TRAINING REPORT OF

PHASE 1
AT 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

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 the equipment 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 (8thSemester) D.D.U, Nadiad

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 Ms. KHAYTI SHAH Mr. RAMESH SINGH (Deputy Manager, HYDROCARBON SECTION) (Chemist) (Process engineer)

Last but not the least I would like to thank head of department of Chemical EngineeringDharmsinh 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.

CONTENTS
SR NO 1 TITLE ABOUT THE COMPANY
1.1 PPRODUCTS 1.2 COMPETITORS

PAGE NO 7

PROCESS ENGINEERING
2.1 BASIC ENGINEERING DOCUMENTS 2.2 DETAIL ENGINEERING DOCUMENTS

PIPING CLASS AND MOC SELECTION GUIDELINES

3.1 CHECK LIST FOR MATERIAL SELECTION 3.2 SELETION OF MATERIAL BASED ON APPLICATION 3.3 SELETION OF MATERIAL BASED ON DIFFERENT CONCENTRATION OF SOLUTONS 3.4 PIPNG MATERIAL SPECIFICATION INDEX

10

VALVES
4.1 DEFINITION 4.2 VALVE TYPES AND APPLICATION 4.3 VALVE SELECTION PROCESS 4.4 CONTROL VALVE

12

PUMPS
5.1 POSITIVE DISPLACEMENT PUMP 5.2 ROTO DYNAMIC PUMP 5.3 TYPES OF PUMP AND APPLICATION 5.4 STANDARD ARRANGE MENT FOR PUMPS 5.5 TROUBLESHOOTING

17

INSTRUMENTS TYPES & APPLICATION

28
4

6.1 PRESSURE MEASURING INSTRUMENTS 6.2 FLOW MEASURING INSTRIMENTS 6.3 TEMPERATURE MEASURING INSTRUMENTS 6.4LEVEL MEASURING INSTRUMENTS

PFD
7.1 INTRODUCTION 7.2 PFD WILL CONTAIN 7.3 PFD WILL NOT INCLUDE 7.4 STANDARDS 7.5 TRACING OF LINES

30

BASICS OF P&ID
8.1 LEGENDS 8.2 P&ID 8.3 CHECKLIST FOR HEAT EXCHANGER 8.4 CHECKLIST FOR PUMPS

32

PUMP HYDRAULICS
9.1 DEFINITION 9.2 EXAMPLE 9.3 NPSH 9.4 SAMPLE CALCULATION

43

10

R&D PARAMETERS
10.1 DEFINITION 10.2 GPCB NORMS

49

1. INTRODUCTION TO THE COMPANY:

Paramount is one of the pioneering Indian companies exclusively engaged in the field of Environmental Management over last four decades. The company developed the skills/technologies through their indigenous R&D efforts and also through foreign technical collaborations to meet the Indian Federal Government regulations related to discharge of treated sewage & Industrial wastes, Emission of Air Pollutants from vehicular as well as different Industries and disposal of Municipal solid wastes as well as hazardous solid wastes. The company has acquired ISO-9001 certification and thus 'PARAMOUNT' is not only a process oriented company but having detailed engineering capabilities also. Paramount is known as one of the leading EPC Company and by now has completed over 200 projects in different areas. PARAMOUNT LIMITED is a multi-discipline engineering and consultancy organisation providing services from concept to construction and commissioning of projects in Water Treatment, Waste Water Treatment, Air Pollution Control and Hazardous Waste Incineration. PARAMOUNT also provides consultancy services in Air Quality Monitoring, Environmental Impact Assessments & Feasibility Studies.

PARAMOUNT has highly qualified and specialized manpower having vast experience in various disciplines of engineering. PARAMOUNT employs technical staff numbering over 280 qualified persons drawn from different disciplines such as Environmental, Chemical, Civil Structural, Mechanical, Electrical, Instrumentation etc. PARAMOUNT is thus an only Company who can offer all the required services under a single roof. In addition to receiving training from our various collaborators, our engineers possess extensive working experience with international renowned consulting and engineering organizations.

PARAMOUNT established its R&D centre in the year 1976, which is the most advanced & largest centre in the private sector. The Department of Science and Technology (Government of India) and most of the Water Pollution Control Boards including that at centre have recognized it. The research carried out in the environment field has been fully implemented in the field on full-scale installations. This R&D centre has also provided its services to world-renowned organizations in the field of environmental engineering including WHO,
6

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.

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 Pl ate 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

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. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Introduction/coversheet Design basis Treatment philosophy/treatment scheme Process description Products of treatment Equipment list Utilities & chemical composition Unit size calculations-Equipment sizing Hydraulic calculations-Pumps Process datasheet for Equipments Process datasheet for Pumps Process datasheet for Instruments Process flow diagram Legend sheet and P&ID Layout Hydraulic flow diagram Hydraulic calculation-Gravity Process control narrative

2.2 Activities involved during detail engineering are following:

1. 2. 3. 4. 5. 6. 7. Updating BEP documents as and when required General Arrangement drawing Line schedule Updating datasheet for MR/PR MR/PR activities Operation & maintenance manual As built documents and drawings

3. PIPING CLASS & MOC SELECTION GUIDELINES:

3.1 Check list for material selection:

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Properties of material (corrosion, mechanical, physical, appearance) Ease of fabrication Compatibility with existing equipment specification coverage Availability of design data Expected total life of plant or process Estimated service life of material Reliability (safety and economic consequences of failure) Need for further testing Material and its fabrication cost Return on investment analysis Maintenance and inspection cost Comparison with other corrosion control methods Availability and delivery time

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

MATERIAL Aluminium Copper alloys(Brass)

ENVIORNMENT Water and steam, NaCL, sea atmosphere 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 Magnesium alloys Lead Nickel Monel Sea and industrial environments Tap water, sodium chloride solutions Lead acetate solutions Bromides, caustics, H2SO4 Fused caustic soda, hydrochloric and

hydrofluoric acids Titanium Sea environments, NaCL in environments 288 C, silver and AgCl, fuming HNO3, chlorinated or fluorinated hydrocarbons

11

3.3 Selection of material based on different concentrations of solutions:

METALS
1 TANTALUM 2 ALLOY 20 3 HASTELLOY B 4 HASTELLOY C 5 S.S-316 6 S.S-304 7 CR-SI STEEL 8 CARBON STEEL 9 BRASS 10 COPPER 11 ALLUMINIUM

H2SO4 H2SO4 NaHSO4 NaHSO3 HCL HCL HNO3 HNO3 HF

CONC,, A A A A B C A B X C C DILUTE A A B B B C A X C B C SOLUTION A A B A B C A X C B C SOLUTION A A C A B C X X C B B CONC.. A X A B X X B X X X X DILUTE A X B A X X A X X C X CONC.. A A X B A A B X X X C DILUTE A A X A A A B X X X X 50% X B B A C X X X X B X

NaoH
50% X B A B A A C A C B X

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

3.4 Piping material specification index:

SR NO 1 2 3 4 5 6 7 PIPING LINE A19A A1K A1Z A22N A2A A3A A3Y RATING 150 150 150 150 150 150 150 CA 3 0 0 1.5 1.5 1.5 0 MATERIAL CARBON STEEL SS304 HDPE SS316 CARBOON STEEL CARBOON STEEL RUBBER LINED CS

For example: A3A 1) 2) 3) FIRST LETTER : RATING e.g. A-150 class

MIDDLE NUMBER : CORROSION ALLOWANCE e.g.1.5 (mm required as CA) 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 1 GATE VALVE ADVANTAGES Low pessure drop when, fully open and tight sealing. DISADVANTAGES Gate valves have slow response characteristics and require large actuating forces. It causes vibration,seat and disc wear in partial open condition. High pressure drop compare to gate valve. APPLICATION Gate valves are used primarily for on-off application. they are suited for high temp. &pressure with wide variety of fluids.they are not normally used for slurries,viscous fluids. Globe valves are used primarily for throttling purposes. globe valve may be consider a general purpose flow control valve specifically used for high temperature applications. Plug valves are extensively used in refinery ,petrochemical and chemical industries. it is also used for on-off service.

2 GLOBE VALVE Faster to open or close,most reliable form of sealing, throttling to control the flow to any desired degree and positive shut off.

3 PLUG VALVE

Normally small in size requires less head room and available in wide range of materials.they provide tight shut off,quick opening and low pressure drop. Low pressure drop,tight shutoff,quarter turn operation, easy to maintain,low torque. they are small in size and low in weight.

operating torque is quite high. lubricated plug valves require periodic lubrication and lubricant may react with the fluid being carried.

4 BALL VALVE

Fluid trapped in the ball in the closed position may cause problem of build up of vapour pressure and corrosion.

Ball valves are used in a wide range of applications including flow control,pressure control and shut off.they are used for corrosive fluids,cryogenic liquid very viscous fluids and slurries. These valves are also used in refinery,petrochemical and LPG application due to bubble tight shut off.

5 BUTTERFLY VALVE

Simple,compact form,Quick Opening,good controllability low pressure drop ,low weight and cost.

SR NO VALVE TYPE 6 DIAPHRAGM VALVE

ADVANTAGES The diaphragm completely keeps the working parts in isolation from process liquids.

Seals may be damaged if the Mainly used in low pressure velocity is high.Usually require applications where leakage high actuating forces,limited is relatively unimportant. to low pressure and elastomers elastoit is now widely being used mer limits the temperature. in majority of process applications. DISADVANTAGES APPLICATION
For high pressure application the valve operation is quite difficult. Due to its economy,the diaphragm valve finds a vast application for handling and corrosive liquids at low tempearature.and they are also used fertilizer,chemical industry,water treatment plants. Extensively used in process industry for avoiding the back flow and for piping with steam handling.

7 CHECK VALVE

Minimizes water hammer and avoids reverse flow.

The pressure drop across the valve is quite high and after continuous operation the composition of the seat gets disturbed re adjustment is very difficult.

14

4.3 Valve selection process:

15

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:

16

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. 2. 3.

Self-priming All the valves at the discharge side of the pumps must be kept open prior starting 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. 2. 3. 4. 5. 6. Cylinder Piston Piston rod Gland Suction valve Discharge valve
SUCTION STROKE DISCH STROKE

Pump may be of Single acting or Double acting type

Single Acting Reciprocating Pump:

1. 2. 3. 4. 5. 6.

There is one suction & one discharge per cycle Piston moves down during suction stroke Causes low pressure to create & fluid to flow into cylinder by opening suction valve Piston moves up during discharge stroke Causes fluid to be compressed and pressurised Discharge takes place by opening discharge v/v by high pressure fluid

19

5.1.2 Gear Pump:

1. 2. 3. 4. 5.

It is a positive displacement pump It consists of two meshing gears with one driving the other Fluid flows between the casing and the gear teeth Commonly employed for lube & fuel oil transfer Must have relief valve installed in the system

5.1.3 Screw Pump:

1. 2. 3. 4.

Screw pumps are positive displacement pumps Screws are meshed together with one driving other Fluid is displaced through the recesses between the screws and the casing May have single, double or triple screws

20

5.1.3 Vane Pump:

1. 2. 3. 4. 5.

Vane pumps are positive displacement pumps Rotors having slots for vanes Centre of rotor is eccentric with casing This causes vanes to move in and out as the rotor rotates Causes change in volume in the respective chamber, similar to reciprocating pump

21

5.2 Roto dynamic Pumps:

1. 2. Often Known as dynamic pumps or centrifugal pumps Centrifugal pumps are more suitable for delivery of large quantities at low discharge

pressure 3. 4. 5. Are Non-self-priming pumps Loses suction and unable to pump once air gets into the pump system Must be primed before starting

22

Centrifugal Pump: Main Components: 1. 2. 3. 4. 5. 6. Impeller Impeller wear ring Volute Casing Shaft Ball bearing Gland

Working Principle:

1. 2. 3.

Impeller rotates at high speed Fluid enters through the eye of the impeller Fluid is thrown by centrifugal force from the centre (suction side) radially outwards to

the periphery of impeller (discharge side) 4. 5. High velocity fluid enters the stationary volute casing Volute casing converts the kinetic energy of fluid into pressure energy at the

discharge of the pump.

23

5.3 Types of pump and application:

Sr No 1 TYPE Centrifugal (Horizontal) FEATURES APPLICATIONS

Horizontal, back pull out General industrial duty closed impeller and suction for moving clear and slightly contaminated

liquids in power stations, waste water, chemical and petro chemical

industries 2 centrifugal Horizontal, back pull out For polluted, erosive and open impeller and suction viscous sewage liquids stations in pulp,

paper, rayon and sugar refining 3 Vertical submersible pump Vertical pump submersed in Used for clear, corrosive the liquid, axial or mixed and abrasive liquids flow 4 Rotary mono block pump Single stage, self-priming, Wide side channel type application for

water transport including domestic and industrial transport

Vertical turbine pump

Multistage

turbine

pump Water supply system, lift cooling,

with high efficiency, low irrigation

space requirement and easy circulation water system accessibility to drive for thermal power

station. 6 Screw pump (Rotary type) Self-priming rotary positive Applicable for free oil, displacement pump. crude oil, cooling oils, molasses pulp, bitumen, coal tar 7 Dosing pump Single acting plunger pump For melting application with variable discharge head

24

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 Pumping for ammonia displacement type and carbonate at high pressure 10 Diaphragm pump Pumping by means of Used for pumping slurry, or chemical

pulsating elastic or flexible sludge diaphragms plastic etc. 11 Rotary gear pump of rubber, solutions

Helical type of gears with Used for viscous liquids meshing of gears in the viscosity range up to 1000cp

5.4 Standard arrangement for pumps:

5.4.1: Loop for screw pump:

25

5.4.2 Loop for centrifugal pump:

5.4.3 Loop for reciprocating pump:

26

5.5 Trouble shooting:

27

5.5.1 Trouble shooting for centrifugal pump:

Speed too low Casing or shaft sealing leaking Suction lift too high Viscosity of delivery liquid too high Specific gravity of delivery liquid too high Improper installation strain on the pump hose or jamming parts in the pump Wear rings clearance too big due to wear Wrong direction of rotation Discharge line friction loss high

A B

A B B B B

B C

B C

B C

B C C C

Bearing temp too high Pump comes to stop jams E E F

28

Capacity too low

Intermittent delivery

Power consumptio n too high

Poor or no suction

Noisy operation

Head too low

Pump leaking

A B

C D

E F G H

Check the frequency and voltage of incoming supply 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 Clean the suction pipe, foot valve and suction strainer. If needed, replace the flange gasket. Check the suction pipe 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 Readjust the alignment of the pump and motor. Check that no stress is transmitted by piping and flange connection. Discharge the pump and replace the defective parts Replace the wear rings Interchange the phase conditions of the motor

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5.5.2 Trouble shooting for Diaphragm pump:

TROUBLE

CAUSE

REMEDY

Pump does not deliver

Pump deliver too low

Pump deliver excessive

Diaphragm rupture

Suction stop valve closed Deliver stop valve closed Pump suction and discharge valve jammed or wrongly fitted Suction line chocked Suction filter chocked Fluid solidified Gas in fluid Pump valve leakage due to foreign particle or wear Gas venting of hydraulic oil is poor PSV or gate valve leakage Piston seal Suction pressure higher than deliver pressure Gas forming because venting valve does not discharge Gas formulation because of replenishing valve is set too high Starting procedure not followed Diaphragm rupture due to foreign particle

Open suction valve Open delivery valve Open valves, inspect and fit correctly Inspect and clean Clean Improve heating of fluid Check installation Inspect and replace Open and clean Clean or replace replace Reduce suction pressure Check dirt trapping Check setting

Read starting procedure carefully and follow Clean chamber and lines thoroughly

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6. INSTRUMENTS-TYPES & APPLICATION:

6.1 Pressure measuring instruments:
Sr No 1 TYPE Diaphragm pressure gauge Bourdon Type Pressure Gauge Differential type pressure instrument APPLICATION Used for liquids containing solid particles or suspension Used for clean liquid REMARKS Provided with isolation valve Isolation valve is provided, used for steam line To be provided with upstream and downstream isolation valve

6.2 Flow measuring instruments:

Sr No 1

TYPE Magnetic Flow meter

APPLICATION Used for slurry , acid

Vortex Meter

Used for high turndown Ratio

3 4 5

Vane/Turbine Type Orifice meter Rota meter

Clean fluid gas Used for clean liquid service Used where local indication is required

REMARKS Provided with upstream and downstream isolation valve, not used for gas application Provided with upstream and downstream isolation valve High accuracy For size < 2 Size up to 3

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6.3 Temperature measuring instruments:

Sr No TYPE APPLICATION REMARKS

RTD

Used where temperature of liquid/gas is up to 600 Used for High Temperature application Range between 0-2500 For Local indication. Range from 0-600

No isolation valve is required No isolation valve is required

Thermocouple

Temperature Gauge

6.4 Level measuring instruments:

Sr No 1 2 TYPE Differential Pressure Type Radar Type APPLICATION For Liquid Level Measurement REMARKS Side Mounted

3 4

Ultra Sonic dipstick

Float and Tape 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. Top mounted, Cheaper than Radar Used only for vented Fast insertion, and underground tank insertion with an angle Widely used in water Used mainly for open storage tank tanks local level indication
Used in low pressure services to avoid breakage Emergency shutdown, alarming, on/off application Fitted externally

Tabular gauge glass

Level switch

Point level sensor which moves with the liquid surface 32

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 Chemical Process 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, ISO or ANSI. Often PFDs are produced on large sheets of paper. PFDs of many commercial processes can be found in the literature, specifically in encyclopaedias 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 their relative positions. E.g. Pumps at ground level Main process streams are always in bold. Streams are numbered within diamond. Equipments are numbered based 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 toward reactor. Products: start with the product (RHS of= PFD) and trace chemicals backward toward reactor.

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).

34

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 Flow Rate Level Pressure Quality Radiation Temperature Weight First Letter F L P Q R T W Indicating only FI LI PI QI RI TI WI Recording only FR LR PR QR RR TR WR Controlling Only FC LC PC QC RC TC WC Indicating and controlling FIC LIC PIC QIC RIC TIC WIC Recording and controlling FRC LRC PRC QRC RRC TRC WRC

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

35

Basic Instrumentation Symbols:

36

Designation of letters used in making P&ID:

37

8.1.2 Legends for fluids:

38

8.1.3 Process Equipment Symbols Used in P&IDs & PFDs :

39

8.1.4 Flow Sensors Symbols Used in P&IDs:

40

8.1.5 Valve Failure Modes Symbols Used in P&IDs:

41

8.1.6 Valve Actuator Types Used in P&IDs:

8.1.7 Valves Symbols Used in P&IDs:

42

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 the Institute of Instrumentation and Control as 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 designations 2. Mechanical equipment with names and numbers 3. All valves and their identifications 4. Process piping, sizes and identification 5. Miscellanea - vents, drains, special fittings, sampling lines, reducers, increasers and swages 6. Permanent start-up and flush lines 7. Flow directions 8. Interconnections references 9. Control inputs and outputs, interlocks 10. Interfaces for class changes
44

8.2.3 Objectives of P&ID: To make pictorial presentation, resembling to real plant as close as possible of all equipment, piping and instruments. To assist plant construction engineers. To assist commissioning engineers for mechanical commissioning. To identify all piping with or without insulation. To identify spot in case of trouble shooting

8.2.3 Input Documents for P&ID: 1 2 3 4 PFD Design Calculations/Fine sizing/Process Data sheet/ Equipment list Tender specification Clients standards

8.3 Checklist for heat Exchanger:

1. 2. 3. Show correct type of Heat exchanger, number of shells and flow arrangement Cooling water or liquid to be heated , inlet direction Cooled liquid or vapour being condensed

8.4 Checklist for Pumps/Blowers:

1. If Spare pump is required, show both pump connection 2. Show correct type of pump 3. Type of pump i.e. horizontal/vertical centrifugal pump 4. Strictly follow legends as per legend sheet 5. Also show start/stop control/interlocks to other equipments/instrument as per project requirement 6. In case of pump, pump suction require strainer and pump discharge should have check valve and pressure gauge

45

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 a negative 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 the liquid 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 diminished because 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 ;

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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=0.37m/s Re= = = 1000 *v

Re<4000, so the flow is laminar and > 5cp so it is viscous fluid f= = 0.016 ; f=friction factor

Friction loss in fitting Entry loss 90 Bend Tee strainer Ball Valve Tee st run Check valve Reducer Net Equivalent length

K 0.5 0.45 2 0.5 2 1 2

Qty 1 4 1 2 1 0 0

Equivalent length = 0.781 2.81 3.125 1.56 3.125 0 0 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 = Re= = * = *v = 0.6m/sec = 1220

Re<4000, so the flow is laminar f= = 0.01311 From Pump to Common Header K Qty Equivalent length = From Common Header to Flocculation Tank Qty Equivalent length = 1 12 0 1 1 0 1.525 8.23 0 0.762 3.051 0

Exit Loss 1 0 0 90 Bend 0.45 0 0 Tee Strainer 2 0 0 Ball valve 0.5 1 0.762 Tee str Run 2 1 3.051 Reducer 2 1 3.05 Net Equivalent Length for pump to common header= 6.863m L=6.863 + 5 = 11.86m

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Friction Loss =

=0.58 (1)

Net Equivalent Length common header to flocculation tank= 13.56m L=13.56 + 320 = 333.56m Friction Loss = hfd = (1) + (2) = 17.08m hs = hss + hps - hfs ; hd =hsd + hpd + hfd ; hs =suction head ; hss =static suction head ; hps = pressure acting on the surface of the liquid hd =discharge head ; hsd = static discharge head ; hfd = friction loss in the discharge line ; hfs = friction loss in the suction line ; hs = (28.8-27.7) + 10.3 - 0.45 =10.95 hd = (21.65-27.7) + 10.3 +17.08 = 21.33 hd-hs = 10.38m =12m = =16.5 (2)

Result NPSH available Discharge Pressure Differential Pressure Differential Head 10.2m 2.2 kg/ 1.2 kg/ 12m

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10. R&D PARAMETRS:

10.1 Definitions:

10.1.1 Biochemical oxygen demand (B.O.D): It is the amount of dissolved oxygen needed by aerobic biological organisms in a body of water to break down organic material present in a given water sample at certain temperature over a specific time period. The term also refers to a chemical procedure for determining this amount. This is not a precise quantitative test, although it is widely used as an indication of the organic quality of water.[1] The BOD value is most commonly expressed in milligrams of oxygen consumed per litre of sample during 5 days of incubation at 20 C and is often used as a robust surrogate of the degree of organic pollution of water. 10.1.2 Chemical oxygen demand (COD): COD test is commonly used to indirectly measure the amount of organic compounds in water. Most applications of COD determine the amount of organic pollutants found in surface water (e.g. lakes and rivers) or wastewater, making COD a useful measure of water quality. It is expressed in milligrams per litre (mg/L) also referred to as ppm (parts per million), which indicates the mass of oxygen consumed per litre of solution. 10.1.3 Total organic carbon (TOC): It is the amount of carbon bound in an organic compound and is often used as a non-specific indicator of water quality 10.1.4 Total suspended solids (TSS): A term that refers to the identical measurement: the dry-weight of particles trapped by a filter, typically of a specified pore size. 10.1.5 Total Dissolved Solids (TDS): It is a measure of the combined content of all inorganic and organic substances contained in a liquid in: molecular, ionized or micro-granular (colloidal sol) suspended form.

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10.2 GPCB Norms for Effluent Water:

Sr No 1 2 3 4 5 6 7 8

Term COD BOD TDS TSS Chloride Sulphate Phenolic Oil and grease

mg/l or ppm 250 100 5000 100 600 1000 1 10

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