Petroleum refining design and applications handbook, volume 2: rules of thumb, process planning, scheduling, and flowsheet design, process piping design, pumps, compressors, and process safety incidents

**A must-read for any practicing engineer or student in this area** There is a renaissance that is occurring in chemical and process engineering, and it is crucial for today's scientists, engineers, technicians, and operators to stay current. This book offers the most up-to-date and comprehensive coverage of the most significant and recent changes to petroleum refining, presenting the state-of-the-art to the engineer, scientist, or student. Useful as a textbook, this is also an excellent, handy go-to reference for the veteran engineer, a volume no chemical or process engineering library should be without. Cover Half-Title Page Series Page Title Page Copyright Page Contents Preface Acknowledgments 13 Rules of Thumb—Summary 13.0 Introduction COMPRESSORS, FANS, BLOWERS, AND VACUUM PUMPS CONVEYORS FOR PARTICULATE SOLIDS COOLING TOWERS CRYSTALLIZATION FROM SOLUTION DISINTEGRATION TOWERS TRAY TOWERS PACKED TOWERS DRIVERS AND POWER RECOVERY EQUIPMENT DRYING OF SOLIDS EVAPORATORS EXTRACTION, LIQUID–LIQUID FILTRATION FLUIDIZATION OF PARTICLES WITH GASES HEAT EXCHANGERS INSULATION MIXING AND AGITATION PARTICLE SIZE ENLARGEMENT PIPING PUMPS REACTORS REFRIGERATION SIZE SEPARATION OF PARTICLES UTILITIES, COMMON SPECIFICATIONS VESSELS (DRUMS) VESSEL (PRESSURE) VESSELS (STORAGE TANKS) 14 Process Planning, Scheduling, and Flowsheet Design 14.1 Introduction 14.2 Organizational Structure 14.2.1 Process Design Scope 14.3 Role of the Process Design Engineer 14.4 Computer-Aided Flowsheeting 14.5 Flowsheets—Types 14.5.1 Block Diagram 14.5.2 Process Flowsheet or Flow Diagram 14.5.3 Piping Flowsheet or Mechanical Flow Diagram, or Piping and Instrumentation Diagram (P&ID) 14.5.4 Combined Process and Piping Flowsheet or Diagram 14.5.5 Utility Flowsheets or Diagrams (ULDs) 14.5.6 Special Flowsheets or Diagrams 14.5.7 Special or Supplemental Aids Plot Plans 14.6 Flowsheet Presentation 14.7 General Arrangements Guide 14.8 Computer-Aided Flowsheet Design/Drafting 14.9 Flowsheet Symbols 14.10 Line Symbols and Designations 14.11 Materials of Construction for Lines 14.12 Test Pressure for Lines 14.13 Working Schedules 14.14 Information Checklists 14.15 Basic Engineering and Front End Engineering Design (FEED) References 15 Fluid Flow 15.1 Introduction 15.2 Flow of Fluids in Pipes 15.3 Scope 15.4 Basis 15.5 Incompressible Flow 15.6 Compressible Flow: Vapors and Gases [4] 15.7 Important Pressure Level References 15.8 Factors of “Safety” for Design Basis 15.9 Pipe, Fittings, and Valves 15.10 Pipe 15.11 Total Line Pressure Drop 15.11.1 Relationship Between the Pipe Diameter and Pressure Drop (ΔP) 15.11.2 Economic Balance in Piping and Optimum Pipe Diameter 15.12 Reynolds Number, Re (Sometimes Used NRe) 15.13 Pipe Relative Roughness 15.14 Darcy Friction Factor, f 15.15 Friction Head Loss (Resistance) in Pipe, Fittings, and Connections 15.15.1 Pressure Drop in Straight Pipe: Incompressible Fluid 15.16 Oil System Piping 15.16.1 Density and Specific Gravity 15.16.2 Specific Gravity of Blended Products 15.16.3 Viscosity 15.16.4 Viscosity of Blended Products 15.16.5 Blending Index, H 15.16.6 Vapor Pressure 15.16.7 Velocity 15.16.8 Frictional Pressure Drop, ft of Liquid Head 15.16.9 Hazen–Williams Equation 15.16.10 Transmission Factor 15.16.11 Miller Equation 15.16.12 Shell–MIT Equation 15.17 Pressure Drop in Fittings, Valves, and Connections 15.17.1 Incompressible Fluid 15.17.2 Velocity and Velocity Head 15.17.3 Equivalent Lengths of Fittings 15.17.4 L/D Values in Laminar Region 15.17.5 Validity of K Values 15.17.6 Laminar Flow 15.17.7 Expressing All Pipe Sizes in Terms of One Diameter 15.17.8 Loss Coefficient 15.17.9 Sudden Enlargement or Contraction 15.17.10 For Sudden Contractions 15.17.11 Piping Systems 15.18 Resistance of Valves 15.19 Flow Coefficients for Valves, Cv 15.20 Flow Meters 15.20.1 Process Design of Orifice Meter 15.20.2 Nozzles and Orifices Conclusion 15.21 Estimation of Pressure Loss Across Control Valves Liquids, Vapors, and Gases 15.22 The Direct Design of a Control Valve 15.23 Water Hammer 15.24 Friction Pressure Drop for Compressible Fluid Flow Vapors and Gases 15.24.1 Compressible Fluid Flow in Pipes 15.24.2 Maximum Flow and Pressure Drop 15.24.3 Sonic Conditions Limiting Flow of Gases and Vapors 15.24.4 The Mach Number, Ma Flow Rate of Compressible Isothermal Flow Pipeline Pressure Drop (.P) 15.24.5 Critical Pressure Ratio 15.24.6 Adiabatic Flow 15.24.7 The Expansion Factor, Y 15.24.8 Misleading Rules of Thumb for Compressible Fluid Flow 15.24.9 Other Simplified Compressible Flow Methods 15.24.10 Friction Drop for Flow of Vapors, Gases and Steam 15.25 Darcy Rational Relation for Compressible Vapors and Gases 15.26 Velocity of Compressible Fluids in Pipe 15.27 Procedure 15.28 Friction Drop for Compressible Natural Gas in Long Pipe Lines 15.29 Panhandle-A Gas Flow Formula 15.30 Modified Panhandle Flow Formula 15.31 American Gas Association (AGA) Dry Gas Method 15.32 Complex Pipe Systems Handling Natural (or Similar) Gas 15.33 Two-Phase Liquid and Gas Flow in Process Piping 15.33.1 Flow Patterns 15.33.2 Flow Regimes 15.33.3 Pressure Drop 15.33.4 Erosion–Corrosion 15.33.5 Total System Pressure Drop 15.33.6 Pipe Sizing Rules 15.33.7 A Solution for All Two-Phase Problems 15.33.8 Gas–Liquid Two-Phase Vertical Down Flow 15.33.9 Pressure Drop in Vacuum Systems 15.33.10 Low Absolute Pressure Systems for Air 15.33.11 Vacuum for Other Gases and Vapors 15.33.12 Pressure Drop for Flashing Liquids 15.33.13 Sizing Condensate Return Lines 15.34 UniSim Design PIPESYS 15.35 Pipe Line Safety 15.36 Mitigating Pipeline Hazards 15.37 Examples of Safety Design Concerns 15.38 Safety Incidents Related With Pipeworks and Materials of Construction 15.39 Lessons Learned From Piping Designs 15.40 Design of Safer Piping 15.40.1 Best Practices for Process Piping 15.40.2 Designing Liquid Piping 15.40.3 Best Practices for Liquid Piping 16 Pumps 16.1 Pumping of Liquids 16.2 Pump Design Standardization 16.3 Basic Parts of a Centrifugal Pump 16.4 Centrifugal Pump Selection 16.5 Hydraulic Characteristics for Centrifugal Pumps 16.6 Suction Head or Suction Lift, hs 16.7 Discharge Head, hd 16.8 Velocity Head 16.9 Friction 16.10 Net Positive Suction Head (NPSH) and Pump Suction 16.11 General Suction System 16.12 Reductions in NPSHR 16.13 Charting NPSHR Values of Pumps 16.14 Net Positive Suction Head (NPSH) 16.15 NPSH Requirement for Liquids Saturation With Dissolved Gases 16.16 Specific Speed 16.17 Rotative Speed 16.18 Pumping Systems and Performance 16.19 Power Requirements for Pumping Through Process Lines 16.20 Affinity Laws 16.21 Centrifugal Pump Efficiency 16.22 Effects of Viscosity 16.23 Temperature Rise and Minimum Flow 16.24 Centrifugal Pump Specifications 16.25 Number of Pumping Units 16.26 Rotary Pumps 16.27 Reciprocating Pumps 16.28 Pump Selection 16.29 Selection Rules-of-Thumb 16.30 Case Studies 16.31 Pump Cavitations 16.32 Pump Fundamentals 16.33 Operating Philosophy 16.34 Piping 16.35 Troubleshooting Checklist for Centrifugal Pumps 17 Compression Equipment 17.1 Introduction 17.2 General Application Guide 17.3 Specification Guides 17.4 General Considerations for Any Type of Compressor Flow Conditions 17.4.1 Fluid Properties 17.4.2 Compressibility 17.4.3 Corrosive Nature 17.4.4 Moisture 17.4.5 Special Conditions 17.5 Reciprocating Compression 17.6 Suction and Discharge Valves 17.7 Specification Sheet 17.8 Performance Considerations 17.9 Compressor Performance Characteristics 17.10 Hydrogen Use in the Refinery 17.10.1 IsoTherming Technology for Kerosene, Vacuum Gas Oil, and Diesel Hydroprocessing Nomenclature Greek Symbols Subscripts References Glossary of Petroleum and Technical Terminology Appendix D Appendix E Index About the Author Also of Interest EULA