oil and gas sample project

7/29/2019 oil and gas sample project

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SHRDCClass Problem

Plant Data

Adapted fromPlant Layout Module:

Lecture 3 -Producing the LayoutIllustration of the Formal Method

ByJames Madden

Zyqad LtdSuite 25

GPT Business Park

Technology DriveBeestonNottingham NG9 2ND


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1. Introduction

In this illustration, we shall consider a small chemical plant containing batch and continuousoperation, with a wide variety of equipment types and flow regimes.

2. The Plant

The process and equipment information is presented below.Key layout conditions to be observed are:-

The plant will be housed in a structure with hot areas open to the elements and qualitycontrolled areas protected from contamination.

Site conditions demand that the raw materials feed and product discharge are on oppositesides of the structure.

The dry raw material loading and final product bagging area are to be protected from theelements by a building enclosure

3. Process Description

The plant shown on the Block Diagram and Flowsheet, Figs 1 and 2 is to produce 4000 tonnes per

year of polymer (notionally polyvinylidene chloride) from monomer. It is loosely based on a plantbuilt by a major manufacturer and changes have made to protect commercial information. Thechanges make the process as described impractical for production purposes, but do not affect thepracticality of the layout.

The reaction is conducted in an acetone/water solution in the stirred tanks R104, R108 and R112,taking eight hours to complete. The reactors are charged, in turn, every three hours from theweighing tanks T101 (water), T102 (make-up monomer) and T103 (acetone, both fresh and

recycled, and recycled monomer). The reaction is catalysed by a consumable organic salt, injected tothe reactors by the metering pumps P107/111/115. Primary control of the reactors is by control ofthe catalyst feed rate. The reaction is rapid and highly exothermic and heat is removed by boiling offlarge volumes of Acetone (and, in the initial stages, some Monomer) which is condensed in the water


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The filtrate - containing the unused monomer and initiator, the Acetone/water from the reactor andwash water - is heated in H123 then distilled in column C124. This ensures that the acetone and

monomer, recycled to the acetone weighing tank, T103 are free of initiator. The water and anyunused initiator it may contain is discharged to effluent.

The filter cake from F119 is dried in the co-current rotary drum drier, D129, which operates at aslight positive pressure. The dryer is operated with sufficient air to keep the Acetone/Monomercontent of the exit foul air below the LFL. The air for the drier is heated by steam in H134 and isblown through the drier by P133. Entrained polymer in the exhaust air is removed in cyclone X132and returned to V130.

The dried polymer is held in hopper V130 until fed to the bagger/palletiser X131. The palletisedsproduct is transferred to the existing warehouse by forklift truck.

All pumps have standbys (not shown on the flowsheet). All utilities are generated outside the batterylimits.

Basic equipment and stream data is attached.


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Item Number T101 T102 T103 R104,108,112 H105,109,113 T106,110,114

Description Water weightank

Monomer weightank

Acetone weigh tank Polymerisationreactors

Reflux condensers Initiator make-up tanks

Number Off 1 1 1 3 3 3Dimns. rate orcapacity

1700 dia x2000

1700 dia x 1600 1900 dia x 2100 2700 dia x 3000 tube length 5.0 mshell dia. 1.14 m

400 dia x 1200

Analysis of

material handled

Mass %

water 100% Monomer 100% Acetone 84%Monomer 16%

Acetone 50%Monomer 10%Polymer 10%Water 30%

Acetone 100% Water 90%Initiator 10%

Material GRP Stainless Stainless Stainless Mild steel StainlessWorking

pressureAtmos Atmos Atmos Atmos Atmos Atmos

Working temp.

degrees CAmbient Ambient Ambient 30 30 Ambient

Services None None None Cooling water power Cooling water Power

Remarks Mounted onload cells

Mounted on loadcells

Mounted on loadcells

Glass fibre-reinforced polyester (GRP) composites are the most popular reinforced plastic materials used in the construction industry

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Item Number P107,111,115 P116 T117 P118 F119 T120

Description Initiator met.pumps

Reactordischarge pump

Filter feed tank Filter feed pump Rotary vacuum filter Filtrate gas/liquidseparator

Number Off 3 1, 1 standby 1 1, 1 standby 1 1Dimns. rate or

capacity4.8 1/min 0.6 m**3/min 14 m**3 working

vol.3.04 1/s 96 m**2 filter area Length 2.5 m

Dia 1.4 mAnalysis of

material handledMass %

Water 90%Initiator 10%

Acetone 50%Water 30%Polymer 10%Monomer 10%




Water 66.4%Acetone 27.9%Monomer 5.7%

Material Stainless Stainless Stainless Stainless Stainless body nyloncloth

Mild steel

Working

pressureAtmos 2 bar g Atmos 2 bar g 0.27 bar abs 0.23 bar abs

Working temp.

degrees C

Ambient 30 Ambient Ambient Ambient Ambient

Services Power Power Power wash water Power Remarks Suffers abrasion Suffers abrasion

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Item Number P121 P122 H123 C124 H125

Description Ejector Filtrate pump Column pre-heater Acetone column Column condenser

Number Off 1 1, 1standby 1 1 1

Dimns. rate or

capacity

2.20 m***3/s 3.16 1/s 3.16 1/s Dia. 550 mm

3 tray modules3000 high

Tube length 2.4 m

Shell 0.54 m

Analysis ofmaterial handledMass %

Air 90%Acetone 10%




Acetone 83.3%Monomer 16.7%

Material Mild steel Stainless Stainless tubesMild steel shell

Stainless Mild steel

Working pressure 4 bar g0.2 bar abs

2 bar g 4 bar g2 bar g

Atmos Atmos

Working temp.

degrees C

140 Ambient Shell 140

Tube 60

Atmos Atmos

Services LP steam Power LP steam Cooling water

Remarks Trayed

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Item Number T126 H127 P128 D129 V130

Description Column refluxdrum

Column reboiler Overheads pump Product drumdryer

Product hopper

Number Off 1 1 1, 1 standby 1 1

Dimns. rate orcapacity

1.3 m**3 liquidTotal vol. 3.8 m3

1.1 l/s Drum length 8.3mDrum dia. 1.5m

10 m**3 workingvol.


Acetone 83.3%Monomer 16.7%


Acetone 83.3%Monomer16.7%

Air 95%Water 3%Polymer 2%

Polymer 100%

Material Mild steel Stainless Mild steel Mild steel Mild steel

Working temp.degrees C

47 60 47 100 Ambient

Services LP steam Power Power Remarks Verticalthermosyphon

Dust explosionhazard

Dust explosionhazard

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Item Number X131 X132 P133 H134

Description Bagger/palletiser Cyclone Blower Air heater

Number Off 1 1 1 1

Dimns. rate or

capacity

8.3 kg/s 7.73 m**3/s 7.73 m**3/s 7.65 m**3/s


Polymer 100% Air 94.5%Water 5%Polymer 0.5%

Air 95%Water 5%

Air 100%

Material N/A Mild steel Mild steel Mild steel

Working pressure N/A 0.03 bar g 0.06 bar g 0.06 bar g

Working temp.degrees C

N/A 40 40 100

Services Power Power LP steam

Remarks Operated one 8

hour shift per day

Dust explosion

hazard

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FMPFig01

F D Hold B

S

F

R

HoldR

R

S

RawMaterial

INProduct

OUT

Air In

Air Out

Waterto

Drain

Block Diagram - Batch Polymer Plant

Plant Layout Example Fig. 1

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H123

T101 T102 T103

R104

H105H109 H113

R108 R112

T114

P115P111

T110T106

P107 P116

P128

T126

H125

C124

H127

T117

T120

D129F119

V130

X132

P133

X131

P122

P118

Acetone in

Water inMonomer in Recycle Acetone

CatalystBags

WatertoEffluent

HPSteam

PolymerPaste

PolymerPowder

BaggedPolymerOut

ExhaustAir

CondensateTo Effluent

P121

H134

Air In

Polymer Slurry

FormMethProbFig02

Fig. 2

Formal Method ProblemBatch Plant

Process Flowsheet

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MAJOR ITEMSKETCHES

R104 - C124 - F119

1000

3000

2700 Dia

R-104/-108/-112

550 Dia

11

50

0 T/

T

Column C124

Filter F119

750

2200

1000

2000

500

FormMethAnsFig09

Fig. 9

500

4,5

00

4,5

00

1,00

0

75

0

75

0

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MAJOR ITEM SKETCHESR104 - C124 - F119

Outlet Box 900 X 2600

3800

2000 Dia

4000

FormMethAnsFig10

1500 Dia1800

1500

Inlet Box 1100 X 2600

9300 Long

Drive Unit below Drum

Dryer D129

Hopper V130

2800

3500

1

500

1000Dia

Cyclone X132

2000

2500

Bagged PolymerOut

Bagger X131

Fig.10

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COLUMN GROUPELEVATIONS

FormMethAnsFig12

2500 to driveControl Valve

1000 piping

1400 dia

540 dia

14400 el

19570 el

3900 el

Liquid level

500 Liquid Depth2400Tubes

1500

9000 PackedHeight

500

1000

Ground level

H127

C124

H125

T126

Fig, 12

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H105 (1140DIA)

T101/2/3

R104

P106

1000

5600 el

2000

3000

600

15006670 el

Ground Level

REACTOR GROUP

ELEVATIONS

FormMethAnsFig11

Fig, 11

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7300 el

V130

X131

D129

X132

F119

2500

500

3800

500

400

1800

10500 el

10100 el

1000Min

Ground Level

DRYERGROUP

ELEVATIONS

FormMethAnsFig13

Minimum pipe angle 45Note effect of horizontaloffsets from sloped pipes.

Fig.13

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VACUUM GROUPELEVATIONS

10600 el

9100 el

P122

SealTank

T120

P121

F119

GroundLevel

700 Dia

800 forgood

pipe slope

8500 MinBarometricSeal

9000 MinBarometricSeal

Presure0.27 Bar

Abs

Ht 1200

10200 el

600

FormMethAnsFig14

Fig. 14

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ASSEMBLING GROUPLAYOUTS INTO PLANT

FormMethAnsFig17

R104

R112

R108

DRYERCOLUMN

FEED

TANKS

VACUUMAIR(Under)

F119

GROUP ASSEMBLY - Not to scale

PRODUCT OUT

RAW MATLS IN

Fig. 17

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Documents

oil and gas sample project