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
, by Coker, A. Kayode
- ISBN: 9781119476412 | 1119476410
- Cover: Hardcover
- Copyright: 4/13/2021
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.
A. Kayode Coker PhD, is Engineering Consultant for AKC Technology, an Honorary Research Fellow at the University of Wolverhampton, U.K., a former Engineering Coordinator at Saudi Aramco Shell Refinery Company (SASREF) and Chairman of the department of Chemical Engineering Technology at Jubail Industrial College, Saudi Arabia. He has been a chartered chemical engineer for more than 30 years. He is a Fellow of the Institution of Chemical Engineers, U.K. (C. Eng., FIChemE), and a senior member of the American Institute of Chemical Engineers (AIChE). He holds a B.Sc. honors degree in Chemical Engineering, a Master of Science degree in Process Analysis and Development and Ph.D. in Chemical Engineering, all from Aston University, Birmingham, U.K., and a Teacher's Certificate in Education at the University of London, U.K. He has directed and conducted short courses extensively throughout the world and has been a lecturer at the university level. His articles have been published in several international journals. He is an author of six books in chemical engineering, a contributor to the Encyclopedia of Chemical Processing and Design, Vol 61 and a certified train — the mentor trainer. A Technical Report Assessor and Interviewer for chartered chemical engineers (IChemE) in the U.K. He is a member of the International Biographical Centre in Cambridge, U.K. (IBC) as Leading Engineers of the World for 2008. Also, he is a member of International Who's Who of ProfessionalsTM and Madison Who's Who in the U.S.
Preface xv
Acknowledgements xvii
13 Rules of Thumb—Summary 1
13.0 Introduction 1
14 Process Planning, Scheduling, and Flowsheet Design 19
14.1 Introduction 19
14.2 Organizational Structure 20
14.2.1 Process Design Scope 21
14.3 Role of the Process Design Engineer 23
14.4 Computer-Aided Flowsheeting 24
14.5 Flowsheets—Types 26
14.5.1 Block Diagram 26
14.5.2 Process Flowsheet or Flow Diagram 26
14.5.3 Piping Flowsheet or Mechanical Flow Diagram, or Piping and Instrumentation Diagram (P&ID) 27
14.5.4 Combined Process and Piping Flowsheet or Diagram 32
14.5.5 Utility Flowsheets or Diagrams (ULDs) 32
14.5.6 Special Flowsheets or Diagrams 36
14.5.7 Special or Supplemental Aids 36
14.6 Flowsheet Presentation 36
14.7 General Arrangements Guide 36
14.8 Computer-Aided Flowsheet Design/Drafting 38
14.9 Flowsheet Symbols 40
14.10 Line Symbols and Designations 43
14.11 Materials of Construction for Lines 46
14.12 Test Pressure for Lines 47
14.13 Working Schedules 56
14.14 Information Checklists 61
14.15 Basic Engineering and Front End Engineering Design (FEED) 63
References 64
15 Fluid Flow 65
15.1 Introduction 65
15.2 Flow of Fluids in Pipes 65
15.3 Scope 70
15.4 Basis 72
15.5 Incompressible Flow 72
15.6 Compressible Flow: Vapors and Gases 73
15.7 Important Pressure Level References 75
15.8 Factors of “Safety” for Design Basis 75
15.9 Pipe, Fittings, and Valves 75
15.10 Pipe 75
15.11 Total Line Pressure Drop 78
15.11.1 Relationship Between the Pipe Diameter and Pressure Drop (ΔP) 80
15.11.2 Economic Balance in Piping and Optimum Pipe Diameter 82
15.12 Reynolds Number, Re (Sometimes Used NRe) 83
15.13 Pipe Relative Roughness 85
15.14 Darcy Friction Factor, f 85
15.15 Friction Head Loss (Resistance) in Pipe, Fittings, and Connections 94
15.15.1 Pressure Drop in Straight Pipe: Incompressible Fluid 94
15.16 Oil System Piping 96
15.16.1 Density and Specific Gravity 97
15.16.2 Specific Gravity of Blended Products 98
15.16.3 Viscosity 98
15.16.4 Viscosity of Blended Products 100
15.16.5 Blending Index, H 101
15.16.6 Vapor Pressure 101
15.16.7 Velocity 101
15.16.8 Frictional Pressure Drop, ft of Liquid Head 104
15.16.9 Hazen–Williams Equation 105
15.16.10 Transmission Factor 107
15.16.11 Miller Equation 112
15.16.12 Shell–MIT Equation 113
15.17 Pressure Drop in Fittings, Valves, and Connections 116
15.17.1 Incompressible Fluid 116
15.17.2 Velocity and Velocity Head 116
15.17.3 Equivalent Lengths of Fittings 117
15.17.4 L/D Values in Laminar Region 120
15.17.5 Validity of K Values 122
15.17.6 Laminar Flow 122
15.17.7 Expressing All Pipe Sizes in Terms of One Diameter 124
15.17.8 Loss Coefficient 128
15.17.9 Sudden Enlargement or Contraction 134
15.17.10 For Sudden Contractions 134
15.17.11 Piping Systems 136
15.18 Resistance of Valves 136
15.19 Flow Coefficients for Valves, Cv 137
15.20 Flow Meters 138
15.20.1 Process Design of Orifice Meter 138
15.20.2 Nozzles and Orifices 142
Conclusion 167
15.21 Estimation of Pressure Loss Across Control Valves 169
15.22 The Direct Design of a Control Valve 173
15.23 Water Hammer 173
15.24 Friction Pressure Drop for Compressible Fluid Flow 175
15.24.1 Compressible Fluid Flow in Pipes 176
15.24.2 Maximum Flow and Pressure Drop 177
15.24.3 Sonic Conditions Limiting Flow of Gases and Vapors 177
15.24.4 The Mach Number, Ma 182
15.24.5 Critical Pressure Ratio 197
15.24.6 Adiabatic Flow 200
15.24.7 The Expansion Factor, Y 201
15.24.8 Misleading Rules of Thumb for Compressible Fluid Flow 203
15.24.9 Other Simplified Compressible Flow Methods 204
15.24.10 Friction Drop for Flow of Vapors, Gases and Steam 205
15.25 Darcy Rational Relation for Compressible Vapors and Gases 213
15.26 Velocity of Compressible Fluids in Pipe 215
15.27 Procedure 228
15.28 Friction Drop for Compressible Natural Gas in Long Pipe Lines 231
15.29 Panhandle-A Gas Flow Formula 235
15.30 Modified Panhandle Flow Formula 237
15.31 American Gas Association (AGA) Dry Gas Method 237
15.32 Complex Pipe Systems Handling Natural (or Similar) Gas 237
15.33 Two-Phase Liquid and Gas Flow in Process Piping 239
15.33.1 Flow Patterns 239
15.33.2 Flow Regimes 242
15.33.3 Pressure Drop 243
15.33.4 Erosion–Corrosion 248
15.33.5 Total System Pressure Drop 250
15.33.6 Pipe Sizing Rules 257
15.33.7 A Solution for All Two-Phase Problems 261
15.33.8 Gas–Liquid Two-Phase Vertical Down Flow 270
15.33.9 Pressure Drop in Vacuum Systems 277
15.33.10 Low Absolute Pressure Systems for Air 279
15.33.11 Vacuum for Other Gases and Vapors 281
15.33.12 Pressure Drop for Flashing Liquids 284
15.33.13 Sizing Condensate Return Lines 286
15.34 UniSim Design PIPESYS 295
15.35 Pipe Line Safety 300
15.36 Mitigating Pipeline Hazards 301
15.37 Examples of Safety Design Concerns 301
15.38 Safety Incidents Related With Pipeworks and Materials of Construction 303
15.39 Lessons Learned From Piping Designs 319
15.40 Design of Safer Piping 320
15.40.1 Best Practices for Process Piping 320
15.40.2 Designing Liquid Piping 321
15.40.3 Best Practices for Liquid Piping 322
Nomenclature 324
Greek Symbols 326
Subscripts 327
References 327
16 Pumps 331
16.1 Pumping of Liquids 331
16.2 Pump Design Standardization 336
16.3 Basic Parts of a Centrifugal Pump 336
16.4 Centrifugal Pump Selection 341
16.5 Hydraulic Characteristics for Centrifugal Pumps 359
16.6 Suction Head or Suction Lift, hs 367
16.7 Discharge Head, hd 369
16.8 Velocity Head 369
16.9 Friction 370
16.10 Net Positive Suction Head (NPSH) and Pump Suction 370
16.11 General Suction System 378
16.12 Reductions in NPSHR 384
16.13 Charting NPSHR Values of Pumps 384
16.14 Net Positive Suction Head (NPSH) 386
16.15 NPSH Requirement for Liquids Saturation With Dissolved Gases 388
16.16 Specific Speed 390
16.17 Rotative Speed 394
16.18 Pumping Systems and Performance 395
16.19 Power Requirements for Pumping Through Process Lines 399
16.20 Affinity Laws 405
16.21 Centrifugal Pump Efficiency 417
16.22 Effects of Viscosity 421
16.23 Temperature Rise and Minimum Flow 436
16.24 Centrifugal Pump Specifications 440
16.25 Number of Pumping Units 441
16.26 Rotary Pumps 448
16.27 Reciprocating Pumps 452
16.28 Pump Selection 456
16.29 Selection Rules-of-Thumb 456
16.30 Case Studies 459
16.31 Pump Cavitations 464
16.32 Pump Fundamentals 474
16.33 Operating Philosophy 475
16.34 Piping 485
16.35 Troubleshooting Checklist for Centrifugal Pumps 485
Nomenclature 493
Subscripts 494
Greek Symbols 495
References 495
17 Compression Equipment 497
17.1 Introduction 497
17.2 General Application Guide 498
17.3 Specification Guides 499
17.4 General Considerations for Any Type of Compressor Flow Conditions 501
17.4.1 Fluid Properties 501
17.4.2 Compressibility 502
17.4.3 Corrosive Nature 502
17.4.4 Moisture 502
17.4.5 Special Conditions 502
17.5 Reciprocating Compression 503
17.6 Suction and Discharge Valves 514
17.7 Specification Sheet 523
17.8 Performance Considerations 524
17.9 Compressor Performance Characteristics 557
17.10 Hydrogen Use in the Refinery 594
17.10.1 IsoTherming Technology for Kerosene, Vacuum Gas Oil, and Diesel Hydroprocessing 595
Nomenclature 829
Greek Symbols 832
Subscripts 832
References 833
Glossary of Petroleum and Technical Terminology 837
Appendix D 929
Appendix E 1005
Index 1019
About the Author 1025
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