Process Engineering Equipment Handbook Claire Soares McGraw-Hill New York Chicago San Francisco Lisbon London Madrid Mexico City Milan New Delhi San Juan Seoul Singapore Sydney Toronto Library of Congress Cataloging-in-Publication Data Soares, Claire. Process engineering equipment handbook / Claire Soares. p. cm. Includes index. ISBN 0-07-059614-X (acid-free paper) 1. Chemical plants—Equipment and supplies. I. Title. TP157.S658 2002 660¢.283—dc21 2001045228 McGraw-Hill Copyright © 2002 by The McGraw-Hill Companies, Inc. All rights reserved. Printed in the United States of America. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any means, or stored in a data base or retrieval system, without the prior written permission of the publisher. 1 2 3 4 5 6 7 8 9 0 CCW/CCW 0 7 6 5 4 3 2 1 ISBN 0-07-059614-X The sponsoring editor for this book was Kenneth P. 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This work is published with the understanding that McGraw-Hill and its authors are supplying information but are not attempting to render engineering or other professional services. If such services are required, the assistance of an appropriate professional should be sought. Contributors A ASME Specifications ASME: 345 East 47 Street, New York, NY 10017 USA Abrasives Abrasive Technology, Inc.: 8400 Green Meadows Drive, Westerville, OH 43081 USA Sandusky-Chicago Abrasive Wheel Co., Inc.:1100 W. Barker Avenue, Michigan City, IN 46360 USA National Metal Abrasive, Inc.: P.O. Box 341, Wadsworth, OH 44282 USA Acid Rain Environment Canada: Environment Canada Enquiry Centre, Ottawa, Ontario K1A0H3 Canada Acoustic Enclosures,Turbine Altair Filters International Limited: Omega Park, Alton, Hampshire GU34 2QE England Actuators J.M. Voith GmbH: P.O. Box 1940, D-89509 Heidenheim, Germany Voith Turbo GmbH & Co., KG: P.O. Box 1555, D-74555 Crailsheim, Germany Air Filtration Altair Filters International Limited: see above Air Pollution Control Alstom (formerly ABB Power Generation): Finspong 61282 Sweden; Hasselstrasse 16, CH-5401 Baden, Switzerland; 5309 Commonwealth Center Parkway, Midlothian, VA23112 USA B Bearings Demag Delaval: 840 Nottingham Way, Trenton, NJ 08638 USA Revolve Magnetic Bearings, Inc.: Calgary, Alberta, Canada Boilers Environment Canada: see above Brakes J.M. Voith GmbH: see above xv xvi Contributors C CFD (Computational Fluid Dynamics) Fluent Inc.: Lebanon, NH USA Carbon;Carbon-Graphite Mix Products Advance Carbon Products: 2036 National Avenue, Hayward, CA94545 USA Carbon Dioxide (CO);CO Disposal 2 2 Vatenfall: S162 87 Stockholm, Sweden Cement;Portland Cement Environment Canada: see above Centrifuges Dorr-Oliver Inc.: 612 Wheelers Farm Road, Milford, CT 06460 USA Chemical Complex;(Petro)Chemical Complex;Chemical Plant Petrochemcial Company of Singapore: Singapore Chemicals ARCO Chemical Company: 3801 West Chester Avenue, Newton Square, PA 19073-2387 USA Chemicals (Toxic),Handling ARCO Chemical Company: see above Chillers;Crystallizers;Chemical Separation Method;Alternative to Distillation/Fractional Distillation Armstrong Engineering Associates: P.O. Box 566M, West Chester, PA 19381- 0566 USA Cogeneration Alstom: Finspong 61282 Sweden Compressors Sulzer-Burckhardt: Winterthur, Switzerland Demag Delaval: see above Aerzener Maschinenfabrik, GmbH: D2358 Aerzen, Germany Condensers Alstom: Hasselstrasse 16, CH-5401 Baden, Switzerland; D6800 Mannheim 1, Germany Condition Monitoring (CM);Condition-Monitoring System(s) (CMS);Engine Condition Monitoring (ECM);Engine Condition–Monitoring System(s) (ECMS) Claire Soares Inc.:P.O. Box 540213, Dallas, TX 75354 USA Control Systems;Controls Sulzer-Burckhardt: see above Voith Turbo GmbH & Co., KG: P.O. Box 1555, D-74555 Crailsheim, Germany Voith Safeset A.B.: Ronningev. 6, S-82434 Hudliksvall, Sweden Controls,Retrofit Petrotech Inc.: 108 Jarrel Drive, P.O. Box 503, Belle Chase, LA70037 USA Demag Delaval: see above J.M. Voith GmbH: see above Contributors xvii Conveyors Sandvik Process System, Inc.: USA Bloch, H., and Soares, C. M., Process Plant Machinery, 2d ed., Butterworth- Heinemann, 1998. Coolant;Engine Coolant ARCO Chemical Company: see above Cooling;Cool,Products That (Air Conditioners);Liquid-Cooled Air Conditioners Thermoelectric Cooling America Corporation (TECA): USA Cooling Towers The Marley Cooling Tower Company:Marley and Lone Elm Roads, Olathe, KS 66061 USA D Drying ARCO Chemical Company: see above E Ecological Parks;Industrial Ecological Parks Environment Canada: see above Ecosystem Environment Canada: see above Electric Motors;Electric Motor Controls Reliance Electric Company: Cleveland, OH USA Emissions;Air Emissions Environment Canada: see above Engines,Gas Cooper-Bessemer Reciprocating: Grove City, PAUSA Environmental Accountability Kodak: USA Cultor: Finland Environmental Economics AssiDomän: Sweden Exhausters,Centrifugal Gas Ansaldo: Milan, Italy Expansion Joints Townson Expansion Joints: United Kingdom Explosion;Explosion Hazard Analysis;Explosion Hazards Eutech Engineering Solutions Ltd.: Billingham, Cleveland TS23 4YS England H.M. Principal Specialist Inspector, Health & Safety Executive, Quay House, Quay Street, Manchester M3 3JB England xviii Contributors F Fans,Centrifugal Ansaldo: see above Bloch, H., and Soares, C. M., Process Plant Machinery, 2d ed., Butterworth- Heinemann, 1998. Filters Peerless Manufacturing Company: 2819 Walnut Hill Lane, Dallas, TX 75229 USA Forest Products AssiDomän: see above Fuel Gas Conditioning System(s) Peerless Manufacturing Company: see above Fuel Systems;Fuel Flow Control J.M. Voith GmbH: see above Whittaker Controls, Inc.:12838 Saticoy Street, North Hollywood, CA91605 USA Fuels,Alternative;Fuels,Gas Turbine Bechtel Power Corporation: Gaithersburg, MD 20878 USA G Generators;Turbogenerators Alstom: see above H Heat Exchangers Armstrong Engineering Associates: see above Heat Pumps;Heat Pumps,Geothermal;Heating Systems with a Renewable Energy Source Enertran: Canada L Life-Cycle Assessment (LCA) (of Turbomachinery) Claire Soares Inc.: P.O. Box 540213, Dallas, TX 75354 USA Liquid Natural Gas (LNG) Peerless Manufacturing Company: see above Lubrication Demag Delaval: see above M Measurement Demag Delaval: see above Metallurgy;Metallurgical Repair;Metallurgical Refurbishment Liburdi Engineering: Hwy. 400, Dundas, Ontario, Canada Contributors xix O Oil Sands;Synthetic Crude;Tar Sands;Shale Syncrude Canada Limited: Ft. McMurray, Alberta, Canada Oxygen Analysis Rosemount Analytical: Orville, OH USA Ozone Environment Canada: see above P Pollutants,Chemical;Pollutants,(from) Chemical Processes;Pollutant Indicators;Pollutants,Toxic;Pollutants, Toxic Chemicals Environment Canada: see above Power Transmission Demag Delaval: see above MAAG Gear Company: Switzerland J.M. Voith GmbH: see above Pulp and Paper AssiDomän: see above Pulsation Dampeners Peerless Manufacturing Company: see above Pumps Bloch, H., and Soares, C. M., Process Plant Machinery, 2d ed., Butterworth- Heinemann, 1998. Demag Delaval: see above Sulzer Pumps: USA Goulds Pumps: USA R Refineries,Petroleum Environment Canada: see above S Seals;Gas Seals Revolve Magnetic Bearing, Inc.: see above Separators Peerless Manufacturing Company: see above Stacks Altair Filters International Limited: see above T Tanks A.O. Smith Engineered Storage Products Company: 2101 S. 21st Street, Parsons, KS 67357 USA Enraf: England xx Contributors Turbines,Gas Alstom: see above ASME: see above Turbines,Steam Demag Delaval: see above Peerless Manufacturing Company: see above Turbochargers Demag Delaval: see above Turboexpanders Demag Delaval: see above U Ultrasonic Cleaning Sonics: USA V Vaporizers;Vaporizor Applications Armstrong Engineering Associates: see above W Waste Management Environment Canada: see above About the Author A registered professional engineer in Texas and Alberta, Canada, Claire Soares graduated with a B.Sc.Eng. in 1972 and an M.B.A. in 1993. Her career began in computational fluid dynamics working for Brian Spalding in Imperial College, London, on the COBALT project. She then spent about two years working on developing structural patents for the marine and the power distribution industries in England and Canada. Her rotating machinery career began in earnest at the oil sands Syncrude site in Fort McMurray, Alberta, in 1975. Four years later, she moved to Esso Resources and conventional oil and gas production until the “oil patch sat on its tail” at the end of 1981. She then accepted a three-year commission with the Canadian Air Force as Propulsion Systems Manager for all transportation engines in the Department of Defence Transport Command in Canada. She took charge of six helicopter engine fleets, as well as projects related to selecting replacements for two of those fleets. After that, she moved to the United States to start work as a senior engineer for Ryder Airline Services Division (ASD was also called Aviall and, before that, CooperAirmotive). At that point ASD was the largest independent overhaul facility for airline engines in the world, with a shop capacity of about 1000 engines a year. She ran technical support on second shift for 250 mechanics and their supervisors on the JT8D, JT3D, and CFM 56 engine lines. Three years later, she was made manager of the V2500 engine repair program, at that time the first and only designated facility for this engine in the United States. Two years later, after the engine line was up and running, she left to become an independent consultant, trainer, and writer. She has now lived and worked on four continents. Ms. Soares organizes one to two conference sessions annually for the International Gas Turbine Division of the American Society of Mechanical Engineers (ASME) and has done so since 1985. In May 2001 she was appointed to Fellow grade by ASME. Process Engineering Equipment Handbook is her fourth book. The first, Process PlantMachinery, Second Edition, was coauthored with Heinz Bloch, P.E. This work and Environmental Technology and Economics: Sustainable Development in Industry helped provide the present handbook with its broad perspective. Turboexpanders and Process Applications, her third book, also coauthored with Heinz Bloch, was released in 2001. All her books are used when appropriate as course instruction material for her own and others’ courses. Ms. Soares writes extensively for technical journals, such as Petroleum Economist, Asian Electricity, and International Power Generation. She also writes for more general audiences, with some television screenplays and articles for various international newspapers and magazines to her credit. A published photographer, she writes poetry and has staged multimedia performances of her work for organizations such as the city of Dallas. She is a scuba diver and licensed commercial pilot, and also enjoys swimming and hiking. In-30 Preface If you picked up this book you are probably one of those lucky people who run plants. Either a thinly spread engineer (branch of specialty is irrelevant), a newly promoted technical manager, or a harassed technologist or senior mechanic, who just was told: “See that plant out there? You’re in charge of making it work!” Even if you’ve been in plants for years, that’s enough to make your innards rumble. If you have just stepped out of school, into your first plant, or into a totally different plant from the previous one you were at, your reaction might be more severe, especially if you belong to one of the numerous organizations with no budget for rotating machinery specialists (who look after what moves a process through its paces) or environmental specialists (who make certain you don’t get fined or jailed, good intentions notwithstanding, as you run your plant). At this point, I should explain where I fit in with your agenda. Twenty-some years ago, some heated arguments on the subject of how much I wanted to be a rotating machinery specialist took place in Canada’s wild and woolly north. I was fencing with my boss, a process engineer, who was recommending I join his field. It was what my company needed, he asserted. I thought it needed both of us doing what we loved best. My career bears witness to the fact that I won the match, in the short- and long-term. Time since has brought a few things forcibly home to me. To start with, the more I dealt with plant machinery in any form, the more I accepted that process conditions could affect the performance of that machinery at least as much as actual mechanical characteristics. In operations, repair and overhaul, or retrofit design and reengineering, what keeps people like me a step ahead of the manufacturer’s field service representatives is knowledge of the process and familiarity with the controls that govern the entire system. In turn, the process engineer who gets handed a plant to run must acquire some basic knowledge of my bread and butter, the machinery that makes everything move up, down, or around. In large facilities, such as the ones I was fortunate enough to spend time in, there generally are in- house rotating machinery specialists. Often, though, the process engineer is not that lucky and gets everything—process components, machinery, controls, and all. Life handed me an education (after formal degree acquisition) in rotating machinery specialization and the environmental technology that goes with it (yes, we machinery “cranks” run the stuff that turns out arguably 80 percent of the gunk in the universe). While doing this, I worked with scores of process engineers, control engineers, and various other specialists on a variety of projects that were among the most high profile in the world in their own right. It was “arranging to be in the right place—an operating plant—to get the best education in the best school in the world.” After all, curriculum, undergraduate or otherwise, is not necessarily any comfort. In my day they rarely taught this stuff to process, chemical, or mechanical engineers xi