Project Nebula

BASIC ENGINEERING

CONCEPT NOTES FOR

Chiller

Document Number
P90-UL72-01-001

NPT/SOP/PBE/005/F01 Rev No. 00 Effective date: 15/11/2017 Page 1 of 5

 Project Nebula
1.0 INTRODUCTION
Aim:

 To design and install chiller facility of capacity 105 TR.

Sources:

Product Tag TR Frequency

KCP 95FL1 Flaking 20.0 Once in a day
Sunbeat 95R2 Vacuum trap load 0.3 Once in week
95V3 Chilled MDC up to 10°C 2.3 Once in week
95V3 Chilled to RB-650 up to 10°C 3.6 Once in week
95R3 RM cooling from RT to 12°C 9.5 Once in week
95R3 Addition of MDC & RB650 Mixture 8.7 Once in week
95R3 Vacuum trap load 0.01 Once in week
95R4 Chilling RM from 30°C to 20°C 12.8 Once in week
95R4 Addition of Caustic lye 9.0 Once in week
95R4 Chilling before filtration from 25°C to 12°c 7.2 Once in week
95R4 Chilling RM (RB -700 with 1:1 water) from 25°C
to 12°C 7.2 Once in week
95R4 Vacuum trap load 1.4 Once in week
95R4 Chilling to the RM RT to 12°C 18.5 Once in month
95R4 Addition of Epichlorohydrine by maintaining
temp 10-15°C 0.3 Once in month
95R4 Digest RM at 10-15°C for 4 hours 0.6 Once in month
95R4 Chilled reaction mass from 12°C to 8°C 3.8 Once in month
GalhueShield 95R2 Vacuum trap load 0.5 Once in 15days
EHT 96R3 Vacuum trap load 1.2 Twice in a day
96R3 Vacuum trap load 0.6 Twice in a day
96R4 Chilling to RM 20°C 7.6 Once in a day
96R4 Chilling to RM 30-20°C 11.3 Once in a day
Galpol Solvent drying 22.9 Twice in a day
Scrubber HCl and SO2 scrubber peak load 30.0 12hr in a day
CCOE Vacuum traps 6.9 Once in a day

Peak Load: 101.7TR

Frequent load: 92.29TR

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 Project Nebula
2.0 PHILOSOPHY
Process:

 MEG 22% will be produced through vapor compression process cooled by water cooled
chiller.
 MEG 22% temperature at battery limits of the system will be 12 oC (in) and 5 oC (out)
 Insulation of MEG lines will be done by PUF insulation joined with bitumen and cladded
with galvalume sheet.
 MEG pumps Supply to plant will be HPS system.

Utility:
 Cooling water for Chiller

Mechanical:

Construction
 Skew Hermetic screw type system will be considered for the compressor
 “Green” refrigerant will be used in the chiller (e.g. R-22, R-134 or R-407C).
 Makeup will be done by adding MEG manually and water line will be provided.
 System will be water cooled.
 Hot well and cold well will be with 10% excess capacity over the entire system volume.
 Both hot and cold well will be vertical rectangular vessels with flat bottom in SS304
construction.
 System will have following in-built safeties
o Low cooling water pressure.
o Low coolant (MEG 22% from hot well) pressure.
o Antifreeze trip.
o High discharge pressure from compressor.
o Low suction pressure to compressor.
o Low oil pressure.
o Crank case heater is “ON” when chiller is not running

Piping
 Two bucket filters; CS body with 24 mesh, SS304 filtering element will be used in the suction
of the circulation pumps to filter any contaminants. One filter will be in line while the other will
be a standby filter.
 Pump suction and discharge pipes and pipe fittings will be C class, ERW. Pipe sizes will be
sized from detail engineering.
 MEG 22% supply and return header at plant locations will have isolation valves.

Valves
 Manually operated butterfly/Ball valves with SS304 body and neoprene seat will be used.

Gaskets
 All gaskets used in MEG 22% line will be klinger make non-asbestos universal gaskets

Insulation
 PUF insulation joined with bitumen and galvalume sheets will be used for chilled MEG 22%
applications.

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 Project Nebula
 Hot and cold well will also have PUF insulation joined with bitumen and cladded with
galvalume sheets
 Pumps will be insulated with PUF insulation. This is to avoid heat loss & also to avoid
condensate formation on pump body. The condensate formed on pump body makes area
around pump foundation water resulting in poor housekeeping.

Civil:
 It will be discussed in separate concept notes

Electrical:
 The system will be considered under non-flameproof area.
 The motors used will be of IE3 class for all the running equipment.
 It will have proper lighting arrangement for proper illumination in night.
 All running equipment’s will have local emergency stop button with protection.
 All the equipment and structure will have double earthing.
 Further more details will be included in concept notes of electrical.

Instrumentation:

 All pumps shall have a Bourdon pressure gauge at the discharge.

 Hot well and cold well will have temperature gauge installed in the tanks.
 Both hot well and cold well will have a local level gauges installed.
 Pressure and temperature gauges will be installed at a few locations in the main headers
running in the pipe rack. This will help in trouble shooting if the need be.
 Chilled MEG inlet and outlet temperatures will be monitored by temperature gauges as well
as RTDs with feedback to PLC
 Turbine type flow meters will be installed at the outlet of the user to check the flow
 Cooling water inlet and outlet temperatures will be monitored by temperature gauges.
 Flow meter will be installed in cooling water inlet line to chiller system.
 PLC feed back will be provided for the following :
o Running feed back of hot / cold well pumps.
o Hot well temperature.
o Cold well temperature.
o Pressures switch indication for cooling water.
o Pressures switch indication for MEG 22%.
o Coolant circulation pump running feed back.
o Level in hot/ cold well.
o Run / trip feedback of chiller

Warehouse and Storage:

 MEG will be stored in Warehouse

Safety:
 Appropriate fire extinguishers and sand buckets will be provided.
 Eye washer and hand shower will be provided

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 Project Nebula
3.0 SIZING

Sr. No. Equipment Tag Capacity

1 Hot well 72T1.G
2 Cold well 72T2.G
3 Return pump
4 Supply HPS system
5 Chiller 72CH1.G 105 TR

4.0 LAYOUT
 Detailed layout will be shared once finalized

5.0 ANNEXURE

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