Professional Documents
Culture Documents
No. 1 (T)
Failure Scenarios Corrosion/erosion of exchanger internals resulting in a heat transfer surface leak or rupture and possible overpressure of the low pressure side
Inherently Safer/Passive
Double tube sheets Emergency relief device on low Corrosion detection device (e.g., Seal welding of tubes to pressure side coupons) tubesheets Periodic inspection/ analysis of Open low pressure side return low pressure fluid for high Design changes to reduce pressure fluid leakage erosion (e.g., lower velocities, inlet baffle) Secondary heat transfer fluid Design pressure of low pressure side equal to design pressure of high pressure side Use of more corrosion resistant alloys Use of less corrosive heat transfer media
2 (T)
Differential thermal expansion/contraction between tubes and shell resulting in tube leak/rupture (Fixed Tubesheet)
U-tube exchanger design Emergency relief device on low Procedural control of Shell expansion joint or internal pressure side introduction of process fluids floating head Automatic control of on start-up and shutdown Design pressure of low pressure introduction of process fluids Periodic inspection/ analysis of side equal to design pressure on start-up and shutdown low pressure fluid for high of high pressure side pressure fluid leakage Use of designs other than shell and tube (e.g., spiral, plate and frame)
9/15/2012
Chapter 6
6-1
Table 6: FailureScenariosforHeatTransferEquipment Potential Design Solutions Active Heat Transfer Equipment (6) Procedural
No. 3 (T)
Failure Scenarios Excessive tube vibration resulting in tube leak/rupture and possible overpressure of the low pressure side
Inherently Safer/Passive
Mechanical design (e.g., proper Emergency relief device on low Periodic inspection/ analysis of baffle spacing) pressure side low pressure fluid for high accommodating maximum pressure fluid leakage anticipated inlet feed pressure/velocity Design pressure of low pressure side equal to design pressure of high pressure side Use of designs other than shell and tube (e.g., spiral, plate and frame)
Overpressure
Excessive heat input resulting in vaporization of the cold-side fluid (e.g., control system failure, coldside blocked in)
Limit the temperature of the heating medium Design pressure of cold-side fluid equal to maximum expected pressure
Emergency relief device High temperature indication with alarm and interlock which isolates the heating medium
9/15/2012
Chapter 6
6-2
Table 6: FailureScenariosforHeatTransferEquipment Potential Design Solutions Active Emergency relief device Back-up cooling medium supply with automatic switch-over Automatic tempering of cooling medium temperature to avoid low tube wall temperature resulting in solids deposition Automatic venting of noncondensables Automatic isolation of input flow on detection of high vent temperature Heat Transfer Equipment (6) Procedural Manual adjustment of cooling medium tempering Periodic exchanger cleaning Manual venting on high pressure indication Manual activation of backup cooling Manual isolation of input flow on detection of high vent temperature
No. 5 (T)
Failure Scenarios Loss of heat transfer due to fouling, accumulation of non-condensables, or loss of cooling medium
Inherently Safer/Passive Design exchanger for suitable velocity to minimize fouling Heat exchanger design less prone to fouling (e.g., direct contact) Provide additional surface area in air cooler to transfer heat via natural convection Continuous open venting of non-condensables Design for maximum expected pressure
Ambient temperature Mechanical design increase resulting in higher accommodating maximum vaporization rate in air heated pressure/temperature exchanger Use heating medium other than air
Emergency relief device Automatic adjustment of vaporization pressure to control vaporization rate
9/15/2012
Chapter 6
6-3
Table 6: FailureScenariosforHeatTransferEquipment Potential Design Solutions Active Heat Transfer Equipment (6) Procedural
No. 7
Failure Scenarios Cold-side fluid blocked in while heating medium continues to flow
Thermal relief device Procedural controls on block Interlock to isolate heating valve closing medium upon detection of no Manual isolation of heating flow on cold-side medium on indication of no flow on cold side
Mechanical design to accommodate minimum expected temperature and pressure Use of alternative heat exchanger designs
Automatic vacuum breaking system Automatic air inlet temperature control via air preheating with steam or air recirculation
9/15/2012
Chapter 6
6-4
Table 6: FailureScenariosforHeatTransferEquipment Potential Design Solutions Active Heat Transfer Equipment (6) Procedural Emergency response plan Manual activation of fixed fire protection water spray (deluge) and/or foam systems
No. 9 (T)
Inherently Safer/Passive
Use alternate heat exchanger Fixed fire protection water design to minimize impact of spray (deluge) and/or foam external fire systems activated by Fireproof insulation (limits heat flammable gas, flame, and/or input) smoke detection devices Slope-away drainage with Emergency relief device remote impounding of spills Locate outside fire affected zone Use cellular glass insulation to avoid insulation fires
10
Mechanical design to Use of exchanger design less accommodate maximum sensitive to fouling (e.g., expected temperature and scraped surface exchanger) pressure Automatic control of heating Design exchanger for suitable medium temperature velocity to minimize fouling Use of heating medium with a maximum temperature that is limited to exchanger design temperature
High temperature indication with alarm Manual control of heating medium temperature Periodic inspection
9/15/2012
Chapter 6
6-5
Table 6: FailureScenariosforHeatTransferEquipment Potential Design Solutions Active Provide air inlet temperature control via air preheating with steam or air recirculation Provide air flow control (e.g., variable pitch fans) Heat Transfer Equipment (6) Procedural Manual adjustment of air temperature or flow
No. 11
Failure Scenarios
Inherently Safer/Passive
Low ambient temperature Select different type of causes fluid freezing and tube exchanger to minimize or rupture eliminate consequences of freezing
22
Wrong Composition
Mixing of fluids resulting in exothermic reactions, phase changes, and/or fluid system contamination due to corrosion/erosion, vibration or differential thermal expansion
Select heat transfer media which are chemically compatible with process materials Mechanical design to accommodate maximum expected temperature and pressure of a possible exothermic reaction Intermediate heat transfer fluid system Double tubesheet design Seal weld tubes to tubesheets
Emergency relief device Downstream fluid analyzers with concentration alarms interlocked with automatic shutdown
Downstream fluid analyzers with concentration alarms Periodic sampling and analysis of fluids
9/15/2012
Chapter 6
6-6
Table 6: FailureScenariosforHeatTransferEquipment Potential Design Solutions Active Vibration monitoring with automatic fan shutdown Heat Transfer Equipment (6) Procedural Manual fan shutdown on indication of excessive vibration
No. 1 3
Failure Scenarios Vibration/fan failure and tube rupture due to impact with fan blade
34
Scraper punctures heat transfer surface due to misalignment or entrance of foreign objects
Screens at entrance of heat exchanger to remove foreign objects Use of alternative exchanger designs
9/15/2012
Chapter 6
6-7
Table 6: FailureScenariosforHeatTransferEquipment Potential Design Solutions Active Automatic fire extinguishing system Heat Transfer Equipment (6) Procedural Emergency response procedures Manual activation of fire extinguishing system
No. 1 5
Inherently Safer/Passive Use of alternative exchanger design Locate exchanger outside fire affected zone Use fire resistant (metal jacketed) gaskets Use of welded plate design Provide splash shields around exchanger
46
Use of alternative exchanger design Locate exchanger outside fire affected zone
9/15/2012
Chapter 6
6-8