Gabriel S.

Gusmo
Dr. Tam
CHE - 175A
Due date: 02/09/12

1

Chemical Process Design Problem Set 2
1. The plant has been down for extensive maintenance and repair. You are in charge of bringing
the plant up and on-line. There is considerable pressure from the sales department to deliver
product. About 4 a.m. a problem develops. A slip plate or blind has accidentally been left in
one of the process lines. A very experienced maintenance person suggests that she can
remove the slip plate without depressurizing the line. She said that she routinely performed
this operation, years ago. Since you are in charge, what would you do?
Answer:
Since there is only few information on the line; for instance, it is only said that it is pressurized,
but it does not on what is in it, what is the temperature, if it is liquid, gas phase or equilibrium,
toxicity, flammable, explosive and other relevant information; I would not let her do it.
Furthermore, depending on how pressurized is the line, regardless of its the composition, it
may represent inherent risk. If the line contains a mixture, in equilibrium, near the bubble
point, any sudden reduction of pressure may result in fast phase transition and consequent
risk of damaging and even ripping the line. Hence, given that the process has been already
stopped a little sooner, this would be an opportune moment to look for more information on
the line composition, as through a MSDS sheet, and then do further safe maintenance. If there
was a previous HAZOP study that could assist in the decision would serve as a source to base
the decision on.
2. Consider the reactor system shown in Figure 1. The reaction is exothermic, so a cooling system
is provided to remove the excess energy of reaction. In the event that the cooling function is
lost, the temperature of the reactor would increase. This would lead to an increase in reaction
rate, leading to additional energy release. The result would be a runaway reaction with
pressures exceeding the bursting pressure of the reactor vessel. The temperature within the
reactor is measured and is used to control the cooling water flow rate by a valve. Perform a
HAZOP study on the cooling coils specifically to improve the safety of the process. Fill in the
blanks in Table 1 with the possible answers provided.
Gabriel S. Gusmo
Dr. Tam
CHE - 175A
Due date: 02/09/12

2


Figure 1. An exothermic reaction controlled by cooling water
Answer:
Table 1. HAZOP study on cooling coils from Figure 1
Guide
word
Property Possible cause Possible Consequence Action required
No Flow
Control valve fails
closed
Loss of cooling, possible
runaway reaction
Select valve to fail open
No Flow Plugged cooling coils
Diminished cooling,
possible runaway
Install filter with maintenance procedure;
Install cooling water flow meter and low flow
alarm; Install high temperature alarm to alert
operator
No Flow
Cooling water service
failure
Loss of cooling, possible
runaway reaction
Check and monitor reliability of water service
High Flow
Control valve fails
open
Reactor cools, reactant
concentration builds,
possible runaway on
heating
Instruct operators and update procedures
Low Flow
Partial water source
failure
Loss of cooling, possible
runaway reaction
Install filter with maintenance procedure;
install cooling water flow meter and low flow
alarm; install high temperature alarm to alert
operator

Gabriel S. Gusmo
Dr. Tam
CHE - 175A
Due date: 02/09/12

3

3. Chapter 1 Question 21
Answer:
a. TE is a local Temperature Element that measures temperature and it is directly
connected to a TT, local Temperature Transmit, which sends the temperature
measured to a remote Temperature Indicator and Controller, TIC, through electric
signal. Local control elements are those which are placed next to the process.
TE TT TIC

b. PS is a local pressure switch that is connected to another control element through
electric binary signal, since it is a pressure switch, and these kind of control elements
are usually added for safe purpose, they are used to shut down some parts of the
process, due to action of solenoid valves or other binary elements, in order to avoid
further consequences of unexpected events.
PS

c. PCV is a local Pressure Valve Control, thus acts pneumatically through a Pneumatic
Valve, represented by the half circle to with it is connected. These kinds of control and
valves are commonly used to constant control and maintain a certain process variable
in its set point, that is defined in the controller by the operator, through changing the
manipulated variable which is the flow of the stream to with the valve is attached.
PCV

Gabriel S. Gusmo
Dr. Tam
CHE - 175A
Due date: 02/09/12

4

d. PAL is a remote Pressure Low Alarm that is located in front panel of the control room
to alert the operator of a decrease in Pressure to an undesired level. This control
element receives an electric signal probably from a pressure transmit or pressure
controller to alert the operator.
PAL


e. LAH refers to a remote Level High Alarm and has the same characteristics of the
before PAL, is a control element located in the front panel of the control room to alert
the operator of increase more than desired in, for instance, tank level, but instead of
receiving an electric signal, it receives a direct signal from the measuring element.
LAH


4. Chapter 1 Question 20
Answer: From Tbale 1.7 Equpment Summary for Toluene Hydrodealkylation PFD
Heat Exchangers E-101 E-102 E-103 E-104 E-105 E-106
Type Fl.H. Fl.H. MDP Fl.H MDP Fl.H
Area (m) 36 763 11 35 12 80
Duty (MJ/h) 15,190 46,660 1055 8335 1085 9045
Shell
Temp. (C) 225 654 160 112 112 185
Pres. (bar) 26 24 6 3 3 11
Phase Vap. Par. Cond. Cond. Cond. 1 Cond.
MOC 316SS 316SS CS CS CS CS
Tube
Temp. (C) 258 40 90 40 40 147
Pres. (bar) 42 3 3 3 3 3
Phase Cond. l l l l Vap.
MOC 316SS 316SS CS CS CS CS
(continued)

Gabriel S. Gusmo
Dr. Tam
CHE - 175A
Due date: 02/09/12

5

Vessels/Tower/
Reactor V-101 V-102 V-103 V-104 T-101 R-101
Temperature (C) 55 38 38 112 147 660
Pressure (bar) 2.0 24 3.0 2.5 3.0 25
Orientation Horiznl Vertical Vertical Horiznl Vertical Vertical
MOC CS CS CS CS CS 316SS
Size
Height/Length (m) 5.9 3.5 3.5 3.9 29 14.2
Diameter (m) 1.9 1.1 1.1 1.3 1.5 2.3
Internals s.p s.p 42 sieve
trays 316SS
Catalyist
packed
bed-10m
Pumps/Compressors
P-101
(A/B)
P-102
(A/B)
C-101
(A/B) Heater H101
Flow (kg/h) 13,000 22,700 6770 Type Fired
Fluid Density (kg/m) 870 880 8.02 MOC 316SS
Power (shaft) (kW) 14.2 3.2 49.1 Duty (MJ/h) 27,040
Type/Drive Recip./Eletri
c
Centrf./Eletr
ic
Centrif./Elet
ric
Radiant Area
(m)
106.8
Efficiency (Fluid
Power/Shaft Power)
0.75 0.50 0.75 Convective
Area (m)
320.2
MOC CS CS CS Tube P (bar) 26.0
Temp. (in) (C) 55 112 38
Pres. (in) (bar) 1.2 2.2 23.9
Pres. (out) (bar) 27.0 4.4 25.5
Key:
MOC Materials of construction Par Partial
316SS Stainless steel type 316 F.H. Fixed head
CS Carbon steel Fl.H. Floating head
Vap Stream being vaporized Rbl Reboiler
Cond Stream being condensed s.p. Splash plate
Recipr. Reciprocating l Liquid
Centrf. Centrifugal MDP Multiple double pipe

Primarily, it is necessary to determine the footprint of the heat exchangers regarded in the project.
Furthermore, it will be necessary to make some assumptions.
For all shell and tube heat exchangers, it will be assumed 12 ft, 1.25 tubes on a 1.5 square pitch
and 2 ft additional length on both hear and front head of them, for the returning of fluid.

Gabriel S. Gusmo
Dr. Tam
CHE - 175A
Due date: 02/09/12

6

For a given square area, the respective circular area that represents it is given through the
hydraulic diameter (D
H
):

Adding 1 in of shell thick, it will be given an OD of 1.18 ft and then adding 2 ft comprehending hear
and front heads, the foot print layout will be of:

Doing the same for Heat Exchanger E-102, 104 and 106 it is found that:



Where the length regards the length of the heat exchanger and the width its internal diameter
added the estimated thickness of the shell.
For the heat exchangers that are multiple double pipe, it will be assumed an 8 schedule 20 OD
and 6 schedule 40 ID pipe with length of 12 ft including u-bend.
From Perry et al
1I
, the effective pipes diameter is given:
8 schedule 20: ID of 8.125 in and wall thickness of 0.250 so that the OD is 8.625 in.
For the 6 schedule 40: ID 6.065 in and wall thickness of 0.280 in; hence, OD is 6.625 in.
Assuming that they are in harp structure, it goes vertically rather than horizontally; in other words,
it does not matter how long is the tube, for footprint determination purposes, as long as it reflects
the necessary area of heat exchange. Therefore, both heat exchangers are going to be 12 ft length
and 8.625 in width.

Regarding other unit operations, the data provided states the following footprints:


1
Perry et. al. Table 10-18 Properties of Steel Pipes
Gabriel S. Gusmo
Dr. Tam
CHE - 175A
Due date: 02/09/12

7



Gabriel S. Gusmo
Dr. Tam
CHE - 175A
Due date: 02/09/12

8


E - 102
H - 101
E - 106
E - 101
E - 104
E - 105
E - 106
P - 102
P - 101
R - 101
T - 101
V - 101
V - 102
V - 104
V - 103
C - 101
Gabriel S. Gusmo
Dr. Tam
CHE - 175A
Due date: 02/09/12

9



5. References
I. Turton, R.; Bailie, R.C.; Whiting, W. B.; Shaeiwitz, J. A.; Anaysis, Synthesis and Design
of Chemical Processes 3
rd
ed.; 2010 by Prentice Hall PTR.
II. Mathcad 15.0 Copyright 2010 Parametric Technology Corporation.
III. Perry, R.H.; Chilton, C.H., Chemical Engineer's Handbook, 8 ed., McGraw Hill, New
York, 2008.
IV. Microsoft Visio 2010; 2010 Microsoft Corporation.