Unit 4 The Use of Fractionating EquipmentFOREIGN DEPOSITS AND LIQUID TRAPS nL. 12, 13. 14. 1s, 16, Foreign deposits present special problems in the normal ‘operation of a feactionating unit Foreign deposits, such as dirt, scale, oF coke, ean block ‘or plug the vapor path or the path. Corrosion seale collecting in bubble caps and downcomers ‘can eause them to become — ‘A blocked downcomer will hinder the normal operation of the path, locked bubble caps will hinder the normal operation of ‘the path. Blocked weepholes will hamper the drainage of liquid from tray during (shutdossn/normal operations). Blocked downcomers and weepholes cause liguid traps Liquid traps occur when liquid is held in a downcomer will occu If liquid is wnable to drain, liquid Pools of oil remaining after shutdown may bea stubborn of combustible vapors Pools of water remaining after washing. and steaming may suddenly vaporize and cause surges in Coking temperatures, dirt in the fed, and corrosive ma: terials are major sources of foreign deposits ‘The coking temperature of hydrocarbon Is the tempera ture at whieh the hydrocarbon combines in a chemieal reaction to form heavy, slld compounds called Solid residues which are formed when hydrocarbons are heated are called Liquid traps are caused by _______downcomers and weepholes. Warped or uneven trays can also cause liquid 0 sete inlow points. "To avoid traps all trays should be perfectly Some problems in normal tower operations are caused by water, Unless water is carefully watched for, it may enter the tower withthe Water may also be fed back Into the tower with Water is most likely to enter the tower with reflux, ithe leaks [30] liquid blocked, oF plugged liquid vapor shutdowen tray trap prssure coke coke blocked level feed reflux condenser11 18 19. 20. 21 2. 23. 2, 25, fg steam reboller begins to leak, water may come into the Bottom of the tower wlth the condensate from the If weather drops below freezing, any water in the tower may tuen to water changes to ie, it cannot be from the tower through weepholes and downeomers. ‘When water changes to fe, it (expande/contracts), ‘The force of ie expanding against equipment may cause metal to weaken of Unlike most olls, water in the tower can suddenly and completely vaporize at a single temperature. Oils are (more/less) Ukely to vaporize over a range of temperatures than water I= ‘Water expands 1600 times its original volume when it is vaporized at atmospheric pressure. If this steam Is not completely free to expand, {t can create great surges of ‘Sudden pressure surges can upset trays and tear off bub ble Large inereases in pressure can EXPLOSIVE MIXTURES 26. 21, Explosive mixtures must be avoided in all handling of equipment. An explosive mixture is a combination of @ hydrocarbon vapor with alr which will when git. [Explosions occur when hydrocarbon vapor combines with te form an explosive mixture, anywhere ‘ear a source of ignition to set it of (31) seboller drained expands rupture, or break pressure caps rupture explode28. For a mixture to be explosive, the proportion of hydro- carbon vapor in it must come within certain limits. For ‘example: alr must have between 1.4% and 7.5% pentane in it to make an explosive mixture of pentane. I any amount of alr contains 5.0% pentane, an explosive mixture (wil/will not) exist 29, Lookat this chart Explosive Range ‘Material low high smathane 5.35 14.0%, thane 328 125%, Dutane 16%, 85% pentane 145% 15% ‘gasoline 13% 6.0% hydrogen 41% 14.2% hexane 12% 69% hydrogen sulfide 4.3% 46.0% ‘The explosive mixture range for gasoline is from % to %. 30, When hydrocarbons are being handled, the lower limit ‘of concentration of vapor needed to ereate an explosive mixture is (low high). 31. Normally, raising the pressure will widen the explosive range of a hydrocarbon Lowering the pressure will (inerease/decrease) the chances of an explosive mixture 82. A decrease in pressure reduces the amount of hydrocar- bons present ‘The possble explosive force is thus (increased decreased “83. If there is any chance that a rilxture may be explosive, ‘operation will be made safer by (decreasing! Increasing) pressure, 34, During depresturing, the explosive mixture should not be allowed to contact a source of such fas a flare. 35, ‘Static electricity, heat, sparks, and tron sulfide ean all be sources of ignition for an 36, Whenever alr begins to mix with @ hydrocarbon, it must be assumed that the mixture will be explosive. Because the hydrocarbons present are seldom precisely kknown, and the ranges are not precisely known, itis good operating practice to avoid mixtures by @ wide margin, 87, To increase safety, all hydrocarbon vapor must be kept away from — 38, Hydrocarbons should be taken out before fs let i, Air should be taken out before —____are let in [32] wat 13% 60%, low crouse decreased decreasing ‘ignition explosive mixture explosive ale hydrocarbons39. "The MSA gas aletector ie designed to detect the presence ‘of hydrocarbons in air, The MSA air-sea «analyzer ts ‘designed to detect alt in steam. The Orsat analyzer and fother commercial sinalyzers on the market detect presence of oxy, ‘The prosence of hydrocarbons, air, and oxygen can be by analyzers, UNNECESSARILY RAPID CHANGES 40. When any operating condition needs to be changed, It should be changed (gradually/suddenty) for the most fMlective operation of the tower, 41, Unnecessarily rapid changes in controlling the tower cause {table/unstable) operations. 42, A quick change in one of the factors, such as the amount fof reflux, wil cause fuetatlon in the balance of qua land vapor on each tray and in the balanced relationship of one tray to another, Rapid changes cause imbalance in conditions 43, During operations of « tower, deposits are usually belng built up inside the tower [A sudden change in operation may cause these deposits {o shift oF loosen so that they may downcomers and bubble caps 44, Blocked downeomers (ineveasa/deerease) the flow of llqu from a tray. Blocked bubble caps (ineresase/deerease) the flow of vapor to a tray, 45, When processing temperatures are changed, the tempera: fore of all metals in the tower and auxiliary equipment ‘also changes. Changes in metal temperatures create ‘or contraction. 46, Fast oF fluctuating changes in temperature create thermal (Iheat) strestes In equipment, 47. ‘These thermal stresses can result in leakage at tower ‘connections, manways and reboilers, Fructionating equipment can be caused to leak by stresses, [33] detected gradually ‘unstable operating block, or plug Aerease decrease expansion fractionating, thermal‘OPERATIONS 48, ‘The feed and the reflux should be closely watched to keep water from entering the tower If water gets into the tower and Is converted to steam, can eause extreme increases in 49, In order to prevent thermal stresses, pressure surges, and other fluctuating tower conditions, operating changes should be made (jradually/suddenly) 50. In order to maintain the most satisfactory and economical tower operations, instructions about throughput and prod- uct quality must be followed. ‘The best tower operations can be achieved by following, SHUTDOWN, 51. To shut down the tower, we must frst gradually shut off to the reboller. 152. After the tower is cool enough and the reflux has been stopped, the How of| {into the tower must then be stopped. 58. As the temperature of the tower decreases, the pressure (ncreases/ decreases). 4, If some pressure is not kept up, a ‘occur in the tower, may 55, Normally, towers are not designed to resist a vacuum, I a vacuum occurs in a tower not designed for vacuum operation, the ower may. 56. To prevent a vacuum, a hydrocarbon gas or an inert material (steam or inert gas) Is fed into the tower. ‘An inert material is one that will not combine with either flr or vapors to form an explosive mixture 57, To prevent @ vacuum, gas is taken Into the tower after it begins to 58 After shutdown, the tower must be pumped out and rained. “Liquld must be pumped out or drained from the tower, after it hae off all the trays. 59, For drainage to be complete, no ‘must occur In the tower. traps 60. If all liquid can be drained from the tower, no new hydro- ‘carbon can be formed. (34) pressure gradually instructions heat feed decreases collapse hydrocarbon drained quia vaporsG1. If liquid is trapped during draining, and if i stays in after draining, new 2 vapors may form. 62, iminating Kqyid traps will allow complete drainage. Complete —____ of the tower will make it easier and faster to gel the (ower ready for entry. 63, Por complete drainage, downcomers and weepholes must be eae PREPARING FOR ENTRY 64, After @ tower has been shut down, pumped out and drained, It smust be purged of hydrocarbons (hydrocar- bons removed), Normally towers are swith steam, 65, Gases and oils are stripped from metal surfaces and from foreign deposits with 66. If blocked weepholes have hindered drainage on a tray, steaming may sfil ave ofl on the GT. Aer « tower has been steamed, it must then be flooded swith water ‘This Mooding operation will float any ol that remains over the ofthe tower. 68, Care mast be taken when flooding the tower. The structure fof cach tower Is designed to handle a limited amount of| weight 1K this weight Load is exceeded, the tower may 69, The weight limit of @ tower must not be exceeded when the tower is being 70. Before Mooding, make sure that the tower is designed to handle the of the water. 71. Oil in the tower (sinks/Moats) during the Moding opera- tion, since oil is (lighter/heavier) than water. 72, During flooding, the oil leaves the tower at the (top/ bottom). 73, When the tower is completely filled with water, there ill bbe no gas or ______ left in the tower. 44, Before starting to drain the tower, open (vent) It to the air, so that a will not occur above the liquid level. 75. Venting a tower opens it to the 76, The tower should be vented at its (higheslowest) point TT. But when the tower is vented to the alr, I Is again pos- sible that en may form, (35) hydrocarbon érainage dear, or unblocked purged tray top collapse flooded weight oats gtr top oil highest explosive mixture78. Hydrocarbon vapors from other parts of the unit can center the tower and combine with the 7 ‘coming in through the vent. 79, Thus while the tower is draining, it must be bsolated from other attached to it 80. The tower is Isolated by blinding all inlets and outlets fs the water level 7 81. Blinding consists of (sealing/opening) all inlets and outlets, 82, A blind is 9 solid metal plate. A lind is inserted in each and 1 the tower. 188. Blinds, rather than valves, are used to seal off the tower. Valves may leak. If & valve were used and it leaked, hydrocarbon vapors could enter and mix with the to form explosive mixtures. 81. In order for a tower to be properly isolated, all inlets land outlets must be CLEANING AND REPAIR 185, Deposits that remain after steaming and washing ean hold ol and later lead to the forming of an, 86, ‘The tower should never be entered when you only assume It ls safe, You must be sure, ‘The tower must be ‘vapors before it Is entered, for hydrocarbon 87. If the tower has not been completely and thoroughly tested, a man beginning a welding: operation inside could an explosive mixture 88. Tower cleaning must be complete and thorough. Steaming and water fooding may not be enough. They ‘may alll leave stubborn in the tower. 89. If any deposits are lef, it may be necessary for someone to enter the tower and them by scraping, 90. Some types of deposits may be removed by solvent leaning. Belore considering solvent cleaning, you must be sure thatthe solvent itself will not damage the 1, Tron sulfide deposits removed from the tower should be carried away and disposed of immediately. Iron sulfide deposits contain materials that will spontancously when they dry. [36] equipment falls sealing Inlet, outlet blinded explosive tented ‘ignite Aeposits metal, or tower buen, oF ignite92, Incomplete cleaning may only loosen deposits without getting them out of the tower. Partial cleaning may leave deposits that will shift and ‘downcomers, bubble caps and weepholes Inter on. TESTING AND CHECKING 93. After a tower has been completely and thoroughly cleaned It must be carefully. checked for corrosion to make sure ‘that all equipment is sill strong enough for further use. Severe corrosion since the last shutdown could make the tower for further operations. 4, A check for corrosion should begin by measuring the thickness of the 98. While the tower is open for repairs, both the vapor path fand the Liguld path must be inspected to make sure that they are free of obstructions. If any bubble eaps are blocked, the —____path will be obstructed. 96. If any downcomers are blocked, the path will be obstructed. 97. Even partial blockage of elther the vapor path or the liquid path causes inefficient —— 98, Total blockage of elther the vapor path or the liquid path will make operation 99, During inspection of the tower a full ist of repairs needed ‘should be made, so that you are sure that no necessary repairs have been. 100. After all repairs have been made, the tower should be tziven a final check to see that no tool, equipment, clothing, fe, has been lef the 101. A Jacket left in the tower could a owscomer. 102. When extensive repairs have been made that could alfct the strength of the tower, a “strength testis required. A liquid pressure above normal. is used to conduct a ok 103. After everything has been checked! and the tower closed, all air in the tower must be 104. Air is purged (removed) by passing an material through the tower. 105. The Inert material sweeps all the out of. the tower, (371 ‘block ‘unsafe metal vapor tiquid fractionation Impossible missed, or overlooked block strength removed106, Air is purged to that no dangerous —_____ ‘may form when the tower resum ‘operations. 107. The absence of al should be proved by 108, After the connecting equipment is ready to operate and ffir all the air has been replaced by an Inert material, the. ‘must be removed from all inlets ‘and owlels 109, The tower eannot be operated at all unless all blinds are 110, The tower is then pressured with an Inert gas or steam to assure that there are no) i it oF in ‘he connecting equipment. 1111, This test for leaks is referred to as atest. 112. After the tower has beon tested for_______, the inert gas oF steam pressure is released. PREPARING TO OPERATE 118, After the inert gas pressure has been released, hydrocarbon {gas is normally backed into the 114, When the tower contains some operallng ga thew ready to pais 115. To prepare for operation, see that all the auxiliary fs ready to operate 116. Water should be deained from all low points in the eauip- ‘ment ‘Water can eause violent surges. 117, ‘The tower should be started up with the rest of the unit (conneeting equipment) in accordance with preseibed procedures Start-up should be in accordance with the established 118, For a good startup, inereass in temperatures or pressures should be made gradually ‘Thermal stresses will be caused by (rapld/ gradual) anges, 119, As temperature and pressure increase all equipment should bbe carefully watehed because stresses change under chang ing conditions ‘Thermal stresses are likely to cause [38] explosive mixture checking, oF testing blinds removed leaks tightness leaks, or ghiness| start up ‘equipment pressure procedures rapid