Unit 1797 Process Module 2 PDF

**Module 2 Objective** ====================== Module 2 provides a detailed description of the Unit 1797 process, focusing on major and minor equipment as well as flow through the unit. **[Note: This Module does not contain any information on control valves, control loops, isolation valves, or shutd...

**Module 2 Objective** ====================== Module 2 provides a detailed description of the Unit 1797 process, focusing on major and minor equipment as well as flow through the unit. **[Note: This Module does not contain any information on control valves, control loops, isolation valves, or shutdown systems. That information will be covered in Module 3.]** In Module 2, you will learn and be required to know the following: - - - - - - The Trainee will not be required to know the size, horsepower, or flow rates. This information is provided to give a better mental image of the equipment in the field. **Module 2 Lessons** -------------------- - Lesson 1: Feed/Compression Section (Area 100) - Lesson 2: Reactor Section (Area 200) - Lesson 3: Stabilization Section-Scrubbers (Area 300) - Lesson 4: Solvent Wash Section (Area 600) - Lesson 5: Stabilization Section- Towers (Area 300) - Lesson 6: Fractionation Section (Area 400) - Lesson 7: Utilities Section (Area 500) - Lesson 8: Product Storage/Tank Field Section (Area 800) - Lesson 9: Environmental - Appendix 1: Chemistry - Appendix 2: Definitions of Key Terms As you go through Module 2, you will be asked to: - Answer questions about each section - Describe equipment in each section - Demonstrate your knowledge of the process flow **[NOTE]:** Refer to Appendix 2 for definitions of some of the words and terms used in the Module 2 discussion. **Unit 1797 Sections Overview** **Purpose of the Feed/Compression Section** =========================================== - - **Fig. 1‑1 Feed** **Process Flow Description** ============================ **Feed** In the Feed Section, heated pipeline ethylene and recycle ethylene combine, and the vapor ethylene is separated from the heavier liquid components (C4+). The Normal Alpha Olefins Unit 1797 (NAOU-1797) primarily receives ethylene from the Chevron Pipeline System via the Houston Pipeline Leg through the Chevron Pipeline Metering Skid outside of battery limits. In cases of pipeline upset that leads to ethylene quality problems for an extended duration, the Chevron Pipeline personnel can switch NAOU-1797 ethylene feed directly from EU-1592. The pipeline ethylene enters a pressure valve as it crosses battery limits causing a pressure drop resulting in auto refrigeration (cooling/condensing) of the ethylene. Ethylene begins to condense into liquid at temperatures below 65°F. Therefore, the ethylene is routed to the tube side of E-100 (Ethylene Preheater) and is heated by 100 psig steam on the shell side, reversing the auto refrigeration of the pipeline ethylene and reducing the risk of sending liquid ethylene into C-120A/B (Charge Gas Compressors). **WARNING** **Liquid or liquid phase process fluid could cause severe damage to the C-120A/B (Charge Gas Compressors) valves, other critical components, and even threaten cylinder integrity with loss of containment.** The preheated ethylene, mixed with recycle gas (mostly ethylene) from D-330 (H.P. Recycle K.O. Drum) and spillback from C-120A/B (Charge Gas Compressors) and C-360A/B (Booster/Recycle Compressors), is routed to D-110 (Charge Gas Compressor Suction Drum). The heavier components (C~4~+) are separated from the vapor ethylene and are routed from the bottom of D-110 (Charge Gas Compressor Suction Drum) to T-340 **(Caustic Wash Vapor Scrubber).**  **Fig. 1‑2 Compression** **Compression** In the Compression Section, vapor ethylene is compressed to the high pressure required to feed into reactors. The vapor ethylene from the overhead of D-110 (Charge Gas Compressor Suction Drum) is routed to the 1^st^ Stage of C-120A/B (Charge Gas Compressors). The vapor ethylene enters D-121A/B-1 (C-120A/B 1^st^ Stage Suction Bottles \#1) then enters D-121A/B-2 (C-120A/B 1^st^ Stage Suction Bottles \#2) prior to entering the 1^st^ Stage of C-120A/B (Charge Gas Compressors). The vapor ethylene enters D-121A/B-3 (C-120A/B 1^st^ Stage Discharge Bottles \#1) then enters D-121A/B-4 (C-120A/B 1^st^ Stage Discharge Bottles \#2) prior to exiting the 1^st^ stage. The vapor ethylene heats up as it is compressed. To remove the heat of compression and keep constant 2^nd^ stage temperature, the vapor ethylene is routed to the shell side of E-120A/B (Charge Gas Interstage Coolers) and is cooled by cooling water on the tube side. Removal of the heat reduces the amount of horsepower required to operate C-120A/B (Charge Gas Compressors), increasing the efficiency. The cooled vapor ethylene is routed to D-120A/B (Charge Gas Interstage K.O. Drums). Trace heavier components are separated from the vapor ethylene and are routed from the bottom of D-120A/B (Charge Gas Interstage K.O. Drums) to T-340 **(Caustic Wash Vapor Scrubber).** The vapor ethylene from the overhead of D-120A/B (Charge Gas Interstage K.O. Drum) is routed to the 2^nd^ Stage of C-120A/B (Charge Gas Compressors). The vapor ethylene enters D-121A/B-5 (C-120A/B 2^nd^ Stage Suction Bottles \#1) then enters D-121A/B-6 (C-120A/B 2^nd^ Stage Suction Bottles \#2) prior to entering the 2^nd^ Stage of C-120A/B (Charge Gas Compressors). The vapor ethylene enters D-121A/B-7 (C-120A/B 2^nd^ Stage Discharge Bottles \#1) then enters D-121A/B-8 (C-120A/B 2^nd^ Stage Discharge Bottles \#2) prior to exiting the 2^nd^ stage at a sufficient pressure for feed to R-201-205 (Reactors). **Pause to Review** Where does the ethylene come from? The ethylene comes from the Chevron Pipeline System via the Houston Pipeline Leg or the EU-1592. What is the purpose of E-120A/B (Charge Gas Interstage Coolers)? The purpose of E-120A/B (Charge Gas Interstage Coolers) is to remove the heat of compression from the 1^st^ stage of C-120A/B (Charge Gas Compressors), keep constant 2^nd^ stage temperature, reduce the amount of horsepower required to operate C-120A/B (Charge Gas Compressors), and increase efficiency. What can cause severe damage to C-120A/B (Charge Gas Compressors) and lead to loss of containment? Liquid or liquid phase process fluid could cause severe damage to C-120A/B (Charge Gas Compressors) and lead to loss of containment. **Fig. 1‑3 Compressors Lube Oil and Crankcase Oil Supply** **Compressors Lube Oil and Crankcase Oil Supply System** **D-130 (Lube Oil Storage Drum) supplies lube oil and D-140 (Crankcase Oil Storage Drum) supplies crankcase oil to C-120A/B (Charge Gas Compressors) and** C-360A/B (Booster/Recycle Compressors)**. Portable, pneumatic pumps use plant air to route the lube oil and the crankcase oil from 55 gallon drums to each storage drum.** **D-130 (Lube Oil Storage Drum) is equipped with E-130 (Lube Oil Drum Plate Coil) that maintains the temperature of the lube oil using 60 psig steam as the heating medium.** The steam condensate is routed to the 60 psig Steam Condensate Header. **D-130 (Lube Oil Storage Drum) has a LP nitrogen purge that vents to the atmosphere. P-130 (Lube Oil Transfer Pump) routes the lube oil to C-120A/B (Charge Gas Compressors) and** C-360A/B (Booster/Recycle Compressors). **D-140 (Crankcase Oil Storage Drum) is equipped with E-140 (Crankcase Drum Plate Coil) that maintains the temperature of the lube oil using 60 psig steam as the heating medium.** The steam condensate is routed to the 60 psig Steam Condensate Header. **D-140 (Crankcase Oil Storage Drum) has a LP nitrogen blanket that routes the crankcase oil to C-120A/B (Charge Gas Compressor) and** C-360A/B (Booster/Recycle Compressors). **Fig. 1‑4 Compressors Motor Purge System** **Compressors Motor Purge System** **Fresh air is routed through a weatherproof 25' air inlet stack and is filtered through F-121 (Purge Air Filter). C-121A/B (Purge Air Blowers) are used to pass the filtered, fresh air through C-120A/B (Charge Gas Compressors) and C-360A/B (Booster/Recycle Compressors) motors in order to make them intrinsically safe and satisfying the requirement for Class I, Division I electrical classification.** **WARNING** **Loss of fresh purge air to C-120A/B (Charge Gas Compressors) and C-360A/B (Booster/Recycle Compressors) motors in conjunction with a flammable gas release could result in an explosion and fire with the motors being the source of ignition.** **Fig. 1‑5 C-120A/B (Charge Gas Compressors) Crankcase Oil and Cooling Water** **C-120A/B (Charge Gas Compressors) Crankcase Oil and Cooling Water System** Crankcase oil is routed from D-140 (Crankcase Oil Storage Drum) to C-120A/B (Charge Gas Compressors) Crankcase Frame Oil Reservoirs as make-up. P-122A/B-1 (C-120A/B Main Lube Oil Pump) routes the crankcase oil to the shell side of either E-122A/B-1 (C-120A/B Lube Oil Coolers) or E-122A/B-2 (C-120A/B Lube Oil Coolers) where it is cooled with cooling water on the tube side. P-122A/B-2 (Auxiliary Lube Oil Pumps) maintain start-up and stand-by service. The crankcase oil is routed to either F-122A/B-1 (Lube Oil Filters) or F-122A/B-2 (Lube Oil Filters) prior to being routed to the main bearings and the outboard bearings of CM-120A/B (Motor Drives). The crankcase oil return is routed back to C-120A/B (Charge Gas Compressors) Crankcase Frame Oil Reservoirs. Cooling water is routed to CM-120A/B (Motor Drivers) cylinders \#1 and \#2. Cooling water is also routed to either FI-123A/B-1 (C-120A/B Packing Cooling Water Filters) or FI-123A/B-2 (C-120A/B Packing Cooling Water Filters) prior to being routed to CM-120A/B (Motor Drivers) piston rods and tail rods. **C-120A/B (Charge Gas Compressors) Rod and Cylinder Lubricator System** P-121A/B (Lubricator Pumps for C-120A/B) routes lubricating oil to the rod packings and cylinders of C-120A/B (Charge Gas Compressors). A hand pump is installed to ensure required lubrication when P-121 is offline for maintenance or repair. The hand pump is isolated from the system unless it is required for use. In addition, a vent has been installed on the discharge of P-121 (Lubricator Pumps for C-120A/B) when it is required to be inventoried or for air to be bled from system. **WARNING** **Any lubricating oil leak is unacceptable. The oil not making it to the high and low pressure piston rod packing could cause damage to the packing resulting in loss of containment.** **Pause to Review** What is used to route the lube oil and crankcase oil from 55 galloon drums to each storage drum? ================================================================================================ **Portable, pneumatic pumps use plant air to route the lube oil and the crankcase oil from 55 gallon drums to each storage drum.** **Loss of [fresh purge air] to C-120A/B (Charge Gas Compressors) and** C-360A/B (Booster/Recycle Compressors) **motors in conjunction with a [flammable gas] release could result in an explosion and fire with the [motors] being the source of ignition.** What can cause damage to the packing resulting in loss of containment? Any lubricating oil leak is unacceptable. The oil not making it to the high and low pressure piston rod packing could cause damage to the packing resulting in loss of containment. **Equipment Description** The following equipment descriptions provide further details about the size, shape, internals, special features, etc. of each piece of equipment. You will [not] be required to know the size of equipment. This information is provided to give the reader an idea about relative sizes in the field. The following equipment is discussed: **Feed System** - - **Compression System** - - - - - - - - - - - **Compressors Lube Oil and Crankcase Oil Supply System** - - - - - **Compressors Motor Purge System** - - **C-120A/B (Charge Gas Compressors) Crankcase Oil and Cooling Water System** - - - - - - - - - **C-120A/B (Charge Gas Compressors) Rod and Cylinder Lubricator System** - P-121A/B (Lubricator Pumps for C-120A/B) **[Feed System]** **E-100 (Ethylene Preheater)** **Heat Exchanger:** *A heat exchanger allows two materials to exchange heat typically by conduction, the hot one giving up some of its heat to the cooler one, and in turn, the cooler one becomes warmer.  This all happens without the two fluids coming in contact with each other.  The streams are typically separated by metal tubes that one side of the process flows through, conducting energy to the metal tube wall, while the other stream passes outside of the tubes and transfers energy through the tube wall as well.  The heat transfer takes place as the fluids pass each other and contact the metal tubes, which conduct the heat.  There are several different designs of tube and shell heat exchangers, but they all accomplish the same, heating one stream while cooling the other.   (Exception: Cooling towers are heat exchangers but do not fit the above description.)* **Shell and Tube Exchanger:** *Shell and Tube exchangers are hollow cylindrical vessels called shells that contain tube bundles.  One product flows through the vessel shell side while a separate product flows through the tubes.  One product will be cool while the other will be warmer.  As they pass in close contact with one another heat is exchanged through the contact with the metal walls of the tubes.  The cool material becomes warmer and the warmer material becomes cooler.  Shell and tube exchangers are used to cool products prior to shipping to tankage but, as energy prices have risen, are now used in heat integration where heat from a process is used to preheat streams entering a unit for processing.*  E-100 (Ethylene Preheater) is a multi-tube, U-type heat exchanger that heats the pipeline ethylene on the tube side with 100 psig steam on the shell side and is installed to superheat the ethylene prior to the next stage of letdown. **D-110 (Charge Gas Compressor Suction Drum)** D-110 (Charge Gas Compressor Suction Drum) (5'6"D x 9'L) is common to both C-120A/B (Charge Gas Compressors) and is equipped with internal demister pads installed below the top vapor outlets, and its function is to knock out any liquid that may be entrained in the pipeline and recycle ethylene streams. The pipeline and recycle ethylene streams enter the side of the drum. The heavier components (C~4~+) exit from the bottom of the drum, and the vapor ethylene exits from the top of the drum. **[Compression System]** **C-120A/B (Charge Gas Compressors)** **Compressor:** *A compressor is a mechanical device used to move vapor by increasing its pressure and reducing its volume.  They work like pumps but with vapor [only] instead of liquids.  The movement of the vapor can be forward through piping for flow or for storage.  The same type of compressors exist as are available for pumps, centrifugal and positive displacement.  They are just constructed to allow for vapor instead of a liquid.*  **Multi-Stage Compressors:** *Multi-stage compressors are compressors that combine the actions of two or more compressors onto a single driver shaft.  They are used where a single stage compressor will not produce the desired pressure to move a gas into the next section of operating equipment because the pressure to be overcome is too high.  The multi-stage compressor typically has the extra stages on the same driver shaft.  Vapor will enter the suction of the 1^st^ stage and is compressed out as 1^st^ stage discharge gas into a KO drum to remove any liquid.  The 1^st^ stage discharge gas then enters the suction of the 2^nd^ stage where it is compressed again and exits.  This scenario can then be repeated for other stages or the higher pressure 2^nd^ stage gas may be able to be used in the desired process.*   When the basic compressor parts function in proper sequence, the result is gas under pressure. The succession of events is: **Compression** The piston is fully extended and the cylinder full of gas ready for compression to take place. With the piston moving towards the closed end (compression stroke) the original volume of gas is decreased and the pressure increases until the cylinder pressure exceeds the discharge pressure. **[Discharge]{.smallcaps}** The cylinder pressure exceeds the discharge pressure forcing the discharge valve to open and pass gas to the receiver. Flow continues until the piston reaches the end of the stroke and the pressure declines as the piston reverse its direction. **Expansion** Both the inlet and discharge valves are closed, the piston is moving toward the point of beginning, and the pressure is decreasing to the inlet pressure.  **Intake** The inlet valve is open and the piston completes the intake stroke to a fully expanded position. The piston movement creates a partial vacuum causing the inlet valve to open and for gas to move into the cylinder causing it to become "loaded" for the next cycle. C-120 A/B (Charge Gas Compressors) are Dresser-Rand (6WIK-149) horizontally opposed, 325 rpm, 2500 hp multistage reciprocating positive displacement compressors. Normal operation is to run both compressors in parallel. A local Panalarm panel is provided for each compressor so the outside operator can monitor the compressor. On the panel is a Panalarm alarm box with 23 alarm windows. This alarm box has a first out sequencing system which lets the first alarm blink and all other alarms just light up in the event of multiple alarms occurring at a time. This system lets the operator know which alarm occurs first. The panalarm alarm box has instrument air pressure on it to meet the Class I, Division I electrical classification. Also on the panel is compressor start and stop buttons, local indication of suction, interstage and discharge pressure, 1st stage and 2nd stage discharge, temperature, motor amps, light indication of compressor loading, light indication of auxiliary lube oil pump running and light indication of the barring rig. Just to the side of each local panel is a compressor E-stop push button switch which is wired directly to the motor breaker contacts in the MCC room. This switch always assures the compressor can be shutdown if there is a problem with the shutdown PLC (Programmable Logic Controller) system. Also included on the panel are three lights indicating the status of the motor and interlock system. The green light indicates the motor is ready to start, the first red light indicates the motor cannot be started, and the second red light indicates the PLC bypass switch is activated and part of the interlock system is bypassed. The third light indicates the barring rig is engaged. A close-up of a switch Description automatically generated When acknowledging the local panalarm panel **never** hit the reset button until the first out (blinking) alarm has been ascertained. A good operator round requires carefully monitoring all the readings on the panalarm panel as well as the field equipment. **D-121A/B-1 (C-120A/B 1^st^ Stage Suction Bottles \#1)** **Suction/Discharge Bottle:** *A suction/discharge bottle, also known as a pulsation dampener, is a device used to dampen pressure pulsations created by the act of compression where suction and discharge valves are open for only part of the compression cycle. Reciprocating compressors generate flow pulsations in the suction and [discharge lines](https://www.sciencedirect.com/topics/engineering/discharge-line) that have to be controlled to prevent over and underloading of the compressors, avoid [vibration problems](https://www.sciencedirect.com/topics/engineering/vibration-problem) in the piping or other machinery, and to provide a smooth flow of gas.* C-120A/B (Charge Gas Compressors) are equipped with pulsation dampeners before and after each cylinder to reduce the vibration cause by the reciprocating stoke of the piston rod. High vibration can be caused by loose metal support straps, broken concrete support slab, and/or a significant oil level in discharge pulsation dampeners. The suction/discharge bottles are specially made for the compressors to provide smooth, quiet operation without sacrificing efficiency. The suction/discharge bottles operate much like check valves allowing for relatively unrestricted flow of gas in one direction only. It is important to monitor the temperature of the suction and discharge valves both on the DCS console and by the outside operator. A high temperature on these valves could indicate a valve failure or leak by. The ethylene enters the side of D-121A/B-1 (C-120A/B 1^st^ Stage Suction Bottles \#1) (2'D x 11'L) and exits the bottom. **D-121A/B-2 (C-120A/B 1^st^ Stage Suction Bottles \#2)** The ethylene enters the top of D-121A/B-2 (C-120A/B 1^st^ Stage Suction Bottles \#2) (2'D x 5'L) and exits the bottom into the 1^st^ stage of compression. **D-121A/B-3 (C-120A/B 1^st^ Stage Discharge Bottles \#1)** The ethylene exits the 1^st^ stage compression and enters the top D-121A/B-3 (C-120A/B 1^st^ Stage Discharge Bottles \#1) (2'D x 4'L) and exits the side. **D-121A/B-4 (C-120A/B 1^st^ Stage Discharge Bottles \#2)** The ethylene enters the top D-121A/B-4 (C-120A/B 1^st^ Stage Discharge Bottles \#2) (2'D x 9'L) and exits the side. **E-120A/B (Charge Gas Interstage Coolers)** E-120A/B (Charge Gas Interstage Coolers) are multi-tube U-type exchangers that cools the ethylene on the shell side with cooling water on the tube side and are installed between the 1^st^ and 2^nd^ stages of the compressor to remove the heat of compression. **D-120A/B (Charge Gas Interstage K.O. Drums)** D-120A/B (Charge Gas Interstage K.O. Drums) (4'D x 8'2"L) are equipped with an internal demister pads installed below the top vapor outlets, and its function is to knock out any entrained liquid from the ethylene that may develop when the ethylene is cooled. The ethylene enters on the side of the drums. The liquid exits from the bottom of the drums, and the vapor exits from the top of the drums. **D-121A/B-5 (C-120A/B 2^nd^ Stage Suction Bottles \#1)** The ethylene enters the side of D-121A/B-5 (C-120A/B 2^nd^ Stage Suction Bottles \#1) (1'8"D x 13'2"L) and exits the bottom. **D-121A/B-6 (C-120A/B 2^nd^ Stage Suction Bottles \#2)** The ethylene enters the top of D-121A/B-6 (C-120A/B 2^nd^ Stage Suction Bottles \#2) (1'8"D x 3'2"L) and exits the bottom into the 2^nd^ stage of compression. **D-121A/B-7 (C-120A/B 2^nd^ Stage Discharge Bottles \#1)** The ethylene exits the 2^nd^ stage compression and enters the top D-121A/B-7 (C-120A/B 2^nd^ Stage Discharge Bottles \#1) (1'8"D x 5'2"L) and exits the side. **D-121A/B-8 (C-120A/B 2^nd^ Stage Discharge Bottles \#2)** The ethylene enters the top D-121A/B-8 (C-120A/B 2^nd^ Stage Discharge Bottles \#2) (1'8"D x 13'2"L) and exits the side. **[Compressors Lube Oil and Crankcase Oil Supply System]** **D-130 (Lube Oil Storage Drum)** **D-130 (Lube Oil Storage Drum)** (2'6"D x 7'L) is common to both C-120A/B (Charge Gas Compressors) and C-360A/B (Booster/Recycle Compressors) and is installed to store the lube oil. **D-130 (Lube Oil Storage Drum)** is equipped with a plate coil and a Roto-Meter that regulates the LP nitrogen purge to the drum and **vents to the atmosphere through a 1-1/2" vent atop D-130 (Lube Oil Storage Drum).** The lube oil enters the top side of the drum and exits the bottom side of the drum. The LP nitrogen enters the top of the drum and vents from the top of the drum **to the atmosphere through a 1-1/2" vent**. **E-130 (Lube Oil Drum Plate Coil)** **E-130 (Lube Oil Drum Plate Coil)** is installed to maintain the temperature of the lube oil inside of **D-130 (Lube Oil Storage Drum)** using 60 psig steam as the heating medium. **P-130 (Lube Oil Transfer Pump)** **Pump:** *A pump is a mechanical device used to move liquids or slurries forward in piping.  This is typically accomplished by piston pressure, rotating vanes, screw type vanes or by increasing the velocity of the fluid.. All pumps have seals to prevent leakage to the atmosphere.*  **P-130 (Lube Oil Transfer Pump) is installed to route the lube oil to** C-120A/B (Charge Gas Compressors) and C-360A/B (Booster/Recycle Compressors). **P-130 (Lube Oil Transfer Pump)is an air-operated barrel pump.** **D-140 (Crankcase Oil Storage Drum)** **D-140 (Crankcase Oil Storage Drum)** (2'6"D x 7'L) is common to both C-120A/B (Charge Gas Compressors) and C-360A/B (Booster/Recycle Compressors)and is installed to store the crankcase oil. **D-140 (Crankcase Oil Storage Drum)** is equipped with a plate coil**.** The crank oil enters the top side of the drum and exits the bottom side of the drum. The LP nitrogen enters the top of the drum. **E-140 (Crankcase Drum Plate Coil)** **E-140 (Crankcase Drum Plate Coil)** is installed to maintain the temperature of the crank oil inside of **D-140 (Crankcase Oil Storage Drum)** using 60 psig steam as the heating medium. **[Compressors Motor Purge System]** **F-121 (Purge Air Filter)** **F-121 (Purge Air Filter) is a panel of 24 filters with each filter assembly consisting of a prefilter and a main filter that is installed to remove any particulates from the incoming air.** **C-121A/B (Purge Air Blowers)** **C-121A/B (Purge Air Blowers) are blower assemblies that consist of inlet guard screens, variable inlet vane manual controllers, blower fans, blower motors and air-actuated butterfly valves.** The variable inlet vanes, upstream of each blower, are installed to restrict airflow, which keeps from overloading the blower motor. The vanes are manually set and locked in position by a wing nut. Each blower is driven by a 50 HP motor and cooled by air flowing around the motors. Each motor has external grease fitting so the motor bearing can be lubricated. The blowers are equipped with variable pitched blades. Located on the outlet of each blower is an air-actuated butterfly valve. The butterfly valve is fail open. In normal operation only one blower is in service. The blower not in service will have the butterfly valve closed to prevent recirculation of air. Each blower is also equipped with a hand/off/automatic switch and a local indicator light to show which blower is in service. **[C-120A/B (Charge Gas Compressors) Crankcase Oil and Cooling Water System]** **P-122A/B-1 (C-120A/B Main Lube Oil Pump)** **Positive Displacement Pump:** *A positive displacement pump has a given volume of liquid displaced from the body of the pump on each cycle and the same volume will again be displaced on the next cycle.  Regardless of discharge pressure, positive displacement pumps produce the same flow for the same speed.  Positive displacement pumps can come in several varieties from diaphragm, piston, screw, gear and vane pumps.*  P-122A/B-1 (C-120A/B Main Lube Oil Pumps) are installed to route the lube oil to C-120A/B (Charge Gas Compressors). P-122A/B-1 (C-120A/B Main Lube Oil Pumps) are crankshaft driven positive displacement pumps. **P-122A/B-2 (Auxiliary Lube Oil Pumps)** P-122A/B-2 (Auxiliary Lube Oil Pumps) are installed to route the lube oil to C-120A/B (Charge Gas Compressors) if P-122A/B-1 (C-120A/B Main Lube Oil Pumps) fail. P-122A/B-2 (Auxiliary Lube Oil Pumps) are single stage centrifugal pump driven by 10 HP 1750 RPM induction electric motors. **E-122A/B-1 (C-120A/B Lube Oil Coolers)** E-122A/B-1 (C-120A/B Lube Oil Coolers) are multi-tube U-type exchangers that cool the lube oil on the shell side with cooling water on the tube side and are installed to cool the lube oil. **E-122A/B-2 (C-120A/B Lube Oil Coolers)** E-122A/B-2 (C-120A/B Lube Oil Coolers) are multi-tube U-type exchangers that cool the lube oil on the shell side with cooling water on the tube side and are installed to cool the lube oil. **F-122A/B-1 (Lube Oil Filters)** F-122A/B-1 (Lube Oil Filters) are installed **to remove contaminants from the lube oil.** **F-122A/B-2 (Lube Oil Filters)** F-122A/B-2 (Lube Oil Filters) are installed **to remove contaminants from the lube oil.** **FI-123A/B-1** **(C-120A/B-1 Packing Cooling Water Filters)** FI-123A/B-1 (Lube Oil Filters) are installed **to remove contaminants from the cooling water.** **FI-123A/B-2** **(C-120A/B-1 Packing Cooling Water Filters)** FI-123A/B-2 (Lube Oil Filters) are installed **to remove contaminants from the lube oil.** **[C-120A/B (Charge Gas Compressors) Rod and Cylinder Lubricator System]** **P-121A/B (Lubricator Pumps for C-120A/B)** P-121A/B (Lubricator Pumps for C-120A/B) are installed to provide lube oil to C-120A/B (Charge Gas Compressors) rod packings and cylinders. P-121A/B (Lubricator Pumps for C-120A/B) are camshaft- driven piston pumps driven by 10 HP 1750 RPM induction electric motors. **Pause to Review** What is the purpose of E-100 (Ethylene Preheater))? E-100 (Ethylene Preheater) heats the pipeline ethylene on the tube side with 100 psig steam on the shell side and is installed to superheat the ethylene prior to the next stage of letdown. What exits from the top of D-120A/B (Charge Gas Interstage K.O. Drums)? The purpose of E-120A/B (Charge Gas Interstage Coolers) is to remove the heat of compression from the 1^st^ stage of C-120A/B (Charge Gas Compressors), keep constant 2^nd^ stage temperature, reduce the amount of horsepower required to operate C-120A/B (Charge Gas Compressors), and increase efficiency. What can cause severe damage to C-120A/B (Charge Gas Compressors) and lead to loss of containment? Liquid or liquid phase process fluid could cause severe damage to C-120A/B (Charge Gas Compressors) and lead to loss of containment. **Equipment List**  Spend some time learning the equipment numbers before moving to the next section.  You will be required to know these numbers and answer related questions.  **Equipment Number**  **Feed/Compression Section: Description**  ------------------------------------------------------------------------------ -------------------------------------------- **Feed System** E-100 Ethylene Preheater D-110 Charge Gas Compressor Suction Drum **Compression System** C-120A/B Charge Gas Compressors D-121A/B-1 C-120A/B 1^st^ Stage Suction Bottles \#1 D-121A/B-2 C-120A/B 1^st^ Stage Suction Bottles \#2 D-121A/B-3 C-120A/B 1^st^ Stage Discharge Bottles \#1 D-121A/B-4 C-120A/B 1^st^ Stage Discharge Bottles \#2 E-120A/B Charge Gas Interstage Coolers D-120A/B Charge Gas Interstage K.O. Drums D-121A/B-5 C-120A/B 2^nd^ Stage Suction Bottles \#1 D-121A/B-6 C-120A/B 2^nd^ Stage Suction Bottles \#2 D-121A/B-7 C-120A/B 2^nd^ Stage Discharge Bottles \#1 D -121A/B-8 (-120A/B 2^nd^ Stage Discharge Bottles \#2 **Compressors Lube Oil and Crankcase Oil Supply System** **D-130** **Lube Oil Storage Drum** **E-130** **Lube Oil Drum Plate Coil** **P-130** **Lube Oil Transfer Pump** **D-140** **Crankcase Oil Storage Drum** **E-140** **Crankcase Drum Plate Coil** **Compressors Motor Purge System** **F-121** **Purge Air Filter** **C-121A/B** **Purge Air Blowers** **C-120A/B (Charge Gas Compressors) Crankcase Oil and Cooling Water System** P-122A/B-1 C-120A/B Main Lube Oil Pump P-122A/B-2 Auxiliary Lube Oil Pumps E-122A/B-1 C-120A/B Lube Oil Coolers E-122A/B-2 C-120A/B Lube Oil Coolers F-122A/B-1 Lube Oil Filters F-122A/B-2 Lube Oil Filters FI-123A/B-1 C-120A/B Packing Cooling Water Filters FI-123A/B-2 C-120A/B Packing Cooling Water Filters **C-120A/B (Charge Gas Compressors) Rod and Cylinder Lubricator System** P-121A/B Lubricator Pumps for C-120A/B **Knowledge Questions**  What routes the crankcase oil from D-140 (Crankcase Oil Storage Drum) to **C-120A/B (Charge Gas Compressors) and** C-360A/B (Booster/Recycle Compressors)**?** **D-140 (Crankcase Oil Storage Drum) has a LP nitrogen blanket that routes the crankcase oil to C-120A/B (Charge Gas Compressors) and** C-360A/B (Booster/Recycle Compressors). **Inside Exercise**  Spend a few minutes reviewing the drawings in this lesson.  When you are comfortable that you know the equipment and flow, sketch the Ethylene Feed Section from memory, including the following equipment, feed sources, and flow destinations.  Label all equipment by equipment number and name.  **Feed/Compression Section Equipment**  **Checked by**  ------------------------------------------------------------------------------ ----------------- **Feed System**     **Compression System**       **Compressors Lube Oil and Crankcase Oil Supply System** **D-130 (Lube Oil Storage Drum** **E-130 (Lube Oil Drum Plate Coil)** **P-130 (Lube Oil Transfer Pump)** **D-140 (Crankcase Oil Storage Drum)** **E-140 (Crankcase Drum Plate Coil)** **Compressors Motor Purge System** **F-121 (Purge Air Filter)** **C-121A/B (Purge Air Blowers)** **C-120A/B (Charge Gas Compressors) Crankcase Oil and Cooling Water System** P-122A/B-1 (C-120A/B Main Lube Oil Pump) P-122A/B-2 (Auxiliary Lube Oil Pumps) E-122A/B-1 (C-120A/B Lube Oil Coolers) E-122A/B-2 (C-120A/B Lube Oil Coolers) F-122A/B-1 (Lube Oil Filters) F-122A/B-2 (Lube Oil Filters) FI-123A/B-1 (C-120A/B Packing Cooling Water Filters) FI-123A/B-2 (C-120A/B Packing Cooling Water Filters) **C-120A/B (Charge Gas Compressors) Rod and Cylinder Lubricator System** P-121A/B (Lubricator Pumps for C-120A/B)   **Outside Exercise**  Have a **qualified** Operator/Trainer/Mentor walk you through the unit, showing you where each of the following pieces of equipment are located and discuss the purpose of each piece.  Don't just look.  If safe to do so, physically touch each item of equipment.  This will help you to recall the information for your long-term memory.  Follow your operator's instructions for safety.  Wear appropriate PPE, do not climb anywhere that requires a harness, and do not touch any machinery parts that are moving or may move suddenly.  **[NOTE to Qualified Trainer/Operator/Mentor]: Ensure you discuss the purpose of each piece of equipment as you show the location.  As part of the End of Module Assessment, the trainee will be required to locate each piece of equipment and discuss its purpose.**  +-----------------------+-----------------------+-----------------------+ | **Feed/Compression | **Trainee**  | **Qualified Persons | | Section Equipment**  | | Initials**  | | | **Initials**  | | +=======================+=======================+=======================+ | **Feed System** | | | +-----------------------+-----------------------+-----------------------+ | **E-100 (Ethylene |   |   | | Preheater)** | | | +-----------------------+-----------------------+-----------------------+ | | | | +-----------------------+-----------------------+-----------------------+ | **D-110 (Charge Gas |   |   | | Compressor Suction | | | | Drum)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose: knocks out | | | | any liquid that may | | | | be entrained in the | | | | ethylene feed | | | +-----------------------+-----------------------+-----------------------+ | **Compression | | | | System** | | | +-----------------------+-----------------------+-----------------------+ | **C-120A/B (Charge |   |   | | Gas Compressors)** | | | +-----------------------+-----------------------+-----------------------+ | | | | +-----------------------+-----------------------+-----------------------+ | **D-121A/B-1 |   |   | | (C-120A/B 1^st^ Stage | | | | Suction Bottles | | | | \#1)** | | | +-----------------------+-----------------------+-----------------------+ | | | | +-----------------------+-----------------------+-----------------------+ | **D-121A/B-2 |   |   | | (C-120A/B 1^st^ Stage | | | | Suction Bottles | | | | \#2)** | | | +-----------------------+-----------------------+-----------------------+ | | | | +-----------------------+-----------------------+-----------------------+ | **D-121A/B-3 | | | | (C-120A/B 1^st^ Stage | | | | Discharge Bottles | | | | \#1)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose:  dampens | | | | pressure pulsations | | | +-----------------------+-----------------------+-----------------------+ | **D-121A/B-4 | | | | (C-120A/B 1^st^ Stage | | | | Discharge Bottles | | | | \#2)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose:  dampens | | | | pressure pulsations | | | +-----------------------+-----------------------+-----------------------+ | **E-120A/B (Charge | | | | Gas Interstage | | | | Coolers)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose:  removes the | | | | heat of compression | | | +-----------------------+-----------------------+-----------------------+ | **D-120A/B (Charge | | | | Gas Interstage K.O. | | | | Drum)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose:  knocks out | | | | any liquid that may | | | | be entrained in the | | | | ethylene feed | | | +-----------------------+-----------------------+-----------------------+ | **D-121A/B-5 | | | | (C-120A/B 2^nd^ Stage | | | | Suction Bottles \#1** | | | +-----------------------+-----------------------+-----------------------+ | Purpose:  dampens | | | | pressure pulsations | | | +-----------------------+-----------------------+-----------------------+ | **D-121A/B-6 | | | | (C-120A/B 2^nd^ Stage | | | | Suction Bottles | | | | \#2)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose:  dampens | | | | pressure pulsations | | | +-----------------------+-----------------------+-----------------------+ | **D-121A/B-7 | | | | (C-120A/B 2^nd^ Stage | | | | Discharge Bottles | | | | \#1)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose:  dampens | | | | pressure pulsations | | | +-----------------------+-----------------------+-----------------------+ | **D-121A/B-8 | | | | (C-120A/B 2^nd^ Stage | | | | Discharge Bottles | | | | \#2)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose:  dampens | | | | pressure pulsations | | | +-----------------------+-----------------------+-----------------------+ | **Compressors Lube | | | | Oil and Crankcase Oil | | | | Supply System** | | | +-----------------------+-----------------------+-----------------------+ | **D-130 (Lube Oil | | | | Storage Drum)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose: stores the | | | | lube oil for C-120A/B | | | | (Charge Gas | | | | Compressors) and | | | | C-360A/B | | | | (Booster/Recycle | | | | Compressors) | | | +-----------------------+-----------------------+-----------------------+ | **E-130 (Lube Oil | | | | Drum Plate Coil)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose: maintains | | | | the temperature of | | | | the lube oil | | | +-----------------------+-----------------------+-----------------------+ | **P-130 (Lube Oil | | | | Transfer Pump)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose: routes the | | | | lube oil to C-120A/B | | | | (Charge Gas | | | | Compressors) and | | | | C-360A/B | | | | (Booster/Recycle | | | | Compressors) | | | +-----------------------+-----------------------+-----------------------+ | **D-140 (Crankcase | | | | Oil Storage Drum)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose: stores the | | | | crankcase oil for | | | | C-120A/B (Charge Gas | | | | Compressors) and | | | | C-360A/B | | | | (Booster/Recycle | | | | Compressors) | | | +-----------------------+-----------------------+-----------------------+ | **E-140 (Crankcase | | | | Drum Plate Coil)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose: maintains | | | | the temperature of | | | | the crankcase oil | | | +-----------------------+-----------------------+-----------------------+ | **Compressors Motor | | | | Purge System** | | | +-----------------------+-----------------------+-----------------------+ | **F-121 (Purge Air | | | | Filter)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose: filters the | | | | air into C-121A/B | | | | (Purge Air Blowers) | | | +-----------------------+-----------------------+-----------------------+ | **C-121A/B (Purge Air | | | | Blowers)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose: **passes the | | | | filtered, fresh air | | | | through C-120A/B | | | | (Charge Gas | | | | Compressors) and** | | | | C-360A/B | | | | (Booster/Recycle | | | | Compressors) | | | | **motors** | | | +-----------------------+-----------------------+-----------------------+ | **C-120A/B (Charge | | | | Gas Compressors) | | | | Crankcase Oil and | | | | Cooling Water | | | | System** | | | +-----------------------+-----------------------+-----------------------+ | **P-122A/B-1 | | | | (C-120A/B Main Lube | | | | Oil Pump)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose: routes the | | | | lube oil to C-120A/B | | | | (Charge Gas | | | | Compressors) | | | +-----------------------+-----------------------+-----------------------+ | **P-122A/B-2 | | | | (Auxiliary Lube Oil | | | | Pumps)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose: routes the | | | | lube oil to C-120A/B | | | | (Charge Gas | | | | Compressors) stand-by | | | | pump | | | +-----------------------+-----------------------+-----------------------+ | **E-122A/B-1 | | | | (C-120A/B Lube Oil | | | | Coolers)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose: cools the | | | | lube oil to C-120A/B | | | | (Charge Gas | | | | Compressors) | | | +-----------------------+-----------------------+-----------------------+ | **E-122A/B-2 | | | | (C-120A/B Lube Oil | | | | Coolers)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose: cools the | | | | lube oil to C-120A/B | | | | (Charge Gas | | | | Compressors) | | | +-----------------------+-----------------------+-----------------------+ | **F-122A/B-1 (Lube | | | | Oil Filters)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose: filters the | | | | lube oil to C-120A/B | | | | (Charge Gas | | | | Compressors) | | | +-----------------------+-----------------------+-----------------------+ | **F-122A/B-2 (Lube | | | | Oil Filters)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose: filters the | | | | lube oil to C-120A/B | | | | (Charge Gas | | | | Compressors) | | | +-----------------------+-----------------------+-----------------------+ | **FI-123A/B-1 | | | | (C-120A/B Packing | | | | Cooling Water | | | | Filters)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose: filters the | | | | cooling water to | | | | C-120A/B (Charge Gas | | | | Compressors) | | | +-----------------------+-----------------------+-----------------------+ | **FI-123A/B-2 | | | | (C-120A/B Packing | | | | Cooling Water | | | | Filters)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose: filters the | | | | cooling water to | | | | C-120A/B (Charge Gas | | | | Compressors) | | | +-----------------------+-----------------------+-----------------------+ | **C-120A/B (Charge | | | | Gas Compressors) Rod | | | | and Cylinder | | | | Lubricator System** | | | +-----------------------+-----------------------+-----------------------+ | **P-121A/B | | | | (Lubricator Pumps for | | | | C-120A/B)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose: provides | | | | lube oil to C-120A/B | | | | (Charge Gas | | | | Compressors) rod | | | | packings and | | | | cylinders | | | +-----------------------+-----------------------+-----------------------+ **Purpose of the Reactor Section** ================================== -  **Fig. 2‑1 Reactor** **Process Flow Description** In order to meet the design production rates, the five reactors operate in parallel with 90 % on-line availability, with all five online approximately 30% of the time. The 10 % non-availability occurs when the reactor is taken off-line for solvent washing. During normal operation, four of the five reactor systems will be in service, while one reactor system will be down for solvent washing. The reactor fouls because the reaction generates a waxy polymer, which gradually accumulates on the inner surface of the coil and reduces the heat transfer. To remove the polymer, ensure good temperature control, and maintain stable reactor operation, each reactor is taken off-line and solvent washed about once a month. In the Reactor Section, the compressed ethylene feed and the aluminum alkyl catalyst (TEA) flow to each of the reactors to react and form NAO products. Approximately 50% of the ethylene will convert to form NAO in the reactors. The pressure and temperature of the exiting reactor effluent is decreased to minimize the reaction occurring outside the reactor vessel. Each of the five parallel reactor systems consists of a reactor and a reactor effluent cooler. The main objective of the reactor section is to produce NAO products with the desired product distribution and quality. Desired product quality means keeping the alpha olefin content in the products high and vinylidenes within specifications. To achieve this operating objective, reactor pressure, temperature, ethylene feed rate and purity, and catalyst feed rate must all be properly controlled. The reactors must be operated so that upsets, which could lead to temperature excursions, are avoided. The compressed ethylene feed exits C-120A/B (Charge Gas Compressors), is routed to R-201-205 (Reactors), and is preheated in four internal preheat tubes. P-201-205(Catalyst Pumps) inject a precise amount of dilute catalyst (5 wt% TEA) from D-210 (Catalyst Surge Drum) at the fifth tube. Each reactor's catalyst injection header has an isolation valve to prevent ethylene from backing into the catalyst injection header if a catalyst pump stops pumping. The resulting ethylene/catalyst mixture reacts to form even carbon-number NAO as it flows isothermally through the remaining 212 tubes in each reactor, with a total residence time in the reactors of ≈50 minutes. **Conversion (based on ethylene) is controlled by adjusting the amount of 5 wt% TEA that is fed to each reactor. The amount of 5 wt% TEA required in a reactor depends on the reactor temperature. In order to ensure good catalyst distribution in the reactor, and thus maintain thermally stable reactor operation, it is desirable to keep the catalyst flow through the reactor as high as possible. The catalyst dilution is increased, and the injection rate is raised, until either the capacity of P-201/202/203/204/205 (Catalyst Pumps), or limitations in the Fractionation Section will not allow the catalyst to be increased any further. At present the limiting factor is P-201-205 (Catalyst Pumps) capacity. P-200 (Catalyst Pump) has been installed on R-205 (Reactor) to eliminate the limiting factor of the catalyst pumps. Future plans are to install the same design type of pump on R-201-204 (Reactors).** Boiler feed water from H-530 (Dowtherm Heater) is routed to the shell of each reactor to remove the heat generated by the NAO reactions and thus ensures a constant reaction temperature. **The actual pressure in the shell is adjusted to obtain the desired average coil temperature. This average coil temperature is manipulated to vary the composition of the reactor effluent components in response to market demands.** ≈220 psig steam is produced and let-down into the 100 psig steam header to D-565 (100 psig Steam Drum). **An ethylene purge is constantly flowing through each reactors' PSVs' inlets and critical transmitters' inlets. The ethylene purge gas is routed to CS-202**-1/2/3/4/5 (Coalescers) and FI-202-1/2/3/4/5 (Pre-filters) prior to being routed to the reactors. **The effluent exits from each reactor and is flashed across a control valve, which greatly reduces the reactions to produce NAOs but does not completely stop the undesirable formation of vinylidenes.** Therefore, the reactors' effluent is routed to the tube side of E-201-205(Reactor Effluent Coolers) and is cooled by cooling water on the shell side. After cooling, the effluent streams combine into one common header, with the exception of R-205 (Reactor), which is routed to a separate designated header that will be used to incorporate possible future reactors. **Pause to Review** What is produced in the shell side of each reactor and where is it routed? 220 psig steam is produced in the shell of each reactor and is let-down into the 100 psig steam header. Why has P-200 (Catalyst Pump) been installed? **P-200 (Catalyst Pump) has been installed on R-205 (Reactor) to eliminate the limiting factor of the catalyst pumps.** When fouling occurs on the tubes of a reactor what action must be taken? **In order to remove this fouling, each reactor and its associated cooler is taken off-line and solvent washed with hot solvent.** **Equipment Description** ========================= The following equipment descriptions provide further details about the size, shape, internals, special features, etc. of each piece of equipment. You will [not] be required to know the size of equipment. This information is provided to give the reader an idea about relative sizes in the field. The following equipment is discussed: - R-201-205 (Reactors) - P-201-205(Catalyst Pumps) - P-200 (Catalyst Pump) - E-201-205(Reactor Effluent Coolers) - CS-202-1/2/3/4/5 (Coalescer) - FI-202-1/2/3/4/5 (Pre-filter) **R-201-205 (Reactors)** R-201-205 (Reactors) are horizontal multi-tube reactors, consisting of 216 tubes. The first four tubes preheat the ethylene feed prior to the catalyst injection at the fifth tube. Conversion occurs in the remaining 211 tubes producing even-carbon, straight-chained normal alpha olefins. The process is exothermic, with the heat being controlled by steam production. **WARNING** **Reactors shall not be operated without PSV purge flows. This presents a significant [ ] risk to equipment, personnel, and the environment. Should catalyst propagate into the relief valve riser piping, two things will occur: (1) the heat generated by the reaction of ethylene and TEA will no longer be carried away by the process flow and (2) it is possible the reaction could exit the water bath, overheat, and decompose--- resulting in catastrophic piping failure and loss of containment.** **P-201-205 (Catalyst Pumps)** P-201-205 (Catalyst Pumps) are axial position variable volume positive displacement piston pumps driven by 40 HP 1800 RPM motors and are installed to inject **a precise amount of dilute catalyst (5 wt% TEA) to the reactors at the fifth tubes.** **The Oilgear/Petrodyne Catalyst Injection Pump is a reciprocating piston type with horizontally opposed plungers powered by a variable volume hydraulic pumping system.** **The liquid fluid ends are held in place by rigid housings made of closely machined steel castings which align the plungers in the fluid cylinder in a manner designed to reduce side loading and thrust on the high pressure seals.** **The hydraulic pump is an axial piston, variable volume type manufactured by the Oilgear Hydura division. An axial piston pump has rotating cylinder similar in appearance to that used in a revolver pistol. This cylinder has a series of pistons which move in or out of the cylinder as the cylinder rotates. The amount of volume produced by the pump is determined by the position of the pump swashplate.** **P-200 (Catalyst Pump)** P-200 (Catalyst Pump) is a Bran+Luebbe diaphragm style positive displacement pump. P-200 (Catalyst Pump) is equipped with a Hand, Off, Automatic (HOA) switch, located southeast of the pump, to energize the motor from the Variable Frequency Drive (VFD). Normally, the HOA switch will be placed in automatic to allow the console operator to press the START button on the console when the pump is ready to be started. Once the VFD and motor are energized the console operator will increase the speed by increasing the output on FC-2104. Placing the HOA switch in hand will start the pump and will enable the console operator to manipulate the FC-2104 output to control the VFD, and pump speed. The pump will indicate it is running (green) on the DCS when 5% output is achieved. P-200 (Catalyst Pump) has an adjustable pump stroke as well as a Variable Frequency Drive (VFD) to control pump speed. Adjusting the pump stroke increases the length of the stroke the pump will make during each revolution while the VFD increases the motor speed. The combination of the pump stroke and the motor speed will determine the amount of catalyst flow being pumped to the reactor catalyst injection point. The VFD for P-200 (Catalyst Pump) is upstairs in the 1797 switchgear on the east wall. To adjust the stroke, turn the stroke hand wheel located on top of the gear box. To increase the pump stroke, turn the handwheel clockwise, to decrease turn the handwheel counter-clockwise. The stroke indicator will begin to turn. The top numbers are the millimeters of stroke starting at 0 increasing up to 120mm. Zero on the pump stroke will pump no catalyst while 120mm is 100% of pump stroke capacity. **E-201-205 (Reactor Effluent Coolers)** E-201-205(Reactor Effluent Coolers) are multi-tube U-type exchangers that cool the reactor effluent on the tube side with cooling water on the shell side and are installed after the reactors to immediately stop undesirable reactions. **CS-202-1,2,3,4,5 (Coalescer)** **Coalescer:** *A coalescer is a device that separates an emulsion into the individual components, whether liquid/liquid, vapor/liquid or multi-phase.  This separation is known as coalescing.  Mechanical coalescing typically involves some type of media such as stainless mesh or filter element, inserted into a vessel and passing the emulsion through this mesh.  Small droplets of the heavier liquid will cling to the mesh/element and form larger droplets, which will eventually become heavy enough to fall to the bottom of the vessel where they will stay separated and can be withdrawn.  The same principle works for removing liquid from a gas that is passed over a mesh/filter element.  Coalescers are frequently used to remove water from hydrocarbon streams and to remove liquid hydrocarbon from gas streams.*  **CS-202**-1,2,3,4,5 (Coalescers) are installed on the **ethylene purge lines to each reactor to remove residual compressor oil.** **FI-202-1,2,3,4,5 (Pre-filter)** FI-202-1,2,3,4,5 (Pre-filter) are installed on the **ethylene purge lines to each reactor to remove contaminants.** **Equipment List**  Spend some time learning the equipment numbers before moving to the next section.  You will be required to know these numbers and answer related questions.  **Equipment Number**  **Reactor Section: Description**  ----------------------- ----------------------------------- R-201-205 Reactors P-201-205 Catalyst Pumps P-200 Catalyst Pump E-201-205 Reactor Effluent Coolers CS-202-1/2/3/4/5 Coalescer FI-202-1/2/3/4/5 Pre-filter **Knowledge Questions**  **Inside Exercise**  Spend a few minutes reviewing the drawings in this lesson.  When you are comfortable that you know the equipment and flow, sketch the Ethylene Feed Section from memory, including the following equipment, feed sources, and flow destinations.  Label all equipment by equipment number and name.  **Reactor Section Equipment**  **Checked by**  -------------------------------- -----------------           **Outside Exercise**  Have a **qualified** Operator/Trainer/Mentor walk you through the unit, showing you where each of the following pieces of equipment are located and discuss the purpose of each piece.  Don't just look.  If safe to do so, physically touch each item of equipment.  This will help you to recall the information for your long-term memory.  Follow your operator's instructions for safety.  Wear appropriate PPE, do not climb anywhere that requires a harness, and do not touch any machinery parts that are moving or may move suddenly.  **[NOTE to Qualified Trainer/Operator/Mentor]: Ensure you discuss the purpose of each piece of equipment as you show the location.  As part of the End of Module Assessment, the trainee will be required to locate each piece of equipment and discuss its purpose.**  +-----------------------+-----------------------+-----------------------+ | **Reactor Section | **Trainee**  | **Qualified Persons | | Equipment**  | | Initials**  | | | **Initials**  | | +=======================+=======================+=======================+ | **R-201-205 |   |   | | (Reactors)** | | | +-----------------------+-----------------------+-----------------------+ | | | | +-----------------------+-----------------------+-----------------------+ | **P-201-205(Catalyst |   |   | | Pumps)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose: injects | | | | catalyst into | | | | reactors | | | +-----------------------+-----------------------+-----------------------+ | **P-200 (Catalyst | | | | Pump)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose: injects | | | | catalyst into R-205 | | | | (Reactor) | | | +-----------------------+-----------------------+-----------------------+ | **E-201-205(Reactor |   |   | | Effluent Coolers)** | | | +-----------------------+-----------------------+-----------------------+ | | | | +-----------------------+-----------------------+-----------------------+ | **CS-202-1/2/3/4/5 | |   | | (Coalescer)** | | | +-----------------------+-----------------------+-----------------------+ | | | | +-----------------------+-----------------------+-----------------------+ | **FI-202-1/2/3/4/5 |   |   | | (Pre-filter)** | | | +-----------------------+-----------------------+-----------------------+ | Purpose:  removes | | | | **contaminants** | | | +-----------------------+-----------------------+-----------------------+ **Purpose of the Stabilization Section- Scrubbers** =================================================== - - - - - A diagram of a chemical process Description automatically generated **Fig. 3‑1 ???????????** **Process Flow Description** ============================ The reactors' effluent exits the common header, is routed to D-310A/B (Reactor Effluent Separators), and is separated into an overhead vapor recycle ethylene stream and a bottom liquid product stream consisting of NAO and catalyst. The overhead vapor recycle ethylene stream from D-310A/B (Reactor Effluent Separators) is routed to T-330 (TEA Scrubber) and is scrubbed with a C10-C12 stream from E-426 (C8 Tower Bottoms Cooler) to remove any vaporized or entrained aluminum alkyls which could cause plugging in downstream equipment by promoting ethylene polymerization. The bottom of D-310A/B (Reactor Effluent Separators) is routed to the Saturate Reduction System to remove aluminum alkyl. The overhead vapor from T-330 (TEA Scrubber) is routed to the shell side of E-330A/B (Ethylene Recycle Coolers) and is cooled by cooling water on the tube side. The vapor is then routed to D-330 (H.P. Recycle K.O. Drum), where any entrained liquid is removed. The overhead vapor from D-330 (H.P. Recycle K.O. Drum) splits into two streams. Most of the vapor is routed to E-373 (Purge Gas Heater) in the Deethenizer System, and the excess vapor is routed back to D-110 (Charge Gas Compressor Suction Drum) as recycled ethylene in the Ethylene Feed Section. The bottom liquid product streams from T-330 (TEA Scrubber) and D-330 (HP Recycle K.O. Drum) are routed T-340 (Caustic Wash Vapor Scrubber).  **Fig. 3‑2 Saturate Reduction** **Saturate Reduction System** The Saturate Reduction System was added to the process and is designed to reduce the paraffin content of the alpha olefin product. Liquid from the bottom of D-310A/B (Reactor Effluent Separators) is routed to the tube side of E-320 (Catalyzed Product Heater) and heated with 60 psig steam on the shell side. 0.2% nickel catalyst is injected into the process stream prior to being routed to M-320 (Static Mixer). The mixture is routed to D-320 (Catalyzed Mixing Vessel). After residence time, NAO product is routed to the tube side of E-321 (Catalyzed Product Cooler) and cooled with cooling water on the shell side prior to being routed to T-340 (Caustic Wash Tower). 2% nickel catalyst is received from an off-site supplier in 55 gallon drums and loaded into D-321 (Catalyst Blend Drum) that is equipped with M-321 (Blend Drum Mixer). The nickel concentration is further reduced to 0.2% in D-321 (Catalyst Blend Drum) using C14 as a diluent. The 0.2% nickel catalyst is routed from D-321 (Catalyst Blend Drum) into the process stream by P-321A/B (Catalyst Solution Injection Pumps). D-322 (Catalyst Drum) is designed to provide adequate storage of 0.2% nickel catalyst to supply P-321A/B (Catalyst Injection Pumps) while D-321 (Catalyst Blend Drum) is isolated for making a blend. D-322 (Catalyst Drum) is refilled after each blend is made in D-321 (Catalyst Blend Drum). Both D-321 (Catalyst Blend Drum) and (D-322 (Catalyst Drum) operate under a 20 psig nitrogen blanket. **Pause to Review** What is the purpose of the Stabilization Section? The purpose of the Stabilization Section is to separate the reactor effluent into a vapor and liquid stream, remove aluminum alkyls from the ethylene vapor to be recycled in the process, deactivate and remove aluminum alkyls from the liquid product stream (Caustic Wash), s**crub any entrained caustic or aluminates from the ethylene vapor to be recycled in the process (Water Wash), and r**educe the liquid product saturate content. What is used inside of T-330 (TEA Scrubber) to remove/scrub vaporized or entrained aluminum alkyls from the recycle ethylene stream? C10-C12 is used inside of T-330 (TEA Scrubber) to remove/scrub vaporized or entrained aluminum alkyls from the recycle ethylene stream. To where is the bottom liquid product stream from D-310A/B (Reactor Effluent Separators) routed? The bottom liquid product stream from D-310A/B (Reactor Effluent Separators) is routed to the Saturate Reduction System and the Caustic Wash System. Why has the Saturate Reduction System been incorporated into the process? The Saturate Reduction System has been incorporated into the process to reduce the paraffin content of the alpha olefin product. What is received from an off-site supplier in 55 gallon drums and loaded into D-321 (Catalyst Blend Drum)? 2% nickel catalyst is received from an off-site supplier in 55 gallon drums and loaded into D-321 (Catalyst Blend Drum). A diagram of a wash washer Description automatically generated **Fig. 3‑3 Caustic Wash** **Caustic Wash System** Liquid streams from the bottoms of D-310A/B (Reactor Effluent Separators), T-330 (TEA Scrubber), D-330 (H.P. Recycle K.O. Drum), and D-344 (Spent Caustic Settling Drum) combine with the liquid streams from the bottoms of D-110 (Charge Gas Compressor Suction Drum) and D-120A/B (Charge Gas Interstage K.O. Drum) from the Ethylene Feed Section. The combined liquids is mixed in M-340 (Caustic Wash Static Mixer) with heated circulating caustic, where the aluminum alkyls react with water to form n-paraffins and aluminum hydroxide. The caustic then immediately reacts with the aluminum hydroxide to form soluble sodium aluminate. Thus, the catalyst is destroyed, removed from the hydrocarbon phase, and solubilized in the caustic phase without dealing with the insoluble flocculent aluminum hydroxide. The nickel catalyst from the saturate reduction system reacts with the caustic to form a nickel salt which is removed with the spent caustic. Keeping the circulating caustic strength at or above 12% free caustic AND less than 30% to ensure that the sodium aluminate remains in solution.  **The resulting three-phase stream from M-340 (Caustic Wash Static Mixer) is routed to the bottom of T-340 (Caustic Wash Vapor Scrubber) where the vapor separates from the two liquid phases. The vapor rises through the packed bed in T-340 (Caustic Wash Vapor Scrubber),** where it is washed free of any entrained caustic by contact with fresh process water, and then flows overhead to E-360 (**Deethenizer Feed Cooler). The two liquid phases drop into D-340 (Caustic Wash Settler) and separate into a hydrocarbon stream and a caustic stream.** The hydrocarbon stream along with water from T-340 (Caustic Wash Vapor Scrubber) flows to T-350 (Water Wash Vapor Scrubber) to be water washed. **Most of the caustic stream from D-340 (Caustic Wash Settler), plus a small stream of make-up caustic routed from TK-342 (Fresh Caustic Storage Tank) is mixed in M-341 (Caustic Makeup Static Mixer) with process water, recycled by P-340A/B (Caustic Wash Circulation Pumps), and heated in the shell side of E-340 (Caustic Wash Heater) by 100 psig steam on the tube side to mix again with the combined liquid stream prior to being routed to M-340 (Caustic Wash Static Mixer). The excess caustic is routed to T-344 (Degassing Tower) in the Spent Caustic System. Waste water is routed to D-353 (Waste Water Degassing Drum).** D-340 (Caustic Wash Settler) is equipped with a continuous skim system. D-345 (Continuous Skim Drum) pulls the rag layer (a mixture of hydrocarbon, caustic water, and particulate matter) from the skim pan located in D-340 (Caustic Wash Settler). The rag layer negatively impacts NAO product quality, particularly heavy waxes, and fouls the F-383A/B (Debutenizer Feed Filters) and D-383A/B (Debutenizer Feed Coalescers).  From the rag layer skim pan, located inside of D-340 (Caustic Wash Settler), a continuous draw- off flows into D-345 (Continuous Skim Drum). Lighter components are separated from the heavier components (oily water) and from the waste water. The lighter components are routed to T-350 (Water Wash Vapor Scrubber) for further stripping. The oily water is routed to T-344 (Degassing Tower) for further stripping, The waste water is routed to D-353 (Waste Water Degassing Drum). Periodically, the rag layer is removed manually from D-345 (Continuous Skim Drum. **WARNING** **D-345 (Continuous Skim Drum) is equipped with a highly effective level sensor comprised of a nuclear source located in a rod centered in the middle of the drum and sensors located on the side of the drum. The sophisticated level system is required to effectively display the hydrocarbon, caustic water, and rag layers contained in the drum. The nuclear source, however, requires specific steps to clear and prepare for maintenance to reduce risk of personnel exposure. A qualified technician will shutter the nuclear source before maintenance can be performed.**  **Fig. 3‑4 Spent Caustic** **Spent Caustic System** **Spent caustic from the bottoms of D-340 (Caustic Wash Settler) and D-345 (Continuous Skim Drum) are routed to T-344 (Degassing Tower), along with a spent caustic stream from Unit 1798. The overhead gas is routed to the Purge Gas Header. The spent caustic drops into D-344 (Spent Caustic Settling Drum) on the water side of the drum. In the event of a high level on D-360 (Booster Cylinder Suction Drum) an intermittent process stream is routed to D-344 (Spent Caustic Settling Drum) to prevent a shutdown of** C-360A/B (Booster/Recycle Compressors)**. The Slop Oil Header is also routed to D-344 (Spent Caustic Settling Drum).** **The spent caustic exits the bottom of D-344 (Spent Caustic Settling Drum) and is routed by** **P-344 (Spent Caustic Transfer Pump) to the tube side of E-344A/B (Spent Caustic Coolers) and is cooled with cooling water on the shell side prior to being routed to storage in Unit 1791 TK-60.** **The hydrocarbon exits the bottom of D-344 (Spent Caustic Settling Drum) and is routed by P-345A/B (Hydrocarbon Recovery Pump) and/or P-346 (Hi Volume Hydrocarbon Recovery Pump) to D-340 (Caustic Wash Settler).** **Fig. 3‑5 Water Wash** **Water Wash System** **The skimmed hydrocarbon stream from D-340 (Caustic Wash Settler) and the water from the bottom of T-340 (Caustic Wash Vapor Scrubber) are routed to M-350 (Water Wash Static Mixer). P-350A/B (Water Wash Circulation Pumps) circulate a water wash stream from the bottom of D-350 (Water Wash Settler) that is heated in the shell side of E-350 (Water Wash Heater) by 100 psig steam on the tube side and joins the three-phase stream prior to being routed to and mixing in M-350 (Water Wash Static Mixer).** **The resulting three-phase stream from M-350 (Water Wash Static Mixer) is routed to the bottom of T-350 (Water Wash Vapor Scrubber). The vapor hydrocarbon separates from the liquid phases, rises through the packed bed inside of** **T-350 (Water Wash Vapor Scrubber), and is scrubbed with process water to ensure the vapor hydrocarbon is free of any** **entrained caustic and/or aluminates, also minimizing the liquid hydrocarbon. The vapor hydrocarbon is routed to the shell side of E-351 (Water Wash Vapor Cooler) and is cooled by cooling water on the tube side. This condenses the water in the vapor hydrocarbon prior to being routed to D-360 (Booster Cylinder Suction Drum). E-351B (Water Wash Vapor Cooler) is placed in service when E-351 (Water Wash Vapor Cooler) is removed from service and cleaned.** **The two liquid phases drop into D-350 (Water Wash Settler) and separate. Most of the water is recycled by P-350A/B (Water Wash Circulation Pumps) to again mix with the hydrocarbon. The waste water flows to D-353 (Waste Water Degassing Drum) before being drained to the Oily Water Sewer (OWS). The skimmed hydrocarbon is routed to the Debutenizer System.** **Pause to Review** What liquid streams are routed to M-340 (Caustic Wash Mixer) to be mixed with heated circulating caustic? Liquid streams from the bottoms of D-310A/B (Reactor Effluent Separators), T-330 (TEA Scrubber), D-330 (H.P. Recycle K.O. Drum), and D-344 (Spent Caustic Settling Drum) combine with the liquid streams from the bottoms of D-110 (Charge Gas Compressor Suction Drum) and D-120A/B (Charge Gas Interstage K.O. Drum) from the Ethylene Feed Section. The combined liquids is mixed in M-340 (Caustic Wash Static Mixer) with heated circulating caustic. Why is D-340 (Caustic Wash Settler) equipped with a continuous skim system? D-345 (Continuous Skim Drum) pulls the rag layer (a mixture of hydrocarbon, caustic water, and particulate matter) from the skim pan located in D-340 (Caustic Wash Settler). The rag layer negatively impacts NAO product quality, particularly heavy waxes, and fouls the F-383A/B (Debutenizer Feed Filters) and D-383A/B (Debutenizer Feed Coalescers).  What could shutdown in the event of a high level on D-360 (Booster Cylinder Suction Drum)? C-360A/B (Booster/Recycle Compressors) could shutdown in the event of a high level on D-360 (Booster Cylinder Suction Drum). What pump is used to route spent caustic from the bottom of D-344 (Spent Caustic Settling Drum) to E-344A/B (Spent Caustic Coolers)? **P-344 (Spent Caustic Transfer Pump)** is used to route spent caustic from the bottom of D-344 (Spent Caustic Settling Drum) to E-344A/B (Spent Caustic Coolers). What is removed/scrubbed from the vapor stream that rises through the packed bed inside of **T-350 (Water Wash Vapor Scrubber)?** **Entrained caustic and/or aluminates is removed from** the vapor stream that rises through the packed bed inside of **T-350 (Water Wash Vapor Scrubber).** **Equipment Description** ========================= The following equipment descriptions provide further details about the size, shape, internals, special features, etc. of each piece of equipment. You will [not] be required to know the size of equipment. This information is provided to give the reader an idea about relative sizes in the field. The following equipment is discussed: - D-310A/B (Reactor Effluent Separators) - T-330 (TEA Scrubber) - E-330A/B (Ethylene Recycle Coolers) - D-330 (H.P. Recycle K.O. Pot) **Saturate Reduction System** - E-320 (Catalyzed Product Heater) - M-320 (Static Mixer). - D-320 (Catalyzed Mixing Vessel). - E-321 (Catalyzed Product Cooler) - D-321 (Catalyst Blend Drum) - M-321 (Blend Drum Mixer) - P-321A/B (Catalyst Solution Injection Pumps) - D-322 (Catalyst Drum) **Caustic Wash System** - M-340 (Caustic Wash Static Mixer) - T-340 (Caustic Wash Vapor Scrubber) - D-340 (Caustic Wash Settler) - M-341 Caustic Makeup Static Mixer) - P-340A/B (Caustic Wash Circulation Pumps) - E-340 (Caustic Wash Heater) - D-345 (Continuous Skim Drum) **Spent Caustic System** - T-344 **(Degassing Tower),** - D-344 **(Spent Caustic Settling Drum)** - P-344 **(Spent Caustic Transfer Pump)** - E-344A/B **(Spent Caustic Coolers)** - P-345A/B **(Hydrocarbon Recovery Pumps)** - P-346 **(Hi Volume Hydrocarbon Recovery Pump)** **Water Wash System** - P-350A/B (Water Wash Circulation Pumps) - E-350 (Water Wash Heater) - M-350 (Wash Water Static Mixer) - **T-350 (Water Wash Vapor Scrubber)** - **E-351 (Water Wash Vapor Cooler)** - **E-351B (Water Wash Vapor Cooler)** - **D-350 (Water Wash Settler)** - D-353 (Waste Water Degassing Drum) **D-310A/B (Reactor Effluent Separators)** D-310A/B (Reactor Effluent Separators) (8'D x 28' 8 5/16"L) are installed to separate the cooled reactor effluent into a liquid product stream and a recycle ethylene vapor stream. The reactor effluent enters the top of the separators. The liquid product stream exits from the bottom of the separators, and the recycle ethylene vapor stream exits from the top of the separators. **NOTE:** One separator is in service at a time, while the other is in standby service. When in standby service, the separator remains under nitrogen pressure to ensure that the standby separator is air freed. **T-330 (TEA Scrubber)** T-330 (TEA Scrubber) (3'D x 23'6"L) is installed to remove any aluminum alkyls that could cause plugging in downstream equipment as a result of ethylene polymerization. A C10-12 stream from the recycle ethylene vapor stream stops the reaction of the aluminum alkyls. The recycle ethylene vapor stream enters the side bottom of the scrubber, and the C10-12 stream enters the side top of the scrubber. The overhead vapor exits from the top of the scrubber, and the liquid exits from the bottom of the scrubber. **NOTE: Due to the possible fouling tendency of T-330 (TEA Scrubber) and the vapor inlet line to the scrubber, periodic cleaning may be needed. In addition, the inlet, outlet, and bypass valves for the tower have been Teflon impregnated to minimize fouling of the valve gates and seats.** If the scrubber fouls, it can be bypassed and shutdown for cleaning. To ease the cleaning operation, the tower is equipped with a manway at each tray.  **E-330A/B (Ethylene Recycle Coolers)** E-330A/B (Ethylene Recycle Coolers) are multi-tube U-type exchangers that cool the ethylene vapor stream on the tube side with cooling water on the shell side and are installed to cool the ethylene vapor stream. **NOTE**: Normally, both coolers are in service. However, when the heat transfer ability has shown to decrease, as indicated by rising effluent temperatures not related to fluctuations in cooling water temperature, the fouled exchanger will be taken out of service and cleaned. **D-330 (H.P. Recycle K.O. Pot)** D-330 (H.P. Recycle K.O. Pot) (3'6"D x 7'9"L) is equipped with an internal demister pad installed below the top vapor outlet, and its function is to knock out any entrained liquid from the ethylene that may develop when the ethylene is cooled. The ethylene enters the side of the pot. The liquid exits from the bottom of the pot, and the vapor exits from the top of the pot. **[Saturate Reduction System]** **E-320 (Catalyzed Product Heater)** **Hairpin Heat Exchanger:** *A hairpin heat exchanger is unique in its design as it is a pipe within a pipe in a "U-shape" design.  This design is often used where space is limited and the risk of thermal shock is high.  The inner pipe serves the same function as tubes would in a shell and tube exchanger.  The outer tube serves the same function as the shell in a shell and tube exchanger.  The design is for counter-current flow with each of the two  fluids (one entering the inner pipe and one entering the outer pipe) entering on opposite ends of the U-shaped exchanger.  In passing each other, the cooler liquid absorbs heat through the inner pipe wall and the hot liquid is cooled at the same time.  Both fluids then exit at the end of the tube from where they entered.*  E-320 (Catalyzed Product Heater) is a hairpin heat exchanger that is installed to heat the product stream consisting of NAO and residual catalyst on the tube side with 60 psig steam on the shell side. **M-320 (Static Mixer)** **Static Mixer:** *A static mixer is a device for the continuous mixing of fluid materials, without moving components. Normally the fluids to be mixed are liquid, but static mixers can also be used to mix gas streams, disperse gas into liquid, or blend immiscible liquids*. M-320 (Static Mixer) is installed to mix 0.2% nickel catalyst into the process. **The mixer is a 28\" long and 6\" diameter schedule 80 pipe with four internal elements. A spare mixer is available with an internal baffle design.** **D-320 (Catalyzed Mixing Vessel)** D-320 (Catalyzed Mixing Vessel) (5'D x 24'L) is installed to provide residence time for the nickel-based catalytic reaction. The product stream mixed with 0.2% nickel catalyst enters the side bottom of the vessel. The converted product stream exits the top of the vessel. **E-321 (Catalyzed Product Cooler)** E-321 (Catalyzed Product Cooler) is a double-pipe heat exchanger that is installed to cool the converted product stream on the tube side with cooling water on the shell side. **D-321 (Catalyst Blend Drum)** D-321 (Catalyst Blend Drum) (5'D x 6'L) is installed to dilute the 2% nickel catalyst with C14 to a dilution of 0.2% and to provide storage and supply for the 0.2% nickel catalyst. The 2% nickel catalyst from a 55-gallon drum enters the top of the drum through a 1" fill line. C14 enters the top of the drum. Nitrogen enters the top of the drum. 0.2% nickel catalyst exits the bottom of the drum. **M-321 (Blend Drum Mixer)** M-321 (Blend Drum Mixer) is installed to blend the 2% nickel catalyst with C14 to a dilution of 0.2%. **P-321A/B (Catalyst Solution Injection Pumps)** P-321A/B (Catalyst Solution Injection Pumps) are installed to route the 0.2% nickel catalyst from D-321 (Catalyst Blend Drum) or D-322 (Catalyst Drum) to M-320 (Static Mixer). P-321A/B (Catalyst Solution Injection Pumps) are positive displacement pumps driven by.25 HP 1750 RPM induction electric motors. **D-322 (Catalyst Drum)** D-322 (Catalyst Drum) (3'D x 4'L) is installed to provide supply for the 0.2% nickel catalyst when D-321 (Catalyst Blend Drum) is isolated and making a blend. D-322 (Catalyst Drum) should be refilled after each blend. 0.2% nickel catalyst enters and exits from the bottom of the drum. Nitrogen enters the top of the drum. **[Caustic Wash System]** **M-340 (Caustic Wash Static Mixer)** M-340 (Caustic Wash Static Mixer) is installed to mix heated circulating caustic into the process. **The mixer is equipped with 2 fixed carbon steel elements.** **T-340 (Caustic Wash Vapor Scrubber)** T-340 (Caustic Wash Vapor Scrubber) (2'D x 26'L) is installed to separate the vapor from the two liquid phases. The three-phase stream enters the side bottom of the scrubber, and the fresh process water enters the side top of the scrubber. The overhead vapor exits from the top of the scrubber, and the two liquid phases exit from the bottom of the scrubber. **D-340 (Caustic Wash Settler)** D-340 (Caustic Wash Settler) (7'D x 28'L) is installed to separate the two liquid phases into a caustic stream and a hydrocarbon stream. **NOTE: A skim system is provided to remove any rag layer developed at the interface. If the rag layer is allowed to accumulate, it will interfere with the hydrocarbon/caustic separation and increases the caustic entrainment in the hydrocarbon phase. The skim system has a skim pan that spans across the drum at 50% of the range of the interface float column. The rag layer is continuously removed to D-345 (Continuous Skim Drum).** **M-341 (Caustic Makeup Static Mixer)** M-341 (Caustic Makeup Static Mixer) is installed to blend the 50% makeup caustic with process water to from a 25% dilution. The mixer is equipped with 6 carbon steel fixed elements. **P-340A/B (Caustic Wash Circulation Pumps)** **Centrifugal Pump: ** *A centrifugal pump uses an impeller to convert mechanical energy to hydraulic pressure, thus moving the fluid forward.  This impeller takes a fluid at low velocity entering the pump and by use of the impeller, changes the velocity of the liquid which converts to flow.  The centrifugal pump consists of a casing where the liquid flows, a shaft that is turned by a driver (often electric motor) on which sits the impeller which spins, taking the inlet liquid from the suction center and by the vanes forcing the liquid to move, increases the velocity and pressure as it exits the discharge of the pump.*  P-340A/B (Caustic Wash Circulation Pumps) are installed to circulate recycle caustic and fresh caustic make-up injected by P-342A/B (Caustic Make-Up Pumps)-to be recycled in the caustic wash process. P-340A/B (Caustic Wash Circulation Pumps) are single stage centrifugal pumps driven by 15 HP 1750 RPM induction electric motors. **NOTE:** Normally one pump is in service, with the other in the standby position. **E-340 (Caustic Wash Heater)** E-340 (Caustic Wash Heater) is a multi-tube U-type exchanger that is installed to heat the circulating caustic on the shell side with 100 psig steam on the tube side. **D-345 (Continuous Skim Drum)** **D-345 (Continuous Skim Drum)** (3'D x 9'L) is installed to remove the rag layer from D-340 (Caustic Settling Drum). **[Spent Caustic System]** **T-344 (Degassing Tower)** T-344 **(Degassing Tower)** (1'18"D x 12'L) is installed to degas the caustic and route the vapors to the Purge Gas Header. The spent caustic enters the side of the tower. The purge gas exits from the top of the tower. The degassed spent caustic exits from the bottom of the tower directly into D-344 **(Spent Caustic Settling Drum).** **D-344 (Spent Caustic Settling Drum)** D-344 **(Spent Caustic Settling Drum)** (6'D x 24'L) is installed to separate the two liquid phases into a spent caustic stream and a skimmed hydrocarbon stream. **P-344 (Spent Caustic Transfer Pump)** P-344 **(Spent Caustic Transfer Pump) is** installed to route the spent c