unit overview module

Hydrocracker Unit 2600

Operator Training

Revision r0, March 24, 2017

Unit Overview

Module


Operator Training

Date Developed: Mar. 24, 2017 Last Reviewed On:Revision Date:

File Name Document Contact

Date Rev Comments

Date Developed: Mar. 24, 2017 Last Reviewed On:Revision Date:

File Name Document Contact

Date Rev Comments

Table of Contents

Hydrocracker Unit Inputs & Outputs

Material Hazards

Safety Systems.

Safety Systems Plot Plan

Plant Equipment

Simplified Process Flow

Page 3

Page 7

Page 8

Page 10

Page 11

Unit Overview

Module

Physical Hazards. Page 9

Objectives and Introduction Page 1

Module Objectives

1. List the inputs and outputs of the Hydrocracker Unit.

2. Describe the types of equipment used in the Hydrocracker Unit.

3. Describe the simplified flow through the Hydrocracker Unit.

4. Describe the material hazards present in the Hydrocracker Unit.

5. Describe the physical hazards present in the Hydrocracker Unit.

6. Describe the safety systems used and their locations in the Hydrocracker Unit.

Module Introduction

The PCR Refining Refinery is an 85,000 barrel per day facility located in Sinclair, Wyoming. The major products of the facility are propane, gasoline, jet fuel, diesel, and asphalt. Opened in 1924, it is one of the largest refineries in the Rocky Mountain Region.

The refinery is a complex operation that consists of a number of different process units, each designed to perform a specific function. The Hydrocracker Unit converts heavy, high boiling compounds produced elsewhere in the refinery into lighter, more valuable products.

The purpose of this Unit Overview Module is to provide a general, introductory overview of the Hydrocracker Unit, the types of equipment used, and the general flow through the unit. Additionally, the safety and health considerations associated with this unit are discussed.


Operator Training

Unit Overview

Module

1

Hydrocracking Unit Inputs & Outputs

Inputs to the HCU include:

• Atmospheric Gas Oil

• Light Vacuum Gas Oil

• Light Cycle Oil

• Light Coker Gas Oil

• Hydrogen

Outputs of the HCU Plant include:

• Light Naphtha

• Heavy Naphtha

• Jet Fuel

• Diesel

Utilities produced in the HCU Plant

include:

• Steam

• Condensate

The following Waste Streams are

produced in the HCU:

• Sour Water

Inputs and Outputs

The Hydrocracker Unit (HCU) consists of a number of related systems. Products from one system may end up as feed to another, or

leave as final products. To fully understand the interaction of the systems, it is important for you to recognize its inputs and outputs.

Chemicals used in the HCU

include:

• Lean Amine

• Anti-foulant

• Corrosion Inhibitor

• H2S Scavenger

• BFW

• Steam

• Condensate

• Nitrogen

• Glycol

The Utilities used to enable the

Hydrocracking facility to function as

intended include:

• BFW

• Steam

• Condensate

• Nitrogen

• Glycol

The Utilities used to enable the

Hydrocracking facility to function as

intended include:

• Cooling Water

• Instrument Air

• Plant Air

• Fuel Gas

• Electricity

Waste Streams

Utilities Used

Outputs

Chemicals Used

Utilities Produced

Lean Amine Hydrocracker Unit Systems

Cooling Water

Instrument Air

Glycol

Steam

Fuel Gas

Electricity

Nitrogen

Rich Amine

Light Naphtha

Heavy Naphtha

Jet Fuel

Diesel

Steam

Sour Water

Condensate

Chemicals Produced

Train 2 Cold

Separation &

Absorption

System

Main

Fractionation

System

Distillate

Fractionation

System

C-001

Compression

System

C-002

Compression

System

Feed Heating &

Reaction

System

Hot Separation&

Train 1 Cold

Separation

System

Anti-foulant

Corrosion Inhibitor

H2S Scavenger

Inputs

Atmospheric Gas Oil

Light Vac Gas Oil

Light Cycle Oil

Light Coker Gas Oil

Hydrogen

BFW

Condensate

Plant Air

2

Cen

trif

ug

al

Pu

mp

Po

sit

ive

Dis

pla

ce

me

nt

Pu

mp

Su

cti

on

an

d D

isch

arg

e P

uls

e B

ott

les

Rec

ipro

ca

tin

g C

om

pre

ss

or

Centrifugal Pump Positive Displacement Pump Reciprocating Compressor

Pumps are used to move process

streams throughout the facility. The

spinning impeller on a Centrifugal Pump

gives the liquid velocity energy. Velocity is

converted to pressure as the liquid leaves

the pump. This increased pressure drives

the liquid to flow to its lower pressure

destination. Centrifugal Pumps are useful

for moving liquids at high flow rates, with

a low to moderate pressure increase.

Positive Displacement Pumps rely on

mechanical energy, rather than kinetic

energy to move liquid. They displace a

known quantity of liquid with each

revolution of the pumping element. This is

done by trapping liquid between the

pumping elements and a stationary

casing. Pumping element designs include

gears, lobes, rotary pistons, diaphragms,

vanes, and screws.

A Compressor is a machine that

increases the pressure of a gas. The

purpose of compressors is to move air

and other gases from place to place by

increasing the gas pressure. A

Reciprocating Compressor is a positive-

displacement compressor that converts

rotational crankshaft motion into pumping

piston motion to deliver gas at a high

pressure.

Suction and Discharge Bottles are

intended to isolate the piping system from

the pulses generated by the compressor.

These bottles smooth out, or dampen,

pressure pulsations created by the act of

compression to prevent excessive

vibration that could damage piping and

equipment.

3Equipment

3Equipment

Suction and DischargePulse Bottles

Sh

ell

an

d T

ub

e E

xc

ha

ng

er

Kett

le T

yp

e S

team

Gen

era

tor

Hair

pin

Exc

ha

ng

er

Air

Co

ole

r

Shell & Tube Heat Exchanger Air Cooler Hairpin Exchanger

Shell and Tube Heat Exchangers consist

of a series of tubes. One set of these

tubes contains the fluid that must be

either heated or cooled. The second fluid

runs over the tubes that are being heated

or cooled so that it can either provide the

heat or absorb the heat as needed. A set

of tubes is called the tube bundle.

Steam Generators produce steam for use

throughout the plant using heat from

process streams. A Kettle Type Steam

Generator is a special type of Shell and

Tube Heat Exchanger. The hot fluid on

the tube side heats boiler feed water on

the shell side to the point that it vaporizes.

Above the bundle of tubes, there is a

large, open space that allows for

separation of vapor.

Air Coolers, also known as Fin Fan

Coolers, can be considered a special type

of shell and tube exchanger. A large fan is

used to blow air past the tubes. Most Fin

Fan Coolers are either induced-draft or

forced-draft, the more common

arrangement being forced draft. The air is

moved by rather large fans. The tubes are

surrounded with foil-type fins, typically

about 1 inch high, that increase the

surface area available for heat transfer.

A Hairpin Exchanger is a double pipe

shell and tube exchanger. They have

been described as single pass

exchangers that have been folded in half

to look like a hairpin.

4Equipment

4Equipment

Kettle TypeSteam Generator

Fu

el

Fir

ed

He

ate

r

Se

pa

rati

on

Ve

sse

l

Str

ipp

er

Fra

cti

on

ato

r

Fuel Fired Heater Fractionator Stripper

A Fuel Fired Heater is a piece of

equipment that burns fuel gas to generate

heat for the process stream. The process

streams flow through tubes within the

firebox. The burner is equipped with a

pilot to light the burner. Fuel for the heater

can be derived from off-gas, natural gas,

or fuel oil.

These vessels are pressure vessels that

provide a moving fluid with a small

amount of storage space. The storage

space is used to smooth out flow

fluctuation. Additionally, the fluid has

enough residence time in the vessel to

separate into phases. Gases are drawn

off the top, and liquids are drawn off the

bottom.

A Fractionator is a vertical vessel, or

column, that separates a feed stream into

two or more components according to the

boiling points of the components. It

contains trays or packing to aid in the

gas-liquid contact. The lower molecular

weight lighter compounds are driven to

the top of the column and removed at the

overhead draw. The higher molecular

weight heavier compounds are driven

to the bottom of the column and removed

at the bottom draw.

A Stripping Column, or Stripper, is a

distillation column where a gas is stripped

from a liquid solution. Stripping is the

removal of a component from a liquid

stream through vaporization and uptake

by an insoluble gas stream. Thus,

absorption and stripping are opposite

operations, often used together in a cycle.

5Equipment

5Equipment

Separation Vessel

Ab

so

rpti

on

Co

lum

n

Pre

tre

ate

r R

ea

cto

r

Hyd

rocra

ck

er

Re

ac

tor

Pretreater Reactor

A Reactor is a pressure vessel designed to

contain and ensure mixing of reactants at

the proper conditions so that the desired

chemical reaction will occur. The Pretreater

shown above is a catalytic reaction vessel

that is used to remove sulfur, nitrogen, and

oxygen compounds from the HCU feed.

The Hydrocracker is a catalytic reaction

vessel that converts higher molecular

weight components that make up the HCU

feed into more valuable, lighter products.

Gas absorption is a process in which one

or more soluble components of a stream

is dissolved in a liquid. An Absorption

Column is a specific type of column used

to separate components from a rising gas,

using a falling liquid to absorb the gas.

The operation may involve just physical

absorption, or may involve absorption of

the material into the liquid, followed by

reaction with one or more components of

the liquid solution.

Absorption Column Hydrocracker Reactor

6Equipment

6Equipment

6Simplified Process Flow

In the XXXXX System,

In the XXXXX System, the



In the Hot Separation & Train 1 Cold Separation System, the process

begins to separate reaction products from reaction byproducts and

recycle gas. This Hot HP Separator collects the heavier hydrocarbon

material that will be sent to the Main Fractionator via the Hot Flash

Drum. The process stream from the top of the Hot HP Separator is

cooled, then again splits into two trains for cold separation. In this

system, the Train 1 stream is cooled to condense water and hydrocarbon

liquid so that it can be separated from the hydrogen-rich recycle.

Recovered hydrocarbon liquid is cooled and routed to the Main

Fractionator.

In the Train 2 Cold Separation & Absorption System, the Train 2

stream from the cooled Hot HP Separator vapor is further cooled to

condense water and hydrocarbon liquid so that it can be separated from

the hydrogen rich recycle. It is separated in 2 stages. The recovered

hydrocarbon liquid is cooled, then mixes with the Train 1 flow to the Main

Fractionator. Hydrogen-rich vapors recovered from Train 1 and Train 2

are treated with amine to remove H2S and increase purity of the stream

so that it can be recycled to the Reactors.

In the C-001 and C-002 Compression Systems, various hydrogen

streams recovered within the unit are compressed so that hydrogen can

be returned to the high pressure reaction system. Each system includes

a six-cylinder reciprocating compressor. Cylinders 1A and 2A compress

sweet recycle hydrogen from the Recycle Absorber to provide hydrogen

feed and quench gas to the reactors. Cylinders 1C and 2C compress

Main Fractionator overhead vapor, which is sent to the FCC Unit. The D

cylinders compress makeup hydrogen from the #1 Reformer. Discharge

mixes with hydrogen feed from the HDS. The combined stream is

compressed in the E and F cylinders, and supplies hydrogen to both

reactor trains.

In the Feed Heating and Reaction System, feed is pumped to the high

pressure reaction circuit, mixed with hydrogen, then heated to the

temperature necessary for reactions to proceed. Due to the unit s high

capacity, two parallel reactor trains are used. The feed is first pretreated

for sulfur and nitrogen removal, as well as for olefin saturation. This is

done primarily to protect the downstream hydrocracking catalyst.

Pretreater effluent flows through the Hydrocracker to convert higher

molecular weight feed components to more valuable, lighter products.

Reactions in both the Pretreater and the Hydrocracker occur at a high

temperature and pressure in a hydrogen-rich atmosphere, and in the

presence of catalyst.

In the Main Fractionation System, feed recovered in the Hot Separator

and in the Low Pressure Separators is separated into valuable products

through the process of distillation. There are two side draws on the Main

Fractionator: heavy and light naphtha. Each naphtha draw is routed to a

stripper for light ends removal. Light and heavy naphtha are cooled in a

series of Heat Exchangers and flow to storage The Fractionator bottoms

is routed to the Distillate Fractionator for further fractionation. A portion of

the bottoms is recycled to the Feed Surge Drum for additional product

conversion.

In the Distillate Fractionation System, Main Fractionator Bottoms is

separated through distillation to yield more valuable products. The

Distillate Fractionator also has two draws: jet fuel and diesel. Each of

these draws is routed to a steam stripper for light ends removal.

Distillate product is routed to storage. Jet Fuel is sent to dryers to

remove water to reduce haze point. Overhead is condensed and

separated to recover heavy naphtha product. Distillate Fractionator

Bottoms is also recycled to the Feed Surge Drum for additional product

recovery.

Train 2 Cold

Separation

&

Absorption

SystemDistillate

Fractionation

System

Coker Naphtha

HCU Feed from

Tank Farm

Reactor Effluent

Ma

in F

ractio

nato

r B

ott

om

s

Recycle Hydrogen

Distillate Fractionator Bottoms

Heat Exchange

Wash Water

Sour Recycle Hydrogen

Fractionator Feed

Hot Flash Drum Bottoms

Heat

Exchange

Wash Water

Fractionator Bottoms to TK-401

Quench & Make-up Hydrogen

Recycle Hydrogen

Recovery Gas to FCC

Fractionator Overhead Sour Gas

to Tank Farm

Recycle Hydrogen

Sweet Recycle Gas

Hydrogen from Header

Hydrogen to FCC

Recycle Hydrogen

Hot Separator Overhead

Light Naphtha to Storage

Heavy Naphtha to Storage

Jet Fuel to PV-2049

Diesel Fuel to Storage

Heavy

Naphtha

Fractionator Feed

Wash Water

Feed Heating

&

Reaction

System

Hot Separation

&

Train 1 Cold

Separation

System

Main

Fractionation

System

C-001 & C002

Compression

Systems

Material Hazards

Flammability

Special

Hazards

Health Instability

Flammability

Special

Hazards

Health Instability

The NFPA diamond is broken into four colored

sections, each representing a specific hazard.

Health, Flammability, and Instability are rated

numerically, and Special Hazards are identified with

symbols or abbreviations.

Numbers in the three colored sections range from 0

to 4, with the following definitions:

0 = Minimal 1 = Slight 2 = Moderate 3 = Serious

4 = Severe

Oxidizer

4: Explosive at room temperature

3: May detonate if shocked, or heated under confinement, or mixed with water

2: Unstable, may react with water

1: May react if heated or mixed with water

0: Normally stable, does not react with water

4: Extremely flammable gas or liquid (Flash point below 73 °F)

3: Flammable (Flash point 73-100 °F)

2: Combustible, requires heating to ignite (Flash point above 200° F)

1: Slightly Combustible

0: Will not burn under normal conditions

4: Highly toxic, may be fatal on short term exposure

3: Toxic, full protective suit and breathing apparatus required

2: Breathing apparatus and face mask must be worn

1: Breathing apparatus may be worn

0: No precautions necessary

OXY

Acid ACID

Alkali ALK

Corrosive COR

Use No Water W

Radiation

HydrogenMSDS: #

CAS: 1333-74-0

Flammable gas that burns with an

almost invisible flame. Asphyxiant.

Primary route of exposure is inhalation.

Ventilate the area to keep concentrations of

hydrogen from building up. A supplied air

respirator should be worn when

concentrations are unknown. Spark-proof

tools should be used to control ignition

sources.

Multiple processes

MaterialMSDS Number

CAS Number(s)Major Hazards

NFPA

RatingsSpecial PPE/Controls Location

Nitrogen CAS: 7727-37-9 Simple asphyxiant

Maintain O2 levels above 19.5%. Use

positive pressure NIOSH approved air

supply.

4

0 0

4

0 0

0

0 0

0

0 0

Fuel GasCAS: 74-98-6

115-07-1

Extremely flammable gas. Vapors are

heavier than air. May explode violently.

Keep away from heat/sparks. Provide local

ventilation, where possible, to minimize

worker exposure and prevent explosive

concentrations.

4

1 0

4

1 0

Hydrocarbons C2 – C5 CAS: By Stream Highly Flammable

Chemical goggles are recommended.

Wear chemical resistant gloves when

handling. Wear approved respirators if

allowable limits are exceeded.

4

1 0

4

1 0

Hydrocarbons C6+ CAS: By Stream Flammable

Chemical goggles are recommended.

Wear chemical resistant gloves when

handling. Wear approved respirators if

allowable limits are exceeded.

3

1 0

3

1 0

Hydrogen Sulfide CAS: 7783-06-4Flammable gas. Toxic at high

concentrations.

If concentration is above allowable limits,

ventilate the area. A supplied air respirator

or SCBA should also be worn.

4

4 0

4

4 0

Ammonia CAS: 7764-41-7Strong alkali. Colorless gas or liquid

with a pungent odor.

Provide adequate ventilation. Wear

chemical goggles, face shield, rubber

gloves, and protective clothing when

handling. Avoid breathing mist or vapors.

1

3 0

1

3 0

Sour Water

Clear to yellow-brown liquid with a foul

odor of rotten eggs. Explosive

concentrations can build up in poorly

ventilated areas.

If the concentration is above allowable

limits, ventilate the area. Supplied air

respirator or SCBA should be worn.

8Material Hazards

8Material Hazards

SA

1

2 0

1

2 0

CAS: 7783-06-4

7732-18-5

7647-14-5

Physical Hazards

Overview:

A Physical Hazard is defined as A factor within the

environment that can harm the body without

necessarily touching it.

Physical hazards include but aren t limited to:

electricity, radiation, pressure, and heights, amongst

many others.

The PCR Refining Refinery contains multiple physical

hazards. They can cause harm to yourself or your

co-workers, if not controlled. The main, physical

hazards found are summarized in the table to the

right. Through awareness and attention to your

surroundings, you can apply the appropriate controls

to keep everyone safe.

Physical HazardsPhysical Hazards9

Physical Hazards9

High Pressure

Pressure is present whenever there is a

need to move a material, raise or lower a

boiling point, or affect the state of a

material (solid, liquid, or gas).

Exposure to pressure over 400 psig could cause

severe damage to the employee, depending on the

length of exposure. The results could be as simple

as causing the loss of balance, or as severe as the

amputation of a limb or injection of material under

the skin or into the blood stream. Overpressure of a

line or vessel could cause a catastrophic failure of

the system(s), release of hazardous material, fire,

explosion, etc.

Be aware that material being released from

piping could be under high pressure, and

approach with caution. Ensure that all

Pressure Relief Valves are in proper working

order, and if there is a block valve

underneath, that it remains locked or car

sealed open at all times. Open all valves

slowly to avoid a sudden release of pressure.

Hazard Explanation ControlAssociated Risks

Electricity

Electrical hazards exist when contact

occurs with exposed live parts due to

faults, which could cause fire or

explosions, or where an electrical fault is

the source of ignition.

Electrocution incidents can be fatal, while non-fatal

shocks can result in serious and permanent burn

injuries to skin, internal tissues, and damage to the

heart, depending on the length and severity of the

shock.

Ensure only appropriately licensed personnel

carries out electrical work. Switch off

electricity where possible before working on

equipment. Ensure electrical equipment is in

good working order. Ensure tag out and

isolation procedures are in place, and always

follow electrical safety standards.

High Temperature

High temperatures can cause instant

injury to personnel, ranging from

blistering (second degree burn) to

charring (third degree burn) of the

affected area. Hydrocracker feed must be

heated to a high temperature for cracking

reactions occur. In addition, the process

flow through the unit uses the transfer of

heat in exchangers to heat other

materials and/or generate steam to

reduce utility costs.

Exposure to piping and equipment in the

temperature range of 200°F to 400°F could cause

burns to the employee, resulting in immediate

blistering (second degree burn) to actual charring or

burning of the skin (third degree burn), depending

on the length and location of the exposure.

Exposure to material from equipment greater than

400°F could cause immediate second and/or third

degree burns, or even death, depending on the

length and location of exposure.

Ensure that all lines subject to high

temperatures are properly insulated or have

personal protective controls in place to

reduce the risk of exposure.

Elevated Platforms

Elevated platforms are in place to allow

access to all parts of the facility. These

platforms can present some unique

hazards as weather conditions change.

Elevated platforms may cause personnel to slip as

the surfaces become slick. Tripping may also cause

injury due to the height of the platform.

Check the surface for debris, oil, water, or

other substances. Ensure that any ladder

safety bar or chain is in place and the railing

is secured.

Rotating Equipment

Rotating equipment, such as centrifugal

pumps and compressors, can be deadly

because of their motion.

Rotating equipment or apparatus can trap clothing,

hair, or body parts.

Do not use a piece of equipment until you are

instructed on its proper use. Do not remove

guards or safety interlock devices. Use the

appropriate personal protective devices:

glasses, gloves, goggles, and/or face shield.

Use approved lock, tag, and try procedures

before working on equipment.

Sa

fety

Sh

ow

er/

Ey

ew

as

h S

tati

on

Bre

ath

ing

Ap

para

tus

Fir

efi

gh

tin

g E

qu

ipm

en

t

Em

erg

en

cy

Sto

p S

wit

ch

PP

E

An Emergency Stop Switch (ESD)

is a safety mechanism used to

shut off equipment in an

emergency situation when it

cannot be shut down in the usual

manner. Unlike a normal

shutdown switch/procedure, which

shuts down all systems in an

orderly fashion, an emergency

stop switch is designed to

completely and as quickly as

possible abort the operation.

Minimum Personal Protective

Equipment (PPE) requirements to

perform work in the plant include:

•Hard Hat

•Impact resistant safety glasses

with side shields attached

•Safety shoes with leather uppers,

safety toes, oil resistant soles, and

a defined heel

•Fire Retardant Clothing (FRC)

•Hearing Protection

•Personal H2S Monitor

There are Safety Showers and

Eye Wash Stations located

throughout the plant. Eye wash

stations should be used whenever

an individual s eye comes into

contact with a chemical hazard.

Safety showers will be used when

an individual is exposed to a

hazardous chemical. The

locations of Safety Showers and

Eyewash Stations switches, as

well as other safety systems, are

shown in the plot plan on page 13.

The Firefighting Equipment consists

of hoses and other equipment

located throughout the plant. All

firefighting equipment is painted red

for easy identification.

Breathing Apparatus Firefighting Equipment Emergency Stop Switch PPE

10Safety Systems

10Safety Systems

11Hydrocracker Safety Systems Plot Plan

11Hydrocracker Safety Systems Plot Plan

unit overview module

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