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
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.
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
Centrifugal Compressors
SECTION ONE - ANTI-SURGE PROTECTION AND THROUGHPUT REGULATION
0 INTRODUCTION
1 SCOPE
2 MACHINE CHARACTERISTICS
2.1 Characteristics of a Single Compressor Stage
2.2 Characteristic of a Multiple Stage Having More
Than One Impeller
2.3 Use of Compressor Characteristics in Throughput
Regulation Schemes
3 MECHANISM AND EFFECTS OF SURGE
3.1 Basic Flow Instabilities
3.2 Occurrence of Surge
3.3 Intensity of Surge
3.4 Effects of Surge
3.5 Avoidance of Surge
3.6 Recovery from Surge
4 CONTROL SCHEMES INCLUDING SURGE PROTECTION
4.1 Output Control
4.2 Surge Protection
4.3 Surge Detection and Recovery
5 DYNAMIC CONSIDERATIONS
5.1 Interaction
5.2 Speed of Response of Antisurge Control System
6 SYSTEM EQUIPMENT SPECIFICATIONS
6.1 The Antisurge Control Valve
6.2 Non-return Valve
6.3 Pressure and flow measurement
6.4 Signal transmission
6.5 Controllers
7 TESTING
7.1 Determination of the Surge Line
7.2 Records
8 INLET GUIDE VANE UNITS
8.1 Application
8.2 Effect on Power Consumption of the Compressor
8.3 Effect of Gas Conditions, Properties and Contaminants
8.4 Aerodynamic Considerations
8.5 Control System Linearity
8.6 Actuator Specification
8.7 Avoidance of Surge
8.8 Features of Link Mechanisms
8.9 Limit Stops and Shear Links
APPENDICES
A LIST OF SYMBOLS AND PREFERRED UNITS
B WORKED EXAMPLE 1 COMPRESSOR WITH VARIABLE INLET PRESSURE AND VARIABLE GAS COMPOSITION
C WORKED EXAMPLE 2 A CONSTANT SPEED ~ STAGE COMPRESSOR WITH INTER-COOLING
D WORKED EXAMPLE 3 DYNAMIC RESPONSE OF THE ANTISURGE PROTECTION SYSTEM FOR A SERVICE AIR COMPRESSOR RUNNING AT CONSTANT SPEED
E EXAMPLE OF INLET GUIDE VANE REGULATION
FIGURES
2.1 TYPICAL COMPRESSOR STAGE CHARACTERISTIC PLOTTED WITH FLOW AT DISCHARGE CONDITIONS
2.2 TYPICAL COMPRESSOR STAGE CHARACTERISTIC PLOTTED WITH FLOW AT INLET CONDITIONS
2.3 PERFORMANCE CHARACTERISTICS OF A COMPRESSOR STAGE AT VARYING SPEEDS
2.4 SYSTEM WORKING POINT DEFINED BY INTERSECTION OF PROCESS AND COMPRESSOR CHARACTERISTICS
2.5 DISCHARGE THROTTLE REGULATION
2.6 BYPASS REGULATION
2.7 INLET THROTTLE REGULATION
2.8 INLET GUIDE VANE REGULATION
2.9 VARIABLE SPEED REGULATION
3.1 GAS PULSATION LEVELS FOR A CENTRIFUGAL COMPRESSOR
3.2 REPRESENTATION OF CYCLIC FLOW DURING SURGE OF LONG PERIOD
3.3 TYPICAL WAVEFORM OF DISCHARGE PRESSURE DURING SURGE
3.4 MULTIPLE SURGE LINE FOR A MULTISTAGE CENTRIFUGAL COMPRESSOR
3.5 TYPICAL MULTIPLE SURGE LINES FOR SINGLE STAGE AXIAL-FLOW COMPRESSOR
4.1 GENERAL SCHEMATIC FOR COMPRESSORS OPERATING IN PARALLEL TO FEED MULTIPLE USER PLANTS
4.2 ILLUSTRATION OF SAFETY MARGIN BETWEEN SURGE POINT AND SURGE PROTECTION POINT AT WHICH ANTISURGE SYSTEM IS ACTIVATED
4.3 ANTISURGE SYSTEM FOR COMPRESSOR WITH FLAT PERFO ..........
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
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
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.
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
Centrifugal Compressors
SECTION ONE - ANTI-SURGE PROTECTION AND THROUGHPUT REGULATION
0 INTRODUCTION
1 SCOPE
2 MACHINE CHARACTERISTICS
2.1 Characteristics of a Single Compressor Stage
2.2 Characteristic of a Multiple Stage Having More
Than One Impeller
2.3 Use of Compressor Characteristics in Throughput
Regulation Schemes
3 MECHANISM AND EFFECTS OF SURGE
3.1 Basic Flow Instabilities
3.2 Occurrence of Surge
3.3 Intensity of Surge
3.4 Effects of Surge
3.5 Avoidance of Surge
3.6 Recovery from Surge
4 CONTROL SCHEMES INCLUDING SURGE PROTECTION
4.1 Output Control
4.2 Surge Protection
4.3 Surge Detection and Recovery
5 DYNAMIC CONSIDERATIONS
5.1 Interaction
5.2 Speed of Response of Antisurge Control System
6 SYSTEM EQUIPMENT SPECIFICATIONS
6.1 The Antisurge Control Valve
6.2 Non-return Valve
6.3 Pressure and flow measurement
6.4 Signal transmission
6.5 Controllers
7 TESTING
7.1 Determination of the Surge Line
7.2 Records
8 INLET GUIDE VANE UNITS
8.1 Application
8.2 Effect on Power Consumption of the Compressor
8.3 Effect of Gas Conditions, Properties and Contaminants
8.4 Aerodynamic Considerations
8.5 Control System Linearity
8.6 Actuator Specification
8.7 Avoidance of Surge
8.8 Features of Link Mechanisms
8.9 Limit Stops and Shear Links
APPENDICES
A LIST OF SYMBOLS AND PREFERRED UNITS
B WORKED EXAMPLE 1 COMPRESSOR WITH VARIABLE INLET PRESSURE AND VARIABLE GAS COMPOSITION
C WORKED EXAMPLE 2 A CONSTANT SPEED ~ STAGE COMPRESSOR WITH INTER-COOLING
D WORKED EXAMPLE 3 DYNAMIC RESPONSE OF THE ANTISURGE PROTECTION SYSTEM FOR A SERVICE AIR COMPRESSOR RUNNING AT CONSTANT SPEED
E EXAMPLE OF INLET GUIDE VANE REGULATION
FIGURES
2.1 TYPICAL COMPRESSOR STAGE CHARACTERISTIC PLOTTED WITH FLOW AT DISCHARGE CONDITIONS
2.2 TYPICAL COMPRESSOR STAGE CHARACTERISTIC PLOTTED WITH FLOW AT INLET CONDITIONS
2.3 PERFORMANCE CHARACTERISTICS OF A COMPRESSOR STAGE AT VARYING SPEEDS
2.4 SYSTEM WORKING POINT DEFINED BY INTERSECTION OF PROCESS AND COMPRESSOR CHARACTERISTICS
2.5 DISCHARGE THROTTLE REGULATION
2.6 BYPASS REGULATION
2.7 INLET THROTTLE REGULATION
2.8 INLET GUIDE VANE REGULATION
2.9 VARIABLE SPEED REGULATION
3.1 GAS PULSATION LEVELS FOR A CENTRIFUGAL COMPRESSOR
3.2 REPRESENTATION OF CYCLIC FLOW DURING SURGE OF LONG PERIOD
3.3 TYPICAL WAVEFORM OF DISCHARGE PRESSURE DURING SURGE
3.4 MULTIPLE SURGE LINE FOR A MULTISTAGE CENTRIFUGAL COMPRESSOR
3.5 TYPICAL MULTIPLE SURGE LINES FOR SINGLE STAGE AXIAL-FLOW COMPRESSOR
4.1 GENERAL SCHEMATIC FOR COMPRESSORS OPERATING IN PARALLEL TO FEED MULTIPLE USER PLANTS
4.2 ILLUSTRATION OF SAFETY MARGIN BETWEEN SURGE POINT AND SURGE PROTECTION POINT AT WHICH ANTISURGE SYSTEM IS ACTIVATED
4.3 ANTISURGE SYSTEM FOR COMPRESSOR WITH FLAT PERFO ..........
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
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
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.
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
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...
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
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
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
The Design and Layout of Vertical Thermosyphon ReboilersGerard B. Hawkins
The Design and Layout of Vertical Thermosyphon Reboilers
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 THE DESIGN PROBLEM
5 COMPUTER PROGRAMS
6 GENERAL CONSIDERATIONS
6.1 Heating Medium Temperature
6.2 Fouling Resistance
7 DESIGN PARAMETERS
7.1 Overall Arrangement and Specifications
7.2 Geometry Elements
8 ANALYSIS OF COMMERCIALLY AVAILABLE
PROGRAM RESULTS
8.1 Main Results
8.2 Supplementary Results
8.3 Error Analysis
8.4 Adjustments to Design
9 OPERATING RANGE
10 CONTROL
10.1 Control of Condensing Heating Medium Pressure
10.2 Control of The Condensate Level
10.3 Control of Sensible Fluid Flow Rate
11 LAYOUT
11.1 Factors Influencing Design
11.2 A Standard Layout
12 BIBLIOGRAPHY
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).
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
How to Use the GBHE Mixing Guides
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 THE MIXING GUIDES
4.1 Mixing Guides
4.2 GBHE Mixing and Agitation Manual
5 DEVICE SELECTION
6 MIXING QUESTIONNAIRE
6.1 What is being mixed?
6.2 Why is it being mixed?
6.3 How is it to be mixed?
6.4 Is Heat Transfer Important?
6.5 Is Mixing Time Important?
6.6 Is Inventory Important?
6.7 Is Subsequent Phase Separation Important?
6.8 What Quantities?
6.9 What are the Selection Criteria?
6.10 What Data are required?
7 BASICS
7.1 Bulk Movement
7.2 Shear and Elongation
7.3 Turbulent Diffusion
7.4 Molecular Diffusion
7.5 Mixing Mechanisms
APPENDICES
A ROTATING MIXING DEVICES
B MIXING DEVICES WITHOUT MOVING PARTS
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
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
Cost Estimating: Turbo Blowers
This GBHE Engineering Guide provides information to assist in preparing an estimate for the cost of single stage, integrally geared, turbo-blowers. The data contained is based on analysis of past purchases for projects and offers by vendors.
Data Sources For Calculating Chemical Reaction EquilibriaGerard B. Hawkins
Data Sources For Calculating Chemical Reaction Equilibria
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 BACKGROUND TO THEORY
5 BIBLIOGRAPHY
Protection Systems for Machines: an Engineering GuideGerard B. Hawkins
Protection Systems for Machines: an Engineering Guide
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 CRITICAL MACHINE SYSTEMS
5 POSITIVE DISPLACEMENT MACHINES
5.1 Protection Against Over Pressure
5.2 Protection Against High or Low Temperature
5.3 Displacement Measuring Devices
5.4 Vibration Detection Devices
5.5 Pulsation Dampers
5.6 Knock-out Pots
5.7 Special Considerations for Dry Vacuum Pumps
6 DYNAMIC MACHINES
6.1 Dynamic Pumps
6.2 Sealless Pumps
6.3 Dynamic Compressors and Blowers
6.4 Gas Turbines/Expanders and Steam Turbines
7 CENTRIFUGES
8 LARGE ELECTRIC MOTORS AND ALTERNATORS
9 GEARBOXES
10 OIL LUBRICATED PLAIN BEARINGS AND LUBRICATING OIL SYSTEMS
11 SEALS AND SEALANT SYSTEMS
12 CONDITION MONITORING
13 TRIP AND ALARM SCHEDULES FOR ALL MACHINE
SYSTEMS
14 TESTING OF PROTECTION SYSTEMS FOR MACHINES
14.1 All Machines
14.2 Critical Machines
15 MACHINES SAFETY DOCUMENTS
APPENDICES
A EUROPEAN COMMUNITIES DIRECTIVES
B REFERENCE DOCUMENTS FOR POSITIVE
DISPLACEMENT MACHINES
C REFERENCE DOCUMENTS FOR DYNAMIC MACHINES
DOCUMENTS REFERRED TO IN THIS ENGINEERING GUIDE
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
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
PROJECT MANAGEMENT: A Handbook for Small Projects
INTRODUCTION
This Information for Engineers document comprises two sections.
Section 1 contains the components of the GBHE Project Process, the capabilities and competencies required by a Project Manager and, finally, specific project management good practices including value improving practices.
Section 2 contains information that supports the practices contained within Section 1. This includes helpful checklists, references and information about deliverables and other examples, all of which will provide practical help to Project Managers and their project teams.
The document assists client sites in meeting the necessary engineering requirements related to safety, health and environmental matters on their sites, and supports the GBHE Safety, Security, Health and Environmental Policy.
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
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.
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
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...
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
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
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
The Design and Layout of Vertical Thermosyphon ReboilersGerard B. Hawkins
The Design and Layout of Vertical Thermosyphon Reboilers
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 THE DESIGN PROBLEM
5 COMPUTER PROGRAMS
6 GENERAL CONSIDERATIONS
6.1 Heating Medium Temperature
6.2 Fouling Resistance
7 DESIGN PARAMETERS
7.1 Overall Arrangement and Specifications
7.2 Geometry Elements
8 ANALYSIS OF COMMERCIALLY AVAILABLE
PROGRAM RESULTS
8.1 Main Results
8.2 Supplementary Results
8.3 Error Analysis
8.4 Adjustments to Design
9 OPERATING RANGE
10 CONTROL
10.1 Control of Condensing Heating Medium Pressure
10.2 Control of The Condensate Level
10.3 Control of Sensible Fluid Flow Rate
11 LAYOUT
11.1 Factors Influencing Design
11.2 A Standard Layout
12 BIBLIOGRAPHY
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).
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
How to Use the GBHE Mixing Guides
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 THE MIXING GUIDES
4.1 Mixing Guides
4.2 GBHE Mixing and Agitation Manual
5 DEVICE SELECTION
6 MIXING QUESTIONNAIRE
6.1 What is being mixed?
6.2 Why is it being mixed?
6.3 How is it to be mixed?
6.4 Is Heat Transfer Important?
6.5 Is Mixing Time Important?
6.6 Is Inventory Important?
6.7 Is Subsequent Phase Separation Important?
6.8 What Quantities?
6.9 What are the Selection Criteria?
6.10 What Data are required?
7 BASICS
7.1 Bulk Movement
7.2 Shear and Elongation
7.3 Turbulent Diffusion
7.4 Molecular Diffusion
7.5 Mixing Mechanisms
APPENDICES
A ROTATING MIXING DEVICES
B MIXING DEVICES WITHOUT MOVING PARTS
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
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
Cost Estimating: Turbo Blowers
This GBHE Engineering Guide provides information to assist in preparing an estimate for the cost of single stage, integrally geared, turbo-blowers. The data contained is based on analysis of past purchases for projects and offers by vendors.
Data Sources For Calculating Chemical Reaction EquilibriaGerard B. Hawkins
Data Sources For Calculating Chemical Reaction Equilibria
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 BACKGROUND TO THEORY
5 BIBLIOGRAPHY
Protection Systems for Machines: an Engineering GuideGerard B. Hawkins
Protection Systems for Machines: an Engineering Guide
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 CRITICAL MACHINE SYSTEMS
5 POSITIVE DISPLACEMENT MACHINES
5.1 Protection Against Over Pressure
5.2 Protection Against High or Low Temperature
5.3 Displacement Measuring Devices
5.4 Vibration Detection Devices
5.5 Pulsation Dampers
5.6 Knock-out Pots
5.7 Special Considerations for Dry Vacuum Pumps
6 DYNAMIC MACHINES
6.1 Dynamic Pumps
6.2 Sealless Pumps
6.3 Dynamic Compressors and Blowers
6.4 Gas Turbines/Expanders and Steam Turbines
7 CENTRIFUGES
8 LARGE ELECTRIC MOTORS AND ALTERNATORS
9 GEARBOXES
10 OIL LUBRICATED PLAIN BEARINGS AND LUBRICATING OIL SYSTEMS
11 SEALS AND SEALANT SYSTEMS
12 CONDITION MONITORING
13 TRIP AND ALARM SCHEDULES FOR ALL MACHINE
SYSTEMS
14 TESTING OF PROTECTION SYSTEMS FOR MACHINES
14.1 All Machines
14.2 Critical Machines
15 MACHINES SAFETY DOCUMENTS
APPENDICES
A EUROPEAN COMMUNITIES DIRECTIVES
B REFERENCE DOCUMENTS FOR POSITIVE
DISPLACEMENT MACHINES
C REFERENCE DOCUMENTS FOR DYNAMIC MACHINES
DOCUMENTS REFERRED TO IN THIS ENGINEERING GUIDE
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
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
PROJECT MANAGEMENT: A Handbook for Small Projects
INTRODUCTION
This Information for Engineers document comprises two sections.
Section 1 contains the components of the GBHE Project Process, the capabilities and competencies required by a Project Manager and, finally, specific project management good practices including value improving practices.
Section 2 contains information that supports the practices contained within Section 1. This includes helpful checklists, references and information about deliverables and other examples, all of which will provide practical help to Project Managers and their project teams.
The document assists client sites in meeting the necessary engineering requirements related to safety, health and environmental matters on their sites, and supports the GBHE Safety, Security, Health and Environmental Policy.
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
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
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
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.
Naphtha Steam Reforming Catalyst Reduction with MethanolGerard B. Hawkins
Procedure for Naphtha Steam Reforming Catalyst Reduction with Methanol
Scope
This procedure applies to the in situ reduction of VULCAN Series steam reforming catalysts using methanol cracking to form hydrogen over the catalyst in the steam reformer.
The procedure is likely to be applied to plants using only heavier feeds (e.g.: LPG and/or naphtha) and some combination of VULCAN Series catalysts.
Introduction
A small number of steam reforming plants do not have an available source of the commonly used reducing media (e.g.: hydrogen, hydrogen-rich off-gas, natural gas). These plants will usually operate on LPG and/or naphtha feed only where cracking of this hydrocarbon is not usually advised for reduction of the steam reforming catalyst ...
This Engineering Design Guide has several aims.
It is intended to take an experienced mechanical engineer through the steps necessary to specify a gear and to carry out an assessment of gears offered against a particular specification for pumps, fans and compressors driven by electric motors, steam turbines, combustion gas turbines or expanders. It is not part of this Engineering Design Guide to show how to decide that a gear is or is not necessary for a particular duty.
CONTENTS
1 SCOPE
2 PROPERTIES OF FLUID
2.1 General Properties of Sodium Hydroxide
2.2 Physical Properties of Sodium Hydroxide and its Solutions
2.3 Chemical Properties and uses of Sodium Hydroxide
2.4 Physiological effects of Sodium Hydroxide
2.5 Specifications of Commercial Caustic Soda Grades
3 CHOICE OF PUMP TYPE
3.1 Pump Duty
3.2 Pump Type
4 RECOMMENDED LINE DIAGRAMS
5 RECOMMENDED LAYOUT
6 CONSTRUCTION FEATURES
7 MATERIALS OF CONSTRUCTION
7.1 Nickel and Nickel Alloys
7.2 Austenitic Stainless Steel
7.3 Aluminium, Aluminium Alloys, etc.
7.4 Non-Metallic Materials
TABLES
1 PHYSICAL PROPERTIES (Solid Form)
2 PHYSICAL PROPERTIES (Solution Form)
3 CAUSTIC SODA GRADES
FIGURES
1.1 LINE DIAGRAM - HORIZONTAL GLANDED, GLANDLESS AND VERTICAL IN-LINE PUMPS
1.2 LINE DIAGRAM - VERTICAL SPINDLE CANTILEVER PUMPS
1.3 LINE DIAGRAM - SELF PRIMING PUMPS
1.4 LINE DIAGRAM - RECIPROCATING PLUNGER METERING PUMPS
1.5 LINE DIAGRAM - POSITIVE DISPLACEMENT DIAPHRAGM METERING PUMPS
1.6 WATER FLUSHING ARRANGEMENT FOR DOUBLE MECHANICAL SEAL
1.7 WATER FLUSH (QUENCH) ARRANGEMENT FOR SINGLE HARD FACED (CARBIDE) SEAL AND BACK-UP LIP SEAL
2 PHASE DIAGRAM OF NaOH-H2O
3 VISCOSITY OF AQUEOUS CAUSTIC SODA SOLUTIONS
4 VAPOR PRESSURE OF AQUEOUS CAUSTIC SODA SOLUTIONS
5 ENTHALPY CONCENTRATION FOR AQUEOUS CAUSTIC SODA SOLUTIONS
6 SPECIFIC GRAVITY FOR AQUEOUS CAUSTIC SODA SOLUTIONS
7 DILUTION OF CAUSTIC SODA LIQUOR
8 THERMAL CONDUCTIVITY OF AQUEOUS CAUSTIC SODA SOLUTIONS
9 SPECIFIC HEAT OF CAUSTIC SODA SOLUTIONS
10 BOILING POINTS OF STRONG CAUSTIC SODA SOLUTIONS AT REDUCED PRESSURE
11 COMMENCEMENT OF FREEZING OF CAUSTIC SODA SOLUTIONS (0 - 52% W/W)
12 TEMPERATURES ATTAINED ON DISSOLUTION OF ANHYDROUS CAUSTIC SODA
13 HEAT OF SOLUTION FOR ANHYDROUS CAUSTIC SODA
14 SOLUBILITY OF SODIUM CHLORIDE IN CAUSTIC SODA SOLUTIONS
15 DENSITY - CONCENTRATION TABLES FOR CAUSTIC SODA SOLUTIONS AT 600 F (15.5 0 C)
16 MATERIAL SELECTION CHART FOR CAUSTIC SODA HANDLING
Naphtha Steam Reforming Catalyst Reduction by NH3 CrackingGerard B. Hawkins
Procedure for Naphtha Steam Reforming Catalyst Reduction by NH3 Cracking
Scope
This procedure applies to the in situ reduction of VULCAN Series steam reforming catalysts using ammonia cracking to form hydrogen over the catalyst in the steam reformer. This procedure covers plants with a dry gas circulation loop for reduction. The procedure is likely to be applied to plants using only heavier feeds (e.g.: LPG and/or naphtha) and some combination of VULCAN Series catalysts.
Introduction
A small number of steam reforming plants do not have an available source of the commonly used reducing media (e.g.: hydrogen, hydrogen-rich off-gas, natural gas). These plants will usually operate on LPG and/or naphtha feed only where cracking of this hydrocarbon is not usually advised for reduction of the steam reforming catalyst. In such circumstances, the plant may be designed to use the installed steam reforming catalyst to crack ammonia to provide hydrogen for the reformer catalyst reduction....
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
(AGRU) ACID GAS SOUR SHIFT: CASE STUDY IN REFINERY GAS TREATMENTGerard B. Hawkins
(AGRU) ACID GAS SOUR SHIFT: CASE STUDY IN REFINERY GAS TREATMENT; Case Study: #0978766GB/H
CASE STUDY OVERVIEW
Syn Gas Sour Shift: Process Flow Diagram
AGR: Acid Gas to VULCAN SYSTEMS Sour Gas Shift
DESIGN BASIS:
ACID GAS REACTOR CATALYST SPECIFICATION
SOUR SHIFT CASE
SHIFT REACTOR CATALYST SPECIFICATIONS
COS REACTOR CATALYST SPECIFICATIONS
SWEET SHIFT CASE
SHIFT REACTOR CATALYST SPECIFICATIONS
PERFORMANCE SIMULATION RESULTS
SOUR SHIFT SECTION
1 Cases Considered
2 Catalyst Used
3 Client Requirements
4 Oxygen and Olefins
5 HCN
6 NH3
7 Arsine
8 Input Data Sour Shift Unit
9 Activity (PROPRIETARY)
10 Results
ADIABATIC SWEET SHIFT SECTION: HTS Reactor followed by LTS Reactor
1 Catalyst Used
2 Inlet Operating Temperature HTS Reactor
3 Feed Flow Rate, Inlet Operating Pressure and Feed Composition HTS Reactor
4 Inlet Operating Conditions LTS Reactor
5 Client Requirements
6 Results: Standard Case as Presented to the Client
7 Results: Inlet Operating Pressure HTS Reactor = 25.2 bara
8 Results: Addition of 100 kmol/h N2
COS HYDROLYSIS SECTION FOR SWEET SHIFT CASE
1 Total Feed Flow Rate, Feed Composition, Direction of Flow, Inlet Operating Temperature, Inlet Operating Pressure
2 Inlet H2S and COS Levels
3 Equilibrium H2S and COS Levels (COS Hydrolysis Reaction)
4 Client Requirements
5 Results
H2S REMOVAL SECTION AFTER AGR UNIT
(2 Absorbent Beds (VULCAN VSG-EZ200) in Lead/Lag Arrangement)
1 Total Feed Flow Rate, Feed Composition, Direction of Flow, Inlet Operating Temperature, Inlet Operating Pressure
2 Inlet H2S and COS Levels
3 Client Requirements (All Cases)
4 Results
ISOTHERMAL SWEET SHIFT SECTION: Alternative Approach
VULCAN Simulation Input Data
1 Enthalpy method
2 Cases considered
3 Feed stream data
4 Kinetics
5 Catalyst
6 Catalyst Activity relative to standard
7 Catalyst size and packing details
8 Catalyst pressure drop parameters
9 Catalyst Volume
10 Standard die-off rate
11 BFW Rate
12 Vapor fraction
13 Steam Temperature
14 Steam Pressure
15 Boiling Model
16 Volumetric UA
Isothermal Shift Simulations Results
APPENDIX
Characteristics of Acid Gas Removal Technologies
Introduction
Catalyst breakage is a well known phenomena that occurs during operation and transients such as reformer trips, whether this be due to,
• Normal in service breakage,
• Breakage due to carbon formation/removal,
• Breakage due to steam condensation or carry over,
• Breakage during a trip.
The effect of catalyst breakage can be observed in a number of ways,
• Hot bands,
• Speckling and giraffe necking,
• Catalyst breakage and settling.
Procedure for Steam Reforming Catalyst Reduction with LPG Feed
Scope
This procedure may be used for the reduction of VULCAN Series Catalysts for the general steam reforming of LPG.
It is strongly advised that this procedure is adopted only where there is no other option available to use hydrogen, a hydrogen-rich gas or natural gas for the reduction stage. Reduction using the cracking of heavier hydrocarbons carries an extreme risk of catastrophic carbon formation in the event of any error in execution of the procedure.
Introduction
LPG is not normally utilized for steam reforming catalyst reduction although it can be used successfully. Caution is required if heavier hydrocarbons are used for catalyst reduction. Although operators have been able to reduce catalysts by using heavier hydrocarbon cracking, this has only been adopted where no other reductant option is available. The risk of carbon formation greatly increases as the carbon number of the feed increases when the catalyst is in the unreduced state. For the purposes of this procedure, LPG may range from a hydrocarbon mixture which is predominantly propane to one which is predominantly butane.
SMR PRE-REFORMER DESIGN
Case Study #0618416GB/H
Contents
1. SMR Pre-Reformer Design
2. Inlet Baffle Design
3. Outlet Collector
4. Hold Down Grating
5. Floating Hold Down Screen
6. Catalyst Drop Out Nozzle
7. Thermowell Detail
8. Technical Performance requirements
9. SMR Pre-Reformer Isolation
Technical Review and Commentary on Proposed Design
APPENDIX
A. Operating / Mechanical Data
B. Materials Specifications
C. Fabrication and Inspection Requirements
D. Weights
E. Nozzle Data
F. Instrument Connections
G. Manholes
SYNGAS CONDITIONING UNIT FEASIBILITY CASE STUDY: COAL-TO-LIQUIDSGerard B. Hawkins
SYNGAS CONDITIONING UNIT FEASIBILITY CASE STUDY: COAL-TO-LIQUIDS
Case Study: #0953616GB/H
HT SHIFT REACTOR CATALYST SPECIFICATION
Process Specification
This process duty specification refers to a Syngas Conditioning Unit which utilizes HT Shift reaction technology on a slip stream of raw gas to produce a recombined gas stream with a H2:CO ratio of 1.57:1. This is an important consideration as the Shift reactor is not required to minimize CO at outlet, and this specification refers to the expected performance that can be achieved in a single stage reactor scheme.
The Syngas Conditioning Unit is part of a proposed coal-to-liquids complex in which synthesis gas is produced by gasification of coal for downstream processing in a Fischer Tropsch reactor and Hydrocracker unit.
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
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
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
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
Physical Properties for Heat Exchanger Design
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 COMPONENT PROPERTIES
4.1 General
4.2 Use of Component Properties for Mixtures
5 INPUT OF MIXTURE CURVES
5.1 General
5.2 Generation of the Mixture Curves
5.3 Selection of Temperature Points
5.4 Extrapolation
6 IMMISCIBLE CONDENSATES
FIGURES
1 TEMPERATURE POINTS SELECTED FOR EQUAL ENTHALPY CHANGE
2 TEMPERATURE POINTS SELECTED FOR GOOD
FIT TO CURVE
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
Selection of Heat Exchanger Types
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 BACKGROUND
5 FACTORS INFLUENCING SELECTION
5.1 Type of Duty
5.2 Temperatures and Pressures
5.3 Materials of Construction 5.4 Fouling
5.5 Safety and Reliability
5.6 Repairs
5.7 Design Methods
5.8 Dimensions and Weight
5.9 Cost
5.10 GBHE Experience
6 TYPES OF EXCHANGER
6.1 Shell and Tube Exchangers
6.2 Cylindrical Graphite Block Heat Exchangers
6.3 Cubic Graphite Block Heat Exchangers
6.4 Air Cooled Heat Exchangers
6.5 Gasketed Plate and Frame
6.6 Spiral Plate
6.7 Tube in Duct
6.8 Plate-fin
6.9 Printed Circuit Heat Exchanger (PCHE)
6.10 Scraped Surface/Wiped Film Exchangers
6.11 Welded or Brazed Plate
6.12 Double Pipe
6.13 Electric Heaters
6.14 Fired Process Heaters
TABLE
(1) ADVANTAGES AND DISADVANTAGES OF DIFFERENT SHELL AND TUBE DESIGNS
FIGURES
1 ESTIMATED MAIN PLANT ITEM COSTS
2 ESTIMATED INSTALLED COSTS
3 TEMA HEAT EXCHANGER NOMENCLATURE
4 F ‘CORRECTION FACTORS' : TEMA E SHELL WITH EVEN NUMBER OF PASSE
5 SHELL AND TUBE HEAT EXCHANGER HEAD TYPES
6 GENERAL ARRANGEMENT OF A CYLINDRICAL GRAPHITE BLOCK HEAT EXCHANGER
7 EXPLODED VIEW OF A CUBIC GRAPHITE BLOCK
HEAT EXCHANGER
8 TYPICAL AIR COOLED HEAT EXCHANGER
9 GENERAL VIEW OF ONE END OF A 3-STREAM
PLATE-FIN HEAT EXCHANGER
10 TYPICAL PCHE PLATE
11 VICARB ‘COMPABLOC' EXCHANGER
12 ‘BROWN FINTUBE' MULTITUBE HEAT EXCHANGER
13 FIRED HEATER : SCHEMATICS AND NOMENCLATURE
The Preliminary Choice of Fan or Compressor
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 METHOD FOR PRELIMINARY SELECTION
OF COMPRESSOR
5 PROCESS DATA SHEET
5.1 Essential Data for the Completion of a
Process Data Sheet
5.2 Gas Properties
5.3 Discharge Requirements
6 PRELIMINARY CHOICE OF FAN AND
COMPRESSOR TYPE
6.1 Essential Data for Preliminary Selection
7 FAN AND COMPRESSOR APPLICATIONS
7.1 Fans
7.2 Centrifugal Compressors
7.3 Axial Compressors
7.4 Reciprocating Compressors
7.5 Screw Compressors
7.6 Positive Displacement Blowers
7.7 Sliding Vane Compressors
7.8 Liquid Ring Compressors
8 PROVISION OF INSTALLED SPARES
9 PRELIMINARY ESTIMATE OF COSTS
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.
Integration of Special Purpose Centrifugal Fans into a ProcessGerard B. Hawkins
Integration of Special Purpose Centrifugal Fans into a Process
0 INTRODUCTION
1 SCOPE
2 NOTATION
3 PRELIMINARY CHOICE OF NUMBER OF FANS
3.1 Volume Flow Q o
3.2 Definitions
3.3 Estimate of Equivalent Pressure Rise Δ P e
3.4 Choice of Fan Type
3.5 Choice of Control Method
4 GAS DENSITY CONSIDERATIONS
4.1 Calculation of Inlet Pressure
4.2 Calculation of Gas Density
4.3 Atmospheric Air Conditions
5 CAPACITY AND PRESSURE RISE RATING
5.1 Calculation of Fan Capacity
5.2 Calculation of Fan Pressure Rise
5.3 Multiple Duty Points
5.4 Stability
5.5 Parallel Operation
6 GUIDE TO FAN SELECTION
6.1 Effect of Gas Contaminants
6.2 Selection of Blade Type
6.3 Selection of Rotational Speed
6.4 Wind milling and Slowroll
6.5 Estimate of Fan External Dimensions
7 POWER RATING
7.1 Estimate of Fan Efficiency
7.2 Calculation of Absorbed Power
7.3 Calculation of Driver Power Rating
7.4 Motor Power Ratings
7.5 Starting Conditions for Electric Motors
8 CASING PRESSURE RATING
8.1 Calculation of Maximum Inlet Pressure ΔP i max
8.2 Calculation of Maximum Pressure Rise Δ P s max
8.3 Calculation of Casing Test Pressure
8.4 Rating for Explosion
9 NOISE RATING
9.1 Estimate of Fan Sound Power Rating LR
9.2 Acceptable Sound Power Level LW
9.3 Acceptable Sound Pressure Level L p
9.4 Assessment of Silencing Requirements
APPENDICES
A RELIABILITY CLASSIFICATION
B FAN LAWS
FIGURES
3.4 GUIDE TO FAN TYPE
4.5 VARIATION OF AIR DENSITY WITH TEMPERATURE AND ALTITUDE
6.3.1 DUTY BOUNDARY FOR SINGLE - INLET IMPELLERS
6.3.3 RELATIONSHIP BETWEEN HEAD COEFFICIENT AND SPECIFIC SIZE
6.3.6 ROTATIONAL SPEEDS FOR FAN IMPELLERS WITH BACK SWEPT VANES
6.3.7 ROTATIONAL SPEED FOR FAN IMPELLERS WITH RADIAL VANES
6.3.8 RELATIONSHIP OF IMPELLER TIP SPEED TO SHAPE
6.3.9 BOUNDARY DEFINING ARDUOUS DUTY
7.1 NOMOGRAPH FOR ESTIMATING THE EFFICIENCY OF A SINGLE STAGE FAN
7.2 GRAPH: COEFFICIENT OF COMPRESSIBILITY vs PRESSURE RATIO
7.5 GRAPH: MOMENT OF INERTIA OF FAN AND MOTOR (wR2) vs kW
VLE Data - Selection and Use
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 DIAGRAMMATIC REPRESENTATION OF IDEAL
AND NON-IDEAL SYSTEMS
4.1 Ideal Mixtures
4.2 Non-Ideal Mixtures
5 REVIEW OF VLE MODELS
5.1 Ideal Behavior in Both Phases
5.2 Liquid Phase Non-Idealities
5.3 High Pressure Systems
5.4 Special Models
6 SETTING UP A VLE MODEL
6.1 Define Problem
6.2 Select Data
6.3 Select Correlation(s)
6.4 Produce Model
7 AVOIDING PITFALLS
7.1 Experimental Data is Better than Estimates
7.2 Check Validity of Fitted Model
7.3 Check Limitations of Estimation Methods
7.4 Know Your System
7.5 Appreciate Errors and Effects
7.6 If in Doubt – Ask
8 A CASE STUDY
8.1 The Problem
8.2 The System
8.3 Data Available
8.4 Selected Correlation
8.5 Simulation
8.6 Selection of Model
9 RECOMMENDED READING
10 VLE EXPERTS IN GBHE
APPENDICES
A USE OF EXTENDED ANTOINE EQUATION
B USE OF WILSON EQUATION
C USEFUL METHODS OF ESTIMATING
D EQUATIONS OF STATE FOR VLE CALCULATIONS
TABLES
1 SUMMARY OF VLE METHODS
2 LIST OF USEFUL REFERENCES
FIGURES
1 VAPOR-LIQUID EQUILIBRIUM - IDEAL SOLUTION
BEHAVIOR
2 VAPOR-LIQUID EQUILIBRIUM - A GENERALISED
Y-X DIAGRAM
3 VAPOR-LIQUID EQUILIBRIUM - MINIMUM BOILING
AZEOTROPE
4 VAPOR-LIQUID EQUILIBRIUM - MAXIMUM BOILING
AZEOTROPE
5 VAPOR-LIQUID EQUILIBRIUM - MINIMUM BOILING
AZEOTROPE -TWO LIQUID PHASES
6 SENSITIVITY TO ERROR IN VLE DATA (BASED ON FENSKE EQUATION)
7(a) FITTING WILSON 'A' VALUES TO VLE DATA - CASE A
7(b) FITTING WILSON 'A' VALUES TO VLE DATA - CASE B
7(c) FITTING WILSON 'A' VALUES TO VLE DATA - CASE C
Fluid Separation
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 A SEPARATION LOGIC TREE
5 METHODS OF DISTILLATION
5.1 Fractional Distillation
5.2 Azeotropic Distillation
5.3 Extractive Distillation
6 LIQUID-LIQUID EXTRACTION
7 OTHER COMMERCIAL METHODS OF SEPARATION
7.1 Adsorption
7.2 Fractional Crystallization
7.3 Ion Exchange
7.4 Membrane Processes
7.4.1 Ultrafiltration
7.4.2 Reverse Osmosis
7.4.3 Pervaporation
7.4.4 Liquid Membranes
7.4.5 Gas Permeation
7.4.6 Dialysis
7.4.7 Electrodialysis
7.5 Supercritical Fluid Extraction
7.6 Dissociation Extraction
7.7 Foam Fractionation
7.8 Clathration
7.9 Chromatography
8. OTHER METHODS OF SEPARATION
8.1 Precipitation
8.2 Paper Chromatography
8.3 Ligand Specific Chromatography
8.4 Electrophoresis
8.5 Isoelectric Focusing
8.6 Thermal Diffusion
8.7 Sedimentation Ultracentrifugation
8.8 Isopycnic Ultracentrifugation
8.9 Molecular Distillation
8.10 Gel Filtration
APPENDICES
A AT A GLANCE CHART BASED ON FENSKE, UNDERWOOD
B A GENERALIZED y - x DIAGRAM
C TEMPERATURE - COMPOSITION DIAGRAMS FOR
AZEOTROPIC MIXTURES
D A TYPICAL y - x DIAGRAM FOR EXTRACTIVE DISTILLATION (SOLVENT FREE BASIS)
E RAPID ESTIMATION OF LIQUID-LIQUID EXTRACTION REQUIREMENTS
F LIQUID - LIQUID EXTRACTION - THE USE OF EXTRACT REFLUX
G SELECTIVITIES REQUIRED FOR EQUAL PLANT COSTS
FIGURE
1 SEPARATION LOGIC TREE
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
Integration of Reciprocating Metering Pumps Into A ProcessGerard B. Hawkins
Integration of Reciprocating Metering Pumps into a Process
Engineering Design Guide
1 SCOPE
2 PRELIMINARY CHOICE OF PUMP
SECTION A - TYPE/FLOW/PRESSURE/SPEED RATING
Al Pumping Pressure
A2 Pump Flowrate and Capacity
A3 Guide to Pump Speed & Type
A4 Metering Criteria
A5 Pressure Pulsation
A6 Over Delivery
SECTION B - INLET CONDITIONS
B1 Calculation of Basic NPSH
B2 Correction for Frictional Head
B3 Correction for Acceleration Head
B4 Calculation of Available NPSH
B5 Corrections to NPSH for Fluid Properties
B6 Estimation of NPSH Required
B7 Priming
SECTION C - POWER RATING
C1 Pump Efficiency
C2 Calculation of Absorbed Power
C3 Determination of Driver Power Rating
SECTION D - CASING PRESSURE RATING
Dl Calculation of Maximum Discharge Pressure
D2 Discharge Pressure Relief Rating
D3 Calculation of Pump Head Outlet Losses
D4 Casing Hydrostatic Test Pressure
APPENDICES
A RELIABILITY CLASSIFICATION
FIGURES
A3.1 ESTIMATE OF CRANK SPEED
A3.3 SELECTION OF PUMPING HEAD TYPE
B5.1 ESTIMATE OF VISCOSITY OF FINE SUSPENSIONS
B6 ESTIMATE OF NPSH REQUIRED
C1.1 GRAPH - VOLUMETRIC EFFICIENCY VS MEAN DIFFERENTIAL PRESSURE
Shortcut Methods of Distillation Design
0 INTRODUCTION/PURPOSE
1 SCOPE
2 ESTIMATIONOF PLATEAGE AND REFLUX
REQUIREMENTS
2.1 Generalized Procedure for Nmin and Rmin
2.2 Equation based Procedure for Nmin and Rmin
3 PREDICTION OF OVERALL PLATE EFFICIENCY
4 SIZING OF MAIN PLANT ITEMS
4.1 Column Diameter
4.2 Surface Area of Condensers and Reboilers
FIGURES
1 NON-IDEAL EQUILIBRIUM CURVE
2 AT A GLANCE CHART BASED ON FENSKE,
UNDERWOOD
3 PLATE EFFICIENCY CORRELATION OF O’CONNEL
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
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
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
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
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
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.
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State of ICS and IoT Cyber Threat Landscape Report 2024 previewPrayukth K V
The IoT and OT threat landscape report has been prepared by the Threat Research Team at Sectrio using data from Sectrio, cyber threat intelligence farming facilities spread across over 85 cities around the world. In addition, Sectrio also runs AI-based advanced threat and payload engagement facilities that serve as sinks to attract and engage sophisticated threat actors, and newer malware including new variants and latent threats that are at an earlier stage of development.
The latest edition of the OT/ICS and IoT security Threat Landscape Report 2024 also covers:
State of global ICS asset and network exposure
Sectoral targets and attacks as well as the cost of ransom
Global APT activity, AI usage, actor and tactic profiles, and implications
Rise in volumes of AI-powered cyberattacks
Major cyber events in 2024
Malware and malicious payload trends
Cyberattack types and targets
Vulnerability exploit attempts on CVEs
Attacks on counties – USA
Expansion of bot farms – how, where, and why
In-depth analysis of the cyber threat landscape across North America, South America, Europe, APAC, and the Middle East
Why are attacks on smart factories rising?
Cyber risk predictions
Axis of attacks – Europe
Systemic attacks in the Middle East
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https://sectrio.com/resources/ot-threat-landscape-reports/sectrio-releases-ot-ics-and-iot-security-threat-landscape-report-2024/
Connector Corner: Automate dynamic content and events by pushing a buttonDianaGray10
Here is something new! In our next Connector Corner webinar, we will demonstrate how you can use a single workflow to:
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Send an interactive Slack channel message (using buttons)
Have the message received by managers and peers along with a test email for review
But there’s more:
In a second workflow supporting the same use case, you’ll see:
Your campaign sent to target colleagues for approval
If the “Approve” button is clicked, a Jira/Zendesk ticket is created for the marketing design team
But—if the “Reject” button is pushed, colleagues will be alerted via Slack message
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And...
Speakers:
Akshay Agnihotri, Product Manager
Charlie Greenberg, Host
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LF Energy Webinar: Electrical Grid Modelling and Simulation Through PowSyBl -...DanBrown980551
Do you want to learn how to model and simulate an electrical network from scratch in under an hour?
Then welcome to this PowSyBl workshop, hosted by Rte, the French Transmission System Operator (TSO)!
During the webinar, you will discover the PowSyBl ecosystem as well as handle and study an electrical network through an interactive Python notebook.
PowSyBl is an open source project hosted by LF Energy, which offers a comprehensive set of features for electrical grid modelling and simulation. Among other advanced features, PowSyBl provides:
- A fully editable and extendable library for grid component modelling;
- Visualization tools to display your network;
- Grid simulation tools, such as power flows, security analyses (with or without remedial actions) and sensitivity analyses;
The framework is mostly written in Java, with a Python binding so that Python developers can access PowSyBl functionalities as well.
What you will learn during the webinar:
- For beginners: discover PowSyBl's functionalities through a quick general presentation and the notebook, without needing any expert coding skills;
- For advanced developers: master the skills to efficiently apply PowSyBl functionalities to your real-world scenarios.
Key Trends Shaping the Future of Infrastructure.pdfCheryl Hung
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This video focuses on the notifications, alerts, and approval requests using Slack for Bonterra Impact Management. The solutions covered in this webinar can also be deployed for Microsoft Teams.
Interested in deploying notification automations for Bonterra Impact Management? Contact us at sales@sidekicksolutionsllc.com to discuss next steps.
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Study 3: Detailed Design Hazards
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-040
Study 3: Detailed Design Hazards
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 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
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
3.0 PURPOSE
Hazard Study 3 involves a detailed review of a firm design aimed at the
identification of hazard and operability problems. Relief and blowdown studies,
area classification, personal protection and manual handling may, if appropriate,
be included at this stage.
This study is a conventional hazard and operability study or ’HAZOP’ carried out
using guidewords. In the case of process plant, this study will be based on a firm
Piping and Instrument Line Diagram (P&ID). Outline operating procedures and
outline commissioning procedures should if at all possible be available for the
study. The consequences of deviations are identified and, where necessary,
appropriate corrective actions initiated. The study also provides an opportunity to
review potential maintenance and product quality issues.
The GBHE Hazard Study 3 is the ’HAZOP’ technique as referred to in US
Federal Legislation on Major Hazard Plants, OSHA 29CFR Part 1910.119
Process Safety Management of Highly Hazardous Chemicals and specified in the
AIChE, Centre for Chemical Process Safety ’Guidelines for Hazard Evaluation
Procedures’.
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’ (available from CCPS)
3.0.1 Team
The 'HAZOP: Guide to best practice' book gives advice on appointing a Hazard
Study Team Leader as well as assistance in selecting the team size and
membership. The team composition should be agreed between the Hazard Study
Leader and the Project Manager.
3.0.2 Timing
Process Hazard Study 3 is best carried out when a firm reviewed Piping and
Instrumentation Diagram or Engineering Line Diagram together with outline
operating, commissioning, maintenance and test procedures is available. Hazard
Study 2 for the relevant section with its actions/recommendations should be
complete as far as is practicable.
4. 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
If required for Programmable Electronic Systems (PES), Hazard Study 3 is best
carried out when the PES system design is at an advanced stage but not
necessarily complete (see Hazard Study 2, section 2.2).
Most major design decisions should have been taken.
5. 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
3.0.3 Preparation
The ’HAZOP: Guide to best practice’ book, chapter 5.3, gives details of the
preparation to be carried out and the information required for a study to begin.
Additional information is given below.
For the study of batch and continuous processes the following should be
available (if applicable):
(a) A firm reviewed Piping and Instrument Diagram (P&ID) or Engineering
Line Diagram (ELD).
(b) Outline operating, commissioning, maintenance and test procedures in so
far as these are not obvious from the design.
(c) Actions/recommendations from Hazard Study 2 should be completed as
far as is practicable.).
(d) Classification of the ’type’ and ’grading’ of alarm and trip systems as
described in GBHE_PSG_EP_3. It would be advantageous to have
preliminary trip logic diagrams available prior to Hazard study 3. Additional
critical safety instrumented systems may be identified in the study.
(e) Area electrical classification drawings where zoned areas have been
identified.
(f) Relief systems philosophy.
(g) A list of vessels and pipework to be registered as requiring Periodic
Inspection (see GBHE_PSG_EP_4) may be provided, but this list is not
essential. In any case this list will be updated as a result of the Hazard
Study 3.
(h) A list of Critical Machine Systems (see GBHE_PSG_EP_5) may be
provided, but this list is not essential. In any case this list will be updated
as a result of the Hazard Study 3.
(j) DCS input/output allocation philosophy if applicable.
6. 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
In addition, for Batch processes a full sequence description is required.
It is important to check that the documentation, e.g. line diagrams, to be studied
is acceptable to the Site.
For Hazard Study 3 of Programmable Electronic Systems the following should be
available:
(1) Specifications.
(2) Configuration diagrams.
(3) Block diagram representation.
(4) Input/output card signal allocation.
System manuals will be useful. The responsibility for input/output card allocation
checks and line for line software (sequence) checks lies with the design engineer
and not with the study 3 team. The Hazard Study 3 should verify that these
responsibilities have been accepted and performed.
Outline operating and maintenance procedures/instructions are important
requirements for the study. These may be refined during the study. The retrieval
of hazard study notes and drawings, relevant at the time of study, should be
facilitated by appropriate referencing and filing because future modifications may
well necessitate recovery of the original detailed design philosophy.
There needs to be a plan for review meetings (for actions and recommendations
raised).
3.0.4 Documentation
Documentation, in the form of the record of the Hazard Study meetings, and
supporting documents together with evidence of the completion of all actions
should be filed in the Project SSHE Dossier (worksheet j). It is important that
drawings and records of the equipment studied, marked up P&IDs used in the
study, are also retained in the Project SHE Dossier together with the Hazard
Study records.
Meeting records for circulation should include copies of the P&ID(s).
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The Project Manager should ensure that project documentation, area
classification, relief philosophy, vessel or piping and critical machine registration
are updated after the study.
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HAZARD STUDY 3: APPLICATION
The following sections 3.1 to 3.12 give further detailed information on the use of
the various Hazard Study 3 checklists and worksheets.
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3.1 CONTINUOUS PROCESSES
It is generally obvious when the Continuous Process Guide
Diagram (appendix A) should be used (i.e. for a steadily
operating continuous process that is on line for a significant
period of time). In some cases the choice is not so clear,
e.g. the feeding of chlorine to a batch reactor over an
extended period from a 1 ton drum or the offloading of a
tanker (tank truck). In such cases the Hazard Study Leader
shall decide if a more productive study will result from the
continuous or the batch checklists. Typical of the things to consider include which
is more important – the rate at which the substance is added or the total quantity
of the substance added.
Studies of continuous chemical processes are carried out in a series of meetings
where P&IDs are examined, line by line, vessel by vessel, using a list of
guidewords to stimulate the Hazard Study team's consideration of all conceivable
deviations from design intent.
The detailed examination of cause and effect of deviations in both normal and
abnormal plant operation is designed to minimize problems at commissioning
and start-up, and to ensure continued safe and reliable operation of the plant.
This systematic study of design detail should identify areas of concern which can,
if necessary, be resolved outside the hazard study meeting.
The guidewords listed in appendix A are considered systematically by the team
of mixed disciplines, led by the trained Hazard Study Leader. The process lines
and vessels examined are marked on the P&ID and listed on the record
worksheet (worksheet n). The Hazard Study Leader is responsible for ensuring
the Hazard Study records are of a satisfactory quality. Should the cause and
effect of a deviation (e.g. low flow) cause no hazard, environmental, health,
operability or quality problems then no comment may be needed in the summary
on the worksheet. It will be assumed that 'deviations' excluded from the standard
list of guidewords have been considered but dismissed and their exclusion from
the worksheet summary is not an oversight, but in the interest of brevity and
team efficiency. In the USA however, full recording is recommended.
Continuous processes also entail discontinuous operations (e.g. start-up,
controlled shutdown, emergency shutdown). These should be treated in a similar
fashion as batch processes.
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Should potential problems be identified, then a record of the preventative or
corrective measures designed to minimize the likelihood and consequences
should be specified. Any further action should be noted and progressed outside
the meeting. Where extensive discussions are held, these should also be
recorded even if they have not lead to identification of a hazard.
Should the Hazard Study 3 call into question the fundamental rationale of the
hazard control measures agreed at Hazard Study 2, then it is the responsibility of
the Project Manager (or nominee) to ensure that the Hazard Study 2 report is
updated. In some countries this may be a legal requirement (e.g. SEVESO
directive).
3.2 BATCH PROCESSES
It is generally clear when the batch process method and
guide diagram (appendix B) should be used, but grey areas
shall be handled in accordance with the Hazard Study
Leader’s judgment.
The general characteristics of batch plants as compared with
continuous plants are as follows:
(a) The status of the various parts of the plants are changing cyclically with
respect to time, and therefore a line diagram alone gives a very
incomplete picture.
(b) The processes are usually multistage and the individual units
multipurpose. For example, in a chemical reactor the process steps could
involve:
(1) Charge solvent;
(2) Charge reactants;
(3) Heat to reaction temperature;
(4) Control at reaction temperature for the required period;
(5) Add final components at controlled rate;
(6) Cool down products to discharge temperature;
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(7) Discharge.
Batch reactions are prone to special problems if the process is exothermic or can
produce gas. Excessive temperature and/or pressure may be developed without
careful control of the progress of reaction.
Two methods of control are commonly used:
(i) In ’all-in’ reactions, all reactants are charged and reaction is
completed by subjecting the mixture to an appropriate
temperature/pressure program. Control may be lost if cooling fails
during an exothermic phase or if the effects of scale-up are not
taken into account.
(ii) In ’progressive addition’ reactions, a key reactant is charged under
conditions that will ensure rapid consumption. Accumulation due to
inappropriate temperature, poor mixing or other reasons is a
common cause of hazard.
The latter technique is preferred, where practicable, for potentially
hazardous batch reactions.
(c) Batch plants are often multi-product, and reaction units usually have to be
cleaned out and modified when changing from one product to another.
(d) From the comments above it will be clear that there can be several ’norms’
for batch plants. At the very least there will be two:
(1) an ’active’ state when the item is in use; and
(2) an ’inactive’ state when the item is not in use.
This is in contrast to a continuous plant where, when in steady state
operation, a fixed ’norm’ in terms of flow, pressure, temperature etc. can
be defined for each and every part of the plant.
(e) Operators may take part in some of the process activities such as
charging material from drums or removing product from filters. Even well
trained and well-motivated operators will make occasional mistakes.
During the study the question should be asked "How often will an operator make
a mistake?" and not "If an operator makes a mistake ...". If the consequences are
serious the possibility of error should be designed out.
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For the purpose of the hazard study it will be necessary to know the sequence of
process operations in addition to having a P&ID, which describe the plant. The
sequence can be in a variety of formats, usually a process summary (such as a
batch master print-out), but could be a logic diagram, dot chart or sequence
flow chart. With complicated or proprietary items of equipment a considerable
amount of preparatory work may be necessary before the study.
The detailed sequence of the examination is shown in appendix B.1.
The approach usually adopted in a hazard and operability study of a batch
process is to apply the guidewords initially (see appendices B.2 & B.3) to each
step of the process. Applied to a vessel such as a reactor this would lead to the
examination of various lines which could then be marked off on the line
diagram as having been examined.
Other lines not identified with a normal process step (e.g., relief lines, vents,
etc.), would then be examined before moving on to the next major item of
equipment.
Significant points to bear in mind in the study of a batch process are:
(1) Multipurpose lines will have more than one ’normal’ state and each should
be examined.
(2) Services, e.g. heating/cooling systems, can be examined in detail at the
heating/cooling step or can be ’mopped up’ before the process sequence
moves on to another vessel.
(3) The omission of one or more steps in the process is not uncommon and
the consequences of such possible mal-operations need to be examined.
(4) In batch processes Quantity is a critical parameter. More of quantity
should always address the possibility of a double charge, which is a
common error.
(5) For many process steps only the first guideword (NO/NOT) will be
relevant. If the operation is to ’check vessel empty’, then it either is or isn’t
(though various causes may be identified for the not empty condition).
(6) In multiproduct plants, the first and last batches of a campaign are
different and need to be treated as such.
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Problems can include:
(i) The need to check that vessels are empty.
(ii) Water contamination of the first batch of a campaign.
(iii) The handling of recycled materials and heels.
(iv) The defeat of instrumented trips to start the first batch of a campaign.
The checklist given in appendix B.2 handles quantities of substances well and is
analogous to the flow guidewords (high flow, low flow, no flow, reverse flow, etc.).
However, there are other considerations such as changes in physical conditions,
start-up and shutdown conditions, registered equipment (critical and controlled),
mechanical integrity, effluents and emergencies. Of particular concern to a batch
process are the effects of agitation failure and temperature deviations.
These could be handled by applying the batch checklist to them. However, use of
the relevant sections of the continuous checklist in appendix A is probably more
convenient.
Lastly, it is worth stressing that a deviation in one part of a batch process
sequence, or at a particular time, may not necessarily result in a hazard at that
time or place, but may manifest itself elsewhere or later.
With batch processes it may be more appropriate to examine the various stages
in the process, from approval of the recipe through the batch cycle to discharge
and decontamination.
3.3 MECHANICAL HANDLING OPERATIONS
In Hazard Study 2, significant hazards of Mechanical
Handling relate to moving objects/equipment, where
inadequate control can lead to serious injury by virtue of
stored potential or kinetic energy (e.g. mixing equipment,
palletizers, conveyors, rail shunting, etc.) should have been
identified.
For the more detailed Hazard Study 3, the guide diagram in appendix C should
be used.
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Packaged units are a common feature in mechanical handling equipment and
’loss of control’ is a foreseeable failure mechanism. The majority of packaged
units are delivered with control units fitted as standard off-the-shelf items - not
always compatible with business purchasing specifications and increasingly
involving programmable microprocessors.
In most cases, it is advantageous to study the interface between such units and
the chemical plant because of the hostile environment, site specific service
constraints and significance of unit failure for the chemical process (e.g. chemical
may solidify if the unit stops). In particular, hazards can arise when electrical
isolation of drives is not independent from associated control/interlock circuits.
One of the main problems in using packaged units is the lack of readily available
information on control circuits and operating function. However, it is suggested
that appendix C will promote useful dialogue with the supplier before the units
arrive on site unsuitable for demanding duties in often novel chemical processes
where routine maintenance and testing have not been addressed.
Guidance on packing lines is included in GBHE-PGP-005 (Specialist
Techniques).
3.4 MAINTENANCE AND OPERATING PROCEDURES
A selective detailed examination of maintenance, operating, start-up
and shutdown procedures may be valuable for moderate to high
hazard operations, to which any of the following apply:
(a) They are largely manual.
(b) Many of the preventative measures are procedural.
(c) Human error has been identified as the cause of a significant number of
undesirable deviations at Hazard Study 2 or 3,
The guide diagram in appendix D.1 may be used for the examination.
Consideration should be given to the initial state of the plant. Should the state be
different from that expected, the action required and/or consequences expected
should be considered and recorded. Where potential events are caused by
operator error then the cause should be stated as operator error.
In selected cases, the hazard study team may wish to use a more detailed
process given in appendix D.2 to examine operating/maintenance procedures
(e.g. reactor start-up). Consideration should be given to the initial state of the
plant.
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Should the state be different from that expected, the action required and/or
consequences expected should be considered and recorded. Where potential
events are caused by operator error then the cause should be stated as operator
error.
3.5 PROGRAMMABLE ELECTRONIC SYSTEMS
Programmable electronic systems should be studied when:
(a) It is a regulatory requirement.
(b) It is part of a safety instrumented system (see
GBHE_PSG_EP_3, where a failure of a critical
system could lead to an unacceptable situation).
Other programmable electronic systems need not be studied.
A programmable electronic system is different from the process units or other
activities in that the PES, itself, has only limited ability to be a direct hazard, e.g.
damage to an operator’s health due to poor ergonomics, electrocution etc. The
main concern is the ability to initiate hazards in the plant or its inability to correct
and avert dangerous process events. The effect of partial or complete PES
failure should be considered when studying the process (i.e. P&IDs). The PES
hazard study is thus directed to understanding, reducing or eliminating PES
failures.
There are some basic problems in applying a conventional Hazard Study 3 line
by line deviation analysis to PES. The complexities of systems involving software
means that rigorous studies are not possible. Any analytical study of a system
involving software will take an impossibly long time. It may be practical and
important to study some of the critical logic flows using the deviation guideword
system (see appendix E.1).
Studies of PESs are best approached with block diagram representations (see
appendix E.2) of the equipment within defined cut points. The interfaces between
each item of equipment can be systematically examined. Identify the hardware
and software features of the system and conduct a Failure Modes and Effects
Analysis (FMEA). This type of analysis is better suited to the nature of a PES and
to the knowledge that the design team will have of the PES.
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3.6 FAILURE MODES AND EFFECTS ANALYSIS (FMEA)
FOR PROGRAMMABLE ELECTRONIC SYSTEMS
Failure Mode and Effect Analysis (FMEA) is most effective for
mechanical and electrical systems such as packing lines,
electrical distribution systems and programmable electronic
systems (PES) (see appendix F.1).
An FMEA considers each part of the PES and asks how can it
fail (mode) and what will the effect be (effect). It then goes on
to ask ’how is the operator made aware?’ and ’What diagnostic or corrective
measures are present?’
The failure mode describes how the equipment fails (open, closed, on, off, leaks,
etc.). The effect of the failure mode is determined by the system’s response to
the equipment failure. An FMEA identifies single failure modes that either directly
result in or contribute to a hazardous situation. Human errors are not usually
examined directly in an FMEA; however the effects of a mis-operation as a result
of human error are usually indicated by an equipment failure mode.
An FMEA is not efficient for identifying an exhaustive list of combinations of
equipment failures that lead to accidents.
The best approach is to start by looking at each type of input signal starting with
the measuring device. In addition to failures, intermittent failures, partial failures
and recovery from failure should be considered. Then consider each type of
output signal and then the identifiable functions of the PES.
Some advice:
(a) Duplicated hardware is a common approach by the suppliers to a
requirement for increased reliability. Their calculations of reliability rates
for duplicate systems are of little value as they usually ignore dependency
(i.e. common cause and common mode errors). The operation and
resetting of duplicate systems should be studied.
(b) Multi-channel cards have a number of different failure modes that should
all be identified. The allocation of signals to cards should be a joint
Control/Electrical and Process activity.
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(c) The DCS system software is beyond the scope of this study. It is
recommended that a statement about the supplier’s quality design system
and their internal or external auditing is obtained.
(d) The features of one supplier’s DCS or PLC may be similar so information
should be sought from previous studies. This can mean that there is no
need to invite a representative from the manufacturer to the study.
(e) There will be many power supplies, most of which will be duplicated for
reliability. All power and utilities failures should be alarmed in a way that
the operator will be aware.
(f) All identified system failures will probably be alarmed to the operator by a
message. These messages are likely to be infrequent and not immediately
understandable. How will the operator respond to these error messages,
who will he contact, and what level of training will they have been given?
(g) Connection to a network or any form of remote communications
introduces security problems due to inadvertent or deliberate contact. The
protection against unwanted access will probably be software based, the
protection means needs to be identified and a periodic test needs to be
defined to demonstrate that the protection is still effective.
(h) PES systems can easily produce an overload of alarms. In the event of a
plant upset, the operator may be faced with hundreds of alarms and miss
a critical alarm in a sea of trivia. Alarms should be prioritized.
Recording may be on a conventional Hazard Study 3 worksheet (worksheet n),
or on the specific FMEA Action List (worksheet p).
Advanced Control Systems can be studied using these techniques but such a
study will not address the control actions that an ACS is capable of taking.
The failure mode guidewords in appendix F.2 have been used on some projects
to prompt detailed consideration of the failure modes of modern PLC type control
systems and, whilst capable of further refinement, the approach does encourage
a structured examination of each key unit in the control loop (e.g. DP cell, P/I,
controller/computer, I/P, control valve). Many new instruments contain PLCs (DP
cells, density meters, controllers etc.) and their failure modes can be very
different from conventional instruments (e.g. loss of input can default, such that
automatic control reverts to manual without any audible alarm).
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Such novel failure mechanisms can only be revealed by lateral consideration of
cause/effect deviations in input/output circuitry and software programs. In
particular, the wider implications of dependency or common mode failure should
be addressed.
The statement on the initial state of the plant implies an inspection, against a
checklist, by the operator. It seems prudent to enquire what may happen if the
operator finds any part of the plant in other than the required state and takes
steps to correct the state, for example, he opens a closed valve which should
have been open before starting the procedure detailed.
3.7 ELECTRICAL SYSTEMS
Consideration should be given to the hazard studying of Electrical
Distribution Systems whose failure will give rise to a hazardous
situation as identified in the emergencies section of a process or
other Hazard Study 3 checklist, as or when higher than normal
reliability is required for other safety or economic reasons.
On electrical systems, a one-line diagram or a block diagram
representation should be examined systematically to identify novel failure
mechanisms only revealed by creative thinking about cause/effect deviations in
input/output circuitry and software programming.
An electrical systems guide diagram is given in appendix G.
3.8 BUILDINGS
In Hazard Study 2, consideration will have been given to the
physical layout of buildings and to the containment of noxious and
harmful substances and the ’top events’ such as fire, explosion,
pollution, etc. At this later stage in the project it is often useful to use
the Hazard Study 3 techniques (see appendix H) to ensure that
there is also a clear understanding of non-SHE items (e.g. the
detailed operating and maintenance aspects) which will be
fundamental to the satisfactory performance of the building.
This is of particular importance when considering novel techniques and/or
systems to be incorporated in the project.
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Factors worthy of further consideration should be highlighted, judged on the
degree of novelty or uncertainty attached to them, and/or on the impact their non-
conformance will have on the final operation of the project.
These factors should be listed and the Hazard Study Leader should then select
the most appropriate form of study normally selected from the previous methods
to examine, for example drains, ventilation systems, etc.
HAZCON and HAZDEM have been developed for construction and demolition
activities.
3.9 OTHER STUDIES
The engineering function should produce or update electrical
area classification drawings (see Hazard Study 1, appendix C,
Additional Assessments) where zoned areas have been
identified during the Hazard Study 2 and 3 stages of a project.
It is the Project Manager’s responsibility to ensure that the
project conforms with local fire codes and to GBHE
Responsible Care Management System (RCMS).
3.10 OTHER RELATED TOOLS
The use of Fault Trees is a specialized technique for hazard
evaluation rather than hazard identification. It is a whole new topic
requiring special skills, so further information on it is given in the
documentation on Quantified Risk Assessment.
3.11 HUMAN FACTORS
A Human Factors Study is a requirement under the US Process
Safety Management legislation 29 CFR 1910.119 for the
Manufacture of Highly Hazardous Chemicals and is recommended
for use elsewhere. It focuses on the factors that are likely to cause
or avoid human error in process operations. (worksheet q).
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3.12 REVIEW OF HAZARD STUDY 3
• Check actions have been assessed, reviewed and closed out.
Have the actions/recommendations from the Hazard
Study 3 been implemented in the way expected
without introducing new hazards?
Have the solutions been adequately thought out –
does the solution deal with the concern, does it
introduce new concerns?
Do the solutions represent significant changes which themselves
require hazard studying.
• Has the Project Manager notified the Hazard Study Leader of significant
changes to the design or operation made after the Hazard Study 3? Have
they been subjected to a Management of Change Procedure approved by
the Project Manager and the Commissioning Manager and referenced in
the Project SHE Dossier? If so, is it necessary to hold a further Hazard
Study meeting to review the changes.
• Have all modifications made to the P&IDs (or ELDs) been formally
recorded? They shall be formally reviewed at the Hazard Study 4 Stage.
• Draft QRAs/Fault Trees prepared before Hazard Study 3 should be
updated to incorporate any additional demands, changes to the P&IDs or
anything else which might affect the logic.
• Any other QRAs/Fault Trees that have not yet been started as a result of a
decision made earlier or due to insufficient information (e.g. trip
quantifications) should be completed.
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
28. 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
29. 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
30. 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
31. 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
32. 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
33. 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