TRAINING MANUAL- PIPING

PIPING STUDY REACTOR PIPING

DOC No. : 29040-PI-UPS-1006 Rev. Page : R0 : 1

Uhde India Limited

CONTENTS Page 0.0 Cover Sheet List of drawings 1.0 2.0 3.0 4.0 5.0 Introduction Design Considerations for Reactors Platform Arrangements Piping Arrangements Key words for Reactor Piping 1 2 3 3-4 4 4-5 5

Applicable Revision: Prepared:

Checked:

Approved:

Date: First Edition: R0 Prepared: AKB

Date: Checked: TNG

Date: Approved: RUD

Date: File Name:

Date: Server:

PUNE: KUMUS 207

Date: VKO: KUMUS 209

TRAINING MANUAL- PIPING

PIPING STUDY REACTOR PIPING

DOC No. : 29040-PI-UPS-1006 Rev. Page : R0 : 2

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LIST OF ILLUSTRATIONS

SR.NO. DWG.NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 RP1 RP2 RP3 RP4 RP5 RP6 RP7 RP8 RP9 RP10 RP11 RP12 RP13 RP14 RP15 RP16 RP17 RP18 RP19 RP20

DESCRIPTION
TYPICAL BATCH REACTOR LAYOUT STANDARD ARRANGEMENT OF REACTOR DESULPHURIZER PROCESS HYDROTREATER PROCESS TYPICAL REACTOR TYPICAL BATCH REACTOR OF A CHEMICAL PLANT PROCESS VESSEL SKETCH OF REACTOR PARTIAL PLOT PLAN FOR A HYDROTREATER UNIT METHODS OF REACTOR SUPPORT MINIMUM REACTOR ELEVATION REQUIREMENTS DIRECT UNLOADING FROM A REACTOR TO A TRUCK TOP HEAD NOZZLE ARRANGEMENTS OF A BATCH REACTOR TOP HEAD NOZZLE ARRANGEMENTS BOTTOM HEAD NOZZLE ARRANGEMENTS SAMPLE PROBE CONNECTION REACTOR PLATFORM AND LADDER ELEVATION REQUIREMENTS SINGLE REACTOR PIPING ARRANGEMENT REACTORS IN SERIES : MANUALLY OPERATED VALVE MANIFOLD REACTORS IN SERIES : REMOTELY OPERATED VALVE MANIFOLD DAVIT AND TROLLEY BEAM ARRANGEMENT ON REACTOR TOP

TRAINING MANUAL- PIPING

PIPING STUDY REACTOR PIPING

DOC No. : 29040-PI-UPS-1006 Rev. Page : R0 : 3

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1.0

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. The top should have access

2.0 2.1

DESIGN CONSIDERATION FOR REACTORS 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. 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.

2.2

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PIPING STUDY REACTOR PIPING

DOC No. : 29040-PI-UPS-1006 Rev. Page : R0 : 4

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

2.4

2.5

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 Nozzle for sample probe connection or the thermowell connection shall be decided keeping the facility for withdrawal space from the shell outside diameter. PLATFORM ARRANGEMENTS Platforms are required for access to valves, instruments, blinds maintenance access, feed openings etc. 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. 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.

2.7

3.0 3.1

3.2

3.3

4.0 4.1

PIPING ARRANGEMENTS 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 inter connection to the related equipment. In refinery type of plant, a single reactor piping arrangement is illustrated in Fig.RP17. 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. 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.

4.2 4.3

4.4

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PIPING STUDY REACTOR PIPING

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Uhde India Limited 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. KEY WORDS FOR REACTOR PIPING 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

5.0 5.1

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 PIPING STUDY REACTOR PIPING

TYPICAL BATCH REACTOR LAYOUT
VENTS

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WATER OUTLET

CONDENSER

WATER INLET

SEPARATOR

AGITATOR

REACTOR

3650

PLATFORM

HEATER CONTROL CUBICLE FLAME PROOF STARTER BOARD FLUSH BOTTOM OUTLET VALVE AIR PURGE FAN CABLE TRAY VACUUM PUMP FINISHED GROUND LEVEL (FGL)

VACUUM RECEIVER

ELEVATION
2350
FLAME PROOF STARTER BOARD CONDENSER AIR BLEED

VACUUM RECEIVER

1850

HEATER CONTROL CUBICLE (UNDER PLATFORM)

VACUUM PUMP

AIR PURGE FAN

PLAN

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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'

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DESULPHURIZER PROCESS

FEED KNOCK OUT DRUM

CATALYST BED (TYPICAL)

INDUCED DRAFT FAN

REFORMER

DESULPHURIZERS

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HYDROTREATER PROCESS

CHARGE FURNACE

FEED

REACTOR

SURGE DRUM

CHARGE PUMPS

FEED EXCHANGERS

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TYPICAL REACTOR
MAINTENANCE ACCESS INLET NOZZLE

INLET BAFFLE

INERT MATERIAL

FLOATING SCREEN

CATALYST BED

TEMPERATURE WELL

(SEE RP15) SUPPORT LUG

SAMPLE PROBE

FIXED GRATING & SCREEN

OUTLET COLLECTOR CATALYST DROP OUT NOZZLE

OUTLET NOZZLE

HANDLE

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TYPICAL BATCH REACTOR OF A CHEMICAL PLANT

N35 ISMC 300 (TYP.) N4 N24 N5 N25 3545 N12 N33 N34 N32 N30 N3 N7 N27 N8 N28 N9 N29 N6 N26 3411

3374

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 N34 - SPARE N35 - SPARE N6 - NOZZLE FOR N26 N26 - PROCESS WATER INLET N13 - NOZZLE FOR N23 N23 - LIQUID INLET

3000

2800 OD

8THK.

1000

5THK. R/L

700

N1A N1 87

10THK. 151

N10 10THK. (TYP.) 10 A 400 (TYP.) 100

160

0.0

400 (TYP.)

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

50x10THK.

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NOZZLE SUMMARY

PROCESS VESSEL SKETCH OF REACTOR

6'-0" I.D. 1830

SYMBOL
A B

SIZE
8" 600#RF 8" 600#RF 3" 600#RF 1" 600#BJ 12" 600#RF 24" 600#RF

SERVICE
INLET OUTLET SAMPLE TEMPERATURE CATALYST DROP OUT MAINTENANCE ACCESS

MA

S T UC MA

UC

2'-0" 610

20'-0" 6100

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PARTIAL PLOT PLAN FOR A HYDROTREATER UNIT

SURGE DRUM

CHARGE PUMPS

ACCESS WAY

CHARGE FURNACE PIPE RACK C L REACTOR FEED EXCHANGERS CATALYST LOADING & UNLOADING AREA

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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)

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MINIMUM REACTOR ELEVATION REQUIREMENTS

REACTOR

CONVEYOR

4'-6"/1370

MINIMUM TO SUIT PIPE SUPPORT or LOW-POINT DRAIN

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DIRECT UNLOADING FROM A REACTOR TO A TRUCK

REACTOR

TRUCK

12'-15' 3650-4600

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TOP HEAD NOZZLE ARRANGEMENTS OF A BATCH REACTOR

LI C L CHEMICAL TOWER (TYP.) VAPOUR OUTLET

LI

C L AGITATOR GEAR BOX MOTOR ASSY.

FEED OPENING

C L BATCH REACTOR

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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

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BOTTOM HEAD NOZZLE ARRANGEMENTS

MINIMUM ONE NOZZLE DIAMETER

REACTOR

KNUCKLE RADIUS TANGENT POINT

BOTTOM OUTLET OPENING CATALYST UNLOADING NOZZLE

BOTTOM OUTLET

OUTLET 9"/230 MIN. OUTSIDE RADIUS

ELEVATION

PLAN

SKIRT SUPPORTED

REACTOR

MINIMUM

4'-0"/1220

CATALYST UNLOADING NOZZLE

OUTLET

OUTLET

ELEVATION

PLAN

LEG SUPPORTED

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SAMPLE PROBE CONNECTION

MESH SCREEN

WITHDRAWAL SPACE

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REACTOR PLATFORM AND LADDER ELEVATION REQUIREMENTS

TOP HEAD PLATFORM VALVE, VENT, TEMPERATURE INSTRUMENT & CATALYST LOADING ACCESS MIN. 10"/250

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

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SINGLE REACTOR PIPING ARRANGEMENT

CHARGE FURNACE

PIPE RACK

REACTOR

CATALYST LOADING & UNLOADING AREA FEED EXCHANGERS

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REACTORS IN SERIES: MANUALLY OPERATED VALVE MANIFOLD

OPERATOR ACCESS

ELEVATION (VIEW-P)

PLAN

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REACTORS IN SERIES: REMOTELY OPERATED VALVE MANIFOLD

ELEVATION(VIEW-P)

PLAN

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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