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TRAINING MANUAL- PIPING

PIPING STUDY
REACTOR PIPING

Uhde India Limited

DOC No. : 29040-PI-UPS-1006


Rev.

: R0

Page

: 1

CONTENTS
Page
0.0

Cover Sheet

List of drawings

1.0

Introduction

2.0

Design Considerations for Reactors

3-4

3.0

Platform Arrangements

4.0

Piping Arrangements

4-5

5.0

Key words for Reactor Piping

Applicable Revision:
Prepared:

Checked:

Approved:

Date:
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Prepared: AKB

Date:

Date:

Checked: TNG

Approved: RUD

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Date:
Server:

Date:
VKO: KUMUS 209

PUNE: KUMUS 207

TRAINING MANUAL- PIPING

Uhde India Limited

PIPING STUDY
REACTOR PIPING

DOC No. : 29040-PI-UPS-1006


Rev.

: R0

Page

: 2

LIST OF ILLUSTRATIONS

SR.NO. DWG.NO.

DESCRIPTION

RP1

TYPICAL BATCH REACTOR LAYOUT

RP2

STANDARD ARRANGEMENT OF REACTOR

RP3

DESULPHURIZER PROCESS

RP4

HYDROTREATER PROCESS

RP5

TYPICAL REACTOR

RP6

TYPICAL BATCH REACTOR OF A CHEMICAL PLANT

RP7

PROCESS VESSEL SKETCH OF REACTOR

RP8

PARTIAL PLOT PLAN FOR A HYDROTREATER UNIT

RP9

METHODS OF REACTOR SUPPORT

10

RP10

MINIMUM REACTOR ELEVATION REQUIREMENTS

11

RP11

DIRECT UNLOADING FROM A REACTOR TO A TRUCK

12

RP12

13

RP13

TOP HEAD NOZZLE ARRANGEMENTS OF A BATCH


REACTOR
TOP HEAD NOZZLE ARRANGEMENTS

14

RP14

BOTTOM HEAD NOZZLE ARRANGEMENTS

15

RP15

SAMPLE PROBE CONNECTION

16

RP16

17

RP17

REACTOR PLATFORM AND LADDER ELEVATION


REQUIREMENTS
SINGLE REACTOR PIPING ARRANGEMENT

18

RP18

19

RP19

20

RP20

REACTORS IN SERIES : MANUALLY OPERATED VALVE


MANIFOLD
REACTORS IN SERIES : REMOTELY OPERATED VALVE
MANIFOLD
DAVIT AND TROLLEY BEAM ARRANGEMENT ON REACTOR
TOP

TRAINING MANUAL- PIPING

Uhde India Limited

1.0

PIPING STUDY
REACTOR PIPING

DOC No. : 29040-PI-UPS-1006


Rev.

: R0

Page

: 3

INTRODUCTION
Reactors are usually a vertical equipment where various chemical reaction takes place. Very often
reactors are having agitators mounted either on top or bottom of the vessel. Reactors may have
external 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 called
as Desulphurisers, Convertors, Hydrotreaters etc. This piping study is also applicable for
equipment called crystallizers, evaporators, thickners etc.

1.1

Batch reactions are often carried out as liquid phase or gas-liquid reactions. These may be carried
out at elevated temperature and pressure in horizontal autoclave supported on concrete saddle at
low elvevation because of heavy weight.
Operation and maintenance access, platform requirements, maintenance facilities are to be
considered 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 the
reactor area.

1.2

Fixed-bed reactors are normally loaded with packing or catalyst in bulk between supports inside
the 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 with
heating 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 sufficiently
to allow removal by mechanical transport equipment.
Several reactors, whether in series or parallel should be arranged in line with common support
structures and an overhead monorail to serve all the reactors. The same overhead structure may
be used for loading catalyst and removing internals.

1.3

The fluidized-bed reactors require handling of solid catalyst or reactant under gravity flow and large
quantities of gas, air or liquid used in the reactor.
The top of the reactor is occupied by overhead feed hoppers.
platform and overhead lifting equipment for removal of internals.

The top should have access

2.0

DESIGN CONSIDERATION FOR REACTORS

2.1

Generally, connections are limited to inlet and outlet, maintenance access, unloading, sample and
temperature.
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 vessel
sketch Fig.RP7.

2.2

Reactors are located within a process unit adjacent to related equipment with the facilities for
catalyst loading and unloading as well as close to furnace to minimize expensive high-temperature
piping.

TRAINING MANUAL- PIPING

Uhde India Limited

PIPING STUDY
REACTOR PIPING

DOC No. : 29040-PI-UPS-1006


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2.3

Reactor supports may be a skirt from RCC foundation, lugs from RCC piers, a ring girder from a
RCC 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 the
following document.

2.5

Nozzle arrangements on top of reactor shall be visualised keeping in view of the following
considerations.
-

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 following
considerations.
- 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 the
facility 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, feed
openings etc.

3.2

Platform elevations are determined by the items that require operation and maintenance and on
tall reactors platform elevations are set to accommodate a maximum ladder run of 9m. This is
illustrated 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. The
nozzles 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 in
series with remotely operated valve manifold (Refer Fig.RP19) are typical examples with platforms
on top of reactors.

TRAINING MANUAL- PIPING

Uhde India Limited

PIPING STUDY
REACTOR PIPING

DOC No. : 29040-PI-UPS-1006


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: 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 assembly
Gravity feed
Barometric leg
NPSH
Platform arrangements
Maintenance access
Manhole
Flush bottom valve
External Jacket
Internal Coil
Lifting tools / overhead monorail with chain pulley block / Davit.
Flanged head.
Vibrations
Sight Glass
Space for chemical storage
Flexible Hose connections
Ventilation ducts

5.2

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

TRAINING MANUAL - PIPING

Uhde India Limited

DOC NO. : 29040-PI-UPS-1006

PIPING STUDY
REACTOR PIPING

Rev.

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: 1 OF 1
DWG. NO. : RP1

TYPICAL BATCH REACTOR LAYOUT


VENTS
WATER OUTLET

CONDENSER

WATER INLET

AGITATOR

SEPARATOR

3650

REACTOR

PLATFORM

HEATER CONTROL
CUBICLE
FLAME PROOF
STARTER BOARD

VACUUM
RECEIVER
FLUSH BOTTOM
OUTLET VALVE

AIR PURGE FAN


CABLE TRAY
VACUUM PUMP
FINISHED GROUND LEVEL (FGL)

ELEVATION
2350
FLAME PROOF
STARTER BOARD
CONDENSER
AIR BLEED

VACUUM

1850

RECEIVER
HEATER CONTROL CUBICLE
(UNDER PLATFORM)

VACUUM
PUMP

AIR PURGE FAN

PLAN

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DOC NO. : 29040-PI-UPS-1006

PIPING STUDY
REACTOR PIPING

Uhde India Limited

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DWG. NO. RP2

STANDARD ARRANGEMENT OF REACTOR

INLET

RELIEF
VALVE

LEVEL GAUGE/
CONTROLLER

PRESSURE
GAUGE

VENT

VAPOUR
OUTLET

MANHOLE

THERMOWELL

STEAM OUT
CONNECTION
SADDLES
LIQUID
OUTLET

DRAIN

1/5`L'

3/5`L'

1/5`L'

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Uhde India Limited

PIPING STUDY
REACTOR PIPING

DOC NO. : 29040-PI-UPS-1006


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DWG. NO. : RP3

DESULPHURIZER PROCESS

FEED
KNOCK OUT DRUM

CATALYST BED
(TYPICAL)

INDUCED
DRAFT FAN

DESULPHURIZERS

REFORMER

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DOC NO. : 29040-PI-UPS-1006

PIPING STUDY
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DWG. NO. : RP4

HYDROTREATER PROCESS

CHARGE
FURNACE

REACTOR

FEED

SURGE DRUM

CHARGE
PUMPS

FEED EXCHANGERS

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DOC NO. : 29040-PI-UPS-1006

PIPING STUDY
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DWG. NO. : RP5

TYPICAL REACTOR
MAINTENANCE
ACCESS
INLET NOZZLE

INLET BAFFLE

INERT MATERIAL

FLOATING
SCREEN

CATALYST BED

TEMPERATURE
WELL

(SEE RP15)

SAMPLE
PROBE

SUPPORT
LUG

FIXED GRATING
& SCREEN

OUTLET
COLLECTOR
CATALYST
DROP OUT
NOZZLE

HANDLE

OUTLET
NOZZLE

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REACTOR PIPING

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DOC NO. : 29040-PI-UPS-1006


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DWG. NO. : RP6

TYPICAL BATCH REACTOR OF A CHEMICAL PLANT


N35
ISMC 300
(TYP.)
N4 N24
N5 N25

3374

N12

N33

N34

N7 N27

N32

N8 N28

N30

N9 N29

N3

N6 N26

3545

3411

3195

NOZZLE
DESCRIPTION :

3000

N1 - NOZZLE FOR TIR


N1A - NOZZLE FOR N1
N3 - WASTE GAS OUTLET
N4 - NOZZLE FOR 24
N5 - NOZZLE FOR 25
N7 - NOZZLE FOR 27
N8 - NOZZLE FOR 28
N9 - NOZZLE FOR 29
N10 - PRODUCT OUTLET
N12 - MANHOLE
N24 - STEAM INLET
N25 - STEAM INLET
N27 - NaOH INLET
N28 - HCL INLET
N29 - NaNO2 INLET
N30 - ICE INLET
N32 - SPARE
N33 - AGITATOR NOZZLE
N34 - SPARE
N35 - SPARE
N6 - NOZZLE FOR N26
N26 - PROCESS WATER INLET
N13 - NOZZLE FOR N23
N23 - LIQUID INLET

2800 OD

8THK.

5THK. R/L

700

1000

N1A

N10
10THK.
(TYP.)
10

0.0
100

160

10THK.
151

87

N1

400
(TYP.)

400
(TYP.)

SECTION `A-A'
* NOTE : NOZZLE ELEVATIONS INCLUDING R/L THICKNESS
TOP COVER IS PANEL TYPE CONSTRUCTION.

50x10THK.

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DOC NO. : 29040-PI-UPS-1006

PIPING STUDY
REACTOR PIPING

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DWG. NO. : RP7

NOZZLE SUMMARY

PROCESS VESSEL SKETCH OF REACTOR

SYMBOL

SIZE

SERVICE

8" 600#RF

INLET

8" 600#RF

OUTLET

3" 600#RF

SAMPLE

1" 600#BJ

TEMPERATURE

UC

12" 600#RF

CATALYST
DROP OUT

MA

24" 600#RF

MAINTENANCE
ACCESS

6'-0" I.D.
1830

MA

20'-0"
6100

2'-0"
610

UC

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DWG. NO. : RP8

PARTIAL PLOT PLAN FOR A HYDROTREATER UNIT

SURGE DRUM

CHARGE PUMPS

ACCESS WAY

CHARGE FURNACE

CL REACTOR

PIPE RACK

FEED EXCHANGERS

CATALYST LOADING
& UNLOADING AREA

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DWG. NO. : RP9

METHODS OF REACTOR SUPPORT

REACTOR

REACTOR

SKIRT

CONCRETE
PIERS

a. SKIRT SUPPORTED (FOUNDATION)

b. LUG SUPPORTED

STEEL
STRUCTURE
REACTOR
(TYP.)
RING
GIRDER

SKIRT

CONCRETE
TABLE TOP

CONCRETE
TABLE TOP

c. RING GIRDER SUPPORTED

d. SKIRT SUPPORTED (TABLE TOP)

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DOC NO. : 29040-PI-UPS-1006

PIPING STUDY
REACTOR PIPING

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DWG. NO. : RP10

MINIMUM REACTOR ELEVATION REQUIREMENTS

CONVEYOR

4'-6"/1370

REACTOR

MINIMUM TO SUIT
PIPE SUPPORT or
LOW-POINT DRAIN

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DWG. NO. : RP11

DIRECT UNLOADING FROM A REACTOR TO A TRUCK

REACTOR

12'-15'
3650-4600

TRUCK

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DWG. NO. : RP12

TOP HEAD NOZZLE ARRANGEMENTS OF A BATCH REACTOR

LI
CL CHEMICAL
TOWER
(TYP.)

VAPOUR
OUTLET

LI

CL AGITATOR GEAR BOX


MOTOR ASSY.

CL BATCH REACTOR

FEED
OPENING

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DWG. NO. : RP13

TOP HEAD NOZZLE ARRANGEMENTS

MAINTENANCE
ACCESS

INLET
NOZZLE
NOZZLE PROJECTION
ABOVE PLATFORM
MIN. 250MM

ELEVATION

PLAN

INLET
NOZZLE
MAINTENANCE
ACCESS

4"/100 MIN.

ELEVATION

PLAN

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DWG. NO. : RP14

BOTTOM HEAD NOZZLE ARRANGEMENTS

MINIMUM
ONE NOZZLE
DIAMETER

REACTOR

BOTTOM OUTLET
OPENING

KNUCKLE
RADIUS
TANGENT
POINT

BOTTOM
OUTLET

CATALYST
UNLOADING
NOZZLE

OUTLET
9"/230 MIN.

OUTSIDE
RADIUS

ELEVATION

PLAN

SKIRT SUPPORTED

4'-0"/1220

CATALYST
UNLOADING
NOZZLE

MINIMUM

REACTOR

OUTLET

OUTLET

ELEVATION

PLAN

LEG SUPPORTED

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DWG. NO. : RP15

SAMPLE PROBE CONNECTION

MESH SCREEN

WITHDRAWAL SPACE

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DWG. NO. : RP16

REACTOR PLATFORM AND LADDER ELEVATION REQUIREMENTS

MIN. 10"/250

TOP HEAD PLATFORM


VALVE, VENT,
TEMPERATURE
INSTRUMENT &
CATALYST LOADING ACCESS

TEMPERATURE
INSTRUMENT ACCESS
BY LADDER OR
PLATFORM

INTERMEDIATE
PLATFORM TO SUIT
MAXIMUM LADDER
RUN

SAMPLE CONNECTION
ACCESS BY
PLATFORM

CATALYST UNLOADING
ACCESS FROM
GRADE OR PLATFORM

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DWG. NO. : RP17

SINGLE REACTOR PIPING ARRANGEMENT

CHARGE FURNACE

PIPE RACK

REACTOR

CATALYST LOADING &


UNLOADING AREA
FEED EXCHANGERS

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DWG. NO. : RP18

REACTORS IN SERIES: MANUALLY OPERATED VALVE MANIFOLD

OPERATOR
ACCESS

ELEVATION (VIEW-P)

PLAN

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DWG. NO. : RP19

REACTORS IN SERIES: REMOTELY OPERATED VALVE MANIFOLD

ELEVATION(VIEW-P)

PLAN

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DWG. NO. : RP20

DAVIT ARRANGEMENT ON REACTOR TOP


RELIEF VALVES

LOADING
NOZZLE

DAVIT
LOADING AND
UNLOADING
AREA

TROLLEY BEAM ARRANGEMENT ON REACTOR TOP


RELIEF VALVES

LOADING
NOZZLE

TROLLEY
BEAMS

LOADING AND
UNLOADING
AREA

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