This document provides guidelines for hydraulic calculations and line sizing for process plants. It outlines the general approach to hydraulic calculations, including pressure drop criteria, equivalent lengths of valves and fittings, and flow regimes for vapor-liquid mixed phase flow. Tables with typical line sizing criteria are included for liquid, vapor, gas and two-phase flow lines. Special considerations and calculation methods are described for thermosyphon reboiler circuits, kettle reboiler circuits, pump NPSH, and vacuum tower transfer lines. Appendices provide references and additional tables and figures to support the guidelines.
Ai Ch E Overpressure Protection Trainingernestvictor
The document provides an overview of overpressure protection and relief system design. It discusses key concepts such as causes of overpressure, applicable codes and standards, the relief system design process, relief device terminology, and methods for determining relief loads from scenarios such as blocked outlets, thermal expansion, external fires, and automatic control failures. The document is intended to educate engineers on important considerations for properly sizing and designing pressure relief systems.
This document summarizes the key steps in designing liquid pipelines according to API 14E standards. It discusses important considerations like ensuring velocity is below 15 feet per second to avoid erosion and pressure drop is below 1 psi per 100 feet. The document then provides an example calculation for sizing a water pipeline using schedule 40 and 80 steel pipes. It determines that an 8-inch schedule 40 pipe meets both velocity and pressure drop requirements and has the lowest annual operating costs.
Safety is the most important factor in designing a process system. Some undesired conditions might happen leading to damage in a system. Control systems might be installed to prevent such conditions, but a second safety device is also needed. One kind of safety device which is commonly used in the processing industry is the relief valve. A relief valve is a type of valve to control or limit the pressure in a system by allowing the pressurised fluid to flow out from the system.
Here are the steps to model the structural steel support:
1. Add a structural steel material (e.g. A36)
2. Define steel sections (e.g. W8x10, W6x15)
3. Add steel elements between the pipe supports and ground
4. Specify the pipe support nodes as CNODEs for the steel elements
5. Run analysis
6. Check stresses in steel
7. Check effect on piping loads and stresses
This models the structural aspect of the supports and incorporates it into the full piping analysis. It allows evaluation of both the piping and support system.
The document summarizes key differences between the 5th and 6th editions of API-2000 standards for venting of atmospheric storage tanks. Some significant differences include:
- The 6th edition includes the EN 14015 venting model which can calculate higher venting loads than the API 2000 model.
- The 6th edition includes a new section on mitigating risks of internal deflagration in tanks.
- Recent experiments show flame propagation through pressure/vacuum valves is possible, inconsistent with statements in the 5th edition.
- Refrigerated tank venting requirements were re-written based on other standards instead of just hexane.
- New section provides consistency in testing venting device capacities
Excel sheet Download Link: https://www.scribd.com/document/385945712/PSV-Sizing-Tool-API-Based-Calc-Sheets
PSV Sizing for Blocked Liquid Discharge Condition
PSV Sizing for Blocked Gas Discharge Condition
PSV Sizing for Fire Case of Liquid Filled Vessel
PSV Sizing for Control Valve Fail Open Case
Relief Valve Sizing for Thermal Expansion
Restriction Orifice Sizing for Gas Flow
Restriction Orifice Sizing for Liquid Flow
Single Phase Flow Line Sizing Tool
Gas Control Valve Sizing Tool
CENTRIFUGAL COMPRESSOR SETTLE OUT CONDITIONS TUTORIALVijay Sarathy
Centrifugal Compressors are a preferred choice in gas transportation industry, mainly due to their ability to cater to varying loads. In the event of a compressor shutdown as a planned event, i.e., normal shutdown (NSD), the anti-surge valve is opened to recycle gas from the discharge back to the suction (thereby moving the operating point away from the surge line) and the compressor is tripped via the driver (electric motor or Gas turbine / Steam Turbine). In the case of an unplanned event, i.e., emergency shutdown such as power failure, the compressor trips first followed by the anti-surge valve opening. In doing so, the gas content in the suction side & discharge side mix.
Therefore, settle out conditions is explained as the equilibrium pressure and temperature reached in the compressor piping and equipment volume following a compressor shutdown
A reciprocating compressor uses pistons driven by a crankshaft to compress gases. It can operate from vacuum to very high pressures. The document discusses the key components of a reciprocating compressor system including cylinders, valves, coolers, pulsation suppression devices, piping, instrumentation, and controls. Process calculations like pipe sizing, blowdown analysis, and hydrate predictions are required. A process simulation and PFD provide design details. Capacity control methods include speed variation, clearance pockets, and suction unloaders.
Ai Ch E Overpressure Protection Trainingernestvictor
The document provides an overview of overpressure protection and relief system design. It discusses key concepts such as causes of overpressure, applicable codes and standards, the relief system design process, relief device terminology, and methods for determining relief loads from scenarios such as blocked outlets, thermal expansion, external fires, and automatic control failures. The document is intended to educate engineers on important considerations for properly sizing and designing pressure relief systems.
This document summarizes the key steps in designing liquid pipelines according to API 14E standards. It discusses important considerations like ensuring velocity is below 15 feet per second to avoid erosion and pressure drop is below 1 psi per 100 feet. The document then provides an example calculation for sizing a water pipeline using schedule 40 and 80 steel pipes. It determines that an 8-inch schedule 40 pipe meets both velocity and pressure drop requirements and has the lowest annual operating costs.
Safety is the most important factor in designing a process system. Some undesired conditions might happen leading to damage in a system. Control systems might be installed to prevent such conditions, but a second safety device is also needed. One kind of safety device which is commonly used in the processing industry is the relief valve. A relief valve is a type of valve to control or limit the pressure in a system by allowing the pressurised fluid to flow out from the system.
Here are the steps to model the structural steel support:
1. Add a structural steel material (e.g. A36)
2. Define steel sections (e.g. W8x10, W6x15)
3. Add steel elements between the pipe supports and ground
4. Specify the pipe support nodes as CNODEs for the steel elements
5. Run analysis
6. Check stresses in steel
7. Check effect on piping loads and stresses
This models the structural aspect of the supports and incorporates it into the full piping analysis. It allows evaluation of both the piping and support system.
The document summarizes key differences between the 5th and 6th editions of API-2000 standards for venting of atmospheric storage tanks. Some significant differences include:
- The 6th edition includes the EN 14015 venting model which can calculate higher venting loads than the API 2000 model.
- The 6th edition includes a new section on mitigating risks of internal deflagration in tanks.
- Recent experiments show flame propagation through pressure/vacuum valves is possible, inconsistent with statements in the 5th edition.
- Refrigerated tank venting requirements were re-written based on other standards instead of just hexane.
- New section provides consistency in testing venting device capacities
Excel sheet Download Link: https://www.scribd.com/document/385945712/PSV-Sizing-Tool-API-Based-Calc-Sheets
PSV Sizing for Blocked Liquid Discharge Condition
PSV Sizing for Blocked Gas Discharge Condition
PSV Sizing for Fire Case of Liquid Filled Vessel
PSV Sizing for Control Valve Fail Open Case
Relief Valve Sizing for Thermal Expansion
Restriction Orifice Sizing for Gas Flow
Restriction Orifice Sizing for Liquid Flow
Single Phase Flow Line Sizing Tool
Gas Control Valve Sizing Tool
CENTRIFUGAL COMPRESSOR SETTLE OUT CONDITIONS TUTORIALVijay Sarathy
Centrifugal Compressors are a preferred choice in gas transportation industry, mainly due to their ability to cater to varying loads. In the event of a compressor shutdown as a planned event, i.e., normal shutdown (NSD), the anti-surge valve is opened to recycle gas from the discharge back to the suction (thereby moving the operating point away from the surge line) and the compressor is tripped via the driver (electric motor or Gas turbine / Steam Turbine). In the case of an unplanned event, i.e., emergency shutdown such as power failure, the compressor trips first followed by the anti-surge valve opening. In doing so, the gas content in the suction side & discharge side mix.
Therefore, settle out conditions is explained as the equilibrium pressure and temperature reached in the compressor piping and equipment volume following a compressor shutdown
A reciprocating compressor uses pistons driven by a crankshaft to compress gases. It can operate from vacuum to very high pressures. The document discusses the key components of a reciprocating compressor system including cylinders, valves, coolers, pulsation suppression devices, piping, instrumentation, and controls. Process calculations like pipe sizing, blowdown analysis, and hydrate predictions are required. A process simulation and PFD provide design details. Capacity control methods include speed variation, clearance pockets, and suction unloaders.
Sizing of relief valves for supercritical fluidsAlexis Torreele
The document provides an overview of Jacobs, an engineering company, and discusses their approach to sizing relief valves for supercritical fluids. It then presents a case study example of calculating the relief requirements for a vessel containing methane undergoing an external fire. The key steps involve: (1) gathering process data; (2) determining heat input from the fire; (3) calculating fluid properties as temperature increases; (4) determining mass and volume relief rates; (5) calculating choked flow rates; and (6) sizing the required relief valve orifice. The example demonstrates that relief of supercritical fluids can involve complex two-phase flow that requires specialized modeling approaches.
Single Phase Liquid Vessel Sizing for HYSYS DynamicsVijay Sarathy
Process Facilities often have intermediate storage facilities that store liquids prior to transporting to downstream equipment. The period of storage is short, i.e., of the order of minutes to hours & is defined as Holdup time. The Holdup time can also be explained as the reserve volume required to ensure safe & controlled operation of downstream equipment.
The intermediate vessel also acts as a buffer vessel to accommodate any surge/spikes in flow rates, and is termed as surge time.
Vessel Volume is an input data required in Process Dynamic Simulation and the following exercise covers estimation of volume required for single phase liquid flow into an intermediate vertical/horizontal/flat bottomed process vessel
Basics of two phase flow (gas-liquid) line sizingVikram Sharma
This document discusses two-phase flow line sizing for liquid-gas flows in piping systems. It describes the different flow regimes that can occur using Baker's flow regime map. The key steps outlined are: 1) determining the flow regime based on fluid properties and flow rates, 2) calculating pressure drops for the liquid and gas phases separately using correlations, 3) using a multiplier to determine the two-phase pressure drop based on the flow regime, and 4) summing pressure drops from friction, elevation changes, and fittings to obtain the total pressure drop. Care must be taken to size each pipe segment separately as properties and regimes can change along the line.
Heat exchanger: Shell And Tube Heat ExchangerAkshay Sarita
The document discusses shell and tube heat exchangers. It describes the basic heat transfer equation and dimensionless numbers used. Shell and tube heat exchangers are relatively inexpensive, compact, and can be designed for high pressures. They have fixed tube sheets, U-tubes, or floating heads. Components include shells, tubes, baffles, and tube sheets. Design considerations include materials, fluids, temperatures, pressures, and flow rates. Standards like TEMA provide guidelines for mechanical design and fabrication.
Here's a presentation on piping engineering in PDF format, now available for all. This presentation covers the basics points of piping for our EPC industry. This presentation covers various aspects of piping engineering
The document provides an introduction to Piping Material Specifications (PMS). It discusses that PMS gives details about all piping components, including material details, dimensions, connection types, applicable codes and standards. It is generated by the piping engineering team. PMS is used to define and specify piping components on piping and instrumentation diagrams. Each pipe class listed in the PMS includes material specifications, dimensions, ratings and other details for items like pipes, flanges, fittings and valves. New piping classes are developed in job-specific PMS documents based on project requirements.
This document provides an overview of early sizing considerations for pressure safety valves (PSVs). It defines important terminology related to PSVs and describes the types and operating principles of conventional, balanced bellow, and pilot-operated PSVs. The document outlines the procedure for early PSV sizing, including identifying capacity requirements, applicable standards, and inter-discipline interfaces. It also notes lessons learned regarding material selection and potential failure modes of bellow-type PSVs.
Three phase separators separate gas, oil, and water. They consist of three zones: an inlet zone, a liquid-liquid settling zone, and a gas-liquid separation zone. Key factors that affect separator efficiency include the inlet flow pattern and devices, feed pipe geometry, entrainment, and internals. Separators can be horizontal or vertical, with horizontal separators often used for foamy streams and liquid-liquid separation, while vertical separators handle large liquid slugs. Proper sizing considers flow rates, residence times, velocities, and droplet sizes to achieve efficient phase separation with minimum carryover.
Accumulation and Over-pressure: difference between accumulation and overpressureVarun Patel
Accumulation is pressure above the maximum allowable working pressure that vessel experience during high pressure event. Hence, when we say ‘accumulation’, its mean we are talking about the vessel or equipment.
On the other hand, Overpressure is pressure above the set pressure of the pressure safety valve that PSV experience during high pressure event. Hence, when we say ‘accumulation’, its mean we are talking about the pressure relief valve.
This document provides an index of pipe support standard specifications for an FPSO. It lists over 100 different pipe support components, each assigned an identification code. For each component, the index specifies the sheet number, revision, description, and indicates whether it is new, existing standard (CES), or has been modified. The components include axial stops, braces, base plates, brackets, base supports, guides, pipe clamps, pipe shoes, and straps to support various types of pipes.
Heat exchangers are devices that transfer thermal energy between two or more fluids at different temperatures. The document discusses several types of heat exchangers including shell and tube, plate, air cooled, and spiral. It covers their basic designs, components, functions, applications, maintenance requirements, and classifications such as counterflow or parallel flow configurations. Selection of heat exchangers depends on factors like temperature ranges, pressure limits, flow capacities, and materials required.
This document discusses simulation of an aspen flare system using Aspen Flare System Analyzer software. It describes defining the composition, flare network scheme, sources such as control valves and pressure safety valves, and scenarios to simulate, such as all relief devices activating. The outcomes of the simulation can be used to design and verify the flare header size and other parameters meet API standards. The simulation aims to size the flare system and verify its performance under different operating conditions.
This document provides design considerations and parameters for fired heaters. It discusses considerations for the radiant and convection sections such as flux levels, heat release, and tube dimensions. It also covers the design of stacks, fans, burners, air preheaters, sootblowers, dampers, instrumentation and refractories. The key parameters for selection and design of these heater components are specified.
Parts of shell and tube heat exchanger
Shell
Shell Side Pass Partition Plate
Baffles
Tube
Tube Side Pass Partition Plate
Tie Rods
Spacers
Tube Sheet
Expansion Joint
This document discusses the process design of shell and tube heat exchangers. It begins by classifying heat exchangers and describing different types of shell and tube heat exchangers such as fixed tube sheet, removable tube bundle, floating head, and U-tube designs. The document then discusses various thermal design considerations for shell and tube heat exchangers, including selections for the shell, tube materials and dimensions, tube layout and count, baffles, and fouling factors. It provides process design procedures and an example problem for designing shell and tube heat exchangers.
A heat exchanger transfers heat between two fluids. There are various types including shell and tube, plate and frame, and air cooled. A shell and tube heat exchanger consists of tubes, a shell, baffles, and nozzle inlets and outlets. Proper design of the baffle cut, spacing, and orientation is important for efficient heat transfer and to prevent bypass and leakage streams from reducing effectiveness. Sealing strips are also used to block leakage paths and improve performance.
Shell & tube heat exchanger single fluid flow heat transferVikram Sharma
This article was produced to highlight the fundamentals of single-phase heat exchanger rating using Kern's method. The content is strictly academic with no reference to industrial best practices.
Calculation of Maximum Flow of Natural Gas through a Pipeline using Dynamic S...Waqas Manzoor
This process report highlights the significance of Dynamic Simulation in Aspen HYSYS for calculation of maximum flow rate of natural gas through a pipeline supplying gas to domestic consumers. The gas pressure at the outlet of pipeline has been considered to be equal to 0 psig in order to calculate the maximum possible gas flow rate. Moreover, the reduction of gas pressure at upstream of gas regulating station due to increased downstream pressure has also been calculated using this simulation.
A heat exchanger transfers heat between two fluids through tube walls. There are two main types: tubular and extended surface. Tubular exchangers include shell-and-tube, U-tube, and double pipe designs. Shell-and-tube exchangers contain tubes in a shell separated by baffles to direct flow. Heat is transferred through the tube walls from one fluid inside the tubes to the other outside. Manufacturing involves forming, welding, inspection, assembly, testing, and documentation. Materials, design, fabrication, and testing must meet codes and standards.
IRJET- Design and Performance Curve Generation by CFD Analysis of Centrifugal...IRJET Journal
This document discusses the design and CFD analysis of a centrifugal pump to generate performance curves. A team of students and professors used software like Pro-E, ANSYS, and CFX to design the impeller and volute casing of the pump, generate meshes, and perform the CFD analysis. The CFD analysis provides pressure distributions and helps optimize the design to reduce cavitation and improve efficiency over a range of operating conditions. Performance curves showing head, power, and efficiency versus flow rate will be plotted to evaluate the pump design and aid in pump selection.
Study of Time Reduction in Manufacturing of Screws Used in Twin Screw PumpIJMERJOURNAL
ABSTRACT: This paper gives the characteristics of Time reduction in manufacturing of screws for Twin screw pumps. Screws are playing a vital role in the performance of pumps, because pumps give the fluids transfer rate with the help of screws. There is a gap in screws which shows its positiveness. This indicates that we are studying about positive displacements pumps. Positive displacements pumps having no point of contact between screws, because of that there will be no any friction formation. Automation is best for development of product to reduce time in manufacturing of any product. In this paper we also tried to explain this feature of Automation to help reduction of time to manufacture of product to increase productivity.
Sizing of relief valves for supercritical fluidsAlexis Torreele
The document provides an overview of Jacobs, an engineering company, and discusses their approach to sizing relief valves for supercritical fluids. It then presents a case study example of calculating the relief requirements for a vessel containing methane undergoing an external fire. The key steps involve: (1) gathering process data; (2) determining heat input from the fire; (3) calculating fluid properties as temperature increases; (4) determining mass and volume relief rates; (5) calculating choked flow rates; and (6) sizing the required relief valve orifice. The example demonstrates that relief of supercritical fluids can involve complex two-phase flow that requires specialized modeling approaches.
Single Phase Liquid Vessel Sizing for HYSYS DynamicsVijay Sarathy
Process Facilities often have intermediate storage facilities that store liquids prior to transporting to downstream equipment. The period of storage is short, i.e., of the order of minutes to hours & is defined as Holdup time. The Holdup time can also be explained as the reserve volume required to ensure safe & controlled operation of downstream equipment.
The intermediate vessel also acts as a buffer vessel to accommodate any surge/spikes in flow rates, and is termed as surge time.
Vessel Volume is an input data required in Process Dynamic Simulation and the following exercise covers estimation of volume required for single phase liquid flow into an intermediate vertical/horizontal/flat bottomed process vessel
Basics of two phase flow (gas-liquid) line sizingVikram Sharma
This document discusses two-phase flow line sizing for liquid-gas flows in piping systems. It describes the different flow regimes that can occur using Baker's flow regime map. The key steps outlined are: 1) determining the flow regime based on fluid properties and flow rates, 2) calculating pressure drops for the liquid and gas phases separately using correlations, 3) using a multiplier to determine the two-phase pressure drop based on the flow regime, and 4) summing pressure drops from friction, elevation changes, and fittings to obtain the total pressure drop. Care must be taken to size each pipe segment separately as properties and regimes can change along the line.
Heat exchanger: Shell And Tube Heat ExchangerAkshay Sarita
The document discusses shell and tube heat exchangers. It describes the basic heat transfer equation and dimensionless numbers used. Shell and tube heat exchangers are relatively inexpensive, compact, and can be designed for high pressures. They have fixed tube sheets, U-tubes, or floating heads. Components include shells, tubes, baffles, and tube sheets. Design considerations include materials, fluids, temperatures, pressures, and flow rates. Standards like TEMA provide guidelines for mechanical design and fabrication.
Here's a presentation on piping engineering in PDF format, now available for all. This presentation covers the basics points of piping for our EPC industry. This presentation covers various aspects of piping engineering
The document provides an introduction to Piping Material Specifications (PMS). It discusses that PMS gives details about all piping components, including material details, dimensions, connection types, applicable codes and standards. It is generated by the piping engineering team. PMS is used to define and specify piping components on piping and instrumentation diagrams. Each pipe class listed in the PMS includes material specifications, dimensions, ratings and other details for items like pipes, flanges, fittings and valves. New piping classes are developed in job-specific PMS documents based on project requirements.
This document provides an overview of early sizing considerations for pressure safety valves (PSVs). It defines important terminology related to PSVs and describes the types and operating principles of conventional, balanced bellow, and pilot-operated PSVs. The document outlines the procedure for early PSV sizing, including identifying capacity requirements, applicable standards, and inter-discipline interfaces. It also notes lessons learned regarding material selection and potential failure modes of bellow-type PSVs.
Three phase separators separate gas, oil, and water. They consist of three zones: an inlet zone, a liquid-liquid settling zone, and a gas-liquid separation zone. Key factors that affect separator efficiency include the inlet flow pattern and devices, feed pipe geometry, entrainment, and internals. Separators can be horizontal or vertical, with horizontal separators often used for foamy streams and liquid-liquid separation, while vertical separators handle large liquid slugs. Proper sizing considers flow rates, residence times, velocities, and droplet sizes to achieve efficient phase separation with minimum carryover.
Accumulation and Over-pressure: difference between accumulation and overpressureVarun Patel
Accumulation is pressure above the maximum allowable working pressure that vessel experience during high pressure event. Hence, when we say ‘accumulation’, its mean we are talking about the vessel or equipment.
On the other hand, Overpressure is pressure above the set pressure of the pressure safety valve that PSV experience during high pressure event. Hence, when we say ‘accumulation’, its mean we are talking about the pressure relief valve.
This document provides an index of pipe support standard specifications for an FPSO. It lists over 100 different pipe support components, each assigned an identification code. For each component, the index specifies the sheet number, revision, description, and indicates whether it is new, existing standard (CES), or has been modified. The components include axial stops, braces, base plates, brackets, base supports, guides, pipe clamps, pipe shoes, and straps to support various types of pipes.
Heat exchangers are devices that transfer thermal energy between two or more fluids at different temperatures. The document discusses several types of heat exchangers including shell and tube, plate, air cooled, and spiral. It covers their basic designs, components, functions, applications, maintenance requirements, and classifications such as counterflow or parallel flow configurations. Selection of heat exchangers depends on factors like temperature ranges, pressure limits, flow capacities, and materials required.
This document discusses simulation of an aspen flare system using Aspen Flare System Analyzer software. It describes defining the composition, flare network scheme, sources such as control valves and pressure safety valves, and scenarios to simulate, such as all relief devices activating. The outcomes of the simulation can be used to design and verify the flare header size and other parameters meet API standards. The simulation aims to size the flare system and verify its performance under different operating conditions.
This document provides design considerations and parameters for fired heaters. It discusses considerations for the radiant and convection sections such as flux levels, heat release, and tube dimensions. It also covers the design of stacks, fans, burners, air preheaters, sootblowers, dampers, instrumentation and refractories. The key parameters for selection and design of these heater components are specified.
Parts of shell and tube heat exchanger
Shell
Shell Side Pass Partition Plate
Baffles
Tube
Tube Side Pass Partition Plate
Tie Rods
Spacers
Tube Sheet
Expansion Joint
This document discusses the process design of shell and tube heat exchangers. It begins by classifying heat exchangers and describing different types of shell and tube heat exchangers such as fixed tube sheet, removable tube bundle, floating head, and U-tube designs. The document then discusses various thermal design considerations for shell and tube heat exchangers, including selections for the shell, tube materials and dimensions, tube layout and count, baffles, and fouling factors. It provides process design procedures and an example problem for designing shell and tube heat exchangers.
A heat exchanger transfers heat between two fluids. There are various types including shell and tube, plate and frame, and air cooled. A shell and tube heat exchanger consists of tubes, a shell, baffles, and nozzle inlets and outlets. Proper design of the baffle cut, spacing, and orientation is important for efficient heat transfer and to prevent bypass and leakage streams from reducing effectiveness. Sealing strips are also used to block leakage paths and improve performance.
Shell & tube heat exchanger single fluid flow heat transferVikram Sharma
This article was produced to highlight the fundamentals of single-phase heat exchanger rating using Kern's method. The content is strictly academic with no reference to industrial best practices.
Calculation of Maximum Flow of Natural Gas through a Pipeline using Dynamic S...Waqas Manzoor
This process report highlights the significance of Dynamic Simulation in Aspen HYSYS for calculation of maximum flow rate of natural gas through a pipeline supplying gas to domestic consumers. The gas pressure at the outlet of pipeline has been considered to be equal to 0 psig in order to calculate the maximum possible gas flow rate. Moreover, the reduction of gas pressure at upstream of gas regulating station due to increased downstream pressure has also been calculated using this simulation.
A heat exchanger transfers heat between two fluids through tube walls. There are two main types: tubular and extended surface. Tubular exchangers include shell-and-tube, U-tube, and double pipe designs. Shell-and-tube exchangers contain tubes in a shell separated by baffles to direct flow. Heat is transferred through the tube walls from one fluid inside the tubes to the other outside. Manufacturing involves forming, welding, inspection, assembly, testing, and documentation. Materials, design, fabrication, and testing must meet codes and standards.
IRJET- Design and Performance Curve Generation by CFD Analysis of Centrifugal...IRJET Journal
This document discusses the design and CFD analysis of a centrifugal pump to generate performance curves. A team of students and professors used software like Pro-E, ANSYS, and CFX to design the impeller and volute casing of the pump, generate meshes, and perform the CFD analysis. The CFD analysis provides pressure distributions and helps optimize the design to reduce cavitation and improve efficiency over a range of operating conditions. Performance curves showing head, power, and efficiency versus flow rate will be plotted to evaluate the pump design and aid in pump selection.
Study of Time Reduction in Manufacturing of Screws Used in Twin Screw PumpIJMERJOURNAL
ABSTRACT: This paper gives the characteristics of Time reduction in manufacturing of screws for Twin screw pumps. Screws are playing a vital role in the performance of pumps, because pumps give the fluids transfer rate with the help of screws. There is a gap in screws which shows its positiveness. This indicates that we are studying about positive displacements pumps. Positive displacements pumps having no point of contact between screws, because of that there will be no any friction formation. Automation is best for development of product to reduce time in manufacturing of any product. In this paper we also tried to explain this feature of Automation to help reduction of time to manufacture of product to increase productivity.
IRJET - Design and Fabrication of PVC Pipe Feeding and Cutting MachineIRJET Journal
The document describes the design and fabrication of a PVC pipe feeding and cutting machine. The machine uses a pneumatic system to automatically feed and cut PVC pipes. Key components include a base frame, pneumatic cylinders powered by a compressor, guide ways to control pipe movement, and a cutting tool. The machine is designed to efficiently cut PVC pipes with high accuracy and minimal waste by automating the feeding, clamping, and cutting processes. The design was created using CATIA V5 software. The pneumatic system and components work together to quickly and precisely cut PVC pipes to desired lengths.
This document provides installation requirements for flexible ducts. It discusses code references, installation restrictions, general installation guidelines, duct sizing and routing, supporting flexible ducts, and connecting, joining and splicing flexible ducts. Some key points include:
- Flexible ducts must be installed according to applicable NFPA codes and within the limitations of their listing.
- Ducts must have a minimum 1 duct diameter bend radius and be properly supported to prevent sagging. Excess duct length should not be used.
- Ducts must be sized properly taking into account friction losses from bends, fittings and compression. Equivalent lengths are used to account for these losses in sizing calculations.
- Flexible duct
IRJET- Computational Fluid Dynamic Analysis of Performance of Centrifugal Pum...IRJET Journal
This document describes a computational fluid dynamics (CFD) analysis of the performance of a centrifugal pump impeller on a cooling system. The study analyzes the design and performance of a centrifugal pump by changing the impeller blade angle using CFD software. The objectives are to perform CFD analysis of the impeller, study the effect of changing the impeller blade angle, develop an impeller design approach, optimize the design, and validate it through experiment and simulation. Various impeller blade angle combinations are simulated and the resulting pressures are recorded and analyzed. The results show how discharge is highly affected by flow velocity and how pressure varies for different impeller blade angles.
The document provides details about coil tubing operations for hydraulic fracturing conducted by Steffones K at Essar Oil Limited in India. It describes the key components of a coil tubing unit including the reel, control cabin, injector head and well control equipment. It also discusses coil tubing string design, bottom hole assembly design and the procedural analysis of fracturing operations using coil tubing. The aim of hydraulic fracturing and the process is briefly outlined.
Improving Energy Efficiency of Pumps and Fanseecfncci
Pumps and Fans are energy consuming equipment that can be found in almost all Industries. Therefore, it is important to check if they are running efficiently. This presentation give an overview about energy saving opportunities in pump and fan equipment. It was prepared in the context of energy auditor training in Nepal in the context of GIZ/NEEP programme. For further information go to EEC webpage: http://eec-fncci.org/
This document provides standard specifications for pipe, valves, and fittings for Andes Petroleum Ecuador Ltd. It outlines requirements for materials, fabrication, welding, inspection, testing, and identification. The specifications cover piping classes from ANSI 150 to 900 and include requirements for pipe, fittings, flanges, valves, and other components. The document has been revised 3 times, with the last revision in 2011 adding new material specifications and updating requirements throughout.
Structural Design and FEM Analysis of Bleeder in Steam Turbine CasingIRJET Journal
1) The document discusses the design and finite element analysis of a bleeder in a steam turbine casing. It provides calculations to determine the diameter of the bleeder pipe based on flow parameters.
2) A CAD model of the casing with integrated bleeder is generated and meshed. Boundary conditions representing pressure and displacement are applied for static structural analysis.
3) Von Mises stress, total deformation, and principal stresses are analyzed. Results show stresses and deformations within acceptable limits. Analysis of the full casing is also performed under pressure boundary conditions.
IRJET- Design and Analysis of Catalytic Converter of Automobile EngineIRJET Journal
This document summarizes a study on the design and analysis of a catalytic converter for an automobile engine. The researchers designed a baseline catalytic converter model using CAD software and analyzed it using computational fluid dynamics (CFD) to study the pressure and velocity distribution. They found high pressure losses and non-uniform flow distribution. Various modifications to the honeycomb structure diameter, thickness, and position as well as the inlet and outlet design were tested. The optimal design was found to have a centered inlet, conical inlets/outlets, and a honeycomb structure with 30mm holes positioned at the casing mid-length. This design showed improved uniform flow distribution and reduced pressure losses compared to the baseline design.
This document provides technical specifications for particulate filters (CPF-20 and CPF-80) that remove mists and particulates from compressed breathing air for one to four operators. The CPF filters feature a pressure regulator, mounting options, and replaceable filter cartridges that last up to three months. They are used between a compressed air source and respirator to clean the air before it reaches the respirator.
This document appears to be a catalogue from Super Seal Flexible Hose Limited listing their various hose products and specifications. It includes an index of contents which lists various hose series for applications like hydraulic, steam, liquefied petroleum gas, fuel dispensing, and more. It also includes sections about the company's infrastructure, SAE recommended practices for hose selection and installation, factors that affect hose service life, and how to analyze hose failures.
IRJET- CFD Flow Analysis of Station PipelineIRJET Journal
This document summarizes a study analyzing the pressure, temperature, and velocity profiles within a station pipeline carrying fuel from booster pumps to a sample point, using computational fluid dynamics (CFD). Three cases were analyzed representing different operating conditions of the booster pumps. The CFD model was developed in ANSYS and divided into two parts due to software limitations. Results showed the pathlines for pressure, temperature, and velocity within the pipeline for each case. Overall, the study used CFD to better understand fuel flow characteristics within the station pipeline under various pump operating scenarios.
IRJET- CFD Simulation and Analysis of Fluid Flow through Concentric Reducer P...IRJET Journal
This document summarizes a study that used computational fluid dynamics (CFD) to simulate and analyze fluid flow through concentric reducer pipe fittings. 3D models of concentric reducers with heights of 178mm, 203mm, and 330mm were created in SolidWorks and ANSYS. CFD analysis was performed in ANSYS Fluent to obtain results like static pressure, velocity, turbulent kinetic energy, and wall shear stress. The analysis found that a reducer height of 203mm produced the best results with optimal pressure and velocity distributions. In general, a shorter reducer height increased inlet pressure while a taller height increased pressure on the pipe walls. This analysis can help optimize reducer selection for industrial piping systems.
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CoVID-19 sprang up in Wuhan China in November 2019 and was declared a pandemic by the in January 2020 World Health Organization (WHO). Like the Spanish flu of 1918 that claimed millions of lives, the COVID-19 has caused the demise of thousands with China, Italy, Spain, USA and India having the highest statistics on infection and mortality rates. Regardless of existing sophisticated technologies and medical science, the spread has continued to surge high. With this COVID-19 Management System, organizations can respond virtually to the COVID-19 pandemic and protect, educate and care for citizens in the community in a quick and effective manner. This comprehensive solution not only helps in containing the virus but also proactively empowers both citizens and care providers to minimize the spread of the virus through targeted strategies and education.
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line sizing-mustang.pdf
1. DG-PPG-0110
Document No.
Process Plants Process Design
Guidelines: Hydraulics and Line Sizing
Department Guidelines
Rev. 0
REVISION and APPROVALS
Rev. Date Description By Approved
0 01JUL04 Initial Issue JAP EP
This document is the sole and exclusive property of Mustang, including all patented and patentable features and/or
confidential information contained herein. Its use is conditioned upon the user's agreement not to: (i) reproduce the
document, in whole or in part, nor the material described thereon; (ii) use the document for any purpose other than as
specifically permitted in writing by Mustang; or (iii) disclose or otherwise disseminate or allow any such disclosure or
dissemination of this document or its contents to others except as specifically permitted in writing by Mustang. "Mustang" as
used herein refers to Mustang Engineering Holdings, Inc. and its affiliates.
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2. DG-PPG-0110
Document No.
MUSTANG
Process Plants Process Design Guidelines:
Hydraulics and Line Sizing Rev. 0
TABLE OF CONTENTS
1.0 SCOPE..........................................................................................................................................3
2.0 HYDRAULICS CALCULATION....................................................................................................3
2.1 Pressure Drop Criteria.......................................................................................................3
2.2 Equivalent Length of Valves and Fitting ............................................................................3
2.3 Flow Regimes of Vapor-Liquid Mixed Phase Flow............................................................3
3.0 LINE SIZING CRITERIA ...............................................................................................................3
4.0 PRELIMINARY ESTIMATE OF EQUIVALENT LENGTH ............................................................4
4.1 Pump Discharge and Compressor Circuit .........................................................................4
4.2 Reboiler Inlet or Return Lines............................................................................................5
4.3 Pump Suction Line from Drums or Tower Bottoms ...........................................................5
5.0 SPECIAL HYDRAULICS CALCULATIONS.................................................................................5
5.1 Thermosyphon Reboiler Circuits .......................................................................................5
5.2 Kettle Reboiler Circuits......................................................................................................6
5.3 Pump NPSH and Pump Hydraulics Calculations ..............................................................6
5.4 Vacuum Tower Transfer Line Sizing .................................................................................6
APPENDICES...........................................................................................................................................8
Appendix A: References ..............................................................................................................8
Appendix B: Tables......................................................................................................................9
Table 1 - Liquid Flow Line Sizing Criteria....................................................................................10
Table 2 - Vapor and Gas Flow Line Sizing Criteria .....................................................................11
Table 3 - Two Phase Flow Line Sizing Criteria ...........................................................................12
Appendix C: Figures...................................................................................................................14
Figure 1 - Baker Chart, Flow Regimes of Two Phase Flow in Horizontal Pipes .........................15
Figure 2 - Aziz Chart, Flow Regimes of Two Phase Up-Flow in Vertical Pipes ..........................16
Figure 3 - Thermosyphon Reboiler Circuit Hydraulic Calculations..............................................17
Figure 4 - Kettle Type Reboiler Circuit Hydraulic Calculations....................................................19
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3. DG-PPG-0110
Document No.
MUSTANG
Process Plants Process Design Guidelines:
Hydraulics and Line Sizing Rev. 0
1.0 SCOPE
This section outlines the general guidelines for hydraulic calculation of piping systems. It is
intended to provide a consistent approach to hydraulic calculations as performed by Process
Engineers / Technical Professionals, but not to cover every special case one may encounter.
Guidelines for calculating pressure drop through equipment such as trays, packings and
reactors are included in other guidelines.
2.0 HYDRAULICS CALCULATION
Mustang has several line sizing programs available in myMustang®. Refer to the Sizing page
within the Process portal. Regardless of the program or method selected, there are
independent variables to consider.
2.1 Pressure Drop Criteria
Absolute Roughness Factor: use 0.00015 ft for commercial steel pipe. For non-steel
pipe, use factors given in the Fluid Flow section of the GPSA Engineering Data Book [2].
Pipe Age Factor: use 1.2 unless noted otherwise in the design basis for a specific
project.
For vapor-liquid mixed phase, the Hughmark "in-place” density may be used, where
available as an option, for calculating static head.
2.2 Equivalent Length of Valves and Fitting
Use the table shown as Figure 17-4 in the GPSA Engineering Data Book [2].
Spreadsheet templates which use average L/D ratios and yield essentially the same
equivalent lengths may also be used. Optionally, Crane No. 410 [1] provides equations
for calculating valve and fitting losses as velocity head equivalents.
2.3 Flow Regimes of Vapor-Liquid Mixed Phase Flow
• Horizontal flow: Use Baker chart shown in Figure 1.
• Vertical flow: Use the Aziz Chart, Figure 2, via Reference 2. This figure is
considered to be conservative and valid for pressure up to 150 psig, which covers
the range of concern.
3.0 LINE SIZING CRITERIA
Tables 1, 2, and 3 in Appendix B give some typical "rules of thumb" for line sizing. Although
these rules are applicable to most situations, they may not be suitable in all cases. For critical
circuits, hydraulics should be checked in detail to confirm the available pressure drop regardless
of whether the lines meet rules-of-thumb criteria. In addition, the optimum line size is
determined by balancing the capital cost of the piping system against the operating cost of
pumps and/or compressors. To minimize initial investment, special attention should be given to
expensive lines, for example:
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4. DG-PPG-0110
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Process Plants Process Design Guidelines:
Hydraulics and Line Sizing Rev. 0
• Alloy pipe
• Carbon steel pipe larger than 12”
• Piping system involving many valves and fitting such as dryers
• Lines longer than 500 ft
In corrosive and erosive environments, however, the line shall be sized based on maximum
velocity considerations to provide satisfactory service life. When a new or unfamiliar service is
encountered, the Process Design Manager shall be consulted for line sizing criteria as well as
its material selection.
4.0 PRELIMINARY ESTIMATE OF EQUIVALENT LENGTH
The following data can be used for preliminary estimates of equivalent length when detail piping
information, such as isometrics, is not available.
4.1 Pump Discharge and Compressor Circuit
Piping Size, inches
On-site
L eq./L straight
Off-site
L eq./L straight
1-1/2 1.30 1.09
2 1.41 1.14
3 1.57 1.18
4 1.74 1.23
6 2.12 1.36
8 2.43 1.42
10 2.82 1.55
12 3.15 1.65
14 3.41 1.74
16 3.75 1.83
18 4.14 1.92
20 4.51 2.06
24 5.19 2.24
These typically conservative equivalent length ratios (to be used for budget estimates)
only are estimated based on the following assumptions:
• For on-site systems: each 100 feet of piping having one fully open gate valve, one
swing check valve, one hard tee and four long radius elbows.
• For offsite systems: each 100 feet of piping with one fully open gate valve and four
long radius elbows.
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5. DG-PPG-0110
Document No.
MUSTANG
Process Plants Process Design Guidelines:
Hydraulics and Line Sizing Rev. 0
4.2 Reboiler Inlet or Return Lines
Pipe Size, inches Typical Equivalent Length, ft
4 100
6 120
8 140
10 160
12 180
14 200
16 220
18 250
20 280
24 330
30 420
If the reboiler is spring supported, the equivalent length can be substantially reduced.
4.3 Pump Suction Line from Drums or Tower Bottoms
Pipe Size, inches Typical Equivalent Length, ft
through 6" 300
8" – 12” 400
14" and larger 250 pipe diameters + 150
Notes:
• If a permanent strainer is installed in the pump suction line, add 200 ft of equivalent
length to calculate the pressure drop through the strainer. If a temporary strainer is
used, the Process Engineer / Technical Professional should clarify with client if it will
stay in place during normal operation.
• The equivalent length for pump suction taken from a tower side draw-off can be
substantially higher than those shown above.
5.0 SPECIAL HYDRAULICS CALCULATIONS
5.1 Thermosyphon Reboiler Circuits
The worksheet shown on Figure 3 should be used to analyze the reboiler circuit
hydraulics for thermosyphon reboilers. Design considerations for the thermosyphon
reboiler system are as follows:
• Do not use the usual age factor of 1.2 for line friction loss. Instead, use a safety
factor of 2 for line friction loss and allowable total reboiler pressure drop when using
homogenous mixed phase density and a safety factor of 1.5 when using Hughmark
in-place density, whichever is more conservative. The criteria may be relaxed for
revamp projects or those systems having high densities in the reboiler return line
such as a deethanizer tower reboiler.
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6. DG-PPG-0110
Document No.
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Process Plants Process Design Guidelines:
Hydraulics and Line Sizing Rev. 0
• Use the percent vaporization specified in the reboiler data sheet. Recirculating
thermosyphon reboilers are generally designed for 30 wt% vaporization.
Once-through thermosyphon reboilers can have up to 50 wt% vaporization.
• Process Engineer / Technical Professional should check the actual operating
pressure of the reboiler if the mean temperature difference between the heating
medium and circulation fluid is sensitive to pressure variation. The pressure of the
boiling medium in the thermosyphon reboiler is equal to the tower operating pressure
plus riser losses including static head based on in-place density.
• The reboiler return line should be sized to avoid slugging problems. However, this
may not always be possible without an excessive elevation of skirt height, especially
for light ends towers operated at high pressure. It is generally recognized that towers
operated above a certain operating pressure (subject to engineering judgment), slug
flow may not exist or is not detrimental to a reboiler/tower operation.
5.2 Kettle Reboiler Circuits
The worksheet shown on Figure 4 should be used for hydraulic calculations associated
with kettle reboiler circuits. Design considerations for the kettle reboiler system are as
follows:
• Use a safety factor of 1.5 for line friction loss and allowable total reboiler pressure
drop.
• If the product from the kettle reboiler flows to a pump suction, the elevation of kettle
should also satisfy pump NPSH requirement.
• If the product from the kettle reboiler flows to a heat exchanger first, free drain from
the kettle to exchanger is preferred. This is not a mandatory requirement if the
product is of multi-component mixtures with wide boiling ranges. However, the pipe
length and elevation rise shall be minimized.
5.3 Pump NPSH and Pump Hydraulics Calculations
Refer to “Pumps" [3] for calculation guidelines and procedures.
5.4 Vacuum Tower Transfer Line Sizing
Transfer lines in crude vacuum units are typically very large and are constructed of
expensive alloy material. It is imperative that the process designer perform a detailed
hydraulic calculation to select the smallest line size.
The maximum velocity should be limited to 90% of sonic velocity. It usually occurs at the
inlet nozzle to the vacuum tower. Sonic velocity is expressed as:
VS = 68.1(kP/ρ)1/2
VS sonic velocity, ft/s
k the specific heat ratio, Cp/Cv
P the absolute pressure, psia
ρ the homogeneous mixed phase density, lb/ft3
The total pressure drop from the heater outlet to the tower inlet is limited by the heater
outlet temperature, which is typically 25°F higher than the flash zone temperature and
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7. DG-PPG-0110
Document No.
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Process Plants Process Design Guidelines:
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should generally be limited to 780°F maximum due to the concern of excessive cracking
and coking.
The design of the transfer line may proceed as follows:
• Starting at the flash zone condition, run a series of adiabatic flashes on the vacuum
tower charge, with a pressure increment of approximately 25% of the downstream
absolute pressure.
• Select the transfer line size based on the sonic velocity limitation stated above.
• Divide the line into several segments. Calculate or estimate the equivalent length of
each segment.
Start from the tower inlet nozzle, calculate the pressure drop in each line segment
using the following equation:
100
)
100
/
(
144
2
V
∆P
2
1
2
2 L
P
g
V
frict
avg
×
∆
+
×
−
=
ρ
Acceleration Loss Friction Pressure Drop
∆P total pressure drop, psi
V1 upstream velocity, ft/s
V2 downstream velocity, ft/s
(∆P/100)frict friction pressure drop, psi/100 ft
L total equivalent length, ft
g 32.2 ft/s2
Pavg average mixed phase density, lb/ft3
The acceleration loss in vacuum service can be a significant part of the total
pressure drop and should not be neglected. Since the amount of flashing depends
on the pressure, the above calculations are iterative.
• The pressure drop between the heater outlet and flash zone (typically 3 psi) is the
sum of the pressure drops for all line segments. The heater outlet temperature can
then be obtained from the pressure-temperature relationship which is generated from
the adiabatic flashes in step (a).
• If the calculated heater outlet temperature exceeds the allowable maximum, a larger
transfer line is selected and steps a. through d. are repeated until the temperature
limitation is satisfied. It should be noted that this rarely occurs unless the transfer
line is unusually long or the flash zone temperature already approaches the
maximum allowable temperature.
• If the calculated heater outlet temperature is more than 10°F lower than the
allowable maximum, a reduction in the line size between the tower and furnace may
be justified. The Process Engineer / Technical Professional should check the sonic
velocity criteria at the point of line size reduction.
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8. DG-PPG-0110
Document No.
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Process Plants Process Design Guidelines:
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APPENDICES
Appendix A: References
[1] “Flow of Fluids through Valves, Fittings, and Pipe,” Crane Technical Paper No. 410,
1988.
[2] “Fluid Flow and Piping,” GPSA Engineering Data Book, 10th ed., 1987, Section 17,
Volume II.
[3] “Process Plants Process Design Guidelines: Pumps”, Mustang Department Guidelines,
DG-PPG-0107.
[4] KYPIPE User's Manual.
[5] "Centrifugal Compressor Inlet Piping - A Practical Guide," Elliott Compressor, Reprint No.
117.
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9. DG-PPG-0110
Document No.
MUSTANG
Process Plants Process Design Guidelines:
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Appendix B: Tables
Table No. Title
1 Liquid Flow Line Sizing Criteria
2 Vapor and Gas Flow Line Sizing Criteria
3 Two Phase Flow Line Sizing Criteria
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10. DG-PPG-0110
Document No.
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Process Plants Process Design Guidelines:
Hydraulics and Line Sizing Rev. 0
Table 1 - Liquid Flow Line Sizing Criteria
Typical
Pressure Maximum
Drop Velocity
Service psi/100 ft ft/s Remarks
1. Pump suction (General Service)
a) Liquid at boiling point or 0.5 max. 3 (4" & smaller) 3.0 ft/s max. for vacuum tower bottoms
less than 50°F below it 5 (6”-10") pump regardless of sizes.
6 (12" & larger)
b) Sub-cooled liquids 2.0 max. 8 Higher than 8 ft/s is acceptable if there is
(50°F below boiling point) substantial length of straight pipe
(5 times of pipe dia.) just ahead of the pump
suction.
2. Side stream draw-off 0.2 max. (Note 1)
3. Liquid to non-pumped reboiler 0.2 (Note 1) The allowable pressure drop (psi/100ft)
can be higher if larger elevation difference
is available.
4. Gravity flow (in waste water 0.5 max. 2.5 ft/s min. The available liquid head
treating unit, etc.) should be at least two times the friction
loss calculated based on piping layout.
5. Pump discharge (Gen. Service) 4.0 max. 15 (Note 2)
6. Cooling water
Short lead 2.0 max. 15 The velocity should be above
Long header 1.0 max. 15 3 ft/s to prevent excessive fouling.
7. Corrosive liquids
Sulfuric acid service 3.0 (C.S.) (Note 3)
in Alky Unit 6.0 (316 S.S.)
“ 8.0 (Alloy 20)
Rich amine (liquid phase) 5.0 (C.S.) (Note 4)
Lean amine 7.0 (C.S.)
Caustic (lower than 140°F) 5.0 (C.S.)
8. Erosive liquids
FCC slurry 7 3 ft/s min. to prevent settling of catalyst
fines.
9. High available delta P 5.0 max 20 Should consider erosion and possible
vaporization.
10. Sea water in concrete 10.0
lined pipe
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11. DG-PPG-0110
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Process Plants Process Design Guidelines:
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Table 2 - Vapor and Gas Flow Line Sizing Criteria
Typical
Pressure Maximum
Drop Velocity
Service psi/100 ft ft/s Remarks
1. Column overhead and condenser rundown
For tower operated under high vacuum
10 mmHg abs. 0.01 100/(ρ)
1/2
condition, calculation based on piping
50 mmHg abs. 0.05 or 300 ft/s layout is required. Typically, the pressure
380 mmHg abs. 0.1 whichever is drop between tower and ejector in crude
Atmospheric - 50 psig 0.2 lower. vacuum column overhead is 1-2 mmHg.
50 psig - 150 psig 0.4 Higher ∆P/100 ft may be used for towers
150 psig + 0.6 operated at high pressure and line
pressure drop only constitutes ≤ 0.5% of
operating pressure.
2. Oil vapors
10 mmHg abs. 0.01 100/(ρg)
1/2
or
50 mmHg abs. 0.06 300 ft/s
380 mmHg abs. 0.2 whichever is
Atmospheric - 50 psig 0.5 lower.
50 psig - 150 psig 1.5
150 psig + 2.5
3. Steam
0 - 50 psig headers 0.5 100/( ρg)
1/2
or
laterals 1.5 300 ft/s
150 psig headers 1.0 whichever is
laterals 2.5 lower.
300 psig+ headers 2.5
laterals 4.0
4. Condensing Steam Turbine 450 Calculation based on exhaust piping
layout is required. Typically, the
pressure drop between turbine and
first condenser is 0.2 psi for air
cooled condenser and 0.1 psi for
water cooled condenser. In many
cases, the line size is governed by
velocity limitation.
5. Kettle Reboiler Return 0.1 - 0.2
6. Compressor Suction
Reciprocating (Note 5) For multistage compressors, the usual
allowable interstage pressure drop
Centrifugal (Note 6) exclusive of pulsation dampers
Is the larger of 5 to 7 psi or 1% of
system absolute pressure for a single
exchanger, separator and associated
piping. Increase the pressure drop if
there is additional equipment.
7. FCC Reactor Vapor 0.2 max. 100 Higher velocity results in excessive
to Fractionator erosion from catalyst fines.
8. Column Hot Vapor Bypass 0.5 Typically, the flowrate of hot vapor
bypass ranges from 10 to 15% of gross
column overhead vapor flowrate.
Process Engineer to confirm the
flowrate based on heat transfer calculation.
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12. DG-PPG-0110
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Process Plants Process Design Guidelines:
Hydraulics and Line Sizing Rev. 0
Table 3 - Two Phase Flow Line Sizing Criteria
Typical
Pressure Maximum
Drop Velocity
Service psi/100 ft ft/s Remarks
1. Thermosiphon Reboiler Return 0.1-0.2 Can be higher if large elevation
difference is available. See Section
5.1 for other considerations.
2. Other Two-Phase Lines
10 mmHg abs. 0.01 Max. velocity Except crude vacuum tower
50 mmHg abs. 0.06 is 100/(ρmix)
1/2
transfer line where the
380 mmHg abs. 0.02 or 300 ft/s maximum velocity is
Atmospheric - 50 psig 0.5 whichever is discussed in Section 5.4.
50 - 150 psig 1.5 lower. ρmix is
150 psig + 2.5 the homogeneous
mixed density
in lb/ft
3
.
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13. DG-PPG-0110
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Process Plants Process Design Guidelines:
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Notes for Tables 1, 2, and 3:
1) Saturated liquid draw-off from vessel should be adequately sized to avoid vaporization and vortexing
at the draw-off nozzle. The maximum allowable velocity is calculated as
Vmax = 3.858 (hmin)½
or hmin = (Vmax / 3.858)2
Vmax : maximum allowable velocity through the draw-off nozzle, ft/s
hmin : the liquid static head above the centerline of draw-off nozzle, ft
Equation for Vmax is valid only when the liquid head is at least one-half of the nozzle diameter above
the top edge of draw-off nozzle. The depth of draw-off sump should be a minimum of 1½ times the
nozzle diameter. See Mustang Process Design Guidelines, Section B, Towers.
The line should turn down immediately and should be a minimum of 6 ft vertical drop before being
swaged down to calculated line sizes.
2) Process engineer should confirm the total pressure drop based on actual piping or plot layouts
especially if high ∆P/100 ft is used to size long lines.
3) Typically, the acid strength ranges from 93% to 99% in the Alky unit. Selection of piping materials
depends on factors including size, velocity, flow turbulence and temperature. Consult with a Sr. level
Process Engineer about the material selection and allowable velocity criteria. For further details, see
Mustang Process Design Guidelines, Section M, Materials of Construction.
4) Stainless steel pipe is commonly used in areas where acid gas is flashed out of rich amine solution.
However, for long runs, heavy wall carbon steel pipe may be used in lieu of stainless steel.
5) The line size and piping layout may be dictated by the compressor acoustic analog study.
6) If inlet and discharge nozzles are oriented normal to compressor shaft and there are three diameters
of straight pipe just ahead of compressor inlet, the maximum velocity in the inlet is
Vmax = (995 T/M)1/2
Vmax : maximum allowable velocity in the suction of centrifugal compressor, ft/s
T : inlet temperature, OR
M : gas molecular weight
Vmax will be lower if the inlet line has less than three pipe diameters of straight run pipe. A review of
inlet piping systems as related to compressor performance is presented in Reference 5.
7) In general, the vapor-liquid mixed phase line should be sized to avoid the slug flow. Wherever this
becomes impractical and results in excessive pressure drop, a Sr. level Process Engineer should be
consulted.
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Appendix C: Figures
Figure No. Title
1 Baker Chart, Flow Regimes of Two Phase Flow in Horizontal Pipes (1 page)
2 Aziz Chart, Flow Regimes of Two Phase Up-Flow in Vertical Pipes (1 page)
3 Thermosyphon Reboiler Circuit Hydraulic Calculations (2 pages)
4 Kettle Type Reboiler Circuit Hydraulic Calculations (2 pages)
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Figure 1 - Baker Chart, Flow Regimes of Two Phase Flow in Horizontal Pipes
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Figure 2 - Aziz Chart, Flow Regimes of Two Phase Up-Flow in Vertical Pipes
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Figure 3 - Thermosyphon Reboiler Circuit Hydraulic Calculations
OPERATING COMMONS - INLET OPERATING CONDITIONS - OUTLET
Temperature. o
F _________ Temperature. o
F ___________
Pressure, psig _________ Pressure, psig ___________
Liquid density. ρ1, @T. lb/ft3
_________ Avg. L/V mixed density, ρ2 @T&P, lb/ft3
___________
Flow, Liq- lb/h _________ Inplace density, ρ3 @T&P. lb/ft3
___________
Flow. Liq., lb/h ___________
Flow. Vap., lb/h ___________
LINE FRICTION LOSS - INLET LINE
FRICTION LOSS - OUTLET
Line size, in _________ Line size. In ___________
∆P per 100 ft. psi _________ ∆P per 100 ft, psi ___________
Equiv. length. ft _________ Equiv. length. Ft ___________
Friction loss (fil), psi _________ Friction loss (fol). Psi ___________
Tower nozzle loss (fin). psi _________ Tower nozzle loss (fon). Psi ___________
Total inlet press. drop fi=fil+fin. Psi _______ Total outlet press. drop fo=fol+fon. Psi ___________
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CALCULATE RESISTANCE TO FLOW
A. RESISTANCE CALCULATION BASED ON AVG. MIXED DENSITY (NOTE 2)
1. ∆P (reboiler) allowed * safety factor (______), psi ________
2. Total line friction loss (fi+fo) * safety factor (______), psi ________
3. Static head in return line, Ft = h2 ________
4. Static head in return line, psi = h2 * ρ2 / 144 ________
5. Total resistance to flow (Pr1), psi = #1 + #2 + #4 ________
B. RESISTANCE CALCULATION BASED ON IN-PLACE DENSITY (NOTE 2)
6. ∆P (reboiler) allowed * safety factor (______), psi ________
7. Total line friction loss (fi+fo) * safety factor (______), psi ________
8. Static head in return line, Ft = h2 ________
9. Static head in return line, psi = h2 * ρ3 / 144 ________
10. Total resistance to flow (Pr2), psi = #6 + #7 + #9 ________
CALCULATE DRIVING FORCE
1. Required driving head (h3) based on avg. density, ft = (2.31 * Pr1) / ( ρ1 / 62.37) ________
2. Required driving head (h4) based on in-place density, ft = (2.31 * Pr2) / (ρ1 / 62.37) ________
3. Actual driving head available (h1), ft ________
4. If h1 is > h3 and h4. it is O.K. ________
Notes:
1. It should be confirmed with the equipment engineer that the ∆P allowed for reboiler shall be from
inlet nozzle flange to outlet nozzle flange, including static head.
2. For a new unit, use a safety factor of 2.0 based on average mixed density, and 1.5 based on in-
place density.
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Figure 4 - Kettle Type Reboiler Circuit Hydraulic Calculations
OPERATING CONDITIONS - INLET OPERATING CONDITIONS - OUTLET
Temperature, o
F ________ Temperature, o
F ________
Pressure, psig ________ Pressure, psig ________
Liquid density, ρ1, @T. lb/ft3
________ Vapor density. ρ2, @T. lb/ft3
________
Flow, Liquid lb/h ________ Flow, Vapor lb/h ________
LINE FRICTION LOSS INLET LINE FRICTION
LOSS - OUTLET
Line size, In. ________ Line size, In. ________
∆P per 100 ft, psi ________ ∆P per 100 ft, psi ________
Equiv. Length, ft ________ Equiv. Length, ft ________
Friction loss (fil), psi ________ Friction loss (fol), psi ________
Tower nozzle loss (fin), psi ________ Tower nozzle loss (fon), psi ________
Total inlet press. drop fi = fil+fin, psi ________ Total inlet press. drop fo = fol+fon, psi ________
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CALCULATE RESISTANCE TO FLOW (NOTE 2)
1. ∆P (reboiler) allowed * safety factor (______), psi ________
2. Total line friction loss (fi+fo) * safety factor (______), psi ________
3. Static head in return line, Ft = h2 ________
4. Static head in return line, psi = h2 * ρ2 / 144 ________
5. Total resistance to flow (Pr1), psi = #1 + #2 + #4 ________
CALCULATE DRIVING FORCE
1. Required driving head (h), ft = (2.31 * Pr) / ( ρ1 / 62.37) ________
2. Actual driving head available (h1), ft ________
3. If h1 is > h, it is O.K. ________
Notes:
1. It should be confirmed with equipment engineer that ∆P allowed for reboiler shall be from inlet
nozzle flange to outlet nozzle flange.
2. For new unit, use safety factor of 1.5