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Transcript of Physical Property Analyzers
PCI 108.04
Saudi Aramco
Physical Property Analyzers for Refinery Applications
Saudi Aramco Professional EngineeringDevelopment Program
PCI 108.04 2
Terminal Objective
Upon completion of this module, the Participant will be able to evaluate physical property analyzers for specific refinery applications, in terms of suitability for installation, operational capabilities, and maintenance requirements, using appropriate guidelines and vendor data.
PCI 108.04 3
Enabling Objectives
1. Evaluate boiling point/distillation analyzers, using applicable guidelines and vendor data.
PCI 108.04 4
Enabling Objectives
1. Evaluate boiling point/distillation analyzers, using applicable guidelines and vendor data.
2. Evaluate vapor pressure analyzers, using applicable guidelines and vendor data.
PCI 108.04 5
Enabling Objectives
3. Evaluate octane analyzers, using applicable guidelines and vendor data.
1. Evaluate boiling point/distillation analyzers, using applicable guidelines and vendor data.
2. Evaluate vapor pressure analyzers, using applicable guidelines and vendor data.
PCI 108.04 6
Enabling Objectives
4. Evaluate flash point analyzers, using applicable guidelines and vendor data
PCI 108.04 7
Enabling Objectives
4. Evaluate flash point analyzers, using applicable guidelines and vendor data
5. Evaluate viscosity analyzers, using applicable guidelines and vendor data.
PCI 108.04 8
Enabling Objectives
4. Evaluate flash point analyzers, using applicable guidelines and vendor data
5. Evaluate viscosity analyzers, using applicable guidelines and vendor data.
6. Evaluate color analyzers, using applicable guidelines and vendor data.
PCI 108.04 9
INTRODUCTION
� Process Analyzer Calibration and Validation
� Scope of Module
• Absolute or real calibration• Relative or arbitrary calibration
BOILING POINT & DISTILLATION ANALYSERS
PCI 108.04 11
Evaluating Boiling Point/Distillation Analyzers
• Function - To measure the temperature of a specific boiling point of a process stream for the purpose of product specification monitoring and/or advanced process control.
PCI 108.04 12
Evaluating Boiling Point/Distillation Analyzers
• Function• General Applications
– Crude Distillation Control
PCI 108.04 13
Crude Distillation Control
Figure 1Figure 1
O/H Accumulator
O/H Cooler
Gas
Overhead Distillate
No. 1 S/S Stripper Steam
No. 1 Sidestream
Pumpback reflux
No. 2 S/S Stripper
Steam No. 2 Sidestream
No. 3 S/S Stripper
Steam No.3 Sidestream
Steam Crude Feed
Preheat Furnace
Mid pump-around
Top pump-around
Flash Zone
Bottoms
PCI 108.04 14
Evaluating Boiling Point/Distillation Analyzers
• Function• General Applications
Ras Tanura Refinery - Plant 52 Diesel Blender - ABB Sim Dis Ras Tanura Refinery - Plant 488 & 493 Rheniformer - ABB Sim Dis
— Crude Distillation Control— Fuels Blending Control
PCI 108.04 15
Evaluating Boiling Point/Distillation Analyzers
• Function• General Applications• Process Analytical Techniques for
Boiling Point/Distillation Measurement– Principles of Operation
PCI 108.04 16
ASTM D86 Test Apparatus
Figure 2
a
2
0
1
Xi Z i Yi 1.00
T
T
T
Vapor
Liquid
Mole Fraction ofComponent
ConstantPressure (P)
Figure 2
Distillation Thermometer
100 mL Sample
Heater
Condenser
Cardboard Cover
Graduated Cylinder
Engler flask
Ice Water Bath
PCI 108.04 17
Typical ASTM D86 Distillation Curve
Figure 3
400(204)
350(177)
300(149)
250(121)
450(232)
Volume Recovered (mL)10 20 30 40 50 60 70 80 90
C4 Polymer
TS-28 Solvent
ASTM-D86
TPB
PCI 108.04 18
Evaluating Boiling Point/Distillation Analyzers
• Function• General Applications• Process Analytical Techniques for
Boiling Point/Distillation Measurement– Principles of Operation– Configuration of Boiling Point/Distillation
Analyzers
PCI 108.04 19
Process Boiling Point Analyzer Manufacturers
Figure 4
Manufacturer Model No. Type
Carlo Erba (Italy) PD-155 5-95% Point
Ludlum Sysco Ltd. 1463 5-97% Point(UK) 1463M 5-97% Point
Distillar 2000 IBP to FBP
Precision Scientific 44520-11 5-95% PointInc. (USA) 44522 5-95% Point
BPA-II 5-95% Point41468 Vac. Dist.
PCI 108.04 20
Configuration of Boiling Point/Distillation Analyzers
• Continuous Boiling Point/Distillation Analyzers
PCI 108.04 21
Precision Scientific BPA-II Boiling Point Analyzer
Figure 5
VHC
P
P
P
P
P
P
PSTS
TI
SamplePressure
Valve
#1Amp.
#2Amp.
ManualFlushingValve
SampleOutletValve
Air Supply
Safety Out
SampleIn
Strainer
Eductor(Optional)
SampleOut
FilterCoalescer
Over-headsOrifice
Bot-toms
Orifice
4-20mA(isolated)
InletValveT/C
T/C
Reboiler
Float
Tower
Note: Valve configuration shown asprior to start-up or upon fail safe.
BPA II
PCI 108.04 23
Precision Scientific Vacuum Distillation Monitor
Figure 6
N.O.N.C.Steam traced andinsulated line
PressureController
PressureTransmitter
Coolant
Steam
Sample In
DistillationTower
ThermocoupleOut
115/230VAC
Reboiler
RuptureDisc
ToAtmosphereVacuum
SurgeVessel
VacuumPump
VacuumDrainVessel
SampleOut
Motor
Condenser
Overheads
Reflux
SightGlass
Overheads Pump
BottomsPump
Oil-filled Bath Housing
VACUUM DISTILLATION MONITOR 441468
PCI 108.04 25
Precision Scientific Model 44522 Boiling Point Analyzer
Figure 7
P P P
H/E
H/E
H/E
H/E
L.E.D.Display
DigitalKeyboard
AlphanumericDisplay
MicroprocessorUnit
(M.P.U.)
Differential PressureRegulator
PressureRegulator
FilterSampleIn
CoolantIn
Remote Set Point
Alarms
Measured Variable
Coolant Temperature
Coolant Out
Sample Out
Pump RPM
Pump Suction Head
Heater Volts and Thermocouple Output
Sample TemperatureAtmospheric Pressure
D/P Sensor
Standpipe
BottomsPump
Filter
ExhaustPump
EvaporatorColumn
% distilled 38 to 343C or 5% to 95% recovered
PCI 108.04 27
Sysco (Rotork Analysis) Model 1463 Boiling Point Analyzer
Figure 8
TI
PI
ThermocoupleSignal Out
LevelController
Power In SampleVent
FlameTrap
Vent
FlameTrap
Dra in
Overflow
Tube in TubeHeat Exchanger
0 to 14 Bar g
0 to 93C
SampleFlowmeter
SampleIn
Bleed
Sample PumpNo. 1 In
Measure Sample PumpNo. 2 Cut
Measure
10 Bar g 14 Bar g
Bleed
HeatExchanger
17 Bar g
Flash Cup
LevelSensor
5% to 97% recovered or % distilled 65 to 350C
PCI 108.04 28
Configuration of Boiling Point/Distillation Analyzers
• Continuous Boiling Point/Distillation Analyzers • Analyzers that Duplicate the ASTM D86 Test
Method
PCI 108.04 29
Rotork Analysis (Hone) Distillar 2000 Boiling Point Analyzer
Figure 9
Drain
Flame Trap
Receiver DrainReceiver Overflow
Flask Drain
Receiver Valve
FlaskValve
BuretteValve
SampleValve
Burette
Burette VentVent toSafe Height
AnalyzerBox
Flask
EndPoint
DetectorDetector
CoolingWater In
Heater
WaterOut
Recov-eryVolume
ReceiverVent
SampleOverflow
SampleIn
Sample
T/C
• Initial Boiling Point• Recovery Point• Distillation Point• End Point• Total Recovery• Continuous Recovery• Continuous Temp
PCI 108.04 30
Rotork Analysis (Hone) Distillar 2000 Boiling Point Analyzer
• Initial Boiling Point• Recovery Point• Distillation Point• End Point• Total Recovery• Continuous Recovery• Continuous Temp
PCI 108.04 31
Configuration of Boiling Point/Distillation Analyzers
• Continuous Boiling Point/Distillation Analyzers • Analyzers that Duplicate the ASTM D86 Test Method • Simulated Distillation Analyzers
– ASTM D2887 & D3710
PCI 108.04 32
Process GC Sim-Dis -Aramco Applications
Ras Tanura Refinery - Plant 52 - Diesel BlendingRas Tanura Refinery - Plant 488 - RheniformerRas Tanura Refinery - Plant 492 - Rheniformer
PCI 108.04 34
Process GC Sim-Dis Analyzer Manufacturers
Figure 10
PROCESS GC SIM-DIS. ANALYZERS
Manufacturer Model No.
ABB Process Analytics VISTA GC(USA) VISTA SFC
Strms.
Applied Automation ADVANCE GC(USA)
Fluid Data/Amscor MS-IV-BP(USA)
Foxboro Analytical Model 931C(USA)
Rosemount Analytical Model 6750(USA)
UOP Monirex Systems B Pt. Monitor(USA)
PCI 108.04 35
Evaluating Boiling Point/Distillation Analyzers
• Function• General Applications• Process Analytical Techniques for Boiling
Point/Distillation Measurement• Installation Considerations
PCI 108.04 36
Evaluating Boiling Point/Distillation Analyzers
• Function• General Applications• Process Analytical Techniques for
Boiling Point/Distillation Measurement• Installation Considerations• Operational Considerations
PCI 108.04 37
Evaluating Boiling Point/Distillation Analyzers
• Function• General Applications• Process Analytical Techniques for
Boiling Point/Distillation Measurement• Installation Considerations• Operational Considerations• Maintenance Considerations
PCI 108.04 38
Evaluating Boiling Point/Distillation Analyzers
• Function• General Applications• Process Analytical Techniques for
Boiling Point/Distillation Measurement• Installation Considerations• Operational Considerations• Maintenance Considerations• Specific Application Evaluation
PCI 108.04 39
Typical Atmospheric Pipestill
Figure 11
O/H Accumulator
O/H Cooler
Gas
Overhead Distillate
No. 1 S/S Stripper Steam
No. 1 Sidestream
Pumpback reflux
No. 2 S/S Stripper
Steam No. 2 Sidestream
No. 3 S/S Stripper
Steam No.3 Sidestream
Steam Crude Feed
Preheat Furnace
Mid pump-around
Top pump-around
Flash Zone
Bottoms
PCI 108.04 40
Flow Diagram - Crude Atmospheric Distillation
Figure 12
No. 1 S/S Stripper
SteamKerosene
No. 2 S/S Stripper
SteamDiesel Fuel
No. 3 S/S Stripper
SteamLight Gas Oil
No. 4 S/S Stripper
SteamHeavy Gas Oil
TopPumparound
MiddlePumparound
BottomPumparound
AT
CrudeFeed
Steam
AtmosphericPipestill
FlashZone
Residue to Vacuum Pipestill
O/H Condenser
Water
To Fuel GasRefluxDrum
95% Point
PCI 108.04 41
Sample Handling System for a Boiling Point Analyzer
Figure 15
SampleReturn
SampleReturn
FastLoop
Fast LoopFlowmeter
FastLoopFilter
LabSamplePoint
SampleCooler
Coolant
PressureRegulator
DualFilter-Coalescer
System
Water toDrain
SecondaryBypass
To SampleRecoverySystem
A
Probe
PCI 108.04 42
Perform Exercise 1
PAGE 197
PCI 108.04 43
Exercise 1 Key
Figure 87
A
PressureRegulator
Waterto Drain
SampleReturn
SampleTap
FastLoop
Fast LoopFlowmeter
FastLoopFilter
LabSample
Point
Coalescer
To SampleRecoverySystem
Probe
BoilingPoint
Analyzer
F
VAPOUR PRESSURE ANALYSERS
PCI 108.04 45
Evaluating Vapor Pressure Analyzers
• Function - to measure the vapor pressure of a liquid process stream in order to monitor a product specification or to provide data for advanced control of fractionators and blending systems.
PCI 108.04 46
Evaluating Vapor Pressure Analyzers
• Function • General Applications
– Fuels Blending
PCI 108.04 47
Vapor Pressure Analysers
Laboratory Methods:ASTM D323 Volatile Crude Oil & Volatile Petroleum ProductsASTM D1267 Liquid Petroleum GasesASTM D5482 (93) Mini Method - Atmospheric
PCI 108.04 48
Evaluating Vapor Pressure Analyzers• Function • General Applications
Juaymah Gas Plant- RVP Tower - TOTCO
PS3 RVP Arab Super Light - ABB– Fuels Blending
Ras Tanura Refinery - Plant 28 MOGAS BLEND - ABB
PCI 108.04 49
Evaluating Vapor Pressure Analyzers
• Function • General Applications
– Fuels Blending– Vapor-Liquid Ratio Measurement
Ras Tanura Refinery - Plant 28 MOGAS Blend - Core Labs
PCI 108.04 50
Evaluating Vapor Pressure Analyzers
• Function • General Applications• Process Analytical Techniques for Vapor Pressure
Measurement– Principles of Operation (Reid Method ASTM
D323)
PCI 108.04 51
Evaluating Vapor Pressure Analyzers
• Function • General Applications• Process Analytical Techniques for Vapor Pressure
Measurement– Principles of Operation (Reid Method ASTM
D323)– Configuration of Vapor Pressure Analyzers
PCI 108.04 52
Configuration of Vapor Pressure Analyzers
• Reid Vapor Pressure Analyzers
PCI 108.04 53
Precision Scientific Reid Monitor Model 44770
Figure 16
Reid Monitor
20 PSIG Air Supply
3-15 PSIG Output
Coolant
Sample In
SampleOut
PressureTransmitter
Coolant
125#
400#
CalibrationValve
FeedPump
PumpMotor Exhaust
Pump
20#
CircPump
SaturationChamber
OilBath
75#
0.3-148PSIG
Feedback
25#
10#
SealPot
PCI 108.04 54
ABB Process Analytics RVP Analyzer Model 4100
Figure 17A
PCI 108.04 55
ABB Process Analytics RVP Analyzer Model 4100
Figure 17B
Transducer Output Once Cycle 1 Purge cell 2 False fill 3,4,5 3 each 20 sec. purges of cell 6 Zero pressure reading 7 20 sec. sample filling cell 8 4 min. equilibration and final pressure reading Diagnostics During One Cycle A. Temperature and temperature runaway monitoring and over pressure protection B Air purge pressure test C Zero reading pressure transducer test D Level sensor test E Sample fill test F Cell leak test and RVP temperature confirmation
A
F 8
7 E
R 5 4 3
D C 6
2 1
PCI 108.04 56
Configuration of Vapor Pressure Analyzers
• Reid Vapor Pressure Analyzers• Kinetic (or Absolute) Vapor Pressure Analyzers
PCI 108.04 57
Precision Scientific Absolute Vapor Pressure Analyzer - Principle
Figure 18
V 1 V 2 Incoming Sample
Sensing Device
Measuring Chamber
P 2
PCI 108.04 58
Principle Precision Scientific Absolute Vapor Pressure Analyzer - Layout
Figure 19
PT
Inlet Pressure Regulator
TemperatureController
BathHeater
Hi-temp C/O
RTD
EjectorAssembly
Back PressureRegulator
ASTMThermometer
SampleOil
StirringMotor
SampleIn
Coolant
Filter
PCI 108.04 59
Configuration of Vapor Pressure Analyzers
• Reid Vapor Pressure Analyzers• Kinetic (or Absolute) Vapor Pressure Analyzers
TOTCO CVPT
PCI 108.04 60
Configuration of Vapor Pressure Analyzers
• Reid Vapor Pressure Analyzers• Kinetic (or Absolute) Vapor Pressure Analyzers• Vapor/Liquid Ratio Analyzers
Ras Tanura Refinery - Plant 28 MOGAS Blender
PCI 108.04 61
Core Labs Volrac V/L Ratio Analyzer
Figure 20
LiquidVolumeSignal
VaporLiquid
Separator
VaporFlowMeter
TempControlHot Oil
Hot Water
ElectricWaterHeaterMechanical
Chiiller CalculateAnalyzed V/L
CalculateDelta V/L
(Anal-Targ)
V/L A V/L
Signal for Remote Devices
V/L = 8/40 V/L = 40StandardFuel
Control Instruments& Analog Computation
V-L SeperatorTemperature
Controller
V/LTemperature
SelectSwitch
VaporVolumeSignal
Target V/LSelectSwitch
FilterCoalescer
Cooler
Fuel Sample Loop
Excess FuelFuelMetering
Pump
Excess Fuel
_ +
PCI 108.04 62
Evaluating Vapor Pressure Analyzers
• Function • General Applications• Process Analytical Techniques for Vapor Pressure
Measurement• Installation Considerations
PCI 108.04 63
Evaluating Vapor Pressure Analyzers
• Function • General Applications• Process Analytical Techniques for Vapor Pressure
Measurement• Installation Considerations• Operational Considerations
PCI 108.04 64
Evaluating Vapor Pressure Analyzers
• Function • General Applications• Process Analytical Techniques for Vapor Pressure
Measurement• Installation Considerations• Operational Considerations• Maintenance Considerations
PCI 108.04 65
Evaluating Vapor Pressure Analyzers
• Function • General Applications• Process Analytical Techniques for Vapor Pressure
Measurement• Installation Considerations• Operational Considerations• Maintenance Considerations• Specific Application Evaluation
PCI 108.04 66
Flow Diagram - Gasoline Blending Process
Figure 21
Ratio
SP SP SP SP SP
FCFC
Ratio
FC
Ratio
FC
Ratio
FC
Ratio
AT
GasolineBlending
Feed Stocks
Master Oscillator
Vapor Pressure
PumpedFast Loop
Blend HeaderGasolineProduct
TurbineMeter
PCI 108.04 67
Sample Handling System for a Vapor Pressure Analyzer
Figure 24
SampleReturn
SampleTap
FastLoop
Fast LoopFlowmeter
FastLoopFilter
LabSample
Point
Coalescer
PressureRegulator
Water toDrain
Probe
A
PressureRegulator
To SampleRecovery
VaporPressureAnalyzer
Water toDrain
PCI 108.04 68
Perform Exercise 2
PCI 108.04 69
Exercise 2 Key
Figure 88
A
PressureRegulator
SampleReturn
SampleTap
FastLoop
Fast LoopFlowmeter
FastLoopFilter
Lab SamplePoint
To SampleRecoverySystem
Probe
F
PressureRegulator
VaporPressureAnalyzer
StandardSample
OCTANE ANALYSERS
PCI 108.04 71
Evaluating Octane Analyzers
• Function - to measure the octane number of intermediate feedstocks for gasoline blending and octane number of the final blended gasoline.
PCI 108.04 72
Evaluating Octane Analyzers
• Function• General Applications
– Gasoline Blending
PCI 108.04 73
Evaluating Octane Analyzers
• Function• General Applications
– Gasoline Blending– Refinery Processes
PCI 108.04 74
Evaluating Octane Analyzers
• Function• General Applications
– Gasoline Blending– Refinery Processes– Feedstocks for Gasoline Blending
PCI 108.04 75
Evaluating Octane Analyzers
• Function• General Applications • Process Analytical Techniques for Octane
Number Measurement– Principles of Operation
PCI 108.04 76
ASTM-CFR Engine for Octane Testing
Figure 25
A
M
N
O B
K D
C
J I
E
G
F L H
A. Inake Surge Pipe B. Coolant Condenser C. Exhaust Surge Tank D. Exhaust Manifold E. Crank for Adjusting Compression Ratio F. Oil Drain Cap G.Waste Fuel Can, Closed for Safety H I. J. K. L. M. N.
Ignition Breaker Cylinder Clamp Intake Air Thermometer Ignition Coil Detonation Meter , Model 501-T Knockmeter
O. Temperature Controller
Oil Filter
PCI 108.04 77
ASTM-CFR Engine for Octane Testing
A
M
N
O B
K D
C
J I
E
G
F L H
•Compression Ratio 4-18•Coil & Distributor Ignition•Spark advance indicated•RON advance set at 13BTDC•RON SPEAD 600rpm
PCI 108.04 78
ASTM-CFR Engine for Octane Testing - Bracketing - Procedure A - ASTM D2699
ENGINE STANDARDIZTION
RUN SAMPLE FUEL
RUN REFERENCE FUEL 1
RUN REFERENCE FUEL 2
ON PRF :•SET CYL HEIGHT•FUEL LEV FOR MAX KI•SET METER TO 50 +/-2
•ADJUST CYL HEIGHT SO KI =MIDSCALE•FUEL LEV FOR MAX KI•ADJUST CYL HEIGHT 50+/- 2•RECORD CYL HEIGHT AND •FROM GUIDE TABLES EST ON
•RUN REFERENCE FUEL 1:•FUEL LEVEL FOR MAX KI
•RUN REFERENCE FUEL 2:•FUEL LEVEL FOR MAX KI
PCI 108.04 79
ASTM-CFR Engine for Octane Testing - Bracketing - Procedure A - ASTM D2699
PCI 108.04 80
Evaluating Octane Analyzers
• Function• General Applications • Process Analytical Techniques for Octane
Number Measurement– Principles of Operation – Configuration of Octane Analyzers
PCI 108.04 81
Configuration of Octane Analyzers
• Analyzers Based on the ASTM-CFR Engine – Knock Intensity Method
PCI 108.04 82
Core Labs Model 8154 Octane Comparator System
Figure 27
O.N. Recorder X FlowIntegrator
Drain
CrankcaseVentExhaust
OctaneAnalyzerConsole
OctaneAnalyzer
Fuel Cooler
OctaneAnalyzer
FuelConditioner
ASTMEngine
byWaukesha
OctaneAnalyzerInterface
Prototype FuelStorage System
ExcessFuel
Return
SampleLoop
Power (Single Phase)Power (Three Phase)Cooling Water
BlenderControlModifier
PCI 108.04 83
Core Labs Model 8154 Octane Comparator System (KI Method)
Figure 28
Rotometer
CoolantExchanger
SolenoidValve
CoolantExchanger
SolenoidValve
ProtoPump
ProtoSafetyCan
SampleLoop
ProtoTanks
FilterCoalescer
Pressure Regulator
FuelSelectionValve
Octane Analyzer-Fuel System
BypassConn.
ASTMEngine
PCI 108.04 84Figure 28
Core Labs Model 8154 Octane Comparator System (KI Method)
SampleTimer
ProtoTimer
Fuel Selector Valve
Proto Track &Hold Module
Sample Track &Hold Module
Octane Analyzer-Programmer Functions
Programmer
PCI 108.04 85
Configuration of Octane Analyzers
• Analyzers Based on the ASTM-CFR Engine – Knock Intensity Method– Compression Ratio Method
PCI 108.04 86Figure 27
Core Labs Model 8154 Octane Comparator System (CR Method)
C RControl
Carburetor
ASTMEngine
DetonationMeter
C RMotor
C R MotionTransmitter
Pump
Excess Fuel
Sequencing
Span
ProductTrack& Hold
Offset
ProtoTrack& Hold
AddSubt
Delta O.N.Display
2 Gal.Aux Proto
Pump
Bulk Proto
Product SampleLoop
Filter &Coalescer
FuelCooler
PCI 108.04 87Figure 28
Core Labs Model 8154 Octane Comparator System (CR Method)
Constant Knock Intensity-CompressionRatio Control System
Knockmeter
Pickup
DetonationMeter
CompressionRatio
Controller
C.R.Motor
ASTMEngine
PCI 108.04 88Figure 28
Core Labs Model 8154 Octane Comparator System (CR Method)
Proto Track &Hold Module
t rack Hold Module
Span Offset
AdderModule
O.N.Output
O.N.Output
O.N.Meter
Sequenc ing
C.R. Measurement and Delta ON SignalGeneration System
ASTMEngine
Sample T
PCI 108.04 89
Associated Octel Octane Comparator System
Figure 29
PCI 108.04 90
Associated Octel Octane Comparator System - Operating Sequence
Figure 30
BD
C
A
LineGasoline
ReferenceGasoline
LineGasoline
ReferenceGasoline
210 sec. Time
PCI 108.04 91
Configuration of Octane Analyzers
• Analyzers Based on the ASTM-CFR Engine • Analyzers Based on Correlative Techniques
PCI 108.04 92
UOP Monirex Octane Analyzer
Figure 31
Inlet
Increase inOctane ShiftsPeak
TE - 1 TE - 2
25.4 mmReactor Tube Length
TE1 TE2
( T)
TE
PSL MM
M
MM
R
R
TE
TRC
TDC
TE
PI
TE
PressureTransmitter
Temperature DifferentialController
(High)(Low)PressureSwitches
ReactorChamber
PressureController
PreheaterMetering
Pump
SampleInlet
SampleBypassLoop Bath
Heater
Afterburner
Vent to Stack
RowController
PressureController
Instrument Air
Increase inPressureShifts Peaks
A. Flow Schematic
B. Peak Temperature Curve
PCI 108.04 93
UOP Monirex Octane Analyzer
Figure 31
Inlet
Increase inOctane ShiftsPeak
TE - 1 TE - 2
25.4 mmReactor Tube Length
TE1 TE2
( T)
TE
PSL MM
M
MM
R
R
TE
TRC
TDC
TE
PI
TE
PressureTransmitter
Temperature DifferentialController
(High)(Low)PressureSwitches
ReactorChamber
PressureController
PreheaterMetering
Pump
SampleInlet
SampleBypassLoop Bath
Heater
Afterburner
Vent to Stack
RowController
PressureController
Instrument Air
Increase inPressureShifts Peaks
A. Flow Schematic
B. Peak Temperature Curve
PCI 108.04 94
Foxboro Model 81P Octane Analyzer - Operating Conditions
Figure 32
Oxidation Reactions of Fuel-Air Mixes vs T emperatures
400350
300250200
Spontaneous Combustion
Cool Flames
Partial Oxidations
Little or Nor Reactions Occur
Thermocouple Output vs T ime for T ypical Gasoline
1.2
1.0
.8
.6
.4
0 6 12 18 24 30Time, (sec)
SampleInjection
InductionPeriod
Heat ofVaporization
Temp. Max. orSeverity
Mv
RON vs Severity vs T emperature
98
96
94
92
90
.2 .6 1.0 1.4 .1.8
300 C 305 C310 C
RON
315 C
C
A.
.B.
C.
PCI 108.04 95
Foxboro Model 81P Octane Analyzer - Operating Conditions
Figure 32
Oxidation Reactions of Fuel-Air Mixes vs T emperatures
400350
300250200
Spontaneous Combustion
Cool Flames
Partial Oxidations
Little or Nor Reactions Occur
Thermocouple Output vs T ime for T ypical Gasoline
1.2
1.0
.8
.6
.4
0 6 12 18 24 30Time, (sec)
SampleInjection
InductionPeriod
Heat ofVaporization
Temp. Max. orSeverity
Mv
RON vs Severity vs T emperature
98
96
94
92
90
.2 .6 1.0 1.4 .1.8
300 C 305 C310 C
RON
315 C
C
A.
.B.
C.
PCI 108.04 96
Foxboro Model 81P Octane Analyzer - Layout
Figure 33
Pump
Customer ServiceConnection(115 VAC)
DisplayHousing
PowerSwitch
FieldConnection
Oven TemperatureController
Flow PanelOutline
Pump AirFilter/Reg./Oiler
Drip PotAssembly
ReactorHousing(Oven)
MicroProcessorHousing
Air Heater/Sensor/Fan
Measuring T.C.
Reactor Block
Insulation
Air and SampleInlets
ChromatographicType Inject ValveSample Outlet
Reference T.C.
Reaction ZoneCavity
Reactor Heaters
Drip PotTo Vent and Flash
Back Arrestor
Reactor Housing
PCI 108.04 97
Configuration of Octane Analyzers
• Analyzers Based on the ASTM-CFR Engine • Analyzers Based on Correlative Techniques• Analyzers Based on FTIR/FTNIR Spectrometry
PCI 108.04 98
Analyzers Based on FTIR/FTNIR Spectrometry
PCI 108.04 99
VISIBLE SPECTRUM
PCI 108.04 100
Near Infra Red
PCI 108.04 101
Analyzers Based on FTIR/FTNIR Spectrometry
PCI 108.04 102
Analyzers Based on FTIR/FTNIR Spectrometry
Ras Tanura Refinery - Plant 28 RON & MON
PCI 108.04 103
Analyzers Based on FTIR/FTNIR Spectrometry
PCI 108.04 104
Analyzers Based on FTIR/FTNIR Spectrometry
PCI 108.04 105
Interferogram
PCI 108.04 107
Interferogram
PCI 108.04 108
Configuration of Octane Analyzers
• Analyzers Based on the ASTM-CFR Engine • Analyzers Based on Correlative Techniques• Analyzers Based on FTIR/FTNIR Spectrometr
PCI 108.04 109
Evaluating Octane Analyzers
• Function• General Applications • Process Analytical Techniques for Octane
Number Measurement• Installation Considerations
PCI 108.04 110
Evaluating Octane Analyzers
• Function• General Applications • Process Analytical Techniques for Octane
Number Measurement• Installation Considerations• Operational Considerations
PCI 108.04 111
Evaluating Octane Analyzers
• Function• General Applications • Process Analytical Techniques for Octane
Number Measurement• Installation Considerations• Operational Considerations• Maintenance Considerations
PCI 108.04 112
Evaluating Octane Analyzers
• Function• General Applications • Process Analytical Techniques for Octane
Number Measurement• Installation Considerations• Operational Considerations• Maintenance Considerations • Specific Application Evaluation
PCI 108.04 113
Flow Diagram - Gasoline Blending Process
Figure 34
RatioFCFC
Ratio
FC
Ratio
FC
Ratio
FC
Ratio
AT
SP SP SP SP SP
Gasoline BlendingFeed Stocks
Master Oscillator
OctaneNumber
PumpedFast Loop
Blend HeaderGasolineProduct
TurbineMeter
PCI 108.04 114
Typical Sample Handling System for an Octane Analyzer
Figure 37
Fast LoopFlowmeter
FastLoopFilter
Coalescer
PressureRegulator
Probe
Fuel Selector Valve
Water toDrain
SampleCooler
Coolant
To ASTM-CFR Engine
ProtoCooler
CoolantPressureRegulator
ShutoffValvesF
PrototypeFuel Storage
ProtoPump
PCI 108.04 115
Perform Exercise 3
PCI 108.04 116
Exercise 3 Key
Figure 89
SampleReturn
SampleTap
FastLoop
Fast LoopFlowmeter
FastLoopFilter
LabSample
Point To SampleRecovery
Probe
F
A
OctaneAnalyzer
FLASH POINT ANALYSERS
PCI 108.04 118
Evaluating Flash Point Analyzers
• Function - to measure the flash point of intermediate and final product streams in order to monitor a final product flash point specification, or to provide data for advanced process control.
PCI 108.04 119
Evaluating Flash Point Analyzers
• Function• General Applications
– Crude Distillation– Fuels Blending
PCI 108.04 120
Evaluating Flash Point Analyzers
• Function• General Applications• Process Analytical Techniques for Flash Point
Measurement– Principles of Operation
PCI 108.04 121
ASTM D56 Flash Point Test Apparatus
Figure 38
Bath Stand forGas Burner
Bath
Overflow
Cup Thermometer
FlameTip
OilChamber
Test Cup
Gas Burner
BathThermometer
FlameSizeBead
PCI 108.04 122
ASTM D93 Flash Point Test Apparatus
Figure 39
4.3741.941.58
. . .57.236.35
5.1642.063.189.52
57.86. . .
(0.172)(1.651)(0.062)(. . . )(2.253)
min max
mm inches
(min) (max)
(0.203)(1.656)(0.125)(0.375)(2.278)(. . .)
ABCDEF (0.25)
Distance PieceD
Note-Lid assembly may be positioned either right or left-handed.
Pilot
Handle (Optional)(Must not tipempty cup)
Stirrer Drive FlexibleShaft (Pulley drive optional)Flame ExposureDevice Shutter Operating
Knob
F-Min. thicknessover cup area i.e.,metal surroundingthe cupHeater Flame-Type or ElectricalResistance Type(Flame Type Shown)
E
Shutter
Test CupStove Top Plate
Air Bath
B C
A
Lid
Air Gap
Front
PCI 108.04 123
Evaluating Flash Point Analyzers
• Function• General Applications• Process Analytical Techniques for Flash Point
Measurement– Principles of Operation– Configuration of Flash Point Analyzers
PCI 108.04 124
Configuration of Flash Point Analyzers
• Analyzers that duplicate ASTM Test Methods
PCI 108.04 125
Precision Scientific General Flash Point Monitor Model 44650
Figure 40
M
PressureSwitch
M
L.P. Steam
PumpAssembly
PP T
FI
FI
P-1 P-2
Measuring Chassis
SampleHeater
P
Press.Reg. Sample
In
F.A.S.
Control Chassis
SolenoidValve
(Heating)
(Cooling)
115V.A.C.H.V.Elect.
Flash Cup
T/C
Sample Out
DrainFilter
115V.A.C.
RTD
Separator
Vent
PCI 108.04 126
Precision Scientific Flashpointer Model 44607
Figure 41
Connections:
1/8 FPT1/4 FPT3/4 FPT1/8 FPT1/4 FPT
Sample Inlet -Sample Outlet -Electrical (2) -Combustion Air -Purge Air -
VaporVent LaneHigh V oltage
Electrode
VaporThermocouple
LiquidThermocouple
Air In
Sample In
118 VAC
SampleHeater
SampleOutlet
LiquidDrainLine
SplashShield
ControlAssembly
PurgePurge
SampleIn
CombustionAir
PowerIn
SampleOut
Purge
FlashChamber
Flash Pointer
(MeasurementAssembly)
PCI 108.04 127
Precision Scientific Integrated Flash Point Monitor Model 44624
Figure 42
TI
Motor
2= Denotes Relief Valve & Setting (kg./cm )5.0
SampleOut
PSDCatalog44807
FlashPointer
Vent FlameArrester
MechanicalRefrigeration
Unit
BlockValve
CalibrationValve
DryFiltered
AirSupply
34
Bleed
SolenoidValve
SampleIn
CheckValve
5.3
FeedPump
FilterCoalescer
ExhaustPump
CheckValve
8.8
Bleed
8.8
34
PCI 108.04 128
Precision Scientific Pipeline Flash Point Monitor Model 44620
Figure 43
Motor
TI
2= Denotes Relief Valve & Setting (kg./cm )5.0
Solenoid
PSDCatalog44807
FlashPointer
SolenoidSample
In
FeedPump Check
Valve
8.8
Vent FlameArrester
CalibrationValve
FilterCoalescer
StandbyReservoir
ExhaustPump
AirCompressor
Bleed Valve
Solenoid
SampleOut
CheckValve
5.0
35Solenoid
35
BleedValve
MechanicalRefrigeration
Unit
PCI 108.04 129
Carlo Erba Flash-o-Matic Series 250 Flash Point Analyzer
Figure 44
PCI 108.04 130
Configuration of Flash Point Analyzers
• Analyzers that duplicate ASTM Test Methods• Analyzers that correlate with ASTM Test
Methods
PCI 108.04 131
Rotork Analysis (Hone) Flashar Flash Point Analyzer
Figure 45
Detector HousingTemperature Sensor
Purge Air to Power PackTerminal Box and Control Box
Flowmeter
Heat Exchangerand Drain Pipe
FilterAir
Inlet
SampleHeater
PurgeAir
MixingChamber
HeatedDetectorHousing
Flash UnitBox
Vent
Air PreheatCoilOverflow Chamber
Flash Point Thermocouple
FlameTrap
FlowmeterPressureRegulator
SampleInlet
Sampleto Drain Cal.
Sample
PCI 108.04 132
Evaluating Flash Point Analyzers
• Function• General Applications• Process Analytical Techniques for Flash Point
Measurement• Installation Considerations
PCI 108.04 133
Evaluating Flash Point Analyzers
• Function• General Applications• Process Analytical Techniques for Flash Point
Measurement• Installation Considerations• Operational Considerations
PCI 108.04 134
Evaluating Flash Point Analyzers
• Function• General Applications• Process Analytical Techniques for Flash Point
Measurement• Installation Considerations• Operational Considerations• Maintenance Considerations
PCI 108.04 135
Evaluating Flash Point Analyzers
• Function• General Applications• Process Analytical Techniques for Flash Point
Measurement• Installation Considerations• Operational Considerations• Maintenance Considerations• Specific Application Evaluation
PCI 108.04 136
Flow Diagram - Crude Atmospheric Distillation
Figure 46
Flash point AT Kerosene
Diesel Fuel
Light Gas Oil
Heavy Gas Oil
Top Pumparound
Middle Pumparound
Bottom Pumparound
No. 1 S/S Stripper
Steam
No. 2 S/S Stripper
Steam
No. 3 S/S Stripper
Steam
No. 4 S/S Stripper
Steam Crude Feed
Steam
Atm
osp
he
ric P
ipe
still
Flash Zone
Residue to Vacuum Pipestill
O/H Condenser
Water
To Fuel Gas
Reflux Drum
Reflux
Straight Run Naptha
PCI 108.04 137
Sample Handling System for a Flash Point Analyzer
Figure 49
Sample Return
Sample Tap
Fast Loop
Fast Loop Flowmeter
Fast Loop Filter
Lab Sample
Point
Sample Cooler
Coolant Pressure Regulator
Dual Filter-
Coalescer System
Water to Drain
Secondary Bypass
To Sample Recovery System
A
Probe
PCI 108.04 138
Perform Exercise 4
PCI 108.04 139
Exercise 4 Key
Figure 90
PressureRegulator
SampleCooler
Coolant
SampleReturn
SampleTap
FastLoop
Fast LoopFlowmeter
FastLoopFilter
LabSample
PointTo SampleRecoverySystem
AnalyzerFlowmeter
F
A
Flash PointAnalyzer
VISCOSITY ANALYSERS
PCI 108.04 141
Evaluating Viscosity Analyzers
• Function - to measure the viscosity of a process stream in order to monitor a product specification or to provide data for advanced process control.
PCI 108.04 142
Evaluating Viscosity Analyzers
• Function• General Applications
- Crude Distillation (Bottoms residue - Vacuum Tower Side streams)
- Fuels Blending- Lube Oil Production
PCI 108.04 143
Evaluating Viscosity Analyzers
• Function• General Applications• Process Analytical Techniques for Viscosity
Measurement– Principles of Operation
PCI 108.04 144
Friction in Solids
Figure 50
fMg
InclinedPlaneF
f=Mg Sin & F=Mg Cos Coefficient of Friction = f/F = Tan
PCI 108.04 145
Friction in Fluids - Viscosity
Dynamic Viscosity in Poise is the force needed per unit area to maintain a velocity difference of 1 cm/sec between layers of fluid 1 cm apart
PCI 108.04 146
Friction in Fluids - Viscosity
Dynamic Viscosity in Poise is the force needed per unit area to maintain a velocity difference of 1 cm/sec between layers of fluid 1 cm apart
Force = Dynamic Viscosity * Area * Velocity Distance
Dynamic Viscosity = F * d Ns/m2
A v
PCI 108.04 147
Kinematic Viscosity
KinematicViscosity()
DynamicViscosity()Density()
Unit of Measurement Stokes or Centistokes
PCI 108.04 148
The Nature of Fluid Flow
PCI 108.04 149
The Effect of Temperature on Viscosity
V = Specific VolumeT = TemperatureA & B = Constants
Viscosity of liquids decreases with temperatureViscosity of gases increases with temperature
PCI 108.04 150
CLASSICAL METHODS OF MEASURING VISCOSITY
• Capillary Method - Poiseuille’s• U Tube Method• Rotating Cylinder Method• Falling Sphere Method - Stoke’s
PCI 108.04 151
Classical Methods - Capillary - dp TypePoiseuille's Method of Viscosity Measurement
Hagen - Poiseulle
Absolute Viscosity = Shear Stress = PR/2LShear Rate 4Q/ R3
= P R 4
8 Q LP = Pressure differential across fluid in tube
R = Radius Inside Tube
L = tube Length
Q = Volumetric rate of fluid
PCI 108.04 152
Classical MethodsU-Tube Method of Viscosity Measurement
Figure 53
T
B D
C
E
A
Constant Temperature Bath
PCI 108.04 153
Classical MethodsRotating Cylinder Method
Figure 54
R2
R1
L
r
A
B
PCI 108.04 154
Classical MethodsStokes' Method of Viscosity Measurement
Figure 55
f 2
f 1
Sphere
Radius Velocity Denisty
Fluid ( Density ) d
D r
PCI 108.04 155
Evaluating Viscosity Analyzers
• Function• General Applications• Process Analytical Techniques for Viscosity
Measurement– Principles of Operation– Configuration of Viscosity Analyzers
PCI 108.04 156
Configuration of Viscosity Analyzers
• Capillary DP Type (Poiseuille Method)
PCI 108.04 157
Process Viscometer - CAPPILARY TYPE Precision Scientific Model 41070
Figure 59
Sample out,3/8 NPT
TransmitterConnections(Typical)
Sample in, 1 /2 NPT
Coolant in , 1/4 NPT
Sample out, 1/2 NPT
Electrical,1/2 NPT
Drain,1/2 NPT
Fast LoopSample In
SpentSampleOut
Low TemperatureInterlock Swi tch
Filter
ASTMThermometer
Coolant
TemperatureController
PressureDrop Tube
HighTemperatureShut-down
Fast LoopSample Out
PrimaryHeat Exch.
Secondary Heat Exch.
Gear Pump
PCI 108.04 158
Process Viscometer- CAPPILARY TYPERotork Analysis - Ludlum Sysco Model 1070
Range - By Capillary Selection Max: 0-2500cP Min: 0-5cP
Repeatability: +/- 0.5% FSPrecision: +/- 1.0% FSResponse time: up to 3 minutes
PCI 108.04 159
Process Viscometer- CAPPILARY TYPE Precicion Scientific Model 44860
Figure 60
T/C E/I
P
TC
MM
TC
Electrical ControlHousing
Air In
Coolant
Steam
SampleIn
Strainer
CheckValve
Purge Air Remote Readout(Optional)
0 - 10 VDC
4 - 20 mA DC
Thermometer(Optional)
PressureRegulator
Overflow
Drain
FeedPump50 LPH
BoosterPump75 LPH
SampleOut
SeeNote 2
400 psigRelief
Capillary
D/P
Thermoswitch
TP
PCI 108.04 160
Process Viscometer- CAPPILARY TYPE Precision Scientific Model 44860
RT Refinery - Plant 52 Diesel Blender
Range: 2- 4000cP by selection of one of 13 capillaries
Accuracy:Correlations with labs +/- 1%Repeatability: +/- 0.5% FSResponse: 2 to 3 minutes
PCI 108.04 161
Configuration of Viscosity Analyzers
• Capillary DP Type (Poiseuille Method)• Vibrational Type
- ABB Model 1800 Viscometer- Dynatrol 900 Series Viscometer
PCI 108.04 162
Process Viscometer - Vibrating ElementABB Process Analytics Ultraviscoson
Figure 61A
Legend
Switching Circuits
Viscosity InformationStandard systemwith multiprobeoption
MultipointUnit
1800 UVControl Recorder
1
Probe
2 3 4 5 6
Standard system withautomatic temperaturecompensation option
AutomaticTemperature
CompensationCircuitry
1800 UVControl Recorder
TemperatureCompensation
Probe
ViscosityProbe
PCI 108.04 163
Process Viscometer - Vibrating Element ABB Process Analytics Ultraviscoson
Figure 61B
Standard Proces Probe – Standard immersion length
Junction Box
3/4 NPT GuardMountingFitting
HermeticSeal
P/N 631761
3/4 NPT ProbeMountingFitting
Probe Guards
P/N 630508Round Slotted Probe Guard
P/N 630624Flat Plate Probe Guard
Standard Proces Probe – For heavy duty applications
P/N 6306013/4 NPT
Junction Box
3/4 NPT GuardMountingFitting
3/4 Pipe
Hermetic Seal1 1/4 NPT ProbeMounting Fitting
Standard Proces Probe – For applications where flangemounting is required
3/8 NPT GuardMountingFitting
3/8 NPTHermeticSeal
3/4 Pipe
P/N 630600
JunctionBoxImmersion
Length
PCI 108.04 164
Process Viscometer - Vibrating Element Automation Products Dynatrol 900 Series
Figure 62
Pickup End Drive Coil Driver
End
Soft Iron Stator
Drive Armature
9/16"
Node Point
3/4" N.P.T.
1/2" Conduit
Hub
Detector
Temperature Element
Converter
Recorder Controller (User furnished)
Detector
Converter
Recorder Controller (User furnished)
Ra
ng
e
*Note: Mid-ranges also available.
1 10 100 1K 10K 100K 0
20
40
60
80
100
Viscosity-Centipoise
CL-10
R
V -3
CL-10
R
V -3
CL-10
R
V -3
PCI 108.04 165
Process Viscometer - Vibrating Element Nametre Vibrating Sphere Viscometer
Figure 63
PrecisionAmplitudeMonitoring
Circuit
Phase Shifterand
Attenuator
SquaringAmplifierOperational
Rectifierand
Low Pass Filter
Display and/orRecording Device
+
+
AmplitudeReference
CircuitPre-
Ampl.
Compliant StainlessSteel Sheath
Driver Detector
Driver Shaft
Liquid LevelGroove
Shear Wave
Oscillatory Member
GainControlledAmplifier
PCI 108.04 166
Configuration of Viscosity Analyzers
• Capillary DP Type (Poiseuille Method)• Vibrational Type• Rotating Disc Type (Torque Measurement)
PCI 108.04 167
Process Viscometer - Rotating Element Brookfield Model VTA120 Process Viscometer
Figure 64
PCI 108.04 168
Brookfield Model TT 100 In-Line Process Viscometer - Ras Tanura Refinery Plant 52
Figure 65
PCI 108.04 169
Contraves Model DC-43 Process Viscometer
Figure 66
Junction Box onlyin case of explosion-proof design
ConnectionCable
Cooling waterconnection inletand outletG 1/4". Casingjacket must beordered separately
Separate thread hereprior to welding
PCI 108.04 170
Eurcontrol Model VISC-21 Process Viscometer
Figure 67
1 7 2 3 4 5
8 9 10 11 10 12 6
Key:
1. Electric Motor 2. Angular Contact Ball Bearings 3. Drive Shaft 4. Mechanical Seal 5. Measuring Vessel 6. Rotating Disc
7. Support Bracket 8. Measuring Disc (Stationary) 9. O-Ring Seal 10. Angular Contact Ball Bearing 11. Measuring Shaft 12. Transducer Cover
PCI 108.04 171
Brabender Convimeter Process Viscometer
Figure 68
1. Protection Sheath 2. Cylindrical Sensing Device 3. Conical Mantle 4. Metal Bellows 5. Drive Shaft 6. Differential Gear 7. Metering Spring 8. Inductive Transducer 9. 2-Speed Synchronous Motor10. Removable Cover
SchematicDiagram
Measuring Head
10
9
876
5
4
32
1
Flow in Protection Sheath
PCI 108.04 172
Configuration of Viscosity Analyzers
• Capillary DP Type (Poiseuille Method)• Vibrational Type• Rotating Disc Type (Torque Measurement)• Falling Piston Type (Stoke’s Method)
PCI 108.04 173
Norcross Falling Piston Viscometer - Operating Principle
Figure 69
Filling Phase
Piston Rod (Attached to
Lifting Mechanism)
End of Measuring Phase
Piston Raised
Tube Opening
Measuring Tube
Piston Bottomed
PCI 108.04 174
Norcross Model M-36 Process Viscometer
Figure 70
3/8" NPT Inlet
3/8" NPT Outlet
Sample Flow Valve
(Adjustable)
Upper Magnet
Piston Position Indicator
Primary Flow
Piston
Lower Magnet
Proximity Switch
Screen
Sam- ple Flow
Sample Solenoid Valve
PCI 108.04 175
Configuration of Viscosity Analyzers
• Capillary DP Type (Poiseuille Method)• Vibrational Type• Rotating Disc Type (Torque Measurement)• Falling Piston Type (Stoke’s Method)• Electromagnetic Type
PCI 108.04 176
Cambridge Applied Systems Process Viscometer
Figure 71
15
Temperature Probe
Slde-Ring
1/2" NPT
Immersion Viscosity Sensor
Slide-Ring Sensor
PCI 108.04 177
Evaluating Viscosity Analyzers
• Function• General Applications• Process Analytical Techniques for Viscosity
Measurement• Installation Considerations
PCI 108.04 178
Evaluating Viscosity Analyzers
• Function• General Applications• Process Analytical Techniques for Viscosity
Measurement• Installation Considerations• Operational Considerations
PCI 108.04 179
Evaluating Viscosity Analyzers
• Function• General Applications• Process Analytical Techniques for Viscosity
Measurement• Installation Considerations• Operational Considerations• Maintenance Considerations
PCI 108.04 180
Evaluating Viscosity Analyzers
• Function• General Applications• Process Analytical Techniques for Viscosity
Measurement• Installation Considerations• Operational Considerations• Maintenance Considerations• Specific Application Evaluation
PCI 108.04 181
Flow Diagram - Crude Atmospheric Distillation
Figure 73
AT
Top Pumparound
Middle Pumparound
Bottom Pumparound
Crude Feed Steam
Atm
osp
he
ric
Pip
est
ill
Flash Zone
Residue to Vacuum Pipestill
O/H Condenser
Water
To Fuel Gas Reflux Drum
Straight Run Naptha
Viscosity
No. 1 S/S Stripper
Steam Kerosene
No. 2 S/S Stripper
Steam Diesel Fuel
No. 3 S/S Stripper
Steam Light Gas Oil
No. 4 S/S Stripper
Steam Heavy Gas Oil
Reflux
PCI 108.04 182
Typical Sample Handling System for a Viscosity Analyzer
Figure 76
F
TA
Fast Loop
A
1.
2.
Notes:
All lines and components to be heat traced and insulated. Solvent injection valves to be actuated on loss of temperature in fast loop, (Signal from low temp. alarm).
Low Temp. Alarm
Fast Loop Filters
Sample Tap
Sample Return
Solvent
Lab Sample
Point
To Sample Recovery
To Solvent Recovery
Probe
Pressure Regulator
Fast Loop Flowmeter
Solvent
Viscosity Analyzer
PCI 108.04 183
Perform Exercise 5
PCI 108.04 184
Exercise 5 Key
Figure 91
SampleReturn
SampleTap
FastLoop
Fast LoopFlowmeter
FastLoopFilter
LabSample
Point
F
A
ViscosityAnalyzer
AnalyzerFlowmeter
PressureRegulator
COLOUR ANALYSERS
PCI 108.04 186
Evaluating Color Analyzers
• Function - to measure the color of a petroleum product or intermediate stream.
PCI 108.04 187
Evaluating Color Analyzers
• Function• General Applications
– Fuels Processing
PCI 108.04 188
Evaluating Color Analyzers
• Function• General Applications
– Fuels Processing– Heat Exchanger Leakage
PCI 108.04 189
Evaluating Color Analyzers
• Function• General Applications• Color Measurement
– Principles of Operation
PCI 108.04 190
Typical Chromophoric Groups
Figure 77
Chromophore Group ExampleEther O C2 H5 O C2H2
Thioether S CH3 S CH3
Amine NH2 CH3 NH2
Mercaptan SH C2H5 SH
Alkyne CC CHC CH2 CH2
Aldehyde CHO CH3 CHO
Alkene CC CH3 CCH2
Alcohol OH C2H5 OH
Ketone CO (CH3)2CO
Nitro-compound NO2 CH3 NO2
Azo-compound NN CH3 NN CH3
a
Benzene
Napthalene
Anthracene
(–C = C–)n
PCI 108.04 191Figure 78
Relationship Between Wavelength and Color
Wavelength (nm) Transmitted Color Complementary Hue
<380 Ultraviolet
380-435 Violet Yellowish-green
435-480 Blue Yellow
480-490 Greenish-blue Orange
490-500 Bluish-green Red
500-560 Green Purple
560-580 Yellowish-green Violet
580-595 Yellow Blue
595-650 Orange Greenish-blue
650-780 Red Bluish-green
>780 Near infrared
PCI 108.04 192
Spectral Response of Color Standards
Figure 79A & B
400 500 600 0
1.0
2.0
Abs
orba
nce
Wavelength
m
APHA 20
APHA 15
APHA 10
A
400 500 600 0
1.0
2.0
Abs
orba
nce
Wavelength
m
SAYBOLT 14.3
SAYBOLT 19.4
SAYBOLT 25.0
B
PCI 108.04 193
Spectral Response of Color Standards
Figure 79C
400 500 600 700 800 0
1.0
2.0 A
bsor
banc
e
Wavelength
ASTM 1
ASTM 2
ASTM 3
ASTM 4
ASTM 5
ASTM 6
m
C
PCI 108.04 194
Evaluating Color Analyzers
• Function• General Applications• Process Analytical Techniques for Color
Measurement– Principles of Operation– Configuration of Color Analyzers
PCI 108.04 195
Customs Sensors & Technology Model 5520 Color Analyzer
Figure 80A
Splitter
Measuring Filterand Detector
Reference Filterand Detector
LightSource
Analyzer
Fiber-Optic Cables
Sample Cell
Elec-tronics
Internal Reference
Splitter
Measuring Filterand Detector
Reference Filterand Detector
LightSource
Analyzer
Fiber-Optic Cables
Sample Cell
External Reference
Elec-tronics
PCI 108.04 196
Customs Sensors & Technology Model 5520 Color Analyzer
Figure 80B
PCI 108.04 197
Precision Scientific Model 42015 Colorimeter
Figure 81
AlarmRelay
(2)
Power Supply
Power Alarm Module
AC
SampleOut
SampleIn
OpticalFillers
Control/Display Module
Lamp DigitalPCB
Display
Fiber Optic Source Photodiodes
4/20 mA
AnalogPCB
DetectorFlow Cell
Source
Flow Cell Enclosure
PCI 108.04 198
Precision Scientific Model 42015 Colorimeter
ASTM D1500 SAYBOLT D-156
Max Temperature: 55CSam Pressure: 147psig 1470psig@ 150CSam Temp: -20 to 150CClass1, Division 1, B,C&D
PCI 108.04 199
Rotork Analysis Model 7613 Color Alarm
Figure 82
PowerSupply
SupervisoryCircuit
AlarmRelay
Meas.Store
Gating
ComparatorPhoto diode
SampleCell
ChoppingDisc
TungstenLamp
Motor
Twist-to-Test
Filter
Ref.Store
PCI 108.04 200
Evaluating Color Analyzers
• Function• General Applications• Process Analytical Techniques for Color
Measurement• Installation Considerations
PCI 108.04 201
Evaluating Color Analyzers
• Function• General Applications• Process Analytical Techniques for Color
Measurement• Installation Considerations• Operational Considerations
PCI 108.04 202
Evaluating Color Analyzer
• Function• General Applications• Process Analytical Techniques for Color
Measurement• Installation Considerations• Operational Considerations• Maintenance Considerations
PCI 108.04 203
Evaluating Color Analyzer
• Function• General Applications• Process Analytical Techniques for Color
Measurement• Installation Considerations• Operational Considerations• Maintenance Considerations• Specific Application Evaluation
PCI 108.04 204
Flow Diagram - Crude Atmospheric Distillation
Figure 83A
Top Pumparound
Middle Pumparound
Bottom Pumparound
AT
Atmospheric Pipestill
Straight Run Naptha
Crude Feed Steam
Flash Zone
Residue to Vacuum Pipestill
O/H Condenser
Water
To Fuel Gas Reflux Drum
Reflux
No. 1 S/S Stripper
Steam Kerosene
No. 2 S/S Stripper
Steam Diesel Fuel
No. 3 S/S Stripper
Steam Light Gas Oil
No. 4 S/S Stripper
Steam Heavy Gas Oil
PCI 108.04 205
Flow Diagram - Crude Atmospheric Distillation
Figure 83B
PCI 108.04 206
Typical Sample Handling System for a Color Analyzer
Figure 86
PressureRegulator
SampleCooler
Coolant
SampleReturn
SampleTap
FastLoop
Fast LoopFlowmeter
FastLoopFilter
LabSample
Point
FilterCoalescer
Water +Sample toRecovery
To SampleRecovery
Probe
AnalyzerFlowmeter
Bypass/IsolationValves
F
A
PCI 108.04 207
Perform Exercise 6
PCI 108.04 208
Exercise 6 Key
Figure 92
SampleReturn
SampleTap
FastLoop
Fast LoopFlowmeter
FastLoopFilter
LabSample
Point To SampleRecovery
Probe
F
A
ColorAnalyzer
PressureRegulator
PCI 108.04 209
Perform Evaluation
PCI 108.04 210
Evaluation Key
Figure 93
SampleReturn
SampleReturn
FastLoop
Fast LoopFlowmeter
FastLoopFilter
LabSample
Point
SampleCooler
Coolant
PressureRegulator
DualFilter-Coalescer
System
Water toDrain
SecondaryBypass
To SampleRecoverySystem
A
Probe
PCI 108.04 211
Pour Point