Understanding process equipment for operators and engineers / Norman Lieberman.

Format:

Book

Author/Creator:

Lieberman, Norman P., author.

Language:

English

Subjects (All):

Chemical plants--Equipment and supplies.

Chemical plants.

Industrial equipment.

Maintainability (Engineering).

Reliability (Engineering).

Physical Description:

1 online resource (434 pages)

Place of Publication:

Amsterdam, Netherlands ; Oxford, England ; Cambridge, Massachusetts : Elsevier, [2019]

Summary:

Understanding Process Equipment for Operators and Engineers explains how process equipment functions. As problems often arise in plants that must be solved by unit engineers, this book offers successful solutions and methods for their implementation. The concepts explained are based on Norm Lieberman's personal, hands-on experience. Like you, Norm attended a university and was exposed to technical seminars which did not always provide the needed solutions. In this text, you will learn the functioning of a variety of equipment types, including Fired Heater Draft, Centrifugal Pump Head, Distillation Tray Efficiency, Vacuum Jets, Recip Compressors, Steam Turbines, Thermosyphon Circulation Reboilers and Air Cooler.- Includes methods and procedures on how to make field measurements- Outlines fire heater principles and operation and how they develop draft- Describes distillation column operation and methods to increase their efficiency- Includes computer modeling and provides use case examples

Contents:

Front Cover

Understanding Process Equipment for Operators and Engineers

Copyright

Dedication

Contents

Author Note

Introduction: An Act of Creation

General Introduction

Chapter 1: Basics of Process Operations and Engineering

Things I Worry About

The Future Without Refineries

Safety Note

Part 1: Fractionation

Chapter 2: Factors Affecting Tray Fractionation Efficiency

Effect of Incremental Reboiler Steam

Entrainment and Tray Efficiency

Tray Efficiency Calculations

The Problem With Valve Trays

Optimizing Fractionation Tray Efficiency

The Nature of Tray Efficiency

Delta ``P´´ Hydraulic

Balancing Delta P Dry and Delta P Hydraulic

Optimizing Tray Efficiency-Process Design Perspective

Optimizing Tray Efficiency-Maintenance

Optimizing Tray Efficiency-Operations

Process Engineering in Action

Bubble Cap Trays

Chapter 3: Function of Reflux in Distillation Towers

Vapor Pressure Limitations

Two-Stage Distillation Process

Origin of a Distillation Column

Removing the Naphtha's Tail

Conclusion

Chapter 4: How Distillation Trays Work

Effect of Foam

Benefits of Reflux

Downcomer Back-Up

Tray Efficiency

Bubble Cap Tray Decks

Chapter 5: De-entrainment of Vapors

Liquid-Liquid Separation

Vapor-Liquid Separators

Vortex Tube Clusters

Wash Oil Sprays

Vapor Distribution

Settling Water Out of Hydrocarbon Liquid Phase

Coalescers

Foam

Summary

Chapter 6: Fractionator Wash Oil Grids

Delayed Coker Wash Oil Section

Excessive Coker Grid Height

Wash Oil Distribution Problems

Selecting ``C´´ Factor for Gravity Settling De-entrainment

Vacuum Tower Wash Oil Grid

Chapter 7: Installation Error Causes Fractionator Flooding

Running a Tower Pressure Drop Survey.

Observed Pressure Measurements

Tower Internal Inspection

Chapter 8: Oil-Water Separation

pH Control

Control Valve Pressure Drop

Improved Feed Distributor

Sloped Settling Baffles

Particle Size and Settling Velocity

Part 2: Hydraulics

Chapter 9: Hydraulics-Head

Pressure

Velocity

Relationship of Pressure, Head, and Velocity

My Bathroom Water Pressure

Converting Head Pressure Into Velocity

Converting Pressure to Feet of Head

Centrifugal Pumps

Orifice Coefficients

``OC´´

Converting Velocity Back to Pressure

Pressure Balancing Holes

Chapter 10: Common Hydraulic Problems

Conversion of Velocity to Pressure

Water Hammer Dampener

Vapor Lock

Condensate Seal

Steam Hammer

Chapter 11: Applying Hydraulics to Process Problems

Pressure Recovery

Vapor Lock in an Emulsion Line

Cooling Water Piping Pressure Drop

Fractionation Tray Efficiency

Chimney Tray Pressure Drop

Part 3: Heat Transfer

Chapter 12: Troubleshooting Cooling Water Circuits

Cooling Towers

Wet Bulb Temperature

Water Pressure

Time, Temperature, and pH

Pressure Drop Survey

Frictional Loss in Water Piping

Hardness Deposits

Water pH Control

A Localized Restriction

Air Leaks in Suction

Approach to Wet Bulb

Chapter 13: Thermosyphon Circulation and Draft

Draft, Thermosyphon Circulation, and the Air Lift Pump

The Air Lift Pump

How Fast Will Water Circulate?

Furnace Draft Losses

Thermosyphon Circulation

Going Home

Chapter 14: Latent Heat Transfer Concepts

Nucleate Boiling Sites

Heat Flux Limited Situation

Sintered Metal Tube Coating

Effect of Circulation Rate on Maximum Reboiler Flux

Vapor Binding

Effect of Vapor Venting

Relationship of Sensible to Latent Heat of Steam.

Conversion of Heat Into Kinetic Energy

Effect of Molecular Attraction

Hydrogen Expansion

Latent Heat Effects

Evaporation

Ambient Heat Losses

Effect of Surfactants on Foaming

References

Chapter 15: Steam Flow Through Reboilers

Lost Reboiler Duty

Condensate Back-Up

Blowing Condensate Seal

Noncondensables in Steam

Lack of Thermosyphon Circulation

The Big Fix

Correcting Design Error

Increasing Thermosyphon Circulation

Chapter 16: Heat Exchange in Condensers and Reboilers

Depropanizer Reboiler Tube Leak

Venting From a Vertical Thermosyphon Reboiler

Carbon Dioxide Accumulation

Air Leaks in Surface Condensers

Surface Condenser Air Baffle

Cooling Water Inlet Location

Effect of Smooth Reboiler Tubes

De-superheating Vapors

Chapter 17: Crude Unit-Heat Exchanger Fouling

Which Side Should Crude Be Placed on

Why Tubes Foul

Effect on Heat Transfer

Surface Roughness

Increasing the Number of Tube Side Passes

On-Line Spalling

Shell Side Cross-Flow Velocity

Part 4: Revamping Process Units

Chapter 18: Guide to Revamping Process Units

Preflash Tower Case History

Simulation Comparison

Design Basis

Distillation Tower Modeling

Selection of Tray Efficiency

Equation of State

Pressure Drop in Process Lines

Rigorous Determination of Friction Factors Inside Process Piping

Crude Preheat Exchanger Network

Vacuum Tower Bottoms Composition

Chapter 19: Problems in Computer Modeling of Process Units

Computer Simulation of Fractionators

Oil-Water Settling Velocity

Heat Exchanger Efficiency

Pressure Drop in Pipes

Fired Heater Limitations

Effective Design Methods

Chapter 20: Does Computer Modeling Reflect Reality?-Diesel Freeze Point

The Lab Analysis.

Post Script

Part V: Fired Heaters

Chapter 21: Effect of Combustion Air Preheat on a Fired Heater

Effect on Flame Temperature

Effect of Improved Air-Fuel Mixing

Excess Air

Effect of Air Preheater

Chapter 22: Fired Heater-Safe Shutdown Due to a Tube Failure

Heater Tube Failed

Upper Explosive Limit

Snuffing Steam

Abandoning Box Steam Installation

Corrective Action

Part 6: Vacuum System

Chapter 23: Vacuum Towers

How Jets Work

Nonlinear Performance of Ejectors

Fixing the Problem

Limitation of Water Vapor Pressure

Steam Turbine Vacuum Surface Condensers

Function of Condenser ``B´´

Chapter 24: Upgrading Vacuum Tower Performance

Reducing Resid Gas Oil Content

Increasing Flash Zone Temperature

Commissioning Spare Steam Ejector

Silicas in Steam Nozzle

Wet Steam

Cooling Water Flow

Tube Material Selection

Drain Leg Leak

Chapter 25: Vacuum Ejectors as Wellhead Compressors

Vacuum System-Steam Ejectors

Converting Heat to Velocity

Steam Ejector as a Compressor

Converging-Diverging Steam Ejectors

Loss of Sonic Boost

Natural Gas Recovery

Part 7: Steam Turbines and Ejectors

Chapter 26: Steam Turbine Vacuum Surface Condensers

Vacuum Condensers

Surface Condenser

Correction for Barometric Pressure

Vacuum Limits Due to Vapor Pressure of Water

FCU Air Blower Horsepower

Career Enhancement

Condensate Back-Up and Blowing the Condensate Seal

Chapter 27: Practical Use of Thermodynamics

Steam in Vacuum Ejectors

Property of Saturated Steam

Field Observations

Steam Turbines

Chapter 28: How Steam Does Work in Engines, Turbines, and Vacuum Ejectors

Reciprocating Steam Engine

The Creole Queen

Thermodynamics

Mollier Diagram

Steam Pressure Converted to Horsepower.

Momentum of Steam

Function of the Turbine Governor

Port or Hand Valves

Isentropic Expansion

Turbine Efficiency

Vacuum Ejector

Momentum Converted to Pressure

Part 8: Rotating Equipment

Chapter 29: Centrifugal Pumps

Velocity, Head, and Pressure

Conversion of Velocity to Flowing Pressure

Function of a Pump Impeller

Converting Velocity to Head

Relationship of Head to Discharge Pressure

Pump Curve

Positive Displacement Pumps

Seal Oil Flow to Idle Pumps

Chapter 30: Centrifugal Pumps: Required Starting NPSH

Start-Up Problems

Nozzle and Piping Losses

The Bhopal Factor

Symptoms of Cavitation

Starting NPSH Requirements

Calculating Starting NPSH

Increasing Process Flow Rate

Increasing Available Starting NPSH on a Crude Unite Preflash Drum

Practical Steps to Minimize Cavitation

Examples of NPSH Circulations

Starting NPSH Requirement

Answer

Volume of Line

Suction Pressure Control

Pump Suction Screens

Chapter 31: How Compressors Work

Centrifugal vs Axial Compressors

Centrifugal Compressors

Centrifugal Compressor Performance Curve

Stopping Surge

Benefit Suction Throttling of Centrifugal Compressors

Shape of Compressor Curve

The Antisurge Valve

Reciprocating Compressors

Carnot Cycle

Temperature Profile

Rod Loading

A Final Word

Chapter 32: Why Centrifugal Compressors Surge

Meeting Girls on Airplanes

Aerodynamic Stall and Surge

Causes of Centrifugal Compressor Surge

Effect of Surge

Function of the Discharge Check Valve

Preventing Surge

My Alky Unit in Texas City

Controlling Vapor Recycle Temperature

Chapter 33: Refrigeration System

Refrigeration Limit

The El Dorado Refinery

The City of El Dorado

Refrigerant Composition

Increasing Refrigerant Volatility.

One Experiment is Worth a Thousand Calculations.

Notes:

Includes index.

Description based on print version record.

ISBN:

9780128161623

0128161620