SAUDI ARAMCO BASE-OIL COMPANY

HYDROCRACKER UNIT
LUBEREF II

Shutdown
Section-iiiIV
Section-iii
 SAUDI ARAMCO BASE-OIL COMPANY
HYDROCRACKER UNIT
LUBEREF II

SECTION IV

UNIT NORMAL SHUT-DOWN

This section presents the guidelines for a controlled, orderly shutdown to prepare the
reactor for catalyst replacement at EOR or to perform general maintenance requiring
reactor de-pressurization and cool down. Cooling rates and de-pressurization must follow
metallurgical and equipment design limits. This shutdown scenario which includes catalyst
replacement was chosen since this incorporates all steps required for a complete
shutdown.

Depending on the necessity of the shutdown, the reactor loop can be brought to any of the
following conditions:

 TEMPORARY SHUTDOWN - Reactor under hot gas circulation at full pressure when
the shutdown will be of short duration.
 MAINTAINANCE SHUTDOWN- Reactor cooled and de-pressured but under nitrogen
purge for reactor loop maintenance.
 SHUTDOWN FOR CATALYST LOADING/ SKIMMING - Reactor cooled and de-
pressured

For a planned shutdown, e.g., catalyst replacement, some work can be done in advance,
such as:

• Prepare blind lists and blind list guidelines for required isolations.

• Have test equipment onsite for:

 CO2 Test for Nickel Carbonyl

 pH Tester for Acid or Caustic Waters
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LUBEREF II

 Explosive Gas and Hydrogen Analyzers

 Oxygen Analyzer (If Vessel Entry Planned)

• If inert atmosphere entry into the reactor is planned, have the necessary equipment on
hand.

• Have the necessary materials onsite to complete the shutdown.

• Inform all interested parties of shutdown plans.

• Have temporary piping spools, blinds, gaskets, etc., onsite.

• Erect staging (scaffolding).

• Ensure adequate storage space is available in off-test oil tankage.

• Plan for any unbalanced utilities.

Precautions must be taken to avoid the following while performing a shutdown:

• Potential formation of highly toxic nickel carbonyl compound when the reactor is cooled.
Cooling below 205°C with greater than 10 ppm CO in the reactor system will result in this
compound formingand there is no reliable way to test for it. The best protection is to ensure
it does not form.

• Exposing personnel to toxic or noxious conditions when catalyst is drained or when

equipment is entered. Explosive hydrogen and/or hydrocarbon and oxygen mixtures.

• Exposure of pyrophoric material to air when the reactor is opened.

• Furnace or catalyst coking, by keeping temperatures under control.

• Cooling reactor at rates that exceed the guidelines.

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LUBEREF II

These shutdown guidelines only cover the reaction section. The feed, fractionation and LER
Recovery Section should be cooled and flushed and drained. The system should then
steamed out or purged with nitrogen to remove the residual hydrocarbon to prepare the
system for maintenance. The Amine Regeneration section and the Sour Water Stripping
Sections can be placed on recirculation and left in standby or flushed and shutdown.

Diagram Below shows major Steps in performing Normal Shut down for maintenance (which
requires catalyst dumping/skimming) and Temporary (short-term) Shutdown. It is worth
noting that the Figure below depicts that the procedure for maintenance shutdown for
catalyst replacement or skimming, requires the complete shutdown procedures. Actions
are numbered in a continuous manner for a holistic view of the procedure and to avoid
confusions.

TEMPORARY S/D * MAINTENANCE Shutdown

* CATALYST DUMPING/REPLACEMENT Shutdown

UNIT FOR
1.1
1.2 1.3 NITROGEN
PULL-OUT PURGING/PRESE
CATALYSTS REACTOR
REACTOR RVATION IF
STRIPPING COOLDOWN
FEED NEEDED

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LUBEREF II

SHUTDOWN PROCEDURE FOR UNIT MAINTENANCE

1.1 PULL REACTOR FEED

Actions:

1. REDUCE FEED TO THE REACTOR gradually by 5% per 15 minutes increment.

2. Adjust bed quench controllers simultaneously with reactor inlet temperatures to lower
all catalyst.
3. Decrease Product draw-off rates as limited by constant Tray temperatures
4. When Fractionator tray temperature cannot be sustained, route that product to slop
and shutdown the stream.
5. When the reactor feed rates is at 50%, check that the emergency circulation flow
controller is operating.
6. Ensure the applicable minimum flow bypass controller performs correctly
7. Closely monitor the Make-Up Hydrogen Compressor, loading and pressure controller as
load is reduced.
8. Shutdown Make-up Gas compressor
9. Reduce reactor inlet temperatures to 315°C.
10. When the feed rate has been reduced to 50%, reduce the reactor feed furnace firing to
pilots only.
11. If the shutdown is of short duration and it is desired to keep the feed and
fractionation sections hot, hot long- loop circulation can be established before
stopping feed to the reactor:

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a. Line up the Feed Surge Drum outlet to the Product Stripper via the internal
circulation.

b. Establish a long loop circulation rate of about 40% of the design feed. The VGO
import rate to the feed system will reduce proportionately

c. Start an internal circulation rate of about 40% of design feed rate.

Note: When Shutdown is not temporary, continue to the describe succeeding procedures
below:

12. Continue to reduce feed rate to the HCR reactor until chopper valve closes on low-low
flow.
13. Stop the HCR reactor Feed Pump and block in the pump discharge
14. Reduce the fractionator feed heater, coil outlet temperature to 200-210°C.
15. When B-4002 COT is at 210°C, isolate the VGO feed line and bring in diesel to displace
the heavier feedstock. Reduce long loop flow to minimum to expedite this task, and
then re-establish the previous long loop circulation conditions.
16. Cool down the product fractionator inlet temperature to either standby conditions or
cooler for complete plant shutdown.

1.2 CATALYST HOT GAS STRIPPING

The objective of this step is to remove any residual hydrocarbon from the catalyst by
passing hot hydrogen over it. During the stripping period, tests will be performed to
determine the carbon monoxide concentration in the recycle gas stream. Carbon monoxide
is tested to verify the absence of nickel carbonyl. Nickelcarbonyl is a deadly toxin and
difficult to test for. If carbon monoxide is present in the recycle gas stream at a level
greater than 10 ppm, it may form deadly nickel carbonyl at temperatures below 205°C
(400°F).Ensuring that is not formed is the best way to verify a safe environment when
opening the reaction system.

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LUBEREF II

The most prevalent source of carbon monoxide/carbon dioxide is in the hydrogen stream
from the hydrogen supply units. The first of two tests to verify if carbon monoxide is present
in the recycle gas stream must be performed while make-up hydrogen is being routed to the
unit. The system will be tested again right before cooling below 205°C.The reactor catalyst
temperatures should not be allowed to decrease below 205°C until the second test for
carbon monoxide content in the recycle gas system is performed. If testing after cooling
below 205°C (400°F) shows the presence of carbon monoxide, then the system will need to
be purged to remove the CO then reheated to above 210°C to destroy any nickel carbonyl
that may have formed.

17. Continue to maintain normal reactor section operating pressure and design recycle gas
rates.
18. Increase reactor inlet temperatures to 315°C. (14℃/hr)
19. When hydrocarbon liquid stops collecting in HHPS D-4003, CHPS D-4005 and HLPS D-
4004, stopwater injection.
20. If the unit is being shut down for brief maintenance, which does not require stopping
the recycle compressor, continue circulation at normal operating pressure.
21. If the feed outage will be 3 days or less, adjust the reactor temperatures to ~30°C
below thetemperature required to achieve the desired conversion at the startup feed
rate (~50% of design). If the feed outage will be more than 3 days, cool all reactor bed
inlets evenly to<205°C.
22. If the shutdown is for catalyst regeneration or replacement, or maintenance that
requires stopping the recycle compressor or de-pressuring the reactor system,
continue circulation at normal pressure for 2 hours after oil buildup stops.
23. Continue to circulate recycle gas at the maximum rate.
24. Monitor the levels and flow rates in the high pressure separator section, as oil flow
diminishes in the system. After gas oil feed is pulled, flow will continue from the reactor
until all oil is stripped off the catalyst. The oil flow will slowly diminish.
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LUBEREF II

25. When oil flow from the HHPS has reduced to the point that the level control valves are
completely closed, isolate the line to HLPS. If the HHPS levels build somewhat after the
controllers are blocked, “batch” the oil to the HLPS and close the block valves again.
26. Ensure that all reactor quench lines are clear and that maximum flow is available for
cool- down.
27. When oil stops building up in the HHPS, continue to strip for an additional four hours.
28. Test the make-up hydrogen stream for CO per the test procedure in the Appendix.
29. If the two consecutive tests verify the CO content of the make-up gas stream is below
10 ppm, continue with the normal sequence of steps in the shutdown.
30. If the two consecutive tests verify the CO content of the make-up gas stream is above
10 ppm, work with the hydrogen suppliers to correct the problem. Maintain reactor
temperatures above205°C (400°F) until the problem is corrected and the CO
concentration is below 10 ppm.
31. Test the recycle gas stream for CO per the test procedure in the Appendix.
32. If the two consecutive tests verify the CO content of the recyclegas stream is below 10
ppm, continue with the normal sequence of steps in the shutdown.
33. If the two consecutive tests verify the CO content of the recyclegas stream is above 10
ppm, purge to the relief to correct the problem. Maintain reactor temperatures above
205°C (400°F)until the problem is corrected and the two consecutive tests show that CO
concentration is below 10 ppm.

1.3 REACTOR COOLDOWN

Cool and de-pressure (preferably by testing the emergency depressuring valves) the reactor
section after hot stripping is completed.The reactor section is then cleared of hydrogen with
nitrogen, depressured, and isolated. Cooling and de-pressuring rates must follow
metallurgical and equipment design limitations. If the feed outage will be 3 days or less,
adjust the reactor temperatures to ~30°C below the temperature required to achieve the
desired conversion at the startup feed rate (~50% of design). If the feed outage will be more
than 3 days, cool all reactor bed inlets evenly to <205°C.
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LUBEREF II

34. Continue circulation at normal pressure for 2 hours after oil stopscollecting in the
separators.
35. Cool all of the reactor beds evenly,
36. Maintain normal operating pressure and maximum recycle rates to reactor to cool the
reactor in the shortest allowable time.
37. Reduce the reactor feed furnace outlet temperature, taking care to stay safely above
MPT.During this step, carefully monitor allreactor temperatures (i.e., catalyst beds, skin
points, etc.)
38. Monitor all reactor skin and internal temperatures every 15 minutes to assure even
cool down and that cool down rates are not exceeded.
39. Displace hydrocarbon liquid from the high and low pressure separators to the product
strippers, then ensure that the liquid letdown valves are blocked in and isolated.
40. Displace any water from the high and low pressure separators.
41. When permitted by cooling rate restrictions, speed cooling as follows:
a) Open the bypasses around the HCR reactor feed/effluentexchangers, E-4005A/B.
b) Close the “pinch valves” at the tubeside inlets to all three reactor feed/effluent
exchangers to their minimum stops in order to bypass as much recycle gas
around these exchangers as possible
c) Open the bypass on the HHPS vapor/feed gas exchanger, E-4007A~C.
d) Adjust the gas flow controllers to balance reactor cooldown times. Use quench as
needed to maintain even temperatures across the reactor.
e) Maximize cooling in E-4008, HHPS Vapor Air Cooler.

42. Before cooling below 205°C, check the recycle gas sample for CO content and ensure it
is below 10 ppm to prevent the formation of highly toxic metal carbonyl compounds.

CAUTION:

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LUBEREF II

If more than 10 ppm CO has been detected in the recycle gas, the CO must be purged
before cooling can continue to eliminate possible formation of metal carbonyls.

43. If CO is greater than 10 ppm:

a) Shutdown burners on B-4001.

b) Stop recycle gas compressor and de-pressure the unit.

c) Check the makeup hydrogen for CO. If it is less than 10 ppm, and re-pressure with
hydrogen.

d) If makeup hydrogen is > 10ppm CO, test the nitrogen. If it is less than 10 ppm, re-
pressure with nitrogen.

e) Restart the RGC and circulate. Test for CO.

44. Reestablish fires in the reactor feed furnaces to maintain the reactor temperatures
above 205°C for at least 2 hours, and then analyze the recycle gas for CO. If the CO
content still exceeds 10 ppm, go back and repeat the de-pressuring, purging, and
pressuring steps.

WARNING!

THE REACTOR SHOULD BE DE-PRESSURED BELOW 25% OF DESIGN, MEASURED AT THE

REACTOR INLET, BEFORE ANY TEMPERATURE ON ANY REACTOR OR HHPS DROPS BELOW
MPT.

45. Continue to reduce reactor feed furnace fires. As the reactor temperatures decrease to
near the MPT, carefully monitor all reactor temperatures.
46. Before MPT is reached, de-pressure the reactor section to below 25% of design,
measured at thereactor inlets. This can be done by testing the Emergency De-
pressuring Valves.

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47. When the reactor feed furnace is no longer needed to control the cooling rate, pull the
fires, and purge the firebox. Block and blind the fuel gas supply.
48. Convert the furnace to an air cooler by opening furnace dampers, air registers,
available inspection ports, etc.

CAUTION:

The exterior of the furnace tubes are susceptible to stress corrosion cracking, especially in
atmospheres near the ocean where the presence of chlorides in the air is higher. Furnace
box temperatures must be maintained at least 15°C above the dew pointduring the entire
shutdown. This can be accomplished using space heaters and/or de-humidifiers.

49. Continue circulating recycle gas until the entire reactor (including the shells) has cooled
to within 10°C of the reactor feed furnace outlet temperatures, or until the hottest
reactor temperatures (including the outer wall skin thermocouples) are below 45°C.
The reactor will not cool down lower than the recycle gas compressor discharge
temperature.
50. When the reactor can no longer be cooled using recycle gas, shut down and isolate the
recycle and make-up hydrogen compressors.
51. Isolate the reactor section from the other sections
52. Shut down amine circulation to the HP Amine Absorber, T-4001.
53. De-pressure the reactor section and then purge the system with nitrogen.
54. Continue sweeping nitrogen through the high pressure loop and out to the flare, via the
recycle gas compressor suction high set point pressure controller, to cool the reactor to
allow for vessel entry. Use reactor shell temperatures as a guide. Independently purge
nitrogen through reactor to accomplish final cooling.

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55. Test that combustibles have been purged from the reactor section. If necessary,
pressure the reactor section with nitrogen, depressure again to the flare, and repeat as
necessary to lower hydrogen concentrations to acceptable limits. The reactor section is
now ready for installation of isolation blinds, and/or opening.

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