SPM-500 Flash Tank Operator Training Manual PDF

Cover English Units SPM-500 FLASH TANK Operator Training Manual Version 6.3 Information: 1-800-730-0760 Simtronics Corporation...

Cover English Units SPM-500 FLASH TANK 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 2 SPM-500 Manual Operator Front Matter Copyright Copyright © 1992-2013 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 2 DSS-100 Version 6.3 Page 2 SPM-500 Manual Operator SPM-500 FLASH TANK Contents Topic See Page Process Description 4 Equipment Specifications 5 Process Flow and ID Diagrams 6 Instrumentation 7 Normal Operations 8 Pre-Startup 10 Startup 11 Shutdown 12 Emergency Operations 13 Doc Revision 2 DSS-100 Version 6.3 Page 3 SPM-500 Manual Operator Process Description Process Flow The objective of the SPM-500 Flash Tank Process is to separate a mixture of the two paraffins hexane (C6) and heptane (C7) by virtue of the difference in their boiling point temperatures. The separated products are then sent to other units for further processing. Product A mixture of approximately 300 GPM of 46 WT % hexane and 54 WT % heptane is Specifications to be separated into its constituent components. The mixture is supplied at a temperature of 85 Deg F. A total of approximately 420 ACFM of hexane rich vapor at 80 PSIG and 319 Deg F is to be produced. A total of approximately 220 GPM of heptane rich liquid at 80 PSIG and 319 Deg F is to be produced. Doc Revision 2 DSS-100 Version 6.3 Page 4 SPM-500 Manual Operator Equipment Specifications Overview The unit consists of a feed preheater (E-401), a flash tank (T-501), an overhead vapor line, and a bottoms liquid line. Flow Control The mixture flow loop is modulated by a flow control valve (V-401) with parabolic Valve flow characteristics. The overhead vapor line is modulated by a pressure control valve (V-501) with quick opening flow characteristics. The bottoms liquid line is modulated by a level control valve with linear flow characteristics. The unit (valves, piping, and vessel) has been designed to process a maximum of approximately 500 GPM of feed. Sufficient upstream pressures and pre-heating capacity are provided to accomplish this task. Flash Tank The flash tank (T-501) is a cylindrical tank 4 feet in diameter by 12 feet in height. The flash tank has a total capacity of 150 ft3 or 1128 gallons of fluid. At design conditions the flash tank provides approximately 2 minutes of holdup running half full. Hand Valves Block valves with bypasses are provided for both the vapor (HV-501 and HV-502) and liquid (HV-503 and HV-504) lines. Doc Revision 2 DSS-100 Version 6.3 Page 5 SPM-500 Manual Operator Process Flow and ID Diagrams SPM-500 Flash Tank Doc Revision 2 DSS-100 Version 6.3 Page 6 SPM-500 Manual Operator Instrumentation Basic Controls The mixture feed flow loop is outfitted with a composition analyzer that measures weight percent hexane and heptane (AI-305 and AI-306 respectively). Feed temperature is controlled by TIC-406 and flow is controlled by flow controller FIC- 401. The overhead vapor line is outfitted with a composition analyzer that measures weight percent hexane and heptane (AI-501 and AI-502 respectively). Flash Tank pressure is regulated by pressure controller PIC-501. Vapor rate is measure by FI- 501. Vapor flow can be blocked in by block valves HV-501 and HV-502. Downstream pressure is measured by PI-502. The bottoms liquid line is outfitted with a composition analyzer that measures weight percent hexane and heptane (AI-503 and AI-504 respectively). Flash Tank level is controlled by level controller LIC-501. Liquid rate is measure by FI-502. Tank temperature and tank bottom pressure are measured by TI-501 and PI-503 respectively. Liquid flow can be blocked in by block valves HV-503 and HV-504. Downstream pressure is measured by PI-504. Advanced The flash tank pressure may be regulated manually by modulating the pressure Controls control valve (PIC-501 controller output), or the pressure controller (PIC-501) may be placed in automatic. In this manner, flash tank pressure may be specified (PIC- 501 setpoint), with no further adjustments required by the operator. Likewise, the flash tank level may be maintained manually by modulating the level control valve (LIC-501 controller output), or the level controller (LIC-501) may be placed in automatic. In this manor, flash tank level may be specified (LIC-501 setpoint), with no further adjustments required by the operator. Doc Revision 2 DSS-100 Version 6.3 Page 7 SPM-500 Manual Operator Normal Operations Normal Design The following table is a list of the normal design conditions (initial condition 1) for Conditions the SPM-500 Flash Tank Simulation as provided by Simtronics. Design Output Tag ID Description Eng Units Value Percent AI-305 MIXTURE TO FLASH 46.0 WT%C6 AI-306 MIXTURE TO FLASH 54.0 WT%C7 AI-501 FLASH TANK VAPOR 58.4 WT%C6 AI-502 FLASH TANK VAPOR 41.6 WT%C7 AI-503 FLASH TANK LIQUID 41.6 WT%C6 AI-504 FLASH TANK LIQUID 58.4 WT%C7 FI-501 FLASH TANK VAPOR 419.9 ACFM FI-502 FLASH TANK LIQUID 220.3 GPM FIC-401 FLASH TANK FEED 298.3 GPM 69.0% HV-501 VAPOR BLOCK VALVE OPEN HV-502 VAPOR BYPASS CLOSE HV-503 LIQ BLOCK VALVE OPEN HV-504 LIQUID BYPASS CLOSE LIC-501 FLASH TANK LEVEL 50.0 % LVL 50.0% PI-502 VAPOR DISCHARGE 0.0 PSIG PI-503 LIQUID BOTTOM 81.8 PSIG PI-504 LIQUID DISCHARGE 0.0 PSIG PIC-501 FLASH TANK PRESS 80.0 PSIG 6.1% TI-501 FLASH TANK TEMP 319.1 DEG F TIC-406 FLASH TANK FEED 390.0 DEG F 24.0% Normal The objective of this process is to separate approximately 300 GPM of a mixture of Production hexane and heptane. These are the major process variables to be polled. Monitoring The other process variables should be periodically polled to ensure normal process operation. Tag ID Description AI-501(2) VAPOR COMPOSITION AI-503(4) LIQUID COMPOSITION FI-501 VAPOR FLOW RATE FI-502 LIQUID FLOW RATE PIC-501 FLASH TANK PRESSURE TI-501 FLASH TANK TEMPERATURE Adjusting To smoothly increase or decrease product flow rates, the feed flow controller (FIC- Production 401) setpoint should be modulated. To smoothly change product compositions, the feed temperature controller (TIC- 406) and flash tank pressure controller (PIC-501) setpoints should be modulated. Continued on next page Doc Revision 2 DSS-100 Version 6.3 Page 8 SPM-500 Manual Operator Normal Operations, continued 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 flash tank simulation, upstream feed composition (AI-305 and AI-306) fluctuations might be the cause of product composition (AI-501, AI-502, AI- 503, and AI-504) and temperature (TI-503) alarms. Doc Revision 2 DSS-100 Version 6.3 Page 9 SPM-500 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-500 Flash Tank: 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 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-500 Flash Tank: 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 any other equipment or instrumentation as required Doc Revision 2 DSS-100 Version 6.3 Page 10 SPM-500 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 10 minutes. Time Check Step Procedure (hh:mm:ss) 1 ADJUST flash tank feed flow controller FIC-401 00:00:11 SETPOINT to 298.3 GPM. 2 PLACE flash tank feed flow controller FIC-401 00:00:13 CONTROLLER MODE in AUTOMATIC 3 ADJUST flash tank feed temperature controller 00:00:26 TIC-406 SETPOINT to 390.0 DEG F. 4 PLACE flash tank feed temperature controller 00:00:29 TIC-406 CONTROLLER MODE in AUTOMATIC 5 OPEN vapor block hand valve HV-501. 00:00:32 6 ADJUST flash tank pressure controller PIC-501 00:00:37 SETPOINT to 80.0 PSIG. 7 PLACE flash tank pressure controller PIC-501 00:00:37 CONTROLLER MODE in AUTOMATIC 8 OPEN liquid block hand valve HV-503. 00:00:44 9 ADJUST flash tank level controller LIC-501 00:00:47 SETPOINT to 50.0 % LVL. 10 PLACE flash tank level controller LIC-501 00:00:47 CONTROLLER MODE in AUTOMATIC 11 MONITOR the system until LINE OUT occurs. 00:00:47 to 00:10:03 12 STARTUP COMPLETE 00:10:03 Doc Revision 2 DSS-100 Version 6.3 Page 11 SPM-500 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 4 minutes. Time Check Step Procedure (hh:mm:ss) 1 PLACE flash tank feed temperature controller 00:00:07 TIC-406 CONTROLLER MODE in MANUAL. 2 ADJUST flash tank feed temperature controller 00:00:10 TIC-406 OUTPUT to 0.0 %. 3 ADJUST flash tank feed temperature controller 00:00:11 TIC-406 SETPOINT to 0.0 DEG F. 4 PLACE flash tank feed flow controller FIC-401 00:00:14 CONTROLLER MODE in MANUAL. 5 ADJUST flash tank feed flow controller FIC-401 00:00:15 OUTPUT to 0.0 %. 6 ADJUST flash tank feed flow controller FIC-401 00:00:16 SETPOINT to 0.0 GPM. 7 PLACE flash tank level controller LIC-501 00:00:23 CONTROLLER MODE in MANUAL 8 ADJUST flash tank level controller LIC-501 00:00:24 OUTPUT to 100.0 %. 9 ADJUST flash tank level controller LIC-501 00:02:26 OUTPUT to 0.0 %. 10 ADJUST flash tank level controller LIC-501 00:02:29 SETPOINT to 0.0 % LVL. 11 CLOSE liquid block hand valve HV-503. 00:02:32 12 PLACE flash tank pressure controller PIC-501 00:02:37 CONTROLLER MODE in MANUAL. 13 ADJUST flash tank pressure controller PIC-501 00:02:40 OUTPUT to 100.0 %. 14 ADJUST flash tank pressure controller PIC-501 00:03:19 OUTPUT to 0.0 %. 15 ADJUST flash tank pressure controller PIC-501 00:03:20 SETPOINT to 0.0 PSIG. 16 CLOSE vapor block hand valve HV-501. 00:03:23 17 SHUTDOWN COMPLETE. 00:04:09 Doc Revision 2 DSS-100 Version 6.3 Page 12 SPM-500 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 4 minutes. Time Check Step Procedure (hh:mm:ss) 1 PLACE flash tank feed temperature controller 00:00:07 TIC-406 CONTROLLER MODE in MANUAL. 2 ADJUST flash tank feed temperature controller 00:00:10 TIC-406 OUTPUT to 0.0 %. 3 ADJUST flash tank feed temperature controller 00:00:11 TIC-406 SETPOINT to 0.0 DEG F. 4 PLACE flash tank feed flow controller FIC-401 00:00:14 CONTROLLER MODE in MANUAL. 5 ADJUST flash tank feed flow controller FIC-401 00:00:15 OUTPUT to 0.0 %. 6 ADJUST flash tank feed flow controller FIC-401 00:00:16 SETPOINT to 0.0 GPM. 7 PLACE flash tank level controller LIC-501 00:00:23 CONTROLLER MODE in MANUAL 8 ADJUST flash tank level controller LIC-501 00:00:24 OUTPUT to 100.0 %. 9 ADJUST flash tank level controller LIC-501 00:02:26 OUTPUT to 0.0 %. 10 ADJUST flash tank level controller LIC-501 00:02:29 SETPOINT to 0.0 % LVL. 11 CLOSE liquid block hand valve HV-503. 00:02:32 12 PLACE flash tank pressure controller PIC-501 00:02:37 CONTROLLER MODE in MANUAL. 13 ADJUST flash tank pressure controller PIC-501 00:02:40 OUTPUT to 100.0 %. 14 ADJUST flash tank pressure controller PIC-501 00:03:19 OUTPUT to 0.0 %. 15 ADJUST flash tank pressure controller PIC-501 00:03:20 SETPOINT to 0.0 PSIG. 16 CLOSE vapor block hand valve HV-501. 00:03:23 17 SHUTDOWN COMPLETE. 00:04:09 Doc Revision 2 DSS-100 Version 6.3 Page 13