Process Plant Equipment

This book provides information and serves as a technical reference for the maintenance, operation, reliability, trouble shooting and control of major equipment used in any aspect of the process plant industry. This information is vital for reducing downtime and unscheduled shutdowns, improving operational excellence, and prolonging the service life of equipment. The coverage provides the reader with technical support and expertise in order for them to gain operational excellence, learn maintenance strategies, troubleshoot problems, monitor issues, and properly select process plant equipment.

Contributors xxiii Preface xxiv SECTION I PROCESS EQUIPMENT OPERATION 1 Introduction 3 Michael D. Holloway 2 Valves 9 Ali Ahammad Shoukat Choudhury, Chikezie Nwaoha, and Sharad Vishwasrao 2.1 Types of Control Valves, 10 2.2 Control Valve Actuators, 12 2.3 Control Valve Sizing and Selection, 13 2.4 Common Problems of Control Valves, 15 2.5 Diagnosing Control Valve Problems, 19 2.6 Control Valve Reliability and Selection, 20 2.7 Control Valve Maintenance, 22 2.8 Control Valve Troubleshooting, 24 References, 24 3 Pumps 27 Craig Redmond 3.1 Types of Pumps, 28 3.2 Pump Applications, 34 3.3 Pump Sizing and Selection, 37 3.4 Pump Maintenance, 40 3.5 Pump Troubleshooting, 44 4 Pipes 45 Shaohui Jia 4.1 Types of Pipes, 45 4.2 Pipe Selection, 46 4.3 Pipeline Network Design and Optimization, 48 4.4 Pipeline Failure, 50 4.5 Pipeline Inspection and Leak Detection, 54 4.6 Pipe Maintenance, 58 4.7 Pipe Troubleshooting, 60 References, 61 5 Cooling Towers 63 Zaki Yamani Zakaria and Chikezie Nwaoha 5.1 Cooling Tower Operation, 63 5.2 Types of Cooling Towers, 69 5.3 Common Problems of Cooling Towers, 74 5.4 Measuring Cooling Tower Performance, 75 5.5 Cooling Tower Maintenance, 77 References, 79 6 Filters and Membranes 81 Flora Tong and Chikezie Nwaoha 6.1 Types of Filters, 81 6.2 Mechanisms of Filtration, 87 6.3 Filter Selection, 87 6.4 Particle–Size Measurement Techniques, 88 6.5 Filter Location, 89 6.6 Membrane Filtration, 89 6.7 Filter Maintenance, 103 References, 104 7 Sealing Devices 107 Matt Tones and Jim Drago 7.1 Gaskets, 107 7.2 Compression Packings, 125 7.3 Mechanical Seals, 131 7.4 Expansion Joints, 147 7.5 General Sealing Device Selection, 157 References, 161 8 Steam Traps 163 Jacob E. Uche and Chikezie Nwaoha 8.1 Steam Trap Operation, 163 8.2 Types of Steam Traps, 164 8.3 Steam Trap Installation, 172 8.4 Steam Trap Checking, 172 8.5 Common Problems of Steam Traps, 175 8.6 Steam Trap Selection, 176 8.7 Steam Trap Applications, 178 8.8 Steam Trap Sizing, 178 8.9 Steam Trap Maintenance, 181 References, 181 9 Process Compressors 183 N. Sitaram and Chikezie Nwaoha 9.1 Types of Compressors, 183 9.2 Continuous Compression Compressors, 184 9.3 Intermittent Compression Compressors, 186 9.4 Centrifugal Compressors, 189 9.5 Reciprocating Piston Compressors, 202 9.6 Compressor Troubleshooting, 209 References, 210 Further Reading, 211 10 Conveyors 213 Okenna Obi–Njoku 10.1 Industrial Use of Conveyors, 213 10.2 Types of Conveyors, 214 10.3 Conveyor Selection, 221 10.4 Conveyor Safety, 221 10.5 Conveyor Maintenance, 222 10.6 Summary, 222 References, 223 11 Storage Tanks 225 Marcello Ferrara and Chikezie Nwaoha 11.1 Types of Storage Tanks, 225 11.2 Storage Tank Classification, 227 11.3 Construction Materials, 227 11.4 Common Problems of Storage Tanks, 229 11.5 Storage Tank Maintenance, 233 11.6 Tank Appurtenances, 241 11.7 Storage Tank Maintenance, 243 References, 244 12 Mixers 245 Jayesh Ramesh Tekchandaney 12.1 Mixing Concepts: Theory and Practice, 246 12.2 Fluid Mixing, 248 12.3 Solid Blending, 264 12.4 Mixing High–Viscosity Materials and Pastes, 274 12.5 Mechanical Components in Mixing Equipment, 284 References, 295 13 Boilers 297 Celestine C. G. Nwankwo 13.1 Types of Boilers, 298 13.2 Boiler Accessories, 303 13.3 Boiler Selection, 305 13.4 Common Problems of Boilers, 306 13.5 Boiler Failure Analysis and Welding Defects, 308 13.6 Boiler Maintenance, 313 13.7 Boiler Troubleshooting, 319 13.8 Boiler Chemicals, 321 13.9 Boiler Efficiency and Combustion, 325 References, 327 Further Reading, 328 SECTION II PROCESS PLANT RELIABILITY 14 Engineering Economics for Chemical Processes 331 Alberto R. Betancourt–Torcat, L. A. Ricardez–Sandoval, and Ali Elkamel 14.1 Time Value of Money, 331 14.2 Cash Flow Analysis, 333 14.3 Profitability Analysis, 336 14.4 Cost Estimation and Project Evaluation, 340 References, 353 15 Process Component Function and Performance Criteria 355 Robert Free 15.1 Material Classification, 355 15.2 General Physical Quantities and Considerations, 356 15.3 Material Transfer and Conveyance Equipment, 366 15.4 Conveyors, 367 15.5 Pumps, 394 15.6 Valves, 400 15.7 Pipes, 405 15.8 Conclusions, 410 References, 410 Corporation Web Sites, 411 16 Failure Analysis and Interpretation of Components 413 Michael D. Holloway 16.1 Assessing the Situation, 413 16.2 Failure Defined, 414 16.3 Taking Advantage of Failure, 415 16.4 Sources of Failure, 416 16.5 Failure of Materials and of Machines, 416 16.6 Types of Forces, 417 16.7 Strength, 418 16.8 Creep (Deformation), 419 16.9 Fatigue (Material), 420 16.10 Wear, 422 16.11 Property Changes, 423 16.12 Temperature, 423 16.13 Oxidation: Molecular Transitions and Chemical Influences, 425 16.14 Deposit Formation, 426 16.15 Factors that Affect Deposit Formation, 428 16.16 Documenting Failure, 429 References, 432 17 Mechanical Integrity of Process Vessels and Piping 435 Oliver A. Onyewuenyi 17.1 Perspectives on Mechanical Integrity, Fitness for Service, and Condition Monitoring, 437 17.2 Types of Flaws and Damage Mechanisms, 439 17.3 Inspection, Characterization, and Monitoring of Flaws, 442 17.4 Fracture Mechanics and Fitness–for–Service Assessment, 443 17.5 Control and Prevention of Brittle Fracture, 452 17.6 Case Histories and Examples of FFS Applications to Cracks in Process Plant Pressure Vessels, 459 References, 464 18 Design of Pressure Vessels and Piping 467 Maher Y. A. Younan 18.1 Modes of Failure, 467 18.2 Basic Stress Analysis, 469 18.3 Design of Pressure Vessels, 470 18.4 Design of Piping Systems, 481 References, 486 19 Process Safety in Chemical Processes 489 Jelenka Savkovic–Stevanovic 19.1 The Hazards, 490 19.2 Hazard Analysis, 499 19.3 Risk Analysis, 503 19.4 Safety Ratings, 511 19.5 Development and Design of a Safe Plant, 524 19.6 Safety Process Operation, 543 19.7 Safety and Reliability Analysis, 557 19.8 Summary, 581 References, 582 SECTION III PROCESS MEASUREMENT, CONTROL, AND MODELING 20 Flowmeters and Measurement 587 Gregory Livelli and Chikezie Nwaoha 20.1 Flow Measurement Techniques, 587 20.2 Flow–Rate Meters, 592 20.3 Common Problems of Flowmeters, 599 20.4 Flowmeter Installation and Maintenance, 601 20.5 Calibration and Certification, 606 20.6 LACT and Prover Descriptions, 607 20.7 Troubleshooting LACT and Prover Systems, 614 20.8 Troubleshooting Flowmeters, 614 References, 617 21 Process Control 619 John A. Shaw 21.1 Control System Components, 619 21.2 Control System Requirements, 620 21.3 Sensor Response, 620 21.4 Control Algorithms, 624 21.5 Loop Tuning, 625 21.6 Multiloop Control, 629 21.7 Final Control Elements, 633 21.8 Process Controllers, 634 Reference, 634 22 Process Modeling and Simulation 635 Mathew Chidiebere Aneke 22.1 Process Modeling, 635 22.2 Process Simulation, 636 22.3 Process Optimization, 636 22.4 Commercial Tools for Process Modeling, Simulation, and Optimization, 637 22.5 Process Modeling Case Studies, 638 22.6 Concluding Remarks, 650 References, 650 Appendix I Methods for Measuring Process Temperature 653 Chikezie Nwaoha Appendix II Airflow Troubleshooting 659 Chikezie Nwaoha Appendix III MIG Shielding Gas Control and Optimization 663 Jerry Uttrachi Appendix IV Rupture Disk Selection 665 Chikezie Nwaoha Appendix V Pressure Gauge Selection 669 Chikezie Nwaoha Appendix VI Corrosion and Its Mitigation in the Oil and Gas Industries 673 Krupavaram Nalli Appendix VII Mixers 681 Jayesh Ramesh Tekchandaney Glossary of Processing Terms 685 Garlock Sealing Technologies Index 693