Lecture Slides CPE 676_Introduction to Equipment

8/2/2019 Lecture Slides CPE 676_Introduction to Equipment

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REFINERY ANDPETROCHEMICAL

EQUIPMENT(CPE 671)


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COURSE OVERVIEW :

REFINERY AND PETROCHEMICAL

EQUIPMENT (CPE 671)

Equipment related to refinery and

petrochemical processes

Conception of the overall plant and

the equipment design


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INTRODUCTION


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INTRODUCTION

Lesson objectives :

By the end of the class, the students are

expected to be able :

to identify the necessary and the most appropriate

equipment for refinery and petrochemical plant.

to understand the importance of safety in plantoperation and equipment.


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INTRODUCTION

What are the petrochemical plants that are

available in Malaysia ?

..can you name some?


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Petrochemical Plants in Pasir Gudang,

Johor


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Petrochemical Plants in Kertih,Terengganu


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Petrochemical Plants in Bintulu

Sarawak


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Petrochemical Plants in Gebeng,Pahang


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Major equipment in refinery andpetrochemical plant

1. Heat exchange equipment :

examples : heat exchanger, fired heaters,

air-cooled exchangers, condenser,

reboiler

- what are the fundamentals

of heat transfer?

- basic heat transfer relations ??

phase change

no phase change


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Examples of common equipment inrefinery and petrochemical plant

2. Separator Equipment

fractionators (distillation column), absorbers (packed

column), scrubber, vapor-liquid separator (knockout

drum/ flash drum, knock-out pot, compressorsuction drum or compressor inlet drum), filterseparator, fixed bed separator.

what are the fundamentals of

separation process?

types of phases

boiling point of

component

relative volatility

pressure difference


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Examples of common equipment inrefinery and petrochemical pant

3. Reactor

stirred tanks, packed tubes or vessels,

shell-and-tube devices or highly specialized

configurations (specially fabricated)

what are the fundamentals of

reaction process?

Chemical kinetics

Stoichiometry of theparticipating reactions

Heats of reaction,

equilibrium data,

rate of reaction,


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Examples of common equipment inrefinery and petrochemical plant

4. Transport and storage of fluids

- pumps

- compressors

- storage tanks


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Why accidents happen??

Accidents in petrochemical industry can be

due to..

poorly designed,

poorly operated, or

poorly maintained


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Poorly designed: A stripper columncollapsed.


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close-up of collapsed strippercolumn..


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Why??Due to improperly protected distillation system

the situation..

Column was flooded with water.

Drain the water by pumping it

out

thus creating vacuum condition

Vacuum relief devices are notoriginally provided on the stripper

Corrective method

Installed vacuum breakers at the

top of the column


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Vacuum relief devices: A pressure reliefdevice which is designed to allow fluid toenter a pressure vessel in order to avoid

extreme internal vacuum. Vacuum breaker: A device used to

relieve a vacuum formed in a water

supply line to prevent backflow. Alsoknown as backflow preventer.


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Poorly operated: Furnace temperaturesafeguard is altereda major fire

erupted


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a tube in furnace ruptured due to

overheating :

1800 gallons (6800L) of combustible

heat transfer fluid spilled and burned

intensively.

Witnesses stated flames were over

50-ft. (15m) high in approximately fiveseconds after fire started.

in 25 minutes, four-level of structures

and associated process equipment

were damaged.

estimated loss :

> USD 1.5 mill

property damageUSD 4 mill - business interruption

Situation..


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What happen ?

The heater was designed to automatically

shutdown and alarm in the control room

in response to high heat-transfer oil pressure,

high tube-wall temperature, low-pressure fuel

gas, or flame failure.

The shutdown setpoint was found to have

been mistakenly raised to the maximum of

the instrument's setpoint range, or 1,600 F

(870 C).

The tube metal high-temperature alarm

should have been fixed at 850 F(454 C ).

The limited burner shutdown instrumentation had not been properly inspected and

tested to ensure the necessary high degree of reliability.


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Poorly designed material: Wrongmaterial.

Caustic soda leaks due to an improper gasket used.


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Molten caustic soda at about 700oF(370oC) sprayed and dripped for about2.5 hours from elevated equipment in a

well maintained unit. The blistering hot caustic soda leak

discovered during the day shift - melted

insulation on wiring and destroyedplastic electrical junction boxes andinstrument control boxes.


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The situation was inadvertently createdwhen someone installed a compressedasbestos gasket (the nearly universal

gasket for this chemical complex at thattime) on a thermocouple flange in thevapor space.

Specifications dictated a metallic nickelgasket, but the compresses asbestoswas installed in error.


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Estimated 15 tons (13,600 kg) of causticsoda (about 98- percent strength) leaked out

of the concentrator.

It cost about USD $40,000 to clean up and

recover from the damages. Luckily, there

were no injuries or environmental insults.


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Poorly designed material: Anothercostly gasket error

A serious oil refinery resulted from theinstallation of the wrong gasket on a heatexchanger.

The unit was operating normally, processing avery flammable naphtha for about six weekfollowing an outage in which the heat

exchangers were clean and tested A spiral-wound metal asbestos gasket was

required by specification, but a compressed

asbestos gasket was installed.


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The gasket failed causing a leakfollowed by a fire.

The heat from the initial fire caused anadjacent hydrogen exchanger flange toopen.

Vapors flashed and impinged on an 18-inch (46cm) hydrogen-oil line which thenruptured.

This piping failure released oil andhydrogen under 185 psig (1275kPa/12.6 atm) pressure.


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The fire was brought under control afterabout two hours, but it was allowed toburn another hour and twenty minutes to

consume the remaining fuel. The fire damages affected the electrical

and instrument systems, piping and

structural steel equipment.


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Corrective action/ counter measure

Preventive measures included a review ofgasket installation and purchasespecification procedures.

Drawings appropriate for turnaround workwere developed to conform to new facilitypractices and have flange ratings marked.

A retaining program covering gasket

installation procedures for craftsmen wasconducted.

Purchasing specifications for gasket now

require color coding.


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Flanges gasket

In some plants three or four types of gasket


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In some plants, three or four types of gasketservices are needed where previously all pressurehandled with compressed asbestos-type gaskets.

For high temperature applications the relativelyexpensive flexible graphite-type gaskets can beused.

For a wide variety of process services, such aspetroleum-based solvents, oxygen, and chlorine,an expensive Teflon-like gasket may be required.

Today, there exists a serious need to spendsufficient time to educate all maintenancepersonnel on details of gasket selection,installation, and the limitations of each type of

gasket.


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A water drain line is altered.a reactor exploded

A supervisor of a solvents plant was concerned about trace


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A supervisor of a solvents plant was concerned about traceemissions of heat transfer fluid from a small diameter waterdrain line.

He, no doubt, felt that with just about 30 ft, (9m) of small1.5 inch (3.8cm) piping, a couple of valves, and a smallconical bottom tank, this heat transfer fluid could berecovered.

The aim was to reduce pollution potentials and wastewatertreatment costs.

The supervisor probably only focused on one area ofconcern. However, this small change in just a cooling

water system contributed to the destruction of a 110 psig(760 kPa) rated 9ft (2.3m) in diameter pressure vessel.

A short-lived fire ensued. The severe overpressuredamage to this highly engineered nickel-clad reactor

resulted in over $500,000 in property damages.


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A water drain line is altered.a reactor exploded


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The modification involved the rerouting

of the discharge water from thebarometric condenser .

Rather than being discharged intoachemical sewer via a sump, the waterstream had been routed to a hopper thatallowed the entrained heat transfer fluiddroplets to drop out of solution and be

recovered. Decontaminated water overflowed to the

chemical sewer.


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Other accidents

A fire in giant floating roof in crude oil tank.


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After the top opened,

the fire burned butthe liquid was still

contained.


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Collapsed coker

drum in a

refinery.

Lecture Slides CPE 676_Introduction to Equipment

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