SONATRACH

NEW LNG TRAIN SKIKDA PROJECT

SKIKDA, ALGERIA
OPERATING MANUAL VOLUME II, SECTION 3-1:
UNIT 58 FRACTIONATION HOT OIL

DOCUMENT NO: PP-AAA-PP1-128

KBR
JOB NO.: J6404

0 LTP Issued for Implementation 23-Nov-10 FV BA AB

B LTP Issued for Client Approval 28-Oct-10 FV BA -

A VK Issued for Client Approval 09-Mar-10 VAS BA -

Rev. By Description Date KBR KBR CLIENT

Chkd App App

 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-128
OPERATING MANUAL VOLUME II, SECTION 3-1: REVISION 0
FRACTIONATION HOT OIL 23 NOVEMBER 2010

TABLE OF CONTENTS
1.0 INTRODUCTION................................................................................................... 3
2.0 SYSTEM DESCRIPTION ...................................................................................... 5
3.0 OPERATIONS....................................................................................................... 6
3.1 Normal Running..............................................................................................................6
3.1.1 Hot Oil Surge Drum, 58-MD01 .....................................................................................6
3.1.2 Hot Oil Furnace, 58-MB01............................................................................................6
3.1.3 Hot Oil Trim Cooler, 58-MC01......................................................................................7
3.1.4 Hot Oil Circulation Pumps, 58-MJ01 & 58-MJ01A ........................................................7
3.1.5 LP Fuel Gas KO Drum, 58-MD02.................................................................................7
3.2 Typical Operating Parameters ........................................................................................8
3.3 Temporary Operation......................................................................................................9
4.0 START-UP .......................................................................................................... 10
4.1 Prior to Start-up ............................................................................................................10
4.2 Fractionation Hot Oil System Start-up...........................................................................11
5.0 SHUTDOWN ....................................................................................................... 13
5.1 Normal Shutdown .........................................................................................................13
5.2 Process Upsets & Production Loss...............................................................................13
6.0 SAFETY/EMERGENCY SHUTDOWN................................................................ 15
6.1 Safety Critical Shutdown Systems ................................................................................15
6.1.1 I-5830 – 58-MB01 Hot Oil System – Circulation Pumps Trip ......................................15
6.1.2 I-5850 – 58-MB01 Hot Oil System – Pilots Trip ..........................................................15
6.1.3 I-5860 – 58-MB01 Hot Oil System – Main Burners Trip..............................................15
6.2 Pressure Safety Valve Summary ..................................................................................16
6.3 Fire Protection Equipment ............................................................................................16
7.0 ATTACHMENTS ................................................................................................. 17
7.1 Attachment I: Equipment List ........................................................................................18
7.2 Attachment II: Utility Consumption...............................................................................19

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-128
OPERATING MANUAL VOLUME II, SECTION 3-1: REVISION 0
FRACTIONATION HOT OIL 23 NOVEMBER 2010

1.0 INTRODUCTION
This operating manual relates to the facilities indicated on Process Flow Diagram
PR-58-PR32-001 and P&ID’s PR-58-SYPI-001 through PR-58-SYPI-005.
The purpose of the Fractionation Hot Oil System is to supply hot oil to the
Demethanizer, Deethanizer, Depropanizer, Debutanizer, and Deisopentanizer
Reboilers and Ethane Product Heater in the Fractionation Unit. In addition, the unit
supplies hot oil to the Feed Gas Heater and the Scrub Column Reboiler located
outside the Fractionation Unit.
Hot oil is heated by a fuel gas fired Hot Oil Furnace. A Hot Oil Surge Drum provides
adequate oil supply with space for heat expansion in the system and ensures a
stable flow to the Hot Oil Circulation Pumps. A Hot Oil Trim Cooler provides cooling
during Hot Oil Furnace start-up when the process users are unavailable.
Refer to sketch on the next page for a simplified process flow diagram of the Hot Oil
System and its associated equipment.

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E

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H

G
KBR HOT OIL SYSTEM
SONATRACH New LNG Train M

8
8

Skikda
18-SYPI-002 18-MC02 3 18-TY
1024A
18-SYPI-001
0-30%
08-PT >
08-PCV-1010 1000 18-TV-1015B 18-HIC 18-TY 30-100%
18-MDO1

18-TV-1024A
1024 1024B
08-SYPI-001

7
7

18-MC01
15-MC07
SKIKDA, ALGERIA

From 16-MJ04-GT 18-TV-1024B 18-TIC

08-PCV-1009 1024
08-MF01 18-TV-1015A 18-SYPI-002

Air Purge
18-K 18-TIC

6
6

Nitrogen
1856 1015 13-MC02
FRACTIONATION HOT OIL

08-MJ02 18-FIC
18-MJ01/A 1013

18-SYPI-003
PDIC

5
5

1003 58-TIC
1004 18-FV-1013
NEW LNG TRAIN SKIKDA PROJECT

12-MC23A/B

58-FV-1013B
75 To 100%

4
4

58-PV-1001A
0 To 75% Drains to 08-MF01
WF 58-PIC
1001A

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58-FY 58-FY 15-MC15
58-PV-1001B 58-PIC 1013B 1013A
1001B 07-MC14 07-MC04 07-MC02 58-SYPI-003
58-TV-1004

58-FIC
58-MD01 58-HIC
1013

3
3

3022 07-MC06 01-MC02

58-FV-1013A

Nitrogen
07-MC01 07-MC24 58-MC01

58-SYPI-001

58-MB01

Drains to 08-MF01

2
2

58-SYPI-002
58-PIC 58-TIC
OPERATING MANUAL VOLUME II, SECTION 3-1: REVISION 0

3135 1017
58-XV-3055
58-SYPI-005
58-PIC
58-MJ01/A
3070
DOCUMENT NO.

58-XV-3059 58-XV-3046 58-PV-3135

PP-AAA-PP1-128

58-XV-3058 8'’ F Gas

58-MD02

1
1

2'’ Pilot gas 4'’ acid gas from 12-MD22

23 NOVEMBER 2010

58-XV-3060 58-XV-3054 58-PCV-3019 To warm liq header

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-128
OPERATING MANUAL VOLUME II, SECTION 3-1: REVISION 0
FRACTIONATION HOT OIL 23 NOVEMBER 2010

2.0 SYSTEM DESCRIPTION

The Hot Oil Surge Drum, 58-MD01, is initially filled with hot oil from the Hot Oil
Storage Tank, 08-MF01, via the Hot Oil Make-Up Pump, 08-MJ02. Once filled, hot oil
is pumped by the Hot Oil Circulation Pumps, 58-MJ01/A, through the gas-fired Hot
Oil Furnace, 58-MB01. The Hot Oil Furnace heats the oil to 220ºC. Hot oil
temperature at the outlet of the Hot Oil Furnace is controlled by adjusting the LP fuel
gas rate to the furnace. LP Fuel gas to the Hot Oil Furnace is supplied by the LP Fuel
Gas Header in Unit 55 via the LP Fuel Gas KO Drum, 58-MD02. Flash vapors from
the HP Flash Column, 12-MD22, in the Acid Gas Removal Unit are also routed to the
Hot Oil Furnace as fuel.
Hot oil at 220ºC is supplied to the following users:
• Feed Gas Heater, 01-MC02
• Deethanizer Reboiler, 07-MC02
• Depropanizer Reboiler, 07-MC04
• Debutanizer Reboiler, 07-MC06
• Ethane Product Heater, 07-MC14
• Deisopentanizer Reboiler. 07-MC24
• Hot Oil Trim Cooler, 58-MC01
Hot oil return from the individual users is combined in a common header and
supplied to the following users at approximately 159ºC:
• Demethanizer Reboiler, 07-MC01
• Scrub Column Reboiler, 15-MC15
Hot oil return from the exchangers is combined in a common header and returned to
the Hot Oil Surge Drum. The Hot Oil Surge Drum elevation is at the highest point in
the hot oil system. It is a horizontal drum designed to accommodate the volume of
expansion in the hot oil circuit. It also allows for removal of gases in the system most
likely caused by tube leaks. The drum is typically operated at 3.0 barg and 115ºC
and is nitrogen blanketed.
The hot oil users have individual temperature controllers that control hot oil flow
based on the process demand. However, hot oil flow through the Hot Oil Furnace is
controlled at a constant rate by the use of two hot oil bypasses. A constant rate
ensures low film temperature that minimizes oil degradation.
The Hot Oil Trim Cooler, 58-MC01, is an air-cooled exchanger that is used to
maintain Demethanizer Reboiler, 07-MC01, and Scrub Column Reboiler, 15-MC05,
inlet temperature below 180ºC. The trim cooler is also used during start-up to remove
heat from the hot oil when the process users are unavailable.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-128
OPERATING MANUAL VOLUME II, SECTION 3-1: REVISION 0
FRACTIONATION HOT OIL 23 NOVEMBER 2010

3.0 OPERATIONS
3.1 Normal Running
This section provides a description of the operating parameters for the Fractionation
Hot Oil System. Refer to Section 3.2 for a list of typical operating variables for this
system.
3.1.1 Hot Oil Surge Drum, 58-MD01
The Hot Oil Surge Drum, 58-MD01, pressure is controlled by dual pressure controller
58-PIC-1001A/B. Controller 58-PIC-1001A opens valve 58-PV-1001A to relieve
excess pressure to the warm flare header, while controller 58-PIC-1001B opens
valve 58-PV-1001B to make-up nitrogen when low system pressure is detected.
Set-point for 58-PIC-1001A should be maintained higher than that for 58-PIC-1001B
in order to avoid nitrogen make-up and flaring to occur at the same time. The hot oil
system is a closed loop with the Hot Oil Surge Drum sized to accommodate volume
expansion in system. The drum operates at a high or low liquid level depending upon
the oil temperature and liquid level in the drum is not controlled.
3.1.2 Hot Oil Furnace, 58-MB01
The Hot Oil Furnace, 58-MB01, is a vertical cylindrical type fired heater with 16
burners and a pilot for each burner. The start-up of the Hot Oil Furnace is controlled
by the Burner Management System (BMS) provided by the vendor.
The BMS is designed for the sequential operations of start-up and safety shut down
operations of the Hot Oil Furnace. The cock valves check sequences, the purge
sequence and pilots start-up is provided from the field through local panel, installed
on the rack close to the Hot Oil Furnace. The burners start sequence will be initiated
from field through the local panel and each individual burner is lit by the relevant
manual valves located on the heater. The Hot Oil Heater has 16 burners and each
burner is provided with one continuous pilot. The pilots and burners are equipped
with detection system, Flame ionization rod for pilots and UV flame scanners for
burners.
The start-up sequence can be initiated from the local panel by hand-switch 58-HS-
3110A. This initiates the cock valves check sequence followed by system purge,
pilots & burners ignition. Hot oil temperature exiting the Hot Oil Furnace is controlled
by master temperature controller 58-TIC-1017, which provides input to the fuel gas
pressure controller 58-PIC-3135. Pressure controller 58-PIC-3135 throttles valve 58-
PV-3135 to meet the minimum firing pressure of the burners.
The Hot Oil Furnace receives fuel gas from the LP fuel gas header and the HP Flash
Column, 12-MD22, in the Acid Gas Removal Unit. Fuel gas from the LP fuel gas
header is controlled by pressure controller 58-PIC-3070, which throttles valve 58-PV-
3070 to vary the supply rate. HP Flash Column, 12-MD22, overhead pressure is
controlled by 12-PIC-1148, which opens valve 12-PV-1148 to release flash vapors to
the Hot Oil Furnace.
The Hot Oil Furnace utilizes natural draft air for combustion, and a negative pressure
should be maintained in the furnace at all times. The negative pressure is controlled
by operating the stack damper 58-HV-3022 via hand controller 58-HIC-3022.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-128
OPERATING MANUAL VOLUME II, SECTION 3-1: REVISION 0
FRACTIONATION HOT OIL 23 NOVEMBER 2010

The main burners can be stopped via hand switch 58-HS-3111A from the DCS while
maintaining the pilots. Fuel gas to the pilots is supplied from the Pilot Gas Header via
pressure regulator 58-PCV-3019.
3.1.3 Hot Oil Trim Cooler, 58-MC01
The Hot Oil Trim Cooler, 58-MC01, is a forced draft air-cooled exchanger consisting
of 1 bay and 3 fixed speed fans and shares its cooling capacity with the Gasoline
Product Cooler, 07-MC13. The fans can be manually started from the DCS.
Flow through the Hot Oil Trim Cooler is controlled by temperature controller 58-TIC-
1004 located on the common header supplying hot oil to the Demethanizer Reboiler,
07-MC01, and Scrub Column Reboiler, 15-MC15. Temperature controller 58-TIC-
1004 throttles valve 58-TV-1004 located at the discharge of the Hot Oil Trim Cooler
to vary the hot oil flow rate through the exchanger.
.
3.1.4 Hot Oil Circulation Pumps, 58-MJ01 & 58-MJ01A
There are two Hot Oil Circulation Pumps, 58-MJ01 & 58-MJ01A; one is on stand-by.
Both the pumps can be manually started from the DCS via hand switches 58-HS-
1010 (for 58-MJ01) and 58-HS-1012 (for 58-MJ01A). DCS logic 58-K-5820
automatically starts the stand-by pump when low pressure is detected in the
discharge header by 58-PSL-1008.
The pumps are provided with a discharge split range flow controller 58-FIC-1013
which throttles valves 58-FV-1013A & 58-FV-1013B located at the discharge of the
Hot Oil Furnace to maintain a constant flow through the furnace. Valve 58-FV-1013B
returns hot oil to the Hot Oil Surge Drum, 58-MD01, directly, thereby protecting the
Hot Oil Circulation Pumps from cavitation and the furnace tubes from over heating.
This ensures low film temperature in the Hot Oil Furnace and minimizes oil
degradation.
Valve 58-FV-1013A bypasses hot oil flow to the common header downstream of
01-MC01, 07-MC02, 07-MC04, 07-MC06, 07-MC14, 07-MC24, and 58-MC01.
Flow to the two valves is split with the help of converters 58-FY-1013A/B. Converter
58-FY-1013A uses the first 75% output from flow controller 58-FIC-1013 to throttle
valve 58FV1013A, while 58-FY-1013B uses the last 25% output from flow controller
58-FIC-1013 to throttle valve 58-FV-1013B. Normally no flow will be bypassed.
3.1.5 LP Fuel Gas KO Drum, 58-MD02
The LP Fuel Gas KO Drum, 58-MD02, receives gas from the LP Fuel Gas Header
and the HP Flash Column, 12-MD22, and supplies fuel to the main burners in the Hot
Oil Furnace, 58-MB01. The LP Fuel Gas KO Drum overhead line is heat traced to
prevent fuel gas from condensing before it reaches the burners.
Liquid level is normally not anticipated in the KO drum.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-128
OPERATING MANUAL VOLUME II, SECTION 3-1: REVISION 0
FRACTIONATION HOT OIL 23 NOVEMBER 2010

3.2 Typical Operating Parameters

The following table contains typical operating variables for the Fractionation Hot Oil
System.

Operating Variables for the Fractionation Hot Oil System

Tag No. Description Typical Value Units

58-AI-3062 O2 and Flue Gas Analyzer - -

58-FI-3045 Fuel Gas to Hot Oil Furnace 9,015 kg/h

58-FIC-1013 Hot Oil Circulation Pumps Discharge 703,633 kg/h

Flow Controller

58-LI-1007 Hot Oil Surge Drum Level 80 %

58-LI-1023 LP Fuel Gas KO Drum Level 0 %

58-PDIC-1003 07-MC01 & 15-MC15 Differential 4.5 bar

Pressure Controller

58-PI-1008 Hot Oil Circulation Pumps 58-MJ01/A 14.3 barg

Discharge Pressure

58-PI-3033 Furnace 58-MB01 Firebox 11.50 barg

58-PIC-1001A/B Hot Oil Surge Drum Pressure 3.0 barg

Controller

15-PIC-3070 LP Fuel Gas Pressure Controller 2.5 barg

15-PIC-3135 Hot Oil Furnace Fuel Gas Pressure 2.5 barg

Controller

58-TI-1006 Hot Oil Return Header Temperature 115 ºC

58-TI-1025 LP Fuel Gas KO Drum Inlet 64 ºC

Temperature

58-TI-1026 Hot Oil Furnace Inlet Temperature 115 ºC

Indicator

58-TI-1033 Hot Oil Trim Cooler Discharge 180 ºC

Temperature Indicator

58-TI-3013A 58-MB01 Heat Exchanger Tube Skin 220 ºC

Temp

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-128
OPERATING MANUAL VOLUME II, SECTION 3-1: REVISION 0
FRACTIONATION HOT OIL 23 NOVEMBER 2010

Operating Variables for the Fractionation Hot Oil System

Tag No. Description Typical Value Units

58-TI-3014A 58-MB01 Heat Exchanger Tube Skin 220 ºC

Temp

58-TI-3063 58-MB01 Furnace Stack 220 ºC

58-TI-3064 A/B 58-MB01 Hot Oil Furnace Bridge 220 ºC

58-TIC-1004 Hot Oil Return Header Temperature 159 ºC

Controller

58-TIC-1017 Hot Oil Furnace Discharge 220 ºC

Temperature Controller

3.3 Temporary Operation

During Hot Oil Furnace, 58-MB01, start-up, the Hot Oil Trim Cooler, 58-MC01,
removes excess heat from the circulating hot oil before the process users are placed
in operation. The Hot Oil Trim Cooler will be operated after a Hot Oil Furnace trip to
relieve excess heat that can cause heat soaking. It is important that circulation
through the Hot Oil Trim Cooler, 58-MC01, is maintained after all the burners are
tripped. This will prevent coking and overheating of the Hot Oil Furnace coils. Hot oil
circulation will continue until the oil is cooled to a safe operating temperature of 60ºC
and the system is drained if necessary.
The Hot Oil Drain system is only designed for system de-inventory after cooling
down. The drain valve will be opened only under administrative control to avoid
exceeding the design temperature of downstream equipment.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
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OPERATING MANUAL VOLUME II, SECTION 3-1: REVISION 0
FRACTIONATION HOT OIL 23 NOVEMBER 2010

4.0 START-UP
This section outlines the steps necessary to place the Fractionation Hot Oil System in
service. For the purpose of this section of the operating manual, it is assumed that
the following conditions exist: utilities are in service, hot oil is available from storage,
downstream units are ready to receive hot oil, plant dryout and cool down has been
completed, and system is purged and ready for start-up.
Note that during black start-up, the start-up strainers for the Hot Oil Circulation
Pumps, 58-MJ01/01A, should be left in service until a period of satisfactory operation
at the operating temperature.
4.1 Prior to Start-up
1. Confirm that Hot Oil Storage Tank, 08-MF01, is filled and ready to supply hot oil
to the Fractionation Hot Oil System.
2. Confirm that the fuel gas supply from the LP Fuel Gas Header is available to the
Hot Oil Furnace, 58-MB01, burners and the pilots. The load on the Fuel Gas
System will increase when the Hot Oil Furnace in brought online.
3. Confirm that the inlet and outlet isolation valves for all the process users including
01-MC02, 07-MC01, 07-MC02, 07-MC04, 07-MC06, 07-MC14, 07-MC24,
15-MC15, and 58-MC01 are closed.
4. Confirm that the following control valves are placed under manual control, and
fully closed:
• 58-FV-1013A: Hot oil bypass from Hot Oil Furnace, 58-MB01, discharge to hot oil
return header upstream of 07-MC01 & 15-MC15
• 58-FV-1013B: Hot oil bypass from Hot Oil Furnace, 58-MB01, discharge to hot oil
return header downstream of 07-MC01 & 15-MC15
• 58-PDV-1003: 07-MC01 & 15-MC15 differential pressure control valve
• 58-PV-1001A: Hot Oil Surge Drum, 58-MD01, overheads to warm flare header
• 58-PV-1001B: Hot Oil Surge Drum, 58-MD01, Nitrogen inlet line
• 58-TV-1004: Hot Oil Trim Cooler, 58-MC01, liquid outlet line
• 58-PV-3070: LP Fuel Gas KO Drum, 58-MD02, fuel gas from LP Fuel Gas
Header
• 58-PV-3135: Hot Oil Furnace, 58-MB01, fuel gas to burners header
5. Confirm that the following isolation valves are in closed position:
• 58-XV-3046: LP Fuel gas to Hot Oil Furnace, 58-MB01, burners header
• 58-XV-3054: LP Fuel gas to Hot Oil Furnace, 58-MB01, pilots header
• 58-XV-3059: LP Fuel gas to Hot Oil Furnace, 58-MB01, burners header
• 58-XV-3060: LP Fuel gas to Hot Oil Furnace, 58-MB01, pilots header
• 58-XV-3117: Plant Air to Hot Oil Furnace, 58-MB01, eductor

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FRACTIONATION HOT OIL 23 NOVEMBER 2010

6. Confirm that the following isolation valves are in open position:

• 58-HV-3022: Hot Oil Furnace, 58-MB01, stack damper
• 58-XV-3055: Burners header LP Fuel Gas vent valve
• 58-XV-3058: Pilots header LP Fuel Gas vent valve
4.2 Fractionation Hot Oil System Start-up
1. Line up hot oil from the Hot Oil Storage Tank, 08-MF01, to the Hot Oil Surge
Drum, 58-MD01, and commence transfer of hot oil to the drum. Place drum
pressure controllers 58-PIC-1001A/B on automatic as the pressure in the vessel
rises.
2. When liquid level is established in the Hot Oil Surge Drum, line-up Hot Oil
Circulation Pumps, 58-MJ01/A, open the suction and discharge valves and flood
the suction of both pumps.
3. Shutdown transfer of hot oil from storage when level in the Hot Oil Surge Drum
reaches 60%. Hot oil make-up to the system will be made as required.
4. Open inlet and outlet isolation valves to the Hot Oil Trim Cooler, 58-MC01, and
gradually introduce hot oil through the trim cooler via 58-TV-1004.
5. Ensure that all piping and the exchangers are filled and vented.
6. When priming is complete, one of the Hot Oil Circulation Pumps, 58-MJ01/A, is
placed in service, while the other is placed on stand-by.
7. Circulate hot oil through the Hot Oil Furnace, 58-MB01, hot oil supply & return
header, and back to the Hot Oil Surge Drum via valves 58-FV-1013A, 58-FV-
1013B, and 58-PDV-1003. When flow is established, place flow controller 58-FIC-
1013 on automatic. Cold circulation through the hot oil system is now established.
8. Line up fuel gas to the Hot Oil Furnace, 58-MB01, and place LP fuel gas header
pressure controller 58-PIC-3070 on automatic at the operating fuel gas pressure.
Place pressure controller 58-PIC-3135 to the burners header on automatic at a
minimum set point of 0.045 barg. If the system is in service, flash vapors from the
HP Flash Column, 12-MD22, can now be routed to the Hot Oil Furnace. Fuel gas
to the pilots is supplied from the LP Fuel Gas Header via pressure regulator 58-
PCV-3019.
9. When safe conditions for the Hot Oil Furnace are met, the main pilots and
burners can be sequentially started by the Burner Management System (BMS)
when activated by hand switch 58-HS-3110A. The hand switch initiates the cock
valves check sequences followed by system purge, and pilot & burner ignition.
Further details are furnished in the BMS Narrative.
10. When all the pilots and burners are lit and stable conditions established, place
furnace temperature controller 58-TIC-1017 on automatic control. The 58-TIC-
1017 varies the fuel gas supply to the Hot Oil Furnace by providing a set-point to
the 58-PIC-3135. Note that the rate of temperature increase in the furnace should
be controlled at 100ºC/hour to prevent damage to the refractory lining.
11. Place Hot Oil Trim Cooler temperature controller 58-TIC-1004 on automatic and
switch on the trim cooler fans as required. This ensures that the hot oil is cooled
before being returned to the Hot Oil Surge Drum.

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FRACTIONATION HOT OIL 23 NOVEMBER 2010

12. When hot oil circulation is established on automatic control, flow to the individual
process users can be sequentially initiated by opening the inlet and outlet
isolation valves and placing the respective flow controllers on automatic.
13. When hot flow to 07-MC01 and 15-MC05 is established, place differential
pressure controller 58-PDIC-1003 on automatic.

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FRACTIONATION HOT OIL 23 NOVEMBER 2010

5.0 SHUTDOWN
5.1 Normal Shutdown
The following steps are based on a planned shutdown of the Fractionation Hot Oil
System.
A shutdown of Unit 58 will be done by reducing the circulation through the unit and is
typically done in conjunction with a planned shut-down of the Fractionation unit.
1. Hot oil flow to the process users can be reduced to zero via their respective flow
controllers. Once flow is reduced to zero, place the controllers in manual and
closed position. Circulation through the Hot Oil Furnace, 58-MB01, is
maintained by opening the two bypasses and adjusting the fans on the Hot Oil
Trim Cooler, 58-MC01, to control the temperature of hot oil returned to the Hot
Oil Surge Drum, 58-MD01.
2. The system can be left in this mode if the shutdown is only for a short duration.
Shutdown for an extended period of time can be achieved by placing
temperature controller 58-TIC-1017 in manual and slowly decreasing the firing
rate to a minimum.
3. When the minimum firing rate is established, the burners may be turned off one
by one. It is recommended that the alternate burners be sequentially turned off
to avoid heat imbalance in the system.
4. The pilots should remain ignited unless a complete shutdown and internal
inspection of the Hot Oil Furnace is required. If the pilots remain ignited, the
heater can be brought back online without the need for re-purging.
5. For complete heater shutdown, when all the pilots and main burners are
extinguished, place fuel gas supply valves 58-PV-3070 and 58-PV-3135 in
manual and closed. Hot Oil Furnace should be purged with all dampers and
burner air registers open. The stack eductor would be normally left open
following shutdown to facilitate purging and cooling of the furnace.
6. It is important that circulation through the Hot Oil Trim Cooler, 58-MC01, is
maintained even after all the burners are shutdown to prevent coking and
overheating of the Hot Oil Furnace coils. Hot oil circulation will continue until the
oil is cooled to a safe operating temperature of 60ºC before the system is
drained.
5.2 Process Upsets & Production Loss
The following events can cause temporary process upsets in the Fractionation
system resulting in production loss.
1. Loss of Electrical Power
Loss of electrical power to the Fractionation Hot Oil Circulation Pump, 58-MJ01/A,
will cause circulation to cease until the spare pump is activated. Loss of hot oil flow
through the Hot Oil Furnace, 58-MB01, will result in high furnace outlet temperature.
DCS logic 58-K-5820 automatically starts the stand-by pump when low pressure is
detected in the discharge header by 58-PSL-1008. If the stand-by pump cannot be
activated in a short period of time, a complete Unit 58 shutdown may be required.

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FRACTIONATION HOT OIL 23 NOVEMBER 2010

Loss of electric power to the Hot Oil Trim Cooler, 58-MC01, fans could result in loss
of temperature control of hot oil to the Demethanizer Reboiler, 07-MC01, and Scrub
Column Reboiler, 15-MC15.
2. Loss of Instrument Air
Loss of instrument air to any one control valve will result in that valve going to its
designated fail safe position. As indicated on each P&ID, FO valves go to a ‘fail open’
position while FC valves go to a ‘fail closed’ position.
The following valves will fail open: 58-FV-1013B, 58-PDV-1003, 58-PV-1001A,
58-TV-1004
The following valves will fail close: 58-FV-1013A, 58-PV-1001B, 58-PV-3070,
58-PV-3135
3. Loss of Fuel Gas
Loss of fuel gas to the Hot Oil Furnace, 58-MB01, will result in loss of heating
medium to the Unit 58 process users.
Hot oil flow to the individual process users can be reduced to zero but circulation
through the Hot Oil Furnace, 58-MB01, should be maintained via the two bypasses
until the oil is cooled to an acceptable temperature. The system can be left in this
mode if the shutdown is only for a short duration.
4. Loss of Nitrogen
Loss of nitrogen to the Hot Oil Surge Drum, 58-MD01, could result in loss of
operating pressure. Monitor hot oil system pressure and reduce hot oil circulation
rate if required.

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6.0 SAFETY/EMERGENCY SHUTDOWN

6.1 Safety Critical Shutdown Systems
6.1.1 I-5830 – 58-MB01 Hot Oil System – Circulation Pumps Trip
On low liquid level alarm, 58-LALL-1031 in the Hot Oil Surge Drum, 58-MD01; high
stack temperature alarm, 58-TAHH-3065, on Hot Oil Furnace, 58-MB01,; or on New
Train ESD I-0000, Hot Oil System Circulation Pumps Trip Interlock I-5830 will trip the
Hot Oil Circulation Pumps, 58-MJ01/A, to prevent vapor breakthrough and cavitation
of the Hot Oil Circulation Pumps.
On high liquid level alarm, 58-LAHH-1024, in the LP Fuel Gas KO Drum, 58-MD02,
interlock I-5830 will force the fuel gas supply valves 12-PV-1148 and 58-PV-3070 to
manual and closed.
6.1.2 I-5850 – 58-MB01 Hot Oil System – Pilots Trip
When initiated by any one of the following events, Hot Oil System Pilots Trip Interlock
I-5850 will trip the pilot gas supply and bleed valves, 58-XV-3054, 58-XV-3060, and
58-XV-3058.
• New Train ESD I-0000
• Low liquid level alarm, 58-LALL-1031 in Hot Oil Surge Drum, 58-MD01
• High stack temperature alarm, 58-TAHH-3065, on Hot Oil Furnace, 58-MB01,
• High liquid level alarm, 58-LAHH-1024, in LP Fuel Gas KO Drum, 58-MD02
• Hand switches 58-HZ-3112A/B
• Low fuel gas pilot pressure alarm, 58-LAHH-3029 or high fuel gas pilot pressure
alarm, 58-PAHH-3029
• Two contiguous flames are extinguished (pilots & UV scanner)
6.1.3 I-5860 – 58-MB01 Hot Oil System – Main Burners Trip
When initiated by any one of the following events, Hot Oil System Main Burners Trip
Interlock I-5860 will trip the main burners fuel gas supply and bleed valves, 58-XV-
3046, 58-XV-3059, and 58-XV-3055; force fuel gas supply valve 58-PV-3135 to
manual and closed; force Hot Oil Furnace Damper 58-HV-3022 to manual and
opened.
• New Train ESD I-0000
• Low liquid level alarm, 58-LALL-1031 in Hot Oil Surge Drum, 58-MD01
• High stack temperature alarm, 58-TAHH-3065, on Hot Oil Furnace, 58-MB01,
• High liquid level alarm, 58-LAHH-1024, in LP Fuel Gas KO Drum, 58-MD02
• Hand switches 58-HZ-3112A/B
• Closure of Hot Oil Furnace, 58-MB01, damper
• Two contiguous flames are extinguished (pilots & UV scanner)
• Low fuel gas burners pressure alarm, 58-LAHH-3024or high fuel gas burners
pressure alarm 58-PAHH-3024
• Low-hot oil flow alarm, 58-FALL-1013A through the Hot Oil Furnace, 58-MB01

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• High temperature alarm,58-TAHH-1018, at the Hot Oil Furnace, 58-MB01, outlet

• High- pressure alarm, 58-PAHH-3021 on Hot Oil Furnace, 58-MB01.
6.2 Pressure Safety Valve Summary
The Fractionation Hot Oil System Pressure Relief Valve Summary contains a listing
of all the pressure relief valves associated with this system.

Fractionation Hot Oil System Pressure Relief Valve Summary

Set Pressure
Valve Number Description/Location
(barg)

58-PRV-1000A/B 58-MD01 Hot Oil Surge Drum/Relief to Warm 7.5

Flare Header

58-PRV-1001A/B 58-MD02 LP Fuel Gas KO Drum/Relief to Warm 7.7

Flare Header

58-PRV-1002A/B Fractionation Hot Oil Header/Relief to Warm 23.0

Flare Header

6.3 Fire Protection Equipment

The Fractionation Hot Oil System Fire Protection Equipment Summary contains a
listing of fire protection equipment associated with the Unit.

Fractionation Hot Oil System Fire Protection Equipment Summary

Description Quantity

CDL- Aircoolers

63-SP-010 Live Hose Reel 5

CDC –Hot Oil Furnace

63-SP-005 Fire Blanket 1

63-SP-013 Hydro-Foam Monitor Cabinet 2

63-SP-051 Four Way Hydrant with Foam Monitor 3

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7.0 ATTACHMENTS
The following attachments are included in this section of the Operating Manual:
7.1 Attachment I: Equipment List
7.2 Attachment II: Utility Consumption

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FRACTIONATION HOT OIL 23 NOVEMBER 2010

7.1 Attachment I: Equipment List

The following is a list of equipment associated with the Fractionation Hot Oil System.

Fractionation Hot Oil System Equipment List

Design Design
Equipment
Description Pressure Temp
No.
(barg) (ºC)

58-MB01 Hot Oil Furnace 23 250

58-MC01 Hot Oil Trim Cooler 23 250

58-MD01 Hot Oil Surge Drum 7.5 250

58-MD02 LP Fuel Gas KO Drum 7.7 110

58-MJ01/A Hot Oil Circulation Pump 1001 m3/hr rated

capacity

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7.2 Attachment II: Utility Consumption

Following are the electric motors associated with the Fractionation Hot Oil System
and their expected consumption.

Fractionation Hot Oil System Motor List

Available Motor
Equipment No. Description Load
(kW)

58-MC01-MJ01/2/3 Hot Oil Trim Cooler Fan 3 fans X 37.0 kW

58-MJ01/A Hot Oil Circulation Pump Electric Motor 520.0

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