CHE 411 UND Chemical Engineering Corn Processing Facility Discussion

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CHE 411

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ChE 411 - Plant Design 1 Homework Assignment #2 – Group Questions This portion of Homework 1 is to be completed in your groups. Please choose 1 group member to submit the completed assignment. Note: Neatness, professionalism, and legibility will count in your grade for all problems. You are an engineer working at a corn processing facility. Your company has decided to replace everything in the process between the corn oil extractor (D-202 on the attached PFD) and the hexane distillation tower (D-203). This includes all piping, pumps, control valve stations, and instrumentation. Your job is to estimate the cost of this project. Prepare a cost estimate using the retrofit method you learned in class. For the pumps, obtain vendor quotes and document that communication using a phone log (date, group member talking, vendor talking, outline of the conversation) or by attaching an email. For all other components, use the guidelines given in Module 3. Descriptio n of this part of the process: Pipe segment 35. This is a liquid phase stream. It begins at a side discharge nozzle on pressure vessel, D-202, the Corn Oil Extractor which operates at 15psia. From the nozzle, the piping runs horizontally 0.5ft to a 100% open gate valve, then 0.5 ft to a 90o elbow, then 15ft vertically downwards to the side nozzle of a tee. From the two flow through sides of the tee, the two pump suction lines are symmetrical. The piping travels 3ft horizontally to 90o elbows, then 3ft horizontally to gate valves. The gate valve on one of the two flow lines is 100% open while the valve on the other line is 100% closed, depending upon which of the two L-207 pumps is in operation, A or B. From the gate valves, the piping runs 2ft horizontally to the suction nozzle of one of the L-207 pumps, either A or B. All pipe segments are 8in Schedule 40. Pump L-207A/B. L-207A and B are 100% redundant 8 HP centrifugal pumps. These pumps raise the pressure of the liquid such that at the entrance to D-203 (end of pipe segment 35A), the pressure is 45 psia. Pipe segment 35A. From the discharge nozzle of the L-207A/B pumps, the two discharge lines are symmetrical until the flow lines merge at the tee. The piping runs 2ft to gate valves. The gate valve on one of the two flow lines is 100% open while the valve on the other line is 100% closed, depending upon which of the two L-207 pumps is in operation, A or B. From the gate valves, the piping runs 3ft horizontally to 90o elbows, then 3ft horizontally to the flow through sides of a tee. From the side nozzle of the tee, the piping runs upwards vertically 20ft to a 90o elbow, then 20ft horizontally to a 90o elbow, then vertically downwards 15ft to a control valve station. See attached diagram 1 for a sketch of a control valve station. From the other connection of the control valve station, the piping travels vertically upwards 15ft to a 90o elbow, then 10ft horizontally to a 90o elbow, then vertically downwards 7ft to a 90o elbow, then 3ft horizontally to a 100% open gate valve, then 2 ft horizontally to the feed nozzle on the side of vessel, D-203. Use the average temperature documented on the diagram for the entire pipe segment. The pressure at the D-203 feed nozzle is 45 psia. All pipe segments are 8in Schedule 40. DIAGRAM 1. CONTROL VALVE STATION 100% open gate valves Control valve and reduced piping is one standard pipe size smaller than the rest of the pipe segment Manually bypass line, one standard pipe size smaller than the rest of the pipe segment, 100% closed. ½ inch diameter drain valves, normally closed ChE 411 - Plant Design 1 Homework Assignment #2 – Group Questions This portion of Homework 1 is to be completed in your groups. Please choose 1 group member to submit the completed assignment. Note: Neatness, professionalism, and legibility will count in your grade for all problems. You are an engineer working at a corn processing facility. Your company has decided to replace everything in the process between the corn oil extractor (D-202 on the attached PFD) and the hexane distillation tower (D-203). This includes all piping, pumps, control valve stations, and instrumentation. Your job is to estimate the cost of this project. Prepare a cost estimate using the retrofit method you learned in class. For the pumps, obtain vendor quotes and document that communication using a phone log (date, group member talking, vendor talking, outline of the conversation) or by attaching an email. For all other components, use the guidelines given in Module 3. Descriptio n of this part of the process: Pipe segment 35. This is a liquid phase stream. It begins at a side discharge nozzle on pressure vessel, D-202, the Corn Oil Extractor which operates at 15psia. From the nozzle, the piping runs horizontally 0.5ft to a 100% open gate valve, then 0.5 ft to a 90o elbow, then 15ft vertically downwards to the side nozzle of a tee. From the two flow through sides of the tee, the two pump suction lines are symmetrical. The piping travels 3ft horizontally to 90o elbows, then 3ft horizontally to gate valves. The gate valve on one of the two flow lines is 100% open while the valve on the other line is 100% closed, depending upon which of the two L-207 pumps is in operation, A or B. From the gate valves, the piping runs 2ft horizontally to the suction nozzle of one of the L-207 pumps, either A or B. All pipe segments are 8in Schedule 40. Pump L-207A/B. L-207A and B are 100% redundant 8 HP centrifugal pumps. These pumps raise the pressure of the liquid such that at the entrance to D-203 (end of pipe segment 35A), the pressure is 45 psia. Pipe segment 35A. From the discharge nozzle of the L-207A/B pumps, the two discharge lines are symmetrical until the flow lines merge at the tee. The piping runs 2ft to gate valves. The gate valve on one of the two flow lines is 100% open while the valve on the other line is 100% closed, depending upon which of the two L-207 pumps is in operation, A or B. From the gate valves, the piping runs 3ft horizontally to 90o elbows, then 3ft horizontally to the flow through sides of a tee. From the side nozzle of the tee, the piping runs upwards vertically 20ft to a 90o elbow, then 20ft horizontally to a 90o elbow, then vertically downwards 15ft to a control valve station. See attached diagram 1 for a sketch of a control valve station. From the other connection of the control valve station, the piping travels vertically upwards 15ft to a 90o elbow, then 10ft horizontally to a 90o elbow, then vertically downwards 7ft to a 90o elbow, then 3ft horizontally to a 100% open gate valve, then 2 ft horizontally to the feed nozzle on the side of vessel, D-203. Use the average temperature documented on the diagram for the entire pipe segment. The pressure at the D-203 feed nozzle is 45 psia. All pipe segments are 8in Schedule 40. DIAGRAM 1. CONTROL VALVE STATION 100% open gate valves Control valve and reduced piping is one standard pipe size smaller than the rest of the pipe segment Manually bypass line, one standard pipe size smaller than the rest of the pipe segment, 100% closed. ½ inch diameter drain valves, normally closed ChE 411 - Plant Design 1 Homework Assignment #2 – Note: Neatness, professionalism, and legibility will count in your grade for all problems. You are an engineer working at a corn processing facility. Your company has decided to replace everything in the process between the corn oil extractor (D-202 on the attached PFD) and the hexane distillation tower (D-203). This includes all piping, pumps, control valve stations, and instrumentation. Your job is to estimate the cost of this project. Prepare a cost estimate using the retrofit method you learned in class. For the pumps, obtain vendor quotes and document that communication using a phone log (date, group member talking, vendor talking, outline of the conversation) or by attaching an email. For all other components, use the guidelines given in Module 3. Description of this part of the process: Pipe segment 35. This is a liquid phase stream. It begins at a side discharge nozzle on pressure vessel, D-202, the Corn Oil Extractor which operates at 15psia. From the nozzle, the piping runs horizontally 0.5ft to a 100% open gate valve, then 0.5 ft to a 90o elbow, then 15ft vertically downwards to the side nozzle of a tee. From the two flow through sides of the tee, the two pump suction lines are symmetrical. The piping travels 3ft horizontally to 90o elbows, then 3ft horizontally to gate valves. The gate valve on one of the two flow lines is 100% open while the valve on the other line is 100% closed, depending upon which of the two L-207 pumps is in operation, A or B. From the gate valves, the piping runs 2ft horizontally to the suction nozzle of one of the L-207 pumps, either A or B. All pipe segments are 8in Schedule 40. Pump L-207A/B. L-207A and B are 100% redundant 8 HP centrifugal pumps. These pumps raise the pressure of the liquid such that at the entrance to D-203 (end of pipe segment 35A), the pressure is 45 psia. Pipe segment 35A. From the discharge nozzle of the L-207A/B pumps, the two discharge lines are symmetrical until the flow lines merge at the tee. The piping runs 2ft to gate valves. The gate valve on one of the two flow lines is 100% open while the valve on the other line is 100% closed, depending upon which of the two L-207 pumps is in operation, A or B. From the gate valves, the piping runs 3ft horizontally to 90o elbows, then 3ft horizontally to the flow through sides of a tee. From the side nozzle of the tee, the piping runs upwards vertically 20ft to a 90o elbow, then 20ft horizontally to a 90o elbow, then vertically downwards 15ft to a control valve station. See attached diagram 1 for a sketch of a control valve station. From the other connection of the control valve station, the piping travels vertically upwards 15ft to a 90o elbow, then 10ft horizontally to a 90o elbow, then vertically downwards 7ft to a 90o elbow, then 3ft horizontally to a 100% open gate valve, then 2 ft horizontally to the feed nozzle on the side of vessel, D-203. Use the average temperature documented on the diagram for the entire pipe segment. The pressure at the D-203 feed nozzle is 45 psia. All pipe segments are 8in Schedule 40. DIAGRAM 1. CONTROL VALVE STATION 100% open gate valves Control valve and reduced piping is one standard pipe size smaller than the rest of the pipe segment Manually bypass line, one standard pipe size smaller than the rest of the pipe segment, 100% closed. ½ inch diameter drain valves, normally closed H•211 B-Pî 0 Masa How rates in 1000 Ih/day Sum of componenfs may not equal total due lo roundirig H-210 uses an elliana refrigeration loog lo cooi lhe oil Sex IJrawirig X Presgure (psia) Stream Numbers Stream Labels Neglgibîe amount hpu Drawing Type: COM§O0Ont Com OfJ Wafer total 37 1000 70 10 0 42 0 0 0 0 43 0 0 J0 0 44 1uu0 70 0 0 45 u 0 0 0 I8 U 0 0 0 8tream Number 47 48 49 1O00 0 1000 0 0 0 0 0 0 0 Nep 0 s0 000 0 0 0 s1 0 0 o 0 5:t 0 0 o 0 53 1000 0 0 o 90 0 o o o c o o o s v o c o u o 0 o 0 tl 0 t 0 4Y U 42 O 0 0 0 Q 10 lI 290 0 Nep 0 250 W U 0 0 U o 0 0 O tj 0 0 0 p 0 o O tj Neg at U 0 0 0 Nwg p 0 0 0 p 0 00 O 11UU 42 52 1100 260 330 1000 Npg 10U0 1000 80 Nog 1000 80 High Pressure Sleam
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Running head: PLANT DESIGN

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Low-Cost Machine Tools Retrofit with A Universal Numerical Control
Worker’s Name
Institution Affiliation
Date

PLANT DESIGN

2

Abstract:
In this article, using Universal Numerical Control (UNC) software, we discuss our experiences
with low-cost machine tool retrofits. UNC software, which allows for the fast and simple
integration of additional components into the machine tool, is described in this paper. Its goal is to
offer a low-cost solution to these issues, thus improving the capabilities of the industrial and
manufacturing systems. The goal of this strategy is to improve modernization while also assisting
in the development of the metalworking sector at the maize processing facility.

PLANT DESIGN

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1. INTRODUCTION
Recently, the demands of contemporary manufacturing have changed significantly, and an
abundance of new capabilities suited to modern manufacturing is now accessible. As a
consequence of this rapid expansion, small and medium-sized businesses that rely on CNC
technology have experienced sluggish development. Because of the high cost of these new
production methods, there is a backlog of modern equipment in the education sector, which has a
disproportionately negative effect on poor nations [1, 2]. We discuss our experiences with lowcost machine tool retrofits that make use of Universal Numerical Control (UNC) software, which
allows for the fast and simple integration of additional components into the machine tool and
reduces the need for specialized training. It is the process of retrofitting outdated systems with new
technology or capabilities that is denoted by the term "retrofit" Because of process adaptability,
servo motors and drives, spindle motors and drives, as well as a part of the related wiring and
electromechanical components, are often upgraded to a Computer Numerical Control (CNC)
system, which is a kind of computerized numerical control system. In this particular instance, the
technique was developed with the help of UNC's technical expertise and development. The UNC's
reconfigurability is at the heart of the refit since it enables numerical control of the machine tool
following the technical specifications of the maize oil extractor [2]. Existing retrofits and
numerical control systems that enable the conversion of traditional machine tools to CNC
machines are widely available today. It is intended that these enhancements be applied to a certain
kind of machine tool that is reconfigurable in terms of size as well as mechanical and electrical
setup, but which lacks a variety of control system options. [3, 4] Although there have been attempts
to build open architectures and reconfigurable CNC (OSACA [3, 4] and OSEC [3, 4]), they have

PLANT DESIGN

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been suited to the requirements of highly developed nations, where standardization regulates
communication between various manufacturers.
Comparatively speaking to current systems, our automation and control system is reconfigur...


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