VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) November 2008

DUNG QUAT REFINERY Rev. : 1

OPERATING MANUAL Chapter : 3
UNIT CDU (011) Page : 30/38



Actions:
Action Tag
No.
P&ID No. Service
P-1121A 124 Water pump stopped
P-1121B 124 Water pump stopped
011-FIC-025 124 Condensate flow controller set to manual and
output 0%
This trip is manually reset by 011-UHSR-016
3.1.2.32. P-1122A/B Tempered water pumps protection (011-UX-024)
Purpose: When there is a low low level in the Tempered Water Drum D-1115, the
Tempered Water Pumps are stopped.
Initiators:
Initiator Tag No.
Time
Delay
P&ID No. Cause
011-LXALL-069
0.5
seconds
126 Low low level in D-1115 (Water)
Actions:
Action Tag
No.
P&ID No. Service
P-1122A 126 Tempered Water pump stopped
P-1122B 126 Tempered Water pump stopped
011-FIC-030 126 Tempered Water flow controller set to
manual and output 0%
This trip is manually reset by 011-UHSR-024.
3.1.2.33. H-1101 Purge and Start-up sequence (011-UX-047 to 051)
For detail description of Heater purge, pilot gas, fuel gas, fuel oil and off gas ignition
sequences refer to the following drawing 8474L-011-A3501-0110-001-003, which has been
included in attachment 2.
3.2. OPERATING CONDITIONS
Refer to Process Flow Diagrams, which have been listed in 14.2 Process Flow Diagrams and
Material Selection Diagrams, included in attachment 6.
3.3. PROCESS VARIABLES
This purpose of this chapter is to explain the main variables in Unit control.
The variables described are: CDU feed rate, fired heater outlet temperature, main
fractionator overhead temperature, pumparounds duty and stabilizer bottom temperature.
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DUNG QUAT REFINERY Rev. : 1
OPERATING MANUAL Chapter : 3
UNIT CDU (011) Page : 31/38



3.3.1. CDU feed rate
The unit is fed by the crude charge pumps in unit 60. The crude oil flows through the cold
preheat train and enters into the desalter. In order to keep constant the desalter pressure,
the crude oil flow at the crude charge pumps is set to the same flow as the measure at the
fired heaters (011-FIC-069), by the controllers 011-FY-092 and 011-HY-002.
If the pressure in the desalter increases the inlet flow from crude charge pumps will be
reduced.
3.3.2. Fired heater outlet temperature
This variable is very important, due to the fact that the column overflash is highly dependent
of this temperature. If an increase in duty is required, the air flow is increased before the fuel
rate is increased. On the other hand, if a decrease in heater duty is required, fuel flow rate is
firstly reduced and secondly air flow rate is reduced. This control scheme ensures that the
fired heater is always operating with an air excess, to ensure a good combustion and avoid
risk of after burning in the stack.
3.3.3. Main fractionator overhead temperature
The overhead vapour temperature is controlled by the amount of heat removed from the top
pumparound circuit. This temperature is important because the overhead product naphtha
end point can be adjusted by changing the set point. If the temperature is higher than the set
point, the top reflux duty will increase. As a result the overhead product end point and
quantity will be reduced. On the other hand, if the temperature is lower than its set point, the
overhead product end point is lower than it should be and the control system will decrease
the top pumparound duty. So, if an increase in the overhead vapour product end point and
quantity is desired, the top pumparound temperature set point will be increased.
3.3.4. Main fractionator pressure.
The column operating pressure depends on the pressure controlled at the main fractionator
accumulator drum D-1103. The operating pressure of a distillation column is related with the
relative volatility of the components to be separated in the different streams. Relative
volatility is a measure of the differences in volatility between 2 components, and hence their
boiling points. It indicates how easy or difficult a particular separation will be. As pressure
increases the relative volatility approaches to one. This means that the vapour pressure
characteristics of the components are more similar, and therefore they are more difficult to
be separated.
In addition, if the remaining variables keep constant, an increase in the column pressure will
decrease the overflash and therefore the internal column flow and the separation achieve will
be lower.
3.3.5. Pumparounds.
Pumparounds must be well controlled to obtain specific products. Pumparound duty control
is essential to keep internal liquid and vapour flow inside the column. The control is acting on
the recycled product flow to the column, and on the total pumparound duty (through duty
controller).
Pumparounds are critical to maintain the optimum vapour/liquid rates in the fractionation of
the column. Inadequate pumparound heat removal and poor pumparound distribution will
result in higher column pressure, poorer fractionation and an increase in the flash zone
pressure. Excessive pumparound heat removal may result in difficulties in maintaining some
end point and may cause internal flooding.
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3.3.6. Specification Adjustement.
The principal specifications to which the products from the fractionator can be adjusted are
the boiling point ranges and the flash point. In general, if the fractionation is good, the end
boiling point of a side-cut equals the initial-point of the next heavier product plus a gap. A
gap is the result of a good fractionation; however overlap is more normal and will increase as
fractionation efficiency decrease. Product withdrawal flow rate are adjusted to provide the
required end points for the products and are generally set up from the top of the column
working down.
As a general rule, increasing the drawoff rate will raise the end point of the side stream cut
whilst decreasing the drawoff rate will lower its end point. An indication of the end point is the
draw off temperature of the stream leaving the column. Increasing the product withdrawn,
increases the draw off temperature and the product end point
The flash point of LGO, and HGO products can be modified by adjusting the flow of stripping
steam via, FIC-017 and FIC-019 respectively (to increase the flashpoint the stripping steam
has to be increased). However, the stripping steam can only be increased to the point where
it starts to interfere with the end point of the next higher product. If a further increase in the
flashpoint is required, other changes must be made, allowing an increase of the end point of
the next higher product.
Kerosene flash point can be adjusted by the kerosene stripper reboiler E-1110 duty via 011-
UIC-031 or, in case reboiler E-1110 is out of service, with steam flow via 011-FIC-015.
The specific gravity is directly related to initial and final product boiling point, so changing the
products yields is required to achieve this specification.
The freeze point is related to chemical composition of the product. As final boiling point
increases, the paraffin content in the product increases too, so the freeze point obtained will
be higher.
If residue entrainment occurs HGO can get black colour. This means that the washing
section (between HGO draw off tray and flash zone) doesnt have enough liquid flow. It is
necessary to increase the overflash or reducing the HGO draw off rate.
3.3.7. Stripping Steam in the Main fractionator column.
Increasing this flow rate, it is possible to decrease the content of lighter fractions still present
in the residue, increasing flash point and the initial boiling point of the residue. The stripping
steam flow, controlled by 011-FV-012 will affect temperature of the flash zone and amount of
overflash.
3.3.8. Overflash
Overflash is that portion of the feed which is vaporized in addition to the overhead and
sidestream products. The overflash condenses on the wash section plates and returns to the
flash zone and bottoms stripping section. Its purpose is to prevent coke deposition in the
wash section plates and preventing entrainment of residue up into HGO section, which
would result in off spec HGO.
The CDU is designed for a minimum of 5% overflash.
3.3.9. Stabilizer temperature
The stabilizer bottom temperature has to be controlled in order to maintain the C4
-

specification in this stream. This control is a cascade loop in which the stabilizer bottom
temperature is controlled by the high pressure steam flow through the desuperheater (DS-
1101). If the bottom temperature decreases, the amount of high pressure steam will
increase, and therefore the reboiler duty, in order to raise the temperature again.
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OPERATING MANUAL Chapter : 3
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The temperature in the top section at constant pressure defines the quality of the LPG
product; this temperature is controlled on E-1122 (auto variable pitch controller). Settling this
control at a lower temperature will decrease LPG C5 content and will increase the tower
reflux. Increasing this temperature will increase quantity and C5 content in the LPG and will
reduce the reflux rate.
3.4. INTER-UNIT CONTROL SCHEME
3.4.1. Atmospheric Residue from the CDU to the RFCC
3.4.1.1. Objective
The objective of this system is to control the level in the bottom of the Main Fractionator
column and route as much of the outgoing atmospheric residue to the RFCC as is required
3.4.1.2. Description
This description should be read in conjunction with the following:
CDU P&IDs:
- 8474L-011-PID-0021-112
- 8474L-011-PID-0021-125
RFCC P&IDs:
- 8474L-015-PID-0021-301
Schematic 1: Atmospheric residue from CDU to RFCC
The level in the Main Fractionator, T-1101 is controlled by a typical Xxx40 three way split
range level controller 011-LIC-007 (direct acting). In the low range (0-33%) the signal from
011-LIC-007 goes to low selector 011-LY-007B, which selects between 011-LIC-007 and the
feed requirement of the RFCC to control the flow to the RFCC. In the mid range (33-67%)
011-LIC-007 resets the set point of 011-FQIC-026 and in the high range (67-100%) 011-LIC-
007 resets the set point of 011-FQIC-027.
011-FQIC-026 and 011-FQIC-027 are parallel controllers used to regulate the flow of residue
to storage. 011-FV-026 is a smaller valve than 011-FV-027 and will normally be sufficient to
control the amount of residue to storage whilst the RFCC is on-line. In the event that the
RFCC is off-line then 011-FQIC-026 will be fully open and 011-FQIC-027 will control the flow
to storage.
The RFCC feed is controlled by a split range level controller, which takes flow preferentially
from the CDU by cascading onto 011-FQIC-029 via 011-LY-007B. If there is not enough
flow coming from the CDU then flow is taken from storage by acting on a flow controller FIC-
402 in the line from storage.
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