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SHUAIBA REFINERY - UNIT OVERVIEW
UNIT OVERVIEW APPENDIX-1B
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APPENDIX-1B
SHU REFINERY - UNIT OVERVIEW
SHUAIBA REFINERY - UNIT OVERVIEW
UNIT OVERVIEW APPENDIX-1B
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CLAUSE TITLE PAGE
1.0 UNIT - 01 OVERVIEW - BUGAN GAS UNIT 04
2.0 UNIT - 02E/W OVERVIEW – HYDROGEN PRODUCTION UNIT 11
3.0 UNIT - 03 OVERVIEW - HYDROGEN COMPRESSION UNIT 19
4.0 UNIT - 04 OVERVIEW - SULPHUR RECOVERY UNIT 25
5.0 UNIT - 05 OVERVIEW - CATALYTIC REFORMER UNIT 31
6.0 UNIT - 06 OVERVIEW - CRUDE AND VACUUM UNIT 37
7.0 UNIT – 06F OVERVIEW - FOUL WATER TREATING UNIT 45
8.0 UNIT – 07A/B OVERVIEW - H OIL TRAIN A/B 47
9.0 UNIT - 08 OVERVIEW - ISOMAX UNIT 56
10.0 UNIT - 09 OVERVIEW - NAPHTHA FRACTIONATOR UNIT 64
11.0 UNIT - 10 OVERVIEW - NAPHTHA UNIFINER UNIT 70
12.0 UNIT - 11 OVERVIEW - KEROSENE UNIFINER UNIT 76
13.0 UNIT - 12 OVERVIEW - LIGHT DIESEL UNIFINER UNIT 83
14.0 UNIT - 13 OVERVIEW - HEAVY DIESEL UNIFINER UNIT 91
15.0 UNIT - 14 OVERVIEW - AMINE TREATING UNIT 98
16.0 UNIT - 15 OVERVIEW - AMMONICAL WATER TREATING UNIT 105
17.0 UNIT - 15C OVERVIEW - SOUR WATER CONCENTRATOR UNIT 111
18.0 UNIT - 17 OVERVIEW - KEROSENE MEROX UNIT 114
19.0 UNIT - 19 OVERVIEW - DIMINERALIZING UNIT 120
20.0 UNIT - 20 OVERVIEW - BOILERS UNIT 125
21.0 UNIT - 22 OVERVIEW - COOLING WATER SYSTEM 130
22.0 UNIT - 23 OVERVIEW - SEA COOLING WATER SYSTEM 135
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CLAUSE TITLE PAGE
23.0 UNIT - 29 OVERVIEW - FUEL GAS SYSTEM, FLARE SYSTEM, FLARE
GAS RECOVERY UNIT & INSTRUMENT AND PLANT AIR 137
24.0 UNIT - 35 OVERVIEW – SULPHUR DEGASSING UNIT 149
25.0 UNIT - 61 OVERVIEW – ACID GAS REMOVAL UNIT 151
26.0 UNIT - 62 OVERVIEW - HYDROGEN PRODUCTION UNIT 158
27.0 UNIT - 63 OVERVIEW - H-OIL VACUUM DISTILLATION UNIT 164
28.0 UNIT - 64 OVERVIEW - COOLING WATER SYSTEM 170
29.0 UNIT - 68 OVERVIEW - ISOCRACKER UNIT 175
30.0 UNIT - 74 OVERVIEW - SULPHUR RECOVERY UNIT 182
31.0 UNIT - 75 OVERVIEW - TAIL GAS TREATING UNIT 189
32.0 UNIT - 60 OVERVIEW - OFFSITE PIPING 197
ANNEXURES
01 ANNEXURE - 01 - SINGLE LINE DIAGRAM UNIT-WISE
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1.0 UNIT - 01 OVERVIEW (Burgan Gas Unit)
1.1 PROCESS OVERVIEW
1.1.1 Objective
To compress and treat Burgan Gas (currently LP Lean Gas from MAA) for providing feed
gas to Hydrogen Units (02/62) and Engine Fuel Gas required for engine drivers on
Hydrogen compressors in Unit – 03 and also used in SRU’s. The Unit also provides low
pressure gas to Refinery Fuel Gas system as make up.
1.1.2 Capacity
The Unit is designed to compress and treat 48.7 MMSCFD (Insurance – 73 MMSCFD) of
LP Lean Gas.
The LP lean Gas Compressors are two stage centrifugal machines with 900 psig steam
driven turbines.
1.1.3 Feed and Products
Refer Tables 1&2 below.
a) Table-1: Typical Material Balance
b) Table-2: Typical Feed & Product Qualities
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1.1.4 Process Description
Refer sketch-1
Lean imported L.P. gas, containing mostly C1, C2, C3 (mostly C1, post Ethane Recovery
Project) is received into the Refinery through a knockout Drum V-01-01 where entrained
liquid condensate is separated and pumped to Unit-09.
Approximately 40 - 60% of the gas is routed directly to the Refinery Fuel Gas system as
make-up. The balance, about 25 MMSCFD of gas is compressed through compressor C-
01-01A/B first stage to 150 psig, cooled and condensed liquid separated. The separated
gas is treated in the Amine Unit 14 Contactor, V-14-02 where H2S and CO2 are
removed. Following treatment, the gas passes through the absorber V-01-04, where
originally most of the C4 and heavier hydrocarbons are removed from the gas stream by
absorption with cold lean oil, Kerosene. Currently V-01-04 is not in service. The lean gas
from the absorber goes to a knockout drum, V-01-03, for removal of entrained
condensate. A part of this dry treated gas is compressed further in Compressor’s second
stage and sent to the Hydrogen plants (02/62). A part of gas is also used in Sulfur Units
as fuel gas at startup & S/D , blanketing gas and back up for Engine Fuel Gas for
Hydrogen compressor C-03-01 A-E.
The mixture of hydrocarbons removed from the L.P Lean Gas by lean oil absorption is
sent as rich oil to Naphtha Fractionation Unit (09) for Naphtha recovery. Condensate
recovered from the various knockout drums is also sent to Naphtha Fractionation Unit
(09).
An additional K.O drum V-01-05 was installed in association with Rich gas injection from
U-61 to help increase gas density when required.
Recently, in 2010, a facility to desulfurize some quantity of Imported LP Gas for use as
part Refinery Fuel was commissioned to reduce H2S content in Fuel gas. Up to about 25
MMSCFD of LP Gas is routed to Amine Contactor V-14-01 through V-29-04. Low H2S
outlet gas is used as component of Refinery Fuel Gas.
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1.1.5 Brief History
C-01-01A Compressor revamped along with new PLC and control systems in the
year 2000.
Vessel V-01-05 knockout drum for rich gas injection added in year 2009
1.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-01 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Exchangers, Shell & Tube 07
2 Air Coolers 03
3 Vessels 09
4 Tanks / Drums 06
5 Filters 08
6 PSVs 26
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1.3 ROTATING OVERVIEW
Unit 01 – This Unit Compress and treat Burgan gas and LP Lean gas for providing feed
gas to Hydrogen units and Fuel gas required for gas engine drivers in unit 03.
All the Rotating equipment in 01 unit are inspected and maintained as per the guidelines
of Process Licensor & good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 01 has 8 Pumps, 6 Fin fans, 2 Turbines & 2 Compressors. List of Rotating
Equipment are furnished vide Appendix 2A hereof.
Pump/Compressor/Blower package auxiliary items (filters, SO/LO Coolers, Gearboxes,
Seals, Couplings, Piping items etc.) are not included in the list. Bidders can collect
relevant details of maintenance records, healthiness of the equipment and inspection
records during PTM/Site visit.
1.4 ELECTRICAL OVERVIEW
Unit -01 is considered as classified area (Class 1 Div. 2 Group D) as per Shuaiba
Refinery Hazardous Area Classification drawing (refer drawing # R-00-6030). The source
of power to the Unit is aided from Substation 04 which is located south side of the Unit.
The substation is Building with Basement Type & facilitated as non-classified area by
employing pressurized / Air conditioned systems. Substation has 3 nos. of “6.6kV”
Switchgears (4A, 4B & 4C) fed from SS1A & SS1B (ref. drawing # R-00-6012), 9 nos. of
“440V” MCC (MCC-4A, MCC-4B, MCC-4C, MCC-4D, MCC-4E, MCC-4F, MCC-4G, MCC-
4H & MCC-4J), 9 nos. of power transformers (1MVA, 6.6kV/440V) and 4 nos. of
Emergency panel (EDB-01-01). The “6.6kV” Switchgears 4C were replaced completely
with latest new ABB panels during GRTA-2011 under contract CS/1955. The Substation
is equipped with Fire Detection, Alarm & Suppression system which was installed under
contract CB/CSPD/2004 & commissioned on 2016. Battery Charger along with Battery
backup bank are also available.
The list of LT Motors associated with this Unit is enclosed vide Appendix 2A hereof.
Motors rated less than or equal to 280HP is designated as LT motor. Unit-01 has 12 nos.
of 440V motors. All motors are under Preventive Maintenance program by maintenance
department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
The Unit-01 is powered from the Substation # 4 and the Single Line Diagram (SLD) for
SS # 4 is as follows (for details Refer Annexure-01, KNPC Sketch # SK-2434 Sheet 01
of 08).
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Note: The Substations are shared between different units and a table that shows the
association of different units to Substation is shown in Appendix 1A - Refinery Overview.
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1.5 INSTRUMENTATION OVERVIEW
Unit – 01 is designed to process low pressure lean gas Burgan gas supplied by KOC
through LP Gas Network. A large portion of the gas is used as Refinery fuel gas make up
and balance is compressed by Compressors C-01-01 A/B treated in Amine Treatment in
Unit – 14 before being further processed in Unit – 01.
1.5.1 Instrumentation System
a) DCS: Honeywell make TPS System installed in SIH #7, SIH # 10 & GUS
Operating stations installed in CCR.
b) ESD System: Honeywell make Safety Manager System installed in SIH # 7, SIH #
10 & CCR.
c) FSC System: Honeywell make FSC system installed for ROIV Control in Unit – 01.
d) PLC System: Allen Bradley make PLC System for C-01-01 A/B Compressor
Interlock Control.
e) Bently System: Bently make Vibration Monitoring System for C-01-01A
Compressor.
f) Speed Governor: Wood ward speed Governor for C-01-01A Compressor.
1.5.2 Critical Safety Interlocks and Controls
a) C-01-01A/B Compressor Interlock & Control.
b) Burgan gas header pressure Control & Interlock.
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c) C-01-01A/B – Anti Surge Control.
d) Engine Fuel Gas Pressure Control.
e) Refinery Fuel Gas Pressure Control.
f) 01-ROIV-1000/01-ROIV-1001/01-ROIV-1002 Interlock Control.
1.5.3 Field Instrument List
SR. # CATEGORY MAKE QTY REMARKS
1 BTU / H2S & SP.GR.
ANALYZER ROSEMOUNT-GCX V 3.2 / YOKOGAWA-
GD43 7
2 CONTROL VALVE MASONEILAN / SAMSON / TYCO /
VIRGO 47
3 CONTROLLER FOXBORO / YOKOGAWA / MOORE /
MASONEILAN 10
4 DISPLACER LT MASONEILAN / MAGNETROL 7
5 FLOW ELEMENT DANIEL 23
6 HMI SIEMENS 2
7 LEVEL GAUGE GLASS JERGUSON / PENBERTHY / K-TEK 21
8 LEVEL SWITCH MAGNETROL / MOORE / SOR 21
9 PLC ALLEN BRADELY (CONTROL LOGIC) 2
10 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL /
AM GAUGE 146
11 PRESSURE SWITCH UE / ASHCROFT / SOR / BOURDON
SEDEME 23
12 SOLENOID VALVE ASCO 7
13 TEMPERATURE SWITCH UE 7
14 THERMOWELL THERMO ELECTRIC / TECNOMATIC /
TC LTD 72
15 TRANSMITTER ROSEMOUNT / YOKOGAWA /
HONEYWELL / ABB / FOXBORO / SMAR 61
16 VIBRATION BENTLY NEVADA-3300 1
17 MISC HONEYWELL 57
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2.0 UNIT – 2E / 2W OVERVIEW (Hydrogen Production Unit)
2.1 PROCESS OVERVIEW – (Unit – 2E/2W)
2.1.1 Objective
Hydrogen Units generate and supply high purity and high pressure Hydrogen needed in other Refinery Units, e.g. H-Oil, Isocrackers, Unifiners.
2.1.2 Capacity
There are three Hydrogen manufacturing Units in Shuaiba Refinery. Each plant is
designed to produce 74 MMSCFD of 95% purity Hydrogen.
2.1.3 Feed and Products
The feed to the Hydrogen Unit is a mixture of treated Burgan Gas and recycle High
Pressure Flash Gas. Burgan Gas is mainly hydrocarbons, while recycle gas is a mixture of
different Hydrogen rich bleed gases from Hydrogen consuming Units (treated in U-14).
The design product Hydrogen purity is 95% and the maximum Carbon Oxides
specifications is 10 PPMV. The battery limit pressure and temperature of export Hydrogen
to consuming Units are 2800 psig and 250oF respectively. The product Hydrogen from
Unit-03 is routed to H-Oil, Isomax / Isocracker and Unifiners.
2.1.4 Material Balance
The attached Table-1 indicates the overall material balance for design and test run
conditions.
a) Table-1: Feed and Product Qualities
DESIGN TEST RUN DESIGN TEST RUN
Hydrogen % Vol 39.96 46.40 94.99 94.93 Methane 41.68 30.57 5.01 5.07 Ethane 13.25 8.26 Propane 4.17 10.41 Butane 0.94 4.36 Mol. Wt. 13.86 15.41 2.74 2.73 Lbs/Hr 36667 38920 22165.00 23075.00 MMSCFD 24.09 22.98 73.79 77.08
FEED PRODUCTS
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2.1.5 Process Description
The Feed Gas is preheated in Hydrogen Reformer Convection Section and the last
traces of organic and inorganic Sulfur compounds are removed in Zinc Oxide beds.
High Pressure steam is mixed with the treated feed gas and further heated up in the
Reformer Convection Coils before it is introduced into the Reformer Catalyst Tubes filled
with Reformer catalyst. Steam and feed gas hydrocarbons react in the presence of Nickel
catalyst to form Hydrogen, Carbon dioxide and Carbon monoxide. This steam reforming
reaction is highly endothermic, requiring heat energy for reaction.
Waste heat is recovered from the Reformer effluent to produce 900 psig steam and partly
for heating Methanator inlet gas.
The carbon monoxide (with excess steam) in the Reformer effluent is further converted
into Hydrogen and Carbon dioxide in High Temperature and Low Temperature Shift
Convertors. Shift conversion reaction is exothermic, producing heat energy.
The Shift Converter Effluent exchanges heat in the MEA Regenerator Reboilers and
further cooled before it is passed through MEA Absorber. A 20% by Wt.
Monoethanolamine solution is used to absorb carbon dioxide. The Rich solution is
regenerated by heating and flashing at low pressure and the regenerated Lean MEA
solution is pumped back to CO2 Absorber after cooling. A slip stream of Lean MEA
solution is filtered in a mechanical filter and a charcoal filter.
The CO2 Absorber effluent gas is heated and in the Methanator the remaining small
quantities of carbon monoxides & carbon dioxide are converted to methane in order to
meet the product carbon dioxide specification.
The Methanator effluent is heat exchanged with the Methanator inlet gas, further cooled
and sent to Unit-03 for compression.
The process scheme is shown in the attached Sketch -1.
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2.1.6 Brief History
Unit 02E and Unit 02W Reformers were revamped.
2.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-02E/02W is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Exchangers, Shell & Tube 27
2 Air Coolers 08
3 Vessels, columns, tanks, drum 38
4 Heaters 02
5 Boilers 02
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6 Filter 04
7 Silencers / Ejectors etc 07
2.3 ROTATING OVERVIEW
Unit 02 East & West Hydrogen units generate and supply high purity and high pressure
Hydrogen needed in other units e.g. H-Oil, Isocrackers and Unifiners.
All Rotating equipment in 13 Unit are inspected and maintained as per the guidelines of
Process Licensor & Good Engineering practices. Turn around schedules are fixed as per
these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 02 E&W has 16 Pumps, 109 Fin fans, 2 Steam Turbines & 1 Mixer. List of Rotating
Equipment are furnished vide Appendix 2A hereof.
Critical pumps packings converted to mechanical seals to the spirit of API 682 to prevent
Gas leakage to environment.
Pump/Compressor/Turbine package auxiliary items (filters, SO/LO Coolers, Gearboxes,
Seals, Clutches, Couplings, Piping items etc.) are not included in the list. Bidders can
collect relevant details of maintenance records, healthiness of the equipment and
inspection records during PTM/Site visit.
2.4 ELECTRICAL OVERVIEW
Unit -02 is considered as classified area (Class 1 Div. 2 Group B) as per Shuaiba
Refinery Hazardous Area Classification drawing (refer drawing # R-00-6030). The source
of power to the Unit is aided from Substation 08 which is located north-west side of the
Unit. The substation is Building with Basement Type & facilitated as non-classified area
by employing pressurized / Air conditioned systems. Substation has a 6.6KV Switchgear
fed from SS1A & SS1B (ref. drawing # R-00-6012), 3 nos. of 440V MCC (MCC-100,
MCC-200 & MCC-300), 3 nos. of power transformers (1MVA, 6.6kV/440V) and an
emergency distribution board (EDB-02-01). The 6.6KV Switchgear were replaced
completely with latest new ABB panels during GRTA-2011 under contract CS/1955. The
Substation is equipped with Fire Detection, Alarm & Suppression system which was
installed under contract CB/CSPD/2004 & commissioned on 2016. Battery Charger along
with Battery backup bank are also available.
The list of HT & LT Motors associated with this Unit is enclosed vide Appendix 2A
hereof. Motors rated above 280HP is designated as HT motor and if less than or equal to
280HP, as LT motor. Unit -02 has 3 nos. 6.6KV motors and 119 nos. 440V motors. All
motors are under Preventive Maintenance program by maintenance department.
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Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
The Unit-02 is powered from the Substation # 8 and the Single Line Diagram (SLD) for
SS # 8 is as follows (for details Refer Annexure-01, KNPC Sketch # SK-2434 Sheet # 06
of 08);
Note: The Substations shared between different units and a table that shows the
association of different units to Substation shown in Appendix 1A - Refinery Overview.
2.5 INSTRUMENTATION OVERVIEW
Hydrogen Unit Processes mixtures of treated Burgan Gas, High Pressure Flash Gas and
stream to produce Hydrogen. Feed gas and process steam reacts at high temperature
and pressure in pressure of Catalyst to produce Hydrogen Gas.
2.5.1 Instrumentation System in Unit-02E
a) DCS: Honeywell make TPS System installed in SIH #2, SIH # 10. GUS Operating
stations installed in SIH # 2 & CCR.
b) ESD System: Honeywell make Safety Manager System installed in SIH # 2, SIH #
10 & CCR.
c) FSC System: Honeywell make FSC system installed in SIH # 10.
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2.5.2 Critical Safety Interlocks and Controls Unit-02E
a) Heater - H-02-01 – Interlock East Cell
b) Heater – H-02-01 – Interlock West Cell
c) Methanator – V-02-03 – Interlock
d) CO2 Absorber – V-02-04 – Interlock.
e) P-02-03A/B MEA Circulation Pump Interlock
f) 02-ROV-1000 – Feed gas Inlet to V-02-21 Interlock.
2.5.3 Field Instrument List Unit-02E
2.5.4 Instrumentation System in Unit-02W
a) DCS: Honeywell make TPS System installed in SIH #2, SIH # 10 & CCR. GUS
Operating stations installed in SIH # 2 & CCR.
b) ESD System: Honeywell make Safety Manager System installed in SIH # 2, SIH #
10 & CCR.
SR # CATEGORY MAKE QTY REMARKS
1 ANALYZER ROSEMOUNT / YOKOGAWA / ABB 6
2 CONTROL VALVE FISHER / MASONEILAN / SAMSON GERMANY
/ TYCO / VIRGO 32
3 CONTROLLER FOXBORO / YOKOGAWA / TAYLOR /
MASONEILAN 12
4 DISPLACER LT MASONEIAN / MAGNETROL 7
5 FLOW ELEMENT DANIEL / SAMIL 42
6 FLOW SWITCH MAGNETROL / ITT BARTON 2
7 LEVEL GAUGE GLASS JERGUSON / PENBERTHY / K-TEK 24
8 LEVEL SWITCH MAGNETROL / MOORE / SOR / 7
9 LOCAL INDICATOR ITT BARTON / BROOKS / KROHNE / WISE /
AMETEK 88
10 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL / AM
GAUGE 184
11 PRESSURE SWITCH UE / ASHCROFT / SOR / BOURDON SEDEME 7
12 SOLENOID VALVE ASCO 24
13 THERMOWELL THERMO ELECTRIC / TECNOMATIC / TC LTD 106
14 TRANSMITTER ROSEMOUNT / YOKOGAWA / HONEYWELL /
ABB / FOXBORO / SMAR 79
15 MISC HONEYWELL 8
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c) FSC System: Honeywell make FSC system installed in SIH # 10.
2.5.5 Critical Safety Interlocks and Controls Unit-02W
a) Heater - H-02-51 – Interlock East Cell
b) Heater – H-02-51 – Interlock West Cell
c) Methanator – V-02-53 – Interlock
d) CO2 Absorber – V-02-54 – Interlock.
e) P-02-53A/B MEA Circulation Pump Interlock
2.5.6 Field Instrument List Unit-02W
SR # CATEGORY MAKE QTY REMARKS
1 ANALYZER YOKOGAWA / ABB 3
2 CONTROL VALVE FISHER / MASONEILAN / SAMSON GERMANY
/ TYCO / VIRGO 31
3 CONTROLLER FOXBORO / YOKOGAWA / TAYLOR /
MASONEILAN 10
4 DISPLACER LT MASONEIAN / MAGNETROL 6
5 FLOW ELEMENT DANIEL / SAMIL 30
6 FLOW SWITCH MAGNETROL / ITT BARTON 2
7 LEVEL GAUGE GLASS JERGUSON / PENBERTHY / K-TEK 22
8 LEVEL SWITCH MAGNETROL / SOR 2
9 LOCAL INDICATOR ITT BARTON / BROOKS / KROHNE / WISE /
AMETEK 71
10 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL / AM
GAUGE 104
11 PRESSURE SWITCH UE / ASHCROFT / BOURDON SEDEME 6
12 SOLENOID VALVE ASCO 18
13 THERMOWELL THERMO ELECTRIC / TECNOMATIC / TC LTD 100
14 TRANSMITTER ROSEMOUNT / YOKOGAWA / HONEYWELL /
ABB / FOXBORO / SMAR 69
15 MISC HONEYWELL 8
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3.0 UNIT – 03 OVERVIEW (Hydrogen Compression Unit)
3.1 PROCESS OVERVIEW
3.1.1 Objective
Hydrogen Compression Unit compress and supply high purity and high pressure
Hydrogen needed in other Refinery Units, e.g. H-Oil, Isocrackers, Unifiners.
3.1.2 Capacity
There are seven compressors in the unit. The total capacity of the unit is 228 MMSCFD
3.1.3 Process Description
Refer to attached Flow schemes SK-01.
There are seven reciprocating compressors for Hydrogen. Two of them are driven by
motors and the rest with internal combustion engines using Refinery Engine Fuel Gas/HP
Lean Gas. The Hydrogen is compressed in three stages with intermediate Coolers and
Separators. Also, Unit-03 contains a Tempered Water cooling circuit for the
Compressor/Engine jacket and Lube Oil Coolers.
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3.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-03 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Exchangers 14
2 Air Coolers 14
3 Vessels / tanks 30
4 Compressor accessories - Filters 10
5 Compressor accessories - Silencers 05
6 PSVs 11
3.3 ROTATING OVERVIEW
Unit 03 – This Unit helps to Compress the Hydrogen from units 02 & 62 and supply high-
pressure nitrogen needed in other units.
All the Rotating equipment in 03 unit are inspected and maintained as per the guidelines
of Process Licensor & good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 03 has 9 Pumps, 38 Fin fans, 5 Engines, 10 Compressors & 10 Blowers. List of
Rotating Equipment are furnished vide Appendix 2A hereof.
Pump/Compressor/Blower package auxiliary items (filters, SO/LO Coolers, Gearboxes,
Seals, Couplings, Piping items etc.) are not included in the list. Bidders can collect
relevant details of maintenance records, healthiness of the equipment and inspection
records during PTM/Site visit.
3.4 ELECTRICAL OVERVIEW
Unit-03 is considered as classified area (Class 1 Div. 2 Group B) as per Shuaiba Refinery
Hazardous Area Classification drawing (refer drawing # R-00-6030). The source of power
to the Unit is aided from three Substations, SS # 8, & SS # 15 which is located south side
of the Unit. The substation is Building with Basement Type & facilitated as non-classified
area by employing pressurized / Air conditioned systems. The Substation is equipped
with Fire Detection, Alarm & Suppression system which was installed under contract
CB/CSPD/2004 & commissioned on 2016. Battery Charger along with Battery backup
bank are also available.
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The list of HT & LT Motors associated with this Unit is enclosed vide Appendix 2A
hereof. Motors rated above 280HP is designated as HT motor and if less than or equal to
280HP, as LT motor. Unit -03 has 3 nos of 6.6KV motors and 55 nos. 440V motors. All
motors are under Preventive Maintenance program by maintenance department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
The Unit-03 is powered from the Substation # 8 & 15 and the Single Line Diagram (SLD)
for SS # 8 & 15 is as follows (for details Refer Annexure-01, KNPC Sketch # SK-2434
Sheet # 06 & 07 of 08);
Note: The Substations shared between different units and a table that shows the
association of different units to Substation shown in Appendix 1A - Refinery Overview.
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3.5 INSTRUMENTATION OVERVIEW
Compression of Hydrogen product from 270 PSIG to about 2800 PSIG is carried out in
Unit – 03 using 07 no. Hydrogen Compressor C-03-01 A to G. Out os these 5 no’s are
Gas Engine driven and 2 no’s are Electric motor drive Compressor.
3.5.1 Instrumentation System
a) DCS: Honeywell make TPS System installed in SIH #2, SIH # 10 Extension &
CCR. GUS Operating stations installed in SIH & CCR.
b) ESD System: Honeywell make Safety Manager System installed in SIH # 2, SIH #
10 & CCR.
c) FSC System: Honeywell make FSC System installed in SIH # 10
3.5.2 Critical Safety Interlocks and Controls
a) C-03-01 A, B, C, D, E, F & G – Compressor – Interlock Control
b) 03-ROV-1000 – C-03-01A – Suction Interlock.
c) 03-ROV-1001 – C-03-01A – Discharge Interlock.
d) 03-ROV-1002 – C-03-01A – Vent Interlock.
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e) 03-ROV-1003 – C-03-01B – Suction Interlock.
f) 03-ROV-1004 – C-03-01B – Discharge Interlock.
g) 03-ROV-1005 – C-03-01B – Vent Interlock.
h) 03-ROV-1006 – C-03-01C – Suction Interlock.
i) 03-ROV-1007 – C-03-01C – Discharge Interlock.
j) 03-ROV-1008 – C-03-01C – Vent Interlock.
k) 03-ROV-1009 – C-03-01D – Suction Interlock.
l) 03-ROV-1010 – C-03-01D – Discharge Interlock.
m) 03-ROV-1011 – C-03-01D – Vent Interlock.
n) 03-ROV-1012 – C-03-01E – Suction Interlock.
o) 03-ROV-1013 – C-03-01E – Discharge Interlock.
p) 03-ROV-1014 – C-03-01E – Vent Interlock.
q) 03-ROV-1015 – C-03-01F – Suction Interlock.
r) 03-ROV-1016 – C-03-01F – Discharge Interlock.
s) 03-ROV-1017 – C-03-01F – Vent Interlock.
t) 03-ROV-1018 – C-03-01G – Suction Interlock
u) 03-ROV-1019 – C-03-01G – Discharge Interlock
v) 22. 03-ROV-1020 – C-03-01G - Vent Interlock
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3.5.3 Field Instrument List
SL. # CATEGORY MAKE QTY REMARKS
1 SP.GR. ANALYZER YOKOGAWA-GD40T 1
2 FT - 50 FT 50 PANEL 5
3 CONTROL VALVE FISHER / MASONEILAN / TYCO /
BETTIS 76
4 CONTROLLER FOXBORO / TAYLOR 3
5 DISPLACER LT MASONEILAN / MAGNETROL 16
6 FLOW ELEMENT DANIEL / SAMIL 16
7 FLOW SWITCH LUBRIQUIP / LUBE SENTRY / GRACO 11
8 LEVEL GAUGE GLASS JERGUSON / PENBERTHY / K-TEK 13
9 LEVEL SWITCH MAGNETROL / MOORE / SOR /
JERGUSON / INTRA AUTOMATION 16
10 LOCAL INDICATOR ITT BARTON / BROOKS / KROHNE /
WISE / AMETEK 69
11 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL
/ AM GAUGE 236
12 PRESSURE SWITCH UE / ASHCROFT / SOR / DELTA
CONTROL 69
13 SOLENOID VALVE ASCO 82
14 TEMPERATURE
SWITCH UE 34
15 THERMOWELL THERMO ELECTRIC / TECNOMATIC /
TC LTD 95
16 TRANSMITTER ROSEMOUNT / YOKOGAWA /
HONEYWELL / ABB / FOXBORO / SMAR
61
17 MISC HONEYWELL 94
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4.0 UNIT - 04 OVERVIEW (Sulphur Recovery Unit)
4.1 PROCESS OVERVIEW
4.1.1 Objective
This unit recovers elemental sulfur from Acid Gases containing H2S generated in
upstream treating units. The process adopted in these units is called Modified Claus
Process.
4.1.2 Capacity
The original design capacity of unit 04 is 600 LT/D. but under normal operation, sulfur
production is 430-460 LT/D. However, after implementation of Oxygen Enrichment
Project in 2004, the capacity of the unit increased to 665 LT/D of sulfur product (700
LT/D of sulfur feed) but not operated under Oxygen enrichment mode.
4.1.3 Feed and Products
Refer Tables 1&2 below
a) Table-1: Original Design : Material Balance
MMSCFD LT/D TYPICAL QUALITY
FEED :
Acid Gas 19.2 768 H2S : 81.2 Vol. % CO2 : 11.0 Vol. % HC : 1.4 Vol. % H2O : 6.4 Vol. %
Combustion Air 42.1 1513
2281
PRODUCTS :
Sulfur - 598 99.5 % wt. Pure Liquid Tail Gas 53.4 1683
2281
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b) Table-2: Oxygen Enrichment Case: Material Balance
LT/D
FEED :
Acid Gas 1200.0 SWS Off Gas 26.8
Air 629.0
Oxygen 218.0
2073.8
PRODUCTS :
Sulfur 665.0
Tail Gas 1408.8
2073.8
MMSCFD
28.2
47.3
1.3
18.8
5.8
-
4.1.4 Process Description – Original Design Unit-04
Refer Sketch-1
4.1.4.1 Original Design Unit-04
Acid gas from upstream treating units is mixed with air and burned in the reaction furnace
(H-04-01). The gas product emerges from the furnace at about 2100oF and passes
through a Waste Heat Boiler (B-04-01), producing 475 psig steam. After leaving the
boiler, the sulfur laden gas enters the first condenser (E-04-01) where sulfur is
condensed and routed to a sulfur sump.
The gas leaving the first condenser is reheated in the first reheater, BR-04-02, by burning
a slip of acid gas feed to reactor inlet temperature of 450oF. Then, reheater effluent gas
passes through the first catalytic reactor (V-04-04) where additional sulfur is formed. The
Sulfur formed in the reactor is removed on the second condenser (E-04-02) and routed to
sulfur sump. The gas is again reheated in the second reheater (BR-04-03) and passed
through a second catalytic reactor (V-04-05) for further conversion to elemental sulfur
which is removed in the third condenser (E-04-03). The overall sulfur recovery is ranging
from 92% to 96%. After leaving the third condenser, the tail gas containing traces of H2S
and other sulfur species is sent to Tail Gas Treating Unit (Unit-75) for further recovery of
sulfur. In case of emergency or Unit-75 Shutdown, the tail gas is then routed to either the
new or old incinerator.
The sulfur from Waste Heat Boiler and all condensers is routed to the sulfur sump where
it is kept molten by steam coils. The molten sulfur is then transferred to Sulfur Degassing
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Facility (SDF) where dissolved H2S is removed from the sulfur before transferring it to
liquid Sulfur storage tanks. From the tanks, it is pumped to Sulfur Flaking Facilities in
Mina Al-Ahmadi refinery for producing solid sulfur.
Note that in Unit-04, 475 psig steam is produced in Waste Heat Boiler and 50 psig steam
in the three condensers.
4.1.4.2 Oxygen Enrichment Project
This project was implemented in 2004. In this project, Unit-04 was modified to increase
its capacity to 665 LT/D sulfur product (700 LT/D sulfur feed), under Oxygen mode. The
project is based on the use of Oxygen enriched air (instead of plain air) to achieve this
increase in capacity.
The main changes involved are the change modification of the Reaction Furnaces to be
able to use both air and Oxygen enriched air and the change of Waste Heat Boilers to
produce 475 psig steam .Also, additional K.O. drum is provided for SWS gas. New tail
gas feedback controller is provided for better adjustment of Air/Acid gas ratio. A layer of
Titania catalyst at the bottom of first reactor and a layer of Oxygen scavenging catalyst at
the top of the second reactor are used.
Process sketch – 2 shows the process flow diagram for Unit-04 after implementation of
Oxygen Enrichment Project.
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4.1.5 Brief History
Unit 04 is revamped in the year 2004.
4.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-04 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Waste heat Boiler 01
2 Heat Exchanger 08
3 Furnace 01
4 Vessels / Tank / drum 13
5 Filter 07
6 Burner 04
7 Stack 01
8 Silencers, Ejectors & Coolers 08
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4.3 ROTATING OVERVIEW
Unit 04 Unit recovers elemental sulfur from acid gases containing H2S generated in
upstream treating units.
All Rotating equipment in Unit 04 are inspected and maintained as per the guidelines of
Process Licensor & Good Engineering practices. Turn around schedules are fixed as per
these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 04 has 11 Pumps & 1 Blower. List of Rotating Equipment are furnished vide
Appendix 2A hereof.
Pump/Blower package auxiliary items (filters, SO/LO Coolers, Gearboxes, Seals,
Clutches, Couplings, Piping items etc.) are not included in the list. Bidders can collect
relevant details of maintenance records, healthiness of the equipment and inspection
records during PTM/Site visit.
4.4 ELECTRICAL OVERVIEW
Unit -04 is considered as classified area (Class 1 Div. 2 Group D) as per Shuaiba
Refinery Hazardous Area Classification drawing (refer drawing # R-00-6030). The source
of power to the Unit is aided from Substation 02 which is located north side of the Unit.
The substation is Building with Basement Type & facilitated as non-classified area by
employing pressurized / Air conditioned systems. Substation has 3 nos 6.6 KV
Switchgears (2A, 2B & 2C) fed from SS1A & SS1B (ref. drawing # R-00- 6012), 4 nos. of
440V MCC (MCC-2A, MCC-2B, MCC-2C & MCC-2D), 4 nos. of power transformers
(1MVA, 6.6kV/440V) and an emergency distribution panel (EDB-32-01). The HT
Switchgear section 2A was replaced completely with latest new ABB panels during
GRTA-2011 under contract CS/1955. The Substation 2 will be retained post SHU. The
Substation is equipped with Fire Detection, Alarm & Suppression system which was
installed under contract CB/CSPD/2004 & commissioned on 2016. Battery Charger along
with Battery backup bank are also available.
The list of HT & LT Motors associated with this Unit is enclosed vide Appendix 2A
hereof. Motors rated above 280HP is designated as HT motor and if less than or equal to
280HP, as LT motor. Unit -04 has a 6.6KV motor and 7 nos. 440V motors. All motors are
under Preventive Maintenance program by maintenance department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
The Unit-04 is powered from the retained Substation # 02.
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4.5 INSTRUMENTATION OVERVIEW
Sulfur is recovered from the gas streams containing Hydrogen Sulphide (H2S) using “Modified Claus Processes” in the Sulfur Recovery Unit – 04. In this process 1/3rd of H2S in the gas stream is burnt with air in the reaction furnace to form SO2. The resulting SO2 then burns with balance H2S to form elemental Sulfur (S) and water in the Vapour Phase.
4.5.1 Instrumentation System
a) DCS: Honeywell make TPS System installed in SIH #8A & GUS Operating
stations installed in CCR.
b) ESD System: Honeywell make Safety Manager System installed in SIH # 8A &
CCR.
4.5.2 Critical Safety Interlocks and Controls
a) SWS / Acid gas feed to unit Pressure Control & Interlock.
b) Engine Fuel gas / combustion Air to start up burner Ratio Control & Interlock.
c) Engine Fuel Gas / Combustion Air to Main Burner Ratio Control & Interlock.
d) Trim Air to Reaction furnace Flow Control.
e) 1st Reheat Burner Interlock & Control.
f) 2nd Reheat Burner Interlock & Control.
g) Incineration Interlock & Temp Control.
h) Waste Heat Boiler Interlock & Control.
4.5.3 Field Instrument List
SR. # CATEGORY MAKE QTY REMARKS
1 ANALYZER ROSEMOUNT / AMETEK 4
2 CONTROL VALVE FISHER / MASONEILAN / HOPKINSON UK/
Virgo/Rotork 37
3 CONTROLLER FOXBORO / YOKOGAWA / MASONEILAN 4
4 DISPLACER LT MASONEILAN / MAGNETROL 16
5 FLOW ELEMENT DANIEL / SAMIL 33
6 LEVEL GAUGE GLASS JERGUSON / PENBERTHY / K-TEK 10
7 LEVEL SWITCH MAGNETROL / MOORE / SOR / 5
8 LOCAL INDICATOR ITT BARTON / BROOKS / KROHNE / WISE
/ AMETEK 70
9 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL /
AM GAUGE 127
10 PRESSURE SWITCH UE / ASHCROFT / SOR 10
11 SOLENOID VALVE ASCO 70
12 THERMOWELL THERMO ELECTRIC / TECNOMATIC / TC
LTD 59
13 TRANSMITTER ROSEMOUNT / YOKOGAWA /
HONEYWELL / ABB / FOXBORO / SMAR 90
14 MISC HONEYWELL 118
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5.0 UNIT - 05 OVERVIEW (Catalytic Reformer Unit)
5.1 PROCESS OVERVIEW
5.1.1 Objective
The Catalytic Reformer is designed to up-grade Naphtha containing low Octane Paraffin
and Naphthenes to high Octane Motor Gasoline blending component. The best
hydrocarbon fuels for internal combustion engines are iso-Paraffines and Aromatics
which have high Octane Number. The Catalytic Reforming converts the low octane
hydrocarbon components to high octane hydrocarbons.
5.1.2 Capacity
The design capacity of the Unit is 15820 BPD producing about 12300 BPD of Reformate
with Octane Number of 96 (clear).
5.1.3 Feed and Products
Refer Tables 1 & 2 below.
a) Table-1 - Material balance
BPSD % VOL. SOURCE / DESTINATION
Feed 15000 100 From Unit 10
Products
Reformate 12000 80.00% To storage
Total Liquid Product 12000 80.00%
b) Table-2 – Feed and Product Qualities
Gravity API 59.20 48.40 Sulfur PPM / % wt. < 1.0 < 1.0 Dist. Range , Deg. F EP 328 96 - 370
PONA : Paraffins 60.5 38.7 Olefins 0.0 1.1 Naphthenes 31.1 0.3 Aromatics 8.4 59.9
PRODUCTS
REFORMATESPEC. FEED
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5.1.4 Process Descriptions
The Unit consists of three Reactors (containing Platinum catalyst), Fired Heaters,
Hydrogen recycle system with gas drier and product debutanizing facilities.
The hydrotreated Naphtha charge from Naphtha Unifiner (Unit-10) is combined with a
hydrogen rich recycle stream and passes through Feed Effluent Heat Exchangers,
Heaters and then first of the three Reactors in series (V-05-01/02/03) at about 930oF and
350 psig. There is intermediate Coil heaters (H-05-01 Coil# 2 & #) for outlet streams of
the first and second Reactors (combined together as Heater H-05-01, Coil 1,2,&3) which
provides the necessary heat and reheat between reaction stages. This set up is due to
the endothermic nature of reaction Naphthenes to Aromatic products and to a lesser
degree of dehydrocyclization of paraffins to aromatic ends that brings down temperature
of reacting stream. This requires reheating of the Reactor feed so as to have the highest
conversion possible.
Reactor effluent is cooled in feed Reactor effluent Heat Exchanger followed by Fin
fan/water trim coolers. It is separated into a liquid product and a hydrogen rich gas in this
product separator. Most of the gas is used as a recycle. The excess gas produced during
reforming reaction is used as a Hydrogen make-up gas to the Naphtha Unifiners,
bleeding off gas as needed to maintain pressure.
The liquid product from the Reactor effluent is stabilized in the Debutanizer Tower, where
light components (C1, C2, C3) are removed as overhead. This overhead gas is sent
directly to the Refinery Fuel Gas System. Condensed liquid from the Debutanizer
overhead is returned to the Column as reflux. The Debutanizer bottom product after heat
exchange with the Debutanizer feed, is cooled and sent to Reformate Storage Tanks for
MOGAS blending.
The process scheme is shown in the attached Sketch SK-1.
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33
5.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-05 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Exchangers 19
2 Air coolers 02
3 Heater 01
4 Reactors 03
5 Vessels / Tanks 12
6 Filters 06
7 Ejectors 02
8 PSVs 26
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5.3 ROTATING OVERVIEW
Unit 05 – The Catalytic reformer is designed to upgrade Naphtha containing low octane
paraffin and Naphthenic to high-octane Motor Gasoline blending hydrocarbons.
All the Rotating equipment in unit-05 are inspected and maintained as per the guidelines
of Process Licensor & good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 05 has 9 Pumps, 20 Fin fans, 1 compressor & 1 Turbine. List of Rotating Equipment
are furnished vide Appendix 2A hereof.
Pump/Compressor/Turbine package auxiliary items (filters, SO/LO Coolers, Gearboxes,
Seals, Couplings, Piping items etc.) are not included in the list. Bidders can collect
relevant details of maintenance records, healthiness of the equipment and inspection
records during PTM/Site visit.
5.4 ELECTRICAL OVERVIEW
Unit-05 is considered as classified area (Class 1 Div. 2 Group D) as per Shuaiba Refinery
Hazardous Area Classification drawing (refer drawing # R-00-6030). The source of power
to the Unit is aided from Substation 5A which is located south side of the Unit. The
substation is Building with Basement Type & facilitated as non-classified area by
employing pressurized / Air conditioned systems. Substation has a “6.6kV” Switchgears
fed from SS1A & SS1B (ref. drawing # R-00-6012), 3 nos. of “440V” MCC (MCC-A, MCC-
B & MCC-C), 3 nos. of power transformers (1MVA, 6.6kV/440V) and an Emergency
panel. The “6.6kV” Switchgear was replaced completely with latest new ABB panels
during GRTA-2011 under contract CS/1955. The Substation is equipped with Fire
Detection, Alarm & Suppression system which was installed under contract
CB/CSPD/2004 & commissioned on 2016. Battery Charger along with Battery backup
bank are also available.
The list of LT Motors associated with this Unit is enclosed vide Appendix 2A hereof.
Motors rated less than or equal to 280HP is designated as LT motor. Unit-05 has 30 nos.
of 440V motors. All motors are under Preventive Maintenance program by maintenance
department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
The Unit-05 is powered from the Substation # 5A and the Single Line Diagram (SLD) for
SS # 5A is as follows (for details Refer Annexure-01, KNPC Sketch # SK-2434 Sheet 02
of 08);
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35
Note: The Substations shared between different units and a table that shows the
association of different units to Substation shown in Appendix 1A - Refinery Overview.
5.5 INSTRUMENTATION OVERVIEW
Catalytic reforming process enables production of High Octane gasoline from Naptha.
Unit – 05 processes unified Naptha at high temperature in presence of Catalyst and
convert into gasoline having higher Octane Components.
5.5.1 Instrumentation System
a) DCS SYSTEM: Honeywell make TPS System installed in SIH # 5, SIH # 10. GUS
operating Stations in CCR
b) ESD SYSTEM: Honeywell make Safety Manager System installed in SIH # 5, SIH
# 10 & CCR.
5.5.2 Critical Safety Interlocks and Controls
a) Unit – 05 Feed Flow Meter.
b) Reactions V-05-01/02/03 temperature control.
c) V-05-04 product separator Level & Pressure Control.
d) Recycle gas compressor C-05-01 Interlock.
e) Feed Pump P-05-01 Interlock.
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5.5.3 Field Instrument List
SR # CATEGORY MAKE QTY REMARKS
1 O2 & H2 ANALYZER ROSEMOUNT-3081FG / ABB-PGC VISTA
2000 4
2 ANNUNCIATOR PANEL 1
3 CONTROL VALVE MASONEILAN / ELLIOT-FISHER UK 19
4 CONTROLLER FOXBORO 2
5 DISPLACER LT MASONEILAN 4
6 FLOW ELEMENT DANIEL 21
7 LEVEL GAUGE GLASS JERGUSON / K-TEK 12
8 LEVEL SWITCH MAGNETROL / SOR 4
9 LOCAL INDICATOR ITT BARTON / BROOKS / KROHNE / WISE
/ AMETEK 35
10 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL /
AM GAUGE 143
11 PRESSURE SWITCH UE / ASHCROFT / SOR 17
12 SOLENOID VALVE ASCO 5
13 TEMPERATURE
SWITCH UE 1
14 THERMOWELL THERMO ELECTRIC / TECNOMATIC / TC
LTD 63
15 TRANSMITTER ROSEMOUNT / YOKOGAWA /
HONEYWELL / ABB / FOXBORO / SMAR 29
16 MISC HONEYWELL 3
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6.0 UNIT – 06 OVERVIEW (Crude & Vacuum Unit)
6.1 PROCESS OVERVIEW
6.1.1 Objective
Crude and Vacuum Unit is the primary Crude Fractionation Unit which processes Kuwait
Export Crude and produces distillates such as Unstabilized Naphtha. Kerosene, light &
heavy Diesel, Vacuum Gas Oil and Residue for further processing in downstream
Processing Units.
The Unit also includes a Foul Water Treating System to treat the Refinery foul water
streams.
6.1.2 Capacity
The Unit is designed to process 180,000 BPSD of Kuwait Export Crude Oil. It, however,
normally operates at 200,000 BPD.
6.1.3 Feed and Products
Refer Tables 1, 2 & 3 for Material balance, Feed & Product Quality
a) Table-1: Typical Material Balance
SECTION FEED BPSD PRODUCTS BPSD
Atmospheric & Crude 200000 Naphtha 57000 Pre-Flash Towers Kerosene 28000
Lt. Diesel 15000 Atmos. Bottom 97000
Vacuum Tower Atmospheric 97000 Vac. Hy. Diesel 16000 Bottoms Vac. Hy. Gas Oil 30000
Vac. Bottoms 50000
Note: Excludes Gas & Loss
b) Table-2: Typical Feed & Product Quality - Atmospheric Section
SPEC. FEED
Preflash Naphtha Atm. Naphtha Kerosene Lt. Diesel
Gravity API 29.4-30.5 -- -- -- -- Sulfur Content wt.% 2.50% -- -- -- -- Salt Content 4 PTB -- -- -- -- End Point , Deg. F -- 450 450 570 740 Flash Point , Deg. F -- -- -- 150 -- Recovery @ 975 Deg. F
DESTINATION U-09 U-09 U-11/13/17&FO U-12/13/GO
PRODUCTS
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c) Table-3: Typical Product quality-Vacuum Section
SPEC.
Hy. Diesel VGO Vac. Btms
Gravity API -- -- --
Sulfur Content wt.% -- -- --
Salt Content -- -- --
End Point , Deg. F 740 -- --
Flash Point , Deg. F -- -- --
Recovery @ 975 Deg. F 90% 12%
DESTINATION U-12/13&68 U-68 U-07 & FO
PRODUCTS
6.1.4 Process Description
6.1.4.1 Preheat Train & Pre-flash Section
This simplified process sketch is indicated in the attached Sketch 1
The Crude Oil received from CrudeTank through booster pumps is pumped by charge
pumps and preheated in parallel trains of preheat Exchangers with hot intermediate
streams and products. A small quantity of water and demulsifier chemical are added
before preheating. The hot crude is mixed with wash water and fed to the Desalters to
reduce its salt content by electric desalting process. A water phase containing most of the
salts is separated out.
The desalted crude is dosed with NaOH (Caustic Soda) solution to avoid formation of the
free HCl acid in towers. It is pumped and further heated through two parallel trains of
Heat Exchangers and fed to Pre-flash Tower, V-06-17. The Pre-flash Tower Overhead
vapors are cooled by exchanging heat with Crude, condensed in Fin Fan Coolers and
routed to Overheads Drum, V-06-18. Part of liquid Naphtha from Overhead Drum is used
as reflux. The Naphtha vapors and liquid from Accumulator are sent to Naphtha
fractionation Unit, U-09. The crude from the bottom of Preflash Tower is pumped through
heat exchangers receiving heat from Vacuum Tower bottoms product and subsequently
to Atmospheric Heaters, H-06-01/03 operating in parallel.
6.1.4.2 Atmospheric Section
Preflashed Crude is heated and partially vaporized in the fired heaters before entering
the Atmospheric Tower, V-06-01. Superheated stripping steam is introduced at the
bottom.
The Tower overhead vapors are cooled by exchanging heat with Crude Oil, condensed in
Fin Fan Coolers and routed to overhead product drum, V-06-05. Overhead gases from
the drum are compressed and sent to Unit-09 along with Preflash Naphtha gas. Naphtha
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is separated from condensed water. A part of this Naphtha is pumped to tower top as
reflux and balance is sent to Unit-09 along with Preflash Tower Naphtha and gases.
Kerosene and Light Diesel cuts are taken as side streams from the Atm. Tower and
steam stripped in side strippers, V-06-02/03. These Kero/LD product streams exchange
heat with Crude Oil feed in Crude preheat Trains and are finally cooled in Fin Fan
Coolers and Trim Water Coolers and sent to storage. Superheated stripping steam is
introduced to V-06-02/03 for flash point and IBP Control. Atmospheric Tower bottoms
(Reduced Crude) is heated in Heaters H-06-02/04 for Vacuum Tower feed.
6.1.4.3 Vacuum Section
The reduced crude from Vacuum Heaters enters the flash zone of Vacuum Tower, V-06-
04. The column operates under vacuum by means of Steam-jet Ejectors & Condenser
system to achieve required separation between heavy components at lower temperature.
From O/H, the un-condensed Sour Gas is compressed using C-06-03 and sent to Gas
Treating Unit (U-14). Condensed water is routed to Desalter feed water surge drum, V-
06-08.
The tower bottom section is equipped with a vacuum residue quench to control the tower
bottom temperature to avoid coke formation. Superheated stripping steam is used at
vacuum tower bottom to maximize distillate recovery.
The Heavy Diesel product, drawn as a side stream, exchange heat with Crude Oil in
preheat train. It is partly used as top/intermediate reflux to the Column as cold recycle
and hot recycle and the balance is sent to storage after cooling.
The Vacuum Gas Oil cut, drawn as lower side stream, is steam stripped in Stripper V-06-
07, routed through Crude Preheat Train and cooled in Fin Fan Coolers before sending to
off-site storage tanks. A part of the vacuum gas oil is recycled back to vacuum tower as
wash oil.
The bottom product, Vacuum Residue exchanges heat with Pre-flash Tower Bottom in
the Crude Preheat Train before being sent to H-Oil unit.
Inhibitor and 3% Ammonia solution is injected into all three Towers Overhead System to
control pH and corrosion
All of the four Heaters in the Unit are provided with steam-air decoking facilities.
6.1.5 Brief History
Commissioned in Year 1968 with 95,000 BPD
Revamped in year 1978 with preflash tower & additional heaters
Desalters revamped in year 2001 to handle higher salt levels up to 10 PTB
As part of safety enhancement ROIV’s provided & Heater safety upgradation done
by providing safety interlocks
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6.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-06 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Exchangers, Shell & Tube 37
2 Air Coolers 07
3 Vessels, Columns, Tanks and Drums 24
4 Heaters 04
5 PSVs 79
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6.3 ROTATING OVERVIEW
Crude and Vacuum unit is the primary crude fractionation unit, which processes Crude
and produces distillates…
All the Rotating equipment in 06 unit are inspected and maintained as per the guidelines
of Process Licensor & good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 06 has 78 Pumps, 88 Finfans, 2 Compressors, 5 Turbines. List of Rotating
Equipment are furnished vide Appendix 2A hereof.
In Many Critical pumps (P-06-01A/B/C/D, 02 A/B, 03A/B, 04 A/B, 06, 08 A/B/C/D, 10 D,
13A,14A/B, 15A/B, 16,17 A/B, 18 A/B, 19 A/B, 21 A/B, 29, 35 A/B,36 A/B/C, 38A/B,
45A/B) Gland packings converted to mechanical seals to the spirit of API 682 (in 2011) to
prevent the gas leakage to environment.
Pump/Compressor/Turbine package auxiliary items (filters, SO/LO Coolers, Gear boxes,
Seals, Couplings, Piping items etc.) are not included in the list. Bidders can collect
relevant details of maintenance records, healthiness of the equipment and inspection
records during Site visit.
6.4 ELECTRICAL OVERVIEW
Unit -06 is considered as classified area (Class 1 Div. 2 Group D) as per Shuaiba
Refinery Hazardous Area Classification drawing (refer drawing # R-00-6030). The source
of power to the Unit is aided from Substation 07 which is located inside the Unit. The
substation is facilitated as safe area by employing pressurized / Air conditioned system.
Substation has 3 nos. of HT Switchgear “6.6kV” (7A, 7B & 7C), 5 nos. of LT MCC “440V”
(MCC-100, MCC-200, MCC-300, MCC-400 & MCC-500), 5 nos. of power transformers
(1MVA, 6.6kV/440V) and Emergency panel (EDB-06-01)along with Automatic Transfer
Switch as per Single Line Diagram enclosed. The HT Switchgear 7A & 7B were replaced
completely with latest new ABB panels during GRTA-2011 under contract CS/1955.
Upgradation of Obsolete Fire Detection, Alarm & Suppression system for the unit
including the phase out of Halon system was carried under contract CB/CSPD/2004 was
completed in 2016. Batteries, Battery Charger, & Air conditioning system are also
available.
The list of HT & LT Motors associated with this Unit is enclosed vide Appendix 2A
hereof. Motors rated above 280HP is designated as HT motor and if less than or equal to
280HP, as LT motor. Unit -06 has 20 nos. 6.6KV motors and 141 nos. 440V motors. All
motors are under Preventive Maintenance program by maintenance department. All open
type HT motors have been replaced over the years with closed type TEFC motors.
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Other electrical equipment such as 6 nos of Desalter Power Transformers(150KVA,
440V/22KV), Light fixtures, Distribution Boards, junction Box, power sockets, push button
stations, , Fire Alarm detectors, Lighting transformers (25kVA 440/415V), above ground
cables, conduits etc. available in the Unit are not listed separately. Bidders can collect
relevant details during Site visit. Single Line Diagrams for Substation # 7 as follows:
The Unit-06 is powered from the Substation # 07 and the Single Line Diagram (SLD) for
SS # 07 is as follows (for details Refer Annexure-01, KNPC Sketch # SK-2434 Sheet 05
of 08);
Note: The Substations shared between different units and a table that shows the
association of different units to Substation shown in Appendix 1A - Refinery Overview.
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6.5 INSTRUMENTATION OVERVIEW
Crude Unit Operations involves Controlling Parameters such as Flow, Level,
Temperature and Pressure. The DCS system provided monitors the above parameters
and provide basic regulatory control.
The field Instruments provided to measure the Process Parameter are SMART (Single
Module Addressable Rangeable transducer) which are state of art Microprocessor based
Electronic Instruments and connected to the DCS system.
The Control Valves in the field are the latest type valves from reputed Manufacturer like
Masoneilan, Fisher, Honeywell etc. The Valves are provided with Electronic Smart
(Digital) Positioners with diagnostic features.
Oxygen Analyzers are provided in the Heater stack to monitor the efficient operation of
the Heaters. Also, PH Analyzers are provided to monitor the PH of condensate,
The RIOVs installed in the plant are Emergency Block valves used to isolate critical
equipments to control the Hazardous situation. The RIOVs are operable from GUS
station in CCR. The ROIVs are also provided with “Partial Stroke Testing” (PST) facility to
check the functionality of the shutdown valve during unit in operation.
ESD system (Safety Manager of Honeywell make) provides Safety Interlock Control for
the unit. List of some critical interlocks are as follows:
a) C-06-01 – Atmospheric Gas Compressor Control.
b) C-06-03 – Sour Gas compressor Control
c) Desalter Interlock.
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d) Heater H-06-01, H-06-02, H-06-03 & H-06-04 Interlock Control.
6.5.1 Field Instrument List
SUMMARY OF UNIT-06 INSTRUMENT LIST
SR. # DEVICE MAKE QTY REMARKS
1 CONTROL VALVE/ ROV FISHER/ MASONEILAN/ HONEYWELL/ SAMSON GERMANY/ TYCO/ VIRGO
148
2 TRANSMITTER ROSEMOUNT/ YOKOGAWA/ HONEYWELL/ ABB/ FOXBORO/ SMAR
246
3 DISPLACER LT MASONEILAN/ MAGNETROL 22
4 FLOW ELEMENT DALIEL / SAMIL 146
5 LEVEL GAUGE GLASS JERGUSON/ PENBERTHY/ K-TEK 47
6 LOCAL CONTROLLER FOXBORO/ YOKOGAWA/ TAYLOR/ MASONEILAN
7
7 LEVEL SWITCH MAGNETROL/ MOORE/ SOR/ JERGUSON/ INTRA AUTOMATION
19
8 PRESSURE SWITCH UE/ ASHCROFT/ SOR/ DELTA CONTROL 61
9 THERMOWELL THERMO ELECTRIC/ TECNOMATIC/ TC LTD
287
10 LOCAL INDICATOR ITT BARTON/ BROOKS/ KROHNE/ WISE/ AMETEK
39
11 SOLENOID VALVES ASCO 61
12 PRESSURE GAUGE ASHCROFT/ WIKA/ WISE/ GENERAL/ AM. GAUGE
249
13 FIXED GAS DETECTOR HONEYWELL 8
14 JUNCTION BOX 20
15 ANALYZER (OXYGEN, PH) ROSEMOUNT/ YOKOGAWA/ AMETEK/ SERVOMAX
12
16 VIBRATION MONITER 3300 BENTLY SYSTEM 1
17 LIMIT SWITCH/ PROXIMETER (MISC)
HONEYWELL 86
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7.0 UNIT – 06F OVERVIEW (Foul Water Treating Unit)
7.1 PROCESS OVERVIEW
7.1.1 Objective
This unit can be run as a Concentrator for foul water from various units to generate Unit-
15 feed or independently as a stripper producing overhead gas only for flaring.
7.1.2 Capacity
The unit designed to process 350 GPM foul water.
7.1.3 Process Description
All the Refinery foul water streams are combined, cooled with cooling water in E-15-19
A/B, degassed to flare in V-15-18 and pumped to Tank for storage. In the tank, oil and
sludge separate from water and are skimmed periodically to Slop Oil System.
From Tank TK-482, foul water is pumped by P-34-23/22S thru Heat Exchanger, E-06-34
to Foul Water Stripper V-06-09 located in Unit-06. Superheated steam is introduced at
the bottom of Tower for stripping H2S and NH3 from the foul water.
The overhead gases are cooled/condensed in air Fin Cooler E-06-27. Non-condensable
gases are routed to the flare header through overhead Accumulator,V-06-20. The
condensed NH3/H2S concentrate is sent to Unit-15 Degasser, V-15-19 for further
processing in Unit-15 or is returned to the column as total reflux.
The hot stripped water from the column bottom is pumped by P-06-21A/B through cold
feed exchanger E-06-34. This stripped water, meeting Effluent water specification for
NH3/H2S, is routed to the sea water pit for discharge with Refinery effluent water. A part
of this Water is reused in Unit-06 Desalter water system through V-06-08 (refer Fig. SK-
100-06-B). The stripped water can also be recycled to the feed tank during start-up or if
the stripped water NH3/H2S/Oil contents are high.
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7.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-06F is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Exchangers, Shell & Tube 02
2 Air Coolers 02
3 Vessels, Columns, Tanks and Drums 04
4 PSVs 03
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8.0 UNIT – 07A/B OVERVIEW (H-Oil Train A/B)
8.1 PROCESS OVERVIEW
8.1.1 Objective
The purpose of the Unit is to upgrade the Crude residual stocks (bottoms of Crude Unit
Vacuum Distillation section) by catalytic hydrocracking process in the presence of
hydrogen and obtain valuable distillate products.
These distillate products are separated as side streams from the Fractionation Tower as
Naphtha, Kerosene and Light Diesel.
The heavy products from Reaction Section and Fractionator Tower Btm are mixed and
further separated in a vacuum distillation tower to produce Heavy Diesel, LVGO, HVGO,
and Vacuum Bottom Residue (Fuel Oil).
8.1.2 Capacity
The H-Oil Unit consists of two parallel Reactor Trains followed by common Fractionation
Section. Each 07 Train was originally designed to Process 36,000 BPD of mixed Feed
(14,400 BPSD Fresh feed ,9.3 Deg. API Crude Vacuum Bottom + 21,600 BPD of
Str./Frac.Btm Recycle).
Since commissioning, the Unit operating mode has been modified to suit the prevailing
refinery operating pattern. Now, up to 25,000 BPSD of Vacuum bottoms is being
processed in each Train.
8.1.3 Feed and Products
Refer Table-1 below
a) Table-1: Material Balance
BPSD % VOL.
Feed
06 Vac. Btms 50000
HVGO Recycle 0
Slops 2000
Total Feed 52000 100
Products
Naphtha 3000 5.77 Kerosene 5000 9.62 Lt Diesel 3500 6.73 Frac./ Str. Bottoms 42000 80.8
Total Liquid Product 53500 102.885
To Unit 13 To Unit 63
SOURSE / DESTINATION
From Unit 06
From Unit 63
From TK-477/478/479/342
To Unit 11 To Unit 11
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8.1.4 Process Description
Refer to Sketch -1 below
8.1.4.1 Reaction Section
The fresh feed, Crude Unit Vacuum Bottoms is received in Feed Drum, V-33. Heavy
vacuum gas oil from U-63 can be taken as diluent up to about 8%, if needed. The
combined streams from feed Surge Drum V-07-33 are pumped to feed Heater H-07-01
and then mixed with high pressure recycle hydrogen gas (80-82% Vol. Purity preheated
in Heater H-07-02) in mixers. Mixer outlet at about 730oF and 2450 psig is fed to H-Oil
Reactor V-07-01. Within the reactors, the charge oil is cracked at elevated temperature
(820oF) and high hydrogen pressure in the presence of catalyst.
The H-Oil reaction takes place in an ebullated bed of catalyst (NiMo Type). Pump P-07-
02 drawing suction form reactor top level maintains a circulation to keep the catalyst
particles in continuous ebullition and near isothermal reaction conditions. The catalyst
level is monitored by a radioactive source (Ohmart Detectors). Some spent catalyst is
withdrawn at regular intervals (daily) and replenished by loading fresh catalyst to maintain
required catalyst activity. Catalyst consumption is about 90 Tons/Month for both Trains
A/B.
The Reactor effluent flows as a vapor-liquid mixture into Separator, V-07-02. The vapor
is a Hydrogen rich stream containing lighter hydrocarbon reaction products. The liquid is
composed essentially of heavier hydrocarbon products, unconverted charge oil and
appreciable amounts of dissolved Hydrogen and light ends.
The flash vapor leaving V-07-02A is cooled with light distillate in Exchanger E-07-02A
and total hydrogen in Exchanger E-07-01A. Cooled vapor effluent is then fed to Primary
Distillate Knockout drum, V-07-03A for removal of condensed liquid. Vapor from V-07-
03A is further cooled to about 140oF in an Air Cooler E-07-03A and enters Distillate
Separator Drum, V-07-04A. The Hydrogen rich gas which upon leaving the separator V-
07-04A, splits into two streams. The larger of the two streams is compressed to
approximately 2500 psig in Recycle Gas Compressor C-07-01A and returned to H-Oil
reactor, as Hydrogen recycle. The smaller purge gas stream, combined with an identical
stream from “B” train is sent to the Unifiners through vessel V-07-11.
Condensed liquid from V-07-03A joins with reactor effluent liquid from V-07-02A and
flashed to remove hydrogen and low molecular weight hydrocarbons in three successive
stages. The first stage let down to 1050 psig is in V-07-07A. The resulting Hydrogen rich
vapor is cooled with light distillate in exchanger, E-07-05A and then with cooling water to
approximately 110oF, in E-07-06A. This cooled stream is flashed again in Flash Gas
Drum V-07-16A.
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The vapor from V-07-16A are let down to a pressure of about 550 psig and joins the High
Pressure Flash Gas from V-07-05A. The liquid (from V-07-16A) is further let down to a
pressure of 550 psig in High Pressure Flash Gas Drum V-07-05A.
Water wash is injected upstream of E-07-03A (about 75 gpm) and E-07-06A (about 10
gpm) to avoid ammonium bisulfide deposits. The Ammonical water from V-07-04A and
V-07-05A are returned to Ammonical Water Treating Unit (Unit-15).
The second stage let down to about 550 psig occurs in High Pressure Temperature Flash
Drum V-07-14A. Vapor from this flash is cooled with light distillate in Exchanger, E-07-
12A and cooling water in E-07-18A. It is fed to Flash drum V-07-05A, in addition to high
pressure condensate from V-07-04A and V-07-16A along with corresponding streams
from Train “B” are sent to Unit-14.
The final let down occurs at 75 psig in the flash drum situated above Steam Stripper V-
07-09A. The resulting vapor is cooled through Light Distillate Exchanger, E-07-19A to
300 oF and then in Water Cooler E-07-21A to 120oF, before it is fed to Low Pressure
Flash Drum V-07-06A at about 30 Psig along with condensate from V-07-05A. The Low
Pressure Flash Gas from V-07-06A along with that from Train-B is sent to Unit-14.
The light distillate from V-07-06A is pumped by P-07-03A, through Exchangers E-07-19A,
E-07-12A, E-07-05A, and E-07-02A and is preheated to approximately 550-600oF. The
light distillate streams from both H-Oil Trains are then combined and fed to the common
Fractionator, V-07-10. Refinery Slop oil is injected in V-06 for reprocessing.
The hot flashed reactor liquid from V-07-09 flows in to the Stripper V-07-09A, where it is
steam stripped to remove the middle distillates. The stripper overhead streams from both
H-Oil trains are fed to Fractionator Tower V-07-10, along with the preheated light
distillates from V-07-06A&B. The Stripper bottoms stream is pumped by P-07-04A be
pumped to Unit 63 Feed Surge Drum, V-07-50. Alternatively, stripper bottoms can also
be pumped to Fuel Oil run down system.
8.1.4.2 Fractional Section
The Fractionator Tower V-07-10 feed consists of light and middle distillates from V-07-06
A/B and stripped gases from Strippers V-07-09 A/B. The Fractionator bottoms are
circulated through H-07-03 for additional heat input and further supplemented by heating
slops and fractionator bottoms through H-Oil Cold Feed Heater, H-07-04.
Fractionator overhead vapor is cooled and partially condensed in Air Cooler E-07-11
before going in Naphtha Accumulator Drum V-07-08. The vapor from V-07-08 is sent to
the Amine Treating Unit. The unstablized liquid Naphtha from V-07-08 is pumped by P-
07-31 & 31S to kerosene Unifiner charge tank TK-34-331. The separated water,
withdrawn from V-07-08 is sent to the Oily Water Condensate System.
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From the fractionator a Kerosene cut is drawn to stripper V-07-12 and light components
removed by steam stripping. The raw kerosene stream is pumped by P-07-07, Cooled in
Air Cooler E-07-09, and sent to Kero Unifiner, U-11, feed tank.
A Light Diesel cut is fed to diesel side Stripper V-07-13, for removal of light ends by
steam stripping. The raw Light Diesel stream is pumped by P-07-06 and cooled in the Air
cooler E-07-08A/B before it is routed to Diesel Unifiner Charge tank.
A pump-around side stream is circulated near the top of the Fractionator Tower with P-
07-08A/S and Air Cooler E-07-10.A lower pump around is taken at the light diesel draw
off by Pumps P-07-05 A/S passing through Air Cooler E-07-07 to the Fractionator. The
Fractionator bottoms product is pumped by P-07-16/16S to Unit-63 Feed Surge Drum, V-
07-50.
8.1.5 Brief History
a) Fuel Oil cooling strings added in 1978
b) Part of the Unit damaged in fire incident in Year 2015.
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8.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-07A/B is listed as follows; List of Static
Equipment with History are furnished vide Annexure – 01 hereof.
Sl. # Equipment Description No of Equipment
1 Exchangers 57
2 Air Coolers 09
3 Heaters 06
4 Reactors 04
5 Vessels / Tanks 54
6 PSVs 166
8.3 ROTATING OVERVIEW
Unit 07 – This Unit is to upgrade the Crude residual stocks (bottoms of crude unit
vacuum distillation section) by catalytic hydrocracking process in the presence of
hydrogen and obtain more desirable middle distillate products.
All the Rotating equipment in 07 unit are inspected and maintained as per the guidelines
of Process Licensor & good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 07 has 80 Pumps, 56 Fin fans, 22 Turbines & 2 compressors. List of Rotating
Equipment are furnished vide Appendix 2A hereof.
Most of the Critical pumps packings converted to mechanical seals to the spirit of API
682 to prevent Gas leakage to environment.
Pump/Compressor/Turbine package auxiliary items (filters, SO/LO Coolers, Gearboxes,
Seals, Couplings, Piping items etc.) are not included in the list. Bidders can collect
relevant details of maintenance records, healthiness of the equipment and inspection
records during PTM/Site visit.
8.4 ELECTRICAL OVERVIEW
Unit -07 is considered as classified area (Class 1 Div. 2 Group D) as per Shuaiba
Refinery Hazardous Area Classification drawing (refer drawing # R-00-6030). The source
of power to the Unit is aided from Substation 06 which is located south side of the Unit.
The substation is Building with Basement Type & facilitated as non-classified area by
employing pressurized / Air conditioned systems. Substation has 2 nos. of “6.6kV”
Switchgears (6A & 6B) fed from SS1A & SS1B (ref. drawing # R-00-6012), 6 nos. of
“440V” MCC (MCC-6A & MCC-6B,MCC-07-600,1,2&3), 6 nos. of power transformers
(1MVA, 6.6kV/440V) and 4 nos. of Emergency panel (EM-PNL-A, EM-PNL-B, EM-PNL-C
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& EM-PNL-D ) along with Automatic Transfer Switch as per Single Line Diagram
enclosed. The “6.6kV” Switchgears 6A & 6B were replaced completely with latest new
ABB panels during GRTA-2011 under contract CS/1955. The Substation is equipped with
Fire Detection, Alarm & Suppression system which was installed under contract
CB/CSPD/2004 & commissioned on 2016. Battery Charger along with Battery backup
bank are also available.
The list of HT & LT Motors associated with this Unit is enclosed vide Annexure - 03
hereof. Motors rated above 280HP is designated as HT motor and if less than or equal to
280HP, as LT motor . Unit -07 has 2 nos. 6.6KV motors and 122 nos of 440V motors. All
motors are under Preventive Maintenance program by maintenance department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit. Details of Electrical
Assets damaged during the Fire Incident in Aug. 2015 are available in SHU Archives for
Bidders reference.
The Unit-07A/07B is powered from the Substation # 06 and the Single Line Diagram
(SLD) for SS # 06 is as follows (for details Refer Annexure-01, KNPC Sketch # SK-2434
Sheet 04 of 08);
Note: The Substations shared between different units and a table that shows the
association of different units to Substation shown in Appendix 1A - Refinery Overview.
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8.5 INSTRUMENTATION OVERVIEW
H-Oil Unit – Heavy Vacuum residue containing Sulfur, Nitrogen & Organic Mettalic
Compounds is Hydrocracked to middle distillates such as Naptha, Kerosene, Diesel &
Gas Oils at high pressure and temperature in presence of Catalyst.
8.5.1 Instrumentation System Unit-07A
a) DCS: Honeywell make TPS System installed in SIH # 4, SIH # 10 & CCR with
GUS operating Stations in CCR
b) ESD System: Honeywell make Safety Manager System installed in SIH # 4, SIH #
10 & CCR.
8.5.2 Instrumentation System Unit-07B
a) DCS: Honeywell make TPS System installed in SIH # 4, SIH # 10 & CCR with
GUS operating Stations in CCR
b) ESD System: Honeywell make Safety Manager System installed in SIH # 4, SIH #
10 & CCR.
8.5.3 Critical Safety Interlocks and Controls Unit-07A
a) Heater H-07-01A – Trip Interlock & Control.
b) Heater H-07-02A – Trip Interlock & Control
c) Feed Pump – P-07-01A – Trip Interlock.
d) Recycle Gas Compressor – C-07-01A – Trip Interlock & Control.
e) V-07-33A – Feed Surge drum level / pressure Control.
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f) H-07-01A – Outlet Temperature Control.
g) V-07-01A, V-07-02A, V-07-03A & V-07-04A Pressure Control.
h) V-07-01A Catalyst Average Temperature Control.
i) V-07-01A – Catalyst bed Level Control.
8.5.4 Critical Safety Interlocks and Controls Unit-07B
a) Heater H-07-01B – Trip Interlock & Control.
b) Heater H-07-02B – Trip Interlock & Control
c) Feed Pump – P-07-01B – Trip Interlock.
d) Recycle Gas Compressor – C-07-01B – Trip Interlock & Control.
e) V-07-33B – Feed Surge drum level / pressure Control.
f) H-07-01B – Outlet Temperature Control.
g) V-07-01B, V-07-02B, V-07-03B & V-07-04B Pressure Control.
h) V-07-01B Catalyst Average Temperature Control.
i) V-07-01B – Catalyst bed Level Control.
8.5.5 Field Instrument List Unit-07A
SR # CATEGORY MAKE QTY REMARKS
1 02 ANALYZER YOKOGAWA-ZR 402T / ABB-ENDURRA
AZ30 3
2 CONTROL VALVE FISHER / MASONEILAN /
VIRGO /ROTORK 41
3 CONTROLLER FOXBORO / YOKOGAWA 3
4 DISPLACER LT MASONEIAN / MAGNETROL 15
5 FLOW ELEMENT DANIEL / SAMIL 45
6 LEVEL GAUGE GLASS JERGUSON / PENBERTHY / K-TEK 13
7 LEVEL SWITCH MAGNETROL / MASONEILAN 8
8 LOCAL INDICATOR ITT BARTON / BROOKS / KROHNE / WISE /
AMETEK 70
9 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL / AM
GAUGE 76
10 PRESSURE SWITCH UE / E-CELLA / BOURDON SEDEME 29
11 SOLENOID VALVE ASCO 17
12 TEMPERATURE SWITCH UE 9
13 THERMOWELL THERMO ELECTRIC / TECNOMATIC / TC
LTD 113
14 TRANSMITTER ROSEMOUNT / YOKOGAWA / HONEYWELL
/ ABB / FOXBORO / SMAR 93
15 MISC HONEYWELL 22
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8.5.6 Field Instrument List Unit-07B
Details of Instrumentation Assets damaged during the Fire Incident in Aug. 2015 are available in SHU Archives for Bidders reference.
SR # CATEGORY MAKE QTY REMARKS
1 02 ANALYZER YOKOGAWA-ZR 402T 2
2 CONTROL VALVE FISHER / MASONEILAN /
VIRGO /ROTORK 39
3 CONTROLLER FOXBORO / YOKOGAWA 6
4 DISPLACER LT MASONEILAN / MAGNETROL 14
5 FLOW ELEMENT DANIEL / SAMIL 42
6 LEVEL GAUGE GLASS JERGUSON / PENBERTHY / K-TEK 13
7 LEVEL SWITCH MAGNETROL / MASONEILAN 8
8 LOCAL INDICATOR ITT BARTON / BROOKS / KROHNE / WISE /
AMETEK 56
9 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL / AM
GAUGE 62
10 PRESSURE SWITCH UE / ASHCROFT / SOR 25
11 SOLENOID VALVE ASCO 14
12 THERMOWELL THERMO ELECTRIC / TECNOMATIC / TC
LTD 97
13 TRANSMITTER ROSEMOUNT / YOKOGAWA / HONEYWELL
/ ABB / FOXBORO / SMAR 94
14 MISC HONEYWELL 23
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9.0 UNIT – 08 OVERVIEW (Isomax Unit)
9.1 PROCESS OVERVIEW
9.1.1 Objective
To convert Heavy Gas Oil feed stocks into light higher value products like Naphtha,
Kerosene and Diesel by hydrocracking. Chemical reactions in Isomax Reactor are
essentially same as those in the Isocracker Unit-68 Reactor, i.e. De-sulfurization, De-
nitrification and cracking in the presence of hydrogen.
9.1.2 Capacity
Isomax Unit is designed for total feed of 36000 BPSD with 23000 BPSD of fresh feed. it
normally operates as a second stage to Isocracker Unit (68), to process U-68 Frac.
Bottom at a rate of about 23000 BPSD. Products are similar to U-68 products, i.e.
Naphtha, Kerosene (JP-5/ATK) and Low Sulfur Diesel.
9.1.3 Feed and Products
Refer to Tables 1&2 below
The feed to the Unit is either fractionator bottoms from Unit-68 or fresh feed from tank,
comprising of heavy diesel & vacuum gas oil from Unit-06 and unifined heavy diesel from
Unit 13.
a) Table-1: Typical Material Balance
BPSD % VOL. SOURCE / DESTINATION
Feed 23000 100 From Unit -68 or Units 06/13
Products
Naphtha 8000 34.78 To Unit 10 / Storage JP-5 8500 36.96 To Storage High Pour Diesel 6500 28.26 To Storage Frac. Bottoms 1500 6.52 To Storage
Total Liquid Product 24500 106.52
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b) Table-2: Typical Feed & Product Quality
PRODUCTS
Spec. Feed Naphtha JP - 5 H. Pour
Fract.
Btms.
Diesel
Gravity API 33 68.7 46.8 41.2 39
Sulfur PPM / % wt. 250 10-15 <10 <10 <10
Nitrogen, PPM <1.0 <1.0 <1.0 <1.0 <1.0
Dist. Range , Deg. F 570 - 960 98 - 350
350 -
570 520 - 720 550 - 950
Flash Point , Deg. F -- -- 150 210 > 230
Smoke Point , MM -- -- 36 -- --
Pour Point , Deg. F 90 -- -- 10 100
Freezing Point , Deg C -- -- -50 --
Nickel + Van. , PPM
Max. -- -- --
-- --
Fe + Na , PPM Max. -- -- -- -- --
Asphaltenes , PPM -- -- -- -- --
Polycyclic Index (PCI) 100-300 -- -- -- <50
9.1.4 Process Description
Refer to attached Sketch -1
This Unit consists of the following two sections:
9.1.5.1 High Pressure Section
The Fractionator bottoms from the first stage (Unit-68) or fresh feed from the tank is
preheated in a Heat Exchanger. It combines with the recycle feed (Fract. Btm. and
passes through self-cleaning filters. The mixed feed is then pumped (to ~2800 psig) by
the feed pump. It mixes with the Recycle Gas from the Compressor before entering the
Feed – Reactor Effluent Exchangers. The mixture is further heated in Heater H-08-01
and enters the Reactor V-08-01, from the top. The make-up hydrogen, after heating in
Reactor Effluent Exchanger E-08-01, enters Rx bottom through annulus of the Reactor.
travels upwards and joins the reactor feed mixture at the top.
The Reactor consist of five catalyst beds (Hydrocracking catalyst) with provision for inter-
bed quenches of recycle gas to control the catalyst temperatures. Under high pressure
and temperature (~2400 psig & 730-780 F), the feed is hydrocracked. Effluent from
bottom of the reactor, is cooled through a series of Heat Exchangers and an Air Cooler to
about 140oF. It then enters the High Pressure Separator, V-08-02 where gases, liquid
hydrocarbons and water are separated. In order to combat corrosion caused by
H
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-
-
-
-
-
-
-
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-
-
-
-
-
-
-
-
-
-
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Hydrogen Sulfide and Ammonia, a small quantity of condensate / Ammonical water is
injected upstream of the Air Cooler.
Water from High Pressure Separator containing Ammonium Sulfides, goes to the
Ammonical Water Treating Unit for further treatment. Gaseous stream from High
Pressure Separator (mainly Hydrogen) is compressed by Recycle Gas Compressor. A
major part of Recy. Gas is sent back to the Reactor along with feed, while part is utilized
for Rx. inter-bed quenches. A small part is bled to the Unifiner Units to maintain the
Recycle Gas purity. Hydrocarbon liquid stream from H.P. Separator is let down to 550
psig in Low Pressure Separator V-08-04. Separated gases are routed to Amine Treating
Unit and liquid hydrocarbons are further let down to 150 psig in Flash Drum V-08-05.
9.1.5.2 Low Pressure Section
Gases from Flash Drum V-08-05 are routed to Amine Treating Unit. The hydrocarbon
liquid is pumped thru and preheated in Rx. Effluent Exchanger E-08-03 and further
heated in Heater H-08-02. It then enters a Fractionation Column V-08-06, called “Recycle
Splitter”. Tower overhead vapors are cooled/condensed in Fan Coolers and flow into
Reflux Drum V-08-07. From here Naphtha is pumped to the tower top as reflux. Excess
condensate and vapor is further cooled and flow into the Product Drum V-08-08.
Kerosene side cut flows to Stripper V-08-09, where heat supplied at bottom by Reboiler
E-08-07, improves the flash point to specification. Diesel side cut is stripped in V-08-14
with superheated stream. Both these products are cooled and sent to off-plot storage.
The Splitter bottom is recycled hot to the feed. A small part is cooled and sent to storage
(UCO) to maintain system cleanliness.
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9.1.6 Brief History
a) Unit fresh feed rate was increased to 23000 BPD and Diesel Withdrawal was
introduced in the year 1974.
b) Unit 68 was commissioned in 1978 and thereafter Unit 08 was functioning as a
second stage Hydrocracker after revamp and designed to process 20900 BPD of
Unit 68 fractionator bottoms.
c) During Iraqi Invasion unit was damaged and restoration was carried out in 1994.
d) During the span of Operation, unit was upgraded with ROIVs and other safety
modifications as a result of HAZOP and Flare Adequacy studies.
9.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-08 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
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60
Sl. # Equipment Description No of Equipment
1 Exchangers, Shell & Tube 19
2 Air Coolers 07
3 Vessels / Tanks 29
4 Heaters 02
5 Reactor 01
6 Filters 10
7 PSVs 45
9.3 ROTATING OVERVIEW
In Shuaiaba Refinery Unit 08- Isocracker being used to upgrade heavy Gas Oil feed
stocks into higher value products like Naptha, Kerosene, Diesel by Hydrocracking.
All the Rotating equipment in 08 unit are inspected and maintained as per the guidelines
of Process Licensor & good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 08 has 29 Pumps, 67 Fin fans, 2 Compressors, 4 Turbines. List of Rotating
Equipment are furnished vide Appendix 2A hereof.
In 2007, C-08-01 Compressor/Turbine upgraded with latest technology Instrumentation &
Control system to monitor Vibrations, Temperature, Speed & Control system.
Many Critical pumps Gland packings converted to mechanical seals to the spirit of API
682 (in 2012) to prevent the gas leakage to environment.
Pump/Compressor/Turbine package auxiliary items (filters, SO/LO Coolers, Gearboxes,
Seals, Couplings, Piping items etc.) are not included in the list. Bidders can collect
relevant details of maintenance records, healthiness of the equipment and inspection
records during PTM/Site visit.
9.4 ELECTRICAL OVERVIEW
Unit-08 is considered as classified area (Class 1 Div. 2 Group B) as per Shuaiba Refinery
Hazardous Area Classification drawing (refer drawing # R-00-6030). The source of power
to the Unit is aided from Substation 06 which is located south-east side of the Unit. The
substation is Building with Basement Type & facilitated as non-classified area by
employing pressurized / Air conditioned systems. Substation has 2 nos. of “6.6kV”
Switchgears (6A & 6B) fed from SS1A & SS1B (ref. drawing # R-00-6012), 6 nos. of
“440V” MCC (MCC-6A & MCC-6B,MCC-07-600,1,2&3), 6 nos. of power transformers
(1MVA, 6.6kV/440V) and 4 nos. of Emergency panel (EM-PNL-A, EM-PNL-B, EM-PNL-C
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& EM-PNL-D ) along with Automatic Transfer Switch as per Single Line Diagram
enclosed. The “6.6kV” Switchgears 6A & 6B were replaced completely with latest new
ABB panels during GRTA-2011 under contract CS/1955. The Substation is equipped with
Fire Detection, Alarm & Suppression system which was installed under contract
CB/CSPD/2004 & commissioned on 2016. Battery Charger along with Battery backup
bank are also available.
The list of HT & LT Motors associated with this Unit is enclosed vide Appendix 2A
hereof. Motors rated above 280HP is designated as HT motor and if less than or equal to
280HP, as LT motor . Unit -08 has 2 nos. 6.6KV motors and 93 nos. 440V motors. All
motors are under Preventive Maintenance program by maintenance department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
The Unit-08 is powered from the Substation # 06 and the Single Line Diagram (SLD) for
SS # 06 is as follows (for details Refer Annexure-01, KNPC Sketch # SK-2434 Sheet 04
of 08);
Note: The Substations shared between different units and a table that shows the
association of different units to Substation shown in Appendix 1A - Refinery Overview.
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9.5 INSTRUMENTATION OVERVIEW
Isomax Unit Processes Vacuum gas oil & Isocracker Fractionation bottoms. It produces
light gases, Naptha, kerosene, Diesel Products.
9.5.5 Instrumentation System
a) DCS: Honeywell make TPS System installed in SIH #3, SIH # 10 & GUS
operating Stations in CCR
b) ESD System: Honeywell make Safety Manager System installed in SIH # 3, SIH #
10 & CCR.
c) FSC System: Honeywell make FSC system installed in SIH # 10 for ROIV
Controls.
d) List of ROIV’s in Isomax Unit
08-ROV-1000 C-08-01 Suction Line
08-ROV-1001 C-08-01 Discharge Line.
08-ROV-1002B P-08-04A Suction Line
08-ROV-1002B P-08-04B Suction Line
08-ROV-1003 P-08-11A/B Suction Line
e) Bently Vibration Monitoring System:
Bently Model 3500 Vibration and Temperature Monitoring & Trip Control for P-08-
01 feed pump to unit.
Bently model 3300 System for recycle gas compressor C-08-01
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f) PLC System:
Modicon PLC System installed in Local for feed pump P-08-01A interlock
control.
Siemens Make PLC system for feed filter control.
9.5.6 Critical Safety Interlocks and Controls
a) C-08-01 - Recycle gas compressor Interlock
b) C-08-02 - Splitter Naptha Gas Compressor Interlock.
c) C-08-02 - Woodwar Governor for speed control of Turbine
d) P-08-01A & HPRT – Interlock Control
e) H-08-01 & H-08-02 – Heater Interlock Control
9.5.7 Field Instrument List
SR # CATEGORY MAKE QTY REMARKS
1 O2 ANALYZER AMETEK – WDG2000 2
2 CONTROL VALVE FISHER / MASONEILAN / HONEYWELL /
SAMSON GERMANY / TYCO / VIRGO 79
3 CONTROLLER FOXBORO / YOKOGAWA / TAYLOR /
MASONEILAN 6
4 DISPLACER LT MASONEIAN / MAGNETROL 13
5 FLOW ELEMENT DANIEL / SAMIL 60
6 LEVEL GAUGE GLASS JERGUSON / PENBERTHY / K-TEK 35
7 LEVEL SWITCH MAGNETROL / MOORE / SOR / JERGUSON /
INTRA AUTOMATION 23
8 LOCAL INDICATOR ITT BARTON / BROOKS / KROHNE / WISE /
AMETEK 94
9 PLC SIEMENS (MOD # S7-200) / MODICON
QUANTUN SERIES 5
10 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL / AM
GAUGE 158
11 PRESSURE SWITCH UE / ASHCROFT / SOR / DELTA CONTROL 47
12 SOLENOID VALVE ASCO 61
13 THERMOWELL THERMO ELECTRIC / TECNOMATIC / TC
LTD 158
14 TRANSMITTER ROSEMOUNT / YOKOGAWA / HONEYWELL /
ABB / FOXBORO / SMAR 107
15 MISC HONEYWELL 83
16 VIBRATION BENTLY NEVADA SYSTEM – 3300 & 3500
SYSTEM 2
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10.0 UNIT – 09 OVERVIEW (Naphtha Fractionator Unit)
10.1 PROCESS OVERVIEW
10.1.1 Objective
Naphtha Fractionation Unit produces Naphtha as finished product and also prepares feed
stock for Naphtha Unifiners, Kero Unifiners and Merox unit by fractionation of full range
Naphtha from Crude Unit, Kero & Diesel Unifiners.It also provides circulating lean
Kerosene to Burgan Gas Unit-01 ( if required). Unit-09 also processes Refinery gas
streams recovering Butane & hexane hydrocarbons for absorption.
10.1.2 Capacity
The unit designed to process 65,000 BPD of Naphtha liquid and 17.5 MMSCFD of vapor.
10.1.3 Feed and Products
Refer to Tables 1 below
a) Table-1: Typical Material Balance
BPSD
Feed
Naphtha Liquid 65,000
Naphtha Gas 22.7 MMSCFD
Rich Oil -
Products
Naphtha 41,500
Kero Product 23,500
Lean Oil to Unit-01 -
LP Gas to Unit-14 / 61 20 MMSCFD
SOURCE / DESTINATION
From Unit-06 / 11 / 12 / 13
From Unit-06 / 07 / 08 / 68 / Unifiners
From Unit-01 ( Currently not in use )
To Unit-10 / Storage
To Unit-17 / Storage
To Unit-01 ( Currently not in use )
To Unit - 14 / C-61-01
10.1.4 Process Description
Naphtha liquid from Crude Unit, Kero and Diesel Unifiner and naphtha gases from Crude,
Isocracker, Iso-Max, Kero and Diesel Unifiners are all combined, cooled and received in
feed drum V-09-01 along with any gas condensate. The separated vapour joins L.P.
Flash gas streams from H-Oil & Iso-caraker Units, and is fed to L.P. Absorber V-09-06
where Heavy hydrocabons are recovered by absorption with lean Kerosene.
The liquid stream from V-09-01 joins Rich Kerosene stream from L.P. Absorber V-09-06,
then exchanges heat with splitter bottom stream in E-09-03. It is further heated by 150
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65
Psig steam in E-09-16. This combined stream is satbilized by removal of butane and
lighter gas in Debutanizer (V-09-08). The overhead gas from V-09-08 joins the lean low
presssure gas from V-09-06 and goes either to Amine Treatment Unit-14 or to C-61-01.
The debutanizer product is fed directly to splitter (V-09-09) for fractionation into Naphtha
and Kerosene streams. A part of Naphtha product goes directly to Napntha Unifiner and
balance is trim cooled in E-09-12 and sent to the Naphtha stroage tank.
The bottom Kerosene stream after heat exchange with debutanizer feed in E-09-03, is
cooled in E-09-04 and part is routed to Kero Unifiner and partly to V-09-06 as lean oil.
In Feb 2011 new facility was commissioned to desulfurize Naphtha product .The facility
involve a fixed bed of ZnO installed in the redundant vessel V-17-05. A slip stream of
Naphtha product from U-09 is routed to this Zinc oxide bed where part of H2S in the
Naphtha is absorbed .Subsequently the treated Naphtha stream joins the rest of
Naphtha product routed to storage.
10.1.5 Brief History
Major debottlenecking to increase the capacity from 38.7 KBPD to 65 KBPD year 1974
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66
10.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-09 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Exchangers 17
2 Air Coolers 03
3 Vessels 10
4 Heaters 01
5 PSVs 16
10.3 ROTATING OVERVIEW
Unit 09 – This Unit prepares Feedstock for Naphtha Kero Unifiners Merox Unit by
fractionation of full range of Naphtha from Crude unit, Kerosene and Diesel Unifiners &
recovering Butane and heavier hydrocarbons by absorption.
All the Rotating equipment in 09 unit are inspected and maintained as per the guidelines
of Process Licensor & good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 09 has 24 Pumps, 60 Fin fans, 1 steam turbine. List of Rotating Equipment are
furnished vide Appendix 2A hereof.
Most of the Critical pumps packings converted to mechanical seals to the spirit of API
682 to prevent Gas leakage to environment.
Pump/Compressor/Turbine package auxiliary items (filters, SO/LO Coolers, Gearboxes,
Seals, Couplings, Piping items etc.) are not included in the list. Bidders can collect
relevant details of maintenance records, healthiness of the equipment and inspection
records during PTM/Site visit.
10.4 ELECTRICAL OVERVIEW
Unit -09 is considered as classified area (Class 1 Div. 2 Group D) as per Shuaiba
Refinery Hazardous Area Classification drawing (refer drawing # R-00-6030). The source
of power to the Unit is aided from Substation 04 which is located south side of the Unit.
The substation is Building with Basement Type & facilitated as non-classified area by
employing pressurized / Air conditioned systems. Substation has 3 nos. of “6.6kV”
Switchgears (4A, 4B & 4C) fed from SS1A & SS1B (ref. drawing # R-00-6012), 9 nos. of
“440V” MCC (MCC-4A, MCC-4B, MCC-4C, MCC-4D, MCC-4E, MCC-4F, MCC-4G, MCC-
4H & MCC-4J), 9 nos. of power transformers (1MVA, 6.6kV/440V) and 4 nos. of
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67
Emergency panel (EDB-01-01). The “6.6kV” Switchgears 4C were replaced completely
with latest new ABB panels during GRTA-2011 under contract CS/1955. The Substation
is equipped with Fire Detection, Alarm & Suppression system which was installed under
contract CB/CSPD/2004 & commissioned on 2016. Battery Charger along with Battery
backup bank are also available.
The list of HT & LT Motors associated with this Unit is enclosed vide Appendix 2A
hereof. Motors rated above 280HP is designated as HT motor and if less than or equal to
280HP, as LT motor . Unit -09 has 5 nos of 6.6KV motors and 78 nos. 440V motors. All
motors are under Preventive Maintenance program by maintenance department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
The Unit-09 is powered from the Substation # 04 and the Single Line Diagram (SLD) for
SS # 04 is as follows (for details Refer Annexure-01, KNPC Sketch # SK-2434 Sheet 01
of 08);
Note: The Substations shared between different units and a table that shows the
association of different units to Substation shown in Appendix 1A - Refinery Overview.
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10.5 INSTRUMENTATION OVERVIEW
Unstabilized Naptha Vapor & Liquid streams provided in other units like 06, 07, 08, 68,
11, 12 & 13 are processed in Unit – 09 to produce stabilized Naptha and Kerosene
feedstock for Unifiners. Unit aslo supplies Lean oil to Burgan Gas Unit – 01 and feed to
Kerosene Merox Unit – 17.
10.5.1 Instrumentation System
a) DCS: Honeywell make TPS System installed in SIH # 7, SIH # 10 & GUS
operating Stations in CCR.
b) ESD System: Honeywell make Safety Manager System installed in SIH # 7, SIH #
10 & CCR.
c) FSC System: Honeywell make FSC system for ROIV Control in unit.
10.5.2 Critical Safety Interlocks and Controls
a) 09-ROIV-1000, 09-ROIV-1001, 09-ROIV-1002, 09-ROIV-1003, 09-ROIV-1004, 09-
ROIV-1005, 09-ROIV-1006, and 09-ROIV-1007, interlock Control.
b) P-09-09A/B Interlock
c) P-09-014A/B – Naptha Splitter Pump Interlock.
d) H-09-01 – Debutanizer Reboiler Heater trip Interlock & Control.
e) V-09-01 – Naptha Feed Surge Drum Control.
f) V-09-06 – LP Absorber Pressure Level Control.
10.5.3 Field Instrument List
SR # CATEGORY MAKE QTY REMARKS
1 O2 ANALYZER YOKOGAWA-ZR 402 1
2 CONTROL VALVE / ROV FISHER / MASONEILAN / TYCO / BETTIS 42
3 CONTROLLER FOXBORO / YOKOGAWA 3
4 DISPLACER LT MASONEILAN / MAGNETROL 10
5 FLOW ELEMENT DANIEL / SAMIL 29
6 FLOW SWITCH FCI – FR70 (THERMAL FLEX SWITCH) 4
7 LEVEL GAUGE GLASS JERGUSON / PENBERTHY / K-TEK 21
8 LEVEL SWITCH MAGNETROL 2
9 LOCAL INDICATOR ITT BARTON / BROOKS / KROHNE / WISE /
AMETEK 32
10 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL / AM
GAUGE 100
11 PRESSURE SWITCH UE / ASHCROFT / SOR 18
12 SOLENOID VALVE ASCO 21
13 THERMOWELL THERMO ELECTRIC / TECNOMATIC / TC LTD 66
14 TRANSMITTER ROSEMOUNT / YOKOGAWA / HONEYWELL /
ABB / FOXBORO / SMAR 44
15 MISC HONEYWELL 32
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11.0 UNIT – 10 OVERVIEW (Naphtha Unifiner Unit)
11.1 PROCESS OVERVIEW
11.1.1 Objective
The Naphtha unifiner serves primarily to make a Naphtha feed suitable for the catalytic
Reforming Unit by removing sulfur and traces of Nitrogen and other poisons to Reforming
catalyst. The unit has reaction and distillation sections.
Hydrogenation reactions occurring in the Reactor are:
11.1.2 Capacity
The unit design capacity is 26060 BPD. It yields approximately 68% Naphtha as reformer
feed stock and 27% as Light Naphtha product. Hydrogen consumption is approximately
200 SCF/BBL.
11.1.3 Feed and Products
Feed to the Naphtha Unifiner is from the following sources:
a) Naphtha Fractionation Unit
b) Isomax
c) Isocracker
d) Kerosene Unifiner
The process scheme is shown in the Sketch -1
Typical Material Balance and feed/products specification are shown in the following table
– 1 & 2.
a) Table-1: Typical Material Balance
BPSD % VOL. SOURCE / DESTINATION
Feed 26000 100 From Units 68/08/09/11
Products
Light Naphtha (Dehex. O/H) 7070 27.19% To storage Heavy Naphtha (Dehex. Btm) 18052 69.43% To storage
Total Liquid Product 25122 96.62%
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b) Table-2 : Typical Feed & Product Qualities
SPEC. FEED Dehexaniser Dehexaniser
Overhead Bottom
Gravity API 67.40 82.89 59.15 Sulfur PPM / % wt. 500 <1 < 1.0 Nitrogen, PPM 330 <1 <1 Dist. Range , Deg. F EP 318 100 - 200 210 - 328
PONA : Paraffins 71.8 60.5 Olefins 0 0 Naphthenes 22.5 31.1 Aromatics 5.7 8.4
PRODUCTS
11.1.4 Process Description
Naphtha Unifiner feed (C5-350oF Naphtha) from various units is pumped and preheated
through a Reactor Effluent-Feed Exchanger and a Fired Heater (vapor phase) into the
top of the Reactor, V-10-01, currently loaded with N-21 catalyst. Hydrogen rich gas from
Catalytic Reformer (export) is compressed by C-10-01A/B,
1st stage, and mixed with the feed stream, upstream of the Reactor Effluent Feed
Exchanger. The Reactor Effluent after hydrotreatment is further cooled in the Effluent
Feed Exchanger, Air cooler and a Water Trim cooler before flowing into the H.P.
Separator, V-10-02.The Hydrogen rich vapors from the H.P. Separator are compressed
again with C-10-01 A/B 2nd & 3rd Stage of the compressor as export bleed gas to the
Unifiners. Hydrogen Sulfide and light hydrocarbons (mainly gases) are released from the
Separator liquid in a Flash Drum V-10-03.
The vapors from the Flash Drum is routed combined with the Stabilizer overhead gas.
The liquid in the Drum is pumped out to the E-10-15 Exchanger then through the
stabilizer feed bottoms Exchanger E-10-07, into the Stabilizer V-10-04.
Stabilizer overhead vapors are condensed in an Air Cooler and a Water Trim Cooler and
flow into an Accumulator V-10-05. The vapors from the Accumulator (butanes and lighter
Gases) along with gas from the Flash Drum are routed to the Amine Unit low pressure
Absorber. The liquid from the Accumulator is returned to the stabilizer as total reflux.
Stabilizer bottoms flow through E-10-07 Exchanger to the Dehexanizer V-10-06. The
Dehexanizer overhead vapors are condensed in an air cooler and flow into an
Accumulator. Part of the Accumulator liquid is pumped back as reflux, the excess is
pumped through Water Trim Cooler to storage as C5/C6 product (Light Naphtha).
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72
Dehexanizer bottoms (Heavy Naphtha) are cooled by pumping through an Air Cooler and
routed to Catalyticfeed. The excess product is further cooled in a Water Cooler and
routed to storage.
11.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-10 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Exchangers 17
2 Air Coolers 04
3 Vessels / Tanks 13
4 Heaters 01
5 Reactor 01
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6 Filters 02
7 PSVs 34
11.3 ROTATING OVERVIEW
Unit 10 – The Naphtha unifiner serves primarily to make a Naphtha feed suitable for
catalytic Reforming by removing sulfur and traces of Nitrogen and other poisons. It has
reaction & distillation sections.
All the Rotating equipment in unit-10 are inspected and maintained as per the guidelines
of Process Licensor & good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 10 has 16 Pumps, 44 Fin fans & 2 compressors. List of Rotating Equipment are
furnished vide Appendix 2A hereof.
C-10-01 A/B has the flexibility of using high Pressure Stages for compressing fluid.
Pump/Compressor package auxiliary items (filters, SO/LO Coolers, Gearboxes, Seals,
Couplings, Piping items etc.) are not included in the list. Bidders can collect relevant
details of maintenance records, healthiness of the equipment and inspection records
during PTM/Site visit.
11.4 ELECTRICAL OVERVIEW
Unit -10 is considered as classified area (Class 1 Div. 2 Group D) as per Shuaiba
Refinery Hazardous Area Classification drawing (refer drawing # R-00-6030). The source
of power to the Unit is aided from Substation 5A which is located south side of the Unit.
The substation is Building with Basement Type & facilitated as non-classified area by
employing pressurized / Air conditioned systems. Substation has a “6.6kV” Switchgears
fed from SS1A & SS1B (ref. drawing # R-00-6012), 3 nos. of “440V” MCC (MCC-A, MCC-
B & MCC-C), 3 nos. of power transformers (1MVA, 6.6kV/440V) and an Emergency
panel. The “6.6kV” Switchgear was replaced completely with latest new ABB panels
during GRTA-2011 under contract CS/1955. The Substation is equipped with Fire
Detection, Alarm & Suppression system which was installed under contract
CB/CSPD/2004 & commissioned on 2016. Battery Charger along with Battery backup
bank are also available.
The list of HT & LT Motors associated with this Unit is enclosed vide Appendix 2A
hereof. Motors rated above 280HP is designated as HT motor and if less than or equal to
280HP, as LT motor. Unit -10 has 4 nos of 6.6KV motors and 61 nos. 440V motors. All
motors are under Preventive Maintenance program by maintenance department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
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74
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
The Unit-10 is powered from the Substation # 05A and the Single Line Diagram (SLD) for
SS # 05A is as follows (for details Refer Annexure-01, KNPC Sketch # SK-2434 Sheet
02 of 08);
Note: The Substations shared between different units and a table that shows the
association of different units to Substation shown in Appendix 1A - Refinery Overview.
11.5 INSTRUMENTATION OVERVIEW
Unit – 10 prepares feed stuck for Unit – 05. Feed from Unit – 10 is supplied from
Isocracker, Isomax & Naptha fractionation Units.
11.5.1 Instrumentation System
a) DCS SYSTEM: Honeywell make TPS System installed in SIH #6, SIH # 10 & &
GUS operating Stations in CCR
b) ESD SYSTEM: Honeywell make Safety Manager System installed in SIH # 6, SIH
# 10 & CCR.
11.5.2 Critical Safety Interlocks and Controls
a) Reactor V-10-01 - Pressure Control.
b) Reactor V-10-01 – Temperature Control.
c) Compressor C-10-01 A/B Interlock.
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d) Feed Pump P-10-01 Interlock.
e) Heater H-10-01 Interlock
11.5.3 Field Instrument List
SR # CATEGORY MAKE QTY REMARKS
1 H2 ANALYZER ABB-PGC VISTA 2000 1
2 CONTROL VALVE MASONEILAN / MESTO /VALTEK UK 26
3 CONTROLLER FOXBORO 2
4 DISPLACER LT MASONEILAN / MAGNETROL 9
5 FLOW ELEMENT DANIEL / SAMIL 20
6 FLOW SWITCH ITT BARTON 1
7 LEVEL GAUGE GLASS JERGUSON / PENBERTHY / K-TEK 27
8 LEVEL SWITCH MAGNETROL / MOORE / SOR 11
9 LOCAL INDICATOR ITT BARTON / BROOKS / KROHNE / WISE /
AMETEK 28
10 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL / AM
GAUGE 120
11 PRESSURE SWITCH UE / ASHCROFT / SOR 13
12 SOLENOID VALVE ASCO 6
13 THERMOWELL THERMO ELECTRIC / TECNOMATIC / TC LTD 96
14 TRANSMITTER ROSEMOUNT / YOKOGAWA / HONEYWELL /
ABB / FOXBORO / SMAR 41
15 ANNUNCIATOR PANEL RONNAN 1
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12.0 UNIT – 11 OVERVIEW (Kerosene Unifiner Unit)
12.1 PROCESS OVERVIEW
12.1.1 Objective
The objective of this Unit is to upgrade Crude Raw kerosene from Crude Unit along with
H-Oil Cracked Naphtha & Kerosene distillates to meet Kerosene and Jet fuel products
specification suitable for marketing.
Kerosene Hydro treatment is carried out using Hydrogen in the presence of a catalyst in
Reactor whereby Nitrogen and Sulfur compounds are converted to Ammonia and
Hydrogen Sulfide. Simultaneously undesirable aromatic hydrocarbons are converted to
saturates.
12.1.2 Feed and Products
The design capacity of the Unit is 34,250 BPSD. However, the present operating capacity
of the unit is 35,000 BPSD.
Material Balance & Feed, Product Qualities is shown in table-1&2
a) Table-1: Typical Material Balance
BPSD % VOL. SOURCE / DESTINATION
Feed 35000 100 From Units 06/07/09
Products
Naphtha 2900 8.3% To Unit 09 Flash Blending Stock 1500 4.3% To Unit 10 or storage Combined Stream 19500 55.7% To storage
Heavy Kerosene 11000 31.4% To storage
Total Liquid Product 34900 99.7%
b) Table-2 : Typical Feed & Product Qualities
Spec. Feed Naphtha JP - 1 Heavy
Kerosene
Gravity API 45.3 59.3 46.8 41.6 Sulfur PPM / % wt. - / 0.56 160 22 30 Nitrogen, PPM 100 - 150 < 1,0 <1,0 Dist. Range , Deg. F EP 560 116 - 404 322 - 482 466 - 570 Flash Point , Deg. F -- 130 222 Smoke Point , MM 22 -- 25 25 Pour Point , Deg. F -- -- < (-) 24 < (-) 20 Freezing Point , Deg C -- -- ( - ) 51 ( - ) 17
PRODUCTS
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12.1.3 Process Description
The process scheme is shown in the Sketch -1
Kerosene feed is preheated in the Effluent Feed Exchanger followed by final heating in
the Fired Heater H-11-05, mixed with preheated Hydrogen Recycle Gas and flows
through reactor ( currently loaded with Albemarle Graded type catalyst). The Reactor
effluent is cooled in the exchanger series, Effluent/Feed, Effluent/Hydrogen,
Effluent/Stabilizer Feed and Air Cooled Exchangers before flowing into the Separator V-
11-03.
The Hydrogen rich gas from the Separator is recycled to the reactor section by a
Centrifugal Compressor (C-12-01 / C-12-02) common to Kerosene and Diesel Unifiners.
Recycle gas is preheated in an Effluent/Hydrogen Exchanger. It is further heated in a
Fired Heater H-11-04 and joins with preheated hydrocarbon feed to the Reactors. Part of
the Recycle Gas is used as quench Hydrogen in the Reactor.
The hydrocarbon liquid from the Separator is depressured into a Flash Drum V-11-04.
The flash gas containing H2S is sent to Amine Unit.
The liquid from the Flash Drum is fed into the Stabilizer, V-11-05, after preheating in E-
11-04 & E-11-29. The Stabilizer overhead vapors are partially condensed in an Air Cooler
and flow into Accumulator, V-11-06. Naphtha gas from Overhead accumulator is routed
to Naphtha Fractionation Unit (U-09) The Accumulator Liquid Naphtha is returned to V-
11-05 as reflux and the excess is sent to U-09.
Stabilizer bottoms flow to the Fractionator V-11-07, where Flash Blending Stock is taken
as overhead. Flash blending stock can be blended as per the flash requirement either in
Combined stream as JP-1 product or diverted to U-10 or directly to Naphtha pool.
Light Kerosene base stock is drawn from the Fractionator as a side stream. It passes
through a kerosene side Stripper V-11-08 for flash point control.
Fractionator bottoms flow to the splitter V-11-10, where ATK base stock is taken as
overhead. Antioxidant is injected into Combined Stream (blend of FBS, Light Kerosene &
ATK) JP-1 or JP-5 product before it is finally sent to storage.
Part of the Splitter bottoms are circulated through a reboiler heater (H-11-06) to provide
heat for the Splitter. The bottoms product stream is pumped through an Air Cooler and a
Water Trim Cooler to storage as Heavy Kerosene, a Diesel Blending component.
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12.1.4 Brief History
a) 2 reactors were replaced with a single reactor.
b) HPRT installed for feed Pump P-11-01.
c) New heat exchanger E-11-29 installed to reduce load on Stabilizer Reboiler H-11-
01.
12.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-11 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Exchangers, Shell & Tubes 19
2 Air Coolers 08
3 Vessels / Tanks 15
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4 Heaters 05
5 Reactor 01
6 Filters 04
7 PSVs 33
12.3 ROTATING OVERVIEW
Unit 11 – Unit Upgrade raw kerosene distillates to produce specification products suitable
for marketing as kerosene and jet fuel.
All the Rotating equipment in 11 unit are inspected and maintained as per the guidelines
of Process Licensor & good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 11 has 30 Pumps, 41 Fin fans, 4 Turbines & 2 Mixers. List of Rotating Equipment
are furnished vide Appendix 2A hereof.
Critical pumps packings converted to mechanical seals to the spirit of API 682 to prevent
Gas leakage to environment.
Pump/Compressor/Turbine package auxiliary items (filters, SO/LO Coolers, Gearboxes,
Seals, Clutches, Couplings, Piping items etc.) are not included in the list. Bidders can
collect relevant details of maintenance records, healthiness of the equipment and
inspection records during PTM/Site visit.
12.4 ELECTRICAL OVERVIEW
Unit -11 is considered as classified area (Class 1 Div. 2 Group D) as per Shuaiba
Refinery Hazardous Area Classification drawing (refer drawing # R-00-6030). The source
of power to the Unit is aided from Substation 04 which is located south-east side of the
Unit. The substation is Building with Basement Type & facilitated as non-classified area
by employing pressurized / Air conditioned systems. Substation has 3 nos. of “6.6kV”
Switchgears (4A, 4B & 4C) fed from SS1A & SS1B (ref. drawing # R-00-6012), 9 nos. of
“440V” MCC (MCC-4A, MCC-4B, MCC-4C, MCC-4D, MCC-4E, MCC-4F, MCC-4G, MCC-
4H & MCC-4J), 9 nos. of power transformers (1MVA, 6.6kV/440V) and 4 nos. of
Emergency panel (EDB-01-01). The “6.6kV” Switchgears 4C were replaced completely
with latest new ABB panels during GRTA-2011 under contract CS/1955. The Substation
is equipped with Fire Detection, Alarm & Suppression system which was installed under
contract CB/CSPD/2004 & commissioned on 2016. Battery Charger along with Battery
backup bank are also available.
The list of HT & LT Motors associated with this Unit is enclosed vide Appendix 2A
hereof. Motors rated above 280HP is designated as HT motor and if less than or equal to
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80
280HP, as LT motor. Unit -11 has a 6.6KV motors and 67 nos. 440V motors. All motors
are under Preventive Maintenance program by maintenance department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
The Unit-11 is powered from the Substation # 04 and the Single Line Diagram (SLD) for
SS # 04 is as follows (for details Refer Annexure-01, KNPC Sketch # SK-2434 Sheet 01
of 08);
Note: The Substations shared between different units and a table that shows the
association of different units to Substation shown in Appendix 1A - Refinery Overview.
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12.5 INSTRUMENTATION OVERVIEW
The unit processes Kerosene streams to produce ATK & Lamp Kerosene products. Feed
is supplied from crude distillation unit, Naptha fraction unit, H-Oil unit.
12.5.1 Instrumentation System
a) DCS SYSTEM: Honeywell make TPS System installed in SIH #6, SIH # 10 & &
GVS operating Stations in CCR
b) ESD SYSTEM: Honeywell make Safety Manager System installed in SIH # 6, SIH
# 10 & CCR.
12.5.2 Critical Safety Interlocks and Controls
a) Feed pump P-11-01 Trip Interlock on Kerosene feed flow low or Recycle gas flow low or Lube oil pressure low.
b) H-11-02 - Trip Interlock & Control Logic
c) H-11-03 - Trip Interlock & Control Logic
d) H-11-04 - Trip Interlock & Control Logic
e) H-11-05 - Trip Interlock & Control Logic
f) H-11-06 - Trip Interlock & Control Logic
g) MOV-11-01 - Open / Close command & Interlock
12.5.3 Field Instrument List
SR # CATEGORY MAKE QTY REMARKS
1 ANALYZER (FLUE GAS
02 & H2S) ROSEMOUNT / YOKOGAWA 4
2 CONTROL VALVE FISHER / MASONEILAN / HONEYWELL /
SAMSON GERMANY / TYCO / VIRGO 45
3 CONTROLLER FOXBORO / YOKOGAWA / TAYLOR /
MASONEILAN 4
4 DISPLACER LT MASONEIAN / MAGNETROL 10
5 FLOW ELEMENT DANIEL / SAMIL 61
6 FLOW SWITCH ITT BARTON 1
7 LEVEL GAUGE GLASS JERGUSON / PENBERTHY / K-TEK 23
8 LEVEL SWITCH MAGNETROL / MOORE / SOR / JERGUSON /
INTRA AUTOMATION 2
9 LOCAL INDICATOR ITT BARTON / BROOKS / KROHNE / WISE /
AMETEK 72
10 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL / AM
GAUGE 188
11 PRESSURE SWITCH UE / ASHCROFT / SOR / DELTA CONTROL 12
12 SOLENOID VALVE ASCO 9
13 THERMOWELL THERMO ELECTRIC / TECNOMATIC / TC
LTD 124
14 TRANSMITTER ROSEMOUNT / YOKOGAWA / HONEYWELL /
ABB / FOXBORO / SMAR 73
15 MISC(LIMIT
SWITCH/PROXIMITY SWITCH ETC..)
HONEYWELL 2
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13.0 UNIT – 12 OVERVIEW (Light Diesel Unifiner Unit)
13.1 PROCESS OVERVIEW
13.1.1 Objective
Upgrade Diesel stocks (from Crude unit) in the high pressure Diesel Unifiner by removal
of Sulfur and Nitrogen compounds and saturating aromatics. H-oil Diesel component are
also upgraded in this as per the defined scenario.
13.1.2 Capacity
The design capacity of the Unit is 12600 BPSD. At present, unit is operating at 17000
BPSD feed rate.
13.1.3 Feed and Products
Material Balance & Feed, Product Qualities is shown in table-1&2
a) Table-1: Typical Material Balance
BPSD % VOL. SOURCE / DESTINATION
Feed 17000 100 From Units 06/07
Products
Naphtha 220 1.29% To Unit 09 Splitter Overhead 7900 46.47% To Storage Splitter Bottoms 9540 56.12% To Storage
Total Liquid Product 17660 103.88%
b) Table-2 : Typical Feed & Product Qualities
Spec. Feed Naphtha Splitter Splitter
Overhead Bottom
Gravity API 26.30 51.89 33.09 31.11 Sulfur PPM / % wt. - / 2.29 260 93 300 Nitrogen, PPM 773 162 336 Dist. Range , Deg. F EP 825 98 - 456 444 - 692 615 - 835 Flash Point , Deg. F -- -- 200 > 230 Pour Point , Deg. C 12 -- (-) 6 21 Asphaltenes -- -- 0.0018 0.0022
PRODUCTS
-
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13.1.4 Process Description
The process scheme is shown in the Sketch -1
Diesel feed is pumped through the Effluent – Feed Exchanger into the Reactor V-12-01
which is loaded with HDS catalyst (currently, Albemarle Graded type). The recycle gas
from compressors discharge (C-12-01 or C-12-02) is heated through Effluent Heat
Exchanger (E-12-02) and subsequently Heater H-12-01 and then mixes with the liquid
feed going to the Reactor. The Reactor effluent is cooled in the effluent – hot feed,
stabilizer feed – Recycle Gas, cold feed Exchangers and air cooler and then flows into
the separator, V-12-02.
The Hydrogen rich gas phase in the Separator, along with makeup Hydrogen (from H-Oil,
08 & 10) is recycled to the reactor by a centrifugal compressor(s) common to the
Kerosene and Diesel Unifiners. The advantage of having two compressors C-12-01 and
C-12-02 is to give more flexibility of shutting down and start up for units 11, 12, 13. Part
of the recycle is used as quench Hydrogen in the Reactor. The hydrocarbon bottoms
from the Separator are routed into the Flash Drum V-12-03. The flash drum off gas (from
V-12-03) is sent to the Amine Unit.
The bottoms from the Flash Drum are preheated by Splitter bottoms and Reactor effluent
streams before they flow into the stabilizer (V-12-04). The Stabilizer overhead vapors
flow through an Air Cooler into the overhead drum.
The overhead liquid (unstabilized naphtha) is used as reflux and the excess is pumped to
the Naphtha Fractionation Unit. Vapors from the overhead drum are also sent to Unit-09.
Stabilizer bottoms are pumped to the splitter and the incremental heat is supplied to
Splitter by a fired heater (H-12-04). Overhead vapors from the splitter are condensed in
air cooler E-12-09 and flow into an accumulator. The accumulator liquid is used as reflux,
and the excess after cooling is pumped to storage as Light Diesel base stock.
The splitter bottoms are recirculated through a fired reboiler. (H-12-03)
A bottoms stream is drawn off at the pump discharge, cooled in two water trim coolers /
Fin fan cooler, and sent to storage as Diesel.
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13.1.5 Brief History
a) V-12-01 was replaced in the year 2006.
b) C-12-02 new compressor was installed in the year 2006
c) E-12-04 shell and Tube exchanger was replaced with Breach Lock type
exchanger.
d) H-12-01 radiant and convection sections, H-12-03 Convection, and tube section
metallurgy changed.
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13.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-12 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Heat Exchangers, Shell & Tubes 21
2 Air Coolers 04
3 Vessels / Tanks / Drums 20
4 Heaters 03
5 Reactor 01
6 Filters 13
7 PSVs 16
13.3 ROTATING OVERVIEW
Unit 12 – Diesel stocks being improved in the high-pressure Diesel unifiner by removal of
sulfur and nitrogen compounds.
All the Rotating equipment in 12 unit are inspected and maintained as per the guidelines
of Process Licensor & good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 12 has 20 Pumps, 18 Fin fans, 4 Steam Turbines & 2 compressors. List of Rotating
Equipment are furnished vide Appendix 2A hereof.
Recycle Gas compressor C-12-02 installed in 2008, which can operates three unifiners
(11/12/13) & independent units. Critical pumps packings converted to mechanical seals
to the spirit of API 682 to prevent Gas leakage to environment.
Pump/Compressor/Turbine package auxiliary items (filters, SO/LO Coolers, Gearboxes,
Seals, Clutches, Couplings, Piping items etc.) are not included in the list. Bidders can
collect relevant details of maintenance records, healthiness of the equipment and
inspection records during PTM/Site visit.
13.4 ELECTRICAL OVERVIEW
Unit -12 is considered as classified area (Class 1 Div. 2 Group D) as per Shuaiba
Refinery Hazardous Area Classification drawing (refer drawing # R-00-6030). The source
of power to the Unit is aided from Substation 04 which is located south-east side of the
Unit. The substation is Building with Basement Type & facilitated as non-classified area
by employing pressurized / Air conditioned systems. Substation has 3 nos. of “6.6kV”
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Switchgears (4A, 4B & 4C) fed from SS1A & SS1B (ref. drawing # R-00-6012), 9 nos. of
“440V” MCC (MCC-4A, MCC-4B, MCC-4C, MCC-4D, MCC-4E, MCC-4F, MCC-4G, MCC-
4H & MCC-4J), 9 nos. of power transformers (1MVA, 6.6kV/440V) and 4 nos. of
Emergency panel (EDB-01-01). The “6.6kV” Switchgears 4C were replaced completely
with latest new ABB panels during GRTA-2011 under contract CS/1955. The Substation
is equipped with Fire Detection, Alarm & Suppression system which was installed under
contract CB/CSPD/2004 & commissioned on 2016. Battery Charger along with Battery
backup bank are also available.
The list of HT & LT Motors associated with this Unit is enclosed vide Appendix 2A
hereof. Motors rated above 280HP is designated as HT motor and if less than or equal to
280HP, as LT motor . Unit -12 has a 6.6KV motors and 33 nos. 440V motors. All motors
are under Preventive Maintenance program by maintenance department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
The Unit-12 is powered from the Substation # 04 and the Single Line Diagram (SLD) for
SS # 04 is as follows (for details Refer Annexure-01, KNPC Sketch # SK-2434 Sheet 01
of 08);
Note: The Substations shared between different units and a table that shows the
association of different units to Substation shown in Appendix 1A - Refinery Overview.
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13.5 INSTRUMENTATION OVERVIEW
The unit processes mixture of Hydrocarbons containing unsaturated components,
Aromatics, Sulphur and Nitrogen compounds to produce Light Diesel, Local Diesel and
unstabilized Naptha
13.5.1 Instrumentation System
a) DCS SYSTEM: Honeywell make TPS System installed in SIH #6, SIH # 10 & &
GVS operating Stations in CCR
b) ESD SYSTEM: Honeywell make Safety Manager System installed in SIH # 6, SIH
# 10 & CCR.
c) PLC SYSTEM: Allen Bradley make PLC System for C-12-02 Interlock control.
d) BENTLY VIBRATION SYSTEM: Bently make Temperature Vibration System for
C-12-02 Vibration Temperature Monitor
e) Woodward Speed Governor System: C-12-02 Turbine Speed Control.
13.5.2 Critical Safety Interlocks and Controls
a) H-12-01 - Trip Interlock & Control
b) H-12-02 - Trip Interlock & Control
c) H-12-03 - Trip Interlock & Control
d) H-12-04 - Trip Interlock & Control
e) MOV-1202 - Open / Close Command & Interlock
f) MOV-1203 - Open / Close Command & Interlock
g) C-12-01 - Trip Interlock
h) C-12-02 - Trip Interlock
i) Feed Pump P-12-01 Interlock Control
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13.5.3 Field Instrument List
SR # CATEGORY MAKE QTY REMARKS
1 02 & HYDROGEN
ANALYZER ABB-PGC VISTA 2000/ PANAMETRIC-TM02 /
TELEDYNE-3000 TB 3
2 CONTROL VALVE FISHER / MASONEILAN /
FARRIS USA 44
3 CONTROLLER FOXBORO / YOKOGAWA / TAYLOR /
MASONEILAN 6
4 DISPLACER LT MASONEIAN / MAGNETROL 13
5 FLOW ELEMENT DANIEL / SAMIL 45
6 FLOW SWITCH ITT BARTON 1
7 HMI SIEMENS 4
8 LEVEL GAUGE GLASS JERGUSON / PENBERTHY / K-TEK 19
9 LEVEL SWITCH MAGNETROL / MOORE / SOR / JERGUSON /
INTRA AUTOMATION 8
10 LOCAL INDICATOR ITT BARTON / BROOKS / KROHNE / WISE /
AMETEK 75
11 PLC ALLEN-BRADLEY / WOODWORD 5009 1
12 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL / AM
GAUGE 171
13 PRESSURE SWITCH UE / ASHCROFT / SOR / DELTA CONTROL 26
14 SOLENOID VALVE ASCO 16
15 THERMOWELL THERMO ELECTRIC / TECNOMATIC / TC
LTD 126
16 TRANSMITTER ROSEMOUNT / YOKOGAWA / HONEYWELL /
ABB / FOXBORO / SMAR 119
17 MISC HONEYWELL 37
18 VIBRATION BENTLY NEVADA- 3300 1
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14.0 UNIT – 13 OVERVIEW (Heavy Diesel Unifiner Unit)
14.1 PROCESS OVERVIEW
14.1.1 Objective
Upgrade Diesel stocks (Cracked H-oil Diesel component) are improved this Unit by
removing Sulfur and Nitrogen compounds and saturating aromatics. Crude raw Diesel
component are also upgraded in this as per the defined scenario.
14.1.2 Capacity
The design capacity of the Unit is 9300 BPSD. At present, unit is operating at 12000
BPSD feed rate.
14.1.3 Feed and Products
The feed to this Unit is mainly a mixture of heavy and light diesel cuts from H-Oil Unit (07)
and H-Oil Vacuum Unit (63) respectively. However, Light and Heavy Diesel from
Atmospheric Distillation Unit can also be included in the Feed.
Material Balance & Feed, Product Qualities is shown in table-1&2
a) Table-1: Typical Material Balance
BPSD % VOL. SOURCE / DESTINATION
Feed 12000 100 From Units 06/07
Products
Naphtha 130 1.08% Unit 09 Splitter Overhead 7510 62.58% Storage Splitter Bottom 4830 40.25% Storage
Total Liquid Product 12470 103.92%
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b) Table-2 : Typical Feed & Product Qualities
Spec. Feed Naphtha Splitter Splitter
Overhead Bottom
Gravity API 25.95 55.03 33.21 30.75 Sulfur PPM / % wt. - / 2.39 1000 100 200 Nitrogen, PPM 753 105 236 Dist. Range , Deg. F EP 820 106 - 424 434 - 698 630 - 830 Flash Point , Deg. F -- -- 216 > 230 Pour Point , Deg. C 12 -- (-) 6 24 Asphaltenes -- -- 0.004 0.008
PRODUCTS
14.1.4 Process Description
The process scheme is shown in the Sketch -1
Feed from charge tank is pumped to suction of feed booster pump P-13-01. Liquid feed
preheated by hot reactor effluent in E-13-01 & E-13-03. Recycle gas from C-12-01
discharge is also preheated in E-13-02 by exchanging heat with hot reactor effluent.
Water was injection facility is provided for E-13-03 to dissolve any accumulated
Ammonium Bisulfite salt which reflect in reduction of pressure drop across reactor
section.
The hot gas from the furnace combines with hot liquid feed at inlet to the Reactor V-13-
01 which is loaded with HDS (currently, Albemarle graded type) catalyst. The
temperature of the combined feed, controlled by firing in the heater, varies from 560-
620oF depending upon the product quality, rate of the feed stock and product
requirements.
The reactor effluent temperature varies from 620 to 720oF depending upon the feed
quality and gas/oil ratio of the combined feed. The effluent is cooled to about 150oF by
flowing through exchangers E-13-01, E-13-04, E-13-02, E-13-03 & E-13-05.
The level of liquid Hydrocarbon product is maintained by the level controller letting down
the liquid product to Flash Gas drum V-13-03.
Flash gas is sent to Amine unit. The liquid from flash drum is heated to 400-450oF by
splitter bottoms in E-13-07 and reactor effluent in E-13-04. Then it flows to the Stabilizer
V-13-04. The Naphtha and lighter components are removed overhead by stripping with
superheated Steam (from convection section of H-13-03).
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The overhead liquid and gas stream from the Stabilizer are sent to the Naphtha
Fractionation Unit (09). The degree of steam stripping is regulated for the flash point of
the overhead product from the Splitter.
The Splitter, V-13-06 is operated under vacuum with a two stage ejector on overhead
drum V-13-07. A Reboiler Heater (H-13-03) provides heat in the bottom section and heat
removed from the top by providing reflux V-13-07. The overhead product from this drum
after air cooling in E-13-10 is sent to Diesel storage. The bottom product after trim
cooling in E-13-11 is routed to Isocracker feed tank.
14.1.5 Brief History
a) Reactor V-13-01 was replaced in the year 1998
b) Splitter Tower V-13-06 was replaced in the year 2002
c) Trim cooler E-13-13 was provided to reduce Splitter Bottom product rundown
temperature.
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14.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-13 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Heat Exchangers 11
2 Air Coolers 05
3 Vessels 09
4 Heaters 02
5 Reactor 01
6 PSVs 17
14.3 ROTATING OVERVIEW
Unit 13 – Diesel stocks are improved in this unit by removing sulfur and Nitrogen
compounds and saturating aromatics.
All Rotating equipment in 13 Unit are inspected and maintained as per the guidelines of
Process Licensor & Good Engineering practices. Turn around schedules are fixed as per
these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 13 has 13 Pumps, 22 Fin fans, 1 Steam Turbines. List of Rotating Equipment are
furnished vide Appendix 2A hereof.
Critical pumps packings converted to mechanical seals to the spirit of API 682 to prevent
Gas leakage to environment.
Pump/Compressor/Turbine package auxiliary items (filters, SO/LO Coolers, Gearboxes,
Seals, Clutches, Couplings, Piping items etc.) are not included in the list. Bidders can
collect relevant details of maintenance records, healthiness of the equipment and
inspection records during PTM/Site visit.
14.4 ELECTRICAL OVERVIEW
Unit -13 is considered as classified area (Class 1 Div. 2 Group D) as per Shuaiba
Refinery Hazardous Area Classification drawing (refer drawing # R-00-6030). The source
of power to the Unit is aided from Substation 04 which is located south-east side of the
Unit. The substation is Building with Basement Type & facilitated as non-classified area
by employing pressurized / Air conditioned systems. Substation has 3 nos. of “6.6kV”
Switchgears (4A, 4B & 4C) fed from SS1A & SS1B (ref. drawing # R-00-6012), 9 nos. of
“440V” MCC (MCC-4A, MCC-4B, MCC-4C, MCC-4D, MCC-4E, MCC-4F, MCC-4G, MCC-
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95
4H & MCC-4J), 9 nos. of power transformers (1MVA, 6.6kV/440V) and 4 nos. of
Emergency panel (EDB-01-01). The “6.6kV” Switchgears 4C were replaced completely
with latest new ABB panels during GRTA-2011 under contract CS/1955. The Substation
is equipped with Fire Detection, Alarm & Suppression system which was installed under
contract CB/CSPD/2004 & commissioned on 2016. Battery Charger along with Battery
backup bank are also available.
The list of HT & LT Motors associated with this Unit is enclosed vide Appendix 2A
hereof. Motors rated above 280HP is designated as HT motor and if less than or equal to
280HP, as LT motor. Unit -13 has a 6.6KV motors and 33 nos. 440V motors. All motors
are under Preventive Maintenance program by maintenance department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
The Unit-13 is powered from the Substation # 04 and the Single Line Diagram (SLD) for
SS # 04 is as follows (for details Refer Annexure-01, KNPC Sketch # SK-2434 Sheet 01
of 08);
Note: The Substations shared between different units and a table that shows the
association of different units to Substation shown in Appendix 1A - Refinery Overview.
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14.5 INSTRUMENTATION OVERVIEW
Unit – 13 processes light as well as heavy diesel produced in Crude and H-oil Units to
reduce the Sulfur Content.
14.5.1 Instrumentation System
a) DCS: Honeywell make TPS System installed in SIH # 6, SIH # 10 & GUS
operating Stations in CCR.
b) ESD System: Honeywell make Safety Manager System installed in SIH # 6, SIH #
10 & CCR.
14.5.2 Critical Safety Interlocks and Controls
a) Feed Pump P-13-01 Interlock
b) Recycle Gas Heater H-13-01 Interlock & Control.
c) Splitter Reboiler H-13-03 Interlock & Control.
d) Oil Water Drum V-13-09 Control.
e) Reactor V-13-01 Bed Temperature Control
14.5.3 Field Instrument List
SR # CATEGORY MAKE QTY REMARKS
1 CONTROL VALVE FISHER / MASONEILAN 33
2 CONTROLLER FOXBORO / YOKOGAWA 6
3 DISPLACER LT MASONEILAN / MAGNETROL 9
4 FLOW ELEMENT DANIEL / SAMIL 24
5 LEVEL GAUGE GLASS JERGUSON / PENBERTHY / K-TEK 11
6 LEVEL SWITCH MAGNETROL 1
7 LOCAL INDICATOR ITT BARTON / BROOKS / KROHNE / WISE
/ AMETEK 32
8 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL /
AM GAUGE 87
9 PRESSURE SWITCH UE / ASHCROFT 6
10 SOLENOID VALVE ASCO 5
11 THERMOWELL THERMO ELECTRIC / TECNOMATIC / TC
LTD 69
12 TRANSMITTER ROSEMOUNT / YOKOGAWA /
HONEYWELL / ABB / FOXBORO / SMAR 46
13 MISC HONEYWELL 2
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15.0 UNIT – 14 OVERVIEW (Amine Treating Unit)
15.1 PROCESS OVERVIEW
15.1.1 Objective
Amine treating unit treats three separate gas streams for removing H2S & CO2
components. This whelps to prepare feed gas for Hydrogen Units & Fuel Gas systems.
Simultaneously unit recovers acid gas for Sulfur Plant feed.
15.1.2 Capacity
The Unit is designed to treat 48.7 MMSCFD of Burgan Gas, 57 MMSCFD of low pressure
Gas and 42 MMSCFD of High Pressure Flash Gas in three separate systems.
15.1.3 Feed and Products
Material Balance & Feed, Product Qualities is shown in table-1&2
a) Table-1: Typical Material Balance
MMSCFD
23 MMSCFD
40 MMSCFD
5 MMSCFD
30 MMSCFD
15 MMSCFD
22.5 MMSCFD
42.3 MMSCFD
37.0 MMSCFD
Acid Gas 11.2 MMSCFD
* : Total LP Refinery Gas is about 44 MMSCFD (30.0 MMSCFD to Unit-14 & 14.0 MMSCFD to C-61-01)
Products
LP Lean Gas to V-14-01 From KOC
To Refinery Fuel Gas To Sulfur Unit
Treated Refinery & LP Gas
Feed
LP Lean Gas to V-14-02 HP Flash Gas to V-14-03 HP Lean Gas to V-14-03 LP Refinery Gas to V-14-01 *
Treated Gas Treated HP Flash Gas & Lean Gas
From Refinery Units
To Hydrogen Unit To Hydrogen Unit
SOURCE / DESTINATION
From KOC
From KOC From Refinery Units
b) Table-2 : Typical Feed & Product Qualities
Specification
H2S % 0.1 6.0 17.0 6-10 PPM 3-5 PPM 40-80 PPM 92.0%
CO2% 2.2 - 0.7 < 0.2 - - 8.0%
Mol. Wt. 21 10.5 29.0 21.0 10.0 29.0 34.8
Treated LP
Gas Acid GasLP Lean Gas
HP Flash &
HP Lean Gas
LP Refinery &
Lean GasTreated Gas
Treated HP
Gas
FEED PRODUCTS
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15.1.4 Process Description
The process scheme is shown in the Sketch -1
Unit has three MEA Contactors. Each of the Amine Contactors has a gas feed at the
bottom and circulting Monoethanoalamine solution from the top. The contactors are
equipped with knockout drum. Overhead treated Gas is sent to other units as feed or
Fuel Gas.
V-14-01 Low Press Contactor, is fed with a mix of Refinery LP Gas from V-09-06, FGRU
recovered Flare Gas and H-Oil unit Naphtha gas and low pressure Flash Gases. The
treated low H2S Gas is sent to the Refinery Fuel Gas Drum, V-29-02.Recently a
modification was implemented in U-14. In this modification a slip stream of Burgan gas is
fed to V-14-01 (through V-29-04) to help reduce H2S content in Fuel gas. This
modification was commissioned in Aug 2010.
V-14-02 Medium Press Contactor, operating at ~ 150 psig is fed with compressed LP
Gas from first stage of Compressors, C-01-01 A/B. The treated gas from top of the
contactor is routed to the second stage of the compressor for further increase in pressure
to about 430 psi to be used as Hydrogen Plant feed.
V-14-03 Low Press Contactor, operating at about 430 psi, is fed with a mix of HP
Bleed/Flash Gases form H-Oil Unit, Unifiners and HP imported Gas from C-14-01 if
needed. The treated H2S free gas from top of the contactor is routed to the Hydrogen
Plant as supplementary feed.
The Rich MEA solution from Low & Medium Press contactors are flashed in V-14-01, and
them pumped out from the bottom to the Regenerators, V-14-04 A/B. The feed is
preheated by Regen Bottoms in E-14-03 A-D. Rich Amine is stripped of H2S with 50#
Steam reboilers.
Lean Amine is cooled in Fan cooler E-01’s and Water Coolers E-02”s and recycled to the
three Amine Contactors.
Acid Gas from the Amine Regenerators overhead is sent to the Sulfur Plant (04/74) for
Sulfur recovery.
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15.1.5 Brief History
a) V-14-01, V-14-09 vessels were replaced
b) Amine filtration facilities were enhanced by adding F-14-03 A/B and F-14-04 in the
year 1986.
c) New compressor C-14-01 was installed in the year 2002.
15.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-14 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Exchangers 21
2 Air Coolers 03
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3 Vessels / Tanks / Drums 20
4 Filters 16
5 PSVs 50
15.3 ROTATING OVERVIEW
Unit 14 – Treat three separate gas streams for removing H2S & CO2 components &
recovers acid gas for sulfur plant feed.
All the Rotating equipment in 14 unit are inspected and maintained as per the guidelines
of Process Licensor & good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 14 has 21 Pumps, 45 Fin fans, 12 Steam Turbines, 1 compressor & 1 Mixer. List of
Rotating Equipment are furnished vide Appendix 2A hereof.
Critical pumps packings converted to mechanical seals to the spirit of API 682 to prevent
Gas leakage to environment.
Pump/Compressor/Turbine package auxiliary items (filters, SO/LO Coolers, Gearboxes,
Seals, Clutches, Couplings, Piping items etc.) are not included in the list. Bidders can
collect relevant details of maintenance records, healthiness of the equipment and
inspection records during PTM/Site visit.
15.4 ELECTRICAL OVERVIEW
Unit -14 is considered as classified area (Class 1 Div. 2 Group D) as per Shuaiba
Refinery Hazardous Area Classification drawing (refer drawing # R-00-6030). The source
of power to the Unit is aided from Substation 04 which is located south side of the Unit.
The substation is Building with Basement Type & facilitated as non-classified area by
employing pressurized / Air conditioned systems. Substation has 3 nos. of “6.6kV”
Switchgears (4A, 4B & 4C) fed from SS1A & SS1B (ref. drawing # R-00-6012), 9 nos. of
“440V” MCC (MCC-4A, MCC-4B, MCC-4C, MCC-4D, MCC-4E, MCC-4F, MCC-4G, MCC-
4H & MCC-4J), 9 nos. of power transformers (1MVA, 6.6kV/440V) and 4 nos. of
Emergency panel (EDB-01-01). The “6.6kV” Switchgears 4C were replaced completely
with latest new ABB panels during GRTA-2011 under contract CS/1955. The Substation
is equipped with Fire Detection, Alarm & Suppression system which was installed under
contract CB/CSPD/2004 & commissioned on 2016. Battery Charger along with Battery
backup bank are also available.
The list of LT Motors associated with this Unit is enclosed vide Appendix 2A hereof.
Motors rated less than or equal to 280HP is designated as LT motor. Unit -14 has 60 nos.
of 440V motors. All motors are under Preventive Maintenance program by maintenance
department.
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102
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
The Unit-14 is powered from the Substation # 04 and the Single Line Diagram (SLD) for
SS # 04 is as follows (for details Refer Annexure-01, KNPC Sketch # SK-2434 Sheet 01
of 08);
Note: The Substations shared between different units and a table that shows the
association of different units to Substation shown in Appendix 1A - Refinery Overview.
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103
15.5 INSTRUMENTATION OVERVIEW
Amine Treating Unit Processes gas Streams for Unit – 01, 06, 07, 09, 29, 08, 10, 11, 12,
13, 68 HP Lean gas from KOC to remove entrained acid gases from the feed gas
streams. The recovered acid gas is routed to Sulfur recovery Unit.
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104
15.5.1 Instrumentation System
a) DCS: Honeywell make TPS System installed in SIH # 7, SIH # 10 & GUS
operating Stations in CCR.
b) ESD System: Honeywell make Safety Manager System installed in SIH # 7, SIH #
10 & CCR.
c) FSC System: Honeywell make FSC system for ROIV Control in unit.
d) PLC System: Duel Redundant Siemens make PLC System for Compressor C-14-
01 Interlock & Control.
15.5.2 Critical Safety Interlocks and Controls
a) 14-ROIV-1000 – Acid gas line Interlock Control.
b) C-14-01 – Compressor Interlock.
c) C-14-01 – Anti Surge Control & Interlock.
d) C-14-01 – Wood ward speed Governor Control.
e) C-14-01 – Bently make Vibration Monitoring System & Interlock control.
15.5.3 Field Instrument List
SR # CATEGORY MAKE QTY REMARKS
1 H2S/02 ANALYZER YOKOGAWA-GD40T / ABB-2000 VISTA 4
2 VIBRATION BENTLY-3500 2
3 CONTROL VALVE FISHER / MASONEILAN / Valtek UK/Virgo / Rotork
35
4 CONTROLLER FOXBORO / YOKOGAWA / TAYLOR /
MASONEILAN 16
5 DISPLACER LT MASONEILAN / MAGNETROL 11
6 FLOW ELEMENT DANIEL / SAMIL 46
7 HMI SIEMENS 5
8 LEVEL GAUGE GLASS JERGUSON / PENBERTHY / K-TEK 32
9 LEVEL SWITCH MAGNETROL 14
10 LOCAL INDICATOR ITT BARTON / BROOKS / KROHNE / WISE /
AMETEK 61
11 PLC WOODWARD - 5009 2
12 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL / AM
GAUGE 193
13 PRESSURE SWITCH UE / ASHCROFT / SOR / BOURDON
SEDEME 15
14 ROTAMETER BROOKS 6
15 SOLENOID VALVE ASCO 15
16 THERMOWELL THERMO ELECTRIC / TECNOMATIC / TC
LTD 39
17 TRANSMITTER ROSEMOUNT / YOKOGAWA / HONEYWELL
/ ABB / FOXBORO / SMAR 76
18 MISC HONEYWELL 51
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16.0 UNIT – 15 OVERVIEW (Ammonical Water Treating Unit)
16.1 PROCESS OVERVIEW
16.1.1 Objective
The Unit serves to strip out Ammonia and H2S from concentrated Ammonical Water produced in Unit – 15C and concentrated Foul Water produced in Unit – 06 foul water system.
16.1.2 Capacity
Unit capacity is 140 GPM.
16.1.3 Feed and Products
Material Balance & Feed, Product Qualities is shown in table-1&2
c) Table-1: Typical Material Balance
LBS/HR. % WT.
Feed Ammonical Water 72630 90.75 Condensate - H2O 7400 9.25
Total 80030 100.00
Products
Stripped Water 70420 87.99
Acid Gas (H2S) 3700 4.62
NH3 Gas 2280 2.85 Overhead liquid 3630 4.54
Total Product 80030 100.00
SOURCE / DESTINATION
Reuse a part & balance to effluent
To Sulfur Recovery Units
To flare / Sulfur Plants To TK-476
From TK-476
d) Table-2 : Typical Feed & Product Qualities
Composition / Spec Feed
NH3, % WT/ (PPM) 4.61 (50 PPM Max.) 270 PPM 90.89 35.13
H2S, % WT/ (PPM) 5.84 (10 PPM Max.) 99.54 5.85 11.70
H2O, % WT 89.55 99.99 0.43 3.26 53.17
PRODUCTS
Stripped
WaterAcid Gas (H2S) NH3 Gas
Overhead
Liquid
-
-
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16.1.4 Process Description
The process scheme is shown in the Sketch -1
Unit has two strippers. Most ( about 85%) of the feed H2S is stripped in H2S Stripper,
operating under higher pressure. In the subsequent lower pressure NH3 Stripper all the
remaining H2S and complete NH3 is stripped off.
In the feed system, the concentrated overhead Accumulator liquids from Unit-06 Foul
Water Stripper, V-06-09 and Unit-15C Ammonical Water concentrator, V-15-16 are
mixed and degassed to flare in V-15-19.The Degasser liquid is pumped by P-15-01A/B/S
to TK-476. From the tank TK-476, separated oil is skimmed to the Slop Oil System and
water is sent (using pump P-15-15) to Unit–15 Stripper Tower, V-15-04.
About 85% of the feed to H2S Stripper is heated in Exchangers, E-15-02 & E-15-03
before it is fed to the column on tray 18. The rest of 15% of the feed is fed to tray 22.
Also, a small amount of HP cold condensate is fed to the top tray 35 as reflux.
The heat required for stripping H2S from the feed is further supplemented by 150 psig
Steam Reboiler E-15-05.
The overhead cold almost pure H2S gas is routed to Sulfur Units 04/74 under pressure
control through a knock-out pot V-15-06.
The H2S Stripper bottom is routed to the NH3 Stripper V-15-07, through E-15-03. Hot H2S
Stripper bottom is heat exchanged in E-15-03, mainly to control the NH3 Stripper feed
temperature. Reboiler E-15-07, uses 150 psig steam to supply necessary heat for
stripping H2S/NH3 in the column. V-15-07 bottom is cooled through E-15-02. A stripped
water almost free of NH3 & H2S is obtained from NH3 Str. Bottom that is recycled partly
as injection water and the excess is routed to Effluent Treatment Plant located in MAB
refinery.
The overhead vapors are condensed in Air Fin Coolers E-15-08, and collected in V-15-
08, which is used partly as reflux to V-15-07 and the rest is recycled to TK-476 via
Degasser V-15-19. The non-condensed H2S/NH3 gases are routed to Sulfur Plants/Flare
under pressure control.
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16.1.5 Brief History
Tower V-15-04 was replaced in the year 2003.
16.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-15 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Exchangers 08
2 Air Coolers 02
3 Vessels, columns, tanks, drums 09
4 PSVs 13
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16.3 ROTATING OVERVIEW
Unit 15 – This Unit serves to strip out Ammonia and H2S from concentrated Ammonical
water produced in Unit 15C and concentrated Foul water produced in Unit 06 foul water
system.
All the Rotating equipment in 15 unit are inspected and maintained as per the guidelines
of Process Licensor & good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 07 has 30 Pumps, 8 Fin fans. List of Rotating Equipment are furnished vide
Appendix 2A hereof.
Most of the Critical pumps packings converted to mechanical seals to the spirit of API
682 to prevent Gas leakage to environment.
Pumps package auxiliary items (filters, SO/LO Coolers, Gearboxes, Seals, Couplings,
Piping items etc.) are not included in the list. Bidders can collect relevant details of
maintenance records, healthiness of the equipment and inspection records during
PTM/Site visit.
16.4 ELECTRICAL OVERVIEW
Unit -15 is considered as classified area (Class 1 Div. 2 Group D) as per Shuaiba
Refinery Hazardous Area Classification drawing (refer drawing # R-00-6030). The source
of power to the Unit is aided from three Substations, SS # 5A which is located south east
side of the Unit & SS # 5B which is located north east side of the Unit. The substation is
Building with Basement Type & facilitated as non-classified area by employing
pressurized / Air conditioned systems. The Substation is equipped with Fire Detection,
Alarm & Suppression system which was installed under contract CB/CSPD/2004 &
commissioned on 2016. Battery Charger along with Battery backup bank are also
available.
The list of LT Motors associated with this Unit is enclosed vide Appendix 2A hereof.
Motors rated less than or equal to 280HP is designated as LT motor. Unit-15 has 34 nos.
of 440V motors. All motors are under Preventive Maintenance program by maintenance
department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
The Unit-15 is powered from the Substation # 05A & 05B and the Single Line Diagram
(SLD) for SS # 05A & 05B is as follows (for details Refer Annexure-01, KNPC Sketch #
SK-2434 Sheet 02 & 03 of 08);
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Note: The Substations shared between different units and a table that shows the
association of different units to Substation shown in Appendix 1A - Refinery Overview.
16.5 INSTRUMENTATION OVERVIEW
Ammonical Water stripping unit processes ammonical water (sour water) to meet
environmental norms H2S and NH3 are removed from ammonical water by steam
stripping. Unit is feed by crude Unit – 06 & Unit – 15C.
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16.5.1 Instrumentation System
a) DCS: Honeywell make TPS System installed in SIH # 5, SIH # 10 & GUS
operating Stations in CCR.
b) ESD System: Honeywell make Safety Manager System installed in SIH # 5, SIH #
10 & CCR.
Note: ESD & DCS system in SIH # 5, SIH # 10 & CCR are not for sale and will be
retained to cater the requirement of remaining operating system in Shuaiba.
16.5.2 Critical Safety Interlocks and Controls
a) V-15-04 – Reboiler Feed flow / pressure control.
b) V-15-04 – Reboiler Temperature Control.
c) V-15-07 – Reboiler Temperature Control.
d) V-15-16 – Feed Flow (Hot & Cold) Control.
e) V-15-16 – Temperature, Pressure & Level Control.
16.5.3 Field Instrument List
SR # CATEGORY MAKE QTY REMARKS
1 O2 ANALYZER ROSEMOUNT-5081 1
2 CONTROL VALVE MASONEILAN 30
3 CONTROLLER FOXBORO 1
4 DISPLACER LT MASONEILAN / MAGNETROL 8
5 FLOW ELEMENT DANIEL 24
6 LEVEL GAUGE GLASS JERGUSON / PENBERTHY 23
7 LEVEL SWITCH MAGNETROL / MOORE / SOR 5
8 LOCAL INDICATOR ITT BARTON / BROOKS 50
9 PRESSURE GAUGE ASHCROFT / WIKA / WISE /
GENERAL / AM GAUGE 96
10 PRESSURE SWITCH UE 1
11 THERMOWELL THERMO ELECTRIC / TECNOMATIC /
TC LTD 56
12 TRANSMITTER ROSEMOUNT / YOKOGAWA /
HONEYWELL / ABB / FOXBORO / SMAR
32
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17.0 UNIT – 15C OVERVIEW (Sour Water Concentrator)
17.1 PROCESS OVERVIEW
17.1.1 Objective
This Unit prepares H2S/NH3 concentrated water stream from the various sour water
streams, for further processing in Unit-15.
17.1.2 Capacity
Unit capacity is 340 GPM.
17.1.3 Feed and Products
Material Balance & Feed, Product Qualities is shown in table-1&2
e) Table-1: Typical Material Balance
FEED & PRODUCTS LBS/HR. % WT.
Feed Ammonical Water 170000 87.46 Stripping Steam 24375 12.54
Total 194375 100.00
Products Stripped Water 148248 76.27 Overhead liquid 46127 23.73
Total Product 194375 100.00
To TK-476
SOURCE / DESTINATION
From TK-481
Reuse a part & balance to sea
f) Table-2 : Typical Feed & Product Qualities
NH3, % WT (PPM) 1.10
H2S, % WT (PPM) 2.01
H2O, % WT 96.89
COMPOSITION / SPECS. FEED
99.99
Stripped Water
(5 PPM Max.)
(20 PPM Max.) 4.05
7.37
88.58
Overhead Liquid
PRODUCTS
-
-
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17.1.4 Process Description
The process scheme is shown in the Sketch -1
Ammonical water streams from various Refinery Units are mixed, cooled with cooling
water in E-15-16A/B, degassed to Flare in V-15-01 and then pumped through P-15-
16A/B to tank TK-34-481 /TK 482
Oil and sludge separated in TK-481/TK 482 is pumped intermittently to Slop Oil System.
Pump P-34-22/22S takes suction from TK-481 and feeds Unit-15C through a filter F-15-
01 (Currently not in use). About 85% of this feed heated in Exchangers E-15-17A/B, by
means of Concentrator bottoms, (i.e. stripped water going to MAB ETF) and routed to the
top tray of the Concentrator Column V-15-16. The remaining 15% of the total feed is
routed as cold feed to the Concentrator overhead gases Static Mixer.
V-15-16 concentrator contains 35 sieve trays. Stripping of NH3 and H2S from the sour
water is done by 150 psig steam.
The overhead gases from V-15-16 after mixing with the cold feed are further
cooled/condensed in Air Fin Coolers E-15-20 and in E-15-18 by means of cooling water.
The condensed concentrate is collected in Overhead Accumulator V-15-17 and pumped
by P-15-18A/B to TK-476 through Degasser V-15-19 and P-15-01A/B/S pumps. This is
further stripped in Unit-15. The overhead non-condensable gases are routed to Flare.
The hot stripped water from Concentrator V-15-16 bottom is pumped by P-15-17A/B
pumps through E-15-17A/B Exchangers to the Effluent Treatment Plant in MAB. A
portion of this stripped water is recycled to the H.P. water injection system Accumulator
V-15-13.
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17.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-15C is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Exchangers, Shell & tube 08
2 Vessels, columns, tanks, drums 05
3 Filters / dampers 06
3 PSVs 08
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18.0 UNIT – 17 OVERVIEW (Kerosene Merox Unit)
18.1 PROCESS OVERVIEW
18.1.1 Objective
The Merox Unit is used for sweetening raw Kerosene.
The process is based upon oxidation of mercaptans to Disulfide using Merox catalyst.
18.1.2 Capacity
The unit is designed to sweeten 15000 BPSD of light Kerosene from the Naphtha
Fractionation Unit (Unit-09). Later the unit was revamped to produce Aviation Turbine
Fuel (ATK) by adding clay filter and salt filter to produce 20000 BPSD of ATK. The Unit
can also be operated on a full range Kerosene from the Crude Unit (Unit – 06), but at a
lower feed rate.
18.1.3 Feed and Products
Material Balance & Feed, Product Qualities is shown in table-1&2
a) Table-1: Typical Material Balance
BPSD % VOL. SOURCE / DESTINATION
Feed 20,000 100.0%
Products
Product ATK 20,000 100.0%
Total Liquid Product 20,000 100.0%
From Unit - 09
To Storage
b) Table-2 : Typical Feed & Product Qualities
Specification
Gravity API
Mercaptan, PPM
H2S, PPM
Dist. Range , Deg. F
Flash Point , Deg. F
49.1
4 - 6
0 - 0.1
305 - 470
105 - 110
49.1
180
5 - 8
305 - 470
Feed PRODUCT ATK
105 - 110
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18.1.4 Process Description
The process scheme is shown in the Sketch -1
Raw Kerosene from Unit-09 at approx. 105-115oF is first bubbled through pre-wash
Tower V-17-01 containing approx. 2% caustic solution, thereby removing traces of H2S
and Naphthenic acid. The outlet stream is mixed with air and fed to two parallel Reactors
V-17-03 A&B, each containing a bed of charcoal impregnated with Merox-FB catalyst.
Reactor bed is kept alkaline by intermittent circulation of approx. 8% caustic solution.
The outlet sweet Kerosene is passed through settler V-17-04 to separate entrained
caustic. The Kerosene from caustic settler is routed to water wash tower (V-17-08) for
wash off the entrained caustic. The water wash outlet is passed through Salt filter (F-17-
01) to remove the moisture content and then through the Clay filter (F-17-02) to improve
color and stability.
The (sweet/water free) Kerosene is routed to ATK product tank.
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18.1.5 Brief History
a) Post treatment facilities such as Salt Filter and Clay filter installed in the year 2000
b) New Air compressor C-17-01 B installed in the year 2009.
18.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-17 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Vessels 13
2 Tanks 04
3 Filters 02
4 PSVs 20
5 Compressor accessories - coolers 02
6 Compressor accessories - Traps 04
18.3 ROTATING OVERVIEW
Unit 17 – The Merox unit is used to sweetening raw Kerosene, based on oxidation of
mercaptans to disulfide, from Naphtha fractionation unit.
All the Rotating equipment in 17 unit are inspected and maintained as per the guidelines
of Process Licensor & good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 17 has 11 Pumps & 2 Reciprocating compressors. List of Rotating Equipment are
furnished vide Appendix 2A hereof.
New compressor C-17-01 commissioned in 2008 with higher capacity.. Most of the
Critical pumps packings converted to mechanical seals to the spirit of API 682 to prevent
Gas leakage to environment.
Pump/Compressor package auxiliary items (filters, SO/LO Coolers, Gearboxes, Seals,
Couplings, Piping items etc.) are not included in the list. Bidders can collect relevant
details of maintenance records, healthiness of the equipment and inspection records
during PTM/Site visit.
18.4 ELECTRICAL OVERVIEW
Unit -17 is considered as classified area (Class 1 Div. 2 Group D) as per Shuaiba
Refinery Hazardous Area Classification drawing (refer drawing # R-00-6030). The source
of power to the Unit is aided from Substation 04 which is located south side of the Unit.
The substation is Building with Basement Type & facilitated as non-classified area by
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employing pressurized / Air conditioned systems. Substation has 3 nos. of “6.6kV”
Switchgears (4A, 4B & 4C) fed from SS1A & SS1B (ref. drawing # R-00-6012), 9 nos. of
“440V” MCC (MCC-4A, MCC-4B, MCC-4C, MCC-4D, MCC-4E, MCC-4F, MCC-4G, MCC-
4H & MCC-4J), 9 nos. of power transformers (1MVA, 6.6kV/440V) and 4 nos. of
Emergency panel (EDB-01-01). The “6.6kV” Switchgears 4C were replaced completely
with latest new ABB panels during GRTA-2011 under contract CS/1955. The Substation
is equipped with Fire Detection, Alarm & Suppression system which was installed under
contract CB/CSPD/2004 & commissioned on 2016. Battery Charger along with Battery
backup bank are also available.
The list of LT Motors associated with this Unit is enclosed vide Appendix 2A hereof.
Motors rated less than or equal to 280HP is designated as LT motor. Unit -17 has 13 nos.
of 440V motors. All motors are under Preventive Maintenance program by maintenance
department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
The Unit-17 is powered from the Substation # 04 and the Single Line Diagram (SLD) for
SS # 04 is as follows (for details Refer Annexure-01, KNPC Sketch # SK-2434 Sheet 01
of 08);
Note: The Substations shared between different units and a table that shows the
association of different units to Substation shown in Appendix 1A - Refinery Overview.
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18.5 INSTRUMENTATION OVERVIEW
The unit processed Kerosene feed stock to remove H2S and Organic acid Compounds.
18.5.1 Instrumentation System
a) DCS: Honeywell make TPS System installed in SIH # 7, SIH # 10 & GUS
operating Stations in CCR.
b) ESD System: Honeywell make Safety Manager System installed in SIH # 7, SIH #
10 & CCR.
c) PLC System: Siemens make Simantic S7-3 PLC for reciprocating Air
Compressor.
18.5.2 Critical Safety Interlocks and Controls
a) C-17-01 – Air Compressor Interlock & Control.
b) C-17-01 – Air Receiver Control.
c) Unit – 17 – Feed Temperature Control.
18.5.3 Field Instrument List
SR # CATEGORY MAKE QTY REMARKS
1 CONTROL VALVE FISHER / MASONEILAN 6
2 CONTROLLER YOKOGAWA 2
3 DISPLACER LT MASONEILAN 1
4 FLOW ELEMENT DANIEL 8
5 LEVEL GAUGE GLASS JERGUSON / K-TEK 11
6 LEVEL SWITCH MAGNETROL 1
7 LOCAL INDICATOR ITT BARTON / BROOKS 19
8 PLC 1 C-17-01B AIR
COMPRESSOR
9 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL /
AM GAUGE 62
10 PRESSURE SWITCH UE / ASHCROFT / SOR 8
11 SOLENOID VALVE ASCO 3
12 THERMOWELL THERMO ELECTRIC / TECNOMATIC / TC
LTD 22
13 TRANSMITTER ROSEMOUNT / YOKOGAWA /
HONEYWELL / ABB / FOXBORO / SMAR 11
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19.0 UNIT – 19 OVERVIEW (Dimineralizing Unit)
19.1 PROCESS OVERVIEW
19.1.1 Objective
Deminerlaizer Unit processes distilled water from MEW to prepare high purity water for the Boilers in the Refinery. This is accomplished by Ion exchange process utilizing a mixed Cation/Anion bed.
19.1.2 Capacity
The Unit has a design capacity of 1450 US GPM of Treated Water during normal operation and 1,800 US GPM at maximum capacity.
19.1.3 Feed and Products
The feed water to Unit – 19 is distilled water supplied by MEW and received in the storage tanks TK-471/475. Tables 1&2 show the material balance and typical analysis of Feed Water and Treated Water from the demineralizer.
a) Table-1: Typical Material Balance
Feed
Treated Distilled Water from MEW
Products
Demineralized Water ( Via TK- 480 )
GPM
To Deaerators in Boiler Unit
SOURCE / DESTINATION
From TK-471/475
1450
1450
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b) Table-2 : Typical Feed & Product Qualities
Specification / Analysis
Cations
Calcium 15 0 Magnesium 5 0 Sodium 9 <0.2 Total Cations 29 <0.2
Anions
Bicarbonate 8 0 Carbonate 0 0 Chloride 13 <0.2 Sulfate 8 0 Total Anions 29 <0.2
TDS 40 1.0 Iron, total 0.1 0.0 Carbon Dioxide 1.0 0.0 Silica 0.1 <0.02 pH 7.2 7.0 - 7.5
Feed Water
as CaCO3 in PPM
Demineralized Water
as CaCO3 in PPM
19.1.4 Process Description
The process scheme is shown in the Sketch -1
Demineralizer Unit contains three parallel mixed Cation/Anion resin beds. Normally two
beds are in line. Feed water enters the resin beds at the top and passes through mixed
bed, containing both Anion and Cation resin in mixed form, exits at the bottom. In the
beds, ion exchange process takes place, i.e. Cations ( Sodium, Calcium, Iron, etc. )
present in the water are removed by cation resin while the Anions ( Chlorides, Sulfates,
etc.) are removed by anion resin, thus producing a high purity water which essentially
free of salts.
The resin gets exhausted after during operation for 3-7 days after which regeneration is
needed. Each of the Demineralizer beds are equipped with automatic regeneration
facilities. Normally, two beds are in commission, the third being under regeneration.
Regeneration is accomplished by treating with dilute sulfuric acid ( for cation resin) and
Caustic Soda ( for anion resin) followed by rinsing before taking back on line again.
Regeneration effluents are neutralized to remove acidity/alkalinity before disposal.
Treated Demineralized water is stored in TK-480 as intermediate tank and from there
pumped to the De-aerators in Boilers area.
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Part of resin bed rinse water is reused as make up to the Cooling Towers with provision
for pH correction as a part of water conservation projects.
19.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-19 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Vessels / Tanks 07
2 Exchangers 01
3 Filters 01
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19.3 ROTATING OVERVIEW
Unit 19 – Demineralizer unit processes distilled water from MEW to prepare high purity
water for the high pressure Boilers in the Refinery, accomplished by Ion exchange
process utilizing a mixed Cation/anion bed.
All the Rotating equipment in Unit-19 are inspected and maintained as per the guidelines
of Process Licensor & good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 19 has 8 Pumps & 1 Blower. List of Rotating Equipment are furnished vide
Appendix 2A hereof.
Pumps/ Blowers package auxiliary items (filters, SO/LO Coolers, Gearboxes, Seals,
Couplings, Piping items etc.) are not included in the list. Bidders can collect relevant
details of maintenance records, healthiness of the equipment and inspection records
during PTM/Site visit.
19.4 ELECTRICAL OVERVIEW
Unit -19 is considered as unclassified area as per Shuaiba Refinery Hazardous Area
Classification drawing (refer drawing # R-00-6030). The source of power to the Unit is
aided from Substation 1A which is located west side of the Unit. substation is Building
with Basement Type & facilitated as non-classified area by employing pressurized / Air
conditioned systems. Substation 1A is one of the main intake substation from Ministry of
Electricity & water (MEW) and has 4 Nos. of 31.5MVA 132/6.9kV Transformers
connected in parallel to 6.6kV Switchgear with Is-Limiters between the bus-sections in
order to limit maximum short circuit fault current at its bus to 31.5kA (ref. drawing # R-00-
6012), 3 nos. of “440V” MCC (MCC-A, MCC-B & MCC-C ), 3 nos. of power transformers
(1MVA, 6.6kV/440V) and an Emergency panel. The 6.6kV Switchgear, section-4 was
replaced completely with latest new ABB panels during GRTA-2011 under contract
CS/1955. The Substation is equipped with Fire Detection, Alarm & Suppression system
which was installed under contract CB/CSPD/2004 & commissioned on 2016. Battery
Charger along with Battery backup bank are also available.
The list of LT Motors associated with this Unit is enclosed vide Appendix 2A hereof.
Motors rated less than or equal to 280HP is designated as LT motor. Unit-19 has 9 nos.
of 440V motors. All motors are under Preventive Maintenance program by maintenance
department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
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Unit # 19 is powered from retained Substation # 01A.
19.5 INSTRUMENTATION OVERVIEW
Unit – 19 has three mixed beds. In these beds cations and anions resin are used. These
resins absorb salts from distilled water. The bed is regenerated with acid & caustic
solution.
19.5.1 Instrumentation System
a) DCS System: Honeywell make TPS System for process parameter monitoring.
b) PLC System: Allen Bradley make PLC System installed in Local Control room for
regeneration of mixed bed.
19.5.2 Critical Safety Interlocks and Controls
a) Dewerator storage vessel V-20-01 &01S Interlock.
b) Acid to regeneration bed concentration high Interlock.
c) Caustic tank level low Interlock.
d) Regeneration of bed Interlock.
19.5.3 Field Instrument List
SR # CATEGORY MAKE QTY REMARKS
1 PH / CONDUCTIVITY
ANALYZER ROSEMOUNT-5081 / FOXBORO-
870EC/871EC 10
2 CONTROL VALVE FISHER / MASONEILAN / WARRON
MORRISON 58
3 CONTROLLER FOXBORO 3
4 FLOW ELEMENT DANIEL 3
5 FLOW SWITCH HEINRICHS 2
6 HMI SIEMENS 2
7 LEVEL SWITCH MAGNETROL 2
8 LOCAL INDICATOR ITT BARTON 5
9 PLC ALLEN BRADLEY 5/30 1
10 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL 25
11 PRESSURE SWITCH UE / ASHCROFT 4
12 SOLENOID VALVE ASCO 70
13 THERMOWELL THERMO ELECTRIC 2
14 TRANSMITTER ROSEMOUNT / YOKOGAWA 5
15 MISC HONEYWELL 25
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20.0 UNIT – 20 OVERVIEW (Boilers & Steam System)
20.1 PROCESS OVERVIEW
20.1.1 Objective
Steam System consists of steam generator and distribution network at different pressure
levels for process and utility requirements. It also distributes BFW for various uses in
refinery.
20.1.2 Capacity
Shuaiba Refinery has four fired boilers with design production capacity of 300,000 lbs/hr
of 900# steam per boiler.
Additional steam is produced from other Waste Heat Boilers:
Hydrogen Units – 02/62 : 900 psig steam.
SRU Unit-04 & 74 and Incinerator : 475 psig Steam
Unit-63/ Unit 68 : 150 psig Steam
20.1.3 Process Description
The process scheme is shown in the Sketch -1
Boiler unit consist of two Deaerators DA-20-01/V-20-01 and DA-20-01A/ V-20-01 A.
Demineralized water along with the CO2 rich condensate from hydrogen units and High
pressure cold condensate stream are deaerated and fed to the Boiler Feed Water Pumps
P-20-01 A/B/C/D. These pumps supply BFW to refinery as well as the boilers. There are
four boilers B-20-01 A/B/C/D each with 300,000 lbs/hr capacity built by Foster Wheeler.
Each boiler consists of a steam drum , water wall tubes , four gas fired burners and a
Forced Draft Fan. Each boiler is also provided with steam superheaters.
The product 900 psig steam is sent to the 900 psig header. There are four different
headers for steam distribution as follows:
a) 900 psig: Steam is supplied to the 900 psig steam header from the Boiler Plant
and Hydrogen Plants. The 900 psig steam is then used by Steam Turbines and as
make-up to 475 psig header through let-down and desuperheating.
b) 475 psig: Sources of 475 psig steam are WHB at units-04/74/75, exhaust of steam
turbines at U-01/U-08 and make-up from 900 psig steam. 475 psig is consumed in
Hydrogen manufacturing process, Steam Turbines and reboilers.
c) 150 psig: Sources of 150 psig steam are Steam Turbine exhaust(U-07/U-68),
Waste Heat Boilers in Units 63/68 and make-up 475 psig steam. The consumers
are steam stripping, reboilers, steam tracing and ejectors. All excess 150 psig
steam is letdown to the 50 psig header.
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d) 50 psig: Sources of 50 psig steam are Steam Turbine exhaust, Sulfur Plant
Condensers and from 150 psig steam letdown. 50 psig steam is consumed for
process steam stripping, reboilers, and steam tracing. All excess 50 psig steam is
condensed in sea water condenser E-29-02 and condensate is returned to Boiler
Plant.
e) BFW: BFW from Deaerators is treated with oxygen scavengers / neutralising
amines and then pumped through pumps P-20-01 A/B/C/D to BFW system. A
small portion of the discharge is routed as despuerpheating water to steam
letdown stations and turbine exhaust steam desuperheaters in various uses.
Treatment chemical is added to the main stream of BFW before routing it to the
boilers and for other refinery Waste heat boilers.
20.1.4 Brief History
Boiler D and additional Deaerator was installed in the year 1978.
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20.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-20 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Exchangers 03
2 Vessels, Stream Drums & tanks 16
3 Deaerator 02
4 Stack 04
5 Boiler Assembly 04
6 PSVs 37
20.3 ROTATING OVERVIEW
Unit 20 – Boilers used to support steam system consists of steam generators and
distribution network at different pressure levels for process and utility requirements.
All the Rotating equipment in Unit-20 are inspected and maintained as per the guidelines
of Process Licensor & good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 20 has 19 Pumps, 4 Blowers, 8 Steam turbines involved in this unit. List of Rotating
Equipment are furnished vide Appendix 2A hereof.
Pumps/ Blowers/ Steam Turbines package auxiliary items (filters, SO/LO Coolers,
Gearboxes, Seals, Couplings, Piping items etc.) are not included in the list. Bidders can
collect relevant details of maintenance records, healthiness of the equipment and
inspection records during PTM/Site visit.
20.4 ELECTRICAL OVERVIEW
Unit -20 is considered as unclassified area as per Shuaiba Refinery Hazardous Area
Classification drawing (refer drawing # R-00-6030). The source of power to the Unit is
aided from Substation 5B which is located west side of the Unit. The substation is
Building with Basement Type & facilitated as non-classified area by employing
pressurized / Air conditioned systems. Substation has a “6.6kV” Switchgears fed from
SS1A & SS1B (ref. drawing # R-00-6012), 3 nos. of “440V” MCC (MCC 5B-A, MCC 5B-B
& MCC 5B-C), 3 nos. of power transformers (1MVA, 6.6kV/440V) and 2 nos. of
Emergency panel (RPP-1 & ATS-29-04). The Substation is equipped with Fire Detection,
Alarm & Suppression system which was installed under contract CB/CSPD/2004 &
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commissioned on 2016. Battery Charger along with Battery backup bank are also
available.
The list of HT & LT Motors associated with this Unit is enclosed vide Appendix 2A
hereof. Motors rated above 280HP is designated as HT motor and if less than or equal to
280HP, as LT motor . Unit -20 has 3 nos of 6.6KV motors and 14 nos. 440V motors. All
motors are under Preventive Maintenance program by maintenance department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
The Unit-20 is powered from the Substation # 05B and the Single Line Diagram (SLD) for
SS # 05B is as follows (for details Refer Annexure-01, KNPC Sketch # SK-2434 Sheet
03 of 08);
Note: The Substations shared between different units and a table that shows the
association of different units to Substation shown in Appendix 1A - Refinery Overview.
20.5 INSTRUMENTATION OVERVIEW
Unit – 20 boilers generate 900 PSIG steam. There are 4 boilers and capacity of each
boilers 300,000 lb/hr. DM water capacity for boiler is supplied by Demineralizer Unit – 19.
20.5.1 Instrumentation System
a) DCS: Honeywell make TPS System installed in SIH # 5, SIH # 10 & CCR with
GUS operating Stations in CCR.
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b) ESD System: Honeywell make Safety Manager System installed in SIH # 5, SIH #
10 & CCR.
c) PLC System: Modicon PLC System for Burner Management & Boiler Interlock
Control housed in BMS House.
20.5.2 Critical Safety Interlocks and Controls
a) Boiler steam drum level control.
b) Boiler feed water pressure control.
c) Deaerator storage Level / Temperature control.
d) Boiler Load Control.
e) Boiler steam superheat Control.
f) Air flow to Boiler Control.
g) Excess Air Control for Boilers.
h) Master Fuel Trip Interlock for Boilers.
20.5.3 Field Instrument List
SR # CATEGORY MAKE QTY REMARKS
1 O2 / DENSITY &
CONDUCTIVITY ANALYZER ROSEMOUNT-5081 / ROSEMOUNT-2081
C / ROSEMOUNT-IFT 3000 / PEEK-HC 900 10
2 CONTROL VALVE FISHER / MASONEILAN / SAMSON 58
3 CONTROLLER FOXBORO / TAYLOR / MASONEILAN 8
4 DISPLACER LT MASONEILAN / MAGNETROL 11
5 FLOW ELEMENT DANIEL / SAMIL 38
6 LEVEL GAUGE GLASS JERGUSON / PENBERTHY / K-TEK 15
7 LEVEL SWITCH MAGNETROL / MOORE / SOR 10
8 LOCAL INDICATOR ITT BARTON / BROOKS / KROHNE / WISE
/ AMETEK 82
9 PLC MODICON 4
10 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL /
AM GAUGE 94
11 PRESSURE SWITCH UE / ASHCROFT / SOR / DELTA CONTROL / BOURDON SEDEME
28
12 SOLENOID VALVE ASCO 71
13 THERMOWELL THERMO ELECTRIC / TECNOMATIC / TC
LTD 52
14 TRANSMITTER ROSEMOUNT / YOKOGAWA /
HONEYWELL / ABB / FOXBORO / SMAR 115
15 MISC HONEYWELL 112
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21.0 UNIT – 22 OVERVIEW (Cooling Water System)
21.1 PROCESS OVERVIEW
21.1.1 Objective
Cooling Water System Unit 22 consists of a cooling tower and pumps and distribution
network to cater to most of the Refinery cooling water requirement.
21.1.2 Capacity
Unit – 22 is designed to supply 40,000 of cooling water respectively to the units.
21.1.3 Process Description
The process scheme is shown in the attached Sketch SK-1.
Unit – 22 has three circulating pumps, eight induced draft fans and four sea water coolers
to pre-cool the returning water before entering the Cooling Tower.
From the main cooling water supply headers, the cooled water flows and branches into
individual area/unit headers and is distributed to area coolers and condensers. The warm
water at about 113oF, returning from the area coolers and condensers is routed to the top
of the Cooling Tower through sea water exchangers, where it is cooled to about 102 Deg
F, where it is cooled to about 88oF by the time it reaches the basin. From the basin, cold
water is pumped out to the supply headers with circulating pumps.
The primary source of cooling water make-up is treated distilled water (from the treated
distilled water tanks) which is required to maintain level in the Cooling Tower basins.
Both systems have chemical treatment facility to control corrosion, scaling and biological
growth which will otherwise seriously affect operations.
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21.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-22 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Exchangers 02
2 Cooling Tower 01
3 Filters 02
4 Vessels & tanks 01
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21.3 ROTATING OVERVIEW
Unit 22 – Cooling water system consists of two cooling towers and distribution network to
cater to refinery cooling water requirement.
All the Rotating equipment in Unit 22 are inspected and maintained as per the guidelines
of Process Licensor & Good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 22 has 6 Pumps, 3 Turbines & 8 Fin-fans. List of Rotating Equipment are furnished
vide Appendix 2A hereof.
Pump/Turbine package auxiliary items (filters, SO/LO Coolers, Gearboxes, Seals,
Couplings, Piping items etc.) are not included in the list. Bidders can collect relevant
details of maintenance records, healthiness of the equipment and inspection records
during PTM/Site visit.
21.4 ELECTRICAL OVERVIEW
Unit -22 is considered as classified area (Class 1 Div. 2 Group D) as per Shuaiba
Refinery Hazardous Area Classification drawing (refer drawing # R-00-6030). The source
of power to the Unit is aided from two substations, Substation # 1A which is the main
SHU intake substation located at north side of the unit and Substation # 18 which is
located north east side of the Unit. The substation 18 is Building with Basement Type &
facilitated as non-classified area by employing pressurized / Air conditioned systems.
Substation has a “6.6kV” Switchgears fed from SS1A & SS1B (ref. drawing # R-00-
6012), a “440V” MCC (MCC-61), a power transformers (1MVA, 6.6kV/440V) and an
Emergency panel. The Substation is equipped with Fire Detection, Alarm & Suppression
system which was installed under contract CB/CSPD/2004 & commissioned on 2016.
Battery Charger along with Battery backup bank are also available.
The list of HT & LT Motors associated with this Unit is enclosed vide Appendix 2A
hereof. Motors rated above 280HP is designated as HT motor and if less than or equal to
280HP, as LT motor . Unit -22 has 1 nos of 6.6KV motors and 10 nos. 440V motors. All
motors are under Preventive Maintenance program by maintenance department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
The Unit-22 is powered from the Substation # 18 and the Single Line Diagram (SLD) for
SS # 18 is as follows (for details Refer Annexure-01, KNPC Sketch # SK-2434 Sheet 08
of 08);
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Note: The Substations shared between different units and a table that shows the
association of different units to Substation shown in Appendix 1A - Refinery Overview.
21.5 INSTRUMENTATION OVERVIEW
Cooling Tower provides cooling water used in Refinery Operation for cooling, condensing
product / process streams and cooling of rotary parts like bearing gland & compressor
jackets etc.
21.5.1 Instrumentation System
a) DCS SYSTEM: Honeywell make TPS System installed in SIH # 5, SIH # 10.
b) GUS operating Stations in CCR
c) ESD SYSTEM: Honeywell make Safety Manager System installed in SIH # 5, SIH
# 10 & CCR
21.5.2 Critical Safety Interlocks and Controls
a) Cooling water basin level control.
b) P-22-01 B/C – Cooling water pump Interlock.
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21.5.3 Field Instrument List
SR # CATEGORY MAKE QTY REMARKS
1 PH & COUNUCTIVITY
ANALYZER ROSEMOUNT-5081 / SENTRY 4
2 CONTROL VALVE MASONEILAN / JORDAN 9
3 CONTROLLER FOXBORO / MASONEILAN 5
4 DISPLACER LT MASONEILAN 1
5 FLOW ELEMENT DANIEL 12
6 LOCAL INDICATOR ITT BARTON / BROOKS 15
7 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL / AM
GAUGE 89
8 PRESSURE SWITCH UE / ASHCROFT / SOR 8
9 SOLENOID VALVE ASCO 2
10 THERMOWELL THERMO ELECTRIC / TECNOMATIC / TC
LTD 25
11 TRANSMITTER ROSEMOUNT / YOKOGAWA / HONEYWELL /
ABB / FOXBORO / 14
12 MISC HONEYWELL 9
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22.0 UNIT – 23 OVERVIEW (Sea Cooling Water System)
22.1 PROCESS OVERVIEW
22.1.1 Objective
Sea water is utilized for cooling circulating water of Unit – 22 cooling Tower, 50# excess
steam condensers, in Flare Gas Recovery Unit, and as cooling water for Unit – 61. It can
also be used as a source of back-up fire water in emergency.
22.1.2 Capacity
Sea water system is designed to receive 64800 GPM of sea water. Actual sea water
intake is 18000-25000 GPM.
22.1.3 Process Description
The process scheme is shown in the Sketch -1
Bot Sea water is supplied to KNPC battery limit by PAI through 72” ID concrete culvert.
Sea water flows in parallel via four 30” inlet lines to the bottom of four parallel sea water
exchangers E-23-01 A/B/C/D tube side for cooling circulating cooling water from Unit –
22 cooling Tower. The outlet of sea water is combined in a 68” ID header and flow by
gravity into the top of Steam Condenser E-29-02 and pass through the tube side for
condensing the Refinery excess 50# steam.
A part of sea water from E-23-01 A/B/C/D outlet header is pumped to Flare Gas
Recovery Unit (FGRU) by pumps P-29-11 A/B as cooling water for surface condenser E-
29-11. Return sea water after heat exchange joins the same E-23-01 A/B/C/D outlet
header at upstream of sea water condenser E-29-02.
Part of sea water is supplied to Unit – 61 as cooling water via 14” header from the main
72” ID header.
Sea water collected in the sea water pit flows back through 60”ID concrete culvert to the
Gulf.
An 18” jump-over is also provided from E-23-01 A/B/C/D suction (72” supply header) as
back-up for the fire water pumps.
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22.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-23 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Exchangers, Shell & tube 04
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23.0 UNIT – 29 OVERVIEW
(Flare Gas Recovery Unit, Flare System & Instrument / Plant Air System)
23.1 PROCESS OVERVIEW (Flare Gas Recovery Unit)
FGRU was not in original Refinery design. As a pollution control and Energy
Conservation measure, a Flare Gas Recovery Unit was installed and achieved its full
operation on January, 2002.
23.1.1 Objective
FGRU provided for recovery of flared gases and reusing the same as fuel gas after
necessary treatment while releasing a minimum amount of residual flare gas for burning
at the stacks. The import gas (LP Gas, Burgan Gas) used as fuel gas was significantly
reduced. The emission of sulfur dioxides gases to atmosphere is reduced to minimum
level and healthy environment is achieved.
23.1.2 Capacity
The unit can recover 18.7 MMSCFD (Max.) of refinery gases routed to flare header.
However, after a successful program to reduce flaring at Shuaiba Refinery, the total Flare
Gas is reduced drastically, i.e. ~ 7-8 MMSCFD.
23.1.3 Feed and Products
Material Balance & Feed, Product Qualities is shown in table-1, 2 & 3
a) Table-1: Typical Material Balance
MMSCFD
16.5 From Refinery Process Units
15.3 To Amine Treating Unit (14) *
1.2 To East Flare Stacks Gases to Flare
SOURCE / DESTINATION
FEED
Total Refinery Flare Gases
(Feed to FGRU)
PRODUCTS
Recovered Gases in FGRU
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b) Table-2 : Typical Feed Qualities
Light Normal Heavy Min. MW
68.0 62.7 54.9 77.5
5.0 5.0 5.0 5.0
0.2 0.2 0.2 0.1
3.0 4.2 4.8 2.3
16.3 17.4 18.6 9.4
3.3 4.3 5.2 2.3
2.4 2.8 4.5 1.5
1.4 2.5 4.3 1.4
0.4 0.9 2.5 0.5
100.0 100.0 100.0 100.0
Components % Vol
n-Butane
Total
Methane
Ethane
Hydrogen
Water
Carbon Dioxide
Hydrogen Sulphide
n-Pentane
Propane
c) Table-3 : Typical Product Qualities
Light Normal Heavy
69.81 64.37 56.36
2.47 2.47 2.47
0.21 0.21 0.21
3.08 4.31 4.93
16.73 17.86 19.10
3.39 4.42 5.34
2.46 2.87 4.62
1.44 2.57 4.41
0.41 0.92 2.56
0.0 100.00 100.00 100.00 Total
Components % Vol
Hydrogen
Water
Carbon Dioxide
Hydrogen Sulphide
Methane
Ethane
Propane
n-Butane
n-Pentane
d) Battery Limit Conditions
Feed Temperature 140 Deg FPressure 1.1 PSIG
Product Temperature 110 Deg F
Pressure 40.3 PSIG
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23.1.4 Process Description
The process scheme is shown in the Sketch -2
In the Flare Gas Recovery Unit, the gases released to the Flare system are recovered
through compressor(s) under specially designed control scheme, to ensure that in no
case the flare header is under negative pressure.
The flare gas available in the East flare header knocks off its condensates in the main
flare knockout drum, V-29-01. The flare gas recovery unit is connected to the outlet of
this knock out drum. Additional amount of gas, which cannot be recovered, bubbles
through two water seal drums, V-29-14 and V-29-15, before being burnt in North and
South stacks, ST-29-01 and ST-29-02 respectively. Water seal maintained in the water
seal drums imposes a positive back pressure in the flare header. This provides a means
of directing flare gases either to the recovery system or to the flare stacks, when gas flow
rate exceeds the capacity of the flare gas recovery unit.
A continuous purge of fuel gas maintains a positive pressure at the downstream of the
water seal drums avoiding any possibility of vacuum formation, burn back situation or air
ingress through flare tip.
Sour gases originating from units 14, 61 and 68 bypass the main flare KOD and are
routed to the sour gas knock out drum, V-29-16. This prevent the sour gases from these
units being compressed in the flare gas recovery unit. The condensate, if any, is knocked
out in this drum. The sour gases then pass through a water seal drum V-29-13, and join
main stream of sweet gas header at the inlet of respective stacks. The ammonia vent
header originating from unit 15 is burnt in sulfur plants and the balance is routed to water
seal drum, V-29-13 and to Flare Stacks.
Make up water to seal drums is provided on level control. The liquid level in drums is kept
just below the external seal height so as to avoid any continuous discharge/overflow of
water from seal drums to the drain pit. Provision is kept for manual periodic
skimming/draining of hydrocarbons from above the water surface to avoid a hydrocarbon
build up in the seal drums. Water, when overflows from seal drums, is routed to existing
drain pit.
The Flare Gas Recovery Unit consists of two 50% capacity water injected single stage
screw compressors designed for a capacity of 7320 CFM (9.58 MMSCFD) each, at inlet
condition. One of the compressors is driven by condensing type steam turbine (LP
Steam), while the other is driven by variable speed electric motor. The Surface
Condenser of the condensing type steam turbine is provided with sea water supply
through Sea Water Supply Pumps (P-29-11 A/B) for cooling.
Prior to entering the suction of the compressors the flare gas passes through suction
KOD, V-29-10 for removal of entrained condensate in the flare gases coming from main
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flare KOD, V-29-01. The KOD, V-29-10, is provided with mist eliminator to allow only
liquid free gases to the suction of the compressors.
In the compressors, the flare gas is compressed from 15.8 psia to 55 psia. After
compression, the flare gas is cooled in the After Cooler (E-29-08 A/B) at individual
compressor discharge using cooling water. Gas from After Coolers combines and enters
discharge KOD (V-29-12) to separate condensate from gas. The gas is then sent to V-
14-01 of existing Amine Unit for further treatment. Condensate generated in the suction
KOD is sent back to main flare KOD through Sour Condensate Pumps, P-29-10A/B while
the same from discharge KOD is pressure transferred to main flare KOD under level
control.
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23.2 PROCESS OVERVIEW (Flare Gas System)
23.2.1 Objective
The flare system is designed to provide safe release and disposal of combustible, toxic
gases and vapors released from Process equipment during normal operations and/or
upset conditions. The released materials is first routed to Flare knock-out drum where
heavy end and condensable are separated out and residual gases are burnt at elevated
stack. Controlled amount of steam is used at the Flare tip to ensure smokeless burning
and easy dispersion of combustion products.
23.2.2 Capacity
Shuaiba Refinery has three Flare Stacks in two systems, East and West. East Flares ST-
29-01 & 02 have design load of 245,380 lb/hr each. West Flare ST-29-03 which is
generally a stand-by, is designed for 647,000 lb/hr under general power failure case.
23.2.3 Process Description
The process scheme is shown in the Sketch -1
Flare system essentially consists of flare K.O. drum and Flare stacks and piping network.
The Flare network includes several headers and sub-headers originating from various
Process Units. The six Flare Headers are routed to the old K.O. Drum. The major 30”
Flare header is connecting both old (East) and new (West) Flare K.O. Drums and also
used by most of the Process Units. Shuaiba has a Flare Gas Recovery Unit (FGRU) for
recovery of Flare Gases and reuse as Fuel Gas. Only a small part, the unrecoverd gases,
is burnt at the Stacks.
23.2.3.1 East Flare System
East flare system consists of flare gas KOD V-29-01, sour gas KOD V-29-16, flare gas
seal drums V-29-14 & V-29-15, sour gas seal drum V-29-13 & two flare stacks ST-29-01
& ST-29-02. Most Flare gases from refinery join in V-29-01 and diverted to Flare Gas
Recovery Unit (FGRU) for recovery of major amount (Ref. Process description of FGRU).
Balance gas is sent to flare stacks ST-29-01 & ST-29-02 via seal drums V-29-14 & V-29-
15.
Sour gas, containing mainly Hydrogen Sulfide, from Unit-14/61/68 is diverted to flare
stacks via KOD V-29-16 & seal drum V-29-13. Ammonia gas from Unit – 15 is directly
routed to sulfur plants with a provision to route to flare stacks via seal drum V-29-13.
23.2.3.2 West Flare System
Normally West Flare is a standby by using a static seal provided at ST-29-03 bottom. In
case of process units major upset, the high rate of gas flowing in the common flare
header exceeds capacity of the East Flare and the common Flare Header gets
pressurized. Consequent back pressure if high enough to break/overcome the static
seal, West Flare comes in action and gas flow is shared by the east and west Flares.
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All flare stacks are provided with:
Fuel gas purge to prevent air ingress inside the stacks
Pilot burner to ensure flame availability at all times
Facility for reigniting the Stack in case of flame outage
23.2.4 Process Description
West Flare system which was installed in the year 1978
Flare Gas Recovery Unit was installed in the year 2004.
23.3 PROCESS OVERVIEW (Instrument / Plant Air System
23.3.1 Process Description
The process scheme is shown in the Sketch -1
Instrument Air is clean dry air that is supplied to almost all control valves in the Refinery.
Air is withdrawn from atmosphere through a suction filter into a compressor first stage.
The air, then, is passed through an inter cooler, compressor second stage, cooler and a
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knockout drum receiver. The air then is passed through driers, a filter and then it is
distributed to the refinery.
Instrument air consists of 3 reciprocating compressors (one motor driven and two steam
turbine driven) with capacity 775 SCFM each, 3 air dryers and 2 Filters.
Coupled with this system is the plant air section that consists of 3 electrically driven
compressors (two reciprocating compressors with capacity of 950 SCFM each and one
centrifugal compressor with capacity of 1500 SCFM) to provide plan air to all the Refinery
Units.
The plant air is not suitable (clean and dry) for use as instrument air. It is only used in
general service where dry air is not essential.
23.4 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-29 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
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Sl. # Equipment Description No of Equipment
1 Exchangers, Shell & tube 16
2 Air Coolers 03
3 Vessels, columns, tanks, drums 15
4 Stack 02
5 Compressor accessories - Exchangers 10
6 Compressor accessories – Air coolers 03
7 Compressor accessories - Filters 14
8 Compressor accessories - Tanks 06
9 Compressor accessories - Dryer 03
10 PSVs 25
23.5 ROTATING OVERVIEW
Unit 29 – Instrument air is clean dry air that is supplied to almost all control valves in the
refinery. Also to maintain supply of Fuel gas required for refinery heaters and boilers.
All the Rotating equipment in Unit 29 are inspected and maintained as per the guidelines
of Process Licensor & Good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 29 has 23 Pumps, 6 Turbines & 4 Engines, 8 compressors. List of Rotating
Equipment are furnished vide Appendix 2A hereof.
Pump/Turbine/Engine package auxiliary items (filters, SO/LO Coolers, Gearboxes, Seals,
Couplings, Piping items etc.) are not included in the list. Bidders can collect relevant
details of maintenance records, healthiness of the equipment and inspection records
during PTM/Site visit.
23.6 ELECTRICAL OVERVIEW
Unit-29 is considered as classified area (Class 1 Div. 2 Group D) as per Shuaiba Refinery
Hazardous Area Classification drawing (refer drawing # R-00-6030). The source of power
to the Unit is aided from three Substations, SS # 18, SS # 4 & SS # 5A which is located
north east side of the Unit. The substation is Building with Basement Type & facilitated as
non-classified area by employing pressurized / Air conditioned systems. The Substation
is equipped with Fire Detection, Alarm & Suppression system which was installed under
contract CB/CSPD/2004 & commissioned on 2016. Battery Charger along with Battery
backup bank are also available.
The list of HT & LT Motors associated with this Unit is enclosed vide Appendix 2A
hereof. Motors rated above 280HP is designated as HT motor and if less than or equal to
280HP, as LT motor . Unit -29 has 2 nos of 6.6KV motors and 23 nos. 440V motors. All
motors are under Preventive Maintenance program by maintenance department.
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Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
The Unit-29 is powered from the Substations # 04, 05B & 18 and the Single Line
Diagram (SLD) for SS # 04, 05B & 18 are as follows (for details Refer Annexure-01,
KNPC Sketch # SK-2434 Sheet 01, 03 & 08 of 08);
Note: The Substations shared between different units and a table that shows the
association of different units to Substation shown in Appendix 1A - Refinery Overview.
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23.7 INSTRUMENTATION OVERVIEW
23.7.1 Instrumentation System – Flare Gas Recovery Unit
The unit is designed for recovery of flared gases and reusing the same as fuel gas after
necessary treatment. This ensures reduction of toxic gases to minimum level and
achieving healthy environment.
a) PLC SYSTEM: HIMA make PLC System installed in the field with connectivity to
Honeywell make DCS system.
b) BENTLY SYSTEM: Bently 3300 Vibration & Temperature monitoring system for C-
29-04 A & B.
c) WOODWARD GOVERNOR: Woodward Speed Governor System Model 505 for
C-29-04A steam turbine driver Compressor.
23.7.2 Instrumentation System – Flare Gas
The unit is designed to provide safe disposal of combustible toxic gases / vapors
released from process units during Normal / Abnormal on upset conditions.
Flare stacks, ST-29-01, ST-29-02 & ST-29-03 provided to ensure burning of the gases. 6
No’s pilot burners are provided in each stack to ensure flame availability at all times. All
flare stacks are provided with fuel gas purge line.
a) PLC SYSTEM: Siemens make PLC System in local for each flare for Auto /
Manual ignition of Pilot Burners.
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b) DCS SYSTEM: Honeywell make TPS System installed in SIH # 9, & GUS
operating stations in CCR.
23.7.3 Instrumentation System – Instrument & Plant Air
Instrument Air and plant air is generated in this unit and supplied to all the units in the
Refinery.
Three reciprocating Compressors C-29-04 A, B & C along with driers DR-29-01, DR-29-
01A & DR-29-02 provided for supply of Instrument Air.
Compressor C-29-03 A, B & C are provided for supply of plant air.
a) PLC SYSTEM: Siemens make PLC System for Air Drier Control.
b) DCS SYSTEM: Honeywell make TPS System installed in SIH # 5, SIH # 10 &
GUS operating stations in CCR.
23.7.4 Field Instrument List - Unit-29
SR # CATEGORY MAKE QTY REMARKS
1 ANALYZER ROSEMOUNT-5081C / SERVOMAX-1902 2
2 CONTROL VALVE FISHER / MASONEILAN / TYCO / BETTIS 85
3 CONTROLLER FOXBORO / MASONEILAN / GERHARDT / FISHER
12
4 GOVERNER
CONTROLLER WOODWARD-505 1
5 DISPLACER LT MASONEILAN / MAGNETROL 8
6 FLOW ELEMENT DANIEL 35
7 LEVEL GAUGE GLASS JERGUSON / K-TEK 34
8 LEVEL SWITCH MAGNETROL / MOORE / SOR 32
9 LOCAL INDICATOR ITT BARTON / BROOKS / KROHNE / WISE / AMETEK
138
10 PLC SIEMENS / HIMA 5
11 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL / AM GAUGE
172
12 PRESSURE SWITCH UE / ASHCROFT / SOR / BOURDON SEDEME
70
13 SOLENOID VALVE ASCO 58
14 THERMOWELL THERMO ELECTRIC / TECNOMATIC / TC LTD
132
15 TRANSMITTER ROSEMOUNT / YOKOGAWA / HONEYWELL / ABB / FOXBORO / SMAR
128
16 MASS FLOW METER QURZ 1
17 MISC HONEYWELL 128
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24.0 UNIT – 35 OVERVIEW (Sulphur Degassing Unit)
24.1 PROCESS OVERVIEW
24.1.1 Objective
Sulfur Degassing Facilities U-35 (SDF) has been designed to reduced hydrogen sulfide
content in the raw liquid sulfur which is produced in the existing sulfur recovery units
(Units -04 & 74) and in tail gas treating unit ( TGTU U-75). Refined (product) liquid sulfur
is delivered to MINA – AL-AHMADI Refinery (MAA) for farther processing. The principle
is to release the free H2S and accelerate the decomposition of the polysulfides to free
H2S.
The H2S dissolved in liquid phase (free H2S) passes into the gaseous phase by physical
desorption .
24.1.2 Capacity
The SDF unit is able to process the raw liquid sulfur of 600 MT/D. normal capacity is 480
MT/D.
24.1.3 Feed & Products
Refer to the below Table-1 for material balance.
a) Table-1: Feed & Product Qualities:
H2S, wt. PPM PURITY, wt. %
FEED : 300 99.5
PRODUCTS : 15 99.5
24.1.4 Process Description
The SDF unit -35 sulfur consist of sulfur pit (TK-35-03), Flasher (FL-35-01) and other
relative equipment. The sulfur pit is divided into 3 compartments provided with steam
coils to maintain the liquid sulfur above 250 ˚ F (121 ˚C).
The raw sulfur from the Claus units flows into the first compartment of the pit which has
14.7 hour residence time at the normal feed rate.
Some parts of hydrogen polysulfides (H2SX ) in the raw sulfur will be decomposed to free
H2S by agitation resulting from recycling of liquid sulfur through flasher (FL-35-01)
submerged feed pump (P-35-05 A/B), pumped the liquid sulfur to static Mixer (MX-35-
01).
The liquid sulfur from mixer is discharged to the flasher which installed above the second
compartment of sulfur pit.
The flasher, which is a cyclone type gas/liquid separator, free H2S in liquid sulfur is
evolved with steam by flashing. The separated off gas ( composed of steam & a small
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amount of H2S) is routed to new (ST-75-01) & old incinerator (ST-04-02). The partition
wall between the first and second compartments of the sulfur pit has some opening at its
bottom which make the degassed sulfur recycle to first compartment. The residence time
in the second compartment is about 7.5 hours based upon the normal flow rate.
In third compartment partition wall height is low that one third of degassed sulfur
inevitably overflows. After residence time 6.6 hours based in normal flow rate, refined
sulfur is continuously pumped ( P-35-06 A/B) up to storage tank (TK-35-271, 272 & 273).
The stored liquid sulfur is delivered to MINA – AL-AHMADI Refinery as product by
product discharge pump (P-35-07 A/B).
24.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-35 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Vessels and Tanks 05
2 Flasher 01
3 PSVs 02
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25.0 UNIT – 61 OVERVIEW (Acid Gas Removal Unit)
25.1 PROCESS OVERVIEW
25.1.1 Objective
Acid gas removal plant treats West Field Gases and West Field Liquid for removal of
Hydrogen Sulfide and Carbon Dioxide using Benfield Solution to provide sweet gas
product to LPG Plant at Mina Al-Ahmadi Refinery. The unit is also designed to treat some
refinery gases after compressing them using C-61-01. The Benfield Solution is a mixture
of Potassium Carbonate (23-30%) and Diethanol Amine (2-3%).
In the Benfield Process, Diethanol Amine is used as an activator for the carbonate
solution.
25.1.2 Capacity
The Unit design capacity is 72.2 MMSCFD of equivalent, i.e. combined Gas and Liquid.
25.1.3 Feed & Products
Refer to the below Table-1 for material balance.
b) Table-1: Feed & Product Qualities:
MMSCFD H2S CO2( BPSD) % VOL. % VOL.
FEED :
West Field Gas 48.5 4.14 11 West Field Liquid (4000) 4.2 5.9 Refinery Gases 15 21 0
PRODUCTS :
Sweet Gas 55 0.07 0.4 Sweet Liquid (2675) 0.06 0.16 Acid Gas 10.3 50.5 44
25.1.4 Process Description
25.1.4.1 Original Design
West Field Gas and West Field Liquid (currently not processed) coming from the fields
join with the Refinery gases compressed in C-61-01 and enter the Feed Surge Drum.
Liquid and gas feeds are recombined and fed as two – phase mixture to the sweet
product heat exchanger E-61-02, where it is preheated with warm overhead product and
then superheated using 50 psig steam in preheater E-61-05 and then fed to the acid gas
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Absorber V-61-05. Lean Potassium Carbonate solution is fed to the Absorber at its top
cold circulation section and middle sections hot circulation. The rich solution reaching the
bottom of the Absorber is routed to the Regenerator V-61-06 via the Flash Drum V-61-08.
Absorber pressure is about 370 psig while Regeneration pressure is about 10 psig.
The sweet gas from the Absorber overhead is cooled in E-61-02 by heat exchanged with
feed and then in Sea Water cooler E-61-07 and then collected in the separator V-61-04,
where condensate is separated. Water and hydrocarbons separate out and the Sweet
Water is returned to V-61-08. The Sweet hydrocarbon product is pumped out to mix with
the sweet gas going to Mina Al-Ahmadi for further processing in LPG Plant.
The rich Benfield Solution is regenerated in V-61-06. The solution is regenerated by
reboiling with steam in Reboiler E-61-03 A/B/C/D at reduced pressure. The Lean solution
is collected at the bottom of the column is returned to the Absorber V-61-05. Four
Storage vessels V-61-11 A/B/C/D for the Benfield Solution are provided to absorb any
fluctuations in the Absorber requirements. The unit is provided with three filters F-61-
01/02/03.
The regenerator overhead is condensed in E-61-04 and collected in the Regenerator
Accumulator V-61-07. The acid gases remain uncondensed and leave the Accumulator
to Sea Water cooler E-61-09. These gases are routed to Sulfur Recovery Units for
recovery of Sulfur. Refinery gases, mainly from U-09 and U-05 is compressed using C-
61-01 and mixed with West Field Gas feed to Unit-61. This provides additional LPG
recovery from rich gas which otherwise would be used as Fuel Gas.
Sketch-2 shows the original process flow diagram of Unit-61.
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25.1.4.2 Feed Filtration Facility
This project was implemented in the unit and put in commission in 2002. This new
system aims to remove dirt, fine corrosion products and sludgy material accompanying
West Field Gas and Liquids causing foaming and major upsets in the unit.
Sketch -1 shows the major equipment involved in Feed Filtration Facility and its general
configuration.
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25.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-61 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Exchangers, Shell & tube 14
2 Air Coolers 03
3 Vessels, columns, tanks, drums 31
4 Filters 11
5 PSVs 46
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25.3 ROTATING OVERVIEW
Unit 61 – AGRP unit treats west field gases and west field liquid for removal of Hydrogen
sulfide and Carbon dioxide using Benfield solution to provide sweet gas products to MAA.
All the Rotating equipment in 61 unit are inspected and maintained as per the guidelines
of Process Licensor & good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 61 has 31 Pumps, 22 Fin fans, 2 Mixers & 1 Compressor. List of Rotating Equipment
are furnished vide Appendix 2A hereof.
Critical pumps packings converted to mechanical seals to the spirit of API 682 to prevent
Gas leakage to environment.
Pump/Compressor/Turbine package auxiliary items (filters, SO/LO Coolers, Gearboxes,
Seals, Couplings, Piping items etc.) are not included in the list. Bidders can collect
relevant details of maintenance records, healthiness of the equipment and inspection
records during PTM/Site visit.
25.4 ELECTRICAL OVERVIEW
Unit -61 is considered as classified area (Class 1 Div. 2 Group B) as per Shuaiba
Refinery Hazardous Area Classification drawing (refer drawing # R-00-6030). The source
of power to the Unit is aided from Substation 18 which is located north east side of the
Unit. The substation is Building with Basement Type & facilitated as non-classified area
by employing pressurized / Air conditioned systems. Substation has a “6.6kV”
Switchgears fed from SS1A & SS1B (ref. drawing # R-00-6012), a “440V” MCC (MCC-
61), a power transformers (1MVA, 6.6kV/440V) and an Emergency panel. The Substation
is equipped with Fire Detection, Alarm & Suppression system which was installed under
contract CB/CSPD/2004 & commissioned on 2016. Battery Charger along with Battery
backup bank are also available.
The list of HT & LT Motors associated with this Unit is enclosed vide Appendix 2A
hereof. Motors rated above 280HP is designated as HT motor and if less than or equal to
280HP, as LT motor . Unit -61 has 6 nos of 6.6KV motors and 48 nos. 440V motors. All
motors are under Preventive Maintenance program by maintenance department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
The Unit-61 is powered from the Substations # 18 and the Single Line Diagram (SLD) for
SS # 18 are as follows (for details Refer Annexure-01, KNPC Sketch # SK-2434 Sheet
08 of 08);
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Note: The Substations shared between different units and a table that shows the
association of different units to Substation shown in Appendix 1A - Refinery Overview.
25.5 INSTRUMENTATION OVERVIEW
Unit – 61 processes the feed gas from KOC, H-oil unit (07), Naptha Fractionation Unit
(09) using Benfield process for removal of H2S & CO2 gas present in the gas & liquid
hydrocarbon feed stream. The sweet gas produced is routed to LPG plant in MAA. The
mixture of removed H2S & CO2 gas (Acid Gas) is sent to Sulfur Recovery Units for
production of Sulfur.
25.5.1 Instrumentation System
a) DCS: Honeywell make TPS System installed in SIH # 7, SIH # 10 & GUS
operating Stations in CCR.
b) ESD System: Honeywell make Safety Manager System installed in SIH # 7, SIH #
10 & CCR.
25.5.2 Critical Safety Interlocks and Controls
a) C-61-01 – Feed Booster Compressor Trip Interlock & Control.
b) V-61-03 – Feed Surge drum Interlock & Control.
c) V-61-04 – Sweet gas separator Interlock & Control.
d) V-61-09 – Condensate drum Interlock & Control.
e) V-61-10 – Sour Water Effluent Interlock & Control.
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f) Oily water sump SU-61-03 Interlock.
g) Area Sump SU-61-01 Interlock & Control.
h) F-61-06 – Filter Separator Interlock.
i) Slog catcher V-61-07 Interlock & Control.
25.5.3 Field Instrument List
SR # CATEGORY MAKE QTY REMARKS
1 H2S / DENSITY & CONDUCTIVITY
ANALYZER
ROSEMOUNT- 2081 C / YOKOGAWA- GD 40T / TELEDYNE- 6000B
5
2 CONTROL VALVE FISHER / MASONEILAN / ELLIOT / SEVERN GLUCON / TOKO VALEX
68
3 LOCAL CONTROLLER HONEYWELL / MOORE / FIELD PAC /
FOXBORO / 15
4 DISPLACER LT MASONEILAN / MAGNETROL 13
5 FLOW ELEMENT DANIEL / SAMIL 48
6 FLOW SWITCH ITT BARTON 5
7 LEVEL GAUGE GLASS JERGUSON / PENBERTHY / K-TEK 38
8 LEVEL SWITCH MAGNETROL / MOORE / SOR 37
9 LOCAL INDICATOR ITT BARTON / BROOKS / KROHNE / WISE /
AMETEK 120
10 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL /
AM GAUGE 286
11 PRESSURE SWITCH UE / ASHCROFT / SOR / DELTA CONTROL 58
12 SOLENOID VALVE ASCO 17
13 THERMOWELL THERMO ELECTRIC / TECNOMATIC / TC
LTD 119
14 TRANSMITTER ROSEMOUNT / YOKOGAWA /
HONEYWELL / ABB / FOXBORO / SMAR 76
15 VIBRATION BENTLY NEVADA – 3300 1
16 MISC HONEYWELL 30
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26.0 UNIT – 62 OVERVIEW (Hydrogen Production Unit)
26.1 PROCESS OVERVIEW
26.1.1 Objective
Hydrogen Units generate high purity Hydrogen needed in other Refinery Units, e.g. H-Oil,
Isocrackers, Unifiners.
26.1.2 Capacity
The unit is designed to produce 74 MMSCFD of 95% purity Hydrogen.
26.1.3 Feed and Products
The feed to the Hydrogen Unit is a mixture of treated Burgan Gas and recycle High
Pressure Flash Gas. Burgan Gas is mainly hydrocarbons, while recycle gas is a mixture
of different Hydrogen rich bleed gases from Hydrogen consuming Units (treated in U-14).
The design product Hydrogen purity is 95% and the maximum Carbon Oxides
specifications is 10 PPMV.
The attached Table-1 indicates the overall material balance for design and test run
conditions.
a) Table-1: Feed and Product Qualities
DESIGN TEST RUN DESIGN TEST RUN
Hydrogen % Vol 39.96 46.40 94.99 94.93 Methane 41.68 30.57 5.01 5.07 Ethane 13.25 8.26 Propane 4.17 10.41 Butane 0.94 4.36 Mol. Wt. 13.86 15.41 2.74 2.73 Lbs/Hr 36667 38920 22165.00 23075.00 MMSCFD 24.09 22.98 73.79 77.08
FEED PRODUCTS
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26.1.4 Process Description
The Feed Gas is preheated in Hydrogen Reformer Convection Section and the last
traces of organic and inorganic Sulfur compounds are removed in Zinc Oxide beds.
High Pressure steam is mixed with the treated feed gas and further heated up in the
Reformer Convection Coils before it is introduced into the Reformer Catalyst Tubes filled
with Reformer catalyst. Steam and feed gas hydrocarbons react in the presence of Nickel
catalyst to form Hydrogen, Carbon dioxide and Carbon monoxide. This steam reforming
reaction is highly endothermic, requiring heat energy for reaction.
Waste heat is recovered from the Reformer effluent to produce 900 psig steam and partly
for heating Methanator inlet gas.
The carbon monoxide (with excess steam) in the Reformer effluent is further converted
into Hydrogen and Carbon dioxide in High Temperature and Low Temperature Shift
Convertors. Shift conversion reaction is exothermic, producing heat energy.
The Shift Converter Effluent exchanges heat in the MEA Regenerator Reboilers and
further cooled before it is passed through MEA Absorber. A 20% by Wt.
Monoethanolamine solution is used to absorb carbon dioxide. The Rich solution is
regenerated by heating and flashing at low pressure and the regenerated Lean MEA
solution is pumped back to CO2 Absorber after cooling. A slip stream of Lean MEA
solution is filtered in a mechanical filter and a charcoal filter.
The CO2 Absorber effluent gas is heated and in the Methanator the remaining small
quantities of carbon monoxides & carbon dioxide are converted to methane in order to
meet the product carbon dioxide specification.
The Methanator effluent is heat exchanged with the Methanator inlet gas, further cooled
and sent to Unit-03 for compression.
The process scheme is shown in the attached Sketch -1.
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26.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-62 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Exchangers, Shell & Tube 15
2 Air Coolers 04
3 Vessels, columns, tanks, drum 25
4 Heaters 01
5 PSVs 40
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26.3 ROTATING OVERVIEW
Unit 62 – Hydrogen units generate and supply high purity and high pressure Hydrogen
needed in other units, H-Oil, Isocrackers, Unifiners.
All the Rotating equipment in 62 unit are inspected and maintained as per the guidelines
of Process Licensor & good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 62 has 15 Pumps, 56 Fin fans, 2 Turbines & 1 Compressor. List of Rotating
Equipment are furnished vide Appendix 2A hereof.
Critical pumps packings converted to mechanical seals to the spirit of API 682 to prevent
Gas leakage to environment.
Pump/Compressor/Turbine package auxiliary items (filters, SO/LO Coolers, Gearboxes,
Seals, Couplings, Piping items etc.) are not included in the list. Bidders can collect
relevant details of maintenance records, healthiness of the equipment and inspection
records during PTM/Site visit.
26.4 ELECTRICAL OVERVIEW
Unit -62 is considered as classified area (Class 1 Div. 2 Group B) as per Shuaiba
Refinery Hazardous Area Classification drawing (refer drawing # R-00-6030). The source
of power to the Unit is aided from Substation 15/16/17 which is located south side of the
Unit. substation is Building with Basement Type & facilitated as non-classified area by
employing pressurized / Air conditioned systems. Substation has a 3 nos. of 6.6KV
Switchgears(15, 16 & 17) fed from SS1A & SS 1B (ref. drawing # R-00-6012), 8 nos. of
“440V” MCC (MCC-200, 300, 400, 500, 00,700 ,800 & MCC-1 at CCR ) and 8 nos. of
power transformers (1MVA, 6.6kV/440V). The Substation is equipped with Fire Detection,
Alarm & Suppression system which was installed under contract CB/CSPD/2004 &
commissioned on 2016. Battery Charger along with Battery backup bank are also
available.
The list of HT & LT Motors associated with this Unit is enclosed vide Appendix 2A
hereof. Motors rated above 280HP is designated as HT motor and if less than or equal to
280HP, as LT motor . Unit -62 has 2 nos. 6.6KV motors and 69 nos. 440V motors. All
motors are under Preventive Maintenance program by maintenance department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
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The Unit-62 is powered from the Substations # 08 & 15 and the Single Line Diagram
(SLD) for SS # 8 & 15 are as follows (for details Refer Annexure-01, KNPC Sketch # SK-
2434 Sheet 06 & 07 of 08);
Note: The Substations shared between different units and a table that shows the
association of different units to Substation shown in Appendix 1A - Refinery Overview.
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26.5 INSTRUMENTATION OVERVIEW
Hydrogen Unit Processes mixtures of treated Burgan Gas, High Pressure Flash Gas and
stream to produce Hydrogen. Feed gas and process steam reacts at high temperature
and pressure in pressure of Catalyst to produce Hydrogen Gas.
26.5.1 Instrumentation System
a) DCS: Honeywell make TPS System installed in SIH #2, SIH # 10. GUS Operating
stations installed in SIH # 2 & CCR.
b) ESD System: Honeywell make Safety Manager System installed in SIH # 2, SIH #
10 & CCR.
26.5.2 Critical Safety Interlocks and Controls
a) Heater - H-62-01 – Interlock East Cell
b) Heater – H-62-01 – Interlock West Cell
c) Methanator – V-62-03 – Interlock
d) CO2 Absorber – V-62-04 – Interlock.
e) P-62 -03A/B MEA Circulation Pump Interlock
26.5.3 Field Instrument List
SR # CATEGORY MAKE QTY REMARKS
1 O2 / H2S & DENSITY
ANALYZER YOKOGAWA- GD 40T / YOKOGAWA- ZR
402T / ABB- 2000 VISTA II GC 4
2 CONTROL VALVE FISHER / MASONEILAN / SAMSON
GERMANY / TYCO / VIRGO 42
3 CONTROLLER FOXBORO 8
4 DISPLACER LT MASONEILAN / MAGNETROL 7
5 FLOW ELEMENT DANIEL / SAMIL 47
6 FLOW SWITCH MAGNETROL / ITT BARTON 3
7 LEVEL GAUGE GLASS JERGUSON / PENBERTHY / K-TEK 22
8 LEVEL SWITCH MAGNETROL / MOORE / SOR 10
9 LOCAL INDICATOR ITT BARTON / BROOKS / KROHNE / WISE
/ AMETEK 93
10 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL /
AM GAUGE 179
11 PRESSURE SWITCH UE / ASHCROFT / SOR / DELTA CONTROL 21
12 SOLENOID VALVE ASCO 17
13 THERMOWELL THERMO ELECTRIC / TECNOMATIC / TC
LTD 129
14 TRANSMITTER ROSEMOUNT / YOKOGAWA /
HONEYWELL / ABB / FOXBORO / SMAR 92
15 MISC HONEYWELL 14
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27.0 UNIT – 63 OVERVIEW (H-Oil Vacuum Distillation Unit)
27.1 PROCESS OVERVIEW
27.1.1 Objective
H-Oil Vacuum Unit processes Unit – 07 Residue (Stripper & Fractionator Bottoms)
separating distillates, i.e. Heavy Diesel, Light Vacuum Gas Oil and Heavy Vacuum Gas
Oil. The old Vacuum Section of H-Oil Unit was abandoned in early 1978 due to capacity
limitation and a new Vacuum Section, Unit – 63, was provided.
27.1.2 Capacity
The Unit is designed to handle 42700 BPSD of feed. The actual Unit throughput is 42-44
KBD with both H-Oil trains in operation. If one H-Oil train is shutdown, the unit operates
at lower feed rate of 28,000 BPSD.
27.1.3 Feed and Products
The Vacuum Distillation Unit feed is a combination of 07 Unit Strippers Bottoms and
Fractionation bottoms. If Unit -07 one train is S/D, the feed to Unit 63 will be Unit – 07
stripper bottoms plus fractionator bottoms, in addition to Heavy Vacuum Gas Oil recycle
(normally about 5000 BBLS/Day HVGO) as per minimum flow requirement
Refer to the below Table-1&2 for material balance and Feed & Product qualities.
a) Table-1: Typical Material Balance
BPSD % VOL. SOURCE / DESTINATION
Feed 44000 100 From unit - 07
Products
Hy. Diesel 9000 20.45 To Unit 13 LVGO 3000 6.82 To Unit 68 HVGO 5000 11.36 To TK-052/Fuel Oil/Recycle Vac. Btms 27000 61.36 To Fuel Oil System
Total Liquid Product 44000 100.00
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b) Table-1: Typical Feed and Product Qualities
H. DIESEL LVGO HVGO VAC. BTMS
Sp. Gravity 0.9868 0.9212 0.9396 0.9402 1.0231
Sulfur % wt. 3.06 1.8 1.9 1.92 3.6
Nitrogen, PPM 3350 1800 1900 2000 4000
Dist. Range , Deg. F 50% @ 975 450 - 840 650 - 920 675 - 950 22 % @ 975
Flash Point , Deg. F -- -- -- -- --
Asphaltenes , % wt. 6.6 -- -- -- --
PRODUCTSSPECS FEED
27.1.4 Process Description
The Fractionator bottoms and the stripper bottoms from both the H-Oil Trains are routed
to Surge Drum, V-07-50, from where it is pumped by P-07-58 to the Charge Heater, H-
63-01. The charge is heated to a temperature of about 715-730oF before it enters the
Vacuum Tower.
Heavy Diesel and LVGO, drawn as side cuts, pass through Waste Heat Boilers,
Exchangers E-63-01/02/03/04/05, cooled and sent rundown as Diesel Unifiners and
Isocracker Units feed, respectively. Heavy Gas Oil side cut is pumped through E-63-06
for 150 psig steam generation, cooled in Fan Cooler, E-63-08 ,Heavy gas oil is sent to
TK-052 from where it can be transferred to the Fuel Oil Tanks. A portion may be sent in
H-Oil feed as recycle diluents.
Vacuum bottoms from Unit-63 is pumped by Fuel Oil Pumps P-07-09A/B/C and P-07-45
thru the Fuel Oil Cooling System and finally to the Fuel Oil Tanks, where it is blended
with the required cutter stocks( mainly Kerosene) to meet the specification of fuel oil.
The process scheme is shown in the attached Sketch -1.
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27.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-63 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Exchangers, Shell & Tube 11
2 Air Coolers 03
3 Vessels, columns, tanks, drum 08
4 Heaters 01
5 PSVs 09
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27.3 ROTATING OVERVIEW
Unit 63 – Unit separates distillates, Heavy Diesel, Light Vacuum Gas Oil and Heavy
Vacuum Gas Oil from unit 07 residue under vacuum conditions.
All the Rotating equipment in 63 unit are inspected and maintained as per the guidelines
of Process Licensor & good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 68 has 17 Pumps, 10 Fin fans, 4 Turbines & 2 Mixers. List of Rotating Equipment
are furnished vide Appendix 2A hereof.
Critical pumps packings converted to mechanical seals to the spirit of API 682 to prevent
Gas leakage to environment.
Pump/Compressor/Turbine package auxiliary items (filters, SO/LO Coolers, Gearboxes,
Seals, Couplings, Piping items etc.) are not included in the list. Bidders can collect
relevant details of maintenance records, healthiness of the equipment and inspection
records during PTM/Site visit.
27.4 ELECTRICAL OVERVIEW
Unit -63 is considered as classified area (Class 1 Div. 2 Group D) as per Shuaiba
Refinery Hazardous Area Classification drawing (refer drawing # R-00-6030). The source
of power to the Unit is aided from Substation 15/16/17 which is located south side of the
Unit. substation is Building with Basement Type & facilitated as non-classified area by
employing pressurized / Air conditioned systems. Substation has a 3 nos. of 6.6KV
Switchgears(15,16&17) fed from SS1A & SS 1B (ref. drawing # R-00-6012), 8 nos. of
“440V” MCC (MCC-200, 300, 400, 500, 00,700 ,800 & MCC-1 at CCR ) and 8 nos. of
power transformers (1MVA, 6.6kV/440V). The Substation is equipped with Fire Detection,
Alarm & Suppression system which was installed under contract CB/CSPD/2004 &
commissioned on 2016. Battery Charger along with Battery backup bank are also
available.
The list of LT Motors associated with this Unit is enclosed vide Appendix 2A hereof.
Motors rated less than or equal to 280HP is designated as LT motor. Unit-63 has 27 nos.
of 440V motors. All motors are under Preventive Maintenance program by maintenance
department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
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The Unit-63 is powered from the Substations # 17 and the Single Line Diagram (SLD) for
SS # 17 are as follows (for details Refer Annexure-01, KNPC Sketch # SK-2434 Sheet
07 of 08);
Note: The Substations shared between different units and a table that shows the
association of different units to Substation shown in Appendix 1A - Refinery Overview.
27.5 INSTRUMENTATION OVERVIEW
Vacuum Distillation Unit – 63 processes H-Oil stripper & fractionation bottoms to recover
Heavy Diesel, Light Vacuum Gas Oil & Heavy Vacuum Gas oil.
27.5.1 Instrumentation System
a) DCS: Honeywell make TPS System installed in SIH # 1, SIH # 10 & GUS
Operating stations installed in CCR.
b) ESD System: Honeywell make Safety Manager System installed in SIH # 1, SIH #
10 & CCR.
27.5.2 Critical Safety Interlocks and Controls
a) HVGO to Unit – 07 – Interlock
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b) BFW Pump P-63-06A – Discharge Pressure Interlock.
c) H-63-01 – A Cell – Interlock.
d) H-63-01 – B Cell – Interlock.
e) V-63-01 – Vacuum Tower Interlock.
27.5.3 Field Instrument List
SR # CATEGORY MAKE QTY REMARKS
1 02 ANALYZER YOKOGAWA – ZR 402T 1
2 CONTROL VALVE MASONEILAN / VIRGO/ROTORK 31
3 CONTROLLER FOXBORO / YOKOGAWA / TAYLOR /
MASONEILAN 2
4 DISPLACER LT MASONEIAN / MAGNETROL 8
5 FLOW ELEMENT DANIEL / SAMIL 51
6 LEVEL GAUGE GLASS JERGUSON / PENBERTHY / K-TEK 14
7 LEVEL SWITCH MAGNETROL / MOORE / SOR /
JERGUSON / INTRA AUTOMATION 3
8 LOCAL INDICATOR ITT BARTON / BROOKS / KROHNE / WISE
/ AMETEK 70
9 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL /
AM GAUGE 105
10 PRESSURE SWITCH UE / ASHCROFT / SOR / DELTA CONTROL 17
11 SOLENOID VALVE ASCO 14
12 THERMOWELL THERMO ELECTRIC / TECNOMATIC / TC
LTD 69
13 TRANSMITTER ROSEMOUNT / YOKOGAWA /
HONEYWELL / ABB / FOXBORO / SMAR 82
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28.0 UNIT – 64 OVERVIEW (Cooling Water System)
28.1 PROCESS OVERVIEW
28.1.1 Objective
Cooling Water System consists of a cooling tower with three cells and distribution
network to cater to some of the Refinery units cooling water requirement.
28.1.2 Capacity
Unit 64 is designed to supply 24,000 GPM of cooling water respectively to the refinery.
28.1.3 Process Description
Unit – 64 is across flow cooling tower with two circulating pumps, and three induced draft
fans
Both systems has two segregated pairs of cooling water supply and return headers.
From the main cooling water supply headers, the cooled water flows and branches into
individual area/unit headers and is distributed to area coolers and condensers. The warm
water at about 113oF, returning from the area coolers and condensers is routed to the top
of the Cooling Tower where it is cooled to about 88oF by the time it reaches the basin.
From the basin, cold water is pumped out to the supply headers with circulating pumps.
The primary source of cooling water make-up is treated distilled water (from the treated
distilled water tanks) which is required to maintain level in the Cooling Tower basins.
Both systems have chemical treatment facility to control corrosion, scaling and biological
growth which will otherwise seriously affect operations.
The process scheme is shown in the attached Sketch -1.
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28.1.4 Brief History
Unit 64 cooling tower was installed in the year 1978.
28.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-64 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Filter 01
2 Cooling Tower 01
3 PSVs 06
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28.3 ROTATING OVERVIEW
Unit 64 – Cooling water system consists of two cooling towers and distribution network to
cater to Refinery cooling water requirement.
All the Rotating equipment in 64 unit are inspected and maintained as per the guidelines
of Process Licensor & good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 64 has 3 Pumps, 3 Cooling tower fans, 1 Turbine. List of Rotating Equipment are
furnished vide Appendix 2A hereof.
Pump/Turbine/Cooling tower package auxiliary items (filters, SO/LO Coolers, Gearboxes,
Seals, Couplings, Piping items etc.) are not included in the list. Bidders can collect
relevant details of maintenance records, healthiness of the equipment and inspection
records during PTM/Site visit.
28.4 ELECTRICAL OVERVIEW
Unit -64 is considered as classified area (Class 1 Div. 2 Group D) as per Shuaiba
Refinery Hazardous Area Classification drawing (refer drawing # R-00-6030). The source
of power to the Unit is aided from Substation 15/16/17 which is located east side of the
Unit. substation is Building with Basement Type & facilitated as non-classified area by
employing pressurized / Air conditioned systems. Substation has a 3nos. of 6.6KV
Switchgears(15,16&17) fed from SS1A & SS 1B (ref. drawing # R-00-6012), 8 nos. of
“440V” MCC (MCC-200, 300, 400, 500, 00,700 ,800 & MCC-1 at CCR ) and 8 nos. of
power transformers (1MVA, 6.6kV/440V). The Substation is equipped with Fire Detection,
Alarm & Suppression system which was installed under contract CB/CSPD/2004 &
commissioned on 2016. Battery Charger along with Battery backup bank are also
available.
The list of HT & LT Motors associated with this Unit is enclosed vide Appendix 2A
hereof. Motors rated above 280HP is designated as HT motor and if less than or equal to
280HP, as LT motor . Unit -68 has a 6.6KV motors and 4 nos. 440V motors. All motors
are under Preventive Maintenance program by maintenance department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
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The Unit-64 is powered from the Substations # 17 and the Single Line Diagram (SLD) for
SS # 17 are as follows (for details Refer Annexure-01, KNPC Sketch # SK-2434 Sheet
07 of 08);
Note: The Substations shared between different units and a table that shows the
association of different units to Substation shown in Appendix 1A - Refinery Overview.
28.5 INSTRUMENTATION OVERVIEW
Cooling Tower provides cooling water used in Refinery Operation for cooling,
condensing product / process streams and cooling of rotary parts like bearing
gland & compressor jackets etc.
28.5.1 Instrumentation System
a) DCS SYSTEM: Honeywell make TPS System installed in SIH # 5, SIH # 10.
b) GUS operating Stations in CCR
c) ESD SYSTEM: Honeywell make Safety Manager System installed in SIH #
5, SIH # 10 & CCR.
d)
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28.5.2 Critical Safety Interlocks and Controls
a) Cooling water basin level control.
b) P-64-01 A/B – Cooling water pump Interlock.
28.5.3 Field Instrument List
SR # CATEGORY MAKE QTY REMARKS
1 PH & CONDUCTIVITY
ANALYZER ROSEMOUNT- 2081C / ROSEMOUNT-
2081PH 2
2 CONTROL VALVE MASONEILAN 5
3 CONTROLLER FOXBORO 1
4 DISPLACER LT MASONEILAN 1
5 FLOW ELEMENT DANIEL 4
6 LEVEL SWITCH MAGNETROL 1
7 LOCAL INDICATOR ITT BARTON / BROOKS 9
8 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL 20
9 PRESSURE SWITCH UE / ASHCROFT / SOR 10
10 SOLENOID VALVE ASCO 3
11 THERMOWELL THERMO ELECTRIC 5
12 TRANSMITTER ROSEMOUNT / YOKOGAWA 4
13 MISC HONEYWELL 3
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29.0 UNIT – 68 OVERVIEW (Isocracker Unit)
29.1 PROCESS OVERVIEW
29.1.1 Objective
Isocracker Unit converts a blend of Heavy Gas Oils and Heavy Diesels to lighter and
high-value distillate products like Naphtha, Kerosene/JP-5 and Low Sulfur High Pour
Diesel by hydrocracking process.
Hydrocracking reactions occur at high temperature in the presence of Hydrogen on a
fixed bed catalyst.
29.1.2 Capacity
Isocracker Unit is designed for feed rate of 44000 BPSD. The Unit however is normally
operated at 46000 BPSD. Feed is a mix of Vacuum Gas Oil & Heavy Diesel from Unit-06
and unifined Heavy Diesel from Unit-13. Sometimes H-Oil LVGO is included in the feed
in small quantity.
29.1.3 Feed and Products
Refer to the below Table-1&2 for material balance and Feed & Product qualities.
a) Table-1: Typical Material Balance
BPSD % VOL. SOURCE / DESTINATION
Feed 46000 100 From Units 06/13/63
Products
Naphtha 6000 13.04 To Unit 10 / Storage JP-5 9000 19.57 To storage High Pour Diesel 10000 21.74 To storage Frac. Bottoms 23000 50.00 To Unit 08 / Storage
Total Liquid Product 48000 104.35
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b) Table-2: Typical Feed and Product Qualities
PRODUCTS
SPEC. FEED NAPHTHA JP - 5 H. Pour Fract. Btms.
Diesel
Gravity API 22.9 60 37.1 34 34 Sulfur PPM / % wt. - / 2.74 <10 <10 <100 <250 Nitrogen, PPM 823 <1.0 <1.0 <1.0 <1.0 Dist. Range , Deg. F EP 1000 120 - 300 330 - 520 510 - 700 680 - 980 Flash Point , Deg. F -- -- 150 >200 -- Smoke Point , MM -- -- 19 -- -- Pour Point , Deg. F -- -- -- 35 90 Freezing Point , Deg C -- -- ( - ) 50 -- Nickel + Van. , PPM Max. <1 -- -- -- -- Fe + Na , PPM Max. <1 -- -- -- -- Asphaltenes , PPM <100 -- -- -- -- Polycyclic Index (PCI) 1050 -- -- -- 150
29.1.4 Process Description
Isocracker Unit consists of the following three sections: Refer to Sketch SK-1
29.1.4.1 High Pressure Section
Feed from storage is passed thru filters and is pumped by high pressure Feed Pump. It
mixes with recycle gas and the mixture is preheated thru Feed/Reactor effluent
Exchanger and further in the Reactor Feed Heater, H-68-01. The mixture then enters top
of the Reactor, V-68-01. Make-up Hydrogen preheated with reactor effluent in E-68-01
enters (at the bottom) annulus of the reactor and combines with the feed at top of the
reactor. Reactor operates at about 2400 psig pressure and temperature 760 – 820oF.
The reactor consists of four catalyst beds with Isocracking catalyst with provision of inter-
bed recycle gas quenches to control catalyst bed temperatures. The reactor effluent is
cooled by series of Heat Exchangers and Coolers and enters High Pressure Separator V-
68-02, where water, gases and liquid hydrocarbons are separated. A small quantity of
condensate / Ammonical water injected just upstream of the final cooler E-68-04 in order
to combat corrosion due to Hydrogen Sulfide and Ammonia. Water separated in V-68-02
is sent to Ammonical Water Treating Unit.
Gas stream from High Pressure Separator (which is mainly Hydrogen and some
Hydrogen Sulfide) enters the H2S Absorber where H2S is removed by circulating DEA
solution. H2S free gas is then compressed by the Recycle Gas Compressor and recycled
back to the reactor feed and inter-bed quench. In order to maintain system pressure and
hydrogen purity, a small portion of the recycle gas is bled to Unifiners.
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29.1.4.2 Low Pressure Section
Hydrocarbon liquid stream from the High Pressure Separator is let down to the L.P.
Seperator, V-68-06, operating at about 550 psig. L.P. Separator gas is routed to Amine
Treating Unit, while the liquid stream is let down to the Flash Drum, V-68-10. The
separated gas from this Drum also goes to Amine Treating Unit and the liquid stream,
after preheating with reactor effluent in a Heat Exchanger, enters the H2S stripper, V-68-
11. Superheated steam is introduced at the bottom of the Stripper.
Gas from Overhead Drum of H2S Stripper goes to Amine Treating Unit. The bottom
stream from H2S Stripper is heated through a series of Heat Exchangers and Fractionator
Feed Heater, H-68-02, before entering the Fractionator, V-68-13.
The Fractionator overhead vapors are cooled/condensed in fan Coolers and flow to the
overhead drum. Part of the liquid Naphtha is pumped to the Tower top as reflux and
balance is rundown as product after cooling. Kerosene and Diesel are drawn as side-cuts
thru strippers, V-68-15 & 16, cooled through Heat Exchangers & Coolers and sent to off-
plot finished product storage tanks. The bottoms product after cooling is routed to feed
the second stage Isomax Unit-08. Under alternate mode of operation, the Fract. Bottom
can be fully or partially recycled back to Unit-68 feed or routed to storage for blending.
29.1.4.3 DEA Section
Rich DEA from H2S Absorber, V-68-04, goes to DEA Flash Drum and to the DEA
Regenerator. H2S is stripped out of rich DEA in the Regenerator and sent to Sulfur
Recovery Units. From regenerator bottom, the DEA solution free of H2S, is cooled and
pumped by High Pressure DEA pump back to the H2S Absorber.
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29.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-68 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Exchangers, Shell & Tube 26
2 Air Coolers 08
3 Vessels, columns, tanks, drum 36
4 Heaters 02
5 PSVs 59
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29.3 ROTATING OVERVIEW
Unit 68- Isocracker used to upgrade a blend of heavy Gas Oils & heavy diesel into higher
value products like Naptha, Kerosene, Diesel & JP5 by Hydrocracking.
All the Rotating equipment in 68 unit are inspected and maintained as per the guidelines
of Process Licensor & good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 68 has 35 Pumps, 66 Fin fans, 1 Compressor, 5 Turbines. List of Rotating
Equipment are furnished vide Appendix 2A hereof.
In 2006, C-68-01 Turbine revamped with revised/improved blades design / internals to
avoid corrosion/erosion & improve the unit performance.
Many Critical pumps packings converted to mechanical seals to the spirit of API 682 to
prevent Gas leakage to environment.
Pump/Compressor/Turbine package auxiliary items (filters, SO/LO Coolers, Gearboxes,
Seals, Couplings, Piping items etc.) are not included in the list. Bidders can collect
relevant details of maintenance records, healthiness of the equipment and inspection
records during PTM/Site visit.
29.4 ELECTRICAL OVERVIEW
Unit -68 is considered as classified area (Class 1 Div. 2 Group B) as per Shuaiba
Refinery Hazardous Area Classification drawing (refer drawing # R-00-6030). The source
of power to the Unit is aided from Substation 15/16/17 which is located south side of the
Unit. substation is Building with Basement Type & facilitated as non-classified area by
employing pressurized / Air conditioned systems. Substation has a 3nos. of 6.6KV
Switchgears(15,16&17) fed from SS1A & SS 1B (ref. drawing # R-00-6012), 8 nos. of
“440V” MCC (MCC-200, 300, 400, 500, 00,700 ,800 & MCC-1 at CCR ) and 8 nos. of
power transformers (1MVA, 6.6kV/440V). The Substation is equipped with Fire Detection,
Alarm & Suppression system which was installed under contract CB/CSPD/2004 &
commissioned on 2016. Battery Charger along with Battery backup bank are also
available.
The list of HT & LT Motors associated with this Unit is enclosed vide Appendix 2A
hereof. Motors rated above 280HP is designated as HT motor and if less than or equal to
280HP, as LT motor . Unit -68 has 2 nos. 6.6KV motors and 101 nos. 440V motors. All
motors are under Preventive Maintenance program by maintenance department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
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The Unit-68 is powered from the Substations # 16 and the Single Line Diagram (SLD) for
SS # 16 are as follows (for details Refer Annexure-01, KNPC Sketch # SK-2434 Sheet
07 of 08);
Note: The Substations shared between different units and a table that shows the
association of different units to Substation shown in Appendix 1A - Refinery Overview.
29.5 INSTRUMENTATION OVERVIEW
Isocracker Unit Processes light and heavy Vacuum Gas Oil, Heavy Diesel and Unifier
bottoms in presence of Catalyst and Hydrogen at High Temperature and High Pressure
to produce Light Gases, Naptha, Kerosene (JP-5), Diesel products unconverted Gas Oil
is supplied to Isomax Unit – 08.
29.5.1 Instrumentation System
a) DCS: Honeywell make TPS System installed in SIH # 1, SIH # 10 with GUS
operating Stations in CCR
b) ESD System: Honeywell make Safety Manager System installed in SIH # 1, SIH #
10 & CCR.
c) FSC System: Honeywell make FSC system installed in SIH # 10 for ROIV
Controls.
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d) VIBRATION MONITORING SYSTEM: Bently make Vibration Monitoring System
installed for C-68-01 Compressor.
e) PLC System: Siemens make PLC System installed for Feed Filter backwashing
facility
29.5.2 Critical Safety Interlocks and Controls
a) Feed Pump P-68-01 & HPRT Interlock
b) P-68-22A – Pump Interlock
c) H-68-02 – Fractionation Feed Heater Interlock
d) H-68-01 – Cell A Interlock
e) H-68-01 – Cell B – Interlock
f) C-68-01 – Recycle Gas Compressor Interlock
29.5.3 Field Instrument List
SR # CATEGORY MAKE QTY REMARKS
1 02 ANALYZER YOKOGAWA-ZR402T / ABB-CALDOS17 5
2 CONTROL VALVE FISHER / MASONEILAN / HONEYWELL /
SAMSON GERMANY / TYCO / VIRGO 87
3 CONTROLLER FOXBORO / YOKOGAWA / TAYLOR /
MASONEILAN 11
4 DISPLACER LT MASONEIAN / MAGNETROL 11
5 FLOW ELEMENT DANIEL / SAMIL 72
6 HMI SIMENS 1
7 LEVEL GAUGE GLASS JERGUSON / PENBERTHY / K-TEK 51
8 LEVEL SWITCH MAGNETROL / MOORE / SOR / JERGUSON /
INTRA AUTOMATION 14
9 LOCAL INDICATOR ITT BARTON / BROOKS / KROHNE / WISE /
AMETEK 138
10 PLC ALLEN BRADLEY-MICROLOGIC-500/
WOODWORD – 505/ SIEMENS 6
11 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL / AM
GAUGE 198
12 PRESSURE SWITCH UE / ASHCROFT / SOR / DELTA CONTROL 51
13 SOLENOID VALVE ASCO 68
14 THERMOWELL THERMO ELECTRIC / TECNOMATIC /
TC LTD 203
15 TRANSMITTER ROSEMOUNT / YOKOGAWA / HONEYWELL
/ ABB / FOXBORO / SMAR 137
16 VIBRATION BENTLY NEVEDA - 3300 1
17 MISC HONEYWELL 15
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30.0 UNIT – 74 OVERVIEW (Sulphur Recovery Unit)
30.1 PROCESS OVERVIEW
30.1.1 Objective
This unit recover elemental sulfur from Acid Gases containing H2S generated in upstream treating units. The process adopted in these units is called Modified Claus Process.
30.1.2 Capacity
The original design capacity of was 600 LT/D of sulfur product, respectively. but under normal operation, sulfur production is 430-460 LT/D. However, after implementation of Oxygen Enrichment Project in 2004, the capacity of the unit increased to 665 LT/D of sulfur product (700 LT/D of sulfur feed) but not operated under Oxygen enrichment mode.
30.1.3 Feed and Products
Refer to the below Table-1&2 for material balance and Feed & Product qualities.
a) Table-1: Original Design: Material Balance
MMSCFD LT/D TYPICAL QUALITY
FEED :
Acid Gas 19.2 768 H2S : 81.2 Vol. % CO2 : 11.0 Vol. % HC : 1.4 Vol. % H2O : 6.4 Vol. %
Combustion Air 42.1 1513
2281
PRODUCTS :
Sulfur - 598 99.5 % wt. Pure Liquid Tail Gas 53.4 1683
2281
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b) Table-2: Oxygen Enrichment Case: Material Balance
LT/D
FEED :
Acid Gas 1200.0 SWS Off Gas 26.8
Air 629.0
Oxygen 218.0
2073.8
PRODUCTS :
Sulfur 665.0
Tail Gas 1408.8
2073.8
MMSCFD
28.2
47.3
1.3
18.8
5.8
-
30.1.4 Process Description
Acid gas from upstream treating units is mixed with air and burned in the reaction furnace
(H-74-01). The gas product emerges from the furnace at about 2100oF and passes
through a Waste Heat Boiler (V-74-09), producing 475 psig steam. After leaving the
boiler, the sulfur laden gas enters the first condenser (E-74-01) where sulfur is
condensed and routed to a sulfur sump.
The gas leaving the first condenser is reheated in the first reheater, BR-74-02, by burning
a slip of acid gas feed to reactor inlet temperature of 450oF. Then, reheater effluent gas
passes through the first catalytic reactor (V-04-07A) where additional sulfur is formed.
The Sulfur formed in the reactor is removed on the second condenser (E-74-02) and
routed to sulfur sump. The gas is again reheated in the second reheater (BR-74-03) and
passed through a second catalytic reactor (V-04-07B) for further conversion to elemental
sulfur which is removed in the third condenser (E-74-03). The overall sulfur recovery is
ranging from 92% to 96%. After leaving the third condenser, the tail gas containing traces
of H2S and other sulfur species is sent to Tail Gas Treating Unit (Unit-75) for further
recovery of sulfur. In case of emergency or Unit-75 Shutdown, the tail gas is then routed
to either the new or old incinerator.
The sulfur from Waste Heat Boiler and all condensers is routed to the sulfur sump where
it is kept molten by steam coils. The molten sulfur is then transferred to Sulfur Degassing
Facility (SDF) where dissolved H2S is removed from the sulfur before transferring it to
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liquid Sulfur storage tanks. From the tanks, it is pumped to Sulfur Flaking Facilities in
Mina Al-Ahmadi refinery for producing solid sulfur.
Note that in Unit-74, 475 psig steam is produced in Waste Heat Boiler and 50 psig steam
in the three condensers.
30.1.4.1 Process Description – Original Design Unit – 74
Refer sketch-1
Unit-74 has the same configuration as unit 04 but differed in some respects:
Unit-74 produced 150 psig steam instead of 900 psig steam in Waste Heat Boiler.
In the third condenser 50 psig steam was not produced, instead Boiler Feed Water
was heated and routed to Waste Heat Boiler and the other two condensers where
150 psig steam and 50 psig steam are produced, respectively.
30.1.4.2 Oxygen Enrichment Project:
This project was implemented in 2004. In this project, Unit-04 and Unit-74 were modified
to increase their capacity to 665 LT/D sulfur product (700 LT/D sulfur feed), under
Oxygen mode. The project is based on the use of Oxygen enriched air (instead of plain
air) to achieve this increase in capacity.
The main changes involved are the change modification of the Reaction Furnaces to be
able to use both air and Oxygen enriched air and the change of Waste Heat Boilers to
produce 475 psig steam in both Units-04 & 74. Also, additional K.O. drum is provided for
SWS gas. New tail gas feedback controller is provided for better adjustment of Air/Acid
gas ratio. A layer of Titania catalyst at the bottom of first reactor and a layer of Oxygen
scavenging catalyst at the top of the second reactor are used.
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30.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-74 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Waste heat Boiler 01
2 Heat Exchangers, S&T 09
3 Reactor 01
4 Vessels, columns, tanks, drum 13
5 Burners 04
6 Filters 08
7 Seal Pots 11
8 PSVs 15
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30.3 ROTATING OVERVIEW
Unit 74 – Sulphur present in crude oil gets converted to hydrogen sulphide H2S during
various refining processes such as reforming, hydrocracking and Unit 74 remove H2S
from other gases to use them in the refining process.
All the Rotating equipment in Unit 74 are inspected and maintained as per the guidelines
of Process Licensor & good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 74 has 6 Pumps & 1 blower. List of Rotating Equipment are furnished vide
Appendix 2A hereof.
Pumps / Blower package auxiliary items (filters, SO/LO Coolers, Gearboxes, Seals,
Couplings, Piping items etc.) are not included in the list. Bidders can collect relevant
details of maintenance records, healthiness of the equipment and inspection records
during PTM/Site visit.
30.4 ELECTRICAL OVERVIEW
Unit -74 is considered as classified area (Class 1 Div. 2 Group D) as per Shuaiba
Refinery Hazardous Area Classification drawing (refer drawing # R-00-6030). The source
of power to the Unit is aided from Substation 02 which is located west side of the Unit.
The substation is Building with Basement Type & facilitated as non-classified area by
employing pressurized / Air conditioned systems. Substation has 3 nos 6.6 KV
Switchgears (2A, 2B & 2C) fed from SS1A & SS1B (ref. drawing # R-00- 6012), 4 nos. of
440V MCC (MCC-2A, MCC-2B, MCC-2C & MCC-2D), 4 nos. of power transformers
(1MVA, 6.6kV/440V) and an emergency distribution panel (EDB-32-01). The HT
Switchgear section 2A was replaced completely with latest new ABB panels during
GRTA-2011 under contract CS/1955. The Substation 2 will be retained post SHU. The
Substation is equipped with Fire Detection, Alarm & Suppression system which was
installed under contract CB/CSPD/2004 & commissioned on 2016. Battery Charger
along with Battery backup bank are also available.
The list of HT & LT Motors associated with this Unit is enclosed vide Appendix 2A
hereof. Motors rated above 280HP is designated as HT motor and if less than or equal to
280HP, as LT motor . Unit -74 has a 6.6KV motor and 6 nos. 440V motors. All motors are
under Preventive Maintenance program by maintenance department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
Unit # 74 is powered from retained Substation # 02.
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30.5 INSTRUMENTATION OVERVIEW
Sulfur is recovered from the gas streams containing Hydrogen Sulphide (H2S) using
“Modified Claus Processes” in the Sulfur Recovery Unit – 04. In this process 1/379 of H2S
in the gas stream is burnt with air in the reaction furnace to form SO2. The resulting SO2
then burns with balance H2S to form elemental Sulfur (S) and water in the Vapour Phase
30.5.1 Instrumentation System
a) DCS: Honeywell make TPS System installed in SIH #8 & GUS Operating stations
installed in CCR.
b) ESD System: Honeywell make Safety Manager System installed in SIH # 8 &
CCR.
30.5.2 Critical Safety Interlocks and Controls
a) SWS / Acid gas feed to unit Pressure Control & Interlock.
b) Engine Fuel gas / combustion Air to start up burner Ratio Control & Interlock.
c) Engine Fuel Gas / Combustion Air to Main Burner Ratio Control & Interlock.
d) Trim Air to Reaction furnace Flow Control.
e) 1st Reheat Burner Interlock & Control.
f) 2nd Reheat Burner Interlock & Control.
g) Incineration Interlock & Temp Control.
h) Waste Heat Boiler Interlock & Control.
Note: DCS & ESD System installed in SIH # 8 and CCR are not for sale.
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30.5.3 Field Instrument List
SR # CATEGORY MAKE QTY REMARKS
1 TAIL GAS ANALYZER AMETEK 1
2 CONTROL VALVE FISHER / MASONEILAN / HOPKINSON UK 37
3 CONTROLLER FOXBORO 4
4 DISPLACER LT MASONEILAN / MAGNETROL 11
5 FLOW ELEMENT DANIEL / SAMIL 39
6 FLOW SWITCH ITT BARTON 1
7 HMI SIEMENS 1
8 LEVEL GAUGE GLASS JERGUSON / PENBERTHY / K-TEK 10
9 LEVEL SWITCH MAGNETROL / MOORE / SOR 15
10 LOCAL INDICATOR ITT BARTON / BROOKS / KROHNE / WISE
/ AMETEK 101
11 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL /
AM GAUGE 122
12 PRESSURE SWITCH UE / ASHCROFT / SOR 15
13 SOLENOID VALVE ASCO 63
14 THERMOWELL THERMO ELECTRIC / TECNOMATIC / TC
LTD 56
15 TRANSMITTER ROSEMOUNT / YOKOGAWA /
HONEYWELL / ABB / FOXBORO / SMAR 81
16 MISC HONEYWELL 81
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31.0 UNIT – 75 OVERVIEW (Tail Gas Treating Unit)
31.1 PROCESS OVERVIEW
31.1.1 Objective
The purpose of the Tail Gas Treating Unit (TGTU) is to convert the remaining sulfur
compounds, mainly H2S and SO2, into liquid sulfur, thus increasing the recovery of sulfur
up to 99.5%.
The Unit uses Clauspol Process which is based on the continuation of Claus reaction
between residual H2S and SO2 in a solvent containing Polyethylene Glycol, molecular
weight 400, Salicylic Acid and Sodium Hydroxide. The tail gas also contains organic
sulfur compounds (COS and CS2) that is being hydrolyzed in the TGTU reactor
The produced H2S from the hydrolysis is used in the Claus reaction to produce liquid
sulfur.
31.1.2 Feed and Products Specification
Refer to attached Table-1 and Table-2. The different cases corresponds to the cases of
the Claus units: Air Mode Case and Oxygen Enrichment Mode. Since Oxygen mode is
not employed currently, only Air mode is recited here.
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a) Table-1: Design Case
Feed Tail Gas (lb/hr) Treated Gas (lb/hr) Sulfur Product (lb/hr)
FEED
H2S 2042.2SO2 1919.4S vapor (S1) 655S liquid (S1) 268.1COS 32.7CS2 155.6H2 0H2O 42353.7CO 0CO2 8237.9N2 116978.1Organic acid 0NaOH 0PEG 0Na elemenet 0
PRODUCTS :
H2S 113.9 0SO2 80.5 0S vapor (S1) 65.2 0S liquid (S1) 0 3619.2COS 19.6 0CS2 132.3 0H2 0 0H2O 43373 0CO 0 0CO2 8261 0N2 116978.1 0Organic acid 3.1 0NaOH 0 0PEG 19.8 2.2Na elemenet 0 0
Total (lb/hr) 172642.7 169046.5 3621.4
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b) Table-2: Actual Case
Feed Tail Gas (lb/hr) Treated Gas (lb/hr) Sulfur Product (lb/hr)
FEED
H2S 3312.5SO2 3113.3S vapor (S1) 1246.7S liquid (S1) 494.8COS 31.1
CS2 148.1
H2 0
H2O 36954.8
CO 0
CO2 14252.5
N2 110684.2
Organic acid 0
NaOH 0
PEG 0
Na elemenet 0
PRODUCTS :
H2S 115.2 0
SO2 83 0
S vapor (S1) 61.8 0
S liquid (S1) 0 6229.9
COS 18.7 0
CS2 125.8 0
H2 0 0
H2O 38644.9 0
CO 0 0
CO2 14274.5 0
N2 110684.2 0
Organic acid 3 0
NaOH 0 0
PEG 18.7 3.7
Na elemenet 0 0
Total (lb/hr) 170238 164029.8 6233.6
31.1.3 Process Description
Refer Sketch-1
The unit was commissioned in 2006. The tail gas exiting the Sulfur Recovery Units (U-04
and U-74), merges into one stream and enters at the bottom of the reactor, V-75-01,
where it is contacted with a countercurrent flow of the solvent. The reactor consist of four
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beds of Intalox saddles, where the gas-liquid is contacted. Above the first bed, a liquid
redistributor is provided for uniform spray of PEG for effective gas liquid contact. The
reactor is equipped with a demister, at the top, to limit PEG entrainment in the off gas
going to the incinerator. The solvent is circulated from the bottom of the reactor to top by
P-75-01 A/B/C and through exchanger E-75-01 that ensures the temperature control of
the reactor. The reactor is also equipped with a decantation system that separated the
liquid sulfur from the solvent and gathered at the bottom of the reactor where the sulfur is
kept in the liquid phase by steam coils mounted at the boot of the reactor. The liquid
sulfur, then, leave the reactor through a seal to a sulfur separator drum V-75-04 which is
also provided with a steam coil. In the sulfur separator, any entrained solvent is
separated. The sulfur separation drum can hold 2 days of production of sulfur. Then, the
sulfur is pumped by batch to degasifier Unit-35. All sulfur lines and valves are steam
jacketed to avoid sulfur solidification.
Catalyst, containing 10% weight of Salicylic Acid and sodium hydroxide, in the reactor is
converted into inactive sodium sulfate salts, insoluble in PEG, that deposits on the
packing and cause a pressure drop across the reactor that tends to increase with time
(hence, water washing of the reactor is required whenever pressure drop reaches to a
level where the unit cannot be operated). A catalyst make-up is required to maintain the
catalyst activity. The catalyst make-up drum is prepared in the mixing drum, V-75-02, with
demineralized water, caustic 32% Wt. solution and organic acid in powder. Another
vessel V-75-03 is provided to allow for easier control of the make-up catalyst quantities
and to hold catalyst make-up when preparing for a new solution in V-75-02. The catalyst
make-up is injected continuously by catalyst pumps P-75-02 A/B into the solvent
circulation pump at the discharge of pumps P-75-01 A/B/C.
31.1.3.1 Incinerator Section – ST-75-01
Refer Sketch 2
The objective of the new thermal incineration system is to convert all sulfur species in the
off gas from U-75 (U-04/74 in case of U-75 by-pass) to SO2 before it is disposed to
atmosphere at safe location. The new incinerator system is provided with Waste Heat
Boiler to recover heat from flue gas for intermediate superheated steam production.
In the incinerator system, air is supplied by two forced draft fans, BL-75-01A/B. BL-75-
01A is driven by steam turbine and BL-75-01B is driven by an electric motor. The steam
outlet from the steam turbine is routed to LP steam network after de-superheated by
BFW in de-super heater DS-75-02.
Off gas from U-75 (Tail Gas U-04/74 in case of U-75 by-pass) is sent to thermal oxidizer,
H-75-01 along with gases from sulfur pits/degasser/vent gases. In case of shutdown or
emergency, gases is routed to the old incinerator, ST-04-02.
Gases and air is mixed and heated in the thermal oxidizer to the required operating
temperature for conversion of sulfur species to SO2. The operating temperature is
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maintained in a range of 1600oF max., normal 1450oF, and 1430oF min. by controlling air
and fuel flow.
Heat from the gas leaving the oxidizer is recovered by Waste Heat Boiler producing
superheated IP steam. The Waste Heat Boiler consists of pre-evaporator E-75-03, super
heater coil E-75-04, evaporator E-75-05, steam drum V-75-07 and mud drum V-75-08.
The required BFW is supplied from the Refinery network to steam drum V-75-07 under
drum level control. The BFW blow-down from steam drum V-75-07 and from mud drum
V-75-08 is collected in blow down drum V-75-10, where hot BFW blow down is flashed at
LP steam header pressure. The waste heat recovery section cools down the flue gas
from thermal oxidizer before routed to vent stack ST-75-01 for safe disposal.
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31.2 STATIC & PIPING OVERVIEW
Brief write-up on Static and Piping equipment are given in Refinery Overview. However,
the summary of the Static Equipment for Unit-75 is listed as follows; List of Static
Equipment with History are furnished vide Appendix 2A hereof.
Sl. # Equipment Description No of Equipment
1 Exchangers, shell & tube 11
2 Air coolers 01
3 Vessels, columns, tanks, drums 15
4 Heaters 01
5 PSVs 31
31.3 ROTATING OVERVIEW
Unit 75 – Tail Gas produced in Sulfur recovery units 04 & 74 is further treated in this Unit
to distillates.
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All the Rotating equipment in 75 unit are inspected and maintained as per the guidelines
of Process Licensor & good Engineering practices. Turn around schedules are fixed as
per these guidelines to ensure safety, integrity, operability, reliability and efficiency of the
plant.
Unit 75 has 14 Pumps, 2 Fin fans, 2 Turbine, 1 Mixer & 4 blowers. List of Rotating
Equipment are furnished vide Appendix 2A hereof.
Pump/Turbine/Blower package auxiliary items (filters, SO/LO Coolers, Gearboxes, Seals,
Couplings, Piping items etc.) are not included in the list. Bidders can collect relevant
details of maintenance records, healthiness of the equipment and inspection records
during PTM/Site visit.
31.4 ELECTRICAL OVERVIEW
Unit -75 is considered as classified area (Class 1 Div. 2 Group D) as per Shuaiba
Refinery Hazardous Area Classification drawing (refer drawing # R-00-6030). The source
of power to the Unit is aided from Substation 20 which is located west side of the Unit.
The substation is Package Type & facilitated as non-classified area by employing
pressurized / Air-conditioned systems. Substation has a 6.6KV Switchgear fed from SS
1A & SS1B (ref. drawing # R-00-6012), 2 nos. of 440V MCC (MCC-75-01 & MCC-75-
02), 2 nos. of power transformers (1MVA, 6.6kV/440V) and an E.D.G control Panel &
emergency MCC (MCC-75-03). The Substation 20 will be retained post SHU. The
Substation is equipped withwith Fire Detection, Alarm & Suppression system installed
under Contract CB/CSPD/2004 & commissioned on 2016. Battery Charger along with
Battery Backup bank are also available.
The list of HT & LT Motors associated with this Unit is enclosed vide Appendix 2A
hereof. Motors rated above 280HP is designated as HT motor and if less than or equal to
280HP, as LT motor . Unit -75 has 3 nos of 6.6KV motor and 19 nos. 440V motors. All
motors are under Preventive Maintenance program by maintenance department.
Other electrical equipment such as Light fixtures, Distribution Boards, junction Box,
power sockets, push button stations, Fire Alarm detectors, Lighting transformers (25kVA
440/415V), above ground cables, conduits etc. available in the Unit are not listed
separately. Bidders can collect relevant details during Site visit.
Unit # 75 is powered from retained Substation # 20.
31.5 INSTRUMENTATION OVERVIEW
Tail Gases produced in Sulfur Recovery Units 04 & 74 is further treated in Tail Gas
Treating Unit to Convert remaining Sulfur compounds to Liquid Sulfur in presence of
Catalyst.
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31.5.1 Instrumentation System
a) DCS: Honeywell make TPS System installed in SIH #8A & GUS Operating
stations installed in CCR.
b) ESD System: Honeywell make Safety Manager System installed in SIH # 8A &
CCR.
31.5.2 Critical Safety Interlocks and Controls
a) Tail Gas feed to Unit Interlock & Control.
b) Tail Gas feed Pressure High Interlock.
c) Solvent Recycle Pumps P-75-01 A/B/C Interlock.
d) Clauspol Reactor V-75-01 Interlock.
e) Area Sump Tank TK-75-04 Interlock.
f) Area Sump Tank TK-75-04 Interlock.
g) Incinerator Section H-75-01 Interlock & Control.
h) Waste Heat Boiler V-75-07 Interlock & Control.
i) Air Blower BL-75-01A Interlock & Control.
j) Gas Detectors Interlock.
31.5.3 Field Instrument List
SR # CATEGORY MAKE QTY REMARKS
1 TAIL GAS/MULTI GAS &
SO2 ANALYZER AMETEK 880NSL / AMETEK 900D2 / AMETEK
920 5
2 CONTROL VALVE FISHER / MASONEILAN / VIRGO/ROTORK 60
3 FLOW ELEMENT DANIEL / SAMIL 23
4 LEVEL GAUGE GLASS JERGUSON 2
5 LOCAL INDICATOR ITT BARTON / BROOKS / KROHNE / WISE /
AMETEK 98
6 PRESSURE GAUGE ASHCROFT / WIKA / WISE / GENERAL / AM
GAUGE 84
7 PRESSURE SWITCH UE 2
8 SOLENOID VALVE ASCO 42
9 THERMOWELL THERMO ELECTRIC / TECNOMATIC / TC LTD 63
10 TRANSMITTER ROSEMOUNT / YOKOGAWA / HONEYWELL /
ABB / FOXBORO / SMAR 155
11 MISC HONEYWELL 44
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32.0 UNIT – 60 OVERVIEW (Offsite Piping)
The main pipe rack interconnecting the Processing Units of SHU Refinery is designated
as Unit 60. All pipelines between Units or tank farm traverse through this pipe rack and
no line is routed directly between Units. The Pipe rack has three decks and is of
structural steel construction & fire proofed. Lines enter / exit each unit at one battery limit
directly to this Unit 60 pipe rack.
Sl. # Equipment Description No of Equipment
1 Vessels 01
2 Desuperheater 03