OHCU

Emergency situations

Block Diagram

Feed Characteristics
Feed Characteristics Sulfur <2.8wt% Nitrogen <800wtppm Ni+V <1.25 wt ppm Sodium < 1 wt ppm Asphaltenes, C7-insolubles < 500 wt ppm CCR< 1wt% Feed Distillation 30 383 50 413 70 450 90 523 95 614 100 750 %
C

0 288 5 323 10 342

Products Characteristics
Products from Hydrocracking unit Off-gas (C1-C2) LPG (C3-C4) Light naphtha (C5-125oC) Heavy naphtha (125-140oC) Kerosene (140-220oC) Diesel (220-370oC) Unconverted oil (370oC+)

OHCU (U-91)
The hydrocracker unit involves high pressure, high temperatures, and exothermic reactions activated by an increase of temperature. The hydrocracker unit also involves treating feed with very high sulfur content (2.8wt%). There are many critical equipments in this unit. Thus OHCU is very critical unit prone to various kinds of emergencies.

Emergency situations
General information about Emergency situations In case of emergency situations, operating staff must : Attempt to follow the normal shutdown procedure as much as possible Know that undesirable ways to shut down the unit is always potentially dangerous, therefore the recommended response and course of actions must be VERY CAREFULLY BUT QUICKLY assessed and decided To prevent emergency situations, operating staff must : Check routinely the spare equipments, and keep them ready to operate Investigate and solve any minor problems before they lead to an emergency scenario

Objectives of an emergency shutdown

Protect all personnel that is present in the unit Protect the equipments and catalysts Put the unit in a safe situation compatible with an easy restart Some actions are carried out by the emergency sequences Operators must always check for satisfactory completion of the sequence Safety sequence can include manual intervention

Automatic Emergency shutdown

Abnormal operation and pre-alarms In case of abnormal operation, all high-high or low-low instrumentation items will be preceded by a pre-alarm Operators shall respond to the initiation of these pre-alarms immediately, in order to avoid the anomaly to lead to the unit shutdown Operators must carefully analyze the initiating events and their possible causes

Automatic Emergency shutdown

Safety logic sequences Safety logic sequences have been installed to automatically lead to safe emergency shutdowns in case of an uncontrolled operation Operators must be familiar with these sequences and able to manually perform the emergency actions, in case the system fails for technical reasons

Automatic emergency shutdown / Interlocks

UC-1 : Feed surge drum UC-2 : Lack of feed UC-3 : Make-up compressor (91-K01A) UC-4 : Cancelled UC-5 : Low HC level in HP separator UC-6 : Water level in HP separator UC-7 : High HC level in HP separator UC-8 : Recycle flow UC-9 : Make-up compressor K.O. drum UC-10 : Low level in washing water surge drum UC-11 : Make-up compressor (91-K01B) UC-12 : Fuel gas to reactor feed heater UC-13 : Low speed depressurization UC-14 : High speed depressurization UC-15 : High level in washing water surge drum

Automatic emergency shutdown / Interlocks

UC-16 : Low level in H2S stripper bottom UC-17 : Fractionator feed heater UC-18 : Naphtha stripper reflux drum UC-19 : Naphtha splitter bottom UC-20 : Gasoil stripper bottom UC-21 : Kerosene stripper bottom UC-22 : Cancelled UC-23 : Fractionator overhead pressure UC-24 : Fractionator bottom UC-25 : Amine scrubber bottom UC-26 : Fractionator feed heater fuel gas UC-27 : Recycle compressor K.O. drum UC-28 : HP amine absorber low flowrate UC-29 : HP amine absorber low level UC-30 : Naphtha stripper overhead

Automatic emergency shutdown / Interlocks

UC-31 : Deethanizer overhead UC-32 : Deethanizer feed drum UC-33 : Deethanizer bottom UC-34 : Debutanizer reflux drum UC-35 : Naphtha splitter overhead UC-36 : LP amine absorber bottom UC-37 : Lean amine surge drum low level UC-39 : Debutanizer overhead UC-40 : Naphtha stripper bottom UC-41 : Naphtha splitter reflux drum UC-42 : Lean amine surge drum high level UC-43 : Very High temperature in a reactor (control point) UC-44 : Very High temperature in a reactor (level) UC-45 : Very high temperature level UC-46 : Second make-up compressor (91-K01C)

Automatic Emergency shutdown

Emergency depressurization system The hydrocracking process involves high pressure, hydrogen, high temperature and exothermic reactions Special emergency devices have been provided to avoid damage to the catalyst and equipment in case of temperature upsets (runaways) Two levels of safety provisions are provided: Low speed depressurization (to avoid temperature runaway) High speed depressurization (in case of temperature runaway)

Automatic Emergency shutdown

Emergency depressurization system Four scenarios can occur: 1. Recycle compressor failure : - No more heat of reaction eliminated - Temperature upset will occur in the reactors unless an artificial circulation is created - Low speed depressurizing is started automatically 2. Fire in the unit : - High speed depressurization required

Automatic Emergency shutdown

Emergency depressurization system 3. Abnormal temperatures increase in the reactors, without any evident reason, and without any possibility to control them with the quench - Low speed depressurization normally sufficient - High speed depressurization is started automatically in case a bed temperature in the cracking reactor exceeds the maximum limit 4. Thermal runaway in the cracking reactor - High speed depressurization required - High speed depressurization is started automatically in case a bed temperature in the cracking reactor exceeds the maximum limit

Automatic Emergency shutdown

Low Speed Depressurization (7 kg/cm2/min) Can be initiated manually, by operator action on a push button To be used in case of abnormal temperature increase in a reactor, without any possibility to control it with the quench system Will be started automatically in case of a shutdown of the recycle gas compressor

Actions: Depressurization of the reaction section at 7 kg/cm/minute Reactor feed heater trip, Make-up gas compressors trip and isolation Main feed pump trip and isolation Isolation of power recovery turbine feed Water washing pump trip and isolation HP amine absorber lean amine UV closing

Automatic Emergency shutdown

High Speed Depressurization (21 kg/cm2/min) Can be initiated manually, by operator action on a push button in case the low speed depressurization fails to take control or in case of very high temperature in the hydrocracking reactor Will be started automatically when a hot spot in the cracking reactor(s) is detected (higher than 445C - all cracking reactor bed temperatures have double dual thermocouple arrangement with 2/3 voting system)

Actions: Depressurization of the reaction section at 21 kg/cm/minute Recycle gas compressor trip and isolation Reactor feed heater trip Make-up compressors trip and isolation Main feed pump trip and isolation Isolation of power recovery turbine feed Water washing pump trip and isolation HP amine absorber lean amine UV closing

Emergency situations
High and uncontrolled catalytic bed temperatures Warning alarm for operators in case of: Temperature reaching the high temperature alarm set at 5V above the reactor normal operating bed temperature Temperature reaching the alarm set at 440C High temperature increase at a rate higher than 2C/minute

Actions: Increase the speed of the recycle gas compressor to maximum Manually wide open the quench valve located above the catalytic bed
If actions fail: Actuate the low speed depressurization If the temperature rises by 30C above the normal operating temperature or is above 445C, actuate the high speed depressurization and proceed to a unit shutdown

Automatic Emergency shutdown

Reaction section shutdown after an emergency depressurization If it is not possible to drain water and hydrocarbons from the HP separator, depressurize to flare to 0.2 kg/cm g Pressurize the reaction section with Nitrogen to 5 kg/cmg Depressurize to flare to 0.2 kg/cmg and pressurize the reaction section again to the nitrogen network pressure Start the recycle gas compressor Cool down the reactors to 200C using the Nitrogen loop flow. Drain hydrocarbons at low points

Automatic Emergency shutdown

Reaction section shutdown after an emergency depressurization Stop the recycle gas compressor. Depressurize the system to flare and pressure up again with Hydrogen up to the minimum pressure at which the recycle compressor can operate Start the recycle gas compressor and increase the system pressure with Hydrogen Cool down the reactors to 180C, then stop the recycle gas compressor until the unit is again ready for start-up Refer to the reactors P/T diagram to avoid hydrogen embrittlement. Use the fired heater to increase the temperature if necessary

Automatic Emergency shutdown

Reaction section shutdown after an emergency depressurization If coke formation from the temperature runaway is suspected, lineup start-up gasoil to the feed surge drum and wash the catalyst bed. Diesel should be slopped from the fractionator until its color indicates that it is clean In case of severe runaway, it may be necessary to completely shutdown the unit to dump, screen and reload the catalyst (or even replace in extreme cases) Never inject H2 alone in the reaction section above 200C. This could initiate hydrocracking reactions and quick temperature increase if the recycle gas is not operated

Emergency situations
General comments All actions must result in a final safe situation compatible with an easy restart To avoid coking, always isolate the feed to the reactors and shutdown the reactors feed heater prior to stopping H2 recycle flow and the H2 make-up flow

Emergency situations
Fire in the unit Use the emergency shutdown pushbutton (UC-14) to initiate the highest ESD level.

Emergency situations
Feed pump failure Consequences: Reactor heater trip on very low feed flow Actions: Start the spare pump within 5 minutes Feed the unit at 60% capacity Monitor the reactor temperatures Relight the reactor heater Stabilize the unit

If actions fail: Shutdown the unit as per normal shutdown procedure Keep the reaction section under recycle gas at 200C

Emergency situations
Washing water pump failure Consequences: Reactor effluent air cooler will be plugged by ammonium salts deposition (depending on the nitrogen content in feed) Ammonia concentration in the recycle gas will increase, reducing the catalyst activity Actions: Start the spare pump within 20 minutes

If actions fail: After 20 minutes without washing water, follow the normal shutdown procedure

Emergency situations
Recycle compressor failure Consequences: No heat removal in the reactors / Temperature increase and runaway Possible catalyst damage Slow depressurization activated Actions: Restart the compressor as soon as possible If the compressor is restarted within 5 minutes after the failure, cool down the reactor at 375C Fire the heater and restart feeding the unit

If actions fail: After 5 minutes or if a catalyst bed temperature exceeds 445C, initiate high speed depressurization Note : Never try to cool down the reactors with make-up compressors

Emergency situations
Make-up compressor failure Consequences: Reaction section pressure decreases Hydrogen partial pressure decrease, leading to catalyst coking Actions: Decrease the feed rate to 60% Decrease the reactor temperatures If actions fail: At 80% of normal operating pressure, if make-up hydrogen can not be restored, shutdown first the reactor heater, then the feed pumps Follow the normal shutdown procedure if make-up gas supply can not be restored

Emergency situations
Reaction heater failure shutdown or fractionator feed heater shutdown Consequences: Reactor temperatures and the conversion level will decrease rapidly Actions: Stop the feed and make-up hydrogen Shutdown the stripper/fractionator section Flush the feed surge drum as well as the stripper/fractionator section with start-up gasoil Stop the recycle gas compressor when the reactor temperatures drop down to 200C Depressurize the reactor if any temperature decreases below 90C (check reactor P/T diagram)

Emergency situations
HP Steam failure Consequences: No more HP steam for the recycle compressor steam turbine entrainment Actions: Automatic emergency shutdown (refer to recycle gas compressor shutdown)

Emergency situations
MP Steam failure Consequences: No more stripping steam in the H2S stripper H2S content will increase in the stripper bottom product H2S will accumulate in the overhead section of the fractionator Actions: Reduce the unit capacity down to 60% Slightly increase the H2S stripping by increasing the stripper inlet temperature Monitor the H2S content in all the products Send products to slops if necessary

Emergency situations
LP Steam failure Consequences: No more steam tracing Actions: Keep plant running to avoid freezing Check all low points and dead zones, drain from time to time to avoid freezing (especially in winter season) The fractionator might be operated without steam, provided that hydrotreated residue could be sent either to storage or to slop

Emergency situations
Instrument air failure Consequences: All the control valves will take their safe position Feed and make-up gas stopped Reactor heater tripped Recycle gas remains in operation Reaction section depressurization valve closed (air reserve) Actions: Keep the recycle gas to cool down the catalyst, to reduce hydrogen consumption and minimize coke formation

Emergency situations
Electrical power failure Consequences: The make-up compressor and the electrical pumps will shutdown The recycle gas remains in service Actions: Restart the unit within 5 minutes If actions fail: Cool down the reactors with the recycle gas compressor in service When the power is restored, restart with Start-up gasoil If any reactor temperature exceeds the normal operating value by25C, the high speed depressurization should be actuated

Emergency situations
Cooling water failure Consequences: Lack of cooling will lead to rotating machines trips: Recycle compressor Make-up gas compressor Feed pumps

Emergency situations
Lean Amine pump failure Consequences: H2S concentration in the recycle gas will increase and inhibit catalyst activity Actions: The unit can continue to operate for a short time although the product may be off spec. Internal Circulation needs to be carried out, stopping any fresh feed to enter the system Decrease the feed to 60% with maximizing recycle gas purge from C01 top. Decrease the R01 temp. to 320 degC and R01 temp. to 280 degC (initial VGO introduction conditions)

Emergency situations
Effluent air cooler failure Consequences: Temperature will increase rapidly in the HP separator Actions: Reduce feed to 50% Adjust heater firing and reactor temperatures Increase recycle gas flow to keep the reactors cool Increase the recycle ratio to avoid coking Increase washing water If actions fail: Proceed to a normal shutdown if temperature can not be controlled

Emergency situations
Reactor heater tube rupture Consequences: Process flow will enter the heater firebox Possible fire extending outside the heater firebox Possible damage to the remaining heater tubes Actions: Actuate the high speed depressurization Actuate the heater emergency shutdown (heater pilots shutdown, purge steam opening to the firebox) Open the stack damper completely Block-in the make-up and recycle gas compressors, the feed pump and the reactor effluent water injection pump When the system is depressurized to 1 kg/cmg, inject nitrogen hoses to both sides of the heater to prevent air back flowing through the rupture, forming an explosive mixture with hydrocarbons in the system

Restart after an emergency shutdown

Unit status Unit in a safe position Procedure Check the exact status of the unit before re-starting the unit Complete corrective actions and reach normal conditions before restart Follw the normal shutdown procedure if additional corrective actions are required A gasoil wash of the feed surge drum and column bottoms is carried outand the start-up gasoil circulation is established

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