DISTILLATION COLUMN OR TOWER WORK SCOPE FOR SHUTDOWN

Why is distillation column or tower maintenance important during refinery shutdowns?

Distillation columns or towers are vital components in many industrial processes, particularly in oil refineries, chemical plants, and petrochemical facilities. These towers are used to separate mixtures of liquids based on their boiling points through the process of distillation. Proper maintenance of these columns is essential for several reasons, especially during plant shutdown:

Safety: Ensuring the structural integrity of distillation columns is paramount to safety. Any weakness or defect in the column can cause leaks, spills or even catastrophic failures during operation. The shutdown provides an opportunity to inspect, repair and strengthen the columns to prevent accidents and protect personnel and the surrounding environment.

Efficiency: Well maintained distillation columns work more efficiently. Over time, dirt, corrosion or other problems can reduce the efficiency of the separation process, leading to reduced throughput or increased energy consumption. Shutdown maintenance allows cleaning, repair and optimization of the internal parts of the column to restore and improve its efficiency.

Compliance: Many industries are subject to stringent regulations regarding environmental protection, workplace safety, and product quality. Regular maintenance of distillation columns helps ensure compliance with these regulations by preventing leaks, emissions, or product contamination that can result from malfunctioning equipment.

Cost Savings: Although shutdown maintenance incurs upfront costs in terms of labor, materials and downtime, it can ultimately lead to significant cost savings in the long run. By addressing small problems before they turn into larger problems, maintenance activities can prevent unplanned shutdowns, production loss, equipment damage and costly repairs.

Longevity: Proper maintenance extends the service life of distillation columns, reducing the need for premature replacement and capital expenditures. Regular inspections, preventive maintenance and timely repairs help maintain the structural integrity and functionality of columns over time.

Operational Reliability: Distillation columns are often critical components in continuous manufacturing processes. Any unexpected downtime or operational disruption can have an impact on the entire plant, causing production delays, lost revenue and customer dissatisfaction. Shutdown maintenance contributes to overall plant uptime and operational continuity, while maintaining the reliability of distillation columns.

In short, maintenance of distillation columns during plant shutdown is essential to ensure safety, efficiency, regulatory compliance, cost-effectiveness, longevity, and operational reliability in industrial facilities. By investing in proactive maintenance strategies, companies can mitigate risks, optimize performance, and maximize the value of their assets.

Maintenance Procedure during Pre-shutdown, Shutdown and Post-shutdown

FOR- MECHANICAL ENGINEER, MECHANICAL SUPERVISOR, MECHANICAL FOREMAN AND MECHANICAL FITTER

JOB DESCRIPTION – INTERNAL INSPECTION,VT,PT,UT,MANWAY OPENING,INTERNAL SCAFFOLDING IF REQUIRED,TRAY MANWAY OPENING & MANUAL CLEANING, BOTTOM CLEANING TO BE DONE, BOX-UP

Pre Shutdown Activities

1. 1. Identify and tag the equipment
   2. Scaffolding to be erected if required
   3. Insulation removal from blind locations/manways & where it is applicable
   4. Apply de-rusting solvent to all the bolts / Hot bolting
   5. Arrangement of blinds, gasket, tools, exhaust fan or air mover, 24V lighting, rope pulley arrangement

Shutdown Activities

1. 1. Obtain work permit for job
   2. Blinding to be done as per blind list
   3. Open all Manways
   4. Install Air Movers at the manholes as per requirement & make arrangement for lighting (24V)
   5. Perform gas test, Obtain confined space permit
   6. Perform Initial Inspection through manways
   7. Tray manway opening
   8. Internal scaffolding as per requirement
   9. Pre-cleaning inspection to be done
   10. Manual cleaning to be performed as per inspection comments / HP cleaning if required
   11. Cleaning Acceptance
   12. Internal Inspection, VT, PT, UT
   13. Buffing of weld joints as recommended by Inspection team
   14. Perform repair if any
   15. Final inspection by Operation, Reliability and Process
   16. Acceptance for box-up
   17. Boxing up of trays.
   18. Final acceptance
   19. Removal of lightening & air mover.
   20. Box up the manways.
   21. De-blind and re-instating the connections & torqueing by following right sequence

Post Turn Around Activities

1. 1. Remove all blinds from location
   2. Re-fixing insulation if required
   3. Remove scaffolding if required
   4. Housekeeping to be done

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