reactor+piping

TRAINING MANUAL- PIPING

PIPING STUDYREACTOR PIPING

Uhde India Limited

DOC No. : 29040-PI-UPS-1006

Rev. : R0

Page : 1

CONTENTS

Page

0.0 Cover Sheet 1

List of drawings 2

1.0 Introduction 3

2.0 Design Considerations for Reactors 3 - 4

3.0 Platform Arrangements 4

4.0 Piping Arrangements 4 - 5

5.0 Key words for Reactor Piping 5

Applicable Revision:Prepared:

Date:

Checked:

Date:

Approved:

Date:First Edition: R0Prepared: AKB

Date:

Checked: TNG

Date:

Approved: RUD

Date:File Name: Server: PUNE: KUMUS 207 VKO: KUMUS 209



Uhde India Limited

DOC No. : 29040-PI-UPS-1006

Rev. : R0

Page : 2

LIST OF ILLUSTRATIONS

SR.NO. DWG.NO. DESCRIPTION

1 RP1 TYPICAL BATCH REACTOR LAYOUT

2 RP2 STANDARD ARRANGEMENT OF REACTOR

3 RP3 DESULPHURIZER PROCESS

4 RP4 HYDROTREATER PROCESS

5 RP5 TYPICAL REACTOR

6 RP6 TYPICAL BATCH REACTOR OF A CHEMICAL PLANT

7 RP7 PROCESS VESSEL SKETCH OF REACTOR

8 RP8 PARTIAL PLOT PLAN FOR A HYDROTREATER UNIT

9 RP9 METHODS OF REACTOR SUPPORT

10 RP10 MINIMUM REACTOR ELEVATION REQUIREMENTS

11 RP11 DIRECT UNLOADING FROM A REACTOR TO A TRUCK

12 RP12 TOP HEAD NOZZLE ARRANGEMENTS OF A BATCHREACTOR

13 RP13 TOP HEAD NOZZLE ARRANGEMENTS

14 RP14 BOTTOM HEAD NOZZLE ARRANGEMENTS

15 RP15 SAMPLE PROBE CONNECTION

16 RP16 REACTOR PLATFORM AND LADDER ELEVATIONREQUIREMENTS

17 RP17 SINGLE REACTOR PIPING ARRANGEMENT

18 RP18 REACTORS IN SERIES : MANUALLY OPERATED VALVEMANIFOLD

19 RP19 REACTORS IN SERIES : REMOTELY OPERATED VALVEMANIFOLD

20 RP20 DAVIT AND TROLLEY BEAM ARRANGEMENT ON REACTORTOP



Uhde India Limited

DOC No. : 29040-PI-UPS-1006

Rev. : R0

Page : 3

1.0 INTRODUCTIONReactors are usually a vertical equipment where various chemical reaction takes place. Very oftenreactors are having agitators mounted either on top or bottom of the vessel. Reactors may haveexternal jacket or internal coil for any heat transfer requirements.

Reactors with agitator, gearbox and motor arrangement make the assembly heavy and vibrating.There are various types of reactors in chemical, fertilizer and refinery plants viz. Batch reactors,Fixed-Bed Reactors, Gas-Fluidized Bed Reactors. Based on the process function, they are calledas Desulphurisers, Convertors, Hydrotreaters etc. This piping study is also applicable forequipment called crystallizers, evaporators, thickners etc.

1.1 Batch reactions are often carried out as liquid phase or gas-liquid reactions. These may be carriedout at elevated temperature and pressure in horizontal autoclave supported on concrete saddle atlow elvevation because of heavy weight.

Operation and maintenance access, platform requirements, maintenance facilities are to beconsidered around the reactors.

Operation at floor during process reaction, floor drainage during maintenance, lifting monorail /hoist arrangements, ventilation ducts / hoods provision are some of the common features in thereactor area.

1.2 Fixed-bed reactors are normally loaded with packing or catalyst in bulk between supports insidethe reactor vessel or in baskets if the temperature is not critical.

When temperature is more critical, the catalyst may be packed within tubes mounted in shell withheating or cooling fluid circulating between shells and tubes.

If the catalyst or packing is to be removed from the base, the reactors must be elevated sufficientlyto allow removal by mechanical transport equipment.

Several reactors, whether in series or parallel should be arranged in line with common supportstructures and an overhead monorail to serve all the reactors. The same overhead structure maybe used for loading catalyst and removing internals.

1.3 The fluidized-bed reactors require handling of solid catalyst or reactant under gravity flow and largequantities of gas, air or liquid used in the reactor.

The top of the reactor is occupied by overhead feed hoppers. The top should have accessplatform and overhead lifting equipment for removal of internals.

2.0 DESIGN CONSIDERATION FOR REACTORS

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

2.2 Reactors are located within a process unit adjacent to related equipment with the facilities forcatalyst loading and unloading as well as close to furnace to minimize expensive high-temperaturepiping.



Uhde India Limited

DOC No. : 29040-PI-UPS-1006

Rev. : R0

Page : 4

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

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

2.5 Nozzle arrangements on top of reactor shall be visualised keeping in view of the followingconsiderations.

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

2.6 Nozzle arrangements on bottom of the reactor shall be decided based on the followingconsiderations.- Bottom product outlet method.- Bottom connections to pumping facility.- Clear space available between support base unloading of catalyst from nozzle. This is

illustrated in Fig.RP11

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

3.0 PLATFORM ARRANGEMENTS

3.1 Platforms are required for access to valves, instruments, blinds maintenance access, feedopenings etc.

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

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

4.0 PIPING ARRANGEMENTS

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

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

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

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



Uhde India Limited

DOC No. : 29040-PI-UPS-1006

Rev. : R0

Page : 5

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

5.0 KEY WORDS FOR REACTOR PIPING

5.1 Heavy Vessel

Support structure (Independent or on reactor)Agitators / Gearbox / Motor assemblyGravity feedBarometric legNPSHPlatform arrangementsMaintenance accessManholeFlush bottom valveExternal JacketInternal CoilLifting tools / overhead monorail with chain pulley block / Davit.Flanged head.VibrationsSight GlassSpace for chemical storageFlexible Hose connectionsVentilation ducts

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

FINISHED GROUND LEVEL (FGL)

AIR PURGE FAN

FLAME PROOFSTARTER BOARD

HEATER CONTROLCUBICLE

PLATFORM

FLUSH BOTTOMOUTLET VALVE

CABLE TRAY

VACUUM PUMP

VACUUMRECEIVER

SEPARATOR

WATER INLET

VENTS

CONDENSER

WATER OUTLET

AGITATOR

REACTOR

AIR PURGE FAN

HEATER CONTROL CUBICLE(UNDER PLATFORM)

FLAME PROOFSTARTER BOARD

AIR BLEED

CONDENSER

2350

1850

3650

ELEVATION

TYPICAL BATCH REACTOR LAYOUT

PLAN

DOC NO.

Rev.

PageUhde India Limited

TRAINING MANUAL - PIPING

PIPING STUDY

DWG. NO.

REACTOR PIPING

: 29040-PI-UPS-1006

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: 1 OF 1

: RP1

RECEIVER

VACUUM

VACUUMPUMP

STANDARD ARRANGEMENT OF REACTOR

INLET RELIEFVALVE CONTROLLER

LEVEL GAUGE/ PRESSUREGAUGE

VENTOUTLETVAPOUR

MANHOLE

CONNECTIONSTEAM OUT

LIQUIDOUTLET

SADDLES

1/5`L' 3/5`L' 1/5`L'

DOC NO.

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PIPING STUDY

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RP2

THERMOWELL

DRAIN

DESULPHURIZER PROCESS

KNOCK OUT DRUM

FEED

CATALYST BED(TYPICAL)

DRAFT FANINDUCED REFORMER

DESULPHURIZERS

DOC NO.

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PIPING STUDY

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: RP3

HYDROTREATER PROCESS

CHARGEPUMPS

FEED

FEED EXCHANGERS

REACTOR

CHARGEFURNACE

DOC NO.

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PIPING STUDY

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: RP4

SURGE DRUM

TYPICAL REACTOR

INERT MATERIAL

MAINTENANCEACCESS

SCREENFLOATING

CATALYST BED

PROBESAMPLE

& SCREENFIXED GRATING

OUTLETCOLLECTOR

NOZZLEOUTLET

CATALYSTDROP OUTNOZZLE

LUGSUPPORT

TEMPERATUREWELL

INLET BAFFLE

INLET NOZZLE

DOC NO.

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PIPING STUDY

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: RP5

HANDLE

(SEE RP15)

TYPICAL BATCH REACTOR OF A CHEMICAL PLANT

DOC NO.

Rev.



PIPING STUDY

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REACTOR PIPING

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: RP6

N12N25N5

N4 N24

N33 N3

N30

N32

N34

N35

N29

N26

N28

N27

N9

N6

N8

N7

N1N1A

N10

ISMC 300(TYP.)

34113195

35453374

3000

160

10TH

K.

151

10THK.(TYP.)

400(TYP.)

AA

1000

700

87

1001

0

0.0

2800 OD 8THK.

5THK. R/L

400(TYP.)

50x10THK.SECTION `A-A'

NOZZLEDESCRIPTION :N1N1AN3N4N5N7N8N9N10N12N24N25N27N28N29N30N32N33N34N35N6N26N13N23

- STEAM INLET

- PROCESS WATER INLET

- LIQUID INLET- NOZZLE FOR N23

- SPARE

- NOZZLE FOR N26- SPARE

- AGITATOR NOZZLE- SPARE

- NaNO2 INLET- ICE INLET

- HCL INLET

- STEAM INLET- NaOH INLET

- PRODUCT OUTLET- MANHOLE

- NOZZLE FOR N1- WASTE GAS OUTLET- NOZZLE FOR 24

- NOZZLE FOR TIR

- NOZZLE FOR 25- NOZZLE FOR 27- NOZZLE FOR 28- NOZZLE FOR 29

* NOTE : NOZZLE ELEVATIONS INCLUDING R/L THICKNESSTOP COVER IS PANEL TYPE CONSTRUCTION.

PROCESS VESSEL SKETCH OF REACTOR

MAA

T

UC B

6'-0" I.D.1830

S

2'-0

"61

0

20'-0

"61

00

SYMBOL SIZE SERVICE

NOZZLE SUMMARY

A 8" 600#RF INLET

8" 600#RFB OUTLET

3" 600#RFS SAMPLE

1" 600#BJT TEMPERATURE

12" 600#RFUC CATALYST

24" 600#RFMA MAINTENANCEACCESS

DROP OUT

DOC NO.

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PIPING STUDY

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: RP7

PARTIAL PLOT PLAN FOR A HYDROTREATER UNIT

CATALYST LOADING& UNLOADING AREA

CHARGE FURNACE

SURGE DRUM

CHARGE PUMPS

ACCESS WAY

PIPE RACK

FEED EXCHANGERS

C R

EA

CT

OR

L

DOC NO.

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: RP8

METHODS OF REACTOR SUPPORT

a. SKIRT SUPPORTED (FOUNDATION) b. LUG SUPPORTED

c. RING GIRDER SUPPORTED

STEELSTRUCTURE

REACTOR(TYP.)

GIRDERRING

TABLE TOPCONCRETE

d. SKIRT SUPPORTED (TABLE TOP)

CONCRETETABLE TOP

DOC NO.

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REACTOR

SKIRT

REACTOR

CONCRETEPIERS

SKIRT

MINIMUM REACTOR ELEVATION REQUIREMENTS

4'-6

"/13

70

CONVEYOR

MINIMUM TO SUITPIPE SUPPORT orLOW-POINT DRAIN

DOC NO.

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PIPING STUDY

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: RP10

REACTOR

DIRECT UNLOADING FROM A REACTOR TO A TRUCK

12'-1

5'36

50-4

600

DOC NO.

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PIPING STUDY

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REACTOR PIPING

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TRUCK

REACTOR

TOP HEAD NOZZLE ARRANGEMENTS OF A BATCH REACTOR

DOC NO.

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PIPING STUDY

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: RP12

LI

LI

C BATCH REACTORL

C CHEMICALLTOWER(TYP.)

VAPOUROUTLET

OPENINGFEED

MOTOR ASSY.C AGITATOR GEAR BOXL

TOP HEAD NOZZLE ARRANGEMENTS

ELEVATION PLAN

ELEVATION PLAN

4"/100 MIN.

MAINTENANCEACCESS

NOZZLEINLET

ACCESSMAINTENANCE

NOZZLEINLET

DOC NO.

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PIPING STUDY

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NOZZLE PROJECTIONABOVE PLATFORMMIN. 250MM

BOTTOM HEAD NOZZLE ARRANGEMENTS

ELEVATION PLAN

ELEVATION PLAN

4'-0

"/12

20

MIN

IMU

M

OUTLET

CATALYSTUNLOADINGNOZZLE

9"/230 MIN.

TANGENT

KNUCKLERADIUS

POINT

RADIUS

ONE NOZZLEDIAMETER

MINIMUM

NOZZLEUNLOADINGCATALYST

OUTLET

SKIRT SUPPORTED

LEG SUPPORTED

DOC NO.

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REACTOR

BOTTOM OUTLETOPENING

OUTLETBOTTOM

REACTOR

OUTLET

OUTSIDE

SAMPLE PROBE CONNECTION

WITHDRAWAL SPACEMESH SCREEN

DOC NO.

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PIPING STUDY

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REACTOR PLATFORM AND LADDER ELEVATION REQUIREMENTS

MIN

. 10"

/250

TEMPERATUREINSTRUMENT ACCESSBY LADDER ORPLATFORM

SAMPLE CONNECTION

PLATFORMACCESS BY

ACCESS FROMCATALYST UNLOADING

GRADE OR PLATFORM

MAXIMUM LADDERPLATFORM TO SUITINTERMEDIATE

RUN

TOP HEAD PLATFORM

INSTRUMENT &TEMPERATUREVALVE, VENT,

CATALYST LOADING ACCESS

DOC NO.

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PIPING STUDY

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SINGLE REACTOR PIPING ARRANGEMENT

CATALYST LOADING &UNLOADING AREA

REACTOR

FEED EXCHANGERS

PIPE RACK

CHARGE FURNACE

DOC NO.

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PIPING STUDY

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: RP17

REACTORS IN SERIES: MANUALLY OPERATED VALVE MANIFOLD

ELEVATION (VIEW-P)

PLAN

DOC NO.

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PIPING STUDY

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: RP18

OPERATORACCESS

P

REACTORS IN SERIES: REMOTELY OPERATED VALVE MANIFOLD

ELEVATION(VIEW-P)

PLAN

DOC NO.

Rev.



PIPING STUDY

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REACTOR PIPING

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: RP19

P

DAVIT ARRANGEMENT ON REACTOR TOP

DOC NO.

Rev.



PIPING STUDY

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REACTOR PIPING

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: RP20

TROLLEY BEAM ARRANGEMENT ON REACTOR TOP

RELIEF VALVES

DAVIT

LOADINGNOZZLE

UNLOADINGLOADING AND

AREA

LOADING ANDUNLOADINGAREA

NOZZLELOADING

TROLLEY

RELIEF VALVES

BEAMS

CONTENTSINTRODUCTIONDESIGN CONSIDERATION FOR REACTORSPLATFORM ARRANGEMENTSPIPING ARRANGEMENTSKEY WORDS FOR REACTOR PIPINGDWG. NO. : RP1DWG. NO. RP2DWG. NO. : RP3DWG. NO. : RP4DWG. NO. : RP5DWG. NO. : RP6DWG. NO. : RP7DWG. NO. : RP8DWG. NO. : RP9DWG. NO. : RP10DWG. NO. : RP11DWG. NO. : RP12DWG. NO. : RP13DWG. NO. : RP14DWG. NO. : RP15DWG. NO. : RP16DWG. NO. : RP17DWG. NO. : RP18DWG. NO. : RP19DWG. NO. : RP20

reactor+piping

Documents

batch reactors

piping arrangements

fixedbed reactors

various types of reactors

insidethe reactor vessel

gasfluidized bed reactors

platform arrangements

batch reactions