PIPING AND INSTRUMENTATION DIAGRAM OF CONTINUOUS VISCOSITY AND ACID/HYDROXY MEASUREMENT SYSTEM OF RESIN

INTRODUCTION Resin is a naturally occurring substance that is produced by certain trees. This viscous fluid has been replicated by scientists and is called synthetic resin. Synthetic resins have properties that are extremely similar to their naturally occurring counterparts, most important of which is the ability to harden with the application of heat or pressure, or a combination of both. Products that are created by using synthetic resin include automotive parts, food containers, and pipes. Synthetic resin is typically manufactured using a chemical polymerization process. This process then results in the creation of polymers that are more stable and homogeneous than naturally occurring resin. Synthetic resins are widely used in the manufacture of a variety of products including paints, inks, adhesives, plastics and many coatings. During the production of synthetic resins such as alkyds and polyesters, the product viscosity and acid number are the primary characteristics used to monitor the overall reaction progress.

CONCEPT OF INSTRUMENTATION The common method for monitoring product viscosity and acid number is for an operator to draw samples from the reactor at regular intervals. The operator then sends these samples to the laboratory for analysis. After receiving an analytical result that matches the value specified in the operating procedures, the operator proceeds to the next processing step. The analytical results are usually available approximately 15 - 30 minutes after sampling. Because the reaction continues during this time interval, the analytical results are not representative of the actual product inside the reactor. Because this method of "intermittent reaction monitoring" is inconsistent, the produced resins vary significantly between batches. In order to improve consistency between batches, many operators have attempted to get more accurate viscosity data during the production of alkyd and polyester resins. Operators have measured the torque of the reactor agitator, but this

only generates trend data ("the viscosity is going up"). Others have installed viscometer sensors inside the reactor. However, the data from these sensors is not reliable because of temperature measurement problems, vapor bubbles in the product mix, solid raw material particles precipitating on the sensor, etc. To avoid all these problems this concept of instrumentation went a different route, developing a system in which the viscosity and acid number are continuously measured in a bypass around the reactor. The Resin Continuous Measurement System includes a product circulation pump, tempering device, viscometer, NIR

spectrophotometer with transmission probe, heating/cooling circuit with pump, interconnecting pipe, and instrumentation, all incorporated on a single skid.

OPERATION OF THE INSTRUMENTATION The process starts at the at the constant stream of product that is pumped from the lower part of the reactor, product reaches first a control valve before approaching through a jacketed pipe (colored red indication in the P&ID diagram), through the tempering device and into the viscometer. The viscosity is measured at a constant, preset temperature maintained by circulating thermal oil through the jacketed pipe and the tempering device. A rotary type viscometer is used because it is largely insensitive to solid particles, encrustations and solidifications. After flowing through the viscometer and the spectrophotometer, the product returns to the reactor. A signal from the viscometer is available in the control system. The temperature of the sample stream is controlled by a thermal oil system which pumps thermal oil through the jacketed pipe and the tempering device. The sample stream temperature is independent of the reactor temperature. This secondary thermal oil system is connected to the primary thermal oil system and accurately controls the product temperature within 0.5 deg Celsius of the preset temperature. For cooling of the product stream, the thermal oil in the secondary circuit is pumped through a distribution valve to the thermal oil cooler. The measured values of the viscosity and the acid number, as well as the corresponding measuring temperature are displayed either digitally on a control panel or on a monitor integrated via the Programmable Logic Control (PLC) or it can be also integrated into a computerized process control system. The online viscosity and acid number measurement system allows the automatic resin production to preset target values. Because all the measuring signals are available continuously, the resin production is terminated at the optimum point in time.

SYMBOLOGY

DESCRIPTION

LOCATION Located just after the

PURPOSE/FUNCTION Used to control the flow of the resin before going to the pump

Control Valve

Reactor and before the Product pump

Located after the after a Product Pump control valve and before viscometer

Used to increase the pressure of the resin before passing through the viscometer

Located after the pump Viscometer and before the Tempering drum

Used to measure the viscosity of the resin, it is a rotary type viscometer because of its insensitivity to solid particles

Located after the Tempering Drum viscometer and before manual valve

Use to maintained the preset temperature, this is also where the acid/hydroxy number is measure

Located after the Manual Valve Tempering Drum and before the inlet of the reactor Use to prevent the flow of resin going to the reactor

Located in between the Reactor jacketed piping of the system

Device used to contain and control the chemical reaction of the resin

Located after a control valve that is from the hot Hot Oil Pump oil source or supply and before a control valve going through the jacketed pipe Situated after the hot oil Hot Oil Cooler pump and before the jacketed pipe

Used to pump thermal oil through the jacketed pipe and tempering device that control the thermal oil system. It is a motor controlled pump.

Use to cool the product stream

Connected to viscometer Automatic Indicator of Viscosity and connected to PLC through electrical signal line Connected to the Automatic Indicator of Acid/Hydroxy Number tempering device and connected to PLC through electrical signal line Located after the hot oil Pressure Indicator pump and before a control valve going to the jacketed pipe Used indicate the pressure of the pumped hot oil before entering the jacketed piping This is the digital computer where the automation of the This is where the Programmable Logic Control automatic devices are connected through electrical signal lines whole system is processed, and it is linked to SCADA which is the database and software program that provide trending and diagnostic data from the process Use to automatically measure the acid and hydroxyl number of the resin Use to automatically measure the viscosity of the resin

REFERENCES: http://www.rhe-america.com/case2.html http://www.wisegeek.com/what-is-synthetic-resin.htm http://www.oilfieldwiki.com/wiki/Piping_and_instrumentation_diagram

UNIVERSITY OF THE EAST COLLEGE OF ENGINEERING MANILA

ME 525N 1A INSTRUMENTATION AND CONTROL

FINAL REQUIREMENT CONTINUOUS VISCOSITY AND ACID/HYDROXY MEASUREMENT SYSTEM (RESIN)

SUBMITTED TO: ENGR. DIOSDADO DOCTOR SUBMITTED BY: ESTOR, RUJEL D.