The function of a Crude Distillation Unit (CDU) in an oil refinery is to separate the raw crude in to

useful products such as gasoline, naphtha, kerosene and gas oil.

Desalter
Crude at ambient conditions is fed to the feed surge drum V100 with the help of a flow
controller FIC012. XV001 is an isolation valve which closes when ESDs are activated. The
feed from the feed surge drum is pumped through feed pump P101A/B in to the desalter
V101. The level of the feed surge drum is controlled by LIC005.

In the desalter, dissolved salts are removed. Crude oils often contain inorganic salts such as
sodium chloride, magnesium chloride, and calcium chloride in suspension or dissolved in
entrained water (brine). These salts must be removed or neutralized before processing to
prevent catalyst poisoning, equipment corrosion, and fouling.

Desalting is done with water and demulsifying agent in presence of high electric voltage.
Electrical desalting is the application of high-voltage electrostatic charges to concentrate
suspended water globules in the bottom of the settling tank.

The DC field between the electrode plates allows a uniform migration of water droplets
towards the opposite charged electrode while maintaining an AC field between the water
interface and the electrode plates to coalesce the larger droplets near the oil/water
interface.

The flow of demulsifying agent is controlled by FIC011 and the flow of wash water is
controlled by FIC019. High electric voltage is applied with the help of a switch “Power ON”.
A power regulator is also provided operating between 0 to 100% which regulates the
voltage across the opposite charged electrode. When the power is on, increasing or
decreasing the power through regulator will increases or decreases the concentration of the
salt at the outlet.  The total concentration of all the salts at the outlet of desalter should not
be more than 50 ppm

 
The level of the crude in the desalter is maintained by LIC008 where as the level of the brine
(water + salt) is controlled by LIC009.
Pre- Heat Train Section
The desalted crude is before entering the Pre-flash V102 is passed through series of heat
exchangers by exchanging heat as follows:
Crude from desalter is heated to around 46 C (114.8 F) by exchanging heat with
1. Kerosene product in E106
Crude is further heated to around 98 C (204.8 F) by exchanging heat with top pump
2. around in E103
Crude is further heated to around 125 C (257 F) by exchanging heat with Diesel product
3. in E107
Crude is further heated to around 152 C (305F) by exchanging heat with middle pump
4. around in E104
Crude is further heated to around 222 C (431F) by exchanging heat with the residue in
5. E101
Crude is finally heated to around 243 C(469F) by exchanging heat with lower pump
6. around in E105
 
The liquid from pre-flash is then fed to furnace F100 on a level control LIC006.
Furnace Section
The liquid from pre-flash vessel is pumped with P109A/B to the furnace.

 The feed to the furnace is controlled by a master level controller cascaded to four
independent pass flow controllers. The master controller LIC006 sends its output to each of
the four pass controllers (FIC015, FIC016, FIC017 and FIC018).
At design conditions each pass will has the same flow rate. In real conditions, the tubes in
the heater will foul differently depending on their location within the firebox.
The outlet temperature of each pass is often different; sometimes some indicators may go
into alarm, while others are not close to alarm conditions. To accommodate this problem,
the four pass controllers’ individual bias terms are used to adjust each flow controller's set
point. While in cascade mode, the master controller continues to adjust the pass controller
set points while the secondary controllers take into account the operator entered set point
in auto mode fir that particular controller. Therefore, when one pass has a higher
temperature than the other passes, the flow can be increased to that pass by increasing the
set point of that flow controller by placing it in auto mode. Increasing the flow, will cause
the outlet temperature to decrease and also cause the other passes to reduce the flow rate
to maintain the set point for the master controller. The decrease in flow through the other
passes causes their outlet temperatures to increase. The procedure of adjusting flows to
maintain similar outlet temperatures is called pass balancing.

Natural gas is used as the fuel for the burner. The flow of fuel gas is controlled by FIC014.
FIC014 is cascaded with the TIC006 which controls outlet temperature furnace. XV004 is an
isolation valve which closes when ESDs are activated.

The flow of combustor air is controlled by FIC013. The flow combustor air mainly depends
up on the concentration of oxygen at the outlet of the furnace. It is very essential to keep
excess air in order to achieve proper combustor of the fuel gas. XV003 is an isolation valve
which closes when ESDs are activated.  The flame of the furnace can be ignited or
extinguished by the switches provided. AI001 indicates the excess oxygen content at the
outlet of flue gas where as ARF001 indicates the air to fuel ratio in the furnace.

 
The pressure of the furnace is controlled by PIC002.

Main Section
Crude column consists of 29 trays. The crude from the furnace enters column at the 28th tray.
Stripping steam is injected at the 29th tray whose flow is controlled by FIC020. XV001 is an isolation
valve which closes when ESDs are activated. Three pump-arounds and three strippers are used to
get the required purity and quantity of the products.

Condenser Section:
The vapor from the column top moves to the condenser section. The temperature and the flow are
indicated by TI010 and FI010 respectively. The vapors are cooled by air cooler A100 (with four fans)
and then by shell and tube heat exchanger E100. TI011 and TI012 indicate the temperature after air
cooler and heat exchanger respectively. The hydrocarbons are separated from non condensable
gases and water in the reflux drum V103. The flow of the non condensable gases is indicated by
FI018. The level of the heavy liquid (water) level is controlled by LIC011. The flow from the reflux
drum is divided in to Naphtha (product) and reflux. The flow of Naphtha is controlled FIC010 which is
cascaded with LIC004 which maintains the level of the reflux drum. The reflux from the reflux drum
is pumped back to column by P100 A/B. The flow of the reflux is controlled by FIC009 which is
cascaded with TIC001 which controls the temperature of the 1st tray of the column. TI013 and TI014
indicate temperature of Naphtha and Reflux. TI051, TI052 indicates 10% and 90% point temperature
respectively. Research octane number of naphtha is indicated by RON-NAPHTHA.

Top  Previous  Next

Kerosene Section:
Kerosene side draw is taken from the 9th tray and returned back to the 8th tray. TI022 and
FI022 indicate the temperature and flow of the side draw respectively. FI024 indicate the
flow of the return stream. The side draw is fed to Kerosene side stripper C101. The volume
of liquid drawn depends up on the level of the stripper which is controlled by LIC001.
XV009 is an isolation valve which closes when ESDs are activated.

The bottom of C101 is sent to reboiler E102 where the reboling takes place with the help
of HP Steam. XV006 is an isolation valve which closes when ESDs are activated. The boil up
is sent back to C101.

The Kerosene product is drawn from E102 and its flow is controlled by FIC004. The product
is pumped with the help of P106A/B before being cooled by E106 by exchanging heat with
the feed.TI053 and TI054 shows 10% and 90% point temperature of kerosene. The flash
point and research octane number is shown by FLASH-KER and RON-KER respectively.
TI023 indicates the temperature of the product stream.
Diesel Section: Top  Previous  Next

Diesel side draw is taken from the 17th tray and returned back to the 16th tray. TI032 and
FI032 indicate the temperature and flow of the side draw respectively. FI034 indicate the
flow of the return stream. The side draw is fed to Diesel side stripper C102. The volume of
liquid drawn depends up on the level of the stripper which is controlled by LIC002. XV010
is an isolation valve which closes when ESDs are activated.

Stripping steam is injected at the bottom whose flow is controlled by FIC007. XV007 is an
isolation valve which closes when ESDs are activated.

The Diesel product flow is controlled by FIC005. The product is pumped with the help of
P107A/B before being cooled by E107 by exchanging heat with the feed. TI033 indicates
the temperature of the product stream. TI055 and TI056 shows 10% and 90% point
temperature of diesel. The flash point and Cetane index is shown by FLASH-DIE and CI-DIE
respectively.
AGO Section: Top  Previous  Next

AGO side draw is taken from the 22nd tray and returned back to the 21st tray. TI042 and
FI042 indicate the temperature and flow of the side draw respectively. FI044 indicate flow
of the return stream. The side draw is fed to AGO side stripper C103. The volume of liquid
drawn depends up on the level of the stripper which is controlled by LIC003. XV011 is an
isolation valve which closes when ESDs are activated.

Stripping steam is injected at the bottom whose flow is controlled by FIC008. . XV008 is an
isolation valve which closes when ESDs are activated.

The AGO product flow is controlled by FIC006. The product is pumped with the help of
P108A/B before being cooled by E108. TI043 indicates the temperature of the product
stream. TI057 and TI058 shows 10% and 90% point temp of AGO. The flash point and
cetane index is shown by FLASH-AGO and CI-AGO respectively.
Upper Pump-Around Section: Top  Previous  Next

Side draw for the top pump-around is taken from the 2nd tray and returned back to the
1st tray. TI020 and PI020 indicate the temperature and pressure of the side draw
respectively. Pump P103 A/B is used to pump the liquid through the shell and tube heat
exchanger where it is cooled by exchanging heat with the feed in E103. FIC001 controls the
flow of the liquid going back to the column. TI021 and PI021 indicate the temperature and
pressure of the return stream respectively.
Middle Pump-Around Section: Top  Previous  Next

Side draw for the middle pump-around is taken from the 17th tray and returned back to
the 16th tray. TI030 and PI030 indicate the temperature and pressure of the side draw
respectively. Pump P104 A/B is used to pump the liquid through the shell and tube heat
exchanger where it is cooled by exchanging heat with the feed in E104. FIC002 controls the
flow of the liquid going back to the column. TI031 and PI031 indicate the temperature and
pressure of the return stream respectively.
Lower Pump-Around Section: Top  Previous  Next

Side draw for the lower pump-around is taken from the 22nd tray and returned back to
the 21st tray. TI040 and PI040 indicate the temperature and pressure of the side draw
respectively. Pump P105 A/B is used to pump the liquid through the shell and tube heat
exchanger where it is cooled by exchanging heat with the feed in E105. FIC003 controls the
flow of the liquid going back to the column. TI041 and PI041 indicate the temperature and
pressure of the return stream respectively
Bottom Section: Top  Previous  Next

The level of the bottom section is controlled by LIC007. The hot residue leaving the column
bottom exchanges heat with the feed in E101. TI050, PI050 and FI050, indicate the
temperature, pressure and flow of the residual stream.
Emergency System Top  Previous  Next

The Crude Unit Standard Model is fitted with an interlock system providing an Emergency
Shutdown button and 15 different levels of trips, to provide protection to the plant.

During initial start up of the plant, all the trip systems must be over-ridden to allow control
of the plant, however all activated over-rides must be removed as soon as the plant is
operating within the trip limits.

A manual shutdown is activated by MNS001 which causes plant Emergency Shutdown.

When MNS001 is turned to off position, manual shutdown is activated which causes the
following sequence of events to occur.
 
Feed to the feed surge drum will be cut off by closing isolation valve XV001 in the
1. desalter section.
Flow of wash water and demulsifying agent will be cut off by closing isolation valve
2. XV002
3. Application of high electric voltage to the desalter will be stopped.
4. Nitrogen will start flowing in to the feed surge drum by opening isolation valve XV012
5. Drain valve for feed surge drum will get open
6. Feed pump will get tripped in case of low level of the feed surge drum
Flow of combustor air will be cut off by closing isolation valve XV003 in the furnace
7. section.
8. Flow of fuel gas will be cut off by closing isolation valve XV004
9. Furnace will get tripped indicated by extinguished flame
10. Nitrogen will start flowing through the furnace by opening FOD041
11. Drain valve for Pre-flash drum will get open
12. Pre-flash pump will get tripped in case of low level of the drum
Flow of the steam to the main column through FCV020 will be cut off by closing
13. isolation valve XV006 in the bottom section
14. Drain valve for column boot will get open
15. Vent valve will get open at the condenser section.
16. Drain valve for reflux drum will get open
17. Reflux pump will get tripped in case of low level of the drum
The pumps for all the three pump-around will get tripped resulting in no flow through
18. them
19. Side draw to the kerosene stripper will be stopped by closing isolation valve XV009
20. HP steam to the kerosene reboiler will be cut off by closing isolation valve XV006
21. Drain valve for kerosene boot will get open
22. Kerosene product pump will get tripped in case of low level of the boot
23. Side draw to the diesel stripper will be stopped by closing isolation valve XV010
24. Stripping steam to the diesel stripper will be cut off by closing isolation valve XV007
25. Drain valve for diesel boot will get open
26. Diesel product pump will get tripped in case of low level of the boot
27. Side draw to the AGO stripper will be stopped by closing isolation valve XV011
28. Stripping steam to the AGO stripper will be cut off by closing isolation valve XV008
29. Drain valve for AGO boot will get open
30. AGO product pump will get tripped in case of low level of the boot
31. The system will be completely purged with Nitrogen
1. Trip A: Low Flow of the Fuel Gas to the Furnace:
As mentioned earlier, the model contains different level of trips. This is the major trip and
will cause the complete shutdown of the whole unit. The plant cannot be recovered when
the trip A is activated.  

Causes:
This trip is activated when there is low flow of the fuel gas through FIC014.

In normal steady state conditions, flow of fuel gas through FIC014 is around 6100
STD_m3/h (215 MSCFH). When the flow is lesser than 2637 STD_m3/h (93.31 MSCFH), low
flow alarm FAL001 will be activated in the Annunciator Panel. If the flow further reduces
below 1582 STD_m3/h (56 MSCFH); low-low flow signal will be sent to the fuel gas
isolation valve. Trip A will be activated and will cause following sequence of events to
occur:

Effects:
1. Furnace will be tripped.
2. Side draws to the strippers will be stopped by closing their respective isolation valve.
3. Fuel gas isolation valve will be closed.
Nitrogen will be purged through the tubes of the
4. furnace.
5. Combustor air isolation valve will be closed.
6. Feed isolation valve will be closed.
7. Application of high electric voltage to the desalter will be stopped.
8. Isolation valve for Demulsifying agent and wash water will be closed.
9. Main Steam isolation valve will be closed.
10. Vent valve will be opened.
11. Kerosene rebolier steam isolation valve will be closed.
12. Diesel stripping steam isolation valve will be closed.
13. AGO stripping steam isolation valve will be closed.
14. All drain valves will be opened.
15. Pump for all the pump-arounds will be tripped resulting in no flow through them.
16. Nitrogen purge for feed surge drum, pre-flash drum and main column will get open.
17. All the pumps would trip when the level in the vessels is less than 10%
 

Please note that the effects will be similar to the turning on manual pushbutton.

 
Trip B: Low Flow Through Each Pass Of The
2. Furnace:
Causes:

This trip is activated when there is low flow through any one of the pass flow controllers
FIC015, FIC016, FIC017 and FIC018.

In normal steady state conditions, flow through each pass is same (170 m3/hr), (748
USGPM). When the flow through any pass is lesser than 45 m3/hr (198 USGPM), low alarm
is indicated. If the flow further reduces below 25 m3/hr (110 USGPM); low-low flow alarm
signal (FAL003 / FAL004 / FAL005 / FAL006) will be activated for that pass in the ESD page.
Trip B will be activated and will cause following sequence of events to occur:
 

Effects:
1. Furnace will be tripped
2. Fuel gas isolation valve will be closed
3. Side draws to the strippers will be stopped by closing their respective isolation valves
3. Trip C: Main Column (C100) bottom temperature high:
Causes:

This trip is activated when the column bottom temperature indicated by TI050 is high.

In normal steady state conditions, the bottom temperature is around 350 C (662 F). When
the temperature rises above 355 C (671 F), temperature high alarm (TAH002) will be
activated in the ESD page. Trip C will be activated and will cause following sequence of
events to occur:

Effects:
1. Furnace will be tripped
2. Fuel gas isolation valve will be closed
3. Side draws to the strippers will be stopped by closing their respective isolation valves
4. Trip D : Main Column (C100) top pressure high:
Causes:

This trip is activated when the column top pressure indicated by PI010 is high.

In normal steady state conditions, the column top pressure is around 0.9246 Kg/cm2_g
(13.2 psig). When the pressure rises above 1.057 Kg/cm2_g (15 psig), high pressure alarm
is indicated. If the pressure further rises above 1.108 Kg/cm2_g (15.7 psig), high–high
pressure alarm signal high (PAH001) will be activated in the ESD page. Trip D will be
activated and will cause following sequence of events to occur:

Effects:
1. Vent valve will get completely opened
2. Pressure would be reduced
3. Level of reflux drum will fall down resulting in reduced flow of naphtha
5. Trip E: Furnace (F100) outlet temperature high:
Causes:

This trip is activated when the Furnace (F100) outlet temperature indicated by TI079 is
high.

In normal steady state conditions, the bottom temperature is around 345 C (653 F). When
the temperature rises above 350 C (662 F), high temperature is indicated. If the
temperature further rises above 355 C (671 F), high–high temperature alarm signal
TAH001 will be activated in the ESD page. Trip E will be activated and will cause following
sequence of events to occur:

Effects:
1. Furnace will be tripped
2. Fuel gas isolation valve will be closed
3. Side draws to the strippers will be stopped by closing their respective isolation valves
6. Trip F: Low Flow Of The Combustor Air To The Furnace:
Causes:

This trip is activated when there is low flow of the combustor air through FIC013.

In normal steady state conditions, flow of combustor air through FIC013 is around 105492
STD_m3/h (3733 MSCFH). When the flow is lesser than 36922 STD_m3/hr (1306 MSCFH),
low flow alarm is indicated. If the flow further reduces below 26373 STD_m3/h (933
MSCFH); low-low flow alarm signal FAL002 will be activated in the ESD page. Trip F will be
activated and will cause following sequence of events to occur:

Effects:
1. Furnace will be tripped
2. Fuel gas isolation valve will be closed
3. Side draws to the strippers will be stopped by closing their respective isolation valves
7. Trip G: Low Oxygen Content At The Outlet Of Flue Gas:
Causes:

This trip is activated when there is low oxygen content at the outlet of flue gas.

In normal steady state conditions, oxygen content at the outlet of flue gas is around 8 %. If
the oxygen content is lesser than 1.5 %, low oxygen alarm is indicated. If the oxygen
content further reduces below 0.75%, low-low alarm signal OAL001 will be activated in the
ESD page. Trip G will be activated and will cause following sequence of events to occur:

Effects:
1. Furnace will be tripped
2. Isolation valve for Natural gas will be closed
3. Feed temperature will reduce
4. Side draws to the strippers will be stopped by closing their respective isolation valves
8. Trip H: High Air to Fuel Ratio:
Causes:

This trip is activated when there is high air to fuel ratio in the furnace.
In normal steady state conditions, air to fuel ratio is around 28. If the air to fuel ratio is
more than 35, high alarm is indicated. If the air to fuel ratio further increases above 40,
high-high alarm signal AFRH01 will be activated in the ESD page.  Trip H will be activated
and will cause following sequence of events to occur:

Effects:
1. Furnace will be tripped
2. Feed temperature will reduce
3. Top stage temperature and pressure will reduce
4. Reflux flow will be reduced
5. Low-low alarm for reflux flow will be activated
9. Trip I: Low Flow Of Reflux:
Causes:

This trip is activated when the there is low flow of reflux flow through FIC009.

In normal steady state conditions, reflux flow is around 90 m3/hr (395 USGPM). When the
reflux flow is lesser than 60 m3/hr (264 USGPM), low flow alarm is indicated. If the flow
further reduces below 45 m3/hr (198USGPM) then low-low flow alarm signal FAL007 is
activated in the ESD page. Trip I will be activated and will cause following sequence of
events to occur:

Effects:
1. Furnace will be tripped
2. Fuel gas isolation valve will be closed
3. Side draws to the strippers will be stopped by closing their respective isolation valves
10. Trip J: Low Level of the Feed Surge Drum:
Causes:

This trip is activated when the level of the feed surge drum is low.

In normal steady state conditions, the level is maintained around 50%. When the level falls
below 15%, low level alarm is indicated. If the level further falls below 10%, low level alarm
signal LAL005 will be activated in the ESD page. Trip J will be activated and will cause
following sequence of events to occur:

Effects:
1. Pump P101A will get tripped
11. Trip K: Low Level of the Pre-Flash Drum:
Causes:
This trip is activated when the level of the pre-flash drum is low.

In normal steady state conditions, the level is maintained around 50%. When the level falls
below 15%, low level alarm is indicated. If the level further falls below 10%, low level alarm
signal LAL006 will be activated in the ESD page. Trip K will be activated and will cause
following sequence of events to occur:

Effects:
1. Pump P109A will get tripped
12. Trip L: Low Level of the Reflux Drum:
Causes:

This trip is activated when the level of the reflux drum is low.

In normal steady state conditions, the level is maintained around 50%. When the level falls
below 15%, low level alarm is indicated. If the level further falls below 10%, low level alarm
signal LAL004 will be activated in the ESD page. Trip L will be activated and will cause
following sequence of events to occur:

Effects:
1. Pump P100A will get tripped
13. Trip M: Low Level of the Kerosene stripper:
Causes:

This trip is activated when the level of the kerosene stripper is low.

In normal steady state conditions, the level is maintained around 50%. When the level falls
below 15%, low level alarm is indicated. If the level further falls below 10%, low level alarm
signal LAL001 will be activated in the ESD page. Trip M will be activated and will cause
following sequence of events to occur:

Effects
1. Pump P106A will get tripped
2. Product flow will be cut off
Trip N: Low Level of the Diesel
14. stripper:
Causes:

This trip is activated when the level of the diesel stripper is low.

In normal steady state conditions, the level is maintained around 50%. When the level falls
below 15%, low level alarm is indicated. If the level further falls below 10%, low level alarm
signal LAL002 will be activated in the ESD page. Trip N will be activated and will cause
following sequence of events to occur:

Effects:
1. Pump P107A will get tripped
2. Product flow will be cut off
Trip O: Low Level of the AGO
15. stripper:
Causes:

This trip is activated when the level of the AGO stripper is low.

In normal steady state conditions, the level is maintained around 50%. When the level falls
below 15%, low level alarm is indicated. If the level further falls below 10%, low level alarm
signal LAL003 will be activated in the ESD page. Trip O will be activated and will cause
following sequence of events to occur:

Effects:
1. Pump P108A will get tripped
2. Product flow will be cut off