Nice — this is a big, useful deliverable.

Below I deliver a professional, practical refinery process

description for a medium crude refinery (100,000 bpd nominal; I’ll show a 100 kbpd mass
example). I state assumptions up front, then give:

 (a) Written explanation: step-by-step textual PFD + detailed unit descriptions (purpose,
T/P, equipment, feeds/products, constraints, failure modes, inspection/maintenance).
 (b) Tabular equipment list (rotating & static) with sizing/selection guidance and key API
standards.
 (c) Simple ASCII PFD sketch.
 Safety & environmental controls, one-page P&ID legend with recommended online
instrumentation and setpoints, and a 10-item mechanical troubleshooting checklist.

Assumptions (explicit)
1. Crude throughput: 100,000 barrels per day (bpd) (≈ 13,600 m³/day; use 1 bbl ≈ 0.159
m³).
2. Refinery type: moderate conversion capability (Atmospheric distillation + Vacuum
distillation + FCC + hydrotreaters; H₂ plant present). No heavy coking unit capacity
beyond small delayed coker (2–5% coke for heavy feed).
3. Crude quality: medium API (28–34°API), sulfur moderate (~1.0–2.0 wt% S). If your
crude is lighter/heavier or sweeter/sour, yields and equipment duty change.
4. Utilities: steam system (LP/MP/HP), sour/hydrogen system, cooling water, process air,
fuel gas, flare, firewater.
5. Materials and operating ranges are “typical” industry ranges — specific design must be
finalized with process licensors and mechanical/economic studies.

1 — Textual PFD (step-by-step from crude

intake → product loading)
High-level ordered list of major process units and main streams (textual PFD):

1. Crude reception & storage

o Tanks, transfer pumps, tank gauging.
o Main stream → crude feed to Desalter.
2. Crude desalting & pre-treatment
o Electrostatic desalting, wash water, heater/flash drum for water removal.
o Output → desalted crude to Charge Heater / Preheat Train.
3. Preheat train / Furnace (charge heater)
 o Multi-stage shell & tube exchangers + fired heater.
o Heated crude → Atmospheric Distillation (CDU).
4. Atmospheric Distillation Unit (CDU)
o Separation into gases/top naphtha/light distillates, kerosene, diesel, atmospheric
residue (AR).
o Overhead vapors → Naphtha fractionation / light ends recovery; AR →
Vacuum Distillation.
5. Naphtha stabilizer / fractionation
o Stabilize light ends, divide into stabilized naphtha, LPG/fuel gas.
6. Kero/diesel treating (hydrotreating)
o Naphtha hydrotreaters, kerosene and diesel hydrotreaters to remove S, N and
saturate olefins.
7. Vacuum Distillation Unit (VDU)
o Separate atmospheric residue into vacuum gas oil (VGO), heavy vacuum resid
(for coking or blending).
o VGO → conversion units (FCC or hydrocracker). Heavy resid → coker or fuel oil
blending.
8. Conversion units
o Fluid Catalytic Cracker (FCC) — converts VGO → gasoline, LPG, light cycle
oil (LCO) + slurry.
o Hydrocracker (optional) — converts VGO → diesel/naphtha; requires H₂.
o Delayed Coker (if present) — converts heavy resid → naphtha, gasoil, petroleum
coke.
9. Treating units for conversion products
o FCC product fractionation (main fractionator), LCO hydrotreat/strip, gasoline
treating (amine/acid wash, hydrotreat/hydrodesulfurization for diesel).
o Sour water stripper, amine units for fuel gas/sour gas, and sour gas to Sulfur
Recovery Unit (Claus + TGTU).
10. Reformer / Naphtha upgrading
o Catalytic reformer for reformate (octane booster) + hydrogen generation for
hydrotreaters.
11. Product fractionation & blending
o Gasoline pool blending (reformate, FCC gasoline, alkylate if present),
jet/kerosene pool, diesel pool, fuel oil blending.
o Product storage tanks.
12. Sulfur recovery & tail-gas treatment
o Claus plant + tail gas treatment (e.g., SCOT, MDEA) → elemental sulfur.
13. Utilities & offsites
o H₂ plant (steam methane reformer or PSA), power plant (gas turbines/boilers),
cooling water, deaerators, wastewater treatment (API separator, biological
treatment), flare system, firewater.
14. Product loading
o Metering, loading arms/hoses, truck/rail/car/ship loading systems.

Main streams summarized: Crude → desalting → hot charge → CDU split → light ends →
naphtha/gasoline processes; middle distillates → hydrotreaters → diesel/kerosene; bottoms →
VDU → VGO → conversion → finished product fractionation → blending → storage →
loading. Fuel gas, LPG, and atmospheric gases are captured and treated (amine for H₂S), with
sour gas to sulfur recovery; sour water to sour water stripper.

2 — Major unit details

Below: for each major unit — concise but complete: purpose, typical operating T/P, principal
equipment (& materials), typical feed/product composition, key constraints, common failures,
recommended inspection/maintenance.

Note: I list the most common units for a 100 kbpd moderate conversion refinery.

A. Crude reception & storage

 Purpose: Receive shipments (tanker, pipeline), store crude in tanks, stabilize level and
send to desalting.
 Typical conditions: Ambient T; tanks atmospheric or floating roof; nominal tank
breathing pressure relief per API 650/2000.
 Principal equipment: Floating-roof tanks (API 650 carbon steel), tank gauging, transfer
pumps (API 610), filters, pigging for pipelines.
 Feed/Product: Feed = crude oil with water/sediment; product = crude for processing.
 Constraints: Tank vapor emissions, slops handling, tank overflow prevention, corrosion
under insulation at piping.
 Failure modes: Roof sinkage, floating roof seal failure, tank weld cracking, leak at
nozzles, pump seal failure.
 Inspection/maintenance: Regular API 653 inspections, corrosion surveys (UT
thickness), floating roof inspection, leak/runoff checks, cathodic protection checks for
buried piping.

B. Crude Desalter
 Purpose: Remove salts, particulates and free water to prevent corrosion & fouling
downstream.
 Operating T/P: Feed ~ 50–120 °C (preheat), atmospheric; electrostatic field ~ kV
applied; wash water (30–80 °C).
 Equipment: Electrostatic desalter vessel (carbon steel with internal electrodes), mixers,
wash water injection skids, demulsifier dosing, coalescers if used.
 Feed/Product: Salted crude → desalted crude (salts <10 lb/1000 bbl typical).
  Constraints: Salt carryover limits; demulsifier selection; water quality and amount;
electrode maintenance.
 Failures: Electrode shorting, emulsion carryover, insufficient salt removal causing
downstream corrosion/fouling.
 Inspection: Visual, internal vessel inspections per API 510/653; electrode electrical tests;
dosing system checks.

C. Preheat Train & Furnace (Charge Heater)

 Purpose: Heat crude to distillation temperature; recover heat via exchangers.
 Operating T/P: Charge heater outlet typically 320–370 °C (600–700 °F) for CDU feed;
furnace pressure slightly negative to small positive depending on design; fuel
gas/combustion air conditions variable.
 Equipment: Shell & tube preheat exchangers (carbon steel, stainless clad where
corrosion risk), fired heater (tubes often 1.25–2.25Cr steel or alloy in high T zones),
pump loops, control valves.
 Feed/Product: Preheated crude → heated crude to CDU.
 Constraints: Tube metallurgy for coking, thermal expansion, flame stability, NOx limits.
 Failures: Tube leaks, coking, tube metallurgical creep, refractory failure, burner
malfunction.
 Inspection/Maintenance: Regular decoking, tube thickness UT, thermocouple checks,
burner tune-ups, refractory inspections.

D. Atmospheric Distillation Unit (CDU)

 Purpose: Primary separation of crude into overhead vapors (LPG/light naphtha),
naphtha, kerosene, diesel, and atmospheric residue.
 Operating T/P: Column top pressure slightly above atmospheric up to 1–2 barg; bottom
temp ~350–370 °C; reflux ratios variable.
 Equipment: Column shell (carbon steel, possible cladding), trays/packings,
pumparounds, condenser & reflux exchangers (shell & tube), vacuum system for side
draws (if needed), pumparound exchangers.
 Feed/Product compositions: Overheads rich in C1–C5 (fuel gas/LPG), naphtha (C5–
C10), kerosene (~C10–C16), diesel (~C12–C22), bottoms heavy fraction.
 Constraints: Tray efficiency, fouling of exchangers and pumparound, corrosion
(naphthenic acid at intermediate temps), flash point separation quality.
 Failures: Tray damage, tray fouling, column flooding/foaming, furnace overheating
leading to coke on tubes.
 Inspection: Column internal inspection per API 510, tray checks, exchanger cleaning,
pumparound pump reliability checks, corrosion monitoring (UT).
E. Naphtha Stabilizer / Light Ends Recovery
 Purpose: Remove light ends (C1–C4) from naphtha; produce stabilized naphtha for
reformer or blending.
 Operating: Stabilizer column pressures ~0.2–1.0 bar abs top to several bars at bottom;
temps moderate.
 Equipment: Stabilizer column, reboiler, condenser, vapor recovery compressors,
receivers.
 Feed/Product: Raw naphtha (C5–C10) → stabilized naphtha (lower vapor pressure) +
LPG/fuel gas.
 Constraints: Vapor pressure specifications, benzene content control if required, olefin
content (if downstream hydrotreating or reformer).
 Failures: Overflash, product off-spec, compressor vapor wetting.
 Inspection: Level and vapour detection, reboiler tube inspection.

F. Hydrotreaters (Naphtha, Kero, Diesel HDS)

 Purpose: Remove sulfur, nitrogen, and saturate olefins to meet product specs and protect
downstream catalysts.
 Operating T/P: Typical T: 300–420 °C (naphtha lower, diesel/hydrocracker higher);
Pressure: 20–100 barg (naphtha lower end, heavy diesel/hydrocracker higher). H₂/feed
ratio variable (50–1000 Nm³/m³ depending unit).
 Equipment: Fixed bed reactors (pressure vessels – carbon steel with internals,
sometimes cladded), heat exchangers, high-pressure pumps, gas-liquid separators,
catalyst baskets (NiMo, CoMo).
 Feed/Product: Sulfurous feed → low S product (<10–50 ppm depending), H₂S-rich gas
to amine.
 Constraints: Catalyst life, metal deposition, bed pressure drop, H₂ partial pressure.
 Failures: Catalyst poisoning, plugging, tube leaks in reactors, high ΔP, reactor thermal
runaway.
 Inspection/Maintenance: Catalyst monitoring and replacement scheduling, ΔP trending,
periodic offline inspections per API 510, leak tests, H₂ purity checks.

G. Vacuum Distillation Unit (VDU)

 Purpose: Separate atmospheric residue into vacuum gas oil (VGO) and vacuum resid for
conversion or blending.
 Operating T/P: Column bottoms under vacuum 20–150 mbar abs; temps in vacuum
heater up to 450–520 °C for heavy resid cracking concerns.
  Equipment: Vacuum column (large shell), vacuum pumps (steam ejectors + liquid ring
or mechanical boosters), vacuum heater (special alloys for high T), fractionation
trays/packing.
 Feed/Product: AR → VGO (feed to FCC/hydrocracker), vacuum resid (fuel oil or coker
feed).
 Constraints: Maintain deep vacuum, prevent coking in heater, maintain high heat flux
without tube failure.
 Failures: Vacuum loss, coking of heater tubes, seal leaks on pumps.
 Inspection: Vacuum system tightness tests, heater tube thickness UT, deferred coker
feed quality checks.

H. Fluid Catalytic Cracker (FCC)

 Purpose: Convert VGO into high-value gasoline, LPG and light products using catalyst
cracking.
 Operating T/P: Reactor regenerator cycle; reactor riser outlet temp ~520–560 °C,
regenerator ~600–700 °C; atmospheric to slightly positive pressure.
 Equipment: Riser reactor, catalyst stripper, regenerator (cyclones), main fractionator,
stripper, steam systems, cyclones (nickel/Cr steel where abrasion), catalyst inventory.
 Feed/Product: VGO → FCC gasoline, LPG, LCO, slurry (coke).
 Constraints: Catalyst attrition, coke burn rate, regenerator NOx, heat balance.
 Failures: Cyclone erosion, catalyst attrition, regenerator tube metal loss, feed injection
nozzle fouling.
 Inspection: Cyclone integrity, catalyst particle size monitoring, regenerator refractory
and tube inspection, vibration monitoring.

I. Hydrocracker (if present)

 Purpose: High conversion of VGO to diesel and naphtha, with H₂ addition.
 Operating: 300–450 °C, 100–200 barg (high pressure); high H₂/feed ratios.
 Equipment: High-pressure reactors (vessels with internals), high-pressure compressors
for recycle H₂, heat exchangers, high-pressure pumps.
 Feed/Product: VGO + H₂ → lighter hydrocarbons (naphtha/diesel) + heavy bottoms.
 Constraints: Catalyst life, high pressure metallurgy, H₂ supply.
 Failures: Reactor tube leaks, high ΔP, catalyst deactivation.
 Inspection: High-pressure vessel inspection (API 510), compressor integrity per API
617.
J. Delayed Coker (if present)
 Purpose: Convert heavy resid → lighter hydrocarbons + petroleum coke.
 Operating: Heater coking at 480–520 °C, coke drum cycles (fill/steam blow).
 Equipment: Heaters (high T alloy tubes), coke drums, fractionators, cutting/decoking
equipment.
 Feed/Product: Vacuum resid → naphtha, light gasoil, heavy gasoil, coke.
 Constraints: Coke drum cycle sequencing, thermal stresses, dynamic loads during steam
blow.
 Failures: Drum bulging, heater tube rupture, coke falling hazards.
 Inspection: Heater tube UT, drum thickness checks, steam blow procedures, mechanical
integrity checks.

K. Sulfur Recovery Unit (Claus) & Tail Gas Treatment

 Purpose: Recover elemental sulfur from H₂S in sour gas and acid gas streams.
 Operating: Claus reaction stages at 200–400 °C; tail gas treatment units at elevated T
with catalysts; pressure near atmospheric to modest pressure.
 Equipment: Thermal reactor, catalytic converters, condensers, amine regeneration
interface.
 Feed/Product: Amine acid gas → elemental sulfur + tail gas (treated).
 Constraints: Sulfur recovery efficiency (>95–99%), tail gas sulfur spec.
 Failures: Catalyst poisoning, condenser fouling, H₂S slip.
 Inspection: Catalyst activity checks, condenser cleaning, sulfur handling equipment
maintenance.

L. Product Fractionators & Blending

 Purpose: Separate conversion products into final cuts and blend final products to specs.
 Operating: Fractionator temps depend on cut; blending at ambient conditions with
controlled additive dosing.
 Equipment: Fractionation columns, reboilers, condensers, surge tanks, metering pumps,
blending skids, storage tanks.
 Products: Gasoline, jet, diesel, fuel oil, LPG.
 Constraints: Product specs (cetane, octane, sulfur, vapor pressure), blending component
availability.
 Failures: Off-spec product due to incorrect flows, pump failures, control valve sticking.
 Inspection: Flowmeter calibration, tank gauging, blending system testing.
M. Sour Water Stripper / Amine Unit / Sour Gas Handling
 Purpose: Remove H₂S/CO₂ from fuel gas and sour streams; remove ammonia and
phenols from sour water.
 Operating: Amine units at 40–60 °C lean amine regeneration 100–140 °C; sour water
stripper 120–160 °C.
 Equipment: Amine contactors, regenerator reboilers, sour water stripper columns, acid
gas blower.
 Constraints: Amine degradation, corrosion, H₂S loading.
 Failures: Amine foaming, corrosion, H₂S slip.
 Inspection: Reboiler tube inspection, amine analysis and reclaiming, corrosion coupons.

N. Hydrogen Plant (SMR or PSA)

 Purpose: Produce/recover hydrogen for hydrotreating and hydrocracking.
 Operating: SMR: 700–900 °C reformer tubes, high pressure shift reactors; PSA: ambient
to moderate pressure swings.
 Equipment: Reformer furnaces (alloy tubes), shift converters, PSA skids, H₂
compressors.
 Constraints: Combustion emissions, catalyst life, carbon formation.
 Failures: Tube coking, catalyst deactivation, compressor seal failures.
 Inspection: Reformer tube UT, catalyst monitoring, compressor checks.

O. Wastewater Treatment & Utilities

 Purpose: Treat process wastewaters (API separator, biological treatment), provide
utilities.
 Equipment: API separators, oil/water coalescers, biological reactors, cooling towers.
 Failures: Biological upsets, hydrocarbon carryover, corrosion in piping.

3 — Consolidated equipment &

sizing/selection guidelines (table + API
references)
Below is a consolidated list of typical rotating & static equipment, recommended types and
sizing guidance, and key API standards to reference.
Key API / industry standards to reference (non-exhaustive)

 API 610 — Centrifugal pumps for refinery services.

 API 614 — Pumps and drivers — lubrication, control.
 API 674 — Positive displacement pumps — reciprocating.
 API 617 — Axial and centrifugal compressors.
 API 618 — Reciprocating compressors.
 API 660 — Shell storage tanks.
 API 650 — Welded storage tanks.
 API 510 — Pressure vessel inspection code.
 API 570 — Piping inspection code.
 API 571 — Damage mechanisms and inspection.
 API 572 — Inspection of pressure vessels.
 API 521 — Pressure-relieving and depressurizing systems.
 ASME Boiler & Pressure Vessel Code (BPVC) Section VIII — pressure vessel design.
 ASME B31.3 — Process piping.
 API 560 — Fired heaters.
 API RP 571/579/580 — Risk-based inspection, fitness-for-service.
 ISO 10438 / API 682 — Mechanical seals for pumps.
 API 598 — Valve inspection/test.
 NEBOSH/OSHA/IEC standards for electrical and safety (locally applicable).

Rotating equipment selection guidelines

(Condensed — pick machine selection with examples)

 Centrifugal Pumps (API 610)

o Use: charge pumps, pumparounds, product transfer.
o Sizing: design for BEP flows; choose multi-stage for high head (boiler feed);
single stage horizontal for low/mid head.
o Materials: Carbon steel (API 0.5–1% S crude) with stainless or cladding for sour
services; duplex stainless for H₂S presence.
o Mechanical seals: API 682 cartridge seals, double seals in hazardous fluids.
o Margins: design for 1.1–1.3× design flow capability; NPSH margin ≥ 1.2.
o Typical issues: cavitation, seal leaks, bearing failure.
 Positive Displacement Pumps
o Use when viscous fluids or precise flow (slurries, asphalt).
o API 674 or vendor specific.
 Compressors
o Steam/air/gas compressors: centrifugal (API 617) for large flows and moderate
pressure; reciprocating (API 618) for high pressure small flows (amine acid gas,
fuel gas, H₂ recycle).
o Materials: carbon steel (with corrosion allowance) or stainless for H₂S/H₂
environments.
 o Margins: surge margin for centrifugal compressors typically 5–10% in map;
rotational speed safety margins per vendor.
o Typical failures: surge, fouling, blade erosion.
 Turbomachinery (power generation, gas turbines): vendor standards; vibration
monitoring essential.

Heat exchangers

 Shell & Tube exchangers (most common)

o Use: preheat trains, condensers, reboilers.
o Materials: carbon steel shells, tube materials vary (Cu alloys, stainless, Inconel for
high T or corrosive fluids).
o Types: fixed tubesheet (low thermal expansion), U-tube (high thermal expansion).
o Design margins: design for fouling factors (0.0001–0.0005 m²K/W), allow 10–
20% over nominal heat duty for safety.
o API: TEMA standards for exchangers; ASME Section VIII.
 Air coolers/fin fans where cooling water limited.
 Plate exchangers for utilities and low-pressure heat transfer.

Columns and internals

 Column internals: Sieve trays, valve trays, bubble cap trays, structured packing.
o Selection: trays preferred for fouling feeds; packing for low pressure drop and
high efficiency.
o Design margins: tray efficiency accounted (Murphree efficiency), turndown
allowances; flood margin >10–20%.
o Materials: carbon steel with cladding where corrosion; stainless for naphthenic
acid or sour water.

Pressure vessels, storage tanks, piping & valves

 Storage tanks: API 650/620 depending on temperature/pressure. Floating roofs for

volatile products.
 Pressure relief devices: API 520/521/526 sizing and setpoints keyed to process
conditions.
 Valves: gate, globe, ball, control (modulating) valves per API 600/602; pressure class per
ASME B16.34.
Typical design margins & safety factors (practical)

 Pumps: NPSH margin ≥ 1.2; design flow margin +10–30% capacity head.
 Heat exchangers: fouling factor allowance 1.5–3× expected; pressure drop margin 1.2×
expected.
 Columns: turndown to 50% capacity without flooding; tray flood margin 10–20%.
 Vessels: corrosion allowance typical 1.5–3 mm depending environment; code design
factor per ASME.
 Mechanical codes: pressure design per ASME & relief per API 521.

4 — Simplified mass balance example

(100,000 bpd crude)
Below is a typical yield split for a medium conversion refinery that includes an FCC and
hydrotreaters. Percentages are by mass (%) of crude input. These are representative; real yields
depend on crude and configuration.

 Crude feed: 100,000 bpd (baseline)

Typical product yield percentages (mass % of crude):

 LPG & fuel gas: 4%

 Gasoline pool (including reformate, FCC gasoline, alkylate etc.): 28%
 Naphtha (light straight-run + stabilized naphtha): 8%
 Kerosene / Jet: 12%
 Diesel / Gas oil: 30%
 Fuel oil / Residual: 13%
 Petroleum coke: 2%
 Process & storage losses / fuel (plant fuel, flaring, small losses): 3%

Totals = 100%

Additional notes:

 Sulfur output: If crude sulfur ~1.2 wt% and most sulfur is concentrated in heavy
fractions, elemental sulfur production (Claus) might be ~1.0–1.5% of crude mass
(depends on conversion & removal efficiency). For a 100,000 bpd plant (~13,600 m³/d),
sulfur production would be several tens to low hundreds of tonnes/day depending on
crude S and conversion.
 H₂ consumption: Hydrotreating/hydrocracking H₂ demand depends on severity —
typical hydrogen make or import 100–500 Nm³ per ton of feed for hydrocracking heavy
duty; naphtha hydrotreaters lower.
  If heavy crude or higher conversion (more coking or hydrocracking), coke and fuel
oil splits shift.

Safety & Environmental controls (key hazards

& systems)
Major hazards
 Fire & explosion (hydrocarbon vapors, H₂)
 High-pressure gas releases and toxic H₂S exposures
 Thermal hazards (furnaces), hot surfaces and steam
 Corrosion/structural failures leading to spills
 Environmental emissions: SOx, NOx, VOCs, particulates, wastewater hydrocarbons, H₂S

Required safety systems

 Emergency Shutdown (ESD) system: skid & plant ESD with safe trip logic, SIL where
required.
 Flare system: sized for emergency relief and continuous relief per API 521; knockout
drum, flare pilots, steam assist.
 Firewater & deluge: ring mains, hydrants, foam systems for tanks and process areas;
firewater redundancy.
 Gas detection & LEL monitoring: distributed LEL, H₂S sensors with auto isolation.
 Pressure relief & blowdown: PSV network sized to API 520/521; flare forwarding and
blowdown headers.
 Isolation valves and emergency isolation (ESIVs).
 Inerting (N₂) for certain tanks.
 Hydrogen safety systems: H₂ detection and ventilation for H₂ plant areas; dedicated
flare lines, PSA ventilation.
 Process control & safety shutdown (DCS + SIS) — alarms, automatic trips.

Emission control technologies

 Sulfur recovery: Claus plant + tail gas treat (SCOT) to reduce SO₂/H₂S stack emissions
to regulatory limits.
 Flares with steam assist to promote combustion and reduce smoke; flare recovery where
possible.
 NOx controls: low NOx burners, selective catalytic reduction on fired heaters/turbines.
 VOC controls: floating roofs, tank vapor recovery (VRU), closed loading with vapor
return.
  Wastewater treatment: API separators, dissolved air flotation, biological treatment,
polishing.
 Particulate filters and SCR for incinerators/HRSGs where required.

5 — One-page P&ID legend & recommended

online instrumentation (critical variables +
example setpoints)
(This is a compact P&ID legend and I/O list suitable for the major units; adapt setpoints to
process specs.)

P&ID legend — common symbols (one-page)

 PUMP: filled circle with tag P-XXX; include seal flush port symbol.
 COMPRESSOR: triangle or oval with shaft symbol and driver tag.
 VALVE:
o Gate valve — straight line with square;
o Globe — line with diagonal;
o Control valve — valve body with diagonal arrow and CV tag;
o Check valve — triangle inside line.
 HEAT EXCHANGER (Shell & tube): two parallel lines with tube bundle symbol.
 FURNACE: brick box with burners symbol.
 COLUMN: tall rectangle with trays/packing marks and side draws.
 POT/DRUM: horizontal cylinder for vessels.
 PUMPAROUND: pump arrow on recycle loop.
 INSTRUMENTS: circle with letter (T=Temp, P=Pressure, F=Flow, L=Level,
A=Analyzer), with control loop tag (e.g., TIC-101).
 Relief device: PRV triangle with arrow to vent header → flare.
 Sample point: small circle with SAMP tag.

Recommended online instrumentation for critical

variables (example tags & setpoints)
(These are example ranges; final setpoints must be agreed with process engineers & safety.)

 CDU Furnace outlet temp (TI-F101): normal 330–360 °C; Hi Alarm 380 °C; Trip 400
°C.
 CDU Column top pressure (PI-C101): normal 0.05–0.5 barg; Hi alarm 1.0 barg; Trip at
1.5 barg.
  CDU Bottom temperature (TI-C101B): normal 340–370 °C; Hi alarm 380 °C (coking
risk).
 Vacuum column suction (PI-V101): vacuum target 40–100 mbar abs; low vacuum
alarm >120 mbar abs.
 Pumparound flow (FI-PUMPRD): set control to maintain bottom product quality; low
flow alarm at 50% design; pump trip at <30%.
 Hydrotreater reactor bed temperature (TIT-HT1): operating 320–420 °C; reactor ΔT
monitoring for hotspot (ΔT per bed limit).
 H₂ partial pressure (PI-HT1): typical 20–80 barg; low H₂ alarm at design setpoint
−10%.
 Amine regenerator temp (TI-AMR): normal 100–140 °C; low temp alarm = decreased
H₂S removal.
 Fuel gas flow & calorific value (FIC-FG): ensure burner stability; gas LEL monitors.
 Flare header pressure (PI-FLR): maintain low pressure; Hi alarm -> overpressure on
relief.
 Tank level (LI-Txxx): high level alarm (90%); high-high (95%) triggers ESD for tank
filling.
 H₂S analyzer at process gas (AN-H2S): trip/ESD if > X ppm (specify by local
safety/regulation; e.g., 10 ppm in certain lines).
 Air/fuel ratio for fired heaters (FIC-AF): optimize for low NOx; low air alarm for CO
formation.
 Vibration monitors on rotating equipment (VM-Pxxx): trigger maintenance if >
threshold (e.g., 70% of alarm level).
 Online sulfur/mercaptan analyzers for product streams (as required for product spec
control).

6 — Troubleshooting checklist (Top 10

mechanical problems for mechanical
engineers)
For each problem: quick symptom → immediate actions → likely root causes → preventive
measures.

1. Pump cavitation
o Symptom: noisy, vibration, reduced flow, overheating.
o Immediate: reduce flow, open discharge slightly, check NPSH / upstream level.
o Root cause: low suction head, vaporizing fluid, blocked suction, high temperature.
o Preventive: ensure NPSH margin, suction strainers, upstream surge tanks,
temperature control.
2. Heat exchanger fouling (preheat train, reboilers)
o Symptom: decreased duty, higher outlet temp, increased pressure drop.
 o Immediate: schedule cleaning; bypass if possible, reduce feed temp.
o Root cause: scaling, coke deposition, corrosion solids.
o Preventive: online monitoring of ΔT and ΔP, improved filtration, chemical
cleaning schedule.
3. Compressor surge (centrifugal)
o Symptom: flow oscillation, surge noise, trips.
o Immediate: open anti-surge recycle, reduce speed, trip safely if unstable.
o Root cause: low flow at high head, poor control tuning.
o Preventive: maintain anti-surge control logic and recycle valves, surge margin
design.
4. Valve packing leaks / seat leakage
o Symptom: visible leakage, pressure drop, emissions.
o Immediate: isolate if safe, adjust packing gland, use temporary containment.
o Root cause: worn packing, thermal cycling, wrong packing selection.
o Preventive: scheduled packing replacement, use appropriate materials (PTFE,
graphite), fugitive emission controls.
5. Heat exchanger tube leaks
o Symptom: cross-contamination, off-spec product, pressure change.
o Immediate: isolate and trip affected exchanger; switch to standby.
o Root cause: erosion-corrosion, corrosion under deposits, vibration.
o Preventive: vibration analysis, proper supports, material selection, tube
inspection.
6. Column tray damage / flooding
o Symptom: product off-spec, pressure rise, foaming.
o Immediate: reduce reflux, reduce feed rate, investigate.
o Root cause: trays clogged/fouled, maldistribution, foaming components.
o Preventive: feed pre-treatment, anti-foaming agents, tray inspection schedule.
7. Furnace tube failure (coke/overheat)
o Symptom: leak, flame instability, radiant tube rupture alarm.
o Immediate: emergency shutdown furnace, isolate fuel, safe cool down.
o Root cause: localized overheating, coking, metallurgical degradation.
o Preventive: regular decoking, thermocouple monitoring, tube metallurgy and
thickness checks.
8. Seal failure on high-pressure pumps
o Symptom: external leak, low pressure, lost product.
o Immediate: stop pump if feasible, use seal flush; drain/contain leaks.
o Root cause: seal face wear, dry running, thermal shock.
o Preventive: API 682 mechanical seals, flushing systems, instrumentation for seal
chamber pressure.
9. Corrosion leaks (piping/vessel)
o Symptom: small seepage, pressure drop, visible pits.
o Immediate: isolate section, pressure test, temporary clamp repair.
o Root cause: H₂S / naphthenic acid corrosion, microbiological corrosion, chloride
stress.
o Preventive: corrosion monitoring, proper alloy selection, cathodic protection,
chemical inhibitors.
 10. Tank floating roof ponding / sinking
o Symptom: stuck roof, vapor emissions, product loss.
o Immediate: stop fill, inspect floating roof, drain collected water.
o Root cause: seal failure, drainage plug blocked, rainwater accumulation.
o Preventive: regular roof drainage checks, seal replacement, roof inspections (API
653).

(b) Tabular equipment list (condensed but

actionable)
Below is a compact table for major equipment — use for procurement & inspection planning.

Typical sizes /
Typical Inspection/
Equipment ranges (100
materials maintenance notes
kbpd)

10,000–100,000 Carbon steel

Crude storage API 653 inspections,
m³ capacities (API 650),
tanks floating roof checks
depending layout roof seals

CS vessel;
0.5–5 m³/s Electrode testing, dosing
Desalter internal
throughput skids pump checks
electrodes

Shell CS;
Shell & tube Large (1–20 m² TEMA; tube UT, cleaning,
tubes
exchangers UA), many in train fouling monitoring
SS/Alloy

Duty sized for Alloy tubes in

Tube UT, burner tune,
Fired heater preheat; ~10–60 radiant,
decoking
MW refractories

Atmospheric CS shell;
Height 40–60 m; Tray inspection, column
distillation trays SS or
diameter varies internals check
column carbon

Vacuum CS; special

Large diameter; Vacuum tightness,
distillation alloys in hot
vacuum pumps ejector maintenance
column sections

FCC unit Riser/regenerator Carbon steel; Cyclone inspections,

 Typical sizes /
Typical Inspection/
Equipment ranges (100
materials maintenance notes
kbpd)

sized for VGO; refractory in

catalyst management
catalyst inventory regenerator

High pressure CS vessels; API 510 vessel

Hydrotreater
vessels (20–200 catalyst inspection, catalyst
reactor
barg) baskets replacement

CS with Drum inspections, cycle

Delayed coker Coke drums (large)
heavy design management

Flows: 10–10,000 CS casing; Vibration, seal, bearing

Pumps
m³/day ranges stainless monitoring
(centrifugal API
internals as
610)
needed

Compressors
0.1–100 MW Alloys per Surge control & vibration
(centrifugal/recip
depending unit gas service monitoring
)

Heat exchangers Fin area sized per Aluminium or Fan bearings, stack
(fin/air coolers) duty SS fins cleaning

ASME code API 510 inspections,

Pressure vessels Per process
materials thickness checks

Storage and 5–20 tanks for API 650, Cathodic protection

product tanks products floating roofs checks

Sulfur recovery Alloy

Sized to H2S load Catalyst activity tests
(Claus) internals

Lean amine Amine analysis and

Amine unit SS internals
circulation rates reclaiming

Sour water Column sized to CS trays or

Stripper reboiler checks
stripper water flow packing

High alloy Reformer tube

Reformers & shift
H₂ plant (SMR) reformer inspection/retube
converters
tubes planning
 Typical sizes /
Typical Inspection/
Equipment ranges (100
materials maintenance notes
kbpd)

FRP or
Utilities: cooling Multiple cells; 10– Basin cleaning, drift
galvanized
towers 50 MW cooling eliminator checks
steel

Header sized to Flare pilot, steam assist

Flare system CS
worst-case relief checks

(c) Simple ASCII PFD sketch

A simple linear ASCII flow: crude → desalting → heater → CDU → VDU + Conversion →
treating → blending → storage → loading.

[Crude Tanks] ---> [Desalter] ---> [Preheat Train] ---> [Charge Heater]
|
v
(slop/water)
|
v
[CDU - Atmos Distillation]
|--- Overheads --> [Stabilizer] --> LPG/Fuel Gas
|--- Naphtha --> [Naphtha HDS / Reforming] --> Gasoline pool
|--- Kero --> [Kero HDS] --> Jet pool
|--- Diesel --> [Diesel HDS] --> Diesel pool
`--- Atmospheric Residue ---> [Vacuum Distillation]
|--- VGO ---> [FCC] --> FCC Main
Fractionator --> gasoline/diesel/LPG
|--- Vacuum Resid ---> (Fuel oil or) --
> [Coker / Hydrocracker]
[H2 Plant] -----------------------------^
[Amine Unit] <-- sour gas from hydrotreaters/FCC fractionators --> [Claus
Unit] --> Sulfur
[Product Fractionation & Blending] --> [Product Storage] --> [Loading
(truck/rail/ship)]
Utilities: Steam / Cooling / Flare / Firewater connected to all units.

Final notes & recommended next steps

 This deliverable is a design-level reference and checklist. For engineering execution you
must integrate with process licensors (CDU/VDU/FCC/hydrocracker licensors),
 mechanical design using ASME/API codes, and dynamic simulation (HYSYS/PROII) for
material balances & sizing.
 If you want, I can:
o produce a detailed PFD drawing in SVG/PDF form (requires unit duty data), or
o run a mass/energy balance with a chosen crude assay and configuration (I can do
an example if you provide a crude assay or let me pick a typical 30°API medium
crude),
o or create a detailed inspection/maintenance schedule (Gantt) for all major
equipment tailored to your plant.

Would you like me to (pick one) — (A) do a more detailed mass/energy balance with an
example crude (I’ll assume a specific assay), or (B) generate a checklist/Gantt for inspection &
turnaround planning for a 100 kbpd medium converter?