PROJECT SEMESTER REPORT

(July – December 2019)

Pre-commissioning and commissioning of a waste plastic to diesel

conversion pilot plant
Under the Supervision of

Dr. Ajay Kumar

Principal Scientist (UWRD Division)

CSIR – Indian Institute of Petroleum, Dehradun

Submitted to: Submitted by:

Dr. H Bhunia Akshat Peswani
(Roll No -101601006)

DEPARTMENT OF CHEMICAL ENGINEERING,

THAPAR INSTITUTE OF ENGINEERING & TECHNOLOGY
(Deemed to be University)
Patiala – 147004, Punjab, India
CERTIFICATE FROM INDUSTRY
 DECLARATION
I, Akshat Peswani hereby declare that the project work entitled “Pre-commissioning and
commissioning of waste plastic diesel conversion”, submitted to Thapar Institute of
Engineering & Technology,(Deemed to be University), Patiala (INDIA), for the partial
fulfilment of the requirement for the degree of Bachelor of Engineering in Chemical
Engineering is an authentic record of my work carried out at CSIR – Indian Institute of
Petroleum, Dehradun during the period 10th June – 10th December 2019, under the
supervision and guidance of Dr.Ajay Kumar, Principal Scientist, CSIR – Indian Institute of
Petroleum, Dehradun.

I declare that this written submission represents my own ideas and wherever the ideas of other’s
are included, it has been adequately cited with the original source of reference. I also declare
that this work has not been submitted elsewhere for a degree or diploma at this or any higher
education institute.

Date: 01-01-2020 Signature of the Student with Date

(AkshatPeswani)
Roll Number: 101601006

Certified that the above statement made by the student is correct to the best of my knowledge
and belief. I have checked all the requirements, formatting and other essential components of
this report and it is as per the guidelines and standards.

Signature of the faculty mentor with Date

(Dr.H.Bhunia)

Department of Chemical Engineering

Thapar Institute of Engineering & Technology, Patiala
 ACKNOWLEDGEMENT

I have tried to fulfil the work activities assigned in the lab in the tenure of two months in
CMSD, CSIR- IIP, which would not have been possible without the kind support and help
extended by the individuals.

Ifeelveryhumbletothankeachofthemwhosupporteddirectlyandindirectly.Firstofall,I am highly
indebted to the respected director, Dr. Anjan Ray for providing the opportunity to carry out
project work in this esteemed organisation.

I am also very thankful to Dr. Anil K. Jain, Head, Training Division for allowing me to carry
out project work in the area of chemical sciences & chemical engineering having high industrial
importance.

I extend my sincere thanks to Dr.Ajay Kumar and Dr. Sanat Kumar for his valuable
guidance and constant motivation throughout the project tenure to think positively and
innovatively.

I would also like to express my sincere gratitude towards my parents for constant support and
motivation in completing the project work.

Finally, I would like to appreciate for their unconditional support for the timely completion of
project work and making my stay fruitful in IIP, Dehradun.
 ABSTRACT
Waste plastics which are presently disposed-off by land filling and incineration resulting in
creation of waste lands and emission of toxic gases. CSIR-Indian Institute of Petroleum (CSIR-
IIP) in collaboration with GAIL (India) Ltd had started the laboratory scale research work on
vaporisation of waste plastics in 2006. The work involve screening/ development of catalysts
and process for converting waste plastics from different sources into value added products.
CSIR-IIP has been successful in developing a novel process by which polyolefin waste plastics
like polyethylene and polypropylene can be converted exclusively into diesel along with
simultaneous production of other liquid petroleum products like, Naphtha & Fuel Oil. The
produced diesel meets most of the Euro-III specifications. The uncondensed gases will be
utilized for internal consumption in plant. The process comprises of pyrolysis followed by
catalytic conversion and subsequent condensation and fractionation to get the desired liquid
hydrocarbons. The uncondensed gases comprise mainly C1-C5 gases along with hydrogen. The
process is completely environment friendly as no toxic gases are evolved. The residue obtained
is dependent upon the fillers and impurities in the waste plastics and could be as low as less
than 0.1 % in the case of clean plastics.

IIP/ GAIL will set up a pilot plant of 1 ton per day (TPD) feed capacity for the above process
at IIP Dehradun. This unit consists of extruder and Pyrolyser for initial pyrolysis of waste
plastic. Waste plastic after pyrolysis goes to catalytic reactor where it is converted to valuable
distillate range hydrocarbons. Products from the reactor are sent to downstream fractionation
section where the products are condensed and separated into fuel gas, naphtha, diesel and fuel
oil.

Akshat Peswani
(101601006)
 TABLE OF CONTENTS

CERTIFICATE
DECLARATION
ACKNOWLEDGEMENT
ABSTRACT
TABLE OF CONTENTS
LIST OF FIGURES

CHAPTER 1 INTRODUCTION
1.1 Brief Information about IIP
1.2 Quality Policy of IIP
1.3 Major Achievements of IIP
1.4 Various Divisions at IIP
1.4.1 R&D Division
1.4.2 Support Division
1.4.3 Administration
1.5 Major Future Programs
1.6 Background and Objectives of the Project
1.6.1 Distillate and Heavy Oil Processing Division (DHOPD)
1.6.2 Basic Knowledge about Hydrocracking
1.6.3 Project Objectives

CHAPTER 2 LITERATURE REVIEW

2.1 Pre-commissioning
2.2.1 Plant Inspection
2.1.2 Pressure test:
2.1.3 Cleaning of Lines and Equipment
2.2 Commissioning:
2.2.1 Introduction
2.2.2 Commissioning of Machinery:
2.2.3 Instrument Commissioning
2.2.4 Catalyst Loading & Unloading
2.2.5 Leak Testing
2.2.6 Purging with Nitrogen
2.2.7 Refractory Dry Out
2.3 Process Description
2.4 Major Components in the Pilot Plant
2.4.1 Distributed Control System:
2.4.2 Control Valves and interlocks
2.4.3 Cooling tower:
2.4.4 Heat exchanger:
2.4.5 Air-nitrogen package:
2.4.6 Combustion Chamber
2.4.7 Extruder:
2.4.8 Pyrolyser:
2.4.9 Catalytic reactor:

2.4.10 Fractionating column & Reflux drum

CHAPTER 3 OBSERVATIONS AND TROUBLESHOOTING

3.1 Instruments & Units

3.1.1 Cooling Tower
3.1.2 Air-Nitrogen package:
3.1.3 Air compressor and Regeneration compressor:
3.1.4 Extruder
3.1.5 Catalytic reactor:
CHAPTER 4 CONCLUSIONS
 LIST OF FIGURES

Figure No. Title Page No.

1.1. CSIR – Indian Institute of Petroleum 09

2.1. Distributed control system (DCS) 32

2.2 Cooling Tower 36
2.3 Heat Exchangers 37
2.4 Air & Nitrogen System 38
2.5 Combustion Chamber 40
2.6 Extruder 41
2.7 Pyrolyser 42
2.8 Catalytic Reactor 43
2.9 Fractionation column 44
 Chapter 1

INTRODUCTION

1.1 Brief Information about IIP

CSIR – Indian Institute of Petroleum is one of the leading constituent laboratories of the Council
of Scientific & Industrial Research (CSIR). Established in 1960, the institute is devoted to
multidisciplinary areas of research and development in the downstream sector of hydrocarbon
and related industry. It has dedicated, experienced and quality staff and is equipped with
comprehensive state of the art R&D facilities including pilot plants.

Figure 1 CSIR – Indian Institute of Petroleum

The institute undertakes R&D work in areas of petroleum refining, natural gases, alternative
fuels, and petrochemical utilization of petroleum products in IC engines and n industrial and
domestic combustion. The institute also provides technical and analytical services to petroleum
refining and related industry including technology transfer for developing novel, state of art
technologies and products. The institute maintains its leading position in conduction training
programmes for technical personnel from refining industry, petrochemical plants, automotive
sector, power plants and other related user industries.
CSIR-IIP is committed to provide globally competitive technologies and services for
hydrocarbon and related industries. This is achieved through total quality management and
byanticipating and exceeding the expectations of customers through innovation, team work and
commitment. The acquirement of ISO-9001 certification by the institute in 1998 and its
accreditation to ISO: 9001-2008 proves commitment towards quality services & management.

1.2 Quality Policy of IIP

Indian Institute of Petroleum is committed to develop into an internationally reputed R&D

centre of excellence for providing globally competitive technologies and services for
hydrocarbon and related industries.In its quest for scientific and technological innovations,
marketing and managerial competence, and continual improvement, it has set the following
quality objective

• Development of innovative technologies and petroleum products

• Providing science based technical support to industry
• Customer satisfaction through committed quality, cost and deliveries
• Emphasis on Knowledge Management (KM)

1.3 Major Achievements of IIP

Institute has developed a larger number of processes and technologies. Thirty eight
technologies having licenced capacity around 25 million tons per annum transferred to the
industry.

• Almost every refinery in the country has technologies licenced by the institute.
• Test techniques developed for evaluation of petroleum products included in BIS
specifications.
• Established global tie-ups for contract research and technical services.
• The intellectual property rights protected with the patents filed and sealed in India and
abroad.
• Based on the research work conducted in the institute PhD degrees awarded to the fifty
research fellows and Scientists of the institute by various universities.
• A large number of research papers published in reputed International and National
Journals.
1.4 Various Divisions at IIP

IIP has three major divisions:

1.4.1 R&D Division

• Analytical Sciences
• Automotive Fuels and Lubricants Application
• Bio Fuels
• Chemical and Material Sciences
• Distillate and Heavy Oil Processing
• Light Stock Processing
• Material Resource Efficiency
• Separation Processes
• Tribology and Combustion
• Upstream and Wax Rheology

1.4.2 Support Division

• Engineering Service Division

1.4.3 Administration

• Administration
• Finance and Accounts
• Store and Purchase

1.5 Major Future Programs

The future programs of IIP will he delivered towards the development of petroleum refining
process, catalysis, speciality chemicals, fuel quality and emission studies, alternate sources of
hydrocarbons, development of fuel-efficient industrial and domestic appliances and microbial
enhanced recovery of oil.

1.6 Background and Objectives of the Project

1.6.1 Distillate and Heavy Oil Processing Division (DHOPD)

Distillate and Heavy Oil Processing is one of the important processes in refining to get
maximum profit margin. CSIR – IIP is working in this area since its inception. This division
mainly is working in several different sub areas such as,

• Coking
• Vis-breaking
• Fluid Catalytic Cracking (FCC)
• Residue Hydroprocessing

Recently an indigenous technology called “Soaker internal vis-breaking” has been

commercialized in three Indian refineries, HPCL (Vizag), IOCL (Mathura) and IOCL (Haldia).
This is an example of outcome from the research work in this division. The division’s focus is
not limited to industrial research work but also the implementation commercially. Slurry
hydrocracking is the most upcoming process and the division is working with Bharat Petroleum
Corporation Limited, Hindustan Petroleum Corporation Limited and Engineers’ India Limited
for the development of a technology to convert the most contaminant feed to the valuable
products.

1.6.2 Waste plastic to diesel conversion process

This is the main section of waste plastics to fuels process. The pre-treated feed is routed to
Pyrolyser 01-PY-101 using Extruder 01-ED-101. In the Extruder the feed is carried from
hopper to melting zone, where the plastics are slowly heated up during transportation and
becomes like liquid in the melting zone. The feed rate is controlled itself by extruder. The
molten plastic is then fed to the Pyrolyser 01-PY-101 where thermal cracking of the plastic
occurs. Vapours produced in Pyrolyser are sent to Catalytic Reactor 01-CR-101 via filter 01-
FD-101 for cracking and promotion of secondary reactions. Catalytic Reactor is filled with
catalyst. The reactor is a vertical down flow reactor which has tubes filled with catalyst inside
it. There are two different catalysts which are filled inside the tube. Top and bottom catalysts
are separated by a layer of inert balls. The vapour from Catalytic Reactor is sent for fractionation to
Fractionator 01-CC-101.
1.7 Project Objectives
The main objective of the project is to study all the activities involved in the start-up of a pilot
plant. Divided into three parts, pre-commissioning, commissioning and the feed cut-in, the
start-up of any plant is dependent on the requirements of the process, the maximum process
parameters it achieves and the products that are to be collected. Another objective is to learn
all about the operation of the plant and the possible areas of troubleshooting associated with
it.This broadly includes each and every aspect concerned with any kinds of problems related
to any process or equipment and dealing it with the most productive way possible.

Chapter 2
 LITERATURE REVIEW

2.1 Pre-commissioning

2.1.1Plant Inspection

Each section of the unit is inspected for conformity with project documentation, and a punch
list is drawn up to record any deviations requiring further construction work. A typical, but not
comprehensive list of items to be checked is given below. Check Unit against Piping and
Instrument Diagrams Following the construction, a careful inspection of the equipment must
be carried out to ascertain that the construction is performed as indicated on Piping and
Instrumentation Diagrams (P&IDs).

Particular attention should be paid to the details, including tracing, drains, vents, etc., where
errors in construction are most likely to occur. Checking can best be accomplished by covering
every line, and marking on a complete set of P&IDs, all piping and equipment that have been
checked and eventually pre-commissioned. Any deviations from design are to be brought for
special consideration to the attention of those concerned.

Vessels, Exchangers, Columns, Filters:

The following checks should be carried out:

• Check name plate

• Check foundation bolts and shims

• Conformity with project documentation (elevation, metallurgy, etc.)

• Pressure and temperature rating

• Nozzle size and orientation

• Internals: Packing type, volume, metallurgy, installation

• Lining insulation: type, thickness, material

• Instrument nozzles and type

• Ladders, platforms, manways: location, size, accessibility, fire proofing

• Grounding connections
• Vents, drains, relief valves provided as specified

• Parallelism of flange coupling

Piping

The following checks should be carried out:

• Conformity with P&I diagrams and process requirement

• Pipes, flanges, gaskets, fittings, valves in conformity with specified piping classes

• Check parallelism of flanges as well as studs and bolts

• All temporary blinds and supports have to be removed

• Expansion loops provided on long hot lines, if any

• Flow direction of check valves and globe valves

• Safety valves location

• Electrical tracing lines have to be installed and properly connected

• Insulation

Instrumentation

The following checks should be carried out:

• Conformity with project specification and design requirements

• Instrument type, range and size

• Material of construction and rating of instruments, accessories, connecting flanges and valves

• Accessibility to instruments for routine checks and maintenance; rigid mounting

• Installation according to detailed drawing

• Process requirements of flow, temperature, pressure, differential pressure, specific gravity

etc.

• Power requirements of voltage frequency; emergency power supply and connections

• Calibration of controllers, transmitters, analyzers, special instrumentation

• Control valve, block and bypass valve sizes for control valve assemblies. Check that control
valves are installed in the right flow direction and that they move freely.

• Check that orifice plates are installed in the right flow direction.

Pumps

The following checks should be carried out:

• Conformity with project specification and design requirements

• Grouting and fixing bolts

• Suction and discharge connections stress-free

• Mechanical seal/packing

• Non-return valve installed between pump discharge and pump discharge valve

• Temporary suction strainer

• Coupling guard fitted

• Discharge pressure gauge readable from discharge block valve

• Suction/discharge valves easily accessible and operable, and near to pump

• Accessibility of auxiliary piping and controls

• Warm-up lines provided across discharge check valve when pumping hot fluids

• Electrical tracing and insulation provided on suction/discharge lines, pump casing, and
process seal flush lines, as required

• Minimum flow bypasses (with restriction orifice), if required

• All seal oil, warm-up, etc. lines fitted with flanged connections and valves to permit removal
of pump

• Correct operation of lubrication and cooling systems

• Adequate means for venting and draining pump casing available

• Pumps and drivers aligned correctly

• Auxiliary service for mechanical seal, in particular for cold pump service
Electric Motors

The following checks should be carried out:

• Check name plate rating and conformity to project specification and design requirements

• Check bearing lubrication

• Check direction of rotation and alignment with driven equipment

• Check foundation bolts and shims

• Check electrical power supply, earthing and location of push button starter

2.1.2Pressure test:

‘Pressure test’ is meant the hydrostatic or pneumatic testing of piping / equipment and should
not be confused with the less severe “leak / tightness test “. The pressure test is usually carried
out by the construction personnel, while the other test will be conducted generally by operations
personnel. Pressure testing has to be made before insulation to detect small leak. The pressure
test is carried out at the end of the plant erection or after eventual repairs, in order to verify the
resistance of piping / equipment to the pressure conditions stated in the design codes. The
pressure test is usually carried out by filling the piping / equipment with water and venting air
from the high points; then increasing the pressure by means of a reciprocating pump, up to the
test pressure, which anyhow, exceeds the average operating values. Normally, the hydrostatic
test pressure for piping systems should not be less than 1.5 times the mechanical design
pressure. Equipment has to be tested 1.3 times the mechanical design pressure according latest
API 521. In pneumatic testing, the test pressure is normally 110 percent of the design pressure.

Safety valves, relief valves and rupture disks must be removed or isolated from the tested
system, since their normal relieving pressure will be exceeded. The time during the pressure
test period can be utilized to bench test and set the safety and relief valves. The section of the
plant to be pressure tested must be isolated from the remainder of the unit by insertion of blinds
between the flanges. The blinds to be used must be rated for the test pressure. Piping should be
checked for supports, if they are sufficient to withstand the weight of water. High point vents
or other connections shall be opened to eliminate air from lines, which are to be hydrostatically
tested. Lines shall be purged of air before hydrostatic test pressure is applied. Vents shall be
open first when systems are drained, so not to create buckling from a vacuum effect. Never
include compressors and pumps in the hydrostatic pressure test circuit. Piping containing check
valves shall have the source of pressure located in the piping upstream of the check valve, so
that pressure is applied under the seat. If this is not possible, the check valve flapper shall be
removed or jacked-up. Each test shall be held for 60 minutes without any loss in pressure. After
completion of hydrostatic testing, all temporary blanks and blinds shall be removed and all
piping completely drained and dried with air.

Stainless steel piping shall NOT be hydraulically tested with water containing more than 40
ppm of chloride. Complete draining and drying of piping is essential after the pressure test is
over otherwise corrosion in the piping may occur. Valves, orifice plates, expansion joints and
short pieces of piping which have been removed shall be re-installed with proper and
undamaged gaskets in place. Records shall be made of each.

2.1.3 Cleaning of Lines and Equipment:

After completion of the unit erection and pressure test (hydrostatic test), all lines and equipment
must be cleaned. The aim of this operation is to eliminate all foreign materials, such as metal
pieces, welding slags and foreign matter which would otherwise block pipes, control valves
and orifices and cause damage to moving parts of turbines and compressors.

The following precautions must be taken before any cleaning operation:

• Program the washing operation by choosing the various circuits that can be washed
simultaneously and those, which must be done successively.

• PID should be used to identify loop for cleaning and for control operation of washing medium.
This activity is carried out during the pre-commissioning phase when PID check is made.

• Systems preparation made up of one or more circuits will be defined at that time. This activity
is strictly related to:

• Status of mechanical completion for that system

• Availability of relative area for cleaning operation

• Availability of flushing medium

• Prepare the loop; install blinds wherever necessary, temporary connections etc., to ensure a
high flow rate and therefore a good cleaning action.

• Measuring orifices, flow meters and thermo wells should not be installed before pipes are
cleaned.
• Control valves and safety valves must be either removed or blocked off during cleaning
operations.

• All instrument connections should be disconnected or adequately protected.

• All connections to compressors suction and discharge lines should be disconnected and casing
nozzles have to be covered to prevent cleaning medium from entering.

• Attention is drawn to the fact that some items of equipment, particularly machinery, may
require special cleaning operations and reference should be made to the manufacturer's
operating manual for details.

• When necessary, check valve flaps can be removed for cleaning.

• All blinds on the equipment or on the lines shall be removed during or immediately after
washing.

• Lines connected with the exchangers have to be flushed without discharging into the
exchangers.

• Block valves and other valves not removed during flushing have to be subsequently checked
with regard to complete closure, and if necessary removed and cleaned in the workshop.

• Lines connected with the vessels provided with demisters or other internals, which could be
fouled, have to be flushed outside the vessels first and then from the vessel bottom.

• Installation of the inner parts of vessels can be carried out, in most cases, after the cleaning
operation.

• Some vents shall always remain open, both during the filling of equipment and during
emptying, in order to avoid over pressure and vacuum condition.

• As a general rule, cleaning is to be executed from top to bottom and following the normal
routes of the lines.

• The cleaning fluid shall be fed into the circuit by means of temporary piping and hose
connections.

• Accessible equipment should be manually cleaned before flushing starts in order to reduce
the amount of material to be removed during this flushing.

• The final cleaning of vessels shall be manually executed during the final inspections.
• Instrument pipes and lead lines are cleaned by blowing out with instrument air.
2.2 Commissioning:
2.2.1 General:

The utility system should be tested and placed into service as soon as allowed by
theconstruction schedule, in order to have utilities available for plant pre commissioning and
commissioning.

After pressure testing has been completed:

• The system is inspected for conformity with relevant PID. This is also done just prior
topressure testing to particularly ensure that all welding jobs have been completed.

• Scale and construction debris are removed using most convenient medium (water, air flushing
or blowing).

• Tightness tests are carried out to ensure that leakage due to damaged gaskets, untightened

flanges, and left open drains or vents are rectified.

• Air is displaced with nitrogen for systems containing hydrocarbons (fuel gas, fuel oil), holding
oxygen content in the system below 0.2 vol. %.

• Instrument air system is air blown as carefully as possible to remove oil or grease.

• Instrument air system is dried, as much as possible, with air available in the plant.

• Temperature rise of lines (fuel oil) is gradual in order to ensure free expansion of supports,
paddings etc.

During the preliminary operations, alertness and care is required from the operators, for
example:

• High level points should be vented frequently to eliminate air from water lines and fuel oil
lines.

• Low level points should be frequently drained to eliminate water or condensate from fuel gas
lines.

• Pump operation checked for vibration, high power absorption and cavitation, due to suction
filter blockage by dirt accumulation.
• Instrumentation carefully observed for manual operation, which is generally required during
start up and/or final tuning and setting.

• The utility lines should be cleaned, preferably with the fluids, which will run through them.

Plant air

Flush the system with air, execute leak test with air and eliminate moisture by blowing.

Instrument air

Disconnect all pneumatically operated equipment from the instrument air system, pressurize
the system with air, check and rectify leakages. All moisture should be eliminated by means of
repeated blowing. Finally, install the filters and connect up the users.

Cooling water

Disconnect the inlet flanges of water coolers and wash the lines; when clean water is seen
emerging, reconnect and continue with the washing. When washing is completed, a tightness
test should be performed and the system commissioned. Note any abnormal pressure losses in
the system during the pre-start-up check of bigger hydrocarbon, which gets promoted by the
increase of the temperature which results in the increase of gas and light oil yields. Also, the
high reaction temperature facilitates the condensation of hydrocarbon free radical resulting in
increased coke yield. Hydrogen gets easily split into hydrogen free radicals on the active site
of a dispersed Mo catalyst, thus the high concentration of a hydrogen free radical could inhibit
the serious cracking and condensation of a hydrocarbon free radical. Therefore, the yields of
gas, naphtha, and coke in slurry phase hydrocracking are lower than that in thermal
hydrocracking at the same temperature which increases the high yield of the liquid product.

Nitrogen network

Perform tightness test of the network with air. Once the test has been completed, purge the
network with nitrogen, blowing through intermittently to eliminate all the air. Commission the
nitrogen system.

Electrical equipment

The commissioning is executed by qualified personnel according to the industry practice.

Fire fighting equipment

Make sure that equipment are in place ready for operation and that the fire water header has
the proper pressure. Try out all water hydrants and check jet length and cooling capacities, as
applicable.

2.2.2 Commissioning of Machinery:

Proper installation and operation of machinery is essential for trouble-free performance.

Running-in of electrical motors

• Ensure that electric motors have the power supply at the right voltage since higher voltage
may cause damage.

• Check rotation with the motor uncoupled from the operating machine.

• Run in for a minimum of four hours uncoupled, verifying operability.

• Check for proper greasing of bearings.

• Check the temperature of bearings and for excessive vibration.

• Check the insulation resistance.

Centrifugal Pump

The operation instructions given below are only general rules supplementing vendor
information and are not intended to overrule vendor's instructions. Before commissioning and
start-up of a pump, the vendor instruction should be read. The pump may have been idle for
some time or there may have been a time delay between running in and actual operation. Under
these circumstances, the pump should be filled with oil or conservation film agent and rotated
once per week.

Start-up:

For the initial start-up of the pump, the pump check and the run test must be completed. During
normal start-up always check that the pump has free rotation, and a proper cooling water
supply.

A daily check of the oil level is required. Open the suction valve slightly, or the warm-up line,
and pressurize the pump. When the pump is up to pressure, bleed off any vapour through the
pump casing or discharge high point vent. Always make sure that any dangerous gases or
highly inflammable liquids are vented / drained to a safe location. Check that the main breaker
for the pump in the sub-station is in the "on" position.

Open the suction valve to full open position and make sure that the discharge valve is in fully
closed position. Start the electric motor. When the motor is up to speed and the discharge
pressure is established, slowly open the discharge block valve to fully open. A close watch
should be kept on the discharge pressure during this time.

Running check:

For routine check during operation, the vendor instructions have to be followed, however, a
general routine check on the following points is required on a regular basis:

1. Discharge pressure

2. Motor amperage

3. Suction pressure

4. Bearing oil

5. Bearing temperatures for pump and motor

6. Seal oil (if present)

7. Vibrations

Trouble shooting

If the discharge pressure drops, it will normally be due to any of following reasons,

1. Suction filter is blocked

2. Loss of head pressure to pump suction

3. Loss of pressure downstream of the pump, due to faulty control valve or wronglyopened
valve

4. Vapour lock in pump casing

Reciprocating compressors

In principle the vendor gives the operation and start up instructions for compressors.
Instructions given below are only intended as a general rule and should never supersede the
vendor instructions. The manufacturer furnishes an operating instruction book with each
machine. It should be studied thoroughly before the unit is started. To ensure successful
performance, these instructions should be followed closely.

The compressor may have been idle for some time. During the idle time period, the compressor
should be barred over once per day. If the loading valves have been removed or pipe work
disconnected, the open ends must be covered to prevent entry of foreign material or water
(moisture) into the compressor. Attention should also be paid to the cooling water circuit.
Cooling water is to be drained off in case of danger of frost, provided machine does not operate.
After completing the compressor checklist and a function test to verify that all alarms and trips
are fully operational, all necessary personnel must be informed about the intention to start.
Check the operations of the loaders and ensure that there is no liquid in the suction, inter stage
and discharge knock-out drum or pipe work. Double check the cooling water flows. Also
ensure that the compressor is free moving by rotating the shaft 360°. Purge the compressor
with nitrogen if there is a possibility of presence of oxygen.

Start-up:

Pressurize the compressor by opening of the suction block valve. When the machine is up to
pressure close it again and checks for leakages. Check that the electric motor is in the “on”
position. Open all discharge block valves. The main motor can be started. Leave for a moment
to allow it to run up to speed. The suction block valve can then be opened. This must be done
slowly to avoid overloading the machine by a sudden surge of gas. Allow the machine to run
for a minute unloaded and check the operation of the lubricators. Also record the current taken
by the motor.

Loading:

In principle a reciprocating compressor should not be running unloaded for a long period, and
should be loaded as soon as possible to avoid over-heating. With the motor running correctly
and all suction and discharge valves open, the compressor may then be loaded. The compressor
must always be loaded from the driver end to outboard end (unloading is the reverse of this).

Running Checklist:

Most of the time, there is a vendor recommended checklist for a machine in service. If this
check list is not available, the following recordings should be made:

• Suction and discharge temperatures at each stage

• Suction and discharge pressures at each stage

• Lube-oil temperature

• Lube-oil pressure

• Pressure drop over Lube-oil filter

• Motor amperage

• Consumption of utilities like nitrogen, cooling water with flow, pressure and temperature

• Flow of compressed medium

At normal operation, these shall be checked minimum 2 times each shift; during initial
operation these should be checked still more times (once per hour) and at each load change.

Blowers and Fans

Check following points:

• Name plate rating and conformity to project specifications and design requirements

• Direction of rotation and make sure that it runs freely

• Shaft alignment.

• Piping to and from fans, supports, insulation and flanges

• Inspect any installed lubrication system

• Drain system and suction filters

• Foundation bolts and shims.

Combustion Chamber

Check following points:

• Refractory for damage and proper construction

• Expansion joint refractory for correct dimensions and packing

• Burner installation, alignment, and projection dimensions.

• Burner data, orifice, etc. for conformity to project specification and design
• Piping transit sealing and packing. All points where piping enters or exits the heater must be
adequately supported, sealed (where applicable) and free to expand

2.2.3 Instrument Commissioning :

Before any instrument is activated, it is necessary to:

•Ensure that all primary elements are installed in accordance with the drawing and
manufacturer’s requirements.

•Remove shipping restrictions, such as lead plugs, tie down wires, protective coverings,etc.
that have been applied to protect the parts.

• Recalibrate the instrument, even if it has been calibrated by the manufacturer (also, calibrate
the entire control loop).

• Verify the continuity of circuits from the control panel to the field and back again.

• Verify the action of the actuating air signal on valve position.

• Verify movements, such as valves by their controller and controllers by their sensing
elements.

• Check the action of interlock and alarm circuits to ensure that tripping an interlock relay from
its sensing point will cause all the dependent instruments to act appropriately.

• Calibrate field analyzer with standard gas mixtures of certified quality.

2.2.4 Catalyst Loading :

Once the reaction section is dried out, catalyst loading can be started. However, before start of
catalyst loading the cleanliness of reactor must be ensured again. The catalyst loading period
must be as short as possible to minimize the risk of moisture entering the reaction system.
Catalyst loading will preferably be interrupted in case of rain or snow, or efficient protection
must be in place. The catalyst must be handled with care to avoid its breakage. Catalyst drum
should not be rolled to avoid catalyst attrition. Before loading of catalyst, the catalyst tubes
should be duly inspected to ensure they are free from any obstruction or foreign material. The
normal method of charging the catalyst tubes is with polythene socks or canvas socks. The
catalyst to be loaded should be inspected prior to charging and any fines (which could cause
excessive pressure drop) should be screened out. The catalyst should be weighed before
charging to provide a check on the quantity of catalyst loaded.

2.2.5 Catalyst Unloading :

Catalyst unloading is by vacuum pulling from the top of the reactor.

2.2.6 Leak Testing:

During equipment cleaning, lines have been disconnected, orifice plates and blinds removed
andre-installed. As a consequence, leak tests are required to eliminate leakage due to gaskets,
which have been damaged; flanges not perfectly tightened and/or drains, which have been left
open. The leak test is to be carried out after final installation by air, nitrogen and the proper
process. All joints, flanges, packaging glands etc. must be tested for leaks, for example by using
a soap solution. Flanged connections are tested by sealing with tape and making a pin hole (for
low temperature duty only).

Air or nitrogen is normally used at supply pressure of about 4-7 kg/cm²g. At this pressure value
the tightness test is considered accepted if a loss of pressure of 2% per hour occurs, with all
connections to instruments and equipment open, and for a length of time of minimum 2 hours.
As a general rule, tightness testing is to be executed according to P&I diagrams circuit marked
up by using proper pressure indicator or pressure controller installed on the circuit.

Preliminary Conditions:
Determine the different test zones and pressure level to be applied.
• Isolate by blind flanges:
- All parts of the unit, which may contain hydrocarbons
• Systematically purge any remaining water in the equipment through all drains. This purge
should be continued during pressurization until all water is eliminated. Break the unit up into
sections to be tested. Isolate the test section by valve (double valve whenever possible), and/or
install blind plate. By this method, when a leak is found that cannot be repaired when the unit
is under pressure, only that section needs to be depressurized.
Leak checking on other areas can then continue.
• Have on hand a large quantity of soap, squirt bottles, colored tagging tape and buckets.
• Stay organized. Start at one end of a section and work your way through to the other end,
checking all flanges, valves, fittings, instruments, etc. Remember, isolate any equipment or
instrument, which could suffer from pressurization (for instance vacuum gauges), as well as
the analyzers.
• Check pumps and compressors independently, because they have packing leaks, which could
interfere with the pressure gauge check on the rest of the unit.
• Shut the vent and purge valves.
• Use large quantities of soapy water when testing. Tag each leak found. Also log the location
of the leak on a list to make it easier for maintenance and the next shift to find it. Maintenance
crews should work along with the leak checking team as much as possible.
• It is preferable that leak checking will be done shortly before start-up. This minimizes the
chance of new leaks developing through additional maintenance.
Leak Testing Procedure:
The following is a generalized procedure to be used when leak checking:
• Isolate the section of the unit from the rest of the unit.
• Slowly pressurize the section to 2.0 kg/cm2g with nitrogen or air. Listen for large leaks or
open valves. Walk through the entire section.
• If no large leaks are found, then continue by slowly pressurizing the section to be tested to
4.5 – 5.5 kg/cm2g, or to design pressure if less. Use at least one pressure gauge to monitor
accurately the leak test.
• Start systematically leak checking the unit with plenty of soapy water (flanged connections
are tested by sealing with an adhesive tape and making a pinhole in thetape)
2.2.7 Purging with Nitrogen
It is assumed that all pre-start operations including drying, catalyst and molecular sieve
loadings have been completed, together with the mechanical check of the unit. It is also
assumed that all piping and equipment have been leak tested and cleaned. Purging operations
have to be done with nitrogen (oil free), introduced by means of temporary hose connections.
The best procedure for purging is by pressure-cycle purging, in which the equipment is
pressurized with an inert gas and then vented to atmosphere. The cycle is repeated until the
desired oxygen level is achieved, which should be less than 0.2 vol.%.
It is recommended to subdivide the plant into various systems in order to optimize the nitrogen
consumption. After having defined which system is to be purged first, the same nitrogen can
be used in successive systems (displacement purging), provided the conditions allow it to do
so. In this manner the overall consumption of nitrogen can be reduced. This procedure can only
be done for the first start up, or after a major shutdown when the plant is devoid of
hydrocarbons. It should be always born in mind that as a basic guideline for safe and efficient
purging: It is impossible to inert a piece of equipment until the entire stored hydrocarbon liquid
has been removed. Never assume that a piece of equipment is safe after purging, simply
because the specified volume of purge gas has been used. Always check the equipment’s
atmosphere foroxygen concentration (O2 meter).

Purged equipment containing a solid residue may be unsafe. Disturbing the solid may release
new flammable materials. In this case, continuous atmosphere monitoring is necessary.
Usually, the faster the purge, the greater the quantity of inert gas needed. A detailed program
of purging operation will be performed by the pre-commissioning team just prior to start up
taking into account the above mentioned points.

2.2.8 Refractory Dry Out

Mainly the combustion chamber and Pyrolyser are the refractory lines equipment in Waste
Plastic to Diesel unit. In general, the refractory lining may not be completely dry in new
furnaces that have been idle for extended periods. In such cases the moisture must be driven
out of the refractory bricks. This must be done by heating up the combustion chamber in a slow
and controlled manner so as to permit the absorbed moisture to vaporize and escape gradually.
If the heating is too rapid, the water may vaporize violently and damage the lining due to
volume expansion. The steps normally followed for carrying out refractory dry out operation
is provided below:

• Start the combustion air blower as per vendor instruction

• Make sure the fuel gas system with start-up LPG is cleaned, leak tested, all logics and
interlocks are checked for proper operation

• Light the combustion chamber burner following vendor instruction. There is a possibility that
the flame may detach itself from the burner tip or get extinguished; this may happen due to
unstable fuel pressure, dirt in the lines or a blockage of the tip by refractory dust. In that case,
close the burner cock, stop the lighting procedure and purge with air. The burner must then be
taken out, inspected and cleaned. After that re- start the lighting up procedure.
• Increase the temperature to 150°C with a rate of about 10°C/h.
• When the outlet temperature has reached 150°C, stop further increasing in firing and hold this
temperature for the next 24 hours. Check if the outside skin temperature of the combustion
chamber is around 50°C. If the refractory is wet the skin temperature may be as high as 100°C;
in that case, extend the holding period until the skin temperature drops to 50°C. The next phase
of dry out can be started once the skin temperature has stabilized.
• Gradually increase firing to raise the flue gas temperature from 150°C to 300°C at a rate of
10°C/h.
• When the outlet has reached 300°C, stop further increases in firing and hold this temperature
for the next 24 hours.
• After 24 hours raise the flue gas flow in small steps so that temperature is increased from
300°C to 550°C at a maximum rate of 20°C/h
• When an outlet temperature of 550°C is reached, the gas rate and temperature should be held
for the next 12 hours. At the end of this stage the refractory should be dry.
2.3 Process Description

The process begins with introducing the agglomerated feed to the pit of the bucket conveyor
which carries it to the hopper of the extruder. It is then heated in the extruder to a temperature
of 350℃ until it turns to liquid state with sufficient flow ability. The process fluid from the
extruder travels to the pyrolyser in which thermal cracking of the feed takes place. The product
is also converted into vapour form and can be seen through sample collection lines to prevent
any metallic dirt or unwanted objects entering the stream it passes through a vapour filter next.
It then goes into catalytic reactor in which the catalytic cracking takes place. Now the process
fluid which is in complete vapour form is sent to the fractionators column at 450℃ where it
undergoes distillation and the various products are obtained from their respective cuts.

2.4 Major Components in the Pilot Plant

2.4.1 Distributed Control System:

A distributed control system (DCS) is a computerised control system for a process or plant
usually with many control loops, in which autonomous controllers are distributed throughout
the system, but there is no central operator supervisory control. This is in contrast to systems
that use centralized controllers; either discrete controllers located at a central control room or
within a central computer. The DCS concept increases reliability and reduces installation costs
by localising control functions near the process plant, with remote monitoring and supervision.

Distributed control systems first emerged in large, high value, safety critical process industries,
and were attractive because the DCS manufacturer would supply both the local control level
and central supervisory equipment as an integrated package, thus reducing design integration
risk. Today the functionality of SCADA and DCS systems are very similar, but DCS tends to
be used on large continuous process plants where high reliability and security is important, and
the control room is not geographically remote.

Figure 2.1: Distributed control system (DCS)

The processor nodes and operator graphical displays are connected over proprietary or industry
standard networks, and network reliability is increased by dual redundancy cabling over diverse
routes. This distributed topology also reduces the amount of field cabling by siting the I/O
modules and their associated processors close to the process plant. The processors receive
information from input modules, process the information and decide control actions to be
signalled by the output modules. The field inputs and outputs can be analog signals e.g. 4–
20 mA DC current loop or two-state signals that switch either "on" or "off", such as relay
contacts or a semiconductor switch.

DCSs are connected to sensors and actuators and use setpoint control to control the flow of
material through the plant. A typical application is a PID controller fed by a flow meter and
using a control valve as the final control element. The DCS sends the setpoint required by the
process to the controller which instructs a valve to operate so that the process reaches and stays
at the desired setpoint. (see 4–20 mA schematic for example).

Typical applications

Distributed control systems (DCS) are dedicated systems used in manufacturing processes that
are continuous or batch-oriented. Processes where a DCS might be used include:

• Chemical plants
• Petrochemical (oil) and refineries
• Pulp and paper mills (see also: quality control system QCS)
• Boiler controls and power plant systems
• Nuclear power plants
• Environmental control systems
• Water management systems
• Water treatment plants
• Sewage treatment plants
• Food and food processing
• Agrochemical and fertilizer
• Metal and mines
• Automobile manufacturing
• Metallurgical process plants
• Pharmaceutical manufacturing
• Sugar refining plants
• Agriculture applications
2.4.2 Control Valves and interlocks:

Valve is a device that regulates, controls or directs the flow of a fluid by opening, closing, or
partially obstructing fluid flow. In simple words, a valve is a mechanical device that controls
the flow and pressure of a fluid within a system or process i.e. it controls flow and pressure.
Selection of valves depends upon the requirements which can be related to the economics or
the operation of the process plants.

Different types of valves used are:

• Gate Valve
Gate valve is the most common type of valve in any process plant. It is a linear motion
valve used to start or stop fluid flow. In service, these valves are either in fully open or fully
closed position. Gate valves are used in almost all fluid services such as air, fuel gas, feed
water, steam, lube oil, hydrocarbon, and almost any service. They provide good shutoff.
• Globe Valve
Globe valve is used to stop, start, and regulate the fluid flow. Globe valves are used in
systems where flow control is required and leak tightness is also necessary. Globe valves
provide better shut off as compared to gate valve and are costlier.
• Ball Valve
A ball valve is a quarter turn rotary motion valve that uses a ball shaped disk to stop or start
the flow. Most ball valves are of the quick acting type, which requires a 90 degrees turn of
the valve handle to operate the valve. The ball valve is smaller and lighter than a gate valve
of same size and rating.
• Butterfly Valve
A butterfly valve is a quarter turn rotary motion valve that is used to stop, regulate, and
start the flow. It has a short circular body. Butterfly valve is suited for large valve
applications due to compact, lightweight design that required considerable less space as
compared to other valves.
• Needle Valve
Needle valves are similar to a globe valve in design with the biggest difference being the
sharp needle like disk. Needle valves are designed to give very accurate control of flow in
small diameter piping systems.
• Pressure Safety Valve
 A pressure relief valve or a pressure safety valve is used to protect equipment or piping
system during an overpressure event or in the event of vacuum. This valve releases the
pressure or vacuum at pre-defined set pressure.
• Air operated valves:
• "Air or current to open" - The flow restriction decreases with increased control signal
value.
• "Air or current to close" - The flow restriction increases with increased control signal
value
There can also be failure to safety modes:
• Air or control signal failure to close" - On failure of compressed air to the
actuator, the valve closes under spring pressure or by backup power.
• Air or control signal failure to open" - On failure of compressed air to actuator,
the valve opens under spring pressure or by backup power.
• Hand valve or actuator
A handle is used to manually control a valve from outside the valve body. Automatically
controlled valves often do not have handles, but some may have a handle (or something
similar) anyway to manually override automatic control, such as a stop-check valve. An
actuator is a mechanism or device to automatically or remotely control a valve from outside
the body. Some valves have neither handle nor actuator because they automatically control
themselves from inside; for example, check valves and relief valves may have neither.
• Interlocks
An interlock is a feature that makes the state of two mechanisms or functions mutually
dependent. It may be used to prevent undesired states in a finite-state machine, and may
consist of any electrical, electronic, or mechanical devices or systems. In most applications,
an interlock is used to help prevent a machine from harming its operator or damaging itself
by preventing one element from changing state due to the state of another element, and vice
versa. Elevators are equipped with an interlock that prevents the moving elevator from
opening its doors, and prevents the stationary elevator (with open doors) from moving.
Although both are idiot proof strategies, an interlock should not be confused with a simple
safety switch. For example, in a typical household microwave oven, the switch that disables
the magnetron if the door is opened is not an interlock. Rather, it would be considered an
interlock if the door were locked while the magnetron is on, and the magnetron were
prevented from operating while the door is open. Interlocks may include sophisticated
 elements such as curtains of infrared beams, photodetectors, a computer containing an
interlocking computer program, digital or analogue electronics, or simple switches and
locks.

2.4.3 Cooling tower:

Figure 2.2: Cooling Tower

A cooling tower is probably the first thing to be installed and commissioned in a pilot plant.
With two centrifugal pumps with a common discharge the cooling tower is essentially used in
the heat exchangers and the compressors. The type used in this plant is induced draft cooling
tower it generally offers most effective and economic solution. The fan induces hot moist air
out of the discharge. This produces low entering and high exit velocities reducing the
possibility of recirculation in which discharged air flows back into the air intake.
2.4.4 Heat exchanger:

Figure 2.3 : Heat Exchanger

A heat exchanger is a system used to transfer heat between two or more fluids. Heat exchangers
are used in both cooling and heating processes. The type used here are shell and tube heat
exchangers. The three products naphtha, diesel and fuel oil have three heat exchangers as their
product coolers while the others are being used to solve different purposes. The design for
every heat exchanger is different depending upon their requirements.

Most of the heat exchangers used are shell and tube heat exchangers. Shell and tube heat
exchangers consist of a series of tubes which contain fluid that must be either heated or cooled.
A second fluid runs over the tubes that are being heated or cooled so that it can either provide
the heat or absorb the heat required. A set of tubes is called the tube bundle and can be made
up of several types of tubes: plain, longitudinally finned, etc. Shell and tube heat exchangers
are typically used for high-pressure applications (with pressures greater than 30 bar and
temperatures greater than 260 °C).
2.4.5 Air-nitrogen package:

Figure 2.4 : Air & Nitrogen System

The air and nitrogen package covers the second part of the utility systems of the plant and is
responsible for producing the plant air, the instrument air and the nitrogen.

Plant air:A two stage discharge compressor produces the plant air which is stored in a storage
vessel. This plant air is used entirely in the plant for flushing purposes.

Instrument air:For the production of instrument air the process used here is pressure swing
adsorption. The instrument air is used in the action of the various control valves and the
solenoid valves present throughout the plant.

Nitrogen:Nitrogen is a very important component in smooth functioning of the plant. As most

of the processes occurring in the plant have hydrocarbons involved in them, any amount of
oxygen in the lines is hazardous and can lead to fires. Thus nitrogen purging before and after
every productive run is very important to prevent any safety hazards.
Nitrogen is also produced by the pressure swing adsorption process. Below is a simple
2.4.6 Combustion Chamber:

Figure 2.5: Combustion Chamber

While most of the pilot plants have burners, this pilot plant has a combustion chamber which
follows a proper BMS (Burner Mass Sequence). The pneumatic control valves control the flow
of air and the flow of fuel is controlled by needle valves thus ensuring an ideal air to fuel ratio;
which for the case of LPG is around 11-15. One product of the process is fuel gas which will
be used later when the desired mass flow rate is established. The flow of LPG is stopped
thereafter by the solenoid valves to continue maintaining a healthy air to fuel ratio which for
the fuel gas is 15-20.

The purpose of the combustion chamber is to provide pyrolyser and the catalytic reactor their
desired temperatures to carry out the respective processes occurring in them. The temperatures
inside the pyrolyser tubes can go upto 500℃ which are experimentally sufficient enough to
carry out the cracking.
2.4.7 Extruder:

Figure 2.6: Extruder

The extruder initiates the process by converting the feed which is in solid form to complete
liquid form. The feed passes through four heating zones each with different temperatures for
different purposes. A screw is present inside the extruder which rotates and takes the feed
forward. The rotation of the screw and the temperature of the heating zones combine to give
different feed rates. These results were optimized by taking experiments on regular basis. These
tests were done until the required feed rate and viscosity was achieved. Generally by increasing
the rpm the feed rate increases but it decreases the residence time of the feed which lead to
uneven and insufficient burning of the plastic thus increasing the viscosity which affected the
flow ability drastically. The flow rate and viscosity also depended on the type of feed used. For
HDPE flow rate and the viscosity both were low in comparison to agglomerated plastic. Being
the initial stage of the main process, a well designed extruder meeting all the specifications is
necessary for a productive result.
2.4.8 Pyrolyser:

Figure 2.7: Pyrolyser

Pyrolysis is the thermal decomposition of materials at elevated temperatures in an inert

atmosphere.[1] It involves a change of chemical composition and is irreversible. Pyrolysis is
most commonly used in the treatment of organic materials. It is one of the processes involved
in charring wood.[2] In general, pyrolysis of organic substances produces volatile products and
leaves a solid residue enriched in carbon, char. Extreme pyrolysis, which leaves mostly carbon
as the residue, is called carbonization.

Pyrolysers can be divided into two main categories on the basis of their mode of operation, i.e.
the continuous type, where the sample is supplied to a furnace preheated to the final
temperature, and pulse mode reactors in which the sample is introduced into a cold furnace
which is then heated to the final pyrolysis temperature. In the analytical pyrolysis of solid and
some liquid materials mainly pulse mode pyrolysers are used. The temperatures however in
this case are provided by the combustion chamber as explained earlier. The values of the
temperatures are controlled by lines of plant air controlled by pneumatic control valves.
2.4.9 Catalytic reactor:

Figure 2.8: Catalytic Reactor

Catalytic cracking is widely used in the petroleum refining industry to convert heavy oils into
more valuable gasoline and lighter products. As the demand for higher octane gasoline has
increased, catalytic cracking has replaced thermal cracking. Two of the most intensive and
commonly used catalytic cracking processes in petroleum refining are fluid catalytic cracking
and hydrocracking.

The type used here is packed bed reactor. The catalyst loading is done in the commissioning
stage of the plant before the start-up. The catalyst degenerates over the course of time during
the process due to coke formation. Therefore a productive feed run should not last for more
than 36 hours as it can damage the catalyst. A regeneration run is done after a process run until
the catalyst is found to be active again.
2.4.10 Fractionating column&Reflux drum :

Figure 2.9: Fractionation column

A fractionating column is an essential item used in distillation of liquid mixtures so as to

separate the mixture into its component parts, or fractions, based on the differences in
volatilities. Fractionating columns are used in small scale laboratory distillations as well as for
large scale industrial distillations.

In the context of this plant the fractionating column is the final stage of the main process. With
three product cuts, a reflux drum is also in line with the top of the column. The cuts are
separated on the basis on the difference in the boiling points of the required products. The
residual gas i.e. the fuel gas leaves the column from the top and is further used as a fuel in the
combustion chamber.

The reflux drum, or accumulator, serves as a distribution point for reflux and distillate.
Condensed liquid leaves the reflux drum under level control. Drum level control is critical to
ensure that the proper amount of reflux will return to the distillation tower. Poor liquid level
indication can cause expensive operating problems and product degradation.
.

Chapter 3

Observations and Troubleshooting

Since the experimentation work in the field job is negligible the majority part of my training
period was spent in covering the field aspects of a pilot plant. This made me thorough with all
kinds of problems and faults occurring in the process and the equipment and boosted my
confidence in carrying a smooth operation of a pilot plant. Below are some of the major
shortcomings of each and every machine I worked on and the possible areas of improvement
and troubleshooting.

3.1 Cooling tower:

• Observation: Cavitation, a common problem occurring in the operation of cooling tower.

Cavitation can occur in the pump, the propeller and the pipelines. The pump here used is a
positive displacement pump. It refers to formation of air pockets thus causing a sudden
decrease in the pressure of the line.

Troubleshoot: Proper priming of the pumps before opening any discharge is a necessary step
and is done everytime a pump is started. The second reason which might lead to air pockets is
a low level in the basin of the tower. A proper supply of make-up water and regular checking
can avoid cavitation.

• Observation: Choking of the strainer can occur since the strainer’s work is to ensure a
clean running supply of water with no metallic or other impurities.

Troubleshoot: Regular checking and cleaning and strainer is necessary.

• Observation: Lube oil contamination can occur due to various reasons. Seasonal changes
and improper working of pump is some of them. These can lead to decreasing the
transparency and thus hinder smooth functioning.

Troubleshoot: Regular checking of lube oil is therefore an important step and increases the
life of the equipment.]
• Observation: Rusting of pipes is a common phenomenon and has to be prevented for the
durability of the pipelines. Also rusty water harms the supply equipment of the cooling
tower.

Troubleshoot: Chemical dosing should be done on a daily basis.

3.2 Air-Nitrogen package:

• Observation: A basic problem occurring in an N2 package is not getting the desired

concentration. For a plant with such use of hydrocarbon a concentration of not more
than 0.2% should be present. Over the time I have seen many reasons why the
adsorption was inadequate and improper.

Troubleshoot: I address all the major reasons of the problem by explaining the troubleshooting
here

1. There should be a regular check of the filters.

2. The solenoid valves used in the adsorption system should function properly.
3. The intervals between the adsorption and re-adsorption should work correctly.
4. The pressure in the surge vessel should be maintained.
5. The pressure safety valves should function properly.

3.3 Air compressor and Regeneration compressor:

• Observation: Most of the problems faced in running both the compressors were
similar. The first being the machine trips occurring due to overload.

Troubleshoot: These trips occur due to high voltage operations and require assistance from
the vendor to overcome them.

• Observation: If the discharge pressure goes too high the machine trips due to safety
reasons.

Troubleshoot: This problem mostly occurs in the Air-N2 compressor as it is a two stage
discharge compressor and both stage pressures should be monitored simultaneously.

• Observation: Much like a positive discharge pump, the lube oil of a compressor is
prone to losing its transparency.

Troubleshoot: Regular checking of the lube oil and changing it whenever necessary.
3.4 Combustion chamber:

• Observation: Achieving and maintain the air-fuel ratio is a tough part without which
the burner light-up is not possible.

Troubleshoot: Following the BMS schedule carefully is one of the mandatory steps. If the
ratio still doesn’t fit, hit and trials of different ratios and flow rates should be made.

3.5 Extruder:

• Observation: As discussed earlier achieving the flow rate and viscosity is not easy
and cause problems during the process

Troubleshoot: Conducting proper experiments and trying all possible combinations of flow
rate and temperatures is essential.

• Observation: Choking of the neck of the extruder can occur if the temp of the neck
increases to an extent that melts some of the plastic

Troubleshoot: Regular monitoring of the neck temperature and a proper flow of cooling water
through the neck can be a way out to this problem.

• Observation: Deposition of carbon on the screw can occur if the screw of the extruder
is not monitored over a long time.

Troubleshoot: Removal and cleaning of the screw every few weeks.

3.6 Pyrolyser:

• Observation: Pressure drop across the pyrolyser

Troubleshoot: Regular checking of joints and pipelines in the top and the bottom of the
pyrolyser.

3.7 Catalytic reactor:

• Observation: The temperatures of the bottom and the top of the reactor have a gradient
and if this gradient increases to more than 100℃ it can cause damage to the tubes.

Troubleshoot: Decreasing the temperature gradient can be done by letting the air pass through
the hand valves present at the ducts from the combustion chamber or decreasing the fuel flow
thus decreasing the heat provided from the chamber.
3.8 Fractionator:

• Observation: A pressure gradient can arise between the top and bottom of the column
and can cause a change in the properties of the products.

Troubleshoot: To adjust the difference either the bottom quenching should be increased or the
top pressure should be adjusted.

3.9 General problems:

• Observation: A general problem that occurs during the running of a plant is the
presence of a leak and all leaks need to be attended with extreme caution and care. Any
kind of leak can cause damage to the equipment and affect the process.

Troubleshoot: The location of the leak should first be found by carefully examining the loops
and considering them in parts. A leak might be visible to the naked eye but confirmation
through a soap solution is also necessary. Only after that all the leaks are attended and rectified
can the process be initiated

Chapter 4
Conclusion
4.1 Conclusion
Taking inferences from the literature survey, there are several parts that need to be attended
right from the beginning of the set-up of the plant. The basic knowledge of the pre-
commissioning and the commissioning activities has been explained theoretically in this report,
but there are alterations to almost every aspect that I presented in this report.

These alterations depend entirely on the process of the plant and the equipment’s that are going
to be used. They depend upon the parameters of the process and the designs that will be done
to meet the requirements. To summarize, I now have knowledge about every activity that is
related directly or indirectly to the set-up of a pilot plant and can assist in the same.

The activities although solve the same purpose in all the conditions which is getting the
products with maximum efficiency and conversion while keeping in mind all the safety
measures,