I AkerSolutions Project: Site: Bayer Project Number ‘APG Project Number: rs EPRO Project Bayer Vapi Private Limited ‘ADOKM-000158 06111-1905 DOCUMENT TITLE: PROCESS & UTILITY DESIGN BASIS BAYER am< >) Project Phase: FEL3 (Basic Engineering) ~ Restricted - Document File Name: = ‘Document Nam ~ | Document Number: PROCESS & UTILITY DESIGN BASIS. 1905-200-00-7007-44-721 Author: Name: Tat Ea Mangesh Kurup 0022-66416496 Mangesh kuryp@akersoluions com Document Revision: nae Le VY 1 | osor.2018 |‘ MSK $3 Issued for Design PMH 703.01.2018 By 103.01-2018 0 [2308207 | _ Pua s Issued for Approval | s5wi2a062017 | JSviz0082017 Foe [vate | 6y | Pemstatus Revision Tite Checked ‘Approved Thdustrial Complex Process Plant Piant section Building —bivision Va SRC= SAKES PRO. Gropscience © Bayer Engineering & Technology ‘Aker Powergas Pvt Ltd. Powergas House, Think Techno Campus, Kanjurmarg (E),, Mumbai - 400042 Tol: +91 22 6891 5901] Fax +91 22 6691 5934 | ‘wn akersolutions.com Confidential © 2017 Aker Solutions Pc1905009_RO% EE AkerSolutions Division: CROPSCIENCE Location: VAPI, INDIA Plant: EPRO Bayer Project No: A00KM-000158 APG Project No:_506111-1905 GDL Chapter No: 03.01 Doc No: 1905-300.00-7007-A4-22 Doc Title: PROCESS & UTILITY DESIGN BASIS Dare-oa012018 | Revnot PAGENO_2 of 68 SIGNATURES: ‘Author Name Date / Signature Mangesh Kurup Wy, 03.01.2018 wy Contributor Name Title _ | __ Date / Signature Checked - Name Date / Signature Parag Mhatre 03.01.2018 No ‘Approved Name Title Date / Signature Satish Joshi 03.1.2018 Vv ‘© Bayer Engineering & Technology Confidential © 2017 Aker Solutions 'P1908009_ROB\ & ) BAYER Division: CROPSCIENCE AR AkerSolutions |P"" — FPR° Rev nod Date 03 012016 Bayer Project No: AOOKM-000158 APG Project No: _506111-1905 ‘GDL Chapter No: 03.01 ‘Doe No: 1905-200-00-7007-A4-221 Doc Title: PROCESS & UTILITY DESIGN BASIS PAGENO. 3 of 68 REVISION HISTOR 1 03. econ Revision ~ Issi Rev. / ; vers. ote) Change Description 0 __| 23.08.2017 | First Revision ~ issued for Approval ‘© Bayer Engineering & Technology Confidential © 2017 Aker Solutions PC1805009_ROPlant: EE AkerSolutions Reno Date-08 07 2078 Division: CROPSCIENCE Location: VAPI, INDIA EPRO Bayer Project No: AOKM-000188 APG Project No:_506111-1905 GDL Chapter No: 03.04 1905-300-00-7007-A4-221 PROCESS & UTILITY DESIGN BASIS PAGENO 4 of 68 DOCUMENT REFERENCES: - Current Rev. / Vers. of this Document Referenced Documents Document Document : sion / Version Name number PED for Process Scheme | EPRO-DWG-090-001 BI PFD for Chlorine Storage | EPRO-DWG-090-002 & preparation of B1 Gaseous Chlorine PFD for Chlorination & EPRO-DWG-090-003 Pyrazole Dissolution B1 Reaction | PFD for Sulfenylation EPRO-DWG-090-004 nm Reaction PFD for Concentration & | EPRO-DWG-090-005 Bi Solvent Exchange | | | PFD for Neutralization , EPRO-DWG-090-006 Solvent Exchange & Bi Oxidation 1 PED for Neutralization, | EPRO-DWG-090-007 Solvent Exchange & B1 Oxidation 2 PED for Crystallizers EPRO-DWG-090-008 BL PFD for Filtration & EPRO-DWG-090-009 BL Drying 1 _ PED for Filtration & EPRO-DWG-090-010 br Drying 2 PFD for DCM & 50% EPRO-DWG-090-011 Acetic Acid Recovery PED for Scrubbing system PFD for Vent Header | EPRO-DWG-090-015 PFD for Storage Material | EPRO-DWG-090-016 BL handling _ | PFD for DEDS STORAGE _ | EPRO-DWG-090-017 Bi PED for Utility 1 EPRO-DWG-090-013 Bi PFO for Utility 3 EPRO-DWG-090-019 Bi Batch Mass and Mass | SMZ/TZB Balance from Bayer - Material & Energy 1905-300-00-7004-A3-224 a Balance ‘G Bayer Engineering & Technology Confidential © 2017 Aker Solutions c1905009_ROBayer Project No: AOOKM-000158 APG Project No: 06111-1905 ‘GDL Chapter No: 03.01 Division: CROPSCIENCE E am<>o)) mi 2 Location: VAPI, INDIA Doc No: 1905 00-007007-A6224 Doc Title: IE AkerSolutions [Pere Pre PROCESS & UTILITY DESIGN BASIS Dae cease [Reno PASENO_S ats Current Rev. / Vers. of this Document -[-|[-[-J-T- Referenced Documents | Document Document isi i Revision / Version | Name number _ | Energy Balance (Utility Consumption) from : - | Bayer _ 7 Block Flow Diagrams ‘AQOKM-000165-FLO-090-002A from Bayer ‘AQOKM-000165-FLO-090-003A ‘AOOKM-000165-FLO-090-004A ‘AOOKM-000165-FLO-090-005A ‘AOOKM-000165-FLO-090-006A ‘ADOKM-000165-FLO-090-007A ‘AOOKM-000165-FLO-090-008A ‘AOOKIM-000165-FLO-090-009A ‘AOOKM-000165-FLO-090-010A ‘AOOKM-000165-FLO-090-011 ‘AOOKM-000165-FLO-090-012A ‘AOOKM-000165-FLO-090-013A Process Description from | AOOKM-000165-MAN-090-001 Bayer R3 02 ~SBayer Engineering & Technology Confidential © 2017 Aker Solutions Pc1905009_ROBayer Project No: AOOKM-000158 APG Project No: _506111-1905 Division: CROPSCIENCE leDU'Ghapisr NSoaD1 Location: VAPI, INDIA Doc No: 1905:300-00-7007.4.221 Doc Title: AkerSolutions |? PR PROCESS & UTLTY DESIGN BASIS Date 0507208 | RevNot PAGENO 6 of 88 Contents 1. Introduction 8 2. Executive summary. 10 3. Project scope 10 4, Project definition 10 44 Project Title 10 42 Terminal Capacity 40 4.3 Feed & Product Specifications “1 4.4 EQUIPMENT, INSTRUMENT AND LINE NUMBERING PHILOSOPHY. 12 5. Abbreviations 12 6. Units of measurement. 13 7. Site Meteorological Data. 15 8. Design Software. “ 16 9. Codes & Standards. 6 10. Facility Description and Design Basis. 7 10.1 Utilities. 7 10.2 Process water / Demineralised water / Potable water system 7 10.3 Compressed air / Instrument Air / Breathing Air system. 19 104 — Nitrogen. 19 105 Steam - 20 10.6 Cooling Water — 24 107 Chilled Water - 2 108 Chilled Brine — 2 10.9 Drainage & Venting system. 23 10.10 Effluent Disposal 23 10.11 Power 25 10.12 Future expansion provisions 25 11. Process Description 25 12, Miscellaneous Points a 13. Mechanical Design Pressure & Temperature: 32 14, Line Sizing Criteria 33 14.1 Flow Rate Basis for Line Sizing 33 142 Pipe Wall Roughness. 34 143 Relief ine sizing 34 ‘© Bayer Engineering & Technology Confidential © 2017 Aker Solutions Pc1905009_ROBayer Project No: ADOKM-000158 APG Project No: _506111-1905 Di : CROPSCIENCE vision: GDL Chapter No: 03.01 Location: VAPI, INDIA 1905-300-00-7007-A4-221 IE AkerSolutions [Pant EPRo PROCESS & UTILITY DESIGN BASIS Dae pao [Rane PAGENO_T a 38 415, Isolation 4 15.1. Isolation at the Unit Battery Limit u 16. Equipment sizing 35 16.1 Vessel (including Storage Vessels). 35 16.2 Pumps 35 1) 463 Compressors 37 16.4 Heat Exchangers. 37 417. Instrumentation 37 Appendix 1: Water Quality . 40 ‘Appendix 2: Utility Conditions. 40 ‘Appendix 3: Preliminary Dimensions and orientation tabie 50 Annexure 4: Line sizing criteria 53 ‘© Bayer Engineering & Technology Confidential © 2017 Aker Solutions Pc1g0s008_ROBayer Project No: ADOKM-000158 APG Project No:_506111-1905 Division: CROPSCIENCE (aol chapterNaroaot (Rt) Bi AkerSolutions |r sro Be ur et Introduction General Bayer CropScience, subsidiary of Bayer AG Germany, is engaged in manufacturing of agrochemicals & seeds. Bayer CropScience, one of the leading Agrochemical manufacturing company in the world is planning to invest in EPRO, an insecticide used against insect attacks on crops, manufacturing facility at their site at Vapi, situated in south Gujrat, India. The capacity of the plant will be 1500 TPA of EPRO. Location of new plant is finalized at existing MPBD 1 plant & old engineering stores in block B400 & in addition some portion of existing MPBD 1 in block B300 as depicted in the site master plan. The manufacturing process is mainly a batch. This plant will be process automated & equipped with measuring & controlling instruments with dedicated DCS. Bayer has planned to implement common venting system & safety upgradation (JUMP) in all its manufacturing plant at vapi. It has been decided to construct a new building & a new plant. The new building will be built including equipment layout to address operational & maintenance aspects, to implement common venting system & process improvements & automation. Power & utilities for this plant will be provided from existing utility block at site. Wastewater, waste gases & solid waste will be treated in existing waste treatment facilities. Bayer Vapi Pvt. Ltd & Engineering & Technology, India form an integrated project team for the execution of the project. The plant has to be designed for a minimum lifetime of 20 years for equipment, piping & PCT instruments. Civil building has to be designed for minimum 30 years, with normal maintenance efforts. The plant is new standalone unit & no shutdown of any existing process plant is anticipated for execution of this project. However shutdown would be required on the central utilities, central solvent tank farm, ETP & pipe rack for necessary hook-ups. The vent from central tank farm DCM system is connected to a new vent gas treatment system. For un-planned or planned longer outages of incinerator, then the unit will have to be shut-down/put in idle mode to minimize vent gases released to the atmosphere. Following are the process steps for manufacturing EPRO: ‘© CES Preparation & Pyrazole Dissolution ‘+ Sulfenylation & Pre Concentration + Concentration & Preparation for Solvent Exchange + Neutralization , Solvent Exchange & Oxidation © Crystallization + Filtration and Washing © Drying Bayer Engineering & Technology Confidential © 2017 Aker Solutions Pc1905009_ROBayer Project No: AOOKM-000158 APG Project No:_506111~1905 Division: CROPSCIENCE \ Ee GDL Chapter No: 03.01 = Location: VAPI, INDIA Doc No: 1905-300-00-7007-A4-221 , Doe Title: AkerSolutions |Pis® PR PROCESS & UTILITY DESIGN BASIS Date api zoIS | —RevNe FAGENO_8 ot 8 (RI) ey) ry rt) © Packing Further, following are the recovery units + DCM Recovery 98% Acetic Acid Recovery (Continuous Process) * 50% Acetic Acid Recovery Pressure controlled Inertisation & venting systems (split range, with adequate high and low pressure protection where required) to be considered. Process control DCS / SIS implementation will include recommendations out of A3 & other safety reviews as a part of JUMP project implementation similar to the other plants. Lay out concept to be developed with consideration of Gravity Transfer (gravity transfers are preferred, pressure transfers to be avoided). For Chlorine gas and Hydrogen Peroxide storage and handling a standard guideline for robust operational concept in addition to solid prevention concept for release scenarios in case of leakage/release. These are included in Codes & Standards. Safe Off-loading of chemical from tanker shall be developed. Vessel jackets and heat exchangers of fluid duties should be equipped with thermal relief valve. Vacuum systems shall be chosen with the intention of minimizing VOC emissions, Energy efficiency and less liquid effluents. Pump-selection-shall-be-according to JUMR flles: Mechanical rotating equipment shall be ATEX certified to the zone for new /replacement equipment. For critical duties consider primary and secondary scrubbers in series with monitoring of flow/pH etc. On-line sampling systems shall be considered for all reactors to avoid spillage. Powder transfer system, big bag charging and filling system is considered for solid charging and to reduce cycle time and hazards associated with manual handling. Secondary heating and cooling is considered for multi utility application and precise temperature control within the reactor. Due to space constraints it is not possible to implement a separate Annex / control room, but an attached control room is considered with fire {blast wall separation to the main plant. Proper scrubbing system to be designed for Cl, vapor, acidic vapor & HCI vapor. For Clz vapour system, additional emergency scrubber to be installed, ‘@ Bayer Engineering & Technology Confidential © 2017 Aker Solutions c1905008_ROBayer Project No: AOOKM-000158 APG Project No:_ 50611-1905 GDL Chapter No: 03.01 Location: VAPI, INDIA Doc No: 1906.900.00-7007-A4.224 Division: CROPSCIENCE Doc Title: AkerSolutions [Pant =e PROCESS & UTILITY DESIGN BASIS Dae eoroe | Rene FAGENO_10_at ‘Assessment to be carried out for the consequences of releases. Releases to be managed or demand rate reduced to avoid safety issues, or vent releases to appropriate scrubbing/abatement. Consideration for reduction of time cycle to be given (either by process development or by adding equipment) Ease of operations will be primary requirement, All hot lines above 60 °C shall have hot insulation, where heat is required to conserve. Personal protection insulation to be provided for hot lines, where heat conservation is not required. All lines operating below 20 'C shall have cold insulation, Hydrocarbon gas detectors shall be installed at-all-four-corners-of the in tank farm area e and plant building. Number of gas detectors will be worked out in Detailed Engineering, ‘Ammonia gas detector shall be installed at utility area. Executive summary The Client has decided to execute the project in two phases, namely Basic Engineering and Detailed Engineering. Present scope of project is limited for Basic Engineering only. Project scope The Client has appointed Aker Powergas Pvt. Ltd. (herein after referred to as APG) to provide Basic engineering services. 4. Project defi 4a Project Title Project name Basic Engineering & Early Civil Design for EPRO Project Site location Vapi Client : Bayer Vapi Pvt. Ltd Licensor Bayer Crop sciences 42 Terminal Capacity Nameplate capacity 1500 MT / annum No. of days of operation per year for the terminal is considered as 330, ‘S Bayer Engineering & Technology Confidential © 2017 Aker Solutions 'P:1905009_RODivision Location: EE AkerSolutions Plant: Date 05 012078 Rev Not CROPSCIENCE : VAPI, INDIA EPRO Bayer Project No: ADOKM-000158 APG Project No: 50611-1905 Doe No: 1905:300-007007A4221 Doc Title: PROCESS & UTILITY DESIGN BASIS PAGENO 11 of 58 43 eR ey Rt) Feed & Product Specifications : Table 4: Feed specification ~ Major raw materials with flow rates are listed below. All feed are intermittent. Description Feed Feed#2 Feed#3 Feed DEDS Pyrazole Chlorine Flowrate, kg/batch 5328 2400 281 Ballery tii Opera nat BR Y6 ATM 84/6 148 Desiga-B e 3/404 grade} Project Project te Set Seepe} Scope} r= Battery Limit Operating + AMBL25 AMBL25 Design Temperaturer26 ro2aodege | to 200-deg.¢ 100% 100% Feed composition 100% DEDS ney cca 7 Description Feeds Feedio Hydrogen Feed Rome NaHSO; cao Flowrate, kg/batch 580.9 242.6 25 50% Hydrogen 38% Feed composition pane rea 100% CaO ‘Description Feed? Feede2 Feed#3 Feed DMF Flowrate, kg/batch 365.6 Feed composition 100% DMF yer Engineering & Technology Confidential © 2017 Aker Solutions '>:1905009_R0va Bayer Project No: AOOKW-000158 {4 APG Project No: 06111-1905 paYer) Di eR x vision: CROPSCIENCE ci chapiee Nora 5 Location: VAPI, INDIA Doc No: 1905,300.00.7007.A4 201 AkerSolutions |Pint PRO PROCESS & UTILITY DESIGN BASIS Doc Title: Date-0507 2018 [Reyne [PaGENO 12 of 58 RN) 44 Ri) eR RD Other raw materials consumption is not listed, as these are used in multiple stages including Acetic Acid, DCM (Di Chloro Methane), caustic, OM Water. PRODUCT ‘The guarantee specifications of all the products shall be as listed in the Table 5 below. Table 5: Product specification Description’ Producti Product EPRO - Powder Flowrate, kg/batch 1500 MT /ANNUM , 2617.6 kg/batch Battery Limit Operating / Design at ric (Powder is packed i Pressure, barg (at grade) psec a (Coa ca Drums / Jumbo Bags) Equipment, Instrument and Line Numbering Philosophy P&ID and PFD document numbering to be as per client numbering philosophy, as informed by ‘mail from Pravin Solanki dated June 29, 2017. EPDS / IPDS / Reports document numbering to be as per APG numbering philosophy (Document Number : G-OS-013.005-A-02 ~ Annexure of Document Identifier- Process & G-OS- 013.000.P-02 ~ Identification & Traceability) Equipment numbering to be as per client numbering philosophy AKZ numbering (Plant structure code AKZ Werknorm 9060 : November 2010). Instrument & tine numbering philosophy to be as per legend P&IDs EPRO-DWG-090-061 /062. Abbreviations [ BEWw Boiler Feed Water | TR : ea - [IDs ~*~”: Total Dissolved Solids a iss [TotalSuspendedSolids = SSSOSOSC*~S~S~S* Outside Diameter ‘© Bayer Enginearing & Technology Confidential © 2017 Aker Solutions Pc1905009_ROBayer Project No: AOOKM-000158 506111-1905 Division: CROPSCIENCE 03.04 Location: VAPI, INDIA Doe No: 1905 30.00-7007-A6221 IE AkerSolutions |Pene Pre PROCESS & UTILITY DESIGN BASIS. Daecasoizo1e | Rene PAGENO_1_a “ip Internal Diameter ETP | Effluent Treatment Plant Local Exhaust Ventilation ro Chior i Methyl Formamide Di Chloro Methane | Ethane Sulfenyle Chloride | Low Pressure | Medium Pressure | Water Column rt) ke [ Dimensions (Dia, Length etc.) Volume [Area sp. gr. TC/15°C ‘Liquid density Vapour density © Bayer Engineering & Technology ‘Confdential® 2017 Aker Solutions PC1805009_RO(7 \ Bayer Project No: AOOKM-000158 4é APG Project No: _506111-1905 BAYER) ision: Y Division: CROPSCIENCE ‘GDL Ghapter Nor 0301 8 Location: VAPI, INDIA Doc No: 1905-300-00-7007-4-221 Doe Title: i Plant: EPRO AkerSolutions PROCESS & UTILITY DESIGN BASIS Date-a3.012018 | RevNot PAGENO 14 of 58 | Parameters eS ‘osity (Dynamic) Viscosity (Kinematic) m'/h, Sm'/h, Nev, ie kcal/h or MMkcal/h | keal/h-m™C Fouling resistance hem**C/kcal "Specific Enthalpy/ Entropy | Specific heat { | Thermal conductivity Corrosion allowance for flowrates: | DTons/day D Tons/day (8) Liquids : Om*/h, © Bayer Engineering & Technology Confidential © 2017 Aker Solutions Pc1e05009_ RO7 S\ Bayer Project No: AOOKM-000158 Gs APG Project No:_506111-1905 (BAYER) vision: sect Net Re Division: CROPSCIENCE ‘GDL Ghapter Nor03.01 » Location: VAPI, INDIA Doc No: 1905.300.00-7007.44.221 Doc Title: Plant: EPRO AkerSolutions PROCESS & UTILITY DESIGN BASIS Date 05012018 [| RevNot PAGENO_15 of 68 Site Meteorological Data ‘This section is to be updated based on the Project document. Parameter Minimum Normal/ ‘Average (A) Meteorological data Elevation Above Sea Level, m 27.5 mtr above sea level ey) | Barometric pressure, bara - 49 50 / 65 (Black body temp.) Ambient Temperature, °C | Relative Humidity, % | RainfallD Data (mm) I fe For 1h period | (b) For 24h period | Max recorded dry bulb temperature (for record only), °C | Min Dry Bulb Temperature, c | Temperature for MOMT, °C jum wet bulb temperature, “c Design ar temperature for ar cooled exchanges, c incidental temperature & Relative Humidity for Air | HOLD% | lower/Air compressor design ‘© Bayar Engineering & Technoloay Confidential © 2017 Aker Solutions Pc1g05008_ROBayer Project No: A0OKM-000158 APG Project No: _506111-1905 Division: CROPSCIENCE Nistor GDL Chapter No: 03.01 Location: VAPI, INDIA ‘Doc No: 1905-300.00-7007.A4-224 : Doc Title: IE AkerSolutions |Pant— =PR° PROCESS & UTILITY DESIGN BASIS Dapeor zoe] —Revno PAGENO_16 of 8 Design Software The Software as listed in the table below for various project activities unless Activities rocess simulation HYSYS Version 8.6 | Line pressure drop In-house validated spreadsheets alculations rafting PFD/P&ID ‘AutoCAD Version 2016 | Excel, Finstrument data sheet | Excel Line list | Excel Codes & Standards The system to be designed in accordance with the below mentioned codes and standards: - - PI-STD 520 Part | Sizing Selection and installation of Pressure-Relieving Devices in Refineries Part | - Sizing and Selection’, Sth Edition (July-2014 ) API-RP 520 Part | Sizing Selection and Installation of Pressure-Relieving Devices in 2 | Refineries Part ll-Installation’, 6th Edition ( March 2015) API-521 | Guide for Pressure Relieving and Depressurizing System’, 6th ____| Edition Ganuary 2014) _ | api-s26 Flanged Steel Pressur z _ | aPi-2000 Venting Atmospheric and Low -Pressure Storage Tanks (Non L | Refrigerated and Refriger h2014) /'BSZ, BS, ENISO Flame Arresters. Performance Requirements, Test Methods and 6852 Limits for Use The Gas Cylinder | The Gas Cylinder Rules, 2004 and the Gas Cylinders Rules, 1981 Rules with the Static and Mobile Pressure Vessel (Unfired) Rules -1981. (25) Code of Practice for Treatment of Water for Cooling Towers (1999 | Amendment 1 (January 2009)) 1EC 6079-10-01 | Classification of areas ~ explosive gas Atmospheres (2008) _ 175-10-12 _| Classification of areas ~explosive dust atmospheres (2015) _ 15-10553 Part 1 | Requirements for Chlorination Equipment-General Guideline for | Chlorination Plants including Handling Storage and Safety of ‘© Bayer Engineering & Technology Confidential ©2017 Aker Solutions PC1805009_ROfan Bayer Project No: ADOKM-000158 fonSen APG Project No:_506111-1905 (BAYER) visi : 2 ee Division: CROPSCIENCE Tara creniscnrosloT Location: VAPI, INDIA Doc No: 1905-300-00-7007.A4-224 Doc Title: Plant: EPRO Ik AkerSolutions PROCESS & UTIITY DESIGN BASIS Date-oa012015 | _Revnot PAGENO_17 af 68 eR 10. 10.1 ey) eR 10.2 Chlorine Cylinders and Drums ( 1983 Amendment 1 (July 1988)) 15 4263-1967 __| Code of Safety for Chlorine ( October 1997 7* Reprint } | H202 Bulk Storage Guideline (CEFIC) September 2005 1 anphit 89 Chorine Scrubbing Systems (Te Chiorne s) Edition 1 October 2001 - Chine Safely Scrubbing Systems (World Chlorine Council) Edition | 4 Apni 2011 "| Pamphiet 9: Chiorine vaporizing systems (The chlorine Institute ) Edition 7 ly 2011 Facility Description and Design Basis Utility system to be designed based on peak flow rate. Appropriate Diversity factor to-be is considered for all Utility system sizing-{HOLD}-Same is listed in Utility Summary (1905-300- 00-7008-A4-222). Header /Sub header to be sized based on peak utility flow rates. ‘Main header from Utility block to be designed to cater utility load of EPRO + future plant. Future plant utility load data is stittawaited-{HOLD) considered as same as EPRO utility ‘consumption except cooling water. For cooling water, future load will be 90 m3/hr. Line sizing Design margin is specified on page 28 /clause14. Process water / Demineralised water / Potable water system ‘The water system design shall have following considerations: + Process water will be received at battery limit from existing Utilities. It will be stored 32 m? CS Vessel. From this Vessel, process water is pumped to 10 m? CS Vessel on terrace for further distribution to users. New 8 m’ PP vessel to be provided for washrooms * Process water will be received from battery limit & it will be used for following users Secondary Heating & Cooling circuit Caustic pool (V100-TA10-BA100) ili, Scrubber Vessels (V500-AG10-B4100 /AG20-BA100 /AG30-BA100 /AG40-8A100) iv. Vacuum Pumps exchanger cooling v. Process Cleaning © Bayer Engineering & Technology Confidential © 2017 Aker Solutions PC1905008_ROBayer Project No: A0OKM-000158 APG Project No: _506111-1905 GDL Chapter No: 03.01 Location: VAPI, INDIA Doc No: 1905.300-00-7007-A4.224 Division: CROPSCIENCE Doe Title Plant: EPRO AkerSolutions PROCESS & UTILITY DESIGN BASIS Date Dora] —RevNot PAGENO_18 of 68 vi. Annex building vii. Washroom (Rt) viii. Decontamination Pit ‘* Overflow process water from buffer vessel of different secondary heating / cooling circuit will be collected in 1.6 m? CS vessel. This water to be pumped to cooling tower as makeup water. © DM water to be received from Battery limit & it will be used for water addition in following users i Agitated Nutsch Filters (V300-FA10-FA100 /FA110) ji, 50% Acetic Acid Preparation Reactor(V300-FA10-RA100) ili, Neutralization, Solvent Exchange & Oxidation Reactors (V300-CA10-CA100 /CA110) iv. NaHS03 salt dissolution Reactor (V300-CA10-RA110) ‘+ Demineralized water to be received at battery limit from existing Utilities. It will be stored 10 m’ SS Vessel on terrace. New booster pump will be provided for transfer DM water. From 10 m’ Vessel, OM water is distributed to users. ‘© Potable water to be received from existing Utility Building. As per instructions from client, there will not be hold vessel for potable water inside plant. Potable water will be distributed inside plant floor wise, Day tank farm & Chlorine shed and provided for Safety showers & eyewash stations in respective areas. ‘Safety shower, eye wash station & face wash station demand are considered as per IS 10592 -1982 standards Emergency Safety Shower = 110 litre/min Eyewash equipment = 15 litre/min RD Process water / Demineralised water / Potable water system shall consist of following equipment: Sr. Descriptic No, Desetiption Process Water Storage Tank Process Water Transfer Pumps 4 | Overflow Vessel () | 5 Overflow Vessel transfer pump I 1 15 m'/he ‘® Bayer Engineering & Technology Confidential © 2017 Aker Solutions Pc1g05009_ROBayer Project No: AOOKM-000158 APG Project No:_506111-1905 GDL Chapter No: 03.01 Division: CROPSCIENCE Location: VAPI, INDIA Doc No: 1905-300.00-7007-A4-221 : . . Doc Title: E AkerSolutions [Pat EPR PROCESS & UTILITY DESIGN BASIS Date-os0r2016 | RevNot PAGENO 19 of 58 6 DM Water Storage Tank 7 Process water Vessel for Wash room em 8 | DM Water Booster Pump 10.3 Compressed air / Instrument Air / Breathing Air system Plant Air is required for Utility stations & Air Operated pumps. Plant air system is received at battery limit & distributed to users Instrument Air is required for plant instruments control valves, on off valves etc. Instrument air system is received at battery limit & distributed to users after receiver. Breathing Air is also received at battery limit & distributed inside plant. The Compressed Air / Instrument Air / Breathing Air system shall have following design considerations: Description | Details as per client’s requirement) 1_| Number of instrument Air receiver 41 (capacity 1 m | - 40°C dew point @ Atm. Pressure (at Battery Limit) 2 Instrument air quality | 3 | Oilcontent, ppm 3 ppm (max) (at Battery Limit) for compressed air demand is considering follows: «The Instrument air demand for current facilities to be estimated based on intermittent operation of on-off valves, control valves considering 40% diversity factor. ‘© Plant air demand is only for Utility Stations & air operated pumps. ‘© Instrument air receiver capacity is frozen as 1 m’ by client based on past project experience considering critical Instrument Air demand for 15 minutes or equivalent time. 10.4 Nitrogen ey 0.6 barg Nitrogen is required for inertisation of systems & 2 barg Nitrogen is required for seal pressurization of all reactors, ANF, Dryer, bagging & charging system, Dry Vacuum Pumps, ANF pressure testing, flushing of lines transferring reaction mass. 2 barg Nitrogen is received at Battery limit from existing Utility. eR) © Bayer Engineering & Technology Confidential © 2017 Aker Solutions PC:1805009_ROS Bayer Project No: ADOKM-000158 fs (ea%er| SRR eeoeeciencel APG Project No:_506111-1905 X Ee ) vision: ‘GDL Chapter No: 03.01 ~ Location: VAPI, INDIA Doc No: 1905.300.00.7007-44221 Doe Title: AkerSolutions |? =PR° PROCESS & UTILITY DESIGN BASIS. Date-Ga0T 20S [Revo PAGENO 20 of 68 (Rt) 10.5 RN) Ry New booster system to be installed for increasing pressure to 6 barg. 6 barg Nitrogen is required for seal pressurization of double mechanical pumps. Nitrogen system shall have following design considerations: Description | Details 1( 75 NM3/hr capacity to be worked out) 40" At re (Purity > | 2 | nitrogen quality cen re \tm. Pressure (Purity > 99.9 3. Oilcontent, ppm 3. ppm (max) Nitrogen demand for current facilities will be estimated based on intermittent operation users considering 40% diversity factor. Steam 8.5 barg steam is required for Thermo compressor package as motive fluid to utilize flash steam from condensate pot. Pure condensate to be routed to Thermo compressor package. 8.5 barg steam is received at Battery limit from existing Utility. First Pressure reducing station to be installed for achieving pressure to 2 barg. Steam generated from Thermocompressor package to be connected to 2 barg steam main header. Condensate from Thermocompressor package to be pumped back to Boiler feed water tank. 2 barg steam is required as heating utility for process equipment. Steam_tequirement_caleulationsfor_project—are—underprogress. For 98% Acetic Acid Recovery, 3 barg & 4 barg steam will be provided using pressure reduction stations. Total steam requirement is considered as 8 TPH. ‘© Bayer Engineering & Technology Confidential © 2017 Aker Solutions PC1905009_ROBayer Project No: AOOKM-000158 56111-1905 Division: CROPSCIENCE 3.04 VAPI, INDIA Doc No: 1905 300-00-7007.06-224 : Doe Title: AkerSolutions [Pant EPRo PROCESS & UTILTY DESIGN BASIS Date-oaoz1e [Reve PAGENO 21a 8 10.6 Cooling Water— Ry 2.x355 570 TR (?40-1140TR) cooling water system to be provided 259 400m’/hr pumps (2. working /1 standby) to cater utility requirement of project & for future. Side stream filter to be provided in pump discharge line. Cooling water treatment system will be provided by client in line with other plants at site. Temperature difference of 3 deg C to be considered for cooling (Sensible heat removal) & 5 deg C for condensation (Latent Heat removal) Blow down from cooling tower to be routed to Effluent treatment plant. Overflow process water from buffer vessel of different secondary heating / cooling circuit to be collected in 1.6 m3 CS vessel. Mixed condensate to be also routed to same vessel. This water to be pumped to cooling tower as makeup water. There will be level controlled make-up water line from Process water. Basin will be common for both cooling towers. Cooling water system shall have following design considerations: S pescription | Details | my | 1. | Cooling Tower 2 (capacity 355 570TR) Single Sump 2 cell {2 | Tow nee a | 2 (working) & 1 (standby | 2. | Circulation Pumps | 2 (vorking) 82 (standby) ey | * | | 250.400 m’/hr each | Side Stream Filter | | ty 2 is J nt) eet pa tan in tht tat © Bayer Engineering & Technology Confidential © 2017 Aker Solutions 'PC1905009_ROBayer Project No: ADOKM-000158 APG Project No:_506111-1905 GDL Chapter No: 03.01 Division: CROPSCIENCE Location: VAPI, INDIA Doe No: 150.80.007007.58 7 Doe Tile: IE AkerSolutions |r =R° PROCESS & UTLITY DESIGN BASIS ToemoTsoe [AEE ENS 10.7 Chilled Water — Detailed Chilled water requirement calculations for project are under progress. Surplus chilled water capacity of 200 TR is available with client utility. Based on EPRO utility RY) calculations & future project requirement {Capacity-on- HOLD), new Chiller system to be u installed. ‘System adequacy check w.r.t. Chilled water requirement for project & existing pump head check is in APG scope. Cooling water for new Chiller to be arranged from existing Utilities. Quantity of cooling water requirement for new chiller system to be informed to client. Hot well & cold well of existing utility system to be used for new Chiller. APG will provide inventory for new Chiller system to client to verify existing hot well & cold well adequacy. Related to routing of chilled water header to plant, APG has following scheme: « | | Details ik ——— 1 Chiller | 1 (capacity 250 TR) | - | teapachy 25 | | i 7 | 2 1 (working : 400 330 m’/hr each ) & 1) (rn 3. | Circulation Secondary Pumps {standby 203,300 m’fhr) 10.8 Chilled Brine — co jineering & Technology Chilled Brine requirement calculations for project are under progress. Client has excess Chilled Brine capacity & will be available at BL-Based-on FEL calculations; client has estimated 80 TR requirement of chilled brine system. New pumps (1 working / 1 standby) to be provided to cater to pressure requirement. Chilled brine system shall have following design considerations: (HOLD) Confidential © 2017 Aker Solutions C10500_ROBayer Project No: AOOKM-000158 APG Project No:_506111-1905 Division: CROPSCIENCE ‘sion: CROPS GDL Chapter No: 03.01 Location: VAPI, INDIA oe Nor 1905300-007007 4-221 EE AkerSolutions [Pant ero PROCESS & UTILITY DESIGN BASIS Daas | — Reve PANO a Re Descrip Det (Rt) 1 Circulation Secondary Pumps 1 (working) & 1 (standby) 60 130 m*/hr each 10.9 Drainage & Venting system © Closed drain facility & vent valve system are not envisaged for this project. ©The RCC sump for the building to be located outside the main plant footprint and operated to maintain a free volume to accommodate the largest vessel volume in the plant. Sump is fitted with impervious lining to avoid leakage. The sump to be equipped with a flame trap in the inlet line and will have a gravity overflow also through a flame trap. Overflow will then be connected via fixed piping to a firewater run-off and collection system. System is designed to collect and retain any contaminated firewater run-off in case a fire occurs in the plant. © 6 barg Nitrogen operated pump of 3 m3/hr capacity to be provided for sump to transfer aqueous material to Effluent Treatment Plant. There will be recirculation line with sampling arrangement provided for pump to check organic material inside sump. © Organic material to be collected in Drum to reduce ETP load. an ‘© There will be decontamination area with pit for drum cleaning provision.-6-barg Nitrogen 5 barg Air operated pump of 3 m3/hr capacity to be provided for pit to transfer material to Effluent Treatment Plant. ‘* Vessel cleaning water to be collected in Bad effluent vessel on ground floor & transferred to ETP. There will be dedicated Organic effluent vessel & aqueous effluent vessel provided to store in process effluent. Also, new 10 kl SS vessel to be provided to store caustic solutions from caustic pit (Chlorine shed) & scrubber vessels. (a) *_ All drain valves will be minimum 25 NB size, Drain valve to be-tocl-Closed-& blinded. 10.10 Effluent Disposal ‘© Bayer Engineering & Technology Effluent disposal norms as stipulated by applicable pollution control board. Various effluents and its disposal methods are listed in the Table below. Table: Effluent disposal methods "Disposal method Type of effluent Gaseous Effluent Confidential © 2017 Aker Solutions Pc1g0s002_ROBayer Project No: AOOKM-000158 fs (A APG Project No: _506111-1905 (BaYer) Division: CROPSCIENCE CE st GDL Chapter No: 03.01 S Location: VAPI, INDIA Doe No: 1905-200-00-7007.A4-221 me Dt ti Plant: EPRO Peet IE AkerSolutions PROCESS & UTILITY DESIGN BASIS Date-toT aI [Reyne PAGENO 24 ot 5 | Type of effluent | Disposal method Hydrocarbons Incinerator (Incinerator is in client scope Chlorine Vent HCI Vent Acidic Vent. Vents from Central Tank farm Equipment eR) Liquid Effluent Hydrocarbon liquid Oily / Lubes Contaminated water ‘© Bayer Engineering & Technology of supply) | Chlorine vent to be diverted to caustic | solutionscrubber. There will be blower (1. working / 1 standby) provided to route vent to safe location (around 40, mtr elevation from ground). Stack monitoring to be done. HCl vent to be scrubbed in water to generate 30% HCI. Vent from HCI scrubber is routed to acidic scrubber. Acidic vent to be scrubbed scrubber system. There will be blower provided to provide required draft to suck all acidic vents. Vent from acidic vent to be routed to. | atmosphere at safe location. Stack | |_ monitoring to be done. | DCM vent to be tapped to vent gas transportation header (client scope). Acetic Acid tank vent to be routed to Atmosphere (HOLD) as per client’s comment on PFO. It is recommended to route vent to scrubber. | Not expected. (to be collected from | sump locally) Locally collected & sent for disposal by third party Confidential © 2017 Aker Solutions PC1g05008_ROBayer Project No: AOKM-000158 APG Project No: _506111-1905 Division: CROPSCIENCE ‘vision GDL Chapter No: 03.01 : VAPI, INDIA Doc No: 1905-300-00-7007-A4-221 Doc Title: Plant: =~ EPRO PROCESS & UTILITY DESIGN BASIS Date-03.07, 2078, Rev Not PAGENO. 25 of 58 et) 10.11 10.12 11. + All vessels handling hydrocarbon are provided with nitrogen blanketing to avoid any explosive mixture. Requirement of oxygen analyzer in incinerator header will be confirmed by client. (HOLD) Oxygen analyzer will be placed in vent lines of both *Oxidation Reactors. No separate stack requirement is envisaged for EPRO project. AILOCM vents & Acetic Acid vents after scrubbing are routed to Incinerator. * Liquid effiuent treatment unit is in client scope of work. Based on properties of effluent & client inputs, individual effluent to be routed to different effluent treatment plants or incinerator. Power Emergency Diesel Generator shall be provided for emergency loads. Refer to Electrical design basis for details. Future expansion provisions For DEDS storage vessel, transfer pump to be considered in future scope. Process Description : CES Preparation © Charge fresh DCM (Dichloromethane) followed by DEDS (Diethyldisulfide) to the reactor and stirring it to facilitate mixing as well as temperature is maintain at-5 °C to.0 °C ‘Dose the reaction with Chlorine gas & maintain temp. at -5 °C to.0°C + Stir the reactor and cool it to -10°C ‘* Transfer the mixture to Sulfenylation reactor ‘+ Rinse the reactor with DCM and transfer the rinse to Sulfenylation reactor. Pyrazole Dissolution ‘+ Fist charge Pyrazole using Big bag charging system followed by regenerated DCM and allow dissolution ‘* Charge DMEF (Dimethylformamide) at room temperture and stir it. Transfer the mixture to Sulfenylation reactor at 34°C cooling is provided to maintain temp. ‘+ Rinse the reactor with DCM and transfer the rinse to Sulfenylation reactor. Sulfenylation Reaction ‘* _Pyrazole solution is received in the reactor ‘+ DCM rinse followed by crude CES which is controlled by inline flowmeter and control valve. The reaction is carried out at 34°C temperature. Maintained at 34°C + 2°C during. addition of CES ~ 2hr. * DCM rinse also received. ‘+ Heat the reaction mass till 36°C ‘@ Bayer Enginesring & Technology Confidential © 2017 Aker Solutions 'P1805009_ROBayer Project No: AQOKIV-000158 APG Project No: _506111-1905 vision; CROPSCIENCE pws GDL Chapter No: 03.04 Location: VAPI, INDIA Doc No: 1905-300-00-7007-A4-221 Doc Title: AkerSolutions |P'ant PRO PROCESS & UTILITY DESIGN BASIS Date.-08.07.2018 Rev Not PAGENO. 26 of 58 et) eR ‘+ Degassing of HCl is done at 40-42°C ‘© Heat the reaction mass to 45°C and extract DCM as distillate ‘+ Cool the reaction mass (Sulphide) to 38°C and transfer it to Concentration & Preparation for Solvent Exchange Reactor ‘© Rinse with DCM and transfer the rinse to the reactor, Concentration and Preparation for Solvent Exchange ‘© Sulphide and DCM rinse is received * Concentrate the sulphide in reaction mass by distilling out DCM till mass temperature reaches to 70°C, About 90% of DCM is recovered, © Charge the reactor with Acetic Acid and transfer the mixture to next reactor, ‘© Rinse with Acetic acid and transfer the rinse to Neutralisation reactor. Neutralisation , Solvent Exchange & Oxidation * Concentrated Sulfide and Acetic Acid rinse is received '* Cool down the reaction mass to 40°C and take out a sample ‘© Charge 39 48% solution of Sodium Hydroxide (NaOH) to neutralize the reaction mass. The load of NaOH solution is calculated based on quantity of residual HCL left in the solution. ‘+ Heating to ~ 58 °C and Solvent Exchange by Vacuum Distillation @125 mbar (Remaining pcm) © Charge Acetic acid. ‘+ Reaction mass is cooled down to 38°C from 60°C. ‘* 50% solution of Hydrogen Peroxide is dosed for oxidation reaction for 4 hours (Time can be optimized based on selection of proper agitator) ‘© Reaction mass on hold for the same time i.e. 4 hours & temp is maintain at 40°C, sampling to be done. ‘* Sodium bisulphite (NaHSO3) is charged into the reactor to destruct any excess unreacted hydrogen peroxide so as to limit the yield of sulfone to 2% i.e. max allowed & stop oxidation reaction, © 30.48% of sodium hydroxide lye added to neutralize NaHSO4 formed from NaHSO3 providing good stability of Ethiprole synthesized during course of oxidation reaction. + Reaction mass of Ethiprole slurry is heated to 60°C to solubilize Ethiprole mass for ease of transfer and ensure homogenous reaction mass before transferring to crystallize. ‘+ Reactor is washed with Acetic acid and rinse is transferred to crystallizer along with Ethiprole Solution, ‘ Bayer Engineering & Technology Confidential © 2017 Aker Solutions 'P:1805008_ROBayer Project No: AOOKM-000158 APG Project No:_506111-1905 Division: CROPSCIENCE vision: GDL Chapter No: 03.01 : VAPI, INDIA Doc No: 1905-300-00-7007-A4-221 rE Doc Title: ns He yti Plant: EPRO EE AkerSolutions PROCESS & UTILITY DESIGN BASIS Dasma [Rene FRGENG_2T a Crystallization ‘* Ethiprole solution and acetic acid wash is received in the crystallization reactor at 60°C and then heated to 80°C after receiving the rinse for complete dissolution of Ethiprole, + Adding soft water will result in drop in temp to 50°C from 80°C (Cooling rate while addition of soft water 10°C/h)and after that the reaction mass is cooled upto 5°C gradually with rate of 15°C /h. ‘+ Transfer half of the Ethiprole slurry to Nutsche filter ‘* Wait for partial filtration in Nutsche filter and transfer the second half of Ethiprole slurry from Crystallization reactor to Nutsche filter. Filtration and Washing ©The Ethiprole mixture is transferred from crystallizer to filter and wet product get isolated on the filter + The Ethiprole filtration is followed by three washing steps in order to get rid of the impurities ‘* Ist washing with 50% of ACOH/H20 in order to displace mother liquors and to eliminate organic impurities ‘First water wash: with water from 2nd filtered water of batch (N-1) by a reslurrying step allows to eliminate soluble salts and acetic acid present in the crystallization environment. ‘+ 2nd water wash: with fresh water allows to eliminate salts and acetic acid completely, and this water to be used for Ist washing water of next batch . © During filter cleaning (bottom layer dissolution) in Acetic Acid is done once in a month. Heating is done with steam through injector (Jacket temperature 75°C) so that the inside mass temperature is 60 °C. Unload the washed cake to Dryer. Drying ‘* _ Ethiprole wet cake composed of Ethiprole, water is received in Dryer. * Cake is heated and maintained to 68°C under vacuum. Its further heated and maintained at 75°C. + Cake is cooled to 50°C, simultaneously releasing vacuum ‘* Dry Ethiprole is extracted and send to packing unit via ribbon blender (To ensure homogeneity). “GS Bayar Engineering & Technology Confidential © 2017 Aker Solutions Pc1205002_ROBayer Project No: AOOKM-000158 APG Project No:_506111-1905 vision: CROPSCIENCE Division: ‘GDL Chapter No: 03.01 Location: VAPI, INDIA Doc No: 1205-300:00,7007.4-221 i Doc Title: AkerSolutions {Pant — PRe PROCESS & UTILITY DESIGN BASIS. Date-osora016 | RevNot PAGENO 26 af 55 rt) Solvent Recovery 98% Acetic Acid Recovery — {The-schemeis under-hold as thesameisunder BFF study.) 2, 98% acetic acid recovery is designed as a continuous process with turndown capacity of 60% and overdesign margin of 30% b. The acetic acid recovery process is performed in two stages i. 1 stage evaporation ii, Acetic acid aistillation (2ed stage). ©. A Crude acetic acid vessel (V400-DS30-8A100) is provided as buffer to facilitate a continuous feed to acetic acid recovery system. The vessel can accommodate crude acetic acid accumulated from one batch (main ML. and mixed cut). This is approximately 12-14 hrs of continuous feed to acetic acid recovery system. d. Crude acetic acid feed pump (V400-DS30-PA100) feeds fo the 1% stage falling film vaporizer (V400-DS30-WA100) on flow control (FICQI-F1012). The process forward flow is 1440 kg/r and rest is recirculated back the source vessel via restriction orice. A provision to sample the feed is available on recirculation line e. The 1 stage falling film vaporizer (V400-DS30-WA100) boils off the low boilers resulting in the heavier getting accumulated in liquid phase. The vaporizer is mounted on a flash vessel (V400-DS30-BA1 10) which facilitates vapour liquid separation and provides a buffer (approx. 3 mins) for residue pump around pump (V400-DS30-PA110) £1" stage vaporizer (V400-DS30-WA100) is a steam heated falling fm vaporizer. Steam is at 3 barg and temp of about 143.6 deg C (max temp. at 160 deg C). The steam flow (vaporizer duty) is controlled based on the ratio control ((FIC-F 1003) ratio with feed flow) and FEV outlet temperature (TI-T1151). Condensate is recovered using a typical steam trap condensate recovery system. @. Bottom liquid outlet from the FFV flash vessel (V400-DS30-BA110) is continuously recirculated back to the FFV using Residue pump around pump (V400-DS30-PA110). A ‘minimum pump around is maintained to avoid the dry-out in FFV. A part of residue is also transferred to residue vessel V400-DS30-BA120 on level control (LIC-L1152). fh. The vapor outlet of the FFV flash vessel goes to a 1 stage condenser (V400-DS30- WA150). The main purpose of the condenser is to remove chloride content present and decrease possible corrosion. Chlorides are vented as a continuous vent from the condenser to HCL vent header. The 1% stage condenser (V400-DS30-WA150) duty can be controlled by throttling the cooling water supply. i. The condensate from the 1 stage condenser is drained to 1 stage Buffer vessel (V400- D830-BA170). This vessel acts as a buffer during plant start-up. In case of off-spec or high chloride content, the condensate can be transferred to Crude acetic acid vessel V400- DS30-BA100. J. A provision to transfer recovered acetic acid from 50% acetic acid recovery system using recovered 50% acetic acid transfer pump is also available. The recovered acid can be directly fed to the 1st stage buffer vessel and can be subsequently fed to acetic acid ‘column (V400-DS30-KF 100). A provision to sample the column feed is available on recirculation line. ‘ Bayer Engineering & Technology Confidential © 2017 Aker Solutions Pc1905009_ROfB\ Bayer Project No: AOOKM-000158 4, 50611-1905 (Baver| Division: CROPSCIENCE \& E 03.01 > Location: VAPI, INDIA Doc No: 1905-300-00.7007-A4-221 Doc Title: \ jo [Plant PRO Aker‘ olutions PROCESS & UTILITY DESIGN BASIS Date-onoT 2015 _[ _RevNot PAGENO_29 of 68 eR ey k Acetic acid column operates at atmospheric pressure, Acetic acid column V400-DS30- KF100 is a packed column, with three sections i. Reatifying section (top) ii, Stripping section 1 (middle) ji, Stripping section 2 (bottom) Acetic acid column feed pump (V400-DS30-PA140) transfers the condensate (feed) on flow control (FICQI-F1005) to acetic acid column (V400-DS30-KF 100). Feed is transferred (on the top of the stripping section 4. Column bottom vaporizer (V400-DS30-WA110) is steam heated falling film vaporizer. ‘Steam is at 4 barg and temp of about 151.8 deg C (max temp at 164 deg C). The column vaporizer duty is controlled using the steam flow control (FIC-F1111). The steam flow shall be adjusted based on the feed flow by manually varying the set point of the steam flow control (FIC-F1111). The circulation flow rate of 50 m3/hr is continuously circulated back to the bottom vaporizer (V400-DS30-WA110) using column bottom pump (V400-DS30- A160). The part of the residue is transferred to Residue vessel (V400-DS30-BA120) on evel control (LIC-L1053). Column bottom provides sufficient buffer time (approx. 5-8 mins) for bottom draw-off and recirculation. Overhead vapors are condensed in primary condenser (V400-DS30-WA120) mainly and low boilers are further condensed in the secondary condenser (V400-DS30-WA130). The primary condenser (V400-DS30-WA120) duty can be controlled by throttling the cooling water supply. The chilled water supply to secondary condenser (V400-DS30-WA130) is kept open to facilitate maximum condensation/recovery. The condensate is accumulated in phase separator (V400-DS30-BA160) which separates DCM and water (major component). Recovered DCM is collected in OVHD DCM vessel (V400-DS30-BA150) on level control (LIC-L 1652) which is transferred by gravity fo organic effluent vessel (C100- WB10-BA110). A provision to sample the recovered DCM is available. Recovered water (major component) is transferred partly on flow control (FIC-F 1004) as reflux and remaining is transferred to OVHD distillate vessel (V400-DS30-BA140) on level control (LIC-L1651). A provision to sample the distilate is available. The 98% acetic acid is recovered as a side- draw in sides stream condenser (V400-DS30- WA140) on flow ratio control (FICQI-F1301 ratio with column feed FICQI-F1005 adjusted based on the % acetic acid in column feed). By regulating the condensate withdrawal, the exposed area for heat transfer is automatically adjusted to control condenser duty. Cooling water flow to. side-stream condenser (V400-DS30-WA140) can also be throttled using a ball valve. A side-stream sub-cooler V400-DS30-WA180 is provided to sub cool the recovered acetic acid to 38 deg C. The subcooled acetic acid is finally collected in 98% acetic acid vessel (V400-DS30-BA130) and finaly transferred to Acetic acid storage vessel (V600-TA20-BA110) on on-off level control on 98% acetic acid transfer pump (V400-DS30- A130). A provision to sample the recovered acetic acid is available on recirculation line The residue collected from the column bottom and tst stage FFV vessel is stored in Residue vessel (V400-DS30-8A120). The residue can be transferred on on-off level contro! to organic effluent vessel (C100-WB10-BA110) using Residue transfer pump (V400-D$30-PA120) via residue cooler (V400-DS30-WA160). This being an intermittent requirement, an automatic cooling water temperature contro! (TIC-T1611) is provided for ‘© Bayer Engineering & Teshnoloay Confidential © 2017 Aker Solutions 'P1905009_ROBayer Project No: ADOKM-000188 APG Project No:_506111-1905 Division: CROPSCIENCE ‘GUL Ghapter Nora01 Location: VAPI, INDIA Doc No: 1905-300-00-7007-A4-221 Doe Title: AkerSolutions |? =PR° PROCESS & UTLITY DESIGN BASIS Dae OTTO [Rane FSENO Ba Rn) residue cooler (V400-DS30-WA160). An alternate provision is also made to transfer the residue to 50% acetic acid distillation reactor (V400-DS20-CA100), where the crude acetic acid is distilled to recover the acetic acid. A provision to sample the residue is available on recirculation line. Note: For inventory purpose, low capacity pumps are standardized to 3.5 m3/hr. 50% Acetic Acid Recovery: ‘© Filtrate of 50% acetic acid wash from nutsche filter containing 48% (w/w) acetic acid and rest water is sent to 50% acetic acid recovery system ‘* [tis heated up to 99-108 °C temperature in still without column to get 51-55% (w/w) acetic acid and rest water. It is reused in the process. ‘Material as residues containing various impurities in the still is sent to incineration via pump/drum. DCM Recovery: Predistilate from Sulfenyk d is collected and em ‘+ Receive Acidic DCM in the reactor V400DS10CA100 from its hold tank V200CA10BA120 by using pump through mass flow meter. © Once the receiving of crude DCM is over, charge slowly solid CaO powder using PTS system for neutralization under stirring ‘+ Check pH of the crude DCM intermittently. © Charge solid Cao till crude DCM pH is neutral. ‘Stir for 30 minutes and start heating in the reactor by circulation of hot water at 70 to 80 deg C (through steam ejector) in the reactor jacket. * Start collection of recovered DCM in the receiver V400DS10BA110 in around 6 hrs till the final temperature of the reactor mass reaches to 45-50 deg C. ‘© After completion of the DCM collection, charge approx. 100 lit process water in the reactor V400DS10CA100 to dilute the left over residual mass and salt CaCi2. ‘© Bayer Engineering & Technology Confidential © 2017 Aker Solutions 'PC1805009_ROey Bayer Project No: ADOKM-000158 APG Project No: 06111-1905 Di : CROPSCIENCE vision GDL Chapter No: 03.01 Location: VAPI, INDIA Doc No: 1905-300-00-7007-A4-221 AkerSoluttions [Pare ®°°° Doc Title: PROCESS & UTILITY DESIGN BASIS Date-05 07 2018 Revno 7 PAGENO 31 of 58 12. ey eR RI) Transfer residual mass to the hold tank V400DS10BAXXx for storage from where it will be filled in tote bin and will send to incineration. Once the reactor is empty, receive 200 lit of crude DCM from vessel V200CA10BA120 for rinsing of the reactor system. (To avoid moisture during next DCM recovery) Transfer this rinsing DCM to Organic waste storage tank V400DS30BA180 from where it will send to incineration. Miscellaneous Points : PFD, Batch SMZ data, Process Description to be referred for time cycle & Process flow. BED & SMZ to be referred for quantity & sequence of batch. Hazardous Area Classification Schedule to be prepared according to IEC-60079-10-2 & IEC 6075-10-12. As per IEC code, hazardous area extent figure of IEC-2152/08 is applicable for ‘Flammable Liquid Storage Tank’ operating at atmospheric pressure. In absence of a relevant figure for pressure vessels, 3 m distance for lateral extent of hazardous area to be considered for all vessels operating at atmospheric & high pressure. Minimum Electrical Hazardous area classification will be Ex’d’, Zone 182, AJB, TA, Zone 21/22 for Dust classification to be put as applicable. All Field PCT shall be intrinsically safe Ex ‘ia’ certified for Zone-1/21, Group IIA/IIB, T6 and will be externally suitable for weather proof of IP 65. In case of non-availability of intrinsically safe Instruments, Ex d shall be used. The entire plant building to be classified as per chemicals being handled (Minimum Zone 2, Zone 22), wherever applicable as per Hazardous Area Drawing. Equipment Material of Construction will be as per IFD PFDs. MOC of connecting line will match MOC of equipment. e.g. Connecting line of $S316L vessel will be SS316L / connecting line of glass lined Vessel will be MS PTFE. When any line connects 2 different MOC vessels, there will be spec break with higher piping spec on off isolation valve — except 50% Acetic Acid lines MOC is MS PTFE, but connecting filter MOC is $5316L. For PTFE piping > 6” 4” &-workingunder-vacuurn-conditions, glass lined piping to be used. “Bayer Enginearing & Technology Confidential © 2017 Aker Solutions PC1905009_ROBayer Project No: ADOKM-000158 APG Project No:_506111-1905 GDL Chapter No: 03.01 Division: CROPSCIENCE Aker. ‘Solutions Location: VAPI, INDIA Doe No: 1905-300.00-7007-A4-221 Doc Title: Plant: EPRO PROCESS & UTILITY DESIGN BASIS PAGENO 32 of 58 Date050T 2018 | _RevNot * Corrosion Allowance to be considered for equipment as 3 mm for Carbon Steel, 0.5 mm for Stainless steel, 0 mm for lined materials. + Dip pipe philosophy: Dip pipe size shall be minimum size of connecting line size. Splash leg to be provided for solvent services. Short Dip pipe to be provided for process lines as per requirement - e.g, caustic addition line in glass lined reactor Long dip pipe to be provided for process lines as per requirement e.g. sampling arrangement, Chlorine addition line in CES reactor. Siphon breaker hole for long dip pipe to be provided for applicable cases e.g. to avoid back flow in case of pumping in pressurized reactor. Chilled brine jacketed piping to be provided for line from CES reactor to Sulfelynation Reactor. ‘Smart earthing to be provided to solvent tanker / drums during unloading operation. Additional smart earthing requirement will be added as per HAZOP / client requirements. en Philosophy-for Note for Jumpers will be included in Line list for lines handling 13. Ry solvents. -Flange- Guards for apphicablelines need to-be finalized. (HOLD) Mechanical Design Pressure & Temperature: Mechanical design criteria laid down in this section shall be followed as standard. For all process systems, design temperature will be -25 / 200° All pipes designed for “-1/10 barg” & "-25/200 deg C”. For utility systems, operating at ambient temperature, the mechanical design temperature shall be 100°C. For utility systems, operating below 0°C, the mechanical design temperature shall be -25°C. Minimum Design Metal Temperature (MDMT) shall be -25°C. Vessel For all vessels, design conditions shall be as follows: CS /SS vessel : Design Conditions : (-1/3 barg) & (-25/200 deg C) (Except few cases. eg Air Receiver : -1 /10 barg) + PRERP vessel Design Conditions {1/3 bara} &{25/200-deg-C} ‘© Bayer Engineering & Technology Confidential © 2017 Aker Solutions PC1905009_ROBayer Project No: ADOKM-000158 APG Project No:_506111-1905 Division: CROPSCIENCE GDL Chapter No: 03.01 Location: VAPI, INDIA Doe No: 1905-200-00-7007-A4-221 Doc Title: jong [Plant EPRO IE AkerSolutions PROCESS & UTLITY DESIGN BASIS Date-sor2018 [| RevNot PAGENO33_of 66 ty ee) 14. 14.4 et) © Bayer Engineering & Technology * Reactors (MSGL /SS /CS) & MSGL Vessel : (-1/6 barg) & (-25/200 deg C) Pumps ‘© Centrifugal Pumps: (-1/16 barg) & (-25/200 deg C) except PTFE /PVDF lined pumps having maximum design temperature of 150 deg C & 120 deg C respectively. Design pressure for PVDF lined pumps will be (-1/10 barg). * Nitrogen / Air Operated Pumps : (10 barg) & (150 deg C ) Tanks: Design Pressure for Tanks shall be derived in accordance with API-620, API-650 & API-2000, as appropriate. It is applicable only for Process water tank (rectangular) / H,0, overflow tote tank, Heat Exchangers For all Heat Exchangers, design conditions shall be as follows: ‘Plate type Heat Exchangers: Design Conditions: (-1/6 barg) & (-25/200 deg C) MOC of PHE shall be minimum $3161. ‘+ Graphite Heat Exchangers: Design Conditions: (-1/6 barg) & (-25/200 deg C) * Spiral Heat Exchangers: Design Conditions: (-1/6 bare) & (-25/200 deg C) MOC of Spiral shall be minimum $S316L for non-acidic services. For acidic services, MOC +0 will be finalised 4HOLD) Graphite Annular Groove. Line Sizing Criteria Flow Rate Basis for Line Sizing The Heat & Mass balance provides the normal or operating fluid flow rate across each process lines & utility lines. Design margins shall be applied over the "Normal flow rate” to obtain the “Design flow rate”, as stated below. Process Lines: © Allprocess lines : 40% ‘* All process lines which are used only during start up or intermittent flow case, or normally no flow lines indicated on PFD : 0% Utility Lines: Confidential © 2017 Aker Solutions Pc10500@_ROBayer Project No: AOOKM-000158 APG Project No:_506111-1905 Division: CROPSCIENCE aol chapter NSIS Location: VAPI, INDIA Doc No: 1905-300-00-7007-A4-221 t Doe Tile: EE AkerSolut Plant: EPRO PROCESS & UTILITY DESIGN BASIS Saemmoroe [Rent TREN HE © Forall other Utility lines : 20% The “Design Flow Rate” shall be used as the basis for sizing of lines for new Projects. 14.2 Pipe Wall Roughness For turbulent flow, the friction factor depends on the roughness of the pipe as well as on the value of the Reynolds number. The pipe roughness factor shall be considered as per the Table below: Table: Typical values of pipe wall roughness _ | 5". | saateriat Pipe Roughness range, | No. mm 1. | Galvanized Iron 0.13 2. | Stainless Stee! 0.025 3. | Carbon Steel 0.047 | 4. | Lined Piping 0.005 (Note 1) Note 1: Additional thickness of to be considered as provided PMS / Vendor inputs provided Rn ‘by Bayer for lined spec. Liquid Lines / Vapor Lines. Criteria are maintained in Appendix 4. ‘The Vapor velocity shall always be maintained less than 40 m/s to avoid noise issues. 143 Relief line si e Relief system line sizing i.e. PSV inlet & outlet line shall be sized in accordance with API-520. 15. Isola n Equipment and vessels will be isolated for safe maintenance without provision of insertion of blind flanges at strategic points or removable spools. 15.1 Isolation at the Unit Battery All pipes entering or leaving a process unit shall have positive isolation valves only. All.utilities to be provided with Flow totalizer to measure consumption. neering & Technology Confidential ©2017 Aker Solutions Pc1905009_ROBayer Project No: ADOKN-000158 APG Project No: 06111-1905 Division: CROPSCIENCE ston ‘GDL Chapter No: 03.01 Location: VAPI, INDIA Doc No: 1905-300.00-7007-A4-221 Doc Title: I AkerSolutions |Pen= Fre PROCESS & UTIITY DESIGN BASIS Date -os012018 [| RevNot PAGENO35_of 58 16. 16.1 16.2 ey eR eR Pressure transmitter & Temperature transmitter to be provided for critical utilities (Chilled Brine, Chilled Water, Cooling Water, Steam, Nitrogen — Only Pressure Transmitter). Non critical utilities (Compressed Air, Breathing Air, Process water, Drinking water) to be provided with local gauges. Equipment Sizing Vessel (including Storage Vessels) Vessel sizes are listed in Equipment list & PED. These sizes to be verified against batch volume data listed in BFD, Day tank shall have storage capacity of minimum 2-3 days consumption. Nozzle sizing Minimum Nozzle size should be same as connecting line size. Minimum sizes of vessel nozzles shall be 2” NB. Equipment process nozzles should not be smaller than the connecting, piping. Nozzle sizes to be followed as per client Work Norms. Refer Annexure 3 attached herewith followed for project for Vessel dimensions & work norm to be followed. Pumps ‘The following design considerations shall be made for the pumps. Design margins ‘The Normal capacity of the pump is specified based on the HMB er-neral flowrate. The design margin is applied to the Normal capacity to arrive at the Rated capacity of the pump. ‘The following design margins are used depending on the pump duty: - ‘+ Process pump 140% © Utility pump : Based on peak utility load calculations * Minimum Pump Head for centrifugal pump is considered as 20 MLC. Pump head is rounded to next § MLC figure. For specific cases, actual head is reported. '* 10% Margin on frictional drop is considered in Pump Hydraulics. Sparing There is no sparing for Process pumps. Only scrubber pumps will have 1 working & 1 standby. Cooling water circulation pumps will have 2 working (50%) & 1 Standby (50%). Chilled water circulation pumps will have 2 1 working (100 58%) & 1 Standby (100 50%). Chilled Brine circulation pumps will have 1 working (100%) & 1 Standby (100%). ‘B Bayer Engineorng & Technology Confidential ©2017 Ake: Solutions PC1805009_ROBayer Project No: A0OKM-000158 APG Project No: _506111-1905 yn: CROPSCIENCE GDL Chapter No: 03.04 Location: VAPI, INDIA Doc No: 1905-300-00-7007-A4-221 = Doe Title E AkerSolutions JP! PR° PROCESS & UTILITY DESIGN BASIS Dae tooo] Rent FAGENO_3_al Ry System Design ‘+ Following API standards are applicable for the pumps, unless otherwise specified. ‘© Centrifugal pump - API 610, ‘© Reciprocating pump - API 674 ‘© Metering (or controlled volume) pump - API 675 ‘+ Ifreducers are required on suction lines, they shall be eccentric and installed flat side up. ‘+ Pressure relief lines shall be provided for positive displacement pumps. ‘+ Strainers shall be provided in all pump suction lines. Centrifugal pump operations below minimum flow rate can cause shaft vibration and reduce the mechanical seal life. These centrifugal pumps shall be equipped with minimum continuous flow arrangement. hall be as per Table below: imum fl {Pumps driver power | Type of Minimum Flow Scheme <15kW & Utility | Constant bypass flow through Restriction orifice. Pumps | ee 5 kW | Minimum flow controlled by automatic Flow control | valve to save pumping energy. ‘or cooling water pumps, minimum flow arrangement is rovided. | Requirement of automatic flow control for Chilled water | & chilled brine pumps will not be provided verified. For pump, where minimum flow protection is done by constant bypass flow through orifice, the rated capacity should be specified considering constant minimum flow (addition to the design flowrate) based on vendor information. For Drum charging / Sampling, Nitrogen Operated Pump to be used. For Sump pit & decontamination pit transfer, Air Operated pump to be used. Mechanical seals Single mechanical seals shall normally be specified for utility pumps. Vendor recommended seal plan to be followed for given process conditions. Double mechanical seal shall be considered for process ser Acetic Acid, Magnetic drive (Seal less) pump to be used for clean process services. e.g. DCM, Fresh Acetic Acid , DEDS, H.0zetc. 's having solids > 2%, Recovered Bayer Engineering & Technology Confidential ©2017 Aker Solutions 'Pc1905009_ROEE AkerSolutions Date-05 07 2078 Revno Division: CROPSCIENCE Location: VAPI, INDIA Plant: EPRO Bayer Project No: AOOKM-000158 APG Project No:_506111-1905 GDL Chapter No: 03.01 Doc No: 1905-300-00-7007-A4-224 Doc Title: PROCESS & UTILITY DESIGN BASIS PAGENO a7 of 68 ey Sparing + No spare for Nitrogen Compressor: a be applied_over-the maximum-operating fo 16.4 Heat Exchangers © Primary heat exchanger to be sized for 0.3% volumetric nitrogen. For sulfenylation reactor primary heat exchanger, only HCI load to be considered as inerts & no nitrogen load to be considered. ‘© Heat transfer coefficient to be considered for tempered water circuit as 300 W/m’C & Heat transfer coefficient for steam circuit as 500 W/m’C. ‘© Keeping limits in mind w.r.t jacket nozzle size, maximize tempered water pumping rate to improve LMTD. 17. Instrumentation The following design considerations shall be made for the instrumentation: Design conditions will be same as line conditions. Design conditions will be lowered for lined ‘material from 200 deg C to 145 deg C. Design conditions can be lowered , in case of non- ‘availability of Instruments to meet specified Design conditions. ee Flow Meter + Magnetic Flow Meter ~ Conductive fluids : Process Water, Caustic, HCI, Brine, H:02 “ + Mass Flow meter ~ Non Conductive fluids : DCM (Di Chloro Methane), DEDS, Chlorine, Ethyl-Acetate ,Acetic Acid, Reaction Mass having DCM or Acetic Acid, ey Mother liquor from Filter, Nitogen ‘Vortex Flow meter- Steam, Air, Nitogen, DM Water ‘© For process fluids & lined pipe specs, where op. temp. is more than 70 deg., Variable area flow meter shall not be used. ‘* Typical pressure drop for different types of flow elements is listed below: |_Flow Element Pressure Drop. Flow orifice | Vortex flow meter EMF me ‘© Bayer Engineering & Technology Confidential ©2017 Aker Solutions PC1g05002_ROBayer Project No: AOOKM-000158 APG Project No:_506111-1905 Division: CROPSCIENCE Stor ‘GDL Chapter No: 03.01 eR R eR ‘© Bayer Engineering & Technology Location: VAPI, INDIA Doe No: 1905-300-00-7007.04-224 4 c Plant: EPRO Peer EE AkerSolutions PROCESS & UTILITY DESIGN BASIS Date 0501208] RevNo-t PAGENO 38_of 5 Coriolis mass flowmeter | 05 Thermal_mass flowmeter 0.05 ‘Variable area meter 02 | | Annubar / Pitot tube L005 | [Turbine meter Flow Switch: ‘* Flow switch: Pump discharge lines (up to 4” line size), where SIL rating is not required /non critical Nitrogen services. Control Valves For each control valve data sheet ‘+ Maximum flow rate shall be the governing HMB flow + selected design margin (typically shallbe the rated-capacity-of the pump} ‘* The normal flow rate shall be the governing HMB flow. ‘+The minimum flow rate shall be the flow associated with the Turndown Case (typically 50% unless dictated by specific process turndown requirement). ‘* The minimum pressure drop at maximum flow for control valves in liquid service should generally be specified as 0.5 bar. * For pumped circuits, the control valve pressure drop is recommended to be approximately 30% (minimum) of the total friction loss in the circuit (excluding the control valve). ‘+ The minimum pressure drop allowance for control valves in gas service will generally be 0.1-0.2 bar. ‘* The maximum differential pressure across a control valve for actuator sizing shall be based on the maximum pressure on either side of the valve, with min (either vacuum or zero, based on minimum design condition of ine) pressure on the other side. e.g. For Design Pressure: -1/10 barg, Shut off pressure = (10+1) = 11 bar * Control valves not to be provided either with bypass valve or hand wheel for manual operation, ‘+ Only for vent header control valve, bypass with on off valve of vent header size to be provided ‘No drains to be provided for all control valves. Relief valves (PSV) ‘+ Relief valves shall be as per API STD 520 PT Il and API STD 521. ‘* No spare is to be considered for the any PSV & thermal relief valve. ‘+ Rupture disc type pressure relief devices shall be used for main process relief devices, Confidential © 2017 Aker Solutions PC1805009_ROBayer Project No: ADOKM-000158 APG Project No: _506111-1905 Division: CROPSCIENCE ‘on: GDL Chapter No: 03.01 Location: VAPI, INDIA Doc No: 1808 300.00-707-44-221 Doc Title: IE AkerSolutions |Pene — £PR° PROCESS & UTILITY DESIGN BASS Dae ceo [Rene PASENO_WS_a eR ey) eR) nt) ‘+ Applicable built up backpressure for conventional valves shall be upto 10% and for balanced bellow type shall be 50%. ‘Thermal relief valves shall be as-a-mininu either Non API (3/4 x 1) or API 0’ orifice. ‘© Venting and breathing equipment for low pressure above ground storage tanks shall be in accordance with the API Std 2000 “Guide for Tank and venting atmospheric and low pressure storage tanks”. + PSV routed to atmosphere to be provided with drain valve with sight glass to drain the holdup liquid + There.wilLnot-be any isolation valve in-uipstream-& downstream-ef PSY. For critical PSV (CES Reactor, Chlorine Vaporizer, Chlorine Buffer vessel, Sulfelynation Reactor), rapture disc to be provided upstream of PSV. There to be focal Pressure gauge-Transmitter in between rapture disc & PSV. Outlets of these PSV are routed to Chlorine scrubber column. Level Switch / Level Transmitter ‘+ Type of Level Transmitter will be Radar type. For equipment with load cell, Level transmitter will not be used. For Interface level measurement, Guided Wave type Level Transmitter will be used. For column level measurement, Differential Pressure type Level Transmitter will be used. * Type of Level Switch will be Tuning fork type. * For critical vessels (e.g. vacuum catch pot), long length (50% vessel height) level switch will be used to get more time for operations to take action. Pressure Gauge / Pressure Transmitter ‘* Diaphragm type to be used for corrosive, slurry services. ‘© Allsimple pressure gauge & pressure transmitter to be provided with minimum 25 NB isolation valve & Diaphragm pressure gauge & pressure transmitter to be provided with ‘minimum 50 NB isolation valve. “Bayar Engineering & Technology Confidential © 2017 Aker Solutions PC1905008_ROBayer Project No: ADOKM-000158 APG Project No:_506111-1905 Division: CROPSCIENCE feof cnaraer NETS! Location: VAPI, INDIA Doc No: 1905-300-00-7007-A4-221 Doe Title: EE AkerSc Plant: EPRO PROCESS & UTITY DESIGN BASIS Daepaoisoe [Rane FAGENO_@ at fs Appendix1: Water Quality DM Water RESULT TABLE SR] TEST PARAMETERS UNITS ] RESULTS [REQUIREMENT AS] TEST METHOD 7 Is 10500:2012 Ht [Color Hazen [ — Y@.9) Where v= Velocity assuming fully filed pipe, mis D = Pipe inside diameter, m 9 = Gravity constant. m/s” For both horizontal and vertical self-venting lines, the Froude Number must be less than 0.3 Therefore, in terms of minimum diameter required, the above equation is rearranged as: a> 42.67 x Que = Pipe inside diameter, mm Q = Flowrate, m°th Non Self-Venting Lines In non-self-venting lines, vapor and liquid phases flow in same direction as a result of gravitational flow. Froude numbers typically lie between 0.3 to 1.0. ~@ Bayer Enginesring & Technology Confidential © 2017 Aker Solutions 'P1808008_ROAPG Project No: Bayer Project No: AQOKIM-000158 50611-1905 Division: CROPSCIENCE GDL Ghapter Nos 0301 Location: VAPI, INDIA Doc No: 1805-300.00-7007-A4-224 AkerSolutions [pare eno Pes i ary ors Date-oa012018 | _RevNot PAGENO_64_of 58 STEAM LINE SIZING Steam Piping Following velocities may be used for preliminary and quick pipe sizing for interconnecting steam Piping + Saturated steam 2510 85 mis ‘+ Superheated steam 25 10 85 mis However, the final line size confirmation should be based on pressure drop criteria. Usually the distribution of saturated steam piping within ISBL is checked for an allowable AP of 0.1 t0 02 kglcm in 100m pipe length. Refer to Table 10 below for guide on saturated steam distribution tine sizing. This table is based on an allowable AP of 0.1 to 0.2 kg/cm’ in 100m pipe length ‘considering the velocity range given above. 0: Maximum permissible saturated steam flow rate in ka/h across standard pipes Saturated steam at | Line size, | 35. 5 7 10 4 17, 20 40 mmNB’ | K9cmg | tolcm’g | kakem’g | kolem’g | kaicm'g | kgem'a | kalem’g | kolem2g 5 50 55 | 65 75 90 +00 105 180 40 15 | 185 | 220 | 250 290 320 345 570 50 320 | 370 | 425 | 500 580 eo | 680 | +100 80 1080 | 1230 | 1400 | 1650 | 1950 | a1so | 2900 | 3200 100 2200 | 2500 | 2800 | 3400 | 3000 | 4200 | 4600 | e700 150 500 | 7360 | e200 | 9800 | 11400 | 12500 | 19400 | te000 200 | 13200 | 15100 | zoo | 20000 | 23500 | 2e000 | 28000 | ss000 | 250 | 24000 | 27500 | stooo | 37000 | 42000 | e000 | 50500 | 70000 300 | 38000 | 43500 | sooo | 58000 | 67500 | 73500 | 79500 | 110000 aso | 49500 | $7000 | «sooo | 76000 | 88000 | geooo | 105000 | 47500 400 | 60000 | 81000 | so000 | 110000 | 120000 | 130000 | 145000 | 200000 450 | 78000 | 100000 | 125000 | 151000 | 170000 | te0000 | 201000 | 270000 500 100000 | 120000 | +s0000 | 198000 | 225000 | zao00 | 265000 | aeso00 | 600 | 150000 | 185000 | 240000 | 225000 | 370000 | sao000 | 440000 | ss0000 ‘© Bayer Engineering & Technology Contfdenti © 2017 Aker Solutions PC1905009_ROAkerSolutions Date-05 072018 Revo Division: CROPSCIENCE Bayer Project No: A0OKM-000158 APG Project No: _506111-1905 GDL Chapter No: 03.01 Doe No: 1905-300-00-7007-A4-221 Doc Title: PROCESS & UTILITY DESIGN BASIS ose PAGE NO_85 Air and Nitrogen Distribution Piping For plant air, instrument air and nitrogen distribution piping, lines should be sized to have pressure drop between 0.2 to 0.3 kglem" per 100 m of length. Table 14 below may be used to ‘size the air/niogen distribution lines, This is based on a maximum pressure drop of 0.2 kgicm® in 400m: pipe. ‘Table 14: Maximum aitfnitrogen flow rate in Nm‘th for standard pipe sizes. Uneszemmys| 20 | 25 | 40 | so | 00 | 10 | 150 | 200 + | 1 [ a | 12 | 20 | 776 | 1600 | «00 | cano 2 | 20 | s6 | 10 | am | oa | 1052 | saso | 11200 a | a | 65 | 102 | «0 | sor | 2208 | eco | 13200 [oe [es [to [ae | ese [treo [00 | roo | sa000 & [5 | ss | 7 | 256 | a0 | 1512 | 2060 | ro40 | 16400 S| 6 | a5 | a | 27 | soe | s72 | soe | ss4o | 17000 E [7 | ar [ o6 | 2 | soe | to2 | sono | ocao | 10400 e | 40 | o | 306 | sos | 1728 | sso | somo | 20000 [0 | «2 | sor | ao | or | re2« | 3600 | 10600 | 21600 so | as | 12 | a0 | ox | 1040 | a500 | 11200 | 22400 Pump Suction Line Sizing Pump suction lines shall be primarily sized to meet the NPSH requirements of the pump. Subject, to meeting the NPSH criteria, the pressure drop per 100 m of pipe length is generally recommended to be between 0.035 kg/cm’ and 0.085 kg/cm’ for the pump suction lines. Table 3 below provides 2 guide based on velocity criterion to select the centrifugal pump suction line size. Table 3: Recommended velocities for centrifugal pump suction lines Line size, mm NB Minimum velocity, mis Maximum velocity, m/s 25 0.22 0.34 40 0.28 0.45 © Bayer Engineering & Technology Confidential © 2017 Aker Solutions PC1805009_ROPlant: AkerSolutions Date-osor2016 | _RevNot Division: CROPSCIENCE Location: VAPI, INDIA EPRO Bayer Project No: ADOKM-000158 APG Project No: _506111-1905 GDL Chapter No: 03.01 Doc No: 1905:300-00-7007-A4-221 Doc Title: PROCESS & UTILITY DESIGN BASIS PAGENO 56 of 58 Line size, mm NB Minimum velocity, m/s | Maximum velocity, mis 50 0.45 0.55 80 0.45 0.75 100 0.55 09 150 0.75 12 200 09 14 250 1 1.65 300 12 18 350 12 20 400 14 22 450 15 25 500 16 2.75 600 18 29 750 24 33 Pump Discharge Line Sizing Table 5 below provides a guide based on velocity criterion to select the centrifugal pump discharge line size. The pressure drop per 100 m of pipe length is generally recommended to be between 0.15 kg/cm* and 0.6 kg/cm* for the pump discharge lines. Table 5: Recomment Line size, mm NB Minimum velocity, m/s Maximum velocity, m/s 25, 0.47 141 40, 0.65 14 50. 08 17 ‘@ Bayer ieeing & Technology Confidential ©2017 Aker Solutions 'P:1908009_ROIE AkerSolutions Dates T2018 | RevNot Divi yn: CROPSCIENCE Location: VAPI, INDIA Plant: EPRO Bayer Project No: AOOKM-000158 APG Project No: _506111-1905 GDL Chapter No: 03.01 Doe No: 1905-300-00-7007-A4-221 Doc Title: PROCESS & UTILITY DESIGN BASIS PAGENO_57 of 68 Line size, mm NB Minimum velocity, m/s | Maximum velocity, m/s 80 4 22 100 1.25 27 150 1.65 35 200 20 4.25 250 23 5.0" 300 26 5.6" 350 28 5.8" 400 3.0 6.0" 450 34 6.0" 500 3.75 6.0" 600 40 6.0" 750 45 6.0" © Bayer Engineering & Technology Confidential ©2017 Aker Solutions P1905009_RO(e~ Bayer Project No: AOOKM-000158 APG Project No: 06111-1905 \\ (eazer) visi Division: CROPSCIENCE GDL Chapter No: 03.01 \E Location: VAPI, INDIA Doc No: 1905-300-00-7007-A4.224 Doe Title: q Sal tigne |Plant: EPRO IE AkerSolutions PROCESS & UTILITY DESIGN BASIS Date-os012018 [Reyne t PAGENO 58_of 58 Recommended Velocity for Vapor Lines in Various Services first estimate, the recommended velocity for vapour lines can be obtained from the formula: vecip™ Where, V = Velocity, m/s ° Gas density at flow conditions, kg/m* © = factor, usually between 13 to 24 Table 13 below provides & guide for vapour line sizing based on velocity and maximum allowable pressure drop criteria for various services. ble 13: Vapor line sizing for various services Type of service Maximum allowable | Recommended pressure drop, kgicn*/ 100 | velocity, m/s. General Recommendation: ‘+ For pressure below 3.5 kg/cm’g 0.044 Velocity as per formula mentioned ‘+ For pressure between 3.5 to 10 kg/om’g 0.066 in section 8.1 ‘+ For pressure between 10 t0 14 kg/om’g 0.132 ‘+ For pressure between 14 to 36 kg/om’g oa 04d ‘+ For pressures above 35 kgicm’g © Bayer Engineering & Technology Confidential ©2017 Aker Solutions PC 1805009_RO