Applied process design for chemical and petrochemical plants vol 1 ernest e ludwig 3rd edition

b le, E - R FOR CHEMlCAl AND PETROCHEMlCRl PLANTS Volume 1, Third Editim Emphasizes how to apply techniques of process design and interpret results into mechanical equipment details APPLIED PROCESS D E S I G N FOR CHEMICRL RHO PETROCHEMlCRl PlANTS Volume 1, Third Edition Volume 1: 1, Volume 2: Distillation Packed Towers Volume 3: Process Planning, Scheduling, Flowsheet Design Fluid Flow Pumping of Liquids Mechanical Separations Mixing of Liquids Ejectors Process Safety and Pressure-Relieving Devices Appendix of Conversion Factors 10 11 12 13 14 Heat Transfer Refrigeration Systems Compression Equipment Compression Surge Drums Mechanical Drivers Gulf Professional Publishing an imprint of Butterworth-Heinemann A P P L I E D PROCESS D E S I G N FOR CHEMlCAl AND PETROCHEMICA1 PlANTS Volume Third Edition Emphasizes how to apply techniques of process design and interpret results into mechanical equipment details Ernest E Ludwig To my wqe, Sue, for her patient encouragement and help I Disclaimer The material in this book was prepared in good faith and carefully reviewed and edited The author and publisher, however, cannot be held liable for errors of any sort in these chapters Furthermore, because the author has no means of checking the reliability of some of the data presented in the public literature, but can only examine it for suitability for the intended purpose herein, this information cannot be warranted Also because the author cannot vouch for the experience or technical capability of the user of the information and the suitability of the information for the user’s purpose, the use of the contents must be at the bestjudgment of the user APPLIED PROCESS DESIGN FOR CHEMICAL AND PETROCHEMICAL PLANTS Volume 1, Third Edition Copyright 1999 by Butterworth-Heinemann All rights reserved Printed in the United States of America This book, or parts thereof, may not be reproduced in any form without permission of the publisher Library of Congress Cataloging-in-PublicationData Ludwig, Ernest E Applied process design for chemical and petrochemical plants / Ernest E Ludwig - 3rd ed p cm Includes bibliographical references and index ISBN 0-88415-025-9 (v 1) Chemical plants-Equipment and supplies Petroleum industry and trade-Equipment and supplies I Title TP 155.5.L8 1994 660’ 283-d~20 9413383 CIP Originally published by Gulf Publishing Company, Houston, TX 10 For information, please contact: Manager of Special Sales Butterworth-Heinemann 225 Wildwood Avenue W o b u , MA 01801-2041 Tel: 781-904-2500 Fax: 78 1-904-2620 For information on all Butterworth-Heinemann publications available, contact our World Wide Web home page at: http:llwww.bh.com Contents reface to the Third Edition viii Process Plannhg, Scheduling and Flowsheet Design 1 Organizational Structure, 1; Process Design Scope, 2; Role of the Process Design Engineer, 3; Flowsheets-Types, 4; Flowsheet Presentation, 10; General Arrangements Guide, 11; Computer-Aided Flowsheet Design/’Drafting, 17; Flowsheet Symbols, 17; Line ,Symbols and Designations, 17; Materials of Construction for L,ines, 18; Test Pressure for Lines, 18; Working Schedules, 29; Standards and Ciodes, 31; System Design Pressures, 33; Time Planning and Scheduling, 36; Activity Analysis, 36; Collection and Assembly of Physical Property Data, 37; Estimated Equipment Calculation Man-Hours, 37; Estimated Total Process Man-Hours, 39; Typical Man-Hour Patterns, 40; Influences, 42; Assignment of Personnel, 43; Plant Layout 45; Cost Estimates, 45; Six-Tenths Factor, 47; Yearly Cost Indices, 47; Return on Investment, 48; Accounting Coordination, 48 Fluid Flow 52 Scope 52; Basis, 5%;Compressible Flow: Vapors and Gases, 54; Factors of “Safety” for Design Basis, 56; Pipe, Fittings, and Valves, 56; Pipe, 56; Usual Industry Pipe Sizes and Classes Practice, 59; Total Line Pressure Drop, 64; Background Information, 64; Reynolds Number, (Sometimes used N ,), 67; Friction Factor, f, 68; Pipe-Relative Roughness, 68; Pressure Drop in Fittings, Valves, Connections: Incompressible Fluid, 71; Common Denominator for Use of “ K Factors in a System of Varying Sizes of Internal Dimensions, 72; Validity of K Values, 77; Laminar Flow, 77; Piping Systems, 81; Resistance of Valves, 81; Flow Coefficients for Valves, C,, p 81; Nozzles and Orifices, 82; Example 8-1: Pipe Sizing Using Kesistance Coefficients, K, 83; Example 2-2: Laminar Flow Through Piping System, 86; Alternate Calculalion Basis for Piping System Friction Head LOSS:Liquids, 86; Equivalent Feet Concept for Valves, Fittings, Etc., 86; Friction ]Pressure Drop for Non-Viscous Liquids, 89; Estimation of Pressure Loss Across Control Valves: Liquids, Vapors, and Gases, 90; Example 2-3: Establishing Control Valve Estimated Pressure Drop Using Connell’s Method, 92; Example 2-4: TJsing Figure 2-26, Determine Control Valve Pressure Drop and System Start Pressure, 94; Friction Loss For Water Flow, 96; Example 2-5: Water Flow in Pipe System, 96; MJater Hammer, 98; Example 2-7: Pipe Flow System With Liquid of Specific Gravity Other Than Water, 99; Friction Pressure Drop For Compressible Fluid Flow, 101; Darcy Rational Relation for Compressible Vapors and Gases, 103; Example 2-8: Pressure Drop for Vapor System, 104; Alternate Solution to Compressible Flow Problems, 104; Friction Drop for Air, 107; Example 2-9: Steam Flow TJsing Babcock Formula, 107; Sonic Conditions Limiting Flow of Gases and Vzpors, 108; Procedure, 118; Example 2-10: Gas Flow Through Sharp-edged Orifice, 119; Example 2-11: Sonic Velocity, 119; Friction Drop for Compressible Natural Gas in Long Pipe Lines, 120; Example 2-12: Use of Base Correction Multipliers, 121; Panhandlea Gas Flow Formula, 121; Modified Panhandle Flow Formula, 121; American Gas Association (AGA) Dry Gas Method, 121; Complex Pipe Systems Handling Natural (or similar) Gas, 122; Example 2-13: Series System, 122; Example 2-15: Parallel System: Fraction Paralleled, 122; Two-phase Liquid and Gas Flow, 124; Flow Patterns, 124; Total System Pressure Drop, 125; Example 2-16: Two-phase Flow, 127; Pressure Drop in Vacuum Systems, 128; Example 2-17: Line Sizing for Vacuum Conditions, 128; Low Absolute Pressure Systems for Air, 129; Vacuum for Other Gases and Vapors, 129; Pipe Sizing for Non-Newtonian Flow, 133; Slurry Flow in Process Plant Piping, 134; Pressure Drop for Flashing Liquids, 134; Example 2-18: Calculation of Steam Condensate Flashing, 135; Sizing Condensate Return Lines, 135; Design Procedure Using Sarco Chart, 135; Example 2-19: Sizing Steam Condensate Return Line, 139 Pumping of Liquids 160 Pump Design Standardization, 161; Basic Parts of a Centrifugal Pump, 164; Impellers, 164; Casing, 165; Bearings, 168; Centrifugal Pump Selection, 173; Single-Stage (Single Impeller) Pumps, 174; Pumps in Series, 175; Pumps in Parallel, 177; Hydraulic Characteristics for Centrifugal Pumps, 180; Example 3-1: Liquid Heads, 183; Static Head, 184; Pressure Head, 184; Example 3-2: Illustrating Static, Pressure, and Friction Effects, 186; Suction Head or Suction Lift, 186; Discharge Head, hd, 187; Velocity Head, 187; Friction, 188; NPSH and Pump Suction, 188; Example 3-3: Suction Lift, 190; Example 3-4: NPSH Available in Open Vessel System at Sea Level, 190; Example 3-5: NPSH Available in Open Vessel Not at Sea Level, 191; Example 3-6: NPSH Available in Vacuum System, 191; Example 3-7: NPSH.&:Available in Pressure System, 191; Example 3-8: Closed System Steam Surface Condenser NPSH Requirements, 191; Example 3-9: Process Vacuum System, 192; Reductions in NPSHR, 192; Example 3-10: Corrections to NPSH, for Hot Liquid Hydrocarbons and U’ater, 192; Example 3-9: Process Vacuum System, 192; Example 3-10: Corrections to NPSH, for Hot Liquid Hydrocarbons and Water, 192; Example 3-11: Alternate to Example 3-10, 194; Specific Speed, 194; Example 3-12: ”Type Specific Speed,” 197; Rotative Speed, 197; Pumping Systems and Performance, 197; Example 3-13: System Head Using Two Different Pipe Sizes in Same Line, 199; Example 3-14 System Head for Branch Piping with Different Static Lifts, 200; Relations Between Head, Horsepower, Capacity, Speed, 200; Example 3-15: Reducing Impeller Diameter at Fixed WM, 203; Example 3-16: Pump Performance Correction For Viscous Liquid, 203; Example 3-17: Corrected Performance Curves for Viscosity Effect, 206; Temperature Rise and Minimum Flow, 207; Example 3-18: Maximum Temperature Rise Using Boiler Feed Water, 209; Example 3-19: Pump Specifications, 209; Number of Pumping Units, 210; Fluid Conditions, 210; System Conditions, 210; Type of Pump, 210; Type of Driver, 210; Sump Design for Vertical Lift, 212; Rotary Pumps, 213; Selection, 214; Reciprocating Pumps, Ejector System Specifications, 373; Ejector Selection Procedure, 374; Barometric Condensers, 375; Temperature Approach, 375; Example 6-12: Temperatures at Barometric Condenser o n Ejector System, 376; Water Jet Ejectors, 378; Steam Jet Thermocompressors, 378; Ejector Control, 378; Time Required for System Evacuation, 380; Alternate Pumpdown to a Vacuum Using a Mechanical Pump 380; Example 6-13: Determine Pump Downtime for a System, 380; Evacuation with Steam Jets, 381; Example 6-14 Evacuation of Vessel Using Steam Jet for Pumping Gases, 381; Evacuating-Selection Procedure, 381; Evacuating-Example, 381; Mechanical Vacuum Pumps, 382; Liquid Ring Vacuum Pumps/Compressor, 383; Rotary Vane Vacuum Pumps, 394; Rotary Blowers or Rotary Lobe-Type Blowers, 395; Rotary Piston Pumps, 397 215; Significant Features in Reciprocating Pump Arrangements, 215; Performance, 217; Discharge Flow Patterns, 218; Horsepower, 218; Pump Selection, 221 Mechanical Separations 224 Particle Size, 224; Preliminary Separator Selection, 224; Example 41: Basic Separator Type Selection, 225; Guide to LiquidSolid Particle Separators, 228; Gravity Settlers, 228; Example 42: Hindered Settling Velocities, 236; MI-Oil Field Separators, 239; Liquid/Liquid, Liquid/Solid Gravity Separations, Decanters, and Sedimentation Equipment, 239; Modified Method of Happel and Jordan, 241; Example : Horizontal Gravity Settlers, 241; Decanter, 242; Example 44: Decanter, 245; Impingement Separators, 246; Example : Wire Mesh Entrainment Separator, 252; Fiber Beds/Pads Impingement Eliminators, 254; Centrifugal Separators, 259; Example 46: Cyclone System Pressure Drop, 263; Scrubbers, 269; Cloth or Fabric Separators or Filters, 270; Specifications 271; Electrical Precipitators, 280 Mixing of Liquids Ejectors and Mechanical Vacuum Systems 399 Types of Positive Pressure Relieving Devices, 400; Pressure Relief Valve, 400; Pilot Operated Safety Valves, 400; Types of Valves, 400; Definition of Pressure-Relief Terms, 403; Example 7-1: Hypothetical Vessel Design, 406; Materials of Construction, 412; General Code Requirements, 415; Relief Mechanisms, 417; Pressure Settings and Design Basis, 420; Establishing Relieving or Set Pressures, 425; Safety and Safety Relief Valves for Steam Services, 426; Selection and Application, 427; Causes of System Overpressure, 427; Capacity Requirements Evaluation for Process Operation (Non-Fire) ,427; Installation, 429; Selection Features: Safety, Safety-Relief Valves, and Rupture Disks, 434; Calculations of Relieving Areas: Safety and Relief Valves, 436; Standard Pressure Relief Valves Relief Area Discharge Openings, 437; Sizing Safety Relief Type Devices for Required Flow Area at Time of Relief, 437; Effect of Two-Phase Vapor-Liquid Mixture on Relief Valve Capacity, 437; Sizing for Gases or Vapors or Liquids for Conventional Valves with Constant Backpressure Only, 438; Example 7-2: Flow through Sharp Edged Vent Orifice, 440; Orifice Area Calculations, 440; Emergency Pressure Relief: Fires and Explosions Rupture Disks, 450; External Fires, 450; Set Pressures for External Fires, 451; Rupture Disk Sizing Design and Specification, 455; Specifications to Manufacturer, 455; Size Selection, 455; Calculation of Relieving Areas: Rupture Disks for Non-Explosive Service, 455; The Manufacturing Range (MR), 456; Selection of Burst Pressure for Disk, Pb, 456; Example 7-3: Rupture Disk Selection, 457; Effects of Temperature on Disk, 458; Rupture Disk Assembly Pressure Drop, 459; Example 7-4: Safety Relief Valve for Process Overpressure, 463; Example 7-5: Rupture Disk External Fire Condition, 463; Example 7-6: Rupture Disk for Vapors or Gases; Non-Fire Condition, 465; Example 7-7: Liquids Rupture Disk, 466; Example 7-8: Liquid Overpressure, 466; Pressure-Vacuum Relief for Low Pressure Storage Tanks, 466; Basic Venting for Low Pressure Storage Vessels, 466; Nonrefrigerated Above Ground Tanks; MI-Std 2000, 468; Example 7-9: Converting Valve Capacities, 470; Example 7-10: Converting Required Free Air Capacity, 474; Example 7-11: Storing Benzene in Cone Roof Tank, 474; Emergency Vent Equipment, 478; Refrigerated Above Ground and Below Ground Tanks, 478; Example 7-12: Venting and Breathing in Oil Storage Tank, 480; Flame Arrestors, 480; Explosions, 482; Confined Explosions, 482; Flammability, 484; Mixtures of Flammable Gases, 486; Example 7-13: Calculation of LEL for Flammable Mixture, 491; Pressure and Temperature Effects, 491; Ignition of Flammable Mixtures, 493; Aqueous Solutions of Flammable Liquids, 496; Blast Pressures, 496; Example 7-14: 288 Mechanical Components, 289; Impellers, 291; Mixing Concepts, Theory, Fundamentals, 297; Flow, 298; Flow Number, 298; Power, P; Power Number, Po;and Reynolds Number, N, 299; Power, 299; Shaft, 306; Drive and Gears, 306; Steady Bearings, 307; Materials of Construction, 307; Design, 307; Specifications, 308; Flow Patterns, 309; Draft Tubes, 309; Entrainment, 309; Scale-up and Interpretation, 312; Impeller Location and Spacing: Top Center Entering, 322; Process Results, 323; Blending, 324; Emulsions, 324; Extraction, 324; Gas-Liquid Contacting, 324; Gas-Liquid Mixing or Dispersion, 325; Heat Transfer: Coils in Tank, Liquid Agitated, 325; Inline, Static or Motionless Mixing, 333; Applications, 336 Process Safety and Pressure-Relieving Devices 343 Ejectors, 343; Typical Range Performance of Vacuum Producers, 344; Features, 345; Types, 346; Materials of Construction, 347; Vacuum Range Guide, 348; Pressure Terminology 348; Example 6-1: Conversion of Inches Vacuum to Absolute, 350; Pressure Drop at Low Absolute Pressures, 353; Performance Factors, 353; Steam Pressure 353; Effect of Wet Steam, 356; Effect of Superheated Steam, 358; Suction Pressure, 358; Discharge Pressure, 358; Capacity, 358; Types of Loads, 359; Air Plus Water Vapor Mixtures, 359; Example 6-2: 70°F Air Equivalent for Air-Water Vapor Mixture, 360; Example 6-3: Actual Air Capacit) for Air-Water Vapor Mixture, 361; Steam and Air Mixture Temperature, 361; Total Weight of a Saturated Mixture of Two Vapors: One Being Condensable, 362; Non-Condensables Plus Process Vapor Mixture, 362; Example 6-5: Actual Capacity for Process Vapor Plus Non-Condensable, 362; Non-Condensables Plus Water Vapor Mixture, 363; Example 6-6: Use of Water Vapor-Air Mixture, 363; Total Volume of a Mixture, 363; Example 6-8: Saturated Water Vapor-Air Mixture, 363; Air Inleakage into System, 366; Example 6-9: Ejector Load For Steam Surface Condenser, 367; Total Capacity at Ejector Suction, 369; Capacities of Ejector in Multistage System, 370; Booster Ejector, 370; Evacuation Ejector, 370; Load Variation, 370; Steam and Water Requirements, 371; Example 6-10: Size Selection: Utilities and Evacuation Time for SingleStage Ejector, 371; Example 6-11: Size Selection and Utilities for Two-Stage Ejector with Barometric Intercondenser, 372; vi Estimating Blast Pressures and Destruction, 501; Blast Scaling, 503; Example 7-15: Blast Scaling, 503; Example 7-16: Estimating Explosion Damage, 504; Explosion Venting for 6ases/Vapors (Not Dusts), 504; Liquid Mist Explosions, 505; Relief Sizing: Explclsions of Gases and Vapors, 505; Vent or Relief Area Calculation for Venting of Deflagrations in LowStrength Enclosures, 507; Example 7-17: Low Strength Enclosure Venting, 508; High Strength Enclosures for Deflagrations, 508; Determination of Relief Areas for Deflagrations of Gases/Vapors/Mists in High Strength Enclosures, 508; Dust Explosions, 513; Example 7-18: Use of the Dust Nomographs, 514; Unconfined Vapor Cloud Explosions, 520; Effects of Venting Ducts, 521; Runaway Reactions; DIERS, 521; Flares/Flare Stacks, 523; Flares, 528; Example 7-19: Purge Vessel by Pressurization, 535; Static E:lectricity, 535 Appendix Is m C 547 A-1: Alphabetical Conversion Factors, 347; A-2: Physical Property Conversion Factors, 571; A-3: Synchronous Speeds, 574; A-4 Conversion Factors, 574; A-5: Temperature Conversion, 577; A-6: Altitude and Atmospheric Pressures, 578; A-7: Vapor Pressure Curves, 579; A-8: Pressure Conversion Chart, 580; A-9: Vacuum Conversion, 581; A-IO: Decimal and Millimeter Equivalents of Fractions, 582; A-11: Particle Size Measurement, 582; -4-12: Viscosity Corcversions, 583; A-13: Viscosity Conversion, 584; 21-14: Commercial Wrought Ste'el Pipe Data, 585; A-15: Stainless Steel Pipe Data, 588; A-16: Properties of Pipe, 589: A-17: Equation of Pipes, 598; A-18: Circumferences and Areas of Circles, 599; A-19: Capacities of Cylinders and Spheres, 605; A-20: Tank Capacities, Horizontal Cylindrical-Contents of Tanks with Flat Ends When Filled to Various Depths, 609; A-21: Tank Capacities, Horizontal Cylindrical-Contents of Standard Dished Heads When Filled to Various Depths, 609;A-22: M i s cellaneous Formulas, 610; A-23: Decimal Equivalents in Inches, Feet and Millimeters, 611; A-24: Properties of the Circle, Area of Plane Figures, and Volume of a Wedge, 612; A-24 (continued): Trigonometric Formulas and Properties of Sections, 613; A-24 (continued): Properties of Sections, 614; A-25: Wind Chill Equivalent Temperatures on Exposed Flesh at Varying Velocity, 617; A-26 Impurities in Water, 617; A-27: MJater Analysis Conversions for Units Employed: Equivalents, 618; A-28: Parts Per Million to Grains Per U S Gallon, 618; A-9: Formulas, Molecular and Equivalent Weigh&,and Conversion Factors to CaCoBof Substances Frequently Appearing in the Chemistry of Water Softening, 619; A-30: Grains Per US Gallons-Pounds Per 1000 Gallons, 621; A-31: Part5 Per Million-Pounds Per 1000 Gallons, 621; A-32: Coagulant, Acid, and Sulfate-I ppm Equivalents, 621; A-33: Alkali and Lime-I ppm Equivalents, 622; A-34: Sulfuric, Hydrochloric Acid Equivalent, 622; A-35: ASME Flanged and Dished Heads IDD Chart, 623; A-35 (continued) : Elliptical Heads 624; A-35 (continued): 80-10 Heads, 625 Index = DI ~s ~ .~~.~ O 626 n Appendix A.29 619 Formulas Molecular and Equivalent Weights and Conversion Factors to CaCO of Substances Frequently Appearing in the Chemistry of Water Softening SUhal