This is a report on the heat exchange process an heat integration in the crude distillation unit of the IOCL Guwahati refinery.Description complète
Full description
My observation on crude oil
FMEA for Input Variable 'Column & Reboiler Drain'
analyzing Potential Failure Modes Associated with Input Variable
Effects Failure Mode Will Have on Customer, if They Occur
y t i r e v e S
Potential Causes of Failure Modes
52 vessel vent given at ground floor Very Hazardous AC2O Vapors emission from Column & vessel around it Reboiler Drain to 9 at ground floor Vessel 52 makes workmen flow difficult in Plant
planning changes Current Process Controls e c n e r r u c c O
No Control/movement in 9 cross direction of wind flow
Suggested Action y t i l i b a t c e t e D
2
N P R
Person Responsible & Target Date
after changes Actual Action 2 y t i r e v e S
Vent to be Provided at height 162 and should be away from plant
2 2 y e t c i l i 2 n b e a N r t r P u c R e c t c e O D
9
9
2
162
FMEA or Input Variable 'Condeser 45' anal zin Potential Failure Modes Associated with Input Variable
Effects Failure Mode Will Have on Customer, if They Occur
y t i i r e e v e S S
Potential Causes of Failure Modes
Tube leakage inside condenser-45
Condser 45 leakage
Accident due to 10 10 Leakage
lannin chan es Current Process Controls e c n e e r r u c c O
2 No control
Suggested Action y t t i l i b b a t c e t e e D
8
N P R
Person Responsible & Target Date
afte afterr chan chan es Actual Action 2 y t i r r e v e e S
Temp Gauge to be provided 160 in Product line at f ield as well as indication on DCS.
2 2 2 y y e t l c i i 2 n l n b e a N r r t r P u c R u c t e R c c t e O D D
2
1 10 0
8
160
FMEA for Input Variable 'Column Top Temp'
analyzing Potential Failure Modes Associated with Input Variable
Effects Failure Mode Will Have on Customer, if They Occur
y t i r e v e S
Potential Causes of Failure Modes
High Steam pressure due to malfunction of C/V Low Production Low Feed rate ( Manual control/ Column Top & Condensor 47 malfunction of C/V) Temp emp High g > leakage 9 0 Vaccum low <500 mm hg -Air frequency will 90 C Ingress and steam flow low in increase Ejector Column Tray damage
Column Top Temp Low > 0
80 C
malfunction of C/V High Feed rate ( Manual control/ malfunction of C/V)
Poor Quality of 8 Product Reboiler trap is not working
Choking of Tray because of carbon particle with feed
planning changes Current Process Controls
Suggested Action y t i l i b a t c e t e D
e c n e r r u c c O
Instrumentation Instrumentation person to 4 check and correct the C/V
1
Periodical checking of Control valve
1
1
N P R
Person Responsible & Target Date
after changes Actual Action 2 y t i r e v e S
Periodical checking of 36 Control valve
9
2 2 y e t c i l i n b e a r t r u c e c t c e O D
2 N P R
4
1
36
1
1
9
Control Valve for steam to be provided in Ejector.
4
2
72
Periodic cleaning (Half yearly) of tray.
1
1
9
4
1
32
1
1
8
2
2
32
5
1
40
Periodical checking of Control valve 9
4
Air ingress point identified and rectified
2
72
1 Column Tray Replaced
1
9
4
1
32
1
8
check and correct the C/V Periodical checking of 1 Control valve 2 Checking,Opening of Bypass
2
32
Cleaning of tray (Schedule is 6 months )
1
40
5
8 Appropriate filter to be installed in feed line.
FMEA for Input Variable 'Column Bottom Temp'
analyzing Potential Failure Modes Associated with Input Variable
Effects Failure Mode Will Have on Customer, if They Occur
y t i r e v e S
Potential Causes of Failure Modes
High Steam pressure due to malfunction of C/V Column bottom emp g >
Vaccum low <500 mm hg
planning changes Current Process Controls e c n e r r u c c O
Instrumentation person to check and correct the C/V Air ingress point identified 7 and rectified 7
Suggested Action y t i l i b a t c e t e D
1
N P
Person Responsible & Target Date
after changes Actual Action 2 y t i r e e S
56
Main Vacuum to be displyed 2 112 on DCS
Production loss 8
8
8
8
o
116 C
Column bottom Temp high > o
112 C
2 2 y e t c i l i n b e a r t r u e c t c e O D
2 N P R
7
1
56
7
2 112
FMEA for Input Variable 'Top product rate'
analyzing Potential Failure Modes Associated with Input Variable
Earthing parameter< 10 ohm
Effects Failure Mode Will Have on Customer, if They Occur
Shock
y t i r e v e S
2
Potential Causes of Failure Modes
planning changes Current Process Controls e c n e r r u c c O
Suggested Suggested Action y t i l i b a t c e t e D
N P
Person Responsible & Target Date
after changes Actual Action 2 y t i r e e S
2 2 y e t c i l i n b e a r t r u e c t c e O D
2 N P R
Broken earthing
6 Scheduled inspection
2
24 None
6
2
24
Corrosion
6 Replacement with GI
1
12 None
6
1
12
Dry earth pit
3 W ater poring in pit
1
6
None
3
1
6
Theft
3 Security checking
1
6
None
3
1
6
2
FMEA for Input Variable 'Column Feed Temp'
analyzing Potential Failure Modes Associated with Input Variable
Refractory ( Skin temp < 70 degC)
Effects Failure Mode Will Have on Customer, if They Occur
Fi re
y t i r e v e S
6
Potential Causes of Failure Modes
planning changes Current Process Controls e c n e r r u c c O
Scheduled Replacement of bricklining
Suggested Action
Person Responsible & Target Date
after changes Actual Action
2 2 y e t c i l i n b e a r t r u c e c t c e O D
y t i l i b a t c e t e D
N P
1
6
none
1
1
6
none
1
1
6
2
3
36
2
7
84
Life
1
Poor bricklining material
1 Repairing
1
6
Poor workmanship
2 SOP
3
36 none
Thermal shocks
2 No control
7
84
To avoid f requent stoppage stoppage of furnace.
2 y t i r e v e S
6
2 N P R
FMEA or Input Variable analyzing Potential Failure Modes Associated with Input Variable
Effects Failure Mode Will Have on Customer, if They Occur
y t i r e v e S
Potential Causes of Failure Modes
planning changes Current Process Controls e c n e r r u c c O
Suggested Action y t i l i b a t c e t e D
N P
Person Responsible & Target Date
after changes Actual Action 2 y t i r e e S
2 2 y e t c i l i n b e a r r t u e c t c e O D
2 N P R
FMEA or Input Variable analyzing Potential Failure Modes Associated with Input Variable
Effects Failure Mode Will Have on Customer, if They Occur
y t i r e v e S
Potential Causes of Failure Modes
planning changes Current Process Controls e c n e r r u c c O
Suggested Action y t i l i b a t c e t e D
N P
Person Responsible & Target Date
after changes Actual Action 2 y t i r e e S
2 2 y e t c i l i n b e a r t r u e c t c e O D
2 N P R
FMEA or Input Variable analyzing Potential Failure Modes Associated with Input Variable
Effects Failure Mode Will Have on Customer, if They Occur
y t i r e v e S
Potential Causes of Failure Modes
planning changes Current Process Controls e c n e r r u c c O
Suggested Action y t i l i b a t c e t e D
N P
Person Responsible & Target Date
after changes Actual Action 2 y t i r e e S
2 2 y e t c i l i n b e a r t r u e c t c e O D
2 N P R
FMEA or Input Variable analyzing Potential Failure Modes Associated with Input Variable
Effects Failure Mode Will Have on Customer, if They Occur
y t i r e v e S
Potential Causes of Failure Modes
planning changes Current Process Controls e c n e r r u c c O
