BASIC ENGINEERING ( Incl Design Calculations)

8/10/2019 BASIC ENGINEERING ( Incl Design Calculations)

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Document No: D/D&P/PRO/G/06 rev 1 w.e.f. 16/9/98

GUIDELINES FOR BASIC ENGINEERING

(Incl. Design Calculations)

Basic engineering includes te !ollo"ing acti#ities$

a) Stud% te DOB

b) &re'are te scee

c) Batc tie c%cle !inaliation * +aterial ,alance

d) &re'are te &FD

e) &re'are te Conce'tual la%out

f) &re'are te e-ui'ent s'eci!ications

) &re'are te &ID

!) &re'are te I&DS (Incl. ON/OFF #al#es)0 RD*SR1 data seet

") &re'are te oter docuents# $"ne%"t' erv"ce %"t' Dr"ve %"t' (ff%uent data' R / *t"%"t+ca%cu%at"on etc)

,) &re'are te O'eration anual and Logic

-) Coissioning o! te 'lant

2. S3UD4 35E DOB.

tud+ t!e DO. "tne t!e e2er"ment carr"ed out "n t!e $ab and/or and d"cu

w"t! R&D / 3utomer to conf"rm t!e undertand"n.

3!ec- for an+ m"matc! between t!e data "n t!e ent"re DO and et "t corrected

b+ R&D.

3!ec- for an+ m""n "nformat"on a re4u"red for en"neer"n and et "t from

R&D

!"%e 2re2ar"n a22ra"a%' for cot"n of P%ant / "nd"v"dua% e4u"2ment / "tem' $5Ndata " ued.

6. &RE&ARE 35E SC5E+E

$"t out t!e -e+ e4u"2ment. $"t out t!e ma,or o2erat"on / te2 and ubte2.

5%%ocate t!ee o2erat"on to t!e -e+ e4u"2ment.

7. BA3C5 3I+E C4CLE FINALI8A3ION * +A3ERIAL BALANCE

- 5ume batc! t"me c+c%e for eac! -e+ e4u"2ment.- 7"nd batc! "e con"der"n P%ant ca2ac"t+ and "e%d # Overa%% and 2er

2a) and atc! t"me c+c%e.

-

atc! "e c!ane from one -e+ e42t to net !ou%d be tud"ed carefu%%+.#3!ec- w!et!er uc! "e c!ane w"%% be 2ract"ca%' e.. %urr+

"ntermed"ate 2%"tt"n from ; batc!e to < batc!e.) =f necear+ correct /"ncreae t!e batc! "e accord"n%+.

- 3a%cu%ate t!e e4u"2ment "e for t!e batc! "e from t!e DO data and

e%ect a22ro2r"ate "e from t!e tandard e4u"2ment "e ava"%ab%e #Refer

e4u"2ment 2ec"f"cat"on ect"on for tandard "e). e%ect t!e re4u"red"e "n cae tandard " not ava"%ab%e /u"tab%e.

- 3a%cu%ate t!e actua% t"me re4u"red for atc! ta-"n "nto account 10 >

mar"n. # for !uman factor' batc! to batc! 2erformance var"at"on etc.)


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- 3!ec- w!et!er t!e aumed and ca%cu%ated t"me c+c%e " matc!"n. =f

not' re2eat t!e above te2 t"%% t!ee matc!.- =n cae t!e e4u"2ment "e " too !"!' more e4u"2ment "n 2ara%%e% can be

con"dered.- ?!ee ca%cu%at"on !ou%d 2referab%+ be done "n (@3($ to fac"%"tate

c!ec- of an+ ot!er a%ternat"ve.

3ON?=N*O* PRO3(.=n cae of a cont"nuou 2%ant a deta"%ed f%ow!eet w"t! tream no added

" to be ued and mater"a% ba%ance #3om2onent w"e) " to be 2re2ared.

9. &RE&ARE 35E &FD

Pre2are t!e P7D a 2er t!e u"de%"ne and fo%%ow"n "nformat"on:

5fter t!e -e+ e4u"2ment and t!e"r "e are dec"ded' 2re2are t!e P7D. !ow a%%e4u"2ment around t!ee -e+ e4u"2ment ta-"n "nto account t!e fo%%ow"n:

- Raw mater"a% u22%+ 2ac-a"n- Product 2!+"ca% 2ec

-3o%%ect"on' torae ' !and%"n and rec+c%e/ d"2oa% of a%% tream # ?r+ toue rav"t+ t!an 2um2"n/ 2reure or vacuum tranfer)

- o%"d !and%"n # Aee2 %urr+ / o%"d !and%"n to t!e m"n"mum b+ re

%urr+"n' d"o%v"n "n "tu after "o%at"on' etract"on etc)- Bent crubber' condener' !"! %eve% vent"n / d"%ut"on

- Re4u"red catc! 2ot / ea% to avo"d m""n / contact w"t! e42t w"t!

d"fferent O3.- =ntermed"ate cut- torae for countercurrent wa!e

- ?ra2 for t!e eff%uent- e"!"n / account"n re4u"rement- Dum2 reactor / tan-

:. CONCE&3UAL LA4OU3

Pre2are t!e conce2tua% %a+out a 2er t!e u"de%"ne.

;. &RE&ARE 35E E


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d) 5eotro2"c Databoo- ' $ee ore%+.

e) ?!e Pro2ert"e of Gae & $"4u"d ' 7ourt! (d"t"on' Robert 3. Re"d'

Eo!n . Praun"t' ruce (. Po%"n.

f) 3om2uter 5"ded Databoo- of Ba2or $"4u"d (4u"%"br"um ' "rata "tu!o'

O!e !uo & Naa ama.

=n cae data " not ava"%ab%e t!en tud+/ ue t!e e2er"menta% data from $ab.

De"n of var"ou e4u"2ment !ou%d be done a 2er t!e reference / u"de%"ne

ment"oned be%ow :

?P( O7 (FP? R(7(R(N3( / G*=D($=N( 7OR5? No

Reactor Anne=ure I D/D&P/PRO/7/03o%umn Anne=ure II

3entr"fue Anne=ure III D/D&P/PRO/7/0 f"%%"n ma D/D&P/PRO/7/08Ot!er e42t 5 2er %"terature data D/D&P/PRO/7/0. &ID &RE&ARA3ION

P&=D !ou%d be 2re2ared a 2er t!e u"de%"ne and after ta-"n "nto account t!e

fo%%ow"n :

- $eend document !ou%d be 2re2ared for eac! 2ro,ect !ow"n t!e

+mbo% ued "n t!e P&=D. 5 %eend draw"n 2re2ared for P009 to beenera%%+ fo%%owed.

- O3 of 2"2"n etc !ou%d be ,ud"c"ou%+ dec"ded to -ee2 t!e cot to t!em"n"mum and ta-"n "nto account t!e corro"on data a ava"%ab%e from t!e

DO and 3orro"on Re"tance ?ab%e' ?!"rd (d"t"on' Part 5 and '

P!"%"2 5. c!we"ter

3orro"on u"de b+ (r"c! Raba%d- One +tem !ou%d 2referab%+ be 2rov"ded w"t! "n%e O3' !owever

va2or / vent e4ua%"at"on %"ne can !ave a d"fferent 2ec.- ?a-e "nto account effect of mo"ture "nre b+ an+ mean on O3

e%ected.- P"2"n 2ec !ou%d be e%ected from t!e ava"%ab%e td 2ec and ued. =n

cae of nonava"%ab"%"t+ of u"tab%e 2ec' 7$*=D erv"ce %"t !ou%d be

"ued to P=P for t!e"r recommendat"on on u"tab%e 2ec to be ued.- Refer D and 2ro2ert"e data to dec"de t!e 3onduct"v"t+ tr"2 # for

tat"c e%ectr"c"t+ 2rob%em) and 7%ane uard # 7or !aardou / !ot f%u"d)

re4u"rement.- Prov"de var"ou afet+ adet %"-e 7%ame arretor' RD' RB' ?RB' Ga

detector etc #mo-e and !eat detector' 7"re a%arm +tem are to be2rov"ded but not to be ment"oned "n t!e P&=D)

- Prov"de ade4uate 2"2"n connect"on to ta-e care of an+ 2robab%e

abnorma% o2erat"on and rec+c%e / re2roce"n of t!e off 2ec mater"a%.


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- Prov"de ade4uate %oca% / 2ane% "ntrument' "!t %ae' and 2ro2er t+2e

of manua% va%ve at 2ro2er %ocat"on o a to fac"%"tate moot! o2erat"on

from f"e%d / 2ane%.- $oca% "ntrument !ou%d be 2rov"ded to croc!ec- t!e Pane% "ntrument

and to contro% of o2erat"on from t!e f"e%d "n ece2t"ona% cae.

- Preure aue to be 2rov"ded on team "n ,ac-et' 2reure and return

tem2 of coo%"n/!eat"n med"a to ae t!e 2erformance of !eat"n /

coo%"n o2erat"on- 5de4uate "o%at"on va%ve to be 2rov"ded for eac! e4u"2ment or a rou2

of e4u"2ment to "o%ate t!em "n cae of emerenc+.- %urr+ 2"2"n !ou%d be con"dered cr"t"ca%%+ for rout"n 2ec"f"ed' va%ve

and "ntrument or an+ ot!er "tem 2ec"f"ed "n t!e 2"2"n. Prov""on forc%ean"n !ou%d a%o be con"dered.

- 5de4uate dra"n and vent !ou%d be 2rov"ded to fac"%"tate 2ro2er

c%ean"n / dra"n"n of t!e +tem.- Eac-ett"n / trac"n re4u"rement !ou%d be carefu%%+ tud"ed / 2rov"ded.

5ct"on 2%an "n cae of ,ac-ett"n / trac"n " not ued # b+ m"ta-e) !ou%d

a%o be t!ou!t of and "ncor2orated.- * ea% #=nc%. "nverted) !ou%d be 2ec"f"ed w!erever re4u"red to avo"d

m"u2 / bac-f%ow.

-%o2e and non!o%d u2 %"ne re4u"rement !ou%d be cr"t"ca%%+ tud"ed and2ec"f"ed.

- 3!ec- va%ve / catc! 2ot to be 2rov"ded to avo"d revere f%ow.- tra"ner re4u"rement to be tud"ed to avo"d fore"n mater"a% "nre from

e42t to / G$ aemb%"e OR to tra2 o%"d.

- Bent"n %ocat"on !ou%d be 2ro2er%+ 2ec"f"ed for afet+.- %"nd !ou%d be 2rov"ded on var"ou no%e / va%ve to avo"d an+

%ea-ae to atmo2!ere of ?o"c mater"a%.- N"troen b%an-et"n / Bacuum connect"on to be 2rov"ded a re4u"red.

- $"ne ""n "n a batc! 2%ant " not o cr"t"ca% due to cu!"on ava"%ab%e "nt!e t"me c+c%e from ot!er act"v"t"e. owever' "t !ou%d be done a 2er

ANNE?URE 1IIIand t!e comment "ven be%ow :

5%% %"ne #ece2t team) !ou%d 2referab%+ be I N "e m"n"mum.

?ranfer %"ne to be "ed a 2er t!e t"m"n ava"%ab%e "n t"me c+c%e and I;

/ec #%"4u"d) ve%oc"t+. Grav"t+ tranfer and %urr+ tranfer to be at J0.6

/ec ve%oc"t+. ?ranfer t"me !ou%d enera%%+ be -e2t be%ow 1 !r.team %"ne to be "ed at 101 /ec ve%oc"t+.

Bent e4ua%"at"on / vent %"ne can be of I/


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@ &RE&ARE I&DS * RD*SR1 DA3A S5EE3

RD/RB data !eet to be 2re2ared a 2er t!e 2rocedure "ven "n.Anne=ure 1II

=PD to be f"%%ed "n t!e 2recr"bed format a 2er t!e e2%anator+ note.

&RE&ARE 35E O35ER DOCU+EN3S # $"ne%"t' erv"ce %"t' Dr"ve %"t' .

. (ff%uent data' (ner+ ba%ance' R / *t"%"t+ ca%cu%at"on etc)

Pre2are t!ee document "n 2recr"bed format a a22%"cab%e a 2er e2%anator+ note.R ca%cu%at"on !ou%d !ave reference to DO data. #Preferab%+ to be done "n (@3($ to c!ec- .

. t!e var"at"on "n DO ea"%+) . 7o%%ow"n norm to be ued for o%vent %oe ca%cu%at"on :

?P=35$O$B(N? K

O2erat"on "nvo%ved

et!ano% ?o%uene /

@+%ene

Genera% !and%"n 1 1

Bac d"t"%%at"on

5tm d"t"%%at"on ;

7"%terat"on ;

(tract"on I I

2 &RE&ARE O&ERA3ION +ANUAL AND LOGIC : ?o be 2re2ared a 2er t!e u"de%"ne.

$o"c re4u"rement !ou%d be "n %"ne w"t! t!e O2erat"on manua%.

11 CO++ISSIONING OF 35E &LAN3 : ?o be done a 2er t!e u"de%"ne

1I LIS3 OF ADDI3IONAL I+&OR3AN3 REFERENCES

( A#aila,le in Li,rar%)

a) 522%"ed Proce De"n for 3!em"ca% & Petroc!em"ca% P%ant Bo%. 1/I/;'

econd (d"t"on' (rnet (. $udw".

b) a ?ranfer O2erat"on' econd (d"t"on' Robert ?re+ba%.

c) 3ou%on & R"c!ardonC 3!em"ca% (n"neer"n Bo%. 6 # De"n ) '

econd (d"t"on' R. A. "nnott.

d) (nc+c%o2ed"a of 3!em"ca% ?ec!no%o+' 7ourt! (d"t"on' A"r- Ot!mer.

e) *%%mannC (nc+c%o2ed"a of =ndutr"a% 3!em"tr+' 7"ft! (d"t"on.

LLLLLLLLLLLLLLLL


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ANNEXURE I

(Prepared by KSS)

REAC3OR

+S SS reactorsMS/GL reactorsMS/LB, MS/LB/TL, MS/R!E/TL, MS/"TL reactors

MS # SS reactors

a) Ca'acit% 7or ca%cu%at"on c%"c- Ca'acit% cart

aed on t!e batc! "e & react"on ma vo%ume t!e ca2ac"t+ of t!e reactor " dec"ded. ?!e R. vo%ume "

ava"%ab%e from R & D "n t!e DO. ?!e "e " dec"ded baed on t!e ca2ac"t+ of t!e 2%ant.

7or a "ven "e t!e vo%ume of R.' %"t. M a R. vo%ume #%"t/-m) "e #-m).

7rom t!" vo%ume of t!e react"on ma t!e u"tab%e reactor " e%ected from t!e G3$ tandard.

tandard reactor "n G3$

f"%%"n " c!ec-ed.

Bo%. R. L100

> 7"%%"n M Nom"na% ca2. of reactor

?!e > f"%%"n c!oen " 80 > to tart w"t! but "t can be a !"! a 90 > baed on t!e G3$ tandard reactor.

7or react"on "nvo%v"n a 2ar"n t!e > f"%%"n !ou%d be more H80 > for a 2ace. 7or wa!"n /

etract"on "t can be a !"! a 9 > even "n ome cae.

b) M$" se%ect&o'

MOC is selected based on the information given in the DOB. If the information is ambiguous theactual corrosion study should be done by corrosion lab (Activities to be co-ordinated by R D ! actual corrosion data to be furnished. "he reaction mi#ture contains so many com$onents in it

that the reference can not be ta%en from boo%s also in most of the cases. &o corrosion study ismust. If the $rocess is to be fitted in the e#isting $lant 'hich is having some eui$ment then thecorrosion study should be done for the MOC of the said eui$ment to certify its suitability.
http://smb//Vmv/iso%20document/process%20Guidelines/Ref%20documents/MS-SS%20VESSELSL.xls#A1http://smb//Vmv/iso%20document/process%20Guidelines/Ref%20documents/MS-SS%20VESSELSL.xls#A1


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c) A&tator des&'

"he design of the agitation system involves)

Se%ect&o' o type o a&tator*ec&d&' s+eep*ec&d&' RPM"a%c%at&o' o %&d po+er"a%c%at&o' o -otor .P / Motor se%ect&o'S&&' / Se%ect&o' o ear bo0Se%ect&o' o p%%eys # be%t

Selection o! t%'e o! agitator

?!e t+2e of a"tator " dec"ded baed on t!e t+2e of a22%"cat"on. Bar"ou t+2e of a"tator & t!e"r

comb"nat"on are ued.

&addle$

I b%aded 2add%e are ued ma"n%+ for b%end"n o2erat"on. ?!e wee2 " norma%%+ 6080 >. Padd%ema+ be ued w"t! or w"t!out baff%e. =f baff%e are 2rov"ded "t w"%% "ve ood "ntene a"tat"on &

vorte format"on w"%% be m"n"m"ed. ("t!er I or < baff%e are ued. Padd%e ma+ be tra"!t or

2"tc!ed #


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+ulti'le agitator:

=n t!" var"ou -"nd of a"tat"on " 2o"b%e de2end"n u2on t!e met!od of "nta%%at"on. =n t!e

reactor ued "n G3$ fo%%ow"n comb"nat"on can be ac!"eved b+ 2ro2er f""n of "m2e%%er. 60 > & H0 > 2add%e' no baff%e.

60 > & H0 > 2add%e' I baff%e or < baff%e.

80 > taered doub%e ate anc!or' no baff%e.

d"c turb"ne' < baff%e.

H0 > 2add%e "n%e ate anc!or' I baff%e.

(am2%e of ome of t!e 3%'ical Agitatorsued are:

6 b%aded f%at b%ade d"c turb"ne " ued "n G3$ for =P condenat"on. ?!e D5 a " 2ared

"n 2cum"d"ne. < baff%e are ued.

6 b%aded f%at b%ade d"c turb"ne " ued for 3+2ermet!r"n condenat"on' ?eme2!o

condenat"on' Na2ro2am"de condenat"on react"on "n G3$. ?!ee react"on are between

a4ueou & oran"c 2!ae w"t! t!e !e%2 of 2!ae tranfer cata%+t. Ber+ "ntene a"tat"on "

re4u"red w!"c! d"c turb"ne " 4u"te ca2ab%e of 2rov"d"n. 80 > taered doub%e ate anc!or " ued for I 3 cr+ta%%"at"on "n 353 2roce' =P

cr+ta%%"at"on etc. Padd%e are ued for d"t"%%at"on o2erat"on.

3omb"nat"on of f%at b%ade d"c & 2"tc!ed turb"ne " ued "n !+droenat"on of veetab%e o"%.

?!" react"on " done u"n rane+ n"c-e% cata%+t. +droen a " 2ared "nto t!e veetab%e

o"%. ?!e f%at b%ade d"c turb"ne " ued for effect"ve d"2er"on of !+droen "n o"%. ?!e 2"tc!ed

turb"ne " ued for u2end"n t!e rane+ n"c-e% cata%+t o%"d. ?!e bottom 2"tc!ed turb"ne "u2ward f%ow t+2e & to2 one " of downward f%ow t+2e. ?!e react"on " ; 2!ae react"on

"nvo%v"n a%"4u"do%"d.

=n ome of t!e a22%"cat"on t!e 2art"cu%ar ue " 2%a+"n "n"f"cant ro%e "n t!e ver+ e%ect"on

of t!e a"tator. 7or eam2%e "n I 3 2re2arat"on "n 353 2roce 2rev"ou%+ mu%t"2%e

a"tator wa ued w!ere d"c turb"ne wa etended w"t! b%ade to ma-e 2add%e. ?!ee b%ade

were connected w"t! vert"ca% to ma-e ate anc!or. =n t!e react"on ome tarr+ mater"a% wa

enerated. efore tart"n net batc! t!e vee% need to be wa!ed ver+ t!orou!%+. ?!e tar

ued to t"c- on t!e d"c turb"ne & wa!"n became rea% 2rob%em. 7or t!" reaon t!e "dea ofmu%t"2ur2oe a"tator wa dro22ed for t!" 2art"cu%ar a22%"cat"on. tandard doub%e ate anc!or

wa made & "nta%%ed. o "n t!" cae t!e ver+ 2roce " 2%a+"n ver+ "n"f"cant ro%e "n

overn"n t!e a"tator t+2e.

3erinolog%s used in agitation

wee2:

=t " t!e rat"o of out"de d"ameter of "m2e%%er to t!e "n"de d"ameter of t!e vee% e2reed a t!e

2ercentae. =f t!e vee% d"a " 100 mm and "m2e%%er d"a " 600 mm t!e wee2 " .

RP:

=t " t!e revo%ut"on 2er m"nute t!e !aft ma-e.

Power 2er un"t vo%ume:=t " t!e 2ower "n2ut to t!e %"4u"d 2er un"t vo%ume of t!e %"4u"d.


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Power number:

=t " a contant & c!aracter"t"c of a "ven t+2e of "m2e%%er. ?!e 2ower number c!art " "ven "n t!e

ca%cu%at"on 2roram.

* + gc + ,

--------------------------------------/ w!ere + 0111 + (2341!5+ D

6 Power number* =n2ut f%u"d 2ower' Pgc 5cce%erat"on due to rav"t+' 9.8 m/ec

Den"t+ of %"4u"d' m/cc

2 RPD wee2 of t!e "m2e%%er' m

av"n -nown t!e 2ower number for 2art"cu%ar a"tator t!e 2ower re4u"red can be ca%cu%ated.

$/D rat"o:

=t " t!e rat"o of t!e %"4u"d !e"!t to t!e d"a of t!e vee%.

Deciding sweep

?!e wee2 " dec"ded b+ t!e a"tator t+2e.

Deciding RPM

=t " dec"ded u"n var"ou ca%e u2 ca%e down cr"ter"a' t+2e of a22%"cat"on.

ome of t!e ca%e u2 cr"ter"a are:

Constancy of power per unit volume.

?!" " t!e cr"ter"a ver+ uefu% & ued "n more t!an 90 > of t!e cae. =f we -now t!e t+2e ofa"tator "n one vee% & "t RP t!e RP of ot!er eometr"ca%%+ "m"%ar vee% can be

determ"ned.

* * --- ---

7 0 7 8

7rom 2ower number formu%a

* + gc + ,

--------------------------------------

+ 0111 + (2341!5+ D

.

. . * 25 D

.. . 20

5D0 28

5D8

--------- ---------- 70 78 035

205D0

70 28 ---------------

70D8


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Constancy of tip speed.

?!" " ued ma"n%+ for react"on. ?o tart w"t! ome va%ue of t"2 2eed " ta-en uc! a 800

900 ft/m"n. for react"on "nvo%v"n a 2ar"n "n %"4u"d. aed on t!" t!e RP " ca%cu%ated.

7rom t!" RP ca%e down " done to %ab ca%e. (2er"ment are conducted "n %ab var+"n

ome 2arameter. ?!e bet reu%t obta"ned "n %ab are aa"n ca%ed u2 to 2%ant ca%e.

7 r, w!ere

7 ?"2 2eed "n ft/m"n.

r wee2/I

5nu%ar 2eed

8

---- 8

"

.

. . 7 8r 2 D2/ D M wee2

2 M RP

70 78.

. . D020 D828 D0

28 ---- + 20

D8

Constancy of Reynolds number

?!" cr"ter"a " ued ma"n%+ for !eat tranfer 2ur2oe uc! a "n a22%"cat"on %"-e

cr+ta%%"at"on' d"t"%%at"on etc. ?!e overa%% !eat tranfer coeff"c"ent con"t of "n"de &

out"de !.t.c. ?!e out"de !.t.c " contant de2end"n on t!e f%ow rate of ut"%"t+ f%u"d "n t!e

,ac-et / %"m2et of t!e vee%. ?!e "n"de !.t.c " d"rect%+ 2ro2ort"ona% to ome 2ower ofRe+no%d number.

D82

Re --------- / w!ere

Re Re+no%d numberD wee2' cm2 RP # revo%ut"on 2er econd )

Den"t+' m/cc

B"co"t+' 2o"e.

Re0 Re8.. . D0

820 1 D88282

------------ ------------

1 2

. D082008

. . 28 -------------- RP

D8881


11/55

"a%c%at&o' o %&d Po+er 6or calculation clic%----A&tator ca%c%at&o'

av"n ca%cu%ated t!e re4u"red RP baed on t!e a22ro2r"ate ca%e u2 cr"ter"a 2ower can be

ca%cu%ated.

*gc + , -----------------------------

+ 0111 + ( 2341!5 D

. f + r + 0111 + (23041!5 + D

. . * --------------------------------------- 9* / w!ere , + :.;0

* 7%u"d 2ower' P

Power number

Den"t+' m/cc

2 RP

D M wee2of im$eller/ m"a%c%at&o' o -otor .P / -otor se%ect&o'

?o t!e f%u"d 2ower ca%cu%ated var"ou %oe added uc! a fr"ct"ona% %o "n bottom u"de' !afttranm""on %oe' ear bo %o' be%t fr"ct"on %o etc. ?!e ca%cu%at"on " !own "n t!e ca%cu%at"on

2roram.

5fter ca%cu%at"n t!e motor P u"tab%e motor " e%ected for t!e re4u"red dut+. ?!e P of t!e

tandard motorC are:0.' 1.0' 1.' I' ;' ' H.' 10' 1I.' 1' I0' I' ;0'


12/55

Out2ut RP of ear

Reduct"on rat"o of ear M =n2ut RP to ear

=n G3$ mot of t!e ear ued are of Rad"con ma-e. P%anetar+ ear !ave a%o been ued of

reven" ma-e. ?!e are !"! 2eed ear w!"c! "ve ver+ !"! eff"c"enc+ com2ared to worm ear.

Se%ect&o' o p%%eys # be%t

7rom 2u%%e+ c!art t!e 2ower carr+"n ca2ac"t+ of 2u%%e+ " "ven. Number of roove " dec"dedbaed on t!e 2ower carr+"n ca2ac"t+ 2er be%t after a22%+"n var"ou correct"on factor uc! a

%"22ae etc. aed on 2ower carr+"n ca2ac"t+ var"ou ect"on of 2u%%e+ come.

*2to 10 P : 5C ect"on 2u%%e+10I0 P : C ect"on 2u%%e+

I0 P & above : 3C ect"on 2u%%e+

7enner ma-e 2u%%e+ are ver+ common & !ave ot %ot of f%e"b"%"t+. =t !a ot two 2art 2u%%e+ &

bu!. + c!an"n t!e bu!e ame 2u%%e+ can be ued for var"ou a22%"cat"on. =n 3C ect"on2u%%e+ m"n"mum < roove come.

Pu%%e+ are norma%%+ de"nated a: I00;' I;63


13/55

carbon be"n ood conductor of !eat. =n ome of t!e t"%e %"ned vee% w!ere !eat tranfer " rea% 2rob%em

!eat " removed b+ ref%u condener.

ANNEXURE II

#Prepared by !R a'd PGB)

Design o! Fractionation S%stes

7ract"onat"on +tem re2reent a ma,or com2onent of c!em"ca% 2roce 2%ant ."nce %are vo%ume of

2ub%"!ed data are ava"%ab%e de"n of d"t"%%at"on +tem e%dom re4u"re 2"%ot 2%ant tud"e.

De"n of fract"onat"on co%umn "nvo%ve t!e fo%%ow"n :

3a%cu%at"on of number of tae

3a%cu%at"on of !e"!t of co%umn

+drod+nam"c

I) Calculation of number of stages:Determ"nat"on of number of tae re4u"red to 2erform t!e re4u"red e2arat"on " f"rt te2 "n de"n.5ccurac+ of de"n to a %are etent " de2endent on va2our%"4u"d e4u"%"br"um data on w!"c! ca%cu%at"on

are baed.

5) ource of va2our%"4u"d e4u"%"br"um #B$() data:

2) Re2orted B$( data are ava"%ab%e "n boo- & Eourna% . 5 few e%ected referance are "ven

be%ow :

a) Ba2our $"4u"d e4u"%"br"um data b+ a%a

b) D(3(5 c!em"tr+ data er"e

c) Eourna% of c!em"ca% & (n"neer"n data

d) 7%u"d P!ae (4u"%"br"a

6) =f re2orted B$( data " not ava"%ab%e 'e"t!er determ"ne B$( b+ e2er"menta% met!od or

de"n baed on re%at"ve vo%at"%"t+ #)ca%cu%ated from va2our 2reure data. va2our 2reure data can beobta"ned from boo-/%"terature or can be determ"ned e2er"menta%%+ .

?!e fo%%ow"n 2o"nt are to be -e2t "n m"nd w!"%e de"n"n co%umn baed on from va2our2reure data .

3onf"rm t!at aeotro2e " not formed. 52en S 5eotro2"c data boo- b+ $ee or%e+ Perr+'

$ane "ve eten"ve data on aeotro2e.

7or !"!%+ 2o%ar com2ound ca%cu%at"on of from va2our 2reure data "ve %are error &

" not to be ued.

Ba2our 2reure "n abence of re2orted data ' can be be e2er"menta%%+ determ"ned . Ba2our2reure a22aratu " ava"%ab%e "n 2"%ot 2%ant w!"c! " u"tab%e for meaurement of va2our 2reure Q H60mm .7or meaurement of va2our 2reure f"rt determ"ne t!e rane "n w!"c! va2our 2reure

tem2erature data are to be made .

(nure t!at'") Data " be co%%ected at evera% 2o"nt #m"n"mum f"ve 2o"nt) .

"") 7or meaurement of vacuum 'correct for barometr"c 2reure.

""") =f we are meaur"n va2our 2reure of two com2ound w"t! Q1. ' enure t!at

tem2erature & 2reure meaur"n dev"ce !ave accurac+ of Q 1 > of fu%% ca%e .


14/55

tandard mercur+ manometer do not "ve re4u"red accurac+ .?!e fo%%ow"n dev"ce

"m2rove t!e accurac+ of 2reure meaur"n dev"ce

O"% f"%%ed abo%ute 2reure manometer for meaur"n 2reure be%ow 10 mm 5.

Aat!etometer w!"c! man"f"e t!e ca%e read"n & "ve %eve% u2 to 0.01 mm .

7) Pred"ct"on of B$( data from t!ermod+nam"c 2!ae e4u"%"br"um mode% u"n 52en etc.

9) B$( data from e2er"ment met!od : ?!e met!od fo%%owed "n G3$ t"%% date " d"t"%%at"on

met!od "n w!"c! ma%% 4uant"t+ of d"t"%%ate " co%%ected .?!" +tem "ve %are error due to

condenat"on of va2our on co%d wa%% of f%a-. 522aratu ca%%ed Eone t"%%C !a been fabr"cated

& " ava"%ab%e "n 2"%ot 2%ant . =n t!" +tem t!e return"n va2our are bubb%ed t!rou! t!e %"4u"d toenure ade4uate m""n & t!u e%"m"nate error due to condenat"on of va2our on co%d wa%% of

f%a- .

II) Calculation of height of column :

A)7"rt te2 " Calculation o! Nu,er o! 3eoretical Stages ( N ) Re!lu= Ratio ( R R)

7or batc! fract"onat"on ue 2roramme atc!

7or cont"nou fract"onat"on ue 2roramme 3ont"nou

?!ee 2roramme " baed on f"ed va%ue of .

Batch fractionations:

") 7or f"tt"n "n e"t"n co%umn NC " f"ed & R R " to be ad,uted accord"n%+. ?!e 2roramme

!a t!ree a%ternat"ve :

5%ternat"ve 1 for ma"n cut : =n2ut de"red com2o"t"on of d"t"%%ate .Proramme ca%cu%ated"t"%%ate & bottom 4uant"t+ Sf"na% bottom com2o"t"on .

5%ternat"ve I for "nter cut : =n2ut de"red com2o"t"on of bottom .Proramme ca%cu%ate

d"t"%%ate & bottom 4uant"t+ S averae com2o"t"on of d"t"%%ate .

5%ternat"ve ; : =n2ut de"red 4uant"t+ of d"t"%%ate .Proramme ca%cu%ate d"t"%%ate & bottomcom2o"t"on S4uant"t+ of bottom .

"" ) 7or new co%umn bot! N & R R " var"ed to obta"n de"red reu%t.

Continous fractionation :=n2ut data 7eed f%ow rate 'com2o"t"on'cond"t"on S S R R S

de"red d"t"%%ate & bottom com2o"t"on

Gu"de%"ne :

a)?a-e at end cond"t"on of t!e cut.?!" "ve conervat"ve de"n.

b) 3!ec- m"n"mum R.R & m"n"mum number. of 2%ate .

O2erat"n R.R M 1.I to 1.0 t"me m"n"mum . N M1. to I t"me Nm"n.

B) Colun 5eigt N 5E3& $

(?P " a funct"on of 2ac-"n "e & t+2e '2!+"ca% 2ro2ert"e#urface ten"on & v"co"t+ )' d"tr"but"on

& ca2ac"t+.7or ca%cu%at"on of (?P of =?P 2ac-"n ue Norton 7ormu%a #eea22end" 1).Norton !a "ven formu%a for +tem bae (?P w!"c! aume un"form d"tr"but"on of va2our & %"4u"d "n

t!e co%umn.?!" conce2t " uefu% becaue "t "o%ate t!e +temC effect on (?P awa+ from d"tr"but"on

cond"t"on.?!e formu%a " va%"d for for +tem w!"c! are non a4ueou ' non "on""n and !ave Q ;

C)G3$ !a standardied eigt o! colun sectionfor d"t"%%at"on M


15/55

Note : 1)/ Aev"n =nd. t!e manufacturer of =?P !a recommended to dr+ 2ac- =?P.

I) ?!"c-ne of =?P " 0. mm & !ence corro"on !ou%d be carefu%%+ c!ec-ed .O3 of 2ac-"n

!ou%d be u2er"or to O3 of co%umn t!u 2rov"d"n a%van"c 2rotect"on .


16/55

III) ydrodynamics$

A) &acingued are =?P #ava"%ab%e "n ;16';16 $) and 3eram"c "nta%o add%e3eram"c 2referent"a%%+ wet a4. +tem w!"%e meta% 2referent"a%+ wet

oran"c +tem.

=?P " 2refered ece2t "n cae w!ere ceram"c !ow better 2erformance.7or e.a4ueou N;/D5 fract"onat"on.

Prefered "e of =?P " 1 mm .5 2er Norton =?P " effect"ve at m"n"mum wett"n rate of 0.

;//!r. 7or ot!er 2ac-"n m"n"mum wett"n rate " 1.I ;//!r .B) 7or 3o%umn w"t! =?P 2ac-"n 'Colun Diaeter" ca%cu%ated a 2er 2rocedure & ca2ac"t+/2reuredro2 corre%at"on "ven "n Norton cata%oue. #ee a22end" I )

3o%umn are to be de"ned for ca2ac"t+ factor of 60 to H0 > at to2.

7or co%umn w"t! ot!er 2ac-"n 'co%umn d"ameter " ca%cu%ated a 2er enera%"ed corre%at"on of $eva &(c-ert "ven "n a)?re+ba% 2ae 160 #"n 7P un"t )

b) Perr+ #B= t! ed"t"on ) 2ae no 18II f" 18;8. #"n = un"t )

3o%umn are to be de"ned for ca2ac"t+ factor of 60 > at to2.

Preure dro2 #P)2erm"tted " 10 > of f%ow t!e m"n"mum !ead #!) re4u"red are a under : P acroco%umn Meometr"c mean of P at to2 & P at bottom .

P acro co%umn rane from 0.; to 1.0 "nc! water/ft of 2ac-"n .7%ood"n can occur w!en P eceed

1.; "nc! water/ft of 2ac-"n . 7or fract"onat"on be%ow 1 mm '2reure dro2 acro co%umn " cr"t"ca% &

" ca%cu%ated at evera% 2o"nt over t!e !e"!t of co%umn.

C) Design o! colun internals $

2)Li-uid distri,utors $"4u"d d"tr"butor " t!e mot "m2ortant "nterna% of 2ac-ed co%umn. $"4u"d

d"tr"butor are e"t!er rav"t+ t+2e or 2reure t+2e. Preure t+2e d"tr"butor con"t of 2erforated 2"2e

and are ued "n aborber w!ere !ead ava"%ab%e " muc! !"!er . $"4u"d d"tr"butor !ou%d be 2o"t"oned of co%umn

area .# r"er area "n"de " of co%umn croect"ona% area.)

"")5rea of a r"er " m"n"mum 1 > of co%umn croect"ona% area .

6) &acing su''ort 'late $

=n 2ac-"n u22ort 2%ate a d"tr"but"on " more "m2ortant t!an %"4u"d d"tr"but"on .

e2arate 2aae are 2rov"ded for a & %"4u"d b+ %ocat"n a "n%et to 2ac-ed bed above t!oe 2o"ntfrom w!ere %"4u"d f%ow from bed.O2en area for a f%ow " e4ua% or eceed 100 > of co%umn cro

ect"ona% area .Ga "n,ect"on t+2e 2ac-"n u22ort 2%ate u22%"ed b+ / Aev"n !ave ma"mum t!"c-ne

of ; mm #due to %"m"tat"on of 2unc!"n mac!"ne ) . ?!"c-ne of 2ac-"n u22ort 2%ate fabr"cated a 2erG3$ de"n " 10 mm.

7or fabr"cated Pac-"n u22ort 2%ate :

a) Ga r"er area " d"tr"buted e4ua%%+ between "n"de and out"de of 0 > of co%umn area .Ga r"er area

"n"de t!e 0 > of co%umn croect"ona% area !ou%d be of co%umn area .?!" " t!e mot"m2ortant cr"ter"a "n de"n of 2ac-"n u22ort 2%ate .Number of a r"er 'd"ameter '2cd of a r"er are

var"ed to arra"ve at o2t"mum de"n .

b) croect"ona% area of a r"er " m"n"mum I > of co%umn area. Ga r"er are e"t!er c"rcu%ar 2"2eor rectanu%ar c!anne% w"t! ca2 at t!e to2. ?!e ca2 " u22orted on t!e r"er b+ mm tr"2e uc! t!at

f%ow area betwen r"er & ca2 " e4ua% to co%umn croect"ona% area.

c)$"4u"d or"f"ce %ocat"on " not cr"t"ca% .D"ameter of %"4u"d or"f"ce " e%ected uc! t!at %"4u"d !ead aboveor"f"ce " m"n"mum. "nce =?P 1 " w"de%+ ued '"norder t!at 2ac-"n !ou%d not 2a t!rou! or"f"ce

e%ect 10 mm d"ameter .

7) Redistri,utors $

Red"tr"butor com2r"e of e2arate 2ac-"n u22ort 2%ate & %"4u"d d"tr"butor . ?!e 2ac-"n u22ort 2%ate

de"n " "m"%ar to t!e 2ac-"n u22ort 2%ate at t!e bottom of co%umn.

=n t!e %"4u"d red"tr"butor ' t!e or"f"ce %ocat"on 'number & d"ameter " ame a "n %"4u"d. d"tr"butor at to2.

?!e a r"er number & d"ameter " ame a "n %"4u"d d"tr"butor at to2 ece2t t!at a f%ow " from "de"m"%ar to a r"er on 2ac-"n u22ort 2%ate.


18/55

A''endi= 2

3a%cu%at"on of +tem bae (?P :

+tem bae (?P M 5#I0/)T0.16 L#1.H8)T for 0.< c2

M #I0/)T0.19 L#/0.I)T0.I1 for K 0.< c2

!ere " urface ten"on of %"4u"d "n d+ne/cm .7or KIH ue MIH

M $"4u"d v"co"t+ "n 3P

Ba%ue of 5C and C de2end on "e of 2ac-"n and are a underBa%ue of 5C and C are "n mm .

&acing sie A B

1 IHI I96

I ;1 ;8;


19/55

A''endi= 6

3a%cu%at"on of ca2ac"t+ & 2reure dro2 "n co%umn .

Column C 3401

FunctionCut Toluene Toluene

Packing IMTP 15 IMTP 15

Vapour rate: V Kg/hr 1400000 !50000

"e#u$ ratio: " 0500 0500

%i&ui' rate %( )"/"*1+,V Kg/hr 4----! .50000

M3/M./" 5401 .3

%i&ui' 'en2it: l Kg/M3 !0000 !0000

Molecular eight: M .000 .000

ur6ace ten2ion 7ne2/cm .100 .1

Pre22ure: P MM g !-0000 .00000

Temperature:T 7eg C 50000 50000

Vapour 'en2it: g( )M,P,.!3+/

)!-0,)t*.!3+,..4+

Kg/M3 34!1 014

%i&ui' 8i2co2it: Cp 0450 0450

Column 7iameter :7 Inch 14000 14000

9rea: 9 M. 00 00

upercial 8elocit: ; M/ec 11. ..-

Capacit 6actor C2 M/ec 00!1 00!4

Parameter < 00.1 0011

Kinematic 8i2co2it:(/l C 051! 051!Capacit Co: From graph gi8en in =otoncatalouge

M/ec 0115 01.0

>?cient capacit

C2c(Co,)/.0+@01-,)/0.+@A011

M/ec 0105 0110

Capacit "ating: )C2,100+/C2c B -!!5 -!.

r'inate 8alue )6rom graph + D .-.0 .4

Pre22ure 'rop:6rom graph gi8en in =ortoncatalouge

MM ./M 55000 55000

Inch ./6t 0--0 0--0

MM g/6t 1.33 1.33


20/55

A&&ENDI? 7

LI.

=ntermed"ate 2erformance d"tr"butor : DF M H 90 >

tandard : DF M ;0 6 >


21/55

&rocedure

1) 5ume no. of or"f"ce uc! t!at t!ere are m"n"mum 6 2o"nt 2er mIof co%umn @n(ac! or"f"ce

corre2ond to a 2o"nt c"rc%e.

5rea of eac! 2o"nt c"rc%e M 3ro ect"ona% area of co%umnno. of 2o"nt

I) 5ume 2"tc! and f" %"4u"d or"f"ce on a tr"anu%ar 2"tc!. =t !a been een t!at DF for or"f"ce onc"rcu%ar 2"tc! " a%wa+ %e t!an DF for or"f"ce on tr"anu%ar 2"tc! .5 a f"rt tr"a% '2"tc! can ta-en M

d"ameter of 2o"nt c"rc%e . Draw 2o"nt c"rc%e w"t! or"f"ce a center .

(nure t!at d"tance or"f"ce from co%umn wa%% M m"n I mm for co%umn of d"ameter K 16 X .

;) Draw 2o"nt c"rc%e tart"n w"t! e"t!er d"tr"but"on 2o"nt at centre of co%umn or non centra%

d"tr"but"on 2o"nt.

. =n ;80mm d"a. "o octane/to%uene +tem no. of

tae "ncreaed from H to 8. w!en d"tr"butor w"t! DF of > wa c!aned to d"tr"butor w"t! DF of 8>.

Conclusion $?!e "m2ortance of %"4. d"tr"butor "ncreae a number of tae 2er ect"on of co%umn "ncreae .

$"4u"d & a f%ow ' 2ac-"n "e and t+2e doe not affect t!e 2erformance of d"tr"butor.


22/55

3ABLE / I

DE3AILS OF LI


23/55


24/55

ca-e !e"!tS !owever' t!" " offet b+ fact t!at t!e !"!er d"fferent"a% 2eed a%o reduce ca-e

re"dence t"me. ?!erefore' an o2t"mum d"fferent"a% 2eed " re4u"red to ba%ance f"%trate c%ar"t+

and ca-e dr+ne.

2. Filtration Centrifuges :- ?!e+ e2arate t!e 2!ae #o%"d Z %"4u"d) b+ f"%trat"on. uc! f"%ter

eent"a%%+ con"t of a rotat"n 2erforated ba-et e4u"22ed w"t! a f"%ter med"um. "m"%ar to

ot!er f"%ter' f"%trat"on centr"fue do not re4u"re a den"t+ d"fference between t!e o%"d and

t!e u2end"n %"4u"d. =f uc! den"t+ d"fference e"t ed"mentat"on ta-e 2%ace "n t!e %"4u"d!ead above t!e ca-e. ?!" ma+ %ead to 2art"c%e "e trat"f"cat"on "n t!e ca-e' w"t! coarer

2art"c%e be"n c%oure to t!e f"%ter med"um and act"n a 2recoat for t!e f"ne to fo%%ow. ?!e

ca2ac"t+ of f"%trat"on centr"fue " ver+ muc! de2endent on t!e o%"d concentrat"on "n t!e

feed.

!s a general rule" sedimentation centrifuges are used #hen it is re$uired to produce a

clarified filtrate #hereas filtration centrifuges are used to produce a pure dry solid.

=t " conven"ent to c%a"f+ t!efiltration centrifuges"nto two broad c%ae' de2end"non !ow o%"d are removed :fi%ed &ed and mo'ing &ed

In the fi$ed " bed type' t!e ca-e of o%"d rema"n on t!e wa%% of t!e 2erforated ba-ete4u"22ed w"t! f"%ter med"um unt"% removed manua%%+' or automat"ca%%+ b+ mean of a -n"fe

arranement. ?!e+ are eent"a%%+ cyclic "n o2erat"on. (op Discharge ) Bottom Discharge

Bas*et Centrifuges and +eeler Centrifuges are fi%ed , &ed centrifuges.

In the moving % bed type' t!e ma of o%"d " moved a%on t!e ba-et b+ a ram.

a!"n and dr+"n one can be "ncor2orated "n t!e mov"n bed t+2e. =t " eent"a%%+continuous "n o2erat"on.+usher Centrifuge is mo'ing , &ed centrifuge.

&as'et Centrifuges ( #op &ottom Discharge):"

?!e+ are a22%"cab%e to 2art"c%e "e rane 10 Z 8'000 m.?!e ba-et !ou"n " u22orted b+ a t!ree Z 2o"nt u2en"on ca%%ed t!e three , column

centrifuge. u2en"on of mac!"ne on t!ree co%umn 2rov"de eten"ve com2enat"on of an+"mba%ance of t!e +tem' t!u d"2en"n w"t! concrete or dam2er foundat"on.

?!e "m2%et of t!e f"ed Z bed centr"fue " t!e 2erforated ba-et centr"fue w!"c!

!a a vert"ca% a". ?!e+ are e4u"22ed to !and%e feed"n' wa!"n and d"c!are re4u"rement"n a d"cont"nuou f"%trat"on 2roce w"t! m"n"mum attr"t"on of t!e o%"d. ?!e u2en"on to

be e2arated enter t!e mac!"ne v"a a tat"onar+ feed 2"2e. !en t!e ba-et " f"%%ed' t!e feed

va%ve " c%oed b+ automat"c contro%. ?!e ube4uent treatment con"t of dra"nae of mot!er

%"4uor' wa!"n of o%"d' dra"nae of t!e wa! %"4u"d' and d"c!are of t!e ca-e.

=n t!e cae of bottom d"c!are' a -n"fe remove t!e ca-e toward t!e o2en centre'

%eav"n a t!"n re"dua% %a+er of ca-e "n t!e ba-et. =n t!e to2 d"c!are mac!"ne' t!e o%"d areremoved manua%%+ # can be removed 2neumat"ca%%+' mec!an"ca%%+' or b+ w"t!drawa% of t!eent"re f"%ter ba).

5fter remova% of t!e ca-e' t!e centr"fue " read+ for anot!er c!are. Proramm"n t!e

e4uence of event can be accom2%"!ed b+ a fu%%+ automat"c contro% un"t.


25/55

(hese types of centrifuges are in use in GC.

Peeler Centrifuges :" ?!e+ are a22%"cab%e to 2art"c%e "e rane 10 Z 8'000 m.(he 'ertical a%is of the &as*et centrifuge may cause some non-uniformity due to the effects of

gra'ity" #ith the accompanying pro&lems #hen ca*e #ashing is used. (his can &e eliminated

&y ma*ing the a%is horiontal. (his is *no#n as +eeler Centrifuge.

5 2ee%er centr"fue " de"ned to dea% w"t! a w"de rane of u2en"ond"cont"nuou%+ "n %ot. (ac! %ot " ubd"v"ded "nto t!e necear+ o2erat"on Z 7eed"n'

2"nn"n= to dra"n off mot!er %"4uor' a!"n' 2"nn"n== to dra"n off wa! %"4u"d' cra2"n

t!e ca-e. ?!" ad,utab%e %ot c+c%e " mot%+ contro%%ed automat"ca%%+. ?!e var"ou o2erat"on

w"t!"n a %ot can be 2erformed at contant or var+"n 2eed of t!e centr"fue drum.

?!e 2r"nc"2a% a22%"cat"on " for !"! out2ut dut"e w"t! nonfra"%e cr+ta%%"ne

mater"a% "v"n reaonab%e dra"nae rate w!"c! re4u"re ood wa!"n and dewater"n.

?!e u2en"on to be e2arated " fed to t!e centr"fue t!rou! a feed 2"2e. =n t!e

f"%trat"on 2roce t!e %"4u"d f"%ter t!rou! a f"%ter c%ot! under t!e effect of centr"fua% force.

7"%trate " dra"ned t!rou! t!e 2erforated ba-et "nto t!e f"%trate tan-. ?!e o%"d mater"a% "

reta"ned "n t!e ba-et b+ f"%ter c%ot! and form a un"form %a+er. ?!e wa! %"4u"d " 2ra+ed on

t!e o%"d %a+er t!rou! a wa! 2"2e to wa! "t. ?!e reu%t"n wa! %"4uor %eave t!e centr"fue"n t!e ame manner a t!e ma"n f"%trate and " tored "n wa! %"4uor tan-. ?!e o%"d are

centr"fued unt"% t!e de"red re"dua% mo"ture / oran"c %"4u"d content " reac!ed' and cra2ed

out b+ a !+drau%"ca%%+ o2erated cra2er -n"fe down to a re"dua% %a+er Z w!"c! rema"n onf"%ter c%ot!. ?!e o%"d mater"a% " d"c!ared b+ mean of a c!ute or crew. ?!e cra2er -n"fe

can not be a%%owed to contact f"%ter med"um' a re"dua% %a+er of o%"d / 2roduct rema"n "n

t!e ba-et after eac! un%oad"n. ?!" erve a a 2recoat to 2revent %o of f"ne to t!e f"%trate

t!rou! t!e f"%ter med"um dur"n net c+c%e. ?!e d"advantae " t!at "t a%o add re"tance tof"%trat"on "m"%ar to f"%ter med"um. ?!e re"dua% %a+er ma+ become %aed and "m2erv"ou

from t!e rubb"n act"on of t!e -n"fe and a r"ne ma+ be fre4uent%+ re4u"red to retore t!e

2ermeab"%"t+.

Disadvantages *dvantages :" Based on e%perience in +olymer pro/ect GC"

+anoli.Centrifuge used: 120 33 dia 3a*e: !45+

Filtering area: 2.67 38

1. Pee%er centr"fue !a 2art rotat"n at !"! 2eed and re4u"re !"! en"neer"n

tandard of manufacture' !"! ma"ntenance cot' and 2ec"a% foundat"on or

u2en"on to aborb v"brat"on.It is a very sophisticated and critical e+uipment.2. Overf%ow of ba-et due to ma%funct"on"n of feedcontro%%er can caue %o of

o%"d to t!e f"%trate a we%% 2rob%em aoc"ated w"t! 2roce"n of f"%trate.

9. =t can be o2erated even U I003 of 2roce tem2erature u"n u"tab%e %ubr"cat"n

o"%. #=t " a%read+ etab%"!ed "n cae of a%t f"%trat"on from P( Po%+mer o%ut"on UI00 3)

6. 3a-e et wa!ed t!orou!%+ even w"t! ,.- Ca'e olumewa! %"4u"d). ere t!e

ca-e ment"oned "final productDCD+S plant.. ?!rou!2ut obta"ned " H ?PD wet ca-e w"t! H > w/w $OD #w"t!


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/ollowing are the details of the Peeler Centrifuges being used in !C0:

a-e : 5N*P (NGG. $?D.' 5(D55D

ode% : [ Z 1IO3 : Z ;0C? the cartridge filters are used for O#yclosanide (7eterinary drug! $urification 'ith finecharcoal. C*6 (Insecticide! $urification 'ith fine charcoal.

Rotary 1ac- dr-

"he arrangement consists of a trough in 'hich slurry is fed. "here is rotating drum on 'hich filtercloth is fi#ed. 7acuum is a$$lied 'ithin the drum. "he drum rotates at very very slo' s$eed. Byvacuum the slurry is suc%ed to the to$ of drum/ it is filtered ca%e is de$osited on the filter cloth."he de$osited ca%e is cut by %nife blade discharged. "his filter is very useful for $asty stic%yca%e. "he disadvantage being that it is not very much air tight so there is smell if some foulsmelling chemical is handled. 6or C*6 filtration this filter is used 'here other ty$es of filters failedto give satisfactory $erformance.

$t2er types o &%ter

&ome other ty$es of filters are $ressure leaf filter/ bag filter/ hori@ontal belt filter etc. 6or detailsrefer boo%s.

&%ter c%ot2 # &%ter a&d

"he filter cloths used in >C? are **/ Cotton/ "erylene etc. "hese cloths are available in variousmesh si@es. 6or fine filtration higher si@e mesh cloth is used. In addition to cloth $orous filtrationtiles (>rind'ell 2orton! have also been used. "hese tiles act as filter cloth. "hese are very fine innature.

6or fine filtration/ say filtration of fine $o'ered charcoal from slurry 9yflo is used. "he $rocedureis to $re$are bed of hyflo over filter cloth by circulating slurry of hyflo $re$ared se$arately. Oncethe filter cloth is embedded 'ith hyflo the slurry is fed to the filter. "he hyflo bed is easy to$re$are. In s$iral filter almost al'ays hyflo bed is $re$ared first then f iltration done.

"a%c%at&o' o &%trat&o' t&-e

By the very nature of the ca%e t'o ty$es of ca%es are there. Com$ressible 2on com$ressible.In filtration t'o resistances are encountered)

Ca%e resistance ( !

6ilter medium resistance ( Rm !

"he $ressure dro$ across filter consists of)

* across ca%e

* across filter medium

"otal $ressure dro$ is the addition of these t'o $ressure dro$s. If the ca%e resistance is

inde$endent of the $ressure dro$ it is called non-com$ressible ca%e. If the ca%e resistance isde$endent on $ressure dro$ it is called com$ressible ca%e. "he method is different forcom$ressible non-com$ressible ca%e. By nature almost all the ca%es are com$ressible to somee#tent or other. It is their degree of com$ressibility that decides 'hether the ca%e is com$ressibleor non-com$ressible.

No' co-press&b%e ca3e 6or calculation clic%---&%trat&o' t&-e
http://smb//Vmv/iso%20document/process%20Guidelines/Ref%20documents/FILTRATION.xls#A1http://smb//Vmv/iso%20document/process%20Guidelines/Ref%20documents/FILTRATION.xls#A1


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6rom lab study time (t! vs filtrate volume (v! data is given. "'o methods are available foranaly@ing these datas.Met2od45

"he t3v on y-a#is is $lotted against v on #-a#is. 6rom the slo$e interce$t the ca%eresistance filter medium resistance are calculated res$ectively. "he values are fedalong 'ith some other values in the I2*=" DA"A in $rogram O="*=" R


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ANNEXURE !

( Prepared by KSS )

!A"UUM E7UIPMENTS

I'trodct&o'

In chemical $rocess industries vacuum is very oftenly used for various $ur$oses e.g.

7acuum distillation of high boiling organic com$ounds. At atmos$heric distillation/ the

$roducts may deteriorate due to higher tem$erature/ but in vacuum distillationtem$erature is lo'er.

6or transferring a material from on $lace to another/ $ressure differential can be

created by a$$lying vacuum.

In chemical reactions 'here gases are generated negative $ressure that is vacuum is

a$$lied for scrubbing gases so that lea%age to atmos$here is minimised.

In filtration and drying o$erations also vacuum is used very freuently.

6or creating vacuum common devices used are)


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T+o4stae

ithout intercondensation/ to com$ress from about 51 torr to atmos$heric $ressure. It is usedfor small suction uantities and as t'o-stage $re-evacuator.

T2ree4 stae

ith intercondensation to com$ress from about 01 torr to atmos$heric $ressure. It is mainly

used to evacuate large condensers. "hese eectors have a smaller steam and 'aterconsum$tion than the t'o stage steam et eectors 'ith intercondensation/ if the 'or%ingconditions are same for both the units.

or4stae

ith surface condenser for vacuum from about 5 torr to about 51 torr 'hen the dra'n offmedium must not come into contact 'ith the cooling 'ater or if the condensate is to berecovered."hese eectors are used e#tensively in the mineral oil industries.

&1e stae

ith mi#ing condensers for vacuum from about 1.0 torr to about 5 torr. 6or suction uantitiesfrom about 1. %g3hr u$to about 0111 %g3hr condensable and in condensable va$or andgases."hese eectors are used for free@e drying 'here large uantities of 'ater va$or are dra'n off

from a vacuum of about 0 torr. Also used in steel de-gassing 'here large uantities ofincondensable gases must be dra'n off.

S&04stae

ith intercondenser and an after condenser/ for vacuum from about 1.1 torr to about torr."hese are used in the manufacture of synthetic fibres 'here vacuum bet'een about 1.0 torrand 1.5 torr is reuired. An after condenser is al'ays used/ if the e#haust from the final stagecan not flo' direct into the atmos$here.

6 Stea- stae 9 +ater r&' 1ac- p-p

6or vacuum from about 1. to torr. "his combined $um$ is $articularly suitable if barometricerection is not $ossible.

5 Ste- stae 9 +ater 8et

"his combination is used for vacuum u$to 01 torr.

6 Stea- stae 9 5 +ater 8et

"his combination is very famous in the chemical $rocess industries. "his gives vacuum in therange of 8 to torr.

Po&'ts to be co's&dered +2&%e prc2as&' stea- 8et e8ector:Sct&o' capac&ty!ac-Pre4e1acatorM$"Type o co'de'serMet2od o &'sta%%at&o'

Sct&o' capac&ty

"he steam consum$tion of a stem et vacuum $um$ does not de$end u$on 'hether the 'hole or

only $art of the suction is eected. 2o steam is saved 'hen a large ca$acity $um$ is o$eratingbelo' full load. 9ence it is im$ortant to ma%e the $lant to be held under vacuum as air tight as$ossible/ to determine the suction ca$acity as accurately as $ossible and to design the $um$ forthis ca$acity. 9o'ever the ca$acity should al'ays be chosen 'ith a safety margin so as not toendanger safe 'or%ing.

"he suction ca$acity is best calculated by 'eight that is Fg3hr. "he suction ca$acity be 'eight ismade u$ of)

Air lea%age or ca%c%at&' t2e a&r %ea3ae rate c%&c3 2ere A&r %ea3ae rate
http://smb//Vmv/iso%20document/process%20Guidelines/Ref%20documents/AIRLEAK.XLS#A1http://smb//Vmv/iso%20document/process%20Guidelines/Ref%20documents/AIRLEAK.XLS#A1


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"his lea%age is that 'hich enters through ga$s in sealing. ( A hole of 0 mmG lets ina$$ro#imately 0.; lbs3hr !.

>ases/ va$or air released from the material handled in the $lant

"he condensable $art must be distinguished from the noncondensables ( Inert gas !. "hemolecular 'eight tem$erature must be ta%en into consideration. 6or discontinuouso$eration/ it is im$ortant to %no' at 'hat vacuum the gas or va$or uantities are released.

>ases air from the cooling 'ater"he air tightness of the vacuum $lants can vary greatly de$ending u$on 'hether the $lant ismainly 'elded or 'hether it has many flange connections/ valves/ coc%s/ ins$ection glasses/stuffing bo#es etc. "he ty$e of sealing material/ the condition of the sealing surfaces and thedegree of the use of the fillings are im$ortant. 9o'ever it is $ossible to give a rough guide fora $ractical evaluation of the suction ca$acity ( 2ot including of course va$ors or gasesreleased in the chemical $rocess !.

!ac-

"he vacuum should not be chosen higher than the absolutely necessary. "oo high a vacuumleads to unnecessarily large suction $i$elines/ unnecessarily large steam et eectors/ e#cessivesteam consum$tion and e#cessive cooling 'ater consum$tion.

Pre4e1acator

If a vacuum $lant is in constant o$eration/ evacuating time on start-u$ is generally not anim$ortant factor and it is not necessary to $rovide s$ecial $re-evacuator ( &tart-u$ eector !. Ifho'ever the vacuum $lant has to be started u$ freuently/ a short evacuating time is desirable. "oachieve this a $re-evacuator is used.

A $re-evacuator is normally a single stage steam et eector 'ith a large suction ca$acity/ 'hich is$ut to o$eration simultaneously 'ith the steam et eector. "ogether 'ith the eector it evacuatesthe $lant very uic%ly to an intermediate vacuum/ say u$to 01 torr. At 01 torr almost ;1 H of theoriginal volume of air in the $lant has already been $um$ed out. "he $re-evacuator is then shut-off and the steam et eector alone evacuates in the remaining time to the reuired 'or%ingvacuum."he $re-evacuator has a high steam consum$tion. 9o'ever this is not of great im$ortance since

it o$erates only for 01-0 minutes during the start-u$ of the $lant. "he steam consum$tion of $re-evacuator decreases considerably 'ith increasing stem $ressure. "he steam consum$tion at 01atm is only 1 of that at 5 atm.

M$"

A steam et vacuum $um$ should be constructed of a material at least resistant to corrosion asthe $lant to 'hich it 'ill be attached. "he various MOCs available are) M&/ &&-51/ &&-504/>ra$hite/ M&36R7< lines/ ** etc."he et comes in various MOCs such as) &&-51/ &-504/ "itanium/ *"6< etc.

Type o co'de'ser

Mi#ing condensers are sim$le/ reliable and ine#$ensive. Mi#ing condensers li%e steam eteectors can be manufactured from many different materials and also ma%e the best use ofcooling 'ater.ith surface condenser/ the cooling 'ater does not enter the vacuum. "he cooling 'ater isse$arate from the condensate. &urface condensers must be used 'hen

"he cooling 'ater must not be contaminated by the condensate of the va$ors dra'n off.

"he condensate is to serve as cooling 'ater for units such as steam turbine condenser.

"he condensate is to be reclaimed.


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advantage of high $ressure steam becomes less $ronounced. In very small units the $hysicalsi@e of steam no@@le may $lace a lo'er ceiling on the $ressure.6or the eectors discharging to the atmos$here/ steam $ressure belo' 41 $sig at the eector aregenerally uneconomical. If discharge $ressure is lo'er in multistage units/ the steam $ressure atinlet can be lo'er. &ingle stage eectors designed for $ressure belo' 811 mm 9g (abs! cannoto$erate efficiently on steam $ressures belo' 8 $sig. "he first stage for t'o of a multistagesystem can be designed although $erha$s not economically to use stem $ressure belo' one$sig."o ensure stable o$erations the steam $ressure must be above a minimum value. "his minimumis called -ot&1e stea- p&c34p pressre, 'hen the $ressure is being increased from unstableregion.

Eect o +et stea-et steam erodes the eector no@@le and interferes 'ith $erformance by clogging the no@@le 'ith'ater dro$lets. "he effect on $erformance is significant and is usually reflected in fluctuatingvacuum.Eect o sper2eated stea-

A fe' degree of su$erheat (-0NC! is recommended/ but if su$erheated steam is to be used its

effect must be considered in the eector design. A high degree of su$erheat is of no advantagebecause the increase in available energy is offset by the decrease in the steam density.

Sct&o' pressre

"he suction $ressure of an eector is e#$ressed in absolute units. "he suction $ressure follo'sthe eector ca$acity curve/ varying 'ith the non-condensable and va$or load to the unit.

*&sc2are pressre

All ty$es of eectors are sensitive to discharge $ressure ust as they are to the steam su$$ly$ressure. 2ormally designed eectors are suitable for o$erating against a $ressure only slightly ine#cess of atmos$heric. In most cases eectors can be designed to discharge at a $ressure of

$si/ $rovided a considerable increase in steam consum$tion can be $ermitted. It must bea$$reciated/ ho'ever/ that the discharge of an eector is contaminated 'ith incondensable gasesand is therefore in many cases unsuitable for further use."he $ressure dro$ through discharge $i$ing and aftercooler must be ta%en into consideration.Discharge $i$ing should not have $oc%ets for condensation.

"oo%&' +ater

"he cooling 'ater tem$erature is of great im$ortance.

ell 'ater ) 01 to 0NCRiver 'ater ) to 8NCRe-circulated 'ater ) 01 to 8;NC

&ea'ater ) 0 to 51NC&team et eectors must be designed for the ma#imum cooling 'ater tem$erature available.&team and 'ater consum$tion are greatly de$endent on the design tem$erature as can be seenfrom the follo'ing e#am$le.

A unit to eect at torr using steam at $sig."he steam consum$tion at a cooling 'ater tem$erature of 8NC is double that of 0NC. If thecooling 'ater tem$erature varies to a large e#tent throughout the year/ it is advisable to adust thesteam consum$tion in relation to the 'ater tem$erature by suing different no@@les/ or by altering


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"o enable the manufacturer to design most suitable ty$e of vacuum system/ it is essential thatcorrect data be available u$on 'hich to base $ro$osals designs. henever $ossible thefollo'ing information should be su$$lied 'ith any enuiry.

Brief descri$tion of $ur$ose for 'hich eui$ment is reuired.

eight of air or va$or to be handled in lbs3hr. If a mi#ture of air/ va$or and 3or other non-

condensable gases. "heir a$$ro#imate $ro$ortions should be stated

?bs3hr of condensable va$orous lbs3hr of non-condensable gases/ either dissolved/inected or carried in $rocess formed by reaction/ air lea%age etc.

"he absolute $ressure reuired at the eector suction in inches mercury/ or millimeters

mercury.

If eector is reuired to discharge at other than atmos$heric $ressure/ the ma#imum

discharge $ressure must be stated.

If normal steam $ressure and also the minimum steam $ressure at 'hich the $lant is reuired

to o$erate. If steam is su$erheated give ma#imum tem$erature.

Ma#imum tem$erature of cooling 'ater.

"ost actors

Of all the classes of Chemical


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!ac- p-ps

7acuum $um$s are mainly used for handling large uantities of air lea%age at relatively lo'vacuum in o$erations such as filtration/ drying etc."he vacuum $um$ may be liuid ring ty$e or dry $um$. Amongst liuid ring more common are'ater ring and oil ring vacuum $um$s.


39/55

vacuum $um$. "he non-return valve for a 'ater ring com$ressor is to be fitted to the $ressure$i$ing. "he 'or%ing $ressure is limited by fitting a safety valve in the delivery $i$ing.

Mater&a% o co'strct&o'

"he standard material of construction is cast iron. 9o'ever/ for s$ecial a$$lication these can besu$$lied in various materials such as bron@e/ >unmetal/ &&-51/ &&-504/ Rubber-lined etc.

*eta&%s o 'or-a% +ater r&' 1ac- p-ps

&$eed/ R*M Ma#. &uctionM5hr

RecommendedMotor/ 9*

ater consum$tion?it3min.

8;18;18;1010101

01:;1:;1:;1,8,8;1

:;0

085041881551

1,8;101;10118151541

,.,.010

8151514:1811

,:

0048151

141;1

0110181151

$&% r&' 1ac- p-ps

Oil ring vacuum $um$ is similar to 'ater ring vacuum $um$ in o$eration e#ce$t that the sealingfluid used is oil instead of 'ater. "he advantage of oil ring vacuum $um$ is that high vacuum canbe obtained due to much lo'er va$or $ressure of oil as com$ared to 'ater. "he disadvantage is

that after some usage oil gets contaminated 'ith chemicals and vacuum starts dro$$ing. "herecovery of oil is very e#$ensive. Because of this reason the oil ring vacuum $um$s are not verycommon.

*ry p-p

By using 'ater ring3oil ring vacuum $um$ the chemicals3solvents get contaminated 'ith 'ater3oil."he recovery of these solvents become very costly affair. In such cases dry $um$ scan be usedthough the initial costs are high."he $rinci$le of dry $um$s is different from ring $um$. In dry $um$ dri$ oil lubrication is used/'hereas in ring $um$/ there is continuous seal of liuid. In dry $um$ oil used is once through$ass. 9eat e#changer can be installed on the discharge side of dry $um$s to condense thegases. "he condensed solvent may be contaminated 'ith little bit of oil/ 'hich is used for dri$

lubrication of dry $um$. "he condensed solvent can be distilled out to se$arate it from oil. "oboost the ca$acity of dry $um$ mechanical boosters can be used.Combination of one roots $um$ and t'o dry $um$s 'ill give ca$acity of ;11 M53hr at 0 torrabsolute $ressure. "he roots $um$ is volumetric flo' device. At high vacuum mass flo' 'ill belo'er. "he oil consum$tion for both the dry $um$s is 81 CC3; hr.6or ;11 M53hr flo' at 0 torr air 0.88 %gs3hr."he combination of t'o dry $um$s and one roots $um$ can be used in $lace of -stage steam eteector.Ad1a'taes o1er stea- 8et e8ector

2o steam consum$tion


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I-pe%%er

"he three common ty$es of im$ellers used are)

6ully closed) =sed for high head high $ressure a$$lications.

&emio$en) =sed for general $ur$ose a$$lications. It has got o$en vane ti$s at the


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It is the rate of liuid or slurry flo' through a $um$. 6or $ro$er selection and corres$ondingo$eration a $um$ ca$acity must be identified 'ith the actual $um$ing tem$eratures of theliuid in order to determine the $ro$er $o'er reuirements as 'ell as the effects of viscosity.*um$s are normally selected to o$erate in the region of high efficiency and $articularattention should be given to avoiding the e#treme rights side of the characteristic curve 'hereca$acity head may change abru$tly.

6= Tota% 2ead

"he $ressure available at the discharge of a $um$ as a result of change of mechanical in$utenergy into %inetic $otential energy. "his re$resents the total energy given to the liuid bythe $um$. 9ead is e#$ressed as feet of liuid being $um$ed. "he head is inde$endent of thefluid being $um$ed is therefore the same for any fluid thorough the $um$ at a given s$eedof rotation ca$acity.

>= Sct&o' 2ead or sct&o' %&t

"he total suction head is the difference in elevation bet'een the liuid on the $um$ suctionside and the centerline of the $um$ the velocity head. hen the liuid level is belo' the

$um$ centerline the difference in elevation is %no'n as suction lift.

"otal suction head ("&9! &tatic head L friction head loss."otal suction lift ("&?! &tatic lift friction head loss.

?= *&sc2are 2ead

"he discharge head of a $um$ is the head measured at the discharge no@@le , is com$osedof static head/ friction losses through $i$es/ fittings/ contractions/ e#$ansions/ entrances e#it/ thermal system $ressure.

@= !e%oc&ty 2ead

As a com$onent of both suction and discharge heads/ velocity head is determined at the$um$ suction discharge flanges res$ectively and added to the gage reading. "he actual$ressure head at any $oint is the sum of the gage reading the velocity head. "he values ofvelocity heads are usually small and negligible often.

= NPS. a'd p-p sct&o'

"he net $ositive suction head (2*&9! is very im$ortant criteria for centrifugal $um$s. "hereare t'o ty$es of 2*&9. 2*&9aand 2*&9r.

2*&9a 2et $ositive suction head available *ressure on suction side L friction loss Lva$our $ressure of liuid being $um$ed at$um$ing tem$.

2*&9r 2et $ositive suction head reuired. It is s$ecified by the $um$ manufacturers. "he2*&9ris very im$ortant consideration in selecting a $um$/ 'hich might handle liuids at ornear boiling $oints or liuids of high va$our $ressures. If this consideration of 2*&9 r isignored/ the $um$ may 'ell be ino$erative in the system or it may be on the borderline andbecome troublesome and e#$ensive. "he significance of 29&9Ris to ensure sufficient headof liuid at the entrance of the $um$ im$eller to overcome the initial flo' losses of the $um$."his allo's the $um$ im$eller to o$erate 'ith a full bite of liuid essentially free of flashingbubbles of va$our due to boiling action of the fluid $oor suction condition to cavitation in


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An im$eller can be cut from one si@e do'n to another on a lathe and $rovided the change indiameter is not greater than 81 $ercent/ the conditions of ne' o$eration can be described bythe ty$e of calculation sho'n in above formulae.

Se%ect&o' o p-p : "apac&ty

.ead Eect o 1&scos&ty

Eect o te-p= r&se a'd -&'&-- sae %o+

M$"

$perat&' co'd&t&o' o %&d / 'atre

Syste- co'd&t&o'

Motor deta&%s

Ca'acit%

Ca$acity is decided by the batch time. Batch time is fi#ed by the ca$acity of the $lant. 6ore#am$le if 01111 litres of liuid is to be transferred from one vessel to another in 0 hr the ca$acitybecomes 01 M53hr. 6or most of the normal o$erations the ca$acity of the $um$s used is of the

order of 01/111 lit3hr.

5ead

After deciding the ca$acity the head is to be calculated. 6or this the total $ressure dro$ in thesuction discharge $i$ing is calculated. "he elevation of discharge $oint suction $oint is ta%eninto account. "he $ressure conditions at suction discharge are also considered.6or discharge $i$ing use velocity in $i$eline as 4-; ft3sec ( &ource ) ?ud'ig vol.0 !. 6or suction$i$ing use velocity E 5- ft3sec. =sing the flo' rate velocity fi# u$ the line si@e. If the line si@eis coming odd/ select nearest si@e. "he si@e of $i$es available is 0/ 81/ 8/ 1/ 1/ 4/ ;1/ 011/01/ 811/ 81/ 511 2B etc. After deciding the $i$e si@e calculate bac% the velocity in $i$e.

6ind out number of fittings/ valves in $i$e as 'ell as total straight length. Calculate euivalent

length of fittings/ valves/ e#$ansion/ contractions etc. Add straight length to euivalent length. "hetotal length thus obtained is %no'n as effective length ?e.

Determine $ressure dro$ in $i$eline. 6or calculation clic%--Pressre drop &' %&;&d %&'e

Calculation for suction discharge $i$ing is to be calculated.

6ind out the static head of liuid on suction and discharge side. &tatic head on suction side is thelevel difference bet'een to$ of liuid on suction side and the centerline of $um$. &tatic head ondischarge side is the level difference bet'een centerline of $um$ and the discharge $oint/ 'hereliuid disengagement ta%es $lace.

6ind out the $ressure at suction discharge end.

A$$ly Bernoullis euation calculate the head to be develo$ed by the $um$.

*0 708 g Q0 9 *8 78

8 g Q8 *

---- ----- ------ ---- ----- ------ / 'here

8gc gc 8gc gcr Density of liuid/ %g3m5

*0 *ressure on suction side of $um$/ %g3m8(abs!

Q0 &tatic head on suction side/ m70 7elocity on suction side/ m3sec
http://smb//Vmv/iso%20document/process%20Guidelines/Ref%20documents/pump%20pre%20drop.XLShttp://smb//Vmv/iso%20document/process%20Guidelines/Ref%20documents/pump%20pre%20drop.XLS


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9 "otal develo$ed head by $um$/ m*8 *ressure on discharge side of $um$/ %g3m

8(abs!78 7elocity on discharge side/ m3secQ8 &tatic head on discharge side/ mD* "otal $ressure dro$ in suction discharge $i$ing/ m

After having calculated ca$acity and head refer to the characteristic curves of $um$s given by$um$ manufacturers. By referring to the various characteristic curves select $um$ to give bestefficiency. In the characteristic curves the bra%e horse$o'er is also given. &elect $articularim$eller si@e. 2ote 'hat is the brea% horse$o'er for that $articular im$eller at cut off $oint. =senearest higher 9* motor for your service. 6ind out the 2*&9 rfrom the characteristic curves andma%e sure that the 2*&9ais greater than that reuired by at least 8 mlc.6or critical services/ 'here vacuum is there on suction side or for $um$ing highly volatile liuidssuch as $ro$ylene/ ammonia/ DMA/ Isobutylene/ the 2*&9 becomes very im$ortant.In such cases $um$s are to be selected 'here the 2*&9r is very lo'."he characteristic curves are given for 'ater. If any other liuid is $um$ed density viscosityeffects should be ta%en into account. 6or liuids other than 'ater

Bra%e horse $o'er B9*'ater + liuidin gm3cc.

E!!ect o! #iscosit%

hen viscous liuids are handled in centrifugal $um$s/ the bra%e horse$o'er is increased/ thehead is reduced and the ca$acity is reduced as com$ared to the $erformance 'ith 'ater. "hecorrections are negligible for the liuids 'hose viscositys are in the range of 'ater but it becomessignificant above 01 centisto%es for heavy materials.

6or agrochemicals $roduct the effect of viscosity is negligible but for $olymeric solutions 'herethe viscosities are very high the effect in tremendous.

6or $um$ing viscous liuids the viscosity correction factor is to be a$$lied. hen the

reuired ca$acity head are s$ecified for a viscous liuid/ the euivalent ca$acityand head can be determined using the viscosity correction factors sho'n belo'. PvisP' ------ P' Ca$acity of euivalent 'ater

C 9' 9ead of euivalent viscous liuid

'


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After finding out the efficiency on 'ater/ ' calculate the efficiency 'hile $um$ing

viscous liuid/ visusing above mentioned formula.

2o' having calculated the efficiency for $um$ing viscous liuid visthe horse$o'er

for $um$ing viscous liuid is calculated as belo'.

B9*vis P7I& + 9vis+ vis

"he chart belo' sho's ho' im$ortant are the correction factors

or +ater or 1&scos %&;&d. 0.; gm3cc

041 c$

At operat&' co'd&t&o'0. Ca$acity 0;.5 m53hr8. 9ead 8:. m5. ra$hite/


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"he efficiency of metallic $um$s is higher than non metallic $um$ because in metallic $um$sclosed as 'ell as semi-o$en im$ellers are $ossible. In non metallic $um$s only o$en im$ellersare $ossible because of basic $roblem of moulding. "he efficiency of o$en im$ellers are lo'erthan closed 3 semi-o$en. "he metallic $um$s are more sturdy so mechanical damage chancesare lo'. Many times the $um$ manufactures do not ta%e the res$onsibility of MOC. In such casesthe MOCs are to be mentioned by the customer himself.

$perat&' co'd&t&o' o %&d / Natre

"he o$erating condition details such as tem$/ $ressure/ density/ viscosity/ H slurry if it isa$$licable/ nature of solids 'hether abrasive or soft must be clearly mentioned in the data sheet."he corrosive nature of the $um$ing fluid also must be clearly mentioned. Incom$lete informationmay lead to 'rong selection of $um$ 'hich may ultimately fail at $lant level.

Syste- co'd&t&o'

"he $um$ manufacturer must %no' if the suction side of the $um$ is associated 'ith vacuumeui$ment or is to lift the liuid. "his can ma%e a difference as to the ty$e of im$eller/ &uctiono$ening to be $rovided. If the system o$erates intermittently it should be noted. A $i$ing diagramis often hel$ful in obtaining full benefit of the manufacturers s$ecial %no'ledge.

P-ps operat&' 'der sct&o' %&tAs centrifugal $um$s need $riming/ there are various methods to $rime. 6oot valve can be usedso that the liuid does not drain out after $um$ sto$$age. Auto-$riming $ot can be used. "heauto $riming $ot is installed above the $um$ centerline. One line from to$ of $ot goes to thesuction tan% another line from bottom of $riming $ot goes to the $um$ suction. Initially someliuid is filled in $riming $ot/ $um$ is started. "he liuid from $ot gets suc%ed into $um$/ vacuumgets created in the $ot. "his vacuum causes the liuid to get lifted from suction tan% into auto-$riming $ot. "his common method of $riming is used for $um$ing 'ater from underground tan%s.

Motor deta&%s

"he details of the electric motors should be clearly mentioned in the data sheet if the sco$e of

su$$ly of motor is in clients sco$e. "he frame si@e of motors should be also very clearlymentioned. If the frame si@e is not mentioned in the data sheet ensure that the $um$manufacturer %no's about it. Also ensure that latest frame details are available for motor. &ometimes the motor manufacturer changes the frame details and the latest information may not beavailable 'ith client as 'ell vendor. In that case 'rong frame si@e 'ill be su$$lied 'hen the$um$ is delivered the motor may not fit e#actly modifications may need to be carried out at site."he R*M of motor must also be mentioned clearly in the data sheet 'hether 01 or 8:11 R*M.

Pos&t&1e d&sp%ace-e't p-p

=nder this category t'o ty$es of $um$ come) Rotary p-psRec&procat&' p-ps.

Rotary p-ps

"here are many ty$es of rotary $um$s e.g. Cam/ &cre'/ vane/ ?obe/ &huttlebloc% etc. "hemaority of this ty$e is ca$able of handling a clean solution essentially free of solids. "hese$um$s handle materials of a 'ide range of viscosity ( u$to 11.111 ssu ! and can develo$ uitehigh $ressures ( over 0111 $si !. In addition the unit s can handle some va$our or dissolvedgases 'ith the liuid being $um$ed. "he ca$acity is generally lo' $er unit and at times are usedfor metering.

"hese $um$s are lo' in cost/ reuire small s$ace and are self-$riming.


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&ome can be o$erated in either direction/ have close clearances/ reuire over-$ressure relief$rotection on discharge and have lo' volumetric efficiency.

"he $erformance characteristics are)

Peror-a'ce c2aracter&st&cs

6lo' is $ro$ortional to s$eed and almost inde$endent of $ressure differential. Internal sli$ reduces efficiency.


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"hese $um$s come in metallic as 'ell as non metallic MOC used for very corrosive liuids. "hemetallic MOCs are C&/ &&-51/ &&-504/ 9astC etc. "he non metallic MOCs are **/ *"6 of a. o2erat"n 2reure burt to%eranceof d"- #w!"c! " e4ua% to > of burt 2reure ).

Preure rat"n of R D I & R D ; : 5P of vee% burt to%erance of d"-

Preure rat"n of RB M a. o2erat"n 2reure 10 > of a. o2erat"n 2reure ).

Note : 1) RD be%ow RB !ou%d of non frament"n t+2e.

I) React"on under H; Preure no Runawa+ :

R.D & RB "n er"e " to be "nta%%ed .


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R D " "nta%%ed before & after RB to 2rotect RB from corro"on ' o%"d 2art"c%e e.t.c

?!e 2reure rat"n of R D M 5P of tan- %e burt 2reure mar"n .

?!e 2reure rat"n of RB M 5P of tan-R D " to be of non frament"n t+2e .

R D & RB are to be "ed baed on eterna% f"re cond"t"on.

eat aborbed due to eterna% f"reF M I1000L# 5w) T0.8IL 7 >ef: ud#ig ?ol. 1 page 270

!ere F " !eat aborbed "n tu/!r

5w " tota% wetted area "n 4. 7eet

7 " t!e env"ronmenta% factor .7M 1 for un"nu%ated tan-

7 M 0.; for tan- w"t! 1 X t!-. "nu%at"on

7 M 0.1 for tan- w"t! I X t!-. "nu%at"on

7 M 0.0H for tan- w"t! < X t!-. "nu%at"on

Bent"n rate B M F /eat of va2our"at"on

?an- " not be "nu%ated un%e re4u"red for 2ur2oe ot!er t!an re%"ef dev"ce ""n.

B. (an*s operating at atmospheric pressure@under 'acuum

R. D to be "ed for eterna% f"re cond"t"on . ?an- " not "nu%ated un%e re4u"red for 2ur2oe ot!er t!an

re%"ef dev"ce ""n. R D to be u"tab%e for vacuuum cond"t"on.

C. >elief de'ices on limpet@/ac*et :

7or %"m2et/,ac-et 2rov"ded w"t! 3/3 #no team) 1/IL;/< X RB " to be "nta%%ed .7or %"m2et/,ac-et

2rov"ded w"t! no team .re%"ef va%ve " not re4u"red "f ma. Preure of team " %e t!an 5P of%"m2et/,ac-et .

=f team 2r. " K %"m2et/,ac-et 'RB " to be "ed for ma"mum f%ow rate 2o"b%e w!"c! " ca%cu%ated

baed on %"ne "e '%ent! & number of f"tt"n.

3%'es o! R D :

2. Con#entional &re,ulged tension loaded solid etal diss .

a. a. o2erat"n of vee% /tan- M H0 > of rated 2reure of d"- for non 2u%at"n erv"ce. 7or

2u%at"n erv"ce ma.. o2erat"n of vee% /tan- M 0 > of rated 2reure of d"- .D"- " "nta%%ed

w"t! dome fac"n awa+ from 2roce "de .b. D"- can be ued for %"4u"d erv"ce a%o.

c. $eat e2en"ve of a%% d"-.

d. Drawbac- : ")D"- frament on burt"n & !ence cannot be "nta%%ed be%ow RB

"") Bacuum u22ort " re4u"red "f vacuum eceed 600 mm . ecaue of vacuumu22ort "f d"- " "nta%%ed u2"de down "t w"%% burt at 2reure !"!er t!an rated

2reure.

6. &rescored tension loaded diss $a. !" d"- " a o%"d meta% d"- 2recored "n a 2ec"f"c 2attern to wea-en t!e d"-.

b. a.. o2erat"n of vee% /tan- M 80 to 8 > of rated 2reure of d"-

c. ?!e+ avo"d d"advantae of convent"ona% ten"on %oaded d"- v".framentat"on & need for vacuuum

u22ort. "nce t!ere " no vacuum u22ort 'd"- w"t! P?7( on 2roce "de " ava"%ab%e. owever t!e+are cot%"er t!an convent"ona% o%"d meta% d"-.

d. D"- "nta%%ed "ncorrect%+ w"%% burt at rated 2reure or %ower.

7. Co'osite dis $


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a. ?!" " 2rebu%ed d"- & !a a %otted to2 meta% ect"on w!ere"n burt 2reure " contro%%ed b+ "e &

%ocat"on of %ot & 2erforat"on.?!e d"- " "o%ated from 2roce b+ P?7( membrane . "nce burt

2reure " not contro%%ed b+ t!"c-ne ' d"- " ava"%ab%e at %ower burt 2reure t!an convent"ona%

d"- .b. a.. o2erat"n of vee% /tan- M 80 > of rated 2reure of d"-.

c. Drawbac- : "m"%ar to convent"ona% meta% d"- v".need for vacuum u22ort S framentat"on & burt

at !"!er 2reure "f "nta%%ed u2"de down.

9. Re#erse ,ucling diss

=nta%%ed w"t! dome fac"n toward 2roce "de & !ence d"- " "n com2re"on. ?!e burt"n act"on of

d"- " due to e"t!er -n"fe b%ade on downtream or 2recor"n on d"-.

5dvantae over ten"on %oaded d"- :b. D"- doe not frament & !ence can be "nta%%ed be%ow RB .

a. Bacuum u22ort " not re4u"red .D"- " ava"%ab%e w"t! P?7( ea% fac"n 2roce & !ence can be ued

for corro"ve a22%"cat"on.

b. D"- can be ued u2 to 90 > of o2erat"n 2reure.c. anufactur"n rane " ero.

d. D"advantae :3ot " !"!er t!an convent"ona% ten"on %oaded d"-.(ce2t R$ ot!er t+2e are not

u"tab%e for %"4u"d erv"ce .

. Non etallic diss:Ru2ture d"- "n ra2!"te are ava"%ab%e w!"c! are uefu% "n !"!%+ corro"ve erv"ce .?!e drawbac- of

ra2!"te d"- are :

a. 3annot be "nta%%ed be%ow RB becaue of framentat"on Sb. %ower !e%f %"fe due to re"n bond"n .

E!!ect o! te'erature $

?!e burt 2reure of d"- " funct"on of tem2erature .?!e tem2. :2reure re%at"on for RD " d"fferent t!ant!at for 2arent meta% .=n order to m"n"m"e effect of tem2. "t " recommended to "nta%% R D at %eat one

metre awa+ from vee% no%e o t!at d"- face muc! %ower tem2. t!an t!e vee%. =n t!" cae o2erat"n

tem2. of d"- can be 2ec"f"ed a 0 3.

Siing o! R D $

7or va2our or a erv"ce area of R D " ca%cu%ated from formu%a :

M 3LAL5LPL#/?)T0.Ref: $o 2revent"on "n 2roce "ndutr"e b+ 7 $ee Pae 1I/6H

!ere " vent"n rate "n A/!r

5 " area of d"- "n 4. mmP " abo%ute 2reure "n bar

" mo%ecu%ar we"!t of a or va2our

? " tem2erature "n A

A " 3oeff. of d"c!are M 0.63 " contant M I.H

7rom 5 ' d"ameter of d"- " ca%cu%ated .


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3%'es o! SR1$a. Con#entional relie! #al#e :

3onvent"ona% re%"ef va%ve o2erate at"factor"%+ w!en bu"%tu2 bac- 2reure " %e t!an 10 > of et2reure .3!ane "n bac- 2reure affect bot! et 2reure & ca2ac"t+.

,. Balanced relie! #al#e$

a%anced re%"ef va%ve !ave be%%ow & t!e+ o2erate at"factor"%+ under var+"n bac- 2reure .=n add"t"on

be%%ow 2rotect RB from corro"on from d"c!are "de .

Def"n"t"on of term :

5ccumu%at"on : Preure "ncreae over 5P dur"n d"c!are e2reed a >.5ccumu%at"on M

10 > of et 2reure or ; 2" w!"c!ever " !"!er .%owdown:%owdown " d"fferance between et 2reure & reeat"n 2reure .?!" " ad,utab%e

from H > to 1I > of et 2reure.

Siing o! SR1 $7or ae & va2our at contant bac-2reure or"f"ce area " ca%cu%ated a under :

5 M L#[L?/)T0.

3LALPLAb

Ref: $*D=G Pae I

Documents

BASIC ENGINEERING ( Incl Design Calculations)