Chemical Engineering Design 4: Assignment 2 Remit

Chemical Engineering Design 4: Assignment 2 remit

The polybutenes plant (Plant No 20) is designed is produce 100kt yr -1 of polybutenes by the catalytic
polymerisation of isobutene in a reactor at 10 barg and 120-130C.
The feedstock is a liquid stream of C4s, principally isobutene, at ambient temperature (30C max). The
feed is pumped directly from bulk storage located on the Tank Farm, (Plant No. 10), located about a mile
from the polybutenes plant. The C4s feed stream contains up to 2wt% propane, is saturated with water
and could contain up to 0.5wt% entrained water.
The feed enters the Feed Preparation Unit 100 of the polybutenes plant where the isobutene is topped
and dried by distillation in the Depropaniser column, 20-T-103, to produce a reactor feed containing 10
ppm wt max water and 100 ppm wt max propane. This reactor feed is then pumped to the Polybutenes
Reactor, 20-R-200, in Reaction Unit 200 of the polybutenes plant.
The overhead propane stream from the Depropaniser Column, 20-T-103, is exported to the Fuel Gas Main
(Plant No 90) and should not contain more than 10 vol % C4s. It can be assumed that all C4s behave as
isobutene. The polybutene product from the Polybutene Reactor, 20-R-200 goes to the Purification Plant
No. 30.
The questions in this 2nd remit are focused on the PROCESS UNIT 100- FEED PREPARATION, which
works according to the following process description:
The C4s stream from the Tank Farm (Plant No. 10) is preheated by the depropaniser column bottoms
product stream in Depropaniser Feed/Bottoms Exchanger, 20-E-102 and enters the Depropaniser
Column, 20-T-103. The feed tray is located approximately half-way up the column. Depropaniser Reboiler,
20-E-111 is a vertical thermosyphon type shell and tube heat exchanger, with steam on the shellside.
The bottoms stream from 20-T-103 is cooled initially by interchange with the C4s feed stream in 20-E102, then by cooling water in Bottoms Cooler, 20-E-104 (by cooling water passing through the tubeside of
a shell and tube exchanger with an even number of tube side passes), before entering the Reactor Feed
Surge Drum, 20-D-105, at the top. This is a horizontally oriented vessel sized for 30 minutes hold up
between HLL and LLL. The C4s are then pumped by Reactor Feed Pump, 20-P-115A/B (one duty, one
standby) from 20-D-105 on flow control (control valve not shown in Fig. 1) to the Polybutenes Reactor,
20-R-200.
The overhead vapour stream from 20-T-103, is cooled and partially condensed against cooling water in
Depropaniser Condenser, 20-E-107, and passes into the Depropaniser Reflux Drum, 20-D-109. The
uncondensed vapour stream from 20-D-109 is exported into the fuel gas main (operating pressure
approx. 4 barg and ambient).
The organic phase in 20-D-109 is pumped by Reflux Pump, 20-P-110A/B (one duty, one standby), back
to the top of the Depropaniser Column, 20-T-103.
The Degasser Drum is not part of the Feed Preparation Unit. It is included in the Hydrocarbon Drain Unit
500.
The Polybutenes Reactor is not shown on the Feed Preparation Unit P&ID but on a separate P&ID for the
Reactor Unit 200.
All heat exchangers on the Polybutenes Plant are designed for a 10C minimum approach temperature
between streams. The maximum cooling water supply temperature is 30C but can be as low as 15C in
winter.
Depropaniser Column, 20-T-103 is 20m tan/tan length and mounted on a skirt such that the vessel bottom
tangent line (BTL) is 2m above grade, while the horizontally mounted 20-D-105 and 20-D-109 are elevated
3.5m above grade.
The process Flow Diagram for PROCESS UNIT 100- FEED PREPARATION is shown in Fig. 1.
Figure 1: Sketch of polybutenes plant (Plant No 20)

Before you start, fill the following fields.
Write in this column if you are SUBMITTER
GROUP NAME or NUMBER:
Write in this column if you are REVIEWER

PEER REVIEWER NAME and NUMBER:
DESIGN GROUP 5
GROUP MEMBERS (including student number):
Catherine Megregian S1305955
Lyle Griffin
S1332937
Alastair Davis
S1305121
Ihsan Kerr
S1332156
Jamie Paisley
S1334531
Intasar Ul Haq
S1137953
Craig Lavetty
S1327775
Clarrisa Chew Lee lean S1212125
Question 1: Sketch a preliminary process and instrumentation diagram in Autocad or Autocad P&ID
that includes controls and Process Safety System. Marks in the region from 21-26 can be assigned
only if also analysis with UNSIM Dynamics is provided. This analysis should be built to include timevariation of the most meaningful variables that in your opinion prove the validity of your scheme (Max
marks 26. Max length 2 pages).
SEE ATTACHED SHEET FOR P&ID
Peer reviewer section
Mark
(short feedback and marks with RED PEN)
Moderator section:
Mark
(short feedback and final mark with GREEN PEN)
Question 2: Size the pressure relief valve of the Reactor Feed Surge Drum 20-D-105.
D-105 dimensions as follows: D=2.75m, L=8.5m (tan-tan), HLL=2.32m, ellipsoidal heads, D-105 design
pressure = 4 barg, LLL in D-105 alarms and shuts down transfer pumps, HLL in D-105 alarms and
closes feed to unit and puts column into reflux, D-105 is designed for steam-out. (Max marks 13. Max
length 2 pages)
Relevant
No.
Scenario Description
Thermal expansion of
fluid
2a
Closed or restricted
process outlet
2b
3a
3b
3c
3d
3e
3f
Closed or restricted
nitrogen vent
Inlet fail open (CV-25)
Inlet fail shut (CV-25)
Drum outlet fail open
Drum outlet fail shut
N2 valve fail open (CV-28)
N2 valve fail shut (CV-28)
Y
N
N
N
N
Y
N
Process feed fail shut

(CV-6)
Instrument air failure
Reboiler steam failure
Electrical failure
Cooling water failure
Refrigerant failure
Reflux failure
10
External fire
11
Tube rupture
12
Chemical reaction
13
Storage tank
inbreathing
14
Plug flow condition
15
Vacuum
3g
Justification
Only relevant if drum is full of liquid as this would induce
mechanical stress However the drum will not be full unless
level control and the high-high liquid level safety valve fail.
Causes level to increase but will not increase pressure unless
level control and the high-high liquid level safety valve both
fail.
Can result in over-pressurisation of the vessel by nitrogen gas
as it has no way to leave the vessel.
Flow will be shut off with the high-high liquid level safety valve.
Does not result in pressure rise in surge drum
See 2a.
Same as 2b.
Sudden failure would result in vaporisation of some of the
bottoms stream before the cooling water control system can
account for the change as cooling water is operating under
feedback control. However, at maximum flow, E-102 removes
40% less energy that E-104 Therefore, this scenario is a similar
but less severe than scenario 7. Due to the uncertainty in the
cooling water control dynamics, it is prudent to use the flowrate
found in scenario 7.
Will result in pneumatic control valve failure, see 3b and 3c.
Would require a failing of the set fail positions to be relevant.
More propane but as shown in table A2, the system will remain
a liquid unless the system is above the operating temperature
or below operating pressure, therefore no vapour pressure
relief is required unless another control failure occurs.
Liquid relief will be required IF: Level control and high-high
liquid level safety valve both fail.
Backflow in to drum (neglecting non-return valve) negligible
amount (assuming no backflow from reactor). High-high liquid
level safety valve will shut preventing further flow from
column. Cooling water will shut down but assuming heat
exchangers are close to column, all remaining fluid between
column and drum will have been cooled. Therefore, pressure
relief will not be required.
Increased temperature will result in more vapour forming.
Not relevant in this plant section.
More propane in bottoms but will be less than scenario 5,
therefore no vapour has to be relieved as justified in scenario 5.
Results in excessive amounts of vapour
E-102 or E-104 rupture - decreased inlet flowrate as isobutene
is the higher pressure stream and does not increase pressure in
surge drum.
Temperature not high enough for polymerisation and
combustion should not be possible as oxygen should be
removed from system at inlet.
Tank is held at higher temperature and pressure than external
conditions, therefore no driving force to increase pressure.
Only relevant if drum is full of liquid as this would induce
mechanical stress However the drum will not be full unless
level control and the high-high liquid level safety valve fail.
Not connected to any vacuum producing equipment
Required
Unrelated
Failures*
Flow-rate
Valve
size
(in2)
196
0.059
2
3
1
-
196
-
0.059
-
see 7
see7
2500
0.57
14663
3.39
16
Excessive Temp
This has been discussed in scenarios 3g, 5, 7, 10 and 13.
* This is the number of unrelated failures (including the scenario failure if applicable) that have to occur for the pressure relief valve to
be required.
Surge Drum Relief Pressure:

Operating Pressure, Pop
Operating Temperature, Top
Isobutene boiling point at Pop, Tbp
Design Pressure, Pd
5 bara (3.99 barg)

313K (40.0oC)
315K (42.2oC)
6.7 bara (5.69 barg)
Relief Pressure, PS
Back Pressure, PB
7.27 bara (6.26 barg)

1 bara (0 barg)
Chosen to give Tbp at Pop > Top as appropriate pump NPSH.

Based on minimum cooling water pinch of 10oC
Found in unisim.
Chosen from greatest of 110% () = . and
() + 1.7 = .
110%
Flare Stack Atmospheric
Nitrogen Buildup (case 2b or 3e)

Not choked flow in to drum since choked flow pressure for diatomic gases is 0.528 Pupstream = 3.96 bara < Pop
Assuming the CV (3.7) given is at normal flowrate at operating pressure, CV max was found using the following relationship for an
equal percentage valve: = (1) where the x is the percentage of valve opening which was selected to be 70% at
normal flow. The constant a was adjusted to give the normal flowrate to be 70% of maximum flowrate. This gives a CV max of
5.29.
Where CVmax =5.29, P1 = 7.5 bara,
Flowrate
P2 = PS = 7.27 bara, M = 28 kg/kmol, T=

max = 27.3 (1) (1 + 2 ) ( ) =
(Worst case)
313K (if equilibrated)
Cooling Water Failure (case 7):

Bottoms Normal Flowrate,
Bottoms Maximum Flowrate,
12,500 kg hr-1
17857 kg hr-1
To meet reactor requirements

Based on the control valve being sized such that
Temperature of bottoms before E-102

Heat removed by feed at
Temperature of bottoms after E-102
346.5 K
176 kW
334 K
Bottoms saturation temperature at 10.7 bara.

See table A1 in appendix for calculation of duty.
Assuming heat removed by feed is constant.
Found with energy balance , = ,
Vapour Pressure C4 (328.7K)
7.04 bara
Vapour fraction by mass after flashing

Temperature after flashing
Max Vapour flowrate released
0.1403
313.4 K (42.3oC)
2500 kg hr-1
Above operating pressure, so C4s will vaporize. The PRV has

been designed to release all vapour formed.
Found from modelling expansion in Unisim
Found from modelling expansion in Unisim
= 0.7
External Fire (case 10):

Wetted Area, Aw
(heads + cylinder section):
Pool fire heat flux, Q
Enthalpy at 330K, H
Relieving Flowrate,
Assuming 2:1 ellipsoidal heads and HLL. Ellipsoidal head

wetter area found using equation shown in appendix.
Assuming plant well designed for fire safety and vessel is
non-fireproofed.
Based on pure isobutene calculation in appendix.
Assumes no entrained vapour.
Largest relief flow so valve will be sized for this.
(9.0 + 54.4) m2 = 63.4 m2

= 1 0.82 = 43185 1 63.40.82
= 1297
318.5 kJ kg-1
= =
Effective Area Calculation Equations for critical flow* (BS EN ISO 4126-7:2013):
max
= 0.9
is an empirical constant, the effective coefficient of
+1
2 1
discharge, can use 0.975 for PRV preliminary design.
)
= 3.948 (
=

+1
*Critical flow if ratio of critical flow pressure to relief pressure is greater than ratio of back pressure to relief pressure.
=
Effective Area Calculations (using above equations):

Case
k=
Cp/Cv
Pcf/PS
PB/PS
Choked
Flow?
TS
(K)
TR
PR
Q m
(kg hr-1)
A (in2)
2b
1.4
0.53
0.14
Yes
313
2.49
0.21
1.00
2.70
196
0.059
7
10
1.07
1.07
0.58
0.58
0.14
0.14
Yes
Yes
313
330
0.75
0.79
0.18
0.18
0.89
0.91
2.46
2.46
2500
14663
0.565
3.386
A pressure relief valve of designation M (effective orifice area = 3.6 in2) should be used.
Valve
Letter
M
Mark
Moderator section:
Mark
Question 3: Complete the pump and line calculation sheet for Reactor Feed Pump P-115. Assume the
following: 1) D-105 vessel pressure is adjustable between 4 and 5.5 bara; 2) Suction losses are
negligible; 3) Pump centre line is 0.5m above grade; 4) P-115 control valve loss 1.0 bar; 5) R-200 reactor
inlet is 8.5m above grade; 6) R-200 pressure is 10 barg; 7) Pumping temperature is 40C; 8) D-105 ID
= 1.6m; 9) D-105 base elevation is 3.5m; 10) HLL is 200mm below top of vessel; 11) Backpressure is
atmospheric. (Max marks 9. No Max length)
Project Name
Project Number
Company Name: Edinburgh University

Address: Old College, South Bridge, Edinburgh EH8 9YL, UK
REV
Surge drum outlet pump

1
Sheet
DATE
BY
APVD
REV
of
DATE
BY
APVD
1 24/11/16
Pump and Line Calculation Sheet

Form XXXXX-YY-ZZ
Owner's Name
Plant Location
Case Description
Equipment label
Plant section
Process service
Fluid
Operating temperature
Edinburgh University
Runcorn, UK
Polybutene plant
P-115
Depropaniser Unit
Reactor feed preparation
Isobutene
Normal
40 C
Min
35 C
Max
42 C
Equipment name
Surge drum outlet pump
Safety Factor
Density
Viscosity
Normal flow rate
Design flow rate
10
588
7.42E-06
3.472222
3.82
%
kg/m3
N.s/m2
kg/s
kg/s
LINE PRESSURE DROP

SUCTION
DISCHARGE
Line size
Note
u1
Df1
L1
Df1 L1
r u 1 2 /2
Velocity
Friction loss
Line length
Line loss
(40 kPa)
Entrance loss
Strainer
(1) Sub-total
z1
Static head
(3) - (4)
(5)/ r g
Normal
Max.
1.24
1.36
0.13
0.19
12.16
12.16
1.62
2.33
mm
Units
m/s
kPa/m
m
kPa
0.449
40.000
42.066
0.543
40.000
42.872
kPa
kPa
kPa
Upstream equipment pressure

(2) Sub-total
3
17.3
500
517.3
3
17.3
500
517.3
m
kPa
kPa
kPa
(3) Suction pressure

(4) Vapor pressure
(5) NPSH available
NPSH available
NPSH available
475.2
457.6
17.6
3.1
1.8
474.4
457.6
16.8
2.9
1.7
kPa
kPa
kPa
m
m water
r gz1
(2) - (1)
78
Line size
Note
u2
Df2
L2
Df2 L2
Flow
Velocity
Friction loss
Line length
Line loss
S&THX
Orifice / Flow meter

Control valve
Equipment
H 205
Total
(6) Dynamic loss
z2
Static head
r gz2
Equip. press (max)
Contingency
(7) Sub-total
Discharge pressure
Suction pressure
(8) Differential pressure
(7) + (6)
(3)
(8)/ r g
Pump head
Valve/(6)
Control valve
% Dyn. loss
78
mm
Normal
Max.
Units
1.2
1.4 m/s
0.13
0.19 kPa/m
83.37
83.37 m
11.09
15.97 kPa
67.7
100
67.7
100
kPa
kPa
29
29
208
213
kPa
kPa
kPa
kPa
8
46.1
1100
0
1146.1
1353.9
475.2
878.7
8
46.1
1100
0
1146.1
1358.8
474.4
884.4
m
kPa
kPa
kPa
kPa
kPa
kPa
kPa
152.3
153.3
48%
PUMP DATA
Pump manufacturer
Catalog No.
Pump flow rate
Fristam Pumps
1742
normal
max.
Differential pressure
NPSH required
Pump type
No. of stages
Impeller type
Mounting
Shut off pressure
SKETCH
21.3 m /h
23.4 m3/h
878.7 kPa
152.3 m
89.6 m water
0.9 m
Centrifugal pump
1
Open radial
Horizontal
16.28 bar
Driver type
Power supply
Seal type
Hydraulic power
Rated power
Efficiency
Suction specific speed
Casing
Casing
Casing
Casing
design pressure
design temperature
type
material
Internal
5.189 kW
11.03 kW
47 %
9.69
2500 kPa
C
Stainless steel
NOTES
1
2
3
4
5
The back up pump will require a slightly higher head due to the presence of more components which give frictional loss, but this should be a relatively small increase.
Heat exchanger pressure loss calculated from Unisim STE simulation.
Frictional losses after heat exchanger are approximate because of phase change of isobutene occuring in heat exchanger.
Pump is not required to provide head for recycle stream (3rd tee).
Back up pump and bypass control valve not shown on diagram.
Pump Sample Calculations

Unless otherwise stated, all values are given to three significant figures. Density and viscosity
were taken from the Merck Index (ONeil, 1989).
Calculation of equivalent length friction losses

From diagram the frictional loss elements identified were:
1. 90 bend
2. Isolation (gate) valves
3. Tees
4. Non-return (ball) valve
5. Sudden contraction and expansion as flow enters and exits heat exchanger
tubes
6. Exit from pipe to reactor
7. Entrance to pipe from surge drum
8. Control valve
9. Heat exchanger
10. Orifice plate
Elements 1-5:
Pipe diameter was determined by using the guideline that process flow of liquid through pipes
has a typical speed of 4-6 ft/s (Santori, 2016). Taking the velocity as 5 ft/s (1.5 m/s):
()
() = () ()
(1)
3600
= 0.00433 2
588 3 1.5
13750
=
4
, = 0.00433 2 = 0.0743
(2)
From this diameter, using the schedule 40 nominal pipe sizes, 3 inch pipes were chosen, with
an internal diameter of 78mm. With this actual diameter, the velocity through the pipe will be:
=
10
(3)
3600
=
= 1.24
2
(0.078 )
588 3
4
13750
= 4.07
This velocity is within the acceptable bounds for process flow.

The equivalent length for elements 1-5 found graphically using the nominal pipe size of 3 inches
from course material on equivalent length method (Santori, 2016). The values for equivalent
length are:
Unit
90 bend
Gate valve
Ball valve
Sudden contraction
Sudden expansion
Tee
Equivalent pipe length (feet)

8.2
1.7
38
3.8
8.2
5.3
Element 6:
The frictional loss of the exit from the pipe to the reactor was take from equivalent length method
notes, where the K factor is 1.0.
To calculate frictional loss from K factor, head is calculated first.
2
Head () = 2
(4)
1.0 (1.24 )2
=
= 0.0784 ( )
2 9.81 2
Converting head to pressure:

=
= 1000
(5)
9.81
0.0784 = 0.769
3
2
To calculate the friction loss per foot of pipe, Figure 13 from equivalent length method notes
was used (Santori, 2016). Friction factor, f, is required for this and was taken from Table 4
(Santori, 2016), since we are using clean commercial steel pipes. To check that flow is
completely turbulent, Reynolds number was calculated.
11
588
(6)
1.24 0.0784
3
= 7.70 106
7.42 106
From a Moody chart (Figure 14) (Santori, 2016) it was confirmed that the flow was completely
turbulent. Therefore f was found to be 0.018.
Using Figure 13 (Santori, 2016), the pressure drop per 100 feet in psig was found to be 0.59
psi/100 feet. Converting this to kPa/foot:
0.59 100 6.89 100 = 0.0407
(7)
It is now possible to convert the pressure drop across the exit into an equivalent length.

=
0.769
0.0407
(8)
= 18.9
To calculate head, the equivalent lengths are converted back to pressure drop using equation
(8) and then converted to head with equation (5).
Elements 7-10:
Elements 7-10 have pressure drops that are input directly into the pump calculation sheet.
The equivalent lengths and heads for each unit are therefore:
Unit
90 bend
gate valve
ball valve
control valve
orifice
heat exchanger
exit
entrance
sudden contraction
sudden expansion
Equivalent length
(ft)
8.2
1.7
38
18.9
4.5
3.8
8.2
Pressure drop
(kPa)
0.333
0.069
1.55
100
67.7
29
0.769
0.183
0.155
0.333
12
Head loss
(m of water)
0.0340
0.00705
0.158
10.2
6.90
2.96
0.0784
0.0187
0.0158
0.0340
tee
pipe length
5.3
36.75 (m)
0.216
4.90
0.0220
0.500
The equivalent line length in suction is (see drawing for details):

Unit
90 bend
Gate valve
Tee
Pipe length
Total
No. of units
2
2
1
4.5
Feet per unit

8.2
1.7
5.3
Total feet
16.4
3.4
5.3
Total meters
5.002
1.037
1.6165
4.5
12.1555
The equivalent line length for discharge is (see drawing for details):
Unit
90 bend
Gate valve
Ball valve
Exit
Sudden
contraction
Sudden
expansion
Tee
Pipe length
Total
No. of Units
8
7
1
1
1
Feet per unit

8.2
1.7
38
18.9
3.8
Total feet
65.6
11.9
38
18.9
3.8
Total meters
20.008
3.6295
11.59
5.7655
1.159
8.2
8.2
2.501
4
32.25
5.3
21.2
6.466
32.25
83.369
References:
Santori G., 2016, Equivalent Length Method Explained, CHEE10010 Chemical Engineering
Design, [online via internal VLE], University of Edinburgh, Available at
https://www.learn.ed.ac.uk/bbcswebdav/pid-2061131-dt-content-rid3815197_1/courses/CHEE1001020167SV1SEM1/PipeSizeEquivalentLengthMethodExplained%281%29.pdf
O'Neil, M.J., ed. The Merck Index: An Encyclopedia of Chemicals, Drugs, and Biologicals. 14th
ed. New Jersey: Merck, 2006
Mark
Moderator section:
Mark
13
Question 4: Write start-up instructions for the depropaniser unit. You will be starting with the unit shut
down from its annual inspection and cleaning (all the vessels and column are empty, clean and full of
breathable air). Spades have been inserted in the feed line from the tank-farm to the depropaniser
section, in the product lines from the depropaniser section to the fuel gas main and to the polymerisation
reactor. The tank-farm has an adequate stock in the crude isobutene tank and the operators are waiting
for a phone call from you to start the crude isobutene transfer pump. (Max marks 6. Max length 1 page)
Start-up Steps:
1.Have the electrical team check all electrical equipment and signals, including all trip systems and all control
and safety indicators/transmitters.
2. Activate emergency water supplies for fire-fighting and check storage hydrants and venting of emergency
water for any leaks.
3. Check plant wide supply of cooling water, steam, nitrogen and instrument air. Ensure adequate supply.
4. Activate air systems, check performance of control valves and steam traps to ensure that they move
properly. Place into correct position for operation.
5. Place spades in all drains and vents, ensuring no release of toxic materials.
6. Introduce cooling water to bottoms cooler 20-E-104 and depropaniser condenser 20-E-13.
7. Remove air from the system by cycle purging with nitrogen until atmosphere is inert and <0.2% v/v oxygen
is present. Nitrogen will enter through lines in 20-D-100; 20-T-103; and 20-D-105 and propagate through the
system. Air will leave through open isolation valves: HA-346, HA-246; HA-342; and HA-341 and will go to
flare, bypassing the relief valve. After oxygen level is achieved in vessels, ensure that all pipes are inert by
sweeping piping and dead-end connections.
8. Check for leaks in vessels by isolating and pressurising vessels with nitrogen; vessels should be
pressurised to above the design pressure but below relief pressure ensuring no relief valves are opened.
Monitor the pressure drop in the vessels for a few hours to ensure that it is not greater 0.1 bar/hour. Wash
joints, flanges, drains and vents on all valves and equipment with soap solution. Check for bubbles as
nitrogen is fed into system and flared. Once leaks are eliminated, depressurise to 30% below operating
pressure to compensate for a pressure kick when feed is introduced.
9. Insert spades into nitrogen lines except for the surge drum. Insert Spade into HA-346 to minimise material
loss.
10. Call operators to start crude isobutene feed. Introduce feed into 20-D-100 which is isolated after the pump
at HA-355. Once correct level is reached spade HA-342, as nitrogen will have vented to flare, and turn on
20-P-111 and pump at the lowest throughput possible. Pumps cannot be run if dry; isolation will occur with
block valve after corresponding pump each time.
11. Feed will be routed through 20-E-100. Turn on steam to 20-E-100 to heat the feed as 20-E-102 is offline.
Initial flow rate into 20-T-103 must be slow to ensure feed does not flash in column, and will ensure a slow
release of nitrogen through the HA-246 flare system to avoid large fluctuations in pressure. The feed will heat
up distillation column metal to operation temperature. 20-T-103 and 20-D-109 will be isolated together. Once
desired liquid level is achieved in 20-T-103, steam is introduced to 20-E-111, vaporising liquid. Vapour
evolved is condensed in 20-E-107, and liquid level is established in 20-D-109. This brings this section up to
operating pressure and temperature whilst purging nitrogen. Open HA-162 and turn on 20-P-110A. HA-246
will need to flare any vapour until specification is met, as stream will be mainly nitrogen at start-up.
12. Open HA-162 and 20-T-103s bottom product will flow through to 20-D-105. Stop routing feed through
20-E-100. Allow level in 20-D-105 to be achieved, and close and spade HA-341. Bring up to pressure with
nitrogen, creating blanket. Open HA-269 and turn on 20-P-115A, recycle all bottoms product to 20-D-100, as
this will not meet specification.
13. Once specification is met at HA-246, the gas is sent to Fuel Gas Main by closing HA-174 and opening
HA-278. Once Bottoms product specification is met, HA-320 is shut and spaded, and HA-301 is opened to
send dry Isobutene to reactor. Sample points will be AI-32 for Fuel Gas, and AI-33 for dry Isobutene.
14. Carry out 72-hour performance test on materials, catalysts, energy and utilities. Increase feed flowrate
up to the required throughput for flowsheet operation over time, troubleshooting along the way. Update
documentation with any new experience or information.
Mark
Moderator section:
Mark
14
Appendix 1: This is additional space available for any other information you wish to provide.
(Max length 1 page)
Table A1: Calculation of Feed Preheater Normal Duty:
Distillation column feed temp
Feed Temperature
Bottoms Temperature
Mass flowrate in to column
Bottoms Flowrate
Heat Capacity Cold Stream
Heat Capacity Hot Stream
Heat removed from hot stream
Calculated Hot Temp Out
(normal flowrate)
323K (50oC)
303K (30oC)
347K (73oC)
12,786 kg hr-1
12,500 kg hr-1
2478 J kg-1 K-1
2843 J kg-1 K-1
176 kW
328.7 K (55.5cC)
Mid-range temperature as feed enters at middle

Worst case ambient temperature
Bubble point of isobutene
Using ratio of feed to bottoms from Unisim
To meet reactor requirements
From Unisim
From Unisim
Using = , (, , )
Using energy balance. This is 20-E-104 inlet temperature and
hence temperature in vessel if cooling water fails.
Table A2: Reboiler steam failure pressure relief scenario:

This table was generated with Unisim from
a simulation of reducing the pressure of a
stream with the feed composition to show
that even if steam fails in the reboiler,
propane will not vaporise at the operating
conditions of the surge drum. Unless
another control system fails.
Table A4: Basis and Assumptions:

Unisim
Basis
Cooling Water
Wetted Area
Water content not considered in Unisim.

Peng-Robinson used to model Unisim.
Mass flowrate of iso-butene assumed to be same as polybutenes.
It was assumed that the feed to the depropaniser will remove the same amount of heat when the bottoms
at normal flowrate and bottoms at maximum flowrate. This is a conservative assumptions and the true
value can be found by finding the change in the overall heat transfer coefficient which will give a lower
vapour flowrate that was found in question 2. Since this is not the limiting scenario in worst case
assumptions, a more accurate calculation of vapour formation is redundant in terms of pressure relief
valve sizing.
The wetted area was found using the following equation:
=
Backflow
2
8
(( 0.5) + 1 +
4( 0.5)+
23
)); = 1 + 12 ( 0.5) ; = 0.866 for 2:1 ellipsoidal
head. h is taken as the high liquid level.

The total volume of the system was found by adding up the pipe volume, valve volumes and heat
exchanger tubes volume from the reactor surge drum to the reactor as was found to be 0.2 m 3. The total
free volume at HLL is 5m3 therefore the back flow surge is negligible. This can be verified using Boyles
law which shows a pressure rise in the nitrogen blanket is only 0.2 bar.
Feedback section:
15
Final request: once you have completed everything, please, upload your distillation column
UNISIM file (optional) and Autocad or Autocad P&ID file (1 mark) on LEARN.
UNISIM file of the dynamic simulation of the distillation system must be uploaded on
LEARN
Autocad or Autocad P&ID file of your most complete P&ID of the whole distillation system Mark
must be uploaded on LEARN
Marks assigned by the moderator for your peer review activity on the script of
GROUP..
(Max marks 5)
Moderator section:
Mark
Marks Summary
Question number
Max Mark
26
13
Marks assigned for peer review quality
UNSIM file uploaded on LEARN (optional)
P&ID sketched with Autocad or Autocad P&ID uploaded on LEARN
Total
60
16
Mark
Chemical Engineering Design 4: Assignment 2 guidelines to the remit

Differently of the first remit, you have now an already defined process. You are in such a situation every time that the
steps leading to the definition of a process flow diagram and mass and energy balances are known (this was the
content of the first remit).
Question 1 asks about P&ID and UNISIM dynamic simulation (optional) aimed to check if your control logic is
working. As far as P&ID is concerned on a copy of the handed out Process Flow Diagram, start by checking its
correct vs the process description and then by adding the following:
1) For the lines that come and go off add contents and where come from/go to;
2) To each vessel/line add known phase(s), contents, mark level if appropriate, pressures, temperatures;
3) Tip: some controls you might add are for D109 pressure, T103 Level, D105 reactor feed flow. Are these
appropriate or enough?;
4) Look at the P&ID Exercise Tips file;
5) One way to sketch the P&ID is to split up the PFD into sections/vessels, take one each and add detail, then
join together to make the P&ID;
6) Typical operating temperatures for cooling water ambient supply with a maximum return temperature of 40C.
P&ID should include the details listed below:
1.
Valves to cover control of stream flows, isolation for maintenance (remembering to include positive
isolation where required), to avoid reverse flow and to prevent equipment being overpressured. Note that for
maintenance purposes, it is also necessary to have facilities to drain liquids from equipment, depressure systems
by venting gas/vapour and sweeping pipes and vessels with inert gas (nitrogen) to remove hydrocarbons/air at
shutdowns/startups, all in an environmentally acceptable manner.
2.
Instrumentation show all varieties (temperature, pressure, level, flow) as simple indicators/recorders and
also suggest where alarms (high/low) and trips (high high/low low) would be useful. Will any trip systems proposed
need remote actuated valves to make the plant safe? Online analysis in this plant area is difficult, but show where
sample points are required to monitor the Depropaniser T-103s performance. Remember that meters will be
needed for calculating feedstock/product/utility flows and hence production costs. D-105 has High and Low level
alarms, High = stop feed in; Low = stop reactor feed pumps. Also T-103 must have level and temperature alarms.
3.
Control how is quality to be measured and controlled? Which pressures, levels, flows and temperatures
need to be controlled? Are there any possibilities for cascade or spilt range control schemes, remembering that
the simplest control is the best as there is less to go wrong or add confusion.
4.
Safety/Environmental Impact. How will you avoid overpressuring equipment? Consider for each control
valve whether it should open or close in the event of air failure. How can emissions to the atmosphere be minimised
when starting up or shutting down this plant section? What about emergency shutdown? If the downstream Unit
200 Reaction stopped working for a few hours or several days what action would you propose to take for the Feed
Preparation Unit. Maybe have storage of purified isobutene?
5.
Plant Reliability P&IDs should show all installed equipment, pipework and instrumentation, including any
spare or duplicated items and equipment only used at start up or shut-down. Add any items of equipment, piping,
valves or instruments which you believe could improve the safety and reliability of this plant section.
In your P&ID the control and operating philosophy must be clear. You must assess which upsets are likely to
happen in your plant to define the most appropriate control scheme. In the lecture material
(MEASUREMENT&CONTROL) the following main upsets have been identified which can be a reference for you:
- Changes in the feed composition;
- Feed flow rate upset;
- Feed enthalpy upset;
- Subcooled reflux changes;
- Loss of reboiler steam pressure and accordingly reboiler duty;
- Column pressure upsets (condenser temperature).
It is important to communicate in concise form that you can identify the important variable which must be kept
stable and the more convenient control strategy for the variable and for the whole system.
Further to control valves you have to include also any alarms and trips. As far as the Process Safety System is
concerned, read carefully the guidelines included in the following linked documents. They are about an Example
Problem on Distillation System that you can follow to answer Question 1 on Process Safety System and Question
2 for failure scenarios analysis (access subscribed by The University of Edinburgh):
http://onlinelibrary.wiley.com/book/10.1002/9780470935286 (example)
http://onlinelibrary.wiley.com/doi/10.1002/9780470935286.gloss/summary (glossary)
http://onlinelibrary.wiley.com/doi/10.1002/9780470935286.acron/summary (abbreviations)
As far as UNISIM dynamics of the process is concerned (optional), go through self-study material on LEARN for
distillation column dynamics, which is very similar to your process. Follow the manual until page 2-18. More
sophisticated implementation of dynamics such as the description after page 2-18 is not needed. Videos uploaded
17
will help you in going through full simulation. Now you have completed your tutorial and you can see that this remit
is not far from the example. The remit is focused on a mixture of only 2 of the hydrocarbons in the self-study
material, but there is a small complications because of the presence of trace amount of water.
Remember that it is much better to have a correct P&ID analysis without UNISIM Dynamics than include UNISIM
Dynamics of a wrong control scheme. So, set UNISIM Dynamics analysis as last thing to do in this remit.
Question 2 concerns sizing of the pressure relief valve needed in the Reactor Feed Surge Drum 20-D-105.
Preliminary inspection of the P&ID extract shows that the Surge Drum D-105 is permanently connected (piped up)
to three other plant sections which operate at pressures above the design pressure of D-105, ie. above a pressure
of 4 barg (vessel pressure 3.37 bara). These are the Depropaniser T-103 (10.7 bara at the base), the plant nitrogen
system (6.5 to 7.5 bara, 15C) and the Polybutenes Reactor R-201 downstream of D-105 (11.0 bara).
Overpressure of the Surge Drum could arise from inflow of material from any of these sources.
Overpressure due to heat energy inflow to D-105 is also a possibility, particularly when considering the risk of a
pool fire occurring in the vessels vicinity. Other sources of heat input such as solar radiation or steam/electric
trace heating are usually only relevant if the blocked in system is full of liquid.
The risk of underpressuring D-105 is very low the vessel is not connected to any vacuum producing equipment
and the normal vessel contents would have to be cooled down to approximately +4C before the vapour pressure
of the C4s became less than atmospheric pressure. There could be a risk of creating a vacuum in the vessel
during a plant shutdown if D-105 required to be cleaned by connecting the drum by flexihose to a steam supply,
but it is normal practice in industry not to consider such events in the pressure relief study and instead rely on
plant procedures for preparing equipment for internal inspection or if steam out is going to be required to have
designed the vessel for full vacuum. The most likely relief conditions which might arise are the following:
1.
Thermal Expansion of Fluid Blocked In
2.
Closed or restricted outlets
3.
Control valve failure
4.
Instrument air failure
5.
Steam failure
6.
Electrical power failure
7.
Cooling water failure
8.
Refrigerant failure
9.
Reflux failure
10.
External fire
11.
Tube rupture
12.
Chemical reaction
13.
Storage tank inbreathing
14.
Plug flow condition
15.
Vacuum/closed or restricted inlets
16.
Excessive temperature
This is a general list and many of these conditions may or not apply to your specific case. Present your analysis
in a final table like the following one
Scenario
Relevance of the Scenario

Y/N
Flowrate
Relief Valve Size

Eg. D 0.110 in
1.5 x 2.5
scenario 1
scenario 2
scenario n
More careful analysis on failure scenarios can be found in the following guidelines for a distillation system:
http://onlinelibrary.wiley.com/book/10.1002/9780470935286 (example)
http://onlinelibrary.wiley.com/doi/10.1002/9780470935286.gloss/summary (glossary)
http://onlinelibrary.wiley.com/doi/10.1002/9780470935286.acron/summary (abbreviations).
Calculate the required relief flow rate only for the RELEVANT CASES. This is the flowrate of material which must
pass through D-105s safety valve to prevent the vessel pressure exceeding 110% of the design pressure (ie. the
relieving pressure) for each case. (This is 10% accumulation).
Identify the governing relief condition, ie., the one which requires the largest relief orifice size and therefore specify
the relief valve required to protect D-105 from all causes of overpressure. Sizing of the safety valve is according
to the procedure and examples that precisely described in BS EN ISO 4126-1:2013, BS EN ISO 4126-7:2013, BS
EN ISO 4126-10:2013 which have been uploaded in specific folder on LEARN.
18
Eventual flowrates of control valves upstream or/and downstream D-105 follow the correlations:
-
Liquid phase fluid:
W 27.3 CV P
; where W = mass flow rate [kg h-1], CV = valve flow coefficient
of discharge, = Liquid density at inlet T [kg m -3], P = (P1-P2) [bar], P1 = valve upstream pressure [bar],
P2 = valve downstream pressure [bar];
-
Gas or vapour phase fluid: W 67 CV
P P1 P2
M
; where W = mass flow rate [kg h-1], P = (P1-P2)
T
[bar], P1 = valve upstream pressure [bar], P2 = valve downstream pressure [bar], CV= valve flow
coefficient, M = molecular weight of the fluid, T = temperature at valve inlet [K].
More detailed knowledge on control valves can be retrieved by your 2 nd year course Plant Engineering 2.
If your plant will have also nitrogen purging line, then a nitrogen line has to be present also on D-105 (check lecture
notes on VESSELS). Please, assume CV=3.7 for the hand control valve in the nitrogen line.
Question 3 is on the pump and line calculation sheet.
Firstly you have to calculate the frictional loss of your line. To do that you must have a distribution of your pipeline.
So you have to decide where to place the equipment and mutual distances. Sketching the distribution of the
pipeline might help. After that, you have to apply equivalent length method to calculate the diameter of the pipe
and corresponding frictional pressure drops. You can find a full set of material for guidance on LEARN, lecture on
pipes. Now you can start filling the pump and line calculation sheet.
1. Prepare a sketch of the system in which the pump is to be installed, including
The upstream and downstream vessels (or some other point at which the pressure will not be affected by the
operation of the pump)
All components which might create loss (both suction and discharge) such as valves, orifices, filters, and heat
exchangers.
2. Show on the sketch:
The datum position (zero elevation line) normally the pump centreline
The pump nozzles sizes and elevations.
The minimum elevation (referred to the datum) of liquid expected in the suction vessel.
The maximum elevation (referred to the datum) to which the liquid is to be pumped.
The head loss expected to result from each component which creates a frictional pressure drop at design
capacity.
3. Note on calculation
Liquid pumped
Pumping temperature
Density and Viscosity at pumping temperature
Capacity
Safety Factor generally added to normal flow requirements, eg tower overhead streams 20% to account for
reflux variations, transfer pumps 10% added capacity
Design Capacity
Convert all the pressures, frictional head losses, and static heads to consistent units
4. Add the static head to the suction vessel pressure, then subtract the frictional head losses in the suction
piping. This gives the total pressure (or head) of liquid at the pump suction flange.
So Ps = P1 + (density x g x h1) r1
where subscript 1 indicates the condition of Reactor Feed Surge Drum, 20-D-105
5. Add the discharge vessel pressure, the head losses in the discharge piping system, and the discharge static
head. This gives the total pressure (or head) of liquid at the pump discharge.
So Pd = P2 + (density x g x h2 + r2) + rcontrol valve
where subscript 2 indicates the condition of the Polybutenes Reactor, 20-R-200
6. Calculate the required pump total head by subtracting the calculated pump suction total pressure from the
calculated pump discharge total pressure and converting to head. So P = Pd Ps / (density x g)
Question 4 Write start-up instructions for the Depropaniser unit. Your job is to list the sequence of operations
necessary to have the column operating in such a way that the bottoms are fit for feeding to the polymerisation
reactor, that the product drum has the proper level of product isobutene and that excessive quantities of isobutene
are not being wastefully discharged to the fuel gas main. The instructions you write should not be as detailed as
an operator training manual, which would list the number and location of every valve that has to be manipulated
and give in mind-numbing repetitiveness everything that has to be done at every stage. On the other hand, they
should be a full and comprehensible (to a professional Chemical Engineer) account of what is needed to be done.
Statements like start-up reboiler E111 are not sufficiently detailed. You should fill up the available space with the
instructions and you may find it useful to add some notes as well, explaining why you have done what you have
19
done. You may find that, when you come to write these instructions, the attached P&ID doesnt have enough detail
for your purposes. You will have to label valves etc. that need to be operated, but in addition you will find that all
kinds of extra details have to be added to make the start-up possible at all. You should have the following
information:
All the information on this process from this series of lectures, eg process description, P&ID feedback,
D105 information etc.;
P&ID;
Control Valve List.

As a guide try looking at the last few slides of the lecture notes on Start-up of Chem Eng Design 3 to see what you
need to do. As general headings try these:
1.
Preparation of Plant;
2.
Purging;
3.
Introducing feed;
4.
Putting column into flowsheet operation;
You also have a number of control valves from the P&ID. Remember that you can use these on manual before
putting into automatic. You also have a number of other instruments that you can use to see what is happening,
for example, temperature in the column.
Remember uploads on LEARN of:
your most complete P&ID drawing using Autocad or Autocad P&ID.
UNISIM file with dynamic simulation of the process (optional).
20
Chemical Engineering Design 4: Assignment 2 marking Scheme

Question 1.
Max 26 marks are available for P&ID:
Marks 0-5: P&ID contains flaws in the control scheme or in some other parts such as valve connections, alarms,
trips, pump connections, etc..
Marks 6-20: The P&ID misses of some information or items which can be more or less relevant to the process.
P&ID is correctly sketched in the main parts although some minor mistakes might be present.
Marks 21-26: P&ID is correct and complete of all details. Assign marks on the basis of the level of detail provided.
This region of marks can be assigned only when the control strategy is verified in UNSIM and graphs are provided
which are descriptive of the dynamics of the fundamental variables affecting the control.
Question 2.
Marks 0-5: Valve has been sized but it is 2 or more sizes distant (bigger or smaller) of the correct size. Moreover
the analysis of failure scenarios is not correctly addressed (not all critical scenarios have been identified), or the
sizing procedure is wrong. Marks are assigned on the basis of level of mistake.
Marks 6-9: Valves are of the correct size and failure scenarios have been analysed correctly, but you cannot give
full marks because sizing procedure has not completely followed the standards and there are minor flows in the
assessment of the correct flow rates.
Marks 10-13: Everything correct. Assign mark on the basis of the level of detail provided.
Question 3.
Marks 0-3: the diameter of the line is too large or too small for the flow rate, resulting in relevant pressure drops
and there are mistakes in the calculations leading to extreme pumps features. Give 3 marks in case the method
and the guidelines have been followed, otherwise give 0 marks.
Marks 4-6: solution is reasonable but there are still minor mistakes mainly in secondary calculations which are not
affecting the gist of the problem. Mark from 4 to 6 on the basis of the detail level and on the basis of the nature of
the mistakes.
Marks 7-9: solution is correct, mark on the basis of the level of detail provided.
Question 4.
Marks 0-1: the start-up procedure cannot work because you have forgotten some practical steps that prevent plant
start-up;
Marks 2-3: You forgot some actions and the plant will not start-up totally correct (minor issues).
Marks 4-5: Start-up is correct but you need for installation of additional units which could be avoided or the level
of detail is low.
Marks 6: Start up fully correct, clear and with great level of detail.
Peer review marking scheme.
0 marks: you did not show up during the peer-review session
1-2 marks: poor peer review. Few corrections on less important aspects. Short feedback is absent or not informative
to the reader.
2-4 marks: good peer review. Some corrections are provided along with an informative short feedback.
5 marks: excellent peer review. The most important mistakes have been caught and the short feedback is really
useful to learn.
Files upload. (these are marks assigned only by the moderators).
0 mark for UNISIM file upload (optional).
1 mark for P&ID made with Autocad or Autocad P&ID.
21

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