Post on 04-Apr-2018
7/29/2019 oil and gas sample project
1/20
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
7/29/2019 oil and gas sample project
2/20
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
7/29/2019 oil and gas sample project
3/20
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.
7/29/2019 oil and gas sample project
4/20
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
4
7/29/2019 oil and gas sample project
5/20
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%
Acetone 50%Water 30%Polymer 10%Monomer 10%
Acetone 50%Water 30%Polymer 10%Monomer 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
5
7/29/2019 oil and gas sample project
6/20
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%
Water 66.4%Acetone 27.9%Monomer 5.7%
Water 66.4%Acetone 27.9%Monomer 5.7%
Water 66.4%Acetone 27.9%Monomer 5.7%
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
6
7/29/2019 oil and gas sample project
7/20
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.
Analysis ofmaterial handledMass %
Acetone 83.3%Monomer 16.7%
Water 97.6%Acetone 2.0%Monomer 0.4%
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
7
7/29/2019 oil and gas sample project
8/20
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
Analysis ofmaterial handledMass %
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
8
7/29/2019 oil and gas sample project
9/20
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
9
7/29/2019 oil and gas sample project
10/20
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
10
7/29/2019 oil and gas sample project
11/20
11
7/29/2019 oil and gas sample project
12/20
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
12
7/29/2019 oil and gas sample project
13/20
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
13
7/29/2019 oil and gas sample project
14/20
14
7/29/2019 oil and gas sample project
15/20
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
15
7/29/2019 oil and gas sample project
16/20
H105 (1140DIA)
T101/2/3
R104
P106
1000
5600 el
2000
3000
600
15006670 el
Ground Level
REACTOR GROUP
ELEVATIONS
FormMethAnsFig11
Fig, 11
16
7/29/2019 oil and gas sample project
17/20
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
17
7/29/2019 oil and gas sample project
18/20
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
18
7/29/2019 oil and gas sample project
19/20
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
19
7/29/2019 oil and gas sample project
20/20
20