A Working Guide to Process Equipment

(continuing professional development CPD Course)

Resource person: Engr. Yasin Zafar

PFL Multan

Todays AGENDA
Introduction Resource person & Audience
Basic Chemical plant Terminologies / Concepts
Steam Steam Turbines Air Compressors
Heat Exchangers Trouble shootings
Pumps Start-up and Operational hazards
Filtration systems Improvements
Absorption & Adsoprtion
Instrumentation & Control - Accidents
Suggested Readings

Basic Concepts
Difference between Heat and
Temperature
Heat:
Heat can never be contained in a body or
possessed by a body.
Heat is energy in transit.
Thermal equilibrium
Units
Heat Transfer & Thermodynamics
(ref. Applied Thermodynamics by A. McCONKEY)

Pressure & Stress

Cross sectional area & Surface area

Pressure and Flow

If end of the piping system is
closed??
If end of the piping system is
opened??
Centrifugal compressors & Axial flow
compressor
Examples

Pressure and Vacuum

Pressure below atmospheric
0 is a perfect vacuum
How we can make vacuum?
Why we need vacuum?
Vacuum in INSULATIONS
Vacuum Hazards?
Jets ejectors require very little attention
and maintenance.

Ejector

Critical Temp. & Critical

Pressure
Above that temp., a gas can not be liquefy.
LCO2 = 31C
Critical pressure = 72 atm
Phase Diagrams
Cryogenics: Cryos: Cold, Genics:
Generation

STEAM
Sensible and latent Heat
Saturated and Superheated Steam Examples
Pressurization of steam circuit
Hammering
Steam traps
(ref. Design of Fluid Systems by Spirax Sarco)

Main Steam Circuit

Steam Turbine

What causes steam turbine to spin?

Air Compressors - Axial

The last stage is Centrifugal

Operational Hazards of Compressors

What is surging?
Why Surging Occurs?
Performance curves of air
compressor
Operational Excellence

SURGING

LEGENDS
NORMAL FLOW
REVRSE FLOW

Is Chemical Engineering an ART or

SCIENCE??

Chemical Engineering is both

an ART and Science (Mccabe
and Smith)
TRUE or FALSE!!!

HEAT EXCHANGERS TYPES

Direct Contact
Cooling towers

In Direct Contact
Shell and tube heat exchangers

Recuperators
Regenerators

Construction of Heat
Exchangers

Components of HEX

Channel baffle and Tube

Sheet

Spiral / Coil Heat Exchanger

Triangular Pitch

Plugging of tubes

Expansion Bellows

Operational Plant
Terminologies

Battery Limit
Raw Material
Final Product with Quality
Plant Load
Consumption factors
Inventories / Stock Level
Reaction Chemistry
Line tracing PFD & P&ID

Centrifugal Pumps
How it works?

Operational Problems

Cavitation
Mechanical Seal Damage
Vibrations
Suction strainer chocking
Discharge NRV stuck
Low level of suction reservoir
High bearing temperature

Major components

Balancing & Min. flow line

Bearing Housing

Filtration System
Importance
Types Dust Louvers, Candles, Dri
packs,
Trouble shootings
Pressure drop across filters if more
P?
Improvements
(Ref. American Air Filters, AAF)

Absorption & Adsorption

Unit Operations & Unit Processes

Physical and chemical
Absorption tower Tray or Packed
Adsorbers & Dryers
Favorable conditions
Trouble shootings

Absorption Tower

Bubble Cap Column

Structure of Bubble Cap

Internals of Absorption Tower

(Sealing)

Weir and Down comer

Instrumentation & Control

Hardware elements of process
control system
RTDs and Thermocouples
Orifice and pitot tube
Ratio Control

TYPICAL CONTROL LOOP

Field

Control Room

Rack Room

RECORDER

TRANSMITTER

INPUT
BARRIER
4-20 mA

CONTROLLER

Control Output
4-20 mA
CONTROL VALVE

OUTPUT
BARRIER

Set Point

Objectives of Control
System
Ensuring the STABILITY of chemical
process
OPTIMIZE the PERFORMANCE of
chemical process
SUPPRESS
the
influence
EXTERNAL DISTURBANCE

of

CONTROL LOOP FACE PLATE

LOOP TAG
PROCESS
CONDITIONS
OF LOOP
SET POINT
Manipulated
Variable
LOOP OUTPUT

LOOP
DESCRIPTION
MODE OF
OPERATION

PROCESS
VARIABLE

Manual

Auto

Cascade

Interlocking & Logics

What are interlockings?
Why Interlockings and Logics?
Examples
Failure of interlockings / logics

Purpose
The
alarm
and
interlocking
system is designed to protect the
plant and personnel from damage
due to dangerous operating
conditions. When such conditions
arise, the plant is shut down and ,
at the same time, the necessary
safety devices go into operation.

Plant Safety

PSVs
Safety Trips
Housekeeping
MSDS
Fire fighting Equipment
Safety Equipments
(ref. MSA, Chemical Safety Board (CSB)

03 FACTORS for SHAFT

CRITICAL
STRESSES
SPEED
VIBRATION

47

STRESSES
Shaft is subjected to the action of
forces called STRESSES.
3 types of stresses:
Torsional stress: twisting
Bending stress
Axial stress

48

CRITICAL SPEED

The speed of shaft

rotation which is equal
to the shaft frequency of
vibration is called critical
speed.
49

Vibration
The cyclic or pulsating
motion of a machine or
machine component from
its point of rest.
Vibration always transmits
as SINE wave. Sine wave
can be measured.

50

Accidents

Suggested Readings
A working guide to process equipment by
Lieberman
Fertilizer Manual by UN Industrial Development
Organization
STOP (Safety training observation program)
Series
Troubleshooting
process
operations
by
Lieberman
www.4shared.com

Resource person email contact:

yasin_zafar@yahoo.com

Q&
?
A

Thank You!