633 Loss of Compressor (63-EOP-5040)

Question 1

info - If a compressor cannot be placed back in service within 10 minutes of the trip, liquid feed to the unit must be stopped.

Answer 1

CCR - 1.1.1 - REDUCE feed rate to minimum once the compressor shuts down.

Question 2

CCR - 1.1.2 - VERIFY that the 633F0001, Reactor Heater SIS has not activated isolating the fuel gas to the burners if running at a minimum rate.

Answer 2

OPER - 1.1.3 - CHECK for cause of compressor shutdown:
- High Level in Makeup H2 KO Drum
- High Level in Recycle H2 KO Drum
- High Level in Interstage KO Drum
- Lube Oil pressure (10 psig)
- High Motor Amps
- High Cylinder Temperature (350 degrees F)
- Compressor unloaded
- Cooling Water pressure
- High Motor Winding Temperature (293 degrees F)

Question 3

1.1.4 - IF the cause of the shutdown can be resolved within 10 minutes of the compressor shutdown,
PERFORM the following:

OPER - A - CORRECT the issues that caused the compressor shutdown

CCR - B - DECREASE set point on 633 Unit Pressure Controller (63PC0201), by ~40 psig.

OPER - C - ATTEMPT TO RESTART the compressor or START the Spare Compressor

OPER - D - RETURN unit to normal unit operation

Answer 3

OPER/CCR - 1.1.5 - IF the cause of the compressor shutdown CANNOT be resolved within 10 minutes of the compressor shutdown or the compressor will not start,
DIVERT feed away from the unit to maintain 50% level in the feed surge drum.

Question 4

CCR - 1.1.6 - NOTIFY the following of loss of compressor:
-Asset Team Shift Supervisor (Shift FLS)
-Chief Operator

Answer 4

CCR - 1.1.7 - If gas flow to 633 Unit is less than Minimum,
PERFORM the following to adjust Quench to Reactor.

A - DECREASE setpoint on 63FC0001 Fresh Feed Controller to minimum feed flow rate for the unit, which is 1550bph

B - Place the following controllers in Auto with a Minimum setpoint:
- Second Reactor Bed Hydrogen Quench Flow Controller (63FC0214)
- Third Reactor Bed Hydrogen Quench Flow Controller (63FC0215)
- Fourth Reactor Bed Hydrogen Quench Flow Controller (63FC0216)

C - ADJUST the following Controllers to maintain Reactor Bed temperatures as needed:
- Second Reactor Bed Temperature Controller (63TC0213)
- Fourth Reactor Bed Temperature Controller (63TC0221)

D - DECREASE setpoint on Stripper Hydrogen Flow Controller (63FC0212) to maintain minimum Hydrogen flow to the reactor

Question 5

OPER/CCR - 1.1.8 - IF Hydrogen Makeup & Recycle Compressor will NOT Start and a Spare 635 Compressor (635C0001), is available,
PERFORM the following:

Answer 5

OPER - A - ENSURE chain operated valves on Makeup and Recycle lines from 635 Unit to 633 Unit located by Makeup and Recycle Knockout Drums in 633 Unit are Open.

B - CLOSE discharge valves on 635 Spare Compressor to 635 Spare Compressor

C - CLOSE valve on Recycle Suction line from 635 Unit to 635 Spare Compressor.

D - OPEN valve on Recycle Suction line from 633 Unit to 635 Spare Compressor.

E - PLACE Safety Protection System (SPS), Hand Switch for 635 Spare Compressor located on north side of 635 Compressor Deck in ENABLE position.

F - OPEN discharge valve on 635 Spare Compressor to 633 Unit.

G - START Spare Compressor in 635 Unit and LOAD Spare Compressor as needed to maintain adequate gas flow to 633 Unit

Question 6

CCR - H - RESET Safety Instrumented System (SIS), on Reactor Feed Heater (633F0001), in accordance with 63-SOP-1007 633F0001 Reactor Feed / 633F0002 Product Fractionator Reboiler Heater Startup procedure

Answer 6

1.2 Complete Supplemental Actions