acetic acid plant - vol. 1

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ACETIC ACID PLANTYANBU - KSA

2004TPIT PROJECT 2121

SABIC PROJECT CO2 - SABIC . 298

OPERATIONS MANUAL

VOL. 1

Technip

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Prq.2121- SABIC ACETIC ACID PROJECT

YANBU - KINGDOM OF SAUDI ARABIA

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GENERAL INDEX

1 GENERAL INFORMATION

1.1 INTRODUCTION

1.2 SABIC ACETIC AGID

1.3 PROGESS CHEMISTRY

1.4 PLANT UNIT

2 PROCESS DESCRIPTION

2.1 DESIGN BASIS2.1.1 Plant Capacity2.1.2 Feedstocks2.1.3 Product Specification2.1.4 Catalysts and Chemicals2.1.5 Climatic Conditions2.1.6 Utilities Specifications

2.2 PROCESS DESCRIPTION

2.3 GUIDELINE FOR PLANT OPERATION2.3.1 Feedstock Preparation and Ethane Desulphurization2.3.2 Nitrogen Purge and HP Nitrogen System2.3.3 Conventional Reactor System2.3.4 Acetic Add Recovery and Purification2.3.5 CO2 Removal System2.3.6 ISBL Tankage2.3.7 Closed and Open Drain Collection System2.3.8 Steam / Condensate System2.3.9 SABOX Reactor2.3.10 Flare System2.3.11 Utilities System

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3. OPERATING PROCEDURES FOR PLANT / PROCESS UNIT

3.1 PREPARATION FOR INITIAL START-UP3.1.1 General3.1.2 Plant Inspection3.1.3 Flushing, Chemical or Mechanical Cleaning3.1.4 Preparation and Functional Testing of Machinery3.1.5 Preparation and Functional Testing of Instrument3.1.6 Preparation and Functional Testing of Electricals3.1.7 Place/Remove Blinds, and Place Car Seals, Locking of Valves and Temporary

Strainers3.1.8 Leak Testing of the Systems3.1.9 Preparation and Testing of Reactor Steam Generation Systems3.1.10 Preparation and Testing of Recycle Gas Loop3.1.11 CatalystandChemicalsLoading/Unloading3.1.12 Dynamic Oxygen Response Test3.1.13 Dynamic ethane response Test3.1.14 Dynamic Leak Testing3.1.15 Dynamic Capacity Test of C02Absorber3.1.16 Purging and lnerting3.1.17 Ethane Fired Heater 100-H161 Dry Out3.1 .18 Steam Out3.1.19 PreliminaryOperations3.1.20 Carbonate Loading

3.2 PRE START.UP3.2.1 Place Utility Header in Service3.2.2 Makeup and Dosage of Chemicals,3.2.3 Place Steam Headers and Boiler Feed Water System in Service3.2.4 Start-up Cooling Water and Chilled Water3.2.5 Check and Get Ready to Start Up the Process3.2.6 Purge and Pressurize the System with Nítrogen3.2.7 lnterlock Tests3.2.8 Heating of the Reactor Steam System3.2.9 Carbonate Circulation - CO2 Removal System Pre Start Up3.21A Start-up Recycle Gas Compressor and Cycle Gas3.2.11 Product Recovery and Purification3.2.12 Heating of Ethane Feed System3.2.13 Ethane feed

3.3 START.UP3.3.1 Start Up Oxygen Feed3.3.2 Reaction Tuning3.3.3 Product Recovery and Purification3.3.4 COz Removal System

Pîoj.2121 - SABIC ACETIC ACID PROJECT


TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

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3.4.3.4.13.4.23.4.33.4.43.4.53.4.63.4.73.4.83.4.93.414

3.53.5.13.5.23.5.33.5.43.5.53.5.63.5.73.5.83.5.93.5.103.5.113.5.123.5.13

3.63.6.13.6.23.6.33.6.43.6.53.6.63.6.73.6.8

4

4.1

4.24.2.14.2.24.2.34.2.4

NORMAL OPERATIONEthane Feed PreparationReactor SystemScrubber 100-C131Dehydration Column 100-C1 32Product Column 100-C133Stripping Column 1 00-C134CO2 Absorber 100-C141CO2 Solution Regenerator 100-C142Drainage SystemTankage

NORMAL SHUT DOWNGeneralFeed Preparation Section Hot Stand ByReaction Section Hot Stand ByCOz Removal Section Hot Stand ByPurification Section Hot Stand ByFeed Preparation Section Complete Shut DownReactor Section Complete Shut DownCO2 Removal Section Complete Shut DownPurification Section Complete Shut DownVessel EntryReactor Conditions During Prolonged Shut DownSteam Production & Utilities Shut DownSkids Units Shut Down

EMERGENCY SHUT DOWNGeneralPlant Electric Power Failurelnstrument Air FailureSteam FailureCooling Water FailureEthane Feed FailureOxygen Feed FailureSABOX Reactor Emergency Shut-Down

SAFETY

GENERAL

SAFETY IN PLANT OPERATIONOperator TrainingPressure Testing and PurgingFeed Preparation SystemCycle Gas and Reaction System

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YANBU - KINGDOM OF SAUDI AMBIA

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4.3 GENERAL SAFE WORKING PROGEDURES4.3.1 Personal Protective Equipment4.3.2 Respiratory Protection4.3.3 Body Protection4.3.4 General Safety Rules during Operation4.3.5 Hazards Due to Pressure and Vacuum4.3.6 Hazards Due to Thermal Expansion4.3.7 Entering Tank and Vessel4.3.8 Housekeeping4.3.9 Sampling4.3.10 Miscellanea

4.4 FIRE PREVENTION AND FIREFIGHTING4.4.1 Prevention4.4.2 Firefighting

5. FIRE & GAS SYSTEMS

5.1. GENERAL

5.2. FIRE & GAS FOR CONTROL ROOM BUILDING & LOCAL PANELDESCRIPTION

5.2.1. Fire & Gas Local Panel 100-FLP-001

5.3. FIRE & GAS FOR ELECTRICAL SUBSTATION BUILDING & LOCAL PANELDESCRIPTION


5.4. FIRE & GAS FOR SATELLITE AND MAINTENANCE BUILDING & LOCALPANEL DESCRIPTION


5.5. FIRE & GAS FOR ANALYSER HOUSE & LOCAL PANEL DESCRIPTION5.5.1. Fire & Gas Local Panel 100-FLP-004

5.6. FIRE & GAS FOR PROCESS UNIT & PANEL DESCRIPTION5.6.1. Fire & Gas Panel 100-FP-001

5.7. FIRE & GAS MAIN COMPONENTS DESCRIPTION

6. ATTACHMENTS

6.1. SPECIFICATIONS6.1.1. Basic Design Data6.1.2. Guidelines for PID Preparation6.1.3. Process Control & ESD Philosophy


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6.2.6.2.1.6.2.2.6.2.3.6.2.4.6.2.5.6.2.6.6.2.7.6.2.8.6.2.9.6.2.10.6.2.11.6.2.12.

6.3.6.3.1.6.3.2.6.3.3.6.3.4.6.3.5.6.3.6.6.3.7.6.3.8.6.3.9.

6.4.6.4.1.6.4.2.6.4.3.6.4.4.6.4.5.6.4.6.6.4.7.6.4.8.6.4.9.6.4.10.

DRAWINGS AND DIAGRAMSPiping & Instrumentation DiagramsProcess Flow DiagramsUtility Flow DiagramsGeneral Plot PlanPlot Plan, Details & Elevations, Key PlansProcess Logic DiagramsCause & Effect ChartOverall Single Line DiagramHazardous Area ClassificationAlarm & Trip ListFire Fighting LayoutGeneral Underground Network

DOCUMENTS, LISTS AND SCHEDULESEquipment ScheduleLine ListFluid ListPSV and RV Summary of RatesEfflgent $mgaryUtilities Consumption SummaryElectrical Consumer ListPiping Class SummaryFire and Gas Detection and Protection System Specification

DATA SHEETSProcess Data SheetsInstrument/Analyzers Data SheetsSafety Valves Data SheetsCatalysts and Chemicals Data SheetsLubricant & Grease ListHazard Study DataCatalyst and Chemicals Loading and UnloadingFire & Gas Detection System SpecificationFire & Gas Cause & EffectFire Fighting & Detection Drawings

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1. GENERAL INFORMATION

1.1. INTRODUCTION

1.2" SABIC ACETIC ACID

1.3. PROCESS CHEMISTRY

1.4. PLANT UNIT

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INDEX

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GENERAL INFORMATION

INTRODUGTION

This manual has been prepared for the purpose of facilitating those personnelwho supervise the expanded SABIC.Acetic Acid Plant in Yambu (SaudiArabia).

The operating conditions and procedures mentioned in this manual and shownon the diagrams should be considered as principles and not as fixed and rigidstandard.

As operating experience is acquired, it maybe possible to improve on theseprocedure to some extent.

sometimes, on the spot changes in procedures may be necessary to cope withspecial situation.

The knowledge of the system and equipment's operating principles are the bestguide to a good operation.

SABIC ACETIC ACID

!_ul9* of the request by sABlc a process engineering design has been made byTPSA for a Acetic Acid plant.

The plant is installed at a site of SABIC property in yambu.

The Acetic Add Plant is designed to produce 34 kVy of "glacial" acetic acid by thecatalytic partial oxidation of ethane with oxygen at elevated temperature andpressure.

The reactor systems include a Conventional Reactor, designed to produce 30 kUyof acetic acid, and a SABOX Reactor, designed to produce 4 k{y.

The reaction is carried out in vapor phase, with the reactants (ethane andoxygen) significantly diluted in a large flow of "inert" recycle gas to maintain theirconcentrations within safe operating limits.

The large flow rate of the recycle gas flowing through the reactor loop will ensurea high heat capacity, necessary to remove a portion of the heat of reaction and toavoid excessive temperature increase in the reactor.

Acetic acid is recovered from the reactor gases by water scrubbing and then isdehydrated by distillation. The recycle gas of the reactor loop is then passedthrough the CO2 removal system to separate the carbon dioxide produced in theoxidation.

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1.3. PROCESS GHEMISTRY

The Acetic Acid section involves the partial oxidation of ethane over a SABOX-300 catalyst at temperatures of about 225 to give Acetic Acid by the followingreaction:

C2H5 + 312 02 CH3COOH + HzO

The overall heat of reactions in conventional reactor per tube is

SOR = 4500 kcal/hrEOR = 8000 kcal/hr

The required oxygen is supplied from IBN Rusd plant through the air separationplant.

Some of traces may be producted from side reactions such as carboxylic acidscomponents, Acetaldehyde, and ethyl acetate the total composition of traces is<0,1Vo weight.

Carbon dioxide and water are also formed in an ethane oxidation reactioncompeting with the main reaction:

C2H6 + 712 02 Oa+3HzO (2)

recycle gas by

(1)

Carbon dioxide produced by reaction (2) is removed from thechemical reaction with aqueous potassium carbonate as follows:

CO2+K2CO3+HzO KHCO3 + 6.4 kcal/gmol

The coz is rejected from the reaction system after steam stripping thebicarbonate rich solution at approximately atmospheric pressure.

Selectivitv

The selectivity to Acetic Acid, i.e. the fraction of ethane converted into Acetic Acidaccording to chemical reaction declines with the age of the sABox-300catalysts. As the price of the ethane and oxygen are the largest contributor to thetotal operating costs, at a certain moment is becomes economical to exchangethe "aged" catalyst with "fresh" catalyst.

TEGHNIP IrALY s.p.A. - 00148 ROMA - Viate casteilo deila Magtiana, 6g

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1.4. PLANT UNIT

The Acetic acid plant described in this manual consists of the following units.

Unit 01 Reactor Feed preparation

Ethane Feed Fired HeaterCirculation CompressorZinc Oxide VesselsFresh Feed CompressorOxygen Addition

Unit 02 Conventional Reactor System

Conventional Reactor SystemConventional Reactor Sieam System

Unit 03 product Recovery and purification

ScrubberDehydration ColumnDehydration Column OverheadsProduct ColumnProduct Column OverheadsStripping ColumnScrubber Feed Water Drum and pump

Unit 04 CO2 Removal System

CO2 AbsorberCOz Solution RegeneratorSolution Storage

Unit 05 |SBL Tankage

fft:$àtfjl':#SHcess Drain co,ection DrumEntrain Holding DrumAcetic Acid Product TankOpen Process Drain Sump

Unit 06 Steam/Condensate System

Condensate and BlowdownSteam SystemDistribution SystemCooling Water DistributionWater and Potable Water DistributionNitrogen, Instrument Air and plant Air DistributionFlare System

TEGHI{IP lrAl.y s.p.A. - 00148 ROMA - Viate casteilo deila Magtiana, 68

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YANBU _ KINGDOM OF SAUDI ARABIA

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Unit 07 ISBL Utilities

HP Nitrogen SystemHP Flare

Unit 08 SABOX Reactor System

SABOX Reactor Oxygen FeedSABOX Reactor Steam System

Unit 01 - Reactor Feed Preparation

Feed ethane gas is supplied at battery limit and is fed to the Zinc Oxide Vessel100-D111A & B connected in series where sulphur compounds (cos and H2S)are removed over a solid ZnO absorption stage to prevent poisoning of thecatalyst and to satisfy environmental concerns in the effluent streams.Thedesulphurised feed from the reactors is first cooled and filtered then it passes tothe Fresh Feed Compressor 100-J111N8" After compression the feed is mixedwith recycle gases exiting the Recycle Gas K.O. Drum 100-D211 constituted bythe gas returned from the CO2 Removal System and the cooled recycle gasesthat bypass thè CO2 Removal System. Nitrogen is added to maintain a constantinert level in the'recycle'gases and hence the reaction feed stream. Recyclegases from the CO2 Removal System are also collected in the Recycle Gas K.O.drum before being mixed with the ethane feed.The fresh feed /recycle gas leaving the K.o. Drum 100-D211 is fed to theCirculation Compressor 100-J112 by which it is compressed up to the requiredreaction pressure. The compressor is driven by Circulation Compressor TurbineSet 100-J112T, a steam turbine using HP steam as motive fluid.The oxygen necessary for the reaction is compressed by oxygen compressor100-J113N8, cooled in the oxygen Feed cooler 100-E11s and fed, via theOxygen Filter 100-F113, to the Static In-line Mixer 100-M111, where it is mixedwith the compressed fresh feed / recycle stream.

Unit 02 - Conventional Reactor Svstem

The mixed feed leaving the ln-Line Mixer 100-M111 is heated tothe reactorfeedtemperature, before being fed to the Conventional Reactor Systems. The reactionis exothermic, takes place in the vapour phase, and is maintained below theflammability limits of the feed for safety and control reasons.The heat of reaction is removed by raising steam in the shell side of the reactor.

Unit 03 - Product Recoverv and Purification

The reactor outlet stream is first cooled then flows to the Scrubber 100-C131,where the acetic acid product is absorbed from the gas stream by water while theScrubber overhead stream is sent to the CO2 Removal System. The DehydrationColumn separates water from the acetic acid using butyl acetate as an entrainer.The bottom stream from the Dehydration Column contains acetic acid andheavies, which are separated by distillation in the Product Column 100-C133.

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ln the Stripping Column 100-C134 all the butyl is recovered while the ScrubberFeed Water Drum 100-D231 collects the water recycled from the StrippingColumn and the condensate from the Recycle Gas K.O. Drum.

Unit 04 - CO^ Removal Svstem

Part of the recycle gas stream from the Scrubber 100-C131 is sent to the COzRemoval System where carbon dioxide is removed before the recycle gas iscooled and returned to the Reactor via the Circulation Compressor. The carbondioxide is removed in the co2 Absorber 100-c141 by absorption in thepotassium carbonate (lean) solution and the carbonate rich solution from thebottom of the Absorber is fed to the Regenerator 100-C142, where carbondioxide is stripped out of solution and removed in the column overhead.

Unit 05 - ISBL Tankaqe

Acetic acid from the Product Column is routed to one of the two Shift Tanks 100-T151 A/B where the product is kept for analysis before transfer to the producttank 100-T153, or off-specification tank 100-T152. Tanks are cylindrical vertical,with fixed cone roof. The vapor space of tanks have a common blanketing systemwith LP nitrogen with the vent gas routed to Vent Gas Scrubber 100-C251. Tankshave an internal heating coil with LP steam for winterizing.

Unit 06 - Steam/Condensate Svstem

Saturated HF steam is generated in the conventional Reactor System. lt issuperheated in the Steam Fired Heater 100-H161 then routed to the éuperheatedHP header. There are two turbines running on the HP steam header level, theydrive the Circulation Compressor and its Lube Oil Pump. These turbines areback-pressure machines, exhausting to the LLP and LP levels.Superheated HP steam is imported from battery limit for low consumptionprocess use (steam added to ethane feed) and for precommissioning and initialstart-up of the plant.

MP steam is produced by SABOX Reactor and/or is letdown from HP steam level(and desuperheated). LP steam is obtained by depressurizing MP steam. LLpsteam is obtained from back pressure turbine 100-J112T and is basicallyexported to battery limit. MP condensate is collected in MP Condensate FlashDrum 100-D262, where flashing steam is recovered in LP steam header andexcess condensate is sent to LP condensate header. LP Condensate is collectedin steam condensate Drum 100-D263, where flashing steam is sent to LLpsteam header and excess condensate is routed to battery limit. Boiler FeedWater is imported from battery limit, preheated in the coil 100-E364 of the SteamFired Heater and then is fed to the steam drums of the Conventional and SABOXReactors. Condensate from the Continuous Blowdown Drum 100-D261 and allintermittent blowdown directly from the steam drums are routed to the Vent GasScrubber. Steam Drum Chemical Dosing Set 100-J361 provides the requiredchemical additivation to boiler feed water upstream the steam drums.

TEGHNIP ITALY S.p.A. - 00148 ROMA - Viale Castetto detta Magtiana, 68

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Unit 07 - ISBL Utilities

The plant has HP Nitrogen System that is required within the process to ensuresafe start-up, controlled shutdown and to render the plant safe during emergencytrips.The plant has also a HP Flare Package 100-J371 , as part of the safety system.

Unit 08 - SABOX Reactor Svstem

Part of the mixed gases from the Reactor System (ethane, recycle gas andoxygen) are fed to the SABOX Reactor 100-R181. The SABOX Reactor Systemoperates in parallel to the Conventional Reactor. The reaction is exothermic,takes place in the vapour phase, and is maintained below the flammability limitsof the feed for safety and control reasons. The heat of reaction is removed byraising steam in the shell side of the reactor.




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INDEX

2. PROCESS DESCRIPTION

2.1 DESIGN BASIS2.1.1 Plant Capacity2"1.2 Feedstocks2.1.3 Product Specification2.1.4 Catalysts and Chemicals2.1.5 Climatic Conditions2.1.6 Utilities Characteristics


2.3 GUIDELINE FOR PLANT OPERATION2.3.1. FeedstockPreparationandEthaneDesulphurization2.3.2 Nitrogen Purge and HP Nitrogen System2.3"3 Conventional Reactor System2.3.4 Acetic Acid Recovery and Purification2.3.5 CO2 Removal System2.3.6 ISBL Tankage2.3.7 Closed and Open Drain Collection System2.3.8 Steam / Condensate System2.3.9 SABOX Reactor2.3.10 Flare System2.3.11. Utilities System

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mmW*2. PROCESS DESCRIPTION

2.1 DESIGN BASIS

2.1.1 Plant Gapacity

The Plant is designed to produce 34 kVy of Acetic Acid:

- 30 kUy by the Conventional Reactor System- 4 kUV by the SABOX Reactor System

The Plant is expected to operate 8000 hours per.year, consequently the aceticacid production rates shall be:

- 3.75 t/h kg/h from the Conventional Reactor System- 0.5 t/h from the SABOX Reactor System.

2.1.2 Feedstocks

Ethane

Source : Gas supplied to the plant battery limits from Aramco

Specification :

Ethane 95.0 mol % min.Methane 2.5 mol o/o trràx.Propane 2.5 mol To max.Carbon Dioxide 0.15 mol o/o trràx.Hydrogen Sulfide 100 ppm vol Normal

(570 ppm peak - Note 1)Carbonyl Sulfide 7 ppm vol Normal

Notes: (30 PPm Peak - Note 1)

1. Peak concentrations occur for a maximum of 120 hours duration (notcontinuous) in total in any one (1) year.

Supply conditions at the battery limit of the Ptant :

Pressure Minimum 10.8 bar gNormal 18.6 bar gMaximum 20.T bar gMechanical Design 31.1 bar g

Temperature Minimum 1S"CNormal 36'CMechanical Design Bs'C

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Nitrosen

Source:

Specification :

Pressure

Temperature

Oxvgen

Source:

Specification : (by SABIC)OxygenNitrogen and Argon

Supply conditions at the battery limit of the

Pressure MinimumNormalMechanical Design

MinimumNormalMaximumMechanical Design

Temperature

Gas supplied to the plant battery limits from external source.

99.8 vol % min.0.2 vol o/o tÍ1ex.

Plant:

27.1 bar g27.9 bar g45.0 bar g

15"C36"C50"cg5'c

Nitrogen is used as a feedstock within the process.is from Nitrogen supplied to the Plant's battery limit.

(by SABIC)

NormalMaximumMechanical Design



25"C35'C50'c85"C


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Butvl Acetate

Source:

SpecificationComposition:n-ButylAcetaten-ButylAlcoholWater ContentColour (Pt-Co Units)Acidity, as Acetic Acid

2.1.3 Product Specification

Acetic Acid (Glaciatl

Acetic acid is pumped from the Aceticlimits.

Specification reference U.S. p GradeCompositionAcetic AcidWaterFormic AcidAldehydeslronHeavy metalChloridesSulphatesSulphuric AcidPropertiesFreezing pointSpecific GravityDistillation rangeInitial Boiling PointDry poinlColour, platinum-cobalt unitPermanganate time (ACS test)

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Butyl Acetate is either supplied from a road tanker or drumsinto the Entrainer Holding Tank (100-D252)"

99.5o/o Urethane Grade

99.5 wt o/o min0.50 wt o/o Í1ax0.050 wt % max10 max0.01 wt o/o fftax

Acid Product Tank to the Plant battery

45476

99.85 wt % min0.15 wt % max0.05 wt o/o Ítax0.05 wt o/o Írax1.0 ppm by wt max0.5 ppm by wt max1.0 ppm by wt max1.0 ppm by'wt max1.0 ppm by wt max

16.350C1.0505 - 1.0520 @ 20t20"c1.0oC max.117.3oC min.1 18.3 oC max.10 max2 hours. min

TEGHNIP IrALY s,p.A. - 00148 ROMA - Viate casteilo deila Magtiana, 68

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Export conditions at the battery limit of the plant:

Pressure Minimum 3.5 bar gMechanical Design 7.g barg

Temperature Minimum ZS}CNormal AmbientMaximum 4ToCMechanical Design gSoC

2.1.4 Catalysts and Ghemicals

Zinc Oxide Catalvst

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Equipment No. : 100-D1 11NBEquipment Name : Zinc Oxide VesselTYPe : Sulphur Absorption CatalystMaker : Synetix (lCl group)

Makers ldentification : KATALCOTM 32-s or equivalentPhysical Form : 3.0 + 4.5 mm Z spherical granulesBulk Density : 1400 kg/m3

Compositioo : Zinc Oxide 93 wt%Binder balance

Charged Volume : 2S7 m3 TotalExpectedLife : lyear

Equipment No. : 100-R121t1OO-R1gj

Equipment Name : Reactor

TYPe : Catalyst details by SABIC.

Physical Form : 3.175 mm x3.175 mm Cylinders

Bulk Density . 1S00 * I 600 kg/m3

Volume : 29.6 m3

Zinc oxide catalyst is used to pre{reat the Ethane feedstock gas.

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Equipment No.

Equipment Name

Type

Physical Form

Bulk Density

Volume

Equipment No. :

Equipment Name :

Type :

Volume:

Expected consumption:

Nalco 1742 or equivalentSABOX Reactor Steamanticorrosion agent.

ButvlAcetate

Equipment No.Equipment NameSupply methodPhysical FormSpecificationComposition

Initial Charge

Expected consumption

is added to the Reactor Steam Drum (D221) andDrum (D281). Phosphate solution is provided as

(EOR Rates)

Butyl acetate is used as an entrainer in the product Recovery Area.

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SABOX Reactor

Catalyst details by SABIC.

3.175 mm x 3.175 mm Cylinders

1 500 + 't 600 kg/m3

2.73 m3

100-J361-T01

Steam Drum Chemical Dosing Set - Tank

Phosphate Solution (Ondeo Nalco 1742 orequivalent)

By the selected treatment chemical, according tophosphate concentration (dilution in demineralisedwater).

135 kgla pure phosphate (EOR Rates)

100-D252Entrainer Holding DrumBy tanker or drumsLiquid99.5% Urethane Graden-ButylAcetate min 9g.S wt%n-ButylAlcohol max 0.50 wt%Water max 0.050 wt%Colour (Pt-Co Units) max 10Acidity, as Acetic Acid max 0.01 wt%30 m3

32 000 kg/a

SABOX 300 Molybdenum base catalyst used for acetic acid reaction isproprietary one


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: Industrial Grade

: Chloride

: 12 100 kg

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Potassium Garbonate

Specification

Composition

Initial Charge

max 100 ppmw

Expected consumption : 9 050 kg/a (EOR Rates)

Potassium Carbonate is used in powder bags in the Solution Sump 100-A141. ltis also provided for equipment passivation.

Catacarb WBU Antifoam

Supplier : Harcros Chemícals Inc.(Eickmeyer & Associates Inc. approvedvendor)

Initial Charge : 0.2 m3

Expected consumption : 0.2 m3la (EOR Rates)

Catacarb WBU antifoam is used in the 100-A141Solution sump. lt is supplied inliquid drums.

Catacarb 922 Catalvst

Equipment No. : 1OO-A141

Equipment Name : Solution Sump

Supply method : Drums

Physical Form : Liquid

Supplier : Harcros Chemicals lnc.(Eickmeyer & Associates Inc. approved vendor)

lnitial Charge : 10.8 m'Expected consumption : 7.2 m3la (EOR Rates)

TEGHNIP IrALY s.p.A. - 00148 ROMA - Viate casteilo deila Magtiana, 68

YXCIXilIP ITALY $.p.4,

2.1.5 Climatic Conditions

Wind

Prevailing wind direction :

Normal wind velocity (97% of thetime):Maximum wind velocity:Highest recorded wind velocity:Wind loading for design (Basic WindSpeed), V30:

Site Exposure Condition:Design velocity for dispersioncalculations:Design velocity for flarecalculations:Topographic Factor K.1

lmportance factor I,Gust Effect Factor G

Barometric Pressure

Design Barometric Pressure :

Annual Minimum :

Annual Maximum :

Notes:1. Design barometric pressure to be

design.

Temperature

Maximum SummerMinimum Winter

Prot.2121 - SABIC ACETIC ACID PROJECT


Page 2-8

Design Maximum S0"CDesign Minimum g'CDesign Ambient (for process design) zS"C

ÀmWrum

Westerly to North-WesterlyLess than 48 km/h (13.3 m/s)

16.94 m/s95 km/h (26.4 m/s)34.7 mls at 10 m elevation (50 yearreturh period)38.9 m/s at 10 m elevation (100 yearreturn period)Exposure "C" to ASCE 7-950.49 m/s

radiation 13.3 m/s (to be confirmed duringdetail engineering)1.01"150.85

1.01325 bara(1 atmosphere absolute)0.991 bara1 .016 bara

used for both equipment and process

48.9'C9.1'C

,,,,,É, rl,,,,t,.ÀJ

Design Maximum AmbientDesign Dry BulbDesign Wet Bulb

40"c50'c29.5"C

(These coincident temperatures are to be used in process design, andequipment design for air coolers, cooling towers, compressors, etc)


Tethnip

TECXIIIP ITALY $.p.4.

Ptoj" 2121- SABIC ACETIC ACID PROJECT


Page 2-9

MaximumMinimum

Design Temperature for Outdoorshelter)

Humiditv

Maximum:Minimum :

Design :

Notes:1. Design figure to be used both for equipment and process design.

Heatino" Ventilation and Air Conditioninq Desisn Data

MaximumMinimum

Design Temperature for Outdoor Steel Structure

85'Cg'c

85'Coon

Electrical Equipment (under 50"C

1O0o/o

22o/o

100%

Summer

40'c28"C

Winter

8"C8"C

Outdoor ConditionDry BulbWet Bulb

Indoor Condition (at 50 + 5%

Control Building, Electricaland Maintenance WorkshopAnalyzer House

Solàr Radiation

Maximum solar radiation is 1.04 kWm2

relative humidity, dry bulb temperature).

Substation' 23'c + 2"c 21"c + 2"c

23"C+2"C 21"C+Z"C

É ,l 1,,,,,,r,,J

mmWr*

Equipment exposed to Sunlight (Black Body Temperature) 85.C

Air Temperature for Cable Sizing SO.CSoil Temperature for Cable Sizing 40"C

Design Temperature for Outdoor lnstrumentation and ElectricalEquipment (excluding cables)


.*Jtl,-r r,--r

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Rainfall

Yearly average : 33.0 mmMaximum per year : 104.0 mmPeak rate for design of sewers : 60 mm/h for 15 minutes duration (10 year

return period)Peak rate for design of sumps : 60 mm/h for 15 minutes duration (10 year

return period)Run-off coefficients: concrete or Asphalt pavement

0.8Gravel Roadway or Shoulder 0.4Unpaved Areas including GravelSurfacing 0.2

rhunderstorms and Lishtnins : B::Ig""t ?o'"11flr,0",. rishtning o:.nrr,^noccasionally

Snowfall

***O"0,"Winterisation

Winterisation Design Temperature g.C(Minimum Ambient Temperatur:e in Winter)

Water Table

water Table Height : 6.0 m to 6.7s m below grade level

2.1.6 Utilities Characteristics

Ptq.2121 - SABIC ACETIC AC|D PROJECT


Page 2-10

Coolinq Water

source: From an off-plot closed circuit cooling tower system. supply andreturn lines are routed to the Plant battery limit above grade on piperacks, with header lines within the plant to be run above groundwithin on-plot piperacks.

Conditions at the battery limit of the Plant:

a. Supply

Pressure Normal 5.4 bar gMaximum 6.9 bar gMechanical Design 11.0 bar g

TEGI{NIP IrALY s.p.A. - 00148 ROMA - Viate casteilo deila Magtiana, 68

&cfinip.-.i.r.#lFilF

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Ptol2121- SABIC ACETTC AC|D PROJECT


Page 2-'11

NormalMechanical DesignMaximumMechanical Design

Ambient40 0c

40 0c

85 0C

3.1 bar g11.0 bar g50 "c85 0C

9.0 - 10.2# mg/L<2000 pS/cm25 mg/L# mg/L# mg/L0.27 mglL0.93 mg/L7.05 mg/L0.25 mg/LNote 1

Note 1

Note 1

O.012mglL0.04 mg/L2.10 mglL12.1 mg/L1.87 mglLNote 1

Note 1

Note 1

Note 1

Note 1

Note 1

8.322 mg/LNote 1

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Temperature MinimumNormalMaximumMechanical Design

b. Return

Pressure

Temperature

Notes:1 . Maximum temperature difference between supply and return is 10 'c.2. Maximum allowable pressure drop between supply and return at the Plant

battery limit is 2.3bar.3. Maximum outlet temperature from any individual heat exchanger is limited

to 50'C.

Specification:pH at 25 "CTotal Hardness as CaCOsConductivity at 25'C

. Total Dissolved SolidsTotal Suspended SolidsTotal Alkalinity as CaCOsCalciumMagnesiumSodiumPotassiumlronCopperZincBicarbonateCarbonateHydroxideChloridesSulphateNitrateManganeseSilica as SiO2FluorideAmmoniaFree CO2P - AlkalinityM - AlkalinityFree causticity as NaOH

Notes:1. Concentration not measurable

Cooling Water Design Fouling Factor 0.0002'Cm'A/r/

TEGHNIP ITALY s.p.A. - 00148 ROMA - Viate casteilo deila Magtiana, 68

Prq.2121- SABTC ACFTTC AC|D PROJECT


Page 2-12

TECHIìllp ITALY $,p.4.

Ghilled Water

Supply conditions at the battery limit of the plant:

a. Supply

Pressure NormalMaximumMechanical Design

Temperature NormalMaximumMechanical Design

b. Return

Pressure NormalMechanical Design

Temperature MaximumMechanical Design

Demineralised Water

Source:

Supply conditions at the battery limit of the ptant:Pressure Normal 7.4 bar gMaximum 11.0 bar g

Mechanical Design 13.0 bar gTemperature Minimum 15 oC


Specification:QualitypH at 25'CConductivity at 20"CTotal Dissolve SolidsTotal Suspended SolidsTotal Alkalinity as CaCOsChlorideSilica as SiO2CalciumSodium Na*Potassiumlron as Fe2*Copper as Cu2*MagnesiumZinc

Ambient50 "c85 0C

Not deaerated5.70.85 pS/cmNote 1

Note 1

Note 1

Note 1

0.01 ppm wtNote INote 1

Note INote 1

Note 1

Note 1

Note 1

, 4 tl ,,,f,,, ,J

mffiWm

4.4 bar g6.4 bar g10.025 0C

25 0C

85 0C

3.1 barg10.0 bar g35 "C85 0C

Demineralised water is produced from process water withinan off-plot lon Exchange Unit.


Proj.2121 - SABIC ACETTC AC|D PROJECT


Page 2-13

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Oxygen as 02SulphateNitrateManganeseFree Causticity NaOHCarbon Dioxide

CombinedFree

Permanganate Value

Notes:1. Concentration not measurable.

Potable Water



Specification:pH at 25'CConductivity at 20"CTotal Dissolved SolidsTotal Suspended SolidsTotal Alkalinity as CaCOelronManganeseCopperZincPotassium

SodiumCalcium as Ca2Magnesium as Mg2Sulphate as SOa2-ChlorideNitrate Nitrogen as NO3-Silica as SiOzFree Causticity as NaOH

Municipal water used (from treatment for chlorination and mineralisation) forlafety showers, eyewashes, drinking water and lawn sprinkling.Supply conditions at the battery limit of the plant:

# mg/LNote 1

Note 1

Note 1

Note 1

# mglL# mglL# mg/L

5.3 bar g6.8 bar g1 1.0 bar g23 0C

Ambient50 oC Note 285 0C

7.4178 prS/cm82 mglLNote 1

25 mglLNote 1

Note 1

0.004 mg/LNote 1

# mglL

# mglL3.6 mg/L1.6 mg/L2.0 mglL9 mg/L0.8 mg/L0.16 mglNil


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TEGHHIP ITALY $.p.4,

Proi2121 - SABIC ACETTC ACtD PROJECT


Page 2-14

,,,,,,4J1, t , ,mmfum

Total Hardness as CaCOaTemporary Hardness as Ca CO3P - AlkalinityM - Alkalinity

Notes:1 Concentration not measurable.2. Temperature can be further lowered by means of 100-E165.

Process Water (Desalinated Waterì

For use as process water, utility water (including chilled and cooling water circuitmake-up), firewater, demineralised feedwater, hose stations and floór washings.

Supply conditions at the battery limit of the plant:


16 mg/L4 mglLNote 1

50 mg/L


Specification:pH at 25'CTotal Hardness as CaCOsConductivity at 25'CTotal Dissolved SolidsTotal Suspended SolidsTotal Alkalinity as CaCOgCalciumMagnesiumSodiumPotassiumlronCopperBicarbonateCarbonateHydroxideChloridesSulphateNitrateSilica as SiO2FluorideAmmoniaFree CO2Manganese

5.3 bar g10.3 bar g13.0 bar g23 0C

Ambient50 0c

85 "C

6.0 - 9.0Note 1

4.8 pS/cm25 mglLNote 1

Note 1

Q.27 mglt0.93 mg/L7.05 mg/L0.25 mg/LNote 1

Note 1

0.012 mgl0.04 mg/L2.10 mglL12.1 mglL1.87 mglLNote 1

0.02 mgllNote 1

Note 1

Note 1

Note 1

TEGHNIP IrALY S,p.A. - 00148 ROMA - Viate casteilo deila Magtiana, 6g

Ptot.2121 - SABIC ACETIC ACID PROJECT


Page 2-15

TECHIì||P IT&LY $,p.4.

Pressure

Temperature

P - AlkalinityM - Alkalinity

Notes:1. concentration not measurable

Steam

HP Steam (lmportl

Supply conditions at the battery limit of the Plant.

Pressure Normal 39.9Maximum 42.0Mechanical Design 47.0

Temperature Minimum 37.1

Normal 400Mechanical Design 427

HP Steam (Produce4)

Supply conditions at users:

MP Steam (produced)


Pressure NormalMechanical

Temperature NormalMechanical

MinimumNormalMechanical DesignMinimumMaximumMechanical Design

Design

Design

LP Steam (lmport) (note llSupply conditions at the battery limit of the Plant:


.,'É rl,-,,,J,

mmwmm

Nil25 mglL

bar gbar gbar g/FVoc

"c

23.7 bar g (future run)38.8 bar g47.0 bar glFV349 0C

390 "C427

14.0 bar g16.0 bar g/FV200 0c

295 "C

3.3 bar g3.9 bar g5.5 bar g/FV

TEGHNIP ITALY S.p.A. - 00148 ROMA - Viale Castelto detta Magtiana, 68



Page 2-16

TECIIHIP ITALY $.p,4.

Temperature

Notes:1. To be


used during plant shut-down

ococococ

LP Steam (produced)


Pressure NormalMechanical

Temperature NormalMechanical

Design

Design

LLP Stealn (exportl



Temperature NormalMechanical Design

Gondensate (Export)

Excess LP Condensate is exported from the Plant.Supply conditions at the battery limit of the Plant:

Pressure

Temperature

NormalMechanical Design


* tl rJ'l*mW**

148160177250

3.0 bar g5.5 bar g/FV146 "C250 0c

1.4 bar g5.5 bar g/FV137 "C190 0c

4.1 bar g12.8 bar g

65'C165'C

TEGHNTP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

Prq.212'l - SABIC ACETIC ACID PROJECT


Page 2-'17

TEGHÍ.XIP l?&LY $,p,4,

Instrument Air and Gompressed (Plant) Air

Supply conditions at the battery limit of the Plant:



Temperature

QualityDew Point



Specification:NitrogenAr, He, NeOzCOzcoQuality

,, ,,4 ,1, ,, t* î-,,1

mmMr*

6.0 barg8.0 bar g12.1 bar g

Ambient40"c50"c85"C

Oil and Dust Free-20"C at 7 bar g

Nitroqen

Nitrogen is used as a feed to the process from an off-plot Air Separation Plantand is also used for tank blanketing, flare header inerting, process inerting andfór Plant start-up and shutdown (within battery limit pressure constraints).

Nitrosen (import)


Pressure 30.9 bar g32.9 bar g40.0 bar g25 "C35 0C

50 0c

85 0C

99.99 vol % min<1 ppm vol10 ppm vol maxNil<1 ppm volOil and Dust Free

TEGHNIP ITALY S,p.A. - 00148 ROMA - Viale Castello della Magliana, 68

frcfiníp

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Ptoj.2121- SABIC ACETIC ACID PROJECT


Page 2-18

HP Nitrosen (producedl




LP Nitrosen(producedl




Specification :

EthaneMethanePropaneCarbon DioxideHydrogen Sulphide

, t ,1,,,,,,, , ,

mmfum

59.0 bar g68.0 bar g50 0c

175 "C

8.0 bar g1 1.0 bar g25 "C35 0C

50 0c

85 0C

95.0 mol % min.2.5 mol % max.2.5 mol % max.0.15 mol o/o tr1àx.100 ppm vol Normal(570 ppm vol peak - Note 1)

LLP Nitroqen (producedl

Supply conditions at users (tank blanketing):

Pressure Normal 0.5 bar gMechanical Design 1 1.0 bar g

Temperatur.e Minimum 25 "CNormal 35 oC

Maximum 50 oC

Mechanical Design 85 oC

Fuel Gas (Ethane)

For use as fuelto the Fired Heater (100-H161) at start-up (see Note 2).

Source: Gas supplied to the plant battery limits from Aramco

Supply conditions and specification of the ethane to be used as fuel is as follow:

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castetto deila Magtiana, 68

Technip

TESI{HIP :TALY $,p.A.

Specification :

WaterEthyleneCarbon dioxideOxygenEthaneNitrogenArgonMethanePropanelmpurities

PressureTemperature

Pressure

Temperature

Carbonyl Sulphide 7 ppm vol Normal(30 ppm vol peak - Note 1)

Supply conditions at the battery limit of the Plant :

Pressure Minimum 16.8 bar gNormal 18.6 bar gMaximum 2O.T bar gMechanical Design 91.1 bar g

Temperature Minimum 15 oC

Normal 36 oC


Notes:1. Peak concentrations occur for a maximum of 120 hours duratiop (not

continuous) in total in any one (1) year.2. The Fired Heater is normally supplied with fuel from within the process

plant and there is, therefore, no continuous external fuel requirement forthis duty.

rF_uefGag (Lesu|phurazed Ethane to I00-HI6I l

Proj.2121- SABIC ACETIC ACID PROJECT


Page 2-'19

4rl ',m,;mmW*

Firewater

Existing firewater ring system to be extended for the process plant:

NormalMaximumMechanical DesignMinimumNormalMechanical Design

0.9 mol%1.6 mol%5.5 mol%0.95 mol%48.4molo/o22.35molo/o0.1Smol%19.9mol%0.1Smol%0.1 molo/o

4.0 bara50'c

8.2 bar g11.9 bar g16.0 bar gAmbient35 "C85 0C

TEGHNIP trALY sì.p.A, - 00148 ROMA - viate casteilo deila Magtiana, 68

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TECFIHIP ITALY $,p,4.

Prol.2121 - SABIC ACETTC AC|D PROJECT


Page 2-20

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mmwm*

Boiler Feed Water

Supply conditions at battery limit of the plant:

Pressure Normal 61.1 bar gMaximum Z j.1 bar gMechanical Design g2.4 bar g

Temperature Normal 107 oC

Maximum 149 oC

Mechanical Design 250 "C

Flare and Relief Headers

HP Flare

Used for HC's releases.

Pressure Normal AtmosphericMaximum 2.5 bar gMechanical Design 3.S bar g

Temperature Normal AmbientMechanical Design 225 oC 3gS .C short time

Decanter Vent to Flare

Used for low pressure HC's vents ànd limited flows.

Pressure Normal AtmosphericMaximum 0.S bar gMechanical Design 3.S bar g

Temperature Normal AmbientMechanical Design gS oC

Atmospheric Vent to Scrubber

Used for nitrogen vents with possible acid content.

Pressure Normal AtmosphericMaximum 0.1 bar g

1.0 bar gTemperature Normal Ambient

120 0c


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Ptot.2121 - SABIC ACETIC ACtD PROJECT


Page 2-21

* t1".., il,, t

mmwm*

Electrical Power

Electrical power will be supplied from dual feeder 3.3 kV incoming lines routedacross the plant battery limit (from lbn Rushd Substation No 1 to the Plant 3.3 kVswitchboard. Each incoming line will be rated to individually supply the plantelectrical load requirements.

Distribution voltage 3,300 V, 3 phase, 3 wire, 60 Hz. 400A neutrallow resistance grounded system

The plant will use the following power levels:

Motor Power:Power 150 kW and above. 3,300 V, 3 phase, 3 wire, 60 HzPower 0.37 kW to 149 kW: 380 V, 3 phase, 3 wire, 60 HzPower below 0.37 kW: 380 V, 3 phase, 3 wire, 60 Hz. 220 V, single

phase to be considered only if 3 phase motorsare not available.

Heaters:2 kW and above 380 V, 60 Hz, 3 phase or 2 phase (2 wire +

earth)Below 2 kW 220V,1 phase, 2wire + earth

Motorcontrol circuits: 220 v, I phase, 2 wre 60Hz for 380 V and 3,300 vmotors.

Lighting distribution

a. Plant Lighting:3801220 V, 3 phase, (4 wire), 60 Hz from 380/220 V transformer withneutral solidly grounded.

b. Plant Building Electrical Services:2201127V 3 phase, (4 wire), neutral solidly grounded for receptacles andlighting.

Switch-gear Circuit Breaker Control

System: 110 V dc

Emergency Power Distribution

Emergency Electrical Power will be provided via a 3.3 kV feeder from the IBNRushd Main Substation No 1 3.3 kV Emergency Switchboard across the Plantbattery limit to the Plant's 3.310.4 kV Emergency power Transformer.

Power distribution will be 380 V, 3 Phase, 4 Wire, 60 Hz.


Techníp

TXCFlSrll P ITALY S,p.A,

Pro!.2121 - SABIC ACETIC ACID PROJECT


Page 2-22

,, ,,t 'l ,l l;*mwm*

I nstrumentation Distribution

Critical" 220V,1 phase, 2wire,60 Hz via the UpS

Non-Critical: 220V,1phase, 2wire, G0 Hz

Receptacle and LV Distribution

Three phase welding socket- 380 V, three poles and earthing contactoutlets:single phase convenience 127 v, two poles and earthing contact. NEMAsocket outlets: type 5-15R or 5-20R configuration. speciat

single phase 15A, 220V outlets (phase andneutral) will be provided where necessary.

onfiguration shall be NEMA type 6-15R.

TEGHII|P IrALY s.p.A. - 00148 ROMA - Viate casteilo deila Magtiana, 6g

1,1 ,,,TECHf{IP IT&LY $,p.4, *mwm*


The Acetic Acid Plant is designed to produce 34 kVa of "glacial" acetic acid fromethane and oxygen. Nitrogen is added to control the inert level in the reactionloop.The ISBL plant contains process units, utility systems and associated tankageare split into eight distinct areas:

Reactor Feed Preparation(21 21 -00-P F D-001 0-01 )

Ethane feed contains sulphur compounds (COS and H2S) that are removed inthis step to prevent poisoning of the catalyst and to satisfy environmentalconcerns in the effluent streams.Sulphur removal is achieved by hydrolysis of the COS to H2S at high temperatureover a zinc oxide bed, followed by reaction of the H2S over a solid ZnOabsorption stage.A small amount of HP steam for COS hydrolysis is added to the feed which isheated in the Ethane Feed lnterchanger, 100-E111N8, followed by the EthaneFeed Electrical Heater, 100-H211, before passing to the Zinc Oxide Vessel,100-D1114 & B.The desulphurised feed is cooled in the Ethane Feed Interchanger and EthaneFeed Cooler, 100-E113. The feed then passes via the Fresh Feed Filter,100-F111N8, to the Fresh Feed Compressor, 100-J1llNB.

Conventional Reactor System(21 21 -00-PFD-001 0-002, 21 21 -00-PFD-001 0-003)

After compression, the feed is mixed with recycle gases returned from the CO2Removal System and cooled recycle gases that bypass the COz RemovalSystem. At this point nitrogen is added to maintain a constant inert level in therecycle gases and hence the reaction feed stream. Condensate is removed fromthe recycle gas that bypasses the COz Removal System, by cooling this streamin the Recycle Gas Cooler, 100-E211, and separating the liquid in the RecycleGas K.O. Drum, 100-D211. Recycle gases from the CO2 Removal System arealso collected in the Recycle Gas K.O. Drum before being mixed with the ethanefeed.

Pîoj.2í21- SABIC ACETIC ACID PROJECT


Page 2-23


TECH$IP ITALY S,p,A,

Pîoj.2121- SABIC ACETIC ACID PROJECT


Page 2-24

1,1 ,,,*mM*

Oxygen is compressed by Oxygen Compressor, 100-J113A/8, cooled in theOxygen Feed Cooler, 100-E115, and fed via the Oxygen Filter, 100-F113, to theStatic In-line Mixer, 100-M111, where it is mixed with the compressed freshfeed/recycle stream.

The fresh feed/recycle stream is compressed in the Circulation Compressor,100-J112, to the required reaction pressure. The compressor is driven byCirculation Compressor Turbine Set, 1 00-J 1 12T , a steam turbine.

The mixed feed is heated in the Reactor Feed/Outlet lnterchanger, 100-E 114N8,to the reactor feed temperature, before being fed to the Conventional andSABOX Reactor systems, operating in parallel.

The basic reaction consists of the partial oxidation of ethane to acetic acid usingpure oxygen over a proprietary SABIC catalyst contained within the Reactor,100-R121.The reaction is exothermic, takes place in the vapour phase, and ismaintained below the flammability limits of the feed for safety and controlreasons.

The reactor is a tubular, fixed bed type with the catalyst contained in verticaltubes surrounded by water in the shell side. The heat of reaction is removed byraising steam in the shell side of the reactor.

The reaction ternperature is controlled by adjusting the steam pressure in theReactor Steam Drum, 100-D221. In order to facilitate start-up and shutdownthere is a Start-up Circulation Pump, lOO-P121, and Reactor Circulation Cooler,100-E121, as well as import HP steam that can be injected into the system.

HP Nitrogen is.required within the process to ensure safe start-up, controlle.dshutdown and to render the plant safe during emergency trips. The NitrogenStorage Area consists of the following items:

. HP Nitrogen Compressor, 100-J171, to compress Nitrogen to the desiredpressure.

. HP Nitrogen Compressor Cooler, 100-E171 , to cool nitrogen aftercompression.. HP Start-Up Nitrogen Vessel, 1OO-D274, provides HP Nitrogen at start-upto the Conventional Reactor loop. lt supplies also HP Nitrogen as make-upto HP Nitrogen Emergency Shutdown Vessel and to HP Nitrogen SABOXVessel.. HP Nitrogen Emergency Shutdown Vessel, 100-D276, provides HPNitrogen to the Static In-Line Mixer in case of an emergency trip.

Product Recovery and Purification(21 21 -00- P F D-00 1 0-004, 21 21 -00- P F D-00 I 0-00 5)

The reactor outlet stream is cooled in the Reactor Feed/Outlet Interchanger andpartially condensed in the Reactor Outlet Condenser, 100-E231. lt then passes tothe Scrubber, 100-C131, where the acetic acid product is removed by scrubbingwith water. The scrubbing stream consists of water recycled from the StrippingColumn and condensate from the Recycle Gas K.O. Drum.


Technip

TEGIIHIP ITALY $,p.4.



Page 2-25

* ,l , ,,,,*,f.,1

omWrym

This water is collected in the scrubber Feed water Drum, 100-D231, and istransferred to the Scrubber via the Scrubber Feed Water Pump, 100-P13'lA/8. Agas washing section is present at the bottom of the Scrubber; liquid recirculationis obtained by means of Scrubber Washing Pump, 100-P138A/8.

The scrubber overhead stream passes to the Co2 Removal system and thebottom stream goes to the Dehydration Column, 100-c132. The DehydrationColumn separates water from the acetic acid using butyl acetate as an entrainer.Heat for the separation in the Dehydration Column is provided by MP steam inthe Dehydration Column Reboiler, 100-E132.

The Dehydration column overhead combines with the stripping columnoverhead before entering the Dehydration Column Condenser, 100-F,232. wherethey are condensed and then passed to the Dehydration Column Decanter,1OO'D232. In order to minimise overhead losses from the Dehydration ColumnDecanter, vapour is further cooled in the Dehydration Column Decanter VentCooler, 100-E131, by chilled water and the condensate is returned to theDehydration Column Decanter. Non-condensable gases are vented to flare. lnthe Decanter, the aqueous and organic phases are separated. The organic phaseis returned to the Dehydration Column via the Dehydration Column Reflux Pump,100-P1354/8, and the aqueous phase is pumped by the Dehydration columnAqueous P,ump, 100-P137NB, to the Stripping Column, 100-C134, that recoversall the butyl acetate in that stream. A purge stream is taken out from this streamto control the impurities built-up.

Heat for the separàtion in the Stripping Column is provided by LP steam in theStripping Column Réboiler, 100-E134. Butyl acetate ends up in the overhead ofthe Stripping Column and the water plus some impurities in the bóttom. Thiswater is pumped by the Recycle water Pump, 100-P134N8, to the scrubberFeed Water Drum and the excess is cooled in the Waste Water Cooler,100.E137, before being r.outed to the Process Drain sump, 100-A1s1 or to theWaste Water Tank, 100-T154.

The bottoms stream from the Dehydration Column contains acetic acid andheavies, which are routed to the Product Column, 100-C133, via the Crude AcidPump, 100-P132NB.

Heat for the separation in the Product Column is provided by MP steam in theProduct column Reboiler, 100-E133, The Product column condenser,100-E233, condenses the overhead stream from the Product Column, which isthen collected in the Product Column Reflux Drum, 100-D233.

The Product Column overheads stream contains product acetic acid, which ispumped by the Product column Reflux Pump, 100-P1364/8, and passes via theProduct Cooler, 100-E135, to the Shift Tanks. The bottoms stream from thiscolumn contains heavy impurlties and is cooled in the Heavies Cooler, 100-E136,and pumped by the Heavies Pump, 100-P133A/B, either to the Process DrainCollection Drum, or sent to battery limits as Heavies.

TEGHNIP ITALY S.p.A. - 00148 ROMA - Viale Castetto detta Magtiana, 68

frcfi*rp

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CO2 Removal System(21 21 -00-P F D-001 0-006)

A licensed process is used for CO2 removal. This is a regenerative hot potassiumcarbonate based process known as "CATACARB', licensed by Eickmeyer &Associates which uses proprietary additives and a corrosion inhibitor and isspecially formulated to handle gases containing oxygen (refer to the Eickmeyerand Associates Process Package for further details).

Part of the recycle gas stream from the Scrubber is sent to the CO2 RemovalSystem where carbon dioxide is removed before the recycle gas is cooled andreturned to the Reactor via the Circulation Compressor. A bypass is providedaround the coz Absorber to control the level of coz in the recycle gases.

The carbon dioxide is removed in the Co2 Absorber, 1oo-c141, by absorption inthe hot carbonate solution. The carbonate solution passes to the COz SolutionRegenerator, 100-C142, where carbon dioxide is stripped out of solution andremoved in the column overheads. The bottom gtream of regenerated carbonatesolution is returned to the COz Absorber via the Lean solution pump,1OO-P142N8. Low pressure steam is used to generate the stripping steam ín theCOz Solution Reboiler, 100-E142, and the COz Solution Regeneràtor overheadstream is cooled in the CO2 Cooler, 100-8242. Condensate is returned to thecoz _solution Regenerator top wash trays, by the coz condensate pump,100-P143A/8, and the COz stream vented to atmosphere. Antifoam is added tocarbonate solution from CO2 Antifoam Injection Drum, 1OO-D243.

Acetic acid in the recycle gas reacts with the potassium carbonate, producingpotassium acetate, which will over time affect the solution capacity to absorbCOz. Other heat stable salts are expected to be formed by reactión of minorimpurities in the process gas with the solution chemicals. In order to maintain thecapacity of the solution to absorb Coz, a periodic purge of a. portion of thesolution and replacement by fresh chemicals will be required. The purge is routedto the Solution Purge Sump, 100-A142, and sent across the battery limits by theSolution Purge sump Pump, 100-P14s, for treatment and dispósal in orsitefacilities.

Lighter impurities will tend to accumulate in the coz K.o. Drum, 1oe-D242, andwill be periodically purged from the tiquid.

The treated gas leaving the CO2 Absorber is cooled in the Treated Gas Cooler,100-E241, and the condensate collected in the Treated Gas K.o. Drum,100-D241, and returned to the bottom of COz Solution Regenerator therebyensuring the COz Removal system is in water balance.

carbonate make-up solution is prepared in the solution sump, 1oo-A141, withthe aid of LLP steam via a steam sparger. Solution is pumped to the Solutionstorage Tank, 100-T141, via the solution sump Filter, 1oo-Fj42, by the solutionSump Pump, 100-P144. Solution is added to the process circuit vià tne SolutionMake-Up Pump, 100-P141. Carbonate make-up solution can also be sent direclyfrom the Solution Sump to COz Regenerator through the Filter bypassing theStorage Tank. A slipstream of carbonate solution is filtered to remov'e impu-ritiesin the solution Filter, 100-F141N8, and returned to the bottom of the cozSolution Regenerator"

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ISBL Tankage(21 21 -00-P F D-001 0-007)

SHrrr TRruxs (1 00-T1 51 A/B)

Acetic acid from the Product Column is routed to one of two Shift Tanks wherethe product is kept for analysis before transfer to the product tank, oroff-specification'tank, as appropriate.

Orr-Sprc Tnrur (1 00-T1 52)

Acetic acid that does not meet the product specification along with waste liquidsfrom the Process Drain Collection Drum, can be tr.ansferred to the Off-Spec Tank,via the Process Drain Collection Drum Pump. lt is possible to reprocess the tankcontents by feeding to the Dehydration column, via the off-spec pump,100-P152.

AcErc Aclo Pnooucr TANK (100-T153)

Product acetic acid is transferred from the Shift Tanks to the Acetic Acid productTank via the Acetic Acid Transfer Fump, 100-P151A/8. Acetic Acid productPump, 100-P153A/8, provides to deliver àcetic acid product to battery limit.

Vent gas from tankage area are collected to the Vent Gas Scrubber, 1OO-C251,where are washed by continuous blowdown before to be discharged toatmosphere.

Tankage and Process Drain Collection System(21 21 -00-PFD-001 0-008)

Pnocess DRAINS

The contents of the Closed Drainage System are routed to the Process DrainCollection Drum, 100-D251. Liquid from this system can be routed either to theOff-Spec Tank or as waste liquid to the Battery Limits for incineration, via theProcess Drain Collection Drum Pump, 100-p156.

For the purpose of controlling impurities in the organic phase of the decanter,there is provision to route a purge stream of the organic phase to the processDrain Collection Drum, if required.

The Product column bottom stream can also be routed to this drum.

The contents of the open Drainage system, passing through a Diverting pit,100-4152, are routed to the open process Drain Sump, 100-A1s1, orto ópenDitch when water quality matches the environmental regulations. The organicstream from this system is routed to the Battery Limits for incineration vià theProcess Drain Sump Oil Pump, 100-P159.

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TECII!*IP ITAIY S,p.A. *mM*The aqueous stream is routed outside the Battery Limits via the process DrainSump Aqueous Pump, 100-P158A/8. There is thé facility to route the aqueousstream to the Closed Process Drain Collection Drum for re-processing, ifrequired, or to the Waste Water Tank, 100-T154.

The Open Process Drain Sump and the Wastewater Tank are and nitrogenblanketed or vented to the flare.

EnrRRrnen HoLDING DRurrlt (1 00-DZS2)

The Entrainer Holding Drum contains fresh butyl acetate transferred as make-upto the dehydration column decanter by means of nitrogen pressurisation. Theexcess organic phase from the Dehydration Column overÉead stream is routed tothe Entrainer Holding Drum.

Steam / Gondensate System(21 21 -00-pFD-001 0-009 I &2, 21 21 -OO-qFD-OO1 0-01 0)

Steam generated in the conventional Reactor System is superheated in thesteam Fired Heater, 100-H161, using the steam Superheater i\o. 1, io0-E362,and steam superheater No.2, 100-E363, then rouied to the superheated Hpheader.

Boiler feed water from battery limit for steam generation is heated in a dedicatedcoil of Steam Fired Heater used as Boiler Èeed Water preheater, 100-E364.Steam Drum Chemical Dosing Set, 100-J361, provides the required chemicaladditivation to boiler feed water upstream the steam drums.

There are two turbines running on the HP steam header level, they drive theCirculation Compressor and its Lube Oil. These turbines are baók-pressuremachines, exhausting both to LLp steam. Turbine 100-J112T has a sideextraction facility, which allows feeding the Lp steam header, if required, withenergy recovery.

Excess HP steam can be letdown to MP level. Excess MP steam can be letdownto the LP level. Excess LP steam can be routed to LLP steam, which is exported.MP condensate is collected in Mp condensate Flash Drum, 1oo-D262, whereflashing steam is recovered in LP steam header and excess condensate is sentto LP condensate header.

LP condensate is collected in steam condensate Drum, 100-D263, whereflashing steam is sent to battery limit as LLP steam and excess condensate isrouted to battery limits via the Export Lp Condensate pumps, 100-p162NF', andcooled in Export Condensate Cooler, 100-E161.

lmported superheated HP steam is available for pre-commissioning and initialstart-up of the plant. lt can potentially be used under normal operatin! conditionsif required.

Facilities also exist to desuperheat the import HP steam and route it through thecoils of Steam Fired Heater and run the steam turbines at start-up. tmport Hfsteam is used to keep the plant steam system in service until steam generated inthe Reactors is available in sufficient quantities.

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Condensate from the Continuous Blowdown Drum, 100-D261, and all intermittentblowdown directly from the steam drums are routed to the Vent Gas Scrubber.

SABOX Reactor(21 21 -00 -PF D-00 I 0-0 I I )

Part of the mixed gases from the Reactor system (ethane, recycle gas andoxygen) are fed to the sABox Reactor, 100-R1g1. The sABox Réactolsystemoperates in parallel to the conventional reactor.The basic reaction consists of the partial oxidation of ethane to acetic acid in thepresence of oxygen over a proprietary SABIC catalyst. The reaction is exothermicand takes place in the vapour phase. The oxygen is added partially in the mixedfeed and further oxygen is added as a stageO àOOition step within t-he reactor. Assuch the oxygen stream enters the sABoX oxygen Heater, 100-E1g1, a coilinside the SABOX Steam Drum, where it is heated to the required temperatureand then passes through the SABOX Oxygen Filter, 100-F1S1, before enteringthe SABOX Reactor.

The reactor is a proprietary tubular, fixed bed type with the catalyst contained invertical tubes surrounded by water in the shell side. There aré oxygen tubeswithin the main catalyst filled vertical tubes to aid with a staged a-OOition ofoxygen. The heat of reaction is rbùoved by raising steam in the shell side of thereactor.

steam generated in the sABox Reactorsteam Drum, 100-D2g1, is letdown tothe plant MP header level. This enables the SABOX reactor to operateindependently as it essentially has, an intermediate, Saturated Hp header level.

Iî"_ tqrylion temperature is controlled by adjusting the steam pressure in theSABOX Reactor Steam Drum. In order to facilitate start-up theie is a SABOXstart-up circulation Pump, 100-p181, as well as import Hp steam that can beinjected into the system.

HP Nitrogen sABoX vessel, 1oo-D2g2, provides Hp Nitrogen to the sABoxReactor for start-up, normal operation, normal shutdown and in case of anemergency trip.

Flare System(21 21 -00-PFD-001 0-01 2)

The plant has a HP Flare Package, 100-J371 , as part of the safety system.The height of the flare will be set by a maximum radiation level & q.zS kWm2 atthe edge of the sterile area, if any.

A closed high-pressure flare header is required to collect discharges frompressure relief valves, blow-down valves and process vent valves, which areflammable or toxic. The system is designed for a maximum velocity in the flare of0.5 Mach during an emergency.

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A Flare K.O. Drum, 100-D272. is provided for the collection of any possiblecondensate within the HP flare system, before the gas is burned in the Hp FlarePackage. Liquid collected in the K.O. Drum flows under gravity to the processDrain Collection Drum.

Non-condensable vapours from decanter, vents from process drain sump andvents from compressor seals pass through Decanter Vent K.o. Drum, 1oo-D271,before being routed to flare.

OSBL Facilities

The following osBL utilities are supplied to the plant from battery timit;

See Chapter 2.3 for utility system description


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2.3

2.3.1.

GUIDELINE FOR PLANT OPERATION

Feedstock Preparation and Ethane Desu lph u rization(2121 -01-PtD-0021 -1 1 )(21 21 -0 1 -P tD -0021 - 1 2)(21 21-0 1 -P I D-00 21 -1 3)(2121-0 1 -P I D-0021 -1 4 1 t2)(21 21 -0 1 -P tD -0021 - 1 4 2 t 2)

Ethane feed contains sulphur compounds (COS andthis step to prevent poisoning of the catalyst andconcerns in the effluent streams.Sulphur removal is achieved bytemperature oVer a zinc oxide bed,ZnO absorption stage.Feed ethane $as is supplied at battery limit at a minimum pressure of about 16.8Barg and is fed to the Ethane Feed Interchanger 100-E111NB where it is heatednormally up to.335 "c by the Zinc oxyde vessel 100-D1 11NB ouflet.Thg ethane admission is pressure controlled by PIC-1109, installed at the inlet ofthe exchànger 100-E111NB and acting on the control valve in the feed line. An:emergency block valve installed in the feed line can be closed by DCS in case ofprocess upset.The temperature of the 100-E111NB ethane feed side outlet is indicated by Tl-11Q4.

A small amount of HP steam for: COS hydrolysis is added to the ethane feeddownstream the exchanger 100-E111N8. The flow rate of steam is controlled byFIC-1 101 , acting on the corresponding control valve FV-1 101.The ethane/steam feed is passed through the Ethane Feed Electrical Heater 100-H211 where it is heated up to 370 "C. This temperature is controlled by TIC-1112which passes its controller output to the control system of the electric heater.At the exit of the heater 100-H211 an abnormal temperature (higher or lower thanexpected) is detected by the alarms TAHH-1111 and TALL-1111, as well as a lowflow operation is indicated by the alarm FALL-1 105.

The ethane feed, heated at the required temperature, is then fed to the ZincOxide Vessel 100-D111A & B. The two vessels are connected in series, but eachone can be by-passed to permit the maintenance.

The desulphurised feed from the vessels is first cooled in the Ethane Feedlnterchanger and then in the Ethane Feed Cooler 100-E-113, using cooling wateras cooling medium.

The cooled feed is fed to the Fresh Feed Filter 100-F1 11NB (one in operationand the other in stand-by) having PDI-120s for pressure drop indication.

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H2S) that are removed into satisfy environmental

hydrolysis of the COS to H2S at highfollowed by reaction of the H2S over a solid

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The filtered feed is then passed to the Fresh Feed Compressor 100-J1 llNBwhich delivers the ethane feed at a pressure of about 25 Barg.Since the compressor is volumetric type, the discharge pressure is controlled byre-circulation of compressed gas to the suction via the control valve PV-1202.

After compression the feed is mixed, under flow rate control made by FV-1301,with recycle gases exiting the Recycle Gas K.O. Drum 1OO-D211 (coÀstituted bythe gas returned from the CO2 Removal System and the cooled recycle gasesthat bypass the CO2 Removal System).

At this point nitrogen is added to maintain a constant inert level in the recyclegases and hence the reaction feed stream. The flow rate of nitrogen is controlledby the flow control valve FV-l312, controlled by FIC-1312.

Condensate is removed from the recycle gas that bypasses the CO2 Removalsystem, by cooling this stream in the Recycre Gas cooler 100-E211 andseparating the liquid in the Recycle Gas K.O. drum 100-D211. The temperatureatthe outlet of 100-E211 is controlled byTlC-1303 acting on the pitch of thefanblades.

, lecycle gases from the CO2 Removal System are also collected in the RecycleGas K.O. drum before being mixed with the ethane feed.Liquid level in this drum is controlled by LIC-1301, which adjust the condensateflow rate to 100-D231. Very high level and very low level alarms are indicatedrespectively by LAHH-1304 and LALL-1304.

The fresh feed /recycle gas leaving the K.o. Drum 1oo-D211 is fed to theCirculation Compressor 100-J112 by which it is compressed up to the requiredreaction pressure. The compressor is driven by Circulation Compressor TurbineSet 100-J112T, a steam turbine using Hp steam as motive fluid.Low flow condition at the compressor discharge is indicated by the alarms FALL-1308 and FALL-1309. Total flow rate handled by this compressor is controlled atthe discharge by FIC-1302, regulating the control valve FV-1302 installed on theby-pass of the reactor system.

The oxygen necessary for the reaction is compressed by oxygen compressor100-J113A/8, cooled in the oxygen Feed cooter 100-E11s ànd fed, via theOxygen Filter 100-F113, to the Static ln-line Mixer IOO-M111, where it is mixedwith the compressed fresh feed / recycle stream.The supply oxygen pressure to 100-M111 is controlled by plc-1417, whichadjusts the oxygen recycle to the suction of 100-J113A/B through the controlvalve PV-1417.The flow rate of the oxygen added to the reactor feed is controlled by FIC-1402adjusting the control valve FV-1402, installed on the oxygen supply line upstreamof the ln-Line Mixer 100-M111.

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In order to prevent any possibility of feed gas backing into the oxygen line in caseof shutdown two double-block and bleed systems have been foreseen on theoxygen supply line. In this way two atmospheric pressure zones will be present,the second of which is purged with nitrogen.

The composition of the reactor feed gas is monitored by the analyzer Al-1404,taking sample on the gas line downstream the In-Line Mixer 11-M111.

2.3.2 Nitrogen Purge and HP Nitrogen System

Nitrogen from battery limit can be sent either to the oxygen shut-down station orto the fresh feed compressor discharge to maintain constant inert level in therecycle gases and hence the reaction feed stream. The flow rate of nitrogen iscontrolled by recirculation of compressed gas to the suction via the control valvePV-1202.

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HP Nitrogen is required within the process to ensure safe start-up, controlledshutdown and to render the plant safe during emergency trips. The NitrogenStorage Area consists of the following items:

- HP Nitrogen Compressor 100-J171, to compress Nitrogen to the desiredpressure.

- HP Nitrogen compressór cooler 100-E171, to cool nitrogen aftercompression

- HP Start-Up Nitrogen Vessel 100-D274 providing HP Nitrogen at start-up tothe Conventional Reactor loop. lt supplies also HP Nitrogen as make-up toHP Nitrogen Emergency Shutdown vessel and to Hp Nitrogen sABoXVessel.

- HP Nitrogen Emergency shutdown Vessel 1oo-D276, providing HpNitrogen to the static ln-line Mixer in the event of an emergency trip.

HP Nitrogen Gompressor

The HP Nitrogen compressor 100-J171is a reciprocating machine designto compress MP nitrogen from battery limits to the Hp start-Up NitrogenVessel, 100-D274 and to Area 08 - SABOX Reactor Area.

HP StaÉ-Up Nitrogen Vessel

The HP start-up Nitrogen Vessel 100-D274 is used to store Hp nitrogenfrom the HP Nitrogen compressor. This vessel is the source of nitrogenused to re-pressurise the HP Nitrogen Emergency shutdown Vessel, 100-D276 and is the source of HP nitrogen for start-up flushing of the oxygenline into the main re-circulation loop via the Static In-Line Mixer 100-M1 1 1 .

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Operatinq Philosophv

The nitrogen supply to this vessel, from the Hp Nitrogen compressor, iscontrolled from a pressure switches that act via the ESD system to siartand stop the compressor motor. when the pressure falls to s7 bara, asignal (PALL-7013) is sent to start the duty machine. when the motoi isconfirmed as running,After pressure drop become healthy across feed line xv-7006 a signal issent to open the xv-7006 on the feed line to this vessel. whèn thepressure then rises to 60 bara (pAHH-7013), a signal is sent to stopcompressor and subsequenily the xv-7006 will be closed direcily. Thexv-7006 on the feed line is to have a quick crosing time (< 1 second).

There are two outlet lines from this vessel to the static on-Line Mixer.These are the start-up line and flushing line. The start-up line is to have arestriction orifice sized for 4500 kg/h of nitrogen flow when the upstreampressure is 56 bara and downstream preséure is 36 bara. The flushing lineis to have an orifice plate sized for 372 kg/h of nitrogen flow whei theupstream pressure is 56 bara and downstream pressuré is 36 bara.

The block valve on the flushing rine from loo-D274 is a block valvecontrolled by the operator and has an open limit switch. This valve mustbe confirmed as open (permissive signal) by its open limit switch beforeallowing ethane feed to be added to the circulation loop.

There is a control valve (Hlc.-7002) and flow transmitter (Fl-7006) on thestart-up line to the circulation loop. This valve is opened on request fromthe operator, or tripped open from the low low flow oxygen trip initiator(FALL-1403). The flow transmitter FT-7007 has a low low low permissive,so that the nitrogen flow in this line must be above the permissive setting3 minutes. The nitrogen flow must be maintained above this setting ano ì'tthe flow drops below the permissive setting at any time during tné timerperiod, the time period will start again. The timer period has beenspecified by SABIC as 30 seconds.

Once the timer is complete then oxygen can be admitted to the circulationloop (i.e. the low low low flow oxygen trip (FALLL-1403) is essentially by-passed as long as the nitrogen is above its required low flow limit. i\oíethe low low flow trip FALL-1403 does not need to be bypassed since thelow differential pressure trip PDALL-1412 wlll be healthy and essentiallybypass this initiator).

The oxygen reset is a push button rocated in the control room that whenpushed will close the oxygen feed line bleed valves and open the oxygenfeed line block valves. Note that the oxygen feed line control vatve (Ètc-1402) is kept shut until the timer period of 3 minutes is succesàfullycomplete and all other trip initiators for this oxygen trip are healthy.

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Nitrogen flow must be maintained above the low flow permissive settinguntil the oxygen flow is above the low low low flow trip setting (FALLL--1403). At this point the nitrogen flow could not be lowered until'oxygenflow exceed low low flow tripping setting, however the low low oxygenf-lowtríp FALL-1403 causes the Hlc-7002 valve to be fulty open until ité FALL-1403 initiator is cleared. The fle-T002 control valve inthis line can onlybe closed, on request from the DCS rogic, when the oxygen flow is abovéits low flow trip. The valve closing ramping down time is 10 minutes.

Note that the oxygen flow system has two flow trips, these are the low lowflow trip (FALL-1403) and tow tow tow ftow trip (FALLL-1403). when theoxygen flow is at the low low flow trip (FALL-1403), the nitrogen HV-7002valve in the start-up line is tripped open to give a nitrogeÀ flow to thecirculation loop (as well as the oxygen flow continuing). li the differentialpressure over the oxygen flow control valve is also low low when theFALL-1403 is active, an oxygen trip is initiated. when the low low low flowtrip (FALLI--1403) on the oxygen line is active and the nitrogen flow on thestart-up line is lower than the permissive flow setting then an oxygen trip isinitiated. Note that the FALLL-1403 trip on its own does not initiate anytrips if all other.signals are healthy

HP Nitrogen Emergency Shutdown Vessel

The HP Nitrogen Emergency shutdown Vessel 1oo-D276 is used to storeHP nitrogen supplied from the Hp start=LJp Nitrogen vessel. This vessel isused to purge the oxygen line and^static ln-Line Mixer, 100-M111 in theevent of an oxygen trip to the main re-circulation loop. The sealingnitrogen to the mixer is also supplied from this vessel.

This vessel is to contain a low low pressure trip initiator (PALL-7013) at 55bara, which causes an oxygen trip. Note an oxygen trip is defined asstopping oxygen feed and ethane feed to the main circulation loop(additionally the HP steam entering the Feed preparation Area are trippedshut). This PALL-7013 also acts as a permissive for oxygen addition to'themain circulation loop.

Operatins Philosophv

The nitrogen gupply to this vessel, from the Hp start-up Nitrogen Vessel,is controlled from a PIC controller at 60 bara. There is a low differentiaipressure trip across this feed control valve that only acts to shut this valveon a low differential pressure reading. There is a manual block valve in theline from 100-D274 to 100-D276 that is used for isolation between thesetwo vessels. This valve is to have an open limit switch on this block valvethat confirms the valve open position in the DCS and alerts the operator ifthe valve is not fully open. The restriction orifice in this line is sized for 37kg/h of nitrogen flow when the upstream pressure is 56 bara anddownstream pressure is 36 bara.

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Flow control to the mixer in the event of an oxygen trip is achieved via arestriction orifice after tripping open the two XV valves in parallel (doubleredundant trip block valves) on the outlet line to the circulation loop. Therestriction orifice is sized for 4500 kg/h of nitrogen flow when the upstreampressure is 55 bara and downstream pressure is 36 bara. The trip XVvalves have open and closed low limit switches for information purposes.These limit switches are to alarm when the DCS requests a change instate and that state is not reached in a certain time.

The double trip XV valves on the outlet line to the circulation loop can bereset (closed) when all of the following conditions are satisfied;

- a timer, set to start as the oxygen trip is initiated, has completed a 5minute periodthe block valve on the flashing line from 1OO-D274 is open(measured by an open limit switch) or start up nitrogen flow ishealthy.

- these valves are requested shut by an operator reset button, locatedin the control room

2.3.3 Conventional Reactor System

(21 21 -0 1 -PtD-0021 -1 4 2t2)(21 21 -02-P tD -0021 -20)

The mixed feed leaving the In-Line Mixer 1OO-M111 is heated in the Reactor. Feed / Outlet Interchanger 100-E1 14NB to the reactor feed temperature(221 "C),

before being fed to the Conventional and SABOX Reactor systems, operating inparallel.The basic reaction consists of the partial oxidation of ethane to acetic acid usingpure oxygen over a proprietary SABIC catalyst contained within the Reactor 100-R121. The reaction is exothermic, takes place in the vapour phase, and ismaintained below the flammability limits of the feed for'safety and controlreasons.

The reactor is a tubular, fixed bed type with the catalyst contained in verticaltubes surrounded by water in the shell side. lt has a 3600 catalyst tubes (O.D.38.1 & l.D 32.56 mm) with length of 10400 mm. The catalyst bed is supported bysprings in the bottom and it has inert bed at the top. Inert balls bed'length isapprox 550 mm. Catalyst has cylindricalshape 3.175mm X 3.175mm and it has adensity 146011550 kg/m3. Inert shape are Q 6mm balls.More details are provided in the "Catalyst Loading" in "Operating Procedures for

Plant / Process Unit".

The heat of reaction is removed by raising steam in the shell side of the reactor.Water circulation is by thermosyphon action.The reaction temperature is controlled by adjusting the steam pressure in theReactor Steam Drum 100-D221. This is accomplished by PIC-2101A/B whichregulates the control valve pV-2101 on the steam drum exit.

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Three elements are necessary to control the Steam Drum 100-D221water level:

o Steam flow measurement Ft-2101o BFWflowratemeasurementFlC-21l2o Steam drum level controller LIC-2101

The control strategy accounts for changes in any of the three measurements.ft is a cascade control structure where the steam drum level (LT-2101) is primaryloop and the BFW flow s the secondary loop.The steam flowrate is a direct feed fonnrard signal to the BFW control loop. Sincethe steam flow is equal to the feed water flow (less continuous blowdown), theBFW control loop compensates immediately for changing in steam demand. Thesteam drum level loop modulates the feed water flow to compensate for shrink,swell and lags in the process. In other words, water level in the steam drum iscontrolled by LIC-2101, which adjust the boiler feed water flow rate sent to thesteam drum 100-D221.

In order to facilitate start-up the cold boiler feed water contained in the steamdrum shall be heated and subsequently the steam pressure will reach theoperating level. This can be done circulating the cold water from the steam drum'to the Reactor'by means of the Start-up Circulation Pump 100-P121and injectin(yHP steam directly into the water stream.

For the shutdown it is necessary to cool the water present in the system: for thisreason there is the Reactor Circulation Cooler 100-8121, through which the hotwater is circulated by means of the pump 100-P121and all this operation is doneby heating/cooling mode control.ln fact twó separàte operating modes exist that may be selected by the operatordepending on the condition whether the Reactor Steam Drum (100-D221) isbeing heated (HEAT MODE) or being cooted (COOL MODE).

When the steam drum is being heated at start up, the operator selects HEATMODE on HS-2002. This allows the circulating water to be heated using HPSteam.

Following a shutdown, the plant has been designed to accelerate the cooling ofthe steam drum and the Reactor. To initiate cooling of the circulating water, theoperator selects COOL MODE on HS-2002. The Reactor Steam Drum vent valve'rv-2101 and the circulation cooler, 100-8121 are both used to lower thetemperature of the water.

The maximum heating or cooling mode for the reactor system is specifieo as15"C per hour.

TEGHI{|P IrALY s.p.A. - 00148 ROMA - Viate casteilo deila Magtiana, 68

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Analvser Svstem

Continuos and fast analysis of reactor feed and product gas is essential for thesafety of operation.

Due to the exothermic nature of partial oxidation of ethane, there is the potentialfor explosive mixtures to occur. To this end, on-line oxygen analysers are utilisedthat send signals directly into the ESD System.

There are four oxygen on-Line Analysers, namely, AT-1402 (downstream of thestatic In-Line Mixer, 100-M111), AT-2004 (downstream of the Reactor, 100-R121), AT-8102 (downstream of the sABox Reactor, 100-R181) and AT.1403(SPARE).

AT-1403 is a spare analyser for AT-1402, AT-2.004 and AT-8102. A vendorselector switch (HS-1408) exists that allows AT-1403 to measure one of the threesample point locations. The information of which sample point location is beingmeasured by the spare analyser (as selected by the vendor switch) must berelayed to the ESD. The data from the spare analyser is routed to the ESD andrepeated to the DCS. A separate switch (HS-1409 Take Over Switch) is to beprovided by the ESD vendor that allows AT-1403 to override the alarms and",tripsof the selected analyser location. This allows the "off-line" analyser to be re-calibrated at regular intervals.

Find below a list of the alarm and trip settings for the on-line analysers.

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AAi{H-1402trips the plantAAHH-1404Trips the plant

Trips theSABOX Reac.

*mWm

Component High High High Action

At-1402

At-2004

At-2002

At-8102

At-3001

2121-06-PlD-0021-68 sh I of 5

2121-06-PlD-0021-68 sh 2 of 5

2121-06-PlD-0021-68 sh 2 of 5

2121-06-PlD-0021-68 sh 3 of 5

Oxygen 6.0 mol% 5.5 mol%

Oxygen 3.0 mol% 2.0 molo/o

Ethane 50.0 mot%

Oxygen 6.0 mol%

2121-06-PlD-0021-68 sh 3 of 5 Acetic Acid 30ppm mol.

Oxygen concentration is analyzed in the reactor feed trough Al-1402. In thereactor product stream Al-2204 is provided to analyze oxygen concentrationwhile Al-2002 is provided to analyze ethane tenor. AAHH-1402 setted at 6.Omol%and AAHH-1404 setted at 3.0 mol% trip the plant.

îEGHNIP ITALY S.p.A. - 00148 ROMA - Viate Casteilo deila Magtiana, 68

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2.3.4 Acetic Acid Recovery and Purification(21 21 -03-Pl D-002 1 -30)Q121-43-PtD-0021-31)(21 21-03- P I D-00 21 -32)(21 21 -03-P I D-002 1 -33)(21 21 -03-P I D-002 1 -34)(21 21-03-P I D-00 21 -35)(21 21-03- P I D-00 21 -36)

Scrubber 100-C131

The reactor outlet stream is cooled to 123'C in the Reactor Feed / Ouiletlnterchanger 100-E114NB and partially condensed in the Reactor OutletCondenser 100-E231. The temperature at the outlet of 100-E231 (85'C) isontrolled by TIC-3001 acting on the pitch of the fan blades..

The cooled gases flow to the Scrubber 100-C131, where the acetic acid productis absorbed from the gas stream by water.A gas washing section is present at the bottom of the Scrubber; liquid re-

'r ' circulation is obtained by means of Scrubber Washing Pump 100-P138A/8.' Washing liquid flow rate is adjusted by hand control valve reading the local flow

indicator Fl-3002.

The Scrubber overhead stream is sent to the CO2 Removal System. A portion ofthis stream by-passes the CO2 Removal System and is recycled back to 100-E211 and combined with the ethane feed.Liquid level in the Scrubber is controlled by LIC-300'1, in cascade to FIC-3102,which adjust the liquid flow rate to the Dehydration Column 100-C132. In case ofvery low liquid level, detected by LALL-3005, the circulation pump 100-P13BA/Bwill be stopped.Very high liquid level condition, detected by LAHH-3005, is passed to the logicsequence l-0106 and constitutes a permissive to start-up the circulationcompressor 100-J112.

Dehvdration Column 1 00-C1 32

The Dehydration Column separates water from the acetic acid using butyl acetateas an entrainer. The feed enters normally at tray #27 (tray numbered fromcolumn top), but additional inlet devices have been foreseen at trays #31, #37and #41.Liquid level on column bottom is controlled by LIC-3103, in cascadeto FIC-3301,which adjust the crude acetic acid flow rate to Product Column 100-C133.

Very low liquid level alarm is indicated by LALL-3105.Top column pressure is indicated by Pl-3107 while ditferential pressure acrossthe whole column, between overhead and bottom, is indicated by PDI-3101.

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Heat for the separation in the Dehydration Column is provided by the DehydrationColumn Reboiler 100-E1 32.The reboiler is a vertical thermosyphon type and the heating medium is Mpsteam, condensing shell side. The duty of the reboiler is adjusted by varying thecondensing steam flow rate through the flow control valve FV-3105, controlled byFFIC-3105 and located on the steam admission line.FFIC-3106 is resetted on the basis of the temperature at tray #68, controlled byTIC-3108, and of the liquid feed rate from the Scrubber.The steam condensing pressure inside the reboiler is controlled by PIC-31 1 1,acting in cascade on the level controller LIC-3101 for the discharge of watercondensate from the reboiler to the MP condensate header via the control valveLV-3101.

The Dehydration column overhead 'combines with the stripping columnoverhead before entering the Dehydration Column Condenser 1OO-E232. wherethey are condensed and then passed !o the Dehydration Column Decanter 100-D232.The temperature at the outlet of 100-E232 (85'C) is controlled by TtC-3201acting on the pitch of the fan blades.

In order to minimise overhead losses from the Dehydi'ation Column Decanter,vapour is sent to the Dehydration Column Decanter Vent Cooler 100-E131 forfurther cooling. The cooling medium is chilled water, which ensures the cooling ofprocess vapours down to 26 'C. The organic liquid recovered in this vent cooleris returned by gravity to the Dehydration Column Decanter. Non-condensablegases leaving the vent cooler arevented to flare via the control valve PV-3106.adjusted by PIC-3106.

ln the Decanter, a horizontal three phase separator, the aqueous and organicphases are separated. The liquid volume in this vessel is divided in two chambersby an internal weir. The organic phase, having a lower density than the aqueousone, stratifies in the upper layer of liquid and overflows to the adjacent chamber.The heavier aqueous phase stratifies in the bottom layer inside the feed chamberof the separator.Liquid level in the organic chamber of the Decanter is controlled by LIC-3203, incascade to FIC-5201, which adjust the entrainer make-up flow coming into theorganic chamber from the Entrainer Holding Drum 100-D252.The organic phase is returned as reflux to the Dehydration Column via theDehydration Column Reflux Pump 100-P13SA/8.The liquid controller LIC-3203, in case of high organic liquid level, will open andkeep under control the valve LV-3203, installed on the entrainer draw-off line to100-D252.

From the discharge line of pumps 100-p135A/B is branched a purge line todischarge, when required, the organic phase to the Closed Drain Collection Drum100-D251. The purge rate is controlled by FIC-3203, adjusting the control valveFV-3203.

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The reboiler is a vertical thermosyphon type andsteam, condensing shell side.The duty of the reboiler is adjusted by varying thethrough the flow control valve FV-3302, contrólledthe steam admission line.

lnterface liquid level in the feed chamber of the Decanter is controlled by LIC-3201, in cascade to FIC-3201, which adjust the aqueous solution 1ow ratepumped by the Dehydration column Aqueous pump 100-P13TNB to theStripping Column 100-C134. ln order to control the impurities built-up in the.lgueoYs phase, a purge stream is taken out from this stream and is routed to theWaste Water Cooler 100-E13T for disposal.

Product Column 100-C1 33

The bottom stream from the Dehydration column, pumped by the crude AcidPump 100-P132NB, contains acetic acid and heavies, which àr" r"prr"t,ed bydistillation in the Product Column 100-C133.

The feed enters normally at tray #1g (tray numbered from column top), butadditional inlet devices have been foreseen at trays #14 and #22.Liquid level on column bottom is controlleO by Uó-S301, in cascade to FIC-33O2,which adjust the MP steam flow rate admittéd to Product Column Reboiler 100-E133, acting on FV-3302.

Very l9w liquid level alarm is indicated by LALL-3303, which cause the automaticstop of the bottom Heavies pump 100-pi33A/8.Top column pressure is indicated by Pl-3301 while differential pressure acrossthe whole column, between overhead and bottom, is indicated by pDl-3303.

Heat for the separatíon in the Product Column is provided by the.product ColumnReboiler 100-E133.

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the heating medium is Mp

condensing steam flow rateby FIC-3302 and located on

Flc-3302 is reset by the bottom corumn level controller Llc-3301.The water condensate is discharged from the reboiler to the Mp condensateheader by means of a steam trap.

The bottoms stream from this column contains heavy impurities and is cooledfrom 174 "c down to 4z "c in the Heavies cooler too-etio and pumpeo oy tneHeavies Pump 100-P133A/B either to the Process Drain Collection brum'100-D251or sent to battery limits as Heavies. These pumps are volumetr.ic alternativetype, with stroke controlled by the temperature atthe column bottom.

overhead vapours from the product column are condensed incolumn condenser 100-E233. The temperature at the ouiletcontrolled by Tlc-3401 acting on the pitch of the fan btades.Liqu]d condensate, which constitutes the product acetíc acid,the Product Column Reflux Drum 100-D233.The acetic acid from the reflux accumulator is pumped by the product ColumnReflux Pump 100-P136A/B and is partially refiuxed to tÉe top of the column.

the Product(110 "C) is

is then collected in

TEGHNIP ITALY s.p.A. - 00148 ROMA - Viate casteilo deila Magtiana, 6g

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Reflux flow rate is controlled by FFIC-3403, having its set point calculated by FY-3403 on the basis of the feed flow rate to the Product Column.

The product acetic acid line branches from the reflux line and send the distillateto the Shift Tanks via the Product Cooler 100-E135, where the product is cooledto 47 "C.

Strippino Column 1 00-C134

ln the Stripping Column 100-C134 all the butyl acetate present in the aqueousphase from Decanter 100-D232 is recovered. Butyl acetate ends up in theoverhead of the Stripping Column and the water plus some impurities in thebottom.

The feed enters at the top of the column. Liquid level on column bottom iscontrolled by LIC-3501, in cascade to FIC-3502, which adjust the waste waterflow rate sent to the battery limit for disposal.Very low liquid level alarm is indicated by LALL-3505, which cause the automaticstop of the bottom Recycle Water Pump 100-P134NBTop column pressure is indicated by Pl-3501 while differential pressure acrossthe whole column, between overhead and bottom, is indicated by pDl-3502.

Heat for the separation in the stripping column is provided by the strippingColumn Reboiler 1 00-E1 34.The reboiler is a vertical thermosyphon type and the heating medium is Lpsteam, condensing shell side.The duty of the reboiler is adjusted by varying the condensing steam flow rate(and the steam condensing pressure) through the flow control valve FV-3501,controlled by FIC-3501 which receives its set point from TIC-3501, controlling thetemperature of the column overhead vapour.The steam condensing pressure inside the reboiler is controlled by PIG35O4,acting in cascade to the level controller LIC-3503 for the discharge of watercondensate from the reboiler to the LP condensate header via the control valveLV-3503.

The bottom water is pumped by the Recycle water pump 100-p134NB to theScrubber Feed Water Drum 100-D231.The water in excess is cooled to 50 'C by the Waste Water Cooler 100-E137 andthen is routed to the Open Process Drain Sump 100-A151

Overhead stripped vapour is added to the Dehydration Column overhead vapourand flows together to the Dehydration Column Condenser.

Scrubber Feed Water Drum 100-D231

The Scrubber Feed Water Drum 100-D231 collects the water recycled from theStripping Column and the condensate from the Recycle Gas K.O. Drum.The liquid level is controlled by LIC-3601, which adjusts the control valve LV-3601 installed on the demineralised water supply line to the drum.

TEGHNIP ITALY S.p.A. - 00148 ROMA - Viate Casteilo deila Magtiana, 68

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TECHHIP IT&LY $.p,4. *mfu*The level controller LIC-3601 is also connected in cascade to the FIC-3603(recycle water from 100-P134A/B) for a split range operation: the control valveFV-3603 is normally in control, but if the recycle water coming from that source isnot sufficient to maintain the level in the drum, the make-up of demineralisedwater is added into the drum by the valve LV-3601.

The water collected in the Scrubber Feed Water Drum is transferred to theScrubber by means of the Scrubber Feed Water Pump 100-P131A/8. The flowrate is adjusted by the vatve FV-3601 controlled by FtC-3601.The pressure of the 100-D231 is controlled in spit range trough the plC-3601acting on the PV-3601A (LP Nitrogen) and pv-36018 (vent gas).

2.3.5 GO2 Removal System

(21 21 -04-Pt D-002 1 -40)(21 21 -p4-PtD-0021 -41 1 t2)(21 21 -0 4-P ]D -002 1 -4 1 2 | 2)(2 1 2 1 -0 4 -P tD -O 02 1 - 42)

A licensed process is qrsed for CO2 removal. This is a regenerative hot potassiumcarbonate based procè'Ss known as "CATACARB", licensed by Eickmeyer &Assòciates whlch uses proprietary additives and a corrosion inhibitor and isspecially formulated to handle gases containing oxygen.

- Absorber 100-C141

Part of the recycle gas stream from the Scrubber 1OO-C131 is sent to the CO2Removal System where carbon dioxide is removed before the recycle gas iscooled and retuined to the Reactor via the Circulation Compressor. A by-pass isprovided around the CO2 Absorber to control the level of CO2 in thé iecyclegases.The carbon dioxide is removed in the CO2 Absorber 1OO-C141 by absorption inthe hot carbonate (lean) solution. The lean solution is fed on the top anddistributed over the packing bed.The CO2 rich gas is entered on the bottom.

Pîoj.2121- SABIC ACETTC AC|D PROJECT


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The liquid level in the absorber is controlled by LIC-4001, adjusting the controlvalve LV-4001 installed on the transfer line of the rich carbonate solution to theCO2 Solution Regenerator 1 0A-C142.

The overhead gas is passed through the Treated Gas Cooler 1OO-E24I and thenis sent to the Treated Gas K.O. Drum 100-D241. The outlet temperature from theCooler 100-F,241 is controlled by the Tlc-4001, adjusting the pitch of the fanblades. Condensate is collected in this drum and is transferred, via the controlvalve LV-4004, to the Regenerator. The gas leaving the K.o. Drum 100-D241 issent back to 100-D21 1 closing the recycle gas loop.


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The carbonate rich solution from the bottom of the Absorber is fed to theRegenerator 100-C142, where carbon dioxide is stripped out of solution andremoved in the column overhead.

Liquid level on column bottom is controlled by LIC-4104, acting on the valve LV-4104 varying the flow rate of condensate make-up from 100-D242.very low liquid level alarm is indicated by LALL-4106, which causes theautomatic stop of the bottom Lean Solution Pump 1OO-P142NB

Heat to regenerate the carbonate solution is provided by the CO2 solutionReboiler 100-E142.The reboiler is a vertical thermosyphon type and the heating medium is Lpsteam, condensing shell side.The duty of the reboiler is controlled indirectly by FIC-4102 which adjusts thecondensing steam flow rate through the flow control valve FV-4102.The steam condensing pressure inside the reboiler is controlled by PIC-4110,acting in cascade to the level controller LIC-4107 for the discharge of watercondensate from the reboiler to the LP condensate header via the control valveLV-4107. .

The regenerated carbonate solution collected in the column bottom is returned tothe CO2 Absorber via the Lean Solution Pump 100-P142NB. A slip stream ofcarbonate solution is filtered to remove impurities in the Solution Filter 100-F141NB and returned to the bottom of the co2 Solution Regenerator.Antifoaming injection is provided at pumps suction. This chemical is stored in theCO2 Antifoam lnjection Drum 100-D243, pressurized with LP nitrogen by the selfactuated PCV-4112, and its injection flow rate is adjusted by the rotameter Fl-4106.

The CO2 Solution Regenerator overhead stream is cooled in the CO2 Cooler1OO-8242 and is sent to the CO2 K.O. Drum 100-D242. The outlet temperaturefrom this cooler is controlled by the TIC-4102, adjusting the pitch of the fanblades.

Condensate from 100-D242 is returned to the CO2 Solution Regenerator topwash trays by the CO2 Condensate Pump 100-P143N8, while the CO2 stream isreleased to atmosphere. The liquid level in the drum 100-D242 is controlled byLfC-4101 which adjusts the control valve LV-4101 to regulate the admission ofdemineralised water make-up to the drum. The same LIC-4101 is connected incascade to FIC-4101 which adjusts the control valve FV-4101 regulating the flowrate of solution sent to waste water treatment, via 100-E137.

Acetic acid in the recycle gas reacts with the potassium carbonate, producingpotassium acetate, which will over time affect the solution capacity to absorbCO2. Other heat stable salts are expected to be formed by reaction of minorimpurities in the process gas with the solution chemicals.

TEGHilIP ITALY S.p.A. - 00148 ROMA - Viate Casteilo deila Magtiana, 68

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In order to maintain the capacity of the solution to absorb COZ, a periodic purgeof a portion of the solution and replacement by fresh chemicals will be required.The purge is routed to the Solution Purge Sump 100-A142 and sent across thebattery limits by the Solution Purge Sump Pump 100-P145, for treatment anddisposal in offsite facilities.Lighter impurities will tend to accumulate in the CO2 K.O. Drum 1QQ-D242 andwill also be periodically purged from the liquid.

Carbonate make-up solution is prepared in the Solution Sump 100-A141, with theaid of LLP steam via a steam sparger. Solution is pumped to the Solution StorageTank 100-T141 via the Solution Sump Filter 100-F142 by the Solution SumpPump 100-P144. Solution is added to the process circuit via the Solution Make-Up Pump 100-P141. Carbonate make-up solution can also be sent directly fromthe Solution Sump to CO2 Regenerator through the Filter by-passing the Storage' Tank.

2.3.6 ISBL Tankage

(21 21 -05-P I D-00 21 -s0)(21 21 -05-PtD-0021 -51 1 t2). (2121-05-PtD-0021 -53)

ShiftTanks 100-T151 A/B

Acetic acid from the Product Column is routed to one of the two Shift Tankswhere the product is kept for analysis before transfer to the product tank, or off-specification tank, as appropriate, by the Acetic Acid Transfer Pump 100-P1514/8.Tanks are cylindrical vertical, with fixed cone roof. The vapor space of both tankshave a common blanketing system with LP nitrogen. The vent gas is routed atfirst to hydraulic guard and then to Vent Gas Scrubber 100-C2b1 .

Tanks have an internal heating coil with LP steam for winterizing.

Off-Spec Tank 100-T152

Acetic acid that does not meet the product specification along with waste liquidsfrom the Process Drain Collection Drum 100-D251, can be transferred to the Off-Spec Tank 100-T152,via the Process Drain Collection Drum Pump 100-P156. ltis possible to re-process the tank content by feeding it to the Dehydration Columnvia the Off-Spec Pump 100-P152.Tank is cylindrical vertical, with fixed cone roof. The vapor space of the tank hasa blanketing system with LP nitrogen. The vent gas is routed at first to hydraulicguard and then to Vent Gas Scrubber 100-C251.Tank has an internal heating coil with LP steam for winterizing.

Pîot.2121 - SABIC ACETIC ACID PROJECT

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Acetic Acid Product Tank 100-T153

Product acetic acid is transferred from the Shift Tanks to ZM-5302 hydraulicguard to avoid returns of air inside the tanks. Hydraulic guard is realised by asmall vessel filled by waste water.Liquid level is held by siphon system collected vent streams are routed to theAcetic Acid Product Tank via the Acetic Acid Transfer Pump 100-P151A/8. AceticAcid Product Pump 100-P153A/B provides to deliver acetic acid product tobattery limit.Tank is cylindrical vertical, with fixed cone roof. The vapor space of the tank hasa blanketing system with LP nitrogen. The vent gas is r.outed to Vent GasScrubber 100-C251.Tank has an internal heating coil with LP steam for winterizing.

. Vent Gas Scrubber 100-C251

The vent gas is routed to Vent Gas Scrubber 100-C251.Vent gases from tankage area are collected to ZM-5302 hydraulic guard to avoidreturns of air inside the tanks. Hydraulic guard is realised by a small vessel filledby waste water.Liquid level is held by siphon system collected vent streams are routed to theVent Gas Scrubber 100-C251where they are washed by a stream of desalinatedwater before to be discharged to atmosphere. Liquíd collected at the bottom ofthe scrubber is discharged to the Open Process Drain Sump 100-A151 bygravity.

2.3.7 Closed and Open Drain Gollection System

(21 21 -05-PtD-0021 -51 2t2)(21 21-05-P I D-00 21 -52)(21 21 -05-PtD-0021 -54 1 t2)(21 21 -05-P tD -0021 -5 4 2t 2)

Closed Drainaqe Svstem

The contents of the Closed Drainage System are routed to the Process DrainCollection Drum 100-D251. Liquid from this system can be routed to either theOff-Spec Tank or as waste liquid to the Battery Limits for incineration, via theProcess Drain Collection Drum Pump 100-P156.For the purpose of controlling impurities in the organic phase of the decanter,there is provision to route a purge stream of the organic phase to the ProcessDrain Collection Drum, if required.The Product Column bottom stream can also be routed to this drum.



Page 246

TEGHNIP ITALY $.p.A. - 00148 ROMA - Viale Castetto detta Magtiana, 68

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The contents of the Open Drainage System, passing through a Diverting Pit,100-4152, are routed to the Open Process Drain Sump, 100-4151, orto OpenDitch when water quality matches the environmental regulations. The organicstream from this system is routed to the Battery Limits fór incineration vià theProcess Drain Sump Oil Pump, 100-P159. The aqueous stream is routed outsidethe Battery Limits via the Process Drain Sump Aqueous Pump, 100-P158A/8.There is the facility to route the aqueous stream to the Closed Process DrainCollection Drum for re-processing, if required, or to the Waste Water Tank,100-T154, if more hold up is required.

The Open Process Drain Sump and the Wastewater Tank are nitrogen blanketedor vented to the flare.

Entrainer Holdino Drur,n 100-D252

The Entrainer Holding Drum 1OO-D252 contains fresh butyl acetate which istransferred as make-up to the dehydration column decanter by means of nitrogenpressurization. The operating pressure is controlled by PIC-5201, adjusting insplit range the nitrogen admission valve PV-5201A and the valve PV-520j8venting the gas to the flare.

The excess organic phase from the Dehydration Column overhead stream isrouted to the Entrainer Holding Drum.

The make-up flow rate of entrainer is regulated by FIC-5201 which receives itsset point by LIC-3203 (organic chamber of Decanter 100-D232) and adjust thecontrol valve FV-5201.

2.3.8 Steam / Condensate System

(21 21 -06-P I D-003 1 -60)(2121 -06-Pt D-003 1 -6 1 I /2)(21 2 1 -06-P tD -003 1 -6 I 2t 2)(21 21 -06-Pt D-003 1 -64)

HP Steam Level

Saturated HP steam is generated in the conventional Reactor System. lt issuperheated in the Steam Fired Heater 100-H161 using the Steam SuperheaterNo. 1 100-E362 and Steam Superheater No. 2 100-E-363, then routed to thesuperheated HP header.The superheating degree is controlled by TIC-6156 which reset the set point ofFIC-6156, regulating the flow rate of fuel gas to burners by means of the valveFV-6156.



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The high temperature of the superheated steam at the exit of the heater, as wellas a low flow of steam through the heater itself, will cause the shut down of theheater. Other typical causes of shut down are the very low pressure and veryhigh pressure of fuel gas to burners and/or to pilots. The shut down of the heateris carried out by automatic activation of double block and bleed system.

There are two turbines running on the HP steam header level, they drive theCirculation Compressor and its Lube Oil Pump. These turbines are back-pressuremachines, exhausting to the LLP and LP levels.

Superheated HP steam is imported from battery limit for low consumptionprocess use (steam added to ethane feed) and for pre-commissioning and initialstart-up of the plant.In case of low production of saturated HP steam in the Reactor, FtC-61Ss(controlling the flow rate of HP steam exiting the 100-E363) increases the flowrate of HP steam imported from battery limit through the valve FV-61ss.

Operating pressure of the HP steam header is controlled by PIC-6103: if thepressure increases HP steam is let down to MP steam level (through valves PV-6101 A/B), if the pressure decreases HP steam is imported from Battery limit(through valves PV-6103 A/B).

Facilities also exist to desuperheat the import HP steam and route it through thecoils of Steam Fired Heater and run the steam turbines at start-up. lmport HPsteam is used to keep the plant steam system in service until steam gener.ated inthe reactor is available in sufficient quantities

MP Steam Level

MP steam is produced by SABOX Reactor and/or is letdown from HP steam level(and desuperheated).

Operating pressure of the MP steam header is controlled by PIC-6102: if thepressure increases MP steam is letdown to LP steam level (through valves PV-6105 A/B), if the pressure decreases HP steam is imported from Battery limit(through valves PV-6103 A/B) and is letdown to MP level.

LP Steam Level

LP steam is obtained by depressurizing MP steam. lt is possible to import LPsteam from battery limit during a plant shut down to maintain in operationwinterizing and some other critical user.Operating pressure of the LP steam header is controlled by PIC-6106: if thepressure increases LP steam is letdown to LLP steam level (through valves PV-6106 A/B), if the pressure decreases MP steam is letdown to Lp level.


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LLP Steam Level

LLP steam is obtained from back pressure turbine 100-J1 12T and is basicallyexported to battery limit.Operating pressure of the LLP steam header is controlled by plC-6115: if thepressure increases LLP steam can be blown off to atmosphere through valve pV-61 15A if greater export (through valve PV-61 158) is not permitted, if lhe pressuredecreases the export of LLP steam to battery limit will be reduced.

Condensate Svstems

MP condensate is collected in MP Condensate Flash Drum 1xL-D262,whereflashing steam is recovered in LP steam header and excess condensate is sentto LP condensate header through valve LV-6007.

LP Condensate is collected in Steam Condensate Drum 't0O-D263, whereflashing steam is sent to LLP steam header and excess condensate is routed tobattery limit via the Export LP Condensate Pumps 100-P162 NB and cooled inExport Condensate Cooler 100-E161 .

Boiler Feed Water: is impor:ted from battery limit, preheated in the coil 100-E364of the Steam Fired Heater and then is fed to the steam drums of the Conventionaland SABOX Reactors.

Condensate from the Continuous Blowdown Drum 1OO-D261and all intermittentblowdown directly fronn the steam drums are routed to the Vent Gas Scrubber. .

Steam Drum Chemiial Dosing Set 100-J361 provides the required chemicaladditivation to boiler feed water upstream the steam drums.

2.g.g SABOX Reactor

(21 21-08-Pt D_002 1 _80)(2121 -08-Pt D-002 1 -81 )(2 1 2 1 -0 8 -P tD -O 02 1 -82)

Part of the mixed gases from the Reactor System (ethane, recycle gas andoxygen) are fed to the SABOX Reactor 100-R181. The SABOX Reactor-Systemoperates in parallel to the conventional reactor.

The basic reaction consists of the partial oxidation of ethane to acetic acid in thepresence of oxygen over a proprietary SABIC catalyst.The reaction is exothermic, takes place in the vapour phase, and is maintainedbelow the flammability limits of the feed for safety and control reasons.

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The oxygen is added partially in the mixed feed and further oxygen is added as astaged addition step within the reactor. As such the oxygen stream enters theSABOX Oxygen Heater 100-E181, a coil inside the SABOX Steam Drum 100-D281, y!9re_ it is heated to the required temperature and then passes throughthe sABoX oxygen Filter 100-F181, before entering the sABoX Reactor.The reactor ís a proprietary tubular, fixed bed type with the catalyst contained invertical tubes surrounded by water in the shell side. There are oxygen tubeswithin the main catalyst filled vertical tubes to aid with a staged

-addition of

oxygen. The heat of reaction is removed by raising steam in the shell side of thereactor. Water circulation is by thermosyphon action.

Steam generated in the SABOX Reactor Steam Drum 100-D281 is letdown to theplant MP header level. This enables the SABOX reactor to operate independenlyas it essentially has, an intermediate, saturated Hp header level.

The reaction temperature is controlled by adjusting the steam pressure in theSABOX Reactor Steam Drum. This is accomplished by PIC-8204 which regulatesthe letdown valve PV-8204 on the steam drum exit.

Water level in the steam drum is controlled by LIC-8201 in cascade to FIC-8202,which adjust the boiler feed water flow rate sent to the steam drum 100-D291.

Three elements are necessary to control the SABOX steam Drum 100-D2g1level:

o Steam flow measurement Fl-8201. BFW flowrate measurement FIC-8202. Steam drum level controller LIC-8201

The control strategy accounts for changes in any of the three measurements.It is a cascade control structure where the steam drum level (LT-8201) is primaryloop and the BFW flow s the secondary loop.The steam flowrate is a direct feed fonruard signal to the BFW control loop. Sincethe steam flow is equal to the feed water flow (less continuous blowdown), theBFW control loop compensates immediately for changing in steam demand. Thesteam drum level loop modulates the feed water flow to compensate for shrink,swell and lags in the process.

In order to facilitate start-up the cold boiler feed water contained in the steamdrum shall be heated and subsequently the steam pressure will reach theoperating level. This can be done circulating the cold water from the steam drumto the SABOX Reactor by means of the SABOX Start-up Circulation Pump 100-P181 and injecting HP steam direcily into the water stream.For the shutdown it is necessary to cool the water present in the system: for thisreason there is the Reactor Ciróulation Cooler 1Od-E121, through which the hotwater is circulated by means of the pump 100-P181 and all this operation is doneby heating/cooling mode control.

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2.3.10

HP Nitrogen sABoX Vessel 100-DzB2 provides Hp Nitrogen to the sABoxReactor for start-up, normal operation, normal shutdown and in the event of anemergency trip.The operating pressure of nitrogen inside this vessel is controlled by plC-800S,acting in split range on the valve pv-800sA (vent to atmosphere; anà ev-eogsB(admission of HP nitrogen from 100-D274).

Flare System(21 21 -07 -P tD -0021 -7 1 )

The plant has a HP Flare Package 100-J371, as part of the safety system.The height of the flare will be set by a maximum radiation level of 4.73 kWm2 atthe edge of the sterile area, if any.A closed ft!g! pressure flare header is required to collect discharges frompressure relief valves, blow-down valves and process vent valves, which areflammable or toxic. The system is designed for a maximum velocity in the flare of0.5 Mach during an emergency.The flare K.O. Drum 100-D272 is provided for the collection of any possiblecondensate within the HP flare system, before the gas is burned in thé Hp FtarePaekage. Liquid collected in the K.O. Drum flows under gravity to the processDrain Collection Drum 100-D251.Low pressure discharge streams from process passes through Decanter VentK.O. Drum 100-D271 before being routed to the top of the flare.The flare package includes:

molecular seal, to reduce the fuel gas purge required to prevent flash-back;local control panel and fiame front genera[or to ignite pilots;

- infrared monitor to check the smokeless operation of the flare.

Utilities System

The following osBL utilities are supplied to the plant from battery limit;

2.3.11.

NitrogenHP SteamLP SteamDemineralised WaterDesalinated (Process) WaterPotable WaterClosed Loop Cooling WaterBoiler Feed Waterlnstrument (& Plant) AirElectricityFire WaterChilled Water

Most of the data characteristics of the Utilities coming outside of Battery Limitsare given in chapter 2.1.6.


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Expanded MP steam is alsosteam) will be replaced by

Nitrogen (called "imported" at -31 barg) is a feed to Nitrogen compressor100-J-171 for emergency s/D and to the process (Recycle loop) to hold inertlevel in cycle loop. lt is used to produce a LP Nitrogen (at I barg) and LLpNitrogen (at 0,5 barg) for vessel/tank inert padding.

lmported HP steam (at -40 barg but superheated) is a main power supply forsteam turbines 100-J-112 T & 100-J-112P}1TA and feeder of two reactorssteam spargers during s/uP phase. Most of this steam during normaloperation will be replaced by own steam production in steam drum feeding aHP header. In case of decreasing of steam internal production, FIC-6155 askfor imported HP steam. During startup phase Mp steam is produced (byexpansion and saturation) from HP imported steam.

LP steam (imported) feeds LP steam header.feeding the same header. Most of this (LPproduced ones during theLP steam from B/L is used for ISBL tankage areashutdown.

Demineralized water is mainly used to feed a scrubber feed water drum 100-D-231(make up), to make up a level in coz Ko drum 100-D-z42for chemicaldosing facilities and hose stations. lt is used also for sump 100,A-142 & sump100-A-141 services.

Desalinated (Process) water via 2" header is supplying a oil clarificator of100-J-112 lubricating all system, vent gas scrubber 100-c-2s1 and Hosestations.

Potable water is burried after B.L. in 3" pipe, mostly used for safety showersand eye wash. Building & workshop are using this water as well.

cooling water is a refrigerant entering the plantthrough 10" pipe headerandsupplying process shell & tube, exchangers, coil, pump seal liquid coolers,sample poínt coolers, machinery etc).

Boiler feed water via 4" header is a main supplier of water to steam drums1oo-D-221 & 100-D-281. For this purpose water needs to be treated(chemical dosing). Next duties are to supply a Hp desuperheaters,intermittent demister washing, and medium seal for pumps 100-p138 A/8.

Instrument air is a motive power and pilot air for air driven actuators of controlvalves and emergency (XV) valves. lt is distributed via 3" line galvanizedheader to every utility station. Plant air is a same quality air connected to theinstrument air header via XV-6501 separation (block) valve. lt suppliesseveral Hose stations.

For electricity see chapter 2.1.6 (Electric Power).

Fire water 12" piping is supplied from two 16" fire water sources (existing).Main facilities are; deluge valve system, fire water monitors, water hydrantsetc. All lines are burried except those of deluge system.

normal operation.wintarisation during plant


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- Chilled water. lt is used to cool down the gaseous phase from dehydrationcolumn decanter by 100-E-131 vent cooler, and for analysers gaspreconditioning and acetic acid separation in analyzers vent.

. 1, ,'".

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INDEX


3.I PREPARATION FOR INITIAL START-UP3.1.1 General3.1.2 Plant Inspection3.1.3 Flushing, Chemical or Mechanical Cleaning3.1.4 Preparation and Functional Testing of Machinery3.1.5 Preparation and Functional Testing of Instrument3.1.6 Preparation and Functional Testing of Electricals3.1.7 Place/Remove Blinds, and Place Car Seals, Locking of Valves and Temporary

Strainers3.1.8 Leak Testing of the Systems3.1.9 Preparation and Testing of Reactor Steam Generation Systems3.1.10 Preparation and Testing of Recycle Gas Loop3.1.11 CatalystandChemicalLoading/Unloading3.1.12 Dynamic Oxygen Response Test3.1.13 Dynamic ethane response Test3.1.14 Dynamic Leak Testing3.1 .15 Dynamic Capacity Test of C02 Absorber3.1.16 Purging and Inerting3"1.17 Ethane Fired Heater 100-H161 Dry Out3.1.18 Steam Out3.1.19 PreliminaryOperations3.1.20 CarbonateLoading

3.2 PRE START.UP3.2.1 Place Utility Header in Service3.2.2 Makeup and Dosage of Chemicals,3.2.3 Place Steam Headers and Boiler Feed Water System in Service3.2.4 Start-up Cooling Water and Chilled Water3.2.5 Check and Get Ready to Start Up the Process3.2.6 Purge and Pressurize the System with Nitrogen3.2.7 Interlock Tests3.2.8 Heating of the Reactor Steam System3.2.9 Carbonate Circulation - COz Removal System Pre Start Up3.2.10 Start-up Recycle Gas Compressor and Cycle Gas3.2.11 Product Recovery and Purification3.2.12 Heating of Ethane Feed System3.2.13 Ethane feed

3.3 START-UP3.3.1 Start Up Oxygen Feed3.3.2 Reaction Tuning3.3.3 Product Recovery and Purification3.3.4 COz Removal System

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3.4. NORMAL OPERATION3.4.1 Ethane Feed Preparation3.4.2 Reactor System3.4.3 Scrubber 100-C1313.4.4 Dehydration Column 100-C1323.4.5 Product Column 100-C1333.4.6 Stripping Column 100-C1343.4.7 CO2 Absorber 100-C1413.4.8 CO2 Solution Regenerator 100-C1423.4.9 Drainage System3.4.10 Tankage

3.5 NORMAL SHUT DOWN3.5.1 General3.5.2 Feed Preparation Section Hot Stand By3.5.3 Reaction Section Hot Stand By3.5.4 COz Removal Section Hot Stand By3.5.5 Purification Section Hot Stand By3.5.6 Feed Preparation Section Complete Shut Down3.5.7 Reactor Section Complete Shut Down3.5.8 CO2 Removal Section Complete Shut Down3.5.9 Purification Section Complete Shut Down3.5.10 Vessel Entry3.5.11 Reactor Conditions During Prolonged Shut Down3.5.12 Steam Production & Utilities Shut Down3.5.13 Single Skids Units Shut Down

3.6 EMERGENCY SHUT DOWN3.6.1 General3.6.2 Plant Electric Power Failure3.6.3 Instrument Air Failure3.6.4 Steam Failure3.6.5 Cooling Water Failure3.6.6 Ethane Feed Failure3.6.7 Oxygen Feed Failure3.6.8 SABOX Reactor

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This chapter shows the specific operation procedures in respect of the initialstart-up, start-up, normal operation, normal shut down and emergency shutdown.

3.I PREPARATION FOR INITIAL START.UP

3.1.1 General

The information described hereafter concern the preliminary operations for thefirst start-up of the new unit.

In addition, for subsequent start-up, it may happen that some preliminaryoperations described hereafter have to be performed or repeated, depending onthe current situation (case of shutdowns for maintenance works,' capac-itiesopening, etc.).

At first start-up the precommissioning activities will be implemented by theContractor precommissioning team, in close coordination with constructionforces.

ln this section general precommissioning guidelines are given with the main ruleswhich prevail. Detailed precommissioning procedure iailored on the specificneeds of the plant will be developed at job site.

Precommissioning activity includes:

- inspection equipment to determine that modified/new equipment are in fullconformity with P&l diagrams, design specifications and applicable codesand regulations;

- making required non operating adjustments and cold alignment checks;- ensuring equipment are free of debris and construction tiash:- cleaning lines and equipment;- performing other required pre-start-up operations.


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3.1.2

3.1.2.1

3.1.2.2

Plant Inspection

The plant should be carefully checked to assure that it is constructed according tothe applicable plans, drawings and specifications. A check off against the plDdiagrams is done for p.iping, equipment and instrumentation. A;punch list,' ofmissing, incomplete, or incorrect items is then prepared for correction. ln additiontemporary identification tags, signs for various lines, valves and equipment canbe installed at this time to assist in subsequent start-up and operation.

'

This check is carried out before the end of construction work in order to checkthat the unit is satisfactory from an operation point of view. All the individualoperations needed for precommissioning, start-up and shut-down the unit areapplied on site.

The work described hereafter is carried out during the final stages of constructionwork under the direclion of the precommissioning group in Aharge of the unit.Typically, this checking (which can be called pieliminary confoimity to plD'scheck) is useful as soon as construction progress is 70% and abovL. Severalchecks can be madg simultaneously depending upon the completeness of eachsection or system of plant at that time.

Smooth start-up will depend to a large degree on the thoroughness with whichthe unit is checked out beforehand. Every installation details must be checkedagainst the design specifications and standards and for good constructionpractice' A first list of applicable checks to be performed is given here below foreach type of equipmenUinstallation.

Givilworks for process plant

- basins & drain wells; dimensions and position of baffles per spec; degree offinishing;

- flooring slopes: uniform srope towards drains with no puddle formation;- fire area kerbs: construction per spec.;: pump and compressor grouting: construction per spec.;- drains: correct quantity and location.

Steel structures

ladders and platforms: accessibility, safety protections, escape routes;pipe supports: correct spring tension; lock-pins duly removed; checksupport of pump intake pipe after disconnection of pump.

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Vessels and exchangers

- conformity with project documentation;- pressure, temperature, rating;- nozzle size and orientation;- allowance for thermal expansion (see detail below);- llternals: types, dimensions, materials per spec. (see detail below);- lining/insulation:type,thickness,material;- instrument nozzles and types;- ladders, platforms, manways: location, size;- code plate information;- test certificate;- grounding connections;- vents, drains, relief valves per spec.- thermowell location and length of immersion- cleanliness.

Pumps inspection

conformity with project documentation;type of pump;piping arranged to allow dismanfling of pump and driver;piping independently.supported from pump; no vapor pockets in piping;suctions strainer easily removable for cleaning; strainer cartridges pópertyfitted so no bypassing can occur; strainer insta'iled;discharge pressure gauge readable from discharge block valve;suction/discharge valves easily accessible and óperable, and near pump.Accessibility of auxiliary piping and controls;NPSH requirements applied;warm-up lines provided across discharge check valve when pumping hot orsubcooled;base plate grouting complete;steam tracing and insulation provided on suction/discharge lines, pumpcasing, and process sealflush lines, as required;minimum flow bypasses (with restriction orifice; if required;all seal oil, warm-up, etc. lines fitted with flanged connections and valves toallow pump removal;lubrication and cooling systems operate correcily;adequate means to vent and drain pump casing-available;vacuum service pumps fitted with discharge vent back to system to allowfilling pump with liquid;pumps and drivers aligned correcily;lube/seal oil system: operability of all sight flow indicators, instrumentation,pumps_ (including auto starts), filters, coolers compressor trips, reservoir,seal oil pot, etc. Addition and removal of seal/lube oil to/from reservoir canbe done easily;

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general cleanliness of all process and lube/seal oil systems, and of pumparea;insulation for heat conservation and personnel protection, as required;access to sour oil and pump casing drains; said drains routed to safelocation or appropriate sewer;proper supports on suction/discharge piping.

Piping inspection

- Conformity with project documentation;dimensions;pipe: flanges, gaskets, fittings, valves in conformity with specified pipingclasses;expansion loops provided on long hot lines;high points vents and low point drains;pipe supports and spring hangers;insulation: type, thickness, material;piping sliding supports and anchors (see detail below);spring supports (see detail below).

Allowance for thermal expansion

when equipment or piping experiences-_a temperature change it undergoesthermal growth. Supports are provided to allow and guide Úris grórath. lf sufportsdo not function as they are intended then dama-ge could result to vessels,columns, heat exchangers nozzles or piping as the Jase might be. lt is thereforeof great importance that all supports be'inspected and special attention be givento large horizontalvessels and heat exchangers

Vessels Slidino Supports

ln general thermal growth of horizontal vessels is guided and controlled byanchoring one end firmly and permitting the other end to slide. To permitmovement the sliding. end is equipped with slotted or elongated bolt frotes.Occasionally long horizontal vessel may be anchored in the

-miOOte p"rrùgnggrowth towards either end" ln any event it is important to see that ti-re vesselgrows in accordance with the design parameters to prevent damage.

- Check that there is no foreign matter lodged in elongated slots. Any objectfirmly wedged between the srot and the bolt could preùent sliding.

- Check that all the bolts in the slots are loose and are located at the correctambient position. Even if the bolt is at the correct end of the slot there should'be some allowance for thermal contraction caused by atmospheric conditionsdifferent from those on the day of inspection.

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- Get the approximate thermal growth from figure on following page(Approximate thermal expansion mm/m of metals versus temperature "Ó;and establish that the sliding plate can travet at least this distance and thatthe slotted holes are large enough to permit this growth.

- Check that the sliding plate is free to slide and that it will not be obstructed inits travel.

- Check that the sliding plate and base plate are not bonded by rust or other.

Exchanqer Slidinq Supports

All comments applying to vessels in the above paragraph also apply toexchangers. ln addition all expansion joints should be checked to ascertain thatany restraints installed for shipping purposes have been removed (especially onair cooled exchangers). Especially for air coolers, ensure that iransportationlocking device is released to allow dilatation (usually a bolted anchor on bothsides).

Slidinq supports and anchors

Especially in high temperatures process relative dilatation of pipes liaison withstructure important.

- Check that relevant lines and expansion joints are free to move in alldirections" Be sure shipping stops are removed on the expansion joints ifany.

- Check that the platforms and other structures will not interfere with the freeexpansion of the piping and material equipment in any direction.

- Check that instrument piping, electrical conduit and other equipment is in nodanger of binding.

Sprino supports

- lnspection prior to Hydrostatic Testing

Check that the spring stops are installed. lf the stop is not installed on thespring support of a vapour line, the weight of water in the pipe duringhydrostatic testing could deform the spring. The characteristic of ine springwould thus change and its performance may not be as predicted.

'pipè

normally transporting water would not be affected as the spring would bedesigned for the weight of water but rather than make them in exóeption it issimpler to state that all spring supports have their stops installed.

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- lnspection after Hydrostatic Testing

After draining the water and prior to any heating the spring stops should beremoved. lf the stops are not removed, the springs will not flex with the pipethermal growth and nozzles will be over stressed resulting in possibledamage.

After the spring stop is removed, check that the spring pointer is somewherebetween the hot and cold settings stamped on the support. The thermalgrowth of the pipe will result in the spring being either compresseo orstretched.

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X = Temperature oC

Y = Thermal expansion mm/m

Gurve l. ALUMINUM2. STAINLESS STEEL3. CARBON STEEL

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APPROXIMATE THERMAL ExPANStoN (mm/m) oF METALS VERSUSTEMPERATURE (.C)


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TECH*IIP IT&LY $,p,4. *mfu*3.1.3 Flushing, Chemical or Mechanical Cleaning

Upon completion of plant erection and hydrostatic testing, all lines and equipmentmust be cleaned. Purpose of this operation is to eliminate foreign matter such asmetal pieces, welding slag etc. which may otherwise plug pipés, control valvesand orifices and cause serious damage to moving parts òf pumps, turbines andcompressors.Lines and equipment are cleaned to the extent suitable for required service.Quality of cleaning is the result of the cleaning medium used, the most commonbeing:

- water:

- air;

- steam:

- mechanical (special cleaning only);

- chemicals (special cleaning only).

Following precautions must be taken before any cleaning operation:

- identify loop and prepare same for cleaning, e.g. install blind discs,temporary connections, etc.;

- disconnect pump turbine, compressor intake and discharge lines and covercasing nozzles to prevent cleaning medium from entering;

- remove orifice plates;

- remove or blank or bypass control valves and safety valves;

- blank and protect instrument connections;

- do not flush into lines connected to equipment, vessels and heat exchangers;disconnect joints and cover flanges; after sufficient flushing, reconnect linesand flush water through equipment, vessels and heat exlhangers to nextsection of line:

- open overhead vents on vessels to prevent vacuum effect.

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3.1.3.1 Water Flushing

Water as a good flushing medium removes and carries away loose foreign matterbut does not remove rust or other matter securely bonded to surfaces.Water flushing requires large volumes of fresh clean water and a large capacitywaste water collecting system, since flushing is often done when paving is notcomplete and this increases operating difficulties.Flushing is accomplished by filling vessels with water and subsequently drain thewater through piping sections.Lines must be flushed downward or horizontally. Towers are flushed from thebottom, overhead and reflux lines are flushed by overflowing from the tower.Where flushing from a vessel is not possible, special connections must be madeto flush remaining lines, including lines to and from tanks.Flushing operations can later be combined with preliminary trial running ofpumps, provided pump drivers are compatible as concerns power absorption.Clean, fresh water must be used; potable water is generally used for thispurpose.Chloride content of water must be restricted in presence of austenitic stainlesssteel. lf chlorides are allowed to accumulate and concentrate, stress corrosioncracking may result. Flushing water should therefore have chloride content not inexcess of 50 ppm by wt.lf chloride content of water exceeds above value and no other water is available,add. 0.5 v'tt% of sodium nitrate as passivation agent and in any case the systemmust be accurately dry out after flushing.Prior to flushing; check that equipment foundations and pipe supports are .

designed to bear calculated water load.

3.1.3"2 Air Blowing

Air blowing or blasting shall be limited to those cases were steam or water cannotbe used or where a low degree of cleaning is required.Special precautions must be taken to prevent injuries to personnel by debrisflying from exhaust opening.It shall be made impossible for any person to enter the area of exhaust blast,allowing ample distance in the direction of the blast and, particularly, observing apossible deflection of the blast.To air blow the lines, the system can be filled with air at high pressure, whereafterthe air can be released successively through various lines. ln other cases, specialconnections can be made from a compressed air tank.Blowing in both directions is often advisable.As with waterflushing, air blowing should not be directed towards exchangers,towers, or vessels where debris could collect and obstruct the flow.Before air blowing, the same precautions are taken as with water flushingregarding pump connections, orifice plates, control and check valves, etc.After flushing or blowing, a considerable amount of dirt may have accumulated incorners of control and check valves or nozzles, etc.The only way to clean these spots is by hand, and this should never be omitted.

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Casteilo deila Magtiana, 68

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3.1.3.3

3.1.3.4

Steam Flushing

Long experiences precommissioning has demonstrated that use of steam is themost economical and efficient way to obtain clean piping and equipment.There are some limitation in the use of steam such us extensive pipes networkdesigned for low or ambient temperature, galvanized pipes or where humidity orhigh temperature are not recommended.steam is rarely used in the flushing of pipes and equipment not requiring deepaction, such as flare headers.Where possible any effort should be made to have enough steam available toflush pipes and equipment, because with appropriate use all unwantedsubstances are removed.steam flushing has not problems of dumping and, if necessary, a simple piece ofpipe at the end of the pipe to be flushed, can divert discharge to an acceptablelocation.ln consideration of the fact that most of piping normally handles hydrocarbonsthat are solvent for rust, welding slangs, paint, grease etc. use of steam seem tobe the only possible good cleaning agent at low cost.In some specific cases (i.e. process requirements, steam turbine supply, etc.)where deep and accurate cleaning is required, can be applied the-herebelowdescribed "spalling technics".Generally internal surfaces of pipes are covered with a layer of rust, several millslags deeply imbedded in the metal, slags produced during tack welding, paintand grease. Most of these foreign materials can be removed bearing in mind theirdifferent thermal expansion coefficientsonce that piping has been properly prepared, such us franges opened, controlvalves removed etc., the pipe shall be warmed slowly while carefully checkingexpansion. When no more condensate is'coming out of opened points, steamspeed shall be increase to remove loose foreign materials and to heat up metalquickly; then stop totally steam flow and let pipe metal temperature drop below60-80.c.Heat up, flush, and cool again as previously described.Due to different thermal expansion coefficients, the material toughly sticked onpipe metalwill be loosen and removed when flushing at high speed.Three/four spalling should be enough to obtain a reasonable cleaning of thepipes.

Special Gleaning

Mill scale must be removed from certain items of equipment such as tanks,vessels, large pipes, intake lines of reciprocating compressors, lube and seal oilsystems, steam lines to turbine to avoid damage to moving parts of machines.Mill scale can be removed by mechanical or chemical cleaning.



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*mW*Mechanical cleaninq

Vessels and piping may be descaled by shot, grit, or sand blasting and in somecase hydroblasting.Vessels and piping cleaned in such manner, must be protected by suitable rustpreventive and maintain during shipment and construction. Specific cleaningtechniques and facilities are provided by specialized firms.

Chemical cleanino

Chemical cleaning is performed either by pickling prior to fabrication (withcleaned surfaces subsequently passivated to stay clean until start-up), or bycirculating a suitable acid cleaning solution through piping and equipment afterfabrication and erection. lf latter method is used, it should be done as near start-up date as possible and cleaned surfaces protected by means of passivatingsolution or nitrogen atmosphere.

Suitable precautions must be taken for this cleaning operation, as follows:

a) prepare a list of materials, alloys, and non-metallic materials and determinetheir suitability for acid cleaning;

b) replace control valves with spool pieces during acidizing;

c) remove qrifice plates from lines;

d) shut block valves and open drain valves on liquid level instruments, such asdisplacement type level transmitters and gage glasses. lnternal displacementtype level instruments must be in place and nozzle through which they areinserted must be blinded off;

e) remove piping strainer screens;

0 remove all relief valves and blank off nozzles;

g) do not use reboilers and exchangers that are part of the process unit to heatacidizing solution. All heating sources to be external from systems beingcleaned;

h) do not use process pump to circulate acid or neutralizing or passivatingsolutions;

i) perform filling, circulating, draining, flushing, neutralizing operations incontinuous manner for each part of the system to be treated. Acidizingsolution must not stand still;

l) closely monitor ferric iron content of circulating acid solution to detect signsof excessive attack on iron metal. lf iron content reaches maximum 213 grllt,dump acid solution and neutralize system before continuing the acidizingprocedure;


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Acid cleaning operations afe generally performed as follows:

- flushinq: flush all sections with water to remove loose dirt, debris and otherforeign matter in lines;

- deoreasino: flush all sections with a degreasing solution (generally alkalinesuch as soda ash solution) to remove all grease or oil that may have beenapplied to internal surfaces as a rust preventive measure;

- chemical cleaninq: treat with acid solution to remove rust and scale frommetal surfaces.

One of the following may be used to acidize systems for mill scale removal (it willnonetheless be responsibility of cleaning contractor to select materials on basisof his experience):

a) inhibited hydrochloric acid;b) inhibited phosphoric acid;c) citric acid;d) inhibited hydrosulfuric acid.

Inhibitor strength shall be in accordance with vendor recommendation.Circulate acid solution through piping for one hour or longer until oxide scale iscompletely removed.Thoroughly rinse or flush piping or equipment with clean water as soon aspóssible after acid cleaning to rid surfaces of all traces of excess acid or iron saltsand to prevent rust formation.Continue rinsing for at least ten minutes after pH of outlet water.equals pH of inletwater" Thorough rinsing eliminates need for subsequent neutralizing stages.

Neutralization

Flush all sections with neutralizing solution (soda ash solution or similar) toneutralize traces of acid left in system.

Passivation

lf acid cleaning was done a long time before start-up, passivation of surfaces isalso necessary.Commercial passivatíng solutions (film-forming amine or equivalent) conferresidual corrosion protection to piping.

Chemical cleanino procedure

A detailed chemical cleaning procedure must be prepared for each individualcircuit requiring chemical cleaning. The procedure must be discussed with allpersonnel involved in the operation and carefully applied.

TECHNIP TTALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

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3.1.4

3.1.4.1

Preparation and Functional Testing of Machinery

Pumps

The most critical period in the life of a pump is during its initial start and severalminutes immediately thereafter. Proper installation and start-up is essential fortrouble-free performance. Before the equipment is ever started it should bechecked as follows:

- Review carefully the manufacturers operating instructions.

- Check that the overall installation is complete.

- Verify that the pump and driver are properly aligned.

- Verify that cooling water piping is connected and in service where required:pedestals, bearing jackets, stuffing boxes. etc. Run cooling water throughbearing housing, stuffing boxes, etc... untilflushed clear.

- Check gland or seal oil piping. Conventionally packed pumps in hot serviceare generally furnished with gland oil. When a pump is furnished withmechanical seals, verify that all components of the flushing system such asstrainers, separators, restriction orifices and coolers have been correctlyinstalled and are clean. lt is very important that the flush system be clean asthe loss or dirty flush can cause the loss of seals.

- Verify that bearings shafts are clean and properly lubricated. All bearingsshould be flushed clean and the correct lubricant in the proper quantity mustbe provided. Record type of lubricant used and date of lubrication.

- Check that temporary strainers are installed at the suction of each pump.These strainers should be installed after the suction lines are flushed. Whentemporary strainers are not more required they shall be removed and onlythe permanent strainer will remain installed to prevent possible pumpdamage.

- Rotate pump and driver by hand, checking that they turn freely.

- Check that run-in water supply and delivery circuits are lined up.

- Check that pump vent and case drains are closed.

- Open suction valves fully, venting air from piping and pump completely, fillingwith liquid.

- Put pressure gauges in service.

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Ensure that electric power is available from switchgear to starter of electricmotor drivers. For steam turbine drivers, the turbine is warmed by slowlyopening exhaust valve. Back in steam while draining water from casing.Exhaust valve is always fully opened before starting. Where exhaust systemis under vacuum, case must be warmed by gradually introducing drivingsteam, after opening exhaust valve. In vacuum exhaust system, sealingsteam must be admitted to turbine shaft labyrinths to avoid loss of vacuumand to prevent air from entering system.

Crack open discharge valve of centrifugal pump and fully open dischargevalve of positive displacement pump before starting.

Start pump and bring up speed immediately, observing discharge pressure. lfpressure does not build immediately, stop pump and find cause. Prime pumpand restart after problem is corrected.

When discharge pressure of centrifugal pump has increased satisfactorily.gradually open discharge valve to obtain desired flow rate.

ln event of unusual noise, vibration, overheating or other abnormal condition,shut down pump immediately. Correct cause before resuming operation.Continue checking for abnormal conditions as these may occur afterprolonged operation.

Check shaft sealing. Mechanical seals should show no leakage.Conventionally packed stuffing boxes must always be allowed to leak slightlyto provide some lubrication and prevent overheating. Stuffing box gland nutsare generally only finger tight. A mechanical seal may show leakage onstartup. After pump has been started and stopped a few times, leakageshould stop. lf seal leakage persists, action must be taken to correctproblem.

Pumps normally deliver a material lighter than water circulated during initialrun-in. The pump driver is sized for the normal pumping fluid; consequently,while pumping water, electric motors are easily overloaded. To avoidoverloading the motor driving a centrifugal pump, flow must be limited bythrottling pump discharge valve.lf possible, check amp absorption against nameplate. Avoid restrictingdischarge to the extent that it will cause internal recirculation and excessheat generation.

The discharge valve of an operating positive displacement pump, (rotating orreciprocating), should never be closed as casing can be overpressurized.

During run-in, strainers may cause some restriction on flow. As debris iscollected, flow to pump willfall off. Do not permit the pump to cavitate, that is,lose suction, which may cause damage to pump.


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- Strainers must be installed before aligning pumps. One 4 mm strainer (3 to 5mesh) is provided for each pump suction line during start-up. To avoid pumpdamage during flushing operation with water, strainers should be temporarilylined with 1 mm screens. (20 mesh).

- Recheck and realign, if required, after any disturbance of piping.

3.1.4.2 AirCoolers/CondensersFans



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After the motors have been run uncoupled, a static check must be implementedprior to run the fan:

Check the electrical report for the motor amperage.

Check that the protection grease has been removed and is replaced by thecorrect grease

Check that the belts are all on the pulley.

Check that all debris has been removed from the air-coolers area.

Check that there is no loose or live electrical wiring.

Check that all air fan platform grating is in place and secured.

Check that all stop and start switches are fully installed.

Check that the correct motor oil has been put in and the storage protection(light) oil removed if any.

Check the fan motor for proper rotation and grounding (never when themotor is energized)

Set the fan blade pitch as per manufacturers specification. Once the fan is inoperation, if motor amperage is too high or too low, pitch readjustment maybe required.

Set the vibration shutdown switches to give the permitted safe vibration level

lf the fan is belt driven adjust the drive belts for proper tension and check beltcondition.

Confirm that the fan safety shields are in place.

Remove protection plywood which may have been laid on the tubes.


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Check operation of louvers (if any).

When all above checks have been made, proceed to a 4 hours (except othenruiseagreed duration) test run and check the following points:

Check that the amperage of the motors is in the normal range.

Check for any noise from the bearings or other.

Check for any screeching or abnormal noises from the pulleys (belts may betoo tight, which will affect bearings).

Check that all belts remain on the pulleys (belts that constantly come offcould indicate offset pulley).

Check that air fan blades are not making any abnormal noise.

Check that air fans on the same cell are all turning at approximately thesame speed.

Stop'the air fans one by one and stand underneath to observe and check thefollowing:

Check that no abnormal noise occurs on the rundown.

Check that the air fans slowly come to a stop in a smooth manner.

Check by hand that the motor has not overheated.

3.1.4.3 Compressors

Compressor shall be prepared and tested in accordance with Manufacturerinstructions. The first start-up of the machine should be carried out under thesupervision of the Vendor specialist.Refer to Manufacturer Operating Manual for any information.

3.1.5 Preparation and Functional Testing of Instrument

Tests and checks on field and panel-mounted instruments shall take place inthree stages, not necessarily according to temporal sequence:

- 1't Stage: Instrument calibration- 2nd Stage: lnstrument installation- 3'o Stage: Instrument activation.

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3.1.5.1 Instruments calibration checks and tests

Checks and test belonging to this stage are mainly intended to detect possibledamages occurred during transport and/or storage of the instruments and toverify Manufacturer's shop calibration.

Calibration checks will vary depending a instrument type:

a) Flow and differential pressure instruments

- Connect the proper test equipment to provide and input signal of 0 to10oo/o range

- Check the corresponding output signal

- Calibration shall check accuracy and repeatability values at Qo/o, 25oA,50o/o,75o/o and 1 OOo/o of range.

b) Pressureinstruments

- Pressure instruments shall be checked using accurate test equipment tomake certain that 0%, 25o/o,50o/o,75Vo and 100% input pressuresproduce output signals in accordance with project specifications.

- The above calibration does not include pressure gauges, except those incritical services.All gauges shall be visually inspected for damages, and repairs made asrequired.

c) Level instruments

- Any shipping stops shall be removed.

- Displacement type level transmitters, controllers and switches shall becalibrated in Contractor's field shop by means of appropriate counter-weights directly applied to the float.

- Displacement instruments shall also be checked with regard to floatlength, specific gravity, controller action and operation of pilot valves.Final adjustment and checks shall be accomplished using processliquids.

- Differential pressure instruments shall be checked to verify range andoutput signal.

- Calibration shall check accuracy and repeatability values at 0o/o, 25o/o,50o/o,75To and 100% of range.

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*mMm- During commissioning and before start up reference legs (low pressure)

and/or impulse lines shall be filled with separation liquid (if required) andsuppression values of the scale fixed with the proper process liquídsavailable during this calibration phase.Vessel taps spacing shall be checked against the instrument scale.

d) Temperature instruments

- Where input signals may be simulated, such as using potentiometricdevices, portable test instruments shall be used to check calibrationthroughout the whole range of the instrument.

- Bulb and capillary systems shall be checked for operation and reliabilityby means of a thermostatic bath.

- Bulb transmitters and controllers, shall be calibrated at OTo,25o/o, 50o/o,75o/o and 10Qo/o of the range.

e) Receivers, controllers, indicators and alarms

Visual check and calibration will be carried out on the local panels beforetheir installation. Field activation will follow after installation.Panel instruments shall be checked in field after installation, using suitablepower supply units to verify input-output signals throughout the scale.Controller alignment, controller action and scale range shall also be checked" .

Alarms shall be set in accordance with specification values.

f) Control valves and accessories

- Accurate signals shall be input in each control valve, in accordance withproject specifications.

- lnput signals shall be varied within maximum and minimum limits to testcontrol valve and/or positioner operation

- Stem travel shall be adjusted (if required) in conformity withManufacturer's specifications. Actualor shall be rotated if required byinstallation or functionality.

- Valve action on air failure shall be in accordance with P&l Diagrams andproject specifications.

g) Analyzers

Contractor shall ensure the installation of the equipment as perManufacturer's specifications and drawings.Testing and calibration shall be carried out by the Contractor under theVendor specialisUmain contractor general instructions.


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h) Safety valves

Contractor shall carry out the set-pressure check using an adequate testbench.

Safety valve pressure setting shall be in accordance with projectspecifications.The setting certificate will be approved by the Client Representative andby the Local Authority Representative.

3.1.5.2 Instrumentsinstallationchecks

At this stage, hydraulic pressure or pneumatic leak tests shall be performed toascertain absence of leaks on the instrument process connections and oninstrument air feed submanifolds. During the pressure tests, instruments shall beduly isolated by means of block valves.

At the same time, the following inspections shall be performed to determine that:

- The instrument is in the right location and position.

- Mechanical and electrical connection conform to project specifications.

.- Control valves and rotameters are correctly positioned and properly oriented'iln line" according to flow direction.

- Orifice upstream and downstream piping runs, orifice tap location and orificesize conform to project specifications.

- Drains, purge systems, winterizing and isolating valves are properly installed.

- By-pass and block valves are installed as required by the project.

- All process connections have been correctly installed as far as slope,insulation and steam tracing are concerned.

- All control valve positioners are properly secured to the valve stem. Theactuators allow an easy maintenance and accessibility.

- Junction box are wired and installed as per specifications and layouts.

After the above checks are completed, the following operations will be performed:

- Check the continuity of signaling cables from plant to control room andviceversa.

- Each pipe or tubing tube involved in the hooking installation shall be blownthrough with dry compressed air or nitrogen.

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- Dimensional check and conformity to specification of calibrated orifice plates.

- ldentification of all cables and/or copper tubing in accordance withspecification and wiring diagrams.

- Check polarity of thermocouple elements and extension wires

- Check insulation resistance on signaling cables.A minimum of 2 megaohm insulation resistance is to be guaranteed betweenconductors, and between conductors'shield and ground.

- All continuity tests, resistance measurements, blowdowns and pressure testsshall be carried-out with disconnected equipment and terminals duly isolated.

3.1.5.3 lnstrumentsactivation

- At this stage, operational checks shall be performed. For this purpose, cleandry instrument air and electrical power shall be available in the plant.

- Checks and tests for instrumentation activation can be split into two basictypes of activity:

a. Preparation activitiesb. Sequential loop checks

a) Preparation activities

Before proceeding with sequential loop checks, the following operationsshall be accomplished:

- Check correct orientation of gauge glasses, pressure gauges andlocal thermometers.

- . Disconnect air supply lines up-stream from filter regular and blowout instrument air header with dry oil-free air, re-connect lines andset filter regulators at specified value.

- Check supply voltages on various remote panels and local panels,as well as special directly-powered instruments in field or controlroom.

- Energize power circuits and check voltage levels.

Verify that all transmitters are on zero and adjust output accordingly.

- Verify that receiving instruments are atzero.

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b) Sequential loop check

Following completion of the activities indicated in previous paragraph a,overall loop continuity will be checked by introducing a simulated signalfrom transmitter to receiver, and hence to element, activating controlvafves from the central control room and check positions 0o/o-25o/o, 50o/o-75Yo and 100o/o for entire stem lift.At the same time, all auxiliary equipment, such as alarms, interlockingdevices, shall be made ready to operate.

lndividual sequential tests shall be performed on each interlock andemergency system. The output signal from the primary element(transmitter or switch) shall be obtained by simulating the processvariable directly in the process connections of the primary element.Once the primary element is activated, a simultaneous check of all thesystems components shall be performed at the various control centers(substations, control room and local panels).The interlock and/or emergency systems shall be checked, finally, for"fail safe" operation which will include power failure and/or "burnout", ifthermocouple are used.Once the sequential loop check has been completed, the followingpreliminary controller adjustment shall be carried out:

- Adjust level controllers to have large proportional band andmoderate reset.

- Adjust pressure controllers to have 30% proportional band andmoderate reset.

- Self-activated pressure control valves will be adjusted during thegperation of the line.

- Adjust panel-mounted controllers as follows:

Flow: 2QQo/o prop. band, moderate reset (on fast resetdial).

Level: 1OO% prop. band, slow reset.

Temperature: 80% prop. band, moderate reset, derivative tobe off.

Final tuning will be carried out later, during plant start-up operations.




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3.1.6 Preparation and Functional Testing of Electricals

3.1.6.1 Electricmotors

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Low-voltaqe motors (up to and incl. 500 V)

The following points are to be checked, inspected or tested:

- Check nameplate rating.Check the hp requirements of the driven unit.Note the special instructions or information regarding auxiliary gear.

- Check the area classification of the location where the motor is installed.Ensure that the motor meets the requirements for the area as classified andas set by the environmental conditions.

- Ensure that the shaft blocking has been removed"

- Inspect the coupling, gnd play of rotor, etc.

- Break coúpling to separate the motor from the drive unit.Ensure that the motor rotates freely.

- Without dismantling the motor inspect the bearings, grease packing, gradeand quality of grease, oil level and rings as far as possible.Inspect the oil level controls.Inspect for leakage.

- Inspect the bolting and weatherproofing of the connecting box.lnspect terminal connections.The weatherproofness should not depend on the application of paint, tape,grease or plastic compounds.

- lf special motor protective devices, such as thermocouples, resistances orinherent protection, have been provided, test the circuit continuity.

- Test the anti-condensation heater and its circuit, if installed.

- lnspect the cable end bells/glands for tightness.Check the cable earth wire connection inside the connecting box.

- Inspect the equipment earthing connection to the earthing grid.Measure the earthing resistance.

- Measure the insulation resistance at the motor terminals, phase to phaseand each phase to the frame, and record the value.The minimum required is 1000 ohms per rated volt.

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- Check the stator winding connections, and whether the system voltageshould be for star or delta connection.

- Check for correct setting of motor protection.

- Start the uncoupled motor (free running) and check the direction of rotation.Compare with the required rotation of the driven unit.

- Run the motor for about 4 hours and check the bearings for unduetemperature rise.

Note: A bearing freshly packed with new grease will initially show aconsiderable temperature rise, for instance, above 70"C measuredby thermometer.Normally, the running temperature of bearings of motors with classB insulation varies between 40"C and 70'C depending on theambient temperature.

- Measure the terminal voltage and line amperes (starting & running current) ofthe free running motor.

- Stop the motor and reassemble the coupling.Check the alignment of coupling and end play.

- Restart the motor coupled with the driven unit but unloaded.Establish the number of seconds required to reach full speed. lf "starting orlocked rotor seconds" of the motor are known, the allowable number of startsper hour can be calculated under unloaded starting conditions.

- Measure the vibration at a number of points.

- Measure the voltage drop during motor starting.A maximum of 20o/o is normally acceptable.lf this value is exceeded, it can only be accepted if it has no impairing effectson the equipment and provided uninterrupted operation of the otherequipment of the installation can be ascertained.

- Check the setting of the thermal overload protection.

- Run the motor at full-load, if possible under actual operating conditions.

- Measure the voltage at the terminals at full-load, to ensure that the motor isoperating at least 95% of its rated terminal voltage.

- Measure the full-load current and compare with the nameplate indication.


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Hiqh-voltaoe motors (above 500 V)

After MV motors have been assembled and erected at site but before the cablesare connected, these motors shall be subjected to the following initial inspection,which shall be done before installation is completed:

- Remove end shields. lf it may be reasonably expected that the interior of themotor is clean. Start with insulation resistance measuring.

- Inspect the interior of the machine and windings for cleanliness.

- Clean the windings, if required, with a stiff brush and where necessary applycarbon tetrachloride.

- Measure the insulation resistance of each phase winding against the frameand between the windings. Use "Megge/' of 5000 V rating.

- Star point should be disconnected.Minimum acceptable value of the insulation resistance varies with the ratedpower and the rated voltage of the motor.

'The following relation may serve as a reasonable guide:

Ri =20xEn

1000+ 2P

= insulation resistance in megaohms at 20'C= rated phase to phase voltage= rated kW.

The insulation resistance, as measured at ambient temperature, does notalways give a reliable value, since moisture may have been absorbed duringshipment and storage. When the temperature of such a motor is raised, theinsulation resistance will initially drop considerably, even below theacceptable minimum.lf any suspicion exists on this score, motor windings must be dried out.

When the insulation resistance of each winding has a satisfactory value,reassemble the motor, and connect and supply the anti-condensationheaters, if available, either temporarily or with the proper cables to maintain amotor temperature of about 5"C - 10'C above the ambient temperature.

Check nameplate rating.Check the kw requirements of the drive unit.Note the special instructions or information regarding auxiliary gear.

Check the area classification of the location where the motor is installed.Ensure that the motor meets the requirements for the area as classified andas set by the environmental conditions.

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Attention should be paid to the classification of the auxiliary gear mounted onthe motor.

- Ensure that the shaft blocking has been removed.

- lnspect the coupling alignment and end play of bearings.

- Break coupling to separate the motor from the driven unit.Ensure that the motor rotates freely.

- Without dismantling the motor inspect the bearings, grease packing, grade ofgrease, oil level and oil level controls.Inspect for leakage.Check the installation of bearing thermometers, if any.lf a separately driven oil pump is installed, test the electrical interlock.

- tnspect the bolting and weatherproofing of the connecting box(es).The weatherproofness should not depend on the application of paint, tape,grease or plastic compounds.

- Ensure that the box and cover are made of sheet steel.Cast iron should not be accepted.

- ln a dry-type cable termination, inspect the tightness of glands and the cablerfinishing.

- Inspect the cable jointing and insulation, there should be no bare live partsinside the connecting box. Taping of line parts is to be done according tomanufacture's instructions to ensure adequate insulation quality for therequired voltage level.

- Check the cable earth wire or armour earth connection inside the connectingbox.

- lf there is a second connecting box, check the star point connection andinsulation.

- lf special motor protective devices, such as thermocouples, resistance orinherent protection, have been provided, test the circuit continuity.

- Test the anti-condensation heater and its circuit, if installed.

- lnspect the equipment earthing connection to the earthing grid.Measure the earthing resistance.

- Inspect components of cooling systems, such as heat exchangers, etc.Check the position and condition of filters.lf cooling is by a separately driven fan, check the unit and test the electricalinterlock with the main contractor.


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Inspect and ensure the proper setting of special instruments and apparatusmounted on the motor, such as temperature indicators, hygrometers, oil levelindicators, etc., used with the coolíng system.Test the electrical circuits for continuity.

Measure the insulation resistance at the motor terminals, phase to phaseand each phase to the frame.The minimum required is 1000 ohms per rated volt, value which should beconsidered as the minimum drying curve value.

Start the uncoupled motor (free running) and check the direction of rotation.Compare with the required rotation of the driven unit.

Measure the vibration at a number of points.

Run the motor for about 4 hours and check the bearings for unduetemperature rise. This is usually adequate to obtain an insight into theoperational condition of the motor.

Measure the terminal voltage (at the board) and line amperes (starting andnormal running) of the free running motor.

Stop the motor and re-assemble the coupling.Check the alignment of coupling and end play.

Restart the motor coupled with the driven unit but unloaded.Establish the number of seconds required to reach full speed. lf "starting orIocked rotor seconds" of the motor are known, the allowable number of startsper hour can be calculated under unloaded starting conditions.

Check the vibration at the same points as mentioned before.

Measure the voltage drop during motor starting (at the board).A maximum oî 20o/o is normally acceptable. lf this value is exceeded, it canonly be accepted if it has no impairing effects on the equipment and provideduninterrupted operation of the other equipment of the installation can beascertained.

Run the motor at full-load under actual operating conditions.

Measure the voltage at full-load (at the board), to ensure that the motor isoperating at least 95o/o of its rated voltage.

Measure the full-load current and compare with the nameplate rating.

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3.1.6.2 Gontactors

All contactors shall be operationally checked together with the correspondingmotor, auxiliary apparatus and power and control circuits.

This should also be done when the contactors are part of a switchboard/motorcontrol board assembly.

Low-voltaoe contactors (up to and incl. 500 V)


- Check nameplate rating and circuit indication.Compare with approved drawings and the connected motor hp.Note the special instructions or information regarding auxiliary apparatus.

- Check the area classification of the location where the contactor is installed.Ensure that the contactor meets the requirements for the area as classifiedand as set by the environmental conditions"

- Check the magnet coil voltage, coil marking and the actual control voltageavailable.

- Remove blocking and/or binding material which may have been used toprotect the magnet yoke and the contacts during transport.

- For oil-immersed contactors check the oil level and oil quality.Inspect the tank lining and bottom for sludge deposits.

- lnspect arcing chutes and replace broken chutes immediately.

- Inspect the main and auxiliary contacts for proper alignment.

Note: In case of unitized or blocktype contactors this will be virtuallyimpossible, since they are factory adjusted and are notsupposed to be tampered with at side.

- Check the thermal overload coils or heaters to ensure that the required ratinghas been used.

- Check the tripping supply voltage and the battery capacity.

- Test the reset mechanism.

- Check the short-circuit protection, for instance the setting of the automaticcircuit breaker or the rating and quality of the fuses in relation to the motorstarting current and installation requirements.

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- Test the alignment of draw-out mechanism, if provided, and the contacts formain and auxiliary connections.

- lnspect the earth fault indication relay (when required). A test can be madeby passing a current through one phase (current injector) and by measuringthe amperage at which the relay trips. The fault current is usually approx.10o/o of the nominal full-load current of the motor.

- Inspect the equipment earthing system, and measure the earthingresistance.

- Inspect the weatherproofing features, such as gaskets, rain covers, etc.Make certain that the enclosure is reasonably verminproof, i.e. all openboltholes and unused punched holes closed, breather screens in place, etc.In dusty atmospheres inspect the filter material capsules required forbreathers

- lf the gear is flameproof (pressure-resisting enclosed) inspect bolts andflanges. Flanges may be lightly greased.Check whether this gear is adequately weatherproof, if located outdoors.

- Inspect the cable glands for tightness.Check the weatherproofing; plastic compound may be required at the cableentrance of the gland.

- lnspect the cable end bells for leakage, check compound level, ensure thatno hygroscopic materials, such as paper or cotton tape, remain above thecompound level"

- Test the anti-condensation heater and its circuits, if installed.

- Test the operation of auxiliary apparatus, such as time delay, time clock,selecting switches, etc.Check the current transformer rating and compare with the design data.

- Check the push-button stations, local and remote, for weatherproofness.Check the area classification of the location where the station is installed.Ensure that the unit meets the requirements as classified and as set by theenvironmental conditions.

- lnspect control and signaling apparatus operating with the contractor, suchas float and pressure switches, stream indicators, etc.Check the area classification of the location where the apparatus areinstalled.

- Ensure that the automatic and remotely controlled contactors and motors areprovided with warning plates to indicate that they may be into operationwithout previous warning.


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- By feeding the control system by temporary supply check for correctoperation, interlocking, signaling and alarms.

Medium voltaqe contactors (above 500 V)


- Check nameplate rating and circuit indication.Compare with approved drawings and the connected motor hp.Note the special instructions or information regarding auxiliary apparatus.

- Check the area classification of the location where the contactor is installed.Ensure that the contactor meets the requirements for the area as classifiedand as set by the environmental conditions.

- Check the magnet coil voltage, coil marking and the actual control voltageavailable.

- Remove blocking and/or binding material which may have been used toprotect the magnet yoke and the contacts during transport.

. Inspect all possible moving parts for safety block or ties.

- Inspect the arcing chutes; make certain that they are clean and unbroken.

- Inspect the closing mechanism, auxiliary contacts, tripping mechanism, etc.

- lnspect the alignment of main and burning contacts.Observe the closing operation, inspect tightness of bolting.

- lnspect bushings and bolted connections.

- For oil-immersed contactors check the oil level and oil quality.lnspect the tank lining and bottom for sludge deposits

- lnspect the safety interlocks, raising and lowering gear of the oil tank.

- Check the setting of protective relays, short-circuit protection, earth faultprotection, etc.Compare the relay setting with the motor rating.

- Check the setting of the automatic circuit breaker or rating and quality offuses.

- Check the reset mechanisms.

- Check the tripping supply voltage and the battery capacity.

- Check grading of protection in relation to the main distribution system.

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magtiana, 68

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TECXHIP lT&tY $.p,4. wmMm

- Inspect the equipment earthing system, and measure the earthingresistance.

- Inspect the weatherproofing features, such as gaskets, rain covers, etc.Make certain that the enclosure is reasonably verminproof, i.e. all openboltholes and unused punched holes closed, breather screens in place, etc.ln dusty atmospheres inspect the filter material capsules required for thebreathers.

- lnspect the cable glands for tightness.Check the weatherproofing; plastic compound may be required at the cableentrance of the gland.

- lnspect the cable end bells for leakage, check compound level; ensure thatno hygroscopic materials, such as paper or cotton tape, remain above thecompound level.

- Test the anti-condensation heater and its circuits, if installed.

- Contactor assembly to be tested with medium voltage.

Measure the temperature rise of the contactor components after the full-loadtest.

- Test the operation of the auxiliary apparatus, such as time delay, time clock,selecting switches, etc.Check the current transformer rating and compare with the design data.

- Check the push-button stations, local and remote, for weatherproofness.Check the area classification of the location where the station is installed.Ensure that the unit meets the requirements as classified and as set by theenvironmental conditions.

- lnspect the control and signaling apparatus operating with the contactor,such as float and pressure switches, stream indicators, etc.Ensure that these apparatus meet the requirements for the arca asclassified.

3.1.6.3 Switchboardassemblies

Motor contactors, even when installed on distribution boards shall be tested inconjunction with the corresponding motor and its control gear.

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3.1.6.4 Medium voltage and low-voltage distribution boards and motor controlboards


- Check nameplate rating and lay-out.Compare with approved drawings and connected circuit.Check the indicated short-circuit rating of the board against the design data.

- Check whether the board enclosure meet the requirements and specification,such as weatherproofness.

- lnspect the board assembly for alignment, levelness, tightness of foundationbolts and bolting in general.

- Inspect the bus-bar connections and supports, control bus-bars, neutral barand connections.

- Inspect the earthing bars and connections inside the board.Inspect the earthing bolts and connections to the equipment earthing grid.Measure the earthing resistance.

- Check the control and signal voltage.Ensure that the operating solenoids are suitable for the actual controlvoltage.

- Remove the blocking and/or binding materialfrom contactors and relays.

- Inspect the safety features, such as horizontal and vertical separationsheets, the bus-bar covers, interlocking door contacts, handle interlocks, etc.

- Check the capacity and rating of the fuses in use.Ensure that the fuses are suitable for motor starting current (slow acting,h ig h-breaking capacity).Check the gauge ring rating of plug cartridge fuse bases.

- Check the capacity and rating of automatic circuit breaker.Check the short circuit setting and tripping time.

- lf installed, inspect the contact alignments of draw-out switchgear and draw-out interlocking features and auxiliary contacts.

- lf oil-immersed gear is used, check the tank lining, condition of paint insidethe tank, oil level, oil quality and condition.

- Inspect the cable and bells (compounded type) for leakage.Check the compound level; ensure that no hygroscopic materials, such aspaper or cotton tape, remain above the compound level.



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TECHI{|P ITALY S.p.A. - 00148 ROMA - Viale Castello della Magtiana, 68

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Test the anti-condensation heaters and the circuits. if installed.

MV switchgear is to be tested with a higher voltage"

when required ensure the temperature rise of the switchgear componentsafter a full-load test"

lnspect the cable clamping and termination (neatness and workmanship).

check the numbering of circuit terminals to compare with approveddrawings.

lf single-conductor cables have been installed, check that the glands aremounted in a non-magnetic plate, or that they are clamped separately withstrips of non-magnetic material.

Inspect relays and measuring instruments, check current transformer ratingand capacity.Check voltage transformers, fuses and holders.

Test indicating and signaling lamps or devices.

Check mimic diagram and circuit indications.

Ensure that the board has all information and instruction plates for self-contained operation, as far as needed by operating personnel.

Measure the insulation resistance of the bus-bars-phase to phase and phaseto ground and record it.

3.1.6.5 Gables

A variety of cable types are used for distribution, power supply, control, lightingdistribution, etc.Inspection and testing are identical for most of the types and vary in detail only.Before starting the testing, make certain that the cable ends are free andinsulated in such a way that if an increased voltage is applied no harm is done topersonnel, and no damage to instruments or apparatus occurs.Beware of ring or tee-off connections in feeder cables.

Low-voltaqe and hiqh-voltaqe cables


- Check the conductor connections at both ends and ensure that all strands ofthe conductors have been used, i.e. that the proper size connections hasbeen used.

TECHNIP ITALY S.p.A. - 00148 ROMA - Viate Castetto delta Magtiana, 68

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Check the size and current capacity, as required by full-load and startingcurrent of motors, and whether they correspond with the design data of theinstallation.

Check the circuit indication and terminal numbering, and compare with theapproved drawings.

Inspect the cable glands for tightness.

Inspect the clamps and connections of single-conductor cables.Glands for single-conductor cables are to be mounted in non-magneticplates.

Check the protective relay settings, current transformer ratios, etc.

Check the protective fuses; type, rating and capacity.

Apply a higher voltage test at 80% of the test voltage, conductor/earth, for3x10 minutes.lf a cable tester is available, make a complete record of the leakage currentvalues obtained, to be used for comparing with future measurement.

Measure the insulation resistance between each conductor and againstearth. The insulation resistance varies with the type of insulation used andwith the length of cable.The following empirical rule gives reasonable guiding values:

Insulation resistance in megaohms =10 x voltage in kV

length in km

Test the earth conductor continuity.

Inspect the earthing connections. Measure the earthing resistance.

Inspect the means of cable protection against mechanical damage at pointswhere cables leave the cable trenches. Single-conductor cables should notbe separately protected with iron pipes.

It is suggested that a record be kept of the location of the straight or teejoints made in the underground cables.

Ensure that cable phasing colour is done (red, yellow, blue) and cablenumber is correctly installed at both ends.


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*mW*3.1.7 Place/Remove Blinds, and Place Gar Seals, Locking of Valves and

Temporary Strainers

- Remove any blinds installed during hydrostatic testing except blinds inreactor feed and product lines.

- Place blinds at necessary location for the following leak test andpreliminary operation using nitrogen and water.

;jî"":r.car seals and lock valves to avoid inadvertent manipulation of

- Place temporary strainers to prevent the introductionof any rust and dust to the units and equipments.

3.1.8 Leak Testing of the Systems

During equipment cleaning, lines will have been disconnected, orifice plates andblinds removed, and later re-installedTightness testing is'therefore required to eliminate leaks caused by gasketswhich may have been damaged, flanges not perfectly tightened and/or drains leftopen.Perform tightness test after final installation by using air, steam, nitrogen or' suitable process fluids.Check alljoints, flanges, packing glands, etc. for leaks using a detection mediumsuch as a soap solution.Perform thermal insulation of flanges only after final pressure test of the section iscompleted.Air or nitrogen is commonly used for tightness test pùrposes.Tightness test pressure will depend on the operating pressure of the systemunder test. Test pressure is normally 1.2 times normal operating pressureprovided that this does not exceed the set point of the PSV in the section.Nevertheless the max. test pressure is normally limited by the available plant orinstrument air pressure. When operating pressure is considerably higher thanthat of said air, a preliminary tightness test is done with process fluid during start-up.Tightness acceptability is determined by the pressure drop that occurs over alimited period of time.Tightness in a section is deemed to be good when said pressure drop is less than1o/o ovèr a two hour period.When the section is subject to special conditions of pressure, temperature and/orprocess fluid, a tighter pressure drop measurement may be specified.

In most cases, leaks can be eliminated by tightening the flanges in the correctmanner to ensure that compression on the flange gasket is uniform. lf this is notsufficient the equipment must be isolated, depressurized, and the gasketreplaced.


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TECINHIP ITALY $,p,4, mmfu*ln most cases, the leakage from a valve bonnet can be eliminated by correctrepacking. The control valves packings must not be tightened when dry until theactual product is passing through.

3.1.9 Preparation and resting of Reactor steam Generation systems

The Steam Generation Systems of both Conventional and SABOX Reactors,consisting of the reactors shell side, the steam drums and the start-up circulationpump, are maintained under slight nitrogen pressure when are not in operation.

Cooled boiler feed water imported from Battery Limit is used to fill the ReactorShell and, through the steam risers, also the Steam Drum up to the normal liquidlevel" The Boiler Feed Water is fed from battery limit via the Reactor CirculationCooler 100-E121 (cooling water in service). This cools the water to 46'C to avoidthermal stress. The steam dium is to be filled via reactor risers.Waiting the filling is completed, drain water from low point drains to be sure thatall dirt and debris is removed from the system. When the water drained from lowpoints appears clean, start circulation by the start-up pump. This pump has beenequipped with a temporary strainer for the flushing operation. After two hours ofwater circulation at maximum'rate, drain the system, remove and clean thetemporary strainer. After having re-installed the strainer refill the system asmentioned above and start again the circulation of water. This procedure isrepeated until the drains are free from rust and debris.Then the system can be filled definitively with boiler feed water, up to theminimum level into the steam drum.Before heating is started, the operator must ensure there is a healthy level in thesteam drum.When the steam drum is being heated at start up, the operator selects HEATMODE on HS-2002.

Selecting HEAT MODE on HS-2002 has the following actions:

o The temperature controller TIC-2047, downstream of the steam spargerZM-2101 resets the set point on the HP Steam flow controller FIC-2103, toallowthe temperature (TlC-2047) to increase at a rate of 15'C / h. (FlC-2103 is switched to cascade and TIC-2047 to automatic). The operator canselect the final desired temperature target, nominally 220"C.

. Shuts the steam drum vent valve -fV-2101 via the temperature controller onthe steam drum, TIC-2101, via the high selector block TY-2101. (lf requiredthe operator can still open the steam vent valve via HIC-2101).

. HY-2102 sends a signal to the two valves (HV-2002A and HV-20028), toensure the Reaction Circulation Cooler 100-E121is fully bypassed.

This operation is continued until the temperature in the steam drum reaches theoperator set temperature target.

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When the temperature reaches this value and the Reactor starts transferring heatinto the coolant after oxygen feed started and plant load reach more than 80%,the start Up circulation pump can be stopped and the Hp Steam isolated.This operation allows the circulating water to be heated using HP Steam. Thestart-up circulation pump can be started to circulate the water through the systemand then HP steam can be injected into the water to increase its temperature.Remember that the maximum heating or cooling mode control for the reactorsystem is specified as 15"C per hour.As the heating steam condenses in the water, the steam drum level will rise. Theexcess condensate is sent from the pump discharge to the Steam CondensateDrum 100-D263"After the temperature of the water has reached 110'C the vent valve on thesteam drum is cracked open to allow the exit of a controlled flow of gas toatmosphere, thus expelling nitrogen from the system. During heating, the systemshould be checked for leaks, and the reactor system checked frequently, as thiswill be the first operation at elevated temperature.

When the circulating water temperature has reached the maximum attainablewith H.P. Steam (approximately 240 "C), the system is held at this condition for12 hours to detect possible leaks from reactor tubes.At the end of this period the steam injection is stopped.The reactor system is cooled at 110 "C with a maximum rate of 15'c per hourregulating the rate of venting. To initiate cooling of the circulating water, theoperator selects COOL MODE on HS-2002.Selecting COOL MODE on HS-2002 has the following actions:

o The operator can be select the final desired temperature target, nominally60 "c.

r fi signal is sent from HS-2002 to the temperature controller TIC-2047forcing the controller into manual.

Two cooling step are provided:

1- when the temperature within the steam drum, as measured by Tlc-2101, isgreater than 120"C, a signal is sent to open the steam vent valve -fV-2101

to control the rate of cooling to 15 "C/h and the signal also ensures the twovalves (HV-2002A and HV-20028) fully bypass the cooler 1oo-E121 viaHY-2102.

2- When the temperature falls below 120"C, the signal from TIC-2101 shutsthe steam vent valve and also opens the valve HV-2002A and closes thevalve HV-20028 to ensure all the circulating water passes through thecooler 100-E121.


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*Wfu*Remember that the Reactor Steam Drum vent valve 'fV-2101 and the CirculationCooler, 100-E121 are both used to lower the temperature of the water.

The heat-up procedure is repeated then using the same procedure as above, andthe system is held at240'C for another 12 hours period.Following the second 12 hours circulation of the water at240 'C, the boiler feedwater make-up control is checked. This is done by manual withdrawn ofcondensate to the Blowdown Drum 100-D261, while maintaining the steam drumpressure by the introduction of start-up steam, and causing the fluctuation in theliquid level of the steam drum.The operation of the BFW make-up flow controller FIC-2102 reset by the steamdrum level controller LIC-2101 can then be checked" The automatic operation ofthe steam pressure controller PIC-2101 A is also checked.

Remember that three elements are necessary to control the Steam Drum level:

. Steam flow measurement Fl-2101o BFW flowrate measurement FIC-2102. Steam drum level controller tlC.-2101

check the control strategy accounts for changes in any of the threemeasurements.Check the cascade control structure where the steam drum level (LT-2101) isprimary loop and the BFW flow s the secondary loop.The steam flowrate is a direct feed fonryard signal to the BFW control loop. Checkthat when the steam flow is equal to the feed water flow (less continuousblowdown), the BFW control loop compensates immediately for changing insteam demand. Control that the steam drum level loop modulates the feed waterflow to compensate for shrink, swell and lags in the process.

When the make-up water and steam control valves are checked satisfactorily,shut off the heating steam and start cooling the system at a rate of 15 'C perhour.

The cooling rate can be controlled by regulated venting from the drum untilsystem temperature is about 110 'C. Then the steam drum is kept pressurized to1 Barg minimum by nitrogen to avoid air ingress ínto the system.

The system is drained and blown dry, then allowed to cool further to allowpersonnel entrance in the reactor heads. Soap solution is then applied to thereactor top and bottom tubesheets. lf the facilities are available, ultrasonic leaktest can be carried out on both tubesheets. The system is pressurized with dryinstrument air to 3.0 Barg and the tubesheets are checked for leaks. Any leaksdetected in the piping during the hot cycle test which could not be completelyrepaired at that time, or any leaky reactor tubes detected, must be repaired at thistime and a new hot cycle test undertaken.

TEGHNIP ITALY S.p.A. - 00148 ROMA - Viate Castetto deila Magtiana, 68

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TECI*NIP l?gLY $.p.4, mmM*The hot cycle test of the steam generation system must be satisfactorilycompleted before the chemical cleaning of the tubes. During the chemicalcleaning of the reactor tubeside, the water can be kept circulating and maintainedat the same temperature as the various cleaning solutions. This control must bemade manually by adjusting the heating steam flow. lf any leaks do appear afterthe chemical cleaning, these must be carefully repaired so as not spoil thepassivation.

3.1.10 Preparation and Testing of Recycle Gas Loop

It is preferred that testing of the Recycle Gas System be done after reactor hottesting, but before chemical cleaning and catalyst loading.

Prior to recycle gas run-in internal leak testing on all valves in the oxygen supplystation should be conducted.

Prior to testing the recycle gas system the recycle compressor will have been runby the manufactureds representative at no load conditions. During that phase ofinitial compressor testing all compressor controls and alarms are set and tested.

' In addition, a check is made that the compressor seals funótion correctly.

The entire recycle gas loop including reactors, scrubber and CO2 absorbershould be pressurized to 25 barg, using the HP nitrogen. During this operationthe system must be thoroughly checked for leaks.

When the system is pressurized open the antisurge valve FV-1302 and keep onlypartially open the control valves of the recycle gas to the reactors to preventexcessive gas flow to the scrubber.

Start the compressor turbine and wait for a stable flow through the compressor.The anti-surge valve should be put in automatic as soon as possible to avoidmaloperation or operator error.While the recycle gas system is in operation the safety shutdown system shouldbe completely checked out for correct functioning. The feed stations should beactivated and tested using nitrogen as the flowing medium. Temporary piping willbe used to get nitrogen into the oxygen and ethane header. The ethane feedblock valve should be checked and tested for automatic closing during simulatedreactor shutdown.

The entire oxygen feed station must be tested, which will include the shutdown.the vents and the purges.

After the completion of this testing, the ethane header should be purged withitrogen to battery limits. A blind should be installed in the line untiljust before the

first introduction of ethane to the plant.



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3.1.11 Catalyst and Ghemicals Loading and Unloading

For catalyst and chemicals loading and unloading procedure refer to the attacheddocument.

TEGHNIP ITALY S.p,A. - 00148 ROMA - Viate Castelto deila Magtiana, 68

Catalyst and Chemical Loading and Unloading

Catalyst loading will be done after the completion of reactor system cleaning andtesting, and after testing of the recycle compressor and recycle gas system. Everyeffort must be made while handling catalyst to prevent it from being contaminated byforeign material.

advance

drawings

Safetv recommendation

available (gloves, dust mask, respirators, safety harness, etc...) as well as meansof communication (walky-talkies)

suitable for entering through instrument suitable for this purpose (measurementof oxygen tenor inside the reactor)

be in attendance outside with equipment and instructions in case of emergency.

dust mask are worn.

Preliminarv check

the reactor

Check their conformity to the drawings and the quality of the materials.

and fines removed.

Recommendation

In case of heavy rains or heavy wind stop loading

To avoid catalyst attrition do not roll drums of catalysts

From the bottom manway a person entering shall be inside the bottom part of thereactor to check if the support springs are present in each of the tubes.Remember safety recommendation.

reactor on the reactor top grid to introduce balls of alluminia and catalyst insideall the tubes. Remember safety recommendation.

and smoothly, using all the volume of the tubes.

boards, tools, boxes, etc.)

Being the internal of the reactor composed by the tube support grids and by the tubebundle (3600 catalyst tubes 1112" O. D. per 12 BWG Min. thk Rotated square pitch),internal reactor catalyst measurements are impossible to be taken.

Being known the height and diameter of each tube to be filled up first by catalyst andthan by inerts, it is possible to know the volume of catalyst and inerts to beintroduced in each tube. So, by the density of the catalyst and inerts, it is possible toknow the weight to be filled up in each tube.

The weight of the catalyst, found in this way, to be introduced in each tube is 12.4kilogram per tube. So, it is necessary to measure the quantity of catalyst loadedOUTSIDE the reactor by precision weighing scale, with 10 grams minimum division.It is also necessary to prepare various boxes, weighed in advance, which have tocontain such quantity (12.4 kg). These boxes, prepared outside and near the reactor,will be introduced inside the reactor on the top tube grid and the catalyst contained ineach box has to be unloaded in each tube. This operation can be performed by twopersons minimum inside the reactor starting from the opposite side of the tube sheetand converging toward the center.

After the loading of the catalyst, introduce the inerts in each tube. For the first tube,using a becker, introduce and weigh a quantity of inerts in such a way to have 100mm of free space from the top of the tube. lntroduce the same quantity of inerts ineach tube as indicated in the following attached drawing (0411-01 sheet 4 of 6 -Detail of Upper Tubesheet and Vent Nozzle N5)

thermocouples: the quantity of inert to be loaded is about 213 of the standardquantity weighed in advance

introduce the inerts.

the temperature indicators.

grid. At the end of the loading check if the bottom part of the reactor is clear ofcatalyst and inerts.

A loading report must be carefully filled. lt should contain, as minimum:

o Number of boxes introduced at any one time (remember: each tube, one box)o Number of drums loaded. Catalyst batch and drums reference numbers

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ascertained.

pressure pressure compatible with the requirements

2o/o ovaf two consecutive hours.

place immediately and kept under a nitrogen atmosphere.

Detailed procedure will be prepared at site by the commissioning staff.

Nitrogen will be admitted to the isolated reactor section though the lines suitable forthis purpose.

Nitrogen pressure is indicated by the local pressure indicators.

Special Loadino Device

The equipment includes:

tube

the catalyst inside each box should be 12.4 kg. Various boxes are transferredbefore on the top of the reactor by a lift than inside the reactor and unloaded ineach tube. Empty drums should be stored on site or immediately returned tostorage facilities.

installed on the top of reactors and ground level platform

the reactor

prepared

Loadinq of the reactor

Check that the quality of the catalyst and the amount are as specified.

The following guideline assumes that the internals have been inspected in advance.When the catalyst loading operation is finished, make sure that no foreign materialsis left in the reactor and check the reactor for right conformity (gaskets, temperaturetapping, manway, ect.)

10

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3.1.12 Dynamic Oxygen Response Test

This test is conducted without hydrocarbons in the system to check the operationof the oxygen control instruments and to provide the plant operators withexperience in the operation of the oxygen makeup station.

The plant staff is expected to provide detailed instructions suitable for use byoperating personnel, and to correct those steps. Although the procedure entailsseveral steps, which require feeding oxygen to the hydrocarbon-free nitrogen atspecific rates, it does not require control of a specific oxygen concentration in therecycle gas loop. Nevertheless the oxygen concentration should be monitoredand kept in a safe range, e.9., below 5o/o at the exit of Oxygen Mixing Nozzle.

1. Leave Recycle Gas Compressor (J-112) running with the recycle loopunder pressure.

2. Adjust the recycle gas flow by FIC-1302 to maintain the design flow throughthe compressor.

3. Place the oxygen and ethane analyzers in operation.

4. Supply nitrogen to the recycle gas loop with FIC-1312 and put the processvent flow to the flare on automatic control by PIC-1311 so that a continuousflow of nitrogen is entering and leaving the system. Adjust nitrogen flow orprocess vent flow to hold the compressor suction pressure at the desiredvalue.

5. Make sure that all components of the oxygen flow control and shutdownsystem, including Nitrogen Compressor, and oxygen compressor havebeen checked and are now running. The safe hydrocarbon purging rate is389 kg/hr for this test it is safe to use the start up N2 purge flow at a designof 389 kg/hr, since there should be no flammable gas in the recycle gasloop at this time.

6. Make sure that all automatic valves in the oxygen system are in theshutdown position. ln addition to that it is assumed that oxygen has notbeen admitted to the plant.

7. Verify that purge nitrogen is available at the correct pressure, and startNitrogen compressor 100-J171 to charge the two nitrogen vessels (100-D-274,100-D246) to their operating pressure.

8. Reset the N2 system so that N2 XV-7003 and XV-7004 are closed andPALL- 7006 is healthy.

9. Start a nitrogen purge flow with controller (HlC-7002), and increase the flowuntil the low purge flow alarm (FALL-7007) clears then wait for 3 min. till the"N2 purge flow is completed" message is appeared.

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11.

12.

13.

14.

15.

Reset HS-1401 to close the automatic vent valves (XV-1403 and XV-140S).This also opens the automatic block valves (XV-1404 and XV-1406), andresets the trip system.

Resetting the trip system takes manual control of the start-up purge awayfrom HIC-7002 and causes the valve to open fully, so that the start-uppurge flow is controlled by RO-7004.

After the purge nitrogen flow through RO-7004 has continued for the periodset on the time delay 10 seconds, open the manual oxygen lhand valveHV-1402.

Now start Oxygen flow by adjusting FIC-1402 until it indicates 1ío/o otrange, (lt may be necessary to begin flow on manual control. And switch toautomatic controlwhen stable control action can be obtained).

Determine with a stopwatch the interval of dead time between addingoxygen to the mixing nozzle until it begins to appear on the feed oxygenanalyzer. Adjust the sample loop flow and the oxygen analyzer sample flowuntil this response interval is less than 20 seconds.

;lncrease the oxygen flow by FIC-1402 until it is about 14o/o of the designmakeup flow. This should clear the low oxygen flow alarm (FALLL-1403),so that the automatic nitrogen purge can be closed, and flow stopped withHIC-7002. All alarms and defeats should now be in the normal runningmode.

fncrease the set point on the oxygen flow controllers (FlC-1402). Theoxygen flow should reach a new set point and level out. Check response ofthe oxygen analyzers to this change in rate of increase of the oxygenconcentration.

Check operation of the spare oxygen analyzer.

Check operation of high flow stop on the oxygen flow controller by sharplyincreasing the setting on the oxygen flow controller.

Check the operation of high-oxygen-concentration automatic cut-off byreducing cut-off setting.

Resume oxygen flow.

Cut off oxygen flow with the manual oxygen trip to verify its operation.Close the manual oxygen block valve.

Stop nitrogen feed to recycle gas loop.

Shutdown recycles Gas Compressor.

16.

17.

18.

19.

20.

21.

22.

23.

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24. Depressure and purge reaction loop as previously outlined.

Dynamic ethane response Test

The action of the ethane analyzer and the ethane flow controller are testedduring this operation.

Purge oxygen from the system, pressure the system with nitrogen (less than 12bar), and start Recycle Gas Compressor (100-J112) as previously outlined.The oxygen concentration should be below 1 %o before any hydrocarbon isintroduced. Verify that the oxygen makeup station is properly secured so thatno oxygen can enter the system.

Adjust the recycle gas flow with FIC-1302 to maintain the design flow from thecompressor to the bypass.

Place the ethane analyzer in operation (previously calibrated).

Check that the nitrogen feed line to Recycle Gas Compressor is blocked off.Setthe pressure controller (PlC-1311) on the process vent line atthe designpressure.

Do not circulate water through COz Absorber (100-C141) and C02 SolutionGenerator (10O-C142).

Open the Ethane feed block valve. Note the Ethane pressure by PIG-1202.With the ethane flow controller (FlC-1301) on manual control, begin ethanefeed at 25% of full-scale chart reading, and then place the controller onautomatic control.

Check the operation of the ethane analyzer Al-20O2. Bring ethaneconcentration up to design level. Watch the response time.

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3.1.14 Dynamic Leak Testing

Leakage from flanges, sample lines, etc., must be minimized to operate the plantwith minimum ethane losses. For this reason, a dynamic leakage rate test shouldbe made îor a 12-hour period. After a static test has shown the plant to be tight,the dynamic test should be made by circulating gas at the design gas recyclesrate.1" Restart Recycle Gas Compressor (100-J112) in accordance with the

vendor's instruction after pressurizing the recycle gas loop with nitrogen upto the required pressure level for the compressor.

2. Recycle Gas Compressor should be checked out and operated with gasflow through the loop via the minimum flow bypass before reactor feed andproduct manual block valves are opened. This is to prevent and trash infeed lines from entering reactor. Of course, prior to this, the feed line shouldhave been blown out to the atmosphere at high velocity to remove rust andscale.

Open the reactor inlet and outlet valves gradually. Don't introduce therecycle gas abruptly. For this test, continue circulation through the reactor.

During the test, there should be no circulation of absorbent liquid in thescrubber 100-C131. Circulation of quench liquid, however, must bemaintained to remove heat which is added to the circulating gas stream byRecycle Gas Compressor.

At the start and end of the test, observe the pressure at the compressorsuction as a means of estimating the leakage rate. The leakage rate shouldbe at an acceptably low level as established by local environmental codes"

lf necessary, it may be possible to import sufficient high pressure nitrogen toconduct this test.

3.1.15 Dynamic Gapacity Test of C02Absorber

The COz removal unit is to be filled with carbonate solution and started up. Theloop gas is to be circulated over the reactor bypass. This test is to be started afterhaving checked that the carbonate solution will remain clean and after the COz

shut down system has been tested to ensure that the gas feed can be tripped ifnecessary. Before starting take a sample from Treated Gas Drum K.O. 100-D241bottoms.

1. lncrease step-by-step volumetric gas flow rate to the CO2 Absorber 100-C141 to 105 percent of design.While increasing the flow rate observe the response of the pressure dropover the COz Absorber 100-C141 with PDI-4003A for the different columnloadings.

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Regularly check drums Treated Gas K.O. Drum 1OO-D241, CO2 K.O. Drum|OO-D242 and CO2 Antifoam Injection Drum 100-D243 for signs ofentrainment or foaming by draining manually after every increase of theloading.Monitor the conductivity of the water in 100-D241 by sampling.

lf necessary add additional condensate the C02 Solution Regenerator 100-C142 to maintain the water balance.

Record the necessary data for the test.

The mechanical minimum stop of the C02 absorber bypass control valueFV-4001 should be adjusted such that the maximum gas flow through theCOz absorber 100-C141 will be 105o/o of the design mass gas flow.

The main gas loop flow should be monitored. lf this mass flow is deviating(lower) from the design flow in ton/hr the minimum stop should be adjusted(to a lower value).

After adjusting check the mechanical strength of the minimum stop bytrying to increase the COz absorber gas feed beyond 1Ù5o/o of design.

Purging and lneÉing

Purging is a necessary operation in those plant process systems thatsubsequently will handle hydrocarbons and flammable materials.

Pipe networks, vessels and other plant equipment normally contain air; theintroduction of hydrocarbon feed for the first time into said equipment canproduce an explosive mixture which poses a serious safety hazard to plant andpersonnel.

Purging eliminates the hazard by replacing the air inside the system with aninert gas such as nitrogen. This renders the environment non-hazardousbecause of the absence of oxygen required for combustion.Hydrocarbon gases can then be introduced safely by displacing the inert gas.

In the reverse situation, that is, the process system is totally filled withhydrocarbons and entry for maintenance work is required, a safe workingatmosphere for personnel must be established. This is accomplished bydisplacing the hydrocarbons with a blanket of inert gas and then displacing theinert gas with air.

5.

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"mmW*Purqe techniques

The selected purge technique will depend on the physical characteristics of theprocess system in question.

Three types of purge technique are available:

a) continuous purgeb) displacement purgec) pressure cycle purge

a. Continuous Purge

Continuous purging is practiced on large tanks in which a significantdensity difference between purge medium and tank contents cannot bemaintained, and mixing of the purge medium and tank contents willinevitably occur. This technique requires introduction of the inert mediumat the base of the tank as far away from the vent point as possible toavoid erratic or incomplete purging.

I Displacement Purge

Displacement purging is most often practiced on pipe systems wherepurge gas can be introduced at one end of the system, will travel throughthe system as a plug, and will vent at the far end of the system

c. Pressure Cycle Purge

Pressure cycle purging is commonly practiced on medium size pressurevessels where vessel connections and purge facilities are not ideal for acombination of continuous/displacement purge.This techníque requires pressurizing the vessel with inert gas to a statedpressure and then depressurizing. The procedure is repeated severaltimes until satisfactory oxygen level is achieved.

Puroe area definition

Prior to commissioning, process plant areas should be divided into the followingcategories for purging:

a) Storage tanks :

b) lndividual vessel :

c) Process pipework,Heat exchangers, pumps(subdivided into convenient

continuous purge.

pressure cycle purge.

sections) : displacement purge.


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Explosive limits

It is generally accepted that when oxygen content in the system being purgeddrops below 0,1 percent, a satisfactory and safe atmosphere has beenachieved.However, the supervisor in charge of work and the safety department mustestablish the exact level of oxygen content to be reached on a case by casebasis.

Specimen for purqe procedures

The purge procedures outlined here are for general guidance and are notintended to specify in detail the requirements for each system purge. This is theresponsibility of the supervising engineer to prepare detailed procedures.

Storaoe Tank (Continuous Purqe)

a) lsolate storage tank from all other systems by means of available valvingand spectacle blinds.

b) Connect inert gas purge to suitable connections at base of tank. Severalconnections may be used to ensure uniform distribution.

c) Purge through the system, out of the tank, through the tank vapour vent,purging the tank vapour line at the same time.

d) continue purge until vent gases have been reduced to required oxygenlevel. To reduce oxygen concentration below 4 percent, approximately twotank volumes of purge gas will be required.

e) Ensure alldead legs are purged by opening vents, draining connections atthese points and blowing through. Close vents and drains.

0 Discontinue purge and isolate tank while maintaining slight positiveoverpressure (150/200 mm Water Gauge) to prevent air entry.

The system is now ready to receive hydrocarbon.

Vessel (Pressure Cvcle Purqe)

a) lsolate vessel from all other systems by means of available valving andspectacle blinds.

b) Connect inert gas purge supply at a suitable point.

c) Pressurize system with inert gas to approximately 3 barg.

d) Vent system at far end ensuring that no undiluted pockets of air remain.

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e) Block in vessel again and repeat pressurizing/venting cycle.

0 Three pressure cycles should be. enough to reduce oxygen content tobelow flammable limit. Sample vent gases at several points in system andtest for oxygen level.

g) Continue purge until acceptable oxygen level is reached.

h) Ensure all dead legs in the system have been purged by opening vents,draining connections, and blowing through. close vents and drains.

i) Discontinue purge and isolate system maintaining a slight positiveoverpressure (0.2/0.3 barg) to prevent air entry.


Process Pipework and Other Equipment (Displacement purqe)

Pipe systems and other equipment should be analyzed and divided intoconvenient sections to carry out displacement purging.

a) Select system and isolate from other pipework or equipmentavailable valving and blinds.

b) lntroduce inert gas at one end of system andgases at far ends.

purge through, venting

c) Purge rate and selected injection points and vent points should be suchthat plug purge mechanism is encouraged.

d) Analyze oxygen level in vented purge gases and continue purge untilacceptable level is reached. Some mixing of air and purge gases will takeplace and plug purge mechanism will not be ideal. Approximately one anda half times system volume of purge gas will be required.

e) Ensure all branches and dead legs in system are purged by venting atsuitable points.lsolate entire system and maintain pressure (0.210.3 barg) slightly aboveatmospheric to prevent air entry.



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3.1.17 Ethane Fired Heater 100-H161 Dry Out

After feed gas lines purging/blowing and instrumentation and valuing,reinstatement, loops and funtions test of logic should be performec.Snuffing steam lines should be checked and steam connections prepared forfurther step.List of tested interlocks should be release.Steam and BFW piping should be washed prior to procede to furnace (heater)dry-out.

Safety and loss prevention facilities should be in service prior to procede to dryout. After interval inspection unit should be boxed-up, ignition device checked asa last check before dry out.

Header Drv Out

Most of small headers can be dried out by the use of pilot flames only, butanyway, the whole burner should be ready for service.The best is to feed the original gas for this operation, so the whole system will bepratically be commissioned.lf the óriginal (as per design'package) arrangement is not ready liquefied gas andevaporasers can be used for this conditions which method can be used.Steam (any available) should be introduces to superheaters 100-F.262 and 100-E-363.Water should circulate trough heater 100-E-364 to avoid hot spots on pipe spool(boundle).Leading temperature should be monitored on DCS.Mainly the dry-out will be performed in three steps as shown here below.

For furnaces completed and naturally dried for at least two weeks, the steps willbe performed in 36 hours but for furnaces completed and a few months naturallydried the procedure com last about 24 hours.

After natural cooldown (to 40/50 "C) internal inspection should be made andreport released (Vendor & Main Contractor).

lf everything is all right (no punch list points) the furnace is technically ready forservice and can be finally boxed-up.



Page 3-50

During the precommissioning it is very important (if original fuel facilities areused) to tune the Control System. So the whole unit will be deemed ascommissioned.

Commissioning of the Fire Heater will be performed with steam after the placesteam and condensate headers in service

TEGHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello detta Magtiana, 68

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3.1.18 Steam Out

Air may be displaced also by steam (steam out) and steam will be thensubstituted with nitrogen before the steam has an opportunity to condense.

Before admitting steam into the vessels and relevant interconnecting lines, allvents and drains have to be open.A sufficient number of low point drains must be left open to remove condensate.The steam out period should continue until all air is removed from the sections.When the purging is completed to less then 1% volume oxygen in all the involvedsections, the steam starts to be stopped and, at the same time, nitrogen is beingadmitted into the sections involved, discharging the water from low points takingthe necessary precautions" Once all steam has been displaced the vessels areready to be loaded with feed.

Purging detailed procedure, which includes:

- marked-up P&l showing the lines and equipment to be steamed out

. indication of the valves to be open or closed

- indication of the position of the spectacle blinds (open/close)

description of depressurization procedure and final gas or nitrogenpressure.

shall be prepared at site by the precommissioning staff.

The following general instructions have to be considered:

- Instruments and their primary connections to lines and equipment shall beisolated.

- Steam out circuits shall be prepared: each circuit shall include anequipment with a connection for the steam inlet and some lines and otherequipment with top vents and bottom drains from which steam and air canbe vented and the condensate drained.

- Valves isolating the selected circuit from other ones have to be closed;isolating valves inside the circuits shall be opened.

- lsolate the safety valves.

- Open the steam connections (permanent and/or temporary); manuallyregulate the steam flowrate and vents and drains opening in order to allowthe steam to flow out freely from each point.

- lt is possible to purge two or more circuits at the same time but anyinterference and accessibility problems to valves shall be avoided.



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Steam out shall be maintained for some hours (4 to 6), during which boltsand tie rods tightening shall be verified

Connect all the pressure safety valves of the circuits.

Reduce to the minimum the major drains opening and close all the smalldrains.

Close the top vents and reduce the steam inlet flow to the minimumsuitable value to maintain a slightly pressure inside the circuit.

Gradually feed nitrogen to the circuit by the dedicated line and, at thesame time, decrease the steam flowrate.

Check the opened drain valves to ensure that nitrogen doesn't flowthrough them.

Close the inlet steam and open slowly all drains, one by one, till all thecondensate is discharged.

check the pressure of the system at different points and ensure that itdoesn't exceed 1 barg.

Purge the instruments primary connections and install instruments on line.

Preliminary Operations

Preliminary runs should be of great value to the operators in familiarizing themwith the plant and its controls. Plant or system are operated with not hazardousfluids (water, air, nitrogen) at conditions as close as possible to the normaloperating ones, in order to detect any defects in machinery, instruments,electrical or piping, which can be immediately corrected, without causing hazardfor operators.

Charge of Product Recovery and, Purification Systems

In order to test the Product Recovery and Purification Systems it is necessary tofill the scrubber and the distillation columns to normal operating levels and thenpressurize the scrubber to near operating pressure. Do not close the block valvesat the scrubber gas inlet line and it is important to pressurize the all cycle gas bynitrogen with scrubber as one unit.

The scrubber system should be filled adding demineralized water to the ScrubberFeed Water Drum 100-D-231. After the normal level is reached, the water is to betransferred from 100-D231 to the Scrubber 100-C131 using the pumps 100-P131A/8.


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Demineralized water should be continuously fed to the Scrubber until it is filled tosomewhat above normal operating level. At this point start circulation of water tothe packing bed of the Scrubber by the Washing Pumps 100-P138 A/8.

Since the Scrubber has been filled, the demineralized water from 100-D231 canbe transferred to the Dehydration Column 100-C132 keeping still in operation theScrubber Feed Water Pump 100-P131 A/B and using the line 1089, connectedto the feed line of the Dehydration Column. In the same time demineralized watershould be added to the Decanter [OO-D232 using a hose connection, allowingboth chambers are filled to normal levels.

when the Decanter is filled, the Reflux Pumps 100-P135 A/B and the AqueousPumps 100-P137 NB should be started to transfer the water to the destinationequipment. The reflux pump 100-P135 A/B will contribute to fill the DehydrationColumn, while the aqueous pump 100-P137 NB will transfer the water to theStripping Column 1 00-C1 34.

After the normal operating level is reached in the bottom of the dehydrationcolumn, the Crude Acid Pump 100-P132 NB can be started to send the water tothe Product Column 100-C133. Then, the product column should be isolatedfrom the remaining closed loop. subsequently, operate the product columnseparately.

During the filling of the columns, all low point drains of lines and equipmentshould be used to remove dirt and rust from the system. Water should be drainedoff until it appears clear and free.of debris.

When the normal operating levels are reached in all columns and the flushingthrough the drains has been accomplished, the demineralized water feed line to100-D231 should be closed and the pumps used to transfer water from oneequipment to the other should be shut down.

Having the normal operating level in all the column, it is possible now to put inoperation the reboilers in order to test the overhead condensers.

A small flow of steam should be started on manual control to the reboilers 100-E132 (Dehydration Column Reboiler), 100-E133 (Product Column Reboiler) and100-E134 (Stripping Column Reboiler) obtaining a heating rate not higher than 25'C per hour.As the pressure in the Dehydration Column / Stripping Column overheadsapproaches the normal operating one, the air-fin Condenser 100-E232 should beenabled to start and the temperature controller at the exit should be set so that100-E232 will condense all of the water vapor.As the level in the Decanter 100-D232 begin to increase, the reflux pump 100-P135 A/B should be started to re-circulate the condensed water back to thecolumn.

TEGHI{IP ITALY S.p.A. - 00148 ROMA - Viale Castello detla Magtiana, 68

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When the pressure at the Product Column 100-C133 reaches the operatingvalue, the air-fin condenser 100-E233 should be put in operation, with thétemperature controller at its outlet line set to condense all the water vapor comingfrom the overhead.

The entire operation should be continued, as near to design conditions aspractical, until all drain water runs continuously clear.

lf the plant is ready to be started-up, keep the reboilers and the condenser inoperation. Othenryise shut down the reboiler and keep the system pressurizedwith nitrogen to avoid a vacuum is developed due to the cooling of the system.

3.1.19.2 Preparation of Carbon Dioxide Removal System

During the testing and preparation of the CO2 removal system, the recycle gassystem should be kept isolated from the carbonate system until shortly beforestart-up of the reaction section. The testing and preparation of the CO2 removalsystem consists of the following major steps:

Water Wash

Demineralized water should be added to the Solution Regenerat or 100-C142from the Solution Storage Tank 1 00-T141 via the Make-up Pump 1OO-P141.When the level reaches the top of the sight glass in the regenerator, pump thewater to the CO2 absorber 'î00-C141 adjusting manually the transfer flow rate tomaintain a stable liquid level in the bottom of 100-C142.

As conditions stabilize, control systems should be placed in automatic.Circulate the water through the system, check strainers and filters frequenily, andremove any foreign material. The system should be drained and refilled withclean water. When the circulating water remains clean, it is to be heated to theboiling point by applying steam to 100-E142 and circulation continued. Again dirtwill be removed and the water circulation, with necessary replacement, shouldcontinue until the water runs clean.

Caustic Wash

The caustic wash should be carried out at about 70 "C using 4.S % NaOHsolution. To prevent caustic embrittlement of the equipment the solution must notbe permitted to exceed 80 "C under any circumstances. Fill the regenerator andcirculate water as in the water wash procedure. The system inventory should beadjusted to allow about 30 o/o increase in volume. When a reasonable rate ofcirculation has been established and the flows are being automatically controlled,start adding caustic to the system. Sufficient caustic should be added to obtain asolution concentration of 4.5 %.lf needed steam can be fed to 1OO-E142 to bringthe solution to about 70'C.

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TEGI{f.II P ITALY $,p.4. mmfu*Circulate the caustic solution through the system to remove oil and grease. pumpstrainers and solution filters should be checked for fouling frequenily duringwashing. The caustic wash cycle should continue for 24 hours (longer if ótraineréor filters are still fouling), then the caustic solution should be drained and thesystem be rinsed for 8-12 hours with demineralized water. The system is thenready for dry running with recycle gas.

3.1.20 Carbonate Loading

Carbonate make-up solution is prepared in the Solution Sump 100-A141, with theaid of LLP steam via a steam sparger. Sufficient demineralized water is added toobtain the required concentration.Test the solution for carbonate concentration. lf the solution is at the properconcentration, the batch is then pumped to the Solution Storage Tank 100-T141.This batchwise procedure is repeated until the solution tank is nearly full.

Then start transfer of carbonate to the regenerator. When the level in 100-C142reaches the top of the sight gtasses, pump some of the carbonate into the COzAbsorber. Bring the system up to design level and start circulation. Adjust theCO2 Absorber pressure as necessary.

Heat the circulating solution to its atmospheric boiling point by applying steam tothe regenerator reboiler 100-E142. The flow of vapor through 100-C142 willdecrease the liquid hold-up in the column, so make-up the regenerator level withfresh solution as necessary.

Once carbonate has been charged and the entire system brought into stableoperation, dry running can commence. At this point it is assumed that the recycle.gas system is on stream with the compressor in operation.

Open the block valve in the recycle gas feed line to the CO2 Removal Systemallowing the gas to flow into the CO2 Absorber. Adjust manually the flow admittedby regulating the flow rate of recycle gas that flows through the by-pass of theCO2 Removal System.

As the gas passes through the COz Absorber, heat will be lost from thecirculating solution due to the vaporization of water and the sensible heatincrease in the recycle gas. Hence, the steam flow to 1OO-E142 will need fo beadjusted.

During the test run, alternate pumps so that they can all be checked underoperating conditions. When the hot solution has been circulated for 5 days, thesystem will then be ready for carbon dioxide removal.

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TECII rìllP ITALY S,p,A.

3.2 PRE START-UP

The following steps and items shouldfeed starts:

Place Utility Header in Service

(1) Place the header of the fotlowing

(a) Power Supply(b) Potable Water(c) DemineralizedWater(d) Desalinate Water(e) Fire Water(0 Boiler Feed Water(g) Instrument and Plant Air(h) Nitrogen(i) Flare

3.2.1

',.,{il1 t,,mmW*-*

be performed and checked before oxygen

utilities: in service:

(PW)(DW)(DSW)(FW)(BFW)(tA)(N)(FR)

' (2) Make sure the all utilities mentioned above are available and in service.

3.2.2 Makeup and Dosage of Ghemicals,

The following chemicals shall be prepared for the operation:

(1) ButylAcetate

(2) Potassium Carbonate (K2 CO3)

(3) Catacarb 922 Catalyst

(4) Catacarb WBU antifoam

(5) Steam Drum Dosing Chemical - phosphate Solution

For the make up and dosage of chemicals refer to 2.1.4.

TEGHNIP IrALY s.p.A. - 00148 ROMA - Viate casteilo deila Magliana, 68

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, 4,,,,JI,,,,,t ,,mmMremTEC*illP IIALY $.p.4,

3.2.3 Place steam Headers and Boiler Feed water system in service

NorE: using import HP steam clean and steam blow the steam headers.

r lmport demineralised water from B/L

. circulate with the Boiler Feed water pumps and make wateravailable to the desuperheaters as and when required.

o Desuperheat as required and commission the steam andcondensate headers to normal operating pressure and temperature.

o Excess steam can be vented or routed to the Dump Condenser.

At the end of this period the steam system is in operation as follows:

. HP lmport in service

o Make sure Boiler Feed water (for Desuperheater) has beencommissioned and at design conditions (at B/L)

. steam condensate Drum (100-D263) has been commissioned andpump in service (circulation) to feed Desuperheater.

r create the level in MP condensate Flash Drum. (Make up manuallyDemiWater)

o By the use of small by-pass valve, introduce the Hp steam from B/L.

o when the HP steam network reach about 20 bar (in not less than ghours) put in service first Desuperheater to produce Mp steam (setpressure about 8 bar).

r when HP steam reach process valve (about 40 bar) open mainvalve (close small by-pass).

. Rise MP pressure from 8 to 14 bar (in not less than g hours) and setthe 200"C temperature.

o simultaneously put in service LP steam production ( about z bar)and desuperheater.

TEGHNIP trALY s.p.A. - 00148 ROMA - Viate casteilo deila Magtiana, 68

4'l mrTECllFllP ITALY $,p.A, *mMr*

o lt is very important to drain out first (dirty) condensate, so all thesteam trap should be out of service for at least one day.

o Once make sure the steam trap up stream piping is free. Put inservice steam trap down stream piping

NOTE: lf the steam trap has a by-pass use it for blowing of downstreampiping to the condensate drum.

. HP, MP, Lp and LLp steam headers at normar pressure andtemperature

o Establish continuous flow of Hp import steam.

o Header vents in service

. Dump Steam Condenser in service

' . Boiler Feed Water Pump on spillback feeding the desuperheaters

. Condensate export system in service

3.2.4 Start-up Cooling Water and Ghilled Water

(1) Open the valve on the cooling water supply every vents and drains on theexchangers

(2) Displace air through each vents" After water filling, close all the vents.

(3) Open the valve on the cooling water supply and establish circulation

(4) Controlwater is circulating trough each exchangers.

(5) Close the drains when water get clear

(6) Start up Chilled Waterfrom B/L to 100-E131 and to the Anatyzer House.

(7) Check and controlTl-3206, Pl-3206 and FQI-3205; FQt-3206 and Tt-3ZOZsfor correct operating value.

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3.2.5

3.2.6

Gheck and Get Ready to Start Up the Process

Check the following items prior to start-up:

(1) Make certain all utility conditions and the plant conditions for ready to startthe operation.

(2) Before start-up begins all block, hand and level controlvalves are closedexcept that block valves on level gauges, orifice leads, and float chambersare open.

(3) All flow, pressure, and temperature controllers are set at zero (calibrated)

(4) cooling water is to be turned on to pump, bearings, heat exchangers, etc.as required

(5) Other incidental operations should be completed.

(6) Tracing and freeze protection should be turned on as required.

(7) Safety and loss prevention equipment in service

(8) Closed and Open Drain Collection System is commissioned and ready forservice

(9) Incinerator outside the battery limit is commissioned ready for service.

Purge ànd Pressurize the System with Nitrogen

(1) Charge Water to Product Recovery Unit

Be sure the water in the Product Recovery Unit is adequate. tf not, chargewater in the same way water was introduced untíl it is adequate

(2) Standby Compressor

Perform the following items in accordance with directions supplied by themanufacturers:

Compressors and Recycle Gas in service, after having commissionedall the protection system.

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(3) Purge and Pressurize System with Nitrogen

Oxygen content in the following portions should be decreased below 1o/o bypurging with nitrogen. Pressurize with nitrogen in order to start up thesystem safety

Oxvoen Line

o Flush 100-M111 through the HP Nitrogen Start-up line from 1OO-D224and flush oxygen line by use Nitrogen line foreseen for this aim, afterhaving connected the temporary quick connection.

Ethane Line

o The line from B/L to the inlet of 100-D111NB Zinc oxide Vesselshould be purged with nitrogen, by use of Nitrogen line after havingconnected the temporary quick connection.

Feed Preparation and Reactor Loop

. lsolate the desulphurisation section from the Reactor loop.

. After having opened the start-up spillback line from the discharge ofthe Fresh Feed Compressor 100-J111 back to the cold side inlet otthe Interchanger 100-E111N8, purge the Feed preparation andReactor Loop with nitrogen. The system should have been alreadypurged with nitrogen, however it shall be checked that oxygeÀconcentration is below 1 % by volume.

. lf necessary, the system shall be purged again until the samplescontains less than 1 % oxygen.

. lf the header outside battery limit has not been purged, this can nowbe done by opening the battery limit block valve and purging to themost distant vent valve.

(B) Circulation of nitrogen throuoh the circuit

. Make sure that the cooling water to the Ethane Feed cooler 100-E1 13 is in service, as this acts as the spillback cooler.

. Start the Fresh Feed Compressor 100-J111NB and circulate nitrogenthrough the circuit at 7 barg

. warm up the Zinc oxide Vessel to approximately 370"c by ethanefeed preheater (electrical heater 100-H211).


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*;l n;.lffiffifurum

The nitrogen shall be circulated through the feed interchanger 100-E111 NB, the heater 100-H211 and the Zinc oxide vessels tóo-ot t tA/8.

The reactor shell side and the Reactor steam Drums (1oo-D221)should be purged with nitrogen prior to charging the boiler feed water.

(D) Purqe the CO2 Removal Svstem

I Flow a small quantity of nitrogen continuously trough CO2 SolutionRegenerator

Also the Purification system, the product Recovery system, AnalyzerSystem and Drain Collection System should be purged-with nitrogen atleast 1 barg.

(4) Purge and Start-up High Pressure Nitrogen System

. Commission 100-J171 NB with import Hp N2"

. Reset emergency trip valves.

. Check the lnterlock system of N2 Compressor (100-J171) for start-up.

o start up Nz compressor following the directions supplied by themanufacturer.

. lntroduce nitrogen, purge and pressurize to all the following HpNitrogen vessels, raising the pressure to normal operating levels.1) HP Start Up Nitrogen Vesset 100-D2742) HP Emergency Shut Down Vesset 100-D2763) HP Nitrogen SABOX Vesset 100-D282

r Test the operation of all isolation and vent valves and vent/purgelogic.

o Note that 100-D276, HP Nitrogen Emergency shutdown Vessel mustbe up to normal operating pressure in order to commencePlanUReactor comm issioning/Start-up.

(5) Pressurize Conventional Reactor Section

. Commission and make sure that all instrument loops are in service.

. Calibrate and test all analysers.

(c)

a


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r Ensure that the HP Nitrogen Emergency shutdown vessel ispressurised to it's normal operating pressure.

. Nitrogen purge, leak test and blanket the system, using the motorisedand block valves within the loop, to isolate 100-R121 , 100-E1 14, 1oo-J112from the rest of the equipment in the loop.

(6) Pressurize Cycle Gas Loop

. Purge the Cycle Gas Loop

. Purge the compressor (100-J112) and line it up with the loop (100-R121and 100-E114 NB are stiil isolated).

. Ensure that the loop now including 100-J112 is under a nitrogenblanket.

o Establish the following circuit: 100-J112, 1oo-M111, Reactor by-pass(via 100-E1 14 NB start-up tine), 100-E231, 100-c1 31, coz RemovalSystem by.pass, 100-E211,100-D211, and back to 1OO-J112. Notethat'the block valve on the suction of 100-J1 12 and the block valve onthe discharge of 100-J112 should now be open.

o Make sure FV-1406 reactor inlet valve and reactor inlet block valveshall be closed, and FV-1302 reactor by pass is open.

o Make sure a small flow of Nitrogen to the mixer from 1oo-D274through the Flushing HP Nitrogen line already started.


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3.2.7 Interlock Tests

Process and safety interlock systems are provided in this plant in order to protectpersonnel and equipment from hazardous situation by shutting down the plantquickly and automatically.

All of the interlock systems have to be tested by using temporary signals beforethe actual process operation to make sure that the interlock system operatescorrectly. Wherever is possible the test should be a real one. Simulation isaccettable only from the field.

Before the test begins, confirm that required utilities such as instrument air,power are already in service.'

Interlock systems are described hereinafter system by system. The test shouldbe performed with referring to the logic diagram for shutdown and sequencesystem, the instrument data sheet, and the engineering flow diagram.

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tJl,, r,,,,,,J

INTERLOCK I-OIOIOXYGEN CUT OFF LOGIC

ITEM DESCRIPTION CAUSEa

a

a

HS-2001PALL-6508PALL-6303

TDAHH-1412

FDAHH-1410

FALLL-1403

TAHH-I411

PDALL-1404

PDALL-1412

TAHH-1406

FZSL-1402

FALL-1412

FALL-2003

TAHH-2001

TAHH-2004

Plant Emergency TripInstrument Air FailureLow. Low Cooling Water SupplyPressureHigh High Differential Temperatureacross Mixer 100-M111High High Oxygen Flow RateChange to Mixer 100-M111Low Low Low Oxygen Flow toMixer 100-M1 11

High Temperature Exit from 100-E114Low Differential Pressure acrossMixer 100-M111Low Low Pressure Differentialacross Oxygen Feed ControlValveHigh High Temperature Exit fromMixer 100-M1 11

Oxygen Feed Control Valve FV-1402 fully closeLow Low Flow to Oxygen AnalyzerAt-1402Low Low Flow to Oxygen AnalyzerAt-2004High High Temperature InletReactor 100-R121High High Temperature Exit fromReactor 100-R121

Close HP SteamValve to 100-E111Close/Open Ethane FeedValve to Reactor LoopClose Oxygen FeedValve to 100-M111Close Oxygen FeedBlock Valve (AudibleAllarm)Open Oxygen FeedBleed Valve to SafelocationClose Oxygen FeedBlock Valve to 100-M111Open Oxygen FeedBleed Valve to SafeLocation XV-1405Close Oxygen FeedBlock Valve to 100-M111xv-1406Open High PressureNitrogen Shut Down to100-M111

TEGHNIP ITALY s.p.A. - 00148 ROMA - Viale casteilo deila Magtiana, 68

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INTERLOCK I-OlOIOXYGEN CUT OFF LOGIC

I t ErYr uEltuKlt, I l()N CAUSE

a

a

TAHHH-2005/49

TAHH-2O5OA-K

LALL-2,I06PAHH-2102

FALL.7OO7

PALL-7006

. High High High Temperature inReactor 1 00-R121 (process)

. High High Temperature in ReactorCatalyst (2 out of 3 ). Low Low Level in 100-D221

. High High Pressure Exit from 100-D221

o Low Low Flow Exit from 100-D274to Mixer 100-M111

. Low Low Pressure Exit from 100-D276

xs-2001 Power failure Close HP SteamValve to 100-E111Close/Open Ethane FeedValve to Reactor LoopClose Oxygen FeedValve to 100-M111Close Oxygen FeedBlock Valve (AudibteAllarm)Open Oxygen FeedBleed Valve to SafelocationClose Oxygen FeedBlock Valve to 100-M111Open Oxygen FeedBleed Valve to SafeLocation XV-1405Close Oxygen FeedBlock Valve to 100-M111xv-1406Open High PressureNitrogen Shut Down to100-M111Stop CirculationCompressor 100-J112and 100-J1127Close Reactor By PassValve FIC-1302Set Loop Pressure SP to13 bara I

J113AM-0000x1

Jl13BM-0000x1

. Oxygen Compressor Running 100-J1 13A

. Oxygen Compressor Running 100-J1138

. Close HP SteamValve to 100-E111

r Close/Open Ethane FeedValve to Reactor Loop

. Close Oxygen FeedValve to 100-M111


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ITEM DESCRIPTION CAUSEClose Oxygen FeedBlock Valve (AudibteAllarm)Open Oxygen FeedBleed Valve to SafelocationClose Oxygen FeedBlock Valve to 100-M111Open Oxygen FeedBleed Valve to SafeLocation XV-1405Close Oxygen FeedBlock Valve to 100-M111xv-1406Open High PressureNitrogen Shut Down to100-M111Close Reactor BypassValve (FlC-1302)

J112M-0000X1

FALL-1308

Circulation Compressor RunningLow Low Discharge Flow From100-J112

Close HP SteamValve to 100-E111Close/Open Ethane FeedValve to Reactor LoopClose Oxygen FeedValve to 100-M111Close Oxygen FeedBlock Valve (AudibleAllarm)Open Oxygen FeedBleed Valve to SafeIocationClose Oxygen FeedBlock Valve to 100-M111Open Oxygen FeedBleed Valve to SafeLocation XV-1405Close Oxygen FeedBlock Valve to 100-M111xv-1406Open High PressureNitrogen Shut Down to100-M111Close Reactor BypassValve (FlC-1302)Set Loop Pressure SP 13bara (PlC-1311)

TEcllNlP IrALY $.p.A- - 00148 ROMA - Viate casteilo deila Magtiana, 6g

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INTERLOCK I.O1OIOXYGEN CUT OFF LOGIC

ITEM DESCRIPTION CAUSEo HZSL-1402 . Oxygen from Battery Límit Switch

Fully Close. Close Oxygen Feed

Block Valve SoundAudible Alarm (HV-1402\

o FAL-1403 Low Low Oxygen Flow to Mixer100-M111

Close HP SteamValve to 100-E111Close/Open Ethane FeedValve to Reactor LoopClose Oxygen FeedValve to 100-M111Close Oxygen FeedBlock Valve (AudibleAllarm)Open Oxygen FeedBleed Valve to SafelocationClose Oxygen FeedBlock Valve to 100-M111Open Oxygen FeedBleed Valve to SafeLocation XV-1405Close Oxygen FeedBlock Valve to 100-M111xv-1406Open High PressureNitrogen Shut Down to100-M111Open High PressureNitrogen Start-Up ValveHV-7002from 100-D274. FALL-3602 Low Low Scrubber Feed Water

Flow to 100-C131Close HP SteamValve to 100-E111Close/Open Ethane FeedValve to Reactor LoopClose Oxygen FeedValve to 100-M111Close Oxygen FeedBlock Valve (AudibleAllarm)Open Oxygen FeedBleed Valve to SafelocationClose Oxygen FeedBlock Valve to 100-M1'11Open Oxygen FeedBleed Valve to SafeLocation XV-1405Close Oxygen FeedBlock Valve to 100-M111xv-1406


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ITEM DESCRIPTION CAUSE. Open High Pressure

Nitrogen Shut Down to100-M111

. Open HP Nitrogen Startup Valve HV-7002 from100-D274

INTERLOGKI.OIO2RAW MATERIAL LOGIC SYSTEM

lTEM DESCRIPTION CAUSEa

o

PDALL-1302

PALL-1415

FSH-7005

PALLL-7o14

. Low Low Differential Pressureacross FV-1301

r Low Low HP Nitrogen Pressureto 100-M111 (Start Up EthanePermissive)

. High High limit Switch toNitrogen Flushing Valve

o Low Low Low Pressure ExitFfrom 100-D274 (Start UpEthane Permissive)

Close HP SteamValve to 100-E111Close/Open EthaneFeed Valve FV-1301to Reactor Loop

INTERLOCK I.O103STEAM TO PROCESS

ITEM DESCRIPTION CAUSEo TALL-1111 o Low Low Differential Pressure

across FV-1301o Close HP Steam

Valve FV-1101 to 100-E111


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INTERLOCK I.O104ANALYZER LOGIC SYSTEM

ITEM DESCRIPTION CAUSEAAHH.14O2

AAHH-2004

High High Oxygen Exit 100-M111

High High Oxygen Exit fromReactor 100-R121

Close HP SteamValve to 100-E111Close/Open EthaneFeed Valve to ReactorLoopClose Oxygen FeedValve to 100-M111Close Oxygen FeedBlock Valve (AudibleAllarm)Open Oxygen FeedBleed Valve to SafelocationClose Oxygen FeedBlock Valve to 100-M111Opgn Oxygen FeedBleed Valve to SafeLocation XV-1405Close Oxygen FeedBlock Valve to 100-M111XV-1406Open High PressureNitrogen Shut Down to100-M111

INTERLOCK I.O105OXYGEN COMPRESSOR LOGIC SYSTEM

ITEM DESCRIPTION CAUSEo HZSH-1402 . Oxygen from Battery Limit HV-

1402 High Limit Switch FuilyOpen

. Oxygen CompressorReady to Start

HS-1403A/B

HS-1414A/B

. Oxygen Compressor 100-J113A/B Emergency SD Switch(Field)

. Oxygen Compressor 100-J1134/B Emergency SD Switch(Control Room)

. Close HP SteamValve to 100-E111

. Close/Open EthaneFeed Valve to ReactorLoop

. Close Oxygen FeedValve to 100-M111

. Close Oxygen FeedBlock Valve (AudibleAllarm)

TEGHI{|P IrALY s.p.A. - 00148 ROMA - Viate casteilo deila Magtiana, 6g

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Page 3-70

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INTERLOCK I.OI05OXYGEN COMPRESSOR LOGIC SYSTEM

ITEM DESCRIPTION CAUSEOpen Oxygen FeedBleed Valve to SafelocationClose Oxygen FeedBlock Valve to 100-Ml11Open Oxygen FeedBleed Valve to SafeLocation XV-1405Close Oxygen FeedBlock Valve to 100-M111XV-1406Open High PressureNitrogen Shut Down to100-M111

INTERLOCK I-OI06CIRGULATION COMPRESSOR LOGIC

ITEM DESCRIPTION CAUSELALL-1304

HS-1306

HS-1302

FALL-1309

High High Level in 100-D211

100-J1,12 Emergency S/DSwitch100-J112 Emergency S/DSwitchLow Low Discharge Flow 100-Jl12

Close HP SteamValve FV-1101 to 100-E111Close/Open EthaneFeed Valve to ReactorLoopStop CirculationCompressor 100-J112I 100-J1127Close Oxygen FeedValve to 100-M111Close Reactor BypassValveClose Oxygen FeedBlock Valve (AudibleAllarm)Open Oxygen FeedBleed Valve to SafelocationClose Oxygen FeedBlock Valve to 100-M111




Page 3-7'l

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INTERLOCK I.O106CIRCULATION COMPRESSOR LOGIC

ITEM DESCRIPTION CAUSE. Open Oxygen Feed

Bleed Valve to SafeLocation XV-1405

o Close Oxygen FeedBlock Valve to 100-M1l1XV-1406

. Set Loop Pressure SPto 13 bara

. Open High PressureNitrogen Shut Down to100-M111

a 7AL-1404

FZSH-1302a

o Reactor Feed Valve FullyClosed

. Reactor Bypass valve HighLimit Switch (Fully Open) (startUp Permissive)

o CirculationCompressor 100-J112Ready to Start

LAHH-3005

zAL-1404

xzL-4006

zsH-1301

zsH-1305

. High High Level in 100-C131(Start Up Permessive)

. CO2 Removal System BypassValve fully closed

o CO2 Removal System GasFeed fully closed

. 100-J112 Manual suction valvefully Open

. 19Q-J112 Manual Dischargevalve fully open

CirculationCompressor Ready toStart

TALL-6117 Low Low Superheated Steamtemperature

o Close HP SteamValve FV-1101 to 100-8111

o Close/Open EthaneFeed Valve to ReactorLoop

. Stop CirculationCompressor 100-J112| 100-J1127

o Close Oxygen FeedValve to 100-M111

. Close Oxygen FeedBlock Valve (AudibleAllarm)

. Open Oxygen Feed

TEGHNTP ITALY s.p.A. - 00148 ROMA - Viate casteilo deila Magtiana, 6g



Page 3-72

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INTERLOCK I.O106CIRCULATION COMPRESSOR LOGIC

ITEM DESCRIPTION CAUSEBleed Valve to SafelocationClose Oxygen FeedBlock Valve to 100-M111Open Oxygen FeedBleed Valve to SafeLocation XV-1405Close Oxygen FeedBlock Valve to 100-M111 XV-1406Set Loop Pressure SPto 13 baraOpen High PressureNitrogen Shut Down to100-M111

INTERLOCK I-OI07ELECTRIC HEATER LOGIC SYSTEM


a

FALL-1105TAHH-111 1

HS-1105

HS-1104

. Low Low Ethane Flow

. High High Temperature out100-H211

r Electric Heater Emergency S/DSwitch "field"

r Electric Heater Emergency S/DSwitch "ccr"

o Electric Heater 100-E211Trip

INTERLOCK I.OI08FRESH FEED COMPRESSOR

ITEM DESCRIPTION CAUSEPALL-1203

PAHH.12O4

HS-1201A/B

HS-1203A/B

. Low Low Suction Pressure Inlet100-J111 NB

. High High Pressure Exit 100-J111 NB

r 100-J111NB Emergency S/DSwitch (field)

. 100-J111NB Emergency S/DSwitch (ccr)

Stop Fresh FeedCompressor 100-J111A/B

TEGHNIP IrALY $.p.A. - 00148 ROMA - Viate casteilo deila Magtiana, 68

? , , Pîoi.2121- SABTC ACETTC AC|D PROJECT

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INTERLOCK I.OI09ITEM DESCRIPTION CAUSE

PALL-1203

PAHH-1204

HS-1201A/B

HS-1203A/B

o Low Low Suction Pressure Inlet100-J111 NB

. High High Pressure Exit 100-J111 NB

. 100-J111NB Emergency S/DSwitch (field)

o 100-J111NB Emergency S/DSwitch (ccr)

Stop Fresh FeedCompressor 100-J111A/B

INTERLOCK I-OIIOITEM DESCRIPTION CAUSEo PDALL-1313 . Low Low Differential Pressure

across FV-1312e Close Nitrogen Valve

FV-1312

INTERLOCK I-0I11ITEM DESCRIPTION CAUSEr PDALL-1110 o Low Low Differential pressure

across FV-1 101. Close HP Steam Valve

To 100-E11î (SOV)

INTERLOCKI-0112ITEM DESCRIPTION CAUSEo VAHH-1301A/B . High High Vibration in 100-

E211MNBo Stop 100-E211MA/B

Motor

INTERLOCKI-0201

ITEM DESCRIPTION CAUSEo PDALL-2104 o Low Low Differential presureAcross PV-2101

. Close Steam ControlValve Exit 100-D221

INTERLOCK I.O3OI

ITEM DESCRIPTION CAUSEuA-6151 1 00-H161 Burners Tripped . Close Ethane Fuel

Valve To 100-H161. Open Purge Gas Fuel

Valve To Flarer Close Fuel Block

Valve To 100-H161. Open Fuel Bleed

TEGHNIP trALY s.p.A. - 00148 ROMA - Viate casteilo deila Magtiana, 68



Page 3-74

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INTERLOCK I-0301

ITEM DESCRIPTION CAUSEValve To SafeLocationClose Fuel BlockValve To 100-H161Shutdown 100-H161Via BurnerManaqement Svstem

PAHH-6153

PALL-6157

PAHH-6162

TAHH-6160

TAHH-6162

FALL-61554

PALL-6161

HS-6154

High High Fuel Pressure To100-H161Low Low Fuel Pressure To100-H161High high Pilot Fuel GasPressureHigh High Temperature Exit100-E363High High Flue GasTemperature Exit 1 00-H1 61Low Low Steam Flow from 100-E363Low Low Pilot Fuel GasPressureFired Heater Emergency Stop

Close Ethane FuelValve To 100-H161Open Purge Gas FuelValve To FlareClose Fuel BlockValve To 100-H161Open Fuel BleedValve To SafeLocationClose Fuel BlockValve To 100-H161Shutdown 100-H161Via BurnerManagement SystemClose Pilot BurnerBlock Valve To 100-H161Open Pilot BurnerBleed Valve To SafeLocationClose Pilot BurnerBlock Valve To 100-H161

uA-6153 o 100-H161 Pilot Burners Tripped . Close Pilot BurnerBlock Valve To 100-H161

o Open Pilot BurnerBleed Valve To SafeLocation

. Close Pilot BurnerBlock Valve To 100-H161


Pîol.2121 - SABIC ACETIC ACID PROJECT

YANBU - KINGDOM OF SAUDI ARABIA ,,, 4, t f,,,,,,r,*l

*mwm*Page 3-75

TECIIHIP ITALY $,p,4.

INTERLOCK I.O3O2

ITEM DESCRIPTION CAUSEo LALL-3205 . Low Low Level ln 100-D232,

Organics. Stop 100-P135A/B

INTERLOCK I.O3O3

ITEM DESCRIPTION CAUSEo LALL-3206 o Low Low lnterface Level ln

1OO-D232, Aqueous. Stop 100-P137NB

INTERLOCK I-0304

ITEM DESCRIPTION CAUSEo LALL-3303 . Low Low Level ln 100-C133 . Stop 100-P133A/B

o LALL-3403 . Low Low Level ln 100-D2323 . Stop 100-P136A/8

INTERLOCK I.0306

ITEM DESCRIPTION CAUSE. LALL-3505 . Low Low Level In 100-C134 a Stop 100-P134NB

Close Recycle WaterValve to 100-D231Close Waste WaterValve to 100-E137

a

a

INTERLOCK I.O3O7

ITEM DESCRIPTION CAUSEr LAL-3206 . Low lnterface Level in 100-

D232. Close Aqueous Purge

Valve. Close Aqueous

Recycle From 100-P137


T&cfiríp ;ìj,1;:"H::.l'::H:,1-. . _---...r.rítf{d6[|r

Page 3-76

?ECHrdlP ITALY $.p.4.

1.1 ',,*m%**

INTERLOCK I.O3O8

ITEM DESCRIPTION CAUSE. PDAL-3607 . Low Differential Pressure

Across FV-3601. Auto Start 100-

PI31A/B

INTERLOCK I-0309

ITEM DESCRIPTION CAUSE. LALL-3603 o Low Low Level ln 100-D231 a Stop 100-P131A/B

Close Feed WaterValve to 100-C131

a

. PDALL-3607 . Low Low Differential PressureAcross FV-3601

o Close Feed WaterValve to 100-C131

INTERLOCK I-O3IO

ITEM DESCRIPTION CAUSE. LAHH-3205 . High High Level in 10O-D232,

Oroanicr Close 100-E131 Vent

Line

INTERLOCK I-O3II

ITEM DESCRIPTION CAUSEo PDALL-3208 . Low Differential Pressure

Across FV-3106. Open To Atmosphere

INTERLOCK I.O3I2

ITEM DESCRIPTION CAUSE. LALL-3105 o Low Low Level In 100-C132 o Stop 100-P132NB

INTERLOCK I-031 3A/B/C/D

ITEM DESCRIPTION CAUSE. VAHH-

3001A/BiClD. High High Vibration in 100-

E23lMNBICID. Stop 100-

E231MA/B/C/D Motor


T&cfinip-'{#Ef

TECllfillF IîALY $,p,A,



Page 3-77

1,1 ,,,mmMm

INTERLOCK I-0314A/B

ITEM DESCRIPTION CAUSEr VAHH-3401 o High High Vibration in 100-

E233MA/B. Stop 100-E233MA/B

Motor

TNTERLOGKT-0401t0402CO2 REMOVAL SYSTEM S/D & CO2 REMOVAL SYSTEM BYPASS


a

LAHHH-4007PDAHH-4003

PDALL-4007

HS-4003

High High Level in 100-D241High High Differential Pressureacross 100-C141Low Low Differential PressureOver FV-4002Emergency Stop CO2 RemovalSystem

Close Lean SolutionValve (SOV)Close Antifoamsolution valveClose Lean Solution to100-c141Close Lean Solution to100-c141Open COz RemovalSystem Bypass ValveClose CO2 RemovalSystem Inlet ValveClose Reboiler Steamon 100-C142Open CO2 RemovalSystem By-Pass(SOV)

INTERLOCK I-0402

ITEM DESCRIPTION CAUSEo PDALL-4002

. FALL-4005

. FALL-3602

o Low Low Differential pressureacross XV-4006

. Low Low Flow to 100-C141

. Low Low Scrubber Feed WaterFlow To 100-C131

. Open CO2 RemovalSystem Bypass Valve

. Close COz RemovalSystem Inlet Vàlve

. Open CO2 RemovalSystem By-Pass(SOV)


Pîoi.2121- SABIC ACETIC ACID PROJECTProj. :

Iecnn/P 'ANBU

- KTNGD.M oF 'AUDTARABTArr<w

Page 3-78

TECIIHIP IT&LY $,p.À.

,,*J1,,,,,t, il,,.,r

*mwm*

INTERLOCK I.O4O3

ITEM DESCRIPTION CAUSE. LALL-4003 . Low Low Level In 100-C141 o Close Rich Solution to

100-c142. Close Rich Solution To

100-c142

INTERLOCKI-0404

ITEM DESCRIPTION CAUSEo LALL-4007 o Low Low Level in 100-D241 . Close Condensate

from 100-D241

INTERLOCK I.O4O5

ITEM DESCRIPTION CAUSEo LAHH-4007 . High High Level In 100-D241 . Open Condehsate to

100-c142

INTERLOCK I.0406

ITEM DESCRIPTION CAUSE. LALL-4'l06 . Low Low Level in 100-C142 . Stoo 100-P142NB

INTERLOCK I.O4O7

ITEM DESCRIPTION CAUSE. LALL-4103 . Low Low Level in 1OO-D242 . stop

Close100-P1434/8

CondensateD242

Excessfrom 100-

INTERLOGK I.O4O8

ITEM DESCRIPTION CAUSEo tALt-4202 . Low Low Level in 100-T141 e Stop 100-P141NB

INTERLOCK I-0409

ITEM DESCRIPTION CAUSE. LALL-4204 . Low Low Level in 10Q-4142 ( o Stop 100-P145


rúJ

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TECllldlP ITALY $.p,4,

wq.2121- SABIC ACETIC ACID PROJECT

Page 3-79

!rúttgcfffifp

'ANBU - KTNGD.M oF .AUDTARABTA 4 r 1,,*, 1,,, ,r,,J

*mMr*

INTERLOCK I.O41O

ITEM DESCRIPTION CAUSE. LALL-4201 o Low Low Level in 100-4141 o Stop 100-P144

INTERLOCK I.O4IIA/B

ITEM DESCRIPTION CAUSEo VAHH-40014/B . High High Vibration in 100-

E241MNB. stop

Motor100-E241MA/B

INTERLOCKI-O412NB

ITEM DESCRIPTION CAUSEo VAHH-4101NB . High High Vibration in 100-

E242MNB. Stop 100-E242MNB

Motor

INTERLOCK I-O5OI

ITEM DESGRIPTION CAUSE. LALL-5005

o LALL-5006

o LAHH-5302

. Low Low Level ln 100-T151A

. Low Low Level In 100-T1518

. High High Level In 100-T153

. Stop 100-P151A/B

INTERLOCK I.O5O2

ITEM DESCRIPTION CAUSE. LALL-S101 . Low Low Level ln 100-T152 o Stop 100-P152

TEGHI{IP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

q- , . Prq.2121- SABIC ACETIC ACID PROJECTEC}F}IU|';}Fsv'

" 'rgt YANBU - KTNGDoM oF sAUDr ARABTA ,, 4Jrl ,,,,, &,1Page 3-80

TECXHIP ITALY $,p.4. mmMre*

INTERLOCK I-0503

ITEM DESCRIPTION CAUSE. LALL-5303 . Low Low Level ln 100-T153 o Stop 100-P153A/B

INTERLOCK I.O5O4

ITEM DESCRIPTION CAUSEo P152M-0000XL . 100-P152 Stopped o Shut Valve From 100-

T152 To 100-C132

INTERLOCK I.O5O5

ITEM DESCRIPTION CAUSEo LALL-S105 . Low Low Level in 100-D251 . Stop pump 100-P156

INTERLOCK I.0506

ITEM DESCRIPTION CAUSEo LALL-5401 i Low Low Level in 100-4151 . stop

NBpump 100-P158

INTERLOCK I-0507

ITEM DESCRIPTION CAUSEo LALL-5402 o Low Low oil Level in 100-A151 o Stop Fump 100-P159

INTERLOCK I.O5O8

ITEM DESCRIPTION CAUSEo LALL-5403 . Low Low Level in 100-4152 . Stop pump 100-P157

NB

TEGHI{IP ITALY S.p.A. - 00148 ROMA - Viate Casteilo deila Magtiana, 68

Ptoj.2121- SABIC ACETIC AC|D PROJECT


Page 3-8f

1,1 ,,,ffiffiWrymTECl.llt I P ITALY S,p,A,

TNTERLOCK t-0601/0602MAIN BURNERS SHUTDOWN & PILOT BURNERS SHUTDOWN

ITEM DESCRIPTION CAUSEuA-6151 o 100-H161 Burners Tripped . Close Ethane Fuel

Valve To 100-H161. Open Purge Gas Fuel

Valve To Flare. Close Fuel Block

Valve To 100-H161. Open Fuel Bleed

Valve To' SafeLocation

. Close Fuel BlockValve To 100-H161

o Shutdown 100-H161Via BurnerManaqement Svstem

PAHH-6153

PALL-6157

PAHH-6162

TAHH-6160

TAHH-6162

FALL-6155A

PALL-6161

HS-6154

High High Fuel Pressure100-H161Low Low Fuel Pressure100-H161High high Pilot FuelPressureHigh High Temperature100-E363High High Flue GasTemperature Exit 1 00-H1 61Low Low Steam Flow from 100-E363Low Low Pilot Fuel GasPressureFired Heater Emergency Stop

To

a To

Exit

Gas

Close Ethane FuelValve To 100-H161Open Purge Gas FuelValve To FlareClose Fuel BlockValve To 100-H161Open Fuel BleedValve To SafeLocationClose Fuel BlockValve To 100-H161Shutdown 100-H161Via BurnerManagement SystemClose Pilot BurnerBlock Valve To 100-H161Open Pilot BurnerBleed Valve To SafeLocationClose Pilot BurnerBlock Valve To 100-H161. UA-6153 . 100-H161 Pilot Burners Tripped e Close Pilot BurnerBlock Valve To 100-H161

. Open Pilot BurnerBleed Valve To SafeLocation

TEGHNIP IrALY s,p.A. - 00148 ROMA - Viate casteilo deila Magtiana, 6g

ftcfiníp ;H1;-"#:,;::^il,:-'r--îtrrmflffi

Page 3-82

TESI{NIP ITALY $,p.4.

..4lJt 1,,.n 1,,..,il n,,f

kmMrem

TNTERLOCK t-0601/0602nr4tN BURNERS SHUTDOWN & ptLOT BURNERS SHUTDOWN

ITEM DESCRIPTION CAUSEr Close Pilot Burner

Block Valve To 100-H161

INTERLOCK I.0603

ITEM DESCRIPTION CAUSEo TAHH-6103 . High High Temperature Exit

zM-6101o Shut HP to MP Steam

Letdown Valves. Close BFW to MP

Desuperheater((ZM-6101)

INTERLOCK I.0604

ITEM DESCRIPTION CAUSEo TAHH-6107 . High High Temperature Exit

zM-6105o Shut MP to LP Steam

Letdown Valveso Close Condensate to

LP Desuperheater(zM-6105)

INTERLOCK I.0605

ITEM DESCRIPTION CAUSEe LALL-6003 o Low Low Level In 100-D261 . Close Blowdown

Condensate Valve Exit100-D261

INTERLOCK I.0606

ITEM DESCRIPTION CAUSE. PALL-6508 . Low Low Pressure of

Instrument Aire Close instrument Air to

Hose Station




Page 3-83

,,, *Jl n ,lmmWremTECHHIP ITALY $.p.4,

INTERLOCK I.0607

ITEM DESCRIPTION CAUSEo PALL-6508 . Low Low Pressure of

Instrument Air. Close instrument Air to

Hose Station

INTERLOCK I.0608

ITEM DESCRIPTION CAUSEo LALL-6006 . Low Low Level in 100-D263 . Stop Export LP

Condensate Pump100-P1624/8

. Close ExportCondensate Valve

INTERLOCK I.0609

ITEM DESCRIPTION CAUSEo LALL-6009 . Low Low Level in 100-D262 o Close MP Condensate

Exit 100-D262

INTERLOCK I.O7O1HP NITROGEN FOR EMER. S/D

ITEM DESGRIPTION CAUSEo ZSH-7001 . High Limit Switch On Valve Exit

1OO-D274 {Flushing Line} (FuilyOpen)

. Open HP NitrogenShutdown To 100-M111

INTERLOCKI-0702NITROGEN COMP. LOGIC SYSTEM

ITEM DESCRIPTION CAUSE. PALL-7013 . Low Low Pressure Exit 100-

D274 (47 barg)o Start Duty HP Nitrogen

Compressor

o PAHH-7013 . High High Pressure Exit 100-D274

. Stop HP NitrogenCompressor 100-J171NB

H5-7006

PAHH-7013

a

a

a

a

100-J171 Emergency S/D "ccr"High High Pressure in 100-D274

. Stop HP NtrogenCompressor


?bcfiníp----..il*f

TECHHIP ITALY S,p.A,



Page 3-84

4.rl ,,,*mwm*

INTERLOCK I.O7O3

ITEM DESCRIPTION CAUSE. PDALL-7016 . Low Low Differential Pressure

Across XV-7006. Open/Close Nitrogen

Feed Valve to 100-D274

INTERLOCK I.O7O4

ITEM DESCRIPTION CAUSEo PDALL-7009 . Low Low Differential Pressure

Across PV-7004r Close HP Nitrogen

Valve Exit 100-D274 to100-D276

3.2.8 Heating of the Reactor Steam System

. Fill the Reactor Shell and Stream Drum with cooled boiler feed water.The Boiler Feed Water is fed from battery limit via the ReactorCirculation Cooler 100-E121. This cools the water to 46"C. The steamdrum is to be filled via the reactor risers.

. Start the Start-up Circulation Pump that shall be kept in operation

. Start blowdown.

o Introduce steam to the Sparger. HP Steam shall be injected into thecirculation water to provide heating

. Follow and lead all these operation by the heating/cooling modecontrol already described.

o Monitor heat-up rate and control at approximately 1s'C/h to a nominaltemperature of 220'C. Vent the steam drum inerts during the start ofthis period and keep costant level in the steam drum by drawing offcondensate, when necessary.

o Reactor temperature is adjusted by the pressure control on the steamdrum following the 3 control element control already described.

3.2.9 Garbonate Girculation - CO2 Removal System Pre Start Up

The CO2 Removal System is charged with a small stream of recycle gas.

. The carbonate solution is circulated between the absorber and theregenerator.

TECHNIP ITALY S,p.A. - 00148 ROMA - Viale Castello della Magliana, 68

lrl ,,,TECHHIP ITALY $,p,4, ffiffiWrym

. Dose anti-foam chemicals, as recommended by Licensor.

. The reboiler 100-E142 and the air coolers 100-E241 and 100-É242 are inservice, ensuring the normal operating conditions within the system. Keepunder hot circulation using import steam in the reboiler, following Licensor'srecommendations / limitations regarding hot stand-by operation

The system is then ready to accept aCO2 rich gas stream.

3.2.10 Start-up Recycle Gas Compressor and Gycle Gas



Page 3-85

r Establish a demineralized water level in the Scrubber via the 100-D233.

r Start the cooling water supply the coolers equipped for Recycle GasCompressor to dissipate the heat input of the compressor and from the gaseventually passing through the heated reactor.

o Start the compressor at 7 bargand establish circulation.

. Pressurize the cycle gas to half-normal operating pressure (12bar) byusing nitrogen from start up line.

3.2.11 Product Recovery and Purification

Prior to starting feeds to the reactor, the scrubber and the downstream distillationcolumns must be operating at or near to normal conditions as a water operationwill allow. So, lead the following instructions.

o After having precommissioned Dehydration, Stripper and Productcolumns including cleaning by water, isolate the Product Column,drain and purge with nitrogen.

o Operate the Dehydration and Stripper columns on total reflux usingwater after purging.

o Operate the Dehydration and Stripper columns.on total reflux usingwater after purging.

o Add Butyl Acetate to achieve the normal reflux composition in theDehydration Column.

. Feed water from the aqueous phase of the Decanter to the Stripper,then boil-up and strip the butyl acetate and recover in the overhead ofthe Stripper.


Pîot.2'121 - SABIC ACETIC ACID PROJECT

YANBU - KINGDOM OF SAUDI ARABLq

Page 3-86

TEGXf*IF I?ALY $.p,4.

. Feed water from the bottom of the Stripper to the Scrubber FeedWater Drum, and then from the Scrubber Feed Water Drum to theDehydration Column.

. Adjust circulation rate to close to normal flow to the DehydrationColumn.

. Keep the Product Column isolated and purged (with a nitrogenblanket) until crude Acetic Acid is available from the bottom of theDehydration Column.

3.2.12 Heating of Ethane Feed System

Zinc Oxide Vessel 100-D111 NB and connected equipment must beheated up to normal operating temperature before starting the ethanefeed.

o 100-H211 is provided to heat the ethane feed to the reactiontemperature. Ensure 100-H211 is commissioned.

. Replace nitrogen with ethane.

o Pressure-up the circuit.

. Ad:iust the set point of the temperature controller TIC-1112 at the outlet ofheater 100-H211 to avoid an excessive temperature increase in the reactorbeds, which should not exceed 25 "C per hour.

o Warm-up the Zinc Oxide catalyst to approximately 250'C. Monitor thetemperature to the Fresh Feed Compressor.

A few hours before the Reactor system is ready to receive ethane feed:

o Make sure the first zinc oxide vessel inlet temperature is 370 'C.

. Pressure up the circuit by introducing the ethane.

e Introduce the process HP steam.

. Monitor the sulphur content of the effluent.

. When sulphur content specification is achieved, gas is ready to be fedto the Reactor System and desulphurized ethane is ready to be usedas Fuel Gas to Fired Heater.

* tl t,t*mW*

TEGHNIP ITALY $.p.4, - 00148 ROMA - Viale Castello della Magliana, 68

TbchnípPtot.2121- SABIC ACETIC ACID PROJECT


Page 3-87

4-rl ,,,*mMr*TEeX*lP ITALY $,p.4.

3.2.13 Ethane feed

. Open the isolating valve of the desulphurisation section from the loopand gradually feed Ethane to the loop and raise the pressure to thenormal operating level. (24.6 bara at inlet to compressor)

. Keep hydrocarbon concentration in cycle gas loop 50%.

. Keep Ethane concentration to that of PFD at all times by introducingLP nitrogen flow to 100-J111, as necessary. (Ethane mol%=46.4 andNitrogen molo/o=23.7 at Reactor inlet).

o Ensure the Reactor and cycle gas loop pressures are slightly same(equalised via the bypass around the Reactor inlet block valve.Confirm that FV-1406 is open and then open the by pass Reactor inlet

pressure, close FV-1406 and open the Reactor outlet hand controlisolation valve fully ZV-1403.

Introduction of the qas to the Reactor

. Introduce gas to the Reactor slowly to a maximum of 1/3 normalvolume flow. To achieve this, slowly open the reactor inlet flow controlvalve FV-1400 and also close the Reactor bypass valve FV-1302.

. Keep the reactor at 220 "C by injecting more steam as required.Maintain steady Reactor and interchanger temperature profiles.

. Set Steam Drum pressure control on automatic with the set point atnormal operating pressure, putting the control valve PV-2101 inautomatic position and controlling the steam drum pressure by PV-2101.

. Check the ethane content in the recycle gas reaching and then keepingconstant at 30 % by volume.

. The oxygen analyser on the Reactor inlet trip point to be set al3o/o


Techníp---.{.nrdw

TECHFIIP ITALY $,p.4,

3.3 START.UP



Page 3-88

1,1 '-,*mM*

This paragraph describes the procedures for starting up the various sections ofthe plant and the relative sequence.It is assumed that all utilities are available in the plant and that the controls of theutility section are in service and functioning correctly (Pre Start-Up is completed)

All testing and preparatory procedures as specified in previous chapter must becompleted before plant start-up.

At this point the condition should be as outlined below:

- the recycle gas compressor is running, with the total gas flow recycledthrough the reactor by-pass;

- the reactor steam generation systems are filled with heated boiler feed water

- the Scrubber 1OO-C131 is in operation, with the normal operating flow ofwater fed from the Scrubber Feed Water Drum 100-D231;

- the Dehydration Column 1OO-C132 is in operation at its normal operatingpressure, running with the water transferred from the Scrubber 100-C131.The water collected into the Decanter 100-D232 is partially refluxed to thecolumn 100-C132 and partially is transferred to the stripping column 100-c134:

- the Product Column 100-C133 is isolated and purged (with a nitrogenblanket) from the closed circulation loop and it is operated separately atnormal operating pressure;

- the CO2 Removal System is ready to use, pressurized with the recycle gasand with the carbonate solution kept in circulation between the regeneratorand the absorber, at the normal operating conditions;

3.3.1 Start Up Oxygen Feed

(a) Start Oxvqen Feed and Adiust the Reaction

, Flush 100-M111 through the HP Nitrogen Start-up line from100-D274.

o After the purge is complete introduce oxygen at the minimumcontrollable rate and record the time from injection of oxygen until areading is shown in the DCS (should be less than 20 sec).

r Monitor the Reactor temperature keep a max of 15'C differencebetween peak temperature and steam temperature in the shellside.

TECHNIP |îALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

fficfinípPage 3-89

TECIIHIP ITALY $.p,4.


YANBU - KINGDOM OF SAUDI ARABIA 4 ril, ,,, ,f,**,r

*mwm*

. Adjust the oxygen flow and reactor feed rate not to exceed thistemperature difference.

. Slowly aim for an oxygen concentration at the Reactor inlet of 2o/o

maintaining the same tenor of ethane. lf the oxygen concentrationreached 3o/o an oxygen shutdown is activated.

. Watch for signs revealing the reaction is started, i.e. change in ethane/ oxygen concentration between inlet / outlet of reactor, increase ofpressure into the steam drum, slight increase of the temperature atreactor outlet.

. When the starting of the reaction has been confirmed, bring up slowlythe recycle gas to the reactor up to the 50 % and increase slowly theflow of ethane feed to get the ethane concentration of 46.4 o/o at theinlet of reactor

o Enable the increasing of the steam generation temperature up to thenormal condition (at Start of Run about 256 'C), and adjust thesteam drum pressure in order to maintain, at the reactor outlet, atemperature equ?l to 258'C.

. As the reaction will become self sustaining the start-up steam can begradually reduced until complete shut off.

. Increase the oxygen and reactor feed flow rates to the reactor up tonormal operating levels. The Reactor bypass should now be fullyclosed.

. The Reactor temperature difference should be monitored during thisoperation.

o Change the oxygen analyser range reading at low scale.

. During this phase monitor continuously the oxygen concentration inthe recycle gas to avoid that it overcomes the maximum permitted.Consider that at start-up the trip set of maximum oxygenconcentration is equal to 3o/o by volume.

(b) Increase Oxvoen Feed

r Once the system has stabilised, increase the oxygen flow tothe normal operating conditions.

. Increase the oxygen concentration up to 5% at the inlet of thereactor.


1,1 ,,,mmW**

Lead smoothly the reaction until the temperature in the steam drumreaches the operator set temperature target (nominally 220 "C).When the temperature reaches this value and the Reactor startstransferring heat into the coolant after oxygen feed started and plantload reach more than 80%, the Start Up Circulation pump can bestopped and the HP Steam isolated.

Start blow down system.

Monitor the acid concentration in the Scrubber overhead.

Route purge gas to the fired heater. (Desulphurized ethanedisplace the raw ethane)

As the reaction proceeds, the CO2 and other inert compounds build-up into the system and when their concentrations reach the normalvalue the reaction can be considered in steady state condition.

Increase the flow of recycle gas to the CO2 Removal System up todesign flow, in order to maintain constant the CO2 concentration inthe gas.

Ptq.2í21 - SABIC ACETIC ACID PROJECT


Page 3-90

TECHI-|IP ITALY $.p,4,


91

TECIIHIP ITALY $,p.4,


YANBU - KINGDOM OF SAUDI ARABIA 4 'Lr nr

*mfum*

3.3.2 Reaction Tuning

. When the reaction is stable the following conditions should be reached andobserved:

o The gas analyzers must be under continued surveillance and they must bemaintained properly. All analyzer including the stand by analyzer should online all the time.

r The reactor can be operated safely and efficiently only when dependable gasanalyses are available.

. Oxygen feed should never be increased in such large steps that itsconcentrations increase rapidly (rate of change on oxygen line).

. Remember that there is a time lag in the response of gas analyzers andhence a rapid increase in feed may result in actual concentrations that areconsiderably higher than the analyzer readings"

o lt should be realized that any sudden change in selectivity or conversion willnoticeably change the ethane concentration, oxygen concentration and/orgenerated steam flow. Therefore, if analyses indicate substantial changes inselectivity and conversion without these features, the analyses should berechecked after the calibration check of the gas analyzer.

r Monitor closely the composition of the circulating gas, adjusting thecoolant pressure, ethane feed and HP nitrogen make-up asnecessary.

r As operation stabilises switch loop controls to automatic and increaseflowrates towards normal.

. Route the HP steam from the steam drum to the HP header (via thesuperheater coils). The HP lmport can be closed when the steamgeneration is sufficient to cool the superheater coils. The superheatercoil exit temperatures should be monitored for this purpose

Parameter Reactor lnlet Reactor OutletEthane Concentration o/o vol. 46.4 44.8Oxvoen Concentration o/o vol. 5.0 1.3CO2 concentration o/o Yol. 5.2 6.2Temperature oC 225 258


?3cfiníp

TECIIHIP ITALY $,p,4. mmW*

3.3.3 Product Recovery and Purification

o When Acetic Acid is produced and fed to the Dehydration Column, the acidwill collect in the column bottoms and displace water.

o As the Acetic Acid is separated and begin to accumulate in the bottom ofcolumn, the boiling temperature in the reboiler begins to increase. This is thesign of a composition change in the column.

. The accumulation of Acetic Acid in the lower section of the column will causethe increase of liquid level.

. Adjust the butyl acetate rate to maintain the organic reflux / aqueousoverhead ratio.

. ln the beginning the high level in the Dehydration Column 100-G132 shouldbe send to Off Spec Tank T152.

o When temperature at the control point reaches set point and the analysisshows no butyl acetate or water, start taking bottoms to the Product Column.

. So, the crude acid pump 100-P132 NB should be in operation to transfer theproduct formed to the subsequent column 100-C133. At this time, in such away, water present in the bottom of the dehydration column will be totallydisplaced to the Product Column 100-C133 by the acetic acid coming fromthe scrubber.

. When the acetic acid product begins to be fed to the product column 100-C133, the temperature profile in the column slowly increase.

. The acetic acid is recovered in the reflux drum, together with the water initiallypresent for the water running. The increase of level in the drum 100-D233 willrequire the transfer of the product to the storage. Due to the water content,this product needs to be collected into the Off-Spec Tank 100-T152 and shallbe reprocessed later in the dehydration column.

. Frequent analysis of acetic acid product shall be conducted in order to checkits quality and to verify if it meets the required specifications. When thishappens, the product will be routed to the Shift Tank 100-T151 A/8.

o At this time put normal control scheme on automatic.



Page 3-92

,,tJl , u


&c*ttíp-_r,f.ffiF

TECilFIIP ITALY $,p.4.



Page 3-93

tJl"*, -.1

*mM*,

3.3.4 GOz Removal System

Make sure the system is filled with CATACARB solution as per spec. and setup flow above 50o/o of the design.

Heat the system to boiling through 100-E141. Introduce makeup water asnecessary to keep a stable solution level at the bottom of 100-C142.

Switch on 100-E241 and start collecting water in 100-D241. Later start 100-P143 for condensate return and bleed.

Start injection of antifoam, as needed. (Expected injection rate. 10 ppm perday during startup, 2-4 ppm during normal operation).

Slowly introduce gas to 100-C141 in order to allow gradual buildup of. operating pressure. Then, increase the gas flow to 50% of design. (To avoidbed churning, feed should be raised gradually, say around 10-15 MT/Hr.

', Start cooling water to 100-8242 and collect condensate in 100-D242. As thelevel builds up in 100-D242, operate level control .to deliver condensate to100-c142.

Adjust the solution circulation to design.

Increase gas flow to 100-C141 to full capacity.

Introduce additional solution to offset the solution held up in packed beds.

Adjust the solution circulation and 100-E141 duty to achieve normaloperation.

Bleed 10-20o/o of inventory if heat stable salts exceeds 2.0 N and makeupwith fresch solution.


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3.4.1

3.4 NORMAL OPERATION

When the plant is operating normally, conditions should exist essentially asdescribed in the following paragraphs. At the end of this section is a tabulatión otkey operating parameters with the designation of the corresponding recordinginstrument and alarm settings.

During normal operations, the operators will function as observers who will watchover the plant, act in the event of emergency, and forecast and attempt toeliminate possible troubles. ln order to keep the plant running smoothly, it isimportant that the operators not only continuously check tÈe control roominstruments, but also regularly check the reading of all local instruments and thefunctioning of all equipment in the field. lt is highly recommended that theoperating personnel be required to keep a detailed log, including a periodicrecord of the values of all the process variables. The act of noting and recordingensures that the operators will take notice of operating variabies which mayothenrise be neglected. ln some cases it may not be possible to have all thecontrol instruments on automatic. However, as the various parameters line out,the instruments should be put on automatic control.

In the following paragraphs it has been identified the most important parametersto be controlled by the operators to ensure a safe and profitablé operation of theplant.

Ethane Feed Preparation

a) HP steam flow rate to ethane feed

Ethane feed contains sulphur compounds (coS and H2s) that areremoved in the Zinc Oxide Vessels 100-D111NB to prevent poisoning ofthe catalyst and to satisfy environmental concerns in the effluent streams.Sulphur removal is achieved by hydrorysis of the cos to H2s at hightemperature over a zinc oxide bed, followed by reaction of the H2S over asolid ZnO absorption stage.

HP steam is added to the ethane feed downstream the'exchanger 100-E111NB for COS hydrolysis. The flow rate of steam, controlled by FIC-1101, acting on the corresponding control valve FV-1101, is calculaied bythe mass flow controller ratio FFIC-1101 ethane process / steam fixed to220, based on the ethane feed.HS-1120 gives the possibility to change the points on which control theethane process flow from the suction of 1 00-J 1 12 or from ethane meteringstation"The desulphurised feed is cooled in the Ethane Feed Interchanger andEthane Feed Cooler. 100-E113.

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TECHl*Xlp IT&LY $.p.4, mffiffimThe feed then passes via the Fresh Feed Filter, 100-F1 11NB., to the FreshFeed Compressor, 100-J111N8. Operator has to check carefully plC-1202, setted at 241 barg, acting on the corresponding control valùe pV-1202 control pressure discharge of the 100-J1 11N8.When the suction filter 100-F1 11NB got planned switch to the clean one,after having it purged with Nitrogen.

Significant changes of COS in the ethane feed may require to adjust thesteam rate accordingly. Periodic comparative analysis of the ethane feedupstream and downstream the Zinc Oxide Vessel will give evidence of theneed to increase the steam flow rate.

b) Zinc Oxide Vessel Inlet Temperature

The desulphurization temperature has been fixed to 370 oC, constant alongthe catalyst cycle length. The temperature is controlled by TIC-1112 whicÉpasses its controller output to the control system of the electric heater. Theselected temperature ensures the best catalyst performances. Reduction ofthis temperature may cause inadequate removal of sulphur compounds inthe feed and potential condensation of steam .inside the catalyst, whilehigher temperature may cause damages to the catalyst.The catalyst life is of one year.Sampling facilities are provided to analyze the concentration.

3.4.2 Reactor System

The following considerations apply to both Conventional Reactor System andSABOX Reaction System, and to the common recycle gas ioop.

a) Ethane concentration in reactor feed

The flow rate of ethane supplied to the reactors system is controlled byFIC-1301, adjusting the control valve FV-1301, installed downstream thèfeed compressor 100-J111NB and upstream the mixing with the recyclegas.Flow rate and concentration figures are listed below, with reference to thematerial balance stream labels:

Parameter Stream SOR EORElhqte flow rate (ethane 94,1+94,3o/oMot) Ks/h 103 3382 3960Ethane concentr. at reactor inlet o/ornol 112 46,4 48,5Ethane concentr. at reactor outlet o/orrrol 201 44.8 46.5Total gas flow at conventional reactor inlet KmoUh 112 4955.5 4954,2

Data shown on this table are referring to the same production rate of aceticacid, independent of the SOR / EOR cases.



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As shown in this table, the ethane consumption will increase along thecatalyst cycle length, due to the reduction of the catalyst selectivity and thesubsequent increase of by-products formation. The reduction of theselectivity is dependent on the reaction temperature, whích is increasedalong the catalyst cycle-length to sustain the catalyst conversion which,otherwise, will decrease giving a lower acetic acid (and by-products)throughput.Following the explosion range of ethane/oxygen/nitrogen mixtures atvarious temperatures and pressure it is easy to understand that theexplosivity area depends by temperature and pressure.For the purpose to keep the mixture outside explosivity limits is important tocontrol and monitor maximum oxygen and minimum nitrogen concentration.

b) Oxygen concentration in reactor feed

Oxygen is supply at battery limit at ambient temperature and 27.9 barg. Thepressure is increased by the 100-J1'l3A/B oxygen compressor to 40 bargto fullfill the demand of the Static Inline Mixer 100-M1 1 1.PIC-1417 controls the pressure acting on the valve PV-1417 l(recycling).operator should keep the pressure on plc-1417 (Dcs) at the normaloperating value.

The flow rate of the oxygen added to the reactor feed is controlled by FIC-1402 adlusting the control valve FV-1402, instailed on the oxygen supplyline upstream of the In-Line Mixer 100-M111.

Flow rate and concentration figures are listed below, with reference to thematerial balance stream labels:

Parameter Stream SOR EOROxygen flow rate Kq/h 105 5941 7728Oxygen concentr. at conventional reactor o6mol

inlet112 5,0 5,0

Oxygen concentr. at conventional reactor %omoloutlet

201 1,3 0,2

Total gas flow at conventional reactor inlet Kmol/h 112 4955.5 4954.2

The sABox Reactor is fed with additional oxygen supplied throughseparate line. Therefore the oxygen concentration at its outlet is higher thanConventional Reactor one.

As shown on this table, the flow rate of oxygen added to the recycle gas iscalculated in order to maintain an oxygen content, at reactor inlet, equal to5 % mol.

The operation with higher 02 concentration is severely restricted by thepossibility of explosion.

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The maximum allowable 02 concentration must be calculated regularly,based on the actual cycle gas composition, and it must be verified that theoxygen concentration is below that value.

Static lnline Mixer 100-M111

oxygen and ethane feed are mixed in 100-M111 that is provided to improvethe homogenous merging of the two feeds to avoid definitely localdangerous concentration in the reactor feed.At the mixer outlet line the analyzer is provided to check the reactor feedgas composition to avoid the explosion range mixture.sampling should be performed on shift basis to reconfirm the on-lineanalyzer data.

Flammable Equation

The flammability limits (lower explosion limits) of gas mixtures the mayoccur in the BoX process are studied in a specialized and produced datawere regressed in order to develop a flammability equation. Such equationwill facilitate quick prediction of the critical oxygen concentration in aspecific gas mixture.

The experimental study was built on the assumption that all fuels in thereacting gas mixture (combustibles such as ethane, ethylene and carbonmonoxide) could be treated as a one lumped as a pseudo-component.while all non-combustibles (such as nitrogen, water and carbon dioxide)could be treated as inert. Those assumptions have been verified during theexplosion limit testing studies.

The range of conditions tested in the experimental study is as follows:

Temperature, C 25.0-270.0Pressure, barg 1.0-40.0Fuel concentration, oó 13.2-82.0lnert concentration, o/o 9.0-85.4

Table (1) provides the data sets compiled from the experimental programand used for regression analysis to develop the flammability equation.

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Table (1): Experimental Flammability data

T P (bar) Fuel% Inert 02%o/o

240 13.6 46 42.7 11,3240 13.6 72 14 14240 30.6 67 26.1 6.9240 30.6 82 9 I270 13.6 48 41.1 10.9270 13.6 74 13 13270 30.6 64 28.4 7.625 1 13.2 68.6 18.225 10 19 64 1725 20 24.1 601 15.925 30 31.5 54.1 14.425 40 36.6 50.1 13.3240 22 64.6 25 10.4270 22 66.4 25 8.6

The regressed flammability equation, which describes the maximum safeoxygen concentration as required for plant operation is as follows:

Lf (02, o/ov)- 19.4- 0.035 *T-0.2*P + 0.065*Fuel - 0.002*lnert

Where,

Lf is the lower flammability limit, Oxygen volume percentageT is the gas mixture temperature in deg. C.P is the gas mixture pressure in bar gaugeFuel is the lumped fuel concentration, volume percentlnert is the lumped inert concentration in volume percent.

The operation with low 02 concentration may cause reduction in yield,particularly at high production rates.

Once stable operation has been attained, it will only be found necessary tooccasionally change the flow of feed. Changes in the feed should be madeslowly in order to avoid rapid or large changes in concentrations.

c) CO2 concentration in reactor feed

CO2 concentration in reactor feed line should be at 5.1o/o mol. This isprovided by either the CO2 Removal System By-pass than the control ofthe right operation condition in the CO2 Removal System.Sampling should be performed on daily base to confirm the COzconcentration in line to Recycle Gas K.O. Drum 100-D211 (less than 2.5mol% of CO2).


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*mwm*Nitrogen feed control in cycle gas

The purpose of nitrogen feed to the recycle gas loop is to keep aconcentration (partial pressure) of inerts far away from explosive / ignitionmixture.Nitrogen is used (at B/L condition about 31 barg) to keep control of inerts inrecycle gas (thus to the reactor feed) and it is controlled by the use ofvafve Fv-1312 with 97kg/hr (normal operation). This is based on the on-lineanalyzer reports . Operator should adjust needed nitrogen flow (FlC-1312)by the informations getting from analyzer.

HP Nitrogen control

1OO-D274 HP Start-up Nitrogen Vessel and 100-D276 HP Nitrogenemergency Shut-down Vessel should be pressurize at 60 barg. Operatorhad to check and to make sure that the HP Nitrogen compressor is in standby and the selector switch is in automode, remembering that PALL-7013gives run signalto the HP Nitrogen Compressor Driver.

Reactor Temperature

ln boiling water cooled reactors the temperature in the catalyst bed is closeto the saturated steam temperature at the pressure on the reactor steamdrum. An increase in steam drum pressure will tend to increase the reactiontemperature and vice versa. The pressure adjustments on the steam drumare done in very small steps of 0.3 Bar ( about 0.5 'C).

Remember that the heat of reaction is removed by raising steam in theshell side of the reactor and that water circulation is by thermosyphonaction.The reaction temperature is controlled by adjusting the steam pressure inthe Reactor Steam Drum 100-D221. This is accomplished by PIC-2101A/8,setted at 41.10 barg, which regulates the control valve PV-2101 on thesteam drum exit.Three elements are necessary to control the steam Drum 100-D221waterlevel:

. Steam flow measurement Fl-2101

. BFW flowrate measurementFlC-2102

. Steam drum level controller LIC-2101

The control strategy accounts for changes in any of the threemeasurements.It is a cascade control structure where the steam drum level (LT-2101) isprimary loop and the BFW flow s the secondary loop.

d)

e)

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The steam flowrate is a direct feed fonruard signal to the BFW control loop.since the steam flow is equal to the feed water flow (less continuousblowdown), the BFW control loop compensates immediately for changing insteam demand. The steam drum level loop modulates the feed water flowto compensate for shrink, swell and lags in the process. In other words,water level in the steam drum is controlled by Llc-2101, which adjust theboifer feed water flow rate sent to the steam drum 1 00-D221.

The following parameters affect the reactor temperature:

- Catalyst Activity and Temperature Range

Catalyst activity will very slow decrease with time due to trace impuritiesin the oxygen and ethane feeds, wear of active surfaces, etc.Temperature is increased with time to compensate for losò of catalystactivity with age, and this is generally done in very small increments. Anincrease in reactor temperature increases catalyst activity when all otherconditions remain constant. under a given set of conditions, thetemperature will, of course, be kept constant for long periods of time.

Steam generation temperature for Conventional Reactor System will beabout 255 'qC (42.2 Barg) at SOR and 27e'C (54,1 Barg) at EOR.

For sABoX Reactor System the steam generation temperature will beabout 252?C (40.1 Barg) at SOR and 260'C (45.9 Barg) at EOR.

changes in temperature should be as small as possible, in the order of0,5 'c. After making such a change, the r,eaction system should beallowed to equilibrate before further adjustments are contemplated.

- Conversion and Selectivity

conversion is defined as the percent ethane reacted compared to thetotal ethane fed to the reactor. Selectivity is defined as the percent aceticacid formed compared to the ethane reacted.

The conversion of ethane increases by increasing the reactortemperature: this means that at given concentrations and conditions, theamount of ethane reacted to form acetic acid and other side productsper pass through the reactor can be increased operating at highertemperature in the reactor, i.e. operating the steam drum at higherpressure.

The selectivity to form acetic acid decreases by increasing the reactortemperature. This effect is opposite to the increasing of conversion. Thismeans that an increase in temperature will cause the increase of ethanereacted but a portion of this over consumption of ethane will give higherconcentration of undesired side-products.


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From an economic point of view it should be desirable to maximize theacetic acid production with the maximum yield, which means maximumconversion together with maximum selectivity. unfortunately theoperation at high conversion will reduce selectivity, i.e. a greater amountof ethane is "lost" in side reactions, with formation of by-products whichhave to be separated from the product itself.The activity of the catalyst is reducing with the age. In order to sustainthe conversion, the reaction temperature is gradually increased duringthe cycle length to counterbalance the loss of activity. The increasing o-freaction temperature cause a reduction of the selectivity, and a-t acertain point it will result convenient to replace or re-activate the catalystrather than to prosecute the operation with low acetic acid yield.

Remembering that

Gonversion = (mol Ethane reacted) / (mol Ethane Fed)

selectivity = (mol Acetic Acid formed) / (mol Ethane reacted)

conversion and selectivity for conventional reactor, for soR and EoRconditions, are shown in the following table.

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As shown in the above Table, the selectivity of the reaction should beincluded_in the range 62-74 % along the cycle length. Higher selectivityis ..not foreseen (it may reveal analyzer troublé), loùer selectivityindicates the catalyst is poisoned or aged, or a greaier amount of aceticacid is lost in heavies.

TABLE 3.1Reaction Conversion and Selectivity (100-R121)

SOR EOREthane in Feed Reactor Kmol/h 2.299,4 2.402Ethane Reacted Kmol/h 87,3 102,5

Acetic Acid Prod. Kmol/h 64,19 64,29

CONVERSION 3,gvo 4,3oSELECTIVIry 73,íVo 62,720/o

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- Hot spots

lf the temperature is raised too high, or too rapidly, it is possible todevelop "hot spots" in the reactor. "Hot spots" are characterized by asharp rise in the rate of steam production and co2 formatíon. ,,Hot

spots" are undesirable since they may cause local damages to the activecenters on the catalyst surface and very low overall selectivity and ashorter catalyst life result.

- Catalyst Life

operation at unnecessarily high temperatures may have an adverseeffect on catalyst life. Therefore the reaction temperature should bemaintained at the lowest temperature possible which still gives thedesired catalyst selectivity and conversion.

Effect of impurities on Acetic Acid Catalyst performances

Sulphur Compounds have deleterious influence on the catalyst and mustbe avoided.

The operator must pay attention to the analysis of the recycle gas and ifabnormal concentrations of any of these compounds are detected,corrective measures should be taken to avoid catalyst poisoning.

Recycle Gas Flow

The recycle gas flow through the reactors should be maintained constant,proportional to the acetic acid throughput (i.e. to the ethane and oxygenflow rates), in order to maintain the design composition at the inlèi ofreactor.When the plant is operated at reduced capacity the flow rate circulatedthrough the reactor could be less than required by the recycle gascompressor: in this case the anti-surge controller will open the reactor by-pass line establishing the necessary flow rate.

1 00-J1 12 Circulation Compressor

100-J112 is provided to pressurize the recycle gas from 23.40 barg to33.40 barg at the discharge.

Operator should carefully check

. Flc-1313 on DCS, acting on FV-1313, controlling in such a way Lpsteam producted in 100-J112T. This is because different on Lp and LLpsteam turbine outlet pressure and, of consequence, differenttemperature in a short time could be cause problems on the powerRPM of turbine. Thus, the compressor will fluctuate as well.


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r PIC-131 1 set at 23.40 barg acting on PV-131 1A controlling the suctionpressure of the 100-J112

o Tl-1304 suction temperature and Tl 1310 discharge temperature

. The value of PDI-1307A differential pressure indicator between suctionand discharge.

. Compressor 100-J112 is provided with the CCC antisurge system thatgovern the FV-1302 reactor by-pass valve in case of low flow isapproaching the surge point of the compressor.Antisurge system is also provided with signals to initiate oxygen cut offin case the compressor is continuing approach to surge point (FALL-1308) and subsequent trip of 100-J112 (FALL-1309).

Recycle Gas Purge

Inert compounds introduced in the recycle gas loop with the feeds orformed by side reactions tend to build up in the system and must bepurged. The purge is made upstream the Circulation Contpressor 100-J112and is sent as fuel gas to the Fired Fleater 100-H161. The purge flow rate isindirectly controlled by PIC-131 1 which adjusts the valve PV-131 1 .

Recycle Gas Pressure

The pressure in the recycle gas loop is controlled at the suction of theCirculation Compressor 100-J112 adjusting the recycle gas purge rate. Thispressure should be adjusted in order to maintain a constant pressure(equal to 33,4 barg) at the compressor discharge. Basically the pressure inthe recycle gas loop is kept at design level for each operating case, fromSOR to EO.R. Significant changes in pressure level will cause variation ofrecycle gas circulation rate and subsequent variation of composition of thereactor feed gas.

Steam Production

The partial oxidation of ethane to form acetic acid is exothermic and theheat of reaction is removed by vaporizing water in the shell side of reactor,resulting in a substantial production of steam.Carbon dioxide is a side-product formed by a complete oxidation of ethane(and other hydrocarbons present in the recycle gas), which is considerablymore exothermic than the primary reaction.The steam production is, therefore, a measure of the reaction rate andselectivity, and it responds very quickly to changes in reaction conditions.Hence, the steam production is one of the most important process variablesto be controlled continuously by the operators.A sudden cessation of the steam production may be caused by theinterruption of the reaction and, if it occurs, requires immediate emergencymeasures to avoid changes in composition of the recycle gas.


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3.4.3

3.4.4

A sudden increase in steam production can mean the formation of a "hotspot".

Steam production may give a measure of the selectivity of the reaction. Agradual increase in the steam production for a constant ethane feed rate,not accompanied by an increase of acetic acid production, means anincrease of CO2 formation and consequently a decrease of the selectivity.

Scrubber 100-C131

a) Scrubbing water

The flow of water should be adjusted to the normal design flow rate or togive an acetic acid concentration in the overhead gas not higher than 25ppm vol.At the scrubber overhead line analyzer house is provided to check thisoverhead gas.Sampling should be performed on a shift basis to reconfirm the on-lineanalyzer data.Operator should check:

o Pl-3003 pressure on overhead line (set at 26.5 barg)o Tl-3007 temperature on overhead line (set at 85"C)o Tl-3009 temperature on the bottom line (set at 85'C)

The feed water flow rate should not be increased above the design in orderto a avoid flooding.

b) Inlet Feed Temperature

The temperature of the feed to the scrubber should be maintained constanttrough TIC-3001 at the design value to obtain the desired condensation ofacetic acid before entering the column.

Dehydration Golumn 100-C1 32

a) Column Feed

The feed point is tray #27 . Trays #31, #37 ,1t41 are an alternate.Feed rate to the column (FlC-3102) is adjusted by the level controller LIC-3001 on the Scrubber bottom and cannot be fixed by the operator.


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*mW*b) Tray #68 Temperature

Tray #68 temperature controller TIC-3108 controls the column performanceso as to give design concentration of Acetic Acid in the bottom of thecolumn. Excessively high temperature can cause excessive Acetic Acid inthe column overhead. A low temperature on Tray #68 may increase thewater content in the Acetic Acid at the bottom.The temperature controller TIC-3108 resets the reflux flow rate throughFFIC-3016, acting on FV-3106: the increase of temperature at tray #68 willinduce an decrease of reflux rate and vice versa.

Reflux Rate

The aqueous reflux flow is maintained by the level controller of theDecanter 100-D232"The organic reflux flow is reset by the feed flow controller to the column andby the temperature controller on Tray #68. Basically the organic reflux flowrate is proportional to the feed rate and is tuned to meet the Tray #68temperature specification (i.e. product specification).

Reboiler Duty

The duty of the reboiler 100-E132 is adjusted by the flow controller on thesteam admission, which is reset by the feed flow controller. The condensingpressure is controlled by PIC-3111: that ensures the pressure will bemaintained constant also at low capacity, by submerging the reboiler tubes.

Crude Acetic Acid Rate

The Lottom stream, constituted by the crude Acetic Acld, is drawn off underbottom column level controller, which resets the flow controller on theproduct.At the bottom line analyzer house is provided to check this bottom stream.Sampling should be performed on a shift basis to reconfirm the on-lineanalyzer data.

Dehydration Column Operating Pressure

The operating pressure of the column is controlled by PIC-3106, located onTray #66. The distillation is enhanced by low pressure and the minimumworkable pressure has been assumed for the column design (vent gasesare routed to flare). The operation at higher pressure will result in a poorseparation water / acetic acid and should not be realized.

Condenser Temperature

The column overhead is partially condensed in the air cooler 100-E233,with the exit temperature controlled by TIC-3201 at the value of 85'C. Thistemperature level is sufficient to condense almost all the vapors.

c)

d)

e)

s)


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The vapors non condensed are routed to the Vent Cooler 100-E131 , cooledby chilled water, to recover as much butyl acetate is possible, by coolingthe vent gas to 26 "C.Operation at higher temperatures may cause loss of butyl acetate in thevent gas stream.

3.4.5 Product Golumn 100-C133

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Column Feed

The feed point is tray #18. Trays #14,#22 are an alternate.Feed rate to the column is adjusted by the level controller on theDehydration Column bottom and cannot be fixed by the operator.

Bottom Column Temperature

Bottom column temperature controller adjusts the draw off of heavyimpurities from the column, controlling the stroke of the Heavies pumps100-P133A/8. lts set point should be fixed to 174 'c. operation at lowertemperature will increase the loss of acetic acid in the bottom stream; Anincrease of this temperature will cause an increase of impurities in theProduct Acetic Acid from the top of column.

Reflux Rate

The reflux flow is reset by the feed flow controller to the column, in order tomaintain constant the reflux ratio. A lower reflux rate will cause poorseparation between acetic acid and heavy impurities. The operation with areflux rate higher than the design will increase the separation but will causean increase of steam consumption at reboiler.

Reboiler Duty

The duty of the reboiler 100-E133 is adjusted by the flow controller on thesteam admission Flc-3302, which is reset by the bottom column levelcontroller LIC-3301.The duty can be adjusted indirectly, if necessary, changing the set point ofthe temperature controller TIC-3305 at the reboiler inlet. A higher duty willcause an increase of impurities in the Product Acetic Acid while a lowerduty may increase the loss of Acetic Acid in the bottom of the stream.

Acetic Acid Product Rate

The distillate stream, constituted by the Product Acetic Acid, is drawn offunder reflux drum level controller. lts flow rate cannot be fixed because it isobtained by the mass balance of the column (the bottom stream is adjustedto meet product specification).

a)

b)

c)

d)

e)


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Product Column Operating Pressure

The operating pressure of the column is controiled by plc-3406, located onthe gas outlet from the reflux drum. The pressure is fixed at 0.4 Barg and ismaintained with nitrogen blanketing.There is no reason to operate at higher pressure since the distillation isenhanced by low pressure.

Condenser Temperature

The column overhead is totally condensed in the air cooler 100-E233, withthe exit temperature controlled by Tlc-3401 at the value of 110'c. Thetemperature should be maintained at this value: higher temperature maycause increase of condensing pressure, lower temperature will causeexcessive sub-cooling of the reflux and subsequenily an increase of thereboiler duty.

Stripping Golumn I 00-Cl 34

a) Column Feed

The feed point is at column top.Feed rate to the column is adjusted by the level controller LIC-3201 on theaqueous chamber of the Dehydration Column Decanter and cannot'befixed by the operator.

b) Column Overhead Temperature

The temperature controller T!C-3501, located on the column overhead,resets the flow controller Flc-3s01 that act on FV-3s01 on steamadmission to reboiler 100-E134. The set point of IC-3501 is 91 "c.

Lower temperature will cause a reduction of boil-up at the reboiler andsubsequently an ineffective recovering of butyl acetate from the aqueousstream. Operation with higher temperature will increase the water contentin the overhead vapors and will cause an higher steam consumption at thereboiler.

c) Reboiler Duty

The duty of the reboiler 100-E134 is adjusted by the flow controller FIC-3501 on the steam admission, which is reset by the temperature controllertic-3501 at column overhead.The condensing pressure is controlled by PIC-3504: that ensures thepressure will be maintained constant also at low capacity, by submergingthe reboiler tubes.

3.4.6


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***MrmThe duty can be adjusted indirectly, if necessary, changing the set point ofthe temperature controller Tlc-3501 at the column overheàd. A higher dutywill enhance the recover of butyl acetate, while a lower duty may result inan excessive loss of butyl acetate in the bottom aqueous stream.

ButylAcetate Recovery

Butyl acetate present in the aqueous phase fed to the stripping column hasto be recovered by stripping. The residual content of Butyl atetate in thestripped water must be less than 5 ppm vol. The specified recovery can beachieved by controlling the heat input to the column, i.e. the temperature ofthe overhead vapors.

Stripping Column Operating Pressure

The stripping column overhead is combined, without any pressure control,with the overhead of the dehydration column. This means that the strippingcolymn operating pressure is almost the same of the dehydration coiumnlwhich is controlled by the PIC-3100.

3,4.7 CO2 Absorber 100-Gl4l

Gas Feed Rate

A portion of the recycle gas is passed through the absorber to remove theCO2 produced by the side reaction.The feed point is at column bottom.Feed rate to the absorber is adjusted by the flow controller FIC-4001 on thefeed line, regulating the control valve FV-4001 on the co2 RemovalSystem by-pass.This flow rate should be adjusted proportionally to the CO2 production ratein order to avoid excessive fluctuation of the CO2 content in the recyclegas.

The maximum flow to the absorber will be kept at EoR operation, when themaximum CO2 formation will be experienced.

Absorber Overhead Tem perature

The temperature controller Tlc-4001, located at the ouflet of the TreatedGas cooler 100-E241, adjusts at 60 'c the temperature of the gas to berecycled to the reactor.

Lean Solution Flow

The flow of carbonate solution should be maintained at the design flow rateto ensure the CO2 content in the recycle gas is reduced at the desired limit(2,5 o/o mol.).

d)

e)

a)

b)

c)


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It is not recommended to increase the flow rate of lean solution due topossible flooding of packing. The operation at low flow rate should be alsoavoided because it is necessary to guarantees the wetting of the packing.

Wash Water Flow

Boiler feed water is used as wash water on the top of the absorber abovethe demister.This water is used as intermitted flow once for month to wash the demisterand / or to fill the column at the preliminary operation.

Absorber Operating Pressure

The absorber column overhead is combined, without any pressure control,in the Recycle Gas K.o. Drum 100-D211 with the recycle gas that has by-passed the co2 Removal system. This means that the absorber columnoperating pressure is almost the same of the 100-D211, which is controlledby the PIC-1311.

Rich Solution Flow

The rich carbonate solution is collected in the bottom of the absorber and,under control of LIC-4001, is sent to the Regenerator 100-C142. This flowrate is dependent on the flow rate of lean solution fed to the absorber andcannot be fixed by the operator.

1OO-D241Treated Gas K.O. Drum

1oo-D241Treated Gas K.o. Drum is provide to separate the condensablescooled in 100-E241 Treated Gas cooler and clean by demister rhe noncondensable recycle gas.ln the overhead line water is condensed by 100-8241 to close waterbalance in the CO2 Removal System.

Boiler feed water is used as wash water on the top of the drum above thedemister to scrub any entrained carbonate from the gas leaving the column.This water is used as intermitted flow twice for month to wash the demisterand / or to fill the drum at the preliminary operation.The condensables will be fonruarded to the column 1oo-c142 by the levelcontrol LlC-4004 acting on LV-4004.

GO2 Sofution Regenerator 100-C142

a) Rich Solution Feed

The rich solution coming from the CO2 Absorber enters the Regenerator inthe top section, above the packing beds.Its flow rate is adjusted by the level controller on the absorber bottom.

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Page 3-109

d)

e)

s)

3.4.8


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TECI{I*|P ITALY S,p.A. *mMr*b) Column Condenser Temperature

The temperature controller TIC-4102, located at the outlet of the CO2cooler 1oo-8242, adjusts the temperature of the cooled gas to 60 "c byregulation of the pitch of the fan blades.This temperature should be kept constant , independenily of the plantproduction rate.

c) Reboiler Duty

The duty of the reboiler 100-8142 is adjusted by the flow controller FIC-4102located on the steam admission line, which regulates the flow controlvalve FV-4102.The condensing pressure is controlled bypressure will be maintained constant also atthe reboiler tubes.

PIC-4100: that ensures theIow capacity, by submerging

The duty can be adjusted (by varying the flow rate of steam) proportionallyto the flow rate of rich solution circulated to the regenerator.The operation with a duty lower than required may cause insufficientregeneration of the rich carbonate solution which affects negatively theabsorption of The CO2 from.the recycle gas.

d) Bottom Liquid Level

The regenerated (lean) solution is collected on the bottom of the columnfrom where it is sent to the absorber, under control of flow rate.The liquid level is controlled by the reflux of condensate water from theregenerator overhead K.o. Drum 100-D242 to the top of the column.

e) Regenerator Column Operating Pressure

The non condensed CO2 stream from the K.O. Drum 1OO-D242 is ventedto the atmosphere, without any pressure control.

Antifoam Svstem

Antifoam system is provided with 100-D243 Injection Drum that dosecontinuously antifoam into lean carbonate line to minimize foaming affects in theAbsorber.100-D243 is blanketed with nitrogen through pCV-4112.Antifoam flow rate is local monitored bv Fl-4106

Filters Svstem

100-F142 is provided to clean carbonate solution prepared in 100-4141 reachingthe 100-T141 Solution Storage Tank, while 100-F141AlB are provided to cleanlean carbonate solution in a closed loop from / to 100-C142 spilling from the leancarbonate line between 100-C142 and 100-C143.100-F141AlB have six way valve.

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3.4.9 Drainage System

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a) Closed Drainage System

Due to the hazardous nature of acetic acid, a closed drain will collecteffluents from all process equipment and associated piping that's Likely tohandle liquid acetic acid in normal operation.The closed drainage system will consist of hard-piped drains from all "on-plot" process plot areas and will be routed to the process drain collectiondrum 100-D251, alone with waste organic stream from the plant.The closed drain system will by steam traced to prevent effluent solidifyingand will have a connection to the LP nitrogen header to blow the systemfor maintenance purpose: the drain collection drum is open to the Hp flaresystem and located in a sump to allow free drainage from the processareas.During plant operation the drum 1OO-D251 receives intermittent waste liquidfrom organic purge of the dehydration column decanter 1OO-D232.The operator can utilize this destination to divert heavies stream from 100-C133 when the outside battery limit incinerator is not available or to handlethe waste liquids from open process drain sump 100-4151 when the.content is not in spec to be treated by slrE ETp (high content of acids).A sample point s-5102 provides to analise the acétic acid content. when100-D251 liquid contain a sufficient amount of acetic acid to bereprocessed in the dehydration column, the operator can decide to send thedrain system content to the off-spec tank 100-T 152.The pump 100-P156, manual started, provide to maintain level in thecollection drum.

Open Drainage System

The open drainage system receives liquid from process area surfacedrains, all of the tankage area process drains, blow down from the steamsystem, plus a continuos stream of waste water coming from aqueouspurge from plant from 100-E-137.Aqueous effluent collected in the sump are to be sampled and, dependingupon the final analysis, will be pumped by the process drain sump AqueousPump, 100-P158 A/8, to 100-D251 (if liquid is high concerted of acetic acid)or outside plant battery limit.The process drain sump oil Pump, 100-P159 pumps oiry water to theoutside incinerator.The first 15 minutes of contaminated rain water will be collected in thesump 100-4151.After this time it is supposed that the surface water is clean enough to besent directly to the royal commission open ditch. Manual valve ZV-5401 willbe close to intercept the open process drain sump.Tank 100-T154 is provided to enlarge the hold up capacity of open drainsystem.

b)


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3.4.10 Tankage

Acetic acid produced in the plant is sent at first to the shift tanks 100-T151 A/8.Sampling shall be conducted before deciding to divert the product to the aceticacid product tank 100-T153 or to tank 100-T1 52 (tf acetic acid quality is notrespecting the specification).Pumps 100-P151 A/B permit to move the acetic acid between tanks 100-T151 Aand 100-T 151 B by operating the manualvalves in the circuit.


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3.5 NORMAL SHUT DOWN

3.5.1 General

The shut down of the plant is defined "normal" when it is planned in advance soto permit that all operating parameters are slowly adjusted to reduce graduallythe throughput of the plant until the complete stop.

The shut down of the process, defined as normal is when it is planned in advanceand Utilities and Off-site center are informed about it.

The normal shut down of entire plant includes the following sections.

. Feed Preparation Section

. Reaction System Shut Down

. CO2Removal System Shut Down

r Purification System

. Steam Production & Utilities System Shut Down

. Single Skids Units Shut Down

lmmediately before to begin the shut down of the plant it is reasonable to switchover the acetic acid product to the off-spec tank.

In case of a temporary shut down of the plant, it could be advantageous to bringthe plant at a condition of "hot stand-by", with operating parameteis as close aspossible to the normal values and the machines kept in service with the use ofthe recycle lines.

s_o, two following separated procedures, one for "Hot stand By,' and one for the"Complete shut-down" are foreseen.



Page 3-113

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Feed Preparation Section Hot Stand By

Reduce plant load to 60% of normal.Before to stop the reaction it is necessary to reduce the oxygen content in therecycle gas. To obtain that, stop the oxyge;r feed by emergeÀòy stop switch HS-2001, thereby activating the automatic nitrogen purge of the oxygen system viathe line from 1OO-D276.When oxygen in cycle gas is less than O.1Vo, the oxygen feed must be shut off"100-J113 will keep running recycling by spill-back.The ethane to the cycle gas loop, Hp steam are required to be shut by thelogic, and process nitrogen shut by the operator. The nitrogen purge of tneoxygen system will be initiated by the interlock.The ethane feed compressor 100-J111 NB is still running with the spillback 1ineopen to 100-E111 shellside, ensuring circulation through the Heater IOO-H211and the Zinc Oxide Vessels 100-D111 NB avoiding temperature decrease in thatsystem.As Steam production decreases HP Steam Header pressure controller willopen the HP lmport steam valve to control the pressure.when steam production from the steam drum drops below 14,000 kg/h,the start-up steam to 100-H101 shourd be opened automaticatty tomaintain a cooling flow to the steam coil.

Reaction Section Hot Stand By

After the Feed Preparation section has been put in "hot stand-by',, the recycleflow through the reactor must be gradually reduced to about BO % of the Oeéignin order to avoid a sudden reduction of temperature and pressure in the ReactorSteam System. The control valve PV-2101, regulating the flow of steam producedin the steam drum, will automatically close since no steam is longer produced inthe system.

when plant load drop to 80%, start coolant circulation pump 1oo-p-121, and keepreactor hot (greater than 200"C, controlling TIC-2047) by injecting HP steam intothe sparger by FIC-2103 and circulation using the pump 1OO-p-111.

HP steam will be admitted from Battery Limit to control the pressure of the Hpsteam header and, when the steam production from the steam drum drops below14000 kg/h, the start-up steam to Fired Heater 100-H161 will be openedautomatically to ensure a cooling flow through the heater coil.

continue loop circulation with 100-J112 circuration compressor.

When oxygen concentration is below Ql% at reactor inlet stop feed (FV-1406) tollre reactor completely, maintain circulation through the reactor bypass openingFV-1302 to Reactor Outlet Condenser 100-E231.

See Table below for additional requirements.



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3.5.3

TEGHIIIP IrALY s.p.A, - 00148 ROMA - Viate casteilo deila Magtiana, 68

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3.5.4

Table: Hot Standby Definition of Requirements

GO2 RemovalSection Hot Stand By

Continue circulation as 60% load in normal operation.

Reduce steam to co2 stripper Reboirer 1oo-E142 as the minimum, tokeep temperature as normal, unless the reactor is to be started up againsoon.

Keep the feed flow about 30 min, until co2 concentration less than 1o/o,then stop gas feed through FV-4002.

observe Licensors recommendation for stand-by operation. Throughoutthe operation, keep a close watch on the solution levels Llc-410+ i-n tne100-C142 COz Solution Regenerator. High levels when the reboiler is stillin service can cause extensive damage to column internals due topossibly hammering.

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SECTION DEFINITION REQUIREMENTSFeedPreparation

Hot circulation with 100-J1 1 1.(Ethane or N2).

Maintain pressure withnitrogen or ethane.

Reactor Hot circulation with 100-J112(Ethane/N2 mixture or N2 only)

Maintain pressure withnitrogen.lmport Steam.Inject steam to steam spargerto keep at temperature.Circulate BFW to steam drumwith start-up circulation pump.

CozRemoval

Solution Circulation with 100-P144NB

Maintain pressure in Absorberat circulation loop pressure.Provide steam to reboiler.

PurificationSection

Circulation through theScrubber,Dehydration Column, StripperColumn and back to theScrubber. Operation at closeto normal conditions. .ProductColumn isolated and on totalreflux.

Provide steam to reboilers.

TEcllNlP IrALY s.p.A. - 00148 ROMA - Viate casteilo deila Magtiana, 6g

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3.5.5

3.5.6

mmwmm

Demineralized water should be added to the solution purge sump 100-4142 to flush this sump after it has been emptied and the contentstransferred to the Battery Limits (lncinerator Holding Tank). The ouiletlines will then be flushed and drained down after use.

Purification Section Hot Stand By

lsolate the Product column 100-c133 from the rest of the system andoperate it on total reflux.

Ensure that the scrubber 100-c-131 pressure does not drop below 5barg.

Keep closed loop circulation from the scrubber 100-c131 to theDehydration column 100-c132, stripper 100-c134 and back to thescrubber 100-c-131 if possible, othenryise maintain the columns on totalreflux (or maintain cir,culation via the scrubber Feed water Drum 100-D231).

operate all the columns as close as possible to normal conditions

Stop butyl acetate feed to the decant er 10tO-D232.

Boil-up any butyl acetate overhead of the stripper 100-c-134 and keepthe 100-c132 Dehydration column reflu/feed ratio close to normal.

Feed Preparation Section Gomplete Shut Down

Reduce plant load to 60% of normal.

Before to stop the reaction it is necessary to reduce the oxygen content in therecycle gas. Stop the oxygen feed FV-1402 by emergency stop switch HS-2001,thereby activating the automatic nitrogen purge of the oxygen system via the linefroml0O-D276.

The system will go into circulation with HP lmport Steam protecting to the SteamCoil in the Fired Heater.

The zinc oxide vessels should be cooled down to ambient temperature, keepingthe compressor 100-J111 NB running and by decreasing gradually the set pointof TIC-1 112. The cooling of the zinc oxide catalyst should be less than S0 'ó perhour. After the cooling is accomplished the fresh feed compressor 100-J111 canbe stopped.

When oxygen in cycle gas is less than O.1o/o, the oxygen feed must be shut otf.100-J113 will keep running recycling by spill-back.

By the interlock l-0101, the HP Nitrogen system 1oo-D276 comes intooperation to purge the oxygen line and mixer 100-M1 1 1 "

TEGHI{IP IrALY s.p.A. - 00148 ROMA - viate casteilo deila Magtiana, 68

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Also by the interlock l-0101 the ethane feed will automatically shut off(positive isolation) to the Reaction System.

Trip the Fired Heater 100-H161, which positively isolates fuelto the heaterand the Fresh Feed Compressor 100-J1 1 1 .

Trip the oxygen compressor 100-J1 13.

Depressurise the Feed Preparation Section by venting to flare, and purgeby nitrogen.

Maintain under a positive pressure with nitrogen

3.5.7 Reactor Section Complete Shut Down

Note:

ln some cases one reactor will run but other will be shut down ln this case therest of the plant should support the running Conventional Reactor. Any waySABOX reactor should be shut down first.In other words, before any shutdown of the conventional Reactor, the SABOXReactor is to be shutdown first.

Close manual block valve HV-1402 on the oxygen feed line and the compressor100-J113.is running by spiil back

Close manual block valve HV-1402 on the oxygen feed line, activating theinterlock l-0101

So, HP Nitrogen via 100-D276 operates to purge the oxygen line and mixer 100-M111.

The circulation compressor 100-J112 shall be kept running during the purge withnitrogen to ensure the equalization of the recycle gas óompoJition inside thewhole system and to consume the oxygen content in óycle through the reactor.

Continue in such a way the loop circulation with 1OO-J112 until oxygenconcentration less than 0.1o/o.

Before shut down the 100-J112, make sure of the following:

' Oxygen content in the recycle gas has been lowered to 0.1% by volume

. scrubber r 00-c131 has no Acetic Acíd in top and bottom.

' CO2 Removal System has cool down (close LP steam to 100-E142).

shutdown 1 00-J1 1 2 following the manufacturer's instructions.

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TEGHI{|P IrALY s.p.A. - 00148 ROMA - Viate casteilo deila Magtiana, 6g

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In such a way, the loop including the Scrubber 100-C131 is automaticallydepressurised up to 1 barg to Flare via the Emergency Vent dump valve, to thóLP nitrogen pressure.

The system will be then purged with nitrogen in order to reduce the hydrocarboncontent to less than 0.1 7o volume.

Feed to the CO2 system will be stopped.

Stop wash water to the Scrubber 100-C131 after confirming again no Acetic Acidis present in the overhead stream by closing the bottom liquid control valve andstopping the Scrubberfeed water pump 100-p131A/8.In such a way the shut down of the scrubber will be completed.

Start up the circulation pump 1OO-P121 and ensure the Reactor shell sidecontents are circulated via this pump.

Vent the Steam Drum 100-D221 to atmosphere enabling the system to cool,control at 1S'C/h.

Once the temperature in the stream drum has drop sufficiently (about 1 10.C), the' steam drum is kept pressurized to 1 barg by nitrogen to avoid air ingress into thesystem. Cool the Boiler Feed Water still present in the Steam Drum further bythe reaction circulation cooler 100-E121, again control at 1S'C/h and this coolingprocess will be done by cooling mode selection (software) already described.

Consider that the cooling of the steam system should be completed only after thepurge with nitrogen of the reactor tube side, to prevent condensation of waterinside the tubes.

Stop the nitrogen purge to mixer 100-M111.

Venting and purge the loop contents to flare with the reactor inlet valve FV-1406closed, using HP Nitrogen keeping the system under positive pressure.

lsolate reactor frgm the Cycle Gas Loop. lsolate the Cycle Gas Loop from FeedPreparation and Purification section Areas and isolate ,l-llz.

3.5.8 CO2 Removal Section Gomplete Shut Down

The CO2 Removal System, already isolated from the recycle gas loop, will bekept in operation until all the carbonate solution has been regenérated. Then thesystem can be shut down, depressurized, the solution drained to the stor:age tank1oo-T141, and the columns maintained under a nitrogen padding.As soon the reactor system has been shut down there are nó needs for CO2removal systern operation. Complete shut down of the system will be done assoon as the carbonate solution has been regenerated in 100-C142 column.Maintain the LP steam to the CO2 Stripper Reboiler 100-E142 untit the CO2 inthe recycle loop is less than 0.1 yo, then stop the steam, as already described.

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The CO2 absorber 100-C141 may be cooled by allowing it to continue contactingthe circulating process gases.After system cooling down, send the carbonate solution to CO2 storage tank100-T141.Bottom pump 100-P142 will be in service up to the draining of the bottoms to thesolution storage tank 100-T141 (low the levef as much as possible). Depressurisethe system with the Cycle Gas Loop, because this loop is already under nitrogen(Oxygen concentration is less than 0.1%)Blanket with Nitrogen.Keep at a positive pressure to stop air ingress.

Purification Section Complete Shut Down

Product Recovery Section Complete Shut Down

lf a prolonged shut down is planned, after the shut down of the Reactor Systemthe downstream acetic acid recovery and purification system can be put óut ofoperation.

By the previous operations of the conventional reactor system shut down, thescrubber 100-C131 has already been shut down and will be depressurized toabout 1 barg. Keep the total reflux for some time. The water normally fed to theScrubber, from 100-D231, is routed directly to the Dehydration Cólumn 100-c132.

The dehydration column 1oo-c1g2 is operating with no bottom productextraction, due to the absence of acetic acid in the water transferred from 100-D231 by-passing the Scrubber, so the reboiler will go out of service (cut thesteam), as the crude acetic acid will be replaced with úater coming from 100-D231.The butyl acetate solution can now be transferred from the Decanter 100-D232 tothe Holding Drum 1Q0-D252 and, in the same time, the crude acetic acidinventory in the bottom of the Dehydration Column should be reduced, loweringthe bottom liquid level up to the low level.Recover as much as possible of the butyl acetate from the DehydrationColumn Decanter back to the Entrainer Holding Drum 1OO-D252"When this operation is over, stop the steam to the Reboilers.

The following pumps should be stopped simultaneously:

o water feed pump 100-P131 A/B

o crude acetic acid pump 100-P132 NB

. dehydration column reflux pump 100-p135 A/B

Level in the 100-C132 bottom should be at minimum value, crude acetic acidpump 100-P132 put in stand by.

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3.5.9

3.5.9.1


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*mwn*As soon as the decanter level is at minimum butyl can be transferred to the drum1o0-D252 thus stopping the pump 100-p-13T NB. This operation strippingcolumn 100-c134 loose the feed so it will go out of service (duty). Bottom pumpP-134 will be stopped keeping low tevel at 100-C134 bottom.After this, depressurize the system, blanket with Nitrogen and keep at apositive pressure to stop air ingress.

Product Purification System Complete Shut Down

The Product Column 100-C133 is operating atfull reflux since no crude productis longer fed to the column, because the pump 100-P132 from Product RecoverySection was shut down"To shut down the column shut off the steam to the reboiler 100-E133, bring tolow level the liquid level in the bottom column and in the reflux drum, aciingmanually on the corresponding level control valves and then stop the followingpumps:

- heavies pumps 100-P133 A/B

- product column reflux pumps 100-p136 A/B

The stripping column 100-C134 is already not running since the water cycle hasbeen stopped. To complete its shut down, shut offthe steam to the reboiler 100-E134.

At this point all column have been shut down, steam reboilers are not inoperation, process pumps are all stopped, cooling water is still supplied tocoolers, and the aircoolers are still running. The vessels and columns frave theliquid at their low level.lf the shut down is finalized to permit maintenance works or internal inspection ofequipment, all liquid shall be drained off from equipment and the entire plant shallbe depressurized down to the atmospheric pressure and thoroughly purged withnitrogen before opening of equipment or piping.All valves on process lines should be closed, all instruments should be left inservice with all controllers set in manual position, except those on utility serviceswhich will continue automatic operation untilthe utilities are in service.

Vessel Entry

Reactor Section

Ensure the Reactor is cooled.

The catalyst does not require stabilisation before exposure to air.

Ensure that all process gas has been swept to flare with nitrogen.

Purge with air prior to entry.

3.5.9.2

3.5.10

3.5.r0.1


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3.5.r0.2

3.5.10.3

3.5.11

3.5.12

3.5.12.1

TEGHIIIP ITALY S.p,A, mmfu*-

GO2 Removal Section

Send the solution in both columns to storage tank by pump

o Steam-out the columns. and washing the unit.

r Purge with air prior to entry

Purification Section

. Empty columns by pumping the contents to the appropriate storagetanks.

o Steam-out the columns, and washing the column.

e Purge with air prior to entry.

Reactor Conditions During Prolonged Shut Down

When the reactor is depressurized and opened up, an important precautionshould be observed as much as póssible during the time that the reactor remainsopened: the tubesheet should be kept sealed or covered to minimize the flow ofatmospheric air (containing potential contaminants) through the catalyst bed.Suitable sealing of a reactor tubesheet can be provided by covering with cottoncanvas and then with a polyethylene film. All manhole openings should besheltered to keep out rain and mist.

lf the reactor is not opened up, it can be kept isolated by blinds and held at aslight positive pressure of nitrogen.

Steam Production & Utilities Shut Down

Steam

There are, as previously described, a few sources of steam:

- LLP is produced by steam turbine expansion work (1oo-J112) and byreducing the pressure of LP steam

"

So, during the turbine 100-J112T shut down, LLP steam will be supplied fromimported LP steam"from battery lirnit.

- LP steam is produced by expansion in steam turbine 1oo-J112 and byreducing the pressure of MP steam. Once the turbine is shut down the onlysource of LP steam will be from battery limit and produced from Mp steam.

- MP steam is fully produced from HP steam by pressure reducing with thePV-61018 To shut down this steam it is necessary to act on tÉis valve.Desuperheating facilities will be tripped as well.

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TEGHNIP IrALY s.p.A. - 00148 ROMA - viate casteilo deila Magtiana, 6g

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- HP steam should be cutted just in case of emergency. The best is to keep itas long possible, due to troubles and risks of goìng tó uacuum pressure andintroducing of the air in the network.

3.5.12.2 Boiler Feed Water

This water is a polished and treated which is consumable (steam production,desuperheating, blowdown).

NOTE

in the system. once there were no need.for Éoiler Feed water thephosphate dosing facilities should be shut down.

NOTE

within Gas Fired Heater will be heated for some period of time. Duringthis period the Boiler Feed water flow will be maintained by draining théwater through blow down system toward Vent Gas scrubber rco_Czs1.This water will be wasted.

NOTE:

act accordinghly.

3.5.12.3 Condensate

The same policy as for the steam. The best is to keep the system on. (no air tobe introduced). Other wise a nitrogen pad is necessary (same as for the steamnetwork)

3.5.12.4 Nitrogen

Generally it is forbidden for such a plant to be without nitrogen supply. In anycase, when it is inevitable to shut down the nitrogen systerà, some temporaryfacilities should be installed to keep a nitrogen paó. rnii

"orld be a set of few

tens of nitrogen bottles / cylindres (with presèure reducers about 0.5 barg)

3.5.13 Single Skids Units Shut Down

Single Skids Units Shut Down should be performed in accordance to themanufacturer's instruction and operating manual.

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3.6.

3.6.1

EMERGENCY SHUT DOWN

General

Emergencies may arise through the failure of the equipment and utility supplíes.The principle that governs the actions to be taken during an emergency is toprevent any increase in the temperature and pressure in the equipment and toprevent, in the reaction section where oxygen is present, the formation of amixture within the flammability range.This is normally achieved by stopping the supply of heat to the unit, by cuttingfeed to the unit, by diverting to the flare excess materials which could cause apressure increase and by purging with inert gas the systems where a flammablemixture could be formed. where possible, equipment should be put on totalrecycle to facilitate bringing the equipment on stream again.Emergencies should be recognized immediately and controlled to avoid damagesto the equipment involved. Sometimes emergency conditions can be tolerated fora short time, providing proper measures are taken. lt is possible to maintain theunit in operation during a localized emergency.As a general rule the following must be considered prior to proceeding:

- Expected duration of emergency conditions.

- Notification of the emergency to other units.

The way to face the emergency will normally be one of the following cases:

- The problem is localized, it is possible to avoid shutting down of the wholeunit.

- Shutdown the whole unit is required as per normal shutdown procedure.

- Shutdown the whole unit under emergency procedure.

- Some operations are necessary to prevent immediate or future dangerwhich may damage equipment.

- Check are necessary on equipment tovalve release.

Emergency conditions are usually caused by:

- Steam failure

- Power failure

- Cooling water / lnstrument Air failure

avoid pressure built up and safety

TEGH]{|P IrALY s,p.A. - 00148 ROMA - Viate casteilo deila Magtiana, 68

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In the following paragraphs the said possible emergencies applicable to theAcetic Acid Plant are described.As a general rule, in all cases where an emergency cessation of flow of ethaneand oxygen is required the operator should press the shutdown button. This de-energizes the solenoid valves which control the oxygen and ethane feeds, and atthe same time purges the oxygen feed station. Once this has been done and theoxygen, ethane and gas purge block valves closed, the plant can be consideredto be in a safe condition and the rest of the equipment can be shut downfollowing the normal shutdown procedure.

Plant Electric Power Failure

Plant Electric Power Failure means that dedicated bus to the plant transformer ortransformers itself failed.

The ethane compressor will trip and oxygen compressor will be tripped. Ethane tothe loop will be tripped shut. oxygen Feed is tripped causing an Hp nitrogenpurge to be initiated. The circulation compressor will not trip immediately in orderto avoid oxygen accumulation in the circuit. For this propose the auxiliary oilpump is driven by turbine and the inlet steam valve of the turbine is under UpS.

The Product Recovery and Purification Section must be shut-down as both theoverhead condenser and the reflux pumps are lost on power failure.

In case of electric power failure all pumps, compressors (except recycle gascornpressor) and air fin fan motors stop except that connected to emergencypower supply.

The Product Recovery and Purification Section must be shut down since theoverhead condenser and reflux pumps are not functioning on power failure.

For power failure of very short duration, restart can be effected in a short time ifthe reactor has not lost very much temperature. Othenrvise the shut down of theplant is completed following the normal shutdown procedure.

Critical pumps and critical equipment (instrumentation and DCS included) willcontinue to work to keep the possibility for safe shut down )if disturbance will beprolonged)

Instrument Air Failure

lf the instrument air pressure dropped below s.s barg then the oxygen supply tothe plant trips along with 100-J1 11NB and 100-J113A/8. tt shoutó be noted thatthe Emergency Loop Depressurisation Valve is an FC valve but is provided with ahand-jack for the operator to manually depressurise the loop on an instrument airfailure, if needed.

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3.6.3

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In the event of an instrument air failure, each pneumatic valve should keep a safeposition assisting automatically in the shutdown of the plant.

Ethane and oxygen feeds shall be blocked. All pumps should be shut down toavoid overfilling of equipment. lf the plant cannot be restarted shortly, the shutdown should be prosecuted as for normal shutdown.Interlock will be activated if the instrument air pressure drops below 5.5 barg,causing the trip of oxygen feed without time delay, along with feed compressors100-J111 and 100-J113.

3.6.4. Steam Failure

Under loss of reactor steam, the HP import steam will automatically opento maintain the HP header at normal pressure. lf there is insufficientsteam for the Circulation Compressor and hence low flow through theStatic In-Line Mixer or the compressor trips for any reason, the oxygenfeed to the plant and ethane feed to the loop will be tripped shut. The HPsteam supply to the process will be isolated and the HP nitrogen purgeinitiated via the ESD system.

The Purification Section can be kept on hot stand-by using import steamor shut down.

Failure of steam (HP or LP) from Battery Limit does not need the shut down of' the plant, since the amount of steam impórteO is negligible.

3.6.5 Cooting Water Failure

lf the cooling water pressure dropped below 2.5 barg then after a time. delay of 10 minutes the oxygen supply to the plant trips along with 100-

J111 and 100-J113A/8. After a further 5 seconds 100-J112 is tripped"

Cooling water failure does not directly affect the Product Recovery andPurification Section, however the system can be kept on hot stand-byusing import steam or shutdown.

Failure of cooling water requires the shut down of machinery that use coolingwater in lube oil systems. Most of distillation columns have air fin overheadcondenser and can be operated even in case of loss of cooling water, but theacetic acid product will be sent to storage at a temperature well higher than thenormal operating one.

lf the cooling water pressure drops below 2.5 barg, the oxygen feed will betripped after a delay of 10 minutes, along with the feed compressors 100-J111and 100-J113.



TECHNIP ITALY S;p.A. - 00148 ROMA - Viale Castetto detta Magtiana, 68

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3.6.6 Ethane Feed Failure

ln case of ethane failure will not cause oxygen trip. lf the ethane supply flow isnot quickly established, the shut down sequence should be actuated by activatingthe HS-2001 trip bottom.

3.6.7 Oxygen Feed Failure

In case of oxygen supply failure the reaction system will be shut down, withimmediate stop of the ethane feed and causing the activation of interlock l-0101.

3.6.8 SABOX Reactor

lf for any reason the main loop has an oxygen trip, the SABOX Reactor isautomatically isolated and the HP Nitrogen purge from 100-D282 isinitiated followed by controlled depressurisation.

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Page 4-1

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INDEX

4. SAFETY

4.1 GENERAL

4.2 SAFETY IN PLANT OPERATION4.2.1 Operator Training4.2.2 Pressure Testing and Purging4.2.3 Feed Preparation System4.2.4 Cycle Gas and Reaction System

4.3 GENERAL SAFE WORKING PROCEDURES4.3.1 Personal Protective Equipment4.3.2 Respiratory Protection4.3.3 Body Protection4.3.4 General Safety Rules during Operation4.3.5 Hazards Due to Pressure and Vacuum4.3.6 Hazards Due to Thermal Expansion4.3.7 Entering Tank and.Vessel4.3.8 Housekeeping4.3.9 Sampling4.3.10 Miscellanea

4.4 FIRE PREVENTION AND FIREFIGHTING4.4.1 Prevention0.0.0 Firefighting

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4. SAFETY

4.1 GENERAL

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Many materials handled in industrial plant present hazard for personnel andequipment.It is therefore essential that all personnel be thoroughly trained and experiencedto:

- safety handle these materials

- recognize the characteristics and the toxic effects of chemicals handled

- enact all necessary first aid and procedures to minimize personnel injury.

Safety problems relevant to the Acetic Acid Plant concern the presence ofhydrocarbon gases such as methane and ethane, which can form flammablemixture in presence of oxygen if their concentration is within the flammabilitylimits. The formation of a flammable mixture may arise as consequence of a lossof containment or, since an oxygenation reaction is carried out in the plant, asconsequence of an inaccurate dosing of the reactants.Safety data sheets for Ethane and Acetic Acid are included in the attachedAppendix


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4.2

4.2.1

4.2.2

4.2.3

SAFETY IN PLANT OPERATION

Operator Training

Operating and maintenance procedures will be useless if personnel are notadequately trained in their correct implementation.

supervisory personnel in charge of such training should be adequatelyexperienced themselves, preferably in chemical plants of similar type andhandling similar materials.

Maximum use should be made of the initial periods of testing, preparation andwater runs in the plant to review and practice the detailed start-up, operation andshutdown procedures. Generally, at this point in the start-up, hazardous materialshave not yet been introduced to the plant, and errors in operation, leaks andspills, etc. tend to be more easily dealt with.

Pressure Testing and Purging

All systems and equipment handling hydrocarbons or potentially 1ammablematerials should be thoroughly purged to a low oxygen content and pressuretested before start-up.Hot testing should be carried out wherever practical to check that the systemremains pressure tight at operating temperatures. Adoption of hot testing willminimize the possibility of leaks developing subsequenfly in operation.

Feed Preparation System

This section of the plant is extensively protected by interlock systems to minimizethe possibility of flammable mixtures forming. However, the safe operation of theplant will only result from the effective implementation of correct procedures andconstant monitoring of the process parameters.

The main hazard in the oxygen system is the potential for contamination of theoxygen feed system by flammable material from the cycle gas system, whichwould undoubtedly ignite causing an explosion.The oxygen in-line mixer is equipped with automatic isolation, venting and purgesystem, and is constantly monitored by extensive instrumentation to avoidbackflow of gas from the reaction system.Before oxygen introduction, the entirecontamination by flammable materials andnitrogen.

system should be checked forthen purged and pressurized with

It is recommended that detailed step-by-step checklists to be made for both start-up and shutdown of the oxygen mixing station. Such checklists help to ensurethat the correct procedures are being followed and remove ambiguities at shiftchanges.

TEGHNIP IrALY s.p.A. - 00148 ROMA - viate castelto deila Magtiana, 6g

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Instrumentation and valve malfunctions may represent a possible cause ofaccidents. In order to minimize this possibility, after any shutdown of the oxygensystem, the following check should be made:

- Verify that all shutdown systems have operated correctly, both in ControlRoom and on the Plant.

- Verify that all valves are fully closed or open, as required.- Verify that oxygen block valves and nitrogen pressurized sections of line are

not leaking by checking pressures and purge flows in the system.- Determine the cause of the shutdown if the initiation was automatic.Rectify any equipment, valve or instrument defects before restart.

4.2.4 Cycle Gas and Reaction System

' The principal hazard in this system is the potential for the formation of flammablegas mixtures. lt is not possible to state fixed limits for the permissible maximumoxygen concentration, since this is dependent on the relative ethane, nitrogen,carbon dioxide and other concentrations. The important point is that the gasmixture is normally above the upper flammable limit (i.e. on the fuel-rich side ofthe flammable range) and hence the oxygen concentration must be kept, belowthe maximum permissible.Extensive instrumentation is provided to monitor the gas composition, inparticular the oxygen level, and to effect a shutdown dt the system in case ofabnormal oxygen concentration. However, since instrument malfunctions can

. occur, after any interlock shutdown the following steps should be carried out:

- Check that the oxygen feed is properly blocked off and that nitrogenpressurized sections of line are not leaking.

- Continually monitor analyzer readings, particularly of oxygen concentrationdownstream of the oxygen injection point, especially after the circulationcompressor trip has occurred.

- Check analyzer readings by means of samples analyzed in the laboratory.- Determine the cause of the shutdown.



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4.3 GENERAL SAFE WORKING PROCEDURES

4.3.1 Personal Protective Equipment

Protective equipment is not a substitute for safe working conditions: adequateventilation and intelligent conduct of the operators are fundamental for accidentprevention.

When protective equipment is necessary, it must be used properly. Theequipment selected must be suitable for the purpose and the person using theprotective equipment must be familiar with it.

All protective equipment for safety of personnel must kept in good workingcondition at alltimes.

Frequent inspection and immediate repairs are essential.

4.3.2 Respiratory Protection

' All gases other than air are harmful to man when inhaled in sufficientconcentrations.

Toxic gases may be classified as either asphyxiating or irritating.

Asphyxiating. gases may cause death by replacing air in the lungs or by reactingwith the oxygen carried in the blood.

Examples: Hydrogen sulphide, carbon monoxide, smoke.

: lrritating gases may cause injury or death not only by asphyxiation but also byboth internal and external burning.

. Examples: chlorine, sulphur dioxide, hydrogen fluoride.

To guard against inhalation of harmful gases, the operator should:

- Secure a gas test certificate showing the gas conditions of the atmosphere(vessel, etc.).

- Avoid entering a confined space which has not been purged and tested.

- Avoid facing an opening where escaping gas will be blow at him.

- Provide ventilation.

- Wear the correct type of gas mask.

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Three types of gas masks are in common use:

- Oxygen cylinder and mask set.

This gives 10Qo/o protection regardless of the presence of the toxic gas.Their disadvantage are that they can be used for a limited time only andrequire skill in proper use.

- Canister type masks

These are full face masks equipped with a cartridge containing chemicalsto remove the toxic component from the air breathed through the canister.Different cartridges are supplied for different groups of toxic gases. Thistype can only be used at low concentrations of toxic gas, so that theconcentration of oxygen in the filtered airis not below 18% by volume. Adisadvantage of this type is the relatively limited capacity of the cartridge.When the chemicals are exhausted, the toxic gas will not be trapped andtherefore the wearer must leave the contaminated area.

- Air line masks

These are full face masks into'which fresh air is blown through a long hosefrom a manually operated blower placed outside the hazardous area.The masks can be used in any concentration of toxic gases, can be usedfor a long time and permit relatively easy breathing.

4.3.3 Body Protection

In order to limit the possibility of hazards, operators should be compelled to wearsuitable protective equipment, as follows:

- Head protection: hard hats whenever working in the plant. These provideprotection from falling objects and against head injury in general.

- Eye protection: while cleaning or purging a line with air, steam or inert gas,all operators and supervisors must wear goggles or other safety equipment.Goggles should be fitted to prevent splashes from entering the eye. Plasticshields with facial protection should be used in addition to goggles when fullface protection is required.

- Ear protection: in some parts of the plant (e.g. compressor room) personalcomfort or safety ear protection.

This can take the form of ear plugs or ear muffs provided individually orlocated in enclosed stations adjacent to high noise areas. Personnel shouldbe instructed to wear ear protection before they enter high noise levelareas.



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- Foot protection: sturdy footwear, preferably leather, with built-in steel toecap. When necessary, boots of chemical resistant material can be wornover safety shoes.

- Skin and hand protection: suits made of synthetic rubber or other approvedmaterialwhen complete body protection is necessary.Gloves made of synthetic rubber or other approved material should be wornto protect the hands. In case of severe leaks only properly protectedpersonnel should remain in the area.

4.3.4 General Safety Rules during Operation

Following are general safety rules to be used by operators:

a. Wear protective clothing and gear provided and required for plantoperation.

b. Wear a safety belt when working at elevated locations if adequateprotection against falling is not available.

c. Wear a suitable air mask when working on pipelines or equipmentcontaining hydrocarbons, toxic gases or chemicals.

d. Use the correct hose for air, water, steam or chemicals; secure it solidlyduring use. Tag any hose that needs repairs and send it to the shop. Cleanchemical hoses after use.

e. Be sure hoses are in good condition and that all connections are tight sothat there is no chance of a leak that could result in a hazard.

f. With steam hose, crack the steam valve at first until all water in the hose isdischarged and the hose is heated up, in order to prevent high velocity jetsof water from issuing from the hose.

g. Report hazards immediately and take all measures to remove the hazard.

h. Wear goggles and gloves when taking samples.

i. Purge all process equipment with inert gas before use.

j. Whenever necessary to block in heated items that operate liquid full, suchas jacketed or traced lines, exchangers and reboilers, ensure that a thermalexpansion relief valve is provided. In any case it is required either to shutotf the heat source prior to block in, or draining enough liquid from theequipment to allow for thermal expansion.

k. Be thoroughly familiar with the location and operation of all fire fightingequipment, blankets, safety showers, gas masks, and other safetyequipment.



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Page 4-8

WARNING

DO NOT CLOSE

INLET OR OUTLET UNLESS

YOU FIRST OPEN THE DRAIN OR VENT

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L When giving clearance to maintenance to perform work in the unit, be surethe equipment is in a safe condition to work on.

Be specific in your ínstructions and be sure that they are understood.Check to see if instructions are being observed.

MANY ACCIDENTS OCCUR BECAUSE INSTRUCTIONS AREMISUNDERSTOOD.

4.3.5 Hazards Due to Pressure and Vacuum

All equipment is designed for pressures higher than normal expected operatingconditions. Relief valves are provided to protect equipment from abnormalincreases of pressure; however close operator surveillance is necessary at alltimes to prevent equipment from operating at higher{han-design pressures.

When steam purging of equipment is performed, formation of a vacuum canoccur due to steam condensation. Caution should also be taken to preventvacuum when pumping liquid from a vessel.

During steam purging and liquid draining operations it is important to open vents.lf the vessel is'hydrocarbon-free, open all vents and drains to permit air entry. lf avessel contains hydrocarbons, introduce steam or inert gas.

DON NOT OPEN VENTS WITH HYDROCARBONS PRESENT IN THE VESSELAS AN EXPLOSIVE MIXTURE MAY FORM.

4.3.6 Hazards Due to Thermal Expansion

Serious accidents may be caused by thermal expansion of liquid trapped inheated items. Thermal expansion relief valves are generally provided to preventsuch hazards.

When the cold side of an exchanger is bypassed and hot fluid is passing throughthe other side, the drain or vent on the cold side must be open.Warming signs must be posted on all exchangers carrying hot fluids wheneverthe exchangers cold side is bypassed.

SIGN EXAMPLE


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Before opening and entering a vessel or tank in which hazardous materials werepreviously present, the following precautions must be taken:

a. Purge vessel with nitrogen or flush with water or steam out until allhazardous materials have been removed.

b. Open vessel or tank man-holes only after obtaining a written permit frompersonnel in charge of unit"

c. Carry out gas test (explosivity test) as soon as possible. lf vessel is notgas-free, close it again a repeat degassing.

d. All connected piping must be blinded in order to prevent any hazardousmaterial from re-entering vessel or tank.

e. Ensure sufficient ventilation and therefore oxygen is available for breathing.

f. lf vessel is ascertained to be not totally gas-free, persons entering must atall times wear a suitable gas mask adequate protective clothing and safety

.belt with cord leading to outside of vessel" In this exceptional case a writtenpermit must be issued stating the time limit for which permit is valid.

g. When a person is working inside a vessel or tank at least one man shall be" óutside vèssel and constantly ready to give assistance

4.3.8 Housekeeping

Good housekeeping is the orderly and proper storage and handling of materials,efficient disposal of wastes, prompt removal of spillage, and maintenance ofequipment free of drippings, spatters, and overflows.

GOOD HOUSEKEEPING IS LEADING TO SAFE OPERATION.

Following is a general guide to good housekeeping:

a. Paper, wood, waste and other refuse must be deposited in refusecontainers

b. Keep process area, control room and other areas clean and orderly.

c. Oil soaked rags and waste may ignite spontaneously; they must, therefore,be discharged into steel containers specially marked and located for thispurpose.

d. Access to ladders, stainrays, fire escapes, fire extinguishers, steam hoses,water hoses and hydrants must be free of obstruction.



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TEC:*t{lP IT&LY $.p.4. *mW*e. Drums, cans and funnels used to dispense lube oil must be cleaned after

use and returned to their proper place.

f. Tools, bolts, nuts, lengths of pipe, flanges, etc. must never be left lying onplatforms, on walkways.

g. Fire fighting equipment is for fire fighting only. Never use it for utilitypurpose or remove it from proper locations.

h. Hang hose on rack when not in use. lf hose is to be used for extendedperiods, string it above walkways to eliminate tripping hazards.

4.3.9 Sampling

a. Samples must be taken only by authorized personnel.

b. Avoid inhaling vapours during sampling; they may contain toxiccompounds.

c. Light oil having a vapor pressure higher than atmospheric at sampling' temperature and LPG gases, must be sampled using steel containers. especially provided for this purpose. Liquid content must not exceed 85o/o ofvolume at sampling temperature.

d" When filling large metal containers carrying more than 20 liters withproducts having a flash point lower than 66 'C, container must be groundedto prevent accumulation of static charges. Grounding is assured by firmlyconnecting sampling outlet to container with a copper wire of at least 5 mm"diameter.

e. Hot oils (residues, asphalts) must be sampled using only welded or forgedsteel containers. Soldered cans may fail at high temperature.

f. Sampling connections must be flushed thoroughly but carefully and slowly,before collecting the sample. Spillage must be avoided at alltimes.

g. lf a large wrench or other means of leverage is required to open a strucksample connection, care must be taken not to break off the connection andcreate a serious hazard.

. Gloves and goggles or face shields must be used when drawing samples ofchemicals, hot oil, hot water, gases and all hazardous liquids.



Page 4-10

TEGHNIP ITALY S.p.A. - 00148 ROMA. Viale Castello della Magliana, 68

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a. Check the direction of wind whenever a drain or vent occurs; duringoperation stay upwind and make sure that the outlet gases do not endangeithe personnel.

b. Never cut off simultaneously the inlet and outlet cooling water of acondenser: water might boil; when necessary open a bleeder or a vent.

c' Never cut otf between valves in piping or in an exchanger liquidhydrocarbons which are subject to be heated. The thermal explnsion orliquids may create stresses such as to cause dangerous rupture. Whennecessary, open bleeder or vent.

d. Valves 11

li19s through which liquid is flowing should be ctosed slowly toavoid a liquid "hammer".

e. Make.sure that all gage glasses are clean and that the connections areunobstructed.

f' Catch basins, manholes, and other sewer connections are points ofpossible gas accumulation. No sparks, flames or hot work are permitted atthese rocations unress the opening are properry covered.When hot work is being done around covered sewers, make absolutelysure that a slight flow is maintained through them at all times so that oil anógas from other operating units cannot flow back into the unit inmaintenance.

g' Do not use light distillates such as gasoline or naphtha for cleaningmachinery or for any other cleaning purposes. Use gasoil for mostmachinery cleaning, or in exceptional cases use white spiriti

h. When starting a unit, extreme care must be taken to drain water from allvessels and lines.

when you see a fire or other emergency in the plant, notify the shiftsupervisor immediately.

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4.4 FIRE PREVENTION AND FIREFIGHTING

4.4,1 Prevention

The best protection against fires is to prevent the conditions that may lead to fire.The 3 components of any fire are: combustible material, air (oxygen), and sourceof ignition.

combustible gases and liquids normally must not be present in the atmosphereor on the ground in process areas.

All leaks must be immediately stopped. When not possible, all available means toprevent spreading must be applied.

sources of ignition must be kept away from process areas.

Where possible, air (oxygen) can be excluded by purging or blanketing withsteam or nitrogen

A fire is always ahazard to personnel and always leads to damage of equipment.

PREVENTION IS A MAJOR OBLIGAT;ON OF PLANT PERSONNEL

Common sources of ignition are:

- open flames;

hot work (welding, cutting, etc.);

- defective electricalequipment;

- automative vehicles:

- overheated metalsurfaces;

- static electricity.

smoking as weil as carrying matches and righters is prohibited.

Hot works such as welding, cutting, grinding, chipping, etc. may be carried outinside process. areas only after written pérmit'ritn-'rpé"ity-iroceoures andprecautions to be taken. Portable lights and lamps of approvód'exptosion proofdesign must be used.

Gasoline and diesel engines are allowed to operate in process areas only afterwritten permit has been obtained from the undesired combustibles in processareas.

TEGHNIP lrAl.y s.p.A. - 00148 ROMA - Viate casteilo deila Magriana, 68

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Frequent inspections must be made to detect leaks and prevent spillage.Spills must be immediately flushed with water or covered with absorbentmaterials for subsequent removal.

4.4.2 Firefighting

In many cases operators can prevent large plant fires by extinguishing smallflame-ups in thelr incipient stage. For this purpose firefighting-equiprient islocated strategically inside process areas.

Firefighting equipment consists of:

- stationary facilities including fire hydrants connected to the fire waternetwork, and snuffing steam connections;

- mobile facirities incruding fire truck and extinguishers.

Common fire extinguishing agents are:

- water to extinguish paper and wood fires; to cool equipment, tanks, etc.; toprotect personnel against r:adiant heat; to extinguish small hydrocarbon fire;

- steam to extinguish hydrocarbon fires in trenches and confined spaces; toextinguish small flame,

. (on leaking flanges, for example); to prevent

flashing of hot vapors and gases;

- foam to extinguish oilfires large and small;

- carbon dioxide to extinguish small fires of oil and other combustibles or drypowder to extinguish fires in confined spaces.

To extinguish a fire in electrical equipment (switches, transformers, motors, etc.)only carbon dioxide and dry powder extinguishers must be used.

Never use water, steam or foam on electrical fires.

Large oil fires are extinguished by plant fire fighting crews using water and foam.

In case of fire it is often necessary_ to protect personnel. An adequate supply ofprotective equipment must be available in the process area. Waier mist seryesthe same purpose when properly applied. Fire blankets are used to extinguishflaming clothing.

Safety hats and gloves are usually necessary.

All operators must be thoroughly familiar with the location of portable fireextinguishers, steam hoses, hydrants and water hoses, and protectiveequipment.

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Operators must know when and how to apply portable extinguishers.

They must also know handling of water hose, foam generators, water mistnozzles, etc.

when a fire occurs, operators must extinguish it immediately using theextinguishers, steam or water and actuate fire alarm.

ln case of large fire caused by mechanicalfailure, operators must:

a) lsolate fire and shut down unit.

b) Fight the fire.

The general procedure is as follows:

1. Stop flow of gas and liquid to equipment on fire, and depressurize to blowdown system, but keep a slight positive pressure inside the equipment.Where possible inject snuffing steam.lf flame is extinguished but elate continues, gas may spread as anexplosive clo-ud which may re-ignite;

2. Follow as closely as possible unit emergency shut-down procedure.

3. Cool any endangered adjacent structure or equipment by water jet or mist.

4. Fight with appropriate extinguishing agent, bearing in mind that oil floatingon water can easily spread the fire. Use foam in such cases.

5. A way to extinguish a fire produced by a leak is to eject steam or nitrogeninto the fire through a temporary connection from the nearest possiblelocation, after cutting off the fire causing fluid"

6. Persons not actually participating in the operations of the unit or in the firefighting are not allowed to be present in the area.


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5.

5.1 .

5.2.

5.2.1.

5.3.

5.3.1.

5.4.

5.4.1.

5.5.5.5.1.

5.6.5.6.1.

5.7.

INDEX

FIRE & GAS SYSTEMS

GENERAL

FIRE & GAS FOR CONTROL ROOM BUILDING & LOCAL PANELDESCRIPTIONFire & Gas Local Panel 100-FLP-001

FIRE & GAS FOR ELECTRICAL SUBSTATION BUILDING & LOCAL PANELDESCRIPTIONFire & Gas Local Panel 100-FLP-002

FIRE & GAS FOR SATELLITE AND MAINTENANCE BUILDING & LOGALPANEL DESCRIPTIONFire & Gas Local Panel 100-FLP-003

FIRE & GAS FOR ANALYSER HOUSE & LOCAL PANEL DESCRIPTIONFire & Gas Local Panel 100-FLP-004

FIRE & GAS FOR PROCESS UNIT & PANEL DESCRIPTIONFire & Gas Panel 100-FP-001

FIRE & GAS MAIN COMPONENTS DESCRIPTION

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YANBU - KINGDOM OF SAUDI ARABIA 1,1 ',,Gmfus*

5. FIRE & GAS SYSTEMS

5.1. General

The F & G system is designed to monitor and protect the entire Acetic Acid Plantfrom fire and gas hazards.The Acetic Acid plant Fire & Gas system is integrated in the complex Fire & Gassystem protecting and monitoring the entire industrial complex (PTA plant,

Aromatic Plant and other units present in the l. Rush lndustrial Complex).The Acetic Acid plant Fire & Gas system is divided mainly in five sub systemseach one dedicate to cover a plant portion:

o Control Building (100-FLP-001)o ElectricalSubstationbuilding (100-FLP-002)o Satellite/MaintenanceBuilding(100-FLP-003). Analyser House and (100-FLP-004). Process Units (100-FP-001)

The fire, smoke and gas monitoring detectors relevant to buildings and AnalyserHouse are connected to the sub system Fire Local Panel where the alarmsmessages are displayed and communicated to the Acetic Acid Plant general Fire& Gas Panel 100-FP-001 located in the control building technical room.Moreover the 100-FP-001 is interconnected with the existing main Fire Gas Panellocated in the CCR Instrument Cabinet Room and with new Acetic Acid PlantDCS.For graphic representation see Spec. 2'121-00-JSD-1900.01 .


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5.2.

5.2.1.

FIRE & GAS FOR CONTROL ROOM BUILDING & LOCAL PANELDESGRIPTION

Fire & Gas Local Panel 100-FLP-001

The Fire & Gas Local Panel 100-FLP-001 is installed inside the Control Building.

The detectors (smoke and heat) installed inside the control building rooms: UPS,Battery, Superintend, Document, Engineering No-1, Engineering No-2,

Supervisor, Meeting, Kitchen, Toilet, Lockers & toilet, Control, Corridors andTechnical rooms assures a continues monitoring on the ambients, any alarm iscommunicated to the FLP, where alarm are displayed on the front panel display,alarms are also communicated to the Acetic Acid Plant General F & Gas Panel100-FP-001 located in the control room and to the DCS display monitor.

The FLP provides to activate the local warníngs acoustic and visible alarm panelslocated inside the building.

ln addition Flammable Gas and Smoke Detectors are installed in the HVAC freshair intake ducts located on the building external roof to detect the presence offlammable gases and smoke in the HVAC fresh air intake sector, furthermore, a

smoke detector is installed in the HVAC air return duct.

The Control Building Fire & Gas system is equipped with a clean agent FM-200fire suppression system activated by the FLP in case smoke is detected by theVESDA Detecting System, located under false floor or by manual push button.

The Clean Agent fire suppression system consist in two cylinders locatedimmediately outside the building, inside a fenced dedicated area. Cylinders areconnected to a discharge pipe distribution system equipped with diffuser nozzles,which provide to convey and discharge the suppression compound under sidethe Technical room false floor and under side the Control room false floor.

On activation of the Clean Agent Fire Suppression System, Warning Panels"Area to Abandon" and " Do Not Enter Extinction in Operation" are activated in

advance (30 seconds before) to advise the operating personnel to evacuate therooms.

The Clean Agent Fire Suppression System is activated by means of the Fire &Gas Local Panel upon receiving the alarm signal generated by the VESDAsystem, which is designed to monitoring the ambient under false floors of theControl and the Technical rooms.

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The Fire & Gas Local Panel 100-FLP-001 installed in control room is suitable forthe following tasks:

a. To receive signalcoming from:

o The Combustible Gas Detectors installed in the fresh air ducts of theHVAC system.

o The Smoke Detectors.o Heat detectors.o VESDA system.o ManualAlarm Call Points.o High Pressure switch signal coming from Clean Agent FM-200

activation.

b. To actuate the audible and visible alarms panels "Fire Alarm", "Area toAbandon" and "No Entry Extinction in Operation".

c. To actuate the clean agent FM-200 system.

d. To send the re-circulation mode signal to the HVAC system control panel(after receiving the relevant combustible gas signal from the CombustibleGas Detector installed in the HVAC fresh air intake ducts).

e. To send the shutdown signal to the HVAC system control panel (after havereceived the smoke, heat and VESDA alarm signals from the detectorsinstalled in the Control Building).

f. To send all common alarms signal to the Fire & Gas Panel 100-FP-001located in technical room.

g. The 100-FP-001 activates the alarms at new DCS display monitor and atexisting lBN. RUSH Control Room main Fire Gas Panel.

TECHNIP ITALY $.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

1,1 ,,,T€GHftllP ITALY S.p,A. **xMq*

5.3. FIRE & GAS FOR ELECTRICAL SUBSTATION BUILDING & LOGAL PANELDESCRIPTION


The Firing Gas System installed in the electrical substation is designed to monitorand detect the presence of smoke inside the building ambients (SwitchgearRoom, Capacitor Bank Room, Mechanical Equipment Room, Battery Room andScada Room), smoke detector are located in the ceiling roof, furthermore,Flammable Gas and Smoke Detectors are installed in the HVAC fresh air intakeduct located on the building external roof to detect the presence of flammablegases and smoke in the HVAC air intake sector.

Manual Alarm Call Points are installed at strategic points of the substation.

Audio Visible Warnings alarm panel are installed at the electrical substation mainand secondary substation entrances.

The Local Fire & Gas Panel 100-FLP-002 is installed in the vicinity of thesubstation secondary entrance.

The Fire & Gas Local Panel 100-FLP-002 is suitable for the following tasks:

a. To receive signal coming from:

The Flammable Gas Detector installed in the fresh air duct of theHVAC system.: ili:ilffiHii:î"Jt;'*.

b. To actuate the audible and visible alarms "fire alarm" located at SS mainand secondary entrances.

c. To send the re-circulation mode signal to the HVAC system control panel(after receiving the relevant flammable gas signal from the Flammable GasDetector installed in the HVAC fresh air intake duct).

d. To send the shutdown signal to the HVAC system control panel (after havereceive the smoke detector alarm signal).

e. To send all common alarm signals to the Control Building Fire Gas panel100-FP-001.

f. The 100-FP-001 activates the alarms at new DCS display monitor and atexisting lBN. RUSH Control Room main Fire Gas Panel.

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TEGHI{lP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

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5.4. FIRE & GAS FOR SATELLITE AND MAINTENANCE BUILDING & LOCALPANEL DESCRIPTION


The Fire Gas System installed in the Satellite & Maintenance Building is designedto monitor and detect the presence of smoke inside the building ambients (threeOffice rooms, Tool and Consumable room, Electrical Work Shop room,lnstruments Workshop room and Corridors), smoke detector are located in thesealing false roof, furthermore, one Flammable Gas and one Smoke Detector areinstalled in the HVAC fresh air intake duct located on the building external roof todetect the presence of flammable gases and smoke in the HVAC fresh air intakesector.

Heat Detectors are installed in the Kitchen, Toilet and Lockers Rooms.

Manual Alarm Call Points are installed along the corridors; an AudioA/isibleWarning Panel is installed in the vicinity of the Cleaner room.

An Audio Visible Warnings alarm panel "Fire Alarm" is installed in the corridor.

The Local Fire & Gas Panel 100-FLP-003 is installed inside the lnstrumentWorkshop room.

The Fire & Gas Local Panel 100-FLP-003 is suitable for the following tasks:


The Flammable Gas Detector installed in the fresh air duct of theHVAC system.

: il:î',rtr'tri:-,";,.,b. To actuate the audible and visible alarms "Fire Alarm".

c. To send the re-circulation mode signal to the HVAC system control panelafter receiving the relevant flammable gas signal from the Flammable GasDetector installed in the HVAC fresh air intake duct.

d. To send the shutdown signal to the HVAC system control panel after havereceive the smoke detector alarm signal.

e. To send all common alarm signals to the Control Building fire & gas panel100- FP-001 located in the Control Building Technical Room.

f. The 100-FP-001 activates the alarms at new DCS display monitor and atexisting lBN. RUSH Control Room main Fire Gas Panel.

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5.5. FIRE & GAS FOR ANALYSER HOUSE & LOCAL PANEL DESCRIPTION


The Fire Gas System installed in the Analyser House is designed to monitor anddetect the presence of smoke, fire and flammable gases inside the housing.Local Firing & Gas Panel 100-FLP-004 is installed inside the analyser house.

The Firing & Gas Local Panel 100-FLP-004 is suitable for the following tasks:


: ffi[fi*5*-:*:"

(hvdrocarbon and hvdrosen)

b. To activate the audible and visible alarms "fire alarm" located inside/outsidethe housing (after having received the alarm signal from the Gas, Smokeand Flame Detectors or the from the ManualActivation Switches).

c. To activate the audible and visible alarms "Fire Alarm" located inside andoutside the Analyser House enclosure.

d. To generate the HVAC back-up start signal after having received theHCIH2-10% LEL alarm signal generated by the gas detectors installedinside the housing.

e. To generate the shutdown signal to the HVAC system control panel afterhaving received the HC-1Oo/o LEL alarm signal generated by the gasdetectors installed in the HVAC duct.

f. To send all common alarm signals to the Control Building Firing & GasPanel 100-FP-001.

g. The 100-FP-001 activates the alarms at new DCS display monitor and atexisting lBN. RUSH Control Room main Fire Gas Panel.


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5.6. FIRE & GAS FOR PROCESS UNIT & PANEL DESCRIPTION

5.6.1. Fire & Gas Panel 100-FP-001

The fire & gas panel 100-FP-001 located in Technical Room shall be suitable forthe following tasks:

1) To receive signals coming from:

Linear heat sensors cable installed as specified in the following point(a)

Flame detectors - UV/IR installed as specified in the following point(b)

Manual alarms call point (MAC) installed as specified in the followingpoint (c)

Flammable gas detectors installed as specified in the following point(d)

High-pressure switch (system activated) of deluge valve systems

All Fire & Gas Local Panels located in:- Control Building (100-FLP-001)- Substation(100-FLP-002)- SatelliteMaintenanceFacilities(100-FLP-003)- Analyser House (100-FLP-004)

2) To open:

The deluge valves for water spray system (after receiving the relevantlinear heat sensor cable alarm or UV/lR detectors alarm).

All deluge valves, for water spray system, from relevant push buttonson DCS graphic displays.

3) To actuate:

The field mounted audible signalling and flash beacon light (afterreceiving fire & gas field alarms and from dedicated buttons on DCSgraphic displays).

4) To send all alarms to the new DCS cabinet located in Technical Room andto the existing Main Fire & Gas Cabinet located in the existing lbn-RushdCCR lnstrument Cabinet Room.



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5) To send the status and condition of various fire & gas detectors and firefighting systems to the new DCS cabinet for visual display on geographicalmimic diagram, indicating the relative locations of all devices.


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mmkt*5.7. FIRE & GAS MAIN COMPONENTS DESCRIPTION

a. Linear Heat Sensor Cables (HSC):

The detector consists of heat sensor cable located above the equipmentsto be protected.The heat sensor cables are installed through the process and utilitiesequipment where light hydrocarbons and flammable gases are present.The heat sensor cables detectors are wired in "2 out of 2 voting loop" to thefire and gas panel 100-FP-001 located in the technical room of the controlbuilding'The HSC activates the:

. Flash Beacon Lights and audible signalling.o The related Water Deluge System.

: Ìffi E[tT#'iliil?ft existins Fire Gas pane, ,ocated at ,BNRUSHF&GPanel.

b. UV/IR Flame Detectors (UV/|R):

Flammable detectors, ultraviolet and infrared type are installed around theethane comPressor.The UV/IR Flame Detectors activates the:

. Flash Beacon Lights and audible signalling.o The related Water Deluge System.

: iffil,,,:tiffii:i:*q1"*,tins Fire Gas pane, ,ocated at,BNRUSHF&GPanel.

c. ManualAlarm call Points (MAC)

Manual alarm call points are installed inside an housing box painted in red,with a breaking glass installed in the box front side and build in accordancewith the related area classification, the manual call points are visibly locatedalong the plant roads and inside the process areas.

The maximum travelling distance inside the process plant to reach one callpoint do not exceed 61 meters, manual call points are grouped per processareas or per geographically areas and the output signal is connected to thefire & gas panel 100-FP-001 located in the control building.


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The MAC activates the:

o Flash Beacon Lights and audible signalling.o The Fire Alarm at 100-FP-001.o The Fire Alarm at new DCS.o The Fire Common Alarm at existing Fire Gas Panel located at IBN

RUSHF&GPanel.

d. Flammable Gas Detectors (AT):

Flammable gas detectors, infrared point type are installed in the processarea where light hydrocarbons are present.They are located around the compressors handling flammable gases orflammable liquids at a temperature exceeding their flash point; they arelocated also in the critical points where there is possibility of combustibleleakage near by the ignition sources.Output signal from the detector is wire to the F&G Panel 100-FP-001located in the control building.Detectors generate a pre-alarm signal at 25o/o of low explosivity limit (LEL)and the alarm signal at 50o/o of LEL.The AT activates the:

o Flash Beacon Lights and audible signalling.o The Fire Alarm at 100-FP-001.. The Fire Alarm at new DCS.. The Fire Common Alarm at existing Fire Gas Panel located at IBN

RUSHF&GPanel.

e. Flash Beacon Light (VA)

The Flash Beacon Lights are installed in the field, the flashing red light isindicating to the personnel present in the site that a Fire Alarm is on going.The VA are activated by:

. Linear Heat Sensor Cables.o Fire Alarm Manual Call Points.. UV/IR Flame Detectors.o Flammable Gas Detectors.

f. Audible signalling (AA)

Emergency/Fire Alarms will be broadcast throughout the site via audiblealarm sounders. The system will inform all personnel on the site via acoding system.

In the event of an Emergency/Fire alarm a standard format coded messagewill be output over the alarm system.

TEGHNIP ITALY $.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

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The zone reference will be output to inform all personnel in what locationthe emergency is. All personnel in the area indicated by the zone referencewill follow the appropriate IBN Rushd safety and evacuation procedures.Personnel in all other areas will remain alert for further information. ln theevent that the entire site needs to be evacuated an alarm will sound with acontinuous tone. All Clear and Reset of the coded alarms shall be from thepush buttons on the F & G Consoles in the Central Control Room (CCR)and Fire Station.

The AA are activated by:

o Linear Heat Sensor Cables.. Fire Alarm Manual Call Points.. UV/IR Flame Detectors.o Flammable Gas Detectors

g. Smoke Detector (SD)

The Smoke Detectors are installed inside the buildings and in the HVACducts.The SD is design to detect the presence of smoke inside the ambients.The SD activates the:

. Shut Down signalto the related HVAC system.

. The Fire Alarm at 100-FP-001.

. The Fire Alarm at new DCS.o The Fire Common Alarm at existing Fire Gas Panel located at IBN

RUSHF&GPanel.

h. VESDA System

The VESDA (Very Early Detection Apparatus) system is installed in theAcetic Acid Plant Control Building.The system detects the presence of smoke under the false floor ambient in

the control room and in the technical room.The VESDA activates the:

. Shut Down signalto the related HVAC system.o The Fire Alarm at 100-FP-001.o The Fire Alarm at new DCS.o The Fire Common Alarm at Existing Fire Gas Panel located at IBN

RUSHF&GPanel.o The Clean Agent Fire Suppression system FM-200.. The Warning Panels, "Area To Abandon", Do Not Enter Extinction In

Operation".


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?kc&*rfpPîoj.2121 - SABIC ACETIC ACID PROJECT

YANBU - KINGDOM OF SAUDI ARABIA 1,1 ,,,**mfug*

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INDEX

6. ATTACHMENTS

6.1. SPECIFIGATIONS6.1.1. Basic Design Data6.1.2. Guidelines for PID Preparation6.1.3. Process Control & ESD Philosophy

6.2. DRAWINGS AND DIAGRAMS6.2.1. Piping & Instrumentation Diagrams6.2.2. Process Flow Diagrams6.2.3. Utility Flow Diagrams6.2.4. General Plot Plan6.2.5. Plot Plan, Details & Elevations, Key Plans6.2.6. Process Logic Diagrams6.2.7. Cause & Effect Chart6.2.8. Overall Single Line Diagram6.2.9. Hazardous Area Classification6.2.10. Alarm & Trip List6.2.11. Fire Fighting Layout6.2.12. GeneralUndergroundNetwork

6.3. DOCUMENTS, LISTS AND SGHEDULES6.3.1. Equipment Schedule6.3.2. Line List6.3.3. Fluid List6.3.4. PSV and RV Summary of Rates6.3.5. Effluent Summary6.3.6. Utilities Consumption Summary6.3.7. Electrical Consumer List6.3.8. Piping Class Summary6.3.9. Fire and Gas Detection and Protection System Specification

6.4. DATA SHEETS6.4.1. Process Data Sheets6.4.2. InstrumenUAnalyzers Data Sheets6.4.3. Safety Valves Data Sheets6.4.4. Catalysts and Chemicals Data Sheets6.4.5. Lubricant & Grease List6.4.6. Hazard Study Data6.4.7. Catalyst and Chemicals Loading and Unloading6.4.8. Fire & Gas Detection System Specification6.4.9. Fire & Gas Cause & Effect6.4.10. Fire Fighting & Detection Drawings




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6. ATTACHMENTS

6.1. SPECIFICATIONS

6.1.1. Basic Design Data

2121-00-JSD-0000-01


TECHNIP.COFIEXIPProject N' Unit Document Code Serial N' Rev. Page

2121 00 JSD 0000 01 1 1ts7

SABIC ACETIC ACID PROJECT

YANBU _ KINGDOM OF SAUDIARABIA

PROJECT DESIGN BASIS

f ,\ l"îA ln {A1 St,tooZ ISSUEO FOR EXECUTION

(tNCLUOES SAErC COMM€NÍ Sl $d,".JllvÀ -; rKLo Í \ì[.,^,.I V,/0 18-SEPT. 2002 ISSUED FOR EXECUÎON

ORLANOINI MOSCHERAI \./ . <-/-

TlttfrntlREV. OATE STATUS WRITTEN BY CHECKED BY

DOCUMENT REVISIONS

TECHNIP ITALY S.p.A.- 00148 ROMA - Viale Castello della Magliana, 68

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INDEX

CONTENTS


SITE CONDITIONS (Climatic and Geological)SITE DATACLIMATIC CONDITIONSPRECIPITATIONSANDSTORMSEARTHQUAKE (SETSMTC CON D|T!ONS)ENVIRONMENTAL CRITERIANOISEFLAREr/E /NS CONDITIONS

PROCESS DESIGN DATAPRODUCTION CAPACITYFEEDSTOCKSPRODUCTSUTILITIESPROCESS EFFLUENTSCATALYST AND CHEMICALSFLAREDRAINS

PLANT LAYOUTPLOT PLANBUILDINGS

STATIONARY EQUIPMENT DESIGN REQUIREMENTS

CIVIL, STRUCTURAL AND ARCHITECTURAL DESIGNCIVIL DESIGN CRITERIABUILDINGS - GENERAL REQUIREMENTS

SHEET NO

1. GENERALDATA1.1. PROJECT TITLE1,2. PROJECT DESCRIPTION AND LOCATION1.3. DEFINITION OF PROCESS AREAS AND ASSOCIATED BATTERY LIMITS1.4. CONTRACT LANGUAGE1.5. UNITS OF MEASUREMENT1.6. OPERATINGREQUIREMENTS1.7. PROVISION FOR FUTURE EXPANSION1.8. PROJECT REGULATIONS, CODES, STANDARDS AND SPECIFICATIONS

444455777

lr|;tt

LEo

2.2.1.2.2.2.3.2.4.2.5.2.6.2.7.2.8.2.9.

3.3.1.3.2.3.3.3.4.3.5.3.6.3.7.3.8.

4.4.1.4.2.

5.

6.6.1.6.2.

15151618191919202020

212121232434343535

363636

36

363637

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7.7.1.7.2.7.3.7.4.7.5.7.6.7.7.7.8.7.9.7 34.

8.8.1.8.2.8.3.8.4.8.5.8.6.8.7.

ELECTRICAL DESIGNDISTRIBUTION LEVELSPOWER DISTRIBUTION SYSTEM DESIGNELECTRICAL EQUIPMENT DESIGNCABLES AND CABLE ROUTING PHILOSOPHYLIGHTING DESIGNPLANT COMMUN ICATIONS SYSTEMSEARTHINGSOIL RESISTIVITYDESIGN CRITERIA/PH ILOSOPH IESELECTRICAL SYSTEM STUDIES AND CALCULATIONS

INSTRUMENT DESIGNINSTRUMENTATION SYSTEM TYPEDISTRIBUTED CONTROL SYSTEMEMERGENCY SHUTDOWN SYSTEMFIRE AND GAS DETECTION SYSTEMPACKAGE UNITS - CONTROL SYSTEMINSTRUMENT CABLINGON-LINE ANALYSERS

3838404141424244444444

4545454546464848

484849

494949

505050505050

9. SAFEry SYSTEMS AND FIRE PROTECTION9.1. GENERAL9.2. FIRE PROOFING

10. INSULATION AND PAINTING10.1. INSULATION14.2. PAINTING

11. SPARE PARTS11.1. SPARES PHILOSOPHY11.2. INSTALLED SPARES1 1.3. COMMlSSIONING SPARES11.4. TWO YEARS OPERAT|ON SPARES (MATNTENANCE SPARES)11.5. CAPITAL SPARES

ATTACHMENTSAttachment I Wind RoseAttachment ll Meteorological DataAttachment lll Monthly Temperature Range and Relative HumidityAttachment lV Intensity - Duration - Frequency Curve of RainfallAttachment V Sandstorm DataAttachment Vl Temperature DataAttachment Vll Tie-lns Data

48495051525354

UJ

to

Ip=

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This document, issued in TPIT headed paper, is an updating of SABIC document 2068-00-W3-s1/'1.

The modifications from the source document are written in ltalic characters.

1. GENERAL DATA

1.1. PROJECT TITLE

Project Title: SABIC ACETIC ACID PROJECT

1.2, PROJECT DESCRIPTION AND LOCATION

1.2.1. ProjectDescription

The Plant is to be designed to produce 34,000 MTPA of 'glacial' acetic acid fromethane and oxygen feedstocks. (30,000 MTPA from a "Conventional Reactor System'and 4,000 MTPA from SABIC's proprietary Reactor System).

1.2.2. Plant Location

The Plant shall be located at the lbn Rushd Site, Yanbu Industrial City, WesternProvince, Kingdom of Saudi Arabia. The site is an existing petrochemicalmanufacturing complex located approximately 19 km south of Yanbu City situated inthe Western part of Saudi Arabia at the intersection of 24" 05' of Northern Latitude and38' 07' Eastern Longitude.

1.3. DEFINITION OF PROCESS AREAS AND ASSOCIATED BATTERY LIMITS

The "lnside Battery Limits" (ISBL) Plant contains process units and associated tankagefor producing 'glacial' acetic acid. The ISBL Plant is split into eight distinct processunits:

Unit 00 - General/Common AreasUnit 01 - Reactor Feed PreparationUnit 02 - Conventional Reactor SystemUnit 03 - Product Recovery and PurificationUnit 04 - COz Removal SystemUnit 05 - ISBL TankageUnit 06 - Steam/Condensate Sysfem and ISBL UtilitiesUnit 07 - HP Nitrogen System/HP FlareUnit 08 - SABOXR Reactor System


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1.4. CONTRACT LA,NGUAGE

English language shall be used in all Project communication and docurnentation.

1.5. UNITS OF MEASUREMENT

In general, Sl metric units are

DescriptionTimeLength I HeightAreaVolume

Pipe DiameterTubing and fitting díameterExternal Diameter of Tubes for HeatExchangerThickness of Heat Exchanger TubesPressure

Vacuum (Pressure)Pressure DropTemperatureVolume Flow Rate

Mass Flow RateMolecular WeightMolar Flow RateMass (Weight)Composition

Concentrations

VelocityDensityEnergyPower

to be used, in accordance with the units outlined below:

Unith (hours), s (seconds), a (years)mm, mm'Liquids - mu, litresGases (at normal conditions) - Nm" (Note 1)lnchesInchesmm

mmbar a (for material balance)bar g (for mechanical data)mm WG HzO (for tanks operating and designpressure)[Note: 1 bar = 1.03 kg/cm2, equivalent]mbar abaroc

Gas Flow - Nm3lh; m3/hLiquid Flow - m3ihkg/h (all streams), Vhkg/kmolkmol/h, kmoliskg, t (i.e. metric tonns)mol % (gas)wt % (solid or liquid)ppm vút

ppq volg/m'mg/L

^mgim"vol %mol %

m/skg/m3KJ, KWhW, KW

uJto

p


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DescriptionHeatHeat DutyThermal ConductivityHeat Transfer CoefficientFouling FactorHeat CapacityViscosity (Dynamic)Viscosity (Kinematic)Surface TensionForceStressMoment of Force or TorqueElectrical PotentialElectrical CurrentElectrical Resistance

Electrical ConductivitvFrequencyRotational SpeedSound Pressure Level (SPL)Sound Power Level (PWL)

Notes:

UnitKJ

KWW/m'Cw/m2'cm"civvkJ/kg "CcPm2ls, cStdynes/cmNorkNN/mm2Nm or kNmVorkVAormAf), kO, MC) (may be written ohmn, kohmn,Mohmn)prS/cmHzor kHzrpmdB [ref. 2 x"1O-' Pa (dB(A) if 'A'weighted)]dB [ref. 10-''W (dB(A) if 'A'weighted)]

1. Normal conditions are based on 1 atmosphere and 0"C dry.

ultod

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1.6. OPERATING REQUIREMENTS

a. Plant Capacity:

b. Plant On-stream Requirement:

c. Plant Required Life:

Refer to Section 3.1

8,000 hours per year

20 years

d. Specific Turndown or Operating Conditions to be met: Plant to operate between70 and 100o/o of thecapacity to be producedin the ConventionalReactor System (seeSection 3.1 for furtherdetails on plant capacity).

1.7. PROVISION FOR FUTURE EXPANSION

None.

,I.8. PROJECT REGULATIONS, CODES, STANDARDS AND SPECIFICATIONS

The design of the Plant shall be in accordance with the following Royal Commission,Saudi Ministry, SABIC (including "DuPont Standards" and "Bechtel Specifications"),lnternational Codes, Standards and Specifications and KPT design specifications.

1.8.1. Royal Commission Regulations

The RoyalCommission Regulations to be followed are:

Royal Commission Environmental Regulations Consultation Document (September1 998)Royal Commission for Jubail and Yanbu

1.8.2, Saudi Ministry Security and Safety Directives

The Saudi Ministry Security and Safety Directives (SSDs) to be followed are:

SSD-01 Standard Security FenceSSD-02 Category ll FenceSSD-03 Category lll FenceSSD-04 Category lll Fence AlternativeSSD-05 Gates in Perimeter FencesSSD-05A Gates in Woven Wire Fabric FencesSSD-06 Barbed "S" TapeSSD-07 Security and Emergency Exit DoorsSSD-08 Locks used on Security and Emergency Exit Doors

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SSD-09 Minimum Standards for Buildings Housing Vital or SensitiveEquipment

SSD-10 Protection of Vital EquipmentSSD-11 Power SuppliesSSD-12 CommunicationsSSD-13 Security Lighting SystemsSSD-14 Check Point LightingSSD-15 Intruder Detection SystemsSSD-16 Automatic Control of Entry Systems (see also SSD-23)SSD-17 Gate House and Vehicle LockSSD-18 Fire Fighting EquipmentSSD-19 Work Permit ProceduresSSD-20 Expanded Steel MeshSSD-21 Protection of Diesel Engines in Hazardous AreasSSD-22 Gasoline Filling StationsSSD-23 Automatic Control of Entry Systems - Buildings TurnstilesSSD-24 TurnstilesSSD-25 lnternal Cleaning of Storage TanksSSD-26 Blast Resistant Control RoomsSSD-29 The Safe Design, Construction, Operation and Maintenance of

Hydrocarbon Carrying Pipelines

1.8.3. SABIC Standards

For SABIC Standards to be followed on the Project, including the order of preferenceof each code and specification to be followed, refer to the following "Guidelines to theUse of SABIC Standards".

a. Guidelines to the Use of SABIC Standards for Plant Layout and Piping Design,( reference 2068-00-P3-S2 )

b. Guidelines to the use of SABIC Standards for Rotating Equipment,(reference 2068-00-J 1 -S1 )

c. Guidelines to the Use of SABIC Standards for Equipment,(reference 2068-00-D 1 -S2)

d. Guidelines to the Use of SABIC Standards for Instrumentation Design,(reference 2068-00-N8-S 1 01 )

e. Guidelines for the Use of SABIC Standards for Electrical Design,( reference 2068-00-R8-S 1 )

f . Guidelines to the Use of SABIC Standards for Civil Design,(reference 2068-00-A4-5 1 )

g. Guidelines to the Use of SABIC Standards for Architectural Design,(reference 2068-00-81 -S 1 )


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h. Guidelines to the Use of SABIC Standards for Structural Design,(reference 2068-00-C1 -S1 )

i. Guidelines to the Use of SABIC Standards for Loss Prevention,(reference 2068-00-T3-5 1 2)

1.8.4. KPT Design Specifications

The following KPT specifications are applicable to the Plant design.

Piping Philosophy for P&lDs, (reference 2068-00-T3-31)

Over-Pressure Protection Philosophy for P&lDs, (reference 2068-00-T3-53)

Relief System Philosophy for P&lDs, (reference 2068-00-T3-S4)

Specification for Plant Layout, (reference 2068-00-P3-S1 )

KPT "DVS" Stationary Equipment Standards No' 177 and 191 (reference Appendixof "Guidelines to the Use of SABIC Standards for Stationary Equipment".

1.8.5. International Codes and Standards

The following principal internationally acceptedfollowed:

Rotating Machinery

Centrifugal CompressorReciprocating CompressorLubricating SystemsVibration MonitoringStearn Turbine (General Purpose)Steam Turbine (Special Purpose)Gear Systems (General Purpose)Gear Systems (Special Purpose)Couplings (Special Purpose)Pumps - Centrifugal

1.8.5.1.

APr 617 - (1e95)

A;P|677 - (1997

Codes and Standards are to be

API 618 - (1995API 614 - (1999APr 670 - (19e3APt 611 - (1997APr 612 - (19e5

APr 613 - (1ees)APr 671 - (1998)APr 610 - (1e95,ASME B73.1MI

8th Edition) and(1991 & 1992

uJso

boPumps - Reciprocating

Purnps - MeteringOiland Lubricating Systems (Process Pump)VacuumMachinery lnstallation and Installation Design

errata)ASME 873.2 Mr - (1991)API 674 - (1995) or Manufacturer'sstandardAPr 675 - (19e4)APr 610 - (1995)Manufacturer's standardAPr 686 - (19e6)


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1.8.5.2. StationaryEquipment

Pressure Vessel

1) ASME Boiler and Pressure Vessel Codea) Pressure Vessels Section Vlll, Div.1 (1998)b) Boilers Section l, Div.1 (1998)c) Non-destructive Examination Section V (1998)d) Welding and Brazing Qualifications Section lX (1998)e) Material Specifications Section ll (1998)

A : Ferrous MaterialsB : Non-Ferrous MaterialsC : Specifications for Welding RodsD: Properties

2) American National Standarda) Pipe Flanges and Flanged Fittings ASME 816.5

(1 996 + lnterpretations)b) Pipe Threads ASME 81.20.1(1983)

3) Large Diameter Carbon Steel ASME 816.47Flanges (1996 + Interpreiations)

4) Calculation of Stresses in Horizontal BS 5500 or LP Zick methodVessels and Saddle Supports

5) Local Stresses Calculation Spheres W.R.C. Bulletin 297 (1987)and Cylinders

6) Screw, Thread, Bolts and Nuts IS0-261 (1998)

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Shell and Tube Type Heat Exchanger

1) ASME Boiler and Pressure Vessel Code (including Addenda)a) Pressure Vessels Section Vlll, Div.1 (1998)b) Non-destructive Examination Section V (1998)c) Welding and Brazing Qualifications Section lX (1998)d) Material Specifications Section ll (1998)

2) TEMA R, TEMA 8th Edition, 1999

3) Shell and Tube Heat Exchangers API 660 - (1993)

4) Gland Condensers to Manufacturer's standard

5) Surface Condensers shall be HEI (Heat Exchanger Institute)

6) American National Standard

a) Pipe Flanges and Flanged Fittings ASME 816.5 (1996 +Interpretations)

b) Pipe Threads ASME 81.20.1 (1983)

7) Bolt Threads 150-261 (1998)

Plate Type Heat Exchangers

Designed and fabricated in accordance with Manufacturer's standard.

Air Coolers

Designed and fabricated in accordance with Manufacturer's standard but to followthe intent of 'Air Cooled Heat Exchangers - API 661 - (1997)'.

Double Pipe Heat Exchangers

Designed and fabricated in accordance with Manufacturer's standard.

Fired Heaters

1) Calculation of Heater - Tube Thickness in API STD 530 - (1996)Petroleum Refineries

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Cone Roof Tank

1) API Standarda) Welded Steel Tanks for Oil API 650 (1993) + Addenda (1994,

Storage 1995, 1996 & 1997) / API 620 (1996) +Addenda (1996 & 1997)

2) American NationalStandarda) Pipe Flanges and Flanged ASME 816.5 (1996 + Interpretations)

Fittingsb) Pipe Threads ASME 81.20.1(1983)

1.8.5.3. Piping

Plant Piping ASME 831.3 -(1996 + Interpretations Nos. 14 to 17)ASME 831.3 - Addenda

Pipe Flanges and Flanged Fittings ASME 816.5 - (1996)ASME 816.5 - lnterpretations

Larse Diameter steer Franses îSilE 313.?? - (1ee8) Addenda

(1 996 + lnterpretations)Face{o-Face and End{o-End Dimensions ASME 816.10-of Valves (1992 + Interpretations)Valves - Flanged, Treaded and Welding ASME816.34-(1996)

îSME B 1 3 SiiliTJBS'ilì""0"Factory Made Wrought Steel Buttweld ASME 816.9 - (1993 + Interpretations)FittingsForged Fittings, Socket-Welding and ASME 816.11 - (1996)ThreadedPipe Threads ASME 81.20.1(1983)Buttweld Ends ASME 816.25 -

(1977 + Interpretations)Power Piping ASME 831.1 - (1998)

ASME B31.1 - Cases No 25 and No 26ASME 831.1 - lnterpretationsASME 831.14 - Addenda

Pipeline Transportation ASME B'31.4 - (1998)Systems for Liquid ASME P,31.4 - Case No 24

ASME 831.4 - Interpretation No 5Gas Transmission and Distribution Piping ASME 831.8-(1999)SystemsPipe Hangers and Supports MSS-SPS8 - (1993)

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1.8.5.4. ReliefSystems

Design of Relief Systems API RP 520 Part 1: 2000Part.2:1994

APl RP 521 - (1997)APr RP 526 - (19e5)

Venting Atmospheric and Low Pressure Storage API STD 2000 - (1998)Tanks

1.8.5.5. Instrumentation

lnstrumentation Symbols and ldentification ISA 5.1 (short form) - (1984) +(1ee2)

Graphs Symbols for DCS lnstrument Logic and ISA 5.3 - (1983)Computer SystemsInstrument Loop Diagrams lSA 5.4 - (1991)Alarm Annunciation Sequences ISA 518.1 - (1979 and 1992 (R))ControlValves Sizing ISA 575.1 - (1985 and 1995 (R))Face{o-Face Dimensions for lntegral Flanged Globe ISA 375.3 - (1992)Style Control Valve BodiesFace-to-Face Dimensions of Flangeless Control ISA S75.4-(1995)ValvesMechanical Protection Degree for Enclosures IEC 60529 - (1989)Orifice Sizing ISO 5167 - (1991 and 1998

Addenda)Leakageof ControlValves ANSI FC170-2-1976 (R1982)Codes for Electrical Enclosure and Installation in IECiCENELECLocation with Explosion or Fire HazardManualof Instrument Installation API RP 551 (1993y552 (1994)Electrical Thread ISO 7-01 - (1981)

rso 7-02 - (1982)

1.8.5.6. Electrical

Hazardous Area Classification lP Model Code of SafePractice, Part 15 (1990)

General Design IEC StandardsElectricalEquipment IEC Standards

1.8.5.7. FireProtection

Fire Protection NFPAuJ

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1.8.5.8. Civil, Structural and Architectural

Structural Steel American Institute of Steel Construction (AISC)American National Standards Institute (ANSI)

Earthquake Seismic Analysis - Uniform Building Code (UBC)1994

Buildings Uniform Building Code (UBC - 1997)Reinforced Concrete American Concrete lnstitute (ACl)

American Society for Testing and Materials(ASrM)

Foundation for Reciprocating and BS (British Standard Institution), CP2A12 - Part 1

Rotating Machinery (974) + Amendment No. 1938 (1976) and/orManufacturer's standard

Supporting Structures for Rotating German DIN 4024Machines

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2.

2.1.

SITE CONDITIONS (Glimatic and Geological)

SITE DATA

a. The Plant is to be built on a green field site within an existing petrochemicalmanufacturing complex. Plant location is near the coast and therefore subjectto sea winds.

Hot and humid weather occurs for a number of months during the year. The airis frequently laden with sand and dust, particularly after a sandstorm.

External corrosion protection shall take into account the environmentalconditions outlined above. ln particular, the Technip ltaly is required duringdetail engineering to give particular attention for providing suitable externalcorrosion protection to stainless equipment and piping. For further details referto the document "Guidelines to the Use of SABIC Standards for StationaryEq uipment" (reference 2068-00-D 1 -S2).

Reference lbn-Rushd Plant Benchmark

Plant Hígh Point of Paving, correspondingto absolute elevation referenced to 8.300mM.Y.A.S.

Plant top of pump foundations

Ob ft m M.Y.A.S datum

100.000 m

100.300 m

d.

e.

Site is not subject to flooding or subsidence.

Limitation of transportation of equipment to site:

Weight Limit: 850 tonnes (for equipmenttransported from Yanbu IndustrialPort to lbn Rushd Plant site)

Dimensional Limits: 7.0 m diameter, 86 m long (forequipment transported fromYanbu Industrial Port to lbn RushdPlant site)

Stacks (point sources) to comply with M.Y.A.S. (Madinat Yanbu Al-Sinaiyah) AirQuality Regulation A.O.-4, ie minimum stack height to comply with the following:

H"= H + 1.5L, where

H": good engineering practice stack height, measured from the ground-levelelevation at the base of the stack.

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H: height of nearby tall structure measured from grade level elevation at thebase of the stack.

L: lesser dimension, height or projected width, of nearby structure(s).(Note: "nearby" rneans the distance up to five times the lesser of theheight or the width dimension of a closest structure but not greater than0.8 km).

s i::ff1$;:lx?:,:r*î"lo

be rocated on 46 m in heisht

2.2. CLIMATIC CONDITIONS

The following Site climatic data shall be used for design purposes:

2.2.1. Wind

Prevailing wind direction : Westerly to North-Westerly(For specific details refer to the windrose shown in Attachment l).

Normal wind velocity (97o/o of the time): Less than 48 km/h (13.3 m/s)Maximum wind velocity: 16.94 misHighest recorded wind velocity: 95 km/h (26.4 mis)Wind loading for design (Basic Wind Speed), 34.7 m/s at 10 m elevation (50 yearV30: return period)

38.9 m/s at 10 m elevation (100 yearreturn period)

Site Exposure Condition: Exposure "C" to ASCE 7-95Design velocity for dispersion calculations: 0.49 misDesign velocity for flare radiation calculations: 13.3 m/s (to be confirmed during

detail engineering)Topographic Factor K4 1.0lmportance factor l* 1.15Gust Effect Factor G 0.85

LUjo

ITECHNIP ITALY S.p.A.- 00148 ROMA - Viale Castello della Magliana, 68

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2.2.2. Barometric Pressure

Design Barometric Pressure :

Annual Minimum :

Annual Maximum :

Notes:

2.2.3.

1.01325 bara(1 atmosphere absolute)0.991 bara1.016 bara

1. For specific details refer to the meteorological data shown in Attachment ll.2. Design barometric pressure to be used for both equipment and process design.

Temperature

Maximum SummerMinimum WinterDesign MaximumDesign MinimumDesign Ambient (for process design)Design Maximum AmbientDesign Dry BulbDesign Wet Bulb(These coincident temperatures are to be used in process design, and equipmentdesign for air coolers, cooling towers, compressors, etc)

Equipment exposed to Sunlight (Black Body 85'CTemperature)

48.9"C9.1"C50"cg"c25"C40"c50"c29.5'C

Air Temperature for Cable SizingSoilTemperature for Cable Sizing

Design Temperature for Outdoorlnstrumentation and Electrical Equipment(excluding cables)

MaximumMinimum

Design Temperature for Outdoor SteelStructure

MaximumMinimum

50'c40'c

85'Cg"c

85"C9'C

Design Temperature for Outdoor Electrical 50"CEq u ip me nt ( u nd er shelter)UJ

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2.2.4. Humidity

Maximum: 10Ao/o

Minimum : 22o/o

Design : 1OA%

Notes:1. Design figure to be used both for equipment and process design.2. For monthly relative humidity data, refer to Attachment lll

2.2.5. Heating, Ventilation and Air Conditioning Design Data

Summer WinterOutdoor Condition

Dry Bulb 40"C 8'CWet Bulb 28'C I'C

lndoor Condition (at 50 t 5o/o relative humidity, dry bulbtemperature).Control Building, Electrical Substation , and 23"C t 2'C 21"C t 2"CMaintenance WorkshopAnalyzer House 23"C t2"C 21"C t2"C

2.2.6. Sofar RadÍation

Maximum sotlar radiation is 1.04 kWm2.

2.3, PRECIPITATION

2.3.1. Rainfall

Yearly average : 33.0 mmMaximum per year : 104.0 mmPeak rate for design of sewers : 60 mm/h for 15 minutes duration (10 year

return period)Peakratefordesign of sumps: 60 mm/h for 15 minutes duration (10 year

return period)Run-off coefficients: Concrete or Asphalt Pavement 0.8

Gravel Roadway or Shoulder 0.4Unpaved Areas including GravelSurfacing 0.2Roof on Building 0.9

Thunderstorms and Lightning : Design to consider lightning occurringoccasionally

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2.3.2.

2.3.3.

2.3.4.

2.4.

2.5.

2.6.

2.6.1.

2.6.2.

Notes:1. Attachment lV contains Intensity-Duration-Frequency Curve for rainfall in the

Yanbu Area.

Snowfall

Zero.

Winterisation

Winterisation Design Temperature 9'C(Minimum Ambient Temperature in Winter)

Water Table

Water Table Height : 6.0 m to 6.75 m below grade level

SANDSTORMS

Typical data associated wíth sand and dust storms is shown in Attachment V.

EARTHQUAKE (SETSM rC CON DTTTONS)

Uniform Buílding Code (1994), with Seismic Zone 2-A (Z Factor = 0.15), with anlmportance Factor | = 1.25.Site Coefficient (according UBC 1994) is Ss=1.5

ENVIRONM ENTAL CRITERIA

Air Environment

a) The maximum permitted limits for discharge of gaseous effluent to atmosphere tobe in accordance with the Royal Commission Environmental Regulations ConsultationDocument (Section 2, September 1998) - Royal Commission for Jubail and Yanbu.For further details refer to the document "Plant Effluent Data (reference 2068-00-T2-z3).

Water Environment

Refer to The Royal Commission Environmental Regulations Consultation Document(Section 3, September 1998) - Royal Commission for Jubail and Yanbu. [Note: Theseare for liquids entering the "environment", not for liquids leaving the Plant routed to thelbn Rushd Site Effluent Treatment Unit.l For further details refer to the document"Plant Effluent Data ( reference 2068-00-T1 -23)" .

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2.6.3. Storm Water Disposal

Clean rain water run-off to be collected by a combination of storm water drains androuted to the Plant Open Process Drain Sump (A151). For further details refer to thedocument "Drainage and Effluent Philosophy (reference 2068-00-T2-S4)".

2.6.4. Sanitary Waste

All sanitary waste (foul water) from the Plant Control and Maintenance Buildings to berouted into the Site's sanitary effluent system. Design details to be developed in detailengineering by the Technip ltaly.

2.7. NOTSE

For limits and design requírements refer to:

a. Guidelines to the Use of SABIC Standards for Rotating Equipment, reference2068-00-J1-S1.

b. SABIC Standard (Bechtel Specification) "Noise Control, reference 22854-SP-000-4-01 5. revision 0".

2.8. FLARE

a. The Flare Headers are to be designed to limit velocities to a maximum of 0.5Mach.

b. Relief valve outlet tailpipes are to be designed to limit velocities to a maximum of0.75 mach.

2.9. TtE 'NS

CONDITTONS

The tables in attachments Vll provide:. Lr'sú and operating conditions of exisfing tie ins. Lisf and conditions of plant battery (imits.

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3. PROCESS DESIGN DATA

a. All pressures are referred to grade elevation unless otherwise stated.b. Molar volume is taken at22.414 Nm'per kilogram mole.

3.1. PRODUCTION CAPACITY

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I

The Plant is designed to produce the following product capacity for a plant onstreamfactor as outlined in Section 1.6 a.

Total Plant Capacity: 34,000 (mtpy) metric tonnes per year ofAcetic Acid as per the productspecification outlined in Section 3.3.1below.30,000 mtpy of which is to be produced ina "Conventional Reactor" System, withthe remaining 4,000 mtpy in the"SABOXR" Reactor System.

3.2. FEEDSTOCKS

3.2.1. Ethane

Source : Gas supplied to the plant battery limits from Aramco

Specification :

Ethane 95.0 mol % min.Methane 2.5 mol o/o tYràx.Propane 2.5 mol o/o trràx.Carbon Dioxide 0.15 mol o/o trràx.Hydrogen Sulfide 100 ppm vol Normal

(570 ppm peak - Note 1)Carbonyl Sulfide 7 ppm vol Normal

(30 ppm peak - Note 1)Notes:1. Peak concentrations occur for a maximum of '120 hours duration (not continuous)

in total in any one (1) year.


Pressure Minimum 16.8 bar gNormal 18.6 bar gMaximum 20.7 bar gMechanical Design 31.1 bar g


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3.2.2.

3.2.3.

3.2.4.

15'C36"C85"C

Gas supplied to the plant battery limits from external source.


Temperature MinimumNormalMechanical Design

Oxygen

Source:

Specification:OxygenNitrogen and Argon


Temperature MinimumMaximumNormalMechanical Design

Nitrogen

Source:

Specification:


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ButylAcetate

Source : Butyl Acetate is either supplied from a road tanker or drums into theEntrainer Holding Tank (D252).

Specification : To be confirmed by SABIC 99.5% Urethane Gradeduring detail engineeringln-ButylAcetaten-ButylAlcoholWater ContentColour (Pt-Co Units)Acidity, as Acetic Acid

15"C50"c36"C85"C

Nitrogen is used as a feedstock within the process. Source is fromNitrogen supplied to the Plant's battery limit.

For specification and battery limit supply conditions refer to 3.4.9 a)below.

99.5 wt % min0.50 wt o/o Ílax0.050 wt % max10 max0.01 wt o/o max


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3.2.5. Road Tanker Details

Bottom Discharge: 3" BSP male external threaded connector closed by stainlesssteel cap. (Note: tanker is not equipped with self-contained off-loading pump,)

N2 Connection: 2%" BSP male external threaded connector closed by stainlesssteel cap.

Tanker is equipped with relief valve set at 3.75kg/cm2g and 0.21kgicm2 of vacuum.

Tanker is rated for an electrical hazardous area classification Zone 2 Gas Group llBTemperature Class T3.

Tanker to be correctly earthed before off-loading can commence. (Earthingconnection to be rated for correct electrical hazardous area.)

3.2.6. Drum Off-Loading Details

Drums are to be off-loaded by portable pneumatic (plant air) pump with connection intoa 1" female coupling system. (Discharge piping system to be rated for 150 lb,)

2-off pneumatic pumps to be provided.

3.3. PRODUCTS

3.3.1. Acetic Acid (Glacial)

Acetic acid is pumped frorn the Acetic Acid Product Tank to the Plant battery limits.

Specification reference U.S.P Grade 45476

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CompositionAcetic AddWaterFormic AcidAldehydeslronHeavy metalChloridesSulphatesSulphuric AcidPropertiesFreezing pointSpecific GravityDistillation rangelnitial Boiling PointDry pointColour, platinum-cobalt unit

99.85 wt % min0.15 wt o/o Írax0.05 wt To max0.05 wt o/o ÍtaX1.0 ppm by wt max0.5 ppm by wt max1.0 ppm by wt max1.0 ppm by wt max1.0 ppm by wt max

16.350C1.0505 - 1.0520 @ zotzT'C1.0

oC max.117.3oC min.118.3oC max.10 max


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YANBU _ KINGDOM OF SAUDIAMBIA

Permanganate time (ACS test) 2 hours, min

Export conditions at the battery limit of the Plant:

Pressure Minimum 3.5 bar gMechanical Design 7.9 barg

Temperature Minimum 25"CNormal AmbientMaximum 47"CMechanical Design 85oC

3.4. UTILITIES

3.4.1. Cooling Water

Source: From an off-plot closed circuit cooling tower system. Supply and return linesare routed to the Plant battery limit above grade on pipe tracks, with headerlines within the Plant to be run above ground within on-plot piperacks.


a. SupplyPressure Normal 5.4 bar g

Maximum 6.9 bar gMechanical Design 11.0 bar g

Temperature Minimum AmbientNormal 40 "CMaximum 40 oC


b. ReturnPressure Normal 3.1 bar g

Mechanical Design 11.0 bar gTemperature Maximum 50 oC

mÉ.s*,f-:rri',;:i+,i'u '"='at.iiÉ; é-i ffi*tÈitrffi s5--. iiH6Notes:1. Maximum temperature difference between supply and return is 10 "C.2. Maximum allowable pressure drop between supply and return at the Plant battery

limit is zi$Fir.3. Maximum outlet temperature from any individual heat exchanger is limited to

50'c.Specification:pH at 25"C 9.0 - 10.2Total Hardness as CaCOs # mg/LConductivity at25 "C <2000 prS/cmTotal Dissolved Solids 25 mg/LTotalSuspended Solids # mg/LTotalAlkalinity as CaCOs # mg/LCalcium 0.27 mg/L


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MagnesiumSodiumPotassiumlronCopperZincBicarbonateCarbonateHydroxideChloridesSulphateNitrateManganeseSilica as SíOzFluorideAmmoniaFree CO2P - AlkalinityM - AlkalinityFree causticity as NaOHNotes:1. Concentration not measurableCooling Water Design Fouling Factor 0.0002 oCm2M

Ghilled Water


0.93 mg/L7.05 mg/L0.25 mg/LNote 1

Note 1

Note 1

0.012 mg/L0.04 mg/L2.1A mg/L12.1 mg/L1.87 mgllNote 1

Note 1

Note 1

Note 1

Note 1

Note 1

8.322 mg/LNote 1

3.4.2.

a. SupplyPressure

Temperature

b. ReturnPressure

NormalMaximumMechanical DesignNormalMaximumMechanical Design

Normal

4.4 bar g6.4 bar g10.0 bar g25 0C

ffiil$ffiffiQ85 "C

3.1 bar g10.0 bar g35 "Cffiliffi

:oÉ.

pDemineralised Water

Source: Demineralised water is produced from Process Water within an off-plot lon Exchange Unit.

Mechanical DesignMaximum

3.4.3.

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Supply conditions at the battery limit of the Plant:Pressure Normal

MaximumMechanical Design


Specification:QualitypH at 25"CConductivity at 20'CTotal Dissolve SolidsTotalSuspended SolidsTotal Alkalinity as CaCOsChlorideSilica as SiOzCalciumSodium Na'Potassiumlron as Fe2*Copper as cu2*MagnesiumZincOxygen as Oz

SulphateNitrateManganeseFree Causticity NaOHCarbon Dioxide

CombinedFree

Permanganate Value

Notes:1. Concentration not measurable.

Potable Water

7.4 bar g1 1.0 bar g13.0 bar g15 0C

Ambient50 "c85 0C

Not deaerated5.70.85 pSicmNote 1

Note 1

Note 1

Note 1

0.01 ppm wtNote 1

Note 1

Note 1

Note 1

Note 1

Note 1

Note 1

# mg/LNote 1

Note 1

Note 1

Note 1

# mg/L# mg/L# mg/L

3,4.4.

Municipal water used (from treatment for chlorination andshowers, eyewashes, drinking water and lawn sprinkling.Supply conditions at the battery limit of the Plant:

mineralisation) for safety

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Specification:lpH at 25'CConductivity at 20"CTotal Dissolved SolidsTotal Suspended SolidsTotal Alkalinity as CaCOslronManganeseCopperZincPotassium

SodiumCalcium as CazMagnesium as tt{g'Sulphate as SO+"-ChlorideNitrate Nitrogen as NO3'Silica as SiOzFree Causticity as NaOHTotal Hardness as CaCOsTemporary Hardness as Ca COsP - AlkalinityM - Alkalinity


23 "CAmbient50 "C Note 285 "C


25 mglLNote 1

Note 1

0.004 mg/LNote 1

# mg/L

# mg/L3.6 mg/L'1.6 mg/L2.0 mglL9 mg/L0.8 mg/L0.16 mglNil16 mg/L4 mglLNote 1

50 mg/L

Notes:1 Concentration not measurable.2. Temperature can be further lowered by means of 100-E165.

3.4.5. Process Water (Desalinated Water)

For use as process water, utility water (including chilled and cooling water circuit make-up), firewater, demineralised feedwater, hose stations and floor washings.

Supply conditions at the battery limit of the Plant:LrJ

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Specification:pH at 25"CTotal Hardness as CaCOgConductivity at25"CTotal Dissolved SolidsTotalSuspended SolidsTotal Alkalinity as CaCOgCalciumMagnesiumSodiumPotassiumlronCopperBicarbonateCarbonateHydroxideChloridesSulphateNitrateSilica as SiOzFluorideAmmoniaFree CO2ManganeseP - AlkalinityM - Alkalinity

Notes:1. concentration not measurable

23 "CAmbient50 "c85 0C

6.0 - 9.0Note 1


Note 1

0.27 mglL0.93 mg/L7.05 mg/L0.25 mg/LNote 1

Note 1

0.012 mgl0.04 mg/L2.10 mgll12.1 mglL1.87 mglLNote 1

0.02 mg/lNote 1

Note 1

Note 1

Note 1

Nil25 mglL

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3.4.6. Steam

3.4.6.1. HP Steam (lmport)

Pressure NormalMaximumMechanical Desígn

Ternperature MinimumNormalMechanical Design

pB,ffittluÉ-fl il;É'nulii8.l*$*atiiqi$iÉ;


3t;9.t rr$'af,$

42.0 bar g47.0 bar g/FV371 "C400 0c

427 0C

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3.4.6.5. LP Steam (produced)

3.4.7. Condensate (Export)

Excess LP Condensate is exported from the Plant.Supply conditions at the battery limit of the Plant:

Pressure

3.4.8.



f nstrument Air and Compressed (Plant) Air




QualityDew Point

I12.8 bar g

65"Cffi#

s$#ffi8.0 bar g12.1 bar g

ffi iHrrttdp,ftp50'c85'C

Oil and Dust Free-20"C at 7 bar g

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3.4.9.

3.4.9.1.

3.4.9.2.

3.4.9.3.

Nitrogen

Nitrogen is used as a feed to the process from an off-plot Air Separation Plant and isalso used for tank blanketing, flare header inerting, process inerting and for Plant start-up and shutdown (withín battery limit pressure constraints).

Nitrogen (import)


Pressure Normal 30.9 bar gMaximum 32,9 bar gMechanical Design 40.0 bar g

Temperature Minimum 25 "CNormal 35 "CMaximum 50 "CMechanical Design 85 oC

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Specification:NitrogenAr, He, NeOzCOzcoQuality

HP Nitrogen (produced)




LP Nitrogen(produced)




LLP Nitrogen (produced)

99.99 vol % min<1 ppm vol10 ppm vol maxNil<1 ppm volOil and Dust Free

59.0 bar g68.0 bar g50 "c175 0C

8.0 bar g11.0 bar g25 "C35 "C50 "c85 "C

3.4.9.4.


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Supply conditions at users (tank blanketing):



3.4.10. Fuel Gas (Ethane)

ffirffi

0.5 bar g11.0 bar g25 "C35 "C50 "c85 "C

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Rev. Page

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3.4.11. Firewater

Existing firewater ring system to be extended for the Process Plant:

3.4.12.

Pressure Normal S :'i;$rt

Maximum 11.9 bar gMechanical Design 16.0 bar g

Temperature Minimum AmbientNormal 35 "CMechanical Design 85 oC

Boiler Feed Water

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3.5.

3.4.13.3. Atmospheric Vent to Scrubber

lgsedlf diil

PROCESS EFFLUENTS

For further details on liquid and gaseous effluents from the Plant, refer to the BEPdocuments "Plant Effluent Data" (2068-00-T2-23), "Drainage and Effluent Philosophy"(2068-00-T2-54) and Battery Limit Schedule (2068-00-T3-28).

CATALYST AND CHEMICALS

For further details, refer to "Catalyst and Chemicals Data, 2068-00-T2-24".

Process Catalysts

Zinc Oxide

Zinc Oxide catalyst is used to pre-treat the Ethane feedstock gas.

Conventional Reactor and SABOXR Reactor Catalyst

Details of the reactor catalyst to be used in the Reactor R121 and SABOXR ReactorR181 to be supplied by SABIC.

Dosing Ghemicals

Phosphate solution (Nalco 1742 or equivalent) is added to the Reactor Steam Drum(D221) and SABOXR Reactor Steam Drum (D281).

ButylAcetate

Butyl acetate is used as an entrainer in the Product Recovery Area. (For furtherdetails see Section 3.2.4)

3.6.

3.6.1.

3.6.1 .1 .

3.6.1.2.

3.6.2.

3.6.2.1.

3.6.3.

4b.

-



2121 00 JSD 0000 01 1 35t57

SABIC ACETIC AGID PROJECT


3.6.4. COz Removal System Chemicals

a. Potassium Carbonate solutionb. Catacarb 922 Catalystc. Catacarb WBU antifoam solution

3.6.5. Lubricating Oil

Lubricating oils (supplied by Mobil or equivalent) are to be used throughout the Plantfor lubricating as necessary, the relevant rotating parts of machinery. Under nocircumstances can such oils be allowed to ingress into the process streams since it isan absolute requirement that the process is'oil free'.

3.6.6. ProcessPre-CommissioningCleaningChemicals

These include, but not limited to:

a. COz Removal System Chemical Cleaning Solution - Naz COy'Nag PO+b. Oxygen System degreasing chemicals

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HP flare header to be designed to limit header velocities to a maximum Mach numberas outlined in Section 2.8.

a HP Flare System

Source: HP Flare System is to collect discharges frorn process reliefvalves and process high pressure control valves discharging intothe HP flare header.

b Decanter Vent

Source: System is to collect discharge of non-condensable from E131.

3.8. DRAINS

For details of the Plant drainage design philosophy, refer to the BEP document"Drainage and Effluent Philosophy" (2068-00-T2-54).


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4.

4.1.

PLANT LAYOUT

PLOT PLAN

The ptot plan arrangement sort out from the BEP document, "specification for PlantLayout", reference 2068-00-P3-Sl is shown in the drawíng 2121 00 DW 0051.01 rev.C"General Plot Plan

BUILDINGS

Types of buildings to be located on the Plant are to be as detailed in Section 6.2.

STATIONARY EQUIPMENT DESIGN REQUIREMENTS

The following specific design requirements need to be taken into account in the designof Stationary Equipment items, i.e. for reactors, columns and towers, pressure vessels,heat exchangers and tanks, etc.

a. Heat exchanger standard tube lengths to be considered - None. (As per TEMA'R' guideline requirements).

b. Heat exchanger tube diameters, pitch shell diameters, etc., to be in accordancewith TEMA'R'.

Air coolers are to be considered for process cooling requirements where economicallyviable. Forced draft air cooled heat exchangers are preferred.

The above specific design requirements need to be taken into consideration inaccordance with the general design requirements outlined in document "Guidelines tothe Use of SABIC Standards for Stationary Equipment, reference 2068-00-D1-S2".

CIVIL, STRUCTURAL AND ARCHITECTURAL DESIGN

CIVIL DESIGN CRITERIA

For detaíls refer to the document "Civil, Structural and Architectural DesignPhilosophies, reference 2068-00-A4-52" and 2121 00 JSD 1700.A1 "General DesignRules for Civil Works and Steel Structures'.

4.2.

5.

6.

6.1.

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6.2. BUILDINGS . GENERAL REQUIREMENTS

6.2.1. Gontrol Building

A dedicated blast resistant building with the following sections to be provided toaccommodate the requirements of the Plant:

a. A Control Room housing the DCS and ESD Systems Operator Work Stations.

b. Technical Room having DCS and ESD Systems Marshalling Cabinets, AramcoMetering PLC, Fire and Gas Detection Systems, E&l Distribution Panels, UPSDistribution for Package Equipment and Local Panels , Telecoms Panels.

c. UPS and Battery Rooms - separate rooms with space requirements for a UPSand emergency back-up batteries.

d. General facilities, to be provided for staff directly associated with Plantoperations.Such facilities to include a prayer area, offices and operator rest room,kitchenette, toilets, operators changing (with shower) room.

e. HVAC System.

Note: For further details refer to drawing "Control Buílding Ground Floor Plan",reference 2121 00 DW 2051.01.

6.2.2. Electrical Substation

a Electrical substation with HV and LV switchroom to accommodate HV and LVswitchgear.

b. Transformer compound to be located next to the electrical substation.

c. HVAC System.

Note: For further details refer to drawing "Substationl1} Ground Floor Plan",reference 2121 00 DW 2052.01.

6.2.3. Process Compressor Houses

Process compressor houses are to be semi-enclosed buildings provided with overheadmaintenance cranes where appropriate.

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2121 00 JSD 0000 0î 1 38157



6.2.4. Analyser House

Analyser House shall be suitably located within the process plot, with enough space toaccornmodate the required on-line analysers with associated sampling conditionsystems and carrier gases. Analyser House is to be provided with dedicated HVACSystems (with emergency back-up) and toxic/explosive gas detector warning systems.

6.2.5. Laboratory

No new laboratory to be located within the Plant Plot battery limit. Any new laboratorytesting equiprnent required for the Plant is to be housed in an existing laboratory closeto the Plant.

6.2.6. Mosque

No new Mosque is required. An existing Mosque within the lbn Rushd Plant Site is

available to the Plant personnel. A prayer area is located within the Plant ControlBuilding.

6.2.7. Maintenance Shop

Maintenance Workshop shall be designed following fhe basr's provided by thedocumentation below:

o 22854-SP-000-A-101o 22854-DR-163-001 Rev.So 22854-DR-163-002 Rev.2. 22854-DR-163-003 Rev.3

7. ELECTRICAL DESIGN

7.1. DISTRIBUTION LEVELS

7.1.1. Electrical powerwill be supplied from dual feeder 3.3 kV incoming lines routed acrossthe plant battery limit (from lbn Rushd Substation No 1 to the Plant 3.3 kV switchboard.Each incoming line will be rated to individually supply the plant electrical loadrequirements.

Distribution Voltage 3,300 V, 3 phase, 3 wire, 60 Hz. 400A neutral lowresistance grounded system

to

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7.1.2. The plant will use the following power levels:

Motor Power:Power 150 kW and above: 3,300 V, 3 phase, 3 wire, 60 HzPower 0.37 kW to 149 kW: 380 V, 3 phase, 3 wire, 60 HzPower below 0.37 kW: 380 V, 3 phase, 3 wire, 60 Hz. 22A V, single phase to

be considered only if 3 phase motors are not available.

Heaters:2 kW and above 380 V, 60 Hz, 3 phase or 2 phase (2 wire + earth)Below 2 kW 22A V, 1 Phase, 2 wire + earth

7 .1 .3. Motor Control Circuits: 220 V, 1 phase, 2 wire 60Hz for 380 V and 3,300 V motors.

7 .1.4. Lighting distribution

a. Plant Lighting:38Ol22O V, 3 phase, (4 wire), 60 Hz from 380/220 V transformer with neutralsolidly grounded.

b. Plant Building Electrical Services:2201127V 3 phase, (4 wire), neutral solidly grounded for receptacles and lighting.

7.1.5. Switch-gear Circuit Breaker Control

System: 110 V dc

7.1.6. EmergencyPowerDistribution

Emergency Electrical Power will be provided via a 3.3 kV feeder from the IBN RushdMain Substation No 1 3.3 kV Emergency Switchboard across the Plant battery limit tothe Plant's 3.3/0.4 kV Emergency Power Transformer.

Power distribution will be 380 V, 3 Phase, 4 Wire, 60 Hz.7.1.7. lnstrumentation Distribution

Critical: 220 V, 1 phase, 2 wire,60 Hz via the UPS

Non-Critical: 22OV,1phase, 2wire,60 Hz

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7.1.8. Receptacle and LV Distribution

Three phase welding socket-outlets:Single phase conveniencesocket outlets:

380 V, three poles and earthing contact

127 V, two poles and earthing contact. NEMA type 5-15R or 5-20R configuration. Special single phase 154,220V outlets (phase and neutral) will be provided wherenecessary. Configuration shall be NEMA type 6-15R.

7.2.

7.2.1.

7.2.2.

7.2.3.

7.2.4.

7.2.5.

7.2.6.

7.2.7.

POWER DISTRIBUTION SYSTEM DESIGN

Two incoming dual feeder lines routed from the lbn Rushd Main Substation No 1 at 3.3kV level. Each line to be rated to individually supply the Plant.

Switchgear to be rated for a Plant maximum demand plus 10% load growth.

(Note: Metal clad 3.3 kV switchgear at lbn Rushd Main Substation will need to beextended from both sides (both left and right, secondary selective substation by theTechnip ltaly during detail engineering.)

Automatic transfers to be provided for both medium voltage and low voltageswítchgears.

Substation to be located in a safe area.

Pens to accommodate such transformers to have blast walls between eachtransformer. Facilities for containing and draining of the total quantity of oil within eachtransformer to be provided. Removable fencing also to be provided on each pen foraccess to each transformer.

A clean and filtered air source to be supplied to the substation and electrical rooms tomaintain a positive pressure relative to the surrounding areas. An air conditioningsystem in accordance with the temperature/humidity requirements outlined in Section2.2.5 to be installed.

Four (4) step load shedding srgna/s derived from existing Load Shedding Panel,equipped with under-frequency relays, located at lbn-Rushd Main Substation, will beused for load shedding purpose.

uJ>or

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7.3. ELECTRICAL EQUIPMENT DESIGN

7.3.1. Medium Voltage Switchgear

The supply for expansion and addition of new electrical equipment at the lbn RushdMain Substation is to be from the same manufacturer (EPS) as the existing equipment.Such switchgear is to be indoor metal clad type, designed for future extensions at bothends.

New 3.3 kV switchgear to consist of either vacuum or SFG withdrawable circuitbreakers and contactors, indoor metal clad type with 1P41.

7.3.2. 380 V Switchgear/Motor Control Gentres

The combined 380 V Switchgear/Motor Control Centres to be metal enclosed type(Form 4, IEC 439) located indoors with 1P41.

Lighting and control transformers to be dry-type, F insulation, self-cooled, three phasetype and have 224 V L-N or 127 V L-N secondary derived from 380 V or 22A V threephase primary, respectively.

7.4, CABLES AND CABLE ROUTING PHILOSOPHY

Cables to be generally laid on cable trays protected from direct sunshine by cable traycovers. Where overhead cable laying cannot be carried out for process or othertechnical reasons, cables to be installed underground directly buried, or in concreteducts or in PVC pipes.Where cables are run underground in process areas, cables to be lead sheath under aPVC jacket.MV cables will be aluminum wire armoured (single core) or galvanized steel wirearmoured (multicore) type, PVC oversheathed, flame retardant.LV Cables will be galvanized steel wire armoured type, PVC oversheathed, flameretardant.Non armoured cables are acceptable for non plant and building servíces and ínterpanel cabling within the substation, and Field Auxiliary Control Room (if applicable)where cable trays are to be used.Power cable core colours will conform wíth lbn Rush cable core colours specification.

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7.5.

7.6.

LIGHTING DESIGN

Three levels of lighting to be designed for:

a. Standard Lighting

b. Emergency Lighting by means of self-sustaining lighting fixtures each providedwith battery and connected to emergency power supply (approximately 10% oftotalplant lighting).

c. Stand-by Lighting, by means of one third of the lighting fixtures of the standardlighting connected to emergency power supply.

Lighting fixtures to be either fluorescent or metal halide or mercury vapour type. Highpressure sodium vapour lamps to be used for road and yard lighting. Maximum use ofmercury vapour type to be followed in the Process Area.

Fluorescent lighting fixture will be used in process area where restrike-time of mercuryvapour after voltage dip is not acceptable.Fluorescent fixture will also be used for low ceiling indoor and outdoor areas and forstand-by lighting and emergency lighting.

PLANT COMMUNICATIONS SYSTEMS

The following telecommunication systems shall be provided:

3:,

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7.7.

7.8.

7.9.

EARTHING

Earthing protection will be executed according to SABIC Standards. (Refer to thedocument "Guidelines to the Use of SABIC Standards for Electrical Design, 2068-00-Rg-S1".)

SOIL RESISTIUry

Soil resistivity : 88 Qm at the lbn Rushd Site Main Substation No 1. (Note: Thisvalue is not consistent around the plant complex.)

DESIGN CRITERIA/PHI LOSOPHIES

a. Electrical Hazardous Area Classification

lP Model Code of Safe Practice, Part 15 (1990).

b. Emergency Power Philosophy

Process drives within the Plant which are specifically required to be kept on-lineduring Plant main electrical supply failure are to be powered from an emergencysupply. Emergency power supply to be from a separate designated cable fromthe lbn Rushd Substation No 1.

An essential/emergency switchboard is to supply power for emergency Plantlighting, including all lighting within the main Plant control building, supervisoryinstrumentation (DCS, ESD, FGD, etc.), UPS supplies (with battery back-up) andswitchgear control battery system.

The Plant is to be designed to operate into fail-safe position during anemergency situation.

A "no break AC" (UPS) static supply system to be provided for criticalinstrumentation that cannot tolerate power interruption (DCS, ESD, packagecontrol panels) to ensure a controlled shutdown of the Plant in an emergencysituation.

d. Motor Auto-Re-start Philosophy

For motors requiring such auto-changeover or re-start facilities, operation andcontrol is to be initiated by the DCS. A field 'local/remote' switch is to be providedfor changing a motor from local stopistart control to DCS auto-changeoverlre-start initiation.

ELECTRICAL SYSTEM STUDIES AND CALCULATIONS7.10.

TECHNIP ITALY S.p.A.- 00148 ROMA - Viale Castello della Magliana,68

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8.

8.1.

System studies, calculations and relay coordination is required for designing theelectrical distribution systern by the Technip ltaly.

These calculations to be carríed out as part of the detaíl engineering design andpresented to SABIC for review. For further details refer to the specification "Scope ofElectrical Power Study, 2068-00-R8-S2".

INSTRUMENT DESIGN

INSTRUMENTATION SYSTEM TYPE

fnstrument signal transmission is to be in general electronic 4+2A mA at 24 VDCutilising 'SMART' type transmitters. Pneumatic transmission is to be kept to aminimum and to be limited to local non-critical controls requiring occasional operationand adjustment only.

DISTRIBUTED CONTROL SYSTEM

A microprocessor based Distributed Control System (DCS) is to be installed in thePlant control building and is to be the basis of Plant control and display.

The DCS is to have the facility of displaying control information or data of the Plant in a'view only' capacity to a remote central control room. Details of the DCS are outlined in

Specification "2068-00-N8-S 1 ".

EMERGENCY SHUTDOWN SYSTEM

An independent Emergency Shutdown system (ESD) is to be based on a TMRProgrammable LogicController (PLC). Signals and valves which are computed by the PLC system tooperate shutdown actions are to be displayed on the DCS. lt shall provide a stand-alone first-up trip annunciator with such alarms repeated to the DCS. Details of theESD are outlined in Specification "2068-00-N8-S2".

8.2.

8.3.

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8.4. FIRE AND GAS DETEGTION SYSTEM

A completely independent Plant Fire and Gas Defection/Protecfion Sysfem shall beprovided.This new system shall be integrated into the existing lbn Rushd Site fire and gassystem. The new system will incorporate, in the DCS, synoptic displays of the Plantidentifying detector locations.Fire and Gas Sysfem shall include the functional facilíties to perform, automatically ormanually, initiated trips and seguences.

Fire detection devices to be typically comprising of smoke detectors, rate of heat risedetectors and manual call points which are to be located to prclvide adequateprotection of individual equipment items and permanently manned areas.

Details of the Fire and Gas Detection System are outlined in specification "2068-00-N8-S3".

8.5.

8.5.1.

8.5.2.

8.5.3.

PACKAGE UNITS - CONTROL SYSTEM

Package U n its I n stru m entati on

Details of the instrumentation required on package units is outlined in SABIC StandardsESX0l-503.

Fired Heater 100-H161 Control and Protection

The Heater shall be provided with a Burner Management System (BMS) which shallprovide safe, controlled start-up, sequencing and shutdown via interlocks andpermrcsives.The BMS shall be performed on a PLC and it will be installed in the field, inside a localcontrol panel, suitable for the area c/assíftcation, containing all operator interfacedevíces, such as sfafus indicating lamps, annunciator panel, local switches, se/ecforsand controls. The control panel shall be with an emergency shutdownpushbutton. This panel shall be electronically the Plant's UninterruptablePower Supply (UPS).All signals acquired in the heater local panel shall be repeated to the DCS via seriallink.

HP Flare 100-J371 - Flame Front Generator Panel.

The HP smokeless flare system shall be provided with a Flame Front Generator Panel(FFGP) that shall comprise a// necessary components for pilot ignition and monitoring.The FFGP shall be a stand-alone, complete package providing only volt free contactsto the DCS for remote alarm on any pilot failure.The flare stack will be located in the centre of a sterile area of 30m radius. Ihe FFGPwill be located on the edge of the sterile area.This panel shatt be electronically backed:up by the IJPS.

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8.5.4.

8.5.4.1.

8.5.4.2.

Compressors Control and Protection.

Common Requirements

The normal analogue control (PtD toops) and process monitoring (process variablesindication) of the colnpressors shal[ be performed in the DCS.All process interlocks and sequences for machinery start-up, protection and shutdownshall be performed in the ESD sysúem.Particular requirements for specía[ monitoríng sysfems (machínery vibration andtemperature monitoring), specíal control sysfems (speed control) and specialprotection sysfems (overspeed protection) are outlined below.The operator interface for the monitoring, normal control and shutdown of themachines shall be performed from the DCS drsp/ays, through serial link between DCSand ESD sysfem.The start-up of the machines shall be performed locally, whíle the shutdown can beeither locaily or from the Control Room. Emergency shutdown pushbuttons for allcompressors sha/l be provided on the local panels as wellas on the Contral Room.All compressors are to be provided with a local panel (one for each machine) suitablylocated near the package item and suitable for the area c/assification.Ihese panels shall be connected with the plant DCS and ESD sysfemg acting as theHuman-Machine lnterface for the start-up operation and for the shutdown andemergency shutdown performed from the field. For this purpose, these panels shallcontaín all push buttons, a[arms, sfafus indicating lights and process rneasurementsnecessa(y for the start-up of the machine, as well as fhe shutdown and emergencyshutdown pushbuttons.

Ce ntrifug al Co m pre ssor - P a rt i c u I a r Req u i rem e nts

The following specialsysfems are províded for the Circulation Compressor 100-J112:- Machinery víbration and temperature monitoring.- Sfeam Turbine speed control with remote set point from the DCS.- Sfeam Turbine overspeed trip.Ihese special sy-sfems are provided by the machinery vendor within a control panellocated in the Technical Room of the Control Building. This panel shall be electronically

#s*é i IJPS and it wilt not contain any Human-Machine lnterface.Alt interfaces between this control panels and the DCS and/or ESD sysfem shall behardwíred.

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8.5.4.3.

8.6.

8.7.

Rec i proc ati n g C om pressors - P a rti c u I a r Req u i rem e nts

Machinery vibration and temperature monitoring is provided for the ReciprocatingCompressors 1 00-J1 1 1 NB, 1 00-J1 I 3NB and I 00-J1 71.The racks of this sysfem will be provided by the machinery vendors and will beassembled within a control panel located in the Technical Room of the ControlBuitding. This pane! shall be electronicatty Uà6;Pe.f$$ by UPS and it witl not contain anyH u m an-M ach in e I nbrtace.AII interfaces befween this control panels and the DCS and/or ESD sysfem shall behardwired.

INSTRUMENT CABLING

a. Generally, single pair cables are to be used to carry field signals from the fieldinstruments to the relevant locally mounted junction box.

b. Only one multi-core cable shall be terminated in one junction box.

c. Multi-core cables (6, 12 or 24 pairs) or communication link cables are to be usedto carry signals between the locally mounted junction boxes/panels and theTechnicatRoom within the Control Building.

d. PVC insulation and steel wire armouring Ís required on all field cables with theexception of packages where steel wire braided cables can be considered forsuch confined

ON.LINE ANALYSERS

The Plant process incorporates the use of a number of "on-line analysers". They arelocated within the plant process area, inside purpose built analyser houses. Details ofthese requirements are outlined in Specification "2068-00-N8-S4".

SAFEW SYSTEMS AND FIRE PROTECTION

GENERAL

Adequate safety facilities are required to be provided to detect unsafe releases offlammable and/or toxic materials and to provide equipment for the prevention ofescalation of safety incidents

9.

9.1.

ttJtor

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TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della MaEliana, 68

ulto

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TECHNIP-COFLEXIPProject N' Unit Document Code Serial N" Rev. Page

2121 00 JSD 0000 01 1 49t57


YANBU - KINGDOM OF SAUDIAR.ABIA

For general safety design refer to the following documents:

a. Fire Fighting Layout 2121 00 DW 1933.01 derived from the drawing "ProcessPlant Safety Plot", 2068-00-P4-D3.

b. Guidelines to the Use of SABIC Standards for Loss Prevention, 2068-00-T3-512.

c. SABIC Standard (Bechtel Specificaton), "Project Loss Prevention Design, 22854-sP-000-A-0lg'.

9.2. FIRE PROOFING

Fire Proofing, extension of application and technical details, are defined in thedocument 2121 00 JSD 1700.02 "General Design Ru/es For Fire Proofing Of StructuralSteel and Vesse/ Support".

10. INSULATION AND PAINTING

10.1. INSULATION

Thermal insulation for Piping, Tanks, Vesse/s and Equipment to be in accordance with2121 00 JSD 220A.U "Engineering Design Specification for Thermal lnsulation"

a. Thickness of insulation shown on BEP documentation are based upon the use ofhigh density mineral wool.

b. Where fireproof insulation and associated fireproof cladding is specified,associated fire relief valves to be designed with an API 'F' Factor of 0.3.

10,2. PAINTING

Paínting of equipment, structures and piping is to be in accordance with SABICStandards:

a. Bechtel Specification "Shop and Field Painting, 22854-SP-000-X-001".

b. DuPont Specificatíon "Recommended Coating Systems for External Protection,SZ5D".

c. Addenda to the above, as outlined in the "Guidelines to the Use of SABICStandards for Stationary Equipment, 2068-00-D1 -S2".

d. TPIT Specification 2121 00 JSD 2300.01 "Engineering Design SpecÌfication forPainting".

TECHNIP ITALY S.p.A. - 00148 ROMA -Viale Castello della Magliana, 68


2121

SABIC ACETIC AGID PROJECT

VANBU - KINGDOM OF SAUDIARABIA


Rev. Page

1 50157Unit

00

11.

11.1.

SPARE PARTS

SPARES PHILOSOPHY

Provision of spares, addressed as either installed, commissioning, maintenance orcapital spares shall be in accordance with the following philosophy.

INSTALLED SPARES

lnstalled spares are those items of equipment which form part of the erected plantwhich are identified on the process equipment list, e.g. A&B pumps. Installed sparesshall be provided as itemised on the Process Equipment List (reference 2068-00-W3-z2).

COMMISSIONING SPARES

Commissioning spares are those items which may be required to be used for the repairor maintenance of the plant during the pre-commissioning and commissioning period.

Commissioníng spares are to be procured and delivered at the same time as theequipment to which they belong but are to be packed separately for separate storageat Site. (Storage area to be advised - location to be for easy access during plantcommissioning).

TWO YEARS OPERATTON SPARES (MATNTENANCE SPARES)

Maintenance spares are those items which are provided to enable the plant to bemaintained in a normal operating condition for a period of two years from plant normaloperation (i.e. from finish of plant commissioning).

Maintenance spares are to be procured and delivered at the same time as the mainequipment to which they belong but are to be packed separately for warehousestorage at Site.

11.2.

11.3.

11.4.

1 1.5. CAPITAL SPARES

Capital spares are those items or part items which are not initially installed in the plantbut may be kept available as a warehouse spare to ensure maximum plant availability.Capital spares normally apply to items or part items of equipment which are normallylong wearing but if fail are on a long delivery from the vendor.

uJjo

I€oTECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68


2121 00 JSD 0000 01 1 51157



ATTACHMENT I

WIND ROSE

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2121 00 JSD 0000 01 1 52t57



ATTACHMENT II

METEOROLOGICAL DATA

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TECHNIP.COFIEXIPProject N" Unit Document Code Seríal N" Rev. Page

2121 00 JSD 0000 0l 1 s3t57



ATTACHMENT III

MONTHLY TEMPERATURE RANGE AND RELATIVE HUMIDITY

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TECHNIP-COFIEXIPProject N' Unit Document Code Serial N' Rev. Page

2121 00 JSD 0000 01 1 54t57



AfiACHMENT IV

INTENSITY - DURATION - FREQUENCY CURVE OF RAINFALL

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2121 00 JSD 0000 01 1 55t57



ATTACHMENT V

SANDSTORM DATA

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ex!st a5lproxlmat,e!y lOt of thefor thi s area.

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TECHHIP-COFIEXIPProject N" Unit Document Code Serial N" Rev. Page

2121 00 JSD 0000 0l 1 56t57



ATTACHMENT VI

TEMPERATURE DATA

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TECHNIP-COFLEXIPProject N" Unit Document Code Serial N" Rev. Page

2121 00 JSD 0000 0l 1 57157



ATTACHMENT VII

TIE{NS DATA

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Pîo!.2121 - SABIC ACETIC ACID PROJECT


Page 6-3

#rl ', '*mfug*

6.1.2. Guidelines for PID Preparation

2121-00-JSD-0000-03

r'l

îEGHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

TECHNIP.COFI.EXIP Project N" Unit Documenl Code Serial N"

2121 0A JSD 0000 03


YANBU. KINGDOM OF SAUDIARABIA

Rev. Page

1 'U52

STANDARD SPECIFICATION FORPID PREPARATION

INDEX

INTRODUCTION

1. INFORMATION TO BE INCLUDED ON PID

2. LIST OF PLANT & UNITS

3. DRAWING NUMBERING SYSTEMS AND GENERAL REOUIREMENTS

Page

2e

4

4

6

B

B

B

I11

13

16

18

18

22

25

27

28

31

32

34

3B

41

43

44

46

46

49

4.E

6.

7.

8.

L10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.21.

22.

23.24.

25.

26.

27.

D'S AND LINE LIST

VESSELS AND TANKS

WATER COOLERS

HEATERS

PUMPS

STEAM TURBINES

RECI PROCATING COM PRESSORCONTROL VALVES

SAFETY VALVES

VENTS AND DRAINS FOR EQUIPMENTSTRAINERS

STEAM TRAPS

UTILIry CONNECTIONS TO PIPING OR EQUIPMENTUTILITY STATIONS

SAMPLING

VALVES AT BATTERY LIMITSVALVING CHECK LIST

SPECTACLE BLINDS CHECK LISTSTEAMING OUT/PURGING

DRAINAGE SYSTEM

WINTERISING

INSTRUMENTATION

,tl24-06-2W2 ""w lat'4.j

'lffittxesuuUv0 29-05-2002 ISSUED FOR EXECUTION &UAMPUS L.sACGHIÈRI

05-o4-2002 ISSUED FOR COMMENTS A.CAMPUS L.SACCHIERI G.FLERESA.À

REV. DATE STATUS WKIIIENÚI(name & visa)

vnEu^tu ór{name & visa)

DOCUMENT REVISIONS

TECI{NIP.COFLEXIPProjecl N" Unil Document Code Serial N'2121 00 JSD 0000 03

Rev. Page

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SABIC ACETIC I\CID PROJECT

YANBU. KINGDOM OF SAUDI ARABIA

INTRODUCTION

The purpose of this doerment is to define the rules which have to be followed to prepare PID's, inthe absence of specific requirements on the subject from Client in the Contract.The present document have been modified according to the following Sabic Standard:

Project Design Basis

Sample Point Details

Piping Philosophy for P&lD's

Over-pressure Protection Phi losophy for P&l D's

Relief System Philosophy for P&lD's

BEP P&ID'S Design Notes

P&lD's Symbols & General Notes

Drawing Details

2068-00-w3-s1

2W$-OA-T2-z7

206&00-T3-51

2068-00-T3-S3

2068-00-T3-34

2068-00-T3-S7

2068-00-T3-D1

2068-00-T3-D2

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SABIC ACETIC ACID PROJEGT


1. INFORMATION TO BE INCLUDED ON PID

All information to be shown on PID shall include at least those reported herebelow:

1.1. Equipment

- ltems and service description;- Elevation of bottom tangent line for:

vessels, towers, condensers and reboilers;- Materials of construction for equipment (shell and internals);- Details for pumps on process PID's, such as: warm-up piping, strainers, casing

vents and drains, cooling water arrangement, flushing facilities, for auxiliary lines,etc';

- Lube and seal oilfacilíties for compressors, turbines and blowers;- Fuel arrangement for heaters and boilers on a separate process PID;- Purging of equipment and associated lines on process PID;- Listing of equipment (lower right-hand area);- Main equipment characteristics;- Extemalfinish code (tracing, insulation).

1.2. lnstrumentation

- Symbols in accordance with ISA Standards S 5.1 "INSTRUMENT SYMBOLSAND IDENTIFICATION" and "BEP SYMBOLS";

- All instrument loops and auxiliary components;- Clear identification of software linkage and alarm shutdown logic systems;- Analyser loop details;- Control and safety valves according to point 13;- Instrument isolation valves, whereas different from instrument standards.

1.3. Piping for Process and Utilities PID's

- Line number according to point 4;- Description of process lines entering or leaving;- Continuation reference to subsequent drawing;- Process/Utilities lines identification (as per point 5.);- Piping speciality items (figure I blinds, strainers, sample connections, car sealed

or locked valves, etc.);- Indications for piping arrangement, such as: slope, min./max distance, hydraulic

seals, etc.;- Types for all isolation valves according to process requirements and piping

specifications;- All process underground lines;- Utility stations and safety showers;- Process drains and vents;- Heat tracing and jacketing arrangements;

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1.4.

Class and Spec. break;Special requirements (chemical cleaning, passivation, flushing, etc. ).

Miscellaneous

Sewage indications (white, oily, chemical);Limit of supply;Utility distribution drawings (geographical arrangement according to plot plan);Skid limits;Spacing requirements (minimum distance, visibility of instruments from otherequipment and platforms).

2. LIST OF PLANT & UNITS

The subdivision of the project into plants and units as following:

Area2 - Conventional Reactor SystemArea 3 - Product Recovery and PurificationArea 4 - CO2 Removal System

DRAWING NUMBERING SYSTEMS AND GENERAL REQUIREMENTS

TPIT numbering system will be adopted (according to the Co-ordination Procedure).ln addition, in each drawing TPIT will report the SABIC drawing number.

Form used for PID will be A0. PID will be printed in 41 and 43 form.

Standard setting of Intergraph PDS 6.4.1 will be used.

3.

5 - ISBL Tankaqe

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b.

Guideline for Grouping Utilities in Utilities Distribution PID's

Utilities will be grouped as follow:

a. SteamCondensate

Desalinated WaterDemineralised waterPotable water

Cooling water

Plant and lnstrument airNitrogen

Flare & Vents

Drains (open and closed)

Firewater (sprinkler,hydrants, deluge)

c.

d.

e.

f.

g.

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S.ABIC ACETIC ACID PROJECT


o4.

4.1.

4.2.

LINES NUMBERING SYSTEM FOR PID'S AND LINE LIST

Unit number: see note 1.

Process and utilíty lines shall be identified by the following numbering system

Line size

Piping class(Three digits)

Line number(See Note 2)

Line service(See Note 2)

Area

NOTES:

1) ln all cases the unit number is mentioned inside PID title block, line list,isometrics and bill of materials.

2) The digits, in general, are defined as follows:

- AAA three digits refer to line service- BB two digits for fluid identification code- CC two digits refer to the sequential line numbers.

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oTABLE 4.1

PIPING INSULATION and PAINTING CODES

DESCRIPTION CODESAcoustical insulation AAcoustical insulation/Pai nted APCold ConservationSold ConservationlPai nted w)ElèÈfÍicalTr:acini- v EElectrical Traci no/Pai nted EPFire Protection FHeat Conservation H

H eat Conservation/Aco ustical HAHeat Conservation/Painted HPHeat Conservation/Painted/Acoustical HPAJacketed J

Not Insulated N

Not lnsulated/Painted NPPersonnel Protection (t > 65'C) P

Personnel Protection (t > 65"C)/Acoustical PAPersonnel Protection (t > 65"C)/Painted PPPersonnel Protection lt > 6 5'C)/Pa inted/Acoustical PPASteam Traced SSteam Traced/Painted SPWinterisino WWinterisino/Painted WP

NOTES:

1. First digit indicates type of insulation, second digit "P" indicates painting, second digit '4"indicates that piping requires also acoustical insulation.

2. In case piping shall be painted and even acoustical insulated, a third digit shall be used.3. lf required, new insulation and painting codes shall be defined.

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5.

6. PIPING AND INSTRUMENT SYMBOLS

The piping and instrument symbols to be used for P&lD preparation are shown on thedrawings "P&lD's Symbols & General Notes" 2068-00-T3-D1 and "Drawing Details"2068-00-T3-D2.

7.

7.1.

7.2.

7.3.

7.5.

7.4.

VESSELS AND TANKS

Unless otherwise dictated by process or licensor requirements, vessels connestionsshall be minimised by installing relief valves, Tl's, vents, Pl's and other connections onpiping where possible instead of vessels.

Minimum size for vent and drain connections of vessels shall be as per para 15.1.3.Minimum flanged connections size shall be 2".

Generally, the liquid nozzles connected to a pump suction, reboiler feed, side drawoffshallbe provided with vortex breakers.

All tanks shall have isolating valves on process and utilities lines both at the tanknozzles and outside the tank dike.

lsolating valves to be installed on each individual level transmitter or gauge glass.

LINK OF THE PROCESS/UTILITIES LINES BETWEEN P&I DIAGRAMS

The link of the process/utilities lines with other P&lds (to/from users in the otherdiagrams) shall be made as shown:

DRAWING NUMBER

\rVhere the first digit indicates the Unit, the second indicates the drawing and 112

(See sheet 1 of 2 of the 3'o P&lD of Area 2)

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8. WATER COOLERS

8.1. Piping arangement forwater lines around coolers is shown in fig. 8.1

8.2. Valves on cooling water service shall be as per piping class. Normal practice will be:

- Inlet side valves : gate

- Outlet side valves < 1Yz": globe> 2" : butterfly

8.3. Water piping shall be arranged so that the equipment remains full of water in case ofwater supply failure.

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Page

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WATER COOLER ARRANGEMENT

FrG.8.1

NOTES:

1) Inlet and outlet valves according to point 8.2.

2) Drain size as per para 15.1.3 (Typically yo") .

3) Typically provide 6" or 4" min. for Tl installation.


2121 00 JSD 0000 03 1 11t52



9. HEATERS

9.1. The fuel gas drum will not be insulated or heat traced and will normally not be providedwith demister.

9.2. The pilot gas header shall be equipped with "Y' type strainer (30-mesh min.) and shallbe picked up from fuel gas header upstream of main fuel gas control valve.Pilot gas header shall be heat-traced to the bumers.

9.3. In generalfuel gas header shall be heat-traced downstream of K.O. Drum.

9.4. Piping to individual burners shall be arranged as shown in fig. 9.1.Locate bumer valves adjacent to observation door to permit bumer adjustments whileobserving the flame.Flexible hose should be used in bumer piping according to vendor requirements.Flexible hose are to permit f2"(50mm) adjustment of oil gun from the positionrecommended by the burner vendor.

9.5. Transfer lines from heaters to distillation columns shall, immediately upon leaving theheater, be led to an elevation above the one at which the column is to be entered toensure free draining.The line shall slope towards the column and should be preferably straight over at leastten times its largest diameter before entering the column.

9.6. All valves at header operated isolation on pilot gas and fuel gas lines must be locatedat safe location (e.9. behind a firewall 15 m. min. away from the heater in an easilyaccessible position at grade).

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TYPICAL ARRANGEMENT FOR HEATER BURNERS

FrG.9.1

NOTES:

1) Connection for portable manometer shall be provided for all bumers.

2) Flexible hose shall be normally used in burner piping.Use ball valves in all fuel lines just before the bumer inlet.

ÉldoU-U1

F

)o-

É.UótJ=a

)LrJlh_

PLATFORM

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PUMPS

Suction and discharge valves shall be line-size.However, if the suction and discharge lines are two or more sizes larger than the pumpnozzles, the valves can be the next size smaller (for suction line process checking isrequired).lf required, recycle lines shall be connected back to the suction vessel, preferablyupstream of a cooling source.Vúhen two or more pumps are manifolded the suction valve and any componentsbetween the pump and the valve shall be specified for full shut off pressure.

Blow down facilities shall be provided for pumps handling C4 and lighter fluids (seepara 15.2.1)

Warm-up/cool-down facilities shall be required when pump is spare or out of service foreither of the following conditions:

a. The pump temperature exceeds 230'C or specific process casesb. The ambient temperature is below the pour or freezing point of the process fluid.c. Cryogenic pumps.

1O.2. Temporary strainers side of pumps,

be analysed in the following cases:

10.

10.1.

10.3.

10.4.

- Pumps in dirty service- Suction line larger than 8" or smaller than 2"- Steam traced suction lines.

In generalthe strainer selection is:

type for lines 2" and smafler- uT" type for lines larger than 2"

They should not be installed if not allowed by the handled fluid (slurries, etc.) or forjacketed lines. Strainers shall be with flanged cleanout nozzles.

Strainer body material shall be suitable for handled fluid.Screen shall be made of S.S. for permanent strainers and carbon steel for temporarystrainers, unless otherwise required by the operating temperature and fluid

On díscharge side of pump where the pump differential pressure exceeds 70 bar,double check valves installation should be analysed, unless otherwise specified.

Piping arrangement for centrifugal and reciprocating pumps are shown in fig. 10.1 and10.2, respectively.

specify that all pumps should have tempor

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1



GENTRIFUGAL PUMP

FlG. 10.1

NOTES:

1) Strainer between the block valve and the suction flange.

2) By-pass line for warm-up or cool-down (if required by process or licensor).

3) Vent and drain requirements, according to Vendor Supplier (A Ya minimum), referto para 15.2

4) The check valve by-pass €n be connected either upstream or downstream theblock valved at pump discharge.

/ A\tl+l\'./iII

i

VX /z\,/\ | z-+ |î \',/irlvllAtrLllii__ ___ __i___ -__

(3)

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Serial N'03

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15t52Rev.

1

PROPORTIONI NG'RECIPROCATI NG PU M P

(2)

(1)

3/4"

NOTES:

1) Permanent type strainer

FrG. 10.2

2)

3)

4)

Safety valve piped back to the suction drum preferably or to the suction line' (optional)

Check valve shall be installed

Pulsatíon dampener to be shown, if required, as per pump supplier

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11, STEAM TURBINES

11.1. Steam feed pipe shall be valved at branching off from the header and near the turbine.A permanent uYu type strainer shall be installed in vertical position as close to theturbine as possible if not included in Vendor supply.

11.2. lf the exhaust steam is connected to a header, the turbine discharge shall be equippedwith a safety valve and a block valveAll low points of turbine casing shall be equipped with steam traps (on Vendor PID).

1 1.3. Piping anangement for steam turlcine is shown in Fig. 1 1.1.

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TO ATM AT

SqFE LOCATION

EXHAUST STEAM HEADER

STEAM TURBINE ARRANGEMENT

FrG. 11.1

TOATM AT

SAFE LOCATION

r-I

><_\I

'1 (sr-r\

I

(s)

NOTES:

1)2)3)4)5)

Locate block valve at min. distance from header (if required);Strainer type according to Vendor requirements;For automatic start of turlcine this valve must be LO;Turbine warm-up by-pass (3/4" min. size to be adapted);Number and connection type for steam traps are in accordance with turbinesupplier requirements;Steam trap to be located at low point of steam line,Vúhereas required On/Off valve for automatic turbine start, globe valve for manualturbine start-up will be provided;

8) By-pass to be sized for turbine start-up. Valve type as per piping class,9) Distance from inlet isolation valve to the turbine inlet to be minimised;10) Installed in horizontal position (Valve and check valve);11) Piping arrangement to allow pipe cleaningless test.

6)7)

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SABIC ACETIC ACID PROJEGT


12.

12.1.

12.2.

13.

13.1.

RECIPROCATING CO MPRESSOR

ln general, suction line routing from K.O. Drum to compressor shall be sloped towardK.O. drum and pockets shall be avoided.In case this would not be possible, drain pots with level gauge/alarms shall be providedat a minimum distance from compressor.

Tracing of the suction piping from K.O. drum to compressor suction pulsation damper isrequired when the minimum ambient temperature is equal or lower than gas dew point.In this case draining pots with automatic draining devices can be ornitted but manualdraining before start-up shall be allowed.

CONTROL VALVES

Automatic control valves shall be fumished with either a hand-wheel or with blockvalves for isolating the control valve and a by pass valve for hand control except asfollows:

a) Control valves which are tripped closed or open in an emergency or whosefunction is to trip open to relieve abnormal conditions shall not be furnishedwith block and by-pass valves or hand-wheels. Control valves in systemsrelieving to atmosphere shall have an upstream block valve furnished. Controlvalves in systems relieving to flare shall have upstream and downstreamblock valve fumished.

b) Control valves which are paired (separate control valves furnished for driversand their stand-by) shall be fumished with an upstream block valve but not ahand-wheel. A by-pass valve shall only be installed if a driver cannot be coldstarted.

13.2. Control valves shall be provided with block valves and by-pass except as follows:

a) Three-way control valves of all sizes shall be fumished with a hand-wheel formanually operating the control valve. By-pass and block valves shall not be

b) Control valves which spared or operated in parallel service shall befurnished with upstream and downstream block valves. By-pass valves andhand-wheels shall not be fumished for spared valves.

c) Control valves of all sizes shall be provided with upstream and downstreamblock and by-pass valves in the following services:

c) Where process/safety requirement specifically requires otherwi

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2121 00 JSD 0000 03 1 19t52



Services with high-pressure drop where frequent planned maintenance isexpected.

: S:Ii::: HîflHi[l;!ii"r'"f'?fi:.ji",1xi,,,?],1i,.",o high that one ha,f thedesign flow rate cannot be attained with the pressure available for startingcirculation (protective heating may be used to reduce viscosity).

o Boiler feed water services.. Steam services with a pressure drop across the control valve greater than 8.6

bar.

13.3. The minimum size for control valve block valves shall be control valve body size. Theblock valves shall not be more that one size below the line size. However, the sizeequal to that of the line shall be selected unless bigger sizes are required to avoidexcessive pressure drop or fluid velocig.

13.4. By-pass valves for control valves shall be provided with a Cv equal to or greater thanthe Cvc required for the control valve at the design flow rate.

13.5. A3/a" valved drain shall be provided for the control valve groups as follows:

. FO controlvalves: one bleed upstream CV. FC control valves: one bleed at each side of the CV

13.6. Bleeds shall be installed on the larger diameter.

13.7. The bypass valve shall be globe type for 6" and smaller, and gate or butterfly type (oraccording to piping class) for sizes larger than 6".

13.8. Controlvalve shall be identified on PID with:

- Tag number;- Size and rating if different than piping class;- Fail safe position (FO, FC, FL);- Flashing service (FS).

13.9. Sizing of Control Valve Manifold

Table 13.1 shows the recommendations for the sizing of control valves manifold.It shall be read in conjunction with the following remarks:

1. lndicated size is main line size;2. Size for by-pass line shall be as the by-pass valve;3. Block valve shall be selected as per piping class;4. By-pass valves shall be globe up to 6" and full bore (gate or. butterfly) for larger

diameters;5. Reference diameter for block valves is the size of the line on which the valve is

located; reference diameter for by-pass valve is the upstream line.

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2121 00 JSD 0000 03 1 20t52



APPROXIMATE Cv VALUES OF GLOBE VALVES

TABLE 13.1

The size of the by-pass valve has to be selected carefully if it has an impact on adownstream relief valve.

Valve size Cv

Y"' 2.9Yo" 5.51', 10

1Yr" 252" 453' 100

4" 180

6rt 425

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TAG NUMBTR

3 / +"xDR (2) DRx3 / 4"-/-\f"-lt/ a\ \",/

I .ì I@ \-/

CONTROL VALVES ASSEMBLY

FtG. 13.1

CONTR VALVI SIZ[

cONTR VALVT RATING (4)

- 300#RFFLANGE FACING (4)

NOTES:

1) Globe valve type for line size <6"

Gate valve type (or according to piping class) for line size >8"

2) lndicate valve action as follows:- FC = closed for air failure- FO = opens for air failure- FL = fails locked (no change of position)

Block and bypass valves, if required, shall be sized as per table 13.1.3)

4)

5) Required for FC (Fail Close) case only.

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SAFETY VALVES

Safety valves shall be located according requirements as close to theequipment as possible, in order to fulfil the API requirements on pressure drops

upstream piping, or on equipment, and be accessible for check and

14.

14.1.

14.2.

Piping arrangements of safety valves are shown in Fig. 14.1, 14.2.

No isolation of any kind is allowed for PSV's.

Safety valves shall be free draining towards flare header; when such arangement isnot possible, facilities to prevent the stagnation of liquid shall be provided.

Branching-off of a discharge pipe to blow down header shall be at top of pipe andsloped 45" in the direction of flow.Flare header shall be sloped, 2V@ min., towards the knockout drum, avoidingintermediate pockets.

Safety valves shall be identified on PID with:

Tag number;Orifice designation;lnlet & outlet size;Set pressure;Rating of flange if different than piping class.

14.3. For further details refers to the following documents:

- OVERPRESSURE PROTECTION PHILOSOPHY FOR P&lD's2068-00-T3-5310

- RELIEF SYSTEM PHILOSOPHY FOR P&ID'S2068-00-T3-S4/0

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SAFETY VALVE ASSEMBLY(DTSGHARGE TO CLOSED SYSTEM)

FtG. 14.1

SIT PRESSURE

SET,,-XXX bOrg .''

Y4

\ rN /ouT CONNECT|ONS

TAG NUMBIR (3) RELIEFH IADIR

NOTES:

1) Connection on top of pipe

2) Locate safety valve above relief header (except thermal expansion)

3) The flare header shall be sloped, 2%o min, towards knockout drum

4) lf required.

66 1/1

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SAFEW VALVE ASSEMBLY(DTSGHARGE TO ATMOSPHEREI

FtG.14.2

SET PRISSURE =\\ StT @ XXX borgIN/OUT CONNTCTIONS 3"x4"

TO

(2)ATM

(r)

TAG NUMBIR

NOTES:

1) Make connection on top of pipe.

2) The vapours vent line shall terminate at least 3 meters above equipment or anyservice platform located within a radius of 15 metres.

3) Vr/hen safety valve discharge steam to the atmosphere at safe location, the ventline shall terminate at least 3 metres above any service platform located within aradius of 8 metres.

4) lf required according to Piping Class.

LOW POINT

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15.

15.1.

15.1.1.

15.1.2.

15.1.3.

15.1.4.

VENTS AND DRAINS FOR EQUIPMENT

Vessels

For maintenance and test purpose, all pressure vessels shall be provided with a ventand drain discharging to atmosphereNot operating vents shall be located on top of vesselwith valve blinded.Drain shall be preferably located on the low point of the bottom outlet piping, outsidethe skirt. lf there is no bottom line or said line does not allow complete drainage of thevessel, the drain shall be connected to a separate nozzle on the bottom head.Vessels with intemal baffling require special consideration (two separate drains or adrip hole on the baffle).

Pressure vessel handling flammable, toxic and highly conosive fluids shall be providedwith additional valved vents and drains enabling depressurisation and disposal ofcontained fluid as follows:

Fluid

Cr and lighter

Other hydrocarbons

Toxic and highly corrosive

Vacuum service

Operating Vent

flare or suction vessel

flare

dedicated venting systemor closed drain

suction vessel

Operating Drain

flare or closed drain

closed drain or oily sewer

dedicated closed drain

For double valving requirements see para22.3.

Minimum size for vent and drain valves for equipment shalt be in accordance with thefigure 1 pag.15 of PIPING PHILOSOPHY FOR P&lD's 2068-00-T3-51/0, unlessotherwise indicated on PlD.

Drains from levelgauges and level controllers shallbe piped per para 15.1.2 above.

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15.2. Centrifugal Pumps

15.2.1. Drain and vent connections on pump casing shall be plugged except for serviceconditions listed below, for which they shall be valved and piped as follows, unlessotherwise required by process considerations.

Fluid Vent (1) Drain

Ce and lighter Flare or closed drain Flare or closed drain

Hydrocarbons (with operating Closed drain or oily sewer Closed draintemperature above their flashpoint)

Hydrocarbons (with operating Flare, oily sewer or Oily sewer or closed draintemperature below their flash closed drainpoint)

Toxic and highly conosive Dedicated venting system Dedicated closed drainor closed drain

Vacuum service Suction vessel

NOTE (1) Valved vent connection is not applicable to self-venting pumps.Self-venting pumps are identified by the machinery specialist after pumpselection.

15.2.2. Vent and drain size shall be as per Vendor standards (sizesA" minimum).

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16. STRAINERS

16.1. Permanent strainers shall be provided in the piping forthe protection of the followingequipment when not furnished as a part of the equipment:

- Steam turbines, steam traps, and steam jet ejectors - in steam inlet line.- Pumps and compressors - in sealing, gland and flushing oil and cooling water

supply piping;- All compressors at suction line (screened intakes shall be provided for air

compressor and air blower);- Bumers - in main fuel oil supply piping;- Hydraulically actuated equipment - in hydraulic oil supply piping;- Pneumatically actuated equipment - in air supply piping;- Desuperheaters - in water and atomising lines;- Hard piped utility connections to stainless steel systems;- Upstream of positive displacement flowmeters (preferably supplied fumished).

16.2. Temporary strainers shall be provided in pump suction lines during initial operation.

16.3. The body material shall conform to the requirements of the piping class.The material of the screen shall be specified as para 10.2

16.4. The provisions of para 1A.2 also apply.

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17.

17.1.

17.2.

17.3.

17.4.

17.5.

17.6

17.7

STEAM TRAPS

Steam traps are utilised to eliminate condensate accumulation at low points ofequipment and steam lines,

All steam traps shall be protected by a 'Y" type strainer unless traps are supplied withan intemal strainer (small diameters).

Normally, float type steam traps shall be used for process service.

The anangement for traps is shown in the Ftg. 17 .1.

On steam headers every 100 ft, at the lowest points and on the header ends, pot withsteam trap will be provided normally not shown on PlD. Pot assembly and dimensionsare indicated in fig. 17.2 as standard in case they have to be shown on PID because ofClient's requirement.

Steam headers will have a slope in the direction of flow (Slope: 1:25$.

Only Flat Bottom Reducers to be used in horizontalruns.

TECHNIP.COFIEXIPProject N' Unit Document Code Serial N"

2121 00 JSD 0000 03



Rev. Page

I 29t52

oPROCESS STEAM TRAP ASSEMBLY

FlG. 17.1

A - TRAPS DISCHARGING INTO RECOVTRY SYSTIN/

B : TRAPS DISCHARGING AT GRADE

NOTES:

1) Strainer to be required if not included in trap supply.


2121 00 JSD 0000 03Rev. Page

I 34t82



POT ASSEMBLY

FaG.17.2

STEAM HIADIR 4" AND LARGIR

HTADTR ON PIPI RACK HTADTR ON SLTIPTR

FOR CONNICTION IN LINT3/4"-1"-1 1/2"

FnD î'i lNln 1" I lNrFeI vr\ 4 nr\u J LrrLJ

NOIIS

1 _ 'B SHALL BE INSTALLTD ONLY IF

STTAM TRAP IS 5 I/ITIRS AND OVER

FRO[/ STTAM POT.

2 - ON SLTEPTR IVAY VALVI A' SHALL

BE INSTALTTD IN HORIZONTAT.

3 - UNITS: mm.

(N0TE 2)

SWAGI OR NIPPLI SUITABLI

3/ 4"P3/4 P

HEADTR POTA B

2

J''

4"

6"

8'

10'

12"

14"

16',

18"

20"

2+"

2"

3'3

4

6',

8"

10'

12"

12"

12"I îrlIL

12

3/4"3/4"314"

314"

3/4"3/4"314"\ /4"

3/4"3/4"314"

3/4"

o_É.-O>

==-u=>ó

TECHNIP.COFLEXIP Projeol N' Unit Documenl Code Serial N'2121 00 JSD 0000 03

Rev. Page

1 31t52



18.

18.1.

UTILITY CONNECTIONS TO PIPING OR EQUIPMENT

Utility lines permanently connected to process piping or equipment, if required, shall bearranged as per Fig. 18.1.

UTILITY CONNECTION TO PIPING OR EQUIPMENT

FlG. 18.1

NOTES:

1) Block and check valve to be installed at min. distance from equipment. Materialand rating for block and check valve shall be suitable for the more corrosivecondition of the process or utility service.Rating and piping class break in A or B according to stronger class.Check valve shall be omitted for connections used only when equipment is notoperating (e.9. steam out).

Spectacle blind to be provided for:- lnfrequent service (e.9. steam out);- Water connections to piping or equipment operating above 100'C and

water and steam connections to piping or equipment operating below 0"C.

A removable spool piece can be used instead of spectacle blind.

ln case of multiple fluids to be provided as utilities (i.e. steam, nitrogen, andwater), but used one only at a time, one connection to piping/equipment will beprovided.

2)

c)

3)

ÎECHNIP.COFIEXIP Project N' Unit Document Codè Serial N' Rev. Page

2121 00 JSD 0000 03 | 32t52



a19. UTILITY STATIONS

Utility stations shall conform to contractual rules fonnalised by Piping and/or ProcessSpecialists. The following rules are generally used.

19.1. Utility stations shall be installed in order to ensure low pressure steam (limited to apressure of 5.5 barg), service water and plant air throughout the process area.Locations shall be such that working area at grade, in buildings and on lowest mainoperating level in structures can be reached with 15 m length of flexible hose.Additional steam and air service outlets shall be provided if required to reach tower andreactor platforms serving manholes.

19.2. Each point shall be equipped with a block valve according to the piping specificationand with fast-acting fittings. The size of each line shall be 314".

19.3. Nitrogen stations can be required for equipment or line purging.The size of hose connections shall be 314" .

19.4. For utility station arrangement see Fig. 19.1.

TECHNIP.COFIEXIPProject N' Unit Document Code Serial N'2121 00 JSD 0000 03



Rev. Page

1 33t52

UTILITY STATIONS

FrG. 19.1

3/4'QUICK CONN.

IYPrcAL)

NOTE:

1) Nitrogen station only where required.

TECHNTP.COFLEXIPProject N' Unit Document Code Serial N"

2121 00 JSD 0000 03Rev. Page

1 34t52



o24.

24.1.

20.2.

20.3.

20.4.

20.5.

20.6.

20.7.

20.8.

20.9.

20i4.

20.11.

20.12.

20.13.

20.14.

SAMPLING

All Sample point connections in gas streams containing condensables are toíncorporate sample probes. These should be stub pipes extending 1/3 pipe diameterinto the pipe. Stub pipe to have a 45' chamfer in direction of flow. Where sample pipesare less than 4 inches, top entry connection should be used with no sample probe.

Sampling connections on piping shall be not less than 3/4". A first block valve shall beprovided as close to the header as possible.It shafl be followed by a globe or needle valve (@ = Tz").

The distance behiveen these valves shall be as short as possible.

Piping and valve materials to conform to pipe specification.

Liquid sample cylinders must be held verticalwith outage tube at top.

For liquefied gases the distance between the two valves shall be 600 mm min.

Where sampling is required for dangerous fluids, the sample outlet shall be connectedto process line or to flare.

When sampling for sulphur, stainless steel tubing must be used, and PTFE lined wheretemperatures permit.

Sample points should be located such that they are readily accessible from platforms,away from enclosed spaces and in a safe location.

The sampling shall not be located at dead points of the process line, Sample points areto be as close as possible to the point of origin, but have to be on straight pipe awayfrom bends.

Sample cooler shall be specified for a process temperature of ...'C and over, accordingto perconnel protection requirements.

Sample pipework should be as short as practical and should not contain pockets.

Insulation and tracing to follow process line requirement unless indicated otherwise onthe P&lD.

All sample points containing oxygen and/or hydrocarbon shall have groundingconnection at inlet.

Sample Point details shall be shown on the_P&lDs. For sampling arrangements see

TECIINIP.COFLEXIPProject N" Unit Document Code

2121 00 JSD 0000



Serial N' Rev. Pago

03 I 35t52

OPEN SYSTTM FOR

NON-TOXIC, NON-ODOUROUS

OR NON-FLAMMABLELIOUIDS OR GASES

SAMPLICOOLER

TYPE: 51 - ÌV|THOUî COOLER

TYPE: 52 - ]|vrlH COOIER

VENÎ ÎOATMOSPHIRI AT

SAFE LOCAIIONFOR GASES ONLY

+ colL oF

V t/c" oD ss TUBTNc|"tr NEEDLE VALVE

I/Î\| ]--

oUTAGE 'ruBE

| | SAI4PLE CYLTNDER

| | 1500 mr

\lTp rureolr valvt

I.orrur.

ISOLATINC

VALVE

NOTE 2

HP PROCESS

[ -l*""

'o'*\7**_

ÍUNOISH WIÍH WRE MESH

SUPPORT FOR SAMPLEBOTTLES

LINE/VAIVE SIZES IN INCHES

NOTES:

1. PIPEWORK A FOR TIOUIDS

PIPEWORK B FOR 6ASES,

2. PROVIDI TOCAL DOUBLE VALVES FOR 9OO Ib RATINC AND ABOVE

3, PROVIDT BREAK FLANGE FOR SAMPLT PROBE IF REOUIRED.

4. AN ADDITIONAL NEEDLE VALVE IO BE PROVIDID DOWNSTR€AM OF

ISOI-ATION VALVT FOR HIGH PRTSSURE,

TECHNIP.COFIEXIPProject N' Unit Document Code

2121 00 JSD 0000



Serial N' Rev. Page

03 1 36t52

o

OPTN SYSTEM FORIOXIC, ODOUROUSOR FLAMMABLE GASTSOR VOLATILE LIOUIDS

ISOLATING

VATVE

NOIE 1

NOÎE 3

NOTES:

î. PROVIDT LOCAL DOUSII VALVTS FOR 9OO Ib RATING AND ABOVE.

2. PROVIDI BREAK FLANGE FOR SAMPLE PROBT IF REOUIRED,

5. AN ADDITIONAL NEEDLE VALVE SHALL BE PROVIDED DOWNSTREAM OF

lSotATlNG VALVT FOR HIGH PRESSURE SERVICE (opprox. 70 bor).

TYPE: SJ - WTHOUT COOLER

IYPE: 54 - WITH COOLER

VINT TO

A''MOSPHERE AT

SATE LOCATION

(roR GAS

SERVICT WITH

c00rER)

LrNt/vALVt S|ZES rN TNCHES

TECHNIP-COFIEXIPProject N" Unit Document Code

2121 00 JSD 0000



Serial N' Rov. Page

03 1 37t52

a

CLOSED SYS'TEM

FOR 'OXIC,

ODOUROUSOR FTAMMABLE

LIOUIDS AND GASES

TYPE: 55 - WTHOUT COOLER

îlPE: 56 - WITH COOLER

VINT "TO ATMOSPHERE AT

SAFE LoCAIoN (NoTE 3)

î

ISOLATING

VALVE

NO]ES 2 & 4NOTE 5

HP PROCTSS

NOÎES:

1.

2.J,

I

5.

PROVIDE BREAK FLANCE FOR SAMPLE PROBE IF REQUIRED.

PROVIDE LOCAL DOUBLT VALVES FOR 9OO Ib RATING AND ABOVE.

VENÍ VALVE TO RTLEASE PRESSURE PRIOR TO UNCOUPLING FOR

LIOUID SERVICE.

PROVIDE LOCAL DOUBTE VATVES FOR PROPYLENE SERVICE.

AN ADDITIONAL NEEDLE VALVE SHALL 8E PROVIDED DOWNSTREAM OF

ISOLATTNC VALVES FoR HIGH PRESSURT SERVICE (opprox. 70 bor).LINE/VALVE SIZES IN INCHES


2121 00 JSD 0000 03 1 38t52



21. VALVES AT BATTERY LIMITS

21.1. All lines leaving or entering the plant battery limits shall be valved.

21.2. The valves shall be grouped at plant battery limits into one or more manifolds.

21.3. All block valves at battery limits shall be equipped with spectacle blinds toward plantside.

21.4. A drain valve shall be installed between BL block valves and the unit.

21.5. For typical arrangement of valves at B.L. refer to Fig. 21.1.

21.6. All process lines leaving from units or block battery limit shall be valved.

21.7. Generally, all utility lines leaving or entering the units or block battery limit shall bevalved, unless otherwise shown on PlD.


2121 00 JSD 0000 03



Rev. Page

1 39t52

VALVES AT PLANT BATTERY LIMITS

FtG.21.l

.. ,L .rgf ,ro*,*roor* T - ..T

(1) (4)PROCESS AREAx_x_Y_x_x_

ABOVEGROUND LINES

r VALVE PIT

TECHNIP.COFLEXIP Project N" Unit Document Codè Seríal N"

2121 00 JSD 0000 03Rev. Page

I 40t52



NOTES:

1) By-pass around steam block valve shall be provided if following conditions aremet:

- either steam operating pressure lower than 6 barg and pipe diameter equalto or larger than 10", or

- Steam operating pressure equal to or higher than 6 barg and pipe diameterequal to or larger than 6".

The by-pass valve will be sized as follows:

- 1" for steam line from 6" to 12"- 1Tz" îar steam line from 14" to 18"- 2" for steam line from 20" and larger

2) The block valve, in the flare header, must be car seal open and the stem inhorizontal position or with minimum angle downwards.

3) Plugging devices will be shown or not on PID according to the procedure. lfshown, plugging device shall comply with Piping classes.

4) Extemal by-pass is not required if main isolating valve is provided with an internalby-pass.

TECHNIP.COFLEXIPProiect N" Unit Document Code Serial N' Rev. Page

2121 00 JSD 0000 03 1 41t52



a22. VALVING CHECK LIST

22.1. Block valves shall be provided:

a) For all lines crossing plant battery limits (the valve on flare header shall be CSOstem downward);

b) At spared equipment;

c) Close to vessels nozzles only when required for operational control and for thefollowing:

- in piping close to all nozzles of vessels containing toxic materials- in liquid draw-off lines close to the nozzles of vessels and tanks containing

5.7cu m or more of a flammable liquid inventory at the maximum normalliquid level and when the line does not contain a block valve located within9m in a horizontal direction from the vessel

and with the following exceptions:

- connections for overhead vapour lines, transfer lines, reboiler lines- vents open to atmosphere

lines from/to safety valves (see point 14.1)

d) r"':i:llil#;1ffi,p3gp flli#;;;'- *,*l**,*'",

operation of the remaining plantat the header in overhead water supply branches located outdoors infreezing climates

0 At utility lines connected to lines or process equipment

g) For isolation purpose of instruments (e.9. control valves) or equipment to beinspected during the normal operation of the plant

h) At utilities hose stations

i) At main line of fuel oil and fuel gas piping to fumaces or fired heaters. lt shall belocated at least 15 m away from the equipment and be accessible for rapidoperation in an emergency

j) At all storage tank connections (except for PSV's) close to tank nozzles below theliquid level and outside the dikes

k) At both the water inlet and outlet piping of exchangers units (butterfly at theoutlet).

TECI{NIP-COFLEXIPProject N" Unit Document Code Serial N" Rev. Page

2121 00 JSD 0000 03 I 42t52



D At steam traps assembly

m) At sampling devices

n) For preventing flow (e.9. at drains, vents, steam out points) or diverting flowthrough an altemative route (e.9. by-passes)

o) At suitable points in fire water ring to allow isolation.

22.2. Block valve type shall be according to piping class.

In case, however, of no specific requirements, the following recommended type shallbe selected:

o plug valves for caustic and fuel gas service;o butterfly valves for cooling water & sea water service (size > 2");. ball valves for liquid LPG service; gate for gaseous LPG;o needle valves at sampling points (open sample);o globe valves for manual regulation flow;. ball valve full bore for slurry service.

22.3. Double valving shall be provided for:

a) PSV by-passes and instrument connections for flammable and toxic services withrating 600# and higher.

b) Operating ventldrains with rating 600# and higher (a single globe is possible forvent only).For vents and drains required for operation only at shut down, and with rating600# and higher, a blind flange in place of the second valve is acceptable.

c) Utility lines permanently connected to process lines or equipment in all cases.d) Preventing product contamination where the use of spectacle blinds is not

suitable.e) Dirty or cocking services as per licensor requirements.

0 Sample connections.g) Liquid hydrocarbon services with a vapour pressure over 4.5 bara at 38'C. The

valves shall be spaced a minimum of 600 mm apart, the downstream valve shallbe a globe valve, the upstream valve shall be a block valve.

h) Operating vents and drains on hydrogen service or LPG service where flashingand consequent freezing can occur.

TEC}INIP.COFLEXIPProject N' Unit Document Code Serial N"

2121 00 JSD 0000 03Rev, Page

1 43t52



22.4.

23.

23.1.

Check valves shall be provided where necessary to prevent back flow:

a) On the discharge of centrifugal and rotary pumps and compressorsb) On the discharge of dosing and volumetric pumps (see fig. 10.2)c) On utilities and service lines permanently connected to process lines or

equipment.d) \ffhen required to prevent bulk contamination in any of two mixed stream due to

reverse flow in one of them.

SPECTACLE BLINDS CHECK LIST

Spectacle blinds shall be provided:

a) At battery limits, for all the lines entering or leaving geographical unit (refer to fig.21.1). Spectacle blinds shall be installed towards plant side.

b) For isolating purpose at vessels to be inspected during normal operation of theplant.

c) To prevent contamination of process or utility lines, during normal or special (i.e.regeneration, etc.) operation

TEGHNIP.COFIEXIPProject N" Unit Document Code Serial N" Rev. Page

2121 00 JSD 0000 03 1 44t52



24, STEAMING OUT/PURGING

24J. The plant shall be designed with steamouVpurging connections adequate in numberand size, to enable ineÉ flushing during start-up, shutdown and maintenance operation.Purge connection shall be preferably located on piping instead of equipment.

Whenever provided on vessels, purge mnnections shall be at min. distance fromtangent line.Connections for emptying vessels shall be selected from figure 24.1.

24.2. Steam out connection 3" and larger shall be permanently connected to steam headeras per para 18.0.

24.3. Equipment and associated lines which will be steamed during start-up or shutdownoperations, shall be designed for thermal expansion for the higher of:

a. steam-out temperature 12A'Cb. design temperature of the line or equipment.

O 24.4. The extension of steam out in the plant will be general with the following exceptions:

- Air Service- Nitrogen- Water

ÎECHNIP.COFLEXIP Project N' Unit Documenl Code Serial N"

2121 00 JSD 0000 03



Rev. Page

1 45t52

olrJÉ,FUJ

=zJu@oIIJ

lroú,tuFUJE

ouloaz

FtG.24.1

SIZE OF AUXILIARY CONNECTIONS

ON PRESSURE VESSELS

8 101214 1618202224STRAIGHT LENGTH OF VESSEL - METRES

Auxiliarv connectionsmm inches25 I40 1%50 280 3

iliV=7li M3

t'/ i

=1 17i PO dFnotes PUMP O

SO dbnotes $îEAMV dehotesTOTALVWF &notesWATER

mm so piped

i

!

40

I

iV ='t 7

i

:

L V=2.6 ME =.ru zsl,'veir,

i25i40

TECI{NIP.COFLEXIPProject N' Unil Document Code Serial N'2121 00 JSD 0000 03

Rev. Page

I 46t52



25.

25.1.

26.

26.1.

26.2.

26.3.

DRAINAGE SYSTEM

All the drains from equipment, lines or instruments, which for process reasons must bepiped into an open sewer or a closed system, shall be shown on PID with the indicationof the destination (oily sewer, chemical sewer, recovery system, etc...).

OPEN DRAIN

- Oily water- Chemical- Storm water

CLOSED DRAIN

- Oily water- Chemical- Chemical- CO2 RemovalArea- Chemical- Refining Area

MARK TYPE

ocS

MARK TYPE

occcCR

WINTERISING

The winterising protection shall be based on the minimum ambient temperature.

Due to warm climatic conditions, winterisation is applicable only on "glacial" acetic acidservice (freezing point 16"C) and carbonate solutions.

Piping shall be designed to avoid tracing whenever possible by circulation of the fluidwithin the piping.Piping shall be designed for normally flowing lines to eliminate stagnant pockets wherefreezing may occur. Where unavoidable, protection by insulation and steam tracingshould be provided.No flowing lines, intermittent service, and dead ended lines should be avoided as far aspossible. Where unavoidable, such lines should be insulated and steam traced.

TECI{NIP-COFLEXIPProject N' Unit Document Code Serial N' Rev. Page

212t 00 JSD 0000 03 I 47t52



O26.4. Wnterising by Draining

Lines where liquid may collect and freeze during shutdown shall be designed forself-draining and provided with appropriate drains and vents.During non-opemting periods these lines may be completely drained and flushed.

26.5. Equipment

1) A drum or vessel containing liquid hydrocarbon that may freeze shall be protecledby heat tracing and by insulating nozzles, block valves and drain piping.

2) Exchangers and coolers containing liquids that may freeze shall have sufficientvalved dr:ain and flushing points to insure complete drainage upon shutdown.

3) For pumps winterising facilities shall be provided alternatively as follows:

a) suctionidischarge by-pass valves installed at min. distance from each otherrespectively, to avoid dead legs as perfig.26.1.

TECHNIP.COFLEXIPProject N" Unit Document Code Serial N'2121 00 JSD 0000 03

Rev. Pagè

1 48t52



PUMP SUCTION AND DISCHARGE LINE WINTERISING ARRANGEMENT

FtG.26.1

NOTES:

1) Circulation by pass for winterisation purpose.

2) 1" of insulation shall be provided around the piping, from the block valves up toincluding, the by-pass, ensuring that dead legs are no longer than 500 mm(measured from the line with flowing fluid).

3) The dimensions of by-pass line are the following:Ya" - f of lines 3" and smalle fi 1" - for lines from 4" to 8"; 1 Yz" ' for lines from 1 0"to 20"; 2" -lor lines larger than 20".

(1) (2) (3) (1) (2) (3)

4 z

ÎECHNIP.COFLEXIPProject N" Unit Documeni Code Serial N" Rev. Page

2121 00 JSD 0000 03 1 49t52



o27, INSTRUMENTATION

27.1. The lnstrumentation shall be shown in accordance with ISA-S5.1 "lnstrumentationSymbols and ldentification" and as per Client's requirements.lnstrument Tags shall conform to contractual rules formalised by Instrumentationspecialists. The following criteria is norrnally adopted:

AAMAA ZZYY K

Where:

AAAAAA The first letter identifies the variable, as: L= Level, F= Flow etc.The succeeding letters identifies the function, as: T= Transmitter,C= Controller, etc.

ZZ PID sheet numberYY Sequential instrument numberK Sub index

BEP instrument numbering system to be adopted.

27.2. The valve installed in each instrument take-off connection shall be located as close tovesselor line as possible.Take-off connections, including the first block valve, shall be compatible with the lineservice classification.

27.3. The take-off connection valves shall not be shown on PlD, in general; for levelsinstrumentOnly they may be shown if required for process reasons.

27.4. Instruments shall be sealed by any of the following process conditions:

- Corrosive fluids- Extremely viscous fluids and where heat tracing will be unsatisfactory- Slunies and fluidised solids.

27.5. The instrumentation located at units or Blocks B.L. will be provided as follow:

Process Lines: according to process or licensor requirements.as per PID's

Utility Lines: as per here attached arrangements (for flare and slop headers, nomeasurement).

27.6. Initiated logic interlock signals shall be numbered.

TECHNIP-COFIEXIP Project N' Unil Document Code Serial N"

2121 00 JSD 0000 03



Rev. Page

1 5At52

STEAM HEADERS

FtG.27.1

o-o-o-O-o-o

L.L.P STEAM

H. P, STTAM

COSTING

L. P. STE AM

TECHNIP.COFLEXIPProject N" Unit Documgnl Code

2',t21 00 JSD 0000



Serial N"

03Page

51t52Rev.

1

WATER HEADERS

FtG.27.2

TECI{NIP.COFIEXIP Projecl N" Unit Document Code Serial N'2121 00 JSD 0000 03



Rev. Page

1 52t52

NITROGEN AND AIR HEADERS

FtG.27.3

cosTlNG Z'--FÀf--It--J-o-ol I' l\ -,'l _ I Otl

NITROGTN

CCSTING

IN STRUMTN T

Prq.2121 - SABTC ACETTC AC|D PROJECTd|È!/FJi lrttiFtf |FL5ttft$j' , YANBU - KINGDOM OF SAUDI ARABIA ,,#,-.tl n m

Page 64

TXeH${lP IYALY $,p.4,

6.1.3. Process Control & ESD Philosophy

2121-00-JSD-0000-04

dmfu**


TSCHHIp-COFIHXIPProject N' Unit Document Code Serial N"

2121 00 JSD 00 00 04



Rev. Page

B 1t12

PROCESS CONTROL&

EMERGENCY SHUT DOWNPHILOSOPHY

nB 16-04-2003 PROCESS RÉVIEW ulTs%4 ./ l' frL:

Dt Bt^sE/{//

L otatase

16-12-2UO2 PRMESS ISSUE L. DI BIASE L: Dl BIASE / G. tsLtHÈs

REV. DATE STATUS WRITTEN BY{name & visa)

UHEUKEO AY(name & visa)

ArrKvvturAu I nvKtaEu E I(name & visa)

DOCUMENT REVISIONS


TfcHHtp-coFtExlPProject N" Unit Document Code

2121 00 JSD 00 00



Serial N"

04Page

2112Rev

B

CONTENTSP:na' ":,"

1. INTRODUCTION

2, SPECIAL INSTRUMENT DESIGN INFORMATION

D ifferential Pressure TransmittersOn-Line Analyser Alarm And Trip Settingslnstruments in CATACARB Solution Streams

PROCESS CONTROL SYSTEMS

3.1 Fuel Gas Header Pressure Control3.2 Oxygen Feed Control System3.3 Oxygen Feed Interlocks3.4 Oxygen Shutdown3.5 High High Reactor Temperature Trip3.6 Reactor Steam Drum Temperature Control System3.7 Reactor Steam Drum Level Control System3.8 Oxygen On-Line Analysers3.9 Circulation Compressor Control System3.10 Dehydration Column Control System3.11 Emergency HP lmport Steam To Fired Heater Coils3.12 Product Column Control System

4, SABOXR SYSTEM

5. LEVEL CONTROL POTS

2.12.22.3

Ar+

11

12


TICHNIP.COFTEXIPProiect N" Unit Document Code

2121 00 JSD 00 00



Serial N"

o4Page

3112Rev

B

1. INTRODUCTION

This document complements and clarifies process design information about the complex control loops andthe emergency shut down philosophy.

2. SPECIAL INSTRUMENT DESIGN INFORMATION

2.1 DifferentialPressureTransmitters

Differential Pressure Transmitters designed to prevent reverse flow down the instrument impulse lines shallbe specified. This is to ensure no reverse process contamination. This design is to be incorporated in thefollowing transmitters:

Tag No. Description P&lD No.

PDALL-1313 Nitrogen to Ethane FeedPDALL-1302 Ethane Feed To Main LoooPDALL-1412 Oxygen Feed From 100-J113A/B Comp.PDI-1403 Mixer (100-M111) Pressure DropPDALL-1404 Mixer (100-M1 1 1) Pressure Drop

-DFI+ZZ Mixer (100-M1 1 1 ) Pressure Drop

rPpl-1793 100-J1 13A/B Nitrogen Valve Pressure Drop

2.2 On-Line Analyser Alarm and Trip Settings

Fínd below a list of the alarm and trip settings for the on-line analysers.

2121-01-PlD-0021-13 Sh. 1 ol 1

2121-O1-PlD-0021-13 Sh. 1 of 1

2121-01-PlD-0021-14 Sh. 2 of 22121-01-PlD-0021-14 Sh. 2 of 22121-01-PlD-0021-14 Sh. 2 of 22121-01-PlD-0021-14 Sh. 2 of 22121-01-PlD-0021-17 Sh. 1 of 1

High HighTag Number

Al-1402

At-2004

Al-2002

At-8102

At-3001

P&lD Number Gomponent

2121-01-P\D-O021-14 sh 2 of 2 Oxvoen

2121-02-PlD-0021-20 sh 1 of 1 Oxvoen

2121-02-PlD-0021-20 sh 1 of 1 Ethane

2121-08-PID-0021-B1sh 1 of 1 Oxygen

2121-03-PlD-0021-30 sh '1 of 1 Acetic Acid

6.0 mol%

3.0 mol%

6.0 mol%

High

5.5 mol%

2.0 molok

50.0 mol%

Action

AAHH-1402trips the plantAAHH.14O4

Trips the plant

Trips theSABOXR Reac.

30ppm rnol.

2.3 Instruments in CATACARB Solution Streams

In order to guard against plugging of the tapings / impulse lines, pressure and level instruments in the CO,

^Removal System in CATACARB solution streams shall be provided with diaphragm type isolation from thef rocess tluiO. For the same reasons, flow instruments shall be of the Ultrasonic type.v

TECHNIP ITALY S.p.l\.- 00148 ROMA - Viale Castello della Magliana, 68

TTCHNIP.COFLEXIPProiect N' Unit Document Code

2121 00 JSD 00 00



Serial N'o4

Page

4112Rev

B

3. PROGESS CONTROL SYSTEMS

This section outlines the principles behind the more important control loops on the plant. lt is not intendedto list the function of every instrument, as thÍs is obvious for most cases from the relevant P&l Diagrams.

Control of the plant by the operator is accomplished via a Distributed Control System (DCS) with the use ofcomplex control loops. This section describes the function and different modes of operation of the followingmajor control loops,

3.1 Fuel Gas Header Pressure Control

Refer to P&lD: 2121-06-PlD-0031-61 sh 2 of 2 for detailed control representation.

Normal pressurecontrol ofthefuel linetotheSteamFiredHeater(100-H161)iscontrolledbyPlC-6151. lfthe pressure is too low, ethane is added to the fuel line by opening PV-61 51 A (0 - 45o/o). lf the pressure is

too high, the excess fuel is vented to flare by opening PV-6151 B (55 - 100%).

It is expected that the controller PIC-6151 will have a dead band around 50%, (normally 45% to 55% to beconfirmed and set during initial plant operation). This is to prevent a cycling operation of the control valvesPV-6151A and PV-61518.

-,-.2

Oxygen Feed Control System

Refer to P&lD No. 2121-01-PlD-0021-14 sh 2 of 2 for detailed control representation.

Due to the exothermic nature of partial oxidation of ethane, there is the potential for explosive mixtures tooccur. To this end, the instrumentation throughout the plant is designed to prevent such mixturesappearing. For the oxygen feed to the main loop the instrumentation guards against excessive oxygenbeing added to the loop and also against hydrocarbons entering the oxygen system.

The oxygen flow to the main loop is indicated on the flow instrumeni FIC- 1402. This flow instrument istemperature and pressure corrected. FIC-14A2 receives the process values from the calculation block FY-1402. The set point of the controller is entered manually by the DCS operator.

FY-14A2 receives three flow signals from three separate transmitters, FT-1402A, FT-14O28 and FT-1402C.This block selects the median of the three values and sends ihe result Io FIC-1402. lf one of the flowtransmitters reads differently from the other two, then FY-1402 applies the following logic:

. lf one of the flow transmitters deviates by more than +l- 1 .5% of the median, then the DCS givesa bad value alarm (FDAH-1402).

lf one of the flow transmitters deviates by more than +l- 3o/o of the median, then FY-1402 selectsthe highest of the remaining two good values and the DCS gives another bad value alarm(FDAHH-1402R).

lf the remaining two good values differ by more than 3%, FIC-1402 switches to manual with thevalve FV-1402 locked in position and the DCS gives two further bad value alarms (FDAHH-1402and UA-1402). FIC-14A2 can be returned to automatic by the operator only when two of thevalues differ by less than 1.5%.


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Oxygen Feed Interlocks

The interlock system has been designed to ensure that prior to the introduction of oxygen, the oxygen linehas been sufficiently flushed with nitrogen and the ethane flow into the main loop is established.Refer to the Process Trip Logic Diagrams (TPIT Doc. 2121-00-DW-1500-13) for detailed description.Refer also to P&lD No. 2121-01-PlD-0021-14 sh 112 of ,2121-07-PlD-0021-70 sh 1 of 1 .

Prior to the introduction of oxygen, all the initiators that cause an oxygen trip need to be healthy. However,some initiators can not be healthy until the oxygen flow is established. To have a healthy Oxygen Tripsignal, these initiators are bypassed at start up.When the plant is to be started, it is necessary to establish a flushing nitrogen flow down the flushing line.The operator must go into the field and fully open ZSH-7001. When the valve is fully open, ZSH-7001gives a healthy signal.

Prior to this stage, ethane will be circulating in the front end of the plant and the pressure drop across theethane feed valve (FV-1301) into the main loop needs to be made healthy. When the pressure drop ishealthy, PDALL-1302 gives a healthy signal.

PDALL-1302 and the Oxygen Trip must all be healthy in order to reset FV-1301. Once FV-1301 is resetand the oxygen trip is healthy, ZSH-7001 is bypassed and remains bypassed until an oxygen trip is

Àitiated.fsfsrs the oxygen feed valve (FV-1402) can be opened delay time of 3 minutes is provided in low flow trip

FALL-7007 to allow nitrogen to flush the oxygen line for a fixed period of time prior to the introduction ofoxygen feed. Prior to starting the nitrogen flow, the operator must go into the field and open the block valvein the start up line (N-4123) downstream of FO-7004. The operator then opens HV-7002 via HIC-7002,which allows the nitrogen flow to be established. Note that HV-7002 will already be tripped open by the"Low Low Oxygen Flow" initiator (FALL-1403).The operator may now open the oxygen trip valve (HV-1402) by manually resetting the solenoid valve inthe field. Once HV-1402 is fully open the Oxygen Compressor is ready to start.Once the delay iime is expired and the oxygen compressor 100-J113A/B has been started, the oxygenblock valves in the line to process are opened, namely, XV-1404 and XV-1406 by oxygen reset HS-1401,and the bleed valves XV-1403 and XV-1405 are closed. Oxvqen is still isolated from the process bv FV-1402 being closed.

At this stage, the operator may now introduce oxygen into the plant by opening FV-14A2.

Oxygen Shutdown

Refer to P&lD No. 2068-07-T3-D70 and Process Trip Loqic Diaoram 2121-00-DW-'1500-13.

The purpose of the shut down timer (5 minute) i, to *nrj,r" u ,rrr,r,"nt amount of nitrogen has flushed theoxygen feed line after an oxygen trip has been initiated, before closing the Emergency HP NitrogenShutdown valves XV -7 0031 4.

Qn initiation of an oxygen trip, the trip valves downstream of the HP Nitrogen Emergency Shutdown Vessel104-D276 (XV-700314). The time period for flushing is 5 minutes.

The trip valves XV-7003 and XV-7004 can only be closed when all of the following conditions are satisfied.

3.3

3.4

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. The delay time of 5 minutes has elapsed since oxygen trip.

. ZSH-7001 on the block valve exit 100-D274 confirms that the valve is fully open.

. Reset Button HS-7003 is activated.

High High Reactor Temperature Trip

Refer to P&lD No. 2121-A2-P\D-AA21-20 sh 1 of 1

High temperature within the reactor catalyst is an indication of the potential for a run-away reaction. This isguarded against by having a high reactor temperature trip.

Reactor 100-R121 has eighttemperature nozzles in the top head of the vessel, T1 to T4 contain the tubeside thermocouples (18 off multi-points) plus the Reactor Inlet thermocouples (2 off). T5 to T8 contain theshell side thermocouples (4 off multi-points).

The 18 tube side multi-pointthermocouple units, each contain five measuring points (A - E). This gives atotal of 90 tube side measuring points. The tube side instrument numbers are numbered TI-2007A-E to TI-2024A-8. The tube side multi-point assemblies are equally divided into two groups, X and Y (9 of each). Xand Y thermocouples are of different sensing point locations (height) and hence, the five different locations

1|n the multi-point assemblies results in ten different elevations within the Reactor.Uix tube side multi-point assemblies, 3 each of X and Y (30 measuring points) are connected to the ESD

System (Emergency Shutdown System). The instrument numbers are as follows: TE-2007A-E, TE2010A-E, TE-2011A-E, TE-201sA-E, TE-2016A-E, TE-2021A-E. Each of these temperatures are repeated fromthe ESD System to the DCS. All the other tube side thermocouples are connected to the DCS only.Out of the six multi-point assemblies that are routed to the ESD, a 2 out of 3 voting system is configured forthe ten separate elevations. See Reactor 100-R121 Thermocouple Specification, document number2068-00-NB-S5. At each elevation, there are 3 measuring points. When 2 out of the 3 measuring points reachthe trip setting, then a trip is initiated. This results in ten trip initiators TAHH-2050 A-J. The configuration is

as follows:

3.5

INITIATOR

TAHH-2O5OA

TAHH-2O50B

TAHH-2O50C

TAHH-2O5OD

TAHH-2O5OE

TAHH-2O50F

TAHH-2O5OG

TAHH-2O5OI

TAHH-2O5OJ

TAHH-205OJ

TE-20074

TE-20104

TE-20078

TE-20108

TE-2007C

TE-2010C

TE-2007D

TE-2010D

TE-2007E

TE-2010E

TEMPERATURE MEASURING POINTS(2 OUT OF 3 VOTTNG)

TE-20114

TE-2015A

TE-2A118

TE-20158

r- 4^44^I E-ZU I IU

TE-2015C

TE-2011D

TE-201sD_- AAA ATtL-4Vt tL

TE-2015E

TE-20164

îE-2021A

TE-20168

TE-24218

TE-2016C

TE-2A21C

TE-2016D

TE-2021D

TE-2016E

TE-20218


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The four shell side multi-point thermocouple units, each contain five measuring points (A-E). This gives atotal of 20 shell side measuring points. The shell side instrument numbers are numbered TF2A25A-E to Tl-2028A-E. The shell side thermocouples are connected to the DCS only.

The two duplex reactor head thermocouples are routed along the inside of the reactor head and thethermocouple tip extends into the vapour space to measuring the inlet process temperature. This provídesan operational element plus a spare for each of the two thermocouples. The instrument numbers arenumbered TAHH-2005 and TAHH-2049. These thermocouples are connected to the ESD System. Anindication of the actual process inlet temperatures is repeated from the ESD System to the DCS.

3.6 Reactor Steam Drum Temperature Control System

Refer to P&lD No. 2121-02-PD-A021-20 sh 1 of 1" 2121-Oz-P lD-0021-21 sh 1 of 1.

Two separate operating modes exist that may be selected by the operator depending on the conditionwhether the Reactor Steam Drum (100-D221) is being heated (HEAT MODE) or being cooled (COOLMODE).

When the steam drum is being heated at start up, the operator selects HEAT MODE on HS-2002. This

^allows the circulating water to be heated using HP Steam.

Uollowing a shutdown, the plant has been designed to accelerate the cooling of the steam drum and theReactor. To initiate cooling of the circulating water, the operator seiects COOL MODE on HS-2002. TheReactorSteam DrumventvalveTV-2101 and the Circulation Cooler, 100-E121 are both used to lowerthetemperature of the water.

The maximum heatino or coolino mode for the reactor svstem is specified as 15'C oer hour.

Selecting HEAT MODE on HS-2002 has the following actions:

. The temperature controller TIC-2047, downstream of the steam sparger ZM-2101 resets the setpoint on the HP Steam flow controller FIC-2103, to allow the temperature (TlC-2047) to increaseat a rate of 15"C / h. (FlC-2103 is switched to cascade and TIC-2047 to automatic). Theoperator can select the final desired temperature target, nominally 220"C.

. Shuts the steam drum vent valve TV-2101 via the temperature controller on the steam drum.TIC-2101, via the high selector block TY-2101. (lf required the operator can still open the steamvent valve via HIC-2101).

. HY-2102 sends a signal to the two valves (HV-2002A and HV-20028), to ensure the ReactionCirculation Cooler 100-E121 is fully bypassed.

This operation is continued until the temperature in the steam drum reaches the operator set temperature

]rget (nominally 220 "C). When the temperature reaches this value and the Reactor starts transferringlheat into the coolant after oxygen feed started and plant load reach more than 80%, the Start Up

Circulation pump can be stopped and the HP Steam isolated.

Before heating is started, the operator must ensure there is a healthy level in îhe steam drum.

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Selecting COOL MODE on HS-2002 has the following actions:

, The operator can be select the final desired temperature target, nominally 60 'C.

. A signal is sent from HS-2002 to the temperature controller TIC-2047 forcing the controller intomanual.

Two cooling step are provided:

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When the temperature within the steam drum, as measured by TIC-2101, is greater than 120"C, asignal is sent to open the steam vent valve TV-2101 to control the rate of cooling to 15'C/h and thesignal also ensures the two valves (HV-20024 and HV-20028) fully bypass the cooler 100-E121 viaHY-2102.When the temperature falls below 120"C, the signal from TIC-2101 shuts the steam vent valve and alsoopens the valve HV-20024 and closes the valve HV-20028 to ensure all the circulating water passesthrough the cooler 100-8121.

Reactor Steam Drum Level Control System

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Three elements are necessary to controlthe Steam Drum level:Steam flow measurement Fl-2101BFW flowrate measurement FIC-2102Steam drum level controller LIC-2101

The control strategy accounts for changes in any of the three measurements.It is a cascade control structure where the steam drum level (LT-2101) is primary loop and the BFW flow sthe secondary loop.The steam flowrate is a direct feed forurard signal to the BFW control loop. Since the steam flow is equal tothe feed water flow (less continuous blowdown), the BFW control loop compensates immediately forchanging in steam demand. The steam drum level loop modulates the feed water flow to compensate forshrink, swell and lags in the process.

This function block (LY-21018) has two parameters to be implemented, named KMAS and BMAS.

FY-21018 = (KMAS. PV(FT-2101)+ BMAS) + OUT(L|C-2101)

Where:PV(FT-2101) is the process value read by FT-2101OUT(L|C-2101 ) is the output signal from LT-2101.

The term (KMAS . PV(FT-2101) + 3X44S) in the equation is equal to zero if the value is negative.

Practically, KMAS value (0 to 1) indicates the effect of the steam Flow on the BFW feed set value,

_ otherwise the BMAS value indicates when the steam flow effect is bypassed.

-(MAS and BMAS shall be set by operators.

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Oxygen On-Line Analysers

Refer to P&lD No. 2121-01-P|D-OA21-14 sh 2 of 2,2121-02-PlD-0021-20 sh 1 of 1,2121-08-PlD-0021-81sh1of1.

Due to the exothermic nature of partial oxidation of ethane, there is the potential for explosive mixtures tooccur. To this end, on-line oxygen analysers are utilised that senci signals directly into the ESD System.

There are four Oxygen On-Line Analysers, namely, AT-1402 (downstream of the Static ln-Line Mixer, 100-M'111), AT-2004 (downstream of the Reactor, 100-R121), AT-8102 (downstream of the SABOXR Reactor,100-R181) and AT-1403 (SPARE).

AT-1403 is a spare analyser for AT-1402, Aî-2004 and AT-8102. A vendor selector switch (HS-1408)exists that allows AT-1403 to measure one of the three sample point locations. The information of whichsample point location is being measured by the spare analyser (as selected by the vendor switch) must berelayed to the ESD. ' The data from the spare analyser is routed to the ESD and repeated to the DCS. Aseparate switch (HS-1409 Take Over Switch) is to be provided by the ESD vendor that allows AT-1403 tooverride the alarms and trips of the selected analyser location. This allows the "off-line" analyser to be re-calibrated at regular intervals.

.9 Circulation Compressor Gontrol System

As the compressor flow decreases, the cycle gas composition moves closer to the potential forexplosive mixture due to the increasing oxygen content.To avoid this scenatio the flow alarmflow FALL-1308 is provided to initiate Oxygen shut down. lf the flow of cycle gas decreasesfurther more, the reactor by-pass valve FV-1302 will be opened to protect the compressoragainst surging point. lf the cycle gas is still decreasing more, then the compressor 100-J112will be tripped by the FALL-1309 to protect the compressor from being surged.As a result of the compressor tripping, the following will occur:

. The reactor by-pass valve FV-1302 will be forced to close fully.o The cycle gas pressure controller PIC-1311 set point will be half of its normal value (13

barg)

ln order to estimate the surge point approach, a calculation algorithm has been implemented withtemperature, pressure and flow input values from compressor suction and discharge. Alarms FALL-1308,FALL-1309 and set point for FIC-1302, are results of the calculation blocks.

3.10 Dehydration Column Gontrol System

Refer to P&lD Nos. 2121-03-PlD-0021-31 sh 1of 1.

The control of the Dehydration Column is configured so that the total feed flowrate to the columnautomaticallv controls both the reboiler rate and the reflux rate both via ratio control.

-fhe reflux rate is automatically ratio controlled against ihe total feed rate to the column. The temperaiure

controller located below the feed tray resets the set point for the ratio controller. The ratio between thereboiler rate and feed rate is adiusted manuallv deoendino uoon feed comoosition.

3.10.1 Dehydration Column Reflux Control System

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The function block FY-3102A calculates the combined feed flow to ihe Dehydration Column by addingtogether the flow from the Scrubber, FIC-3102 and the recycle off-spec produci, FIC-5101. The value fromthis block is routed to two ratio blocks. FY-31028 and FY-3102C.

The function block FY-3102C divides the reflux flow, as measured by Fl-3104, by the flow signal from FY-3102A. The resultant value is routed to the ratio controller FFIC-3106 and is compared against the setpoint. The temperature controller on the column, TfC-3108 (reverse action) automatically resets the setpoint of FFIC-3106. The controller output is sent to the reflux flow control valve, FV-3106. Typical setpoints for the controller FFIC-3106 are between 1 .636 to 1 .629, for SOR and EOR cases respectively.

3.10.2 Dehydration Column Reboiler Control System

FY-31028 divides the reboiler flow rate, as measured by Fl-3103, by the flow signal from FY-3102A. Theresultant value is routed to the controller FFIC-3105 and is compared against the set point. The set point isadjusted manually dependent upon the composition of the feed. The controller output is sent to the reboilersteam flow control valve FV-3105. Typical set points for the controller FFIC-3105 are between 1.046 to1.047, for SOR and EOR cases respectively.

3.11 Emergency HP lmport Steam To Fired Heater Goils

tÌefer to P&lD No. 2121-06-PlD-0031-61 sh 2 of 2,2121-06-PlD-0031-62 sh 1 of 1.

v3.11.1 Superheated Steam Low Flow.

When the superheating steam flow is decreasing, due to a reduced steam production in the Steam Drum(for instance, afterthe oxygen trip) the controller FIC-6155 send a signal to the valve FV-6155 asking theHP steam from battery limit. The flow ratio controller FFIC-6103, reset by temperature control TIC-6109downstream of the desuperheater ZM-6103, controls the BFW flow to achieve a steam superheatingiemoerature of 5"C.

3.11.2 Superheated Steam Low Temperature.

After the Steam Fired Heater (100-H161) trip, the superheated steam temperature falls down. Lowtemperature alarm TALL-6155 is connected to DCS in order to ciose ihe valve PV-2101 in the steam linefrom 100-D221 in 2 minutes and FIC-6'155 asks for HP steam from battery limit.In orderto keep in superheating condition the HP sieam, the trip signal from 100-H161 provides to set thecontroller FFIC-6103 to 0%.

3.12 Product Column Control System

In orderto avoid losses of AceticAdd in the impurities line at bottom of the Product Column 100-C133, a

temperature controller TIC-3305 provides a stroke control of 100-P133,4/8, to ensure that the liquid comingout has a boiling point high enough to guarantee low quantity of Acetic Acid in the Heavies.

pfhe liquid level control on the column bottom is provided by the LIC-3301 that regulates the MP steam flowto the reboiler 100-E133.


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SABOXR SYSTEM

process work associated with the SABOXR System has been enqineered by SABIC.


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LEVEL CONTROL POTS

Level control pots are special piping items that are required for certain distillation column reboilers. A levelcontrol pot will normally be specified when the process side outlet temperature is near or below thetemperature of steam at the condensate system pressure.

Where the reboiler is to provide heating with just minimal control, this can be performed with a steam trap.When a trap is used the operation is cyclic. The condensate level in the reboiler will rise until the pressureis sufficient to expel the condensate.

More control can be obtained by the use of a level control pot. By controlling the level in the pot, level ofcondensate in the reboíler and thus the rate of heat transfer can be set.

The following reboilers are designed with level control pots;

1) 100-E132 Dehydration Column Reboiler, ZM-31012) 100-E134 Stripping Column Reboiler, ZM-35013\ rcA-il4z CO2 Solution Reboiler, ZM-41O1

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DRAWINGS AND DIAGRAMS

Piping & Instrumentation Diagrams

2121-00-PrD-0021-012121-00-PtD-0021-022121-01-PtD-0021-'102121-01-PtD-0021-112121-01-PtD-0021-122121-01-PlD-0021-132121-01-PtD-0021-142121-02-PtD-0021-202121-02-PtD-0021-212121-03-PtD-0021-302121-03-PtD-0021-312121-03-PtD-0021-322121-03-PtD-0021-332121-03-PtD-0021-342121-03-PlD-0021-352121-03-PlD-0021-362121-04-PtD-0021-402121-04-P1D-0021-412121-04-PtD-0021-422121-05-PtD-0021-502121-05-PtD-0021-512121-05-PtD-0021-522121-05-PlD-0021-532121-05-PlD-0021-542121-06-PtD-0021-602121-06-PrD-0021-612121-06-PaD-0021-622121-06-PlD-0021-632121-06-PtD-0021-642121-06-PtD-0021-652121-06-PtD-0021-662121-07-PtD-0021-702121-07-PlD-0021-712121-08-PtD-0021-802121-08-PtD-0021-812121-08-PtD-0021-82

TEGHI{IP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

acetic acid plant - vol. 1

Documents

catacarb solution

complex control

detailed control

level control

shell side

additional

flow transmitters

tube side