Sulfiding Contingency Guideline

Loss of Recycle Gas Compressor

In case of Recycle Gas Compressor Tripping, Charge pump and Combined Feed Heater
will automatically trip by ESD112 and ESD136
a) Below 245°C – Temperature is low enough that metal reduction is not possible.
Await reinstatement of Recycle Gas Flow if duration of non-availability of the
Compressor is less than 4 hours. If duration is longer than 4 hours, reduce Reactor
Bed Peak temperature below 205°C.
b) Above 245°C – Temperature is high enough to cause metal reduction. Start routing
Make up Hydrogen in the Compressor discharge to bring down the temperature. If
Hydrogen routing can not be done, depressurize to bring down Bed Peak
temperature to less than 245°C. Upon completion of low rate de-pressuring, re-
pressurize the unit with make up Hydrogen to increase the Reactor pressure. For
non-availability of the Compressor for longer duration, it is recommended to cool the
Unit further to below 150°C.

Loss of Hydrogen Make up

Hydrogen is consumed during activation by the liquid Feed. With the loss of make up
Hydrogen gas flow, Hydrogen level can deplete and can affect sulfiding of the catalyst.

If the make up Hydrogen flow can be re-instated in less than 4 hours, reduce Reactor
temperature to below 205°C and stop the Sulfiding agent injection. Monitor Hydrogen in
the Recycle Gas stream.

If the make up Hydrogen flow can be re-instated only in more than 4 hours, reduce
Reactor temperature to below 205°C, stop the Sulfiding agent injection and stop Charge
Pump. Monitor Hydrogen in the Recycle Gas stream.

Loss of Charge Pump

If the Charge pump trips, DMDS injection also stops. This is critical during the sulfiding
stages as sulfur is still being absorbed by the catalyst and H2S level in the recycle gas
can drop to a level where metal reduction is possible.

a) Below 245°C – Loss of Feed pump is not critical as long as Reactor temperatures
are less than 245°C. If pump non-availability is longer than 4 hours, reduce Reactor
temperature below 205°C.
b) Above 245°C – Reduce Reactor temperature below 245°C using Recycle Gas
circulation and await for the Pump to be fixed. If duration of the pump non-availability
is more than 4 hours, reduce Reactor temperature below 205°C.

Exotherm during Sulfiding

Sulfiding reactions are exothermic and particularly at the start of the sulfiding, sharp
increase of catalyst bed temperature might be observed. In the event that a temperature
excursion occurs during Sulfiding, fuel to the Combined Feed Heater should be cut and
DMDS injection to be stopped.
Decline in H2S level of the Recycle Gas
This contingency is specially aimed at the Second stage Sulfiding where maintaining
H2S level above 1000 ppm is critical to prevent metal reduction.

Reactor outlet H2S concentration should be maintained min 3000 ppm always.

If H2S level falls below 1000 ppm, keep Reactor temperature constant until H2S
concentration greater than 3000 ppm is re-established. Increase DMDS injection rate. If
after 2 hours H2S level does not come back to more than 3000 ppm, then reduce
Reactor temperature at the rate of 20°C per hour monitoring H2S content in Recycle
Gas. Once 245°C Reactor temperature has been achieved, stop Reactor Temperature
reduction.

Loss of DMDS Pump

This contingency is specially aimed at the First and Second stage Sulfiding where
maintaining H2S level above 1000 ppm is critical to prevent metal reduction.

a) Below 245°C – If DMDS can be reintroduced in less than 4 hours, hold Reactor
temperature below 245°C. If the DMDS injection can not be restarted within 4 hours,
reduce Reactor temperature below 205°C.

b) Above 245°C – If DMDS can be reintroduced in less than 4 hours, reduce Reactor
temperature below 245°C and monitor H2S in Recycle Gas. If H2S content in the
Recycle Gas is less than 1000 ppm, reduce Reactor temperature to 205°C. If
duration of the pump non-availability is more than 4 hours, start Feed only sulfiding
with once through line up of the Unit.