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This practical guide contains everything plant operators, supervisors, technicians, and field consultants need to know to troubleshoot process equipment malfunctions. Process Equipment Malfunctionsoffers proven techniques for detecting and fixing process plant problems. This new book extends and expands upon the subject matter covered in the author's classic, Working Guide to Process Equipment, 3rd Edition, but focuses more specifically on troubleshooting equipment malfunctions. This in-depth resource offers comprehensive coverage of all types of process plant tools and potential issues, such as rust, corrosion, failures, and limitations. Process Equipment Malfunctions: Features diagnostic tips, examples, illustrations, and worked calculations for pinpointing trouble and correcting problems in chemical process and petroleum refining equipment Focuses on process equipment malfunctions and solutions Serves as a practical, hands-on field guide
Table of Contents
1. Distillation Tray Malfunctions 2. Packed Tower Problems 3. Distillation Tower Pressure and Composition Control 4. Salt and Rust Formation on Tray Decks 5. Fractionator Bottoms Product Stripping 6. Heat Extraction with Pumparounds 7. Reboiled and Steam Side Strippers 8. Inspecting Tower Internals--Checklist 9. Process Reboilers--Shell and Tube 10. Shell-and-Tube Heat Exchangers in Sensible Heat Transfer Service 11. Condenser Limitations 12. Air Coolers--Forced- and Induced-Draft Air Side Malfunctions 13. Cooling Water: Towers and Circulation 14. Steam Condensate Collection Systems 15. Steam Quality Problems 16. Level Control Problems 17. Excessive Ambient Heat Losses 18. Process Plant Corrosion 19. Vapor-Liquid Separation Vessels 20. Knock-Out Drums; Demisters and Impingement Plates 21. Hydrocarbon--Water Separation--Electric Desalters and Gravity Settling 22. Natural Draft-Fired Heaters 23. Tube Failure in Fired Heaters 24. Fired Heaters: Air Preheaters 25. Disabling Safety Systems 26. Vacuum Systems and Steam Jets 27. Vacuum Surface Condensers and Precondensers 28. Excess Gas Overloads: Vacuum System Ejectors 29. Centrifugal Pump NPSH Limitations: Cavitation, Seal, and Bearing Failures 30. Centrifugal Pump and Driver Capacity Limits: Lubrication Failures 31. Steam Turbine Drivers 32. Centrifugal Compressors: Surge, Fouling, and Driver Limits 33. Reciprocating Compressors: Unloading and Efficiency 34. Summary: Typical Energy Savings and Efficiency Projects Glossary Index The Norm Lieberman Video Library of Process Operations