PRESENTATION ON

NHT EMERGENCY
HANDLING
Presented By
Md. Siddiqur Rahman
NHT EMERGENCY SITUATION

NHT reaction Section

1. P-201A/B Shut down.
2. H-201 Shut down.
3. K-201A/B Shut down.
4. R-201 bed temperature increase above
280°C.
5. H2S in R/G above 250 ppm.
6. NHT reaction section pressure decrease
below 13.5 Kg/cm2.
7. DMDS Pump Failure.
 TROUBLESHOOTING
P-201A/B Shut down
Cause
 P-201A/B discharge flow decrease (200-FSLL-105).

Action
 Stop DMDS Pump M-P 201A/B.
 Normal 200-UV-102 & 200-UV-403.
 Immediately Start Stand by pump P-201A/B.
 Normal H-201 & Start H-201.

H-201 Shut down

Cause
 H-201 inlet Flow decrease (SIS-NHT-FI-236).

Action
 Both naphtha & Recycle gas shall be kept in service.
 Take 200-TV-223 in Manual mode.
 200-TV-223 open 1% & VFD set 30%.
 Start H-201.
 If H-201 can not start before temperature reach 200°c.
 Stop DMDS injection and cut the feed.
 K-201A/B Shut down.
Cause of K-201A/B Shut down
 Very high liquid level in recycle compressor KO drum D-203.(200-
LSHH-401)
 Very high temperature at recycle compressor K-201 A discharge.
 Very low flowrate at recycle compressors K-201 A/B discharge.

(200-FSLL-405)
 Close 200-UV-0401 &200-UV-402.
 Emergency depressurization.

Action
 Feed Heater H-201 Shutdown.
 Feed pump P-201A/B Shut down .
 Stop DMDS injection.
 The catalyst temperature must be look after with particular attention.
 If the temperature tend to increase a bit or do not decrease at all,
EDPS the NHT reaction section.
 Open 200-UV-0401 &200-UV-402.
 Sequence start of K-201A/B.
 Increase Load of K-201A/B.
 R-201 bed Temperature increase above 280°C
Action
 Take 200-TV-223 in Manual mode.
 Decrease 200-TV-223 opening.
 Adjust Reactor bed temperature 280°C.
 Check H2S in R/G.

H2S in R/G above 250ppm.

Action
 Decrease stock of M-p 201A/B.
 Maintain H2S in R/G 200-250ppm.
 NHT reaction section pressure decrease below 13.5
Kg/cm2.
Action
 Open 200-FV-401.
 Increase NHT Reaction section Pressure upto 15
Kg/cm2.
 Maintain Reaction section (200-PIC-301) pressure

15 Kg/cm2.
DMDS Pump Failure
Action
 Decrease Reactor Temperature to 250°C.
 Check H2S In R/G. If found H2S decrease, Decrease
Reactor Temperature to 200°C.
 If sulfiding shortage is for along duration, then
decrease further temperature down to 150°C.
NHT STRIPPER SECTION
1. H-202 Shut down.
2. C-201 Bottom Doctor Test
Positive.
3. C-201 Pressure Very High.
4. P-202 Shut down.
5. P-203 Shut down.
6. D-204 level full.
 TROUBLESHOOTING
H-202 Shut down.
Cause of H-202 Shut down.
 Very low flowrate at stripper reboiler H-202 inlet

(200-FSLL-736).
 Very low liquid level in stripper column bottom C-201.

 Stripper bottom pumps shutdown.

Action
 Check doctor Test. If DT positive.

 Then Stripper bottom product should be diverted To T-004.

 Increase C-201 bottom level upto 50%.

 Start pump P-203A/B.

 Normal H-202.

 Start H-202.

 Increase H-202 outlet Temperature.

C-201 BOTTOM DOCTOR TEST POSITIVE.

Action
 If the DT is positive at the C-201 bottom then decrease the
PIC-0601 SP down to -0.1 kg/cm2 . Wait 2 hours like this and
then adjust again if DT is still positive by decreasing the
pressure by-0.1 kg/cm2g.
 Increase the stripper bottoms temperature and reflux rate.
 Recheck the stripper bottoms sulfur content, if no change.
 Increase the reactors inlet temperature by 5deg. C.
 Recheck the stripper bottoms, if no change, increase the
reactor inlet temperature by another 5deg. C.
 At this point if the sulfur level is still high reduce the feed
rate to 50% capacity. Recheck.
 If the sulfur level remains high, switch the stripper bottoms
to the sour naphtha storage.
 C-201 Pressure Very High.
Action
 Increase opening of 200-PV-601.
 If also increase pressure of C-201, Slightly by
pass valve open of 200-PV-601.
P202 Shut down
Action
 Start p-202.
 Start reflux to C-201.
 Maintain Reflux 2000-2500Kg/cm2.
 P-203 Shut down
Cause of P-203 Shut down.
 Very low liquid level in stripper column bottom C-
201.
 Very low pressure at stripper bottom pumps P-203
A/B discharge (200-PSLL-702).
 Action
 Increase C-201 bottom Level upto 50%.
 Start P-203 A/B.
 Maintain flow 12360Kg/cm2 at 200-FIC-701.
 Start H-202.

D-204 level full

Action
 Open bypass line P-202 discharge to SBP.
 EMERGENCY SHUTDOWN

 Loss of feed.
 Recycle gas failure.
 Stripper reboiler failure.
 Stripper reflux failure.
 Utilities failure: fuel gas.
 Utilities failure: cooling water.
 Utilities failure : power supply.
 Instrument failure: air or power.
 Major leak/fire
 LOSS OF FEED
 Feed Pump p-201A/B Shut down.
 Maintain H2 circulation, reset the reactor inlet
temperature to 250 deg. C.
 When the separator D-202 level starts to decrease,
close and block-in the 200-FV-0301.
 When the level in the stripper starts to fall, close and
block-in valves to Semi-Regeneration Reforming unit
on the stripper bottom.
 Allow the stripper to operate on total reflux.
 Maintain these conditions until feed is available again.
Maintain pressure in the reaction and stripper section
by hydrogen make-up.
 If interruption is to take place for several hours, short
shutdown procedure should be implemented.
RECYCLE GAS FAILURE (K-201A/B)
Actions
 Immediately stop the reactor feed heater H-201.(normally automatically
carried out)
 Simultaneously shutdown the naphtha feed pump P-201A/B, close the
200-FV-0102 and block in.
 Close H2 Make Up valve 200-FV-0401.
 Watch the tube skin temperatures, if there is a runaway trend open the
air damper and inject snuffing steam.
 Note that the catalyst bed thermocouples will not provide accurate
temperature measurements, as there will be no flow across the
thermocouples. As the feed contains unsaturated compounds,
hydrocracking reactions may occur. It should be necessary to block in
the reaction section and depressurize to flare. The estimated time
between the recycle compressor shutdown and the depressurization is
20 minutes.
 When the separator drum D-202 level starts to decrease, block in valve
200-FV-0301 on the stripper feed line.
 Close valve on the stripper bottom line to the Semi-Regeneration
Reforming unit, allow the stripper to operate on total reflux.
 Let the reactor cool down. This could take several days due to lack of
flow. Cool down can be assisted with a hydrogen make-up sweep,
through the recycle compressor by-pass, provided the reaction pressure
has been reduced.
STRIPPER REBOILER (H-202) FAILURE

 Actions
 In case of heater reboiler shutdown, stripper
bottom product should be diverted and capacity of
the unit reduced.
 Naphtha with H2S cannot be sent to the reformer
unit. Route the stripper bottom to the Hydrotreated
Naphtha Storage tank T-004.
 Reduce unit capacity to 50% of design as fast as
possible.
 Work the unit at 50% capacity until the situation is
back to normal.
 When H2S stripping is achieved and stripper
bottom product specifications met, stabilized
naphtha can be routed back to Semi-Regeneration
Reforming unit.
STRIPPER REFLUX FAILURE
THIS REFERS TO FAILURE OF THE STRIPPER REFLUX PUMPS WITHOUT
RESTART OF THE STANDBY. WITHOUT REFLUX IT WILL BE DIFFICULT TO
MAINTAIN THE STRIPPER BOTTOM ON-SPEC.

Actions
 Reduce unit capacity to 50% of design as fast as
possible.
 Switch the stripper bottom back to the Storage tank
T-004.
 Reduce the stripper bottoms temperature to
minimise reflux, purge the level in the reflux drum to
flare, if necessary.
 If reflux will not be available for a long duration,
bypass the reaction section through the start-up
bypass or shut-off the feed and follow the procedure
for loss of feed.
UTILITIES FAILURE: FUEL GAS

 The reactor feed heater H-

201 will shutdown.
 Cut naphtha feed
immediately.
 Follow the same procedures
as for loss of feed.
UTILITIES FAILURE: COOLING WATER

 In the case of partial cooling water failure, it should be sufficient to

reduce the feed flowrate to 60% of design capacity to maintain
reasonable vessel and product temperatures. The stripper bottom
should be carefully monitored to be sure the pre treated naphtha
remains on-spec. As the molecular weight of the recycle gas
increases with higher separator temperature, the recycle gas
compressor may shutdown on high load or high discharge
temperature.
 In the case of total failure, it is recommended that the unit be
shutdown immediately rather than waiting for the compressor to
shutdown on high load or high temperature.
 Shutdown the naphtha feed pumps and follow the procedure for loss
of feed.
 Reduce the reactor feed heater outlet temperature as necessary to
lower the separator temperature.
 Keep the H2 recycle compressor in service as long as possible
without risking the machine. This will strip the hydrocarbons off the
catalyst.
 Allow the stripper to operate on total reflux with air cooling only.
 Maintain pressure in the reaction section with hydrogen make-up.
UTILITIES FAILURE : POWER SUPPLY

 It is assumed that all electrical equipment in the unit 200 will

shutdown i.e. recycle compressor, air coolers and all pumps.
 Immediately shut-off fuel to the reactor feed heater H-201
(normally automatically achieved due to compressor shutdown)
and stripper reboiler H-202.
 Isolate the feed and product lines by closing the control valves
and block valves.
 Block-in the recycle compressor K-201 A/B.
 Isolate the stripper from the reaction section by closing and block
in-in 200-FV-0301.
 Watch the tube skin temperatures. If there is a runaway trend,
open the air damper and inject snuffing steam.
 Maintain pressure in the reaction section. If necessary, inject
fuel-gas or nitrogen in the stripper to maintain pressure.
 There is a potential for increased hydrocracking in the reactor
which is idle with no flow to strip the hydrocarbons. If power
outage is suspected for a long duration, depressurize the
reaction section to flare.
INSTRUMENT FAILURE: AIR OR POWER

 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). The valves
are dedicated to placing the Unit in a
safe position.
MAJOR LEAK/FIRE

 Stop the fuel gas supply to heaters H-201 and H-202 by

actuating the fuel gas emergency shutdown system from
the control room.
 Shutdown the naphtha feed pump P-201 A/B and isolate
the feed lines.
 Isolate stripper from reaction section by closing 200-FV-
0301 and block-in.
 Block-in all products lines and H2 make-up.
 Depending on the severity of the leak and location,
shutdown the recycle compressor immediately and
depressurize the reaction section to flare.
 Depressurize stripper section to flare.
 Drain all the vessels to the hydrocarbon sewer or to
blowdown.
 As the depressurized hot vessels cool down, watch the
pressure and inject N2 as necessary to avoid vacuum.
EMERGENCY DEPRESSURIZATION (EDPS).
How to EDPS
 In case of extreme emergency, the reaction section can be
depressurized to the flare.
 using the quick depressurization valve 200-UV-0302 by
actuating 200-UV-0302.
 200-UV-0302 is activated by push buttons in the control room
or on site (200-HS-0301 A or B).
Action
• Close valve 200-UV-0102 on the NHT feed pumps P-201 A/B
discharge line.
• Stop the reactor feed heater H-201.
• Close valve 200-UV-0403 on the hydrogen make up feed.
• NHDT Feed pumps shutdown.
• Closes Valve 200-UV-301, 200-UV-303.
• Stop K-201A/B.
• NHT Reaction Section shutdown.
 SHORT PERIOD SHUTDOWN
 Reduce unit capacity to 60% of design. It should not be necessary to adjust reactor
temperatures immediately for this short period before shutdown. Maintain maximum
hydrogen recycle flow.
 Start cooling down the R-201 reactor inlet temperature down to 200deg. C at a rate of
20deg. C/hour. Closed loop liquid recirculation under hydrogen at 200deg. C can be
maintained as
long as a sufficient concentration of H2S in the recycle gas is kept. Should it fall below
0.1 vol%
then the reactor bed temperature should be decreased further down to 180deg. C.
 If required for maintenance, when reactor inlet temperature is at 140deg. C, shutdown
the naphtha feed pump P-201 A/B.
 Block-in the level control valve of the separator drum boot (200-LV-0301).
 When the level in the separator begins to fall and reaches 30%, shutdown the stripper
feed
from separator drum by closing 200-FV-0301.
 Continue hydrogen circulation at maximum rate through the reactor to strip off the
hydrocarbons.
 At this stage the reaction section is considered to be on standby with the naphtha
feed stopped and hydrogen circulating through the catalyst beds at reduced
temperature.
 When NHT unit is under maintenance, feed to Semi-Regeneration Reforming unit will
be stopped. Refer to operating instructions of 300 for shutdown procedure.
 Divert stripper bottom product to T-004.
LONG PERIOD SHUTDOWN
 When required for entering the equipment, the whole unit is drained and inerted. This
shutdown is required for major repair of some equipment or some sections of the unit.
The procedure described above for short period shutdown is followed and completed
with full cooling of equipment to ambient temperature.

 A stripping procedure is established to remove hydrocarbon from the catalyst by using

the recycle hydrogen.
 After two hours of stripping the hydrocarbons from the catalyst beds, reduce the reactor
inlet at a rate of 20deg. C/h to 100deg. C. Monitor the separator drum level during
stripping and drain to the hydrocarbon sewer if necessary.
 When 100deg. C is reached, shutdown the heater, block in the fuel gas and steam purge
the heater box.
 Keep hydrogen circulating until the temperature of the catalyst bed reaches 50deg. C.
 When 50deg. C is reached, shutdown the compressor, isolate and purge with nitrogen.
 Maintain the reaction section pressure with nitrogen.
 Shutdown the reactor effluent air and trim coolers
 For stripper column, if it has been maintained in total reflux operation, stop stripper
reboiler (H-202). When the bottom temperature falls below 120deg. C stop the reflux
pump and let the stripper to cool down. Maintain a positive pressure with nitrogen if
necessary.
 Shutdown the stripper overhead air condenser and the stripper trim-cooler. The
extended period of shutdown requires the introduction of nitrogen in the reflux drums D-
204 in order to keep equipment under positive pressure.
 The unit is now considered totally shutdown under hydrogen/nitrogen pressure with low
hydrocarbon levels in all the vessels.
 Thanks To
All