March 25,2010 HAZOP : Major Cointainment Equipment HEX

Today, as per Aida request, we gonna discuss a bit on HAZOP for heat exchanger..for any personnel in an engineering field who didnt

HEX Tube Sheet know any of this equipment , DO SLAP YOURSELF HARD lol OkThere are many types of heat exchangers used in the process industries. However the most common type is the shell and tube exchanger, which is used in virtually all heating or cooling services. The major hazard associated with heat exchangers is the potential to exceed the design pressure or design temperature of the shell or tube side, leading to loss of containment. Tube Rupture In a shell and tube exchanger, the tubes are subject to failure from a number of causes, such as thermal shock, vibration, or corrosion. Whatever the cause, the possibility of the high pressure streams over pressuring the equipment in the lower pressure side must be evaluated. The pressure rise must be ascertained to determine whether additional pressure relief will be required if flow from the split tube were to discharge into the low pressure stream. The low pressure side of heat exchanger must be protected by pressure relieving facilities if the design pressure on the high pressure side is more than 1.5 times the design pressure on the low pressure side and the low pressure side cannot handle the discharge from a split tube without exceeding 1.5 times its design pressure. The entire flow pressure system must be examined for potential overpressure by a split tube. Equipment may be considered to be adequately protected against overpressure in certain low probability situations, such as a tube rupture, if the maximum possible pressure cannot exceed the hydrostatic or pneumatic test (proof test) pressure or 1.5 times design pressure, whichever is lower. This rule is applied in special situations which have a low probability of occurrence but

which cannot be completely ruled out. This rule assumes that the equipment is ultimately protected by a pressure relief system sized to handle sufficient quantity of fluid to prevent the built-up pressure on the equipment from exceeding either the proof test pressure or 1.5 times the design pressure. If the decisions is to up-rate the design pressure of low pressure side system to eliminate the need for pressure relieving facilities, it is imperative that the entire low pressure side be checked according within the 1.5 times Design Pressure rule (also referred to as 2/3 rule), see Figure A. If a heat exchanger does not satisfy 2/3 rule and the low pressure side does not have pressure relieving facilities, the HAZOP team needs to note that concern on the HAZOP worksheet. The consequences of tube rupture and the design implications would be reviewed by the HAZOP follow-up team. Even if a heat exchanger satisfies the 2/3 rule, the implication of a tube leak from the high pressure side to the low pressure must be evaluated. A tube leak could result in contamination of a process or utility stream, or hazardous chemistry. Overpressure The HAZOP team needs to evaluate whether the design pressure of the equipment on either side of the heat exchanger can be exceeded. Typically this means checking the design pressure versus the shutoff pressure of the pressure source (i.e. pump). Another consideration is overpressure by thermal expansion. Can the cold side fluid be blocked in the heat exchanger with the hot side still operating? If so, engineered or administrative controls should have been provided for this contingency.

Figure A : Tube Rupture - Overpressure Protection Over temperature

The HAZOP team needs to evaluate whether the design temperature of the equipment can be exceeded. This is done by comparing the design temperature of both sides of the heat exchanger versus the maximum upstream process fluid temperature. If the design provides for the capability to bypass upstream heat removal equipment, then the design temperature of the downstream equipment needs to reflect this increased temperature. For rundown coolers to tankage, the design should provide for a high temperature alarm in the rundown line to alert operators of the loss of cooling. Example Problems Heat Exchangers

Figure B : Example - Heat Exchanger

Table A : Example - Heat Exchanger's HAZOP Worksheet

March 14,2010 HAZOP : Major Cointainment Equipment Piping

The majority of piping flanges used in refineries, chemical plants, gas

Pipe Burst processing facilities and offshore process equipment, are manufactured in accordance with ANSI B.16.5, Steel Pipe Flanges and Flanged Fittings. ANSI B16.5 pressure and temperature ratings are also assigned to other piping components such as tees, reducers and strainers. In this manner, flanges or other piping components with standard dimensions may be used freely or at below their pressure-temperature rating without the need for design calculations. The designer has the responsibility to determine the appropiate flange rating (or primary pressure class) corresponding to the required pressure-temperature design conditions for the piping system. The primary pressure class, as established by the designer, is usually specified for each line in Design Specification. As example : Problem Pressure Rating of a Piping Flange Find the pressure rating of an insulated, Class 300, normal carbon steel flange for continous operation @ 300F design fluid temperature. Solution Using Table A below (reproduced from ASME B16.5 Pipe Flanges and Flanged Fittings ) , read down the temperature column to 300F & over to Class 300. The pressure rating is 655 psig.

Table 1 Pressure-Temperature Ratings for Normal Carbon Steel Flanges

As part of HAZOP review, you need to check the piping flange ratings are correct for the design pressure & temperature. In addition, where there is a change in the pressure class, you should check that the change in pressure class, or spec break, is in the correct location. The pressure class can change when either a change in the design temperature or a change in the design presssure occurs. For an example, a process stream passing through a control valve to a downstream vessel protected by relief valve set at a lower pressure may be able to use a lower pressure class rating. First, the pressure-temperature rating of the piping upstream and downstream of the control valve is determined.If the dowstream pressure class is lower, then the determination of spec break location is needed. Typically, the spec break is located at then farthest downstream point that can be blocked in and which is subject to the upstream pressure. This is best illustrated by the examples in Figure A to C. The question is where to locate the spec break. Example 1 Spec Break 1

Figure A Spec Break 1 For the upstream design conditions of 450 psig and 150F, Class 300, as shown is correct. For the downstream design conditions of 250 psig and 190F, Class 150, as shown is correct. If the control valve fails closed, then the piping through the control valve will be exposed to the more severe pressure-temperature rating. Therefore, the spec break should be at the downstream of the control valve. Example 2 Spec Break 2

Figure B Spec Break 2

Figure B shows the same configuration as Figure A except that the upstream and downstream block valves and a bypass have been added.Where is the spec break now? The most severe condition occurs if the block valve downstream of the control valve is closed. Therefore, the spec break should be at the downstream flange of the downstream block valve. How about the bypass valve? Since the bypass valve would normally be closed, its spec break needs also to be at the downsteam flange. Example 3 Spec Break 3

Figure C Spec Break 3 Figure C has the same configuration as Figure B except that a set of flanges to insert a blind has been provided at the inlet of T-1. Where is the spec break now? The spec break should be located as in the Figure B example. Why is this? To insert the blind, the vessel would need to be isolated and depressurized. However, once the blind is inserted, procedures would need to be in place to ensure that the upstream flange could not be exposed to Class 300 condition. If the pipe run between the last block valve and the blinding location is short, an alternative would be to make it comform to Class 300 and thus avoid covering it with a procedure.

March 03,2010 Low flow protection in a centrifugal pump

Low flow can cause overheating, hydraulic instabilities (suction and discharge recirculation) and mechanical unreliability in centrifugal pumps. To prevent such problems, options include both continuous and automatic (active) low-flow protection systems. Figure 1 shows four major types of configurations that provide recirculation back to an upstream feed vessel. Alternatives include recirculation to the pump suction piping. A continuous system is frequently chosen because of its simplicity. It uses a restriction orifice in a return line. This orifice is typically sized in one of two ways. The more conservative approach selects an orifice for the full minimum flow required. The less conservative one sizes the restriction orifice for a rate that, when added to the minimum expected process flow, gives the minimum flow the pump requires. Because it operates at all times and the pump needs to have a higher capacity than the process alone requires, a continuous system may impose substantial pump and energy costs. Moreover,

its difficult to put into place when the minimum flow is a large fraction of the pumps bestefficiency-point operation. In these situations, recirculation rates and energy costs are high.

Figure 1. Four common options involve recirculation to an upstream feed vessel. Automatic systems get around this problem. Active flow control systems can use either modulated flow or on/off flow through a control valve. For high-head pumps, a control valve may be placed in series with one or more orifices. The series pressure drops reduce the energy lost at each step and avoid problems of erosion, noise and potential flashing. In automatic systems, low flow can be detected either by monitoring pump discharge pressure or flow directly. Discharge pressure measurement is typically cheaper but only suits some situations. To make discharge pressure work, the upstream pressure changes must be small compared to the effect of flow on pump discharge pressure. Using a more-complex differential pressure system across the pump suction can eliminate the effect of upstream pressure changes. Additionally, the discharge pressure curve must always be rising as flow decreases. Discharge pressure control systems work best when the pump curve is relatively steep. Many pumps have relatively flat curves for discharge pressure versus capacity. So, for these pumps, its better to directly measure pump discharge flow and have a bypass control valve respond as required to maintain minimum flow. While more expensive in the short run, directly measured flow reduces required pump size and minimizes overall operating costs. For most large installations its the most suitable option for low flow protection. Which method works best depends upon the specifics of your installation. Keep the basic requirements of the pump and how each system works in mind to make the right choice
..

A few things you should know about your pumps piping system 1. There should be at least 10 diameters of pipe between the suction of the pump and the first elbow. This is especially critical in double-ended pump designs as the turbulent inlet flow can cause shaft thrusting, and subsequent bearing problems. If an elbow must be installed be sure it is in a plane at right angles to the pump shaft to prevent an uneven flow to both sides of a double suction impeller. 2. Pipe from the pump suction flange to the pipe rack, not the other way around. 3. Make sure eccentric reducers are not installed upside down at the pump suction. The top of the reducer should go straight into the suction flange. 4. Piping should be arranged with as few bends as possible. If bends are necessary use a long radius when ever possible 5. If an expansion joint is installed in the piping between the pump and the nearest point of anchor in the piping, It should be noted that a force equal to the area of the expansion joint (which could be a lot larger than the normal piping size) times the pressure in the piping will be transmitted to the pump proper. Pipe couplings that do not provide an axially rigid connection have the same affect. If an expansion join or non-rigid coupling must be used, it is recommended that a pipe anchor be installed between it and the pump. 6. Be aware that radial forces are being generated in the pump housing from the pressure in the piping system acting on the volute area. The magnitude and direction of the forces is dependent upon the piping arrangement along with the areas and pressures involved. 7. It is always a good idea to increase the size of the suction and discharge pipes at the pump nozzle in order to decrease the head loss from pipe friction. 8. Suction piping should be at least one size larger than the suction flange at the pump. 9. If increasers are used on the discharge side to increase the size of discharge piping, they should be installed between the check valve and the pump. 10. Both a check and gate valve should be installed in the discharge piping with the check valve placed between the pump and the stop valve to protect the pump from reverse flow and excessive back pressure. Manually operated discharge valves that are hard to reach should have some facility for quick closing. A sprocket rim wheel and chain or a remotely operated motor are two alternatives you might consider. 11. Suction piping must be kept free of air leaks. 12. The installation of check valves should be avoided in the suction piping although they are often used to reduce the number of valves that have to be operated in switching between series and parallel pump operation.

13. A foot valve is often installed in the suction piping to aid priming. Do not install them if the pump is operating against a high static head because failure of the driver would allow liquid to rush back suddenly causing water hammer. This is especially true for vertical turbine and submersible pumps that are not designed for use with a foot valve. 14. Foot valves should be of the low loss flap type rather than the multiple spring variety and have a clear passage for the liquid at least the same area as the suction piping. 15. A horizontal suction line should have a gradual rise or slope to the pump suction. 16. Cast iron pumps should never be provided with raised face flanges. If steel suction or discharge piping is used, the pipe flanges should be of the flat face type and not the raised face type. Full-faced gaskets must be used with cast iron flanges. 17. The optimum control valve location is within five feet (1.5 meters) of the pump discharge to prevent too much surging of fluid in the system when the discharge is throttled. 18. The optimum pipe size will consider the installed cost of the pipe (the cost increases with size) and the pump power requirements (the power required increases with pipe friction) 18.1 Try to limit the friction loss at design flow to 2-5 feet for each 100 feet (1-2 meters for each 30 meters) of pipe). 18.2 To prevent the settling of solids you need a minimum velocity of about 4 to 7 feet per second (1.5 to 2.5 meters per second) 18.3 Velocities of no more than 10 feet (3 meters) per second are recommended in the suction side piping to prevent abrasive wear. Hope the above explanation suffice.