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  • Safety Moment For CoP June 2006

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    Gagan Sidhu
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    A slurry settler failed catastrophically during startup. The settler contained a pocket of water that did not heat up along with the oil above it, which reached 650°F. When flow was initiated through the settler's underflow line, the hot oil and cold water mixed rapidly. This caused the water to heat up very quickly to 650°F as well. As the water temperature increased, so did the pressure inside the settler, exceeding its design pressure and causing it to crack and release the steam pressure built up from the vaporizing hot water. The key lesson is to not mix hot oil and water to avoid rapidly increasing pressure.

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    Safety Moment

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    Safety Moment for CoP June 2006

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    A slurry settler failed catastrophically during startup. The settler contained a pocket of water that did not heat up along with the oil above it, which reached 650°F. When flow was initiated through the settler's underflow line, the hot oil and cold water mixed rapidly. This caused the water to heat up very quickly to 650°F as well. As the water temperature increased, so did the pressure inside the settler, exceeding its design pressure and causing it to crack and release the steam pressure built up from the vaporizing hot water. The key lesson is to not mix hot oil and water to avoid rapidly increasing pressure.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    12 views14 pages

    Safety Moment For CoP June 2006

    Uploaded by

    Gagan Sidhu
    A slurry settler failed catastrophically during startup. The settler contained a pocket of water that did not heat up along with the oil above it, which reached 650°F. When flow was initiated through the settler's underflow line, the hot oil and cold water mixed rapidly. This caused the water to heat up very quickly to 650°F as well. As the water temperature increased, so did the pressure inside the settler, exceeding its design pressure and causing it to crack and release the steam pressure built up from the vaporizing hot water. The key lesson is to not mix hot oil and water to avoid rapidly increasing pressure.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    Download as pdf or txt
    of 14

    Safety Moment

    FCC Technology
    June 30, 2006

    Slurry Settler Failure

    Failure Overview

    Unit was in startup


    Feed was in riser for almost 1 day
    MC Botts circulation was routed thru the
    settler and out the top
    Settler underflow line was plugged
    SS was just heating up to 650F
    Underflow line appeared to start flow
    SS failed catastrophically

    Possible Failure Mechanism

    Water in low point does not heat up with oil


    because of slurry settler geometry
    Oil above the water heats up to 650F
    When slurry settler bottom flow was started, the oil
    and water mixed, rapidly increasing the water
    temperature to 650F
    The settler pressure would increase per
    water/steam equilibrium curve as temperature
    increased (600F=1550psi)
    If the pressure exceeds the vessel design, it will
    crack and relieve the hydrostatic liquid oil/water
    pressure. As pressure is released, the hot water will
    rapidly vaporize to steam

    Pieces found

    Origin

    Do Not Mix Hot


    Oil and Water

    Operating procedures for all units with the potential for water
    pockets (startup or exchanger maintenance) with hot oil should
    include precautions for water removal. Training and refresher
    training for all operators on a periodic basis is recommended.

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