INTRODUCTION

To shut down the Perstorp formaldehyde plant in a safe way, the procedures presented in these
chapters should be followed carefully. The shutdown procedure differs if the plant is shut down
for maintenance or to stand-by conditions.

In case the safety system shuts down the plant or parts of the plant, the procedures in section 10
(doc.no. 64-D2. 10.2 to 64-D2.lO.4) should be followed.
2 SHUTDOWN

The following procedure describes how the whole plant should be shut down for an
extended period or to stand-by conditions. The procedure is not a checklist, but describes
what actions should be taken and what to take into consideration.

2.1 Stop feeding Urea

• Stop the caustic feed pump to the urea feed line to the top of first stage absorber.

• Re-route the condensate to the first absorber by closing the manual valve(50117c)
to the condensate tank and opening (50118a) to the top tray of the first absorber.

• Place the urea controller FQIC-81001 in manual mode and close.

• Close one manual valve in the urea feed line and shut off the urea feed pump.

2.2 Stop feeding methanol

• Afler urea feed is stopped run the methanol feed until the urea is diluted on the
valve trays (15 minutes recommended).

• Decrease the methanol flow until the inlet is below 6.5 %.

• Stop the methanol feed with the B-interlock from the DCS.

• Valves AV-30045, FV-30042 and HV-30024 will automatically close.

• Set the oxygen controller (AIC-30023) to manual and freeze the position of valve
AV-30023.

• Close at least one manual valve in the methanol line.

2.3 Stop feeding Caustic

• Stop the caustic feed pumps.

2.4 Stop the fans

• Wait one minute afier the methanol has been shut off.

• Stop at least one fan in the field.

 • The A-interlock will be activated and the other fans will automatically be shut off.

2.5 Decrease the pressure in the HTF system

• Set pressure controller PICS-40026 to manual and freeze the positions of valves
PV-40026 A/B.

• Open the atmospheric valve (40122a) when the HTF temperature (TI-40021) is
below 257 °C. (There is a risk of flashing HTF if the atmospheric valve is opened too
early.)

• Set overpressure controller PICS-40026 to zero.

2.6 Reduce the cooling water through the plant

• Minimize the cooling water flow to absorber C-5004, heat exchanger H-5009 and
heat exchanger H-5010 by closing valves 91140c, 9111la and TV50101 (Place in
manual mode and close).

• Open by-pass valve 91103c partly.

2.7 Stop feeding caustic to the absorber (FA)

• Stop the caustic pump.

• Close the manual valve to the second absorber.

2.8 Prepare the plant for stand-by

• Close one manual valve in the BFW line to the HTF condenser.

• Decrease the process water flow (FICS-83021) in “auto” to the minimum level
that will not allow the trays to become dry.

Check regularly:
 • The product temperature (TIC-50011).

• The product concentration (AIC-50064).

• If the temperature falls below the concentration, dilute the lower absorber
circulation with BFW from the BFW tank or with low pressure steam.

• If the HTF temperature (TI-40021) falls below 250 °C, start to circulate HTF
over the reactor and the HTF condenser.

• Start to circulate HTF in accordance with the procedure in section 8 (doc.no.

64-D2.8.4 chapter 4.5).

• Start the HTF heater in accordance with the procedure in section 8 (doc.no. 64-
D2.8.2 chapter 2.2 or 64-D2.8.3 chapter 3.2).

2.9 Prepare the plant for shutdown for an extended period or maintenance

• Prepare the systems in accordance with the procedure in doc.no. 64-D2.9.3.

• Prepare the absorber system in accordance with the procedure in chapter 3.1.

• Prepare the BFW system in accordance with the procedure in chapter 3.2

• Prepare the HTF system in accordance with the procedure in chapter 3.3.

• Turn off the condensate pump.

If there is a risk of freezing, drain the systems which have no steam or electrical tracing.

3 PREPARATIONS FOR AN EXTENDED SHUTDOWN

Preparations when the plant should be shutdown for an extended shut down or
maintenance.

3.1 Absorber system

• Wash down the absorbers with water and empty the towers. It will take
approximately one day.

• Decrease the liquid level in absorption tower C-5002 to the lower limit of the
level glass in order to reduce amount of off spec product.
• Open the bypass valve (83102a) over control valve FV—83021 to increase the

water flow to absorber C-5004.

• Check the valving if the dilute formaldehyde/UFC should go to a separate tank.

To get proper washing of the valve trays run the fans on minimun circulation for two
times one hour during the washing period.

Continue when the formaldehyde concentration has dropped to less than 1% in the
lower circulation. Please observe local regulations.

• Close the bypass valve (83102a) over control valve FV-83021.

• Set process water controller FIC-83021 to manual and close valve FV-83021.

• Close the manual valves around FV-83021.

• Stop the circulation pumps.

• Close the valves after the circulation pumps.

• Empty the towers.

• Set level controller LIC-50043 to manual and close valve LV-50043.

• Close the manual valves around LV-50043.

• Set level controller LIC-50021 to manual and close valve LV-50021.

• Close the manual valves around LV-50021.

3.2 BFW system

• Close one manual valve in the BFW line to the HTF condenser.
• Turn off the BFW pump.
• Close the valves afier the pump.
• Close one manual valve in the BFW line to the BFW tank.
• Close the valves in the LP steam lines to the BFW tank.
• Close manually the steam valves from the HTF condenser.
3.3 HTF system

 Ensure that the manual valve (40122a) between HTF condenser and tank is open.
 Close the manual valves around PV-40026 A/B.
 The HTF can be drained into the storage tank when the HTF temperature is less than
100°C.
 Open the valve between the HTF heater and the reactor (40106a).
 Open the valve between the HTF heater and the storage tank (40105a).
 Drain the HTF into the tank.
 Close the valves.
 If the HTF is not drained into the storage tank, it should be circulated over the reactor and
the HTF condenser.
 Start to circulate HTF in accordance with the procedure in section 8 (doc.no.
64-D2.8.5 chapter 4.5).
 Start the HTF heater in accordance with the procedure in section 8 (doc.no. 64-
D2.8.2 chapter 2.2 or 64-D2.8.3 chapter 3.2).

During every extended shutdown, test the time it takes to close the methanol safety valve,
AV 30045. If possible, check the other parts of the safety system.