PETRONAS TECHNICAL STANDARDS

STEAM INJECTION SYSTEMS FOR SAFEGUARDING

THERMAL CRACKING UNIT

PTS 10.02.51.11
NOVEMBER 2012

2012 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means
(electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.

PTS Circular
2012 - 1

PTS No:
PTS Title:

10.02.51.11
Steam Injection Systems for Safeguarding Thermal Cracking Units

This revision of PTS 10.02.51.11 - Steam Injection Systems for Safeguarding Thermal Cracking
Units (November 2012, Revision 3) has been updated to incorporate PETRONAS Lessons Learnt, Best
Practice and new information issued by relevant industry code and standards. All updates in the
document are highlighted in italic font.
The previous version of this PTS 10.02.51.11 (November 2009) will be removed from PTS binder / erepository from herein onwards.
The custodian of this PTS is:
Name: Srinivasa Karthikeyan
Tel. No: 03-27836154
Please direct any questions regarding this PTS to the above-named.
Document Approval

Revision History
Rev No.

Reviewed by

Approved by

Date

Revision 0

Oct 1984

Revision 1

Dec 1994

Revision 2

Kazuo Tanaami

Zainab Kayat

Nov 2009

Revision 3

S Karthikayen

Zainab Kayat

Nov 2012

PTS 10.02.51.11
November 2012
Page 4
PREFACE
PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication, of
PETRONAS OPUs/Divisions.
They are based on the experience acquired during the involvement with the design, construction,
operation and maintenance of processing units and facilities. Where appropriate they are based on, or
reference is made to, national and international standards and codes of practice.
The objective is to set the recommended standard for good technical practice to be applied by
PETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemical plants,
marketing facilities or any other such facility, and thereby to achieve maximum technical and economic
benefit from standardisation.
The information set forth in these publications is provided to users for their consideration and decision to
implement. This is of particular importance where PTS may not cover every requirement or diversity of
condition at each locality. The system of PTS is expected to be sufficiently flexible to allow individual
operating units to adapt the information set forth in PTS to their own environment and requirements.
When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the quality of
work and the attainment of the required design and engineering standards. In particular, for those
requirements not specifically covered, it is expected of them to follow those design and engineering
practices which will achieve the same level of integrity as reflected in the PTS. If in doubt, the Contractor
or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the owner.
The right to use PTS rests with three categories of users:
1)
2)
3)

PETRONAS and its affiliates.

Other parties who are authorized to use PTS subject to appropriate contractual
arrangements.
Contractors/subcontractors and Manufacturers/Suppliers under a contract with users
referred to under 1) and 2) which requires that tenders for projects, materials supplied or
- generally - work performed on behalf of the said users comply with the relevant
standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with users,
PETRONAS disclaims any liability of whatsoever nature for any damage (including injury or death)
suffered by any company or person whomsoever as a result of or in connection with the use, application
or implementation of any PTS, combination of PTS or any part thereof. The benefit of this disclaimer
shall inure in all respects to PETRONAS and/or any company affiliated to PETRONAS that may issue
PTS or require the use of PTS.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual
arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed by users to
any company or person whomsoever and the PTS shall be used exclusively for the purpose they have
been provided to the user. They shall be returned after use, including any copies which shall only be
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The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe custody and
PETRONAS may at any time require information satisfactory to PETRONAS in order to ascertain how
users implement this requirement.

PTS 10.02.51.11
November 2012
Page 5
TABLE OF CONTENTS
1.0

INTRODUCTION ..........................................................................................................................................6

1.1
1.2
1.3
1.4
1.5
1.6

SCOPE ............................................................................................................................................................ 6
DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS .......................................................... 6
DEFINITIONS .................................................................................................................................................. 6
CROSS-REFERENCES ...................................................................................................................................... 6
SUMMARY OF CHANGES ............................................................................................................................... 7
ABBREVIATION .............................................................................................................................................. 7

2.0

AUTOMATED STEAM-OUT SYSTEM .............................................................................................................8

2.1
2.2
2.3

WHY STEAM INJECTION / DECOKING REQUIRED? ......................................................................................... 8

PRINCIPLE OF OPERATION ............................................................................................................................. 8
LOSS OF FEED (REFER TO FIGURE 2.1) ................................................................................................................ 9

3.0

CONTROL NARRATIVE (REFER TO FIGURE 3.1)...........................................................................................11

3.1
3.2
3.3

GENERAL FEATURES OF STEAM-OUT SYSTEM ............................................................................................. 13

STEAM SUPPLY ............................................................................................................................................ 13
ISOLATION OF FEED GAS AND INTRODUCING STEAM ................................................................................. 13

4.0

UTILITY FAILURES ......................................................................................................................................14

4.1
4.2

INSTRUMENT AIR FAILURE (REFER TO APPENDIX 8, 9 AND 10) .......................................................................... 14

ELECTRICITY FAILURE (REFER TO APPENDIX 8, 9 AND 10) ................................................................................... 14

5.0

INSTRUMENTATION ..................................................................................................................................15

5.1

RESET OF SYSTEM AFTER USE ...................................................................................................................... 15

6.0

REFERENCES ..............................................................................................................................................16

APPENDICES
APPENDIX 1: AUTOMATED STEAM-OUT SYSTEM ...................................................................................................... 17
APPENDIX 2: STEAM SUPPLY ...................................................................................................................................... 18
APPENDIX 3: BLOCK AND CONTROL VALVES FOR STEAM INJECTION ........................................................................ 19
APPENDIX 4: FURNACE FEED CONTROL VALVES ........................................................................................................ 20
APPENDIX 5: RESIDUE CRACKING FURNACE WITHOUT BACK-PRESSURE CONTROL VALVE ...................................... 21
APPENDIX 6: RESIDUE OR DISTILLATE CRACKING FURNACE WITH BACK-PRESSURE CONTROL VALVE OR RESIDUE
CRACKING FURNACE WITH SOAKER AND BACK-PRESSURE CONTROL VALVE ................................................... 23
APPENDIX 7: BARRIER-STEAM INJECTION INTO RESIDUE FURNACE TRANSFER LINE OF SOAKER-TYPE THERMAL
CRACKING UNITS ................................................................................................................................................ 24
APPENDIX 8: STEAM INJECTION INTO RELIEF VALVE INLET/OUTLET CONNECTIONS ................................................ 25
APPENDIX 9: AUTOMATED STEAM INJECTION SYSTEM - RESIDUE OR DISTILLATE CRACKING FURNACE COILS WITH
BACK-PRESSURE CONTROL VALVE IN FURNACE OR SOAKER OUTLET LINEAUTOMATED STEAM INJECTION
SYSTEM - RESIDUE OR DISTILLATE CRACKING FURNACE COILS WITH BACK-PRESSURE CONTROL VALVE IN
FURNACE OR SOAKER OUTLET LINE ................................................................................................................... 26
APPENDIX 10:BARRIER-STEAM INJECTION IN TRANSFER LINE OF RESIDUE CRACKING FURNACES FOLLOWED BY
SOAKERS, AND PURGE STEAM INJECTION INTO RELIEF VALVE CONNECTIONS ................................................. 27
APPENDIX 11: VALVES POSITIONS AND FAIL-SAFE POSITIONS AND CORRESPONDING SOLENOID POSITIONS ......... 28
APPENDIX 12: EXAMPLE P&ID OF CRACKER HEATER ................................................................................................. 29
APPENDIX 13: EXAMPLE P&ID OF STEAM SUPPLY SYSTEM ....................................................................................... 30

PTS 10.02.51.11
November 2012
Page 6
1.0
1.1

INTRODUCTION
SCOPE
This PTS describes the minimum requirements for the design and engineering of the steam
injection facilities in various thermal cracking units, for safeguarding their integrity and
operation. The purpose of the system is to protect the furnace tubes from coking up during an
emergency situation, e.g. In the event of unexpected feed failure. After initiation, the steam-out
operation should therefore be quick, reliable and automated.
This PTS is a revision of the publication with the same number dated November 2009. This
PTS explains the principles of the steam-out system but it does not cover furnace control
systems except where certain control features are necessary for the operation of the steam-out
system.
These facilities consist of:
- Automated steam-out facilities for the radiant section coils of the hydrocarbon cracker furnace.
This PTS shall be used for all new designs and applied to existing installations if modifications
are required. Some design details may need modification to suit the requirements of individual
installations.

1.2

DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorized by PETRONAS, the distribution of this PTS is confined to
companies forming part of PETRONAS group and to Contractors nominated by them. This PTS
is intended for use in oil refineries.
If national and/or local regulations exist in which some of the requirements may be more
stringent than in this PTS, the Contractor shall determine by careful scrutiny which of the
requirements are the more stringent and which combination of requirements shall be
acceptable as regards safety, economic and legal aspects. In all cases the Contractor shall
inform the Principal of any deviation from the requirements of this document which is
considered to be necessary in order to comply with national and/or local regulations. The
Principal may then negotiate with the Authorities concerned with the object of obtaining
agreement to follow this PTS as closely as possible.

1.3

DEFINITIONS
The Contractor is the party which carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a facility.
The Principal may undertake all or part of the duties of the Contractor.
The Manufacturer/Supplier is the party which manufactures or supplies equipment and
services to perform the duties specified by the Contractor.
The Principal is the party which initiates the project and ultimately pays for its design and
construction. The Principal shall generally specify the technical requirements. The Principal
may also include an agent or consultant authorized to act for, and on behalf of, the Principal.
The word shall indicate a requirement.
The word should indicate a recommendation.

1.4

CROSS-REFERENCES
Where cross-references to other parts of this PTS are made, the referenced section number is
shown in brackets. Other documents referenced in this PTS are listed in (5).

PTS 10.02.51.11
November 2012
Page 7
1.5

SUMMARY OF CHANGES
The previous edition of this PTS was dated November 2009. Other than editorial changes, the
following are the major changes to the previous edition. Hydrocarbon cracker unit has been
chosen. However certain information shall be retained in APPENDICES.
Old Section

New Section
4

1.6

2.0

2.0

3.0

3.0

4.0

4.0

5.0

5.0

5
6

Change
This section is completely revised with new process
Automated steam out system : Principle of operation, loss
of feed
This section is completely revised with new process Control
narrative
This section is completely revised with new processUtility
failure
This section is completely revised with new process
Instrumentation

ABBREVIATION

HP

High Pressure

LP

Low Pressure

BFW

Boiler Feed Water

N2

Nitrogen Gas

B/V

Block Valve

QC

Calorific Controller

PC

Pressure Controller

COT

Coil Outlet Temperature

FC

Flow Controller

HC

Special Controller

O/L

Outlet

TLV

Transfer Line Valve

LEL

Low Explosive Limit

TLE

Transfer Line Exchanger

PTS 10.02.51.11
November 2012
Page 8
2.0

AUTOMATED STEAM-OUT SYSTEM

Note: Refer to APPENDIX 11 & 12 for P&ID Illustration

2.1

WHY STEAM INJECTION / DECOKING REQUIRED?

Periodically, the Cracking heaters shall be taken out of service periodically to remove coke that
builds up in the radiant tubes. The parameters which indicate whether a heater needs to be
decoked are the maximum tube metal temperature, the Primary TLE outlet temperature and the
pressure drop across the heater's radiant coil.
Decoking is accomplished when the heater is operated on steam only, and isolated from the
effluent header. Air along with dilution steam is injected into the heater at a carefully controlled
outlet temperature (approximately 850 C) to "burn off" the coke. Burning of the coke forms
carbon oxides (CO and CO2). The steam-air decoking reaction is exothermic. Therefore, hot
spots can develop on tube wall. Care shall be taken during decoking to limit the radiant coil
tube metal temperatures to the maximum tube wall temperature (design) to avoid damaging the
tubes. If excessive temperature occurs the air flow should be reduced. The decoking effluent
shall be sent through the Primary Transfer Line Exchangers (TLE) and Secondary TLE and
then back to the firebox of the same heater. Any coke fines in the effluent shall be burned by
burner fire.

2.2

PRINCIPLE OF OPERATION
A hydrocarbon cracker unit (e.g hydrocarbon cracker) shall be decoked on a regular basis for
operating flexibility. Usually decoking procedure is done before a shutdown. There are times
when it has to be done during trips and emergency shutdowns. Lengthening the cycle run for
decoking could minimize cost of utilities usage e.g steam; and also increase profitability due to
longer on-stream time. Decoking however is required when one of the following abnormal
situations occurs:

Tube wall metal temperature reaches maximum temperature as per licensor specification in
the radiant coil. A pyrometer survey using a temperature gun should be done based on the
operations Preventive Maintenance or requirements.
Excessive pressure drop across Transfer Line Exchangers (TLE). High pressure drops
normally is an indication of blockage or fouling. Depending on design, an increase of certain
pressure as specified by licensor could indicate fouling has occurred.
When overall pressure drop of TLE and radiant coils increase by differential pressure
(specified by licensor) above the start of run.
When fouling of TLE causes outlet temperature to reach temperature specified by licensor
(mechanical design limit).

During emergency shutdown, the hydrocarbon feed supply shall be cut off immediately to
prevent severe coking in the furnace tube. It should be an automated control system that shall
trigger the control valve to shut off hydrocarbon feed inlet to the cracking unit. Provision shall
be made to shut off the feed inlet to the cracking unit by an automated control system.
The remaining reactant shall be purged off with steam to prevent coking at the tube. About 2030 minutes of time shall be considered to purge off the gas in the tubes completely. Steam is
triggered by fully opening the stream valve during emergency shutdown of the cracking unit.
The steam shall be supplied from reliable source such as auxiliary reboiler or utility boiler which
has sufficient pressure for purging.
The steam shall be supplied with a high selector controller from the two inputs below:
1. Minimum flow rate of steam supply to prevent coking
2. Steam to hydrocarbon gas ratio specified by licensor.

PTS 10.02.51.11
November 2012
Page 9
The cracker trip shall be initiated by any of the initiators, as listed below. The automated steam
injection the facility shall be activated for decoking/ cooling of the coils. All other effects shall be
as per the original C&E (cause and effect) matrix.

2.3

Loss of Amine Treatment System

Loss of hydrocarbon feed

Loss of Dilution steam

Loss of fuel gas

Loss of boiler feedwater (BFW)

Loss of steam superheat temperature control

Radiant Coil Failure

Convection section hydrocarbon coil failure

BFW preheat coil Failure

Primary Transfer Line Exchanger failure

Secondary Transfer Line failure

Low Level in the Steam Drum BFW

Loss of Induced Draft Fan

Fire in fire box

LOSS OF FEED (Refer to Figure 2.1)

Loss of hydrocarbon feed to any of the heaters shall trip an interlock (via a low-low-low
pressure switch (PSLLL-1) which cause the hydrocarbon feed valve to shut and force dilution
steam valve (FV-5) to a minimum preset position, equivalent to 90% of normal flow.
Note: The emergency makeup dilution steam shall be free of condensation. The rapid expansion of any condensate in
this line may cause damage in the heater.

The heater draft shall be reset to minus specific level (mm) H2O (depending on
licensor) and the induced draft damper shall remain under normal control.
Following the emergency action, dilution steam flow shall be adjusted (by the operator)
to maintain dilution steam temperatures at the crossovers (TIA-1) to a maximum
temperature specified by licensor. As the refractory lining in the fire box cools down,
further manual adjustment of the damper position (or burner register openings) and
dilution steam rate shall be required in order to proceed with an orderly shutdown, a
heater decoke or holding a high steam standby condition. Maintain the tube metal
temperature as uniformly as possible by relighting some wall burners as required.
Makeup dilution steam availability shall be reliable, even during a total feed failure. Maintain at
least specific ratio of dilution steam flow. Convection section shall be protected but it cannot
stop the rapid cool down of the radiant coil and the formation of coke being spalled off the tube
wall.

PTS 10.02.51.11
November 2012
Page 10
Any Other Signal
PALLL

FY2

SV1

PIA1

PT

PT1

H
L
LL

FY

TDC

HIC1

MY
FV6

Feed Gas

PSLLL1

FICA1

FT1

Heating
Coils

MV1

P-37
FICA

Pressure Compensation

FV1
FT3
FT

Heating
Coils

P-21
FICA2

FY1

HIC2

FV2
TIA1

FV5

FV3
FV4

MV2

TIC

FT2

Steam

Figure 2-1: Common Setup for Hydrocarbon Feed and Steam Injection

Below are the associated valves for safeguarding of thermal cracker

2-1: List of Valves for safeguarding Thermal Cracker

Valve

Fluid

Tag

Type of
Valve

Description

Action

Dilution
Steam
(manual block
valve)

Steam

MV2

Globe
valve

Steam isolation from K.O

drum to heater coils

Manually open
at control room

Steam
control
header)

Steam

FV-5

Globe
valve

Controlling steam to coil

flow header

ATO/ FC

Individual
Flow
controller

Steam

FV1/2/3/4

Globe
valve

Controlling
steam
respective coil

ATO/FC

Hydrocarbon
Feed isolation
valve

Hydrocarbon

MV1

Globe
valve

Hydrocarbon isolation for

feed
gas
during
emergency

flow
(to

to

Manually close
at control room

PTS 10.02.51.11
November 2012
Page 11
3.0 CONTROL NARRATIVE (Refer to Figure 3.1)

The control scheme has two main transmitters: FT-1 and FT-2 and two controllers HIC-1
and HIC-2.

FT-1 is the measurement of the feed flow rate to determine the corresponding flow rate of
the dilution steam.

FT-3 is the minimum flow rate set point for dilution steam supply to produce syn gas and
protect the tube from coking.

Both controller output shall be fed to a HIGH SELECTOR function block FY-1 which then
shall drive FV-5 control valve opening to adjust the dilution steam supply.

When FICA-1 detects higher flow rate than set point, the controller output shall shift to high
(controller direct action), FY-2 select FICA-2 and drive FV-5 to open and release more
dilution steam from reliable steam source such as boiler.

When PIA-1 detects lower flow rate than the set point, the controller output shall shift to high
(controller reverse action), FY-2 select HIC-2 to drive FV-5 to maintain at minimum opening
to prevent the flow rate from decreasing lower than minimum dilution steam flow rate
required. This precaution measurement is to prevent coking in the tube. This addition of
control shall remove the current human intervention of opening the FV-5.

The feed gas line shall be installed with a ESD (Emergency shut down) valve (Air to Open)
which link to the furnace heating element. In the event that the furnace is tripped, the feed
gas supply shall be cut off automatically and immediately through ESD (MOV). Human
intervention using MOV (motorized valve) shall cause delay and hence more hydrocarbons
shall be brought forth into the furnace even after the Cracking heater is tripped.

PTS 10.02.51.11
November 2012
Page 12

Caution: Analyzer shall be

taken out of operation to
prevent steam condensing
inside the tubings and damage
the analyzers.

Some controllers should be

switched from auto to manual so
that operators can control steam
injection rate more thoroughly.

Hot spots on coil should be close

monitored
with
pyrometer
(temperature gun). Air flow
should be decrease or switch off
burner close to the hot spot.

For each coil, adjust flowrate so

that each coil shall have the
same flow rate. If flow stable, it is
advised to put FICA control in
auto.

Figure 3.1: Process flow chart for steam Injection to safeguard cracker tube from coking during
emergency shutdown

PTS 10.02.51.11
November 2012
Page 13
3.1

GENERAL FEATURES OF STEAM-OUT SYSTEM

Two main important components for a steam-out /decoking procedure shall be provided.
1. Steam supply
2. Isolation of feed gas and introducing steam

3.2

STEAM SUPPLY
Steam shall be taken from normal medium pressure or high pressure supply system depending
on the required pressure and design of the heaters. It is most important that the steam is dry to
avoid surges in downstream equipments.
A knock out drum is required to remove condensate and supply steam to the coils for steamout. A dedicated steam line connected to the feed gas line shall be available with flow control
(FICA) to adjust the steam flowrate.

3.3

ISOLATION OF FEED GAS AND INTRODUCING STEAM

Table below indicates common valves which shall be open or isolated during the steamout/decoking procedure:

3-1: List of Valves and Their Actions

Valve

Description

Open

Dilution Steam (manual block

valve) MV-2

Steam from K.O drum to heater

coils

Steam flow control (to header)

FV-5

Controlling
header

Steam flow control (individual

coils) FV-1/2/3/4

Controlling steam from header to

individual coils.

Hydrocarbon feed to heater

(manual block valve) MV-1
Hydrocarbon feed to heater
(Solenoid) SV-1
Cracked gas (XV)

Feed of hydrocarbon to cracker

Decoking effluent (XV)

Outlet of decoking from cracker

steam

to

coil

Close

flow
X

X
X

Feed of hydrocarbon to cracker

X
Cracked gas outlet
X
X

PTS 10.02.51.11
November 2012
Page 14
4.0

UTILITY FAILURES
The furnace coil steam-out system shall be designed to remain operable in the event of either
electricity or instrument air failures. The following description is for a residue furnace without
back-pressure control valve but it also applies to any cracking furnace system with a backpressure control valve.

4.1

INSTRUMENT AIR FAILURE (Refer to Appendix 8, 9 and 10)

The spring actions of valves FV-1/2/3/4, FV-6,SV-1, FV-5 are such that when local or total air
failure occurs, the valves affected move to their fail-safe positions, bleed valve closes, FV1/2/3/4 shall open fully since the pre-setting devices, which limit the steam flow, depend on
instrument air. However, the first steam valve FV-5 shall remain shut, preventing steam from
entering the system. The furnace feed control valves FV-6 open fully, so the feed pump shall
continue to supply feed to the furnace.
If desired, it is possible to steam-out the coils in these circumstances. Switch HZA shall trip the
feed pump and condensate pump (if the furnaces are still being fired, the loss of feed shall shut
the fuel supply) and de-energize the solenoids, but the steam shall not flow because valve FV-5
remains shut.
When the pump is tripped, steam shall be admitted and controlled by opening of valve FV-5
using its hand wheel. The steam flow is controlled by the degree of opening of this valve.
Valves E and F shall still be open, and the non-return valve downstream of the feed pump is
relied upon to prevent steam backing up the feed line through the pump. Hence, the block valve
on the pump discharge should be closed at the first opportunity.

4.2

ELECTRICITY FAILURE (Refer to Appendix 8, 9 and 10)

The system is based on the use of an uninterrupted instrument electricity supply. However, the
possibility of instrument electricity failure has been allowed for in the design of the steam-out
system, without increasing its complexity.
The solenoid-operated valves are normally energized and, upon instrument electricity failure,
shall take up their de-energized positions. Furthermore, the feed pump shall be tripped by the
absence of instrument electricity supply to a relay in the mains supply to the pump. The same
holds for the condensate injection pump. The system then comes into operation automatically.
Controllers HIC-1 and HIC-2 can be used to control the steam flow.
Interruptions of the main electricity supply shall not affect the steam-out system, only the feed
pump and the condensate injection pump. The furnace feed FZAs shall therefore trip the
furnace fuel shut-off valves.
In case of loss of feed flow, if the feed pump can be restarted within about 5-10 minutes (for a
coil cracker) or 10-20 minutes (for a soaker cracker) there is no need to use the system at all. If
the pump remains out of action for longer periods, the steam-out system shall be initiated.

PTS 10.02.51.11
November 2012
Page 15
5.0

INSTRUMENTATION
The instruments for the steam-out system shall be grouped together with the relevant furnace
instrumentation. The logic diagrams are shown in Standard Drawings S 31.008 and S 31.009.

5.1

RESET OF SYSTEM AFTER USE

After activation of the steam-out system, the solenoids shall remain de-energized until the
electric circuit is reset manually, also from the panel room. This resetting system is divided into
two groups, one for the steam supply valve solenoids (HIC-2), and the other for the furnace
feed and back-pressure control valves (HIC2-1). First reset the steam supply solenoid and then
the furnace feed and back-pressure control valves.
If, in case of instrument air failure, the steam valve FV-5 has been forced (partly) open, its
handwheel should be used to ensure that, upon resetting, this valve is indeed returned to its
original position: closed by the spring action of valve FV-5, and decoupled from its handwheel.

PTS 10.02.51.11
November 2012
Page 16

6.0

REFERENCES
In this PTS reference is made to the following publications:
Unless specifically designated by date, the latest edition of each publication shall be used, together with any
amendments/supplements/revisions thereto.

PETRONAS STANDARDS
Index to PTS publications and standard specification

PTS 00.00.05.05

STANDARD DRAWINGS
Automated steam injection system of distillate (thermal)

S 31.008

cracking furnaces

Automatic steam injection system of residue cracking

(visbreaker) furnaces

S 31.009

PTS 10.02.51.11
November 2012
Page 17
Appendix 1: AUTOMATED STEAM-OUT SYSTEM

PRINCIPLE OF OPERATION
After manual initiation, a number of switches and control valves are activated in a controlled
sequence by an electrical/pneumatic automatic system as follows:
-

The furnace feed pump is automatically tripped and the feed control valves are closed. The
low-flow trip device then cuts out fuel supply to the burners.
A back-pressure control valve, if present in the furnace or soaker outlet, is opened.
After a delay to allow the above actions to be taken, a double block and bleed control valve
set is operated to admit dry, medium-pressure steam to the inlet of each coil.
The steam valve opening is preset but can be monitored and, if necessary, adjusted from the
control room. This steam flushes the tube contents into a vessel (the cyclone, soaker or
column) downstream of the furnace. The furnace effluent can be pumped out of the thermal
cracker by the bottoms pump of the cyclone or column through the residue rundown system.
If a soaker is installed downstream of a residue cracking furnace, its contents can be pumped
out from the soaker bottom to the column bottoms pump via a separate pump-out line.
Provisions are made to operate the system even in the event of failure of mains electricity or
instrument air, albeit with some manual intervention. Most of the equipment of the system shall
be used during routine shutdowns and steam-air decoking.
In case of loss of feed flow, if the feed pump can be restarted within about 5-10 minutes (for a
coil cracker) or 10-20 minutes (for a soaker cracker) there is no need to use the system at all. If
the pump remains out of action for longer periods, the steam-out system shall be initiated.
The same basic type of system may be used for all types of thermal cracking furnaces.

PTS 10.02.51.11
November 2012
Page 18
Appendix 2: STEAM SUPPLY
Steam for injection shall be taken from the normal refinery medium-pressure main, usually at
about 18 bar (ga). Alternatively, high-pressure steam may be used instead. The steam supply
pressure is independent of the inlet pressure of the furnace. To avoid surges in downstream
equipment, it is most important that this steam is dry upon injection.
To remove condensate, the following measures shall be taken:
-

A knock-out vessel shall be installed as close as possible to the injection point(s), having a
condensate steam trap with bypass and a high-level alarm. A permanent water level is to be
avoided and therefore an automatic level control is not required.
For thermal crackers with more than one cracking furnace, one common knock-out vessel
shall be used for the steam supply to the furnace coils. However, each furnace shall have its
own block valve and bleeder in the steam supply lines to different furnaces, because in
certain circumstances leaking valves could let furnace feed into the steam system.
The steam line between the knock-out vessel and the first control valve (A in Appendix 1)
shall be as short as possible and slope towards the knock-out vessel.

PTS 10.02.51.11
November 2012
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Appendix 3: BLOCK AND CONTROL VALVES FOR STEAM INJECTION
In the automated steam supply to each furnace coil valves shall be lined up as a double block
and bleeder system.
A + B and A + C are the double block valves, and D is a common bleeder to the flash zone of
the distillation column. Tie-in shall be below the gas oil draw-off, but above the flash zone to
prevent coking of "stagnant" nozzles.
These valves shall be of the tight shut-off type of the cheapest class. They shall be so located
that the lines between A and the furnace inlets are as short as possible.
There shall be no pocket between valve B or C and the corresponding furnace inlet. The pipe
connections of valve A with valves B, C and D shall have one common lowest point. This point
shall be at or as close as possible to the branch to valve D. At this lowest point a drain valve
shall be installed and opened at least once per day to check whether or not the non-return
valves or control valves are passing.
Occasionally, on opening the drain valve some vapours or condensate may be vented. If a
control valve or non-return valve is passing, this shall be readily apparent from the composition
of material draining from the valve.
The non-return valve at column inlet should prevent hot column vapours being vented via the
bleed line.
All the lines between valve A and the furnace inlets and the bleeder inlet to the distillation
column shall be steam-traced.
Bleed valve D shall be fitted with a restriction orifice to limit flow to approximately 25% of the
total design steam flow through A. This shall prevent all the steam passing through the bleeder
should it have failed to close.
Locked-open isolating valves shall be installed, downstream of the non-return valves in the
steam lines close to the injection point to the furnace feed, in the supply lines from the steam
knock-out drum and in the bleed line. These shall enable the non-return valves and the double
block and bleeder control valves to be serviced.
The spring actions for the valves are shown in Appendix 1. Instrument air shall be supplied to
each valve via solenoid-operated valves UZ-101 to UZ-104 for valves A to D respectively. The
solenoid valves shall have electric manual resets and be electrically energized when plant
operation is normal. Valves A to D shall then be held in position as follows:

Valve A Valve B Valve C Valve D -

Vented
Instr. air admitted
Instr. air admitted
Instr. air admitted

by UZ-101
by UZ-102
by UZ-103
by UZ-104

Normally closed
Normally closed
Normally closed
Normally open

The purpose of HIC-001 and HIC-002 is to give a preset restriction to the opening of valves B
and C. This shall prevent an excessive steam flow to the furnace tubes when the system is in
use, and ensure that the refinery steam demand does not increase to a level where the
operation of other units is endangered.
The injection point shall be positioned immediately downstream of the furnace feed flow control
valves so that the convection bank, if present, shall also be protected, although the prime aim is
protection of the more vulnerable radiant tubes.

PTS 10.02.51.11
November 2012
Page 20
Appendix 4: FURNACE FEED CONTROL VALVES
The furnace feed control valves are marked by E and F. These valves are normally set by
FRCs acting through solenoid valves UZ-105 and UZ-106. The solenoid valves are similar to
UZ-101 to UZ-104, i.e. normally energized and with electric manual resets. The usual furnace
fuel trips at low-low feed flow (FZA) are provided.
On reaching the low-low flow setting, these FZAs act on the fuel shut-off valves in the fuel
supply lines to the furnace.
It is possible to override the furnace feed low-low flow signal to the fuel shut-off valves using
panel-mounted decoking override switch HS-004, which is part of the fuel control system. This
switch shall be used only during non-standard operating conditions, such as start-up and
decoking operations.

PTS 10.02.51.11
November 2012
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Appendix 5: RESIDUE CRACKING FURNACE WITHOUT BACK-PRESSURE CONTROL VALVE
General
Appendix H is a diagram of the system required for a residue cracking furnace having 2 coils.
For coil arrangements with more than 2 coils similar equipment shall be installed, so that each
coil shall be equipped with an individual steam-out line.
Sequence of operation
When the steam-out system is initiated by HZA-001, the sequence of events shall be fully
automatic:
Immediately:

The feed shall be tripped (UZ-107).

The condensate injection pump, if present, shall be tripped

(UZ-108).

Solenoids UZ-104, UZ-105 and UZ-106 shall be de-energized.

De-energizing UZ-104 shall vent bleed valve D, which shall close.

De-energizing UZ-105 and UZ-106 shall switch full instrument air to

furnace feed control valves E and F, thus closing them.

Closing E and F shall cut off the feed to the furnace, and the lowlow flow FZAs shall trip the furnace fuel supply shut-off valves.
As a consequence, the furnace inlet pressure as indicated by PRA001 and PRA-002 shall drop.

After 10 seconds: -

Solenoids UZ-101, UZ-102 and UZ-103 shall be de-energized

De-energizing UZ-101 shall switch instrument air to steam valve a,

opening it.

De-energizing UZ-102 and UZ-103 shall switch the air supply to

steam valve B and C, from full instrument air supply pressure to a
lower pressure supply from control stations HIC-001 and HIC-002,
causing valves B and C to open partly.

The 10 seconds delay between the two steps of the valve-switching sequence is provided to
ensure that the furnace feed valves and the steam bleed valve shall be shut before the steam
valves start to open.
The degree of opening of B and C is pre-set by HIC-001 and HIC-002, as indicated by their
output indicators.
The preset values of HIC-001 and HIC-002 shall be determined during tests during
commissioning of the furnace. HIC-001 and HIC-002 should set valves B and C such that about
1000 kg/h of steam flows into each coil during conditions where the coils are empty.
Steam shall then be admitted into the furnace coils initially at a rate governed by the liquid
discharge rate from the coils (1-5 min) and subsequently by the degree of opening of B and C
as indicated on the panel by FR-003 and FR-004. If necessary, the flow rates can be adjusted
by means of HIC-001 and HIC-002 to ensure adequate protection of the tubes.

PTS 10.02.51.11
November 2012
Page 22
The unit line-up assumes that the bypass block valves of the feed control valves FRC-001 and
FRC-002 shall normally be closed.
A condensate injection pump to supply condensate into the furnace coils may be present for
process reasons. If a condensate pump is not present but HP process steam is injected via an
FRC, this steam flow can remain in use.
The steam flow should be maintained for about 5 minutes to completely flush out the furnace
tubes. The steam flow may be reduced to conserve steam, but should be continued for about
30 minutes to let the tubes cool down gradually.

PTS 10.02.51.11
November 2012
Page 23
Appendix 6: RESIDUE OR DISTILLATE CRACKING FURNACE WITH BACK-PRESSURE CONTROL
VALVE OR RESIDUE CRACKING FURNACE WITH SOAKER AND BACK-PRESSURE
CONTROL VALVE
General
The arrangements for this type of line-up are shown in Appendix H and are basically the same
as those for a residue cracking furnace without a back-pressure control valve.
The only difference is that the back-pressure control valve shall be fully opened to lower the
furnace inlet pressure before steam can be admitted into a furnace coil.
Hence, compared with a residue furnace system without a back-pressure control valve, an
additional solenoid is installed in the air supply to the back-pressure control valve.
Valves in Appendix 2 are designated similar to Appendix 1.
Sequence of operation
When the steam-out system is initiated, the sequence is the same as for residue furnaces
without back-pressure control valves.
Panel-mounted switch HZA-001 is manually operated, and the following automatic actions shall
take place:
Immediately:
-

The feed pump shall be tripped (UZ-107).

The condensate injection pump shall be tripped (UZ-108).

Solenoids UZ-104, UZ-105, UZ-106 and UZ-110 shall be deenergized.

De-energizing UZ-104 shall vent bleed valve D, which shall

close.

De-energizing UZ-105 and UZ-106 shall switch full instrument

air to furnace feed control valves E and F, thus closing them.

Closing E and F shall cut off the feed to the furnace, and the
low-flow FZAs shall trip the furnace fuel supply cut-off valves.

De-energizing UZ-110 shall vent furnace or soaker backpressure control valve K, opening it fully.

As a consequence, the furnace inlet pressure as indicated by PRA001 and PRA-002 shall drop.
After 10 seconds:

Solenoids UZ-101, UZ-102 and UZ-103 shall be de-energized.

De-energizing UZ-101 shall switch instrument air to steam valve

A, opening it.

De-energizing UZ-102 and UZ-103 switches the air supply to

steam valves B and C from full instrument air supply pressure to
a lower pressure supply from control stations HIC-001 and HIC002, causing valves B and C to open partly.

PTS 10.02.51.11
November 2012
Page 24
Appendix 7: BARRIER-STEAM INJECTION INTO RESIDUE FURNACE TRANSFER LINE OF
SOAKER-TYPE THERMAL CRACKING UNITS
PRINCIPLE OF OPERATION
For residue cracking furnaces equipped with a soaker vessel, the eventuality, however remote,
of a furnace tube rupture and consequent backflow of the soaker contents through the rupture
has to be taken into account. Such an event is to be countered primarily by depressurizing the
soaker as quickly as possible and by pump-out of the soaker contents, but the latter cannot be
done immediately.
To provide for additional safety, a barrier-steam injection system is installed in the transfer line
from furnace to soaker. The purpose of this injection system is to create sufficient pressure
build-up by steam to prevent backflow of the soaker contents as much as possible. The system
is in permanent use through a small flow via a restriction orifice, whilst a control valve can
immediately admit more steam once a tube rupture has been detected.
Furthermore, in order to prevent siphoning back of hydrocarbons into the furnace, the highest
part of the transfer line should be at least 1 metre above the mid-height of the soaking vessel.
FEATURES OF THE BARRIER-STEAM INJECTION SYSTEM
The injection system should be located on the common furnace transfer line as close to the
furnace as possible. The MP-steam supply system consists of a control valve, which can be
controlled from the panel. The control valve is equipped with a bypass in which are installed a
panel-mounted low-flow indicator/alarm and a restriction orifice of 3 mm minimum diameter,
preferably in a vertical line with the flow upwards. The continuous steam purge flow shall be
such that the purge velocity in the injection point is at least 0.3 m/s. In practice, the minimum
steam flow shall be approximately 700 to 1000 kg/day for a DN 80 injection line.
The steam connection to the transfer line is equipped with a non-return valve and an isolation
valve. The injection point should be located on the top part of the transfer line.
It is essential that a permanent steam purge is maintained via the bypass, since otherwise coke
build-up may occur in the injection line near the injection point. The MP steam supply line
should come from the emergency steam knock-out vessel.
When a tube rupture occurs, the system shall be used as follows; in addition to the actions for a
normal tube leak (which is not covered by this DEP):
-

Depressurize the soaker completely by opening the back-pressure control valve, and
depressurize downstream cyclone or fractionators;
Fully open the barrier-steam control valve.
Steam flow with full opening of the control valve shall be approximately 120 tonnes/day. This
flow is based on a 4-inch OD schedule 80 furnace tube; for other tube diameters the maximum
steam flow should be adjusted in accordance with the cross-sectional area of the ID of the tube.

PTS 10.02.51.11
November 2012
Page 25
Appendix 8: STEAM INJECTION INTO RELIEF VALVE INLET/OUTLET CONNECTIONS
PRINCIPLE OF OPERATION
In thermal cracking units, there are a number of locations where relief valves are installed on
process lines containing hot (above 350 C) cracked residual liquid and/or cracked vapours
where plugging by coke can take place. Such locations are:
-

back-pressure control valve of residue cracking furnace;

back-pressure control valve of soaking vessel;
back-pressure control valve of distillate cracking furnace;
isolation valves of residue cracking furnaces (multi-string units).
Relief valves shall be fully reliable at all times. In the above-mentioned locations, coke build-up
may occur in the dead-end connections of the relief valve which is installed across the
control/isolation valve. To prevent such coke build-up, a steam purge system shall be installed
on these dead-end connections, which shall be in continuous use.
FEATURES OF THE PURGE-STEAM SYSTEM
(see Appendix 3)
The injection system on each relief valve connection consists of:

an injection point as close to the relief valve as possible;

an isolation valve and a non-return valve;
a restriction orifice (of 3 mm minimum diameter) preferably installed in a vertical line with the
flow upwards;
a panel-mounted low-flow indicator/alarm.
The steam line has a dedicated supply header, which may be the same as for the barrier-steam
injection.
The continuous steam purge shall be such that the purge velocity in the relief valve connections
is at least 0.3 m/s. In practice the minimum steam flow shall be approximately 1.5 to 2.0
tonnes/day for DN 150 inlet connections and 1.0 to 1.5 tonnes/day for DN 200 outlet
connections.

PTS 20.04.10.10
October 2012
Page 26
Appendix 9: AUTOMATED STEAM INJECTION SYSTEM - RESIDUE OR DISTILLATE CRACKING FURNACE COILS WITH BACKPRESSURE CONTROL VALVE IN FURNACE OR SOAKER OUTLET LINEAUTOMATED STEAM INJECTION SYSTEM RESIDUE OR DISTILLATE CRACKING FURNACE COILS WITH BACK-PRESSURE CONTROL VALVE IN FURNACE OR
SOAKER OUTLET LINE

PTS 20.04.10.10
October 2012
Page 27
Appendix 10:BARRIER-STEAM INJECTION IN TRANSFER LINE OF RESIDUE CRACKING FURNACES FOLLOWED BY SOAKERS, AND
PURGE STEAM INJECTION INTO RELIEF VALVE CONNECTIONS

PTS 10.02.51.11
November 2012
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Appendix 11: VALVES POSITIONS AND FAIL-SAFE POSITIONS AND CORRESPONDING SOLENOID POSITIONS

Valve
A
12
18
24
30
36
42

7
B 13
C 19
D 25
E
31
F
37
K
43

Valve normal
position
closed
8
closed
14
closed
20
open
26
open 32
open 38
closed44

Solenoid
UZY-1019
UZY-10215
UZY-10321
UZY-10427
UZY-105
33
UZY-106
39
UZY-110
45

Solenoid normal
position
Vented
10
Instr. air admitted
16
Instr. air admitted
22
Instr. air admitted
28
Instr. air admitted
34
Instr. air admitted
40
Instr. air admitted
46

Instrument
air failure
close
11
open
17
open
23
close
29
open35
open41
open47

Electricity
failure
open
open
open
close
close
close
open

PTS 10.02.51.11
November 2012
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Appendix 12: EXAMPLE P&ID OF CRACKER HEATER

PTS 10.02.51.11
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Appendix 13: EXAMPLE P&ID OF STEAM SUPPLY SYSTEM