Updated 2 weeks ago
By Alex Johnson
Safety Warning
- Ensure all personnel are wearing appropriate PPE including flame-resistant clothing
- Verify all lockout/tagout devices have been removed
- Confirm all confined space entry permits are closed
- Ensure all pressure tests have been completed and documented
Equipment Information
This SOP applies to the following equipment
Equipment Type
Distillation Column
Applicable Models
Koch-Glitsch, Sulzer, UOP
1
Pre-Startup Safety Review
Verify all safety systems and pre-startup conditions
60-90 minutes
Tools: Pre-startup checklist, P&ID drawings, Blind list, Radio communication
- Conduct pre-startup safety meeting with all involved personnel
- Verify all maintenance work has been completed and signed off
- Confirm all blinds and isolation points are removed and documented
- Check all safety systems including PSVs, alarms, and emergency shutdown systems
2
Establish Utility Services
Start up all required utilities in the correct sequence
45-60 minutes
Tools: Utility checklist, Pressure gauges, Flow indicators, Control system access
- Establish instrument air supply and verify pressure
- Start cooling water circulation and verify flow
- Establish steam supply to reboiler and verify pressure
- Verify electrical systems and control system functionality
3
Column Warm-up
Gradually warm up the column to prevent thermal shock
3-4 hours
Tools: Temperature indicators, Steam flow control, Expansion indicators, Thermal imaging camera
- Slowly introduce steam to reboiler at minimum flow
- Monitor column differential temperature and limit to <50°C/hour
- Verify expansion of column internals is not restricted
- Gradually increase steam flow as column temperature rises
4
Establish Reflux
Start reflux system and establish proper circulation
60-90 minutes
Tools: Flow meters, Level indicators, Pressure gauges, Pump performance curves
- Verify condenser operation and cooling water flow
- Start reflux pump and establish minimum flow
- Gradually increase reflux rate to operating conditions
- Monitor overhead receiver level and pressure
5
Introduce Feed
Begin feed introduction and transition to normal operation
2-3 hours
Tools: Feed flow control, Temperature profile monitoring, Product analyzers, Control system
- Verify feed preheater operation and temperature
- Start feed pump at minimum flow rate
- Gradually increase feed rate while monitoring column parameters
- Adjust reflux ratio and reboiler duty to achieve desired separation
6
Transition to Normal Operation
Stabilize column and transition to normal operating parameters
2-3 hours
Tools: Product analyzers, Control system, Operating procedures, Handover documentation
- Adjust column parameters to achieve product specifications
- Verify all automatic controls are functioning properly
- Establish product withdrawal rates at design conditions
- Complete startup documentation and handover to operations