Showing posts with label General. Show all posts
Showing posts with label General. Show all posts
PRE-SHUTDOWN INSPECTION PROGRAM
On-stream inspection is also important to
identify problems which can not be seen while the equipment is out-of-service.
A discussion with operations and maintenance personnel is highly recommended to
identify problem areas. At this time, a review of the operating conditions may
also help to indicate problems, such as: O2 percentage, (inability to maintain
target O2 could indicate leaks or burner problems), draft (unsteady/pulsating
draft can damage heater/boiler components), drum levels, pressures and
temperatures.
An infrared scan of the casing can allow a hot
spot map to be created so that these areas can be investigated during the
maintenance outage. Flame locations and appearance can help identify problems
with burner tiles, refractory, and floors. Flames emanating from a portion of
floor or wall indicate a problem that needs follow-up inspection. Complete an
external inspection to determine condition of the structure, such as buckstays,
to look for signs of expansion/buckling. Also, inspect external equipment such
as blowdown valves, soot blowers, level gauges, external hangers/rods,
insulation, etc. for damage that would need to be addressed at the outage.
Specific Conditions to obtain environmental clearance for any industry
| No objection certificate from SPCB |
| Coastal Regulation Zone Notification 1991 |
| A report from Wildlife Department marine Impact assessment and risk assessment along with the Disaster Management Plan shall be prepared |
| Ambient air quality along with SO2 Nox and other parameters shall put up in a dedicated website to the public |
| Emission levels of pollutants shall be within permissive levels |
| 33% of the area shall be dedicated green belt development (Local Forest Department) |
| The traffic in the city shall not get affected |
| Water supply to the nearby places shall not get affected |
| Detailed monitoring program shall be designed and information shall be provided to the public in a dedicated website by online monitoring |
| Low sulfur internal fuel and fuel gas shall be fired in process heaters and boilers |
| Quarterly monitoring of fugitive emissions shall be carried out by Fugitive Emission Detectors |
| Regular Ambient air quality monitoring - SPCB |
| Online data for air emissions shall be transferred to the CPCB and SPCB regularly |
| The practice of acoustic plant design shall be adopted to limit noise exposure for personnel to an 8 hr time weighted average of 90 dB |
| Adopt Leak Detection and Repair program for quantification and control of fugitive emissions |
| No halogenated organic is sent to flare |
| Regular monitoring of underground water parameters shall be carried out in nearby areas |
| Solid waste generated shall be disposed of as per SPCB |
| Oil shall be recovered firm oily sludge and oil to be reused and sludge will be stored in HDPE lined pit |
| Follow recommendations mentioned in the charter on CERP (Corporate Responsibility for Environmental Protection |
| Rainwater harvesting, storm water drains to recharge the ground water - conserve fresh water |
| Occupational Health surveillance of the workers should be done on regular basis - Factories Act |
| Environmental Impact Assessment/EMP Report and Risk Assessment Report |
| Expansion and modification shall be made after prior approval |
Traits - Appraisal system
| Traits | |
| Potential | Managing Change |
| Boundary Management | |
| Entrepreneurship | |
| Commitment to total organisation | |
| Enhancement of quality and output | |
| Value | Care |
| Innovation | |
| Passion | |
| Trust | |
| Competency | |
| Generic | Achievement Orientation |
| Team Effectiveness | |
| Communication Skills | |
| Analytical ability | |
| Customer service orientation | |
| Planning & organising | |
| Decision Making | |
| Functional | Employee relation management |
| Knowledge of Plant & Equipment | |
| Knowledge of Unit operations | |
Dimensionless numbers
Reynold's Number : It is the ratio of inertia force of a flowing fluid and the viscous force of the fluid.
Froude's Number: It is defined as the square root of the ratio of inertia force of a flowing fluid to the gravity force.
Euler's Number: It is defined as the square root of the ratio of the inertia force of a flowing fluid to the pressure force.
Weber's Number: It is defined as the square root of the ratio of the inertia force of a flowing fluid to the surface tension force
Mach's Number: It is defined as the square root of the ratio of the inertia force of a flowing fluid to the elastic force.
Froude's Number: It is defined as the square root of the ratio of inertia force of a flowing fluid to the gravity force.
Euler's Number: It is defined as the square root of the ratio of the inertia force of a flowing fluid to the pressure force.
Weber's Number: It is defined as the square root of the ratio of the inertia force of a flowing fluid to the surface tension force
Mach's Number: It is defined as the square root of the ratio of the inertia force of a flowing fluid to the elastic force.
Common Heater Tube Metallurgies
|
|
|
|
Design Metal
|
|
|
Seamless Tube
|
Seamless Pipe
|
Temperature
|
|
Material
|
Specification
|
Specification
|
Limit per API
RP530
|
|
Carbon Steel
|
A53
|
A106
|
1000°F (540°C)
|
|
1¼Cr-½Mo
|
A213 T11
|
A335 P11
|
1100°F (595°C)
|
|
2¼Cr-1Mo
|
A213 T22
|
A335 P22
|
1200°F (650°C)
|
|
3Cr-1Mo
|
A213 T21
|
A213 P21
|
1200°F
(650°C)
|
|
5Cr-½Mo
|
A213 T5
|
A335 P5
|
1200°F (650°C)
|
|
5Cr-½Mo-Si
|
A213 T5b
|
A335 P5b
|
1300°F
(705°C)
|
|
9Cr-1Mo
|
A213 T9
|
A335 P9
|
1300°F (705°C)
|
|
9Cr-1Mo-V
|
A213 T91
|
A335 P91
|
1200°F
(650°C)1
|
|
Type 304H
|
A213 TP304H
|
A312 TP304H
|
1000°F (540°C)
|
|
Type 316
|
A213 TP316
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A312 TP316
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1000°F (540°C)
|
|
Type 321
|
A213 TP321
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A312 TP321
|
1000°F (540°C)
|
|
Type 347
|
A213 TP347
|
A312 TP347
|
1000°F (540°C)
|
|
Alloy
800H/800HT
|
B407 Gr
800H/800HT
|
B407 B407 Gr
800H/800HT
|
1800°F
(985°C)1
|
|
HK
|
A608 Gr HK402
|
|
1850°F (1010°C)1
|
|
HP
|
|
A297 HP
|
|
Pyrolysis Heaters
Pyrolysis
heaters are similar to steam/methane-reforming heaters. The same
materials are often used for both. There are a few notable
differences. Both Ys and U-bends are used in pyrolysis heaters and
suffer erosion. The reaction in the tubes is usually carburizing and
requires that the surfaces be smooth from boring or honing and that
the material be more resistant to carburization. The material used in
pyrolysis heaters is often a modification of a high-strength material
that is adequate in reforming heaters.
Box-type Heaters
A
box-type heater is a heater whose structural configuration forms a
box. There are many different designs for box-type heaters. These
designs involve a variety of tube coil configurations, including
horizontal, vertical, and arbor configurations.
This type of heater can have locations or
zones of different
heat densities. The size and arrangement of the tubes in a box-type
heater are determined by the type of operation the heater is meant to
perform; for example, crude oil distillation or cracking, the amount
of heating surface required, and the flow rate through the tubes.
Box-type heaters are usually updraft, with gas- or oil-fired burners
located in the end or side wall, the floor or downdraft with the
roof. After the process convection section tubes, auxiliary tubes are
often added to preheat combustion air or to generate or superheat
steam. In Figure 2, the convection section is centered in the upper
portion of the box-type heater and the radiant tubes are on the two
side walls.
Heaters with Vertical Coils, Helical coil, Arbor Coils
Heaters
with Vertical Coils
A
vertical coil heater may be positioned cylindrical or in a
rectangular (box-type heater). Most vertical coil heaters are bottom
fired, with the stack mounted directly on top of the heater.
Downdraft vertical heaters have also been used.
Heaters
with Helical Coils
Helical
coil heaters are cylindrical with the surface of the radiant section
in the form of a coil that spirals up the wall of the heater. They do
not usually have a convection section, but if one is included, the
convection surface may be in the form of a flat spiral or a bank of
horizontal tubes. The stack of a helical coil heater is almost always
mounted directly on top of the heater.
Heaters
with Arbor Coils
Heaters
with arbor or wicket coils are used extensively in catalytic
reforming units for preheat and reheat service and as heaters for
process air or gases. These heaters have a radiant section that
consists of inlet and outlet headers connected with inverted or
upright L or U tubes in parallel arrangement. The convection sections
consist of conventional horizontal tube coils.
What covers under IBR
Steam
lines with conditions listed below fall in the scope of Indian Boiler
Regulations (IBR). All lines falling under IBR purview must comply
with IBR requirements.
·
Lines having design pressure (maximum working pressure) 3.5 Kg/cm2 (g) & above
·
Line sizes 10" inside diameter & above having design pressure 1.0 Kg/cm2 (g) & above
·
Lines with pressure less than 1.0 Kg/cm2 (g) are exclusion.
·
User
of steam like steam tracing lines, jacket of the steam jacketed lines,
steam heating coil within the equipment are excluded from IBR scope.
·
All steam users where downstream piping is connected to IBR i.e. condensate flushed to generate IBR stream are covered under IBR
Latest Technologies in automobiles
ABS with EBD
Leather cum fabric upholstery
dual tone exteriors
Indicators on side view mirrors
Ultrasonic reverse guide system
Alloy wheels
Seven speed DSG box
LED Tail lamp and integrated Rear Turn Signal
Beige Interiors
new grille
Chrome strip on ORMV's
Rubrails with chrome inserts
TDi(Turbo)
DiCOR(Commom Rail)
TDI Common Rail Engine
iVTec engine
ABS
AMGS
ECO Mode
VCM Technology requires you to drive sedately to reap the benefits of cylinder switching
Iron embedded wood
TiO catalyst
shift-on-fly
Alloy Wheel
DICOR Engine
Personalization Kit
Keyless entry with immobilizer
Electrical outer mirrors with turn indicators
Ventilated Rear Disk Brake
Kevlar Belt
Quiet Steel
Micro Nuclear weapons
Scanning Control Microscope
Brushless DC Motors
Surface Engg
Dunlop Valve
Shrudder Valve
Toroidal CVT
Wheel Holder Kerb
Puncture Proof Tyres
DDHC VVT-IV8 Petrol Engine (Land Crusier)
Dredger - to increase the draft
Suspension Types - Double wishbones, Front and rear
Leather cum fabric upholstery
dual tone exteriors
Indicators on side view mirrors
Ultrasonic reverse guide system
Alloy wheels
Seven speed DSG box
LED Tail lamp and integrated Rear Turn Signal
Beige Interiors
new grille
Chrome strip on ORMV's
Rubrails with chrome inserts
TDi(Turbo)
DiCOR(Commom Rail)
TDI Common Rail Engine
iVTec engine
ABS
AMGS
ECO Mode
VCM Technology requires you to drive sedately to reap the benefits of cylinder switching
Iron embedded wood
TiO catalyst
shift-on-fly
Alloy Wheel
DICOR Engine
Personalization Kit
Keyless entry with immobilizer
Electrical outer mirrors with turn indicators
Ventilated Rear Disk Brake
Kevlar Belt
Quiet Steel
Micro Nuclear weapons
Scanning Control Microscope
Brushless DC Motors
Surface Engg
Dunlop Valve
Shrudder Valve
Toroidal CVT
Wheel Holder Kerb
Puncture Proof Tyres
DDHC VVT-IV8 Petrol Engine (Land Crusier)
Dredger - to increase the draft
Suspension Types - Double wishbones, Front and rear
Consultant Companies
Alstom Power Turbo System
Alstom Power India Ltd.
Ansaldo Energia, Italy
Blake Durr, Germany
Bechtel, USA
Black and Veatch, USA
Daelim Engineers and Contractors
Hanjung, Korea
Humphreya and Glasgow
Hyundai, Korea
Hitachi, Japan
Kvaerner Power Gas
Marubeni Corporation, japan
Man Ferrostaal, Germany
Mitsubishi Corporation, Japan
Raytheon Engineering, USA
Rolls Royce, UK
Siemens Power Gen., Germany
Sumitomo Corporation, Japan
Technip, France
Toshiba Corporation, Japan
Toyo Engineering Corporation, Japan
Toyo Engineering India Ltd.
Engineers India Ltd.
Tata Consulting Engineers
L&T
Alstom Power India Ltd.
Ansaldo Energia, Italy
Blake Durr, Germany
Bechtel, USA
Black and Veatch, USA
Daelim Engineers and Contractors
Hanjung, Korea
Humphreya and Glasgow
Hyundai, Korea
Hitachi, Japan
Kvaerner Power Gas
Marubeni Corporation, japan
Man Ferrostaal, Germany
Mitsubishi Corporation, Japan
Raytheon Engineering, USA
Rolls Royce, UK
Siemens Power Gen., Germany
Sumitomo Corporation, Japan
Technip, France
Toshiba Corporation, Japan
Toyo Engineering Corporation, Japan
Toyo Engineering India Ltd.
Engineers India Ltd.
Tata Consulting Engineers
L&T
Licensors in Refineries:
UOP, USA
PORNEA, Austria
ABB LUMMUS, Holland
KTL, Netherland
Technip KT, Italy
Linde AG, Germany
GE
SKODA
ALSTOM
EIL, India
Toyo Engineering
L&T
Fabtech Projects & Engineering Pvt. Ltd., India
Japan Energy Corporation
JEUMONT
Ericson
PORNEA, Austria
ABB LUMMUS, Holland
KTL, Netherland
Technip KT, Italy
Linde AG, Germany
GE
SKODA
ALSTOM
EIL, India
Toyo Engineering
L&T
Fabtech Projects & Engineering Pvt. Ltd., India
Japan Energy Corporation
JEUMONT
Ericson
Different types of machines in a manufacturing industry
Engraving Machine
Inline Slitter
Adhesive Dispenser
Industrial Hot Plate
Twin Door Hot Drying Oven
Pleating Machine
Arc Welding Machine
MIG Welding Machine
Pulse TIG Welding Machine
Hacksaw Machine
Bench Grinder
Drilling Machine
Horizontal Honing Machine
High Pressure Test Rig
Hi-Low Cycle Test Rig
Flow Measuring Equipment
Differential Pressure Test Stand
Accumulator Assembly Bench
High Pressure Nitrogen Charging Equipment
Multi Pass Test Stand
Bubble Point Test Stand
Bottle Flushing Stand
Air Permeability Tester
Inline Slitter
Adhesive Dispenser
Industrial Hot Plate
Twin Door Hot Drying Oven
Pleating Machine
Arc Welding Machine
MIG Welding Machine
Pulse TIG Welding Machine
Hacksaw Machine
Bench Grinder
Drilling Machine
Horizontal Honing Machine
High Pressure Test Rig
Hi-Low Cycle Test Rig
Flow Measuring Equipment
Differential Pressure Test Stand
Accumulator Assembly Bench
High Pressure Nitrogen Charging Equipment
Multi Pass Test Stand
Bubble Point Test Stand
Bottle Flushing Stand
Air Permeability Tester
Oil Industry Safety Directorate - Standards
OISD has issued approximately 110 Standards relating to installation, commissioning and operation of oil facilities
in India. Some of the
standards are as given below (Details available on web site http://www.oisd.nic.in):
1. OISD-STD-105 Work Permit System
2. OISD-STD-106 Process design and operating philosophies on pressure relief and disposal system
3. OISD-STD-108 Recommended Practices on Oil Storage and Handling
4. OISD-STD-109 Process Design and Operating philosophies on blow down and sewer system
5. OISD-RP-110 Recommended Practices on Static Electricity
6. OISD-STD-111 Process design and operating philosophies on fired process furnace
7. OISD-STD-112 Safe handling of air hydrocarbon mixtures and pyrophoric substances
8. OISD-STD-113 Classification of Area for
electrical installation at Hydrocarbon and handling facilities
9. OISD-STD-114 Hazardous Chemicals and their Handling
10. OISD-GDN-115 Guidelines for fire fighting equipment /appliances in petroleum industry
11. OISD-STD-116 Fire Protection facilities for Petroleum Refineries and Oil/Gas Processing Plants
12. OISD-STD-117 Fire Protection Facilities for Petroleum Depots and Terminals
13. OISD-STD-118 Layouts for Oil and Gas Installations Rev.I
14. OISD-STD-119 Selection, Operation and Maintenance of Pumps
15. OISD-STD-120 Selection, Operation and Maintenance of Compressors
16. OISD-STD-121 Inspection of turbines and Diesel Engines
17. OISD-STD-122 Selection, Operation and Maintenance of Fans, Blowers, Gear Boxes, Agitators & Mixers
18. OISD-RP-123 Selection, Operation and Maintenance of Rotary Equipment Components
19. OISD-RP-124 Predictive Maintenance Practices
20. OISD-RP-125 Inspection and Maintenance of Mechanical Seals
21. OISD-RP-126 Specific maintenance practices for rotating equipment
22. OISD-STD-127 History recording of rotating equipment (withdrawn)
23. OISD-STD-128 Inspection of unfired pressure vessels
24. OISD-STD-129 Inspection of storage tanks
25. OISD-STD-130 Inspection of Piping Systems
26. OISD-STD-131 Inspection of Boilers
27. OISD-STD-132 Inspection of pressure relieving devices
28. OISD-STD-133 Inspection of fired heaters
29. OISD-STD-134 Inspection of heat exchangers
30. OISD-STD-135 Inspection of loading and unloading hoses for petroleum products
31. OISD-STD-137 Inspection of electrical equipment
32. OISD-STD-138 Inspection of cross country pipelines – Onshore
33. OISD-STD-139 Inspection of pipelines - Offshore
34. OISD-STD-140 Inspection of jetty pipelines
35. OISD-STD-141 Design and Construction requirements for cross country hydrocarbon pipelines
36. OISD-STD-142 Inspection of fire fighting equipment's and systems
37. OISD-STD-144 Liquefied Petroleum Gas (LPG) Installations
38. OISD-GDN-145 Guidelines on Internal Safety Audits (Procedures and Checklist) Rev.I
39. OISD-RP-146 Preservation of ideal electrical equipment
40. OISD-RP-147 Inspection & safe practices during electrical installations
41. OISD-RP-148 Inspection & safe practices during overhauling electrical equipment
42. OISD-RP-149 Design aspects for safety in electrical systems
43. OISD-STD-150 Design and Layout of Liquefied Petroleum Gas Mounded Storage Vessels
44. OISD-STD-151 Safety in Design, Fabrication and Fittings ; Propane Tank Truck
45. OISD-STD-152 Safety instrumentation for process system in hydrocarbon industry
46. OISD-STD-153 Maintenance & inspection of safety instrument in hydrocarbon industry
47. OISD-STD-154 Safety aspects in functional training
48. OISD-STD-155 Personnel Protective Equipment Part I Non-respiratory equipment Part II Respiratory Equipment
49. OISD-GDN-156 Fire Protection Facilities for Port Oil Terminals
50. OISD-RP-157 Recommended Practice for Transportation of Bulk Petroleum Products
51. OISD-RP-158 Recommended Practices on Storage and Handling of Bulk Liquefied Petroleum Gas
52. OISD-STD-159 LPG Tank Trucks - Requirements of Safety on Design/Fabrication and Fittings
53. OISD-STD-160 Protection to fittings mounted on existing LPG tank trucks
54. OISD-STD-161 Rescue & relief operations involving tank truck accidents carrying LPG
55. OISD-STD-162 Safety in installations and maintenance of LPG Cylinder Manifold
56. OISD-STD-163 Process Control Room Safety
57. OISD-STD-164 Fire Proofing in Oil and Gas Industry
58. OISD-STD-165 Guidelines for Rescue and Relief Operations for POL Tank Truck Accident
59. OISD-GDN-166 Guidelines for Occupational Health Monitoring in Oil and Gas Industry
60. OISD-STD-167 POL Tanklorry Design & Safety
61. OISD-GDN-168 Preparation of On-site Emergency Plan for the Marketing Locations
62. OISD-GDN-169 OISD Guidelines on Small LPG Bottling Plants (Design and Fire Protection facilities)
63. OISD-RP-170 Inspection, Maintenance, Repairs and Rehabilitation of foundations and structures
64. OISD-STD-171 Preservation of Idle Static and Rotary Equipment
65. OISD-RP-173 Fire Protection Systems for Electrical Installations
66. OISD-STD-174 Well Control
67. OISD-STD-175 Cementing Operations
68. OISD-STD-176 Safety Training for Offshore Personnel
69. OISD-STD-177 Inspection and Maintenance of Thermal Insulation
70. OISD-GDN-178 Guidelines on Management of Change
71. OISD-STD-179 Safety Requirements for Compression, Storage and Refueling Stations for CNG in Automotive sector
72. OISD-STD-180 Lightning Protection.
73. OISD-STD-181 Geophysical Operations
74. OISD-STD-182 Recommended Safe Procedures and Guidelines for Workover and Well Stimulation Operation
75. OISD-STD-183 Logging Operations
76. OISD-GDN-184 Replacement of Personnel Protective Equipment and Life Saving appliances
77. OISD-STD-185 Wire line Operations
78. OISD-STD-186 Simultaneous Operations in Exploration & Production Industry
79. OISD-STD-187 Care & Use Of Wire Rope
80. OISD-STD-188
Corrosion Monitoring of Offshore
& Onshore Pipelines
81. OISD-STD-189 Fire Fighting Equipment for Drilling rigs, Work over Rigs and Production Installations.
82. OISD-STD-190 Derrick Floor Operation (Offshore Drilling/ Work over rig)
83. OISD-STD-191 Oil Field Explosives Safety
84. OISD-GDN-192 Safety Practice during Construction
85. OISD-STD-193 Gas Lift Operations and Maintenance
86. OISD-STD-194 Storage and Handling of Liquefied Natural Gas (LNG)
87. OISD-STD-195 Safety in Design, Operation, Inspection and Maintenance of Hydrocarbon Gas Compressor Stations and Terminals
88. OISD-GDN-196 Guidelines for seeking Environmental Clearance of Development Projects in Petroleum Industry
89. OISD-GDN-197 Guidelines on Environmental Impact Assessment
90. OISD-GDN- 199 Guidelines for Environment Audits
91. OISD-GDN-200 Guidelines for Development of Contingency Plan for Oil Spill Response.
92. OISD-GDN-201 Environment Management in Exploration & Production Sector
93. OISD-GDN-202 Inspection of Drilling and Workover Rig Mast./ Sub-structure.
94. OISD-GDN-203 Operation, Maintenance and Inspection of Hoisting Equipment
95. OISD-STD-204 Medical Requirements, Emergency Evacuation and Facilities
96. OISD-RP-205 Crane Operation, Maintenance and Testing (For upstream)
97. OISD-GDN-206 Guidelines on Safety Management System in Petroleum Industry
98. OISD-GDN-207 Contractor Safety
99. OISD-STD-210 Storage, Handling and Refueling of Liquefied Petroleum Gas for Automotive Use
100. OISD - GDN-211 Safety in Petroleum Laboratories
101. OISD-GDN-212 Guidelines on Environmental Audit (Internal) in Downstream Petroleum Sector
102. OISD-STD-214 Cross Country LPG Pipelines
103. OISD-STD-216: Electrical Safety in Onshore Drilling and Workover Rigs
104. OISD-GDN-217 Formulation of Environment Management Plan for Drilling Operations
105. OISD -GDN -218 Safe Rig-up and Rig-down of Drilling and Work-over Rigs
106. OISD -GDN -219 Field Inspection, Handling and Testing of Casing Pipe and Tubing
107. OISD-STD-224 Monitoring & control of VOC Emission and LDAR Programme
108. OISD-STD-225 Storage, Handling & Dispensing at Petroleum Retail Outlets
109. OISD-STD-226: Natural Gas Transmission Pipelines and City Gas Distribution Networks
110. OISD-GDN-227: Emergency Response Preparedness in E&P Industry
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