KLM Page 1 of 10
Technology Group
Rev 1.0
Practical Engineering Engineering Solutions
Guidelines
for Processing Plant Solutions Consulting, Guidelines, and Training
www.klmtechgroup.com
Introduction to Distillation Operation,
Control, and Troubleshooting
Training Course
for Refinery Personnel
Introduction
The success of every company depends of each employee's understanding of
the business's key components. Employee training and development will unlock
the companies' profitability and reliability. When people, processes and
technology work together as a team developing practical solutions, companies
can maximize profitability and assets in a sustainable manner.
It is strategically important that your operations group understands the
fundamentals of process tank design, operations and troubleshooting concepts.
This is the difference between being in the best quartile of operational ability and
being in the last quartile. There is vast difference in the operational ability of
operating companies and most benchmarking studies have confirmed this gap in
operational abilities.
Whether you have a team of new or seasoned employees, an introduction or
review of these concepts is greatly beneficial in closing the gap if you are not in
the best quartile or maintaining a leadership position. Most studies show that a
continuous reinforcement of best practices in operational principles is the most
effective way to obtain the desired results. Training and learning should be an
ongoing continuous lifelong goal.
Distillation is the most common separation technique and is energy intensive.
Distillation can consume more than 50% of a process plant’s operating energy
cost. A way to improve an existing plant’s operating cost or to reduce a new
distillation system’s operating cost is to improve the efficiency and operations by
correct equipment selection, maintenance, process optimization and control.
KLM Page 2 of 10
Technology Group
Rev 1.0
Practical Engineering Engineering Solutions
Guidelines
for Processing Plant Solutions Consulting, Guidelines, and Training
www.klmtechgroup.com
Course Objective
This course will guide the participates to develop key concepts and techniques to
design, operate, maintain and troubleshoot a distillation system. These key
concepts can be utilized to make design, maintenance and operating decisions.
Training and development is an investment in future success - give yourself and
your employees the keys to success.
Product recoveries, purities and energy utilization can be improved in most
distillation systems. This cannot be achieved without first an understanding of
distillation principles and design. These principles need to be understood in
advance of designing, operating, maintaining and trouble shooting a distillation
column for the operator, maintenance, designer, or problem solving to be
effective.
The goal of the course would be to refresh the knowledge of those who have a
basic understanding of distillation and process simulation software techniques
and to build a foundation to those who are new to the distillation.
Course Duration and Delivery
Typical course duration is 3 to 5 days based on the background of the
participates. One of our Senior Technical Professional with over 25 years of
experience would lead the class. Instruction can be in house or in an online
webinar.
This course is an introduction to these topics – for a more detailed overview
consider attending our advance course.
KLM Page 3 of 10
Technology Group
Rev 1.0
Practical Engineering Engineering Solutions
Guidelines
for Processing Plant Solutions Consulting, Guidelines, and Training
www.klmtechgroup.com
Course Syllabus
Typical Course Outline
A. Introduction to the Chemical Processing Industry
B. Safety for the Chemical Processing Industry
C. Characteristics of Crude Oil
Sources of Crude
Composition of Crude
Description of Crude Oil Fractions
Definition of Physical and Chemical Processes
Crude Oil Testing
Crude Assays
D. Introduction to the Refinery Flow Sheet
Refinery Flow Sheet
Gasoline Processing Options
Bottoms Heavy Oil Processing Options
Alkylation
Hydrotreating
Gas Sweeting
Sulfur Recovery
E Introduction to Distillation
1. General Column Design
The components of a distillation system, more than just a tower – it
is a system of different components
History of distillation
Different types of distillation columns
Differences among batch, flash, and multistage distillation process
KLM Page 4 of 10
Technology Group
Rev 1.0
Practical Engineering Engineering Solutions
Guidelines
for Processing Plant Solutions Consulting, Guidelines, and Training
www.klmtechgroup.com
Relative advantages of tray and packed columns
Steps in the process design
F. Column Design
1. Tray Column Design
The major design differences between tray types
1. Baffle Trays
2. Bubble Cap Trays
3. Sieve Deck Trays
4. Valve Trays
5. Downcommer Types
6. Feed Nozzles
The operational limits for trays – operating window
Process Design
1. Tray Efficiency
2. Tray Capacities
3. Collector Trays
Mechanical Design
1. Metallurgy Selection
2. Mechanical Strength
3. Collector Tray Design
2. Packed Column Design
The different types of packing and their characteristics
1. Grids
2. Random Packing
3. Structured Packing
KLM Page 5 of 10
Technology Group
Rev 1.0
Practical Engineering Engineering Solutions
Guidelines
for Processing Plant Solutions Consulting, Guidelines, and Training
www.klmtechgroup.com
The best type of packing for a given system
Process Design
1. Packing Efficiency
2. Packing Capacities
3. Distributor Design
Mechanical Design
1. Metallurgy Selection
2. Mechanical Strength
3. Distributor Tray Design
G. Crude Oil Distillation
Description of the Distillation Process
Cut Points of the Various Fractions
Crude Tower Design
Vacuum Tower Design
H. Troubleshooting
Introduction
1. Evaluate operation of a packed column
2. Evaluate operation of a tray column
3. Use tools to diagnosis problems
KLM Page 6 of 10
Technology Group
Rev 1.0
Practical Engineering Engineering Solutions
Guidelines
for Processing Plant Solutions Consulting, Guidelines, and Training
www.klmtechgroup.com
I. Crude Oil Trouble Shooting Case Studies
Distillation
1. Typical Problems
2. Flooding and Its Detection
3. Pressure Surveys
4. Saltation
5. Entrapment
6. Damaged Equipment
7. Entrainment and Product Quality
8. Intermittent Draws
Heat Exchangers
1. Preheat and Crude Fouling
2. Leaks
3. Flooded Exchangers and Tubesheet Failures
4. Hot Vapor Bypass and Sealing
5. Vapor Blanketing
6. Heat Integration and Startup
7. Heat Flux Limits
8. Thermosyphon Reboilers
J. Process Control
1. Distillation Column Control
Functions of Process Control
Characteristics of a Continuous Process
2. Typical controlled and manipulated process variables
Level
Pressure
Composition
KLM Page 7 of 10
Technology Group
Rev 1.0
Practical Engineering Engineering Solutions
Guidelines
for Processing Plant Solutions Consulting, Guidelines, and Training
www.klmtechgroup.com
Temperature
Flow
3. Controller Performance Criteria
Final Control Elements
Control Algorithms
4. Feed Forward Control of an Ideal Process
Feedback and Feed forward Control Loops
K. Reboiler and Condenser
Review Heat Exchange Design Fundamentals
Reboiler Design, Operation and Maintenance
Condenser Design Operation and Maintenance
L. Demister Pad
Demister Pad Design Review
Demister Pad Mechanical Review
M. Designing Columns for improved operation and maintenance
Maintenance Intervals
Designing for Fouling Service
Designing for Vacuum Service
N. Installation
Common column installation mistakes
List tasks to insure a proper installation
Revamp Installation Case Study
KLM Page 8 of 10
Technology Group
Rev 1.0
Practical Engineering Engineering Solutions
Guidelines
for Processing Plant Solutions Consulting, Guidelines, and Training
www.klmtechgroup.com
O Inspection
New tower inspection guidelines
Turn Around inspection guidelines
P Tower Scanning
Tower Scanning Overview
Tower Scanning Case Study
Q Commissioning
1. Tower Pre Commissioning Guidelines
2. Tower Start Up Guidelines
Common start up problems and understand how to correct them
3. Tower Shut Down Guidelines
R. Turn Around Planning
1. Estimating Replacement Parts Needed
2. Estimating Inspection
3. Project Management
KLM Page 9 of 10
Technology Group
Rev 1.0
Practical Engineering Engineering Solutions
Guidelines
for Processing Plant Solutions Consulting, Guidelines, and Training
www.klmtechgroup.com
What You Can Expect To Gain;
The operation, maintenance, control and trouble shooting of a distillation
columns and it’s associated equipment,
An overview of distillation, practical solutions as well as theory
Valuable Crude Distillation concepts
An understating of essential distillation concepts,
Valuable practical insights for trouble free design and field proven
techniques for commissioning, start up and shutdown of distillation
operation.
The fundamental knowledge of distillation control.
Mechanical design of tower internals
To tailor your approach to specific design, analysis and trouble shooting
problems.
KLM Page 10 of 10
Technology Group
Rev 1.0
Practical Engineering Engineering Solutions
Guidelines
for Processing Plant Solutions Consulting, Guidelines, and Training
www.klmtechgroup.com
Who Should Attend
People who are making day to day decisions regarding operation, design,
maintenance, and economics of process industry plants.
1. 1st Line Operations personnel,
2. Operation Supervisors,
3. 1st Line Maintenance personnel,
4. Maintenance Supervisors,
5. Senior Plant Supervisors,
6. Operations Engineers
7. Process Support Engineers,
8. Design Engineers,
9. Cost Engineers
A supervisor or engineer who must troubleshoot and solve distillation
problems in a plant.
Technical Engineers, Operating Engineers, Process Support Personnel,
and Managers
Plant Operation Support Engineers checking plant performance under
different operating conditions, and who are involved in design of new
facilities or revamps of existing facilities.
Ideal for veterans and those with only a few years of experience who want
to review or broaden their understanding of process safety.
Other professionals who desire a better understanding of the subject
matter.
