Oil and Gas Drilling Plant System and Instruments
Submitted By
Mustafa Hassan
22-ME-153
Aamir Waqas
22-ME-37
Haroon Abdullah
22-ME-169
Muhammad Haseeb Kayani
22-ME-73
Muhammad Faizan Javed
22-ME-189
Ali Hassan
22-ME-165
Submitted to
Engr. Muhammad Noman
DEPARTMENT OF MECHANICAL ENGINEERING
FACULTY OF MECHANICAL AND AERONAUTICAL ENGINEERING
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
TAXILA
January 2023
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Contents
1.
Types of Oil and Gas Facilities ................................................................................................................................... 6
1.1 Oil/NG – Well Site ....................................................................................................................................................... 7
1.2 Central Tank Battery ................................................................................................................................................... 7
1.3 Produced Water Injection Facility ............................................................................................................................... 8
1.4 NG – Gathering Compressor Station ........................................................................................................................... 8
1.5 NG—Treatment Without Compression ...................................................................................................................... 9
1.6 NG Plant – NGL Extraction and/or Fractionation ........................................................................................................ 9
1.7 NG – Transmission Compressor Station.................................................................................................................... 10
1.8. NG – Underground Storage Facility ......................................................................................................................... 10
1.9. Oil – Pipeline Breakout Facility/Truck Station.......................................................................................................... 10
1.10 Oil – Tank Farm ....................................................................................................................................................... 11
1.11 Oil/NGL/Refined Petroleum – Pipeline Pump Station ............................................................................................ 12
1.12 Oil Refinery.............................................................................................................................................................. 13
Refineries are large facilities that process crude oil into refined petroleum products. ................................................. 13
1.13 Refined Petroleum – Product Terminal .................................................................................................................. 13
1.14 Oil/NG/NGL – Other ................................................................................................................................................ 13
2. Equipment ................................................................................................................................................................... 14
2.1Wildcat Drilling........................................................................................................................................................... 14
2.2 Gas Condenser .......................................................................................................................................................... 14
2.3 Heat Exchanger ......................................................................................................................................................... 15
2.4 Air Cooler .................................................................................................................................................................. 15
2.5 Reactor Equipment ................................................................................................................................................... 16
2.6 Boiler Equipment ...................................................................................................................................................... 17
2.7 Evaporators ............................................................................................................................................................... 17
2.8 Pumping Equipment.................................................................................................................................................. 18
2.9 Pipeline Connecting Accessories ............................................................................................................................... 19
2.10 Dust Collectors ........................................................................................................................................................ 19
2.11 Broom and Mops..................................................................................................................................................... 20
2.12 Puller ....................................................................................................................................................................... 20
2.13 Millimeter................................................................................................................................................................ 21
2.14 Crimpers .................................................................................................................................................................. 21
2.14.1 Types of Crimping Tools: ...................................................................................................................................... 21
........................................................................................................................................................................................ 22
2.15 Types of pipes in Oil and Gas .................................................................................................................................. 22
........................................................................................................................................................................................ 23
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2.16 Hand Saw ................................................................................................................................................................ 23
2.16.1 Hack Saw: ............................................................................................................................................................. 23
........................................................................................................................................................................................ 23
2.17.1 Adjustable Wire Stripper...................................................................................................................................... 23
2.17.2 Gauged Stripper ................................................................................................................................................... 24
2.18 Hammer .................................................................................................................................................................. 24
2.18.1 Types of Hammers: .............................................................................................................................................. 24
2.18.2 Hand Hammer ...................................................................................................................................................... 24
2.19 Types of Wrenches.................................................................................................................................................. 25
2.19.1 Crescent Wrenches .............................................................................................................................................. 25
2.19.2 Open-End Wrench................................................................................................................................................ 25
2.19.3 Ratchet Wrench ................................................................................................................................................... 25
2.20 Types of Drilling....................................................................................................................................................... 26
2.21.1 Orbital Sander ...................................................................................................................................................... 26
2.22 Circular Saws ........................................................................................................................................................... 26
2.22.1 Corded Circular Saw ............................................................................................................................................. 26
2.22.2 Cordless Circular Saw ........................................................................................................................................... 26
2.23 Impact Wrenches .................................................................................................................................................... 26
2.23.1. Cordless Impact Wrenches ................................................................................................................................. 27
2.24 Screw Drivers .......................................................................................................................................................... 27
2.24.1 Flat–Head Screwdriver ......................................................................................................................................... 27
2.24.2 Phillips Screwdriver .............................................................................................................................................. 28
3.0 Flanges ...................................................................................................................................................................... 28
3.1 Types of Flanges ........................................................................................................................................................ 28
3.1.1 Slip-on Flanges ....................................................................................................................................................... 28
3.1.2 Threaded Flanges ................................................................................................................................................... 28
3.1.3 Blind Flanges: ......................................................................................................................................................... 29
3.1.4 Lap Joint Flanges: ................................................................................................................................................... 29
3.1.5 Socket Flanges:....................................................................................................................................................... 29
3.1.6 Weld Flanges: ......................................................................................................................................................... 29
4. Gasket ......................................................................................................................................................................... 30
4.1 Types of Gasket ......................................................................................................................................................... 30
4.1.1 Envelope Gasket:.................................................................................................................................................... 30
4.1.2 Flat Metal Gasket: .................................................................................................................................................. 30
4.1.3 Ring Type Gasket .................................................................................................................................................... 30
4.1.4 Kammprofile Gasket............................................................................................................................................... 30
4.1.5 Spiral Wound Gasket.............................................................................................................................................. 31
4.1.6 Corrugated Metal Gasket ....................................................................................................................................... 31
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5.0 Pipe Fitting ................................................................................................................................................................ 31
5.1.1 Pipe Elbow.............................................................................................................................................................. 31
5.1.2 Reducing Elbow ...................................................................................................................................................... 32
5.1.3 Pipe Tee.................................................................................................................................................................. 32
5.1.4 Cross: ...................................................................................................................................................................... 32
5.1.5 Pipe Union: ............................................................................................................................................................. 32
6.0 Industrial Pumps ....................................................................................................................................................... 33
6.1 Types of pumps ......................................................................................................................................................... 33
6.1.1 Centrifugal Pump ................................................................................................................................................... 33
6.1.2 Oil Transfer Pump .................................................................................................................................................. 34
6.1.3 Positive Displacement Pumps ................................................................................................................................ 35
6.1.4 Diaphragm Pumps .................................................................................................................................................. 36
6.1.5 Gear Pumps ............................................................................................................................................................ 37
6.1.6 Petrochemical Pumps ............................................................................................................................................ 38
6.1.7 Reciprocating Plunger Pumps ................................................................................................................................ 39
6.1.8 Progressive Cavity Pumps ...................................................................................................................................... 41
6.1.9. Metering Pumps.................................................................................................................................................... 42
6.1.10 Booster Pumps ..................................................................................................................................................... 43
7. Valves .......................................................................................................................................................................... 43
7.1 Types of valves .......................................................................................................................................................... 43
7.1.1 Ball valves ............................................................................................................................................................... 43
7.1.2 Butterfly valves ...................................................................................................................................................... 45
7.1.3 Check valves ........................................................................................................................................................... 46
7.1.4 Gate valves ............................................................................................................................................................. 47
7.1.5 NEEDLE VALVES ...................................................................................................................................................... 48
8. CONDENSER ................................................................................................................................................................ 49
8.1 TYPES OF CONDENSER: ............................................................................................................................................. 49
8.1.1 AIR COOLED CONDENSER: ..................................................................................................................................... 49
8.1.2 WATER COOLED CONDENSER: ............................................................................................................................... 51
9. ENGINERING DRAWING SYMBOLS: ............................................................................................................................. 52
9.1 LINE TYPES: ................................................................................................................................................................ 52
9.1.1 Solid Line ................................................................................................................................................................ 53
9.1.2 Dashed Line ............................................................................................................................................................ 53
9.1.3 Double Solid Line.................................................................................................................................................... 53
9.1.4 Double Dashed ....................................................................................................................................................... 53
9.2 CONTROL VALVES:..................................................................................................................................................... 54
9.3 ACTUATORS:.............................................................................................................................................................. 55
9.4 Pipes .......................................................................................................................................................................... 58
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10 Health Hazards ........................................................................................................................................................... 58
10.1 Safe Work Practices and Procedures ...................................................................................................................... 60
10.2 PPE .......................................................................................................................................................................... 60
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1. Types of Oil and Gas Facilities
Below is a list of the oil and gas facility categories. Please classify each permitted facility using the
classification that best represents operations at that facility. Definitions and guidance about how to
appropriately choose a facility category are provided later in the document. Figure 1 is included as a reference
showing the locations of different oil and gas facility types within the
network of industry operations.
1. Oil/NG – Well Site
2. Central Tank Battery
3. Produced Water Injection Facility
4. NG – Gathering Compressor Station
5. NG – Treatment Without Compression
6. NG Plant – NGL Extraction and/or Fractionation
7. NG – Transmission Compressor Station
8. NG – Underground Storage Facility
9. Oil – Pipeline Breakout Facility/Truck Station
10. Oil – Tank Farm
11. Oil/NGL/Refined Petroleum – Pipeline Pump Station
12. Oil Refinery
13. Refined Petroleum – Product Terminal
14. Oil/NG/NGL –
Definitions of each facility category are provided below. The definitions focus on the equipment located at
each facility and the location of the facility within the network of oil and gas sector operations. Guidance is
provided in the definitions for instances where a facility may fit the definition of two facility categories.
Overall, if it is unclear which facility category to choose for a facility, decide based upon the primary purpose
of the facility. For example, consider a facility that includes a wellhead, heater treater, produced water and
condensate storage tanks, a flare, compressors, and engines. If the primary purpose of the facility is to gather
and boost natural gas from surrounding wells, choose NG-Gathering Compressor Station. If the compressors
at the site only boost the pressure of the natural gas from the wellhead on site, choose Oil/NG-Well Site as the
primary purpose of the site. Another example is provided by underground natural gas storage at a gas plant.
The primary purpose of the facility is NGL (natural gas liquids) extraction and/or fractionation and the natural
gas storage happens to occur on site.
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1.1 Oil/NG – Well Site
(Crude Oil & Natural Gas – Well Site)
A well site or well pad is the physical location on which one or more oil and/or gas well(s) are drilled and oil
and/or natural gas is produced. Several well sites that are owned by the same company and are within a quarter
mile of each other can be permitted as a single facility. A facility must have at least one wellhead within the
facility boundary to receive this classification. Common emission sources located at well sites include: crude
oil, condensate, or produced water storage tanks; process heaters; heater treaters; dehydrators; other two or
three phase separators; crude oil, condensate, and/or produced water tanker truck loading sites; engines used
to power compressors or pump jacks; fugitive sources; and pneumatic controllers. Pneumatic pumps and
dehydration units may also be located at well sites. If a facility could be classified as a production well site
and another type of facility (e.g., a compressor station), choose the facility classification based upon the
primary purpose of the site. If the primary purpose of the site is production of oil and/or natural gas, choose
O&NG-Well Site as the classification. If a wellhead is located on site and the primary purpose of the site
isgathering and compression of natural gas from surrounding wells choose NG-Gathering Compressor Station
as the classification. The 10 digit API/US well number should be provided for all wells on site no matter which
facility classification is chosen.
1.2 Central Tank Battery
Central tank batteries also known as central distribution points, receive crude oil, condensate, and/or produced
water from surrounding well sites via a pipeline system. The crude oil, condensate, and/or produced water is
typically separated and then stored in atmospheric storage tanks and routinely loaded into trucks for
transportation from the site. The crude oil or condensate may also leave the facility by pipeline. The primary
function of a central tank battery is storage. If the facility includes a well on site, provide the API/US well
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number of the well and choose Central Tank Battery as the classification if the primary purpose of the site is
storage from surrounding well sites and not production from the single well on site. Please provide the API/US
well number for each well feeding into the tank battery. If a compressor is present on site and the primary
purpose of the site is compression instead of storage, classify the site as a NGGathering Compressor Station.
1.3 Produced Water Injection Facility
At produced water injection sites, produced water/salt water is transported to the site by truck or pipeline and
pumped into injection wells for disposal. If the produced water injection occurs at a well site as part of an
enhanced oil recovery system (waterflooding), classify the facility as a Produced Water Injection Facility.
1.4 NG – Gathering Compressor Station
(Natural Gas – Gathering Compressor Station)
A gathering compressor station receives natural gas from area well sites via pipeline or another compressor
station. The received gas is compressed and sent down the pipeline forprocessing at a natural gas plant or
another compressor station. For classification purposes, gathering compressor stations occur prior to the
natural gas plant. If there is no natural gas plant (used to remove natural gas liquids) between the well field
and the distribution point or end user, classify the facility as a NG-Gathering Compressor Station, unless it is
located on a natural gas pipeline regulated by the Federal Energy Regulatory Commission (FERC). In that
case, classify it as a NG-Transmission Compressor Station. In addition to compression, dehydration and
sweetening (amine treatment) may occur at gathering compressor stations. A compressor station may have a
fuel treatment skid, such a Joule Thomson (JT) skid that performs some natural gas liquid (NGL) removal
from the gas that is used to fuel engines or other equipment at the site. The presence of a small NGL removal
skid is not enough to classify a facility as a NGPlant.
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1.5 NG—Treatment Without Compression
(Natural Gas – Treatment Without Compression)
There are a small number of treatment facilities that perform dehydration and/or sweetening without
compression. If a facility has compression and treatment, classify it as a NG-Compressor Station if the primary
purpose of the site is compression.
1.6 NG Plant – NGL Extraction and/or Fractionation
(Natural Gas Plant – Natural Gas Liquids Extraction and/or Fractionation)
Natural gas plants extract natural gas liquids (NGLs) from the gas stream. Most natural gas plants use
cryogenic processes, where high pressure gas is expanded in a turbo-expander or across a Joule-Thompson
valve to drop the temperature and to condense NGLs, which are then separated from the residue gas in a
demethanizer tower. A few plants may use other processes (e.g., lean-oil contactors). Natural gas plants
typically have compression on site (upstream of the NGL removal or downstream or both), but that is not a
requirement. A very small number of Oklahoma natural gas plants fractionate the NGLs into individual
components (propane, isobutene, n-butane, etc.). In addition to NGL removal and compression, dehydration
by molecular sieves and/or contactor towers almost always occurs at a natural gas plant. Sweetening, typically
through amine treatment, may also occur on site. Residue gas (natural gas, mainly methane, with a substantial
quantity of the NGLs removed) and NGLs leave the facility in separate pipelines.
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1.7 NG – Transmission Compressor Station
(Natural Gas – Transmission Compressor Station)
Transmission compressor stations are located after the natural gas plant and prior to the city gate or large
industrial user. If the NGL content of the natural gas is low, the natural gas may not be processed in a natural
gas plant between the well field and end user. Under these circumstances, classify the facility as a NGTransmission Compressor Station if it is located on a natural gas pipeline regulated by FERC. mainly methane,
with a substantial quantity of the NGLs removed) and NGLs leave the facility in separate pipelines.
1.8. NG – Underground Storage Facility
(Natural Gas – Underground Storage Facility)
Natural gas is often stored underground under pressure in depleted oil and gas fields, an aquifer, or salt cavern
formation. Natural gas can also be stored in above-ground storage tanks as LNG, but that is very rare in the
Central U.S. Storage may occur at facilities that perform NGL extraction and/or fractionation. If NGL
extraction or fractionation occurs on site, classify the facility as a NG-Gas Plant. If storage occurs at a facility
with compression and/or dehydration or sweetening, classify the facility as a NG-Underground Storage
Facility if storage is the primary purpose of the site.
1.9. Oil – Pipeline Breakout Facility/Truck Station
(Crude Oil – Pipeline Breakout Facility/Truck Station) Pipeline breakout stations are facilities along a pipeline
containing storage vessels used to relieve surges or receive and store crude oil from the pipeline for later re10
injection and continued transportation along the pipeline. Often the pipeline breakout facility will include a
Lease Automatic Custody Transfer (LACT) unit to allow crude oil or condensate to be transferred from tanker
trucks into storage vessels at the facility. Some pipeline breakout facilities store large quantities of crude oil
or condensate and it may be difficult to distinguish a large pipeline breakout facility from a tank farm. If the
storage capacity is less than or equal to 300,000 barrels of crude oil or condensate, classify the facility as a
Pipeline Breakout Facility. Pipeline pumps may be located at these facilities. If the facility has pipeline pumps
and storage vessels with less than or equal to 10,000 barrels of total storage capacity, classify the facility as a
Pipeline Pump Station.
1.10 Oil – Tank Farm
(Crude Oil – Tank Farm)
A tank farm is a collection of large storage tanks of crude oil and/or condensate. To be considered a tank farm,
the facility should have a storage capacity greate r than 300,000 barrels.
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1.11 Oil/NGL/Refined Petroleum – Pipeline Pump Station
(Crude Oil/Natural Gas Liquids/Refined Petroleum – Pipeline Pump Station) Pipeline pump stations are
facilities along a pipeline that contain pumps to maintain the desired pressure and flow of liquid product
through the pipeline. Often pipeline pump stations have storage vessels used to relieve surges or receive and
store product similar to pipeline breakout/truck station facilities. If the facility has pipeline pumps and storage
vessels with greater than 10,000 barrels of total storage capacity, classify it as a Pipeline Breakout Facility. If
the storage capacity is greater than 300,000 barrels, classify the facility as an Oil Tank Farm.
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1.12 Oil Refinery
Refineries are large facilities that process crude oil into refined petroleum products.
1.13 Refined Petroleum – Product Terminal
A refined petroleum product terminal is located downstream of an oil refinery. It may belocated immediately
adjacent to the refinery or it may be distant from the refinery but connected by a pipeline. It is a collection of
tanks that store refined petroleum products. These sites typically include tanker truck loading facilities for
distribution of the refined product (gasoline, diesel fuel, etc.). Refined petroleum product terminals are also
commonly referred to as bulk terminals.
1.14 Oil/NG/NGL – Other
(Crude Oil/Natural Gas/Natural Gas Liquids – Other)
If an oil and gas facility does not belong to any of the current categories, classify it as Oil/NG/NGL—Other.
In addition to this classification, give a brief description of the facility in the facility comment field.
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2. Equipment
2.1Wildcat Drilling
It is the process of drilling for oil or natural gas in unproven or fully exploited areas that either have no concrete
historic production records or have been completely exhausted as a site for oil and gas output. A wildcat driller
may alternatively seek to return to existing or older wells that are no longer profitable or useful for larger oil
companies. Wildcatting often involves smaller firms and can involve both high risk and high reward for
stakeholders. At the same time, this type of exploratory drilling will tend to result in far more misses than hits,
making it expensive to operate without successes.
Investors in such companies can reap significant rewards if such drilling results in locating large energy
reservoirs. Conversely, wildcat drilling that repeatedly results in dry holes can lead to adverse stock
performance or even bankruptcy for small-cap energy companies.
2.2 Gas Condenser
A gas condenser is a highly efficient system that you can use to recover sensitive and latent heat from polluted
gases. A condenser is designed to transfer heat from a working fluid (e.g. water in a steam power plant) to a
secondary fluid or the surrounding air. The condenser relies on the efficient heat transfer that occurs during
phase changes, in this case
during the condensation of a
vapor into a liquid.
Figure: Condenser Diagram
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2.3 Heat Exchanger
used in the Heat exchangers play an important role in processing oil and gas. They are refining process in
cracking units as well as in the liquefaction of natural gas. Cracking is the process of breaking the
hydrocarbons that compose crude oil into smaller pieces, according to Chemguide. Cracking takes place after
the first round of distillation. Then, lubrication and heavy gas oils go through a cracking process. After
cracking, a second round of distillation separates the pieces into groups. TechNavio says that heat exchangers
come into play to separate oil from any water that is produced during the process.
Figure: Heat Exchanger
2.4 Air Cooler
An air cooler is any device for cooling the air inside a building, room, or vehicle.]Air coolers are used in
thermally insulated casings to form refrigerators and are also used in buildings to cool rooms. In buildings
they are only required when the building itself is not constructed so that it is able to dissipate enough heat.
Methods to construct buildings in such a fashion that additional air coolers are not required are eg Earth
sheltering or specific building designs.Used to control the temperature of the flow stream, coolers are forced
draft ambient air heat exchangers and are available with gas engines or electric motors. Process Coolers are
heat exchangers used to reduce gas and liquid wellstream temperatures to allow further process
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2.5 Reactor
Equipment
Reactors are vessels designed to perform chemical reactions that take place in the presence of a catalyst
between reactants in feedstock, or reactants in multiple feed streams. The activity in the reactor is the heart of
the process and is constantly trying to maximize net present value for the given reaction by enhancing yield
at optimum conditions. The chemical reactions occurring in the reactor may be exothermic or endothermic
Severe service isolation valves are installed at both the beginning (injection) and the end (withdrawal) of the
reactor. Those located at the end of the reaction process are usually subjected to harsh conditions that can be
punishing to a common commodity valve. Reactor and reaction engineering play a vital role in petroleum and
chemical processing. The aim of this article is to acquaint the reader with the interaction between reactor
design selection and the characteristics of the chemical reaction of interest. Reactor selection and design are
the basis of economical and safe operation. Chemical reactions in petroleum refining include a huge spectrum
of unique properties. This includes how the the reactants are contacted, whether a catalyst is used, how much
heat is evolved or absorbed and how fast reaction takes place. This article guides the reader in selecting and
designing reactors that will best carryout the reactions of interest. The reactor types discussed focus on those
in a petroleum refinery, but many can be used in chemical processing as well.
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2.6 Boiler Equipment
The basic components of a typical BWR and the functions they perform are illustrated in the animation above,
and can be broken down into five essential systems.The recirculation system takes water from the reactor
vessel and pumps it back in it at an adjustable flow rate, which allows operators to control the reactor's power
output.The main steam system transports steam from the reactor vessel to the turbines that power the plant's
electrical generator.The circulating water system cools the steam after it passes through the turbines,
converting it back to water.
2.7 Evaporators
Evaporators (reboilers, boilers) are a special group of heat exchangers.Evaporators are used for heating the
bottom of distillation columns, additional heat is applied to the bottom of the column with their help. The
liquid phase from the bottom of the column enters the intertubular part of the evaporator and evaporates
partially or completely in the evaporator and is evaporated from the top of the evaporator to the lower tray of
the column. Heat-supplying medium is steam, hot effluents, high-temperature organic heat transfer agent
(HTOC). Superheated steam or effluent hot oil products, or high-temperature organic heat transfer agents are
used as a heat transfer agent
Kettle-type evaporators are used as reboilers. They are horizontal heat exchangers that have an extensive steam
chamber that allows the generated steam and liquid to be separated, as well as vertical and horizontal gravity
reboilers, which, as a rule, are shell-and-tube heat exchangers.
The design of evaporators can be:
with floating head – «П» type;
with Y-shape tubes – «У» type;
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2.8 Pumping Equipment
Centrifugal pumps are the most common types of pumps used in the oil and gas industry. Centrifugal pumps
use centrifugal force through the rotation of the pump impeller to draw fluid into the intake of the pump and
force it through the discharge section via centrifugal force. The flow through the pump is controlled by
discharge flow control valves Plunger pumps are some of the most ubiquitous industrial pumps in the oil and
gas industry. Plunger pumps use the reciprocating motion of plungers and pistons to pressurize fluid in an
enclosed cylinder to a piping system. Plunger pumps are considered constant flow pumps since at a given
speed, the flow rate is constant despite the system pressure. A relief valve is an essential part of any plunger
pump discharge piping system to prevent over pressuring of the pump and piping system.
A progressive cavity pump is a type of positive displacement pump and is also known as an eccentric screw
pump or cavity pump. It transfers fluid by means of the progress, through the pump, of a sequence of small,
fixed shape, discrete cavities, as its rotor is turned. Progressive cavity pumps are used in high viscosity
applications or if blending the of the pumped fluid is not desired. Diaphragm pumps are one of the most
versatile types of oil and gas pumps in the industry and transfer fluid through positive displacement with a
valve and diaphragm. The working principle of this pump is that a decrease in volume causes an increase in
pressure in a vacuum and vice versa.Diaphragm pumps are suitable for high-volume fluid transfer operations
in oil refineries. They also require much less maintenance than positive displacement pumps due to their fewer
moving parts and less friction during operation and are available in compact designs.
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2.9 Pipeline Connecting Accessories
Petroleum pipelines transport crude oil or natural gas liquids, and there are three main types of petroleum
pipelines involved in this process: gathering systems, crude oil pipeline systems, and refined products
pipelines systems. The gathering pipeline systems gather the crude oil or natural gas liquid from the production
wells. Natural gas pipelines transport natural gas from stationary facilities such as gas wells or import/export
facilities, and deliver to a variety of locations, such as homes or directly to other export facilities. This process
also involves three different types of pipelines: gathering systems, transmission systems, and distribution
systems. Similar to the petroleum gathering systems.
2.10 Dust Collectors
Filters are used in within the oil and gas industry. They are used to remove impurities from different process
systems such as fuel gas, glycol dehydration units or glycol dehydrators, oil lubrication, and even the main
inlet gas feed to a gas plant. It is essential to use the right filter and maintain it well to increase the overall
efficiency of a process and prolong equipment life. Read on to learn more about the benefits of using filters
and how they work to separate oil and gas. Cartridge filters are lightweight and can be used to meet a variety
of filtration requirements. They are available in various diameters and lengths, as well as construction
materials, including woven, nonwoven, and membranes. Oil and gas filtration specifications are quite divers.
Gas Filter Separators are mostly used in glycol dehydrators, gas storage facilities, and more. Gas filters are
used to separate entrained liquids and fine and medium-sized contaminants from gas streams. Gas Coalescing
Filters are primarily used to remove liquid aerosols and water from gas streams. They are used in
petrochemical plants, oil and gas facilities, and power generation plants. Liquid Particulate Filters can help
with the removal of solid particulates from liquid streams while ensuring that no solid particles are present in
the fluid. They can separate small and moderately sized solids as well as carryover contaminants, which is
why they are used in so many applications.
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2.11 Broom and Mops
Brushes are widely used in the oil and gas sector Industrial brushes can also be used to service pumps, engines
and valves, for which it is necessary to regularly remove dirt and corrosion Pipeline brushes are suitable
forwelding preparations on oil-, gas- and water pipelines in construction.
2.12 Puller
Throughout the oil or gas mining process, you'll have plenty of occasions where you'll need to use plugs and
other temporary devices that will later need to be removed. Pulling tools can be lowered down into the
wellbore to retrieve debris as well. In some cases, debris may block subsurface tools, hindering their operation
or preventing them from working altogether. The fishneck at the end of the pulling tools is efficient at grabbing
debris and other items so they can be removed. The other end is attached to the wireline for easy lowering and
retrieval. Pulling tools falls under the well workover and intervention processes and are used to maintain the
life of an oil well. One end of Pulling tools have fishing necks that can grab the bits & pieces from the wellbore
and other end is attached to the wireline equipment.The SB type pulling tool purpose is to get connected with
the fishing latch of the subsurface tool to retrieve it when this subsurface tool’s fishing latch is covered or
blocked by the debris inside. This tool jars down the shear tool and helps in either retrieving the subsurface
tool or either setting the subsurface tool.
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2.13 Millimeter
Oil and gas exploration and production companies, or E&P companies, use three basic formats for measuring
and reporting oil and gas production: Oil production is measured and reported in barrels, or “bbl.” Production
rates are typically reported in terms of barrels per day, which may be abbreviated in several different ways,
including bpd, b/d and bbl/d. Production volume may be rounded to the nearest thousand or million barrels,
denoted with “m” or “mm,”respectively.
2.14 Crimpers
A crimping tool to be simply put is a machine that is used to make weld joints in low temperature also called
cold weld joints between t he connector and the wires through deforming either one or other
respectively.Crimping is commonly used in electrical work, to attach wires together or wire to other
connectors. "Crimp connectors" is the general name for the fittings that attach to the wire using this method,
which usually have an insulated sleeve attached to a metal connector. The purpose of the crimping tool is to
form a secure connection that is properly sealed from any gas or moisture, preventing shortages or faulty
electrical connections.
2.14.1 Types of Crimping Tools:
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2.15 Types of pipes in Oil and Gas
Seamless Pipe
Generally, these types of pipes are produced from steel billets. The experts heat and perforate these billets for
creating the tubular section. There is no presence of seam welds in this pipe that’s why the name of the pipe
is seamless. There are various applications of this pipe such as Transmitting and distributing the gas, steam,
acids and oil,Upstream operations and Plumbing work for utility services
The most popular types of pipes are A106, A333, API 5L and ASTM A53, ASTM A312 Series 400, 300
ASTM A335 Grades from P5 to P91 used in the oil & gas industry.
The experts generally manufacture this type of pipe by using steel coils. At first, they uncoil the coil, then cut
and finally join the two extremities electrically to build it in a pipe shape. You can get the pipes according to
your requirement. Mainly, sizes between 1/2 and 20 inches are available in the market. You can find it in
stainless steel and carbon steel. Keep in mind that nowadays, Electric Resistance Welding is used as a popular
alternative to seamless pipes. The reason behind this is the performance and affordability.
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LSAW Pipe
The manufacturers produce this type of pipe by bending, cutting and welding the steel plates in the JCOE
process. You can find the pipes in the size of 16 and 24 inches. There are mainly two types of LSAW pipes –
longitudinal and spiral. The spiral pipes are also known as SSAW, SAWL pipe and HSAW. There is a main
difference between DSAW vs. LSAW pipes. Generally, the DSAW pipes have a seam weld on the inside
whereas there is a single seam weld on the outside surface of LSAW pipes.
2.16 Hand Saw
Hand saws are referred to as those instruments which are found to be powered by the force of the user. These
are one amongst those instruments which are being neither powered by electricity, battery nor by gas.
2.16.1 Hack Saw:
The hacksaw was found to be created to fulfil the cut through metal, which is possible due to its thin blade.The
instrument is found working well in order to cut through the thin materials like plastic or metal pipes. These
can also be used as a multi-purpose saw for cutting through the wood, which can damage the blade too. This
saw is found holding a fine-toothed blade which is under the actions of tension across a C-frame.
Adjustable wire stripper
2.17.1 Adjustable Wire Stripper
This type has a simple design, with a single notch in each blade. It has a stop screw that allows the user to set
the cut based on the thickness of the wire to be stripped. To work more efficiently, choose a stripper that
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eopens after each cut. Some people find that these strippers can be difficult to adjust to the wire thickness, so
it can lead to a few mistakes. The Irwin Self Adjusting Wire Stripper is a good example.
2.17.2 Gauged Stripper
This is a very popular type since it is easy to use. The blades have holes matching wires of different gauges,
making the stripping job simpler and quicker since no adjustment is needed. Some types can also work as a
cutter or crimper so it is suitable for different types of wiring jobs. There is a limit to the number of gauges on
a single wire stripper, so it might be necessary to buy more than one. The Milwaukee 48-22-6109 is a good
example.Self-adjusting Stripper: Just like the name says, this stripper automatically adjusts to wires of
different thickness levels. Strippers like the Irwin-2078300 make the work go much faster since there is no
need to constantly make adjustments. For added convenience, choose a self-adjusting stripper that has a built
in crimper or cutter.
Gauged Wire Stripper
2.18 Hammer
It is used to beat or striking blows on jobs or metals or jobs driving nails etc. It is used to straighten or bend a
job made of metal. In addition, it is also used for riveting, chipping, and forging jobs.
2.18.1 Types of Hammers:
Based on their utility the hand hammers are of several types.
2.18.2 Hand Hammer
These hammers are made of cast steel of carbon steel. Their pan and face are hardened and tempered. The
middle body is kept soft. On one end of the body, face and pan are made. An oval-shaped hole is made in the
body in which the handle is fitted by using a wedge. Because of the wedge, the hole is somewhat enlarged and
there is no risk of handle becoming loose and coming out. The length of the hammer depends on its weight.
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Figure: Ball Pen Hammer
2.19 Types of Wrenches
2.19.1 Crescent Wrenches
A wrench is meant to provide secure grips when applying torque to turn numerous objects. Whether you want
to loosen or tighten bolts, nuts, screws, and other mechanical caps, an appropriate wrench is required.
2.19.2 Open-End Wrench
Adjusts the tightness of nuts and bolts. Both metric and standard sizes. Two open ends of different size. Models
with a joint or a flex head let you work with hard-to-reach bolts. Figure: Open- end wrench.
Open End Wrench
2.19.3 Ratchet Wrench
Adjusts the tightness of nuts and bolts. Both metric and standard sizes. One end has a ratchet that moves freely
in one direction and locks into the fastener in the other. This lets you tighten or loosen nuts and bolts without
taking the tool off.Some have ratchet ends that can turn so they can be used in tight spaces.
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2.20 Types of Drilling
Percussion or Cable Drilling
Rotary Drilling
Dual-Wall Reverse-Circulation Drilling
Electro-Drilling
Directional Drilling
2.21.1 Orbital Sander
Sanding by hand is a very taxing process. It exhausts you, and even a momentary lack in focus can leave
stroke marks on the surface. As a result, getting the necessary precision is quite difficult. Can be used in
industry to clean down rusty surfaces and apply new rust resistant paint.
2.22 Circular Saws
2.22.1 Corded Circular Saw
Can be used for cutting wooden fittings for different purposes in Oil and Gas Plant
2.23 Impact Wrenches
Impact wrenches are high torque production tools. It is named a rattle gun, impactor, air wrench, torque gun,
windy gun etc. Lug nuts are with different diameters and should be tight to recommended torque. When the
diameter of the nut is increased, it should be subject to high tension. High tension will require more torque. In
order to apply high torques impact, wrenches are manufactured.1. Electrical Impact Wrenches Electrical
impact wrenches are the most popular impact wrenches in the world. Normally domestic lug nuts are not
higher diameter, and those can be tighten using a below 500 ft-lb impact wrench. So using the impact
mechanism that much torque is really easy to produce. According to the power supply method, electrical
impact wrenches can be divided into two.
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2.23.1. Cordless Impact Wrenches
Cordless impact wrenches are really useful for
lightweight tasks. Especially for the DIYs and domestic usage. Cordless impact wrenches are powered bythe
Battery. The batteries can be Li-Ion or Ni-Cd. Li-Ion is the most used impact wrench battery and it is more
advantageous to use than Ni-Cd. Available batteries are 12V,18V, 20V, 24V, and 36V etc. According to the
capacity of the battery, its torque capacity has increased. Normally cordless impact wrench can produce less
than 500 ft-lb torque for lightweight tasks, and for the special task, there are tools that can produce 2000 ft-lb
torque.
2.24 Screw Drivers
2.24.1 Flat–Head Screwdriver
It is one of the oldest types of screwdriver. It was invented in the 15th century in Europe and one of the most
common types of screwdrivers. As the name suggest it has a flat shape shaft tip with a single slot which
engages with the slotted screw head only. It can be manual driven or power driven, but not often power driven
because slotted head has ‘cam- out effect’. Now what does it mean? Well ‘cam-out effect’ is a process by
which the screwdriver tends to slips off from the surface of the screw head, when the torque applied on the
surface of the screw exceeds a certain limit or sometimes due to lack of centering, which usually causes the
damage to the screw head or screwdriver tip.
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2.24.2 Phillips Screwdriver
As today’s world is moving from a manual driven to power or motor driven, these were the first step towards
power driven screwdrivers to save time and do things more precisely and accurately. These were invented in
19th century by Henry Phillips with an aim to introduce the power driven screwdrivers in most of the
industries. When you see these screwdrivers from the front, the tip looks like a cross sign. These types of
screwdrivers also shows cam- out effect but it does purposely when the torque exceeds a limit while tightening
up of screw which resist the damage of screwdriver profile and screw and clearly extends the life of the tool.
3.0 Flanges
A rib or rim used for strength, for guiding, or for attachment to another object.
3.1 Types of Flanges
3.1.1 Slip-on Flanges
Slip on Flange is essentially a ring that is placed over the pipe end, with the flange face extending from the
end of the pipe by enough distance to apply a weld bead on the inside diameter.
3.1.2 Threaded Flanges
The threaded flange design (also called a 'screwed flange') uses a screw thread to connect the flange to a pipe.
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3.1.3 Blind Flanges:
The blind flange is basically a flange that does not have a hub or a bored center. Blind flanges have the face
thickness of a flange, a matching face type, and similar bolting pattern. Blind flanges can also be used to seal
a nozzle opening on a pressure vessel.
3.1.4 Lap Joint Flanges:
A lap-joint flange is a two-component assembly, with a stub end that has a lap-joint ring flange placed over
it.
3.1.5 Socket Flanges:
Socket-weld pipe flanges are typically used on smaller sizes of high pressure pipes. These pipe flanges are
attached by inserting the pipe into the socket end and applying fillet weld around the top. This allows for a
smooth bore and better flow of the fluid or gas inside of the pipe.
3.1.6 Weld Flanges:
The socket weld flange is designed to standard dimensions stipulated by ASME B16. 5. The flange comprises
a drilled flanged blade with a machined face on one side and, on the other, a female socket into which the pipe
is placed. As with the weld neck, these flanges are generally made from forged steel.
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4. Gasket
A gasket is a common term used to describe any seal or grommet that holds two things together.
4.1 Types of Gasket
4.1.1 Envelope Gasket:
A envelope gaskets is a composite gasket where the product consists of an envelope of PTFE with an insert
material. The main advantage of an envelope gaskets is that it gives the strength and characteristics of the core
material along with the properties of PTFE.
4.1.2 Flat Metal Gasket:
Elastomer flat metal gaskets are seals typically used in applications where temperature and pressures rule out
the use of rubber or plain elastomer rubber gaskets materials.
4.1.3 Ring Type
Gasket
Ring type joint gasket (RTJ Gasket) is a high integrity sealing gasket, high temperature and high pressure
gasket for applications in petroleum industry, oilfield drilling, pressure vessels joints, pipes and valves etc.
4.1.4 Kammprofile Gasket
Kammprofile gaskets, also known as Grooved Gaskets, are widely used industrial sealants that contain a
serrated metal core covered by a soft material such as graphite or PTFE, with or without a ring.
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4.1.5 Spiral Wound Gasket
The spiral wound gasket is semi-metallic, comprising of a spirally wound v-shaped stainless steel strip and a
non-metallic filler material, such as graphite or PTFE.
4.1.6 Corrugated Metal Gasket
The structure of a corrugated gasket consists of a metal core that's corrugated and sealing elements for extreme
environments. These are made of corrugated stainless steel ring and come with a soft material layer like PTFE
or graphite on both sides. The gaskets can take a load of 160 bar pressure.
5.0 Pipe Fitting
A piece (such as a coupling or elbow) used to connect pipes or as accessory to a pipe.5.1 Types of Pipe Fitting
5.1.1 Pipe Elbow
Steel pipe elbow (sometimes also refereed as bends) is a key part in a pressure piping system used to change
the fluid flow direction. It is used to connect two pipes with same or different nominal diameters, and to make
the pipe and thus the fluid direction turn to a certain direction of 45 degree or 90 degree.
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5.1.2 Reducing Elbow
A reducing elbow is a type of fitting which is used to join two pipes of different sizes. The reducing elbow is
so called because it looks like a reducing piece and elbow combined into one. The reducing elbow eliminates
one pipe fitting (reducer) and reduces the welding by more than one-third.
5.1.3 Pipe Tee
Pipe Tee is a most frequently used pipe fitting or connector nowadays. It functions the same as olets that
means it is used to take a branch connection for linear pipeline.
5.1.4 Cross:
Cross Pipe Fittings are also referred to as four-way fittings or cross branch lines. These SS Equal Cross, have
one inlet and three outlets or they could also be manufacturer vice versa i.e. three inlets and one outlet. Often
the Buttweld Lateral Cross have a solvent-welded socket or female-threaded ends.
5.1.5 Pipe Union:
A union is a threaded fitting which allows the pipe work to be separated and reconnected without any
horizontal movement in the pipe. It can be a standalone pipe fitting connecting two pieces of pipe, or an
integral part of another fitting (such as a ball valve) which allows it to be separated.
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6.0 Industrial Pumps
Industrial pumps are designed specifically for heavy duty purposes. They flow or move a range of material
types, including oils, chemicals and other fluids.
6.1 Types of pumps
1. Centrifugal pumps: One of the most commonly available dynamic pump types, centrifugal pumps use one
or more rotating impellers to create suction.
2. Reciprocating pumps: These positive displacement pumps rely on a piston that pushes in and out of the
fluid to create suction.
3. Rotary pumps: Rotary pumps use two gears that work together to create a high level of pressure to allow
the fluid to flow.
6.1.1 Centrifugal Pump
A centrifugal pump is a mechanical device designed to move a fluid by means of the transfer of rotational
energy from one or more rotors, called impellers.
Working:
Fluid enters the rapidly rotating impeller along its axis and is moved thoroughly through the edges by the
means of centrifugal force. The energy conversion is mainly due to the two main parts, the impeller and the
casing. The rotating part of the pump is the impeller and the airtight area which surrounds the impeller is the
casing part.
This action of the impeller increases the velocity of the fluid (oil) and pressure and also directs it towards the
pump opening. The pump casing is specially designed to restrict the fluid from the pump inlet, directing it into
the impellers and then slow and control the fluid before discharge.
Figure: Impellers of Centrifugal Pump
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This process continues until it leaves the impeller into the diffuser part of the casing. The fluid is gaining both
pressure and velocity while passing through the impeller.
Industrial Uses of Centrifugal Pumps
•
To boost pressure
•
To supply water for utilization
•
To assist fire protection setup
•
To assist in hot water circulation
•
To regulate boiler water
6.1.2 Oil Transfer Pump
Oil transfer pump is driven by electricity and diesel engines for the transmission of liquid and oils. Fuel and
oil transfer pumps move oil, fuel, lubricants, and other substances from one container to another.
Working
Transfer pumps work by creating a pressure difference between two areas to move oil from one area to another.
Electric power can maybe used to draw oil into the pump and also to push the oil out of the pump to its new
destination
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Figure: Oil Transfer Pump
Industrial uses of oil transfer pump
•
They are common in servicing truck fleets and heavy equipment with fuel and lubricants. Transfer
pumps remove liquids from tanks, either above or below ground, so the tanks can be cleaned.
•
Oil change systems transfer liquids for cars, trucks, and farm equipment
6.1.3 Positive Displacement Pumps
Positive displacement pumps add energy to a fluid by applying force to the liquid with a mechanical device
such as a piston or plunger. Positive displacement pumps can be divided into two major types: rotary and
reciprocating. All Rotary pumps use some form of rotating element, such as gears, shafts, or lobes to increase
the discharge pressure. Reciprocating pumps use pistons or wobble plates to increase the pressure.
Industrial Uses of Positive displacement pumps
•
Positive displacement pumps are an integral part of fuel systems in the transportation sector.
•
They are also used in petrochemical industry for precise flow.
•
Used for metering or dispensing oils
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Figure: Types of Displacement Pumps
6.1.4 Diaphragm Pumps
Diaphragm Pump also called Air Operated Double Diaphragm is a type of double diaphragm positive
displacement pump operated by using compressed air. The diaphragm pump has an air-filled valve that directs
compressed air back and forth between the two sides of the pump
Working:The flexing diaphragm creates a vacuum at the inlet of the chamber that draws the fluid into the
chamber. When the diaphragm moves in the opposite direction it causes the volume of the pumping chamber
to decrease, forcing the fluid out the discharge port of the pump.Diaphragm pumps use check valves at the
inlet and outlet of the pumping chamber to ensure that the fluid flows in one direction and out the other without
leaking backwards.
: Diagram of Diaphragm Pump
Components
of
a
diaphragm pump:
The main components that constitute and regulate the operation of a double diaphragm pump are as follows.
The Central Body: includes the inlet and outlet of the supplied air and the exchanger, which provides
alternating pressure to the air valve and contributes to the movement of the membranes and at the same time
to the pumping action.
The Fluid Chambers contain the volumes within which fluid is drawn in and pumped out. The fluid chambers
include the membranes. A vacuum is created inside the chamber where diaphragms alternately draw in fluid
and push it out from each side to create the pumping action.
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Manifolds: These provide the connection interface to the system and are attached to the outer chambers to
provide a seal while at the same time creating a fluid flow path. Sometimes they include ball housing that has
check valve functionality to prevent the sucked fluid from returning to its starting point.
The air valve: It directs compressed air into the chambers and helps move the membrane assembly. At the
same time, the air valve, directs compressed air into the opposite chamber allowing it to be discharged to the
atmosphere through the exhaust port located in the central block.
The diaphragms: These are available in a wide variety of materials and designs and function both as a barrier
with the task of separating the fluid side of the pump from the air side and to create the pumping action through
their expansion.
Industrial Uses of Diaphragm Pumps:
Because diaphragm pumps are so versatile, they are used in virtually every industry that requires fluid transfer.
•
They are often used for dewatering or water removal across many different industries.
•
They are used for filling, dispensing and metering due to their efficiency and accuracy.
•
They can produce plenty of pressure for spraying and cleaning applications.
•
They are often used for filter press applications.
6.1.5 Gear Pumps
A gear pump is a rotary positive displacement pump which develops flow by carrying fluid between the teeth
of two meshed gears. One gear is driven by the drive shaft and turns the other.
Working:
Gear Pumps operate via two moving gears, where fluid travels between cavities within the teeth and cavity.
A partial vacuum is created at the inlet as the gear teeth move backwards. Fluid flows in to fill the space and
is carried around the outside of the gears. As the teeth connect again at the outlet, the fluid is forced out. The
fluid is trapped by the teeth as they rotate and then the fluid flows towards the discharge via the connected
parts.
Figure 1: Gear Pump
There are two types of gear pumps in design either External or Internal differentiated in the given table below.
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They can be used across various industries such as:
•
Fuel Industry: Lube oils, furnace, diesel, grease and waste oil.
•
Food Industry: Transfer of Syrups, Chocolate, Honey, Creams, molasses
•
Construction: Polyurethane, bitumen and fillers.
•
Paint: Paint, inks, latex.
•
Chemical: Handling of Resins, soaps, pigment, polymers, chemicals and polyurethane.
•
They are also used in extrusion.
Table
6.1.6 Petrochemical Pumps
Petrochemical pumps are used to extract or move petrochemicals or viscous, toxic, corrosive fluids. They are
capable of generating high rates of flow and pressure. Petrochemical pumps work at high pressure and high
flow rates within a refinery system to treat or refine compounds.
The advantages of petrochemical pumps is that they avoid leaks, which means they protect the environment.
The petrochemical pump’s simple design, ease of use, and compactness provide it with the durability it needs
to keep up with the rigors of oil drilling.
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Figure: Petrochemical Pump Working
Application and Industrial Uses of Petrochemical Pumps:
Petrochemical pumps are used to extract or move petrochemicals or viscous, toxic, corrosive fluids.
Petrochemical pumps are capable of generating high rates of flow and pressure.
They are also designed to prevent leaks that could result in catastrophic environmental damage.
6.1.7 Reciprocating Plunger Pumps
Reciprocating Plunger pumps are positive displacement devices ideal for pumping a range of liquids, even
liquids with high levels of solid content.
Many plunger pumps are constructed using various materials. The material used to create the plunger depends
upon its specific use. Ceramic plungers are preferred for irregular slurries and fluids, and other plungers are
coated with metal to work better in applications that require high strength.
Working;
Reciprocating plunger pumps use a crankshaft to move the plunger back & forth during the pumping process.
Plunger pumps operate according to the displacement principle. A plunger is used from the liquid end of the
system to create a suction effect. This effect opens the suction valve and allows the medium to flow into the
liquid end of the system. After this the plunger moves forward. This process displaces the available volume
within the system which increases the pressure of the fluid being pumped. The discharge valve opens after the
suction valve closes which opens a path to the process area. This is where pressurized fluid ends up.
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Figure: Reciprocating Plunger Pump
Industrial use of Reciprocating Plunger Pumps:
A reciprocating plunger pump can carry any liquid, for example water, oils, and liquid gases are moved easily
by these systems in a production industry. They’re perfect for a wide range of industries and applications
because of their ability to stand up to most abrasion and their withholding strength.
Industrial
For accurate metering and mixing of paint & pigment additives, catalyst for foundry resins, plating bath
regeneration, petroleum additives, photo chemicals, inks, monomers and adhesives.
Spraying Systems
For injection of insecticides, herbicides, and agricultural nutrients. Also used in ULV spray equipment for
mosquito control.
Environmental & Pollution Control
For sampling stack gases, ground water & waste water, as well as injection of monomers, polymers, and
chemicals for water & waste treatment.
Cosmetic & Hygiene
Precision dispensing of pigments used in cosmetic colour mixing systems. Also for moisture control and
fragrance addition.
Battery Manufacturing
Precision dispensing of electrolytes & slurries into batteries, as well as for lubrication of fine blanking
machines used to form and stamp battery components.
Automotive
Hydrogen fuel cell research & development for both the humidification and fuel injection systems. For
dispensing insulating and encapsulating coating materials in the manufacture of stators, armatures, and
distributors. Also used in instrumentation to verify gasoline octane rating.
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Food & Dairy
Sugar coating and polishing, vitamin fortification for milk addition of flavours & colours for brewing and
sanitising agents for aseptic packaging.
Also used for sample and reagent fluid control in milk analysers and other food quality control
instrumentation.
6.1.8 Progressive Cavity Pumps
A progressive cavity pump is a type of positive displacement pump that is designed to handle extremely tough
pumping applications and high viscous fluids.
Like all positive displacement pumps, progressive cavity pumps are flow creating devices. They move fluid
at a consistent speed regardless of the pressure on the inlet end.
Working;
Progressive cavity pumps draw fluid in through a suction inlet which feeds into an elongated casing. Within
the casing is a helical rotor and stator assembly. The rotor helix is offset to the stator. As the rotor turns and
contacts the surface of the stator, a series of small cavities begin to form. The fluid progresses through these
cavities until it is expelled through a discharge outlet.
Figure: Progressive Cavity Pump
These pumps cannot be allowed to run dry, as the heat generated by the rotor and stator can cause pump
failure.
Industrial Uses of Progressive Cavity Pumps:
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•
Progressive cavity pumps are used for a wide variety of applications, including the following.
•
metering and dosing of chemicals
•
wastewater treatment
•
chemical manufacturing
•
oil pumping/petroleum production
•
food and beverage processing
•
pulp and paper production
•
sewage, sludge, and slurry pumping
•
grout or cement pumping for building purposes
•
limited energy well water pumping for farming
•
lubrication oil pumping
6.1.9. Metering Pumps
A metering pump is used to add small but accurate volumes of a liquid to other fluid streams or
vessels. They are also called dosing pumps and proportioning pumps. A metering pump must be able to deliver
liquid with an accuracy of greater than 3% across a wide range of discharge pressures.
Figure: Metering Pump Diagram
Industrial Uses of Metering Pumps:
Maintaining a constant flow rate regardless of differential pressure or fluid viscosity.
Delivering a variable flow to maintain a system parameter (for example, pH).
Injecting a discrete dose (typically required in batch processing).
Metering is required in many industries, including pharmaceuticals, water and waste treatment, food and
beverage production, power generation, chemical processing, petrochemicals and oil and gas extraction.
Liquids can be anything from fragrances and pigments in the production of toiletries or food or acids and
alkaline solutions for chemical processes and water treatment.
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6.1.10 Booster Pumps
Booster pumps increase fluid pressure, forcing fluid to flow through the pipes at a faster rate. It provides the
extra boost needed to bring oil pressure to the desired level. A booster pump provides pressure to move oil
and fluids from a storage tank or throughout a whole industry or commercial facility.
Working:
Booster pumps increase fluid pressure as a way to increase flow. A booster pump works like a fan with blades
that rotate to increase air flow, and a booster pump has an impeller inside that increases oil flow and pressure
in the same way.
Most of them are centrifugal pumps that take oil or any other fluid from the source and move it through an
impeller (single stage) or multiple impellers (multi-stage) to increase the fluids pressure. The high pressure
fluid then flows through the outlet.
Industrial Uses of Booster Pumps
Filtration
Reverse Osmosis
HVAC (Heating, ventilation, and air conditioning)
7. Valves
A valve is a component in a piping system that is used to control and regulate the flow of fluids through the
system.
Functions
The function of valves are
Regulating flow and pressure within a piping system.
Controlling the direction of flow within a piping system.
Throttling flow rates within a piping system.
Improving safety through relieving pressure or vacuum in a piping system.
7.1 Types of valves
7.1.1 Ball valves
Ball valves are quarter turn on/off devices. A pivoting ball in the center of the valve controls the flow of liquid
or gas. The pivoting ball is known as a rotary ball, and it is designed with a hole in the center. A stem on the
top of the ball rotates the ball to open or close the valve. The stem can be turned using manual levers or
automation.
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Figure: Ball Valve Stem (A) and Rotary Ball (B)
Working
Ball valves can have multiple ports, which are the openings in the valve. Two-way ball valves have two ports
and are used for traditional on/off control. Multi-port valves 3-way, 4-way, etc. are used in applications that
require more than one source of media or that need to divert media in different directions.
The port of a ball valve can be opened or closed to control media either manually or through actuation. The
manual option requires handles or levers and an operator to control the valve. Electric, hydraulic and
pneumatic actuation don’t require an operator to control the valve.
Actuation is ideal for complex control systems or those that are in remote areas that an operator cannot easily
access.
Ball Valve Diagram & Parts
Figure: Ball valve diagram
To understand the working principle of a ball valve, it is important to know the 5 main ball valve parts and 2
different operation types. The 5 main components can be seen in the ball valve diagram in Figure above. The
valve stem (1) is connected to the ball (4) and is either manually operated or automatically operated
(electrically or pneumatically). The ball is supported and sealed by the ball valve seat (5) and their are o-rings
(2) around the valve stem. All are inside the valve housing (3). The ball has a bore through it. When the valve
44
stem is turned a quarter-turn the bore is either open to the flow allowing media to flow through or closed to
prevent media flow.
Applications:
Ball Valves are mainly used for flow and pressure controlling purposes and it acts as a shut off for corrosive
fluids, slurries, normal liquid and gases. Ball Valves are used in oil, natural gas industries, manufacturing
sectors, chemical storage, and even for residential uses. Ball Valves are used for flow and pressure control
and shut off for corrosive fluids, slurries, normal liquid and gases.
7.1.2 Butterfly valves
Butterfly valves are quarter turn valves that are popular for on/off or modulating services. They are
lightweight, have a small installation footprint, lower cost, quick operation, and are available with large orifice
sizes.The butterfly valve has a unique body style unlike the other valves we have discussed. It uses a circular
plate or wafer operated by a wrench to control flow.
Butterfly Valve Diagram and Parts:
Butterfly valves have a relatively simple construction. Figure shows the main components of a butterfly valve,
which are the body, seal, disc, and stem. The disc (E) of a butterfly valve aligns with the center of the connected
piping and the stem (B) connects to an actuator or handle on the outside of the valve. In the closed position,
the disc is perpendicular to the flow, as shown in Figure, and seals against the valve seat (D). An o-ring (C)
in the stem packing seals against leakage along the stem. When the handle rotates the butterfly valve stem
90°, the disc also rotates 90° to become parallel to the flow. Partial rotation allows for the flow to be throttled
or proportional.
Figure:Parts of a butterfly valve: disk (A), stem (B), handle (C), seal (D), O-ring (E), valve body (F)
45
Applications:
Butterfly valves are used in diverse industries and applications such as pharmaceutical, chemical and oil, food,
water supply, wastewater treatment, fire protection, gas supply, fuel handling, and sanitary fittings. Butterfly
valves for water are used as control valves in pipelines to shut off water flow. These valves are available in
huge sizes and are suitable for handling slurries and liquids with relatively large amounts of solids at low
pressures. Stainless steel butterfly valves are used in corrosive and marine environmental applications as the
material is highly durable and resistant to corrosion.
7.1.3 Check valves
A check valve is a unidirectional valve that passes fluid in one direction but prevents any flow in the opposite
direction. The main purpose of a check valve in a system is to prevent backflow, which could damage
equipment or contaminate media upstream.
Check valve diagram & parts
Applications
Check valves are often used with some types of pumps. Piston-driven and diaphragm pumps such as metering
pumps and pumps for chromatography commonly use inlet and outlet ball check valves. These valves often
look like small cylinders attached to the pump head on the inlet and outlet lines.
Check valves are also used in the pumps that supply water to water slides. The water to the slide flows through
a pipe which doubles as the tower holding the steps to the slide. When the facility with the slide closes for the
night, the check valve stops the flow of water through the pipe; when the facility reopens for the next day, the
valve is opened and the flow restarts, making the slide ready for use again.
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Check valves are also used in many fluid systems such as those in chemical and power plants, and in many
other industrial processes.
In aircraft and aerospace, check valves are used where high vibration, large temperature extremes and
corrosive fluids are present.
Check valves are also often used when multiple gases are mixed into one gas stream. A check valve is installed
on each of the individual gas streams to prevent mixing of the gases in the original source. In 2010, NASA's
Jet Propulsion Laboratory slightly modified a simple check valve design with the intention to store liquid
samples indicative to life on Mars in separate reservoirs of the device without fear of cross contamination.
7.1.4 Gate valves
A gate valve is ideal for applications that have slurries, large flow rates, cost sensitive, and for shut off
purposes. A gate valve is typically cheaper, better for higher flow rates, and requires a smaller installation
space.
Gate valve diagram & parts
A gate valve has seven main parts, which can be seen in Figure below, which are handwheel (A), stem (B),
gasket (C), bonnet (D), valve body (E), flange (F), and gate (G).
Figure: Gate Valve
Working/Operation:
A gate valve operates similar to other valves. To open the valve, turn the handwheel (A), which moves the
gate (G) up or down on the stem (B) via the threads. A gate valve requires more than one 360° turn to open or
close the valve fully. When the gate is lifted up, it opens the inlet to the outlet allowing an unobstructed
passageway for the media to flow. When the gate is lowered, it closes and blocks the media flow.
Applications:
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Gate valves are generally found in older plumbing systems and in applications where frequent shut off is not
required. Large water supply lines use gate valves due to their straight flow path and less flow restrictions.
Gate valves are used for application with slurries and viscous media because they are easier to clean and
maintain. Ball valves are not desirable because they are difficult to clean, and the slurry particles may damage
the rotary ball. Gate valves are used in power plants, mining and water treatment applications which are high
temperature and high-pressure environments.
7.1.5 NEEDLE VALVES
A needle valve is a type of valve with a small port and a threaded, needle-shaped plunger. It allows precise
regulation of flow, although it is generally only capable of relatively low flow rates.
USES:
Needle valves, sometimes referred to as plunger valves, are regulating valves and enable engineers to finely
control and regulate water flow and pressure.Needle valves are commonly used products. They are specifically
useful in regulating precise flow and exact calibration in small channel applications. Needle valves are used
across a wide range of industries that work with fluid control applications.
USED FOR PLUMBING:
Needle valves are used for isolation, regulation, and throttle of liquids and gases. Needle valves offer flow
control with precision unlike any other valve. With each turn of the stem, there is only a minimal increase in
flow. This allows the operator exact control over the flow of the fluid or gas.
NEEDLE VALVE CONTROL FLOW:
An instrument needle valve uses a tapered pin to gradually open a space for fine control of flow. The flow can
be controlled and regulated with the use of a spindle. A needle valve has a relatively small orifice with a
long, tapered seat, and a needle-shaped plunger on the end of a screw, which exactly fits the seat.
OPEN OR CLOSED:
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In order to tell if the valve is open or closed, the general rule is, if the handle is switched 90deg to the flow, it
is off. As you can see from the diagram above, if the handle is in line with the flow path, it is on. Simple.
Hitting a valve is such a common way of blowing veins. This happens because valves are stronger than vein
walls, so when you advance your catheter, hit a valve, then keep advancing, it will often push out the side of
the vein or cause so much damage to the wall that the vein blows
Instead of a ball, a needle valve has a plunger in the shape of a needle, hence the name. To control the position
of the needle-shaped plunger, there is a threaded rotating stem mechanism, which makes the control very
precise.
8. CONDENSER
A condenser is designed to transfer heat from a working fluid (e.g. water in a steam power plant) to a
secondary fluid or the surrounding air. The condenser relies on the efficient heat transfer that occurs during
phase changes, in this case during the condensation of a vapor into a liquid.
The purpose of using a steam condenser is: helping keep the pressure low (below atmospheric pressure)
at the steam turbine end to get maximum possible energy and reduce the specific steam consumption of
a power plant.
8.1 TYPES OF CONDENSER:
Condenser is one of the key equipment in the refrigerant system, usually placed outside the building or may
be placed in a Chiller room. The main forms are used today are 2 types: Shell and tube condenser and Air
cooled condenser.
They are the condenser coil, evaporator, expansion valve, and compressor.
8.1.1 AIR COOLED CONDENSER:
An air cooled condenser (ACC) is a direct dry cooling system where steam is condensed inside air-cooled
finned tubes. The cool ambient air flow outside the finned tubes is what removes heat and defines the
functionality of an ACC.
WORKING:
An air cooled condenser (ACC) is a direct dry cooling system where steam is condensed inside air-cooled
finned tubes. The cool ambient air flow outside the finned tubes is what removes heat and defines the
functionality of an ACC.
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ADVANTAGES:
The advantages of air cooled heat exchanger are as following: High Heat Transfer Coefficient: The air-cooled
heat exchanger has a high heat transfer coefficient, which is generally considered to be three to five times that
of the shell-and-tube heat exchanger
In air-cooled condensers, condenser heat is rejected directly to the ambient air. Thus, the condensing
temperature is a function of the ambient air dry-bulb temperature. The obvious advantage of air-cooled
condensers relative to water-cooled condensers is that cooling water is not needed.
FUNCTION:
An air cooled condenser (ACC) is a direct dry cooling system where steam is condensed inside air-cooled
finned tubes. The cool ambient air flow outside the finned tubes is what removes heat and defines the
functionality of an ACC.
An air cooled condenser (ACC) is a direct dry cooling system where steam is condensed inside air-cooled
finned tubes. The cool ambient air flow outside the finned tubes is what removes heat and defines the
functionality of an ACC.
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Air-cooled condensers usually have copper coils where refrigerant flows in. But this is not the whole story;
this type is subcategorized into two subsets: natural convection and forced convection.
An air-cooled condenser consists of a coil of ample surface where a fan blows air, or is induced by natural
draft. This type of condenser is universally used in small capacity refrigerating units. It is mostly designed for
residential or small office air conditioners.
8.1.2 WATER COOLED CONDENSER:
A Water-Cooled Condenser is a heat exchanger that removes heat from refrigerant vapour and transfers
it to the water running through it. Having the refrigerant vapour condensed on the outside of a tube achieves
this. In doing so, the vapour condenses and gives up heat to the water running inside the tube.
WORKING:
A Water-Cooled Condenser is a heat exchanger that removes heat from refrigerant vapour and transfers
it to the water running through it. Having the refrigerant vapour condensed on the outside of a tube achieves
this. In doing so, the vapour condenses and gives up heat to the water running inside the tube.
ADVANTAGES:
A water-cooled system typically lasts years longer, assuming maintenance is not neglected. It has higher
heat transfer rate. It consumes far less overall energy, which can lead to savings on energy costs and
consumption. It does not require any external power.
FUNCTION:
A Water-Cooled Condenser is a heat exchanger that removes heat from refrigerant vapour and transfers
it to the water running through it. Having the refrigerant vapour condensed on the outside of a tube achieves
this. In doing so, the vapour condenses and gives up heat to the water running inside the tube.
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A water-cooled condenser is a chiller component that removes heat generated by an industrial or
commercial process.
9. ENGINERING DRAWING SYMBOLS:
Process diagrams can be broken down into two major categories: process and instrument diagrams (P&IDs)
and Process Flow Diagrams (PFDs). A P&ID is complex while a PFD is more of an overview of a process.
A flow diagram is a simple illustration that uses process symbols to describe the primary flow path through
the production equipment. It provides a quick snapshot of the operating unit and includes all primary
equipment and piping symbols that can be used to trace the flow of the well stream through the equipment.
Secondary flows, complex control loops and instrumentation are not included. These PFDs are more helpful
for visitor information and new employee training.
9.1 LINE TYPES:
No line means the instrument is installed in the field near the process.
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•
Located in field
•
Not panel, cabinet, or console mounted
•
Visible at field location
•
Normally operator accessible
9.1.1 Solid Line
means the instrument is in a primary location in a central control room (accessible to the operator).
Located in or on front of central or main panel or console
Visible on front of panel or on video display
Normally operator accessible at panel front or console
9.1.2 Dashed Line Dashed line tells us that the instrument is in an auxiliary location in a central control
room (not accessible to the operator).
•
Located in rear of central or main panel
•
Located in cabinet behind panel
•
Not visible on front of panel or on video display
•
Not normally operator accessible at panel or console
9.1.3 Double Solid Line
Double Solid Line means that it is in a local control room or on a local control panel
•
Located in or on front of secondary or local panel or console
•
Visible on front of panel or on video display
•
Normally operator accessible at panel front or console
9.1.4 Double Dashed
Double Dashed line means it’s in an auxiliary location in a local control room or local control panel.
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•
Located in rear of secondary or local panel
•
Located in field cabinet
•
Not visible on front of panel or on video display
•
Not normally operator accessible at panel or console
The following Diagram illustrates the line types and their meanings. These line types are commonly used in
the oil and gas plants to depict various features.
9.2 CONTROL VALVES:
Engineers use control valve symbols to identify the type of control valve they want to specify for a given
application
A valve is a mechanical device that controls the flow of fluid and pressure within a system or process. Basic
Parts of Control Valves are Actuator and Body.
The valve design equation relates the pressure drop ΔPv Δ P v across the valve to the volumetric flow rate q .
The Cv is a measure of the size of a valve and valve suppliers have different valve body sizes, each with a
different Cv value. The valve position or lift l is adjusted to regulate flow through the valve.
WORKING PRINCIPLE:
The working principle of control valve is opening or closing internal passages in order to regulate the flow of
a liquid or gas. Control valves are part of a control loop that controls a process. Control valves adjust internal
openings in response to instructions from the controller.
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FUNCTION: The control valve is used to control different parameters of fluid, by which the required specific
task is completed in a proper way as desired. The other functions mentioned in the options are the functions
of the Direction control valve. Sequence valve and hydraulic fuse respectively.
A control valve is a power-operated used to regulate or manipulate the flow of fluids, such as gas, oil, water,
and steam. It is a critical part of a control loop and is an example of a final control element. The Control Valve
is by far the most common final control element used in industry today in mechanical engineering, device
for controlling the flow of fluids (liquids, gases, slurries) in a pipe or other enclosure. Control is by means of
a movable element that opens, shuts, or partially obstructs an opening in a passageway.
9.3 ACTUATORS:
An actuator is a component of a machine that is responsible for moving and controlling a mechanism or
system, for example by opening a valve. In simple terms, it is a "mover". An actuator requires a control device
and a source of energy.
WORKING PRINCIPLE:
Actuators generate operating energy through the efficient use of compressed air. The instrument air builds up
force or pressure which applies against the diaphragm or piston. This then moves the valve actuator to position
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on the valve stem and the result is mechanical motion. An actuator is a device that converts energy, which
may be electric, hydraulic, pneumatic, etc.
The hydraulic actuator operates on the principle of Pascal's Law by the use of which the applied pressure is
converted into extremely large force.
FUNCTION:
Actuators work behind the scenes in vehicles to convert energy into a physical action or force. They perform
a variety of performance and convenience functions, from controlling the throttle to directing airflow in the
climate control system, and operating power seats and liftgates.
ADVANTAGES:
•
Very accurate control and positioning.
•
Able to stop at any point of the stroke.
•
Easy to set acceleration and deceleration.
•
No external sensors.
•
Low operating costs.
•
Help adapt machines to flexible processes.
•
Superior performance at high speeds.
•
Minimal maintenance.
TYPES:
Linear Actuators. Implied by their name, linear actuators are devices that produce movement within a straight
path. ...
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•
Rotary Actuators. ...
•
Hydraulic Actuators. ...
•
Pneumatic Actuators. ...
•
Electric Actuators. ...
•
Thermal and Magnetic Actuators. ...
•
Mechanical Actuators. ...
•
Supercoiled Polymer Actuators.
EXAMPLE:
Common examples of actuators include electric motors, stepper motors, jackscrews, electric muscular
stimulators in robots, etc.
IMPORTANCE:
In the oil, gas and petrochemical industry, precision control of the flow of product through valves in the system
is vital, and modulation of that flow depends on the valve actuator. These critical pieces of equipment must
perform reliably and safely under the most extreme conditions: very high and low temperatures, drought or
high-rainfall environments, remote situations in deserts or the arctic, and the corrosive effects of chemicals,
high humidity or salinity for extended periods. In potentially explosive atmospheres, explosion protection is
required; and in some applications, fireproof operation is critical.
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9.4 Pipes
Piping symbols have various important uses you’ll want to be familiar with. For example, one important
symbol to note here would be the concentric and eccentric reducers. This will help you identify when piping
changes sizes. You’ll see these sometimes immediately upstream or downstream of a control device. This
information is helpful for understanding flow capacity and sizing.
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Health Hazards
Because of their inherent hazards, especially from explosion, fire, and chemicals, oil refineries are tightly
regulated places in which to work. Work permits must always be obtained and followed. Plant practices,
warnings, and emergency procedures must be observed at all times. When in doubt, remember to exercise
your “right to know” under WHMIS legislation. Check labels and MSDSs. Any required protective equipment
and procedures must be explained and available when hazardous exposure is possible.
Health and Safety Hazards
The plant and equipment of refineries are generally modern, and the processes are largely automatic and totally
enclosed. Routine operations of the refining processes generally present a low risk of exposure when adequate
maintenance is carried out and proper industry standards for design, construction, and operation have been
followed. The potential for hazardous exposures always exists, however. Because of the wide variety of
hydrocarbon hazards and their complexity, it is impossible to identify all of the hazards here – and impossible
for construction crews to know everything they may need for protection when performing maintenance, repair,
or installation work in an oil refinery
Hazardous Chemicals
In a refinery, hazardous chemicals can come from many sources and in many forms. In crude oil, there are not
only the components sought for processing, but impurities such as sulphur, vanadium, and arsenic compounds.
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The oil is split into many component streams that are further altered and refined to produce the final product
range. Most, if not all, of these component stream chemicals are inherently hazardous to humans, as are the
other chemicals added during processing. Hazards include fire, explosion, toxicity, corrosiveness, and
asphyxiation. Information on hazardous materials manufactured or stored in a refinery should be supplied by
the client's representative when a work permit is issued.
Fire and Explosion
The principal hazards at refineries are fire and explosion. Refineries process a multitude of products with low
flash points. Although systems and operating practices are designed to prevent such catastrophes, they can
occur. Constant monitoring is therefore required. Safeguards include warning systems, emergency procedures,
and permit systems for any kind of hot or other potentially dangerous work. These requirements must be
understood and followed by all workers. The use of matches, lighters, cigarettes, and other smoking material
is generally banned in the plant except in specially designated areas.
Health and Hygiene Hazards
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10.1 Safe Work Practices and Procedures
Personnel
• Hearing protection and safety glasses must be worn in all operating areas or as posted.
• Respiratory protection or equipment must be fittested. Facial hair is unacceptable where the mask must make
an airtight seal against the face.
• Shirts must be long-sleeved and worn with full-length pants or coveralls.
• Clothing must not be of a flammable type such as nylon, Dacron, acrylic, or blends. Fire-resistant types
include cotton, Nomex, and Proban.
• Other PPE required may include acid hood, impervious outerwear, rubber boots, face shields,
rubber gloves, disposable coveralls, mono-goggles, and fall-arrest equipment.
• Smoking is allowed only in designated areas.
The types of safe work permits required typically include the following. Specific categories may vary
from site to site.
• Hot work – covers any work that involves heat or an ignition source, including welding, grinding, and the
use of any kind of motor. In high-risk areas, a spark watch may be required.
• X-ray and radiation
• Benzene – required when a benzene exposure hazard exists.
• Confined space entry hot work – involving potential ignition hazards.
• Confined space entry cold work – involving work that will not produce a spark.
• Hoisting – permit.
• Electrical – for other than routine work.
• Camera – typically requires a hot work permit when lighting is required.
• Asbestos – required whenever an asbestos exposure hazard exists.
• Hydrant – permits the use of plant fire hydrants.
10.2 PPE
Personal Protective Equipment
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Oil and gas products and chemicals can be irritating, corrosive, flammable and worse. To help prevent workers
from coming into contact with these hazards, employers will provide them with personal protective equipment
(PPE). On oil and gas sites, required PPE usually includes eye protection, hearing protection, hand and foot
protection, and flame-resistant clothing (FRC). Many workers are also required to wear portable monitors that
detect hydrogen sulfide (H2S) or other gases.
Hazards Unique to the Oil and Gas Industry
Oil and gas wells can expose workers to hydrogen sulfide gas. If your workplace uses sand for any process,
such as hydraulic fracturing, workers may be exposed to crystalline silica. Crystalline silica is a known lung
carcinogen, and can cause silicosis, which can be debilitating and even fatal. Oil-and-gas-related flash fires
can reach up to 1900 degrees Fahrenheit and can last up to five seconds. These fires most commonly occur in
well drilling, servicing, and production-related operations. Fortunately, there are many different types of
personal protective equipment (PPE) to protect against these hazards.
Head, Face and Eye PPE
Safety glasses with side shields are effective at protecting against flying objects. Impermeable goggles can be
worn while working around liquid, gas or vapor hazards. Face shields can protect the entire face from both
flying objects and chemicals. Welders use special filtered helmets to protect their eyes from radiant light,
sparks, flying particles and glare. If there’s a danger of falling objects, overhead electrical hazards or fixed
objects that workers could bump into, they’ll need to wear head protection. All classes of hard hats provide
impact and penetration protection. Class G hard hats also provide protection against up to 2,200 volts of
electricity. Class E hard hats protect against up to 20,000 volts. Class C hard hats provide no electrical
protection, so they aren ’t usually worn on oil and gas sites.
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