Design & Engineering of Pressure Vessels and Heat Exchangers (ASME Sec. VIII / TEMA Standards)
⭐ PROJECT DESCRIPTION
A chemical manufacturing client required full engineering consultancy for setting up a new process block that included reactors, heat exchangers, cooling tower, chilling system, utility pipelines, and structural pipe rack.
The scope covered everything from utility load estimation, equipment design, P&IDs, piping layout, foundation planning, and integrated floor layout, ensuring safe, efficient, and compliant plant operation.
Adhyntra Pvt Ltd provided end-to-end engineering, delivering accurate designs aligned with ASME, API, IS standards, and ensuring the facility was ready for installation and commissioning.
⭐ PROJECT PROCESS / APPROACH
⭐ 1️⃣ Data Collection & Process Understanding
- Study of process flow diagrams
- Batch size, reaction profile & heat duty requirements
- Raw material & solvent list
- Utility consumption & cycle time
- Equipment list & load data
This helped finalize utility sizing, equipment ratings, and piping strategy.
⭐ 2️⃣ Reactor Design & Specifications
Designed reactors considering:
- Working pressure & temperature
- MOC selection based on chemical compatibility
- Agitator speed, HP & torque requirement
- Jacket/coil heat transfer requirement
- Nozzle orientation & instrumentation ports
- Support type: lug, skirt, or leg support
Delivered:
- GA Drawing
- Detailed fabrication drawing
- Nozzle schedule
- Foundation load data
⭐ 3️⃣ Heat Exchanger Design
Designed heat exchangers based on:
- Heat load (kcal/hr)
- Cooling/Heating media availability
- LMTD & heat transfer coefficient
- Tube-side vs shell-side selection
- MOC selection (SS/MS/Alloy)
Outputs:
- Mechanical design
- Thermal design report
- Tube sheet, baffle design
- Fabrication drawing
⭐ 4️⃣ Utility Requirement & Load Calculation
Calculated total utility demand for:
- Cooling water
- Chilled water / Brine
- Steam
- Hot water
- Compressed air
- Vacuum
- Nitrogen
Generated a utility summary sheet, essential for plant sizing.
⭐ 5️⃣ Cooling Tower & Chilling Plant Design
🔹 Cooling Tower:
- Heat load calculation
- FRP cooling tower sizing
- Water circulation rate
- Pump head & flow calculation
- Basin sizing & drift eliminator specification
🔹 Chilling/Brine Plant:
- Compressor capacity
- Evaporator/Condenser specification
- Refrigerant selection
- Secondary coolant pump sizing
- Piping & insulation thickness calculation
⭐ 6️⃣ Pipe Rack & Utility Routing Design
Designed a multi-tier pipe rack with:
- Structural design calculations
- Pipe spacing & routing philosophy
- Anchor, guide & support plan
- Stress considerations
- Access walkway & maintenance platform
Prepared:
- Plan view
- Elevation drawings
- Isometric sketches
⭐ 7️⃣ P&ID Preparation
Developed full P&IDs for:
- Reactor loop
- Heat exchanger loop
- Cooling water network
- Chilled/Brine system
- Steam & Condensate
- Vacuum & Compressed air
- Vent & Safety system
Included:
- Instruments
- Control valves
- Interlocks
- Safety relief lines
⭐ 8️⃣ Floor Plan & Equipment Layout
Provided:
- Production hall layout
- Utility block floor plan
- Reactor & exchanger placement
- Safe movement path
- Maintenance clearance
- Electrical & automation interface plan
⭐ WORK SCOPE SUMMARY
- ✔ Reactor design & fabrication drawings
- ✔ Heat exchanger mechanical & thermal design
- ✔ Utility load & demand calculation
- ✔ Cooling tower & chilling plant sizing
- ✔ Pipe rack structural design
- ✔ P&ID preparation for all utilities
- ✔ Equipment GA drawings
- ✔ Floor layout & installation planning
- ✔ Material, MOC & safety guideline documentation
