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1 Introduction to Plant Operation

By

Dr. AA
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Objectives of Plant Operation

Ensuring that the plant has the capacity and flexibility to achieve a range of operating conditions safely, reliably, profitably and with good dynamic performance.
We need to establish good operability Follow work system & procedure troubleshoot problems Making decision & taking effective action
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Consider a Flash Separator

Vapor product P 1000 kPa T 298 K
L1

T6

P1

T1

T2

T5

Feed
F1 Methane Ethane (LK) Propane Butane Pentane F2 T4 T3

F3 A1

Process Steam fluid

L. Key

Liquid product
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Control Objectives - Major Hazards

T6

P1

Vapor product

T1

T2

T5

Feed
F1 T4 T3 L1

F2

F3

Process fluid

Steam

A1
L. Key

Liquid product

Provide Some examples

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Control Objectives Protecting the environment

T6

P1

Vapor product

T1

T2

T5

Feed
F1 T4 T3 L1

F2

F3

Process fluid

Steam

A1
L. Key

Liquid product

Provide Some examples

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Control Objectives Protecting Equipment

T6

P1

Vapor product

T1

T2

T5

Feed
F1 T4 T3 L1

F2

F3

Process fluid

Steam

A1
L. Key

Liquid product

Provide Some examples

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Control Objectives Smooth Operation

T6

P1

Vapor product

T1

T2

T5

Feed
F1 T4 T3 L1

F2

F3

Process fluid

Steam

A1
L. Key

Liquid product

Provide Some examples

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Control Objectives Product Quality

T6

P1

Vapor product

T1

T2

T5

Feed
F1 T4 T3 L1

F2

F3

Process fluid

Steam

A1
L. Key

Liquid product

Provide Some examples

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Control Objectives High Profit

T6

P1

Vapor product

T1

T2

T5

Feed
F1 T4 T3 L1

F2

F3

Process fluid

Steam

A1
L. Key

Liquid product

Provide Some examples

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Quality System
99.73 %

0.135 %
-3s 2s -1s m +1s +2s +3s

0.135 %
Traditionally threesigma is acceptable, now, the industry is on six-sigma

m3s

99.9999998%
-6s -3s 2s -1s m +1s+2s+3s +6s

m6s

Control Benefits
When we control a process, we reduce the variability of key variables to achieve the seven objectives. Without feedback control
T P

Concentration

T A

Feed
F

outlet concentration

6 55 4 4 3 23
2 0 50

Composition (% H. Key)
50 100 150 200 250(min) time 300 350 400 450 500 Time (min)
100 150 200 250 300 350 400 450 500

0 51 50.5 50.5 50
50

51

valve position

49.5 49 49.5
49 0 50 100

A1

valve position (% open)

Reflux valve position

50 100 150 200 250(min) 300 350 400 450 500 time Time (min)
150 200 250 300 350 400 450 500

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Control Benefits
When we control a process, we reduce the variability of key variables to achieve the seven objectives.

With feedback control

3.5 Concentration 3.0
3 outlet concentration 3.5

Composition (% H. Key)

2.5
2.5 0

50

50

100 150 200 250 300 350 400 450 500 time (min) Time (min)

100

150

200

250

300

350

400

450

500

valve position

60
60

40 20 40
20 0

valve position (% open)

100 80 80

100

Reflux valve

50

50

100 150 200 250 300 350 400 450 500 time (min) Time (min)

100

150

200

250

300

350

400

450

500

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Goal: Maximize conversion of feed ethane but do not exceed 864 o C Which operation, A or B, is better? Explain why.
Flue gas
FC AC Conversion

0.25 0.2
frequency

0.15 0.1 0.05 0 842 846 850 854 858 862 Temperature (C)

Ethane Feed

0.6 0.5
Temp. 864 C
frequency

0.4 0.3 0.2 0.1 0 842 846 850 854 858 862 Temperature

TC

Air

Fuel

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Goal: Maximize burner efficiency and prevent fuelrich flue gas.

low O2 % low thermodynamic efficiency high O2 % - efficiency drops. Also flame temp is low so heat transfer is less (burn more fuel) Very low O2 % unburnt fuel, possible secondary explosion O2 Flue > 0.75%! gas
FC AC

88
Efficiency %

Ethane Feed

86 84 82 80 0 1 2 3 4 O2 mole % 5 6 7
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TC

Air

Fuel

Flue gas

Which operation, A or B, is better? Explain why.

FC

AC

Ethane Feed

TC

Air

Fuel

A
0.25 0.2
frequency

B
Frequency Efficiency 88 86 84 82 80

0.5 0.4
Efficiency %

88 86 84 Frequency Efficiency 82 80 0.25 1.25 2.25 3.25 4.25 O2 mole % 5.25

0.15 0.1 0.05 0 0.25 1.25 2.25 3.25 4.25 O2 mole % 5.25

0.3 0.2 0.1 0

15

Efficiency %

frequency

Between Design & Operation

Set goals and design specifications

Select process technology

Define process structure (sequence) Simulate the flowsheet Design equipment

Often performed for one operating point

Construct and start up

Operate the plant over a range of conditions, many operating points and transitions between them

Inconsistency!

PROCESS DESIGN WITH OPERABILITY

The design procedure should ensure that the plant is operable, that it functions well. This requires a specification that addresses a range of conditions, for example: Feed compositions and rates Product qualities

Equipment capacities and availabilities

Environment (summer, winter)

Major disturbances

Class Workshop
What do the following words have in common?

Music

Love

Happiness

Operability

Class Workshop
Difficult to define exactly, but we know when we have achieved or fallen short!!

Music

Love

Happiness

Operability

From the simplest to most complex process, we must think about operability!

I need to regulate the flow, but how complex should the equipment be? Does the need for operability affect this decision?

Conclusion Ill think about it !!

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