Troubleshooting Duty/Standby Pumps Controlled by Level Bridles in Brighton

Question:

In Brighton, a new thread has been initiated with a question regarding duty/standby pumps controlled by level bridles on the reboiler upstream. These 4 KW pumps with mechanical seals experience shutdown when draining the level bridles, restarting shortly after. This process has been ongoing for 12 months, prompting the suggestion of implementing a Maintenance Override Switch (MOS) to prevent pump shutdowns. However, caution is advised before making any changes without a thorough HAZOP analysis. While the proposed solution may enhance pump performance, potential hazards related to monitoring and control of the MOS need to be evaluated to avoid any disasters. It is important to approach the problem with proper engineering and risk assessment before implementing any solutions. Rushing into a solution without fully understanding the issue and its consequences could lead to unforeseen complications.

Top Replies

Why is it necessary to drain the bridle and reboiler in Brighton? Shouldn't this be a standard procedure in boiler system maintenance?

The reboiler system is primarily designed to handle Mono Ethylene Glycol (MEG), however, there is an issue with MEG and Gas Condensate mixing together. This causes condensate to build up on top of the MEG in the reboiler over time, resulting in inaccurate reboiler level readings in the control room due to the upper section of the bridles becoming filled.

Indeed, removing the excess steam from a steam drum's level gauge is akin to draining it when steam builds up above the water level. This process is crucial for maintaining optimal performance and safety in steam systems.

I couldn't agree more with your call for a thorough HAZOP analysis before making any changes. The implications of implementing a Maintenance Override Switch indeed need to be rigorously evaluated. Even if it could potentially solve the immediate pump shutdown issue, we must remain vigilant about any unexpected chain reactions that might occur downstream, or even completely unrelated outcomes altering safety protocols. Engineering solutions need to be comprehensive and encompassing. Therefore, a holistic risk assessment and an in-depth understanding of the issue are essential before proceeding with any modifications.

I completely agree with your caution for a thorough HAZOP before implementing the MOS. It's easy to want to rush to a perceived solution, especially when dealing with a problem that's persisted for so long. However, it's critically important that we fully understand the potential consequences before proceeding. A failed MOS could potentially result in a loss of control scenario that could be far worse than the intermittent pump shutdowns we're currently dealing with. The risk outweighs the benefit without proper assessment and engineering planning. Also, let's not forget, maintainability and reliability are as important as operational efficiency. A detailed failure mode and effects analysis (FMEA) in addition to HAZOP could be very beneficial for understanding the complete picture.

A worthy topic to be discussed indeed, and I appreciate your prioritizing of safety measures. Indeed, implementing an MOS could offer a practical solution, but I also agree with the necessity for a detailed HAZOP study beforehand. As an additional consideration, maybe the broader context of the operation could be evaluated. For instance, understanding whether this issue is a symptom of a larger problem like ineffective level bridle design or mechanical seal selection may also prove beneficial. Let's not treat just the symptom but also examine underlying causes before moving forward.

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Frequently Asked Questions (FAQ)

FAQ: 1. Why do the duty/standby pumps with mechanical seals in Brighton keep experiencing shutdowns when draining the level bridles?

Answer: - The pumps are experiencing shutdowns due to the draining of the level bridles, which prompts a restart shortly after.

FAQ: 2. What is the suggested solution to prevent pump shutdowns in Brighton?

Answer: - Implementing a Maintenance Override Switch (MOS) is suggested as a solution to prevent pump shutdowns.

FAQ: 3. Why is caution advised before implementing the Maintenance Override Switch (MOS)?

Answer: - Caution is advised to conduct a thorough HAZOP analysis to evaluate potential hazards related to monitoring and controlling the MOS before making any changes.

FAQ: 4. Why is it important to approach the pump issue with proper engineering and risk assessment?

Answer: - It is crucial to conduct proper engineering and risk assessment to avoid unforeseen complications and disasters while implementing solutions.

FAQ: 5. What are the potential consequences of rushing into a solution without understanding the issue in Brighton?

Answer: - Rushing into a solution without a full understanding of the problem and its consequences could lead to unforeseen complications and hazards.

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