Process Engineering Equipment Handbook P1 pdf

CFD Computational Fluid Dynamics Fluent Inc.: Lebanon, NH USA Carbon; Carbon-Graphite Mix Products Advance Carbon Products: 2036 National Avenue, Hayward, CA 94545 USA Carbon Dioxide CO

Process Engineering Equipment Handbook Claire Soares

McGraw-Hill

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Soares, Claire.

Process engineering equipment handbook / Claire Soares.

p cm.

Includes index.

ISBN 0-07-059614-X (acid-free paper)

1 Chemical plants—Equipment and supplies I Title.

1 2 3 4 5 6 7 8 9 0 CCW/CCW 0 7 6 5 4 3 2 1

ISBN 0-07-059614-X

The sponsoring editor for this book was Kenneth P McCombs, the editing supervisor was Stephen M Smith, and the production supervisor was Sherri Souffrance It was set in New Century Schoolbook by Best-set Typesetter Ltd., Hong Kong.

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Information contained in this work has been obtained by The McGraw-Hill Companies, Inc (“McGraw-Hill”) from sources believed to be reliable However, neither McGraw-Hill nor its authors guarantee the accuracy or completeness of any information published herein and neither McGraw-Hill nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information This work is published with the understanding that McGraw-Hill and its authors are supplying information but are not attempting to render engineering or other professional services If such services are required, the assistance of an appropriate professional should be sought.

McGraw-Hill

Acoustic Enclosures, Turbine

Altair Filters International Limited: Omega Park, Alton, Hampshire GU34

2QE England

Actuators

J.M Voith GmbH: P.O Box 1940, D-89509 Heidenheim, Germany Voith Turbo GmbH & Co., KG: P.O Box 1555, D-74555 Crailsheim, Germany Air Filtration

Altair Filters International Limited: see above Air Pollution Control

Hasselstrasse 16, CH-5401 Baden, Switzerland; 5309 Commonwealth CenterParkway, Midlothian, VA 23112 USA

B

Bearings

Demag Delaval: 840 Nottingham Way, Trenton, NJ 08638 USA Revolve Magnetic Bearings, Inc.: Calgary, Alberta, Canada Boilers

Environment Canada: see above Brakes

J.M Voith GmbH: see above

xv

CFD (Computational Fluid Dynamics)

Fluent Inc.: Lebanon, NH USA Carbon; Carbon-Graphite Mix Products

Advance Carbon Products: 2036 National Avenue, Hayward, CA 94545 USA Carbon Dioxide (CO 2 ); CO 2 Disposal

Vatenfall: S162 87 Stockholm, Sweden Cement; Portland Cement

Environment Canada: see above Centrifuges

Dorr-Oliver Inc.: 612 Wheelers Farm Road, Milford, CT 06460 USA Chemical Complex; (Petro)Chemical Complex; Chemical Plant

Petrochemcial Company of Singapore: Singapore Chemicals

ARCO Chemical Company: 3801 West Chester Avenue, Newton Square, PA

19073-2387 USA

Chemicals (Toxic), Handling

ARCO Chemical Company: see above Chillers; Crystallizers; Chemical Separation Method; Alternative to Distillation/Fractional Distillation

Armstrong Engineering Associates: P.O Box 566M, West Chester, PA

Claire Soares Inc.: P.O Box 540213, Dallas, TX 75354 USA

Control Systems; Controls

Sulzer-Burckhardt: see above Voith Turbo GmbH & Co., KG: P.O Box 1555, D-74555 Crailsheim, Germany Voith Safeset A.B.: Ronningev 6, S-82434 Hudliksvall, Sweden

Sandvik Process System, Inc.: USA

Bloch, H., and Soares, C M., Process Plant Machinery, 2d ed.,

Butterworth-Heinemann, 1998

Coolant; Engine Coolant

ARCO Chemical Company: see above Cooling; Cool, Products That (Air Conditioners); Liquid-Cooled Air Conditioners

Thermoelectric Cooling America Corporation (TECA): USA Cooling Towers

The Marley Cooling Tower Company: Marley and Lone Elm Roads, Olathe, KS

Ecological Parks; Industrial Ecological Parks

Environment Canada: see above Ecosystem

Environment Canada: see above Electric Motors; Electric Motor Controls

Reliance Electric Company: Cleveland, OH USA Emissions; Air Emissions

Environment Canada: see above Engines, Gas

Cooper-Bessemer Reciprocating: Grove City, PA USA Environmental Accountability

Kodak: USA Cultor: Finland Environmental Economics

AssiDomän: Sweden Exhausters, Centrifugal Gas

Ansaldo: Milan, Italy Expansion Joints

Townson Expansion Joints: United Kingdom Explosion; Explosion Hazard Analysis; Explosion Hazards

Eutech Engineering Solutions Ltd.: Billingham, Cleveland TS23 4YS England

H.M Principal Specialist Inspector, Health & Safety Executive, Quay House, QuayStreet, Manchester M3 3JB England

Contributors xvii

Fans, Centrifugal

Ansaldo: see above

Bloch, H., and Soares, C M., Process Plant Machinery, 2d ed.,

Bechtel Power Corporation: Gaithersburg, MD 20878 USA G

Life-Cycle Assessment (LCA) (of Turbomachinery)

Claire Soares Inc.: P.O Box 540213, Dallas, TX 75354 USA Liquid Natural Gas (LNG)

Peerless Manufacturing Company: see above Lubrication

Demag Delaval: see above M

Oil Sands; Synthetic Crude; Tar Sands; Shale

Syncrude Canada Limited: Ft McMurray, Alberta, Canada Oxygen Analysis

Rosemount Analytical: Orville, OH USA Ozone

Environment Canada: see above P

Pollutants, Chemical; Pollutants, (from) Chemical Processes; Pollutant Indicators; Pollutants, Toxic; Pollutants, Toxic Chemicals

Environment Canada: see above Power Transmission

Demag Delaval: see above MAAG Gear Company: Switzerland J.M Voith GmbH: see above

Pulp and Paper

AssiDomän: see above Pulsation Dampeners

Peerless Manufacturing Company: see above Pumps

Bloch, H., and Soares, C M., Process Plant Machinery, 2d ed.,

Butterworth-Heinemann, 1998

Demag Delaval: see above Sulzer Pumps: USA Goulds Pumps: USA R

Refineries, Petroleum

Environment Canada: see above S

Seals; Gas Seals

Revolve Magnetic Bearing, Inc.: see above Separators

Peerless Manufacturing Company: see above Stacks

Altair Filters International Limited: see above T

Turbines, Gas

Alstom: see above ASME: see above Turbines, Steam

Demag Delaval: see above Peerless Manufacturing Company: see above Turbochargers

Demag Delaval: see above Turboexpanders

Demag Delaval: see above U

Ultrasonic Cleaning

Sonics: USA V

Vaporizers; Vaporizor Applications

Armstrong Engineering Associates: see above W

Waste Management

Environment Canada: see above

xx Contributors

About the Author

A registered professional engineer in Texas and Alberta, Canada, Claire Soaresgraduated with a B.Sc.Eng in 1972 and an M.B.A in 1993 Her career began incomputational fluid dynamics working for Brian Spalding in Imperial College,London, on the COBALT project She then spent about two years working ondeveloping structural patents for the marine and the power distribution industries

in England and Canada Her rotating machinery career began in earnest at the oilsands Syncrude site in Fort McMurray, Alberta, in 1975 Four years later, shemoved to Esso Resources and conventional oil and gas production until the “oilpatch sat on its tail” at the end of 1981 She then accepted a three-year commissionwith the Canadian Air Force as Propulsion Systems Manager for all transportationengines in the Department of Defence Transport Command in Canada She tookcharge of six helicopter engine fleets, as well as projects related to selectingreplacements for two of those fleets After that, she moved to the United States tostart work as a senior engineer for Ryder Airline Services Division (ASD was alsocalled Aviall and, before that, CooperAirmotive) At that point ASD was the largestindependent overhaul facility for airline engines in the world, with a shop capacity

of about 1000 engines a year She ran technical support on second shift for 250mechanics and their supervisors on the JT8D, JT3D, and CFM 56 engine lines.Three years later, she was made manager of the V2500 engine repair program, atthat time the first and only designated facility for this engine in the United States.Two years later, after the engine line was up and running, she left to become anindependent consultant, trainer, and writer She has now lived and worked on fourcontinents Ms Soares organizes one to two conference sessions annually for theInternational Gas Turbine Division of the American Society of MechanicalEngineers (ASME) and has done so since 1985 In May 2001 she was appointed toFellow grade by ASME

Process Engineering Equipment Handbook is her fourth book The first, Process Plant Machinery, Second Edition, was coauthored with Heinz Bloch, P.E This work and Environmental Technology and Economics: Sustainable Development in Industry helped provide the present handbook with its broad perspective Turboexpanders and Process Applications, her third book, also coauthored with

Heinz Bloch, was released in 2001 All her books are used when appropriate ascourse instruction material for her own and others’ courses Ms Soares writes

extensively for technical journals, such as Petroleum Economist, Asian Electricity, and International Power Generation.

She also writes for more general audiences, with some television screenplays andarticles for various international newspapers and magazines to her credit Apublished photographer, she writes poetry and has staged multimedia performances

of her work for organizations such as the city of Dallas She is a scuba diver andlicensed commercial pilot, and also enjoys swimming and hiking

In-30

If you picked up this book you are probably one of those lucky people who run plants.Either a thinly spread engineer (branch of specialty is irrelevant), a newly promotedtechnical manager, or a harassed technologist or senior mechanic, who just was told:

“See that plant out there? You’re in charge of making it work!” Even if you’ve been

in plants for years, that’s enough to make your innards rumble If you have juststepped out of school, into your first plant, or into a totally different plant from theprevious one you were at, your reaction might be more severe, especially if youbelong to one of the numerous organizations with no budget for rotating machineryspecialists (who look after what moves a process through its paces) orenvironmental specialists (who make certain you don’t get fined or jailed, goodintentions notwithstanding, as you run your plant) At this point, I should explainwhere I fit in with your agenda

Twenty-some years ago, some heated arguments on the subject of how much Iwanted to be a rotating machinery specialist took place in Canada’s wild and woollynorth I was fencing with my boss, a process engineer, who was recommending Ijoin his field It was what my company needed, he asserted I thought it neededboth of us doing what we loved best My career bears witness to the fact that I wonthe match, in the short- and long-term

Time since has brought a few things forcibly home to me To start with, the more

I dealt with plant machinery in any form, the more I accepted that processconditions could affect the performance of that machinery at least as much as actualmechanical characteristics In operations, repair and overhaul, or retrofit designand reengineering, what keeps people like me a step ahead of the manufacturer’sfield service representatives is knowledge of the process and familiarity with thecontrols that govern the entire system In turn, the process engineer who getshanded a plant to run must acquire some basic knowledge of my bread and butter,the machinery that makes everything move up, down, or around In large facilities,such as the ones I was fortunate enough to spend time in, there generally are in-house rotating machinery specialists Often, though, the process engineer is notthat lucky and gets everything—process components, machinery, controls, and all.Life handed me an education (after formal degree acquisition) in rotatingmachinery specialization and the environmental technology that goes with it (yes,

we machinery “cranks” run the stuff that turns out arguably 80 percent of the gunk

in the universe) While doing this, I worked with scores of process engineers, controlengineers, and various other specialists on a variety of projects that were amongthe most high profile in the world in their own right It was “arranging to be in theright place—an operating plant—to get the best education in the best school in theworld.”

After all, curriculum, undergraduate or otherwise, is not necessarily any comfort

In my day they rarely taught this stuff to process, chemical, or mechanical engineers

xi

at universities They still don’t That leaves all the young engineers in the sameboat—without any practical guide for reference.

My editor at McGraw-Hill was keen that they should have one, and one that waseasy to read We soon found we were on the same page on the subject of readability

We do not like technical material that sounds more intellectual than it absolutelyhas to, and we do like many diagrams, photographs, tables, and figures

I add two other ingredients to my books and courses: (1) information on items (such as condition monitoring and specialized controls) that will help the engineeroptimize cost-effective operations and (2) information that will help the engineerstay out of trouble with legislators, particularly environmental legislators (regardless of whether the legislation is current or impending) Fines levied forignoring emissions or pollutant statutes may not be high enough to be a deterrent

in themselves when weighed against a process plant’s gross production revenue.They can, however, whittle away at profits while adding to overall costs per operating hour Frequently, though, environmental equipment can actually result

in machinery’s attaining longer times between overhauls Also, the loss of goodwill

—that priceless commodity on annual reports—is immense if environmental standards are not followed

In this competitive age, plants do vie for national, state, or provincial qualitycontrol awards Clever managers can turn those into longer customer lists.Attaining these awards is not something that many accountants, lawyers, andMBAs, who run major corporations but may have little or no technical exposure,can pull off without their engineers It is the engineers who are likely to be the keyfigures in putting together the action framework for what will buy their firm new

or continued goodwill Environmental accounting plans, holistic management ofresources and waste products, environmental policy, waste and toxic management—they mean pretty much the same thing and they are not a feature at all in manyother process engineers’ reference books

It is painfully evident that the emphasis given to waste and toxic managementvaries globally It reaches a high in Sweden and Norway, England is fast developing

an aggressive proactivity in this vein, and Canada has excellent technology, whichmay or may not get enforced to the appropriate extent depending on the politicalbalance of power at any time The United States has some large loopholes that aresurprising for a country so advanced; shared emissions legislation is one And yet,it’s in the area of waste and toxic management that companies receive the mostvocal and widespread media coverage (and loss of business) when exposed Some ofthe world’s youth appear to have a sense of resources running low and therefore aneed to conserve them In these days of increasing international joint ventures, thegaps between all these preferences is fast diminishing and the stable point for theresultant system can tend to reflect the highest standards among the partners.One could argue that subjects that infringe on environmental and wastemanagement turf belong in another handbook and with another kind of engineer.That is not entirely true though this is becoming a specialist field The reasons forthis statement are rooted in profit margins If environmental considerations andwaste products can be integrated into production in a way that what might havebeen a hazard or waste now contributes to revenue, this is obviously preferable

to that hazard or waste being isolated with its own disposal/neutralization systemthat does not contribute revenue Some examples are biomass waste in pulp andpaper production, formerly disposed of, that can be converted to gaseous fuel for aturbine (see Pulp and Paper) and chemical by-products in complex downstream

petrochemical plastics production, otherwise waste, that can now also be used asturbine fuel The controls and system modifications that assist incorporation ofthese profitable adaptions into process plants are given some space

xii Preface

I have also included some basic information on specific controls and monitoringsystems They are a fact of life on a process engineer’s turf; the ones I havehighlighted have a proven track record for adding profit margins to processes byminimizing downtime or fluctuations.

Similarly, a process engineer may have to make decisions related toturbomachinery performance or capacity that are affected by metallurgicalprocesses Included is some information on common critical alloys used in today’splants

This book contains information on the major components and basic systems,including instrumentation and controls, and some optimization techniques that Iwish I had had when I landed, albeit happily, in my first major plant It also containsexamples, drawn from knowledgeable sources, of action plans that have keptvarious process companies in good standing and high esteem with their public andgovernments worldwide Selected extracts of the technology that are the bases ofthese policies are also included These examples and technology extracts arefrequently missing from engineering handbooks; I would be doing users of thishandbook a disservice to leave out this information

Increasingly process plants are becoming small power producers Governmentsare now beginning to offer incentives to small power producers The Thaigovernment, which buys the excess power from Esso’s Sriracha refinery, is just onesuch example The Alberta, Canada, government buys excess power from SyncrudeCanada Limited, which produces 170,000 barrels of crude oil a day The Britishpower network buys excess power from Elf Acquitaine’s Flotta terminal, whichcollects North Sea petroleum products

In other words, this book aims to provide a process engineer with:

 Knowledge of the basics the process engineer will meet up with

 Enough knowledge to help the process engineer optimize operation safety,efficiency, and profit margins

 Information about environmental systems and avoiding trouble with the law

 Tools to integrate the plant’s operation with other services, such as powerproduction and waste management, to further optimize profits and minimizelosses due to interruptions in services provided by external companies

Claire Soares claire_soares@compuserve.com

Preface xiii

The contemporary process engineer has to be an all-around generalist Thishandbook contains basic information on items that cause or assist chemicalreactions, such as chillers In today’s environment, information on additionalsectors is also required to help the plant engineer function

To begin with, besides the components in a plant that produce required chemicaland physical state changes, such as fractionating distillation columns and reactors,the plant engineer needs to know the process plant machinery that transports anddelivers raw material and products It is this machinery that is very often the bane

of the engineer’s existence The good news is that with a little knowledge one cankeep most of it running

When that happens, the process plant engineer may have to troubleshootequipment if the plant does not have a rotating machinery engineer That may bewhy so many of the process plant engineers I talked with asked me to includematerial on condition monitoring and life-cycle (of machinery components)assessment These two items alone can save a plant a huge amount of its costs perplant operating hour, if properly utilized I have included some of my notes fromtwo of my basic courses on these subjects

Interestingly enough, plant problems are common at system interfaces—atexpansion joints, rather than at what they connect, and at gearboxes, couplings,and torque measurers, rather than the parent items of machinery they link Also,certain accessories can be weak points if improperly applied Air filtration canprotect a machine from icing and erosive particles or it might build up excessivepressure drop and penalties on turbine output power The quantity of informationprovided on these items, such as air filtration and power transmission equipment,reflects this fact

Environmental technology and economics is another area now integral to aprocess engineer’s world Without this knowledge, the company could be fined andmanagement imprisoned Even if this is not an issue, environmental savvy can buy

a corporation an inestimable amount of goodwill and a high profile in proactivecommunity service It has resulted in national quality control awards and otherrecognition This may mean that corporation is preferentially selected as a product

or services supplier Environmentally sound cohabitation of industrial real estate

in what are termed ecological industrial parks can also save utility costs

Most importantly, however, taken over the life of a plant, environmentally soundmethodology saves in overall operating costs per unit time What seems likecleanliness and politically correct “extras” saves in parts longevity This is notcommon knowledge in the engineering world In fact, one common motivation forfitting environmental accessories is that operators are aware that if they wait until

xxi

use of same is forced upon them, retrofits of items such as flue gas desulphurizationcost as much as 300 percent more than installation with initial construction.Process plant engineers will probably also have to run their own in-house powerplant at some point They will have to manage interfaces with the power plant andtheir main process facility The power is primarily for their own needs, but theyfrequently sell their excess power to the national grid Even more interesting is thefact that process fluids that would otherwise be waste can sometimes be used asfuel Examples include flue gas from a mining process used as a heat source andwaste biomass from pulp and paper production gasified to use for steam productionfor running a steam turbine In turn, waste heat from turbines is used for processpurposes Excess steam from the heat recovery steam generator in the independentpower plant at Kuala Langat, Malaysia, is used in the owner’s neighboring mill.Heat recovery schemes in Alberta, Canada, are being used to provide heat tovegetable greenhouses.

This cooperative effort between power generation and process technology isunderlined by three major factors First, the major oil companies, such as Shell,Amoco, and Esso, are now actively involved in major independent power production

as a policy—the fuel they produce has a certain market as power production fuel.Second, the drive toward environmentally economic technology to dampen thestrain on the world’s sagging natural resources has played a major part inintegrating the process engineer’s world with that of power production Last butnot least, internal power production gives process engineers a much better handle

on avoiding the brownouts, fluctuations, and power cuts that an external utilitysupplier can cause They can also have the flexibility to use products within theplant for “unusual” fuel when they work with manufacturers who will accommodatetheir requirements The contemporary competitive business environment is making

it much easier for an engineer to negotiate this adaptability from a manufacturer.With this complex, mobile, and fascinating framework, know that one could neverfit representative information on everything a process engineer might need in onevolume The compromise I have struck is to cover the basics succinctly and spendeffort on items that the process engineers I talk to and work with have very littleinformation on, but ask about all the time Not surprisingly, these items can costthe most in terms of cost per operating hour Costs include lost production time,machinery problems, troubleshooting efforts, useless expense in overdesignedmachinery condition monitoring systems, premature parts replacement, and powersupply problems

Then there was the matter of highly specialized process sectors, such as pulp andpaper, agriculture, and food processing This book hits the highlights with theseindustries and others, and a specifications and standards section is provided for theprocess engineer to use in conjunction with this book All the common items in anyprocess industry, such as pumps, motors, couplings, controls, and so forth, are inthis book As terminology for an item varies so much between industries, it is agood idea to read through the Contents and the Index a few times to get the mostout of this book

Last, but not least, although this book might be more for process engineers inplant operations, I have included some design information where I felt it wouldassist logic Design and specification work gains from operations and maintenanceexposure

xxii Introduction

Preface xi Contributors xv Introduction xxi

Aerfoils; Airfoils (see Metallurgy; Turbines)

Air Filtration; Air Inlet Filtration for Gas Turbines A-49

Balancing Problems, Troubleshooting (Turbomachinery) (see Condition Monitoring) Batteries (see Cells)

Castings (see Metallurgy)