Module 7 - Emergency Procedures

Module from the Hydroprocessing Operations Curriculum curriculum.

EMERGENCY PROCEDURES · Learning Objectives · 1. Respond to reactor temperature runaway with immediate quench and feed cut 2. Manage loss of quench gas or recycle gas compressor trip 3. Execute controlled depressurization during emergencies 4. Handle hydrogen leaks in high-pressure systems 5. Coordinate emergency response with control room and safety teams · Emergency Response Matrix

Emergency	Immediate Action (0-2 min)	Operator Response (2-10 min)	FOS Chief Role	Communication	Post-Incident
Reactor Temp Runaway (ΔT >50°F/min)	1) CUT FEED 2) Max quench all beds 3) Emergency depressure if ΔT >100°F/min	Monitor all bed TCs, maintain H2 circulation, prepare for controlled shutdown	Direct response, coordinate with control room, authorize depressure	Radio all boards, notify plant manager, call technology center	Root cause analysis, catalyst assessment, inspect internals if depressured
Loss of Recycle Gas Compressor	1) CUT FEED immediately 2) Maintain reactor temperature 3) Do NOT increase temperature	Start spare compressor if available, prepare for controlled cool-down if no spare	Authorize feed cut, coordinate compressor restart	Notify maintenance, control room, management	Investigate cause, check for coking (H2 starvation), monitor restart carefully
Loss of Quench Gas	1) Reduce feed rate 50% 2) Reduce heater firing 3) Monitor bed ΔTs closely	Investigate cause (valve failure, header pressure), restore quench ASAP	Direct troubleshooting, authorize feed rate reduction	Notify instrument/maintenance, control room	Check bed temperature profiles, verify no catalyst damage
High Reactor ΔP (>2× normal)	1) Reduce feed rate 2) Monitor for further increase 3) Prepare for controlled shutdown	Check for rapid increase (indicates catalyst migration or internal failure)	Assess severity, determine if shutdown required	Notify operations management, plan shutdown if needed	Inspect internals, check catalyst bed, assess cause (fines, fouling, migration)
H2 Leak (high-pressure system)	1) Evacuate area 2) Eliminate ignition sources 3) Isolate source if safe	Gas detection monitoring, determine leak source, prepare for isolation	Direct response, authorize isolation, coordinate with safety	Emergency alarm, notify fire brigade, H2S/LEL monitoring	Investigate cause, repair, pressure test before restart
Power Failure	1) Verify auto-start of emergency generator 2) Confirm critical loads on UPS 3) Execute emergency shutdown procedure	Verify all critical instruments on UPS, control valves fail-safe, compressor coast-down	Coordinate orderly shutdown, ensure safety systems functional	Notify all personnel, confirm muster, update management	Restart procedure — follow full startup sequence, do not rush
Source: FOS Chief Files — Emergency_Procedure_Template_Library_v1.xlsx, Hydroprocessing Design Manual, Chief School Module G

Source: Hydroprocessing_Operations_Curriculum_v1.xlsx · Sheet: Module 7 - Emergency Procedures

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