SPM-700 Distillation Operator Training Manual

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Questions and Answers

What is the primary purpose of the SPM-700 Distillation Operator Training Manual?

  • To provide technical support contact information
  • To instruct operators on how to use the SPM-700 (correct)
  • To list all trademarks and copyrights of the company
  • To outline the company's history and achievements

Which of the following is true regarding Simtronics Corporation?

  • It is a publicly traded company
  • It is based in Little Silver, NJ (correct)
  • It was established in the 1960s
  • It specializes in diverse product lines unrelated to distillation

What is indicated by the document revision number in the manual?

  • The current version of the manual (correct)
  • The number of revisions that have occurred since the first version
  • The year the manual was first published
  • The frequency of updates to the manual

What characteristic do the flow control valves FCV-801 and FCV-802 share?

<p>Linear flow characteristics (D)</p> Signup and view all the answers

What is the primary function of the block valves BV-801 and BV-802?

<p>To block flow in the overhead product line (A)</p> Signup and view all the answers

How is the feed flow controlled in the SPM-700 system?

<p>Through flow controller FIC-101 (A)</p> Signup and view all the answers

Which instrument tracks the weight percent of lights in the feed flow loop?

<p>AI-101 (A)</p> Signup and view all the answers

What maximum flow rate can the reflux flow line and overhead product flow line handle?

<p>500 GPM (A)</p> Signup and view all the answers

Which temperature indicators are associated with the ThermOil flow loop?

<p>TI-201 and TI-202 (B)</p> Signup and view all the answers

What is the role of temperature controller TIC-102 in the system?

<p>To control the ThermOil flow (D)</p> Signup and view all the answers

How many theoretical stages in the distillation column have temperature indicators and composition analyzers?

<p>Eight stages (B)</p> Signup and view all the answers

What is the default binary mixture configured in the SPM-700 Distillation Column Process Simulation?

<p>Hexane and Heptane (C)</p> Signup and view all the answers

Which equipment is responsible for raising the feed temperature to the optimum level in the distillation process?

<p>Preheater (E-101) (A)</p> Signup and view all the answers

What type of distillation column is utilized in the SPM-700 process?

<p>C-301 process column (C)</p> Signup and view all the answers

What happens to the vapors from the distillation column (C-301) after they are condensed?

<p>They enter a reflux drum (D-701). (B)</p> Signup and view all the answers

What is the maximum flow rate of hot ThermOil to the preheater (E-101)?

<p>1000 GPM (D)</p> Signup and view all the answers

Which pump is used to move the bottoms product out of the distillation column?

<p>P-501/2 (D)</p> Signup and view all the answers

How many theoretical stages does the distillation column (C-301) consist of?

<p>8 (D)</p> Signup and view all the answers

During the distillation process, what is the purpose of the thermosyphon type reboiler (E-401)?

<p>To provide heat to the distillation column (C)</p> Signup and view all the answers

What is the role of the temperature control valve (TCV-501) in the reboiler (E-401)?

<p>To modulate the flow rate of hot ThermOil (B)</p> Signup and view all the answers

What is the role of the vent line in the SPM-700 distillation process?

<p>To vent uncondensed vapors (C)</p> Signup and view all the answers

Which component is used to accumulate liquid in the distillation process?

<p>Reflux drum (D-701) (D)</p> Signup and view all the answers

What is the capacity of the primary bottoms product pump (P-501)?

<p>500 GPM (D)</p> Signup and view all the answers

What type of heat exchanger is the reboiler (E-401)?

<p>Countercurrent tube and shell type (B)</p> Signup and view all the answers

When operating under design conditions, how is the condenser (E-601) operated?

<p>As a total condenser (A)</p> Signup and view all the answers

What is the purpose of the block valves (BV-401 and BV-402) in the reboiler system?

<p>To block in the hot ThermOil (D)</p> Signup and view all the answers

How is the bottom product flow rate controlled in the distillation column system?

<p>With a level control valve (A)</p> Signup and view all the answers

What is the purpose of cascading the feed tray temperature to the preheated feed temperature?

<p>To ensure the feed enters the column at the optimum temperature. (D)</p> Signup and view all the answers

Which component directly affects the reflux drum outlet temperature?

<p>Condenser cooling water flow rate (FIC-601) (B)</p> Signup and view all the answers

How does an increase in reflux rate impact the column bottoms temperature?

<p>It decreases the column bottoms temperature. (D)</p> Signup and view all the answers

What does the pressure differential (PDI-301) indicate?

<p>The load on the distillation column. (C)</p> Signup and view all the answers

What is the relationship between tray 8 temperature and reflux rate in a cascaded control system?

<p>Reflux rate is controlled based on tray 8 temperature. (C)</p> Signup and view all the answers

How can reflux flow rate be controlled in the distillation simulation?

<p>By setting the reflux flow rate controller (FIC-801) to automatic. (C)</p> Signup and view all the answers

Which of the following parameters does NOT affect the overhead temperature?

<p>Feed tray temperature (TI-305) (D)</p> Signup and view all the answers

What should be done to keep the temperature of the feed consistent with the feed tray?

<p>Cascade the feed tray temperature to the preheated feed temperature. (A)</p> Signup and view all the answers

What is the setpoint for the reflux to tower flow controller FIC-801?

<p>200.0 GPM (C)</p> Signup and view all the answers

What action should be taken with the bottoms temperature controller TIC-501 at 00:15:39?

<p>Set controller mode to automatic (B)</p> Signup and view all the answers

What should the output of the reflux drum level controller LIC-701 be adjusted to at 00:19:06?

<p>28.0% LVL (C)</p> Signup and view all the answers

What was the output set for the bottoms level level controller LIC-301 at 00:08:15?

<p>15.0% (B)</p> Signup and view all the answers

Which of these outputs was adjusted during the time frame provided, and what was one of those adjustments for LIC-301?

<p>Output set to 14.0% (C)</p> Signup and view all the answers

What should the output for the reflux drum level controller LIC-701 be at 00:14:45?

<p>26.0% LVL (A)</p> Signup and view all the answers

During the procedure, how much was the output adjusted to for the reflux drum level controller LIC-701 at 00:17:04?

<p>27.0% LVL (B)</p> Signup and view all the answers

What action is specified after adjusting the bottoms temp temperature controller TIC-501 to 204.6 DEG F?

<p>Place the controller mode in automatic (A)</p> Signup and view all the answers

Flashcards

FCV-801

A flow control valve that regulates reflux flow with linear characteristics.

FCV-802

A flow control valve that regulates overhead product flow with linear characteristics

BV-801 & BV-802

Block valves used to stop the flow of overhead product.

500 GPM

Maximum liquid flow capacity for reflux and overhead product lines.

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Composition Analyzer (AI-101)

Measures the weight percent of 'lights' in the feed stream.

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Feed Flow Controller (FIC-101)

Controls the flow of feed to the distillation column.

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ThermOil Flow Indicator (FI-201)

Displays the flow rate of the ThermOil in the preheater loop.

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Temperature Controller (TIC-102)

Regulates the flow of ThermOil in the preheater based on temperature.

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Simtronics Corporation

A privately held company that develops and distributes products and documentation.

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SPM-700 Distillation

A specific distillation unit model.

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Operator Training Manual

A document that provides instructions for operating the machine.

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Document Revision 9

Version of the document, indicating updates or changes.

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Copyright (1992-2014)

Ownership and rights related to the content.

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ThermOil Flow Rate (Preheater)

The rate at which hot ThermOil is pumped to the preheater, controlled by TCV-102.

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Distillation Column Capacity

The maximum feed rate the distillation column (C-301) can handle, approximately 500 GPM.

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Reboiler ThermOil Flow

The rate of hot ThermOil to the reboiler (E-401), controlled by TCV-501.

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Bottoms Product Pump Capacity

Maximum liquid flow the bottoms product pump (P-501) can manage, approximately 500 GPM.

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Distillation Column Description

Cylindrical vessel with multiple trays, reboiler, and condenser (E-601) for separating liquid components—C-301

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Total Condenser Operation

Condenser (E-601) operating at design to condense all vapors

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Reboiler Type

The reboiler (E-401) is a thermosyphon countercurrent tube and shell heat exchanger.

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Bottoms Product Flow Control

Bottoms product flow rate is controlled by level control valve (LCV-301).

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SPM-700 Distillation

A process simulation that separates paraffin mixtures (methane to octane).

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Distillation Column (C-301)

The core piece of equipment in the process that separates components by boiling point.

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Feed Tray (Default Tray 5)

A specific location within the distillation column where the mixture enters the column.

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Reboiler (E-401)

Heats the distillation column from the bottom to vaporize the components.

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Overhead Condenser (E-601)

Cools vapor to condense into liquid, collecting the higher-boiling fraction.

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Reflux Drum (D-701)

Accumulates the condensed liquid from the overhead condenser after the separating process.

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Paraffins C1-C8

A group of hydrocarbons; methane, ethane, propane, butane, pentane, hexane, heptane, and octane.

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Process Description

A detailed explanation of the process flow in the SPM-700 distillation column.

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Adjust bottoms temp. TIC-501

Modifying the temperature of the bottoms material using the temperature controller TIC-501.

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Reflux to tower flow FIC-801

Adjusting the flow of reflux to column using controller FIC-801.

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Reflux drum level controller LIC-701

Adjusting the level of reflux in a drum using a level controller.

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Bottoms level LIC-301

The controller managing the level of the bottoms product.

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Setpoint to 200.0 GPM

Setting the target flow rate of reflux at 200 GPM.

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Controller Mode (AUTOMATIC)

Operating the controller in automatic mode, allowing the controller to automatically maintain a desired value.

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OUTPUT to 25.0 % LVL

Setting the output of the reflux drum level controller to 25% to regulate the level.

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OUTPUT to 15.0 %

Setting the controller's output to 15% for bottoms level control.

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Feed Temperature Control

Controlling the temperature of feed entering the distillation column by using a temperature controller (TIC-102), often cascaded to the feed tray temperature.

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Reflux Rate Control

Controlling the reflux flow rate (FIC-801) to the distillation column. Sophisticated methods cascade the tray temperature to control reflux.

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Column Bottoms Temperature

The temperature at the bottom of the distillation column. Changes in reflux rate or ThermOil rate directly affect the temperature in this area.

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ThermOil Rate Relationship

The ThermOil rate (TIC-501) is related to the column bottoms temperature. Changes in bottoms temperature affect this rate.

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Column Pressure Differential

The pressure difference across the distillation column (PDI-301). This indicates problems with reflux and/or ThermOil flow rates.

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Condenser Cooling Water

Regulated by the flow controller (FIC-601) to adjust condenser cooling water flow

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Reflux Drum Temperature

The temperature of the reflux drum outlet (TI-801). Impacts overhead temperature.

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Overhead Temperature Control

Controlling the temperature of the overhead product (TIC-308) done through cascading the tray temperature with reflux rate.

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Study Notes

SPM-700 Distillation Operator Training Manual

  • Version: 6.3
  • Revision: 9
  • Contact Information: Simtronics Corporation, phone numbers, email, and address are provided.
  • Business Hours: 8 AM - 5 PM Eastern Time, Monday through Friday.
  • Technical Support Hours: 8 AM - 5 PM Eastern Time, Monday through Friday.
  • Product Specifications: The SPM-700 distillation column can separate a binary mixture of any two paraffins C1 through C8. Default configuration is hexane (C6) and heptane (C7).
  • Equipment Specifications:
    • Feed Pump (P-101): Rated at 25 horsepower, capable of supplying 500 GPM of feed. Spare pump (P-102) is provided.
    • Preheater (E-101): Countercurrent tube and shell heat exchanger. 500 GPM of hot Thermoil at 500 Deg F, raising the feed temperature to 175.9 Deg F.
    • Distillation Column (C-301): Cylindrical, 10 feet in diameter, 36 feet high with 8 theoretical stages and a condenser (E-601) stage. Designed to process a maximum of approximately 500 GPM of feed.
    • Reboiler (E-401): Thermosyphon countercurrent heat exchanger with approximately 1000 GPM of hot Thermoil.
    • Bottoms Product Pump (P-501): 25 horsepower, 500 GPM capacity, pumps the bottoms product from the distillation column. A spare pump (P-502) is also provided.
    • Overhead Condenser (E-601): A countercurrent heat exchanger. Requires 2000 GPM of cooling water to condenser.
    • Overhead Condenser (E-601)- Overhead vapor is condensed, and the liquid is accumulated in the reflux drum. Further refining to 91.1 Wt % of lights (hexane) and 156.6 Deg F.
    • Reflux Drum (D-701): Cylindrical drum, 5 feet in diameter and 15 feet in length, has a total capacity of 2,666 gallons of fluid.
    • Process Flow & ID Diagrams: Multiple diagrams provide visual representation of the system components, process flows, process variables, and instrument IDs.
    • Instrumentation: Basic and advanced control systems, composition and temperature indicators, flow rate indicators, level indicators, pressure indicators, etc.

Process Description

  • Feed pumped to preheater, temperature raised.
  • Column heated by a thermosyphon reboiler.
  • Bottoms product pumped to storage.
  • Overhead vapors condensed in an overhead condenser (E-601)
  • Liquid accumulates in the reflux drum (D-701).
  • Liquid pumped back to column as reflux.
  • Approximately 235 GPM of 50 wt % hexane and 50 wt % heptane separation.

Normal Operations

  • Detailed table with tag IDs, description, design value, engineering units, and output values (Percent) for various process parameters.

Pre-Startup Procedure

  • Notify personnel
  • Clean and purge lines and equipment
  • Pressure test lines
  • Calibrate instruments
  • Commission equipment.

Startup Procedure

  • Step-by-step instructions with time estimations in hours and minutes.
  • Examples of procedure actions: Open valves, adjust controllers, set points etc

Shutdown Procedure

  • Step-by-step instructions with time estimations in hours and minutes
  • Examples of procedure actions: Close valves, adjust controllers, etc.

Emergency Operations

  • Steps to take in emergency situations
  • Procedures to follow for emergency shutdowns.

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