fad plant with precut column
TRANSCRIPT
EURRESTRA INDUSTRIES LTD.MUMBAI
OPERATION MANUAL
FOR
FATTY ACID DISTILLATON PLANT WITH PRECUT COLUMN
FATTY ACID DISTILLATION PLANT WITH PRECUT COLUMN
EURRESTRA INDUSTRIES LTD.MUMBAI
OPERATION MANUAL
The Operation Manual is intended to give the operating personnel a brief idea of ;
Process
Equipment details
Safe & efficient operation of the Plant
However, it must be clearly understood, that the operating personnel, for whom the
Operation Manual is intended, should have the basic knowledge of operation of
Chemical Plants.
Before ‘Start up’ of any Plant, the operating personnel shall familiarize themselves
with:-
Operation Manual and PFD/P&I drawings.
Instruments / valves etc., required for the safe and efficient operation of the Plant.
‘Emergency Shut-down Procedures.”
At regular intervals. Simulate conditions for ‘Emergency shut-down’ for enabling
operating personnel to be fully aware of the procedures involved in the same.
Ensure that all equipment, measuring/metering instruments, etc., are in working
conditions.
In case of any malfunctions, the same shall be immediately reported to the
Maintenance Department/Personnel for immediate corrective action.
Tag Nos. of Equipment/Instrument/Valves.
The information stated in the Operation Manual is subject to Secrecy and Indemnity
Clauses, as detailed on subsequent pages, and as stipulated in the Contract.
FATTY ACID DISTILLATION PLANT WITH PRECUT COLUMN
EURRESTRA INDUSTRIES LTD.MUMBAI
1.
2.
2.1
2.2
SECRECY & INDEMNITY CLAUSE
General:-
The information stated in the Operation Manual is subject to Secrecy &
Indemnity Clauses, as detailed below and as stipulated in the contract.
Secrecy:-
M/s. Pan Century Edible Oils SDN.BHD agrees and undertakes that it
shall not either by itself or through its agents/servants and/or any other
persons claiming under or through them divulge /disclose or communicate
at any time during the period of this agreement or thereafter, any of the
secrets, information, operations, procedures or other documents,
materials or things coming of its knowledge or possession through or
relating to EURRESTRA and shall not use or attempt to use the same in
any manner whatsoever.
The drawings, plans and specifications that may be handed over or made
known Pan Century Edible Oils SDN.BHD under this Agreement shall
remain the exclusive property of EURRESTRA and the same shall be
entrusted to Pan Century Edible Oils SDN.BHD only for the purpose of
this Agreement. Pan Century Edible Oils SDN.BHD guarantees and
covenants not to in any manner use the said drawings, plans and
specifications for any other purpose whatsoever or make known the same
to any third parties excepting to its officers, technicians and other
employees or its consultants/advisers connected with this Agreement.
FATTY ACID DISTILLATION PLANT WITH PRECUT COLUMN
EURRESTRA INDUSTRIES LTD.MUMBAI
2.3
2.4
2.5
2.6
Pan Century Edible Oils SDN.BHD also agrees and undertakes that
in the event any of its employees, agents or servants get to know of
these processes, know-how specifications, drawings and such similar
and other sources of information, Pan Century Edible Oils SDN.BHD
shall not use the same except in the manner provided for under this
Agreement.
Nothing contained in this clause shall apply to information
which was in the possession of Pan Century Edible Oils
SDN.BHD from a source other than EURRESTRA or which is or
subsequently falls into the public domain.
EURRESTRA agrees and undertakes that it shall not, either by itself
or through its agents/servants and or/ any other persons claiming
under or through them divulage/disclose or communicate, at any time
during the period of this Agreement or thereafter, any of the secrets,
information, operations, procedures or other documents, materials or
things coming to its knowledge or possession relating to Pan Century
Edible Oils SDN.BHD or any of its parent, holding, or affiliated
companies or any other transactions between the parties hereunder
and shall not use or attempt to use the same in any manner
whatsoever.
Nothing contained in this clause shall apply to information which was
in the possession of EURRESTRA from the source other than Pan
Century Edible Oils SDN.BHD or which is or subsequently falls into
the public domain.
FATTY ACID DISTILLATION PLANT WITH PRECUT COLUMN
EURRESTRA INDUSTRIES LTD.MUMBAI
3.
3.1
3.2
Indemnity:-
EURRESTRA represents and warrants that the technical information,
know-how, plant, machinery, equipment and components supplied by it
to Pan Century Edible Oils SDN.BHD does not infringe any patent,
design and/or trade mark of any third party. If any design, technical
information, know-how,plant,machinery, equipment or components
provided by EURRESTRA shall infringe any patent, design or
trademark then EURRESTRA shall fully indemnify Pan Century Edible
Oils SDN.BHD against all liabilities, claims, cost and expenses that
may result from such infringement.
In the event of any claim being made or proceedings instituted against
Pan Century Edible Oils SDN.BHD to which the above indemnity
applies Pan Century Edible Oils SDN.BHD shall promptly notify
EURRESTRA within 15 days thereof and EURRESTRA shall
thereupon undertake all necessary steps to ensure that the
infringement, if any, is not continued.
FATTY ACID DISTILLATION PLANT WITH PRECUT COLUMN
EURRESTRA INDUSTRIES LTD.MUMBAI
FATTY ACID DISTILLATION PLANT
WITH PRECUT COLUMN
FATTY ACID DISTILLATION PLANT WITH PRECUT COLUMN
EURRESTRA INDUSTRIES LTD.MUMBAI
CHAPTER – 1
OPERATING PROCESS & INSTRUCTIONS
FATTY ACID DISTILLATION PLANT WITH PRECUT COLUMN
EURRESTRA INDUSTRIES LTD.MUMBAI
1.0
1.1
1.2
1.2.1
OPERATING PROCESS & INSTRUCTIONS
Refer Process Flow Chart
Drg.No.34/2005-PR-DR-PF-301
Drg.No. 34/2005-PR-DR-PF-302
General:
The Crude Faty Acid, produced in the Continuous Fat Splitting Plant,
contains Fatty Acids, Neutral Oil, Unsaponifiables, Impurities and
Water. This Crude Fatty Acid has to be further purified by distilling the
Fatty Acid and leaving neutral oil and other impurities in the Precut
Column, Fatty Acid Distillation Column and Fatty Acid Stripper. This
“Distillation Operation” is carried out under low absolute pressure viz.
2 – 3 mm Hg(a). In addition, the low boiling Fatty Acids present
pretreated Oil Crude Fatty Acid are also removed in Precut Column
which is operating under absolute pressure of 40 – 100 mm of Hg (a).
Process :
The distillation of Crude Fatty Acids is carried out in various stages.
Deaerated / Dried Crude Fatty Acid:
Settled Crude Fatty Acid is pumped from Off-sites Storage Tanks to
Crude Fatty Acids Filter (F-301 A/B) for removing any extraneous
matter. The filtered Crude Fatty Acid is then preheated in Crude Fatty
Acid Pre Heater (E-301) with the low pressure steam. The Crude Fatty
Acids temperature is controlled by Temperature indicator and
Controller (TIC-301). In Crude Fatty Acid Degasifier (V-301), the water
vapour and air is removed from the incoming Crude Fatty Acid
producing Deaerated / Dried Crude Fatty Acids.
FATTY ACID DISTILLATION PLANT WITH PRECUT COLUMN
EURRESTRA INDUSTRIES LTD.MUMBAI
1.2.2 Crude Fatty Acids to Precut Column (C-301):
The Deaerated / dried Crude Fatty Acid is pumped by Feed Pump
(P-301) to Crude Fatty Acids Heater (E-302) where it is preheated with
Thermic Fluid, before entering to the Precut Column (C-301). Level
Indicator and Controller (LIC-301) controls level of Crude Fatty Acid
Degasifier (V-301). Temperature indicator and Controller (TIC-302)
maintain the set temperature of the Crude Faty Acid entering to the
Precut Column. The Precut Column (C-301) is composed of four
sections starting from the bottom and these are:-
A bottom section, where Fatty Acids and odorous compounds are
distilled by means of an External Reboiler (E-303) with forced
circulation by means of Reboiler Recirculation Pump (P-302).
Thermic Fluid is used as heating medium is Precut Reboiler
(E-303). The temperature of Reboiler (E-303). The temperature of
Reboiler Outlet is controlled by Turbo flow circuit containing
circulation pump P302A & Temperature Control Loop (TIC-303).
First packing layer (Filled with random packings) is a stripping
stage where the Distilled Fatty Acid vapour is separated. Open
steam given in Deodoriser passes through this packing layer to
remove odorous Fatty Acid.
FATTY ACID DISTILLATION PLANT WITH PRECUT COLUMN
EURRESTRA INDUSTRIES LTD.MUMBAI
The second pcking layer, which is the rectification section, where
the Distilled Fatty Acid condensed in the Third packing layer
overflows to second packing layer and is rectified by counter
current washing of the vapours in order to recover good quality
Distilled Fatty Acid.
FATTY ACID DISTILLATION PLANT WITH PRECUT COLUMN
EURRESTRA INDUSTRIES LTD.MUMBAI
The third packing layer is the condensation stage, where odorous
Fatty Acid and Distilled Fatty Acid condense by means of already
condensed and cooled distilled Light Fatty Acid. The distilled
Light Fatty Acid from the bottom of the condensation bed is
pumped by Pump Around Pump (P-304) and is recycled back to
the condensation bed after being cooled in Pump Around
Cooler (E-304). Depending on the quality of raw materials after
further cooling in LFA Cooler (E-305) by means of FIC 302 are
sent to the Storage Tank. Excess Light Fatty Acid from
condensation bed bottom tray, overflows back to the rectification
bed for the recovery of good quality Fatty Acids. The bottom tray
of condensation bed is designed such that the excess quantity is
always refluxed back to the Rectification Bed. Temperature
Control Loop (TIC-309) maintain the set temoperature of Light
Fatty Acids (outlet of Pump Around Cooler E-304) entering the
condensation bed of Precut Column (C-301). Temperature
Control Loop (TIC-310) maintains the set temperature of Light
Fatty Acid (outlet of LFA Cooler E-305) going to storage.
FATTY ACID DISTILLATION PLANT WITH PRECUT COLUMN
EURRESTRA INDUSTRIES LTD.MUMBAI
The fourth packing layer, is the final condensation stage where
the scrubbing of vapours is carried out with Light Fatty Acids.
The Light Fatty Acids are extracted at the bottom of the layer by a
total draw – off plate and collected in Scrubber Receiver (V-302).
The Light Fatty Acids collected in Scrubber Receiver (V-302) are
pumped back to the scrubbing section for the condensation of
vapours by Scrubber Pump (P-305) after being cooled to the set
temperature in Scrubber Cooler (EP-301). Temperature of Light
Fatty Acids, is controlled by Temperature Control Loop
(TIC-311). Level Controller Loop (LIC-304) maintains the set level
in Scrubber Receiver (V-302) by sending Light fatty Acids
continuously to the Storage Tank. The Precut Column (C-301) is
operated under absolute pressure of 40-60 mm of Hg(a).
Demister Pad is provided at the top of Precut Column to separate
the Fatty Acid droplets from the non-condensables going to the
Vacuum System (PK-301). The Vacuum System (PK-301)
consists of Barometric Condensers (Indirect) (CS-301 and
CS-302) Ejectors (J-302 & J-303 and Booster Compressor
(J-301). Medium pressure steam is used to produce vacuum in
the system.
FATTY ACID DISTILLATION PLANT WITH PRECUT COLUMN
1.2.3 Feed to Fatty Acid Distillation Column (C-302):
The Fatty Acid Distillation Column (C-302) operates under absolute
pressure of 2-4 mm of Hg (a) and vacuum is produced by Vacuum
System (PK-302). The Vacuum System (PK-302) consists of
Barometric Condensers (Indirect) (CS-303, CS-304 and CS-305)
Ejectors (J-306, J-307 and J-309) and Booster Compressors
(J-304 & J-305). Low pressure steam is used to produce vacuum in
the system. Common Hoooer (J-309) is used for both the vacuum
system. (PK 301 & PK 302)
After distillation and removal of Light Fatty Acids / Odorous Fatty
Acids in Precut Column (C-301), the Crude Fatty Acids from Precut
Column is fed to Fatty Acid Distillation Column (C-302) by Bottom
Pump (P-303). The Level Control Loop (LIC-302) maintains the level
in Precut Column by controlling the Controle Valve (LV-302)
opening to feed the Fatty Acid Distillation Column (C-302)
The Fatty Acid Distillation Column is composed of three sections
starting from bottom and these are:
o
Bottom Section :
In bottom section the Fatty Acids are evaporated by means of and
External Reboiler (E-306) with forced circulation by means Reboiler
Circulation Pump (P-306). Thermic fluid is used as heating medium in
Reboiler (E-306). The distillation temperature is controlled by Turbo
flow circuit, containing circulation Pump P-306A & Temperature
Controle Loop (TIC-314).
The bottom section is divided into two sections by partition plate with
the opening at the bottom . Part of the heavier product over flows to
the Fatty Acid Stripper (E-307). The residual crude Fatty Acids from
heavier product are again heated with thermic fluid and steam striped.
The distillation temperature in Fatty Acid Stripper (E-307) is controlled
by Temperature Control Loop (TIC-312).
The stripped Fatty Acids are condensed in stripped Fatty Acid
Condenser (E-311). The Fatty Acids from stripped Fatty Acid
Condenser (E-311) are collected in LFA Receiver (V-304).
First Packing Layer:
The first packing layer, is a washing stage where distilled vapours are
washed in counter current flow by condensed distilled Fatty Acids. In
this section, all heavy components which could be carried over in
distillation are scrubbed from the vapours.
Second Packing Layer:
The second packing layer is the condensation stage where the
Distilled Fatty Acid vapour condenses by means of already
condensed, distilled and cooled Fatty Acids. The distilled Fatty Acids
from the bottom of condensation bed flow to DFA receiver (V-303).
The product distilled Fatty Acid Pump (P-308) recycles / pumps
Distilled Fatty Acids as described below:
DFA to Washing bed
Measured quantity (through F1-306) to the Washing bed (first
packing layer) for washing the Distilled Fatty Acid Vapours.
• DFA to condensation and LP steam generation
Recycles at a fixed flow rate after being cooled in Pump Around
Cooler (E-309) to condensation bed for condensing the Distilled
Fatty Acid Vapours.
The Pump Around Cooler (E-309) temperature is controlled by
Temperature Control Loop (TIC-320) and heat recovered on cooling
of Distilled Fatty Acid is utilized for generating low pressure steam.
The low pressure steam generated is used as motive steam in
Vacuum System (PK-302) for obtaining vacuum in main Distillation
Column (C-302).
The low pressure steam generating system consists of Water
Recirculation Drum (V-305) for seperation of steam and water,
Circulation Pump (P-310) for circulating water through Pump
Around Cooler (E-309) for the recovery of heat from Distilled Fatty
Acids. The water recirculation drum is provided with Level Control
Loop (LIC-309) to maintain the set water level and also provided
with pressure control loop to maintain the desired pressure required
for Vacuum System (PIC-304)
DFA to Deodorizer
Pumps DFA to deodorizer and the quantity of DFA is controlled by
Level Control Loop (LIC-307) which maintains the set level in DFA
Receiver (V-303).
Third Packing Layer:
The Third Packing Layer is the final condensation stage where
the scrubbing of vapours are carried with Light Fatty Acids. The
Light Fatty Acids are extracted at the bottom of layer by total
draw off plate and collected in Scrubber Receiver (V-304). The
Light Fatty Acids collected in Scrubber Receiver (V-304) are
pumped back to the scrubbing section for the condensation of
vapour Scrubber Pump (P-309) after being cooled to the set
temperature in Scrubber Cooler (EP-302). Level Controller Loop
(LIC-308) maintains the set level in Scrubber Receiver (V-304)
by sending Light Fatty Acids continuously to the off site storage
tank. The temperature of Light Fatty Acids to storage is
controlled by Temperature Control Loop (TIC-319).
Demister pad is provided at the top of the Column for the separation
of DFA droplets from the non-condensables going to the Vacuum
System (PK-302).
Residue / Pitch to Storage:
The residue / pitch from Fatty Acid Stripper (E-307) is pumped to offsite
storage after being cooled in Pitch Cooler (E-308). The temperature of
residue / pitch is controlled by Temperature Control Loop (TIC-313),
Level Control Loop (LIC – 306) controls the residue / pitch to off site
storage by maintaining the set level in Fatty Acid Stripper (E-307).
Quantity of outgoing residue/ pitch is measured by means of moss flow
mofor FI-310.
Deodrization and DFA to Storage:
The deodorizer is specially designed to remove odour from Distilled
Fatty Acids. It contains special purpose internals like mammoth
pumps. Stripping steam sparged at the Bottom of deodorizer
removes odour from final DFA and also from the CFA in Precut
Column (C-301).
The deodorized DFA is pumped to off site Storage tank by Deodorizer
Outlet Pump (P-311) after being cooled in Distilled Fatty Acid Cooler
(E-310). Level Control Loop (LIC-310) maintains the set level in
Deodorizer (V-306) and Temperature Control Loop (TIC-321) maintains
the set temperature of DFA going to the storage and also it is measured
by means of moss flow mofer (FI 311).
CHAPTER - 2
EQUIPMENT DESCRIPTION
2.0 EQUIPMENT DESCRIPTION
As Per 163 Contract
FATTY ACID DISTILLATION PLANT WITH PERECUT COLUMN :
The various equipment provided in the Fatty Acid Distillation Plant
alongwith the Tag No. Quantities, Title and Description are detailed
below:
Tag No. Qty. Title DescriptionC-301 1 Precut Column Vertical Cylindrical packed tower
(Combination of structuted & random
packings) with efficient distribution
system. Tower is in SS – 316 &
internals in SS-316.
C-302 1 FA Distillation Column Vertical Cylindrical packed tower
(Structuted packings) with efficient
distribution system Tower & Internals
in SS-316.
E-301 1 CFA Pre-Heater Shell & Tube Heat Exchanger, SS-304
for all process contacting parts & MS
(IS-2062) for rest.
E-302 1 CFA Heater Shell & Tube Heat Exchanger, SS-316
for all process contacting parts & MS
(IS – 2062) for rest.
E-303 1 Pre-Cut Reboiler Shell & Tube Heat Exchanger, SS 316
for al process contacting parts & MS
(IS-2062) for rest.
E-304 1 Pump Around Cooler (C-301)
Shell & Tube Heat Exchanger, SS-316
for all process contacting parts & MS
(IS-262) for rest.
Tag No. Qty. Title Description
E-305 1 LFA Cooler Shell & Tube Heat Exchanger, SS-316 for
all process contacting parts & MS (IS-
2062) for rest.
E-306 1 Distiller Reboiler Shell & Tube Heat Exchanger, SS-316 for
all process contacting parts & MS
(IS-2062) for rest.
E-307 1 Fatty Acids Stripper
Shell & Tube Heat Exchanger, SS-316
for all process contacting parts & MS
(IS-2062) for rest.
E-308 1 Pitch Cooler Shell & Tube Heat Exchanger, SS-316
for all process contacting parts & MS
(IS-2062) for rest.
E-309 1 Pump Around Cooler (C-302)
Shell & Tube Heat Exchanger, SS-316 for
all process contacting parts & MS
(IS-2026) for rest.
E-310 1 DFA Cooler Shell & Tube Heat Exchanger, SS-316
for all process contacting parts & MS
(IS-2062) for rest.
E-311 1 Stripped FA Condenser
Shell & Tube Heat Exchanger, SS-304
for all process contacting parts & MS
(IS-2062) for rest.
EP-301 1 Scrubber Cooler (C-301)
Plate Heat Exchanger, frame in Carbon
Steel, plate in SS-304.
EP-302 1 Scrubber Cooler(C-302)
Plate Heat Exchanger, frame in carbon
steel, plate in SS-304
EP-303 1 TW Cooler Plate Heat Exchanger, frame in carbon
steel, plate in SS-304.
Tag No. Qty. Title Description
F-301 A/B 2 CFA Filter Cartridge Filter, SS-304P-301 1 Feed Pump (C-301) Centrifugal Pump with Mechanical
Seal, SS-304 for all process contacting parts.
P-302 1 Reboiler Recirculation Pump (C-301)
Centrifugal Pump with Mechanical Seal, SS-316 for all process contacting parts
P-303 1 Bottom Pump (C-301)
Centrifugal Pump with Mechanical Seal, SS-316 for all process contacting parts.
P-304 1 Pump Around Pump (C-301)
Centrifugal Pump with Mechanical Seal, SS-316 for all process contacting parts
P-305 1 Scrubber Pump Centrifugal Pump with Mechanical Seal, SS-304 for all process contacting parts.
P-306 1 Reboiler Recirculation Pump
(C-302)
Centrifugal Pump with Mechanical Seal, SS-316 for all process contacting parts
P-307 1 Residue Pump Centrifugal Pump with Mechanical Seal, SS-304 for all process contacting parts.
P-308 1 Product DFA Pump Centrifugal Pump with Mechanical Seal, SS-316 for al process contacting parts.
P-309
P-310
1
1
Scrubber Pump
Water Recirculation Pump
Centrifugal Pump with Mechanical Seal, SS-304 for all process contacting parts.
Centrifugal Pump with gland packing.
Tag No. Qty. Title Description
P-311 1 Deodoriser Outlet Pump
Centrifugal Pump with Mechanical Seal, SS-316 for all process contacting parts.
P-312 1 DFA Pump Centrifugal Pump with Mechanical Seal, SS-304 for all process contacting parts.
P-313 1 TW Circulation Pump Centrifugal Pump with gland packing, cast iron.
PK-301 1 Precut Vacuum System
Vacuum system based on ejectors & direct contact condensers, Body: MS, Nozzles:SS-304
PK-302 1 Distillation Vacuum System
Vacuum system based on ejectors & direct contact condensers, Body: MS, Nozzles:SS-304
V-301 1 CFA Degasifier High efficiency vapour – liquid separator fitted with internals SS-304
V-302 1 Scrubber Receiver (C-302)
Horizontal Cylindrical Vessel SS-304.
V-303 1 DFA Receiver Horizontal Cylindrical Vessel SS-316
V-304 1 Scrubber Receiver (C-302)
Horizontal Cylindrical Vessel SS-304
V-305 1 Circulation Water Drum
Horizontal Cylindrical design with built in vapour – liquid separator MS (IS-2062)
V-306 1 Deodoriser Horizontal cylindrical design with static pumps fitted in for high mass transfer rate, SS-316.
V-307 1 TW Tank Vertical Cylindrical Vessel, MS (IS
2062)
CHAPTER - 3
OPERATING INSTRUCTIONS
- PRELIMINARY START-UP AND CHECKS
- START UP PROCEDURE
3.0
3.1
3.1.1
3.1.1.1
OPERATING INSTRUCTIONS
PRELIMINARY START UP AND CHECKS
The following ‘CHECKS’ are to be carried out prior to the ‘start-up’ of the Plant :
NOTE :
- Skip ‘CHECKS’ if not applicable to this Plant.
UTILITY PIPE LINES
Testing :
Globe / piston and N.R. Valves and Steam Traps are installed in the correct flow direction.
Steam and other utilities lines are hydraulically tested to the required test pressure, as per the design, and/or as per Indian Boiler Regulations.
Thermic fluid lines are tested with compressed air.
Temporary blanks / spades, etc., installed at various points in the pipe lines, during hydraulic testing, are removed.
3.1.1.2
3.1.1.3
Flushing:
Pipe lines are flushed well so as to be free from mill scales, dirt
weld burrs, etc. Once the flushing is completed, the blank
flanges at terminal ends of lines are to be removed, debris
collected and removed and blank flanges reinstalled.
NOTE:
The Control Valves, Flow meters, Pressure Gauges, Transmitters,
etc., are bypassed during the testing / flushing operations.
Steam lines are flushed with steam only.
Clean l Line Strainers and Steam Trap Strainers after flushing.
Drain out water from the pipe lines, equipment etc., after
hydraulic test and subsequently flush with compressed air,
wherever required.
All lines are to be charged with water at operating pressure, to
ensure free flow and no leakages through the flanges / gaskets
etc., prior to the start-up. In the event of any leakages etc.,
tighten bolts or replace gaskets, if required.
3.1.2
3.1.3
Hydrogen gas lines, (wherever provided) after testing/flushing are to be
evacuated by Vacuum system before charging with hydrogen gas and
flushing to be carried out by Nitrogen.
Steam Pressure Reducing Stations are to be set at predetermined outlet
pressure during “START-UP” of the Plant.
Check settings of Safety Valves, wherever provided, and periodically
operate the Safety Valves to ensure their functioning at the set
pressures.
Note :
After testing/flushing/charging, all valves are to be in “CLOSE: position prior
to the ‘start-up’ of the Plant.
TANKS / VESSELS :
Fill all Tanks and Vessels with clear water and make sure that there are
no leakages. Then empty the Tanks / Vessels.
MECHANICAL EQUIPMENT :
Oil/grease is filled in all the mechanical equipment/gearboxes etc., and
of the correct specifications and to the correct level as per Vendor’s
recommendation.
Mechanical equipment are running smoothly – free of vibration / noise,
during idle runs.
Plants operating under vacuum are tested pneumatically with air
pressure (0.8 kg/cm2g)
Centrifugal pumps, especially if provided with mechanical seals, are
not to be run dry, even during start-up. At the initial start-up, fill the
pumps with the materials that is required to be pumped.
Vendor’s instructions are to be followed in case of Mechanical
Seals.
Rotary equipment, wherever possible, are to be first rotated by hand, to
ensure smooth and trouble free rotation, before switching the motor.
Electric motors are properly aligned with the driven equipment.
Vacuum Pumps are to be started after partially opening the inlet valve
of the cooling and sealing liquid.
For positive displacement pumps, blowers, reciprocating compressors,
check that the valve on the suction and discharge line, if provided, are
kept open before starting the electric motor.
3.1.4 CONTROL VALVES:
Control Valves are freely stroking when simulated from the control
Room.
Controllers are efficiently operating when simulated from the
control Room.
Dew Point of Instrument Air is -20°C.
Thermowells are filled with Thermic Fluid, wherever possible.
Instruments/indicators/recorders/integrators, etc. are in working
condition. They are to be checked by simulating from control Room
wherever possible.
In-line Instruments are calibrated, wherever required.
Pneumatic Control Loops are air tight.
Level Controllers are to be checked for maintaining the required
level.
Float Valves are operating smoothly.
Note :
For Control Room System, refer Vendor’s Operation &
Maintenance Manual.
3.1.5
3.1.5.1
3.1.5.2
3.1.5.3
ELECTRICAL INSTALLATION:
Control Panel :
Fuse Ratings and Relay Settings are as per requirements.
Sequence Interlocking Systems are effectively operating, when
simulated from the Control Panel.
Alarm settings are as required.
Indicating Lamps are operating.
Alarm sirens have been connected and are operational along with
indicating lamps.
Electric Motors :
Electric Motors are to be decoupled and idle run taken to check
that the no load current is within limits.
Check the direction of rotation of motor as indicated by the
relevant arrow on the equipment.
Earthing
Earthing installations are tested as per Indian Electrical
Regulations.
3.1.5.4
3.1.5.5
3.1.6
3.1.7
Instrumentation :
Electrical Instruments like Ammeters, Voltmeters, Energy
Meters, etc., are in order.
Power Wiring :
Electrical conections have been made correctly as per the
Wiring Diagram.
GENERAL :
All Cooling Tower Basins and Hot Wells are filled to the desired
operating level. Make up water arrangement is to be operative
during start-up of the Plant, as the operating level will fall down
during start up.
Tanks are filled with water to the operating level.
Adequate Fire Fighting arrangements are available prior to start
–up.
Off siter facilities are operating well.
WATER TRIALS :
After completing hydraulic tests and cleaning of the lines,
proceed with a water trial in order to familiarize operators wih the
equipment and its mechanical functionality. For instance, it will
be appropriate to check that there are no leakages. The
process is simulated by using only water instead of the usual
process fluid.
3.1.8
As water trials are being carried out, observe the various
temperatures reached in the exchangers with respect to the operating
temperatures, considering the difference between the physical
properties of water and those of the process liquids. Likewise, this
difference in physical properties should be considered for valves and
instruments.
At the end of the tests, the water should be drained completely, if
required, the system should be flushed with air to remove water from
all process pipe lines.
AVAILABILITY OF RAW MATERIAL ETC :
Adequate quantities of raw materials, chemicals, additives packaging
materials etc., of the desired specifications, are available at site.
3.2
3.2.1
3.2.2
START-UP PROCEDURE :
Refer the following P & I drawings
Drg. No. 163-PI-P-301 – Rev.2 Sheet 1 of 8
Drg. No. 163-PI-P-301 – Rev.4 Sheet 2 of 8
Drg. No. 163-PI-P-301 – Rev.4 Sheet 3 of 8
Drg. No. 163-PI-P-301 – Rev.3 Sheet 4 of 8
Drg. No. 163-PI-P-301 – Rev.3 Sheet 5 of 8
Drg. No. 163-PI-P-301 – Rev.1 Sheet 6 of 8
Drg. No. 163-PI-P-301 – Rev.2 Sheet 7 of 8
Drg. No. 163-PI-P-301 – Rev.1 Sheet 8 of 8
The ‘start-up’ operation is carried out as detailed below:
Energise the Control Panel :
Switch on the main electric power supply to the Control Panel
from Off-site facilities.
Switch on the Main Incoming Switch to the Control Panel
and Control Room.
Open Pressure Gauge Valves:
Open Pressure Gauge Valves for all equipment, pumps, vessels,
etc. within the Battery Limits.
3.2.3
3.2.4
Commission Instrument Air Supply / Pneumatic Control
Circuits :
Commission the supply of instrument air to the Battery Limits of the
Plant from Off-site facilities.
Set the Air Filter Pressure Regulator/s as required.
Charge the main line and subsidiary lines upto the User points.
Adjust the stroke of the Controle Valves and keep them in
“CLOSE” position.
Keep all valves at User Points in ‘CLOSE” position.
Commission Plant Air Supply System:
Commission the supply of plant air to the Battery Limits of the plant
from Off-site facilities.
Open drain valves, wherever provided, to drain out accumulated
water, prior to charging of line, and close them after draining.
Keep all valves at User Points in “CLOSE” position.
Charge the main line and subsidiary lines upto the User points.
3.2.5 Commission Steam Supply & Condensate Return System :
Commission the supply of steam to the Battery Limits of the Plant
from off-site facilities.
Open all condensate by pass valves of Steam Traps within
Battery limits to drain out accumulated water and air prior to
charging of lines with steam.
Commission Steam Pressure Reducing Station/s within the
Battery Limits of Plant.
Charge steam at 3 kg/cm2g, 12 kg/cm2g and 15 kg/cm2g in the
various headers/main lines and subsidiary lines upto User points
within the Battery Limits of the Plant.
After all headers/lines are charged \, close condensate bypass
valves, once all the condensate is removed and steam traps are
functioning normally.
Keep all steam valves at User points in “CLOSE” position.
Steam and its Condensate Return Tracer Lines / Jackets:
Open steam valves and condensate valves, including by pass
valves, on tracer lines / Jackets of equipment vessels etc.
3.2.6
3.2.6.1
3.2.6.2
After tracer lines / Jackets are charged, close condensate by pass
valves, once all the condensate is removed and steam traps are
functioning normally.
Commission Water Supply System :
Soft Water Supply
Commission Soft water system upto first isolation valve in the
Battery Limit of the Plant from off site facilities.
Charge soft water to Expansion Tank for TW (V-307) by opening
isolation valve.
Cooling Water (Supply & Return) – Direct
Start Cooling Water Circulation Supply Pump and allow the cooling
water to flow through various vessels / equipment and return to Hot
Well.
Start Cooling Tower Fans.
Start Cooling Water Circulation Return Pump to Pump return water
from Hot Well to top of Cooling Tower.
Open ‘make – up’ water supply to Cooling Tower Basin.
3.2.6.3
3.2.6.4
Cooling Water (Supply & Return) – indirect
(Closed Circuit)
Start Cooling Water Circulation Supply Pump and allow the
Cooling water to flow through various vessels / equipment and
return to Cooling Tower.
Start Cooling Tower Fans.
Open ‘make-up’ water supply to Cooling Tower Basin.
Tempered Water Cooling System
Open soft water valve to Tempered Water Tank (V-307). Float
Valve will maintain the level in this Tank.
Open valve on suction line of TW Recirculation Pump (P-312)
Start TW Recirculation Pump (P-312)
Open valve on discharge line carrying Warm Water to TW Cooler
(EP-303)
Open isolation valves at both ends of the following Control
Valves. Also keep the Control Valves partially open by keeping
them in manual mode from PC. (Bypass valves are closed).
TAG NO. CONTROL VALVE
EP - 302 TV – 319 (TIC – 319)
E - 308 TV – 313 (TIC – 313)
EP – 301 TV – 311 (TIC – 311)
E – 305 TV – 310 (TIC – 310)
E – 304 TV – 309 (TIC – 309)
NOTE :
Temperature indicating Control Valve (TV – 322) of TW Cooler
(EP-303) is closed, since temperature is low, open Control Valve
partially by keeping Controller (TIC-322) in manual mode.
Vent out air from the high point vents provided in the system.
Open all valves at User points to allow circulation of tempered
water to the various equipment / vessels.
Allow indirect cooling water circulation through TW Cooler EP –
303 for 10 – 15 minutes for the removal of air from Pipelines. Set
temperature of Temperature indicating Controller (TIC – 322) to
50°C and put the controller in auto mode.
Commence cooling water circulation system (indirect) through
TW Cooler (EP-303).
Commission the Off – site Thermic Fluid Unit as per Vendor’s
Operation Manual.
Open the up stream isolation valves and respective bypass valves
of following Control valves.
Control Valve (TV-302) for Crude Fatty Acid heater (E-302).
Control Valve (TV-303) for Reboiler (E-303)
Control valve (TV – 314) for Reboiler (E-306)
Control valve TV – 312 for Fatty Acid Stripper (E-307).
Start the Thermic Fluid Circulation System (TFCS) via the bypass
valves and maintain 100-125°C outlet temperature initially.
3.2.8
3.2.9
3.2.10
3.2.11
3.2.11.1
Check availability of Raw Materials :
Check that adequate quantity of Crude Fatty Acid is available
in Off site Storage Tank and that the same is of the required
specification.
Check the Instrument / Interlocking System :
Check the various instruments / electrical interlocking system,
wherever provided, by simulating suitable conditions in the
equipment.
Energise Vacuum Systems (PK-301 & PK-302) :
Since, both the vacuum systems are connected with one
common Hogger Start up Ejector (J – 309) with an isolation
Valve, both the systems can be started simultaneously /
independently.
Start – up of Vacuum System PK – 301 for precut Column
(C-301) :
Ensure the air vent valves are closed in the system.
First Step – upto 250 – 196 mm Hg (a)
Open medium pressure steam to Hogger Ejector (J-309)
Open direct water to Secondary surface Condenser
(CS-302).
3.2.11.2
3.2.11.3
3.212
Open medium pressure steam to Dry Ejector (J-303).
Open direct water primary o Surface Condenser (CS-301)
Second Step upto 60 – 50 mm Hg (a)
After attaining 250 – 196 mm Hg (a) in the system open medium
pressure steam to Wet Ejector (J – 302).
Close the steam to Hogger Ejector (J – 309) and close the isolation
valve.
Third Step upto 30 – 20 mm Hg (a)
After attaining 60 – 50 m Hg (a) vacuum in the system, open steam
to booster Compressor (J – 301).
Adjust the water flow to the surface Condensers (CS 301 & CS 302)
to obtain the desired vacuum.
Start up of Vacuum System PK – 302 for Fatty Acid
Distillation Column (C – 302):
Since, no steam is generated from the heat recovery system of the
Plant, start Low Pressure steam from the offsite as described below:
3.2.12.1
3.2.12.2
Open the Isolating Valves of Control Valve (PV-304) of
Pressure Indicating Controller (PIC – 304).
Put the pressure Indicating Controller (PIC – 304) in manual
mode and open the valve (PV-304) completely.
If required, open Bypass Valve of Control Valve (PV – 304) since
external steam is only for make up requirement.
First Step upto 250 – 156 mm Hg (a)
Open Isolating Valve connecting Vacuum System (PK – 302) to
the common Hogger Ejector (J – 309).
Open medium pressure steam to Hogger Ejector (J – 309).
Open Direct Water to surface Condenser (CS-305).
Open low pressure steam to Dry Ejector (J – 308)
Open direct water to surface Condenser (CS – 304)
Open low pressure steam to Wet Ejector (J – 307).
Second Step upto 60 – 50 mm Hg (a)
After attaining 250 – 156 mm Hg (a), close isolating valve of
Hogger Ejector (J-309) and close the medium pressure steam to
the Hogger Ejector (J – 309).
3.2.12.3
3.2.12.4
3.2.13
Open direct water to Surface Condenser (CS – 303)
Open low pressure steam to Wet Ejector (J – 306).
Third Step upto 15 – 10 mm Hg (a)
After attaining 60 – 50 mm Hg (a) in the System, open low
pressure steam to booster Compressor (J – 305).
Fourth Step upto 4 – 2 mm Hg (a)
After attaining 15 – 1mm Hg (a) in the system, open low
pressure steam to Booster Compressor (J – 304).
Open low pressure steam to Jacket heating of Booster
Compressor (J – 304)
Close by pass valve of trap assembly of Jacket heating system
of Booster Compressor (J – 304). Once all the condensate is
removed and steam trap functioning normally.
Filling Water Recirculation Drum (V – 305) :
Open vent valve of Water Recirculation Drum (V – 305)
Fill the Water Recirculation Drum with DM Water by opening
bypass valve of Control valve (LV – 309) till the Level Indicating
Controller (LIC – 309) indicator shows 80 – 90 % level.
On obtaining the desired level in water Recirculation Drum
(V - 305) close the Bypass Valve of DM Water Feed Control Valve
(LV – 309).
Open Suction Valve of water Recirculation Pump (P – 310).
Start the Pump (P – 310) and open discharge valve gradually to
put water in circulation. On circulation, the level in Water
Recirculation Drum (V – 305) reduces due to filing of pipelines.
Open Bypass Valve of Control Valve (LV – 309) and maintain
water level 30 – 40%.
For initial heating, open low pressure steam valve to Water
Recirculation Drum (V – 305).
Close the steam condensate trap assembly bypass valve of Water
Recirculation Drum (V – 305), once all the condensate is removed
and steam trap functioning normally.
On reaching temperature at 90 – 95 ° C in Water Recirculation
Drum (V – 305), adjust the flow of the steam to water Recirculation
Drum (V – 305) and maintain the temperature till the distillation
starts.
3.2.14 Filling Scrubber Circulation Systems:
Filling of Scrubber Circulation System is carried out after the vacuum
trials of the Plant. Before filling the system with Crude Fatty
Acids/Distilled Fatty Acids/Neutral Oil, ensure complete draining of
water from Scrubber Receiver (V – 302 & V – 304), Scrubber Coolers
(EP-301 & EP-302), Scrubber Pump (P – 305 & P – 309) and
connecting pipelines.
Filling of Scrubber Receivers (v-302 & v-304) can be carried out either
by using hand pump or by sucking the material under vacuum (60 –
100 mm Hg).
Connect hose to the drain valve of Scrubber Pump
(P – 305 / P-309) and to Crude Fatty Acid / Distilled Fatty Acid /
Neutral Oil Drum.
Since the system is under vacuum, the material from drum flows to
Scrubber Receiver (V-302 & V – 304) on opening of the drain
valve & suction valve of Scrubber Pump (P-305 / P-309).
Discharge valve should be closed.
Fill the Scrubber Receiver (V-302 / V-304) till Level Indicating
Controller shows 80 – 90% level. The level of material can be
seen from the equipment sight glass.
3.2.15
Feed the material till the desired level is obtained in Scrubber
Receiver (V-302 / V-304) and close Pump Suction Drain Valve.
Start the Scrubber Pumps (P – 305 / P-309) and open discharge
valve and ensure proper circulation. During circulation, if the level of
Scrubber Receiver (V-302 / V – 304) goes below minimum level,
feed the material again. The quantity of Distilled Fatty Acid / Light
Fatty Acid required for filling both the Scrubber Circulation systems
is 1500 – 2500 Litres approximately.
Commissioning of Precut Column Scrubber Recirculation
System :
Open low pressure steam to Scrubber Cooler (EP-301) and open
the condensate drain valve in order to heat the material which is in
circulation.
Open Suction Valves of Scrubber Pump (P-305) and start the Pump.
Open discharge Valve gradually.
Open the by pass valve of Flow Indicator (F1-304) gradually and
allow the material to go to the Scrubbing Section (Bed-4) of Precut
Column (C-301) for few seconds. Close bypass valve of Flow
indicator (F1-304) and adjust the isolating valves such that the rate
of flow is maintained at 1000 – 2500 Kg/Hr.
Till the process starts, maintain the temperature of Scrubber Cooler
outlet 75 - 85°C by adjusting the low pressure steam to Scrubber
Cooler (EP-301) .
Now, Light Fatty Acid is being circulated across the Bed No.4 and
same could be seen in Sight Flow Indicator provided on the return
line of Scrubber Receiver (V-302).
On starting of the Scrubber Pump (P-305), the Light Fatty Acid level
in Scrubber Receiver (V-302) comes down due to filling of pipe lines
and wetting of Scrubber bed (Bed – 4). Fill again Light Fatty Acid
Receiver (V-302) if level falls below the ‘Low Level” of LIC –304.
Refilling can be carried out during the circulation since the feeding
hose is connected to the Suction side of Scrubber Pump (P-305).
Disconnect the filling arrangement on attaining the minimum level
(20-30%) in Scrubber Receiver (V-302).
The Light Fatty Acid circulation is through, Scrubber Cooler
(EP-301) where the Light Fatty Acid is cooled with tempered water
to desired temperature by Temperature Control Loop (TIC-311).
3.2.16
Presently, Scrubber Cooler (EP-301) is being heated with low
pressure steam to remove the moisture from the Light Fatty Acid. This
heating is required only during initial start up of the Plant.
Close the low pressure steam to Scrubber Cooler (EP-301) and close
the condensate drain valve.
Set the temperature of Light Fatty Acid through temperature Indicating
Controller (TIC-311) TO 75-85°C.
Put the Controller (TIC-311) in Auto Mode and open the Isolating
Valves of Control valve (TV-311) and let the Controller maintain the
set temperature.
Commissioning of Scrubber Circulation System of Fatty Acid
Distillation Column (C-302):
Open low pressure steam to Scrubber Cooler (EP-302) and open the
condensate drain valve in order to heat the material which is in
circulation.
Open Suction Valve of Scrubber Pump (P-309) and start the Pump.
Open Discharge valve gradually.
Open the by pass valve of Flow Indicator (F1-307) gradually and
allow the material to go to the Scrubbing Scction (Bed – 3) of
Fatty Acid Distillation Column (C-302) for few seconds. Close
bypass valve of Flow indicator (F1-307) and adjust the isolating
valve such that the rate of flow is maintained at 1000-2500 Kg/Hr.
Till the process starts, maintain the temperature of Scrubber Cooler
outlet at 75 - 85° by adjusting the low pressure steam to Scrubber
Cooler (Ep-302).
Now, Light Fatty Acid is being circulated across the Bed No.3 and
same could be seen in Sight Flow Indicator provided on the return
line of Scrubber Receiver (V-304).
On starting of the Scrubber Pump (P-309), the Light Fatty Acid level
in Scrubber Receiver (V-304) comes down due to filling of pipe lines
and wetting of Scrubber bed (Bed – 3). Fill again Light Fatty Acid
Receiver (V – 304) if level falls below the ‘Low Level” of LIC – 308.
Refilling can be carried out during the circulation since the feeding
hose is connected to the Suction side of Scrubber Pump (P – 309).
Disconnect the filling arrangement on attaining the minimum level
(20-30%) in Scrubber Receiver (V-304).
The Light Fatty Acid circulation is through Scrubber Cooler (EP-302)
where the Light Fatty Acid is cooled with tempered water to desired
temperature by Temperature Controller (TIC – 319).
3.2.17
Presently, Scrubber Cooler (EP-302) is being heated with low
pressure steam to remove the moisture from the Light Fatty
Acid. This heating is required only during initial start up of the
Plant.
Close the low pressure steam to Scrubber Cooler (EP-302)
and close the condensate drain valve.
Set the temperature of Light Fatty Acid through Temperature
Indicating Controller (TIC – 319). to 75 – 85° C.
Put the Controller in Auto Mode and open the Isolating
Valves of Control Valve (TV-319) and let the Controller
maintain the set temperature.
Filling Distilled Fatty Acid Receiver (V-303) and
Starting Recirculation System :
The quantity of Distilled Fatty Acid required for filling DFA
Receiver Circulation System is 4000 – 5000 Litres. Since the
quantity required for filling is higher, temporary pumping
arrangement may be made to pump Distilled Fatty Acid /
Light Fatty Acid to DFA Receiver (V-303).
Filling of DFA Receiver (V-303) system is carried out after the
vacuum trials of the Plant. Before filling the system with
Distilled Fatty Acids, ensure complete draining of water from
DFA Receiver (V-303), Pump Around Cooler (E-309) and its
connecting pipelines.
Open isolating valves of DFA Receiver (V-303) and Level
Transmitter (LT-307).
Connect hose pipe to drain valve of Product Distiled Fatty
Acid Pump (P-308) and DFA Drum. Since the system is
under vacuum the Fatty Acid from Drum flows to DFA
Receiver (V-303) on opening of drain valve and suction valve
of Product Distilled Fatty Acid Pump (P-308).
Filling should be carried out when the system is under
absolute pressure of 60-80 mm Hg (a).
Fill the DFA Receiver (V-303) till the Level Indicating
Controller shows 50-60% level. The level of Distilled Fatty
Acid can be seen from the equipment Sight Glass.
Feed Distilled Fatty Acid till the desired level is obtained in DFA
Receiver (V-303) and close Pump Suction Drain valve of
Product Distilled Fatty Acid Pump (P – 308).
The water recirculation in Water Recirculation Drum (V-305) is
already commissioned earlier. Keep the hot water circulation in
Pump Around Cooler (E-309) in order to avoid any solidification
of Distilled Fatty Acid inside the Cooler.
Open Suction valve of Product Distilled Fatty Acid Pump (P-308)
and start the Pump and open the discharge valve gradually
(bypass valve of Flow Indcator (F1-308) and allow the material to
go to Condensation Bed (Bed No.2) of fatty Acid Distillation
Column (C-302) for few seconds.
Close bypass valve of Flow Indicator (F1-308) and adjust the
isolating valve, such that the rate of flow is maintained at 4000-
5000 Kg/hr.initially.
Now the Distiled Fatty Acid is in circulation across the Bed No.2
and the Circulation could be seen in sight glass provided on the
return line of Fatty Acid Distillation Column (C-302) to Distilled
Fatty Acid Receiver (V-303).
On starting of the Pump, the Distilled Fatty Acid level in DFA
Receiver (V-303) comes down due to filling of discharge
pipelines and wetting of Condensation Bed (Bed No.2).
Fill again DFA Receiver (V-303) if level falls below the ‘Low
Level’ of LIC –307. Refilling can be carried out during the
circulation. Since the feeding hose is connected to the suction
side of the Product Dstilled Fatty Acid Pump (P-308).
Disconnect the filling arrangement on attaining the minimum
level (30-40%) in DFA Receiver (V-303).
3.2.18
3.2.18.1
Charging of CRUDE FTTY ACID to Fatty Acid Precut Column
(C-301):
Stage 1 – Commissioning of CFA Degasifier (V-301)
Ensure that the desired Vacuum in both the Systems (PK-301 &
PK-302) are maintained.
CRUDE FATTY ACID to CFA Degasifier (V-301):
Pump Crude Fatty Acid from Offsite Storage facilities.
Open respective valves on lines depending upon the source of
supply.
Open Inlet and Outlet of Filter (F-301).
Open low pressure steam to Filter (F-301) and close the bypass
valve of Loop assembly oce all condensate is drained.
Start CRUDE FATTY ACID Feed Pump of Offsite Storage Tank
and set the flow rate initially at reduced load.
Open Isolating Valves of LT-301 on CFA Degasifier (V-301)
3.2.18.2
3.2.18.3
Steam to CRUDE FATTY ACID Pre Heater (E-301)
Open isolating valves of Control valve (TV-301), set the
TIC –301 temperature to 90 - 120°C.
Put Temperature Controller (TIC – 301) in Manual mode and open
the control valve gradually (15-30%).
Open condensate valves of CRUDE FATTY ACID Pre Heater
(E-301) trap assembly.
Close the condensate bypass valve after all the condensate is
removed and Steam Trap is functioning normally.
Put the Controller (TIC –301) in Auto Mode and let the Controller
maintain the set temperature.
Steam to CFA Degasfier (V-301)
Open Steam valve on CFA Degasifier (V-301).
Open condensate valves of CFA Degasifier (V-301) trap assembly.
Close the condensate bypass valve of trap assembly once all the
condensate is removed and Steam Trap is functioning normally.
Set LIC –301 of CFA Degasifier (V-301) to 40-50% level operation.
Manually increase / decrease to the set value.
Switch over to “Auto” mode and let the Controller maintain the
desired set level.
NOTE :
Check temperature in CFA Degasifier (V-301) on TG –302. It
should be 90 - 120° C.
Steam is required in CFA Degasifier (V-301) and Filter (F-301) for
melting of solidified material.
3.2.19
3.2.19.1
Commissioning of Precut Column (C-301), Light Fatty Acid (LFA)
Recovery System and transfer of Light Fatty Acid to Off-site
Storage Tank :
Close bypass valves of all the Control valves installed in the thermic
fluid lines. The thermic fluid system is always designed with a
recycling arrangement so that minimum flow required is always
circulated during closure of all process valves.
Close thermic fluid outlet valves of all the equipments.
Now gradually increase the thermic fluid outlet temperature of
thermic fluid system to 200 – 240 °C.
Precut Column (C-301)
After desired level is reached in CFA Degasifier (V-301), open
suction Valve of Feed Pump (P – 301).
Stat Feed Pump (P – 301) and open recycle valve gradually.
Open bypass valves of Flow Transmitter (FT-301), Control valve
(FV-301) allow the material to go to CFA Heater (E-302) for few
seconds.
Set the flow rate of FIC – 301 to 2000 – 3000 Kg./hr.
Open isolaion valves of Control Valve (FV-301), FT-301put the Flow
Indicating Controller in Manual Mode and adjust the Control Valve
opening close to the set value (± 200 Kg/hr.). Put the Control Valve
in Auto Mode and let the Controller maintain the desired flow arte.
Thermic fluid to CFA Heater (E-302):
Open thermic fluid outlet valve of CFA Preheater (E-302).
Open isolation valves of Control Valve (TV-302).
Set the temperature of Controller (TIC-302) TO 200°C initially.
Adjust the control valve opening manually till the temperature
reaches close to the approximate set point (± 15 °C).
Put the Controller (TIC – 302) to Auto Mode and let the Controller
(TIC-302) maintain the desired set temperature.
Commissioning of Reboiler Circulation System (C-301) :
Feed to Precut Column is provided at two points. One at the top of
Rectification Bed (Bed 2) and the second at the top of Strippping Bed
(Bed 1). Feeding of rude Fatty Acids is always given at the top of
stripping bed (Bed 1). Feeding at the top of Rectification bed (Bed
2) is given to heat the packings in case they are choked with Light
fatty Acid on sudden stoppage of the Plant.
Open feed valve of Precut Column so that feeding goes to the top
of Stripping Bed (Bed 1).
Open isolating valves of Level Transmitter LT-302) of the Precut
Column (C-301), put the Level Indicating Controller (LIC-302) in
Manual mode and close the Control Valve (LV-302).
Once Crude Fatty Acid level in Precut Column reaches the
40 – 50% (LIC – 302), open suction valve of Reboiler Circulation
Pump (P-302), start the Pump and open discharge valve
gradually.
Opening thermic fluid to Precut Reboiler:
Open thermic fluid outlet valve of Precut Reboiler (E-303).
Open isolating valves of Control Valve (TV-303) and put the
Temperature Indicator Controller (TIC-303) in Manual Mode.
Set Temperature Indicator Controller (TIC – 303) to 200°Cinitially,
and adjust the Control Valve opening to bring the Precut Reboiler
(E-303) outlet temperature close to the set point (±15°C). Put the
Controller (TIC-303) in Auto Mode and let the controller maintain
desired set value.
During the initial start up, the Precut Column and its internal
temperature are much lower. Due to this reason , most of the Fatty
Acids which are distilled will be condensed and refluxed back to the
Column. To increase temperature of internals of Precut Column
(C-301), stop the feed and carry out recirculation through Precut
Reboiler (E-303) till the required temperature is attained.
Stopping Feed to CFA Degasifier (V-301) / Precut Column (C – 301)
Check the level of the Precut Column and when the level of LIC – 302
reaches 80 – 90% stop feed to the Precut Column as described below:
Put the Controller (TIC – 302) (I.E Thermic Fluid to CFA Heater E-
302) in Manual Mode and close the Control Valve (TV-302)
completely.
Put the Controller FIC –301 (i.e Crude Fatty Acid feed to Precut
Column) in Manual Mode and close the Control Valve (FV-301)
completely and let the Crude Fatty Acid in circulation in CFA
Degasifier (V-301).
When the level increases in the CFA Degasifier (V-301) LIC –301
closes the Control valve (LV-301). But it is advisable to close the
isolating valves of Control valve (LV-301) since the entire system is
under vacuum.
Put the Controller (TIC-301) in Manual Mode and close the Control
valve (TV-301) completely thereby stopping the steam to CFA Pre
Heater (E-301).
Open trap assembly bypass valve of CFA Pre-Heater (E-301)
and drain the condensate.
Stop low pressure steam to CFA Filter (F-301) and to CFA
Degasifier (V-301).
Distillation in Precut Column (C-301):
During initial start up, the pressure in Precut Column is much lower
than the normal operating pressure, since there is no steam vapour
coming from Deodorizer (V-306) and the distillation of Light Fatty
Acid starts at 180-200 °C in Precut Column (C-301).
Open stea to Precut Column and maintain the pressure at open
steam 0.2 to 0.5 Kg/Cm2 (g) in order to increase the rate of
distillation and to heat tower internals faster.
Increase the set point of (TIC-303) gradually to 220° (Precut
Reboiler outlet temperature).
Due to the distillation at Light Fatty Acid in Precut Column, the
temperature of the rectifying bed (Bed 2) gradullay increases.
3.2.19.2 LFA Recovery System
Starting of Pump Around system of Precut Column :
The Pump Around System may not be required to fill before start up.
The condensation of Light Fatty Acid takes place due to low
temperature of structural packings and Light Fatty Acid start collecting
at the bottom of condensation bed (Bed 3).
The flow of the Light Fatty Acid could be seen in the sight glass
provided in the Inlet line of Pump Around (Receiver (V-302A) and the
low level indication(LAL - 303) goes off. This indicates the Light Fatty
Acid level in bottom collecting tray at condensation bed (Bed 3).
Set Temperature Controler (TIC-309) temperature to 85-125 °C, Light
Fatty Acid outlet of Pump Around Cooler (E-304).
Open isolating valves of Control Valve (TV-309) and put the Controller
(TIC-309) in Manual Mode and close the Control Valve (TV-309) .
(Tempered water to Pump Around Cooler E-304).
Check the level of the Precut Column, the minimum level (20%)
should be maintained. In case the level goes down, start feeding to
the Precut Column as described earlier.
Open suction valve of Pump Around Pump (P-304) ad start the
Pump.
Open discharge valve of Pump Around Pump (P-304) gradually
without allowing the Pump to run dry. Sudden opening of
discharge valve of Pump Around Pump (P-304) leads to dry rum of
Pump, since Pump Around Cooler is to be filled for recirculation of
Light Fatty Acid.
Open bypass valve of Flow indcator (F1-303) and let Light Fatty
Acid go to condensation bed (Bed 3) for few seconds.
Close the bypass valve of Flow Indicator (F1-303).
3.2.19.3
Open Isolation Valves of Flow Indicator (F1-303) and set the Flow
rate to 2000-4000 kg/hr. The Flow rate of F1-303 and temperature
of Light Fatty Acid at the outlet of Pump Around Cooler (E-304)
mainly depends on the quality of the raw materials to be
processed. Similiarly, pressure and temperature of Precut Column
(C-301) also depends upon the quality of raw materials.
On establishing the onstant flow in Pump Around Circulation
System Light Fatty Acid can be pumped to the storage.
Transfer of Light Fatty Acid to the Storage (Precut Column
(C-301)
The quantity of Light fatty Acid to be pumped to the storage is in
the range of 2 to 5% on Input Feed. Some time, it may exceed this
rate when the quality of Input material is poor.
Open the bypass valves of Flow Transmitter (FT-302) and Control
Valve (FV-302) to allow some Light Fatty Acid to Storage (for few
seconds).
Set Flow Indicating Controller (FIC-302) 50 to 75 Kg/hr. (i.e., Light
Fatty Acid from LFA Cooler (E-305).
Open isolating valves of Control Valve (Fv-302). Put the Controller
(FIC-302) in Manual Mode and adjust the Control valve openings to
bring the flow rate close to the Set Value (±15 Kg/hr).
Put the Controller (FIC – 302) in Auto Mode and let the Controller
maintain the desired flow rate.
Set the Temperature Indicating Controller (TIC-310) temperature to 75
to 85°C (LFA Outlet of LFA Cooler E-305).
Open the solating valves of tempered Water Control Valve (TV-310) to
LFA Cooler (E-305).
Put the Controller (TIC-310) in Manual Mode and adjust the Control
Valve opening to bring the temperature close to the Set Value (±10° C).
Put the Temperature Indicating Controller (TIC-310) in Auto Mode and
let the Controller maintain the desired set temperature.
Since the Light Fatty Acid to the storage from the Pump Around
System is at measured quantity the excess Distilled Fatty Acid / Light
Fatty Acid condensed in Condensation Bed (Bed 3) overflows to the
rectification bed (Bed 2) for rectification.
In rectification section, the good Distilled Fatty Acid refluxes back to
the Precut Column (C – 301) and thereby allowing Light Fatty Acid /
Odorous Fatty Acid with a small quantity of istilled Fatty Acid vapour
gows to the Condensation Bed (Bed 3).
The pumping of the Light Fatty Acid to the Storage also can be
started after stabilizing the main Distillation Column (C-302) thereby
allowing the 100% reflux back to the rectification bed (Bed 2). But it
is always advisable to remove a small quantity of Light Fatty Acid
from the beginning to obtain better quality of Distilled Fatty Acid.
Starting the Light Fatty Acid to Storage from the Scrubber
Circulation System :
The level of Light Fatty Acid in Scrubber Receiver (V-302)
increases during the Distillation in Precut Column (C-301).
Set the level of Light Fatty Acid in Scrubber Receiver (V-302)
Controller (LIC – 304) to 40 – 50%.
Open the isolation valve of the Control Valve (LV-304) and put
the Controller (LIC –304) in Manual Mode and adjust the
Control Valve opening to bring the level close to the set value
(±10%)
Put the Controller (LIC – 304) in Auto Mode and let the
Controller maintain the desired set level in Scrubber Receiver (V
– 302).
Depending on the Light Fatty Acid level in the Scrubber
Receiver (V – 302). The Light Fatty Acid goes to the Storage.
3.2.20 Feeding to the Distillation Column (C-302):
Start Crude Fatty Acid feed to Precut Column as described
earlier.
The level in Precut Column (LIC – 302) will be increasing.
Open Suction valve of Bottom Pump (P – 303).
Open discharge valve (i.e. Recycle arrangement to Precut
Column C – 301) gradually and let small quantity of Crude Fatty
Acid recycle back to Prect Column (C-301).
Set the level of Precut Column (LIC – 302) to 40-50% and open
the Isolation Valves of the Control Valve. Put Controller in
Manual Mode. Adjust the Valve opening to ring the level close
to the set level (± 10%).
Put the Controller in Auto Mode and let the Controller (LIC –
302) maintain the desired set level.
The Level Indicating Controller (LIC – 302) maintain the Set
level in Precut Column (C – 301) by sending the Crude Fatty
Acid to the main Distillation Column (C-302).
3.2.21
Once Crude Fatty Acid level reaches to the sight glass in
Distillation Column (C – 302), the level in the Distillation Column
should be 200-300 mm lower than the top of overflow line.
Open Suction Valve of Reboiler Circulation Pump (P-306), start the
pump and open discharge valve of the pump gradually.
Thermic Fluid heating to Reboiler (E-306):
Open the isolating valves of Control Valve (TV – 314), set the
controller (TIC – 314) temperature to 200° initially.
Put the Controller in Manual Mode and adjust the Control Valve
openig, to bring the temperature close to the set temperature
(±10%).
Put the Controller (TIC – 314) in Auto Mode and let the Controller
maintain the desired set temperature.
On starting of Reboiler Circulation Pump (P-306), the level in the
Distiller goes down due to filling of pipeline and Reboiler.
Check the level and see that the Reboiler Circulation Pump (P-306)
should not run dry.
The temperature in Fatty Acid Distillation Column (C – 302)
increases very fast due to the forced circulation through the Reboiler
(E-306).
Gradually increase the set point ofr Temperature Controller (TIC-
314) to 230-250°C.
The Distillation Column (C-302) temperature depends on the type of
oil and quality of the Distilled Fatty Acid required for the end use.
The Distillation of Fatty Acid in the Distillation Column (C-302) starts
when the temperature is around 190 - 200°C.
During the process of increasing the temperature in the Distillation
Column (C-302), the level in the Distillation Column does not
increase. In case of increase in level above the overflow, stop feed to
the Distillation Column (C-302), stop feed to the Precut Column as
described earlier.
To stop the feed to main Distillation Column (C-302) put the Level
Controller (LIC-302) in manual Mode and close the Control Valve
(LV-302) completely. Let the bottom Pump (P-303) circulate the rude
Fatty Acid back to the Precut Column (C-301).
The overflow from Distillation Column (C-302) takes some time,
since the Distiller is to be filled with the residue due to the Distillation
of Fatty Acid. But however, it is advisable to start heating in Fatty
Acid Stripper (E-307) as explained below:
Open the Thermic Fluid outlet Valve of Fatty Acid Striper (E-307).
Put the Controller (TIC-312) in Manual Mode and open the Valve (TV-
312) to 10%
NOTE :
Set the supply and return temperature of thermic fluid heater as per
process requirement.
3.2.22
3.2.22.1
3.2.22.2
Stabilisation of Pump Around System (Condensation System):
Increasing the Condensation Flow Rate
On Distillation of Distiled Fatty Acid due to increase in
temperature, the level in Distilled Fatty Acid Receiver (V-303)
increases.
Increase the flow to the condensation bed (Bed 2) to 15000 –
30000 Kg/hr by adjusting the isolation valve of Flow Indicator.
(F1 – 308)
Steam Generation
The Distilled Fatty Acid is being circulated through Pump Around
Cooler (E-309) for the condensation of the Fatty Acid vapour.
Close the low pressure steam to Water Circulation Drum (V-305)
and open the trap bypass valve to drain the condensate.
Set the temperature of Controller (TIC – 320) to 125 –135°C and
put the Controller directly in auto Mode. Let the Controller maintain
the desired Set Point.
The water circulation system is already started due to the cooling
of the Distilled Fatty Acid, the water gets heated and generates
steam in water Recirculation Drum.
The vent valves of water Recirculation Drum are opened to vent
out the Air from Water Recirculation Drum (V-305).
Check the water level in Water Recirculation Drum (V-305).
Set the Level Indicating Controller (LIC-309) to 45 – 55% and open
the isolating valve of Control Valve (LV-309).
Put the Controller (LIC-309) in Manual Mode and adjust the
opening of the Control valve to bring the water level in Water
Recirculation Drum close the set point (± 10%)
Put the Controller in Auto Mode and let the Controller (LIC –309)
maintain the desired set level in Water Recirculation Drum (V-305).
Presently Vacuum System (PK-302) is operating on low pressure
steam from Offsite Boiler.
Vent out steam vapour from Water Recirculation Drum for 1 – 15
minutes so that entire air is vented comes out from the Water
Recirculation Drum (V-305).
Close the vent valve of Water Recirculation Drum (V-305).
Set the Pressure Indicating Controller (PIC – 304) pressure to
1.5 – 2.5 Kg/cm2 and put the Controller in Auto Mode.
Open the Isolating Valve of Water Recirculation Drum (V-305)
gradually. At the same time close the bypass valve of Pressure
Control Valve (PV-304) gradually.
3.2.23
Observe the Control Valve (PV-304) functioning . If required, put the
Controller (PIC-304) in Manual Mode and adjust the Control Valve
(PV-304) opening to bring to the set pressure.
Put the Controller (PIC-304) in Auro Mode and let the Controller
maintain the desired set pressure.
NOTE :
In case, no steam is generated from the Plant, it is essential to open
Control valve (PV-304) in Manual Mode and bypass valve of the
Control Valve (PV-304). This Control Loop is designed to supply
only make up steam. But not the total steam required for the
Vacuum System.
Transfer of Distilled Fatty Acid to Deodoriser :
This transfer of Distilled Fatty Acid is carried out simultaneously with
the steam generation operation.
Set the Level Indicating Controller (LIC-307) of DFA Receiver
(V-303) to 45 – 55%.
Open the Suction Valve of product DFA Pump (P-308). Start the Pump.
Open the bypass valve of Flow Indicator (F1-306) for few seconds.
Open Isolating valve of Flow Indicator (F1 – 306) for sending Distilled
Fatty Acid to Washing Bed (Bed 1) at a flow rate of 200-500 Kg/hr.
The Distilled Fatty Acid to the Washing bed generally is not required all
the time.
Open Isolating Valve of Control Valve (LV-307).
Put the Controller (LIC – 307) in Manual Mode and adjust the Control
Valve opening close to the set level (±10%).
Put the Controller (LIC-307) in Auto Mode and let the Controller maintain
the desired set value and transfer Distilled Fatty Acid to Dedoriser.
3.2.24
Transfer of Light Fatty Acid from Distillation Column
(C-302) to Storage :
The Light Fatty Acid level in Scrubber Receiver (V-304) will not
increase in a faster way since all the Light Fatty Acid are
removed in Precut Column (C-301). Sometimes the level may
not increase at all.
Set the Level Indicating Controller (LIC-308) to 45-50%.
Open isolating valves of Control Valve (LV-308).
Put the Controller (LIC-308) in Auto Mode and let the Controller
maintain its desired set level in Scrubber Receiver (V-304) by
transferring Light Fatty Acid to the Storage.
Residue Stripping :
Open tempered water inlet to Stripped Fatty Acid Condenser
(E-311).
Open isolating valves of Level Transmitter (LT-306) of Fatty
Acid Stripper (E-307).
The level in Fatty Acid Distillation Column (C-302) should not
exceed above the over flow pipe. Always the circulation of the
material should be visible from the sight glass of the Distillation
Column (C-302) during the running of Reboiler Circulation Pump (P-
306).
Open the vent valve to overflow loop of Fatty Acid Distillation
Column (C-32). The loop is provided with a balancing line to
maintain the constant level, so that all the time forced circulation of
Crude Fatty Acid takes place in Distillation Column (C-302) through
Reboiler (E-306).
Open gradually Overflow Valve to Fatty Acid Stripper (E-307).
On observing the material flow to Fatty Acid Stripper (E-307)
through the sight glass. Set the Temperature Indicating Controller
(TIC-312) temperature to 240 - 260°C.
Put the Controller (TIC-312) in Auto Mode and let the Controller
control the desired set temperature. The temperature Controller
(TIC-312) will be put in Auto Mode only after reaching minimum
level in Fatty Acid Stripper (E-307).
3.2.25
Drain the water from the low pressure sparging steam line to
fatty Acid Stripper (E-307).
After draining the condensate from the open steam line, adjust
the open steam such that the Pressure Gauge
(PG-311) indicates 0.2 – 0.5 Kg/cm2 (g).
The flow of open steam can be seen from the sight glass of the
Fatty Acid Stripper (E-307).
Open isolating valves of Level Transmitter (LT-306).
Residue Pumping to Storage :
On attaining the level (10-20%) in Level Transmitter (LT-306), set
the Level Indicating Controller (LIC-306) to 30 – 40%.
Open the Suction Valve of Residue Pump (P-307). Start the
Pump and open recycle valve gradually.
Set the Temperature Indicating Controller (TIC- 313) [tempered
water to Pitch Cooler (E-308)] to 90 - 100° C and put the
Controller in Manual Mode and adjust the Control Valve
(TV-313) to bring the temperature close to the set temperature.
Put the Controller (TIC – 313) in Auto Mode, let the Controller
maintain the desired set temperature.
Open the isolating valves of Control Valve (LV-306). (i.e.,
Resuide / Pitch to Storage).
Put the Level Controller (LIC-306) in Manual Mode and adjust
the opening of the Control Valve to bring the level in Fatty Acid
Stripper (E-307) closer to the set value.
Put the Controller in Auto Mode, let the Level Controller
(LIC-306) maintain the desired set level in Fatty Acid Stripper
(E-307) by transferring the residue / pitch to the Storage Tank.
3.2.26 Transfer of Heavy Fatty Acids to Storage :
On starting of the Distillation in Fatty Acid Stripper (E-307), the
Heavy Fatty Acid distilled will be condensed in Stripped Fatty
Acid Condenser (E-311).
The distilled heavy Fatty Acid will be accumulated in the, open
the Suction Valve Scrubber receiver (V-304).
Set the Level Indicating Controller (LIC-308) Scrubber receiver
40-50% and open isolation valves of Control Valve (LV-308).
Put the Controller in Manual mode and open the Control Valve
– 10 – 15% (Minimum level in Scrubber receiver should be
maintained).
Open discharge valve of (LFA / HFA) Heavy Fatty Acid Pump
(D-309) gradually to cool the Fatty Acids in Scrubber Cooler
(EP-302) before pumping to Storage.
Set Temperature Indicator Controller (TIC-319) temperature to
75-85° (LFA/ Heavy fatty Acid temperature at the outlet of Heavy
Fatty Acid Cooler (EP-302).
Open isolating valves of Control Valve (TV-319) and put the
Controller (TIC-319) in Auto Mode. Since tempered water is used for
cooling of LFA/Heavy Fatty Acids in Scrubber Cooler EP-302 sudden
cooling does not occur and material does not get solidified.
3.2.27 Deodorisation of Distilled Fatty Acid
The Distilled Fatty Acid from DFA Receiver (V-303) is transferred
to Deodoriser (V-306) continuously by product DFA Pump (P-308)
as described earlier.
The Deodoriser (V-306) is divided into 7 compartments. In that
6 compartments are provided with mammoth Pumps and last
compartment is only for collecting the Deodorised Distilled Fatty
Acid.
On starting of transfer of Distilled Fatty Acid to Deodoriser, one
has to observe the filling of each compartment. The flow from
the first compartment to last compartment is by underflow /
overflow arrangement.
Drain the condensate from the self acting Pressure Control
Loop (PCV – 301).
On filling of the first compartment to the overflow level, open
bypass value of Pressure Control loop (PCV-301) And open
steam to the first compartment such that the pressure on
Pressure Gauge (PG-318) show 0.2 Kg/cm2 initially.
On filling of the subsequent compartment, open steam to the
respective compartment by maintaining the 0.2 Kg/cm2 pressure
in Pressure Gauge (PG-318) by adjusting the bypass valve of
the Pressure Control Valve (PCV-301).
On opening of the steam to the each compartments, the
circulation of Distilled Fatty Acid could be seen through the
equipment sight glasses.
Set the Level Indicating Controller (LIC-310) level to 45 – 55%.
Put the Pressure Control valve (PCV-301) in operation by
opening the isolating valves of the same and close the by
bypass valve gradually.
Set the Pressure Control valve (PCV-301) pressure to 0.5
Kg/cm2.
The quantity of steam required, depends upon the quality of
the input Crude Fatty Acid. The operating pressure is in the
range of 0.3 to 0.8 Kg/cm2.
Since no open steam is possible to be given to the Deodoriser
during the start up of Precut Column (C-301), open steam was
given for spraging in Precut Column (C-301).
3.2.28
Close the open steam valve to the Precut Column (C-301).
Transfer of Distilled Fatty Acid to Storage :
On obtaining the set level in Deodoriser (V-306), put the Level
Controller (LIC – 310) in Manual Mode and open the isolating valves
of Control Valve (LV-310) and close the Control valve (LV-316).
Open Suction Valve of Deodoriser Outlet Pump (P-311). Start the
Pump.
Open gradually discharge Recycling Valve of Deodoriser Outlet Pump
(P-311).
Put Temperature Controller (TIC – 321) in Manual Mode and open the
Control valve (TV-321) 10-15%, so that small quantity of water flows to
DFA Cooler (E-310).
Adjust the Level Control Valve (LV-310) so that the level of the
Deodoriser comes near to the set value.
Put the Level Indicating Controller (LIC-310) in Auto Mode ad let the
Controller maintain the set level in Deodoriser (V-306).
3.229
Set the Temperature Indicating Controller (TIC – 321) to 60 - 75° C,
(DFA outlet of Distilled Fatty Aid Cooler (E-310) adjust the
Control valve (TV-321) opening such that temperature of
Distilled Fatty Acid comes close to the set value (±5° C).
Put the Temperature Indicating Controller (TIC-321) in Auto
Mode and let the Controller maintain the set temperature.
The temerature to e maintained in Deodoriser (V-306) is in the
range of 160-18575° C. To obtain this temperature, open
thermic fluid inlet and outlet valves to Deodoriser (V-306). This
thermic fluid valves must not be opened till the compartments of
Deodoriser (V-306) are full of Distilled Fatty Acid.
Stabilitsing Precut Column :
The operating pressure of Precut Column (C-301) mainly depends
on the quantity of the open steam given in Deodoriser (V-306).
The open steam is generally given in the range of 0.3 – 0.8
Kg/cm2(g). (Refer Pressure Gauge (PG-318).
3.2.30
The open steam to the Deodoriser is to be opened such that the
pressure in the Precut Column (C-301) is maintained 40 – 80 mm
Hg(abs).
Set the FIC – 302 flow rate to 400-750 Kg/hr. (when the Plant is
operating at the 3 Tons/hr.input).
Adjust the Precut Column (C-301), Temperature Indicator
Controller (TIC-303) and CFA Heater outlet Temperature Indicator
Controller (TIC – 302) to obtain the desired quantity of Light Fatty
Acid.
Production Increase to Rated Output:
Gradually increase the Crude Fatty Acid feed to the Plant, to attain
the “Rated Output”.
The Plant is now operating at the “Rated Output” producing
Distilled Fatty Acid of desired specification.
From here onwards, the “Normal Operation Procedure” detailed in
subsequent pages (Chapter 4) are to be followed to maintain the
“Rated Output” and the “Product Quality”.
CHAPTER - 4
NORMAL OPERATION PROCEDURE
4.0
4.1
4.1.1
4.1.2
NORMAL OPERATION PRCEDURE
The following periodic “Checks” are to be observed to maintain the
“Normal Operation” of the Plant.
Checks
Raw Material Supply
Raw Materials are available in the required quantities and of desired
specifications at all times.
Crude Fatty Acid (Pumped to the Plant at “Steady Rate”
Utilities Supply
General :
Utilities are available in required quantities and at desired
temperature, pressure etc., at all times
In particular, ensure the following :
4.1.3
4.1.4
Off-site Facilities :
Steam pressure at entry to ‘Battery Limits’ of the Plant is steady
and that the Pressure Reducing Station are working satisfactorily,
maintaining steady steam pressure at the outlet of Reducing
Stations under varying load conditions.
Cooling Water Systems – direct and indirect, are working
satisfactorily and water levels are maintained in Hot Wells / Cooling
Tower Basins.
Vacuum Systems – (PK – 301 & PK-302)
Desired Vacuum is maintained .
Inlet cooling water temperature should not exceed 32°C.
Outlet cooling water temperature on barometric legs of the
Barometric Condensers are to be maintained at 38°C max.
The booster in the Vacuum System should have a steady
drone and not have any pulsation effects.
Water level in Hot Well should be maintained to ensure proper
seal to the Vacuum System.
4.2Plant Operating Parameters
Pressure in the Precut Column (C-301).
Open Steam quantity in Deodoriser (V-306).
Feed temperature (E-302 outlet) and Precut Column (C-301)
temperature (TIC-303).
Light Fatty Acid quantity to storage with respect to Feed (FIC-302).
Quantity of flow F!-303 to condensation bed (Bed 3) of Precut Column
(C-301) and its temperature.
Pressure in main Distillation Column (C-302) and Fatty Acid Stripper
(E-307).
Distillation Column temperature (TIC-314)
Fatty Acid Stripper temperature (TIC-312)
Flow to Condensation Bed (Bed 2) of Main Distillation Column (C-
302) and its temperature.
Pressure of Water Circulation Drum (V-305) PIC –304
Deodoriser (V-306) temperature.
Temperature of Distilled Fatty Acid to the Storage (TIC-321)
Residue / Pitch temperature (TIC-313).
Quality of the Distiled Fatty Acid.
Quality of Residue.
Inlet steam pressure of Ejector and Boosters.
Inlet Cooling Water (Direct / Indirect) pressure and temperature.
Feed water pressure to Water Circulation Drum (V-305).
4.3
Maintain operating level of the liquid in : -
Crude Fatty Acid Degasifier (V-301) LIC – 301
Precut Column (C-301) LIC – 302
Scrubber Receiver (V-302) LIC – 304
Fatty Acid Stripper (E-307) LIC-306
Distilled Fatty Acid Receiver (V-303) LIC – 307
Scrubber Receiver (V-304) LIC – 308
Water Circulation Drum (V-305) LIC – 309
Deodoriser (V-306) LIC – 310
The Operation of all Controllers PIC, TIC, LIC & FIC.
Return of flow in Flow Indicators. (F1).
Set Points :
Set Points of Controlling Instruments
The normal operation of various Plant Controlling Instruments
viz. TIC/PIC/FIC/LIC 7 FI are detailed in subsequent pages.
SET POINTS OF CONTROLLING INSTRUMENTS FOR NORMAL OPERATION FATTY ACID DISTILLATION PLANT WITH PRECUT COLUMNS.No. Tag No. Instrument Name Location Set Point for
Normal Operation
1.
2.
3
4
5
6
7
8
9
10.
11
TIC-301
TIC-302
TIC – 303
TIC – 309
TIC – 310
TIC – 311
TIC – 312
TIC – 313
TIC – 314
TIC - 319
TIC - 320
Temperature Indicating Controller
Temperature Indicating Controller
Temperature Indicating Controller
Temperature Indicating Controller
Temperature Indicating Controller
Temperature Indicating Controller
Temperature Indicating Controller
Temperature Indicating Controller
Temperature Indicating Controller
TemperatureIndicatingController
Temperature Indicating Controller
Crude Fatty AcidPre-heater (E-301)
Crude Fatty AcidPre-heater (E-302)
Precut Column(C-301)
Pump AroundCooler (E-304)
LFA Cooler(Precut Column)(E-305)
Scrubber Cooler(Precut Column)(EP-301)
Fatty Acid Stripper(E-307)
Pitch Cooler(E-308)
Fatty AcidDistillation Column(C-302)
Heavy Fatty AcidCooler (E-312)
Scrubber Cooler(C-302)EP-302.
90-120°C
200-235°C
200-235°C
85-125°C
75 –85°C
75 –85°C
240-260°C
90-120°C
230 - 250°C
75 –85°C
75 – 85°C
S.No. Tag. No. Instrument Name Location Set Point forNormal
Operation12
13
14
15
16
17
18
19
20
21
22
23
24
TIC – 320
TIC – 322
LIC - 301
LIC - 302
LIC – 303
LIC - 304
LIC – 305
LIC - 306
LIC – 307
LIC - 308
LIC – 309
LIC – 310
PIC - 303
Temperature Indicating Controller.
Temperature IndicatingController
Level Indicator Controller
Level IndicatorController
Level IndcatingController
Level IndicatorController
Level IndicatingController
Level IndicatorController
Level IndicatorController
Level IndicatorContoller
Level Indicator Controller
Level IndicatorController
Pressure IndicatorController
Pump Around Cooler (C-302) (E-309)
Tempered waterCooler CEP – 303
Crude Fatty AcidDegasifier(V-301)
Precut Column(C-301)
LFA Receiver(V – 302 A)
Scrubber Receiver(C-301) V-302
F.A.Distiller(C-302)
Fatty Acid Stripper(E-307)
DFA Receiver(V-303)
Scrubber Receiver(C-302) V – 304
Water RecirculationDrum (V-305)
Deodorizer (V-306)
Water RecirculationDrum (V-305)
125 -135°C
40-65°C
40-50%
40 – 60%
45 – 65%
40 – 50%
40 – 50%
40 – 50%
45 – 65%
45 – 55%
45 – 55%
45 – 65%
1.5 – 2.3 Kg/cm2
S.No. Tag.No. Instrument Name Location Set Point for Normal
Operation25
26
27
28
29
30
31
32
33
34
35
FIC - 301
FIC - 302
F1 – 303
F1 – 304
FI – 306
FI – 307
FI – 308
FT – 305
FT– 309
FT - 310
F1 - 311
Flow Indicator Controller
Flow Indicator Controller
Flow Indicator
Flow Indicator
Flow Indicator
Flow Indicator
Flow Indicator
Flow Indicator
Mass Flow Meter
Mass Flow Meter
Mass Flow Meter
Feed Pump Outlet(P-301)
Outlet of LFA Cooler (E-305)
Feed Bed – 3 ofPrecut Column
Feed-Bed-2 ofPrecut
DFA to washing bed of C-302
Scrubber Cooler (EP-302) outlet
Pump Around Cooler (E-309) Outlet
Scrubber Cooler outlet (EP-301)
L.F.A outlet to storage
Residue outlet to storage
DFA outlet to storage
2000 –4000 Kgs/hr.
75-300 Kgs/hr.
2500 – 15000 Kgs/hr
1000 – 3000 Kg/hr
150 – 600 Kgs/hr.
1000 – 3000 Kg/hr.
15000 – 35000 Kgs/hr.
CHAPTER – 5
SHUT DOWN PROCEDURE
- NORMAL / PLANNED SHUTDOWN
- EMERGENCY SHUTDOWN
5.0
5.1
5.1.1
5.1.2
5.1.3
SHUT DOWN PROCEDURE
NORMAL / PLANNED SHUTDOWN
Stop Feeding :
Stop Crude Fatty Acid feeding to CFA Degasifier (V-301) and close the
feed Valves at the outlet of Feed Filters F 301 A/B.
Stop heating to Filters by closing Steam valves to filter F 301 A/B.
Drain the Crude Fatty Acid from the Filters.
Inform the Off. Site Operators to stop the Crude Fatty Acid Feed Pump
to Fatty Acid Distillation Plant.
Stop steam heating to CFA Preheater (E-301):
Put the Controller (TIC-301) in Manual Mode, close the valve completely
and close the isolating valves of Control Valve (TV-301).
Open bypass valve of condensate trap assembly to drain the
condensate from CFA Preheater (E-301).
Close Steam Valve of CFA Degasifier (V-301) and open bypass valve
of trap assembly to drain the condensate.
Emptying of CFA Degasifier (V-301):
Close the recycling valve of Feed Pump (P-301) gradually.
5.1.4
Put the Level Indicator Controller (LIC-301) of CFA Degasifier
(V-301) in Manual Mode adjust the opening of Control Valve till the
material is emptied out to Precut Column (C-301).
Close the Isolating Valves of Flow Indicator (FT-301).
Put the Flow Indicator Controller (FIC-301) in Manual Mode and
close the Control valve (FV-301).
Close the Isolating Valves of Control Valve (FV-301).
Stop Thermic Fluid Heating to CFA Heater (E-302) :
Put the Controller (TIC-302) in Manual Mode and close it
completely. Close the Isolating Valves of Control Valve (TV-302).
Close the Feed Valve to Precut Column (C-301). (Feed given to
the top of Bed No.1 of C-301).
If the Plant is not required to shut down for longer period, CFA
Degasifier (V-301) need not be emptied. Leave the level as such, put
the Controller (FIC-301) on Manual Mode and close it completely.
Bring the set point of Flow Indicating Controller (FIC-301) to minimum
value (000 kgs/hr.) If required, close the Isolating Valves of FV – 301
and FT-301.
5.1.5 Emptying out Precut Column (C-301) :
On stopping of the feed to Precut Column (C-301), let the Circulation
through Reboiler (E-303) continue for 20-45 minutes under the same
operating conditions.
Close the Sparging Steam to Precut Column (C-301) if at all open.
Reduce the flow of Flow Indicator (F1-303) to 3000 Kg/hr. i.e., Light
Fatty Acid feed to the condensation bed (Bed No.3).
Put the FIC - 302 in Manual Mode and close the valve completely
thereby stopping the transfer of Light Fatty Acid to Storage from LFA
Cooler (E-305) to Storage.
Close the Isolating Valve of FV – 302.
Flush the Light Fatty Acid transfer lines to the storage by open steam
sufficiently to clear the line.
Put the Temperature Indicating Controller (TIC-310) in Manual Mode,
close the Control Valve (TV-310) and Isolating Valves.
Put Temperature Indicating Controller (TIC-303), thermic fluid to
Precut Reboiler (E-303) in Manual Mode and close the Control Valve
completely.
Close the Discharge valve of Reboiler Recirculation Pump.
(P-302). Stop the Pump and close the suction valve.
5.1.6
Close the recycling valve of Bottom Pump (P-303)
Put the Level Indicating Controller (LIC-302) in Manual Mode and
empty out the Precut Column gradually by adjusting the opening of
Control Valve (LV-302).
On emptying out Precut Column (C-301), close Control Valve (LV-
302) completely and close the Isolation Valves.
Stop the Bottom Pump (P-303) and close the suction valve.
If the Plant need not be stopped for longer time do not empty the
Precut Column (C-301):
Set the Temperature Controller (TIC-303) to 100°C and leave the
Controller in Auto Mode and let the circulation through Precut
Column Reboiler (E-303) continue.
Put the LIC-302 in Manual Mode and close the Control Valve
(LV-302) completely and close Isolation Valves.
Let Bottom Pump (P-303) recirculate the material in the Precut
Column (C-301).
Precut Pump Around System :
Let the circulation of Pump Around Pump (P-304) recirculate light
Fatty Acid across the condensation bed (Bed No.3).
Since distillation of Fatty Acids is stopped in Precut Column, it is
necessary to stop the transfer of Light Fatty Acid to Storage.
Put the Flow Indicating Controller (FIC-302) in Manual Mode , close
the Control Valve (FV-302) and close the Isolating Valves.
Flush the Light Fatty Acid transfer line from LFA Cooler (E-305) to
Storage with open steam irrespective of the length of stoppage.
During the circulation of Light Fatty Acid across the Bed No.3, it is
advisable to keep watch on LSL –303 (Low level in Receivers
(U-302A) due to following reasons.
The distillation in the Precut Column is stopped due to the closure
of thermic fluid to Precut Reboiler (E-303).
The carry over of Light Fatty Acid with the open steam given in the
Deodorizer (V-306), may condense in bed No.3 at the same time, it
carries Light Fatty Acid from condensation Bed (Bed No.3) to
scrubbing section.
As and when low level alarm is signaled, close the Isolating Valves of
Flow Indicator (F1-303), close the discharge valve of Pump Around
Pump (P-304).
Close Suction Valve of Pump Around Pump (P-304) since Tempered
Water is circulated in LFA Cooler (E-305), leave the Controller (TIC-
310) as it is.
5.1.7 Stoppage of Distillation in Distillation Column (C-302):
The feed to the Distillation Column (C-302) is stopped. If the
Plant is to be stopped for a longer time, empty the Distillation
Column (C-302) as described below:
Increase the Temperature of Distillation Column by 10°C from
normal operating temperature by setting the Temperature
Indicating Controler (TIC-314).
Let the circulation in the Reboiler (E-306) continue for 30 – 40
minutes to distill the entire Fatty Acids.
After completion of 30-40 minutes, put the Temperature
Indicating Controller (TIC-314) in Manual Mode and close the Control
Valve (TV-314) completely and close its Isolating Valves.
Close the Isolating Valves of (F1-306) thereby stopping Distilled
Fatty Acids to the Washing Bed (Bed No.1).
Adjust the solating Valves of Flow Indicator (F1-308) to reduce
the Distilled Fatty Acid Flow rate to Condensation Bed (Bed No.2) to
8000 – 9000 Kg/hr. by adjusting the Isolating Valves of (F1-308).
This circulation is necessary only to condense the vapour, if at all,
present in the Distillation olumn (C-302) and cooling of the
condensation bed.
5.1.8
Due to the Non distillation of Distilled Fatty Acid in Distillation Column
(C-302), the steam will not be generated in Water Recirculation Drum
(V-305). Therefore, the low pressure steam from the offsites will be
fed to the low pressure steam header of the Vacuum System (PK-302)
through Control valve (PV-304) by Pressure Indicating Controller
(PIC-304).
In case, the Control Valve (PV-304) does not feed the required
quantity of steam, open bypass valve of the Control Valve (PV-304) to
maintain the desired pressure in the low pressure steam header of
PK-302.
Emptying Fatty Acid Distillation Column (C-302) :
To complete the distillation of Fatty Acids from Fatty Acid Stripper
before stopping the Plant, increase the set point of temperature
Indicating Controller (TIC-312) by 10°C.
Close the discharge Valve of Reboiler Recirculation Pump
(P-306). Stop the Pump (P-306) and close the suction valve.
Gradually drain the material from Fatty Acid Distillation Column
(C-302) to Fatty Acid Stripper (E-307) by opening the drain
valve of overflow loop.
The draining of the material should be carried out gradually.
5.1.9 Draining Fatty Acid Stripper (E-307):
On completion of draining of material from Fatty Acid Distillation
Column (C-302) into Fatty Acid Stripper (E-307), close the drain valve
of overflow loop of Fatty Acid Distillation Column (C-302).
The completion of distillation in Fatty Acid Stripper (E-307) can be
observed from the level (LIC-308) of striped Fatty Acid Condenser
(E-311). After complete draining of material from Distillation Column
in the Fatty Acid Stripper (E-307), let the thermic fluid heating
continue for 30 minutes to complete the distillation.
Close the Low Pressure Steam Valve to Fatty Acid Stripper (E-307)
thereby stopping open steam to Fatty Acid Stripper (E-307).
Put the Temperature Indicating Controller (TIC-312) in manual Mode
and close the Control valve (TV-312) completely. Close the Isolating
Valves of Control Valve (TV-312) [Thermic fluid to Fatty Acid Stripper
E-307].
Instruct the Offsite thermic fluid operator to stop the thermic fluid
heating and let the thermic fluid be in circulation till the temperature
reaches 100 - 100° C.
Open the bypass valves of the Control valves of all the heat
exchangers in order to cool down the thermic fluid faster.
Let the Residue Pump (P-307) circulate the residue in Fatty Acid
Stripper (E-307), till the temperature in E-307 reaches 120 – 150 °C.
Open the Drain Valve of E-307 in order to circulate the material
across the thermic fluid tube bundle of E-307.
Let Residue be in circulation till the temperature in Fatty Acid
Stripper (E-307) comes to 140 – 160 °C.
On attaining the desired temperature in Fatty Acid Stripper
(E-307), put the Level Indicating Controller (LIC-306) in Manual
Mode and open the Control Valve (LV-306) and empty the Fatty
Acid Stripper (E-307).
Close the discharge recycle value of Residue Pump (P 307)
stop the Pump and close the Suction Valve.
Flush the residue transfer line to the Storage with low pressure
steam.
Drain the Residue Pump by opening the drain plug / drain valve
of the Pump.
5.1.11 Stopping Distilled Fatty Acid transfer to Deodoriser :
If the Plant is to be stopped for a longer time, it is advisable to cool down
the condensation bed (Bed No.2) of Main Fatty Acid Distillation Column
(C-302) as described below:
Set the Controller (TIC-320) i.e temperature of Distilled Fatty Acid
from Pump Around Cooler (E-309) to 80 - 90° C and continue the
circulation for at aleast 30 – 45 minutes.
On attaining the temperature of Temperature Indicating
Controller (TIC-320) to 80 - 90°C, close Isolating valves of Flow
Indicator (FI-308).
5.1.12
Put Temperature Indicating Controller (TIC-320) in Manual Mode,
close the Control Valve (TV-320) and close the Isolating Valves.
(Distilled Fatty Acid at the outlet of Pump Around Cooler (E-309)]
Put the Level Indicating Controller (LIC-307) of DFA Receiver
(V-303) in Manual Mode and close the Control valve (LV-307)
completely. Close the Isolation Valves of Control Valves (LV-307).
Stop the product DFA Pump (P-308) and close the suction valve.
Water Recirculation Drum System :
Since no steam is generated and Distilled Fatty Acid in Pump
Around System is also cooled to 80-90°C. Stop the water circulation
system as described below:
Close the Isolation Valve to isolate of Water Recirculation Drum
(V-305) from Offsite low pressure steam header.
If steam vapour still exists in Water Recirculation rum (V-305) it is
essential to vent out and cool the system.
Increase the water level in Water Recirculation Drum (V-305) by
20-30% more than the normal operating level.
Put the Level Controller (LIC-309) in Manual Mode and close the Control
Valve (LV-309) on attaining the desired level in Water Recirculation
Drum (V-305).
5.1.13
Close the Isolation Valves of Control Valve (LV-309)
Open gradually the valve of Water Recirculation Drum (V-305) to
vent out the steam vapour, if any, present in Water Recirculation
Drum.
Close the Discharge Valve of Water Recirculation Pump (P-310),
stop the Pump and close the Suction Valve.
In case, the Plant is stopped for a longer time, empty out the
water from Pump Around ooler (E-309), Water Recirculation Drum
(V-305) and connecting pipelines by opening respective drains.
The draining of water from above equipments are required to
remove the dirt and other impurities.
Do not empty the DFA Receiver (V-303) since refilling is required
before next start up.
Empty out DFA Receiver (V-303) only when some maintenance work
is to be carried out.
Stopping Deodorisation Section :
On Stopping of product DFA transfer Pump (P-308), close the
thermic fluid heating to deodorizer.
After stopping of Product DFA Transfer Pump (P-308), let the
open steam continue in Deodoriser (V-306) for 20-30 minutes to
deodorize the entire Distilled Fatty Acid in the Deodriser.
Since the Distilled Fatty Acid transfer from the DFA Receiver
(V-303) is stopped. Here is no increase in Distilled Fatty Acid
level in Deodoriser.
Level Indicating Controller (LIC-310) closes the Control Valve
(LV-310) and only recycling is in progress.
Close the open steam to Deodoriser (V-306) Compartments,
and leave the Distilled Fatty Acid as it is in the Deodoriser
(V-306).
Put the Level Indicating Controler (LIC-310) in Manual Mode
and close the Control Valve (LV-310).
Close Isolation Valves of Control Valve (LV-310).
Close the Recycle Valve Deodoriser Outlet Pump (P-311)
gradually.
Stop the Deodoriser Outlet Pump (P-311) and close the Suction
valve.
In case, the Plant is to be stopped for longer time, empty out
the Deodoriser as described below:
Put the LIC-310 in Manual Mode and open the Contrl Valve
20- 30%
Open the Drain valve of all the Compartments of Deodoriser
(V-306).
Close the recycling valve and empty out the deodorizer gradually.
5.1.14
5.1.15
On emptying out of the eodoriser, close the Control valve (LV-310)
in Manual Mode and close the Isolating Valves.
Stop te Deodoriser outlet Pump (P-311) and close the suction valve
of the Pump.
Close the drain valves of all the compartments of Deodoriser (V-
306).
Stopping Deodorisation Section :
Put the Temperature Indicating Controller TIC-321) in Manual Mode
and close the Control valve completely and close the Isolating Valves
of the Control valve (TV-321).
Flush the Distilled Fatty Acid transfer line to the storage with low
pressure steam.
Stopping of Precut Column (C-301) :
On completion of pumping of Distilled Fatty Acid from the
Deodoriser (V-306) to the storae, let the Precut Scrubber bed
recirculation continue at least for 2 hrs. to condense the entire Fatty
Acid vapour in the Precut Column (C-301) and cooling the internals of
the same.
5.1.16
Since the level in the Scrubber Receiver (V-302) will not increase due to
the absence of Distillation in the Precut Column (C-301), put the Level
Indicator Controller (LIC-304) in Manual Mode and close the Control
valve (LV-304) completely. Close the Isolation Valves of the same.
Flush the LFA transfer line to the storage with low pressure steam [From
the Scrubber Cooler (EP-301)].
Close the discharge valve of Scrubber Pump (P-305) gradually and
stop the pump. Close the Suction Valve of the Pump.
Stopping of Main Distillation Column (C-302) Scrubbing System :
storage with low pressure steam.
Close the discharge valve of Scrubber On completion of pumping of
Distilled Fatty Acid from the Deodoriser (V-306) to the storage, let
the Main Distillation Column Scrubber bed recirculation continue at
least for 2 hrs to condense the entire Fatty Acid vapour in the Main
Distillation Column (C-302) and cooling of the same.
Since the level in the Scrubber Receiver (V-304) will not increase
due to absence of Distillation in the Main Distillation Column (C-302),
put Level Indicating Controller (LIC-308) in Manual Mode and close
the Control valve (LV-308) completely. Close the Isolation Valves of
the same.
Flush the LFA transfer line to Pump (P-309) and stop the pump.
Close the Suction Valve of the pump. [From Scrubber Cooler (EP-
302)].
5.1.17
5.1.18
Stopping Tempered Water System :
Close the Control Valves and Tempered Water circuit by putting
all the Controllers (TIC-309, TIC311, TIC-310, TIC-313, TIC-319)
on Manual Mode.
Clsoe the Tempered Water Inlet and Outlet Valves of Stripped
Fatty Acid Condenser (E-311).
Put the Controller (TIC-322) in Manual Mode and close the
Control valve completely and close the Isolation Valves of the
same. [Cooling Water TW Cooler (EP-303)].
Close the discharge valve of Tempered Water Recirculation
Pump (P-312), stop the Pump and close the Suction Valves of the
Pump.
Stopping vacuum System (PK-301):
Close steam to Booster Compressor (J-301)
Close steam to wet Ejector (J-302) and close the water to surface
condenser (CS-301 & CS 302).
Close the steam to Dry Ejector (J-303).
Close the main steam valve to header of medium pressure
steam and drain the condensate.
5.1.19
5.1.20
Stopping Vacuum System (PK-302) :
Close steam Booster Compressor (J-304) Close steam to the
Jacket of J – 305. Drain the condensate by opening the bypass
valve of trap assembly.
Close the steam to the Booster Compressor (J-305).
Close the steam to Wet Ejector (J-306). Close the Water to
surface condenser (CS-303).
Close the steam to Wet Ejector (J-307). Close the water surface
condensers (CS-304).
Close the steam to ry Ejector (J-308). Close the water to surface
condenser (CS-305).
After all steam condensate is drained from Booseter
compressors and steam heater, close steam condensate valves.
Stop Utility Supply System :
Stop the following utility supply systems within the
‘Battery Limits’ of the Plant.
Steam Supply System.
Istrument Air Supply System.
Plant Air supply System.
5.1.21
5.1.22
Water Supply System
Soft Water
Cooling Water (Supply & Return) – Direct
Cooling Water (Supply & Return) – Indirect
Condesnate Return System
Switch off the Control Panel
Stop Off – Site Facilities :
Stop the relevant Off – Site facilities supplying utilities to the
‘Battery Limits’ of the Plant, ensuring that utility supplies to other
Plants are maintained if they are operating.
NOTE :
Ensure that all lines / drawn are flushed with steam/air wherever
flusing arrangement is provided for.
Ensure that all valves are in CLOSE position.
Restarting After Normal / Planned Shut Down :
During Normal / Planned Shut down, the following equipment need
not be emptied unless some maintenance work involved in the
respective equipment.
Precut Column (C – 301)
Deodoriser (V-36)
Precut crubber Receiver (V-302)
LFA Receiver (Cu-302A)
DFA Receiver (V-303)
Distillation Column (C-302)
F.A. Stripper (E-307)
Main F.A Distillation Column (C-302)
Scrubber Receiver (V-304)
Water Recirculation Drum (V-305)
During the Planned Shut Down, if it is decided not to empty out the
Main Distillation Column (C-302) and Fatty Acid Stripper (E-307). Do
not distil the Fatty Acid completely in the respective equipment. Before
stopping the feed to the plant, first stop thermic fluid heating to the
respective equipments and feed fresh material to avoid chocking of the
lines and make restarting easier.
Particularly, the Precut Column (C-301) and main Distillation Column
(C-302) packings should be clean and clear (i.e Bed 1, Bed 2, etc)
before restarting feed to the Plant.
Due to longer period of shut down there are always chances of
structural packings getting chocked due to the solidification of Fatty Acid
and makes restarting very difficult since feed material does not percolate
through to the Bottom of Columns.
If the material is present in the bottom of the Columns, the structural
packing heating is easier to clear the solidified Fatty Acid due to the
forced circulation through Reboilers with thermic fluid heating.
If the systems are not emptied, follow the following procedures :-
Put both the vacuum systems in operation without opening the
steam to the boosters.
Maintain the pressure in the systems 70 – 80 mm Hg(a).
Open Low Pressure steam to Precut Column for heating the
packing and internals.
Start thermic fluid heating system.
Increase the temperature to 100 – 120 ° and maintain the temperature.
Circulate the thermic fluid through CFA heater (E-302), Precut Reboiler (E-303), Main Distillation Reboiler (E-306), Fatty Acid Stripper (E-307) and Deodoriser (V-306) to melt the material solidified.
Overheating of Distilled Fatty Acid in Deodoriser, when the material is not in circulation, should be avoided.
Close the thermic fluid to Deodoriser (V-306) soon after the temperature reached 100 – 120 ° C (TG-317). Open thermic fluid to Deodoriser only after the Distillation starts.
DFA cooler is provided with heating arrangement also. Ensure the
closure of valves in the water circuit.
Open Low Pressure steam valve and drain valve till the entire
material inside is melted.
Open Low Pressure steam to Scrubber Receiver (V-302), DFA
Receiver (V-303), Scrubber Receiver (V-304) and LFA receiver
(V-302A).
Close the bypass valve of trap assemblies once all the condensate
is drained.
Heat the following Heat Exchangers after closing the water inlet
and Outlet valves. Heating should be carried out by opening the
Low Pressure steam valaves and their respective drain valve.
Pump Around Cooler (E-304).
LFA Cooler (E-305).
Scrubber Cooler (EP-301)
Pitch Cooler (E-308).
Scrubber Cooler (EP-302).
Stripped Fatty Acid Condenser (E-311).
When all the equipments are heated adequately, start the
recirculation systems as described in Start Up Procedure. Ensure
the circulation of material before opening steam to the boosters and
feed to the Plant.
If any of the equipments are emptied during the Shut down,
charge the material as described in Start Up Procedure.
After putting the systems (Precut Scrubber Circulation, Main
distillation Scrubber Circulation, DFA Circulation in Receiver,
Deodoriser, Water Circulation in Water Recirculation Drum, etc.)
in operation, close the Low Pressure steam and put the controllers
in operation as explained in Start Up Procedure.
Open steam to the boosters and start the feed to the Plant as
explained in Start Up Procedure.
Ensure the transfer lines are clear.
NOTE :
Ensure that all transfer lines are flushed with steam and
wherever steam flushing arrangement is provided for.
Ensure that all valves are in CLOSE position.
5.2
5.2.1
EMERGENCY SHUTDOWN
Emergency Shut Down may be due to any one of the following
main reasons or a group of them.
Raw Material Supply Failure :
This situation arises due to non-availability of any of the raw
materials viz Crude Fatty Acid from Off-site Storage Tanks.
Follow the procedures as below :
Switch over to alternative supply, if available
If the alternative supply is not available, then follow the
“Shut Down Procedure – Normal” and do not empty any
equipment unless stoppage is for longer period.
Stop the burner of thermic fluid heating system and close all the
Control valves in the thermic fluid circuit in Manual Mode.
Let both the Vacuum Systems (PK-301 & PK-302) under vacuum.
Let Precut Scrubber Circulation System and main Distillation
Scrubber System continue.
Let Crude Fatty Acid be in circulation in CFA Degasifier (V-301)
and Precut Column (C-301) through discharge recycle valves.
5.2.2
Let Pump Around Systems circulate material across the
condensation beds ar reduced flow rate.
Let Distilled fatty Acd be in recirculation in Deodorizer (V-306)
through discharge recycle valve Deodorizer Outlet Pump (P-311).
Close Thermic Fluid Heating to Deodorizer (V-306).
NOTE :
Ensure that all the pipe lines are flushed and heated wherever
such arrangements are provided.
Ensure that all valves are in CLOSE position
Raw Material Supply Resumes :
Follw the procedure for ‘restart’.
Restart the Plant as per “Start-up Procedure”, initially at a reduced
load.
Gradually increase the Plat throughout till the “rated output” is
attained and bring the Plant to “Normal Operation”.
5.2.3 Electric Power Failure:
In case of electric power failure, all the equipment and the
various utility supply stop.
Follow the under-mentioned procedure :
Shut down Vacuum System by closing valves for Seam
supply to Ejectors and Boosters.
Cooling water supply to Condensers.
Retain the vacuum in the system by ensuring that no air
vents are open to break the vacuum.
Close all the vales of the following finished products
going to Off-site Storage Facilities.
Heavy Fatty Acid to Storage.
Light Fatty Acid to Storage
Distilled Fatty Acid to Storage
Residue to Storae
Isolating Valves of Control Valves (LV-301), FT-311, FV-
302, LV-304, LV-306 and FT-309.
5.2.4
Continue steam supply for steam tracings with the steam available
in the lines, and ensure that all steam tracing lines are on.
Take all Controllers on ‘Manual’ mode and close Isolating valves
wherever it is essential.
Close inlet valves of Crude Fatty Acid to the CFA Preheater (E-
301).
Close inlet steam valves to lines where direct sparging of stea is
provided for
Deodoriser (V-306)
Precut olumn (C-301)
Fatty Acid Stripper (E-307)
Electric Power Resumes :
Follow the under mentioned procedure for ‘restart’
Start the Vacuum System and bring it to the desired value.
Startall the Scrubbing Recirculation, DFA ecirculation, CFA
Recirculation and Water Recirculation system.
Start charging the Crude Fatty Acid to CFA Preheater (E-301)
Restart the Plant as per ‘Start-up Procedure”, initially at reduced
load.
5.2.5
5.2.6
Observe fotr any ‘chokes’ in lines, equipment, etc.
If ‘chokes’ exist.
Steam flush the system and remove chokes.
Gradualy increase the Plant through put till the ‘rated output’ is
attained and bring the Plant to “Normal Operation”.
Recycle the istilled Fatty Acid for redistillation till correct quality is
achieved.
Steam Supply Failure :
This situation arises when Off-site steam supply system fails due to
some reason.
Follow the under-mentioned procedure :
Shut down the Plant immediately, as indicated in “Shut Down
Procedure-Normal” by keeping all recirculation systems as it is.
Steam Supply Resumes :
Follow the under-mentioned procedure for ‘restart’
Restart the Plant as per “Start-up Procedure” initially at reduced load.
Gradullay increase the Plant throughout till the “rated output” is
attained and bring the Plant to “Normal Operation”.
Instrument Air Failure:
This situation arises when Off-site instrument air supply system fails
due to some reason.
In case of instrument air failure, the Control valves go to the ‘safe’
position, thereby stopping the heating in the various vessels and flow
of the materials to or from the vessels.
Follow the under-mentioned procedure:
Check the Air Compressor (Instrument Air Generation) and try to
restart immediately.
If it restarts immediately, then run the Plant normally.
If not, open bypass of Control Valves, close the Isolation Valves
of Control Valves and run the plant on manually.
In case the temperatures are not controllable then take ‘Shut
Down Procedure – Emergency’ due to Power Failure, generally
as follows:
Stop supply of feed viz Crude Fatty Acid.
Stop burner of the thermic fluid system.
Shut down the Vacuum System.
Ake all the Controllers on ‘Manual’ mode.
Stop other pumps.
Close all valves to steam/air sparging lines in the vessels.
5.2.8
5.2.9
5.2.9.1
Instrument Air Supply System Resumes :
Follow the under-mentioned procedure for “restart”
Start the burner of thermic fluid system.
Start the Vacuum System
Commence supply of feed viz Crude Fatty Acid.
Start the Pumps that have been stopped.
Open all the valves of the finished products.
Light Fatty Acid, Heavy Fatty Acid, Distilled Fatty Acid, going to Of-site
Storage Facilities.
Ake all Controllers in ‘Auto’ mode.
Gradually increase the throughput till the ‘rated output’ is attained and
bring the Plant to ‘Normal Operation”.
Cooling Water Supply Failure :
This situation arises when Off-site Cooling Water Supply and / or
Return Pumps trip due to mechanical and / or electrical problems.
The failure can occur to either of the following two Cooling Water
Systems.
Cooling Water (Direct) Supply Fails :
In case of Cooling Water System (Direct) failure, there is no supply of
cooling water to te Vacuum System with the result that vacuumin the
system will drop.
5.2.9.2
Follow the under-mentioned procedure :
Start the ‘Stand-by” Cooling Water Pumps at Off-site facilities.
If there is no water supply within short time, say about five
minutes, then follow the following procedures for Shut down –
Emergency.
Shut down the Vacuum System
Shut down the Thermic Fluid System
Stop supply of Feed viz. Crude Fatty Acid.
Stop Burner of the Thermic Fluid System.
Take all Controllers on “Manual” Mode.
Close all the valves of the finished products – Light Fatty Acid,
Heavty Fatty Acid, Distilled Fatty Acid, going to Off-site Storage
Facilities.
Cooling Water (Indirect) System Fails:
In case of Cooling Water System (Indirect) failure, there will be no
supply of cooling water to Plate Heat Exchangers and Condenser with
the result that Distillation will have to be stopped.
5.2.10
5.2.10.1
Follow the under-mentioned procedure :
Start the “Stand-by” Cooling Water pumps at Off-site facilities.
If there is no supply within short time, then follow the following
procedures for Shut down-Emergency.
Stop burner of the thermic fluid heating system.
Stop steam to all heaters.
Stop supply of Feed viz rude fatty Acid.
Take all Controllers on “Manual” mode.
Stop all the pumps.
Close all the valves of the finished products – Light Fatty Acid,
Heavy Fatty Acid and Distilled Fatty Acid, going to Off-site
Storage Facilities.
Cooling Water Supply Resumes :
Cooling Water Supply (Direct) esumes:
Follow the under-mentioned procedure for “restart”
Start the Vacuum System
Start Burner after Thermic Fluid Syste
Commence supply of Feed viz. Crude Fatty Acd.
Start pumps which have been stopped.
5.2.1.2
Open all valves of finished products
Light Fatty Acid, Heavy fatty Acid and Distilled Fatty Acid going to Off-
site Storage Facilities.
Take all Controllers on “Auto” mode.
Gtradually increase the throughput till “rated output” is attained and
bring the Plant to “Normal Operation”.
Cooling Water System (Indirect) Resumes :
Follow the under-mentioned procedure for “restart”
Commence supply of Feed viz Crude Fatty Acid.
Start burner fo thermic fluid heating system.
Start pumps which have been stopped
Open all valves of finished products.
Light Fatty acid, Heavy Fatty Acid and Distilled Faty Acid, goingto Off-
site Storage Facilities.
Take all Controllers on “Auro” mode.
Gradually increase the throughput till “rated output” is attained and
bring the Plant to “Normal Operation”
Whenever the plant stops (even for few minutes) the quality of the
Distilled Fatty Acid is reduced. It is advisable to recycle the Distilled
fatty Acid till the correct quality is achieved before sendig the same to
the Offsite Storage.
Close steam to the Boosters of both the vacuum Systems
(PK-301 & PK-302)
If the raw material is not resumed to the plant, it will take
more time to resume.
Stop the Plant as described in “Normal Shutdown
Procedure “.
CHAPTER – 6
TROUBLE SHOOTING
6.0
6.1
6.2
6.3
TROUBLE SHOOTING
The following are the points for trouble shooting encountered during the
normal operation of the Plat.
The ‘indication’ of trouble, its ‘cause/s’ and the ‘remedial action/’s to
be taken are given below:
Electric Motors Do Not Start :
Relay might have tripped/fuse may have blown
Reset the relay and / or replace the fuse
Restart.
Foaming in Crude Fatty Acid Degasifier (V-301):
Water content in Feed Crude Fatty Acid Storage Tank before feeding
Crude Fatty Acids to Distillation Plant.
Feeding to Crude Fatty Acid Degasifier (V-301) is not uniform :
Filters (F-301 A/B) in feed lines are choked.
Change the standby Filter (F-301 A/B)
Level is not there in Offsite Storage Tank
Change the Storage Tank.
Vacuum Not Steady in Precut Column (C-301):
Offsite Storage Tank is empty.
Air is being sucked by CFA Degasifier (V-301).
Change the Crude Fatty Acid Storage Tank (offsite).
Water content in Crude Fatty Acid is very high.
Drain water completely from Crude Fatty Acid Storage Tank
before feeding to the Plant.
Inlet Steam Pressure low at Ejectors.
Increase steam pressure at the inlet to Ejector. Check
Offsite steam producing / distribution system.
Build up of condensate at Ejectors.
Attend to the steam trap ad put them back on line.
Open Steam given in Deodoriser (V-306) is very high.
Reduce the quantity of open steam by reducing the set
pressure self acting Control Valve (PCV – 301) installed in
inlet of Deodoriser.
6.5
Air Leakages in the System.
Attend air leakages and rec tify
Check leakage of air through Mechanical Seals and rectify.
Check the functioning of non return valves installed on transfer lines of
Light Fatty Acid to Storage. Lack of liquid sealing in respective
equipments and failure of non return valves leads air leakage to the
system.
Maintain liquid level and rectify non return valves.
Inadequate direct cooling water circulation in the surface Condensers.
Increase cooling water circulation in the condenser. Check Offsite
operations of the cooling water circulating system.
Vacuum Not Steady in Fatty Acid Distillation Column (C-302):
Precut Column is empty (C-301)
Lack of liquid sealing and leakage of Control Valve (LV-302) due to
different operating temperatures since Precut Column (C-301) is
connected to Fatty Acid Distillation Column (C-302) via LV-302.
Maitain liquid sealing in Precut Column (C-301) andrectify the Control
Valve (LV-302).
Similarly, maintain liquid sealing in DFA Receiver (V-303) to avoid
inter connection of Precut Column (C-301) and Distillation Column(C-
302), which are operating at different pressures.
Open steam given Fatty Acid Stripper (E-307) is very high.
Reduce the quantity of open steam by reducing the pressure (PG-
311)
Condensate in open steam lines.
Drain the condensate.
Air leakage through transfer lines.
Maintain liquid sealing in DFA Receiver (V-303), Scrubber Receiver
(V-304), Stripped Fatty Acid Condenser (E-311) and Fatty Acid
Stripper (E-307) by maintaining the desired levels.
Check the functioning of non return valves and Control Valves
installed in transfer lines to Storage and rectify them.
Air leakages in the system
Check air leakage through Mechanical Seals of Pumps and rectify
the same.
Attend to air leakages.
Restart.
Inadequate coolig water circulation in the Surface Condensers.
Increase cooling water circulation in te Surface Condensers.
Direct water Inlet temperature is high.
Check the cooling tower fans and rectify.
Check Off-site operations of the Cooling Water Circulating System.
Inlet Steam pressure is low at Ejectors
Increase steam pressure at the inlet to Ejector.
Check Off-site steam producing / distribution system.
Check heat recovery system.
Build-up of Condensate at Ejectors.
Attend to the Steam Trap and put them back on line.
Direct water inlet temperature is high, check the cooling tower fans
and rectify.
6.6
6.7
Light Fatty Acid Production is higher [Precut Column (C-301)]
Light Fatty Acid quantity to Condensation bed (Bed No.3) of Pump
Around System is low (P-304 & E-304).
Increase the flow rate by adjusting isolation valves of Flow Indicator (F1-
303).
Pump Around Cooler (E-304) LFA temperature is high.
Reduce the set point of Temperature Indicating Controller (TIC-309).
Light Fatty Acid Production is higher [Fatty Acid istillation Column
(C-302)].
Distilled Fatty Acid quantity to Condensation Bed (Bed No.3) of
Pump Around system is low (P-308 and E-309).
Distilled fatty Acid Temperature at the Outlet of Pump Around
Cooler (E-309) is high.
Reduce the set point of Temperature Indicating Controller (TIC-320)
[Distilled Fatty Acid to Condensation Bed of Fatty Acid Distillation
Column (C-302)].
6.8
6.9
Light Fatty Acid Production is higher :
Vacuum is not steady in Main Distillation Column (C-302)
Follow the Cause/s and remedial action/s described earlier.
Distillation temperature is low in Fatty Acid and Distillation Column (C-
302).
Increase the temperature of Temperature Indicating Controller (TIC-314)
(Reboiler Outlet temperature).
Pressure drop across Scrubber Bed (Bed No. 3) of Main Distillation
Column is very high :
Feed Light Fatty Acid temperature is low.
Increase set point of Temperature Indicating Con troller (TIC-319)
[Outlet of Scrubber Cooler (EP-302)].
Reduce flow rate of Light Fatty Acid to Scrubbing Bed (Bed No.3) to
avoid flooding.
If the bed is choked, rectify the same by cleaning.
6.10
6.11
Residue Production is higher / Free Fatty Acid content is higher
in Residue :
Vacuum is not steady in Distillation Column (C-302) and Fatty Acid
Stripper (E-307).
Refer Cause/s and remedial action/s described earlier.
Temperature in Distillation Column (C-302) and Fatty Acid Stripper
(E-307) is low.
Increase set point of Temperature Indicating Controllers (TIC-314 &
TIC-312) and maintain correct temperature.
Pump around flow rate is not adequate.
Increase flow rate to condensation bed by adjusting flow indicator F1-
308.
Odour of Distilled Fatty Acid is Higher :
Light Fatty Acid taken out is lower from the outlet of LFA Cooler
(E-305).
Increase the Set Point of Flow Indicating Controller (FIC-302).
Quantity of open steam given in Deodoriser (V-306) is low.
Increase the set point of self Acting Control Valve (PCV-301).
6.12
6.13
Precut Column Distillation temperature is low.
Increase the set point of Temperature Indicating Controller (TIC-
303).
Precut Column is operating with low reflux Ratios.
Increase the Temperature of Distillation under correct vacuum
conditions.
Deodorisation Temperature is low.
Increase the temperature of deodorizer (V-306) by adjusting
thermic fluid valve.
Pumps are not Pumping (P-301, P-302, P-303, P-304, P-305,
P-306, P-307, P-308, P-309, P-311 & P-312):
Leakage from suction of mechanical seal.
Tighten the bolts, replace or repair the mechanical seal.
Cavitation Problem
Close the discharge valve and stop the pump. Restart the
pump and open discharge valve so that the required
discharge pressure is maintained.
Light Fatty Acid carry over to hot well :
Air leakage is more in distillation column
Tighten the bolts and rectify the leakage and take the air test.
6.14
Light Fatty Acid to scrubbing bed temperature is high.
Reduce the temperature of Light Fatty Acid to scrubbing bed
(TIC-319).
Flow rate to scrubbing bed is too low.
Increase quantity of flow to scrubbing bed by adjusting isolating
valves of respective Flow Indicator (FI-305 of C-301 and FI –
307 of C-302).
NOTE :
Light Fatty Acid carry over from Precut Column (C-301) to hot well
can not be avoided due to open steam given for deodorisation.
Unsap content in Distilled Fatty Acid is higher :
Lack of Distilled Fatty Acid flow to Washing Bed (Bed No.1) of
Distillation Column (C-302).
Start / increase Distilled Fatty Acid flow to Washing Bed by adjusting
Isolation Valves of Flow Indicator (F1-306).
CHAPTER – 8
PLANT MAINTENANCE AND LUBRICATION
8.0
8.1
8.2
PLANT MAINTENANCE AND LUBRICATION
Routine Maintenance:
The Plant calls for no special repairs or replacement of parts, except
as caused by foreign bodies accidentally entering the moving parts or
by lack of maintenance.
The plant personnel shall in particular make sure that the following
mechanical parts perform as described below:
Pumps run noiseless, without vibrations. For their maintenance
peruse the relevant instruction manuals.
Support bearings run quietly and not get overheated.
Mechanical seals in pumps do not leak; if they do, repair or replace
them.
For Temperature Controllers, see the Vendor’s Instruction Manual.
Maintenance during prolonged Shutdowns :
In addition to carryin g out routine maintenance :
Overhaul all pumps.
Overhaul cocks, valves, joints and fittings
C lean strainers on steam traps.
Check and tighten bolts in mechanical moving parts.
Wash the machines internally and externally and the associated
pipes and valves to remove any deposits.
Make sure that flexible couplings are not worn; replace rubber
elements, if necessary.
Check for integrity of driving belts; replace if necessary.
Air test of the Plant at least once in a year.
Before air testing ensure cooling of distillation columns to the room
temperatures. Circulate Cold Fatty Acids across the all structural
packings. Before opening the manholes of distillation columns and
equipment operating at higher temperature, purge nitrogen gas by
keeping the plant under absolute pressure of 500-600 mm of Hg.,
which can be obtained by opening of water to Barometric
condensers.
Check the Reboiler Outlet Nozzles thickness atleast once in a
year and replace, if required.
8.3 Equipment List and Procedures :
Tag.No. Description Clean Internal Clean Method
V – 301
C-301/C-302
E-303/E-306
E-307
V-302/V-302 A
V-303/V-304
E-301
E – 302
EP-301/302/
303
CFA Degasifier
Precut Column/
Distillation Columns
Reboilers
Fatty Acid Stripper
Receivers
CFA Preheater
CFA Heater
Plate Heat Exchangers
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
½ Year
A
A
A
A/B
A
A
A
Process Side
Process Side
Process Side
Physical
Cleaning
Process Side.
8.4
All the tube bundles should be removed and cleaned physically
before NaOH wash. Same applies to Plate Heat Exchangers.
NOTE :
CYCLE A : WASHING WITH NaOH 4-10°- Be SOLUTION THEN WASH UNTIL PH = 7.
CYCLE B : FLUENT STEAM.
Lubrication :
Refer Vendors Mainteanace Manual.
CHAPTER – 9
DRAWINGS
9.0
9.1
9.2
DRAWINGS
Process Flow Diagrams (PFDs)
Drg.No. 34/2005-PR-DR-PF-301
Drg.No. 34/2005-PR-DR-PF-302
Piping and Instrumentation Diagrams (P & IDs)
Drg. No. 163-PI-P-301 – Rev.2 Sheet 1 of 8
Drg. No. 163-PI-P-301 – Rev.4 Sheet 2 of 8
Drg. No. 163-PI-P-301 – Rev.4 Sheet 3 of 8
Drg. No. 163-PI-P-301 – Rev.3 Sheet 4 of 8
Drg. No. 163-PI-P-301 – Rev.3 Sheet 5 of 8
Drg. No. 163-PI-P-301 – Rev.1 Sheet 6 of 8
Drg. No. 163-PI-P-301 – Rev.2 Sheet 7 of 8
Drg. No. 163-PI-P-301 – Rev.1 Sheet 8 of 8