Chemical Processing Qualification Standard Reference Guide FEBRUARY 2010

Chemical Processing Qualification Standard Reference Guide FEBRUARY 2010

Chemical Processing Qualification Standard Reference Guide FEBRUARY 2010 This page is intentionally blank. Table of Contents LIST OF FIGURES ...................................................................................................................... ii LIST OF TABLES ........................................................................................................................ ii ACRONYMS................................................................................................................................iii PURPOSE...................................................................................................................................... 1 SCOPE ........................................................................................................................................... 1 PREFACE...................................................................................................................................... 1 TECHNICAL COMPETENCIES............................................................................................... 3 1. Chemical processing personnel must have a working level knowledge of the operation of chemical processes.................................................................................................................... 3 2. Chemical processing personnel must demonstrate an expert level knowledge of mass transfer and mass balances...................................................................................................... 13 3. Chemical processing personnel must demonstrate an expert level knowledge of stoichiometry and reaction kinetics. ....................................................................................... 21 4. Chemical processing personnel must demonstrate an expert level knowledge of process safety....................................................................................................................................... 31 5. Chemical processing personnel must demonstrate a working level knowledge of DOE Safety Basis requirements....................................................................................................... 49 6. Chemical processing personnel must demonstrate a working level knowledge of safety and relief devices. ................................................................................................................... 55 7. Chemical processing personnel must demonstrate working level knowledge of general piping systems......................................................................................................................... 61 8. Chemical processing personnel must demonstrate a working level knowledge of mechanical diagrams, including: ............................................................................................ 74 9. Chemical processing personnel must demonstrate a working level knowledge of the general construction, operation, and theory of valves. ........................................................... 83 10. Chemical processing personnel must demonstrate a working level knowledge of measurement, data collection, and analysis. ........................................................................... 88 11. Chemical processing personnel must demonstrate a working level knowledge of pump theory and operation. ............................................................................................................ 105 12. Chemical processing personnel must demonstrate a working level knowledge of fluid mechanics and properties...................................................................................................... 116 13. Chemical processing personnel must demonstrate the ability to calculate flow rates in fluid systems. ........................................................................................................................ 121 14. Chemical processing personnel must demonstrate a working level knowledge of thermodynamics.................................................................................................................... 127 15. Chemical processing personnel must demonstrate a working level knowledge of steady- state heat transfer. ................................................................................................................. 136 16. Chemical processing personnel must demonstrate a working level knowledge of the construction and operation of heat exchangers..................................................................... 138 17. Chemical processing personnel must demonstrate a working level knowledge of the components, operation, and theory of pneumatic systems. .................................................. 142 18. Chemical Processing Personnel must demonstrate a working level knowledge of the basic components, operations, and theory of hydraulic systems. ......................................... 148 19. Chemical processing personnel must demonstrate a working level knowledge of Project and Contract Management. ................................................................................................... 156 i Table of Contents 20. Chemical processing personnel must demonstrate a familiarity level of knowledge of software quality assurance when addressing chemical process safety problems. ................ 174 21. Chemical processing personnel must demonstrate a familiarity level of knowledge of software quality assurance functional interfaces between safety system software components and the system-level design.............................................................................. 182 Selected Bibliography and Suggested Reading ...................................................................... 188 Figures Figure 1. Distillation example.........................................................................................................8 Figure 2. Solvent extraction process.............................................................................................11 Figure 3. Mass balance example...................................................................................................15 Figure 4. Phase diagram example .................................................................................................18 Figure 5. Pressure set points .........................................................................................................57 Figure 6. Typical design of a pressure relief valve mounted on a rupture disk device.................61 Figure 7. Bourdon tube .................................................................................................................90 Figure 8. Rotameter.......................................................................................................................91 Figure 9. Nutating disk..................................................................................................................92 Figure 10. Ball float level mechanism ..........................................................................................93 Figure 11. Graph of a normal probability distribution................................................................103 Figure 12. Centrifugal pump.......................................................................................................108 Figure 13. Reciprocating positive displacement pump operation...............................................109 Figure 14. Sample centrifugal pump characteristic curve...........................................................110 Figure 15. Discharge throttling modified curves ........................................................................112 Figure 16. Pressure-volume diagram ..........................................................................................127 Figure 17. Carnot cycle representation .......................................................................................132 Figure 18. Rankine cycle ............................................................................................................134 Figure 19. Example Mollier diagram..........................................................................................135 Figure 20. Pneumatic actuator: Air-to-close, spring-to-open .....................................................144 Figure 21. Pneumatic drive .........................................................................................................146 Figure 22. Basic hydraulic system ..............................................................................................151 Figure 23. Non-pressurized reservoir designed for pump to be mounted on top........................153 Figure 24. Cross sectional views and symbols for hydraulic accumulators ...............................155 Figure 25. Work control processes .............................................................................................162 Tables Table 1. Processing hazards...........................................................................................................37 Table 2. Incompatible substances..................................................................................................42 Table 3. Classes of incompatible chemicals..................................................................................44 Table 4. Grading criteria and facility categorization illustration ................................................176 ii Acronyms ΔP differential pressure ABS acrylonitrile butadiene styrene AIChE American Institute for

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