Emergency shut down, trips and hot restart

MRPL Phase-III Refinery Project, Hydrogen Generation Unit

General overview

Passive alarms warn against deviating operating

conditions to avoid development towards danger and/or
damage.

Active alarms causes safety actions shutting down
necessary process sections.

Two categories of trip system:
• IS- Group: Performed by system independent of the digital Control
system (DCS) – Typically PLC based system
• I- Groups: Performed by redundant DCS.

General Overview

Operators should maintain safe operating conditions as below:

– Check that all automatic trip actions have taken place
– Check in field that all trip valves have been activated
– Carry out specific action related to each trip
– Investigate cause of trip
– Remedy the fault
– Reset the trip group
– Restart according to normal start-up (jump unnecessary steps)

1
General overview

Inactivation of certain inputs possible

– Only inactivate if necessary e.g. low flow/pressure at SU

– Always monitor inactivated parameters carefully

IS-1 interlocks and I-101

IS-1: Tubular Reformer

Operator actions to be taken:

– General actions as mentioned
– Supervise the steaming out
– Primary reformer inspection
– Avoid exceeding mechanical design temperatures
– Cooling as such not desired, prolongation of succeeding SU
– Reduce/stop steaming if/when possible
– Purge section with nitrogen
– Monitor temperature development in shift (depressurise/purge )

2
IS-2, IS-3 Interlocks and I-102, I-103

IS-4, IS-5 and IS-6 Interlocks

IS-7 and IS-8 Interlocks

3
IS-10 Interlocks and I-110

IS-11 Interlocks and I-111

I-112 A, I-112 B, IS-13 Interlocks and I-113

4
IS-14 Interlocks and I-114

I-115, I-116 and I-117

I-120, I-121 and I-122

5
I-125, I-165 and I-166

I-191, I-192 and I-193

I-311, I-311 A and I-311 B

6
I-312 and I-313

Hot Restart

Check the availability of import steam and hydrogen.

Check that Prereformer catalyst temperature is minimum 430°C

Introduce nitrogen to mix-point

Ignite burners

Hot Restart

Introduce steam and hydrogen when flue gas temperature reaches

550°C

Interrupt nitrogen to mix-point

Continue igniting burners

Increase system pressure to 10 kg/cm2 g

Continue normal start-up procedures

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 QUESTIONS?

Thank you for your attention!