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    Crude Column Relief Design

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    99 просмотров7 страниц

    Crude Column Relief Design

    Загружено:

    myself_ritesh
    Crude Column Relief Design

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    © All Rights Reserved
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    REFINING Crude column relief design Examination of a crude unit's behaviour using a dynamic model can provide significant insight into the operation and transient behaviour of the process, preventing unnecessary investments in relief system upgrades Uwe Nagel OMV Deutschland GmbH Howard B Jemison and Cal Depew SimSci-Esscor Ralph-Uwe Dietrich Invensys Process Systems MV Deutschland Gmb#t (MVD) recently completed a revamp of the crude distillation unit (CDU) at the Burghausen reflnery. This revamp Jnchided mechanical design modifica tions that requlzed the re-ating of the column's design condition and. the implementation of a highly reliable, redundant emergency shutdown (ESD) system. German authorities required, recertification to confirm that the ‘existing relief systems could handle fapected relief scenarios and were in compliance with safety regulations with the new ESD system in place. SimSci- ‘sscor carried out an engineering study to determine the maximum column pressure and relief loads of the OMVD fnide unit for various abnormal conditions and. relief scenarios. The study employed a rigorous dynamic model ofthe crude tower and associated squipment, Rigorous dynamic process simulation proved to be an effective supplement to Conventional methods when these produced unrealistically high rellet Toads. A dynamic model generates far ‘more realistic, yet still conservative, predictions of CDU relief loads. The Geral and thermodynamic rigour of the dynamic simulation model allow it to be validated to actual plant dynamic behaviour. The validated model can then provide high-quality rellet load predictions. ‘A pre-condition of the use of the dynamic process model results for relief studies was the approval ofits accuracy by both the OMVD operation personnel and the German authorities, The model was validated against the results from both the OMVD steady-state and transient plant operating data. The model reached excellent agreement (<1 ditference) with the OMVD steady-state crude unit flows, temperatures and pressures. A comparison with the ldynamie plant operating data showed a good match between plant -measure- ments and model results. Some snismatches in pressure and temperatures were identified, but the model was designed to have slightly moze and lighter material in the overhead system to provide a more conservative estimate cof the relief loading during abnormal ‘conditions. The model also had a sight faster dynamic response on the upper temperatures than the actual plant, but this difference will provide 2 more pessimistic estimate of column, Dehaviout. With these discrepancies explained, it was determined that the dynamic model was properly validated and accurate for the pressure relief stud. ‘New ESD logic was included in the dynamic model, as well as all the necessary regulatory control for normal plant operation, ESD logic is a certified redundant system approved by the TOV. Siiddeutschland (TOV) as failsafe. The regulatory controls that improved the safety and stability of the crude unit ‘vere not inchided in the model (ie, the overhead temperature controller of the ‘overhead pressure controller that vents to the flare), but the controls that may Increase the reli load were included. The dynamic model test cases Indicated ‘that the current shutdown, logic and pressure relief systems. were capable of handling all of the investigated relief scenarios. These conclusions enhanced the results of carlier calculations using conventional mcthods, and the dynamic study results ‘obtained approval by the TOV. No additional equipment for the relief “a dynamic simulation study of a process can provide a more accurate and quantitative understanding 31 Pra az 2008 wwwepta.com system was recommended and wnneces- sary relief system upgrade investment wvas prevented, “The proprietary Dynsim model provides Very reliable indications of the dynamic responses of the crude unit to various abnormal conditions and failures inorder to predict the possible loading on the relief system, This study strongly confirms that the use of dynamic Simulation technology complements conventional calculation techniques by providing more accurate models that Consider the transient behaviour of the process and control system. Further use of the model to improve the unit's control regime or as a basis for an operator ‘taining simulator system is possible. Dynamic simulation Refineries continuously debottleneck key processing units such as CDUs for improved separation to stay competitive and increase throughput. Following this path, the predicted column relief load (estimated using eanventional methods) eventually reaches the capacity of the Connected relief system. Therefore, Significant non-prodietive investments say be necessary to comply with acept cd safety standards and regulations. In recent years, the use of dynamic simulation has. become increasingly common inthe design and specification ff pressure relief systems. dynamic Simulation study of a process can provide a more accurate and quantita- tive understanding of a pressure zlit event, including information not avallable via conventional techniques. Before relevant conclusions canbe obtained from a simulation, the ‘dynamic simulation madet should be validated against operating data. to prove its accuracy, if possible Tm this example, the crude unit revamp included the implementation of new, enhanced ESD logic. A mechanical resting of the column identified that the section of crude tower where the liameter is reduced (the cone section) required a lower allowable working REFINING Profash 1 Crude cetiation Mower Figure 1 Schematic diagram of the OMVD crude tower and all necessary associated ‘equipment for on accurate representation of the refinery’s crude distillation process E Motes eqipment = certs ee, uncer sie cle Teh poe creator fame) Roe ceane Sane ron eas ga matte conocer ie 0503) Table 1 pressure for the column. Therefore, the refinery looked for recertification that ‘the existing relief system was stil able to handle expected tellef scenarios and that the relief would be fast enough to maintain the crude tower pressures vithin limits. Hopefully, the revamp would not require additional invest- sents in the reli system, The primary goal of the study was to reassure the ‘operating staff and the safety authorities that the existing relief system was adequate for the tested emergency cases Inadaition, the study would provide the engineers and operators with a better ‘understanding of the dynamic response of the crude unit during abnormal situations. If crude refiners reviewed thetr plant history, very few cases of crude unit rellef valve openings would be observed, fand any such events result in almost immediate column pressure reduction Maximum column pressures (design pressure plus allowable overpressure) are rarely reached due to conservatively sized relief and flare systems, The challenge is to apply this experience to an appropriate CDU relief system design, while ensuring that operations meet the safety and enviconmental protection requirements. Since the mid- 1970s, considerable development effort has been spent by industry groups, such as the American Institute of Chemical Engineers (AIChE) design institute for emergency relief systems (DIERS), to improve methods for reliet flow prediction and to standardise pressure relief device sizing methodologies Conventional methodologies make many assumptions concerning the nature of the event, which often lead to total pressure relief loads that are overly ‘conservative, thas predicting relief loads ‘that are in excess of the actual relief loads experienced in the refinery. These methods da not account for the following conditions ‘= Strong Interaction between heat. Integrated equipment, such as. pump: around heat exchangers 33 Pra 02 2006 — Interactions between different relief devices connected 10 a common flare header system = Time delay to reach the relief pressure after an event, and the ‘maximum pressure obtained "Change of relief flow composition iter the intial opening of the valve — The effect of operating controls is not considered, although some of the control responses will happen automat leally (le, emergency shutdown Logie), some regulatory control action may exacerbate a relief scenario, In recent years, the use of dynamic simulation to predict more accurate relict leads has become “used and accepted” in the petroleum and petrochemical Industries" Some literature sources conclude that the overestimation of total relief rates and loads based on these procedures is. S0-200%, An accurate rigorous dynamic model of the process, ‘major contol loops and the associated Telief system (including the pressure relle valves) provides a more detalled and accurate description of the process Interactions during a relieving scenario. Work scope “The study employed a rigorous dynamic model of the crude tower and associated equipment using the previously noted Dynsim software. The model scope was discussed in great detail 10 include everything that might influence the relict flows and pressures using previous refinery operation experience. The final ‘model scope is summarised in Figure 1 and a lst of major equipment included in the model is given in Table 1. All the equipment provides accurate estimates fof mass_and energy balances and rigorous thermodynamic calculations For example, the individual tray geometry in the erude tower is inched in detall to ensure comet calculations of hydraulic effects and hold-ups. Each tray is modelled rigorously, taking ito account the following: = "Calculations for variable liquid hold- = Tray hydraulic equations that relate liquid flow off the tray and the height of liguid over the weir —Non-equilibrium flash calculations based on tay efficiency — Rigorous pressure drop calculation based on the vapour flow rate and liquid level on the tay. The process heat exchangers were modelled using the rigorous mti-phase ‘models that use the rating equations as the defining equation for heat transfer ‘The vessel equipment provided models forthe reflux accumulator and naphtha accumulator, including the following functionality — Total volume and level calculations REFINING based on the vessel's length, diameter Model validation is required for trusting designed to insure that the dynamic and orientation the results and predictions of any results fom the model were consistent sndvjuse separation of feeds into process model. As previously mentioned, with actual plant behaviour dealy, the Tapote and Ie holdsups within the Operators sequire model accuracy and dynamic model should be, valldated Taper using a agorous Mash calculation, reliablty at a very high level, especially against actual plant data that js similar Min en optional water phase decanted i they expect fo get relevant safety to the actual operating conditions of fom the liquid phase in a water boot information. interest. However, for plant relief studies, froniter Tphise calculations, if Two types of valldation tests were it is impractical and unwise to expose appropriate performed, Fist, the steady-state results. the plant to a tellef scenario jut to get aprile. pressure calculation based from the dynamic model were dynamic plant test data for validation of gm the vapour hold-up and volume compared to several sets of steady-state the dynamic model. Thus, a more inside the vesse] plant data and accepted run results with practical and safer plant test was applied insifiguld vapourisation calculations the proprietary PROMI software. Pure For this dynamic valkation test = hen appropriate (lor example, when and pseudo-component data, feed step change wes made In the reflux flow the cellef valves open). Eompositions and initial estimates of rate by about 15%. The dynamic ‘the tap locations and inlet and exit intermediate temperatures, pressures responses of Key measurements in the locations provide accurate calculations, and compositions coukl be taken from overhead section of the crude tower cate Cro Vie vessel dries out or the PRO/II Tun, The dynamic model was were then recorded. Careful test ‘becomes liquid-full fumed by adjusting tray efficiencies, heat planning and operations execution ae care aaitient and control logic transfer coefficients and pressure drops ecessary to keep all other process database for the process model of the to match the steady-state plant data, conditions ‘under control during the cea uier and its associated equip. Excellent agreement was obtained brief test period. Crude oll feed rate and caine oer maiucted using the control between the plant data and the model: composition should remain constant to ret Towle modules available in Dynsim. — All iynsim model product flow rates get comparable ‘dynamic plant, data The model used over 20 controllers, $0. matched the flow measurements Using these data, the model was camel and a variety of logic — Minimal pressure discrepancies adjusted using the same tuning modules Tasted Between model and plant parameters as before to match the reasurements Gynamic plant data, The tuning Model validation miecThe product temperatures as well constants from the DCS controls were aroceronced process engineer must the intemal column temperature profile Incorporated into the analogous control, Re oPerGynamie model fesuls with were met within

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