A REPORT ON

SEMESTER LONG TERM

INTERNSHIP IN

Sigma C Process Engineering

Submitted to the Chemical Engineering Dept.

VISHWAKARMA INSTITUTE OF TECHNOLOGY, PUNE

In Partial Fulfillment of the Requirements

For the Award of the Degree of

BACHELOR OF TECHNOLOGY (CHEMICAL)

SUBMITTED BY

Nishant Deepak Nagekar

(GR. NO. 141489)

Department of Chemical Engineering

BRACT’S Vishwakarma Institute of Technology,

666, Upper Indiranagar, Bibwewadi, Pune – 411 037

May 2018

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 Bansilal Ramnath Agarwal Charitable Trust’s

VISHWAKARMA INSTITUTE OF TECHNOLOGY

(An Autonomous Institute Affiliated to University of Pune)
666, Upper Indiranagar, Bibwewadi, Pune – 411 037
December 2017

CERTIFICATE

It is certified that the project work entitled

INTERNSHIP REPORT

Submitted by

Nishant Deepak Nagekar

(G.R.NO: 141489)

is the original work carried out by them under the supervision of Prof.G.D.Gawande is
approved for the partial fulfilment of the requirement of Chemical Engineering Department,
VIT Pune, for the award of the Degree of Bachelor of Engineering (Chemical). This Project
Work has not been earlier submitted to any other Institute or University for the award of any
degree or diploma.

Prof.G.D.Gawande Prof. Dr. M. P. Deosarkar

Internal Guide Examiner Head of Department

Dept. of Chemical Engg Dept. of Chemical Engg

VIT, Pune VIT, Pune

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3|Page
 Acknowledgement

It is my great pleasure to acknowledge the assistance and contribution of the individuals who
co-operated with us to complete our project successfully. First and foremost, I wish to
express our deep gratitude and thanks to our internship guide Mr. Prashant Chavre for his
enthusiastic guidance and helping in successful completion of projects. He provided us his
precious time for valuable suggestions and encouragement throughout the work. It is for his
patience, guidance and encouragement at all the time that this work has shaped up the way it
is. A number people contributed their time and efforts in making our internship work success.
I would like to thank Prof.G.D.Gawande and my friends Shakunt Chaudhari and Abrar
Momin who contributed their time and efforts to help in completing the projects of
internship.

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 Declaration
I hereby declare that projects done under Sigma C Process Engineering is an original work
done by me under the guidance of Mr. Prashant Chavre, Marketing head of Sigma C Process
Engineering. This internship work done for the fulfillment of customer’s demand and for the
award of the degree of Bachelor of Technology in Chemical Engineering. The results
embodied in this report have not been submitted to any other University or Institute for the
award of any degree or diploma.

Nishant. D. Nagekar

B.Tech in Chemical Engineering

GR No.141489

VIT,Pune

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 Table of Contents

Sr Title Page No.

No.
1. Introduction 1

2. Literature Review 2

3. Design of Heat Exchanger 5

4. Hydrotesting 12

5. Purification of Cow Urine 14

6. Heat Exchanger for Methanol Water 16

System
7. Heating Tank Design 21

8. Sparger 27

9. Commissioning of Heating Tank 30

10. Demister Pads 33

11. Vortex Breaker 36

12. Conclusion 38

13. Appendix 39

14. References 48

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 List of Figures

Sr Title for Figure Page No.

No.
1. Various types of tube layout 3
2. Segmental Cut Baffle 4
3. Doughnut Shaped Baffle 4
4. Orifice Baffle 4
5. Cow Urine Distillation Unit 15
6. Glimpses from Commissioning at 15
Chattisgarh
7. Coils and Limpets for Tanks 22
8. Different type of Sparger 28
9. Glimpses from commissioning of the 32
Tank
10. Wire Mesh 33
11. Baffle type 34
12. Fiber bed 34
13. Types of Vortex Breaker 35
14. Formation of Vortex 36
15. Vortex Breaker after Fabrication 36

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 List of Tables

Sr No. Title for Table Page No.

1. Design Parameters for Acetone 5
Water
2. Tube Parameters for Acetone 7
Water
3. Design Parameters for 16
Methanol Water
4. Tube Parameters for Methanol 18
Water
5. Heating Tank Parameters 22
6. Tank Specifications 23
7. Overall Heat Transfer 24
Coefficient
8. Steam Velocities 25
9. Sparger Design Parameters 28

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 Abstract

Sigma C Process Engineering is established in 2015, are a highly

acclaimed Manufacturer and Service Provider of premium quality Demister Pad, Industrial
Plant, Static Mixer, Debottlenecking Services, Plant Revamping Services, Pilot Plant
Commissioning Service and many more. These products are manufactured at our spacious
infrastructure facility by using raw materials and components of the best quality. These are
manufactured in strict adherence to industry specified quality guidelines and are acclaimed for
their sturdiness, hassle free installation, durable designs and minimal servicing needs. Our
products are available to clients in different specifications of shape, size and design at budget
friendly market prices. These are highly demanded for use in various industrial applications.
Products are stringently inspected on their quality by a team of experienced professionals to
assure clients of their flawless quality and efficient performance. Our hardworking
professionals leave no stone unturned to ensure that clients get only the best products from us
on a consistent basis.

The project will be focused on design of shell and tube heat exchanger, Sparger and
Heating Tank. The main objective for all the above mentioned equipments is to achieve target
temperature by either heating or cooling the service fluid. The process may differ but the design
specifications will be provided by the clients’ side and further design will be carried out. The
following report deals with clients like Balaji Formalin, Panvel, ITC, Bhadrachalan and Cent
Pro Entp. The cow urine distillation plant was delivered to Jagdalpur, Chattisgarh. The
experience with the client interaction as well as other information for transportation is also
included. Briefing about Demister pads and Vortex Breaker is provided in this report.
Calculations of above mentioned equipments are enlisted below for reaching the desired output

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 Chapter 1
Introduction
1.1 About Sigma C
• Sigma C Process Engineering, are a highly acclaimed Manufacturer and Service
Provider of premium quality Demister Pad, Industrial Plant, Static Mixer,
Debottlenecking Services, Plant Revamping Services, Pilot Plant Commissioning
Service and many more.
• The company’s mission is to Integrate, Develop and deliver cost-effective and reliable
solutions that will maximize prosperity of our Customers, at the same time be a socially
responsible communal citizen.
• The company’s vision is “We aspire to be the most preferred organization for all clients
through efficient & accurate supply and sustainable solutions that can make the world
a better place for them”.

1.2 Work Done

The work done till date:
1. Hydro testing of cow urine plant.
2. Heat Exchanger design for acetone- water system.
3. Heat Exchanger design for methanol-water system.
4. Erection and commissioning of Cow Urine Distillation Unit at Jagdalpur, Chattisgarh.
5. Drilled pipe type Sparger be determined.
6. Heating tank with limpets design.
7. Commissioning of Heating Tank at Panvel was done at Patalganga MIDC.
8. Commissioning of heating tank at Panvel for Balaji Formalin

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 Chapter 2
Literature Review
2.1 Shell and Tube Heat Exchangers:

It is the most common type of heat exchanger in chemical processes and is suited for higher-
pressure applications. This type of heat exchanger consists of a shell with a bundle of tubes
inside it. One fluid flows through the tubes, and another fluid flows over the tubes to transfer
heat between the two fluids. The set of tubes is called a tube bundle, and may be composed of
several types of tubes: plain, longitudinally finned, etc.

Two fluids, of different inlet temperatures, flow through the heat exchanger. One flows
through the tube side and the other flows outside the tubes, i.e. shell side. Heat is transferred
from one fluid to the other through the tube walls, either from tube side to shell side or vice
versa. The fluids can be either liquids or gases on either the shell or the tube side.

Double Pipe Heat Exchanger requires large ground area, making the requirement of ground
area to Heat transfer area high. Shell and tube gives high heat transfer area in less ground area
making it efficient than DPHE.

2.2 Design Considerations:

Thermal design of a shell and tube heat exchanger typically includes the determination of
heat transfer area, number of tubes, tube length and diameter, tube layout, number of shell and
tube passes, type of heat exchanger (fixed tube sheet, removable tube bundle etc), tube pitch,
number of baffles, its type and size, shell and tube side pressure drop.

2.2.1 Shell

Shell is the container for the shell fluid and the tube bundle is placed inside the shell. Shell
diameter should be selected in such a way to give a close fit of the tube bundle. The clearance
between the tube bundle and inner shell wall depends on the type of exchanger. Shells are
usually fabricated from standard steel pipe with satisfactory corrosion allowance.

2.2.2 Tube

The most efficient condition for heat transfer is to have the maximum number of tubes
in the shell to increase turbulence. The tube thickness should be enough to withstand the
internal pressure along with the adequate corrosion allowance. The tube thickness is expressed
in terms of BWG (Birmingham Wire Gauge) and true outside diameter (OD).

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2.2.3 Tube Layouts and Tube Pitch

Heat exchanger tubes are also known as condenser tubes. Tube pitch is the shortest
centre to centre distance between the adjacent tubes. The number of tubes that can be
accommodated in each shell ID is called tube count. The tube count depends on the factors like
shell ID, OD of tube, tube pitch, tube layout, number of tube passes, type of heat exchanger
and design pressure.

Fig 2.1 Various types of tube layout

2.2.4 Tube Passes

The number of passes is chosen to get the required tube side fluid velocity to obtain
greater heat transfer co-efficient and to reduce scale formation. The tube passes vary from 1 to
16. The tube passes of 1, 2 and 4 are common in application. The partition built into exchanger
head known as pass partition is used to direct the tube side flow.

The Appendix 1 and 2 is obtained from Process Heat Transfer by Donald Q Kern. This are
widely used for calculation purpose in Shell and Tube Heat Exchangers.

2.2.5 Baffle
It is seen that high heat transfer coefficients are achieved when fluid is in state of
turbulence. This work is done by baffles in shell side of the heat exchanger. Even small quantity
of fluid is brought in state of turbulence because of baffle. These also provide support to the
tube bundle. Centre to centre distance between baffles is called Baffle Spacing. Closer baffle
spacing gives greater transfer co-efficient by inducing higher turbulence. The pressure drop is
more with closer baffle spacing. Various types of baffles are shown below. A baffle cut of 20
to 25% provide a good heat-transfer with the reasonable pressure drop.

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 Fig 2.4 Segmental Cut Baffle

Fig 2.5 Doughnut Shaped Baffle

Fig 2.6 Orifice Baffle

2.2.6 Fouling Considerations

The effect of fouling is considered in heat exchanger design by including the tube side
and shell side fouling resistances. The material deposited reduces the effective heat transfer
rate due to relatively low thermal conductivity. This leads to poor performance of heat
exchanger, increased maintenance cost and energy consumption due to poor performance.
Appendix 3 show values to be taken into considerations while calculations.

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 Chapter 3
Design of Heat Exchanger

Product Name: Shell and Tube Heat Exchanger

Client Name: Cent Pro Entp

3.1 Problem Statement

We wish to reduce the temp of acetone coming from a stream at 55 0C by 8 to 15 0C at 0.5-1

bar pressure. Flowrate of acetone is 10 m3/hr. Design a suitable equipment for the given
requirements. Designing of Shell and Tube Heat Exchanger for Acetone-Water System.
Acetone is to be cooled with help of water. As acetone is at higher side of temperature it is
passed through tube side while cooling water flows though the shell. The following is the data
which is necessary for design point of view:

Table 3.1 Design Parameters

Parameters Shell Side Tube Side

Fluid Name Cooling Water Acetone
Density (lb/ft3) 62.54 51.64
Inlet Temp. (oF) 80.6 131
Outlet Temp (oF) 95 113
Mean Temp (oF) 87.8 122
Viscosity (cP) 1 0.25
Flowrate (lb/hr) ? 18232
The mean temperature for shell side fluid is 87.8 oF and 122 oF for tube side fluid. The flowrate
of the utility is to be determined and hence it is unknown parameter. The cooling water is taken
in at room temperature taking cost into picture.

3.2 Consideration of Arithmetic Mean Temperature

There are basically 2 types of temperature consideration first being Arithmetic Mean
Temperature and Calorific Temperature. The Calorific Temperature is considered only when
viscosity varies largely with temperature. This can be studied using viscosity temperature
charts available in literature properties of that compound. The process for calorific temperature

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is rather complex and time consuming and hence avoided and considered when accuracy is to
be increased. The physical properties at that temperature are determined to use them for further
calculations.

Table 3.2 Fluid Parameters

Parameters Shell Side Tube Side

Viscosity (lb/ft.hr) 1.92 0.604
Thermal Condu.(BTU/hr.ft.oF) 0.358 0.091
o
Heat Capacity (BTU/lb.ft. F) 1 0.55
Thermal Condu. Of MOC(BTU/hr.ft.oF) 70

3.4 Logarithmic Mean Temperature Difference

It is used when overall system is taken into consideration. This varies according to
nature of the flow whether it is counter current or parallel flow. The temperature difference of
one side of heat exchanger and same for other side is incorporated. The formula being:

(𝑇ℎ𝑖 − 𝑇𝑐𝑜) − (𝑇ℎ𝑜 − 𝑇𝑐𝑖)

𝐿𝑀𝑇𝐷 =
(𝑇ℎ𝑖 − 𝑇𝑐𝑜)
𝑙𝑛
(𝑇ℎ𝑜 − 𝑇𝑐𝑖)

The correction factor FT comes into picture while calculation of LMTD in case of Heat
Exchanger. This is a thumb rule to incorporate FT in case of shell and tube heat exchanger and
cross flow patterns. The Value can be determined using Appendix 4. The parameters needed
are R and S which can be determined by following formula:

(𝑇ℎ𝑖−𝑇ℎ𝑜) (𝑇𝑐𝑜−𝑇𝑐𝑖)
𝑅= 𝑆=
(𝑇𝑐𝑜−𝑇𝑐𝑖) (𝑇ℎ𝑖−𝑇𝑐𝑖)

Once values of R and S are determined, we can use fig 18 to deduce value of FT

Value of R and S for this system is 1.25 and 0.285. The corresponding value for FT is 0.98. The
corrected LMTD is 33.48 oF.

3.5 Heat Transferred and Utility flowrate

We know that utility flowrate can be calculated by using the common heat equation at
ideal condition. At ideal conditions, the heat transferred will be equal to heat gained. The
following equations were used for calculations:

𝑄ℎ = 𝑚ℎ ∗ 𝐶𝑝ℎ ∗ ∆𝑇ℎ

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 =18232*0.55*(131-113)

𝑄𝑐 = 𝑚𝑐 ∗ 𝐶𝑝𝑐 ∗ ∆𝑇𝑐

𝑚𝑐 = 12534 𝑙𝑏/ℎ𝑟

As the parameters for Hot fluid are known, we can calculate Qh. And substituting values in 2nd
equation we get mass flowrate of the utility. The values of Qh and mc are 180496 BTU/hr and
12534 lb/hr.

3.6 Assumption of Overall Heat Transfer Coefficient

A value of OHTC is assumed according to fluid system you are handling. There are
various values for variety of system used in industry. This step is important as the value
calculated should correspond to the value assumed. This tells us if the exchanger is allowable
for service or not. Appendix 5 gives us the idea of value that must be assumed.

This system falls under Light Organics and Water system. The range is 75-150 BTU/lb.ft2.oF.
the assumed value is 100 BTU/lb.ft2.oF.

3.7 Calculation of Number of Tubes

We assume 1-2 Heat exchanger and lookout for tube dimensions and other parameters.
This is trial and error method and hence we might have to change the dimension depending on
the Reynolds Number. We must check that Reynolds Number should be greater than 104. This
justifies that the dimensions selected are correct for the service. We must check Fig 2.2 and 2.3
for tube data. According to this assumption, we have following data:

Table 3.2 Tube Parameters

Pitch (in) 1.25

Tube OD (in) 1

Tube Length (ft) 16

Tube ID (in) 0.834

Surface per lin ft,ft2 (in) (OD) 0.2618

(ID) 0.2138

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The surface per linear feet value is taken at 14 BWG tube as it is considered ideal for most
conditions. We can calculate overall are by: 𝑄ℎ = 𝑈 ∗ 𝐴 ∗ ∆𝑇m.

A= 180496/(100*33.48)= 53.91 ft2

The value of area is 53.91 ft2. Hence, we can further calculate no. of tubes by the formula:

𝐴 53.91
𝑁𝑡 = 𝜋∗𝐷𝑜∗𝐿 = 1 =13
𝜋∗( )∗16
12

The number of tubes obtained are 13. But according to Fig 2.3 we can see that there are
minimum 16 tubes available for 2 Tube side passes. Hence, we assume 16 units of tubes. The
Shell ID corresponding to this value is 8 inches.

3.8 Tube Side Heat Transfer Coefficient

The first thing to be done during this step is to check that Reynolds Number is higher
than 104. If it exceeds the value, the we can assume that we have correct dimensions. If not,
then we must assume different set of parameters.

The formula for Reynolds Number is:

𝑁𝑝 2
4∗𝑚ℎ∗( ) 4∗18232∗( )
𝑁𝑡 16
𝑅𝑒 = = 0.834 = 65159
𝜋∗𝐷𝑖∗𝜇 𝜋∗ ∗0.604
12

Reynolds Number after Calculation is 69159, which is higher than 104. So, the assumed tube
parameters are acceptable. The tube side heat transfer coefficient can be calculated by
following equation:

ℎ𝑖 𝑑𝑖 𝞵ℎ 𝐶ℎ 1 𝞵 −0.14
𝑗ℎ = ( )3 ( )
𝑘 𝑘ℎ 𝞵𝑤

jh which can be calculated from appendix 6, Reynolds number plays vital role in this
calculation. The ratio of viscosity of fluid to that of wall is always taken as unity.

Value of jh from graph is 200. Hence, we have all parameters to calculate hi. The value of hi is
403.2 BTU/hr.ft.oF.

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3.9 Shell Side Heat Transfer Coefficient

We assume 25% Cut Segmental Baffle, as it is used ideally for various services around
the world. Baffle Spacing is 50% of Shell ID and is 4 in. We need to calculate Equivalent
Diameter by following formula:

𝜋
4 ∗ (𝑃𝑡 2 − ( 4) ∗ 𝐷𝑜2 )
𝐷𝑒 =
𝜋 ∗ 𝐷𝑜
𝐶∗𝐵∗𝐷𝑠
Area can be Estimated as where C is tube clearance (Pitch – OD of tube). Value of
𝑃𝑡
𝐺𝑠∗𝐷𝑒
De and area is 0.0825 ft and 0.0448 ft2. The Reynolds no can be estimated by 𝑅𝑒 = .
𝜇𝑐

Where Gs is mass velocity and value being 279787.9 lb/ft.hr. The value of Re is 12095. We
can estimate jh from the appendix 8 and value is 38. The Shell side Heat Transfer Coefficient
can be estimated by:

ℎ𝑜 𝑑𝑒 𝞵𝑐 𝐶𝑐 1 𝞵 −0.14
𝑗𝑐 = ( )3 ( )
𝑘 𝑘𝑐 𝞵𝑤

The value of Shell Side Heat Transfer Coefficient is 288.5 BTU/ft.hr.oF.

3.10 Verification of Overall Heat Transfer Coefficient

As we obtained value of Heat Transfer Coefficients for shell side and tube side, we can
determine the overall heat transfer coefficient. Here, the thermal conductivity of material of
construction is to be known. For this service, Brass is selected as MOC. The thermal
conductivity is 70 BTU/hr.ft.oF. This is denoted as Kw. The dirt Factor for shell side is 0.001
and 0.0005 hr.ft2.oF/BTU. This are denoted as Rdh and Rdc respectively. The overall heat
transfer coefficient can be calculated by:

1 𝐴𝑜 𝑑𝑜 − 𝑑𝑖 𝐴𝑜 1 𝐴𝑜
𝑈𝑎,𝑐𝑎𝑙𝑐 = [ + 𝑅𝑑ℎ + ( )+ ( )+ 𝑅𝑑𝑐]−1
ℎ𝑜 𝐴𝑖 2𝑘𝑤 𝐴𝑖 ℎ𝑖 𝐴𝑖

The value obtained is 95.64 BTU/hr.ft2.oF. This value is close to value assumed i.e. 100 and
error is less than 30%. Hence, this heat exchanger is acceptable.

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3.11 Pressure Drop Calculation

We must determine the pressure drop on both shell side and tube side. For shell side,
pressure drop can be calculated from the formula below:

𝑓 ∗ 𝐺𝑠2 ∗ 𝐷𝑠 ∗ (𝑁 + 1)
∆𝑃 =
5.22 ∗ 1010 ∗ 𝐷𝑒 ∗ 𝑆 ∗ 𝜑𝑡

S is specific Gravity and can be calculated using oAPI and Arithmetic mean temperature.

o
API for water is 10. From Appendix 7, we can estimate the value of S.

Value of S is 1. 𝜑𝑡 is assumed as 1. Value of friction factor can be found out by f vs Re graph.

As we know the Re we can find the value of f from the Appendix 8

Value of friction factor from this graph is 0.002. As all parameters are known, ∆𝑃 can be
estimated as 1.18 psi.

The same way pressure drop across tube side can be estimated by the formula:

𝑓 ∗ 𝐺𝑡2 ∗ 𝐿 ∗ 𝑛
∆𝑃 =
5.22 ∗ 1010 ∗ 𝐷𝑜 ∗ 𝑆 ∗ 𝜑𝑡

Table 3.3 Tube & Shell Side ∆𝑷

Tube side
Shell Side
F 0.000175
F 0.002
φ 1
φ 1
API Gravity 40
API Gravity 10 S 0.825
Specific Gravity S 1 no of passes 2
no. of crosses 48 flow area per tube(in2) 0.515
C 0.25 at 0.0286111
as (ft2) 0.044444444 Gt 637234.95
Gs(lb/hrft2) 282026.25
∆P (psi) 0.6336421
∆P (psi) 1.181514461 Return loss (psi) 0.1641501

total pressure drop (psi) 0.7977921

Here value of S is estimated as 0.8. The value of friction factor is estimated as 0.000175. Here,
𝑚ℎ 𝑛𝑡 ∗𝑓𝑙𝑜𝑤 𝑎𝑟𝑒𝑎 𝑝𝑒𝑟 𝑡𝑢𝑏𝑒
𝐺𝑡 = where 𝑚ℎ is mass flowrate of hot fluid and 𝑎𝑡 = . 𝑛𝑡 is number
𝑎𝑡 𝑛𝑜. 𝑜𝑓 𝑝𝑎𝑠𝑠𝑒𝑠

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of tubes. Flow area per tube can be estimated from surface area per linear feet and length which
is 0.515 in2. Hence, 𝑎𝑡 is 0.028 ft2. Hence, value of 𝐺𝑡 can be estimated as 637234.9 lb/hr.ft2.

As all parameters are known we can estimate the pressure drop as 0.633 psi. But as this tube
side has 2 passes, we must incur the return loss. The formula for return loss is

𝐺𝑡2
∆𝑃𝑟 =1.334*10−13 ∗ (2 ∗ 𝑛𝑝 − 1.5) ∗
𝑆

Here, 𝑛𝑝 is number of passes. As we know the parameters in the equation, return loss is
calculated as 0.164 psi. hence, the total pressure drop across tube side is given by ∆𝑃 =
∆𝑃𝑡 +∆𝑃𝑟 . The total pressure drop is 0.8 psi.

The values for both tube side and shell side are less than 10 psi, hence heat exchanger is
acceptable.

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 Chapter 4
Hydro Testing
4.1 Concept

Hydrotesting is procedure carried out in design industry to test a vessel or equipment if

it can withstand pressure. This is even called Hydrostatic testing. The test involves filling the
vessel or pipe system with a liquid, usually water, which may be dyed to aid in visual leak
detection, and pressurization of the vessel to the specified test pressure. Pressure tightness can
be tested by shutting off the supply valve and observing whether there is a pressure loss. The
location of a leak can be visually identified more easily if the water contains a colorant.

4.2 Testing Procedure

Hydrostatic tests are conducted under the constraints of either the industry's or the
customer's specifications, or may be required by law. The vessel is filled with a nearly
incompressible liquid - usually water or oil - pressurised to test pressure, and examined for
leaks or permanent changes in shape. Red or fluorescent dyes may be added to the water to
make leaks easier to see. The test pressure is always considerably higher than the operating
pressure to give a factor of safety. This factor of safety is typically 166.66%, 143% or 150%
of the designed working pressure, depending on the regulations that apply. Hydraulic fluids
and oils may be specified where contamination with water could cause problems. These fluids
are nearly incompressible, therefore requiring relatively little work to develop a high pressure,
and are therefore also only able to release a small amount of energy in case of a failure - only
a small volume will escape under high pressure if the container fails. If high pressure gas were
used, then the gas would expand with its compressed volume resulting in an explosion, with
the attendant risk of damage or injury.

If the vessel withstands the pressure without any leakage or reduction in pressure, the
vessel is said to be allowable for service. The flaws if any during hydrotest are to be
immediately taken care as it may damage the vessel if directly put in service. The hydrotested
vessel may be taken due to customers requirement or by the law. Most pressure vessel like
boiler are to be tested for its strength and pressure it can withstand. The cracks and leakages in
vessel may lead to damage and loss of property.

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4.3 Precautions to be taken during test

1. The person handling the task should wear protective wares in case of failure.
2. The pressure in the equipment’s should be raised gradually and slowly. In case of
sudden rise in pressure, the pressure gauge may get damaged.
3. The mechanical seals should be present during the test as sudden increase in
pressure will rupture it and will not damage the equipment.

4. A leak of high pressure liquid can cut or penetrate the skin and inject itself into
body tissues. This can cause serious direct injury to the operator, and if the fluid is
toxic or contaminated there will be additional adverse effects.

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 Chapter 5
Purification of Cow urine

Product Name: Cow Urine Distillation System

Client Name: Murarka Enterprises, Jagdalpur, Chattisgarh

5.1 Operating of plant

1. Fill the bottom tank with water and the vertical tank with cow urine.

2. Water is heated with the help of electrical heater. Cow urine is getting heated with
this heated water.

3. It can heat until the first drop of purified urine appears in the condenser.

4. Temp. controller is set at the boiling point of cow-urine.

5. As temperature reaches to boiling point valve of heat exchanger is opened for

releasing ammonia and other residues to remove them for 15-20 mins.

6. Distilled urine is collected from bottom of heat exchanger.

7. Solids are removed from vertical as all the urine is evaporated.

5.2 Precautions

1. Please ensure that there is no leakage in the plant.

2. All valves should be closed properly before implementation.
3. Check the pressure of tanks at regular intervals.
4. Drain the vertical tank when all urine is evaporated.
5. Cleaning should be done in every 8 days using Nirma and hot water

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 Fig 5.1 Cow Urine Distillation Unit

Fig 5.2 Glimpses from Commissioning at Chattisgarh

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 Chapter 6
Heat Exchanger for Methanol Water System

Product Name: Shell and Tube Heat Exchanger

Client Name: Balaji Formalin, Panvel

6.1 Problem Statement and Background

We wish to reduce the temp of acetone coming from a stream at 150 0F by 8 to 120 0F
. Flowrate of acetone is 20000 lb/hr. Design a suitable equipment for the given requirements.
The heat exchanger previously designed was an Acetone-Water System. This heat exchanger
has service of Methanol to be cooled with the help of water. The product is formaldehyde and
byproduct is methanol. Methanol is cooled and used as a raw product for formaldehyde. This
was the main objective of the client company to cool the methanol to the target temperature so
it can be stored and used as a raw material after the process runs for another cycle. The literature
review is same as that of Acetone-Water System designed above. The procedure and other
calculations are also like above system as well. Below mentioned will be the different
properties and other parameters that differ from the above calculated system.

6.2 Calculations of Heat Exchanger

Here methanol is at higher side of temperature so is passed through tube side and
cooling water is passed through shell side. The following data is necessary for design point of
view:

Table 6.1 Design Parameters

Parameters Shell Side Tube Side

Fluid Name Cooling Water Methanol
Density (lb/ft3) 62.54 46
Inlet Temp. (oF) 80 150
Outlet Temp (oF) 100 120
Mean Temp (oF) 90 135
Viscosity (cP) 0.6 0.95
Flowrate (lb/hr) ? 20000

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Table 6.2 Fluid Parameters

Parameters Shell Side Tube Side

Viscosity (lb/ft.hr) 0.6 0.96
Thermal Condu.(BTU/hr.ft.oF) 0.36 0.0095
o
Heat Capacity (BTU/lb. F) 1 0.3745
o
Thermal Condu. Of MOC(BTU/hr.ft. F) 70

The Viscosity and density are calculated at the mean temperature of the respective fluid. The
mean temperature for shell side fluid is 90 oF and 135 oF for tube side fluid. Counter Current
Flow is assumed and LMTD is calculated as 44.81 oF.

From R and S graphs we get Correction Factor as 43.46 oF. As Viscosity of fluid does not vary
largely with respect to temperature, we go with arithmetic mean temperature.

6.3 Heat Transfer Coefficient Calculation for both sides

We know that utility flowrate can be calculated by using the common heat equation at
ideal condition. At ideal conditions, the heat transferred will be equal to heat gained. The
following equations were used for calculations:

𝑄ℎ = 𝑚ℎ ∗ 𝐶𝑝ℎ ∗ ∆𝑇ℎ

Qh=20000*0.376*(150-120)

𝑄𝑐 = 𝑚𝑐 ∗ 𝐶𝑝𝑐 ∗ ∆𝑇𝑐

224700
𝑚𝑐 = 1∗(100−80) = 11235 lb/hr

As the parameters for Hot fluid are known, we can calculate Qh. And substituting values in 2nd
equation we get mass flowrate of the utility. The values of Qh and mc are 224700 BTU/hr and
11235 lb/hr. Overall Heat Transfer Coefficient is assumed from table to be 50 BTU/lb.ft2.oF.
Area is calculated to be 103.3 ft2.

Tube calculations start with assumptions of type of heat exchanger and tube selection
is done accordingly. Here, we assume 1-4 Heat Exchanger. Following is the data that is
assumed:

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Table 6.2 Tube Parameters

Pitch (in) 1.25 0.104167 ft

Tube OD (in) 1 0.083333 ft
Tube Length (ft) 16 1.333333 ft
Tube ID (in) 0.834 0.0695 ft
Surface per lin ft,ft2 (in) 0.2618 OD
0.2183 ID

The surface per linear feet value is taken at 14 BWG tube as it is considered ideal for most
conditions. We can calculate overall are by: 𝑄ℎ = 𝑈 ∗ 𝐴 ∗ ∆𝑇m.

224700
𝐴= = 103.3 𝑓𝑡 2
50 ∗ 44.81

𝐴 103.3
𝑁𝑡 = = = 25
𝜋 ∗ 𝐷𝑜 ∗ 𝐿 𝜋 ∗ ( 1 ) ∗ 16
12

Number of tubes calculated are 24.6. But according to the table no. 9 we have the closest
number that happens to be 26.

𝑁𝑝
4∗𝑚ℎ∗( )
𝑁𝑡
Reynolds number can be calculated by 𝑅𝑒 = . The value obtained is 58747.7 which
𝜋∗𝐷𝑖∗𝜇

is higher than 104. This value is acceptable. Value of jh from jh v/s Re graph is 200. The Tube
ℎ𝑖 𝑑𝑖 𝞵ℎ 𝐶ℎ 1 𝞵
Side Heat Transfer Coefficient can be calculated as: 𝑗ℎ = ( )3 (𝞵 )−0.14 . The value
𝑘 𝑘ℎ 𝑤
o
obtained is 91.78 BTU/hr.ft. F. Assuming 25% cut baffle for shell side, we get Re to be 22078.8
and from jh v/s Re we get jh as 65. Shell side heat transfer coefficient is calculated to be 336.13
BTU/ft.hr.oF. The Overall heat transfer coefficient can be calculated by:

1 ′
𝐴𝑜 𝑑𝑜 − 𝑑𝑖 𝐴𝑜 1 𝐴𝑜 ′ −1
𝑈𝑎,𝑐𝑎𝑙𝑐 = [ + 𝑅𝑑ℎ + ( )+ ( )+ 𝑅 ]
ℎ𝑜 𝐴𝑖 2𝑘𝑤 𝐴𝑖 ℎ𝑖 𝐴𝑖 𝑑𝑐

The value obtained is 45.23 BTU/ft.hr.oF. The obtained value is near about same to that
assumed so the design is acceptable.

6.4 Pressure Drop Calculations

We must determine the pressure drop on both shell side and tube side. For shell side,
pressure drop can be calculated from the formula below:

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 𝑓 ∗ 𝐺𝑠2 ∗ 𝐷𝑠 ∗ (𝑁 + 1)
∆𝑃 =
5.22 ∗ 1010 ∗ 𝐷𝑒 ∗ 𝑆 ∗ 𝜑𝑡

S is specific Gravity and can be calculated using oAPI and Arithmetic mean temperature.

o
API for water is 10. From graph 3.4, we can estimate the value of S.

Value of friction factor graph f v/s Re is 0.002. As all parameters are known, ∆𝑃 can be
estimated as 0.388 psi.

The same way pressure drop across tube side can be estimated by the formula:

𝑓 ∗ 𝐺𝑡2 ∗ 𝐿 ∗ 𝑛
∆𝑃 =
5.22 ∗ 1010 ∗ 𝐷𝑜 ∗ 𝑆 ∗ 𝜑𝑡

Table 3.3 Tube & Shell Side ∆𝑷

Tube side
Shell Side
F 0.0002
F 0.002
φ 1
φ 1 API Gravity 57.166667
API Gravity 10 S 0.75
Specific Gravity S 1 no of passes 4
flow area per tube(in2) 0.515
no. of crosses 38.4
at 0.0232465
C 0.25 Gt 860343.54
as (ft2) 0.069444444 ∆P (psi) 4.7190722
Gs(lb/hrft2) 161784 Return loss (psi) 0.7779632
total pressure drop (psi) 5.4970353
∆P (psi) 0.388804349

Here value of S is estimated as 0.75. The value of friction factor is estimated as 0.0002. Here,
𝑚ℎ 𝑛𝑡 ∗𝑓𝑙𝑜𝑤 𝑎𝑟𝑒𝑎 𝑝𝑒𝑟 𝑡𝑢𝑏𝑒
𝐺𝑡 = where 𝑚ℎ is mass flowrate of hot fluid and 𝑎𝑡 = . 𝑛𝑡 is number of
𝑎𝑡 𝑛𝑜. 𝑜𝑓 𝑝𝑎𝑠𝑠𝑒𝑠

tubes. Flow area per tube can be estimated from surface area per linear feet and length which
is 0.515 in2. Hence, 𝑎𝑡 is 0.023 ft2. Hence, value of 𝐺𝑡 can be estimated as 860343.54 lb/hr.ft2.

As all parameters are known we can estimate the pressure drop as 4.711 psi. But as this tube
side has 4 passes, we must incur the return loss.

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The formula for return loss is

𝐺𝑡2
∆𝑃𝑟 =1.334*10−13 ∗ (2 ∗ 𝑛𝑝 − 1.5) ∗ 𝑆

Here, 𝑛𝑝 is number of passes. As we know the parameters in the equation, return loss is
calculated as 0.777 psi. hence, the total pressure drop across tube side is given by ∆𝑃 =
∆𝑃𝑡 +∆𝑃𝑟 . The total pressure drop is 5 psi.

The values for both tube side and shell side are less than 10 psi, hence heat exchanger is
acceptable.

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 Chapter 7
Heating Tank Design

Product Name: Shell and Tube Heat Exchanger

Client Name: Balaji Formalin, Panvel

7.1 Problem Statement and Background

Calculate the number of limpets for heating the tank for capacity of 3.5 m3/hr. The
target temperature is 138 oC. The water is an important utility in industry. This is needed at
various temperatures as per requirement. The same arrived at Balaji Formalin, Panvel. The
requirement was to heat a tank of capacity of 3.5 m3. The heating medium used was steam. The
coils were eliminated ad limpets are used instead. Limpets are coil cut into half. A coil makes
2 limpets. The insulation was to be wrapped around the limpets. The purpose for heating tank
water was not specified or revealed by the company because of its restriction to their design
aspects. The target temperature was to be achieved and hence a control valve was provided at
the inlet for precise inlet of steam. The valve was pneumatically operated. This was under the
scope of the provisions that come with the design as well as commissioning.

Water heating is a heat transfer process that uses an energy source to heat water above
its initial temperature. Typical domestic uses of hot water include cooking, cleaning, bathing,
and space heating. In industry, hot water and water heated to steam have many uses. These
metal vessels that heat a batch of water do not produce a continual supply of heated water at a
present temperature. Rarely, hot water occurs naturally, usually from natural hot springs. The
temperature varies with the consumption rate, becoming cooler as flow increases.

Appliances that provide a continual supply of hot water are called water heaters, hot
water heaters, hot water tanks, boilers, heat exchangers, geysers, or calorifiers. These names
depend on region, and whether they heat potable or non-potable water, are in domestic or
industrial use, and their energy source. In domestic installations, potable water heated for uses
other than space heating is also called domestic hot water (DHW).

Fossil fuels (natural gas, liquefied petroleum gas, oil), or solid fuels are commonly used
for heating water. These may be consumed directly or may produce electricity that, in turn,
heats water. Electricity to heat water may also come from any other electrical source, such

21 | P a g e
as nuclear power or renewable energy. Alternative energy such as solar energy, heat
pumps, hot water heat recycling, and geothermal heating can also heat water, often in
combination with backup systems powered by fossil fuels or electricity. Tank coils are not
generally used for the continuous heating or cooling of a flowing stream, but are usually applied
in the heating or cooling of a liquid contained in a tank on a batch basis. The flow of heat into
or out of the liquid, involves unsteady or transient heat transfer. The heating and cooling media
can flow through a coil immersed in the liquid as shown in or the media can be made to flow
through a coil fastened (welded) on the outside of the vessel as shown in figure. The latter
arrangement may be referred to as "limpet coils" whereas the former is usually termed "coil in
tank". The limpet coil is an improvement on the simple arrangement where a jacket through
which the heat transfer medium flows, fits onto the outside of the vessel as illustrated in figure.
The benefits of the limpet coil are due to the uniform fluid velocity through the channel and
the good distribution of heat transfer medium around the vessel periphery.

Fig 7.1 Coils and Limpets for Tanks

7.2 Design Parameters

The system is Water-Steam system. The water is stored in tank which is heated with
the help of limpets through which steam flows. The following primary parameters were taken
into considerations:

Table 7.1 Heating Tank Parameters

Parameters Shell Limpets

Service Water Steam
Cp (KJ/kg.K) 4.187 1.91

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 Inlet Temp (oC) 38 138
Outlet Temp (oC) 95 95
The operating pressure for the shell side is 1.01 bar and for limpet’s side it is 3.5 bar. The tank
parameters provided by company were listed below

Table 7.2 Tank Specifications

Tank Dia (m) 1.1

Tank Length (m) 3.75
Tank Capacity (m3) 3.5
MOC of Shell/Limpet MS

7.3 Heat Duty and Area Calculations

The heat required to heat the tank needs to be calculated. This can be calculated by
simple heat equation:

𝑄ℎ = 𝑚ℎ ∗ 𝐶𝑝ℎ ∗ ∆𝑇

= 10000 ∗ 4.187 ∗ (95 − 38) = 232.02 𝐾𝑊

Here, mass flowrate can be altered to capacity of the tank as this is stationary fluid and is batch
process. The alteration can be done using density of water i.e. 1000 kg/m3. The heat duty
calculated as 835306.5 KJ that can be converted to 232.02 KW.

The area calculations can be done assuming the whole system. This takes into picture
the Overall Heat transfer coefficient. The overall heat exchanged can be calculated by:

𝑄ℎ = 𝑈 ∗ 𝐴 ∗ ∆𝑇m1

232.02 ∗ 103
𝐴= = 4.32 𝑚2
750 ∗ 71.5

Where, ∆𝑇m1= Ts-Tm

Tm is Mean Temp. of Liquid

Ts is Steam Inlet Temp.

U is assumed according to Table on the next page.

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Table 7.3 Overall Heat Transfer Coefficient

The value of Overall Heat Transfer coefficient should be between 550-1300 W/m2.oC. So, the
value assumed is 750 W/m2.oC. The value of ∆Tm1 is 71.5 oC. As all parameters are known
area can be calculated to 4.32 m2. But for design purpose we assume 15% more of the value
obtained. So, the value assumed is 5 m2.

7.4 Heating Capacity and Steam flowrate calculations

The heating capacity of coil is required to be calculated as it gives the estimate of the
capacity of coil to provide the amount of heat to the tank. The heating capacity of coil can be
calculated by:

𝑄 𝑐𝑜𝑖𝑙 = 𝑈 ∗ 𝐴 ∗ ∆𝑇m2

= 750 ∗ 4.32 ∗ 100 = 375 𝐾𝑊

Where, ∆𝑇m2 is Ts-Tm

Tm is Water Inlet Temperature

Ts is Steam Inlet Temperature

The maximum heating capacity calculated from the formula above is 375 KW. This is amount
of heat that will be provided by the steam to reach the target temperature.

The steam flowrate required to deliver the heating capacity can be calculated by:

𝑄𝑐𝑜𝑖𝑙∗3600
Steam Flowrate = = 375*3600/2147.7
𝐸𝑛𝑡ℎ𝑎𝑙𝑝𝑦 𝑜𝑓 𝐸𝑣𝑎𝑝𝑜𝑟𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟

= 628.63 kg/hr

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The enthalpy can be taken as 2147.7 KJ. This value can be determined from the steam table.
Therefore, all the parameters are known in the formula and the steam flowrate can be calculated
as 628.63 kg/hr.

7.5 Limpets Calculations

The most important parameter taken into consideration during limpet calculations is
steam velocity. The velocity is chosen from the table below.

Table 7.4 Steam Velocities

The Steam Velocity is taken in range of 30-40 m/s as the pressure is medium to low. The value
assumed is 40 m/s. The specific volume from steam table for this particular pressure is 0.524
m3/kg.

The Diameter of the limpets is dependent on the steam velocity and can be calculated by:

𝜋
𝐷2 = 𝑆𝑡𝑒𝑎𝑚 𝐹𝑙𝑜𝑤𝑟𝑎𝑡𝑒 ∗ 𝑆𝑝. 𝑉𝑜𝑙𝑢𝑚𝑒/(3600 ∗ ∗ 𝑆𝑡𝑒𝑎𝑚 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦)
4

628.63 ∗ 0.524
= 𝜋 = 2809
3600 ∗ ( 4 ) ∗ 40

D = 53 mm

As all the parameters are known in the formula, diameter is calculated as 53 mm. Due to size
availability, 50 mm is used. The length of the coil can be estimated by use of calculated
diameter and heat transfer area by:

𝐻𝑒𝑎𝑡 𝑇𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝐴𝑟𝑒𝑎 4.32

𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝐶𝑜𝑖𝑙 = = = 31.28
𝜋 ∗ 𝐷𝑖𝑎 (𝜋 ∗ 0.05)

The length of the coil is estimated as 31.28 m. This approximate value of 32 m is used. We can
estimate the length of one coil by:

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 𝐻. 𝑇. 𝐴𝑟𝑒𝑎 4.32
𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑜𝑛𝑒 𝑐𝑜𝑖𝑙 = = = 1.444
2∗𝜋∗𝑟 2∗𝜋∗1

The length of one coil is estimated as 1.44m. So, number of coils will be approximately 22
units. But as we are using limpets, coil is cut into half. So, the number of limpets will be 44
units. Therefore, to reach target temperature for 3.5 m3 capacity water tank is to be heated using
44 limpet coil carrying steam.

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 Chapter 8
Sparger Design

Product Name: Drilled Pipe Sparger

Client Name: ITC, Bhadrachalan

8.1 Introduction

A leak of high pressure liquid can cut or penetrate the skin and inject itself into body
tissues. This can cause serious direct injury to the operator, and if the fluid is toxic or
contaminated there will be additional adverse effects. If a pressurized gas is forced through
the fine network of pores in a porous metal Sparger, very small diameter bubbles (0.5 to 10
micrometres) are produced to allow a high efficiency transfer of the contact gas to the liquid.
8.2 Problem Statement and Background

Calculate the number of holes to be drilled on pipe inserted in pipe for increasing the
temperature of liquid from 60 to 100 oC. Direct steam injection involves the discharge of a
series of steam bubbles into a liquid at a lower temperature. The steam bubbles condense and
give up their heat to the liquid. Heat is transferred by direct contact between the steam and the
liquid, consequently this method is only used when dilution and an increase in liquid mass is
acceptable. Therefore, the liquid being heated is usually water.

Direct steam injection is seldom used to heat solutions in which a chemical reaction
takes place, as the dilution of the solution would reduce the reaction rate.
Direct steam injection is the most widely used method for boiler feed tank heating throughout
industry. This method is often chosen because of its simplicity. No heat transfer surface or
steam trap set is required, and there is no need to consider the condensate return system.

This is usually done using sparging equipments. There are two types of Sparger namely
Plate Type Sparger and Pipe Type Sparger. The requirement for the ITC Ltd was Steam Sparger
Pipe Type. The holes are to be drilled in this Sparger which bubbles out the steam in the stream.
The main objective was heating of the liquid in the flowing pipe. The steam basically gives out
the heat to the liquid and condenses as it was mentioned above. The following calculations deal
with the calculation of Number of holes on the pipe.

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The figure below shows Sparger in column, the same fashion is used in the pipe.

Fig 8.1 Different type of Sparger

8.3 Design Parameters

The client company provides some data around which the design should revolve. This
are design parameters that are used for calculation. The main objective was to determine the
no. of holes and the required calculation to reach the area for the same. The system is steam
and water service. The following data is provided by the company:

Table 8.1 Sparger Design Parameters

PARAMTERS Steam Liquid

Inlet Temp (oC) 136 60
Out Temp (oC) 110 100
Specific Heat (KJ/kg.K) 1.901 2.162
Mass Flowrate (kg/hr) ? 250
Enthalpy (KJ/kg) 2170 Nil
Pressure (bar) 3.5

The data is used for steam flowrate calculation, sparging area and number of holes calculations.

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8.4 Steam Flowrate and Steam Velocity Determination

Before determining the area, steam velocity is an important factor which should be
determined. This goes hand in hand with steam flowrate determination. Steam flowrate can be
calculated by:

𝑚. 𝐶𝑝. ∆𝑇
𝑆𝑡𝑒𝑎𝑚 𝐹𝑙𝑜𝑤𝑟𝑎𝑡𝑒 =
𝐸𝑛𝑡ℎ𝑎𝑙𝑝𝑦 + 𝐶𝑝. 𝑇𝑠
= (250 ∗ 2.162 ∗ (100 − 60))/((2170 + (1.901 ∗ 136))

= 10.19 kg/hr

Where, m is mass flowrate of liquid

Cp is specific heat of liquid

Del T is temperature difference.

As all parameters are known steam flowrate can be determined to be 10.19 kg/hr

Steam Velocity can be determined by the graph which has parameters like pipe diameter, steam
pressure and temperature and unknown parameters like steam velocity itself. The following
graph is velocity determination graph:

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 Chapter 9
Commissioning of Heating Tank
9.1 Background

Project commissioning is the process of assuring that all systems and components of
a building or industrial plant are designed, installed, tested, operated, and maintained
according to the operational requirements of the owner or final client. A commissioning
process may be applied not only to new projects but also to existing units and systems subject
to expansion, renovation or revamping.

In practice, the commissioning process comprises the integrated application of a set

of engineering techniques and procedures to check, inspect and test every operational
component of the project, from individual functions, such as instruments and equipment, up to
complex amalgamations such as modules, subsystems and systems.

Commissioning activities, in the broader sense, are applicable to all phases of the
project, from the basic and detailed design, procurement, construction and assembly, until the
final handover of the unit to the owner, including sometimes an assisted operation phase.

9.2 Commissioning of Tank

The commission of the tank was done at Balaji Formalin, Patalganga MIDC, Panvel.
The following checkpoints are necessary to be carried out during commissioning of the tank:

1. Checking of leakage in the equipment at the project site.

2. Checking of electrical components and fixing of the at the respective positions.
3. Ensuring safety of self and other companions during process.
4. Using standard gaskets provided by the company.
5. Ensuring insulation material is properly wrapped outside the limpets.
6. Checking the temperature of outlet as well as inlet of water.
7. Checking the temperature of outlet as well as inlet of steam.
8. Using standard test procedure for pressure test.
9. Check for pressure of steam to be maintained at required value for at least 30 mins.
10. Ensuring all pipes and fittings are done properly to avoid leakage.

30 | P a g e
9.3 Difference Between Erection, Installation and Commissioning

Installation of a system or machinery up to the point of being able to start running is

erection. Commissioning is preparing for running or taking into use of the installed system or
machinery by making preliminary tests and checks (pre-commissioning) and initially running
the system or machinery or taking it into use while checking and setting all of its running
parameters in accordance with its design (hot commissioning).

Building commissioning is a quality-focused process necessary for both non-complex

and complex modern construction projects. But "Erection and Commissioning" is quite a bit
different. It typically refers to larger construction of industrial plant systems and equipment.
"Erection and commissioning" primarily refers to the installation and professional oversight of
major industrial plant facilities and large equipment installation by qualified design engineering
companies, etc. This type of Erection and Construction Commissioning activities may include
oversight of construction of Oil Refineries, Rolling Mills, Reheating furnaces, Galvanizing
lines, Annealing Furnaces, fabrication and erection of towers, piping, hydraulics, or the
erection of giant steam turbines, power generators, etc. There is no room for mistakes in that
size of project. If someone specs the wrong size piping, or wrong steel, this delays the entire
project, and may become million-dollar mistakes. It is necessary to dovetail the commissioning
aspect of these projects right into the construction activities. The "Erection and
Commissioning" agents must take responsibility for the correctness of the design documents,
checklists, and the delivery of the plant equipment as well. So, the entire "erection and
commissioning" process is an integrated on-going process.

After the erection of the plant and large equipment, then the equipment needs to be
properly "commissioned" by well-experienced seasoned professionals. This is especially
critical for large very expensive energy utilization equipment, such as natural gas turbines and
compressors. These final commissioning activities include verifying construction phase tests,
and commissioning testing. The goal of the commissioning processes to deliver to the owner,
a project that is on schedule, has reduced first cost of delivery, and substantial life cost
reductions, and meets the needs of the user and occupants, including a fully operational and
optimized plant and systems.

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32 | P a g e
 Fig 9.1 Glimpses from commissioning of the Tank

Chapter 10
Mist Eliminators / Demister Pads
Project Name: Mist Eliminators
Client Name: FloTech Solutions
10.1 Introduction

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 Mist eliminators are used to remove liquid from different gas streams, and are
regularly found in cooling towers, ventilation systems and air scrubbers. They operate using a
variety of methods, from changing the direction of the gas flow and centrifugal force to
various filters. Originally, mist eliminators simply consisted of a collection of packed plates,
but advanced materials and techniques have allowed them to become smaller and more
efficient.

Fig. no. 10.1 Wire Mesh

10.2 Working principle of demister pad

When the gas with mist rises at a constant speed and passes through the wire mesh, the
rising mist will have collided with the mesh filament and attached to the surface filament due
to the inertia effect. The mist will be diffuse on the filament surface and the droplet will follow
along the filaments of the two-wire intersection. The droplet will grow bigger and isolate from
the filament until the droplets gravity exceeding gas rising force and liquid surface tension
force while there is little gas passing through the demister pad.

Separate the gas in the droplets can improve the operating condition, optimize process
indicators, reduce corrosion of the equipment, extend equipment life, increase the amount of
processing and recovery of valuable materials, protect the environment, and decrease air
pollution.

10.3 Types of mist eliminators:

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Wire-Mesh
Wire-mesh mist eliminators are by far the most common. Knitted wire mesh pads remove
entrained liquid droplets from gas streams.

Fiber-Bed
Fiber-bed mist eliminators consist of columns of fibrous material that remove mist from a gas
stream as it passes through them.

Baffle-Type
Baffle-type, also known as chevron or vane, mist eliminators change the direction of the gas
flow in an attempt to force liquid droplets to collect on the baffle surface. The pictures below
show baffle-type mist eliminators.

Fig. no 10.2 Baffle Type Fig. no. 10.3 Fiber bed

Chapter 11
Vortex Breaker
Project Name: Vortex Breaker
Client Name: L&T Hydrocarbons
11.1 Introduction

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 A vortex breaker is a device used in engineering to stop the formation of a vortex when
a fluid (liquid or gas) is drained from a vessel such as a tank or vapor-liquid separator. The
formation of vortices can entrain vapor in the liquid stream, leading to poor separation in
process steps such as distillation or excessive pressure drop, or causing cavitation of
downstream pumps. Vortices can also re-entrain solid particles previously separated from a gas
stream in a solid-gas separation device such as a cyclone. Below listed are some types of vortex
breaker:

Fig 11.1 Types of Vortex Breaker

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 Fig 11.2 Formation of Vortex

Fig 11.3 Vortex Breaker after Fabrication

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 Conclusion

This internship has allowed us the opportunity get the industrial experience. I had a
chance to design heat exchanger for Acetone-Water system, Methanol-water system, Sparger
and a heating tank. I got to learn about the various constraints to be taken into consideration
for various natures of system. The process of fabrication testing and transport was also studied
and done in this tenure. Hydro testing and pneumatic testing was done for testing of cow urine
purification plant. And this equipment was transported to Jagdalpur, Chhattisgarh.

In the design of Heat Exchanger for Acetone-Water system, the number of tubes
required was 16 tubes for 2 Tube side passes with tube length 16 ft. and tube outer diameter of
1 inch and shell inner diameter of 8 inch with a square pitch of 1.25.

In the design of Heat Exchanger for Methanol-Water system, the number of tubes
required was 26 tubes for 4 Tube side passes with tube length 16 ft. and tube outer diameter of
1 inch and shell inner diameter of 8 inch with a triangular pitch of 1.25.

The design of Sparger for ITC Bhadrachalan was done according to their requirement
for heating fluid from paper and pulp industry. 28 numbers of holes of diameter 6mm were
calculated for the Sparger.

In the design of heating tank for Balaji Formalin the number of limpets calculated was
44, with the length of 1.47m.I also went for the commissioning of heating tank and heat
exchanger supplied by us.

This internship has provided me the exposure to industrial and technical environment.
I also learnt little bit of marketing too.

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 Appendix
Appendix 1: Tube Sheet Data

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Appendix 2: Tube Sheet Layout

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Appendix 3: Fouling factor

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Appendix 4: LMTD Correction Factor

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Appendix 5: Overall Heat Transfer Coefficient

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Appendix 6: Jh vs Re Tube Side

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Appendix 7: Specific Gravity Chart

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Appendix 8: Jh vs Re Shell Side

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Appendix 9: Overall Heat Transfer Coefficient for Coolers

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 References
1. Kern D Q. “Process Heat Transfer”,3rd edition, Page 820-860.
2. Kern D Q. “Process Heat Transfer”,3rd edition, Page 127-175.
3. “Steps for HE designs”, NPTEL.
4. Mott Corporation “Guide for Sparger Design”, Pg1-10
5. Jidon Janaun, 2014, “Gas Flow through vertical pipe and perforated vertical pipe”, Pg
1-5.
6. Doolin, John H., 1963” Centrifugal Pumps and Entrained-Air Problem,” Chemical
Engineering, pp.103-106

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