DRY  VRU Training

JTI – Service Division June 5, 2009

 TRAINING OUTLINE

I. General Process Review IV. Operator Interfacing

II. Main Components a. Modes of Operation
Overview b. Main parameters to monitor
a) Carbon Beds V. Maintenance Requirements
b) Activated Carbon a. Daily Maintenance
c) Vacuum Pump Requirements
d) Absorber Tower b. Quarterly Maintenance
e) Motor Operated Valves Requirements
f) Instrumentation VI. Documentation Review
g) Controls System a. Equipment Manual
III. Process Description b. Troubleshooting Guide
a) Adsorption
b) Regeneration
c) Absorption

JTI – Service Division June 5, 2009

 KNPC Training Schedule
• JORDAN TECHNOLOGIES
• VAPOR RECOVERY SYSTEM TRAINING
• Activated Carbon Adsorption / Absorption VRU Training Schedule
Day 1  Sunday 19/07/2008: Session 1 
08:00 to 16:00:
Class Room Lecture (Explanation of the VRU process, Maintenance, Operation, 
Troubleshooting on projector as per training outline)

Day 2  Monday 20/07/2008: Session 2 
08:00 to 16:00:
Class Room Lecture (Explanation of the VRU process, Maintenance, Operation, 
Troubleshooting on projector as per training outline)

Day 3  Tuesday 21/07/2008: Session 3
08:00 to 16:00:
On site Training (Visit the control room and the VRU location to give more description 
about the system)

Day 4  Wednesday 22/07/2008: Session 4
08:00 to 16:00:
On site Training (Visit the control room and the VRU location to give more description 
about the system)

JTI – Service Division June 5, 2009

 General Process
Vapor
Check Gasoline
Valve Storage Tank

Open Closed

Purge CarbonAdsorber
Carbon Adsorber
Carbon Air
Adsorber Closed Regenerated
Regenerating
Closed Open

C
L
O
O
S
P
E E
N C Absorber Tower
D
O L Recycle Line
P O
E S
E
N
D

Condensate Absorber
Knock Out Tank

DRY Vacuum Supply

Pump Pump

Return
Pump

JTI – Service Division June 5, 2009

 CARBON BED

Carbon Recharge
Nozzles
Vent Diffuser
Hot Spots RTDs
Carbon Support
Screen
Inlet Diffuser

JTI – Service Division June 5, 2009

 ACTIVATED CARBON

•Typical life 10 to 15
years depending on
Equipment
Maintenance
•It requires to be
topped off after first
few weeks of use
•Review
troubleshooting
guide for issues
exposing carbon to
contaminants

JTI – Service Division June 5, 2009

 DRY VACUUM PUMP

JTI – Service Division June 5, 2009

 DRY VACUUM PUMP

Jacket Cooling
Gasoline Outlet Gear Oil

Vapor Outlet
Vapor
Injection Jacket Cooling
Inlet Cooling Gasoline Inlet
Gasoline Inlet
JTI – Service Division June 5, 2009
 Vacuum Pump Cooling

Jacket Cooling
Gasoline Outlet

Vapor
Vapor Outlet
Inlet

Jacket Cooling
Injection Cooling
Gasoline Inlet
Gasoline Inlet

JTI – Service Division June 5, 2009

 Vacuum Pump Seal Arrangement

Mechanical Seal
Lip Seal

Potential leak
detection

JTI – Service Division June 5, 2009

 ABSORBER TOWER

Demister Pad
Spray Nozzle
Packing
Vapor Inlet
Level transmitter
Liquid Gasoline
Discharge

JTI – Service Division June 5, 2009

Absorber Tower Level Control
 RCS TXT Actuators

JTI – Service Division June 5, 2009

 Butterfly Valves

JTI – Service Division June 5, 2009

 INSTRUMENTATION

JTI – Service Division June 5, 2009

 INSTRUMENTATION

JTI – Service Division June 5, 2009

 CONTROL SYSTEM

JTI – Service Division June 5, 2009

 PROCESS DESCRIPTION

The process comprises of three steps:
1. Adsorption
a. Vapors are captured
b. Vapors are sent to Carbon Beds
c. Carbon beds trap VOCs and release air to the atmosphere

2. Regeneration
a. VOCs trapped in saturated bed are released by Vacuum pump
b. Vacuum pump sends VOCs to absorber

3. Absorption
a. Liquid gasoline is circulated through the Absorber
b. VOC vapors travel counter flow through absorber and are 
trapped/condensed by the liquid gasoline
JTI – Service Division June 5, 2009
 Process Description ‐‐ ADSORPTION

1. Vapors travel from loading

rack to Carbon Bed
2. CIM totalizes the amount
of VOCs based on vapor
concentration
3. When the Bed is saturated
(80% ) as per the CIM the
second bed starts to be
used and the first one goes
on to regeneration
080
15
30
50
65
0 Gal
4. The Vent is monitored by a
CEM

JTI – Service Division June 5, 2009

 Process Description ‐‐ REGENERATION

10
155
20
290 Inch Hg

100 Inch Hg
15
20
29

1. Vacuum Pump(s) are started at 25% and build vacuum up to the regen. valve
2. When the vent and inlet valve positions are correct the regen. valve opens
3. The vacuum pump speed ramps from 25% to 100% in 180 seconds
4. In the later portion of regeneration the air purge valve opens and some fresh air is allowed
in to help cleanse the beds

JTI – Service Division June 5, 2009

 Process Description ‐‐ ABSORPTION

1. Supply and Return valves 540 and 570 are

open.
2. Supply pump is energized and flow is
measured to confirm it is within the proper
range.
3. The absorbent (Fresh Gasoline) flows
through packing counter flow to the vapors
condensing them.
4. A small portion of the vapors gets recycled
5. The return pump is energized and the level
control is enabled.
6. The level is controlled by speeding
up/slowing down the return pump via a VFD.
7. For safety reasons there are redundant sensors
monitoring the Absorber gasoline high level.

JTI – Service Division June 5, 2009

 Process Display

JTI – Service Division June 5, 2009

 Alarm Summary

JTI – Service Division June 5, 2009

 Data Logging

JTI – Service Division June 5, 2009

 Absorber Level Control

JTI – Service Division June 5, 2009

 VRU Emissions

JTI – Service Division June 5, 2009

 Vapor Inlet Stream

JTI – Service Division June 5, 2009

 Control Set Points

JTI – Service Division June 5, 2009

 Alarm Set Points

JTI – Service Division June 5, 2009

 Local Runtime Displays

JTI – Service Division June 5, 2009

 Runtime Reporting 

Daily Runtimes Annual Runtimes Continuous Runtimes

7/19/2007 7/18/2007 7/17/2007 7/16/2007 2007 2006

VRU 7.0 13.0 24.0 20.5 225.6 875.2 1100.8

VRU Fault Shutdown 0.1 0.0 0.0 0.1 25.5 0.0 25.5

Vacuum Pump P-550 0.4 0.0 0.0 0.0 140.3 872.8 1013.1

Vacuum Pump P-551 7.0 13.0 24.0 20.5 225.5 849.0 1074.5

Vacuum Pump P-552 6.7 13.0 24.0 20.4 85.3 28.3 113.6

Return Pump P-570 6.7 13.0 24.0 20.4 85.3 68.4 153.7

Return Pump P-571 0.4 0.0 0.0 0.0 140.3 806.6 946.9

Supply Pump P-540 7.2 13.0 24.0 20.6 256.2 881.1 1137.3

Supply Pump P-541 7.2 13.0 24.0 20.6 256.1 819.2 1075.3

Chilled Water Pump P-590 7.1 12.9 24.0 20.5 204.8 807.2 1012.0

Chilled Water Pump P-591 7.0 13.0 24.0 20.5 85.5 3.8 89.3

Total Liters Loaded 753.9 1387.2 2565.0 2197.8 171899.3 0.0 20015.1

Vessel V520 Liters Loaded 380.1 705.3 1295.4 1104.8 7739.7 0.0

Vessel V530 Liters Loaded 381.0 695.3 1294.2 1129.3 45371.6 0.0
JTI – Service Division June 5, 2009
 Manual MOV Control

JTI – Service Division June 5, 2009

 Trending

JTI – Service Division June 5, 2009

 P&ID Review

JTI – Service Division June 5, 2009

 Vapor Inlet 1

JTI – Service Division June 5, 2009

 Vapor Inlet 2

JTI – Service Division June 5, 2009

 Vapor Inlet 3

JTI – Service Division June 5, 2009

 Carbon Vessels 1

JTI – Service Division June 5, 2009

 Carbon Vessels 2

JTI – Service Division June 5, 2009

 Inlet Tee

JTI – Service Division June 5, 2009

 Vacuum Pumps

JTI – Service Division June 5, 2009

 Absorber Tower

JTI – Service Division June 5, 2009

 Supply Gasoline

JTI – Service Division June 5, 2009

 Gasoline Cooling

JTI – Service Division June 5, 2009

 Introduction A
Safety B
VRU Performance Summary C
Site Preparation and Installation Procedures D
Vapor Recovery Start Up Procedures E
General Process Description F
Dry Screw Set Points G
Recommended Spare Parts H
Troubleshooting I
Warranty J
Service Bulletins K
Drawings L
Material Safety Data Sheets M
Equipment Specifications N
Vendor Literature O

JTI – Service Division June 5, 2009

 Questions/Comments

JTI – Service Division June 5, 2009

VRU Troubleshooting Guide 
‐ Excel

JTI – Service Division June 5, 2009