Injection and Mixing Points - Design and Inspection Considerations Published on December 16, 2021 Baher Elsheikh Injectior Points Baher Elsheikh Sr. Mechanical Engineer at SABIC AN 6 articles Introduction Injection and mixing points are locations used frequently in refineries, petrochemical and power plants and carry a potential risk of increased degradation rate compared to the mainline due to the changes in temperature, pH, phase changes, and the concentration of corrosive species. Because of that, dedicated publications and literature addressed the requirements for the design and inspection of the mixing areas. In order to maintain the injection and mixing locations free of surprising failure events, careful attention shall be taken during engineering to apply the proper design c onfigurations, material of onstruction, type and location of isolation valves, ... etc.) and also during perations for monitoring of the chemicals quality and operating parameters flow,MyNetwork — Jebs Mees plans. Defintions Injection Point: Injection Points are locations where chemicals, or process additives, are introduced into a process stream. Corrosion inhibitors, desalter demulsifiers, neutralizers, process antifoulants, oxygen, hydrogen scavengers, caustic, and water washes are most often considered to be requiring special attention during injection point design. [1] Mix Points: Mix points or Mixing Points are points of joining of process streams of differing composition and/or temperature where additional design attention, operating limits, and/or process monitoring are utilized to avoid damage mechanisms (e.g., corrosion). Design Precautions of Injection PointsHe MyNetwark Jabs Messagir should be designed to allow proper mixing and dilution of the chemical in order to avoid the concentration of chemical on hot metal surfaces. [4] Static Mixer Injection Quills Materials Selection for Mixing Zone While selecting materials for mixing zone, consideration shall be made for local erosion, corrosion-erosion, and corrosion rates influenced by flow regime and turbulence. High corrosion-resistant alloys or internallyMyNetwork — cbs Messagin Each lined pipe and fitting shall be provided with a venting system that will release any annular pressure between the polymer liner and the host metallic component, NOTE —Venting is not required with PVDF, PP, ETFE, or PVDC liners. Plastic liner | |Typieal vent hele PTFE LINED PIPE SPOOL WITH VENT HOLE Injection Devices Injection device designs should include the design of piping tees, spray nozzles, quills, and/or static mixers, Design Considerations of Quillsinjectant with the pipe wall. Quill designs shall include flow calculations to determine the natural frequency and whether fatigue is an issue. © Quills with beveled ends should be considered, as they promote better dispersion and mitigate potential corrosion or fouling caused by concentrating chemical injectant at the pressure boundary, Considerations of Spray Nozzles Sray nozzles should be considered for injecting liquids into gas streams or when the injectant is required to coat/wet the pipe wall. Spray nozzles are used to more rapidly disperse the injectant stream. « The co-current injection is suggested when wetting is the desired result. ¢ Cross-flow injection should be avoided because it results in impingement on the pressure boundary wall. Impingement can also occur when the injection is too close to a change in direction,fi 3 Hone yeh a) Co-current Discharge ic) Cross-current Discharge d) Co-current Discharge with impingement with Impingement |= Injectant Stream _f=Recelving Stream M= Mixed! Stream Injection Nozzle Discharge Orientation JebsRr. iM a) Tee b) Quills 1 R M R M <) Sparger d) Spray Nozzie ' r e) Multiple Spray Nozales 4) Multiple Spray Nozzles in Parallel in Sequence | = Injectant, R = receiving Stream, M = Mixed Stream Injection Devices Injection to Vessels or Tanks For injection to vessels or tanks, designs that tend to concentrate corrosive media in a small area should be avoided. For example, tank inlets should be designed in such a way that the concentrated solutions are mixed and diluted when they are introduced. Otherwise, excessive corrosion can be caused by localized pockets of concentrated solutions. The poor design causes concentration and uneven mixing of incoming chemicals along the vessel wall (circled areas). Good design allows concentrated solutions to mix away from vessel walls. [3]Home VyNetwork Jes Concentrated Solution Concentrated Solution Dilute Solution Temperature Difference High-temperature difference between the injected stream can the mainstream can cause thermal shock or fatigue, this shall be considered in the design of the injection nozzle to avoid direct contact of the injected stream to the metallic wall of the main stream. isolation of the components through the use of insulation, thermal sleeves, or reduction in mechanical stiffness may remediate the fatigue Another approach can be by changing the temperature of the injected stream (heating or cooling) to approach the temperature of the mainstream. Thermal isolation, such as the use of thermal sleeves, or thermal insulation, has as its goal the reduction of thermal differentials between different equipment components, An example is that of an alloy nozzle designed for high temperatures intersecting refractory lined vessel. The thermal sleeve, often containing some insulation, reduces the temperature difference, and thus the thermal stresses, at the junction of the components. [6]My Netwerk -2 “Typical Thormal Stove Detail with No insulation Operations Considerations points. For the operating schemes where the flow of the mainstream is not continuous, the chemical injection shall be stopped while the mainstream is flowing, then the mainstream can be stopped. And for starting chemical injection, the operator shall ensure that the mainstream is flowing before starting the chemical injection. This can be best achieved by design through the application of interlock. Otherwise, operating procedures with a check-list shall be developed with proper protocol to avoid mistakes. In addition to the application of strict program / checklist to monitor the identifed integroty Operating Windows (IOW) for flow, velocity, chemical composition, pH, temperature, pressure, and other factors as applicable for each case. Inspection Considerations Injection points are sometimes subject to accelerated or localized corrosion, Those susceptible should be treated as separate inspection circuits, and need to be inspected thoroughly on a regular schedule. [2] At the time of scheduled periodic inspections, extensive inspection should be applied to an area beginning 300 mm upstream of the injection JobsHome yNetwok obs. Messagir The choice of inspection techniques and inspection locations are also important. Consideration should be given to inspection techniques and access during design. During unit shutdown, the quills and nozzles should be inspected as well as all parts of the circuit. Installation of platforms, manways or removable spools may be required for proper inspection. [7] Incase of the use of plastic-lined pipes equipped with vent holes, in the event of a liner failure the steel housing is likely to corrode evenly within the pipe and cause a catastrophic and unannounced failure. Vent holes shall not be Plugged. If the line is insulated, extend the vent out of the cladding and include the check of leaks through the vent holes in the periodical inspection and patrolling checklist, oF 12:n. minimum, La is greater 30 “Typical condition monitoring locations (CML) within injection point circuits Typical Injection Point Piping CircuitHome — VyNetwork cbs [1] NACE SP0114-2014: Refinery Injection and Process Mix Points [2] API 570: Piping Inspection Code: In-service Inspection, Rating, Repair, and Alteration of Piping Systems [3] ASM Metals Handbook, Volume 13 — Corrosion [4] API 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry [5] ASTM F1545 Standard Specification for Plastic-Lined Ferrous Metal Pipe, Fittings, and Flanges [6] API 579, Fittness For Service [7] The Many Parts of Injection Points, Marc MCConnel, P.E, Inspectioneering Journal, July 2013 Report this Published by Baher Elsheikh 6 articles ‘St. Mect SABIC AN. rical Engi Published « 8 Injection and Mixing Points = Design, operations and Inspection Considerations Injection and mixing points are locations used frequently in refineries, petrochemical and power plants and carry a potential risk of increased degradation rate compared to the mainline due to the changes in temperature, pH, phase changes, and the concentration of corrosive species. Because of that, dedicated publications and literature addressed the requirements for the design ang inspection of the ring areas. In order to maintain the injection and mixing locations free of surprising failure events, careful attention shall be taken curing engineering to apply the proper design c onfigurations, material of onstruction, type and location of isolation valves, .. etc) and also during perations for monitoring of the chemicals quality anc operating parameters flow, pressure, temperature, purge requirements, sequence of operations,..tc). In addition to the aplication of the proper inspection plans,Home — VyNetwork cbs Reactions ° o °6® 6 ° o 6 6 6 ° +17 6 Comments Most relevant ¥ @ Acd @ comment. ©e Peter Clymans « 2n¢ Sr Mecharical and Inspectior iineer Project One bij INEOS Thank you for this very detailed and comprehensive summary. Injection points, Mixing points and deac encs shall be an integral part of the RBI program for refinery anc chemical industry. Do you have specific presentations or incident cases that helps to create awareness in engineering phase of projects 7 Like - 1 | Reply - 1Reply Baher Elsheikh » 2nd n Sr. Mechanical Engineer at SABIC AN Thanks Peter Clymans for the reflection. Yes the RBI program shall identify ‘and manage such locetions in addition the further highlited consiceration for the design and operations. For the requested presentations, that is not available with me. Like | Reply Mohamed Ali » 2nd Tree ‘Asset Integrity General Menager @ WEPCO Petroleum Co. Thanks for sharing Like - 1 | Reply + 1Reply Baher Elsheikh + 2nd Tree St. Mect SABIC AN Thanks so much Mohamed Ali Like» © 1 | Reply Luciano Almeida + 2nd aien Técnico de Inspecao de Ecuipamertos e InstalagGes Sénior - NR 13 - SPIE Great material! Like - 1 | Reply + 1Reply MesseginThanks so uch Luciano Almeida Like » ©7| Reply Baher Elsheikh Sr. Mechanical Engineer at SABIC AN More from Baher Elsheikh ‘Common Mistakes That Can Be Avoided in Using Standards for Static Equipment Baher Elsheikh on LinkecIn Main Changes in APIS7A, 3" Key Changes in API RP 571 Third Edition « 2020 Sheikh on Linkecin Exchangers Home My Network JobsHome — VyNetwork ——_Jebs STEAM REFORMER Baher Elsheikh on Linkecln See all 6 articles Linked [i About Accessibilty Talent Solutions Questions? select Language Community Guidelines Careers Marketing Solutions Visit our Felp Center, English (English) Privacy & Terms“ Ad Choices Advertising $F Manage your account and Sales Solutions Mobile Small Business Poser Settnes, Safety Center LinkedIn Corporation © 2021