Happier with the performance of my Ammonia plant simulation package, I went on to write performance evaluation program, General in nature - means a program which can be used for any gas or gaseous mixture, any centrifugal compressor without any limitation on discharge pressure etc, considering real gas. It was writtten in C++. It took me ~25 Days to compile & do the total testing of the program.
This program uses generalized co-relations of Equation of states (EOS) from thermodynamics. So you can input any gas mixture in the basic program. The only basic information needed is Tc, Pc, Vc & omega of the gases handled. No other compressor evaluation program uses these thermodynamic properties to my knwoledge till date.
For example in case of ammonia synthesis compressor N2, H2, Ammonia, Methane & Argon properties are used. The compressor operates from 26 Ata to ~220 Ata in 4 different stages. The program is tested for the entire range of operation. Only Suction & Discharge pressure & temperatures are required for efficiency calculation and flow is required for power calculation.
It also calculates critical properties of mixture Tcm, Pcm & Vcm and Entropy & Compressibility Z at inlet & discharge conditions. Power & Polytropic head is also calculated.
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Normally a project passes through various phases e.g. basic engineering, detail engineering, equipment fabrication, erection, commissioning etc. The conceptual idea of business from the process development cell is converted to executable documents during basic engineering.
This is the step where we need P&ID or piping and Instrumentation diagram
P&ID is one of the important drawing representing all the engineering info required to build a process plant.
What is considered in a good P&ID?
Various aspects are considered during the preparation of P&ID which are:
- Plant Operation
- Plant Hardware
- Equipments connectivity
- Operational controls & instruments
- Safety controls & instruments
- Instruments interlocks
- Complete Piping information
- other details
Steps for P&ID Preparation- Show all equipments with necessary piping to carry out the process
- Show all connecting process piping necessary to carry out the process
- Show all other pipings required for auxiliaries
- Show all required valves and major fittings
- Show all required instruments
- Mark size, fluid code, material code & identification numbers of all pipe lines
- Mark interlock numbers as per interlock description
- Review P & ID considering all operational, startup/shutdown, safety, maintenance & aesthetic aspects.
There are specified formats for each kind of equipments, Instruments etc to be filled in as data sheets in the Basic Engg Package. So BEP includes
- P&IDs
- Line List with operating & Design conditions, each line is represented with Size, No, Area code, MOC, Insulation etc.
- Equipment List
- Instrument List
- Data sheet for each equipments called PDS (Process Data Sheet) depending on the type of equipment specific formats are to be used
- Tie In points list which is required for the marking of point where from process or utility is connected in the existing systems
This BEP package is sufficient for converting & implementing the technology in actual process plant.
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This is a notable blog on chemistry. Since long I was searching for a single good blog on chemistry which are useful for others. Thanks to Michelle who is a professor of chemistry at Bryn Mawr College. You can read her Blog Here.......The Culture of Chemistry......Its my first preferred blog on the subject.
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Common problem of carrying out calculation of optimum insulation thickness, Yet loosing lot of energy in the form of heat loss or cold loss, need re-work on insulation due to damage over a certain period of 2-3 years during annual turnaround etc. etc..............
Poor process engineers. Need survey of thickness, need good maintenance & monitoring program....lots of cost items..& still not satisifed.
After so many years of struggle, I thought about this Idea which is very cost effective & higher savings for lifetime. No need of re-work etc. No maintenance cost.
Interesting.........Ya....Very good business idea too....here is my input.
The idea came to my mind when I was looking for a cold insulation in ASU unit for liquid oxygen lines & found that best insulation also need of lot of investment still we would be incurring >2% losses in our system.
Therefore I thought if I can utilize some kind of vacuum on the surface of process pipes, the losses can be reduced to minimum due to poor conductivity of heat in vacuum.
Now the next question was how to design such a system which can be easily implemented from mechanical erection point of view and can be maintained without much problems.
So I prepared a sketch & its implementation strategy. The sketch is attached below for giving you exact idea how it will be done.
There is inner pipe which is carrying process fluid say it is 4" in size. Then next higher size pipe of 6" can be considered for insulation & it can be any cheapest material available e.g. CS etc. irrespective of the type of fluid handled. So the difference in ID is 2" therefore put some bars welded on the inner pipe of slightly smaller size of the difference in the radius of these two pipes. May be 0.8 Or 0.9" in this case. The allowance depends on the linearity of your pipe layout & size but should be sufficient to push bigger size pipe over the main process pipe.
Therefore, it also requires that this insulation is done in many smaller parts instead of doing it in lengths. Weld it at the ends to the process pipes with some reducers of B to S ratio (B is bigger pipe ID & S is smaller pipe ID.
Keep a tapping from the bigger pipe to vacuum system with PI for indication & combine all such smaller segments to one single vacuum system which will not be very large & high capacity due to practically nil losses in welded construction.
That's It.......................
- So Simple,
- One time construction,
- No change, No maintenance,
- Limited running cost due to only intermittent running of Vacuum system, leakage thru PI tappings only,
- Very low energy losses,
- Very low payback period
- No fire hazards due to enclosed vacuum,
- Immediate knowledge of system leak - saving costly products / raw materials loss,
- Less effluent cost,
- Need less safety instruments,
- Easy construction in grass root projects,
- No special material of separate services,
- No expert needed, In-house team can do it,
- ....................You can fill more benefits here if you can identify them.............
Hope You Enjoyed it........
If somebody need any guidance to use it for business purpose I can support the design with very nominal charges for my time only.
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