1 BAB 1 PENDAHULUAN
Sepanjang hidup kita selalu ingin merasa aman karena dengan aman kita bisa
melakukan sesuatu yang lebih nyaman. Pertumbuhan proses industri yang sangat pesat
tentunya juga dapat meningkatkan kecelakaan dalam pekerjaan juga akan meningkat. Ada
banyak jenis alat pengaman untuk personil maupun perangkat pengaman untuk peralatan
itu sendiri. Perangkat keamanan akan menjaga peralatan saat terjadi kegagalan sistem.
Pada industri perminyakan tentunya separator adalah peralatan yang tidak akan
bisa dipisahkan. Secara umum minyak dan air adalah fluida cair yang tidak dapat disatukan atau
dicampurkan. Pemisah memiliki kontribusi besar dalam proses produksi minyak dan gas
bumi. Ini memisahkan cairan dan gas (2 Phase separator) atau minyak, gas dan air (3 Phase
separator). Untuk alasan ini, pemisah penting untuk menjaga pekerjaan pemisah dalam
kondisi aman. Sistem kontrol dan sistem shutdown adalah cara untuk mewujudkannya. Dan
di alat pengaman perusahaan minyak dan gas sangat dibutuhkan karena bisa menjaga
proses berjalan lancar saat terjadi masalah. Pemisahan minyak dan air diatur dengan
menggunakan PLC (Programmable Logic Controller).
1.2 Tujuan
Adapun tujuan dari Praktek Kerja Industri dapat dibagi menjadi 2 (dua) yaitu :
a. Melatih siswa untuk membuat karya tulis yang didasarkan atas fakta dan
hasil kerja.
Chapter 4 Conclusion
2.1 Separator
2.1.1 Description
When these fluids are mixed and placed in a closed glass jar, the oil being lighter
than water floats to the top of the water. The gas is being lighter than oil, rises above
the oil into the empty space. This separation is achieved by the difference in gravity
or weight of each fluid.
The separation process is affected by the temperature, pressure and density of the
fluid components
3. The Weir or Weir plate: Used for increasing the liquid residence (also called
retention) time as, depending on where it is located, it increases the volume
offered to the liquid.
2.2.1 Overview
In Separator, There are many instrumentation systems such as Sensing Elements,
Transmitters, Control Devices, Safety Devices and
Emergency Shutdown System (ESD).
2.2.3 Transmitter
The separators also have pressure
transmitters. They ensure the correct
working of the pressure control valve
and its regulator.
Rupture Disk
A rupture disk device is a one of
kind non-reclosing pressure-relief device
actuated by the static differential pressure
between the inlet and outlet of the device
and designed to function by the bursting
of a rupture disk. In the next part I will
explain about PSV and rupture disk.
In the ESD system, there are several interconnected instrumentation tools, among
others:
Switch
Pressure
PSHH: Pressure Switch High High
PSLL: Pressure Switch Low - Low
Level
LSHH: Level Switch High High
LSLL: Level Switch Low Low
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ESD within the SDV system is the main component that moves as the final
element. SDV energized usually have characteristic which means if he does not get
power then the SDV will be active and perform shutdown action.
Figure 2.19
Shutdown
Valve
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3.1 Overview
Separator is a very important tool for the processing of oil. It is a tool that
always works and has many potential hazards. So there is need for the equipment
that can maintain security and stability of the separator. Therefore Safety devices
installed in order to maintain the safety of equipment and personnel.
minimum thickness for each element and calculations are not made to
determine the value of the MAWP.
Backpressure
The pressure that exists at the outlet of a pressure relief device,as a
result of the pressure. in the discharge system. It is the sum of the
superimposed and built-up backpressures.
Blowdown
The difference between the set pressure and the closing pressure
of a pressure-relief valve, expressed as a percentage of the set
pressure or in pressure units.
Built-up backpressure
The increase in pressure at the outlet of a pressure-relief device that
develops as a result of flow after the pressure- relief device opens.
Burst pressure
The burst pressure of a rupture disk at the specified temperature is the
value of the upstream static pressure minus the value of the
downstream static pressure just prior to when the disk bursts. When
the downstream pressure is atmospheric, the burst pressure is the
upstream static gauge pressure.
Burst-pressure tolerance
The variation around the marked burst pressure at the specified disk
temperature in which a rupture disk will burst.
Closing pressure
The value of decreasing inlet static pressure at which the valve disc
reestablishes contact with the seat or at which lift becomes zero, as
determined by seeing, feeling or hearing.
Built-up backpressure
The increase in pressure at the outlet of a pressure-relief device that
develops as a result of flow after the pressure- relief device opens.
Burst pressure
The burst pressure of a rupture disk at the specified temperature is the
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As already explained in previous chapters in this chapter I will only explain about
safety device in the form of PSV devices and rupture disk can be found above the
separator device safety devices is located at the top because this device is only
useful for relieving devices eliminate the overpressure in the separator.
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3.3.1.1 Description
Safety Valve - A valve which automatically, without the
assistance of any energy other than that of the fluid
concerned, discharges a certified amount of the fluid so
as to prevent a predetermined safe pressure being
exceeded, and which is designed to re-close and prevent
the further flow of fluid after normal pressure conditions
of service have been restored.
Figure 3.2 PSV design
The main purpose of designing a pressure relief valve is to prevent pres- sure in
the system being protected from increasing beyond safe design limits. The other
purpose of a pressure relief valve is to minimize damage to other system
components due to operation of the PRV itself.
American Petroleum Institute (API). A designer should conform that all the parts
meet the code requirements so that complete pressure relief valves can be stamped
with code symbols.
Adjusting screw: A screw used to adjust the set pressure or the reseat pressure
of a reclosing pressure relief valve.
Balanced bellows: A bellows designed so that the effective area of the bellow
is equivalent to that of the valve seat, thereby canceling out the additive effect of
back pressure.
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Body: Part that containing member of a pressure relief device that supports the
parts of the valve assembly and has provision(s) for connecting to the primary
and/or secondary pressure source(s).
Cap: A component used to restrict access and/or protect the adjust- ment screw in
a reclosing pressure relief device. It may or may not be a pressure containing part.
Huddling chamber: The annular pressure chamber located beyond the valve
seat for the purpose of generating a popping characteristic.
- Full nozzle: A single member extending from the face of the inlet flange
to the valve seat.
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- Semi-nozzle: The lower part of the inlet throat is formed by the body
casting and the upper part is valve seat threaded or welded into the valve
body.
Orifice: A computed area of flow for use in flow formulas to deter- mine the
capacity of a pressure relief valve.
Piston: The moving element in the main relieving valve of a pilot operated
piston type pressure relief valve which contains the seat that forms the primary
pressure containment zone when in contact with the nozzle.
Seat: The pressure-sealing surfaces of the fixed and moving pressure containing
components.
Spring: The element in a pressure relief valve that provides the force to keep the
disk on the nozzle.
Stem: A part whose axial orientation is parallel to the travel of the disk. It may
be used in one or more of the following functions:
3.3.1.3.1 Lifting
When the inlet static pressure rises above the set pressure of the safety valve,
the disc will begin to lift off its seat. However, as soon as the spring starts to
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compress, the spring force will increase; this means that the pressure would have to
continue to rise before any further lift can occur, and for there to be any significant
flow through the valve.
The additional pressure rise required before the safety valve will discharge
at its rated capacity is called the overpressure. The allowable overpressure
depends on the standards being followed and the particular application. For
compressible fluids, this is normally between 3% and 10%, and for liquids
between 10% and 25%.
In order to achieve full opening from this small overpressure, the disc
arrangement has to be specially designed to provide rapid opening. This is
usually done by placing a shroud, skirt or hood around the disc. The volume
contained within this shroud is known as the control or huddling chamber.
Figure 3.4 typical disc and shroud arrangement used on rapid opening safety
valves.
As lift begins (Figure 3.4) and fluid enters the chamber, a larger area of the
shroud is exposed to the fluid pressure. Since the magnitude of the lifting force (F)
is proportional to the product of the pressure (P) and the area exposed to the fluid
(A); (F = P x A), the opening force is increased. This incremental increase in
opening force overcompensates for the increase in spring force, causing rapid
opening. At the same time, the shroud reverses the direction of the flow, which
provides a reaction force, further enhancing the lift.
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These combined effects allow the valve to achieve its designed lift within
a relatively small percentage overpressure. For compressible fluids, an additional
contributory factor is the rapid expansion as the fluid volume increases from a
higher to a lower pressure area. This plays a major role in ensuring that the valve
opens fully within the small overpressure limit. For liquids, this effect is more
proportional and subsequently, the overpressure is typically greater; 25% is
common.
3.3.1.3.2 Reseating
Once the safety valve has discharged fluid, it is required to close. Since
the larger area of the valve is still exposed to fluid, the valve will not close
until the pressure has dropped below its original set pressure. The difference
between the set pressure and this reseating pressure is known as the blowdown,
and it is usually expressed as a percentage of the set pressure. The blowdown is
usually less than 10% for compressible fluids.
The valve is designed in such a manner that it offers both rapid opening
and relatively small blowdown, so that as soon as a potentially hazardous
situation is reached, any overpressure is relieved, but excessive quantities of
fluid are prevented from being discharged. It is necessary to ensure that the
system pressure is reduced to prevent immediate reopening.
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Figure 3.6 Relationship between pressure and lift for a typical safety valve
The blowdown rings on the safety valves are used to make fine adjustments to
the overpressure and blowdown values. The upper adjusting ring is usually factory
set and if it is adjusted, this takes out the manufacturing tolerances which affect
geometry of the huddling chamber. The lower adjusting ring is also factory set but
can be adjusted under certain conditions. When the lower adjusting ring is adjusted
to its top position, the valve pops rapidly, minimizing the overpressure, and
requires a greater blowdown before the valve reseat. When the lower adjusting ring
is adjusted to its lower position, a greater overpressure is required before the valve
is fully open and the blowdown value is reduced.
Lift
Seat design
Lever
Bonnet
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Safety valves may be classified based on lift. The term lift refers to the amount
of travel the valve undergoes as it moves from its closed position to the position
required to produce the certified discharge capacity.
Safety valves may be classified as full lift, high lift, and low lift based on the amount
of lift, which affects the discharge capacity of the valve.
Full-lift safety valves
A full-lift safety valve is a safety valve in which the valve lifts sufficiently
so that the curtain area no longer influences the discharge area. This occurs when
the valve lifts a distance of at least a quarter of the bore diameter. That is, the
discharge area, and therefore the capacity of the valve, is determined by the bore
area.
Full-lift safety valves are considered the best choice for general steam applications.
High-lift safety valves
A high-lift safety valve is a safety valve in which the valve lifts a distance
of at least 1/12th of the bore diameter. This means that the curtain area, and
ultimately the position of the valve, determines the discharge area. The discharge
capacity of a high-lift valve is significantly lower than that of a full-lift valve. For a
given discharge capacity, a full-lift valve has smaller size than a corresponding
high-lift valve.
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High-lift safety valves are used on compressible fluids, where their action is more
proportional.
Low-lift safety valves
A low-lift safety valve is a safety valve in which the valve lifts a distance of
1/24th of the bore diameter. The discharge area is determined by the position of
the valve. Since the valve has a small lift, the capacity of a low-lift safety valve is
much lower than that of full- or high-lift valves
Classication based on seat design
Based on seat design, safety valves are classified as soft-seat safety valves
and metal-seat safety valves.
Soft-seat safety valves
Resilient disks can be fixed to either or both of the seating surfaces where
tighter shut-off are required, typically for gas or liquid applications (Fig. 3.5a).
These inserts are made from a number of different materials, but Viton, nitrile, or
EPDM are the most common. Soft seal inserts are not recommended for steam use.
Seating materials and their applications are shown in Table 3.1.
Metal-seat safety valves
Metal-to-metal seats, commonly made from stainless steel, are normally
used for high-temperature applications such as steam. Stellite is used for wear
resistance in tough applications. A view of metal seat design is shown in Fig. 3.5b.
Open-lever type
An open lever is the standard lever for most safety valves. It is typically used in
applications such as steam or air, where a small leakage of fluid to the atmosphere
is acceptable. A typical open lever is shown in Fig. 3.6a.
Packed-lever type
If fluid cannot be permitted to escape, a packed-lever safety valve is used. This type
uses a packed gland seal to ensure that the fluid is contained within the cap. A packed
lever is shown in Fig. 3.6b.
Process fluid enters the bonnet (spring housing) if bellows or diaphragm sealing is
not used. The amount of fluid depends on the particular design of the safety valve.
Based on the design of the bonnet, safety valves are classified as open-bonnet or
closed-bonnet type.
Open-bonnet type
An open bonnet is used if discharge of fluid to the atmosphere is permitted. This
has advantage when the safety valve is used in high-temperature fluid or boiler
applications, because high temperature can cool the spring. However, an open
bonnet exposes the spring and internals to environmental conditions that can lead
to corrosion of the spring. An open bonnet is shown in Fig. 3.7a.
Closed-bonnet type
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3.3.1.3.4 Application
A safety valve is normally used with compressible fluids. Safety valves are used on
steam boiler drums and super- heaters. They are also used for general air and steam
services in refinery and petrochemical plants. Safety valve discharge piping may
contain a vented drip pan elbow or a short piping stack routed to the atmosphere.
3.3.1.3.5 Limitations
Safety valves should not be used:
in corrosive services (unless isolated from the process by a
rupture disk),
In liquid service.
As pressure control or bypass valves.
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3.3.1.3.6 Installation
In a first step the initial installation make sure the installation in accordance
with the direction of the flow inlet.
Figure 3.12 Installation by accordance with the direction of the flow inlet
Safety Valves should normally be mounted vertically, unless otherwise
agreed by the manufacturer
Figure
3.13 The Incorrect installation inlet and outlet of PSV.
Under no circumstances should it be possible to isolate the pressure relief
valve from the protected system, also isolating valves must not be fitted to the
valve outlet.
Changeover valves can be placed on
the inlet or outlet of Safety Valves. They
allow for the valves to be removed for
maintenance without shutting down the
plant
Figure 3.14 Changeover Installation
In order to limit the pressure drop
The inlet connecting pipe should be as
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3.3.2.1 Description
A rupture disk device is a non-reclosing pressure-relief
device actuated by the static differential pressure between
the inlet and outlet of the device and designed to function by
the bursting of a rupture disk. A rupture disk device includes
a rupture disk and a rupture disk holder (see Figure 3.17).
Figure 3.17 Rupture Disk with Disk Holder
a) A rupture disk is a pressure containing, pressure and
temperature sensitive element of a rupture disk device.
Rupture disks may be designed in several configurations, such as flat, domed
(prebulged), or reverse-acting. The rupture disk holder secures the disk in place.
b) A no fragmenting rupture disk is a rupture disk designed and manufactured to
be installed upstream of other piping components, such as pressure-relief valves, and
will not impair the function of those components when the disk ruptures.
c) A rupture disk holder is the structure which encloses and
clamps the rupture disk in position.
Rupture disks normally require a rupture disk holder although some disk designs
can be installed between standard flanges without holders.
3.3.2.2.1 Design
A rupture disk assembly comprises mainly two parts:
A rupture disk, which is a thin metal diaphragm bulged to a spherical shape,
providing both a consistent burst pressure within a predictable tolerance and
an extended service life
A rupture disk holder, which is a flanged structure designed to hold the rupture
disk in position.
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The rupture disk is oriented in a system with the process fluid against the concave
side of the disk (Fig. 3.15). The disk may have a flat seat (Fig. 3.15a) or a 30 angle
seat (Fig. 3.15b). As the pressure of process fluid increases beyond the allowable
operating pressure, the rupture disk starts to grow. This growth will continue as the
pressure increases, until the tensile strength of the material is reached and rupture
occurs.
Figure 3.19 Process fluids against the concave side of the disk
position. Some disks are designed to be installed between standard flanges without
holders.
o Gasket: Used with graphite disks for sealing.
3.4 Installation
In the rupture disk installation of the functions performed by looking at rupture
disk itself. By Purpose Rupture disks may be used for the following purposes: (1)
primary relief, (2) secondary relief, and (3) in series with a relief valve.
o Primary Relief
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o Combination Relief
The rupture disk is installed upstream of the pressure relief valve
when it is used in series (Fig. 4.5). The disk protects the valve from
process fluid that can corrode or prevent relief valve operation. The
space between the rupture disk and the pressure relief valve should have
a pressure gauge; try cock, free vent, or telltale indicator. This
arrangement is provided to eliminate the possibility of, or facilitate the
detection of, a back-pressure build up.
The ASME Pressure Vessel Code permits the use of a rupture disk
device at both a pressure relief valve inlet and outlet. The combination of
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rupture disks and pressure relief valves is becoming more common in oil,
chemical, and petrochemical plants.
The following are advantages of rupture disks when used in
combination with pressure relief valves:
o Zero process leakage to the atmosphere.
o Allows pressure relief valves to be tested in
place.
o Life of valve is extended.
o Longer periods between major overhauls.
o Less expensive valve materials can be used.
Figure 3.26 Combination relief applications.