SECTION ONE Equipment Design 1
1：Fluid Flow 2
Velocity head 3
Piping pressure drop 4
Equivalent length 4
Recommended velocities 5
Two-phase flow 7
Compressible flow 9
Sonic velocity 12
Metering 12
Control valves 13
Safety relief valves 16
2：Heat Exchangers 19
TEMA 20
Selection guides 24
Pressure drop shell and tube 27
Temperature difference 29
Shell diameter 30
Shellside velocity maximum 30
Nozzle velocity maximum 31
Heat transfer coefficients 31
Fouling resistances 38
Metal resistances 40
Vacuum condensers 42
Air-cooled heat exchangers:forced vs induced draft 42
Air-cooled heat exchangers:pressure drop air side 43
Air-cooled heat exchangers:rough rating 44
Air-cooled heat exchangers:temperature control 46
Miscellaneous rules of thumb 48
3：Fractionators 49
Introduction 50
Relative volatility 50
Minimum reflux 51
Minimum stages 52
Actual reflux and actual theoretical stages 52
Reflux to feed ratio 53
Actual trays 54
Graphical methods 54
Tray efficiency 55
Diameter of bubble cap trays 59
Diameter of sieve/valve trays(F factor) 60
Diameter of sieve/valve trays(Smith) 61
Diameter of sieve/valve trays(Lieberman) 63
Diameter of ballast trays 63
Diameter of fractionators,general 65
Control schemes 65
Optimization techniques 69
Reboilers 72
Packed columns 76
4：Absorbers 97
Introduction 98
Hydrocarbon absorber design 98
Hydrocarbon absorbers,optimization 100
Inorganic type 101
5：Pumps 104
Affinity laws 105
Horsepower 105
Efficiency 105
Minimum flow 105
General suction system 106
Suction system NPSH available 107
Suction system NPSH for studies 108
Suction system NPSH with dissolved gas 109
Larger impeller 109
Construction materials 109
6：Compressors 112
Ranges of application 113
Generalized Z 113
Generalized K 114
Horsepower calculation 115
Efficiency 119
Temperature rise 121
Surge controls 121
7：Drivers 122
Motors:efficiency 123
Motors:starter sizes 124
Motors:service factor 124
Motors:useful equations 125
Motors:relative costs 125
Motors:overloading 126
Steam turbines:steam rate 126
Steam turbines:efficiency 126
Gas turbines:fuel rates 127
Gas engines:fuel rates 129
Gas expanders:available energy 129
8：Separators/Accumulators 130
Liquid residence time 131
Vapor residence time 132
Vapor/liquid calculation method 133
Liquid/liquid calculation method 135
Pressure drop 135
Vessel thickness 136
Gas scrubbers 136
Reflux drums 136
General vessel design tips 137
9：Boilers 138
Power plants 139
Controls 139
Thermal efficiency 140
Stack gas enthalpy 141
Stack gas quantity 142
Steam drum stability 143
Deaerator venting 144
Water alkalinity 145
Blowdown control 145
Impurities in water 145
Conductivity versus dissolved solids 147
Silica in steam 148
Caustic embrittlement 148
Waste heat 150
10：Cooling Towers 153
System balances 154
Temperature data 154
Performance 156
Performance estimate:a cast history 158
Transfer units 158
SECTION TWO Process Design 161
11：Refrigeration 162
Types of systems 163
Estimating horsepower per ton 163
Horsepower and condenser duty for specific refrigerants 164
Refrigerant replacements 182
Ethylene/propylene cascaded system 183
Steam jet type utilities requirements 183
Ammonia absorption type utilities requirements 186
12：Gas Treating 187
Introduction 188
Gas treating processes 188
Reaction type gas treating 190
Physical solvent gas treating 191
Physical/chemical type 191
Carbonate type 192
Solution batch type 192
Bed batch type 193
13：Vacuum Systems 194
Vacuum jets 195
Typical jet systems 196
Steam supply 197
Measuring air leakage 198
Time to evacuate 198
Design recommendations 199
Eiector specification sheet 200
14：Pneumatic Conveying 202
Tvpes of systems 203
Differential pressures 204
Equipment sizing 204
15：Blending 206
Single-stage mixers 207
Multistage mixers 207
Gas/liquid contacting 208
Liquid/liquid mixing 208
Liquid/solid mixing 208
Mixer applications 209
Shrouded blending nozzle 210
Vapor formation rate for tank filling 210
SECTION THREE Plant Design 211
16：Process Evaluation 212
Introduction 213
Study definition 213
Process definition 215
Battery limits specifications 222
Offsite specifications 226
Capital investments 230
Operating costs 237
Economics 240
Financing 244
17：Reliability 247
18：Metallurgy 249
Embrittlement 250
Stress-corrosion cracking 256
Hydrogen attack 257
Pitting corrosion 259
Creep and creep-rupture life 260
Metal dusting 262
Naphthenic acid corrosion 264
Fuel ash corrosion 265
Thermal fatigue 267
Abrasive wear 269
Pipeline toughness 270
Common corrosion mistakes 271
19：Safety 272
Estimating LEL and flash 273
Tank blanketing 273
Equipment purging 275
Static charge from fluid flow 276
Mixture flammability 279
Relief manifolds 282
Natural ventilation 288
20：Controls 289
Introduction 290
Extra capacity for process control 290
Controller limitations 291
False economy 292
Definitions of control modes 292
Control mode comparisons 292
Control mode vs application 292
Pneumatic vs electronic controls 293
Process chromatographs 294
SECTION FOUR Operations 295
21：Troubleshooting 296
Introduction 297
Fractionation:initial checklists 297
Fractionation:Troubleshooting checklist 299
Fractionation:operating problems 301
Fractionation:mechanical problems 307
Fractionation:Getting ready for troubleshooting 311
Fractionation:"Normal"parameters 312
Fluid flow 313
Refrigeration 316
Firetube heaters 317
Safety relief valves 318
Gas treating 319
Compressors 323
Measurement 325
22：Startup 326
Introduction 327
Settings for controls 327
Probable causes of trouble in controls 328
Checklists 330
23：Energy Conservation 334
Target excess oxygen 335
Stack heat loss 336
Stack gas dew point 336
Equivalent fuel values 338
Heat recovery systems 339
Process efficiency 340
Steam traps 341
Gas expanders 343
Fractionation 344
Insulating materials 344
24：Process Modeling Using Linear Programming 345
Process modeling using linear programming 346
25：Properties 351
Introduction 352
Approximate physical properties 352
Viscosity 353
Relative humidity 357
Surface tension 358
Gas diffusion coefficients 358
Water and hydrocarbons 360
Natural gas hydrate temperature 364
Inorganic gases in petroleum 366
Foam density 368
Equivalent diameter 369
Autoignition temperature 371
Gibbs free energy of formation 376
New refrigerants 386
26：Approximate Conversion Factors 387
Approximate conversion factors 388
Appendixes 389
Appendix 1：Shortcut Equipment Design Methods—Overview 390
Appendix 2：Geographic Information Systems 392
Appendix 3：Internet Ideas 394
Appendix 4：Process Safety Management 397
Appendix 5：Do-It-Yourself Shortcut Methods 399
Appendix 6：Overview for Engineering Students 406
Appendix 7：Modern Management Initiatives 409
Appendix 8：Process Specification Sheets 410
Vessel data sheet 411
Shell and tube exchanger data sheet 412
Double pipe (G-fin)exchanger data sheet 413
Air-cooled(fin-fan)exchanger data sheet 414
Direct fired heater data sheet 415
Centrifugal pump(horizontal or vertical) data sheet 416
Pump(vertical turbine—can or propellor) data sheet 417
Tank data sheet 418
Cooling tower data sheet 419
Index 423