a list of engineering process flow diagrams and process

Elsevier US Job Code:CAPA Chapter:0capaappA 22-12-2006 5:26p.m. Page:771 Trimsize:8.5in×11in

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Appendix A

A LIST OF ENGINEERING PROCESS FLOW DIAGRAMSAND PROCESS DATA SHEETS

A-1 PROCESS FLOW DIAGRAMS USING VISIO 2002SOFTWARE

Figure 1-12b Process flow diagram (Feed and fuel desulfurizationsection).

Figure 1-12c Typical process flow diagram for the productionof Methyl Tertiary Butyl Ether (MTBE).

Figure 1-14 Piping and instrumentation diagram for Ammoniaplant CO2 removal.

Figure 1-15 Piping and instrumentation diagram: Ammoniasynthesis and refrigeration unit (2).

A-2 PROCESS DATA SHEETS

1. Air cooled heat exchanger process data sheet2. Centrifugal pump schedule: driver3. Centrifugal pump schedule: pump4. Centrifugal pump summary5. Column schedule6. Deaerator process data sheet: Deaerated water storage tank7. Deaerator process data sheet: Deaerator head8. Drum process data sheet9. Effluent schedule

10. Equilibrium flash calculation11. Fabricated equipment schedule12. Fan/Compressor process duty specification13. Fractionator calculation summary14. General services and utilities checklist15. Hazardous chemical and conditions schedule16. Heat and mass balances

17. Heat exchanger rating sheet18. Hydrocarbon dew point calculation19. Line list schedule20. Line schedule21. Line schedule sheet22. Line summary table23. Mass balance24. Mechanical equipment schedule25. Pipe line list26. Pipe list27. Piping process conditions summary28. Plate heat exchanger data sheet29. Calculation of pressure drop in fixed catalyst beds30. Process engineering job analysis summary31. Pump calculation sheet32. Pump schedule33. Relief device philosophy sheet34. Tank and vessel agitator data sheet35. Tank process data sheet36. Tank schedule37. Tie-in-schedule38. Tower process data sheet39. Tray loading summary40. Trip schedule41. Utility summary sheet42. Vessel and tank schedule43. Vessel and tank summary: driver44. Vessel schedule45. Water analysis sheet

771



772 A LIST OF ENGINEERING PROCESS FLOW DIAGRAMS AND PROCESS DATA SHEETS

A.K.C.TECHNOLOGY

Document No.

Sheet of Rev.

Job Item No.(s)Item Name No. Working Total No. Off

Unless otherwise stated, fluid properties are for mean fluid temperature. For lines 30-36 this is mean from dewpoint to outlet temperatures.

1 TUBE SIDE DATA2 Fluid Circulated Tubes3 Total Fluid Entering (Normal) kg/h lb/h Fins

4 Flow Margin % % Header Boxes

5 Temperature: In/Out °C °F Tubesheets

6 Max. Pressure Drop at Line 4 bar psi Stress Relief Yes/as Codes

7 Inlet Pressure: Operat./Design barg psig Radiography Yes/as Codes

8 Normal Heat Load kW Btu/h Sour Service Yes/No

9 Heat Load Margin % %

10 Design Temperature °C °F11 Corrosion Allowance mm in.

12 Fouling Resistance m2 °C/W °Fft2h/Btu13 Line N.B.: In/Out mm. in.

14 GAS (AND VAPOR) PROCESS CONTROL REQUIREMENTS

15 Flow of Vapor & Gas at Inlet kg/h lb/h Local / Remote Set

16 Molecular Weight: In/Out Hand / Automatic

17 Thermal Conductivity: In/Out W/m °C Btu/h.ft. °F Adjustable Pitch Fans

18 Specific Heat kJ/kg °C Btu/lb. °F Variable Speed Motor

19 Compressibility Factor Louvres20 Viscosity In / Out cP lb/ft.h Air Recirculation

21 LIQUID IN

22 Total Flow of Liquid at Inlet kg/h lb/h

23 Thermal Conductivity: In/Out W/m °C Btu/h.ft. °F24 Specific Heat kJ/kg °C Btu/lb. °F25 Density kg/m3 lb/ft3

26 Viscosity cP lb/ft.h

27 CONDENSATION

28 Fluid Condensed kg/h lb/h

29 Molecular Weight

30 Thermal Conductivity W/m °C Btu/h.ft. °F31 Specific Heat kJ/kg °C Btu/lb. °F32 Density kg/m3 lb/ft3

33 Viscosity cP lb/ft.h

34 Latent Heat kJ/kg Btu/lb

35 %Condensate Forming Film % %36 Temps. for Phase Change: In/Out °C °F37 COOLING CURVE DATA

38 %Heat Load

39 Condensing Fluid Temp. °C40

41 AIR SIDE DATA

42 Design Inlet Temp. Max/Min °C °F43 No. of Fans Assumed44 Estimated Power per Fan kW

45 SITE DATA

46 Altitude

47 Plot Size Limitations Length: Width:

48 Noise Limits

49 Atmospheric Contamination50

51 NOTES

52

53

54

55

1 Date 2 Date 3 Date 4 Date 5 DateDescription

Made/Revised by

Checked by

Approved ProcessApproved by

AIR COOLED HEAT EXCHANGERPROCESS DATA SHEET

MATERIALSUNITS



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.C.

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APPENDIX A 777

Document No.Sheet of Rev.

Job Item No.(s)

Item Name DEAERATED WATER STORAGE TANK No. Working Total No. Off

NOTE: ∗ indicates delete as necessary: ∗∗ indicates for other than code reason.

123456789

1011121314151617181920212223242526 Shell Diameter (O.D.) Shell Length: (T.L. - T.L.) No. Required27 Center Line: ∗Horizontal28 Pressure: Temperature: Nozzles Mark No. Size In Qty29 psig bar g °F °C Inlet C-1 130 Operating 3.0 0.237 223 106 Steam In C-2 1 NOTE 431 Design 10.0 0.73 241 116 Vapour Out C-3 132 emergency Vacuum Design: ∗Yes Sample Point C-4 133 Liquid Out C-5 134 Shell 1/16" (1.6mm) Cond. Out C-6 1 NOTE 435 Heads36 Liner Vent C-37 Type of Heads Drain C-7 138 Code: Steam Out C-39 Stress Relieve∗∗: Yes Pressure Relief C-8 140 Radiography∗∗: No Spill Back C-9 141 joint Efficiency: Start Up C-10 1 NOTE 342 Weight Empty: Weight Full:43 Is vessel subject to mechanical vibration? NOTE 244 Insulation: Conservation45 ∗Yes46 NOTES47 1) Corrosion Allowance on Tank Only Manhole A-1 1

48 2) Water Hammer Only49 3) Sparge Pipe To Have Delavan Type BB Nozzles Thermocouple R-1 150 and Terminate 1000mm Before Baffle. Pressure Gauge R-2 151 4) Allow for Temp of Desuperheating Steam Gauge Glass R-3 252 or condensate at Inlet Nozzles. Level Control R-4 2 Incl.LAHL/LL53 5) Normally at 0.67 Dia. Above Base.5455 Min. Base Elevation: Skirt Length:

56 Material:1 Date 2 Date 3 Date 4 Date 5 Date

DescriptionMade/Revised byChecked byApproved ProcessApproved by

CS 1/16" (1.6MM)

DEAERATOR PROCESS DATA SHEET

by In

st. G

p.

Material Corr. AllowanceCS

R-3

R-4

R-3

BAFFLE WALLCROSS SECTION

VORTEX BREAKER

MANWAY

R-4R-2

MANWAY

NOTE 5NWL

C-4

C-1

C-3

C-2C-6C-8C-9

FOR DETAILS AND MATERIALSOF DEAERATOR HEAD

SEE SHEET 2.

C-7

C-10

R-1

C-5

A-1

A.K.C.TECHNOLOGY

TANKSIZE O.D. LENGTH O.D. LENGTH2 m3

5 m3 1600 310010 m3 1800 500015 m3 2000 600020 m3 7′–0″

6′–9″6′–0″5′–3″

21′–0″18′–6″15′–0″10′–3″

2200 6600

VERTICAL TANK ONLY

ENGLISH METRICSTANDARD TANK DIMENSIONS

NOTE1





Job Item No.(s)

Item Name DEAERATOR HEAD No. Working Total No. Off

1. DESIGN FOR FULL VACUUM. OPERATING TEMPERATURE _______________ OPERATING PRESSURE __________________

2. TRAYS TO BE SEALED TO SHELL WITH STEAM QUALITY RUBBER GASKETS.

3. C4 TO BE CAPPED FOR SITE INSTALLATION OF STANDARD SAMPLING EQUIPMENT.

4. HEAD TO BE IN S.S OR COATED M.S. BELOW 120°C MAX. EPOXY RESIN BELOW 180°C MAX. STOVED PHENOLIC RESIN (SAKAPHEN). PROCESS TO ADVICE ON SPECIFICATION & APPLICATION.

5. TRAYS TO BE IN 18/8 S/S. TRIANGULAR PERFORATION. PATTERN TO BE N.GREENING'S___ OR EQUAL.

6. SPRAY NOZZLE TO BE IN 18/8 S/S. SIMILAR TO DELAVAN WATSON S. _______________ AND WITHDRAWABLE THROUGH C-1.

NOTE: Bubbling Area Is Any Part Of Tray Within 4" Distance Of A Hole

MARK SIZE QTYC-1C-3C-4 STD 1 Water Feed 1

Water Feed 2Water Feed 3Heating SteamStart-Up SteamVent SteamDeaerated Feed Water

∗ No. Of Hole Is More Important Than Pitch1 Date 2 Date 3 Date 4 Date 5 Date

Water InletVentSample PointPerf. Area/TrayBubbling Area/TrayNo. Of TraysTray ThicknessHole DiameterPitch. Approx.No. of Holes/Tray

DescriptionMade/Revised byChecked byApproved ProcessApproved by

DESIGNFLOWS (kg/hr)

DEAERATOR PROCESS DATA SHEET

NORMAL

NOZZLES

A.K.C.TECHNOLOGY

C4

C3

NOTE 6

MIN C1

PERFORATED AREA

GASKET

½" S.S.PIPE

1" S.S. FLANGE

1" N.B.S.S.PAD

11/4"(30 mm)

SEAL PAN

DETAILS OF C4

(12 mm)

1/2"



APPENDIX A 779

Doc. No:

Item No.

Job: Sheet of

Distribution: Item Name:

NOTE: ∗indicates delete as necessary; ∗∗indicates for other than Code reason

5

10

15

20

2526 Shell Diameter (O.D. / I.D.): Shell Length: No. Required:27 Center+C71 Line: ∗Horizontal / Vertical28 Pressure: g Temperature: °F /°C Nozzles Mark No. Size Number29 Item Number Inlet C-30 Operating31 Design Vapor Out C-32 Emergency Vacuum Design: ∗ Yes / No33 Liquid Out: C-34 Shell35 Heads36 Liner Thermocouple R-37 Type of Heads Pressure Gauge R-38 Code: Gauge Glass R-39 Stress Relieve∗∗: Radiography∗∗: Level Control R-40 Joint Efficiency: Safety Valve R-41 Density of Contents: at ∗°F / °C42 Weight Empty: Weight Full:

43 Is vessel subject to mechanical vibration? ∗Yes / No Vent C-44 insulation: Type: ∗Frost and Personnel Protection / Cold Drain C-45 ∗Yes / No / Anticondensation / Heat Conservation Steam Out C-46 REMARKS:47 Manhole A-484950515253 min. Base Elev'n:54 Material:

Issue No. 1 Date 2 Date 3 Date 4 DateMade/Revised byChecked byApproved - ProcessApproved by

Material Corr. Allowanceby

Inst

. Op.

DRUM PROCESS DATA SHEETA.K.C.TECHNOLOGY



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A.K

.C.

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APPENDIX A 781

Job No.

Item No.

Job: Sheet of

Temperature: °FPressure: psiaPg: psia

Assumed

m K

H2

COCH4

CO2

C2H6

C3H8

C2H4

C3H6

C6H6

i-C4H10

n-C4H10

Issue No. 1 Date 2 Date 3 Date 4 Date 5 DateMade/Revised byChecked byApproved - ProcessApproved by

EQUILIBRIUM FLASH CALCULATION (Form 1 of 2)

PROCESS DATA SHEETA.K.C.

TECHNOLOGY

m

LV

K +1

m

LV

K +1

m

LV

K +1

m

LV

K +1

m

LV

K +1LV

K +1LV

K +1 LV

K +1LV

K +1LV

K +1

=LV

Calculated =LV

m

LV

K +1

=∑

LVCalculated −1= 1

m

K LV +1∑




Job No.

Item No.

Job: Sheet of

Temperature: °FPressure: psiaPg: psia

Vy = m − Lx

Issue No. 1 Date 2 Date 3 Date 4 Date 5 DateMade/Revised byChecked byApproved - ProcessApproved by

EQUILIBRIUM FLASH CALCULATION (Form 2 of 2)

PROCESS DATA SHEET

Feedm

LiquidLx

GasVy

Liquidx

Gasy

MOLES MOL. FRACTION

L xm

K LV + 1

=

H2

COCH4

CO2

C2H6

C3H8

C2H4

C3H6

C6H6

i-C4H10

n-C4H10

A.K.C.TECHNOLOGY



FAB

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Not

es: 1

. H.E

. T

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Cod

ing

- A

.C. =

Air

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ler;

K

= K

ettle

; U

.B. =

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. = F

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.S. =

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.C.

TE

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783





Job Item No.(s)\Item Name No. Working Total No. Off

12 Operating Case3 Mass Flowrate kg/h lb/h

4 Standard Volumetric Flowrate nm3/h std ft3/h5 Volume at Suction m3/h6

7 Pressure bara psia8 Temperature °C °F9 Molecular Weight

10 Cp/Cv11 Compressibility

12 DISCHARGE CONDITIONS13 Pressure bara psia14 Temperature oC oF15 Cp/Cv16 Compressibility

17

18 Mol % Mol %19202122232425262728293031 Entrained Liquids/Solids32

33 Compression Ratio34 Estimated Efficiency % %

35 Estimated Absorbed Power kW hp36 Recommended Driver Power kW hp

37 MECHANICAL ARRANGEMENT38 Compressor/Fan Type39 Number of Stages40 Gas to be kept Oil Free Yes / No4142 Driver Type4344 Casing Design Pressure45 Design Pressure46

47 Material - Casting

48 - Impeller49

50 Sour Service Yes / No

51 NOTES52 1. Cooling medium available:-535455

1 Date 2 Date 3 Date 4 Date 5 DateDescriptionMade/Revised byChecked byApproved ProcessApproved by

PERFORMANCE

UNITS

OPERATING CONDITIONS PER UNIT

FAN/COMPRESSOR PROCESS DUTY SPECIFICATION

INLET CONDITIONS

GAS ANALYSIS

A.K.C.TECHNOLOGY

SKETCH

ft3/h



APPENDIX A 785

Job No:Item No:Sheet ____ of _____

Job:Item Name:

1 Operate at psig Units: Metric / British (delete one)

Distribution 2 Fractionation: Reflux Ratio & No. of Plates:

3 Ovhd Prod: C < Reflux Ratio: Actual: ; Use

4 Bottoms: C < Rectifying Plates: Theoretical: ; Use

5 Stripping Plates: Theoretical: ; Use

6

7 Vapour

8 Pressure

9 1

10 2

11 3

12 4

13 5

14 6

15 7

16 8

17 9

18 10

19

20 Ext. Rflx.

21

22

23 1

24 2

25 3

26 4

27 5

28 6

29 7

30 8

31 9

32 10

33

34 Thermal Conditions of Feed: Reboiler Vapour Quantity:

35

36

37

38

39

40

41 Sp.Gr.

42 at 15oC

43 at 60oF

44 Feed

45 Net Bottoms

46 Net Overheads

47 Gross Overheads

48 Gross Bottoms

49 Reboiler Vapour

50

51

52

53 REMARKS

54

55

56 Issue No. 1 Date 2 Date 3 Date

57 Made/Revised by

58 Checked by

59 Approved - Process

60 Approved by

Kg/hr lb/hr

cu. m/kg

cu. Ft/lb

Mol % K

Sp. Vol. At T

o

Mols/hr Mol. Wt.Stream oAPI Temp.Sp.Gr. at

To

KX or Mols MolsComponent Mols Mol % K

KX Pat

Net Overheads Gross Overheads

FRACTIONATOR CALCULATIONSUMMARY

Feed Net Bottoms

Component Mols Mol % Mols Mol % K

A.K.C.TECHNOLOGY

F

Co

o

Fpsia

CKscao

o

Fpsia

CKscao

o

Fpsia

CKscao

o

K

Y

K

Y

Co

Fo




GENERAL SERVICES AND UTILITIES CHECKLIST

Job No.: PREPARED BY:Job Name:Document No. DATE:Project No.ClientLocationPlant

SERVICE QUANTITY OPERATING PRESSURE AND REMARKSSUSTAINED PEAK UNIT TEMPERATURE

ELECTRICAL 13.8 KV *KVA

ELECTRICAL 2300 V *KVA

ELECTRICAL 440 V *KVA

MISC. LIGHTING, ST. ETC., (110 V) *KVA

WELL WATER (CITY) gpm

SEA WATER gpm

RIVER WATER – PROCESS gpm

RIVER WATER – FIRE PROT. gpm

FUEL GAS SCFMODORIZED GAS SCFM

COMPRESSED AIR SCFM

STEAM lb/h(400 OR 475) Psig lb/h235 Psig lb/h150 Psig lb/h30 Psig lb/hCONDENSATE RETURN lb/hCONDENSATE USAGE lb/hPROCESS TRANSFER AND RAW MATERIALSCAUSTIC (–%) lb/hBRINE (–%) lb/hLPG lb/h

SITE DEV. (AREA FILL)

RAIL ROADS

BLOCK ACCESS ROADS

SANITARY SEWERS gpmgpm

WASTE WATER

* ASSUME 1 HORSE POWER = 1 KVA

NOTE: ONE COPY OF THIS LIST TO BE GIVEN TO SERVICE AND UTILITY SECTION.

A.K.C.TECHNOLOGY

Sheet of



HA

ZA

RD

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out a

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ibili

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n th

e pa

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f A

KC

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hnol

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4. C

olum

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A –

Wat

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– F

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5. C

olum

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B.A

. – B

reat

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olum

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Vap

or –

V,

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uid

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alc

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Rem

arks

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icity

: Den

otes

Thr

esho

ld L

imit

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A.K

.C.

TE

CH

NO

LO

GY

787



H

EA

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AL

AN

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S

Job

No.

:Sh

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:1

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e2

Dat

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Dat

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ade/

Rev

ised

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106

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am

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47

↓

→?

??

A.K

.C.

TE

CH

NO

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* de

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788



APPENDIX A 789

Document No.

HEAT EXCHANGER RATING SHEET

Sheet of Rev.PART 1 - TO BE FILLED IN COMPLETELY Items No. (s)

1 Exchanger Name: *

2 Job: * * * Arrangement: Horiz = 0; Vert = 1

3 Type of Unit: F.T.S.=0; FLTG.HEAD=1; U-TUBE=2; FOR KETTLES ADD 3 Units: S.I. 0; Engineering = 14 Hot Side: Either=0; Shell=1; Tubes=2

5 Units

6 Fluid Circulated - -

7 Total Fluid Entering (Normal) kg/hr lb/hr

8 Flow Margin % %

9 Temperature In/Out °C °F

10 Max Pressure Drop at line 8 bar psi

11 Inlet Pressure Operating/Design barA psia

12 Normal Heat Load kW Btu/hr

13 Heat Load Margin % %

14 Design Temperature °C °F

15 Corrosion Allowance mm ins

16 Fouling Resistance °Cm2/Wl °F hr ft2/Btu

17 Line N.B. In/Out mm ins

18 Part 2

19 GAS (AD VAPOR) IN - -

20 Flow of Vapor and Gas at Inlet kg/hr lb/hr

21 Code Number - -

22 Molecular Weight - -

23 Thermal Conductivity W/m °C Btu/hr ft °F

24 Specific Heat kJ/kg °C Btu/lb °F

25 Compressibility Factor - -

26 Viscosity cP lb/ft hr

27 LIQUID IN - -

28 Total Flow of Liquid at Inlet kg/hr lb/hr

29 Code Number - -



32 Density kg/m3 lb/ft3


34 Viscosity at Ave. Temp. other side cP lb/ft hr

35 CONDENSATION AND VAPORIZATION - -

36 Fluid Condensed or Vaporized kg/hr lb/hr

37 Code Number - -

38 Molecular Weight - -



41 Density (Hot Fluid) kg/m3 lb/ft3

42 Compressibility Factor (Cold Fluid) - -


44 Latent Heat kJ/kg Btu/lb

45 Surface Tension N/m lb/ft

46 Expansion Coefficient 1/ °C 1/ °F

47 % Condensate Forming Film % %


49 Density kg/m3 lb/ft3


51 Temps for Phase Change Start/Finish °C °F

52 LMTD weighting Factor 'F' - -

53 PART 3

54 Number of Points in Table Below

55 % Heat Load % % 1 2 3 4 5 6 7 8 9 10

56 Hot Fluid Temperature °C °F

57 Cold Fluid Temperature °C °F

58 PART 4 - CODE NUMBERS TO BE FILLED IN COMPLETELY

59 Material for Description Code No. O.D. Thickness Length Passes Number Contents Lethal?

60 Tubes

61 Shell

62 Floating Head Tube Pitch = mm/in. o Δ �

63 Channel

64 Tube Sheets

NOTES

Issue No. 1 Date 2 Date 3 Date 4 Date 5 Date

Made/Revised by

Checked by

Approved- ProcessApproved by

Yes/No

Yes/No

Location:

S.I. Engineering HOT FLUID COLD FLUID

A.K.C.

TECHNOLOGY




Job No:Item No.

Job: Page of

Pressure: psia

Heaviest Compound: PROPANE Convergence Pressure: psia

oFFeL TbFeL FeH TbFeH K y/K K y/K K y/K K y/K x

H2 67 1.000 67.000N2 130 0.0229 2.972 0.105CO 172 0.0046 0.797 0.180CH4 201 0.0019 0.383 0.244C2H4 305 0.548CO2 330 0.638C2H6 332 0.646C2H2 340 0.676C3H6 406 0.954C3H8 416 1.000

13.6131.0049.02167.0210.6214.3229.9387.3416.0

1.000 Σ y/K 1.000

x for H2

Σ (yFeL/K)Σ (yFeH/K)E.B.PLE.B.PHPg

Estimate of Dewpoint: oFat Estimate Pg of: psia

Issue No. 1 Date 2 Date 3Made/Revised byChecked byApproved - ProcessApproved by

HYDROCARBON DEWPOINTCALCULATION

TbyASSUMED TEMPERATUREoF oF oF

Date

HEAVYCOMPONENT

LIGHTCOMPONENT oF

A.K.C.TECHNOLOGY



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.C.

TE

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.C.

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793



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A.K

.C.

TE

CH

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CFS

794



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NE

NT

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L W

Tkg

mol

/hM

ol %

kg m

ol/h

Mol

%kg

mol

/hM

ol %

kg m

ol/h

Mol

%kg

mol

/hM

ol %

kg m

ol/h

Mol

%kg

mol

/hM

ol %

1W

ater

2H

ydro

gen

3N

itrog

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Car

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mon

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diox

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6M

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Prop

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14Is

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30 31 32 33 34 35 36 37 38 39 40 41 42N

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:43 44 45 46 47 48

A.K

.C.

TE

CH

NO

LO

GY

795



ME

CH

AN

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L E

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Job

No.

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b N

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Plan

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FLU

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A.K

.C.

TE

CH

NO

LO

GY

796



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.C.

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A.K

.C.

TE

CH

NO

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798



PIPI

NG

PR

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Job

No.

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No.

:1

Dat

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Dat

e3

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eJo

b N

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Des

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A.K

.C.

TE

CH

NO

LO

GY

799




Document No.

Sheet of Rev.

Job Item No.(s)

Item Name No. Working Total No. Off

1 FLUID 1 FLUID 2 FLUID 32 Fluid Circulated - -3 Total Fluid Entering (Normal) kg/h lb/h

4 Flow Margin % %5 Inlet Vapor and Gas (&MW) kg/h lb/h6 Inlet Liquid kg/h lb/h7 Fluid Vaporized/Condensed (&MW) kg/h lb/h8 Temperature In/Out oC

oF9 Max. Pressure Drop bar psi

10 Inlet Pressure (Operating) bar g psig

11 Normal Heat Load kW Btu/h12 Heat Load Margin % %13 Fouling Resistance m2 ο 2 ο

C/W ft Fh/Btu14 FLUID PROPERTIES15 Specific Heat kJ/kg C Btu/lb F

16 Thermal Conductivity W/m C Btu/hr ft F17 Density kg/m3 lb/f t3

18 Viscosity cP lb/hr.ft19 Liquid Viscosity (at Temp.) cP lb/hr.ft20 Latent Heat kJ/kg Btu/lb

21 ENGINEERING DESIGN22 Process Design Pressure bar g psig23 Process Design Temperature C F24 Corrosion Allowance (Header) mm in.25 Line N.B. In/Out in in.26 Minimum Flow Passage mm in.27 Plate Material28 Frame Material29 Gasket Material30 Desgin Code31 NOTES3233 1. Unless otherwise stated fluid properties are for mean fluid temperatures.34 2. Sour Service Yes / No3536373839404142434445464748495051525354

1 Date 2 Date 3 DateDescriptionMade/Revised byChecked byApproved ProcessApproved by

UNITSPROCESS DESIGN

PLATE HEAT EXCHANGER DATA SHEET

A.K.C.

TECHNOLOGY

ο

ο

ο ο

ο

ο



APPENDIX A 801

MadeJob No.

Checked

Item No.Date

Job Sheet of

REQUIRED DATAVESSEL NO:SERVICE:CATALYST: VOLUME REQUIRED V ft3

MANUFACTURER & NO.DIMENSIONSEQUIV. PARTICLE DIA. Dp ft.SHAPE/SIZE FACTOR Sf

GAS DATA: FLOW RATE W lb/hW2 (lb/h)2

MIN. MOLECULAR WEIGHTBED OUTLET PRESSURE P psiaMAX. BED TEMPERATURE CABS. TEMPERATURE (ο ο

ο

K = C + 273) T K

CALCULATION

=

SYMBOLS UNITS CALCULATION CASE 1 CASE 2 CASE 3 CASE 4BED DIAMETER D ftBED C.S.A. A ft2 0.7854D2

BED DEPTH L ft. V/ASUPERFICIAL MASS FLOW G lb/h.ft2 W/AMASS FLOW FACTOR Gf -DpG -

REYNOLDS NO. FACTOR Ref -

k2k2 - k1Ref

CLEAN PRESSURE DROP/UNIT DEPTH ΔPc psi/ft. k2Gf

CLEAN OVERALL PRESSURE DROP ΔPc psi LΔPc

SAFETY/FOULING FACTOR f - 1.25/ FLOW SHEET PRESSURE DROP ΔP psi fΔPc

* IF VALUE OF DpG > 200 (750 FOR RING CATALYSTS) PUT Ref = 1.0IF VALUE OF DpG < 200 (750 FOR RING CATALYSTS) CALCULATE Re = DpG/μ(WHERE μ = DYNAMIC VISCOSITY OF GAS, lb/ft.hr)

1 2 3 4 5 6DescriptionMade/Revised byChecked byApproved ProcessApproved by

CALCULATION OF PRESSURE DROP IN FIXED CATALYST BEDS

PROCESS DATA SHEET

( )( )( )( ) ==

PM

STk f

1

A.K.C.

TECHNOLOGY




PROCESS ENGINEERING JOB ANALYSIS SUMMARY

Job Title

Job No. Charge No. Date

Based Upon Cost Estimated Dated or Actual Construction Cost

Summary Prepared By Information Dated

Production Basis (lb/day, tonnes/day, lb/month)

SERVICE REQUIREMENTS: UNIT RATE UNIT RATE/PRODUCTION BASIS

1 Steam (30 lb) lb/h



4 Steam ( lb) lb/h

5 Treated R.W. gpm

6 Untreated R.W. gpm

7 Fresh Water gpm

8 Sea Water gpm

9 Fuel Gas ( psi) cfm (60° F and 1atm)

cfm (60° F and 1atm)10 Air ( psi)

11 Power ( )

12 Horsepower

13 Condensate lb/h

14

RAW MATERIALS UNIT RATE

1 Chlorine

2 Hydrogen ( %)

3 Caustic ( %)

4 Salt

5 Sat. Brine

6 Natural Gas

7 Air

8 Ethylene

9

10

11

PRODUCTS AND BY- PRODUCTS UNIT RATE

1 Chlorine

2 HCl ( %)

3 Salt ( %)

4 Caustic ( %)

5 Ammonia ( %)

6 H2SO4 ( %)

7 Gas ( )

8

9

10

11

A.K.C.

TECHNOLOGY



APPENDIX A 803

PUMP CALCULATION SHEET Document No.Sheet of Rev.

Job Item No. (s)Item Name. No. Working Total No. off

UNITS CASE I CASE II SKETCH OF PUMP HOOK-UP12 Liquid Pumped3 Corrosion/Erosion4 Due To

5 Operating Temp. (T ) ° C ° F

6 Specific Gravity at T7 Viscosity cP cP8 Vapor Pressure at T bara psia9 Normal mass Flowrate kg/h lb/h

10 Normal Vol. Flowrate m3/h gpm

11 Min. Vol. Flowrate

12 Design Vol. Flowrate m3/h gpm13 SUCTION CONDITION14 Pressure at Equipment barg psig + +15 Static Head bar psi + / –16 Total – Lines 14 + 15 bar psi + +17 Suction Line bar psi – –18 Filter/Strainer bar psi – –1920 Total Suction Pressure barg psig + +21 DISCHARGE CONDITION22 Pressure at Equipment barg psig + +23 Static Head bar psi + / – + / –2425 Exchanger bar psi + +2627 Furnace bar psi + +28 Orifice bar psi + +29 Control Valve bar psi + +3031 Line bar psi + +3233 Total Discharge Press. barg psig + +34 Differential Pressure bar psi35 Differential Head bar psi36 NPSH NOTES

37 Total Suction Pressure bara psia 1. Pump shut-off head not to exceed………38 Vapor Pressure bara psia39 NPSH – Lines 37 – 38 bara psia 2. Relief valve on pump discharge to be set at ……………40 = m ft41 Safety Margin m ft 3. Pump case design pressure…………42 NPSH – Lines 40–41 m ft design temperature……..43 Hydraulic Power kW Hp44 Estimated Efficiency % % 4. Sealing/flushing fluid available:45 Estimated Abs. Power kW Hp46 Type of Pump 5. Cooling medium available:47 Drive48 6. Insulation required: 49 Material – Casing50 – Impeller 7. Start-up/commissioning fluid SG.51 – Shaft5253 Sour Service Yes/No

54 HEAD m = 10.2 × bar/SG m = 10 × kg/cm2/SG ft = 2.31 × psi/SG

55 VOLUME m3/h × SG × 1000 = kg/h igpm × SG × 600 = lb/h

56 POWER kW = m3/h × bar/36.0 kW = m3/h × kg/cm2/36.71 Hp = igpm × psi/142757 1 Date 2 Date 3 Date 4 Date 5 Date58 Description

59 Made/Revised by

60 Checked by61 Approved Process62 Approved

ΔP

ΔP

ΔP

ΔP

ΔP

ΔP

ΔP

A.K.C.

TECHNOLOGY



PU

MP

SC

HE

DU

LE

Job

No.

:Sh

eet o

fIs

sue

No.

:1

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e2

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Plan

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umbe

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unni

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d4

Pref

erre

d T

ype

Uni

ts5

Liq

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ting

- T

empe

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reο

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F7

Spec

ific

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vity

at O

pera

tiong

Tem

pera

ture

8

Vis

cosi

ty a

t Ope

ratin

g T

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recP

lb/f

t.h9

Vap

or P

ress

ure

at O

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ting

Tem

pera

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psia

10D

esig

n C

apac

ity (

per

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3 /h

11N

orm

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apac

ity (

per

pum

p)m

3 /hft

3 /h12

Dis

char

ge P

ress

ure

bar

gps

ig13

Suct

ion

Pres

sure

bar

gps

ig14

Dif

fere

ntia

l Hea

dba

r /m

psi/f

t15

Min

imum

NPS

H A

vaila

ble

/ Req

uire

dm

ft.

16H

ydra

ulic

Pow

er (

per

pum

p)kW

hp

17R

.P.M

--

18E

stim

ated

Pum

p E

ffic

ieny

--

19E

stim

ated

Sha

ft P

ower

( p

er p

ump)

kWhp

20T

ype

of D

rive

r-

-

21D

river

Rat

ed P

ower

( p

er p

ump)

kWhp

22D

esig

n P

ower

Con

sum

ptio

n (

per

pum

p)kW

hp23

Nor

mal

Pow

er C

onsu

mpt

ion

(per

pum

p)kW

hp24

Max

. Shu

t-O

ff H

ead

bar

psi

25

26M

ater

ial:

Cas

ing

27Im

pelle

r28

Shaf

t29

Sour

Ser

vice

30Pa

ckin

g T

ype

/ Mec

hani

cal S

eal T

ype

31

32Se

rvic

es /

Util

ities

33C

oolin

g W

ater

34Se

al /

Flus

h Fl

uid

m3 /h

ft3 /h

35Q

uenc

hm

3 /hft

3 /h

36N

otes

37 38 39 40 41 42 43 44 45

A.K

.C.

TE

CH

NO

LO

GY

804



APPENDIX A 805

A.K.C.TECHNOLOGY

RELIEF DEVICE PHILOSOPHY SHEET DOCUMENT / ITEM REFERENCE

EQUIPMENT No.:

DATE: SHEET No.: OF

CHECKED BY: MADE BY: 1

2

DESIGN CODES: VESSELS EXCHANGERS LINES 3

4

OTHER REQUIREMENTS 5

6

BASIS FOR CALCULATION: 7

8

SET PRESSURE, PSIG: MAX. BACK PRESSURE: (a) BEFORE RELIEVING (b) WHILE RELIEVING 9

NORMAL CONDITIONS UNDER RELIEF DEVICE: Calculated 10

STATE: TEMPERATURE, °F: PRESSURE, PSIG: POSSIBLE FLUID

RELIEVED

RELIEF

RATE, lb/h

ORIFICE

AREA, in2.

11

CAUSE? 12

HAZARDS CONSIDERED 13

1. Outlets blocked 14

2. Control Valve malfunction 15

3. Machine trip/ overspeed/density change 16

4. Exchanger tube rupture 17

5. Power failure/ Voltage dip 18

6. Instrument air failure 19

7. Cooling failure 20

8. Reflux failure 21

9. Abnormal entry of volatile liquid 22

10 . Loss of liquid level 23

11. Abnormal chemical reaction24

12. Boxed in thermal expansion25

13. External fire26

14. (specify)27

15. (specify)28

16. (specifty)29

SELECTED DESIGN CASE: 30

31

RELIEVED FLUID: STATE DENSITY / MW: TEMPERATURE: Cp/Cv: 32

COMPOSITION: FLASHING: 33

RELIEF RATE REQUIRED, lb/h: ORIFICE SELECTED: AREA, in2: TYPE: 34

ACTUAL CAPACITY, lb/h 35

REMARKS/SKETCH 36

37

38

39

40

41

42

43

44

45

Issue No: 1 Date 2 Date 3 Date 46

Description 47

Made/Revised by 48

Checked by 49

Approved- Process 50

Approved 51




Drawing No:Project Name: Project No.:

sheet …….. Of ……..

No. Off: Associated Vessel/Tank* Item No:1. Largest and smallest charge:2. Components added during mixing:3. Agitator operating while vessel is being filled or product withdrawn? Yes/No* 4. If continuous, throughput per hour:5. Process duty: Mixing liquids/Dissolving/Suspensions/Emulsions/Gas absorption/Homogenisation*6. Mixing effect: Violent/Medium/Moderate* Time available for mixing:7. Working Pressure: Design Pressure:8. Working Temperature: Design Temperature:

2

9. Special Remarks:

Dat

e 10. Components % by weight:

11. Temperature during mixing:12. Specific gravity of components:13. Viscosity of mixing at mixing temperature:14. Specific gravity of product at mixing temperature:15. Size of solid particles:16. Special Remarks:

17. Type of impeller:18. Number of impellers on shaft:19. Position of impellers:20. Distance between shaft end & vessel: Bottom bearing:21. Preferred impeller speed: Shaft diameter:22. Type of drive: Direct/Vee belt/Fluid*23. Type of seal: Vapor/Packed gland/Mechanical/Easy replacement*24. Method of installation: Assembled in/Assembled out* of vessel25. Entry position:26. Materials of construction:

27. Absorbed HP/KW*: Installed HP/KW*:28. Other information:

29. Dimensions: Capacity:30. Coils, baffles, etc.:31. Fixing agitator (beams, flanges, etc.):32. If at atmospheric pressure: Closed/Open* Can stuffing box be greased? Yes/No*33. Headroom available above agitator:34. Other information:

35. Agitator installed: Indoors/Outdoors Motor enclosure:36. Electrical specification:37. Any other electrical information:

38. Motor to be included: Yes/No*39. Motor Will/Will not* be sent to manufacturer for assembly and alignment.40. Threads: Unified /*41. All rotating parts must be strictly guarded to BS 1649/ASME42. Fixing bolts supplied by:43. Net weight including motor:

44. Witnessed run in air:45. General notes:

NOTE: * Indicates delete as necessary.

TANK AND VESSEL AGITATOR DATA SHEET

Equipment No:

DE

SIG

N D

EPT

. IN

FO

RM

AT

ION

IMPE

LL

ER

TA

NK

OR

VE

SSE

LE

LE

CT

.

Dat

e

MIX

ING

3D

ate

1

PRO

CE

SS

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CE

SS D

EPT

. IN

FOR

MA

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N

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evis

ed b

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Che

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by

App

rove

d Pr

oces

s

GE

NE

RA

L

A.K.C.TECHNOLOGY



APPENDIX A 807

Doc. No:Item No.

Job: Sheet of

Item Name:

NOTE: * indicates delete as necessary; ** indicates for other than Code reason

5

10

15

20

2526 Shell Diameter (O.D. / I.D.): Shell Length: No. Required:

27 Center Line: *Horizontal / Vertical28 Pressure: g Temperature: F / C Nozzles Mark No. Size Number29 Item Number Inlet C-30 Operating31 Design Vapor Out C-32 Emergency Vacuum Design: * Yes / No33 Liquid Out: C-34 Shell35 Heads36 Liner Thermocouple R-37 Type of Heads Pressure Gauge R-38 Code: Gauge Glass R-39 Stress Relieve**: Radiography**: Level Control R-40 Joint Efficiency: Safety Valve R-41 Density of Contents: at * °

° °

°F / C

42 Weight Empty: Weight Full:

43 Is vessel subject to mechanical vibration? *Yes / No Vent C-44 insulation: Type: *Frost and Personnel Protection / Cold Drain C-45 *Yes / No Anticondensation / Heat Conservation Steam Out C-

46 REMARKS:

47 Manhole A-

484950515253 min. Base Elev'n: k-Skirt Length

54 Material:

Issue No. 1 Date 2 Date 3 Date 4 DateMade/Revised byChecked byApproved - ProcessApproved by

Material Corr. Allowance

by In

st. O

p.

TANK PROCESS DATA SHEETA.K.C.

TECHNOLOGY




TA

NK

SC

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Job

No.

:Sh

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:1

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2It

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3N

umbe

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equi

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4T

ype

Uni

ts5

Len

gth

x W

idth

mm

in.

6H

eigh

tm

min

.7

Dia

met

er8

Min

imum

Bas

e E

leva

tion

mm

in.

9T

otal

Vol

ume

m3

ft3

10W

orki

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itym

3ft

3

11In

tern

als

/ Fitt

ings

12 13 14O

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ting

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gps

ig

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ting

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pera

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°C°F

16D

esig

n Pr

essu

re

+/ -

bar

gps

ig17

Des

ign

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pera

ture

°C°F

18V

acuu

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Mat

eria

l: Sh

ell

20

Lin

er21

I

nter

nals

22 23Sh

ell C

orro

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Allo

wan

cem

min

.24

Sour

Ser

vice

25St

ress

Rel

ieve

d fo

r Pr

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s R

easo

ns26

Insu

latio

n27 28 29 30

Not

es31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

A.K

.C.

TE

CH

NO

LO

GY



TIE

-IN

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A.K

.C.

TE

CH

NO

LO

GY

809




Made by: Document No.

Date:Job Item No:(s)

Checked by: Item NameSheet of

Tower Name:

NOTE: * indicates delete as necessary; ** indicates for other than code reason1 Top Bottom2 Shell Diameters O.D. - I.D.3 No. of Trays4 Pressure Operating5 *psig Design6 Temperature Operating7 *oF / oC Design8 Material Shell9 Trays10 Caps11 Liner or Clad12 Corrosion - Shell13 Allowance Heads14 Trays15 Tray Spacing16 Type of Liquid Flow17 Type of Trays18 Joint Efficiency19 Code Emergency Vac. Design *Yes / No20 Stress Relieved **Yes / No Radiography **Yes / No21 Is vessel subject to mechanical vibration *Yes / No22 Insulation Type: *Frost and Personnel Protection / Cold /23 *Yes / No /anticondensation / Heat Conservation /24 Min. Base Elevation: Skirt length:25 Weight Empty: Full:26 Nozzles Mark No. Size Number27 Feed C-2829 Overhead Vpr. C-30 Reflux In C-3132 Bottoms C-33 Reboiler Vpr C-34 Reboiler liq C-353637 Thermocouple R-38 Level Glass R-39 Press Gauge R-40 Level Control R-41 Safety Valve R-424344 Vent C-45 Drain C-46 Steam Out C-47 Manholes A-48 Handholes A-49 Cap Type: Tray Layout Ref:50 NOTES5152535455 1 Date 2 Date 3 Date 4 Date56 Description57 Made/Revised by58 Checked by59 Approved Process60 Approved by

.pG.tsni

yb

TOWER PROCESS DATA SHEETA.K.C.TECHNOLOGY



APPENDIX A 811

Job No.item No.

Job: Sheet of

Tower Name: Type of Tray1 Manufacturer Mfr. Ref:2 Pressure at top of Tower barg psia3 Max. ΔP over Tower bar psi units Used: METRIC/BRITISH (delete one)4 No. of Trays Aboved Feed Below Feed5 Tray location6 Tray Number*7 Tray Spacing mm in.8 Tower Internal Diameter I.D. mm in.9 Vapor to Tray

10 Temperature oC oF11 Compressibility12 Density kg/m3 lb/ft3

13 Molecular Weight14 Rate kg/h lb/h1516 Liquid from Tray17 Temperature °C °F18 Surface Tension dynes/cm lb/ft19 Viscosity cps lb ft/hr20 Density kg/m3 lb/ft3

21 Rate kg/h lb/h22 Foaming Tendency **23 Number of Passes24 Minimum Hole Diameter *** mm in.25 Minimum DC Residence Time*** secs s26 Maximum Rate as % Design27 Minimum Rate as % Design28 Design Rate % Flood Rate***2930 Tray Material31 Valve or Cap Material32 Corrosion Allowance mm in.33 Tray Thickness*** mm in.3435363738 NOTES: * Trays are numbered from the bottom of the tower upwardstop of the tower downwards39 ** Indicate whether 'non', 'moderate', 'high' or 'severe'40 ∗ ∗ ∗ Data to be supplied by tray manufacturer unless special Process/Client requirement entered here.41 REMARKS:4243444546474849505152535455 1 Date 2 Date 3 Date56 Description57 Made/Revised by58 Checked by59 Approve - Process60 Approved by

TRAY LOADING SUMMARYA.K.C.

TECHNOLOGY



TR

IP S

CH

ED

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Job

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816



APPENDIX A 817

WATER Submitted by:ANALYSIS Address: Location:SHEET

Date:Analysis No.

Date:pH ValueSuspended Solids mg/lTotal Dissolved Solids mg/l at 110° CTotal Dissolved Solids mg/l at 180° CAlkalinity to Pp as mg/l CaCO3

Alkalinity to MO as mg/l CaCO3

Sulphate as mg/l SO4

Chloride as mg/l ClNitrate as mg/l NO3

Silica as mg/l SiO2

Phosphate as mg/l PO4

Total Anions as mg/l CaCO3

Total Hardness as mg/l CaCO3

Calcium as mg/l CaMagnesium as mg/l MgSodium* as mg/l NaPotassium* as mg/l KIron as mg/l FeManganese as mg/l MnFree and Saline Ammonia as mg/l NH3

Total Cations as mg/l CaCO3

Free Dissolved CO2 as mg/l CO2

Dissolved O2 as mg/l OColor Hazaen UnitsTurbidity Formazin Units+ FTU APHALead as mg/l PbCopper as mg/l CuResidual ChlorineFlouride as mg/l FSulfite as mg/l SO3

NOTES: 1. Please state if units other than milligrams per liter, or different conditions of test, are used.2. * If Na and/or K form an appreciable amount of total cations, please state Alkalinity to

Phenolphthalein (p), Alkalinity to Methyl Orange (MO), and Carbonate Hardness.3. + DO NOT use Formazin Units as defined by British Standard BS. 2690 Pt. 9.4. ** Tick if item definitely to be included in analysis.

5. 100 mg/L CaCO3 = 2 milliequivalents/(m val/L).

**

A.K.C.

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