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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