Laporan PKL

LAPORAN PRAKTEK KERJA LAPANGAN
SOUTH PROCESSING UNIT

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1 BAB 1 PENDAHULUAN
1.1 LATAR BELAKANG
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 :
1. Tujuan kegiatan Praktek Kerja Industri
a. Meningkatkan terus kemampuan dan keterampilan siswa, memperluas
dan memantapkan keterampilan mahasiswa sebagai bekal kerja yang
sesuai dengan program Teknik elektro.
b. Menumbuh kembangkan dan memantapkan sikap profesionalisme
mahasiswa dalam rangka memasuki lapangan kerja sebagai analis kimia.

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c. Meningkatkan wawasan mahasiswa pada aspek-aspek yang potensial
pada dunia kerja, antara lain: struktur organisasi, disiplin lingkungan
dalam sistem kerja.
d. Meningkatkan pengetahuan mahasiswa dalam hal penggunaan
instrument kimia analisis yang lebih moderen, dibandingkan fasilitas
yang ada disekolah, terutama dalam kesempatan praktek yang diberikan
oleh lembaga penelitian dan perusahaan industri.
e. Meningkatkan, memperluas dan memantapkan kemampuan siswa dalam
mengaplikasikan teknologi baru dalam lapangan kerja.
f. Memperoleh masukan dan umpan balik guna memperbaiki dan
mengembangkan pendidikan di Politeknik Negeri Samarinda
2. Tujuan penulisan Laporan Praktek Kerja Industri
a. Melatih siswa untuk membuat karya tulis yang didasarkan atas fakta dan
hasil kerja.
b. Siswa mampu mencari alternatif lain dalam pemecahan masalah di
bidang analisis kimia secara rinci dan lebih mendalam.
c. Menambah koleksi pustaka di perpustakaan sekolah, sehingga dapat
meningkatkan pengetahuan bagi dirinya dan peminat lain.
1.3 Scope of Discussion

Safety Devices may be installed at any related installation, such as:
safety devices in a separator, in a boiler, in pipeline and in the well. But on
this paper will focus to describe about safety devices in separator
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especially Pressure Relieving Devices (PRD) in separator such as PSV and

Rupture Disk.
1.4 Outline of Paper

Chapter 1 Introduction
It contains about background, Objective, Scope of Discussion and Outline

of the paper.
Chapter 2 Basic Theory
It contains about description separator, classification, principle of

separator, internal parts of the separator, And Instrumentation System in separator.
Chapter 3 Safety Devices
It contains about description about safety devices in separator, Detail about

Pressure safety valve like Description, Basic Principle, Classification, and
Installation. The Second Device Rupture Disc will describe about Description,
Principle, Classification and Installation
Chapter 4 Conclusion
It is about summary conclusion about my paper

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2 Chapter 2 Basic theory
2.1 Separator
2.1.1 Description
2.1.2 Principle of Separator

Well stream fluids, sometimes called emulsions, may include gas, liquid (oil and
water). The proportion of each component varies between wells. Gravity normally
separates gases from liquids by causing heavy components to settle to the bottom
the lighter components to the top. Consider a simple separation example using gas,
oil and water, the three common fluids produced by oil and gas wells.
Figure 2.1 Basic Principle Of Separator
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
2.1.3 Types of Separator
2.1.3.1 Classification by Configuration

Oil and gas separators can have three general types there are:
1. Vertical separator
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Separator vertical is cylindrical-shaped vessel length that is placed upright and

mounted on a strong foundation. Separator vertical is very advantageous when used
for fluid due to muddy or sandy bottom of a curved shape so as to facilitate spending
mud or sand from the vessel. In addition to the above separator is also good for the
process fluid that has a gas-liquid ratio is small. Suction power and have a good
separator liquid level setting that is not critical.
2. Horizontal separator
Horizontal separator is more economical to process fluids that have a gas-liquid
ratio is high and for the production fluid containing large amounts of sand.
3. Spherical separator
Separator Spherical is relatively low-cost and compact, but with a limited liquid
retention time and decantation section. Use in three-phase separation is, therefore,
very difficult if not impossible. Their advantage is their compact size but they offer
small capacities. They are very easy to handle. Another interesting point of
importance is that owing to their spherical shape, they can support all pressure
ranges.
2.1.3.2 Classification by Function

The two configurations of separators are available for two-phase and three-
phase operation.
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1. Two phase Separator
Figure 2.2 Two Phase Separator

In the two-phase separator units, gas is separated from the liquid with the gas and
liquid being discharged separately.
2. Three phase separator.
In three-phase separators units, well fluid is separated into gas, oil, and water with
the three fluids being discharged separately.
Figure 2.3 Three Phase Separator

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2.1.3.3 Classification by Application

Oil and gas separators may be classified according to application as a test
separator and production separator.
1. Test Separator
A test separator is used to separate and to measure the well fluids. The test separator
can be referred to as a well tester or well checker. Test separators can be vertical,
horizontal, or spherical. They can be two- phase or three-phase.
2. Production Separator
A production separator is used to separate the produced well fluid from a well,
group of wells, or a lease on a daily or continuous basis.
2.1.4 Internal Part of Separator

The most common internal parts used for improving the efficiency of a separator
are:
1. The Deflector (Deflector or diverter plate): When the fluid hits the plate, the
velocity slows and the liquid droplets fall to the bottom of the separator. The
gas continues its path around the plate.
Figure 2.4 Inlet deflector Figure 2.5 Demister

2. The Coalescer (Demister pad/Coalescing pack): Used so that tiny droplets
combine with larger droplets. A device equipped with filler, -multiple
baffles, wire mesh, various fibers so as the liquid particles can be gathered
into droplets and be separated from gas or vapor as well as from non-
miscible liquids.
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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.
Figure 2.6 Perforated weir plate

1. The Vortex breaker or anti-Vortex: Installed to prevent the formation of
whirlpools in the liquid, which would entrain (or carry over) the gas with
the liquid being evacuated from the separator.
Figure 2.7 Vortex breaker Figure 2.8 Straightening Vanes

2. The Straightening vanes: used for eliminating turbulence in the gas current
after the initial separation of the inlet deflector.
3. Float Shield: Internal float is

used to control the liquid level.
4. F
Figure 2.9 Float Shield
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2.2 Instrumentation Devices in Separator
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).
2.2.2 Sensing Element

This name refers to the device that measures the value
of a controlled variable. Sensing elements are used to
convert a measurement, such as pressure, temperature,
or flow, into a movement or signal that can be used for
transmission to a controller, recorder, or indicator.
They are also called detectors or sensors. There are
several sensing elements used in the separator:
Figure 2.10 Sight Glass
Displacer or Sight glass(sensing element for level )

Bourdon Tube at Pressure Gauges ( sensing element for pressure)
Thermocouple ( sensing element for temperature )
2.2.3 Transmitter
The separators also have pressure
transmitters. They ensure the correct
working of the pressure control valve
and its regulator.
D/P Transmitter for pressure.

Level Transmitter
D/P Transmitter for flow
Figure 2.11 Pressure

Transmitter
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2.2.4 Control Devices
Figure 2.12 Displacer and Level Transmitter
Of course, to maintain stable oil separator is required in the processing tool

that can control some elements that should always be maintained as pressure and
level. At the level of fluid in the separator vessel to determine the ability to perform
tasks designed. Fluid - level control valve (exhaust valve) is operated by fluid -
level controller.
The liquid level control valves (discharge valves) are actuated (Operated) by
liquid level controllers.Same as gas pressure must also be controlled. Pressure in a
process must also be stabilized.
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Figure 2.13 Automatic Regulation Valve
Pressure is controlled by pressure regulators installed at the gas outlet. They

maintain the separator pressure by acting on the pressure control valve
2.2.5 Pressure Relieving Devices

Pressure-relieving devices protect equipment and personnel by automatically
opening at predetermined pressures and preventing the adverse consequences of
excessive pressures in process systems and storage vessels.
In Separator there are 2 type of relieving devices that equipped in separator:
PSV ( Pressure Safety Valve )

Pressure Safety Valve (PSV): The safety valves
which evacuate the potential energy surplus from the
system. This system must be protected to limit the
maximum pressure in the equipment. So the valves
protect the device with an admissible pressure.
Figure 2.14 Pressure Safety Valves
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Pressure safety valve is a safety device which operates in particular situations.

Its normal position is the closed position. This valve is designed to evacuate, in
general, a gaseous flow since, at equal volume; more energy (pneumatic) is
evacuated in the gas phase than in the liquid phase. Two valves are usually installed
so that when one is in use, the other can use for back-up and for maintenance.
Figure 2.15 PSV in Separator
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.
Figure 2.16 Rupture Disk

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2.2.6 Emergency Shutdown System

ESD (Emergency Shutdown System) is a safety system that aims to avoid or prevent
the loss of both personal, equipment, and the environment from any damages caused
by a fatal condition due to uncontrolled or non-functioning of the tools in a process.
Figure 2.17 Shutdown Systems in Separator
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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Figure 2.18 Pressure Switch

Alarm
Alarm at a plant serves to give notice of the interruption that occurs so as to
prevent the occurrence of abnormal conditions (unsafe), or minimizing the
consequences of those events.
3-Way Solenoid Valve
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 Safety Devices in Separator
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.
3.2 Term and Definition

Accumulation
The pressure increase over the MAWP of the vessel allowed during
discharge through the pressure-relief device, expressed in pressure
units or as a percentage of MAWP or design pressure. Maximum
allowable accumulations are established by applicable codes for
emergency, operating, and fire contingencies.
Design pressure
The design pressure of the vessel along with the design temperature is
used to determine the minimum permissible thickness or physical
characteristic of each vessel component, as determined by the vessel
design rules.
Maximum allowable working pressure (MAWP)
The maximum gauge pressure permissible at the top of a completed
vessel in its normal operating position at the designated coincident
temperature specified for that pressure. The pressure is the least of the
values for the internal or external pressure as determined by the vessel
design rules for each element of the vessel using actual nominal
thickness, exclusive of additional metal thickness allowed for corrosion
and loadings other than pressure. The MAWP is the basis for the
pressure setting of the pressure-relief devices that protect the vessel. The
MAWP is normally greater than the design pressure but can be equal to
the design pressure when the design rules are used only to calculate the
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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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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.
Maximum operating pressure
The maximum pressure expected during normal system operation.
Overpressure
The pressure increase over the set pressure of a pressure relief of a
relieving device allowed achieving rated flow. Overpressure is
expressed in pressure units or as a percentage of set pressure. It is the
same as accumulation only when the relieving device is set to open at
the MAWP of the vessel.
Pressure relief valve
A spring-loaded pressure relief valve which is designed to open to
relieve excess pressure and to reclose and prevent the further flow of
fluid after normal conditions have been restored.
Safety valve
A pressure relief valve actuated by inlet static pressure and
characterized by rapid opening or pop action.
Relief valve
A pressure relief device actuated by inlet static pressure having a
gradual lift generally proportional to the increase in pressure over
opening pressure.
Safety relief valve
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A pressure relief valve characterized by rapid opening or pop action,

or by opening in proportion to the increase in pressure over the
opening pressure, depending on the application, and which may be
used either for liquid or compressible fluid.
3.3 Type of Safety Devices in Separator
Figure 3.1 Safety Devices in Separator
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 Pressure Safety valve
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
3.3.1.2 Design and Component of Pressure Safety Valve

Design
The main purpose of designing a pressure relief valve is to prevent pressure 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.
The following design features should be considered when designing a pressure

relief valve:
Leakage at system operating pressure is within acceptable standards of
performance.
Opens at specified set pressure, within tolerance.
Relieves the process products in a controlled manner.
Closes at specified reseat pressure.
Easy to maintain, adjust, and verify settings.
Cost effective maintenance with minimal downtime and spare parts

investment.
Parts of the pressure relief valves are designed in accordance with the code
requirements of the American Society of Mechanical Engineers (AMSE) and
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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.
Figure 3.3 Design of Pressure Safety Valve

Major Components
Adjusting ring: A ring assembled to the nozzle or guide of a direct spring

valve, used to control the opening characteristics and/or the reseat pressure.
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).
Bonnet: A component of a direct spring valve or of a pilot in a pilot- operated

valve that supports the spring. It may or may not be pressure containing.
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.
Disk: A moveable component of a pressure relief device that contains the

primary pressure when it rests against the nozzle.
Disk holder: A moveable component in a pressure relief device that contains

the disk.
Guide: A component in a direct spring or pilot operated pressure relief device

used to control the lateral movement of the disk or disk holder.
Huddling chamber: The annular pressure chamber located beyond the valve
seat for the purpose of generating a popping characteristic.
Lifting device (lever): A device to open a pressure relief valve manually, by

the application of external force to lessen the spring loading which holds the valve
closed. Lifting devices can be open levers or packed levers (fully enclosed
design).
Nozzle: The pressure-containing element which constitutes the inlet flow

passage and includes the fixed portion of the seat closure. Nozzles can be divided
into two types:
- 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 determine the
capacity of a pressure relief valve.
Pilot: The pressure or vacuum sensing component of a pilot operated pressure

relief valve that controls the opening and closing of the main relieving 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:
(a) Assist in alignment
(b) Guide disk travel, and
(c) Transfer of internal or external forces to the seats
Trim: Internal parts, especially the seat (nozzle) and disk.
3.3.1.3 Basic Principle of Safety Valve
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.
Figure 3.5 Operation of a conventional safety valve
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.
3.3.1.3.3 Classification of Safety Valves

Many types of safety valves are used in modern applications. These safety valves
are classified based on:
Actuation
Lift
Seat design
Lever
Bonnet
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Classification based on Actuation
Dead-weight safety valves

Although dead-weight safety valves have in general been superseded by
spring-loaded safety valves, the dead weight variety (Fig. 3.3) is still sometimes used
for low-pressure applications. The closing force of this safety valve is provided by a
weight rather than a spring. As the closing force is provided by a weight, it remains
constant and once the set pressure is reached, the safety valve opens fully.
Figure 3.7 Dead-weight safety valves (Courtesy Seetru Limited, U.K.)

Pop action safety valves
The pop-action safety valve is the standard or conventional safety valve. It
is actuated by inlet static pressure and characterized by rapid opening or pop action.
This type of safety valve is a simple, basic spring loaded, and self-acting device
that provides overpressure protection (Fig. 3.4).
The basic elements of the design consist of a right-angle-pattern valve body with the
valve inlet connection, or nozzle, mounted on the pressure- containing system. The
outlet connection may be screwed or flanged for connection to a pipe discharge
system.
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Figure 3.8 Pop action safety valves (Courtesy Conbraco

Industries, Inc.)
In some applications, such as com- pressed air systems, the

safety valve does not have an outlet connection and the air
is vented directly to the atmosphere.
The valve is held against the nozzle seat by the spring,
which is housed in an open or closed spring housing
arrangement (bonnet) mounted on the top of the body. The
disks
Classication based on lift
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.
Figure 3.9 Safety valve seats.

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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.
Figure 3.10 Lever types (Courtesy Spirax Sarco, U.K.)
Classication based on bonnet design
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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It is necessary to use a closed bonnet if fluid is not permitted to discharge to the

atmosphere. The closed-bonnet safety valve is used for small screwed safety valves.
It is becoming increasingly common to use closed-bonnet safety valves, particularly
for steam, discharge of which can be hazardous to personnel. A closed bonnet is
shown in Fig. 3.7b.
Figure 3.11 Types of bonnets (Courtesy Spirax Sarco, U.K.)
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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straight and as short as possible

The safety valve should be mounted as close as possible to vessel being
protected
Foreign matter or liquid may accumulated in long horizontal inlet piping,
this may affect flow
The inlet line to the valve should have an effective area of flow at least
equal to that of the valve bore (DN)
Figure 3.15 Installation PSV caused by factor pressure drop

Where multiple valves discharge into a manifold, the capacity of the manifold
must be capable of simultaneously accommodating the capacity of all valves
connected
Separate manifolds must be used for Safety Valves set at different pressures.
Figure 3.16
Installation
PSV
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3.3.2 Rupture Disk
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 Design and Components
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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Figure 3.18 Design of Rupture Disk
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
3.3.2.2.2 Major Component

o Rupture disk: A pressure-containing, pressure- and temperature- sensitive
element of a rupture disk device.
o Disk holder: The structure which encloses and clamps the rupture disk in
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position. Some disks are designed to be installed between standard flanges without
holders.
o Gasket: Used with graphite disks for sealing.
3.3.2.3 Types of Rupture Disk
3.3.2.3.1 Conventional Rupture Disk

A conventional domed rupture disk is a prejudged solid
metal disk designed to burst when it is overpressure on the concave
side (see Figure 3.16 ).
The conventional domed rupture disk of flat-seat or angular-
seat design generally provides a satisfactory service life when
operating conditions are 70 % or less of the rated burst pressure of
the disk and when limited pressure cycling and temperature
variations are present. If vacuum or backpressure conditions are
present, the disk must be furnished with a vacuum support to prevent
reverse flexing or implosion. Vacuum supports are designed for
continuous service at full vacuum or less.
Figure 3.20 Conventional Rupture Disk
3.3.2.3.2 Reverse Acting Rupture Disk

A reverse-acting rupture disk (Fig. 4.9) is a domed solid metal disk designed
to burst when it is overpressure on the convex side. As the burst pressure rating
is reached, the compression loading on the rupture disk causes it to reverse,
snapping through the neutral position and causing it to open by a predetermined
scoring pattern or knife-blade penetration. Reverse-acting rupture disks are
designed to open by various methods, such as shears, knife blades, knife rings, or
scored lines.
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Figure 3.21 Reverse-acting rupture disks

3.3.2.3.1 Graphite Rupture Disk
A graphite rupture disk (Fig. 3.18) is manufactured from graphite

impregnated with a binder material and is designed to burst by bending or
shearing. Graphite rupture disks are resistant to most acids, alkalis, and organic
solvents.
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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The rupture disk may be used for primary relief

(Fig. 3.19). In such a case, the rupture disk is
the only device utilized for pressure relief. The
advantages of using rupture disks as primary
devices are that they are leaktight and have
instantaneous response time, minimum
pressure drop, low cost, high reliability, and
minimum maintenance.
Figure 3.22 primary relief applications
o Secondary relief
A rupture disk may be used as a secondary
device (Fig. 4.4) providing backup vent to
a primary relief device. The purpose of this
secondary device is to provide additional
protection for an event that would exceed
the capacity of the primary relief device.
Figure 3.25 secondary relief applications
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.

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LAPORAN PRAKTEK KERJA LAPANGAN

SOUTH PROCESSING UNIT

1.1 LATAR BELAKANG

1. Tujuan kegiatan Praktek Kerja Industri

a. Meningkatkan terus kemampuan dan keterampilan siswa, memperluas

dan memantapkan keterampilan mahasiswa sebagai bekal kerja yang

sesuai dengan program Teknik elektro.

b. Menumbuh kembangkan dan memantapkan sikap profesionalisme

mahasiswa dalam rangka memasuki lapangan kerja sebagai analis kimia.

c. Meningkatkan wawasan mahasiswa pada aspek-aspek yang potensial

pada dunia kerja, antara lain: struktur organisasi, disiplin lingkungan

dalam sistem kerja.

d. Meningkatkan pengetahuan mahasiswa dalam hal penggunaan

instrument kimia analisis yang lebih moderen, dibandingkan fasilitas

yang ada disekolah, terutama dalam kesempatan praktek yang diberikan

oleh lembaga penelitian dan perusahaan industri.

e. Meningkatkan, memperluas dan memantapkan kemampuan siswa dalam

mengaplikasikan teknologi baru dalam lapangan kerja.

f. Memperoleh masukan dan umpan balik guna memperbaiki dan

mengembangkan pendidikan di Politeknik Negeri Samarinda

2. Tujuan penulisan Laporan Praktek Kerja Industri

b. Siswa mampu mencari alternatif lain dalam pemecahan masalah di

bidang analisis kimia secara rinci dan lebih mendalam.

c. Menambah koleksi pustaka di perpustakaan sekolah, sehingga dapat

meningkatkan pengetahuan bagi dirinya dan peminat lain.

1.3 Scope of Discussion

especially Pressure Relieving Devices (PRD) in separator such as PSV and

1.4 Outline of Paper

It contains about background, Objective, Scope of Discussion and Outline

Chapter 2 Basic Theory

It contains about description separator, classification, principle of

Chapter 3 Safety Devices

It contains about description about safety devices in separator, Detail about

It is about summary conclusion about my paper

2 Chapter 2 Basic theory

2.1.2 Principle of Separator

Figure 2.1 Basic Principle Of Separator

2.1.3 Types of Separator

2.1.3.1 Classification by Configuration

Separator vertical is cylindrical-shaped vessel length that is placed upright and

2.1.3.2 Classification by Function

1. Two phase Separator

Figure 2.2 Two Phase Separator

Figure 2.3 Three Phase Separator

2.1.3.3 Classification by Application

2.1.4 Internal Part of Separator

Figure 2.4 Inlet deflector Figure 2.5 Demister

Figure 2.6 Perforated weir plate

Figure 2.7 Vortex breaker Figure 2.8 Straightening Vanes

3. Float Shield: Internal float is

2.2 Instrumentation Devices in Separator

2.2.2 Sensing Element

Displacer or Sight glass(sensing element for level )

D/P Transmitter for pressure.

Figure 2.11 Pressure

2.2.4 Control Devices

Figure 2.12 Displacer and Level Transmitter

Of course, to maintain stable oil separator is required in the processing tool

Figure 2.13 Automatic Regulation Valve

Pressure is controlled by pressure regulators installed at the gas outlet. They

2.2.5 Pressure Relieving Devices

In Separator there are 2 type of relieving devices that equipped in separator:

PSV ( Pressure Safety Valve )