PETRONAS TECHNICAL STANDARDS

Wash Water Injection System In Hydroprocessing

Units For Mitigation Of Fouling And Corrosion

PTS 16.32.01
August 2017

Internal
© 2017 PETROLIAM NASIONAL BERHAD (PETRONAS)
All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form
or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner. PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.
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FOREWORD

PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practices of the PETRONAS group supplementing National and International
standards where appropriate. The key objective of PTS is to ensure standard technical practice across
the PETRONAS group.

Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes
all phases of work activities.

Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of
work, goods and services meet the required design and engineering standards. In the case where
specific requirements are not covered in the PTS, it is the responsibility of the
Contractors/manufacturers/suppliers to propose other proven or internationally established
standards or practices of the same level of quality and integrity as reflected in the PTS.

In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall
ensure accuracy and completeness of the PTS used for the intended design and engineering
requirement and shall inform the Owner for any conflicting requirement with other international
codes and technical standards before start of any work.

PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored
in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or
otherwise) or be disclosed by users to any company or person whomsoever, without the prior written
consent of PETRONAS.

The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information to
PETRONAS that this requirement is met.

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Table Of Contents
1.0 INTRODUCTION ..................................................................................................... 4
1.1 SCOPE ............................................................................................................................ 4
1.2 GLOSSARY OF TERMS .................................................................................................... 4
1.3 SUMMARY OF CHANGES ............................................................................................... 5
2.0 INTRODUCTION TO HYDROPROCESSING UNITS ...................................................... 6
2.1 REQUIREMENT FOR WASH WATER INJECTION ............................................................ 6
3.0 DESIGN CRITERIA OF WASH WATER INJECTION ..................................................... 7
3.1 PROCESS VARIABLES DETERMINING THE WASH WATER DESIGN ............................... 7
3.2 FEATURE OF WASH WATER INJECTOR ....................................................................... 10
3.3 PIPING CONFIGURATION OF THE WATER SUPPLY ...................................................... 13
3.4 RECEIVING STREAM .................................................................................................... 13
3.5 GUIDELINE ON WASH WATER QUALITY...................................................................... 14
3.6 MAINTENANCE CONSIDERATIONS FOR INJECTION SYSTEM ...................................... 17
4.0 OTHER TYPES OF WATER INJECTORS .................................................................... 19
4.1 DESIGN OF WATER QUENCHING SPRAY NOZZLE ........................................................ 19
5.0 RECORD AND DOCUMENTATION ......................................................................... 20
6.0 BIBLIOGRAPHY .................................................................................................... 21
APPENDIX 1: EXAMPLE OF WATER INJECTION FACILITY WITH CONCURRENT SPRAY NOZZLE
...................................................................................................................................... 20
APPENDIX 2: EXAMPLE OF WATER INJECTION FACILITY WITH COUNTERCURRENT SPRAY
NOZZLE .......................................................................................................................... 23
APPENDIX 3: EXAMPLE OF WASH WATER SUPPLY CONFIGURATION IN A PROCESS UNIT 24
APPENDIX 4: EXAMPLE OF SINGLE POINT WATER INJECTION UPSTREAM OF FIN FAN
COOLER WITH MULTIPLE BANKS ..................................................................................... 25
APPENDIX 5: SAMPLE OF DATA SHEET ............................................................................ 26

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1.0 INTRODUCTION

This PTS specifies requirements and provides the recommendation for the design of the wash
water injection systems in hydroprocessing units to ensure proper corrosion control.

The wash water arrangement in hydroprocessing units is used as a mitigation of fouling and
corrosion. This PTS also incorporates PETRONAS lesson learnt and best practices.

1.1 SCOPE

The scope of the PTS covers the guideline, process envelopes and design requirement for
implementing wash water injection in hydroprocessing units.The waterwash injection covers
washing of components from a vapour stream, quenching or as a carrier for chemical
additives.

1.2 GLOSSARY OF TERMS

1.2.1 General Definition of Terms & Abbreviations

Refer to PTS Requirements, General Definition of Terms, Abbreviations & Reading Guide PTS
00.01.03 for General Definition of Terms & Abbreviations.

1.2.2 Specific Definitions of Terms

No Term Definition

1 Halide Halide is a binary compound, of which one part

is a halogen atom and the other part is an
element or radical that is less electronegative
(or more electropositive) than the halogen, to
make a fluoride, chloride, bromide, iodide, or
astatide compound. Many salts are halides.

2 Hydroprocessing Production of high-octane petroleum fuel by

hydrogenating large or complex hydrocarbons.

3 Injection quill Hardware used in the oil & gas industry to

insert substance, including water, chemical etc
for proper mixture with the process stream.

4 Salt deposition Salt to laydown and leave behind.

5 Spray nozzle Device or hardware that facilitates dispersion

of liquid or gas to a surface or into a system.

6 Sublimation temperature Refers to temperature of phase transition from

solid to gas.
Table 1.1: Specific Definitions of Term

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1.2.3 Specific Abbreviations

No Abbreviation Description

1 ARDS Atmospheric Residue Desulfurisation Unit

2 CNHT Cracked Naphtha Hydrotreater

3 BFW Boiler Feed Water

4 CO2 Carbon Dioxide

5 DHT Diesel Hydrotreater

6 H2S Hydrogen Sulfide

7 HCK Hydrocracker

8 HCl Hydrogen Chloride / Hydrochloric Acid

9 HF Hydrogen Fluoride / Hydrofluoric Acid

10 HHPS Hot High Pressure Separator

11 KHT Kerosene Hydrotreater

12 NH3 Ammonia

13 NH4Cl Ammonium Chloride

14 NH4HS Ammonium Bisulfide

15 NHT Naphtha Hydrotreater

16 REAC Reactor Effluent Air Fin

Table 1.2: Specific Abbreviations

1.3 SUMMARY OF CHANGES

This PTS 16.32.01 (August 2017) replaces PTS 16.32.01 (August 2014).

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2.0 INTRODUCTION TO HYDROPROCESSING UNITS

Hydroprocessing are process units using hydrogen at elevated temperature and pressure
along with suitable catalyst to improve the quality of feedstock. The main objectives are to
remove sulfur, nitrogen & metals in the hydrocarbon feed. Removal of the impurities from the
hydrocarbon feed is to ensure commercial petroleum product specification is achieved. As for
the intermediate process unit, the purification is to protect the catalyst for downstream unit.
Example of hydroprocessing units in the refinery are NHT, CNHT, KHT, DHT, ARDS and HCK.

Feedstock to hydroprocessing units can vary from light naphtha to heavy vacuum residue. The
heavier the hydrocarbon feed, the higher concentration of sulfur and nitrogen that will result
in higher concentration of H2S and NH3. This will also include the conversion of halides in the
feed, e.g. chloride to HCl. The production of H2S, NH3 and HCl if not properly managed will
result in severe fouling and corrosion in the process unit through formation of NH4HS and
NH4Cl salts.

These salts will deposit and build up in the exchangers or air coolers resulting in lower heat
transfer. If uncorrected, the salt accumulations will restrict flow and completely plug the heat
exchangers and air cooler tubes. This scenario will promote maldistribution of flow in the
exchangers and cooler tubes and result in under deposit corrosion.

2.1 REQUIREMENT FOR WASH WATER INJECTION SYSTEM

2.1.1 Hydroprocessing units are normally designed with continuous water injection facility. The
wash water will be injected at the reactor effluent stream, typically upstream of the reactor
effluent air cooler or shell and tube exchangers to ensure no salt deposition on the exchangers
metal surface in view of approaching sublimation temperature of NH4HS and NH4Cl as the
result from the reaction processes. The application of corrosion inhibitor such as sodium
polysulphide to mitigate NH4HS corrosion was found to be ineffective whilst the use of wash
water have been proven to control corrosion.

2.1.2 Proper design of the wash water injection is important to prevent fouling and corrosion of
the equipment, mainly the heat exchanger and air cooler tubes located at downstream of
injection point. The NH4HS and NH4Cl are highly soluble in water, hence, properly injected
and distributed wash water will effectively scrubs the vapour stream and removes any salt
deposit.

2.1.3 Some locations in the process units are designed with intermittent cleaning using wash water
such as inlet to Hot High Pressure Separator (HHPS) exchanger upstream of Reactor which can
suffer from fouling due to NH4Cl deposition. Deposition can be minimized and eliminated
through intermittent wash water injection by keeping the temperature above its salt
sublimation temperature. At sublimation temperature, salt will be in vapour phase and will
not have the tendency to deposit. This can also slows down corrosion issue at the identified
piping and equipment. Continuous or intermittent injection depends on salt deposition
temperature, salt concentration and expected salt formation rate. It is recommended to
inspect downstream piping of injection point after every injection or every six months,
whichever necessary.

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3.0 DESIGN CRITERIA OF WASH WATER INJECTION

Criteria below shall be considered for the wash water injection system design covering all
process conditions, e.g. start up, shut down, turndown & abnormal operating case.

i. Ensure minimum 25% of the injected water remains in liquid phase after
equilibrium flash, in all cases, including the most severe process case. Additional
liquid water may be required if the stream requires to be split further
downstream.

ii. Concentration of NH4HS in the sour water that will be collected in the separator
water boot located downstream of the cooler shall be below the maximum
allowable limit. The amount of wash water shall ensure the concentration of
NH4HS is lower than the allowable limit for the material of construction. Typical
limit for NH4HS concentration in the sour water is in the range of 4-6wt%. API
Recommended Practice 932-B, Annexure A, section A.2 can be referred for
estimating concentration of NH4HS in the condensed sour water at separator.

iii. Concentration of halides (e.g. HCl and HF) in the reactor effluent vapor stream at
the separator outlet which is located upstream of the wash water injection point
must be taken into consideration.

iv. Guideline for amount of water injection rate is typically 3-5 vol% of the total feed
rate. However, this is totally depending on the level of impurities in the feed also
existing effluent temperature. API Recommended Practice 932-B, Annexure A,
section A.2.2 can be referred for estimating amount of water required to Saturate
Vapor Phase.

All design criteria for Licensed processes shall be confirmed by Licensor and agreed by Owner.

3.1 PROCESS VARIABLES DETERMINING THE WASH WATER DESIGN

3.1.1 Halide Concentration

Halide concentration of greater than 3 ppmv in the reactor effluent vapor phase located at
upstream of wash water injection point is considered as high halide case and concentration
of lower than 3 ppmv is considered as low halide case.

3.1.2 Ammonium Bisulfide (NH4HS) Concentration

The NH4HS concentration in the sour water of separator water boot is one of the indications
on corrosivity of a reactor effluent stream NH4HS concentration shall be limited based on
materials of construction per below:

Materials NH4HS maximum concentration (wt%)

Carbon Steel 2-3
Duplex Alloy 3-12
Alloy 825 12-15
Table 3.1: Typical Guideline on Material of Construction vs NH4HS Content

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Apart from NH4HS concentration, the appropriate stream velocity (e.g 3-6 m/s for carbon
steel) shall be maintained to achieve acceptable corrosion control. Refer Table 3.2 below on
API RP 581 guidelines on the estimated corrosion rates for carbon steel.
NH4HS (wt%) Velocity (m/s)
3.05 4.57 6.10 7.62 9.14
2 0.08 0.10 0.13 0.20 0.28
5 0.15 0.23 0.30 0.38 0.46
10 0.51 0.69 0.89 1.09 1.27
15 1.14 1.78 2.54 3.81 5.08

Table 3.2: API RP 581 Guidelines on Estimated Corrosion Rates for Carbon Steel
(mm/year)

The lower and upper limit of velocities in the piping is one of the important factor in deciding
the material of construction. This shall be decided in consultation with material specialist
taking into consideration all aspects including contaminants level. The final selection of the
material (e.g. carbon steel, stainless steel, alloy 2205, alloy 825 etc) shall meet the equipment
life cycle, respect the minimum and maximum velocity limit, material availability and
constructability. For Licensed Unit, the Licensor will have internal guidelines on material
selection with regards to NH4HS concentration and minimum / maximum stream velocity and
will require approval by OWNER.

3.1.3 Ammonium Chloride Concentration

Source of chlorides in a hydrotreater is either from feedstock containing organic chlorides or

from make-up hydrogen that is sourced from a catalytic reformer unit. The ammonia formed
in the reactor reacts with the HCl to precipitate as NH4Cl. Dry NH4Cl salt at high temperature
is not corrosive, but could foul equipment and plug heat exchanger tubes. NH4Cl salt is
hygroscopic (i.e. absorbs moisture from its surrounding environment) and can get wetted due
to trace amounts of free water in the reactor effluent stream when operating below the water
dew point temperatures. A low pH condition can be created beneath the wet salt producing
localized corrosion. Thus, if NH4Cl salts form upstream of the wash water injection, the salts
can be corrosive if sufficient moisture is present in the vapor stream.

3.1.4 Injection of wash water is typically used to prevent fouling and corrosion of heat exchanger
and air cooler tubes. Both NH4HS and NH4Cl are highly soluble in water, so properly injected
and distributed wash water effectively scrubs the vapor stream and removes any salt deposits.
The wash water injection point(s) is usually located upstream of the predicted location where
salts will deposit.

3.1.5 The Sublimation temperature (deposition temperatures) for NH4HS and NH4Cl salts can be
estimated from the partial pressures of NH3, H2S, and HCl in the effluent and is calculated
according to the procedure in API-932B,

Figure 3.1—Estimating NH4HS Deposition Temperature from Process Stream Composition.

Figure 3.2—Estimating NH4CI Deposition Temperature from Process Stream Composition.

For detail calculation, refer to API-932B.

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Corrosion by these aqueous salt solutions can occur if the injection system is not correctly
designed and operated and the quality, quantity and distribution of wash water are
inadequate.

Figure 3.1—Estimating NH4HS Deposition Temperature from Process Stream Composition

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Figure 3.2—Estimating NH4CI Deposition Temperature from Process Stream Composition

3.2 FEATURE OF WASH WATER INJECTOR

3.2.1 General

Water injectors shall have following design features:

i. Injection quill with spray nozzle attached.

ii. Injection quill shall be analysed for flow induced vibration to ensure its
mechanical integrity.

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iii. The assembly of the water injectors shall be removable for cleaning and
inspection when process unit is not in operation, thus the injector should be made
self- draining.

iv. All connections between spray nozzle and injection quill shall be fully welded.

v. The materials of construction for the injection quill and spray nozzle shall(PSR) be
of the same or more superior material of the effluent line. Typical materials of
construction for water injector facilities in hydroprocessing units are Alloy 20Cb3,
Alloy 825, Alloy 625, Alloy C-276 etc. The metallurgy selection is heavily depending
on the process fluid quality, impurities and cycle life of the plant.

3.2.2 Single Point and Multi-Point Injection

The design of the injection system can be selected based on single or multi-point injection.
However, single point injection system is preferred due to its simplicity and cost if it can
achieve the desired objective of uniform water distribution. Appendix 4 shows single point of
wash water injection upstream of fin fan cooler.

The multi-point injection system can provide a more uniform water distribution as compared
to the single point injection but it is more difficult to install and maintain.
For plant modification, computational fluid dynamic (CFD) study shall be performed to
determine the most suitable location for Wash Water injection.

3.2.3 Design Feature of Spray Nozzle

Spray nozzle shall have following design features:

i. Design of the spray nozzle should be of a full cone spray centrifugal swirl nozzle
with internal vanes. If there is a static mixer following the spray nozzle, a vaneless
full cone nozzle is permitted. External spiral or hollow cone nozzles shall not be
used.

ii. Spray nozzle can be in horizontal or vertical section of process line. However, for
Licensed Unit, specific requirement from the Licensor should be followed. Nozzle
position shall ensure uniform discharge of the water to the center line of the
process pipe. The location of the spray nozzle shall be accessible for servicing and
maintenance.

iii. Spray angle shall be between 60 and 120 degrees.

iv. Pressure drop in the spray nozzle shall be minimum of 100 kPa at the lowest
anticipated wash water flow rate for uniform spray in pipe cross section.

v. A maximum water exit velocity of 30 m/s at the highest anticipated water flow
rate. The bulk velocity after water mixing with hydrocarbon shall respect the
guideline for the material of construction of the associated piping.

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3.2.4 Spray Nozzle For High Halide Case

i. Injector facilities typically include injection quill, a static mixer and spray nozzle in
a spool integral with process line.

ii. The design criteria of the static mixer for the maximum allowable pressure drop
and scrubbing efficiency shall be verified and endorsed by Technical Authority
(TA), in due consultation with a specialist like equipment vendor

iii. Spray nozzle angle and distance between spray nozzle and static mixer shall be
designed so the water spray cone just fills the static mixer inlet.

iv. The position of the injection spool is preferred to be in a horizontal position of the
receiving stream in the process unit. The installation of the injection spool can
also be at the vertical downslow section of the receiving stream.

v. The material of construction for the injection pipe spool shall be of high alloy,
namely Alloy C-276 , Alloy 625, or Alloy 825 depending on the impurities level of
the process stream. The material shall be either solid or clad or weld overlayed.
Strip lining or loose liners are not allowed. The static mixer internals shall have
similar metallurgy as the injection pipe spool.

vi. The design of the static mixer shall allow sufficient removal of halides from the
process vapor stream by targeting halides content of 1 ppmv, or less in the vapor
exiting static mixer. Scrubbing efficiency (chloride removal) of as high as 90%-95%
is preferred if the hydraulic (e.g. piping pressure drop) and/or other conditions
allow.

3.2.5 Spray Nozzle For Low Halide Case

i. Preferred orientation of the spray nozzle shall be countercurrent to the process

flow.

ii. Spray nozzle is preferred to be installed with the distance of at least fifteen (15)
line diameters upstream of equipment, namely the air cooler, exchanger or
nearest elbow. Minimum distance shall be equals to five (5) line diameters to
ensure good contact and mixing between the injected water and process stream.

iii. Minimum distance between the injection nozzles and upstream elbow, heat
exchanger, separator or specification break shall be at least 1.2 m for counter
current injection nozzles. The metallurgy of the piping upstream of the water
injection point shall be of alloy while respecting the minimum distance
requirement of 1.2 metres. However, the actual distance shall be verified and
endorsed by TA.

iv. Similarly to the high halide design case, detail calculations shall be done for the
nozzle at the operating conditions of the piping to understand the drop size, drop
vaporization and travel and overall srubbing efficiency.

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v. Both horizontal and vertical upflow section of the effluent line are acceptable for
the installation of the water injector.

vi. Alternatively, the guideline indicated for the high halide case can be applied for
low halide case.

3.3 PIPING CONFIGURATION OF THE WATER SUPPLY

The water supply piping shall include the following:

3.3.1 Block Valves and Check Valves

i. Wash water is usually supplied to the process stream via piping. Depending on
the operating pressure of the hydroprocessing units, the piping shall have
minimum double block valves and double check valves between water injection
pump and the injector. The final number of block valves is based on the actual
operating pressure of the unit. In most cases, the hydroprocessing units have high
reactor operating pressure ( >50 barg).

ii. Each individual water injector shall be installed with check valve and strainer for
backflow prevention if multiple water injectors are supplied from one water pump
with the same supply pressure.

3.3.2 Strainer

i. A strainer shall be installed at upstream of the block valve on the wash water
supply stream downstream of the pump. Strainer that is integral with the spray
nozzle is not acceptable due to its low capacity for solids and it cannot be cleaned
on-line.

ii. The objective of the strainer is to protect all instruments located downstream
including flow orifice, check valve, control valve etc, as well as the spray nozzle.

iii. Openings on the strainer shall not be larger than 1/3 the minimum clearance in
the spray nozzle. The smallest opening in a spray nozzle may be the orifice
diameter or the swirl passage opening.

iv. Strainer shall be able to be cleaned if they become fouled, without interrupting
injected water flow. The following options to accomplish this are acceptable:

v. Parallel strainers to enable one to be cleaned while the other one is in service.

vi. Strainer that can be cleaned without shutting off the flow of injected water.

vii. Bypass line is acceptable only if there is no expectation of CO2 corrosion (FeCO3
deposits) in the water and the water has no particles that can plug the spray
nozzle.

viii. Proper blowdown piping shall be provided, for any of the three options, when
implemented.

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ix. Strainer shall be installed unless the particles are smaller than 1/3 the size of the
minimum spray nozzle free passage and smallest opening in the spray nozzle is
12mm (1/2 in) or greater.

3.3.3 Material of Construction

The water supply piping from the injector back to, and including the first block valve shall be
made from the same or higher alloy material as the effluent line at the water injection point.

3.3.4 Flow Meter

i. Flow meter with low flow alarm shall be provided on the water supply piping.
Local flow meter alone is not acceptable. High flow alarm can be considered to
avoid excessive water injection to the piping which may result in flow induced
vibration / damage to injector.

ii. Installation of multiple flow meters for a single injection system are acceptable
and preferably not more than two. It is acceptable to have flow meter on fresh
water make up and on recycled water piping respeactively.

iii. For the case of multiple water injections, each water injector shall be provided
with individual DCS based flow measurement and control. Manual operated
valves for flow control is not adequate with multiple injection systems in view of
high possibility of imbalanced flows.

3.4 RECEIVING STREAM

3.4.1 Receiving Stream

i. Wash water injection point downstream piping shall maintain reasonable

velocities to ensure proper flow distribution. Unless otherwise specified, the
stream velocities in the piping shall not exceed 17 m/s, irrespective of material of
construction. Higher velocities may be acceptable subject to TA approval. Lower
velocities or change in line material may be required if recycle sour water is used.
TA shall be consulted if recycle sour water is used.

ii. Vertical upflow piping runs in the receiving line downstream of the injection point
are optional. If present, these lines shall be sized for churn or annular flow, as
distint from slug flow.

iii. Receiving line shall have a horizontal run with stratified flow and with a minimum
length equal to 7 line diameters. A length of 10 diameters is recommended
between the end of the vertical run and the distribution header, if stratified flow
is required in a downstream distribution header.

iv. During process unit upset or unit trip, there is every possibility of wash water back
up to upstream hot separator. Therefore, provision shall be made to prevent wash
water backup to hot separator. This includes safeguarding system to
automatically trip the wash water system.

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v. Material of construction of the piping at upstream of water injection point shall

take into consideration the scenario of backflow.

vi. In most of the cases, the hydroprocessing and hydrocracker recycle gas
compressor spillback line will be connected to the wash water receiving line,
upstream of the air cooler. The compressor spillback line shall be free-draining to
the process and shall have either top or side entry.

vii. In a typical design of hydroprocessing unit, the compressor spillback line will be
routed to the downstream of the water injection point and is the preferred
location. By selecting this route, the spillback line may not be required to be
upgraded to alloy. The material of construction for the piping at upstream of the
injection point are normally made of alloy resistant to NH4Cl and/or HCl to
prevent wet HCl attack. For the case of multiple injection point systems, the
compressor spillback tie-in location is preferred at the vapour space of the hot
high pressure separator.

viii. The make up hydrogen supplied to the process unit should be of chloride free. If
the presence of chloride cannot be eliminated, the material of construction of the
piping at the mix point and downstream piping shall be designed to withstand the
potential corrosion impact due to the presence of chloride.

3.5 GUIDELINE ON WASH WATER QUALITY

3.5.1 Wash water quality shall be ensured and monitored to limit contaminant levels to achieve
good washing effect of the piping and to avoid potential corrosion issue and/or impact to
catalyst in the reactor circuit.
The main concern on the quality of the wash water is the oxygen content which will have
adverse effect on the corrosion rate of the piping. Presence of O2 will accelerate piping
corrosion rate.

Wash water quality shall be maintained by proper design of the equipment in the injection
system. For example, proper design of pump seals will limit the oxygen entry, nitrogen
blanketing of the wash water vessel, de-aeration, etc.

3.5.2 In a typical hydroprocessing units, the wash water is typically made up of recycled sour water
from the same or other hydroprocessing unit. Stripped sour water is usually preferred.

3.5.3 Boiler feed water (BFW) may be considered for some cases. The BFW is deaerated and usually
will go through a process of demineralised or ion-exchange-resin softened resulting in lower
O2 content.

DBFW that has only been lime softened should not be used due to potential calcium
deposition. In some licensed unis, the supply of DBFW is taken directly at the outlet of the
deaerator before injection of any chemical. This is to prevent presence of chemical in the
injected water carry over to the reaction section leading to potential catalyst deactivation, if
carried over. Licensor input shall be obtained before deciding the source of water.

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3.5.4 The Wash Water specification shall be as follows :

Property Preferred Maximum

H2S, ppmwt < 100 1000

NH3, ppmwt < 100 1000

O2, ppbwt < 10 50

pH 7-9 9.5

Iron (Fe), ppmwt < 0.2 1

Chlorides, ppmwt < 10 50

Chlorides + Fluorides, ppmwt 100

Cyanide None detectable

Calcium, ppmwt < 2*

Phenol Nil

Non volatiles residue, ppmwt 2

Total suspended solids (TSS) Nil

Table 3.3: Wash Water Specifications

* Note : Calcium shall not be >20 ppb if fluorides are present in the system

3.5.5 It is necessary to verify the quality of water, when recycled sour water is planned to be used.
The NH4HS content measured in the downstream equipment sour water boot will indicate
the suitable material of construction. In case of stripped sour water is considered as the
injection water, the material of construction of the water supply piping and process line shall
be compatible with the impurities that could be present in the water, e.g. carbonates and/or
sulfates. Suitable metallurgy shall be in place to ensure the integrity of the piping.

3.5.6 The hydroprocessing units will typically have more stringent wash water quality specification
particularly on the phenol and cyanide contents. Sour water from a sour water stripper that
treats DCU or the RFCC/cat cracker effluent water is not acceptable in view of potential phenol
and cyanide contents. Some operating refineries will separate the sour water from the sour
water stripper into phenolic and non-phenolic types. The phenolic sour water will be shared
between CDU, DCU, RFCC units, whereby the non-phenolic sour water will be supplied to the
hydroprocessing units.

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3.5.7 Below are some of the typical guideline for the monitoring of sour water quality from process
units:

Component Unit Guideline

Iron ppm 1-5

pH 7-9

Chloride ppm 1

Ammonia ppm 500

Sulphide Wt% 8
Table 3.4: Typical guideline for sour water monitoring
If the sour water quality exceeds the typical value in Table 6, following corrective action can
be considered:

i. Investigate for process changes like feed quality , contaminants and operating
conditions

ii. Confirm the quality of the make up water at source

iii. Adjust the amount of fresh make up water intake not exceeding the maximum
design limit

iv. Proven performance of corrosion inhibitor may be used in consultation with

Licensor and Chemical

v. Increase the frequency of Inspection of the piping downstream of the water

injection point

3.6 MAINTENANCE CONSIDERATIONS FOR INJECTION SYSTEM

3.6.1 During initial design of a process unit, it is best to consider and include the provision for
injection system maintenance which will ensure availability of the injection system all the
time. This will also allow necessary action to be taken promptly at the earliest signs of
corrosion on piping or equipment.

3.6.2 In order to continuously monitor and verify the performance of the injection system, several
sampling points should be provided in the process unit. Following are list of recommended
sample points:

i. Quality of the fresh make up water.

ii. If a process unit has alternate water source, sampling facilities shall be provided
to both the sources. This will ensure continuous monitoring of the make up water
quality.

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iii. For measurement of NH4HS, sampling point at low pressure low temperature
separator water boot shall be provided if the operating pressure at the high
pressure low temperature separator water boot is too high and risky for the
operator to take sample. If there are other streams that enter the low pressure
low temperature separator, it is deemed necessary to have the water boot
sampling point installed at the high pressure low temperature separator to ensure
representative water sample. Sampling system in this case has to be properly
designed with inherent safety.
3.6.4 Apart from sufficient sampling points, periodic inspection should be carried out in the piping
downstream of the wash water injection as per RBI recommendation. This will ensure
rigorous monitoring on corrosion and erosion rate and ensure corrective action to be taken
promptly.

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4.0 OTHER TYPES OF WATER INJECTORS

Water injection facilities are typically equipped with injection quill and an attached spray
nozzle to ensure good water dispersion and proper mixing between water and process
effluent. The injection facility is applicable to both gas and mixed phase streams.

Spray nozzle is usually not required if the water is injected into liquid streams though a quill
may be required for centreline injection.

4.1 DESIGN OF WATER QUENCHING SPRAY NOZZLE

4.1.1 Quenching is typically required to cool down the process temperature. This is normally
applicable to process with exorthermic reaction where temperature rises substancially due to
heat of reaction.

i. There are a few criteria to determine the design or type of the spray nozzle,
namely the distance between the quench and downstream equipment, process
conditions and process sensitivity in introducing water on the wall. To avoid water
on the wall, the quench design needs to ensure very small droplets (<200 µm). To
obtain such small droplets, two-fluid nozzles using atomizing gas are typically
required.

ii. Air, steam and N2 are typically the source for atomizing fluids.

iii. Steam condensation will lead to significant loss of atomization. Superheated

steam shall be used for the steam atomizing nozzles to ensure no condensation
on the steam side of the nozzle.

iv. Detailed quench calculations are necessary to ensure complete evaporation in the
available distance.

v. In order to generate desired spray size, it is necessary to control the flow of both
the atomizing medium and the injected liquid.

vi. It is preferred to have the injection nozzle to inject water at the centerline of the
receiving stream. In other occasions like erosive environment or large pipes,,
nozzle may be shielded or mounted to inject flush with the wall.

vii. The design criteria on pressure drop and velocity from (3.2.2) can be applied if
two fluid nozzles are not required for the spray application.

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5.0 RECORD AND DOCUMENTATION

Below are list of documents on wash water injection facility to be made available for ease of
future reference:

i. PEFS indicates the injector location, reactor effluent piping and water supply
piping.

ii. Isometric of the water supply piping, effluent piping around the injector from the
nearest vessel upstream of the injector, typically a reactor, to the nearest vessel
or equipment downstream of the injector, typically a cooler or separator.
Isometric shall indicate specification breaks in the piping.

iii. Comprehensive data sheet as provided in Appendix 5.

iv. Detail calculations to determine pressure and amount of wash water to be

injected.

v. Drawing of the injection facility with injection quill and spray nozzle detail
including the manufacturer and model number of the spray nozzle.

vi. Manufacturer specifications for any calculations on static mixer and the scrubbing
efficiency.

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6.0 BIBLIOGRAPHY

In this PTS, reference is made to the following other Standards/Publication. Unless specifically
designated by date, the latest edition of each publication shall be used, together with any
supplements/revisions there to:

PETRONAS TECHNICAL STANDARDS

Index to PTS PTS 00.01.01
PTS Requirements, General Definition of Terms, Abbreviations & PTS 00.01.03
Reading Guide
Index to Standard Drawings PTS 00.11.01

INTERNATIONAL STANDARDS
Design, Materials, Fabrication, Operation And Inspection API Recommended
Guidelines For Corrosion Control In Hydroprocessing Practice 932 B
Reactor Effluent Air Cooler (Reac) Systems
Risk Based Inspection Technology API Recommended
Practice 581

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APPENDIX 1: EXAMPLE OF WATER INJECTION FACILITY WITH CONCURRENT SPRAY NOZZLE

Injection water supply

Process stream downstream of

Process stream upstream of injector
injector

Spray Nozzle

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APPENDIX 2: EXAMPLE OF WATER INJECTION FACILITY WITH COUNTERCURRENT SPRAY

NOZZLE

Injection water supply

Process stream upstream of

Process stream downstream of
injector
injector

Spray Nozzle

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APPENDIX 3: EXAMPLE OF WASH WATER SUPPLY CONFIGURATION IN A PROCESS UNIT

N2 Supply To flare

Main Water Source Intermittent Water Wash

Process

Alternate Water Source

Continuous Water
Wash
Process

Symbol

Control
V-13Valve Pump Check Valve Spectacle Blind

Gate Valve Strainer Vessel

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APPENDIX 4: EXAMPLE OF SINGLE POINT WATER INJECTION UPSTREAM OF FIN FAN

COOLER WITH MULTIPLE BANKS

To downstream
equipment

Process stream
upstream of water
injection

Water injection

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APPENDIX 5: SAMPLE OF DATA SHEET

DATA SHEET OF WASH WATER INJECTION FACILITY

PAGE 1 OF 2

A. PROCESS STREAM
DETAIL______________________________________________________________________
OPERATING TEMPERATURE, degC:___________________________________________________
OPERATING PRESSURE, barg: _______________________________________________________
PROCESS STREAM CONDITION:
PHASE (G = GAS, L = LIQUID, S = SOLID)
G L G/L L/L G/S L/S
IF MULTIPHASE, ESTIMATE PHASE VOLUME FRACTIONS: _______________________________
IF SOLIDS PRESENT, ESTIMATE SIZE, RANGE, & COMPOSITION: ___________________________
PROCESS LINE SPECIFICATION:
FLOW RATE, m3/hr:
(A) NORMAL: _________; (B) MIN: __________; (C) MAX: ____________
PIPE SIZE: ______________________________________________________________________
PIPE MATERIAL: _________________________________________________________________
INJECTION UPSTREAM EQUIPMENT: ________________________________________________
INJECTION DOWNSTREAM EQUIPMENT:
_____________________________________________
PEFS NO: ______________________________________________________________________
B. INJECTION WATER STREAM
DETAIL
OPERATING TEMPERATURE, degC:__________________________________________________
OPERATING PRESSURE, barg: ______________________________________________________
INJECTION WATER FLOW RATE, m3/hr:
(A) NORMAL: _________; (B) MIN: __________; (C) MAX: ____________
TYPE OF INJECTION: CONTINUOUS INJECTION INTERMITTENT INJECTION
PIPE SIZE: ______________________________________________________________________
PIPE MATERIAL: _________________________________________________________________
PEFS NO: _______________________________________________________________________
C. INJECTION HARDWARE
INJECTION POINT TYPE:
INTERNAL QUILL INTERNAL SPRAY TEE CONNECTION
NUMBER OF INJECTION POINT:
SINGLE MULTIPLE

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DATA SHEET OF WASH WATER INJECTION FACILITY

PAGE 2 OF 2

INJECTION IS FROM:
(A) HORIZONTAL PIPE
TOP BOTTOM SIDE OF HORIZONTAL PIPE
OR
(B) VERTICAL PIPE
NORTH EAST WEST SOUTH OF VERTICAL PIPE
INJECTION DIRECTION:
COCURRENT COUNTERCURRENT CROSSCURRENT
(A) DISTANCE TO NEAREST DOWNSTREAM BEND, TEE, REDUCER ORIFICE, THERMOWELL,
OTHER INJECTION POINT, ETC.
DISTANCE, METER:_____________________________________________________________
TYPE OF DEVICE: ______________________________________________________________
IF INJECTION POINT, DESCRIBE:
__________________________________________________________________________
(B) DISTANCE TO NEAREST DOWNSTREAM BEND, TEE, REDUCER ORIFICE, THERMOWELL,
OTHER INJECTION POINT, ETC.
DISTANCE, METER:____________________________________________________________
TYPE OF DEVICE: _____________________________________________________________
IF INJECTION POINT, DESCRIBE:
___________________________________________________________________________
D. CHEMICAL & PHYSICAL REACTIONS
ANTICIPATED CHEMICAL REACTION (Y/N)?
DESCRIBE: __________________________________________________________________
ANTICIPATED PHYSICAL REACTION (PHASE CHANGE, EROSION, HEATING, ETC.) (Y/N)?
DESCRIBE: __________________________________________________________________
E. STARTUP, SHUTDOWN, AND TURNDOWN OPERATION
DESCRIBE STARTUP PROCEDURE:
__________________________________________________________________________
STARTUP FLOW RATE, m3/hr: __________________________________________________
TURNDOWNFLOW RATE, m3/hr: _____________________________________________
DESCRIBE SHUTDOWN PROCEDURE:
______________________________________________________________________
DESCRIBE PROPOSED FREQUENCY, LOCATIONS, AND METHODS OF INJECTION POINT INSPECTION:

F. EFFECT TO CATALYST WITH THE PRESENCE OF CHEMICAL IN THE WASH WATER

A) TEMPORARY EFFECT:
B) PERMANENT EFFECT:

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