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Reactors
[Tip Number 27] This tip about Reactors is for Layout personnel:
When locating Reactors in a plant, here are some items to consider. The general objectives
are to locate the reactor such that the reactor inlet line (typically coming from a furnace) is
at a minimum length. At the same time, maintenance access to the reactor for catalyst
loading and unloading must be carefully considered since this maintenance activity has a
direct bearing on the profitability of the plant. Some specific objectives in locating a reactor
are to assure that the reactor elevation is set such that the client has clearance for the
outlet piping and the client can access the catalyst unloading nozzle with the equipment
they intend to use for catalyst unloading. For example, the client may be removing catalyst
with a truck (which typically requires 12-15 feet of clearance), or they may be removing
catalyst with a conveyer (which may require 4-6 feet clearance).
Definitions relevant to this design topic
Catalyst loading and regeneration: Designing for the operation management of the
catalyst is the principal layout feature of Reactor areas. Catalysts promote a reaction but do
not react in any way themselves. Some typical catalyst materials are alumina, zinc oxide, or
platinum. Since catalyst is used up during the process, it either has to be replaced in bulk
or it has to be regenerated (which usually means the catalyst is subjected to very high
temperatures.)
Reactors: The purpose of reactors is to change the chemical composition of the process
fluid; or, to remove undesirable agents from the process fluid, by exposing the fluid to a
combination of catalyst, pressure, and temperature. Most reactors are vertically mounted
vessels with elliptical heads. There are fewer connections than typical vertical vessels.
Generally, connections are limited to inlet and outlet, maintenance access, unloading,
sample, and temperature. Internally, reactors are furnished with bed supports, screens,
inlet baffles, outlet collectors, catalysts, and inert materials.
Compressors
[Tip Number 3] This tip about Compressors is for Layout personnel:
When estimating the width of a rack (sleepers) in a reciprocating
compressor area, do not use the minimum spacing requirements between
piping lines for a typical pipe rack. Straps are almost always
required on reciprocating compressor piping. Room will be needed
between pipelines in the rack to attach the ears of the straps to
steel inserts on the concrete piers (sleepers). Also, the straps are
often adjustable and room will be needed to reach the adjusting
nuts.
[Tip Number 2] This tip about Compressors is for Layout personnel:
Reciprocating Compressors: During the bid phase of the compressor,
determine who is responsible for the adjustable surge bottle
supports and what the design is. Be sure to allow clearance for
these supports as they are often large.
[Tip Number 1] This tip about Compressors is for Layout personnel:
Lube oil consoles are typically a vendor supplied skid that will
have required clearances for maintenance defined by the compressor
manufacturer. Be sure that a) there is room to service the cooler
bundle, b) that the filters can be serviced; and, c) heating coils
located under the skid can be pulled (heating coils are often found
in cold climates).
[Tip Number 5] This tip about Compressors is for Stress and Supports
personnel:
In a reciprocating compressor area, typically the mechanical study
(the calculation of the natural frequency response of the piping
systems) is done in-house (this is a different study than the
acoustic study which is typically done by the reciprocating
compressor vendor or else the acoustic study is done by an outside
subcontractor such as Southwest Research Institute in San Antonio,
tower's liquid outlet nozzle is located on the bottom head and can
be oriented in any direction but is usually driven by the stress
analysis of the suction pump lines. Nozzles for temperature and
pressure probes are located throughout the tower as described by the
instrument sketch supplied by the Instrument group. Temperature
probes will be located in a liquid space while the pressure probes
will be located in a vapor space. Nozzles for level instruments are
located in a liquid space usually at the bottom of the tower. When
setting the elevation and location of any nozzle on a tower, make
sure your nozzle and associated internal piping (if any) are clear
of tray support beams. If the beam depths are unknown, a rule of
thumb is: the depth of the tray support beam (in inches) is equal to
the diameter of the vessel (in feet) divided by 2, then add 2".
Definitions relevant to this design topic
Towers: Towers, also referred to as columns, are one of the principal
pieces of equipment of any processing facility. Towers are a combination
of multiple stills where a feedstock is separated into its hydrocarbon
components, then drawn off from the side of the tower at the appropriate
elevation for the product.
Towers, packed: In a packed tower, instead of having trays, the units are
packed with beds of metal rings. On entering the tower, the liquid passes
through a distributor that routes the liquid evenly down through the
packed beds of metal rings. Rising vapors passing through the beds come
into contact with the descending liquid. In a manner similar to trayed
tower operation, the liquid is partially vaporized by the heat from the
vapors and the vapors are condensed by the cooler liquid.
Towers, trayed: This type of tower has internals that are trays.