
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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