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Equipment Calculations

This document provides guidance on selecting and sizing equipment for engineering projects. It outlines the types of data needed, including process conditions, equipment specifications, costs, codes and standards. Scale-up methods are described to estimate costs for larger equipment based on catalog data. Vendor information and industry cost indices are also recommended sources of data.

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processpipingdesign
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© Attribution Non-Commercial (BY-NC)
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Download as PDF, TXT or read online on Scribd
133 views

Equipment Calculations

This document provides guidance on selecting and sizing equipment for engineering projects. It outlines the types of data needed, including process conditions, equipment specifications, costs, codes and standards. Scale-up methods are described to estimate costs for larger equipment based on catalog data. Vendor information and industry cost indices are also recommended sources of data.

Uploaded by

processpipingdesign
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PDF, TXT or read online on Scribd
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EQUIPMENT CALCULATIONS

SELECTION & SIZING

DETAIL REQUIRED FOR A PROJECT


COMPONENTS NEEDED FOR EVALUATION M & E BALANCE DATA EQUIPMENT COSTS OPERATING COSTS OTHER FACTORS
http://ecb.jrc.it/testing-methods/

SIMULATION DATA
ENERGY CONSUMPTION FOR ROTATING EQUIPMENT
MECHANICAL EFFICIENCY DATA THERMODYNAMIC EFFICIENCY DATA APPROACH TEMPERATURES TRANSFER COEFFICIENTS STAGE EFFICIENCIES CAPACITIES MINIMUM/MAXIMUM FLOW VELOCITIES AND/OR PRESSURE DROPS TOTAL HEAD LOSS ESTIMATES
http://www.mcnallyinstitute.co m/06-html/6-01.html

HEAT TRANSFER DATA MASS TRANSFER DATA MOMENTUM TRANSFER

CAPITAL EQUIPMENT
TO ESTIMATE EQUIPMENT CAPITAL COSTS (REFER TO APPENDIX E HUERISTICS FOR PROCESS EQUIPMENT DESIGN DIMENSIONAL DATA
MASS AREA

TYPES OF EQUIPMENT
HEAT EXCHANGE PUMPS REACTION INVENTORY

PROCESS DATA
DESIGN PROCESS CONDITIONS http://www.geeco.co.uk/storage UTILITY REQUIREMENTS tanks.php MATERIALS OF CONSTRUCTION DATA

INSTALLATION COSTS
SEE DETAILS IN CHAPTER 6 RANGE OF COSTS TYPICALLY RUN FROM 4.7 TO 5.9 TIME EQUIPMENT (SEE TABLE 69)
COSTS DEPEND ON:
TYPE OF PROCESS, FLUID, SOLID OR MIX MATERIALS OF CONSTRUCTION LOCATION OF FACILITIES SIZE OF PLANT

SEE COST ESTIMATOR AT PAGE xvi IN TEXT AND http://highered.mcgrawhill.com/sites/0072392665/student_view0/cost_e stimator.html

TYPICAL ESTIMATE FACTORS

CODES AND STANDARDS


HEAT EXCHANGER STANDARDS
THERMAL EXCHANGER MANUFACTURERS ASSOCIATION (TEMA) TYPES R, B & C CONFIGURATION OF HEADS AND TUBES NDE AND TESTING REQUIREMENTS SUPPORT & INSULATION DATA NOZZLE SIZES & LOCATIONS ASME CODE REQUIREMENTS

SEE CHAPTER 14 FOR DETAILS


http://www.heatexchangersonline.com/images/i ndex.jpg

VESSEL DESIGNS
SEE CHAPTER 12 FOR DETAILS NOZZLE DIMENSIONS & LOCATIONS DESCRIPTION OF INTERNALS SURFACE FINISHES INSULATION REQUIREMENTS CODE REQUIREMENTS - ASME OR API FABRICATION & TESTING DATA
http://www.ubh.co.uk/procve s.htm

VESSEL DESIGNS
TYPICAL LIMITS
PROCESS TANKS - 20% FREEBOARD STORAGE TANKS - 10% FREEBOARD PUMP TANKS - 5-10 MIN. SURGE

ACCESS NOZZLES FOR ALL INTERNALS MINIMUM NUMBER OF WELDED SEAMS MAXIMUM DIAMETER - 4 m FOR SHOP FABRICATION HOLD POINTS AT FAB DRAWINGS, INSPECTION OF SHOP FAB STANDARDS, REVIEW OF NDE, PRESSURE TEST PRIOR TO PAINTING

ROTATING EQUIPMENT
MOTOR OR TURBINE DRIVEN CHAP. 12 TOTAL PACKAGE - DRIVEN UNIT, DRIVERS, GEARS, COUPLINGS, SHAFTS, BELTS, BASES & SUPPORTS GUARANTEE PERFORMANCE POINT - TO BE TESTED IN SHOP PRIOR TO SHIPMENT TYPES OF BEARINGS & LUBRICATION TYPES OF SEALS NOISE LIMITS
http://www.hydrocarbonstechnology.com/contractors/compress ors/elliott/

PUMPS
LOW HEAD/HIGH FLOW - RADIAL, CENTRIFUGAL, NOT SELF-PRIMING HIGH HEAD/LOW FLOW - TURBINE, POSITIVE DISPLACEMENT INSTALLATION CONFIGURATION HORIZONTAL, VERTICAL, INLINE, SUBMERGED, JACKETED, SINGLE OR MULTI-STAGE
MINIMUM NPSH NORMAL DISCHARGE P STANDARD CASINGS MACHINED IMPELLERS

http://www.arrowengine.com/chemical.htm

COMPRESSORS
SMALL UNITS ARE TREATED LIKE PUMPS DYNAMIC AND TORSIONAL ANALYSES FOR THE TRAIN
1ST CRITICAL - SEVERE STRESS 2ND CRITICAL - NOT AS BAD 3RD CRITICAL - RELATED TO 1ST BUT NOT AS BAD HIGHER VALUES - NOT NORMALLY CONSIDERED
http://usdidactic.com/refpdf/g unt/04062000%202.pdf.

COMPRESSORS
FOR LARGER UNITS VIBRATION MONITORS ALARMS SHUTDOWN CIRCUITS LOCAL CONTROL PANELS
http://www.nt.ntnu.no/users/lovlan d/SIK3035/pictures/compress.htm

COST CALCULATIONS
DETAIL AND SOURCE DEPEND ON LEVEL OF ESTIMATE REQUIRED (FIGURE 6-4)
FEASIBILITY - OUTLINE SPECIFICATION QUOTATION - COMPLETE SPECIFICATION BUDGET - AWARDED CONTRACT COSTS IN TEXT ARE BASED ON 2002 DATA COST ESTIMATES ON WEB SITE MAY BE MORE CURRENT COSTS IN SUPERPRO ARE MORE CURRENT VENDOR DATA IS CURRENT BUT MUST BE VERIFIED WRITTEN OR E-MAIL QUOTE

COST ADJUSTMENTS
SCALE-UP FACTORS DEPEND ON
TYPE OF EQUIPMENT SIZE OF EQUIPMENT CATALOG VERSUS CUSTOM EQUIPMENT

COST2 CAPACITY2 = COST1 CAPACITY1

SEE TABLE 6-4 FOR TYPICAL EXPONENT VALUES MATERIALS OF CONSTRUCTION

COST SCALE-UP DUE TO TYPE OF EQUIPMENT


FLUID FLOW EQUIPMENT SCALES UP BY 0.67 WHICH IS THE RATE THE AREA OF THE PIPE INCREASES WITH VOLUME EQUIPMENT LIKE HEAT EXCHANGERS
HAVE FIXED COSTS FOR HEADS VARIABLE COSTS FOR TUBES (AREA)

ROTATING EQUIPMENT DRIVE MOTORS COSTS VARY BY VOLTAGE

TYPICAL FACTORS IN COST SCALE-UP FOR FACILITIES


MATERIALS OF CONSTRUCTION
SS TYPICALLY THREE TIMES CARBON STEEL SEE FIGURE 12-41 FOR OTHERS

PRESSURE AND TEMPERATURE


AS PER FIGURE 14-15 ALSO MAY CHANGE CODE REQUIREMENTS

EXAMPLE FOR SOLID OXIDE FUEL CELL STACK IS ON THE NEXT SLIDE
http://www.iit.edu/~smart/garrear/fuelcells.htm

SOFC SCALE-UP EXAMPLE

www.netl.doe.gov/publications/proceedings/06/seca/pdf/Thijssen.pdf

SCALE-UP FOR INFLATION


INFLATION - USE M&S OR CHEMICAL ENGINEERING INDICES
COSTNOW CEI NOW = COSTTHEN CEI THEN

VALUES ARE AVAILABLE IN CHEMICAL ENGINEERING MAGAZINE SEE TABLE 6-2 FOR INDICES THROUGH 2002

MARSHALL & SWIFT INDEX


CHEMICAL ENGINEERING MAGAZINE, DEC 2006

10

CHE PLANT COST INDEX (CEPCI)


CHEMICAL ENGINEERING MAGAZINE, DEC 2006

CURRENT BUSINESS INDICATORS CHEMICAL ENGINEERING MAGAZINE, DEC 2006

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DATA SOURCES VENDOR INFORMATION


EQUIPMENT VENDORS CAN BE VALUABLE SOURCES OF DATA FEASIBILITY PROJECTS
RECOMMEND TYPES OF EQUIPMENT BASED ON PROCESS REQUIREMENT PROVIDE DATA FOR OUTLINE SPECIFICATIONS PROVIDE COST & SCHEDULE DATA PROVIDE OUTLINE DIMENSIONAL & UTILITY DATA

VENDOR SUPPORT
PROJECT EVALUATION
EXAMPLES OF SIMILAR EQUIPMENT INSTALLATIONS ACCURATE COST DATA FOR ESTIMATE ACCURATE UTILITY DATA FOR DESIGN ACCURATE OUTLINE DRAWINGS

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VENDORS AS CLIENTS
PROJECT AUTHORIZATION AND FINANCING
HARD MONEY QUOTATION ALL DESIGN DATA NEEDED FOR INSTALLATION ALL INTERFACE DATA DETAILED FABRICATION, TESTING & DELIVERY SCHEDULE DETAILED CASH FLOW SCHEDULE QUALITY CONTROL DATA

WITH AWARD

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