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Key Operability issues 1. Operating window 2. Reliability 3. Flexibility/ controllability

Key Operability issues 1. Operating window 2. Reliability 3. Flexibility/ controllability 4. Safety & equipment protection 5. Efficiency 6. Startup & Shut down 7. Dynamic Performance 8. Monitoring & diagnosis. STARTUP AND SHUTDOWN.

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Key Operability issues 1. Operating window 2. Reliability 3. Flexibility/ controllability

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  1. Key Operability issues 1. Operating window 2. Reliability 3. Flexibility/ controllability 4. Safety & equipment protection 5. Efficiency 6. Startup & Shut down 7. Dynamic Performance 8. Monitoring & diagnosis STARTUP AND SHUTDOWN Special equipment and procedures are required for starting and stopping process operations. • These are when most accidents and serious hazards occur - be very thorough in planning and training • Need to load material to startup and drain material for shutdown. • Need to heat and/or cool to approach normal process conditions.

  2. Key Operability issues 1. Operating window 2. Reliability 3. Flexibility/ controllability 4. Safety & equipment protection 5. Efficiency 6. Startup & Shut down 7. Dynamic Performance 8. Monitoring & diagnosis STARTUP AND SHUTDOWN Equipment and process structure: Identify extra equipment needed for startup of the reactor. Cold product Cold feed Hot effluent

  3. Key Operability issues 1. Operating window 2. Reliability 3. Flexibility/ controllability 4. Safety & equipment protection 5. Efficiency 6. Startup & Shut down 7. Dynamic Performance 8. Monitoring & diagnosis STARTUP AND SHUTDOWN Equipment and process structure: Identify extra equipment needed for startup of the reactor. Cold product Is the design complete? Cold feed Heating fluid Hot effluent

  4. Key Operability issues 1. Operating window 2. Reliability 3. Flexibility/ controllability 4. Safety & equipment protection 5. Efficiency 6. Startup & Shut down 7. Dynamic Performance 8. Monitoring & diagnosis STARTUP AND SHUTDOWN Equipment: Identify extra equipment needed for startup of the distillation column reboiler. Bottom tray Thermsiphon reboiler Bottoms product

  5. Before reboiler is functioning, no vapor flows, liquid weeps through trays Key Operability issues 1. Operating window 2. Reliability 3. Flexibility/ controllability 4. Safety & equipment protection 5. Efficiency 6. Startup & Shut down 7. Dynamic Performance 8. Monitoring & diagnosis Valve is normally closed, opened only during startup STARTUP AND SHUTDOWN Identify extra equipment needed for startup of the distillation column reboiler. Bottom tray Thermsiphon reboiler Bottoms product From: Lieberman, N.L., Process Design for Reliable Operations, Gulf Publishing, Houston, 1983

  6. Key Operability issues 1. Operating window 2. Reliability 3. Flexibility/ controllability 4. Safety & equipment protection 5. Efficiency 6. Startup & Shut down 7. Dynamic Performance 8. Monitoring & diagnosis STARTUP AND SHUTDOWN Process flow: Occasionally, equipment must be shutdown for preventative maintenance and modifications. What is needed? Unit B Unit A

  7. Key Operability issues 1. Operating window 2. Reliability 3. Flexibility/ controllability 4. Safety & equipment protection 5. Efficiency 6. Startup & Shut down 7. Dynamic Performance 8. Monitoring & diagnosis STARTUP AND SHUTDOWN Process flow: Occasionally, equipment must be shutdown for preventative maintenance and modifications. What is needed? Discuss advantages and disadvantages. How big is the tank? • Cooling • Storage • Pumping • Heating Unit B Unit A

  8. Key Operability issues 1. Operating window 2. Reliability 3. Flexibility/ controllability 4. Safety & equipment protection 5. Efficiency 6. Startup & Shut down 7. Dynamic Performance 8. Monitoring & diagnosis STARTUP AND SHUTDOWN Process flow: Occasionally, equipment must be shutdown for preventative maintenance and modifications. What is needed? Cooling and subsequent heating and cooling is inefficient. Let’s by-pass the tank when possible. The tank must have a holdup time equal to the unit shutdown time. The inventory can be adjusted just before the shutdown. • Cooling • Storage • Pumping • Heating Unit B Unit A

  9. Key Operability issues 1. Operating window 2. Reliability 3. Flexibility/ controllability 4. Safety & equipment protection 5. Efficiency 6. Startup & Shut down 7. Dynamic Performance 8. Monitoring & diagnosis STARTUP AND SHUTDOWN • INDUSTRIAL PRACTICE • The first step is to prepare a detailed startup (shutdown) procedure. • Then, we check the availability of the appropriate equipment to perform the procedure • This is very detailed work and requires considerable experience in plant operation and plant equipment • (Talk with operators and shift supervisors.)

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