Reactor+Piping

TRAINING MANUAL- PIPING PIPING STUDY REACTOR PIPING

Uhde India Limited

DOC DOC No. No. : 29040-PI-UPS-1006 Rev.

: R0

Page

:

1

CONTENTS

Page 0.0

Cover Sheet

1

List of drawings

2

1.0

Introduction

3

2.0

Design Considerations for Reactors

3-4

3.0

Platform Arrangements

4

4.0

Piping Arrangements

4-5

5.0

Key words for Reactor Piping

5

App li cab le Rev is io n: Prepared:

Checked:

App ro ved :

Date: First Edition: R0 Prepared: AKB

Date:

Date:

Checked: TNG

App ro ved : RUD RU D

Date: Fi l e Nam e:

Date: Ser v er :

Date: VK O: K UMUS 209

PUNE: K UMUS 207

TRAINING MANUAL- PIPING

Uhde India Limited

PIPING STUDY REACTOR PIPING

DOC DOC No. No. : 29040-PI-UPS-1006 Rev.

: R0

Page

:

2

LIST OF ILL USTRATIONS

SR.NO. DWG.NO.

DESCRIPTION

1

RP1

TYPICAL BATCH REACTOR LAYOUT

2

RP2

STANDARD ARRANGEMENT OF REACTOR

3

RP3

DESULPHURIZER PROCESS

4

RP4

HYDROTREATER PROCESS

5

RP5

TYPICAL REACTOR

6

RP6

TYPICAL BATCH REACTOR OF A CHEMICAL PLANT

7

RP7

PROCESS VESSEL SKETCH OF REACTOR

8

RP8

PARTIAL PLOT PLAN FOR A HYDROTREATER UNIT

9

RP9

METHODS OF REACTOR SUPPORT

10

RP10

MINIMUM REACTOR ELEVATION REQUIREMENTS

11

RP11

DIRECT UNLOADING FROM A REACTOR TO A TRUCK

12

RP12

13

RP13

TOP HEAD NOZZLE ARRANGEMENTS OF A BATCH REACTOR TOP HEAD NOZZLE ARRANGEMENTS

14

RP14

BOTTOM HEAD NOZZLE ARRANGEMENTS

15

RP15

SAMPLE PROBE CONNECTION

16

RP16

17

RP17

REACTOR PLATFORM AND LADDER ELEVATION REQUIREMENTS SINGLE REACTOR PIPING ARRANGEMENT

18

RP18

19

RP19

20

RP20

REACTORS IN SERIES : MANUALLY OPERATED VALVE MANIFOLD REACTORS IN SERIES : REMOTELY OPERATED VALVE MANIFOLD DAVIT AND TROLLEY BEAM ARRANGEMENT ON REACTOR TOP


Uhde India Limited

1.0


DOC No. : 29040-PI-UPS-1006 Rev.

: R0

Page

:

3

INTRODUCTION

Reactors are usually a vertical equipment where various chemical reaction takes place. Very often reactors are having agitators mounted either on top or bottom of the vessel. Reactors may have external jacket or internal coil for any heat transfer requirements. Reactors with agitator, gearbox and motor arrangement make the assembly heavy and vibrating. There are various types of reactors in chemical, fertilizer and refinery plants viz. Batch reactors, Fixed-Bed Reactors, Gas-Fluidized Bed Reactors. Based on the process function, they are called as Desulphurisers, Convertors, Hydrotreaters etc. This piping study is also applicable for equipment called crystallizers, evaporators, thickners etc. 1.1

Batch reactions are often carried out as liquid phase or gas-liquid reactions. These may be carried out at elevated temperature and pressure in horizontal autoclave supported on concrete saddle at low elvevation because of heavy weight. Operation and maintenance access, platform requirements, maintenance facilities are to be considered around the reactors. Operation at floor during process reaction, floor drainage during maintenance, lifting monorail / hoist arrangements, ventilation ducts / hoods provision are some of the common features in the reactor area.

1.2

Fixed-bed reactors are normally loaded with packing or catalyst in bulk between supports inside the reactor vessel or in baskets if the temperature is not critical. When temperature is more critical, the catalyst may be packed within tubes mounted in shell with heating or cooling fluid circulating between shells and tubes. If the catalyst or packing is to be removed from the base, the reactors must be elevated sufficiently to allow removal by mechanical transport equipment. Several reactors, whether in series or parallel should be arranged in line with common support structures and an overhead monorail to serve all the reactors. The same overhead structure may be used for loading catalyst and removing internals.

1.3

The fluidized-bed reactors require handling of solid catalyst or reactant under gravity flow and large quantities of gas, air or liquid used in the reactor. The top of the reactor is occupied by overhead feed hoppers. platform and overhead lifting equipment for removal of internals.

2.0

The top should have access

DESIGN CONSIDERATION FOR REACTORS

2.1

Generally, connections are limited to inlet and outlet, maintenance access, unloading, sample and temperature. A typical batch reactor layout is illustrated in Fig.RP1. A typical horizontal reactor in Fig.RP2 and vertical reactor in Fig.RP5 are illustrated. A typical process flow scheme around reactor is depicted in Fig.RP3, 4. A typical batch reactor of a chemical plant is illustrated in Fig.RP6. Nozzle requirements and overall dimensions of reactor are highlighted on the process vessel sketch Fig.RP7.

2.2

Reactors are located within a process unit adjacent to related equipment with the facilities for catalyst loading and unloading as well as close to furnace to minimize expensive high-temperature piping.


Uhde India Limited



: R0

Page

:

4

2.3

Reactor supports may be a skirt from RCC foundation, lugs from RCC piers, a ring girder from a RCC table top or a skirt from a RCC table top as illustrated Fig.RP9.

2.4

To determine the minimum elevation of reactor (Refer Fig.RP10) the designer shall consult the following document.

2.5

Nozzle arrangements on top of reactor shall be visualised keeping in view of the following considerations. -

Feed material entry method. Additional chemical additions on top of reactor. Support arrangement of agitator / gearbox / motor operation facilities of nozzle valves. Maintenance access to top manhole. Instrument requirements on top head. Nozzle arrangements on top head is illustrated in Fig.RP12, RP13.

2.6

Nozzle arrangements on bottom of the reactor shall be decided based on the following considerations. Bottom product outlet method. Bottom connections to pumping facility. Clear space available between support base unloading of catalyst from nozzle. This is illustrated in Fig.RP11

2.7

Nozzle for sample probe connection or the thermowell connection shall be decided keeping the facility for withdrawal space from the shell outside diameter.

3.0

PLATFORM ARRANGEMENTS

3.1

Platforms are required for access to valves, instruments, blinds maintenance access, feed openings etc.

3.2

Platform elevations are determined by the items that require operation and maintenance and on tall reactors platform elevations are set to accommodate a maximum ladder run of 9m. This is illustrated in Fig.RP16.

3.3

Reactors taller than 9m shall be treated like towers for platform requirements. In case of Reactors, intermediate platforms and ladders are required only for access to temperature instruments, sample probes, catalyst unloading nozzles and maximum ladder runs.

4.0

PIPING ARRANGEMENTS

4.1

Reactor piping shall be arranged in suitable group at Top of steel (TOS) for ease of support. The piping is to be located as per i nter connection to the related equipment.

4.2

In refinery type of plant, a single reactor piping arrangement is illustrated in Fig.RP17.

4.3

In chemical plants, a typical reaction vessel top arrangement is illustrated in Fig.RP12. The nozzles are arranged around the outer zone of the reactor opposite the feed material entry point. The central zone is occupied by the agitator, gearbox and motor mountings.

4.4

The reactors in series with manually operated valve manifold (Refer Fig.RP18) and the reactors in series with remotely operated valve manifold (Refer Fig.RP19) are typical examples with platforms on top of reactors.


Uhde India Limited



: R0

Page

:

5

4.5

The relief valve arrangements on top platform of reactors with Davit or Trolley beam arrangement (Refer Fig.RP20) are typical examples of maintenance provisions.

5.0

KEY WORDS FOR REACTOR PIPING

5.1

Heavy Vessel Support structure (Independent or on reactor) Agitators / Gearbox / Motor assembly Gravity feed Barometric leg NPSH Platform arrangements Maintenance access Manhole Flush bottom valve External Jacket Internal Coil Lifting tools / overhead monorail with chain pulley block / Davit. Flanged head. Vibrations Sight Glass Space for chemical storage Flexible Hose connections Ventilation ducts

5.2

Generally, during piping study around the reactor, the above mentioned keywords should be considered for, as a clue or guideline for finalising the piping and its supports as well as Electrical / Instrumentation requirements.

TRAINING MANUAL - PIPING

DOC NO. : 29040-PI-UPS-1006

PIPING STUDY Uhde India Limited

REACTOR PIPING

Rev.

: R0

Page

: 1 OF 1 DWG. NO. : RP1

TYPICAL BATCH REACTOR LAYOUT VENTS WATER OUTLET

CONDENSER

WATER INLET

AGITATOR

SEPARATOR

REACTOR 0 5 6 3

PLATFORM

HEATER CONTROL CUBICLE FLAME PROOF STARTER BOARD

VACUUM RECEIVER FLUSH BOTTOM OUTLET VALVE

AIR PURGE FAN CABLE TRAY VACUUM PUMP FINISHED GROUND LEVEL (FGL)

ELEVATION 2350 FLAME PROOF STARTER BOARD CONDENSER AIR BLEED

VACUUM RECEIVER 0 5 8 1

HEATER CONTROL CUBICLE (UNDER PLATFORM)

VACUUM

AIR PURGE FAN

PUMP

PLAN


DOC NO. : 29040-PI-UPS-1006


Uhde India Limited

Rev.

: R0

Page

: 1 OF 1 DWG. NO. RP2

STANDARD ARRANGEMENT OF REACTOR

INLET

RELIEF VALVE

LEVEL GAUGE/ CONTROLLER

PRESSURE GAUGE

VENT

VAPOUR OUTLET

MANHOLE

THERMOWELL

STEAM OUT CONNECTION SADDLES LIQUID OUTLET

DRAIN

1/5`L'

3/5`L'

1/5`L'



REACTOR PIPING

DOC NO. : 29040-PI-UPS-1006 Rev.

: R0

Page

: 1 OF 1 DWG. NO. : RP3

DESULPHURIZER PROCESS

FEED KNOCK OUT DRUM

CATALYST BED (TYPICAL)

INDUCED DRAFT FAN

DESULPHURIZERS

REFORMER


DOC NO. : 29040-PI-UPS-1006


Uhde India Limited

Rev.

: R0

Page

: 1 OF 1 DWG. NO. : RP4

HYDROTREATER PROCESS

CHARGE FURNACE

REACTOR

FEED

SURGE DRUM

CHARGE PUMPS

FEED EXCHANGERS


DOC NO. : 29040-PI-UPS-1006


REACTOR PIPING

Rev.

: R0

Page

: 1 OF 1 DWG. NO. : RP5

TYPICAL REACTOR MAINTENANCE ACCESS INLET NOZZLE

INLET BAFFLE

INERT MATERIAL

FLOATING SCREEN

CATALYST BED

TEMPERATURE WELL

(SEE RP15)

SAMPLE PROBE

SUPPORT LUG

FIXED GRATING & SCREEN

OUTLET COLLECTOR CATALYST DROP OUT NOZZLE

HANDLE

OUTLET NOZZLE



Uhde India Limited


: R0

Page

: 1 OF 1 DWG. NO. : RP6

TYPICAL BATCH REACTOR OF A CHEMICAL PLANT N35 ISMC 300 (TYP.) N4 N24 N5 N25

3374

N12

N33

N34

N7 N27

N32

N8 N28

N30

N9 N29

N3

N6 N26

3545

3411

3195

NOZZLE DESCRIPTION : N1 - NOZZLE FOR TIR N1A - NOZZLE FOR N1 N3 - WASTE GAS OUTLET N4 - NOZZLE FOR 24 N5 - NOZZLE FOR 25 N7 - NOZZLE FOR 27 N8 - NOZZLE FOR 28 N9 - NOZZLE FOR 29 N10 - PRODUCT OUTLET N12 - MANHOLE N24 - STEAM INLET N25 - STEAM INLET N27 - NaOH INLET N28 - HCL INLET N29 - NaNO2 INLET N30 - ICE INLET N32 - SPARE N33 - AGITATOR NOZZLE

0 0 0 3

2800 OD

8THK.

N34 - SPARE N35 - SPARE N6 - NOZZLE FOR N26

5THK. R/L

1000

N26 - PROCESS WATER INLET N13 - NOZZLE FOR N23 N23 - LIQUID INLET 0 0 7

N1A N1 7 8

. K H T 1 0 5 1 1 0 6 1

A

N10

10THK. (TYP.)

0.0 A

400 (TYP.)

400 (TYP.)

SECTION `A-A' * NOTE : NOZZLE ELEVATIONS INCLUDING R/L THICKNESS TOP COVER IS PANEL TYPE CONSTRUCTION.

50x10THK.

0 1

0 0 1


DOC NO. : 29040-PI-UPS-1006


Uhde India Limited

Rev.

: R0

Page

: 1 OF 1 DWG. NO. : RP7

NOZZLE SUMMARY

PROCESS VESSEL SKETCH OF REACTOR 6'-0" I.D. 1830

A

MA

SYMBOL

SIZE

SERVICE

A

8" 600#RF

INLET

B

8" 600#RF

OUTLET

S

3" 600#RF

SAMPLE

T

1" 600#BJ

TEMPERATURE

UC

12" 600#RF

CATALYST DROP OUT

MA

24" 600#RF

MAINTENANCE ACCESS

" 0 0 - 0 ' 0 1 2 6

T

S

" 0 0 - 1 ' 2 6

UC

B



Uhde India Limited


: R0

Page

: 1 OF 1 DWG. NO. : RP8

PARTIAL PLOT PLAN FOR A HYDROTREATER UNIT

SURGE DRUM

CHARGE PUMPS

ACCESS WAY

CHARGE FURNACE PIPE RACK R O T C A E R L C

FEED EXCHANGERS

CATALYST LOADING & UNLOADING AREA


DOC NO. : 29040-PI-UPS-1006


REACTOR PIPING

Rev.

: R0

Page

: 1 OF 1 DWG. NO. : RP9

METHODS OF REACTOR SUPPORT

REACTOR

REACTOR

SKIRT

CONCRETE PIERS

a. SKIRT SUPPORTED (FOUNDATION)

b. LUG SUPPORTED

STEEL STRUCTURE REACTOR (TYP.) RING GIRDER

SKIRT

CONCRETE TABLE TOP

CONCRETE TABLE TOP

c. RING GIRDER SUPPORTED

d. SKIRT SUPPORTED (TABLE TOP)


DOC NO. : 29040-PI-UPS-1006


REACTOR PIPING

Rev.

: R0

Page

: 1 OF 1 DWG. NO. : RP10

MINIMUM REACTOR ELEVATION REQUIREMENTS

REACTOR

CONVEYOR

0 7 3 1 / " 6 ' 4

MINIMUM TO SUIT PIPE SUPPORT or LOW-POINT DRAIN



Uhde India Limited


: R0

Page

: 1 OF 1 DWG. NO. : RP11

DIRECT UNLOADING FROM A REACTOR TO A TRUCK

REACTOR

TRUCK

0 ' 0 5 6 1 - 4 ' 2 0 1 5 6 3


DOC NO. : 29040-PI-UPS-1006


REACTOR PIPING

Rev.

: R0

Page

: 1 OF 1 DWG. NO. : RP12

TOP HEAD NOZZLE ARRANGEMENTS OF A BATCH REACTOR

LI CL CHEMICAL TOWER (TYP.)

VAPOUR OUTLET

LI

C L AGITATOR GEAR BOX MOTOR ASSY.

CL BATCH REACTOR

FEED OPENING


DOC NO. : 29040-PI-UPS-1006


Uhde India Limited

Rev.

: R0

Page

: 1 OF 1 DWG. NO. : RP13

TOP HEAD NOZZLE ARRANGEMENTS

MAINTENANCE ACCESS

INLET NOZZLE NOZZLE PROJECTION ABOVE PLATFORM MIN. 250MM

ELEVATION

PLAN

INLET NOZZLE MAINTENANCE ACCESS

4"/100 MIN.

ELEVATION

PLAN



Uhde India Limited


: R0

Page

: 1 OF 1 DWG. NO. : RP14

BOTTOM HEAD NOZZLE ARRANGEMENTS

MINIMUM ONE NOZZLE DIAMETER

REACTOR

BOTTOM OUTLET OPENING

KNUCKLE RADIUS TANGENT POINT

BOTTOM OUTLET

CATALYST UNLOADING NOZZLE

OUTLET 9"/230 MIN.

OUTSIDE RADIUS

ELEVATION

PLAN

SKIRT SUPPORTED

REACTOR

CATALYST UNLOADING NOZZLE

OUTLET

0 M 2 2 U 1 M / " I 0 I - N ' 4 M

ELEVATION

OUTLET

PLAN

LEG SUPPORTED



REACTOR PIPING


; R0

Page

: 1 OF 1 DWG. NO. : RP15

SAMPLE PROBE CONNECTION

MESH SCREEN

WITHDRAWAL SPACE



REACTOR PIPING


: R0

Page

: 1 OF 1 DWG. NO. : RP16

REACTOR PLATFORM AND LADDER ELEVATION REQUIREMENTS

TOP HEAD PLATFORM VALVE, VENT, TEMPERATURE INSTRUMENT & CATALYST LOADING ACCESS 0 5 2 / " 0 1 . N I M

TEMPERATURE INSTRUMENT ACCESS BY LADDER OR PLATFORM

INTERMEDIATE PLATFORM TO SUIT MAXIMUM LADDER RUN

SAMPLE CONNECTION ACCESS BY PLATFORM

CATALYST UNLOADING ACCESS FROM GRADE OR PLATFORM



Uhde India Limited


: R0

Page

: 1 OF 1 DWG. NO. : RP17

SINGLE REACTOR PIPING ARRANGEMENT

CHARGE FURNACE

PIPE RACK

REACTOR

CATALYST LOADING & UNLOADING AREA FEED EXCHANGERS



REACTOR PIPING


: R0

Page

: 1 OF 1 DWG. NO. : RP18

REACTORS IN SERIES: MANUALLY OPERATED VALVE MANIFOLD

OPERATOR ACCESS

ELEVATION (VIEW-P)

P

PLAN



REACTOR PIPING


: R0

Page

: 1 OF 1 DWG. NO. : RP19

REACTORS IN SERIES: REMOTELY OPERATED VALVE MANIFOLD

ELEVATION(VIEW-P)

P

PLAN



REACTOR PIPING


: R0

Page

: 1 OF 1 DWG. NO. : RP20

DAVIT ARRANGEMENT ON REACTOR TOP RELIEF VALVES

LOADING NOZZLE

DAVIT LOADING AND UNLOADING AREA

TROLLEY BEAM ARRANGEMENT ON REACTOR TOP RELIEF VALVES

LOADING NOZZLE

TROLLEY BEAMS

LOADING AND UNLOADING AREA

Reactor+Piping

Recommend Documents