RELIANCE INDUSTRIES DIESEL

CRUDE COMPLEX
LIMITED HYDROTREATER
UNIT 351/352
JAMNAGAR

DHT

QUESTION BANK

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INDEX [Link]
PLANT DESIGN BASIS 3

PROCESS DESCRIPTION 4

PFD AND P&ID 5

UTILITIES 15

AUXILARY SYSTEM 16

EFFLUENT MANAGEMENT 18

PLANT LAYOUT 19

STANDARD OPERATING PROCEDURE 20

MAJOR EQUIPMENT & MACHINES 25

INSTRUMENTATION AND CONTROL 27

ELECTRIC POWER MANAGEMENT 29

PROCESS INTERCONNECTIVITY 30

PROCESS SAFE GUARDING DEVICES 31

HSE 32

CORROSION & EROSIONS 36

PLANT PERFORMANCE ANALYSIS 38

QUALITY CONTROL 39

TECHNOLOGY ADVANCEMENT & MARKET SCENARIO 40

PLANT DESIGN BASIS

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1. What is the designed capacity of DHTs before and after QYI?

Basic design 394 MT/Hr and after QYI-145% of design value.

2. What is max allowed EP in Diesel product?

396

3. What is the catalyst we are using in DHT

Co Mo

4. What is the design capacity of S01?

Feed preheating facility is provided in ME-RH-351-S01 located in unit 351, which
is capable of heating cold feed ex tankage equal to 40 % of capacity of both the
units such that design throughput of both the units will not be affected in case of
one Crude Unit down. The 40% of both units capacity is the amount of feed
originating from one Crude Unit.

5. What is the purpose of Coalescer and salt drier?

Coalescer and Salt driers are designed for Diesel product circuit so as to meet
Diesel product water content specification of wt 0.05%.
6. What are design values of Desulfurisation and Denitrificaton?
Unit is designed for 70% De Nitrification and 98 % Desulfurisation.
7. What is the objective of Diesel Hydrotreater?
Objective is to make Diesel pool to meet 0.25 wt % sulfur specification for the
present operation and will meet 0.05 wt % sulfur specification during NCR run.

8. What is the feed Spec of DHT while in kero mode?

DHT Feed Specific Gravity 0.82 to 0.86 @ 15 oC
If in HK Mode Color [Link]. 10 Min.
o
Flash point C 56 Min.
o
Distillation C 310 FBP, Max.

9. What is the turn down ratio?

The ratio of the plant designed load below which plant cannot be run due hydraulic
considerations and channeling in the reactor. Turn down ratio for unit 351 and 352
is 50%

PROCESS DESCRIPTION
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10. What are all reactions taking place in Hydrotreaters?

 De Sulfurization
 De Nitrification
 Aromatics Saturation
 Olefin Saturation
 Halides Removal
 Oxygen Removal
11. What is the max allowed DT across each bed of reactor?
40 Deg C

12. What are all feed source of DHT?

CDU, DCU, FCCU,

13. Name the three parameters of Diesel Feed which decides the crude Blend
i. Distillation
ii. Density
iii. Sulfur
14. Name the three reasons of Diesel Hydrotreatment.
Desulfurisation
Saturation of Olefins and Aromatics
Denitrificaton

15. What portion of Crude feed is fed to Diesel Unit?

DHT  16 to 18 %Created by
16. Why HK Hydrotreatment is required and in which Unit it is done?
HK Hydrotreatment is required as and when demand for domestic Kerosene
increases over Diesel pool. HK Hydrotreatment is done to reduce Sulfur in LCGO
and straight run HK. This Hydrotreatment is done in 352 Unit.

17. What are the different DHT modes operated? Which one is a normal DHT
mode.
Diesel Mode 0.2 % sulfur--- Normal Mode
NCR Grade Mode 0.05 % Sulfur (NCR)
Kero Mode (Unit 352 Only)
Naphtha Mode (Unit 351 Only)

18. Mention the three main parameters of Diesel Product

Sulfur, End Point & Flash point
PFD AND P&IDS
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19. Draw simplified flow diagram of DHT?

20. What ISO documents do you have in operator portacabin.?

SOP manual
Sampling schedule

21. What is the minimum wash water injection rate in % of Feed.

5%

22. What will happen if feed surge drum level goes high ?mention about cause
and effect
Feed gets cut off at high level & Feed XV gets closed..

23. What is LDT and where is its location?

Line Designation Table located in R Docs.

24. What is the max allowed pressure in compressor D/C & why
56 as its discharge PSV Set point is 58KSC

25. Why we inject antifoam?

Anti Foam is injected into the scrubber via Lean Amine Pump to avoid foaming in
the scrubber, this is not Continuous. If foaming is allowed to happen in the
scrubber liquid may get carried over to the compressor resulting in damage to the
machine and resulting in production loss.

26. Where and why we use DMDS?

As the catalyst is Pyrophoric in nature it is difficult to handle, so the fresh catalyst
will be in Oxide form. Catalyst is more active in Sulfide form. Di Methyl Di Sulfide
is used for Sulfiding the Catalyst

27. What is the function of MDEA in HTs and what is its concentration?
To remove the H2s in the Recycle Gas. It is used in the Scrubber. We are using
35% MDEA.

28. Why do we do water washing in S15?

To remove salts to avoid fouling of exchanger.

29. How much of H2S is removed in scrubber?

Around 99 %
30. What is maximum allowed H2S in compressor suction?
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Less than 10 PPM

31. What is the maximum allowed temp of HP & MP steam coil of heater?
540 for HP Steam and 350 Deg C for MP Steam coil.

32. Where and why we use corrosion inhibiter?

Stripper Overhead is a severe corrosive service, Corrosion Inhibitor is used to
protect the equipment and piping of the Stripper Overhead.

33. How much ppm of corrosion inhibiter is injected?

5 PPM of Stripper Reflux

34. What is the PH allowed in BD water of steam generator?

9.2 to 10

35. How much P04 ppm is allowed in BD of steam generator?

4-10 PPM

36. What are conditions that will trip heater?

 Combustion Air Flow Low
 Flue Gas to APH T High
 Fuel Gas Pressure Low
 Pilot Gas Pressure Low
 Manual De Pressurization of Reactor / Stripper.
 Low Liquid /Hydrogen pass flow.

37. When the total heater tripping will take place?

 Pilot Gas Pressure Low
 Emergency trip of the Heater from Panel

38. When reactor run away occurs what will be your first action?
Reduce Firing, If required cut off the furnace, Reduce Cracked Feed Stock, if still
it is uncontrollable Manual De Pressurization of Reactor. Hydrogen consumption
will be more.

39. How do you know that reactor run away had happened?
By Seeing the Temperature Profile and Del T Across the Bed.

40. Why do we have XVs on P07 pump suction? Why Manual lock provision is
given in P07 suction?

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Since the Stripper Bottom T is at Auto Ignition, In Case of fire due to seal leak to
cut off the feed to pump. Manual Lock provision is given as an extra safety to
avoid spill and avoid injury to the personnel working on the pump during
maintenance.

41. On what % of XV opening P07 will trip?

< 80%

42. If LCO feed is more what will happen to reactor and stripper?
Cracking takes place more in the reactor, This will generate more off gas in the
stripper. Del T across reactor and Del P across Stripper go high.

43. In NCR grade diesel production what are all feed we are taking and why?
LCO, HK apart from regular feed LCGO, AGO, Diesel, HCN to reduce the
product sulfur.

44. If diesel product is +ive in lead acetate test what will be your action?
Inform to SFE and PO, Check for any water content in Salt dryers and drain if any.
(Increase Stripper feed T/ Stripper Steam/ Decrease the Stripper Pressure).

45. If naphtha product EP higher what parameter will you change?

Reduce the Top temperature of stripper.

46. If charge pump high alarm appears what are actions will help for the
improvement?
Increase the V-01 Temperature and Pressure; if the Amps still doesn’t decrease
reduce the plant load.
Check for any passing of valves like Minimum spillback.

47. Write down the DHT compressor capacity control. Steps

Recycle Gas Compressor capacity control is of 5 stage i.e. 0/50/75/90/100%. Valve
unloader /actuator are designed for air to unload condition. So incase of instrument
air failure, compressor will run on 100% load. Compressor can run for maximum
of 12 min. on no load condition.
While Startup The Capacity control steps shall be,
(1) After 1 minute of starting of Compressor motor (when AOP is stopped) load
compressor in steps, (0%50%75%90%100%), checking vibration &
amps. Start loading within 12 minutes from starting of the machine, as per
capacity requirement.
Since the SOV’s are designed for air to unload, at 0% capacity XY-
011/012/&013 will be in activated condition. At 50% Capacity XY- 012 &
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013 will be in activated condition. At 75% Capacity condition Only XY-013

will be in activated condition. When we put the compressor in 90% mode only
XY- 014 will be activated and at 100% Capacity No valves will be in
activated condition.
While stopping the compressor the unloading sequence shall be
(1) Unload the compressor in steps to zero load in steps100%90%75%
50%10%0%.

While changing over the compressor the loading/unloading sequence shall be.
Run both compressors on 50% load for 1 min. then take C01B on 90 % than 100%
and at the same time C01A to 0%.

48. Is 351/352 Recycle gas compressor discharge temperature depends solely on

the discharge pressure.
No, it also depends on the Compression ratio.

49. The Steam Ejector is used to

remove water resulting from partial condensation of steam
create vacuum
superheat the steam
non of these

50. What is the reflux ratio at total reflux

 zero
 infinity
 unity
 data insufficient

51. Cavitation can be prevented by

a) suitably designing the pump
b) Maintain the suction head sufficiently grater than the vapour pressure.
c) Maintain the suction head = developed head
d) Maintain the suction head lower than the vapor pressure

52. Priming is needed in a

 reciprocating pump
 gear pump
 centrifugal pump
 diaphragm pump

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53. While starting a centrifugal pump its discharge valve should be kept
a) open
a) closed
b) either open or closed

54. LPG stands for

 liquid petroleum gas
 liquified petrol gas
 liquid petrol gas
 liquefied petroleum gas

55. With Increase in Temperature viscosity of a liquid

 increase
 decrease
 remains constant
 may increase or decrease depends on the liquid

56. Boiler feed pump is usually a

 reciprocating pump
 gear pump
 multistage centrifugal pump
 diaphragm pump

57. Check valves are used

 at high pressure
 in bends
 for controlling water flow
 for unidirectional flow

58. Which of the following valves incur maximum pressure drop for the same
discharge of water
 globe valve
 gate valve
 needle valve
 butterfly valve

59. A rotameter works on the principle

 constant pressure drop
 variable pressure drop
 both a & b
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 non of these

60. Centrifugal compressors compared to reciprocating compressors

 require low space
 have quiter operation
 have lower operating cost
 all a, b & c

61. Cracking is a
 exothermic reaction
 endothermic reaction
 favored at very low temperatures
 non of these

62. Which has the highest flash point of all?

 diesel
 kerosene
 petrol
 furnace oil

63. LPG When brought to atmospheric pressure and temperature will be a

 liquid lighter than water
 liquid heavier than water
 gas lighter than air
 gas heavier than air

64. loss of heat from unlagged steam pipe to the ambient air is by
 conduction
 convection
 radiation
 all a,b & c

65. Steam trap is used to

a) condense the steam flowing in pipeline
b) remove water resulting from partial condensation of steam
c) stop the supply of steam
d) none of these.
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66. Stripper bottoms liquid is used to backwash 351- Feed Filters.

67. What is the Sulfur percentage in the Diesel Feed (Design Fig) and Diesel
Product?
1.5% 0.05%

68. What is the Alarm and trip setting of Charge Pump Vibration and
Temperature?
Alarm Trip
Motor NDE Bearing Housinng Vibration 11 ---
NDE Bearing Housing Vibration 11 --
Pump NDE/DE Bearing coupling end vibration 80 100
Motor NDE side Bearing T 90 --
Motor Winding T 124 130
Pump DE/NDE Bearing T 90 95

69. What is the Alarm and trip setting of Compressor Vibration and Temperature
Alarm Trip
Frame Vibration----------------------- 14 20
Bearing Vibration ---------------------- 1.6 1.9
Compressor Coupling------------------ 85 95
Cylinder stuffing box------------------- 100 125
Motor bearing Housing Vibration----- 40 50
Motor Bearing T ------------------------ 90 100
Motor Winding T ---------------------- 100 155

70. The Diesel furnace is Balanced draft.

71. Number of Emergency Depressurization systems are there in Diesel Plant

1) Reactor loop depressurization & 2) Stripper loop Depressurization.
72. What is the Type of Recycle gas Compressor?
Single stage Double acting

73. 351/352 Recycle gas compressor discharge temperature depends solely on the
discharge pressure. No, it also depends on the compression ratio.

74. Why Reciprocating compressor is selected in DHT

Reciprocating compressor is generally selected for Moderate conditions of Flow
and Pressure. And Moderate to Low Flow and High Pressure.

75. Why Power recovery turbine is not provided DHT.

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It is Not Economical Seeing the Pay Back Period, as compared to VGO HT

pressure drop from V02 to stripper C07 is marginal & thus lower recovery.

76. What are the checks that are to be carried out on a standby Equipment?
Warm up Condition for Hot Pumps, Seal Pot levels, Oil Cup levels. Seal Plan
Outlet Temperature. Cooling water circulation.

77. What is the Purpose of Steam Air Preheater in the Combustion air circuit to
the Furnace?
To Heat the combustion Air to an extent so that Temperature of Flue Gas exit Flue
Gas Air Pre Heater is above the Dew Point so that Corrosion can be avoided.

78. What is the type of Control in Furnace?

Lead Lag Control

79. The valve used for very accurate control of fluid is

 needle valve
 globe valve
 gate valve
 butterfly valve

80. Thermocouple is suitable for measuring

 liquid temperatures only
 very high temperature only
 very low temperature only
 both high & low temperatures

81. Instrument in the plant offer the advantage of

a) greater safety of operation
b) better quality of product
c) grater operation economy
d) All A, B & C

82. Cascade control means

1. feed forward control
2. more than one feed back loop
3. on off control
4. one feed beck loop

83. Which of the following controllers has least maximum deviation?

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1. P- Controller
2. P-I Controller
3. P-I-D Controller
4. P-D controller

84. Final Control Element is a

 valve
 switch
 signal
 non of these

85. Which controller has zero offset

 P
 P-I
 P-I-D
 BOTH B & C

86. Solenoid valve works like

 P
 P-D
 P-I-D
 On –off

87. For Batch operation which type of control is used?

 DCS
 PLC

88. XV are generally used for.

on off control
controlling flow
o intermittent flow

89. Write down the most significance observation you have to do during your
round in compressor area. write down min.5 observation ,check points.
1. Lubricator & Lube oil sump level.
2. LO pressure.
3. LO Filter Del P.
4. Local Alarm Status.
5. Discharge PT reading.
6. Discharge Temperature.

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7. Jacket Cooling Water Over head Tank level.

8. AOP shall be in Auto.
9. Any abnormal sound.
10. Any H2S Leak.
11. Any oil leak.

12. Motor current.

13. Any abnormal sound.
14. Visual vibration.

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UTILITIES
90. What is HP steam pressure at B/L?
42

91. What is LP Steam temp at B/L?

167

92. Where do we use cold condensate?

 Used for Phosphate batch Preparation
 Used as wash water.

93. Why do we use HP steam in stripper?

To strip of the H2s in the Diesel Product. MP steam cannot be used as the Delp is
less.

94. Where do we use Neutralization solution?

All Austenitic stainless steel should not be directly exposed to atmosphere as
polythionic Acid may form resulting in cracking of the metal. These acids are
formed by action of water and oxygen with hydrogen sulfide or sulfurous scale.
So Neutralization solution is used to protect the Equipment by forming a layer
prior to exposure to air.

95. What is the concentration of Neutralisation solution?

Na2Co3 – 3-5 %, NaNo2 – 0.2 to 0.4 %, Cl < 30ppm.

96. What is austenitic Stainless steel? Give 3 Examples.

Steels of 300 Series, the composition which are Normally 18% cr & 8% Ni
 304 , 316, 321, 347

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AUXILIARY SYSTEM
97. What is a max allowable chloride in ASS?
50ppm

98. What are all closed BD system in the unit?

Amine drain, Light Slops drain

99. What is the purpose of deluge system?

To give an alarm and extinguish fire by spraying water on the pump in case of leak
in the hot pump area.

100. Where is the sprinklers system used?

P02, P07, A01, A02

101. Why do we have BULB in IA line of deluge skid?

This bulb gets ruptured when it gets heated, in case of fire when the bulb ruptures
it releases the air pressure opens the deluge valve which will sprinkle fire water.

102. At What temp the bulb in IA line of deluge will break?

75

103. How many Flare Systems we have and above what are the pressure range for
routing.
 HP Flare above 9Ksc
 LP Flare below 9 Ksc

104. What is the purpose of diversion chamber?

To Separate Oil and Water and diverting it to appropriate place.

105. What is the purpose of vent line in OWS manhole?

To Vent the Hydrocarbon vapors formed if any to a safe and higher Location.

106. What is the purpose of rupture disc in feed surge drum?

To Release the Pressure to HP Flare in case of Over Pressure/ Water Flash.

107. Expand the following

DSO Optical Type Smoke Detector

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DGH Hydrogen Gas Detector

DGT Toxic Gas Detector

DGC Combustible Gas Detector

108. How many assembly points are there in the unit? And its location.
Near south west of unit 351/352.

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EFFLUENT MANAGEMENT
109. What are effluents we are generating?
Scrap, Oily water, Storm water, Slops

110. How many scarp yard we have in the unit?

2 One in Unit 311 & and One in Unit 312 for crude Complex

111. What is the max allowed CO in FO1 heater stack?

50 PPM

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PLANT LAYOUT
112. Locate emergency depressurization valve of stripper?

113. Locate all safety showers

114. Locate on line breathing apparatus locations & SCBA Set.

115. Locate make up H2 valve at B/L

116. Locate N2 Purge line of compressor.

117. Locate Remote Operated switch for P07A/B Suction XV.

118. Locate the Assembly Point.

119. Locate compressor PSV.

120. Locate all the escape routes.

121. Locate the diversion chambers

122. Locate corrosion probes in the unit.

123. Locate breathing air points in the unit

124. Locate charge pump PSV.

125. Locate Emergency Depressurization valve of HP Loop.

126. Locate TSP storage area.

127. Locate Oily rags drum in the unit.

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SOP
128. What is the max pressure allowed on S05 steam generator?
Shell is designed for 51 Kg, PSV 053A Set Pressure is 49.5 and PSV 053B set
pressure is 51.

129. Why do we have time delay after giving start command of compressor?
Pre Lubrication

130. Write down the emergency procedure in brief in case of power failure?
On power failure RG Compressor and Feed pump trip but reaction continues in
the reactor, which may lead to run away temperature.

Following actions are to be taken:

1. Immediately line up make up gas at the compressor discharge and continue
venting from separator at the maximum possible rate, maintaining normal
separator pressure.
2. In case make up gas is also not available and any bed temperature is 28 °C
above normal, start depressurising the reactor.
3. The combined feed heater should shutdown automatically on loss of recycle
gas flow; ensure that following actions have been actuated.
 XV009 Fuel gas supply I/v close.
 Closure of TV005A/B, temperature control around pre heater train.
 XV037, wash water discharge ESV closes.
 FV-016, Lean amine pump discharge valve closes
Ensure Steam is on to stripper and reduce the stripping steam 2-3 Tons

131. Write Down the Emergency procedure in brief in case of Instrument Air
Failure.
The instrument air failure will cause emergency depressurising valve to go in fail
in position. All other control valve will go in fail safe condition.
Following actions are to be taken:
1. Ensure the following actions have been actuated on Instrument air failure.

 Combined feed heater Fuel gas XV009 closes and bleed XV033 opens.

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 Combined feed heater Pilot gas XV010 closes and bleed XV031 opens

 FD/ID fans continue to run with full damper open.

 Make up gas valve PV009A closes. Purity vent valve FV 040 closes.

 Charge Pump minimum circulation FV 005 opens and Individual Spillback vales
of P02A & B FV851 and FV 852 Opens in 351.
 Temperature control around S03, TV005A/B Closes
 Lean Amine Pump P04 discharge FV 016 closes and minimum circulation valve
FV 093 opens.
 Feed valves to Combined feed heater FV046- 049 closes and Recycle gas valves
FV 082- 084 get full open.
 RG Compressor continues to run on full load.
2. Take all the control valves into manual and for FC valves set output to 0% and for
FO valves set output to 100%.
3. Close Isolation valve on furnace fuel gas line.
4. Stop the Pumps –05/06/07 watching the levels.
5. If instrument air can not be restored within half an hour trip Charge Pump.
6. If instrument air can not be restored even within 1 hr stop RG compressor and
maintain separator and stripper pressure at normal value.

132. How do you change over the Lube oil Filter of Compressor?
Inform PO about the changing of the filter.
Note down the Del p of Filter in Line.
Very slowly open the balancing Line. Keeping watch on the Lube oil header
pressure.
See that Filter is slightly warmed up and change over the Filter.
Again note down the Filter Del P and cross check it with the PDT.

133. What are the 3 major emergencies you faced so far and how did you
handle.
Verbal

134. Write down the compressor startup steps.

Unit 351/352 RG Compressor Startup Steps:

1. Get Clearance from the Mech., Electrical and Instrument Departments.

2. Ensure all utilities are available i.e., CW, IA, N2 etc.
3. Ensure that all machine related interlocks are in line.
4. RG Loop inertization by keeping compressor in isolated condition.
5. Ensure compressor suction and discharge valves are in closed position.
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6. 1” N2 supply line to compressor suction spectacle blind reversed to open

7. Pressurize the compressor with N2, and depressurize to flare 3-4 times.
8. Reverse the Sp. Blind to close.
9. Check the N2 content in the line.
10. Check the loader /unloader valve operation is OK.
11. N2 to motor/ stuffing box is lined up.
12. Line up H2 to suction and pressurize the compressor with RG slowly by
opening first suction I/V fully and second I/V gradually.
13. Check LO Level in the main reservoir, cylinder lubrication box, and
gearbox.
14. Open CWS and CWR valves to LO cooler and circulation water for jacket
cooling.
15. Take suction line PG (PG-121), discharge line PG (PG-122) and suction
strainer PDT (PDT-047) in line.
16. Fill Expansion Tank with water.
17. Energize local Panel. Reset Local Panel. Check Enunciator Lamps

18. Drain suction, discharge dampener for possible liquid.

19. Start AOP and check LO Pressure developed. (min.2kg/cm2 in header)
20. Check Air supply switch for Loading Mechanism on compressor local
panel is latched.
21. Check cylinder lubricator is working OK.
22. Do barring of the Compressor in the direction of rotation. And disengage
the barring device after barring is over (During barring run AOP).
23. Check Vent valves on suction and discharge dampeners are tightly closed.
24. Put AOP and lubricator pump on AUTO.
25. Reset Alarm on the local panel and check for “Ready to start “indication
on the local panel.
26. Get Clearance from CPP for starting the motor.
27. Start the Compressor on zero load .See that the motor running lamp ML-20
is ON.
28. Check the machine for Noise and Vibration.
29. After one minute (When AOP is stopped) Load compressor in steps 0% ---
50%----90%----100%)
30. Check vibration and amps. Start loading within 12 minutes from starting of
the machine, as per capacity requirement.
31. Check Discharge Temperature is not crossing 120C
32. Ensure all PSVs are in line and connected to flare
33. Ensure Given Check List is filled.
34. Ensure that Steam Tracing line on suction drum is ON.
35. For 351 unit ensure that PIC 850 (compressor bypass CV) is in line.

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135. How you will take SO1 feed heater in line & how you will take shutdown.
1. Ensure S01 is available & steam ring (snuffing steam) is in line at s01
channel cover.
2. Check S01 psv is in line.
3. Open S01 o/let valve.
4. Keep B/L iso valve closed & inform control room for DUF cold feed pump
start up.
5. After starting cold feed pump check for leak, line vibration, psv, etc.
6. Open S01 B/l valve slowly after clearance from control room (after opening
Fv002 5 to 10%)
7. Take cold feed @100M3. Minimum After taking cold feed open Fv001
control valve u/s
LPD & start slowly S01 w/up through S01 steam line w/up valve.
8. Check for condensate temperature, hammering, channel cover leak etc.
9. After reaching condensate temp.120c .line up condensate header after
confirming no oil ingress in condensate header..
10. Slowly open main steam valve & increase temperature slowly 200c.
11. Increase feed first & than steam slowly.

136. S01 FEED PREHEATER TO BE TAKEN SHUTDOWN.

1. Slowly close main steam isolation valve.

2 Check condensate temperature during this activity.
3. Check for channel cover leak, hammering etc.
4. Once main steam [Link] closed fully & cold feed flow is minimum
[Link] close w/up i/v.
5. At condensate temperature [Link] Fv001 U/S LPD & start floor
drainig communication with panel officer.
6. Isolate Fv001 D/s i/[Link] for any oil in condensate header LPD.
7. Slowly close B/L iso valve.
8. Close S01 o/let valve.

137. What precaution to be taken during sampling of Hydrocarbon Sample?

Hydrocarbon sample:
Check the integrity of sample bottle; if possible take sample in dedicated
sample bottle. Check that sample line is lined up properly and is under
circulation. In case of hot sample, take sample cooler in line and run cooling
water. (Considering climate, line up required quantity of cooling water. It is
possible that during winter, heavy hydrocarbon sample like VGO may
congeal. ). Open sample point very slowly and check that sample line is not
choked. Flush sample line and sample bottle in to appropriate oily sewer.
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Take appropriate quantity of sample to carry out required analysis. Tag the
sample properly with date and time. Too much quantity of sample is waste
and required to reprocess which loss to the company.

138. What Precaution to be taken during sampling of Recycle Gas Sample?

Recycle gas sample.

Check the integrity of sample line, its isolation valve and quick release
coupling which holds the sample bomb. Place the sample bomb in close
sample assembly and open its inlet and outlet valves. As this sample don't
have return line up sample bomb outlet to flare. Very slowly open inlet valve
of the sample bomb and Check rise in pressure on the pressure gauge
available with sample assemble. flush the bomb till it becomes hot. based on
sample pressure, sample bomb is to pressurized followed by depressurized.
Caution! isolate sample bomb first to avoid its depressurization and then
inlet and outlet of the sample point. Tag the sample point with date and time
with required analysis to carry out.

139. What is the sequence of Isolation of steam at B/L during shutdown?

HP then. MP and then LP

140. What all can be done when pump cavitates?

 Venting
 Cooling the Suction Liquid
 Increasing the S/c Pressure
 Decreasing the flow by throttling the Discharge.

141. What are the Operating conditions of the Following

Temperature Pressure
1. C05 55 34
2. C07 Top 197 Btm 325 13.5-14
3. V01 270 3.5

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MAJOR EQUIPMENTS/ MACHINES

142. What are the permissives for starting the compressor?
Pressure should be More than 22.5, barring device should be locked in disengaged
Position.
143. What is the function of Tempered water in the compressor?
It should be 5Deg C more than the S/c T to see that Gas doesn’t condense and at
the same times it serves the purpose of cooling to make the compression more
towards Adiabatic.
144. What is the Capacity of Charge Pump
575 M^3/hr (Normal); Rated Capacity is 632M^3/hr.

145. What is the capacity of Compressor?

198000 NM3/hr

146. Write Down Check Points of charge pumps during your normal round.
(Unit351)
During normal round following points should be checked.

1. Pump Amps. OK
2. Pump Vibrations if any. Vibrating lines if any.
3. Abnormal Noise/sound if any
4. Leakages from joints, valves etc.
5. Suction and Discharge Pressure OK.
6. LO level in the LO Cup.
7. Pump Cooling fans are ON.
8. Seal Pot level OK.
9. Cooling water line up
10. Seal pot vent line up
11. Snuffing steam lined up
12. Pump Drain Lines Closed.
13. Pump cavitations if any.
14. Gland Leak if any
15. Any burning smell
16. Spill back line up
17. Stand By pump w/u line up
18. S/B pump body Temp.
19. S/B pump suction valve open
20. Running pump suction and discharge valves fully open
21. Suction strainer delta P
22. Hot line Insulation OK.
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23. Pump suction vessel drum level (V01 Level)

147. Write steps for charge pump changeover. P02A B
1. Check P02B is sufficiently warm (temp above 100 deg.c)and close the
warm up line valves
2. Full open Minimum spillback valve of P02B.
3. Check Lube Oil, Seal Oil and C.W., Steam for P02B.
4. Take clearance from CPP.
5. Start the pump, slowly open discharge valve of P02B keeping a watch on
the pressure gauge at d/s of the discharge valve and maintain the same
between 55-60 kg/cm2g.
6. After getting pressure start opening the Minimum spillback globe valve of
P02A and closing discharge valve.
7. Check amps of both the pumps and flow, and accordingly adjust the
Maintenance spill back valves and the main discharge valves.
8. Close the Minimum spill back of the pump B (give the set point).
9. If feed pass flows, pressures, amps are normal stop P02 A.
10. Open the warm-up isolation valves for P02A and keep it ready as hot
standby

148. What is maximum allowed Bed temp in Reactor?

415 Deg C
149. Show how you reset the alarm of Compressor in the PIB.

150. Show how do you give filter backwash from the PIB

151. How do you unlock the filter from PIB

152. What are the different seal plans we have in the unit and which type of seal
plan is provided in P02, and P07.
 P-02 & P07 ---- Plan 23 and Plan 52

153. What are the different seal plans we have in the unit and which type of seal
plan is provided in P03, and P04?
 P03------- Plan 13
 P04------- Plan 11

154. How do you identify when primary seal leaks?

If primary seal leaks secondary seal pot level increases.

155. How do you identify if secondary seal leaks?

If secondary seal leaks, seal pot level decreases.

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INSTRUMENTATION AND CONTROL

156. What are the different types of control valves?
Fail Open, Fail Close, Fail In Position/ Fail Safe

157. How does the Control valve operate?

Set Point is given to the controller, it generates a 4-20 MA signal which inturn
will generate a pneumatic signal which will act on the control valve by adjusting
the opening.

158. How Steam Generator Level is controlled.

It is controlled by a Two Element control. In two element control scheme a

summing function is configured, which will accept the linearised steam flow signal
and add a signal which is the difference between the steam drum level controller
output and a bias signal. The bias signal is set at 50% signal to enable the level
controller to make changes for both increasing and decreasing levels. The resultant
output signal from summing function is the set point signal to the BFW flow
controller. BFW flow controller can operate as an independent controller on local
mode operation during startup initial filling or if required.

Operation:

The system is designed so that for every weight unit of steam, a weight unit of
BFW is introduced and the level controller signal is used to compensate for
blowdown and error in steam to water ratio. A wide proportionate band and a slow
reset on the level controller are given so that sudden changes in level will not affect
the BFW flow controller. Only average level changes are to affect the feedwater
flow control.

Summer output = Steam Flow + (Level controller Output – Bias)

159. Which cylinders will be in line when compressor is loaded at

0% Clearance Pocket
50% Cy-1 Head End and Cy-2 Crank End
75% Cy-2head and Crank end & Cy-2 Crank End
90% Cy-1 & CY -2 head and crank end

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100% Cy-1 & Cy-2Head and Crank end and Clearance

pocket.

160. Why Quench is given for Reactor?

Hydrotreating reactions are Exothermic, If quenching is not done Temperature run
away may take place, and it may also result in coking and reduced cycle length.
This is also given to have uniform Del T across the bed.

161. Is APC implemented in 351 and 352 Units?

Implemented in 352 and to be done in 351.

162. What Precautions are to be taken before entering the analyzer House?
LEL to measured, PO to be Informed and F & G Alarms to be Inhibited and fire
station to be Informed.

ELECTRIC POWER MANAGEMENT

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163. Write down the FLC of the Following Equipment:

 MC-RH351/352- C01-------------------------330

 MP-RH351/352 P07A/B---------------------260

 MP-RH351/352- P02A/B --------------------132

 MP-RH351/352- P04A/B --------------------208

 MP-RH351/352- P03A/B --------------------149

164. What is the Power rating of Motor for Charge pump and Compressor?
4 375 KW for compressor; 1300 KW for Charge Pump.

165. Can Charge pump be started and stopped 3-4 times within an hour, Give
Reason? Above What rating clearance is to be taken from CPP before
starting?
No High rated pumps should not be started that frequently as while starting due to
high torque Motor gets damaged. Motor winding T may go high and get damaged.

166. Do we have any Emergency Power supply to our unit?

Yes

167. Why Turbine driven Product pump not given in DHT unit?
It is not required as stripper is being operated at higher pressure, and with that
pressure Liquid can flow through the pump at lower throughput in case of any
emergency.

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PROCESS INTERCONNECTIVITY
168. What is the normal routing of the diesel product and where else can it be
routed to?
Normally routed to diesel product tank at RTF, It can be routed to Light Slop tank
and DUF tank. In 351 unit it can be routed to Aromatics in case of HNUU
shutdown. In Case of Kero mode in 352 unit, it can be routed to Kero run down
line.
169. Which will be a higher elevation Inlet of the OWS pit or its Outlet to its
downstream OWS Pit?
Outlet to its downstream OWS Pit

170. Where normally should Light slop tank level transferred to in a running
plant?
Feed Tank

171. Where do you line up Kero Product while DHT-2 is running in Kero Mode?
Kero Product is lined up to Cold Feed line after flushing the kero product up to
351 S01.

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PROCESS SAFE GUARDING DEVICES

172. What is the set pressure of the Following PSVs? Fill in the Blank in Terms of
PSV.
Equipment PSV No Set Pressure D/S Routed to

 C07 63A/B/C 20 HPF

 P14B 67 24.7 Suction
 P07A/B 78A/B/C 25.6/26 HPF

173. What is the normal vibration of Fin fans and what is the alarming value?
2-3

174. Name any five Car seal Open Valves

1.P02 A/B Suction Valves,
2. PSV D/s Valves.
[Link] depressurization valve s u/s and d/s isolation valves

175. Where is FM 200 in the unit and the purpose?

It is Located in Plant Interface Buildings and is used for Extinguishing fire.

176. What is min pressure allowed in SCBA?

200
177. What is MCP?
Manual Call point

178. How many nos of 70 Kgs DCP cylinder are in the unit and where?
1. near P07A/B

179. How many PSVs are there in Stripper and why?

There are 3 PSV s in the stripper for Gas Blow by Case from the separator.

180. What is the Maximum Temperature at which Liquid can be drained into an
underground system?
It should be less that 80 Deg C.

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HSE
181. Mention the role of the operator in the work permit system:

 Should be clear about what actually has to be done, if any doubts consult
SFE for Clarification.
 Should make necessary preparations from Process side and checking the
preparedness from Maintenance side for carrying out the work in a safe
manner.
 Should be very clear about the Permit system and has to follow the same
strictly.
 For Critical jobs he has to be standby.
 Should inform PO if the job is related to instrument before starting the job.
 After Job completion, Should Check the Integrity of the system, and
ensure house keeping, and inform SFE if any abnormality is found.

182. Mention the role of the operator as an area owner w.r.t. housekeeping /
Quality of scaffolding.
 Should take proper round of field and ensure good house keeping.
 He can take the help from superiors and from the house keeping personnel.
 While errection of the scaffolding he should ensure good safe working
practices.
 If the quality of the scaffolding is not good, work to stopped counseling to
be done and after rectifying the problem , he should inspect and allow to
carry out the work.

183. What is the range of Explosivity for Hydrogen?

4- --- 74%
184. What is the STEL value for H2s?
STEL 15 PPM

185. What is the LEL of H2S?

LEL- 4-46%,

186. What is the TLV of H2S

TLV 10ppm

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187. Above what ppm of H2S does a person become instantly fatal?
Above 1000ppm instantly fatal
188. What should be the Oxygen, H2s content and LEL for a vessel Entry?
Oxygen: 205, H2s – nil, LEL- 0%

189. What are the Different levels of Emergencies and who is the controller at
different levels?
Level-1--------------SSM
Level 2--------------Site President
Level-3--------------Collector of the District

190. Write five PPE normally used & its significance.

 Safety helmet
 safety goggles
 hand gloves
 safety shoes
 ear plug
 The PPE provides good defense against hazards of toxic exposure, dusting,
chemical splashes, steam, water, liquids, flying particles, hot substances,
radiation, sharp edges, welding, striking against and stepping over objects,
personal falls and injury due to falling bodies, noise, scrap cleaning, material
handling, electric shocks, burns and fire fighting. Many fatal accidents are
caused due to these reasons and use of appropriate PPE can prevent or lessen
many of them.

 Significance of PPE

 PPE can act as a barrier between the human and hazard to save from the
injury.
 It effectively avoids the contact of dangerous substances including chemicals.
It protects from atmospheric contaminants

191. What is the significance of Safety Helmet?

Head protection:
Head protectors may be hard hats and caps made of PVC, Fiberglass, HDPE.
Everyone in the plant must wear Safety helmets. Safety head band and
suspension system must be adjusted so that the helmet is firmly held. Safety
helmet protects Head so that fatal accident can be avoided.

192. What is the significance of Safety goggles?

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Eye protection: Dusts, Flying particles, splashes and harmful radiation cause
numerous eye injuries.

193. What is the significance of Hand Gloves?

Hand and Arm protection:
 Protection of hand and arm becomes necessary when workers have to
handle materials having sharp edges or when handling hot and molten
materials, chemicals and corrosive substances. The protective devices may
be gloves .

194. What is the significance of Safety Shoes?

Foot and leg protection:
Some typical risks are handling of heavy materials, caustic and corrosive
liquids, wet conditions, etc. Common foot and leg protective Equipments are
Safety shoes, Gumshoes etc Safety shoes must be worn by every person inside
the refinery.

195. What is the significance of Ear Plugs?

Ear protection:
 Noise level above 85 dBA is hazardous for an exposure more than 8
hrs/day or 48rs/week. It may cause loss of efficiency, irritation and also
loss of hearing.
 Earplugs give an attenuation of 25 dBA and. Ear muffs gives an
attenuation of 15-20 d BA.
196. How many wind socks are there in the unit and where?
1. On V-01
2. On Substation

197. In plant where u need to use ear plugs in routine round in normally running
plant?
Near Compressor house or any area which has >85db noise

198. What is the use of Deluge system and where are these skids located in the
plant?
It is used for cooling hot pump area under fire. It helps in extinguishing the fire. It
is on P02/P07.

199. Write down 5 major hazards in DHT plant.

1. Hydrocarbon like Diesel / Naphtha.

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2. Recycle gas / Hydrogen / off gas.

3. Sour water.
4. H2S.
5. High temperature and high pressure (Operating conditions).
6. Catalyst.
7. Bad housekeeping.

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CORROSION & EROSIONS

200. What is the MOC of reactor?
1.25 cr—0.5 Mo with 3mm lining of 347 stainless steel.

201. Why inner lining is there in separator bottom section?

To avoid / Limit Corrosion due to presence of high H2s and NH3.

202. Purpose of adding Corrosion inhibitor in Stripper is to avoid overhead corrosion

due to condensation of Acidic water vapors

203. The stripper top temperature to be maintained below dew point. T F

204. What is Cathodic Protection and for which systems is it done and why?
Cathodic protection is done for underground lines to protect the lines from
Corrosion.

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PLANT PERFORMANCE ANALYSIS

205. What is the % Yield of Diesel?
97%

206. What is the consumption of Hydrogen per ton of Diesel Feed?

0.006Ton

207. What is the yield of Naphtha in %?

1.7%

208. What is yield of Off Gas?

0.4%

209. What is % of Amine allowed in wash water Section?

5% max

210. Why P05 Seal fails frequently?

Seals are not designed for high h2s service; new type seals are being envisaged.

211. What could be the reason when the fin fan amps has drastically reduced?
Belt might have damaged or disengaged from the pulley.

212. Why wash water section is needed in scrubber?

To remove the entrained amine in the recycle gas.

213. Are the compressors loaders Fail open or fail close, In case of Inst air failure
what will be position of loaders position?
These are fail open vales and in case of IA Failure compressors will be 100%
Loaded.

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QUALITY CONTROL
214. What is the Frequency of sampling for Separator Boot Water
Weakly (Wednesday Morning 05:00hrs in 351 and Wednesday 23:00hrs in unit
352)

215. What is our feed quality?

DHT Feed Specific Gravity 0.89 Max.
(Diesel Mode) Sulfur Wt % 2.00 Max.
o
ASTM Distillation C 385 95%, Max.

216. What will be the effect of distillation range & API Gravity and UOP K in
Feed?
1. Distillation Range  End Point of 396, Increase in End point will make
Desulfurisation and De Nitrification Reactions more difficult. It require more
Bed T which may result in coke formation and reducing Cycle Length.

217. What will be the effect of sulfur & Nitrogen in Feed?

 Sulfur content Higher sulfur content increases operating severity and
increases hydrogen consumption besides increasing operating load on RG
scrubber. It is designed for 1.469 max

218. What will be the effect of Bromine Number & Conradson carbon in Feed?
 Bromine number – Higher Bromine number of the feedstock is an indication
of higher unsaturates content. The feed with higher Bromine number will
result in increased hydrogen consumption and higher temperature rise across
the reactor bed. This will also enhance the condensation reaction to form more
coke in the reactor. This will reduce the cycle length. It is designed for 3.88.

219. What will be the effect of ASTM Color in Feed?

ASTM Colour - ASTM Colour is a measure of residue entrainment. Higher value
will reduce the cycle length

220. What will be the effect of Metal content in Feed?

Metal Content - Metals will poison the catalyst activity, which can not be

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restored by regeneration. Metals may come into the system via additives ( Si
from antifoam), feedstock contaminant (Pb, As, Fe, P, Na, Ca, Mg) or
organometallic compounds

221. What will be the effect of Conradson carbon in Feed?

Conradson carbon – Conradson carbon is a measure of residue after destructive
distillation. The feed with higher Conradson carbon is an indication of higher
coking tendency and this will reduce the cycle length.

222. What will be the effect of Nitrogen in Feed?

Nitrogen content -Higher Nitrogen content increases operation severity and
hydrogen consumption. It is designed for 258ppm max

223. What will be the effect of API Gravity in Feed?

API Gravity Unit is designed for API of 35, Reduction in API is an indication of
higher Unsaturates and may require more Hydrogen consumption and high t Rise
across the Bed.

224. What will be the effect of UOP K in Feed?

UOPK Higher UOP K of the feedstock is an indication of higher paraffinicity of
the feedstock. The feed with lower UOP K will result in increased hydrogen
consumption and higher temperature rise across the reactor bed. It is designed for
11.78.

225. What is our product quality? What will be the effect if it is increase or
decrease beyond specified limit.

[Link]. Product Parameter UOM Specification Remarks

1 Diesel Specific Gravity 0.87 Max.
o
Ex- HTU Flash point C 66 Min.
Sulfur Wt % 0.25 Max.
o
Distillation C 382 95 %, Max.
Copper Corrosion - 1B
2 HK Specific Gravity 0.82 Max., @ 15 oC
Ex-DHT2 Sulfur Wt % 0.1 Max.
Smoke Point mm 18 Min.
o
Distillation C 310 FBP, Max.

Increase in specification of the parameter will have adverse effects on the

environment and also reduce the life of the engines by increasing the wear and
tear.
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TECHNOLOGY ADVANCEMENT & MARKET

SCENARIO
226. Who is the Process Licensor and by whom the Engineering is done?
Process Licensor is UOP and Detailed Engineering done by Bechtel.

227. What type of catalyst is used and who is the vendor?

DC2118 and DC3110 are the main catalyst supplied by Criterion
N40 is the main catalyst in 352 which will get changed by Akzo Nobel KF 757.

228. Which specification of Diesel are we producing?

 Euro -1
 Euro-2------ 500 ppm of sulfur
 Euro-3 ----- 350 ppm of sulfur.

229. Which Product has higher cost? Naphtha or Diesel

Naphtha

230. When Euro 2 diesel is to be used in all over the country besides metro cities?
By Year 2005

231. What are the main metal component of DC2118 and DN 3110?
DC2118 is Co Mo
DN3110 is Ni Mo

232. Mention the changes carried out Unit 351, Mention the purpose of the same:

233. What are the main advantages of DC2118 and DN3110 over N40 catalyst?
DC2118 & DN3110 are more active even at lower temperature thus giving higher
cycle length and consumes low fuel at SOR.

234. Why vacuum dryer is being installed?

As per Euro 3 requirement, moisture in diesel should be <200ppm. Presently with
Coalescer & salt dryer moisture content in diesel product is 300- 1000ppm.

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