Plant design and operations
Ian Sutton provides practical guidance on the design, operation, and maintenance of process facilities. The book is based on years of hands-on experience gathered during the design and operation of a wide range of facilities in many different types of industry including chemicals, refining, offshore...
Saved in:
| Main Author | |
|---|---|
| Format | Electronic eBook |
| Language | English |
| Published |
Oxford :
Gulf Professional Publishing,
[2017]
|
| Edition | Second edition. |
| Subjects | |
| Online Access | Full text |
| ISBN | 9780128128848 0128128844 9780128128831 0128128836 |
| Physical Description | 1 online resource : illustrations (some color) |
Cover
Table of Contents:
- Front Cover
- Plant Design and Operations
- Copyright Page
- Contents
- Preface
- 1 Safety in Design
- Introduction
- Standard Examples
- Terminology
- Regulations, Standards, and Guidance
- Regulatory Agencies (the United States)
- Regulations (International)
- Industry Standards
- Health, Safety, and Environment
- Process Safety Management
- Risk Management
- Units of Measurement
- SI Units
- Date Format
- Engineering Drawings
- Block Diagrams
- Process Flow Diagrams
- Piping and Instrument Diagrams
- Symbols
- Equipment numbering
- Spec Breaks
- Isometric Drawings
- Electrical Single-Line Diagrams
- Materials of Construction
- Flammable and Combustible Materials
- Fire Triangle
- Flammable Range
- Flash Point
- Flammable/Combustible Liquids
- Class I liquids
- Class II liquids
- Class III liquids
- Ignition Sources
- Lightning
- Area Classification
- IEC Code
- Regulations and Standards
- Temperature Code
- Classification Plan
- Fireproofing Insulation
- Fireproofing Materials
- Cryogenic Systems
- Maintenance
- 2 Siting and Layout
- Introduction
- Regulations and Standards
- Siting
- Layout
- Layout Risk Analysis
- Facility Orientation
- Hazardous Areas
- Blocks and Roads
- Piping
- Drainage Systems
- Loading/Unloading Facilities
- Tank trucks
- Tank (rail) cars
- Wharves and piers
- Routine Access and Egress
- Explosion Protection
- Safe Areas
- Emergency Escape
- Manual Alarm Call Points
- Process Isolation Valves
- Firefighting
- Emergency Showers and Eyewashes
- Equipment Spacing
- Pressure Vessels
- Hydrocarbon Storage Tanks
- Pumps
- Compressors/Compressor Drivers
- Heat Exchangers
- Boilers
- Fired Equipment
- Air Intakes
- Equipment Stacking
- Piping and Valves
- Piping
- Valves
- Flares and Vents
- Buildings
- Utilities
- Stairways and Ladders.
- Stairways
- Dimensions
- Landings
- Load capacity
- Stair rails
- Stair treads
- Ladders
- Dimensions
- Safety cages and gates
- Rungs and stringers
- Platforms
- Guardrails, Handrails, and Toeboards
- Ramps
- 3 Equipment and Buildings
- Introduction
- Regulations and Standards
- Pressure Vessels/Columns
- Pressure Vessel Code
- Fire Hazard
- Maximum Allowable Working Pressure
- Vessels Under Vacuum
- Storage Vessels
- Reflux Vessels
- Manways
- Nameplate/Documentation
- Storage Tanks
- Functions of Storage Tanks
- Types of Storage Tank
- Fixed Roof Tanks
- Floating Roof Tanks
- Plastic Tanks
- Bund Walls/Berms
- Tank Farms
- Stairs and Platforms
- Tank Design
- Static electricity
- Blanket/padding gas
- Vents
- Connections, nozzles, and manways
- Overflow systems
- Instrumentation
- Temperature control
- Tank Fires
- Boilover/Foamover
- Rag Layers
- Bottoms Sediment and Water
- Pumps
- Types of Pump
- Centrifugal pumps
- Positive displacement pumps
- Shutdown and Alarm Systems
- Suction Piping
- Minimum Flow Protection
- Fire Protection
- Sealless Pumps
- Sparing
- Pump Isolation
- Vibration
- Pump Casing
- Seals and Packing
- Compressors
- API 618
- Seals
- Shutdown and Alarm Systems
- Liquid Knockout
- Relief Valves
- Compressor Isolation
- Surge Protection
- Sparing Policy
- Turbines
- Gas Turbines
- Steam Turbines
- Heat Exchangers
- Shell and Tube Exchangers
- Tube/Shell Side
- Tube Leakage
- Air-Cooled Exchangers
- Cooling Towers
- Natural/Forced Draft
- Safety
- Fired Heaters
- Heat Transfer Fluids
- Air Preheaters
- Safety
- No process flow
- Start-up/operations
- Flares/Blowdown
- Emergency Depressurization
- Flaring
- Types of flare
- Flare design
- Ground flares
- Smokeless operation
- Thermal Oxidizers
- Boilers
- Internal Combustion Engines.
- Starter Systems
- Intake, Exhaust, and Fuel Systems
- Electrical Equipment
- Transformers
- Equipment Grounding
- Ground-Fault Circuit Interrupters
- Buildings
- Administrative Buildings
- Control Buildings
- Control rooms
- Computer rooms
- Electrical equipment buildings/substations
- Heating, ventilating, and air-conditioning
- Process Buildings
- Equipment buildings
- Analyzer houses/operator laboratories
- Warehouses and Workshops
- Temporary Buildings
- 4 Piping
- Introduction
- Regulations and Standards
- Pipe Specifications
- Pipe Sizing
- Nominal Pipe Sizes
- Pipe Schedule
- Fluid Velocity
- Materials
- Steel
- Other Metals
- Cast iron
- Aluminum
- Nickel
- Copper/brass
- Polymers
- Equipment
- Underground Piping
- Fittings
- Welding
- Threaded Piping
- Expansion Loops/Compensators
- Expansion loops
- Axial joints
- Bellows
- Small Pipe Connections
- Flanges
- Gaskets
- Blinds
- Line Blinds
- Spectacle Blinds
- Insulation
- Heat Tracing
- Steam Tracing
- Electrical Tracing
- Flame Arrestors
- Thermal Flame Arrestors
- Water Seal Flame Arrestors
- Velocity Flame Arrestors
- Detonation Arrestors
- Vortex Breakers
- Hoses
- 5 Valves
- Introduction
- Regulations and Standards
- Valve Symbols
- Block Valves
- Gate Valves
- Ball Valves
- Butterfly Valves
- Plug Valves
- Needle Valves
- Excess Flow Valves
- Self-Closing Valves
- Globe/Control Valves
- Check (Non-return) Valves
- Rotary Valves
- Flangeless Valves
- Emergency Isolation Valves
- Valve Seat Materials
- Valve Position
- Steam Traps
- Pressure Relief Devices
- Causes of Overpressure
- Pressure Safety Relief Valves
- Pilot-Operated Pressure Relief Valves
- Block Valves
- Thermal Relief Valves
- Rupture Disks
- Below relief valves
- Setting the pressure
- Hatches/Doors
- 6 Instrumentation and Control.
- Introduction
- Regulations and Standards
- Operating/Safe Limits
- Process Control
- Distributed Control Systems
- Supervisory Control and Data Acquisition Systems
- Safety Instrumented Systems
- Safety Integrity Level
- Testing and Inspection
- High-Integrity Pressure Protection System
- Fire and Gas Detection
- Fire Detection
- Flammable gas detection
- Fire/flame detection
- Heat detection
- Fusible links
- Smoke detection
- Ultrasonic detectors
- Closed-circuit television
- Detection by persons
- Toxic Gas Detection
- Layout of Detectors
- Portable Gas Detectors
- Alarm Systems
- Alarm Signaling
- Response to Alarms
- Response Matrix
- Limitations
- Alarm Flooding
- 7 Transportation
- Introduction
- Terminology
- Regulations and Standards
- International Safety Guide
- CAP 437
- Offshore Helicopter Landing Areas
- Tank Trucks
- Loading/Unloading
- Loading Racks
- Static Electricity
- Bonding
- Switch Loading
- Additives
- Vacuum Trucks
- Tank (Rail) Cars
- Tank Car Markings
- Pressure Vessels
- Empty Cars
- Graffiti
- Marine Operations
- Ships and Barges
- Small Boats
- Jetty Terminals
- Personnel Transfer
- Personnel net baskets
- Rigid frame baskets
- Cargo Baskets
- Helicopters
- Personnel movement
- Helidecks
- Pipelines
- One Call
- Pigging
- Hazards
- Pig launching
- Pig receiving
- Smart pigs
- Slug Catchers
- 8 Operations
- Introduction
- Regulations and Standards
- Housekeeping
- Storage and Handling of Hazardous Materials
- Flammable Liquids
- Oxidizing Agents
- Catching Samples
- Gas Storage Cylinders
- Tank Operations
- Filling and Emptying
- Purging and Cleaning
- Rotating Equipment
- Emergency Response
- Manual Emergency Shutdown
- Evacuation, Escape, and Rescue
- Personnel Tracking
- Nonprocess Operations
- Outside Storage
- Coal and Coke Storage.
- Drum Storage
- Cranes and Rigging
- Lifting Precautions
- Wire Ropes, Chains, and Slings
- Tag Lines
- Start-Up
- Commissioning
- Operational Readiness Review
- Start-Up
- 9 Maintenance
- Introduction
- Regulations and Standards
- Maintenance Management System
- Types of Maintenance
- Repair Maintenance
- Condition-Based Maintenance
- Scheduled Maintenance
- Reliability-Centered Maintenance
- Procurement
- Spare Parts
- Documentation
- Factory Acceptance Tests
- Maintenance Task Organization
- Step 1-Plan the Work
- Step 2-Conduct a JHA
- Step 3-Prepare/Issue a Work Permit
- Step 4-Shutdown and Isolate Equipment
- Step 5-First Break
- Step 6-Perform the Work
- Step 7-Close Out the Work
- Step 8-Handover to Operations
- Equipment check
- Inspected, tested, and documented
- System completion
- Operational readiness/prestartup safety review
- Pressure Tests
- Testing Procedure
- Installing Blinds
- Test Medium
- Hydrostatic/liquid test
- Pneumatic/gas
- Tightness Test
- Strength Test
- Pressure Test Manual
- Records
- Online Cleaning and Repair
- Corrosion
- Cathodic Protection
- Corrosion Under Insulation
- CO2 Corrosion
- Sulfide Stress Cracking
- Controlling Corrosion
- Simultaneous Operations
- Managing SIMOPs
- SIMOPs Matrix
- Conducting SIMOPs
- Kickoff meeting
- Communication meetings
- Closeout
- 10 Energy Control
- Introduction
- Regulations and Standards
- 29 CFR 1910.119
- Rule
- Guidance
- API 2015
- API 2026
- API 2217A
- ANSI Z117.1
- NFPA 69
- Example
- Risk Management
- Energy Control Program
- Step 1-Job Hazards Analysis
- Step 2-Work Permit
- General Work Permits
- Hot Work Permits
- Confined Space Permits
- Issuing the Permit
- Multiple Work Permits
- Changes in Conditions
- Barrier Tape
- Step 3-Vent, Drain, and Purge
- Inert Gas.