Process Equipment Malfunctions: Techniques to Identify and Correct Plant Problems

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McGraw Hill Professional, Dec 2, 2011 - Technology & Engineering - 560 pages
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A PRACTICAL GUIDE TO TROUBLESHOOTING PROCESS EQUIPMENT MALFUNCTIONS

Process Equipment Malfunctions offers proven techniques for finding and fixing process plant problems and contains details on failure identification. Diagnostic tips, examples, and illustrations help to pinpoint and correct faults in chemical process and petroleum refining equipment. Complex math has been omitted. An essential resource for plant operators and process engineers, this book is based on the author's long career in field troubleshooting process problems.

COVERAGE INCLUDES:

  • Distillation tray malfunctions
  • Packed tower problems
  • Distillation tower pressure and composition control
  • Fractionator product stripping
  • Pumparounds
  • Reboiled and steam side strippers
  • Inspecting tower internals
  • Process reboilers--thermosyphon circulation
  • Heat exchangers
  • Condenser limitations
  • Air coolers
  • Cooling water systems
  • Steam condensate collection systems
  • Steam quality problems
  • Level control problems
  • Process plant corrosion and fouling
  • Vapor-liquid separation vessels
  • Hydrocarbon-water separation and desalters
  • Fired heaters--draft and excess O2
  • Disabling safety systems
  • Vacuum systems and steam jets
  • Vacuum surface condensers
  • Centrifugal pump limitations
  • Steam turbine drivers
  • Centrifugal compressors
  • Reciprocating compressors
 

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Contents

1 Distillation Tray Malfunctions
1
2 Packed Tower Problems
21
3 Distillation Tower Pressure and Composition Control
33
4 Salt and Rust Formation on Tray Decks
47
5 Fractionator Bottoms Product Stripping
61
6 Heat Extraction with Pumparounds
73
7 Reboiled and Steam Side Strippers
85
8 Inspecting Tower InternalsChecklist
99
20 KnockOut Drums Demisters and Impingement Plates
269
21 HydrocarbonWater SeparationElectric Desalters and Gravity Settling
281
22 Natural DraftFired Heaters
295
23 Tube Failure in Fired Heaters
309
Air Preheaters
323
25 Disabling Safety Systems
339
26 Vacuum Systems and Steam Jets
351
27 Vacuum Surface Condensers and Precondensers
373

9 Process ReboilersShell and Tube
107
10 ShellandTube Heat Exchangers in Sensible Heat Transfer Service
123
11 Condenser Limitations
141
12 Air CoolersForced and InducedDraft Air Side Malfunctions
157
Towers and Circulation
169
14 Steam Condensate Collection Systems
179
15 Steam Quality Problems
195
16 Level Control Problems
209
17 Excessive Ambient Heat Losses
229
18 Process Plant Corrosion
243
19 VaporLiquid Separation Vessels
257
Vacuum System Ejectors
391
Cavitation Seal and Bearing Failures
405
Lubrication Failures
423
31 Steam Turbine Drivers
437
Surge Fouling and Driver Limits
451
Unloading and Efficiency
471
Typical Energy Savings and Efficiency Projects
487
Glossary
495
Index
507
The Norm Lieberman Video Library of Process Operations
527
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About the author (2011)

Norman P. Lieberman is a chemical engineer with 46 years of experience in process plant operation, design, and field troubleshooting. An independent consultant, he troubleshoots oil refinery and chemical plant process problems and prepares revamp process designs. Mr. Lieberman teaches 20–25 seminars a year on “Troubleshooting Process Plant Operations,” and this book is based on his long experience in field troubleshooting refinery and process plant problems.

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