View
379
Download
0
Category
Preview:
Citation preview
8/6/2019 Sulphuric Acid Plant
1/24
SULPHURIC ACID PLANTCriteria of erection of Equipments
to Built in Reliability
8/6/2019 Sulphuric Acid Plant
2/24
CORRECTNESS IN CIVIL CONSTRUCTION
Proper layout to be done with proper
measurements.
Excavation of the Ground for EquipmentFoundations.
Proper mixing of Concrete to be used
Confirm the Concrete Temperature and itsproper setting.
Control of Measurements.
8/6/2019 Sulphuric Acid Plant
3/24
CORRECTNESS IN CIVIL
CONSTRUCTION
Reference with other foundation orMeasurements.
Prepare template for foundation bolts to be kept
in position and check with vessel to be installed. Concrete surface leveling to be controlled.
Homogeneous Mixing to be done whileconcreting.
Surface finish to be considered for long life.
Proper leveling of Foundation to be taken care.
8/6/2019 Sulphuric Acid Plant
4/24
CORRECTNESS IN CIVIL
FOUNDATIONS Proper curing to be done.
Honey combings should not be allowed.
Torrsteel rods should not be projected from the
surface of concrete. Proper care to be taken for Concrete Joints by
providing Rubber or PP Joint seal or Propersealant to be provided to avoid leakages.
After removing of centering, plastering to becompleted immediately. So that proper jointingto be possible to give extra strength.
8/6/2019 Sulphuric Acid Plant
5/24
IMPORTANCE OF GOOD LAYOUT
Consider that the pressure drop in the systemshould not be effected while running of the plant.
Energy saving should be considered.
Heat loss should be avoided from the system. Generation of Heat to be converted into the
power generation.
Laying of Pipe lines and Ducts should not be
effected by layout. Pressure drop should not effected unless
otherwise stated.
8/6/2019 Sulphuric Acid Plant
6/24
IMPORTANCE OF ERECTING
VESSELS
Check the Measurements of Foundation.
Check the elevation of Foundations.
Check the Equipment FoundationMeasurements, which is installing onFoundation.
Check the foundation bolts location and its
Measurements. Check the Foundation bolt holes on the Base
plate of the Equipments.
8/6/2019 Sulphuric Acid Plant
7/24
8/6/2019 Sulphuric Acid Plant
8/24
Welding
1. Welding is the major role in the projects.
2. Weld Type of Arc, Tig and Mig
3. Arc welding is considered for ducting, Unpressurised
vessels, Structural, General etc.4. Tig. welding is for Pressure vessels, Pipe lines of Lowand High Lines. Ducting of Gas or Air flow.
5. Where the Expansion bellows are provided on DuctLines, there is a chance of Leakage of gasses during
sudden expansion. Tig welding is preferred.6. Arc welding may not give that much chance for
welding of ducts where the expansion joints areprovided.
8/6/2019 Sulphuric Acid Plant
9/24
8/6/2019 Sulphuric Acid Plant
10/24
Welding
11.Provide curtains to reduce the joint failure.
12.Better to provide closed area like Tig welding tobe done with closed room.
13.Field joints are not possible to do like that, soyou have to provide close atmosphere for doingthe welding of joints of high or low pressurelines.
14. It is also important to take the welding joint intonormality by doing the Annealing process. Sothat joint failure will reduce.
8/6/2019 Sulphuric Acid Plant
11/24
Plant Flooring, Position of Valves
and Flat forms
1. Valves should be provided in such a location to avoidloss of heat or Loss of Pressure etc.
2. Valves should be positioned in such a way for free
maintenance.3. Flat forms should be provided for opening and closing
of valves, maintenance of valves in that location.
4. Flat forms structural should not be effected for
movement of the plant operating people, movementof equipments like trolleys, Fork lifts etc.
5. Flat forms should be inter-connected, if possible withother supports or flat forms.
8/6/2019 Sulphuric Acid Plant
12/24
8/6/2019 Sulphuric Acid Plant
13/24
Plant Flooring, Position of Valves
and Flat Forms
9. Plant area to be covered with proper flooring tomaintain neat and clean.
10.Plant area to be provided walk ways, so that
visitors should follow the proper approach tothe plant area.
11.Name Plates are to be provided to identify theequipment name, Location of the plant area etc.
12.W
hile considering the flat forms you have tocare about the safety to the work force toescape from the position, if any suddenly unsafeconditions are generated.
8/6/2019 Sulphuric Acid Plant
14/24
Plant Flooring, Position of Valves
and Flat Forms
13. Considering of Gland leaks, which are common
from Gas Duct valves due to high gas
temperature at inside the ducts while running of
the plant.
14. You have to design properly about the glands,
which are to cooled with atmospheric air.
15. Gland cooling to be provided which is projectedfrom the Insulation to reduce the damage (or
burn) of Gland rope by high temperature.
8/6/2019 Sulphuric Acid Plant
15/24
Plant Flooring, Position of Valves and
Gland Leaks
16. Proper gland ropes are to be used which aresuitable to the particular atmosphere to avoidthe gland leakages.
17. Plant area should be maintained neat andclean to avoid unwanted accidents.
18. Inside the plant, you have to earmark the
locations to keep the maintenanceequipments during the maintenance period.
8/6/2019 Sulphuric Acid Plant
16/24
1. While circulation of Sulphuric Acid in Towers, some ofbroken saddle pieces are flow along with acid intowers and collected in to the Acid Circulation tank.
2. These are extracted by pump which are floated inliquid while running due to agitation in acid pumptank by returning acid from tower with velocity.
3. These ceramic pieces are pass though pump and willjam at inlet of the plate heat exchangers or shell andtube heat exchanger on shell side. There by reducethe flow of Sulphuric acid to the towers.
Plate Heat Exchangers & Towers
8/6/2019 Sulphuric Acid Plant
17/24
Plate Heat Exchangers and Towers
5. If these are ceramic particles pass through Plate HeatExchanger, will get jam at acid distribution Headerthere by pressure drop will increase across the PlateHeat Exchangers and Distribution Headers.
To avoid, you have to provide mesh of lower the size ofthe Plate Heat Exchanger Openings and Lower size ofthe Acid Distribution holes.
6. Acid will flow across the openings and reduce thepressure drop in the circulation system.
7. Acid is highly corrosive at higher temperature, so thatsuitable material and proper shape to be required touse.
8/6/2019 Sulphuric Acid Plant
18/24
Sulphur Gun for Spraying
1. Sulphur gun spraying is basically based on Air flow aswell as swirling motion of Sulphur flow.
2. Sulphur should not fall on furnace inside before
spraying. To avoid that falling of Sulphur Nozzleshould be Pressurized by flow and swirling motion tobe provided.
3. Sulphur Furnace inlet air flow is also required toprovide swirling flow along with Sulphur Gun nozzle.
4. Gun barrel pipe as well as supply jacketed pipe to bedesigned as required to provide sufficient flow to theGun nozzle.
8/6/2019 Sulphuric Acid Plant
19/24
Instrument Erection and
PLC Positioning
a. PLC Control panel to be installed in Plantoperation control room.
b. Cable racks and Cable identification should be
properly earmarked by provided tags, likenumbers or letters.
c. Cable joints are not allowed for instrumentationsystem.
d. Cable junction boxes are to be provided in sucha location to avoid the damage of junction boxesby rain, sun rays etc.
8/6/2019 Sulphuric Acid Plant
20/24
Instrument Erection and
PLC Positioning
e. Local Indicators are to be provided with proper
cover.
f. Control valves and Controllers are to be provided
in proper direction to look locally by the
operating peoples.
g. Proper controlling system to be provided based
on the operational condition of the plant.h. Plant tripping is to be provided in proper way, it
should not deviate the system failure.
8/6/2019 Sulphuric Acid Plant
21/24
Instrument Erection and
PLC Positioning
i. Plant tripping should help us the Process
failure, System failure and to reduce the
damage of the plants.
j. Plant tripping will help us to control the
Environmental pollution based on the
settings of the plant with ventilations
through chimneys.
8/6/2019 Sulphuric Acid Plant
22/24
CLOSEUP
a. Plants should run at clean atmosphere.
b. Plants should operate with in controlledenvironmental conditions.
c. Plants should operate with in the recommendedoperating condition.
d. Plant should be the unit, the Operating peopleas well as Management should feel happy to
run.e. Management should not feel burden to run theplants with in the controlled conditions.
8/6/2019 Sulphuric Acid Plant
23/24
8/6/2019 Sulphuric Acid Plant
24/24
PREPARED BY
YALAMATI SATYANARAYANA
PROJECT MANAGER
M/S. HARIKA INDUSTRIES
HYDERABAD
INDIA
CELL: +919849963639 / +966590288534
YALAMATI.SATYANARAYA@GMAIL.COM
Recommended