Technical Manual - Section 3 (Safety Hazards)

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TREATMENT PROCESSES *Amine Treating Treatment Absorption Remove acidic Sour gas, HCs Acid free contaminants w/CO 2 & H 2 S gases & liquid HCs Desalting Dehydration Absorption Remove Crude oil Desalted contaminants crude oil Drying & Sweeten- Treatment Abspt/therm Remove H 2 O Liq HCs, LPG, Sweet & ing & sulfur cmpds alky. feedstk dry hydrocarbons *Furfural Extrac- Solvent extr. Absorption Upgrade mid Cycle oils & High tion distillate & lube feedstocks quality dielubes sel & lube oil Hydrodesulfur- Treatment Catalytic Remove sulfur, High-sulfur Deization contaminants residual/gas oil sulfurized olefins Hydrotreating Hydrogenation Catalytic Remv impurities Residuals, Cracker saturate Hcs cracked HCs feed, distillate, lube *Phenol extraction Solvent extr. Abspt/therm Improve visc. Lube oil base High index, color stocks quality lube oils Solvent deasphalting Treatment Absorption Remove asphalt Vac. tower resi- Heavy lube dual, propane oil, asphalt Solvent dewaxing Treatment Cool/filter Remve wax Vac. tower lube Dewaxed from lube stocks oils lube basestock Solvent Extraction Solvent extr. Abspt/precip. Separate unsat. Gas oil, reform- Highoils ate, distillate octane gasoline Sweetening Treatment Catalytic Remv H2S,con- Untreated distil- Highvert mercaptan late/gasoline quality distilate/ gasoline *NOTE: These processes are not depicted in the refinery process flow chart. III:2-14
D. DESCRIPTION OF PETROLEUM REFINING PROCESSES AND RELATED HEALTH AND SAFETY CONSIDERATIONS CRUDE OIL PRETREATMENT (DESALTING) Crude oil often contains water, inorganic salts, suspended solids, and water-soluble trace metals. As a first step in the refining process, to reduce corrosion, plugging, and fouling of equipment and to prevent poisoning the catalysts in processing units, these contaminants must be removed by desalting (dehydration). The two most typical methods of crude-oil desalting, chemical and electrostatic separation, use hot water as the extraction agent. In chemical desalting, water and chemical surfactant (demulsifiers) are added to the crude, heated so that salts and other impurities dissolve into the water or attach to the water, and then held in a tank where they settle out. Electrical desalting is the application of high-voltage electrostatic charges to concentrate suspended water globules in the bottom of the settling tank. Surfactants are added only when the crude has a large amount of suspended solids. Both methods of desalting are continuous. A third and less-common process involves filtering heated crude using diatomaceous earth. The feedstock crude oil is heated to between 150 o and 350 o F to reduce viscosity and surface tension for easier mixing and separation of the water. The temperature is limited by the vapor pressure of the crude-oil feedstock. In both methods other chemicals may be added. Ammonia is often used to reduce corrosion. Caustic or acid may be added to adjust the pH of the water wash. Wastewater and contaminants are discharged from the bottom of the settling tank to the wastewater treatment facility. The desalted crude is continuously drawn from the top of the settling tanks and sent to the crude distillation (fractionating) tower. HEALTH AND SAFETY CONSIDERATIONS Fire Prevention and Protection The potential exists for a fire due to a leak or release of crude from heaters in the crude desalting unit. Low boiling point components of crude may also be released if a leak occurs. <strong>Safety</strong> Inadequate desalting can cause fouling of heater tubes and heat exchangers throughout the refinery. Fouling restricts product flow and heat transfer and leads to failures due to increased pressures and temperatures. Corrosion, which occurs due to the presence of hydrogen sulfide, hydrogen chloride, naphthenic (organic) acids, and other contaminants in the crude oil, also causes equipment failure. Neutralized salts (ammonium chlorides and sulfides), when moistened by Table III:2-4: DESALTING PROCESS Feedstocks From Process Typical products............ To Crude Storage Treating Desalted crude..........Atmospheric distillation tower Waste water..........................Treatment III:2-15
Page 1 and 2: OR-OSHA TECHNICAL MANUAL OR-OSHA TE
Page 3 and 4: SECTION III: CHAPTER 1 OIL WELL DER
Page 5 and 6: C. STABILITY CONSIDERATIONS FOUNDAT
Page 7 and 8: D. OBSERVATIONS, DIRECTIONS, AND CO
Page 9 and 10: SECTION III: CHAPTER 2 PETROLEUM RE
Page 11 and 12: Year Process name Purpose By-produc
Page 13 and 14: Crude oils are also defined in term
Page 15 and 16: (dicycloparaffins) found in the hea
Page 17 and 18: and boilers can leave deposits of v
Page 19 and 20: C. PETROLEUM REFINING OPERATIONS IN
Page 21: Table III:2-3 OVERVIEW OF PETROLEUM
Page 25 and 26: CRUDE OIL DISTILLATION (FRACTIONATI
Page 27 and 28: Even though these are closed proces
Page 29 and 30: The solvent is separated from the p
Page 31 and 32: Table III:2-9 VISBREAKING PROCESS F
Page 33 and 34: HEALTH AND SAFETY CONSIDERATIONS Fi
Page 35 and 36: Figure III:2-14 Fluid Catalytic Cra
Page 37 and 38: HYDROCRACKING Hydrocracking is a tw
Page 39 and 40: egeneration and changeover. Catalys
Page 41 and 42: CATALYTIC HYDROTREATING Catalytic h
Page 43 and 44: chemicals and other hazards such as
Page 45 and 46: needed to prevent HCl from entering
Page 47 and 48: ALKYLATION Alkylation combines low-
Page 49 and 50: HEALTH AND SAFETY CONSIDERATIONS Fi
Page 51 and 52: Figure III:2-23 Molecular Sieve Dry
Page 53 and 54: SATURATE GAS PLANTS Saturate gas pl
Page 55 and 56: Table III:2-21. STEAM REFORMING PRO
Page 57 and 58: Safety Control of treater temperatu
Page 59 and 60: minerals and dissolved impurities t
Page 61 and 62: phenols, ammonia, sulfides, and oth
Page 63 and 64: GAS AND AIR COMPRESSORS Both recipr
Page 65 and 66: Safety Depending on the product and
Page 67 and 68: APPENDIX III:2-1. GLOSSARY ABSORPTI
Page 69 and 70: DEWAXING The removal of wax from pe
Page 71 and 72: interaction of sulfur compounds in
Page 73 and 74:
SECTION III: CHAPTER 3 PRESSURE VES
Page 75 and 76:
Figure III:3-1. Some Major Parts of
Page 77 and 78:
spherical with wall thickness in th
Page 79 and 80:
LIQUID PENETRANT TEST (PT) This met
Page 81 and 82:
D. INFORMATION FOR SAFETY ASSESSMEN
Page 83 and 84:
@ Other design code vessels -- Maxi
Page 85 and 86:
SECTION III: CHAPTER 4 INDUSTRIAL R
Page 87 and 88:
Regulator Coordinate Robot Cylindri
Page 89 and 90:
Figure III:4-2. Industrial Robots:
Page 91 and 92:
DEGREES OF FREEDOM Regardless of th
Page 93 and 94:
OTHER ACCIDENTS Other accidents can
Page 95 and 96:
SAFEGUARDING DEVICES Personnel shou
Page 97 and 98:
F. BIBLIOGRAPHY American National S
Page 99 and 100:
Enabling Device A manually operated
Page 101 and 102:
Start-up, Initial Initial drive pow
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Technical Manual - Section 3 (Safety Hazards)

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