Petroleum Refinery Troubleshooting Part 2 Prepared by: Barhm Abdullah Mohamad PhD Researcher in Mechanical Engineering University of Miskolc, Hungarya

Petroleum Distillation unit: The purpose of distillation is to separate the different boiling fractions, obtain final or 95 % boiling point purity of the product streams at minimum required energy and maximum product yield. The common technical problems occur due to quality and impurities of crude oil.

Petroleum Refinery Rotational equipment [pumps] : a mechanical device using suction or pressure to raise or move liquids and compress gases. Pumps operate by some mechanism (typically reciprocating or centrifugal). The common technical problem usually occur due to stalling phenomena and slip losses due to the speed of impeller (2000-3000) rpm.

Heat transfer equipment [Heat Exchanger]: A heat exchanger is process equipment used for transferring (heat) from one fluid to another fluid through a separating wall. The most technical problems are corrosion and leakage, to repair this damages apply regular hydrostatic test to heat exchangers and controlling corrosive material in crude oil.

Furnace [Heater]:One of heat transfer equipment where the fluids are heated by the gases produced by combustion of liquid or gaseous fuel. The main technical problem occur from the furnace burner and furnace tube structure during start up and overheating. Energy-efficient heater operations involve proper control, maintenance and monitoring of process fluid outlet temperature, draft, excess air and fuelfiring rate. In multipass heaters it is important to control the flow rates for optimum residence time. Leaking valves will result in valve sticking and poor control behaviour.

Steam Boiler: Steam can be used for heating, drying, moistening and sterilization of products in industry and other fieldsThe main technical problem occur from the furnace burner and furnace tube structure during start up, water feed properties, overheating and fuel quality.

Control valves: used to control conditions such as flow, pressure, temperature, and liquid level by fully or partially opening or closing in response to signals received from controllers that compare a "set point" to a "process variable" whose value is provided by sensors that monitor changes in such conditions. The main technical problem of that equipment is continuity of air supply and power supply.

Storage facility: The purpose of storage tanks to keep the petroleum products, there is many type of storage tanks, its need

Healthy and Safety Environment [HSE]:All workers in the refinery are sensitized about HSE issues and the results have been very rewarding. HSE issues have been made a culture at the refinery. All new persons to the refinery must receive a safety induction before commencing work, The safety message is disseminated through, for example, tool box talks and weekly “safety standstills”. Job safety analyses are done to assess the hazards and put in place control or mitigation measures before commencing work.

Facilities & Refinery Maintenance The maintenance of petroleum refineries and chemical processing facilities poses unique challenges in health, safety, and environment monitoring. Plant shutdowns and turnarounds present inherent safety risks to employees and consultants. The strategic planning, organization and execution of a shutdown or turnaround project must include a variety of disciplines such as standby rescue and medical teams. HSE has experienced professionals and leading-edge equipment to ensure that all plant personnel, project consultants, and company assets are protected throughout such operations. HSE has the services, equipment, and expertise to ensure clients meet or exceed government, industry, and corporate safety regulations for petrochemical facilities.

References 1) Nelson, W. L. Petroleum Refinery Engineering, Tata McGraw Hill Publishing Company Limited, 1985. 2) B.K. Bhaskara Rao, “Modern Petroleum Refining Processes” Edn. 5, Oxford & IBH Publishing Company Pvt. Ltd. New Delhi. Online References http://lorien.ncl.ac.uk/ming/distil/distil0.htm http://science.howstuffworks.com/oil-refining.htm