Petroleum Refining Design and Applications Handbook, Volume 2

A. Kayode Coker PhD, is Engineering Consultant for AKC Technology, an Honorary Research Fellow at the University of Wolverhampton, U.K., a former Engineering Coordinator at Saudi Aramco Shell Refinery Company (SASREF) and Chairman of the department of Chemical Engineering Technology at Jubail Industrial College, Saudi Arabia. He has been a chartered chemical engineer for more than 30 years. He is a Fellow of the Institution of Chemical Engineers, U.K. (C. Eng., FIChemE), and a senior member of the American Institute of Chemical Engineers (AIChE).  He holds a B.Sc. honors degree in Chemical Engineering, a Master of Science degree in Process Analysis and Development and Ph.D. in Chemical Engineering, all from Aston University, Birmingham, U.K., and a Teacher's Certificate in Education at the University of London, U.K. He has directed and conducted short courses extensively throughout the world and has been a lecturer at the university level. His articles have been published in several international journals. He is an author of six books in chemical engineering, a contributor to the Encyclopedia of Chemical Processing and Design, Vol 61 and a certified train — the mentor trainer. A Technical Report Assessor and Interviewer for chartered chemical engineers (IChemE) in the U.K. He is a member of the International Biographical Centre in Cambridge, U.K. (IBC) as Leading Engineers of the World for 2008. Also, he is a member of International Who's Who of ProfessionalsTM and Madison Who's Who in the U.S.

"...the author is committed to sharing a career's worth of lessons and design experiences, offering clear explanations on individual topics...a useful addition to an experienced engineer's library of information. It could also be extremely helpful to engineering students..."The Chemical Engineer, November 2021

• Preface xvAcknowledgements xvii13 Rules of Thumb—Summary 113.0 Introduction 114 Process Planning, Scheduling, and Flowsheet Design 1914.1 Introduction 1914.2 Organizational Structure 2014.2.1 Process Design Scope 2114.3 Role of the Process Design Engineer 2314.4 Computer-Aided Flowsheeting 2414.5 Flowsheets—Types 2614.5.1 Block Diagram 2614.5.2 Process Flowsheet or Flow Diagram 2614.5.3 Piping Flowsheet or Mechanical Flow Diagram, or Piping and Instrumentation Diagram (P&ID) 2714.5.4 Combined Process and Piping Flowsheet or Diagram 3214.5.5 Utility Flowsheets or Diagrams (ULDs) 3214.5.6 Special Flowsheets or Diagrams 3614.5.7 Special or Supplemental Aids 3614.6 Flowsheet Presentation 3614.7 General Arrangements Guide 3614.8 Computer-Aided Flowsheet Design/Drafting 3814.9 Flowsheet Symbols 4014.10 Line Symbols and Designations 4314.11 Materials of Construction for Lines 4614.12 Test Pressure for Lines 4714.13 Working Schedules 5614.14 Information Checklists 6114.15 Basic Engineering and Front End Engineering Design (FEED) 63References 6415 Fluid Flow 6515.1 Introduction 6515.2 Flow of Fluids in Pipes 6515.3 Scope 7015.4 Basis 7215.5 Incompressible Flow 7215.6 Compressible Flow: Vapors and Gases 7315.7 Important Pressure Level References 7515.8 Factors of “Safety” for Design Basis 7515.9 Pipe, Fittings, and Valves 7515.10 Pipe 7515.11 Total Line Pressure Drop 7815.11.1 Relationship Between the Pipe Diameter and Pressure Drop (ΔP) 8015.11.2 Economic Balance in Piping and Optimum Pipe Diameter 8215.12 Reynolds Number, Re (Sometimes Used NRe) 8315.13 Pipe Relative Roughness 8515.14 Darcy Friction Factor, f 8515.15 Friction Head Loss (Resistance) in Pipe, Fittings, and Connections 9415.15.1 Pressure Drop in Straight Pipe: Incompressible Fluid 9415.16 Oil System Piping 9615.16.1 Density and Specific Gravity 9715.16.2 Specific Gravity of Blended Products 9815.16.3 Viscosity 9815.16.4 Viscosity of Blended Products 10015.16.5 Blending Index, H 10115.16.6 Vapor Pressure 10115.16.7 Velocity 10115.16.8 Frictional Pressure Drop, ft of Liquid Head 10415.16.9 Hazen–Williams Equation 10515.16.10 Transmission Factor 10715.16.11 Miller Equation 11215.16.12 Shell–MIT Equation 11315.17 Pressure Drop in Fittings, Valves, and Connections 11615.17.1 Incompressible Fluid 11615.17.2 Velocity and Velocity Head 11615.17.3 Equivalent Lengths of Fittings 11715.17.4 L/D Values in Laminar Region 12015.17.5 Validity of K Values 12215.17.6 Laminar Flow 12215.17.7 Expressing All Pipe Sizes in Terms of One Diameter 12415.17.8 Loss Coefficient 12815.17.9 Sudden Enlargement or Contraction 13415.17.10 For Sudden Contractions 13415.17.11 Piping Systems 13615.18 Resistance of Valves 13615.19 Flow Coefficients for Valves, Cv 13715.20 Flow Meters 13815.20.1 Process Design of Orifice Meter 13815.20.2 Nozzles and Orifices 142Conclusion 16715.21 Estimation of Pressure Loss Across Control Valves 16915.22 The Direct Design of a Control Valve 17315.23 Water Hammer 17315.24 Friction Pressure Drop for Compressible Fluid Flow 17515.24.1 Compressible Fluid Flow in Pipes 17615.24.2 Maximum Flow and Pressure Drop 17715.24.3 Sonic Conditions Limiting Flow of Gases and Vapors 17715.24.4 The Mach Number, Ma 18215.24.5 Critical Pressure Ratio 19715.24.6 Adiabatic Flow 20015.24.7 The Expansion Factor, Y 20115.24.8 Misleading Rules of Thumb for Compressible Fluid Flow 20315.24.9 Other Simplified Compressible Flow Methods 20415.24.10 Friction Drop for Flow of Vapors, Gases and Steam 20515.25 Darcy Rational Relation for Compressible Vapors and Gases 21315.26 Velocity of Compressible Fluids in Pipe 21515.27 Procedure 22815.28 Friction Drop for Compressible Natural Gas in Long Pipe Lines 23115.29 Panhandle-A Gas Flow Formula 23515.30 Modified Panhandle Flow Formula 23715.31 American Gas Association (AGA) Dry Gas Method 23715.32 Complex Pipe Systems Handling Natural (or Similar) Gas 23715.33 Two-Phase Liquid and Gas Flow in Process Piping 23915.33.1 Flow Patterns 23915.33.2 Flow Regimes 24215.33.3 Pressure Drop 24315.33.4 Erosion–Corrosion 24815.33.5 Total System Pressure Drop 25015.33.6 Pipe Sizing Rules 25715.33.7 A Solution for All Two-Phase Problems 26115.33.8 Gas–Liquid Two-Phase Vertical Down Flow 27015.33.9 Pressure Drop in Vacuum Systems 27715.33.10 Low Absolute Pressure Systems for Air 27915.33.11 Vacuum for Other Gases and Vapors 28115.33.12 Pressure Drop for Flashing Liquids 28415.33.13 Sizing Condensate Return Lines 28615.34 UniSim Design PIPESYS 29515.35 Pipe Line Safety 30015.36 Mitigating Pipeline Hazards 30115.37 Examples of Safety Design Concerns 30115.38 Safety Incidents Related With Pipeworks and Materials of Construction 30315.39 Lessons Learned From Piping Designs 31915.40 Design of Safer Piping 32015.40.1 Best Practices for Process Piping 32015.40.2 Designing Liquid Piping 32115.40.3 Best Practices for Liquid Piping 322Nomenclature 324Greek Symbols 326Subscripts 327References 32716 Pumps 33116.1 Pumping of Liquids 33116.2 Pump Design Standardization 33616.3 Basic Parts of a Centrifugal Pump 33616.4 Centrifugal Pump Selection 34116.5 Hydraulic Characteristics for Centrifugal Pumps 35916.6 Suction Head or Suction Lift, hs 36716.7 Discharge Head, hd 36916.8 Velocity Head 36916.9 Friction 37016.10 Net Positive Suction Head (NPSH) and Pump Suction 37016.11 General Suction System 37816.12 Reductions in NPSHR 38416.13 Charting NPSHR Values of Pumps 38416.14 Net Positive Suction Head (NPSH) 38616.15 NPSH Requirement for Liquids Saturation With Dissolved Gases 38816.16 Specific Speed 39016.17 Rotative Speed 39416.18 Pumping Systems and Performance 39516.19 Power Requirements for Pumping Through Process Lines 39916.20 Affinity Laws 40516.21 Centrifugal Pump Efficiency 41716.22 Effects of Viscosity 42116.23 Temperature Rise and Minimum Flow 43616.24 Centrifugal Pump Specifications 44016.25 Number of Pumping Units 44116.26 Rotary Pumps 44816.27 Reciprocating Pumps 45216.28 Pump Selection 45616.29 Selection Rules-of-Thumb 45616.30 Case Studies 45916.31 Pump Cavitations 46416.32 Pump Fundamentals 47416.33 Operating Philosophy 47516.34 Piping 48516.35 Troubleshooting Checklist for Centrifugal Pumps 485Nomenclature 493Subscripts 494Greek Symbols 495References 49517 Compression Equipment 49717.1 Introduction 49717.2 General Application Guide 49817.3 Specification Guides 49917.4 General Considerations for Any Type of Compressor Flow Conditions 50117.4.1 Fluid Properties 50117.4.2 Compressibility 50217.4.3 Corrosive Nature 50217.4.4 Moisture 50217.4.5 Special Conditions 50217.5 Reciprocating Compression 50317.6 Suction and Discharge Valves 51417.7 Specification Sheet 52317.8 Performance Considerations 52417.9 Compressor Performance Characteristics 55717.10 Hydrogen Use in the Refinery 59417.10.1 IsoTherming Technology for Kerosene, Vacuum Gas Oil, and Diesel Hydroprocessing 595Nomenclature 829Greek Symbols 832Subscripts 832References 833Glossary of Petroleum and Technical Terminology 837Appendix D 929Appendix E 1005Index 1019About the Author 1025