Mangalore Refinery and Petrochemicals Ltd, Mangalore Doc No.

DHDT Unit – Phase-3 - Operating Manual F ……

Section-1-Chapter VIII –Emergency Handling 20-6-2012

Emergency Handling

1. Loss of Feed
2. Loss of Wash Water
3. Loss of Recycle Gas / Compressor
4. Recycle gas flow low-low
5. Loss of Make Up Gas
6. Loss of Quench Gas
7. High Temperature at the Charge Heater Outlet
8. Temperature Excursions
9. Loss of Rx Effluent Air Cooler
10.Charge Heater Trip
11.Loss of Amine System
12. Steam Failure
13. Instrument Air Failure
14. Power Failure
15. Cooling Water Failure
16. Major leak / Fire or Line Rupture
17. Charge Heater Tube Rupture
18. External Fire
19. Emergency Shutdown
20. RGC Seal Gas Supply Failure

Introduction.

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 Mangalore Refinery and Petrochemicals Ltd, Mangalore Doc No.
DHDT Unit – Phase-3 - Operating Manual F ……
Section-1-Chapter VIII –Emergency Handling 20-6-2012

Emergencies that occur in units must be recognized and acted upon immediately.
The operators and supervisory personnel should carefully study in advance, and
become thoroughly familiar with, the proper steps to be taken in such situations.
Some of the emergency conditions described here will not only result in a unit
shutdown, but if the situation is not handled properly, can lead to serious
damage to the catalyst and equipment.
These procedures are intended as guidelines for the development of detailed
emergency instructions for each particular equipment. It is strongly recommended that
they be understood by all persons involved in the operation. In general, the objective
of the emergency procedures is to avoid damage to equipment and catalyst.
This is accomplished by rapid cooling of the catalyst beds below reaction
temperature and by reducing the pressure whenever there is a possibility of a
temperature excursion.
In addition, specific rules cannot be made to cover all situations that might arise.
Therefore, the following procedures cover only those emergency situations that
are the most common and, for the most part, only the immediate steps to be taken
are listed. It should be noted that the procedures outlined here concentrate on
the reactor section. In most cases, the corrective actions will result in upsets in
the fractionation section. It is advised that care be taken to adjust the
fractionation section operation whenever flows and/or severity are reduced.
It should also be noted that the protection of austenitic stainless steel equipment
must always be kept in mind. The proper precautionary measures must be taken to
prevent oxygen and water from coming into contact with any austenitic
material that has sulfide scale. These measures should not conflict with the
immediate steps required as a result of the emergency condition.
Any time an emergency situation occurs, especially when a reduction in space
velocity or capability of removing the heat of reaction from the catalyst is involved, a
condition exists which could lead to the generation of localized high temperatures.
Therefore, if during any type of emergency there is a rapid temperature rise in the
reactor or catalyst bed, immediate steps should be taken to depressurise the
system to suppress the reactions. The objective is to prevent a further rise in
temperature and minimize the danger of damage to the reactor and other
equipments.

1. Loss of Feed
Loss of can be due to various reasons such as
* Feed Pump failure / Low discharge pressure / Low Surge drum level
Loss of one Feed Pump (GA-33301A/B) will first affect the Reactor Heater (BA-
33301) which will trip it on very low feed flow. It is necessary to keep the Reactor
inlet temperature under control and try to restore feed to the unit. If it is not
possible, the normal shutdown procedure shall apply.

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DHDT Unit – Phase-3 - Operating Manual F ……
Section-1-Chapter VIII –Emergency Handling 20-6-2012

In case of working feed pump is lost then proceed as follows:

 Lower the reactor temperatures by 28°C as rapidly as possible.
 Hold the system pressure at the normal level to minimize coke formation and
cool the Reactor catalyst beds below reaction temperature with recycle gas.
 Start the spare feed pump within 5 minutes and bring up feed rate to 60% of the
unit capacity. Monitor the reactor temperatures very closely. Relight the feed
heater, stabilize the unit feed at 60%capacity and continue as per normal start-
up.
 If the feed flow is not established within 5 minutes, proceed with unit shut down
as per normal shutdown procedure. Keep the reaction section under recycle gas
circulation and 200°C in reactor before re introducing the feed to the unit.
 When feed pump (GA-33301A or B) fails, UV003 in the common discharge valve
will close by actuation of IS-02.

2. Loss of Wash Water.

Injection of Wash Water is Prevent formation of ammonium salts and the
resultant fouling of the reactor effluent cooler. The lack of water to the reactor
effluent air cooler (EC-33301) may lead to tube plugging by deposition of ammonium
salts.
Loss of wash water for an extended period will force a shutdown. Ammonia
will no longer be removed from the reactor effluent and will begin to build up in the
recycle gas causing ammonium salts to deposit in the products condenser. Rapid
fouling and tube plugging can occur. If neither wash water pump can be started
within 30 minutes, follow the shutdown procedure presented in Normal Shutdown
Procedures.

3. Loss of Recycle Gas / Recycle gas compressor failure

The recycle gas provides the means of carrying the heat of reaction out of
the reactor, where it is removed in the effluent heat exchanger train and final air
cooler. Cold recycle quench gas is also used to control catalyst bed inlet
temperatures and thereby control the rate of reaction. When recycle and quench
gas flows are lost the means of controlling the reaction and removing heat are also
lost. Residual feed and hydrogen will continue to react and generate heat. Catalyst
bed temperatures can then increase at an uncontrollable rate. The only way to stop
the reactions is to remove the reactants. The reactor feed is removed by stopping
the feed pump. However, enough oil will remain on the catalyst to sustain reaction.
Therefore, the unit pressure must be rapidly reduced at the same time to remove

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 Mangalore Refinery and Petrochemicals Ltd, Mangalore Doc No.
DHDT Unit – Phase-3 - Operating Manual F ……
Section-1-Chapter VIII –Emergency Handling 20-6-2012

the other reactant, hydrogen. This is accomplished via the manual depressurizing
system upon loss of recycle gas compressor.

Very low recycle gas flow rate will activate IS-02 (stop feed pumps, isolates
reactor feed, trips the reactor heater & Wash water pump). In this case, the heat of
reaction cannot be controlled and a temperature increase will occur which is likely
to damage the catalyst. An immediate operator action is to attempt to restart the
recycle compressor (GB-33301) as quickly as possible, in order to restore the
recycle gas flow.
 The Operator should attempt to restart the machine as soon as possible
but only after finding the cause & attending the same.
 Start decreasing the temperatures to 300°C in the reactor.
 If the recycle gas compressor (GB-33301) can be restarted within 5-10
minutes after the failure
 Restart feed pump (GA-33301 A/B).Open the discharge valve and oil-in
after having fired the charge heater.
 If the recycle gas compressor cannot be restarted in 5 minutes or any bed
temperature is rising quickly, then reduce the reactor temperature by
opening the recycle gas purge valve on manual and stop the make-up
compressor.
 When the recycle gas compressor becomes available, re-establish
recycle gas flow and line out catalyst temperatures 260-290°C. Then,
continue with normal procedure for startup with used catalyst.

4. Recycle gas low-low flow

This will activate IS-02 (stop feed pumps, isolates reactor feed, trips the reactor
heater). The resulting actions are a precursor to the above, and are designed to
allow the operator a certain time to restore recycle gas flow - whilst still protecting
the catalyst from potential damage.

5. Loss of Make-up Gas

The reaction section pressure will drop quickly and, if no action is taken, the
catalyst will coke due to hydrogen shortage to saturate with the cracked material, if
present. Therefore, to reduce hydrogen consumption and minimize coke formation,
decrease the feed rate rapidly to 60% of design, while reactor temperatures are to
be dropped accordingly.
If at 80% of the normal operating pressure, the Hydrogen flow is not restored to the
reaction section, the feed has to be cut off by first shutting down the reactor heater
(BA-33301), and then the feed pump (GA-33301 A/B), until the make-up gas supply
is re-established; if the makeup gas supply cannot be re-established, the normal
shutdown procedure should be followed.
 The loss of any portion of makeup gas hydrogen will require a feed rate
reduction. The fresh feed reduction should be proportional to the makeup gas
loss. If there is a substantial loss in makeup gas, pressure will decrease
rapidly while hydrogen consumption exceeds makeup capacity. As the

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 Mangalore Refinery and Petrochemicals Ltd, Mangalore Doc No.
DHDT Unit – Phase-3 - Operating Manual F ……
Section-1-Chapter VIII –Emergency Handling 20-6-2012

system pressure declines, the capacity of the recycle gas compressor will be
reduced and control of reactor temperatures will become more difficult.
 Lower reactor temperature sufficiently to reduce hydrogen consumption.
Restore reactor pressure as quickly as possible. After the pressure has
returned to normal, adjust reactor temperature to obtain as much
desulphurization as is possible with the available hydrogen.
 If there is a total loss of makeup hydrogen, it will be necessary to shutdown.
Lower reactor temperatures to 300°C and follow normal shutdown
procedures.
 If the makeup compressors shut down (i.e. due to a dip in power) and can be
immediately restarted, a shutdown may not be necessary. Lower
temperatures and feed rate as quickly as possible to minimize hydrogen
consumption. Restart the makeup gas compressors GB-33302A/B and
restore system pressure as soon as possible. If the HP Separator FA-33304
pressure drops to less than 70 percent (Approx. 45 Kg/cm 2g) of its normal
pressure it is advisable not to start the compressor and proceed with the unit
shut down, to prevent excessive catalyst coking and deactivation.

6. Loss of Quench Gas Flow.

The loss of the quench gas flow to any bed of the reactor can cause a sudden
temperature rise. Reduce the inlet temperature of the bed above the non-operating
quench point to maintain the normal bed outlet temperature on the bed below the
quench failure. If any temperature in the reactor exceeds 28°C above normal, the
unit must be immediately depressurised via the emergency depressurising valve
UV-33310.

7. High Temperature at the Charge Heater outlet.

If a high temperature is detected at the inlet of the reactor (DC-33301), then fuel to
the main burners on the reactor charge heater (BA-33301) is cut - off automatically.
When the Temperature falls back within the normal range, due to the cooling effect
of the recycle gas, the reactor heater (BA-33301) can be restarted.

8. Temperature Excursions
A temperature excursion is a serious situation that requires immediate attention.
During a temperature excursion highly exothermic cracking reactions can take
place. These temperatures can rise rapidly to well above the equipment design
temperature. Hence the thrust is to prevent catalyst temperatures from exceeding
the design limits. A temperature excursion can be brought about by equipment or
utility failures that result in any one of the following problems:
 A significant reduction in space velocity over the catalyst.
 A reduction in capability of removing the heat of reaction from the catalyst.
 By overheating during a startup or during normal operation.

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DHDT Unit – Phase-3 - Operating Manual F ……
Section-1-Chapter VIII –Emergency Handling 20-6-2012

The period during a fresh catalyst startup, before the catalyst has been thoroughly
sulphided, is perhaps the most critical time when very special care should be taken
to control the reactor temperatures, as outlined in the startup procedure.
Desulphurising Catalysts have been formulated to provide a high desulphurization
activity with very little hydrocracking activity, and therefore they are much
less susceptible to temperature runaways than a hydrocracking catalyst.
The possibility of a temperature runaway still does exist, however, and all
appropriate precautions should be taken.
In order to sustain a temperature runaway, both hydrocarbons and heat must be
available. Therefore, removing one or the other will cause the reactions to stop. The
quickest way to achieve this, and still maintain hydrogen pressure in order to
minimize coke formation, is to remove the feed from the unit and to cool the
catalyst with recycle gas. However, if the temperature rise cannot be controlled, then
the unit should be rapidly depressurised to suppress the reactions and to minimize
the danger of damage to the reactor and other equipments.
If a temperature in the reactor starts to rise above normal, the following steps
should be taken:
 Reduce the inlet temperature of the bed in which the high temperature
occurs. Also, reduce inlet temperatures to the catalyst beds below.
 If the temperatures are not controlled by the corrective action of step
(1), reduce the reactor inlet temperature by reducing firing rate of the
charge heater.
 If the temperatures continue to rise 28°C above normal, remove feed from
the unit.
 If the catalyst bed temperatures are 28°C above normal and continue to
rise despite the above corrective actions, or if the temperatures exceed the
maximum allowable operating temperature of the reactor, then
depressuring will be necessary to regain control of the reactor. If the
operator decides to manually depressurise the unit via the
manual emergency depressuring system, the following should
occur automatically:
o The feed pump GA-33301 A/B shuts down.
o The shutoff control valves in the fuel gas and fuel oil lines to the
charge heaters close, the pilots will stay lit.
o The control valve in the makeup gas line will close, or the spillback
valve in the last stage of makeup gas compression will fully open.
Manual unloading of the makeup gas compressor and subsequent
shutdown may be necessary.
o The wash water pump will shut down.
o The lean amine pump will shut down.
NOTE: When manual depressurising system is activated, the recycle gas
compressor will continue to operate.
 Verify that the charge heater burners are out. Open the stack damper and
all air registers to the full open position to establish the maximum flow of

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DHDT Unit – Phase-3 - Operating Manual F ……
Section-1-Chapter VIII –Emergency Handling 20-6-2012

cooling air through the box.

 Put the Rx Effluent air cooler (EC-33301) fans on maximum cooling. The
Reactor Effluent - Combined Feed exchanger EA-33301A/B/C can be
bypassed to avoid picking up reactor effluent heat. Be careful not to
exceed EC-33301 maximum design temperature ( °C).
 The depressurising valve may be closed when all reactor temperatures
are at least 28°C below normal operating temperatures. If temperatures
remain high after the unit has been depressurised, then begin purging
the reactor with Nitrogen at the maximum rate possible.
 If recycle compressor operation can be maintained, continue maximum gas
circulation and cool all catalyst temperature points and the reactor outlets
to 300°C.
 With all temperatures below 300°C start the makeup compressor and
pressurise to the normal operating pressure with hydrogen.
 Hold until ready for startup. If any reactor skin temperature drops below
82°C, pressure should be reduced subject to temper embrittlement
precautions or minimum gas circulation and heater firing should be resumed.
Monitor temperatures closely.

9. Loss of Reactor Effluent Air Cooler

 Reduce feed to minimum turn down (60%). Adjust reactor charge heater
(BA-33301) firing and reactor temperature accordingly.
 Increase recycle gas flow to keep reactor bed temperatures under control,
as well as recycle ratio in order to avoid excessive coking.
 Increase wash water, if possible.
 If temperature cannot be controlled, then proceed to a complete shutdown
using procedure for normal shutdown.

10. Charge Heater Trip

 The Rx inlet temperature will drop resulting in rapid drop of bed
temperatures as well as the conversion.
 Stop the feed and make-up hydrogen.
 Shut down the stripper and splitter sections since feed is no longer
available.
 Stop the recycle gas compressor (GB-33301) when the reactor
temperature drops below 200°C.

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DHDT Unit – Phase-3 - Operating Manual F ……
Section-1-Chapter VIII –Emergency Handling 20-6-2012

 Depressurize the reactor if any skin temperature indication of the reactor

decreases below 80°C. (temperature to be checked against P / T
diagrams).

11. Loss of Amine Section

It may be necessary to proceed to an immediate shutdown of the amine absorber in
case of incident of amine supply failure. In any event, the operating staff shall try to
follow the normal shutdown procedure. To prevent this kind of situations, spare
equipment must be routinely checked so that it is ready to operate and any minor
problem must be fixed and solved before it leads to an emergency. It is virtually
impossible to list all the emergency conditions, which could arise through mechanical
failure, faulty construction, or maloperation. General or local electric, steam, cooling
water, or instrument air failure will necessitate shutdown of the amine unit. Be
familiar with the procedures under "Immediate Shutdown" and proceed as quickly as
possible. However following actions shall be carried out.
 Stop gas feed to HP amine absorber (DA-33301, if not done) and have the
recycle gas pass through the HP amine absorber by-pass line. As H2S
content will begin increasing in the recycle gas. Open HP purge and maintain
H2S content under control by allowing fresh make-up gas.
 Close and block in the both the LP and HP amine absorber bottom rich amine
level control valves (LV-333069 and LV-333030 respectively).
 Stop the lean amine HP pump (GA-33303 A / B) and block in the pump
discharge.
 Switch the lean amine flow controllers (FIC-333080 and FIC-333086) to
manual mode, then close and block in the lean amine flow control valves (FV-
333080 and FV-333086).

12. Steam failure

 HP steam.
The recycle gas compressor (GB-33301) is steam turbine driven. A HP steam failure
causes an emergency shutdown as detailed in "Recycle gas compressor failure".
 MP steam.
Stripping steam will be lost to the stripper (DA-33302) and process fluid may enter
into MP steam header system due to reverse flow. So, operator to close the UV-
333024 located on MP steam line to stripper either from field through HS-333065 or
from control room through HS-333064 immediately. Route products to slops.
The start-up ejector (EE-33301) uses MP steam at start-up / shutdown.
Splitter reboiler pump GA-33309A is MP steam turbine driven. Auxiliary lube oil
pump, GB33301-GAT51 of RGC is MP steam turbine driven.
Condensate extraction pump, GB33301-GAT52A is also MP steam turbine driven.
These are having auto-cut in facility to the stand by pumps on PAL.
 LP steam.

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DHDT Unit – Phase-3 - Operating Manual F ……
Section-1-Chapter VIII –Emergency Handling 20-6-2012

Lean amine heater (EA-33313) will be lost. Because of HC condensation, foaming

problems likely to be encountered in amine absorbers. Refer chapter-6 “ Normal
Operation of the unit” for more details.

13. Instrument air failure

Unit control and shutdown valves will adopt their design "fail-safe" position in
the event of an instrument air failure: FC (fail close), or FO (fail open). Put all
controllers on manual mode and set their output signal to zero (unless reverse
acting), so that they will remain closed when instrument air is restored.
The valves are dedicated to placing the unit in a safe position:
 Feed stopped.
 Make-up gas stopped.
 Reactor heater (BA-33301) tripped.
 Recycle gas compressor (GB-33301) stopped
 The reactor section depressurization valve stays closed since its actuator is
provided with a reserve air bottle. This valve can be opened in the event of
an instrument air loss as well since the reserve air bottle contains sufficient
air for 3times 100% valve movements: (meaning open-close-open).
 Shut down all heater firing and maintain maximum recycle gas circulation as
long as possible to cool the catalyst rapidly. Be careful not to exceed the
reactor product condenser maximum temperature. Put the EC-33301 fans on
maximum cooling.
 The makeup gas control valve will be fail closed, or the spillback valve in the
last stage of makeup gas compression will fully open, which will stop the flow
of makeup gas to the unit.
 Once recycle gas circulation is resumed, and all catalyst bed temperatures are
stable, pressurise the unit and continue with the normal startup procedure.

14. Electrical power failure

In case of power failure Recycle Gas Compressor which is on Steam turbine will
continue to run, however the Charge pump, Wash water pump and air cooler
motors will stop. Turbine driven Splitter bottom pump GA33309A) will be running.
If recycle gas compressor (GB-33301) is still working (steam turbine driven),
proceed with normal shutdown. If not, proceed with emergency shutdown as detailed
in section recycle gas compressor failure. If it is not possible to restore and restart
the amine circulation within a short period, initiate "Immediate Shutdown".

15. Cooling water failure

Loss of cooling water may lead to a subsequent shutdown of the unit due to lack of
cooling to the rotating machines and their auxiliaries’; recycle gas compressor (GB-
33301), make-up gas compressor (GB-33302A/B), and feed pump (GA-33301A/B).

16. Major Leak / Fire or Line rupture

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DHDT Unit – Phase-3 - Operating Manual F ……
Section-1-Chapter VIII –Emergency Handling 20-6-2012

In case of major leak, fire or line rupture, the section has to be shut down, by
stopping the feeds (refer to "Immediate Shutdown") to minimize the possible
extension of the hazard. As a consequence, the upstream section has to be
shutdown.

17. Charge Heater Tube Rupture

Stop all hydrogen and hydrocarbons going to the fire in the heater box through the
process lines. Then purge the process lines with Nitrogen at the rupture point to
prevent air ingress to the process lines and equipment.
 Depressure the unit with the manual emergency depressuring system.
 Shut off all fuel supply to the heaters.
 Open the stack damper completely.
 Shut down and block in any of the following equipment that has not already
been automatically shut down by the depressuring interlocks: the makeup and
recycle gas compressors, the feed pump, the lean amine pump, if applicable,
and the reactor effluent water injection pump.
 After the system is depressurised, purge the system with Nitrogen. Adequate
precautions shall be taken if the purging is through the Reactor to protect the
catalyst.
 Snuffing steam can be introduced to the fire box once the fire has been
extinguished to provide additional cooling if needed. Snuffing steam should
not be used until the fire is out since adding snuffing steam to the fire box
with a tube rupture could push the fire out of the fire box.

18. External Fire

 Rapidly shut down the unit and depressurise to prevent further damage. Keep
the recycle gas compressor running if practical, to cool the reactor and sweep
oil from the high pressure system. Do the following if possible, as applicable.
 Shut down and block in fresh feed.
 Shut off all fuel supply and return lines to all heaters.
 Shut down and block in the makeup gas compressor, but maintain the recycle
gas compressor operation as long as possible or till catalyst bed cools to
300°C.
 Shut down and block in the reactor effluent water injection pump.
 Depressurise to flare and purge with nitrogen as applicable to the situation.

19. Seal gas supply to RGC GB-33301

The objective is to keep the seal gas supply pressure always more then the
compressor equalizing line pressure to have seal chamber side pressure should be
higher than the compressor side pressure. This is to avoid process gas leaking
through the seal. This can be observed through PDI-333725/727 (local) of seal
system.
RGC seal has three sources of seal gas supply.
 Nitrogen from battery limit (Secondary & Separation Seal).
 Nitrogen from skid mounted storage bottle (Primary Seal).

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DHDT Unit – Phase-3 - Operating Manual F ……
Section-1-Chapter VIII –Emergency Handling 20-6-2012

 Compressor Discharge (for Primary Seal after Start - up)

 For the initial start-up when the compressor is started at pressure less then
B.L. Nitrogen pressure the Nitrogen shall be used for seal gas. Once the
compressor starts and pressure starts building up in the compressor
discharge, the seal gas supply should be lined up from compressor discharge.
A prolonged stoppage of the compressor will result in fall of seal chamber
pressure hence in case of RGC GB-33301 shutdown (Normal or Emergency)
the suitable action has to be taken to ensure that proper seal gas supply
pressure is maintained.

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