Troubleshooting a C3 splitter tower

Part 2: root cause and solution

Distillation trays are prone to channelling and multi-pass maldistribution in large
diameter towers. Multichordal gamma scanning is used for solving such problems
HENRY Z KISTER Fluor
BRIAN CLANCY-JUNDT and RANDY MILLER PetroLogistics

he PetroLogistics giant C3
splitter started up in October
2010 and had experienced
RSHUDWLRQDO GLIFXOWLHV GXULQJ LWV
LQLWLDO HLJKWPRQWK UXQ 7UD\ HIciency appeared to be very low,
about 40-50%, compared to a typiFDO

WUD\
HIFLHQF\
experienced
with
conventional
trays in a C3 splitter. Due to the low
WUD\ HIFLHQF\ LW FRXOG QRW SURGXFH
on-spec polymer grade propylene.
PetroLogistics, Fluor (which was
not involved in the tower design),
and the tray supplier formed a
taskforce to conduct a troubleshooting investigation to determine the
root cause of this performance and
WRSURSRVHDQGHQJLQHHUD[
The troubleshooting investigation
combined hydraulic analysis and
detailed multipass distribution
calculations with the specialised
technique of multichordal gamma
scanning with quantitative analysis.7 +\GUDXOLF DQDO\VLV FRQUPHG
that the trays are prone to channelling and maldistribution due to
their large open areas. It also ruled
out several other theories.
The gamma scans showed a maldistributed pattern on the trays, with
high L/V ratios on the inside panels
and low L/V ratios on the outside
panels. The scans showed vapour
FURVV RZ FKDQQHOOLQJ 9&)& RQ
the outside panels. Flooding was
observed on the inside panels well
EHORZ WKH FDOFXODWHG RRG SRLQW
The scans pointed at a combination
of VCFC and multipass maldistribution as the root cause.
,QYHVWLJDWLRQ LGHQWLHG WKH KLJK
open slot area (15% of the active
DUHD RI WKH [HG YDOYHV WR EH WKH
prime factor inducing channelling

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and maldistribution. A likely initiator of the multipass maldistribution

ZDV OLTXLG SUHIHUHQWLDOO\ RZLQJ WR
the inside panels from the false
GRZQFRPHUV GLVWULEXWLQJ WKH DVKLQJ UHX[ WR WKH WRS WUD\V SDQHOV
7KLV SUHIHUHQWLDO RZ LV EHOLHYHG WR
have occurred through the gap at
ZKLFK WKH UHX[ SLSHV HQWHUHG WKH
false downcomers. Another likely
initiator was channelled vapour
blowing liquid from the outside to
inside panels across the off-centre
downcomers.
A short plant outage due to a
problem elsewhere provided the
RSSRUWXQLW\IRUDTXLFN[7KHNH\
PRGLFDWLRQ ZDV EODQNLQJ DERXW D
quarter of the valves on each tray
to reduce the tray open slot areas
from 15% to 11%. The gaps at the
UHX[SLSHHQWU\WRWKHIDOVHGRZQcomers were sealed and the false
downcomer heights were raised to
HQVXUH JRRG UHX[ VSOLW WR WKH WRS
WUD\ SDQHOV $QWLMXPS EDIHV ZHUH
added across the centre and
off-centre downcomers to prevent
the possibility of channelled vapour
from blowing liquid from the
outside to the inside panels
towards the middle. Some downcomer blocks were installed to
improve liquid distribution. The
PRGLHG WRZHU DFKLHYHG WUD\ HIciencies comparable to those
obtained in well-operated, smaller
diameter, low pressure C3 splitters.
The investigation is described in
two parts. Part 1 (see PTQ, Q4
2014) described the initial tower
operation, as well as our hydraulic
analysis and how it directed the
investigation to focus on the combination of VCFC and multipass
maldistribution as the most likely

root cause. Part 2, the current article, describes the application of the
specialised technique of multichordal gamma scanning with
quantitative analysis7 to validate
WKLV WKHRU\ FORVHO\ GHQH DQG PDS
the channelling and maldistribution
patterns, and lead to the correct
solution. All of the literature references in Part 2 were listed at the
end of Part 1.

Gamma scans investigation

To diagnose the nature of the
suspected channelling or maldistribution, and to implement an
HIIHFWLYH [ ZH SHUIRUPHG H[WHQsive multichordal gamma scans
together with quantitative analysis
of the gamma scans.
The gamma scanning technique
normally practised for distillation
trays shoots a single chord, or at
most one chord per panel, with
qualitative interpretation. Often,
downcomer chords are also shot.
The early gamma scans of the C3
splitter used this simple technique
which is excellent for detecting
JURVV DEQRUPDOLWLHV VXFK DV RRGing, missing trays, foaming, fouling,
and high base levels, but is unable
to detect subtle abnormalities such
as channelling, abnormal froth
structure, and blow-by in unsealed
downcomers.
For the C3 splitter, the early qualitative gamma scans established that
WKHLQVLGHDFWLYHDUHDVZHUHRRGHG
Centre and off-centre downcomers
ZHUHRRGHGLQVRPHVFDQVEXWQRW
RRGHG LQ RWKHUV 7KLV WLHG XS ZHOO
with the conclusion based on Figure
3 in Part 1 that the trays were at
LQFLSLHQW RRG DW WKH RSHUDWLQJ
rates.

PTQ Q1 2015 39

30

53

82

123

148

148

123

tower end). For each of these

chords, froth heights, froth densities, entrainment indexes, and clear
liquid heights were calculated. Due
to scan quality issues, some chords
needed re-shooting to verify
repeatability.

Quantitative analysis of gamma

scans: results

63

Figure 1 Chords used for the mapping gamma scan study

To identify more subtle abnormalities, multichordal gamma scans

with quantitative analysis are invaluable. This technique, seldom
applied by gamma scan vendors
GXH WR LWV KLJK FRVWV ZDV UVW
proposed by Harrison,6 and later
developed by Kister.7 The lead
author has used it with great
success to diagnose a multitude of
subtle abnormalities on trays,
including various modes of channelling, abnormal froth structure,
blow-by in unsealed downcomers,
and many others. This technique
requires top-quality multichordal
scans of each tray panel. Froth
heights, froth densities, clear liquid
heights, and hydraulic gradients
can be calculated as described in
references 7 and 8.
Initial
multichordal
scans
FRQUPHG WKH SUHVHQFH RI FKDQQHOling both on the outside and inside
active areas of the trays. The scans
showed a similar and quite uniform
channelling pattern throughout the
tower. There were no signs of
unbolted manways.
The uniformity of the channelling
pattern throughout the tower made
it possible to focus on a relatively
small section, map it in detail, and

40 PTQ Q1 2015

use this section to represent most of

the tower. This mapping provided
a cost-effective way of gaining a
FRQFLVH GHQLWLRQ RI WKH QDWXUH RI
the channelling. The costs of multichordal scanning with quantitative
analysis rapidly escalate with the
number of trays scanned and the
number of chords per tray. The
small section mapping permitted
shooting a large number of chords
SHUWUD\WRJLYHDJRRGGHQLWLRQRI
the channelling while keeping the
costs down by limiting the number
of trays scanned.
,Q WKLV PDSSLQJ VWXG\ YH
chords were shot on the inside eastHUQ SDQHOV DQRWKHU YH FKRUGV RQ
the inside western panels, and
three more chords on the outside
western panels (see Figure 1). The
spacing between any two successive inside panel chords was about
6in, and their locations were chosen
to minimise interference from the
support trusses (also shown in
Figure 1). Spacing between successive outside chords was 23-29in.
Two of the three outside chords
passed through the mod arc downcomers (MOAD). These MOADs
are marked as dashed lines in
Figure 1 (extending to 63in from the

Figure 2 shows the results derived

from the multichordal gamma
scans of the active areas. These
results are shown on Kistergrams,7
which are tray sketches drawn to
scale with the various measurements also shown to scale. As such,
they give a visualisation of the key
hydraulic parameters.
The quantitative interpretation
required several estimates. In the
interpretation, allowance was made
for variation in chord length and,
where relevant, for the liquid in the
mod arc downcomer above the
outside even-numbered panels. No
allowance was made for radiation
absorption by the support trusses
above the odd-numbered trays, but
these are shown in Figure 2 and
where relevant were considered in
the interpretation. Also, the chords
were chosen in a manner that minimises interference of the beams
with the measurements. Even
though the numbers in Figure 2 are
not accurate, the inferred trends are
quite independent of the estimates
and are therefore real and valid.
Figure 2 shows results only for
the western half of the tower. The
results from the eastern and western inside panels were very similar.
From left to right on each diagram
(west to east in the tower) are the
side downcomers, the outside
panels, the off-centre downcomers,
WKH LQVLGH DFWLYH DUHDV DQG QDOO\
the centre downcomers. Each
sketch terminates just to the right
(just east of) the centre downcomer.
Figure 2a shows the froth densities (using 1.0 for pure liquid
propane/propylene, 0 for pure
vapour). The values plotted were
obtained by numerical integration
of the gamma scan transmission vs
height above the tray for each scan
chord7 and are drawn on a scale of
0 to 0.5, so that a point on the tray
above means a froth density of 0.5,

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that is 50% liquid and 50% vapour

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ZLWK D ORZ IURWK GHQVLW\ LQGLFDWLQJ
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Figure 2a VKRZV KLJKHU IURWK
densities in the inside than in the
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panels.
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SDQHOVZKHUHWKHIURWKGHQVLWLHVDUH
similar to those in the inside panels
are at the outside panel inlets. The
GLIIHUHQFH EHWZHHQ WKH KLJK GHQVLties (at the inside panels and at the
inlets to the outside panels) and
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inlets are less dense than near the
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ratios at the panels inlets and
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Tray
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119

Tray
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
Tray
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119

[a]

[c]

Tray
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119

[b]

[d]

Figure 2 Results from multichordal gamma scans of active areas: (a) froth densities,
(b) froth heights, (c) clear liquids heights, and (d) entrainment

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Figure 2b VKRZV RRG DOVR DW WKH
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outside panels. In the outside
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WKH LQOHW VLGH WR RIIFHQWUH SDQHOV
7KHRRGREVHUYHGKHUHZDVGLIIHUent to that observed in the inside
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in Figure 2a DQG UHSUHVHQWV IURWK
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PTQ Q1 2015 41

Tray
104
105
106
107
Hosted by:

108
109
110

THE 2015
BITIO
ON
EXHIB
SE
EMIN
NAR
RS
CA
ALL
L FO
OR
PR
RESE
ENT
TAT
TION
NS
IS
S NO
OW OP
PEN
N!

111
112
113
114
115
116
117
118
119

Figure 3 Clear liquid heights with VCFC on outside panels

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42 PTQ Q1 2015

the inside panels. The only exceptions were the clear liquid heights
at the inlets to the side to off-centre
panels. The clear liquid heights
there ranged from 6in to 7in, except
on tray 108. On these trays (the
even trays) there appeared to be a
hydraulic gradient of around 3in.
This pattern is typical of VCFC.
Figure 2d shows entrainment from
the trays. For the entrainment
index, we deviated from the index
we usually use7 in favour of an
alternative index that we believe is
more meaningful here. For the
entrainment index, we took the
froth density at the maximum
transmission point, that is at the
vapour peak. The scale is 0-0.5, the
same as the froth density. The
shading shown in Figure 2d is the
same as in Figure 2a and represents
froth densities, with blue being
high and red being low.
The shading shows that the
entraining regions closely track the
high froth density regions.
For the three middle chords of
the inside panels, most of the
entrainment index values (froth
densities at the peaks) ranged
between 0.19 and 0.36. For the

chord closest to the off-centre

downcomers, the index was much
less, ranging from 0.07 to 0.14. For
the chord closest to the centre
downcomers the index ranged from
0.12 to 0.27.
For the outside panels, the
entrainment index (froth densities
at the peaks) ranged from 0.06 to
0.22. The only exceptions were the
inlets to the side to off-centre
panels, where most indices were
0.28-0.3. These were also the peaks
that had high clear liquid heights in
Figure 2c. These outside side to
off-centre panels had entrainment
gradients which tracked the clear
liquid heights, showing lessening
entrainment from panel inlet to
outlet.

Patterns distinguished from analysis

of gamma scans: results
The side panels appear to operate
at lower L/V ratios than the centre
panels. This means that either the
inside panels contained more
liquid, or the outside panels
contained more vapour, or both.
There appears to be VCFC on the
outside panels, with hydraulic
gradients of the order of 3in on the

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side to off-centre panels. Figure 3

illustrates this mechanism. The
low-density regions nicely correspond to the path of the vapour in
Figure 3 . The entrainment is mostly
from the inlet areas of the side to
RIIFHQWUH SDQHOV 7KH RRG
observed on the outside panels is
on the outlet of the off-centre to
side panels (see Figure 2b). Even
WKRXJK WKH RRG DSSHDUV WKHUH
there is not much entrainment
(compare Figures 2b and 2d). The
reason for the low entrainment
there could be drying up in this
region. This ties in with the low
clear liquid heights observed in the
middle and outlet of the off-centre
to side panels. Note that the inlet
weep from this panel comes from
the inlet region that is much wider
than the panel width near the
outlet.
With the outside panels operating
at VCFC, there will be an easy path
for the vapour to travel without
encountering a high liquid head.
This will induce preferential
YDSRXU RZ WKURXJK WKH RXWVLGH
panels and induce multi-pass maldistribution. The horizontal vapour
velocity component through the
outlet regions of the even
numbered outside panels may blow
liquid across the off-centre downcomers from the outside into the
inside panels. This too may induce
PXOWLSDVVPDOGLVWULEXWLRQ2%DUD9
who consulted our team on maldisWULEXWLRQ LGHQWLHG DGGLWLRQDO
sources conducive to diversion of
vapour and liquid into the inside
panels. These include the effective
OHQJWK RI WKH PRGLHG DUF GRZQ
FRPHU02$'EHLQJOHVVWKDQWKDW
used in the design calculations,
making it shorter than the centre
weir length; the formation of
UHJLRQV RI UHWURJUDGH RZ RQ WKH
outer panels caused by the impact
of the liquid on the outlet weir near
the tower wall on both sides of the
02$' DQG WKH LQ GHHS LQWHJUDO
trusses perpendicular to the liquid
RZ ZKLFK ZRXOG FDXVH PRUH
hydraulic resistance on the side
panels.
This theory of VCFC alone
H[SODLQHG WKH UHVXOWLQJ RRG LQLWLD
tion on the inside panels. The lower
HIFLHQF\ LV WKHQ ERWK GXH WR WKH

www.eptq.com

43

18

18

18

24

18

24

30
36.5

Figure 4 Reux inlet arrangement

seem much, but 3% by weight is

48% vapour by volume due to the
GHQVLW\ GLIIHUHQFH 7KH DVKHG
UHX[ HQWHUV WKH WRZHU YLD DQ
H-distributor (see Figure 4). The
inlet nozzle and the pipe feeding
the H are 24in, branching into two
short 18in pipes which later split
into four 18in laterals. Each lateral
has more than 40 2.5in diameter
holes, squirting the feed horizontally onto the walls of two
off-centre false downcomers that
VHUYH DV DVK ER[HV (DFK IDOVH
downcomer is 43in wide at the top,
tapering towards the bottom. The
false downcomers begin tapering
6in below the bottom of the laterals. In the false downcomers,
Reux inlet
vapour disengages upwards, while
While closely reviewing the tower OLTXLG GHVFHQGV DQG RZV RQWR WKH
internals, we found our missing top tray through 2in clearances in
OLQNUHX[HQWU\PDOGLVWULEXWLRQ
the
bottom
of
each
false
7KH UHX[ HQWHULQJ WKH WRZHU LV D downcomer.
DVKLQJ OLTXLG 8SRQ DVKLQJ WR
7KH IHHG PL[WXUH LV GLVFKDUJHG
the tower top pressure, it generated horizontally towards the wall of the
about 3% vapour by weight at the false downcomer at a velocity of
operating conditions. That may not about 10 ft/s, and the distance from

VCFC
and
the
multi-pass
maldistribution.
The channelling pattern on the
LQVLGH FKRUGV ZDV PRUH GLIFXOW WR
H[SODLQ 2QH K\SRWKHVLV ZDV WKDW
above the off-centre downcomers,
the VCFC on the outside panels
generated a strong horizontal
vapour velocity component in the
direction of the inside panels. This
velocity component would supply
the horizontal push in a direction
RSSRVLWH WR WKH OLTXLG RZ RQ WKH
inside centre to off-centre panels.
Although possible, this hypothesis
was not considered likely. It was
realised that there was still a missing link.

PTQ Q1 2015

43

rich. The high liquid heads

generated on the inside panels
would induce vapour to preferenWLDOO\ RZ LQWR WKH RXWVLGH SDQHOV
With the high open area of
the trays, the dry tray pressure
drop would be too low to counter
this maldistribution, so the maldistribution would persist throughout
the tower. The result is high
froth densities on the inside panels
and low froth densities on the
outside panels as seen in the
gamma scans.

Modications for overcoming the

problem

Figure 5 Reux pipe entering the false downcomer, showing gap at the entrance to the
downcomer

the holes to the false downcomer

walls is only about a foot. This is
likely to produce some upward lift
on the feed liquid when it hits the
false downcomer walls, and generate turbulence in this region. The
downward liquid velocity in the
false downcomer at the holes elevation is about 0.2 ft/s, which is quite
typical of downcomer entrance
velocities, a region of considerable
turbulence. The presence of vapour
at this region will aggravate the
turbulence. The top of the false
GRZQFRPHU LV RQO\ LQ DERYH WKH
centreline of the holes, and it is
possible that some of the feed
OLTXLGOLIWHGXSZRXOGRYHURZWKH
top of the false downcomers. Such
RYHURZ
LV
OLNHO\
WR
EH
maldistributed.
Figure 5 shows the entry of one of
WKH LQ EUDQFK SLSHV LQWR WKH IDOVH
downcomer. Where each pipe
HQWHUV WKHUH LV DQ LQ [ LQ JDS
mostly above the pipe, through
which liquid would pour out if
froth or liquid built up above the
UHX[ SLSH RU LI WKHUH ZDV WXUEX
lence in the region. A calculation
using the Francis weir formula
showed that if liquid built to the
WRSRIWKHIDOVHGRZQFRPHURI
WKH UHX[ ZRXOG SRXU WKURXJK WKH
gap above the pipe. If it only built
up to 6in above the gap, this fracWLRQ ZRXOG GHFOLQH WR  (LWKHU
way, there would be a large scale

44 PTQ Q1 2015

PDOGLVWULEXWLRQ ZLWK H[FHVV OLTXLG

pouring through the gaps into the
inside panels.
The validity of the assumption of
pure liquid may be questioned. The
region of the gap did not have any
pipe holes on either side of the
pipe, so it is likely to be liquid-rich.
So while the assumption may not
be precise, it should be quite a
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The modied
tower achieved
tray efciencies
comparable to those
obtained in welloperated, smaller
diameter, low
pressure C3 splitters
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panels can now be combined with
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through the gaps would be totally
directed to the inside panels,
making the inside panels liquid-

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the problem. During these deliberations, the heat pump main
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vibration incident. It was discovered that the compressor had
thrown a blade and that the unit
would be out of service for several
weeks. The team discussions turned
immediately from What can we
do? to What will we do?
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and the inside-to-outside pass
maldistribution, it was necessary to
mitigate the channelling and maldistribution. The key to eliminating
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inside passes, and to raise the
heights of the false downcomers to
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to block the horizontal velocity
component from the outside panels
that may blow vapour or carry
liquid or froth into the inside
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overkill since eliminating the
channelling should be enough to
mitigate the horizontal velocity
component, yet was a small price to
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channelling will be completely
mitigated. Finally, off-centre downcomer clearance blocks were added
to improve the split of liquid from

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Acknowledgement
The authors express their gratefulness to
Tracerco, in particular to Lowell Pless, for the
excellent gamma scans.

Henry Z Kister is a Fluor Corp. Senior Fellow

and Director of Fractionation Technology. He
is the author of three books, 100 articles and
has taught the IChemE-sponsored Practical
Distillation Technology course more than 400
times. He holds BE and ME degrees from the
University of NSW in Australia, is a Fellow of
IChemE and AIChE, a Member of the NAE.
Email: henry.kister@uor.com.

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Brian Clancy-Jundt currently works in one of

the largest propane dehydrogenation plants
in the world with PetroLogistics and has had
direct engineering oversight over all aspects of
an olens plant. He graduated from Texas Tech
University with a BS in chemical engineering.
Randy Miller served as Vice President,
Engineering for PetroLogistics (2007-2014),
instrumental in the design and development
of the facility since the commencement of
front end engineering design. He has worked
in the petrochemical industry for over 20 years
and holds a BS in chemical engineering from
Texas A&M University, an MBA from University
of Houston at Clear Lake, and is a Registered
Engineer in Texas.

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PTQ Q1 2015 45