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1 Work Instructions
1.1 Splitter Section
1.2 Splitter section splits heavy naphtha and light straight run naphtha and
produces solvent oil through side stream stripper.
1.3 Feed to splitter is taken from following three sources:
1.3.1 From tank # 17
1.3.2 Direct from Howe Baker Units
1.3.3 From tank # 9 (During startup and shutdown)
1.4 Solvent oil is also produced from splitter through solvent side stripper as
per demand of oil movement by adjusting the splitter operating conditions.
1.5 Light straight run naphtha is stored in rundown tanks for blending to
produce premium gasoline.
1.6 Heavy naphtha is used as feed to hydrotreater section.
1.7 Field Operator takes the reading of the different pumps after every two
hours and logs it in the “Log Sheet of Splitter Section”.
1.8 Shift Engineers of morning, evening and night shifts signs the “Log Sheet
of Splitter Section”.
1.9 Hydrotreater Section
1.10 Hydrotreater section produces sweet feed for reformer section by
removing mainly sulfur, nitrogen, oxygen, heavy metals, etc.
1.11 Heavy naphtha feed from splitter bottom is charged to hydrotreater
section. Minimum 15 wt ppm sulfur is maintained in feed naphtha. If it is
less in heavy naphtha feed, dimethyldisulfide is injected to maintain the
above value.
1.12 By product hydrogen from reformer section is fed to hydrotreater reactor
for the removal of poisonous material from naphtha.
1.13 Field Operator takes different reading of the section after every two hours
and logs it in the “Log Sheet of Hydrotreater Section”.
1.14 Shift Engineers of morning, evening and night shifts signs the “Log Sheet
of Hydrotreater Section”.
1.15 Reformer Section
1.16 Reformer section produces 90 RONC reformate.
1.17 Sweet feed from hydrotreater section is charged to reformer section.
1.18 Following materials are injected and maintained in the feed to provide
proper chemical balance on the reformer section catalyst.
1.18.1 Chloride is injected to maintain <0.5 wt ppm chloride in hydrogen
recycle gas.
1.18.2 Water is injected to maintain 15-40 wt ppm water in hydrogen
recycle gas.
1.19 Hydrogen is also recycled through reformer reactor to ensure proper
reactions in the reformer reactors.
1.20 Field Operator takes different readings of the reformer section after every
two hours and logs it in the “Log Sheet of Reformer Section”.
1.21 Shift Engineers of morning, evening and night shifts signs the “Log Sheet
of Reformer Section”.
1.22 New Cooling Tower
1.23 New cooling tower supplies cooling water to reformer plant and heavy
crude unit.
1.24 Dozing rate of chemicals (sulfuric acid, performax 2021A, chlorine) is
maintained for proper quality of cooling water as per instructions of
utilities operations department.
1.25 Field Operator takes different readings of the cooling tower after every
two hours and logs it in the “Log Sheet of New Cooling Tower”.
1.26 Shift Engineers of morning, evening and night shifts signs the “Log Sheet
of New Cooling Tower”.
1.27 Records
1.28 Under normal operation of the reformer plant following records are
generated:
1.28.1 Reformer Shift Report (Three shift in one day)
1.28.2 Reformer Daily Report
1.28.3 Reformer Monthly Report
1.28.4 NHT/Platformer Daily Summary (prepared by using the data from
Laboratory Reformer Analysis Report (T01-FM024)
1.28.5 Reformer Daily Average Report
1.29 Shift Duty Handing Over
1.29.1 Shift Engineer logs all important parameters/activities being done
at plant and during overlap time (10 minutes) verbally
communicate the same to next Shift Engineer.
1.29.2 Board Operator logs important parameters and conveys the same to
next Shift board man during overlap time (10 minutes).
1.29.3 Plant Operator logs all important conditions of plant and conveys
the same to next Shift Operator during overlap time (10 minutes).
2 Work Environment at CCR
2.1 Preference be given for location of the CCR in the safe Area
2.2 Inside temperature conditions to suit local occupational health regulations
2.3 The Central Control Room (CCR) is such that it is dust proof and the
humidity should be kept low.
2.4 There be no opening on the plant side from where vapors or dust can enter
2.5 All wiring inside CCR is Zero halogen
2.6 Flooring inside the CCR is of the raised floor type
2.7 Entry to CCR is restricted only to concerned staff and to ensure dust free
environment shoes are not allowed and if required with dust covers or
slippers
2.8 Smoke detectors and fire alarm buttons are installed
2.9 Communication system is such that the operator uses the same with out
getting distracted from the process control
2.10 Lights installed are such that there is no glare on the screens or the panel
2.11 Lighting is at least 85-90 Lux
2.12 Noise level should be less then 85-db max
3 Statistical Analysis
3.1 All the data of different parameters of reformer plant is stored in the
Digital Control System, which can be viewed and printed whenever
required.
3.2 Digital Control System can generate 72 hours trend line of different
parameters on each point during the process.
3.3 In case more than 72 hours old data is required, then only averages of the
weekly trend can be obtained.
3.4 Shift Engineer daily takes the printout of the trend obtained from the
Digital Control System of different parameters and files it.
In case of any problem, Research and Development work or continual improvement this
statistical data are used
Reformer Shutdown Procedure
3.5 All safety concerns given in “UOP Platforming Process Safety Manual”
are applicable to this work instruction.
4 Work Instructions
4.1 Reduce the feed of NHT and Reformer to 28 m3/hr. maintain RIT of NHT
@315°C and reduce the reformer RITS 480°C.
4.2 Switch over the Reformer charge to sweet feed, (Change feed from Tank #
17 to Tank 09). It takes “1 hr” to flush the system.
4.3 Reduce NHT feed to 50% of the design (17m3/hr) at the temperature of
315°C compensate the reformer feed through FI-069.
4.4 Reduce RIT of NHT 300°C. At this temperature stop feed to NHT. Also
stop the injection of Unicor C.
4.5 Stop Dimethyldisulfide injection (If in service).
4.6 Maintain the maximum H2 flow through NHT rector to sweep the
hydrocarbons. Reduce the RIT of NHT @ 260°C during sweeping (Don’t
go bellow 260°C. the reducing rate is 30°C to 40°C/hr. if catalyst is
required to dump reduce RIT 65°C to 38°C).
4.7 Keep circulation of H2 through NHT until liquid stops accumulating in
product separator HT-V005 (It takes ‘1 hr’).
4.8 After circulation keep 50% level in HT-V 005 and block LCV-085 HTH-
002 automatically shut off when gas flow to NHT stop).
4.9 Divert the reformate R/D to tank # 16.
4.10 Decrease reformer RIT’s to 455°C, also reduce the feed to reformer
simultaneously to 50% of the design (17m3/hr).
4.11 Stop feed to reformer @450°C, also stop the TCE & condensate
injections.
4.12 Keep circulation of H2 to reformer for 2 hours until there is no further
accumulation of liquid is SR-V001.
4.13 Reduce RIT’s of reformer to 400°C during sweeping.
4.14 Shutdown the heater at 400°C and also stop the compressor after the 15
min of shutdown of heaters.
4.15 Depressurize the system to required pressure 07 kg/cm2 in fuel gas or flare
(The rate of depressurizing is 01 kg/cm2 in 01 min).
4.16 For further details about the normal shutdown and emergency shutdown,
refer to “Reformer Plant Operating Manual”.
Reformer Startup
5 Work Instructions
5.1 Startup After Short Shutdown
5.2 Start compressor overhead fans, SR-E003 and all other overhead fans.
5.3 Start recycle gas compressor SR-C001 as per the procedure given in
operating instruction manual.
5.4 Check the compressor suction vessel level time to time. When it increases,
start the pump SR-P001 to maintain its level about 30-50%.
5.5 Line up sweet naphtha from Tank # 9 to OSBL Reformer Plant charge
pump and start it.
5.6 Start the splitter charge pump HT-P001.
5.7 When the level in the splitter is around 120%, start splitter re-boiler pump
HT-P005 (before starting, confirm the opening of control value HT-FV021
around 10%).
5.8 Start one main burner in each reformer heater as per reformer plant heaters
operating procedure.
5.9 By pass hydrotreater unit by closing HT-FC011 and operating HT-FI069
(direct to stripper HT-V006).
5.10 Start hydrotreater feed pump HT-P004 as per reformer plant high-speed
centrifugal pump operating procedure.
5.11 Line up stripper bottom to Tank # 16 through FI-90 bypassing reformer
unit (closing of SR-FC001).
5.12 Keep tank to tank circulation from tank # 9 to splitter (HT-V001), stripper
and back to Tank # 16 for one hour and ensure complete flushing of sour
naphtha from the system.
5.13 Increase the reformer furnaces outlet temperature @ 40-50°C per hour, up
to 370°C.
5.14 Cut the reformer feed to reformer unit by opening SR-FC001 and stopping
tank to circulation by closing FI-090 globe value.
5.15 Maintain reformer feed rate 17 m3/hr as early as possible.
5.16 Start all the main burners of reformer heaters and increase the reformer
heaters outlet temperatures up to 470°C.
5.17 After 15 minutes divert reformate to storage tank i.e., tank-15 or tank-19.
5.18 Keep close eye on compressor suction vessel SR-V001 and start the
bottom pump SR-P001 when level starts increasing.
5.19 Start chloride injection pump SR-P003 to maintain chloride level in
recycle gas between 0.1 to 0.5 ppm.
5.20 Commission hydrogen gas to hydrotreater unit through HT-FC073 when
excess hydrogen gas is available from reformer unit.
5.21 Start hydrotreater furnace HT-H002 by putting one main burner in
operation as per operating procedure, when hydrogen from to hydrotreater
reaches more than 1800 m3/hr.
5.22 Start increasing hydrotreater reactor outlet temperature up to 290°C
(temperature difference in hydrotreater reactor inlet and outlet should not
be more than 50°C in any case).
5.23 Cut the hydrotreater feed at 290°C hydrotreater reactor outlet temperature
@ 17 m3/hr, by opening HT-FC011.
5.24 Keep a close eye on hydrotreater heater and increase firing to maintain the
required temperature i.e., around 310°C.
5.25 Stop feed through F1-069 when level in HT-V005 is enough to maintain
level in HT-V006.
5.26 Start stripper reflux when the level is available in HT-V007.
5.27 Start Unicore-C injection pump to maintain 0.2-0.4 ppm of Unicore-C in
the overhead system.
5.28 Change the reformer feed tank from tank # 9 to tank # 17, also change the
reformat rundown tank to tank # 15.
5.29 Check the HCl, H2S and moisture in the recycle gas, and increase the
reformer feed up to 33 m3hr.
5.30 Adjust the hydrotreater reactor outlet temperature > 315°C (maximum
design 335 °C).
5.31 Increase reformer reactor inlet temperatures to maintain 90 RONC
(maximum design (530°C).
5.32 Startup After Turnaround and Catalyst Regeneration
5.33 Startup after turnaround and catalyst regeneration is done as per the
NHT/Platformer Startup Procedure.