SPM-700 Distillation Operator Training Manual PDF

Cover English Units SPM-700 Distillation Operator Training Manual Version 6.3 Information: 1-800-730-0760 Simtronics Corporation...

Cover English Units SPM-700 Distillation Operator Training Manual Version 6.3 Information: 1-800-730-0760 Simtronics Corporation +1-732-747-0322 P.O. Box 38 1-732-224-0009 Fax Little Silver, NJ 07739-0038 USA Technical Support: 1-800-730-0760 [email protected] +1-732-869-6651 Document Revision 9  SPM-700 Manual Operator Front Matter Copyright Copyright © 1992-2014 by Simtronics Corporation. All rights reserved. The Notice Simtronics name and all Simtronics products are trademarks or registered trademarks of Simtronics Corporation. Simtronics Corporation is a wholly owned, privately held, independent, New Jersey Corporation. All Simtronics products, documentation, and sales and marketing literature are developed solely by Simtronics Corporation and are distributed only under the Simtronics name. Any representations to the contrary are false. Other brand and product names mentioned or referred to in this document are trademarks or registered trademarks of their respective holder. Contact Us Hours Business: 8 a.m. – 5 p.m. Eastern Time, Monday through Friday Technical Support: 8 a.m. – 5 p.m. Eastern Time, Monday through Friday Phone Simtronics main: 1-800-730-0760, +1-732-747-0322 Simtronics support: 1-800-730-0761, +1-732-859-6651 Email General information: [email protected] Technical support: [email protected] World Wide Web www.simtronics.com Doc Revision 10 DSS-100 Version 6.3 Page 2  SPM-700 Manual Operator SPM-700 Distillation Contents Topic See Page Process Description 4 Equipment Specifications 5 Process Flow and ID Diagrams 7 Instrumentation 10 Normal Operations 12 Pre-Startup 15 Startup 16 Shutdown 18 Emergency Operations 20 Doc Revision 10 DSS-100 Version 6.3 Page 3  SPM-700 Manual Operator Process Description Process Flow The SPM-700 Distillation Column Process Simulation can be configured to separate a binary mixture of any two of the paraffins C1 through C8 (methane, ethane, propane, butane, pentane, hexane, heptane, and octane respectively). The default configuration is for hexane (C6) and heptane (C7). Any feed tray can be selected. The default is tray 5. The distillation column (C-301) feed is pumped (P-101/2) through a preheater (E- 101) where its temperature is raised to the optimum temperature of the feed tray. The distillation column (C-301) is heated with a thermosyphon type reboiler (E-401). The bottoms product is pumped (P-501/2) out of the distillation column (C-301) to a product storage facility. The distillation column (C-301) vapors are condensed in an overhead condenser (E- 601) and enter a reflux drum (D-701) where the liquid is accumulated. The uncondensed vapors can be vented through a vent line. Reflux pumps (P-801/2) draw liquid from the bottom of the reflux drum (D-701) and pump part of the liquid back (reflux) to the distillation column (C-301). The balance of the liquid is sent to a product storage facility. Product Approximately 235 GPM of 50 WT % hexane and 50 WT % heptane are separated in Specifications the distillation column (C-301). The feed is supplied to the preheater (E-101) at 68 Deg F where its temperature is raised to 175.9 Deg F (the temperature of feed tray 5). 48 GPM of 500 Deg F ThermOil is required to accomplish this task. 240 GPM of 500 Deg F ThermOil heats the bottom of the distillation column (C-301) to 204.6 Deg F in a reboiler (E-401). Approximately 113.4 GPM of bottoms product at 7.3 WT % Lights (Hexane) is produced. Approximately 322 GPM of overhead vapor is condensed in the overhead condenser (E-601). Since all of the overhead vapor is condensed no venting is required. 350 GPM of 68.0 Deg F cooling water is required for this task. Approximately 200 GPM of the condensed vapor is pumped (P-801/2) back to the distillation column (C-301) as reflux. The balance of 121.7 GPM is drawn off as overhead product at 91.1 Wt % Lights (Hexane) and 156.6 Deg F. The distillation column (C-301) is operated at approximately 0 PSIG (atmospheric pressure) and the total column pressure drop is 0.973 PSI. Doc Revision 10 DSS-100 Version 6.3 Page 4  SPM-700 Manual Operator Equipment Specifications Feed Pump A primary feed pump (P-101) is rated at 25 horsepower and is capable of supplying a maximum of approximately 500 GPM of feed to the distillation column (C-301). A spare feed pump (P-102) with the same rating as the primary feed pump is provided. Block valves (BV-101 and BV-102) are provided to block in the feed. Feed flow to the column is modulated by a feed control valve (FCV-101) with linear flow characteristics. Preheater The preheater (E-101) is a countercurrent tube and shell type heat exchanger. The feed passes through the preheater on the shell side while the hot ThermOil passes through on the tube side. The ThermOil flow rate is modulated by a temperature control valve (TCV-102) with linear flow characteristics. Block valves (BV-201 and BV-202) are provided to block in the hot ThermOil. The ThermOil flow loop is designed to provide a maximum of approximately 1000 GPM of hot ThermOil to the preheater (E-101). Distillation The distillation column (C-301) is a cylindrical vessel 10 feet in diameter by 36 feet Column in height consisting of eight theoretical stages (approximately 16 real valve trays with 24 inch tray spacing), plus a reboiler (E-401) stage, and a condenser (E-601) stage. By appropriately adjusting the condenser (E-601) cooling water flow rate and the overhead vapor vent rate, the condenser (E-601) may be operated as a partial condenser or a total condenser. At design conditions, the condenser (E-601) is operated as a total condenser. The distillation column (C-301) is designed to process a maximum of approximately 500 GPM of feed. Reboiler The reboiler (E-401) is a thermosyphon countercurrent tube and shell type heat exchanger. The process fluid passes through the reboiler (E-401) on the shell side, while the hot ThermOil passes through the reboiler (E-401) on the tube side. The ThermOil flow rate is modulated by a temperature control valve (TCV-501) with linear flow characteristics. Block valves (BV-401 and BV-402) are provided to block in the hot ThermOil. The ThermOil flow loop is designed to provide a maximum of approximately 1000 GPM of hot ThermOil to the reboiler (E-401). Bottoms The bottoms product is pumped out of the distillation column (C-301) with a primary Product Pump bottoms product pump (P-501) rated at 25 horsepower. The pump is capable of displacing a maximum of approximately 500 GPM of liquid. A spare bottoms product pump (P-502) with the same rating as the primary pump is provided. Block valves (BV-501 and BV-502) are provided to block in the bottoms product. The bottoms product flow rate is modulated by a level control valve (LCV-301) with linear flow characteristics. The bottom of the distillation column (C-301) allows for approximately 4 feet of liquid before reaching the first real tray. This is approximately a total capacity of 387 ft3 or 2894 gallons of liquid. At design conditions the bottom of the distillation column (C-301) provides approximately 3 minutes of holdup running half full. Continued on next page Doc Revision 10 DSS-100 Version 6.3 Page 5  SPM-700 Manual Operator Equipment Specifications, continued Overhead The overhead condenser (E-601) is a countercurrent tube and shell type heat Condenser exchanger. The overhead vapor passes through the condenser (E-601) on the shell side, while the cooling water passes through the condenser (E-601) on the tube side. The cooling water flow rate is modulated by a flow control valve (FCV-601) with linear flow characteristics. Block valves (BV-601 and BV-602) are provided to block in the cooling water. The cooling water flow loop is designed to provide a maximum of approximately 2000 GPM of cooling water to the condenser (E-601). Reflux Drum The reflux drum (D-701) is a cylindrical drum 5 feet in diameter by 15 feet in length. The reflux drum (D-701) has a total capacity of 2,666 gallons of fluid. At design conditions the reflux drum (D-701) provides approximately 4 minutes of holdup running half full. Overhead The overhead vapor vent line is modulated by a pressure control valve (PCV-701) Vapor Vent with equal percentage flow characteristics. Block valves (BV-701 and BV-702) are Line provided to block in the overhead vapor vent line. The vent line (piping and valves) is designed with sufficient capacity to vent the distillation column (C-301) completely down in an emergency condition. Reflux Pump A primary reflux pump (P-801) rated at 25 horsepower is capable of pumping a maximum of approximately 500 GPM of liquid. A spare reflux pump (P-802) with the same rating as the primary reflux pump (P-801) is provided. The reflux pumps (P- 801/2), pump both the distillation column (C-301) reflux and the overhead product. The reflux flow is modulated by a flow control valve (FCV-801) with linear flow characteristics. The overhead product flow is modulated by a flow control valve (FCV-802) with linear flow characteristics. Block valves (BV-801 and BV-802) are provided to block in the overhead product. Both the reflux flow line and the overhead product flow line are designed to carry a maximum of approximately 500 GPM of liquid. Doc Revision 10 DSS-100 Version 6.3 Page 6  SPM-700 Manual Operator Process Flow and ID Diagrams SPM-700 Distillation: Overview SPM-700 Distillation: Feed System Continued on next page Doc Revision 10 DSS-100 Version 6.3 Page 7  SPM-700 Manual Operator Process Flow and ID Diagrams, continued SPM-700 Distillation: Column Profiles SPM-700 Distillation: Bottoms Continued on next page Doc Revision 10 DSS-100 Version 6.3 Page 8  SPM-700 Manual Operator Process Flow and ID Diagrams, continued SPM-700 Distillation: Overhead Doc Revision 10 DSS-100 Version 6.3 Page 9  SPM-700 Manual Operator Instrumentation Basic Controls The feed flow loop is outfitted with a composition analyzer (AI-101) that measures weight percent lights. Feed supply temperature is indicated by TI-101. Feed block valves can be opened and closed with switches HV-101 and HV-102. Feed pumps can be turned on and off with switches HS-101 and HS-102. Feed flow is modulated by flow controller FIC-101. The preheater (E-101) ThermOil flow loop is outfitted with a flow indicator (FI-201), a ThermOil supply temperature indicator (TI-201), and a ThermOil return temperature indicator (TI-202). ThermOil block valves can be opened and closed with switches HV-201 and HV-202. ThermOil flow is modulated by temperature controller TIC-102. Temperature indicators (TI-301 through TI-308) and composition analyzers measuring weight percent lights (AI-301 through AI-308) are provided for each of the eight theoretical stages of the distillation column (C-301). An overall column pressure drop indicator (PDI-301) is also provided. The reboiler (E-401) is outfitted with a ThermOil supply temperature indicator (TI- 401) and a ThermOil flow rate indicator (FI-401). ThermOil block valves can be opened and closed with switches HV-401 and HV-402. ThermOil flow is modulated by temperature controller TIC-501. The distillation column (C-301) bottoms product line is outfitted with a composition analyzer (AI-501) and a bottoms product flow rate indicator (FI-501). Bottoms product flow rate is modulated by level controller LIC-301. Bottoms product block valves can be opened and closed with switches HV-501 and HV-502. Bottoms product pumps (P-501/2) can be started and stopped with switches HS-501 and HS- 502. The overhead condenser (E-601) is outfitted with a cooling water supply temperature indicator (TI-601). Cooling water flow rate is modulated by flow controller FIC-601. Cooling water block valves can be opened and closed with switches HV-601 and HV-602. The overhead vapor vent line is outfitted with a vent flow rate indicator (FI-701). Column pressure is modulated by pressure controller PIC-701. The vent line block valves can be opened and closed with switches HV-701 and HV-702. Reflux pumps (P-801/2) can be started and stopped with switches HS-801 and HS- 802. Reflux flow rate is modulated by flow controller FIC-801. The overhead product line is outfitted with a temperature indicator (TI-801), a composition analyzer that measures weight percent lights (AI-801), and an overhead product flow rate controller (FIC-802). The overhead product flow rate is controlled by a level controller (LIC-701). Overhead product block valves can be opened and closed with switches HV-801 and HV-802. Continued on next page Doc Revision 10 DSS-100 Version 6.3 Page 10  SPM-700 Manual Operator Instrumentation, continued Advanced Distillation column control can be very simple or very complex, depending upon your Controls particular process and plant. The flexibility and realism of the Simtronics SPM-700 Distillation Simulation allows you to configure the column to more closely resemble your system. The following are a few examples of various ways to control the distillation column. The preheated feed temperature may be controlled by placing temperature controller TIC-102 in automatic and entering the desired setpoint. Since it is optimum for the feed to enter the distillation column (C-301) at the same temperature as the feed tray, the feed tray temperature (TI-305) can be cascaded to the preheated feed temperature (TIC-102) in a master-slave type arrangement. In this manner the feed would always enter the column at the optimum feed tray temperature, and no further adjustments would be required by the operator. Reflux rate (FIC-801) may be controlled simply by putting reflux flow rate controller (FIC-801) in automatic with the desired setpoint. More sophisticated methods of controlling the distillation column (C-301) are possible. By design tray 8 temperature (TIC-308) is cascaded to the reflux rate in a master-slave arrangement. In this manner overhead temperature may be specified with no further adjustments required by the operator. Operating in this manner affects the column bottoms temperature control. An increase in reflux rate (FIC-801) will cool the column bottoms temperature, as will, a decrease in reflux will heat the column bottoms. The temperature change in column bottoms will increase or decrease the ThermOil rate (TIC-501). The column (C-301) pressure differential (PDI-301) is a key indicator in identifying reflux rate (FIC-801) and ThermOil rate (TIC-501) discrepancies. PDI-301 indicates the load on the column. Condenser cooling water flow rate (FIC-601) is specified locally by placing the flow controller in automatic with the appropriate setpoint. FIC-601 flow rate affects the the reflux drum (D-701) outlet temperature (TI-801)..Increasing or decreasing the reflux drum (D-701) temperature will also affect the overhead temperature (TIC- 308) via the reflux flow (FIC-301). Column pressure (PIC-701) is typically controlled by allowing the pressure to float with overhead accumulator (D-701) temperature (TI-801) and composition (AI-801). One alternative is to control column pressure (PIC-701) by varying cooling water flow rate (FIC-601). This is done by cascading the overhead pressure controller (PIC-701) to the cooling water flow rate controller (FIC-601) in a master-slave type arrangement. Another alternative is to adjust condenser cooling water flow rate (FIC-601) such that not all of the overhead vapor is condensed (partial condenser). In this manor column pressure (PIC-701) may be controlled by venting the column. This is accomplished by placing the column pressure controller (PIC-701) in automatic and entering the correct setpoint. Doc Revision 10 DSS-100 Version 6.3 Page 11  SPM-700 Manual Operator Normal Operations Normal Design The following table is a list of the normal design conditions (initial condition 1) for Conditions the SPM-700 Distillation Simulation as provided by Simtronics. Design Output Tag ID Description Eng Units Value Percent AI-101 FEED LIGHTS 50.0 WT% AI-301 TRAY 1 LIGHTS 13.4 WT% AI-302 TRAY 2 LIGHTS 21.7 WT% AI-303 TRAY 3 LIGHTS 31.4 WT% AI-304 TRAY 4 LIGHTS 40.6 WT% AI-305 TRAY 5 LIGHTS 47.9 WT% AI-306 TRAY 6 LIGHTS 56.4 WT% AI-307 TRAY 7 LIGHTS 67.5 WT% AI-308 TRAY 8 LIGHTS 79.9 WT% AI-501 BOTTOMS PRODUCT 7.3 WT% AI-801 OVERHEAD PRODUCT 91.1 WT% FI-201 PREHEAT THERMOIL 48 GPM FI-401 REBOILER THERMOIL 240 GPM FI-501 BOTTOMS PRODUCT 113.4 GPM FI-701 VENT VAPOR 0.0 ACFM FIC-101 FEED TO TOWER 235.0 GPM 30.8% FIC-601 CONDENSR COOL WTR 350 GPM 17.5% FIC-801 REFLUX TO TOWER 200.0 GPM 27.4% FIC-802 OVERHEAD PRODUCT 121.7 GPM 16.7% HS-101 FEED PUMP Run HS-102 FEED SPARE Stop HS-501 BOTTOMS PUMP Run HS-502 BOTTOMS SPARE Stop HS-801 REFLUX PUMP Run HS-802 REFLUX SPARE Stop HV-101 FEED BLK VLV Open HV-102 FEED BYPASS Close HV-201 PREHEAT THERMOIL Open HV-202 PREHEAT BYPASS Close HV-401 REBOILER THERMOIL Open HV-402 REBOILER BYPASS Close HV-501 BOTTOMS PRODUCT Open HV-502 BOTTOMS BYPASS Close HV-601 CONDENSR COOL WTR Open HV-602 CONDENSR BYPASS Close HV-701 TOWER VENT Open HV-702 VENT BYPASS Close HV-801 OVERHEAD PRODUCT Open HV-802 OVERHEAD BYPASS Close LIC-301 BOTTOMS LEVEL 50.0 % LVL 14.1% LIC-701 RFLX DRM LEVEL 50.0 % LVL 24.3% PDI-301 DELTA P COLUMN 0.972 PSI PIC-701 TOWER PRESSURE 0.0 PSIG 0.0% TI-101 FEED SUPPLY 68.0 DEG F TI-201 THERMOIL SUPPLY 500.0 DEG F TI-202 THERMOIL RETURN 82.9 DEG F TI-301 TRAY 1 TEMP 199.2 DEG F Doc Revision 10 DSS-100 Version 6.3 Page 12  SPM-700 Manual Operator Design Output Tag ID Description Eng Units Value Percent TI-302 TRAY 2 TEMP 192.6 DEG F TI-303 TRAY 3 TEMP 185.9 DEG F TI-304 TRAY 4 TEMP 180.2 DEG F TI-305 TRAY 5 TEMP 175.9 DEG F TI-306 TRAY 6 TEMP 171.4 DEG F TI-307 TRAY 7 TEMP 166.1 DEG F TI-401 THERMOIL SUPPLY 500.0 DEG F TI-601 COOL WTR SUPPLY 68.0 DEG F TI-801 OVERHEAD PRODUCT 156.6 DEG F TIC-102 FEED TEMP 175.9 DEG F 4.8% TIC-308 TRAY 8 TEMP 160.9 DEG F 0.0% TIC-501 BOTTOMS TEMP 204.6 DEG F 24.0% Continued on next page Doc Revision 10 DSS-100 Version 6.3 Page 13  SPM-700 Manual Operator Normal Operations, continued Normal Below are the major process variables to be polled. Production Monitoring The other process variables should be periodically polled to ensure normal process operation. Tag ID Description AI-101 FEED COMPOSITION AI-501 BOTTOMS COMPOSITION AI-801 OVERHEAD COMPOSITION FI-501 BOTTOMS PRODUCT FLOW RATE FI-701 VAPOR VENT RATE FIC-101 FEED FLOW RATE FIC-601 REFLUX FLOW RATE FIC-802 OVERHEAD PRODUCT FLOW PIC-701 COLUMN PRESSURE TI-801 OVERHEAD TEMPERATURE TIC-102 FEED TEMPERATURE TIC-501 BOTTOMS TEMPERATURE Adjusting To smoothly increase or decrease feed flow rate, the feed flow controller (FIC-101) Production setpoint should be modulated. To smoothly change product compositions, the column bottoms temperature controller (TIC-501), column pressure controller (PIC-701), condenser cooling water flow rate controller (FIC-601), and reflux rate flow controller (FIC-801) setpoints should be modulated. Responding to An instrument in alarm indicates that there is an upset condition in the process. A Alarms swift response to an alarm can prevent a dangerous condition from occurring. Responding directly to a key process variable that is in alarm may not always be the best corrective action. Understanding and observing the relationships of all process variables can help you troubleshoot the problem and take proper corrective action to return the process to design conditions. For example, in the distillation column, overhead and bottoms composition alarms might be caused by changes in column feed temperature and composition. Reboiler fouling might be the cause of column temperature, pressure, composition, product flow rate, and level alarms. Condenser cooling water fluctuations could cause column temperature, pressure, composition, flow rate, and level alarms. Doc Revision 10 DSS-100 Version 6.3 Page 14  SPM-700 Manual Operator Pre-Startup Pre-Startup Pre-startup procedures must be performed before any startup may begin. Procedure Normal Pre- All Simtronics process simulations assume that the following normal procedures have Startup already been completed. However, trainees should be made aware of these Procedure procedures and any other procedures particular to your process plant. SPM-700 Distillation: Normal Pre-Startup Procedure  Notify all personnel involved with the startup:  Shift Supervisors  Process Engineers  Control Engineers  Outside Operators  Instrument Technicians  Flush, clean, and purge all lines  Flush, clean, and purge all equipment  Pressure test all lines  Pressure test all equipment  Check, calibrate, and zero all instruments  Commission all pumps  Commission all heat exchangers  Commission any other process equipment as required Cold Start Pre- The cold start initial condition provided by Simtronics ensures that the following Startup procedures have already been completed. However, trainees should be required to Procedure perform these procedures as a matter of course. You may change the cold start initial condition provided by Simtronics, to ensure that trainees do in fact perform these procedures SPM-700 Distillation: Cold Start Pre-Startup Procedure  Check position of all block valves (open or closed)  Check position of all control valves (open or closed)  Check status of all controllers (manual, automatic, or cascade)  Check status of all switches (on or off)  Check status of all pumps (run or stop)  Check status of any other equipment or instrumentation as required Doc Revision 10 DSS-100 Version 6.3 Page 15  SPM-700 Manual Operator Startup Normal The following is a startup procedure recommended by Simtronics. You may modify Startup this procedure to more closely reflect your particular process plant startup Procedure procedures. The entire startup should take approximately 40 minutes. Time Check Step Procedure (hh:mm:ss) 1 OPEN tower vent hand valve HV-701. 00:00:10 2 OPEN condenser cool water hand valve HV-601. 00:00:17 3 PLACE condenser cool water flow controller 00:00:20 FIC-601 CONTROLLER MODE in AUTOMATIC 4 ADJUST condenser cool water flow controller 00:00:25 FIC-601 SETPOINT to 350 GPM. 5 OPEN overhead product hand valve HV-801. 00:00:33 6 SWITCH reflux pump hand switch HS-801 to RUN 00:00:34 position. 7 PLACE overhead product flow controller FIC-802 00:00:37 CONTROLLER MODE in CASCADE 8 ADJUST reflux drum level level controller LIC-701 00:00:43 SETPOINT to 50.0 % LVL. 9 OPEN bottoms product hand valve HV-501. 00:01:12 10 SWITCH bottoms pump hand switch HS-501 to 00:01:14 RUN position. 11 ADJUST bottoms level level controller LIC-301 00:01:18 SETPOINT to 50.0 % LVL. 12 OPEN feed block hand valve HV-101. 00:01:24 13 SWITCH feed pump hand switch HS-101 to RUN 00:01:25 position. 14 PLACE feed to tower flow controller FIC-101 00:01:29 CONTROLLER MODE in AUTOMATIC 15 ADJUST feed to tower flow controller FIC-101 00:01:36 SETPOINT to 235.0 GPM. 16 OPEN preheat thermoil hand valve HV-201. 00:01:41 17 PLACE feed temp temperature controller TIC-102 00:01:44 CONTROLLER MODE in CASCADE 18 OPEN reboiler thermoil hand valve HV-401. 00:01:50 19 ADJUST bottoms temp temperature controller 00:02:08 TIC-501 OUTPUT to 24.0 %. 20 PLACE reflux to tower flow controller FIC-801 00:03:57 CONTROLLER MODE in AUTOMATIC 21 ADJUST reflux to tower flow controller FIC-801 00:04:05 SETPOINT to 200.0 GPM. 22 ADJUST reflux drum level controller LIC-701 00:06:13 OUTPUT to 25.0 % LVL. 23 ADJUST bottoms level level controller LIC-301 00:08:15 OUTPUT to 15.0 %. 24 ADJUST bottoms temp temperature controller 00:08:37 TIC-501 SETPOINT to 204.6 DEG F. 25 ADJUST bottoms level level controller LIC-301 00:13:56 OUTPUT to 14.0 %. 26 ADJUST reflux drum level controller LIC-701 00:14:45 OUTPUT to 26.0 % LVL. Doc Revision 10 DSS-100 Version 6.3 Page 16  SPM-700 Manual Operator Time Check Step Procedure (hh:mm:ss) 27 PLACE bottoms temp temperature controller TIC- 00:15:39 501 CONTROLLER MODE in AUTOMATIC 28 ADJUST bottoms level level controller LIC-301 00:16:55 OUTPUT to 13.0 %. 29 ADJUST reflux drum level controller LIC-701 00:17:04 OUTPUT to 27.0 % LVL. 30 ADJUST bottoms level level controller LIC-301 00:18:50 OUTPUT to 12.0 %. 31 ADJUST reflux drum level controller LIC-701 00:19:06 OUTPUT to 28.0 % LVL. 32 PLACE reflux drum level controller LIC-701 00:21:39 CONTROLLER MODE in AUTOMATIC 33 PLACE bottoms level level controller LIC-301 00:28:37 CONTROLLER MODE in AUTOMATIC 34 PLACE reflux flow controller FIC-801 00:35:23 CONTROLLER MODE in CASCADE 35 MONITOR the system until LINE OUT occurs. 00:35:23 to 00:40:01 36 STARTUP COMPLETE 00:40:01 Doc Revision 10 DSS-100 Version 6.3 Page 17  SPM-700 Manual Operator Shutdown Normal The following is a shutdown procedure recommended by Simtronics. You may Shutdown modify this procedure to more closely reflect your particular process plant shutdown Procedure procedures. The entire shutdown should take approximately 9 minutes. Time Check Step Procedure (hh:mm:ss) 1 PLACE reflux drum level controller LIC-701 00:00:19 CONTROLLER MODE in MANUAL 2 PLACE bottoms level level controller LIC-301 00:00:28 CONTROLLER MODE in MANUAL 3 PLACE feed to tower flow controller FIC-101 00:00:38 CONTROLLER MODE in MANUAL 4 ADJUST feed to tower flow controller FIC-101 00:00:41 OUTPUT to 0.0 %. 5 PLACE bottoms temp temperature controller TIC- 00:00:50 501 CONTROLLER MODE in MANUAL 6 ADJUST bottoms temp temperature controller 00:00:54 TIC-501 OUTPUT to 0.0 %. 7 PLACE reflux to tower flow controller FIC-801 00:01:02 CONTROLLER MODE in MANUAL 8 ADJUST reflux to tower flow controller FIC-801 00:01:05 OUTPUT to 0.0 %. 9 ADJUST feed to tower flow controller FIC-101 00:01:46 SETPOINT to 0.0 GPM. 10 SWITCH feed pump hand switch HS-101 to STOP 00:01:52 position. 11 CLOSE feed block hand valve HV-101. 00:01:58 12 PLACE feed temp temperature controller TIC-102 00:02:14 CONTROLLER MODE in MANUAL 13 ADJUST feed temp temperature controller TIC- 00:02:20 102 OUTPUT to 0.0 %. 14 ADJUST feed temp temperature controller TIC- 00:02:26 102 SETPOINT to 0.0 DEG F. 15 CLOSE preheat thermoil hand valve HV-201. 00:02:33 16 ADJUST bottoms temp temperature controller 00:02:59 TIC-501 SETPOINT to 0.0 DEG F. 17 CLOSE reboiler thermoil hand valve HV-401. 00:03:11 18 ADJUST reflux drum level level controller LIC-701 00:05:26 OUTPUT to 0.0 %. 19 ADJUST reflux drum level level controller LIC-701 00:05:32 SETPOINT to 0.0 % LVL. 20 PLACE overhead product flow controller FIC-802 00:05:42 CONTROLLER MODE in MANUAL 21 ADJUST overhead product flow controller FIC-802 00:05:46 OUTPUT to 0.0 %. 22 ADJUST reflux to tower flow controller FIC-801 00:06:27 SETPOINT to 0.0 GPM 23 SWITCH reflux pump hand switch HS-801 to 00:06:43 STOP position. 24 CLOSE overhead product hand valve HV-801. 00:06:48 25 CLOSE tower vent hand valve HV-701. 00:07:01 Doc Revision 10 DSS-100 Version 6.3 Page 18  SPM-700 Manual Operator Time Check Step Procedure (hh:mm:ss) 26 PLACE condenser cool water flow controller 00:07:08 FIC-601 CONTROLLER MODE in MANUAL 27 ADJUST condenser cool water flow controller 00:07:12 FIC-601 OUTPUT to 0.0 %. 28 ADJUST condenser cool water flow controller 00:07:16 FIC-601 SETPOINT to 0 GPM. 29 CLOSE condenser cool water hand valve HV-601. 00:07:22 30 ADJUST bottoms level level controller LIC-301 00:07:36 OUTPUT to 0.0 %. 31 ADJUST bottoms level level controller LIC-301 00:07:41 SETPOINT to 0.0 % LVL. 32 SWITCH bottoms pump hand switch HS-501 to 00:07:47 STOP position. 33 CLOSE bottoms product hand valve HV-501. 00:07:52 34 SHUTDOWN COMPLETE. 00:08:52 Doc Revision 10 DSS-100 Version 6.3 Page 19  SPM-700 Manual Operator Emergency Operations Emergency All emergencies should be handled quickly. The particular steps taken in an Operation emergency are specific to the problem at hand. As always, your trainees should Procedure follow the emergency procedures particular to your process plant. If an emergency cannot be handled quickly, then an emergency shutdown should be performed. Emergency The following is an emergency shutdown procedure recommended by Simtronics. Shutdown You may modify this procedure to more closely reflect your particular process plant Procedure emergency shutdown procedures. The entire shutdown should take approximately 9 minutes. Time Check Step Procedure (hh:mm:ss) 1 PLACE reflux drum level controller LIC-701 00:00:19 CONTROLLER MODE in MANUAL 2 PLACE bottoms level level controller LIC-301 00:00:28 CONTROLLER MODE in MANUAL 3 PLACE feed to tower flow controller FIC-101 00:00:38 CONTROLLER MODE in MANUAL 4 ADJUST feed to tower flow controller FIC-101 00:00:41 OUTPUT to 0.0 %. 5 PLACE bottoms temp temperature controller TIC- 00:00:50 501 CONTROLLER MODE in MANUAL 6 ADJUST bottoms temp temperature controller 00:00:54 TIC-501 OUTPUT to 0.0 %. 7 PLACE reflux to tower flow controller FIC-801 00:01:02 CONTROLLER MODE in MANUAL 8 ADJUST reflux to tower flow controller FIC-801 00:01:05 OUTPUT to 0.0 %. 9 ADJUST feed to tower flow controller FIC-101 00:01:46 SETPOINT to 0.0 GPM. 10 SWITCH feed pump hand switch HS-101 to STOP 00:01:52 position. 11 CLOSE feed block hand valve HV-101. 00:01:58 12 PLACE feed temp temperature controller TIC-102 00:02:14 CONTROLLER MODE in MANUAL 13 ADJUST feed temp temperature controller TIC- 00:02:20 102 OUTPUT to 0.0 %. 14 ADJUST feed temp temperature controller TIC- 00:02:26 102 SETPOINT to 0.0 DEG F. 15 CLOSE preheat thermoil hand valve HV-201. 00:02:33 16 ADJUST bottoms temp temperature controller 00:02:59 TIC-501 SETPOINT to 0.0 DEG F. 17 CLOSE reboiler thermoil hand valve HV-401. 00:03:11 18 ADJUST reflux drum level level controller LIC-701 00:05:26 OUTPUT to 0.0 %. 19 ADJUST reflux drum level level controller LIC-701 00:05:32 SETPOINT to 0.0 % LVL. 20 PLACE overhead product flow controller FIC-802 00:05:42 CONTROLLER MODE in MANUAL Doc Revision 10 DSS-100 Version 6.3 Page 20  SPM-700 Manual Operator Time Check Step Procedure (hh:mm:ss) 21 ADJUST overhead product flow controller FIC-802 00:05:46 OUTPUT to 0.0 %. 22 ADJUST reflux to tower flow controller FIC-801 00:06:27 SETPOINT to 0.0 GPM 23 SWITCH reflux pump hand switch HS-801 to 00:06:43 STOP position. 24 CLOSE overhead product hand valve HV-801. 00:06:48 25 CLOSE tower vent hand valve HV-701. 00:07:01 26 PLACE condenser cool water flow controller 00:07:08 FIC-601 CONTROLLER MODE in MANUAL 27 ADJUST condenser cool water flow controller 00:07:12 FIC-601 OUTPUT to 0.0 %. 28 ADJUST condenser cool water flow controller 00:07:16 FIC-601 SETPOINT to 0 GPM. 29 CLOSE condenser cool water hand valve HV-601. 00:07:22 30 ADJUST bottoms level level controller LIC-301 00:07:36 OUTPUT to 0.0 %. 31 ADJUST bottoms level level controller LIC-301 00:07:41 SETPOINT to 0.0 % LVL. 32 SWITCH bottoms pump hand switch HS-501 to 00:07:47 STOP position. 33 CLOSE bottoms product hand valve HV-501. 00:07:52 34 SHUTDOWN COMPLETE. 00:08:52 Doc Revision 10 DSS-100 Version 6.3 Page 21