JNTUK B.Tech Process Troubleshooting gives you detail information of Process Troubleshooting R13 syllabus It will be help full to understand you complete curriculum of the year.
Learning Objectives
- To have working knowledge of various process equipment and range of operating parameters and variables. The equipment refer to pumps, heaters, refrigeration systems, process heaters, water coolers, distillation and vacuum towers and reactors.
- To have basic knowledge of various reasons for equipment malfunctioning.
- To have working knowledge of various petroleum refinery processes such as Crude Distillation Unit, Delayed Coking Unit, Fluid Catalytic Cracking, Sulfur Recovery and Alkylation Units
- To have basic knowledge of various reasons for process malfunctioning
- To have basic philosophy of integrating, analyzing and retrospection of time dependent process data.
UNIT-I: Introduction to Process Troubleshooting and guidelines for process troubleshooting Centrifugal pumps: What can go wrong?; How pumps work: Rattling Equals Cavitation; Why pumps cavitate on start- up; Origins of cavitation; Starting troublesome pumps and ensuring minimum recirculation flow; Consequences of cavitation : Oversized pumps surge, When not to pull a pump, Internal recirculation; Worn- out impeller; Blowing seal : Rough running, check spare pumps, Avoiding motor failures, Expanding pump capacity.
Process Heaters: Draft; Reduced draft; Combustion air supply; Trimming burner operation; Optimizing excess air; Optimizing heater draft; Excessive draft; Plugged draft gauges; Insufficient Air; Optimizing excess air; Flue gas oxygen; Flame appearance; Fin tube damage; Sealing skin leaks; Convection and radiation; Draft measurements; Leak prevention; Air preheaters; Preheater vibration; Other Ideas to save energy; Measuring heater temperatures; Spotting hot tubes; Cooling overheated tubes; Coke deposition; Oil burning; Heater huffing and puffing; Expanding heater capacity; Draft limited; Heat absorption limited.
UNIT-II: Process Heat exchangers: Process heat transfer, fouling, high pressure drop and chemical cleaning.
Water Coolers: Plugged tubes; Back flushing; Air bumping; Acid cleaning; Calculating water flow rate; Hydrocarbons leaking into cooling towers; Which exchanger is leaking?; Warm cooling tower; High exchanger outlet temperature; Water side fouling; Biological growth; pH control; Cycles of condensation; Monitoring exchanger fouling.
Refrigeration Systems – Is refrigeration efficiency falling?; Diagnosing refrigeration compressor problems; Short of horsepower; Cooling the motor; Steam drivers; Valves a problem on reciprocating compressors; Refrigerant composition; Speed limited; Horse power limited; Accumulator relief valve; Minimum suction pressure problems; Importance of the throttle valve; Missing accumulation drum; Evaporating problems; Drown tubes in refrigerant; Increasing plant throughput; Evaporator Fouling; Refrigerant condenser difficulties.
UNIT-III: Distillation Towers: Confusing Incidents; High liquid level induces flooding; Vertical temperature survey; Two phase bottom level problem; Foaming; Expanding tray capacity; Damaged trays; Liquid filled towers; reflux changes; Level control; Reboiler problems; Trapout pans; Plugged reboilers; Repair of trapout pans; steam side problems; Blown condensate seal; Reflux problems.
Vacuum Towers: Loss of bottoms pump suction pressure: Insufficient quench, TGO pan overflows, Grand oil, Suction screen, Air leak; High flash zone pressure; Thermal cracking; Ejector problems: Air leaks, Motive steam quality, Condensers, Plugged seal legs, Ejector internals; Black gas oil; Excessive production of trim gas oil; Low pumparound draw temperatures; Light resid; Steam to heater passes; Projects to improve gas oil recovery; Transfer line failures: Furnace tube failures.
UNIT-IV: Crude Distillation – Interpreting process drop data; The solution is an aspect of the problem; Eliminating the gas oil; A tray construction error; Correcting the tray problem; Typical troubleshooting problems: Decreased fractionation, upset tray decks; Improper heat balance, Raise pumparound to save energy, Light naphtha end point, Dirty naphtha; Steam stripping cat cracker feed;Causes of inadequate stripping; Steam stripping summary; Defining the project scope; Stripping steam rates; Gathering the artificial intelligence; Diesel oil stripping; Jet fuel stripper; Bottom’s stripper; The wrap up meeting; Leaking Drawoff trays; Welded trapout pans; Overhead Condenser corrosion; Exchanger train fouling; Preflash towers save energy; Energy saving; Preflash tower foaming; Rising energy index.
Delayed Coking processes – Coking heater; Mass velocity and heat flux; Feed interruptions; Velocity steam; Sodium; Light resid; Foamovers; Parallel Passes; Steam air decoking; On-line spalling; Wet gas compressor; A fouled overhead condenser; Vapor line restrictions; Wet gas compressor rotor fouling; Combination tower; Explosion proof trays; Energy savings; Coke drum cycles affect combination tower operation; Minimizing coke yields.
UNIT-V: Reactors – Low conversion, deviations in feed ratios, deviations in operating parameters, catalyst damage, balance life assessment of catalyst. and spent catalyst distribution, Identifying air grid damage; Catalyst deactivation; Catalyst deactivation Vs. refactory feed; Reducing regenerator temperature; Troubleshooting cyclone malfunctions: Dipleg unsealed, plugged dipleg, Dipleg failure; Air blower problems; Catalyst feed mixing; Cracking catalyst data.
Amine Regeneration and Scrubbing – Dirty amine; The seeds of destruction; Dirty amine ruins operation; Cleaning up amine: Corrosion inhibitors; reboiler corrosion; Regenerator feed temperature; Reclaimer operation: Washing the reclaimer, How much soda ash to use; Extending reclaimer tube life, Using a reclaimer instead of a filter; Foaming: Early warning system, Causes
and cures of foaming; Liquid – liquid amine scrubbers; Declining amine strength; Retrofitting tips; Cut reboiler steam usage; Minimizing CO2 recovery.
UNIT-VI: Alkylation – The alkylation process; Process flow; Acid carry over; Physical carry over; Low isobutene concentration; Reduced acid circulation; Poor mixing.
Sulfur Recovery – Sulfur recovery chemistry; Process flow; What can go wrong : Finding lost conversion, measuring sulfur losses, Wrong air ratio, Plenty of catalyst, Reactor problems, COS and CS2, Leaking reheat exchanger, Sulfur fog, Cold reheat gas, When to change catalyst; Pressure drop; Carbon deposits; Leaks cause pressure drop; Preventing boiler leaks; Condenser leaks; Routine pressure surveys; Plugged seal legs; Shortened seal legs; Catalyst support screens; Start- up tips; Avoid deficient oxygen; Start up atmospheric vent; Maximizing plant capacity; Oxygen enrichment; Fail safe with O2; Bypass reheat exchanger; increased front end pressure; Hydrocarbon in acid gas ; Water vapor and carbon dioxide; Reactor inlet baskets; Pyrophoric iron; Tail gas clean up.
Outcomes
After the course, the students will become adept in Process Troubleshooting Course and must be able to do the following:
- For each equipment, prepare a summary document that provides the operating range of parameters and variables of all important sections of the equipment. The equipments refer to pumps, heaters, refrigeration systems, process heaters, water coolers, distillation and vacuum towers. The graduate engineer will be able to identify process upsets in advance and take necessary corrective actions proactively.
- Monitoring of reactors/converters – root cause analysis for low conversion – optimizing feed ratios and operating parameters.
- Classify and identify all important parameters associated with safety regulations of the process equipment.
- Be able to analyze the impact of variations in operating parameters on the performance of process /equipment.
- Identify possible reasons for malfunctioning of an equipment.
- Suggest possible remedial mesures for process startup and regular operation of the equipment and overall process.
- For a process, identify all possible reasons for its process deviation/upset. The processes may refer to Crude Distillation Unit, Delayed Coking Unit, Fluid Catalytic Cracking, Sulfur Recovery and Alkylation Units.
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