INDIAN OIL CORPORATION LIMITED

MATHURA REFINERY

OPERATING MANUAL

SULPHUR RECOVERY BLOCK

AMINE REGENERATION UNIT

(ARU)

(UPDATED : APR- 2009)

PREPARED BY REVIEWED BY APPROVED BY

Sh. V.P. Singh Sh. Siya Ram Sh. D. Thakur
PNM SPNM CPNM

SL. No. PARTICULARS PAGE No.

_________________________________________________
1.0 INTRODUCTION 6
1.1 General Introduction 7
1.2 Sulphur Block over view 8
2.0 Design Specification 9
2.1 Design Capacity 10
2.2 Turn down capacity 10
2.3 Stream hours 10
3.0 Feed and Product Analysis
3.1 Feed characteristics of New and OLD ARU 12
3.2 Product characteristics of New
and OLD ARU 13
3.3 H2S Rich Gas analysis 13
3.4 Battery limit condition 14
3.5 Utility specification 15-16
3.6 Chemical Consumption 17-20
4 EQUIPMENTS
4.1 Equipments lists 21-23
5 CHEMISTRY 24-28
6 PROCESS DESCRIPTION 29
6.1 Process Variables 30
6.2 New Amine Regeneration unit process
description 31-35
6.3 Amine Storage 36
6.4 Utilities 36
6.5 Process Description of OLD ARU 37-38
7 OPERATION OF UNIT 39
7.1 Flow Controllers 40
7.2 Pressure Controllers 40
7.3 Level Controllers 41
7.4 Temperature Controllers 41
7.5 Relief Valve System 41-42
8 UNIT START UP PREPARATION 44
8.1 Preparation and start up 45-46
8.2 Pre start up wash 46-47
 8.3 Elimination of Air 47-48
8.4 Fuel Gas back up 49
8.5 Preparation of MDEA Solution 49
8.6 Amine Charging, Circulation and heat up 49-55
8.7 Normal start up operation 55-66
9 AMINE SYSTEM DESCRIPTION 67
9.1 Amine Regeneration and lean Amine 68-72
filtration System
9.2 Amine Storage System 72-74
9.3 Amine Drain System 74-75
9.4 Critical Operating Parameters 76
10 SHUT DOWN 77-78
11 SAFE GUARDING 79
11.1 Cooling Water failure 80
11.2 Power failure 80
11.3 Amine Acid gas line failure 81
11.4 Sour gas line from SWS failure 81-82
11.5 Personnel safety 82
11.6 Precautions in plant operations 82
12 PLANT OPTIMISING 83
12.1 Plant optimising Guide lines 84-88
12.2 Plant Monitoring 88-90
12.3 List of PSV in NEW ARU 91
12.4 List of PSV in Revamp ARU 91

13 PROCESS MODIFICATION 92
13.1 Wash water injection facilities 94
13.2 Changeover of DEA with MDEA solvent 94
 CHAPTER - 1

1.0 INTRODUCTION
1.1 GENERAL INTRODUCTION

The purpose of this manual is to provide basic information for pre-

commissioning/commissioning and start-up of the Sulphur Block. The
general operational guidelines and procedures for normal operation and
emergency shutdown.

The overall process description and design basis outline the limitation of
the process equipment. The detailed description of the major equipment
enable operating personnel to understand the process, purpose and
operating objective of each.

Every effort has been taken to cover almost all aspects related to safe and
smooth start-up and subsequent efficient operation of the plant. However,
it is cautioned that all scenarios and emergencies arising during plant
operation cannot be visualized and explained in operating manual. The
systematic guide line of the operating and supervisory personnel to
acquaint themselves with all the documents prior to Re-commissioning of
the plant for safe and efficient operation.

Prior to the start-up the operating personnel must be thoroughly familiar

with all facilities, the design conditions, operating conditions, the
equipment manufacturers instruction, the safety equipment and the fire
fighting equipment locations / details. During the actual start-up, the
start-up supervisor shall have final authority and responsibility for the
facility and for the personnel safety. While reading through the manual, P
& I drawings and manufacturers data books should be referred and
required for easier understanding.

1.2 SULPHUR BLOCK OVERVIEW

Sulphur Block commissioned along with DHDS and OHCU project at
Mathura Refinery of Indian Oil Corporation comprises of following three
units:

i) Sour Water Stripper (SWS)

ii) Amine Regeneration Unit (ARU)

iii) Sulphur Recovery Unit (SRU)

The following new / old units are also included in Sulphur Block along with
DHDT, and MSQU projects:

i) New sour water stripper (NSWS)

ii) Amine Regeneration Unit (Old ARU Revamp)
iii) Tail gas Treatment Unit (TGTU)

Single stage sour water stripper configuration has been adopted for sour
water stripper unit (SWSU). H2S, ammonia and other light components
present in the raw sour water are stripped off as overhead product from
the sour water stripper column. Treated water recovered as part of the
bottom product of sour water stripper is sent to the battery limit.

New Amine Regeneration Unit (ARU) and Old revamp ARU is a

conventional distillation column equipped with associated reboiler and
overhead condenser facilities. Diethanol amine almost saturated with
Hydrogen Sulphide (Rich Amine) and received at Battery limit from
DHDS,OHCU, DHDT and FCCU units is processed in both the ARUs to
separate out hydrogen sulphide and amine solution (lean amine) which is
obtained as bottom product from ARU. Hydrogen sulphide and other light
components present in the rich amine are separated out as overhead
product.

Hydrogen Sulphide bearing gases such as ARU overhead product and sour
water stripper overhead product are processed in the Sulphur Recovery
Unit (SRU) for recovering the elemental solid bright yellow sulphur.
Conventional Claus process hooked up with Super Claus configuration has
been adopted for achieving the overall sulphur recovery more than 99%
in the Sulphur Recovery Unit (SRU)

The major utilities required for the entire sulphur block are available at
the battery limit. Major utilities required for the sulphur block are :
HP Steam, MP Steam, LP Steam, Fuel Gas, Nitrogen, Cooling Water, DM
Water, Instrument Air And Plant Air.

The purpose of Sour water stripper unit is to strip off the acid gases (i.e.
H2S & NH3) from the sour water obtained from the DHDS, DHDT, CCRU,
OHCU, FCCU and VBU units by means of single stage sour water stripper.
The sour gas from the sour water stripper overhead will be routed to
Sulphur Recovery Unit (SRU) while the stripper bottom the Stripped water
will be routed to OHCU, Desalter in AVU in part and the rest will be sent to
Effluent Treatment Plant (ETP).

The SWS 1 (03 unit) is designed by Engineers India Limited (EIL) and
front end engineering also carried out by EIL. The SWS-2 (303 unit) is
designed by IFP and front end engineering was done by M/s L&T.

The SWS-1 unit is designated by 03 and SWS 2 unit is designated by

303.All the equipment, lines and instruments are prefixed by these unit
numbers.

 CHAPTER - 2

2.0 BASIS OF DESIGN

2.1 Design Capacity

New Amine Regeneration Unit is designed for a total throughout of

306 Tons/hr of Rich Amine. The Old Revamped Amine Regeneration
Unit is designed to handle 100 TPH of rich amine

2.2 Turn Down Capacity for New ARU and Revamped ARU:
Turn down (as % of Max capacity) : 50%

2.3 Stream Hours

On stream factor for New ARU Hrs/Year : 8000

On stream days for Revamped ARU : Expected to operate

only 20-30 days per year. However adequate sparing to be
considered for equipments to ensure total plant availability during
the specific days.
 CHAPTER - 3

3.0 FEED & PRODUCT ANALYSIS

3.1 Feed Characteristics for New ARU :

Feed to ARU is Rich amine containing H 2S received from the

DHDS/OHCU/FCCU unit and its characteristics is as mentioned
below :

Rich Amine
Flow Rate : 269044 kg/h
Components Kg/hr WT%
DEA : 65666.9 24.4
NH3 : 0.0 0.0
H2S : 7017.5 2.61
H2 : 5.6 0.002
H2O : 196276.5 73.0
CH4 : 20.1 0.0075
C2H6 : 9.1 0.0044
C3H8 : 8.1 0.0030
C4H10 : 3.1 0.0011
IC4H10 : 3.6 0.0013
CUT 28-122 : 1.0 0.0004
CO2 : 32.4 0.0124

Feed Characteristics for Revamped ARU (old):

Component FCCU FCCU DHDS OHCU SR CR

(case1) (case2) LPG LPG
Merox Merox
H2S, kg/hr 88 694 2127 3400 60 14
CO2, kg/hr 339 339 0 0 0 0
DEA, kg/hr 3281 8950 19885 31815 600 150
Water, 9843 26850 59597 95445 2340 836
kg/hr
HC, kg/hr 0 0 0 30 0 0
H2, kg/hr 0 0 0 5 0 0
Total, 13551 36833 81609 130695 3000 1000
kg/hr
Temp., Deg 55 55 67 75 55 55
C
3.2 Product Characteristics of New ARU
Product leaving the ARU is Lean amine from the bottom of amine
Regenerator and H2S rich gas from the overhead of the Amine
Regenerator Reflux Drum. The characteristics of both the product is
as mentioned below :
 Lean Amine Characteristic at the suction of 04-P-07 (L.P.
Lean Amine Circulation Pump)

Flow Rate : 326528.8 kg/hr

Components Kg/hr WT%
DEA : 81499.8 24.96
NH3 : 0.0 0.0
H2S : 528.5 0.16
H2O : 244499.1 74.88
H2 : 0.0 0.0
CH4 : 0.0 0.0
C2H6 : 0.0 0.0
C3H8 : 0.0 0.0
C4H10 : 0.0 0.0
C6 + : 0.0 0.0
CO2 : 1.5 0.0005

3.3 H2S Rich Gas at the Outlet of Amine Regenerator Reflux

Drum
Flow Rate : 6774.5 kg/h
Components Kg/hr WT%
DEA : 0.0 0.0
NH3 : 0.0 0.0
H2S : 6591.4 97.3
H2 : 0. 0.0044
H2O : 144.1 2.13
CH4 : 2.0 0.03
C2H6 : 1.7 0.0025
C3H8 : 1.7 0.0025
IC4H10 : 0.8 0.012
nC4H10 : 1.4 0.021
CO2 : 31.1 0.0459

Product Characteristics of Revamped ARU (OLD):

Lean Amine : The acid gas (H2S & CO2) loading shall not be
 more than 0.03 moles per mole of

regenerated lean amine.

Acid Gas : To be consistent with the quality of regenerated

lean amine.

3.4 Battery Limit Condition for New ARU

SERVICE PRESSURE TEMPERATURE

(kg/cm2 g) (0C)
RICH AMINE 0.25 70.2

LEAN AMINE 13.0 45.0

H2S RICH GAS 0.9 40.0

3.4.1 Battery Limit Condition for Old Revamped ARU

SERVICE PRESSURE TEMPERATURE

(kg/cm2 g) (0C)
RICH AMINE 0.9 55-75

LEAN AMINE 13.0 45.0

H2S RICH GAS 0.9 40.0

3.5 UTLITY SPECIFICATION FOR NEW ARU

Min Normal Maximum Design

LP Steam
Pressure Kg/cm2-g 2 3 4 5
Temperature deg. C 130 150 170 220
Kg/cm -g 2
4 4.5 10.5
Instrument
Air
Pressure
Temperature deg. C Amb Amb 65
Dew Point deg. C - -15 -

Plant Air
Pressure Kg/cm2-g 5 7 10.5

Inert Gas
Pressure Kg/cm2-g 5 6 10.5
Temperature deg. C Amb Amb 65

Cooling
Water
Supply Press. Kg/cm2-g 3 3.5 4 7.0
Return Press. Kg/cm -g 2
- 2.2 2.8 7.0
Supply Temp. deg. C - 30 34 65
Return Temp. deg. C - 45 65

DM Water
Pressure Kg/cm2-g - 7.0 - 13.0
Temperature deg. C 110 Amb - 65

LP
Condensate
Pressure Kg/cm2-g 1 2 2 5
Temperature deg. C - - - 220

Fuel Gas
Pressure Kg/cm2-g 2 2.5 4.5 7
Temperature deg. C - 40 - 100

3.5.1 UTLITY SPECIFICATION FOR REVAMPED ARU (OLD)

Min Normal Maximum Design

LP Steam
Pressure Kg/cm2-g 3.5 4 5 6
Temperature deg. C 130 150 170 220

Instrument
Air
Pressure Kg/cm2-g 5 5.5 - 10.5
Temperature deg. C Amb Amb 50 65
-15 Deg C
Dew Point deg. C - at 6.5 -
kg/cm2A
Plant Air
Pressure Kg/cm2-g 4 5 6 11.5
Temperature Deg C - Amb 50 65

Cooling
Water
Supply Press. Kg/cm2-g 3 4 - 8.0
Return Press. Kg/cm -g 2
- 2.0 - 8.0
Supply Temp. deg. C - 33 - 65
Return Temp. deg. C - 45 - 65
DM Water
Pressure Kg/cm2-g - 8.0 - 14.0
Temperature deg. C - Amb - 65
LP
Condensate
Pressure Kg/cm2-g - 2 - -
Temperature deg. C - 112 - -
Fuel Gas
Pressure Kg/cm2-g 3 3.5 5.5 8
Temperature deg. C - 40 - 100

3.6 CHEMICAL CONSUMPTION

Following are the Chemicals required for the Amine Regeneration Unit :

Di-Ethanol Amine, Granular Carbon, Soda Ash, Antifoaming agent.

0.1 Methyl Di-Ethanol Amine (MDEA)

MDEA of 99% purity is required at the Amine Tank which is
further diluted to 45% weight solution in the Amine Storage
tank using DM water. The dilute Amine solution is required
during first start-up of the plant for initial filling. During
normal plant operation the certain quantity of amine loss is
envisaged which need to be made up periodically. For
 specification of MDEA refer Annexure-I at the end of this
chapter.

0.2 Granular Carbon

The Granular activated Carbon is required for the filling Lean
Amine Carbon filter. The Carbon life will vary widely depending
on severity of operation, but is typically 3-6 months. For
specification refer Annexure-II at the end of the end of this
chapter.

0.3 Soda Ash

Soda Ash with a maximum of 500ppm chloride is required
during start-up for degreasing.

0.4 Anti-foaming Agent

The Anti-foaming Agent is injected at the 04-C-04 feed diluted

at 10% in demineralized water at the rate of 20 wt ppm of
pure product compared to each stream.

3.7 UNIT HOLD UP

Basis : Only Regeneration section hold-up volume is 350 M3

Detailed unit hold up is enclosed as Annexure -III

Annexure -I

Specification of MDEA:

Product Name : Lean MDEA

Common Synonms : MethylDiethanolamine
Chemical Family : Amine
Formula : (HOCH2CH2)2NCH3
Formula wt : 119
Physical state : liquid
Odour : Pungent
Boiling Point : 99-104 Deg C
Solubility in Water : Complete
Freezing Point : -21 Deg C
 Annexure-II

SPL.SPECIFICATION OF GRANULAR ACTIVATED CHARCOAL GRADE

1CA-

STANDARDS : IS-2752,1995 TYPE 1

TYPE : COCONUT CHARCOAL
MOISTURE : 5% Max
ASH (WT%) : 5% Max
IODINE No. : 900 Min.
ABRASION No.: 75 Min.
SIZE : +8 / - 30 US Sieve Series
SURFACE AREA: 900 M2 /gm Min
M.P.D mm : 1.5 Min. 1.7 Max.
BULK DENSITY : 0.4 0.7 gm/cc
 Annexure -III

S.NO EQPT. NO EQPT DIMENSION TYPE HOLDUP VOLUME BASIS/ASSUMPTION FOR

m3 HOLD UP CALCULATION+G14

1 04-AC-04 20mm ID X 10.5 m (L) 3.1

No OF TUBES-640

2 04-E11 SHELL 0.750m DIA X 3.5m T/T H 2.1 FLOATING HEAD VOLUME
NOT SUBTRACTED

3 04-E-10A/B/C/D 1.75 m DIA X 8.01 m (T/T) H 62 U TUBE BEND VOL. NOT

SHELL SUBTRACTED

4 04-E-09 A/B 0.875 m DIA X 5.5 m (T/T) H 4.6 FLOATING HEAD VOLUME
SHELL / TUBE NOT SUBTRACTED

5 04-J-02 0.01

6 04-E-12A/B 8.6 FLOATING HEAD VOLUME

SHELL NOT SUBTRACTED

7 04-T-01 9m DIA X 8.0 M (H) V 32 NLL IN TANK = 1 m

AMINE SECTION 4m

8 04-AC-05 20 mm ID X 10.5 m (L) 5.7

No OF TUBES 1104

9 04-G-03 / 05 OD (32) X 1.45 m (H) V 1.65 FILTER IS FILLED WITH

AMINE SOLUTION

10 04-G-04 OD (2.6 m) X 4.4 m (H) V 25.66

11 04-C-04 1.8m/ 3.1m DIA V 44

12 04-V-11 1m DIA X 3.4 m (T/T) V 1.11 NILL OF TANK = 1.25 m

13 04-V-14 4m DIA X 12 m (T/T) H 78.8 NILL OF TANK = 50%

AMINE SECTION T/T= 11.2
m
14 04-T-02 H 21.1 NILL OF TANK = 50%
1.8m DIA X 4.85 m (T/T)
AMINE SECTION T/T =4.0 m
Total 269.3

15 PIPELINES 20% Above VOLUME 53.9

TOTAL VOLUME 323.2 SAY 350m3 OF 25% DEA SOLUTION

=1020*350 =357000 kg
 CHAPTER - 4

4.0 EQUIPMENTS

4.1 EQUIPMENT LIST FOR NEW ARU

 S.No. EQUIPMENT TAG No. EQUIPMENT NAME
1 04-AC-04 AMINE REGENERATOR AIR CONDENSER
2 04-AC-05 LEAN AMINE AIR COOLER
3 04-E-09 A/B AMINE REGENERATOR FEED/BOTTOM
EXCHANGER
4 04-E-10A/B/C/D AMINE REGENERATOR REBOILER
5 04-E-11 AMINE REGENERATOR TRIM CONDENSER
6 04-E-12 A/B LEAN AMINE TRIM COOLER
7 04-P-06 A/B AMINE REGENERATOR REFLUX PUMP
8 04-P-07 A/B- LP LEAN AMINE CIRCULATION PUMP
9 04-P-08 ARU AMINE SUMP DRUM H.C. PUMP
10 04-P-09 ARU AMINE SUMP DRUM PUMP
11 04-P-10 A/B AMINE REGENRATOR FEED PUMP
12 04-P-17 AMINE CHARGE PUMP
13 04-P-18A/B ARU ANTI FOAMING PUMP
14 04-V-11 AMINE REGENERATOR REFLUX DRUM
AMINE REGENERATOR REBOILER
15 04-V13
CONDENSATE POT
16 04-V-14 AMINE DEGASSING DRUM
17 04-V-22 ARU ANTI FOAMING TANK
18 04-T-01 AMINE STORAGE TANK
19 04-T-02 ARU AMINE SUMP DURM
20 04-J-02 DEA MAKE UP EJECTOR
21 04-M-04 ARU ANTI FOAMING MIXER
22 04-G-03/04/05 LEAN AMINE FILTERS
23 04-C-04 AMINE REGENERATOR

4.1.1 EQUIPMENT LIST FOR REVAMPED ARU (OLD)

S.No. EQUIPMENT TAG No. EQUIPMENT NAME

1 28-E-03 OVERHEAD CONDENSER
2 28-E-01 A/B LEAN AMINE COOLER
3 28-E-04 A/B REGENERATOR REBOILER
4 28 AC-01 LEAN AMINE AIR COOLER
5 28-P-03 A/B AMINE REGENERATOR REFLUX PUMP
6 28-P-07 A/B- LP LEAN AMINE CIRCULATION PUMP
7 28-P-02 DEA SUMP PUMP
AMINE FLASH COLUMN (28-C-02) FEED
8 04-P-19 A/B
PUMP
9 28-P-8A/B RICH AMINE CHARGE PUMP
10 28-P-05 ARU ANTI FOAMING PUMP
11 28-P-04 COR. INHIBITOR PUMP
12 28-P-07A/B LEAN AMINE TRANSFER PUMP
13 28-P-07 COOLING WATER BOOSTER PUMP
14 28-V-1 AMINE REGENERATOR REFLUX DRUM
AMINE REGENERATOR REBOILER
15 28-V-05
CONDENSATE POT
AMINE DEGASSING DRUM (Common for
16 04-V-14
New ARU & Revamped ARU
17 28-V-03 ARU ANTI FOAMING TANK
18 28-T-01 AMINE STORAGE TANK
19 28-V-04 Revamped old ARU AMINE SUMP DURM
20 28-G-01/02/03 LEAN AMINE FILTERS
21 28-C-01 AMINE REGENERATOR
22 28-C-02 AMINE FLASH COLUMN
 CHAPTER - 5

5.0 CHEMISTRY

The chemistry involved in H2S removal is discussed below:

 Hydrogen Sulphide, H2S or HSH, is a weak acid and ionizes in water to
form hydrogen ion and sulphide ion:

H2S + H2O H30+HS (1)

Since it is a fairly weak acid, only a fraction of the H2S will ionize.

Diethanolamine is a weak base and ionizes in water to form amine ion

and hydroxyl ion.

(HOCH2CH2)2NH + H20 (HOCH2CH2)2NH2 + OH (2)

When H2S dissolved into the solution containing the amine ion it reacts
to form a weakly bonded salt of the acid and the base:

(HOCH2CH2)2NH2++ HS (HOCH2CH2)2NH2SH (3)

The sulfide ion is thus absorbed by the amine solution

This salt formation reaction does not proceed to completion. As the

arrows indicate, an equilibrium level of hydrogen sulfide remains in the
hydrocarbon stream. The overall reaction can be summarized by the
following equation:

(HOCH2CH2)2NH + H2S (HOCH2CH2)2NH2SH (4)

Operating variables are adjusted to favour the forward reaction of

equation (4) in the absorption step of the process and conversely
adjusted to favour the reverse reaction in the amine regeneration step
of the process. It is the reversibility of this reaction that permits
solution regeneration and continuous removal of H 2S by amine
treating.

One of the main features of the IFPs process is the use of two
catalysts in the same reactor. In order to achieve a high sulfurization
activity the most suitable catalyst consists of a mix of cobalt and
molibdenum sulfides on an alumina support of large surface area which
exhibits also an acidic function. However, the acidity of the support
factors olefins polymerization and also H2S addition to the olefins.

l Absorption independent variables

The process variables are :
 Temperature
Acid gas loading
Amine concentration
Rate of circulation
H2S partial pressure in the feed stream
Contacting
Note : In general practice, the 2 last items are not operating variables,
since having been fixed by the design criteria for the unit and choice of
equipment. Nevertheless, it is worth mentioning that the absorption of
H2S partial pressure in the feed stream and intimate contacting.
a) Temperature
The lower the temperature of the lean amine solution, the better the
H2S removal. When treating a hydrocarbon gas, however, the lean
amine temperature is limited by the temperature of the gas being
treated. The lean amine temperature must be maintained between 7 to
1300C higher than the temperature of the gas feed stream to avoid any
possible condensation of these hydrocarbon vapors.
b) Acid gas loading
Good acid gas removal efficiency depends on good amine solution
regeneration, as it will be discussed later. However, it also depends on
restricting the H2S loading in the rich amine to favour the forward
direction of the reaction given in equation (4). The H 2S loading of the
amine solution is controlled by adjustment of the amine circulation
rate. In most cases, unless special design considerations have been
employed, the rich amine acid gas loading (H2S) should not exceed 0.4
to 0.5 mole total acid gas per mole of amine present. The amine
circulation rate is based on a total acid charge to amine ratio of 0.33
mole/mole.
c) Amine concentration
The concentration of uncombined amine is favored by high amine
concentration in the amine solution, good regeneration, and freedom
from strong acids. Practical and economical considerations, confirmed
by field experience, have generally shown that the optimum amine
concentration for this unit is 25% wt DEA.
This is based on the lowest heat requirement for the desired H 2S
removal, the lowest chemical losses, and experienced operational
problems.

The available amine concentration in the lean amine is mainly affected

by the efficiency and control of amine regeneration. The lower of the
 sulfide content of the lean amine, the greater the available amine
concentration for removal of H2S.

l Regeneration independent variables

The regeneration of the amine solution, actually the breakdown of the

weakly bounded amine-hydrosulfide salt is favored by:

1. High temperature
2. Low pressure
3. High stripping steam rates
4. Low amine concentration
5. Intimate contacting

These conditions are controlled in the amine stripping column, subject

to the following limitations. Item 5 are not truly an operating variable
and are fixed during plant design.

The amine temperature in the regenerator re-boiler is limited to 130 0C

in order to prevent amine degradation and corrosion problems.

1) High temperature

The breakdown of the amine-hydrosulfide salt into H 2S and amine, the

reverse of equation (4), is promoted by higher temperatures. However,
the ethanol amines can be thermally decomposed at temperatures
beginning at approximately 1350C and becoming excessive at 1500C.
The LP steam is used for reboiling.

The decomposition temperature need not be approached to provide

adequate regeneration of ethanol amine solutions. This temperature is
subject to variation with column operating pressure, amine
concentration and acid gas loading.

The amine solutions are mostly water. Therefore, temperature changes

with composition are small and it is the operating pressure of the
regenerator that determines the temperature of operation.

2) Low pressure

The regenerator (H2S stripping column) is operating at the lowest

overhead receiver pressure consistent with downstream acid gas
processing requirements.

As noted above, the lower the pressure, the lower the regenerator
temperature.

3) High stripping (reboiler) steam rates

 This liberation of the H2S from its amine salt by temperature is assisted
by the generation of steam in the stripper reboiler. The steam dilutes
and carries away H2S vapour as it is dissociated from the amine. The
resulting decrease in H2S concentration in the vapour allows fur further
amine-hydrosulfide dissociation.

Normal regenerator operations require a heat input at the reboiler of

100 to 120 kg of reboiler steam per m3 of ethanol amine solution
circulated through the absorbers system. This reboiler system rate will
result in a reflux rate of approximately 2 to 4 liquid volume % of the
circulating amine rate.

4) Low amine concentration

Higher amine concentrations favour the retention of acid gas in

solution. Thus, the amine concentration is chosen to be high enough
for efficient absorption but low enough for efficient regeneration.
Unless special considerations are provided for during design, the unit
will operate most efficiently at 25% wt DEA amine concentration.

Thus more water is lost with the acid gas than introduced with the
absorber feedstock. Thus, a water injection point is provided directly at
the suction of regenerator reflux pumps to avoid amine concentration
increase.
 CHAPTER - 6

6.0 PROCESS DESCRIPTION FOR NEW ARU

The primary function of the Amine Regeneration Unit is to
regenerate the rich amine from the various amine users located in
 the FCC, OHCU,DHDS to supply the lean amine solution back to the
users in DHDS. The circulating amine is a 25wt % DEA solution.

The Rich Amine System collects rich amine from the amine
absorbers located in the DHDS. H.C.U feed and received in the
Amine Degassing drum located in the Amine Regeneration Section.

Rich Amine from the bottom of Amine Degassing Drum is pumped

by Amine Regenerator feed pumps (04-P-10 A/B) (1 working + 1
standby) and flow through the tube side of the Amine Regenerator
Feed/Bottom Exchanger (04-E-09 A/B).

The Amine Regenerator strips nearly all of the H 2S from the rich
amine, thus regenerating it to lean amine. The stripper contains 25
valve trays, with in the stripping section and 4 trays in the
rectification section.

Offgas from the top of the amine Regenerator containing H 2S some

light hydrocarbons, and water vapor, flows to the air cooled Amine
Regenerator air Condenser (04-AC-04) and water cooled Amine
Regenerator Trim condenser (04-E-11) where the temperature is
reduced to minimise the water loss in this overhead stream. As the
vapors are cooled some water vapor is condensed.

The bottom of the Amine Regenerator is used as a surge volume for

lean amine. The level is not controlled directly. Amine flows from
Amine Degassing drum to maintain the Amine Regenerator level.
Lean amine from the bottom of the Amine Regenerator flows to the
shell side of Amine Regenerator the exchanging heat to the rich
amine stream, stripper feed, thereby recovering the heat. The
cooled lean amine is pumped by the Lean Amine circulation pump
(04-P-07 A/B) (1 working + 1 standby) and flows through the air
cooled Lean Amine Air coller (04-AC-05) and then through the water
cooled Lean amine Trim cooler (04-E-12 A/B).

6.1 Process Variables

The entire plant is monitored and control by a central DCS. Control

system ranging from single loop pneumatic analog control to
multiple microprocessor shared-displays arrays having several
process units accessed from a single console is used to achieve the
necessary functionality. Following are the major controls provided in
the ARU ;

6.1.1 Flow Controllers

LP steam flow to Amine Regenerator Reboiler (04-FFIC-

1105)
 Flow of steam to the amine regenerator reboiler is controlled by this
controller by modulating the flow control valve (04-FFV-1105) in the
LP steam inlet line.

Lean Amine Filters flow Control 04-FIC-1201

A slip stream of lean amine flows to the filtration system which

filters a 18% of lean Amine through series of filters. The slip stream
flow is controlled by this controller by modulating the control valve
04-FV-1201 in the bypass line around the filters which maintains
the defferential pressure and thereby the filtration system.

6.1.2 Pressure Controllers

Amine Degassing Drum Pressure Control (04-PIC-1007)

This pressure controller controls the pressure in the Amine

Degassing Drum by modulating the 04-PV-1007 located in the vent
line of Amine Degassing Drum.

Amine Stripper Overhead Pressure Control (04-PIC-1106)

The operating pressure of the amine regenerator (04-C-04) needs

to be controlled for efficient stripping of acid gas and to keep the
pressure of the system much below the design pressure as this is
the lowest operating pressure unit in the entire amine circuit. This
split range controller controls the pressure in the amine regenerator
(04-C-04) by modulating the 04-PV-1106A and 04-PV-1106B which
are located in the amine regenerator reflux drum acid gas outlet.
The acid gas has a priority to flow to the Sulphur Recovery Unit via
04-PV-1106A. In case of reduced flow or shut down of entire SRU
the acid gas will be vented to Acid gas relief header by 04-PV-
1106B.

6.1.3 Level Controllers

Amine Regenerator Level Control (04-LIC-1102)

This controller controls level in the amine regenerator 04-C-04 by

modulating the flow control valve 04-FV-1101 in the amine stripper
feed.
Condensate Pot Level Control (04-LIC-1107)
This controller level in the condensate pot (04-V04) by modulating
the level control valve 04-LV-1107 which transfers the condensate
to condensate recovery drum in the SWS unit. This level control
helps in preventing the steam break through from reboiler and also
to vary the heat transfer by varying the level of condensate in the
reboiler.
 Amine Regenerator Reflux Level Control (04-LIC-1109)
This controller controls level in the amine regenerator reflux drum
(04-V-11) by modulating the flow control valve 04-FV-1104 in the
discharge of amine regenerator reflux pump (04-P-06 A/B) to avoid
the gas break through and eventually cavitation of the reflux pump.

6.1.4 Temperature Controllers

Lean Amine Temperature Control (04-TIC-1208)
This controls the lean amine temperature by modulating the
temperature control valve 04-TV-1208 in the steam line and thereby
maintaining the temperature of DEA during startup in amine storage
tank 04-T-01.

6.1.5 Controller Set Point

For Controller set point list refer Annexure-I at the end of chapter-6.
These set points are preliminary and for guideline only. However,
the plant operation philosophy should evolve correct set point for
smooth, safe and efficient operation by experience.
6.1.6 Alarm List and Set Point
For the alarm list and their set points refer Annexure-II at the end
of chapter-6.
6.1.7 Relief Valve System

The plant safety relief system have been disigned taking into
consideration the design pressure of the equipment/system like
operational upset and emergency situation arising during failure of
electrical power or cooling water or mechanical failure of rotating
equipment. While designing the safety relief system, consideration
have been given for logical grouping of equipment and system
operation under similar condition. Sectioning of equipment by
design/operation philosophy such as location of control valve or
isolation valve etc.

The safety valves handling hydrocarbon gases and H 2S/acid gases

discharge into an acid gas relief header. The liquid relief valves
handling amine discharge into a closed system routed to amine
stripper. The safety valves handling water and steam are discharged
to atmosphere at safe location. Refer Annexure-III at the end of
chapter-6 for the details of safety relief valve.

6.2 Amine Regeneration Unit

The primary function of the Amine Regeneration Unit is to
regenerate the rich amine from the various amine users located in
the FCC ,OHCU ,DHDS to supply the lean amine solution back to the
users in FCC,OHCU,DHDS. The circulating amine is a 25 wt% DEA
solution. The Amine Unit consists of four sections: the Rich Amine
Section, the Amine Regeneration Section, the Lean Amine Section,
and the Amine Storage Section.

Rich Amine Section

The Rich Amine System collects rich amine from the amine
absorbers located in the DHDS. Sources include the Recycle Gas
Scrubber located in the reactor section and the Stripper Gas Amine
Absorber located in the fractionation section. Rich amine from the
Recycle Gas Scrubber and Stripper Gas Amine Absorber is combined
and sent directly to the Amine Degassing drum located in the Amine
Regeneration Section.

The 04-V-14 separates any entertained liquid or gaseous

hydrocarbon from the rich amine. Liquid hydrocarbon is separated
into a reservoir in the Amine Degassing drum and can be
periodically drained. Hydrocarbon vapor separated in the Amine
Degassing drum which also contains some H 2S and water vapor is
scrubbed with a small lean amine slipstream in the stack portion of
the Amine Degassing drum. The stacked portion of amine Degassing
drum consists of randomly packed Raschig Ring to provide intimate
contact between the off gas and the lean amine. The sweetened off-
gas flows through a back pressure control valve to the Acid Gas
Relief Header.

Amine Regeneration Section

Rich Amine from the bottom of Amine Degassing Drum is pumped

by Amine Regenerator feed pumps (04-P-10 A/B) (1 working + 1
standby) and flow through the tube side of the Amine Regenerator
Feed/Bottom Exchanger (04-E-09 A/B). In this exchanger, the rich
amine is heated by the lean amine from the bottom of the Amine
Regenerator which is cooled thereby recovering the heat of the lean
amine. The heated rich amine flows through a level control valves
used to control the level in the Amine Degassing drum into the
Amine Regenerator (04-C-04).

The Amine Regenerator strips nearly all of the H 2S from the rich
amine, thus regenerating it to lean amine. The stripper contains 25
valve trays, with 21 trays in the stripping section and 4 trays in the
rectification section.
Stripping gas is generated in the Amine Regenerator Reboiler (04-
E10-A/B/C/D) by vaporizing a portion of the lean amine in the
column bottom. The stripping gas flows up through the column,
thereby stripping H2S from the rich amine flowing counter current.
The Amine Regenerator Reboiler uses LP steam as the heating
medium. Reboiler heating rate is controlled by controlling the steam
flow. The absolute maximum temperature of the steam is 149 0C in
order to prevent amine degradation. Condensate from the reboiler
flows through a lelvel control to the condensate header. Most of the
condensate is returned to the Condensate header.

Off-gas from the top of the Amine Regenerator containing H 2S some

light hydrocarbons, and water vapor, flows to the air cooled Amine
Regenerator air Condenser (04-AC-04) and water cooled Amine
Regenerator trim condensers (04-E-11) where the temperature is
reduced to minimize the water loss in this overhead stream. As the
vapors are cooled some water vapor is condensed. The two phase
stream, hence flows to the Amine Regenerator Reflux drum, where
the liquid is separated from the remaining acid gas stream. The
liquid from the receiver is pumped by the Amine Regenerator Reflux
Pump (04-P-06 A/B) (1 working + 1 standby) as Reflux back to the
top trays of the Amine Regenerator. The Acid Gas from the top of
the Receiver flows to either Sulphur Recovery Unit or to the Acid
Gas Relief header. The pressure control provided in the amine
regenerator maintains the pressure of the system by relieving to the
flare header when acid gas flow is reduced or stopped due to shut
down of SRU:

The bottom of the Amine Regenerator is used as a surge volume for

lean amine. The level is not controlled directly. Amine flows from
Amine Degassing drum to maintain the Amine Regenerator level.
Lean amine from the bottom of the Amine Regenerator flows to the
shell side of Amine Regenerator the exchanging heat to the rich
amine stream, stripper feed, thereby recovering the heat. The
cooled lean amine is pumped by the Lean Amine circulation pump
(04-P-07 A/B) (1 working + 1 standby) and flows through the air
cooled Lean Amine Air cooler (04-AC-05) and then through the
water cooled Lean amine Trim cooler (04-E-12 A/B).

Lean Amine Section

A slip stream of lean amine then flows to the filtration system,

which filters 14- 16% of the lean amine through a series of three
filters. The slipstream flow is controlled by a flow control valve in a
bypass line around the filtration system. This control valve keeps
the flow across the filtration system constant. The filters allow a
 large flow to pass through the filters initially when the filters are
clean. The flow through the filters decreases as the filters become
plugged. When the flow becomes too low through the filtration
system, the filters are changed out and the process begins again.

The filtration system contains a series of three filters. First, the lean
amine flows through the upstream Lean Amine First cartridge filter
(04-G-03). This filter removes various solids from the amine stream
down to 20 microns. The lean amine then flows through the Lean
amine Carbon Filter (04-G-04) which contains a packed bed of
activated carbon used to remove organic matters from the amine.
The filter is temporarily by passed while the carbon bed is changed.
Subsequently the amine flows through the downstream Lean Amine
second cartridge filter (04-G-05). These filters are of the same
design as the upstream Mechanical Filters, and are used to remove
any entrained carbon fines from carbon filters.

Some lean amine is used inside the Amine Regeneration Units

Battery Limits for use in the Amine Degassing Drum. There is also a
start up line which allows lean amine to be re-circulated through the
Regeneration section only flowing back to the Amine Degassing
Drum. The lean amine from the Amine Regeneration Unit is
discharged to FCC,OHCU,DHDS unit.

6.3 Amine Storage section

High purity amine (99 wt % DEA) solid amine will be unloaded to
the Amine Regeneration Unit in drums. The solid amine is melted in
the barrels using steam, to form amine solution. Amine is diluted to
25 wt % DEA solution used in the refinery at the Amine Storage
Tank (04-T-01). The DEA is transferred to the Amine Storage Tank
from the drums via an amine change pump (04-P-17) and DEA
ejector 04-J-02. This pump can also be used to mix the contents of
the Amine Storage Tank through a recirulation line with a jet mixer
located inside storage tank. The 25 % DEA solution is
periodically pumped by the amine charge pump to the Regeneration
Section to replenish the amine losses. The amine can be pumped to
the suction of the LP lean amine circulation pump. The make up of
amine is based on the operating levels in the equipment and by
monitoring the quality of the circulating amine. As the amine quality
degrades the amine purge must be carried out and fresh amine
makeup to be done.
 The Amine Storage Tank is also envisaged to hold the entire
inventory of the amine absorber and Regeneration Section when
plant needs to be shutdown. The pumpout line is on the lean amine
stream downstream of the Lean Amine Trim Cooler. The cooled lean
amine is transferred to the Amine Storage Tank by the Lean Amine
Circulation Pumps and can be replaced using the amine charge
pump when the train is ready to be re-inventoried.
Draining of Amine Solution

The amine from the amine circuit and its associated equipment can
be drained into amine sump drum (04-T-02) for the maintenance
purpose. This tank is located below the ground to facilitate the free
draining of the amine solution. The amine solution from the amine
sump tank is transferred back to the system by ARU amine sump
drum pump (04-P-09) . The sump pump is provided with auto stop
based on the level in the sump tank. This tank also has hydrocarbon
compartment which collects all the hydrocarbon and other lighter
foreign materials. These hydrocarbon/lighter foreign materials are
transferred to OWS by ARU amine sump drum HC pump (04-P-08).

6.4 Utilities
Main utilities required for the Amine Regeneration unit are LP
steam, cooling water, nitrogen, plant air and instrument air. These
utilities are available at the battery limit of the plant. The
condensate leaving the unit is transferred SWS unit for the
condensate recovery under level control (LIC-1107).

6.5 PROCESS DESCRIPTION FOR NEW ARU

AMINE FLASH COLUMN

The rich amine received from the upstream units in Degassing drum (04-
V-14) is sent to revamp old ARU by pump 04-P-19A/B. Rich amine enters
the amine flash column (28-C-02) where it is flashed to liberate the H/C
dissolved in the amine. The column top pressure is maintained at 0.5
kg/cm2g by a split range controller which controls the pressure either by
letting the H/C to flare in case of high pressure or by injecting fuel gas in
case of low pressure.

A slip stream of lean amine solution is fed into the top of flash
column under flow control above the packing to reabsorbs any H2S
liberated during flashing. From the bottom of the flash column,
amine is pumped out by Rich Amine Charge Pump 28-P-08 A/B
(new) on column bottom level control to the Amine regenerator (28-
C-01).

Amine Regeneration
Rich amine enters the Regenerator column which is a packed cum
trayed column where it is stripped off of H2S and CO2 by using LP
steam as the stripping medium in the reboiler 28-E-04A/B (new).
Steam flow to the reboiler is adjusted to maintain regenerator
overhead temperature. Condensate from reboiler flows to the
battery limit under level control of condensate drum, 28-V-05
(new).

The overhead vapours are passed through the regenerator overhead

Condenser 28-E-03 (existing) where it is cooled to 40 Deg C by
cooling water on the tube side and reflux drum 28-V-01 (existing)
where the Acid gas is separated from condensed stream. The reflux
drum is provided with a demister pad which knocks out any liquid
carry over with the gases. The acid gases from the reflux drum top
goes to sulphur recovery plant on split range control with
regenerator O/H pressure by letting excess acid gas to flare.

Reflux is pumped from the reflux drum to regenerator column using

reflux pumps 28-P-03 A/B. Lean Amine from bottom of the
regenerator is cooled to 65 Deg C by air cooler 28-AC-01 followed
by trim coolers 28-E-01 A/B where it is cooled to 45 Deg C by
water. A pair of new lean amine transfer pumps 28-P-07 A/B route
lean amine through air cooler, trim coolers and finally under level
control of regenerator lean amine is routed to existing amine tank
28-T-01. To control the lean amine temperature at 45 Deg C a
bypass for lean amine air cooler and trim coolers has been
provided. A small stream (approx. 5 wt % of cooled lean amine
from lean amine pump 28-P-01 A/B discharge is sent to flash
column as areflux to absorb any H2S liberated during flashing.

Filtration of Regenerated amine

To eliminate iron sulphides/oxides, pipe scale and dust, silicone anti

foam compounds, degradation products from DEA etc. A portion of
lean amine solution (about 10 % of total circulation) is drawn from
discharge of amine pump 28-P-01A/B and is continuously filtered
through a set of filters namely 1 st cartridge filter 28 G-01 charcoal
filter 28 G-02 and 2nd cartridge filter 28-G-03.

DEA SUMP AND SURGE TANK

Drains from all DEA vessels, pump, piping and other equipments are
drained into a closed a closed system which leads to DEA sump 28-
V-04 located under ground. It is provided with a LP steam sparger.
Tank buffer stock is maintained By lean amine from New ARU.

Anti Foaming Agent Dosing System

Antifoaming agent is dosed into the amine system to prevent
foaming. The system comprises of an antifoaming agent drum 28-V-
03 in which the antifoaming agent is unloaded manually and
antifoaming agent pump 28-P-05 which takes suction from the
drum and doses the agent on the amine reflux line to regenerator.

Corrosion Protection

Sulphur compounds combine with water in the regenerator to form

acid solution which is very corrosive. A system is provided to inject
corrosion inhibitor at controlled rates into the regenerator to assist
in controlling corrosion.

The system comprises of an inhibitor drum 28-V-02, in which the

inhibitor solution is unloaded manually and corrosion inhibitor pump
28-P-04 which takes suction from this drum and doses the inhitor
on the vapour line at the top of regenerator.A small portion of reflux
controlled thorugh restriction orifice is used as carrier for the
corrosion inhibitor which is injected into the overhead vapour line.

CHAPTER - 7
7.0 OPERATION OF UNIT
The entire plant is monitored and control by a central DCS. Control
system ranging from single loop pneumatic analog control to
multiple microprocessor shared-displays arrays having several
process units accessed from a single console is used to achieve the
necessary functionality. Following are the major controls provided in
the ARU ;
7.1 Flow Controllers

LP steam flow to Amine Regenerator Reboiler (04-

FFIC-1105)

Flow of steam to the amine regenerator reboiler is controlled by this

controller by modulating the flow control valve (04-FFV-1105) in the
LP steam inlet line.

Lean Amine Filters flow Control 04-FIC-1201

A slip stream of lean amine flows to the filtration system which

filters a 18% of lean amine through series of filters. The slipstream
flow is controlled by this controller by modulating the control valve
04-FV-1201 in the bypass line around the filters which maintains
the differential pressure and thereby flow through the filtration
system.

7.2 Pressure Controllers

Amine Degassing Drum Pressure Control (04-PIC-1007)

This pressure controller controls the pressure in the Amine

Degassing Drum by modulating the 04-PV-1007 located in the vent
line of Amine Degassing Drum.
Amine Stripper Overhead Pressure Control (04-PIC-1106)
The operating pressure of the amine regenerator (04-C-04) needs
to be controlled for efficient stripping of acid gas and to keep the
pressure of the system much below the design pressure as this is
the lowest operating pressure unit in the entire amine circuit. This
split range controller controls the pressure in the amine regenerator
(04-C-04) by modulating the 04-PV-1106A and 04-PV-1106B which
are located in the amine regenerator reflux drum acid gas outlet.
The acid gas has to flow to the Sulphur Recovery Unit via 04-PV-
1106A. In case of reduced flow or shut down of entire SRU the acid
gas will be vented to Acid gas relief header by 04-PV-1106B.

7.3 Level Controllers

Amine Regenerator Level Control (04-LIC-112)
This controller controls level in the amine regenerator 04-C-04 by
modulating the flow control 04-FV-1101 in the amine stripper feed.
Condensate Pot Level Control (04-LIC-1107)
This controller controls level in the condensate pot (04-V04) by
modulating the level control valve 04-LV-1107 which transfers the
 condensate to condensate to condensate recovery drum in the SWS
unit. This level control helps in preventing the steam break through
from reboiler and also to vary the heat transfer by varying the level
of condensate in the reboiler.
Amine Regenerator Reflux Level Control (04-LIC-1109)
This controller controls level in the amine regenerator reflux drum
(04-V-11) by modulating the flow control valve 04-FV-1104 in the
discharge of amine regenerator reflux pump (04-P-06A/B) to avoid
the gas break through and eventually cavitation of the reflux pump.
7.4 Temperature Controllers
Lean Amine Temperature Control (04-TIC-1208)
This controls the lean amine temperature by modulating the
temperature control valve 04-TV-1208 in the steam line and thereby
maintaining the temperature of DEA during start-up in amine
storage tank 04-T-01.
Controller Set Point
For Controller set point list refer Annexure-I at the end of this
chapter. These set points are preliminary and for guideline only.
However, the plant operation philosophy should evolve correct set
point for smooth, safe and efficient operation by experience.
Alarm List and Set Points
For the alarm list and their set points refer Annexure-II at the end
of this chapter.

7.5 Relief Valve System

The plant safety relief system have been designed taking into
consideration the design pressure of the equipment/system like
operational upset and emergency situation arising during failure of
electrical power or cooling water or mechanical failure of rotating
equipment. While designing the safety relief system, consideration
have been given for logical grouping of equipment and system
operation under similar condition. Sectioning of equipment by
design/operation philosophy such as location of control valve or
isolation valve etc.
The safety valves handling hydrocarbon gases and H2S/acid gases
discharge into an acid gas relief header. The liquid relief valves
handling amine discharge into a closed system routed to amine
stripper. The safety valves handling water and steam are discharged
to atmosphere at safe location. Refer Annexure-I at the end of the
chapter 12 for the details of safety relief valve.
 CHAPTER - 8

8.0 UNIT START UP PREPARATION

 Before start-up of the unit all the pre-commissioning /
commissioning activities as described in Volume-IV must be
completed.
8.1 Preparation and Start-up
A Inspection and Testing
Before this plant can be commissioned, there are several
checks and operations which must be performed in order to
prevent damage to the equipment and injury to operating
personnel. Some of the items are construction details, but the
operator must be certain that they have been performed. It
will not be necessary to repeat all of these items on
subsequent start-up. The attention devoted to preliminary
preparations for start-up contributes greatly to a safe and
successful start-up. The following general rules should be
followed :
1) Final Inspection
a) The unit should be checked to verify that it has been
constructed according to the P & IDs / Piping
arrangement drawings.
1) All items are installed and proper sizes and ratings
are used.
2) Control and check valves are installed in the
proper flow direction.
3) Relief valve nameplate settings are checked
correct for the service.
4) Free operation and full travel on all manual valves
are verified.
5) The position of valves indicated as Locked Open
or Locked Closed in the P & ID are verified for
conformity.
6) Removal of temporary bracing / tie downs
installed for modular shipment.
b) The condition of the unit should be checked in detail,
both inside and outside. Particular emphasis
should be placed on the following :
1) Equipment lines and instruments must be properly
connected.
2) Vessels and pipes must be clean and any dirt,
pieces of metal, superfluous material, etc. must
have been removed, If any vessel has obviously
been subjected to lots of dirt, remove the line off
the bottom of the vessel and clean. Check vessel
 internals (trays, packing, etc.) for correctness of
installation.

3) Manways, test plugs plugs and vent / drain plugs

must be in place.
4) All construction equipment must have been
removed, particularly scaffolding and combustibles
such as canvas, ropes and lumber. The area
should be free of construction debres.
5) All unnecessary piping connections should be
removed.
6) Stairs, walks and platforms should be clear of
scraps of metal or other obstructions.
7) Make a final inspection of all utility lines and
system in the plant. All utility lines should be
checked for leaks and confirmed to be free of
trash, dirt, scale, etc. Utility lines can be blown
down to atmosphere to clean them.
b) All safety equipment, fire fighting equipment and first
aid equipment and expendable supplies for this
equipment must be in place and must be fully
functional. This fact must be checked and verified in
writing by the IOCL, Mathura Safety and Audit Team.
All operating personnel assigned to this start-up must
be equipped with proper safety glasses, hearing
protection and face shields, rubber gloves and aprons
for safely handling chemicals.
c) Using compressed air, blow liens to remove scale and
dirt.
d) Add oil / lubricants to all pumps. motors, blowers, etc.
as required and recommended by vendors. Remove
couplings on pumps Bump motors to confirm direction
of rotation of motors. Correct, if reversed. Verify motor
alignment, reconnect coupling, install coupling guard.
e) All spare parts, lubricants and expendables are on hand
in adequate quantities for start-up.
f) Check out instruments and controls :
1) Verify proper installation and ranges for PIs.
2) Verify proper installation of orifice plates and
thermocouples.
 3) Verify installation and continuity of all
interconnections between the unit and central
control room.
4) Verify alarm / interlock actions and shutdown
valve operations.

g) All utility system (electrical power generation or supply,

instrument air supply, cooling water supply and LP
steam. etc.) are fully functional and ready for operations
described in chapter 9.
h) All piping has been pressure tested, flushed, clean,
drained and is ready for service.
8.2 Pre-Start-up Wash
This activity is recommended to be performed along with Amine
Absorber in FCC,OHCU,DHDS unit and interconnecting piping so that
any rust, dirt, oils, grease or other foreign material or particulate
left inside the amine system after installation are removed, which
can contribute to serous foaming and fouling problem during star-
up and operation of the unit. These problems can cause inability to
achieve the required H2S content in the product gas, high amine
loosed, and chronic system upsets, Therefore the system should be
thoroughly cleaned prior to amine charging and start-up. The
procedure for this wash is as follows :
1) The wash should be done prior to the installation of the filter
elements and filter media. Alternatively, the filters are to be
isolated and the wash carried out via the bypass line.
2) After establishing the levels of DM water in the regenerator
add concentrated soda ash solution at a convenient location in
the system to make a 2% wt. Solution of soda ash. (The
amine make-up connection at the amine change pump suction
could be one such location).
3) Heat the solution to about 65 85 0C by using the regenerator
reboiler.
4) Circulate the warm solution for a period of minimum 72 hours
in the entire circuit.
5) The solution should be cooled before draining by stopping the
heating medium to the reboiler and using lean amine air
cooler. 04-AC-05 and team amine trim cooler (04-E-12 A/B) to
remove the heat from the cleaning solution.
 6) After draining the soda ash solution, add DM water to the
system again to the operating levels and circulate 4 5 hours
to clean as much as soda ash possible from the system.
7) Depressurize and open the absorber, amine degassing drum
and regenerator and visually inspect for cleanliness. If they do
not appear clean or if the rinse water appear dirty, add soda
ash and repeat the warm water wash.
8) Drain and rinse with DM water again : continue this process
until the system shows no sign of contamination.

9) After completion of the water flush and draining, install the

filter elements and the carbon filter media. The amine system
is now ready to be purged for removal of oxygen. (the filter
element should be thoroughly washed with DM water prior to
installation).
8.3 Elimination of Air
This activity is recommended to be performed along with Amine
Absorber in the FCC,OHCU,DHDS unit and interconnecting piping so
that entire amine system purging is simultaneous.
Before hydrocarbon gas or amine is introduced first time in the ARU,
It is important that the air present in the system is removed by
purging it with inert(N2) gas. This protects against the formation of
an explosive mixtures and also prevents the degradation of the
amine solution.
Before starting the purging of the unit, ensure the following :
1) All the lines are hydrotested, cleaned, flushed and leak tested.
2) All the hydrocarbon lines connected to the units are blocked.
3) All the utilities connection is isolated.
4) Pre start-up wash as described in para 2.3.2. is completed.
Suggested groupings of the equipment which may be purged
together are :
Amine degassing drum 04-V-14 Amine Regenerator feed bottom
(04-E-09) tube side, amine regenerator (04-P-10 A/B) feed pump
and interconnected piping.
Amine Regenerator feed/bottom (04-E-09 A/B) shell side, amine
regenerator (04-C-04) amine regenerator reboiler (04-E10 A/B/C/D)
amine regenerator air condenser (04-AC-04), amine regenerator
trim condenser (04-E-11), amine regenerator reflux drum (04-V-11)
and interconnected piping.
 LP lean amine, circulation pump (04-P-07 A/B) lean amine, air
cooler (04-AC-05), lean amine trim cooler (04-E-12 A/B, mechanical
filters (04-G-05, 04-G-05) and carbon filter (04-G-04) and
interconnected piping.
Amine charge pump (04-P-17), amine storage tank (04-T-01),
amine sump drum (04-T-02), drain header and interconnected
piping. Introduce nitrogen slowly to the equipment at convenient
low point in the system and vent out at high point at safe location.
Typically nitrogen is admitted at around 1 bar(g) and vented out at
0.2 ~ 0.3 bar(g) until the oxygen content of the gas less than 1%
as measured by a portable oxygen meter.
Special care shall be taken while purging the amine storage tank. It
should be purged separately as its design pressure is lower than
other system. (150 mm WCg). Introduce the nitrogen from the top
of the tank and purge it by maintaining the tank pressure of around
50~ 100 mm water column. Purging shall be carried out until the
oxygen concentration in the outlet gas is below 1%.

Note :
Do not vent the purge gases to the flare (if the flare has been
already commissioned) as this could produce an explosive or
explosive or flammable mixture in the flare header.

When purging is completed, the system may be maintained at

around 0.5 bar(g) by admitting the nitrogen as required to avoid
ingress of air in system. Amine storage tank is to be maintained at
its normal operating pressure.
After the amine sump, drain system and amine storage tank is
purged the blanketing of the amine sump and storage tank is to be
started through 04-PCV-1217 / 1213 respectively.
8.4 Backing in Fuel Gas
It is recommended to fill up the system, immediately after inert gas
purging, with amine solution. However, if amine charging does not
take place soon, it is recommended to provide fuel gas in the
system as back up for nitrogen for maintaining the inert
atmosphere. The fuel gas must be admitted to the system with
great care to avoid the over pressurization. The purging point may
be suitably chosen in ARU unit.
8.5 Preparation of DEA Solution
DEA to be used in the process is a 25% concentration by weight
solution. This solution is to be prepared in the amine storage tank
 using 99 wt. % DEA. The 99 wt.% amine is melted in the amine
melt tank using LP steam by steam hoses. Prior to the melting of
amine charge the known quantity of DM water into the amine
storage tank. Transfer the melted DEA from the melt tank to amine
storage tank by amine charge pump (04-P-17). For initial charge
approx. 195 M3 of 25% wt. DEA solution will be required (this
includes volume required for regeneration system plus all absorber
in the DHDS unit). Based on the total quantity of 25% DEA, the
required amount of water and 99% DEA are added into the amine
storage tank. To achieve uniform concentration of amine solution, it
is re-circulated into the tank by amine transfer pump. It is
recommended to recirculate atleast three times the Volume of the
tank content to ensure the mixing for homegeneous solution.
Withdraw the sample from the tank and measure the concertration
of the solution at regular intervals.

8.6 Initial Charge and Circulation

It is recommended that this activity is carried out along with DHDS
unit to ensure filling of amine in the entire system.
Prior to the filling of amine solution into the system, following
should be ensured:
The FCCU, OHCU,DHDS unit is ready to receive the amine
solution.The flare lines are ready and steam is started in the
jacket/tracer to heat the flare lines.
Remove all blinds as necessary to allow normal system flows. If any
equipment remains open after purging, purge the system again
ensuring complete boxing of the equipment/piping.
The amine solution in the tank is of required concentration and
quality for initial charge.
Below is the stepwise procedure to be followed for the filling of
amine solution:
1) Start the amine transfer pump and charge amine into amine
Regenerator through Amine Regenerator feed/bottom
exchangers. Also charge amine into Amine Degassing Drum
by opening the valve in the fill line.
Check pre-determined level is achieved in the amine
Regenerator and the rich amine flash drum.
2) Start amine Regenerator feed pump and ensure flow from
amine Degassing drum to amine Regenerator. When amine
level starts rising in the amine Regenerator, start LP lean
 amine circulation pump and charge lean amine circulation
system.
3) Charge lean amine into absorber in FCC ,OHCU,DHDS unit and
build-up levels in absorbers. Ensure that lean amine circuit
flow is quite small to avoid over filling in absorbers.
4) While absorbers in FCC, OHCU,DHDS units are charged :
Keep amine filing into amine Degassing drum from
amine storage tank.
Ensure the flow of amine from amine Degassing
drum and amine Regenerator are same to
maintain constant levels in respective equipment.
Commission level control in amine Degassing
drum.
5) When levels in DHDS unit absorbers reach normal operating
level,
pressurise the contractor to about 4-kg/cm 2 a pressure by fuel
gas purge connection. (To be verified in the DHDS unit
equipment).
6) Allow amine to flow from absorbers into flash drum through
interconnecting piping. Commission the level control valve of
the absorbers to maintain absorbers levels.
7) Commission level/flow control valves in the amine circuit and
establish flow.
8) Once the piping system is completely filled up with amine and
equipment levels are at normal operating level, stop the
amine transfer pump and discontinue amine filling through
storage tank.
9) Keep circulating the amine through the system by operating
amine regenerator feed pump, LP lean amine circulation pump
and maintaining the pressure in the contractor by fuel gas.
10) Circulate the solution for 3-4 hours, measures the amine
concentration in the circulation and monitor the levels in the
equipment.
Amine Heat-UP
1) Ensure that all flow/pressure/level/temperature controllers are
commissioned. Verify the proper operation of control valves.
2) Ensure that the pressure control valve 014-PV-1106B in acid
gas line to flare line from amine Regenerator reflux drum
receiver is operational and is not blocked.
3) Ensure the amine circulation is maintained and operating
levels of amine absorbers, amine degassing drum and amine
Regenerator are at normal operating levels.
4) Start the lean amine air cooler fan as per start up procedure
of the coolers vendor and ensure that the cooling water flow is
normal in lean amine trim cooler.
5) Start the amine Regenerator air condenser fan as per vendor
start up procedure and ensure that cooling water flow is
normal in amine Regenerator trim condenser.
6) Slowly add LP steam into amine Regenerator reboiler by
adjusting FFIC-1105 in manual mode. Monitor steam pressure
and temperature in the reboiler through PIC-6506 and TI-
6503 and heat up the amine solution slowly.
7) The heat input evaporates amine solution in reboiler and
starts stripping H2S from the amine flowing down in the
Regenerator. The water vapor condenses in the amine
condenser and amine trim condenser and water accumulates
in amine Regenerator receiver. Monitor the level in the
receiver when the level reaches normal value.

Start the reflux pump.

Ensure that receivers level control is functional to
maintain receiver level.
Ensure reflux to amine Regenerator.
8) Increase the heating rate in the reboiler in steps up to normal
operating temperature at the Regenerator liquid outlet.
Monitor Regenerator liquid output temperaturee by 04-TI-
1110.
9) On achieving the normal operating temperature, the steam
flow control may be put on auto mode.
10) Monitor the amine level in amine Regenerator, if level
decreases, make-up with fresh amine from amine storage
tank.
11) Continue to hold the amine Regenerator liquid outlet
temperature and circulation rete at normal operating values.
At this point of time, the amine circulation system and all the
associated equipment are fully commissioned and is ready to
receive sour gas/acid gas for treatments.
Introduction of Sour Feed Gas
The sour feed gas admission to the amine system is to be done at
to be done at the absorbers in FCC,OHCU,DHDS unit. Hence, the
sour gas feed to amine regeneration unit shall be by rich amine
generated in FCC,OHCU,DHDS unit absorbers. The following
procedure for amine regeneration unit assumes that the fuel gas
backing in the absorbers is already receiving the sour gas feed and
the rich amine is discharged to amine regeneration unit through
level control system of respective absorbers. Procedures also
assume that the SRU is fully commissioned and it is ready to receive
amine acid gas for sulphur recovery.
1) Ensure that the rich amine flow from amine absorbers in
FCC,OHCU,DHDS unit to amine Degassing drum is
established.
2) Maintain absorbers pressure for flow of rich amine to amine
Degassing drum.
3) Ensure that any hydrocarbon absorbed in amine absorbers are
flash separated and discharged to acid gas flare header from
amine degassing drum after amine wash, through 04-PV-
1007. Ensure that 04-PIC-1007 is in auto control mode.
4) Maintain lean amine flow to stacked portion of amine
degassing drum through 04-FI-1004A at design value.
5) Monitor the amine degassing drum level in both amine
compartment and hydrocargon compartment. Hydrocarbon
carry over in rich amine should be overflowing into
hydrocarbon compartment.
6) Confirm that slop oil pump (04-P-05 A/B) is in the auto
operation mode to ensure withdrawal of hydrocarbon from
amine degassing drum. The slop oil pump is actuated by 04-
LSHH-6203 and 04-LSLL-6204 in amine degassing drum.
7) Rich amine is regenerated in Regenerator. Adjust the heating
rate in reboiler such that the lean amine temperature from
Regenerator bottom is at its normal operating value.
8) The acid gas with waters vapor flows to amine Regenerator
condensers and amine Regenerator trim conde3nser. Water
vapor is condensed and collected in amine Regenerator reflux
drum The reflux to Regenerator is maintained by the amine
Regenerator reflux pump (04-P-06 A/B).
9) The stripped acid gas from Regenerator receiver is discharged
to SRU through 04-PV-1106A by pressure controller 04-PIC-
1106.
10) Monitor the pressure of amine Regenerator and ensure that is
at its normal operating pressure.
11) If fluctuation is observed in Regenerator pressure, check the
steam flow to reboiler and reflux medium flow.
12) Monitor the temperature of reflux medium and lean amine
from amine Regenerator, lean amine air cooler and lean amine
trim cooler outlet from ensuring normal operation.
13) Monitor pressure differential across filters and lean amine
outlet temperature from ARU battery limit.
14) Analyse the lean amine sample for H2S content at regular
intervals for ensuring the proper performance of Regenerator.
15) Monitor level in amine sump drum and make-up with amine
solution at the suction of LP lean amine pump if level
decreases due to loss of water or amine. Maintain circulating
amine concentration at 25%.
16) When plant is operating normally, ensure the operation of
control valve 04-PV-1106B by opening the control valve and
simultaneously closing the feed to SRU and observe the back
pressure in the Regenerator while discharging to flare header.
After confirmation of the above, restore the controller 04-PIC-
1106 in auto mode and resume acid gas flow to SRU.
17) Monitor the flow rate of rich amine to Regenerator by 04-FI-
1101.
18) Analyse the rich amine H2S concentration for the acid gas
loading and confirm that it is as per design value.
19) While starting the amine regeneration system on rich amine
feed, the flow controller 04-FFIC-1105 in LP steam inlet line to
the reboiler is recommended to be taken on a manual mode
for step wise increase in heat input.
It is important to recognise that any adjustment in operating
parameter shall reflect its effect only after about 2~2 1/2
hours as the system volumes of amine is about 200 m 3 and
the lean amine circulation pump flow rate is about 100 m 3/hr.
Hence next adjustment must be carried out in span of 2~2
hours after recording/monitoring the effects of previous
change. Every change must be carried out after the operation
has stabilised due to previous change
The heat input is to be raised in small incremental steps from
the initial value at the start of rich amine feed to the normal
value to achieve complete stripping of H 2S. It must be carried
out in steps monitoring.
 Acid gas loding
Lean amine H2S content.
20) The complete amine regeneration system is commissioned
fully and normal operation is established when :
Rich amine flow to Regenerator is at its design value.
The rich amine acid gas loading has reached at its design value.
The circulating amine concentration is maintained at 25% by
weight.The lean amine residual H2S is as per the design value.
The lean amine temperature at the exit of all heat exchangers are
as per the design value and lean amine temperature leaving ARU is
at its normal condition.
The amine Regenerator operating pressure is table at its normal
condition.
The reflux medium temperature is at its normal value.
The flow of acid gas to SRU is established and acid gas discharge to
flare is not taking place except during upsets in SRU or flow to SRU
is interrupted.
All the controllers which were in the normal mode for stepwise
increase to flow, are set on the auto mode.

21) Plant Optimisation

Once the plant is finally operational in stable manner after
first start-up, it is imperative to optimize the plant operation
by adjusting the operating

parameters which could result in cost savings for energy

input, trouble-free operation, reduced maintenance reduced
corrosion, increased acid gas removal and reduced amine
circulation, etc. The guidelines to obtain the optimum
operating conditions which can be further improved by
operating experience gained by the company are outlined
under chapter 10.10 normal operation.
8.7 Normal Start-up
The following sequence describes the plant start-up procedure after
PSD (Process Shut Down) or a normal short duration shutdown.
It is assumed that the unit has normal operating levels of 25% wt.
Amine solution, that the system is under pressure, and that there
are no liquid or gas flows through the unit. Also, it is assumed that
SRU is ready to receive gas streams from the amine unit.
1) Establish amine circulation to and from the amine absorbers
at a rate consistent with the anticipated sour gas feed rate.
2) Begin operating the reboiler and bring the amine Regenerator
upto operating temperature.
3) Set the lean solution temperature to the absorber at the
normal operating temperature.
4) Keep the set point of steam flow control valve 04-FFIC-1105
at zero and open 04-FV-1105 manually.
5) Bring in rich amine feed to the plant by slowly opening the
absorber LVs to the desired value. Avoid sudden changes to
the set point to ensure a smooth start-up.
6) Keep the steam flow control valve 04-FV-1105 in manual
mode.
7) Increase heating rate to Regenerator reboiler, slowly as
required to hold Regenerator outlet temperature.
8) Follow procedures from point number 10 to 20 of first start-up
as described under para 10.8.
Normal Operation
Amine degassing drum
System Description
When all the equipment are in normal/smooth operation, the
degassing drum separates hydrocarbon liquid by overflowing into
separates hydrocarbon compartment. The rich amine under flown
and gets collected in the amine compartment of the flash drum. The
flashed hydrocarbon and water vapor separates on entering the
degassing drum and flashed vapor flown upward

through a packed tower where it is washed with lean amine. Any

entrained H2S is washed and returned to drum while hydrocarbon
and water vapor are discharged to acid gas flare through the
pressure control valve 04-PV-1007.
The rich amine is pumped to amine Regenerator through a flow
control valve 04-FV-1101 which maintain the flash drum level. For
the required capacity, only one rich amine pump need to operate.
The rich amine pumps through rich lean amine exchanger where
lean amine from Regenerator bottom (04-C-04) exchanges heat
with incoming rich amine, thereby recovering the heat. Any
hydrocarbon collected in the hydrocarbon compartment of
degassing drum to be discharged by manual operation through level
gauges (04-LG-1105 A/B) to amine drain system/OWS.
Normal Operating Mode
1) Ensure that Degassing Drum has sufficient level.
2) Ensure that the amine regenerator feed pumps are lined up
such that they are ready for start at any time. Only one pump
need to run while the other is standby.
3) If the level in the flash drum falls below normal operating
level :
Check the feed inlet isolation valve position (Whether open) of the
flash drum.
In case of low level in flash drum, alarm 04-LAL-1004 is enunciated
in the control room for corrective action.
4) In case of level rising in the flash drum above normal
operating level :
Ensure that atleast one rich amine pump is running. Confirm
this by run indication of motor in the control room.
Ensure that the suction strainers of rich amine pump are not
choked. If so, switch over to standby pump. Clean the first
pumps suction strainers and keep ready for operation by
lining up the pump.
5) Monitor level in the hydrocarbon compartment of the amine
degassing drum.
6) Ensure that 04-PIC-1007 is in auto mode and monitor the
drum operating pressure from DCS.
7) Ensure that the flashed vapor scrubber is in operation by
monitoring 04-FI-1004 in the lean amine to scrubber on the
degassing drum. This ensures that only hydrocarbon and
water vapor are purged out and H2S is not discharged to flare
stack during normal operation.
8.8 CHECKLISTS

Checklist for planned Start up

Sl /
No.
Description of job Time Name & Sign Remarks
1. Check 04-C-04 column feed inlet,
reflux, reboiler circuit for
deblinding as per blind list
2. CBD line blinding to be ensured

3. PSVs to be fixed back and to be in

line.

4. All flow/pressure/level/
temperature controllers /control
valves are to be checked for
instrument connections. Stroke
checking of All C/V is to be done
jointly with I/M

5. Isolation valves of all the control

valves should be open.
6. Pumps/air fin cooler motor rotation
to be checked in decoupled
condition.
7. Check all Pumps and air cooler
motors are energized and shafts
freeness to be ensured.
8. lube oil are to be checked for all
the pumps.
9. Cooling water circulation to be
ensured.
10 Level gauge of column, reflux
vessel & 04-V-04 in line and to be
checked.
11. Pre- wash of the system as per the
procedure after M&I shutdown
12. Elimination of the air is done
initially by charging steam in the
column for 6 hrs and then N2 is
charged in the system to maintain
the positive pressure i.e. 1.0
kg/cm2g
13. If N2 is not available then fuel gas
back up can be provided.
14. Sufficient DEA solution of minimum
strength 14 wt% is to be ensured.
15. Internal circulation of amine is to
be established after taking level in
amine column.
16. Reboiler steam is charged and
gradually temp. is increased and
unit is established as per the
procedure.
8.9 Checklist for planned Shutdown

Sl /
No.
Description of job Time Name & Sign Remarks
1. Plant is to be taken in internal
circulation keeping rich/lean
amine valve closed at B/L.
2. Gradually reboiler steam is to be
reduced and ARU gases is to be
released to flare.
3. N2 back up is to be provided as
soon as the top pressure is
difficult to maintain.
4. Stop internal circulation and all
the amine solution is to be
recovered in amine tank.
5. Purge column and air cooler with
N2 and release it to flare hr.
6. Empty out the entire system in
Amine blow down by deblinding
the drain line to ABD.
7. DM water circulation is to be
established by taking level in 04-
V-14 and column (04-C-04).
8. Column top Temp. is to be
increased to 100 Deg C by
charging steam in the reboilers
for 6 Hrs release the gases to
flare and liquid stream is
recovered in tank through ABD.
9. Steaming of the entire circuit is
to be started after DM water
washing.
10 Deblinding of top vent/blinding
of the column as per the blindlist
is to be done in puffing steam.
11 Steaming of the system is to be
 done for 36 hrs and pH of the
condensate is to be monitored
for 78.

8.10 Checklist of Emergency Handling Procedure for Panel Operator:

Sl/ No. Description of job Time Name & Remarks

Sign

1. Electrical power failure (Total)

Reboiler steam is to be reduced.

Open flare C/V of 04-C-04.
Close acid gas C/V and S/D valve of
SRU
As soon as the power is available again
the unit can be restarted as per the
above procedure

2. Cooling water failure

Reduce Steam in reboiler to avoid

04-C-04 safety popping.
Open flare C/V of 04-C-04.

Close acid gas C/V and S/D valve of

SRU
If cooling water failure is for longer
time unit can be kept in internal
circulation depending on the
condition of secondary process
units.
3. Steam Failure
Open flare C/V of 04-C-04.
Close acid gas C/V and S/D valve of SRU

Total Instrument air failure

4.

Transmitters and controllers, control valves

and shut-down systems are affected. The
 unit is automatically shut-down as all
solenoid valves are depressurised and the shut-down
valves
return to the fail safe position.

5. AMINE REGENERATOR OVERHEAD

LINE FAILURE

Secondary process units are to be

informed for necessary action at their
end.
Reboiler steam is to be reduced.
Open flare C/V of 04-C-04.
Unit is to be taken in internal
circulation
N2 purging is to be done for hrs
and empty out the column to amine
tank.
Blinding of the column is to be
done in puffing steam.
N2 purging is to be started and
positive pressure of the column is
maintained.
8.11 Checklist of Emergency Handling Procedure for Field Operator:

Sl/ No. Description of job Time Name & Remarks

Sign

1. Electrical power failure (Total)

Physical verification at site for flare C/V position is to

be done.
Inlet to V-14 is to be isolated after informing
the upstream units
2. Cooling water failure

Physical verification of flare control valves at site.

3. Steam Failure

Physical verification of control valves at site.

Total Instrument air failure

4.

Physical verification of control valves at site.

8.12 EQUIPMENT HAND OVER AND TAKE OVER CHECKLIST

VESSEL CHECKLIST
Vessel No: Service:
Activity Status/Date Op Remarks, Shift I/C sign
Sign
Drain/Pump Out
Isolation
Depressurization
Steaming
Blinding
Steaming
Water Washing
Access (m/h
open)
Ventilation

Gas Test Results

Reading Limits Op Remarks, Shift I/C sign
Sign
Hydrocarbons
O2
H2S
Pyrophoric Iron kept in wet condition: (Yes/No)
Vessel Handover Date/I/C Sign:

Vessel Take Over Status

Activity Status/date Remarks, Op, Shift I/C sign
Cleanliness
checked
Manhole Box up
Deblinding /Box
Up
Steaming
PSV Line up
Gas Back Up
Leak Test
Vessel ready:(Yes/No)
VESSEL LINED UP FOR NORMAL OPERATION: (YES/NO)
I/C Sign/Remarks:

Date:
EXCHANGER CHECKLIST
 Exchanger No:
Shell Side (S/S) Fluid:
Tube Side (T/S) Fluid:
Note: Isolate the shell side inlet/outlet and tube side
inlet/outlet valves as per procedure outlined in manual.

Activity Status/ Op Sign, Remarks

Date
Isolation T/S
Isolation S/S
S/S Flushing/
Draining
T/S Flushing/ Draining
S/S Steaming
T/S Steaming
S/S, T/S CBD blinding
S/S Blinding
T/S Blinding

Exchanger Hand over date/ Sign of I/C:

Exchanger Take Over
Cleanliness checked/Op sign:
Hydro test Pressures/Remarks:
Shell side:
Tube side:
Exchanger drained/Op sign:
Box Up cleared, I/C sign (date):

Activity Status/Date Remarks, Op Sign

S/S deblinded
T/S deblinded
S/S, T/S drains
isolation
S/S air removal
T/S air removal
Vent/Flushing
media blinded

Exchanger Ready for Operation: (Yes/No)

Shift I/C Sign:
Date:
 COLUMN CHECKLIST
Column Number:
Handover Activities
Activity Status/Date Op Sign Remarks, Shift (I/C)
Sign/Date
Draining
Depressurization
Steaming/vent open
Blinding jobs
Steaming
Water washing
Manhole Open
Ventilation

Note: LP steam to be blinded after steaming.

Gas Test Results

Reading Operator Shift (I/C)
(Sign/Date) (Sign/Date)
H2S
Hydrocarbon
O2

Handover Date/Sign (I/C):

Column Take Over Status
Activity Status/Date Remarks Sign of
Op, /I/C
Final Check
Manhole Box Up
Deblinding Jobs
Steaming
PSV Line Up
Gas back Up
Leak Test
Column Take Over

Column Lined up for Normal Operation (Yes/No):

Remarks:

Sign (i/c):
Date:
CHAPTER - 9
9.0 AMINE DESCRIPTION
9.1 Amine Regeneration System
System Description
The amine Regenerator removes nearly all H 2S from 1.7 mol % of
H2S in the lean amine, thus regenerating the rich amine to lean
amine. The rich amine enters the Regenerator at the 20 th tray, the
feed tray and flows down to the bottom of amine Regenerator. The
stripping steam is generated in the amine Regenerator reboiler by
vaporising a portion of the lean amine in the column bottom. The
stripping steam flows up through the column and strips all H 2S from
the rich amine. The gaseous steam leaving the top of the
Regenerator contains water vapor. CO2 and H2S while the liquid from
the bottom sump contains hot lean amine.
The pressure is maintained by a split range controller PIC-1106 in
the top of Regenerator which modulates the PV-1106A in acid gas
line to SRU and PV-1106B in the acid gas line to relief header. The
vaporisation in the amine Regenerator reboiler is controlled by FFIC-
1105 in the LP steam line. The absolute maximum temperature of
the steam is 149 0C. in order to prevent amine degradation. The
condensate from the reboilers flows into the Amine Regenerator
Reboiler Condensate pot (04-V-13) and finally it is transferred to
condensate Recovery drum in SWS or to DHDS unit based on the
level control LIC-1107.
The off-gas leaving the amine Regenerator contains H 2S, CO2, some
light hydrocarbon and water vapor. It flows into the air cooled amine
Regenerator air condenser (04-A-04) and water cooled amine
Regenerator trim condenser (04-E-04) where the liquid is sub-
cooled to minimise the water content in the overhead steam. The
amine Regenerator condenser is an air cooler and is provided with
manual control from DCS. 50% fans are auto variable pitch and
50% manually adjustable type. The two phase stream then flows to
the amine Regenerator reflux drum (04-V-11). Where the water is
separated from the acid gas. The water from the receiver is pumped
by the amine Regenerator reflux pump (04-P-06 A/B) as reflux back
to the top tray of the amine Regenerator based on the levelcontrol
in the amine Regenerator reflux drum (04-LIC-1109). The acid gas
from the top of the receiver normally flows to SRU under pressure
control (04-PIC-1106) will open the control valve in the acid gas
relief line and there by maintain the required pressure in the amine
Regenerator.
The lean amine from the amine Regenerator is partially cooled upto
83 0C in the amine regenerator feed/bottom exchanger (04-E-09
A/B) by the rich amine and the lean amine is pumped by LP lean
amine circulation pump. (04-P-07 A/B) The lean amine is further
cooled in the lean amine cooler (04-AC-05) and lean amine is
further cooled in the lean amine cooler (04-AC-05) and lean amine
trim cooler (04-E-12). The lean amine leaves the cooler section at
43.3 0C. The lean amine cooler is an air coolers and is provided with
manual control from DCS. 50% fans are auto variable pitch and
50% manually adjustable type.

To avoid the excessive foaming in the Regenerator anitifoam

chemical shall be injected in the Regenerator. Separate anti-foam
chemical injection system is provided for the ARU. Operator should
start the antifoam chemical injection pump (04-P-18 A/B) whenever
required. Level in the antifoam chemical injection vessel (04-V-22)
shall be checked by the operator on regular basis. This solution shall
be prepared in the antifoam chemical injection vessel by mixing the
chemical (silicone antifoam agent) with DM water and kept ready all
the time.
Normal Operating Mode
1) Ensure that all controllers of amine regeneration section are in
auto mode.
2) Ensure that all control valves bypass valves are closed and
clock valves are open.
3) Ensure that LP lean amine circulation pumps are lined up such
that they are ready to start at any time. Only one pump need
to run while the other is standby.
4) Ensure that both the reflux pumps are lined up such that they
are ready to start at any time. Only one pump need to run
while the other is standby.
5) Ensure that the lean amine air cooler and amine Regenerator
air condenser fan motors are running.
6) Ensure that reboiler steam supply is available at its normal
condition.
7) Ensure that antifoam injection system is operational.
8) Ensure that amine Regenerator bottom level is at its normal
operating level. If the level rises. Check ;
a) Whether at least one of the LP lean amine circulation
pump is in operation. If not start the pump.
b) Whether the suction strainers of the running pump is
clogged; first start the standby pump and then clean the
suction strainer of the first pump after isolation.
c) Whether any on line control valve is fail closed.
 d) Check reboiler steam flow, if the steam supply is
reduced or stopped, the loss of vaporization shall reflect
as increase in level of reboiler.
9) If the Regenerator level is below normal operating level, check
;
a) Whether feed control valve is open and feed flow rate is
normal.
b) Whether any leakage in the system.

c) Whether the reboiler steam flow is normal, If too much

vaporization takes place, it results in loss of hold-up and
eventual fall in level. The level is monitored by 04-LI-
1103 and low level is enunciated in DCS by 04-LAL-
1103.
If amine losses from the system are detected, first take
corrective measure to eliminate the same and then add make-
up amine from the amine storage tank.
10) The amine solution has tendency to foam. Excessive foaming
results inefficient performance of trays and eventual inefficient
stripping of H2S. Foaming can be detected by unstable level
control of the Regenerator, analysis of lean amine solution,
etc. If excessive foaming is detected, check for :
a) Cleanliness of carbon filter and mechanical filters.
b) Presence of foreign materials.
c) Purity of process water.
As all these affect the purity of the amine, antifoam chemical
should be injected in the Regenerator in the event of foaming.
Start the injection pump (04-P-18 A/B) when necessary. Level
in the antifoam chemical injection vessel (04-V-22) to be
monitored regularly.
11) Monitor column operating pressure through 04-PIC-1106.
a) If pressure falls below normal operating pressure :
- Check for reboiler heat input as reduced heat input
would reduce stripping and thereby the pressure.
Correct the flow rate of steam, if so.
b) If pressure rises above normal operating pressure :
- Check for increased reboiler heat input.
- Check for proper reflux medium flow.
 - Check for air cooled condenser air flow through
motor current.
- Check for cooling water flow through trim condenser.
- Check whether acid gas discharge control valves are
properly operating.
Monitor regularly :
- Reboiler steam condition, in the steam line.
- Reflux pump flow rate through 04-FIC-1104.
- Air cooled condenser motor ampere.
- Fouling of air cooled condenser and water cooled
trim condenser.
12) Monitor Amine regenerator feed bottom exchanger lean
amine outlet temperature. 04-TI-1203 for proper heat
exchanger.
Lean Amine Filtration System
System Description
A slip stream of lean amine from the trim cooler outlet flows to the
filtration system, which filters around 18% of the lean amine
through a series of three filters. The slipstream flow is controlled by
a flow control valve (04-FV-1201) in a bypass line around the
filtration system. This control valve maintains the differential
pressure across the filtration system. The filters allow a large flow
to pass through initially when the filters are clean. The flow through
the filters decreases as the filters become plugged. When the flow
becomes too low through the slipstream, the filters are changed out
and the process begins again.
The filtration system contains a series of three filters. First, the lean
amine flows through the upstream lean amine 1 st cartridge filter
(04-G-03). This filter removes foreign particles such as rust, amine
salts, etc. from the amine stream of sizes 20 microns and above.
Second filter, the lean amine carbon filter (04-G-04), is a packed
bed of activated carbon used to remove organic matter such as
hydrocarbon from the amine. This bed needs to be changed much
less frequently than the mechanical filters, so no spare is required.
The filter is temporarily bypassed while the carbon bed is changed.
Finally, the amine flows through the duplex type lean amine
mechanical filters (04-G-05). These filters are of the same design as
the upstream mechanical filters and are used to catch carbon fines
from the carbon filters.
 A small slipstream of filtered lean amine is sent back to the amine
degassing drum stack on flow control to scrub the off-gas from this
drum. The rest of the lean amine flows to the diesel unionfining unit
recycle gas scrubber and Regenerator gas amine absorber and is
controlled via flow control valves located at the individual columns.
1) Monitor 04-PDG-1203/ 1204 /1205 across the filtration
system and 04-FIC-1201 regularly.
2) Monitor differential pressure across each filter regularly. In
case the differential pressure across each filter increases
beyond normal value, isolate the filter and line-up the
standby filter. Change the clogged filter elements from the
mechanical filter and keep it ready for use. In case if carbon
filter bed is clogged, isolate it and open the carbon filter
bypass line. Change the carbon bed from carbon filter vessel.
Once the carbon filter is ready connect it to the system and
close the bypass line.
3) The efficient filtration is key to smooth operation of amine
unit, reducing the probability of foaming of amine, life of the
filtration system and quality of circulating amine.
4) All filters in the system should be isolated, opened and the
internals inspected at regular intervals.
9.2 Amine Storage System
System Description
This system consist of amine melt tank (04-T-02), amine charge
pump 04-P-17, amine storage tank 04-T-01. The 99 wt. % DEA
(solid amine) supplied to ARU in the drum. The DEA is melted in the
amine melt tank using steam to form the amine solution. Steam
hoses are provided near the amine melt tank. Amine is blended with
DEA solution inventory in the amine storage tank and diluted to
25% wt. DEA solution by adding DM water in the amine storage
tank. The transfer of DEA from the amine melt tank to amine
storage tank is effected by amine transfer pump. This pump can
also be used to mix the contents of the amine storage tank through
a recirculation line and a jet mixer located inside the storage tank.
Continuous mixing of tank content is necessary to maintain
homogeneous solution and avoid salting out of amine.
Amine losses may occur due to various reasons such as evaporation
losses, degradation of circulating amine, leakage from the system,
water purge, etc. The 25 wt.% DEA solution is periodically pumped
by the transfer pump to the regeneration section to replenish the
amine loses. The amine can be pumped to the suction of the lean
amine pumps or the suction of the rich amine pumps. Adding amine
will boost the overall amount of amine in the unit and the surge will
be seen as an increase in level in the bottom of the amine
Regenerator.
The amine storage tank is also used to hold entire inventory of the
regeneration section when it needs to be shutdown. The pump
outline is on the lean amine stream just downstream of the lean
amine cooler. The cooled lean amine is transferred to the amine
storage tank by the lean amine pumps and can be replaced using
the transfer pump when the train is ready to be re-inventoried. The
amine storage tank is provided with inert gas (nitrogen) blanketing
to prevent the ingress of air during inbreathing o the tank. This is
necessary to prevent the amine solution degradation in presence of
air.
Normal Operating Mode
1) Ensure that the tank operating pressure is within the specified
limit all the time as the tank design pressure and vacuum are
only +150 mm WCg and 25 mm WCg respectively.
Ensure the supply of blanketing gas at all the time at specified
pressure
and tank breather valve 04-PVRV-1204 and pressure
regulating valve in the blanketing gas line 04-PCV-1213 are in
good operating condition.
2) Ensure amine transfer pumps (04-P-17) is in operation for
recirculation of amine solution at all the time. Confirm this by
pump running indication of pump motor in the DCS.
3) Tank normal operating level should not be more than 10 ~
15% of the effective storage capacity. This is necessary to
provide the adequate spare volume in the tank to transfer the
entire inventory in the amine system into amine storage tank
in the event of a shutdown, planned or unplanned. This
inventory must be confirmed during first fill of the plant and
logged for normal tank level maintenance.
4) Ensure the amine make-up into amine circulation system is
just adequate quantity only to avoid any drainage of amine in
the event of overfilling. The excess of amine make-up will
result in increase in level in the amine Regenerator, which
should be drained back to the amine storage tank by opening
the isolation valve in the amine pump outline downstream of
the lean amine trim cooler.

Remark :
 During this pump out operation, operator to ensure that
the 6 isolation valve in the interconnecting line
between amine transfer pump and pump outline is
closed.

5) Monitor the quality of amine solution in the circulation system

for any degradation and concentration of the solution. The
operating level in the amine Regenerator should be also
monitored regularly.

9.3 Amine Drain System

System Description
Amine solution is expensive and also toxic especially when handling
rich amine. During normal plant operation, generally amine solution
is not drained from the system except when needed to purge water
from amine reflux pump discharge. However, during plant or
individual equipment shutdown and maintenance, it is necessary to
drain out the amine hold-up in the equipment / piping under
maintenance.
Amine Drain system is provided for draining the amine from
equipment, piping and instruments. The blowdown is routed
through a buried blowdown header into the amine sump drum (04-
T-02). The sump tank is also buried to effect gravity flow from
equipment and piping drain points. The amine sump is provided
with a amine sump pump (04-P-08) which pumps out amine from
the sump tank to either lean amine cooler or to amine degassing
drum. Thus the amine blowdown is recycled back to circulation
system. A provision is also made to transfer the amine to a waste
drum for eventual disposal outside plant B.L. The amine sump pump
is provided with an auto stop based on the low level in the sump
tank. The pump start is manual based on the level in the sump
tank. A level indicator is also provided for monitoring the sump tank
level.
To avoid the ingress of air into the sump tank, it is continuously
purged with the fuel gas in the sump tank vent line and vented to
flare header.
Normal Operating Mode
1) Ensure that the level switch (04-LSLL-1203) is regularly
maintained for proper operation. The failure of the switch may
result in pump cavitation and eventual damage to the pump.
 2) Monitor level in the sump at regular intervals for starting the
pump when level rises in the sump tank due to maintenance
drainage.
3) Ensure proper operation of 04-PCV-1217 for supply of fuel gas
to the sump tank confirm this by positive pressure in the 04-
LG-1216.
4) Ensure that atleast one destination valve is opened while
pumping out the solution from the sump tank.

9.4 Critical Process parameters:

SL.no Description Unit Process Operating values

.
1 Degassing drum Kg/cm2g 0.25
Pressure
2 Degassing drum Deg C 70
temp.
3 Regenerator top Kg/cm2g 0.9
pressure
4 Regenerator top Deg C 40
temp.
5 Regenerator bottom Deg C 130
temp.
CHAPTER - 10
10.0 SHUTDOWN

For total shutdown procedure indicated in Chapter 8 (8.9 checklist for

Planned Shutdown) all the steps for normal shutdown shall be followed,
and the gases from the system should be vented to flare and then (when
the pressure is nearby atmospheric) displaced with nitrogen. After
ensuring the complete removal of the gases the relief line valve should be
closed.
CHAPTER - 11
11.0 SAFE GUARDING

11.1 COOLING WATER FAILURE

Following equipment used the cooling water in the amine regeneration
unit.
* Lean amine trim cooler (04-E-12A/B)
* Amine Regenerator trim condenser (04-E-11).
The failure of cooling water will cause the pressure build-up in the amine
Regenerator due to the over heating in the reboiler hence as a first
precautionary measure operator should close the steam supply to the
reboiler to avoid the opening of safety valve in the amine Regenerator
overhead (04-PSV-6506 A/B). After stopping the heating monitor the
column pressure as it will start dropping. Close the vent valve 04-PV-
1106B in the acid gas line to flare and 04-PV-1106A in the acid gas line to
SRU once the pressure near to atmospheric value. Try to retain some
positive pressure in the column so as to avoid ingress of air into the
Regenerator. This will prevent the formation of explosive mixture in the
column.
Shutdown of following equipment should also be initiated in the sequential
order as mentioned if the cooling water does not resume in time :
* Amine Regenerator reflux pump (04-P-06 A/B) upon receiving
the low level alarm in the amine Regenerator reflux drum 04-
LAL 1109.
* Lean amine pump (04-P-07 A/B) upon receiving the low level
alarm in the amine Regenerator (04-LAL-1102).
* Subsequently the feed to the column should be cut off by
stopping the amine regenerator feed punp (04-P-10 A/B).
11.2 POWER FAILURE
The power failure will result in stoppage of air fin cooler motors and
will have the same effect as that of cooling water failure
11.3 Amine Acid gas Line Failure

This will cause the uncontrolled H2S release to the atmosphere. The gas will
form dense cloud of H2S in the whole SRU area. The intensity of the gas in
direction will depend on the wind direction.

Normally it will not be possible for men to approach the area.

The above will be detected by the visual sight & H 2S detectors provided in the
area.

In the above case the following actions will be taken.

1. All the Upstream units shall be informed.

1. Trip the SRU from control room.

2. As above line is not having any isolation valve bottle up ARU unit by taking
the following action.
a) Cut the steam of 04E-10A/B/C/D by closing 4 FFC-1105.
b) Stop pumps O4P-10, 04P-07, 04P-06.
c) Close the amine battery limit valves. If required use gas mask.

11.4 SOUR GAS LINE FROM SWS TO SRU FAILURE

This will result in uncontrolled releasing of H 2S with ammonia vapours to the

atmosphere.

The intensity will be high in unit area. As the above system hold up volume is
not high, it will disperse with a time interval of 15-30 minutes depending on
the volume of the leakage.

In the above case following steps should be taken.

1. All the Upstream units shall be informed

1. Trip the SRU from control room.

2. Cut the steam to 03C-01 by closing 03FRC-1202

 3. Depressurise 03C-01 by opening 03PC-1210 to flare.

Following personal are to be informed of the H2S Release by any of the above line
Leakage:

1. CPNM
2. RSM
3. SFSM

11.5 PERSONNEL SAFETY

Personnel safety data and toxicological data of H 2S are described in
volume III A. Sulphur recovery unit manual, Chapter 7.0.
11.6 PRECAUTIONS IN PLANT OPERATIONS
The following are some of the precautions to be observed in normal
plant operating procedures :
a) All precautions applicable for a sour gas system should be
observed especially in operating equipment handling the feed
gas and rich amine. Filters should be purged thoroughly with
nitrogen gas to flare before opening up.

b) The amine solution is strongly alkaline and can cause severe

irritation to eyes and skin. Caution should be observed when
sampling, draining or otherwise handling products containing
amine. Precautions similar to handling caustic soda should be
observed.
c) During operation, iron sulfide scale may form inside
equipment exposed to hydrogen sulfide. This material may
auto ignite when exposed to air even at ambient temperature.
Observe proper precautions when opening equipment which
may contain iron sulfide scale.
d) Draining of rich amine into the sump should be avoided to the
extent possible. By running the amine circuit with the reboiler
on duty for 3 ~ 4 hours after stopping the feed gas to the
plant, the H2S levels in the amine will be brought down to low
levels.
e) With equipment under pressure, the equipment drain valves
should never be fully opened. This could pressurize the drain
system to higher than acceptable levels.
CHAPTER - 12
12.0 PLANT OPTIMISING GUIDELINES
12.1 Plant Optimising Guidelines

a) Amine Circulation Rate

The guidelines below are provided to optimise the plant operations
after the plant is started up as described earlier and is operating in
a stable manner. However, during the start-up phase, the amine
circulation rate and the heat input to the reboiler should be as
specified to ensure a thoroughly regenerated amine solution.

1) Confirm that the plant is operating at design gas capacity. At

this point, with the design circulation and stripping rates, the
plant should be achieving all acid gas specifications, and the
solvent should be regenerated down to very low lean loading.
2) Gradually reduce the circulation rate until either the H 2S levels
in the treated gas at the absorber outlet begin to increase and
approach specification. At this point, increase the circulation
rate by approx. 2 10% to bring the acid-gas levels back
down to comfortably within specification and to add a safety
factor to the operation. This 2 10% excess circulation rate
can be increased or decreased slightly, depending on the
stability of the feed gas rate and composition. It is desirable
not to over circulate the amine solution, as this will lead to an
increased reboiler duty requirement.
3) After the circulation rate has been optimised, gradually reduce
the reboiler duty until the optimised overhead temperture is
obtained, as described later in this section, or until the H 2S
level in the treated gas begins to increase. When the treated
gas is close to exceeding specification, increase the reboiler
duty by approx. 5% or until the outlet acid gas levels are
comfortably back within specification. It may be necessary to
increase the circulation rate slightly once the reboiler duty has
been reduced in order to keep the treated gas well within
specification. Ultimately, the goal is to achieve a balance
between the circulation rate and reboiler duty. Whenever
decreasing the reboiler duty, it is important to monitor the
lean amine solvent loading to ensure that the amine solution
is being adequately regenerated.
4) It is important to monitor the operating data and mass
balance around the system during start-up and optimistaion.
These data are useful for troubleshooting and optimisation
should process conditions chacge significantly. After making a
significant change in circulation rate or reboiler duty, it is
 recommended that the system be allowed to settle out for
atleast 2 times the system residence time so that steady state
is achieved before recording data or making another process
change as the amine system has a capacity of 230 m 3 and
circulation rate of 100 m3/hr. Which result in about 2 hours of
residence time. After making a process change, wait about 4
hours before recording data or making another process
change.
5. For a selective gas treating application, it is desirable to
operate with the lean amine temperature as cool as possible
to enhance both H2S absorption and CO2 slip. Also, it is
important in selective gas-treating not to over circulate the
amine solvent as this will significantly increase the absorption
of CO2. For absorbers with multiple feed points in selective
applications, it is typically recommended to feed the lean
amine solvent to the lower tray where the H2S specifications
can be achieved, since this will maximise the CO2 slip.
b) Regenerator Conditions Overhead Temperature,
Pressure and Reflux Ratio
It is recommended that a plot of Regenerator overhead
pressure (X-axis) Vs. Overhead temperature as a function of
reflux ratio (constant reflux curves) be prepared based on
licenser simulation information. The reflux ratio is expressed
as the Kg mole steam / Kg mole acid gas, and is defined as
the ratio in moles of water returned to the amine
Regenerator per mole of acid gas leaving the reflux drum or
accumulator. For the design condition, with the overhead
pressure of 1.84 kg/cm2(g) and a reflux ratio of 2.69 and
regenerator overhead temperature of about 1210C is required.
c) Reboiler Temperature
During normal operations, the reboiler temperature will vary
depending on the amine concentration and the reboiler
pressure. It is recommended that a plot of reboiler pressure
be prepared based on licenser simulation. It is important that
the amine solution be at its boiling point in the reboiler to
ensure an adequately regenerated solution be at its boiling
point in the reboiler to ensure and adequately regenerated
solution. However, the reboiler temperature is very insensitive
to the heat input rate and therefore should not be used to
control the regenerator operations. It is easier and more
accurate to control the regenerator operations by monitoring
the overhead temperature and the lean loading, as discussed
previously.
12.1.1 Procedure and Schedule of Skimming oil/HC from amine
solution in ARU and ATUs

Sl Description Schedul Brief Description of Operation Remarks

No ed Day and coordination
1 Amine Every 1. Level of OHCU- HHPS (07-
Treating Units Monday C-01) , CLPS( 07-C-08),
(Absorbers) LAS Drum (07-V-8) ,
of OHCU, DHDS- HPA Absorber (02-
DHDS, DHDT, C-01), LPA Absorber ( 02-
FCCU & C-03), LAS Drum (02-V-
Merox Oil 12 ), DHDT- HHA Aborber
Skimming (0301-C-02), LPA
Absorber (0301-C-03 ),
LAS Drum (0301-V-01)
and FCC Merox , FG
Absorber, 20-C-06, KOD,
20-V-07 Product Merox
CR LPG (022-C-01& 22-C-
02 ), SR LPG Absorber
( 024-C-02 ), LAS Drum
024-V-07, are to be
increased and over
flowing through any
bleeder of FT or PG point
or LPD point.

2. Checking to be done for

any oil accumulation as
per need operation, So
that excessive oil
accumulation in system
can be avoided.

3. Before that all

coordination is to be
carried out by Shift in-
charge of respective units
2 Amine Every 1. The level of Degassing Drum
Regeneration Friday (04 -V-14) will be increased so
Unit oil that any oil accumulated in drum
Skimming is transferred to H/C chamber
from there it is drained to OWS
till oil / HC is noticed.
4 Checking of Every 1. Perform the level checking Panel
level Saturda jobs through Inst. Maint. of AAU officers
indication of y Sections ie FFC-Merox, Product- to
AAU and ARU Merox, DHDS, OHCU, DHDT, and coordinat
columns ARU 04-C-04 and Rich amine e among
Surge Drum 04-V-014 , Revamp them self
ARU 028-C-01, Revamp ARU on each
Rich amine Surge Drum 028-C- Saturday
02. for level
checking
jobs with
Inst.
maint.

12.2 Plant Monitoring

It is important to monitor the unit regularly to make sure that all
the temperatures, pressures, flows and levels are at their normal
conditions.
Prompt corrective action to any abnormal condition will result in
increased safety, less unit downtime and more on-spec product.
Under normal operating conditions, the amine unit will be controlled
from the control room with a few exceptions (e. g. pressure
indicators in pump

discharges, amine Regenerator receivers, amine storage tank,

amine sump tank, etc.) The unit should be visited on periodic basis,
preferably every two (2) hours, by a qualified operator who will take
readings of locally indicated instruments and observe that all
equipment is functioning correctly.
Regular analysis of the amine solution and of the inlet and outlet
gases are vitally important to the operation of the unit. Sample
points are provided in the rich amine and lean amine lines at
suitable places. The rich and lean amine sample should be titrated
periodically to determine the degree of loading of the amine and
completion of the regeneration cycle.
 Amine solution should be analysed preferably once each eight (8)
hours, but atleast once degree of loading is determined once a
week.
The amine strength should be adjusted by adding either water or
amine at the make-up points at the circulation pump inlet.
A listing of expected instrumentation settings at design capacity is
included under normal operating conditions. The normal duties of
operators will be directed at maintaining operating conditions which
give suitable treating of the incoming gas. The major items to be
monitored and maintained by the operators by the operators are :
a) Amine circulation rate : Under normal plant operation, the design
amine circulation rate should be maintained. The circulation rate is
to be reduced only if the gas rate or H 2S content is drastically less,
say less than 50% of design.
b) Solvent Strength : The amine content of the circulating solvent
should be maintained at 25% by weight at all times. Connections
are provided at the transfer pump inlet for addition of make-up
quantities of amine, if required. In course of operation, there will
normally be a small loss of water from the syste, which is make-up
by adding live steam in the amine Regenerator bottom sump.
Since the levels in all other major liquid inventories are controlled,
the water loss would be reflected in the drop in the Regenerator
level. It is desirable that the level in amine Regenerator is topped
up to the maximum operating liquid level once a day.
In the likely extent that water need to be removed from the system.
It can be drained at the reflux pumps 04-P-03 A/B which discharges
waters into the surge drum at Sour Water Regenerator (SWS) unit.
c) Solvent Cleanliness : the single most imprtant item leading to good
unit operations is keep the circulating solvent stream free of
contamination. The operator must :
1) Keep the filter elements in 04-G-03, 04-G-04 and 04-G-05
changed on a regular basis. The flow across the filter section is
maintained by flow indicator controller FIC-1201, which opens or
closes the bypass control valve FV-1201. If the differential pressure
increases, the control valve opens more to increase the flow across
the bypass thus decreasing the flow through filter system. When the
pressure drop across the filter system decrease the flow through
filter system 2.0 kg/cm2 as indicated on the differential pressure
indicator, the elements must be changed. If the solution appears
dirty, the elements should be changed even though the pressure
drop is below the maximum. (during carbon bed changeover the
carbon filter shall be bypassed).
 2) Regularly check at site to ensure that the circulation rate through
the mechanical filters and carbon filter is at the design flow rate.
Change carbon media on a regular basis. One of the most
troublesome causes of foaming in amine systems is the presence of
minute quantities of surface active agents of unidentifiable origin.
These are not removed by the cartridge filters but can be absorbed
on the surface of the activated carbon in the carbon filter. Regular
testing of the solution for foaming will determine the effectiveness
of the carbon filter and indicate along with the differential pressure
indicated on when the media should be changed.
3) Regularly check to ensure that the DM water quality is to the
specification, used for preparation of the amine solution.
Contaminate present in the DM water can accumulate in the system
and cause a variety of operating problems such as foaming,
corrosion, etc.
d) During operation, the operator should regularly check that the anti-
foam injection system is operating as per the specification.
e) Gas/amine losses from the system to the flare/drain should be
prevented by routine check to ensure that the PSVs and vent valves
to the flare and drain valves are not passing.
f) The flash gas flow rates from the amine degassing drum should be
monitored. If the flow is excessive (which is unlikely, but may
happen if the inlet sour gas specification changes), the operating
pressure may have to be raised to reduce the flow and prevent
amine carryover losses.
g) The temperature levels in the amine system should be monitored to
ensure that high temperature levels do not occur as the amine
solution will start to degrade. The amine degradation temperature is
approx. 149 0C for the bulk fluid and 160 0C for local hot spots in
the system.
 ANNEXURE-I
12.3 LIST of PSV in New ARU :

EQUIPMENT
UNIT NO. LOCATION SET PR.
4 PSV 1001A 4-V-14 3.5
4 PSV 1001B 4-V-14 3.5
4 PSV 1101A 4-C-04 3.6
4 PSV 1101B 4-C-04 3.6
4 PSV 1102A LP STEAM 4-E-10A 4.5
4 PSV 1102B LP STEAM 4-E-10A 4.5
4 PSV 1102C LP STEAM 4-E-10A 4.5
4 PSV 1102D LP STEAM 4-E-10A 4.5
4 PSV 1205A 4-T-02 3.5
4 PSV 1205B 4-T-02 3.5
4 PSV 1207A 4-P-07 17.32
4 PSV 1207B 4-P-07 17.32

12.4 LIST of PSV in Revamp ARU (OLD) :

EQUIPMENT
UNIT NO. LOCATION SET PR.
4 PSV 1001A 4-V-14 3.5
4 PSV 1001B 4-V-14 3.5
4 PSV 1101A 4-C-04 3.6
4 PSV 1101B 4-C-04 3.6
4 PSV 1102A LP STEAM 4-E-10A 4.5
4 PSV 1102B LP STEAM 4-E-10A 4.5
4 PSV 1102C LP STEAM 4-E-10A 4.5
CHAPTER - 13
13.0 Process Modifications :

13.1 The Scheme no. MR/TS/PS/ARU/2004/01 REV-2 has been

developed to provide a wash water injection facility at the
overhead circuit of ARU to reduce the existing corrosion
problem of overhead circuit. It was proposed to maintain the
wash water in the range of 2-3 M3/hr. Same amount of reflux
water is required to be purged out of the system from purge
line provided at the reflux control valve upstream.

The Scheme no. MR/TS/PS/ARU/2004/02 has been developed

to provide a globe valve and flowmeter (rotameter) in ARU
reflux water purge line for better control of purging.

13.2 Diethanol Amine (DEA) was used to scrub the H2S from LPG,
Fuel gas, Recycle gas in various Amine absorbers of the
refinery. The DEA Solvent has been changed with superior
MDEA solvent. The Comparison of various parameters of
MDEA with DEA is as follows:

Sl.No. Specifications Unit DEA MDEA

1. Molecular Wt. - 105.14 119.2

2. Specific Gravity @ - 1.09-1.096 1.09

20/20 Deg C
3. Boiling Point at 760 Deg C 269.1 247.2
mm Hg
4. Vapour Pressure at 20 MmHg <0.01 <0.01
deg C
5. Freezing Point Deg C 27.5 -21
6. Flash Point Deg C 138 135