Study 1: Concept Hazard Review
CONTENTS
1.0 PURPOSE
1.0.1 Team
1.0.2 Timing
1.0.3 Preparation
1.0.4 Documentation
HAZARD STUDY 1: APPLICATION
1.1 Project Definition
1.2 Process Description
1.3 Materials Hazards
1.4 External Authorities
1.5 Organization and Human Factors
1.6 Additional Activities to be Completed
1.7 Review of Hazard Study 1
APPENDICES
A Chemical Hazard Guide Diagram
B Safety Risk Criteria - Limit Values for Tolerable Risk
C List of Additional Assessments
Overflows and Gravity Drainage Systems
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 OUTLINE OF THE PROBLEM
5 DESIGNING FOR FLOODED FLOW
6 DESIGNING NON-FLOODED PIPELINES
6.1 Vertical Pipework
6.2 From the Side of a Vessel
6.3 Established (uniform) Flow in Near-horizontal Pipes
6.4 Non-uniform Flow
7 NON-FLOODED FLOW IN COMPLEX SYSTEMS
8 ENTRAINING FLOW
9 SIMPLE TANK OVERFLOWS
9.1 Venting of the Tank
10 BIBLIOGRAPHY
11 NOMENCLATURE
TABLE
1 GEOMETRICAL FUNCTIONS OF PART-FULL PIPES
FIGURES
1 TYPICAL SEQUENCE OF SURGING FLOW
2 DESIGNING FOR FLOODED FLOW
3 CAPACITY OF SLOPING PIPELINES
4 OVERFLOW FROM SIDE OF VESSEL
5 METHODS OF AVOIDING LARGE CIRCULAR SIDE
OVERFLOWS
6 CAPACITY OF A GENTLY SLOPING PIPE AS A FUNCTION OF LIQUID DEPTH
7 COMPLEX PIPE SYSTEMS
8 REMOVAL OF ENTRAINED GASES
Introduction to Hazard Studies
CONTENTS
1 INTRODUCTION
2 HAZARD EVALUATION TECHNIQUES
2.1 Hazard Identification and Control
2.2 Selection of Technique
2.3 GBHE Hazard Study Procedure
2.3.1 Study One – Concept stage hazard review
2.3.2 Study two - Front-end engineering design
and project definition
2.3.3 Study three – detailed design hazard study
2.3.4 Study four – construction/ design verification
2.3.5 Study five – pre-commissioning safety review
2.3.6 Study six – project close-out/ post start-up review
2.4 Application of Hazard Study Procedure
2.5 Outcomes from the Process
2.6 the Hazard Study Toolkit
2.7 Change Management/Modifications
3 HAZARD STUDY LEADER CAPABILITY AND APPOINTMENT
REFERENCES
APPENDICES
A THE PROJECT PROCESS
B GBHE HAZARD STUDY TOOLKIT
Reactor and Catalyst Design
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 CATALYST DESIGN
4.1 Equivalent Pellet Diameter
4.2 Voidage
4.3 Pellet Density
5 REACTOR DESIGN
6 CATALYST SUPPORT
6.1 Choice of Support
TABLES
1 CATALYST SUPPORT SHAPES
2 SECONDARY REFORMER SPREADSHEET
FIGURES
1 GRAPH OF EFFECTIVENESS v THIELE MODULUS
2 VARIATION OF COSTS WITH CATALYST SIZE
3 VARIATION OF COSTS WITH CATALYST BED VOIDAGE
4 VARIATION OF COSTS WITH VESSEL DIAMETER
VULCAN Series VSG-Z101 Primary Reforming
Initial Catalyst Reduction
Activating (reducing) the catalyst involves changing the nickel oxide to nickel, represented by:
NiO + H2 <==========> Ni + H2O
Natural gas is typically used as the hydrogen source. When it is, the catalyst reduction and putting the reformer on-line are accompanied in the same step.
Getting the Most Out of Your Refinery Hydrogen PlantGerard B. Hawkins
Getting the Most Out of Your Refinery Hydrogen Plant
Contents
Summary
1 Introduction
2 "On-purpose" Hydrogen Production
3 Operational Aspects
4 Uprating Options on the Steam Reformer
4.1 Steam Reforming Catalysts and Tube Metallurgy
4.2 Oxygen-blown Secondary Reformer
4.3 Pre-reforming
4.4 Post-reforming
5 Downstream Units
6 Summary of Uprating Options
7 Conclusions
Pressure Relief Systems Vol 2
Causes of Relief Situations
This Volume 2 is a guide to the qualitative identification of common causes of overpressure in process equipment. It cannot be exhaustive; the process engineer and relief systems team should look for any credible situation in addition to those given in this Part which could lead to a need for pressure relief (a relief situation).
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide Gerard B. Hawkins
Amine Gas Treating Unit Best Practices - Troubleshooting Guide for H2S/CO2 Amine Systems
Contents
Process Capabilities for gas treating process
Typical Amine Treating
Typical Amine System Improvements
Primary Equipment Overview
Inlet Gas Knockout
Absorber
Three Phase Flash Tank
Lean/Rich Heat Exchanger
Regenerator
Filtration
Amine Reclaimer
Operating Difficulties Overview
Foaming
Failure to Meet Gas Specification
Solvent Losses
Corrosion
Typical Amine System Improvements
Degradation of Amines and Alkanolamines during Sour Gas Treating
APPENDIX
Best Practices - Troubleshooting Guide
Overflows and Gravity Drainage Systems
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 OUTLINE OF THE PROBLEM
5 DESIGNING FOR FLOODED FLOW
6 DESIGNING NON-FLOODED PIPELINES
6.1 Vertical Pipework
6.2 From the Side of a Vessel
6.3 Established (uniform) Flow in Near-horizontal Pipes
6.4 Non-uniform Flow
7 NON-FLOODED FLOW IN COMPLEX SYSTEMS
8 ENTRAINING FLOW
9 SIMPLE TANK OVERFLOWS
9.1 Venting of the Tank
10 BIBLIOGRAPHY
11 NOMENCLATURE
TABLE
1 GEOMETRICAL FUNCTIONS OF PART-FULL PIPES
FIGURES
1 TYPICAL SEQUENCE OF SURGING FLOW
2 DESIGNING FOR FLOODED FLOW
3 CAPACITY OF SLOPING PIPELINES
4 OVERFLOW FROM SIDE OF VESSEL
5 METHODS OF AVOIDING LARGE CIRCULAR SIDE
OVERFLOWS
6 CAPACITY OF A GENTLY SLOPING PIPE AS A FUNCTION OF LIQUID DEPTH
7 COMPLEX PIPE SYSTEMS
8 REMOVAL OF ENTRAINED GASES
Introduction to Hazard Studies
CONTENTS
1 INTRODUCTION
2 HAZARD EVALUATION TECHNIQUES
2.1 Hazard Identification and Control
2.2 Selection of Technique
2.3 GBHE Hazard Study Procedure
2.3.1 Study One – Concept stage hazard review
2.3.2 Study two - Front-end engineering design
and project definition
2.3.3 Study three – detailed design hazard study
2.3.4 Study four – construction/ design verification
2.3.5 Study five – pre-commissioning safety review
2.3.6 Study six – project close-out/ post start-up review
2.4 Application of Hazard Study Procedure
2.5 Outcomes from the Process
2.6 the Hazard Study Toolkit
2.7 Change Management/Modifications
3 HAZARD STUDY LEADER CAPABILITY AND APPOINTMENT
REFERENCES
APPENDICES
A THE PROJECT PROCESS
B GBHE HAZARD STUDY TOOLKIT
Reactor and Catalyst Design
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 CATALYST DESIGN
4.1 Equivalent Pellet Diameter
4.2 Voidage
4.3 Pellet Density
5 REACTOR DESIGN
6 CATALYST SUPPORT
6.1 Choice of Support
TABLES
1 CATALYST SUPPORT SHAPES
2 SECONDARY REFORMER SPREADSHEET
FIGURES
1 GRAPH OF EFFECTIVENESS v THIELE MODULUS
2 VARIATION OF COSTS WITH CATALYST SIZE
3 VARIATION OF COSTS WITH CATALYST BED VOIDAGE
4 VARIATION OF COSTS WITH VESSEL DIAMETER
VULCAN Series VSG-Z101 Primary Reforming
Initial Catalyst Reduction
Activating (reducing) the catalyst involves changing the nickel oxide to nickel, represented by:
NiO + H2 <==========> Ni + H2O
Natural gas is typically used as the hydrogen source. When it is, the catalyst reduction and putting the reformer on-line are accompanied in the same step.
Getting the Most Out of Your Refinery Hydrogen PlantGerard B. Hawkins
Getting the Most Out of Your Refinery Hydrogen Plant
Contents
Summary
1 Introduction
2 "On-purpose" Hydrogen Production
3 Operational Aspects
4 Uprating Options on the Steam Reformer
4.1 Steam Reforming Catalysts and Tube Metallurgy
4.2 Oxygen-blown Secondary Reformer
4.3 Pre-reforming
4.4 Post-reforming
5 Downstream Units
6 Summary of Uprating Options
7 Conclusions
Pressure Relief Systems Vol 2
Causes of Relief Situations
This Volume 2 is a guide to the qualitative identification of common causes of overpressure in process equipment. It cannot be exhaustive; the process engineer and relief systems team should look for any credible situation in addition to those given in this Part which could lead to a need for pressure relief (a relief situation).
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide Gerard B. Hawkins
Amine Gas Treating Unit Best Practices - Troubleshooting Guide for H2S/CO2 Amine Systems
Contents
Process Capabilities for gas treating process
Typical Amine Treating
Typical Amine System Improvements
Primary Equipment Overview
Inlet Gas Knockout
Absorber
Three Phase Flash Tank
Lean/Rich Heat Exchanger
Regenerator
Filtration
Amine Reclaimer
Operating Difficulties Overview
Foaming
Failure to Meet Gas Specification
Solvent Losses
Corrosion
Typical Amine System Improvements
Degradation of Amines and Alkanolamines during Sour Gas Treating
APPENDIX
Best Practices - Troubleshooting Guide
High Temperature Shift Catalyst Reduction ProcedureGerard B. Hawkins
High Temperature Shift Catalyst Reduction Procedure
The catalyst, as supplied, is Fe2O3. This reduces to the active form, Fe3O4, in the presence of hydrogen when process gas is admitted to the reactor.
1. The mildly exothermic reactions are:
3 Fe2O3 + H2 ========= 2 Fe3O4 + H2O
3 Fe2O3 + CO ========= 2 Fe3O4 + CO2
Fouling Resistances for Cooling Water
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 GENERAL
5 COOLING WATER FOULING
6 CHROMATE SYSTEMS
6.1 General
6.2 Constraints
6.3 Requirements
6.4 Fouling resistances
7 NON-CHROMATE SYSTEMS
7.1 General
7.2 Requirements and Constraints
7.3 Fouling resistances
8 UNTREATED COOLING WATER
9 MATERIALS OTHER THAN MILD STEEL
APPENDICES
A FOULING RESISTANCES FOR COOLING WATER
B FOULING FILM THICKNESS
Liquefied Natural Gas (LNG) Life Cycle; LNG a safe fuel? ; Quality of LNG ; Sales LNG/Gas Specifications ; NATURAL GAS VALUE CHAIN; LNG TRANSPORTATION; Global Movement of Natural Gas; Movement of Natural Gas; Movement: Pipelines and Storage; Natural Gas Infrastructure: Pipeline Systems; Types of Pipelines; Offshore Pipelines; Movement: LNG; Liquefied Natural Gas (LNG); LNG Markets (R)evolution; LIQUEFACATION; REGASIFICATION; PIPELINE NETWORK; Revolutionary LNG Technologies: FLNG and FSRU; FLOATING LNG (FLNG); FLOATING STORAGE AND REGASIFICATION (FSRU); Global Natural Gas Trade; Natural Gas Price Formation; Liberalizing Market Dynamics; Natural Gas Contracts
COURSE LINK:
https://www.chemicalengineeringguy.com/courses/petrochemicals-an-overview/
Introduction:
The course is mainly about the petrochemical industry. Talks about several chemicals and their chemical routes in order to produce in mass scale the demands of the market.
Learn about:
Petorchemical Industry
Difference between Petroleum Refining vs. Petrochemical Industry
Paraffins, Olefins, Napthenes & Aromatics
Market insight (production, consumption, prices)
Two main Petrochemical Processes: Naphtha Steam Cracking and Fluid Catalytic Cracking
The most important grouping in petrochemical products
Petrochemical physical & chemical properties. Chemical structure, naming, uses, production, etc.
Basic Gases in the industry: Ammonia, Syngas, etc…
C1 Cuts: Methane, Formaldehyde, Methanol, Formic Acid, Urea, Chloromethanes etc…
C2 Cuts: Ethane, Acetylene, Ethylene, Ethylene Dichloride, Vinyl Chloride, Ethylene Oxide, Ethanolamines, Ethanol, Acetaldehyde, Acetic Acid, Ethylene Glycols (MEG, DEG, TEG)
C3 Cuts: Propane, Propylene, Propylene Oxide, Isopropanol, Acetone, Acrylonitrile, Propediene, Allyl chloride, Acrylic acid, Propionic Acid, Propionaldehyde, Propylene Glycol
C4 Cuts: Butanes, Butylenes, Butadiene, Butanols, MTBE (Methyl Tert Butyl Ethers)
C5 cuts: Isoprene, Pentanes, Piperylene, Cyclopentadiene, Dicyclopentadiene, Isoamyl, etc…
Aromatics: Benzene, Toluene, Xylenes (BTX), Cumene, Phenol, Ethyl Benzene, Styrene, Pthalic Anhydride, Nitrobenzene, Aniline, Benzoic Acid, Chlorobenzene, etc…
At the end of the course you will feel confident in how the petrochemical industry is established. You will know the most common petrochemicals as well as their distribution, production and importance in daily life. It will help in your future process simulations by knowing the common and economical chemical pathways.
Pumps for Ammonium Nitrate Service
Engineering Design Guide: GBHE-EDG-MAC-1503
CONTENTS
1 SCOPE
SECTION ONE: INTEGRATION OF PUMPS INTO THE PROCESS
2 PROPERTIES OF FLUID
2.1 Decomposition
2.2 Combustion
2.3 Detonation
2.4 Deliquescence
2.5 Density
2.6 Viscosity
2.7 Vapor Pressure
2.8 Freezing Point
2.9 Specific Heat
2.10 Surface Tension
2.11 Thermal Conductivity
3 CALCULATION OF DUTY
3.1 Centrifugal Pumps
4 CHOICE OF PUMP TYPE
4.1 Centrifugal Pumps
4.2 Rotary Pumps
4.3 Reciprocating Pumps
5 LINE DIAGRAMS
5.1 Centrifugal Pumps with Mechanical Seals
5.2 Vertical Suspended Cantilever Shaft Pumps for
Melt Service
5.3 Horizontal Self-Priming Pumps
5.4 Reciprocating Pumps
5.5 Seal Water Supply System
6 LAYOUT
6.1 Vertical Cantilever Shaft Pumps - Tank Proportions
SECTION TWO: CONSTRUCTION FEATURES OF PUMPS
7 SEALS FOR CENTRIFUGAL PUMPS
7.1 Below 30% AN
7.2 30-45% AN
7.3 45-90% AN
7.4 Above 90% AN
8 PACKED GLANDS FOR RECIPROCATING PUMPS
8.1 Below 90% AN
9 SEAL WATER SUPPLY SYSTEMS
10 CONSTRUCTION FEATURES OF CENTRIFUGAL PUMPS
10.1 Casing
10.2 Rotor
10.3 Bearing Lubrication
10.4 Coupling
10.5 Baseplate
11 CONSTRUCTION FEATURES OF VERTICAL CANTILEVER SHAFT IMMERSED PUMPS
11.1 Motor
11.2 Insulation and Jacketing
11.3 Rotor
11.4 Bearing Lubrication
11.5 Preservation
12 CONSTRUCTION FEATURES OF RECIPROCATING PLUNGER PUMPS
12.1 Speed Limits
12.2 Casing and Gearbox
12.3 Couplings
13 MATERIALS OF CONSTRUCTION
13.1 Recommended Materials
13.2 Forbidden Materials
APPENDIX A: BEARING LUBRICANTS
FIGURES
2.5.1 DENSITY OF AMMONIUM NITRATE SOLUTIONS
2.5.2 DENSITY OF AMMONIUM NITRATE SOLUTIONS
2.6 KINEMATIC VISCOSITY OF AMMONIUM NITRATE SOLUTIONS
2.7.1 WATER VAPOR PRESSURE ABOVE AMMONIUM NITRATE SOLUTIONS
2.7.2 AMMONIA VAPOR PRESSURE FOR AM!AMMONIUM NITRATE MELT
2.8 FREEZING POINT OF AMMONIUM NITRATE SOLUTIONS
2.9 SPECIFIC HEAT OF AMMONIUM NITRATE SOLUTIONS
4 SELECTION OF PUMP TYPE
5. 1 RECOMMENDED LINE DIAGRAM CENTRIFUGAL PUMPS WITH MECHANICAL SEALS
5.2 RECOMMENDED LINE DIAGRAM: VERTICAL SUSPENDED CANTILEVER PUMPS
5.3 RECOMMENDED LINE DIAGRAM: HORIZONTAL SELF
PRIMING PUMPS
5.4 RECOMMENDED LINE DIAGRAM: RECIPROCATING PLUNGER PUMPS
5.5 RECOMMENDED LINE DIAGRAM SEAL: WATER PUMPS AND INJECTION PUMP SYSTEMS
7.2 TYPICAL ARRANGEMENT OF SEAL WITH NO INJECTION FLUSH
7.3 TYPICAL ARRANGEMENT OF CRANE TYPE 52B WITH 'J' SEAT INCORPORATING TETRALIPS INBOARD AND OUTBOARD
7.4 TYPICAL ARRANGEMENT OF LABYRINTH SEAL FOR VERTICAL SUSPENDED CANTILEVER SHAFT PUMPS
8.1 TYPICAL ARRANGEMENT OF SOFT PACKED GLAND FOR RECIPROCATING PLUNGER PUMPS FOR DELIVERY PRESSURES UP TO 10 BAR G.
12 TEMPERATURES ATTAINED ON DISSOLUTION OF ANHYDROUS CAUSTIC SODA
TABLES
13.1 MATERIALS OF CONSTRUCTION CENTRIFUGAL PUMPS
13.2 MATERIALS OF CONSTRUCTION VERTICAL CANTILEVER
SHAFT IMMERSED PUMPS
13.3 MATERIALS OF CONSTRUCTION RECIPROCATING PLUNGER PUMPS
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS Gerard B. Hawkins
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS
CONTENTS
1 INTRODUCTION
1.1 Purpose
1.2 Scope of this Guide
1.3 Use of the Guide
2 ENVIRONMENTAL ISSUES
2.1 Principal Concerns
2.2 Mechanisms for Ozone Formation
2.3 Photochemical Ozone Creation Potential
2.4 Health and Environmental Effects
2.5 Air Quality Standards for Ground Level Concentrations of Ozone, Targets for Reduction of VOC Discharges and Statutory Discharge Limits
3 VENTS REDUCTION PHILOSOPHY
3.1 Reduction at Source
3.2 End-of-pipe Treatment
4 METHODOLOGY FOR COLLECTION & ASSESSMENT OF PROCESS FLOW DATA
4.1 General
4.2 Identification of Vent Sources
4.3 Characterization of Vents
4.4 Quantification of Process Vent Flows
4.5 Component Flammability Data Collection
4.6 Identification of Operating Scenarios
4.7 Quantification of Flammability Characteristics for Combined Vents
4.8 Identification, Quantification and Assessment of Possibility of Air Ingress Routes
4.9 Tabulation of Data
4.10 Hazard Study and Risk Assessment
4.11 Note on Aqueous / Organic Wastes
4.12 Complexity of Systems
4.13 Summary
5 SAFE DESIGN OF VENT COLLECTION HEADER SYSTEMS
5.1 General
5.2 Process Design of Vent Headers
5.3 Liquid in Vent Headers
5.4 Materials of Construction
5.5 Static Electricity Hazard
5.6 Diversion Systems
5.7 Snuffing Systems
6 SAFE DESIGN OF THERMAL OXIDISERS
6.1 Introduction
6.2 Design Basis
6.3 Types of High Temperature Thermal Oxidizer
6.4 Refractories
6.5 Flue Gas Treatment
6.6 Control and Safety Systems
6.7 Project Program
6.8 Commissioning
6.9 Operational and Maintenance Management
APPENDICES
A GLOSSARY
B FLAMMABILITY
C EXAMPLE PROFORMA
D REFERENCES
DOCUMENTS REFERRED TO IN THIS PROCESS GUIDE
TABLE
1 PHOTOCHEMICAL OZONE CREATION POTENTIAL REFERENCED
TO ETHYLENE AS UNITY
FIGURES
1 SCHEMATIC OF TYPICAL VENT COLLECTION AND THERMAL OXIDIZER SYSTEM
2 TYPICAL KNOCK-OUT POT WITH LUTED DRAIN
3 SCHEMATIC OF DIVERSION SYSTEM
4 CONVENTIONAL VERTICAL THERMAL OXIDIZER
5 CONVENTIONAL OXIDIZER WITH INTEGRAL WATER SPARGER
6 THERMAL OXIDIZER WITH STAGED AIR INJECTION
7 DOWN-FIRED UNIT WITH WATER BATH QUENCH
8 FLAMELESS THERMAL OXIDATION UNIT
9 THERMAL OXIDIZER WITH REGENERATIVE HEAT RECOVERY
10 TYPICAL PROJECT PROGRAM
11 TYPICAL FLAMMABILITY DIAGRAM
12 EFFECT OF DILUTION WITH AIR
13 EFFECT OF DILUTION WITH AIR ON 100 Rm³ OF FLAMMABLE GAS
Air / Steam Regeneration Procedure for Primary Reforming CcatalystGerard B. Hawkins
VULCAN Series VSG-Z101 Primary Reforming
Air steam regeneration procedures can be used either on start-up of a reformer after it has cooled, or can be done in the shut down process.
AIR STEAM REGENERATION ON SHUT DOWN
AIR STEAM REGENERATION ON START-UP
How to use the GBHE Reactor Technology Guides
0 INTRODUCTION / PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 BACKGROUND
5 THE DECISION TREE
6 GBHE REACTION ENGINEERING
7 GENERAL ASPECTS OF REACTOR TECHNOLOGY
7.1 Criteria of Reactor Performance
7.2 Factors of Economic Importance
7.3 Physicochemical Mechanisms
8 GENERAL GUIDE TO SELECTION OF REACTOR TYPE AND OPERATION
8.1 Choice of Reactor Type
8.2 Reaction Mechanism and Kinetics
8.3 Thermodynamics
8.4 Other Factors
9 GENERAL REFERENCES AND SOURCES OF
INFORMATION
APPENDICES
A RELATIONSHIP BEWTEEN DEFINED TERMS
FIGURES
1 DECISION TREE
2 RELATIVE YIELDS OF B FOR BATCH (OR PLUG FLOW) AND CST REACTORS
3 REACTOR SURVEY FORM
High Temperature Shift Catalyst Reduction ProcedureGerard B. Hawkins
High Temperature Shift Catalyst Reduction Procedure
The catalyst, as supplied, is Fe2O3. This reduces to the active form, Fe3O4, in the presence of hydrogen when process gas is admitted to the reactor.
1. The mildly exothermic reactions are:
3 Fe2O3 + H2 ========= 2 Fe3O4 + H2O
3 Fe2O3 + CO ========= 2 Fe3O4 + CO2
Fouling Resistances for Cooling Water
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 GENERAL
5 COOLING WATER FOULING
6 CHROMATE SYSTEMS
6.1 General
6.2 Constraints
6.3 Requirements
6.4 Fouling resistances
7 NON-CHROMATE SYSTEMS
7.1 General
7.2 Requirements and Constraints
7.3 Fouling resistances
8 UNTREATED COOLING WATER
9 MATERIALS OTHER THAN MILD STEEL
APPENDICES
A FOULING RESISTANCES FOR COOLING WATER
B FOULING FILM THICKNESS
Liquefied Natural Gas (LNG) Life Cycle; LNG a safe fuel? ; Quality of LNG ; Sales LNG/Gas Specifications ; NATURAL GAS VALUE CHAIN; LNG TRANSPORTATION; Global Movement of Natural Gas; Movement of Natural Gas; Movement: Pipelines and Storage; Natural Gas Infrastructure: Pipeline Systems; Types of Pipelines; Offshore Pipelines; Movement: LNG; Liquefied Natural Gas (LNG); LNG Markets (R)evolution; LIQUEFACATION; REGASIFICATION; PIPELINE NETWORK; Revolutionary LNG Technologies: FLNG and FSRU; FLOATING LNG (FLNG); FLOATING STORAGE AND REGASIFICATION (FSRU); Global Natural Gas Trade; Natural Gas Price Formation; Liberalizing Market Dynamics; Natural Gas Contracts
COURSE LINK:
https://www.chemicalengineeringguy.com/courses/petrochemicals-an-overview/
Introduction:
The course is mainly about the petrochemical industry. Talks about several chemicals and their chemical routes in order to produce in mass scale the demands of the market.
Learn about:
Petorchemical Industry
Difference between Petroleum Refining vs. Petrochemical Industry
Paraffins, Olefins, Napthenes & Aromatics
Market insight (production, consumption, prices)
Two main Petrochemical Processes: Naphtha Steam Cracking and Fluid Catalytic Cracking
The most important grouping in petrochemical products
Petrochemical physical & chemical properties. Chemical structure, naming, uses, production, etc.
Basic Gases in the industry: Ammonia, Syngas, etc…
C1 Cuts: Methane, Formaldehyde, Methanol, Formic Acid, Urea, Chloromethanes etc…
C2 Cuts: Ethane, Acetylene, Ethylene, Ethylene Dichloride, Vinyl Chloride, Ethylene Oxide, Ethanolamines, Ethanol, Acetaldehyde, Acetic Acid, Ethylene Glycols (MEG, DEG, TEG)
C3 Cuts: Propane, Propylene, Propylene Oxide, Isopropanol, Acetone, Acrylonitrile, Propediene, Allyl chloride, Acrylic acid, Propionic Acid, Propionaldehyde, Propylene Glycol
C4 Cuts: Butanes, Butylenes, Butadiene, Butanols, MTBE (Methyl Tert Butyl Ethers)
C5 cuts: Isoprene, Pentanes, Piperylene, Cyclopentadiene, Dicyclopentadiene, Isoamyl, etc…
Aromatics: Benzene, Toluene, Xylenes (BTX), Cumene, Phenol, Ethyl Benzene, Styrene, Pthalic Anhydride, Nitrobenzene, Aniline, Benzoic Acid, Chlorobenzene, etc…
At the end of the course you will feel confident in how the petrochemical industry is established. You will know the most common petrochemicals as well as their distribution, production and importance in daily life. It will help in your future process simulations by knowing the common and economical chemical pathways.
Pumps for Ammonium Nitrate Service
Engineering Design Guide: GBHE-EDG-MAC-1503
CONTENTS
1 SCOPE
SECTION ONE: INTEGRATION OF PUMPS INTO THE PROCESS
2 PROPERTIES OF FLUID
2.1 Decomposition
2.2 Combustion
2.3 Detonation
2.4 Deliquescence
2.5 Density
2.6 Viscosity
2.7 Vapor Pressure
2.8 Freezing Point
2.9 Specific Heat
2.10 Surface Tension
2.11 Thermal Conductivity
3 CALCULATION OF DUTY
3.1 Centrifugal Pumps
4 CHOICE OF PUMP TYPE
4.1 Centrifugal Pumps
4.2 Rotary Pumps
4.3 Reciprocating Pumps
5 LINE DIAGRAMS
5.1 Centrifugal Pumps with Mechanical Seals
5.2 Vertical Suspended Cantilever Shaft Pumps for
Melt Service
5.3 Horizontal Self-Priming Pumps
5.4 Reciprocating Pumps
5.5 Seal Water Supply System
6 LAYOUT
6.1 Vertical Cantilever Shaft Pumps - Tank Proportions
SECTION TWO: CONSTRUCTION FEATURES OF PUMPS
7 SEALS FOR CENTRIFUGAL PUMPS
7.1 Below 30% AN
7.2 30-45% AN
7.3 45-90% AN
7.4 Above 90% AN
8 PACKED GLANDS FOR RECIPROCATING PUMPS
8.1 Below 90% AN
9 SEAL WATER SUPPLY SYSTEMS
10 CONSTRUCTION FEATURES OF CENTRIFUGAL PUMPS
10.1 Casing
10.2 Rotor
10.3 Bearing Lubrication
10.4 Coupling
10.5 Baseplate
11 CONSTRUCTION FEATURES OF VERTICAL CANTILEVER SHAFT IMMERSED PUMPS
11.1 Motor
11.2 Insulation and Jacketing
11.3 Rotor
11.4 Bearing Lubrication
11.5 Preservation
12 CONSTRUCTION FEATURES OF RECIPROCATING PLUNGER PUMPS
12.1 Speed Limits
12.2 Casing and Gearbox
12.3 Couplings
13 MATERIALS OF CONSTRUCTION
13.1 Recommended Materials
13.2 Forbidden Materials
APPENDIX A: BEARING LUBRICANTS
FIGURES
2.5.1 DENSITY OF AMMONIUM NITRATE SOLUTIONS
2.5.2 DENSITY OF AMMONIUM NITRATE SOLUTIONS
2.6 KINEMATIC VISCOSITY OF AMMONIUM NITRATE SOLUTIONS
2.7.1 WATER VAPOR PRESSURE ABOVE AMMONIUM NITRATE SOLUTIONS
2.7.2 AMMONIA VAPOR PRESSURE FOR AM!AMMONIUM NITRATE MELT
2.8 FREEZING POINT OF AMMONIUM NITRATE SOLUTIONS
2.9 SPECIFIC HEAT OF AMMONIUM NITRATE SOLUTIONS
4 SELECTION OF PUMP TYPE
5. 1 RECOMMENDED LINE DIAGRAM CENTRIFUGAL PUMPS WITH MECHANICAL SEALS
5.2 RECOMMENDED LINE DIAGRAM: VERTICAL SUSPENDED CANTILEVER PUMPS
5.3 RECOMMENDED LINE DIAGRAM: HORIZONTAL SELF
PRIMING PUMPS
5.4 RECOMMENDED LINE DIAGRAM: RECIPROCATING PLUNGER PUMPS
5.5 RECOMMENDED LINE DIAGRAM SEAL: WATER PUMPS AND INJECTION PUMP SYSTEMS
7.2 TYPICAL ARRANGEMENT OF SEAL WITH NO INJECTION FLUSH
7.3 TYPICAL ARRANGEMENT OF CRANE TYPE 52B WITH 'J' SEAT INCORPORATING TETRALIPS INBOARD AND OUTBOARD
7.4 TYPICAL ARRANGEMENT OF LABYRINTH SEAL FOR VERTICAL SUSPENDED CANTILEVER SHAFT PUMPS
8.1 TYPICAL ARRANGEMENT OF SOFT PACKED GLAND FOR RECIPROCATING PLUNGER PUMPS FOR DELIVERY PRESSURES UP TO 10 BAR G.
12 TEMPERATURES ATTAINED ON DISSOLUTION OF ANHYDROUS CAUSTIC SODA
TABLES
13.1 MATERIALS OF CONSTRUCTION CENTRIFUGAL PUMPS
13.2 MATERIALS OF CONSTRUCTION VERTICAL CANTILEVER
SHAFT IMMERSED PUMPS
13.3 MATERIALS OF CONSTRUCTION RECIPROCATING PLUNGER PUMPS
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS Gerard B. Hawkins
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS
CONTENTS
1 INTRODUCTION
1.1 Purpose
1.2 Scope of this Guide
1.3 Use of the Guide
2 ENVIRONMENTAL ISSUES
2.1 Principal Concerns
2.2 Mechanisms for Ozone Formation
2.3 Photochemical Ozone Creation Potential
2.4 Health and Environmental Effects
2.5 Air Quality Standards for Ground Level Concentrations of Ozone, Targets for Reduction of VOC Discharges and Statutory Discharge Limits
3 VENTS REDUCTION PHILOSOPHY
3.1 Reduction at Source
3.2 End-of-pipe Treatment
4 METHODOLOGY FOR COLLECTION & ASSESSMENT OF PROCESS FLOW DATA
4.1 General
4.2 Identification of Vent Sources
4.3 Characterization of Vents
4.4 Quantification of Process Vent Flows
4.5 Component Flammability Data Collection
4.6 Identification of Operating Scenarios
4.7 Quantification of Flammability Characteristics for Combined Vents
4.8 Identification, Quantification and Assessment of Possibility of Air Ingress Routes
4.9 Tabulation of Data
4.10 Hazard Study and Risk Assessment
4.11 Note on Aqueous / Organic Wastes
4.12 Complexity of Systems
4.13 Summary
5 SAFE DESIGN OF VENT COLLECTION HEADER SYSTEMS
5.1 General
5.2 Process Design of Vent Headers
5.3 Liquid in Vent Headers
5.4 Materials of Construction
5.5 Static Electricity Hazard
5.6 Diversion Systems
5.7 Snuffing Systems
6 SAFE DESIGN OF THERMAL OXIDISERS
6.1 Introduction
6.2 Design Basis
6.3 Types of High Temperature Thermal Oxidizer
6.4 Refractories
6.5 Flue Gas Treatment
6.6 Control and Safety Systems
6.7 Project Program
6.8 Commissioning
6.9 Operational and Maintenance Management
APPENDICES
A GLOSSARY
B FLAMMABILITY
C EXAMPLE PROFORMA
D REFERENCES
DOCUMENTS REFERRED TO IN THIS PROCESS GUIDE
TABLE
1 PHOTOCHEMICAL OZONE CREATION POTENTIAL REFERENCED
TO ETHYLENE AS UNITY
FIGURES
1 SCHEMATIC OF TYPICAL VENT COLLECTION AND THERMAL OXIDIZER SYSTEM
2 TYPICAL KNOCK-OUT POT WITH LUTED DRAIN
3 SCHEMATIC OF DIVERSION SYSTEM
4 CONVENTIONAL VERTICAL THERMAL OXIDIZER
5 CONVENTIONAL OXIDIZER WITH INTEGRAL WATER SPARGER
6 THERMAL OXIDIZER WITH STAGED AIR INJECTION
7 DOWN-FIRED UNIT WITH WATER BATH QUENCH
8 FLAMELESS THERMAL OXIDATION UNIT
9 THERMAL OXIDIZER WITH REGENERATIVE HEAT RECOVERY
10 TYPICAL PROJECT PROGRAM
11 TYPICAL FLAMMABILITY DIAGRAM
12 EFFECT OF DILUTION WITH AIR
13 EFFECT OF DILUTION WITH AIR ON 100 Rm³ OF FLAMMABLE GAS
Air / Steam Regeneration Procedure for Primary Reforming CcatalystGerard B. Hawkins
VULCAN Series VSG-Z101 Primary Reforming
Air steam regeneration procedures can be used either on start-up of a reformer after it has cooled, or can be done in the shut down process.
AIR STEAM REGENERATION ON SHUT DOWN
AIR STEAM REGENERATION ON START-UP
How to use the GBHE Reactor Technology Guides
0 INTRODUCTION / PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 BACKGROUND
5 THE DECISION TREE
6 GBHE REACTION ENGINEERING
7 GENERAL ASPECTS OF REACTOR TECHNOLOGY
7.1 Criteria of Reactor Performance
7.2 Factors of Economic Importance
7.3 Physicochemical Mechanisms
8 GENERAL GUIDE TO SELECTION OF REACTOR TYPE AND OPERATION
8.1 Choice of Reactor Type
8.2 Reaction Mechanism and Kinetics
8.3 Thermodynamics
8.4 Other Factors
9 GENERAL REFERENCES AND SOURCES OF
INFORMATION
APPENDICES
A RELATIONSHIP BEWTEEN DEFINED TERMS
FIGURES
1 DECISION TREE
2 RELATIVE YIELDS OF B FOR BATCH (OR PLUG FLOW) AND CST REACTORS
3 REACTOR SURVEY FORM
Study 3: Detailed Design Hazards
CONTENTS
3.0 PURPOSE
3.0.1 Team
3.0.2 Timing
3.0.3 Preparation
3.0.4 Documentation
HAZARD STUDY 3: APPLICATION
3.1 Continuous Processes
3.2 Batch Processes
3.3 Mechanical Handling Operations
3.4 Maintenance and Operating Procedures
3.5 Programmable Electronic Systems
3.6 Failure Modes and Effects Analysis (FMEA) for Programmable Electronic Systems
3.7 Electrical Systems
3.8 Buildings
3.9 Other Studies
3.10 Other Related Tools
3.11 Human Factors
3.12 Review of Hazard Study 3
APPENDICES
A Continuous Processes
B Batch Processes
C Mechanical Handling Operations Guide Diagram
D Maintenance / Operating Procedure
E Programmable Electronic Systems
F DCS FMEA Method
G Electrical Systems Guide Diagram
H Building Design and Operability
Study 2: Front-End Engineering Design and Project DefinitionGerard B. Hawkins
Study 2: Front-End Engineering Design and Project Definition
CONTENTS
2.0 PURPOSE
2.0.1 Team
2.0.2 Timing
2.0.3 Documentation
HAZARD STUDY 2: APPLICATION
2.1 Study of Process and Non-Process Activities
2.2 Study of Programmable Electronic Systems (PES)
2.3 Risk Assessment
2.4 Defining the Basis for Safe Operation
2.5 Review of Hazard Study 2
APPENDICES
Appendix A Hazard Study 2 Method
A.1 Significant Hazards Flowsheet
A.2 Event Guide Diagram
A.3 Consequence Guide Diagram
A.4 Typical Measures to Reduce Consequences
Appendix B Programmable Electronic Systems (PES) Guide Diagram
Appendix C Risk Assessment
C.1 Risk Assessment Procedure
C.2 Risk Matrix
C.3 Risk Matrix Guidance for Consequence Categories – Safety and Health Incidents
C.4 Risk Matrix Guidance for Consequence Categories – Environmental Incidents
Appendix D Key Hazards and Control Measures
Appendix E Content of Hazard Study 2 Report Package.
Determination of Argon in Ammonia Plant Process Gas Streams by Gas Chromatogr...Gerard B. Hawkins
Determination of Argon in Ammonia Plant Process Gas Streams by Gas Chromatography
SCOPE AND FIELD OF APPLICATION
This document is a method for the determination of argon in process gas streams in the range 0-10% v/v.
BENFIELD LIQUOR:Determination of Diethanolamine Using an Auto TitratorGerard B. Hawkins
BENFIELD LIQUOR:Determination of Diethanolamine Using an Auto Titrator
1 SCOPE AND FIELD OF APPLICATION
This method is suitable for the determination of diethanolamine in Benfield Liquor.
2 PRINCIPLE
Diethanolamine is converted quantitatively into ammonia by boiling in the presence of sulfuric acid and copper sulfate. The ammonia is distilled from an alkaline medium and absorbed into boric acid. The solution is titrated with standard acid.
Integration of Special Purpose Centrifugal Pumps into a ProcessGerard B. Hawkins
Integration of Special Purpose Centrifugal Pumps into a Process
CONTENTS
1 SCOPE
2 PRELIMINARY CHOICE OF PUMP
SECTION A - INLET CONDITIONS
Al Calculation of Basic Nett Positive Suction Head (NPSH)
A2 Correction to Basic NPSH for Temperature Rise at Pump Inlet
A3 Correction to Basic NPSH for Acceleration Head
A4 Calculation of Available NPSH
A5 Correction to NPSH for Fluid Properties
A6 Calculation of Suction Specific Speed
A7 Priming
A8 Submergence
SECTION B – FLOW / HEAD RATING SEQUENCE
B1 Calculation of Static Head
B2 Calculation of Margins for Control
B3 Calculation of Q-H Duty
B4 Stability and Parallel Operation
B5 Corrections to Q-H Duty for Fluid Properties
B6 Guide to Pump Type and Speed
SECTION C – DRIVER POWER RATING
C1 Estimation of Pump Efficiency
C2 Calculation of Absorbed Power
C3 Calculation of Driver Power Rating
C4 Preliminary Power Ratings of Electric Motors
C5 Starting Conditions for Electric Motors
C6 Reverse Flow and Reverse Rotation
SECTION D - CASING PRESSURE RATING
D1 Calculation of Maximum Inlet Pressure
D2 Calculation of Differential Pressure
D3 Pressure Waves
D4 Pressure due to Liquid Thermal Expansion
D5 Casing Hydrostatic Test Pressure
SECTION E – SEALING CONSIDERATIONS
E1 Preliminary Choice of Seal
E2 Fluid Attributes
E3 Definition of Flushing Arrangements
APPENDICES
A RELIABILITY CLASSIFICATION
B SYMBOLS AND PREFERRED UNITS
DOCUMENTS REFERRED TO IN THIS ENGINEERING DESIGN GUIDE
Determination of Carbon Dioxide, Ethane And Nitrogen in Natural Gas by Gas C...Gerard B. Hawkins
Determination of Carbon Dioxide, Ethane
And Nitrogen in Natural Gas by Gas Chromatography
1 SCOPE AND FIELD OF APPLICATION
This document is a method for the determination of carbon dioxide, ethane and nitrogen in natural gas in the range 0-10% v/v.
2 PRINCIPLE
The gas sample will be injected automatically by a ten port valve onto the poraplot U column. The nitrogen will elute first and be switched to the mole sieve column. The mole sieve column will be isolated and the poraplot column will elute the carbon dioxide and ethane via a restrictor column to the detector. After the elution of the carbon dioxide and ethane the poraplot column will be back flushed. Then the nitrogen will be allowed to elute from the mole sieve column (see figure 1.) ...
Biological Systems: A Special Case
Up till now we have discussed various aspects of the separation and processing of fine solids without too much reference (except in the examples) to the specifics of the properties of the materials concerned. Though the material properties are the dominant influence on efficient process design and operation, it has been postulated that the necessary characteristics for process selection and optimization can be found fairly readily using easily-applicable rheological and other techniques. This underlying assumption also seems to hold good for biological suspensions; however, certain aspects of the behavior of these systems are sufficiently specialized for them to merit a separate discussion viz:
1 TYPES OF BIOLOGICAL SEPARATION
1.1 Whole-Organism Case
1.2 Part-Cell Separations
1.3 Isolation of Individual Molecular Species
2 SETTING ABOUT DEVISING AN EFFECTIVE
PROCESS FOR SEPARATION OF A BIOLOGICAL MATERIAL
2.1 Whole-Organism Case
2.1.1 Characterization of Biopolymers in the Liquor
2.1.2 Release of Internal Water
2.2 Part -Cell Separations
2.2.1 Selectivity
2.2.2 Cost
2.3 Isolation of Individual Molecular Species
3 Examples
3.1 Effective Design and Operation of a Process for Harvesting of Single Cell Protein
3.2 Harvesting of Mycoprotein for Human Consumption
3.3 Thickening of a Filamentous Organism Suspension
3.4 Separation of Poly-3-hydroxybutyrate Polymer (PHB) from Alcaligenes Eutrophus Biomass
3.5 Isolation of Organic Acid Produced by an Enzymatic Process
4 REFERENCES
Table
Figures
BENFIELD LIQUOR: DETERMINATION OF IRON
SCOPE AND FIELD OF APPLICATION
This method is suitable for the determination of the total iron in Benfield liquor samples up to a concentration of approximately 100 ppm m/v.
Reactor Modeling Tools – Multiple Regressions
CONTENTS
0 INTRODUCTION
1 SCOPE
2 THEORY
3 EXCEL 2007: MULTIPLE REGRESSIONS
3.1 Overview
3.2 Multiple Regression Using the Data Analysis ADD-IN
3.3 Interpret Regression Statistics Table
3.4 Interpret ANOVA Table
3.5 Interpret Regression Coefficients Table
3.6 Confidence Intervals for Slope Coefficients
3.7 Test Hypothesis of Zero Slope Coefficients ("Test of Statistical Significance")
3.8 Test Hypothesis on a Regression Parameter
3.8.1 Using the p-value approach
3.8.2 Using the critical value approach
3.9 Overall Test of Significance of the Regression Parameters
3.10 Predicted Value of Y Given Regressors
3.11 Excel Limitations
4 SPECIAL FEATURES REQUIRING MORE SOPHISTICATED TECHNIQUES
5 USER INFORMATION SUPPLIED
A SUBROUTINE
B DATA
C RESULTS
6 EXAMPLE
Carbon Formation in Mixed Feed Preheat Coils:
Maximum Mixed Feed Pre-heat Temperature
What follows is a crude but effective routine, which evaluates the maximum possible temperature allowable to prevent excessive carbon laydown in the mixed feed pre-heat coils.
0 INTRODUCTION
The four main sources of Fugitive Emissions on most plants are valves, machine seals, re-makable joints and pressure relief devices. Other possible sources include open-ended lines, sampling connections, drains and vents.
Sometimes special precautions are taken to minimize Fugitive Emissions, for example the use of bellows seal valves. However, generally no special precautions are taken and the subsequent Fugitive Emissions to atmosphere represent a significant amount of plant losses.
Regulatory requirements covering Fugitive Emissions exist in many countries and therefore a leak reduction program should be implemented. Fugitive Emissions also represent financial losses to the business as well as potential damage to the environment.
Other Separations Techniques for Suspensions
PRESSURE-DRIVEN MEMBRANE SEPARATION
PROCESSES
1.1 INTRODUCTION
1.2 MEMBRANES
1.3 OPERATION
1.4 FACTORS AFFECTING PERFORMANCE
1.4.1 Polarization / Fouling
1.4.2 Pressure
1.4.3 Crossflow
1.4.4 Temperature
1.4.5 Concentration
1.4.6 Membrane Pore Size
1.4.7 Particle Size
1.4.8 Particle Charge
1.4.9 Other Factors
1.5 ADVANTAGES / LIMITATIONS
1.6 SUMMARY OF SYMBOLS USED
2 ELECTRO-DIALYSIS
2.1 INTRODUCTION
2.2 EQUIPMENT
2.3 IMPORTANT PARAMETERS IN ED
2.4 EXAMPLES
3 ELECTRODEWATERING AND ELECTRODECANTATION
3.1 INTRODUCTION
3.2 PRINCIPLES AND OPERATION
3.3 EQUIPMENT AND OPERATING PARAMETERS
3.4 EXAMPLES
4 MAGNETIC SEPARATION METHODS
5 REFERENCES
FIGURES
1 APPLICATION RANGES FOR MEMBRANE SEPARATION TECHNIQUES
2 SIMPLE UF / CMF RIG
4 FLUX VERSUS PRESSURE
5 ELECTRODIALYSIS PROCESS
6 ELECTRODIALYSIS PLANT FOR BATCH PROCESS
7 DEPENDENCE OF MEMBRANE AREA AND ENERGY ON
CURRENT DENSITY
8 DIFFUSION ACROSS THE BOUNDARY LAYER
Determination of Hydrocarbons in Anhydrous Ammonia By Gas ChromatographyGerard B. Hawkins
Determination of Hydrocarbons in Anhydrous Ammonia By Gas Chromatography
SCOPE AND FIELD OF APPLICATION
The method is suitable for the determination of hydrocarbons from C1 to C4 (see 6.4.2) in gaseous ammonia, or in mixtures of ammonia and air. It is valid for concentrations in the range 10-10000 ppm.
The method may be used for the analysis of the atmosphere from a ships hold After purging with ammonia and for the analysis of gasified liquid anhydrous ammonia during or after loading. In these cases, hydrocarbon contamination may arise from the previous cargo of the vessel, the nature of which should be ascertained prior to carrying out the analysis
Study 5: Pre-commissioning Safety Review
CONTENTS
5.0 PURPOSE
5.0.1 Team
5.0.2 Timing
5.0.3 Preparation
5.0.4 Documentation
HAZARD STUDY 5: APPLICATION
5.1 TOUR OF THE PROJECT
5.2 REVIEW OF HAZARD STUDY 5
HAZCON / HAZDEM
CONTENTS
1.0 PURPOSE
1.0.1 Team
1.0.2 Timing
1.0.3 Preparation
1.0.4 Documentation
HAZCON / HAZDEM: APPLICATION
1.1 SPECIFICATION OF THE WORK
a) HAZCON
b) HAZDEM
1.2 METHOD STATEMENT
1.3 HAZCON STUDY
1.4 HAZDEM STUDY
1.5 MONITORING OF ACTIVITIES
1.6 REVIEW OF HAZARD STUDY
Troubleshooting in Distillation Columns
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 FLOW DIAGRAM FOR TROUBLESHOOTING
5 GENERAL APPRAISAL OF PROBLEM
5.1 Is the Problem Real?
5.2 What Is the Magnitude of the Problem?
5.3 Is it the Column or the Associated Equipment which is Causing the Problem?
6 PROBLEMS IN THE COLUMN
6.1 Capacity Problems
6.2 Efficiency Problems
7 PROBLEMS OUTSIDE THE COLUMN
7.1 Effect of Other Units on Column Performance
7.2 Column Control System
7.3 Improper Operating Conditions
7.4 Auxiliary Equipment
8 USEFUL BACKGROUND READING
9 BIBLIOGRAPHY
FIGURES
1 FLOW DIAGRAM FOR TROUBLESHOOTING
2 DETERMINATION OF COLUMN CAPACITY
Hygiene: Estimating and Understanding Personal Exposure to Inhalation of Vapo...Gerard B. Hawkins
Hygiene: Estimating and Understanding Personal Exposure to Inhalation of Vapors on Chemical Plants
It is a vital aspect of chemical plant design and operation to minimize any contact of the operating and maintenance personnel with the chemicals on the plant. Often the most significant route of exposure to chemicals is by inhalation, and in this case it is relatively easy to measure exposure. This has led to the development of standards which indicate levels of exposure which should minimize any risk to health. These will be called Occupational Exposure
Limits (OELs) in this Guide as a generic name...
Application of Process to Management of Change and ModificationsGerard B. Hawkins
Application of Process to Management of Change and Modifications
Hazard Study Process: GBHE-PGP-006
CONTENTS
1.0 PURPOSE
1.1 THE NEED FOR MODIFICATIONS
1.2 GENERAL DESCRIPTION OF A MODIFICATION
1.3 PRINCIPLES TO BE FOLLOWED
1.4 REPLACEMENT OF ’LIKE WITH LIKE’
1.5 REMOTE / SMALLER SITES
1.6 GENERAL GUIDANCE TO INDIVIDUALS DOING SHE ASSESSMENTS FOR MODIFICATIONS
1.7 MODIFICATIONS HAZARD STUDY DECISION MECHANISM
1.7.1 Purpose
1.7.2 Methodology
FIGURE 1 MODIFICATION FLOWCHART
M1 Title, description, registration and process flowsheet
Gate 1 Preliminary authorization
Table 1 Difference between a Modification and a Project
M2 Risk Assessment
Gate 2 Approval
M3 Detailed design and implementation
Gate 3 Pre-Commissioning check
M4 Commissioning
Gate 4 Commissioned
M5 Final review and file
APPENDIX
APPENDIX A CHECKLIST FOR MODIFICATIONS
APPENDIX B DOCUMENTATION PROMPT LIST
APPENDIX C TYPICAL MODIFICATION FORM
G1 PRELIMINARY AUTHORIZATION
M2 PRELIMINARY SSHE ASSESSMENT
G2 REVIEW PRELIMINARY SSHE ASSESSMENT
M3 DESIGN and ESTIMATION
SSHE ASSESSMENT
G3 APPROVAL
M4 DETAILED DESIGN AND IMPLEMENTATION
G4 PRE-COMMISSIONING CHECK
M5 COMMISSIONING
G5 COMMISSIONED
M6 FINAL REVIEW AND FILE
Pressure Systems
CONTENTS
0 INTRODUCTION
1 SCOPE
2 DEFINITIONS ADDITIONAL TO THOSE IN THE EP GLOSSARY
2.1 PRESSURE VESSEL
2.2 ATMOSPHERIC PRESSURE STORAGE TANK
2.3 VESSEL
2.4 PIPING SYSTEM
2.5 NON-PRESSURE PROTECTIVE DEVICE
2.6 ASSOCIATED RELIEF EQUIPMENT
3 APPLICATION OF PRINCIPLES
3.1 IMPLEMENTATION OF PEG 4
3.2 DESIGN, MANUFACTURE, REPAIR AND MODIFICATION
3.3 VERIFICATION OF DESIGN
3.4 GBHE REGISTRATION AND RECORDS
3.5 PERIODIC EXAMINATION
4 AUDITING
4.1 General
4.2 Scope of Audit
APPENDICES
A EQUIPMENT WHICH MAY BE EXEMPTED FROM GBHE REGISTRATION
C DOCUMENTATION FOR INCLUSION IN FILES OF REGISTERED EQUIPMENT
D ADDITIONAL REQUIREMENTS FOR THE PERIODIC EXAMINATION OF SPECIAL CATEGORIES OF EQUIPMENT
E DIAGRAMMATIC REPRESENTATION OF PRESSURE SYSTEMS PROCEDURES
F DECISION TREE FOR REGISTRATION OF PIPING SYSTEMS
G REGISTERED EQUIPMENT WHICH MAY BE EXEMPTED FROM DESIGN VERIFICATION
TABLES
1 REGISTERED VESSELS AND PIPING SYSTEMS: MAXIMUM EXAMINATION INTERVALS
2 EQUIPMENT TO BE CONSIDERED FOR CATEGORY LLT
FIGURES
1 SIMPLE PRESSURE RELIEF ARRANGEMENT
2 COMPLEX PRESSURE RELIEF ARRANGEMENT
DOCUMENTS REFERRED TO IN THIS INFORMATION FOR ENGINEERS DOCUMENT
Fixed Bed Reactor Scale-up Checklist
The purpose of this checklist is to identify the stages and potential problems associated with the scale up of fixed bed reactors from the drawing board to the full scale plant, and to determine how they should be checked.
The checking can be done using various methods. These are:
• Literature data.
• Lab testing.
• Calculation.
• Modeling.
• Semi-tech testing.
• Piloting or Sidestream testing.
Identifying the stages that need to be addressed for a particular catalyst/reactor development will help in estimating the time needed for the development of the reactor
Chemical Process Conception
0 INTRODUCTION / PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 PRODUCT STRATEGY
4.1 General
4.2 Market for the Product
4.3 Production Costs
4.4 Process Technology
5 PRELIMINARY PROCESS INFORMATION
6 REACTION AND REACTOR
6.1 Batch vs Continuous
6.2 Multiple Reactors
7 RECYCLE
7.1 Recycle Structure
7.2 Classification of Chemicals
7.3 Effect of Recycle
7.4 Preliminary Estimation of Conversion
8 REACTOR TYPE AND PERFORMANCE
8.1 Conversion-Yield Effects
8.2 Heat Effects
8.3 Equilibrium Effects
8.4 Kinetic Effects
8.5 More Help with Reactor Design
9 SEPARATION SYSTEM
10 REVIEW
11 BIBLIOGRAPHY AND REFERENCES
11.1 Preliminary Flowsheeting
11.2 Physical Properties
11.3 Reactors
11.4 Separation
11.5 Costing
APPENDICES
A BASIC REACTOR SYSTEM DESIGN
B DISCUSSION BETWEEN A CHEMIST AND A
CHEMICAL ENGINEER
C BASIC SEPARATION STRATEGY
TABLES
1 CLASSIFICATION OF MATERIALS
FIGURES
1 FLOWCHART OF THE ITERATIVE PROCEDURE REQUIRED IN PROCESS AND PRODUCT SELECTION AND DEVELOPMENT
SYNOPSIS
The principles underlying centrifugal separation of particulate species are briefly considered, and the main types of separator available are noted. The procedures available for scale-up from laboratory or semi-technical data are then discussed in detail with particular reference to perhaps the most important class of machine for fine particle processing: the disc-nozzle centrifuge.
Starting with the basic concepts behind their design, discussion follows to explain the factors which may limit centrifuge performance. It is shown how a few simple; laboratory scale tests can give a valuable insight into the design and operation of full-scale industrial machines.
Reactor Modeling Tools - An Overview
CONTENTS
1 SCOPE
2 OPTIONS IN REACTOR MODELING
2.1 General
2.2 Level of Complexity of Model
2.3 Mode of Operation of Model
2.4 Deterministic versus Empirical Modeling
2.5 Platforms for Model
2.6 Steady State versus Dynamic Model
2.7 Dimensions Modeled in Reactor
2.8 Scale of Modeling for Multiphase Reactors
2.9 Writing and Using the Model
APPENDICES
A CHARACTERISTICS OF DIFFERENT REACTOR MODELS
B NEEDS FOR MODELING AT DIFFERENT SCALES IN
HETEROGENEOUS CATALYTIC REACTORS
C REACTOR MODELS EMPLOYED WITHIN GBHE
DOCUMENTS REFERRED TO IN THIS PROCESS ENGINEERING GUIDE
Filtration
0 INTRODUCTION
1 The Theory Underlying Filtration Processes
1.1 The Mechanism of Simple Filtration Systems
1.1.2 Cake Filtration
1.1.3 Complete Blocking
1.1.4 Standard Blocking
1.1.5 Intermediate Blocking
1.2 Cake Filtration – Models and Mechanisms
1.2.1 Classical Theory for the Permeability of Porous Cakes and Beds
1.2.2 The Rate of Filtration through a Compressible Cake – The Standard Filtration Equation
1.2.3 The Compression or Consolidation of Filter Cakes – Ultimate degree of dewatering
1.2.4 The Rate of Consolidation
1.2.5 Useful Semi-Empirical Relations for Constant Pressure and Constant Rate Cake Filtration
1.2.6 Constant Pressure Filtration
1.2.7 Constant Rate Filtration
1.2.8 Multiphase Theory of Filtration
1.3 Crossflow Filtration
2 The Range and Selection of Filtration Equipment Technology
2.1 Scale
2.2 Solids Recovery, Liquids Clarification or Feed stream Concentration
2.3 Rate of Sedimentation
2.4 Rate of Cake Formation and Drainage
2.5 Batch vs Continuous Operation
2.6 Solids Loading
2.7 Further Processing
2.8 Aseptic or “Hygienic” Operation
2.9 Miscellaneous
2.10 Shear versus Compressional Deformation
2.11 Pressure versus Vacuum
3 Suspension Conditioning Prior to Filtration
3.1 Simple Filtration Aids
3.2 Mechanical Treatments
4 Post-Filtration Treatments and Further Downstream Processing
4.1 Washing
4.1.1 Air-Blowing
4.1.2 Drying
5 Testing and Characterization of Suspensions
5.1 Introduction – Suspension
5.2 Properties relevant to Filtration Performance
5.2.1 Pre-Filtration Properties of Suspension
5.2.2 Properties of Filter Cake
5.2.3 Laboratory Scale Filtration Rigs
5.3 Means of Monitoring Flocculant Dosage
5.4 Filter Cake Testing
5.4.1 Strength Testing (See also piston press described earlier)
5.4.2 Cake Permeability or Resistance
5.4.3 Rate of Cake Formation
6 Examples of the Application of the Forgoing Principles
6.1 Dewatering of Calcium Carbonate Slurries
6.2 Dewatering of Organic Products – Procion Dyestuffs
6.3 Filtration of Biological Systems – Harvesting a Filamentous Organism
References
Tables
Figures
Batch Distillation
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 BACKGROUND TO THE DESIGN
4.1 General
4.2 Choice of batch/continuous operation
4.3 Boiling point curve and cut policy
4.4 Method of design
4.5 Scope of calculations required for design
5 SIMPLE BATCH DISTILLATION
6 FRACTIONAL BATCH DISTILLATION
6.1 General
6.2 Approximate methods
6.3 Rigorous design - use of a computer model
6.4 Other factors influencing the design
6.4.1 Occupation
6.4.2 Choice of Batch Rectification or Stripping
6.4.3 Batch size
6.4.4 Initial estimate of cut policy
6.4.5 Liquid Holdup
6.4.6 Total reflux operation and heating-up time
6.4.7 Column operating pressure
6.5 Optimum Design of the Batch Still
6.6 Special design problems
7 GENERAL ASPECTS OF EQUIPMENT DESIGN
7.1 Kettle reboilers
7.2 Column Internals
7.3 Condensers and reflux split boxes
8 PROCESS CONTROL AND INSTRUMENTATION IN
BATCH DISTILLATION
9 MECHANICAL DESIGN FEATURES
10 BIBLIOGRAPHY
APPENDICES
A McCABE - THIELE METHOD - TYPICAL EXAMPLE
PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...Gerard B. Hawkins
PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF AQUEOUS ORGANIC EFFLUENT STREAMS
CONTENTS
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
3.1 IPU
3.2 AOS
3.3 BODs
3.4 COD
3.5 TOC
3.6 Toxicity
3.7 Refractory Organics/Hard COD
3.8 Heavy Metals
3.9 EA
3.10 Biological Treatment Terms
3.11 BATNEEC
3.12 BPEO
3.13 EQS/LV
3.14 IPC
3.15 VOC
3.16 F/M Ratio
3.17 MLSS
3.18 MLVSS
4 DESIGN/ECONOMIC GUIDELINES
5 EUROPEAN LEGISLATION
5.1 General
5.2 Integrated Pollution Control (IPC)
5.3 Best Available Techniques Not Entailing Excessive Costs (BATNEEC)
5.4 Best Practicable Environmental Option (BPEO)
5.5 Environmental Quality Standards(EQS)
6 IPU EXIT CONCENTRATION
7 SITE/LOCAL REQUIREMENTS
8 PROCESS SELECTION PROCEDURE
8.1 Waste Minimization Techniques (WMT)
8.2 AOS Stream Definition
8.3 Technical Check List
8.4 Preliminary Selection of Suitable Technologies
8.5 Process Sequences
8.6 Economic Evaluation
8.7 Process Selection
APPENDICES
A DIRECTIVE 76/464/EEC - LIST 1
B DIRECTIVE 76/464/EEC - LIST 2
C THE EUROPEAN COMMISSION PRIORITY CANDIDATE LIST
D THE UK RED LIST
E CURRENT VALUES FOR EUROPEAN COMMUNITY ENVIRONMENTAL QUALITY STANDARDS AND CORRESPONDING LIMIT VALUES
F ESTABLISHED TECHNOLOGIES
G EMERGING TECHNOLOGY
H PROPRIETARY/LESS COMMON TECHNOLOGIES
J COMPARATIVE COST DATA
Process Synthesis
INTRODUCTION
1 A SUGGESTED GENERAL APPROACH
2 EXAMPLES OF PROCESS SELECTION
2.1 Harvesting and Thickening of Single Cell Protein
2.2 Dewatering of a Specialty Latex
3 REFERENCES
TABLES
1 THE ADVANTAGES AND DISADVANTAGES OF DIFFERENT RANGE OF PH FOR “PROTEIN” ORGANISM FLOCCULATION
2 THE ADVANTAGES AND DISADVANTAGES OF VARYING EXTENTS OF CELL BREAKAGES
3 PREDICTED AND OBSERVED FILTER CAKE SOLIDS CONTENTS FOR THE VARIOUS LATICES AFTER COAGULATION
FIGURES
1 THE “PROTEIN” BACTERIAL HARVESTING SYSTEM
2 PROCESS FOR MANUFACTURE OF CALCIUM CARBONATE FILTERS
3 H-ACID ISOLATION
4 A SUGGESTED APPROACH TO DETERMINING FEASIBLE PROCESS OPTIONS, AND OPERATING CONDITIONS FOR SEPARATION OF FINE SOLIDS FROM SUSPENSION
5 MODULI VERSUS SOLIDS CONTENT FORTYPICAL FORWARD FLOCCULATED “PROTEIN” SUSPENSIONS
6 DECISION TREE FOR SELECTION OF AS1 HARVESTING CONDITIONS WHEN PRINCIPAL CONSTRAINT CONCERNS THE DEGREE OF THICKENING REQUIRED IN THE CONCENTRATE
7 DECISION TREE FOR SELECTION OF AS1 HARVESTING CONDITIONS WHEN PRINCIPAL CONSTRAINT CONCERNS THE USE OF FLOTATION AS A UNIT OPERATION FOR THICKENING
8 DECISION TREE FOR SELECTION OF AS1 HARVESTING CONDITIONS WHEN PRINCIPAL CONSTRAINT CONCERNS THE QUALITY OF THE RECYCLED LIQUOR
9 MODULUS SOLIDS CONTENT CURVES FOR THEVARIOUS COAGULATED LATICES
Design and Simulation of Continuous Distillation ColumnsGerard B. Hawkins
Design and Simulation of Continuous Distillation Columns
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 FRACTIONAL DISTILLATION
5 ROUGH METHOD OF COLUMN DESIGN
5.1 Sharp Separations
5.2 Sloppy Separations
6 DETAIL DESIGN USING THE CHEMCAD DISTILLATION PROGRAM
6.1 Sharp Separations
6.2 Sloppy Separations
7 COMPLEX COLUMNS
7.1 Multiple Feeds
7.2 Sidestream Take-Offs
8 DESIGN USING A LABORATORY COLUMN
SIMULATION
9 DESIGN USING ACTUAL PLANT DATA
9.1 Uprating or Debottlenecking Exercises
10 REFERENCES
APPENDICES
A WORKED EXAMPLE
B SLOPPY SEPARATIONS
C SIMULATION USING PLANT DATA : CASE HISTORIES
TABLES
Pressure Relief Systems
BACKGROUND TO RELIEF SYSTEM DESIGN Vol.1 of 6
The Guide has been written to advise those involved in the design and engineering of pressure relief systems. It takes the user from the initial identification of potential causes of overpressure or under pressure through the process design of relief systems to the detailed mechanical design. "Hazard Studies" and quantitative hazards analysis are not described; these are seen as complementary activities. Typical users of the Guide will use some Parts in detail and others in overview.
GAS DISPERSION - A Definitive Guide to Accidental Releases of Heavy GasesGerard B. Hawkins
GAS DISPERSION - A Definitive Guide to Accidental Releases of Heavy Gases
This Process Safety Guide has been written with the aim of assisting process engineers, hazard analysts and environmental advisers in carrying out gas dispersion calculations. The Guide aims to provide assistance by:
• Improving awareness of the range of dispersion models available within GBHE, and providing guidance in choosing the most appropriate model for a particular application.
• Providing guidance to ensure that source terms and other model inputs are correctly specified, and the models are used within their range of applicability.
• Providing guidance to deal with particular topics in gas dispersion such as dense gas dispersion, complex terrain, and modeling the chemistry of oxides of nitrogen.
• Providing general background on air quality and dispersion modeling issues such as meteorology and air quality standards.
• Providing example calculations for real practical problems.
SCOPE
The gas dispersion guide contains the following Parts:
1 Fundamentals of meteorology.
2 Overview of air quality standards.
3 Comparison between different air quality models.
4 Designing a stack.
5 Dense gas dispersion.
6 Calculation of source terms.
7 Building wake effects.
8 Overview of the chemistry of the oxides of nitrogen.
9 Overview of the ADMS complex terrain module.
10 Overview of the ADMS deposition module.
11 ADMS examples.
12 Modeling odorous releases.
13 Bibliography of useful gas dispersion books and reports.
14 Glossary of gas dispersion modeling terms.
Appendix A : Modeling Wind Generation of Particulates.
APPENDIX B TABLE OF PROPERTY VALUES FOR SPECIFIC CHEMICALS
Theory of Carbon Formation in Steam Reforming
Contents
1 Introduction
2 Underpinning Theory
2.1 Conceptualization
2.2 Reforming Reactions
2.3 Carbon Formation Chemistry
2.3.1 Natural Gas
2.3.2 Carbon Formation for Naphtha Feeds
2.3.3 Carbon Gasification
2.4 Heat Transfer
3 Causes
3.1 Effects of Carbon Formation
3.2 Types of Carbon
4 What are the Effects of Carbon Formation?
4.1 Why does Carbon Formation Get Worse?
4.1.1 So what is the Next Step?
4.2 Consequences of Carbon Formation
4.3 Why does Carbon Form where it does?
4.3.1 Effect on Process Gas Temperature
4.4 Why does Carbon Formation Propagate Down the Tube?
4.4.1 Effect on Radiation on the Fluegas Side
4.5 Why does Carbon Formation propagate Up the Tube?
5 How do we Prevent Carbon Formation
5.1 The Role of Potash
5.2 Inclusion of Pre-reformer
5.3 Primary Reformer Catalyst Parameters
5.3.1 Activity
5.3.2 Heat Transfer
5.3.3 Increased Steam to Carbon Ratio
6 Steam Out
6.1 Why does increasing the Steam to Carbon Ratio Not Work?
6.2 Why does reducing the Feed Rate not help?
6.3 Fundamental Principles of Steam Outs
TABLES
1 Heat Transfer Coefficients in a Typical Reformer
2 Typical Catalyst Loading Options
FIGURES
1 Hot Bands
2 Conceptual Pellet
3 Naphtha Carbon Formation
4 Heat Transfer within an Reformer
5 Types of Carbon Formation
6 Effect of Carbon on Nickel Crystallites
7 Absorption of Heat
8 Comparison of "Base Case" v Carbon Forming Tube
9 Carbon Formation Vicious Circle
10 Temperature Profiles
11 Carbon Pinch Point
12 Carbon Formation
13 Effect on Process Gas Temperature
14 How does Carbon Propagate into an Unaffected Zone?
15 Movement of the Carbon Forming Region
16 Effect of Hot Bands on Radiative Heat Transfer
17 Effect of Potash on Carbon Formation
18 Application of a Pre-reformer
19 Effect of Activity on Carbon Formation
Calculation of an Ammonia Plant Energy Consumption: Gerard B. Hawkins
Calculation of an Ammonia Plant Energy Consumption:
Case Study: #06023300
Plant Note Book Series: PNBS-0602
CONTENTS
0 SCOPE
1 CALCULATION OF NATURAL GAS PROCESS FEED CONSUMPTION
2 CALCULATION OF NATURAL GAS PROCESS FUEL CONSUMPTION
3 CALCULATION OF NATURAL GAS CONSUMPTION FOR PILOT BURNERS OF FLARES
4 CALCULATION OF DEMIN. WATER FROM DEMIN. UNIT
5 CALCULATION OF DEMIN. WATER TO PACKAGE BOILERS
6 CALCULATION OF MP STEAM EXPORT
7 CALCULATION OF LP STEAM IMPORT
8 DETERMINATION OF ELECTRIC POWER CONSUMPTION
9 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT ISBL
10 ADJUSTMENT OF ELECTRIC POWER CONSUMPTION FOR TEST RUN CONDITIONS
11 CALCULATION OF AMMONIA SHARE IN MP STEAM CONSUMPTION IN UTILITIES
12 CALCULATION OF AMMONIA SHARE IN ELECTRIC POWER CONSUMPTION IN UTILITIES
13 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT OSBL
14 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT
Ammonia Plant Technology
Pre-Commissioning Best Practices
GBHE-APT-0102
PICKLING & PASSIVATION
CONTENTS
1 PURPOSE OF THE WORK
2 CHEMICAL CONCEPT
3 TECHNICAL CONCEPT
4 WASTES & SAFETY CONCEPT
5 TARGET RESULTS
6 THE GENERAL CLEANING SEQUENCE MANAGEMENT
6.6.1 Pre-cleaning or “Physical Cleaning
6.6.2 Pre-rinsing
6.6.3 Chemical Cleaning
6.6.4 Critical Factors in Cleaning Success
6.6.5 Rinsing
6.6.6 Inspection and Re-Cleaning, if Necessary
7 Systems to be treated by Pickling/Passivation
Ammonia Plant Technology
Pre-Commissioning Best Practices
Piping and Vessels Flushing and Cleaning Procedure
CONTENTS
1 Scope
2 Aim/purpose
3 Responsibilities
4 Procedure
4.1 Main cleaning methods
4.1.1 Mechanical cleaning
4.1.2 Cleaning with air
4.1.3 Cleaning with steam (for steam networks only)
4.1.4 Cleaning with water
4.2 Choice of the cleaning method
4.3 Cleaning preparation
4.4 Protection of the devices included in the network
4.5 Protection of devices in the vicinity of the network
4.6 Water flushing procedure
4.6.1 Specific problems of water flushing
4.6.2 Preparation for water flushing
4.6.3 Performing a water flush
4.6.4 Cleanliness criteria
4.7 Air blowing procedure
4.7.1 Specific problems of air blowing
4.7.2 Preparation for air blowing
4.7.3 Performing air blowing
4.7.4 Cleanliness checks
4.8 Steam blowing procedure
4.8.1 Specific problems of steam blowing
4.8.2 Preparation for steam blowing
4.8.3 Performing steam blowing
4.8.4 Cleanliness checks
4.9 Chemical cleaning procedure
4.9.1 Specific problems of cleaning with a chemical solution
4.9.2 Preparation for chemical cleaning
4.9.3 Performing a chemical cleaning
4.9.4 Cleanliness criteria
4.10 Re-assembly - general guideline
4.11 Preservation of flushed piping
PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGA...Gerard B. Hawkins
PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGANIC COMPOUNDS (VOCs)
FOREWORD
CONTENTS
1 INTRODUCTION
2 THE NEED FOR VOC CONTROL
3 CONTROL AT SOURCE
3.1 Choice or Solvent
3.2 Venting Arrangements
3.3 Nitrogen Blanketing
3.4 Pump Versus Pneumatic Transfer
3.5 Batch Charging
3.6 Reduction of Volumetric Flow
3.7 Stock Tank Design
4 DISCHARGE MEASUREMENT
4.1 By Inference or Calculation
4.2 Flow Monitoring Equipment
4.3 Analytical Instruments
4.4 Vent Emissions Database
5 ABATEMENT TECHNOLOGY
5.1 Available Options
5.2 Selection of Preferred Option
5.3 Condensation
5.4 Adsorption
5.5 Absorption
5.6 Thermal Incineration
5.7 Catalytic Oxidation
5.8 Biological Filtration
5.9 Combinations of Process technologies
5.10 Processes Under Development
6 GLOSSARY OF TERMS
7 REFERENCES
Appendix 1. Photochemical Ozone Creation Potentials
Appendix 2. Examples of Adsorption Preliminary Calculations
Appendix 3. Example of Thermal Incineration Heat and Mass Balance
Appendix 4. Cost Correlations
EMERGENCY ISOLATION OF CHEMICAL PLANTS
CONTENTS
1 Introduction
2 When should Emergency Isolation Valves be Installed
3 Emergency Isolation Valves and Associated Equipment
3.1 Installations on existing plant
3.2 Actuators
3.3 Power to close or power to open
3.4 The need for testing
3.5 Hand operated Emergency Valves
3.6 The need to stop pumps in an emergency
3.7 Location of Operating Buttons
3.8 Use of control valves for Isolation
4 Detection of Leaks and Fires
5 Precautions during Maintenance
6 Training Operators to use Emergency Isolation Valves
7 Emergency Isolation when no remotely operated valve is available
References
Glossary
Appendix I Some Fires or Serious Escapes of Flammable Gases or Liquids that could have been controlled by Emergency Isolation Valves
Appendix II Some typical Installations
Burner Design, Operation and Maintenance on Ammonia PlantsGerard B. Hawkins
Burner Design, Operation and Maintenance on Ammonia Plants
Brief History
Reformer Burner Types/Design
Types of Reformers
Combustion Characteristics
Excess Air/Heater Efficiency
Maintenance, Good Practice
Low Nox Equipment
Summary
Debottlenecking Claus Sulfur Recovery Units: An Investigation of the applicat...Gerard B. Hawkins
Debottlenecking Claus Sulfur Recovery Units: An Investigation of the application of Zinc Titanates
1 Executive Summary
2 Claus Process
2.1 Partial Combustion Claus
2.2 Split Flow Claus
2.3 Sulfur Recycle Claus
3 Zinc Titanates
4 Application of Zinc Titanate to Debottleneck Partial Combustion Claus by 10%
4.1 Process
4.2 ASPEN Modeling Results
4.3 Cost of Zinc Titanate Bed Installation
4.3.1 Basis of Costing
4.3.2 Zinc Titanate Beds
4.3.3 Regen Cooler
4.3.4 Blowers
4.3.5 Results
4.4 Alternative Debottlenecking Technology for Partial Combustion Claus
4.5 Cost of 10% Debottlenecking Using COPE Process
5 Debottlenecking Claus Split Flow System by 10% with Zinc Titanates
6 Debottlenecking Claus Sulfur Recycle System With Zinc Titanate
7 Effect of Zinc Titanate Debottlenecking on Existing Tail; Gas Treatment Systems
7.1 Selectox
7.2 SuperClaus99
7.3 Superclaus 99.5
7.4 SCOT Process
7.5 Zinc Titanate as a Claus Tail Gas Treatment
7.6 H2S Removal Efficiency With Zinc Titanate
8 Effects on COS and CS2 Formation
9 Questions for further Investigation
FIGURES
Figure 1 Claus Unit and TGCU
Figure 2 Claus Process
Figure 3 Typical Claus Sulfur Recovery Unit
Figure 4 Two-Stage Claus SRU
Figure 5 The Super Claus Process
Figure 6 SCOT
Figure 7 SCOT/BSR-MDEA (or clone) TGCU
REFERENCES: PATENTS
US4333855_PROMOTED_ZINC_TITANATE_CATALYTIC_AGENT
US4394297_ZINC_TITANATE_CATALYST
US6338794B1_DESULFURIZATION_ZINC_TITANATE_SORBENTS
DEACTIVATION OF METHANOL SYNTHESIS CATALYSTS
CONTENTS
1 INTRODUCTION
2 THERMAL SINTERING
3 CATALYST POISONING
4 REACTANT INDUCED DEACTIVATION
5 SUMMARY
TABLES
1 DEACTIVATION PROCESSES ON METHANOL SYNTHESIS CATALYSTS
2 MELTING POINT, HUTTIG AND TAMMANN TEMPERATURES OF COPPER, IRON AND NICKEL
3 SINTERING RATE CONSTANTS CALCULATED INLET AND OUTLET SIDE STREAM UNIT FOR VULCAN VSG-M101
4 COMPARISON BETWEEN CALCULATED S∞ AND DISCHARGED MEASUREMENTS ON VULCAN VSG-M101
5 EFFECT OF POSSIBLE CONTAMINANTS AND POISONS ON CU/ZNO/AL2O3 CATALYSTS FOR METHANOL SYNTHESIS
6 GUARD SCREENING TEST RESULTS ON METHANOL MICRO-REACTOR. EFFECT OF DEPOSITED METALS ON METHANOL ACTIVITY
FIGURES
1 THE HΫTTIG AND TAMMANN TEMPERATURES OF THE COMPONENTS OF A SYNTHESIS CATALYST
2 A SCHEMATIC REPRESENTATION OF TWO CATALYST SINTERING MECHANISMS
3 SIDE STREAM DATA FOR VULCAN VSG-M101. INLET TEMPERATURE 242 OC, PRESSURE 1500 PSI, GAS COMPOSITION 6% CO, 9.2% CO2, 66.9% H2, 2.5% N2 AND 15.4% CH4, SPACE VELOCITY 17,778 HR-1. MEAN OUTLET TEMPERATURE 280 OC
4 TEMPERATURE DEPENDENCE OF THE RATE OF SINTERING
5 MECHANISM OF SULFUR RETENTION
6 CORRELATION OF SULFUR CAPACITY WITH TOTAL SURFACE AREA
7 EFFECT OF DEPOSITED (NI+FE) PPM ON METHANOL SYNTHESIS CATALYST ACTIVITY
8 DISCHARGED (FE + NI) DEPOSITION LEVELS ON METHANOL SYNTHESIS PLANT SAMPLES
9 EPMA ANALYSIS OF DISCHARGED LABORATORY SAMPLE OF POISONED VULCAN VSG-M101
10 THE EFFECT OF CO2 ON SYNTHESIS CATALYST DEACTIVATION
REFERENCES
Catalyst Catastrophes in Syngas Production - II
Contents
Review of incidents by reactor
Primary reforming
Secondary reforming
HTS
LTS
Methanator
Reactor loading
Support media
Some general comments on alternative actions when a plant gets into abnormal operation
Catalyst Catastrophes in Syngas Production - I
The Hazards
Review incidents by reactor
Purification….
Through the various unit operations to
Ammonia synthesis
Nickel Carbonyl
Pre-reduced catalysts
Discharging catalysts
Conclusion
Securing your Kubernetes cluster_ a step-by-step guide to success !KatiaHIMEUR1
Today, after several years of existence, an extremely active community and an ultra-dynamic ecosystem, Kubernetes has established itself as the de facto standard in container orchestration. Thanks to a wide range of managed services, it has never been so easy to set up a ready-to-use Kubernetes cluster.
However, this ease of use means that the subject of security in Kubernetes is often left for later, or even neglected. This exposes companies to significant risks.
In this talk, I'll show you step-by-step how to secure your Kubernetes cluster for greater peace of mind and reliability.
UiPath Test Automation using UiPath Test Suite series, part 4DianaGray10
Welcome to UiPath Test Automation using UiPath Test Suite series part 4. In this session, we will cover Test Manager overview along with SAP heatmap.
The UiPath Test Manager overview with SAP heatmap webinar offers a concise yet comprehensive exploration of the role of a Test Manager within SAP environments, coupled with the utilization of heatmaps for effective testing strategies.
Participants will gain insights into the responsibilities, challenges, and best practices associated with test management in SAP projects. Additionally, the webinar delves into the significance of heatmaps as a visual aid for identifying testing priorities, areas of risk, and resource allocation within SAP landscapes. Through this session, attendees can expect to enhance their understanding of test management principles while learning practical approaches to optimize testing processes in SAP environments using heatmap visualization techniques
What will you get from this session?
1. Insights into SAP testing best practices
2. Heatmap utilization for testing
3. Optimization of testing processes
4. Demo
Topics covered:
Execution from the test manager
Orchestrator execution result
Defect reporting
SAP heatmap example with demo
Speaker:
Deepak Rai, Automation Practice Lead, Boundaryless Group and UiPath MVP
Accelerate your Kubernetes clusters with Varnish CachingThijs Feryn
A presentation about the usage and availability of Varnish on Kubernetes. This talk explores the capabilities of Varnish caching and shows how to use the Varnish Helm chart to deploy it to Kubernetes.
This presentation was delivered at K8SUG Singapore. See https://feryn.eu/presentations/accelerate-your-kubernetes-clusters-with-varnish-caching-k8sug-singapore-28-2024 for more details.
Software Delivery At the Speed of AI: Inflectra Invests In AI-Powered QualityInflectra
In this insightful webinar, Inflectra explores how artificial intelligence (AI) is transforming software development and testing. Discover how AI-powered tools are revolutionizing every stage of the software development lifecycle (SDLC), from design and prototyping to testing, deployment, and monitoring.
Learn about:
• The Future of Testing: How AI is shifting testing towards verification, analysis, and higher-level skills, while reducing repetitive tasks.
• Test Automation: How AI-powered test case generation, optimization, and self-healing tests are making testing more efficient and effective.
• Visual Testing: Explore the emerging capabilities of AI in visual testing and how it's set to revolutionize UI verification.
• Inflectra's AI Solutions: See demonstrations of Inflectra's cutting-edge AI tools like the ChatGPT plugin and Azure Open AI platform, designed to streamline your testing process.
Whether you're a developer, tester, or QA professional, this webinar will give you valuable insights into how AI is shaping the future of software delivery.
Transcript: Selling digital books in 2024: Insights from industry leaders - T...BookNet Canada
The publishing industry has been selling digital audiobooks and ebooks for over a decade and has found its groove. What’s changed? What has stayed the same? Where do we go from here? Join a group of leading sales peers from across the industry for a conversation about the lessons learned since the popularization of digital books, best practices, digital book supply chain management, and more.
Link to video recording: https://bnctechforum.ca/sessions/selling-digital-books-in-2024-insights-from-industry-leaders/
Presented by BookNet Canada on May 28, 2024, with support from the Department of Canadian Heritage.
Builder.ai Founder Sachin Dev Duggal's Strategic Approach to Create an Innova...Ramesh Iyer
In today's fast-changing business world, Companies that adapt and embrace new ideas often need help to keep up with the competition. However, fostering a culture of innovation takes much work. It takes vision, leadership and willingness to take risks in the right proportion. Sachin Dev Duggal, co-founder of Builder.ai, has perfected the art of this balance, creating a company culture where creativity and growth are nurtured at each stage.
The Art of the Pitch: WordPress Relationships and SalesLaura Byrne
Clients don’t know what they don’t know. What web solutions are right for them? How does WordPress come into the picture? How do you make sure you understand scope and timeline? What do you do if sometime changes?
All these questions and more will be explored as we talk about matching clients’ needs with what your agency offers without pulling teeth or pulling your hair out. Practical tips, and strategies for successful relationship building that leads to closing the deal.
Smart TV Buyer Insights Survey 2024 by 91mobiles.pdf91mobiles
91mobiles recently conducted a Smart TV Buyer Insights Survey in which we asked over 3,000 respondents about the TV they own, aspects they look at on a new TV, and their TV buying preferences.
JMeter webinar - integration with InfluxDB and GrafanaRTTS
Watch this recorded webinar about real-time monitoring of application performance. See how to integrate Apache JMeter, the open-source leader in performance testing, with InfluxDB, the open-source time-series database, and Grafana, the open-source analytics and visualization application.
In this webinar, we will review the benefits of leveraging InfluxDB and Grafana when executing load tests and demonstrate how these tools are used to visualize performance metrics.
Length: 30 minutes
Session Overview
-------------------------------------------
During this webinar, we will cover the following topics while demonstrating the integrations of JMeter, InfluxDB and Grafana:
- What out-of-the-box solutions are available for real-time monitoring JMeter tests?
- What are the benefits of integrating InfluxDB and Grafana into the load testing stack?
- Which features are provided by Grafana?
- Demonstration of InfluxDB and Grafana using a practice web application
To view the webinar recording, go to:
https://www.rttsweb.com/jmeter-integration-webinar
UiPath Test Automation using UiPath Test Suite series, part 3DianaGray10
Welcome to UiPath Test Automation using UiPath Test Suite series part 3. In this session, we will cover desktop automation along with UI automation.
Topics covered:
UI automation Introduction,
UI automation Sample
Desktop automation flow
Pradeep Chinnala, Senior Consultant Automation Developer @WonderBotz and UiPath MVP
Deepak Rai, Automation Practice Lead, Boundaryless Group and UiPath MVP
Epistemic Interaction - tuning interfaces to provide information for AI supportAlan Dix
Paper presented at SYNERGY workshop at AVI 2024, Genoa, Italy. 3rd June 2024
https://alandix.com/academic/papers/synergy2024-epistemic/
As machine learning integrates deeper into human-computer interactions, the concept of epistemic interaction emerges, aiming to refine these interactions to enhance system adaptability. This approach encourages minor, intentional adjustments in user behaviour to enrich the data available for system learning. This paper introduces epistemic interaction within the context of human-system communication, illustrating how deliberate interaction design can improve system understanding and adaptation. Through concrete examples, we demonstrate the potential of epistemic interaction to significantly advance human-computer interaction by leveraging intuitive human communication strategies to inform system design and functionality, offering a novel pathway for enriching user-system engagements.
Generating a custom Ruby SDK for your web service or Rails API using Smithyg2nightmarescribd
Have you ever wanted a Ruby client API to communicate with your web service? Smithy is a protocol-agnostic language for defining services and SDKs. Smithy Ruby is an implementation of Smithy that generates a Ruby SDK using a Smithy model. In this talk, we will explore Smithy and Smithy Ruby to learn how to generate custom feature-rich SDKs that can communicate with any web service, such as a Rails JSON API.
Generating a custom Ruby SDK for your web service or Rails API using Smithy
Study 1: Concept Hazard Review
1. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
GBH Enterprises, Ltd.
Process Safety Guide:
GBHE-PSG-HST-020
Study 1: Concept Hazard Review
Process Information Disclaimer
Information contained in this publication or as otherwise supplied to Users is
believed to be accurate and correct at time of going to press, and is given in
good faith, but it is for the User to satisfy itself of the suitability of the information
for its own particular purpose. GBHE gives no warranty as to the fitness of this
information for any particular purpose and any implied warranty or condition
(statutory or otherwise) is excluded except to the extent that exclusion is
prevented by law. GBHE accepts no liability resulting from reliance on this
information. Freedom under Patent, Copyright and Designs cannot be assumed.
2. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Process Safety Guide: Study 1: Concept Stage Hazard Review
CONTENTS
1.0 PURPOSE
1.0.1 Team
1.0.2 Timing
1.0.3 Preparation
1.0.4 Documentation
HAZARD STUDY 1: APPLICATION
1.1 Project Definition
1.2 Process Description
1.3 Materials Hazards
1.4 External Authorities
1.5 Organization and Human Factors
1.6 Additional Activities to be Completed
1.7 Review of Hazard Study 1
APPENDICES
A Chemical Hazard Guide Diagram
B Safety Risk Criteria - Limit Values for Tolerable Risk
C List of Additional Assessments
3. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
1 PURPOSE
The depth of hazard identification and risk assessment and the methodology
used should be appropriate to the risk to the Business, safety, health or the
environment.
This document covers Hazard Study 1, where the basic hazards of the materials
and the operation are identified and SHE criteria set. It identifies what information
is needed and the program of studies required, ensuring that all safety, health
and environmental hazards and risks are adequately addressed. In addition, any
constraints due to relevant legislation are identified.
An outcome from this study is a decision on which of the remaining hazard
studies (two to six) should also be undertaken.
This document should be used in conjunction with a process safety publication
such as ’HAZOP: Guide to best practice’ (available from IChemE) or ‘Guidelines
for Hazard Evaluation Procedures’.
1.0.1 Team
The team composition should be agreed between the Hazard Study Leader and
the Project Manager. Assistance in selecting team size and membership can be
found in chapter 5.2.3 of the 'HAZOP: Guide to best practice' book.
The final outcome of Hazard Study 1 should be agreed by the full team. Separate
sub-groups may be formed to progress specific parts of the study.
1.0.2 Timing
Hazard Study 1 should start as early as possible in the life of a project. enerally,
the Business or project management will have formed a basic idea of the project
before appointing the project team and Hazard Study Leader.
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Since the study defines the key parameters for the project on safety, health and
environmental issues it should be completed prior to the production of a sanction
estimate on every project.
1.0.3 Preparation
Before the first formal meeting it is advisable that the project team has been
identified and that the following is available:
(a) A draft project definition.
(b) A process description.
(c) A project plan that is part of a capital project management process. This
will include defined project stage-gates. A typical project process model is
available from GBHE.
(d) A review of SHE incidents with respect to the same or similar technology.
(e) A block diagram or flowsheet of the process.
(f) Completed chemical hazard, interactions and handling worksheets
(information from MSDS’s).
GBHE's preferred approach to the control of hazards will always be their
elimination where this is reasonably practicable. This is aided by the application
of the concept of Inherent SHE. This concept can be applied particularly
effectively at the early stages of a project and it is therefore specially valuable
and important at Hazard Study 1. Inherent SHE is explained in the book
'Guidelines for Engineering Design for Process Safety'.
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1.0.4 Documentation
A draft Hazard Study 1 Report (worksheet f) should be issued as soon as
practicable, giving details of the information still lacking and actions to be
completed.
The study report should be updated and reissued when all the actions have been
resolved. A copy of this report should be filed in the Project SSHE dossier
(worksheet j). This document should be retained and updated throughout the life
of the plant.
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HAZARD STUDY 1: APPLICATION
The following sections 1.1 to 1.7 describe how to conduct Hazard Study 1.
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1.1 PROJECT DEFINITION
Designs that will be safe and meet environmental and health standards require a
clear understanding of the objective of the project and the processes involved.
The Business Manager or the Project Manager should provide a definition of the
project. The project definition should cover:
(a) Objective.
(b) Scope:
(1) Capacity and patterns of demand;
(2) Overall equipment effectiveness (OEE);
(3) Process operating philosophy;
(4) Maintenance philosophy;
(5) Control principles (see 1.6.1);
(6) Containment philosophy;
(7) Buildings (e.g. purpose, numbers of people);
(8) Demolition.
(c) Timetable.
(d) Location.
(e) Project risks (e.g., the effect on the Business of loss or unavailability of the
plant).
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1.2 PROCESS DESCRIPTION
The Project Manager should ensure that a brief description of the process or
proposed operations is produced. This should also include:
(a) Process raw materials, intermediates, and catalysts; specification,
quantities and storage.
(b) Products; specification, conditions and storage.
(c) Effluents; quantities and treatment philosophy.
(d) Utilities.
It is recommended that at least a simple block diagram or
process flowsheet be provided.
1.3 MATERIALS HAZARDS
The purpose is to ensure that the material hazards will be
fully understood by the project team and, subsequently,
operating personnel, by use of the Chemical Hazard Guide
Diagram shown in appendix A. In cases where large numbers of similar
chemicals are involved, it may be appropriate to group these generically.
1.3.1 Material List
Prior to the first Hazard Study Meeting a list of the materials,
chemicals or substances involved should be produced (see Hazard
Study 1 Chemical Hazards Worksheet, Part 1 - Materials List)
(worksheet a).
This should cover:
(a) Raw materials, intermediate and/or intermediate mixtures,
main product or products, by-products.
(b) Effluents, Emissions and Waste produced from this process - gaseous,
liquids, solids, slurries.
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(c) Emissions from adjacent facilities or materials from elsewhere which may
be airborne, encountered in drains, utilities or in the ground and which
may impact this process.
(d) Support materials including catalysts, inhibitors, biological, radio-chemical,
decontamination and detoxification materials, fumigants, any special
maintenance materials or materials involved in supporting activities.
(e) Services, including heat transfer oils, dielectric fluids, gases, steam, oil,
nitrogen, cooling water, water, instrument air, waste disposal. (Include
additives and contaminants in the list).
(f) Principal materials of construction/construction materials
(g) Materials encountered during construction/demolition. For example,
contaminated ground, in ducts, drains, pipes and vessels or on surfaces:
PCBs, insulation material (e.g. asbestos), lead, flammable materials, etc.
Describe the material including, as far as possible, the composition and
appropriate name (e.g. trade names, abbreviations, product codes/numbers).
When the same material is present in different physical states, it may be helpful
to list each physical state separately.
1.3.2 Hazard Data Sheets
The Hazard Study should confirm that all necessary Material Safety Data Sheets
(MSDS) are available and identify where data is lacking and needs to be
collected/determined. Often data will initially only be available for a limited
number of process streams and individual component substances. Identify
limitations in the data that could affect decision making and factors of safety
which need to be applied.
1.3.3 Chemical Hazards
Quantities of materials stored on plants may trigger the enforcement of major
hazards legislation such as 29 CFR 1910.119 The Process Safety Management
of Highly Hazardous Chemicals and 40 CFR Part 68, Chemical Accident
Prevention Provisions (The EPA’s Risk Management Program – the RMP) and
SARA, (The Superfund Amendments and Reauthorization Act) in the US.
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These regulations may have a significant impact on the capital and operating
costs of manufacturing facilities. Non compliance could result in significant fines
and other sanctions.
(a) Consider the hazards associated with the handling, storage and use of
materials this can be done using the Chemical Hazards worksheet
(worksheet a) to record relevant hazards and identify any need for
additional information on the materials involved.
Much of the information can be assembled before the meeting possibly
with the help of an Occupational Hygienist, Environmental Specialist,
Chemist or other specialist. In all cases, the worksheet and resulting notes
should be reviewed by the Hazard Study team.
Confirm that the required data is available or will be obtained. The
purpose of the Chemical Hazards worksheet is to indicate the hazards of
the materials used in the process and to ensure that the means of
handling is commensurate with the hazards posed.
(b) Identify potential hazardous interactions between the
chemicals/substances To identify potential hazardous interactions
between the chemicals/substances in the process, materials of
construction and services, the Hazard Study 1 Chemical Interaction
worksheet (worksheet b) should be completed outside the meeting and
reviewed by the Hazard Study team.
The purpose of the worksheet is to identify any combinations of materials
used in or near the process which are incompatible or have a significant
hazard. Fill the worksheet in a similar fashion to the Chemical Hazards
worksheet. Materials of construction should be listed in the lower section
of the worksheet: these include materials in direct contact with process
fluids but consideration should also be given to other tools and equipment
or building/construction materials which may come into contact with the
process material.
Use the matrix to consider possible hazardous interactions of each
material with each of the other materials in the top section of the
worksheet and with materials of construction in the lower section.
The materials section may also be used to signal materials that are
incompatible (e.g. copper with ammonia solutions) and should therefore
not be used.
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Information on interactions is available in Bretherick's 'Handbook of
Reactive Chemical Hazards'.
Ambient materials (e.g. air, water, soil) may be added to prompt possible
oxidation, reactions with water and/or corrosion issues.
When processing operations are being undertaken with reactive
chemicals, the possibility of an exothermic run away reaction should be
considered and will probably require further action in the form of a
Chemical Hazard Assessment (assuming that one has not already been
carried out for the exact system). Reactive Chemical Hazards are most
often encountered in exothermic batch reactors and may impact on the
design of the relief system. Some form of screening study should be
carried out for these reactors. Materials which exotherm (start to
decompose) at temperatures below 60º C or 140º F can also give
problems in handling, storage and transportation. In this category are
organic peroxides often used as catalysts. A full assessment will involve
experimental work by a specialist contractor. The results of this work will
ensure safe operation and the correct sizing of reliefs, etc.
With research projects, where the material hazards are not precisely
known, the appropriate safeguards should be established.
1.3.4 Loss of Containment
Consider whether a quantity of material released from any section of the plant, or
from any operation, with total loss of containment and under the conditions of
storage or use, can give rise to unacceptable consequences for safety, health or
the environment.
If so, review the consideration that has been given to Inherent SHE acceptability
and identification of Critical Equipment for the control of these hazards (e.g.
GBHE_EP’s).
Consider the potential effect of loss of containment on occupied buildings, (e.g.
control rooms, workshops, offices, laboratories, houses, schools, hospitals, retail
and sports centers, etc.).
Methods of assessing risks are available. If risks appear to be significant then
seek specialist advice.
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Where the quantity of material to be handled is not known, the quantity that will
cause off-plot effects should be estimated.
1.4 EXTERNAL AUTHORITIES
Consideration needs to be given to the authority approval process.
This should involve the full co-operation of staff with experience of
the country in which the plant will be located.
It is most important that a full and exhaustive list of the regulatory
requirements for the project is obtained. The following questions
should be addressed:
(a) Which authorities will need to be contacted?
(b) Who will be responsible for each contact?
(c) Will the project change the status of the site under any
existing legislation?
(d) Do plant or site inventory lists need to be updated?
(e) Are chemicals handled that are controlled by international protocols
(e.g. chemical warfare).
1.5 ORGANIZATION AND HUMAN FACTORS
In addition to the physical/geographical factors associated with site
selection already considered, assess if it is necessary to review the
major organizational and human factors.
More detailed study of any of the following outside the meeting may
need to be commissioned:
(a) Will the site be able to provide suitably qualified and
experienced staff for the construction, project development,
commissioning, operation and maintenance? These
considerations will be of prime importance where new
hazards and/or a new technology is being introduced to a site, particularly
if significantly different from those existing and familiar to site personnel.
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The Training and Experience worksheet (worksheet c) may be used to
assess requirements.
(b) Does the project introduce hazards for which new systems of work or
procedures are required? If so, who will be responsible for providing
these?
(c) Are the key control, operational and manning concepts clear?
(d) Have facilities for construction manning been considered, (e.g., medical,
hygiene and eating facilities)?
1.6 ADDITIONAL ACTIVITIES TO BE COMPLETED
1.6.1 Control Philosophy
Describe the basic control philosophy. For example:
(a) What is it and what does it do.
(b) Is the proposed application suitable for the intended type of
process control (e.g. Programmable Electronic Systems)?
(c) What type of trip system is proposed and how does it
interface with the process control (e.g. PES)?
(d) Is there an existing plant and how does any PES fit in?
(e) Who is responsible for ergonomic (man-machine communication and
health) aspects?
(f) Vulnerability in an emergency or calamity?
1.6.2 Incident Review
Initiate a review of any incidents with significant safety, health or environmental
effects that have occurred on similar projects or processes/projects using the
same or related technology. This should cover GBHE experience and other
known incidents.
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Information should be sourced externally if not available within the company.
The incidents identified above should be reviewed to ensure that the precautions
necessary to control the hazard are understood. It is recommended (mandatory
in the USA) to consider and document how repetition of each incident will be
prevented.
Describe how findings from previous relevant incidents are being incorporated
into this project.
1.6.3 Inherent SHE
Inherent SHE is important.
Inherent SHE emphasizes changing the design as early as possible and makes
use of the concepts of:
(a) Substitute (e.g. replace solvents with water);
(b) Minimize (e.g. lower inventory);
(c) Simplify (e.g. remove separations);
(d) Moderate (e.g. lower temperature or pressure).
Guidance on the application of Inherent SHE is available. This is covered by a
book ’Guidelines for Engineering Design for Process Safety’ published by the
Center for Chemical Process Safety (CCPS), part of the American Institute of
Chemical Engineers.
1.6.4 Safety Risk Criteria
It is a requirement of Group SHE Standards that risks should be reduced as far
as is reasonably practicable. In general, this will be achieved by the proper
application of appropriate codes, standards and good working practices.
In some cases it will be judged necessary (or a regulatory requirement) to use
Quantitative Risk Assessment (QRA) to help decide the level of precautions
needed. Any relevant risk criteria set by site requirements or by local or national
authorities should be identified, e.g.:
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(a) Toxic gas emission criteria.
(b) Employee risk.
(c) Off-site individual risk.
(d) Off-site ‘group’ risk (‘societal’ risk).
(e) Major incident frequency.
Normally the business unit will establish agreed safety risk criteria. The limit
values for tolerable risk are summarized in appendix B.
1.6.5 Health
The Occupational Health issues associated with the project should be considered
and any special features should be identified. This should give guidance to the
project team in relation to risk control either by specifying design criteria,
recommending involvement of experts or recommending further studies.
This should identify health hazards resulting from:
(a) Chemical and biological properties of the materials.
(b) Noise.
(c) Ergonomics:
(1) Health related (manual handling, repetitive movements, posture,
visual display terminals);
(2) Human factors (human error and things likely to cause it).
(d) Radiation (radioactive sources, ultraviolet, lasers).
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The health risks that may arise during the life cycle of the plant should be
identified:
(1) Construction.
(2) Commissioning.
(3) Operation.
(4) Maintenance.
(5) Demolition.
1.6.6 Environment
As with safety hazards the preferred approach to environmental hazards is their
elimination through choice, selection and development of appropriate process
routes and technology.
The study should consider the 'Environmental Impact’ issues offsite and onsite.
This is normally achieved through an Environmental Statement and an
Environmental Impact Assessment. Hazard Study 1 reviews and agrees the
Environmental Statement. Have means of waste reduction at source been
adequately considered? Is the impact acceptable?
The Environmental Statement should identify:
(a) Process route options.
(b) The treatment options considered and justification of the chosen option.
(c) How will the material be disposed of, controlled and monitored?
(d) Are the potential effects of this disposal understood?
(e) The impact of discharges to the environment.
In comparison with the EIA criteria or national legislation, do you need an
Environmental Impact Assessment for this project? To decide this, Hazard Study
1 should further consider whether:
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(1) There are any effluents not included on the list considered within the
Environmental Statement.
(2) The data for the environmental effects of the materials being handled are
sufficient for the project and for ongoing operation.
(3) There are any problems associated with the disposal of catalysts,
inhibitors, decontamination, detoxification, radioactive or biological
/pathological materials, maintenance wastes and packaging from received
materials.
(4) Consideration has been given to the disposal of out of specification,
returned or contaminated material.
(5) Consideration has been given to the need to build on contaminated land
and to the disposal of contaminated land, materials encountered during
construction or demolition, demolition material and building wastes.
(6) Special precautions are needed to prevent dust or leakage of materials
during construction/demolition affecting drains.
(7) It will be necessary to take measures to prevent soil or groundwater
contamination.
(8) Special provision will be needed for containment/treatment of
contaminated firewater.
(9) Consideration is necessary for the disposal of customers' waste (including
packaging).
(10) Any special mechanisms can result in loss of containment and spread
(e.g. flood, wind, storm, fire water runoff).
(11) Harmful or toxic/biologically environmentally active materials can be
created accidentally during unusual conditions, such as process upsets or
fire exposure. Can these have an effect beyond the site boundaries?
(12) Construction, demolition or operation may involve significant effect on tree
removal, natural vegetation or flora and fauna.
(13) Special measures are required to reduce or monitor fugitive emissions
(e.g. leaks from glands or seals).
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(14) The location is the site of any endangered flora or fauna.
(15) There are any native titles (access, burial grounds).
Agree and record the responsibility for any further Environmental Assessments’’.
1.6.7 Material Transport and Siting
(a) Material Transport Stages
Consider those factors that are relevant to the selection of a site and a plot,
including the transport between sites and plots. The study should include
consideration of potential knock-on effects on existing hazardous or vulnerable
pipe routes, buildings, services, storage, etc. A key objective is to ensure that the
overall risk is minimized:
(1) Define the transport stages involved in broad terms (e.g., road, rail, ship,
pipeline, etc.) taking account of the flow of major raw materials through to
the destination of the products.
(2) Define in broad terms the transport stages involved in demolition
/construction taking account of the flow and storage of demolition and
construction materials and equipment.
(3) Review whether the risks arising from the construction/demolition work or
from the transport and storage of hazardous materials could be minimized
by the choice of plant location, material to be transported, etc. A simple
diagram showing material and transport movement may assist.
(4) In difficult cases, a Quantified Risk Assessment (QRA) may be called for.
In all of the above it is important to concentrate on the major material flows.
Detailed assessment of routes to individual customers will only be necessary in a
very limited number of cases and will generally not require consideration in the
case of established businesses.
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(b) Existing Plants
Consider the potential effect of existing plants or operations on the proposed
development. Existing plants may need modifying or their impact studies
updating. Give consideration to bulk storage of potentially hazardous materials.
Include potential hazards of chemical interactions in or from drains and
contamination of intake air.
Consider if the proposed project will restrict future site development.
1.6.8 Design Guidelines and Codes
Internal GBHE and national guidelines to be followed should be listed.
Consideration should be given as to whether the project requires any new design
guidelines, codes of practice, guides and standards.
1.6.9 Emergency Facilities
Review the adequacy of site emergency facilities to ensure that these are
adequate to meet the needs of the proposed project.
The Site Emergency Facilities worksheet (worksheet d) may be used in
consultation with site personnel to ensure a full coverage.
1.6.10 Further Studies
Consider and agree what additional safety, health, environmental, quality or
financial related studies will be required during the design of the project, and
whether these will be covered as part of the Hazard Study process or carried out
as independent studies. A list of additional assessments is shown in appendix C
and a worksheet (worksheet e) is available to record which studies are to be
considered as part of the project.
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1.7 REVIEW OF HAZARD STUDY 1
At the completion of this study the following key activities should have been
completed:
• Agreed the extent of further hazard studies and the need for
any QRA.
• If the hazard study process is to be curtailed then justify and
document the reason, using the Extent of Further Hazard
Studies worksheet (worksheet g).
• Additional assessments to be considered as part of the
project (worksheet e).
• Actions identified (worksheet h).
• Agreed the responsibility and date for progressing actions.
The Project Manager is responsible for progressing any identified hazard studies
and actions.
21. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
22. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
23. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
24. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
25. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
26. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
27. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com