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1Q Recertification > 1Q Recertification > Flashcards

1Q Recertification Flashcards

1
Q

What is the purpose of 01HIC1006?

A

The purpose of 01HIC1006 is to protect the Feed Preheat Coils from overheating in the event the process gas flow is lost. It is also used for establishing a flow through the Feed Preheat Coils during startup will keep the coils cool and also heat up the 01R005.

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2
Q

What changes take place to the gas in the 01R005? List Catalyst type and reactions

A 
Cobalt Moly (Top Bed)     H2  +  COS  = C2H6  +  H2S
Zinc Oxide (Bottom Bed)    ZnO  +  H2S  = ZnS  +  H2O
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3
Q

Describe how to restart the ID fan after a trip out?

A

When the ID Fan trips, inquire with the DCS Operator the cause of the trip. If the trip was the result of vibrations, do not attempt to restart the fan without approval of Supervision. If the cause of the trip was oil pressure, remedy the cause of low oil pressure. If the cause of the trip was an unrelated process condition, continue restarting the ID Fan. Examine the ID Fan Train to ensure no apparent mechanical damage. Verify DCS Operator has reset X03.45 Flue Gas Fan Train Logic. Turn the OFF/AUTO/ON switch to the OFF position. Verify ID Fan has come to a complete stop. Notify DCS Operator that fan is ready to be restarted. Turn the OFF/AUTO/ON switch to the ON position to start the fan. Refer to Field 1 SOP 01.01.18 for reference.

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4
Q

Name all the coils in the Convection Section. List them in order from hottest to coldest.

A

E-12 High Temperature Mixed Feed Coil, E-32 High Temperature Steam Superheat Coil, E-52 High Temperature Air Coil, E-31 Low Temperature Steam Superheat Coil, E-11 Low Temperature Mixed Feed Coil, E-22 High Temperature Feed Gas Coil, E-51 Low Temperature Air Coil, and E-21 Low Temperature Feed Gas Coil.

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5
Q

What are the various gas feeds that tie into the Fuel Gas Header?

A

Natural Gas via 03PV1166A/B/C, Flash Gas via 05PV3006A, Low Pressure Purge Gas via 10PV8001A, and Fuel Return from the Cold Box via 11PV8151A.

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6
Q

How many catalyst tubes and arch burners are in the 03B001?

A

408 tubes, 189 burners.

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7
Q

What is the single largest user of MP Steam?

A

03FIC1151- Steam to Process

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8
Q

What protects the air coil in the event the process air flow is lost?

A

03FV1162 protects the air coil in the event the air flow is lost.

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9
Q

What is an exothermic reaction? What is an endothermic reaction? List catalyst vessels in Field 1 and whether the reaction is endothermic or exothermic.

A

An exothermic reaction is a chemical reaction that gives off heat. An endothermic reaction is a chemical reaction that requires heat. 01R005-Endothermic, 03B001-Endothermic, 03R001-Endothermic, 04R001-Exothermic

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10
Q

What major upset condition trips the Process Gas out the Front End of the plant? Why?

A

Low Low Steam Flow to the process trips the Feed Gas out of the process. This is done to prevent coking of the catalyst in the Primary Reformer.

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11
Q

What major upset condition trips the Process Air out the Front End of the plant? Why?

A

Low Low Gas Flow to the process trips the Air out of the process. This is done to prevent the possibility of having an explosive mixture in the 03R001.

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12
Q

What is the purpose of the 03E301?

A

To cool the process gas out of the Secondary Reformer (03R001) and to generate High Pressure Steam.

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13
Q

What is the purpose of the 03E302?

A

To further cool the process gas out of the 03E302 and to begin superheating High Pressure Steam.

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14
Q

What are 03TIC1170 and 03TIC1182?

A

03TIC1170 is an internal bypass of the 03E301 which controls the Superheated Steam temperature at the outlet of the 03E302. 03TIC1182 is an internal bypass of the 03E302 which controls the Process Gas temperature on the inlet to the 04R001 (HTS)

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15
Q

What controls the flow of Process Gas to the Primary Reformer?

A

03FIC1152A/B. The DCS operator adjusts the set point as needed to control plant rates. One valve typically runs in MANUAL in order to keep the valve in AUTO in control.

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16
Q

What controls the flow of Process Steam to the Primary Reformer?

A

03FIC1151 in running in CASCADE to 03FFIC1151 (Steam/Gas Ratio Controller)

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17
Q

What is the source of the Process Steam?

A

The Medium Pressure Steam header.

18
Q

What is the purpose of steam sent to the stem of 03TV1170 and what is its source?

A

The steam to 03TV1170 is sent through the stem and through passages on the center paddle of 03TV1170 in order to keep it cool. The seam then escapes into the Process Gas stream through a small orifice at the bottom of the stem. The source of this steam is the MP Steam Header.

19
Q

During start-up, why do we circulate nitrogen for initial heat up? What conditions must be met before Steam is admitted to the Front End

A

Nitrogen is circulated through the Front End during startup in order to evenly heat up all process piping and vessels before admitting steam. Steam can be admitted to the Front End once the Primary Reformer outlet is above 600°F, all HTS bed temperatures are 50°F above saturation, and verify steam is dry at Steam to Process valves.

20
Q

What is important about a “hot tube” in the reformer?

A

A hot tube will be weakened by the high metal temperature.

21
Q

What is the purpose of the HTS and LTS? Why do we need to complete this reaction?

A

The purpose of the HTS and the LTS is to Convert CO to CO2 and liberate hydrogen. Shift CO to CO2. This reaction is completed so that CO2 can be removed in the Amine Section.

22
Q

What is the purpose of the 06R001?

A

The purpose of the 06R001 is to convert CO and CO2 to CH4 and H2O, consuming H2 in the process.

23
Q

Where would you expect a bad leak in the 06ET01 to show?

A

If you had a bad leak in the 06ET01, unconverted CO and CO2 gas would bypass the Methanator. This would result in shorter runs on the Mole Sieves and high DP across the Ammonia Converters (08R003, 08R001, and 08R002) due to carbamate formation

24
Q

How do we sweep out the Low Temperature Shifter on a shutdown? Why?

A

The LTS is swept with nitrogen through the Nitrogen Loop to remove any condensables (water) and to replace the process in the vessel with nitrogen gas since the process gas contains some water.

25
Q

What types of gases are used during the Reduction of the LTS?

A

Nitrogen and Hydrogen (N2 and H2).

26
Q

What is the sole purpose of the Amine System?

A

The sole purpose of the Amine System is to absorb the CO2 from the Process Gas stream.

27
Q

What controls the level in the LP Flash?

A

LP Flash level is controlled manually by adjusting the Extraction BFW flow to the top of the Absorber.

28
Q

Why do we blowdown boilers and waste heat boilers?

A

The waste heat boilers are blown down to remove any solids that may have come out of solution and settled out on the bottom of the vessel.

29
Q

What controls HP Steam header? MP Steam header? LP Steam header?

A

07PIC1170 Master Controller controlling 07 and 09 Extraction Racks, 07PIC1170D 07MT01 Bypass, and 07PIC1170A HP Steam Vent.

03PIC6003 Master Controller controlling 03PIC6003B Generator Output, 03PIC6003C Letdown from Package Boiler, 03PIC6003A MP Steam Vent, or 03PIC6003D 09MT01 Bypass.

82PIC9171 MP to LP Letdown, 82PIC9172A LP Steam Vent, or 82PIC9172B LP Steam to 02K001 Induction.

30
Q

What is the purpose of the ARC valve and how does it work?

A

The ARC valve is a multifunctional valve that protects the BFW pump. The ARC valve provides protection for centrifugal pumps during low flow conditions. It recirculates a minimum flow requirement automatically to the Deaerator to prevent the pump from overheating and causing internal damage. The ARC valve is designed to flow normal capacities through the main valve and also size the bypass to handle the minimum flow and acts as a check valve to prevent reverse flow to the pump.

31
Q

Where are the three Boiler PSV’s located, which has the lowest set pressure, and why is one set lower?

A

There are two relief valves on the Boiler Steam Drum and one relief valve on the outlet of the Superheat Coils before the steam outlet check valve. The relief valve downstream of the superheater is set at a lower pressure so that it relieves first to assure that flow through the superheater section is maintained

32
Q

What are the main parameters we monitor in our boiler samples?

A

The main parameters the Boiler Water is sampled for are pH and conductivity

33
Q

What is the purpose of the Cooling Tower and how does it work?

A

The purpose is to remove heat from the returning cooling water. It also acts as a suction reservoir for cooling water pumps. Hot returning water is distributed evenly throughout the top of the cooling tower and naturally falls downward. This downward flow of water comes in contact with the upward flow of cool, dry air being sucked up by the cooling tower fans. Thus, the heat is removed from the water before entering the cooling tower basin.

34
Q

What is the purpose of the rupture disks on cooling water exchangers?

A

To provide protection for the Cooling Water System and the vessel it is mounted on during a tube rupture in the exchanger.

35
Q

List the sources of water lost in the cooling water system.

A

Water is lost from the cooling water system 3 ways. Evaporation, drift, and blowdown.

36
Q

What happens if the cooling water pH gets too low and what happens if the pH gets too high?

A

If the cooling water pH gets too low the protective coating of the piping and exchangers will be stripped off and corrosion will occur. If the Cooling Water pH gets too high fouling of the exchangers will occur.

37
Q

What is the control range of the cooling tower for the following and the corrective actions?

A 
Test Parameters	Control Range	Corrective Actions
pH	7.0-7.5	Acid/Caustic Feed
Calcium Hardness	300 ppm max	Blow Down
Cycles of Concentration	6-8	Blow Down
Ortho Phosphate (PO4)	12-14	CW-1010 Feed
Filtered/Unfiltered PO4	<2	CW-2040 Feed
Free Chlorine	2-5 ppm	Bleach Feed
Turbidity	<15 NTU	Blow Down
38
Q

Who controls our pumping rate to the river?

A

The Main Lab controls our pumping rate to the river.

39
Q

What safety precaution do an acid and or a caustic truck driver have to take before unloading?

A

The truck driver must contact the control room before any unloading operations take place. He must be wearing a hard hat, safety glasses, face shield, chemical gloves, chemical boots, chemical suit, and have the truck wheels chocked. It is also his responsibility to have the correct fittings for unloading.

40
Q

What is the purpose of the Effluent System?

A

To gather, store if necessary, and make suitable effluent water for return to the Mississippi River. The collected water is treated before it is returned to the river. The reason for treating the water is to meet the requirements set forth by the Department of Environmental Quality (DEQ). DEQ requires that the pH of the return water be maintained within a specified range. The water must also be free of oil and any other contaminants that have been classified by DEQ to be environmentally hazardous. Therefore this system must be monitored at all times so that in the event of an out of range pH or hazardous chemical condition that threatens the allowable permit limit takes place, corrective actions will take place immediately.

41
Q

What is the minimum and maximum range for the combined effluent pH from the facility?

A

6.0 to 9.0 pH.

42
Q

What is the control range of pH from our effluent system?

A

6.4 to 8.6 pH.

1Q Recertification (2 decks)

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