Document aEYeb94XkoVjEK1k3Yr0b17M

Process and Power Dictate the Desigl Qf Refinery When An industrial plant requires Expansion of Whiting, Indiana is marked by: comprehernivi team for both power and process, these demands rarely parallel each other for water treatment for high-makeup operation, extensive red any appreciable period. At Whiting, the following steps were taken to sat ing-desuperheating facilities for ironing out Inequalities isfy this condition: (1) high Initial pressure (2) steam-conditioning equip power and process loads, overload protection for topping uniftfl ment for radacing steam from Initial boiler pressure and temperature- down to turbine-exhaust conditions. In addi 6y D A MONRO end A T MILBROOK Standard O/l Ca of Indio** tion design precautions guard against accidental overloading of generators, > and deposit of scale on boiler end tur steam from the initial pressure sad tem steam from the 1250-pii 900-F toppb bine surfaces from feedwater chemicals. perature conditions ol the topping cy cycle level down to 400-psl 650-F. a Selection of a high enough initial op erating pressure permits generating the peak eleetrieal-energy demand even cle down lo turbino-cxhaust level, takes care ol inequalities in demands for steam and power. houst conditions. One of these senes s a standby; the second safeguards i supply to refinery process (see "Omj daring periods of the lowest process- For normal operation two pressure- load Precautions," p 103) if s lopplaj steam needs. Beyond this base require reducing and desuperheating stations turbine trips out ment, e surplus over present demands perform this conditioning function. A Each pressure-reducing sad deiuper should be bails into the topping cycle to 75,000-lb-pcr-hr station operates first, besting station consists of (1) <fa meet future load growth. followed up by a second, a 300,000-lb- phragm - operated pressure redacini -Our experience dating back to 1928 per-hr unit that cuts In automatically valve of the pilot typo (2) a stesmde indicates the soundness ol building-in when the smaller one reaches its limit water-spray nonle desuperheater. a surplus over and above present needs. Two additional stations of 300,000 At that time one of .the earliest in lb per hr can reduce this high initial dustrial applications of byproduct gen eration of power was made at Whiting with a power station operating at 400- pal and 650-F initial steam conditions. Exhaust from turbine-generators was delivered to the refinery for process (tSOpti(Hotter 95QF end power at 100 psi and approximately 450 F. The quantity of steam re quired by the refinery produced con \t-(0,000 *w * ''"I* turbine* siderably more byproduct power than was needed at that time. Refinery operations change, however. Over the years it became the practice lOOpai 650 ftofirocea_^ La $ ^ to replace uneconomical steam drives with motor drives utilizing inexpensive byproduct electric energy. Process de Mdy sign changes over this same period further reduced refinery steam demands per barrel of crude oil. In fact, the tendency has been for Tbprocttt steam demand to stay static or possibly increase at a slight rate. Electric en beating,*it ergy demand, on the other hand, has increased at a high rato. Our former surplus soon disappeared. It became apparent that total byproduct power available at the then existing back pressure cycle would fall far abort of ultimate power demands. All this back ground figured heavily in our selection of initial steam conditions for our new plant Stoom Conditioning. Providing steamconditioning equipment, to reduce FLOW DIAGRAM, obove, shows arrangement of molor equipment In new garnet pTM-"^ os well as its relotion to existing sJeom-generating copoclty Hcort of tho expansion program Is the new dual-circulation boonidlersp,rocUesPsP.*Jj*ft.. They supply 1250-psi steom under 100% makeup conditions with llttie I 100 (734} PO*WER Apr* |N*J for spray water comes ^,io| *P<r froTM the dea6r' ^-cr in oversited vent conTb, condensing medium in rel- jSitlZ.y.,cciwoldilerMenN- "11<"!' " P1*"1- "r * * j iba deleintor.alernge Unk `*i condensate from this procen. it bu been deneratnd In n nep- . jesUan ol thn deneralor. 'condenime xuppl, exceed, de II ll orerdowi Into ndjneenl corn ea ol tb" morag" Unk where creted boiler leedwntei In kept. A unk st the deaerator-storage l sets as sn emergency storage for the pressure-reducing valves -selves. Reduction of pressure. In w of tho type usually employed in i service, gives off an obiectlonabie .he. especially if they ore close to the rsting stations. Today's valves plus _xir piping lower this noise level ap* -ttdibly. But there is still s noise siisiace. Becsuss there ere so many pressure- redocisg stations.si the Whiting Refaery say measures toward isolating lib ooise became desirable. All stations ) pii to 400, 400 to 100, and 100 10 psi--occupy a separate room L:ve the roof qf the turbine room, isoI Iron the boiler room by a solid i wall. An acoustic material deada sound to contribute to the comfort those who work in this spaco. .Fttdvoter Treotmant. With steam "tsar pressure levels, 1250, 400, 100 'd 10 pii md makeup approaching (or the 1250-psi boilers, water nenl is an important phase of "i operation. s treatment system is set next to > power station ond is laid out to per't' ultimate expansion to that of the . .m-generating capacity. At present 4 consists ol three lime-sods sediments' tanks--one serves ss a spare--ond t phosphate sedimentation tanks. pair ol tanks comprising n unit net capacity ol 80,000 ga) per hr. Mention time runs 1% hr. 'A 4700-tq-lt storage room ediscent : railroad siding houses watertment chemicals in bags and bar^ Qtcmical mixing and- proportion- takes place in s room next to this r,l space. Mixing tanks - stand `tly above grade elevation, ^ttiageotent ol these tanks permits dumping chemical charges from a plat form that connects with the storage room st its floor level. Separate tanks mix lime and sods, phosphote and retordsnt solutions. Each tank carries its own agitator, proportioning mechanism, auction pump tank and chemical pump.* Controls (or all chemical proportioning and feeding mechanisms and pumps mount on a central control board. The same board holds all flow and level recorders, pressure gages and other in struments needed to control the entire water-treating system. Eoch sedimentation tank can recircu late sludge from the sludge cone to the top of the tank. This accelerates precipitation. An ejector, o flowmeter and a dear-water pump make up the recirculating equipment. The ejector and flowmeter are placed close to the unk to reduce length ol sludge -pipes: the dear-water pumps are in the mix ing room. Row Water Cycle. Row water prosettlea in two storage tanks, SO x 50 ft Its incoming temperature varies with the season and with process changes over a range of about 120 to 180 F. Water to the new power plant, Sta tion No. 3. flows through two lBen. pipes to raw-water pumps in the pump bay of the boiler room. It passes from here through vent condensers on the deaerating heaters lo spray heater* on the sedimentation tanks. At maximum capacity, water at 180 F entering the vent condensers leaves st 238 F> In the sedimentotion tanks this temperature rises to 240 F, corresponding to a 10-psi exhaust-steam pressure. Under emergency conditions wkh raw water at, 40 F entering the de aerator vent condensers, outlet temper ature reaches 162 F. Full espadty of tho treating tanks can be maintained with raw-water inlet temperature as low as 90 F. Steam for heating In treating tonka comes from refinery exhaust-steam mains and from continuous-blowdown flash drums. Because many steamdriven reciprocating engines operate throughout the refinery, exhaust from these mains is kept out of the deaeret* ora. Uncontaminated steam for dCaere* P.Wfk April (235) 101