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Reactor Piping
Reactor Piping
PIPING STUDY
REACTOR PIPING
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CONTENTS
Page
0.0
Cover Sheet
List of drawings
1.0
Introduction
2.0
3-4
3.0
Platform Arrangements
4.0
Piping Arrangements
4-5
5.0
Applicable Revision:
Prepared:
Checked:
Approved:
Date:
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Prepared: AKB
Date:
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VKO: KUMUS 209
PIPING STUDY
REACTOR PIPING
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LIST OF ILLUSTRATIONS
SR.NO. DWG.NO.
DESCRIPTION
RP1
RP2
RP3
DESULPHURIZER PROCESS
RP4
HYDROTREATER PROCESS
RP5
TYPICAL REACTOR
RP6
RP7
RP8
RP9
10
RP10
11
RP11
12
RP12
13
RP13
14
RP14
15
RP15
16
RP16
17
RP17
18
RP18
19
RP19
20
RP20
1.0
PIPING STUDY
REACTOR PIPING
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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.
2.0
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.
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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.
-
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
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.
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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
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.
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REACTOR PIPING
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DWG. NO. : RP1
CONDENSER
WATER INLET
AGITATOR
SEPARATOR
3650
REACTOR
PLATFORM
HEATER CONTROL
CUBICLE
FLAME PROOF
STARTER BOARD
VACUUM
RECEIVER
FLUSH BOTTOM
OUTLET VALVE
ELEVATION
2350
FLAME PROOF
STARTER BOARD
CONDENSER
AIR BLEED
VACUUM
1850
RECEIVER
HEATER CONTROL CUBICLE
(UNDER PLATFORM)
VACUUM
PUMP
PLAN
PIPING STUDY
REACTOR PIPING
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DWG. NO. RP2
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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DWG. NO. : RP3
DESULPHURIZER PROCESS
FEED
KNOCK OUT DRUM
CATALYST BED
(TYPICAL)
INDUCED
DRAFT FAN
DESULPHURIZERS
REFORMER
PIPING STUDY
REACTOR PIPING
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DWG. NO. : RP4
HYDROTREATER PROCESS
CHARGE
FURNACE
REACTOR
FEED
SURGE DRUM
CHARGE
PUMPS
FEED EXCHANGERS
PIPING STUDY
REACTOR PIPING
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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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DWG. NO. : RP6
3374
N12
N33
N34
N7 N27
N32
N8 N28
N30
N9 N29
N3
N6 N26
3545
3411
3195
NOZZLE
DESCRIPTION :
3000
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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DWG. NO. : RP7
NOZZLE SUMMARY
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
SURGE DRUM
CHARGE PUMPS
ACCESS WAY
CHARGE FURNACE
CL REACTOR
PIPE RACK
FEED EXCHANGERS
CATALYST LOADING
& UNLOADING AREA
PIPING STUDY
REACTOR PIPING
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DWG. NO. : RP9
REACTOR
REACTOR
SKIRT
CONCRETE
PIERS
b. LUG SUPPORTED
STEEL
STRUCTURE
REACTOR
(TYP.)
RING
GIRDER
SKIRT
CONCRETE
TABLE TOP
CONCRETE
TABLE TOP
PIPING STUDY
REACTOR PIPING
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DWG. NO. : RP10
CONVEYOR
4'-6"/1370
REACTOR
MINIMUM TO SUIT
PIPE SUPPORT or
LOW-POINT DRAIN
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DWG. NO. : RP11
REACTOR
12'-15'
3650-4600
TRUCK
PIPING STUDY
REACTOR PIPING
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DWG. NO. : RP12
LI
CL CHEMICAL
TOWER
(TYP.)
VAPOUR
OUTLET
LI
CL BATCH REACTOR
FEED
OPENING
PIPING STUDY
REACTOR PIPING
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DWG. NO. : RP13
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
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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REACTOR PIPING
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DWG. NO. : RP15
MESH SCREEN
WITHDRAWAL SPACE
PIPING STUDY
REACTOR PIPING
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DWG. NO. : RP16
MIN. 10"/250
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
CHARGE FURNACE
PIPE RACK
REACTOR
PIPING STUDY
REACTOR PIPING
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DWG. NO. : RP18
OPERATOR
ACCESS
ELEVATION (VIEW-P)
PLAN
PIPING STUDY
REACTOR PIPING
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DWG. NO. : RP19
ELEVATION(VIEW-P)
PLAN
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REACTOR PIPING
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DWG. NO. : RP20
LOADING
NOZZLE
DAVIT
LOADING AND
UNLOADING
AREA
LOADING
NOZZLE
TROLLEY
BEAMS
LOADING AND
UNLOADING
AREA