CHAPTER 8.

PUMPS, PIPING, FITTINGS AND CONTROL VALVES

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8.1 INTRODUCTION:

In an industry, the equipment’s are needed to be connected for transportation of fluid or chemicals.
Therefore, pipelines are required to connect these equipment’s. Also, the chemicals are required to
flow through specific rate to maintain the flow rate through this equipment’s. Hence, pumps are used
for this purpose.

8.2 PUMPS:
A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by
mechanical action, typically converted from electrical energy into hydraulic energy.
Mechanical pumps serve in a wide range of applications such as pumping water from
wells, aquarium filtering, pond filtering and aeration, in the car industry for water-cooling
and fuel injection, in the energy industry for pumping oil and natural gas or for operating
cooling towers and other components of heating, ventilation and air conditioning systems.
In the medical industry, pumps are used for biochemical processes in developing and
manufacturing medicine, and as artificial replacements for body parts, in particular the
artificial heart and penile prosthesis.
8.2.1 Dynamic Pumps:
A dynamic pump uses centrifugal force to create velocity in the liquid. This velocity
is further converted into pressure energy by decreasing the kinetic energy. This
difference in pressure moves the fluid through the system.

• Centrifugal Pump:
➢ Centrifugal pumps are employed to move the fluid through the transfer of
rotational energy from the rotor, this device is known as an impeller. The fluid
enters the rotating impeller and is ejected by centrifugal force through the vane
tip of the impeller.
➢ This action of the impeller causes the fluid velocity and pressure to increase
and also directs it towards the outlet. The pump casing is specially designed to
compress fluid from the pump inlet, direct it into the impeller and control the
fluid before discharging.
➢ Pumps of this type are used for the water supply, fire protection systems, and
beverage industries. These are also classified into three types, which are
explained below.

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8.2.2 Positive Displacement:
A positive displacement pump uses the reciprocating, rotary, or pneumatic motion to move the
liquid through the pump.
Here, the discharge of the fluid occurs in the form of pulses instead of a smooth liquid flow.
• Reciprocating Pump:
Reciprocating pumps use the amount of water that is collected in an enclosed volume and is sent
to discharge by applying pressure. Reciprocating pumps are used with low volume flow at high
pressure.
This pump consists of a piston that moves back and forth in a fixed cylinder. The piston is fastened
to the crankshaft via a connecting rod. This piston moves as the movement of the connecting rod
are due to the movement of the crankshaft. This crankshaft connects to a motor which helps it to
turn.
• Rotary Pump:
It is also a type of positive displacement pump in which a fixed volume of fluid is moving with
each revolution. These pumps can provide continuously delivered capacity regardless of pressure.
Rotary pumps use rotating gears to move the fluid.
This revolving gear forms a liquid seal with the pump casing and makes suction at the pump inlet.
The fluid now drawn into the pump is locked within the teeth of its rotating gears and transferred
to the discharge. It certainly gives an advantage that it is a 100% oil-free operation.
8.3 PIPINGS:
Piping systems in a chemical plant through which fluid, vapors, slurries, solids etc. flow under
various conditions as imposed by the process design of the plant. Piping network is subjected to
almost all the severest conditions of the plant such as high temperature, pressure, flow and
combination of these. In addition to the above, corrosion, erosion, toxic conditions and
radioactivity add to more problems and difficulties in piping design. With the advancement of
process design and technological development, a continuous effort is required to be carried on to
cope up with the demands of process. This makes the job of a piping engineer more complex and
responsible.
In almost all chemical industries, the installed capital cost of piping is major factor in plant
investment. As far as material procurement is concerned, excluding equipment costs, piping is the
largest plant cost component. It is also observed that piping exceed all other field costs by a
substantial amount. Also design engineering utilize approximately 45% of engineering man-hours
and 50% of these man-hours are used in piping design.

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 Some piping materials used in plant as follow:
➢ PVC & CPVC
➢ Galvanized Pipes
➢ Acrylonitrile Butadiene Styrene.

8.4 FITTINGS:
Pipe fittings are an important component of the plumbing system. In plumbing, many types of
fixtures are joined with the help of various types of material as per the requirement. Fittings are fixed
in the plumbing system to join straight pipes or any section of tubes. We can say that the water-supply
fittings like elbow, tee, socket, reducer, etc., are fitted to change the direction of flow, distribute the
water supply from the main pipe to other pipes of equal size or lower size, etc.
Any part used in connection with water supply, distribution, measurement, controlling, use and
disposal of water is known as a pipe fitting.
Few examples of fittings :
➢ Collar
➢ Elbow
➢ Gasket
➢ Union Reducer
➢ Tee
➢ Nipple

8.5 CONTROL VALVES:

For proper functioning of the pipeline, valves made of iron or brass are used in the water-supply
mains. Valves stop or control the flow of fluid like liquid, gas, condensate, etc. These are classified
according to their usage like isolation, throttling and non-return corrector. Various types of valves are
manufactured depending upon their use and type of construction.
8.5.1 Linear Motion Valves:
Linear Valves have a sliding-stem design that pushes a closure element into an open or closed
position. Linear valves, also known as multi-turn valves.
• Gate valve:
It is used for starting or stopping flow. For a straight-line flow of fluid, minimum flow restriction
can also be done with gate valve. In service, these valves are generally either fully open or fully
closed. These valves are used for various types of liquids and make a tight seal when closed.

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 • Globe valve:
It is a type of valve used for controlling flow in a pipeline. A component of valve includes a
movable disc element and a stationary ring seat fitted in a generally spherical body. The globe
valve is used for controlling flow control.
8.5.2 Rotary Motion Valves:
Rotary valves, or quarter-turn valves. They use a closure element that rotates, usually through
a quarter-turn or 90° range, to block the flow.
• Ball Valve:
A ball valve is a flow control device which uses a hollow, perforated and pivoting ball to control fluid
flowing through it. It is open when the ball's hole is in line with the flow inlet and closed when it is
pivoted 90-degrees by the valve handle, blocking the flow. The handle lies flat in alignment with the
flow when open, and is perpendicular to it when closed, making for easy visual confirmation of the
valve's status. The shut position 1/4 turn could be in either clockwise or counter-clockwise direction.
• Butterfly Valve:
A butterfly valve is from a family of valves called quarter-turn valves. In operation, the valve is fully
open or closed when the disc is rotated a quarter turn. The "butterfly" is a metal disc mounted on a
rod. When the valve is closed, the disc is turned so that it completely blocks off the passageway. When
the valve is fully open, the disc is rotated a quarter turn so that it allows an almost unrestricted passage
of the fluid. The valve may also be opened incrementally to throttle flow.

8.6 CONCLUSION:
In this chapter we discussed about various pumps and valves used for material handling. It is noted
that mostly Centrifugal pumps are used for this purpose. In valves, Ball valve and Gate valve are
preferred owing to the smoothness in operation. However, we have discussed about hypothetical
automatic control loop which can be implemented to avoid runaway reaction and get desired
conversion in reactor.

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 CHAPTER 9.

SAFETY, HEALTH AND ENVIRONMENT

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9.1 SAFETY:

Safety is becoming very important with every management as it has come to play a very
vital role in the modern development. Before many years, accidents were considered as
acts of God and nature. Scientific minded people have analyzed accidents and developed
a separate engineering branch of accident prevention. This analysis was required due to:
➢ Rising trend of accidents
➢ Increased use of machinery
➢ Increased material handling
➢ Lack of safety standard
➢ Lack of training
➢ Better reporting of accidents

• Safety:

• Safe use of man, material and machine by safe system method of work is to achieve zero accidents
which results in higher productivity.

• Accident:

• An accident is unplanned and unexpected events which interfere or interrupts the planned process
of work and results in personal injury.

• Accident Factor:
➢ A personal accident injury occurs as a result of an accident
➢ An accident due to unsafe act and/or unsafe condition
➢ Unsafe act/unsafe condition exists due to fault of persons
➢ Fault of persons are due to negligence.
Thus, if we can remove fault of persons we can prevent 98% accidents.
No industry can afford to neglect the fundamentals of safety in design and operation of its plant
and machinery. It is important that all the people responsible for management and operation of any
industry should have a good knowledge of industrial safety.
“Safe use of man, material and machine by safe systems and method of work so as to achieve
zero accidents which results in higher productivity.”
Accident: An accident is unplanned/ unexpected events which interfere or interrupts with the
planned process of work and results on personal injury.

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9.2 SAFETY MEASURES TAKEN BY INDUSTRY:
• Accidents & incidents are investigated & records are maintained. Employees are informed about
the cause of accident. Internal Safety Inspection is done regularly by safety department.
• Work Permit is also issued for work like hot work, Cold work, confined space entry, work at height.
• To ensure safe, healthy and clean environment various health and safety policies like SHE policies,
Quality policy, Energy management policy, Training and development policy are developed.
• Occupational Health Centre is present in plant with working 24 hours under the guidance of doctor.
For emergency purpose they also have ambulance service.
• To deal with fire, water lines are provided in entire plant. Fire extinguishers are also provided at
each place in plant for fire safety.
• Mock drills are also conducted in plant to ensure working of fire alarm.
• Personal protective equipment is also provided to each and every employee and worker to
minimize the accidents.
• To avoid fire cause of static charge equipment is grounded. Fire alarm is provided at each site of
plant. To ensure safety of equipment safety interlocks like safety valve, rupture disc, pressure relief
valves are also installed.
• Proper care is taken to prevent any spillage/leakage. Proper storage facility is provided for raw
material and hazardous waste. So, there is no hazardous effect on ground water and surface water
quality.
• Safety department provides training to all operators and trainees.
• Adequate safe assembly point is mentioned in some locations in plant where workers can gather
in case of emergency.

9.3 SAFETY INSTRUCTIONS:

All trainees reporting to training centre and vocational trainees have to follow safety instruction as
follows:
• Trainees are allowed for entering inside the plant battery after getting permission from HOD of
production department.
• All trainees have to have safety helmet and safety shoes during plant visit.
• Touching or operating any part of the plant equipment is not allowed during plant visit.
• Wearing of loosed clothes is not allowed inside the plant battery limit.
• In case of any emergency all trainees have to immediately assemble at assembly points.
• Smoking and chewing any thing is strictly prohibited in plant.
• No electrical devices are allowed in plant without special permission and photography is strictly
prohibited.

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 • All trainees have to walk on the showed footpath.
9.4 LIST OF SAFETY EQUIPMENT:
• Helmet
• Ear muff and earplugs
• Goggles
• Face shield
• Hand gloves
• Aprons
• Safety Shoes
• Suits
❖ Warning Instrument:
Oxygen, carbon dioxide indicator with replaceable sensors. Explosive meters for measuring
explosive range.
9.5 PLANT HAZOP STUDIES:

What is HAZOP and why it is important for industries?

• HAZOP means Hazard & operability analysis.

➢ HAZOP is systematic method to identify potential hazard and operating
problem.
➢ It is identifying cause and the consequences of perceived mal operations of
equipment and associated operator interfaces in the context of the complete
system.
➢ It based upon the operating integrity of a system, thereby leading methodically to
most potential and detectable deviations which could conceivably arise in the
course of normal operating routine.

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• HAZOP study procedure:

➢ Select P&ID and Mark node.

➢ Now select parameter (pressure, temperature, flow rate, etc.) and usethe guide word (N0,
MORE, LESS, HIGH, LOW, etc.) to describe behaviour of that parameter.
➢ Think about the possible cause of deviation of selected parameter
➢ Also note that how deviation of selected parameter were occur from thedesign and operating
condition.
➢ Think about the consequence of the deviation
➢ What kind of action required to overcome that deviation?
➢ If any recommendation for that selected parameter.

Figure 9.5 guide words for safety

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HAZEOP study over the reaction section of soya 80% lecithin oil .
NODE: soya 80% lecithin oil reaction section.
Parameter: Flow Rate.

Table 9.5.1 HAZEOP study for flow rate

GW Deviation Causes Consequences Existing Recommendation

Provisions

No/Less 1. No/Less Non Low level in FAL Review configuring

flow of availability tank and provided interlock on LAL of
Soya oil of liquid possible on LT203 to trip pump.
from pump Soya oil damage to FIC203.
to reactor. from BL. pump due to
cavitation. FAL
provided
on FI at
ammonia
plant.

LAL
provided on
LT203.

2. No/Less Non availability Low temperature FAL -

flow of N2 of N2 from BL. at reactor bottom
from source. and possible provided on
pressurization in FIC.
reactor due to Pressure
unreacted NH3.
switch PS
high alarm is
provided and
on PS
interlock
provided to
trip the plant.

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Parameter: Temperature,
Table 9.5.2 HAZEOP study for
temperature

GW Deviation Causes Consequences Existing Recommendation

Provisions

Low 1. Low No feed Pressure Refer 2 in -

temp. in available. increases in flow rate.
reactor reactor.

High 1. high Refer 1 in

temp. in flow rate.
reactor

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 Parameter: pressure

Table 9.5.3 HAZEOP study for

pressure

GW Deviation Causes Consequences Existing Recommendation

Provisions

Low 1. Low PIC101B Low pressure PAL -

pressure in malfunction in reactor provided
reactor open. leading to on PI104.
improper
reaction and
conversion.

High 1. high PIC101 Possible Pressure -

pressure in malfunction pressurization switch PS
reactor closed. of high- high alarm
pressure loop. is provided
and on PS
interlock
provided
to trip the
plant.

9.6 WATER POLLUTION CONTROL:

• The water needed to be used in industry is taken from GIDC water and recycled treated

• water from ETP.

• • Water is consumed in two ways in industry namely plant uses and domestic uses.

• • Domestic uses include gardening, canteen uses, housekeeping, washrooms uses,

• drinking purposes etc.

• • Water Segregation: Water coming from various sources of plant does not content same

• level of COD (Chemical oxygen demand), BOD (biological oxygen demand) and TDS

• (total dissolved solid) content. So, in our company we pre-segregate this water based
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• on its content and store them in different tanks. Due to this there will be fewer loads on

• Effluent Treatment Plant.

9.7 CONCLUSION:

In this chapter we discussed about importance of safety in any chemical process industry.
We studied how formaldehyde can be hazardous. We also noted the important safety measures
to be taken by industry and also discussed about various personal protecting equipment
required to be used in the plant. We also traced the ways in which the plant impacts
environments. Different methods in which these pollutants are handled by industry is also
discussed. We also Carried out HAZOP Over entire plant.

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