Accessing the software

The simulation software for this practical assignment is DSS-100 Operator.

Follow the Simtronics DSS100 and VFO quickstart software instructions V1.0 for instructions on how

to use Simtronics for this practical.

Reference materials:

Schematics for Advanced Distillation

1	Advanced Distillation Overview	SPM-720_Overview
2	Advanced Distillation Distillation Column	SPM-720_Distillation Column
3	Advanced Distillation Feed System	SPM-720_Feed System
4	Advanced Distillation Feed Tank	SPM-720_Feed Tank
5	Advanced Distillation Flare System	SPM-720_Flare System
6	Advanced Distillation Overhead System	SPM-720_Overhead System

Simtronics DSS100 and VFO quickstart software instructions V1.0

Simtronics SPM-720 Advanced Distillation Operator Manual

IEC 60529 Standard: Degrees of protection provided by enclosures (IP Code)

Training videos

Question 1:

Run DSS-100 and choose exercise 5. Monitor the process, look at the parameters of the equimpment and refer to alarms summary tab. Identify any faults and specify how to recover from the problem. Terminate the simulation after 15 minutes of run time.

Question 2:

Include a screen shot of the failure. Use print screen or your preferred method to show your answer.

Question 3:

Walk around the virtual plant using the VFO software and identify what can be the hazards expected for the operators and/or the maintenance staff.

Question 4:

Refer to schematic SPM-720_Distillation Column and argue your reasoning as to why is it important to have vapor liquid equilibrium (VPE) in a distillation column?

Question 5:

Operating pressure has a very complex influence on distillation performance. It affects relative volatility between the components, molar vapour flow rates, flooding limitations and vapour density. Taking account of all these factors, explain what happens if the operating pressure in the distillation column is disturbed?

Question 6:

Keeping in mind the procedures of a HAZOP study and FTA, write some possible causes of disturbances in operating pressure of a distillation column?

Question 7:

At elevated temperatures, with exposure to the atmosphere, small quantities of hydrocarbons have the potential for self-ignition. Are there any specific fire and explosion considerations for distillation process? Please defend your choices.

Question 8:

The results of HAZOP study and risk evaluation on the distillation process showed that the most dangerous potential risks in the distillation column can rise from an interruption of power, valve closure due to a malfunction or manual valve control by the operator, and plugging of pipelines. The most extreme case is a power outage. Since this problem leads to the failure of coolant fed to the vent gas condenser connected to the top part of the distillation column, this creates a problem that cannot adequately be taken care of by the capacity of the current flare stack design. Using your understanding of safety instrumented system, what design safety measures will you recommend to deal with this risk?

Question 9:

The traditional approach to composition control of continuous distillation is simply to control the overhead temperature with reflux flow and control the bottom temperature with heat (usually steam) to the reboiler. What will be the consequences if the boiler heater controller in distillation column fails high resulting in too fast heatup? What is the approperiate HAZOP recommendation?

Question 10:

Results of a HAZOP study suggest that a number of internal damages can occur in a distillation column. What are the consequences if there is material failure (e.g. design flaw, undetected flaw) or tray damage or a leak at the flange connection at head connections or a welding failure in the distillation column?

Question 11:

Refer to the IEC 60529 standard. What does IP65 enclosure mean?

Question 12:

To ensure hazard free maintenance activity, measures to prevent, control or mitigate major accidents involving design faults, presence of chemicals or flammable liquids and vapors, wrong/defective tools, etc. must be implemented. What can be the posiible consequences if the column is not purged with nitrogen before breaking into the system by maintenance team during shut down? Please list some preventive or mitigation measures.