TRAINING MANUAL- PIPING

PIPING STUDY
REACTOR PIPING

Uhde India Limited
DOC No. : 29040-PI-UPS-1006
Rev. : R0
Page : 1
CONTENTS
Page
0.0 Cover Sheet 1
List of drawings 2
1.0 Introduction 3
2.0 Design Considerations for Reactors 3 - 4
3.0 Platform Arrangements 4
4.0 Piping Arrangements 4 - 5
5.0 Key words for Reactor Piping 5
Applicable Revision:
Prepared:
Date:
Checked:
Date:
Approved:
Date:
First Edition: R0
Prepared: AKB
Date:
Checked: TNG
Date:
Approved: RUD
Date:
File Name: Server: PUNE: KUMUS 207 VKO: KUMUS 209
TRAINING MANUAL- PIPING
PIPING STUDY
REACTOR PIPING

Uhde India Limited
DOC No. : 29040-PI-UPS-1006
Rev. : R0
Page : 2
LIST OF ILLUSTRATIONS
SR.NO. DWG.NO. DESCRIPTION
1 RP1 TYPICAL BATCH REACTOR LAYOUT
2 RP2 STANDARD ARRANGEMENT OF REACTOR
3 RP3 DESULPHURIZER PROCESS
4 RP4 HYDROTREATER PROCESS
5 RP5 TYPICAL REACTOR
6 RP6 TYPICAL BATCH REACTOR OF A CHEMICAL PLANT
7 RP7 PROCESS VESSEL SKETCH OF REACTOR
8 RP8 PARTIAL PLOT PLAN FOR A HYDROTREATER UNIT
9 RP9 METHODS OF REACTOR SUPPORT
10 RP10 MINIMUM REACTOR ELEVATION REQUIREMENTS
11 RP11 DIRECT UNLOADING FROM A REACTOR TO A TRUCK
12 RP12 TOP HEAD NOZZLE ARRANGEMENTS OF A BATCH
REACTOR
13 RP13 TOP HEAD NOZZLE ARRANGEMENTS
14 RP14 BOTTOM HEAD NOZZLE ARRANGEMENTS
15 RP15 SAMPLE PROBE CONNECTION
16 RP16 REACTOR PLATFORM AND LADDER ELEVATION
REQUIREMENTS
17 RP17 SINGLE REACTOR PIPING ARRANGEMENT
18 RP18 REACTORS IN SERIES : MANUALLY OPERATED VALVE
MANIFOLD
19 RP19 REACTORS IN SERIES : REMOTELY OPERATED VALVE
MANIFOLD
20 RP20 DAVIT AND TROLLEY BEAM ARRANGEMENT ON REACTOR
TOP
TRAINING MANUAL- PIPING
PIPING STUDY
REACTOR PIPING

Uhde India Limited
DOC No. : 29040-PI-UPS-1006
Rev. : R0
Page : 3
1.0 INTRODUCTION
Reactors are usually a vertical equipment where various chemical reaction takes place. Very often
reactors are having agitators mounted either on top or bottom of the vessel. Reactors may have
external jacket or internal coil for any heat transfer requirements.
Reactors with agitator, gearbox and motor arrangement make the assembly heavy and vibrating.
There are various types of reactors in chemical, fertilizer and refinery plants viz. Batch reactors,
Fixed-Bed Reactors, Gas-Fluidized Bed Reactors. Based on the process function, they are called
as Desulphurisers, Convertors, Hydrotreaters etc. This piping study is also applicable for
equipment called crystallizers, evaporators, thickners etc.
1.1 Batch reactions are often carried out as liquid phase or gas-liquid reactions. These may be carried
out at elevated temperature and pressure in horizontal autoclave supported on concrete saddle at
low elvevation because of heavy weight.
Operation and maintenance access, platform requirements, maintenance facilities are to be
considered around the reactors.
Operation at floor during process reaction, floor drainage during maintenance, lifting monorail /
hoist arrangements, ventilation ducts / hoods provision are some of the common features in the
reactor area.
1.2 Fixed-bed reactors are normally loaded with packing or catalyst in bulk between supports inside
the reactor vessel or in baskets if the temperature is not critical.
When temperature is more critical, the catalyst may be packed within tubes mounted in shell with
heating or cooling fluid circulating between shells and tubes.
If the catalyst or packing is to be removed from the base, the reactors must be elevated sufficiently
to allow removal by mechanical transport equipment.
Several reactors, whether in series or parallel should be arranged in line with common support
structures and an overhead monorail to serve all the reactors. The same overhead structure may
be used for loading catalyst and removing internals.
1.3 The fluidized-bed reactors require handling of solid catalyst or reactant under gravity flow and large
quantities of gas, air or liquid used in the reactor.
The top of the reactor is occupied by overhead feed hoppers. The top should have access
platform and overhead lifting equipment for removal of internals.
2.0 DESIGN CONSIDERATION FOR REACTORS
2.1 Generally, connections are limited to inlet and outlet, maintenance access, unloading, sample and
temperature.
A typical batch reactor layout is illustrated in Fig.RP1.
A typical horizontal reactor in Fig.RP2 and vertical reactor in Fig.RP5 are illustrated.
A typical process flow scheme around reactor is depicted in Fig.RP3, 4.
A typical batch reactor of a chemical plant is illustrated in Fig.RP6.
Nozzle requirements and overall dimensions of reactor are highlighted on the process vessel
sketch Fig.RP7.
2.2 Reactors are located within a process unit adjacent to related equipment with the facilities for
catalyst loading and unloading as well as close to furnace to minimize expensive high-temperature
piping.
TRAINING MANUAL- PIPING
PIPING STUDY
REACTOR PIPING

Uhde India Limited
DOC No. : 29040-PI-UPS-1006
Rev. : R0
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2.3 Reactor supports may be a skirt from RCC foundation, lugs from RCC piers, a ring girder from a
RCC table top or a skirt from a RCC table top as illustrated Fig.RP9.
2.4 To determine the minimum elevation of reactor (Refer Fig.RP10) the designer shall consult the
following document.
2.5 Nozzle arrangements on top of reactor shall be visualised keeping in view of the following
considerations.
- Feed material entry method.
- Additional chemical additions on top of reactor.
- Support arrangement of agitator / gearbox / motor operation facilities of nozzle valves.
- Maintenance access to top manhole.
- Instrument requirements on top head.
- Nozzle arrangements on top head is illustrated in Fig.RP12, RP13.
2.6 Nozzle arrangements on bottom of the reactor shall be decided based on the following
considerations.
- Bottom product outlet method.
- Bottom connections to pumping facility.
- Clear space available between support base unloading of catalyst from nozzle. This is
illustrated in Fig.RP11
2.7 Nozzle for sample probe connection or the thermowell connection shall be decided keeping the
facility for withdrawal space from the shell outside diameter.
3.0 PLATFORM ARRANGEMENTS
3.1 Platforms are required for access to valves, instruments, blinds maintenance access, feed
openings etc.
3.2 Platform elevations are determined by the items that require operation and maintenance and on
tall reactors platform elevations are set to accommodate a maximum ladder run of 9m. This is
illustrated in Fig.RP16.
3.3 Reactors taller than 9m shall be treated like towers for platform requirements. In case of Reactors,
intermediate platforms and ladders are required only for access to temperature instruments,
sample probes, catalyst unloading nozzles and maximum ladder runs.
4.0 PIPING ARRANGEMENTS
4.1 Reactor piping shall be arranged in suitable group at Top of steel (TOS) for ease of support.
The piping is to be located as per inter connection to the related equipment.
4.2 In refinery type of plant, a single reactor piping arrangement is illustrated in Fig.RP17.
4.3 In chemical plants, a typical reaction vessel top arrangement is illustrated in Fig.RP12. The
nozzles are arranged around the outer zone of the reactor opposite the feed material entry point.
The central zone is occupied by the agitator, gearbox and motor mountings.
4.4 The reactors in series with manually operated valve manifold (Refer Fig.RP18) and the reactors in
series with remotely operated valve manifold (Refer Fig.RP19) are typical examples with platforms
on top of reactors.
TRAINING MANUAL- PIPING
PIPING STUDY
REACTOR PIPING

Uhde India Limited
DOC No. : 29040-PI-UPS-1006
Rev. : R0
Page : 5
4.5 The relief valve arrangements on top platform of reactors with Davit or Trolley beam arrangement
(Refer Fig.RP20) are typical examples of maintenance provisions.
5.0 KEY WORDS FOR REACTOR PIPING
5.1 Heavy Vessel
Support structure (Independent or on reactor)
Agitators / Gearbox / Motor assembly
Gravity feed
Barometric leg
NPSH
Platform arrangements
Maintenance access
Manhole
Flush bottom valve
External J acket
Internal Coil
Lifting tools / overhead monorail with chain pulley block / Davit.
Flanged head.
Vibrations
Sight Glass
Space for chemical storage
Flexible Hose connections
Ventilation ducts
5.2 Generally, during piping study around the reactor, the above mentioned keywords should be
considered for, as a clue or guideline for finalising the piping and its supports as well as Electrical /
Instrumentation requirements.
FINISHED GROUND LEVEL (FGL)
AIR PURGE FAN
FLAME PROOF
STARTER BOARD
HEATER CONTROL
CUBICLE
PLATFORM
FLUSH BOTTOM
OUTLET VALVE
CABLE TRAY
VACUUM PUMP
VACUUM
RECEIVER
SEPARATOR
WATER INLET
VENTS
CONDENSER
WATER OUTLET
AGITATOR
REACTOR
AIR PURGE FAN
HEATER CONTROL CUBICLE
(UNDER PLATFORM)
FLAME PROOF
STARTER BOARD
AIR BLEED
CONDENSER
2350
1
8
5
0
3
6
5
0
ELEVATION
TYPICAL BATCH REACTOR LAYOUT
PLAN
DOC NO.
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Uhde India Limited
TRAINING MANUAL - PIPING
PIPING STUDY
DWG. NO.
REACTOR PIPING
: 29040-PI-UPS-1006
: R0
: 1 OF 1
: RP1
RECEIVER
VACUUM
VACUUM
PUMP
STANDARD ARRANGEMENT OF REACTOR
INLET RELIEF
VALVE CONTROLLER
LEVEL GAUGE/ PRESSURE
GAUGE
VENT
OUTLET
VAPOUR
MANHOLE
CONNECTION
STEAM OUT
LIQUID
OUTLET
SADDLES
1/5`L' 3/5`L' 1/5`L'
DOC NO.
Rev.
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Uhde India Limited
TRAINING MANUAL - PIPING
PIPING STUDY
DWG. NO.
REACTOR PIPING
: 29040-PI-UPS-1006
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RP2
THERMOWELL
DRAIN
DESULPHURIZER PROCESS
KNOCK OUT DRUM
FEED
CATALYST BED
(TYPICAL)
DRAFT FAN
INDUCED REFORMER
DESULPHURIZERS
DOC NO.
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Uhde India Limited
TRAINING MANUAL - PIPING
PIPING STUDY
DWG. NO.
REACTOR PIPING
: 29040-PI-UPS-1006
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: RP3
HYDROTREATER PROCESS
CHARGE
PUMPS
FEED
FEED EXCHANGERS
REACTOR
CHARGE
FURNACE
DOC NO.
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Uhde India Limited
TRAINING MANUAL - PIPING
PIPING STUDY
DWG. NO.
REACTOR PIPING
: 29040-PI-UPS-1006
: R0
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: RP4
SURGE DRUM
TYPICAL REACTOR
INERT MATERIAL
MAINTENANCE
ACCESS
SCREEN
FLOATING
CATALYST BED
PROBE
SAMPLE
& SCREEN
FIXED GRATING
OUTLET
COLLECTOR
NOZZLE
OUTLET
CATALYST
DROP OUT
NOZZLE
LUG
SUPPORT
TEMPERATURE
WELL
INLET BAFFLE
INLET NOZZLE
DOC NO.
Rev.
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Uhde India Limited
TRAINING MANUAL - PIPING
PIPING STUDY
DWG. NO.
REACTOR PIPING
: 29040-PI-UPS-1006
: R0
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: RP5
HANDLE
(SEE RP15)
TYPICAL BATCH REACTOR OF A CHEMICAL PLANT
DOC NO.
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Uhde India Limited
TRAINING MANUAL - PIPING
PIPING STUDY
DWG. NO.
REACTOR PIPING
: 29040-PI-UPS-1006
: R0
: 1 OF 1
: RP6
N12 N25 N5
N4 N24
N33 N3
N30
N32
N34
N35
N29
N26
N28
N27
N9
N6
N8
N7
N1
N1A
N10
ISMC 300
(TYP.)
3411
3195
3545
3374
3
0
0
0
1
6
0
1
0
T
H
K
.
1
5
1
10THK.
(TYP.)
400
(TYP.)
A
A
1000
7
0
0
8
7
1
0
0
1
0
0.0
2800 OD 8THK.
5THK. R/L
400
(TYP.)
50x10THK.
SECTION `A-A'
NOZZLE
DESCRIPTION :
N1
N1A
N3
N4
N5
N7
N8
N9
N10
N12
N24
N25
N27
N28
N29
N30
N32
N33
N34
N35
N6
N26
N13
N23
- STEAM INLET
- PROCESS WATER INLET
- LIQUID INLET
- NOZZLE FOR N23
- SPARE
- NOZZLE FOR N26
- SPARE
- AGITATOR NOZZLE
- SPARE
- NaNO2 INLET
- ICE INLET
- HCL INLET
- STEAM INLET
- NaOH INLET
- PRODUCT OUTLET
- MANHOLE
- NOZZLE FOR N1
- WASTE GAS OUTLET
- NOZZLE FOR 24
- NOZZLE FOR TIR
- NOZZLE FOR 25
- NOZZLE FOR 27
- NOZZLE FOR 28
- NOZZLE FOR 29
* NOTE : NOZZLE ELEVATIONS INCLUDING R/L THICKNESS
TOP COVER IS PANEL TYPE CONSTRUCTION.
PROCESS VESSEL SKETCH OF REACTOR
MA A
T
UC B
6'-0" I.D.
1830
S
2
'
-
0
"
6
1
0
2
0
'
-
0
"
6
1
0
0
SYMBOL SIZE SERVICE
NOZZLE SUMMARY
A 8" 600#RF INLET
8" 600#RF B OUTLET
3" 600#RF S SAMPLE
1" 600#BJ T TEMPERATURE
12" 600#RF UC
CATALYST
24" 600#RF MA
MAINTENANCE
ACCESS
DROP OUT
DOC NO.
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Uhde India Limited
TRAINING MANUAL - PIPING
PIPING STUDY
DWG. NO.
REACTOR PIPING
: 29040-PI-UPS-1006
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: RP7
PARTIAL PLOT PLAN FOR A HYDROTREATER UNIT
CATALYST LOADING
& UNLOADING AREA
CHARGE FURNACE
SURGE DRUM
CHARGE PUMPS
ACCESS WAY
PIPE RACK
FEED EXCHANGERS
C

R
E
A
C
T
O
R
L
DOC NO.
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Uhde India Limited
TRAINING MANUAL - PIPING
PIPING STUDY
DWG. NO.
REACTOR PIPING
: 29040-PI-UPS-1006
: R0
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: RP8
METHODS OF REACTOR SUPPORT
a. SKIRT SUPPORTED (FOUNDATION) b. LUG SUPPORTED
c. RING GIRDER SUPPORTED
STEEL
STRUCTURE
REACTOR
(TYP.)
GIRDER
RING
TABLE TOP
CONCRETE
d. SKIRT SUPPORTED (TABLE TOP)
CONCRETE
TABLE TOP
DOC NO.
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Uhde India Limited
TRAINING MANUAL - PIPING
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DWG. NO.
REACTOR PIPING
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: R0
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: RP9
REACTOR
SKIRT
REACTOR
CONCRETE
PIERS
SKIRT
MINIMUM REACTOR ELEVATION REQUIREMENTS
4
'
-
6
"
/
1
3
7
0
CONVEYOR
MINIMUM TO SUIT
PIPE SUPPORT or
LOW-POINT DRAIN
DOC NO.
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TRAINING MANUAL - PIPING
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REACTOR PIPING
: 29040-PI-UPS-1006
: R0
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: RP10
REACTOR
DIRECT UNLOADING FROM A REACTOR TO A TRUCK
1
2
'
-
1
5
'
3
6
5
0
-
4
6
0
0
DOC NO.
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Uhde India Limited
TRAINING MANUAL - PIPING
PIPING STUDY
DWG. NO.
REACTOR PIPING
: 29040-PI-UPS-1006
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: RP11
TRUCK
REACTOR
TOP HEAD NOZZLE ARRANGEMENTS OF A BATCH REACTOR
DOC NO.
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Uhde India Limited
TRAINING MANUAL - PIPING
PIPING STUDY
DWG. NO.
REACTOR PIPING
: 29040-PI-UPS-1006
: R0
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: RP12
LI
LI
C BATCH REACTOR
L
C CHEMICAL
L
TOWER
(TYP.)
VAPOUR
OUTLET
OPENING
FEED
MOTOR ASSY.
C AGITATOR GEAR BOX
L
TOP HEAD NOZZLE ARRANGEMENTS
ELEVATION PLAN
ELEVATION PLAN
4"/100 MIN.
MAINTENANCE
ACCESS
NOZZLE
INLET
ACCESS
MAINTENANCE
NOZZLE
INLET
DOC NO.
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TRAINING MANUAL - PIPING
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REACTOR PIPING
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: RP13
NOZZLE PROJECTION
ABOVE PLATFORM
MIN. 250MM
BOTTOM HEAD NOZZLE ARRANGEMENTS
ELEVATION PLAN
ELEVATION PLAN
4
'
-
0
"
/
1
2
2
0
M
I
N
I
M
U
M
OUTLET
CATALYST
UNLOADING
NOZZLE
9"/230 MIN.
TANGENT
KNUCKLE
RADIUS
POINT
RADIUS
ONE NOZZLE
DIAMETER
MINIMUM
NOZZLE
UNLOADING
CATALYST
OUTLET
SKIRT SUPPORTED
LEG SUPPORTED
DOC NO.
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: RP14
REACTOR
BOTTOM OUTLET
OPENING
OUTLET
BOTTOM
REACTOR
OUTLET
OUTSIDE
SAMPLE PROBE CONNECTION
WITHDRAWAL SPACE MESH SCREEN
DOC NO.
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TRAINING MANUAL - PIPING
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REACTOR PIPING
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; R0
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: RP15
REACTOR PLATFORM AND LADDER ELEVATION REQUIREMENTS
M
I
N
.

1
0
"
/
2
5
0
TEMPERATURE
INSTRUMENT ACCESS
BY LADDER OR
PLATFORM
SAMPLE CONNECTION
PLATFORM
ACCESS BY
ACCESS FROM
CATALYST UNLOADING
GRADE OR PLATFORM
MAXIMUM LADDER
PLATFORM TO SUIT
INTERMEDIATE
RUN
TOP HEAD PLATFORM
INSTRUMENT &
TEMPERATURE
VALVE, VENT,
CATALYST LOADING ACCESS
DOC NO.
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: RP16
SINGLE REACTOR PIPING ARRANGEMENT
CATALYST LOADING &
UNLOADING AREA
REACTOR
FEED EXCHANGERS
PIPE RACK
CHARGE FURNACE
DOC NO.
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: RP17
REACTORS IN SERIES: MANUALLY OPERATED VALVE MANIFOLD
ELEVATION (VIEW-P)
PLAN
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: RP18
OPERATOR
ACCESS
P
REACTORS IN SERIES: REMOTELY OPERATED VALVE MANIFOLD
ELEVATION(VIEW-P)
PLAN
DOC NO.
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P
DAVIT ARRANGEMENT ON REACTOR TOP
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TROLLEY BEAM ARRANGEMENT ON REACTOR TOP
RELIEF VALVES
DAVIT
LOADING
NOZZLE
UNLOADING
LOADING AND
AREA
LOADING AND
UNLOADING
AREA
NOZZLE
LOADING
TROLLEY
RELIEF VALVES
BEAMS