulfur, wppm
20
20
20
20
20
20
Nitrogen, wppm
IBP (1%)
650
650
650
650
650
650
10
696
696
692
692
692
692
50
734
734
716
716
716
716
90
783
783
750
750
750
750
EP (98%)
843
843
818
818
818
818
Viscosity, cSt at 100F

at 140F
Gas Oil
Viscosity, cSt at 210F

at 275F

Page 22 of 100
01 Aug 2002
Section 1.0
Rev. 12

1.2
Description of Flow
The Light Oil Hydrotreater is designed to hydrotreat a mixture of straight-run distillates
from the Crude Unit (Unit 10), and cracked naphtha and light coker gas oil from the
Delayed Coking Unit (Unit 12). The Light Oil Hydrotreater is a fixed-bed catalytic
process designed to remove nitrogen and sulfur from the feedstock and to improve
product properties such as cetane index and smoke point.
Unit feed and hydrogen-rich gas are mixed, heated to reaction temperature, and
contacted with hydrotreating catalyst in two fixed-bed reactors arranged in series.
Reactor effluent passes through heat exchangers and a cooler to a separator, where
hydrogen-rich recycle gas, sour water, and liquid product are separated. The recycle gas
is contacted with amine to remove hydrogen sulfide, combined with makeup gas, and
returned to the reactor. Liquid from the separator passes through a flash drum to the
Hydroprocessing Support Unit (Unit 15) for further processing.
The Light Oil Hydrotreater (Unit 14) consists of the following major sections:
Unit Feed and Feed Surge Drum
Charge Pump and Feed Heating
Reactors
Reactor Effluent Cooling
Separator
Flash Drum
Recycle Gas Scrubber
Recycle Gas Compressor
Recycle Gas Heater
The Light Oil Hydrotreater Unit Process Flow Diagrams (PFDs) and selected overall
refinery Control Interface Diagrams (CIDs), which are located in Section 4.3 of the
Operating Manual, can be used as a supplemental reference to the process descriptions.

Page 23 of 100
01 Aug 2002
Section 1.0
Rev. 12

1.2.1 Sectional Descriptions
1.2.1.1 Unit Feed and Feed Surge Drum
The Light Oil Hydrotreater (Unit 14) receives straight run
combined distillate feed from the Crude Unit (Unit 10), light coker
gas oil (LCGO), coker naphtha, and coker light ends from the Gas
Plant (Unit 18), and cold distillate from intermediate tankage.
Typically, most of the unit feed is routed hot directly from the
Crude Unit and Gas Plant. During normal operation,
approximately 10% of the Crude Unit combined distillate is cooled
and routed to the gas blanketed Light Oil Hydrotreater Feed Tank.
This cold distillate is then pumped to the Light Oil Hydrotreater
under flow control reset by level control at the Feed Surge Drum,
14-V-001.
The cold distillate is routed through the Feed Coalescer, 14-V-005,
which removes from the distillate any water that may have been
picked up in storage. The Feed Coalescer prevents water from
mixing with the hot contents in the Feed Surge Drum, 14-V-005.
Water removed in the Feed Coalescer is routed to the phenolic sour
water collection header under interface level control.
The individual unit feeds are combined and routed through the
Feed Filters, 14-F-001A/B. Each of the two filters is sized for
100% of design capacity. These cartridge type filters remove
particulate matter from the feed that would otherwise foul the
reactor catalyst beds. Combined feed exiting the Feed Filters
enters the Feed Surge Drum, 14-V-001. The Feed Surge Drum is a
vertical vessel blanketed with natural gas to maintain a constant
suction pressure for the Charge Pump, 14-P-001.
1.2.1.2 Charge Pump and Feed Heating
The Charge Pump, 14-P-001, is a multi-stage, high-head, motor
driven pump that increases the pressure of the unit charge to
reactor feed pressures. A common spare Charge Pump, 16-P-001B,
is provided to serve as a 100% spare for both the Light Oil
Hydrotreater Charge Pump and the Gas Oil Hydrocracker Charge
Pump.
Feed exiting the Charge Pump is transferred under flow control to
the tubeside of the Reactor Effluent Feed Exchangers 14-E002A/B/C, where the feed is heated against reactor effluent. A
fraction of the fresh feed is bypassed around the exchangers
Page 24 of 100
01 Aug 2002
Section 1.0
Rev. 12

through an automatic valve that controls the temperature of the
mixed feed at the outlet of the exchangers. A portion of the unit
recycle gas is injected into the fresh feed entering the tubeside of
the exchangers. The Reactor Effluent Feed Exchangers consist
of three shells operating in series.
1.2.1.3 Reactors
Feed exiting the Reactor Effluent Feed Exchangers flows to the
reactors. Before entering the reactors, the feed is mixed with
recycle gas exiting the Recycle Gas Heater, 14-H-001. The mixed
feed then enters the top of Reactor No. 1, 14-R-001. Reactor No. 1
contains three beds. The first bed contains a guard bed, denitrogenation catalyst, and a silica trap. The second bed contains
more silica trap catalyst and hydrotreating catalyst. The third bed
contains hydrotreating catalyst. Cold recycle gas is added on flow
control (reset by temperature) between the first and second beds
and the second and third beds to reduce and control (quench) the
temperature of the material flowing through the reactor. A quench
distributor, mixing chamber and liquid re-distribution trays are
provided between each bed.
Effluent from Reactor No. 1 is cooled with a flow controlled
recycle gas quench and then enters the top of Reactor No. 2, 14-R002. Reactor No. 2 contains two beds; both beds contain
hydrotreating catalyst. Cold recycle gas is added on flow control
(reset by temperature) between the beds to reduce and control
(quench) the temperature of the material flowing through the
reactor. A quench distributor, mixing chamber and liquid redistribution trays are provided between the beds.
1.2.1.4 Reactor Effluent Cooling
Effluent from Reactor No. 2 enters the shellside of Reactor
Effluent Hot Recycle Gas Exchanger, 14-E-001, where it is
cooled against hot recycle gas. The effluent then enters the
shellside of Reactor Effluent Feed Exchanger, 14-E-002A/B/C,
where the effluent is cooled against fresh feed. This exchanger
consists of three shells in series.
Reactor effluent exiting 14-E-002A/B/C enters the shellside of the
Reactor Effluent Cold Recycle Gas Exchanger, 14-E-003, where
it is cooled against cold recycle gas. The effluent then enters the
shellside of Reactor Effluent Flash Drum Liquid Exchanger, 14E-004A/B/C, where the effluent is cooled against liquid exiting the
Page 25 of 100
01 Aug 2002
Section 1.0
Rev. 12

Flash Drum, 14-V-004. This exchanger consists of three shells in
series.
The reactor effluent then flows to the air-cooled Product
Condenser, 14-EA-001A-P. Before entering the Product
Condenser, wash water is injected under flow control into the
reactor effluent to prevent the deposition of salts that can corrode
and foul the condenser. Wash Water Pumps 15-P-009A/B in the
Hydroprocessing Support Unit (Unit 15) provide the wash water to
Unit 14. The Product Condenser consists of 16 bays; each bay is
provided with two fans.
1.2.1.5 Separator
Reactor effluent exiting the Product Condenser, 14-EA-001A-P,
enters the Separator, 14-V-002. The Separator is a high pressure
vessel that provides the requisite residence time for separating
recycle gas and sour water from hydrotreated light oil product. A
boot section at the bottom of the vessel collects the separated sour
water, while the lighter hydrocarbon product accumulates in the
main vessel.
Vapor exiting the Separator is routed to the Recycle Gas Scrubber,
14-C-001. The pressure in the Separator is maintained by
controlling the flow of make-up hydrogen into the recycle loop, or
alternatively by venting excess vapor from the recycle loop to the
flare header. The vent to flare is not utilized under normal
operating conditions.
NOTE: The vapor outlet from the Separator has a high
concentration of wet hydrogen sulfide (H2S), which makes this line
prone to corrosion and leaks. Ensure that detailed Refinery
procedures are followed for thoroughly inspecting the vapor outlet
line from 14-V-002 for potential corrosion at specified intervals,
including during every turnaround.
Liquid hydrocarbon and sour water streams leaving the Separator
are sent to the Flash Drum, 14-V-004, under level control, via
multi-stage control valves.
1.2.1.6 Flash Drum
The Flash Drum, 14-V-004, receives flashing hydrocarbon liquid
and flashing sour water from the Separator, 14-V-002. The Flash
Drum provides the requisite residence time for separating flash gas
and sour water from hydrotreated light oil product. A boot section
Page 26 of 100
01 Aug 2002
Section 1.0
Rev. 12

at the bottom of the vessel collects the separated sour water, while
the lighter hydrocarbon product accumulates in the main vessel.
Vapor exiting the Flash Drum is routed to the Flash Gas Scrubber,
15-C-005, in the Hydroprocessing Support Unit (Unit 15). The
pressure in the Flash Drum is maintained by controlling this flow
of flash gas to the Flash Gas Scrubber, or alternatively by venting
excess vapor from the Flash Drum to the flare header. The vent to
flare is not utilized under normal operating conditions.
NOTE:
The vapor outlet from the Flash Drum has a high

concentration of wet hydrogen sulfide (H2S), which
makes this line prone to corrosion and leaks. Ensure
that detailed Refinery procedures are followed for
thoroughly inspecting the vapor outlet line from 14-V004 for potential corrosion at specified intervals,
including during every turnaround.
Liquid hydrocarbon exits the Flash Drum under level control and is
sent to the tubeside of the Reactor Effluent Flash Drum Liquid
Exchanger, 14-E-004A/B/C, where the liquid is heated against
reactor effluent before flowing to the Stripper, 15-C-001, in the
Hydroprocessing Support Unit (Unit 15). A bypass is provided
around the tubeside of 14-E-004A/B/C to control the temperature
of flash drum liquid flowing to Unit 15.
Sour water exits the Flash Drum under level control and is sent to
the non-phenolic sour water collection header.
1.2.1.7 Recycle Gas Scrubber
Recycle gas from the Separator, 14-V-002, flows to the Recycle
Gas Scrubber, 14-C-001, which is a high pressure column where
recycle gas is contacted with lean amine to remove H2S and
improve the hydrogen partial pressure. Lean amine is pumped
from the High Pressure Lean Amine Pumps, 15-P-006A/B, in the
Hydroprocessing Support Unit (Unit 15) under flow control to the
Recycle Gas Scrubber.
The recycle gas is contacted with the lean amine in the scrubber,
and the rich amine, which is now saturated with H2S, collects in the
bottom section of the column. The rich amine is pressured out
under level control to the Fuel Gas Scrubber, 15-C-007, in the
Hydroprocessing Support Unit (Unit 15) via a multistage control
valve.
Page 27 of 100
01 Aug 2002
Section 1.0
Rev. 12

Recycle gas flows into the top section of the Recycle Gas Scrubber
where the gas is contacted with a circulating water stream to wash
residual amine from the gas. Water Circulating Pumps 14-P002A/B circulate the wash water through the upper section of the
Recycle Gas Scrubber. Water Circulating Pump 14-P-002B is a
100% spare. The water circulating system can be replenished
periodically by opening the manual valve off the wash water
header fed by the Wash Water Pumps, 15-P-009A/B, in the
Hydroprocessing Support Unit (Unit 15). The system can also be
bled periodically by opening the manual valve connected to the
rich amine outlet from the Recycle Gas Scrubber.
1.2.1.8 Recycle Gas Compressor
Recycle gas exiting the Recycle Gas Scrubber, 14-C-001, flows to
the Recycle Gas Compressor Knockout Drum, 14-V-003, which
knocks out any liquid carryover from the scrubber. Liquid
accumulated in this drum is manually drained to the relief header.
Recycle gas from the Recycle Gas Compressor Knockout Drum
mixes with makeup hydrogen gas from the Makeup Gas
Compressor, 15-K-001. Makeup gas enters the system under
Separator pressure control. The mixed recycle gas and makeup gas
flows to the Recycle Gas Compressor, 14-K-001.
The Recycle Gas Compressor is a steam turbine driven centrifugal
compressor. It circulates recycle gas back to the Recycle Gas
Heater, 14-H-001; to an injection point in the fresh feed line
upstream of the Reactor Effluent Feed Exchangers, 14-E002A/B/C; and to quench injection points at Reactor No. 1, 14-R001, and Reactor No. 2, 14-R-002. Before entering the Recycle
Gas Heater, 14-H-001, the recycle gas is heated on the tubeside of
the Reactor Effluent Cold Recycle Gas Exchanger, 14-E-003, and
the Reactor Effluent Hot Recycle Gas Exchanger, 14-E-001.
1.2.1.9 Recycle Gas Heater
The Recycle Gas Heater, 14-H-001, is a twin-cell double-fired
vertical box-type with a total of eight passes. Each pass is
individually flow controlled to maintain a balanced flow through
the heater. Fuel gas is supplied to the heater under temperature
control that is monitored both at the fired heater outlet and at the
Reactor No. 1, 14-R-001, inlet. Recycle gas exiting the Recycle
Gas Heater mixes with feed from the Reactor Effluent Feed
Exchanger, 14-E-002A/B/C.
Page 28 of 100
01 Aug 2002
Section 1.0
Rev. 12

1.2.2 Process Variables and Chemical Reactions
This section includes a description of the process variables and chemical
reactions associated with the Light Oil Hydrotreater Unit (Unit 14), which
utilizes the UOP-licensed Unionfining process technology. The figures and
graphs presented in this section were provided by UOP for the Unionfining
process and can be used as guidelines. Specific graphs can be developed as
required based on actual unit operating data, possibly in consultation with the
licensor.
Detailed descriptions of the unit process control systems are presented in
Section 1.3. Process control and alarm set points are provided in Section 6.7.
1.2.2.1 Sulfur Removal
Typical feedstocks to a distillate hydrotreater contain simple
mercaptans, sulfides, and disulfides. These compounds are easily
converted to H2S. However, feedstocks containing heteroatomic
aromatic molecules are more difficult to process. Desulfurization
of these compounds proceeds by initial ring opening and sulfur
removal followed by saturation of the resulting olefin. Thiophene
is considered 15 times more difficult to process compared to
diethylsulfide.
a. Mercaptan
C-C-C-C-SH + H2
C-C-C-C + H2S
b. Sulfide
C-C-S-C-C + 2H2
2 C-C + H2S
c. Disulfide
C-C-S-S-C-C + 3H2
2 C-C + 2H2S
d. Cyclic Sulfide
e. Thiophenic

Page 29 of 100
01 Aug 2002
Section 1.0
Rev. 12
1.2.2.2 Nitrogen Removal

Denitrogenation is generally more difficult than desulfurization.
Side reactions may yield nitrogen compounds more difficult to
hydrogenate than the original reactant. Saturation of heterocyclic
nitrogen-containing rings are also hindered by large attached
groups, as indicated in Figure 1.2.2-1.
The reaction mechanism steps are different compared to
desulfurization. The denitrogenation of pyridine proceeds by
aromatic ring saturation, ring hydrogenolysis, and finally
denitrogenation.
a. Pyridine
b. Quinoline
c. Pyrrole
1.2.2.3 Oxygen Removal

Organically combined oxygen is removed by hydrogenation of the
carbon-hydroxyl bond forming water and the corresponding
hydrocarbon.

Page 30 of 100
01 Aug 2002
Section 1.0
Rev. 12
Figure 1.2.2-1 Denitrogenation

Page 31 of 100
01 Aug 2002
Section 1.0
Rev. 12
a. Phenols
1.2.2.4 Olefin Saturation

Olefin saturation reactions proceed very rapidly and have a high
heat of reaction.
a. Linear Olefin
C-C=C-C-C-C + H2
C-C-C-C-C-C (and isomers)
b. Cyclic Olefins
1.2.2.5 Aromatic Saturation

Aromatic saturation reactions are the most difficult. The reactions
are influenced by process conditions and are often equilibrium
limited. Unit design parameters consider the desired degree of
saturation for each specific unit. The saturation reaction is very
exothermic.
1.2.2.6 Metals Removal

The mechanism of the decomposition of organo-metallic
compounds is not well understood. However, it is known that
metals are retained on the catalyst by a combination of adsorption
and chemical reaction. The catalyst has a certain maximum
tolerance for retaining metals. Removal of metals normally occurs
in plug flow fashion with respect to the catalyst bed. Typical
organic metals native to most crude oils are nickel and vanadium
(Normal feed to the Light Oil Hydrotreater contains negligible
Page 32 of 100
01 Aug 2002
Section 1.0
Rev. 12

nickel and vanadium). Iron can be found concentrated at the top of
catalyst beds as iron sulfides, which are corrosion products.
Sodium, calcium and magnesium are due to contact of the feed
with salt water or additives. Improper use of additives to protect
fractionator overhead systems from corrosion or to control foaming
account for the presence of phosphorus and silicon.
The useful life of the catalyst may be determined by the amount of
metals that are accumulated on it during the course of operation.
Most Unionfining units are able to go through several operating
cycles without exceeding the ability of the catalyst for removing
metals. In a typical Unionfining unit, metal removal is essentially
complete above temperatures of 600F to a metals loading of 2-3
wt% of the total catalyst. Above this level, the catalyst begins to
approach equilibrium saturation and metals breakthrough is likely.
The total metals retention of the catalyst system is increased by
using a guard bed of catalyst specifically designed for
demetallization. Some demetallization catalysts may retain as
much as 100 wt% metals based on fresh catalyst weight. Such
catalysts typically have a lower activity for desulfurization and
denitrogenation.
1.2.2.7 Halides Removal
Organic halides, such as chlorides and bromides, are decomposed
in the reactor. The inorganic ammonium halide salts that are
produced when the reactants are cooled are then dissolved by
injecting water into the reactor effluent or leave with the stripper
off-gas. Decomposition of organic halides is considered difficult
with a maximum removal of ~90% for a typical Unionfining unit.
HCl + NH3
NH4Cl
1.2.2.8 Reaction Rates

The relative reaction difficulty for several major hydrotreating
reactions are indicated in Figure 1.2.2-2.

Page 33 of 100
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Section 1.0
Rev. 12
Figure 1.2.2-2 Hydroprocessing Reaction

Difficulty Levels

Page 34 of 100
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Section 1.0
Rev. 12
The approximate relative heats of reaction per unit of hydrogen

consumption for these reactions are:
Desulfurization
Olefin Saturation
Denitrogenation
Aromatic Saturation
1
2
1
1
All of the reactions discussed above are exothermic and result in a

temperature rise across the reactor. Olefin saturation and some
desulfurization reactions have similarly rapid reaction rates, but it
is the saturation of olefins that generates the greatest amount of
heat. The temperature rise expected for a given charge stock along
with the desired product quality plays a very important role in
determining the number, size, and arrangement of the reactors, heat
exchange, and hydrogen circulation rate.
1.2.2.9 Hydrocracking Reactions
The products of the Unionfining reactions are of a lower density
than the feedstock. Therefore, the total liquid yield will be greater
than the feed. Some hydrocracking may take place in the
Unionfining process. This is especially evident toward the end of
an operating cycle when reactor temperatures are raised to
compensate for lower catalyst activity. Total liquid yield and
hydrogen consumption will increase as hydrocracking reactions
proceed. In general, most of the increase in liquid volume yield
will come from more net stripper overheads at the expense of
lower stripper bottoms product. The typical Unionfining unit is
designed for maximum bottoms production. Economic
considerations determine the amount of bottoms product that can
be lost before the unit is shutdown for regeneration or catalyst
change.
1.2.2.10 Hydrogen Consumption
The hydrogen consumed by Unionfining reactions is supplied
externally and must be boosted to reaction system pressure. The
amount of hydrogen required to complete the above reactions
varies depending upon feed and desired product quality.

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1.2.2.11 Catalyst Deactivation
Catalyst activity is reduced whenever molecules cannot reach
active sites. Catalyst deactivation may be caused by one or more
of the following mechanisms:
a. Coke Deposition
Each catalyst system is designed to promote selective
hydrogenation reactions while suppressing undesirable side
reactions. The most undesirable side reaction is the
condensation of polynuclear and olefinic compounds into
high molecular weight, low hydrogen content compounds
commonly referred to as coke. Coke formation begins with
adsorption of high molecular weight molecules and proceeds
with further loss of hydrogen. Coke laydown is a timetemperature phenomenon.
Deactivation increases with time and magnitude of the
temperature catalyst is exposed to. Coke deposition occurs at
a relatively slow rate and the catalyst is able to operate
effectively for periods of one year or more before
regeneration becomes necessary (The Light Oil Hydrotreater
is designed for a 2 year expected catalyst cycle length). The
coke can cover active sites and/or prevent access to these
sites by physical blockage of the entrance to the pores leading
to the sites. Reactor temperatures must be increased to
compensate for the slow decline in activity caused by the
accumulation of coke (and metals) on the catalyst. During
upsets or when the catalyst is subjected to operating
conditions beyond the design limits of the unit, coke
formation accelerates and catalyst life is reduced. Most of
the catalyst activity can usually be recovered by regeneration.
However, when deactivation is caused by extreme conditions,
such as reactor temperatures over 800F (the normal
maximum reactor outlet temperature of the Light Oil
Hydrotreater is 770F) or high end point feed, the
regeneration may not be successful.
b. Metals Accumulation
Metals may come into the system via additives (anti-foaming
agents), feedstock contaminants (Pb, Fe, As, P, Na, Ca, Mg),
or organometallic compounds. The deposition of metals
usually occurs at the pore entrances or near the outer surface
Page 36 of 100
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Rev. 12

of the catalyst. This deposition creates a layer affecting the
accessibility to the catalyst interior and active sites.
c. Catalyst Sintering
Catalyst support and active metal sites can be sintered upon
exposure to high temperatures. High water partial pressures
contribute to this effect as well. The active metals can
become mobile and agglomerate under these conditions. The
resulting loss in active surface reduces catalyst activity. The
catalyst support will also lose surface area from the collapse
of pores or from an increase in pore diameter with pore
volume remaining constant.
d. Reactor Temperature
Reactor temperature should be minimized while maintaining
desired product quality. Increasing reactor temperature will
greatly accelerate the rate of coke formation and reduce the
length of the operating cycle. The required temperature is
dependent upon feed rate and quality. A general practice is to
reduce reactor temperature prior to reducing feed rate and
conversely, to increase feed rate prior to increasing
temperature.
e. Feed Boiling Range
Sulfur, Nitrogen, and metal content of typical feedstocks
increase with relative volatility and endpoint requiring higher
reactor temperatures. Heavier feeds contain more coke
precursors, solids, and metals contributing to catalyst
deactivation and increased reactor pressure drop. Ultimate
catalyst life and cycle length will decrease with heavier feeds.
f. Charge Rate
Unit operation may become difficult at reduced charge rates
due to mechanical and hydraulic considerations. Liquid
distribution in the reactor may become unequal resulting in
preferential flow and poor catalyst utilization. For these
reasons, the unit should not be operated at feed rates below
the design turndown rate for extended periods (The Light Oil
Hydrotreater is designed for a turndown to 50% of the design
feed rate).

Page 37 of 100
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Rev. 12

g. Hydrogen Partial Pressure
Hydrogen partial pressure is the value of the system pressure
times the hydrogen purity. At a given system pressure, the
recycle gas purity will determine the partial pressure of
hydrogen in the reactor. At reduced hydrogen purities, the
Unionfining reactions do not proceed at the same rate. A
hydrogen deficient atmosphere also creates a greater
tendency to form coke. These conditions cause the catalyst to
lose apparent activity. To compensate, the process technician
may increase reactor temperature to maintain the same
product quality, which would further aggravate the problem.
If recycle gas purity cannot be increased, action should be
taken to reduce hydrogen consumption. This would require
reducing reactor temperatures and/or feed rate. Increasing
make-up hydrogen purity and/or rate will increase the recycle
hydrogen purity and minimize catalyst deactivation.
h. Recycle Gas Rate
The large quantity of gas recycled from the high pressure
separator to the reactor serves the following purposes:
Provides the excess hydrogen needed to assure that the

reactions are carried to completion.
Absorbs some of the heat of reaction, thereby minimizing

the catalyst bed temperatures.
Helps hold down recycle gas heater and feed and effluent
exchanger tube wall temperatures by increasing the flow
through the equipment. The excess hydrogen prevents
the formation of coke as the charge is heated to reaction
temperature.
The recycle gas heater, feed and effluent exchangers,

compressors, etc. have been designed to allow for the
circulation of a minimum ratio of recycle gas to hydrocarbon
charge. This ratio, expressed as standard cubic feet of recycle
gas per barrel of feed (SCFB) is commonly referred to as the
gas-to-oil ratio. The gas-to-oil ratio is an economic optimum,
balancing initial investment against catalyst life.
If the unit is operated at less than the design gas-to-oil ratio,
higher catalyst bed temperatures will be required to achieve
the same product quality. This accelerates coke formation
Page 38 of 100
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Rev. 12

and equipment wear. A complete loss of recycle gas can
result in very serious damage to the catalyst and equipment.
A safety device is incorporated in the unit to shut down the
recycle gas heater and unit charge whenever the recycle gas
flow drops to a predetermined minimum. Other steps to be
taken during such an emergency are explained in the
Description of Emergency Systems section (Section 1.4) of
this Operating Manual.
i. Catalyst Regeneration
Unionfining catalysts may be regenerated to remove coke and
sulfur compounds from the catalyst to recover activity. The
catalyst may be regenerated several times before replacement
becomes necessary if the catalyst is not subjected to extreme
operating conditions or exposed to permanent poisons such as
alkaline metals. The regeneration procedure consists of
burning the carbon and sulfur accumulated on the catalyst
under controlled conditions. This procedure may be done exsitu by a merchant catalyst regenerator. The Light Oil
Hydrotreater is not designed for in-situ catalyst regeneration.
j. Reactor Temperatures
The reactor inlet temperature is most easily and commonly
controlled by the process technician to adjust the sulfur or
nitrogen removed from the feed. The reactor outlet
temperature is a function of the feed quality and cannot be
easily varied except by changing the reactor inlet
temperature. The inlet temperature must always be
controlled at the minimum required to achieve the desired
product properties (see Figure 1.2.2-3). Temperatures above
this minimum will only lead to higher rates of coke formation
and reduced processing periods.
The weight average bed temperature (WABT) is typically
used to compare the relative catalyst activity. The WABT can
be calculated as indicated in Figure 1.2.2-4.

Page 39 of 100
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Section 1.0
Rev. 12
Figure 1.2.2-3 Desulfurization and Denitrification vs. Catalyst

Temperature

Page 40 of 100
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Section 1.0
Rev. 12
Figure 1.2.2-4 Weight Average Bed Temperature Calculation

Page 41 of 100
01 Aug 2002
Section 1.0
Rev. 12

The rate of increase in this temperature is referred to as the
deactivation rate expressed as F per barrel of feed per pound
of catalyst, or simply as F per day. During the course of an
operating cycle, the temperature required to obtain the
desired product quality will increase as a result of catalyst
deactivation (see Figure 1.2.2-5). The gradual loss in catalyst
activity can be compensated for by gradually increasing
reactor temperatures up to the maximum bed temperature (An
upper limit of 770F is used for the Light Oil Hydrotreater).
In general, above this level, coke formation becomes very
rapid and little improvement in performance is obtained.
The reactor temperature profile should be adjusted to
maintain equal peak temperatures across each catalyst bed.
This ensures equal utilization of the catalyst inventory. The
design temperatures of the reactor and recycle gas heater will
also determine the maximum allowable operating values.
The temperature rise across the reactors must be monitored
continuously in order to assure that the design limitation of
the unit is not exceeded. This can be especially important
when changing feedstocks since olefin saturation results in
considerably higher heats of reaction.
k. Feed Quality and Rate
The amount of catalyst loaded into the reactors as well as
other design parameters are based on the quantity and quality
of feedstock the unit is designed to process. While minor
changes in feed type and charge rate can be tolerated, wide
variations should be avoided since they will tend to reduce
the useful life of the catalyst.
An increase in the charge rate will require higher reactor
temperature to achieve a constant desulfurization, as well as
higher recycle gas rate to maintain a constant ratio of H2 to
hydrocarbon. The increased reactor temperatures will also
lead to a faster rate of coke formation, which will reduce the
period between regenerations. A reduced feed rate may lead
to bad flow distribution through the catalyst, such that higher
temperatures will be required to obtain good product quality.
In order to minimize the effect of variations in charge rate, it
should be made common practice to reduce the reactor
temperature before lowering the feed rate, and conversely, to
increase the feed rate before raising the reactor temperature.

Page 42 of 100
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Section 1.0
Rev. 12
Figure1.2.2-5 WABT vs. Catalyst Life

Page 43 of 100
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Rev. 12

The type of feed being processed is best indicated by its
distillation range and API gravity. An increase in the end
point of the feed will make sulfur and nitrogen removal more
difficult, thus requiring higher reactor temperatures which, in
turn, accelerate coke formation and catalyst deactivation, as
indicated in Figure 1.2.2-6. Coke deposition is also
accelerated by the fact that heavier feed contains more of the
precursors that favor coke formation.
In addition to the above, high boiling fractions also contain
increased quantities of metals which lead not only to higher
reactor pressure drop, but to rapid catalyst deactivation as
well. It must be remembered that regeneration will not
restore the activity of a catalyst that has been poisoned by
excessive quantities of metals.
Thus, it is seen that processing higher than design end point
feeds will, at best, reduce the length of the operating cycle,
and under extreme conditions, may lead to an irrecoverable
loss of catalyst activity. Therefore, every effort must be made
to maintain the end point of the feed within the design limits
by operating the crude and other units such that an acceptable
feed stock is obtained. Storage tanks used for the
accumulation of feed to the unit must be gas blanketed (with
nitrogen) or floating roof tanks with torroidal seals in order to
minimize the formation of coke producing and polymer
forming materials that will foul the catalyst bed and increase
pressure drop.
A reduction in the API gravity of the feed for the same
boiling range is an indication of higher unsaturates content.
This type of feed will result in increased hydrogen
consumption and higher temperature rise across the catalyst
bed. It also contains more of the materials that easily
condense to form coke in the reactor and associated
equipment.

Page 44 of 100
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Section 1.0
Rev. 12
Figure 1.2.2-6 Effect of Feedstock Quality on Catalyst

Deactivation

Page 45 of 100
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Section 1.0
Rev. 12

l. Pressure
The reactor section operating pressure is controlled by the
pressure maintained at the Separator. This pressure,
multiplied by the H2 purity of the recycle gas, determines the
partial pressure of H2 in the reactor. The hydrogen partial
pressure required for the operation of the unit is chosen based
on the degree of sulfur (or nitrogen) removal that must be
achieved and is an economic optimum that balances initial
investment and operating costs against catalyst life (see
Figure 1.2.2-7).
Hydrogen partial pressure is also a critical design parameter
for achieving the desired degree of feed saturation, as
indicated in Figures 1.2.2-8 and 1.2.2-9.
The operating pressure (i.e., the Separator pressure) must be
held constant at the design value for the following reasons:
While higher than design operating pressure directionally

favors catalyst life and may result in somewhat better
catalyst activity, such operation would be detrimental
since the equipment (heaters, reactors, compressors,
exchangers, safety valves, etc.) has been designed based
on a fixed Separator pressure. An increase in the
Separator pressure will lead to accelerated wear on the
equipment, and in extreme cases could result in costly
and dangerous equipment failures.
A reduction of the operating pressure below the design

level will have a negative effect on the activity of the
catalyst and will accelerate catalyst deactivation due to
coke formation, as indicated in Figure 1.2.2-10.
m. Gas-to-Oil Ratio
The importance of this variable to the satisfactory
performance of the unit has already been described in this
manual. It is once again emphasized that the unit should not
be operated at less than design gas-to-oil ratio since rapid
catalyst deactivation will result. The design ratio is set to
provide sufficient hydrogen for the reactions (assuming
recycle gas purity is maintained) and to provide enough heat
sink to continuously remove the heat of reaction.

Page 46 of 100
01 Aug 2002
Section 1.0
Rev. 12
Figure 1.2.2-7 Desulfurization vs. Hydrogen Partial

Pressure
Figure 1.2.2-8 Hydrogen Partial Pressure vs. Distillate

Cetane Number

Page 47 of 100
01 Aug 2002
Section 1.0
Rev. 12
Figure 1.2.2-9 Effect of Hydrogen Partial Pressure on

Saturation of Aromatics
Figure 1.2.2-10 Catalyst Deactivation vs. Hydrogen Partial

Pressure

Page 48 of 100
01 Aug 2002
Section 1.0
Rev. 12

The gas-to-oil is calculated as follows:
Gas-to-Oil Ratio =
Total gas at standard conditions

per unit time to reactors
Raw oil charge per unit time
The quantity of gas circulated from the Separator to the

reactor is relatively large. The gas flow is required for the
following purposes:
Provides the excess H2 needed to assure that the reactions

are carried to completion.
Absorbs some of the heat of reaction minimizing the

catalyst bed temperatures.
Minimizes recycle gas heater and feed and effluent

exchanger tube wall temperatures by increasing the flow
through the equipment. The excess H2 also prevents
formation of coke as the charge is heated to reaction
temperature.
A gradual reduction in recycle gas rate may be observed

during the course of an operating period as a result of higher
reactor system pressure drop. This effect is especially
pronounced on units that use a centrifugal recycle gas
compressor. Such a reduction in the recycle gas rate is
acceptable as long as the calculated gas-to-oil ratio does not
fall below the design value. When it is no longer possible to
maintain the minimum gas-to-oil ratio, the catalyst must be
regenerated and screened in order to reduce the reactor
pressure drop. In all cases that result in less than design gasto-oil ratio due to pressure drop or mechanical difficulties, the
raw oil charge rate must be lowered in order to obtain the
required gas-to-oil ratio. In the event of a complete loss of
recycle gas, immediate remedial action must be taken to
protect the catalyst and equipment, as indicated in the
Description of Emergency Systems section of this manual.
n. Space Velocity
The design quantity of catalyst per unit of feed depends upon
feedstock properties, operating conditions, and product

Page 49 of 100
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Section 1.0
Rev. 12

quality required. The liquid hourly space velocity (LHSV) is
defined as follows:
LHSV
volume of charge per hour

volume of catalyst
A simplified kinetic expression based on sulfur and/or

nitrogen removal determines the initial liquid hourly space
velocity for most feedstocks and processing objectives. This
initial value may be modified due to other considerations
such as unit size, extended catalyst cycle life, abnormal levels
of feed metals, and requirements of other processing units in
the refinery flow scheme.
A unit design is based on operation to achieve optimum
performance. One criterion is liquid mass flux across the
catalyst bed. At reduced throughput, unit operation may
become difficult due to hydraulic considerations (i.e., control
valves operating closed, etc.). Also, reactant distribution in
the reactor may become unequal as preferential flow paths
are established. For these reasons, the unit should not be
operated below the minimum turndown capacity for extended
periods. The Light Oil Hydrotreater is designed for a unit
turndown of 50% of design capacity.
o. Recycle Gas Hydrogen Purity
The effective completion of the hydrogenation reactions
occurring over the catalyst requires that a certain quantity of
hydrogen be present at a minimum partial pressure. As noted
previously, both the quantity (gas-to-oil ratio) and partial
pressure are dependent upon the hydrogen content, i.e.,
purity, of the recycle gas. Practical considerations, such as
the cost of compression, catalyst life, etc., limit the purity of
the recycle gas to a minimum value. Low hydrogen purities
are detrimental to the performance of the unit since higher
temperatures must be used to achieve the desired product
quality. The purity of the recycle gas is determined by the
following factors:

The purity of the makeup gas.
The amounts of light hydrocarbons and H2S that are

allowed to accumulate in the recycle gas.
Page 50 of 100
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Rev. 12

In most instances, the makeup gas H2 purity cannot be easily
manipulated since it is fixed by the operation of the H2
manufacturing plant. Light hydrocarbons present in the
recycle gas enter the system with the makeup gas in addition
to those being formed in the reactor. These are either vented
from the Separator or accumulate to an equilibrium value
with excess dissolved in the liquid hydrocarbon leaving the
Separator (the Light Oil Hydrotreater does not normally
require venting of purge gas). The amount of hydrogen
required is determined by:
Chemical Hydrogen Consumption The hydrogen

consumed during the hydrotreating reactions.
Solution Losses The hydrogen that is removed from the

reactor circuit dissolved in the liquid hydrocarbon leaving
the Separator.
Mechanical Losses The hydrogen lost through the

makeup and recycle gas compressors packing vents and
seals. This value may be roughly estimated at 3-5% of
the combined chemical consumption plus solution losses.
Venting Losses The hydrogen lost in the purge stream

from the Separator to maintain recycle gas purity (the
Light Oil Hydrotreater does not normally require venting
of purge gas).
The H2S formed in the reactors can accumulate to an

equilibrium value in the recycle gas. This concentration of
H2S has a depressing effect on the activity of the catalyst.
Therefore, in many cases it is desirable to remove the H2S
from the recycle gas. The removal of H2S is performed in a
Recycle Gas Scrubber where the recycle gas in contacted
with MDEA solution. In this manner, the H2S content of the
recycle gas is reduced to a part per million range.
p. Catalyst Contaminants
1.
Temporary Contaminants
Process variables influence catalyst life by effecting the
rate of carbon deposition on the catalyst. There is a
moderate accumulation of carbon on the catalyst during
the initial days of operation. The rate of increase will
Page 51 of 100
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Section 1.0
Rev. 12

be reduced to very low levels under normal processing
conditions. In a typical Unionfining unit, a carbon
level of 5 wt% may be tolerated without a significant
decrease in desulfurization. However, denitrogenation
activity would be reduced.
The sulfur and nitrogen found in the feed can be
considered contaminants to the extent that they produce
hydrogen sulfide and ammonia, which can react to
form ammonium bisulfide. The water injected into the
reactor effluent dissolves the ammonium bisulfide and
prevents exchanger fouling. Organic nitrogen in the
feed, if present in amounts higher than expected, will
require higher reactor temperatures for processing, and
will lead to a reduction in catalyst life.
If the water injection should be stopped for any period
of time, the H2S and NH3 may accumulate in the
recycle gas and result in a sudden loss in catalyst
activity. The activity will return to normal once wash
water is reestablished. Catalyst bed temperatures
should not be increased to compensate for the
temporary activity loss.
Small amounts of molecular nitrogen, CO, and CO2
that enter the system with the makeup gas are not
harmful to the catalyst, but must be vented to prevent
accumulation in the recycle gas (venting is not
normally required in the Light Oil Hydrotreater).
Excessive amounts of CO and CO2 may have an
adverse effect on catalyst performance, as they may be
methanated by the catalyst taking up active sites and
liberating heat. This will raise the outlet temperature
and reduce the apparent catalyst activity. The unit
should never be pressured up with high CO + CO2
containing makeup gas as a temperature runaway may
result. The presence of O2 could increase equipment
fouling (especially the feed/effluent exchangers).
2.
Permanent Contaminants
Permanent loss of catalyst activity is usually caused by
the gradual accumulation of inorganic species picked
up from the feed, makeup hydrogen, or effluent wash
water. Examples include arsenic, lead, calcium,
sodium, silicon and phosphorus. Low concentrations
Page 52 of 100
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Section 1.0
Rev. 12

of these elements (and other alkaline metals) can cause
deactivation over time as they are deposited on the
catalyst and the integrated effect of time and
temperature.
Organic msetal compounds are decomposed and
typically deposit in the upper section of the catalyst bed
as a metal sulfide. The graded catalyst bed, if used,
may contain demetallization catalysts, which have a
high metals retention capacity. Some of these catalysts
may retain as much as 100 wt% of the fresh catalyst
weight as metals from the feed. These demetallization
catalysts typically have a lower activity for
desulfurization and denitrogenation.
Unionfining catalysts exhibit a moderate tolerance for
metals such as arsenic and lead. Total metal content of
2-3 wt% of the Unionfining catalyst have been
observed. However, product analysis frequency should
be increased to monitor breakthrough when
calculations show the metals level on the Unionfining
catalyst exceeds about 0.5 wt%. Metals cannot be
removed during regeneration. In a typical Unionfining
unit, catalyst replacement should be considered when
metal loadings of 1-2 wt% are exceeded on the
Unionfining catalyst.
Apparent catalyst deactivation may be caused by the
accumulation of deposits on top of the catalyst bed.
Solid material, such as corrosion products and coke,
will lead to rapid fouling of the catalyst bed if allowed
to enter the reactor. This problem can be remedied by
skimming a portion of the catalyst, screening, and
reloading. Feed filtering is quite effective in removing
solid material, and as such results in longer operating
cycles due to the lower rate of reactor pressure drop
build-up.

Page 53 of 100
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Section 1.0
Rev. 12

1.3
Description of Process Controls

This section describes the key features of complex control loops designated by CNnumber. For a more detailed description and loop diagrams, see Section 6.1 of this
Operating Manual.
Refer to the Normal Operating Procedures and Safe Upper and Lower Operating Limits
sections of this Operating Manual (Sections 2.2 and 2.5.1, respectively) for discussions
of the effect of changes in controlled variables upon the dynamics of a process system.
The Light Oil Hydrotreater Unit Process Flow Diagrams (PFDs) and selected overall
refinery Control Interface Diagrams (CIDs), which are located in Section 4.3 of the
Operating Manual, can be used as a supplemental reference to the process control
descriptions.
Light Oil Hydrotreater Feed System (14-CN-001)

Refer to P&ID No: 421300-14-A1-0100, 0101, and 0107.
During normal operation the flow rates of the LCGO, coker naphtha and coker
light ends streams are maintained in the Gas Plant using flow control reset by
level control (refer to following Complex Loop Narratives: LCGO 42130012-CN-006; coker naphtha 421300-18-CN-007; coker light ends 42130018-CN-010).
The flow rate of combined distillate from the Crude Unit to the Light Oil
Hydrotreater is maintained on flow control by 14-FIC-001.
Within the Crude Unit, the pressure controller (10-PIC-581) on the combined
distillate header diverts remaining combined distillate (in excess of the
demand for hot distillate from 14-FIC-001) to intermediate tankage (61-TK009/013). The flow rate of cold distillate, which is pumped from tankage to
the LOH, is maintained on flow control, 14-FIC-005, reset by the Feed Surge
Drum level control, 14-LIC-004.
The overall Unit 14 fresh feed rate is maintained on flow control by 14-FIC025. This flow controller should normally be set at a rate approximately equal
to the combined rate that the Unit 14 feed streams are produced in the
respective source units. The intermediate distillate tankage provides a buffer
to handle variations between the source rates and the Unit 14 fresh feed rate.
The flow rates of LCGO, coker naphtha, and coker light ends to the LOH are
measured (14-FIC-003, 14-FIC-002 and 14-FIC-004, respectively) and
summed (14-FY-055).

Page 54 of 100
01 Aug 2002
Section 1.0
Rev. 12

The distillate streams from the Crude Unit and intermediate tankage are
measured (14-FIC-001 and 14-FIC-005, respectively) and summed (14-FY053).
The Unit 14 feed ratio controller, 14-FFIC-054, receives summed flow rates
from 14-FY-055 and 14-FY-053. Whenever the ratio of the combined Gas
Plant stream feed rate to the total Unit 14 feed rate exceeds 0.60, 14-FFIC-054
sends a set point signal to the respective Gas Plant stream flow controllers (14FIC-002/003/004). These controllers then send a signal to the respective Gas
Plant control valves (via a low selector) to reduce the flow rates of LCGO,
coker naphtha and coker light ends (refer to following Complex Loop
Narratives: LCGO 421300-12-CN-006; coker naphtha 421300-18-CN007; coker light ends 421300-18-CN-010). A DCS alarm will sound when
the ratio exceeds 0.60.
The Feed Surge Drum level control, 14-LIC-004, which provides the set point
for flow controller 14-FIC-005, will shut off the flow of cold distillate from
tankage on high surge drum level by closing 14-FV-005. In addition, a
shutdown system (14-YC-002) is provided to shut off the flows of the hot Unit
14 feeds on high high level in the Feed Surge Drum (refer to Logic Definition
Document 421300-14-YC-002).
Feed Surge Drum Pressure Control System (14-CN-002)
Refer to P&ID No: 421300-14-A1-0101.
The Feed Surge Drum pressure control systems maintains the pressure in Feed
Surge Drum (14-V-001) at an average value of 75 psig. If the pressure begins
to falls below 73 psig, pressure controller 14-PIC-005A allows natural gas to
flow into the drum by regulating pressure control valve 14-PV-005A.
Similarly, if the pressure begins to rise above 77 psig, pressure controller 14PIC-005B releases natural gas from the drum to the low pressure relief header
by regulating pressure control valve 14-PV-005B. Both control valves should
be in the closed position (0%) if the pressure is between 73 and 77 psig. Only
one of the two control valves should be open at any given time.
Recycle Gas Heater Pass Flow Balance Control System (14-CN-003)
Refer to P&ID No: 421300-14-A1-0103.
The Recycle Gas Heater (14-H-001) has eight passes, each with its own flow
controller and control valve. Controller 14-FIC-060 regulates control valve
14-FV-060 to modulate the flow of recycle gas through Pass #1. Similarly,
controllers 14-FIC-061, -062, -063, -064, -065, -066, and -067 regulate their
corresponding control valves to maintain the same flow rate in each pass.

Page 55 of 100
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Each flow controller generates a 0% to 100% signal, which corresponds to the
reverse valve position. The control valve is fully open when the controller
output is 0%, and completely closed when the output is 100%. Low signal
selector 14-ZY-001 monitors the output signals from each of the eight flow
controllers, and transmits only the lowest signal to the master controller, 14ZIC-001. The master controller resets this signal to 10% and sends it to the
corresponding controller to hold the associated control valve in this pass at
approximately 90% open. The master controller also cascades the flow
measured from this pass as a setpoint to the flow controllers in the other seven
passes.
Typically, the flow controller outputs from the other seven passes will all be
above 10%, with the corresponding control valve positions all less than 90%
open. However, hydraulic resistances in each pass may change over a period
of time. If the flow controller output in any of these passes drops below 10%,
signal selector 14-ZY-001 will automatically select that output and identify it
as the pass with the highest hydraulic resistance. Controller 14-ZIC-001 will
then reset this signal to 10% to hold the corresponding control valve in the
90% open position, and cascade the measured flow as the new setpoint to the
other seven flow controllers.
Recycle Gas Heater Firing Control System (14-CN-004)
Refer to P&ID No: 421300-14-A1-0103, 0104, and 0105.
The function of the Recycle Gas Heater Firing Control System is to adjust the
firing of Fuel Gas so that the resultant temperature when the heated Recycle
Gas is mixed with the Feed stream is within the specified limits for the
hydrotreating reactions. A temperature controller 14-TIC-020 located in the
feed stream at the inlet to Reactor No. 1 cascades a setpoint to temperature
controller 14-TIC-017 located in the Recycle Gas stream at the outlet of the
heater. Fuel Gas flow controller 14-FIC-058 regulates fuel control valve 14FV-058 based on the setpoint it receives from temperature controller 14-TIC017.
Combustion air is supplied by means of a natural draft. To fine-tune the
amount of combustion air, the process technician can manually adjust the
position of blade damper 14-HV-006 using DCS hand controller 14-HIC-006.
Pressure controllers 14-PIC-066 and 14-PIC-018 monitor the fuel gas pressure
at the inlet to the burners. These controllers are programmed with setpoints to
override the output of fuel flow controller 14-FIC-058 if the flow controllers
output results in firing above or below safe operating limits. The upper
operating limit is typically set at the fuel gas pressure corresponding to the
firing rate limited by the combustion air supply. The lower operating limit is
set at the minimum pressure required for flame stability.
Page 56 of 100
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Section 1.0
Rev. 12

First, the DCS compares the output from the flow controller with that from 14PIC-018, which is set at the upper operating limit. Low signal selector 14-FY058B prevents over firing by blocking the flow controllers output only when
it is higher than the output from 14-PIC-018. The DCS next compares the
resultant signal from 14-FY-058B with that from 14-PIC-066, which is set at
the lower operating limit. High signal selector 14-FY-058C prevents operation
at fuel gas pressures below minimum firing conditions by selecting the higher
of the two signals to regulate the position of control valve 16-FV-058.
Reactor Temperature Measurement
Refer to P&ID No: 421300-14-A1-0105, 0106.
Multiple thermocouples are provided for Reactor No. 1 (14-R-001) and
Reactor No. 2 (14-R-002) to measure catalyst bed and reactor wall (skin)
temperatures. These temperature points, which are displayed in the DCS as
temperature indicators, are used to monitor reactor operation. In addition,
each temperature indicator has a high temperature alarm to alert the process
technician to take corrective action. One of the temperature points at the top
of the second and successive catalyst beds in each reactor is used to control the
bed inlet temperature by adjusting the flow of cold quench gas to the quench
zone upstream of the bed.
The Unit 14 Reactor temperature instruments are summarized in Table 1.3.5-1.
Table 1.3.5-1 - Unit 14 Reactor Temperature

Measurement
Tag Number
Reactor
Location
14-TI-069 thru 071
14-R-001
Catalyst Bed #1 Top
14-TI-072 thru 074
14-R-001
Catalyst Bed #1 Bottom
14-TIC-075
14-R-001
Catalyst Bed #2 Top
14-TI-076 thru 077
14-R-001
Catalyst Bed #2 Top
14-TI-078 thru 080
14-R-001
Catalyst Bed #2 Middle
14-TI-081 thru 083
14-R-001
14-TIC-084
14-R-001
Catalyst Bed #3 Top
14-TI-085 thru 086
14-R-001
Catalyst Bed #3 Top
14-TI-087 thru 089
14-R-001
14-TI-090 thru 092
14-R-001

Page 57 of 100
01 Aug 2002
Section 1.0
Rev. 12
Table 1.3.5-1 - Unit 14 Reactor Temperature

Measurement
Tag Number
Reactor
Location
14-TI-022 thru 034
14-R-001
Skin at Bed #1 Bottom
14-TI-035 thru 047
14-R-001
14-TI-048 thru 060
14-R-001
14-TI-061 thru 068
14-R-001
Skin at Reactor Bottom Head
14-TI-136 thru 138
14-R-002
Catalyst Bed #1 Top
14-TI-139 thru 141
14-R-002
14-TIC-142
14-R-002
Catalyst Bed #2 Top
14-TI-143 thru 144
14-R-002
Catalyst Bed #2 Top
14-TI-145 thru 147
14-R-002
14-TI-148 thru 150
14-R-002
14-TI-102 thru 114
14-R-002
14-TI-115 thru 127
14-R-002
14-TI-128 thru 135
14-R-002
Skin at Reactor Bottom Head
Product Condenser Fin-Fan Control System (14-CN-005)

Refer to P&ID No: 421300-14-A1-0109.
Fin Fan Cooler 14-EA-001 cools the Reactor Effluent from the Reactor
Effluent/ Flash Drum Liquid Exchangers 14-E-004A/B/C. The Cooler has
sixteen bays (A through P), each with two fans.
The Central Control Building process technician is provided with DCS screen
handswitches (14-HS-023A through 14-HS-024P) to remotely start/stop each
individual cooler fan to adjust cooler duty and maintain the temperature of the
product flowing into Separator 14-V-002.
The Central Control Building process technician is also provided with an
Emergency Group Start DCS screen hand switch to remotely re-start all 32
fans simultaneously in the event of an electrical power dip.
Page 58 of 100
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Section 1.0
Rev. 12

Separator Level Control System (14-CN-006)
Refer to P&ID No: 421300-14-A1-0109 and 0110.
The Separator (14-V-002) is a high pressure vessel that provides the requisite
residence time for separating recycle gas and sour water from hydrotreated
light oil product. A boot section at the bottom of the vessel collects the
separated sour water, while the lighter hydrocarbon product accumulates in the
main vessel.
Individual level controllers regulate the flow of light oil and sour water from
this high pressure source into substantially lower pressure systems via
individual multi-stage control valves. Due to this large difference in pressure,
proper operation of the level controllers and control valves is considered to be
critical for safe operation, and significant redundancy has been built into the
system.
14-LT-010A and 14-LT-010B measure the interface (water) level in the boot
section of Separator 14-V-002 and provide inputs to controllers 14-LIC-010A
and 14-LIC-010B, respectively. The process technician can select only one of
the two controller outputs using switch 14-LY-010D. Another switch, 14-LY010C, allows the process technician to direct the controller output to either 14LV-010A or 14-LV-010B. For safety reasons, only one of the two control
valves can be selected.
14-LT-011 and 14-LT-030 measure the hydrocarbon level in the main vessel
and provide inputs to controllers 14-LIC-011 and 14-LIC-030, respectively.
The process technician can select only one of the two controller outputs using
switch 14-LY-031. Another switch, 14-LY-011C, allows the process technician
to direct the controller output to either 14-LV-011A or 14-LV-011B. For safety
reasons, only one of the two control valves can be selected.
Flash Drum Level Control System (14-CN-008)
Refer to P&ID No: 421300-14-A1-0111.
The Flash Drum (14-V-004) provides the requisite residence time for
separating Flash Gas and Sour Water from the hydrotreated Gas Oil product.
A boot section at the bottom of the vessel collects the separated sour water,
while the lighter hydrocarbon product accumulates in the main vessel.
Individual level controllers regulate the flow of light oil and sour water from
this vessel into lower pressure systems. Redundant transmitters and
controllers are provided for each service to increase system reliability.
14-LIT-012 and 14-LT-013 measure the interface (water) level in the boot
section of Flash Drum 14-V-004 and provide inputs to controllers 14-LIC-012
Page 59 of 100
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Section 1.0
Rev. 12

and 14-LIC-013, respectively. The process technician can select only one of
the two controller outputs using switch 14-LY-013A to control 14-LV-013.
14-LIT-015 and 14-LT-014 measure the hydrocarbon level in the main vessel
and provide inputs to controllers 14-LIC-015 and 14-LIC-014, respectively.
The process technician can select only one of the two controller outputs using
switch 14-LY-015 to control 14-LV-014.
Recycle Gas Scrubber Rich Amine Level Control System (14-CN-010)
The Recycle Gas Scrubber (14-C-001) is a high-pressure column in which
Recycle Gas is contacted with Lean Amine to remove H2S and improve the
hydrogen partial pressure. The Rich Amine, which is now saturated with H2S,
collects in the bottom section of the column from where it pressured out under
level control to a substantially lower pressure system via a multi-stage control
valve. Due to this large difference in pressure, the proper operation of the
level controller and control valve is considered to be critical for safe operation,
and significant redundancy has been built into the system.
14-LT-019 and 14-LT-033 measure the rich amine level in the bottom of the
Recycle Gas Scrubber 14-C-001 and provide inputs to controllers 14-LIC-019
and 14-LIC-033, respectively. The process technician can select only one of
the two controller outputs using switch 14-LY-033. Another switch, 14-LY019C, allows the process technician to direct the controller output to either 14LV-019A or 14-LV-019B. For safety reasons, only one of the two control
valves can be selected.
Flash Drum Pressure Control System (14-CN-012)
Refer to P&ID No: 421300-14-A1-0111.
The Flash Drum Pressure Control System maintains the pressure in Flash
Drum (14-V-004) at 360 psig by preferentially sending the flashed vapors to
Unit 15. The Flash Drum has two DCS pressure controllers that obtain their
process variable from pressure transmitter 14-PT-044. Pressure controller 14PIC-044A is operated at low range (0 to 50%) to regulate the normal flow of
flash gas to Unit 15 by modulating control valve 14-PV-044A. Pressure
controller 14-PIC-044B is operated at higher range (50 to 100%) to regulate
excess flow to the high pressure flare by modulating 14-PV-044B in case the
pressure in the Flash Drum continues to rise even though 14-PV-044A has
opened all the way.

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Rev. 12

Condensate Pump Auto-Start Logic (14-CN-013)
Refer to P&ID No: 421300-14-A1-0117.
Condensate Pumps 14-P-003A/B pump condensate from Surface Condenser
14-E-005 to the cold clean condensate header via the Surface Condenser
vacuum package. During normal operation, only one pump is running (either
Pump-A or Pump-B) and is designated as the main pump.
The remaining pump functions as a hot-standby spare set in AUTO mode,
ready to be started automatically if the pressure in the common discharge
header falls below minimum acceptable system conditions. Pressure
transmitter 14-PT-208 and low pressure switch 14-PSL-208 initiate the
automatic start of the standby pump. The purpose of this interlock is to
automatically restore the normal circulation of condensate in the event of a
partial or total failure of the main pump.
Charge Pump Lube Oil Auxiliary Pump Auto-Start Logic (14-CN-018)
Refer to P&ID No: 421300-14-A1-0300.
Lube oil is supplied to Charge Pump 14-P-001 by Main Lube Oil Pump 14-P001-P1, or by Auxiliary Lube Oil Pump 14-P-001-P2. The main lube oil pump
is a shaft driven pump that runs continuously when the Charge Pump is in
operation. The Auxiliary Lube Oil Pump is used to supply lube oil for startup
of the Charge Pump and to act as a standby lube oil pump for automatic
operation if the lube oil pressure falls below a preset value.
Low pressure switch 14-PSL-238 initiates the automatic start of the standby
pump.
Compressor Lube Oil Auxiliary Pump Auto-Start Logic (14-CN-019)
Lube oil is supplied to the Recycle Gas Compressor 14-K-001 by Main Lube
Oil Pump 14-K-001-P1A and the Auxiliary Lube Oil Pump 14-K-001-P1B.
The main lube oil pump is steam turbine driven and is normally in service.
The auxiliary lube oil pump acts as a standby lube oil pump for automatic
operation if the lube oil pressure falls below a preset value.
Either the low lube oil header pressure switch, 14-PSL-104, or the low lube oil
supply pressure switch, 14-PSL-112, will initiate the automatic start of the
standby pump.

Page 61 of 100
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Section 1.0
Rev. 12

1.3.1 Typical DCS Input Bypass Functionality (00-CN-901)
Unless noted otherwise on a specific complex loop narrative, all inputs to the
Distributed Control System (DCS) that effect automatic equipment protective
shutdowns and/or modify the process control/mode or operation have
programmed bypass override capability. This typically includes transmitters,
position switches, or process switches used in DCS logic that effect automatic
equipment protection trip
Each DCS input, which effects an automatic equipment protection shutdown
has an associated DCS software bypass hand-switch and alarm. These
individual software hand-switches are configured with restricted access to
Supervisor personnel only. In cases where two or three transmitters are used in
DCS voting logic to effect a shutdown, only one software bypass switch and
alarm is provided to bypass the voted protective trip function.
The individual DCS software bypass switches and alarms are not shown on the
P&IDs but are instead specifically listed in the Complex Loop Narratives
provided for each DCS logic application. The tagging convention for bypass
switches is of the following format:
XX-HSY-ZZZ
Where XX is the bypassed instruments process unit number, Y is the bypassed

instrument loops measured or initiating variable designator, and ZZZ is the
bypassed instrument loops sequence number. Thus, the software bypass
switch for the condensate header pressure transmitter 14-PT-208 would be 14HSF-208. Likewise, the associated alarm would be labeled as 14-HAF-208.
The bypass logic is implemented in such a way that the protective trip action
of the input(s) is bypassed, but the individual trip alarm(s) generated by the
input(s) remain active. For more details of this special logic, see Section 6.1.

Page 62 of 100
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Section 1.0
Rev. 12

1.4
Description of Emergency Systems

This section describes the key features of Process Safeguarding Systems designed to
abort normal operations to ensure safety of personnel and plant equipment. The
descriptions are excerpts of the Logic Definition Documents, designated by YC-number.
The Logic Definition Documents, which describe the Emergency Systems in more detail
and include cause and effect tables or logic diagrams, are located in Section 6.2 of this
Operating Manual.
Firefighting and Safety Equipment and Emergency Equipment Plot Plans are also
addressed in this section.
1.4.1 System Descriptions
1.4.1.1 Feed from Feed Coalescer Shutdown System (14-YC-001)
Refer to P&ID No: 421300-14-A1-0100.
The Light Oil Hydrotreater receives hot feed directly from the
Crude Unit and the Gas Plant and cold feed from tankage. The
feed from tankage (only) is routed through the Feed Coalescer 14V-005.
The interface (water) level in the Feed Coalescer boot is measured
by 14-LT-002. A high high interface (water) level condition will
trip 14-LSHH-002. This function triggers the closure of cold
distillate feed flow control valve 14-FV-005 via solenoid valve 14UY-001. This action prevents carryover of water into the Feed
Surge Drum 14-V-001, which normally operates at approximately
250F.
14-FV-005 is also closed by the Depressuring and Charge Pump
Shutdown Logic. (See Logic Definition Document 421300-14YC-002 for details)
1.4.1.2 Depressuring and Charge Pump Shutdown System (14-YC002)
Refer to P&ID No: 421300-14-A1-0101, 0102, 0107, 0108, 0110,
0112, 0300, and 0301.
This SIS encompasses several functions, including protecting the
Light Oil Hydrotreater reactor system from a temperature
excursion, shutting down the charge pump on low low flow or low
low suction drum level, and shutting off feeds into the high
pressure loop when low low flow is detected. When a temperature

Page 63 of 100
01 Aug 2002
Section 1.0
Rev. 12

excursion occurs in the reactor system, the process technician can
initiate depressuring of the high pressure loop using a switch on the
control room panel, which will systematically shut down the
Charge Pump (14-P-001 and 16-P-001B, when lined up) and
Recycle Gas Heater (14-H-001). In addition, control valves are
closed to shut off the flow of fresh feeds, makeup hydrogen, lean
amine and wash water. At the same time, the depressuring valve
on the Separator gas outlet line is opened to vent recycle gas to the
flare, thereby reducing the loop pressure and lowering the reactor
hydrogen partial pressure to curtail the exothermic
hydroprocessing reactions.
The Charge Pump, which is a high head multi-stage pump, is
automatically shutdown on low low discharge flow or low low
level in the Feed Surge Drum (14-V-001). The Charge Pump is
also shutdown if its suction Emergency Isolation Valve (EIV) is
closed or not fully open. The valve may only be opened and closed
from a local panel provided outside the fire area of the pump. The
pump may not be restarted unless the EIV has been fully opened.
Charge Pump 16-P-001B is a standby unit that serves either Unit
14 or Unit 16 as selected by the process technician using a console
mount selector switch 16-HS-043.
The level in the Feed Surge Drum 14-V-001 is measured by 14-LT005. The detection of a low low level condition is performed by
14-LSLL-005. This function triggers the following events:
Shutdown Charge Pump 14-P-001.
Shutdown Charge Pump 16-P-001B when lined up in Unit 14

service.
The detection of a high high level condition in Feed Surge Drum

14-V-001 is performed by 14-LSHH-005. This function triggers
the following events:

Close 14-FV-001 controlling the flow of Combined Distillate

from Unit 10.
Close 18-FV-103 controlling the flow of Coker Naptha from

Unit 18.
Close 18-FV-064 controlling the flow of LCGO from Unit 18.
Page 64 of 100
01 Aug 2002
Section 1.0
Rev. 12
Close 18-FV-162 controlling the flow of Coker Light Ends

from Unit 18.
Close 14-FV-005 controlling the flow of cold Distillate feed

from storage. (Refer to Logic Definition Document 14-YC001).
14-HS-001 is an ESD switch located in the Control Room. The

actuation of 14-HS-001 triggers the following events:
Shutdown Charge Pump14-P-001.

service.

from Unit 10.

Unit 18.

from Unit 18.

The detection of low low charge pump discharge flow is performed

by 14-FSLL-009A and 14-FSLL-009B. Utilizing 1 out of 2 voting
logic, the voted output 14-FSLL-009 triggers the following events:


service.

from Unit 10.

Unit 18.
Page 65 of 100
01 Aug 2002
Section 1.0
Rev. 12

from Unit 18.

The detection of low low fresh feed flow to the reactor

effluent/feed exchangers is performed by 14-FSLL-026A and 14FSLL-026B. Utilizing 1 out of 2 voting logic, the voted output 14FSLL-026 triggers the following events:
Close 14-FV-025 controlling the Fresh Feed to Reactor

Effluent-Feed Exchangers (14-E-002A/B/C).
Close 14-TV-168, which is the bypass valve for Reactor

Effluent- Flash Drum Liquid Exchangers (14-E-004A/B/C).
Close Recycle Gas Heater 14-H-001 fuel gas shutoff valves 14XV-014 and 14-XV-016 respectively (refer to Logic Definition
Document 14-YC-003).
Open Recycle Gas Heater 14-H-001 fuel gas vent valve 14XV-015 (refer to Logic Definition Document 14-YC-003).
Open Recycle Gas Heater stack damper 14-HV-006 (refer to

Logic Definition Document 14-YC-003).
Depressuring switch 14-HS-049A is a backlighted console mount

hardware switch located in the Control Room and 14-HS-049B is a
local panel mount switch. The actuation of 14-HS-049A or 14-HS049B triggers the following events:


service.

from Unit 10.

Unit 18.
Page 66 of 100
01 Aug 2002
Section 1.0
Rev. 12

from Unit 18.

Close 14-FV-025 controlling the Fresh Feed to Reactor

Effluent-Feed Exchangers (14-E-002A/B/C).
Close 14-TV-168, which is the bypass valve for Reactor

Effluent- Flash Drum Liquid Exchangers (14-E-004A/B/C).
Close Recycle Gas Heater 14-H-001 fuel gas shutoff valves 14XV-014 and 14-XV-016 respectively (refer to Logic Definition
Document 14-YC-003).
Open Recycle Gas Heater 14-H-001 fuel gas vent valve 14XV-015 (refer to Logic Definition Document 14-YC-003).
Open Recycle Gas Heater stack damper 14-HV-006 (refer to

Logic Definition Document 14-YC-003).
Close 14-PV-036 controlling the Make-up Gas from Unit 15.
Open depressuring valve 14-HV-049.
Close 14-FV-038 controlling Lean Amine to the Recycle Gas

Scrubber (14-C-001).
Close 14-FV-130 controlling Wash Water to the Product

Condenser (14-EA-001) inlet.
The detection of low low charge pump lube oil pressure is

performed by 14-PSLL-237. This function triggers the shutdown
of charge pump 14-P-001.
The axial displacement of Charge Pump 14-P-001 is monitored in
the Bentley-Nevada vibration monitoring system. The detection of
high high axial displacement is performed by 14-ZSHH-230. This
function triggers the shutdown of charge pump 14-P-001.

Page 67 of 100
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Section 1.0
Rev. 12

The detection of Lean Amine to Recycle Gas Scrubber (14-C-001)
low low flow is performed by 14-FSLL-039A and 14-FSLL-039B.
Utilizing 1 out of 2 voting logic, the voted output 14-FSLL-039
deenergizes 14-UY-011 to close 14-FV-038 controlling Lean
Amine to the Recycle Gas Scrubber.
The detection of Wash Water to Product Condenser (14-001) inlet
low low flow is performed by 14-FSLL-131A and 14-FSLL-131B.
Utilizing 1 out of 2 voting logic, the voted output 14-FSLL-131
deenergizes 14-UY-024 to close 14-FV-130 controlling the flow of
Wash Water to the Product Condenser inlet.
Recycle Gas Heater Shutdown logic 14-YC-003 triggers the
shutdown of charge pump 14-P-001. It will also trigger the
shutdown of charge pump16-P-001B when lined up in Unit 14
service. 14-YC-003 also deenergizes 14-UY-014 to close 14-PV036 controlling the flow of Make-up Gas from Unit 15.
If the Emergency Isolation Valve (EIV) 14-HV-050 is not fully
open or if it is closed it will trigger the shutdown of Charge Pump
14-P-001. It will also trigger the shutdown of Charge Pump16-P001B when lined up in Unit 14 service.The EIV has open and
closed position switches 14-ZSO-050 and 14-ZSC-050. In the
event of fire, or potential fire, the process technician may effect
closure of the emergency isolation valve by pulling the palm button
on the local panel. When the SIS detects the open position switch
14-ZSO-050 input as an open contact (EIV not fully open), or if it
detects the closed position switch 14-ZSC-050 input as a closed
contact (EIV fully closed), it initiates the shutdown of the Charge
Pump.
NOTE:
If 14-HV-050 malfunctions closed and 14-YC-002 is not

activated, damage may result to 14-P-001 (or 16-P-001B
when in Unit 14 service). In addition, high level in 14V-001 may lead to liquid carryover to the LP flare.
Ensure that proper refinery maintenance procedures are
followed for maintaining the limit switches associated
with 14-HV-050.
1.4.1.3 Recycle Gas Heater Shutdown (14-YC-003)

Refer to the simplified system sketch (Figure 1.4.1-1) and P&ID
No: 421300-14-A1-0103, 0104, and 0116.
The Light Oil Hydrotreater Recycle Gas Heater (14-H-001) heats
the recycle gas before it is mixed with the preheated fresh feed and
Page 68 of 100
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Section 1.0
Rev. 12

routed to the Reactors (14-R-001/002). This SIS safely shuts down
the heater by closing the two fuel gas isolation valves and opening
the fuel gas vent valve to atmosphere and the heater damper.

Page 69 of 100
01 Aug 2002
Section 1.0
Rev. 12

R EC YC LE G AS H EATER SH UTD O W N
(1 4 -Y C -0 0 3 )
S N U F F IN G /
P U R G IN G
STEAM
@
C CR
PT
0 4 7 A /B
H V
006
FSLL
060
@
G RAD E
THR U
067
TYP. O F 8
PASSES
TYP. O F 8
PASSES
R EC YC LE G AS
FRO M
RXR. EFFL. - H O T
RECY. G AS EXC H.
1 4 -E -0 0 1
H S
008B
R EM O TE LO C ATED
E S D S W IT C H E S
TH RU
067
FV
060
H S
008A
TO O TH ER
HEATER
PASSES
TSH H
019
1 4 -H -0 0 1
RECYCLE G AS
H EATER
AR CH
RECYCLE G AS
TO REAC TO R
1 4 -R -0 0 1
FR O M O THER
H EATER
PASSES
TSHH
018
PSHH
016
AR CH
TO ATM
TO ATM
XV
018
XV
015
XV
016
XV
014
XV
019
XV
017
FUEL G AS
P S LL
022
PC V
0121
P IL O T
G AS
FV
058
ZSO
002
ZSC
002
PSLL
019
PSH H
019
LC
1 5 -V -0 1 0
FUEL G AS
K .O . D R U M
ZSO
009
ZSC
009
LC
LSHH
036
Figure 1.4.1-1 Recycle Gas Heater Shutdown (14-YC-003)

Page 70 of 100
01 Aug 2002
Section 1.0
Rev. 12

The SIS is initiated by various process inputs to prevent heat input
to the recycle gas, including low low recycle gas flow, high high
heater outlet temperature, and initiation of the Depressuring and
Charge Pump Shutdown SIS (14-YC-002). In addition, this SIS is
initiated to protect the heater upon detection of low low or high
high fuel gas pressure, low low pilot gas pressure, high high heater
arch temperature and high high liquid level in the Fuel Gas
Knockout Drum (15-V-010).
Switches are provided on the DCS Console panel and locally in
Unit 14 that can be used to initiate the Recycle Gas Heater
shutdown system.
Depressuring and Charge Pump Shutdown Logic 14-YC-002 when
activated trigger the following events:
Close Fuel Gas Shut-off valve 14-XV-014.
Open Fuel Gas Vent valve 14-XV-015.
Open Damper 14-HV-006.
The detection of low low Recycle Gas flow is performed by 14FSLL-060B through -067B and 14-FSLL-060C through 067C for
Heater Passes 1 through 8, respectively. Utilizing 1 out of 2 voting
logic, the voted output 14-FSLL-060 (through 067) triggers the
following events:

Shutdown Charge Pump 14-P-001 or 16-P-001B, whichever is

in service (Refer to Logic Definition Document 14-YC-002).
Close Make-up Gas valve 14-PV-036 (Refer to Logic

Definition Document 14-YC-002).
Page 71 of 100
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Section 1.0
Rev. 12

The detection of high high Recycle Gas Heater arch temperature is
performed by 14-TSHH-019A and 14-TSHH-019B. Utilizing 1
out of 2 voting logic, the voted output 14-FSHH-019 triggers the
same events as 14-YC-002 logic described above.
The detection of low low Pilot Gas pressure is performed by 14PSLL-022A and 14-PSLL-022B. Utilizing 1 out of 2 voting logic,
the voted output 14-PSLL-022 triggers the following events:
Close Pilot Gas shutoff valve 14-XV-017.
Open Pilot Gas vent valve 14-XV-018.
Close Pilot Gas shutoff valve 14-XV-019.
The detection of low low Fuel Gas pressure is performed by 14PSLL-019A and 14-PSLL-019B. Utilizing 1 out of 2 voting logic,
the voted output 14-PSLL-019 triggers the same events as 14-YC002 logic as described above.
The detection of high high Fuel Gas pressure is performed by 14PSHH-019A and 14-PSHH-019B. Utilizing 1 out of 2 voting
logic, the voted output 14-PSHH-019 triggers the same events as
14-YC-002 logic as described above.
The detection of high high Heater outlet temperature is performed
by 14-TSHH-018A and 14-TSHH-018B. Utilizing 1 out of 2
voting logic, the voted output 14-TSHH-018 sends a signal to the
DCS to ramp down the flow of fuel gas to the Heater.
The detection of high high Heater arch pressure is performed by
14-PSHH-016A and 14-PSHH-016B. Utilizing 1 out of 2 voting
logic, the voted output 14-PSHH-016 sends a signal to the DCS to
ramp down the flow of fuel gas to the Heater.
The detection of high high level in the Fuel Gas Knockout Drum
(15-V-010) is performed by 15-LSHH-037. It will trigger the same
events as 14-YC-002 logic as described above.
Page 72 of 100
01 Aug 2002
Section 1.0
Rev. 12

Backlighted ESD switch 14HS008A in the Central Control Room
or the ESD switch 14HS008B at grade remote from the Recycle
Gas Heater trigger the same events as 14-PSLL-022 as described
above.
Field mounted handswitch 14-HS-060 resets Pilot Gas Solenoid
Valves 14-XY-017, 14-XY-018, and 14-XY-019.
Field mounted handswitch 14-HS-061 resets Fuel Gas Solenoid
Valves 14-XY-014, 14-XY-015, and 14-XY-016.
1.4.1.4 Water Circulating Pumps Shutdown System (14-YC-004)
Refer to P&ID No: 421300-14-A1-0113.
The Water Circulating Pumps (14-P-002A/B) recirculate wash
water from the chimney tray below Tray No. 10 of the Recycle Gas
Scrubber (14-C-001) back to the top of 14-C-001 at Tray No. 12.
This SIS shuts off the pumps on low low flow in the discharge line
to prevent the pumps from running dry, which could cause seal
damage and subsequent release of high pressure recycle gas to
atmosphere.
The detection of low low pump discharge flow is performed by 14FSLL-046A and 14-FSLL-046B. Utilizing 1 out of 2 voting logic,
the voted output 14-FSLL-046 triggers the shutdown of pumps 14P-002A and 14-P-002B.
1.4.1.5 Recycle Gas Compressor Shutdown System (14-YC-005)
Refer to the simplified system sketch (Figure 1.4.1-2) and P&ID
No: 421300-14-A1-0115, 0310, 0311, 0312, 0314 and 0315.
The Recycle Gas Compressor (14-K-001) circulates the hydrogenrich recycle gas through the reactor loop. This SIS shuts down the
compressor on high-high liquid level in the Recycle Gas
Compressor Knockout Drum (14-V-003) to prevent any liquid
carryover into the compressor.
The compressor will be tripped on a manual ESD, on high-high
axial displacement, on turbine overspeed, on low-low lube oil
pressure or on steam turbine governor trip.
The manual ESD can be engaged from either the Central Control
Room or the Local Control Panel (14-LCP-0101).

Page 73 of 100
01 Aug 2002
Section 1.0
Rev. 12

RECYCLE GAS COMPRESSOR 14-K-001 SHUTDOWN
(14-YC-005)
PT
057
TE
185
FT
049
SEAL GAS
SYSTEM
RECYCLE GAS
CONTROL
OIL
SYSTEM
HV
062
PSLL
100
LSHH
023
RECYCLE GAS
FROM RECYCLE
GAS SCRUBBER
14-C-001
14-V-003
RECYCLE
GAS
COMPRESSOR
K.O.
DRUM
SE
AL
G
AS
PSLL
082
SE
AL
G
AS
ZSO
010
HIGH
PRESSURE
STEAM
SPILL BACK
TO PRODUCT
CONDENSER
14-EA-001
TE
186
FV
070
PT
063
QUENCH GAS
TO REACTORS
14-R-001
AND 14-R-002
MAKEUP H2 GAS
FROM UNIT 15
ZSHH
253
PV
036
SSHH
022
14-K-001
RECYCLE GAS
COMPRESSOR
14-KST-001
TURBINE
EXHAUST
TO SURFACE
CONDENSER
14-E-005
HS
041B
ESD SWITCH
@ CCR
VIBRATION
MONITORING
SYSTEM
RECYCLE GAS
TO REACTOR
EFFLUENT-COLD
RECYCLE GAS
EXCHANGER
14-E-003
PSLL
114
LUBE OIL SUPPLY

HS
041A
FV
049
LUBE OIL RETURN
ESD SWITCH
@ LCP
LUBE OIL
SYSTEM
LSL
051
Figure 1.4.1-2 Recycle Gas Compressor 14-K-001 Shutdown (14-YC-005)

Page 74 of 100
01 Aug 2002
Section 1.0
Rev. 12

14-LT-023A and 14-LT-023B measure level in the Recycle
Compressor Knockout Drum 14-V-003. 14-LAHH-023A and 14LAHH-023B are the corresponding high high DCS level alarms.
The SIS will use 1 out of 2 voting logic to initiate a compressor trip
signal when either one of the two measured values is above a
preset value.
14-PT-082 measures seal gas pressure and 14-PI-082 indicates the
measured value in the DCS. 14-PAL-082 is the low seal pressure
alarm in the DCS. Seal gas pressure is one of the permissive
signals to start the compressor. The pressure has to be above a
preset value for the compressor to start and disalarm 14-PAL-082.
14-LT-051 measures level in the lube oil run down tank 14-K-101TK1 and 14-LI-051 indicates the measured value in the DCS. 14LAL-051 is the low level alarm in the DCS and 14-LAL-051A is
the same alarm at the annunciator on 14-LCP-0101. The tank level
is one of the permissive signals to start the compressor. The level
has to be above a preset value for the compressor to start and
disalarm 14-LAL-051 and 14-LAL-051A.
14-PT-114A and 14-PT-114B measure lube oil pressure and 14-PI114A and 14-PI-114B indicate the measured values in the DCS.
14-PAL-114A and 14-PAL-114B are the corresponding low lube
oil pressure alarms in the DCS. The SIS will use 1 out of 2 voting
logic to prevent the permissive signal to start the compressor when
either one of the two measured values is below a preset value. 14PAL-114A and 14-PAL-114B will disalarm when the preset value
is reached.
14-PALL-114A and 14-PALL-114B are the low low lube oil
pressure alarms in the DCS. The SIS will use 1 out of 2 voting
logic to initiate a compressor trip signal when either one of the two
measured values is below a preset value.
14-ZSO-010 is the Open limit switch for the compressor recycle
valve 14-FV-049 and 14-ZLO-010 is the status indication in the
DCS. A confirmation of the recycle valve being open is one of the
permissive signals to start the compressor.
The axial displacement of the compressor frame is measured in the
Bentley-Nevada monitoring system, which is mounted in 14-LCP0101. The detection of high high axial displacement (via 14ZSHH-253) trips the compressor.

Page 75 of 100
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Section 1.0
Rev. 12

The turbine speed is monitored in the CCC guardian overspeed
prevention system, which is mounted in 14-LCP-0101. The
detection of overspeed (via 14-SSHH-022) trips the compressor.
A backlighted console mount ESD hand switch 14-HS-041A is
located in the central control room. Another ESD handswitch 14HS-041B is located at 14-LCP-0101. The DCS alarms associated
with the above ESD switches are 14-HA-041A and14-HA-041B
respectively. 14-HL-041A represents the backlight on 14-HS041A. This light will come on when ESD is activated manually or
through process trips. At the same time trip signals will be sent to
antisurge controller 14-XIC-005 and speed controller 14-SIC-002.
Immediately, the speed controller will ramp the compressor down
to a pre-programmed rate to the minimum control speed. After this
is completed, the controller will fully close the throttle valve 14FV-070 and the antisurge controller will fully open the recycle
valve 14-FV-049. The SIS will close the trip valves 14-XY-033A
and 14-XY-033B.
14-PT-100 measures control oil pressure and 14-PI-100 indicates
the measured value in the DCS. 14-PALL-100 is the control oil
pressure alarm in the DCS. The SIS will initiate a compressor trip
signal when the measured value is below a preset value.
14-ZSO-022A and 14-ZSO-022B are the trip valve Open limit
switches. 14-ZLO-022A and 14-ZLO-022B are the status lights in
the DCS. When both 14-ZLO-022A and 14-ZLO-022B indicate
trip valves 14-XV-030 and 14-XV-031 are fully open, the SIS will
maintain a contact closure Run input 14-XO-040 to the speed
controller 14-SIC-002 and 14-XO-043 to the antisurge controller
14-XIC-005.
14-ZY-021 is an input to the SIS. An open condition of 14-ZY-021
indicates a malfunction of the Electro-Hydraulic converter via DCS
alarm 14-ZA-021.
A normally open contact, which is maintained closed when the
turbine is at or above minimum control speed, is connected to the
local panel 14-LCP-0101. This contact is multiplied at the local
panel to energize light 14-XL-031 at the local panel and another
contact 14-XS-031 is used for the SIS logic.
14-XS-037 is a digital input signal from 14-SIC-002 to the SIS.
This is a potential free Normally Open contact which is maintained
closed when the speed controller is ready to start. The SIS will
Page 76 of 100
01 Aug 2002
Section 1.0
Rev. 12

repeat this signal to energize ready to start light 14-XL-035 on 14LCP-0101.
14-XO-039 is a digital output from the SIS to 14-SIC-002 that is
made true by the SIS when all start permissive conditions are true.
This input must be maintained as a true input until the speed
controller and the anti-surge controller receive the Run signal
from the SIS. After the two controllers receive the Run signal,
the Start Permissive signal is not required to be maintained true.
The two controllers will continue to run until they receive either a
Stop command or an ESD occurs.
14-HS-045 provides a Reset input to the SIS and to 14-SIC-002
to reset external trip conditions and clear all speed controller
shutdown and internal trip interlocks that had previously activated
and may now be reset to allow the next start-up sequence.
14-HS-046 is Start pushbutton on 14-LCP-0101. It is connected
to the SIS. When this pushbutton is activated, the SIS checks that
all trips are healthy, all required start permissives are satisfied, and
the speed controller is ready to start. If all are satisfied, the SIS
will energize the trip valve solenoids (14-XY-033A and 14-XY033B) to open the trip valve.
14-XY-032 is the turbine pre-loading valve. When the start
pushbutton 14-HS-046 is activated, 14-XY-032 is energized.
Thirty seconds after the start command, the trip valve solenoids 14XY-033A and 14-XY-033B are energized. Sixty seconds after the
start command, the pre-load solenoid 14-XY-032 is deenergized.
14-XS-038 is a digital input from 14-SIC-002 to the SIS indicating
zero speed of the turbine. Due to the fact that the CCC speed
controller cannot measure speed below 5 Hz, it may not be a true
zero speed. When 14-XS-038 is closed, indicating zero speed, the
logic will look to see that the P&F speed relay (14-SSL-023)
shows no change of state for a period of one minute. If both 14XS-038 and 14-SSL-023 indicate a zero speed, the logic will allow
the barring gear to be engaged. After the barring gear is engaged
the logic will check that at least every minute it receives one
change of state from the speed switch 14-SSL-023. If the logic
does not see a change of state within one minute, the SIS will
generate the Barring Gear Failure alarm 14-SAL-023 in the DCS
and 14-SAL-023A in the local panel.
14-HS-042 is a local panel mounted Start/Stop switch for the
barring gear. 14-ZSL-020 is the barring gear position switch. The
Page 77 of 100
01 Aug 2002
Section 1.0
Rev. 12

barring gear has to be disengaged before the compressor can be
started.
A local panel is provided a safe distance from the compressor.
This panel contains a pneumatic shuttle valve with a palm operator
(14-HS-062) which extends through the panel front. Open and
closed indicating lights are also provided on the panel (14-ZLO062, 14-ZLC-062). The pneumatic shuttle valve is piped to the
double acting cylinder actuator on emergency isolation valve (EIV)
14-HV-062 located in the compressor suction line.
The EIV has open and closed position switches (14-ZSO-062, 14ZSC-062) that are wired as inputs to the SIS. In the event of a leak
or fire, the process technician may effect closure of the emergency
isolation valve by pulling the palm button on the local panel. This
action moves the pneumatic shuttle valve such that air is directed to
close the EIV valve. When the SIS detects the open position
switch 14-ZSO-062 as an open contact input, or if it detects the
closed position switch 14-ZSC-062 input as a closed contact it
shuts down the compressor.
The SIS also has two digital outputs that are used to energize the
local panel indicating lights. The output for 14-ZLO-062 is
energized when 14-ZSO-062 is a closed contact input status, and is
de-energized when 14-ZSO-062 input is an open contact input.
Similarly, the output for 14-ZLC-062 is energized when 14-ZSC062 is a closed contact input status, and is de-energized when 14ZSC-062 is an open contact input.
DCS screens are able to monitor the valve open / closed position
(14-ZL-062). Additionally, SIS logic generates EIV trip alarm 14HA-062 whenever it determines the valve to be not open or fully
closed, and transmits this alarm to the DCS for annunciation and
display.
1.4.1.6 SIS Input Bypass Functionality (00-YC-901)
All inputs to the SIS that effect automatic shutdown action have
programmed bypass capability. This typically includes
transmitters, position switches or process switches used in SIS
logic to effect an automatic shutdown.
Bypass permissive key-switches and bypass permissive activated
lights are provided on the operator consoles for each process unit.
These switches and lights are hard-wired I/O to the SIS system. In
the Light Oil Hydrotreater Unit console, the switch and the light
Page 78 of 100
01 Aug 2002
Section 1.0
Rev. 12

are labeled 14-HS-900 and 14-HL-900, respectively. The bypass
commands can be effected only when the key-switch is placed in
the Bypass position.
The bypass logic is implemented in such a way that the trip action
associated with the input(s) is bypassed, but the individual trip
alarm(s) generated by the input(s) remains active. For more details
of this special logic, see Section 6.2 of this Operating Manual.
1.4.2 Firefighting and Safety Equipment
The Hydroprocessing Area Firefighting and Safety Equipment is described in
the Unit 67 Fire Protection Systems, Area 50 Logic Definition Document
(421300-67-YC-005), a copy of which is located in Section 6.2 of this
Operating Manual.
The location of firefighting and safety equipment is shown on the following
P&IDs (located in Section 4.10):
421300-67-A1-0107
Process Units 14, 15, &16 (North)
421300-67-A1-0108
Process Units 14, 15, &16 (South)
421300-67-A1-0116
General Notes and Legend
These drawings show the plot locations of fire fighting equipment such as fire
hydrants, fire water monitors, etc., and safety devices such as gas detectors,
safety shower and eyewash stations, etc.
The owner shall take noise measurements and identify operating areas where
hearing protection is required.
Process technicians working in Unit 14 must follow the refinery procedures
regarding the use of personal hydrogen sulfide (H2S) detectors.
1.4.3 Emergency Equipment Plot Plans
The Emergency Equipment Plot Plans are provided in Section 4.10 (Fire and
Safety Drawings) of this Operating Manual.

Page 79 of 100
01 Aug 2002
Section 1.0
Rev. 12

1.5
Chemicals and Materials

1.5.1 Summary of Catalysts and Chemicals
The catalysts and chemicals used in the Light Oil Hydrotreater Unit (Unit 14)
are listed in Table 1.5.1-1.
1.5.2 Maximum Intended Inventory Table
The normal and maximum intended inventories of hydrocarbon or hazardous
liquids in the Light Oil Hydrotreater Unit (Unit 14) are listed in Table 1.5.2-1.
Table 1.5.2-1 Hydrocarbon and Hazardous Liquid Inventories
Equipment Tag
Equipment Service
14-C-001
Recycle Gas Scrubber
14-F-001A/B
Feed Filters
14-R-001
Reactor No. 1
14-R-002
Reactor No. 2
14-V-001
Feed Surge Drum
14-V-002
Separator
14-V-003
14-V-004
14-V-005
Recycle Gas Compressor KO Drum

Flash Drum
Feed Coalescer
14-E-001
Reactor Effluent Hot Recycle Gas

Exchanger
Reactor Effluent Feed Exchanger
Reactor Effluent Cold Recycle Gas
Exchanger
Reactor Effluent Flash Drum Liquid
Exchanger
Product Condenser
Estimated Pipe Inventory
14-E-002A/B/C
14-E-003
14-E-004A/B/C
14-EA-001A thru P
Piping
TOTAL INVENTORY
Content
Amine
HC
HC
HC
HC
HC
Sour Water
HC
HC
HC
Sour Water
HC
Volume (gal) (Note 1)

Normal
Maximum
Inventory Inventory
2479
3414
454
454
9069
9069
4535
4535
12646
20590
9841
17369
704
952
0
1272
11176
19918
2062
2062
40
61
88
88
HC
HC
1777
118
1777
118
HC
1088
1088
HC
HC
Amine
Sour Water
HC
1163
10804
496
149
64,800
1163
10804
496
149
90,300
Amine
3,000
3,900
Sour Water
900
1,200
NOTE:
1. Includes estimated inventories for liquid holdup on trays as applicable.

Page 80 of 100
01 Aug 2002
Section 1.0
Rev. 12

Table 1.5.1-1 Light Oil Hydrotreater (Unit 14) Summary of Catalysts and Chemicals
Usage Point
Item /Type
CHEMICALS
Dimethyl Disulfide
Container/Receipt
Method
Equipment
No.
Equipment
Description
Frequency
of Use
(intermittent
or
continuous)
14-P-001
Charge Pump
Intermittent
Rate of
Consumption
Annual Consumption
(Catalyst Expected
Life - years)
Up to
11,000 lb/hr
419,000 lbs
every 2 years
Stored Operating
Inventory
(Catalyst Initial
Charge Note 1)
Purpose
Comment
436,458 lbs
Pre-sulfiding
Quantity required to
be charged to 15-V008 and injected at
14-P-001.
PA has decided not to
reuse neutralization
solution.
Consumption is
estimated at two
storage tank volumes.
PA has decided not to
reuse neutralization
solution.
Consumption is
estimated at two
storage tank volumes.
Soda Ash
By PA / Supplier
15-TK-001
Neutralization
Storage Tank
Intermittent
N/A
106,920 lbs
every 2 years
Neutralization
Sodium Nitrate
By PA / Supplier
15-TK-001
Neutralization
Storage Tank
Intermittent
N/A
10,692 lbs
every 2 years
Neutralization
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
(2 years)
(2 years)
(2 years)
(2 years)
(2 years)
(2 years)
(2 years)
(2 years)
(2 years)
(2 years)
(2 years)
(2 years)
(2 years)
(2 years)
CATALYSTS
UOP TK-10 5/8
By PA / Supplier
14-R-001
UOP TK-551 3/16
By PA / Supplier
14-R-001
UOP N-204 1.3Q
By PA / Supplier
14-R-001
UOP N-204 1.3Q
By PA / Supplier
14-R-001
UOP HC-K 1/20
By PA / Supplier
14-R-001
UOP HC-K 1/20
By PA / Supplier
14-R-001
UOP HC-K 1/20
By PA / Supplier
14-R-002
UOP HC-K 1/20
By PA / Supplier
14-R-002
1/8 Inert Balls
By PA / Supplier
14-R-001
1/4 Inert Balls
By PA / Supplier
14-R-001
3/4 Inert Balls
By PA / Supplier
14-R-001
1/8 Inert Balls
By PA / Supplier
14-R-002
1/4 Inert Balls
By PA / Supplier
14-R-002
3/4 Inert Balls
By PA / Supplier
14-R-002
NOTES:
1.
Initial charge includes an additional 10% contingency.

Reactor
Reactor
Reactor
Reactor
Reactor
Reactor
Reactor
Reactor
Reactor
Reactor
Reactor
Reactor
Reactor
Reactor
(118 ft3)
(471 ft3)
(3,914 ft3)
(488 ft3)
(2,147 ft3)
(4,348 ft3)
(5,990 ft3)
(7,057 ft3)
(199 ft3)
(309 ft3)
(277 ft3)
(146 ft3)
(257 ft3)
(248 ft3)
Guard-type
Guard HDN
De-sil
De-sil
Hydrotreat
Hydrotreat
Hydrotreat
Hydrotreat
Support
Support
Support
Support
Support
Support
Bed 1A
Bed 1B
Bed 1C
Bed 2A
Bed 2B
Bed 3
Bed 1
Bed 2
Page 81 of 100
01 Aug 2002
Section 1.0
Rev. 12

1.5.3 Hazardous Chemicals and Materials
CAUTION
Always refer to relevant material safety data sheets for specific hazards.
CAUTION
For a successful and uninterrupted operation of the Light Oil Hydrotreater
Unit (Unit 14) the operating company must issue a set of safety regulations for
the operating personnel as well as for personnel not permanently working in
the unit, such as maintenance crews, who would generally be less familiar with
the plant.
The following may serve as a guide for the identification of hazardous
chemicals and materials in the Light Oil Hydrotreater Unit (Unit 14) and offers
some suggestions for plant and personnel protection.
1.5.3.1 Nickel Carbonyl
Nickel carbonyl can form over nickel catalyst in an oxidizing
atmosphere, like that present in a regeneration. The possibility of it
being present is low. Nevertheless, the atmosphere above an
unregenerated, spent catalyst bed must never be inhaled.
To avoid this, fresh air masks must be worn when working in a
vessel which contains or has contained a nickel catalyst.
The maximum average exposure to nickel carbonyl recommended
by NIOSH is 0.001 wt-ppm (1 wt-ppb), and a maximum spot
exposure of 0.04 wt-ppm (40 wt-ppb).
In hydroprocessing units, the potential for forming nickel carbonyl
exists only with catalysts containing nickel and only during
regeneration or during the handling of unregenerated catalyst.
Care must be used to ensure that the procedures used will prevent
the formation of nickel carbonyl. Data has been published
showing the equilibrium concentration of Ni(CO)4 versus
temperature, pressure, and CO concentration in a gas. The nickel
carbonyl concentration drops rapidly with increasing temperature
and decreasing CO concentration. At 100 psig (7 kg/cm2g) with
0.5 mol-percent CO in the gas, the nickel carbonyl concentration is
at the maximum recommended spot level of 0.04 wt-ppm at 300F
(149C), and drops to 0.001 wt-ppm at 360F (182C).

Page 82 of 100
01 Aug 2002
Section 1.0
Rev. 12

Symptoms: Nickel carbonyl Ni(CO)4 is known to be an extremely
toxic gas. Its primary effect is to cause lung damage with a lesser
effect on the liver.
The following practices should be followed to prevent the
formation of nickel carbonyl:
Once a reactor containing a nickel catalyst has been exposed to

oxidizing conditions (i.e., during regeneration), a measurable
concentration of oxygen must be maintained until the
combustion of all carbon ceases and all CO and CO2 has been
purged from the system.
Unregenerated nickel catalyst should be maintained in a

reducing or inert atmosphere until all the catalyst has been
cooled to below 65C (150F). All unregenerated catalyst
should be cooled below this temperature and unloaded under a
nitrogen purge.
1.5.3.2 Carbon Monoxide

The toxicity of carbon monoxide (CO) is well known, and the
tolerable limits are well defined in the process industry. The MAC
value (maximum allowable concentration over an 8-hour period) is
55 mg/m3, and the explosion limit range is 12.5 - 74.2 vol%.
The most likely place where carbon monoxide may exist in
excessive concentrations is in the equipment and piping
downstream of the heater. When access to this equipment is
required, the issuance of vessel entry permits must be subject to
investigation of the atmosphere of the vessel to be entered.
1.5.3.3 Hydrogen Sulfide
Hydrogen sulfide is both an irritant and an extremely poisonous
gas. Breathing even low concentrations of hydrogen sulfide (H2S)
gas can cause poisoning. Many natural and refinery gases contain
more than 0.11) mol-percent H2S. The current OSHA permissible
exposure limits are 20 mol-ppm ceiling concentration and 50 molppm peak concentration for a maximum 10 minute exposure.
The Hydroprocessing recycle gas and debutanizer or stripper
overhead gas can contain from 0.5 to 5 mol-percent H2S. These
gases must NEVER be inhaled. Also, the water in the high pressure
separator, the flash drum and the fractionator overhead receivers
contains dissolved H2S which will flash at atmospheric pressure.
Page 83 of 100
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Section 1.0
Rev. 12

NEVER drain this water to an open sewer. One full breath of high
concentration hydrogen sulfide gas will cause unconsciousness and
could cause death, particularly if the victim falls and remains in the
presence of the H2S.
The operation of any unit processing gases containing H2S remains
safe, provided ordinary precautions are taken and the poisonous
nature of H2S is recognized and understood. No work should be
undertaken on the unit where there is danger of breathing H2S, and
one should never enter or remain in an area containing it without
wearing a suitable fresh air mask.
There are two general forms of H2S poisoning - acute and
subacute:
a. Acute Hydrogen Sulfide Poisoning
Breathing air or gas containing more than 500 mol-ppm H2S
can cause acute poisoning and possibly be fatal.
Symptoms: The symptoms of acute H2S poisoning are
muscular spasms, irregular breathing, lowered pulse, odor to
the breath and nausea. Loss of consciousness and suspension
of respiration quickly follow.
Even after the victim recovers, there is still the risk of edema
(excess accumulation of fluid) of the lungs which may cause
severe illness or death in 8 to 48 hours.
First Aid Treatment : Move the victim at once to fresh air. If
breathing has not stopped, keep the victim in fresh air and
keep him quiet. If possible, put him to bed. Secure a
physician and keep the patient quiet and under close
observation for about 48 hours for possible edema of the
lungs.
In cases where the victim has become unconscious and
breathing has stopped, artificial respiration must be started at
once. If at Pulmotor or other mechanical equipment is
available, it may be used by a trained person; if not, artificial
respiration by mouth-to-mouth resuscitation must be started
as soon as possible. Speed in beginning the artificial
respiration is essential. Do not give up. Men have been
revived after more than four hours of artificial respiration.

Page 84 of 100
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If other persons are present, send one of them for a physician.
Others should rub the patients arms and legs and apply hot
water bottles, blankets or other sources of warmth to keep
him warm.
After the patient is revived, he should be kept quiet and
warm, and remain under observation for 48 hours for the
appearance of ederna of the lungs.
b. Subacute Hydrogen Sulfide Poisoning
Breathing air or gas containing H2S anywhere between 10 to
500 mol-ppm for an hour or more may cause subacute or
chronic hydrogen sulfide poisoning.
Symptoms: The symptoms of subacute H2S poisoning are
headache, inflammation of the eyes and throat, dizziness,
indigestion, excessive saliva, and weariness. These can be
the result of continued exposure to H2S in low concentrations.
Edema of the lungs may also occur.
Treatment: Keep the patient in the dark to reduce eyestrain
and have a physician treat the inflamed eyes and throat.
Watch for possible edema. Where subacute poisoning has
been suspected, the atmosphere should be checked repeatedly
for the presence of H2S by such methods as testing by odor,
with moist lead acetate paper, and by Tutweiler H2S
determination to make sure that the condition does not
continue.
1.
Prevention of Hydrogen Sulfide Poisoning

The best method for prevention of H2S poisoning is to
stay out of areas known or suspected to contain it. The
sense of smell is not an infallible guide as to the
presence of H2S, for although the compound has a
distinct and unpleasant odor (rotten eggs), it will
frequently paralyze the olfactory nerves to the extent
that the victim does not realize that he is breathing it.
This is particularly true of higher concentrations of the
gas.
Fresh air masks or gas masks suitable for use with
hydrogen sulfide must be used in all work where
exposure is likely to occur. Such masks must be
checked frequently to make sure that they are not
Page 85 of 100
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exhausted. People who must work on or in equipment
containing appreciable concentrations of H2S, must
wear fresh air masks and should work in pairs so that
one may effect a rescue or call for help should the other
be overcome.
As mentioned above, the atmosphere in which people work should
be checked from time to time for appreciable concentrations of
H2S.
CAUTION
Remember - just because your nose says it's not there, doesn't mean that it is not.
CAUTION
1.5.3.4 N-Methyl Diethanolamine (MDEA)

N-Methyl Diethanolamine (MDEA) is used for selective H2S
removal. MDEA is a light-colored liquid with a characteristic
ammonia like odor, is readily soluble in water, benzene and
alcohol, and has weak alkali properties. MDEA has flash point of
240 F and an auto-ignition temperature of 770 F. Its upper/lower
explosion limits are 8.8/1.4 volume percent respectively.
Symptoms: MDEA is moderately toxic by swallowing. It does not
cause any significant irritation of the skin, and occasional skin
contamination will not result in any adverse effects due to
absorption. However, prolonged and extensive contact may result
in potentially harmful amounts of material being absorbed.
Moderately severe eye injury may result from splash
contamination. Inhalation of vapors is unlikely to cause any
harmful effects in the short-term.
First Aid Treatment: If in contact with eyes immediately flush with
large amounts of water for 15 minutes while holding eyelids open.
Obtain medical attention.
If in contact with skin flush with large amounts of water for 15
minutes while removing contaminated clothing and shoes. Obtain
medical attention.

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If inhaled immediately remove victim to fresh air. If breathing has
stopped give artificial respiration. If breathing is difficult
administer oxygen. Obtain medical attention.
If ingested induce vomiting. Give two glasses of water and obtain
immediate medical attention. Never give anything by mouth to an
unconscious or drowsy person.
1.5.3.5 Nitrogen
Nitrogen is an asphyxiating gas that is used for purging and
blanketing equipment and piping. Due to its asphyxiating
properties, entry into equipment containing nitrogen is extremely
dangerous.
The owner-process technician shall require a period of air
ventilation prior to personnel entry into confined spaces in their
safety procedures.
Symptoms: In spaces where most of the oxygen required for
breathing has been depleted, or replaced by nitrogen, inhalation
will rapidly lead to unconsciousness.
First Aid Treatment: If a person has lost consciousness from
entering a vessel or confined space due to lack of oxygen from
excess nitrogen the following procedure is advised.
Do not attempt to enter the confined space to render assistance
without the use of compressed air breathing apparatus or air hose
mask. Entering the confined space without breathing apparatus can
cause immediate loss of consciousness.
Immediately contact medically trained personnel, identifying the
nature of the emergency.
Remove the victim to fresh air or a well-ventilated area and loosen
any restrictive clothing.
Only a person familiar with the use of oxygen inhalation apparatus
should carry out application of oxygen to a victim. An attempt to
apply oxygen by a person not familiar with the use of the apparatus
may result in the loss of valuable time and/or may harm the victim.
Keep the victim comfortably warm, but not hot. If the victim
regains consciousness during this period, keep him as calm as
possible as he might be in a state of shock.
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If, however, respiration of the victim has stopped, commence
artificial respiration treatment at once and continue until trained
medical assistance arrives.
Do not attempt to give food or liquids to anyone who has lost
consciousness.
1.5.3.6 Anhydrous Ammonia and Aqueous Ammonia
Ammonia is toxic and can be a hazard to human health. It may be
harmful if inhaled at high concentrations. The Occupational Safety
and Health Administration (OSHA) Permissible Exposure Level
(PEL) is 50 parts per million (ppm), 8-hour time-weighted average.
Effects of inhalation of ammonia range from irritation to severe
respiratory injuries, with possible fatality at higher concentrations.
The National Institute of Occupational Safety and Health (NIOSH)
has established an Immediately Dangerous to Life and Health
(IDLH) level of 300 ppm for the purposes of respirator selection.
Ammonia is corrosive and can burn the skin and eyes. Liquefied
ammonia can cause frostbite.
The American Industrial Hygiene Association (AIHA) has
developed Emergency Response Planning Guidelines (ERPGs) for
a number of substances to assist in planning for catastrophic
releases to the community. The ERPG-2 represents the
concentration below which it is believed nearly all individuals
could be exposed for up to one hour without irreversible or serious
health effects. The ERPG-2 for ammonia is 200 ppm. EPA has
adopted the ERPG-2 as the toxic endpoint for ammonia for the
offsite consequence analysis required by the Risk Management
Program (RMP) Rule under section 112(r) of the Clean Air Act.
Although pure ammonia vapors are not flammable at
concentrations of less than 16% in air, they may be a fire and
explosion hazard at concentrations between 16 and 25%.
An important property of ammonia is its pungent odor. Odor
threshold varies with the individual but ammonia can be usually
detected at concentrations in the range of about 5 ppm to 50 ppm.
Concentrations above about 100 ppm are uncomfortable to most
people; concentrations in the range of 300 to 500 ppm will cause
people to leave the area immediately.
Anhydrous ammonia is lighter than air. The explosive limits are
15.5% to 26.6%.
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Symptoms: Ammonia is a corrosive chemical and can irritate and
burn the skin and eyes, leading to permanent damage. Exposure to
Ammonia can irritate the nose, mouth, and throat causing coughing
and wheezing. Breathing Ammonia can irritate the lungs causing
coughing and/or shortness of breath. Higher exposures can cause a
build-up of fluid in the lungs (pulmonary edema), a medical
emergency, with severe shortness of breath. Exposure can cause
headache, loss of sense of smell, nausea and vomiting.
Anhydrous ammonia can be recognized by its odor. It has irritating
effects on the eyes, skin and the mucous membranes of the
respiratory tract. It may cause immediate coughing and respiratory
trouble, even respiratory arrest, when inhaled in high
concentrations.
The effects of ammonia are listed in Table 1.5.3-1.
Table 1.5.3-1 Effects of Ammonia
Approximat
e
Concentrat
ion
(ppm vol)
Duration
Effects
25
Threshold limit value (TLV) for 8

hours per day, 40 hours per week
Odor threshold
50
Odor threshold
125
Irritation
200 - 400
Throat irritation
700
Eye irritation
2500 - 6500
30 minutes
Dangerous to life
5000 - 10000
Few minutes
Fatal
First Aid Treatment: Remove victim to a non-contaminated

location. Do not attempt to enter a hazardous area to render
assistance without the use of compressed air breathing apparatus or
air hose mask. Immediately contact medically trained personnel,
identifying the nature of the emergency. Artificial respiration
and/or administration of oxygen may be required. Keep the victim
warm. In case of skin contamination, remove contaminated clothes
and wash the skin with copious amounts of water. In case of eye

Page 89 of 100
01 Aug 2002
Section 1.0
Rev. 12

contact, flush the eyes immediately with large amounts of water for
at least 15 minutes. Have the eyes checked by a physician.
1.5.3.7 Aromatic Hydrocarbons
Toxicity and safe handling information on most of the aromatic
materials present in the unit can be found in the following
references:
Dangerous Properties of Industrial Materials. N., Irving Sax

Van Nostrand Reinhold
Pattys Industrial Hygiene Toxicology, Craley and Craley, eds.,

1979
ASTM D-270, Standard Method of Sampling Petroleum and

Petroleum Products
Data Sheet D-204 Xylene and Toluene. Published by the

National Safety Council.
Data Sheet D-308 Benzene. Published by the National Safety

Council.
a. Benzene
Small amounts of benzene can be present in a
hydroprocessing unit. Benzene is extremely toxic. Avoid
draining benzene to the concrete or into the sewers where it
can vaporize and create a health hazard. If benzene is
accidentally spilled, flush it from the concrete and sewer
catch basin with large quantities of cold water. Do not use
hot water or steam which aggravates the vaporization of
benzene. If you must enter an area of high benzene vapor
concentration resulting from a spill, wear appropriate
respiratory protection, such as self-contained breathing
apparatus or an air mask with external supply.
A large benzene spill may result in a health hazard from
benzene vapor at the separator. The separator must be
skimmed as completely as possible and all slop pumped out
of the sump to the refinery recycle system.
Though not specifically a health hazard, an environmental
problem can result from benzene entering the sewer, since
benzene is much more soluble in water than any other

Page 90 of 100
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hydrocarbon. This places an extra load on the effluent
treating system.
Symptoms: A summary of health effects which can occur
from exposure to benzene appear in Documentation of the
Threshold Limit Values (Benzene), 4th edition, 1980,
ACGIH.
First Aid Treatment: If clothing (including gloves, shoes)
becomes contaminated with benzene, the clothing should be
removed immediately. Wash any skin areas exposed to
benzene with soap and water. Take a complete bath if the
body area is wetted with benzene. Do not wear clothing that
has been wet with benzene until the garment has been
decontaminated by washing or dry cleaning. Wearing
clothing that has been wet with benzene almost assures that
the person will inhale benzene vapors over a long period of
time, resulting in potential health hazards.
b. Toluene, Xylenes and Heavier Aromatics
Such aromatic compounds may be present in small amounts
in a hydroprocessing unit.
Symptoms: These compounds are moderately toxic and are
believed to not have the destructive effect on the bloodforming organs as does benzene.
First Aid Treatment: If clothing (including gloves, shoes, etc.)
becomes wet with such aromatics, remove the clothing, bathe
and put on fresh clothing. Avoid breathing aromatic vapors.
c. Minimizing Exposure to Aromatics
Operating and laboratory personnel involved in obtaining
samples should wear chemical-type safety goggles or shield,
protective apron or laboratory coat, solvent-resistant gloves,
and approved respiratory protective equipment where
ambient concentrations exceed allowable limits. This
protective equipment is not, however, a substitute for safe
working conditions, proper ventilation, good personal
practices, and proper maintenance of both operating and
safety equipment. In all cases, skin contact (especially eyes)
and inhalation must be minimized.

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Sampling liquid hydrocarbons always requires some care to
limit personal exposure and release to the atmosphere. Even
greater care is needed when the liquid to be sampled contains
aromatic hydrocarbons, especially benzene.
In order to minimize vaporization, hot hydrocarbon streams
must be routed through a cooler before drawing a sample. In
all sampling situations, the personnel involved should be
instructed to remain at arms length from the sample
container and to situate themselves upwind of the container if
at all possible. These simple precautions will greatly
minimize exposure to the hydrocarbon vapors.
1.5.4 Material Safety Data Sheets (MSDS)
Material Safety Data Sheets (MSDSs) for the following catalysts, gases,
hydrocarbon streams and chemicals are included in Section 7.5 of this
Operating Manual.
IMPORTANT: The MSDSs included in Section 7.5 are not necessarily
specific to the Hamaca Upgrader operation. They are provided for reference
only. It is the owners responsibility to obtain updated MSDSs for the specific
chemicals and catalysts that are used in the refinery.
UOP Catalyst
TK-10 5/8"
TK-551 3/16"
N-204 1.3Q
HC-K 1/20"
(14-R-001, Reactor, guard type)

(14-R-001 Reactor, guard HDN)
(14-R-001 Reactor, De-sil)
(14-R-001 Reactor, Hydrotreating)
Gases
Hydrogen Sulfide
Hydrogen
Natural Gas
Refinery Gas
Nitrogen
Feeds
Distillate
Coker Naphtha
LCGO
Coker Light Ends
Intermediate Streams and Products
LPG
Page 92 of 100
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Naphtha
Kerosene
Diesel
Gas Oil
Fuel Gas
Chemicals
Dimethyl Disulfide
N-Methyl Diethanolamine (MDEA)
Ammonia
Caustic Soda
Sodium Carbonate
Sodium Nitrate
Lube Oils
ISO 32 Lube Oil
Oil Mist

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1.6
Environmental Protection
Pollution control for the protection of personnel and the environment is a vital part of
day-to-day operations. The Hamaca Crude Upgrader is designed to satisfy the applicable
Venezuelan environmental, health and safety regulations. It is ultimately the
responsibility of the plant operations personnel to utilize good operations/maintenance
policies and procedures in order to comply with these requirements and to minimize
environmental emissions, discharges, and company liabilities. Failure to comply with
environmental requirements may result in substantial fines, shutdown of individual units
or the entire plant, and/or criminal penalties such as imprisonment.
Petrolera Ameriven is legally obligated to operate the facility in compliance with the
applicable regulations and several additional environmental control measures as
described in the project pre-construction environmental application and approval.1 This
approval requires the development of an environmental supervisory plan (PSA, for plan
de supervision ambiental) to provide the basic framework for facility environmental and
safety compliance, in accordance with ISO 14000. Implementation of the PSA rests with
the PA Environmental, Health, and Safety Department (ASHI). ASHI provides training
programs to ensure that plant operations personnel understand the environmental and
safety features and special concerns regarding their individual units as well as their
responsibilities and duties for environmental and safety compliance. ASHI may also
provide written instructions and procedures for proper compliance with environmental
and safety requirements for certain units. It is recommended that this documentation be
incorporated into this operating manual for easy access when needed. ASHI is also
responsible for monitoring environmental, health, and safety regulations and standards
and advising operations personnel when new requirements are imposed.
If environmental/safety problems or issues arise during operations or maintenance
activities, the appropriate ASHI personnel should be consulted, if possible, before
corrective measures are taken.
It is the responsibility of the Process Technician to ensure that hydrocarbons are not
deliberately vented to the atmosphere and that all process low point drains and vents are
properly capped/plugged. When depressuring the unit, the equipment should first be
vented to the flare, and the low-pressure material should be displaced to flare by
nitrogen or low-pressure steam (if possible). Depressuring to atmosphere (at a safe
location) should occur only if no other methods are feasible.
The amine drain system, the light slop oil header (SOL), and the heavy slop oil header
(SOH) are provided to accept most equipment and instrument drains.
Additionally, two sewer systems are available for use in the Light Oil Hydrotreater Unit:
the Accidental Oily Sewer (AOS) and the Oily Water Sewer (OWS). The AOS is
Estudio Impacto Ambiental Proyecto Hamaca Planta de Mejoramiento (EIA), August 1999, and the project approval
from the Minesterio del Ambiente y de los Recursos Naturales Renovables (MARNR) contained in correspondence from
Migual A. Luna Perez, MARNR, to Ramon Loreto, PA, dated November 29,1999.

Page 94 of 100
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designed to handle any water overflow due to a fire and/or storm. The OWS is primarily
used for vessel maintenance and rotating equipment casing drains.
The discharge from process equipment containing predominantly water should be routed
to the underground oily water sewer (OWS), which leads to the effluent plant API
separator. If the discharge from process equipment is predominantly oil, such as
draining of equipment removed from service, it should be disposed to the SOL before
steam-out. If the discharge is mostly amine, then it should be disposed to the amine
drain system. The oily water from equipment after steaming is routed to the OWS. This
procedure reduces the load on the OWS system.
Any oil or chemical spills should be dealt with immediately and the surrounding area
should be washed down or otherwise cleaned accordingly. Use approved solvents or
adsorbents to handle oil spills around pumps as they pose a major safety hazard if not
dealt with.
Sampling should be performed with minimum discharge of excess material to the
atmosphere (vapor streams) or sewer (liquid streams).
Wash down of dry solids (e.g., dirt) into the sewer should be avoided if feasible. This
material is more properly disposed as solid waste.
Noise pollution may be a problem in some areas of the plant. The owner shall take
noise measurements and identify operating areas where hearing protection is required.
Environmental protection can be achieved by ensuring that all plant emissions are
properly controlled and dealt with according to specified instructions.
Plant emissions can be described as follows:
Vapor Emissions
Liquid Waste
Solid Waste
The Light Oil Hydrotreater Unit (Unit 14) emissions and liquid waste are summarized in
Table 1.6-1.
Table 1.6-1
Unit 14 Vapor Emissions & Liquid Wastes Summary
Vapor Emission/Liquid
Waste
Flue gases from Recycle Gas Heater,
Treatment and Disposition

Released to atmosphere. NOX maintained
Page 95 of 100
01 Aug 2002
Section 1.0
Rev. 12

Table 1.6-1
Unit 14 Vapor Emissions & Liquid Wastes Summary
Vapor Emission/Liquid
Waste
Treatment and Disposition
14-H-001
below 60 ppm by use of low-NOX burners.
Primary vent from Recycle Gas

Compressor, 14-K-001, seal system
Routed to HP Flare header for controlled

burning.
Secondary vent from Recycle Gas

Compressor, 14-K-001, seal system
Released to atmosphere. Only nitrogen

present in vent stream.
Vent at Feed Surge Drum, 14-V-001
Routed to low pressure flare header for

controlled burning.
Off-gas from the Flash Drum, 14-V004
Scrubbed and routed to either the Hydrogen

Production Plant (Unit 22) as fuel source, or
to HP flare header for controlled burning.
Sour water from Feed Coalescer, 14V-005
To phenolic sour water collection header in

Unit 15 which is routed to Unit 26.
Sour water from the Flash Drum, 14V-004
To non-phenolic sour water collection header

in Unit 15 which is routed to Unit 26.
Oil skimmed in Recycle Gas

Scrubber, 14-C-001
Steam stripped from Rich Amine at 15-V012 Interface Pot and routed to LP flare for
controlled burning.
Liquid hydrocarbon knocked out at

recycle Gas Compressor Knock-out
Drum, 14-V-003
Flashed off to HP flare header for controlled

burning.
Atmospheric Emissions
The Light Oil Hydrotreater Unit (Unit 14) has been designed such that most
hydrocarbon vent locations (e.g., PSV outlets) have been connected up to the
plant flare system for controlled burning.
It is the unit process technicians responsibility to ensure hydrocarbons are not
deliberately vented to the atmosphere and that all process low point drains and
vents are correctly capped/plugged.
Liquid Hydrocarbon Waste Disposal
The Light Oil Hydrotreater Unit (Unit 14) is equipped with two sewer
systems, an Accidental Oily Sewer (AOS) and an Oily Water Sewer (OWS).
The AOS system is designed to handle any condensate that is continuously
Page 96 of 100
01 Aug 2002
Section 1.0
Rev. 12

drained from the process equipment and rain water collection. The OWS is
primarily used for vessel maintenance and rotating equipment casing drains.
Avoid draining hydrocarbons to the sewer at all times. Any oil or chemical
spills should be dealt with immediately and the surrounding area washed down
accordingly.
Use approved solvents or adsorbents to handle oil spills around pumps or
compressors as they pose a major safety hazard if not dealt with.
Amine Drain System
To minimize soil and surface water contamination by MDEA, a closed drain
system is provided to collect amine drained from equipment and instruments
during maintenance. The sources are gravity drained through sloped
underground lines to the Amine Sump, 15-SU-001, where collected liquids can
be returned to the Amine Regeneration Unit (Unit 24) process or discharged
manually to a mobile container for disposal.
Solid Waste Disposal
Solid wastes from the Hydrotreater consist of spent catalyst from the Reactors
(14-R-001 and 14-R-002), which may be removed during major plant
shutdowns.
Special precautions should be taken when handling spent catalysts, and it is
recommended to follow catalyst manufactures instructions for handling and
disposal of spent catalyst.
Reactor unloading can present extraordinary health risks, especially to
personnel working in the reactor. During the unloading, large quantities of
catalyst dust may be generated. Additional hazards may include a
contaminated atmosphere in the reactor, residual hydrocarbons or toxic forms
of catalyst chemicals (e.g., nickel carbonyl). See Section 2.4 (Special
Procedures) of this Operating Manual for further details on catalyst unloading.

Page 97 of 100
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Rev. 12

1.7
Utilities
Utility Conditions
Utility conditions in the Light Oil Hydrotreater Unit (Unit 14) are summarized
in the Utility Design Information Table included in Section 7.1 of this
Operating Manual.
Utility Requirements
The Utility Summary Tables, which list the utility consumption and production
for the Light Oil Hydrotreater Unit (Unit 14), are included in Section 7.3 of
this Operating Manual.

Page 98 of 100
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Section 1.0
Rev. 12

1.8
Design Codes and Standards

Listed below are the organizations, standards and codes that had been used in the design
of this project:
AASHTO
American Association of State Highway and Traffic Officials
ABMA
American Boiler Manufacturing Association
ACI
American Concrete Institute
AGMA
American Gear Manufacturers Association
AISC
American Institute of Steel Construction
ANSI
American National Standards Institute
API
American Petroleum Institute
ASCE
American Society of Civil Engineers
ASHI
American Standards of Hydraulic Institute
ASME
American Society of Mechanical Engineers
ASNT
American Society for Non-Destructive Testing
ASTM
American Society of Testing and Materials
AWS
American Welding Society
AWWA
American Water Works Association
CEMA
Conveyer Equipment Manufacturers Association
CMAA
Crane Manufacturers Association of America
COVENIN
Comision Venezolana de Normas Industriales
CTI
Cooling Towers Institute
DEMA
Diesel Engines Manufacturers Association
EJMA
Expansion Joint Manufacturers Association
FAA
Federal Aeronautics Administration
FM
Factory Mutual

Page 99 of 100
01 Aug 2002
Section 1.0
Rev. 12

HEI
Heat Exchange Institute
ICEA
Insulated Cable Engineers Association
ICEI
Internal Combustion Engine Institute
IEEE
Institute of Electrical and Electronics Engineers
INOS
Instituto Nacional de Obras Sanitarias
ISA
International Society for Measurement and Control
MPTA
Mechanical Power Transmission Association
MSS
Manufacturers Standardization Society of the Valve and Fitting

Industry, Inc.
NACE
National Association of Corrosion Engineers
NBFU
National Board of Fire Underwriters
NBS
National Bureau of Standards
NEC
National Electric Code
NEMA
National Electrical Manufacturers Association
NFPA
National Fire Protection Association
OSHA
Occupational Safety and Health Act
PFI
Pipe Fabrication Institute
SSPC
Steel Structures Painting Council
TEMA
Tubular Exchanger Manufacturer Association
Texaco GEMS
Texaco General Equipment and Material Specification
UBC
Uniform Building Code 1997

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Unit 14 Light Oil Hydrotreater

Process System Description

PROCESS SYSTEM DESCRIPTION.............................................2

Process Design Basis...........................................................................................................2

Description of Process Controls.........................................................................................54

Description of Emergency Systems...................................................................................63

Chemicals and Materials....................................................................................................79

Design Codes and Standards..............................................................................................98

Petrolera Ameriven, S.A.

Hamaca Crude Upgrader

Unit 14 Light Oil Hydrotreater

Process System Description

PROCESS SYSTEM DESCRIPTION

Process Design Basis

Petrolera Ameriven, S.A.

Feed Case 1 is based on 165,000 BPSD of Hamaca Crude feed

Feed Case 2 is based on 165,000 BPSD of Hamaca Crude feed

Unit 14 Light Oil Hydrotreater

Process System Description

Feed Case 3 is based upon 190,000 BPSD of Hamaca Crude

1.1.2.2 Feed Sources

Feed rate, BPSD

Hamaca Crude Upgrader

Unit 14 Light Oil Hydrotreater

Process System Description

Petrolera Ameriven, S.A.

Hamaca Crude Upgrader

Unit 14 Light Oil Hydrotreater

Process System Description

Table 1.1.2-3 Feed Properties - Case 2

Unit 14 Light Oil Hydrotreater

Process System Description

Petrolera Ameriven, S.A.

Hamaca Crude Upgrader

Unit 14 Light Oil Hydrotreater

Process System Description

Table 1.1.2-4 Coker Naphtha Light Ends - Case 2

Table 1.1.2-5 Feed Properties - Case 3

Feed rate, BPSD

Unit 14 Light Oil Hydrotreater

Process System Description

Petrolera Ameriven, S.A.

Hamaca Crude Upgrader

Unit 14 Light Oil Hydrotreater

Process System Description

1.1.2.4 Makeup Hydrogen

Petrolera Ameriven, S.A.

Hamaca Crude Upgrader

Unit 14 Light Oil Hydrotreater

Process System Description

1.1.3.2 Reactor Conditions

LHSV, Catalyst 2, hr-1

Reactor Inlet Temp, F

Reactor Outlet Temp, F

Cold Separator Temp, F

Makeup Gas, SCF/BBL FF

Reactor Treat Gas, SCF/BBL FF

Reactor quench, SCF/BBL FF

Reactor Outlet Pressure, psig

Purge Gas, SCF/BBL FF

Petrolera Ameriven, S.A.