Ch 1: Process Auxiliaries ‘QUE: Draw the differences between a block diagram, process flow diagram and P&I diagram. [4-M]GTU ANS: | Block Diagram =| Process Flow Diagram PRID Diagram [eShows the logical flow ofthe |»Shows the main equipment and the |» Shows both major and minor processing phases of the product connections between them: details of the chemical process + Uses blocks to represent ‘Uses symbols to represent the __* Uses standard symbols to treatment units of the process equipment represent the equipment, plant instrumentation, and valves '* Does not show details, minor ‘Shows operational data ‘* Shows all kinds of valves, components, piping systems, or_| (temperature, pressure, flow rate, | instruments, pipe properties, designations etc) and main tools (control valves, | routing information, and vendor safety valves, ete) items «Provides an overview of the _» Provides information for the Provides detailed information process. construction and operability of the for the interpretation and plant, governance of the plant QUE : Classify piping insulation based on function and materials type. [3-M] GTU ANS: > Based on the function of the insulation, piping insulation can be categorized as: * Hot insulation: This type of insulation is applied on hot surfaces of the piping system. Some examples of hot insulation materials are mineral wool, glass wool, and calcium silicate. * Cold insulation: This type of insulation is used on cold surfaces of the piping system. Some examples of cold insulation materials are polyurethane foam, expanded perlite foam, and expanded polystyrene foam. = Personal protection insulation: This type of insulation is provided to avoid personal injury from contact with hot or cold surfaces. All exposed piping surfaces that exceed 65°C are provided with personal protection insulation. This type of insulation is used to absorb sound and vibration from the piping system Some examples of acoustic insulation materials are fiberglass, rubber, and cork >B in naterial, piping insulation can be categorized as: * Fibrous insulation: Fibrous insulation can operate at high temperatures and has good thermal and acoustic properties. Some examples of fibrous insulation materials are rock wool, slag wool, and glass wool.* Cellular insulation: Cellular insulation can operate at low temperatures and has low thermal conductivity and high moisture resistance. Some examples of cellular insulation materials are polyurethane foam, polyisocyanurate foam, and phenolic foam * Granular insulation: Granular insulation can operate at moderate temperatures and has moderate thermal conductivity and low moisture absorption, Some examples of granular insulation materials are expanded perlite, expanded vermiculite, and calcium silicate. QUE : Discuss the use of various types of pipe fittings with neat sketches. [7-M] GTU ANS = Pipe fittings are components that are used to connect, regulate, or change the direction of pipes ina piping system Elbow: An elbow is a fitting that changes the direction of the pipe by a certain angle, usually 90° or 45°. a as 90 Reduce * Reducer: A reducer is a fitting that reduces the size of the pipe from a larger diameter to a smaller one, = A reducer can be used to connect a main pipe to a branch pipe, or to connect a pipe to an equipment or valve = Tee: A tee is a fitting that has one inlet and two outlets, forming a T-shape ~ Tees are used to split or combine the flow of fluid in the pipe. YDS EqualTee Reducing Tee Cross Tee 4 WayTee * Cross: A cross is a fitting that has four openings in four directions, forming a cross-sha= Coupling: A coupling is a fitting that connects two pipes of the same size or different sizes. = Couplings are used to extend or repair Full Coupling Half Coupling * Union: A union isa type of coupling that can be easily detached and reattached without cutting or welding the pipes. = Unions are used to connect pipes that need frequent disconnection and reconnection for maintenance or replacement. = Adapter: An adapter is a fitting that connects pipes of different materials, sizes, or shapes. ~ Adapters are used to adapt pipes to different standards or specifications ev Mate Adapter Female Adapter Ref : Types of Pipe Fittings - The Home Depot‘QUE : Enlist the all materials used for the fabrication of the pipe and explain alloy steel. ANS ~ Manufacturing of pipe uses many different materials including : ‘© Conerete : Reinforced Concrete pipes (RCP), Prestressed Concrete pipes (PCP), and Concrete Cylinder pipes (CCP) © Ceramic: Alumina pipes (41203), Zirconia pipes (2r02), and Silicon carbide pipes (SiC) © Plastic : Fibre reinforced plastic (FRP), polypropylene (PP), polyethylene (PE) ‘© Metals : Carbon steel pipes (CS), Stainless steel pipes (SS), Alloy steel pipes (AS), ” special piping materials such as glass or lined pipe : Glass, Rubber lined pipe, PTFE(polytetrafluoroethylene) lined pipe ~ Alloy stee! is a type of steel! that contains alloying elements, such as manganese, silicon, nickel, titanium, copper, chromium, and aluminium. ~ These alloying elements are added to = Alloy stee! pipes have a higher strength-to- weight ratio than conventional carbon steel pipes + They also have greater temperature resistance and better weldability than carbon steels due to their lower carbon content levels. + Additionally, they ar than traditional carbon steel pipes due ‘to the addition of alloying elements which protect against oxidation. QUE : How do you calculate the schedule number of a pipe from the knowledge of working pressure and allowable stress of the MOC? [3-M] GTU ANS: = The schedule number of a pipe is a dimensionless value that indicates the thickness of the pipe wall. = Itis based on the ratio of the design pressure to the allowable stress of the material of construction at working conditions. According to Barlow's formula; Schedule Number = 1000 x 5 QUE: Explain in brief about Various pipe joints. ANS Pipes are connected with the help of joints (Threaded Joins : These are the joints where pipes are screwed together using threads provided on the pipes. (il) Welded Joins : These are the joints where pipes are joined by welding them together using heat and filler metal“(lil) Socket-welded Joins: These are a type of welded joint where a smaller pipe is inserted into a larger pipe and welded around the joint iv) Brazed joins: These are the joints where pipes are joined by heating them and applying a filler metal that melts above 450°C but below the melting point of the pipes. (W) Soldered joins : These are similar to brazed joints, but the filler metal melts below 450°C. (Wi) Flanged joins : These are the joints where pipes are connected by bolting them together with flanges (flat rings) at their ends. (vil) Compression joins: These are the joints where pipes are connected by compressing them with fittings that have tapered or conical endsP.A.U, (3170516) Steam-based heating processes use latent heat and transfer it to a given product. When the work is done (i.e, steam has given up its latent heat), steam condenses and becomes condensate. In other words, condensate does not have the ability to do the work that steam does. Heating efficiency will therefore suffer if condensate is not removed as rapidly as possible, whether in steam transport piping or in a heat exchanger. Each model of steam trap has its own characteristics, and differences in traps’ operating processes directly relate to whether or not they are suitable for a particular application. Steam traps can be divided into three different types based on their operating principles: 1. Mechanical Steam Traps Mechanical traps operate by utilizing the difference in density between sieam (or air) and condensate, 2. Thermodynamic Steam Traps There are two varieties of thermodynamic steam trap: the thermodynamic disc and piston types. Thermodynamic steam traps operate by utilizing the difference in kinetic energy between high velocity steam (a gas) and slower moving condensate (i liquid): 3. Thermostatic Steam Traps These include bi-metal, balanced pressure, and expansion thermostatic traps. Thermostatic traps operate by utilizing the difference in temperature between condensate that is close to steam temperature and sub-cooled condensate (or low teftiperature air). Q-9 Explain in brief about types of vacuum pumps. Ans: A vacuum pump is a device that draws gas molecules from a sealed volume in order to leave behind a partial vacuum. The job of a vacuum pump is to generate a relative vacuum within a capacity. Positive displacement pump ‘The manual water pump draws water up from a well by creating a vacuum that water rushes in to fill. In sense, it acts to evacuate the well, although the high leakage rate of dirt prevents a high quality vacuum from being maintained for any length of time. Mechanism: A partial vacuum may be generated by increasing the volume of a container. To continue evacuating a chamber indefinitely without requiring infinite growth, a compartment of the vacuum. S.N.P.I.T & R.C. UMRAKH-BARDOLIP.A.U. (3170516) can be repeatedly closed off, exhausted, and expanded again. This displacement pump, for example the manual water pump. s the principle behind a positive Inside the pump, a mechanism expands a small sealed cavity to reduce its pressure below that of the atmosphere. Because of the pressure differential, some fluid from the chamber (or the well, in our example) is pushed into the pump's small cavity. The pump's cavity is then sealed from the chamber, opened to the atmosphere, and squeezed back to a minute size.More sophisticated systems are used for most industrial applications, but the basic principle of cyclic volume’ removal is the same: © Rotary vane pump, the most common © Diaphragm pump, zero oil contamination © Liquid ring high resistance to dust Piston pump, fluctuating vacuum Scroll pump, highest speed dry pump Screw pump (10 Pa) Wankel pump External vane pump Momentum transfer pump: Ina momentum transfer pump, gas molecules are accelerated from the vacuum side to the exhaust side (which is usually maintained at a reduced pressure by a positive displacement pump). Momentum transfer pumping is only, possible below pressures of about 0.1 kPa. Matter flows differently at different pressures based on the laws of fluid dynamics. At atmospheric pressure and mild vacuums, molecules interact with cach other and push on their neighboring molecules in what is known as viscous flow. When the distance between the molecules increases, the molecules interact with the walls of the chamber more often-than with the other molecules, and molecular pumping becomes more effective than positive displacement pumping. This regime is generally called high vacuum. Molecular pumps: Molecular pumps sweep out a larger area than mechanical pumps, and do so more frequently, making them capable of much higher pumping speeds. They do this at the expense of the seal between the vacuum and their exhaust. Since there is no seal, a small pressure at the exhaust can easily cause backstreaming through the pump; this is called stall. In high vacuum, however, pressure gradients have little effect on fluid flows, and molecular pumps can attain their full potential, Regenerative pumps: S.N.P.L.T & R.C. UMRAKH-BARDOLIP.A.U. (3170516) Advantages of Hot Oil syste1 Non pressurized system No loss system/ Closed circuit Point of use location No water treatment or Chemic: Less effluent disposal No freezing hazards Low maintenance cost Relatively simple di . . . . usage . . . . Limitations Escaping vapors © Overheating © Leakage Ignitability Applications Chemical Plants Textile Manufacturing Facilities Food Processing Pharma Laundries Marine Applications Oil and Gas production Petrochemicals Wood Processing Plastic & rubber processing Metal, paper and cardboard processing Building Materials © Paper and Pulp Q-6 Explain in brief about various types of air compressors. ANS: An air compressor is a mechanical device that increases the pressure of air by reducing volume. Air is compressible, the compressor reduces the volume of air and induces pressure in the air S.N.P.I.T & R.C. UMRAKH-BARDOL!P.A.U. (3170516) An air compressor converts electrical energy into kinetic energy in the form of the air. The compressed air is stored in the air receiver and can be used for cleaning under pressure, generating torque and develop force using actuators. This source is free of cost, safe, flexible and convenient Air compressor has very few parts hence maintenance is very low. Air compressors are classified according to method of energy transfer and pressure generation ie. positive displacement and dynamic compressors. Positive displacement compressors work on the principle of increasing the pressure of ‘air by reducing the volume of air in an enclosed chamber. Dynamic compressors works on the principle of imparting the energy by rotating vanes of impeller on air flowing through casing that increases pressure in air. Air Compressors Positive Displacement Air Dynamic (Turbo) Air Compressor Reciprocating Air oma Centrifugal Axial flow Ejector Piston Labyrinth Diaphragm Lobe id (Water) Si M Twin (cata) Rg me rai Screw Fig. 9.1 : Classification of air compressor 1,.Rotary lobe and straight lobe: It doesn’t have any internal compression. The gas travels from intake to discharge through the trapping by two straight mating lobed impellers. 2. Reciprocating piston: The reciprocating compressors come under the positive displacement devices where the displacing and compressing element is a piston which will be in a cylinder and contains a reciprocating motion. 3. Sliding vane: The sliding vane compressors come under the category of rotary positive displacement compressors. The eccentric is placed within a tube and the slotted cylinder is fitted with vanes of nonmetallic, After this, if the slotted cylinder is turned then the vanes S.N.P.I.T & R.C. UMRAKH-BARDOLIP.A.U, (3170516) form areas of transforming volume due to sliding of the vanes along the interior walls of the tube, 4, Helical lobe compressors: The rotor pockets contain the trapped gas at one end point, the intermeshing rotors compressor it and then the gas discharges from the opposite endpoint. Few helical screw compressors work with fluid and such compressors are known as flooded screw compressor 5. Liquid ring: The liquid ring compressors make use of squirrel cage fan type impeller which places eccentric in a tube. A liquid which is compatible is introduced into a chamber along with gas and they both undergo compression in a chamber, Due to the structuré of inner cavity and centrifugal force, the liquid makes an eccentric shape genefating the areas of transforming. After the process of recirculated and compression, the liquid has to take apart from the compressed gas. 6. Axial compressors: The axial compressors are dynamic devices and in this, the flow of the gas is accelerated in a peripheral direction and also in the axial direction of the rotation of unique shaped blades. Stator blades permit the recovery of velocity to pressure. 7. Centrifugal compressors: These centrifugal compressors are dynamic devices and in these compressors, the fast moving rotating impeller makes the gas to accelerate. Q-7 Discuss about STEAM EJECTORS. ANS: Steam ejectors use steam or gas instead of moving parts to compress a gas. In a jet or ejector, a relatively high-pressure gas, like steam or air, expands through a nozzle. The steam or air converts that pressure or potential energy to velocity or kinetic energy. The jet of high-velocity steam or gas entrains the gas to be evacuated or pumped in the suction of the ejector. The resulting mixture enters the diffuser where velocity energy is converted to pressure at the ejector discharge. This is oftenused in applications such as deaeration when the vacuum system must be able to pull down to the vapor pressure of the water that is being degassed. Air jets of this type are convenient because no steam or pressurized air source is required to make it work, just the vacuum pump. S.N.P.I-T & R.C, UMRAKH-BARDOLIwhat is aircompressors? An air compressor is a pneumatic device that converts power (using an electric motor, diesel, or gasoline engine, etc.) into potential energy stored in pressurized air (i.e., compressed air). By one of several methods, an air compressor forces more and more air into a storage tank, increasing the pressure. When the tank's pressure reaches its engineered upper limit, the air compressor shuts off.The compressed air, then, is held in the tank until called into use. The energy contained in the compressed air can be used for a variety of applications, utilizing the kinetic energy of the air as it is released and the tank depressurizes. When tank pressure reaches its lower limit, the air compressor turns on again and re-pressurizes the tank. An air compressor must be differentiated from a pump because it works for any gas/air, while pumps work ona liquid. 2.what is an air receiver? An air receiver is a type of compressed air tank that is an integral part of any compressed air system. Its main purpose is to act as temporary storage to accommodate the peaks of demand from your system and to optimize the running efficiency of your plant. Air receivers are used to store compressed air before it enters into the piping system and/or equipment. In simpler terms, air receivers act as a buffer mechanism between the compressor and the fluctuating pressure caused by the changing demand. {t is important to note that while an air compressor installation can run without a receiver, not having one in your air system can increase the loading and unloading cycles on the compressor, making it work harder. Load/unload cycles will depend on the demand fluctuation within your facility.When it comes to sizing of an air receiver, a good rule of thumb to remember is to allow 3-4 gallons for each CFM or 10-15 liters for each liters/second of compressed air depending on the type of an air compressor used and the application 1. It is highly recommended to consider minimizing pressure fluctuations/drops by selecting the right air tank for your compressor. This requires you to be mindful of two values: your compressor's output pressure and what your application needs at the point of use. Note that the compressed air stored in your air receiver is only useful as long as its pressure is sufficient for the process which uses it. This is why it is important to consider the duration (in minutes) that the air receiver can supply air at the necessary pressure for your end-user/equipment. Distribution systems A distribution system is a system that involves the delivery of material right from manufacturing, to distributors to the end customer. It consists of all the methods, procedures, equipment required for the flow of goods from a business to end-users of a product. The success of a business largely depends on its distribution system. There are two important aspects of a business. One is to create or manufacture a product which is better than the similar products available in the market. Second is the distribution system. If the distribution system of an organization is sound, then it will surely generate more sales than its competitors .There are different types of distribution systems depending on the nature of the product and the target market. For instance, there are direct and indirect distribution systems 1. Direct distribution systems involve sellingproducts directly to customers without intermediaries, while indirect distribution systems involve selling products through intermediaries such as wholesalers, retailers, and agents.In addition to this, there are also different types of distribution channels such as intensive, selective, and exclusive distribution channels, Intensive distribution channels involve making products available in as many outlets as possible, while selective distribution channels involve making products available in selected outlets only. Exclusive distribution channels involve making products available in only one outlet or location. 4.what is an air dryers? ‘An air dryer is a system or piece of equipment that is used to remove moisture present in the air, particularly compressed air. Ambient air typically has a relative humidity of around 30 to 50%. Compressing air packs higher quantities of moisture in a small volume . The compression of air raises its temperature and concentrates atmospheric contaminants, primarily water vapor, as resulting in air with elevated temperature and 100% relative humidity. As the compressed air cools down, water vapor condenses into the tank(s), pipes, hoses and tools connected downstream from the compressor which may be damaging. Therefore water vapor is removed from compressed air to prevent condensation from occurring and to prevent moisture from interfering in sensitive industrial processes. There are various types of compressed air dryers. These dryers generally fall into two different categories: primary, which includes coalescing, refrigerated, and deliquescent; and secondary, which includes desiccant, absorption, and membrane . Their performance characteristics are typically defined by flow rate in standard cubic feet per minute (SCFM) and dew point expressed as a temperature. A regenerative desiccant dryer typically delivers a dew point of between —40 °C (-40 °F) and -73 °C (-100 °F) . A refrigerated dryer delivers a dew point not lower than approximately 2 °C (35 °F) 5.Various types of _air dryers? There are different types of air dryers, each with its own unique characteristics and applications. The following are some of the most common types of air dryers: 1 Refrigerated air dryers: These dryers remove water from compressed air by cooling the compressed-air temperature and causing condensation. They typically generate air with pressure dew points between 35 and 40° F 2.Desiccant air dryers: These dryers work on a different principle than refrigerated air dryers, They adsorb moisture from the air stream and onto a desiccant material in a reversible process. They produce low dew points, so they are a good choice in subfreezing conditions or when processes require extremely dry air. 3.Membrane air dryers: These dryers use a membrane to separate water vapor from compressed air. They are typically used in applications where low dew points are not required.4.Chemical air dryers: These dryers use a chemical reaction to remove moisture from compressed air. They are typically used in applications where low dew points are not required. ir dryers: These dryers use a salt to absorb moisture from compressed air. They are typically used in applications where low dew points are not required. 6.Absorption air dryers: These dryers use a liquid desiccant to remove moisture from compressed air. They are typically used in applications where low dew points are not required . 6.Different types of ejetors? There are different types of ejectors, each with its own unique characteristics and applications. The following are some of the most common types of ejectors: 1.Single-Stage Ejector: This is a simple and frequently used nozzle in the industry. It discharges pressure near or equal to atmospheric pressure. It is usable for force from atmospheric to 80 torrs or compression ratio <10 2.Multi-Stage Ejector: This type of ejector is used when a higher vacuum level is required. Multi-stage ejectors can be non-condensing or condensing, depending on the application 3. Multi-stage ejectors with both condensing and non- condensing stages are also available. 3.Liquid Ejector: This type of ejector is used to pump liquids from one location to another. 4.Gas Ejector: This type of ejector is used to pump gases from one location to another. 5.Steam Ejector: This type of ejector uses steam as the motive fluid and is commonly used in power plants, chemical plants, and refineries