Process Equipment Procurement in the Chemical and Related Industries (eBook)

Kiran Golwalkar (Autor)

eBook Download: PDF

2014 | 2015
XXI, 259 Seiten
Springer International Publishing (Verlag)
978-3-319-12078-2 (ISBN)

Infos

This concise volume explains when to procure new equipment, how to prepare specifications for floating inquiries, and guidelines for detailed technical discussions with vendors in the chemical and related industries. It covers the common equipment and supplies used in chemical plants, refineries-please delete reference to refineries, and effluent treatment facilities such as pumps, blowers, reactors, heat exchangers, waste heat recovery boilers, heat and acid resistant lining etc. The book serves as a checklist to the plant managements for procurement of the correct equipment in the most efficient timeframe insuring that projects are not delayed due to long time required for procurement of new equipment.

Kiran Golwalkar is a Consulting Chemical Engineer.

Inhalt

Preface 6
Acknowledgement 8
Sources of my information 8
References 9
Contents 10
About the Author 19
Chapter-1 20
Process Equipment Procurement: Need and Options 20
1.1 Introduction 20
1.2 Procurement of an Entire Manufacturing Facility or Technology 21
1.3 Options to Be Considered 22
1.3.1 Procurement of an Entire Plant on “Turnkey Basis” Procuring an old plant and Reva 22
1.3.2 Purchase of Know-How 25
1.3.3 Options for External Procurement 26
1.4 History Cards 28
1.5 Need to Purchase New/Additional Equipment 29
1.6 Deciding on New Purchase 30
1.7 Options to Be Considered for External Procurement of Some Equipment 31
1.8 Technical Specifications 31
1.9 Financial Implications of Procurements 32
Chapter-2 35
Classification of Equipment, Inquiry Document and Instructions to Vendors 35
2.1 Instructions to Vendor 36
2.1.1 Exclusion from Scope of Supply 38
2.1.2 General Conditions 38
2.2 Quality Assurance Plan (QAP) 40
2.2.1 The Vendor Should Include the Following Points in the QAP 40
2.2.2 Visit by Purchaser's Inspection Engineer to Vendors Works 40
2.2.3 Documents to Be Included in the QAP 41
Chapter-3 42
Solid Material Feeding Equipmentsfor Process Units 42
3.2 Electrical Overhead Travelling EOT Cranes 43
3.2.1 Procurement/Selection Criteria 43
3.2.2 Vendor to Give Details of 43
3.3 Hoists 44
3.4 Belt Conveyors 45
3.4.1 Main Components of the System 45
3.4.2 Properties of Materials to be Taken into Account 45
3.4.3 Considerations for Selection 45
3.4.4 System Design Considerations for Belt Conveyor 46
3.4.5 Safety Arrangements 47
3.4.6 Tightening of Conveyor Belt 48
3.5 Bucket Elevators 48
3.5.1 Continuous Discharge Type 49
3.5.2 Centrifugal Discharge Type 49
3.5.3 Properties of Materials to be Taken into Account 49
3.5.4 Main Components of the System 49
3.5.5 Purchaser to Discuss with Vendor 50
3.5.6 General—Vendor to Inform the Following 51
3.6 Screw Conveyors 51
3.6.1 Purchaser Should Inform the Following 52
3.7 Pneumatic Conveying System 52
3.7.1 Important System Components 53
3.7.2 Limitations of the System 53
3.7.3 Considerations For Pneumatic Conveying Systems 53
Chapter-4 55
Equipments/Accessories for Handling of Fluids 55
4.1 Pumps 55
4.1.1 Considerations for Selection of Pumps 55
4.1.2 Special Precautions for Boiler Feed Water Pumps 58
4.1.3 Metering Pumps 58
4.2 Blowers and Compressors 59
4.2.1 Compressors 61
4.2.2 Positive Displacement Type (Roots Blower) 62
4.2.3 Induced Draft Fans 63
4.3 Vacuum Pumps and Exhausters, Steam Jet Ejectors 63
4.3.1 Vacuum Pumps 63
4.3.2 Industrial Exhausters 64
4.3.3 Steam Jet Ejectors 65
4.4 Valves, Pipelines, Gaskets and Flanges 65
4.4.1 Valves 65
4.4.2 PIPELINES 67
4.4.3 Gaskets 68
4.4.4 Flanges 68
4.4.5 Expansion Bellows 68
Chapter-5 70
Procurement of Raw Materials and Catalysts 70
5.1 Raw Materials 70
5.1.1 Starting Materials 70
5.1.2 Intermediate Items 70
5.1.3 Selection/Procurement Criteria 71
5.1.4 Other Specifications 71
5.1.5 Types of Packing for Procurement 71
5.1.6 Purchasing by Tanker loads 72
5.1.7 Solids/Powders 72
5.2 Catalysts 73
5.2.1 Considerations for Procurement of Catalyst 73
5.2.2 Fixed Bed of Catalyst 73
5.2.3 Fluidised Bed of Catalyst 73
5.2.4 Loss due to Attrition 74
5.2.5 Deactivation/Poisoning of Catalyst 74
5.2.6 Initial Cost and Royalty 74
5.2.7 Handling, Storage, etc. 75
5.2.8 Performance Guarantee 75
Conclusion 75
Chapter-6 77
Process Reactors 77
6.1 Chemical Reactors 77
6.1.1 Fixed-Bed Reactors (Catalytic) 78
6.1.2 Fluidised-Bed Reactors 78
6.1.3 Stirred-Tank Reactors 79
6.1.4 Gas Induction Reactors 81
6.1.5 Selection of Agitators 82
6.1.6 Standard Fittings and Mountings to Be Considered 83
6.2 Properties of Reaction Mass and Process Conditions 84
6.3 Electric Furnaces 85
6.3.1 Installation/Ordering an Electric Furnace 85
6.3.2 Instrumentation to Be Provided 86
6.3.3 Whether Water-Cooling of the Electrodes Is Required 86
6.3.4 Furnace Accessories to Be Supplied by Vendor 86
6.4 Electrolytic Cells 87
6.4.1 Selection of Electrolytic Cells 87
6.4.2 Instrumentation Provided 88
6.4.3 Cell Grouping 88
6.5 Rectifier 88
Chapter-7 90
Pressure Vessels, Glass Vessels and Glass-lined Vessels 90
7.1 Considerations for Procurement of Pressure Vessels 90
7.1.1 Arrangements 91
7.1.2 External Fittings 91
7.1.3 Factors for Deciding Wall Thickness of Pressure Vessels 92
7.1.4 Heads for Pressure Vessels 92
7.1.5 General Considerations for Design and Fabrication 92
7.1.6 Materials of Construction 93
7.1.7 Fabrication Drawings 94
7.1.8 Steps for Ordering and Procurement 94
7.1.9 Quality Assurance Plan 95
7.1.10 Visit to Vendors Shop 96
7.1.11 Statutory Documents Required 98
7.1.12 Safety Valves 98
7.2 Glass Equipment/Glass-lined Equipment 99
7.2.1 Special Precautions 99
7.2.2 Details To Be Given to the Vendor 100
Chapter-8 102
Mechanical Screening and Filtration Equipment 102
8.1 Vibratory Screens 102
8.2 Rotary Screens 103
8.3 Filters 103
8.3.1 Important Considerations for Procurement 104
8.3.2 Rotary Vacuum Filter Procurement 105
8.3.3 Pressure Leaf Filter 106
8.3.4 Filter Press 107
8.3.5 Centrifuge 108
8.4 Filters for Gases 109
8.4.1 Quick Discharge Type Filter (Case Study-Please See the two figures given below for 110
8.4.2 Filter with Horizontal Beds of Filter Media 111
8.4.3 Supports for Filter Media 112
8.4.4 General Features to be Provided 112
Chapter-9 113
Heat Exchangers 113
9.1 Criteria for Selection of Heat Exchangers 113
9.2 Allowable Pressure Drop 114
9.3 Expansion Bellows 114
9.4 Floating Tube Bundle 114
9.5 Margin for Fouling of Heat Transfer Surfaces 114
9.6 Tie Rods 115
9.7 Segmental Baffles 115
9.8 Radiography 115
9.9 Pressure Test 115
9.10 Heat Exchangers with Disc-and-Donut-Type Baffles 115
9.11 Plate Heat Exchangers (PHEs) 116
9.11.1 Information Required from Manufacturer 117
9.11.2 PHE-Based Heat Recovery System 117
9.12 Other Types of Heat Exchangers 120
9.12.1 Trombone Coolers 120
9.12.2 Atmospheric Cooling Loops 120
9.12.3 Finned Tube Banks and Radiators 121
9.13 Condensers 121
9.13.1 Pressure Test 121
9.13.2 External Reinforcement for the Shell 122
9.14 Evaporators 122
9.14.1 Open Type 122
9.14.2 Closed Type 123
9.14.3 Multiple Effect Evaporators 123
Boiling Points 123
9.14.4 Separate Measurement of Condensate 124
Information to be included in the inquiry document: 124
Chapter-10 129
Air Pollution Control Equipment 129
10.1 Cyclone Separators 129
10.2 Bag Filters 131
10.3 Absorption Equipment for Pollution Control 132
10.3.1 Inquiry for Gas Scrubbing Systems 132
10.3.2 Venturi Scrubber 133
10.3.3 Packed Towers 135
10.3.4 Jet Scrubber/Ejector Scrubber 135
10.3.5 Spray Tower 137
10.3.6 Tangential Scrubbing Tower 137
10.4 Tower Packing Items 137
10.4.1 Loading Pattern in the Towers 137
10.4.2 Spray Nozzles 138
10.5 Candle Demisters and Entrainment Separators 139
10.6 Electrostatic Precipitators (ESP) 141
10.6.1 Dry ESP 142
10.7 Wet ESP 142
10.8 Chimney 143
Chapter-11 146
Heat Recovery Equipments 146
11.1 Selection of Waste Heat Boilers (WHB) Depends on 146
11.2 Steaming Economiser 148
11.2.1 Selection Criteria 149
11.3 Air Preheater/Heat Recuperators/Other Devices for Heat Recovery 150
11.3.1 Selection Criteria for Air Preheaters 150
11.3.2 Recuperators 150
11.4 Cogeneration of Power 153
11.4.1 Feasibility Study 154
11.4.2 Steam Turbines 155
11.5 Steam Pressure Reducing Station 156
11.6 Steam Superheaters 156
11.7 Steam De-Superheaters 157
Chapter-12 159
Instruments 159
12.1 Introduction 159
12.1.1 For Safety of Personnel 159
12.1.2 For Pollution Control 160
12.1.3 For Energy Efficiency 160
12.1.4 For Ensuring Quality of Product 160
12.1.5 For Efficiency of Operations 160
12.2 Selection Criteria for Procuring Instruments 161
12.3 Dial Designs 161
12.4 Desirable Features of Dials on Instruments 161
12.5 General Considerations for the Instrumentation System 162
12.6 Accessories Required 162
12.7 Installation and Commissioning Assistance from Vendor 163
12.8 Common Instruments 164
12.9 Special Instruments 164
12.10 Dial Gauges for Temperature 164
12.11 Thermocouples 165
12.11.1 Types of Thermocouple 165
12.11.2 Multi-point Temperature Indicator 167
12.12 Thermowells 168
12.13 Pressure Gauges (for Higher Range) and Manometers (for Lower Range) 169
12.14 Flow Meters for Liquids 170
12.14.1 Rotameters 170
12.15 pH Meter 170
12.15.1 Considerations for Procurement 171
12.16 Humidity Meter (Hygrometer) 172
12.17 Concentration Analysers 173
12.18 Contactless Instruments 174
12.18.1 Contactless Magnetic Flow Meters 174
12.18.2 Ultrasonic Level Indicators 174
12.18.3 Level Indicators 175
12.18.4 Level Controllers 175
12.19 Flow Meters for Liquids 175
12.19.1 Turbine Meters for Liquid-Flow Measurement 175
12.19.2 Vortex Meters for Liquid-Flow Measurement 176
12.19.3 Gas Flow Meters 176
12.20 Stack Gas Analysers 177
12.20.1 High-Volume Sampler for Fine Particulate Matter in Gas 177
12.20.2 Analyser for Gases 178
12.21 Special Instrument Feeding 178
12.22 Controllers 178
12.22.1 Controller Types 179
12.23 Recorder Types 179
12.24 Connecting Cables 180
12.25 Dist ributed Control System 180
12.25.1 Considerations for Selection of a DCS 181
Chapter-13 182
Utilities 182
13.1 Heating Arrangement for Chemical Plant 182
13.1.1 Use of Gaseous Fuels 182
Accessories 182
Safety Precautions 183
13.1.2 Use of Liquid Fuels 183
Arrangements and Accessories 183
13.1.3 Use of Solid Fuels 184
Facilities 184
13.1.4 Heating Plant Units by Steam 185
Vendor Should Be Asked to Indicate the Following in the Offer for CFB 185
13.1.5 Combustion Air for Firing Systems 186
Important Considerations 186
Safety Devices to Be Supplied by Vendor of Firing System 186
13.1.6 Factors to be Considered for Selection of Fuel 186
Practical Considerations of Fuel Handling Facilities 187
13.1.7 Thermic Fluid System 187
Various Options as Below Should Be Closely Looked into 187
Selection Criteria/Information Necessary for Procurement 188
The Important Components 188
13.1.8 Air Drying Plant 190
13.1.9 Procurement 190
13.2 PSA Nitrogen Plant 190
13.3 Membrane Process for Nitrogen Gas 193
13.3.1 Purchaser Should Examine 194
13.4 Electrical Transformers 195
13.5 Electrical Power Distribution in the Plant 196
13.6 Electrical Motors 197
13.7 Diesel Generator Set 198
13.8 Refrigeration Systems 200
13.8.1 Working of a Conventional Refrigeration Plant 200
13.8.2 Criteria for Selection/Procurement 201
13.9 Producing Chilled Water by Using Low Pressure Steam (Thermax System) 202
13.9.1 Main Components of the System Are 202
13.9.2 Selection of this Unit Is Based on Following Considerations 203
13.10 Another Method to Produce Chilled Water 204
13.10.1 Another Method to Produce Chilled Water 204
13.10.2 Selection Depends on Certain Specific Situations 205
13.11 Cooling Towers 205
13.11.1 Selection Criteria 205
Chapter-14 207
Effluent Treatment Plants 207
14.1 Thickeners 207
14.1.1 Selection/Discussions with Vendor for the Following 207
14.1.2 Rake Mechanism Details 208
14.1.3 Unit Geometry 208
14.1.4 Outlet Liquor 208
14.1.5 Civil Foundation 208
14.1.6 Removal of Sludge 209
14.1.7 Estimation of Sludge Level Build-Up 209
14.2 Lamella Clarifier 210
14.2.1 Selection Criteria for Lamella Clarifiers 210
14.3 Tube Settler 211
14.3.1 Shape and Inclination of Tubes 211
14.3.2 For Minimising Disturbance of Settled Sludge 212
14.3.3 Other Features 212
14.4 Dissolved Air Flotation 212
14.4.1 Working principle 212
14.4.2 Main Components of the System 212
14.4.3 Considerations for Selection 213
14.4.4 Disposal of Skimmed Out Material 215
14.5 Sequential Batch Reactor Technology for Wastewater Treatment 216
14.5.1 Items Required Generally 216
14.5.2 Aeration Equipment and Air Blowers 216
14.5.3 Effluent Removal Systems 217
Chapter-15 218
Protective Linings 218
15.1 Types of Linings 218
15.2 General Methods 218
15.3 Materials Used for Lining 219
15.4 Selection Criteria for Lining Materials 219
15.4.1 Test Certificates 220
15.4.2 Typical Specifications for Bricks 220
Acid-Resistant Bricks 220
Iinsulating Bricks 221
15.5 High Alumina Bricks 221
15.6 Ceramic Paper 221
15.6.1 Properties 222
15.6.2 Typical Applications 222
15.7 Work Order for Brick Lining Work at Site 223
15.7.1 Vents 224
15.7.2 Curing 224
15.7.3 Important Precaution 224
15.8 Rubber/Fibreglass Reinforced Linings 224
15.8.1 Important Considerations 224
15.8.2 Work Order for Rubber/Fibre Glass Lining 225
15.8.3 Lining Contractor to Inform 225
15.8.4 Poly Tetra Flouro Ethylene (PTFE) Lining 226
15.9 Insulation and Cladding 226
15.9.1 Hot Insulation 226
15.9.2 Cold Insulation 227
15.9.3 Work Order 227
Appendices 228
Appendix A 228
A.1 Ball Mill 228
A.2 Jaw Crusher 228
A.3 Grinding Mill 230
Appendix B: Safety-Related Equipment and Services 231
B.1 Elevated Storage Reservoir 231
B.2 Safety Valves 232
B.3 Fire Fighting Systems 233
B.4 Safety Equipment and Personal Safety Devices 234
B.5 Structurals and Work Platforms 235
B.2.5 Proposed Safe Handling System for Collection and Feeding Chemicals 236
Appendix C: Solid Waste Disposal and Some More Effluent Treatment Facilities 237
C.1 Incineration Plants for Wastes 237
C.2 Some More Effluent Treatment Facilities 239
C.3 Up Flow Anaerobic Sludge Blanket Reactor (UASB) 241
C.4 Producing Potable Water from Sea Water 241
Appendix D: Steam-Related Equipment and Water Treatment Plants 242
D.1 Packaged Boiler Selection 242
D.2 Thermal Vapour Recompression 245
D.3 Mechanical Vapour Compression 246
D.4 Selection of Steam Traps 246
D.5 Water Treatment Plants 248
D.5.1 Following Points shall be Considered for This Purpose 248
D.5.2 Reverse Osmosis 249
Appendix E: General Process Equipment 250
E.1 Distillation Equipment 250
E.2 Dissolvers for Solids 252
E.3 Tray Dryers 253
E.4 Rotary Kiln with Girth Gear Drive 253
E.5 Control Valves 257
E.6. Product Despatch 260
E.6.1 Solids 260
E.6.2 Liquids 261
E.6.3 Metering Tanks 262
Appendix F: Other Essential Services and Facilities 263
F.1 Laboratory Facilities 263
F.2 Maintenance Facilities 264

Produkt-Details

• Erscheint lt. Verlag: 25.11.2014
• Zusatzinfo: XXI, 259 p. 33 illus., 12 illus. in color.
• Verlagsort: Cham
• Sprache: englisch
• Themenwelt: Naturwissenschaften ► Chemie
• Themenwelt: Technik
• Schlagworte: Boilers • Chemical Manufacturers • chemical plants • Chemical Process Equipment Procurement • Effluent Treatment Facilities • Financial Aspects of Chemical Processing Equipment • Power Cogeneration Plants
• ISBN-10: 3-319-12078-6 / 3319120786
• ISBN-13: 978-3-319-12078-2 / 9783319120782