Professional Documents
Culture Documents
Daryl W. Hanson
Process Consulting Services Inc., Houston, Texas
Norm P. Lieberman
Process Improvement Engineering, Metairie, LA
roubleshooting refinery vacuum unit revamps(Photo 1) begins with accurate differential pressure measurements. Specific pressure measurement elevations and detail drawings of the column internals are essential to properly interpret the data. Without complete information wrong conclusions can be drawn from the differential pressure measurements. Three case studies will show how accurate field measured differential pressure can be interpreted incorrectly. These cases present only a few of the ways to misinterpret data.
Column internals generate pressure drop if they are functioning properly, but so will liquid level. Because pressure drop generated by packed column internals is very low, two gauges must be used with the readings taken simultaneously. To ensure there is no offset between the two instruments, they should both be connected to the same process point and each should have the same reading. By measuring differential pressure simultaneously the readings are not affected by normal pressure variations. When measuring pressures less than 10
mmHg absolute, most digital gauges read a few mmHg low. Special high precision gauges are required if accurate pressure readings are required. When measuring pressure drops, this is not a problem.
Rules of Thumb
Column internals generate pressure drop and so does liquid head. Properly functioning stripping section trays will generate between 3.5-5 mmHg per tray. Liquid level also produces P, therefore 10 of 0.75 specific gravity liquid generates approximately 13-14 mmHg. Since packing gener-
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sures and the locations. Measured P across the slop wax (dirty gas oil or overflash) collector tray and five feet of wash section packing was only 3 mmHg. Interpreting pressure drop correctly requires complete knowledge of column internals and how they influence pressure. Pressures were taken above the wash bed and at the same location as the flash zone pressure instrument. Detailed review of vendor drawings showed a vapor horn had been installed; yet it did not appear on the vessel elevation drawing. The flash zone pressure measurement was taken inside the vapor horn. Pressure should never be measured inside vapor horns because vapor and liquid velocities are very high. Kinetic energy can make the pressure reading lower or momentum from liquid impinging on the pressure point can produce readings higher than the flash zone pressure. Pressure in the flash zone was 8 mmHg higher than inside the horn. Therefore, the kinetic energy component of system pressure was very high causing the measured pressure to be lower than the flash zone. Because the true pressure drop across the packing was very high, it confirmed the bed was badly coked (Photo 2 and 3) and a shutdown was needed to replace the packing. Furthermore, high column pressure drop reduced HVGO product yield. Conversely, pressures outside the vapor horn and below the overflash pan can be 3 to 6 mmHg lower than the measurement inside the horn due to liquid impingement
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Flash zone
25
Measured
Measured
Five (5) sieve trays With steam 755 No steam 757 Stripping steam
Initial P Actual P
20 mmHg 0 mmHg
LC
Transfer line
Flash zone
15,000 15,000
Case #2: Black HVGO Product High Wash Section Pressure Drop
Black HVGO product contained 1.6 wt % microcarbon residue that increased FCC catalyst consumption by more that 4 tons/day. Black HVGO is a symptom of wash bed coking, yet the refiner had no history of coking. Moreover, flash zone temperature was only 730F and the wash bed packing depth was only 4 feet. Experience shows it is nearly impossible to form coke in short crude vacuum column (versus visbreaker or hydrocracker) wash zones. Because entrainment from the flash zone and wash liquid from the top keep the packing sufficiently wetted to avoid dryout in short packed beds and operating temperature was only 730F, coking was not likely. Yet in spite of low temperature
and a short bed, black HVGO product pointed to coke. In addition, the pressure survey measured 15 mmHg across the wash bed. High P indicated that coke was likely causing the black HVGO. Figure 2 shows pressure was measured at the upper level tap on the slop wax collector, below the wash bed and in the vapor space above. Furthermore, slop wax tray level measured 60% which indicated the upper instrument tap was in the vapor space. But, slop wax collector trays have no level glass to confirm the instrument reading is a true level and these instruments often do not work. Therefore, pressure was measured in the flash zone as a check of slop wax tray liquid level. Measured flash zone pressure was only 21 mmHg versus the 31 mmHg measured on the slop wax tray. Level on the tray was reduced until the instrument reading was 15%, at the same time the measured pressure decreased from 31 to 18 mmHg. Thus, the initial pressure reading on the tray included 10 inches of liquid, which increased the pressure by 13 mmHg. Further review showed that the top of the collector tray risers were 10 inches higher than the instrument top tap. Consequently, slop wax was overflowing the riser during
Reprinted from PTQ Revamps & Operations, Autumn 2003
Case #3: Low HVGO Product YieldNormal Stripping Section Pressure Drop
HVGO product yield had dropped by 4,000 bpd following start-up even though the same crude rates and blends were being processed. Problems with column boot level instrumentation were common during start-up and throughout normal operation. High liquid level is the most common cause of stripping section tray damage. Yet in the most recent turnaround no tray damage was found. Until the refiner switched to heavier crude, very little emphasis was placed on stripping section performance. But as crudes get heavier, stripping section performance plays an increasing important role in meeting HVGO product yield targets. Properly functioning stripping trays generate 3-5
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When troubleshooting vacuum column strippers, the quench flow rate should also be monitored. If stripping trays are working properly there will be temperature drop. Thus when steam is blocked in, the temperature of the liquid leaving the stripping trays increases, hence quench flow rate must increase to maintain constant temperature in the boot or the columns bottom temperature will increase. When stripping trays are not working, there is little or no change in quench flow rate or bottoms temperature when steam is blocked in. High liquid level also results in loss of vacuum due to liquid phase cracking. If lowering the pool level restores vacuum, liquid phase cracking is occurring.
THE AUTHORS
Daryl W. Hanson is a chemical
engineer with Process Consulting Services in Houston, TX. His responsibilities include process and equipment design. He specializes in all phases of refinery distillation from process simulation through field inspection. Previously he was lead process specialist for Koch-Glitsch Inc. where he was involved with more than 100 column revamps including heavy oils and light-ends recovery towers. Hanson has authored more than 20 technical papers on revamping and distillation. He holds a BS degree in Chemical Engineering from Texas A&M University.
Process Consulting Services, Inc. 3400 Bissonnet Suite 130 Houston, Texas 77005 U.S.A. Phone: [1]-(713)-665-7046 Fax: [1]-(713)-665-7246 E-mail: info@revamps.com Website: www.revamps.com