Equipments

Voluntary environmental codes

STATIC EQUIPMENT About Instructor Current job position:Working experiences:

EMERGENCY EVACUATION INSTRUCTIONWhenever you hear the building alarm or are informed of a general building emergency:Leave the building immediately, in an orderly fashion;Do not use elevators;Follow quickest evacuation route from where you are;If the designated assembly point/area is unsafe or blocked due to the emergency, proceed to the alternate assembly point;Report to your Work Area Rep at the assembly point to be checked off as having evacuated safely; Specific safety requirements for TODAY.Today: NO testingof firealarm systems COURSE OBJECTIVESWhen you complete this module you will be able:To learn the different types of fixed equipment and their main applications.To explain operating principles and key performances of these equipments.To describe the technology of the fixed machinery and the main operating constraints.To analyze the technical solutions applied in their units.To establish a diagnosis of the incidents, and participate in the troubleshooting meetings.To explain how the machines and their components work COURSE OUTLINETotal duration: 5 days;Lecture: 3 days;Workshop: 2 days; COURSE ASSESSMENTLecture: The multiple-choice (knowledge based questions) section of the test is scored based on the number of questions you answered correctly; Multi-choice test : 40 questionsPassing grade: 36/ 40;No additional points are subtracted for questions answered incorrectly;Even if you are uncertain about the answer to a question, it is better to guess than not to respond at all.Workshop: Passing grade: Implement an extract operation procedure for 15 minutes; OUTLINEI. PIPINGII. VALVESIII. STORAGE TANKS, VESSEL

OUTLINEPipe Pipe FittingsFlangesGasketsPipeline FailurePipe inspection and leak detectionPipe MaintenancePipe TroubleshootingI. PIPING OUTLINEGate ValvesGlobe ValvesPlug ValvesDiaphragm ValvesCheck ValvesButterfly valveControl ValvesSafety valveII. VALVES OUTLINETypes of Storage TanksVesselVessel ThicknessMaterialsInspectionVessel Design SheetsCommon Problems of Storage TanksStorage Tank MaintenanceIII. STORAGE TANKS, VESSEL I. PIPINGPiping includes pipe, flanges, fittings, bolting, gaskets, valves, and the pressure-containing portions of other piping components:

PIPEFLANGEFITTINGBOLTINGGASKETVALVE I. PIPING1. PIPE:a.Pipe side:IPS: Iron Pipe SizeSTD: Standard LaterSTD.WT: Standard WeightNPS: Nominal Pipe Size I. PIPING1. PIPE:b. Pipe Wall ThicknessSchedule is expressed in numbers (5, 5S, 10, 10S, 20, 20S, 30, 40, 40S, 60, 80, 80S, 100, 120, 140, 160). Schedule = 1000*P/S; where P is the service pressure and S is the allowable stress, both expressed in pounds per square inch (psi).Schedule number refer to ASME B36.19M and ASME B36.10M I. PIPING2. PIPE FITTING:Fittings permit a change in direction of piping, a change in diameter of pipe or a adding branch to the main run of pipe.Dimensional StandardFor Socket Weld & Threaded end: ANSI/ASME B16.11For Bevelled end: ANSI/ASME B16.9Thickness for Beveled end fittings = Thickness of pipe I. PIPING2. PIPE FITTING:a. Elbow:For Bevelled end: ANSI/ASME B16.9Thickness for Beveled end fittings = Thickness of pipe

I. PIPING2. PIPE FITTING:b. Tee

Reduce TeeTee I. PIPING2. PIPE FITTING:c. Reducer EccentricReducerConcentricReduces

I. PIPING2. PIPE FITTING:d. Fitting for small line Weldolet

I. PIPING2. PIPE FITTING:d. Fitting for small line Sockolet

I. PIPING2. PIPE FITTING:d. Fitting for small line Full coupling

Haft coupling Full coupling

I. PIPING3. FLANGES:Flanges are used to make a joint that is required to be dismantled. Various attributes of Flanges are described belowPressure Rating: Rating is maximum allowable non-shock working gauge pressure. There are 150, 300, 600, 900, 1500, 2500 ratings. To select a pressure class the following two steps are followedTypes of FlangesEnd TypeFlange Face I. PIPING3. FLANGES:a. End Types

Weld neck flange: Regular welding-neck flanges are used with butt-welding pipe and fittings. Suitable where extreme temperature, shear, impact and vibratory stresses apply. Regularity of the bore is maintained.

I. PIPING3. FLANGES:a. End Types

Socket weld flange: The socket welding flange is similar to a slip-on flange except it has a bore and a counter bore dimension.


Slip-on flange: The internal weld is slightly more subject to corrosion than the butt weld. The flange has poor resistance to shock and vibration.


Threaded flange: The threaded flange is similar to the slip-on flange, but the bore is threaded. Its chief merit is that It can be assembled without welding, explaining its use in low pressure services at ordinary atmospheric temperatures, and in highly explosive areas where welding create a hazard.


Blind flange: The blind flange is a flange without a bore, It is used to close off the end of a piping system and/or pressure vessel opening

I. PIPING3. FLANGES:b. Flange Face

Flat Face: Most commonly used for mating with non-steel flanges on the bodies of pumps, valves, etc. The gaskets used (see Gaskets below) have an outside diameter equal to that of the flange itself.


Raised Face: The raised face is the most common type of flange, in which the gasket covers only the raised faces.


Ring-Type Joint: Ring-joint flange is a more expensive facing, and considered the most efficient for high- temperature and high-pressure service.


Lap Joint: Lap-joint flange is shaped to accommodate to the stub end. The combination of flange and stub end presents similar geometry to the raised-face flange and can be used where severe bending stresses will not occur.

I. PIPING3. FLANGES:c. Design and Dimension StandardThe dimensional standards generally used are ANSI/ASME B16.5 for size up to 24 ; ANSI/ASME B16.47 series A & B for size above 24 I. PIPING4. GASKETS:Gaskets are used to avoid Static leakage and metal to metal contact. There are 2 types of gaskets from material point of view.Design & Dimension Standard:ANSI/ASME B16.20 for Metallic GasketsANSI/ASME B16.21 for Non-Metallic Gaskets

I. PIPING4. GASKETS:Metallic Gaskets: Metal is used in the construction of Gasket either as main material or as reinforcing material. e.g. Spiral wound gasket Non-metallic Gaskets: Metal is not used in the construction of gaskets. e.g. Flat Gasket

Metallic GasketsNon-metallicGaskets I. PIPING5. PIPELINE FAILURE:a. Pipe External CorrosionThe external corrosion mechanism of buried pipeline is electrochemical corrosion, and the corrosion rate is dependent on such factors as the nature of the soil. In a moist atmosphere or soil, a thin layer of water film, which induces pipeline corrosion, is formed on the surface of steel pipeline I. PIPING5. PIPELINE FAILURE:a. Pipe External CorrosionWhen the film is neutral, the steel and the water film, which contains oxygen, constitute the galvanic cell:Fe 2e = Fe2+(anodic)2H2O + O2 + 4e = 4OH-(cathodic)When the film is acidic, the steel and the water film, which contains carbon dioxide, constitute the galvanic cell:Fe 2e = Fe2+(anodic)2H+ + 2e = H2(cathodic) I. PIPING5. PIPELINE FAILURE:b. Pipe Internal Corrosion

Pipe internal corrosion is of several types, such as pitting corrosion and groove corrosion. The presence of corrosive agents and conditions inside a pipeline can result in premature failure, loss of service, possible pollution, injury, property damage, or fatalities I. PIPING5. PIPELINE FAILURE:b. Pipe Internal Corrosion

Common causes of internal corrosion includeHydrogen sulfideCarbon dioxideWater vapor

I. PIPING5. PIPELINE FAILURE:c. Stress Corrosion CrackingStress corrosion cracking (SCC) is cracking due to a process involving conjoint corrosion and straining of a metal due to residual or applied stresses. SCC may occur through a number of mechanismsHigh-pH SCC: High-pH SCC normally occurs in a relatively narrow cathodic potential range (600 to 750 mV Cu/CuSO4) in the presence of a carbonate/bicarbonate environment in a pH window from 9 to 13. Nearly Neutral pH SCC: There is a free corrosion condition below the coating that results in an environment with a pH of about 5 to 7. I. PIPING6. PIPELINE INSPECTION AND LEAK DETECTIONA. Magnetic Flux Leakage Inspection Magnetic flux leakage (MFL) is a magnetic method of nondestructive testing that is used to detect corrosion and pitting in pipelines.

The basic principle is that a powerful magnet is used to magnetize the steel. At areas where there is corrosion or missing metal, the magnetic field leaks from the steel. In an MFL tool, a magnetic detector is placed between the poles of a magnet to detect the leakage field.

I. PIPING6. PIPELINE INSPECTION AND LEAK DETECTIONB. Ultrasonic Testing A typical UT inspection system consists of several functional units, such as pulser/ receiver, transducer, and display devices. Ultrasonic testing (UT) uses high-frequency sound energy to conduct examinations and make measurements. Ultrasonic inspection can be used for flaw detection and evaluation, dimensional measurements, material characterization, and more. I. PIPING6. PIPE INSPECTION AND LEAK DETECTIONB. Ultrasonic Testing Ultrasonic inspection is a very useful and versatile NDT method. Some of the advantages of ultrasonic inspection that are often cited include: It is sensitive to both surface and subsurface discontinuities.It is highly accurate in determining reflector position and estimating size and shape .It has other uses, such as thickness measurement, in addition to flaw detection. I. PIPING6. PIPELINE INSPECTION AND LEAK DETECTIONC. Inspection tool:MagneScan tools offer true high-resolution performance, delivering the detailed data and high confidence levels essential for a productive integrity management program. They can be used in every conceivable type of pipeline inspection: in dry or liquid product, overland or subsea, in diameters from 6 to 56 in. (15 to 42 cm). UltraScan WM can detect and measure precisely midwall anomalies such as laminations and inclusions. Many pipeline operators use a baseline UltraScan WM inspection to confirm the quality of new construction before commissioning. I. PIPING6. PIPELINE INSPECTION AND LEAK DETECTIOND. Leak detection methods:Negative Pressure Wave Leak Detection in Oil: The negative pressure (NP) wave technique is an effective method for paroxysmal oil leakage detection and location. The leak location can be calculated : X= L + v.t/ 2

Where:X : distance from leak-point to head of pipelineL : length of the pipelineV : propagation velocity of NP wavet : differential time of NP wave to 2 receivers (up- / down-stream)

I. PIPING6. PIPELINE INSPECTION AND LEAK DETECTIOND. Leak detection methods:Acoustic Leak Detection in Natural Gas Pipelines: Acoustic techniques are being employed to detect leakage. When a leak or rupture occurs, the pressure balance of the pipeline is damaged.The leak location can be calculated by the formula: S= L + v.t/ 2where S is the distance between the leak point and the upstream acoustic sensor, L the distance between the upstream and downstream acoustic sensors, V the acoustic wave velocity in the pipeline, and t the time difference in receiving acoustic signals between the upstream and downstream sensors. I. PIPING7. PIPE MAINTENANCE:a. Pipeline CoatingsFive main coating systemsThree-layer PE (3LPE) Fusion-bonded epoxy (FBE or Dual FBE) Three-layer PP (3LPP) Coal tar enamel (CTE) Asphalt enamel, and polyurethane (PUR)

3LPE structure I. PIPING6. PIPE MAINTENANCE:b. Pipeline RepairDressing: Dressing is a procedure that involves careful removal of metal from around a defect to produce a smooth profile that eliminates stress pointsWeld Repair: There are two principal methods of weld repair: weld deposition and welded patch. The concept behind weld deposition repair is to deposit weld metal onto the outside diameter of a pipe to replace a pipe wall lost due to corrosionShell Repair: There are several methods of shell repair: snug-fitting sleeve, stand-off sleeve, hot tapping, epoxy sleeve repairs, and petro sleeve. Epoxy sleeve repairs is are the focus in this section I. PIPING7. PIPE MAINTENANCE:b. Pipeline RepairReplacement: The defective section is removed and replaced by a new, problem free-pipeline.Clock Spring Repair Method: Clock spring is the leading permanent pipeline repair solution and it is now recognized as an effective permanent repair alternative for corrosion, mechanical damage, or other defects on high-pressure pipelines. I. PIPING8. PIPE TROUBLESHOOTING:In the sections above we discussed pipe types, pipe selection, the problems pipes encounter, and pipe maintenance II. VALVES1. GATE VALVES:One of the most common valves found in industry is a gate valve. A gate valve places a movable metal gate in the path of a process flow in a pipe-line. The gates are sized to fit the inside diameter of a pipe, so very little restriction occurs when it is in the open position

Gate valves typically are operated in the wide open or completely shut positionGate valves Gate valves should not be used to throttle flow for extended periods II. VALVES1. GATE VALVES:Gate valves component

Gate valves component II. VALVES1. GATE VALVES:a. Common Gates

Solid wedge gateSolid split gate Parallel, or Double, Discs gate II. VALVES1. GATE VALVES:b. Gates Valves materialsGate valves are designed to be used in a variety of process conditions. The specific condition dictates what type of material the valve will be made ofStainless steel gate valves are used in corrosive, high- and low-temperature services. Specialty alloy gate valves are used in high-temperature, high-pressure service.Bronze gate valves are used in low-temperature, low-pressure serviceBrass gate valves are used in low-temperature, low-pressure serviceCast iron gate valves are used in water, lubrication, and some low-pressure steam services. II. VALVES1. GATE VALVES:c. Rising Stem and Non-rising StemThe stem on a gate valve comes in two designs: rising stem and non-rising stem- Rising tem: As the hand-wheel is turned counterclockwise, the stem in the center of the hand-wheel rises. - Non- Rising tem: A non-rising stem gate has a collar that keeps the stem from moving up or down. The hand-wheel is attached firmly to the stem of a non-rising gate.

II. VALVES1. GATE VALVES:d. MaintenanceValve stem threads exposed to weather need to be lubricated with anti-seize compound to keep them operating properly.The packing should be inspected, and the gland nuts tightened evenly if a leak is foundValve stems should not be painted, and every effort should be made to keep them free of dirt and dust. When closing a gate valve, the operator should take care not to damage the valve seatsMany valves have grease fittings, which admit lubricant to moving parts. Process technicians routinely inspect, clean, and lubricate valves. II. VALVES2. GLOBE VALVES:Globe valves are the second most common valves used in industry. A globe valve places a movable metal disc in the path of a process flow. This type of valve is most commonly used for throttling service. The disc is designed to fit snugly into the seat and stop flow.

GLOBE VALVES II. VALVES2. GLOBE VALVES:Process fluid enters the globe valve and is directed through a 90 turn to the bottom of the seat and disc

GLOBE VALVESGlobe valves must be installed properly to work efficiently. If the valve is installed backward, it wi ll tend to wear unevenly and push the flow-control element down. II. VALVES2. GLOBE VALVES:Globe Valve Components

The disc is attached to the stem in three ways: slip joint, threading, or one-piece manufacturingThe disc can be classified as plug, ball, composition, or needle shaped. It is composed of a variety of materials. The disc, or flow-control element, rests in the seat, directly in the path of a process flow when it is shut II. VALVES2. GLOBE VALVES:Globe Valve Components

The body is the largest part of the valve. The body can connect to the process piping in three ways: flanges, threaded connections, or welding. The seating area comes in four designs: cone-shaped, beveled flat surface, O-ring or washer, and tapered or needle-shaped cone. II. VALVES2. GLOBE VALVES:a. Four Common Disc Designs

PlugNeedleCompositionBall II. VALVES2. GLOBE VALVES:b. Globe Valve materialThe stainless steel globe valve is used in corrosive, high- and low-temperature services. The specialty alloy globe valve is used in high-temperature and high-pressure servicesSome common alloys used are nickel and iron or steel and titaniumThe bronze globe valve is used in low-pressure and low-temperature systems. The brass globe valve is used in low pressure and low temperatureThe cast iron globe valve is used in water lubrication and some low-pressure steam systems II. VALVES3. PLUG VALVES:In the open position, the port lines up with the inner diameter of the pipeQuick-opening, one-quarter turn plug valves are very popular in the process industry. The plug valve takes its name from the plug-shaped flow-control element it uses to regulate flowPlug valves provide very little restriction to flow and can be opened 100% with a one-quarter turn on the valve handleIn the closed position, the port is turned away from the process flow

Plug Valve II. VALVES3. PLUG VALVES:

a. Plug Valve DesignPlug valves come in a variety of shapes and sizes. The plug valve is de-signed for fuel gas piping systems, low-pressure situations, slurry and lubrication service, on/off service, low-temperature service, and multiport operation.In on/off service, prolonged exposure can damage the seats. In low-temperature service, the seats are made of a plastic-coated material that tends to break down during higher temperatures.Plug Valve Components II. VALVES3. PLUG VALVES:b. MaintenanceWith proper care and maintenance, a plug valve can last indefinitely. Lubrication plays a big part in the life of a plug valve. Plug valves depend on a lubricant inside the body of the valve. This lubricant helps the valve provide a leak-free seal II. VALVES4. DIAPHRAGM VALVES:Diaphragm valves use a flexible membrane and seat to regulate flow. The handwheel operates just like the handwheel on a gate or globe valve. The stem is attached to a device called the compressor.

The compressor pushes on a flexible diaphragmThe diaphragm valve seats are made of chemical-resistant plastic, rubber, or neoprene. This type of valve does not use packing II. VALVES4. DIAPHRAGM VALVES:

Straight-Through-Diaphragm ValveDiaphragm Valve ComponentsDiaphragm valves come in two designs: weir and non-weir II. VALVES5. CHECK VALVES:A check valve is designed to prevent reverse flow and to avoid possible contamination or damage to equipment. The check valve limits backflow but is not considered a tight shutoff. Check valves come in a variety of de-signs and applications. Check valves have flow direction stamping on the valve bodyTypes of Check valvesSwing Check ValveLift Check ValveBall Check ValveStop Check Valve II. VALVES5. CHECK VALVES:Swing Check Valve

Flow lifts the disc and keeps it lifted until flow stops or reverses. The body of the check valve has a cap for easy access to the flow-control element II. VALVES5. CHECK VALVES:Lift Check ValveWhich has a disc that rests on the seat when flow is idle and lifts when flow is active. Special guides keep the disc in place

The Lift check valves is designed to close when flow reverses II. VALVES5. CHECK VALVES:Ball Check ValveThe ball check is as durable as a lift check and more durable than a swing check. A fourth design is the stop check design, which has characteristics of a lift check and a globe valve

In the closed position, the stop check disc is firmly seatedIn the open position, the stem rises out of the body of the flow-control element and acts as a guide for the disc II. VALVES5. CHECK VALVES:Stop Check Valve

In the open position, the stop check functions like a lift check with one exception. II. VALVES6. CONTROL VALVES:Control Valves can be of the following types based on parameters to be controlled:Pressure control valve-Receives signal from Pressure Indicator/ Pressure Transmitter.Temperature control valve-Receives signal from Temperature Indicator/ Temperature TransmitterFlow control valve-Receives signal from Flow Indicator/Flow Transmitter. II. VALVES6. CONTROL VALVES:There are two types of signal:Pneumatic Valve has pneumatic actuator. (tubing is used)Electric Valve has electrical (solenoid) actuator. (cables are used)Based on construction, control valve has following typesButterfly ValveGlobe ValveBall Valve II. VALVES6. CONTROL VALVES:Control Valves Maintenance:Reactive maintenance is usually dened as running equipment until it fails, with no planned maintenance.Having some form of program in place involving regularly scheduled maintenance is described as preventive maintenance or scheduled maintenance.These programs increase the reliability of the equipment, can be scheduled as part of a routine program, and can increase equipment life while garnering energy saving II. VALVES6. CONTROL VALVES:Control Valves Maintenance:Predictive maintenance is the best way to extend the life of valves As soon as you observe a leak, determine its cause and then apply the proper corrective maintenance, and later, follow its predictive maintenance. Maintenance may be as simple as tightening a packing nut or glandWhen you install valves, ensure that they are readily accessible and allow enough headroom for full operation III. STORAGE TANKS, VESSEL1. TYPES OF STORAGE TANKS:Aboveground Tanks

Spheroid Tanks: A spheroidal tank is essentially spherical in shape but somewhat attened. These tanks are generally used for storing products above 35 kPag .

Horizontal Cylindrical Tanks: The working pressure of these tanks can be from 100 to 7000 kPag or greater. These tanks often have hemispherical heads.Spherical Tanks: Spherical storage tanks are generally used for storing products at pressures above 35 kPag.

III. STORAGE TANKS, VESSEL1. TYPES OF STORAGE TANKS:Aboveground TanksFixed Roof: Fixed roofs are attached permanently to the tank shell. Welded tanks of 80 m3 capacity and larger may be provided with a frangible roof in which case the design pressure must not exceed the equivalent pressure of the dead weight of the roof, including rafters, if external.

Floating Roof: Floating roofs are designed to move vertically within the tank shell to provide a constant minimum void between the surface of the stored product and the roof. This type of tank is used primarily for storage near atmospheric pressure.

III. STORAGE TANKS, VESSEL1. TYPES OF STORAGE TANKS:Aboveground TanksBolted Tanks: Bolted tanks are designed and furnished as segmental elements that are assembled on location to provide complete vertical, cylindrical, aboveground, closed, and open-top steel storage tanks. Standard American Petroleum Institute (API) tanks are available in nominal capacities of 16 to 1600 m3 , designed for approximately atmospheric internal pressures. III. STORAGE TANKS, VESSEL1. TYPES OF STORAGE TANKS:b. Underground TanksSolution- mined Caverns: The cavern is constructed by drilling a well or wells into the salt and circulating low-salinity water over the salt interval to dissolve the salt as brine. The cavern may be operated by brine displacement of product, pump-out methods, vapor displacement, or as in the case of gas, by product expansionConventional- mined Caverns: Conventional mined caverns can be constructed any place that a nonporous rock is available at adequate depth to withstand product pressures. III. STORAGE TANKS, VESSEL1. TYPES OF STORAGE TANKS:b. Underground TanksRefrigerated Storage: The decision to use refrigerated storage in lieu of pressurized storage is generally a function of the volume of the liquid to be stored, the ll rate, the physical and thermodynamic properties of the liquid to be stored, and the capital investment and operating expenses of each type of system III. STORAGE TANKS, VESSEL2. VESSEL:Each vessel will include a code stamp that will indicate high-pressure and high-temperature ratings, manufacturer, date, type of metal, storage capacity, and special precautionsMost vessel documentation includes strapping tables that will allow a technician access to data that can be used to identify capacityCommon storage designs include spheres, spheroids, horizontal cylindrical tanks (drums), bins, and tanks with fixed and floating roofs III. STORAGE TANKS, VESSEL2. Vessel:Tanks, drums, and vessels are typically classified as low pressure, high pressure, liquid service, gas service, insulated, steam traced, or water cooledWall thickness and shape often determine the service a vessel can be used in. Some tanks are designed with internal or external floating roofs, double walls, dome or cone roofs, or open top III. STORAGE TANKS, VESSEL3. Vessel THICKNESS:Essentially, the thickness of pressure-retaining equipment depends on the diameter of the pipe, vessel, exchanger, or other equipment; pressure; temperature; strength of material used; and anticipated corrosion rates (a 1/8" corrosion allowance is normally provided). Of these, the operator has control of pressure, temperature, and process changes that might affect the amount of corrosion. III. STORAGE TANKS, VESSEL3. Vessel Thickness:a. PressureThe equipment is designed for normal operating pressures plus an incremental increase in pressure to allow for operating upsetsThe relief valve on the equipment or in the system is set to relieve when the design pressure is exceeded and is provided for equipment protection and safety of personnelThe operator should be aware that such unsafe practices can exceed design conditions and may cause failure. III. STORAGE TANKS, VESSEL3. Vessel Thickness:b. TemperatureIn general, the strength of metals decreases as temperature increasesIt is important that pressure in equipment be reduced and exposed metal surfaces cooled with water during fire conditionsBesides affecting strength, temperature also has a profound effect on corrosion rates III. STORAGE TANKS, VESSEL4. Materials:a. Low Carbon SteelFortunately, low-carbon steel, which is familiar to everyone, is a very satisfactory material for most plant applications. Carbon Steel, Alloys, and Nonferrous AlloysIt is relatively inexpensive yet provides the strength, workability, and welding properties requiredMost of the equipment used in a plant is made of this versatile material III. STORAGE TANKS, VESSEL4. Materials:a. Low Carbon SteelCarbon Steel, Alloys, and Nonferrous AlloysThe steel used for equipment is low in carbon (0.3% or less), sulfur, and phosphorus and contains sufficient manganese to offset the effect of sulfur. It may also contain small quantities of silicon or aluminumAlthough low-carbon steel is suitable for the majority of services, a number of other materials have been developed to cope with the severe conditions encountered as new processes were developed III. STORAGE TANKS, VESSEL4. Materials:b. Low Alloy SteelThe strength and resistance to oxidation (rushing) required for these conditions are secured by adding small amounts of alloying elements. Molybdenum in quantities as small as 0.5% greatly increases the strength above 900F (482.22C).Chromium is added in amounts up to 9% to combat the tendency to oxidize at high temperatures and to resist corrosion from materials that contain sulfur. The chrome alloys are used in pressure vessels, piping, furnace tubes, and exchangers operating at high temperatures and pressures. III. STORAGE TANKS, VESSEL4. Materials:b. Low Alloy SteelSome of the processes used in refining and chemical plants employ hydro-gen at high temperature or high pressure or both. Low-carbon steel normally becomes brittle in this service above 500F (260C). Embrittlement is prevented by using steels that contain small amounts of chromium or molybdenum or both III. STORAGE TANKS, VESSEL4. Materials:c. High Alloy SteelThe properties of steel can be varied widely by small additions of other elements to produce steels that are satisfactory for most servicesSteels that contain 10% or more of alloying metals are generally called high-alloy steels.The members of this group most often used in plants are chromium steel and austenitic (that is, stainless) steel. III. STORAGE TANKS, VESSEL4. Materials:d. Chromium SteelChemical components containing appreciable amounts of sulfur com-pounds become quite corrosive to steel at temperatures ranging from about 550 to 850F (287.77C to 454.44C).Chromium steels withstand this type of attack very well, but in some cases the low chromium alloys previously described are not resistant enough to be economically attractive. In these cases, alloys containing from 12 to 17% chromium are used. III. STORAGE TANKS, VESSEL4. Materials:d. ChromiumSteelThe 17% chrome steels were used rather extensively initially for severe sulfur corrosion, but they had a tendency to become brittle after extended heating cycles in the 700 to 1,000F (371.11C to 537.77C) range.Their primary use is now largely confined to pump and compressor parts. The 12% chromium materials are widely used as protective linings in steel equipment, thermowells, and valve trim subject to this type of sulfur corrosion. III. STORAGE TANKS, VESSEL4. Materials:e. Austenitic (Stainless) SteelWhen both nickel and chromium are added to steel in amounts totaling somewhat over 20%, the microscopic structure undergoes a pronounced changeThe most common composition of stainless steel is commonly referred to as 18-8. This name comes from the fact that this stainless steel contains about 18% chromium and 8% nickelTwo conditions that cause these steels to deteriorate are stress-corrosion cracking and a high coefficient of expansion. Stress-corrosion cracking is a mechanical-chemical type of deterioration. III. STORAGE TANKS, VESSEL4. Materials:f. Nonferrous AlloysA metal or alloy that contains little or no iron is called a nonferrous materialThere are a great many elements other than iron that are metals in their pure form, and the combinations of these as alloys are almost limitless III. STORAGE TANKS, VESSEL4. Materials:g. Nickel AlloysIn a few locations around a chemical plant where extreme resistance to chemicals is required and the stainless steels are unsatisfactory, a group of alloys containing large amounts of nickel are usedThese alloys usually contain additions of iron, copper, aluminum, chromium, cobalt, and molybdenum. Some typical examples of these alloys are Monel, Hastelloy, and Inconel III. STORAGE TANKS, VESSEL4. Materials:h. Copper AlloysBrass is the term used to describe a family of alloys of copper and zincThe copper content ranges from 90% to about 60%, with the balance being zinc. Some brasses have small amounts of other elements such as lead, tin, antimony, arsenic, and phosphorus They are weaker than steel and lose much of their strength when heated III. STORAGE TANKS, VESSEL4. Materials:i. Aluminum AlloysThe outstanding characteristics of aluminum are its good resistance to corrosion from sulfur compounds and its resistance to continuous oxidation when exposed to the atmosphereThere are many alloys of aluminum, which contain small amounts of other metals that greatly increase its room temperature strength. This strength in most aluminum alloys decreases rapidly with increasing temperatureAluminum coatings over iron-base alloys have been used rather extensively in recent years to protect equipment from high-temperature sulfur and hydrogen sulfide corrosion as well as high-temperature oxidation III. STORAGE TANKS, VESSEL4. Materials:j. Lead AlloysLead is a heavy, extremely ductile, relatively weak material that melts at a rather low temperature. It is used as a lining material in sulfuric acidtreating equipment III. STORAGE TANKS, VESSEL5. Inspection:Prolonged and safe operation depends upon good inspection practices for assurance that equipment is being maintained in a safe condition and that off-stream time is reduced to a minimum by anticipation of necessary repairsIn general, the scope of work includes all pressure vessels, heat exchangers, storage tanks, process piping, pumps, relief valves, furnace tubes, fittings, breechings, stacks, and tube supports III. STORAGE TANKS, VESSEL5. Inspection:Power boilers and auxiliaries are subject to state regulations and inspection. Representatives of an insurance company may also inspect the boilersThe nature of the material contained, the pressure, temperature, flow conditions, and other factors may cause or contribute to deterioration of equipment III. STORAGE TANKS, VESSEL5. Inspection:The frequency and extent of inspection depend on factors such as pressure, temperature, corrosive action of the materials handled, and materials of construction, corrosive allowance, and past experience with the equipment involvedEquipment in high-pressure, high-temperature service subject to corrosion is, of course, inspected frequentlya. Inspection Frequency and ExtentThe frequency and extent of inspection are established independently for each item and are subject to change with changes in operating conditions III. STORAGE TANKS, VESSEL5. Inspection:The equipment or line is tapped with a hammer and the feel and the sound are noted. The hammering sets up a vibration, and the sound depends on the thickness of the point struckA variety of remote-reading instruments are available for measuring internal diameters of furnace and exchanger tubesb. Inspection Methods and Equipment III. STORAGE TANKS, VESSEL6. VESSEL DESIGN SHEET:Vessel design sheets are sketches that include information necessary for the selection, use, and need for periodic inspection of materials used to make vessels III. STORAGE TANKS, VESSEL7. COMMON PROBLEMS OF STORAGE TANKS :a. CorrosionProtective coatings:For internal tank corrosion, bottom coatings have been proven to be very effective. Not only do they reduce interior bottom (top-side) pitting but also effectively reduce nished fuel contamination and tank cleaning costsCoatings protect those areas that suffer the most aggressive attack by corrosion. Economic analyses, not even considering product purity and product integrity issues, show that coating tank bottoms pays off III. STORAGE TANKS, VESSEL7. COMMON PROBLEMS OF STORAGE TANKS :a. CorrosionProtective coatings:One measure found to improve tank underside corrosion resistance is using plate that has been descaled. Scale is iron oxide that results from the mill process III. STORAGE TANKS, VESSEL7. COMMON PROBLEMS OF STORAGE TANKS :a. CorrosionCathodic Protection:Use of cathodic protection to reduce both interior and exterior corrosion is controversial and complexIndustry experience shows that it is very useful for interior corrosion on crude oil tanks when used in conjunction with liners III. STORAGE TANKS, VESSEL7. COMMON PROBLEMS OF STORAGE TANKS :a. CorrosionCathodic Protection:Theoretically, cathodic protection will work if installed properly, but in reality there are many obstacles to overcome for it to work right. Unless these systems are installed, tested, maintained, and operated by trained and qualied people, they can be totally ineffective and, in fact, can cause accelerated corrosionCathodic protection should not be mandated as a blanket solution but should be evaluated and weighed individually against other alternatives on a site-specic basis III. STORAGE TANKS, VESSEL7. COMMON PROBLEMS OF STORAGE TANKS :a. CorrosionDouble Bottoms:Although this fact is not well known, a double bottom is an effective corrosion prevention method that increases tank life signicantlyAdding a double bottom raises the new steel bottom up off the mud and dirt. The elevation generally mitigates the corrosive environment by reducing contact with moisture and salts III. STORAGE TANKS, VESSEL7. COMMON PROBLEMS OF STORAGE TANKS :a. CorrosionDouble Bottoms:Concrete in the presence of moisture becomes alkaline. Alkaline water is much less corrosive than acidic water. Measurements from standing water under tank bottoms have been about pH 11 to 12, so the concrete is actually a corrosion inhibitorA double-bottomed tank has a more uniform foundation, with less likelihood of clay balls or foreign objects. In other words, development of corrosion cells, galvanic corrosion, and other problems are less likely when a concrete foundation is used. III. STORAGE TANKS, VESSEL7. COMMON PROBLEMS OF STORAGE TANKS :b. Vapor LossesDisplacement losses:The combined loss from lling and emptying is considered a working loss or displacement lossEvaporation during lling operations is a result of an increase in the liquid level in the tankThe pressure inside the tank exceeds the relief pressure, and vapors are expelled from the tank.Evaporative loss during emptying occurs when air drawn into the tank during liquid removal becomes saturated with organic vapor and expands, thus exceeding the vapor space capacity III. STORAGE TANKS, VESSEL7. COMMON PROBLEMS OF STORAGE TANKS :b. Vapor LossesVaporization losses:Vapors are generated by heat gained through the shell, bottom, and roof. The total heat input is the algebraic sum of the radiant, conductive, and convective heat transfer.Vaporization loss is especially prevalent where light hydrocarbon liquids are stored in full pressure or refrigerated storage. This is less prevalent but still quite common in crude oil and nished product storage tanksThese vapors may be recovered by using the vapor recovery system. To calculate vaporization in tanks, the sum of radiant, conductive, and convective heat inputs to the tank must be taken into accountApproximate vapor losses (kg/h) can be calculated by dividing the total heat input by the product latent heat of vaporization at uid temperature III. STORAGE TANKS, VESSEL8. STORAGE TANK MAINTENANCE:a. Tank BlanketingTank blanketing, also referred to as tank padding , is the process of applying a gas to the empty space in a storage container.The term storage container here refers to any container that is used to store products, regardless of its sizeIt typically involves using a buffer gas to protect products inside the storage container III. STORAGE TANKS, VESSEL8. STORAGE TANK MAINTENANCE:a. Tank BlanketingThe most common gas used in blanketing is nitrogen. Nitrogen is widely used due to its inert properties as well as its availability and relatively low costTank blanketing is used for a variety of products, including cooking oils, volatile combustible products, and puried water . In the case of cooking oils, lipid oxidation can cause the oil to change its color , avor , or aroma. It also decreases the nutrient levels in the food and can even generate toxic substances III. STORAGE TANKS, VESSEL8. STORAGE TANK MAINTENANCE:b. Holiday DetectionAn important evaluation of bottom linings after application to aboveground storage tanks (ASTs) is holiday (i.e., discontinuity) detectionFor thin bottom linings under 20 mils of dry lm thickness (DFT), low voltage/wet sponge detectors are speciedFor those linings greater than 20 mils DFT, high-voltage spark detectors are employedA low-voltage wet sponge detector is a simple electronic device; it consists of a wet sponge, an energy source (a 5- to 90-V battery), a ground wire connector, and another connecting lead wire to the wet sponge III. STORAGE TANKS, VESSEL8. STORAGE TANK MAINTENANCE:b. Holiday DetectionThere are both advantages and disadvantages to this type of detectorThe wet sponge is low in costIt is fairly easy to use and extensive training is not requiredIt is a nondestructive test III. STORAGE TANKS, VESSEL8. STORAGE TANK MAINTENANCE:b. Holiday DetectionThere are several disadvantages, includingThe lining must be dry and free of moistureLocating a holiday after audible indication may be time consumingThe lining must be dried after locating a holiday; otherwise, telegraphing can result. Telegraphing is current traveling along a wet path and indicating a holiday where none exists III. STORAGE TANKS, VESSEL8. STORAGE TANK MAINTENANCE:c. Tank CleaningEnvironmental legislation is becoming increasingly restrictive with regard to waste disposal. This requirement becomes even more important in the cleaning of tanks, as the removal of tank sludge is an expensive, time-consuming step before achieving gas-free certicationITW has patented a novel technology for asphaltene stabilization. Such technology makes use of chemical additives to hydrocarbons and has proved very effective in many industrial applications III. STORAGE TANKS, VESSEL8. STORAGE TANK MAINTENANCE:c. Tank Cleaning

Existing Tank Cleaning TechnologiesManual cleaning is the most widespread method currently used in cleaning tanks. Its disadvantages are that:It is unsafe.It generates a huge amount of waste.It is time consuming.It is costly. III. STORAGE TANKS, VESSEL8. STORAGE TANK MAINTENANCE:c. Tank CleaningCrude oil washingThis method simply moves the sludge from one tank to another (it is a mechanical dispersion method). In some cases, reprocessed crude oil sludge led to unscheduled topping unit shutdown

Sludge suspension process III. STORAGE TANKS, VESSEL8. STORAGE TANK MAINTENANCE:c. Tank CleaningChemical Cleaning: For chemical cleaning, most chemicals used until now have been dispersants: again, they transfer the problem from one point to anotherRobot machines: Robot machines improve the safety and sometimes the length of the operations, but they do not have an impact on sludge reduction and therefore generate the same amount of sludge. THANK YOUwww.pvmtc.com.vn

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