KILL SYSTEM FOR THE

UNIVATION REACTOR
Bhartendu Vimal
Shreyosi De
WHAT IS KILL?
 A “KILL” involves injection of a CATALYST POISON (modifier C) into the cycle gas line
downstream of the Cycle Gas Cooler

 Carbon Monoxide (CO) gas in high pressure (~155 Kg/cm 2g) cylinders is the kill poison.

 CO quickly mixes into the fluidized bed polymer, deactivates the catalyst and stops or
inhibits the reaction.

 KILL may be either manually or automatically actuated by any of several methods.

 CO may be purged (removed) from the system with nitrogen (N2) or ethylene (C2H4).

 According to severity types of kill are:

 Mini Kill
 Type-I
 Type-III
 Type-II

 KILL SYSTEM ACTIVATED alarm comes on the activation of KILL

SIGNIFICANCE OF KILL PERMISSIVE
Kill permissive is required for the following systems to operate:
 Permissive to operate Liquid Recycle Valves (logic 52-2-1)
 FIC-41106 controls modifier RO valve FV-41106 (valve fails close otherwise)
 FIC-41108 controls Butene-1 / Hexene-1 valve FV-41108 (valve fails close
otherwise)
 FIC-41104 controls ICA valve FV-41104 (valve fails close otherwise)
 Run Dry Catalyst feeders (logic 40-1-2)
 Permissive to open vent to PPB KV-51101A (valve fails close otherwise)
 Open HPPN supply (logic 40-2)
 Open Alkyl supply (logic 40-3-5)
 Open Hydrogen supply (logic 40-2)
 Initiate modifier C injection sequence. (logic 40-3-6)
 Permissive for slurry injection (logic 40-15)
 Open ethylene purge to catalyst injection nozzles, FV-42301,42302,42303,42304
 Ethylene Feed Valve FV-41102 closes
WHAT ARE SIGNALS
Signals are various inputs to the KILL LOGICS which are used to define the severity of the
problems in the Cycle Gas Compressor. The logic allows for four different input signals.

 SIGNAL A
 SIGNAL B
 SIGNAL C
 SIGNAL D

The function of these separate signals is to ensure that most desirable type of kill is initiated
depending on the gravity of the mechanical troubles of the Cycle Gas Compressor:

 least disruptive to operations,

 most complete kill and
 lowest probability of compressor or turbine damage
SIGNAL A
 Signal A is an indication from the Cycle Gas Compressor motor contactor that the Cycle Gas
Compressor motor has stopped.

 This typically happens due to a breaker failure, Loss of Run Feedback.

SIGNAL B
 Signal B is based on the low level operational alarms during the running of Cycle Gas
Compressor. In Kobe logic; following parameters are added to generate Signal B.
Tag No Service Set Point
FIT-44201A/B/C Low Low Seal Gas Supply Flow 90 Nm3/Hr
FIT-44203A/B/C High High Primary Seal Gas Vent Flow 40 Nm3/Hr
High High Secondary Seal Gas Vent
FIT-44204A/B/C 20 Nm3/Hr
Flow
PIT-44401A/B/C Low Low Lube Oil Pressure 1 Kg/cm2g
 Signal B indicate that LIMITED DURATION FULL SPEED OPERATION is
ACCEPTABLE.
SIGNAL C
 Signal C is based on the mid-level alarms from the Cycle Gas Compressor that indicate that
LIMITED DURATION REDUCED SPEED OPERATION is ACCEPTABLE.

Tag No Service Set Point

ZE-44502A/B High High Compressor Axial Displacement ±600 µm
TE-44501A/B/C High High Compressor Journal Bearing Temperature 100 ºC
TE-44502A/B/C High High Compressor Thrust Bearing Temperature 105 ºC
TE-44503A/B/C High High Compressor Thrust Bearing Temperature 105 ºC
TE-44504A/B/C High High Compressor Journal Bearing Temperature 100 ºC
VE-44501A/B High High Compressor Shaft Vibration (Un-Cplg) 65 µm
VE-44504A/B High High Compressor Shaft Vibration (Cplg) 65 µm
VE-44505A/B High High Main Motor Shaft Vibration (C-side) 90 µm
VE-44506A/B High High Main Motor Shaft Vibration (T-side) 90 µm
XS-44402A/B/C Low Low Main Motor Purge Pressure  
SIGNAL D
 Signal D is based on the highest level of alarms from the Cycle Gas Compressor that indicate
that LIMITED DURATION REDUCED SPEED OPERATION is UNACCEPTABLE.
Tag No Service Set Point
ZE-44502 A/B High High High Compressor Axial Displacement ±700 µm
TE-44501 A/B/C High High High Compressor Journal Bearing Temperature (Un-Cplg) 105 ºC
TE-44502 A/B/C High High High Compressor Thrust Bearing Temperature (Un-Cplg) 110 ºC
TE-44503 A/B/C High High High Compressor Thrust Bearing Temperature 110 ºC
TE-44504 A/B/C High High High Compressor Journal Bearing Temperature 105 ºC
VE-44501 A/B High High High Compressor Shaft Vibration (Un-Cplg) 75 µm
VE-44504 A/B High High High Compressor Shaft Vibration (Cplg) 75 µm
VE-44505 A/B High High High Main Motor Shaft Vibration (C-side) 100 µm
VE-44506 A/B High High Main Motor Shaft Vibration (T-side) 100 µm
PIT-44401 A/B/C Low Low Low Lube Oil Pressure 0.7 Kg/cm2g
TT-42401 A/B/C Low Low Turbine Outlet Temperature -29 ºC
FIT-44201 A/B/C Low Low Low Seal Gas Supply Flow 60 Nm3/Hr
FIT-44203 A/B/C High High High Seal Gas Vent Flow (Primary) 45 Nm3/Hr
FIT-44204 A/B/C High High High Seal Gas Vent Flow (Secondary) 25 Nm3/Hr
START UP
HWC SWITCHES
HS-41905
 HS-41902: Four position hand-switch
• AUTO
• TYPE-I Manual Kill
• TYPE-II Manual Kill
• DISARM/ RESET

 HS-41905: Two position hand-switch

• START- UP/ BYPASS: Momentary
• Normal

HS-41902
KILL & KA-403
 Before starting the Cycle Gas Compressor:
• Put HS-41902 in DISARM/RESET position (Green light will appear)
• Press HS-41905 to START-UP BYPASS, wait for latch (Red light will appear)
• Start the compressor as per SOP

 Arming the Kill, once compressor is running normally when:

 Signal A, B, C, D are healthy
 Cycle gas flow (FIA-41202) is above minimum 524255.3 Nm3/ Hr
OR
Bed weight (WICA-41401) and Lower Bed Density (PDIA-41404) above 33000 Kg and
0.075 kg/cm2 respectively
 Bed temperature (TIA-41403A) below 125 ºC
 Bed Differential temperature (TIA-41403B) i.e. difference between P.V. of TIA-41403A
and S.P. of TICA-41404 is below 7 ºC
NORMAL RUNNING CONDITION
TYPE-I KILL
TYPE-I KILL
 Manually or automatically initiated
 Poison circulated through the fluidized bed by Cycle Gas Compressor (KA-403) driven by
its electric motor at normal speed resulting in rapid kill

Reason Parameter Kill

Bed temperature (TIA-41403A) high 125 ºC (Operator adjustable)
Bed Differential temperature (TIA-41403B) i.e. 7 ºC
difference between P.V. of TIA-41403A and S.P.
of TICA-41404 high 7 ºC Type-I
Signal B Not healthy
HS-41902 position (Manually) Type-I kill
TYPE-I KILL
 Actions:
 All feed to reactor stops:
 Liquid Recycle Valves LV-51601, LV-51701, LV-51501 closes
 Vent Recovery Compressor KA-522 Trips
 Modifier RO valve FV-41106 closes.
 Butene-1 / Hexene-1 valve FV-41108 closes.
 ICA valve FV-41104 closes.
 Dry Catalyst feeders trips
 Vent to PPB KV-51101A closes and KV-51101B opens.
 HPPN supply FV-41103 closes
 Alkyl supply HV-41502 closes, Alkyl pump PA-152A/B trips
 PPB slide gate HV-51108 closes
 Hydrogen supply FV-41108C/D and HV-41107 closes.
 Permissive for slurry injection lost.
 Ethylene Feed Valve FV-41102 closes
 Initiate Modifier C injection sequence. (logic 40-3-6)
TYPE-I KILL
TYPE-I KILL
 Remedy:
 Eliminate the cause behind Type-I kill.
 Put HS-41902 in DISARM position
 KILL SYSTEM ACTIVATED alarm disappears
 Put HS-41902 in AUTO once all the alarms clear
 Start feed again.

 Duration:
 100 sec maximum injection of CO.
 Can be disarmed anytime.
TYPE-III KILL
TYPE-III KILL
 Manually or automatically initiated
 Poison circulated through the fluidized bed by KA-403, driven by the expander turbine
(driven by exhausting cycle gas through the turbine to the flare) at reduced speed
adequate to maintain bed fluidization.

Reason Parameter Kill

Signal A Not healthy
Signal C Not healthy
Cycle gas flow (FIA-41202) low 524255.3 Nm3/ Hr
Type-III
OR
Bed weight (WICA-41401) and Lower Bed 33000 Kg
Density (PDIA-41404) both high 0.075 kg/cm2
HS-41902 position (Manually) Type-III kill
TYPE-III KILL
 Actions:
 Same as TYPE-I
 Stops Compressor KA-403
 Ethylene purge to Reactor HV-41901 closes
 Catalyst support tube valves FV-42301/42302/42303/42304 closes
 Turbine operation activates.
 KA403 IGV position becomes 100% automatically

 Turbine Operations:
 Turbine supply valve HV-42402 opens to 20%
 Wait for clutch engagement.
 After clutch engages the valve opens fully
 The reactor gas vented to flare via turbine
 Turbine operation can be stopped only after 3.5 min
 Can continue to maximum 10 min time after which TYPE-II kill gets activated
automatically.
TYPE-III KILL
TYPE-III KILL
 Remedy:
 Eliminate the cause behind Type-III kill.
 Wait for 3.5 min for adequate poisoning of catalyst
 Put HS-41902 in DISARM position
 Immediately put HS-41905 in START-UP position
 Start the compressor KA-403
 KILL SYSTEM ACTIVATED alarm disappears
 Put HS-41902 in AUTO once all the alarms clear
 Start feed again

 Duration:
 100 sec injection of CO.
 Can be stopped only after 3.5 min and continues to a maximum time of 10 min
TYPE-II KILL FROM TYPE-III

 Type-III kill TERMINATED when:

 Turbine exhaust temperature TA2L-42401 <-290C
 Turbine speed not above 300 rpm in 20 secs
 Turbine speed greater than 3000 rpm trips the OSV-42401which in turn closes HV-42402
 Signal C give rises to Signal D due to extreme mechanical problem

 Type III kill can be ABORTED when:

 Putting HS-41902 in DISARM position after 3.5 mins
 After 10 min of TYPE-III kill it is automatically aborted.
TYPE-II KILL
TYPE-II KILL
 Automatically generated
 Poisoning by venting gas from the top of the reactor (bed has settled) and using the
expansion of the bed to draw the poison through the settled bed
 Most undesirable because of sintering and chunk formation in the reactor due to insufficient
vent rate.

Reason Parameter Kill

Signal D Not Healthy
Type-II
Type-III cannot be sustained Aborted or Terminated
TYPE-II KILL
 Actions:
 Same as TYPE-I
 Stops Compressor KA-403
 Ethylene purge to Reactor HV-41901 closes
 Catalyst support tube valves FV-42301/42302/42303/42304
 Cycle gas Shut off valve HV-41201 closes
 Blow down of reactor starts.

 Reactor Venting Sequence:

 Type-II kill activated
 Cycle gas shutoff valve HV-41201 closes
 PICA-41202 overriden by kill to manual 30%
 5 sec later emergency blowdown valve HV-41202 opens
 After 5 sec PICA-41202 set to AUTO with a set point of 7 kg/cm2 g
TYPE-II KILL
TYPE-II

 Remedy:
 Eliminate the cause behind Type-II kill.
 Continue venting the reactor.
 Nitrogen purge reactor after venting stops.

 Duration:
 No additional injection of CO
 Continues venting till it is disarmed and bypassed
MINI KILL
MINI KILL

 Used to slow reactions without changing reactor conditions

 Can be actuated from DCS and field
 DCS actuated
• A timed small flow of CO is injected, the time of injection being operator adjustable
• Initiated from DCS by HS-41904.
 Field Actuated
• Injects a small amount of CO trapped between two block valves
• Serves as a back up to the DCS Mini Kill
MINI KILL

 Reasons:
 Reactor temperature growing high
 Bed level becoming high
 Undesirable reaction
• Particle size problems
• Specifications
• Continuity issues
DCS MINI KILL
FIELD MINI KILL- Pressure Up
FIELD MINI KILL- Injection
KILL SYSTEM FAILURE

 After KILL SYSTEM ACTIVATED alarm comes, if

 CO cylinder pressure PIA-41901 < 84.4 kg/cm2 g
OR
 PIA-41901 does not drop below 42.2 kg/cm2 g within 25 sec
OR
 PIA-41901 drops below 84.4 kg/cm2 g within 2 sec

KILL SYSTEM FAILURE Alarm comes

MODIFIER C INJECTION SEQUENCE
• Normal Position of Valves
• KV-41902A: Closed
• KV-41902B: Closed
• KV-41902C: Open

• When Kill System activated:

• KV-41902B: Opens instantaneously
• KV-41902C: Closes Instantaneously
• KV-41902A: Opens after 2 sec

• When Mini Kill Activated

• KV-41902C: Closes Instantaneously
• KV-41902A: Opens after 5 sec
• KV-41904 : Opens after 5 sec
• Injection time is operator adjustable
Questions???????