IPE-TM-500-06 — Critical Service Equipment Guide

1. Purpose

This procedure describes the criteria for selecting critical service rotating equipment and lists some critical equipment used in Inflection Point Engineering processes.

2. Critical Equipment

2.1 Definition

Critical equipment is defined as rotating equipment which must remain in operation in order to protect personnel, equipment or catalyst.

2.2 Function of Spare Equipment

Continuous operation makes it necessary to provide spare equipment that will run if a piece of normal operating equipment fails. The spare equipment enables the replacement of mechanical failures without shutting down a particular unit or process.

2.3 Type of Motive Power

There are two types of failure: mechanical and motive power. Depending on the reliability of the motive power, consider the type of motive power used for the normal operating and spare equipment accordingly. The normal operating and spare equipment may require two different types of motive power such as electric and steam.

2.4 Automatic Starting

Some services cannot be interrupted for even for short periods. In these cases the spare equipment or both spare and normal operating equipment are on automatic start. See Procedure

3. Critical Equipment for Inflection Point Engineering Processes

This section shows the pumps, compressors and fans which are considered critical equipment:

Unlisted units have no critical equipment.

Critical Equipment	Explanation	Suggested Action	Suggested Action
Crude, Vacuum and Asphalt	Crude, Vacuum and Asphalt
1. Ram Pump	Not used during normal operation; design to develop high differential pressures to remove heavy hydrocarbons from piping after unscheduled shutdown; heavy hydrocarbons have potential to solidify in lines if they cool down too much	Ram pump shall be a gas (steam) driven. Alternatively, steam turbine drive or motor on UPS power supply may also be suitable.	Ram pump shall be a gas (steam) driven. Alternatively, steam turbine drive or motor on UPS power supply may also be suitable.
Demex
1. Light Oil Flush Pump	The light oil flush pumps flush the heavy hydrocarbons from the lines before the lines cool down.	oil pump specified with remote start and steam turbine driven spare.	oil pump specified with remote start and steam turbine driven spare.
2. Ram Pump	Not used during normal operation; design to develop high differential pressures to remove heavy hydrocarbons from piping after unscheduled shutdown; heavy hydrocarbons have potential to solidify in lines if they cool down too much	Ram pump shall be a gas (steam) driven. Alternatively, steam turbine drive or motor on UPS power supply may also be suitable.	Ram pump shall be a gas (steam) driven. Alternatively, steam turbine drive or motor on UPS power supply may also be suitable.
FCC
1. Main Column Bottoms Circulating Pump	Temperatures in the bottom of the Main Column are high enough to create massive amounts of coke if flow is lost before temperature in the column can be safely reduced.	Inflection Point Engineering’s standard design philosophy incorporates steam turbine drivers for both the operating and standby pump. This ensures flow can be circulated in the event of a power failure. Autostart is not required.	Inflection Point Engineering’s standard design philosophy incorporates steam turbine drivers for both the operating and standby pump. This ensures flow can be circulated in the event of a power failure. Autostart is not required.
2. Catalyst Cooler Pumps	This pump provides water circulation through the convection section tubes of the catalyst cooler; loss of circulation may result in overheating of the tubes with potential for tube rupture.	Prime movers for operating and standby pump shall either be steam turbine/motor or motor/motor on separate (UPS-uninterruptible) power supplies, both on auto start.	Prime movers for operating and standby pump shall either be steam turbine/motor or motor/motor on separate (UPS-uninterruptible) power supplies, both on auto start.
HF and Detergent Alkylation	HF and Detergent Alkylation
1. KOH Circulating Pump on relief gas scrubber	If a PRV in the acid relief header lifts, then the KOH circulating pump plays a critical role in treating the acidic gas before going to the flare.	Prime movers for operating and standby pump shall either be steam turbine/motor or motor/motor on separate (UPS-uninterruptible) power supplies both on auto start.	Prime movers for operating and standby pump shall either be steam turbine/motor or motor/motor on separate (UPS-uninterruptible) power supplies both on auto start.
2. Alkylate Pumps	This pump provides flush for HF acid pump mechanical seals. If the flow is lost the HF acid pump mechanical seals could be damaged possibly resulting in a HF release.	Prime movers for operating and standby pump shall either be steam turbine/motor or motor/motor on separate (UPS-uninterruptible) power supplies both on auto start.	Prime movers for operating and standby pump shall either be steam turbine/motor or motor/motor on separate (UPS-uninterruptible) power supplies both on auto start.
Oleflex
1. Water Circulation Pump	This pump provides water circulation through the convection section tubes of the fired heaters; loss of circulation may result in overheating of the tubes with potential for tube rupture.	Prime movers for operating and standby pump shall either be steam turbine/motor or motor/motor on separate (UPS-uninterruptible) power supplies both on auto start.	Prime movers for operating and standby pump shall either be steam turbine/motor or motor/motor on separate (UPS-uninterruptible) power supplies both on auto start.
2. Sulfur Injection Pumps	Provide DMDS injection into reactor circuit; loss of pumps will result in rapid formation of soot coke on catalyst and reactor internals causing high pressure drop.	Three installed and operating pumps are normally required such that loss of single pump does not result in insufficient DMDS injection; each pump should be on separate power supply.	Three installed and operating pumps are normally required such that loss of single pump does not result in insufficient DMDS injection; each pump should be on separate power supply.
Phenol
Oxidizer No. 1 Pump	This pump provides the net effluent and the pump-around for cooling and mixing the oxidizer, which contains cumene hydroperoxide (CHP), an unstable self-heating material. Loss of circulation could lead to unsafe conditions.	This pump is spared with auto-start of the standby pump and is typically motor-driven. The emergency power may be provided by either a redundant power source or an emergency power generator.	This pump is spared with auto-start of the standby pump and is typically motor-driven. The emergency power may be provided by either a redundant power source or an emergency power generator.
2. Oxidizer No. 2 Circulation Pump	This pump provides the net effluent and the pump-around for cooling and mixing the oxidizer, which contains CHP, an unstable self-heating material. Loss of circulation could lead to unsafe conditions.	This pump is spared with auto-start of the standby pump and is typically motor-driven. The emergency power may be provided by either a redundant power source or an emergency power generator.	This pump is spared with auto-start of the standby pump and is typically motor-driven. The emergency power may be provided by either a redundant power source or an emergency power generator.
3. Dedicated Cooling Water Circulation Pump	This pump provides cooling water supply to the oxidizers. Loss of cooling water could lead to unsafe conditions in the oxidizers (see above).	Typically set up in a 3-pump hook-up, i.e. 2 pumps normally running with a standby spare wired for auto-start. The emergency power may be provided by either a redundant power source or an emergency power generator.	Typically set up in a 3-pump hook-up, i.e. 2 pumps normally running with a standby spare wired for auto-start. The emergency power may be provided by either a redundant power source or an emergency power generator.
4. Fresh Feed Pump	This pump aside from supplying the net feed to the phenol complex also provides emergency quench supply to the Oxidizers and also the other CHP-containing sections of the Phenol unit, in case of a temperature-runway. Loss of the pump will lead to a shutdown of the Phenol unit, which on the long-term could lead to unsafe condition due to the stagnation and self-heating of CHP in the oxidation and concentration sections of the plant.	Typically spared with the standby pump being wired for auto-start. The emergency power may be provided by either a redundant power source or an emergency power generator start.	Typically spared with the standby pump being wired for auto-start. The emergency power may be provided by either a redundant power source or an emergency power generator start.
5. Dedicated Cooling Tower Fan	See Dedicated Cooling Water Circulation Pump	See Dedicated Cooling Water Circulation Pump	See Dedicated Cooling Water Circulation Pump
6. CHP Sump Pump	This pump recycles CHP accumulated from the various drain headers in the sump back to the oxidizers to keep it from stagnating and self-heating to a temperature runaway condition.	Service could be intermittent with high level activating the pump and with automatic shutoff at low level.	Service could be intermittent with high level activating the pump and with automatic shutoff at low level.
7. Emergency Dedicated Cooling Water Circulation Pump	See Dedicated Cooling Water Circulation Pump	See Dedicated Cooling Water Circulation Pump	See Dedicated Cooling Water Circulation Pump
8. Emergency Dedicated Cooling Tower Fans	See Dedicated Cooling Water Circulation Pump	See Dedicated Cooling Water Circulation Pump	See Dedicated Cooling Water Circulation Pump
9. Flash Column Bottoms Pump	The fluid being pumped contains hot and concentrated CHP. Loss of the pump will cause a plant shutdown leading to stagnation and self-heating of the concentrated CHP.	Typically spared with the standby pump being wired for auto-start. The emergency power may be provided by either a redundant power source or an emergency power generator.	Typically spared with the standby pump being wired for auto-start. The emergency power may be provided by either a redundant power source or an emergency power generator.
Platformer
1. Water Circulation Pump	This pump provides water circulation through the convection section tubes of the fired heaters; loss of circulation may result in overheating of the tubes with potential for tube rupture.	Prime movers for operating and standby pump shall either be steam turbine/motor or motor/motor on separate (UPS-uninterruptible) power supplies both on auto start.	Prime movers for operating and standby pump shall either be steam turbine/motor or motor/motor on separate (UPS-uninterruptible) power supplies both on auto start.
RCD Unibon
1. Assured partial cooling for Hot Separator Vapor Condenser	Service limits separator temperature during compressor loss or depressurizing.	Air cooler should be designed for at least 50% of normal duty during power failure.	Air cooler should be designed for at least 50% of normal duty during power failure.
2. Light Oil Emergency Flush Pump	Flushes out heavy oil so that it does not set up in normally flowing lines and equipment.	oil pump specified with remote start and steam turbine driven spare.	oil pump specified with remote start and steam turbine driven spare.
3. Product Fractionator or Stripper Bottoms Pump	Assures removal of liquid for unit during power failure.	Pumps specified with steam turbine driven spare.	Pumps specified with steam turbine driven spare.
4. Assured cooling of Product Fractionator or Bottoms Streams	Limits run down temperature during power failure.	Air cooler should be designed for at least 50% of normal duty during power failure.	Air cooler should be designed for at least 50% of normal duty during power failure.
Selexol
1. All Solvent Pumps	These pumps provide solvent to remove sulfur compounds from Syngas which provide fuel for the gas turbine in the power generation unit. Loss of flow will increase the H2S content of this fuel gas and damage the gas turbine.	All pumps have motor drivers wired for auto start.	All pumps have motor drivers wired for auto start.
Unicracking
1. Fractionator or Vacuum Column Bottoms Pumps	Assures removal of liquid for unit during power failure.	Pumps specified with steam turbine driven spare.	Pumps specified with steam turbine driven spare.
2. Assured cooling of Fractionator or Vacuum Column Bottoms Streams	Limits run down temperature during power failure.	Air cooler should be designed for at least 50% of normal duty during power failure.	Air cooler should be designed for at least 50% of normal duty during power failure.
3.. Water Circulation Pump	This pump provides water circulation through the convection section tubes of the fired heaters; loss of circulation may result in overheating of the tubes with potential for tube rupture.	Prime movers for operating and standby pump shall either be steam turbine/motor or motor/motor on separate (UPS-uninterruptible) power supplies both on auto start.	Prime movers for operating and standby pump shall either be steam turbine/motor or motor/motor on separate (UPS-uninterruptible) power supplies both on auto start.
Offsites
General Comments	Each process unit in a refinery or petrochemical plant depends on reliable utilities (cooling water, steam, etc.). The loss of any of these systems may create safety issues in the plant.	Provide spare equipment with different drivers. Exact driver breakdown will be different for each refinery. Automatic cut-in of spares should be provided.	Provide spare equipment with different drivers. Exact driver breakdown will be different for each refinery. Automatic cut-in of spares should be provided.
1. Cooling Water Pump	Continued supply of cooling water is required to reduce/minimize safety valve releases. Continued supply of cooling water also prevents damaging stagnation of water in heat exchangers.	Provide at least one spare cooling water pump. At least one pump should have a motor driver. At least one pump should have a steam turbine driver. Spare cooling tower cells/fans do not need to be provided.	Provide at least one spare cooling water pump. At least one pump should have a motor driver. At least one pump should have a steam turbine driver. Spare cooling tower cells/fans do not need to be provided.
2. Boiler Feedwater Pump	Continued boiler feedwater supply is required to maintain steam production.	Provide at least one spare BFW pump. At least one pump should have a motor driver. At least one pump should have a steam turbine driver. Also, provide a deaereator with minimum 10-minute storage section.	Provide at least one spare BFW pump. At least one pump should have a motor driver. At least one pump should have a steam turbine driver. Also, provide a deaereator with minimum 10-minute storage section.
3. Boiler Fans	Continued supply of steam is required to operate steam turbine drivers and continue steam supply to other critical users.	Provide at least one spare fan. Provide boiler fans with steam turbine drivers. Individual boilers do not need spare fans.	Provide at least one spare fan. Provide boiler fans with steam turbine drivers. Individual boilers do not need spare fans.
4. Air Compressors	Continued instrument air supply is required to maintain control of process units during upset conditions.	Provide at least one spare air compressor. At least one air compressor should have a motor driver. At least one compressor should have a steam turbine driver. Plant/utility air should be cut off on low instrument air pressure. Provide air receiver sized for at least two minutes of storage. Provide spare air dryer and/or temporary bypass.
5. Fuel Oil Circulating Pump	Continued fuel supply is required to maintain steam production. These pumps are only critical when boilers consume fuel oil.	Provide at least one spare fuel oil pump. At least one pump should have a motor driver. At least one pump should have a steam turbine driver.
6. Potable Water Pump	Potable water is typically required for safety showers and eyewashes.	If a public water supply with sufficient water supply is not available, provide two pumps, one with a motor driver and one with a steam turbine driver.
7. Desuperheating Water Pump	Loss of desuperheating water can lead to high temperature steam damaging equipment.	If desuperheating water pumps are required, provide two 100% pumps, one with a motor driver and one with a steam turbine driver.
8. Deaerator Makeup Pump	Makeup water must be continually sent to deaerator to maintain steam production. Makeup water can be condensate, treated fresh water, or both.	Provide at least one spare pump on services coming from water storage tanks. At least one pump should have a motor driver. At least one pump should have a steam turbine driver.
9. Firewater Pump	Firewater is required on demand.	Provide sufficient firewater pump capacity to handle required loads. Provide one additional pump as spare. Provide at least one pump with motor driver. Provide one pump with diesel engine driver. Provide 500 gpm jockey pump with motor driver to maintain normal water pressure.
10. Flare Blowdown Drum Pump	Excessive liquids in blowdown drum can lead to liquid carryover to flare and then 'fiery rain' from flare.	Provide two pumps, one with a motor driver and one with a steam turbine driver.
General
1. Surface Condenser Condensate Pump	Needed to continuously operate a condensing steam turbine driven compression train; in many Inflection Point Engineering processes, continued gas circulation removes heat from the reactor reducing potential for coking and maximizing catalyst life.	Steam driven with a motor driven standby pump; Inflection Point Engineering’s standard design incorporates autostart for this service.
2. Lube Oil Pumps	Lube oil must continue to flow to large compressors, gas turbine generators, etc.	Provide steam turbine driven main lube oil pump and electric motor driven spare pump on auto start for each large piece of machinery.