User Manual

SYSTEM MANUAL
For
HIGH PRESSURE REACTOR SYSTEM

(Xytel Project No. J05292)
Prepared for:
B.M.S.College of Engineering
Bangalore
Prepared by:
XYTEL INDIA PVT LTD

El-31/14, ‘J’ Block, MIDC, Bhosari
Pune-411026
FEBRUARY, 2006
CONTENTS
CHAPTER - 1 PROCESS DESCRIPTION
CHAPTER - 2 DESIGN SPECIFICATIONS
CHAPTER – 3 START-UP PREPARATION
CHAPTER – 4 CATALYST LOADING
CHAPTER – 5 PRESSURE TEST
CHAPTER – 6 START-UP PROCEDURE
CHAPTER – 7 SHUT DOWN PROCEDURE
APPENDIX – I P & ID
APPENDIX – II PROCESS DATA SHEET
APPENDIX – III PROCESS BILL OF MATERIALS
APPENDIX – IV EQUIPMENT LAYOUT
=============
System Manual
CHAPTER - 1
PROCESS DESCRIPTION
1.1 PROCESS DESCRIPTION
The High Pressure reactor system includes a high pressure gas feed system, a
liquid feed module, a reactor assembly and a gas-liquid separation system. The
system can be operated at 600oC (max.) temperature and upto 50 bar g (max.)
pressure.
The system is represented on the enclosed P&ID (Drawing no. J05292-101).
The system will incorporate elaborate active safe guards to ensure the safe
operation. The control system is a single loop controller based.
1.1.1 High Pressure Gas feed Module
Hydrogen :
The function of this module is to deliver Hydrogen at constant flow

rates into the system at pressure upto 50 bar g. Hydrogen is provided at
constant and accurately metered flow rates.
It is assumed that the Hydrogen is available from a cylinder at a stable

pressure of around 60 bar g using suitable cylinder pressure regulators.
The self-contained mass flow controller consists of a mass flow meter

(FT), flow controller (FIC), and control valve (FV). The flow
transducer measures the flow based on thermodynamic principles
which eliminates the need to correct the flow values for changing
temperature and pressure conditions. The flow control valve (FV),
which is an integral part of the mass flow controller, regulates the gas
flow using a set point signal from the controller and a mass flow signal
from the sensor.
The mass flow controller is capable of delivering hydrogen in the range

of 6-300 SLPH.
Client: B.M.S.College of Engg. Page 1 of 16 Project: High Pressure Reactor System

System Manual
The gas feed system also includes pressure gauges, manual valves, and
an isolation check valve to prevent contamination.
High Pressure Nitrogen
Nitrogen is used for purging and pressure testing. It is assumed that the
nitrogen is available from a cylinder at a stable pressure of around 60
bar g using suitable cylinder pressure regulators. The mass flow
controller available on Hydrogen line should be used for feeding
Nitrogen to the system for purging as well as pressure test.
This gas feed system also includes isolation valves and check valves to
prevent contamination from the other streams.
1.1.2 Liquid feed module
Diesel stored in feed vessel (V-101) is pumped into the reactor using a
HPLC type feed pump with necessary filters, isolation valves and
pressure gauges.
The feed pump is an HPLC type metering pump with maximum flow
capacity of 6-600 ML/Hour equipped with inbuilt speed controller and
key pad for changing the flow rate.
The diesel feed at the outlet of the pump is mixed with hydrogen before
entering to the reactor.
1.1.3 Reactor Module
The reactor system is configured such that the flow through the reactor
can be in downward mode through the catalyst bed.
The reactor capacity is 35 CC. The MOC of the reactor is SS 316. The
reactor is designed for a maximum operating pressure of 50 bar g and
maximum operating temperature of 650oC. The reactants enter and exit
through the socket welded nozzles.
The reactor has a vertical thermowell in the middle along the reactor
length containing two thermocouples to measure catalyst bed
temperature at two different locations along the length of the reactor.

System Manual
The reactor furnace (FRN-100) is a split-type isothermal three-zone

furnace. It has a preheat and a post heat zone at the top and bottom.
The wattage of preheat zone will be such that the feed vapour
temperature at the exit of the preheat zone will be the reaction
temperature for the entire feed range. The reactor skin temperature is
measured at three points. Each zone of the furnace has a thermocouple
mounted on the outside of the reactor along with the controller to
control the temperature of that zone. Also, catalyst zone of the furnace
has a dedicated analog temperature safety switch (TSS).
A pressure pressure gauge is provided on the reactor inlet line to know

the reactor inlet pressure. A high pressure safety valve and a rupture
disc are provided at the top of the reactor for safety purpose.
1.1.4 Gas/Liquid Separation and Product Recovery

The product (exit of reactor) is cooled by a water cooled condenser
(E-101) and passed through a High pressure separator (V-103). The
High pressure separator will act as a collection vessel. The liquid
product has to drain manually after a periodic interval.
The High pressure separator exit gas is passed through a filter. System
pressure is controlled by using a back pressure regulator installed on
the gas line. The system pressure is to be set manually by turning the
knob clockwise or anticlockwise.
1.2 INSTRUMENTATION, CONTROLS AND ELECTRICALS

1.2.1 INSTRUMENTATION
The High pressure reactor system is equipped with all necessary
instrumentation on all vital points in order to control, monitor and
collect data wherever necessary. The system instrumentation hardware
is specified for the safe area classification as in case of pilot plants.
1.2.2 CONTROL SYSTEM
The control system to be used in the unit is described below.
The plant operation, control and safety management of the

unit is done by Microprocessor based stand-alone, panel mounted
controllers.

System Manual
The control system consists of microprocessor based single loop

controllers and indicators mounted on an IBX facilitating local
indication. Process values are continuously displayed on the controllers.
Further, the values of set point, auto/manual selection,
direct/reverse action and tuning parameters can be changed using the
keys available on the controllers.
The IBX also houses other instruments such as relays, power supplies,
fuses, contractors etc. Incoming isolator with necessary
voltmeter/ammeter are in NCL’s scope of supply. Remaining switchgear
(MCBs, fuses, contactors etc.) shall be in our scope of supply.
Sufficient protection for electrical surges and over current will be

provided.
1.2.3 ELECTRICAL DESIGN
The Unit is designed for location in a general purpose (non-explosion

proof) electrically classified area. AC wiring is run through cable ducts
and incorporates metallic and nonmetallic flexible cord provided with
approved bushed fittings, enclosed wireways, gasketed device boxes,
attachment plugs and receptacles, and gasketed conduit outlet bodies.
DC wiring methods incorporate the same wiring methods as the AC

with the exception that plastic wiring duct with cover and plastic spiral
wrap may be used wherever required. Where termination of AC and
DC wiring is required at the edge of the skids, junction boxes are used.
IP65 cable glands/junction boxes shall be used.
Please note that we strongly recommend on-line Uninterruptable Power

Supply (UPS) for the control system (2kVA, 20 minutes back-up). It is
assumed that it will be made available by BMS College.
===========

System Manual
CHAPTER – 2
DESIGN SPECIFICATIONS
2.1 DESIGN SPECIFICATIONS
The High Pressure Reactor System for Hydro-desulphurization and De-

aromatization of Diesel is designed based on the following specifications:
System Specifications :
Reactor Operating Temperature (Max) - 600oC

Reactor Operating Pressure (Max) - 50 bar g
Hydrogen flow rate - 6-300 SLPH
Liquid feed rate - 6-600 ml/hr
2.2 GENERAL SPECIFICATIONS
2.2.1 Materials
• Reactor material is SS316.

• Process tubing handling process liquid will be SS316.
• Vessels and equipment handling process liquid will be SS316.
• Utility and instrument air tubing is brass.
• Vent header is carbon steel.
• Sealing materials are Viton, Teflon or other compatible materials
2.2.2 Other
• Process and utility lines are brought to the edge of the skid
• Unit is designed for safe operation of pilot plant
• Tubing systems are gas tested at 1.25 times design condition
2.2.3 Utility Specifications
Following utilities are assumed to be sufficient in quantity and supplied

by BMS College at the skid battery limits:

System Manual
Electrical Power
• Single phase : 220V AC, 50 Hz
• The earthing connection will be brought to the edge of the skid.

Two nos. of earthing pits as per IS 3043 and two nos. of earthing
strips for connection with the skid shall be made available by BMS
college at site.
===========

System Manual
CHAPTER - 3
START-UP PREPARATION
3.1 PRE –START- UP CHECK LIST:
Pre start up check list includes list of activities to be performed before startup.
Kindly refer P&ID Nos.J05-292-101(Rev. C)
Operator should ensure that the completion of the following activities before start-
up of the plant.
3.1.1 Availability of the
A) Hydrogen
B) Nitrogen
C) Liquid Feed
D) Catalyst
Nitrogen is initially use for the pressure test. After doing pressure test, line
up hydrogen valves as per requirement. Close valve (HV-102) and open
valve (HV-101)
3.1.2 Check mass flow controller is working properly.
3.1.3 Ensure feed tank (V-101) is filled with process fluid.

3.1.4 Ensure feed pump (P-101) is working properly.
3.1.5 At starting of process Furnace must be properly closed.
3.1.6 Make sure cooling water supply given to product condenser and vent
condenser.
3.1.7 Check High Pressure Separator (V-103) is empty.
3.1.8 Check the three way valve (HV-109) is diverted towards vent.
===========

System Manual
CHAPTER - 4
CATALYST LOADING
4.1 Remove the bed thermocouple adapters by loosening it.
4.2 Disconnect inlet and outlet tubing of the furnace.
4.3 Remove the reactor from the furnace.
4.4 Open the end fittings of the reactor. Open top fitting first and remove catalyst.
Bottom end fittings should be opened with care so as not to damage the inside
surface of the reactor if it is tightly fit because of the catalyst. (While opening
the catalyst may fall down if catalyst is not removed from top end.
4.5 Clean the reactor inside surface by blowing air through the reactor pipe.
4.6 Clean end fittings by clean fine cloth or by a jet of air.
4.7 Put back bottom fitting and hand-tighten it.
4.8 Add predetermined quantity of catalyst & inert into the reactor by holding it
vertical and continuously tapping the pipe.
4.9 Fix top fitting of the reactor.
4.10 Flush the reactor with nitrogen to drive out any catalyst fines.
4.11 Install the reactor in the furnace and close the furnace.
4.12 Connect inlet and outlet tubing of the reactor.
4.13 Connect the bed thermocouples into the thermocouple adapters.
=============

System Manual
CHAPTER – 5
PRESSURE TEST
Pressure test is necessary after loading of the reactor to ensure that reactor nozzle and
reactor end connections are leak free.
Reactor is pressurized by passing Nitrogen through mass flow controller for slow
pressurization of the system. Set system pressure by positioning back pressure
regulator. It is advisable to increase the setting in steps so that leakages can be found
out at lower pressures and fixed up.
Now pressure drop is to be observed and should not be more than 2 bar in 12 hours
i.e. ~0.2 bar/hr. If this drop is more than 0.2 bar/hr, then the leakage has to be
identified by soap solution / gas detector.
Most probable leaking joints :
1. Reactor inlet/outlet connections

2. Reactor end fittings
3. Isolation valves of MFC
For easy and fast detection of leakage, partitioning the system is advisable. That is,
first isolate feed section; then reactor and then product section and so on.
After the pressure test, depressurize the system slowly.
============

System Manual
CHAPTER – 6
START-UP PROCEDURE
6.1 PLANT START-UP
After completion of pre-startup check-up activities, next set of activities to be

completed for start-up of the pilot plant.
i) Switch on the Power supply to IBX panel.
ii) Put on the MCB’s as per list provided in the panel.
iii) Hydrogen gas inlet is connected and maintain at required pressure

condition. Inlet pressure to MFC indicated on PI-101.
iv) When gas is flowing from MFC then make sure isolation valve (HV-103)
must be open.
v) Give set point to Hydrogen mass flow controller as per requirement.

(Set point unit is SLPH)
vi) Set desired liquid flow rate by using a keypad available on the pump. Start
the pump and make sure discharge valve will be open (HV-106). (Pump
flow rate in ml/min.)
vii) Hydrogen gas and liquid feed will be mixed before entering the reactor.
The mixture will be preheated in the first zone of the furnace.
viii) Furnace consists of three zones. First zone will act as a pre heat zone.
Middle zone consists of a catalyst called as catalyst zone and third zone
will be post heat zone.
ix) Heat the furnace by using the controllers available on control panel. The
set point to the controller can be changed as explain below

System Manual
There are two ways to heat furnace.
a. Manual Heating: - By putting required value of CV, furnace heating

can be done but after reaching desire temperature value of CV must
make to zero.
b. Auto Heating: - Give direct required set point. (Furnace will heat up to
that set point value taking required value of CV)
x) System pressure can be control by using a Back Pressure Regulator (PCV-

102) and set at desired pressure by turning the knob clockwise or
anticlockwise.
xi) Reactor outlet will passed through a HP Separator where product liquid
will get separated from a mixture. Liquid product will get collected inside
a HP Separator.
xii) HP Separator should be drain periodically based on feed flow rate.
xiii) Sample Collection
Liquid Sampling:-
Two valves are provided at the outlet of HP Separator for collecting liquid
sample first open hand valve (HV-107) and crack open the needle valve
(HV-108) then collect the desired amount of sample and close both valve.
Gas Sampling: -
For gas analysis divert three way valve (HV-109) towards G.C
xiv) Using three way valve(HV-109) divert flow to vent or to the G.C
===========

System Manual
CHAPTER – 7
SHUT-DOWN PROCEDURE:
7.1 Give zero set point to Mass Flow Controller.

7.2 Close battery limit valves.
7.3 Stop liquid pumps P-101.
7.4 Put temperature control loops in manual mode CV= 0.
(Furnace, TIC 104A, TIC 105A, TIC 106A)
7.5 Stop supply of cooling water to product condenser and vent condenser.
7.6 Drain HP separator (V-103).
7.7 Switch off all MCB’s.
7.8 Switch off power supply to control panel (IBX).
7.9 Switch off the single phase supply.
7.10 Isolate Hydrogen, Nitrogen cylinder.
==============

System Manual
APPENDIX - I
PROCESS & INSTRUMENTATION DIAGRAM
Process & Instrumentation Diagram for High Pressure Reactor System with
Drawing No. J05292-101, Rev. C.
===========

System Manual
APPENDIX - II
PROCESS DATA SHEETS
Process Data Sheets for Tubular Reactor and High Pressure Separator for High
Pressure Reactor System.
===========

SHEET 1 OF 2
TUBULAR REACTOR DATA SHEET REVISION
NUMBER NUMBER
NO. BY APR'D DATE REVISION J05292/R-100 0
HIGH PRESSURE 0 RBB VTJ 14-Dec-05 ISSUED WITH BEP JOB NUMBER DATE
REACTOR SYSTEM J05-292 14-Dec-05
R 1 TAG NUMBER R-100 4 SERVICE H2+HYDROCARBONS

E GENERAL 2 MANUFACTURER XYTEL (CUSTOM MADE) 5 MODEL NUMBER CUSTOM MADE
V 3 P&ID NUMBER J05-292 6 LINE/VESSEL NO.
8 VESSEL JACKET
O
9 MAX OPERATING TEMP. - TOP C 600
O
10 MAX OPERATING TEMP. - BOTTOM C 600
11 MAX OPERATING PRESSURE - TOP Kg/cm2 48
12 MAX OPERATING PRESSURE - BOTTOM Kg/cm2 48
O
13 DESIGN TEMP C 650
14 DESIGN PRESSURE Kg/cm2 60
O
15 MIN DESIGN METAL TEMP C 5
16 RELIEF SET PRESSURE Kg/cm2 50
17 CORROSION ALLOWANCE mm NIL
18 MAT'L OF CONSTRUCTION SS316
19
20 CPV FITTINGS MAT'L OF CONSTRUCTION SS316
21 CPV O-RING MAT'L OF CONSTRUCTION VITON
22 RESIDENCE TIME: HLL TO LLL MINS
23 DESIGN IN ACCORDANCE WITH ASME PRESSURE CODE SECTION VIII, DIV. 1 YES NO
24 INSULATION REQ'D: YES NO BY OTHERS VENDOR TO PROVIDE SUPPORT RINGS
25 INSULATION TO COVER: (See Note 4) TOP FITTING BOTTOM FITTING STRAIGHT SIDE
26 SUPPORT: SKIRT LEGS LUGS OTHER
27 ORIENTATION VERTICAL HORIZONTAL
28 NOMINAL CATALYST VOLUME: 35 CC (Cat+Diluent) (NOMINAL REACTOR VOLUME = 100 CC)
29
30 NOZZLES AND CONNECTIONS
31 MARK SERVICE SIZE REMARKS
32 A INLET / OUTLET 1/4"
33 B OUTLET / INLET 1/4"
34 C THERMOWELL 1/4"
35 D
36 E
37 F
38 G
39 H
40 J
41 K
42 L
43 M
44 N
45 P
46 Q
47 R
48 S
49 T
50
SHEET 2 OF 2
TUBULAR REACTOR DATA SHEET REVISION
NUMBER NUMBER
NO. BY APR'D DATE REVISION J05292/R-100 0
R HIGH PRESSURE 0 RBB VTJ 14-Dec-05 ISSUED WITH BEP JOB NUMBER DATE
E REACTOR SYSTEM J05-292 14-Dec-05
V
51
52
53
54
55 Thermowell Cap
C
56
57 Cap Fitting
58
59 Union Nut
60
61 Thermowell
62 245 mm SS 316 Hand tight Vessel Fitting
63
64
65
66
A
67
68 150 mm Preheat Zone
69
70
71
72
73 150 mm Catalyst Zone 650 mm
74
75
76 Postheat Zone
77 150 mm
78
79 B
80
81
82
83 245 mm Reactor Shell 3/4" Sch 80 Pipe
84
85
86
87
88
89
90 Notes
91 1. Mounting bracket not shown for clarity. To be provided.
92 2. See data sheet FRN-300 for furnace details.
93 3. Hand tight fittings O-ring not shown for clarity.
94 4. Top and bottom fittings not insulated to keep O-ring cool.
95 5.Other details (deadmen, catalyst support plate) will be shown in fabrication drawing
96
SHEET 1 OF 1
VESSEL DATA SHEET REVISION
NUMBER NUMBER
NO. BY APR'D DATE REVISION J05-292/V-103 0
HIGH PRESSURE REACTOR 0 RBB VTJ 26-Dec-05 ISSUED FOR ORDER JOB NUMBER DATE
SYSTEM J05-292/V-103 26-Dec-05
TAG NUMBER V-103 R SERVICE HP SEPARATOR / PRODUCT TANK

MANUFACTURER Xytel E MODEL NUMBER Custom made
V UNITS Column JACKET
MAX OPER TEMP-TOP C 40
MAX OP TEMP BOTTOM C 40
MAX OP PRESS TOP KG/CM2 G 50
MAX OP PRESS BOTTOM KG/CM2 G 50
DESIGN TEMP C 60
DESIGN PRESSURE KG/CM2 G 55
MIN DESIGN METAL TEMP C 5
RELIEF SET PRESSURE KG/CM2 G 52
B
CORROSION ALLOWANCE INCH Nil
MATERIAL OF CONSTRUCTION SS 316
GASKET TYPE: SPIRAL WOUND FLAT
OTHER:
GASKET MATERIAL:
A
250
100 NB Sch 40
STUD / NUT MATERIAL: NA
PIPE
RESIDENCE TIME HLL TO LLL (MINS):
150
DESIGN IN ACCORDANCE WITH ASME CODE, SECTION

VIII, DIVISION 1: YES NO
ASME CODE STAMP REQUIRED: YES NO
INSULATION REQUIRED: YES BY OTHERS
NO VENDOR TO PROVIDE SUPPORT RINGS
C COVERAGE THICKNESS
TOP HEAD
STRAIGHT SIDE
BOTTOM HEAD
SUPPORT SKIRT LEGS LUGS
OTHER:
ORIENTATION: HORIZONTAL VERTICAL
NOMINAL VOLUME: 2000 CC
NOZZLE SCHEDULE
MARK SERVICE SIZE REMARKS
A INLET 3/8" NPTF
B VENT 1/4" NPTF
C DRAIN 1/4" NPTF
D
E
F
G
H
NOTES J
* = VENDOR TO CONFIRM OR SPECIFY K
All dimensions in mm unless specified. M
1 NOZZLE 'A' SHOULD BE PROVIDED WITH AN INCLINATION N
OF 100. P
R
T
System Manual
APPENDIX – III
PROCESS BILL OF MATERIALS
Process Bill of Materials, Rev. B for High Pressure Reactor System.
===========

Client:B.M.S.College of Engg.
REV. Tag No. P&ID Description Manufacturer Model No.

A CK- 101 101 Check valve, 1/3 psi cracking pressure, 316 SS body, Excelock --
Viton bonded 316 SS poppet, 302 SS spring, Viton O-
ring/body seal, 413 bar at 37°C (6000 psig at 100°F),
1/4" end connections
A E- 101 101 Product Condenser, tube in tube design, 12 inches of Xytel special
1/4" OD x 0.049 wall inner 316 SS tube in and 3/4"
316 SS outer pipe, straight
A E- 102 101 Vent Condenser, tube in tube design, 12 inches of Xytel special
1/4" OD x 0.049 wall inner 316 SS tube in and 3/4"
316 SS outer pipe, straight
A F- 101 101 Gas filter, 2 micron pleated mesh element, 316 SS Swagelok SS-4F-2
body, 304 SS element, 413 bar (6000 psig) at 37oC
(100oF), 1/4" Swagelok end connections
A F- 102 101 Swagelok SS-4FW-7
Gas filter, 7 micron pleated mesh element, 316 SS
body, 304 SS element, 413 bar (6000 psig) at 37oC
(100oF), 1/4" Swagelok end connections
A F- 103 101 -- --
Liquid filter
A FT/F 101 101 Mass flow controller, 316 SS and Viton wetted parts, Bronkhorst F-201C-FGB-
C/FV- 910 psig (64 Kg/cm2) max. operating pressure, 4- 22-V
20mA output signal and 4-20mA command input
voltage, +/-24 VDC power requirement, D-type
electrical connector, calibrated for 6-300 SLPH of
Hydrogen at 25 barg (782 psig) Inlet pressure and 20
barg (626 psig) of outlet pressure, 1/4" tube fittings
B FRN- 100 101 Furnace, Split tube type, 10” O.D (254 mm) X 1.65" ATS, USA Custom made
I.D(42mm) x 18" (450 mm) heated length. Furnace elements
overall length of 22" (455 mm). Three zone with each assembled by
zone of 6" long and 600 watts, Opposing heaters to be Xytel
wired in parallel, Enclosure to have one each 1/4”
thermocouple ports located in middle of each half
zone, SS outer enclosure hinged on left with support
brackets for vertical mounting.
A HV- 101 101 Hand valve, ball type, 316 SS body and ball, Teflon Excelock --
seat and packing, 1/4" end connections
Project: High Pressure Reactor System, Rev.B 1 of 3 As Built


A HV- 108 101 Hand Valve, Regulating stem, 316 stainless steel Swagelok SS-1RS4
body, 316 SS ball, Kel-F seat, Viton A O-rings, 266
bar at 148°C (3875 psig at 300°F), 1/4" Swagelok end
connection
A HV- 109 101 3-way hand valve, ball type, 316 SS body and ball, Excelock --
Teflon seat and packing,1/4" end connections
A P- 101 101 PUMP: Metering pump, plunger type HPLC pump, SSI, USA Series I
316 SS construction, range:10 to 600 ml/hr, 60
Kg/cm2 maximum discharge pressure, local flow rate
adjustment with digital display, special adopter with
1/4" SS tubing connections, 230VAC, 50 Hz power
supply,
A PCV- 102 101 Back Pressure regulator, 316 stainless steel body, Tescom 44-1768-24
Teflon valve seal, Viton A o-rings, Maximum inlet
pressure - 700 psig (48.3 barg) , Control pressure
range - 100-800 psig (6.9-55 barg), 1/4" FNPT end
connections, line mount
A PI- 100 101 Safety pattern pressure gauge with SS Bourdon Tube, Wika 232.30-100-
100mm dia casing with bayonet, Glycerine filled, 0-70 bar
bottom radial entry, Range 0-70 barg, stainless steel
movement, accuracy class 1,6, connection ¼” NPT
(M), field mounted
(M), field mounted
(M), field mounted
(M), field mounted


A PSE- 100 101 Rupture disk with safety head; Disk: 1/2" Inconel, BS&B 1/2" Type-B
tagged at 55 barg pressure at 104oF (40oC), 90%
crown, 1/4% manufacturing: 1/4" MNPT inlet, 1/2"
MNPT outlet, 303 SS
A PSV- 100 101 Pressure relief valve, 316 SS body and poppet, Viton Excelock --
Seals, 17-7 pH SS spring, 0.14" orifice, 1/4" end
connection, relief pressure set at 52 barg (765 psig)
A R- 100 101 Reactor, 35 cc catalyst+diluent capacity; 100 cc XIPL's regular Special

nominal Reactor volume, 3/4" Sch.80 pipe and 450 fabricator
mm heated length, SS316 material of construction,
Design Cond: 60 bar g at 650 deg. C.
A TE- 101 101 Thermocouple K-type ungrounded junction, Inconel Temp-Tech Special
sheath, 0.04” O.D., 40”long with standard plug and
jack, special limits of calibration
A TE- 102 101 Thermocouple K-type ungrounded junction, Inconel Temp-Tech Special
sheath, 0.04” O.D., 40”long with standard plug and
jack, special limits of calibration
A TE- 104A 101 Thermocouple, K-type, ungrounded junction, Inconel Temp-Tech Special
600 Sheath, 1/8" O.D., 8" long, with standard plug and
jack
jack
jack
A TSS- 105B 101 Temperature safety switch, with latching relay, PPI Neuro 102
upscale thermocouple break, for K-type thermocouple
A V- 101 101 Feed tank, 3 liters capacity, MOC : Glass, 1 barg at Rainbow special
50°C (14.5 psig at 122°F); 1/4" end connection for Scientific
drain / liquid out
A V- 102 101 Knock out pot, 200 cc capacity, 316 SS, 60 barg at Snowtech special
50°C (853 psig at 122°F); 1/4" FNPT end connections
on both ends
A V- 103 101 High pressure separator / Product collection vessel, Serview special
2000 cc capacity, 316 SS, 60 barg at 50°C (853 psig
at 122°F); 1/4" FNPT end connections on both ends
A GC- Gas Chromatograph for analysis of Mercaptans, Mayura Model 2500

Aromatics and Hydrocarbons in Diesel Analytical Pvt
Ltd

System Manual
APPENDIX – IV
EQUIPMENT LAYOUT
Equipment Layout for High Pressure Reactor System with Drawing No. J05292-
200, Rev. B.
===========

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SYSTEM MANUAL

HIGH PRESSURE REACTOR SYSTEM

XYTEL INDIA PVT LTD

CHAPTER - 1 PROCESS DESCRIPTION

CHAPTER - 2 DESIGN SPECIFICATIONS

CHAPTER – 3 START-UP PREPARATION

CHAPTER – 4 CATALYST LOADING

CHAPTER – 5 PRESSURE TEST

CHAPTER – 6 START-UP PROCEDURE

CHAPTER – 7 SHUT DOWN PROCEDURE

APPENDIX – II PROCESS DATA SHEET

APPENDIX – III PROCESS BILL OF MATERIALS

APPENDIX – IV EQUIPMENT LAYOUT

1.1 PROCESS DESCRIPTION

The system is represented on the enclosed P&ID (Drawing no. J05292-101).

1.1.1 High Pressure Gas feed Module

The function of this module is to deliver Hydrogen at constant flow

It is assumed that the Hydrogen is available from a cylinder at a stable

The self-contained mass flow controller consists of a mass flow meter

The mass flow controller is capable of delivering hydrogen in the range

Client: B.M.S.College of Engg. Page 1 of 16 Project: High Pressure Reactor System

High Pressure Nitrogen

1.1.2 Liquid feed module

1.1.3 Reactor Module

Client: B.M.S.College of Engg. Page 2 of 16 Project: High Pressure Reactor System

The reactor furnace (FRN-100) is a split-type isothermal three-zone

A pressure pressure gauge is provided on the reactor inlet line to know

1.1.4 Gas/Liquid Separation and Product Recovery

1.2 INSTRUMENTATION, CONTROLS AND ELECTRICALS

1.2.2 CONTROL SYSTEM

The control system to be used in the unit is described below.

The plant operation, control and safety management of the

Client: B.M.S.College of Engg. Page 3 of 16 Project: High Pressure Reactor System

The control system consists of microprocessor based single loop

Sufficient protection for electrical surges and over current will be

1.2.3 ELECTRICAL DESIGN

The Unit is designed for location in a general purpose (non-explosion

DC wiring methods incorporate the same wiring methods as the AC

Please note that we strongly recommend on-line Uninterruptable Power

Client: B.M.S.College of Engg. Page 4 of 16 Project: High Pressure Reactor System

2.1 DESIGN SPECIFICATIONS

The High Pressure Reactor System for Hydro-desulphurization and De-

Reactor Operating Temperature (Max) - 600oC

2.2 GENERAL SPECIFICATIONS

• Reactor material is SS316.

2.2.3 Utility Specifications

Following utilities are assumed to be sufficient in quantity and supplied

Client: B.M.S.College of Engg. Page 5 of 16 Project: High Pressure Reactor System

• The earthing connection will be brought to the edge of the skid.

Client: B.M.S.College of Engg. Page 6 of 16 Project: High Pressure Reactor System

3.1 PRE –START- UP CHECK LIST:

Kindly refer P&ID Nos.J05-292-101(Rev. C)

3.1.1 Availability of the

3.1.2 Check mass flow controller is working properly.

3.1.3 Ensure feed tank (V-101) is filled with process fluid.

3.1.5 At starting of process Furnace must be properly closed.

3.1.7 Check High Pressure Separator (V-103) is empty.

Client: B.M.S.College of Engg. Page 7 of 16 Project: High Pressure Reactor System

4.1 Remove the bed thermocouple adapters by loosening it.

4.2 Disconnect inlet and outlet tubing of the furnace.

4.3 Remove the reactor from the furnace.

4.6 Clean end fittings by clean fine cloth or by a jet of air.

4.7 Put back bottom fitting and hand-tighten it.