Mtbe Online Operating Manual

1
MTBE UNIT
OPERATING MANUAL
REV DATE DOC Rev By CHECKED APPROVED

UPDATED,
ISSUED FOR B.D.PARMAR S.V.SONI B.V.RAMGOPAL
0 20.05.05 RECORDS DMPN SPNM CPNM
UPDATED,
ISSUED FOR B.D.PARMAR S.V.SONI B.V.RAMGOPAL
UPDATED,
ISSUED FOR A.L.SAHU S.V.SONI A.K.DAS
UPDATED,
ISSUED FOR M M RAMANI A.L.SAHU S. V. SONI
3 25.06.10 RECORDS PNE DMPN CPNM
UPDATED,
ISSUED FOR T.R.DESAI A.L.SAHU S. V. SONI
4 30.06.11 RECORDS DMPN PNM CPNM
UPDATED,
ISSUED FOR A N JADHAV A.L.SAHU P. V. SOLANKI
5 20.06.12 RECORDS PNE PNM CPNM
UPDATED,
ISSUED FOR A N JADHAV A.K.ROY P. V. SOLANKI
6 20.09.13 RECORDS SPNE PNM CPNM
2
PREFACE
The MTBE Unit has been commissioned In September 1999. This is the Third issue of the
MTBE Unit OPERATING MANUAL.
The Manual contains necessary guidelines for normal Start up, Shut down, Emergency
Procedures.
It covers the guideline for Safety in chemicals handling, Fire fighting and Safety facilities,
Operation procedure of Equipments, Hand over of Equipments to Maintenance and
Inspection and brief description of DCS facilities.
The various operating parameters are indicative only. Modification and change may be
done as per requirement based on actual operating experience.
In previous revision, Tasks to be performed by operators and Pre-fire fighting plan has
been added as per System audit recommendations. The Sampling Schedule has also
been updated with respect to SEQM&S Documents.
In this revision of operating manual, chapter no.6 “Equipment standard operating

procedure” has been updated and “Equipment drain line dechocking procedure” is added
as a separate annexure.
GUJARAT REFINERY
P V SOLANKI
Date: 20/09/2013 (CPNM)
3
TABLE OF CONTENTS
SNO DESCRIPTION Page no.
1 GENERAL INTRODUCTION 9
1.1 Introduction 10
1.2 Process Chemistry 11
1.3 Process Design Basis 12
1.3.1 Design Philosophy 12
1.3.2 Feed Specifications 15
1.3.2.1 Hydrocarbon Feed 15
1.3.2.2 Methanol feed 16
1.3.3 Product Specifications 16
1.3.4 Catalyst Specification 19
1.3.5 Chemical 20
1.4 Material Balance 20
1.5 Battery Limit Conditions 20
1.5.1 Battery Limit Conditions- Feed 20
1.5.2 Battery Limit Conditions- Utility 21
1.6 Estimated Utility Consumption 23
2 LIST OF EQUIPMENTS / CONTROL VALVES / PSVS 24

2.1 Columns 25
2.2 Reactors 25
2.3 Vessels 25
2.4 Heat Exchangers 26
2.5 Pumps 26
2.6 Filters 27
2.7 Control valves 27
2.8 PSV s 29
3 PROCESS DESCRIPTION 31
3.1 C3/C4 Fractionation 32
3.2 Feed Water Wash 33
3.3 Primary Reaction (Reactor No.1) 34
3.4 Primary Reaction (Reactor No.2) 34
3.5 Catalytic Distillation 35
4
3.6 Methanol Extraction 36

3.7 Methanol Recovery 36
3.8 Lights Removal 37
4 OPERATING VARIABLES AND CONTROL 39

4.1 Normal Operation and Control 40
4.2 Input and Output List for DCS 53
4.3 Design Operating Condition 55
5 SAFETY IN CHEMICALS HANDLING 56

5A Material Safety Data Sheet 61
5B MTBE- master blind list 70
6 EQUIPMENTS - STANDARD OPERATING PROCEDURE 76

6.1 Equipment handing over to maintenance 77
6.2 Equipment taking over from maintenance 79
6.3 Standard operating procedure 81
6.4 Tank operations 85
7 CATALYST LOADING / UNLOADING 88
7.1 Catalyst Loading in Reactor & Guard Beds 89

7.2 Catalyst Unloading from Reactor & Guard Beds 90
7.3 Catalyst Loading of CD Reaction Column 95
7.4 Catalyst Unloading from CD Reaction Column 96
8 START-UP ACTIVITIES 99
8.1 Initial Start-Up 100
8.2 Subsequent Start-Ups 114
8.3 Commissioning Methanol Guard Beds After Re-Charge 116
9 SHUT DOWN PROCEDURES 117

9.1 Planned Shutdown 118
9.2 Emergency Shutdown 122
5
9.3 Automatic Shutdown & Interlock System 124

9.4 DCS Failure 126
9.5 MODIFICATION 127
10 INSTRUMENTATION AND DCS 129
11 OFF SITE FACILITIES AND STORAGE TANKS 135
12 INTERLOCK SYSTEM 139
13 EQUIPMENTS HAND OVER TO MAINTENANCE / 146

INSPECTION
13.1 Pumps 147
13.2 Vessels 148
13.3 Columns 153
13.4 Exchangers / Coolers / Re-boilers 156
13.5 Tanks 156
14 FIRE FIGHTING / WORK PERMIT / 157

ACCIDENT REPORTING
14.1 Fire Fighting Facilities 158
14.2 Pre-Fire Fighting Plan For MTBE Unit 164
14.3 Work Permits 173
14.4 Accident Reporting 180
14.5 Fire & Safety Facilities in MTBE plant 183
15 ANNEXURES 184
15.1 Equipment Data Sheets 185
15.1.1 Column 185
15.1.2 Reactor 187
15.1.3 Vessel 189
15.1.4 Heat Exchanger 192
15.1.5 Pump 199
15.2 Sampling Schedule And Sample points 202
6
15.3 Equipment drain line dechocking procedure 204

15.4 Modifications during MTBE M&I shutdown (April 2012) 205
16 TASK TO BE DONE BY OPERATORS 206
17 ANNEXURES 213
1. Procedure for dechocking of equipment drain line 214
2. Flare KOD/ vessel draining procedure 215
3. List of work instructions 216
17 DRAWINGS 217
DRG NO-1 C3/C4 Feed Surge Drum / Splitter
DRG NO-2 Splitter Reflux Drum
DRG NO-3 Waste water Column / Drum
DRG NO-4 Methanol Feed system
DRG NO-5 C4 Coalescer drum
DRG NO-6 Ratio Control System
DRG NO-7 Reactor No-1
DRG NO-8 Reactor No-2
DRG NO-9 CD Reaction Column
DRG NO-10 Reaction Column O/H System
DRG NO-11 Methanol Column
DRG NO-12 Methanol Recovery section
DRG NO-13 Lights Column / O/H System
DRG NO-14 Lights Column Feed / Bottom System
DRG NO-15 Condensate Recovery System
DRG NO-16 Slops and Methanol Drains Drums
DRG NO-17 Utilities
DRG NO-18 Indication block
DRG NO-19 Calculation block
DRG NO-20 OWS System
DRG NO-21 Methanol Storage, Transfer Facilities
DRG NO-22 LPG Supply/Return Modification Lines Ex FCCU
DRG NO-23 Flare System
DRG NO-24 Cooling Water System
DRG NO-25 N2 / Inst. Air / Plant air Distribution
7
DRG NO-26 LP Steam System

DRG NO-27 MP System
DRG NO-28 Methanol Drains and CBD System
DRG NO-29 PFD : C3/C4 Splitter
DRG NO-30 PFD : Water Wash and Reactor no –1
DRG NO-31 PFD : CD Reaction Column
DRG NO-32 PFD : Methanol Recovery
DRG NO-33 PFD : Lights Column
18 PROCESS FLOW DIAGRAM 218
8

SECTION – 1
GENERAL INTRODUCTION

9
SECTION -1
1.0 GENERAL INTRODUCTION
1.1 INTRODUCTION:
Indian Oil Corporation Ltd., Gujarat Refinery has set up 37,000 TPA MTBE (Methyl
Tertiary Butyl Ether) plant and has been commissioned in September 1999. The
objective of putting up the MTBE unit is to produce MTBE for blending into gasoline
for octane enhancement as well as increasing the oxygen content as required by
future statutory regulations.
The Operating Manual for the MTBE Process Unit provides information to
supervisory& operating personnel about plant systems and unit operating
procedures.
The process licensor for the unit is M/s. CATALYTIC DISTILLATIONS

HOUSTON, TEXAS. The MTBE unit consists of seven major sections: -
– C3/C4 Fractionation
– Feed Water Wash
– Primary Reactors
– CD Reaction Column
– Methanol Extraction Column
– Methanol Recovery Column
– Lights Column
The feed consisting of Hydrocarbon feed and Methanol is fed to the MTBE
Section from storage to form MTBE.
Cracked LPG ex FCC unit is the feedstock. And methanol is procured from
G.N.F.C. Bharuch a near by Industry.
10
1.2 PROCESS CHEMISTRY
The reaction of Isobutene and Methanol over a strong acidic catalyst

produces Methyl Tertiary Butyl Ether (MTBE). The liquid phase reaction
proceeds as follows:
CH3 CH3
CH3 - C = CH2 + CH3 - OH CH3 - C - O - CH3
CH3
The reaction is reversible and exothermic; therefore, a lower reaction

temperature favours MTBE production. The heat of reaction at 25°C is
approximately 9,450 kcal/kmol. The concentration of Isobutene, the ratio of
Methanol to Isobutene, and the residence time are parameters, which control
the overall conversion of Isobutene. Increasing either of the first two
variables increases conversion of Isobutene to MTBE. As the reaction
reaches equilibrium increasing the reaction time has no effect on conversion.
Following is a summary of major side reactions:
Methanol + 1-Butene - Methyl Secondary Butyl Ether

(MSBE)
Isobutene + Isobutene - Di-isobutene (DIB)
Isobutene + Water - Tertiary Butyl Alcohol (TBA)
Methanol + Methanol - Dimethyl Ether (DME) + Water
High reaction temperatures favor production of DIB and DME. Increased
water content contributes to higher TBA production. Lower concentrations of
Isobutene, without adjusting the Methanol rate, increases the quantity of
DME and TBA produced.
Methanol in sub stoichiometric concentrations significantly increases the

amount of DIB production. Excess Methanol has less impact on by-product
formation than other process variables. Methanol present in excess of the
11
azeotropic limit with C4 Hydrocarbon increases the Methanol concentration
in the MTBE product.
1.3 PROCESS DESIGN BASIS
1.3.1 DESIGN PHILOSOPHY

DESIGN CAPACITY: 37000 TPA Production of MTBE.
The MTBE Unit is designed as a stand-alone unit. The calculated production
of MTBE product is 1,026 BPSD or 4986 kg/h for Case I and 981 BPSD or
4814 kg/hr for Case II, at Start of Run condition, based on the feed
compositions and rates as defined in Section 1.3.2. The unit is designed to
process, at its maximum capacity, 120% of the feed rates specified in
Section 1.3.2. Unit turndown is expected to be 50% of the maximum
capacity. No additional over-design is applied.
The reflux pumps are designed to handle 120% of the required reflux flow;
whichever is the controlling case, to ensure proper operation. The normal
turndown flow for the unit is 50% of the maximum capacity.
The expected concentration of Isobutene in the hydrocarbon feed for both

design cases 1 and 2 is 12 weight percent. The feed compositions and the
rates specified in Section 3.2 were utilized for the design.
Other operating cases with alternate feedstock were considered for the
design of the unit. The feed rate and Isobutene concentrations of these
cases are: -
Alternate Feed A B C D
Rate, kg/hr 30615 30615 26450 26450
Wt% / Isobutene 16.0 8.0 16.0 8.0
A fifth alternate operating case with the following feed composition and feed
rate was also considered in the design of the unit.
12
Component Wt%
Propane 16.54
Propylene 1.02
Isobutane 23.93
N-Butane 6.29
T-2-Butene 14.84
1-Butene 12.23
Isobutene 14.76
C-2-Butyene 9.08
1,3 Butadiene 0.50
I-Pentane 0.78
N-Pentane 0.03
Total 100.00
Rate, kg/hr 11,213
Two Primary reactors are used in the design and piping facilities have been
included so that the spent catalyst in any one of the two reactors can be
changed out with the unit remaining on stream.
The affluent from the Primary Reactor is fed to the CD Reaction Column,
which consists of a total of twelve reaction beds which are used to achieve
the required high Isobutene conversion. The “baled” catalyst in the CD
Reaction Column has an expected run-length of five (5) years between
changes. Longer run times between catalyst change-outs may be
achievable depending upon operating experience and conversion
requirements.
Secondary Methanol is directly fed to the column on flow control to meet the
reaction requirement. An on-line infra-red Methanol Analyzer / Control is
used to reset the secondary Methanol feed flow rate.
The MTBE Unit utilizes a maximum Methanol concentration of 4% (wt) in the

C4 overhead of the CD Reaction Column. During normal operation, the
Methanol concentration in the C4 overhead is in the range of 3 to 3.5 weight
13
percent. Higher Methanol concentrations improve overall conversion, but
increase utility consumption by the Methanol Recovery System.
The Water Wash Column has been designed to remove 50 ppmw,

maximum, ACN from the C4 feed with a wash water of 20 wt% of the C4 feed
rate (normal operation).
The Methanol Drains and Slop Drums are provided for smoother start-up
operation as well as to provide a more environmentally sound unit design.
Although non-condensable material is not envisaged, vents are provided

from each condenser header, as well as from the CD Reaction Column
Overhead Drum, to remove accumulations of non-condensed material.
During the start-up, vents will be used to purge nitrogen from the unit.
Pump Minimum Flow bypass lines are provided on four pumps (1100-P-
3A/B, 1100-P-4A/B, 1100-P-6A/B and 1100-P-13A/B) based on pump
vendor specification.
All vessels that require steam out have been designed for full vacuum.
However, certain vessels have been recommended to have full vacuum for
normal operational reasons. These vessels are Methanol Recovery Column
and its re-boiler, condenser and overhead drum. Also full vacuum has been
specified for liquid-filled vessels such as the Water Wash Column, Methanol
Extraction Column, and Primary Reactors.
14
1.3.2 FEED SPECIFICATIONS
1.3.2.1 HYDROCARBON FEED
The Design Hydrocarbon Feed is as follows:
Case I Case II
Component Wt% Wt%

Ethane 0.04 0.02
Propane 15.31 17.9
Propylene 22.26 12.33
I-Butane 19.99 27.27
N-Butane 5.81 6.17
Isobutene 12.00 12.00
1-Butene 7.41 7.55
T-2-Butene 8.94 9.10
C-2-Butene 5.78 5.89
1, 3-Butadiene 1.00 1.00
C5 + 1.46 0.77
Total 100 100

Rate, kg/hr 30,615 26,450
Impurity Ppmw max.

Nitrogen Compounds (as N2) * 40
Total Cat ions 0.2
Diolefins 1.0 wt%
Acetylene 10
Acetonitrile 50
Propionitrile 1
Dimethyl Sulfides 1
Oxygen (as O2) 10
* Excluding acetonitrile and propionitrile.
15
1.3.2.2 METHANOL FEED
The Methanol make-up to the unit is expected to be:
Case I Case II
Rate, kg/hr 1691 1693
The Methanol feed is commercial grade Methanol meeting the specifications

of ASTM D1152-89 (Grade AA) as follows:
Purity, wt% 99.85 (min.)
Specific Gravity, 20/20°C 0.7920 to 0.7930
25/25°C 0.7883 to 0.7893
Acetone, ppmw 30 (max.)
Acidity as Acetic Acid, ppmw 30 (max.)
Hydrocarbons To pass test
Water, ppmw 1000 (max.)
Sulfuric Acid Wash Test 50
Potassium Permanganate Test > 50 minutes
Distillation Range <1.0°C to
include 64.6 ±
0.1°C
Colour, Pt-Co Scale 10 (max.)
Odour Non residual
Non-volatile matter, mg/100ml 5.0 (max.)
In addition, the following specifications are required:
Basic Impurities as NH3, ppmw 1.0 (max.)
Total Cationic Impurities, ppmw 0.2 (max.)
1.3.3 PRODUCT SPECIFICATIONS
When the unit receives hydrocarbon and Methanol feed at the rates listed in
Sections1.3.2 and 1.3.2.2 at normal operating conditions, the overall
16
conversion of Isobutene is expected to be ninety-nine and nine-tenth (99.9)
percent at SOR conditions.
MTBE Product
The expected MTBE product has the following typical compositions for Start-
of-Run conditions.
ASTM D Case I Case II
Component 5983-97 Wt% Wt%
MTBE 95%(min) 92.1 95.4
C4 Hydrocarbons - 0.10 0.10
C5 + Hydrocarbons - 7.2 3.9
Methanol 0.5%(max) 0.10 0.10
Sulfur (max) 300 ppm - -
By-products * - 0.5 0.5
Water 0.1%(max) 50 ppm 50 ppm
API @ 15.6 - -
Colour +5 (max) - -
Total 100.00 100.00
Rate, kg/hr 4,986 4,814
* By-products consist of Tert-Butyl Alcohol, (TBA) Di-Isobutene, (DIB)

and Methyl Secondary Butyl Ether (MSBE).
Blending RON : 118
Blending MON : 100
Blending RVP(Kpa) 55-70
Oxygen, % wt 18.2
C4 Product
After Methanol extraction and lights removal, the C4 Product containing non-
reactive hydrocarbons and unreacted C4 s is expected to have the following
characteristics under Start-of-Run conditions.
17
Case I Case II
Component Wt% Wt%

C3 Hydrocarbons 0.02 0.02
C4 s (Note 1) 99.97 99.97
C5 + Hydrocarbons 0.01 0.01
Oxygenates Wppm. max Wppm. Max

Water 5 5
Methanol 5 5
DME 10 10
MTBE 10 10
Rate, kg/hr 11,881 13,798
Note 1 - Isobutene content is 250/220 ppmw for Case 1/ Case 2 resp.
VENT-GAS
Vent Gas from the Lights Column Overhead Drum is expected to have the
following characteristics under Start-Of-Run conditions :
Case I Case II
Component Wt% Wt%
Propylene 11.1 5.6
Propane 34.9 36.3
C4 ‘s 48.4 53.1
Water 1.4 1.4
Methanol 0.1 0.1
DME 3.7 3.5
Total 100.00 100.00
Rate, kg/hr 252 309
18
1.3.4 CATALYST AND ITS SPECIFICATION
CATALYST :
The MTBE units utilises catalyst supplied in two forms, viz., the”bulk” form as
in the Reactor No.1 and No.2 and the Methanol Guard Beds and the
proprietary catalyst “bales” loaded in the CD Reaction Column. When
handling the catalyst bales, proper safety apparel should be worn such as
gloves and eye protection to prevent injury from the wire mesh support. Any
bulk catalyst found on the ground should be cleaned up promptly as the
material acts like “ball-bearings” on smooth surfaces and can cause injuries
to personnel as result of falls.
CATALYST SPECIFICATIONS AND CONSUMPTION
Rohm & Haas’ Amberlyst 15, Dowex M-31, Purolite CT-175, Bayer K2611 or
K2631, or equivalent catalyst to be used for MTBE synthesis in the Primary
Reactor. These are bead-form, strongly acidic resins. AMBERLYST-15
(wet) is used in Gujarat Refinery.
The catalyst swells upon contact with water and other polar solvents such as
Methanol. The wet density of the catalyst is approximately 770 kg/m3.
Catalytic activity of the catalyst depends upon proton concentration from
acidic functional groups. If the protons or hydrogen ions are replaced by
other cations, the catalytic activity decreases. To maintain high catalytic
activity, traces of metal cations, which arise through corrosion, and erosion
of equipment and piping should be eliminated or minimized in the reaction
mixture. Basic compounds also neutralize the catalyst acid sites and are
also significant poisons.
Catalyst for the Primary Reactor is purchased as 50% by weight in water.

The catalyst in “bale” form is purchased from CDTECH.
The catalyst quantities required per charge are as follows:
Reactor No.1 / Reactor No. 2: Amberlyst-15 (wet) or equivalent 6,050 kg

water wet (50% by weight) for each
19
Methanol Guard Beds (2): Amberlist-15 (wet) or equivalent 210 kg
water wet (50% by weight) for each
CD Reaction Column CDTECH catalyst bales for twelve beds at 3.125
m³ each (approximate total weight of 19,200 kg).
Catalyst Name: ETHERCATID
1.3.5 CHEMICAL:
Diethanolamine (DEA) addition to the Reaction Column bottoms is required
whenever catalyst is suspected or known to be present in the Reaction
Column bottoms. Typically, only 0.5 to 1 drum of DEA is added to neutralise
the small quantity of catalyst fines normally found after a Primary Reactor
catalyst change out.
1.4 MATERIAL BALANCE:

Refer to Annexure (SOFT COPY NOT AVAILABLE)
1.5 BATTERY LIMIT CONDITIONS
1.5.1 Following are battery limit conditions for both feed and product streams. :
Temperature Pressure State

(°C) (kg/cm²g
)
Hydrocarbon Feed 40 10.0 Liquid
Methanol Feed 40 3.0 Liquid
MTBE Product 40 5.0 Liquid
C3 Product 40 15.0 Liquid
C3/C4 bypass 40 10.0 Liquid
C4 product 40 14.5 Liquid
Wash Water 40 5.0 Liquid
Waste Water 40 Atm Liquid
Vent gas to fuel gas 45 6.0 Gas
20
1.5.2 UTILITY CONDITIONS AT BATTERY LIMIT
The design conditions of available utilities at the MTBE unit battery limits and
the conditions assumed for calculations are as follows:
Min. Normal Max. Mech.

Design
Steam LP STEAM
Press, kg/cm²g 3.5 4 4.5 6.5
Temp. °C 155 165 170 200
MP STEAM
Press, kg/cm²g 7.5 9 10 12
Temp. , °C 200 230 240 300
Cooling Supply press, 3.5 4.5 5.0 7.0

Water kg/cm²g
Return Press, 2.0 2.5 3.5 7.0
kg/cm²g
Supply Temp., °C -- 33 -- 65
Return Temp., °C -- -- 45 65
DM Water Press. Kg/cm²g 5.0 5.0 6.0 8.0

Temp. °C 40 40 40 65
Ph -- 7.5 9.0 --
Hardness, ppm -- 0.5 -- --
TDS -- Nil -- --
Silica, ppm as -- 0.2 -- --
SiO3
Chlorides, ppm -- Nil -- --
Iron as Fe, ppm -- 0.07 -- --
Plant Air Pressure, kg/cm²g 3.5 5.5 6.0 9.0

Dew Point, °C - No free moisture -
Oil content, ppm Traces
21
Instrument Pressure, kg/cm²g 3.5 5.5 6.0 9.0
Air
Dew Point, °C -15° C at 6.5 kg/cm²a
Oil content, ppm Oil free
Nitrogen Pressure, kg/cm²g 3.0 4.0 6.0 9

Temp. °C -- 40 -- --
Power Voltage 440V / 240 V

Frequency 50 Hz + 3% - 5%
No. of Feeders Duplicate Feeders
Voltage Variation ± 5%
22
1.6 ESTIMATED UTILITY CONSUMPTION
The expected utility consumptions under normal operation are as follows :
SOR EOR
Case 1 Case 2 Case 1 Case 2
kg/h kg/h kg/h kg/h
LP Steam
1100-E-1 5,400 5,640 5,400 5,640
1100-E-20 2,282 2,336 2,282 2,336
Total 7,682 7,976 7,682 7,976
MP Steam
1100-E-6 0 0 547 611
1100-E-9 5,150 5,865 4,798 5,510
1100-E-15 1,270 1,477 1,270 1,477
Total 6,420 7,342 6,615 7,598
Cooling Water M³/hr M³/hr M³/hr M³/hr

1100-E-2 253.8 261.6 253.8 261.6
1100-E-3 6.4 6.8 6.4 6.8
1100-E-5 48.8 57.8 48.8 57.8
1100-E-7 30.2 26.7 32.6 32.5
1100-E-10 208.2 238.4 203.0 233.8
1100-E-11 16.4 15.1 22.2 20.6
1100-E-12 10.3 10.8 22.6 25.4
1100-E-13 19.4 22.5 19.4 22.5
1100-E-16 42.1 49.0 42.1 49.0
1100-E-17 1.7 1.9 1.7 1.9
1100-E-19 23.3 26.6 23.3 26.6
1100-E-21 69.8 84.8 69.8 84.8
Total 660.6 807.0 745.7 823.3
Demineralised Water kg/hr kg/hr kg/hr kg/h

1100-C-2 3,085 3,445 3,088 3,449
23

SECTION – 2
LIST OF EQUIPMENTS / CONTROL VALVES / PSVS

24
SECTION-2 :
LIST OF EQUIPMENTS
2.1 COLUMN NOS DESCRIPTION
1100 C-1 C3/C4 Splitter
 C-2 Wash water column
 C-3 CD. Reaction column
 C-4 Methanol Extraction column
 C-5 Methanol column
 C-6 Lights column
2.2 REACTOR NOS DESCRIPTION
1100 R-1 Primary Reactor No-1
 R-2 Primary Reactor No-2
 R-3A/B Methanol Guard Beds
2.3 VESSEL NOS DESCRIPTION
1100 V-1 C3/C4 feed surge drum
 V-2 C3/C4 splitter over head drum
 V-3 Wash water break drum
 V-4 Water degasser drum
 V-5 Methanol surge drum
 V-6 CD Reaction column over head drum
 V-7 Methanol column over head drum
 V-8 Lights column over head drum
 V-9 Methanol drains drum
 V-10 Flare knock out drum
 V-11 Slops (CBD) drum
 V-12 Condensate pot for CD column re-boiler
 V-13 Condensate pot for reactor no-1 feed heater
 V-14 Condensate pot for Methanol column re-boiler
 V-16 MP condensate vessel
 V-17 LP condensate vessel
 V-18 C4 feed coalescer drum
25
2.4 HEAT EXCHANGER DESCRIPTION
NOS.
1100 E-01 C3/C4 splitter re-boiler
 E-02 C3/C4 splitter condenser
 E-03 C3 product cooler
 E-04 C3/C4 splitter feed / bottom exchanger
 E-05 Water wash column feed cooler
 E-06 Reactor no-1 feed heater
 E-07 Reactor no-2 feed cooler
 E-08 CD column feed / bottom exchanger
 E-09 CD Reaction column re-boiler
 E-10 CD Reaction column condenser
 E-11 MTBE product cooler
 E-12 Extraction column feed cooler
 E-13 Recycle water cooler
 E-14 Methanol column feed / bottom exchanger
 E-15 Methanol column re-boiler
 E-16 Methanol column condenser
 E-17 Recycle Methanol cooler
 E-18 Lights column feed / bottom exchanger
 E-19 C4 product cooler
 E-20 Lights column re-boiler
 E-21 Lights column condenser
2.5 PUMP NOS DESCRIPTION

1100 P-1A/B C3/C4 feed pump
 P-2A/B C3/C4 splitter reflux pump
 P-3A/B DM water booster pump
 P-4A/B Methanol feed pump
 P-5A/B CD Reaction column reflux pump
26
 P-6A/B Methanol column bottom pump
 P-7A/B Methanol column reflux pump
 P-8A/B Lights column reflux pump
 P-9A/B C4 product pump
 P-10 Methanol drains drum pump
 P-11 Flare knock out drum pump
 P-12 Slops (CBD) drum pump
 P-13A/B Methanol transfer pump
 P-14A/B Condensate pump
 P-15 Amine injection pump
 P-15A Cooling water booster pump for E-2
2.6 FILTERS DESCRIPTION
1100 G-1A/B C4 feed filters
 G-2A/B Methanol feed filter
 G-3 Methanol drain filter
 G-4 Slop filter
CONTROL VALVE LIST.
SL. TAG NO. SERVICE SIZE FAILURE

NO. POSITION
1 FV 102 DM WATER CIR. TO V-3 1" FO
2 FV 201 C3/C4 EX P1A/B TO E-4 4" FC
3 FV 202 Ex E-5 TO C-2 3" FC
4 FV 203 LP COND. Ex. E-1 2" FC
5 FV 204 C3/C4 BY PASS 2" FC
6 FV 302 C-1 REFLUX 3" FO
7 FV 303 E-3 TO C3 product 2" FC
8 FV 401 DM WATER TO C-2 1.5" FC
9 FV 501 P4A/B CIR. TO V-5 1" FO
10 FV 601 METHANOL TO C-3/ R-1/ R-2 1" FC
11 FV 701 R-3A/B TO REACTOR 1" FO
12 FV 704 MP STEAM TO E-6 3" FC
13 FV 801 MTBE R/D 1.5" FC
27
NO. POSITION
15 FV 1001 C-3 REFLUX 3" FO
16 FV 1003 E-12 TO C-4 2" FC
17 FV 1102 C-4BOTT TO E-14 1" FC
18 FV 1103 E-13 TO C-4 1" FC
20 FV 1202 P6A/B TO C-5 (CIR.) 1" FO
21 FV 1301 REFLUX TO C-5 1" FO
22 FV 1302 E-17 TO V-5 (RECYCLE) 1” FC
23 FV 1401 C4 PRODUCT 3" FC
24 FV 1501 LP COND. TO E-20 1.5" FC
25 FV 1601 C-6 REFLUX 3” FO
26 FV 1602 V-8 TO FG SYSTEM 1" FC
27 FV 2001 Ex CBD DRUM TO KO DRUM 1.5" FC
28 FV 2002 Ex MEOH DRAIN DRUM TO E-14 1" FC
29 FV 2102 V-10 H/C TO CD COL. 1.5" FC
30 HV 1201 DM WATER MAKEUP TO C-5 1" FC
31 HV 1501 C-6 TO METHANOL DRAIN 1" FC
32 LV 101 OSBL TO V-1 4" FC
33 LV 102 DM WATER TO V-3 1.5" FC
34 LV 401 C-2 BOTTOM TO V-4 1.5" FC
35 LV 402 H/C TO E-6 1" FC
36 LV 501 Ex P13A/B TO V-5 1" FC
37 LV 701 MP COND. FROM V-13 1" FC
38 LV 902 MP COND. Ex V-12 2" FC
39 LV 1202 MP COND. Ex V-14 1" FC
40 LV 1701 V-16 BOTT. TO V-17 3" FC
41 LV 1702 Ex V-17 TO LP COND (OSBL) 2" FC
42 PV 106A VENT FROM V3 1" FO
43 PV 106B N2 TO V-3 1" FC
44 PCV 201 LP STEAM TO E-1 6”
45 PV 301 E-2 TO V-2 4" FO
46 PV 302 C-1 TOP TO V-2 4" FC
47 PV 402 C4 FEED TO R-1 4" FC
48 PV 406 V-4 O/L TO FLARE 2" FC
49 PV 503A V-5 TO FLARE 1" FO
50 PV 503B N2 TO V-5 1" FC
51 PV 1001 E-10 TO V-6 4" FO
52 PV 1002 V-6 TO FLARE 1.5" FC
53 PV 1004 C-3 TO V-6 4" FC
54 PV 1104 RAFF. TO LIGHTS COL. 3" FC
55 PV 1301 E-16 TO V-7 1.5" FO
56 PV 1302 C-5 TOP TO V-7 3" FC
28
NO. POSITION
57 PV 1303 V-7 TO FLARE 1.5" FC
58 PCV 1501 LP STEAM TO E-20 4" FC
59 PV 1601 C-6 TOP TO E-21 6" FO
60 PV 1602 C-6 TOP TO V-8 ( BYPASS) 3" FC
61 TV 2101 LP COND. EX V-10 1" FC
62 TV 803A E-7 TO R-2 3" FO
63 TV 803B E-7 BYPASS TO R-2 3" FC
64 XV 101 V-1 TO P1A/B 6” FC
65 XV 201 LP STEAM TO E-1(REBOILER) 8" FC
66 XV 301 V-2 TO P2A/B 6”
67 XV 401 E-5 TO C-2 4” FC
68 XV 801 MTBE R/D 3” FC
69 XV 1001 V-6 TO P5A/B 6” FC
70 XV 1601 V-8 TO P8A/B 4” FC
2.8 LIST OF PRESSURE RELIEF VALVES
SL. TAG NO. LOCATION SET RELESE TO

NO PR.
FLARE ATMOSPHERE
1 PSV 101A NEAR V1 12 YES
2 PSV 101B NEAR V1 12 YES
5 PSV 201A C - 1 TOP 19.3 YES
6 PSV 201B C - 1 TOP 19.3 YES
7 PSV 301A NEAR V2 19.3 YES
8 PSV 301B NEAR V2 19.3 YES
9 PSV 401A C - 2 TOP 21.8 YES
10 PSV 401B C - 2 TOP 21.8 YES
13 PSV 403A V - 18 TOP 21.1 YES
14 PSV 403B V - 18 TOP 21.1 YES
15 PSV 501A V - 5 TOP 7 YES
16 PSV 501B V - 5 TOP 7 YES
17 PSV 502 G 2 A TOP 19 YES
18 PSV 503 G 2 B TOP 19 YES
19 PSV 601 R-3 A TOP 20.4 YES
20 PSV 602 R-3 B TOP 20.4 YES
21 PSV 701 G 1 A TOP 21.1 YES
29
SL. TAG NO. LOCATION SET RELESE TO
NO PR.
FLARE ATMOSPHERE
22 PSV 702 G 1 B TOP 21.1 YES
23 PSV 704A R-1 TOP 20.4 YES
24 PSV 704B R-1 TOP 20.4 YES
25 PSV 801A R-2 TOP 20.7 YES
26 PSV 801B R-2 TOP 20.7 YES
27 PSV 901A C - 3 TOP 8.7 YES
28 PSV 901B C - 3 TOP 8.7 YES
29 PSV 1001A V - 6 TOP 8.7 YES
30 PSV 1001B V - 6 TOP 8.7 YES
31 PSV 1101A C - 4 TOP 24.3 YES
32 PSV 1101B C - 4 TOP 24.3 YES
33 PSV 1201A C - 5 TOP 6.5 YES
34 PSV 1201B C - 5 TOP 6.5 YES
35 PSV 1301A V - 7 TOP 6.5 YES
36 PSV 1301B V - 7 TOP 6.5 YES
37 PSV 1501A C - 6 TOP 13.2 YES
38 PSV 1501B C - 6 TOP 13.2 YES
39 PSV 1601A V - 8 TOP 13.2 YES
40 PSV 1601B V - 8 TOP 13.2 YES
41 PSV 2001A V - 11 TOP 6.3 YES
42 PSV 2001B V - 11 TOP 6.3 YES
43 PSV 2002A V - 9 TOP 8.4 YES
44 PSV 2002B V - 9 TOP 8.4 YES
45 PSV 202 E–5 6 SEWER
49 PSV 802 E – 11 6 SEWER
50 PSV 1002 E – 10 6 SEWER
51 PSV 1102 E – 13 6 SEWER
52 PSV 1103 E – 12 6 SEWER
53 PSV 1302 E – 16 6 SEWER
54 PSV 1303 E – 17 6 SEWER
55 PSV 1401 E – 19 6 SEWER
56 PSV 1602 E – 21 6 SEWER
30

SECTION – 3
PROCESS DESCRIPTION

31
SECTION-3
3 PROCESS DESCRIPTION
The unit functions to produce MTBE for blending into gasoline for octane
enhancement as well as increasing the oxygen content as may be required
by future statutory regulations.
MTBE formation occurs by the selective reaction between Isobutene and

Methanol. Non-reactive C4 s return to battery limits after Methanol recovery
and lights removal.
Following is a brief description of the processing scheme as shown on the

Process Flow Diagrams MTBE-DRG NO 1, 2, 3, 4& 5.
3.1 C3/C4 FRACTIONATION
The C3/C4 Feed Surge Drum, 1100-V-1 receives the hydrocarbon feed from
Outside Battery Limit (OSBL) on flow control. The C3/C4 hydrocarbons is fed
to tray No. 33 in the C3/C4 Splitter, 1100-C-1 by C3/C4 Feed Pumps 1100-P-
1A/B through C3/C4 Splitter Feed Bottom Exchanger 1100-E-4.
The C3 s and lighter components in the feed vary from about 17 weight
percent to about 38 wt %. Tray No.33 is the optimal feed tray location. The
Splitter is designed to achieve 1 wt % of total C3 s in the bottom product and
1 wt % percent of C4 s and heavier in the C3 product.
The C3/C4 Splitter Feed / Bottom Exchanger, 1100-E-4 preheats the feed to
64°C. A total of 50 valve trays is used to achieve the required fractionation.
Column overhead vapour is condensed against cooling water in C3 / C4
Splitter condenser, 1100-E-2. The C3 product is further subcooled to 40°C in
C3 Product Cooler 1100-E-3 and sent to OSBL for storage. The Splitter
Reboiler (1100-E-1) is provided by low pressure steam. The C4 product is
32
cooled to 40°C in the C3 / C4 Splitter Feed/ Bottoms Exchanger (1100-E-5)
before being charged to the Water Wash column (1100-C-2).
3.2 FEED WATER WASH
The bottom product from 1100-C-1 is fed below, the bottom packed bed in
the Water Wash Column (1100-C-2) where it is washed with a counter
current stream of demineralized water to remove catalyst poisons such as
acetonitrile, metal ions, and other basic nitrogen compounds. The washed
C4 stream containing about 1 ppmw acetonitrile is fed to the C4 Feed
Coalescer Drum (1100-V-18). The C4 Coalescer Drum has a coalescer pad
which provides additional protection against water carryover. The washed
C4 is filtered through C4 Feed Filters (1100-G-1A/B) before being mixed with
the Methanol feed stream.
The Water Wash Column consists of two packed beds. Each bed is 7.8m
high and is packed with a random packing of 2” stainless steel pall rings.
The water feed rate is at least 20 wt% of the design feed rate of the
hydrocarbon.
Wash water from OSBL is fed to the Wash Water Break Drum (1100-V-3).
The wash water is Demineralized Water which has a pH of about 7.5 to 9.
The DM water from Wash Break Drum (1100-V-3) is pumped by DM Water
Booster Pumps (1100- P-3 A/B) to the Wash Water Column (1100-C-2) on
flow control. Temperatures higher than 40°C adversely impact the efficiency
of acetonitrile removal and increase hydrocarbon losses in the effluent water.
The effluent water is degassed in the Water Degasser Drum (1100-V-4) then
discharged to the Oily Water Sewer (OWS). This waste water typically
contains 200-250 ppmw acetonitrile and 0.06 wt% hydrocarbon.
33
3.3 PRIMARY REACTION (REACTOR NO.1).
Fresh Methanol from the tank farm area is pumped by Methanol Feed
Pumps (1100-P-13 A/B) to the Methanol Surge Drum (1100-V-5) on level
control. Before being fed to the surge drum it is mixed with re-cycled
Methanol from the Methanol Recovery section. About 2.0 m³/hr of Methanol
is circulated back to the pump suction continuously based on pump vendor
requirements. The mixed Methanol from 1100-V-5 is pumped by Methanol
Feed Pumps (1100-P-4 A/B) through the Methanol Filters (1100-G-2A&B)
and then through the Methanol Guard Beds (1100-R-3A & B) to remove
foreign particles and catalyst poisons. The Methanol stream is combined
with the washed C4 stream. The two streams are mixed on ratio control.
The C4 / Methanol mixture is then fed to Reactor No.1. If necessary, the C4 /
Methanol mixture can be pre-heated by the Medium Pressure (MP) steam in
the Reactor No.1 Feed Heater (1100-E-6). The normal inlet temperature to
Reactor No.1 is 40°C for Start-of-Run and 65°C for End-of-Run operation.
The feed enters Reactor No.1 (1100-R-1) where MTBE and a limited
quantity of by-products are formed. Under normal operating conditions,
ninety (90) percent of Isobutene conversion takes place in Reactor No.1. A
temperature gradient across the reactor results from the exothermic MTBE
reaction. Vaporisation of the reactor contents limits the temperature rise.
The CD Reaction column overhead pressure controls the pressure of
the reactor system. The expected percent vaporisation is between 5-10
weight percent. A Johnson Screen, provided on the outlet of the reactor
prevents the catalyst migration to the CD Reaction Column and downstream
equipment.
3.4 PRIMARY REACTION (REACTOR NO. 2)
The effluent from Reactor No.1 is condensed / cooled against cooling water
in Reactor No.2 Feed Cooler (1100-E-7) and then fed to Reactor No.2
(1100-R-2). The normal inlet temperature to Reactor No.2 is 50°C for Start
of Run (SOR) condition and 65°C for End of Run (EOR) condition. This
34
temperature is controlled by bypassing a slip stream around 1100-E-7 if
necessary.
About 60% of Reactor No.2 feed Isobutene conversion takes place in this
reactor. The actual percent conversion of the Isobutene in each of the two
reactors depends on the condition / “age” of the catalyst. The total percent
conversion in the two reactors combined is expected to be about 96%.
3.5 CATALYTIC DISTILLATION
The effluent from Reactor No. 2 is preheated to 67°C (SOR) and 78°C
(EOR) against CD Reaction Column bottom product in the CD Reaction
Column Feed / Bottoms Exchanger (1100-E-8) and then fed directly to the
CD Reaction Column (1100-C-3). Isobutene conversion is completed in the
reaction column. A total of twelve beds packed with CDTECH proprietary
catalyst “bales” is provided in this design. The expected conversion across
the CD Reaction Column is 97.5% of the Isobutene in the feed to the
column.
The amount of Methanol carried overhead in the CD Reaction Column is

limited by the azeotropic composition of 4 weight percent Methanol in C4
hydrocarbons. Methanol in feed is not sufficient to meet the stoichiometric
requirement of the reaction and methanol carried over in distillate. A
secondary Methanol feed is directly injected to the reaction zone on flow
control reset by an online Methanol analyser / controller. Three alternate
locations for the secondary Methanol injection have been provided.
The overhead vapour is condensed against cooling water in the CD Reaction

Column Condenser (1100-E-10). Distillate flows to the CD Reaction Column
Overhead Drum (1100-V-6) and is pumped via the CD Reaction Column
Reflux Pump (1100-P-5 A/B) to the column as reflux. A part of 1100-P-5A/B
discharge is fed to the Methanol Extraction Column through the Feed Cooler
(1100-E-12). Non-condensable if present are vented to the flare.
35
Medium pressure (MP) steam supplies the heat to reboil the column bottoms
in the CD Reaction column Reboiler (1100-E-9). The steam is on flow
control reset by the temperature on tray No. 12. MTBE product from the
bottom of the Reaction Column flows to the CD Reaction Column Bottoms /
Feed Exchanger (1100-E-8) where heat is recovered by heating the Reactor
No.2 effluent. Further cooling to battery limit temperature (40°C) is achieved
in the MTBE Product Cooler (1100-E-11). against cooling water.
3.6 METHANOL EXTRACTION
The Methanol Extraction Column Feed Cooler (1100-E-12) cools the CD

Column distillate product to 40°C before the distillate is fed to the Methanol
extraction column (1100-C-4). Counter-current contact with water recycled
from the Methanol Recovery Column (1100-C-5) extracts the Methanol from
the distillate. The extraction occurs across two packed beds. Each bed is
randomly packed with 2” stainless steel pall rings 5.15m high. The
hydrocarbon effluent leaves the top of the Extraction Column to feed the
Lights Column (100-C-6) under pressure control. The water-Methanol
mixture leaves the bottom of the Extraction Column on flow control reset by
the interface level in the top section of the column.
The Recycle water is a closed circulation system between 1100-C-4 and

1100-C-5. Recycle water from the Methanol Recovery column Feed /
Bottoms Exchanger (1100-E-14) heats the Methanol and water from the
Methanol Extraction column to 76°C. The recycle water is further cooled to
40°C in the Recycle Water Cooler (1100-E-13) against cooling water prior to
being fed to the Methanol Extraction Column.
3.7 METHANOL RECOVERY
The Methanol Recovery Column (1100-C-5) utilises four packed beds. Each
bed is randomly packed with 1” metal stainless steel pall rings. Each of the
36
two packed beds above the feed point is 3.66m high and the two beds below
the feed are 3.1m high. Medium pressure steam provides heat in the
Methanol Recovery column Reboiler (1100-E-15). Water exits the bottom of
the column for recycle to the Methanol Extraction Column, via the Methanol
Recovery Column Bottoms Pump (1100-P-6 A/B). The overhead vapour is
condensed against cooling water in the Methanol Recovery Column
Condenser (1100-E-16). Condensate collects in the Methanol Recovery
Column Overhead Drum (1100-V-7). The Methanol Recovery Column
Reflux Pump (1100-P-7 A/B) transfers recovered Methanol to the column as
reflux. The net overhead from the Methanol Recovery Column is cooled to
40°C against cooling water in the Recycle Methanol Cooler (1100-E-17) and
then recycled to the Methanol Surge Drum (1100-V-5).
To limit fouling the column bottoms are purged once every two weeks until
the low liquid level in the column bottom sump is reached. The water is
purged by the operator observing the level in the sump of the Methanol
Recovery Column. The purged water is sent via the OWS to wastewater
treatment for disposal. The purged water under normal operating conditions
contains about 25 ppm Methanol (max.). Make-up water (demineralized)
from OSBL is also hand controlled by the operator watching the liquid level in
the sump of the column.
Water accumulates in the Methanol Recovery Section due to dissolved water

in the C4 feed from the water wash column and production of water by side
reactions. A portion of the water is removed from the unit by the saturated
C4 raffinate. Accumulation exits the system by the periodic purge to the
waste treatment via OWS.
3.8 LIGHTS REMOVAL
The overhead stream from the Methanol Extraction Column is preheated in

the Lights Column Feed / Bottom Exchanger (1100-E-18) before entering the
lights column (1100-C-6). A total of 68 valve trays are installed in the column
to separate lights from the C4 hydrocarbons. DME, Methanol and other non-
37
condensable are vented to the fuel gas system on flow control from the
Lights Column Overhead Drum (1100-V-8).
The overhead vapour is partially condensed in the Lights Column Condenser

(1100-E-21) against cooling water. The condensed liquid is returned to the
column as reflux by the Lights Column Reflux Pump (1100-P-8 A/B). Excess
water which may build up in the column is removed as a separate liquid
phase from the overhead drum or from a special draw-off tray located
immediately below the column feed tray. Normally water is removed as a
portion of the vent gas.
The column bottom is reboiled against Low Pressure (LP) steam in the
Lights Column Reboiler (1100-E-20). The C4 bottoms product from Feed /
Bottoms Exchanger (1100-E-18) is pumped through the C4 Product Cooler
(1100-E-19) and transferred to OSBL storage at 40°C .
38

SECTION – 4
OPERATING VARIABLES AND CONTROL

39
SECTION-4
4.0 OPERATING VARIABLES AND CONTROL
4.1 NORMAL OPERATION AND CONTROL
Operation and control of the MTBE section is relatively simple and does not
normally require more attention than expected for a unit of this complexity.
Following is a thorough review of the normal operation and process control
of the MTBE section.
C3 / C4 SPLITTER SECTION
Fresh C3 / C4 hydrocarbon feed is sent to the C3 / C4 Feed Surge Drum

(1100-V-1) under level control (LIC-101). The drum operates at the vapour
pressure of the C3 / C4 feed.
C3 / C4 Feed Pumps (1100-P-1 A/B) pump the C3 / C4 feed to tray # 33 of the

C3/C4 Splitter (1100-C-1) through the C3/C4 Splitter Feed / Bottoms
Exchanger (1100-E-4). The flow is controlled by FIC-201. Any excess C3/C4
feed is bypassed before the C3/C4 Feed/Bottoms Exchanger via flow
controller FIC-204 to storage.
The C3/C4 Splitter operates similar to any distillation column with

conventional controls. When the overhead pressure is below the preset
pressure, pressure controller PIC-301 closes PV-301 to restrict flow to the
C3/C4 Splitter Condenser (1100-E-2). The C3/C4 Splitter Condenser operates
as a total condenser. The C3/C4 Splitter Overhead Drum (1100-V-2) pressure
is maintained by PDIC-302 via bypass around the condenser. Under normal
operation, there will be no vent to flare.
Reflux to C3/C4 Splitter is provided by the C3/C4 Splitter Reflux Pumps (1100-
P-2 A/B) on flow control (FIC-302). The level controller LIC-301 on the C3/C4
Splitter Overhead Drum regulates the flow of C3 product by resetting the flow
40
controller (FIC-303) after the C3 Product Cooler (1100-E-3). The cooled C3
product is sent to battery limits.
The temperature controller TIC-207 on tray #18 controls the heat input to the
C3/C4 Splitter by resetting the LP steam flow (FIC-203) to the C3/C4 Splitter
Reboiler. C4 product to the water wash column (1100-C-2) is on flow control
reset by the liquid level in the column sump (LIC-201).
WATER WASH SECTION
Wash water (demineralized) is fed under level control (LIC-102) to the Wash
Water Break Drum (1100-V-3). Operating pressure is maintained (PIC-106)
via split range control of blanket nitrogen and vent to atmosphere.
Wash water is pumped by the Wash Water Booster Pump (1100-P-3 A/B)
via flow control (FIC-401) to the Wash Water Column (1100-C-2). The wash
water rate is to be maintained as high as possible to maximise feed washing
efficiency. The rate should not be reduced below 20 wt% of the hydrocarbon
feed rate. The wash water rate during normal operations is 3.5 m³/h. This
water rate is also recommended during turndown operations unless an
extended turndown operation is anticipated.
The Wash Water Column operates full of liquid with the hydrocarbon liquid
introduced near the base of the column and water introduced near the
column top. Adequate settling area for water hydrocarbon separation is
provided at the top of the column. In addition, a coalescer pad installed in the
C4 Coalescer Drum (1100-V-18) removes any residual free water from the
exiting C4 stream. The washed hydrocarbon flows from the C4 Coalescer
Drum to the C4 Feed Filters (1100-G-1 A/B) and is then fed to the primary
reactor section under pressure control (PIC-402).
To maintain steady operation of the column the hydrocarbon/water interface

in the top section of the tower is maintained by controlling the water effluent
flow from the Water Wash Column bottom via LIC-401 to the Water
41
Degasser Drum (1100-V-4). Water degasser drum vents free hydrocarbons /
inerts on pressure control (PIC-406). The degassed effluent water is sent to
Battery Limits via Oily Water Sewer (OWS).
PRIMARY REACTOR SECTION
Fresh Methanol from storage is pumped by Methanol Transfer Pumps

(1100-P-13 A/B) on level control (LIC-501) in Methanol surge drum (1100-V-
5). Recycle Methanol from Recycle Methanol Cooler (1100-E-17) is also fed
to the Methanol Surge Drum ( 1100-V-5 ). Pressure in the Methanol Surge
Drum is maintained by PIC-503 via split range control of blanket nitrogen and
vent to flare.
Fresh and recycle Methanol from the Methanol Surge Drum is pumped by
Methanol Feed Pumps (1100-P-4 A/B) to the Methanol Guard Beds (1100-
R-3 A&B) via Methanol Filters (1100-G-2 A/B) to remove catalyst poisons
such as Ammonia and other impurities.
Most of the Methanol is mixed with the washed and filtered hydrocarbon
stream. The required Methanol feed rate is governed by the amount of :
a) Isobutene in the feed

b) Methanol that is taken overhead in the CD Reaction Column (1100-C-
3) and
c) Methanol directly injected into the Reaction Column. The feed ratio
control (FFIC-702) maintains the quantity of Methanol such that the
following requirements are met :
1. An excess of Methanol is always present in the reactors.

2. The Methanol in the CD Reaction Column feed does not
exceed the azeotropic limit of Methanol which can be carried in
the overhead C4 product.
42
The required molar ratio (Methanol : Isobutene) for the design case I and II is
1.31 and 1.36 respectively. Some on-line fine tuning may be required
particularly during the start-up period to maximise conversion and minimise
Methanol in the MTBE product. Based on the hydrocarbon feed rate (FT-
702), the on-line analysis of Isobutene concentration (AI 701A) and the
(Methanol : Isobutene) molar ratio set-point, the calculator (AY 701)
determines the required Methanol flow and resets the Methanol flow
controller (FIC-701) accordingly. Significant changes in the Isobutene feed
concentration will require the operator to manually adjust the molar ratio set
point. High and low alarms are provided to warn operators of problems.
Lower Methanol concentration will result in less than desired coversion of
Isobutene to MTBE, while excess Methanol will appear in the MTBE product.
Interlock I-3601 is provided to respond to loss of Methanol to the reaction

section. When the (Methanol : Isobutene) mole ratio drops below the low low
value, the interlock will
a) Stop steam flow (FV-704) to Reactor No.1 Feed Heater (1100-E-6)

and
b) Auto-start the standby Methanol Feed Pump (1100-P-4 A/B).
If the (Methanol : Isobutene) mole ratio is not re-established after 30

seconds, the interlock will stop C4 feed flow by closing XV-401.
For high concentration feed cases (i.e. 16 wt% Isobutene in C3/C4

feedstock), the mixed hydrocarbon/Methanol stream can be diluted with a
recycle stream from the Methanol Extraction Column (1100-C-4) overhead if
necessary. The recycle stream serves as a heat sink to Reactor No.1 and
limits the effluent temperature to about 78 °C at start of run (SOR)
conditions.
The combined hydrocarbon/Methanol (and recycle stream for the high

Isobutene concentration case) is preheated by MP steam at the Reactor
No.1 Feed Heater before feeding to Reactor No.1.
43
The Reactor inlet temperature is controlled by TIC-704 by regulating steam
flow to the Reactor No.1 Feed Heater via FIC-704. The inlet temperature is
set between about 40 °C and 55 °C. The temperature is initially lower when
the Reactor No.1 catalyst is fresh. At this point the bulk of the etherification
activity takes place in Reactor No.1. This results in a high heat release and
consequently high vaporisation at the Reactor outlet. To maintain high
conversion the feed temperature set point is set at a minimum. An inlet
temperature of approximately 40 °C is desired when the bulk of the
etherification activity occurs in Reactor No.1. As Reactor No.1 gradually
loses etherification capability, the inlet temperature should be increased to a
maximum of 55 °C.
The Reactor No.1 outlet temperature should be maintained in the range of

78 °C (SOR) to 84 °C (EOR). This temperature is affected by the operating
pressure in the CD Reaction Column (1100-C-3).
Interlock I-3602 is provided to respond to a high inlet or outlet temperature

around Reactor No.1 for catalyst protection. The interlock will stop steam
flow to 1100-E-6 by closing FV-704. The interlock trip points are provided in
Section-10.3. The action will be initiated by TY-702 on the reactor inlet and
TY-711 on the reactor effluent.
Prior to the activation of interlock I-3602, high temperature alarms (TIC-704

and TI-709) are triggered to warn operators of abnormal conditions requiring
parameter adjustments. A high inlet temperature indicates operational
problems with the steam. A high outlet temperature can result from excess
DIB formation or loss of recycle required for the high Isobutene concentration
case.
The partially vaporised effluent from Reactor No.1 is sent to Reactor No.2
Feed Cooler (1100-E-7) via a vertical pipe arrangement (20” nominal pipe
diameter). A bypass around the cooler is used to control the temperature of
Reactor No.2 feed. The 20” vertical pipe section allows liquid to degas and
44
settle down. This ensures that the bypass stream is free of vapour. A 2” line
(line no. 2"-P-1100-07B03-A1A-IH) is provided from the top of the pipe
section to the CD Reaction Column for venting non-condensable if
necessary.
The inlet temperature to Reactor No.2 is set between 50 °C and 65°C. When
the catalyst is fresh, the bulk of the etherification reaction takes place in
Reactor No.1. As etherification activity falls off in Reactor No.1, the formation
of MTBE shifts gradually to Reactor No.2. This results in a higher heat
release in Reactor No.2 and higher vaporisation in the reactor outlet. Reactor
No.2 inlet temperature is set at approximately 50 °C. As Reactor No.2
gradually loses etherification capability, the inlet temperature should be
increased to 65 °C, while maintaining an effluent temperature no higher than
75 °C. Normally vaporisation is minimal, since only a small amount of
conversion occurs in Reactor No.2.
During long-term operation, catalyst poisons in the C4 feed will gradually

decrease the activity of catalysts in both Reactor No.1 and No.2. Catalyst
etherification poisons include metal ions such as Sodium, Calcium, Iron,
Chromium, as well as other cations. Basic components such as Ammonia,
Amines and Nitriles, most notably Acetonitrile (ACN), are common poisons
found in C4 feed stocks. Catalysts in both reactors are acidic ion-exchange
resins which will be neutralised by these compounds. As neutralisation
occurs, the MTBE reaction will decrease in the reactors.
At SOR, a significant temperature rise is observed across the top portion of

the catalyst beds. Over time, the isotherm in both reactors will gradually
move lower into the reactor beds as indicated by TI-705, TI-706, TI-707 and
TI-708 in 1100-R-1 and TI-804, TI-805, TI-806 and TI-807 in 1100-R-2. The
temperature profile data should be complemented with laboratory analysis of
the reactor effluent to evaluate the condition of the catalyst. A historical plot
of conversion data across Reactor No.1 and No.2 can be utilised to plan
shutdowns and change-out of catalyst.
45
A high temperature interlock, I-3603, is provided to respond to a high inlet or
outlet temperature in Reactor No.2. When the interlock is activated, TV-803B
will be closed and TV-803A will be opened. The entire Reactor No.1 effluent
will be sent to Reactor No.2 Feed Cooler (1100-E-7). The interlock action will
be initiated by TY-802 on the reactor inlet and TY-808 on the reactor outlet.
CATALYTIC DISTILLATION UNIT
Reactor No.2 effluent flows through the CD Reaction Column Feed /

Bottoms Exchanger, 1100-E-8 into the CD Reaction Column (1100-C-3)
above Tray No.23.
The Column operates similar to any distillation column with conventional

controls. When the overhead pressure is below the preset pressure,
pressure controller PIC-1001 closes PV-1001 to restrict flow to the
condenser. The Reaction Column Condenser (1100-E-10) operates as a
total condenser. The Reaction Column Overhead Drum (1100-V-6) pressure
is maintained by PDIC-1004 via bypass of hot vapour around the condenser.
Under normal operation there will be no vent to flare via PIC-1002.
Methanol forms a minimum boiling azeotrope with C4 hydrocarbons. Within

the azeotropic limit of about 4 wt%, the Methanol is carried overhead. Above
the azeotropic limit, Methanol exits the column bottoms with the MTBE
product. This behaviour requires controlling the Methanol fed to the system
so that unreacted Methanol exiting Reactor No.2 does not exceed the
azeotropic limit in the CD Reaction Column.
The conversion of Isobutene in the CD Reaction Column is highly dependent

upon the Methanol concentration in the catalyst zone. To maximize the
amount of Methanol in the catalyst zone, secondary Methanol from the
Methanol Guard Beds (1100-R-3 A&B) is fed to the CD Reaction Column
above the top catalyst bed (bed #12). Alternative secondary Methanol
injection points are also provided above Catalyst Beds 2 and 7. The
secondary Methanol flow is controlled by the infrared (IR) Methanol analyser
46
which measures the Methanol concentration on Tray no.12 (AIC-903). This
is aimed to maximize the Methanol concentration in the catalyst zone without
exceeding the azeotropic limit. Methanol concentration on trays 27, 16 and 6
(AIC-901, AIC-902 and AIC-904) are also measured on-line.
The azeotropic composition of Methanol in the CD Reaction Column

depends on the composition profile of C4 hydrocarbons. The target Methanol
concentration on tray no.12 for CASE 1 is about 0.3 wt. percent. After
operating experience is gained, the target Methanol concentration, the
control tray location and the secondary Methanol injection point should be
reviewed and optimized as necessary to achieve maximum Isobutene
conversion.
The design C4 feed for CASE 1 contains about 19 wt% Isobutene. In this
case, most of the Methanol needed to achieve required Isobutene
conversion can be carried up the catalyst zone by the non-reacted C4
hydrocarbons in the CD column feed. The secondary Methanol flow will be
relatively small. For higher Isobutene concentration feed stocks, the non-
reacted C4 hydrocarbons in the CD Reaction Column feed will be smaller,
which will reduce the amount of Methanol that can be carried up to the
catalyst zone. The secondary Methanol requirement will be increased to
maximize Isobutene conversion.
Methanol also forms a minimum-boiling azeotrope with MTBE. The

azeotrope permits Methanol to be separated from MTBE. Periodic sampling
(SC-802) of the MTBE product can detect the presence of excess Methanol
in the column bottoms. If large amounts of excess Methanol pass down the
column, care must be taken to ensure the correct response. Because of the
minimum-boiling azeotrope, TIC-916 will sense a lower temperature and,
accordingly increase steam flow to the reboiler. This will not increase column
bottom temperature but will be an indication that the Methanol supply
controls should be checked. If no corrective actions are taken, the increase
in reboiler duty will result in excessive amounts of MTBE in the overhead
product.
47
Isobutene and Isobutane readings from the analyzers on the C4 feed and
reaction column overhead streams facilitate the calculation of isobutene
conversion by the following equation :
( A  B)
Percent conversion = (100%) x
(A)
Where
A = Percent Isobutene in the feed

percent isobutane in the feed + percent n-butane in the feed
B = Percent isobutane in the

Percent feed + Percent
Isobutene n-butanes in the
in the overhead
feed
Percent Isobutane in the ovhd + Percent n-butanes in the
ovhd
Reflux for the Reaction Column is provided by the Reaction Column Reflux
Pump (1100-P- 5 A/B) on flow control (FIC-1001). The net distillate product
flow to the Methanol Extraction Column (1100-C-4) is on flow control (FIC-
1003) reset by the liquid level (LIC-1002) in the Reaction Column Overhead
Drum (1100-V-6).
Tray no.12 temperature (TIC-916) controls the heat input to the column. TIC-
916 regulates the MP steam flow (FIC-904) to the CD reaction column
reboiler (1100-E-9) via a reset action. When column pressure is increased,
such as when approaching end-of-run conditions, the targeted control
temperature requires compensation for the increased column bottoms
pressure to maintain the desired temperature profile.
Level in the column bottoms is controlled by LIC-901 which resets the MTBE
product flow (FIC-801) from the MTBE Product Cooler (1100-E-11) to
storage.
Each CDMTBE catalyst bed has a temperature indicator, TI-902 through TI-
913 to monitor operating temperature. High temperatures in the catalyst
zone will permanently damage the temperature sensitive catalyst. A high
48
alarm is provided on each of the temperature indicators in the catalyst
section.
A connection to the Reaction Column sump is provided to permit injection of

Amine into the system to neutralize fugitive CDMTBE catalyst fines in the
column bottom after catalyst installation. The Amine is injected while the
column is in operation. No special controls apart from close manual
supervision is required.
A boot on the overhead drum collects water that accumulates during catalyst
conditioning, start-up operations and normal operation. Free water should
not be present during normal operation. Presence of free water in the boot
during normal operation can be a result of water leaks from exchangers. An
interface level indicator (LI-1001) with a high alarm is provided.
Water/Methanol is manually drained to the Methanol drains drum (1100-V-9)
for later recovery. Drainage is critical during start-up to prevent refluxing
water directly back to the column as this may cause the catalyst to
swell and, in extreme cases, this may damage the catalyst bales.
METHANOL RECOVERY SECTION
Net distillate from the Reaction Column Reflux Pump (1100-P-5 A/B) is
cooled in the Extraction Column Feed Cooler (1100-E-12). This stream
should be kept at or below 40 °C. Lower temperatures favor Methanol
extraction. The Methanol Extraction Column (1100-C-4) operates in the
same manner as the Feed Wash Column. The column is under interface
level control with the interface in the settling zone at the top of the column.
The interface is kept at a steady level (LIC-1101) by cascade controlling the
extract water flow (FIC-1102), leaving the bottom of the column. The extract
is 20 wt% Methanol by design. Low Methanol concentrations in the extract
favor complete removal of Methanol from the C4 raffinate. Water feed to the
top of the Methanol Extraction Column is cooled with cooling water in the
Recycle Water Cooler (1100-E-13). High temperature alarms are provided
on TI-1103, TI-1101 and TI-1102 to warn of problems.
49
Pressure in the Methanol Extraction Column is maintained via pressure
control (PIC-1104) of the C4 raffinate exiting the top of the column. The C4
raffinate is sent to the Lights Column Feed/Bottoms Exchanger (1100-E-18).
The Methanol Column (1100-C-5) separates Methanol from water using

conventional distillation techniques. The pressure of the column is controlled
with the pressure control valve (PV-1301) throttling flow from the condenser.
The pressure differential control valve (PV-1302) controls the receiver
pressure via bypass of hot vapor around the condenser. The Methanol
Column Condenser (1100-E-16) operates as a total condenser. A pressure
control valve (PV-1303) on the overhead drum vent line allows venting of
non-condensable to the flare header when the drum pressure exceeds the
maximum operating pressure.
The temperature controller (TIC-1205) in the third bed of the Methanol

Column (from bottom) controls heat input to the column via the reboiler
(1100-E-15). TIC-1205 resets the flow of MP steam (FIC-1201) to the
Methanol Column Reboiler (1100-E-15).
Level indicator LI-1201 monitors the liquid level in the bottom of the column.
Bottoms from the Methanol Column is pumped by Methanol Column
Bottoms Pump (1100-P-6 A/B) to the Methanol Extraction Column via the
Methanol Column Feed/Bottoms Exchanger (1100-E-14) and Recycle Water
Cooler (1100-E-13). This circulated water is to be purged to the wastewater
system periodically (every 2-3 weeks) and cannot be reused. To purge to
waste treatment, the Globe Valve to OWS is opened and the level in the
sump of 1100-C-5 is decreased to the low liquid level. Make-up water is then
added via HIC-1201 until the normal liquid level is reached.
Reflux for the Methanol Column is provided by the Methanol Column Reflux
Pump (1100-P-7A/B) on flow control (FIC-1301). The Methanol Column
Overhead Drum (1100-V-7) provides the surge for the reflux and the
50
overhead product. The overhead product is routed to the Methanol Surge
Drum (1100-V-5) on flow control (FIC-1302) with reset from LIC-1301.
LIGHTS REMOVAL UNIT
C4 raffinate stream from Lights Column Feed/Bottoms Exchanger is fed to

the Lights Column (1100-C-6) at tray #44. The Lights Column operates with
68 valve trays to remove lights from the raffinate. After partial condensation
of the column overheads against cooling water in the Lights Column
Overhead Condenser (1100-E-21), the remaining vapor phase contains
most of lights such as DME. Liquid and vapor are separated in the Lights
Column Overhead Drum (1100-V-8). The vapor is vented to the fuel gas
header at OSBL on flow control (FIC-1602). Liquid condensate is pumped
back to the column as reflux on flow control (FIC-1601), reset by the level
controller (LIC-1601).
Normally, water is removed as a portion of the vent gas. In case, free water
builds up in the column, it will be indicated either in the water boot of the
Lights Removal Overhead Drum (LI-1602) or on a special draw-off tray
located immediately below the column feed tray (LI-1501). In both cases, the
feed water is decavited manually to the Methanol Drains Drum (1100-V-9).
The pressure in the column is controlled with pressure control valve PV-1601
throttling feed to the overhead condenser. The pressure differential control
valve (PV-1602) controls the overhead drum pressure via bypass of hot
vapor around the condenser.
The vent gas to the flare header is regulated under direct flow control (FIC-
1602). The expected vent gas flowrate is provided in section 3.5. To
minimize C4 hydrocarbon loss, the flow controller set point should be
adjusted accordingly based on the amount of DME in the C4 product.
The C4 product exiting the column bottom passes through the Lights Column
Feed/Bottoms Exchanger (1100-E-18) for heat recovery. The product draw is
51
on flow control (FIC-1401) reset by the level controller (LIC-1502). It is then
pumped by the C4 Product Pump (1100-P-9 A/B) through the C4 product
cooler (1100-E-19) to OSBL for storage. Samples will be collected at SC-
1401 and analysed to monitor the oxygenate level in the C4 product.
CONDENSATE RECOVERY SECTION
MP condensate from ;
a) The Reactor No.1 Feed Heater (1100-E-6)

b) The CD Reaction Column Reboiler (1100-E-9) and
c) The Methanol Column Reboiler (1100-E-15)
d) Butene-1 reactor feed heater (1200-E-11) and
e) Butene-1 stripper column C-11 bottom reboiler (1200-E-13)
are collected in individual Condensate pots 1100-V-13, 1100-V-12 and 1100-

V-14 respectively. The condensate is then sent to the Condensate Vessel-I
(1100-V-16) on level controls. The vapor line from the Condensate Vessel-I
is open to the LP Steam header for recovery of flash steam. The condensate
is sent to Condensate Vessel-II (1100-V-17) on level control (LIC-1701)
alongwith LP condensates from the C3/C4 Splitter Reboiler (1100-E-1) and
Lights Column Reboiler (1100-E-20). The LP condensate from the Flare K.O.
drum steam coil is also returned to Condensate Vessel-II for condensate
recovery.
Condensate from the Condensate Vessel-II is pumped to battery limits on

level control LIC-1702 by the Condensate Pumps (1100-P-14 A/B). High and
low level alarms are provided to warn operators of problems.
UTILITY SYSTEMS
The Methanol Drains Drum (1100-V-9) is located below grade and collects
all Methanol and Methanol-water drains from various locations in the MTBE
52
unit. A level indicator (LI-2003) measures the level in the drum. The
Methanol Drains Drum Pump (1100-P-10), is started manually. A low level
switch (LSLL-2004) will automatically shut off the pump at low liquid level.
Light hydrocarbons and inerts are vent to the flare. The Methanol Drains
Drum Pump, (1100-P-10), transfers the contents of the drum through the
Methanol Drains Filter (1100-G-3) via flow controller FIC-2002 to Methanol
Column Feed / Bottoms Exchanger (1100-E-14) or back to the storage tanks
at OSBL. A local pressure differential indicator monitors filter blockage.
The Slop Drum (1100-V-10) is located below grade and collects hydrocarbon
drains from various vessels and pumps located in the MTBE unit. Material
drained during various shutdown operations can be reprocessed at a later
time. The drum has similar level instrumentation as the Methanol Drains
Drum. Light hydrocarbon vapors are vented directly to the flare. The Slops
Drum Pump (1100-P-12) transfers the contents to the Flare K.O. drum
(1100-V-10). The flow rate is controlled by FIC-2001 downstream of the
slops filter (1100-G-4). A pressure differential indicator monitors the
accumulation of solids in the filter.
The Flare K.O. drum (1100-V-10) collects discharges from pressure safety
valves and vents from various operating equipment, as noted on the P&ID’s,
plus the slops from the slops drum. A level gauge (LG-2101) measures the
level in the drum. The Flare K.O. Drum Pump (1100-P-11) is manually
started. A low level switch (LSLL-2103) automatically shuts down the pump.
A steam coil at the bottom section of the drum vaporizes light hydrocarbons
in the liquid collected in the drum. Steam flow through the coils is controlled
by TIC-2101. Liquid remaining in the drum is pumped to the CD Reaction
Column (1100-C-3) for re-processing Flow rate is controlled by FIC-2103.
4.2 INPUT AND OUTPUT LIST FOR DCS
Refer to Enclosures for the controller and alarm set points under normal
conditions operation for the design feedstock. The list enclosed contains set
points and alarm set point for Case I & II. But in some places where 2 values
53
are stipulated it signifies for SOR/EOR condition. The following values are
mandatory:
Tag No. Location/Service Alarm Value Type

FFALL/ Methanol to Isobutene Ratio 0.6 LL
FFSLL-702
FFI-702 Methanol to Isobutene Ratio 0.9 LL
LSLL-903 Low Level In CD Column Bottom Sump 250mm LL
LI-1501 Trapped Water On Chimmney Tray Of Methanol 150mm H
Column
LSLL-2002 Low Low Level In Slops Drum 250mm LL
LSLL-2004 Low Low Level In Methanol Drum 250mm LL
LALL/ Low Low Level In Flare Knock Out Drum 250mm LL
LSLL-2103
TAHH-702 High High Temp Of Ractor No.1 Feed 75°C HH
TIC-704 Reactor No.1 Feed Temperature 70°C H
35°C L
TIC- Temp. Profile In Reactor No.1 85°C H
705/706/
707/708
TI-710 Reactor No.1 Outlet Temperature 82°C H
35°C L
TAHH-711 High High Reactor No.1 Outlet Temp. 90°C HH
TAHH-802 High High Reactor No.2 Inlet Temp. 75°C HH
TIC-803 Reactor No.2 Feed Temp. 70°C H
35°C L
TAHH-808 High High Reactor No.2 Outlet Temp. 90°C H
TI-810 High High Reactor No.2 Outlet Temp. 88°C H
35°C L
TI-811 Reactor No.2 Effluent to CD Column 88°C H
TI-902 CD Reaction Column Bed #12 Temp. 75°C H
54
Tag No. Location/Service Alarm Value Type
TI-914 High High CD Column Bed #1 Temp. 90°C H
PSHH-307 High High C3/C4 Splitter Once Head Pressure 18.7 kg/cm²g HH
4.3 DESIGN OPERATING CONDITION
DESCRIPTION C-1 C-2 C-3 C-4 C-5 C-6

FEED 64 40 67 40 78 62
TEMP TOP 47 40 56-60 40 86 62
BOTTOM 101 40 125-132 40 131 83
ºc SPECIAL 87 - - - 107 (3rd -
TRAY (18th) bed)
REFLUX 45 - 50-54 40 78 53
PRESSUR TOP 17.3 12.5 5.8-6.7 14.9 1.3 11.2
E BOTTOM 17.8 - 6.5-7.4 - 2.0 12.0
COL. O/H 17.3 - 5.5-6.4 - 78 53
Kg/cm2 DRUM
FLO FEED 54.6 26.1 28.0 21.3 2.7 20.7
W REFLUX 49.8 - 26.6 28.0 21.3 2.7
M DM.WATE - 3.1 - 2.02 - -
3/ R
hr
TOP R/D 18.0 - - - - 252kg/h
r
Kg STEAM 5400 - 5150 - 1270 2282
/hr TO
REBOILE
R
INLET TEMP OUTLET TEMP TOP PR. BOT. PR. FEED
ºc ºc kg/cm2 kg/cm2 m3/hr

R-1 40-65 78-84 9.7 9.2 28.8
R-2 50-65 53-70 8.0 - 28.8
55

SECTION – 5
SAFETY IN CATALYSTS AND CHEMICAL HANDLING

56
SECTION-5
5.0 SAFETY IN CATALYST AND CHEMICALS HANDLING
General
The operation of the MTBE process unit requires handling of catalyst. All
other chemicals are handled in closed systems and consists of
hydrogen, methanol and hydrocarbons, mainly C3 and C4.
Hydrocarbons with small contrations of C4s. Since specific hazards
are associated with most of these materials, this section provides
information pertinent to safe handling and storage.
METHONAL :
Product name : Methanol
Formula : CH3OH
Common names / synonyms : Methyl alcohol, wood alcohol, carbinol,

wood naphtha, and methyl hydroxide
Toxic chemical in concentrations exceeding 1.0%.

Maximum allowable concentration in air : 200 PPM
Health hazard First aid

1. Inhalation: Remove to fresh air. To give artificial respiration if
Prolonged / repeated exposure or no breathing. Get immediate medical attention.
breathing very high concentration
may cause headaches, nausea,
vomiting, dizziness,
unconsciousness and even death.
2. Eye contact: Flush with running water for 15 min. Medical

Vapor will irritate the eyes. Liquid attention.
and mist will irritate and may burn
the eyes.
3. Skin contact: Wash the skin with soap and water. Remove
Brief contact may dry the skin, contaminated clothing.
Prolonged / repeated contact may
irritate the skin
4. Swallowed : If conscious, immediately induce vomiting by giving

Swallowing of 100-250 ml of 2 glasses of water. Get immediate medical
methanol can be fatal. Lesser attention. Do not give anything in unconscious
quantity can cause blindness, head condition.
aches or nausea. Initial symptoms
may only be mild intoxication but this
may become more severe 12-18 hrs
later. Toxic effects are exerted on the
central nervous system, especially
the optic nerve.
57
Protective equipment:
Breathing apparatus, chemical goggles, face shield, rubber aprons rubber gloves, and
safety shoes.
Fire and explosion information

Flammable limits in air: lower: 6% upper 36.5%
Extinguishing media:
Water spray, Dry chemical powder, CO2 or alcohol foam. DO not use water stream.
A. Storage and handling

This material should be stored in a cool place away from areas of cute fire hazard and
open flame. Containers should be kept closed and plainly labeled. It should be stored in
a ventilated area so that small leaks cannot build up enough concentration of vapor to
cause exposures or the intoxication of individuals who enter such area. Storage tanks of
this material should be electrically grounded to prevent the accumulation of dangerous
amounts of static electricity. Drums are to be stored out of the direct rays of sun with the
plugs upward. To put out fires of this material, dry chemical, carbon dioxide or large
quantities of water may be used effectively.
Personnel Safety
Personnel who are exposed to methanol should wear safety goggles and a full-face shield
for protection of the face and eyes and in the concentration of vapor is high or unknown, a
respirator should be worn to avoid excessive inhalation. Furthermore protective clothing is
advisable to avoid skin contact. Deluge type safety showers are provided in the area to
quickly rinse the body if spillage occurs. Also bubbler type eye washing equipment are
installed in case it is splashed in to eyes. Blankets should be provided in such areas in
which to wrap patients to keep them in the event of intoxication.
For other information, refer to material safety data sheet (MSDS).
MTBE
Product name : Methyl T-butyl Ether
Formula : (CH3 )3 – C - O – CH3
58
1.Inhalation: Remove to fresh air. To give artificial respiration if
May cause dizziness and drowsiness no breathing. Get immediate medical attention.
2. Eye contact: Flush with running water for 15 min. Medical
Irritation attention.
3.Skin contact : Wash the skin with soap and water. Remove
irritation contaminated clothing.
4.Ingestion : Give two glasses of water. Get medical attention

If more than several mouthfuls have
been swallowed
Fire and explosion information

Flammable limits in air: lower: 0.9% upper: 9.5%
Extinguishing agents:
Dry chemical, Alcohol foam, water spray (no direct water)
Diethanolamine:
Product name : Di ethanolamine, DEA

1.Inhalation: Remove to fresh air. To give artificial respiration if
Vapour and mists can produce upper no breathing. Get immediate medical attention.
respiratory tract irritation.
2.Eye contact: Flush with running water for 15 min. Medical
Produces severe eye irritation and attention.
possibly irreversible injury.
3.Skin contact : Wash the skin with soap and water. Remove
May cause mild skin irritation contaminated clothing.
4.Ingestion : If swallows do not induce vomiting, give 1 or 2

Can cause irritation of mouth, glass of water to drink. If required get medical
pharynx, esophagus and stomach attention.
followed by gastrointestinal distress,
nausea vomiting and diarrhea.
Fire and explosion information :

Flammable limits in air: LEL & VEL : no data
Dry chemical, Alcohol foam, water fog, CO2
59
Catalyst for reactors
Catalyst name: Amberlyst 15 (wet)

1.Eye contact: Flush eyes with water. If irritation persists consult
can cause irritation doctor.
2.Skin contact : Wash the skin with soap and water thoroughly.
Prolonged / repeated skin contact
can cause irritation.
Fire and explosion properties: no special
Dry chemical.
Catalyst for CD reaction column
Catalyst name: ETHERCAT TM ID
Health hazard, first aid and extinguishing agents same for Amberlyst-15
60
5A MATERIAL SAFETY DATA SHEET
MTBE
1. CHEMICAL IDENTITY
Chemical Methyl Tertiary Butyl Chemical Ether

Name Ether Classification
Synonyms Alkyl Ether Trade MTBE

Name
Formula CH3OC(CH3)3 C.A.S. NO. 1634-04-4 UN 1149

NO.
Regulated Shipping Name MTBE

Identification Codes/Label
Hazardous waste Class 3
I.D. No.
Hazchem Code
HAZARDOUS C.A.S. NO. HAZARDOUS C.A.S. NO.

INGREDIENTS INGREDIENTS
1. Methyl Tertiary Butyl 1634-04-4

Ether
2. PHYSICAL AND CHEMICAL DATA
Boiling 11.7 Physical State Liquid Appearance Colourless

Point/
Range oC
- 77 Vapour pressure 245 mm Odour Terpene like
Melting/ @ 35 oC, mm Hg at
Freezing Hg 20oC
Point oC
Vapour 3.1 Solubility in Moderate Solubility in

Density water @ 30 oC others
(Air = 1)
61
Specific 0.747 pH
Gravity
(Water = 1)
3. FIRE AND EXPLOSION HAZARD DATA
Flammability Yes LEL (%V) 1.6% Flash Point (OC) oC
TDG 3 UEL (%V) 8.4% Flash Point, (CC) oC - 27

Flammability
Auto ignition Temperature oC 435
Explosion Sensitivity to Impact Not available
Explosion Sensitivity to Static Not available

Electricity
Hazardous Combustion Nil

products
Does not occur
Hazardous Polymerization
Combustible Yes Explosive No Corrosive No
Liquid Material Material
Flammable Yes Oxidiser No Others
Material
Pyrophoric No Organic No
Material Peroxide
4. REACTIVITY DATA
Chemical Stability Not available
Incompatibility with other Not available

material
Reactivity Fire hazard
Hazardous Reaction Products Nil

5. HEALTH HAZARD DATA
Routes of Entry Inhalation, Ingestion, skin and Eyes

Effects of Exposure/ Inhalation May cause signs of central nervous depression such
Symptoms as headaches, dizziness, loss of appetite, weakness
and loss of co-ordination.
Ingestion
Contact Skin contact: Repeated contact may cause skin to

become dry or cracked from defatting
Action of this material.
62
Eye Contact: May cause irritation upon direct
contact.
Emergency Treatment Flush with low pressure water for at least 15 minutes.
Obtain medical help immediately. Remove from
contaminated to fresh air . Do not induce vomiting-
aspiration into lungs. May cause chemical
pneumonia.
LD50 (Oral-Rat), 3865 LD50 , mg/kg

mg/kg
Permissible Odor Threshold,
mg/kg ppm
Exposure Limit
ppm mg/kg
TLV (ACGIH) STEL,
ppm ppm
mg/kg mg/kg
NFPA Hazard Health Flammability Reactivity/Stabilit Special
Signals y
6. PREVENTIVE MEASURES
Personal Protective Equipment Chemical type goggles, face mask, respiratory

euipment approved by NIOSH/MESA
Handling and Storage Avoid repeated skin contact, practice good
Precautions
personal hygiene, such as frequent cleaning with
soap water. Keep away from sparks, open flame
and heat. All electrical equipment should be
suitable for atmosphere containing MTBE.
7. EMERGENCY AND FIRST AID MEASURES
FIRE Fire Extinguishing Use dry chemical powder, foam or carbon dioxide
Media
Special For fires involving this material, do not enter any

Procedure
enclosed or confined fire space without proper
protective equipment including self contained
breathing apparatus.
Unusual Hazards
63
Flammable vapours are released at standard
conditions which can form explosive mixture with
air.
EXPOSURE First Aid Inhalation : Remove to fresh air
Measures Ingestion : Do not induce vomiting
Eye Contact : Flush with water for at least 15 min.
and obtain medical attention immediately. Prompt
attention is essential.
Not available
Antidotes/
Dosage
SPILLS Steps to be taken Stop flow of product. Remove all sources of

ignition. Contain spill using sand or absorbent
material. Run-off to sewer may create explosion
Waste Disposal
hazard
Method
Recover or inject in combustion system such as

boilers or flare system.
8. ADDITIONAL INFORMATION/ REFERENCES
9. MANUFACTURER/ SUPPLIERS DATA
Name of firm :
Mailing Address :
10. DISCLAIMER
Information contained in this material safety data sheet is believed to be reliable but no
representation, guarantee or warranties of any kind are made as to its accuracy,
suitability for a particular application or results to be obtained from them.
Material Safety Data Sheet
64
METHANOL
1 CHEMICAL IDENTITY
Chemical Name: Methanol Chemical Classification

: Methanol, Wood alcohol,
Carbinol, Wood naphtha,
GE material
Synonyms: Methyl Alcohol, carbinol, Wood alcohol

Trade Name: Methanol
Formula: CH3OH C.A.S.NO. 67-56-1 UN. NO. 1230
Regulated Shipping Name : Methanol,

Identification
Codes/Label : Class 3
Hazardous waste I.D. No: 17
Hazchem Code : 2PE
HAZARDOUS INGREDIENTS C.A.S.NO. HAZARDOUS

INGREDIENTS C.A.S.NO.
1. 99.8% Methyl Alcohol 67-56-1 2. 100% Methlyl Alcohol

67-56-1,F003,U154
2. PHYSICAL AND CHEMICAL DATA
Boiling Point/Range oC 64.5 Physical State : Liquid

Appearance : Clear
Colourless
Melting / Freezing --97.8 oC Vapour pressure

Odour: Alcohol
65
Point 100 mm Hg @ 21.2oC
_____________________________________________________________________
______________________________
Vapour Density 1.1 Solubility in water @ 30oC Others:

Fully soluble in halogenated
(Air = 1) Totally miscible
hydrocarbons, alcohols ,ketones
and esters.
Specific Gravity 0.791 pH: N.A.

(Water = 1)
3. FIRE AND EXPLOSION HAZARD DATA
Flammability Yes LEL 5.5 % Flash Point oC 16.1

(OC)
TDG Flammability UEL 36.5% Flash Point oC

12.2 (CC)
Autoignition Temperature oC 465
Explosion Sensitivity to Impact stable
Explosion Sensitivity to Static Vapour is explosive

Electricity
Hazardous Combustion products Smoke, CO, Aldehyde & other products.
Hazardous Polymerization Does not occur. Keep away the

material from heat spark, pilot lamps,
Static electricity, isolated outside
storage is preferred. Inside storage should be in a
flammable liquid cabinet or storage area.
Combustible Liquid Yes Explosive Material Yes Corrosive

Material : No
Flammable Material Yes Oxidiser No Others Nil
Pyrophoric Material No Organic Peroxide No
66
4. REACTIVITY DATA
Chemical Stability Stable under normal storage and use conditions. It does
not undergo hazardous polymerization.
Incompatibility with Acids, Oxidising agents,

other material
Reactivity Not available.
Hazardous Reaction Avoid contact with strong oxidizing agents such as

nitrates, perchlorates or sulphuric acid.
Products Oxidation in air include oxides of carbon and nitrogen.
5. HEALTH HAZARD DATA
Routes of Entry Inhalation, skin absorption or ingestion.
Effects of Exposure/ Ingestion can produce blindness. Symptoms of over-

exposure include dizziness,
Symptoms visual impairment, nausea, respiratory failure,
muscular in-coordination and narcosis. Repeated skin contact
will cause dermatitis, erythema and scaling.
Ingestion of 100 to 250 ml can be fatal.
Emergency Treatment Remove contaminated clothing & wash affected area

with soap & water and apply skin lotion. Irrigate with running
water for 15 minutes. Remove victim to fresh air and prevent
further exposure for 7 days. Give 3 glasses milk, water or 4%
sodium bicarbonate, gastric lavage by medical personnel.
L.D50 (Oral-Rat) More than 5000 mg/1 kg L.D50
Permissible 200 ppm (skin) mg/m3 Odour Threshold

ppm mg/mg3
Exposure Limit
TLV (ACGIH) 200 ppm 260 mg/m3 STEL 250

ppm 328 mg/m3
NFPA Hazard Signals Health Flammability Reactivity

Special -
2 3 0
6 PREVENTIVE MEASURES
67
Personal Protective Rubber gloves, apron, boots and face shield should
be used where splashing may occur
Equipment. safety goggles, breathing apparatus.
Handling and Storage Store in well ventilated fire proof area, away from
sources of heat, open flame and
Precautions ignition. No smoking in areas of storage. Avoid
prolong breathing of vapour or contact with skin. Avoid contact
with eyes. This material is poisonous when introduced into
body metabolism. Do not ingest.
7. EMERGENCY AND FIRST AID MEASURES

FIRE Fire Extinguishing Media CO2, DCP, Alcohol foam. Water
can be used to cool and protect the exposed
material.
Special Procedures Recommend wearing self

contained breathing apparatus.
Water may be in-effective in
fighting fires.
Unusual Hazards Toxic fumes, gases or vapours

may evolve on burning, vapours may be heavier
than air and may travel along the ground to a
distant ignition source and flash back. Container
may rupture on heating.
EXPOSURE First Aid Measures Skin : Wash with soap & water.
Immediately remove contaminated
clothing before reuse.
Eye : Flush immediately with water
for at least 15 minutes. Get immediate medical
attention.
Inhalation : Remove the exposed
person to the fresh air. If breathing has stopped,
apply artificial respiration. If the irritation persists
or if the toxic symptoms are observed, get
medical attention.
Oral : If conscious, give several
glasses of water and induce vomiting. get
immediate medical attention. In the victims
displaying signs of central nervous system
depression do not induce vomiting.
Additonal : Note to physician : Treat
symptomatically.
Antidotes/Dosages: Baking soda in a glass of water

SPILLS
Steps to be taken May form explosive mixtures with
68
air. Immediately evacuate all personnel from
danger area. PPE’s must be worn. Eliminate all
sources of heat, sparks, pilot lights, static electricity
and open flames. Ventilate spill area. Prevent
entry into sewers and waterways. Pick up free
liquid for recycle and / or disposal. It can be
accomplished safely by explosion proof equipment.
Residual liquid can be absorbed on inert material.
Waste Disposal Method Spray into a furnace, incineration will

become easier by mixing with a more flammable
solvent..
8. ADDITIONAL INFORMATION/REFERENCES
A human poison by ingestion. Poison also by skin contact. The main toxic effect is
extended to the nervous system, particularly optic nerves & retina, which may lead to
permanent blindness. Once absorbed, it is slowly eliminated. coma by severe
exposure may last for 2-4 days. Persons with eye, liver, kidney & lung problems should
avoid contact. Periodic medical check up is recommended. Dangerous fire hazard
when exposed to heat, flame, and oxidisers.
9. MANUFACTURER/SUPPLIERS DATA
Name of firm :
Mailing Address :
10. DISCLAIMER
Information contained in this material safety data sheet is believed to be reliable but no
representation, guarantee or warranties of any kind are made as to its accuracy,
suitability for a particular application or results to be obtained from them.
5B MTBE MASTER BLIND LIST
69
MASTER BLIND LIST MTBE
DESCRIPTION RUNNI
SL NO. SIZE NG S/D TYPE
1 V3 DM WATER INELT 1.5 "OUT IN SPECT.
2 V3 N2 BLANKETING 1.5 "OUT IN SPECT.
3 V3 LEVEL GLASS DRAIN TO FLARE 0.75 "IN OUT SPECT.
4 V1 C3/C4 FEED 4 "OUT IN SPECT.
6 V1 DRAIN TO CBD 2 "IN OUT SPECT.
7 E4 DRAIN TO CBD 1 "IN OUT SPECT.
8 V1 TO C3/C4 BYPASS TO OSBL 3 "OUT IN SPECT.
10 C1 LEVEL GLASS DRAIN TO FLARE 0.75 "IN OUT SPECT.
11 C1 DRAIN TO CBD 1 "IN OUT SPECT.
12 C1 REBOILER INLET 12 "OUT IN SPECT.
13 C1 REBOILER OUTLET 20 "OUT IN SPECT.
14 C1 REBOILER DRAIN TO CBD 1 "IN OUT SPECT.
17 C1 TOP PRODUCT TO OSBL 3 "OUT IN SPECT.
19 V2 BOOT LEVEL GLASS DRAIN 0.75 "IN OUT SPECT.
20 V2 BOOT DRAIN 2 "OUT IN SPECT.
21 C2 BOTT. DRAIN TO OWS 2 "IN OUT SPECT.
22 V18 BOTT. DRAIN TO OWS 2 "OUT IN SPECT.
23 V18 LEVEL GLASS DRAIN TO CBD 0.75 "IN OUT SPECT.
24 V18 BOOT LEVEL GLASS DRAIN 0.75 "IN OUT SPECT.
25 V5 MeOH INLET FROM OSBL 1.5 "OUT IN SPECT.
26 V5 VENT 1.5 "OUT IN SPECT.
27 V5 LG DRAIN TO MeOH DRAIN DRUM 0.75 "IN OUT SPECT.
70
28 G2A INLET 2 "OUT IN SPECT.
29 G2A OUTLET 2 "OUT IN SPECT.
30 G2B INLET 2 "OUT IN SPECT.
31 G2B OUTLET 2 "OUT IN SPECT.
32 R3A INLET 2 "OUT IN SPECT.
33 R3A OUTLET 2 "OUT IN SPECT.
34 R3A DRAIN TO MeOH DRAIN DRUM 1.5 "IN OUT SPECT.
35 R3A N2 BLANKETING 1.5 "IN OUT SPECT.
36 R3B INLET 2 "OUT IN SPECT.
37 R3B OUTLET 2 "OUT IN SPECT.
38 R3B DRAIN TO MeOH DRAIN DRUM 1.5 "IN OUT SPECT.
39 R3B N2 BLANKETING 1.5 "IN OUT SPECT.
40 G1A INLET 4 "OUT IN SPECT.
41 G1A OUTLET 4 "OUT IN SPECT.
42 G1B INLET 4 "OUT IN SPECT.
43 G1B OUTLET 4 "OUT IN SPECT.
45 R1 INLET 4 "OUT IN SPECT.
46 R1 OUTLET 4 "OUT IN SPECT.
47 R1 MeOH INLET STARTUP 2 "IN OUT SPECT.
48 R1 N2 PURGING 1.5 "IN OUT SPECT.
49 R1 BYPASS 4 "IN OUT SPECT.
50 R1 LG/ LT DRAIN TO CBD 0.75 "IN OUT SPECT.
51 R1 DRAIN 1.5 "IN OUT SPECT.
53 R2 INLET 4 "OUT IN SPECT.
54 R2 OUTLET 4 "OUT IN SPECT.
55 R2 MeOH INLET STARTUP 2 "IN OUT SPECT.
56 R2 N2 PURGING 1.5 "IN OUT SPECT.
57 R2 BYPASS 4 "IN OUT SPECT.
71
58 R2 LG/ LT DRAIN TO CBD 0.75 "IN OUT SPECT.
59 R2 DRAIN 1.5 "IN OUT SPECT.
61 C3 BOTT MTBE R/D 3 "OUT IN SPECT.
62 C3 BOTT DRAIN TO CBD 2 "IN OUT SPECT.
64 C3 LG/ LT DRAIN TO CBD 0.75 "IN OUT SPECT.
REBOILER TO MeOH DRAIN
67 C3 DRUM 3 "IN OUT SPECT.
68 C3 REBOILER TO CBD 1 "IN OUT SPECT.
71 V6 LG/LT DRAIN TO V9 0.75 "IN OUT SPECT.
73 C4 TOP TO R1 INLET 2 "OUT IN SPECT.
74 C4 LG/LT DRAIN TO V9 0.75 "IN OUT SPECT.
75 C4 BOTTOM DRAIN TO V9 2 "IN OUT SPECT.
76 C5 BOTTOM DRAIN TO V9 1.5 "OUT IN SPECT.
77 E13 DRAIN TO V9 1 "IN OUT SPECT.
78 C5 REBOILER DRAIN TO V9 2 "IN OUT SPECT.
79 E16 DRAIN TO V9 1 "IN OUT SPECT.
81 V7 BOTTOM DRAIN TO V9 2 "IN OUT SPECT.
84 C6 TO OSBL B/L 4 "OUT IN SPECT.
85 C6 TO R1 4 "OUT IN SPECT.
86 C6 LG/LT DRAIN TO V9 0.75 "IN OUT SPECT.
87 C6 REBOILER DRAIN TO CBD 3 "IN OUT SPECT.
72
91 V8 LG/LT DRAIN TO CBD 0.75 "IN OUT SPECT.
92 V8 BOOT LG/LT DRAIN TO V9 0.75 "IN OUT SPECT.
95 V10 OUTLET TO FLARE 14 "OUT IN SPECT.
96 V10 DRAIN TO CBD 0.75 "OUT IN SPECT.
97 P1A DRAIN TO CBD 0.75 "IN OUT SPECT.
98 P1B DRAIN TO CBD 0.75 "IN OUT SPECT.
101 P3A DRAIN TO OWS 0.75 "IN OUT SPECT.
102 P3B DRAIN TO OWS 0.75 "IN OUT SPECT.
103 P4A DRAIN TO V9 0.75 "IN OUT SPECT.
104 P4B DRAIN TO V9 0.75 "IN OUT SPECT.
115 P11 DRAIN TO CBD 0.75 "IN OUT SPECT.
116 MP STEAM B/L 8 "OUT IN SPECT.
117 LP STEAM B/L 12 "OUT IN SPECT.
73
118 CW INLET B/L 18 "OUT IN SPECT.
119 CW OUTLET B/L 18 "OUT IN SPECT.
120 INSTRUMENT AIR B/L 4 "OUT IN SPECT.
V1 INLET
121 4 "OUT IN TAIL
V1 OUTLET
122 6 "OUT IN TAIL
V1 TO FLARE
123 2 "OUT IN TAIL
V2 INLET
124 6 "OUT IN TAIL
V2 OUTLET
125 6 "OUT IN TAIL
V2 TO FLARE
126 6 "OUT IN TAIL
127 C1 FEED ENTRY 6 "OUT IN TAIL
128 C1 CONDENSER LINE 6 "OUT IN TAIL
129 C1 FLARE 10 "OUT IN TAIL
130 C1 REFLUX 6 "OUT IN TAIL
132 C2 OUTLET 4 "OUT IN TAIL
133 C2 DM WATER 2 "OUT IN TAIL
135 R1 INLET 4 "OUT IN TAIL
136 R1 OTLET 6 "OUT IN TAIL
137 R1 FLARE 4 "OUT IN TAIL
138 R2 INLET 4 "OUT IN TAIL
139 R2 OTLET 6 "OUT IN TAIL
140 R2 FLARE 4 "OUT IN TAIL
141 C3 METHONAL ENTRY -TOP 2 "OUT IN TAIL
142 C3 METHONAL ENTRY -MID. 2 "OUT IN TAIL
143 C3 METHONAL ENTRY -BOT. 2 "OUT IN TAIL
74
152 C5 REFLUX 1.5 "OUT IN TAIL
153 C5 MEOH COND. 6 "OUT IN TAIL
155 C5 REBOILER 4 "OUT IN TAIL
157 C6 CONDENSER 6 "OUT IN TAIL
159 C6 MEOH DRAINS HEADER 1.5 "OUT IN TAIL
75

SECTION – 6
EQUIPMENTS - STANDARD OPERATING PROCEDURE

76
SECTION-6
STANDARD OPERATING PROCEDURE
6.1 EQUIPMENT HANDING OVER TO MAINTANANCE:

Equipments are required to be handed over during shutdown/normal operations for
maintenance purposes. Procedures given below should be followed to ensure their safe release
and safe maintenance work.
A. PUMPS
I. For electrical maintenance
 Stop motor as per procedure.
 De-energise the motor from substation.
 Ensure that “DO NOT OPERATE, MEN AT WORK” board is put on the switch.
 Give clearance to decouple the motor, if required.
 Give clearance for electrical job.
II. For mechanical maintenance
1. Cold pumps
 Stop the pump as per procedure.
 Close cooling water.
 Close suction and discharge B/Vs.
 Ensure the B/Vs are holding.
 Depressurise/drain the pump gradually.
 De-energise the motor from Sub-station.
 Ensure that “DO NOT OPERATE, MEN AT WORK” board is put on the switch.
 Give clearance for maintenance job.
2. Hot pumps
 Stop the pump as per procedure.
 Before depressurizing, close warm up B/Vs.
 Close gland sealing, flushing oil.
 Stop steam to mechanical seal.
 Allow the pump to cool.
 Flush the pump with FLO if material is heavy.
 Drain/depressurize the pump.
Note: Keep the water hose running. In case of high pour point materials like RCO, VR, etc
open FLO line to suction and run the pump to displace heavy material into discharge circuit. If
FLO is not available drain preferably through cooler or drain gradually.
 Rest steps are same as those for cold pumps.
B HEAT EXCHANGER / CONDENSER COOLER / REBOILER
77
 Isolate and decommission the equipment as per procedure.
 Flush the equipment handling heavy material with FLO and steam.
 Drain hydrocarbons to CBD vessel E-8. Open the vent valves to ensure complete draining.
 Provide blinds/wedge opening towards the exchanger on both the side.
 Give steam connection on top nozzle.
 Carry out steamimg for 4 hours.
 Water flush condensers and coolers handling light hydrocarbons.
 Release the equipment for maintenance.
C. VESSEL
 Pump out the vessel completely.
 Drain out remaining portion of hydrocarbons to CBD/OWS.
 For heavy material vessel, flush and then drain.
 For caustic, chemical vessels, dilute the contents with water and then empty out.
 Close inlet and outlet valves, safety valves and any other connected lines.
 Keep the vent open.
 All inlet/outlet flanges should be blinded with wedge opening towards vessel side.
 Give steam connection.
 Thoroughly steam the vessel for 4 hours. For vessel containing heavy hydrocarbons, more
steaming will be needed.
 Keep the drains and vents of instrument taps open for flushing. Ensure that steam comes
out from all the wedge openings.
 Give water hose connection and over-flow water from vessel for about 4 hours.
 Drain water completely.
 Ensure caustic branch nozzles are free from caustic by opening weep holes etc.
 Blind water and steam lines.
 Open man-way cover.
 Test inside for presence of hydrocarbons with explosimeter.
 If above gas test is negative, give ‘ENTRY PERMIT’ for maintenance job.
D. COLUMN
 Pump out oil / hydrocarbon from the column completely.
 Drain out remaining oil to CBD/OWS.
 Deblind steam purging line.
 Steam the system for 6 hours. Steam will wet the entire column such that flange opening for
blinding and wedge opening can be done safely.
 Install blinds with wedge opening towards column on all inlet and outlet nozzles except
steam and top reflux line.
78
 Keep the drains and vents of all instrument tappings open.
 Steam the column for 6--8 Hrs.
Note : Ensure that sufficient steam issues from all the wedge openings. Keep the vent open.
Do not exceed working pressure of column while steaming.
 Provide water connection to reflux line.
 Keep the column drain fully open.
 Stop steaming and water wash for about 4 hours. Do not allow water level to build up high
in the column.
 Repeat steaming and water washing.
 Open top man-hole cover.
 Carry out gas test by explosimeter.
 If gas test is positive, box up man-hole and repeat steaming and water washing.
 If gas test is negative give clearance to open rest of the manholes.
 Get steam and top reflux lines blinded.
 Ensure for proper ventilation in the column.
 Provide air hose / fan, if required.
 Give clearance for inspection/maintenance jobs.
E. CONTROL VALVE
 Bypass the control valve.
 Close up-stream and down-stream B/Vs.
 Isolate gland seal oil / flushing oil.
 Drain C/V loop. Ensure isolation valves are holding.
 Give clearance for removing the control valve.
 End-blind the open flanges.
6.2 EQUIPMENT TAKING OVER FROM MAINTENANCE

If equipment is not properly checked while taking over from Maintenance it may result in
accidents or give trouble during start up. Check the following items while taking over any equipment
from Maintenance.
A. PUMP/MOTOR
 Check that electrical and earthing connections are complete.
 Ensure the correct direction of rotation.
 Ensure mechanical completion. Check coupling guard is in position.
 Ensure cooling water, quenching steam and flushing oil lines are clear.
 Pressure gauges should be in position.
 Ensure that shaft is free to rotate.
79
 Check that associated lines are de-blinded.
B. HEAT EXCHANGER / CONDENSER / COOLER / REBOILER
Ensure the following:-
 Tube and shell cleaning is proper.
 Leaky tubes are plugged/replaced.
 Shell is painted as per Inspection.
 Exchanger is properly boxed up with gaskets.
 Check for short bolting.
 Bull plugs, thermowells, pressure gauge, assemblies, PSV/TSV are in position.
 Insulation is complete.
 Earthing connections are completed.
C. VESSEL
While taking over vessel from maintenance check and ensure following items :
 Vessel is thoroughly cleaned.
 No foreign material is left inside.
 Drain points and instrument taps are clear.
 Vessel internal including instruments are in their respective positions and properly secured.
 Vessel is coated/painted as per Inspection report. Take clearance from Inspection.
 No person is left behind in the vessel.
 If all the above things are satisfactory give clearance to box up the manholes.
Note : Manhole should be boxed up on four bolts in presence of Production staff.
 Remove the blind as per master blind list.
 Connect all the instruments.
 Line up safety valves.
 The vessel is ready for service.
D. COLUMN
Ensure the following:
 Start boxing up from top.
 The tray decks below the manhole are clean and free of foreign materials.
 Temporary connections are removed.
 All instrument tappings, drain points, distributors, down-comers, inlet and outlet nozzles are
clean.
 All internals are fitted properly.
 All inside fittings like distributors, thermo-wells, floats of level indicators etc are in position.
 Tray man-way covers are boxed up.
80
 Manholes are to be boxed up on four bolts after ensuring that nobody is left inside.
Note: Tray man-way and manholes should be box up on four bolts in presence of
production staff.
 All man-way covers are boxed up as above.
 Blinding/de-blinding is done as per master blind list.
 NRV’s are installed in their proper direction.
 Column bottom drains are connected properly.
 Safety valves are installed and lined up.
 The instruments are in their respective position.
 The column is ready for service.
6.3 STANDARD OPERATING PROCEDURE :

6.3.1 PUMPS
Pump is used to transfer liquids from one place to other. Pumps are of three types :
(A) Centrifugal pump
(B) Reciprocating pump
6.3.1(A) CENTRIFUGAL PUMP
These are most widely used. A centrifugal pump consists of following parts :
Motor, bearing housing, coupling, pump casing, impeller and shaft, mechanical seal/gland packing,
cooling, flushing and quenching systems.
(A) Start-Up Procedure
COLD PUMP
 Check the mechanical/electrical completion.
 Check the quality and level of lube oil. Change/top up lube oil,if required.
 Rotate the shaft by hand to ensure that it is free.
 Energise the motor.
 Commission cooling water if provided.
 Commission quenching/flushing medium to seal /gland packing. Adjust pressure.
 Open suction valve and fill the casing with liquid. Bleed if necessary.
 Press/start button and check direction of rotation.
 Check the discharge pressure and open discharge valve gradually.
 Check the amperage of the motor. Adjust the load, if required.
 Check for any abnormal conditions like vibrations, abnormal sound, leakage, bearing
temperature etc.
HOT PUMP
The procedure is same as that for cold pump except for the following additional points.
81
 Open warm-up valve (across NRV of discharge line) to heat the pump before starting.
 Pinch /close the warm-up valve after the pump is on full load.
(B) Shut down procedure
 Close the discharge block valve fully.
 Stop the motor.
 Open warm up b/v for hot pump to keep it hot. Ensure that the pump is not rotating.
(C) Changeover of the pumps
 Start the stand-by pump as per standard procedure.
 Open the discharge valve gradually. Simultaneously close the discharge valve keeping a
watch on the discharge pressure gauge/flow-meter.
 Switch off the originally running pump.
 Open warm up b/v of hot pump to keep it warm up.
6.3.1(B) RECIPROCATING PUMP
This is positive displacement pump; hence an outlet must be available for the liquid displaced
otherwise the system will get over-pressurized.
In reciprocating pump liquid is displaced from suction to discharge by the reciprocating
movement of the piston or plunger in a cylinder. The pump consists of following parts :
Motor, gear-box coupling, pump cylinder, piston/plunger, stroke adjuster, safety valves,
suction/discharge valves.
(A) Start Up Procedure
 Check mechanical/electrical completion.
 Check the quality and level of lube oil.
 Rotate the shaft by hand to ensure that it is free.
 Check the minimum flow circuit and discharge relief valve.
 Adjust the stroke length in case of dosing pumps.
 Start the motor by push-button.
 Watch the discharge pressure. If pressure continues to increase beyond normal pressure,
 stop pump immediately and check the line-up.
 Check for unusual noise, vibrations, and rise in bearing temperatures of motors and
 pumps.
Note : Discharge valve of reciprocating pump should never be closed/throttled while the motor
is running.
(B) Shut-Down Procedure
 Stop the motor.
 Do not close suction/discharge valve unless it is to be handed over to maintenance.
(C) Change-Over Of The Pumps
82
 Start the stand-by pump as per standard procedure.
 Immediately switch off originally running pump as soon as the pressure starts increasing.
Routine Checks
Following checks should be carried out regularly.
 Quality and level of lube oil.
 Pump and motor bearing temperatures.
 Abnormal sound and vibrations
 Leakage
 Pressure gauges
6.3.2 HEAT EXCHANGERS
These are equipments in which heat is exchanged between hot and cold fluids of the process,
to increase process efficiency. It is used to transfer heat from one fluid to another. Exchangers
normally consist of tube bundle enclosed in a shell. Shell and tube type of heat exchangers are
used in this Unit.
Commissioning Procedure
 Get the HE system de-blinded.
 Keep the vent valves of both shell and tube sides open.
 Remove air by steaming or filling with flushing oil.
Note: In case of flushing oil filling, provide an extension hose on vent line for safe
disposal of oil.
 Line up PSV/TSV.
 Close the vents and provide caps.
 Carry out pressure test with steam/FLO for any leaks.
 Commission cold side gradually.
 Open outlet of heating medium gradually.
 Open inlet of heating medium gradually.
 Close bypass valve of cold side.
 Close bypass valve of hot side.
 Check for any leaks.
 Carry out hot bolting.
 Put blinds on CBD lines and caps on drains.
6.3.3 COOLERS
Coolers are used to cool a liquid normally prior to storage.
 Air displacement on cooling water side is done by water. Rest of the procedure is same as
that of heat exchanger.
83
 Adjust cooling water flow to obtain desired product outlet temperature.
6.3.4 CONDENSERS
Condensers are used to condense vapors’ into liquid form.
 Steam shell side to displace air.
 Pressurize and check for leaks.
 Open hydrocarbon inlet valve slowly.
 Commission water and displace air from tubes.
 Open outlet valve of hydrocarbon side gradually keeping a close watch on column
pressure.
 Adjust cooling water flow to get desired condensate temperature.
 Plug / cap the vents and drains
Decommissioning Of Exchangers / Coolers / Condensers
 Gradually open bypass valve on heating medium side.
 Close the inlet valve on heating medium.
 Close outlet valve on heating medium.
 Leave outlet valve open if exchanger is not to be drained/depressurized.
 Stop cooling water of coolers/condensers.
 Open bypass valve of cold medium of exchangers.
 Close inlet and outlet valve of cold medium side.
 Flush the shell/tube side of the HE elements which are handing high pour point
hydrocarbons if the system pressure is higher than FLO pressure, drain the exchanger to
CBD and then flush with FLO to CBD.
 If the system pressure is lower than FLO pressure, open FLO to inlet and open the outlet
valve of the HE element to displace heavy hydrocarbons into the system itself.
 Isolate PSV/TSV.
 If the exchanger is not to be handed over to Maintenance, it need not be
depressurized/drained.
Routine Checks Of Exchangers / Coolers /Condensers
Following checks should be carried out regularly.
 Inlet/outlet temperatures and pressures on both sides to assess the performance
and leakage.
 Water outlet temperature in coolers should not exceed 45OC to avoid scale formation.
84
6.4 TANK OPERATIONS
6.4.1 TANK HANDING OVER FOR MAINTENANCE:
1. Pump out tank materials to OM&S respective tank till pump looses suction.
2. Get water hose connection from drain or through dip hatch and build up level for pumping
out more hydrocarbon. As far as possible hydrocarbon to be pumped out.
3. Get tank's inlet / outlet and other connected lines (except drain) blinded.
4. Drain tank content to OWS.
5. Get sky light cover and manhole opened.
6. Take further water inside the tank for over flowing of rest hydrocarbon through manhole.
7. Overflowing to be continued till all hydrocarbon remove.
8. Check by explosive meter. If OK then water to be drained out. Leave
9. tank for air circulation.
10. Check explosivity. If OK, hand over the tank for cleaning / M & I job. If explosivity. is not OK,
then repeat the overflowing by water more.
6.4.2 CHECK LIST FOR TAKING OVER STORAGE TANK AFTER MAINT AND INSPECTION
(Common for all types of tanks)
01) Tk inside has been cleaned thoroughly and all debris has been taken out.
02) Water draw off line has been cleaned and is through.
03) Datum plate is properly fixed and the top surface is cleaned.
04) Dip tape bob is touching the Datum plate properly, when the dip tape lowered from Dip
Hatch.
05) The Actual reference height is matching with the calibration chart value (physical checking).
06) Flame Arrestor has been checked for through ness and fitted properly.
07) Gooseneck has been checked for through ness and fitted properly and wire mesh has been
provided at the mouth of gooseneck to prevent entry of bird etc.
08) P.V. valve has been checked for proper working and fitted in position.
09) Mechanical level indicator float movement (up and down) along with guide strings has been
checked and found OK and its zero reading has been checked when the float is kept at the
datum plate level.
10) Dial thermometer has been provided.
11) Steam coil pressure testing was done and certified ok by inspection.
12) Side entry mixer shaft propeller is properly fitted inside the tank and the shaft is freely
rotating.
13) Jet nozzle / euducator is fitted properly with its tip facing 45 degree upward.
14) The slope of Tk bottom is towards the water draw-off line.
15) Steam coils are properly supported to prevent bending / hanging of the coil.
16) Staircase condition is ok.
17) Tank insulation is in good condition.
18) Roof skylight covers and all manhole covers have been properly boxed up with fresh gaskets
and all bolts have been tightened (after ensuring that there is nobody inside the tank).
19) All tank valves have been fitted properly with fresh gaskets and all bolts have been tightened.
20) Drain funnel to underground OWS is clear and dechocked.
21) Tank shell earthing is properly provided.
22) Fire fighting facilities like foam lines etc. are properly fitted.
23) Deluge cooling facility / spray nozzle cooling water ring are pr provided and their performance
has been tested.
85
24) Operating platform for tank valve operation is as per requirement.
25) Tk pad is in good condition.
26) Approach path from the road to the tank dyke and from the dyke to the tank valve manifold,
stair case etc. are clear and safe for movement of personnel.
27) All oil spillage / sludge etc. have been removed from tank dyke enclosure and the area has
been properly dressed up.
28) Reference height, safe filling height and product name have been painted properly on the
tank shell near the entry point of the staircase and also near the dip hatch platform.
29) Opening in the tank dyke has been repaired properly.
30) Rotary jet mixer assembly at the center is through and properly fitted.
31) Tank bottom having concave shape water collecting sump is cleared at the center.
32) All the scrap and unwanted material is removed from the tank farm.
33) All inlet, outlet, jet nozzles are cleaned and through.
34) Lightening arrester is in position.
35) All tank valves, drain valves, steam inlet/outlet valves are revisioned and fitted.
36) Tank automation instruments are fitted properly and zero check is done.
37) Inside / outside painting is done.
38) Base plates if removed for inspection purpose are welded again.
39) Checking of calibration of tank done.
ADDITIONAL CHECKS FOR FLOATING TANKS:
01) Pontoon boxes have been checked and found to be free of leaks and pontoon box lids have
been properly fixed.
02) Floating rooftop has been cleaned and all debris taken out.
03) Roof drain sump on the floating roof has been cleaned and the perforated cover has been
fixed on the sump.
04) NRV at the top end of roof drain has been serviced and fitted back properly.
05) Water seal in the emergency roof drain have been topped up properly and cover is fitted.
06) Floating roof foam seal is in good condition and foam seal weather protector is in good
condition.
07) Foam seal vents have been checked for throughness, and also the flame arrestor fitted on the
seal vent.
08) Emergency vents on the floating roof are in proper working condition.
09) The non sparking guide ring provided between the floating roof and the dip hatch pipe is
properly fitted and is in good condition and it's free movement is observed while receiving /
draining water.
10) The sliding ladder on the floating roof is in proper working condition.
11) The earthing wires are properly provided from the deck of the floating roof to the roof ladder
and also from the roof ladder to the tank shell (two sets of earthing wires are to be provided in
each case).
12) Free up and down movement of the floating roof has been checked by filling with water and
then draining.
13) Roof drain system was serviced / pressurize tested and approved by the inspection.
14) Foam dam provided on the floating roof is in good condition.
15) Whether floating roof-supporting legs have been adjusted to lower position.
6.4.3 COMMISSIONING OF TANK
 Gravitate, at a slow rate, from another tank filled with same product, into the tank to be
commissioned. The rate has to be slow till the suction pipe is completely dipped under
86
liquid. This precaution is needed mainly in case of lighter oils/hydrocarbons, to minimize
static charge generation inside the tank.
 In case of fixed roof tank normal rate of receipt can be resumed after the above mentioned
level is reached.
 In case of floating roof tank, the intake of product has to be maintained low till the roof flats
fully. Thereafter normal rate of receipt can be restored to.
87

SECTION – 7
CATALYST LOADING AND UNLOADING

88
SECTION-7
7.0 CATALYST LOADING / UNLOADING :
7.1 CATALYST LOADING IN REACTORS AND GUARD BEDS:
a) Preliminary check
 Check that the reactor is properly isolated.

 Open the top manhole. Aerate and check that the atmosphere
inside the reactor is suitable for entering.
 Ensure that all the necessary safety and personnel protection
equipment is available (gloves, dust masks, respirators, safety
harness, etc..) as well as means of communication (walkie-
talkie).
b) Inside checking of Reactors and Methanol Guard Beds
Prior to catalyst loading, the outlet basket (Johnson screen or

equivalent) in the Reactors and Methanol Guard Beds must be
thoroughly inspected to ensure there are no gaps or cracks through
which catalyst fines could migrate and escape out of the bed. The
outlet basket should be a fully welded design to minimize the
possibility of catalyst leakage. Johnson screen gap should be less
than 0.25 mm.
c. Loading procedure:
Amberlyst-15 (wet) or equivalent catalyst is used in the reactors and
methanol guard beds which is supplied in sacks containing about 25
litres (19 kg) each. To load the reactor/methanol guard beds, the
sacks are lifted over the charging manway and the unloading sock
untied, allowing the resin to drop freely into the reactor/guard beds. It
is recommended that the first few sacks be loaded with a chute to
prevent catalyst breakage. Johnson screen at the bottom of the
Reactors / Guard beds should be covered first with a layer of catalyst.
When specified amount of resin has been loaded, the top bed should
89
be raked level to avoid unequal flow patterns. The resin is supplied in
the “wet” form, in which condition it contains about 50% water by
weight. As it dries out during operation, it will shrink by about 20-
30%. Re-hydration will expand the resin to its original volume.
7.2 CATALYST UNLOADING FROM REACTORS/METHANOL GUARD BEDS

Under normal circumstances, the only reason for opening the Reactors is to
replace the catalyst. This can be done by steaming the catalyst bed to the
flare using low pressure steam (25 psig or less). During steaming, avoid
temperatures above 120°C in order to avoid occurrence of corrosive
conditions. Long term catalyst exposure to temperatures above 120°C will
deactivate the catalyst.
When the entire bed has been heated by the steam for atleast 8 hours and
followed by air purge to clear the vessel, the reactor can be safely opened
and the catalyst dumped. (Note : Steam contains amines and other
additives which are catalyst poisons and therefore should not be used for
degassing a reactor if the catalyst is to be used again).
If catalysts are to be reused after unloading and screening, it should be
purged with sufficient amount of Nitrogen till MTBE smell disappears
from catalyst bed. Then start unloading of the catalyst from the
reactors.
Catalyst removal from each reactor is accomplished by dumping the

resin directly into a bin or hopper through the nozzles provided, or by
vacuuming the resin out through the top manway using a vacuum
truck or hose.
A catalyst loading diagram and log sheet are attached for additional
information.
90
REACTOR No. 1 AND No. 2
Catalyst Loading Diagram
Catalyst Bed
4700 mm
1500
mm
91
Reactor No. 1 No. 2 Catalyst Loading Record
BAG LOT NET NUMBER TOTAL LOADING OPERAT

TYPE NO NUMBER WEIGHT OF BAGS NET DATE OR
PER BAG WEIGHT
Distance from top flange to catalyst surface ...........................mm.

Average bulk (loaded) density....................... kg/m3
92
METHANOL GUARD BED
Catalyst Loading Diagram
Catalyst Bed
1700 mm
500 mm
93
METHANOL GUARD BED CATALYST LOADING RECORD
BAG LOT NET NUMBER TOTAL LOADING OPERAT

TYPE NO NUMBER WEIGHT OF BAGS NET DATE OR
PER BAG WEIGHT
Distance from top flange to catalyst surface ...........................mm.

Average bulk (loaded) density ....................... kg/m3
94
7.3 CATALYST LOADING OF CD REATION COLUMN
The proprietary CDMTBE catalyst loaded in the Reaction Column is supplied

in the form of “bales” which consist of spirally wound fibreglass cloth bags
containing pockets of resin alternating with a stainless steel wire mesh which
holds the cloth bags shape and provides open area for vapour and liquid
flow. The resin contained in the bales has been partially dried to a moisture
content of approximately 25% by weight. The large bales are 300 mm in
diameter by 510 mm high, and are stacked in a geometrical pattern inside
the tower cross section in twelve (12) beds, each four (4) layers deep.
Smaller diameter bales (100 mm diameter by 510 mm high) are provided to
fill in the sides of the geometrical pattern to match the curvature of the tower
wall and cover the entire tower cross sectional area. After stacking is
complete for the bottom layer, subsequent layers are stacked slightly offset
to cover interstitial areas in the layer below. A typical loading pattern and log
sheet is attached.
The stacking is done by hand, with one person inside the tower and one
outside. Bales are lifted from the ground to the platforms at each catalyst
manway, unloaded onto the platform, and then passed into the person
working inside. Multiple teams can work on different levels at the same time,
for faster loading. A team on the ground unpacks the bales and loads them
into a man lift basket or other container which is then lifted by crane or winch
to the loading man ways.
For this entire operation, six to eight people would be required for about one
to two days to complete the loading. Typically, a single bed can be loaded in
about 3 hours. The bed redistributors can be fully installed prior to catalyst
loading if so desired, as the top two (2) catalyst layers of each bed may be
installed concurrently.
95
7.4 CATALYST UNLOADING FROM CD REACTION COLUMN
If the catalyst in the Reaction column is to be removed and discarded, low-

pressure steam may be used to clear the vessel of hydrocarbons, followed
by air. In this case, rupturing of some of the catalyst bales may be expected
with some loss of resin particles in the column. These may be removed by
washing and/or neutralization.
Unloading of the proprietary catalyst bales from the CD Reaction Column is

accomplished in much the same manner as loading, however, in reverse.
Once the column has been drained and purged of hydrocarbons, a person
may enter the tower and begin handing out bales one-by-one to a co-worker
located on the platform. The spent bales are lowered to grade using a
basket lifted by crane or winch. The integrity of the spent bales is similar to
the fresh bales, therefore, the unloading operation will take no longer than
the loading operation to complete.
96
CD Reaction Column CDMTBE Catalyst Loading Record
During MTBE S/D in JUNE 2003
Date M/H Bed Layer No. of No.of No.of Total
No. No. large small loose Bales.
Bales Dia Bales Bales.
300 mm. Dia 100
Height mm.
510 mm. Height
510 mm.
07/06/03 13 01 Top 15 19 34
Mid Top 14 19 33
Mid Bot 16 12 28
Bottom. 16 19 35
Sub. 61 69 130
Total
08/06/03 12 02 Top 15 21 36
Mid Top 14 18 32
Mid Bot 14 18 32
Bottom. 16 09 25
Sub. Total 59 66 125
08/06/03 11 03 Top 15 29 45
Mid Top 15 16 31
Mid Bot 15 17 32
Bottom. 15 15 30
Sub. 60 77 138
Total
09/06/03 10 04 Top 16 19 35
Mid Top 15 15 30
Mid Bot 16 12 28
Bottom. 16 12 28
Sub. Total. 63 58 121
09/06/03 09 05 Top 15 22 37
Mid Top 16 15 31
Mid Bot 15 21 36
Bottom. 16 16 32
Sub. Total. 62 74 136
10/06/03 08 06 Top 15 28 33
Mid Top 16 18 34
Mid Bot 17 13 30
Bottom. 17 13 30
Sub. Total. 65 72 137
10/06/03 07 07 Top 17 26 43
Mid Top 16 16 32
Mid Bot 17 14 31
Bottom. 16 15 31
97
Sub. Total. 66 71 137
M/H Bed Layer No. of No.of No.of Total
Date No. No. large small loose Bales.
Bales Dia Bales Bales.
300 mm. Dia 100
Height mm.
510 mm. Height
510 mm.
10/06/03 06 08 Top 16 23 39
Mid Top 16 15 31
Mid Bot 16 14 30
Bottom. 16 17 33
Sub. Total. 64 69 133
11/06/03 05 09 Top 16 23 39
Mid Top 14 22 36
Mid Bot 15 16 31
Bottom. 16 18 34
11/06/03 04 10 Top 15 18 33
Mid Top 15 17 32
Mid Bot 15 19 34
Bottom. 15 17 32
Sub. Total. 60 71 131
12/06/03 03 11 Top 15 28 43
Mid Top 16 14 30
Mid Bot 16 18 34
Bottom. 15 18 33
12/06/03 02 12 Top 15 25 40
Mid Top 16 18 34
Mid Bot 17 13 30
Bottom. 16 17 33
98

SECTION – 8
START UP PROCEDURE

99
SECTION-8
8.0 START-UP ACTIVITIES
8.1 INITIAL START-UP
This procedure covers the situation when the MTBE unit is ready to start up
with fresh catalyst in the Primary Reactors and CD Reaction Column, such
as during the initial start-up of the unit or after a major unit turnaround during
which the column and reactor catalyst are replaced.
General
Prior to start-up, the CDMTBE catalyst in the Reactors No.1 and No.2, CD
Reaction Column and Methanol Guard Beds require conditioning. This
conditioning consists of dewatering the catalyst.
Bulk catalyst as loaded into the Reactors and Methanol Guard Beds is
typically supplied in a ‘wet’ form, in which it contains about 50% water by
weight. The removal of the bulk of this water is accomplished by passing
Methanol through the catalyst beds. The resulting Methanol-water mixture is
sent to the Methanol Drains Drum and is then pumped to the Methanol
Column where the Methanol can be recovered. Initially the miscible
Methanol-water stream contains as much as 50% water by weight
decreasing as Methanol is circulated or batched through the catalyst beds.
When samples of the effluent stream from the Reactors and Methanol Guard
Beds show no further change in water content (water concentration less than
1 wt%), the Methanol ‘dry-out’ of the reactor catalyst can be stopped as the
bulk of the water has been removed. At least two bed volumes of Methanol
will be required to obtain this desired dewatering of the catalyst.
The catalyst in the Reaction Column has already been partially dried to
about 25 wt% water during catalyst bale manufacturing and as a result there
is much less water in this catalyst than in the Reactors. The water present in
the catalyst will react with Isobutene in the CD Column feed and form TBA
100
producing off-spec MTBE. Once all the water in the catalyst is reacted away,
MTBE product will meet the specifications.
Following is a step-by-step procedure for start-up of the CDMTBE unit with

fresh catalyst in the Primary Reactors and CD Reaction Column.
Initial Start-Up Procedure
The following procedure describes the sequence of activities during an initial

start-up of the CDMTBE unit and assumes that all pre-commissioning and
commissioning activities such as pressure testing and inert gas purging, etc.,
are completed. The Methanol Recovery Section will be put in service first,
followed by the catalyst conditioning activities in the Primary Reactors. The
MTBE Unit is then ready to receive C3/C4 hydrocarbon feed.
Inform FCC,RSM and TPS regarding start up of the unit. Ask FCC
regarding preparedness of feed for MTBE. Check availability of Methanol at
LPG station..
Feed will be received as follow.
1) Line up B/L b/v to receive feed from FCC

B/L/ b/v.LC-101.V-1.P-1 A/B suc. .Dis. .FV-201.E-4.C-1.

FV-204 OSBL
C-1.O/H . .  E-2. PV-301.  V-2.

 
. 
PV-302 . . . . . 
V-2. XV-301  P-2A/B.FC-302. C-01 as reflex.


E-3 FV-303  R/D.
101
C-1 BottomE-4   E-5  FC-202  XV -401 C-2 .


----- ---------- -------- -----
 -
OSBL V-1( FOR CIRCULATION)
A1. Begin demineralized (DM) water flow to the Wash Water Break Drum
(1100-V-3) from OSBL, placing LIC-102 in automatic mode.
A2. Begin (DM) water flow to the Methanol Column (1100-C-5) bottoms
by opening HIC-1201. When a sufficient water level is available in the
column sump (LI-1201), start Methanol Column Bottoms Pump (1100-
P-6 A/B) and establish water flow to the Methanol Extraction Column
(1100-C-4). Add water (HIC-1201) as necessary to keep the Methanol
column bottoms level at low liquid level.
A3. Increase the pressure of the Methanol Extraction Column to about 3.5
kg/cm²g with nitrogen to facilitate water circulation between the
Methanol Extraction Column and the Methanol Recovery Column.
A4. When water level appears in the Methanol Extraction Column (LIC-
1101), open FIC-1102 to begin water circulation between the
columns. Add make-up water as necessary to keep both columns at
low liquid level.
A5. Begin wash water flow to the Water Wash Column (1100-C-2) by
starting DM Water Booster Pumps (1100-P-3 A/B) and opening FIC-
401. When low liquid level appears (LIC-401), establish waste water
flow to Water Degasse Drum (1100-V-4) by opening LV-401. Once
102
liquid builds up in the Water Degasser Drum, open LV-402 to allow
waste water flow to OWS. Put LIC-402 on automatic control and open
PV-406 if pressure builds up. To conserve DM water during this
period, the wash water flow (FIC-401) can be reduced to the
minimum required to sustain flow through the equipment.
A6. Begin Methanol flow from storage tank to the Methanol Surge Drum
(1100-V-5) by Methanol Transfer Pump (1100-P-13 A/B). Put LIC-501
in automatic mode.
A7. Close the Reactor No.1 (1100-R-1) inlet valves, TV-803A and TV-
803B. Start Methanol Feed Pump (1100-P-4A/B) and fill the Methanol
Filters (1100-G-2 A/B) and the Methanol Guard Beds (1100-R-3 A/B).
Begin sending Methanol to Reactor No.1. Fill the reactor with
Methanol, venting inerts through the vent located atop the reactor to
ensure reactor is liquid full. A temporary connection from the vent line
to an environmentally approved container may be used. Stop
Methanol feed when reactor is liquid full.
A8. Line up the reactor effluent to the Methanol Drains Drum by opening
the appropriate reactor outlet valves.
A9. Drain contents of the reactor to the Methanol Drains Drum (1100-V-9)
by opening the nitrogen purge. When finished, repeat step A15 and
refill Reactor No.1 (1100-R-1) with Methanol. Note that the Methanol
Guard Beds will be dewatered as well.
A10. The Methanol Column is started at this time follow normal distillation
column startup procedures as follow. :
Start the Methanol Column in operation by slowly starting MP steam

to the Methanol Column Reboiler (1100-E-15) maintaining a low liquid
level in the column sump. Once the column bottoms temperature
reaches about 95 °C, bring in contents from the Methanol Drains
103
Drum (1100-V-9) using Methanol Drains Drum Pump (1100-P-10).
Column overhead pressure control is a conventional design which
uses condenser outlet throttling and a hot vapor bypass. PIC-1301
and PDIC-1302 can be placed in automatic or manual control. When
pressure in the Methanol Column builds up to the normal operating
pressure of 1.3 kg/cm²g, activate Methanol Column Condenser
(1100-E-16). As the column heats up, condensed liquid is collected in
the overhead drum. Once sufficient liquid level is reached in the
Methanol Column Overhead Drum (1100-V-7), start the Methanol
Column Reflux Pump (1100-P-7 A/B) to begin feeding reflux liquid
(FIC-1301) to adjust the column temperature profile. Until the
Methanol quality reaches specification as confirmed by laboratory
analysis, keep the column on total reflux. Withdraw water periodically
from the column bottoms and purge to OWS. Add make-up water to
maintain liquid level in the column bottoms.
(Note : It will be necessary to vent inerts from the reflux drum

and condenser periodically during initial startup to maintain
pressure control).
A11. Regularly, open the water bleed to waste water treatment off the
recycle water system as the water recovered from the catalyst
dewatering operation should be removed from the system due to its
initial high acidity. The acidic water results from leaching residual acid
out of the fresh catalyst.
A12. Once the Methanol recovery system is lined out and in operation,
open the reactor outlet valves to the Methanol Drains Drum. Once a
sufficient level of Methanol-water is available in the Methanol Drains
Drum (1100-V-9) Start the Methanol Drum Drains Pump (1100-P-10)
and begin pumping the contents to the Methanol Recovery Column
(1100-C-5) for recovery of the Methanol.
104
A13. Re-establish Methanol feed from the surge drum at a reduced rate
through Reactor No.1 to the drains drum thereby setting up a
continuous flow of Methanol through the reactor to the drains drum
and to Methanol Recovery Column.
(Note : Methanol conditioning (drying) of the reactor catalyst

can be accomplished batchwise or by continuous circulation.
The circulation of Methanol through the reactor should be done
at a controlled rate,
i.e., at a rate consistent with the handling/processing capability

of the Methanol recovery system).
A14. Continue this circulation until it is established through sampling and

analysis that the water concentration in the Methanol exiting the
Reactor No.1 is less than about 1 wt%, at which point, Methanol
circulation through Reactor No.1 can be stopped. It may take about
18-24 hours to achieve the desired dewatering of the Reactor No.1
catalyst and saturation of the catalyst with Methanol. Once this drying
step is completed, divert Methanol to Reactor No.2. ( Previously
there was no isolation block valve on out let of Reactor R-1 it’s
outlet was diverted via pipe separator to remove water content
from hold up material of pipe separator.) Close the drain valve to
the Methanol Drain Drum and close the outlet valve of Reactor No.2.
Open the nitrogen to the connection on the Reactor No.1 (1100-R-1)
inlet header and blow the reactor contents to Reactor No.2 through
1100-E-7. Vent inserts through the vent located atop the Reactor
No.2 to ensure reactor is liquid full. A temporary connection from the
vent line to an environmentally approved container may be used
A15. Ensure that Reactor No.2 (1100-R-2) inlet and outlet block valves are
closed and begin a small flow of Methanol from the Methanol Guard
Beds (1100-R-3 A&B) to the reactor through the Methanol
commissioning line. Fill the reactor with Methanol venting inerts
105
through the vent located atop the reactor and ensure that the reactor
is liquid full.
A16. When Reactor No.2 is liquid full, close the vent valve atop of the
reactor and start sending the contents of the reactor to the Methanol
Drains Drum (1100-V-9) by opening appropriate reactor outlet valves.
Keep pumping Methanol-water mixture from the Methanol Drains
Drum to the Methanol Column.
A17. Continue Methanol feed from the surge drum at a reduced rate
through Reactor No.2 to the drains drum thereby setting up a
continuous flow of Methanol through the reactor to the drains drum
and to Methanol Recovery Column. Continue this circulation until it is
established through sampling and analysis that the water
concentration in the Methanol exiting Reactor No.2 is less than about
1 wt%, at which point, Methanol circulation through Reactor No.2 can
be stopped. Empty Methanol from Reactor No.2 to Methanol Drains
Drums (1100-V-9). At this point the catalyst conditioning in both
reactors is complete, and the MTBE unit is ready to receive
hydrocarbon feed.
A18. Begin C3/C4 feed flow from OSBL to the C3/C4 Feed Surge Drum
(1100-V-1) placing LIC-101 in automatic mode.
Line up B/L b/v to receive feed from FCC

B/L/ b/v.LC-101.V-1.P-1 A/B suc. .Dis. .FV-201.E-4.C-1.

FV-204 OSBL
C-1.O/H . .  E-2. PV-301.  V-2.
 
. 
PV-302 . . . . . 
106
V-2. XV-301  P-2A/B.FC-302. C-01 as reflex.

E-3 FV-303  R/D.
C-1 BottomE-4   E-5  FC-202  XV -401 C-2 .

-------------------
 
V-1 OSBL
A19. Start C3/C4 Feed Pump (1100-P-1 A/B) at 50% of the design flow rate
to fill C3/C4 Splitter (1100-C-2) bottoms through FIC-201.
A20. Once a level is established in the column bottoms, slowly start MP

steam to the C3/C4 Splitter Reboiler (1100-E-1), manually operating
FIC-203 to maintain low liquid level in the column sump. Pressurize
the column to its normal operating pressure of 17.3 kg/cm²g.
A21. Activate C3/C4 overhead condenser (1100-E-2) and close the

overhead hot vapor bypass valve (PV-302). Column overhead
pressure control is a conventional design. PIC-301 and PDIC-302 can
be placed in automatic or manual mode.
A22. Once a sufficient level is established in the C3/C4 Overhead Drum

(1100-V-2) to sustain a steady reflux flow to the column, start the
C3/C4 Splitter Reflux Pump (1100-P-2 A/B) and establish reflux
through FIC-302 on manual control.
A23. Set PIC-301 and PDIC-302 on automatic mode to control the column
pressure at 17.3 kg/cm²g and overhead drum pressure at 16.8
kg/cm²g.
A24. Start sending C3 product to OSBL by setting LIC-301 on automatic

control to reset FIC-303.
107
A25. Draw C4 hydrocarbons from the bottom of C3/C4 Splitter by opening
FV-202 and send it to battery limits through the C3/C4 bypass. Until
1100-C-1 operation is lined out and on specification product is
produced, the C4 product will not be sent to MTBE unit. Put LIC-201
in automatic control resetting FIC-202.
A26. Stabilize and line out 1100-C-1 operation. When on-specification

products are produced, get ready to feed the C4 to the Water Wash
Column (1100-C-2). Increase the DM water flow to 1100-C-2
accordingly.
A27. Line-up the unit to receive C4 hydrocarbons from the C3/C4 Splitter
Bottoms and Methanol from Methanol Surge Drum via Methanol Filter
and Methanol Guard Beds.
A28. Open XV-401 to slowly introduce C4 hydrocarbons to Reactor No.1

via Water Wash Column (1100-C-2).
MEOH FROM TK 1103/1104 
P-13A/B  LV-501  V-5 P-4 A/B  FC-701R-3A/B



E-6R1

C-1 BOT. XV-401C-2V-18G-1A/BFV-702 
E-7TV-803A
 
 
E-6R1 
 
 TV-803B  R-2E-8C-3
108
A29. Start Methanol flow into Reactor No.1 by opening FV-701 and C4
hydrocarbons by opening FV 702.
A30. Put the ratio controller (FFIC-702) on manual control. Continue filling
Reactor No.1 with Methanol and C4s until liquid full. Commission
cooling water to Reactor No.2 Feed Cooler (1100-E-7), close TV-
803B and gradually fill Reactor No.2 through Reactor No.2 Feed
Cooler.Continue forward flow into the CD Reaction Column1100-C-3.
A31. When a low liquid level is established in the sump of the CD Reaction
Column, slowly start MP steam flow to the CD Reaction Column
Reboiler (1100-E-9) by putting FIC-904 on manual control and
adjusting the steam flow to maintain the bottoms level (LIC-901) at
about 50%. Activate CD Reaction Column Condenser 1100-E-10 and
begin reflux to the column when there is a sufficient level in the
Reaction Column Reflux Drum (1100-V-6). Column overhead control
is a conventional design with throttling at the condenser outlet and a
hot vapour bypass around the condenser. Control the top pressure of
the column at about 5.8 kg/cm²g (PIC-1001). The pressure of the
overhead drum should be controlled at 5.5 kg/cm²g (PDIC-1004 on
automatic mode). For controlling the reflux, use FIC-1001 on manual
control.
C-3 BOT. E-8E-11FV-801XV-801MTBE TO OSBL
Note : The water contained in the column catalyst will be

carried overhead by C4's-Methanol vapor. The column bottoms
will contain MTBE, TBA and small amount of other byproducts
and will not meet the normal MTBE product specification.
Operation should determine if they can be directly blended into
the gasoline pool. If it is determined that excessive
water/Methanol remains in the bottom, a small stream may be
109
withdrawn to the Methanol Drains or Slops Drains. Samples of
the effluent stream leaving the Reactor No.2 should be checked
periodically for Methanol content to ensure a 3 to 4 percent by
weight Methanol concentration.
IMPORTANT : WATER/METHANOL MUST BE DRAINED

REGUALARLY FROM THE BOOT IN THE REACTION COLUMN
OVERHEAD DRUM (1100-V-6) TO THE METHANOL DRAINS. DO
NOT ALLOW WATER TO BE REFLUXED TO THE COLUMN.
A32. Adjust the Methanol feed rate to give a concentration of about 3-4
wt% Methanol in the CD Reaction Column Overheads.
C-3 O/H  PDC1004V-6FI-1002FLARE.

 
 
 
 E-10PV-1001 
FV-1001C-3 REF.


V-6  XV-1001  P-5A/B  E-12 FV-1003C-4.
A33. Commission cooling water to the Extraction Column Feed Cooler

(1100-E-12). As the Reaction Column stabilizes, gradually start flow
of C4s distillate to the Methanol Extraction Column (1100-C-4) by
opening FIC-1003. Pressure up the raffinate system while venting
inert from the system. Activate LIC-1101 resetting FIC-1102
establishing automatic control of the Methanol/water stream to the
Methanol Column.
110
C-4 O/H PV-1004 E-18 C-6PDC-1602 V-8 F.G.


C-6 REF.  FV-1601 P-8A/B  XV-1601
C-6 BOT. E-18P-9A/BE-19FV-1401OSBL.
A34. Begin a small flow of C4 raffinate from the Extraction Column

overhead to the Lights Column (1100-C-6) by opening PV-1104 and
establish a level in the Lights Column bottom sump.
A35. Recycle the balance of the C4 raffinate to the Reactor No.1 inlet on
manual control (FI-1104). Adjust the Methanol feed rate to ensure 3-4
wt% Methanol in the CD Column feed.
A36. Commission LP steam to the Lights Column’s re-boiler (1100-E-20)

and control the level in column bottoms by manually adjusting steam
flow to Reboiler (FC-1501). Pressure up the column to the normal
operating pressure of 11.2 kg/cm²g.
A37. Once a working level is established in the Lights Column Overhead

Drum (1100-V-8), start Lights Column Reflux Pump (1100-P-8 A/B)
and begin reflux to tower.
A38. Gradually establish the column bottoms draw back to Reactor No.1
inlet through Lights Column Feed/Bottoms Exchanger (1100-E-18)
and C4 Product Cooler (1100-E-19). Close the C4 raffinate flow from
the Extraction Column Overhead to Reactor No.1 and put PIC-1602
in automatic mode. Set PIC-1601 and PDIC-1602 in automatic mode
to control the column and overhead drum pressures.
A39. Stop C4 hydrocarbon flow from C3/C4 Splitter by closing XV-401,

when there is sufficient inventory to maintain hydrocarbon circulation
111
through the MTBE section. Send the C4 hydrocarbons to OSBL for
storage. The MTBE section is now on total recirculation.
A40. Continue the hydrocarbon circulation through the unit; adding

Methanol as required and draining water from the Reaction Column
Reflux Drum boot as necessary. If excessive water appears in the
bottom section of the reaction column as indicated by a high
temperature in the column bottoms, it may be purged to the Methanol
Drains Or Slops Drum.
Note : The CDMTBE section and lights column is now operating

on total circulation with hydrocarbons and Methanol. This
condition can continue as long as necessary. Drain water
frequently from all water connection points. When no more water
appears in the Reaction Column Reflux Drum, the drying of the
column and reactor catalyst is complete. Commission the online
analyzer controllers AIC-901, AIC-902, AIC-903, AIC-904.
A41. Line out and stabilize the MTBE section on the recirculated C4 feed,
checking the unit for any mechanical or instrumentation problems,
etc. Stabilize the various column operations and place as many
controllers in automatic mode as possible.
A42. Once unit operations are stabilized on the recirculated C4

hydrocarbons, and the C4 product specification in 1100-C-6 is
achieved, slowly start the C4 hydrocarbon flow from C3/C4 Splitter. At
the same time stop the recirculation of the C4 product from the Lights
Column bottom rerouting it to battery limits. Put the Methanol ratio
controller (FFIC-702) and the on-line analyzer controller AIC-903 in
automatic mode.
112
A43. Minor adjustment of the Methanol feed to the Primary Reactors may
be necessary to get a concentration of about 3 to 4 wt% Methanol in
the Reaction Column overhead. As discussed in section 6, the
amount of Methanol charged to the system is dictated by the reaction
needs and by the zoetrope limit in the CD Reaction Column. The
temperature indicators in Reactor No.1 (TI-705 through TI-708) will
indicate how the reaction is taking place in Reactor No.1. Set the
Reactor No.1 inlet temperature at 40 °C (TIC-704) and set the
Reactor No.2 inlet temperature at 50 °C (TIC-803).
A44. Monitor the temperature profile in the Reaction Column and set the
reflux ratio to 1.25 (for design case I). As MTBE is formed, the
bottoms temperature will increase as MTBE replaces the C4s. When
the bottoms temperature reaches about 132-134 °C the MTBE
product may be withdrawn. Withdraw MTBE on manual control
initially. When temperatures in the bottom of the column reaches the
normal operating conditions, put the tower bottoms level on automatic
with LIC-901/FIC-801 in cascade and commission Reaction Column
Overhead on-line analyzer AT-1002.
A45. Sample MTBE product to monitor product purity.
A46. Increase the C3/C4 hydrocarbon feedstock and C4 hydrocarbon flow

from C3/C4 Splitter bottom to design capacity and increase
proportionally the Methanol feed rate. The MTBE unit is now in full
operation.
General Notes
A. During initial start-up operations, it is important to monitor the

Reaction Column Reflux Drum boot for signs of water. Any water
113
found in v-6 boot should be drained from the system and not to be
allowed to reflux to the tower.
B. Within a few days after initial start-up, it may be necessary to

neutralize a small amount of catalyst fines, which will collect in the
bottom of the column and will promote decomposition of the MTBE.
Neutralization is done by injecting a small amount, usually about one
drum, of a heavy………. amine such as DEA into the tower through
the nozzle provided. The presence of amine in the MTBE product is
not a quality problem. This neutralization procedure can be used
whenever the presence of catalyst in the tower bottoms is suspected
or known. Indication of the presence of catalyst is the identification of
Isobutene and Methanol in the MTBE product through GC analysis.
8.2 SUBSEQUENT START-UPS
The procedure for subsequent start-ups of the CDMTBE section is simplified

from that initial start-ups in the Methanol and C4 circulation steps may be
omitted. The CDMTBE catalyst has been conditioned from previous
operations and therefore, water removal steps are not required. The
procedure for restarting the CDMTBE section after a shutdown in which
catalyst has not been replaced is outlined below. The Methanol Column
should already be in operation and the Methanol Extraction and Water Wash
Columns filled with water. The C3/C4 column should be in operation
producing C3 product and sending C4 hydrocarbons to OSBL. It is also
assumed that both reactors are empty and under N2 pressure.
B1. Start Methanol flow into both Reactors (1100-R-1 and 1100-R-2) by
opening FIC-701, venting as required. Once the reactors are full of
Methanol, pressure out the Methanol into the Methanol Drains Drum
(1100-V-9) which is pumping the contents to the Methanol Recovery.
114
B2. Line up and begin C4 hydrocarbons form C3/C4 Splitter (1100-C-1) to
the Water Wash Column (100-C-2) at a reduced rate. Start the
Reactor No.1 Feed Heater (1100-E-6) if necessary. Once Reactor
No.1 is full of C4s, gradually fill Reactor No.2 via Reactors No.2 Feed
Cooler (1100-E-7). Once both the reactors are full of C4
hydrocarbons, start Methanol flow into the reactors and continue
forward flow of Reactor No.2 effluent into the CD Reaction Column.
B3. Establish a proper liquid level in the CD Reaction Column bottom as

indicated by LIC-901 and activate CD Reactioin Column Re-boiler
1100-E-9 and CD Reaction Column Condenser 1100-E-10.
B4. Manually control MP steam flow to the re-boiler setting the rate to
control the column bottoms level until the temperature profile in the
tower is normal, at which time the bottoms level can be put on normal
control.
B5. As overhead product is produced, establish reflux to the CD Reaction

Column to control the temperature profile. Start secondary Methanol
injection to the column on flow control and adjust the Methanol feed to
the primary reactors to give a concentration of about 3 to 4 wt%
Methanol in the Reaction Column Overhead.
B6. After stabilizing the operation of the CD Reaction Column, begin flow
of overhead distillate to the Methanol Extraction Column. Pressure up
the raffinate system. Recycle C4 raffinate from the Extraction Column
(1100-C-4) overhead or Reactor No.1 (1100-R-1).
B7. Start-up Lights Column (1100-C-6) using steps A31 to A38 in section
9.1 before fully bringing all the C4 raffinate from the Extraction Column
(1100-C-4) to the Lights Column (1100-C-6). Gradually establish C4
product flow from the lights column bottoms to OSBL through Lights
115
Column Feed/Bottoms Exchanger (1100-E-18) and C4 Product Cooler
(1100-E-19).
B8. Follow steps A44 - A46 in section 9.1 to bring the unit up to full
capacity.
8.3 COMMISSIONING METHANOL GUARD BEDS AFTER RE-CHARGE
The procedure for start-up after Methanol Guard Bed catalyst change outs
will generally follow the reactor procedure with some additional preliminary
steps designed to condition the fresh catalyst before placing the guard bed in
service. One of the two Methanol Guard Beds will be shutdown for catalyst
change out while the other remains in operation. The conditioning steps
required for the reactors are as follows:
C1. Fill the Methanol Guard Bed (bed under nitrogen blanket with fresh
catalyst already loaded) with Methanol venting as required until liquid
full. Drain the reactor contents to the Methanol Drains Drum and refill
reactor with Methanol.
C2. Process the Methanol-water stream in the Methanol Drains Drum

through the Methanol Column to recover the Methanol.
C3. Re-establish and then continue flowing a small amount of Methanol

through the bed to the Methanol Drains Drum. Once the water
content in the Methanol exiting the bed is below about 1 wt%, stop the
Methanol flow to the Methanol Drains Drum. The bed is now ready for
Methanol feed.
Note : Methanol conditioning (drying) of the Methanol Guard Bed catalyst

can be accomplished batch wise or by continuous circulation.
116

SECTION – 9
SHUTDOWN PROCEDURE

117
SECTION-9
9.0 SHUTDOWN PROCEDURES
9.1 PLANNED SHUTDOWN
A shutdown of the CDMTBE section can be planned or may be the result of

an emergency or automatic shutdown.
In general, the normal, scheduled shutdown of the CDMTBE section follows

any ordinary unit shutdown, with due caution for safety and product
contamination.
SHORT TERM SHUTDOWN
When the unit is to be shut down for short periods, no longer than a few
hours, the Reactor feed and the Reaction Column Distillate and bottoms
streams may be “stopped” and contents retained in the vessels. The C4
hydrocarbon stream should be stopped first and Methanol feed (FIC-701)
after a minute or two so as to have excess Methanol in the reactors. The
Reaction Column can be put on total reflux.
The Reactors may be shut down for periods less than an hour simply by
stopping the feeds, provided the exit of the reactors remains open to the CD
Reaction Column for pressure relief. The liquid feed within the reactors will
continue to react to equilibrium with a small evolution of heat, but this is not a
problem since the contents of the reactors are already at or near their boiling
point. However, it is recommended that during the first month of
operation on fresh catalyst, if the reactors are shut down for longer
than about one hour, the reactors should be purged empty, using
nitrogen pressure to push the reactor contents into the Reaction
Column or Slops Drum. This is done to prevent the possibility of
dimerization reactions occurring with the fresh catalyst which results in a
higher heat release which in turn increases the reactor temperatures to a
118
level that could damage the catalyst. To avoid this situation fill the reactor
with methanol instead of purging it with nitrogen. MTBE expert advises this
during his last visit in the year 2004.
Stopping the overhead distillate and bottoms streams can shut down the
Reaction Column. The column can then be put on total reflux. On the other
hand, the column may be shut down entirely by stopping the reflux and re-
boiler stream flows and the contents retained in the column for later start-up.
There is no danger of continued reaction within the column, because the
liquid drains from the catalyst beds to the column sump.
Shutdown of the C3/C4 Splitter, Water Wash Column, Methanol Extraction

Column, Methanol Recovery Column and Lights Column is done
conventionally with the towers simply blocked in and the contents retained.
The C3/C4 Splitter, Methanol Column and Lights Column can be put on total
reflux. Methanol Column may continue to operate processing material from
the Methanol Drains Drum.
LONG TERM SHUTDOWN
If the shutdown is for long term, for example, over several days, it is
generally advisable to displace the liquid from the reactors. The contents of
the reactors can be pressured out into the Reaction Column and/or Slops
Drum using nitrogen. For a long-term shutdown, it may also be desirable to
purge the reactive material entirely from the unit by blowing the unit empty
with nitrogen. This additional step would be recommended when a long-term
shutdown occurs and relatively fresh catalyst is in the unit.
The following general operating procedure covers the situation when the
MTBE section is shut down for an extended period and the inventory of
hydrocarbon is removed from the reaction section.
D1. Stop the C4 hydrocarbon feed stream from the C3/C4 Splitter to the
MTBE unit and close XV-401.
119
D2. Stop Methanol feed to the reaction area by closing FIC-701 and FIC-
801. Close fresh Methanol inlet block valve. Continue secondary
Methanol feed to the CD Column to ensure sufficient Methanol in the
catalyst beds to prevent any runaway reaction.
D3. Empty feed lines by venting to the flare system.
D4. Open the nitrogen connection and pressure out the contents of the
reactors at a controlled rate into the Reaction Column and./or Slops
Drum.
D5. Continue operation of the Reaction Column including removal of

overhead distillate and bottoms streams until the low liquid level is
reached in the Reaction Column Overhead Drum and the bottom
sump.
D6. Shutdown Reaction Column by stopping steam flow to re-boiler 1100-

E-9. Continue reflux to the column until reflux pump, 1100-P-5 A/B
loses suction.
D7. Stop reflux pumps and reset FIC-1001 and FIC-1003 to zero.
D8. Continue to empty tower by drawing bottoms from the column to

Slops Drum.
D9. Drain Reaction Column Overhead Drum to Slops Drum through
drains on reflux pump suction lines.
D10. Follow similar procedures as above for the shutdown and draining of
overhead and bottoms streams from the C3 / C4 Splitter, Methanol
Column and Lights Column. The contents in the Water Wash Column
and Methanol Extraction Column can be retained under automatic
pressure control.
D11. Keep unit under positive nitrogen pressure.
120
SHUTDOWN FOR ENTRY
Special procedures need to be followed if it is necessary to enter the

Reactors or Reaction Column for maintenance work because the catalyst
holds Methanol and MTBE within its pores which cannot be easily removed
by normal degassing procedures.
Steam Out
Steam out of vessels is recommended when vessel entry is desired. Mostly

vessels in hydrocarbon service are designed for steam out. During steam out
of vessels, the vessel should be isolated by closing all the incoming and out
going valves and then steamed out but make sure that high point vents are
open.
LP Steam is then injected into the system two or three times so as to remove
any hydrocarbon traces.
During steam out of re-boilers care should be taken to isolate the system
from the column, if the column and re-boiler are to be done separately.
But in any case care should be taken to see that the differential
temperature between shell side and tube side does not exceed 60°F.
Under normal circumstances, the only reason for opening the Reactors is to
replace the catalyst. This can be done by steaming the catalyst bed to the
flare using low pressure steam (25 psig or less). During steaming, avoid
temperatures above 120°C in order to avoid occurrence of corrosive
conditions. Long term catalyst exposure to temperatures above 120°C will
deactivate the catalyst.
When the entire bed has been heated by the steam for at least 8 hours and
followed by air purge to clear the vessel, the reactor can be safely opened
121
and the catalyst dumped. (Note: Steam contains amines and other
additives, which are catalyst poisons and therefore should not be used for
degassing a reactor if the catalyst is to be used again. In this case, follow
the procedure below for clearing the catalyst from the Reaction Column for
entry).
If the catalyst in the Reaction column is to be removed and discarded, low-

pressure steam may be used to clear the vessel of hydrocarbons, followed
by air. In this case, rupturing of some of the catalyst bales may be expected
with some loss of resin particles in the column. These may be removed by
washing and/or neutralization. However, if the catalyst bales are not to be
removed, it is necessary to displace the Methanol and MTBE by operating
the column at normal pressure with reflux on a non-reactive C4 hydrocarbon
stream (butane) for about 8 hours. This will take the Methanol overhead
where it is sent to Methanol recovery. The MTBE and heavier material
(byproducts) will go to the bottom of the column. The MTBE, with a
minimum of C4’s, can continue to be sent to storage. The column is then
vented to the flare and drained of residual liquid to remove all the
hydrocarbons, then purged with nitrogen and finally air. A residual odor
similar to “fresh hay” (grass) will be present in the column upon opening.
Appropriate tests of the atmosphere within the column must be carried out
before permitting entry:
a) Flammability
b) Oxygen content
c) Organic vapor content
If the butane-washing step is not adequately carried out, it may be necessary

to wear fresh air masks for entry.
9.2 EMERGENCY SHUTDOWN
Any time an emergency shutdown of the unit is anticipated, other units

affected by the shutdown should be notified as soon as possible in order to
122
take proper action. The object of an emergency shutdown procedure is to
first make the unit safe for personnel and equipment and second to have the
unit in condition for prompt start-up when the emergency condition has
passed.
This section of the manual presents various plant emergency situations and
outlines the steps necessary to bring the plant to a safe condition. These
procedures are of a general nature and do not cover every contingency. A
through understanding of the unit by the operator is imperative. In all cases,
it is necessary to shutdown feed pumps, block in the column overhead and
bottom product draws and stop steam to the re-boilers.
NITROGEN FAILURE (PAL-2301)

Nitrogen is used as a purge medium during start-up or shutdown operations.
Loss of nitrogen therefore would not require a shutdown of the unit.
COOLING WATER FAILURE (PAL-2201 )
Loss of cooling water would adversely affect the operation of the C3 / C4

Splitter, Reaction System, Methanol Recovery system and Lights Column.
Therefore, shutdown of the unit is required.
STEAM FAILURE (PAL-2405 & PAL 2501)
Medium Pressure (MP) steam is used to re-boil the Reaction Column and
Methanol Column. Low Pressure (LP) steam is used to re-boil the C3/C4
Splitter and Lights Column. Therefore, loss of MP or LP steam would
require a shutdown of the unit as heat input to one or more of the columns
would be lost.
INSTRUMENT AIR FAILURE (PAL-2302)
Loss of instrument air will require a shutdown of the MTBE Unit. All control
valves will move to their fail-safe positions to leave the unit in a relatively
123
safe condition. In general, all feed and steam flow control valves should
close on loss of air pressure. However, this state is potentially a dangerous
situation, since as air pressure is restored, reset may cause many of the
control valves to fly wide open. To avoid this event upon loss of instrument
air pressure, move the controller set points to zero on all feed streams to the
unit. Proceed with the normal shutdown of the unit.
ELECTRICAL FAILURE
Loss of electrical power will necessitate a shutdown of the MTBE Unit. All
pumps will cease functioning, stopping feed to the unit. Move all controllers
to the zero flow condition and begin the normal shutdown procedure for the
entire unit.
FIRE EMERGENCY
In case of a fire emergency, it should be determined what effect the

emergency will have on the MTBE Unit. If it is required to shutdown the unit,
the normal shutdown procedure should be followed as closely as possible.
9.3 AUTOMATIC SHUTDOWN AND INTERLOCK SYSTEM
The CDMTBE Section has the following interlock systems that automatically
take certain shutdown actions upon conditions as explained below:
I) Interlock I-3601 - Loss of Methanol
A. Condition:
1. Low flows ratio of Methanol to Isobutene in feed (FFSLL-702).
B. Action:
1. Stop steam flow to 1100-E-6 (FV-704).
124
2. Auto start inactive Methanol Feed Pump (1100-P-4 A/B).
3. If (Methanol: Isobutene) molar ratio is not re-established after
30 seconds, close XV-401 to shutdown C4 feed.
II) Interlock I-3602 - High Temperature Around Reactor No.1.
A. Condition:
1. High high temperature at inlet to Reactor No. 1 (1100-R-1)

(TY-702).
2. High high temperature out of Reactor No. 1 (1100-R-1) (TY-
711).
B. Action:
1. Stop steam flow to Reactor No.1 Feed Heater (1100-E-6) by

closing FV-704.
III) Interlock I-3603 - High Temperature Around Reactor No.2.
A. Conditions:
1. High high temperature at outlet of 1100-R-2 (TY-802).

2. High high temperature into 1100-R-2 (TY-808).
B. Action:
1. Open TV-803A and close TV-803B.
125
9.4 DCS FAILURE
9.4.1 PARTIAL FAILURE OF 110V AC SUPPLY
- 440 AC Supply is coming from TPS to UPS in Udex and it is converted to 110v AC in
UPS.
- Partial failure of 110V AC supply will affect respective cabinet. Alarm indication of that
particular cabinet will be available on screen.
- Failure of 110V AC supply to AMC, then no C/ V will be operated, but PV indication will
be available on the screen for some time depending upon supply and discharge
capacity of the battery. C/ V opening will be fixed like just before failure.
- Failure of 110 V AC supply to IPC, then no PV indication will be available on the
screen.
- Failure of 110V AC supply to LCN (HM, AM, HG) then screen will be totally blank.
- Necessary action to be taken according to failure to control system.
9.4.2 TOTAL FAILURE OF 110V AC SUPPLY
- In case of total failure of 110V AC supply. Supply will be available from battery back up
system for some time.
- If failure is for longer time then unit to be shut down as per normal procedure.
9.4.3 110V DC SUPPLY FAILURE

- 110V DC Supply is coming from AU-3 sub station.
- Failure of 110V DC supply will affect CPC.
- All S/D valves will be closed.
- S/D valves to be got opened manually with the help of instrument maintenance.
- After resuming supply, S/D valves to be taken on control system.
9..5 MODIFICATIONS.
Feed supply.
Initially feed for MTBE feed was provided from OM&S (LPG) from HS NO. 903 / 904which
are engaged for receiving LPG return stream from IPCL. During this operation it was not
possible not possible to run the unit continuously as LPG was facing problem with line up
126
of FCC LPG supply to IPCL from HS No.901/902, and receiving return stream from IPCL
to HS No.903/904. For this reason unit was running in batch operation.
To avoid this problem a direct line from FCC run down was provided to MTBE and return
stream from MTBE diverted to LPG. A bypass line is provided to route FCC LPG to HS
No.901/902 directly. When MTBE plant remains shut down FCC LPG is directly routed to
om&s by this facility at MTBE b/l.
C-6 bottom R/D
C-6 bottom run down was initially going to GR LPG receiving bullets at LPG. As
requirement comes to route C-6 bottom to Butene-1 plant .a separate tapping was
provided to route this product to feed that plant.
LP /MP steam/N2/Air
Separate tapings are provided from utility lines like N-2 line, instrument airline; plant air
line, LP steam line and MP steam line of MTBE plant to Butene-1 plant.
COOLING WATER LINE
As we are getting less cooling water pressure at column C-1’s condenser E-2, tapings are
provided from supply & return lines of this condenser to provide booster pump. this will
help in increasing unit through-put. Also back flushing facility is provided at E-2 in case of
chocking.
CHANGING SEQUENCES OF REACTORS
C-4 feed from C-1 bottom enters R-1 where 90% conversion takes place. So R-1 catalyst
is more effected then R-2 catalyst. In start of run R-1/R-2 in let temp is kept 40/50 (0c).
C-1 bottom C-2  V-18 E-6R-1E-7 Tv-803AR-2E-8C-3

 
 
127
Tv803B 
When R-1 temp reaches 50 (0c), it is planned to change series of R1/R2 reactors. special
lines have been provided to change this series. In this case feed from E-6 will be diverted
to R-2 by R-1 bypass line. R-2 out let will be diverted to R-1 inlet via pipe separator and
R-1 outlet will be sent directly to CD reaction column.
C-1 bottom C-2  V-18 E-6R-2E-7 Tv-803AR-1E-8C-3

 
 
Tv803B 
128

SECTION – 10
INSTRUMENTATION / DCS

129
SECTION-10
10.0 INSTRUMENTATION / DCS
10.1 WRITE-UP ON DCS
GENERAL
MTBE Plant for IOCL - Gujarat refinery is controlled by DCS which is a open
control system. DCS offered for this job is Yokogawa Centum CS, which
works on UNIX operating system, is 'OPEN' to third party devices at TCP/IP
level and the same is being utilized to integrate the system with IOCL's MIS
package Honeywell UNIFORMANCE RTDBMS.
CONTROL PHILOSOPHY
All field transmitters considered for this project are SMART which work on
HART protocol su
signals are used for control and monitoring purpose in the DCS and HART
signal is being used for remote calibration and diagnostics via hand held
nals for
controlling control valves. All analog signals are intrensically safe; intrinsic
safety is achieved through active barriers.
Interlocks and shutdown is performed by dedicated TMR (Triple Modular

Redundant) PLC which is hooked on to the DCS via RS232C serial link.
130
SYSTEM ARCHITECTURE
Yokogawa Centum CS unix based DCS is considered for MTBE Plant. The
system comprises of 1 No. HICS (Engg. console) and 3 Nos. ICS (Operator
console). The system communicates with the FCS's (Controller cards) on
dual redundant V-net bus at 10 Mbps communication speed. Communication
between ICS's and MICS is through dedicated E-net bus which is non-
redundant. 2 Nos. alarm and 1 No. Logging printer is considered for this
project.
The system comprises of 2 Nos. dual redundant FCS's (One for process
control and one for PLC interface). Single channel AI/AO cards are used for
closed loops so as to maintain loop integrity. For open loops 16 channel AI
and 32 channel DI/DO cards are being used.
Dedicated FCS is used for PLC serial interface PLC serial interface 32
channel DI/DO cards are used in PLC. Separate programme PC terminal is
provided for PLC ladder programming.
10.2 ONLINE ANALYSERS
Following are application reviews for hydrocarbon stream on-line analysers :
Washed and Filtered HC (AI-701)
Stream Data
Sample phase at tap : Liquid

Sample phase to analyse : Liquid
Temperature : 40 °C
Pressure : 12.0 kg/cm²g
Stream : Washed and filtered HC
a) Measurement - Component range, wt%
131
Isobutane 0-50
Isobutene 0-50
b) Stream composition, wt%
Case I Case II
Propene 0.18 0.10
Propane 0.58 0.67
Isobutane 31.58 38.64
Isobutene 19.06 17.07
1-Butene 11.71 10.75
1, 3-Butadiene 1.51 1.42
N-Butane 9.30 8.82
Trans-2-Butene 14.31 13.01
Cis-2-Butene 9.26 8.42
C5s+ 2.35 1.10
Water 0.00 0.00
Application Review
1. Carrier : Helium or Hydrogen

2. Analysis Time : 6-8 minutes
3. Sample Phase to Analyser : Vapor
4. Oven Temperature : 110 °C
5. Detector : Thermal Conductivity with Constant Temperature Bridge
6. Eight hour reproducibility ± 1% of full scale for each component
7. Vendor : ABB Process Analytics
Reaction Column overhead (AI-1002)
Stream Data
Sample phase at tap : Liquid
132
Sample phase to analyse : Liquid
Temperature : 50/59 °C (SOR/EOR)
Pressure : 12.2/14.0 kg/cm²g (SOR/EOR)
Stream : Reaction column overhead
a) Measurement - Component range, wt%

Isobutane 0-50
Isobutene 0-1.0
Methanol 0-10
MTBE 0-1.0
b) Stream composition, wt% (at SOR)
Case I Case II
Propene 0.22 0.12
Propane 0.71 0.78
Isobutane 38.52 45.27
Isobutene 0.02 0.02
1-Butene 14.36 12.58
1, 3-Butadiene 1.94 1.67
N-Butane 11.34 10.33
Trans-2-Butene 17.44 15.23
Cis-2-Butene 11.27 9.85
C5s+ 0.01 0.01
Water 0.06 0.06
Methanol 4.00 4.00
DME 0.10 0.10
Application Review
1. Carrier : Helium or Hydrogen
2. Analysis Time : 10-11 minutes
3. Sample phase to Analyser : Liquid
4. Oven Temperature : 80 °C
5. Detector : Flame Ionization
6. Eight hour reproducibility ± 3% of full scale for each component
133
7. Vendor : ABB process analytics
Note : The detectable limit for MTBE will be in the 1-3 ppm range.
10.3 PUBLIC ADDRESS (P.A) SYSTEM
There are 4 nos of P.A Station in MTBE plant manufactured by Philips India Limited for
communication between field area and Control room.
.
134

SECTION – 11
OFF SITE FACILITIES & STORAGE TANKS

135
SECTION-11
11.0 OFF SITE FACILITIES AND STORAGE TANK

Following are the off site facilities for MTBE Plant.
A. Hydrocarbon and methanol feed supply.
B. Supply of utilities.
C. Product routing to storage.
Brief description of off site facilities.
 Hydrocarbon feed supply: Hydrocarbon feed is supplied from Horton sphere (HS
903 and HS 904) situated in old LPG storage area. Cracked LPG from FCC or cracked
LPG after IPCL return is used as MTBE feed. One modification job done near MTBE
plant for receiving LPG from FCC directly to MTBE plant. And its return is connected to
FCC LPG return header (Ref. Drg no:22 ).
 Methanol feed is supplied from off site site storage tanks (TK no 1105/1106, under LPG
section and tank capacity is 500 KL each) to TK 1103 / TK 1104 situated at MTBE area
whose capacity is 400 KL each. From TK 1103 / 1104 methanol is transferred to MTBE
unit (Ref. Drg. No 21 ) via pump P-13A/B.Methanol is received from outside agency via
tank truck to Tank no-1105/1106. Initially some temporary connection has been given
in MTBE area for unloading methanol from truck to TK 1103 / 1104. Tank farm and
Pump House are restricted area as because of poisonous property of methanol. Pumps
and tanks drain system is connected to a under ground CBD vessel(box type). Caution
boards and safety showers are provided at appropriate area.
 Supply of Utilities: MP steam, LP steam, Instrument air, Plant air, Nitrogen gas,
Service water, DM water, Cooling water and Fire water.
 MP steam is coming from FCC area.
 LP steam is coming from AU-3 area.
 Instrument air, Plant air, Service water and DM water lines come from FCC area.
 Cooling water supply come from New Cooling Tower and its return is going to New
Cooling Tower return header.
 Nitrogen gas is connected to nitrogen plant of Hydro cracker unit via CRU.
 Fire water is coming from GR fire water net work.
136
 Product MTBE is routed to run down TK no 1101 and Tk.no. 1102 capacity 2700 KL
and 3000 KL each respectively , situated in OM&S. Another two tanks Tk.NO. 405
and Tk.No.406 capacity 350 KL each are provided at TTL.
C3 product and un-reacted C4 product is returned to LPG area. C4 product was used as
feed for Butene-1 plant which is under shut down now a days
137
TANKS IN MTBE PLANT.
There are two tanks TK no 1103 / 1104 for storage of methanol. These tanks are
day tanks. These tanks can receive methanol from off site tanks and from ISBL
methanol drains drum. Pump P-13A/B is used for transferring methanol to MTBE
unit. Tank drains are connected to one under ground CBD vessel near the tank
farm
Details of the tanks 1103 / 1104 are given below.
TANK NO. TK 1103 TK 1104
Type Floating cum fixed Floating cum fixed
Product Methanol Methanol
Capacity m3 400 400
Reference Height m 10.56 10.56
Safe Filling Height m 8.442 8.442
Nominal Diameter m 7.50 7.50
Critical zone cm 154.0-172.7 156.6-175.3
Factor kl/cm 0.44 0.44
Man hole 2 ( 24” ) 2 ( 24” )
Sky light 1 1
Extra man-way for ladder 1 1
Deluge System  
Foam chamber 1 1
Drains 2 2
Over flow drain 1 1
Inlet / Outlet line 4” common 4” common
Level Gauge At the top At the top
Height of datum plate cm 4 3
138

SECTION – 12
INTERLOCK SYSTEM

139
SECTION-12
INTERLOCKS OF M.T.B.E.
C3/C4 FEED SURGE DRUM
XV-101
OUTLET VALVE OF C3/C4 FEED SURGE DRUM IS OPEN/CLOSED BY A HAND

SWITCH (HS-101)AT DCS
THE VALVE IS IN THE SUCTIONLINE OF PUMP 1A/1B
XL-101
WHEN THE VALVE IS OPEN THE LIMIT SWICH XL-101 ON THE VALVE IS CLOSED
AND IN THIS POSITION THE PUMPS P1A/P1B CAN BE STARTED. WHEN THE VALVE
IS CLOSED THE LIMIT SWITCH IS OPEN AND THE PUMP TRIPS.
THE PUMP CANNOT BE STARTED WHEN THE VALVE XV-101 IS CLOSED.
C3/C4 SPLITTER OVERHEAD DRUM
XV-301
OUTLET VALVE OF C3/C4 SPILTER OVERHEAD DRUM IS OPEN /CLOSED BY THE
HAND SWITCH (HS-301) AT DCS.
THE VALVE IS IN THE SUCTION OF THE PUMP P 2A & 2B.
XL-301
WHEN THE VALVE IS OPEN THE LIMIT SWITCH XL-301 ON THE VALVE IS CLOSED
AND IN THIS POSITION THE PUMPS P-2A /2B CAN BE STARTED.
WHEN THE VALVE IS CLOSED THE LIMIT SWITCH IS OPEN AND THE PUMP TRIPS.
THE PUMP CANNOT BE STARTED WHEN THE VALVE XV-301 IS CLOSED.
140
C3/C4 SPLITTER REBOILER
XV-201
LP STEAM SHUT DOWN VALVE CUTS OFF STEAM TO C3/C4 SPLITTER REBOILER
WHEN THE C3/C4 SPLITTER TO REFLUX DRUM PRESSURE IS HIGH AND EITHER
OF THE TWO SPLITTER REFLUX PUMPS P 2A/2B ARE RUNNING.
SET PRESSURE FOR PRESSURE SWITCH PSHH-307-----18.5Kg/cm2
METHANOL TO ISOBUTENE RATIO IN THE FEED
HS-501
HAND SWITCH HS-501 CHANGES PUMP P-4A/4B RUNNING CONDITION FROM

AUTO/MANUAL
FFSLL-702
WHEN THE RATIO OF METHONAL TO ISOBUTENE IN THE FEED IS LOW LOW THE
STAND-BY METHONAL FEEDPUMP P-4A/4B IS AUTOMATICALLY STARTED IF THE
PUMP IS ON AUTO MODE.
XV-401
IF THE RATIO OF METHONAL TO ISOBUTENE IN THE FEED IS NOT

REESTABLISHED WITH IN 30 SECONDS THE SHUT VALVE XV-401 IS CLOSED.
VALVE XV-401 IS FITTED ON C4 FEED FROM WASH WATER FEED COOLER TO
WASH WATER COLUMN.
FV-704
141
MP STEAM TO REACTOR R-1 FEED HEATER CONTROL VALVE IS CLOSED WHEN:-
a) THE RATIO ASMETHANOL TO ISOBUTENE INFEED IS LO LO
TSHH-702 b) REACTOR R-1 INLETE TEMP IS HIGH
TSHH-711 c) REACTOR R-1 OUTLET TEMP IS HIGH
THE SET POINT FOR TSHH-702-------75ºC

TSHH-711------90ºC
REACTOR 2 INLET / OUTLET TEMPERATURE
TSHH 802 & TSHH 808 IF EITHER OF THE TEMPERATURE i.e. INLET
TEMPERATURE / OUTLET TEMPERATRUE OF REACTOR R-2 IS HIGH FOLLOWING
ACTION TAKES PLACE.
a) FEED TO REACTOR NO 2 FROM REACTOR –2 FEED COOLER CONTROL

VALVE TV-803 A IS OPEN.
b) FEED TO REACTOR NO.2 FROM REACTOR 1 CONTROL VALVE TV-803 B IS
CLOSED.
SET TEMPERATURE IS AS FOLLOWS :
TSHH-802-----75ºC & TSHH-808 ----90ºC
CD REACTION COLUMN LEVEL
LSLL-903 WHEN THE LEVEL OF THE CD REACTION COLUMN C-3 IS LOW

LOW THE MTBE PRODUCT STORAGE SHUTDOWN VALVE XV-801 IS CLOSED.
142
CD REACTION COLUMN REBOILER
HS-901 THIS HAND SWITCH AT DCS OPENS OR CLOSE THE MP STEAM TO CD

REACTION COLUMN REBOILER CONTROL VALVE FV-804.
CD REACTION COLUMN OVERHEAD
XV-1001
CD REACTION COLUMN OVERHEAD DRUM OUTLET IS OPEN /CLOSE BY A HAND
SWITCH (HS-1001) AT DCS.
THE SHUTDOWN VALVE IS IN THE SUCTION LINE AS CD REACTION COLUMN

REFLUX PUMP P-5A/5B.
XL-1001
WHEN THE VALVE IS OPEN THE LIMIT SWITCH XL-1001 ON THE VALVE IS CLOSED
AND THE PUMP P-5A / 5B CAN BE RUN. WHEN THE VALVE IS CLOSED THE LIMIT
SWITCH ON THE VALVE IS OPEN AND THE PUMP TRIPS IF IT IS RUNNING.
THE PUMP CANNOT BE STARTED IF THE VALVE XV-1001 IS CLOSED.
METHANOL COLUMN REBOILER
HS-1201
THE HAND SWITCH HS-1201 AT THE DCS OPEN / CLOSED THE CONTROL VALVE
FV-1201 ON MP STEAM TO METHONAL COLUMN RE-BOILER . THE HAND SWITCH
IS USED IN CASE OF EMERGENCY.
METHONAL COLUMN REBOILER
HS-1502
143
THE HAND SWITCH HS-1502 AT THE DCS OPEN / CLOSE THE COTROL VALVE FV-
1502 ON THE LP CONDENSATE FROM LIGHT COLUMN RE-BOILER.
LIGHTS COLUMN OVERHEAD DRUM
XV-1601
THE SHUTDOWN VALVE ON THE LIGHT COLUMN OVERHEAD DRUM OUTLET IS

OPEN / CLOSED BY A HAND SWITCH (HS-1601).
THE SHUTDOWN VALVE IS IN THE SUCTION LINE AS SHUTDOWN LIGHTS

COLUMN REFLUX PUMPS P-8A/8B.
XL-1601
WHEN THE VALVE IS OPEN THE LIMIT SWITCH THE LIMIT SWITCH XL-1601 ON
THE VALVE IS CLOSED AND THE PUNP P-8A /8B CAN BE STARTED. WHEN THE
VALVE IS CLOSED THE LIMIT SWITCH IS ON THE VALVE IS OPEN AND THE PUMP
TRIPS IF IT IS RUNNING.
THE PUNP CANNOT BE STARTED IF THE VALVER XV-1601 IS CLOSED.
SLOPS DRUM LEVEL
LSLL-2002
THE PUMP P-12 STOPS WHEN THE LEVEL IN THE SLOPS DRUM LOW. TH8IS
SENSED BY LEVEL SWITCH.
METHANOL DRAINS DRUM LEVEL
LSLL 2004
144
THE PUMP P-10 STOPS WHEN THE LEVEL IN THE METHONAL DRAINS DRUM IS
LOW LOW WHICH IS SENSED BY LEVEL SWITCH.
FLARE KNOCKOUT DRUM LEVEL
LSLL-2103
THE PUMP P-11 STOPS WHEN THE LEVEL IN THE FLARE KNOCKOUT DRUM IS
LOW LOLW.
145

SECTION –13
EQUIPMENT HAND OVER TO MAINTENANCE / INSPECTION

146
SECTION: 13
PROCEDURES FOR PREPARATION OF EQUIPMENT HANDING OVER
13.1 PUMP
13.1.1 COLD PUMP
1.0 De-pressuring the pump:

Following steps are to be followed for pump de-pressuring.
1.1 Close first discharge valve then suction valve, (close MOV & MOV bypass
valve).
1.2 Pump casing liquid drain in to ows (for LPG & high RVP product service
pump casing liquid to be vent into flare and after de-pressuring the pump
vent to flare valve to be closed)
1.3 If pump service is for heavy product, take FLO and drain into ows (for
flushing the pump casing).
1.4 If pump service for Caustic, Amine, Anti-oxidant or other chemical drain
pump casing liquid into chemical drum and then flush with water two or three
times.
1.5 If mech. Seal flush line is their, close seal flush line valve.
2.0 If mech. Seal and pump bearing cooling water line is there, close cooling water line
valve.
3.0 Pump motor & its auxiliary motors power supply isolate from sub-station.
Now pump is ready for handing over to maintenance.
13.1.2 HOT PUMP
1.0 De-pressuring the pump
Following steps are to be followed for pump de-pressuring.

1.1 Close first discharge valve and warm-up valve then suction valve, (close
MOV & its bypass valve)
1.2 Cool pump below 200 deg. C
1.3 Pump casing liquid drain into ows
1.4 If mech. Seal flush line is there, close seal flush line valve.
1.5 If quench steam line is there, close quench steam valve
1.6 If pump service is for heavy product, take FLO and drain in to ows (for
flushing the pump casing)
1.7 If auxiliary oil pump is there, stop oil pump after cooling the main pump below
70 deg. C.
147
NOTE: 1.0 Ensure pump casing liquid free by checking drain line and seeing pump
pressure gauge.
2.0. If mech. Seal and pump bearing cooling water line is there, close cooling water
line valve.
3.0. Pump motor and its auxiliary power supply isolate from sub-station.
Now pump is ready for handing over to maintenance.
13.2 Handing over of Vessel for maintenance & inspection
els The vessel used in oil refineries are mainly for light / heavy hydrocarbons and some
chemicals. When the necessity arises for a person to enter into the vessel, the following
procedures should be followed:
1. Equipment to be electrically isolated and tagged wherever necessary. It should be

ensured that electrical switches are locked out and properly tagged duly signed with
date and time.
2. Equipment to be isolated / closed disconnected.
Vessel should be completely isolated from other equipments, in order to ensure that
there should be no change in the work environment.
3. Equipment to be properly depressurized / drained
 Vessel under pressure should be depressurized after isolation

 De-pressurization to be done by opening flare line B/V.
 Keep some pressure 0.5 kg/cm2, if vessel has heavy hydrocarbon for proper
draining.
 If the vessel has hot material (> 200 deg. C) then drain after sufficient cooling.
 Vessel to be drained in Closed Blow down
 Watch the level and pressure during draining.
 Vessel having sour water and hydrocarbon the sour water to be drained in
O.W.S.
 To ensure the complete draining, open O.W.S. B/V and check for liquid draining /
or gas may come.
 After complete draining close C.B.D. / O.W.S. B/V
 De-pressurize completely to flare if there was some pressure.
 Vessels containing liquid / light hydrocarbons should be drained completely by
opening all low point drains (L.P. D) of connected pippins, level gauges and
stand pipes etc. by unplugging the L.P.D
 Vessels containing any chemical should be drained in chemical blow down
vessel (Ch. BA vessel) only.
148
4. Vessel to be disconnected / blinded / wedged open
 Ensure complete draining

 Inlet / outlet of any injection line is there to be blinded wedged opened and /or
disconnected.
 Vent and utility system lines to be de-blinded.
5. Vessel to be properly steamed / purged.

 Open saturated steam drain B/V for condensate draining.
 Charge steam to the vessel minimum and watch the pressure.
 Open all high point vent and drain points.
 Open stem B/V as per requirement.
 Open drain (vessel) to O.W.S.
 Check the condensate for oil contamination.
 Ensure complete removal of hydrocarbon by condensate checking.
 If necessary stop steaming for sometime and recharg the
steam.
 Vessel containing only gas purging can be done with inert
gas ,nitrogen.
 Ensure venting/draining of steam from all H.P.V as L.P.D.
of level gauges, stand pipes and other pipes.
6. Vessel to be water flushed:
 Water flushing is an effective means of cleaning ,gas firing and cooling.
 Vessel containing liquid hydrocarbon – hot water flushing to be done.
 Vessels metallurgy must be considered before using water for washing.
 Hot water washing to be done by using steam and water.
 Ensure proper draining of the vessel.
 Observe for any abnormal sound (steam hammering) in the vessel.
 Reduce water and open drains sufficiently, if not opened fully.
 Stop the water drains the condensate and watch for any oil or small of gas etc.
 Start again water & steam and repeat ¾ times till the clear condensate is not
coming.
 Ensure complete hydrocarbon / chemical washed out.
 Stop the steam.
 Stop water after sufficient cooling.
 Left the vessel for natural cooling.
 Open top and side manways.
 Put exhaust fan on top/ side manways (if required).
 Utility steam line to be blinded.
149
 Water hose to be disconnected
7. Gas / Oxygen deficiency test to be done:
 Check the vessel material, hydrocarbon or mud at the bottom.

 Do gas (hydrocarbon) test by explosivity meter.
 Oxygen deficiency by oxygen meter.
 Toxic gases like hydrogen sulphide, carbon monoxide, chlorine etc. Test to be done by
special techniques.
 No hot work shall be permitted unless the explosivity meter reading is zero.
 Vessel entry where no hot job is to be carried out may be permitted if combustible
gases are up to 5% of lower explosivity limit (LEL)
 Vessel entry with an air supplied mask may be permitted with LEL of 50%.
 The oxygen level should be at least 19.5 vol. % and the concentration of toxic gases
below the threshold limit.
8. Proper Ventilation and lighting provisions :
 Where natural (sufficient) ventilation is not available, fans / air eductor, air hose
to be provided.
 Only approved reduced voltage extension (24 volts) lights are to be provided for
work inside vessels.
 Flood light to be provided outside of the Vessels.
9. Proper means of exit to be provided:
 Proper means of exit to be provided if an alternate route of escape not existing.
150
10. Precautionary tags / boards to be provided.
 To prevent any unwarranted entry in the work area precautionery tags / boards
are to be provided – such as “ No entry “ or “Caution – Men at the work inside”
on the manhole of the vessel.
11. Iron sulphide to be removed / kept wet:
 The vessel containing light hydrocarbon and sour water may contain
pyrophonic substance.
 Vessel to be kept wet with water.
 Sludge to be removed along with water and kept wet until they are removed
from the site, at safe location.
12. Standby person to be provided outside the vessel (minimum – 2) near the manway.
All the above activities to be completed and vessel are cleaned with proper
precautions, then man entry can be given for inspection and maintenance
purposes.
151
13.3 Handing over of column for maintenance and inspection
The columns used in oil refineries mainly are for the services like distillation and absorption
/adsorption, regeneration etc. When the necessity arises for a person to enter into the
column, the following procedures should be followed for handing over the column to
maintenance & inspection.
1. Column to be isolated / closed / disconnected:
 Column should be completely isolated from other equipments, pipings, etc. In

order to ensure that there should be no change in the work environment.
2. Column to be properly de-pressurized/ drained :
 Column under pressure to be de-pressurized to flare after isolation.

 De-blind the closed blow down (C.B.D.) as O.W.S. connection / pipes of column
and connected pipings, such as pump suction header and reflux line.
 De-cap the low point drain (L.P.D.) and High point vents (H.P.V.) of pipelines, level
gauges.
 Stand pipes and other tappings connected.
 Drain the column to C.B.D.
 Drain the pumps suction headers of draw-off products to C.B.D., if provision is not
there then in O.W.S.
 Drain the other connected pipelines at L.P.D. through hose connections to C.B.D. or
O.W.S.
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 Ensure complete draining by opening O.W.S. LINE.
 Close all drain B / V and watch the column pressure and level, if any increase then
again draining to be done.
 Columns containing chemicals like caustic amine etc. To be drained in chemical
blow down (Ch. B.D.) vessel only.
3. Column to be disconnected / blinded / wedged open:
 Ensure complete draining

 De-blind top vent and utility steam.
 Blind / wedge open all the take off (draw off) and return lines.
4. Column to be properly steamed / purged
 Open saturated steam/utility steam to the column

 Open vent and other high point vent of all instruments and other connected piping.
 Open all L.P.D. of level gauges and stand pipes etc.
 Watch column pressure and level.
 If required, wedged to be increased and /or increase the steam.
 Check the condensate for oil in condensate.
 Ensure complete steaming/ oil removal by observing condensate.
 Columns where steaming is not admissible, purge with inert gas /N2 gas.
 Columns in which N2 purging is to be done wedged opening not required.
 Ensure that all H.P.V. & L.P.D. are clear /de-choked.
5. Column to be water flushed / Hot water washed:

 Water flushing is an effective means of cleaning, gas freeing and cooling.
 Columns containing hydrocarbons – hot water flushing to be done.
 Columns metallurgy must be considered before using water types (cooling water
/D.M. water) for washing.
 Hot water washing to be done by using steam from bottom and water from top.
 Ensure proper draining of column.
153
 Observe for any abnormal sound (steam hammering) in the column.
 Ensure complete washing by checking condensate drains.
 Stop steam and continue water washing for sufficient cooling.
 Stop water washing
 Open alternate Man – ways starting from top of the column.
 Install exhaust fan / evacuator on top manway.
6. Gas /Oxygen deficiency Test to be done.
 Check inside through manways e.g. safety torch for any foreign material /
hydrocarbon / coke etc.
 Do gas (hydrocarbon) test by explosivity meter.
 Oxygen deficiency test by oxygen meter.
 Toxic gaes like hydrogen sulphide, carbon monoxide, chlorine etc.test to be done
by special technique.
 Cloumn entry where no hot job is to be carried out may be permitted if combustible
gases are upto 5% of lower explosivity limit (LEL)
 Entry with an air mask may be permitted LEL of 50%.
 The oxygen level should be at least 19.5% by volume and the concentration of toxic
gases below the threshold limit.
 No hot job shall be permitted unless the explosivity meter reading is zero.
 After man entry get opened the trays man-ways for inspection.
 Open all the manways.
 Make arrangement inside column of rope ladder etc.
 Blond the utility steam and water lines.
7. Proper ventilation and lighting to be provided:
 Where natural (sufficient) ventilation is not available, fan /air educter / air hose to be
provided.
8. Proper means of exit to be provided
154
 To prevent any unwanted entry in the work area precautionary tags/ boards to be
provided such as “No entry” or “Caution – men at work inside” on the manhole of
the column.
10. Standby persons to be provided outside the column (minimum –2) near the manway.
 All the above activities got completed, then column to be handed over for inspection
and maintenance work.
13.4 EQUIPMENT HANDOVER TO MANITENANCE AND INSPECTION

Exchanger / Cooler / Condenser/ Reboiler
1. Drain the contents of the exchanger to the drain tank (CBD) after it has cooled
down.
2. Install blinds on the inlets and outlets at the shell and tube side of the exchanger.
3. Flush with water till it is oil free.
4. Steam flushing with wedge opening to be done till the system is hydrocarbon free.
5. Clearance to be given to hand over for cleaning/ maintenance job.
13.5 TANK HANDING OVER FOR MAINTENANCE:
1. Pump out tank materials to OM&S respective tank till pump looses suction.
2. Get water hose connection from drain or through dip hatch and build up level for
pumping out more hydrocarbon. As far as possible hydrocarbon to be pumped out.
3. Get tank's inlet / outlet and other connected lines (except drain) blinded.
4. Drain tank content to OWS.
5. Get sky light cover and manhole opened.
6. Take further water inside the tank for over flowing of rest hydrocarbon through
manhole.
7. Overflowing to be continued till all hydrocarbon remove.
8. Check by explosive meter. If OK then water to be drained out. Leave
9. tank for air circulation.
10. Check explosivity. If OK, hand over the tank for cleaning / M & I job. If explosivity. is
not OK, then repeat the overflowing by water more.
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
SECTION – 14
FIRE FIGHTING / WORK PERMIT / ACCIDENT REPORTING

156
SECTION: 14
14.1 FIRE FIGHTING FACILITIES:
“Fire is a burning matter”. In technical terms, fire is a chemical reaction where matter
reacts with oxygen under certain conditions to release heat and light energy.
14.1.1 Classification of fire:
Class A Fires involving solid carbonaceous materials Eq. Wood, Paper, cloths,
rubber plastic.
Class B Fires involving flammable or combustible liquids or liquified solids, grease
etc.
Class C Fires involving gases or liquified gases such as methane, propane, butane,
LPG etc.
Class D Fires involving certain combustion metals such as Mg, Titanium, Zircomium,
Sodium, Potassium.
14.1.2 Causes of Fires:
Sparks from electrical equipments, heat from friction, open flames, smoking and matches,
spontaneous ignition, hot surfaces and heated lines, static electricity, lightening, auto
ignition, etc.
14.1.3 Methods of extinguishing fires:
Starvation: Elimination of fuel

Smothering: Limitation of oxygen
Cooling : Remove of heat
Chemical interference : Interrupt chain reaction
14.1.4 Different agents used for fire flighting:
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Water, steam, foam, dry chemical powder, carbon-dioxide, sand etc.
14.1.5 Fire Prevention and Protection:
Fire Prevention:
1. Regulation for the prevention of Fire:
Ban on carrying of a potential source of ignition, Ban on lighting fires in battery area.
Ban on smoking, Ban on carrying lamps, use of spark arrestors.
2. General precautions:
Maintain good housekeeping. Follow the laid down procedure strictly. Sampling and
draining of hydrocarbon should be done under strict supervision. Do not operate an
equipment unauthorizedly. Use only approved type of tools. Anticipate the hazards
during vessel cleaning and take preventive steps in advance.
FIRE PREVENTION ACTIVITIES:

Fire prevention can best be achieved with the application of:
SOUND ENGINEERING:
Design of the plant materials used for construction, means of escape etc.
GOOD HOUSEKEEPING:
Cleanliness of the plant, methods of storage.

Good habits: Observation of fire prevention rules etc.
Commen sense: No smoking near inflammable material etc.
158
INSTRUCTION TO PERSONNEL:
1. knowledge of the job.

2. Safe practices
3. Action in case of fire
4. Knowledge of fire extinguishers etc.
REGULAR TRAINING OF EMPLOYEES:
1. Induction training programme

2. Refresher courses
3. specia lised training programmes
SAFETY AUDITS:
* Internal * External
VARIOUS SAFETY STUDIES:
Ex risk analysis, hazop, hazan, etc. prior to commissioning of any plant or equipments.
COMPLIANCE OF STAUTORY REQUIREMENTS:

INSPECTIONS:
To check for proper placement and operation of fire protection equipment and seek
correction of common fire causes, such as poor house keeping, improper storage of
flammable materials, smoking violations and excessive accumulation of dust of flammable
material.
FIRE EMERGENCY DRILL:

An emergency manual can be prepared to outline procedures and drills and detail
responsibilities of each individual involved.
159
 Training
 Valuable check on the adequacy and condition of exits and alarm system.
 Instills a sense of security among the occupiers if careful plans are made.
 Exit drills
 Plant drills (mock drills in plant area)
 Mutual aid drills
 On-site / off site drills etc.
FIRE STATION: Our refinery has two fire stations. Equipped with all modern equipments &
trained manpower.
COMMUNICATION:
Ex-telephones : Fire call numbers 7333 & 6333, Hotlines for communicating mutual aid
member, P.A., paging, walkie- talkie system, fire alarm: By breaking the glass of any of the
alarm located in the refinery area: At GR-62 nos. & at GHC –53 nos., Sirens 11 nos at
various locations.
FIRE PROTECTION:
Following fire protection facilities provided depending upon / risk of the installation:
FIRE WATER SYSTEM
1. Fire water storage – 22,400 m3

2. Fire water pumps – 8300 m3/hr
3. Distribution piping network – approx. 50 km
Hydrants Monitors Water spray system

(Around 1000) (Around 400) (Oil tanks & hydrocarbon
pump houses) LPG area as
per OISD – 116.
160
FOAM SYSTEM:
Semifixed : Provided an oil storage tanks. Railway gantry no. 6

Mobile : Foam tenders 5 nos. & foam nurser: 1
MOBILE FIRE FIGHTING EQUIPMENTS:
Foam tender :5
DCP tender :1
Emergency tender :1
Foam nurser :1
CARBONDIOXIDE PROTECTION SYSTEM:
Turbines and generators in power plants
FIRST AID FIRE FIGHTING EQUIPMENT :
First team comprising of operation / maintenance staff at site & any other refinery person
available at site this persons will handle the situation till the arrival of trained fire fighter with
the help of.
PORTABLE FIRE EXTINGUISHERS:
Dry chemical powder, foam, Water type, CO2, Halon

10 kg: 2000nos., 25 kg Trolly mounted : 100 nos * DCP Trolly mounted 75 kg:
175 nos * Foam type Trolly mounted 45 lts: 30 nos.
FIRE FIGHTING TEAM:
First main team comprising of shift incharger of fire stations & fire operators on duty with
fire fighting equipments. Officers from fire and safety & CISF personnel.
161
Second main team: Fire operators (Re- inforcement), CISF staff (reserve as well as on
duty except for gate staff), fire fighting crew from external sources (like neighbouring
industries, BMC etc.)
162
14.2 PRE-FIRE FIGHTING PLAN FOR MTBE UNIT
Pre fire fighting plan is an important aspect of fire protection and helps to review the
major fire hazards and possible emergency scenarios of a unit vis-à-vis the fire
protection facilities available to deal with the various possible emergencies. It also helps
in making a pre-plan on the methodology of approach to fire and actions required for
effective fire fighting and mitigation of emergency.
With the above objective, a joint survey and study was carried out by Fire & Safety and
production to identify critical fire hazards and facilities available to deal with such
emergencies.
The following methodology was adopted:
(A) Identification of possible emergency scenarios

(B) Developing pre-plan for each scenario with following parameters:
(i) Consequence of scenario
(ii) Identification of critical equipments w.r.t scenario
(ii) Identification of Fire protection facilities available to deal with the emergency.
(iii) Approachability of fire tenders to scene of emergency
(iv) Strategy to be adopted in handling emergency scenario
(C) Identification of deficiency in the existing system and remedial action.
(A) IDENTIFICATION OF POSSIBLE EMERGENCY SCENARIOS

Based on the criticality of equipments, hazardous material handled by the equipments
and experience of production and Fire & Safety the possible emergency scenarios
envisaged in GHC units are:
I) SITUATION : I
FIRE EMERGENCY IN SPLITTER COLUMN
I) Critical equipment :
1) Column CC-1100-01
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II) Hazardous material being handled : LPG
III) Critical parameters : Temperature and pressure (Temp 40-100 oC
Pr. 16 Kg/cm2)
IV) Probable scenarios :
i) LPG leakage from valves/ gland/ flanges etc., caught fire due
to out source ignition.
ii) LPG vapour clod formation from flange leak resulting fire due
to out source ignition .
V) Extinguishing Media : Water, DCP, Foam and Steam
VI) Nearest FA point : FA No. 228 , 230 & 231 as marked on drawing
VII) Nearest Eyewash / drench shower : South side of C1
VIII) Approach for Fire tenders and Ambulance :
Emergency turn out to be taken from two different direction with three foam tenders (
two nos. from Main Fire Station and one from 2nd Fire Station) with one ambulance from
hospital. 1st tender and 2nd tender will follow road no.2 and take position in between PDF
and MTBE as indicated on plot plan.. Ambulance to be parked at safe position at Rd. .2
. 1st Turnout from 2nd Fire station shall follow rd no.4, then rd.11 , then rd no. 16 and
take position in approach road as shown in plot plan. ( Location marked “1 “ on plot
plan )
IX) Strategy to be adopted by Production

Column fires are extinguished principally by fuel removal. This is accomplished
by making operational changes to reduce pressure, by introducing steam to the
affected systems and by blowing down sections of unit as required. Near by water
monitors are to be operated and focussed at source of leak to prevent spreading of fire
and dilution of vapour cloud. All the other nearby ground and elevated monitors as
shown in plot plan within the target are to be opened up for exposure protection of
surrounding critical equipments . Water spray system of Pump house to be opened up
for exposure protection. ( See location of valve in plot plan) The initial fire or vapour
cloud due leakages is to be combated by effective application of portable 10kg , 25 kg
and 75 kg fire extinguishers and application of available steam kept close to leaky areas
till fire vehicle are reached to site.
X) Strategy to be adopted by Fire and safety :
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Roof mounted Water monitors from 1st turn out and 2nd turn out parked in between PDF
and MTBE to be operated for immediate extinction of fire at source. Two foam hand
lines from each foam tenders are to be laid and extended to column areas and fire
fighting to be continued as per situation demands . Additional hand lines for the purpose
of cooling from nearest hydrants to be started as per requirements . Water curtain to be
established in between Column and Vessel (V1) . Attempt should be made for
continuous cooling of Vessel V1 as exposure protection. Water curtain to be established
between Column and PH . Close monitoring and necessary blanketing of area to be
ensured to prevent flash back on spilled oil all around leaky areas as well as nearby
pump house. In case of a large spill fire, high pressure water fog is to be
targeted in to the source of leakage . Foam to be applied to prevent fire in nearby
pools or trenches.
II) SITUATION : II
FIRE EMERGENCY IN LPG/METHANOL VESSEL
I. Critical equipment :
Vessel : 1100-V-01
II. Hazardous material being handled ; LPG and Methanol
III. Critical parameters : Temp and pressure
IV. Probable Scenarios :
i) LPG leakage from valves/ gland/ flanges etc.. caught fire
due to out source ignition.
ii) LPG vapour clod formation from flange leak resulting fire
due to out source ignition .
V. Extinguishing Media : Water, DCP , ATC Foam and Steam
VI. Nearest FA point : FA No. 228 west side of V1
VII. Nearest Eyewash / drench shower : south side of C1
VIII. Approach for Fire tenders and Ambulance :
hospital. 1st tender and 2nd tender will follow road no.2 and take position in between PDF
and MTBE and approach road as indicated on plot plan.. Ambulance to be parked at
safe position at Rd. .2 . 1st Turnout from 2nd Fire station shall follow rd no.4, then rd.11
165
, then rd no. 16 and take position in approach road as shown in plot plan. ( Location
marked “2 “ on plot plan )
IX. Strategy to be adopted by Production

Vessel fires are extinguished principally by fuel removal. This is
accomplished by making operational changes to reduce pressure or by isolation
and bypassing the affected equipment or by introducing steam to the affected
systems and by blowing down sections of unit as required. Near by water
monitors are to be operated and focussed at source of leak to prevent spreading of fire
and dilution of vapour cloud. All the other nearby ground and elevated monitors as
shown in plot plan within the target are to be opened up for exposure protection of
surrounding critical equipments . Water spray system of Pump house to be opened up
for exposure protection. ( See location of valve in plot plan) The initial fire or vapour
cloud due leakages is to be combated by effective application of portable 10kg , 25 kg
and 75 kg fire extinguishers and application of available steam kept close to leaky areas
till fire vehicle are reached to site.

Roof mounted Water monitors from 1st turn out and 2nd turn out parked in between PDF
and MTBE and approach route to be operated for immediate extinction of fire at source.
Two foam hand lines from each foam tenders are to be laid and extended to vessel areas
and fire fighting to be continued as per situation demands . Since the product contains
polar solvent like methanol , ATC to be applied in place of AFFF. Additional hand lines for
the purpose of cooling from nearest hydrants to be started as per requirements . Water
curtain to be established in between Column and Vessel (V1) . Attempt should be made
for continuous cooling of Vessel V1 and C1 as exposure protection. Water curtain to be
established between V1 and PH . Close monitoring and necessary blanketing of area to be
ensured to prevent flash back on spilled oil all around leaky areas as well as nearby pump
house. In case of a large spill fire, high pressure water fog is to be targeted in to
the source of leakage . ATC Foam to be applied to prevent fire in nearby pools or
trenches.
III) SITUATION : III

FIRE EMERGENCY IN REACTORS
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I. Critical equipment :
Reactors : 1100-R-1 & 1100-R-2
II. Hazardous material being handled ; MTBE, Methanol , LPG
III. Critical parameters : Pressure & Temperature
IV. Probable Scenarios :
i) Flange leak leading to vapour cloud
formation/ fire/explosion
ii) Instrument tapping failure leading vapour
cloud formation/ fire/explosion
iii) Thermal shock leading to joint leak and
vapour clod formation from flange resulting
fire .
V. Extinguishing Media : Water, DCP , ATC and Steam
VI. Nearest FA point : FA No. 224 , 225, 232 East side of R-1& R-2
VII. Nearest Eyewash / drench shower : : south side of C1
VIII. Approach for Fire tenders and Ambulance :
hospital. 1st tender and 2nd tender will follow road no.2 and take position on rd no.2 and
approach road at East side of reactor as indicated on plot plan.. Ambulance to be
parked at safe position at Rd. .2 . 1st Turnout from 2nd Fire station shall follow rd no.4,
then rd.11 , then rd no. 16 and take position in approach road East side of reactor as
shown in plot plan. between ( Location marked “3 “ on plot plan )
IX. Strategy to be adopted by Production

Reactor fires are extinguished principally by fuel removal. This is accomplished by
making operational changes to reduce pressure, by introducing steam to the
affected systems and by blowing down sections of unit as required. Near by
monitors is to be operated and focussed at source of leak to prevent spreading of fire
and dilution of vapour cloud. All the other nearby ground monitors as shown in plot plan
within the target are to be opened up for exposure protection of surrounding critical
equipments nearby unaffected reactor . The initial fire or vapour cloud due leakages is
to be combated by effective application of portable 10kg , 25 kg and 75 kg fire
extinguishers and application of available steam kept close to leaky areas till fire vehicle
167
are reached to site. Water spray system of Pump house to be opened up for exposure
protection. ( See location of valve in plot plan)
X. Strategy to be adopted by Fire and safety :
Foam monitors from 1st turn out and 2nd turn out parked near plant as indicated in plot
plan to be operated for immediate extinction of fire at source. Two hand lines from
each foam tenders are to be laid and extended to reactor areas and fire fighting to be
continued as per situation demands . Additional hand lines for the purpose of cooling
from nearest hydrants to be started as per requirements . Simultaneously water spray
application on the unaffected pump and ATC in neighbouring pool fire to be applied.
Water curtain to be established in between PH and Reactors. 1 st turn out from 2nd Fire
station is to make close monitoring and necessary blanketing to prevent flash back on
spilled oil all around leaky areas as well as nearby pump house. In case of a large
spill fire, high pressure water fog is to be targeted in to the source of leakage .
IV) SITUATION : IV
FIRE EMERGENCY IN MAIN PUMP HOUSE

I) Critical equipment :
Pumps : I) 1100-P-1A/B to 1100-P-14 A/B
II) Hazardous material being handled ; LPG
III) Critical parameters : Temperature and pressure

IV) Probable Scenarios :
i. Mechanical seal leak leading to vapour cloud formation and fire
ii. Thermal shock leading to gasket failure resulting leakage and
vapour cloud formation and fire .
iii. Electrical fire due to loose terminal contacts
iv. Pump / Motor bearing temperature high leading to fire
V) Extinguishing Media : Water, DCP , ATC and Steam

VI) Nearest FA point : FA No. 224 – FA No. 232 as shown in plot plan
VII) Nearest Eyewash / drench shower : south side of C1
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VIII) Approach for Fire tenders and Ambulance :
hospital. 1st tender and 2nd tender will follow road no.2 and take position on rd no.2 as
well as East side of plant as indicated on plot plan.. Ambulance to be parked at safe
position at Rd. .2 . 1st Turnout from 2nd Fire station shall follow rd no.4, then rd.11 ,
then rd no. 16 and take position in approach road north side of PH as shown in plot
plan. ( Location marked “4 “ on plot plan )
IX) Strategy to be adopted by Production
Operators should switch immediately to spare Pump. If this is not possible,
operation should be adjusted to take the affected pump out of service and isolate
it. If condition permit, drain or de - pressurize the pump by connecting lines.
Apply steam or dry powder from portable extinguisher to the leak. Water spray
system of Pump house to be opened up for exposure protection. ( See location of valve
in plot plan)
In case of Electrical fires due to loose terminal contacts Operators should switch over
to spare, machines , if possible, and machinery can be switched off. Do not use
water or foam. De- energise the circuit of the concerned machine. Apply dry
powder to extinguish the fire. Operate Fixed water monitor near by and direct the jet
to source of leak and fire )

Hand lines from turn outs parked to be connected and extended up to pump house. If
the flame can not be extinguished by use of portable fire extinguishers by
operation people, blanket the fire area with water spray and direct jets of high
pressure water fog in to the source of fuel until the operators have succeeded in
stopping the leak. Apply ATC in to the trenches in which burning oil may
accumulate .Covering the sewer drain to prevent fire entering the sewers. Avoid
working above sewer drains or near fire traps. Maintain adequate drains of fire
area. Put water curtain in between
I) Main Pump House and Column
II) Main Pump House and Vessel
III) Main Pump House and Reactors
169
SPECIAL TECHNIQUES TO BE ADOPTED FOR NON LOCALISED GENERIC IN
NATURE CRITICAL FIRES
A) SITUATION : V
SPILL FIRES ABOVE GROUND LEVEL
Operation people should immediately determine the source of leakage or spill and
stop it, if possible. If it is a continuous leakage which can not be stopped, the
particular piece of equipment involved should be taken out of service,
depressurised and steamed. If necessary. Blanket small fire with steam or dry
powder or ATC to avoid scattering of burning material. In case of a large spill fire,
direct high pressure water fog in to the source of leakage. protect surrounding
structures with water spray. Apply foam to extinguish fire in pools or trenches.
Maintain adequate drainage of the fire area. Avoid Working Above Sewer Drain or
Near Fire Traps.
B) SITUATION :XIV
SEWER/ OWS LINE FIRE
In most of the cases a sewer fire may follow a sewer explosion. In such a case
production people must see that steam from steam hoses is directed at sewer outlets
in all gaseous area. If there is a sewer fire and no explosion has occurred then
first ensure that no one is starting or working on or near the sewer outlets. Apply
dry powder at each manhole or drain from which flame is emanating. F&S people
are to direct ATC streams in to involved trenches and near by other connected
trenches to maintain foam blanketing by preventing spreading of fire .
C) SITUATION :XV
TRENCH OR PIT FIRES
Check immediately to locate and stop the source of leakage in to the trench or
pit. Apply steam, carbon – di – oxide or dry chemical powder to the fire area. If this is
not successful, apply ATC covering the sewer drain. Apply high pressure water fog or
water spray to prevent damage to adjacent equipment. Avoid overflowing trenches
or pits with water as this may cause spread of the fire. Avoid working above sewer
drain manholes or near fire traps.
170
D) SITUATION :XVI
ELECTRICAL MECHAINERY FIRES
Switch over to spare, machine, if possible, and machinery can be switched off. Do
not use water or foam. De- energise the circuit of the concerned machine. Apply
carbon – di - oxide or dry powder to extinguish the fire.
171
14.3 WORK PERMIT
WHAT IS PERMIT TO WORK?
WORK PERMIT IS A
Written document that categorically spells out
 The task
 Equipment involved & its condition
 Its location
 Personnel involved
 Time limitation
 Precautionary measures to be taken together with likely hazard to be encountered if
any.
 Act as a predetermined checklist for various safety precautions.
 Serves as a media of information.
 Instills a sense of security from accident.
WHAT IS THE OBJECTIVE OF SYSTEM?
 To make the work method or the procedure of the work foolproof leaving nothing to
chance.
 Is a guarantee against accidental starting of machinery or entry of any hazardous
liquide or gas into a vessel whose jobs are proposed.
WHY IT IS REQUIRED?
 Sec.7 (A) (2a) SSW

 OISD –105
 Rule 172 of petroleum rules, 1976
172
WHAT ARE THE TYPES OF WORK PERMIT?
 Hot work permit

 Cold work permit
 Excavation permit
WHAT ARE HOT WORK & COLD WORK?
 Hot work: Hot work is an activity, which may produce enough heat to ignite a
flammable substance.
 Cold work: Cold work is an activity, which does not produce sufficient heat to ignite
a flammable air hydrocarbon mixture or a flammable substance.
WHEN VESSEL ENTRY SHOULD BE GIVEN?
 No hot work shall be permitted unless the explosivity meter reading is zero.
 Vessel entry where no hot work is to be carried out may be permitted. If
combustible gases are upto 5% of lower explosivity limit (LEL)
 The oxygen level should be atleast 19.5 vol % and the concentration of toxic gases
below the threshold limit.
WHO WILL BE THE SIGNATORIES?

 List of gas safety inspectors, fire permit signatories distributed.
 Hot work / vessel entry: for any holiday / Sunday and extended hours Chief
Manager / HOD of that area. Clearance from RSM in each shift.
 Cold work / excavation permit: For extended hours & holidays Manager / Sectional
head.
 Dyke cutting: Chief Manager / HOD
173
WHAT IS THE VALIDITY OF PERMIT?
One week only and renewal if the same job needs to be continued. In instances like plant
turnaround or an activity where work is of continuous nature involving round the clock
activity, blanket hot work permit could be given if the owner –incharge is fully satisfied that
the conditions are totally safe for the multiple jobs to be performed.
Even when construction activity has to be undertaken in non – operating areas in

integrated units, it is recommended that approval be obtained from designated senior
management for issuing Blanket hot work permit.
WHO WILL KEEP THE COPIES OF PERMIT?
1. With person doing the job and shall be available at site.

2. Area in charge.
3. Fire station
4. After completion or stoppage of the job the person to whom the permit was issued
should thoroughly check the area for clearing of debris, removal of temporary
electrical installations, etc. and then shall sign the work permit and return it to the
issuer.
WHAT POINTS ONE SHOULD ENSURE WHILE GIVING CLEARANCE?
1. Equipment / area inspected.

2. Surrounding area checked / cleaned.
3. Sewers, manholes, CBD etc. and hot surfaces covered.
4. Considered hazard from other routine / non-routine operations and persons alerted.
5. Equipment electrically isolated and togged.
6. Running water hose / portable extinguisher provided.
7. Equipment blinded / disconnected / closed / isolated wedged open.
8. Equipment properly drained /depressurized, steamed / purged.
9. Equipment water flushed.
10. Gas / oxygen deficiency test done and found OK.
174
11. Shield against sparks provided.
12. Proper ventilation and lighting provided
13. Proper means of exit provided.
14. Precautionary tags / boards provided.
15. Portable equipment / hose nozzles properly grounded.
16. Standby personnel provided for fire watch from process / maintenance / contractor.
17. Iron sulphide removed / kept wet.
18. Area cordoned off.
19. Precaution against public traffic taken.
20. Clearance obtained for excavation / road cutting from technical / fire /concerned
department.
14.3B
Procedure for Accessing Roof of Floating and Fixed Roof Storage

Tanks
1.0 Program Description
The purpose of this program is to specify safe procedures while inspecting/ working on
Floating and Fixed Roof Storage Tanks.
Employees who are required to inspect/ work at Roof in Floating and Fixed Roof
Storage Tanks are required to attend training on fall protection, Permit system and skill
training in respective work area.
2.0 Scope
This program applies to all employees who perform duties or required to access on
Floating and Fixed Roof Storage Tanks.
Contractors working on Floating and Fixed Roof Storage Tanks are required to comply
with all applicable factory rules related to workplace safety and shall have their own fall
protection program in addition to this procedure.
3.0 Procedure for accessing roof of Floating roof tanks
175
3.1 All concerned persons required to access the roof of a floating roof tank, for
inspection, project and maintenance activities, have to take a work permit in the
prescribed format for Confined space entry permit.
3.2 Following process/procedure to be ensured before issuing Permit to access

the roof of a floating roof tank: -
3.2.1 Gas test to check presence of H2S & Hydrocarbon. Gas concentration should be below
10% of the lower explosive limit and H2S concentration to be nil in the ambient.
3.2.2 One man shall be standby at the top of platform with a canister mask / breathing
apparatus.
3.2.3 A lifeline with safety belt is to be used for the man going on the roof. The other end
of the line held by the standby person at the top platform.
3.2.4 No inspection and maintenance of tanks should be undertaken during abnormal
weather, thunder or hail storms and insufficient illumination.
3.2.5 Conductive footwear e.g. leather soles or electrically conducting rubber soles,
should be worn while gauging, sampling or taking temperatures. Nylon rope shall
not be used for lowering sample bottles in the tank.
3.2.6 Check for deck plate internal corrosion: For safety, before accessing the roof,
Check with ultrasonic instrument or lightly use a ball peen hammer to test the deck
plate near the edge of the roof for thinning. Corrosion normally attacks the deck
plate at the edge of a fixed roof & at the rafters in the center of the roof first. (API
STD. 653, Tank Inspection, Repair, Alteration & Reconstruction - Refer Section C
1.4)
4.0 Procedure for accessing roof of fixed roof tanks
4.1 All concerned persons required to access the roof of a fixed roof tank, for
inspection, project and maintenance activities have to take a work permit.
4.2 The following Checks/ procedures are to be ensured before accessing a

fixed roof tank.
176
4.2.1 Planks/ grating long enough to cover at least two rafters as bottom
support shall be laid and used as walkways for safety reasons.
Corroded roof plates may be a safety hazard for people to walk.
4.2.2 A person shall not go alone on the roof of storage tanks for
inspection. For repair/maintenance/testing, the entry to the roof deck
shall be allowed through a work permit.
4.2.3 No walking shall be done on the roof plates where thinning/
perforations are observed. Necessary planking may be provided for
walking on such roofs.
4.2.4 Ultrasonic thickness measurements shall not be carried out when the
tank is receiving or dispatching.
4.3 Following process/procedure to be ensured before issuing Permit

to access the roof of a floating roof tank:
4.3.1 Gas test to check presence of H2S & Hydrocarbon. Gas concentration should be
below 10% of the lower explosive limit and H2S concentration to be nil in the
ambient.
4.3.2 A lifeline with safety belt is to be used for the man going on the roof.
4.3.3 No inspection, maintenance, gauging or sampling of tanks should be
undertaken unless any emergency during abnormal weather, thunder or hail
storms and insufficient illumination at the area.
4.3.4 Conductive footwear e.g. leather soles or electrically conducting rubber soles,
should be worn while gauging, sampling or taking temperatures. Nylon rope
shall not be used for lowering sample bottles in the tank.
4.3.5 Check for deck plate internal corrosion: For safety, before accessing the roof,
check with ultrasonic instrument or lightly use a ball peen hammer to test the
deck plate near the edge of the roof for thinning. Corrosion normally attacks the
deck plate at the edge of a fixed roof & at the rafters in the center of the roof
first. (API STD. 653, Tank Inspection, Repair, Alteration & Reconstruction -
Refer Section C 1.4).
4.3.6 Wherever the roof is found perforated /fragile by Inspection dept., a board
depicting “Fragile / perforated roof – Entry prohibited” to be displayed at the
approach staircase and access to such tank roof should be prohibited. However
177
the permit can be given in special circumstances like M&I job by the area
manager after ensuring that fall protection system along with suitable crawling
boards, roof ladders, guardrail for edge protection is in place.
In addition to above, the following precautions are to be ensured
before issuing permit: -
a. All covers for openings in roofs should be of substantial construction and be

secured in position.
b. Sufficient and suitable crawling boards or roof ladders should be provided

and firmly secured in position.
c. During extensive work on the roof, strong barriers or guardrails and toe-
boards should be provided to stop a person from falling off the roof.
d. Where works have to be carried out at or near the edge, a simple barrier
consisting of crossed scaffold tubes supporting a tubing guardrail may be
provided.
e. No walking shall be done on the roof plates where thinning/ perforations are
observed. Necessary planking may be provided for walking on such roofs a
minimum of two boards should be provided so that it is not necessary for a person
to stand on a fragile roof to move a board or a ladder, or for any other reason.
178
14.4 ACCIDENT REPORTING
Procedure:
With a view to timely transmission of the information or submission of the notice of the
accident to the inspector of Factories within the stipulated time prescribed under rule 103
of Gujarat Factories Rule, 1963 the following procedure has been followed by Gujarat
Refinery.
Any accident, however, small to an employee is reported to his supervisor / shift- in-
charge.
When the injured person is not in a position to report himself, such reports are made by
anybody present at the site of the accident. As soon as the supervisor gets the information,
he arranges for the ambulance from the hospital and also informs the following:
1. Fire station
2. Hospital
3. Sectional /Department head
4. Refinery Shift Manager.
The supervisor also fills the accident form no. A-1 in triplicate. The original copy of the form
is sent along with the injured to hospital. The medical officer on duty examine the injured
employee, if the nature of the injury is such that the injured person require rest for more
then 48 hours. A lost time accident report is prepared by the medical officer in the form A-II
and sent the same to fire and safety department. The medical officer indicates the
probable days of rest required by the injured person.
179
On receipt of the Medical Officer report, the personnel department informs the factory
inspector as required under the provisions of factories act 1948 and Gujarat factory rules
1963. After receiving from A-II from the fire and safety section in form no. 21. One copy is
sent to fire and safety section and third is retained by the personal department.
Medical Fitness Certificates: Form no. A-IIl
1. In a case the injured person is fit to resume duty immediately after first aid or after
taking rest for some time (before the end of the shift) he will be allowed to resume
the duty accordingly.
2. In case the injured person is likely to become disabled for 24 hrs. or more he shall
be marked as on “ Accident leave” and is allowed to join duty on production of
fitness certificate in form A-III to Fire & Safety section, Personal Department, Time
office and the concerned section. The medical officer concerned shall send the
copies of form A-III to the fire and safety department, Personnel department and the
concerned department. In case the employee has developed any permanent
disability the medical office assess the disablement of the injured person on form A-
IV and sends the report to Personal Department, Fire & Safety Section, Accounts
Department and the concerned section.
1. The Personnel Department, on receipt of the joining report of the injured person, the
recommendation of the Department Head and the report of the Medical Department
on form number A-IV, shall take action for the payment of leave wages and
compensation, if due, by issuing necessary memos to the Account Department.
180
FATAL INJURIES:
In case of fatal injury the statutory obligation requires that the situation when the accident
occurred, should remain as far as possible undisturbed till arrival of police. Therefore, with
the exemption of removing the casualty from the scene of accident this requirement is
strictly observed and following persons are immediately informed:
1. General Manager /Executive Director

2. Chief Medical Officer
3. Manager (Fire & Safety)
4. Chief Human Resources Manager.
Personal department immediately informs the relatives of the injured, Police and Inspector
of Factories.
Investigation report:
In case of any accident, whether minor or of lost time nature, the supervisor will arrange to
send an investigation report to the fire and safety department and the concerned
departmental head on form number A-V within 48 hours of the accident
181
14.5 FIRE AND SAFETY FACILITIES IN MTBE PLANT :
A. FIRE EXTINGUISHERS : 78 NOS

B. FIRE GLASS : 10 NOS
C. FIRE WATER MONITOR : 6 NOS
D. TOWER PLATFORM MONITOR: 4 NOS
E. WATER SPRINKLER IN PUMP: IN 17 NOS OF PUMPS
F. DELUGE SYSTEM : IN TANK NO 1103 AND 1104
G. HYDRO CARBON GAS DETECTOR : 4 NOS

(Infra red type)
(1) Near V-1 (2) Near methanol drains vessel (3) Near Reactor no 1
(4) Near Pump no P-7B
H. SAFETY SHOWER AND EYE WASHER: 4 NOS (ISBL) + 1 NO (Methanol transfer
pump house).
182

SECTION – 15
ANNEXURES
EQUIPMENT DATASHEET

183
15.1 EQUIPMENT DATA :
15.1.1 COLUMN DATA
COLUMN NO 1100 C-1 1100 C-2 1100 C-3

Service C3/C4 splitter Water wash column CD. Reaction column
I.D (m.m) 2100 1100 / 1300 1600 / 1400
Shell th (mm) 22 16 12
Total ht (mm) 30450 T/T 24200 T/T 58375 T/T
Empty wt (kg) 55610 15900 91680
Operating temp c 47.0 / 101.0 40.0 / 40.0 52-60 / 122-132
top/bott
Operating pr 17.3 / 17.8 12.5 / 14.7 5.8-6.7 / 6.5-7.4
kg/cm2g top/bott
Hyd.test pr kg/cm2 g 28.95 36.8 13.05
Design temp / pr 200.0 / 19.3 200.0 / 22.5 200 / 8.7
c / kg/cm2
Capacity m3 107.9 25.96 94.622
Insulation th mm 25 - 40 / 25
No of trays 50 2 packed beds 45 / 12 catalyst beds
Type of trays Float Valve 2” pall ring Float Valve
Type of flow 1-32 DF - SF
33-50 SF
Feed entry tray 33 Bottom 23
from bottom
Tray spacing mm 1-32 : 500 - 1-7 : 500
32-33 : 1200 7-23 : 450
33-34 : 34-50 : 23-24 : 1125
450 24-35 : 450
36-45 : 450
No of man-ways / dia 3 / 24” 3 / 20” 16 / 24”
184
COLUMN DATA
COLUMN NO 1100 C-4 1100 C-5 1100 C-6

Service Meoh ext. col Meoh column Light column
I.D (m.m) 1000 / 1200 1200 / 800 1300 / 1100
Shell th (mm) 18 10 10-20
Total ht (mm) 18200 T/T 21320 T/T 42800 T/T
Empty wt (kg) 11800 11800 40684
Operating temp c 40.0 / 40.0 86.0 / 132.0 61.0 / 82.0
top/bott
Operating pr 14.9 / 16.5 1.3 / 1.9 11.1 / 11.6
kg/cm2g top/bott
Hyd.test pr kg/cm2 g 39.4 11.932 19.8
Design temp / pr 200.0 / 25.0 200.0 / 6.5 200 / 13.2
c / kg/cm2
Capacity m3 14.257 14.26 53.0
Insulation th mm - 40 / 25 25
No of trays 2 packed beds 4 packed beds 68
Type of trays 2” pall ring 1” pall ring Float Valve
Type of flow - - SF
Feed entry tray Bottom Above two beds 44
from bottom
Tray spacing mm - - 1-21 : 500

21-22 : 1000
22-43 : 500
43-44 : 1600
44-45 : 1850
45-68 : 450
No of man-ways / dia 3 / 18” 1 (20”) + 4 (10”) 1 (20”) + 3(24”)
185
15.1.2 REACTOR DATA
REACTOR NO 1100 R-1 1100 R-2 1100 R-3A/B
Service Primary Reactor Primary Reactor Methanol Guard
No-1 No-2 Beds
Operating Fluid C4 HC +MEOH C4 HC +MEOH MEOH
Length 4700 4700 1700
mm
I.D 1500 1500 500
mm
Shell Thk 18 18 8
mm
Type of head Ellipsoidal (2:1) Ellipsoidal (2:1) Ellipsoidal (2:1)
Empty Wt 8380 8380 660
kg
Operating Pr. Top / Bott. 9.7-11 / 9.3-10.6 8.3-9.8 / 7.9-9.4 14.7 / 14.7
kg/cm2 g
Design Pr 21 21 21
kg/cm2 g
Hyd. Test Pr 31.5 31.5 31.5
kg/cm2 g
Operating Temp. Top / Bott. 40-65 / 68-86 50-65 / 52-72 40 / 40
C
Design Temp 230 230 200
C
Capacity 9.2 9.2 0.37
m3
Nozzle Dia. I / L 4 4 2
inch
Nozzle Dia. O / L 6 6 4
inch
No of Man-way / Dia. 3 / 24” 3 / 24”
Vent 2 2 3
inch
Hand hole 2 (6”) 2 (6”) 1 (8”)
Drain 2”
Catalyst Name Amberlyst-15(wet) Amberlyst-15 Amberlyst-15(wet)
186
(wet)
Catalyst Quantity 6050 6050 210
kg
Johnson screen slot size 0.15 0.15 0.15
mm
187
15.1.3 VESSEL DATA
VESSEL NO 1100 V-1 1100 V-2 1100 V-3 1100 V-4 1100 V-5 1100 V-6
SERVICE Feed surge Splitter o/h DM water Degasser Meoh CD col.
drum drum drum surge o/h drum
drum
Length (T-T) 6000 4700 2300 2400 2400 4100
mm
ID 2300 1500 900 800 1000 1500
mm
SHELL TH 20 20 6 8 10 12
mm
EMPTY WT kg 9300 5735 946 828 1650 3710
OPERATING 8.1 16.8 3.5 3.0 3.0 5.5
PR kg/cm2
DESIGN PR 12.0 19.3 8.0 5.0 7.0 8.7
kg/cm2
HYD TEST PR 18.0 28.95 12.4 7.5 10.5 13.05
kg/cm2
OPERATING 40 45.2 40 40 40 50
TEMP
c
DESIGN TEMP 200 200 70 70 200 200
c
CORROSION 3 3 0 3 3 3
ALLOW
mm
CAPACITY 27.29 9.2 1.609 1.34 2.15 8.3
m3
NOZZLE DIA. 4 6 / 8 2 2 2 6 / 8
I/L(MAIN)
inch
NOZZLE DIA. 6 6 2 2 2 6
O/L (MAIN)
inch
MAN-WAY 24 24 - - 18 24
DIA inch
VENT inch 2 2 2 - 2 2
LC-LG 2 (2”) 4 (2”) 2 (2”) 1 (2”) 2 (2”) 4 (2”)
DRAIN /BOOT 2” / - 2” / yes 2” / - - 2” / - 2” / yes
188
VESSEL DATA
VESSEL NO 1100 1100 1100 1100 1100 1100

V-7 V-8 V-9 V-10 V-11 V-12
SERVICE Meoh col. Light col. Meoh drain Flare KO CBD Cond. Pot
o/h drum o/h drum drum drum drum of E-6
Length (T-T) 2000 4300 4600 6800 3600 1500
mm
ID 900 1200 1700 2900 1200 500
mm
SHELL TH 8 14 12 16 10 8
mm
EMPTY WT kg 1050 3035 4760 13234 2875 580
OPERATING 1.0 10.9 1.75 0,3 1.75 9.0
PR kg/cm2
DESIGN PR 6.5 13.2 6.5 6.5 6.5 12
kg/cm2
HYD TEST PR 9.75 19.8 9.75 9.75 9.75 18
kg/cm2
OPERATING 74 53 40 40 40 230
TEMP
c
DESIGN TEMP 200 200 200 200 200 300
c
CORROSION 3 3 3 3 3 3
ALLOW
mm
CAPACITY 1.71 5.33 11.77 51.45 4.54 0.32
m3
NOZZLE DIA. 2 / 4 4 6 16 6 2
I/L (MAIN) inch
NOZZLE DIA. 3 4 Pump 4 / 14 Pump 2
O/L (MAIN) mount (vap) mount
inch
MAN-WAY 18 20 18 18 18 -
DIA inch
VENT inch - 2 - 2 - 2
LC-LG 2 (2”) 4 (2”)
DRAIN /BOOT 2” / - 2” / yes 2” / yes 2” / - 2” / yes - / -
189
VESSEL DATA
VESSEL NO 1100 V-13 1100 V-14 1100 V-16 1100 V-17 1100 V-18
SERVICE Cond. Pot Cond. pot MP cond LP cond C4 coalescer
of E-9 of E-15 pot pot drum
Length (T-T) mm 1100 1100 2600 3200 3000
ID mm 350 350 1700 1700 1800
SHELL TH mm 6 6 16 10 20
EMPTY WT kg 390 407 3200 2160 6930
OPERATING PR 9 9 4 ATM 12.5
kg/cm2
DESIGN PR 12 12 12 5 22.5
kg/cm2
HYD TEST PR 18 18 18 7.5 33.75
kg/cm2
OPERATING 230 230 151 100 40
TEMP c
DESIGN TEMP 300 300 300 200 200
c
CORROSION 3 3 3 3 3
ALLOW mm
CAPACITY m3 0.118 0.118 7.2 8.57 9.0
NOZZLE DIA. I/L 2 2 4 8/4/6 4
(MAIN) inch
NOZZLE DIA. O/L 2 2 4 6 4
(MAIN) inch
MAN-WAY DIA - - 18 18 2 (24”)
inch
VENT 2 2 2 2 2
LC-LG 2 (2”) 2 (2”) 2 (2”) 2 (2”) 4 (2”)
DRAIN /BOOT - / - - / - - / - - / - 2 (2”)/ -
190
15.1.4 EXCHANGER DATA
EXCHANGER NO 1100 E-1 1100 E-2 1100 E-3

Type BEM (ver) AES (hor) AEM (hor)
ervice Splitter Reboiler Splitter C3 Product
Condenser Cooler
Fluid shell / tube LP steam C3 HC / CW C3 HC / CW
/C4 HC
No.of pass shell / tube 1 / 1 1 / 6 1 / 6
Shell dia-ID / th mm 787 / 22 1372 / 32 307 / 20
Surface area m2 114.7 896.6 10.6
No of tubes / length mm 495 / 3000 2540 / 6100 60 / 3000
Tube dia-OD / th mm 25.4 / 2.1 19.05 / 1.65 19.05 / 1.65
Tube pitch mm 31.75  23.81  23.81 
Shell nozzle in / out inch 8 / 3 10 / 6 3 / 3
Tube nozzle in / out inch 14 / 10 12 / 12 2 / 2
Operating pr shell / tube 1.8 / 17.8 17.3 / 3.5 19.0 / 3.5
kg/cm2 g
Hyd pr shell / tube 26.7 / 29.7 28.95 / 25.95 37.5 / 28.5
kg/cm2 g
Shell in / out temp c 130 / 130 47.3 / 45.2 45.2 / 40
Tube in / out temp c 101.8 / 102.3 33 / 43 33 / 38
Heat Duty million kcal/hr 3.6 3.1 0.42
Fouling Resistance S / T hr 0.0001 / 0.0002 0.0002 /0.0004 0.0002 / 0.0004
m2 c / kcal
Allow. Pr drop S / T kg/cm2 g 0.1 / 0.179 0.35 / 0.5 0.5 / 0.5
MTD corrected c 26.9 7.5 6.4
Baffles type Single seg /hor Single seg /ver Single seg/hor
 Nos/ % cut / th mm 4 / 41 / 10 9 / 26 / 13 36 / 25 / 3
 Spacing mm 610 594 75
Exchanger Materials S / T CS / CS CS / CS CS / CS
191
EXCHANGER DATA
EXCHANGER NO 1100 E-4 1100 E-5 1100 E-6

Type AEM (hor) AEM (hor) BEM (hor)
Service C3-C4 Feed / Water Wash R-1 Feed Heater
Bott Exchanger
Fluid shell / tube C3-C4 HC / C4 C4 HC / CW MP Steam /
HC C4 HC+Meoh
Shell dia-ID / th mm 386 / 20 488 / 20 205 / 20
Surface area m2 30.3 48.5 4.2
Tube dia-OD / th mm 19.05 / 1.65 19.05 / 1.65 19.05 / 1.65
Tube pitch mm 23.81  23.81  23.81 
Operating pr shell / tube 20 / 17.8 17.3 / 3.5 8.8 / 12.3
kg/cm2 g
Hyd pr shell / tube 33 / 9.75 28.95 / 25.95 18.45 / 31.5
kg/cm2 g
Shell in / out temp c 40.8 / 63.6 66.6 / 40.0 230.0 / 178.0
Tube in / out temp c 102.1 / 66.6 33 / 40 40.1 / 65
m2 c / kcal
Baffles type Single seg / hor Single seg/hor Single seg/ver
 Nos/ % cut / th mm 22 / 25 / 5 44 / 25 / 5 5 / 25 / 3
 Spacing mm 112 50 250
192
EXCHANGER DATA
EXCHANGER NO 1100 E-7 1100 E-8 1100 E-9

Type AES (hor) AES (hor) BEM (ver)
Service R-2 Feed Cooler CD Col Feed / CD Col
Bot Exchanger Reboiler
Fluid shell / tube R-1 Effl / CW HC+Meoh+ MP Steam/C4
MTBE /MTBE HC+MTBE
Shell dia-ID / th mm 387 / 20 307 / 20 635 / 19
Surface area m2 49 15.9 73
Tube dia-OD / th mm 19.05 / 1.65 19.05 / 1.65 25.4 / 2.1
Tube pitch mm 25.4  25.4  31.75 
kg/cm2 g
Hyd pr shell / tube 31.5 / 21.0 17.1 / 14.1 18.0 / 15.0
kg/cm2 g
Shell in / out temp c 82.5 / 50 70.2 / 78.5 170 / 170
Tube in / out temp c 33 / 45 132.2 / 81 128.8 / 130.7
m2 c / kcal
MTD corrected c 26 22.1 38.9
Baffles type Single seg / ver Single seg / ver Single seg/hor
 Nos/ % cut / th mm 18 / 31 / 5 21 / 30 / 3 7 / 46 / 6
 Spacing mm 300 263 400
193
EXCHANGER DATA
EXCHANGER NO 1100 E-10 1100 E-11 1100 E-12

Type AES (hor) AEM (hor) AEM (hor)
Service CD Col O/H MTBE R/D Ext Col Feed
Condenser Cooler Cooler
Fluid shell / tube HC+Meoh / CW MTBE / CW HC+Meoh / CW
Shell dia-ID / th mm 1118 / 26 307 / 20 386 / 20
Surface area m2 521.1 16.2 28.2
Tube dia-OD / th mm 19.05 / 1.65 19.05 / 1.65 19.05 / 1.65
Tube pitch mm 25.4  23.81  23.81 
kg/cm2 g
Hyd pr shell / tube 14.55 / 10.5 13.35 / 10.5 37.5 / 28.2
kg/cm2 g
Shell in / out temp c 55.6 / 49.6 81 / 40 55.5 / 40
Tube in / out temp c 33 / 45 33 / 38 33 / 38
m2 c / kcal
Baffles type Double seg / ver Single seg/ hor Single seg/hor
 Nos/ % cut / th mm 9 / 27 / 13 50 / 25 / 3 50 / 25 /5
 Spacing mm 600 50 50
194
EXCHANGER DATA
EXCHANGER NO 1100 E-13 1100 E-14 1100 E-15

Type AEM (hor) DOUBLE PIPE BEM (ver)
(hor)
Service Recycle Water Meoh Col Meoh Col
Cooler Feed-Bot Exch Reboiler
Fluid shell / tube Recycle Water Water+Meoh MP Steam /
/ CW / Recy Water Meoh+Water
Shell dia-ID / th mm 257 / 20 2”NPS / SCH- 305 / 16
80
Tube dia-OD / th mm 19.05 / 1.65 1”NPS / SCH- 25.4 / 2.1
80
Tube pitch mm 23.81  - 31.75 
kg/cm2 g
Hyd pr shell / tube 37.5 / 27.6 28.5 / 37.5 18 / 13.5
kg/cm2 g
Shell in / out temp c 88.1 / 40 40 / 78 178.1 / 178.1
Tube in / out temp c 33 / 40 132.1 / 88.1 131.7 / 132.1
Fouling Resistance S / T hr 0.0002 / 0.0004 0.0002/0.0002 0.0001 / 0.0002
m2 c / kcal
Baffles type Single seg / hor - Single seg/hor
 Nos/ % cut / th mm 54 / 25 /3 - 5 / 40 / 6
 Spacing mm 50 - 600
195
EXCHANGER DATA
EXCHANGER NO 1100 E-16 1100 E-17 1100 E-18

Type AES (hor) Double Pipe AEM (hor)
(hor)
Service Meoh Col Recycle Meoh Lt. Col Feed / Bot.
Condenser Cooler Exch
Fluid shell / tube Meoh / CW Meoh / CW C4 HC / C4 HC
Shell dia-ID / th mm 340 / 20 1.5” NPS / 386 / 20
SCH 80
Tube dia-OD / th mm 19.05 / 1.65 1” NPS / SCH 19.05 / 1.65
80
Tube pitch mm 23.81  - 23.81 
kg/cm2 g
Hyd pr shell / tube 9.75 / 10.5 12 / 10.5 22.8 / 20.4
kg/cm2 g
Shell in / out temp c 86.2 / 73.5 73.5 / 40 40 / 62
Tube in / out temp c 33 / 45 33 / 40 83 / 62
Fouling Resistance S / T hr 0.0002 / 0.0004 0.0002/ 0.0004 0.0002 / 0.0002
m2 c / kcal
Baffles type Single seg / ver - Single seg/ ver
 Nos/ % cut / th mm 12 / 32 / 5 - 34 / 25 / 5
 Spacing mm 370 - 75
196
EXCHANGER DATA
EXCHANGER NO 1100 E-19 1100 E-20 1100 E-21

Type AEM (hor) BEM (ver) AES (hor)
Service C4 Product Lt. Col Reboiler Lt. Col Condenser
Cooler
Fluid shell / tube C4 HC / CW LP Steam / C4 HC / CW
C4 HC
Shell dia-ID / th mm 488 / 20 489 / 19 610 / 20
Surface area m2 46.4 41.2 154.7
Tube dia-OD / th mm 19.05 / 1.65 25.4 / 2.1 19.05 / 1.65
Tube pitch mm 23.81  31.75  23.81 
kg/cm2 g
Hyd pr shell / tube 31.5 / 25.35 18.0 / 20.4 19.65 / 16.65
kg/cm2 g
Shell in / out temp c 62 / 40 119 / 119 61.4 / 53.3
Tube in / out temp c 33 / 40 82.6 / 82.7 33 / 45
Fouling Resistance S / T hr 0.0002 / 0.0004 0.0001/ 0.0002 0.0002 / 0.0004
m2 c / kcal
Baffles type Single seg / hor Single seg /hor Single seg/ver
 Nos/ % cut / th mm 50 / 25 / 5 4 / 38 / 10 8 / 31 / 10
 Spacing mm 50 610 666.5
197
15.1.5 PUMP DATA
ALL ARE CENTRIFUGAL PUMPS
PUMP NO 1100 P-1 A/B 1100 P-2 A/B 1100 P-3 A/B 1100 P-4 A/B
Service Splitter Feed Splitter Reflux DM Water Pump MEOH Feed
Pump Pump Pump
Maker KEPL IRL KEPL KEPL
Type Horizontal Horizontal Horizontal Horizontal
100*80R2M40 3HP*13A 80*50UCWM35 80*50R2M33
No of Stages 2 1 1 2
Pumping Temp c 40 45.2 40 40
Sp.Gr.at P-T 0.523 0.461 0.989 0.775
Suc Pr / Disch Pr 9.3 / 22.5 17.7 / 22.2 4.4 / 19.7 3.94 / 18.2
Kg/cm2 ab
Differential Head m 254 97.6 154.9 183.8
NPSH Avail / Req m 4.25 / 3.59 2.8 / 2.4 44 / 3.05 40.5 / 3.155
Design Capacity 50 / 59 / 77 57 / 80 / 115 - / 6 / 12 - / 3 / 8
min / nor / max m3/hr
Min Cont Flow m3/hr 50 - 11 7
Impeller Dia. mm 348 292 351 304
Seal Mech Seal (D) Mech Seal Mech Seal Mech Seal
Lube Oil : Grade Servo S- 46 Servo Prime 32 Servo S- 46 Servo S- 46
Max. Allow. Bearing Temp 80C 80C 80C 80C
Rated Motor Cap. KW 110 30 37 30
Motor RPM 2975 2935 2950 2935
Volt / Phase / Cycle 415 / 3 / 50 415 / 3 / 50 415 / 3 / 50 415 / 3 / 50
Full Load amps 184 62 50
Decoupled Motor Load 35.7 / 35.4 10.62 / 10.8 14.2 / 14.85 9.8 / 10.2
amps
KEPL : Kirloskar Ebara Pumps Limited. K.B : Kirloskar Brothers. I.R.L : Ingersoll Rand
(India) Limited
198
PUMP DATA
PUMP NO 1100 P-5 A/B 1100 P-6 A/B 1100 P-7 A/B 1100 P-8 A/B
Service CD Col Reflux Meoh Col Meoh Col Pump Lights Col
Pump Bottom Pump Reflux Pump
Maker KEPL KEPL IRL IRL
Type Horizontal Horizontal Horizontal Horizontal
100*80R2M40 80*50R2M33 1HP*11A 1.5HP*12A
Pumping Temp c 46 131 78 53
Sp.Gr.at P-T 0.555 0.934 0.733 0.494
Suc Pr / Disch Pr 6.2 / 21.9 3.3 / 20.9 2.4 / 8.7 11.9 / 16.6
Kg/cm2 ab
Differential Head 282 188.4 85.5 95.1
m
NPSH Avail / Req 4.3 / 3.84 3.9 / 2.955 3.65 / 2.25 3.01 / 2
m
Design Capacity 35.4 / 60 / 86.4 1.5 / 2.5 /.55 1.7 / 3 / 4.2 - / 28.4 / 34.1
min / nor / max
m3/hr
Min Cont Flow 32 7
m3/hr
Impeller Dia. 319 / 368 308 253 274
mm
Seal Mech Seal (D) Mech Seal Mech Seal Mech Seal
Lube Oil : Grade Servo S- 46 Servo S- 46 Servo Prime 32 Servo Prime 32
Max. Allow. Bearing 80C 80C 80C 80C
Temp.
Rated Motor Cap. 90 30 7.5 15
KW
Motor RPM 2970 2935 2885 2920
Volt / Phase / Cycle 415 / 3 / 50 415 / 3 / 50 415 / 3 / 50 415 / 3 / 50
Full Load 151 50
amps
Decoupled Motor Load 42.4 / 42.2 9.75 / 9.3 2.22 / 2.12 5.54 / 4.95
amps
199
(India) Limited
PUMP DATA
PUMP NO 1100 P-9 A/B 1100 P-10 1100 P-11 1100 P-12
Service Lt. Col Bottom Meoh Drain Flare KO Drain CBD Pump
Pump Pump pump
Maker IRL KB KEPL KB
Type Horizontal Vertical Horizontal Vertical
1.5HP*13A Submerge 80*50UCWM35 Submerge
Pumping Temp c 53 40 40 40
Sp.Gr.at P-T 0.599 0.755 0.750 0.750
Suc Pr / Disch Pr 12.4 / 18.6 1.6 / 7.1 1.6 / 12.5 1.1 / 4.5
Kg/cm2 ab
Differential Head m 114.5 72.4 145.7 43
NPSH Avail / Req m 65.6 / 1.68 10.3 / - 4.5 / 3.055 4.0 / -
Design Capacity 15 / 25 / 33 - / 4.5 / 4.5 - / 12 / 12 - / 6 / 6
Min Cont Flow m3/hr 3.84 11 2.64
Impeller Dia. mm 298 - 342 -
Seal Mech Seal Balanced Mech Seal Balanced
Lube Oil : Grade Servo Prime 32 Not Req. Servo S-46 Not Req.
Max. Allow. Bearing Temp. 80C 80C 80 80C
Rated Motor Cap. KW 18.5 9.3 30 3.7
Motor RPM 2925 2935 2935 2935
Volt / Phase / Cycle 415 / 3 / 50 415 / 3 / 50 415 / 3 / 50 415 / 3 / 50
Full Load amps 32 16.5 50 16.5
Decoupled Motor Load 8.45 / 7.5 4.52 10.1 2.8
amps
(India) Limited
200
PUMP DATA
ALL ARE CENTRIFUGAL PUMPS EXCEPT P-15
PUMP NO 1100 P-13A/B 1100 P-14A/B 1100 P-15

Service Meoh Transfer Condensate Amine Dosing
Pump Pump Pump
Maker KEPL IRL SEPL
Horizontal Horizontal Horizontal Horizontal
50*40UCWM25 1.5HP*12A Positive disp.
No of Stages 1 1 -
Pumping Temp c 40 100 25
Sp.Gr.at P-T 0.775 0.980 1.010
Suc Pr / Disch Pr 0.8 / 6.3 1.6 / 8.7 0.01 / 11.89
Kg/cm2 ab
Differential Head m 71 72.3 -
NPSH Avail / Req m 4.4 / 3.055 2.03 / 1.52 10 / 2.5
Design Capacity - / 3 / 6 - / 19 / 24 120 LPH
Min Cont Flow m3/hr 5
Impeller Dia. mm 248 242 -
Seal Mech Seal (D) Mech Seal Gland
Lube Oil : Grade Servo S- 46 Servo Prime 32 Enklo 320
Max. Allow. Bearing Temp. 80 C 80 C 80 C
Rated Motor Cap. KW 7.5 18.5 0.37
Motor RPM 2885 2925 1395
Volt / Phase / Cycle 415 / 3 / 50 415 / 3 / 50 415 / 3 / 50
Full Load amps 12 32 1.1
Decoupled Motor Load, 2.28 / 2.3 8.35 / 8.4 0.52
amps
(India) Limited SEPL :Swelore Engineering Pvt Ltd
201
15.2 MTBE PLANT - SAMPLE SCHEDULE
SL.NO LOCATION STREAM FREQUENCY TEST

1 C-1 feed H/C C3/C4 H/C Once Daily. Component Analysis
Time: 07-00 hr. (G.C)
2 C-1 bottom H/C C4 H/C Once daily. - DO -
Time: 07-00 hr.
3 C-2 top C4 H/C Once in a week.  Acetonitrile ppm
Time: 07-00 hr.  Water %
4 Methanol feed (V-5) Methanol As per requirement  Water %
Time: 07-00 hr.  Methanol %
5 V-4 Waste water Water As per requirement PH, H/C ppm
Time: 07-00 hr. COD, Acetonitrile ppm
6 C-5 top methanol Methanol Once daily.  Water %
Time: 07-00 hr.  Methanol %
7 C-5 bottom methanol Methanol - DO - - DO -
8 MTBE R/D MTBE - DO -  Component Analysis
 Methanol %
SAMPLE POINTS
202
POINT NO. TAG NO. SERVICE LOCATION
1 SC-1401 C-6 BOTTOM BETWEEN P-1A & E-19
2 SC-102 C-1FEED BETWEEN P-1B & E-1
3 SC-501 V-5 OUTLET NEAR P-4B
4 SC-601 R-3A/B MEOH OUTLET NEAR R-3A
5 SC-701 G-1A/B H/C OUTLET NEAR G-1A
6 SC-702 R-1 OUTLET NEAR E-7
7 SC-801 R-2 OUTLET BELOW R-2
8 SC-802 MTBE R/D BETWEEN E-11
&ANALYSER
9 SC-1001 V-6 OUTLET NEAR C-3 & P-5A/B
10 SC-1301 V-7 O/L (C-5 TOP) NEAR C-5 & E-17
11 SC-1103 C-4 BOTTOM MEOH NEAR E-14
12 SC-1601 V-8 FUEL GAS 1ST FLOOR BETWEEN V-8
&V-6
13 SC-1501 C-6 MIDDLE 2ND FLOOR BETWEEN V-8
& C-6
14 SC-901 EX TRAY NO 27 C-3 REBOILER E-9
15 SC-902 EX TRAY NO 18 NEAR C-3 BETWEEN TWO
POLES
16 SC-903 EX TRAY NO 12 NEAR C-3 & FV-904
17 SC-904 EX TRAY NO 5 NEAR P-15
18 SC 101 WASH WATER P-3A/B DISCHARGE
19 SC-401 WASH WATER V-4 BOTTOM EX C/V
20 SC-1101 EXTRACTION COLUMN NEAR PV-1104
O/H
21 SC-1102 METHANOL COLUMN E-13 OUTLET
BOTTOM
203
15.3 Equipment drain line dechocking procedure
1. Ensure the first block valve from the equipment is closed.
2. Heat the line with steam lancers from drain point to first block valve, in case of heavy oil.
3. Connect LP/MP steam hose at drain point, provided the equipment pressure is less than LP/MP
steam header pressure. Ensure proper hose connection (flange / clamp type) to avoid removal
of hose during pressurization by steam.
4. Open the first block valve from the equipment and pressurize with steam for dechocking.
Ensure positioning of manpower at both locations (i.e. near equipment and steam charging
point). Confirm dechocking of drain line by touching the equipment valve / line.
5. In case the above procedures fail, isolate the equipment, pump out the material from the
equipment to maximum possible extent (till the pump looses suction) and depressurize. Ensure
no fresh material is entered into the equipment. Hand over the equipment to Maintenance for
dechocking the line.
6. Ensure proper PPE is used during decoking operation.
7. Risk assessment to be done by shift officer & maintenance engineer before executing the
dechocking activity.
204
15.4 Modifications during MTBE M&I shutdown (April 2012)
Following modifications were done during M&I shutdown held during April 2012
1. Installation of MOV at C-6 column bottom
MOV 1508 has been installed at C-6 column bottom line to exchanger E-18. It has been linked
with C-6 column bottom pumps P-9A/B. In case of pump seal failure, nobody can access the
pump house because of HC cloud. In order avoid this situation MOV has been installed. When
we close MOV, pump will automatically get closed. This MOV can be operated from control
panel. Local switch is also provided out side pump house from where it can be opened or
closed.
2. Installation of SDV at V-2 vessel boot drain line
Accumulation of water has been observed in V-2 (C-1 column overhead vessel) frequently
which needs to be drained. Earlier there were 2 B/Vs on drain line. In case of failure of both of
the block valves spillage of HC (LPG) is certain. In that situation LPG cloud will get formed and
it will continue to form until V-2 vessel gets emptied. Now SDV 11HS311 has been installed at
V-2 vessel boot drain line at upstream of 2 block valves. It can be operated from control panel.
Now if block valves get failed we can close SDV from control panel avoiding any further
unwanted situation.
205

SECTION – 16
TASK TO BE DONE BY OPERATORS

TASK TO BE DONE BY OPERATORS
16.1.0 INTRODUCTION
206
These work instruction shall be followed by the operating personnel of MTBE plant for carrying out
various activities during normal operation of the plant. Additional instruction as and when required shall
be given by DMPN/PNM.
16.2.0 DESCRIPTION
All operating parameters shall be closely monitor and controlled by the panel operator so as to achieve
and maintain product qualities as given in SEQ/PN(GR-II)/WI/7.5.1/37. For this purpose, he shall work
in co-ordination with field & off site operators as per instruction of shift in-charge.
16.3.0 JOBS TO BE DONE BY OPERATORS
Pump and Off-site Operator
 Check healthiness of running pump like the following:
Observation Action
Low LO level on oil cup Make up. Ensure oil level in bearing.
LO color / contaminated with water / Drain & replace it. Inform S/I or
product maintenance
Inform PNE for attending the same by
LO leak from cup / bearing housing
maintenance
Inform S/I. If abnormally high, C/O the
Vibration / high bearing temperature
pump & inform S/I.
Suction/discharge PGs not functioning Inform S/I for attending it by maintenance
Suction pressure low& pump load not
C/O pump, after informing to S/I
increasing
Bearing CW flow low Inform S/I for attending it by maintenance
Throttle discharge after consulting panel
High amperage of pump
operator
Uneven amperage of pumps running in
Adjust load by adjusting discharge valve
parallel
Seal flush cooler of hot pump leaking / CW
Inform S/I for attending it by maintenance
line chocked
 If leak is more, immediately C/O
the pump
Seal flush cooler-pherulle leak
 If leak is less, report to PNE for
attending it.
Inform S/I for attending it by
Leakage from pump gland / seal maintenance. Keep steam lancer if
required
Immediately C/O the pump & isolate the
Heavy leakage from pump gland / seal leaky one. Inform S/I & take the help of
others.
Seal quenching steam for hot pump is low /
Adjust the quenching steam flow rate
high
Leak from suction and discharge flanges / Keep steam lancer & inform S/I for
207
valve gland etc attending it by maintenance
Coupling guard is not properly fixed Inform S/I for attending it by maintenance
Abnormal sound from pump/motor Inform S/I for attending it by maintenance
Poor illumination in pump house Inform S/I for attending it by maintenance
Earthing of motor is not proper Inform S/I for attending it by maintenance
Seal quenching steam b/v gland leak Inform S/I for attending it by maintenance
As per procedure, laid down in the
Unit Start up/Shut down
operating manual
As per procedure, laid down in the
Emergency Handling
operating manual
Damaged / leaky hot water pot & water
Inform S/I for attending it by maintenance
hose to clean pump house
Check readiness of stand by pump in respect to proper line up (In case multi-service
pump), Proper warm up, shaft rotation, bearing CW flow, lube oil quality and seal
quenching steam flow is normal.
Periodically drain out water from stand by pump for cold service.
Schedule change over of pumps.
Collection of routine & non-routine samples.
Checking of any hydrocarbon leaks in the plant
Taking the dip of tanks 4 hourly and making necessary change over of
feeding/receiving tanks as per the advice of panel operator or shift in-charge and
record the same in the dip register.
Other job as & when asked by shift in-charge.
Methanol is received in OM&S tanks 1101 and 1102. Pump operator shall
communicate with OM&S and receive methanol from OM&S to tanks 1103 & 1104 in
MTBE unit.
Logging of abnormalities and filling of pump house log book
During energisation and de-energisation of motor, motor to be checked by switching
ON along with S/S technician and subsequently TAGGING to be done.
While getting pump strainers and seal flush coolers cleaned, complete isolation and
depressurization to ensured, and operator not to leave work place till completion of
job
Other jobs as and when asked by Shift In charge.

Panel Operator
Observation/Task Action
Receiving of LPG in V-1 1. Panel operator shall communicate with
field operator to line up control valve in
the field. He shall communicate with
FCC/LPG merox to line up LPG rundown
towards MTBE
Receiving of Methanol in V-5 1. Panel operator shall communicate with

field operator to line up control valve in
the field.
2. He shall communicate with pump operator
to run pumps P-13A/B to transfer
methanol from tanks 1103 and 1104 to V-
5
C-3/C-4 fractionation section Following operating parameters shall be
208
maintained by panel operator unless otherwise
instructed by shift in-charge/PNM/CPNM
Top temperature : 47-55C

Bottom temperature :101C
Top pressure : 16.6 kg/cm2
To maintain 1 wt% of total C3 in the bottom

product and 1 wt% of C4 and heavier in C3
product panel operator may adjust the
parameters which may vary from the above
given figures depending on the feed
composition.
He shall get water in V2 boot drained by field

operator when ever level in the boot is
observed.
Feed water wash system Following parameters shall be maintained by
Panel operator unless otherwise instructed by
shift in-charge/DMPN/PNM.
Top temperature : 40C

Top pressure : 12.5 kg/cm2
DM water shall be adjusted so that temperature

is not more than 40C and flow is not less
than 20% of c4 feed otherwise it will
adversely impact the efficiency of aceto-
nitrile removal and increase hydrocarbon
losses in effluent water.
Reactor R-1 Following parameters shall be maintain by

panel operator seeing ratio control of two
streams (washed C4 stream & METHANOL
stream)
Methanol/IB ratio to be maintained at 1.0

to 1.2 as per requirement
SOR EOR
R-1 I/L temperature 40 65
R-1 O/L temperature 72 84
For maintaining R-1 inlet temp heater 1100-E-
6 shall be utilized.
Reactor R-2 Following parameters shall be maintain by
panel operator
SOR EOR
209
R-2 I/L temperature 50 65
R-2 O/L temperature 53 70
For maintaining R-2 inlet temp cooler 1100-E-7
shall be utilized.
CD reaction column Following parameters shall be maintain by
panel operator
SOR EOR
Top temp deg c 50 80
Top pressure kg/cm2 5.6 6.7
Feed temp 23rd tray 67 78
Bottom temp 125 132
High reaction temp favors production of DI
ISOBUTENE (DIB) and DI-METHYLE ETHER
(DME) and water. Increased water content
contributes to higher TERTIARY BUTYL
ALCOHAL (TBA). Panel operator shall
reduce reaction temp to bring down TBA if
Lab analysis of product shows presence of
above component.
V6 boot shall be drain by field operator
whenever level is observed in V6 boot.
Methanol recovery section Following parameters shall be maintained by

(Extraction column C-4) panel operator unless otherwise instructed by
Shift in charge/ PNM/CPNM.
TOP PRESSURE (KG/cm2g) 14.5

INTERPHASE LEVEL 70%
Methanol recovery section (Methanol Following parameters shall be maintained by

column C-5) panel operator unless otherwise instructed by
Shift in charge/PNM/CPNM.
TOP PRESSURE (KG/cm2g)

1.3(MAX.)
TOP TEMP DEG C 88
BOT.TEMP DEG C 131
C-5 bottom water is to be drained periodically

by field operator co-ordinating with panel
operator.
Lights removal section (C-6) Following parameters shall be maintained by

panel operator unless otherwise instructed by
Shift in charge/PNM/CPNM.
210
TOP PRESSURE (KG/cm2g) 11.2
TOP TEMP DEG C 62
BOT.TEMP DEG C 85
Data preparation Daily material balance and utility balance sheet
to be prepared as specified, The same to
be communicated to PNM/RSM/CPNM
Logging of parameters Unit parameters are to be logged regularly and
any abnormal changes to be conveyed to S/I.
Monitoring of abnormality of rotating Any alarm of high vibration of any rotary
equipments equipment , High seal pot pressure of pump
appears on DCS, pump/field and S/I to be
alerted
DCS system Any DCS/PLC system alarm appears S/I and
concern ITE to be alerted
Gas detectors If any gas detector alarm appears, concern area
operator and S/I to be alerted
Pump change over Total attention t be given to concern
parameters while getting pump change over
done
Exchanger hand over/take over Clearance to be given for take over& hand over
after adjusting the parameters(if required).
Abnormal change in any other parameter to be
reported to S/I
Field Operator
Sl.No Observation / Task Action

1. Water level in column over head Drain water. (Do not leave the place till
accumulator drum. draining is over)
2. LPG rundown temperature & pressure If any gauge is not working, inform to S/I.
to log.
3. Inlet / outlet TG / PG of heat exchanger / Inform S/I to attend it by maintenance
cooler / condenser not working
4. Heat exchanger / cooler bypass valves Close the bypass valve after consulting
are open S/I
5. Heat exchanger and coolers As per procedure/checklist, heat
commissioning/decommissioning exchangers/coolers are to be
commissioned/decommissioned
6. Leak from floating head cover / flanges / Keep steam lancer & inform S/I to attend it
block valve flange/gland by maintenance
7. Excessive leak in heat exchanger Take assistance of others and
bypass/isolate the heat exchanger.
8. Abnormal change in HE inlet / outlet Inform to S/I
temperature
9. Abnormal change in HE pressure drop. Inform to S/I.
10. Over head reflux drum pressure high Divert PCV outlet to flare by coordinating
with panel operator.
11. Any leak vessel & its piping, valves Inform S/I to attend it by maintenance
12. PSV passing Take stand by PSV inline. Isolate the
passing PSV. Inform S/I to attend it
211
13. Liquid level in Flare KOD  Inform to panel operator
 Drain out liquid in CBD.
 If draining in OWS, Keep running
water on it.
14. Defective pressure/temperature gauge  Inform S/I to replace it.
15. Check proper tracing steam flow in Pre-  Inform S/I to attend if not sufficient.
fractionators & main fractionators level
instrument
16. Unit Start up/Shut down  As per procedure/check list, laid down
in the operating manual
17. Emergency Handling  As per procedure/check list, laid down
in the operating manual
 As directed by panel operator / shift in-
charge
18. Any hydrocarbon leaks in the plant  Inform to S/I
 Keep a steam lancer at the location, if
required
19. Product / feed / gas sampling A per procedure product / feed / gas
sampling to be carried out
20. Other job As & when asked by shift in-charge.
212

SECTION – 17
ANNEXURES

213
ANNEXURE: 1
Procedure for dechocking of equipment drain line
8. Ensure the first block valve from the equipment is closed.
9. Heat the line with steam lancers from drain point to first block valve, in case of heavy
oil.
10. Connect LP/MP steam hose at drain point, provided the equipment pressure is less
than LP/MP steam header pressure. Ensure proper hose connection (flange / clamp
type) to avoid removal of hose during pressurization by steam.
11. Open the first block valve from the equipment and pressurize with steam for dechoking.
Ensure positioning of manpower at both locations (i.e. near equipment and steam
charging point). Confirm dechocking of drain line by touching the equipment valve / line.
12. In case the above procedures fail, isolate the equipment, pump out the material from
the equipment to maximum possible extent (till the pump looses suction) and
depressurize. Ensure no fresh material is entered into the equipment. Hand over the
equipment to Maintenance for dechoking the line.
13. Ensure proper PPE is used during decoking operation.
14. Risk assessment to be done by shift officer & maintenance engineer before executing
the dechoking activity.
214
ANNEXURE: 2
FLARE KOD DRUM / VESSEL DRAINING PROCEDURE
SR. DESCRIPTION STATUS Remarks

NO. Yes/No
1  Inform S/I, panel operator. Ensure
steam in coil inside drum is ON for
Flare KOD.
 Carry personal gas Detectors and

Walkie-Talkie
2  Get confirmation of the vessel level from

Panel
 Stand Up-stream of the Wind direction
 Follow the following procedure:
o Crack Open 2nd Isolation valve
o Crack Open Root Valve
o Close Root valve as soon as gas/
vapours are noticed
o Close the 2nd isolation valve
3  Drain to CBD. If draining is required to
be done in OWS, keep running water
hose on it.
4  Do not leave the place. In case of any

abnormality, stop draining and inform
Shift-In-Charge
5 After draining is over, isolate the drain valves.

Ensure that the valves are holding, leave the
place. Inform panel operator
Don’ts
 Don’t leave the drain valve open – unattended
 Don’t close the 2nd isolation valve before the root valve
 Don’t stand in the Downstream of the wind direction
 Don’t open the drain valve wide open
 Don’t deviate from the standard procedure for draining
 Don’t start draining if ‘hot job’ is in progress in the surrounding area.
215
ANNEXURE: 3
List of work instructions

Following work instructions mentioned in detail in SEQMS manual. Kindly do refer
SEQ /PN(GR-II)/R/4.2.4/1
NORMAL OPERATIONS OF CENTRIFUGAL PUMPS FOR GR-II

SEQ / PN (GR-II)/WI/7.5.1 / 2 UNITS
NORMAL OPERATIONS OF HEAT EXCHANGERS FOR GR-II UNITS

SEQ / PN (GR-II)/WI/7.5.1 / 3
NORMAL OPERATIONS OF COOLERS FOR GR-II UNITS
SEQ / PN (GR-II)/WI/7.5.1 / 4
NORMAL OPERATIONS OF CONDENSERS
SEQ / PN (GR-II)/WI/7.5.1 / 5
NORMAL OPERATION OF RECIPROCATING PUMPS FOR GR-II
SEQ / PN (GR-II)/WI/7.5.1 / 6 UNITS
NORMAL OPERATIONS OF IFO/VR PUMPS FOR GR-II UNITS

SEQ / PN (GR-II)/WI/7.5.1 / 7
NORMAL OPERATION OF REFLUX DRUMS FOR GR-II UNITS
SEQ / PN (GR-II)/WI/7.5.1 / 8
NORMAL OPERATION OF FURNACES FOR GR-II UNITS
SEQ / PN (GR-II)/WI/7.5.1 / 9
NORMAL OPERATION OF CHEMICAL/SOLUTION/ WATER/IFO
SEQ / PN (GR-II)/WI/7.5.1 / 10 TANKS FOR GR-II UNITS
NORMAL ROUTING OF PRODUCTS FOR GR-II UNITS

SEQ / PN (GR-II)/WI/7.5.1 / 11
NORMAL OPERATION OF DESALTER IN AU-III
SEQ / PN (GR-II)/WI/7.5.1 / 12
NORMAL OPERATION OF FRACTIONATING COLUMNS IN AU-III
SEQ / PN (GR-II)/WI/7.5.1 / 13
SEQ / PN (GR-II)/WI/7.5.1 / 14 NORMAL OPERATION OF VR BURNING FACILITY IN AU III
QUALITY CONTROL OF AU III PRODUCTS

SEQ / PN (GR-II)/WI/7.5.1 / 15
PREPARATION OF CHEMICAL SOLUTION IN AU-III
SEQ / PN (GR-II)/WI/7.5.1 / 16
NORMAL OPERATION OF UDEX
SEQ / PN (GR-II)/WI/7.5.1 / 17
SEQ / PN (GR-II)/WI/7.5.1 / 18 NORMAL OPERATION OF FGH
SEQ / PN (GR-II)/WI/7.5.1 / 19 NORMAL OPERATION OF MTBE / BUTENE-I
216

SECTION – 17
DRAWINGS
NOTE: SOFT COPY OF DRAWINGS IS NOT AVAILABLE

217
218
219

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REV DATE DOC Rev By CHECKED APPROVED

In this revision of operating manual, chapter no.6 “Equipment standard operating

Date: 20/09/2013 (CPNM)

SNO DESCRIPTION Page no.

2 LIST OF EQUIPMENTS / CONTROL VALVES / PSVS 24

3.6 Methanol Extraction 36

4 OPERATING VARIABLES AND CONTROL 39

5 SAFETY IN CHEMICALS HANDLING 56

6 EQUIPMENTS - STANDARD OPERATING PROCEDURE 76

7 CATALYST LOADING / UNLOADING 88

7.1 Catalyst Loading in Reactor & Guard Beds 89

9 SHUT DOWN PROCEDURES 117

9.3 Automatic Shutdown & Interlock System 124

10 INSTRUMENTATION AND DCS 129

11 OFF SITE FACILITIES AND STORAGE TANKS 135

12 INTERLOCK SYSTEM 139

13 EQUIPMENTS HAND OVER TO MAINTENANCE / 146

14 FIRE FIGHTING / WORK PERMIT / 157

15.3 Equipment drain line dechocking procedure 204

DRG NO-26 LP Steam System

1.0 GENERAL INTRODUCTION

The process licensor for the unit is M/s. CATALYTIC DISTILLATIONS

The reaction of Isobutene and Methanol over a strong acidic catalyst

CH3 - C = CH2 + CH3 - OH CH3 - C - O - CH3

The reaction is reversible and exothermic; therefore, a lower reaction

Following is a summary of major side reactions:

Methanol + 1-Butene - Methyl Secondary Butyl Ether

Methanol in sub stoichiometric concentrations significantly increases the

1.3 PROCESS DESIGN BASIS

1.3.1 DESIGN PHILOSOPHY

The expected concentration of Isobutene in the hydrocarbon feed for both

Rate, kg/hr 11,213

The MTBE Unit utilizes a maximum Methanol concentration of 4% (wt) in the

The Water Wash Column has been designed to remove 50 ppmw,

Although non-condensable material is not envisaged, vents are provided

The Design Hydrocarbon Feed is as follows:

Component Wt% Wt%

Total 100 100

Impurity Ppmw max.

* Excluding acetonitrile and propionitrile.

The Methanol make-up to the unit is expected to be:

The Methanol feed is commercial grade Methanol meeting the specifications

1.3.3 PRODUCT SPECIFICATIONS

Rate, kg/hr 4,986 4,814

* By-products consist of Tert-Butyl Alcohol, (TBA) Di-Isobutene, (DIB)

Component Wt% Wt%

Oxygenates Wppm. max Wppm. Max

Rate, kg/hr 11,881 13,798

Note 1 - Isobutene content is 250/220 ppmw for Case 1/ Case 2 resp.

Rate, kg/hr 252 309

CATALYST SPECIFICATIONS AND CONSUMPTION

Catalyst for the Primary Reactor is purchased as 50% by weight in water.

The catalyst quantities required per charge are as follows:

Reactor No.1 / Reactor No. 2: Amberlyst-15 (wet) or equivalent 6,050 kg

1.4 MATERIAL BALANCE:

1.5 BATTERY LIMIT CONDITIONS

Temperature Pressure State

Min. Normal Max. Mech.

Cooling Supply press, 3.5 4.5 5.0 7.0

DM Water Press. Kg/cm²g 5.0 5.0 6.0 8.0

Plant Air Pressure, kg/cm²g 3.5 5.5 6.0 9.0

Nitrogen Pressure, kg/cm²g 3.0 4.0 6.0 9

Power Voltage 440V / 240 V