Polymerizer Vessel Cleaning

Current Cleaning Methodology

Analysis of the Current Method
Way Forward and Scenarios
Ideal Sizing for Hydro-Jetting
CURRENT CLEANING METHODOLGY
Jetter Pump PU-1309 installed, Specification of Pump (132KW,
310 bar, 220 lpm)

Two Rotating Nozzles installed (Nozzle Orifice : 2.8mm) with a
7.5m Manual lance (1.5 inch, Sch-80)

Manual Lance inserted through Manway of Polymerizer and
then rotated inside the vessel.

Due to Harder Deposition with time on the Vessel Walls over
time, the Current Cleaning quality of Water-Jetting is not
satisfactory and leading to Gel-Formation etc

Analysis of Current Method
Pump Pressure is 294bar with 220 lpm, With the Given Rating the KW of the
Water Stream at the Discharge would be approximately 108 KW and velocity
of Water Stream would be 300m/s

Good design of Nozzle considered (Nozzle Factor : 0.9)

Based on Line Losses in Piping (Approximated 30 bar) and Line losses in
Nozzles (10 bar), the Final Pressure Expected is 244 bar.

Net Delivery of KW to water stream as flow would be distributed in two
nozzles and pressure losses in the existing piping system would be 44KW
at nozzle discharge

Further Power Loss would be based on standoff distance and as much as
50-60 % power loss could be expected. Final Hitting Jet would only be
carrying 25-33 KW approx starting from the Original 108KW




Way Forward and Scenarios
SCENARIO-1
Procurement of New Water-Jetting Machine by with increased 70-80%
power to radically increase the cleaning efficiency based on previous
analysis.
SCENARIO-2
Enhancement of the Existing System i.e Pressure Increase of the Pump by
installing VFDs etc and reducing piping losses and procurement of new
nozzles as pressure losses and jetting profile is severely effected with
erosion etc
SCENARIO-3
Contracting Out the job to Specialized Company e.g. Pressure-Jetters.
Many parameters required are currently not available with us for e.g
Chemistry/Hardness of the Deposition etc. Some Companies also provide
CFD analysis for Cleaning of the Vessels, but this option could prove to be
very expensive in terms of returns.

IDEAL SYSTEM SIZING
An Ideal Water Jetting System would consider the following guidelines.

Jetting Dia to be kept as original (2.8mm) to avoid the Air-Shearing Factor and
as our travel distance is very high compared to conventional, Therefore not
only Pressure Increase but also Pump Flow would be required.

Nozzle Type would remain the same to keep the same jetting profile as
originally provided by Mitsubishi. Nozzle Type to be verified from Mitsubishi.

Keeping in view the following requirement, an Ideal Water-Jetting could be
around 13000 psi, with 380 LPM flow. Nozzle Orifice Dia to be kept as original
and type as originally given by Mitsubishi Corporation. Based on this the final
KW delivery to Water Stream after all the energy losses could be increased
from 40 KW to 175KW approx resulting in a much higher efficiency cleaning.

This sizing is decision and experience based, i.e. increase in power
requirement.