FAD Plant With Precut Column

EURRESTRA INDUSTRIES LTD.MUMBAI

OPERATION MANUAL

FOR

FATTY ACID DISTILLATON PLANT WITH PRECUT COLUMN

FATTY ACID DISTILLATION PLANT WITH PRECUT COLUMN


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.



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.



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.



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



CHAPTER – 1

OPERATING PROCESS & INSTRUCTIONS



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.



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.



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.



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.



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.


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


(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


(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



(IS-2062) for rest.

E-308 1 Pitch Cooler Shell & Tube Heat Exchanger, SS-316


(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


(IS-2062) for rest.

E-311 1 Stripped FA Condenser



(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.


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)


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)


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 gland packing.


P-311 1 Deodoriser Outlet Pump


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








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









TemperatureIndicatingController


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 IndicatingController



Level IndicatorContoller

Level Indicator Controller


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


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.


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


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


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


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:


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 :


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)









FAD Plant With Precut Column

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