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1 Chapter 14Figure 14.1 A process engineering section supervision chart (Ludwig [1]).Figure 14.2 Typical organization of “engineering planning team” [2].Figure 14.3 The total plant design project.Figure 14.4 Partitioning the process design task into interrelated subtasks (sou...Figure 14.5 Block flow diagram of hydrocracker overview.Figure 14.6a Heat and material balance-established material and thermal requirem...Figure 14.6b Process flow diagram of (feed and fuel desulfurization sections) [9...Figure 14.6c Process flow diagram of atmospheric fractionator.Figure 14.7 Mechanical detail flow diagram [9].Figure 14.8 Piping and Instrumentation (P & ID) diagram for ammonia plant [9].Figure 14.9 Piping details isometric diagram [9].Figure 14.10 Isometric diagram of a process line [9].Figure 14.11 Standard type laying for service piping diagram.Figure 14.12 Process Engineering flow scheme (Crude distiller unit 1000 air cool...Figure 14.13 Typical process area plot plan and study elevations [9].Figure 14.14 Flowsheet scale reference diagram [11].Figure 14.15 (a) Computer-generated P & ID flowsheet [9] (b) Computer-generated ...Figure 14.16 (a) Process variables; (b) Pumps and solids [9]. (c) Storage and eq...Figure 14.17 (a) Special types of descriptive flowsheet symbols [9]. (b) Commonl...Figure 14.18 Examples of line numbering.Figure 14.19 Use of alphabetic suffixes with line symbols.Figure 14.20a Line schedule.Figure 14.20b Pipe line list.Figure 14.20c Line schedule sheet.Figure 14.20d Line summary table.Figure 14.21 Typical valve codes and specifications. By permission, Borden Chemi...Figure 14.22 Partial presentation of piping materials specifications for a speci...Figure 14.23 Centrifugal pump summary.Figure 14.24a Centrifugal pump schedule.Figure 14.24b Centrifugal pump schedule.Figure 14.25 Vessel and tank summary sheet.Figure 14.26 Vessel and tank schedule.Figure 14.27 General services and utilities checklist.Figure 14.28 Process engineering job analysis summary.

2 Chapter 15Figure 15.1 Refinery and chemical plant layouts (source: (a, b) Coker, A. K. [Lu...Figure 15.2 Distribution of fluid energy in a pipeline.Figure 15.3 Pressure level references. Adapted by permission from Crane Co., Tec...Figure 15.4 Portion of a plant piping system (by permission from Spiral Sarco, I...Figure 15.5 Moody or “regular” Fanning friction factors for any kind and size of...Figure 15.6a Forged steel threaded pipe fittings (water, oil, or gas service). N...Figure 15.6b Forged steel socket weld fittings. WOG (water, oil, or gas service)...Figure 15.6c Forged steel welded—end fittings (source: Tube Turn Technologies, I...Figure 15.6d Dimension comparison of tubing and IPS (iron pipe size) steel pipin...Figure 15.7 Branch connections for welding openings into steel pipe. See Figure ...Figure 15.7a A block diagram for calculating ΔP for a given flow rate/velocity.Figure 15.7b Optimum economic pipe diameter.Figure 15.8a Relative roughness of pipe materials and friction factors for compl...Figure 15.8b Relative roughness of pipe materials and friction factors for compl...Figure 15.9a Resistance coefficients for valves and fittings (source: Hydraulic ...Figure 15.9b Resistance coefficients for valves and fittings (source: Hydraulic ...Figure 15.10 Variation of specific gravity with temperature for various petroleu...Figure 15.11 Viscosity and Newton’s law.Figure 15.12 Vapor pressure chart for various petroleum products (source: E. Sha...Figure 15.13 The Excel spreadsheet snapshot of Example 15.2.Figure 15.14 Configuration of 60°F crude oil conduit system.Figure 15.15a Various tap locations for orifice meter.Figure 15.15b Pipe diameter from the inlet face of the orifice plate. Extracted ...Figure 15.15c Orifice meter with vena contracta formation.Figure 15.15d Flow nozzle with differential gauge.Figure 15.15e Venturi meter.Figure 15.15f Coriolis mass flow meter (source: Micro Motion, Inc. USA).Figure 15.16 Flow coefficients “C” for nozzles. C based on the internal diameter...Figure 15.17 Flow coefficients “C” for squared-edged orifices (source: Crane [4]...Figure 15.18 Orifice discharge coefficient for square-edged orifice and flange, ...Figure 15.19 Piping layout for Example 15.8.Figure 15.20a Piping and instrumentation diagram of the debutanizer unit 1000.Figure 15.20b Piping and instrumentation diagram of the debutanizer pump accumul...Figure 15.21 Pipe flow chart nomogram (source: Sandler, H. J and E. T. Luckiewic...Figure 15.22 Establishing control valve estimated pressure drop.Figure 15.23 Fluid flow through heat exchanger, relief valve, and tail pipe.Figure 15.24 The Excel spreadsheet snapshot of Example 15.13Figure 15.25a Net expansion factor, Y, for compressible flow through pipe to a l...Figure 15.25b Net expansion factor, Y, for compressible flow through pipe to a l...Figure 15.25c Critical pressure ratio, rc, for compressible flow through nozzles...Figure 15.26a Pressure drop in compressible flow lines (reprinted/adapted with p...Figure 15.26b Pressure drop in compressible flow lines (metric units) (reprinted...Figure 15.27a Simplified flow formula for compressible fluids (reprinted/adapted...Figure 15.27b Simplified flow formula for compressible fluids (metric units) (re...Figure 15.28 Steam flow chart (by permission from Walworth Co. Note: Used for es...Figure 15.29a Velocity in compressible flow lines (reprinted/adapted with permis...Figure 15.29b Velocity in compressible flow lines (metric units) (reprinted/adap...Figure 15.30 Discharge coefficients for liquid flow (by permission, Cameron Hydr...Figure 15.31a Flow patterns for horizontal two-phase flow (based on data from 1,...Figure 15.31b Baker parameters for horizontal two-phase flow regimes with modifi...Figure 15.32 Representatives forms of horizontal two-phase flow patterns, same a...Figure 15.33 Lockhart–Martinelli pressure drop correlation (source: Lockhart–Mar...Figure 15.34 Estimating pressure drop in uphill sections of pipeline for two-pha...Figure 15.35 Configurations of piping for sample problem of Example 15.24 [56].Figure 15.36 Excel spreadsheet calculation of Example 15.25.Figure 15.37 Flow patterns in vertical liquid–gas flow (source: S. M. Walas, Che...Figure 15.38 Slug/forth transition in concurrent vertical upflow of air–water mi...Figure 15.39 Evaluation curves for friction losses of air steam flowing turbulen...Figure 15.40 Friction factor for streamlined flow of air at absolute pressures f...Figure 15.41 Absolute viscosity of air (source: Standard for Steam Jet Ejectors,...Figure 15.42 Typical flow velocities for vacuum lines. Note: 1 torr = 1.33 mb = ...Figure 15.43 Acceptable pressure losses between the vacuum vessel and the vacuum...Figure 15.44 Typical steam condensate flashing operation.Figure 15.45 Sarco flashing steam condensate line sizing flow chart (source: Spi...Figure 15.46 Flashing steam condensate line sizing chart (source: Ruskin, R. P.,...Figure 15.47 Line size sheet. Example of pressure drop for a vapor system, Examp...Figure 15.48 Pressure drop, Dowtherm “A” ® vapor in steel pipe (by permission fr...Figure 15.49 Process flow diagram of the Case study using PIPESYS software (cour...Figure 15.50a Flowing pressure profile of Pipe-100.Figure 15.50b Flowing temperature profile of Pipe-100.Figure 15.50c Flowing pressure profile of Pipe-101.Figure 15.50d Flowing temperature profile of Pipe-101.

3 Chapter 16Figure 16.1 Cross-sectional view of a vertical inline pump (by permission from K...Figure 16.2 Turbine pump (courtesy of Roth Pump Co.).Figure 16.3 Centrifugal pump increases process head by adding energy to a fluid....Figure 16.4 Head required to produce similar pressures is higher for lower densi...Figure 16.5 Impeller types. Open impeller for corrosive or abrasive slurries and...Figure 16.6 Stuffing box details lined pump with porcelain or Teflon^® shaft slee...Figure 16.7 Packed stuffing box (courtesy of Dean Brothers Pumps, Inc.).Figure 16.8a Basic components of all mechanical seals (by permission from Adams,...Figure 16.8b The three sealing points in mechanical seals (by permission from Sn...Figure 16.9 (a) Double mechanical seal, two rotary elements against common stati...Figure 16.9 (c) Typical seal flush arrangement for double mechanical seals.Figure 16.9 (d) Typical seal flush arrangement for tandem mechanical seals.Figure 16.10 Typical single mechanical seal inside pump stuffing box (courtesy o...Figure 16.11 Area relationship for unbalanced seal construction (by permission f...Figure 16.12 Area relationship for balanced seal construction (by permission fro...Figure 16.13 Single outside balanced seal (courtesy of Durametallic Corp.).Figure 16.14 General service centrifugal pump (courtesy of Dean Brothers Pumps, ...Figure 16.15 Cut-a-way section of single-stage pump, Part 1 (above) enclosed typ...Figure 16.16 Comparison of impeller types for centrifugal pump performance (adap...Figure 16.17 Performance of turbine type centrifugal pump (courtesy of Roy E. Ro...Figure 16.18 Characteristics of a centrifugal pump are described by the pump per...Figure 16.19 Impeller performance guide. Wrap refers to curvature of vanes on im...Figure 16.20a Operating point for centrifugal pumps in series [38].Figure 16.20b Operating curves of two duplicate centrifugal pumps in series and ...Figure 16.21a Typical centrifugal pump curves (adapted by permission from Allis-...Figure 16.21b Typical performance curves showing NPSHR in convenient form (by pe...Figure 16.21c Exact same pump casing and impellers at different shaft speeds (by...Figure 16.21d Operating point for centrifugal pumps in parallel [38].Figure 16.21e Pump sizing calculation (SI units) for reflux centrifugal pump of ...Figure 16.22 Motor driven centrifugal pump for the pre-flashed crude in the crud...Figure 16.23 Main distillation tower and a mild vacuum column with associated ce...Figure 16.24a Comparison of columns of various liquids to register 43.3 psig on ...Figure 16.24b Comparison of columns of various liquids to register 3.0 barg on p...Figure 16.25 Suction head system.Figure 16.26 Suction lift system.Figure 16.27a Static head, overall = H + L (adapted by permission, Centrifugal P...Figure 16.27b Static head, overall = H – S (adapted by permission, Centrifugal P...Figure 16.27c Pressure head (adapted by permission, Centrifugal Pumps Fundamenta...Figure 16.27d Pressure head, positive suction (adapted by permission, Centrifuga...Figure 16.27e Pressure head with negative suction (adapted by permission, Centri...Figure 16.27f Pumping arrangement for Example 5-2 (adapted by permission, Centri...Figure 16.28 Typical suction systems (adapted by permission, Carter, R. and Kara...Figure 16.29 Typical discharge systems.Figure 16.30 Static pressure losses occur as the fluid travels into the pump suc...Figure 16.31 NPSH_A equals 20 ft [27].Figure 16.32 NPSH_R increases with flow [27].Figure 16.33 Subcooling increases NPSH_A [27].Figure 16.34 (a) Cavitation damage has occurred on an impeller and (b) erosion–c...Figure 16.35 Liquid vortex in vessel and suggested design of vortex breaker.Figure 16.36 NPSH_A and NPSH_R vs. capacity in a pumping system [37].Figure 16.37 Effect of insufficient NPSH on the performance of a centrifugal pum...Figure 16.38 Effect of throttling the discharge valve on the operating point of ...Figure 16.39 Surface condenser condensate removal. Closed system steam surface c...Figure 16.40 High altitude process vacuum system, NPSH requirements.Figure 16.41 NPSH reductions for pumps handling hydrocarbon liquids and high tem...Figure 16.42 Head, NPSH_R vs. flow rate [25].Figure 16.43 Net positive suction head for high pressure centrifugal hot-water p...Figure 16.44 Temperature correction chart for net positive suction head requirem...Figure 16.45 Impeller designs and corresponding specific speed range (by permiss...Figure 16.46 Upper limits of specific speeds for single suction overhung impelle...Figure 16.47 Upper limits of specific speeds for single suction, mixed, and axia...Figure 16.48 Typical centrifugal pump characteristic curve with auxiliary specif...Figure 16.49 System head curves for single pump installation.Figure 16.50 System head curves for variable static head.Figure 16.51 System head using two different pipe sizes in same line.Figure 16.52 System head for branch piping with different static lifts.Figure 16.53 Relation of speed change to pump characteristics.Figure 16.54 Piping and equipment layout for the suction and discharge lines to ...Figure 16.55 Pump sizing calculation of Example 16.20.Figure 16.56 Pump sizing calculation (metric units) for reflux LPG centrifugal p...Figure 16.57 Pump efficiency calculation at varying flow rate for a 6-in. impell...Figure 16.58 Pump efficiency calculation at varying flow rate for an 8-in. impel...Figure 16.59a Viscosity performance correction chart for centrifugal pumps...Figure 16.59b Viscosity correction chart (source: Hydraulic Institute, USA).Figure 16.59c Performance correction chart (source: The Hydraulic Institute, USA...Figure 16.60 Viscosity performance correction chart for small centrifugal pumps ...Figure 16.61 Typical curves showing the effect on a pump designed for water when...Figure 16.62 Sample performance curve.Figure 16.63 Typical temperature rise for boiler feed water pump (by permission ...Figure 16.64 Temperature rise in centrifugal pumps in terms of total head and pu...Figure 16.65a Centrifugal pump specification.Figure 16.65b Centrifugal pump calculation sheet.Figure 16.66 Sump design. Note: S = (1.5 – 2)Bd.Figure 16.67 Acceptable sump arrangement for multiple pumps.Figure 16.68 Rotary pumps (by permission from Dolman, R. E., Chem. Eng., Mar. 19...Figure 16.69a Diaphragm metering pump, “Pulsa” series. One of several styles/typ...Figure 16.69b Typical rotary gear pump (by permission from Viking Pump, Inc., Un...Figure 16.69c Sliding vane rotary pump (by permission from Blackmer Pump, Dover ...Figure 16.70 General service duplex steam-driven piston pump (courtesy of Worthi...Figure 16.71 Duplex double-acting plunger pump, power driven (courtesy of Worthi...Figure 16.72 Reciprocating pump discharge flow pattern (courtesy of the Aldrich ...Figure 16.73 Horizontal direct-acting steam pump or power pump.Figure 16.74 A conceptual diagram of P-100 with the variables.Figure 16.75 PFD of a centrifugal pump (UniSim Design R443, Honeywell^® and UniSi...Figure 16.76 Head vs. flow rate of a centrifugal pump (UniSim Design R443, Honey...Figure 16.77 Efficiency vs. flow rate of a centrifugal pump (UniSim Design R443,...Figure 16.78 PFD of a centrifugal pump (UniSim Design R443, Honeywell^® and UniSi...Figure 16.79 Simulation results of centrifugal pump P-100 (UniSim Design R443, H...Figure 16.80 Simulation results of centrifugal pump P-100 (Continued) (UniSim De...Figure 16.81 Simulation results of centrifugal pump P-100 (Continued) (UniSim De...Figure 16.82 Process flow diagram of the piping network from the supply tank via...Figure 16.83 Isometric diagram of the piping network from the supply tank via N-...Figure 16.84 Centrifugal pump characteristics (source: Pump-FLO^TM, Engineered So...Figure 16.85 Pump data sheet of N-S centrifugal pump (source: Pump-FLO^TM, Engine...Figure 16.86 Partly plugged drawoff nozzle [27].Figure 16.87 Most common cause of cavitation [27].Figure 16.88 Main column bottom system [34].Figure 16.89 Main column bottom pump level [34].Figure 16.90 Main column bottom quench system [34].Figure 16.91 Pressure survey of the pump suction line [44].Figure 16.92 Pressure survey of the pump suction line across strainer [44].Figure 16.93 Column outlet piping scheme and pressure survey.Figure 16.94 Original and modified strainer.Figure 16.95 Suction valve and position indicator as found after the incident (s...Figure 16.96 Depressurizing hose (source: www.csb.gov).Figure 16.97 Damage to area of the pump (source: www.csb.gov).Figure 16.98 Plugging material found in discharge valve (source: www.csb.gov).Figure 16.99 Spare pump valve wrench collar (source: www.csb.gov).Figure 16.100 Plug valve in the open position (source: www.csb.gov).Figure 16.101 Suction valve and position indicator (source: www.csb.gov).Figure 16.102 Typical root causes of pump failures and resulting impacts [40].

4 Chapter 17Figure 17.1A General areas of compressing equipment application (source: De Jard...Figure 17.1B Approximate ranges of application for usual process reciprocating c...Figure 17.1C Typical application ranges for turbocompressor capabilities extend ...Figure 17.1D Basic compressor types (used by permission: Coker, A. K. Hydrocarbo...Figure 17.1E Types of compressors.Figure 17.2A Sectional assembly. Worthington single stage, belt-driven air compr...Figure 17.2B Cutaway view of typical high pressure gas cylinder showing double-d...Figure 17.2C Dry vacuum pump cylinder for very low absolute suction pressures. V...Figure 17.2D Standard air compressor cylinder for 125 psig discharge pressure. S...Figure 17.2E A 250 psig working pressure cylinder used in refrigeration service....Figure 17.2F Typical linear-type cast iron cylinder.Figure 17.2G Typical non-lubricated recycle cylinder.Figure 17.2H Double-acting cast steel cylinder to 3500 psi pressure (used by per...Figure 17.2I Double-acting cast Meehanite or ductile iron cylinder to 1250 psi p...Figure 17.2J Double-acting Meehanite metal or ductile iron cylinder to 1000 psi ...Figure 17.2K Forged steel single-acting for 6000 psi pressure (used by permissio...Figure 17.2L Typical forged steel cylinder with tail-rod.Figure 17.2M For low compression ratios, designed for 1000 psi discharge pressur...Figure 17.2N Designed for working pressure up to 6500 psi. A similar design cyli...Figure 17.2O Fourth and fifth-stage cylinder assembly of 3500 psi pressure hydro...Figure 17.2P Fifth and sixth-stage cylinder assembly of 15,000 psi gas compresso...Figure 17.2Q Cast or nodular iron cylinders for pressures to 1500 psi. Note doub...Figure 17.2Q (a) Long, single compartment distance piece (sufficient length for ...Figure 17.2R Fabricated carbon or stainless-steel cylinders for special applicat...Figure 17.2S Forged steel cylinder with tail-rod design (right) for pressure to ...Figure 17.2T Medium or high pressure, double-acting cylinder with flanged liner....Figure 17.2U High pressure, circulator-type cylinder, double-acting. The steel c...Figure 17.3A Typical cross-section of motor-driven, single-stage compressor.Figure 17.3B Partial cross-section of balanced opposed compression cylinders.Figure 17.4 Cylinder action.Figure 17.5A–D Cylinder arrangement.Figure 17.5E Balanced arrangement for Dresser-Rand shaft system, 1–10 crank thro...Figure 17.5F Lubricated and non-lubricated balanced opposed process reciprocatin...Figure 17.6A Double-deck feather valve (used by permission: Dresser-Rand Company...Figure 17.6B Double-deck valve with valve cap unloader (used by permission: Coop...Figure 17.6C Action of gas flow through strip-type feather valve (used by permis...Figure 17.6D Plate-type valves (used by permission: Dresser-Rand Company).Figure 17.6E Channel-type valves (used by permission: Ingersoll-Rand Company).Figure 17.6F Ring channel valves (used by permission: Cooper-Cameron Corporation...Figure 17.6G AJAX® APV-100, high-efficiency compressor valve. Suction and discha...Figure 17.6H Dresser-Rand specialized valve (used by permission: Bul. 3640. Dres...Figure 17.6I Dresser-Rand HPS proprietary valve design, using proprietary blend ...Figure 17.6J Variety of standard and special valves designed and fabricated by t...Figure 17.7 Piston rods. Precision-manufactured rolled threads and induction har...Figure 17.7A Stuffing box with rod packing direct and indirect cooling (used by ...Figure 17.8 Piston and rings. Lubricated and non-lubricated pistons with PTFE or...Figure 17.8A Piston rings. The piston rod is manufactured from heat treated stai...Figure 17.9 Piston rod packing. To meet the latest environmental requirements fo...Figure 17.10 Reciprocating compressor specifications.Figure 17.11 Ideal pressure–volume cylinder action for single acting compressor ...Figure 17.12 Reciprocating compressor compression diagrams. Actual losses and ef...Figure 17.12A Illustration of isentropic path on log pressure-enthalpy diagram, ...Figure 17.12B Section of ethane pressure-enthalpy diagram illustrating five comp...Figure 17.13A Enthalpy-entropy chart for natural gas, Sp.Gr. = 0.6 (used by perm...Figure l7.13B Enthalpy-entropy chart for natural gas, Sp.Gr. = 0.7 (used by perm...Figure l7.13C Enthalpy-entropy chart for natural gas, Sp.Gr. = 0.8 (used by perm...Figure l7.13D Enthalpy-entropy chart for natural gas, Sp.Gr. = 0.8 (used by perm...Figure 17.14A Compressibility factor for gases, Part 1 of 5 (used by permission:...Figure 17.14B Compressibility factor for gases, Part 2 of 5 (used by permission:...Figure 17.14C Compressibility factor for gases, Part 3 of 5 (used by permission:...Figure 17.14D Compressibility factor for gases, Part 4 of 5 (used by permission:...Figure 17.14E Compressibility factor for gases, Part 5 of 5 (used by permission:...Figure 17.14F Compressibility factor for air (used by permission: From 3519 D (1...Figure 17.14G Compressibility chart for ammonia (used by permission: From 3519 D...Figure 17.14H Compressibility chart for chlorine (used by permission: From 3519 ...Figure 17.14I Compressibility chart for nitrogen (used by permission: From 3519 ...Figure 17.14J Compressibility chart for low pressure carbon dioxide (used by per...Figure 17.14K Compressibility chart for high pressure carbon dioxide (used by pe...Figure 17.14L Compressibility chart for methane (used by permission: From 3519 D...Figure 17.14M Compressibility chart for low pressure ethylene (used by permissio...Figure 17.14N Compressibility chart for high pressure ethylene. Note: special ch...Figure 17.14O Compressibility chart for low pressure ethane (used by permission ...Figure 17.14P Compressibility chart for high pressure ethane (used by permission...Figure 17.14Q Compressibility chart for propylene (used by permission from 3519D...Figure 17.14R Compressibility chart for low pressure propane (used by permission...Figure 17.14S Compressibility chart for high pressure propane (used by permissio...Figure 17.14T Compressibility chart for low pressure N-butane (used by permissio...Figure 17.14U Compressibility chart for high pressure N-butane (used by permissi...Figure 17.14V Compressibility chart for low pressure iso-butane (used by permiss...Figure 17.14W Compressibility chart for high pressure iso-butane (used by permis...Figure 17.15 Compressibility factor for natural gas (used by permission: G.G. Ob...Figure 17.16A–C Deviations from the ideal gas law.Figure 17.16D Typical compressor aliments and how they look on P-T diagrams (use...Figure 17.17A Combined indicator cards from a two-stage compressor showing how c...Figure 17.17B Effects of clearance volume on performance efficiency of reciproca...Figure 17.18A Compressor volumetric efficiency curve for gas with k or n of 1.15...Figure 17.18B Compressor volumetric efficiency curve for gas with k or n of 1.20...Figure 17.18C Compressor volumetric efficiency curve for gas with k or n of 1.25...Figure 17.18D Compressor volumetric efficiency curve for gas with k or n of 1.30...Figure 17.18E Compressor volumetric efficiency curve for gas with k or n of 1.35...Figure 17.18F Compressor volumetric efficiency curve for gas with k or n of 1.40...Figure 17.19 Loss factor curve (used by permission: Cooper-Cameron Corporation).Figure 17.20 Chart for solving theoretical work of compression or expansion (use...Figure 17.21A Brake horsepower required to deliver 1 million ft³ of gas per day,...Figure 17.21B Brake horsepower required to deliver 1 million ft³ of gas per day,...Figure 17.21C Brake horsepower required to deliver 1 million ft3 of gas per day,...Figure 17.22 Compression temperature rise (used by permission: Rice, W. T., Chem...Figure 17.23 Barometric and atmospheric pressure at altitudes.Figure 17.24 Conventional Trickle Bed Process Flow Diagram.Figure 17.25 Iso Therming process flow diagram.Figure 17.26 Horizontal configuration of recycle pump [170].Figure 17.27 Liquid flow path in IsoTherming ® Recycle pump [170].Figure 17.28 Photograph: Top view of IsoTherming ® Recycle pump [170].Figure 17.29 A photograph of IsoTherming recycle pump [170].Figure 17.30 Feed sulfur content data during commercial operation of the IsoTher...Figure 17.31 Chemical hydrogen consumption data during commercial operation of t...Figure 17.32 IsoTherming® 3-D layout plot [170].Figure 17.33 A photograph of IsoTherming® hydroprocessing unit [170].Figure 17.34A UniSim Design Desktop (source: UniSim Design® R460.1. Honeywell® a...Figure 17.34B (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34C (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34D (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34E (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34F (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34G (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34H (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34I (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34J (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34K (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34L (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34M (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34N (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34O (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34P (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34Q (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34R (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34S (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34T (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34U (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34V (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34W (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34X (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34Y (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34Z (source: UniSim Design® R460.1. Honeywell® and UniSim® are registe...Figure 17.34Z1 (source: UniSim Design® R460.1. Honeywell® and UniSim® are regist...Figure 17.34Z2 (source: UniSim Design® R460.1. Honeywell® and UniSim® are regist...Figure 17.35A Mollier chart for properties of ammonia (used by permission: Dept....Figure 17.35B Mollier diagram of the properties of ammonia. Note the different c...Figure 17.35C Mollier diagram of the properties of methane (used by permission. ...Figure 17.35D Mollier diagram of the properties of ethane (used by permission. E...Figure 17.35E Mollier diagram of the properties of ethylene. Note: ethylene char...Figure 17.35F Mollier diagram of the properties of propylene (used by permission...Figure 17.35G Mollier diagram of the properties of propane (used by permission. ...Figure 17.35H Mollier diagram of the properties of iso-butane (used by permissio...Figure 17.36 Combined compression and mechanical efficiency of reciprocating com...Figure 17.37 Horsepower characteristic curves for constant discharge pressure, k...Figure 17.38 Horsepower characteristic curves for constant suction pressure, k =...Figure 17.39 Automatic cylinder unloading (used by permission: Worthington Bul. ...Figure 17.40A Five-step clearance pocket control for compressor unloading (used ...Figure 17.40B Five-step control for compressor unloading (used by permission: Wo...Figure 17.41A Fixed volume clearance pockets (used by permission: Worthington Bu...Figure 17.41B Variable volume clearance pockets (used by permission: Worthington...Figure 17.42A Pneumatically operated clearance bottle (used by permission: Bul. ...Figure 17.43 Compressor cylinder performance curve for unloading conditions.Figure 17.44A Single-stage horizontal compressor (used by permission: Dresser-Ra...Figure 17.44B Two-stage angle-type vertical compressor (used by permission: Dres...Figure 17.44C Two-stage horizontal duplex compressor (used by permission: Dresse...Figure 17.45 Typical air compressor performance, single and two-stage (adapted a...Figure 17.46 Air properties compression chart (used by permission: Rice, W. T., ...Figure 17.47 Benefits of interstage cooling for air compression system (used by ...Figure 17.48 Work associated with three types of air compression (used by permis...Figure 17.49 Moisture as precipitated by aftercoolers (used by permission: Bul. ...Figure 17.50A Internal construction features of multistage centrifugal compresso...Figure 17.50B Construction features of multistage centrifugal compressor (used b...Figure 17.50C Single-stage gas compressor with integrally geared drive shaft (us...Figure 17.50D Oil-free air compressor with two impellers, Elliot Company. “Plant...Figure 17.51A Centrifugal compressor case types. These usually apply to multista...Figure 17.51B Flow path arrangements: Compound flow (used by permission: Bul. 42...Figure 17.51C Flow path arrangements: Sidestream flow (used by permission: Bul. ...Figure 17.51D Flow path arrangements: Back-to-Back flow (used by permission: Bul...Figure 17.51E Barrel type compressor section, horizontal mounting (used by permi...Figure 17.52 Single impeller centrifugal blower (used by permission: Elliot® Com...Figure 17.53 Results of internal chlorine gas fire and extensive corrosion in ce...Figure 17.54A Multistage centrifugal compressor uncooled diaphragms for horizont...Figure 17.54B Diaphragms (used by permission: Bul. PROM 526/15/95, © S.pA. Nuovo...Figure 17.55A Water-cooled diaphragm (used by permission: Dresser-Rand Company).Figure 17.55B Single stage centrifugal compressor with variable inlet vanes, dia...Figure 17.56 Labyrinth seals (used by permission: Dresser-Rand Company).Figure 17.57A Impeller with milled vanes on solid disc forging (used by permissi...Figure 17.57B A special design riveted wheel, used only on small wheels where we...Figure 17.57C Cutaway of riveted wheel. Blades are riveted to hub disc, and the ...Figure 17.57D Part 1. View toward inlet of 4½ in. diameter brazed aluminum impel...Figure 17.57D Part 2. Close-up welding of section of welded impeller (used by pe...Figure 17.57E Radial impeller for single stage compressor (used by permission: A...Figure 17.57F Open radial blade impeller, Type “R” (used by permission: Bul. “Ce...Figure 17.57G Open impeller with backward-leaning blades, Type “SR” (used by per...Figure 17.57H Advanced datum impeller design reduces operating stresses and impr...Figure 17.57I Part 1. Impeller geometry versus flow y, dimensionless to define t...Figure 17.57I Part 2. The graph shows the influence of the flow coefficient, Φ o...Figure 17.57 Part 3. Stage performance of a compressor is usually represented in...Figure 17.58 Gas flow through inlet guide vanes; power wheel shows a head of fir...Figure 17.59A Inlet prerotation vanes (used by permission: York International).Figure 17.59B Single stage blower with automatically controlled inlet vanes (use...Figure 17.60A Kingsbury-type thrust bearing (used by permission: Elliot® Company...Figure 17.60B Kingsbury-type thrust bearing for centrifugal compressor (used by ...Figure 17.61A Centrifugal compressor auxiliaries–forced feed lubrication system ...Figure 17.61B A forced feed lube system ensures that journal and thrust bearings...Figure 17.61C The seal of oil system filtered oil to the liquid film rings or to...Figure 17.61D A photograph of a turbine for the crude distillation unit.Figure 17.62A Multistage centrifugal compressor shaft seal arrangements (used by...Figure 17.62B Shaft seal options (used by permission: Bul. 2781005301, © 1988. A...Figure 17.63 (A) Straight-pass labyrinth seal; (B) staggered labyrinth seal; (C)...Figure 17.64 Packing box arrangement.Figure 17.65 Mechanical wet contact type seal (used by permission: Elliot® Compa...Figure 17.66 Liquid film seal (used by permission: Elliot® Company).Figure 17.67 Estimates of process gas seal leakage using nitrogen as sealing gas...Figure 17.68 Centrifugal compressor specifications.Figure 17.69 Generalized centrifugal compressor pressure–capacity chart for vert...Figure 17.70 Performance ranges for special high-speed/high pressure, single-sta...Figure 17.71 Compressor in a centrifugal machine.Figure 17.72 Manufacturer’s typical centrifugal compressor characteristic curve.Figure 17.72A Typical performance map of centrifugal compressor (used by permiss...Figure 17.72B Performance examination of one set of centrifugal compressor condi...Figure 17.72C Performance examination of a second set of centrifugal compressor ...Figure 17.72D Centrifugal compressor surge control schematic diagram shows instr...Figure 17.72E Control system monitors discharge pressure and flow to prevent sur...Figure 17.73 Representative centrifugal compressor performance with inlet guide ...Figure 17.74 Ratio of specific heats (n − 1)/n (used by permission: Dresser-Rand...Figure 17.75 Specific volume chart (used by permission: © Elliot Co.).Figure 17.76 Relationship between adiabatic and polytropic efficiencies (used by...Figure 17.76A Polytropic to adiabatic efficiency conversion (used by permission:...Figure 17.77 Comparative efficiencies of a 1550 bhp centrifugal compressor based...Figure 17.78 Approximate head selection (used by permission: Elliot® Co.).Figure 17.79 Brake horsepower per million ft³ per day for compressors as a funct...Figure 17.80 Correction factor for compressor bhp/million ft³ per day at 14.7 ps...Figure 17.81 Entropy–temperature diagrams help to solve compression work problem...Figure 17.81A Basic concepts for solutions using the Mollier diagram of a specif...Figure 17.81B Typical mechanical losses for seals on shafts of centrifugal compr...Figure 17.82 Polytropic compressor discharge temperature (used by permission: El...Figure 17.83 Sonic velocity of common gases (used by permission: Koenig, C. F.II...Figure 17.84 Centrifugal compressor size versus capacity (used by permission: Dr...Figure 17.85 Compression ratio versus number of impellers; uncooled compression ...Figure 17.86 Peripheral velocity or impeller tip speed versus head per impeller ...Figure 17.87 Uncooled compressor relationship between adiabatic efficiency and p...Figure 17.88 Reciprocating compressor efficiencies.Figure 17.89 The Simulation Basis Manager window of UniSim Design R451 (courtesy...Figure 17.90 Component List View Component List-1 of UniSim Design R451 (courtes...Figure 17.91 Fluid Package of UniSim Design R451 (courtesy, Honeywell Process So...Figure 17.92 Composition tab of Worksheet window of UniSim Design R451 (courtesy...Figure 17.93 Connection tab of Compressor of UniSim Design R451 (courtesy, Honey...Figure 17.94 Parameter tab of Design of Compressor of UniSim Design R451 (courte...Figure 17.95 Conditions page of Worksheet tab of Design of Compressor of UniSim ...Figure 17.96 Worksheet tab of UniSim Design R451 (courtesy, Honeywell Process So...Figure 17.97 PFD of UniSim Design R451 (Honeywell® and UniSim® are registered tr...Figure 17.98 Schematic flow diagram of a two-phase compression process.Figure 17.99 Worksheet window of the adiabatic flash vessel showing fraction of ...Figure 17.100 Worksheet window of the pump P.101 showing pump power of 7274 kJ/h...Figure 17.101 Worksheet window of the compressor C1 showing compressor power of ...Figure 17.102 Worksheet window of the Cooler E-1 showing the duty of 3.079 × 10⁵...Figure 17.103 Process flow diagram of the two-phase compression simulation (cour...Figure 17.104 Stream information in the compressor connection of the Design page...Figure 17.105 Specifying compressor adiabatic efficiency in the connection of th...Figure 17.106 Calculated results in the Worksheet page of the simulated compress...Figure 17.107 Process flow diagram of Example 17.14 (courtesy, Honeywell Process...Figure 17.108 Process flow diagram of the two-stage compression of natural gas.Figure 17.109 Screen shot of the Connection Tab of Recycle RCY-1 (courtesy, Hone...Figure 17.110 Screen shot of the Parameters Tab in the Connection page (courtesy...Figure 17.111 Screen shot of The Numerical Page containing the numerical options...Figure 17.112 Screen shot of the Monitor page (courtesy, Honeywell Process Solut...Figure 17.113 Process flow diagram of the two-stage compression of natural gas (...Figure 17.114 Compressor performance curve, head reduction (source: Scott Golden...Figure 17.115 Compressor and connected system.Figure 17.116 Suction pressure vs. wet gas production (source: Scott Golden, et ...Figure 17.117 Suction temperature vs. wet gas production (source: Scott Golden, ...Figure 17.118 Basic horsepower for a machine with intake of 14.5 psia, with “k” ...Figure 17.119 “k” value correction factor (used by permission: Cole, S. L., Oil ...Figure 17.120 Basic head for machine with “k” value for air (1.396), molecular w...Figure 17.121 Temperature rise multiplier (used by permission: Cole, S. L., Oil ...Figure 17.122 Compressor speed in rpm (used by permission: Cole, S. L., Oil and ...Figure 17.123 Effect of changing inlet conditions on performance curves. Fixed o...Figure 17.124 Relative effects of inlet temperature change on head and horsepowe...Figure 17.125 Relative effects of inlet gas specific gravity change on head and ...Figure 17.126 Effect of gas system flow resistance on comparative performance in...Figure 17.127 System operation of variable speed centrifugal compressor.Figure 17.128 Typical effects of capacity control on horsepower for centrifugal ...Figure 17.129 Changing characteristics with variable speed.Figure 17.130 Simplified multilevel refrigeration process; an example of three d...Figure 17.131 Effects of 2% and 5% “Head Rise To Surge” (HRTS) (used by permissi...Figure 17.132 Effects on inlet pressure for HRTS variations (constant speed driv...Figure 17.133 Comparison of the energy potential of turboexpanders versus thrott...Figure 17.134 Section of ethane, pressure-enthalpy diagram illustrating five exp...Figure 17.135 Typical geared-turbine-driven axial flow compressor unit (used by ...Figure 17.136 Cross section of typical nine-stage axial flow compressor (used by...Figure 17.137 Axial compressor Type AV 100-16, during erection. Note stationary ...Figure 17.138 Stator blade control mechanism on four-stage axial compressor (use...Figure 17.139 Axial rotor assembly (used by permission: A. C. Compressor Corpora...Figure 17.140 Performance of axial compressor at various speeds (used by permiss...Figure 17.141 Stable volume range extended by stator blade control (used by perm...Figure 17.142 Pressure – capacity characteristic compression of an axial compres...Figure 17.143 General axial flow compressor performance for typical 100 psia air...Figure 17.144 Speed comparison between axial and centrifugal compressor (used by...Figure 17.145A Functional operational schematic of Nash liquid ring compressor (...Figure 17.145B A partly disassembled Nash liquid ring compressor view shows the ...Figure 17.145C In a compound pump, the gas is compressed in two stages. First, t...Figure 17.146 Liquid ring compressor as gas compressor (used by permission: Nash...Figure 17.147 Automatic operating of primer by pressure control (used by permiss...Figure 17.148 Lobe-type blower construction (used by permission: Sutorbilt Corp....Figure 17.149 Operating principle for two-lobe blowers (used by permission: Bul....Figure 17.149A Roots Whispair ® Blower principle (used by permission: Bul. B-05 ...Figure 17.150 Typical performance curve for lobe-type blower (used by permission...Figure 17.151 Typical performance curve for variable-speed operation for lobe-ty...Figure 17.152A A typical cross-section showing the spiral screw rotors, lubricat...Figure 17.152B Type H Axi ® Helical Rotor positive displacement compressor. Appl...Figure 17.152C Exploded view of a screw compressor (used by permission: Price, B...Figure 17.152D Rotor set for oil-free rotary screw compressor (used by permissio...Figure 17.152E Type L Axi ® Helical rotor assembly and rotation details (used by...Figure 17.153 Typical constant-speed performance of spiral screw rotor compresso...Figure 17.154 Performance characteristics for a typical single-stage rotary heli...Figure 17.155 Typical test results of a medium-capacity spiral lobe compressor v...Figure 17.156 Cross-section of sliding-vane rotary compressor (used by permissio...Figure 17.157 Coupling drive end of Ro-Flo Sliding Vane compressor showing vanes...Figure 17.157A Performance curves for rotary-vane compressor (used by permission...Figure 17.158A Screw compressor in Howden process gas package (used by permissio...Figure 17.158B Rotary twin screw compressor (used by permission: Howden).Figure 17.158C Screw compressor (used by permission: Howden).Figure 17.158D Single screw rotor forces (source: Mark McCormick).Figure 17.158E Single screw compressor (source: Mark McCormick).Figure 17.159A General cutaway of integrally geared compressor (source: Wehrman,...Figure 17.159B General cutaway of integrally geared compressor (source: Wehrman,...Figure 17.159C Oxygen compressor, integrally geared design (source: Wehrman, Jos...Figure 17.159D Steam turbine driven integrally geared compressor with gearbox (s...Figure 17.159E Integrally geared compressor with pinion drive direct from steam ...Figure 17.160 Diaphragm gas compressor. Gas remains oil-free capable of handling...Figure 17.161 Motion of the displacing element causes the diaphragm to move into...Figure 17.162 Evolution of impeller performance (source: Renard, D.).Figure 17.163A Refrigeration compressor with multiple side streams (source: Rena...Figure 17.163B Typical compressor component upgrades.Figure 17.163C Typical steam turbine component upgrades (source: Renard, D.).Figure 17.164A Reciprocating compressor with ruptured water jacket (source: Roy ...Figure 17.164B Close-up of ruptured water jacket on compressor (source: Roy Sand...Figure 17.165 Compressor suction line arrangement [112].Figure 17.166 Correct suction volume bottle arrangement of a compressor [112].Figure 17.167 Existing suction piping of the compressor [112].

5 Glossary of Petroleum and Technical TerminologyFigure 1 (a) A plot of °API vs. specific gravity of hydrocarbons compounds. (b) ...Figure 2 ALARP determination process overview. DEP = Design Engineering...Figure 3 Distribution of fluid energy in a pipeline.Figure 4 The Bow-Tie – Analysis.Figure 5 A Bubble cap tray.Figure 6 A consequence.Figure 7 Moody diagram.Figure 8 Diagram of a fire triangle.Figure 9 (a)Flow patterns for horizontal two-phase flow (Based on data from 1, 2...Figure 10 Coal.Figure 11 Economic efficiency of fossil fuel usage.Figure 12 TBP and gravity – mid percent curves.Figure 13 A hazard.Figure 14 Diagram of a cylinder as found in 4-stroke gasoline engines.Figure 15Figure 16Figure 17Figure 18Figure 19 Orifice Meter with Vena contracta formation.Figure 20 Phase diagram (Phase Envelope).Figure 21 The plus-minus principle guides process design to reduce utility consu...Figure 22 Piping and instrumentation diagram.Figure 23 Lockhart-Martinelli two-phase multiplier.Figure 24 Relief valve Safety valve.Figure 25 Process flow diagram (Feed and fuel desulfurization section).Figure 26 This new process design work process implements process integration ef...Figure 27 Process integration starts with the synthesis of a process to convert ...Figure 28 General service centrifugal pump.Figure 29 General service duplex steam-driven piston pump.Figure 30 (a) Reid vapor test gauge (b) Vapor pressure vs. temperature (c) Reid ...Figure 31 A shell and tube heat exchanger showing the direction of flow of fluid...Figure 32 A sieve plate.Figure 33Figure 34 Symbols of chemical apparatus and equipment.Figure 35 The Onion model (LOC = Loss of containment).Figure 36 A threat.Figure 37 Top event.Figure 38 A diaphragm valve.Figure 39 A gate valve.Figure 40 A globe valve away section of a globe valve.Figure 41 Plug valves Cutaway section of a plug valve.Figure 42 A Control valve.Figure 43 Relief valves.Figure 44 A valve tray.

6 Appendix DFigure D-1. Process Flow diagram (Feed & Fuel Desulfurization Section).Figure D-2. Typical process flow diagram for the production of Methyl Tertiary B...Figure D-3. Piping & Instrumentation diagram for Ammonia plant CO₂ removal.Figure D-4. Piping & Instrumentation flow diagram (Ammonia synthesis and refrige...