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55
PRESENTATION ON OPERATION OF CRUDE AND VACUUM DISTILATION UNIT By: SK. M.RAHMAN GM- Operation

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Page 1: CDU VDU Operation

PRESENTATION ON

OPERATION OF CRUDE AND VACUUM

DISTILATION UNIT

By: SK. M.RAHMANGM- Operation

Page 2: CDU VDU Operation

Crude Distillation UnitCrude Distillation Unit

ObjectiveTo separate crude into different products by

boiling point differences. Prepare feed for secondary processing units

Key FeaturesTwo kerosene draw-off flexibility to meet

changing market and product specifications. Heavy gas oil (HGO) draw off minimizes load

on Vacuum Heater and Vacuum columnOver flash facility provided in atmospheric

and vacuum column as part of advance process control.

Page 3: CDU VDU Operation

CapacityCapacity

Case - 131500 MT/D - 70/30 Arab Light / Arab Heavy

Case - 231500 MT/D - 50/50 Arab Light / Arab Heavy

Case - 327000 MT/D - Bombay High

Licensor - ABB LUMMUS CREST Ltd. Detailed engineering - ENGINEERS INDIA Ltd

Page 4: CDU VDU Operation

ATMOSPHERIC DISTILATION UNITATMOSPHERIC DISTILATION UNIT

Distillation of Crude Oil to produce :Product Name Cut Range UsageFuel Gas C1 - C2 Internal FuelLPG C3 - C4 Domestic FuelOverhead Naphtha C5 - 120 Feed for NHT/CCRHeavy Naphtha 120 - 140 Diesel ComponentKerosene 140 - 270 Domestic FuelATF 140 - 240 Aviation FuelLight Gas Oil 240/320 Diesel ComponentHeavy Gas Oil 320 - 370 Diesel ComponentReduced Crude Oil 370 - 560+ VDU Feed / IFO

Page 5: CDU VDU Operation

CRUDE SPECIFICATIONCRUDE SPECIFICATION

Properties Case 1 Case 2 Case 3

Specific gravity 60/60 0.864 0.87 0.832

Density at 20oC kg/m3 862 867 830

Sulfur wt% 2.2 2.4 0.17

Pour point Below ambient Below ambient 30 deg C

Viscosity at 20oC cSt 18 24 4.8

Viscosity at 50oC cSt 7.5 9 2.6

Viscosity at 100oC cSt 2.8 3.2 1.3

Nickel ppm wt% 8.4 10.5 1.15

Vanadium ppm wt% 31 38 0.44

CCR value wt% 5.35 6.14 1.29

UOP K 11.89 11.88 11.93

oAPI 32.27 31.14 38.57

B S&W (vol %) 0.5 0.5 0.5

Page 6: CDU VDU Operation

Atmospheric Distillation ProcessAtmospheric Distillation Process

16000 M3X2

Desalter-I Desalter-I

Desalter-II Desalter-II

Preflash

Preflash

Off Gas / Ovhd Naphtha - SGUOff Gas / Ovhd Naphtha - SGU

Heavy Naphtha -NHTHeavy Naphtha -NHT

L Kero - KMU,FOL Kero - KMU,FO

H Kero - KMU, FOH Kero - KMU, FO

LGO -DHDS, FOLGO -DHDS, FO

HGO - DHDS, FOHGO - DHDS, FO

RCO to VDURCO to VDU

3640C3640C

280 0C280 0C

20 0C20 0C

20kg/cm2 g20kg/cm2 g

125 0C125 0C

130 0C130 0C

11kg/cm2 g11kg/cm2 g

Page 7: CDU VDU Operation

Process DescriptionProcess Description

Crude is pumped from day tanks to DesaltersAfter preheating with product streams crude

enters in to Desalters. Two stage desalting is done to remove salts

Salt removal from crude helps in prevention of– Heat exchangers fouling– Corrosion of atm column from hydrolyzing of salts

Desalter outlet is sent to Pre-flash vesselFor removal of lighter fractions

Removal of lighter fractions helps in – Reduction of vapor phase and two phase flow in preheat

exchangers and fired heater– Facilitates higher throughput and optimum equipment

sizing

Pre flashed vapors are directly fed to Atm Column

Page 8: CDU VDU Operation

Process Description…Process Description…

Pre flashed liquid sent for further preheating.Preheating of crude with hot product streams Helps

in Heat optimization Lower loads on fired heaters Lower cooling water requirement for products cooling

Preheated crude comes to Fired HeatersWhere it is further heated to 364 0C

Heated crude finally enters Atm Column. Where it is fractionated as per required

specifications Product streams are sent to storage /

secondary processing

Page 9: CDU VDU Operation

DESALTER OPERATIONDESALTER OPERATION FUNCTION OF DESALTER IS TO REMOVE SALT FROM CRUDE. OPERATING VARIABLES TEMPERATURE : 130 DEG. C OUTLET CRUDE SALT CONTENT : <0.5 ptb PRESSURE: 8-11 kg/cm2 BRINE OIL CONTENT: 165 ppm (max) WATER INJECTION RATE: 4 - 6 % Vol. Of Crude INTERFACE LEVEL: 40 - 50% DEMULSIFIER INJECTION: 6 - 8 ppm on crude

DESALTER - 1 DESALTER - 2

MIXING VALVECRUDE

DEMULSIFIER DEMULSIFIERWATER WATER

Page 10: CDU VDU Operation

PREFLASH VESSELPREFLASH VESSEL

Pre flash vessel helps to remove around 3-4% of lighter ends from the crude and send them to the main fractionating column by-passing the furnace, thus reducing un-necessary furnace load.

Pre flash vessel is also acting as a surge vessel for CDU Heater Feed.

Pre-flashed vapors is introduced in the Crude Column LK section.

PR

EFL

ASH

VESSEL

PV

PRE-FLASHED VAPOURS

PRE-FLASHED CRUDE

DESALTED CRUDE

(3-4% OF CRUDE)

Page 11: CDU VDU Operation

CRUDE HEATERSCRUDE HEATERS

Crude heater 24 burners in each heater. Dual fired burners arranged into 6 groups.

Each group has four burners. Each groups has two pilot flame detectors.

– Pilot flame detractors are arranged on alternate burners.

Two FD fans and one ID fan. MP steam is generated in convection section. 8 Pass flows in each heater.

Page 12: CDU VDU Operation

CRUDE COLUMN OPERATIONCRUDE COLUMN OPERATION

FLASH ZONE : Partially vaporized crude from heater at 364 °C enters the flash zone of the crude column. Here the vapors travel upward and the liquid travel downward. The section of the column below the flash zone is the stripping section and the one above is the rectifying section.

STRIPPING SECTION : Here the liquid traveling downwards is stripped off its lighter components by the stripping steam traveling upwards. There are 6 fixed valve trays in this section.

RECTIFYING SECTION : Here the hydrocarbon vapors traveling upwards are rectified through mass transfer, whereby its heavier components are condensed by the comparatively cold circulating reflux, which travel down and in turn the lighter components of the down-coming liquid are taken up by the hot vapors.

There are 63 nos. valve trays and 6 nos. chimney trays in the rectifying section.

Page 13: CDU VDU Operation

CRUDE COLUMN OPERATIONCRUDE COLUMN OPERATION

REFLUXES : Refluxes serve two purposes - provide liquid in the rectifying section to cause liquid and vapour contact for fractionation - maintain temperature gradient in the column

OVERFLASH : The flashed vapors of the crude which condenses on the first tray above the flash zone are dropped down to the stripping section. This is known as over flash and it helps in (a) stabilizing the bottom product and (b) proper fractionation of Gas Oil. Over flash should be ideally 3-5% of crude vol.

STRIPPING STEAM : This helps in removing the lighter ends from the bottom product by decreasing the partial pressure. It is introduced below the valve trays in the stripping section.

Page 14: CDU VDU Operation

CRUDE COLUMN FLASH ZONECRUDE COLUMN FLASH ZONE

Combined heater outlet enters flash zone.A vane type feed inlet and a large empty space allows

vapor/liquid separation by gravity with minimum entrainment.

Flash zone is large enough to contain foaming.The incoming vapor from the heater produces significant

turbulence – This is controlled by passing the vapor from the flash zone through a

chimney collector tray 69 which also serves as vapor distributor.

Hot Crude

Page 15: CDU VDU Operation

Bottom SectionBottom Section

Liquid from flash zone and gas oil from the collector tray 69 is collected on tray 70Routed to the stripping section.

In the stripping section (trays 70 to 75) hydrocarbon vapors are stripped out from the residue by medium pressure stripping steam injected at the bottom of this section.

Atmospheric residue or Reduced Crude Oil (RCO) is drawn from the bottom Pumped to vacuum Distillation Unit.

Where it is further heated in fired heaters before vacuum distillation process.

Page 16: CDU VDU Operation

Overhead Section..1Overhead Section..1

Two-stage condensation with wash water circulation.First stage condensation

In Crude / overhead exchanger, 10E-102, Then in air fin exchanger, 10EA-301, to 90 0C To avoid corrosion by strong acids

– Wash water is circulated and injected at the inlet of 10E-102.

– Corrosion inhibitors injected in overhead vapor.

After air cooler it is sent to the reflux vessel,10V-301,– For separation of vapor, hydrocarbon liquid and water.

Second Stage Condensation Uncondensed vapor from the reflux vessel is sent to

– Air cooler 10EA-302

– Then to exchanger 10E-301(cooling water) to 40 0C where the overhead naphtha product is condensed .

» The mixed phase this exchanger is sent to naphtha vessel 10V-302.

Neutralizers & corrosion inhibitors are added in vapor line

Neutralizers & corrosion inhibitors are added in vapor line

Page 17: CDU VDU Operation

From the reflux Vessel Naphtha is sent by the reflux pump 10P-302 to

column. Sour water is sent to battery limit

In Naphtha Vessel water, hydrocarbons and uncondensed vapor are

separated. Liquid naphtha sent to the battery limit as overhead

naphtha product. Water, is preheated against the sour water going to battery

limit, and sent back as recycled wash water to the inlet of the overhead exchanger.

uncondensed off gas sent to off gas compressor 10K-301 Compressed to 10 kg/cm2a and sent to saturated gas separation

unit.

Overhead Section…2Overhead Section…2

Page 18: CDU VDU Operation

Col Ovhd Col Ovhd

Air Fin Air Fin Air Fin Air Fin

Exch Exch

OFF Gas COMPOFF Gas COMP

TreatingTreating

Nap ProdNap Prod

Crude Pht

Reflux Vessel

Nap Vessel

Wash WaterWash Water

Overhead CircuitOverhead Circuit

Reflux

Page 19: CDU VDU Operation

Heavy Naphtha section

Fractionation between heavy naphtha and lighter fractions of crude occurs between tray 1 and 11.

Product is drawn from tray 12 to H naphtha stripper, 10C-401 under level control.

In the stripper light components are removed by thermo siphon reboiling against Top Pump Around.Stripper vapors are sent back to column

Product is cooled in air fin cooler followed by CW cooling and sent to storage.

Page 20: CDU VDU Operation

Light kerosene section

Fractionation between Lkero H- naphtha between tray 13 & 24.

Product is drawn from tray 25 to Lkero stripper, 10C-501 under level control.Light components are removed from the light

kerosene by reboiling with LGO PA. Use of steam is avoided for stripping to prevent

presence of water in product

From Stripper it is sent to crude preheat exchangersFollowed by cooling in air fin cooler and CW

cooler.

Cooled product is sent for treatment / storage.

Page 21: CDU VDU Operation

Heavy kerosene Section

Fractionation between Hkero & Lkero between trays 26 & 40.

Drawn from tray 41 to Stripper 10C-601 under Level Control Steam is injected to strip out

lighter components Hkero is pumped with 10P 601 to

10E105 (crude) Then to 10EA 601 air fin cooler and then to Hkero Dryer 10C602

– Dryer vapor outlet is connected to ejector inlet of vacuum column

– Moisture is removed by vacuum Then to 10EA 602 before sending to

storage/treating Storage

HK/Crude

37 Stripper

Air Fin

Dryer

Air Fin

41

Page 22: CDU VDU Operation

Hkero Pump AroundHkero Pump Around

Hkero pumparound is provided from tray 41 to 37.

Medium pressure steam is generated in exchanger 10E-903.

Hkero is then sent to the stabilizer reboiler in the SGU unit

HK PA from SGU is preheat the dry crude in 10E-155 and then it is returned back to the crude column.

Page 23: CDU VDU Operation

TOP Pump AroundTOP Pump Around

Provided from tray 30 to 26. The top pumparound is first

used as heating medium in the heavy naphtha reboiler, 10E-401

Subsequently to preheat crude.

PurposeHeat removal from tower which

helps in Maintaining temperature profile Draw off temperatures and

product quality control

TPA/HNAP TPA/Crude

30

26

Page 24: CDU VDU Operation

LGO Stripping & RundownLGO Stripping & Rundown

Fractionation between LGO/ Hkero in trays 42 & 57.

LGO Drawn from tray 52 to stripper 10C 701 under Level Control 10LV-104Steam is injected to remove lighter fractions

Then pumped to 10E-902 to generate MP steam.

Subsequently sent to LGO/Crude exchanger 10E-109.

Then to cooler 10EA-701 and to 10E-701 trim cooler.

Finally sent to HDS/storage/blending

Page 25: CDU VDU Operation

LGO Pump AroundLGO Pump Around

LGO PA is provided from tray 48 to 52

The duty is utilized to generate MP steam in exchanger 10E-901.

LGO from 10E-901 is sent to the light kerosene reboiler 10E-501, as a heating medium

Finally returned back to the crude column 10C-201.

LGO/LKero

48

52

LGO/MPst

Page 26: CDU VDU Operation

HGO stripper & rundownHGO stripper & rundown

Fractionation between HGO and LGO occur between tray 53 to 58.

HGO product is drawn from tray 63 under level control

After steam stripping product sent to 10E-905 to generate MP steam.

HGO is further cooled in Crude preheat exchanger 10E-108

Finally through air cooler 10EA-801 Product HGO is sent to HDS unit/ storage/ blending.

Page 27: CDU VDU Operation

HGO Pump AroundHGO Pump Around

HGO pump around is provided from tray 59 to 63.

heat is utilized to preheat crude before the furnace in exchanger 10E-153 A/B.

Subsequently HGO is used to generate MP steam in 10E-904

Finally sent back to crude column as pump around.

Page 28: CDU VDU Operation

VACUUM DISTILLATION UNIT

Page 29: CDU VDU Operation

Vacuum Distillation UnitVacuum Distillation Unit

Crude Crude Crude Crude Atmospheric Atmospheric DistillationDistillation

Atmospheric Atmospheric DistillationDistillation

Middle Middle DistillateDistillatess

RCO RCO

TO VDUTO VDUTO VDUTO VDU

BlendingBlending BlendingBlending

Secondary Secondary ProcessingProcessing

Secondary Secondary ProcessingProcessing

StorageStorage StorageStorage

Page 30: CDU VDU Operation

Process Description-1Process Description-1

Feed to vacuum heater is received from atmospheric column bottom Which is further separated

into middle and heavy distillates under vacuum

Feed flow is cascaded with crude column level.

The atmospheric residue feed to the unit is combined with recycle HHVGO and (in case of Bombay high feed) recycle vacuum residue.

The joint feed is sent to heaters 11F-101 A/B.

F-101 A/B F-101 A/B

FC FCLCLC

Recycle HHVGO(AL/AH) / VR

(BH)

Recycle HHVGO(AL/AH) / VR

(BH)

Page 31: CDU VDU Operation

VACUUM HEATERSVACUUM HEATERS

Velocity steam is mixed in the radiant section of heater to start vaporization by lowering hydrocarbon partial

pressure. Here most of the heat is absorbed as heat of vaporization as

opposed to temperature increase. Thus rise in COT temperature is prevented.

It also helps in slowing down coking process

Vacuum heater Sixteen burners in each heater. Dual fired burners arranged into four groups.

Each group has four burners. Each groups has two pilot flame detectors.

– Pilot flame detractors are arranged on alternate burners.

Two FD fans and one ID fan. LP steam is generated in convection section. LP superheater coil is also given to superheat LP steam.

Velocity Steam

Velocity Steam

Page 32: CDU VDU Operation

Vacuum Column-1Vacuum Column-1

Combined heaters outlet goes to vacuum column at 403 0C

Height 50 m Diameter

Top 8.2 m Middle 12.5 m Bottom 6.8 m.

Four structured packed bed.

COT - Coil Outlet Temperature is kept below 420 0C To avoid cracking which

may cause coking and overload vacuum system

50 m50 m

6.8 m6.8 m

12.5 m

12.5 m

8.2 m8.2 m

Page 33: CDU VDU Operation

Flash Zone and Stripping Flash Zone and Stripping

Liquid from flash zone is collected on a chimney tray and passed to the stripping section.

Vapors are passed through chimney tray and packed bed no 4

Light hydrocarbon are stripped on valve trays with superheated LP steam.

Residue is quenched to 360oC with cooled vacuum residue in order to prevent cracking in the bottom section.

FeedFeed

Flash Zone - vane type inlet

Flash Zone - vane type inlet

Stripping Section

Stripping Section

Chimney Tray

Chimney Tray

Bed 4Bed 4

SteamSteam

Valve Trays

Valve Trays

Page 34: CDU VDU Operation

VDU ProductsVDU Products

Vacuum DistillateVacuum Distillate

FEED FEED

LVGO LVGO

HVGOHVGO

HHVGOHHVGO

VRVR

Ejectors and Vacuum PumpEjectors and

Vacuum PumpBED-1BED-1

BED-2BED-2

BED-3BED-3

BED-4BED-4

RefluxReflux

Air Cooled TPAAir Cooled TPA

HVGO - PAHVGO - PA

HVGO - RefluxHVGO - Reflux

Page 35: CDU VDU Operation

Overhead SectionOverhead Section

VDU Overhead

VDU Overhead

Vapor from CDU Dryers

Vapor from CDU Dryers

Ejector PackageEjector

Package

SteamSteam

Condensation and Vapor

Liquid Separation

Condensation and Vapor

Liquid Separation

Vacuum Pump Package

Vacuum Pump Package

UncondensUncondensed vapored vapor

UncondensUncondensed vapored vapor

Vent Gas Seal

Vessel

Vent Gas Seal

Vessel

Water / Slop Oil

Water / Slop Oil

Slop Oil Storage

Sour Water Stripper UnitSour Water

Stripper Unit

Vent Gases incineratedVent Gases incinerated

Page 36: CDU VDU Operation

Vacuum pulling is done with steam ejectors. The load on the ejectors is determined by the overhead vapours, which comprise :

- Non condensibles like cracked gas from furnace and air leaks- Condensible hydrocarbon vapours- Entrainment- Furnace velocity steam- Tower stripping steam

PRESSURE PROFILE ( Not To Scale)

100 psig

DISCHARGENOZZLE

DIFFUSER

SUCTION

MOTIVESTEAM

1.16 psig

0.1 psig

EJECTOR SYSTEMEJECTOR SYSTEM

Page 37: CDU VDU Operation

Ejectors convert pressure energy of motive steam into supersonic velocity from the motive nozzle, thereby creating a low pressure zone for pulling the suction load into the ejector.

OIL WATER

FROM

VAC. COL.

1st Stage 2nd Stage 3rd Stage

HOT WELL

OFF GAS

THEORY OF EJECTOR SYSTEMTHEORY OF EJECTOR SYSTEM

Page 38: CDU VDU Operation

BAROMETRIC LEG : The drain line from condensers to hot well is thebarometric leg. Draining is by gravity, so barometric legs should be high enough to avoid flooding of the condenser tubes. Hot wellpressure is atmospheric. Hence minimum barometric height shouldbe 34ft in case of pure water and 45ft in case of hydrocarbon.Various barometric arrangements are shown below :

HOT WELL HOT WELL HOT WELL

45 deg. (min.)

PREFERRED ACCEPTABLE INCORRECT

THEORY OF EJECTOR SYSTEMTHEORY OF EJECTOR SYSTEM

Page 39: CDU VDU Operation

VACUUM DISTILLATEVACUUM DISTILLATE

StorageStorage

Vac Dist Vess

el

Vac Dist Vess

el

FCFC

TCTC

FCFC Bed 2 Temp is controlled by Vac Dist reflux

This provides desired separation between LVGO and Vac Dist

Part of Vac Dist is cooled at crude preheat train and air fin cooler

Cooled Vac Dist is sent as pump around over bed-1 on flow control.

Rest goes to storage

Air Fin Cooler

Crude/ Vac Distillate

exchangers

Crude/ Vac Distillate

exchangers

RefluxReflux

PAPA

142 0C142 0C

60 0C60 0C

142 0C142 0C

60 0C60 0C

BED-1BED-1

BED-2BED-2

Vac DistVac Dist

Page 40: CDU VDU Operation

LVGOLVGO

Drawn off from chimney tray below bed no 2 into LVGO Vessel

Vessel level is controlled by adjusting rundown flow

From vessel it is pumped through MP steam generator exchanger of CDU

Then to crude preheat exchangers

Finally cooled with tempered water and sent to storage / FCC feed

LVGO

Vessel

LVGO

Vessel

MP Steam GeneratorMP Steam Generator

Crude Crude

Tempered Water

Tempered Water

LVGO ProductLVGO Product

ReturnReturn

Return Return

BED-1BED-1

BED-2BED-2

238 0C238 0C

80 0C80 0C

Page 41: CDU VDU Operation

HVGOHVGO

Drawn off from chimney tray below bed - 3

Vessel level is controlled by adjusting rundown flow

Pump discharge goes back as reflux

Remaining goes as pump around, FCC/Storage after cooling with crude / tempered water.

CrudeCrude

BED-2BED-2

BED-3BED-3

BED-4BED-4

Reflux Reflux

FCFC

CrudeCrude

Storag

e

Storag

e

Tempered Water Supply

Tempered Water Supply

FCCUFCCU

Return Return

HVGOHVGO

293 0C293 0C

230 0C230 0C

293 0C293 0C

170 0C170 0C

80 0C80 0C

Page 42: CDU VDU Operation

HHVGOHHVGO

Draw off is from below Draw off is from below Bed-4 into HHVGO Bed-4 into HHVGO vessel.vessel.

Vessel level is cascaded Vessel level is cascaded with rundown flow control.with rundown flow control.

HHVGO is first cooled by HHVGO is first cooled by MP steam generation MP steam generation (CDU)(CDU)

Then split in twoThen split in two First part goes as quench to First part goes as quench to

HHVGO vessel. HHVGO vessel. Quench flow is regulated by Quench flow is regulated by

pump discharge pump discharge temperaturetemperature

Second Part goes for LP Second Part goes for LP steam generation (VDU), steam generation (VDU), then to FCCU / Storage.then to FCCU / Storage.

HVGOHVGO

BED-4BED-4

MP Steam GeneratorMP Steam Generator

TCTC

LP Steam GeneratorLP Steam Generator

StorageStorageFCCUFCCU

HHVGOHHVGO

FCFC

QuenchQuench

390 0C390 0C

230 0C230 0C

170 0C170 0C

Page 43: CDU VDU Operation

VACUUM RESIDUEVACUUM RESIDUE

Vac Residue is the bottom product - first pumped through Crude preheat train to cool it down to 290 0C

Then Sent back to tower as

quench, to control cracking Cooled further against crude

to 190 0C

Vac residue finally leaves the unit as VBU Feed Storage VBU Blending

CrudeCrude

CrudeCrude

TCTC

FCFC

Superheated LP SteamSuperheated LP Steam

QuenchQuench

VBU FeedVBU Feed

Bitumen unit

Bitumen unit

StorageStorage

360 0C360 0C

290 0C290 0C

190 0C190 0C

Page 44: CDU VDU Operation

•Introduce stripping steam before pulling vacuum so that sudden expansion is not there•While stripping steam is introduced, care should be taken so that column bottom level is not too high•Vacuum pulling / vacuum breaking should be done gradually

PRECAUTIONS & TROUBLE SHOOTINGPRECAUTIONS & TROUBLE SHOOTING

Page 45: CDU VDU Operation

START UP SEQUENCE FOR START UP SEQUENCE FOR CDU/VDU CDU/VDU

Page 46: CDU VDU Operation

•Flushing of all the Process and utility Systems•Chemical Cleaning of Compressor piping•Alkali boil out of the Steam generation drums•Leak test of all the Process and Utility Systems•Pump no load and Load trials•Commissioning of Utilities system inside the unit•Refractory dry out of the Furnaces•Vacuum hold test of the Vacuum column section•Removal of air from the system by Steaming out the unit•Backing-in fuel gas into all the systems•Draining water from the system•Preparation for cold oil circulation in CDU

START UP SEQUENCE START UP SEQUENCE

Page 47: CDU VDU Operation

START UP SEQUENCE START UP SEQUENCE

•Charging crude for cold oil circulation in CDU•Preparation for crude heaters light up•Crude heaters burner light up:•Raising temperature for hot oil circulation•Stripping steam injection in crude column•Routing of atmospheric residue to VDU•Chemical injection in crude column overhead section

Page 48: CDU VDU Operation

START UP SEQUENCE START UP SEQUENCE

•Establishing pump around and product circuit

(I )Heavy Naphtha Product Circuit(II) Light kerosene Product Circuit(III) Top Pump around Circuit(IV) Heavy Kerosene Pump around Circuit(V) Heavy Kerosene Product Circuit(VI) LGO Pump around Circuit(VII) LGO Product Circuit(VIII) HGO Pump around Circuit(IX) HGO Product Circuit

Page 49: CDU VDU Operation

VDU START UP SEQUENCE VDU START UP SEQUENCE

•Preparation for cold oil circulation in VDU•Charge LDO for circulation in VDU bottom•LDO circulation in HHVGO system•Vacuum heaters light up and hot oil circulation•Replacement of LDO with RCO after raising temperature•Fill up of vacuum distillate and LVGO system with LGO and HGO from CDU•Introduction of stripping steam and vacuum pulling•Switch over of atmospheric residue to vacuum column•Rising of vacuum heater O/L temperature to 350 °c and injection of turbulizing steam in to heater coil•Vacuum furnace cot raising and product routing

Page 50: CDU VDU Operation

SHUTDOWN SEQUENCE FOR SHUTDOWN SEQUENCE FOR CDU/VDU CDU/VDU

Page 51: CDU VDU Operation

CDU/VDU SHUT DOWN SEQUENCE CDU/VDU SHUT DOWN SEQUENCE

•General•Through Put Reduction•Vacuum Furnace COT reduction and Vacuum product routing to off spec•Stripping steam cut off in Vacuum column•Vacuum breaking in Vacuum column•Velocity steam cut off and Vacuum column product thinning with Wash oil•CDU Off Gas compressor Shutdown•Crude Heater COT reduction and Routing Crude products to Off spec

Page 52: CDU VDU Operation

CDU/VDU SHUT DOWN SEQUENCE CDU/VDU SHUT DOWN SEQUENCE

•Stripping steam cut off in Crude Column and Switching off of Chemical injections in Crude column overhead•Shutdown of Sat Gas Unit•Desalters Isolation and Switching off Chemical injections•Establishing hot oil circulation in bottom loop•Deinventoring

Page 53: CDU VDU Operation

EMERGENCY SHUTDOWN EMERGENCY SHUTDOWN

Page 54: CDU VDU Operation

EMERGENCY SHUTDOWNEMERGENCY SHUTDOWN•Loss Of Feed•Power Failure•Power Dip•Instrument Air Failure•Cooling Water Failure•Sea Cooling Water Failure•LP Steam Failure•MP Steam Failure•DCS Failure•Heater Tube Rupture•Crude Charge Pump Failure

Page 55: CDU VDU Operation

THANK YOU