Autodesk Plant 2012 Instructor Workbook Unit 2: Process Equipment

Contents
Unit 2 Process Equipment ............................................................................................ 2 Lesson 1 Pumps and Compressors ........................................................................... 2 Centrifugal Pumps .................................................................................................... 2 Positive Displacement Pumps .................................................................................. 4 Compressors ............................................................................................................ 5 Exercise 2.1.............................................................................................................. 7 Student Exercise 2.2 ................................................................................................ 7 Assessment 2-1........................................................................................................ 9 Lesson 2 Heat Exchangers ...................................................................................... 10 Shell and Tube Exchangers ................................................................................... 11 Kettle Reboilers ...................................................................................................... 13 Plate Exchangers ................................................................................................... 14 Air Cooled Exchangers ........................................................................................... 15 Student Exercise 2.3 .............................................................................................. 15 Assessment 2-2...................................................................................................... 16 Lesson 3 Vessels and Tanks ................................................................................... 18 Vertical Vessels ...................................................................................................... 18 Horizontal Vessels .................................................................................................. 20 Vessel Design ........................................................................................................ 21 Exercise 2.4............................................................................................................ 23 Student Exercise 2.5 .............................................................................................. 23 Storage Tanks, Bullets and Spheres ...................................................................... 25 Tank Design ........................................................................................................... 28 Student Exercise 2.6 .............................................................................................. 29 Assessment 2-3...................................................................................................... 29 Bibliography............................................................................................................ 29

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Unit 2 Process Equipment

The largest and most expensive components of a process plant are the various pieces of equipment located throughout. Lets face it: the purpose of piping is to get the process fluids from one place to another; typically pieces of equipment. The function of process equipment is to perform essential changes to the process fluids. These changes might be as simple as increasing the pressure or temperature, to complex chemical changes at the molecular level. In this unit we will introduce the various basic equipment types found in many process plants. We will briefly examine the common types of process equipment, learn how they function, and we will also discuss some of the piping design considerations associated with each type of equipment.

Lesson 1 Pumps and Compressors

When it comes to moving fluids through pipe, pumps are typically the piece of equipment that gets this done. Pumps are basically a closed case containing some sort of moving part (i.e. impeller, piston, etc.) that increases the pressure of the fluid and pushes it along. Piping will connect to the pump suction and be expelled at a higher pressure from the pump discharge. When it comes to piping design, pumps have some special considerations that make them unique among equipment types: The moving parts in pumps require constant maintenance, so leave room above and around them for removal and repair. Usually they are located near an aisle way or road so that forklifts or other maintenance equipment can be used to work on them. Avoid locating any piping above them to ensure clearance for lifting the pump or motor for removal. Typically process plants install two pumps for every service one operating pump and one spare. The extra expense of spare pumps is usually offset by avoiding the lost revenue of a partial or total plant shutdown due to pump failure. A block valve should be located in both the suction and discharge piping so that the pump can be isolated from the process during maintenance. In a two pump system, where one pump is operating and the other is the spare, check valves are required at the discharges of the pumps (before the block valve). This prevents backflow of fluid through the idle pump to the suction piping creating a fluid short circuit. Avoid excessive loads on the nozzles when designing your piping (this is actually true of all equipment nozzles but especially rotating equipment). Place piping supports near enough to pumps to reduce some of the load. Keep suction piping as short as possible to increase the pumps efficiency. To avoid damage to moving parts, a strainer is often placed in the suction piping - between the pump and the block valve - to catch large solid particles before they enter the pump.

Centrifugal Pumps There are as many types of pumps as there are types of process fluids and conditions. The pumps more commonly found in process plants will be covered in this lesson. The most popular type is the centrifugal pump. This type of pump has a rotating impeller that is usually connected by a drive shaft to an electric motor, diesel engine or steam turbine. The orientation of the drive shaft determines whether it is a horizontal or vertical pump. Fluid enters the pump suction near the axis of the impeller and discharges near its radial

AUTODESK CURRICULUM periphery, using the centrifugal force of the spinning vanes to propel the fluid. Centrifugal pumps are popular because of their simplicity, low maintenance and relative efficiency. However, they are not self-priming they must be filled with fluid in order to operate. Also, if the inlet pressure, or Net Positive Suction Head (NPSH), is too low they have a tendency to cavitate. Cavitation is caused when a liquid is exposed to forces which cause rapid changes in pressure creating cavities in the liquid and then rapidly collapsing them. Centrifugal pumps must be inspected periodically for impeller wear due to suspended solids (or collapsing cavitation bubbles) striking the high-speed vanes. NPSH requirements (NPSHR) for any centrifugal pump are available from the manufacturer. This is usually shown on a graph called a pump curve for a given flow rate and pump efficiency. To ensure that the available NPSH (NPSHA) is communicated to the entire design team the elevation to the bottom of the vessel or tank is usually shown on the P&ID (discussed further in Unit 3). Figure 2-1. Centrifugal Pump (End Suction Top Discharge)

NPSH is the liquid suction force at the intake of a pump. It is usually expressed in units of length (e.g. feet) of water and is simply expressed as the force of liquid pushing into the pump due to gravity and the height of the column of liquid in the suction piping minus friction losses.

Centrifugal pumps come in many different configurations: inline, vertical sump, endsuction top-discharge, top-suction top-discharge, and more. Figure 2-2. Vertical Inline Centrifugal Pump

AUTODESK CURRICULUM To minimize turbulence at centrifugal pump suctions, it is good practice to provide a minimum of 5 diameters (i.e. 5 x nominal pipe diameter) of straight piping right before the suction nozzle. This is important to consider because even a medium size centrifugal pump with 6 ND nozzles will require 30 (5 x 6 = 30) of straight piping at the suction nozzle. In situations where space is limited it is best to check with the pump manufacturer to verify the need for straight inlet piping. It is also important with centrifugal pumps to avoid entrained vapor bubbles in the liquid as it can cause damage to the impellers (just like cavitation). One common cause of this is due to the fact that since the suction piping is typically at least one pipe size larger in diameter than the pump suction nozzle (to minimize resistance) the designer will put a reducer right before the suction nozzle. A concentric reducer in this location may trap vapor bubbles in the piping. To avoid this it is recommended to place a top flat eccentric reducer right before the straight run of pipe that connects to the nozzle flange. Figure 2-3. Centrifugal Pump Suction Piping

Positive Displacement Pumps Another method for moving fluids is to capture a volume of liquid or gas from the suction piping and physically move it (displace) it into the discharge piping. This is what positive displacement pumps do, and it is usually done in two ways. Rotary displacement pumps move fluids through rotating parts; this may be done by gears, vanes or screws. They are well suited to heavy or viscous commodities like grease and asphalt. Piston or diaphragm displacement pumps have a reciprocating cylinder or membrane that pushes the fluid in pulses from the suction to the discharge. Your average household liquid hand soap dispenser operates this way. Positive displacement pumps typically operate at a much lower speed than centrifugal pumps. Also, the clearances between the moving parts and the pump case must be tighter than with centrifugal pumps for them to work properly. A benefit of positive displacement pumps is that they create a vacuum at the pump suction so they do not need to be flooded to start working. However, there is a physical limit to each pumps ability to draw liquid from a lower elevation. Also, these types of pumps will continue to pump the same volume of fluid even if the discharge piping pressure increases which means that putting a safety relief valve on the discharge piping is a good idea! For process fluids which are slurries, consisting of a mix of liquid and solids, the positive displacement pump is a good choice. It can move the mixture through its slow-moving gears, vanes or pistons without being affected by changes in density or consistency of the fluid. It can also be a good choice where precise measurement is important; they are commonly used for addition of chemicals to the process fluid.

AUTODESK CURRICULUM Design considerations for positive displacement pumps vary. If the pump is reciprocating (e.g. a piston pump) then vibration is an issue not only in the pump foundation design but also in the connected piping. Special pipe supports are usually required in the suction and discharge piping of reciprocating pumps and compressors. Pump Outline Drawings Pump outline drawings are drawn by the manufacturer to communicate the technical specifications and dimensions for a particular pump. These drawings are used by the process piping designers to create the 3D models and piping drawings necessary for final fabrication and assembly of piping systems. When ordering off the shelf pump models the outline drawings are often available from the manufacturers catalog or website. Figure 2-4. Centrifugal Pump Outline Drawing

If the required pump is a custom design, the piping designer may have to wait for a certified vendor drawing which means designing with preliminary information until that drawing arrives. Compressors Because liquids are for the most part are incompressible, when you exert a force on a given volume of liquid it increases its pressure but basically maintains its volume. Gases however are compressible so exerting a force on them and thus increasing their pressure will simply cause their volume to decrease (this is called Boyles Law). Therefore, using a pump designed for liquids to try and move gases is like pushing a string you do not get the intended output. Compressors are designed specifically for gases, whereas pumps tend to work best for liquids and slurries. Just like pumps, there are different types of compressors including: centrifugal, piston reciprocating and vane.

Boyles Law states that for an ideal gas at a constant temperature, the pressure and volume are inversely proportional: If the pressure doubles, the volume halves.

AUTODESK CURRICULUM Figure 2-5. Types of Compressors

Two common types of compressors used in process plants are reciprocating and centrifugal. Reciprocating compressors are basically a piston driven by a crankshaft to move fluids. Like reciprocating pumps, they are sources for a lot of vibration. Special dampeners and a well-engineered pipe support scheme is a requirement for all piping systems connected to a reciprocating compressor. Centrifugal compressors are comprised of three main components: Centrifugal Turbine blows the gas, increasing its velocity Diffuser slows the gas, thus increasing its pressure Collector is a space, or plenum, where the gas is released to the discharge piping when it achieves the desired pressure.

Some centrifugal compressors have multiple stages to create very high pressures in the discharge gas. Each stage is a separate turbine that increases the gas pressure in steps with eventual output pressures as high as 10,000 psi. In general, compressors are large, complex pieces of equipment, with many auxiliary piping systems involved in their operation. Some of the systems involved around compressors are: Suction Scrubbers, Dryers and Separators To remove liquids from the gas. Seal Oil or Seal Gas To prevent process gas from leaking through the compressor seals a pressurized gas or oil is used to improve the sealing ability of the compressor. Lube Oil With its own pumps, reservoir, etc. to keep the machinery lubricated. Cooling systems Because gases get hotter when compressed, cooling of the machinery and process gas are sometimes necessary.

Turbines A turbine is a type of engine that is driven by the pressure of steam, water or air against the curved vanes of a rotor. Some process plants use steam turbines to drive pumps or electric generators. In the case of steam-driven turbines, high pressure steam enters the turbine and a mix of low pressure steam and condensate exits it. It does this because its thermal energy is being converted into kinetic energy by the turbine. A special type of valve called a steam trap automatically separates the condensate from the low pressure steam. The low pressure steam can be used for other purposes in the plant or sent through piping back to the steam plant along with the condensate to be reheated into high pressure steam.

AUTODESK CURRICULUM Exercise 2.1 In this exercise you will learn how to: Start a new 3D equipment model using AutoCAD Plant 3D. Insert a vertical centrifugal pump.

Video Tutorial 2.1 Creating a New Pump Tutorial 2.1.mp4 Student Exercise 2.2 In this exercise you will: Start a new 3D equipment model using AutoCAD Plant 3D. Place a horizontal split case centrifugal pump using the dimensions from the pump outline drawing below. Figure 2-6. Spit-Case Pump P-203 Outline Drawing

Use the outline drawing above and the steps below to create the P-203 pump: 1. Start a new drawing named Pump P-203.dwg in your P3D_Training AutoCAD Plant 3D project. Override the default naming convention. 2. On the Home tab, Equipment pane, select Create. From now on we will indicate this command location as Home Equipment Create. 3. In the upper left corner, use the drop-down list to select the Horizontal Splitcase Pump. 4. Starting at the top of the dialog, enter the Long description (size) as Smith 1506x4x10M-364-405. 5. Click on the Tag box that contains P-? and leave the Type as P and set the Number to 203. Click the Assign button.

AUTODESK CURRICULUM Next you will enter the dimensional values to create a representation of the pump that is close to accurate. Remember: they are not fabricating the pump from your 3D model. The purpose of this pump model is to establish exact locations for piping connections to the nozzles and a reasonable depiction of the pump for space allocation. So some of the dimensions you are about to enter will be approximations from the drawing above. 6. If you hover your cursor over the dimension SL a tooltip will tell you that this dimension is the length of the pumps mounting base. You can also see the dimension SL indicated in the dialogs picture (see figure below leftmost image). This is the same as the HB dimension for our pump (from the outline drawing on the previous page). Enter 64 for SL. Figure 2-7. Pump Dimensions

Using the values circled in red from the pump outline drawing continue filling in the pump dimensions. The correlating dimensions are shown below (AutoCAD Plant 3D on the left, outline drawing on the right). Any numbers shown below are approximations. SB = HA SH = 4 SI = HP + HR SO = HD HC = HR x 2 (approx.) DC = VH (approx.) BC = 0 L1BB = W HR (approx.) D1BB = 5.5 D2BB = 4 L2BB = (set same as L1BB) 8. Once all of your numeric values are input select the Create button. 9. Insert the pump at location 0,0,0 with a rotation of 0. If your visual style is not already set to Realistic, set it via Home View Visual Styles. You can use the Orbit tool examine the pump from all sides. 10. Select as Home Equipment Edit to change any of the pump dimensions or data that you input above. Next we will set the pump nozzles to be the correct size and flange rating. We will also ensure that the nozzle locations are set per the pump outline drawing. This is extremely important so that our piping will fit correctly during final installation. 11. Click on pump P-203 to highlight it. Notice the glyphs shaped like pencils located near the pump nozzles. Selecting these allows you to edit the nozzle data. Looking at P-203 from the pump end (as opposed to the motor end), our suction will be the left nozzle while the discharge will be the right. Select the suction nozzles pencil glyph. 12. You will be presented with the nozzle editing dialog. At the top left you will see the tag N-1 indicating the nozzle which you have selected. You could change to the discharge nozzle (N-2 in this case) by selecting it from the drop down list.

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AUTODESK CURRICULUM For now, leave it on the suction nozzle N-1. Also, the pump tag P-203 is shown in the upper right. From the pump outline drawing, the pump model is a 6x4. Pumps are usually listed suction x discharge so we need to set the suction nozzle to be 6 150#RF. This is done on the Change Type tab of the dialog. Select 6 next to Size, the End Type is FL for flanged and the Pressure Class is 150. Finally, select the raised face choice (Nozzle, flanged, 6 ND RF, 150, ASME 16.5) from the list by double clicking on it. Switch to the Change Location tab and make sure you are still editing the suction nozzle N-1. The dimension HF2C in the nozzle editing dialog represents the vertical distance from the centerline of the pump to the center of the suction nozzle N-1. On the pump outline drawing this corresponds to dimension S. Enter the numeric value. The dimension LF2C in the nozzle editing dialog represents the horizontal distance from the centerline of the pump to the center of the suction nozzle N-1. On the pump outline drawing this corresponds to dimension YY. Enter the numeric value. Now, select nozzle N-2 and enter the values for its type and location: HF1C = Z LF1C = X Size = 4 Pressure Class and Type = 150# RF Close the dialog. Exit and Save the drawing.

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Assessment 2-1 1. What is the function of process equipment? To perform essential changes to the process fluids 2. Explain backflow with regards to pumps. What can the piping designer do to prevent this? If the idle pump in a spared arrangement is not blocked in (i.e. both suction and discharge block valves are closed) then fluid may flow backwards through it. To prevent this backflow a check valve is usually placed by the designer in the discharge piping after the block valve. 3. Name two advantages with centrifugal pumps. Name two disadvantages. Advantages: simplicity, low maintenance and relative efficiency. Disadvantages: Not self-priming, require inspection periodically for impeller wear 4. Explain pump cavitation. Cavitation is caused when a liquid is exposed to forces which cause rapid changes in pressure creating cavities in the liquid and then rapidly collapsing them. 5. Where is one place you find the NPSHR for a pump? Manufacturers Pump Curve 6. Why should you use a top flat eccentric reducer at a centrifugal pumps suction? To avoid entrained vapor bubbles in the liquid as it can cause damage to the impellers 7. Compare centrifugal and positive displacement pumps. Positive displacement pumps typically operate at a much lower speed than centrifugal pumps. Also, the clearances between the moving parts and the pump case must be tighter than with centrifugal pumps for them to work properly. Positive displacement pumps are typically self-priming where centrifugal pumps are

AUTODESK CURRICULUM not. Some positive displacement pumps work well moving slurries while centrifugal pumps are liquid only. 8. True or false: Compressors are designed for pumping gases not liquids. True 9. Explain Boyles Law and give an example where you might observe it. Boyles Law states that for a given volume of an ideal gas at a constant temperature, the pressure and temperature are inversely proportional. One example: As a balloon rises in the sky the air pressure around it decreases so its volume increases proportionately. 10. List four examples of compressor auxiliaries. Suction Scrubbers, Dryers, Separators, Seal Oil, Seal Gas, Lube Oil, and Cooling systems

Lesson 2 Heat Exchangers

Heat exchangers are the most common method for raising or lowering the temperature of a process fluid. They do this through the process of transferring thermal energy (heat) from a hotter fluid to a cooler one. Usually the two fluids are separated by a wall of heatconductive material, oftentimes metal, which is heated by the warmer fluid while the cooler fluid then carries this heat away. Flow between the two fluids is either concurrent or counter-current, the latter being more efficient. In concurrent flow, the fluids flow parallel to one another in the same direction, while counter-current flows are in the opposite direction. As you can see by Figure 2-8 below, more heat is transferred if the flows are counter-current. In essence, two flows will try to reach thermal equilibrium (i.e. the same temperature) when transferring heat so the optimal configuration is to have the hotter liquid coming into the exchanger heat the other liquid as it leaves the exchanger. Figure 2-8. Optimal Heat Transfer with Countercurrent Flow

Also important to the piping designer is the knowledge that exchangers are typically connected to piping such that fluids which are losing heat flow down and those gaining heat flow up. Another way of remembering this is: hot stream in the top nozzle and cold

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AUTODESK CURRICULUM stream in the bottom. This is typically a precaution in the event that any condensation or vaporization occurs, since vapors rise and condensation falls. There are different types of heat exchangers for different process requirements. Some are cooled by air while some use steam to heat a process fluid. The most common types of exchangers in process plants are shell and tube, kettle reboilers, plate exchangers and air coolers. Shell and Tube Exchangers These are historically the most common industrial exchanger type. They are simple in design, have low maintenance, are versatile in application and have minimal sealing surfaces that could leak. Figure 2-9. Shell and Tube Exchanger

The parts of a shell and tube exchanger are: The shell, or exchanger body, which usually has integral nozzles to connect to the piping. The shell side fluid flows through the shell and around the tubes. The tube sheet, or tube bundle, which resides within the shell and is either fixed to it or removable. The tube bundle may have transverse baffles on it to direct the shell fluids up and down, resulting in more efficient tube contact and thus ensuring the most heat transfer. The front end stationary head, where at least one nozzle will connect to the tube side fluid. The rear end stationary head, where the tube side fluid either returns back to the tubes or leaves the exchanger via a nozzle.

The Tubular Exchanger Manufacturers Association (TEMA) has established an alphabetic classification system for the different types of shell and tube exchangers as shown in the figure below. According to TEMA, the shell, front head and rear head of an exchanger are the three parts that define an exchanger type. By combining the letters corresponding to each part type you get the three letter code that represents that shell and tube exchanger configuration.

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AUTODESK CURRICULUM Figure 2-10. TEMA Exchanger Types

Just like with pumps, the piping designer will receive outline drawings showing the critical dimensions as well as the TEMA exchanger code. Below are some examples:

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AUTODESK CURRICULUM Figure 2-11. TEMA Exchanger Examples

It is clear from the three-letter code which type of exchanger the manufacturer is providing and the piping designer arranges the piping accordingly. Each TEMA exchanger type is designed for a particular service or environment. For example, if the tubes require cleaning (called rodding out) then you would not want to use and exchanger with a u-tube bundle (TEMA code ending in U). Likewise, TEMA 1 codes ending in P or W are not appropriate for hazardous liquids or chemicals. For exchangers that have removable tube bundles, the piping designer needs to leave room directly in front of the front head of the exchanger for the tube bundle to be pulled out for maintenance. This distance needs to be a minimum of the bundle length plus about 5. If the shell cover is removable on the rear head then space must be left clear at that end as well. This shell cover is usually removed using a small crane so the area above the rear head needs to remain clear of piping and other obstructions. Kettle Reboilers These exchangers are a subset of the shell and tube exchanger class (TEMA code second letter K). They are specifically designed to re-boil a liquid into a vapor so that it can be re-introduced into a process cycle, like distillation. Consequently, the shape of the kettle is wider at the end where vapor expands and is collected. Anything can be used as a heating fluid, but typically steam is used as shown in the example below for a distillation tower. The steam flows through the tubes and heats the heavy tower bottoms liquid which enters from a bottom nozzle usually a mixture containing liquids with different boiling points. The bottoms liquids with lower boiling points vaporize in the shell and exit from a top nozzle. The weir shown in the diagram is a dam which keeps the tube bundle flooded with bottoms liquid. Any surplus liquid flows over the weir and exits through another bottom nozzle back into the process stream. The proper bottoms liquid level is maintained in the reboiler via a level controller and control valve which limits the amount of tower bottoms entering the reboiler. Once the steam has cooled it becomes condensate and is recirculated via piping back to the steam boiler.

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Figure 2-12. Kettle Reboiler

Plate Exchangers Plate exchangers are becoming increasingly popular because of their great efficiency and simplistic design. Essentially, they are made up of stacked metal plates with alternating gasket ports which allow the fluid to spread out over the entire surface of the plate. Figure 2-13. Plate Exchanger

Although they are very efficient, plate heat exchangers have some drawbacks that affect how widely they can be used: They have a greater chance for leakage due to a large gasket area. There is a relatively high pressure drop across them requiring a high inlet pressure. The narrow space between plates can trap particulates and cause blockage.

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AUTODESK CURRICULUM Air Cooled Exchangers In some environments, liquids can be cooled by using a fan that blows air past a radiatorlike exchanger. These air-cooled exchangers have finned tubes that carry the fluid and help radiate the heat. These types of exchangers are divided into two types: forced draft, where the fan blows air up through the exchanger and induced draft, where the fan is above the exchanger and draws the air through. Because of the great quantities of air required, these exchangers can be quite large. Air cooled exchangers usually are constructed in cells; complete units with cooling coils and inlet and outlet nozzles for connecting to piping. Even-pass cells have inlet and outlet nozzles on the same end, since the fluid passes from one end of the cell to the other an even number of times; usually two, four or six times. Odd-pass cells would have the inlet nozzles on the opposite side of the outlet nozzles. A common location for these relatively large pieces of equipment is on the top of pipe racks, where they dont take up valuable at-grade space and can be easily connected to piping. Because only one fluid is involved in the cooling process, they are a relatively lighter exchanger type; this lightweight design facilitates being mounted up high. Finally, it is preferable to have the fans up away from the dirt and volatile gases that may be located at grade. Particular care must be taken to achieve symmetry in flow when connecting piping to air cooled exchangers especially those with multiple cells. Symmetric flow through air cooled exchangers ensures optimal heat transfer. This is best accomplished by using a symmetrical piping manifold like the one shown in Figure 2-14 below. Figure 2-14. Air Cooler Piping Manifold

Student Exercise 2.3 In this exercise you will learn how to: Create a new 3D equipment exchanger model using AutoCAD Plant 3D. Build an equipment item from primitive equipment shapes. Assign and locate nozzles on a piece of equipment.

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AUTODESK CURRICULUM Use the knowledge you gained while creating the 3D pump model in Student Exercise 2.2 to help create a new exchanger model. 1. Start a new drawing named Exchanger E-305.dwg in your P3D_Training AutoCAD Plant 3D project. Override the default naming convention. 2. Select Home Equipment Create. 3. In the upper left corner, use the drop-down list to select the Heat Exchanger New Horizontal Heat Exchanger. You will create a rudimentary shell and tube exchanger from the equipment shape library included with AutoCAD Plant 3D. 4. Make sure the Equipment tab is selected. Click on the Add button and select a Halfsphere to create the read end stationary head. Set dimension D to 2-6. 5. Next, select a cylinder to represent the shell body. Set D to 2-6 and H to 16. 6. Finally, select another cylinder to front end head. Set dimension D to 2-9 and H to 3. 7. Under the General section set the equipment tag to be E-305. Select the Create button. 8. Locate the exchanger at 0,0,6 with a rotation of 0. 9. Highlight the exchanger by clicking on it and select the Add Nozzle glyph: 10. Insert four nozzles on the exchanger using data from the table below. Nozzle # Type H A L Tube-side Cooling Inlet N-1 4-300#RF 1 270 6 Tube-side Cooling Outlet N-2 4-300#RF 1 90 6 Shell-side Process Inlet N-3 6-300#RF 4 90 6 Shell-side Process Outlet N-4 6-300#RF 18 270 6 11. Close the dialog. 12. Exit and Save the drawing. Assessment 2-2 1. Countercurrent flow of two fluids with different temperatures results in a more complete transfer of heat than concurrent flow. 2. In a typical exchanger nozzle arrangement, would the cooling water inlet be on the top or the bottom? On the bottom since the cooling water is getting warmer as it absorbs heat through the exchanger and warming fluids rise. 3. How many passes does the shell of an exchanger with a TEMA classification of AFT have? Two 4. True or False: In some shell and tube exchangers the tube bundle can be removed and cleaned. True 5. What special considerations must a designer allow for when allocating clear space near a shell and tube exchanger? For exchangers with removable tube bundles, leave room directly in front of the front head of the exchanger for the tube bundle to be pulled out for maintenance. For exchangers with removable rear heads leave room above that end for crane access. 6. What type of shell and tube exchanger is specially designed to accommodate fluids changing from liquid to gas? Kettle reboiler 7. Explain the purpose of the weir in a kettle reboiler. The weir is a dam which keeps the tube bundle flooded with bottoms liquid. Any surplus liquid flows over the weir and exits through another bottom nozzle back into the process stream. 8. List two reasons why you might not use a plate heat exchanger in a particular design application. If the plate exchanger produces too high of a pressure

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AUTODESK CURRICULUM drop for the system; if the process fluid contains particulates which could block flow in the plate exchanger; or if the risk of gasket leakage is too great. 9. True or False: Air coolers are best located at grade where they are easily accessible for maintenance. False they are best located above pipeways or structures for adequate airflow 10. Why do air coolers require symmetric piping connections? To keep flow symmetric so that the most efficient exchange of heat occurs.

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Lesson 3 Vessels and Tanks

Although pumps and exchangers may have applications across industries, vessels are very specialized pieces of equipment, and therefore are defined by the type of process plant they are part of. An elutriator, or air classifier, may be common in mineral processing but would not be found in an oil refinery; a fractionating column is more common in oil refining than in silicon processing, and so forth. In any process plant there will usually be a number of different types of vessels and tanks. In process plants, the difference between a vessel and a tank is: A vessel is a place where some sort of process change takes place, often involving higher pressures and/or temperatures. Examples of these changes are: dehydrating, cooking, distillation, separation, or any number of chemical reactions. It is common for vessels to have internal components and enough instrumentation to monitor what happens within them. A tank is usually used for storage, although some slower, natural processes (i.e. settling) may occur in tanks. High pressure storage (for example, propane) is accomplished with specialized tanks called bullets and spheres.

There are way more different types of vessels than is possible to introduce in one chapter. In the simplest classification, vessels can be either vertical or horizontal. Each type has its own set of design considerations, some of which we will cover in the next few pages. Vertical Vessels Vessels may be orientated vertically for process reasons (e.g. distillation requires vertical separation at different boiling points) or physical reasons (vertical vessels take up less plot space). Regardless, there are common subjects to deal with in all vertical vessels: Platforms To operate, access or otherwise work with any part of a vertical vessel over 15 tall - or its attached piping - a platform is usually required. Platforms can be constructed of any sturdy material, but are usually steel grating or checkered plate. If a structure is built to surround the vessel, concrete may be used as a platform surface. Platforms need to be wide enough for plant operations and maintenance people to perform their work. They may also need to provide common utilities (compressed air, water, or nitrogen) as well as electrical receptacles for tools. Usually lighting is also attached to platforms since work may occur on the vessel at night or during inclement weather. The Occupational Safety and Health Administration (OSHA) sets rules for industry in two standards: 29 CFR OSHA 1910 (General Industry) and 29 CFR OSHA 1926 (Construction). An example of an OSHA standard for platforms is the requirement that any platform over 4 feet above grade or adjacent platform must have a handrail that includes a top rail, mid rail and toe board. Figure 2-15. Vessel Platforms

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Egress Stairs and ladders are typically used to access the different platform levels on a vertical vessel. Stairs will have handrails and usually are constructed of similar material to platforms. Ladders over 20 feet tall are enclosed by a safety cage to prevent falling. Also, the height of any single ladder run is limited to 30 feet between platforms, to prevent possibly fatal falls (per OSHA 29 CFR 1910.27 (d)(1)(ii)). If a structure has been built adjacent to or around the vessel, it may include an elevator for easier access. Davits and Manways A manway is a large flanged vessel nozzle (typically 24 to 30 NPS) with a blind flange attached. During maintenance or repairs, this flange is removed to allow access to the vessel internals by qualified personnel. The blind flange is unbolted and then - since it is quite heavy - usually swings on a hinge or hangs from a pivoting davit (a small crane permanently mounted to the vessel or platform). Figure 2-16. Manway and Davit

Piping Connections With vertical vessels the connected piping should be routed together up the side of the vessel, with some piping going all the way to the top. By grouping the vertical piping together on the side of the vessel nearest the pipeway there is more room for platforms around the vessel. Also, providing support for the vertical piping (usually off the vessel itself) is much easier if it is located together, since smaller pipes can sometimes be grouped together and supported by a common support. Instrument Connections Most instrument connections to a vessel will be on a vessel nozzle, normally located at a platform for ease of access. The designer needs to also make sure that instrumentation connections on the piping running up the side of a vertical vessel are also accessible from a platform or ladder. Vessel Internals Depending upon the function of the vessel, it will have different internal appurtenances, mechanisms and structures. Vertical vessels like distillation columns have internal components called trays, which facilitate the separation of hydrocarbons by letting the heavier liquids flow down the tower while lighter vaporized hydrocarbons are flowing up the column. Some vertical vessels use internal demisters - a mesh which helps vapors condense by collecting droplets of a certain size and larger.

A senior piping designer is normally responsible for orienting all of the nozzles, platforms, ladders and manways on a vertical vessel, while the vertical elevations of nozzles and all vessel internals are specified by the mechanical and chemical engineers. It is important that all engineering disciplines work together to get an efficient, functional final vessel design.

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AUTODESK CURRICULUM Horizontal Vessels Horizontal vessels can be located at grade or on an elevated platform depending upon pump NPSH. One example of a horizontal vessel is a knockout drum. It takes the twophase hydrocarbon stream from a vertical column and separates it into hydrocarbon vapors and liquids. Elevating this vessel means the NPSH requirements of the pumps are easily met.. For level control, there is often a level bridle that connects to two vessel nozzles; one above the other. For support, the horizontal vessel will usually have two steel saddle supports that are bolted to concrete foundations or structural steel if the vessel is elevated in a structure. Figure 2-17. Horizontal Vessel with Saddle Supports

Two-phase flow means the process stream contains both liquid and vapor phases of a single chemical.

If a horizontal vessel requires a top platform to access valves and instrumentation then it may be necessary to specify taller top vessel nozzles so that the back of the flanges are at least 6 inches above the platform. Some separation vessels will have a vertical leg or section of large diameter pipe attached called a boot. The boot might collect a heavier liquid (like water from a hydrocarbon process stream) and allow it to be drawn off from a bottom nozzle. Figure 2-18. Horizontal Vessel Model with Boot

Below are some other important items to pay attention to when designing piping for horizontal vessels: As with vertical vessels, the vessel itself is specified by process and/or mechanical engineers, but the piping designer has some ability to negotiate nozzle locations as long as all of the items below are considered. Inlet nozzles should be at the opposite end of the vessel from the liquid and vapor outlets to maximize fluid time spent in the vessel. Level instruments and vessel boot should be at opposite end of vessel from inlet. There is less turbulence at the outlet end. To allow for horizontal growth due to thermal expansion, one support of the vessel is anchored (bolted tight to the foundation) while the other end is allowed to grow by means of a slide plate and slotted holes for the support bolts move in.

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AUTODESK CURRICULUM The inlet is normally located on the end of the vessel away from the pipeway. This arrangement then locates the level instruments next to the operating aisle (under the pipeway) for good accessibility.

Vessel Design Piping designers work from a vessel outline drawing when creating a 3D equipment model. These drawings are not the actual shop fabrication drawings the manufacturer uses to build the vessel. This outline drawing is typically not to scale but shows the location, orientation, size and rating of every nozzle on the vessel. It also shows the vessel diameter and tangent-to-tangent length; this is the length from where the cylinder body shape ends and the head shape begins. The nozzles on a vessel are each assigned a nozzle number on the drawing and a corresponding nozzle chart shows each nozzles size, rating, projection from vessel centerline, elevation and orientation. Any internals will be located and any necessary details regarding the arrangement of these components will be shown. In addition, the drawing lists any specifications that need to be adhered to during fabrication. The vessel name, tag number, service, design and operating conditions are also included. This will be the primary document for the piping designer to work with. Figure 2-19. Parts of a Vessel Outline Drawing

When 3D modeling, the piping designer will assign the same nozzle numbers from the outline drawing to the vessel model. As we mentioned earlier, the outline drawing shows the vessel shape as well as the type of heads. The shapes for common head types for pressure vessels are: Hemispherical A sphere is the ideal shape for a head, because the pressure in the vessel is divided equally across the surface of the head. Unfortunately,

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AUTODESK CURRICULUM spherical shapes are hard to manufacture so these heads are uncommon. The diameter of the head equals the diameter of the cylindrical part of the vessel. Elliptical A dish head in the shape of half of an ellipse where the ratio between the major and minor axes varies 2:1 Semi-Elliptical A nearly elliptical dish head whose height is of the vessel diameter. This head is very common in pressure vessels. Torispherical A spherical dish head with round toroidal knuckles where the head meets the vessel. 2:1 Torispherical The same as above where the height of the dish is the diameter of the vessel. Flat A head formed of flat plate with a slight radius where it meets the vessel cylinder. Conical a head in the shape of a cone typically ending in a nozzle Figure 2-19. Pressure Vessel Heads

The piping designer is responsible for making sure that all piping and instrumentation connected to the vessel is both functional and accessible. Accurate 3D representations of the vessel are an excellent aide to accomplishing a good piping layout. For example, you can see from Figure 2-19 above that most head types end with a 2 long straight section that gets welded to the vessel cylinder. The designer needs to verify the location of all nozzles and if required to move them keep the edge of any nozzle at least 2 away from the weld seams. Nozzles are commonly categorized by their location and orientation. An axial head nozzle is parallel to the vessel axis and is located on the head. Below are some common vessel nozzle types: Radial Nozzle projects radially from the vessel. It is located by its distance from tangent line and angle around the vessel. Axial nozzle projects from one of the heads in a direction parallel to the vessel axis. It is located by its offset from the vessel centerline. Tangential Nozzle projects from the cylindrical vessel shell such that the outside edge of the nozzle is tangential to the vessel wall. This is typically used in cases where high pressure inlet piping needs to have its flow redirected and

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AUTODESK CURRICULUM slowed or if a vortex effect in the vessel is desired. It is located by its distance from the tangent line, centerline offset and angular direction. Elbow nozzle the neck of this nozzle incorporates a 90 bend before ending in a flange or other connection. These are often located at the bottom of vessels because it improves clearance above grade or platforms. Manway nozzle the purpose of these nozzles are to access the inside of the vessel for inspection or maintenance. Unless they are an inspection port then they will be large enough for a worker to climb through. Figure 2-20. Nozzle Orientations

Exercise 2.4 In this exercise you will learn how to: Place a vertical vessel in a 3D model.

Video Tutorial 2.4 Creating a New Vertical Vessel Tutorial 2.4.mp4 Student Exercise 2.5 In this exercise you will learn how to: Create a new AutoCAD Plant 3D vertical vessel model. Add nozzles to the vessel.

Equipment manufacturers use programs like Autodesk Inventor to create accurate models of the equipment as part of their engineering development. These or other models can be inserted into AutoCAD and used as geometry for Plant 3D equipment. One word of caution: using too many high detail equipment models can degrade performance of larger plant models.

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AUTODESK CURRICULUM In this exercise you will use a 3D block drawing that we can imagine was created by a vessel manufacturer. You will assign a new tag to the block and associate it with the project. 1. Start a new drawing named Vessel V-1001.dwg in your P3D_Training AutoCAD Plant 3D project. Override the default naming convention. 2. Insert the block V-1001-Vendor.dwg located in your P3D_Training project\Vendor Models folder at coordinates 100, 100, 0 with an insertion scale=1.0 and rotation=0 as shown below: Remember that the aim of the 3D plant model is to be a representative model, not an exact model. Its purpose is to effectively communicate the design and generate the engineering drawings needed for final construction.

3. 4. 5.

Select Home Equipment Convert Equipment. Select your vessel block. Convert it to a Vessel type of equipment as shown below:

6. 7.

Specify the insertion point as 100, 100, 0 Set the tag number to V-1001 as shown below:

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AUTODESK CURRICULUM 8. Give it a long description of Custom Vessel and select the Create button. Now youve got an intelligent equipment model which is linked to the project database. Next, we need to add intelligence to the top axial nozzle and side radial nozzles that are part of the model. This will allow future AutoCAD Plant 3D piping to connect to the equipment. 9. Select the V-1001 vessel so that it is highlighted and select the add nozzle glyph: Note: When used on converted equipment, this command only adds intelligence to existing graphics. 10. Select the center of the face of the axial nozzle on the top vessel head using object snap:

11. Drag the nozzle direction up in the Z direction. 12. Assign the nozzle to be a 8-300#RF straight nozzle via the Change Type button in the dialog below:

13. Using the procedure above, assign intelligence to the 4-300#RF radial nozzle. Storage Tanks, Bullets and Spheres One of the more familiar sites in process plants are the large tanks, bullets and spheres used to store either raw materials or finished product. These components of a process plant could be considered the most valuable in that they contain large quantities of raw or final product. The proper design and construction of storage facilities is enormously important not only to protect valued commodities but also the employees who work there.

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AUTODESK CURRICULUM Secondary containment around tanks in the form of lined ponds surrounded by earthen berms is very common for this as well as environmental reasons. Figure 2-21. External Floating Roof Tank

Tanks Storage tanks are used to store anything as safe as water to more volatile liquids like gasoline. Because of the different fluid requirements, tank designs can vary greatly. Storing fluids under pressure is the best form of containment as far as minimizing losses from evaporation; however that solution is cost-prohibitive - especially for large volumes. Because most tanks store their fluids at or near atmospheric pressure their contents might eventually evaporate if left uncovered. To prevent this, tanks often use innovative roof designs to: Minimize loss of product through evaporation, Reduce damage caused by air mixing with vapors to create corrosive chemicals, Eliminate exposure risks to employees, and Minimize the threat of explosions or fires due to flammable vapors.

The American Petroleum Institute (API) sets standards for storage tank design, construction, repair, cleaning and examination. API Standard 650 covers above-ground tanks with internal storage pressures up to 2.5 psi this covers almost 70% of the tanks in 2 use. Tank roof designs are just one of the topics covered in this standard. Some common tank roof types that designers will encounter are: Open Top There is no roof on the tank so evaporation and contamination are issues. This is used for non-volatile products. Fixed Conical Roof The roof is connected to the walls and the entire tank is typically made of welded steel plates. Because of atmospheric temperature changes throughout the day, the liquids in the tank will cyclically warm and cool. During the hottest part of the day, the liquid will expand and may even begin to evaporate, causing pressure to build in the tank unless vented. The same vents are also important when the cooler night temperatures cause condensation and cooling of the liquid within the tank. This breathing loss is repeated daily and over time can cause a lot of product to be lost to the atmosphere. A similar loss

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AUTODESK CURRICULUM of vaporized product occurs when the tank is emptied or filled. Hence, this roof type is used for non- and low-volatility liquids. Floating Roof This is for storage of volatile liquids or liquids whose vapors are volatile. The roof is constructed of steel supported by steel trusses, floats on the surface of the liquid within the tank and rises or lowers along with it. There is a gasket seal around the perimeter of the roof and special flexible or articulated drain piping to capture water runoff from the roof. Floating roofs are more expensive than fixed roofs; the gasket seal requires some maintenance and heavy or uneven snow loads can be a problem. However the benefits to the environment as well as the savings regained in usable product typically offset the costs of floating roof tanks.

Bullets and Spheres Any product which boils at normal atmospheric pressures and temperatures will require pressurized storage. These vessels are specially shaped to equalize internal pressure forces across the tank shell to provide strong, secure storage. Bullets are cylinders with elliptical or hemispherical heads. They can withstand pressures exceeding 200 psi but are limited in the volume they can store. Bullets look very much like process vessels in shape and construction. Spheres and spheroids can store higher volumes but at lower pressures. Spheres are typically supported by legs around their equator. Figure 2-22. Storage Spheres

If you filled a rubber balloon with air or gas, it would assume a spherical shape due to the internal force of pressure acting equally in all directions. However, if you fill the balloon with liquid and set it on a table, the shape it assumes due to gravitational forces is a spheroid. Spheroid Elevated Tanks (SET) are commonly used for elevated water towers as it maximizes volume and strength in one design.

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AUTODESK CURRICULUM Figure 2-23. Elevated Spheroid

Tank Design For the piping designer, tank layout is primarily about nozzle location since the structural or mechanical engineers will dictate the tank design itself. Some items to consider with tanks in general: Tank fill or charge nozzles usually are near the bottom of the tank. It may extend some distance into the tank and even have an internal elbow if mixing of the tank contents upon filling is required. Tank suction or draw nozzles may be also connected near the bottom or be of the swing type. Swing suction lines are supported internally by a winch or lever that can set the elevation where liquid draw off will occur. This is especially important if sediment or water vapor contamination of the product is possible. Water draw-off nozzles enter the tank from the bottom and either draw directly from the bottom of the tank or from a sump designed into the tank floor. The purpose of this nozzle is to remove water from the tank without having to empty the tank of product. Foam lines are only necessary on tanks containing flammable liquids. They are ring headers that surround the top of the tank and release fire suppressing foam in case of fire. Settlement of the tank after commissioning can be as much as 6 or more depending upon the soil properties at the site. A geotechnical report by a qualified engineer will determine the amount of settling that will occur once the tank is filled with liquid. Design all connected piping with adjustable supports or with enough flexibility in the piping to accommodate this movement without overstressing the piping system or the tank nozzles. Locate all nozzles so that they are away from weld seams in the tank shell. The tank is made of plate steel and you will be able to locate the weld lines on the tank construction drawings. Keep any nozzle welds at least 2 from the tank seam welds. Locate access to the tank roof so that it is on the prevailing upwind side of the tank. This will help protect personnel from exposure to toxic vented fumes.

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AUTODESK CURRICULUM Student Exercise 2.6 Create an AutoCAD Plant 3D equipment model containing the vessel shown in the vessel outline drawing in the DWF link below. Be sure to include all nozzles and locate them per the drawing. Ignore any vessel internals in your model. Name it Vessel-2_6.dwg. VESSEL OUTLINE.dwf Instructors Note: This exercise may be demonstrated in front of the class rather than having the students do it on their own. Use the Vessel-2_6.dwg example in the Instructors version of the P3D_Training project as a model for the various nozzle settings. Assessment 2-3 1. Describe the differences between a pressure vessel and a storage tank. A pressure vessel is a place where some sort of process change takes place, often involving higher pressures and/or temperatures. A tank is usually used for atmospheric storage, although high pressure storage can be accomplished with bullets and spheres. 2. OSHA standards mandate that any platform over four feet above grade or adjacent platform must have a handrail. 3. OSHA standards mandate that the height of any single ladder run is limited to thirty feet between platforms. 4. What is the name of the small crane device often seen on vertical vessels? A davit 5. Are inlet and outlet nozzles on horizontal vessels usually on the same or opposite ends? Opposite 6. A 2:1 torispherical head is a spherical dish head whose height is the diameter of the vessel and it has round toroidal knuckles where it connects to the vessel cylinder. 7. List 5 categories of vessel nozzles Axial, Radial, Elbow, Tangential and Manway 8. Explain breathing loss as it applies to storage tanks. Because of atmospheric temperature changes throughout the day, the liquids in the tank will cyclically warm and cool causing expansion of the contents which forces vapors out of the vents. 9. Are tank draw lines usually near the top or bottom of the tank? Usually near the bottom so they draw liquid not vapors. 10. True or False: Piping connected to a new, large storage tank should be supported from grade as near as possible to the nozzle. False especially if the tank is expected to settle the supports should be far enough back to allow the piping connections to nozzles to flex. Bibliography 1. David Knightbridge, Take the TEMA Test, Process Engineering April 2005, pp. 20-21 (http://www.funke.de/files/tema_funke_process_engineering_uk.pdf) 2. Shell Oil Company, Manual of Refinery Equipment, 1961 pp. 210

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