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LM 8 COMPLEX PIPING SYSTEMS

HOMEWORK PROBLEM

A few years ago, one of the Senior Design Class Groups developed a preliminary design for a plant to produce hydrogen from a light waste gas stream generated during a renewable fuels process. Our class has been asked to help in performing some of the detailed fluid flow calculations associated with this design. Their process flow diagram (broken into four separate sheets) is attached. It shows the piping segments between unit operations plus the approximate average temperature of each segment. A table on the diagram shows the overall and component mass flow rates in kilograms per day (kg/day) for each stream. If you are missing any physical property data you feel you need to complete this assignment that you cannot obtain from ChemCad, please contact the Instructor. On the process flow diagrams, pipe segments are marked with either a diamond stream number symbol or with a hand drawn hexagon. You will work on the pipe segments identified for your “section” of the process. Other members of the class will work on other portions of the process. If you have any questions about this, see the Instructor. Your job is to determine the correct piping for your specified portion of the plant. Using the metric system of pipe diameters and thicknesses, identify the correct pipe size and pipe thickness that should be used assuming velocities of ~2.3 mps (meters per second) for liquid streams and ~23 mps for gas phase stream. Note, you won’t be able to get the exact target velocity and still specify real pipe sizes. Choose the best pipe size based on your calculations. If there is a pump included in your portion of the plant, determine if there is sufficient NPSH available for the pump and determine the actual power required in kW (kilowatts) assuming a pump/motor efficiency of 65%. If you have a compressor included in your portion of the plant, determine the actual power required in kW assuming a polytropic efficiency of 70%. You may use ChemCad, and/or hand calculations as appropriate to solve this problem. For this assignment you will be graded both on the technical accuracy of your work and on your ability to report your information in the form of a report. Attached is the grading metric that will be used to determine your grade from this assignment. Use this as a guide as to the contents of your report. Your report should include a Problem Approach and Results Description (explain and justify your approach to sizing the different pipe segments, report and explain your results), Methods Description (describe how you did your calculations with and without ChemCad), Drawing Documentation (mark your final answers for pipe, pump, compressor sizes, etc. on the process flow diagram you were given), and ChemCad documentation (don’t include the entire detailed ChemCad report, just the summary sheets necessary to fully document how you obtained your results).

In each section of the plant, there are multiple configurations you must consider. You must perform the calculations for each possible case and find the one with the highest pressure drop, then use that flow scheme to size all of your piping. The temperatures shown on the various pipe segments should assume to be average temperatures for the entire pipe segment (unless there is a heat exchanger in the segment, then it is the average for those portions of the piping before or after the heat exchanger as appropriate). Below are the sections of the plant you need to work on. A pipe routing and equipment layout plan is attached to help you visualize the descriptions. There are a few minor differences between the descriptions and the drawings. If you come across one of these differences, follow the descriptions below rather than the drawings. SECTION A Pipe segment 24a (A). This is a liquid phase stream. At the point it becomes your responsibility, it has just entered the process area horizontally from a pipeway. The pressure at a 100% open gate valve located at ground level at the pipeway is 15.0 bara. From the valve, the piping runs 0.5m horizontally to a 90o elbow then upwards 7m to a 90o elbow then horizontally 38m to a 90o elbow then 4m horizontally to the side nozzle on a tee. From the two flow through sides of the tee, symmetrical pump suction lines for L-102A and B are connected. From each flow side connection of this tee, the piping travels 0.25m horizontally to 90o elbows, then 7.5m downwards to 90o elbows then 0.25m horizontally to a gate valve. The gate valve on one of the two pump suction lines is 100% open while the valve on the other line is 100% closed. From the gate valve the piping runs 0.6m horizontally to the suction nozzle of one of the L-102 pumps, either A or B. Pump L-102A/B (A). L-102A and B are 100% redundant centrifugal pumps. These pumps raise the pressure of the liquid such that at the entrance to D-102 (end of pipe segment 40), the pressure is 21.0bara. You must size the pump correctly to achieve this condition and evaluate the NPSH condition for every possible piping configuration described (for example when L-102A is in service and L-102B is out of service and vice versa). Pipe segment 24b (A). From the discharge nozzle of the L-102A/B pumps, the two discharge lines are symmetrical until the flow lines merge at the tee. The piping runs 0.6m horizontally from the pump nozzles to gate valves. The gate valve on one of the two flow lines is 100% open while the valve on the other line is 100% closed, depending upon which of the two L-102 pumps is in operation, A or B. From the gate valves, the piping runs 0.3m horizontally to 90o elbows, then 7.5m upwards to 90o elbows then 0.25m horizontally to the flow through sides of a tee. From the side nozzle of the tee, the piping runs 1m horizontally to a 90o elbow, then 2m horizontally to a 90o elbow, then 3m horizontally to a 90o elbow, then 7.5m vertically downwards to a control valve station. See attached diagram 1 for a sketch of a control valve station. From the other connection of the control valve station, the piping travels vertically upwards 4m to a 90o elbow, then 3m horizontally to a 90o elbow, then 1m horizontally one of the flow through connections of a tee where it joins pipe segment 23b, which is connected to the

side connection of this tee to form pipe segment 41, which joins the other flow through connection of the tee. Pipe segment 23a (A). This is a liquid phase stream. At the point it becomes your responsibility, it has just entered the process area horizontally from a pipeway. The pressure at a 100% open gate valve located at ground level at the pipeway is 14.5 bara. From the valve, the piping runs 0.5m horizontally to a 90o elbow then upwards 7m to a 90o elbow then horizontal 33m to a 90o elbow then 3.5m horizontally to the side nozzle on a tee. From the two flow through sides of the tee, the two pump L-103 suction lines are symmetrical. The piping travels 0.25m horizontally to 90o elbows, then 7.5m downwards to 90o elbows then 0.25m horizontally to a gate valve. The gate valve on one of the two pump suction lines is 100% open while the valve on the other line is 100% closed. From the gate valve the piping runs 0.6m horizontally to the suction nozzle of one of the L-103 pumps, either A or B. Pump L-103A/B (A). L-103A and B are 100% redundant centrifugal pumps. These pumps raise the pressure of the liquid such that at the entrance to D-102 (end of pipe segment 40), the pressure is 21.0bara. You must size the pump correctly to achieve this condition and evaluate the NPSH condition for every possible piping configuration described. Pipe segment 23b (A). From the discharge nozzle of each of the L-103 pumps, the two discharge lines are symmetrical until the flow lines merge at a tee. The piping runs 0.6m horizontally to gate valves. The gate valve on one of the two flow lines is 100% open while the valve on the other line is 100% closed, depending upon which of the two L-103 pumps is in operation, A or B. From the gate valves, the piping runs 0.3m horizontally to 90o elbows, then 7.5m upwards to 90o elbows then 0.25m horizontally to the flow through sides of a tee. From the side nozzle of the tee, the piping runs 3m horizontally to a 90o elbow, then 7.5m downwards to a control valve station. See attached diagram 1 for a sketch of a control valve station. From the other connection of the control valve station, the piping travels vertically upwards 7.5m to the side connection of the same tee that is connected to pipe segments 24b and 41. Pipe segment 18a (A). This is a liquid stream that starts at the side nozzle of a tee. This tee splits the inlet flow of stream 17 (for a description of segment 17, see section E) into pipe segments 18 and 19 and is located 8m above ground level in the pipe rack. The inlet pressure at the tee should be assumed to be 21.7bara. From the tee the piping goes 6m horizontally to the flow through side of a tee, which splits the flow into streams 18b and 18c. Pipe segment 18b (A). From the side nozzle of the tee connected to pipe segments 18a and 18c, the piping travels 3m horizontally to a 90o elbow then 2.75m downwards to a 90o elbow then 0.5m horizontally to a gate valve, then 0.5m horizontally to the inlet nozzle of E-105A. This valve is 100% open when E-105A is in service and 100% closed when E-105B is in service. Pipe segment 18c (A). From the flow through side of the tee connected to pipe segments 18a and 18b, the piping travels 0.35m horizontally to a 90o elbow then 3m horizontally to a 90o elbow then 5m downwards to a 90o elbow then 0.5m horizontally to a gate valve then 0.5 m horizontally to the inlet nozzle of E-105B. This valve is 100% open when E-105B is in service and 100% closed when E-105A is in service.

E-105A/B (A). The two heat exchangers are stacked – E-105A on top of E-105B. Only one of the two heat exchangers is in operation at any one time. If E-105A is in service, the gate valves on pipe segments 18b and 18d are 100% open and the gate valves on pipe segments 18c and 18e are 100% closed. If E-105B is in service, the gate valves on pipe segments 18c and 18e are 100% open and the gate valves on pipe segments 18b and 18d are 100% closed. There is a 3 psia pressure drop within the operating E-105 exchanger. Pipe segment 18d (A). This is a liquid stream starting at the discharge nozzle located on the top of the E-105A exchanger. From the discharge nozzle, the piping travels upwards 1m to a 90o elbow then horizontally 3m to a gate valve, then 1m horizontally to the flow connection of a tee where it joins pipe segments 18e and 18f. This valve is 100% open when E-105A is in service and 100% closed when E-105B is in service. Pipe segment 18e (A). This is a liquid stream starting at the discharge nozzle located on the bottom of the E-105B exchanger. The discharge nozzle is directly connected to a 90o elbow. For the elbow the piping travels 3m horizontally to a gate valve, then 1m horizontally to a 90o elbow then 7.5m upwards to the side connect of the tee connected to pipe segments 18d and 18f. This valve is 100% open when E-105B is in service and 100% closed when E-105A is in service. Pipe segment 18f (A). From one of the flow sides of the tee connected to pipe segments 18d and 18e, the piping runs 1.5m horizontally to a 90o elbow then 2m horizontally to the flow end of a tee where it connects with pipe segments 19f and 41. Note, you must size the pipe segment 18 branches such that at the entrance to D-102 (end of pipe segment 40), the pressure is 21.0bara. regardless of which E-105 heat exchanger is in service. Pipe segment 19a (A). This is a liquid stream that starts at one of the flow through nozzles of a tee. This tee splits the inlet flow of stream 17 into 18 and 19 and is located 8m above ground level in the pipe rack. The inlet pressure at the tee should be assumed to be 21.7bara. From the tee the piping goes 3m horizontally to the flow through side of a tee, which splits the flow into streams 19b and 19c. Pipe segment 19b (A). From the flow through nozzle of the tee connected to pipe segments 19a and 19c, the piping travels 2.5m horizontally to a gate valve, then 0.5m horizontally to the inlet nozzle of E-106A. This valve is 100% open when E-106A is in service and 100% closed when E-106B is in service. Pipe segment 19c (A). From the side nozzle of the tee connected to pipe segments19a and 19b, the piping travels 5m downwards to a 90o elbow then 2.5m horizontally to a gate valve then 0.5 m horizontally to the inlet nozzle of E-106B. This valve is 100% open when E-106B is in service and 100% closed when E-106A is in service. E-106A/B (A). The two heat exchangers are stacked – E-106A on top of E-106B. Only one of the two heat exchangers is in operation at any one time. If E-106A is in service, the gate valves on pipe segments 19b and 19d are 100% open and the gate valves on pipe segments 19c and 19e are 100% closed. If E-106B is in service, the gate valves on pipe segments 19c and 19e are

100% open and the gate valves on pipe segments 19b and 19d are 100% closed. There is a 4 psia pressure drop within the E-106 exchangers. Pipe segment 19d (A). This is a liquid stream starting at the discharge nozzle located on the top of the E-106A exchanger. From the discharge nozzle, the piping travels upwards 0.2m to a 90o elbow then horizontally 11m to a gate valve, then 1m horizontally to a flow through connection of a tee where it joins pipe segments 19e and 19f. This gate valve is 100% open when E-106A is in service and 100% closed when E-106B is in service. Pipe segment 19e (A). This is a liquid stream starting at the discharge nozzle located on the bottom of the E-106B exchanger. From the discharge nozzle, the piping travels downwards 0.15m to a 90o elbow, then 11m horizontally to a gate valve, then 1m horizontally to a 90o elbow then 8.5m upwards to the side connect of the tee connected to pipe segments 19d and 19f. This valve is 100% open when E-106B is in service and 100% closed when E-106A is in service. Pipe segment 19f (A). From one of the flow sides of the tee connected to pipe segments 19d and 19e, the piping runs 1.5m horizontally to the side connection of a tee where it connects with pipe segments 18f and 41. Note, you must size pipe segment 19 such that at the entrance to D- 102 (end of pipe segment 40), the pressure is 21.0bara. Pipe segment 41 (A). This segment connects the piping from 23/24 and 18/19 together to form segment 40. Starting from the tee where pipe segments 18f and 19f join, the piping travels 6m horizontally to a 90o elbow, then 2m horizontally to a flow through connection on a tee. Starting from the tee where pipe segments 23b and 24b join, the piping travels horizontally 2m to the side connection of the same tee (connected to the segment 41 piping from 18/19). The other flow connection of this tee connects to pipe segment 40. Pipe segment 40 (A). This is a liquid stream that connects the tee from pipe segment 41 to the inlet nozzle of D-102. From the flow through connection of the tee, the piping travels 2m horizontally to a 90o elbow then downwards 1.0 to a 100% open gate valve, then 0.5m downwards to a 90o elbow then 0.5 m horizontally to the feed nozzle of D-102 which is located in the side of the vessel, near the top. The pressure at the D-102 feed nozzle must be at least 21.0bara.

SECTION B Pipe segment 21 (B). This portion of the piping routes the overhead gas from D-102 to the inlet nozzle on each of four parallel D-105 pressure swing absorption (PSA) units. At any time, any two of the four PSA units will be accepting this feed stream. You must design the piping to accommodate every combination (and demonstrate that you have done so). The gas phase stream leaving the top of D-102 is at 20.0 bara. The inlet gas pressure at the inlet nozzle of each D-105 vessel must be at least 19.7 bara. Pipe segment 21a (B). This is a gas phase stream. From the outlet nozzle on the top of D-102, the piping travels upwards 0.2m to a 100% open gate valve, then 2.3m upwards to a 90o elbow, then horizontally 5m to a 90o elbow, then horizontally 15m to a 90o elbow, then 10m horizontally to a 90o elbow, then downwards 7.8m to a 90o elbow. This elbow connects the piping to a manifold, pipe segment 21b, that feeds four parallel pressure swing absorption (PSA) units, D- 105A, B, C, and D. Pipe segment 21b (B). From the elbow the piping travels horizontally 0.5m to the flow through connection of a tee. The side connection of the tee is pipe segment 21c and the other flow connection is pipe segment 21d. Pipe segment 21c (B). This is a gas phase stream connected to the side connection of the tee connected to pipe segments 21b and 21d. From the tee, the piping travels 3m to a remotely operated block valve, then 0.5m to the inlet nozzle of D-105A. The block valve will either be 100% open or 100% closed depending upon whether D-105A is in or out of service. Pipe segment 21d (B). From the other flow through connection of the tee connected to pipe segments 21b and 21c, the piping travels 4m to the flow through connection of a tee. The side connection of the tee is pipe segment 21e and the other flow connection is pipe segment 21f. Pipe segment 21e (B). This is a gas phase stream connected to the side connection of the tee connected to pipe segments 21d and 21f. From the tee, the piping travels 3m to a remotely operated block valve, then 0.5m to the inlet nozzle of D-105B. The block valve will either be 100% open or 100% closed depending upon whether D-105B is in or out of service. Pipe segment 21f (B). From the other flow through connection of the tee connected to pipe segments 21d and 21e, the piping travels 4m to the flow through connection of a tee. The side connection of the tee is pipe segment 21g and the other flow connection is 21h. Pipe segment 21g (B). This is a gas phase stream connected to the side connection of the tee connected to pipe segments 21f and 21h. From the tee, the piping travels 3m to a remotely operated block valve, then 0.5m to the inlet nozzle of D-105C. The block valve will either be 100% open or 100% closed depending upon whether D-105C is in or out of service. Pipe segment 21h (B). From the other flow through connection of the tee connected to pipe segments 21f and 21g, the piping travels 4m to a 90o elbow (elbow to D-105D). From the elbow, the piping travels 3m to a remotely operated block valve, then 0.5m to the inlet nozzle of D-

105D. The block valve will either be 100% open or 100% closed depending upon whether D- 105D is in or out of service. Pipe segment 22 (B). This piping routes the bottoms liquid from D-102, which starts at 22.0 bara, through a pair of pumps, L-101A/B, to the inlet nozzle near the top of D-103. The pressure at the inlet nozzle should be at least 22.3 bara. Only one of the two L-101 pumps will be in service at one time. When L-101A is in service, the gate valves on the inlet (22b) and outlet (22d) piping of L-101A will be 100% open and the gate valves on the inlet (22c) and outlet (22e) piping of L-101B will be 100% closed. When L-101B is in service, the gate valves on the inlet (22c) and outlet (22e) piping of L-101B will be 100% open and the gate valves on the inlet (22b) and outlet (22d) piping of L-101A will be 100% closed. Pipe segment 22a (B). From the outlet nozzle on D-102, the piping travels horizontally 0.2m to a 100% open gate valve, then horizontally 0.2m to a 90o elbow, then upwards 7.5m to a 90o elbow, then horizontally 3.5m to a 90o elbow, then horizontally 4m to the flow connection of a tee. The other flow connection of this tee is pipe segment 22b. The side connection from the tee routes flow to L-101A (segment 22c). Pipe segment 22b (B). From the other flow connection of the tee attached to pipe segments 22a and 22c, the piping travels horizontally 1m to a 90o elbow, then downwards 7.6m to a 90o elbow, then horizontally 0.2m to a gate valve, then horizontally 0.2M to the inlet connection of L-101A. This gate valve is 100% open when L-101A is in service and 100% closed when L-101B is in service. Pipe segment 22c (B). From the side connection of the tee in pipe segments 22a and 22b, the piping travels downward 7.6m to a 90o elbow, then horizontally 0.2m to a gate valve, then horizontally 0.2M to the inlet connection of L-101B. This valve is 100% open when L-101B is in service and 100% closed when L-101A is in service. Pump L-101A/B (B). L-101A and B are 100% redundant centrifugal pumps. These pumps raise the pressure of the liquid such that at the entrance to D-103 (end of pipe segment 22f), the pressure is at least 22.3 bara. You must size the pump correctly to achieve this condition and evaluate the NPSH condition. Pipe segment 22d (B). From the outlet connection of L-101A the piping travels horizontally 0.2m to a gate valve, then 0.3m horizontally to a 90o elbow, then upwards 7.8m to a 90o elbow, then horizontally 1m to the flow through side connection of a tee where it joins pipe segment 22e. The outlet from the tee is pipe segment 22f. This gate valve is 100% open when L-101A is in service and 100% closed when L-101B is in service. Pipe segment 22e (B). From the outlet connection of L-101B the piping travels horizontally 0.2m to a gate valve, then 0.3m horizontally to a 90o elbow, then upwards 7.8m to the side connection of the tee connected to pipe segments 22d and 22f. This gate valve is 100% open when L-101B is in service and 100% closed when L-101A is in service.

Pipe segment 22f (B). From the flow through connection of the tee connected to pipe segments 22d and 22e, the piping travels horizontally 4m to a 90o elbow, then downwards 7.5m to a control valve station (see attached drawing detail of a control valve station). You should assume that the throttling control valve has an average opening of 50% for the purposes of sizing your pump and piping. From the control valve station the piping travels upwards 7.5m to a 90o elbow, then horizontally 5m to a 90o elbow, then horizontally 2m to a 90o elbow, then horizontally 10m to a 90o elbow, then downwards 1.5m to a 100% open gate valve, then 0.5 downwards to a 90o elbow, then horizontally 0.1m to the inlet nozzle on D-103.

SECTION C Pipe segment 31 (C). This is a gas phase stream that routes the overhead outlet streams from the D-105 pressure swing adsorption (PSA) units, which contain nearly pure hydrogen, to two destinations. One is located in another process unit of the same plant where it is consumed. The other is a high pressure product storage vessel so that it can be sold. Each of our parallel D-105 PSA units has an outlet line that contains a remotely operated block valve. Two of these four units are in service at any one time. You must size the piping to accommodate every combination of in-service and out-of-service units. All of the hydrogen from D-105 flows to two parallel compressors, G-101A/B. Only one of these units is in service at a time, so you must size the piping to accommodate both configurations. After G-101, the flow splits into two separate streams. The mass flow rates are provided on the Process Flow Diagram. Pipe segment 32 routes the hydrogen going to the other process unit while pipe segment 34 routes the hydrogen that is being pressurized for sale. Pipe segment 31a (C). This is a gas phase stream that exits the top nozzle of D-105D at 19.3 bara. From the nozzle the piping travels horizontally 2m to a 90

o elbow, then downwards 15.1m to a 90o elbow, then horizontally 0.2m to a remotely operated block valve, then horizontally 0.1m to a 90o elbow, then horizontally 4m to the flow through side connection of a tee. The side connection of this tee brings flow from D-105C (31b). The other flow side connection of this tee is pipe segment 31c. Pipe segment 31b (C). This is a gas phase stream that exits the top nozzle of D-105C at 19.3 bara. From the nozzle the piping travels horizontally 2m to a 90

o elbow, then downwards 15.1m to a 90o elbow, then horizontally 0.2m to a remotely operated block valve, then horizontally 0.1m to the side connection of the tee connected to pipe segments 31a and 31c. Pipe segment 31c (C). From the other flow through connection of the tee connected to pipe segments 31a and 31b, the piping travels horizontally 4m to the flow through side connection of a tee. The side connection of this tee brings flow from D-105B (31d). The other flow through connection is pipe segment 31e. Pipe segment 31d (C). This is a gas phase stream that exits the top nozzle of D-105B at 19.3 bara. From the nozzle the piping travels horizontally 2m to a 90

o elbow, then downwards 15.1m to a 90o elbow, then horizontally 0.2m to a remotely operated block valve, then 0.1m horizontally to the side connection of the tee connected to pipe segments 31c and 31e. Pipe segment 31e (C). From the other flow through side connection of the tee connected to pipe segments 31c and 31d, the piping travels horizontally 4m to the flow through side connection of a tee. The side connection of this tee brings flow from D-105A (31f). The piping attached to the other flow through connection is designated pipe segment 31g. Pipe segment 31f (C). This is a gas phase stream that exits the top nozzle of D-105A at 19.3 bara. From the nozzle the piping travels horizontally 2m to a 90

Pipe segment 31g (C). From the other flow through connection of the tee connected to pipe segments 31e and 31f, the piping travels horizontally 0.2m to a 90o elbow, then upwards 7.5m to a 90o elbow, then 7m horizontally to a 90o elbow, then horizontally 9m to the flow through connection of a tee. The side connection of this tee (31h) connects to the inlet nozzle of G-101A and the other flow through connection is pipe segment 31i. Pipe segment 31h (C). From the side connection of the tee connected to pipe segments 31g and 31i, the piping travels horizontally 13m to a 90o elbow, then downwards 2m to a 90o elbow, then horizontally 0.1m to a gate valve, then horizontally 0.2 m to the inlet nozzle of G-101A. This valve is 100% open when G-101A is in service and 100% closed when G-101B is in service. Pipe segment 31i (C). From the other flow through connection of the tee connected to pipe segments 31g and 31h, the piping travels horizontally 11m to a 90o elbow, then horizontally 13m to a 90o elbow, then downwards 2m to a 90o elbow, then horizontally 0.1m to a gate valve, then horizontally 0.2 m to the inlet nozzle of G-101B. This gate valve is 100% open when G-101B is in service and 100% closed when G-101A is in service. Compressor G-101A/B. There are two parallel gas compressors. When G-101A is in operation, the gate valves on pipe segments 31h and 31j are 100% closed and the gate valves on pipe segments 31i and 31k are 100% open. When G-101B is in operation, the gate valves on pipe segments 31i and 31k are 100% closed and the gate valves on pipe segments 31h and 31j are 100% open. You need to size the compressor to provide a discharge pressure such that the pressures at the end of pipe segment 34 and pipe segment 32 are both 48.0 bara. Pipe segment 31j (C). From the G-101B discharge nozzle, the piping travels horizontally 0.2m to a gate valve, then 0.2m horizontally to a 90o elbow, then upwards 2m to a 90o elbow, then horizontally 4.8m to the flow through connection of a tee. This gate valve is 100% open when G-101B is in service and 100% closed when G-101A is in service. The side connection of this tee is connected to pipe segment 31k. The other flow connection is 31l. Pipe segment 31k (C). From the G-101A discharge nozzle, the piping travels horizontally 0.2m to a gate valve, then 0.2m horizontally to a 90o elbow, then upwards 2m to a 90o elbow, then horizontally 4.8m to a 90o elbow, then 11m horizontally to the side connection of the tee connected to pipe segments 31j and 31l. This gate valve is 100% open when G-101A is in service and 100% closed when G-101B is in service. Pipe segment 31l (C). From the other flow connection of the tee connected to pipe segments 31j and 31k, the piping travels horizontally 0.2m to a 90o elbow, then downwards 7.5m to a control valve station (see attached drawing detail of a control valve station). You should assume that the throttling control valve has an average opening of 50% for the purposes of sizing your compressor and piping. From the control valve station the piping travels upwards 7.5m to a 90o elbow, then horizontally 3.5m to a 90o elbow, then horizontally 4m to the flow through connection of a tee. The side connection of this tee is pipe segment 34a. The other flow side connection of this tee is pipe segment 32.

Pipe segment 32 (C). From the flow connection of the tee connected to pipe segments 31l and 34a, the piping travels horizontally 9m to a 90o elbow, then downwards 5m to a 90o elbow then horizontally to 0.5m to a 100% open gate valve located at ground level at the pipeway. Pipe segment 34a (C). From the side connection of the tee connected to pipe segments 31l and 32, the piping travels horizontally 3.2m to a 90o elbow then downwards 7.5m to a control valve station (see attached drawing detail of a control valve station). You should assume that the throttling control valve has an average opening of 50% for the purposes of sizing your compreossor and piping. From the control valve station the piping travels upwards 7.5m to a 90o elbow, then horizontally 2.5m to a 90o elbow, then downwards 6m to the flow through connection of a tee. The side connection of this tee is pipe segment 34b and the other flow through connection is pipe segment 34c. Pipe segment 34b (C). From the side connection of the tee connected to pipe segments 34a and 34c, the piping travels horizontally 1m to a gate valve, then 1m horizontally to a 90o elbow, then downwards 0.1m to the inlet nozzle of E-109B. If E-109B is in service, the gate valve is 100% open and the gate valve on pipe segment 34c is 100% closed. If E-109A is in service, the gate valve is 100% closed and the gate valve on pipe segment 34c is 100% open. You must size your system to accommodate both cases. Pipe segment 34c (C). From the other flow connection of the tee connected to pipe segments 34a and 34b, the piping travels downwards 1.8m to a 90o elbow, then horizontally 1m to a gate valve, then horizontally 1m to a 90o elbow, then upwards 0.1m to the inlet nozzle of E-109A. If E-109A is in service, the gate valve is 100% open and the gate valve on pipe segment 34b is 100% closed. If E-109B is in service, the gate valve is 100% closed and the gate valve on pipe segment 34b is 100% open. You must size your system to accommodate both cases.

SECTION D Pipe segment 25 (D). This piping routes the overhead gas from D-103 through the E-107A/B condensers to D-104. E-107A and B are in parallel with only one in service at a time. You must size your system to handle the piping for both configurations. There is a 3 psi pressure drop in the operating E-107 unit. Pipe segment 25a (D). This is a gaseous stream starting at a pressure of 20.0 bara. From the top outlet nozzle of D-103, the piping travels 1.6m upwards to a 90o elbow, then horizontally 0.5m to a 100% open gate valve, then 15m horizontally to a 90o elbow, then 12m horizontally to a 90o elbow, then downwards 4m to the flow connection of a tee. The side connection of the tee is connected to pipe segment 25b. The other flow connection is pipe segment 25c. Pipe segment 25b (D). From the side connection of the tee connected to pipe segments 25a and 25c, the piping travels horizontally 0.1m to a gate valve, then 0.2m horizontally to the inlet nozzle of E-107B. When E-107B is in service, the gate valve is 100% open. When E-107A is in service, the gate valve is 100% closed. Pipe segment 25c (D). From the other flow connection of the tee connected to pipe segments 25a and 25b, the piping travels downwards 3.7m to a 90o elbow, then horizontally 0.1m to a gate valve, then 0.2m horizontally to the inlet nozzle of E-107A. When E-107A is in service, the gate valve is 100% open. When E-107B is in service, the gate valve is 100% closed. Pipe segment 25d (D). This is a mixed liquid/gaseous stream (hint, use liquid velocities to size your piping). The outlet nozzle of E-107A is located on the bottom of the heat exchanger. It is directly connected to a 90o elbow. From the elbow, the piping travels horizontally 0.1m to a gate valve, then 0.2m horizontally to a 90o elbow, then upwards 3.7m to the flow connection of a tee. This gate valve is 100% open when E-107A is in service and 100% closed when E-107B is in service. The side connection of the tee is connected to pipe segment 25e. From the other flow connection of this tee is pipe segment 25f. Pipe segment 25e (D). This is a mixed liquid/gaseous stream. From the outlet nozzle of E- 107B, located on the top of the heat exchanger, the piping travels upwards 0.1m to a 90o elbow, then horizontally 0.1m to a gate valve, then horizontally 0.2m to the side connection of the tee connected to pipe segments 25d and 25f. This gate valve is 100% open when E-107B is in service and 100% closed when E-107A is in service. Pipe segment 25f (D). From the other flow through connection of the tee connected to pipe segments 25d and 25e, the piping travels upwards 4m to a 90o elbow, then 7.5m horizontally to a 90o elbow, then horizontally 5m to a 90o elbow, then horizontally 3.5m to a 90o elbow, then 7m downwards to a 90o elbow, then 0.1m horizontally to a 100% open gate valve, then 0.2m horizontally to the inlet nozzle of D-104. D-104 (D). Assume there is a 5 psi pressure drop from the inlet of D-104 to both gas and liquid outlet nozzles. Note, the pressure in D-104 is set by the pressure requirements of both pipe

segments 28 and 29. Segment 28 is the overhead nozzle of D-104 and contains a gaseous stream. Segment 29 is the liquid bottoms nozzle of D-104. Pipe segment 28 (D). From the overhead outlet nozzle of D-104, the piping travels upwards 0.3m to a 100% open gate valve, then 6m upwards to a 90o elbow, then 5m horizontally to a 90o elbow, then 1m horizontally to a 90o elbow, then 7.5m downwards to a control valve station (see attached drawing detail of a control valve station). You should assume that the throttling control valve has an average opening of 50% for the purposes of sizing your system. From the control valve station the piping travels upwards 7.5m to a 90o elbow, then 22m horizontally to a 90o elbow, then downwards 7.5m to a 90o elbow, then horizontally 0.3m to a 100% open gate valve located at ground level at the entrance to the pipeway. At this point the pressure should be at least 2 bara. Pipe segment 29 (D). This piping routes the liquid from the D-104 reflux drum through the L- 104A/B reflux pumps, and then into the reflux inlet nozzle near the top of D-103. L-104A and B are in parallel and only one pump is in service at a time. You must design your system to accommodate both configurations. Pipe segment 29a (D). The outlet nozzle on the bottom of D-104 is directly connected to a 90o elbow. From the elbow the piping travels horizontally 0.3m to a 100% open gate valve, then 0.2m horizontally to a 90o elbow, then upwards 7.75m to a 90o elbow, then horizontally 5m to a 90o elbow, then horizontally 1m to a 90o elbow, then horizontally 4.5m to the flow through connection of a tee. The side connection of this tee connects to pipe segment 29c and the other flow connection begins pipe segment 29b. Pipe segment 29b (D). From the other flow through connection of the tee connected to pipe segments 29a and 29c, the piping travels horizontally 0.5m to a 90o elbow, then downwards 7.5m to a 90o elbow, then horizontally 0.2m to a gate valve, then horizontally 0.3m to inlet nozzle of L-104A. When L-104A is in service, this gate valve is 100% open. When L-104B is in service, this gate valve is 100% closed. Pipe segment 29c (D). From the side connection of the tee connected to pipe segments 29a and 29b, the piping travels downwards 7.5m to a 90o elbow, then 0.2m horizontally to a gate valve, then horizontally 0.3 m to the inlet nozzle of L-104B. When L-104B is in service, this gate valve is 100% open. When L-104A is in service, this gate valve is 100% closed. Pipe segment 29d (D). From the outlet nozzle of L-104A, the piping travels horizontally 0.2m to a gate valve, then horizontally 0.3m to a 90o elbow, then 7.5m upwards to a 90o elbow, then horizontally 0.5m to the flow through connection of a tee. The side connection of this tee is connected to pipe segment 29e while the other flow through connection is pipe segment 29f. When L-104A is in service, this gate valve is 100% open. When L-104B is in service, this gate valve is 100% closed. Pipe segment 29e (D). From the outlet nozzle of L-104B, the piping travels horizontally 0.2m to a gate valve, then horizontally 0.3m to a 90o elbow, then 7.5m upwards to the side connection of

the tee connected to pipe segments 29d and 29f. When L-104B is in service, this gate valve is 100% open. When L-104A is in service, this gate valve is 100% closed. Pipe segment 29f (D). From the other flow through connection of the tee connected to pipe segments 29d and 29e, the piping travels horizontally 4.5m to a 90o elbow, then downwards 7.5m to a control valve station (see attached drawing detail of a control valve station). You should assume that the throttling control valve has an average opening of 50% for the purposes of sizing your system. From the control valve station the piping travels upwards 7.5m to a 90o elbow, then horizontally 4m to a 90o elbow, then 9m horizontally to a 90o elbow, then downwards 3.3 m to a 90o elbow, then horizontally 0.2m to a 100% open gate valve, then 0.1m horizontally to the reflux inlet nozzle near the top of D-103. The pressure at this nozzle must be at least 23.5 bara.

SECTION E Pipe segments 26/30 (E). Pipe segment 26 is a liquid stream starting at the bottom discharge nozzle of D-103. At this point the pressure is 22.0 bara. In order to maintain a thermosyphon recycle, the pressure drop from this point through the E-108 reboilers, which vaporize part of the liquid to gas, and back through pipe segment 30 must be no more than the equivalent of the hydrostatic pressure generated by 7ft of water. Therefore, the velocity in these two segments should be at least one order of magnitude lower than the normal rule of thumb velocity. Only one of the E-108 reboilers is in service at one time. Your design should accommodate either configuration. Pipe segment 26a (E). A long radius 90o elbow is directly connected to the bottoms liquid nozzle of D-103. From this elbow the piping travels horizontally 1.5m to the flow through connection of a 45o angle tee (the side connection comes off at a 45o angle rather than 90o to reduce pressure loss). The side connection of this tee is pipe segment 26c and the other flow through connection is pipe segment 26b. Pipe segment 26b (E). From the other flow through connection of the tee connected to pipe segments 26a and 26c, the piping travels horizontally 0.6m to a gate valve, then 0.4m horizontally to the inlet nozzle of E-108A. When E-108A is in service this gate valve is 100% open. When E-108B is in service this gate valve is 100% closed. Pipe segment 26c (E). From the side connection of the 45o angle tee connected to pipe segments 26a and 26b the piping travels upwards at a 45o angle for 3.5m to a long radius 45o elbow then horizontally 1.1m to a gate valve, then 0.4m horizontally to the inlet nozzle of E-108B. When E- 108B is in service this gate valve is 100% open. When E-108A is in service this gate valve is 100% closed. Pipe segment 30a (E). This is a gaseous stream. A long radius 90o elbow is directly connected to a top nozzle on E-108A. From the elbow the piping travels horizontally 0.1m to a gate valve then 1.1m horizontally to the inlet flow through connection of a 45o angle tee. When E-108A is in service this gate valve is 100% open. When E-108B is in service this gate valve is 100% closed. The side connection of this tee is connected to pipe segment 30b and the other flow through connection to pipe segment 30c. Pipe segment 30b (E). This is a gaseous stream. A long radius 90o elbow is directly connected to a top nozzle on E-108B. From the elbow the piping travels horizontally 0.1m to a gate valve then 0.1m horizontally to a long radius 45o elbow then travels at a 45o angle downwards for 3.5m to the side inlet connection of the 45o angle tee connected to pipe segments 30a and 30c. When E-108B is in service this gate valve is 100% open. When E-108A is in service this gate valve is 100% closed. Pipe segment 30c (E). From the other flow through connection of the tee connected to pipe segments 30a and 30b, the piping travels 1.5m horizontally to the reboiler vapor return inlet nozzle on D-103.

Pipe segment 17 (E). This piping routes the bottoms liquid from the E-108a/B reboilers through pumps L-105A/B and to a tee where this pipe segment connects to pipe segments 18 and 19 (see section A for a description of these sections). You must design your pump and piping such that the pressure at this tee is 21.7 bara. Only one of the E-108 reboilers is in service at one time and the liquid experiences a 2 psi pressure drop in the operating E-108 heat exchanger. You must design your system to handle either configuration. Only one L-105 pump is in service at one time. You must design your system to handle either configuration. Pipe segment 17a (E). From the liquids outlet nozzle of E-108A, the piping travels horizontally 0.3m to a gate valve, then horizontally 0.2m to a 90o elbow, then upwards 5m to the flow through connection of a tee. The side connection of this tee is connected to pipe segment 17b and the other flow through connected is pipe segment 17c. When E-108A is in service this gate valve is 100% open. When E-108B is in service this gate valve is 100% closed. Pipe segment 17b (E). From the liquids outlet nozzle of E-108B, the piping travels horizontally 0.3m to a gate valve, then horizontally 0.2m to the side connection of the tee connected to pipe segments 17a and 17c. When E-108B is in service this gate valve is 100% open. When E-108A is in service this gate valve is 100% closed. Pipe segment 17c (E). From the other flow through connection of the tee connected to pipe segments 17a and 17b, the piping travels upwards 2.5m to a 90o elbow, then 5m horizontally to a 90o elbow, then horizontally 7.5m to the flow through connection on a second tee. The other flow through connection of this tee is connected to pipe segment 17d and the side connection is connected to pipe segment 17e. Pipe segment 17d (E). From the other flow through connection of the tee connected to pipe segments 17c and 17e, the piping travels horizontally 1m to a 90o elbow, then downwards 7.5m to a 90o elbow, then 0.2m horizontally to a gate valve, then 0.3m horizontally to the inlet nozzle of pump L-105B. When L-105B is in service, this gate valve is 100% open. When L-105A is in service, this gate valve is 100% closed. Pipe segment 17e (E). From the side connection of the tee connected to pipe segments 17c and 17d, the piping travels downwards 7.5m to a 90o elbow, then 0.2m horizontally to a gate valve, then 0.3m horizontally to the inlet nozzle of pump L-105A. When L-105A is in service, this gate valve is 100% open. When L-105B is in service, this gate valve is 100% closed. Pipe segment 17f (E). From the outlet nozzle of L-105B, the piping travels 0.2m horizontally to a gate valve, then 0.3m horizontally to a 90o elbow, then upwards 7.5m to a 90o elbow, then horizontally 1m to the flow connection side of a tee. When L-105B is in service, this gate valve is 100% open. When L-105A is in service, this gate valve is 100% closed. The side connection of this tee is connected to pipe segment 17g and the other flow connection is pipe segment 17h. Pipe segment 17g (E). From the outlet nozzle of L-105A, the piping travels 0.2m horizontally to a gate valve, then 1.3m horizontally to a 90o elbow, then 7.5m to the side connection of the tee connected to pipe segments 17f and 17h. When L-105A is in service, this gate valve is 100% open. When L-105B is in service, this gate valve is 100% closed.

Pipe segment 17h (E). From the other flow connection of the tee connected to pipe segments 17f and 17g, the piping travels 9m horizontally to a 90o elbow, then 12m horizonally to a flow connection of a second tee. The other two connections to this tee are pipe segments 17 and 18 (see section A for a description). The pressure at this point must be 21.7 bara.

Control valve and reduced piping is one standard pipe size smaller than the rest of the pipe segment

½ inch diameter drain valves, normally closed

Manually bypass line, one standard pipe size smaller than the rest of the pipe segment, 100% closed.

DIAGRAM 1. CONTROL VALVE STATION

100% open gate valves