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Best Practices for Startup and Shutdown in Process Operations

Effective startup and shutdown procedures are critical for ensuring safety, reliability, and efficiency in process operations. This guide discusses key operability issues like operating window, flexibility, dynamic performance, and equipment protection. It emphasizes the importance of thorough planning and training to prevent accidents and hazards during these phases. It covers the identification of necessary equipment, the steps for loading and draining materials, and the requirement for temperature normalization. Careful attention to these factors can enhance operational control and safety.

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Best Practices for Startup and Shutdown in Process Operations

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

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

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

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

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

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

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

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

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

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