Report on Desiging company

7/30/2019 Report on Desiging company

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TRAINING REPORT

OF

PHASE 1AT PARAMOUNT LTD, VADODARA

SUBMITTED AS A PARTIAL FULFILLMENT TOWARDS THE

BACHELORS DEGREE IN THE FIELD OF CHEMICAL ENGINEERING.

PREPARED BY:

ARPIT D THUMAR.

(ID-064060)

DEPARTMENT OF CHEMICAL ENGINEERING

FACULTY OF TECHNOLOGY,

DHARMSINHDESAIUNIVERSITY,

COLLEGE ROAD, NADIAD-387001

JANUARY 2013


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PREFACE

Theory of any subject is important but without its practical knowledge it becomes useless for

the technical students. A technical student cannot be a perfect engineer or technologist

without practical understanding of the scenario of the branch. Hence this training provides a

golden opportunity for all the students.

The principle objective of the training report is to get details about the operation

process & operation condition which are carried out in the industries and more about theequipment used in the chemical industries. Thus it is important for every person to be

exposed to training in some kind of an industry or other to enhance ones knowledge.

In the context, our college Dharmsinh Desai University, Nadiad arranges an Industrial

Training Program.

Prepared by:

ARPIT D THUMAR

B.Tech.Chemical (8th

Semester)

D.D.U, Nadiad


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ACKNOWLEDGEMENT

This training report takes effort, hard work and time. Many people are involved in it directly

or indirectly during the course of my training work I have been guided by many. It is my

sincere desire to express thanks for their guidance and support.

I would like to take this opportunity to thanks Mr. SAMIR TULI (MANAGING

DIRECTOR) and Mrs. MANJU PILLAI (Manager) for their guidance.

I am also thankful to

Mr. RITESH H ANASANE (Deputy Manager, HYDROCARBON SECTION)

Ms. KHAYTI SHAH (Chemist)

Mr. RAMESH SINGH (Process engineer)

Last but not the least I would like to thank head of department of Chemical Engineering-

Dharmsinh Desai University, Dr. PREMAL SHUKLA for sending me to such a reputed

company which has really helped me in boarding the horizon of my knowledge and I am also

thankful to my guide Assistant Professor HITESH PANCHAL for giving me such a great

guidance.


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6.1 PRESSURE MEASURING INSTRUMENTS

6.2 FLOW MEASURING INSTRIMENTS

6.3 TEMPERATURE MEASURING INSTRUMENTS

6.4LEVEL MEASURING INSTRUMENTS

7 PFD 30

7.1 INTRODUCTION

7.2 PFD WILL CONTAIN

7.3 PFD WILL NOT INCLUDE

7.4 STANDARDS

7.5 TRACING OF LINES

8 BASICS OF P&ID 32

8.1 LEGENDS

8.2 P&ID

8.3 CHECKLIST FOR HEAT EXCHANGER

8.4 CHECKLIST FOR PUMPS

9 PUMP HYDRAULICS 43

9.1 DEFINITION

9.2 EXAMPLE

9.3 NPSH

9.4 SAMPLE CALCULATION

10 R&D PARAMETERS 49

10.1 DEFINITION

10.2 GPCB NORMS


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WORLD BANK etc.

The Manufacturing Unit of PARAMOUNT is fully equipped with the most modern

machinery & facilities to manufacture wide range of equipment. In-house facilities for testing

& inspection make it completes to produce high quality equipment. PARAMOUNT

Manufacturing facilities are approved by most of leading consultants. PARAMOUNT also

exports some systems and equipment that are exported to Far East Countries as well as USA.

During last two decades PARAMOUNT have designed and executed over 200 installations,

in all the related fields referred above. It is worth mentioning that some of these installations

include tertiary treatment of waste water, for using it for industrial purposes such as cooling,

feed to DM or R.O. Plant to produce water of ultra-fine quality.


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1.1 Products:

In Effluent & Waste Water Treatment we undertake the turnkey execution of complete

treatment plants, from concept to commissioning. The equipments & systems we offer

are Advanced Oil/Solid Separation Systems (Tilted Plate Interceptors), D.M.Plants,

Reverse Osmosis & Ultrafiltration Systems. We indigenously manufacture & supply the

whole range of equipments like Clarifiers, Clariflocculators, Surface Aerators,

Agitators/Flash Mixers, Thickeners, Dissolved Air Flotation Units and Plastic Media for

Bio-Towers, Bio-Tower etc.

1.2 Competitors:

UPL ENVIORNMENTAL ENGINEERS LIMITED

KADAM ENVIORNMENTAL CONSULTANT


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2. PROCESS ENGINEERING:

In paramount process engineering which includes tendering activities, basic engineering and

detail engineering activities.

2.1 In general the basic engineering documents consist of following:

1. Introduction/coversheet

2. Design basis

3. Treatment philosophy/treatment scheme

4. Process description

5. Products of treatment

6. Equipment list

7. Utilities & chemical composition

8. Unit size calculations-Equipment sizing

9. Hydraulic calculations-Pumps

10. Process datasheet for Equipments

11. Process datasheet for Pumps

12. Process datasheet for Instruments

13. Process flow diagram

14. Legend sheet and P&ID

15. Layout

16. Hydraulic flow diagram

17. Hydraulic calculation-Gravity

18. Process control narrative

2.2 Activities involved during detail engineering are following:

1. Updating BEP documents as and when required

2. General Arrangement drawing

3. Line schedule

4. Updating datasheet for MR/PR

5. MR/PR activities

6. Operation & maintenance manual

7. As built documents and drawings


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3. PIPING CLASS & MOC SELECTION GUIDELINES:

3.1 Check list for material selection:

1. Properties of material (corrosion, mechanical, physical, appearance)

2. Ease of fabrication

3. Compatibility with existing equipment

4. specification coverage

5. Availability of design data

6. Expected total life of plant or process

7. Estimated service life of material

8. Reliability (safety and economic consequences of failure)

9. Need for further testing

10. Material and its fabrication cost

11. Return on investment analysis

12. Maintenance and inspection cost13. Comparison with other corrosion control methods

14. Availability and delivery time


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3.2 Selection of material based on application/Fluid/Service:

MATERIAL ENVIORNMENT

Aluminium Water and steam, NaCL, sea atmosphere

Copper alloys(Brass) Ammonical solutions, amines, mercury-salt

solutions

Austenitic stainless steels Chlorides, including FeCl2,FeCl3,NaCl,sea

enviornments,H2SO4,flurodies,condensing

steam from chloride waters

Ferritic stainless steels Chlorides, NaCL, fluorides, bromides,

iodides, caustics, nitrates, water steam

Carbon and low alloy steels HCL, caustics, nitrates,HNO3,HCN,H2S,

H2SO4,sea water

High strength alloy Sea and industrial environments

Magnesium alloys Tap water, sodium chloride solutions

Lead Lead acetate solutionsNickel Bromides, caustics, H2SO4

Monel Fused caustic soda, hydrochloric and

hydrofluoric acids

Titanium Sea environments, NaCL in environments

288 C, silver and AgCl, fuming HNO3,

chlorinated or fluorinated hydrocarbons


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3.3 Selection of material based on different concentrations of solutions:

METALS H2SO4 H2SO4 NaHSO4 NaHSO3 HCL HCL HNO3 HNO3 HF NaoH

CONC,, DILUTE SOLUTION SOLUTION CONC. . DILUTE CONC.. DILUTE 50% 50%

1 TANTALUM A A A A A A A A X X2 ALLOY 20 A A A A X X A A B B

3 HASTELLOY B A B B C A B X X B A

4 HASTELLOY C A B A A B A B A A B

5 S.S-316 B B B B X X A A C A

6 S.S-304 C C C C X X A A X A

7 CR-SI STEEL A A A X B A B B X C

8 CARBON STEEL B X X X X X X X X A

9 BRASS X C C C X X X X X C

10 COPPER C B B B X C X X B B

11 ALLUMINIUM C C C B X X C X X X

A=EXCELLENT,B=GOOD,C=FAIR,D=UNSATISFACTORY

3.4 Piping material specification index:

SR NO PIPING LINE RATING CA MATERIAL

1 A19A 150 3 CARBON STEEL

2 A1K 150 0 SS304

3 A1Z 150 0 HDPE

4 A22N 150 1.5 SS316

5 A2A 150 1.5 CARBOON STEEL

6 A3A 150 1.5 CARBOON STEEL

7 A3Y 150 0 RUBBER LINED CS

For example:

A3A

1) FIRST LETTER : RATING e.g. A-150 class

2) MIDDLE NUMBER : CORROSION ALLOWANCE e.g.1.5 (mm required as CA)

3) THIRD LETTER : MATERIAL e.g. A-carbon steel


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4. VALVES:

4.1 Definition:

A valve is a mechanical device that controls the flow of fluid and pressure within a system by

performing any of the following functions:

Stopping and starting fluid flow

Varying the amount of the fluid flow

Controlling the direction of the fluid flow

Regulating downstream system or process pressure

Receiving component or piping over pressure

Plug and Globe valve


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4.2 Valve types and application:

SR.NO. VALVE TYPE ADVANTAGES DISADVANTAGES APPLICATION

1 GATE VALVE Low pessure drop when, Gate valves have slow - Gate valves are used primarily

fully open and tight sealing. response characteristics and for on-off application.

require large actuating forces. they are suited for high temp.

It causes vibration,seat and &pressure with wide variety

disc wear in partial open of fluids.they are not normally

condition. used for slurries,viscous fluids.

2 GLOBE VALVE Faster to open or close,most High pressure drop compare Globe valves are used primarily

reliable form of sealing, to gate valve. for throttling purposes.

throttling to control the flow globe valve may be consider

to any desired degree and a general purpose flow control

positive shut off. valve specifically used for

high temperature applications.

3 PLUG VALVE Normally small in size - operating torque is quite high. Plug valves are extensively

requires less head room and lubricated plug valves require used in refinery ,petrochemical

available in wide range of periodic lubrication and lubri- and chemical industries.

materials.they provide tight cant may react with the fluid it is also used for on-off service.

shut off,quick opening and being carried.

low pressure drop.

4 BALL VALVE Low pressure drop,tight shut- Fluid trapped in the ball in the Ball valves are used in a wide

off,quarter turn operation, closed position may cause range of applications including

easy to maintain,low torque. problem of build up of vapour flow control,pressure control

they are small in size and low pressure and corrosion. and shut off.they are used for

in weight. corrosive fluids,cryogenic liquid

very viscous fluids and slurries.

These valves are also used in

refinery,petrochemical andLPG application due to bubble

tight shut off.

5 BUTTERFLY Simple,compact form,Quick Seals may be damaged if the Mainly used in low pressure

VALVE Opening,good controllability velocity is high.Usually require applications where leakage

low pressure drop ,low high actuating forces,limited is relatively unimportant.

weight and cost. to low pressure and elasto- it is now widely being used

mer limits the temperature. in majority of process

applications.

SR NO VALVE TYPE ADVANTAGES DISADVANTAGES APPLICATION

6 DIAPHRAGM The diaphragm completely For high pressure application Due to its economy,the

VALVE keeps the working parts in the valve operation is quite diaphragm valve finds a vastisolation from process difficult. application for handling and

liquids. corrosive liquids at low temp-

earature.and they are also

used fertilizer,chemical

industry,water treatment

plants.

7 CHECK Minimizes water hammer The pressure drop across the Extensively used in process

VALVE and avoids reverse flow. valve is quite high and after industry for avoiding the back

continuous operation the flow and for piping with steam

composition of the seat gets handling.

disturbed re adjustment is

very difficult.


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4.3 Valve selection process:


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4.4 Control valve:

Process plants consist of hundreds, or even thousands, of control loops all networked together

to produce a product to be offered for sale. Each of these control loops is designed to

keep some important process variable such as pressure, flow, level, temperature, etc. within a

required operating range to ensure the quality of the end product. Each of these loops receives

and internally creates disturbances that detrimentally affect the process variable, and

interaction from other loops in the network provides disturbances that influence the process

variable.

To reduce the effect of these load disturbances, sensors and transmitters collect information

about the process variable and its relationship to some desired set point. A controller then

processes this information and decides what must be done to get the process variable back to

where it should be after a load disturbance occurs. When all the measuring, comparing, and

calculating are done, some type of final control element must implement the strategy selected

by the controller. The most common final control element in the process control industries is

the control valve. The control valve manipulates a flowing fluid, such as gas, steam, water, or

chemical compounds, to compensate for the load disturbance and keep the regulated process

variable as close as possible to the desired set point.

4.4.1 Loop for ON/OFF valve:


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4.4.2 Loop for control valve:


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5. PUMPS:

Definition:

Pump is a device that imparts energy to a fluid passing through it to enable the fluid to move

from one point to another.

In practice, pumps change both the velocity and the pressure passing through them.

Pumps fall into two broad classes:

1) Positive Displacement Pumps

2) Rotor dynamic Pumps

5.1 Positive Displacement Pumps:

Working Principles:

1. Fluid is displaced from the suction to the discharge by the mechanical variation of the

volume of chamber or chambers at every stroke or rotation of the pump

2. Volume of pump chamber alternately increases to draw the liquid in from suction pipe& then decreased to force the liquid out into the delivery pipe

3. This may be done by either a reciprocating motion of a piston or by a rotary motion of

specially designed vanes, gears or screws

Characteristic:

1. Self-priming

2. All the valves at the discharge side of the pumps must be kept open prior starting

3. Failure to do so will cause rapid increase of fluid pressure, leading to failure at the

weakest point in the system

4. Relief valve is always fitted in the system to avoid such failure


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Subdivided into Two main categories:

1. Reciprocating Pumps

- Where plunger or piston is reciprocated in a fluid cylinder

- Suitable for delivering small quantities at high pressure

2. Rotary Pumps ( Gear, Screw, Vane pumps )

- Where the liquid is forced through the pump casing by means of screws, gears or vanes

- used for delivering moderate quantity at moderate pressure

5.1.1 Reciprocating Pump:

Main Components:

1. Cylinder

2. Piston

3. Piston rod

4. Gland

5. Suction valve

6. Discharge valve

Pump may be of Single acting or Double acting type

Single Acting Reciprocating Pump:

1. There is one suction & one discharge per cycle

2. Piston moves down during suction stroke

3. Causes low pressure to create & fluid to flow into cylinder by opening suction valve

4. Piston moves up during discharge stroke

5. Causes fluid to be compressed and pressurised

6. Discharge takes place by opening discharge v/v by high pressure fluid

SUCTION STROKE DISCH STROKE


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5.1.2 Gear Pump:

1. It is a positive displacement pump

2. It consists of two meshing gears with one driving the other

3. Fluid flows between the casing and the gear teeth

4. Commonly employed for lube & fuel oil transfer

5. Must have relief valve installed in the system

5.1.3 Screw Pump:

1. Screw pumps are positive displacement pumps

2. Screws are meshed together with one driving other

3. Fluid is displaced through the recesses between the screws and the casing

4. May have single, double or triple screws


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5.1.3 Vane Pump:

1. Vane pumps are positive displacement pumps

2. Rotors having slots for vanes

3. Centre of rotor is eccentric with casing

4. This causes vanes to move in and out as the rotor rotates

5. Causes change in volume in the respective chamber, similar to reciprocating pump


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5.2 Roto dynamic Pumps:

1. Often Known as dynamic pumps or centrifugal pumps

2. Centrifugal pumps are more suitable for delivery of large quantities at low discharge

pressure

3. Are Non-self-priming pumps

4. Loses suction and unable to pump once air gets into the pump system

5. Must be primed before starting


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Centr if ugal Pump:

Main Components:

1. Impeller

2. Impeller wear ring

3. Volute Casing

4. Shaft

5. Ball bearing

6. Gland

Working Principle:

1. Impeller rotates at high speed

2. Fluid enters through the eye of the impeller

3. Fluid is thrown by centrifugal force from the centre (suction side) radially outwards to

the periphery of impeller (discharge side)

4. High velocity fluid enters the stationary volute casing

5. Volute casing converts the kinetic energy of fluid into pressure energy at the

discharge of the pump.


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8 Lobe pump Two lobes rotating Used in nuclear, food

processing and chemical

units for handling

sensitive fluids

9 Piston and plunger pump Reciprocating and positive

displacement type

Pumping for ammonia

and carbonate at high

pressure

10 Diaphragm pump Pumping by means of

pulsating elastic or flexible

diaphragms of rubber,

plastic etc.

Used for pumping slurry,

sludge or chemical

solutions

11 Rotary gear pump Helical type of gears with

meshing of gears

Used for viscous liquids

in the viscosity range up

to 1000cp

5.4 Standard arrangement for pumps:

5.4.1: Loop for screw pump:


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5.4.2 Loop for centrifugal pump:

5.4.3 Loop for reciprocating pump:


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5.5 Trouble shooting:


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5.5.1 Trouble shooting for centrifugal pump:

Capacityt

oo

low

Headtoo

low

Poororno

suction

Intermitte

nt

delivery

Noisy

o

eration

Pump

leaking

Power

consumpt

io

ntoohigh

Bearing

temptoo

hih

Pumpcom

es

tostopjams

Speed too

low

A A

Casing or

shaft

sealing

leaking

B B B B B

Suction lifttoo high

B B B B

Viscosity

of delivery

liquid too

high

C C C C C C

Specific

gravity of

delivery

liquid too

high

D D D

Improper

installation

strain on

the pump

hose or

jamming

parts in

the pump

E E E E E

Wear rings

clearancetoo big

due to

wear

F F F F

Wrong

direction

of rotation

G G

Discharge

line

friction

loss high

H H


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A Check the frequency and voltage of incoming supply

B Ensure if the trouble is caused by the casing, shaft, sealing, suction pipe, foot valve or suction

strainer .Accordingly take the following action

Renew the gasket on the casing Tighten the gland or renew the packing ring

Ensure the leak tightness of the suction pipe

Check the leak tightness of the foot valve

Clean the suction strainer

C Clean the suction pipe, foot valve and suction strainer. If needed, replace the flange gasket.

Check the suction pipe

D Pump model and motor rating are determined on the basis of data specified in the purchase

order. Troubles arising due to different data can be cleared only after consulting the pump

supplier

E Readjust the alignment of the pump and motor. Check that no stress is transmitted by piping

and flange connection.

F Discharge the pump and replace the defective parts

G Replace the wear rings

H Interchange the phase conditions of the motor


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6. INSTRUMENTS-TYPES & APPLICATION:

6.1 Pressure measuring instruments:

6.2 Flow measuring instruments:

Sr No TYPE APPLICATION REMARKS

1 Magnetic Flow meter Used for slurry , acid Provided with

upstream and

downstream isolation

valve, not used for gas

application

2 Vortex Meter Used for high

turndown Ratio

Provided with

upstream and


valve

3 Vane/Turbine Type Clean fluid gas High accuracy

4 Orifice meter Used for clean liquid

service

For size < 2

5 Rota meter Used where local

indication is required

Size up to 3


1 Diaphragm pressure

gauge

Used for liquids

containing solid

particles or suspension

Provided with isolation

valve

2 Bourdon Type Pressure

Gauge

Used for clean liquid Isolation valve is

provided, used for

steam line

3 Differential type

pressure instrument

To be provided with

upstream and


valve


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6.3 Temperature measuring instruments:


1 RTD Used where

temperature of

liquid/gas is up to 600

No isolation valve is

required

2 Thermocouple Used for High

Temperature

application Range

between 0-2500

No isolation valve is

required

3 Temperature Gauge For Local indication.

Range from 0-600

6.4 Level measuring instruments:


1 Differential Pressure

Type

For Liquid Level

Measurement

Side Mounted

2 Radar Type Top mounted ,The

measurement

accuracy is unaffected

by changes in density,

conductivity and

dielectric constant of

the product being

measured or by air

movement above the

Product.

3 Ultra Sonic Top mounted,

Cheaper than Radar

4 dipstick Used only for vented

and underground tank

Fast insertion,

insertion with an

angle

5 Float and Tape Type Widely used in water

storage tank

Used mainly for open

tanks local level

indication

6 Tabular gauge glass Used in low pressure

services to avoid

breakage

Fitted externally

7 Level switch Emergency shutdown,

alarming, on/offapplication

Point level sensor which

moves with the liquidsurface


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7. BASICS OF PFD (PROCESS FLOW DIAGRAM):

7.1 Introduction:

In PFD the Entire process is represented sequentially by means of equipment symbols and

lines indicating all equipment and flow directions.

Symbols are based on codes and standards Consists of Pictorial interrelationship between

various unit operations and process units.

Material balance at all major steps.

Energy balance in the form of specific heat, temperature and state of materials.

A PFD can be computer generated from process simulators (see List of ChemicalProcess Simulators), CAD packages, or flow chart software using a library of chemical

engineering symbols.

Rules and symbols are available from standardization organizations such as DIN, ISOor ANSI.

Often PFDs are produced on large sheets of paper.

PFDs of many commercial processes can be found in the literature, specifically inencyclopaedias of chemical technology.

7.2 A typical PFD will consist of following things:

Process piping

Major bypass and recirculation lines Major equipment symbols, names and identification numbers

Flow directions

Control loops that affect operation of the system

Interconnection with other systems

System ratings and operational values as minimum, normal and maximum flow,temperature and pressure

Composition of fluids

7.2.1 Following things should be considered while making PFD:

It is desirable to show equipments at theirrelative positions.E.g. Pumps at ground level

Main process streams are always in bold.

Streams are numbered within diamond.

Equipments are numberedbased on function or Area or both.

Also show utilities and ETPs.

While continuing on other sheet, must indicate

Interconnection between various streams.

Horizontal lines are dominant Number streams left to right when possible


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7.3PFD will not include:

Pipe classes or piping line numbers

Process control instrumentation (sensors and final elements)

Minor bypass lines

Isolation and shutoff valves

Maintenance vents and drains

Relief and safety valves

Flanges

7.4 Standards used for making PFD:

ISO 10628: Flow Diagrams for Process Plants - General Rules

ANSI Y32.11: Graphical Symbols for Process Flow Diagrams (withdrawn 2003)

SAA AS 1109: Graphical Symbols for Process Flow Diagrams for the Food Industry.

7.5 Tracing of Primary Chemicals in PFD:

Reactants: start with the feed (LHS of PFD) and trace chemicals forward towardreactor.

Products: start with the product (RHS of= PFD) and trace chemicals backward towardreactor.

Tactics applicable for tracing lines in PFD:

(1) Any unit operation, or group of operations, that has a single or multiple input stream(s)

and a single output stream is traced in a forward direction. If chemical A is present in any

input stream, it must appear in the single output stream.

(2) Any unit operation, or group of operations, that has a single input and single or multiple

output stream(s) is traced in a backward direction. If chemical A is present in any output

stream, it must appear in the single input stream.(3) Systems such as distillation columns are composed of multiple unit operations with a

single input or output stream. It is sometimes necessary to consider such equipment

combinations as blocks before implementing Tactics (1) and (2).


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8. BASICS OF P&ID:

8.1 Legends:

Legends are the basic requirement for making of P&ID. They contain symbols for different

equipments, instruments and lines present in a plant.

8.1.1 Instrument Legend:

Property

Measured

First

Letter

Indicating

only

Recording

only

Controlling

Only

Indicating

andcontrolling

Recording

andcontrolling

Flow Rate F FI FR FC FIC FRC

Level L LI LR LC LIC LRC

Pressure P PI PR PC PIC PRC

Quality Q QI QR QC QIC QRC

Radiation R RI RR RC RIC RRC

Temperature T TI TR TC TIC TRC

Weight W WI WR WC WIC WRC

Instrument Short-Hand Symbols or Bubbles Used in P&IDs:


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Basic Instrumentation Symbols:


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Designation of letters used in making P&ID:


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8.1.2 Legends for fluids:


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8.1.4 Flow Sensors Symbols Used in P&IDs:


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8.1.5 Valve Failure Modes Symbols Used in P&IDs:


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8.1.6 Valve Actuator Types Used in P&IDs:

8.1.7 Valves Symbols Used in P&IDs:


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8.1.8 Line Type & Control Signals Symbols Used in P&IDs:

8.1.9 Piping Connection Symbols Used in P&IDs:


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8.2 P&ID:

8.2.1 Definition:

P&ID is defined by theInstitute of Instrumentation and Controlas follows: A diagram which shows the interconnection of process equipment and the instrumentation

used to control the process.

In the process industry, a standard set of symbols is used to prepare drawings of processes.

The instrument symbols used in these drawings are generally based on Instrumentation,

Systems, and Automation Society (ISA) Standard S5. 1.

The primary schematic drawing used for laying out a process control installation.

In term of processing Facilities It is a pictorial presentation of

Key piping and instrument details

Control and shutdown schemes

Safety and regulatory requirements and

Basic start up and operational information

8.2.2 P&ID will contain:

P&ID will include following things:

1. Instrumentation and designations2. Mechanical equipment with names and numbers3. All valves and their identifications4. Process piping, sizes and identification5. Miscellanea - vents, drains, special fittings, sampling lines, reducers, increasers andswages

6. Permanent start-up and flush lines7. Flow directions8. Interconnections references

9. Control inputs and outputs, interlocks10. Interfaces for class changes


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9. PUMP HYDRAULICS:

9.1 Definition:

9.1.1 Suction Head:

If the water to be pumped has its surface ABOVE the center of the pump, then this

relationship is called a "suction head". More technically, it is the positive vertical distance

between the pump datum and the liquid surface in the suction well.

9.1.2 Static Head:

"Static head is the distance that the water is to be lifted."

Therefore, if the liquid level is above the datum, then it is a "positive value", as the water

does not need to be pumped to that elevation. In the calculation:(Static Head, ft.) = (Discharge Head, ft.) - (Suction Head, ft.)

"Once more for emphasis", the suction elevation is subtracted from the discharge head as the

water is already at a positive, "not needed to be pumped elevation" ABOVE the pump. This

resulting value is known as the static head.

9.1.3 Discharge Head:

It is the vertical distance between the pump datum point and the liquid surface in the

receiving tank. The pump datum is at the center line for horizontal pumps and at the entrance

eye of the impeller for vertical pumps.

9.1.4 Friction Head:

It is the head necessary to overcome the friction in the pipes, fittings, valves, elbows, etc.

This information is gathered empirically, and then recorded in tables so that we can estimate

these values according to the flow, the pipe size, the pipes material it is constructed out of,

pipe age and any deposits, the type of valve, etc. This additional resistance to flow must be

compensated for, in order to deliver the desired flow rate. Please refer to the illustrations for

suction head and suction lift, where you will notice that the friction head in feet, is added to

the static head which results in a new value called the Total Head or Total Dynamic Head.


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9.2 Example:

In the calculation:

(Static Head, ft) = (Discharge head, ft) - (Suction Elev. ft)

Note that the suction elevation (lift) is below the pump datum. In this case the elevation is anegative number (minus) and therefore "a minus subtracting a minus is a positive value in

the equation. To illustrate a suction liquid level 5 feet BELOW the pump datum, with a

Discharge head of 35 ft.

(40 ft.) = (35 ft.) - (-5 ft.)


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9.3 Net Positive Suction Head (NPSH):

In a hydraulic circuit, net positive suction head (NPSH) is the difference between the actual pressure

of a liquid in a pipeline and the liquid's vapor pressure at a given temperature.

NPSH is an important parameter to take into account when designing a circuit: whenever theliquid pressure drops below the vapor pressure, liquid boiling occurs, and the final effect will

be cavitation: vapor bubbles may reduce or stop the liquid flow, as well as damage the

system.

Centrifugal pumps are particularly vulnerable especially when pumping heated solution near

the vapor pressure, whereas positive displacement pumps are less affected by cavitation, as

they are better able to pump two-phase flow (the mixture of gas and liquid), however, the

resultant flow rate of the pump will be diminishedbecause of the gas volumetrically

displacing a disproportion of liquid. Careful design is required to pump high temperature

liquids with a centrifugal pump when the liquid is near its boiling point.

The violent collapse of the cavitation bubble creates a shock wave that can carve material

from internal pump components (usually the leading edge of the impeller) and creates noise

often described as "pumping gravel". Additionally, the inevitable increase in vibration can

cause other mechanical faults in the pump and associated equipment.

NPSH (Net Positive Suction Head) = hss + hps - hfs - hvp ;

hss = static suction head ;

hps = atmospheric pressure acting on the surface of the liquid ;

hfs = head loss due to friction in the pipe ;

hvp = vapour pressure ;
http://en.wikipedia.org/wiki/Hydraulichttp://en.wikipedia.org/wiki/Vapor_pressurehttp://en.wikipedia.org/wiki/Boilinghttp://en.wikipedia.org/wiki/Cavitationhttp://en.wikipedia.org/wiki/Centrifugal_pumphttp://en.wikipedia.org/wiki/Pump#Positive_displacement_pumphttp://en.wikipedia.org/wiki/Pump#Positive_displacement_pumphttp://en.wikipedia.org/wiki/Centrifugal_pumphttp://en.wikipedia.org/wiki/Cavitationhttp://en.wikipedia.org/wiki/Boilinghttp://en.wikipedia.org/wiki/Vapor_pressurehttp://en.wikipedia.org/wiki/Hydraulic


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9.4 sample calculation:

Q Calculate NPSH available, discharge pressure, differential pressure, differential head for the pump

carrying effluent from aeration tank to flocculation tank with the following data given.

Data Given:

=10cp

=1000 kg/

Q=666 l/h

d=25mm

Answer:

Q=A*v

= * *v

V=0.37m/s

Re= = = 1000

Re 5cp so it is viscous fluid

f= = 0.016 ; f=friction factor

Friction loss in fitting K Qty Equivalent length

=

Entry loss 0.5 1 0.781

90 Bend 0.45 4 2.81

Tee strainer 2 1 3.125

Ball Valve 0.5 2 1.56

Tee st run 2 1 3.125

Check valve 1 0 0

Reducer 2 0 0

Net Equivalent length 11.01

Straight Pipe Length=10m;

L=10 + 11.401=20.85m


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Friction Loss = = =0.45

Pump suction centre line =27.7m

Minimum Water level in the Tank=28.8m

Vapour Pressure =0.75m

Top of the unit of flocculation tank=21.65m

NPSH (Net Positive Suction Head) = hss + hps - hfs - hvp

= (28.8-27.7) + 10.3 - 0.75 - 0.45

= 10.2m

For Discharge

d=20mm

Q=700 l/h

From pump to Header=5m

From Header to flocculation tank=320m

Q=A*v

= = * *v = 0.6m/sec

Re= = = 1220

Re


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10.2 GPCB Norms for Effluent Water:

Sr No Term mg/l or ppm

1 COD 250

2 BOD 100

3 TDS 5000

4 TSS 100

5 Chloride 600

6 Sulphate 1000

7 Phenolic 1

8 Oil and grease 10

Documents

Report on Desiging company