Emergency Handling Processors

TYPE OF EMERGENCIES
The following type of emergencies may come:

Feed failure.
Fire due to a serious leak.
Instrument air failure.
Power failure.
Steam failure.
Cooling water failure.
110 V DC failure.
Fuel failure.
Critical pumps failure.

Feed Failure
Naphtha feed surge drum level will decrease.
1st 06LAL1101 will appear (Low level of feed surge drum).
If the feed flow not has been established with in 30 minutes,
06LSAL-1102 will activate Is-2.
Plant will be shut down automatically.

Fire Due To A Serious Leak

Fire alarm should be activated.
Personnel working in the Hydrogen plant should be evacuated.
Fire should not be extinguished until the leak can shut off.
In the period prior to the leak is brought under control the
surroundings are cooled by water.
Bring down the pressure in the plant by taken shut down.

Instrument Air Failure

If the instrument pressure starts to decrease, the operator will be
warned.
If the pressure drops further it will cause a trip of plant.
All pneumatic valves will go their safe position.
Plant will be shut down automatically.

Power Failure

A power failure will cause all electric motor to stop (fan, blowers,
compressors, pumps etc)
Which again will cause of plant trip.
The valves with electrical actuators will remains in their position.
UPS unit will keep the PLC and DCS system operational for an
appropriate time.

Steam Failure
Since the plant is processing the steam needed for process.
Also exporting the excess steam.
Plant will not affected in case of steam failure.
In case that it is not possible to export the excess steam due to
a failure of the HP-steam grid, the excess steam has to be vented
via 06PI5103.

Cooling Water Failure

A cooling water failure will be indicated to the operator by a
alarm.
The temperature increase ex 06E12, result in a alarm from
06TAH-2002.
Hydrogen recycle compressor will trip at high discharge temp.
If cooling water flow can not be re-established within 1-2
minutes, plant shall be tripped due to possibility of damaging prereforming catalyst when operating without hydrogen recycle.
Condensate import should be minimized this to ensure better
cooling of gas leaving 06E11.

110V DC Supply Failure

110V DC supply failure will make the DCS/PLC system non
operational.
Plant will trip and CV will take fail-safe position.
The program in the DCS/PLC system is protected by battery
back up.

Fuel Failure
The only fuels imported to the plant are refinery fuel gas, natural
gas and fuel Naphtha.
In case of failure, refinery fuel gas shall be replaced by fuel
naphtha.
If the total fuel fails plant will trip.

Critical Pumps Failure

Only two pumps 06P001A/B feed pump and 06P002A/B BFW

pump are considered to be critical pumps.
Both pumps are duplicated and under auto start control.
In case both pumps fails, the plant will trip and shut down
automatically.

Trip Of Tubular Reformer

Action to be taken in control room
Check steam flow 06FIC-1507 set point is 1900Kg/Hr and ramping down.
Check hydrogen flow 06FIC-1508 set point is 2500Nm/Hr and ramping
down.
If no steam stop Hydrogen.
If no hydrogen flow allow steam for 90 seconds, than stop steam.

Check PIC-2001 is ramping down to below @ 2.0Kg/minute. If not, open

06PV-2001 manually.
Stop steam & Hydrogen flow to 06F-01, when R-03 inlet temp (06TIC-1513)
<410C.
Decrease pressure on 06PIC-2001 further and inform field operator to start
nitrogen purge.
Close manual block valve and open bleed on steam and hydrogen lines.
Purge with nitrogen for 20 minutes. Pressurize/ Depressurise using 06PV2001 (2-3times) check for CH4, CO, CO2, H2and Heavy H/C total below

Trip Of Tubular Reformer

Action to be taken in field
Check double block & bleed Naphtha feed line.
Check double block & bleed in Naphtha fuel, fuel gas & off gas line.
Close 06K006discharge valve.
Checked Naphtha pump stopped.
Check ID/FD fans stopped.
Check MOV`s in R-004 main line closed & 06R-004 bypass is opened.
Check 06-USV-2052 is opened
Start nitrogen purge as soon as instructed by control room.
3 Nitrogen purge valve must be fully opened for at least 1hour conforming O2
<0.2%

Trip Of Tubular Reformer

Action to be taken in field
Close all manual block valves in steam & hydrogen lines. Establish bleed in
steam line.
Close burner fuel valves
Open all peepholes at lowest level on reformer for cooling
Close block valves in Naphtha feed lines.
Check boiler 06V001 level.
Establish double block & bleed at 06R-004 inlet & outlet.
Depressurized to flare & purge with nitrogen if long shut down.
Depressurized to 5Kg/cm2, if short shut down. (Purge with nitrogen if catalyst
temp gets below 410C

Hydrogen generation unit

Operation