mo DANTE BAérbiio 5 Ap! 2eoo uop INTRODUCTION TO PROCESS DESIGN ~ LIMITED DISTRIBUTION ~ This material is UOP LLC technical information of aconfidential nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC April, 2000uop Introduction to Process Design Section VII Line Sizing/Hydraulics - LIMITED DISTRIBUTION — ‘This material is UOP LLC technical information of aconfidential nature for use only by personnel within ) your organization requiring the information. The material shall not be reproduced in any manner or distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC. April, 2000WED raining services Line Sizing and Hydraulics General Line Sizing Comments Guides and Approximations Reduce Time for Line Sizing Computer Not Required Good Judgment and ExperienceGuidelines = Use “normal” flow rates and “normal” pressures from process design = Consider effect of: = Design flow rates - Maximum flow rates = Startup Shutdown ~ Upset Guidelines = Use flow sketch to summarize hydraulics and line sizing data = Flow sketch will help to visualize effect of static headPrinciple Criteria ™ Pressure drop in psi/100 feet ™ Velocity in feet per minute Required Physical Properties = Flowing Specific Gravity - ratio of the density of the liquid at its flowing temperature to the density of water at a base temperature, usually 60°F (15.6°C) or 39.2°F (4°C), its point of maximum density (1000 g/em®) ™ Vapor Density - pounds per cubie foot = Vapor Specific Volume - cubic feet per poundSonic Velocity of a Vapor = A compressible fluid cannot move faster than the speed of sound in that fluid ® Typical problem in vacuum heater transfer lines, pressure relief piping, and high pressure drop systems ™ Usually occurs at end of a pipe or system (at a change in cross-sectional area) = Ifsonic velocity is disregarded, the flow rate may be over-calculated Sonic Velocity of a Vapor ™ For a typical Cp/Cy of 1.1, the speed of sound is equal to: {Temperature °R Vs = 14,000, | SPST Te Molecular Weight ™ Sonic velocity is expressed in units of feet per minute ™ Sonic velocity is proportional to: \CpievSpecific Volume Change = If total line AP < 10% of upstream absolute pressure, either upstream or downstream, specific volume is acceptable for line AP calculation = If total line AP < 40% but > 10% of upstream absolute pressure, use average specific volume = If total line AP > 40% of upstream absolute pressure, design line in sections Mechanical Considerations = Minimum size rack piping 1” = Minimize purchasing, detailing and inventory by avoiding 114", 2¥4", 3%", and 5" pipe = For 2" and smaller pipe size, Schedule 80 minimum is recommendedPipe Wall Thickness ® Pipe O.D. is constant = LD. changes as walll thickness changes = Be careful of L.D. in high pressure or high SS corrosion allowance systems [° _., = Wall thickness tolerance is + 12% for . seamless pipe up to 24” O.D. = Wall thickness tolerance is + 0.01" if pipe is fabricated from rolled plate Revamp Considerations = Economics and decision factors are different = Line size can often be smaller than for new plantsPressure Drop for Liquid Flows = The general equation for pressure drop of a liquid in a pipe can be expressed as the Darcy ‘Equation in the form: fxpxLx Vv? 144x Dx2xg Pressure Drop for Liquid Flows where: AP = Pressure Drop (psi) p = Density (ib/ft?) f = Darcy Friction Factor four times the Fanning Friction Factor L_ = (Equivalent) Length of pipe () V = Velocity (ls) D = Internal Diameter (ft) 4 = Internal diameter in) g = Gravitational Constant (32.2 ft/s?) Q = Flow (pm)Pressure Drop for Liquid Flows = By rearrangement of the equation, we can obtaii Pressure Drop for Liquid Flows ™ Simplifications ~ Assume L = 100 ft of equivalent length Define AP,1oq)= 100 AP ‘Substituting p = 62.4 Ib/ft? x SG where SG = Specific Gravity of fluid By substitution and rearrangement yields: APjoo _ 1.348f x Q? 8G aPressure Drop for Liquid Flows APi00 ~ Define APoaoo) = “SE = By substitution: 1348 fx Q? @ = For small changes in flow, Q, assume Fanning Friction Factor remains constant. Thus we can define a constant K as follows: AP (100) = Pressure Drop for Liquid Flows 1 The equation then becomes: Poaso) = K @ which plots as a straight line on a Log-Log graphAPo(100) UOP Pressure Drop Chart for Liquid Flow GPM |APo(100) based on liquid viscosity of 0.6 centistoke and turbulent flow Viscosity Correction = Chart AP is based om a liquid with a kinematic vis For multiply chart AP correction factor (v/0.6)"2 cure cosity of 0.6 centistoke r materials with different viscosities, 02 ae (ee) Kinematic viscosity in centistoke Absolute viscosity in centipose Density, grams/ec @ 4°C # °Viscosity Correction = Example: ~ For v= 20 Centistokes 02 02 v 29) | =(=) =2.016 Gd -G (Correction is for turbulent flow, Reynolds ‘Number > 2000)Liquid Flow Line Sizing/AP Calculation = Flow Rate 500 gpm. Flowing Sp.Gr. 0.75 Viscosity 0.6 centistoke a, Find AP/100’ in 6" Sch 80 Pipe b. Find AP/100' in 8" Sch 40 Pipe ¢. Find Velocity in 8" Sch 40 Pipe d. Find Corrected AP/100' in 6" Sch 80 Pipe if'o=50 centistoke e. What size pipe would result in a AP/100' = 0.28 psi if flow is 4000 gpm, Sp.Gr. = 0.8 and v= 0.6 centistoke? Pressure Drop for Vapor Flows = The general equation for pressure drop of a vapor in a pipe can be expressed as the Darcy Equation in the form: 3.36 x 106 x fx L x W? x V e AP =Pressure Drop for Vapor Flows Where: AP = Pressure Drop (psi) p = Density abit?) f = Darcy Friction Factor four times the Fanning Friction Factor ‘Length of pipe () Specific Volume (feb) Internal diameter (in) Mass flow rate (lbh Pressure Drop for Vapor Flows = Simplifications — Assume L = 100 ft ~ Define AP, (190) = By substitution and rearrangement we obtain: ser wy ‘APyiaon) = 3204 (100) “= (1000)Pressure Drop for Vapor Flows = For small changes in flow, W, assume the fanning friction factor, f, remains constant. Thus: 3368 - Constant.K a 2 Ww. eum = &( 59) © This plots as a straight line on a Log-Log graph UOP Pressure Drop Chart Sor Vapor Flow ‘APO (100)a Vapor Flow thru Commercial Steel Pipe beg AR 2 NEXIS 2 1,35 Vapor Flow thru Commercial Steel Pipe (See Other Ch Smaller Sizes)Vapor Flow thru Commercial Steel Pipe Vapor Flow Line Sizing/AP Calculation = Flowing Quantity 40,000 Ib/h Specific Volume 0.9 fb a, Find AP/100’ in 6" Sch 80 Pipe Find AP/100' in 8" Sch 40 Pipe Find Velocity in 8" Sch 40 Pipe What size pipe would result in a AP/100" equal to or less than 0.4 psi, if the flow is 100,000 tb/h and density is 2 Ib/ft?? e. What is the velocity in the line? eosTwo Phase Flow Pressure Drop = Correlating Factors = Liquid volume fraction = Ratio of pseudo 100% gas AP and pseudo 100% liquid AP ~ Ratio of AP two phase and pseudo 100% liquid AP sn TS amanTwo-Phase Flow Pressure Drop 1. Calculate fictitious all vapor pressure drop, AP’ using total mass flow and flowing vapor Properties 2. Calculate fictitious all liquid pressure drop, AP’, by converting total mass flow to liquid (gpm) and use the flowing properties of the liquid phase Two-Phase Flow Pressure Drop 3. Calculate the ratio AP’g / AP", 4. Calculate the actual liquid volume fraction a ViL+VG Liquid Volume Fraction =Two-Phase Flow Pressure Drop 5. Using these last two values and chart, determine factor, f, where f= APyp/ AP", 6. Caleulate two-phase pressure drop, APrp APyp= fx AP", Two-Phase Flow Pressure Drop Note: If the line size is to be determined, calculate AP*, and AP based upon an assumed line size. Then, if necessary after Step 6, re- estimate the line size and repeat the calculation until AP; is sufficiently close to the desired rate.Two-Phase Flow Pressure Drop Calculation Process Conditions Vapor Flow Specific Volume Liquid Flow Specific Gravity Line Size 47,000 Ib/h 0.303 f°Ab 443 gpm 0.494 12 inch Sch 40Two-Phase Flow Pressure Drop Calculation = Step 1 — Calculate the mass flow rates Wootal = Wiiguia + Wvapor Wiigsia = 443 gal/min x 8.34 Ib/gal x 0.494 x 60 min/h = 109,508.5 Ib/h Weapor = 47000 Ib/h Worn = 109508.5 + 47000 = 156,508.5 Ib/a Two-Phase Flow Pressure Drop Calculation = Step2 Caleulate AP"g assuming all of the material is vapor and use the vapor fraction properties = Use AP chart to get APy9) — AP oo = 0.47 (for 12" Sch 40) ~ AP joo = 0.47 x 0.303 = 0.142 psi/100"Two-Phase Flow Pressure Drop Calculation = Step3 ~ Calculate AP*, ~ Calculate the liquid volumetric flow assuming all of the material is liquid and has the properties of the liquid fraction 1565085 Ib: 1095085 bb ~ Use the DP chart for liquids to get APg9 AP yop 0.034 ps for 12 inch Sch 40 pipe AP pgp” 0.034 x 0.494 = 0.017 psi00" Qgpm = 443gpm x = 633gpm Two-Phase Flow Pressure Drop Calculation = Step 4 ~ Calculate the ratio of the fictitious gas to liquid pressure drop AP" g/ AP", = 0.142 / 0.017 = 8.4Two-Phase Flow Pressure Drop Calculation = Step 5 = Calculate the liquid volume fraction Vu Vu+Ve ~ Calculate the liquid volume 443 gpm x 8.34 Ib/gal x 0.494 x 60 mi 0.494 x 62.4 Ib/ft3 v= » Vi = 3552.5 £8/h Two-Phase Flow Pressure Drop Calculation = Step 5 (continued) ~ Calculate the vapor volume V,, = 47000 Ib/h x 0.303 ft/lb = 14241 f8/h 3582.5 ~ Liquid volume fraction = >">? ___ 3552.54 14241 Say 02Two-Phase Flow Pressure Drop Calculation = Step 6 ~ From two-phase flow chart ~ £=3.0 = f= AP'yp/ AP*, = AP*yp=3.0 x 0.017 = 0.05 psi/100" Two Phase Flow Line Sizing AP Calculation = Find a Schedule 80 pipe size that will result in approximately a pressure drop of 0.5 psi/100" as a result of two-phase flow having the following parameters ~ Liquid flow Rate 500 gpm Sp.Gr. 0.75 - Vapor flow Rate 40,000 tb/h Sp.Vol. 0.9 fbFlow Patterns Check for Slug Flow in 12" Schedule 40 Pipe = Annular or mist flow is usually assured if the velocity in ft/s is approximately equal to (or greater than) 60 divided by the square root of the mixed phase density in Ibs/eu.ft. vee in felsee. emp Flow Patterns 156,508 _ Pap = “Fpang 7 880 Ibseu.tt 17,794 oe As 6.36 < 202 fe ‘2 3600 x 0.7773 6.36 < 20.2 ft/s Check further by use of chartApproximate Two-Phase Flow Patterns Wertical Upflow) Flow Patterns = Calculate Chart Coordinates 156,508 _ 5.910/s—1e? Mass velocity = 96508. 3600%0.773 1 1 (We Wo) '(ee PL) SU, Hg) 214 x 0.33 135 aFlow Patterns (Wz We )*® = (109,509 /47,000)" (06 / px)" = (3.30/30.8)" = 0.33 (4/46 = (0.6 x 0.494/0.015)" =1.35 Slug flow is indicated Line Sizing Criteria u Tables give pressure drop and velocity for various flows and pipe sizes - BUT - m= The engineer needs to be familiar with the reasonable and desirable piping design pressure drop and velocity for a given service - HENCE - = Line sizing criteria which are based upon years of experience and studies, but should always to treated as a guideLine Sizing Criteria ™ Assumptions for Economic Pipe Sizing - Flow in pipe is turbulent - Motive power is supplied by pump or compressor ~ Pump NPSH requirement must be met — Slurry lines to have velocity high enough to avoid settling, but low enough to avoid excessive erosion Line Size Criteria Index of Type Numbers Type Description L Gravity Flow a Pump Suction 3. Pump Discharge 4. Liquid To Non-Pumped Reboiler 5. Reboiler Return To Column 6. ‘Column Overhead VaporLine Size Criteria Index of Type Numbers Type Description 7 ‘Column Hot Vapor Bypass 8. Column Overhead Condenser Rundown % ‘Compressor Suction 10. Compressor Discharge 11. Bligh Available Pressure Drop (25 psi or more available for piping friction) 12, Feed toa Column Line Size Criteria Index of Type Numbers Type Description 13. Vacuum Unit Heater Transfer 16. Liquid at its Bubble Point to a Control ‘Valve or Steam Trap i. ‘Steam Condensate After a Control Valve or Steam Trap 18. Makeup Gas to a Hydrogen Consuming Process 23. Cooling Water 24. Static Electricity Consideration:Type 1 Gravity Flow ™ Criteria: AP/100 (psi) = 0.15 max. = Remarl : Can be higher if line is mostly vertical Type 2 Pump Suction = Liquid at bubble point or less than 50°F below it ~ Criteria: AP/100 (psi) = 0.15 max. - IfFCC main column bottom or similar solids- carrying stream, velocity should be 180 feet per minute minimum (fpm) to avoid settling of solids ~ For lines 3" and smaller, 180 fpm will result in AP/100 in excess of 0.20 psi which should be ‘accommodated in determining NPSH availabilityType 2 Pump Suction (continued) = Liquid 50°F or more below bubble point or having vapor pressure 25 psi below system pressure — Criteria: AP/100 (psi) = 0.35 max. Type 3 Pump Discharge = Single Line Pump Discharge AP/100 (psi) = 1.5 max. Velocity (fpm) = 700 max. ™ Applies To Carbon Steel Piping - “Low pressure level” includes pump discharge lines with design pressure of 1400 psig and design temperature of 150°F, or other combinations of pressure and temperature to give equal or lesser required pipe thickness and flange ratings. = CriteriType 3 Pump Discharge (continued) = Applies to Carbon Steel Piping (cont.) ~ “High pressure level” results in increased pipe thicknesses and flange ratings. Pump discharge lines are usually sized close to the upper limit. ~ Alloy pump discharge piping is more likely to be sized at or above the limits of the above criteria due to the very high cost of alloy materials. Type 3 Pump Discharge (continued) - For laminar flow, LS-R00-18 is not optimum. Laminar flow exists for Reynolds Numbers below 2000 Reynolds Number = G160(Q), (@(estks) Where Q = flowing gpm d= id. (inches) estks = flowing viscosity in centistokesType 3 Pump Discharge (continued) = Downstream of a pump discharge with different conditions than at the pump = Criteria: AP/100 (psi) 1.5 max. ~ 1f100% liquid, velocity (fpm) = 700 max. ~ 1£100% vapor, velocity (fpm) = 6000 /./2, where p,= flowing density, Ib/f? Type 3 Pump Discharge (continued) — If the line is the transfer line of a fired reboiler heater or other pumped reboiler, and itis desired to minimize heater outlet temperature: — AP/100 (psi) max. = 2.5% of column bottom absolute pressureType 3 Pump Discharge (continued) = Avoid slug flow in vertical upward two-phase flow. If it is impossible to satisfy this criterion (which sets a maximum permissible diameter) and those given previously, then Take (and allow for) more pressure drop ~ Specify more vapor Type 4 Liquid to Non-Pumped Reboiler = Criteria: AP/100 (psi) = 0.15 to 0.20Type 5 Reboiler Return to Column ® Criteria: - Kettle type: AP/100 (psi) = 0.15 max. ~ Thermosyphon or once-through type, non- kettle, non-pumped. For pumped types, see Type3 — AP/100 (psi) — Velocity < 5.0} in a Remarks: Maximum permissible size = 30" 10 - 0.20 max. nominal Type 5 Reboiler Return to Column = For two-phase flow, the line should be checked for slug flowType 6 Column Overhead Vapor = All except FCC main column and crude vacuum column overhead vapor lines Operating Pressure, psia AP/100 >300 1.25 150 to 300 0.75 14.7 to 150 03 3.75 to 14.7 0.15 <3.78 4% of absolute pressure Type 6 Column Overhead Vapor ~ Criteria: limiting equations , 100 _ — AP/100 (psi) = 02g 190 _\mnax, - *(javeaa)™ — Velocity (fpm)= 6000/,/py Max. P = receiver pressure, psia a Py id, inches overhead vapor flowing density, Ib/f?Type 6 Column Overhead Vapor = FCC main column overhead vapor ~ Criteria: AP/100 (psi) = 0.10 max. = Crude vacuum column overhead - AP over its entire length is not more than 7% of flash zone absolute pressure, limited to flash zone pressures of 35mm and greater Type 7 Column Hot Vapor Bypass = Criteria: AP/100 (psi) = 0.5 max. ~ Remarks: For amount of vapors through hot vapor bypass, use the following formula: W= [(Mol), + 0.06 (Mol/4),}IM} W = bypass vapor, Ib/h (Moh), = normal mols/h of net gas (MoV/h), = normal mols/h of gross column overhead vapors M, = mol weight of gross overhead vaporsType 8 Column Overhead Condenser Rundown = Totally condensing, single phase: ~ Criteria: Limiting equations 100 \ AP/100 (psi) = 0.10 Jp ( max. 333 + 278d Velocity (fpm)=200 max. — p = receiver pressure, psia —4 = id, inches Type 8 Column Overhead Condenser Rundown ~ Reduce to 50% where minimum pressure at column is critical aType 8 Column Overhead Condenser Rundown = Totally condensing, with traces of a second liquid present and a piping arrangement that would permit pockets of the second liquid phase to accumulate = Velocity > 350 fpm Type 8 Column Overhead Condenser Rundown = Partially condensing, vapor and liquid present ~ criti: P00) = 040 ges" ne 53 +2, — Use half of the above limiting pressure drop for columns where minimum pressure at column is critical — p = receiver pressure, psia —d = id, inchesType 8 Column Overhead Condenser Rundown = Check for slug flow on vertical upflow lines ™ Special attention should be given to the rundown line if it is part of a pressure relief route Type 9 Compressor Suction m Reciprocating compressor = Criteria — AP/100 (psi) = 0.043. Jp max. — AP/100 (psi) = 1.0 max. , a — Velocity pm) = 2000 285. max. + p= line pressure, psia + MW = gas molecular weightType 9 Compressor Suction = Centrifugal compressor ~ Criteria — AP/100 (psi) =0.043,/p max. — AP/100 (psi 1.0 max. 02s — Velocity (fpm) = 3540 / py max. line pressure, psia eo , = gas flowing density, Ib/ft Type 10 Compressor Discharge = Reciprocating compressor ~ Criteria — AP/100 (psi) = 0.043.Jp max. — AP/100 (psi) = 1.0 max. —— — Velocity (fpm) = 3000 fae + p__ = line pressure, psia + MW = gas molecular weightType 10 Compressor Discharge = Centrifugal compressor — Criteria 7 — AP/100 (psi) = 0.043 fp max. — AP/100 (psi) = 1.0 max. — Velocity (fpm) = 6000 / [py max. P= line pressure, psia by = gas flowing density, Ib/ft? Type 11 High Available Pressure Drop > 25 psi ™ Criteria: Use up, but do not exceed, the available pressure drop. Also, observe the following limitations, except for pressure relief: = 100% liquid AP/100 (psi ‘Velocity (fpm)Type 11 High Available Pressure Drop > 25 psi ~ 100% vapor ‘AP/100 (psi) = 1.0 max. Velocity (fpm)= 6000 // py max. — Vapor plus liquid ‘AP/100 (psi) = 2.0 max. Type 11 High Available Pressure Drop > 25 psi Remarks: Allow high piping AP, but consider erosion, noise, and vaporization. For vaporizing materials, use downstream conditions for calculations of AP.Type 12 Feed to a Column = Ifline is a pump discharge, treat as Type 3, except limit the 100% liquid case to a velocity of 700 fpm. = Ifline has high available pressure drop, treat as Type 11, except limit the 100% liquid case toa maximum velocity of 700 fpm. Type 12 Feed to a Column = Ifline is other as indicated above 100} = AP/100 (psi) = 3.0 | NO | max = If flow is 100% liquid — Velocity (fpm) = 700 max.Type 12 Feed to a Column — If flow is 100% vapor: — Velocity (fpm) = 6000 /7>y max If flow is two-phase: Apply the criteria for slug flow Type 13 Vacuum Unit Heater Transfer = Determine equivalent length of the line = Determine heater outlet pressure, which is often 3.0 psia ™ Base line sizing calculations on only the vapor portion of the flow, use 98% of the actual inside diameter to account for presence of liquid = Observe the sonic velocity limitationType 16 Liquid At Its Bubble Point to a Control Valve or Steam Trap = Criteria: AP/100 (psi) = 0.5 to 1.5 max. Velocity (fpm) = 700 max. Remarks: Consider elevations of liquid surface and control valve. Consider length of line. ‘The pressure drop due to friction should be well below the static head increase in pressure due to lower elevation of the control valve in order to avoid vaporization before valve. Type 17 Steam Condensate after a Control Valve or Steam Trap = With control valve located in steam line — AP = 1/2 (Psatstm at exchanger temp) ~ (P cond. at battery limit) = With control valve in condensate line = AP/100 (psi) =7.5 max. = Limit AP/100 to 67% of above to allow for roughing of pipe wallType 18 Make-up Gas to a Hydrogen Consuming Process = Criteria = Remarks: Consider length of line. Take smaller AP/100 for long lines. Type 23 Cooling Water = Criteria 0-700 gpm: Max. AP/100 = 1.3 psi 701-2800 gpm: Max. Velocity = 500 fpm 2801-7000 gpm: Max. Velocity = 600 fpm Over 7001 gpm: Max. Velocity = 700 fpm ~ If film type corrosion protection is used, maximum velocity should be reduced to 350- 500 fpm.Type 24 Static Electricity Consideration ™ Criteria: Velocity (fpm) = 400 max. m= Remarks: For hydrocarbons whose vapor pressure is such as to form an explosive mixture with air; such as kerosene and jet fuel to storage tanks. | M7 expbenes | Hydraulics Objectives Procedure Equipment Elevations Typical Equipment Pressure Drops Operating at Non-Design Conditions Examples — NPSH for a pump ~ Pumped circuitObjectives Establish Logical Piping/Equipment Systems Determine Performance Requirements of Pumps, Compressors, Control Valves Set Location for Relief Valves Establish Design Pressure for Equipment Procedure = Establish Process Conditions = Lay Out Hydraulic System = Size Lines and Determine Pressure Drop = Set Equipment Elevations & Select Fixed Pressure PointProcedure = Select Equipment Pressure Drops & Determine Variable Pressure Drop/Increase - Pressure drop for control valves ~ Differential head for pumps and compressors = Tabulate Pressure Values in Cireuit = Determine Equipment Maximum Operating Pressure = Select Relief Valve Location and Set Pressure = Establish Equipment Design Pressure Elements of a Hydraulic System Fixed Pressure Point Statie Pressure Requirements Variable Pressure Requirements Pressure Source or Generator Pressure ControllerColumn Elevation Set By = Bottoms Pump Suction Head Requirement = Thermosyphon Reboiler Head Requirement = Mechanical Requirement Receiver Elevation Set By = Overhead Pump Head Requirement ™ Mechanical Requirements - Water bootNet Positive Suction Head NPSH = Pressure requirement in excess of the fluid vapor pressure at the suction flange of a pump = NPSH(R) is a characteristic of the pump = NPSH(A) is set by the design engineer m= Expressed in feet of fluid being pumped NPSH = Contractor’s Calculation = Engineer’s CalculationNPSH = Engincer’s Calculation to Set a Vessel Evaluation - Estimate minimum NPSH required ~ Estimate pump centerline above base line — Estimate suction piping friction loss — Investigate system absolute pressure — Determine minimum controlled liquid level in the vessel ~ Evaluate need for contingency Single Stage Centrifugal Pumps Minimum Required NPSHNPSH(R) for Single Centrifugal Pumps = 18 3 16E a 3 2 0 3 8 é SOT eer = esta) [sas (90H zg ¢ We {oso Sa = 4 ee g, $= Seton Spite Spent zo sua ° 100 200~=—«300S 400500 Rated Capacity, gpm Typical Column Bottoms Pump ro n = el erin From Chart BastineNPSH m Design a system that provides sufficient NPSH for the following column bottoms pump Single Stage Pump Capacity 500 gpm Specific Gravity 0.65 Line Frequency 50 Hz Pump RPM 1450 (Half Speed) Assume Vapor Pressure = System Pressure NPSH Example Calculation 1, NPSH(R) from chart or manufacturer 62 ft 2. Pump centerline above base line 25f 3. Friction loss For 8" line APyip= 0.11 psi 1500 equivalent feet 2of ‘Suction valve (Assume gate valve - one Tine size smaller) Equivalent length = 13 D AP = (0.11 psi)(8"/6")(3)(6"N12")(1/100)2.31/0.65) 0.1 Suction strainer Equivalent length = 300 ft (0.46 psi)(300/100)(2.31/0.65) 4g ftNPSH Example Calculation 4. System Pressure - Vapor Pressure =0 oon 5. Minimum Level in Vessel 0st 6. Contingency 20f 15% of NPSH(R) 2.0 ft Minimum NPSH Example Problem Summary 1. NPSH(R) 62ft 2. Pump Centerline Elevation 25ft 3. Friction Loss = (2.0 + 0.1 + 4.9) 7.0 ft 4. System Pressure 0.0 ft 5. Minimum Level 05 ft 6. Contingency 2.0 ft TOTAL 172 ft (From Baseline to Bottom of Vessel)Thermosyphon Reboiler Hydraulics xt Loe Colaran T Two Phase Sec Exciget nance Las mesma Exchanger rion Loss Thermosyphon Reboiler Systems Trial Line Size for Maximum 30% Vaporization = Inlet Piping = 12 Mninen oe | 112 bia ote = SS ia. pe | |e cariee 1-0" Buedon Ve! SiMinimum Reboiler Elevation umn) a 12x Dia. of Pipe Piping Pressure Drop = AP charts give pressure drop for 100 feet of Piping = But piping circuits consists of straight piping and fittings, like ~ Elbows ~ Tees - Valve = Solution is to convert fitting AP to equivalent straight pipe lengthRepresentative ‘quivalent Length in Pipe Diameters (L/D) of Various Valves and Fittings Typical Calculation of Piping Equivalent Length - 8" Pump Discharge LineResistance Due to Sudden Enlargements and Contractions TT TT41 s oem _ yaat SE |" Lt t iF i 4a, esse, Resistance Due to Pipe Entrance and Exit tbe ££ L ae leet Gel ge K-07 — Ke0So Kx023 K=004 Inward ‘Sharp Sigh ‘Wall Projecing Edged Rounded Rounded Pipe Emrance Entrance Entrance Enizance K=10 Keo K-10 Projecting Sharp Rounded Pipe Esgea Et Eat BatTypical Heater Pressure Drops = Crude Heaters 125 psi = Vacuum Heaters 75 psi = Hydrotreating Heaters 20-60 psi = Platforming (per heater) 3-20 psi = Thermal Crackers 200 psi Typical Heater Pressure Drops = Coker Heaters 300 psi &™ Visbreakers 250 psi = Hot Oil Heaters 20-40 psi = Fired Reboilers 50 psi «= Fractionator Charge 40 psi Preliminary pressure drops - Must be confirmed or corrected based on final heater design~ Typical Heat Exchanger Pressure Drops = For normal, fluid exchangers, allow at least 5 psi pressure drop on each side of each shell Typical Heat Exchanger Pressure Drops = Exceptions = Cooling Water Side 10 psi ~ Combined Feed Exchangers 2-5 psi/side = Condensers 1.5 psi ~ Reboilers - Kettle and 02-05 psi Thermosyphon = Reboilers - Forced 5-10 psi Circulation Vacuum Condensers 10-25 mm mercurySdlecsasen LA Mayen A los > Control Valve Pressure Drops dis Meco COMTA| = Control valves in pump discharge circuits - allow greatest of: = 25 psi ~ 50% of system friction pressure drop ~ 17-10% of pump differential Control Valve Pressure Drops ® For other control valves, allow pressure drop in accordance with available pressure ™ Control valve rangeability consideration is from turndown to 110% capacity determines normal AP = Control valve compensates for changes in operations and system agingSystem Hydraulic Curves Atmospheric Fixed Point Pressure ' — rR Head, ft Pop Cure Capacity, gpm P Vveonth { ther beh, et —s System Hydraulic Curves Elevated Fixed Point Pressure A Sysem Fc asim Open Head, ft Conse ave ‘oP Pap Carve Sasi or Eke (ae Capacity, gpm a abertir_. sof bat 9) Newel bee Leu Aig )System Hydraulic Curves Fixed Available Pressure Source __ Marin Opering hou Fase Contr Valve Sys Friction e enue Bop _ ae = a > Capacity, gpm Control Valve AP Selection Situations Fixed 0 0 250 500 Frictional 25 100 100100 Total 25° 100 «350 = 600 AP Options 25 Min. 25 25 25 25 30% Friction 12.5 50} 50 7-10% Diff 25 10 35 60 P Pump Discharge 50 150 400660Hydraulics of a Fractionating Column ™ Goal - Determine normal operating pressure profile — Determine relief valve settings and location ~ Determine equipment design pressure Hydraulics of a Fractionating Column = Procedure — Establish process flow diagram for fractionator ~ Establish fixed pressure locations ~ Establish line sizes and lengths ~ Establish pressure drops for each piping segment — Establish fixed pressure drops (static head) ~ Establish equipment and control valve pressure drop - Establish the pump differentialHydraulics of a Fractionating Column = Procedure ~ Recalculate control valve pressure drop, system pressure drop, and pump differential for alternate cases — Establish relief valve setting and location ~ Establish equipment pressure at relief valve setting = Set Design pressure of equipment Check for overcapacity requirements ~ Check for alternate operations Aromatics Fractionationvop _Heat and Weight Balances Banner ve Ses OyAy = Aromatics Fractionation = Reflux Line DetailsFractionator Hydraulic Diagram BetteLINE SIZING/HYDRAULICS - ANSWERS, LIQUID LINE AP Flowing GPM = 300 Viscosity (centistokes) = 0.6 Flowing Sp. Gr. = 015 ‘A. Find AP/100° in 6” Sch 80 pipe AP = 0,88 x 0.75 = 0.66 psi/100" B. Find AP/100" in 8” Sch 40 pipe AP = 0,185 x 0.75 = 0.14 psi/100° C. Find velocity in 8” Sch 40 pipe Velocity = 200 fom D. Find corrected AP/100" in 6” Sch 80 pipe if v = $0 centistokes AP = 0.88 x 0.75(50/0.6)92 = 1.60 psi/100" E. What size pipe would result in a AP/100° = 0.28 if flow is 4000 gpm, Sp. Gr. = 0.80 and v =0.6 St? AP = 0.28/0,80 = 0.35 psi/100" 16” - 3/8” wall TPOIS-99 vop TSP)VAPOR LINE AP Flowing Quality Specific Volume 40,000 lb/hr 0.9 cu.ft/Ib A. Find AP/100" in 6” Sch 80 pipe AP = 1.6.x 0.9 = 1.44 psi/100° B, Find AP/100" in 8” Sch 40 pipe AP = 0.275 x 0.9 = 0.25 psi/100 C. Find velocity in 8” Sch 40 pipe Velocity ~ 1950 x 0.9 = 1430 fom ‘What size pipe would result in a AP/100° equal to or less than 0.4 psi if flow is 100,000 Ib/h and density is 2 Ib/cu.ft.? ‘What is velocity in line? 1 2ibleufe Spec. Vol, = = 05 cuftlb APp =0.4/0.5 = 0.8 psi/100° 10" Sch 40 Velocity = 3000 x 0.5 = 1500 fom IPD/S-99, uop LSP-2TWO PHASE FLOW Wy Liquid Volume Fraction = ie me a = SGx625° a) p> 500 x60 x 8.33 x0,75 = O75x625 500 x 60x 8,33x0.75 40,000 ri 0.75 x 62.5 1/09 _ 4000 4000 _ 919 4000 + 36,000 40,000 Total Flow Gas =W, +Wg = 187,500 + 40,000 = 227,500#/h We Total Flow Liquid W+Wa , e2rs0r 607, SG.x500° 075x500. Try 12" LINE (Schedule 80) t 1 AGOX 09x Total Flow AP °°" af 3 *709 _ 0.81 _ Total Flow AP, AP;g XS.G._0.032x0.75 0.024 AP,» = Total Flow AP, x Factor = 0.024 x 7.0 = 0.168 TPDI5.89 uop TsP3TWO PHASE FLOW Try 10" LINE (Schedule 80) 24x Wo9 216 _ Total Flow AP _ i 008x075 0.06 Total Flow AP, AP» = Total Flow AP, x Factor 8 x7 =0.56 Use 10" LINE TPDIS-99 ro} TSPHYDRAULIC TABULATION WORKSHEET PROJECT NO, SHEET, al BY. = DATE VAPOR AND LIQUID LINE (TWO PHASE FLOW) (CuQuID FLOW USGeM 300 @UIQUID FLOWING SP. GR. 075 UU FLOW LB FAR. x107 187,500 (VAPOR FLOW LB TAR, x 10° 40,000 QO TWTALLBAR. «105 2270 (© VAPOR SP. VOL CU. FTALB. 09 (@UIQUID VOLUME CP: 12 VAPOR 10 (@) TOTAL VOLUME CFS Taz (VOL TTOTAL VOL = LVF 0.40 © (@ LINE SIZE, INCHES i (5) PIPESCHEDULE 0 (3 FF ALL LIQUID UsPMIT) x GY@| oor (5 FRICTION PSU100 FT. (UNCOR) O08 @ ae CORR CHG) ‘06 OIF ALL GAS TBR x 10°) 27 (@ FRICTION PSI/I00 FT. (UNCOR} 24 Ore CORR] OO 216 @ Dero {OO @ 36 OFT TET) @ @, BE SEATON @O® 056 aPrp" (CORR) ® [Gi VELOCITIES FFM” (CORY aPL° FICTYTIOUS ALL LIQUID aP ‘aP? = FICTITIOUS ALL GAS 4P- EDS-RO2-2231 TPDIS-99 LSP-5Typical Calculation of Piping Equivalent Length. 8” Pump Discharge Line G Orifice Meter Pipe Lengths -4 4 Valves & Fittings Pipe Diameters ‘Swing Check Vave 2Gate Valves 890° Elbows 1 Tee (Branch Flow) 1 Tee (Through Flow) 267 ‘Total Equivalent Feet = 358 (Say 350 ft) ‘Total line friction drop is determined by multplying the total equivalent feet by the corrected friction pressure drop per 100 feet as determined from line sizing. 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Tap wana or Bu jmp ue gon Jo A doo sonaoswy osodind Kut Jo} pasn 20 souueus Kve wy paonpoides 20810410 6} POH038}P 29 0 a. ouop shee 25 East Algooqaio Road Des Pines noi 60017 US.A HYDRAULIC TABULATION Project A ecenerrcd Avge ht rape, Fiving SPR pve Cab nl Flow Vis, Centistokes Vis Corr Factor I Line ‘Nor |_Max | Nor | Max | Nor | Max | Nor_| Max | Nor | Max Flowing USGPM Flow, lbh x 10" Destination, psig Static, psi Exchange, psi [fens L Valve, psi th dal Pump Discharge, psig LT pap Suction pig Differential pi || Differential Head, ft Pressure Level, Th | not be disclosed to others or reproduced in any manner or used for any purpose et Fow [Sa | Dak [So [|S [ou [S[k [Dk re cia ano | == t 1 the property of UOP and sh Pump Description ‘permission of 8 provi Oper | Spare | Oper | Spare | Oper | Spare | Oper | Spare | Oper | Spare Type em No. Driver Power Condition NPSH Available Nas NOTE - These data ae confide ‘whatsoever except by L LS-R00-41 IPOILS-144Spr-svadl Us6+ ainsseig Buyesado (_) i mss ufo ra UDASDIG, INDAPAP] LOJDUOYIVAT €~~ MIXED PHASE LINE SIZING \, Liquid Volume Fraction = _“t_ = Vee SGx 625 WFP x 625 x 625 i . + Total Flow Gas = W,+W, = + = amr Total Flow Liquid = Mito _ = cpm SG. x 500 x 500 Try _" LINE f Total Flow 4Pa _ APoo x PR x Total Flow sPL Pi x S.G. x Pon = 1x 338 x x36x 2 Goa, 1 APre = Total Flow APL x Factor= x = Try __" LINE 1 Total Flow APs _ APoo x HER _ Total Flow APL APL x S.G. apo = 1x Sx x36 x? ona, rs APrp = Total Flow APL x Factor = x Use “LINE~ PIPE DATA Carbon and Alloy Steel — Stainless Steel (aleo see next tee pages) CRANE Nom [wside |__liesiienion Taatde [Ares | Transvere | Nomen] Weigh] Weigh [Extermall Secon ina! | Diam. 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Tom [Owais [_Wenifenion | Wal] Teale] Arca | Tranmere] Moment] Weir] Waigh [Ena Socioe imal | Diam | Sieel | Stin= | Thick-| Diam-| of | toueal rea | of | Pipe | Water | SurtaceModulve Pee test | nese | et | Met Ines a toon | sche. | Sioa | "Wo" |) © | | Cy” rowel Pouns| Bie | No | Sched. Savare| Square | Square [oer tn Inches | taces | Stef Ro tches] tches| tches| inches | Fect| tnchest| fon [ope = Pe |S Tat | uses |.aeoi7] 1960 | ae | 500 10s Kea | Maes [orn | 2388 | er | Set | Loe | 1am wm | com | std | “ie | os 200 | ‘nee |'ocem0| ee | a1 | 4am | Loe | 2258 xs | a | as Zera | te |‘onr0| 6m | so | $64 | toe | Sho ~[~ 1s vise [42s [tomes] 2810 | aee | eae | Lae | 120 10s Yesi | 1425 [ove | 3.968 | ser | ots | aie | L201 sina] 1223. |‘casao | 7289 | 10.79 | So | Lire | sine 4407 | 1150 |07966| s.e10 | sve | oe | Vim | azn Sid | “i | as Slee S595 | wat [lore | aves | i900 | ar | vive | Same s | wo | cea | oz fous | iszr |zsi | oe | vie | sass xx5 sin | rao [ose | isze | 24 | Sse | vite | ez yess faze |asse | sou | a3s |. 972 | ase | 2000 225 | mm Jism | ses | 77 | 9's | Lass | 3009 sD ‘288 | som | 4300| 2001 |‘1390 | isis | wer | ser | Lass | Sast s | sso | xs 35 | ces | C12] tery [aoe | aoe | a07 | Tes | ase | an soo | 456s | 7953 | 163s [luuse | asts | 2206 | 7.00 | 1ase | 9.230 | “es | 313 | ses | tear ors | 3003 | S296 | 63s | ass | 10.756 v0 | 403 [1340 | 297 |: | 33.63 | sass | St | Lass | 12000 oo | ear [az [sem | zoe [aes 1 2 | ass | iim | ate ‘ase | 6357 | 2.23} 314 [i200 | tea | 999 | ists | ame | ane ‘200 | 6.065 | s.sei | 2589 | 2005 | 2a | iso7 | 12st | 174 | 2a 3S 6 | 66s “sz | ster | sans | 2607 |fasi0 | ou | 2ns7 | iia | vas | zee . ‘sez | sso [ano | 2577 [lasso | oct | 3639 | 10.90 | cz | 498 cme | sam [isa | 23s |e | seo | sas | ous | itm | iz sx | S| aoe | door [asia | tee [i500 | esas | sate | aie | 1754 | 2000 zoe | sssi [sass | 26es | 995 | 2006 east son | sca |'3re | 50 | isa | 22.61 a2 6st | suas |'3om | sr | 22% | are a» Tae | suis [35s | 633s [20% | 217 ue amo | soa (34% | t249 | uss | 2170 168 8 | aes 2258 2258 ose ase peg reas | azo |'se29 | sez | as4 | ane | 2258 w16 | ase [sin fios7 | asso | as | 228 | 2st ras | 4a [5m fiers | S095 | ies | 228 | 2214 rat | 4059 fans pais | oon | 1759 | 2258 was | eso [ae fise? | erie | 1ece | 2250 2388 2288 36 aise | sta |‘2sre feo | 24 | isto 3156 ie ‘306 | ais [aver | 3045 [ose freso | 7469 | isa Ey 55 | am fiom | 42s | oso [som | eo | isis | aza0 | 2am | Hi | aos | Tes fino | sa | a2 f'sm2 | te9 | ass | 369s | 2a | 1450 S| “mw | | ‘250 fto2so | size | azse |isesi fais | 220s | 3576 | 2aie | aris go | 2: | “30 ftoise jroor | soo [sins [ise | daze | dto6 | dee | ans7 30 | 43 | “36s fiowo |ir9 | ras |‘sers jtoo7 | does | ac20 | dee | 29.90 0 e | 905 | ‘soo |'950 facto | r465 |-sias |aizo | sez | aaas | aan | ane wo |... | sos | ose [iss | r.8e [90 fous | ora | 31a | 2a | scs6 wo |<. | Sno | siz |226s | ois |‘srs2 [esc | ras | 20s | aan | soz i 44 } 9.002 25-26 | oss [sea |3262 | o.z0 | an96 | 201 | oo.ae xxs | 0 L000 | 2730 |3n63 | sats |‘si7e [sors |rocts | 2506 | 214 | oes Woo | 22. |aas | e500 |snce | sors [So [3003 [uses | 2030 | 2am | 2429 ce | = | SS | ase [izwe [or frase [ease fixe [2ose [os | sam | io2 . wos | ‘160 jiza50 | 711 frase fasts figos | 247 | Se | Same | 220 Nl) “ge |. | ‘20 fizaso | oe finzas Y'aras fio | sass | sior | sue | soz oe | al 330 fizoe lazer [nice ("7972 Jose | anz7 | ante | 38 | a9.0 sm |... | 463 | ‘ais hizow Jrese firszo [ese 279.3 | ao'so | do.on | ase | ane | © a6 |it.9g8 jis. fines [2773 |s003 | sao | asso | sas | a1 xs 5 | “Soo |itto i824 floes [tom [sors | asae | deve | 3358 | ser nea) ae lee |e se2 filers |2is2 poste [rar leone 46.00 | 338 | 628 80 8 Jitsve 260s hioves 7036 fazs.a ‘4604 | 2558 | te 100 ‘as (ioe [ss loots [osm |soue aves | 3358 | o8.1 S&S [am Koto fia7s0 |sesi | 90.26 eons fete fissee | sess | 3.58 |1007 140 his fiasoo |atos | asso [eo froos lisse | 312 | 338 fies i 160, raz fies |azis | oss [Sse fret frenzr | see | 30 [ioeAPPEND, b= ENGINEERING DATA CRANE PIPE DATA—cont. Wom [Bit | Teen Wal ate [er | ramsey] Waa] WA Emel Selon SS ect eg ee fee | cee | reg ae me ted oleae wa Size eon | Sched. | Steel | | (@) () | (4 | "Cy" |Pounds| Pounds | Sq.Ft} 77 be [Sac |S sans |S | gowe | |Poer ere |S ES (agdy tates | tees | SE Ti | tnt oct RS [FSS | SET ieee] [BS = S| ame] ee ee [ree ee] Be] Oe] se ae co [cy ]am |i TBS] 8 fie [ise | ie | BS SE] Sey Be a Be [iasee facan [ics | ‘Se | BS | Ea] S| 368) Ze 218 $e [tess | ie fies | Sas | Sut | Sa] SB] 68) es so] B | co | 38 Vea |e [ie | ee | et] £8] 8) es) se ve] | co | Se fibise | Hess AES | $58 | Et] a) S| aes) sz we frown | ss | |] Sh [ike | at [ES | oe | aa | st] ae | aes) oe ‘|e & lieu | te |e | ou | Sos] oe | S| is) 23 8 % |e | 82 BS | we) es | Be | sel ies) Be Sfoasd ) | a ibaa | eg (UES | S| Ges |) Se | Sas) 2 2) vis [ites | MSS Jie | i | Se |S | Se | ae | ne Bo [oo |1mo [iti | Sor fice | 8 [aes [HZ] Ze) es) ue co fim | |S Fae | [sess |e Re ate | Sos | Sas | ae 1 json | ea fires isms | ers] npr Pom] aes : te (iGen | 2h line fige | 53 | he Se ae] Be ie Bo liswo | ter [ima [tne | sar | Be | 8% | 2B) ss = Sie [ise | eae [ise (Las | gaz | 28 | oss | UB) Bo S| o | 38 [ieee | lea lie [128 | $4] 2h) Be) ve) se 6 [ise 8 ‘i liste | esd [ite [ides | Sie | Ba | Ra] | me 8 ‘sien |S [dha [te | se [meso | | OB | RS 8 soe lies | ate [loa [iis [vss [iat | oon | 28 | eS i | |e [Se | as [ie [roe [ies |e | a | cue | as HB fc JERR [ARS | Se | ies |e [aes |e | Go| cam | me we | |S AR | ae iste | ses [sss jae | Se] fie ie iio | sc: |iSs [ite | Seve [lina | ss [toes (se | $28 | 2H | BBS ~ os lace iam | aie] aa [ima | ara] we : 22 [ee [ibe | 182 | Be liee | GE[ Ss ii Em loos lige | $2 | bolita | se] 5 ES lone fate | goa | Set jiee | SM] 7 Be [aon [igi | S87) So |i | 3%] Ss ela Stir [Bao Jide | sos | aoe [BM | $23] Be |aw |e | ® Hip |meor [ise (ines | seu | at | 23 | 18s ® BS [ee (LBS Ss |e | Be | cae) ue 8 ie (se [tae [isis [er | 8 | 27 | 3 & secs (bine [iim [ies [nse | S| 272 | 2 GE ive [iSie [ame [ans | ee | 72 | BE 8 ai inves Jigen [dees [But | Sas | $22 | 252 | sass [item [iam [aeo [Rts | 22 | tne | Ere : 8 sors [ice [iin [smo lace | ‘uae | 22 | 355 = ue fea [aise] 2 | 3pm |i | sae ape : Be fame [Bare | G2 | Ua [ioe | BS] Bs |) ie | | Be lisse | ee [ace tte |e | oe ma | see] so | 3 Sis |lnzn | ia [boo leore [uso | Sea |e | S26 | eS (32 | 3 Sh |iem | fame lien [lure june |e | S26] BES 3 ot ligne | iets [oma liste [ime (ih (lam | £2 | 1st [mo 8 i a8 | dee oe fii Jame Ju |g | au | ue % it sie [Bete Jitu [eras [iter ims | S28 | 1s is BS lose [idee [See (eh [ibe | S| Sad te |< |r [ira | eran [esos [ies [ieee (Rew |e | sae | ms S List [iss peas [ase [rae [ince (oe | Se | $35 | fas Ls 15s [iso [as liar (nam (ease [See | BS | $88 | 2 : a [ae pow pam lm [ants [sie] or ae [ise | ite ee se | a2 | ge [ee | ee] er | “is 2 jitse | oe [sae fesne jing’ | 22 (BES | £08 | Bee so | 8 se vse |Bar [estes (pus flag? | a [ioe | 219 | 2 |S sie jiran |v lowes fies |iges hse [ioe | ote | Hs z jaw |S | 2 sis fang | eer [amas lease [isms [ee jie | B10 | es g ue fee [2% Be ies | sis | Bet oan UB (BS [aa es tae | Sa | Ss ) [oo fae We |e ee tee | £4 | Sas 8 ME WIR [as Be vot | E48 | 82CRANE _ B19 PIPE DATA—cont. Tom- [Outside | Wdeniicatn | Wall | Yoside | Aves | Transverse | Moment] Weigh] Weight [External] Section inal | Diam, [Steel [Stain | Thicke| Diam- | of | tnernal Area | of | Pipe | Water | Surtace [Modulus Pipe tess | neat | esr | Metal oer Ste ron | Sched. | Sie | “| (0) | |G)" |Pounds| Pounds) Se. Fe fp 7 Pipe | “No. | ened. Square | Square | Square et | per fot} er fot (a5) Inches | toches | Sie Nox |tnches| tncher | Inches | inches | Feet | tochet|_fowe_['o pie | of pipe = [ss 23.568 | 16.29 [436.10 | s.0zas | nisi. | $5.37 [188.98 | 6.28 | 96.0 io | 0s 250 | teas [asn7s [Som |isise | és. | ez9s | am | 109.5 sid | 2 23250 | zas |sonse [2040 | 10120 | 98.62 | 129s | eas | 169 KS ae | 25.000 | Sa91 |sis.ae | 2.009 | 2098 fias.ee |e | é2es | 225 of 22.816 | 4139 [$11.00 | 2a | 25030 |iao.ss | 7000 | cams | 2370 2 | 2400 ° zzens | ssn [aazo7 | 2.79 | sezrs |17129 | 17423 | 62m | 2251 o 22.062 | Taos [seo 3s | 2.sso | cosas |aunas | 168-52 | Czas | Sen? | 21562 | arrt |3es.20 |2s002 | sorz0 [aysss | 1ss26 | czas | s728 100 ‘2o9se | roeor |3ecs2 [2.3911 | oes |sorao | 90s | czas | S708 wo | 20.36 | 12531 |so608 {22045 | e2s.0 |aao'ae | aL17 | €2as | eset 1 sare [ion |sioz |2 190 | esas |sani2 | 144s | 62 | Tes | to | 95t2 |is9.a1 |oae | 20006 | oases [Seis | 1ases | 2m | 179 =| 0 |. | a2 50575 [size [2orz2 | aseo [210.16 | sow | ise 26° | 2600 | stb 35 s0n7s | 3.a7z6 | aera |aozes | 21699 | cane | 1906 x8 | 3 50 soa7 |3ooe | s257.0 [tse | aio | ean | 2505 =| 0 |. | ae sean [oars | ooo | oa. |ms.o7 | 7330 | ies Si 3a sean | osor | Siosa 0. | 227% | Zao | 23 zs |2so [XS | 36 | oc. | 00 srase [Sore | soon |iascs | 2enni | i300 | 8 we | 90 | [es 5200 | 3.9008 | sos? [teas | 2en3s | 7300 | 98 3s | ao fas [ares | 2sas2 | ros [2ooi8 | za | 13 ws | “32 lerz6 | 1067 | 300s | 93.93 [25.20 | Zase | 238 30 | 30.00 = lenis6 |cces | s20-« [nies |2ov38 | 7as6 | 225.3 | So leco.se |asacs | sovo2 |io7ss | zaazz | 7-884 | 3061 es joo.as | sone | e2080 |1occs | Zat'si | tase | sia 3a Fras [Sse |sae9 [iosse [sss0s | eam | 207 xs 76659 |Saes | asses [izes |sa236 | eave | 2012 22 | 5200 0 sez |saus | 61386 [ios |szz06 | ere | 3037 Bes 742.66 |s.asza | sass amos [sana | are | a740 J acs? [siasi | eas [25008 |dias | 378 | sine a leriss [aosze | sisas [izes |srz7 | aon | soso | 3s essai ecase | ssons lisser |3rezt | aon | s4 34 | 00 ‘son | S000 | see Jessa0 |Ssoos | 730s |rrea9 | 370.43 | aon | 44s ‘eas | 22730 | 6553 [oa |58959 | oizrs [22276 | 315.0 | aon | soo 6a | szczt | 72.00 |sss.sa [senso | ois |2uer7 | cz. | soot | se7.7 = |e 2 [asane | soe foazoo [omar [scons |unasz [ase | oes | soma sD Si | ‘ars | 82so | ais |orson Jem Jeasas fiszes i222 | o:0s | Sexe 36 su | xS) | 6 | ‘so | Ss.000 | ste focznn [seis |sre62 liens |sicm | a5 | sea a0 | 2. | Coes | 5450 | esas foasier |osecz howse.s Jascis |ainze | sas | ones a0 | son | 2.06 fsocee |éeoi8 fovos1 |2maas | ans. | 9.025 | 7170 Wiican od weigh avec fom ANG 09819 rd BO Te emsGENERAL LINE SIZING COMMENTS. When faced with the time limitations of production engineering, the design engineer must have available to him various guidelines and rules of thumb to reduce the time consumed in line sizing, Although optimization of line sizing should not be ignored, the available increments of pipe size normally encountered make the expenditure of an extensive amount of time involved in line size optimization very questionable. UOP employs a computer program with built-in optimization procedures to assist the design engineer in the performance of his line sizing job. However, for this discussion, we will approach line sizing without the aid of the computer and rely upon good judgement and experience to reduce the time required and still provide a reasonable approach to optimization. Following are some general comments to keep in mind as we proceed through this discussion: A. Line sizing will be based on "normal" flow rates and "normal" pressures as developed by the process design. However, the engineer should keep in mind the effect of “design” flow rates, maximum flow rates and start-up, shutdown and upset conditions that may have a significant influence on the plant pressure profile. It is generally helpful to develop a simple sketch of the plant or system piping arrangement to indicate the normal pressure profile and to record the results of investigations of alternate considerations. The sketch also provides a good means to visualize the possible effect of static head on pressure considerations used in line sizing. The principle criterion for line size selection will be pressure drop, expressed as pounds per square inch (PSI) per 100 equivalent feet of pipe. Velocity, expressed in feet per minute, will also be an important factor. 9-1and 40% of the upstream pressure, use the average specific volume. If the total pressure drop is greater than 40% of the upstream pressure, divide the line into sections for calculation purposes. For strength considerations, good practice limits the minimum permissible line size to 1" nominal for pipe rack runs and pipe spans between supports. In order to reduce purchasing and detailing problems and to minimize inventory requirements, pipe sizes such as 1%, 2¥4, 3% and 5 inch will normally be avoided. Schedule 80 minimum is recommended for 2 inch and smaller pipe size. Pipe sizes have a constant outside diameter. Therefore, as the wall thickness increases, the flowing area will be reduced. The engineer should keep this point in mind when working in piping systems at high pressure or when high corrosion allowances are required. ‘When considering the wall thickness for pressure requirements or corrosion allowance, remember that the wall thickness tolerance is + 12¥5% thru 24" seamless pipe size. The wall thickness tolerance is normally reduced to + 0.01 inch for welded pipe and sizes greater than 24" when fabricated from rolled plate. Although most of the information contained in this discussion is directed toward new piping, the engineer should keep in mind that the economics and decision factors involved in revamps are different. Consequently, smaller line sizes can often be used on revamps compared to new construction. 93‘When designing two phase upflow lines, such as column feeds, reboiler returns and condenser rundowns, the flowing velocity should be kept high enough to prevent slug flow. Annular or mist flow is usually assured if the velocity in ft/sec is approximately equal to 60 divided by the square root of the mixed phase density in Ibs/ft?. The chart "Approximate Two-Phase Flow Patterns’ (Page 9-11) may also be used to determine the approximate flow condition. At UOP, the engineers use hydraulic tabulation forms to assist in their line sizing work, These forms simplify the work of the engineer and provide a convenient means to communicate the hydraulic information to specialty equipment engineers. Three examples are as follows: Page 9-12 is a form used for single phase line sizing, vapor or liquid, and for pump and control valve information. The form is used in conjunction with charts PD 435-C, PD 436, PD 437 and PD 438, 2, Page 9-13 is a form used for two phase line sizing and is used in conjunction with chart PD 395-A. This form provides a convenient means for tabulating the two phase flow line sizing data. 3. Page 9-14 is an additional form which defines the two phase sizing procedure in equation form. Some engineers may prefer to use this method to record their line sizing calculations. 95ucop Introduction to Process Design Section IX Pressure Vessels — LIMITED DISTRIBUTION — This material is UOP LLC technical information of aconfidential nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or ) distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC. April, 2000USP Training Services Pressure Vessels Pressure Vessel Design Code Requirements Process Design Requirements Configuration and Sizing Mechanical Design FeaturesPressure Vessel Design (continued) Pressure vessel design is a two-step process 1 Process engineer establishes process requirements ; = Pressure vessel designer applies code and fabrication requirements Pressure Vessel Design (continued) = An equipment specification is usually used to transmit the process requirements ~ Design pressure and temperature ~ Diameter and length ~ Material of construction ~ Nozzle size and location ~ Details of internalsCode Requirements = Rules found in the codes represent hundreds of man-years of experience = Ifused wisely, the code requirements ean: ~ Communicate design requirements Utilize know-how and technology ~ Keep equipment costs low ~ Reduce insurance costs ~ Reduce chance of legal entanglements Code Requirements (continued) ASME Code - Section 1 & Governs the design of vessels used for generatingsteam ( 5/)o,y ) = When steam is generated by process fluid (no flame), user may waive Section 1Code Requirements (continued) ASME Code - Section VIII, Division 1 = General requirement for the design of all unfired pressure vessels . ‘= Does not apply to small vessels made of pipe and atmospheric vessels for water and injection chemicals Code Requirements (continued) ASME Code - Section VIII, Division 2 4 = For high pressure vessels. | 2OGOPSi = Safety factor less than Division 1, 3 vs. 4 ™ Special requirements for material and fabrication quality control Non-Code Vessels = Code construction not required for atmospheric vessels handling water and injection chemicalsCode Requirements (continued) Related Codes = API Standard 620 - Low Pressure Storage Tanks API Standard 650 - Welded Tanks Up to 0.5 psi ANSI B31.3 - Petroleum Refining Piping ANSI B16.5 - Flanges, Valves, and Fittings TEMA - Heat Exchangers Local Codes and Standards - If More Stringent Process Design Requirements Pressure = Normal Operating ~ Pressure at which equipment operates at design or specified conditions = Maximum Operating Previsy ~ Highest operating pressure foreseen for specific equipmentProcess Design Requirements Pressure (continued) = Design Pressure — Maximum operating pressure plus a certain margin - Normal margins are: MAX. OPER. P.PSI_| DESIGN P, PSI Lessthan 25 | 50 25.t0 250, ‘Oper P +25 250 to 1000 (Oper P) * (1.1) 1000 to 2000 (Oper P) + 100 ‘More than 2000, (Oper P)* (1.05) | Process Design Requirements Pressure (continued) = Vacuum Design ~ Ifnecessary, vessels are designed for both internal and external pressure ~ Equipment that operates under vacuum or are subject to vacuum during purging or on loss of reboiler heat may need to be specified for vacuum design ‘Vacuum due to operator error normally not consideredProcess Design Requirements Pressure (continued) m Effect of Pressure Drop on Design ~ ASME considers design pressure at the top of the vessel ~ Design conditions at the bottom should consider: + Liquid head + Upflow or downflow pressure drop + Hydrostatic test conditions Process Design Requirements Temperature = Normal Operating ~ Temperature at which equipment operates at design or specific condition = Design Temperature ~ Normal operating temperature plus a margin or, if eryogenic application, could be minus a margin NORM. opeR.T,°F | pEsIGNT.°F | Less than 200 250 i More than 200 OperT+50 |Process Design Requirements Temperature (continued) = Fractionators ~ Design temperature is normally bottom T plus 30°F top to bottom ~ For fractionators with large delta T’s, the top to bottom design is graduated = Cold Wall Design NESENAAP Internally insulated vessels allow the outside shell design T to be considerably lower than Le FCC the operating T Process Design Requirements Temperature (continued) = Cooler Failure ~ Failure of coolers upstream of equipment could require a greater increment than 50°F «= Heat Exchanger Shells ~ Design temperature of exchangers is based upon the higher of the inlet or outlet temperature = Flange Ratings ~ In setting design temperature, the effect of flange rating should be considered to minimize costsProcess Design Requirements Corrosion Allowance (CA) Normal CA for carbon steel vessels is 1/8 inch = Normal CA for alloy is 1/16 inch = When cladding or weld overlay is used to protect the base metal, the CA of the base cat be nil ‘When a corrosive aqueous phase is present, a layer of cement or Monel is used to protect the base metal Refinery Vessel Functions Storage Surge Volume Separation = ReactionSurge Drum Orientation = Vertical - Most economical orientation considering vessel cost ~ Level reacts more quickly to changes in flow than in a horizontal vessel = Horizontal ~ Greater liquid surface area results in less ‘change in liquid level during flow variations Examples of Uses ‘= Smooths liquid flow variations resulting from large distance pumped (e.g. from tank farm) or the type of pump (reciprocating, ete.) = Allows operator reaction time in the event of loss of liquid feed to the unit = Protects pump suctions from loss of liquid feed by allowing time for pump shutdown (e.g. separator liquid pumps) = Absorbs temporary increases or “slugs” of liquid flow (e.g, short term steam injection upstream) nResidence Time = Major factor affecting cost and size of the vessel is residence time of the liquid phase = Factors which determine residence time are: ~ Experience with the same services = Difficulty of phase separation ~ Effects of loss of level or high level on downstream equipment ~ Settling of two liquid phases ~ Properties causing foaming or emulsions ~ Source/destination of liquid phase ~ Presence of suspended solids Residence Time Guidelines PROCESS SERVICE I RESIDENCE TIME. \Vapor/Liquid Separation center] centerline Liquid Surge for Controt ‘High to low level Horizontal vessel, liquid at pacer | 'Vapor/Liquid/Liquid Separation | 10 minutes on liquid Horizontal vessel, liquid at 5 minutes on liquid 2-4 minutes Critical Separator Vertical vessel 2minutes from | highest liquid level to 2 inlet nozzleResidence Time Guidelines (continued) PROCESS SERVICE | RESIDENCE TIME Drop Leg (Boot) 5-10 minutes Controlled level -_ Drop Leg (Boot) 600 minutes Manually drained ! Feed Surge Drum 15-30 minutes Reflux Drums imutes (50% full) [Product Receiver 5-20 minutes (50% full) Residence Time thi Heavy fage TW0 Liquid Phases Li Lisht tes = pa-PL > 14 Ib/fe © py-pL. <7 Ib/fe = Viscosity of lighter phase > 1 Cp 5Min 30 Min 30 MinPhase Separation Examples PHASES EXAMPLE ‘Vapor/Liquid ‘Separator Flash Drum Liquid/Liquid Caustic Settler Desalter Vapor/Liquid/Liquid | Hydrotreater Separator ‘Wet Overhead Receiver Vapor/Solid FCC Regenerator Liquid/Solid Slurry Separator Separation Methods = Momentum = Gravity Settling = Coaleseing Separation using a combination of these methods isMomentum Separation = Denser fluid changes direction more slowly than less dense fluid ™ Often used for initial, or “bulk” separation ~ Gravity Separation = For separation to occur, the fluids must be immiscible and of different densities = The closer the fluid densities, the more difficult the separation = No separation method is complete - the degree of desired separation must be definedCoalescing Pa m Increased size of () droplets aids separation m Process accelerated by coalescing medium Gravity Settling Laws Particle Moving in a Fluid = For Vessel Design ~ Calculate droplet terminal velocity ~ Size vessel to keep velocity of continuous phase less than particle terminal velocity to allow separation Size the vessel to permit the particle to escape from the continuous phase before the continuous phase (or the particle phase) is withdrawn from the vessel’ Gravity Settling Laws Particle Settling ina Fluid Fytk, Fy = Drag F, = Buoyant Force F, = Gravitational Force F = Resultant Force a = Particle Acceleration Fy, u = Particle Velocity Gravity Settling Laws Particle Moving in a Fluid a At Steady State du dt and u= = terminal velocity SoF,=Fy+Fy hGravity Settling Laws Particle Moving in a Fluid = Where: me Gravity Settling Laws Particle Moving in a Fluid = Mass of Particle = Gravitational Acceleration Gravitation Constant = Density of Continuous Fluid Density of Particle Projected Area of Particle Diameter of Particle = Drag Coefficient (based upon velocity relative to continuous phase) = Viscosity of Continuous Fluid Terminal VelocityGravity Settling Laws Particle Moving in a Fluid Substitute and solve for uz: Ct —eEEE . Sabacal* For Heavy Droplet - a Light Continuous Phase” L 3€pp For Light Droplet - Heavy Continuous Phase, use P— Py Gravity Settling Laws Particle Moving in a Fluid = Limitations ~ Spherical particle ~ Stagnant fluid ~ No interaction with other particles - Nowall effects = The terminal velocity for a particle can now be calculated if Cy can be quantified hkDrag Coefficient Plot Site C, = Ny Dp Depot Neate ine ZO ee cya Newton’s Equation = For: 500 500 liquid droplets falling in vapor will deform ‘Then: Cy 40.44 Let: For: And: 0s DpelPL—Pv)]” _(4(0-175X32.2))"*/ py -pv\* 3Dpev 3(1)(304.8) Pv 0s = oas7 2 es] cu romerve Mesh Blankets = Higher terminal velocities are achieved by using coalescing devices 12, ( } Pv PRESSURE, | (INCHES OF HG ABSOLUTE) | _K_| psta |_K [Less than 1” a7 | 15 _| 038 oa7 | so_| 034 = 023 | 100 | 032 10" 028 | 300 | 030 | 20" 032 | s00 | 028 30" 035 [ 1000 | 027Stokes’ Equation . > g 2 Stoke’s Equation Applications ™ Separating vapor bubbles from liquid phase = Separating heavy liquid drops from lighter liquid phaseIntermediate Equation = For: 2 } b oo “Aol Inlet Distributor hs U u Note: Use side inlet and horizontal distributor if liquid volume flows are approximately equal.Types of Vessels Vapor/Liquid/Liquid Separator Equivalent Light and Heavy Liquid Rates Feed Vapor Out Inlet Distributor — ~Baffes Heavy Liquid ‘Our Out Horizontal Separator Sizing Example = Problem — Design a reactor products separator for a naphtha hydrotreating process unit ~ The relevant portion of the heat and material balance is reproduced below; then complete the vessel sketchHorizontal Vessel Sizing Example Tabulate data and calculate volumetric flows WvpROcARBON| WaTER | TOTAL | varor |" "Liguib | Liguip | LiQu Flow, this | 693, 58586 2250 60836 (ors 1st 038 oor | 036 120 in [8 5 163 | Dens it ans x68 as Vien ep on on oat Wtsee G10) | ase 282 3a Flow Schematic 0 = —+ Vapor Out BQ. Liebe Ligsia Giydrocarbon) Out Heavy Liguid| (Ovater) Out 3Horizontal Vessel Sizing Example Sizing Steps ™ Select LD = Determine Liquid Residence Time = Determine Normal Liquid Level = Calculate Diameter to Satisfy Residence Time Horizontal Vessel Sizing Example Sizing Steps ® Calculate diameter for each phase separation ~ Liquid from vapor - Vapor from liquid ~ Liquid from liquid = Ifa liquid coalescing blanket is used, calculate diameter for 3 ft/m liquid velocity = Select governing (largest) diameter = Round up to nearest multiple of 6" or 100mm ASO omLiquid Coalescing Blanket = Coalescing blankets are often used to accelerate the separation of two liquid phases; because of the often close densities, gravity separation only may result in a large vessel = When removing water, blankets are always used by UOP ™ Liquid velocities over 3 feet per minute may re-entrain droplets from the blanket Vessel Configuration Feed! ae out —E \- my T 7 eit a = ‘Water OutHorizontal Vessel Sizing Example = Calculate the diameter based on residence time ~ Select L/D = 3 (the most common, economical value) ~ For settling water phase from light hydrocarbon phase, use 10 minute residence time ~ Set normal liquid level (N,,) at centerline Horizontal Vessel Sizing Example ~ Caleulate liquid volume 3 Wi =@ys-( S268 )aomin = 21680 ss \imin) ~ If vessel is 1/2 full, then full vessel volume is: Vi _2168t° =432 80° F osoHorizontal Vessel Sizing Example & Vy is a cylinder with L/D = 3; ignoring the head volume: _7D*L _3xb? 4 4 v-[Sv + deco an} | an} Ww. im D=5.7 feet Round up to 6 feet Check Vapor/Liquid Separation © Ung for droplet/vapor separation is 3 ft/s os Ues ~o157(2u=Pe) Py 157-0108)" (0425 =3.04/sCheck Vapor/Liquid Separation (continued) = Horizontal gas velocity is: Un =Q/CSA 1548? s vain) =0.108f/s Check Vapor/Liquid Separation (continued) = Distance needed for droplet to fall three feet (2D) L=(H/Upes)Vn st (0.108 /s) s) =01fCheck for Water/Hydrocarbon Separation = Up, for water/hydrocarbon separation is 0.035 fs = Horizontal liquid velocity is: n= Q/CSA 0.36 3's Check for Water/Hydrocarbon Separation (continued) = Distance needed for droplet to separate in three feet (1/2 D) L=(H/Upes Vn = (3/0.035)(0.025) aHorizontal Vessel Sizing Example Drop Leg (Boot) Sizing Steps = Determine residence time = Calculate diameter based on phase separation = Calculate diameter based on process velocity limits (if any) Calculate diameter based on residence time (UOP standard length =3.5 feet) Horizontal Vessel Sizing Example Drop Leg (Boot) Sizing Steps (continued) u Select governing (largest) diameter = IfDpy greater than half vessel diameter, then set Dp, = 1/2 vessel diameter and recalculate Lor = Round up to the next pipe sizeHorizontal Vessel Sizing Example (continued) 35Ft (OP STD) 12 DMAX. Horizontal Vessel Sizing Example Vessel Drop Leg (Boot) = Size the drop leg for 10 minute residence time for the water phase ™ Size drop leg for separation of dispersed hydrocarbon liquid phase from a continuous water phaseHorizontal Vessel Sizing Example Vessel Drop Leg (Boot) (continued) = Calculate the drop leg diameter based upon. the 10 minute residence time and a drop leg length of 3.5 feet D}LL 4 ‘Sgal a ft? ( min joo nial gal 2 Dbr =2.43 Voi = Qcuit Dp 56 ft = 18.7 inches Horizontal Vessel Sizing Example Vessel Drop Leg (Boot) (continued) = Use Stokes’ Law to determine the terminal velocity of the dispersed liquid droplet Uy) ~ SDeLOun-PLL) an 18H (2.2\(0.00041) (61.55 - 46.34) (18\(0.000342) = 0.013 f/sHorizontal Vessel Sizing Example Vessel Drop Leg (Boot) (continued) = The velocity of the continuous heavy liquid phase (water) is the volumetric flow rate divided by the cross-sectional area of the drop leg =Qcur __Qcu UcHt 2 ApL 0.785D5, O01 (orss{ in ‘] Horizontal Vessel Sizing Example Vessel Drop Leg (Boot) = Round to the next larger standard pipe size, 20 inch outside diameter = Drop leg diameter is less than half of the 6 foot vessel diameter ~ Length of the drop leg is 3 feet, 6 inches ~ Since the drop leg is less than 30 inches outside diameter and the vessel is internally lined, the drop leg will be flanged to the vesselReactor Products Separator TANGENT i Vertical Separator Sizing Without Disentraining Device ™ Calculate Diameter Based on Phase Separation in Vapor Phase = Calculate Diameter Based on Phase Separation in Liquid Phase = Select Governing (Largest) DiameterVertical Separator Sizing Without Disentraining Device (continued) = Determine the Liquid Depth = The distance between Hy, and Ly, is determined from the required residence time | (surge volume) ~ Provide 6" from vessel TL to Lay — Set N,—and center of float (COF) on the level glass — at the Ny, Vertical Separator Sizing Without Disentraining Device (continued) = Determine the Required Tangent Length ~ Determine the distance from the H,, to the inlet nozzle — use 1' 6" (minimum) ~ For critical services, where moisture carryover is a major concern, provide 2 minutes of surge volume, with a 1' 6" minimum ~ Determine the distance from the inlet nozzle to the top TL — use 3° 0" (minimum) ~ Add liquid depth +H, to inlet + inlet to TL + inlet nozzle size to determine the overall TL ~ If TL is too long, consider a larger vessel diameterVapor/Liquid Separator sserbee Process Data Summary 0.125 itt | 695 tbh |_1.54 f%s HC | 464 tb/fe | 58586 Ibm | 0.38 f¢/s | \__H,0 623 Ib/ft’ |_ 2250 Ib/h | 0.01 ft/s 60636 | 0.36 }Diameter Based on Residence Time Size for 10 minute residence time Normal liquid level = 8 feet 0.35 ft/s x 60 sim x 10 m = 210 £8 08 )"=39% Use6ftdiameter L=Max LL + clearance to feed nozzle + distance above feed nozzle m= L=(NLL+YANLL) + 4D +15 + 4D +3.0 ft mL = (8448 +46 + 1.5 +46 +3.0=22.5 ft = Round up to 23 feet Diameter Based on Gas Velocity vos Umax =os7P=Pv) Unaax =3.0t/sDiameter Based on Liquid Velocity Upes = 0.075 ft/s Process Data Summary (continued) = Summary of Calculated Diameters Residence Time 8 ft diameter Vapor Velocity 0.8 ft diameter Liquid Velocity 2.5 ft diameterUOP Manways and Auxiliary Nozzles = Manways (18" min ID) ~ Vertical Vessels + Provide on top head + Flange top head if vessel diameter < 30", ~ Horizontal Vessels + Provide on the side at or below the centerline; place above the centerline if vessel is lined + Flange vessel head if diameter < 30” + Locate near one end UOP Manways and Auxiliary Nozzles (continued) = Ventilation ~ Required for safety on horizontal vessels > 10" diameter — Locate on top, at the end opposite the manway - Minimum sizes 210'diameter 4" nozzle >15'diameter 6" nozzle >25'diameter 8" nozzle “UOP Manways and Auxiliary Nozzles (continued) = Vents and Drains — Generally required on the vessel or on piping near the vessel — Locate to completely vent and drain the vessol (no pockets) ~ Minimum sizes <15' diameter 2" nozzle 15'-20' diameter 3" nozzle >20' diameter 4" nozzle poamumenn Vortex Breakers m Provide vortex breakers on liquid outlets to eliminate possible vapor entrainment (especially objectionable on a pump suction) = When two liquid phases are present, raise the light phase vortex breaker to prevent possible inflow of heavy phase liquid — For water, it is typically raised 6 inchesInlet Distributors = Inlet distributors change the liquid direction to provide momentum separation = Horizontal Vessels = Subcooled liquids use an open ended pipe from the top or bottom of the vessel; distributor exit located to always remain beneath liquid ~ Bubble point liquids (e.g. small amount of vapor) use a vertical slotted pipe the same size as the inlet ~ Two liquids of approximately equal volume — use a horizontal slotted inlet pipe near the normal liquid interface (i.e. the vessel centerline); pipe is the same size as the inlet Inlet Distributors (continued) * Horizontal Vessels (continued) - Mixed Phases — use a vertical slotted inlet one pipe size larger than the inlet pipe + Slot area is 2 to 3 times the distributor area + If there are two approximately equal liquid phases, locate the inlet near the center of the vessel and use two slots facing the shellInlet Distributors (continued) = Horizontal Vessels (continued) — Unless otherwise noted: + Slots begin 6" from the inlet nozzle + Slots end at the end of the distributor + Distributor ends 6" from the vessel bottom + Slot area is twice the distributor area + Use one slot + Use intermittent rather than very narrow (<3/16" (mm) stots + Slot to face the nearest head (to maximize vessel gravity separation length and residence time and provide additional momentum separation) Inlet Distributors (continued) = Vertical vessels use a tee style distributor, except on small vessels with flanged headsvy Sealing of Spees i Sil Fluid Meth ‘Gravity Sening of Spheres in Sul FI co ae Covel Pail Des Parc Sie ped Laws of Setting above Which Law Will No = ovr ‘iemetineLw const _ase8 nf Keqrnas ids Move ike MoleINTRODUCTION The design and analysis of modem pressure vessels is a complex task requiring the pressure vessel designer to have a broad and in-depth understanding of various specialized fields such as applied mechanics, strength of materials, fatigue, fracture mechanics, plasticity, creep, stress rupture, ‘metallurgy, heat transfer and computational methods. The pressure vesse! designer must also maintain an up-to-date working knowledge of the various codes and fabrication processes as they relate to vessel materials and construction. He must also provide coordination between process and project engineers and the vessel fabricator in order to properly communicate the requirements of the ‘vessel process design. This presentation will provide an overview of the various facets of pressure vessel design in order to provide process and project engineers with additional background to communicate with the pressure vessel designer. The design code referred to herein is the ASME (American Society of Mechanical Engineers) Boiler and Pressure Vessel Code which UOP utilizes as a minimum requirement. However, it should be recognized that other country and local codes may ultimately govem in design where their requirements are more stringent. CODE REQUIREMENTS ASME Code + Section I All vessels used for the purpose of generating steam with a process fluid or within a process heater will be designed according to the ASME Code, Section I, Boiler Code (latest edition), In some instances where steam generated by a process stream without the use of direct fire, the vessels may also be designed according to Section VIII of the ASME Code, but it is not mandatory. «Section VII, Division 1 A\ll process vessels should be designed according to the ASME Code, Section VIII, Unfired Pressure Vessel Code (latest edition) and/or the codes which govern in the particular country in IPD/11-99 ‘vop PV-1~“ which the unit is to be installed. This does not apply to small vessels made of pipe and atmospheric vessels handling water and injection chemicals. + Section VIII, Division 2 In cases of vessels operating at pressures above 1000 psig and less than 900°P, consideration should be given to designing to the ASME Code, Section VII, Division 2. This division of the code is similar to the ASME Code, Section III, Nuclear Code and permits using a higher design stress level than Section VIII. However, there are special requirements on the design, fabrication and material testing which can offset much of the savings due to the higher allowable stresses permitted by Division 2. Non-Code Vessels Many atmospheric vessels handling water and injection chemicals need not be code vessels. ‘There is a nominal savings due to not having to be fabricated in a code shop and not requiring a code stamp. Other Related Codes « API Standard 620, Large Low Pressure Storage Tanks Pressure 0.5 to 15 psig « API Standard 650, Welded Storage Tanks Pressures up to 0.5 psig «ANSI B31.3, Petroleum Refining Piping « ANSI BI6.5, Steel Pipe Flanges, Flanged Valves and Fittings TEMA, Heat Exchangers Foreign Codes and Standards The requirements of foreign codes and standards vary considerably, but usually any savings or additional costs due to the calculated wall thicknesses are compensated for by variations in quality and fabrication control requirements. TPD/N1-99 vop ~ Pv2DESIGN CONDITIONS AND REQUIREMENTS, Design Conditions ‘The operating temperatures, pressures, flowing quantities, and densities determined by the process design engineer is the basic criteria used in setting the vessel design conditions. Additionally, climatic conditions relating to wind and earthquake must also be taken into consideratiag. With this information, the following guidelines can be utilized in setting vessel design requirements. «Pressure ‘Normal Design - The design pressure should, normally, be a minimum of 25 psi or 10% above the maximum operating pressure, whichever is greater. Minimum design pressure is normally 50 psig. Very Large Vessels - In cases of very large vessels operating at low pressures, the 25 psi increment is sometimes used for design above operating pressure rather than the minimum of 50 psig. High Pressure - At operating pressures above 1000 psig, the design conditions are taken as a minimum of 100 psi or 5% above operating pressure, whichever is greater. A pilot operated relief valve is required for this lower design margin to be used, however, so as to obtain bubble tightness at 95% of set pressure. Vacuum - Vessels operating under any condition of vacuum should be designed for full vacuum. Possible Vacuum - Vessels not operating under a vacuum, but subject to a vacuum condition due to failure of a control or heat source, should be designed for full vacuum or provided with a vacuum breaking device. Designing for vacuum usually only requires the addition of stiffening rings to the shell for most vessels designed for a reasonable intemal pressure, although some vessels may also require an increase in wall thickness. IPD/11-99 op Pv3.— Liquid Filled Vessels - Vessels operating liquid full, where a sudden drainage or other circumstance such as flow stoppage and subsequent cooling could produce a vacuum condition, should be designed for vacuum. Hydrostatic Test - In some instances, the design pressure at the bottom of the vessel may be dictated by the static head of liquid required for hydrostatic testing of the vessel. Temperature ‘Normal Design - The design temperature should be about 50°F above the normal operating temperature or 250°F minimum. Consideration should be given to failure of coolers ahead of vessels, which could require a greater increment than 50°F. High Temperature - Reactors operating at high temperatures and high pressures, where the allowable stress drops rapidly with each temperature increment, are usually designed for the maximum expected operating temperature at end of run. This practice is usually conserva- tive if the reactions are endothermic. Consideration should be given to the accuracy of the temperature-sensing element so as not to exceed the design temperature without sensing it Flange Rating Consideration - In setting the design temperature of vessels, the effect on flange rating should always be taken into account so as not to increase cost unduly. Pressure and temperature limitations are as indicated in ANSI B16.5 (latest edition). Cold Wall Design - When temperatures are well above levels which can be reasonably designed for and, in some instances, to reduce alloy and thickness requirements in high pressure vessels, internally insulated (cold wall) vessels are used where the outside shell is designed for a temperature lower than the operating temperature, Minimum Design Metal Temperature - The ASME Code requires that the Minimum Design Metal Temperature (MDMT) be specified. The MDMT will be the lowest of the normal operating temperature minus 25°F (14°C), the lowest 24-hour mean ambient temperature, or the result of an auto-reftigeration calculation based upon the process fluid, IPDI-99, uop«Corrosion Allowance ‘Normal Corrosion Allowance - The normal corrosion allowance on carbon steel vessels in non-corrosive service is 1/8 inch. Cladding - Vessels in severely corrosive service are usually alloy clad or have "weld- overlay" for protection. Where cladding or weld-overlay is used to protect against corrosion, no corrosion allowance is added to the base metal. Cement Lining - Where corrosive aqueous phases are handled at low temperatures, the metal is sometimes protected with a layer of "acid proof cement" or monel. The monel lining is easier to inspect than the metal behind the cement lining. Minimum Wall Thickness — 0.25" for carbon steel vessels with 1/16" corrosion allowance. ~ 0.3125" for carbon steel vessels with 1/8" corrosion allowance. ~ 0.1875" for stainless steel vessels with 1/16” corrosion allowance. Wall thickness must be great enough to assure structural stability. Setting Basic Dimensions The size and shape of most process vessels is determined by the process design engineer. By training and experience, he is the logical person to make such decisions. The diameter and height of a distillation tower are basically set by the distillation design calculation. The volume of accumulator drums, reactors, and settling vessels are similarly dictated by process calculations. Anyone who has made such calculations, however, realizes that there is considerable leeway in the final choice of dimensions. For example, an accumulator drum must have a certain volume, but a great number of length-to-diameter ratios can be employed to give that volume. Other factors being, equal, it is necessary to choose the most economical ratio. A length to diameter ratio of 3:1 or 4:1 is usually most economical. Other factors, such as plant layout, appearance and foundation conditions must also be considered. Above all, the process design engineer must set vessel dimensions so standard components can be employed throughout. The use of standard heads, for example, will avoid extra charges for special pattems. PDII-99 op PV-SIf possible, the process design engineer should consult with the vessel designer during the early stages of vessel planning so that the most economical design can be realized. Engineers concerned with the detailed mechanical design and fabrication of a vessel are not in a position to change basic dimensions, since these dimensions are required for the process. Therefore, itis imperative that the basic dimensions be set intelligently by the process design engineer so that they will fulfill both process requirements and the requirements of economical design. Residence Time ‘The determination of a residence time for the liquid phase should consider the following factors: + Arecommendation based on experience with the process + The effects of loss of level or over filling on upstream or downstream equipment = The difficulty in separating phases. Fluid properties, emulsifying or foaming tendencies, upstream mixing, surface active agents and suspended solids can affect phase separation in varying degrees. ‘Cominon residence times used for sizing vessels are as follows: «Fora horizontal vessel with a vapor phase and one liquid phase, 5 minutes based on the liquid phase rate, ¥ full, is usually adequate Fora horizontal vessel with a vapor phase and two liquid phases, 10 minutes based on the total liquid rate, ¥ full, is usually suitable for most conditions. When the difference in densities of the liquid phases is low (7 Ibift’ or less) and/or the lighter liquid viscosity is high (1 centipoise or more), 30 minutes or more may be necessary. When the difference in densities of the liquid phases is high (14 Ib/ft* or more), 5 minutes may be adequate. Experience with the system is especially important in liquid/liquid separations. IPD/N1-99 op PV-6+ For liquid surge time from high to low level, 2-4 minutes is normally adequate for most conditions. For vertical separators upstream of compressors or other critical equipment, a minimum of two minutes surge time is provided between the bottom of the inlet nozzle and the maximum controlled level. For horizontal vessels, consideration should be given to the location of the normal liquid level. If the vapor rate is small and the liquid rate is large, it may be advantageous to set the normal liquid level above the vessel centerline to maximize the liquid residence time. If the vapor rate is large and the liquid rate is small, it may be advanta- geous to set the normal liquid level below the vessel centerline to minimize the vapor velocity. «For drop legs with a level controlled outlet, 5-10 minutes is a suitable range for the drop leg capacity, + For drop legs with a manually controlled outlet, 600 minutes of drop leg capacity is adequate for one draining during an eight-hour shift. Phase Separation Designing for phase separation assumes that a droplet falling under the influence of gravity will accelerate until the frictional drag force balances the gravitational force. The droplet then falls at a constant velocity, which is defined as the terminal or free settling velocity. This relationship is shown in Figure 10-1. The curve has been divided into three sections where the drag coefficient can be considered a linear relationship relative to Reynolds number. There are three laws for determining the terminal velocity, which is the basis of the criteria recommended for sizing vessels for phase separation. These laws have limits based on the particle Reynolds number as follows: Parlcle Reyolds No iw © “Terminal Veoaiy Equation 24 2 2s (op ~ 0) eb} 2 stokes’ Wee seene)ePe ma aipii.,, ppt 18s 0.15397! Db! *(pp - P) 210 <500 Imemedne | Tease | 8880/1 Del lop =A) (ne) ap 05 Dolor - | 00.0 «200,000 ror ose 0r(or-2)] > | _ L IPDI1-99 op Pv-7The terms in these equations are as follows: p = density of the continuous phase pP = density of the droplet Dp= diameter of the droplet viscosity of the continuous phase g = gravitational constant Figure 10-1 Drag Coefficient vs. Reynold’s Number ‘Spheres Disks Cylinders | Teed 16.000 0,000 "7G00,000, ot ‘oor Goo) oo) 0100 Design conditions for receivers, separators, and drums fall into the categories of the Stokes’ and Intermediate Laws. Stokes’ Law is used for disentraining vapor from the liquid phase and gravity settling the dispersed liquid phase from the continuous liquid phase; the Intermediate Law is used for gravity settling liquid from the vapor phase. The droplet size or diameter used in these laws is often difficult to determine. In selecting the droplet diameter, the effect of entrainment on downstream equipment, effluent quality, and overall economics should be considered. TPD/I-99 op ~PV-8The following droplet diameters are used in these guidelines in lien of more definitive sizes: c «250 microns for gravity settling liquid from the vapor phase «175 microns for disentraining vapor from the liquid phase «125 microns for gravity settling the dispersed liquid phase from the continuous liquid phase In range of Newton's equation, Nz, > 500, liquid droplets falling in vapor will deform and C will, not be 0.44. It is reasonable to set Cp = 1 as the curve indicates for cylinders and discs. pp is substituted for pp and py for p and a typical droplet diameter of 175 microns is selected, then the terminal velocity becomes: Mesh blankets are frequently used to enhance coalescing of the liquid drops so that separation can be achieved at higher vapor velocities. The following relationship applies when mesh blankets are Cc used. PSIA. K 15 50 100 300 500 1000 IPD/11-99 op PV-9GUIDELINES FOR SIZING VERTICAL VESSELS Surge/Storage Vessels «Choose a desirable length/diameter (L/D) ratio, Usually 3:1 is a good choice. «Determine the liquid residence time required and percent liquid full at normal liquid level «Calculate the liquid holdup volume required to satisfy the liquid residence time. This is the volumetric liquid flow rate, O7, multiplied by the liquid residence time, 7. YL= QUT «Calculate the volume of the vessel, Vy. This is simply the liquid volume, VZ, divided by the percent liquid full, F. vy=VyF Since the volume of the vessel equals the volume of a cylinder, set the vessel volume, V7, equal to the volume of a cylinder. _aD?L y, voz «Substitute for Z the D determined by the L/D ratio and solve for the vessel diameter, D. For a L/D ratio of 3, the equation is as follows: xD? (3D) ry = GD aD a 3 My ia « Round off diameters and tangent lengths to the next larger standard increment. Standard head sizes usually are available in 6 inch or 100 millimeter increments. 1PD/11-99 vop PV-10Phase Separation Vessels without Demisting Blanket ‘The method used sizes the vessel diameter so that the vapor velocity is equal to or less than the € terminal velocity of a liquid droplet falling through the continuous vapor phase. The liquid velocity must also be equal to or less than the terminal velocity of a bubble rising through the continuous liquid phase. Refer to Figure 10-2 for a sketch of the system and a definition of terms. Subscripts DL and CV refer to the dispersed liquid and continuous vapor phases. «Calculate the terminal velocity of the liquid droplet, pz, using the Intermediate equation. 071 _01538°7! DBL (oy - py) ‘DL 929,043 way «The vapor velocity rising in the vessel, Vcy, is equal to the vapor volumetric flow rate, Ocy, divided by the vessel cross-sectional area, and the cross-sectional area is the area of a circle with diameter D. Cc «Substitute for pz, and solve for D. a) Ee Orossieuee ee 2 DG, a) ] «Similarly, the terminal velocity of the bubble rising through the continuous liquid phase can be calculated using Stokes’ equation. IPD/I1-99 op PV-11«The liquid velocity flowing downward in the vessel, VCz, is equal to the liquid volumetric flow rate, QJ, divided by the vessel cross-sectional area, and the cross-sectional area is that of a circle with diameter D. Von = «Substitute for Vpy and solve for D. ° 0s D=0. jt | Q) L sDbr(o1 - av) ° « Based on the largest calculated vessel diameter from Equations 1 and 2 above, determine ‘whether an ellipsoidal or a flanged flat top head is suitable. Vessels smaller than 30 inches in diameter should have a flanged flat top head. Vessels with a diameter of 30 inches can have either type of top head. Vessels larger than 30 inches in diameter should have ellipsoidal heads. «Determine the liquid level range for the vessel based on residence time considerations. «Calculate the vessel tangent length based on the type of top head, the liquid level range, and any necessary surge time above the maximum controlled level by using the equations in the sketches in Figure 10-2. «Round off diameters and tangent lengths to the next larger standard increment. Standard head sizes usually are available in 6 inch or 100 millimeters increments. IPDII1-99 op PV-I2Figure 10-2 jc i A Crossectins ae, 8 Vapor/Liquid Separation case Dy Diameter of es aks, + Je Dy Nomal pipe amet ofinet in fo Noma pipe lamer of ous L Dy Liguid parte diameter, (000082 8) Dug. Heavy liquid parce damewr, (000081 8) Dp Uihy Tui pare ame, (0.0081) a yu’ Vapor parle diameter, “(000057 8) : PTY percent igi fl lS prin Tangent eg, Flow rate of lige phase, gpm Flow rate of liquid phate," Liquid residence tne nies Liquid density, 10 Heavy liquid density, IN Ligh gui desiy To? Vapor dzasiy, 3 Ligue vieceky, I see Hen liquid viecosity, vt se Ligh guid viscosity, it see apo desi, bf ee Use in the absence of spect process data 04Dg (Min) O5Dp 23-0" 0507 05Dp, 3050, 6 2 050) + € © Wont Maxim Level limits 6° (Min) Not: Flowing dat at at operating conditions GUIDELINES FOR SIZING HORIZONTAL VESSELS Vessel Shell Phase separation in a horizontal vessel should account for the fact that the forces acting on the droplet to be separated are not acting in the same plane. The traditional drag/gravity/buoyant forces are acting in a vertical direction, but the continuous fluid movement and its drag forces are acting in a horizontal direction. Our method takes into consideration the direction of these forces, as well as the vessel geometry in determining the vessel size. Focus on the separation of a liquid droplet from a continuous vapor phase. Refer to Figure 10-3 for a sketch of the system and a definition of terms. The droplet must fall through the vertical distance of the vapor space to the continuous liquid phase before the horizontal forces of the vapor carry the droplet out of the vessel. To assure that the separation is maintained at all operating conditions, we IPD/L-99 uop PV-13will investigate the separation when the liquid level is at its highest. The highest liquid level will ‘be no more than 0.25 diameter above the centerline. «Select the tangent length/diameter (L/D) ratio. «Determine the liquid residence time required and percent liquid full at normal liquid level. The normal liquid level is usually at the centerline, but exceptions can be considered. «Determine the normal liquid level for vessels not liquid full. A standard level control range should be selected so that the level at maximum range of level controller does not exceed 0.75D. «Calculate the vessel diameter to satisfy the residence time «Determine the terminal velocity, Vpz, of the droplet using the Intermediate equation. 071 0.153¢°7 Dp (or - pr) Bg Vow «The maximum distance the droplet must fall is the height of the vapor space from the top of the drum to the maximum liquid level. Let this distance by XD, where X is the vapor space height expressed as a fraction of D. The time, T, to drop through the vapor space is: T=XDVpL « The velocity of the vapor through the vessel, Vy, is the volumetric flow rate of the vapor, Ocv, divided by the flow area, where the flow area is expressed as a fraction, Z, of the vessel cross-sectional area, 0.785D*. 1PDN1-99 uop PV-1dFigure 10-3, Horizontal Vessels ‘Vessel dimension based on vaprTiquiliguid separation with drop les Von ame. coalescing ‘option Diameter for gravity Seng liquid from vapor phase Tenth of drop les, ‘Velocity of continuous vapor phase, Velosiy of dispersed vapor phase, fs Velocity of total guid phase, fs ‘Velocity of eispersed liquid phase, Us ‘Velocity of dispersed liek liquid phase, is locity of persed heavy qui phase ‘Velocity of cominuous ent ligud phase, is Distance top of vee to maxim lig evel, asa fracion of rel = : Fraction of eos-sction sea coresponding to X Time, minutes igi density, in ‘Vapor deni. IRS ‘Vapor fw rate, 2.5 Vapor viscosity, bi -t Lig parle diam, (Use 0.00057 inthe absence of specifi process da) «The time for the vapor to pass through the vessel is the distance between the inlet and outlet nozzles divided by vapor velocity. We can express this distance as a factor, (Y), imes the diameter, (D), where ¥ is (L/D)-1 if we assume that the inlet and outlet nozzles are each a maximum 0.5D from the vessel tangent. Now, if the time for the droplet to fall is set equal to the time for the vapor to pass through the vessel, we have: XD YD 7-22 _ WD. Vor Vey + Substitute for Vpz, Vcy, and Y and solve for D. 5 ps —— [__ccvel?up _] 0.783(0.153)¥Z. es yr TPD/I1-99| PV-IS«If X is 0.25, then Z is 0.20, and if we selected an L/D of 3, then ¥ is 2. The equation then simplifies to: 5 9.29 0.43 Qev ey Hy J D=228 —_ O71 pit a7 2°" De, a) | Using a similar analysis, the vessel diameter can be calculated for separation of a vapor bubble from the continuous liquid phase. For this, Stokes’ equation must be used in place on the Intermediate equation. «If liquid/tiquid separation is required, the calculation of the vessel diameter proceeds as in the paragraph above using the properties of the two liquid phases in Stokes’ equation. «Ifa vertical coalescing mesh blanket is to be installed in the vessel, calculate the diameter necessary for a maximum liquid velocity of 3 fi/m. The clearance between the mesh blanket and the drop leg should be approximately one-half of the vessel diameter. «Size the vessel on the basis of the largest of the preceding calculated diameters. «Round off diameters and tangent lengths to the next larger standard increment. Vessel Drop Leg « Determine the residence time. «Calculate the drop leg diameter for phase separation by using Stokes’ equation. «Based on the recommended maximum drop leg velocity, calculate the drop leg diameter by using that maximum velocity. 1PDIN-99| ‘op Pv-16«Calculate the drop leg diameter based on the residence time and a drop leg length of 3.5 feet (1070 millimeters). «If the largest of the preceding calculated drop leg diameters is less than one-half of the vessel diameter, round this diameter up to the next larger pipe diameter. If the largest of the preceding calculated drop leg diameters is equal to or larger than one-half of the vessel diameter, round one-half of the vessel diameter down to the next lower whole even inch increment. Use that value as the drop leg diameter, and increase the drop leg length beyond 3.5 feet to satisfy the residence time requirement and round the length to the next largest 3 inch increment. If the drop leg length becomes larger than 6 feet, a smaller residence time or a different vessel configuration, such as a baffled separator, should be considered. Drop leg diameters should be specified as OD (outside diameter) in order to allow standard pipe material to be used. The minimum drop leg outside diameter is 14 inches. The minimum drop leg length is 3.5 feet. IPD/11-99 op Pv-I7~ HORIZONTAL VESSEL EXAMPLE The following data is to be used to size a horizontal Product Separator in a naphtha hydrotreating, process, wa owing or | roving ve | car seer roe | nine | “Cree ws seem | [wen | x | sew | comes | or | comin | ‘atey | ny | man | wn | arm | on Faner Seen Taare wT we | ao [aw | eas 2 Poe Teaver | 0m oe [en [wo | am [em | a |mal| w | aa | on Taso ne | a war | we eae we | a 3a | m wae ve [a ws | Feats ve |e ie [ww [ane a tesa | oa | or [ve [we | ome | on | ao ws _[ see [awe | [oes wr [ ost | too > | oon [aw | Bo 3 [wee [ae [ae [oe Tabulate data and calculate volumetric flows. Hydrocarbon ‘Water Vapor Liquid Liquid Flow, yh 695 58586 20 | «fs 134 035, 001 + gain e 158 5 Density, of? os | asa | ss Viscosity, cP 001 02 ast sibiftsee (x10) | 0.06 282 342 1 Calculate the diameter based on residence time. IPD/I1-99 op Pv-18Select L/D = 3 € For settling water phase from light hydrocarbon phase, use a 10 minute residence time. Set normal liquid level at centerline. Calculate liquid volume: V,=Ot= 036? (22)¢c0 min) = 216 fi? Oe s min. ~ If vessel is ¥ full, then full vessel volume is: M26 f 45, 93 VE 959 7 AF Vyis acylinder with L/D = 3 C a My yr Ae28?) ia ae) | oe D=57 feet Calculate the diameter based on liquid from vapor separation. For normal liquid level at centerline, maximum level is 0.2SD from top of vessel (X= 0.25 and Z = 0.20), and L/D = 3 (thus ¥ = 2), use the equation from page 10-16. “TPD/1I-99 uop PV-1905 a aod cv elf? | 077 [2”"DH(a.-a)” | Oey = 1.54 f/s py = 0.125 bf p> p= 46.4 Ibf fi? by = 0.06 x 10 Ib/ 3 g= 322 fils? os cE (1.54)(0.125)°29 (0.000006)? |" (32.2)"7"(0.00082)""¥(46.4- 0.125)" | D= 068 feet Calculate the diameter based on vapor from liquid separation. The terminal velocity of the bubble rising in the liquid, py; is calculated with Stokes’ Law. Vy = &Dbvlon- ov) ae 18, IfX is the distance from the bottom of the vessel to the minimum level, expressed as a fraction of the diameter D, then the time, T, for the bubble to rise a distance XD is: XD Vv The horizontal velocity of the liquid phase is the volumettic flow of liquid divided by the flow area. a © 2(0785D7\7.48)(60) 3523 Z IPDII1-99 op PV-20where: Qy is the liquid flow rate, gpm Zris the fraction of cross-sectional area corresponding to X € 0.785D? is the total cross-sectional area (7.48)(60) converts from ft'/s to gpm. If Y= L/D 1, then the time for the liquid to flow from the inlet to the outlet is: D 7 In the worst case, the time for the bubble to rise XD is equal to the time for the liquid to flow ¥D, and: = AD __¥D Voy Vy XDV, = YDV py Substitute: YDgD}v (01 - py) 18u, Solve for D: For X= 0.25, then Z = 0.20 For L/D = , then Y= 2 IPD/I-99 op PVv-210s _ a Le Dév(o.-pr)] _ (163)(0.000282) re pao 4 aa ete 4-0. al D=175 feet This does not govern Calculate the diameter based on liquid/liquid separation, “The method uses Stokes’ Law to calculate the terminal velocity of the heavy liquid droplet and is very similar to the vapor from liquid case. Use subscripts HL and LL. for heavy liquid and light liquid. From Stokes’ Equation: D3 en - Pus) Wb Vin = and: Van Vb Substitute and solve for D: 305 18X i HLL 23YZ) |g Dbulen ~ pu) | IPD/11-99 op Pv-22For.X = 0.25, then Z = 0.20 For L/D = 3, ¥= 05 D=0. 14 Du orn ~ Put) 1». pas (1630000282), (32.2)(0.00041)? (61.55 ~ 46.4) D=42 feet The governing diameter, 5.7 feet, was that determined based on the liquid residence time, Round to D=6 feet L=3D=18 feet Vessel Drop Leg (Boot) Size the drop leg for 10 minute residence time for the water phase. Size drop leg for separation of dispersed hydrocarbon liquid phase from a continuous water phase. Use Stokes’ Law to determine the terminal velocity of the dispersed liquid droplet. TPD/I1-99| op 7 PV.23The velocity of the continuous heavy phase (water) is the volumetric flow rate divided by the cross- sectional area of the drop leg. Qcm __ Qcu Ap, 0785 Diy Vout Now set the velocity of the continuous water phase, VCH, equal to the terminal velocity of the hydrocarbon droplet, Vp, and solve for the diameter of the drop leg, Dr. 2 Dpx(om ~ Pu) Vout =Vou 360s/min) 18upp fe 05 Dopp =271| Louis a a5 | 0.5 (5.000342) (32.2\(0.00041)° (61.55 - 46.4 I] Dp = 124 inches Calculate the drop leg diameter based upon the 10 minute residence time and a drop leg length of 3.5 feet. Dby = 243 Dpy = 1.56 ft = 187 in IPD/I1-99 op PV-24Select the largest calculated drop leg diameter, 18,7 inches, and round to the next larger standard pipe size, 20 inch outside diameter. Length of the drop leg is 3 feet, 6 inches. Since the drop leg is less than 30 inches outside diameter and the vessel is internally lined, the drop leg will be flanged to the vessel. VESSEL FABRICATION ‘Vessel Shell Pressure vessels for process plants are usually of cylindrical shape. Bending rollers consisting of three stacked rolls, one on top and two below, are used to form the cylinder. The length and sturdiness of the rollers will determine or limit the width of plates to be rolled. The top roller imposes the bending forces on the plate and the distance between the top and bottom rollers control the diameter of the cylinder. The rolling may be done cold on thin plates of smaller size. Prior to rolling, the ends of the plates are shaped to the desired radius in a press using a radius-forming die. By this procedure, perfectly round vessels can be made. After rolling, the edges of the plate are prepared for welding Plates for the fabrication of vessels are usually ordered by thickness. Plates made by a sheared- plate mill are of better quality and are available in a greater number of sizes. They can be obtained in a wide variety of thicknesses, the most common being from 3/16 inches to 1 inch in increments of 1/16 inch, 1 inch to 12 inch in increments of 1/8 inch, and 12 inch to 4 inches in increments of 3 inch, Lengths up to 800 inches are produced in the thinner plates. The maximum width available is about 195 inches, but extra charges on width may start at 100 inches. Therefore, it may prove economical to use more than one plate in certain instances for vessel sizes requiring plates over 100 inches wide. A comparison between plate width extras and the additional costs of fabrication with multiple plates must be made. IPD/I-99 op PV-25Vessel Heads Ideally, a spherical-shaped pressure vessel is the most desirable since it withstands higher pressures for a given metal thickness, Spherical vessels are used in the storage of volatile liquids and gases, but they are not suitable for the construction of the usual process vessels. ‘The cylindrical-shaped vessel is the next best design and is used most extensively. The heads for such vessels may be flat, ellipsoidal, elliptical dished, dished, hemispherical or conical. Flat heads can be employed economically only on small vessels (3 feet or less in diameter) or on vessels operating at low pressures. Flat heads may be welded to the vessel or installed as blind flanges on smaller vessels. Heads other than flat heads are manufactured by pressing or spinning large flat plates to the desired shape. Sizes from twelve inches to twenty-two feet in diameter can be manufactured by spinning, Pressing is more generally confined to smaller heads and is only economical when there is a demand for a large number. Often the process requirements dictate the style head to be used. A conical head, for instance, ‘would be used for the bottom head of a settling drum. If no certain style is dictated, however, the choice between hemispherical, standard dished, and ellipsoidal heads is a question of economics. As the thickness required to withstand a given pressure increases in the order hemispherical, ellipsoidal, and dished, the cost of forming decreases in the same order. Although it is difficult to generalize, it may be said that in the range of low to moderate pressures, the standard dished head is used. At higher pressures (above 100 psig), it proves to be more economical to employ the ellipsoidal (elliptical dished) head with 2:1 ratio of major to minor axis. A wide assortment of standard heads is manufactured and itis always desirable to use these whenever possible. The use of a non-standard head requires the manufacture of additional dies needed in the forming process and thus entails additional expense. Nozzles Alll process vessels require nozzles for fluids, vapors or solids to enter and leave the vessel and for instrument connections, drains, vents, handholes, and manholes. These nozzles may consist of pipe couplings, forged steel nozzles, built-up nozzles, integrally reinforced nozzles or other suitable arrangements in accordance with the code requirements. Although the code permits the use of both fusion welded or threaded nozzles, the use of threaded nozzles is generally avoided. IPD/11-99 op PV-26Cutting of holes into the shell of the vessel for the installation of nozzles weakens the vessel; therefore, reinforcement around the nozzle is required. Detailed rules for such reinforcement are given in the code, Forged steel welding necks of lengths sufficient to protrude beyond vessel insulation are mass-produced by several manufacturers. The lengths of such nozzles have been standardized and it is customary in designing vessels to adhere to these standard lengths whether the nozzle be purchased or fabricated from pipe. So-called welding-type nozzles with integral reinforcing necks are also available. These nozzles do not require the additional reinforcement necessary for welding neck nozzles. ‘UOP recommends a minimum nozzle size of 1-inch on pressure vessels. This ensures mechanical strength and reduces the chance of plugging of the nozzle. There are other minimum size requirements for certain services such as vents, drains, steamout, level, temperature, and manways which will be discussed later. Nozzles larger than helf the vessel diameter require additional investigation and possibly additional reinforcement and are not commonly recommended by UOP. According to the ASME Section VIII Pressure Vessel Code, all nozzles on vessel heads must be located inside a circle of diameter 0.8 times the inside diameter of the vessel. On very small fractionators, itis sometimes necessary to install the vapor outlet on the side rather than on the head to satisfy this requirement. Consult a flange table for the outside diameter of flanges. To avoid interference with the vessel weld line, 2-inch nozzles and smaller are normally located with a minimum of 6 inches from the tangent line to the centerline of the nozzle. Nozzles greater than 2 inches should be located a minimum distance of the nozzle diameter plus 5 inches from the tangent line to allow for the reinforcing pad. Generally, for tangential nozzles on horizontal vessels, the maximum permissible distance from the centerline of the vessel to the nozzle is 0.45 times the vessel diameter for diameters greater than 12 feet. For more information and a table of maximum permissible distances versus vessel diameters, refer to Figure 10-4. 1PD/11-99 vop PvarInside Diameter A Inside Diameter A B of Vessel Maximum | of Vessel Maximum | Minimum 340" rage 70" 3" 346" 76 3454" 3M a0" 8-0" 3-814" 3K" 46" 3 a so 23K" a S68" 2-6" ae o0 294" s” 6" at sue To simplify fabrication, a minimum “B” dimension of 6 inches is recommended when processing conditions will permit. UOP practice is to specify manway sizes as inside diameter and to provide a minimum manway size of 18-inch inside diameter, including lining, if applicable. Larger size manways should be used if required to accommodate intemals. On unlined horizontal vessels, the manway should normally be located on the side of the vessel at or below the horizontal center line. If the bottom half of the horizontal vessel is lined, the manway will be located on the upper side or the top of the vessel. Horizontal vessels with a diameter of 2 feet-6 inches or less can have a full flanged head. Vertical driers, treaters, etc., usually combine the top manway with the process piping and also use it for loading solids or packing. The size should be a minimum of 18 inches inside diameter and may be larger to permit installation of internals. A manway is provided on some driers or clay towers on the side near the bottom of the vessel to unload solids directly into a truck, IPD/11-99 uvopFigure 10-4 Design Limatations for Tangential Nozzles on Horizontal Vessels heat A (Max) 1%", 2" Nozzles Alt Classes For safe entry reasons, horizontal vessels 10 feet and greater in tangent length should be provided with a blanked off ventilation nozzle on top of the vessel near the end opposite the manway. Vessel Tangent Length Nozzle Size 10 feet through 15 feet 4 inches (Over 15 feet through 25 feet 6 inches Over 25 feet 8 inches A steamout connection should be provided on each vessel which is steamed out as part of the normal startup or shutdown operation, Examples of vessels which should not be provided a steamout connection are reactors in hydrogen-rich gas circuits, vessels containing caustic, and vessels containing materials such as molecular sieves which could be damaged by water. The steamout conn ion will be located near the bottom head on vertical vessels and on the head furthest from the ventilation nozzle on horizontal vessels. 1PD/11-99 vop‘The UOP recommendations for minimum sizes of vents, steamouts, and drains follows. Vent Steamout Vessel Diameter and Drain Size 15 feet and less 2 inches Over 15 feet through 20 feet 3 inches Over 20 feet 4 inches For vertical vessels, the atmospheric vent nozzle and valve are located on the vessel, or on the piping near the vessel, at the highest point and are used for venting to atmosphere, for steamout, purging, and hydrostatic testing. 7 For horizontal vessels, the atmospheric vent valve is located on the vessel with a vent valve to atmosphere, ‘When a steamout connection is specified, the vent nozzle is located on the vessel with a vent valve to atmosphere. The vent valve to atmosphere is not required when there is no steamout connection or when a vessel is purged and evacuated during the startup. A depressuring connection to the pressure relief header is always required. The drain is located on the vessel or piping near the vessel at the lowest point for draining hydrostatic test water to the sewer or hydrocarbon to a closed drain or pumpout system. The design and pressure rating of the flanges on flanged nozzles are governed by the following codes: + Chemical Plant and Petroleum Refinery Piping Code (ANSI B31.3) ‘+ Steel Pipe Flanges and Flanged Fittings (ANSI B16.5 - Latest edition that has been approved by ANSIB 31.3) « ASME Boiler and Pressure Vessel Code, Section VII, Division 1 IPD/N1-99 op PV-30‘The nominal pressure ratings for flanges are Class 150, 300, 400, 600, 900, 1500 and 2500. The pressure temperature ratings of these classes are tabulated in ANSI B16.5. The ratings are for the maximum allowable non-shock pressures at the temperatures indicated. Interpolation between temperatures is acceptable. Markings on flanges usually consist of the manufacturer's name, material, nominal pressure class rating, temperature, size and ring joint groove number, if appropriate. Flange facings include raised face, male and female, tongue and groove, ring joint and lap joints. The raised face flange is the most commonly used. ‘Vessel Internals . Usually, vessel intemals, such as trays and mesh blankets, are not manufactured by the vessel fabricator. The design and fabrication of these items requires a specialized technical know-how. However, support rings and bars for trays and mesh blankets will commonly be welded to the shell by the vessel fabricator. Other vessel internals such as baffles, distributors and vortex breakers may be fabricated and installed by the vessel fabricator. It is desirable for all vessel internals to be designed so that they may be removed through the manways on the vessel. Coalescing blankets are used to coalesce fine droplets of the dispersed phase from the continuous phase in a shorter period of time than could be accomplished in an empty vessel. If salts or corrosion products exist, coalescing blankets may plug. Demisting blankets are used to remove entrained liquid in vapor streams where such liquid could cause damage to downstream equipment such as compressors or result in loss of product to the fuel system, ete. If excessive entrainment of liquid in the vapor outlet stream could be economically significant or detrimental to equipment, safety, or operation, the vessel is sized to allow gravity settling of liquid from the vapor phase in addition to providing a partial mesh blanket. For less critical situations, a full dimension demisting blanket which meets the vapor velocity criteria can be used, Distributors are used to ensure that the introduction of streams into vessels does not disturb the liquid present or interfere with the separation desired. Some of the factors to consider are: TPD/NT-99 ‘uop _ Pv3I«For subcooled total liquid inlets such as cold feed surge drums or overhead systems with the final condenser at grade, the liquid inlet distributor should remain sealed under the minimum liquid level «For bubble point liquid inlets where the possibility of small quantities of vapor may exist, such, ‘as a bubble point system, low pressure system, or overhead condensing systems with an equalizing line to the condenser rundown line, the inlet will be through the top of the vessel with an intemal closed end, slotted pipe distributor. The inlet nozzle and internal distributor pipe will be the same size as the line size to the vessel. The closed end will terminate 6 inches above the bottom of the vessel. The slotted area is approximately twice the cross-sectional flow area of the distributor pipe and is provided by one slot, oriented on the vessel centerline, facing the nearest head of the vessel. The slotted section of the distributor starts approximately 6 inches from the top of the vessel and extends the length of distributor to the closed area. For small diameter distributor pipes, intermittent larger slots should be considered in preference to very narrow slots. « For total liquid systems with two immiscible liquids present in sufficient quantities to establish an interface level at or near the centerline of the vessel, the inlet will be on the side of the vessel with an internal distributor perpendicular to the major axis of the vessel. The inlet nozzle and the internal distributor will be the same size as the line size to the vessel. The horizontal pipe will be located at the normal elevation of the interface between the two liquids and will be closed at the end opposite the inlet and slotted on the side opposite the vessel outlet. The length of the horizontal pipe should be great enough to permit a slot area approximately twice the cross-sectional flow area of the distributor inlet pipe. Pipe lines carrying mixed phase streams are quite ofien sized for higher velocities than total liquid lines. If these higher velocities were carried into the vessel, the resulting turbulence ‘would interfere with the disengaging function of the vessel. Therefore, both the inlet nozzle and the inlet distributor will be expanded one pipe size greater than the line size to the vessel in order to reduce the inlet velocity. IPD/11-99 op PV-32The inlet is located at the top of the vessel and will have a closed end, slotted internal distributor pipe terminating 6 inches above the bottom of the vessel. The slotted area is between two and three times the cross-sectional flow area of the distributor pipe. The slotted section of the distributor starts approximately 6 inches from the top of the vessel and extends the length of the distributor to the closed end. The slotted area for all vessels, except those with a vapor phase and baffles for separate ends for light and heavy liquid phases, is provided by one slot facing the nearest head of the vessel. For vessels with a vapor phase and baffles for separate ends for light and heavy liquid phases, the slotted area is provided by two slots arranged perpendicular to the major axis of the vessel. . + Vertical receivers or separators should use a tee-type distributor located close to the vessel wall. «Vortex breakers (VBs) are used in any vessel outlet nozzle from which a pump is taking suction or if gas entrainment would present a problem in downstream equipment to which an outlet is feeding. The standard VB is made of two plates forming a cross extending down into the nozzle and overlapping the nozzle above the outlet. An extended pipe vortex breaker 6 inches long is provided if there is a drop leg on the vessel For pump suction nozzles on the side of a vessel, or for very large nozzles, a grating is installed as a VB when the outlet is close to a liquid-vapor interface. A VB is not required for a fractionator tray drawoff nozzle. External Appurtenances In addition to nozzles, manholes and handholes that must be installed in the average process vessel, certain other exterior attachments are usually required. These include insulation support angles or rings, platform and ladder support lugs and brackets, davits and supports, and skirts or lugs for the support of the vessel. These items are supplied by the vessel fabricator and welded to the vessel shell before shipment. The items are usually fabricated from structural grade steel. IPD/11-99 op PV-33Vessel Supports Most vertical vessels are supported by a skirt. The bottom nozzles must project through the skirt to avoid flanges inside the skirt, reducing the hazards associated with leaks. Generally, straight skirts, are specified based on economics. ‘There are exceptions for supports and good engineering judgement should be used. For small vessels less than 3 feet-6 inches in diameter and the support length from the base of the support to the bottom tangent line is 5 feet-0 inches or less, then support legs are provided. ‘Lugs are used for equipment support when good ventilation of the vessel ‘surface is required, or a small diameter does not allow a skirt or legs to be provided. Table top support is used where access to the bottom of a vessel is required. It is the most expensive type of support and is generally avoided. The vessel can be supported on the table top with lugs or a short straight or flared skirt. Most horizontal vessels are supported on saddles, which sit on concrete supports. Saddles are normally 6-10 inches wide and are located at a distance from the vessel tangent lines no greater than 0.25 times the vessel diameter. Insulation rings are used to support block insulation on the walls of vessels. Insulation is called for whenever heat loss or heat gain would affect the process. When insulation is required, the vessel project specification should indicate a requirement for insulation clips and rings, required for personnel protection. Insulation is ‘Weather shielding is sometimes specified to minimize thermal stress and differential thermal expansion of uninsulated nozzles and flanges, Davits are a type of crane installed on fractionators and vessels to facilitate the raising of intemals and for handling manway covers. IPD/11-99 uop PV-34Platforms are installed at all manways and wherever required to reach equipment, such as controls, more than about 8 feet above grade. The vessel project specification indicates that ladder and platform clips are to be provided as required by the contractor. Welding ‘There exists a wide variety of welding processes and techniques, but the basic types are arc, gas and resistance. These three types cover 90% of all welding done today « Welding Processes Shielded arc welding is perhaps the most common method used in vessel fabrication. An arc is produced between a metal electrode and the base metal. The heat created causes melting of the electrode and portions of the base metal near the arc. The weld is formed by the fusion of the ‘metal from the electrode and the base metal. The welding rods (electrodes) are coated with a flux which, when heated, produces an inert gas blanket around the arc and deposits a protective coating of slag over the weld to prevent oxidation. Arc welding can be manual or automatic. For large longitudinal and circumferential seams, automatic welding machines prove particularly advantageous. For circumferential seams, the cylinder is moved and the torch remains stationary. The opposite procedure is followed for longitudinal seams. TIG welding is chiefly used for welding light gages of stainless steel from less than .025 inch to V8 inch thick. Heavier sections may also be TIG welded, where the highest quality weld metal is required. A nonconsumable tungsten electrode is used. Inert gas is fed around the arc to protect the hot metal. Filler metal, when required, is added separately with a rod of continuous wire. Spray-are MIG welding is often used for high-deposition-rate welding of stainless steel from less than 3/16 inch and thicker. A continuous electrode wire, which melts and forms filler metal for the joint, is used. The metal from the melting electrode is transferred in fine droplets across the arc to the work. A protective shield of inert gas or gas mixture is used. IPD/1-99 vop PV-35Shorting-are MIG welding is usually used for welding light gage stainless from less than 1/16 inch to about 1/8 inch thick, and for out-of-position welding. Shorting-are is similar to spray- are welding except that lower currents and smaller diameter electrode wires are used. Molten metal is not transferred across the arc as in spray-are, but is deposited in large size drops as the molten electrode tip makes contact with the weld puddle and the arc shorts out. This automatically occurs as much as 100 times or more per second. ‘Submerged-arc welding is most frequently used for welding stainless heavier than about 2 inch thick, but lighter gages to less than .078 inch can also be welded. A continuous wire electrode is used as in MIG welding, but the wire is usually of larger diameter. Instead of gas, a granular flux is used for shielding Acetylene gas welding is common, especially for welding thin plates and small attachments. In addition, acetylene welding is a necessity in any vessel fabrication shop for many utility purposes. A few of its uses are: flame hardening of small parts, cutting, and tack-welding sections prior to automatic arc welding. Gas welding is also used in brazing which is the joining of metals with a nonferrous filler without melting the base metal. The filler material melts at 800°F+ and bonding is completed by capillary action. «Type of Electrode ‘The electrode may melt (consumable) during welding and become part of the weld or remain intact (nonconsumable), depending on the welding process. Consumable electrodes are the type most commonly used in the welding of steel and stainless steel and usually are similar in composition to the base metal. Individual coated electrodes or a continuous length of wire are used depending on the welding process. The type of coating or electrode flux, and the size and composition of the electrode, will influence the weld penetration, the melt rate and the size of the finished weld bead. Nonconsumable electrodes made of tungsten can withstand the high arc heat without melting and are used in one major process (TIG) for welding stainless steel. 1PDN11-99 op PV-36«Welding Qualification Good welds are made by competent welders. Tests to qualify or certify welders are given in various vessel codes. The most commonly used is Section IX of the ASME Boiler and Pressure ‘Vessel Code titled "Welding & Brazing Qualifications". Welding of vessel seams generally requires the application of several layers of weld material. It is necessary that great care be exercised in making such "multi-pass” welds. The surface of each weld pass must be thoroughly cleaned and examined before proceeding with the next pass to insure good penetration and freedom from cracks, slag inclusion, and other weakening defects. A faulty weld can be disguised by a satisfactory final weld pass. Postweld Heat Treatment Residual stresses are produced around the welded seams of vessels. Such stresses weaken the vessel at these points, particularly in thicker vessels (above 13 inches thick). In these instances, and in all cases where maximum safety is required, the vessel is postweld heat treated to eliminate such residual stresses. PWHT term is commonly interchanged with stress relieving. Stress relieving is an annealing or heat treating process which relieves residual stresses. The operation varies, depending on the material of construction. For instance, carbon steels are heated to approximately 1100°F and then cooled slowly. Austenitic stainless steels, if required, are heated to around 2000°F and then cooled rapidly in order to prevent carbide precipitation characteristic of these metals in the range of §00-1600°F. Precipitation of the carbides in stainless steel destroys the corrosion resistance. Information of PWHT procedures can be found in the ASME Code, Section VIII, UHA-32 for stainless steel, and UCS-56 for carbon steel and low alloy steels. ‘A well-equipped vessel fabrication shop has large gas heated furnaces capable of receiving almost, any size vessel that can be shipped in one piece. Large vessels that must be welded in the field can be stress-relieved around the welds using gas fired portable furnaces. Several low temperature stress-relieving processes are also used. These employ special oxyacetylene torches which apply heat to the area at the welds, followed by a water spray. Because of the wide differences in IPDIL1-99 op PV-37physical properties of metals, it is imperative that the proper stress-relieving procedure be outlined by a competent welding engineer. Radiographing When the greatest confidence in the soundness of the construction of a vessel is desired, radiographing (X-raying) of all welds is done in order to detect defects. Because of the greater knowledge of weld quality, the code permits a lower safety factor in the form of a higher joint efficiency. It is particularly advisable to radiograph the large longitudinal and circumferential seams of all important vessels. Joint efficiencies can be found in the ASME Code, UW-12. Plate thickness requiring X-ray are noted in UW-11 and UCS-57. Other inspection approaches include ultrasonic, magnaflux (magnetic particle) and dye penetrant check. Shop and Field Fabrication Because of the superior equipment and working conditions in a fabricator's shop, field fabrication should be kept to a minimum, Large diameter vessels (20 to 40 feet), however, must be field fabricated. Rolled sections (arcs) of the shell 7 to 8 feet wide are shipped to the job-site. When planning any vessel over 10 feet diameter by 35 feet long, railroad agents should be consulted. Sizes above this, which can be shipped, depend largely on the railroad facilities serving the area. Vessel Inspection ‘The vessel codes require inspection by some public inspector, such as state, municipal, or insurance company inspectors, before the vessel can be certified as complying with the codes. Prior to this inspection, the purchaser should have inspected the vessel during all phases of its fabrication. This includes inspection of the plates and heads as they arrive at the fabricator's shop, study of mill test reports, and the following of all operations including the final hydrostatic test of the completed vessel. Mill test reports give the physical and chemical properties of the particular steel that was used by the steel mill in manufacturing the plates being used for the vessel. 1PD/11-99 uop Pv.38PRESSURE VESSEL DESIGN ‘The ASME Code, Section VIII, Division 1, Article UG-27, and Appendix 1, Articles 1-1 through 1- 4, provide instructions and equations for the design of pressure vessels under internal pressure. The requirements of these articles must be satisfied in the final design of a pressure vessel. However, for the limited purpose of determining an approximate wall thickness for planning and cost estimating purposes, the following basic equations are often usefia Cylindrical Shells The minimum thickness or maximum allowable internal working pressure of a cylindrical shell may be calculated by means of the following equations. The symbols below are used in the equations. 1 = minimum required thickness of shell, in. intemal design pressure, psi (or maximum allowable working pressure) R= inside radius of the shell, in. Ro = outside radius of the shell, in S. = maximum allowable stress value, psi E = jointefficiency ‘These equations are limited to thicknesses not exceeding one-half of the inside radius or pressures not exceeding 0.385 SE. « Based on inside radius: PR SEt or P= SE-06P R+061 + Based on outside radius: IPD/I1-99 op Pv.39Ellipsoidal Heads Within the limitations indicated above for cylindrical shells, the following equations may be used to calculate the minimum thickness or maximum allowable intemal working pressure of a formed ellipsoidal head. The symbols below are used in the equations. minimum required thickness of head after forming, in. P= internal design pressure, psi (or maximum allowable working pressure) D_— = _ inside diameter of the head skirt; or inside length of the major axis of an ellipsoidal head Do = outside diameter of the head skirt; or outside length of the major axis of an ellipsoidal head S = maximum allowable working stress, psi = _ joint efficiency hk = one-half of the length of the minor axis of the ellipsoidal head, or the inside depth of the ellipsoidal head measured from the tangent line (head-bend line), in. K = a factor in the formulas for ellipsoidal heads depending on the head proportion D/2h Dith = ratio of the major to the minor axis of ellipsoidal heads, which equals the inside diameter of the skirt of the head divided by twice the inside height of the head 2SEt « Based on inside diameter: “Run + [Based on outside diameter: PRK po SE SE+PAK-01) ”* ~ KR,=(K-01) 2 _Ellipsoidal head factor: 2) ] 2h) | ‘Note that K = 1 fora 2:1 ellipsoidal head 1PD/11-99 op 7 7 Pv-a0Stress Values ‘Stress values used in the equations above are as indicated in the ASME Code, Section VIII, Division 1. The values are usually one-fourth of the tensile strength, resulting in a factor of safety of 4. Designs based upon Division 2 requirements use higher stress values, resulting in a factor of safety of 3. At temperatures in the creep range, stress values are based on creep rates, Joint Efficiencies Table UW-12 in the ASME Code, Section VIII, Division 1, provides maximum allowable joint efficiencies for welds under various degrees of radiographic examination. Some commonly used joint efficiencies are as follows: + Double-welded butt joints — Fullyradiographed - 100% ~ Spotradiographed - 85% ~ No radiographing 70% « Single-welded butt joints with backing strip — Fully radiographed - 90% - Spotradiographed - 80% = Noradiographing - 65% IPD/11-99 uop PV-41o~ op Introduction to Process Design Section X Pumps ~ LIMITED DISTRIBUTION ~ ‘This material is UOP LLC technical information of aconfidential nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or > distributed for any purp: hhatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC. April, 2000| = DP rainina seovce | | Pumps-———— | Pumps | = Introduction = Pump Curves - Head versus Capa | NPSH | - Efficiency| Pumps | (coitinued) = Single-Stage Centrifugal Pump Design Pump Components - Impellers ~ Axial Thrust | Shaft Sealing ~ Cooling and Flushing ~ Bearings ~ CouplingsPuimps (continued) Sealless Pumps Pump Selection and Performance Double Suction, Multi-Stage, and Sundyne Pumps Fan Laws Pump Control Standards Other Pumps Problems1300, T | Emde als < wl “7 Til), = | Tn Ese en ‘This is a typical pump curve. The pump curve gives information on how the pump will perform, the NPSH required by the pump, and the impeller size range for the casing. All pump manufacturer's curves are similar so, if you can read one manufacturer's curve, you can read anyone’s. er fo Oriol [bi277 | 250 | S50 ba | 200) 000 8001200 1600 2000 2400 Gallons Per Minute Head-capacity curve. Once this curve is established based on the impeller diameter and speed, the pump will always operate on this curve. Note how the curve rises as the flow goes down. This is a characteristic of all centrifugal pumps.i 7 Single Stage Centrifugal Pump | [- Cooling Outer Mechel Se a ee Hh] er Ring Impeller Z [| Deatng Bon Vet Tf Anal That secon >| owing Wear Rings — Coup shat Baring Box Cooling Defiecir Sleeve Inlet Ring Single stage centrifugal pump. As the centrifugal force of the impeller throws the fluid out towards the casing, the velocity of the fluid goes up. As the fluid leaves the pump, this velocity energy is changed to pressure energy.Identical Pumps Handling Liquids of Different Specific Diseh. 100" x 0.75 | Gasoline, S Pres spi Ph LOO 2 espe PASH LO ao a4ppsi Pash S0orxt2 a Ce Pump performance is measured in feet or meters of head. Head is the height of the column that the pump can move the fluid. Pump head is a function of impeller diameter and speed. It is not a function of the density or specific gravity of the pumped fluid. Here are three identical pumps pumping out of three identical tanks. Note that the head or column height is identical even though the specific gravity of the fluid is different.Differential 0 400800 1200 1600 2000 2400 Gallons Per Minute awa Each pump casing size can handle more than one size impeller. This pump casing can handle impeller diameters between 9 and 11 inches. Also, the impeller can be trimmed to any size between 9 and 11 inches to meet the rated operating point. The impeller diameter does not have to be a whole inch size. énNPSH i 9 400 800 1200 1600 2000 2400 Gallons Per Minute The pump curve also gives the NPSH required by the pump. Note how the NPSH ry required curve rises with increasing flow.TBntrange|Loss B | tnereabine Pressurf Due TRON Turbulence ction, Enranes ors Vane Panto heen Pee Ld Lives Vagheation Sis} B Point Along Liquid Path | The fluid loses pressure in the pump before the pressure starts to rise. As the fluid enters the pump, there are entrance and friction losses. As the fluid enters the rotating impeller, there are turbulence and friction losses at the vane tips. If this pressure drop is enough to drop the pressure of the fluid below its vapor pressure point, flashing will occur. This phenomena, called cavitation, will quickly destroy an impeller and a pump. The NPSH available must be greater than the NPSH required nNcartes lie | of He pup tigen Las 7 phat HE Hy ‘psi By Pap Manufacture poops ‘The NPSH available is a function of the pumping system. NPSH available is the pressure at the pump suction minus the fluid vapor pressure. It is the pressure that can be lost in the pump inlet area before flashing or cavitation begins. For a bubble point or vapor pressure point fluid, the NPSH available is gained with vessel elevation,« 500 450 400 360 300 200, S746 al 80% | 400 800 1200 1600 2000 2400 Gallons Per Minute The pump curve shows the efficiency of the pump at any operating point. Note that the efficiencies rise with rising flow to the best efficiency point (BEP), and then quickly drop off. Optimum pump operation is at or near best efficiency point. Cu.) tf >) < ta. APS borin tn. Sombe ae 3-Sate , Loe intel waz be ceadin, 22 Pea Mengre aruba ceo om boye Siw.bhp 1" Dia so ° 0400800 1200 1600 20002400, Gallons Per Minute tL a too wes, | Pump curves also show the HP requirement for the pump. Do not use these curves CALCULATE HP. These HP curves only apply if the specific gravity of the fluid is 1.0. Also, it is difficult to get a good, accurate reading. HP is a simple calculation shown later in this talk 0 4Pump Selection | aaa | | Eee ee | Ss | ° soggiaan | itsdemn | 0200 #0 lniad ata DomDeNDH Et | This chart shows the approximate head-capacity ranges of single stage full and half speed pumps, double suction pumps, and two and multi-stage pumps. Low flow, high head applications are Sundynes.All API pumps today are centerline mounted. The centerline mount allows the pump casing to grow both up and down as the casing heats up. This keeps the shaft in the horizontal plane and helps prevents seal leaks and shaft mis-alignment. 16ae) | impellers | ia ane All API pumps today have closed impellers with covers or shrouds on both sides of the vanes. This gives the fluid a more defined path through the pump and raises efficiency. The flow splitter in the outlet or double volute equalizes the radial forces around the impeller and minimizes the load on the radial bearings.Single Suction Enclosed Impeller Single suction enclosed impeller.Large single suction impeller. Note the impeller vanes at the inlet and outlet, This is a half speed impeller. Full speed impellers are only allowed up to 15 inches in diameter to control tip speeds. 19| Axial Thrust | | Seer | _ Driver = | phesst __. Discharge Pressure as Vane WN] This Force Balances a ‘Theust from. faa oe i oie. ear fee — coe rm | The motor puts an axial thrust on the impeller. This is offset somewhat by the suction pressure acting in the opposite direction. To put the impeller in axial balance, some process fluid is allowed to flow across an orifice from the back side of the impeller. Some small holes are drilled in the back cover of the impeller to equalize the pressure on either side. ‘This minimizes the force on the thrust bearings. 20Impeller Specific Speed | ‘pm (gpm)'? / (HS | ® Below 4200 - centrifugal or radial | = Between 4200 - 9000 mixed flow | = Above 9000 = axial flow | Impeller specific speed is an index of hydraulic design defined as the speed at which an impeller, geometrically similar to the one under consideration, would run if it were reduced in size to deliver one gpm at one foot of head. This is a useful tool for the hydraulic designer in designing impellers to meet varying conditions of head, capacity, shape of the curve, suction conditions, and speed. The specific speed helps define the fluid path through the impeller, if there is a sharp right angle, centrifugal, or a very gradual right angle, mixed flow.| Suction Specific Speed | | S = rpm (gpm)'2 / (NPSH)** | | ™ Can range between 3000 - 20000 | = UOP limits to 11000 | | A 2 PIpere ly pat, | Ae nturrte 7 aod, S77. Mesa. | Pte And The suction specific speed relates rpm, gpm, and NPSH required. UOP limits the suction specific speed to 11000. If a pump manufacturer wants to reduce the NPSH required of a certain pump, he can increase the impeller eye area to reduce friction drop and reduce NPSH required. This increased eye area increases the internal circulation in the suction area of the pump. This can build up heat which can also flash the fluid and reduce pump reliability. This also reduces the stable operating range of the pump. As the flow is reduced, the pump becomes less efficient and more heat is built up in the pump. At higher suction, specific speeds this can promote cavitationModel 3735 High Temperatureéiligh Press e Toial Risitg Heavy Duty Desigit Features to Mee of Process Industries Impetier Rings Reliability Renewable Stung Box + Throat Bushing Smoothly — Large Cooling Sees Dual Efficient oe eniaue Volute Mechanical ca Casing. Seal Cooling — isis This is a single stage (one impeller), single suction (one entry into the impeller), overhung (impeller is cantilevered on one set of bearings) pump, This is called a Process pump. The metallurgy is as follows Casing Carbon Steel Impeller Carbon Steel <500°F, 11-13% Cr >500°F Shaft Carbon Steel Wearing rings 11-13% Cr Throat bushing 11-13% Cr Throttle bushing Bronze or non-sparking materialos hese beh GV Cuncmmee 5 Single stage, single suction, overhung pump. Note the vent connection on the top ry of the casingSingle Stage Pump Single stage, single suction, overhung pump. This pump is self-venting as the discharge is at the high point of the casing. This design is typical.Packing a Stove Nite” ealtower Typical Packing —— J /980 es im tay Covered Preformed Gaphicd sseioe Rings Asbestos oe, Before there were mechanical seals, pumps were sealed by “stuffing” an absorbent material called packing around the shaft. Since the process fluid had to lubricate the surface between the stuffing and the shaft, the packing had to leak, typically about 200 ce/hr for a new application. Over time, the packing would become saturated with fluid and the leakage would increase until the pump had to be shut down and the packing replaced. Today, UOP does not specify any pumps with packing 2Single mechanical seal. Most API pumps today have single mechanical seals. The single mechanical pusher type seal has two members, a rotating member and a stationary member. The main sealing takes place due to the friction between the rotating seal face and the stationary seal face. Since the pumped fluid lubricated this seal face, the single mechanical seal does leak. Typical leak rates are about 2 cefhr or about 100 ppm of emissions in the air surrounding the seal. As the seal faces wear, springs in the rotating member keep a tight fit between the two seal faces. O-rings prevent leakage between the seal and the shaft and between the seal and the pump casing,| | | Seal Box — Conaees Theoa. Bushing | Sha Sleeve! Single Seal ion A (eer to appropriate Connection B (refer to appropriate eimary seal pip rangement) KS Seal piping aangement) Cc) 2 se Seal End Plate : es ‘Seai Member Rotating Seal Member ‘Throttle Bushing (mechanical sl restrictive bushing) or auxiliary ‘sealing device Single mechanical seal. Used for most non-hazardous services.Single Mechanical Seal Here is another view of the single mechanical seal. Note the yellow process fluid coming from the pump discharge to the process side seal face. The rubbing seal faces generate heat. If the pumped fluid is at vapor pressure or bubble point and heat is added, the fluid could flash around the seal and the seal faces could lose their lubricant, Process fluid flows from the discharge of the pump through an orifice. The pressure is kept high enough around the seal to stay above the vapor pressure point even though with the seal faces are adding heat.seetmettows —¥S Stelite Sea ater nee Carbon oF Tun, Spiral Wound | MetaliAsbesios Gasket | Gland Solid Stet Routing Drive Lugs Seal : Assembly Bellows seals are specified for high temperature applications, above 550°F. Bellows seals have two members, a rotating member and a stationary member, similar to the pusher type seal3 ype PB-D | Dura Seal | /<~ inser: Mounting | When the seal face wears on a bellows seal, the metal bellows expands like an accordion, The o-rings between the seal and the shaft do not move along the shaft as they do in a pusher type seal. Since the ring material starts to break down at higher temperatures, pusher type seals are temperature limited due to the dynamic o-ring. Since the o-ring on the bellows seal is static, the bellows seal can operate effectively at temperatures up to 800°F.gle Seals = <1000 ppm (Most <100 ppm) = Comply with Regulations in Most Cases & 3+ Years 32Liquid Tandem Seals | (Cupressurized Dual Seals) | <50 ppm (Most <10 ppm) | Vent to Flare | Diesel Buffer Liquid | 3+ Years Life | [- 9 Tandem seals are now referred to as unpressurized dual seals. The buffer between the two seals is vented to flare and is unpressurized. Leakage of process fluid is greatly reduced from the single mechanical seal. Any process fluid that leaks across the inner seal is contained by the outer seal. Release of process fluid to the atmosphere is under 10 ppm.Unpressurized Dual Seals Connection A (refer to appropriate Connection C (refer to appropi primary seal piping arrangement) tandem seal piping arrangemeat) | | | i | | Connection 8 \\teoferte appropriate auxiliary seal piping arrangement) Unpressurized dual mechanical seal. Used for following: + Light hydrocarbons - Vapor pressure over 30 psig + Lwt % Benzene + 25 wt % C,-Cy aromatics +5 mol% H,S + Other environmentally hazardous materialsfey =— ee) _ InarmertinY Unpressurized | a No : Dual Seat Tose Using Prestre “tus” Axial Flow | sen La, Pumping Ring ei =a | (ok: Dish Wing “inte. Seat Chanter | Buffer fluid is circulated from the seal pot to the buffer area and back to the seal pot with pumping rings on the shaft. Leakage of process fluid is into the buffer area, The seal pot has a pressure alarm for flashing fluids and a level alarm for non-flashing fluids to warn of an inner seal leakvreswe_ \ ee Fie Unpressurized Dual | with Buffer Fluid Reservoir and Ancillary Equipment Mechanical Seals | ‘Mai Sea Pressure Note that the seal pot is vented to flare. Buffer is at a lower pressure than the lant process so leakage is into the barrier. No buffer fluid enters the process. If the pump is double bearing or multi-stage with two sets of seals, there are two separate seal pots. 16= ae Spring beaded Chock Vaive oq} Supaticd Suppied | SUP eee Bt = Schedule 80 1g Sone Rojaion | _ Gooner | Sue Vai - Geko! | Mx 10Sewer 1° Mrinamleng moidhnsifpsie OSI, 4 Tenuta Stace 5 oglu ig conan the ange sow 4 Rbthcrmante nee on poring fo crc pip 5 Pog salve nam uci of tiga Heat and conn cow hope 0 | A API Piping Plan 52. If the pumped fluid is hazardous and non-flashing, the drain is piped to a closed drain header.Tandem Mechanical Seal es Pinte cena Barrier Fluid Note the orange buffer fluid between the seal faces. Also note the O-ring (above and to the left of the “P” in Primary to prevent leakage between the shaft and the seal. The O-ring above the “e" in Primary Seal prevent leakage of process fluid between the seal and the pump casing,Arrangement 2: Standard Dual Seal | | Buffer Pressure < Process Pressure L | ao Unpressurized Dual Seals. Buffer fluid pressure (between the seal faces) is less than process pressure. No buffer fluid will leak into the process.Series 6000 Slurry Pumps Seals and API Support Piping Plans Photograph of actual API Plan 52. wmPressurized Dual Seals. Barrier fluid is pressurized to a higher pressure than the process and leakage is into the process. Barrier fluid must be compatible with the process. Most UOP processes do not allow the addition of an “alien * fluid. Therefore, pressurized dual seals are used only in special cases. 4l| Pressurized Dual Seals Connession A (eferw appropiate, | imary seal piping arangement) Connection 8 (reler 19 appropriate auxiliary seal piping arrangement) ‘Throwle Bushing (mechanical seal | restrictive bushing) or auxiliary sealing device Pressurized dual seals. The barrier between the seals is pressurized from a header or a seal pot pressurized with nitrogen, Barrier fluid lubricates both sets of seal faces and leaks into the process. Therefore, the barrier fluid must be compatible with the process. Pressurized dual seals are used when pumping very corrosive fluids such as HF acid and when pumping from a vacuum.| Arrangement 3: Standard Duai Seal Barrier P > Process P L = cod Pressurized dual seals. Barrier fluid is at a higher pressure than the process. This is a zero emissions seal. 4B| Double Seal Piping | Regulator vent (Normally Closed) _ Pressure Switch (Optional) i 4 a Heat Exchange (Optional) Nitrogen | SO Bottle —> u Level Gage Reservoi Pipe Compatible Buffer Fluid In & Out of Double Seal Cavity | Maintain At 25 PSI Above S'Box Pressure. Drain Noe: 3/8" 0.0 x.035 Wall Tube Min | Must Have Continuous Down-Slope from Reservoir to Seal Flange. ‘Two Smooth 45° Bends Allowable Max. Migimum Fitting Thru Hole | Is 280 Inches, Reservoir Must Be Mounted 18 10 24 Inches ‘Above Shaft Centerline API Plan 53. Similar to an API Plan 52. The seal pot is pressurized with nitrogen to pressurize the barrier between the seals. A pressure switch on the seal pot will war of loss of nitrogen and a seal leak.| Circulation Tube | Sealless canned motor pump. Zero fugitive emissions. The motor windings tum a ‘magnet on the pump shaft across a containment barrier. The process fluid lubricate the bearings on the pump shaft and remove heat from the motor windings. erefore, the pump cannot be run dry (bearings will not be lubricated) or be run blocked in (heat will not be removed from the motor). UOP specifies instrumentation (alarms and shutdowns) to prevent pump damage in the event of mis-operation.SUNDSTRAND @ | oor Sealless canned pump. Note the process fluid circulating from the pump discharge CT to the back end of the pump. The fluid then travels though the pump, lubricating the shaft bearings and removing heat from the motor windings. If the process fluid is corrosive, (HF acid) the bearing fluid could be from an extemal source. 46aia | Sees aun ‘SUNDST RAND @ ~ 6 Sealless canned pump. For this type, the process fluid is circulating back through the shaft instead of externally.AD ap les S cc - Zz | Magnetic Drive Pump set | Sealless magnetic drive pump. Magnets on the motor shaft tum magnets on the pump shaft across a containment barrier. This is an alternate design to the canned motor pump. Process fluid still lubricates the pump shaft bearings. Zero fugitive emissions. jp om neeMagnoseal™ Standard Features = ASMEJANSI Dimensions ™ Magnetic Couplings to 100 HP Engineered Composite andMeal Ld Containment Shel redision Cast Semi- Open Impeller Wear Resistant Siticon | Carbide Bearing System Sealless magnetic (Mag) drive pump. Note that the magnetic couplings are good only to 100 HP. 97 Theory of Operation Radu crag rN) eae ry Pfam Clancy sas SUNDSTRAND we Magnetic drive pump. Note the inner and outer magnet rings. critical between the two rings to avoid slippage. Alignment is nr 50SUNDSTRAND @ | Bearing wear monitors.| A Simple Flexibox Seal (Type R) | in a Typical Process Pump Application | Pp Discharge 1 Seaman Sea ing SSR 2, Sonar Sealing (SSR) Pacing 5. Row Sealing (SR) 5, Roasy Sea Rigg SRP Packing 1. Drive Sing omg Re ep | 1 Spe Slee API Piping Plan 11. Process fluid at discharge pressure piped to the process side of the seal face. Pressure in this area is maintained with a throat bushing. The friction of the seal faces create 50-100°F of heat, The pressure must be raised around the seal face to prevent the bubble point fluid from vaporizing. At a pumping temperature of 300°F, a cooler is added to this line so the seal is flushed with pressurized, cooled fluid| API Piping Plan 1] Schematic of API Piping Plan 11| API Piping Plans 21 and 23 | Schematic of API piping Plans 21 and 23. Plan 23 is the preferred plan for pumping temperature over 350°F, There is a small pumping ring on the shaft behind the impeller to create enough head to circulate the process fluid through the cooler. The advantage of Plan 23 over Plan 21 is that the cooler only has to remove heat from the seal. In Plan 21, since discharge fluid is used, the cooler must remove heat from the seal and the heat created by the pump. 4> | API Piping Plan 52 | _ sxenost Schematic of API Piping Plan 52.| API Cooling Water Piping Plan M | API Cooling Water Piping Plan M. This plan is, used when the pumping temperature is between 350°F (177°C) and 500°F (260°C). The cooler is the same cooler used for Piping Plan 23. 56API Cooling Water Pi Plank iping 7 “| API Cooling Water Piping Plan K. This plan provides cooling water for the seal flush cooler and the bearing box. 7Bearing Box Double Axial “Thrust Bearings © Normal Oil Dettecror \\ Level Rings Oi Slinger Rings to Lubricate Besrings Bearings locate the shaft. They also are designed to absorb any extraneous forces. Most pumps have ball type bearings as shown, The bearing box has an oil level, The oil is distributed to the bearing with a ring around the shaft. The ring, sitting loose on the shaft, rotates with the shaft and carries oil up to the bearings, Larger multi-stage pumps have sleeve type bearings with an extemal, pressurized oil system. External oil mist lubrication systems are becoming popular. In a oil mist system, a mist of about 1000 parts water to 1 part oil is pumped through the bearing box and exhausted. The bearing box is then always in a clean, fresh environment. The operators do not have to worry about changing or topping off the oil. 58Anti-Friction Ball BearingsSingle Stage Process Pump € w/Ring Oil Bearing Lubrication “ 2 | a : sro 60Flex ble Couplings | T Series-Type TSC | | a la disc type coupling. The coupling is flexible to absorb any mis-alignment { between the pump and driver shafts or vibration from the driver, ~~ 46 End (S79K€ orISingle-Engagemen | € Cushioned Single-Engagement Flexible Couplings |Laminated Metal Ring Couplings — | Driven Shaft | The rings must take up any vibration or misalignment between the driver and pump.Gear Coupling (End View) Gear type coupling. This type of coupling has to be lubricated. It is not used much anymore. ~ ryDetermining Pump Performance When Handling Viseous Fluids ‘When the fluid is viscous, over 20 centipoise, the pump has to work harder to move the fluid and there is an efficiency correction factor. The factor is in addition to the normal pump efficiency. 6sMinimum Continuous Piow | Depends On: | | a Temperature Rise H,0 = iad at Mint ose (Ey | 778 (Ef = NPSH | | = Radial Reactions On Impeller | L ecaeoue Every pump has a minimum continuous flow rate. The pump should not be operated at a lower flow. If a tumdown case requires a flow rate lower than the pump’s minimum continuous flow, a spillback must be added. Temperature rise across the pump is limited to 15°F, As can be seen from the above formula, as the flow decreases, the temperature rise increases. When looking at catalog pump curves, typically the minimum continuous flow rate is where the NPSH required curves end. 66| Double Suction Single Stage Pump | ‘Suction | Double Suction Le | Vent Connection Inboard Rings Seal | Bearing Housing ‘Flush, Vent Oil Seal Cuieat) | fees | St tachometer | ote i sat Double suction, single stage pump. Double suction pumps are used for high flow rates, typically over 1000 gpm. ‘The single impeller has two eyes. Half of the flow is distributed to either side of the impeller. Note that there is one suction nozzle. {t is important to have a long straight length of pipe at the suction (at least 6 pipe diameters) and the last elbow should be in the vertical plane perpendicular to the pump shaft to ensure an even distribution of fluid on either side of the impeller. Note the between bearing design. All double suction, two-stage, and multi-stage ‘pumps have the impeller(s) between the bearings and not cantilevered on one set of bearings. This is to prevent the heavy impeller(s) from putting too much of a load on a single set of bearings. 0Double Suction Single stage, double suction between bearing pump 68Single Stage Double Suction | Single stage, double suction pump. Note the between bearing design.‘o Stage Single Suction | Between Bearing Two stage, single suction pump, 70Horizontally (axially) spilt multi-stage pump.Stage Centrifugal Pump | ‘Opposed Impellers a, . | ca _ seal ] ohn inet Denese Ring. Diffuser Wear Rings “TT outboard Bearing Housing ‘Cross Over from Inside of horizontally split multi-stage pump. The impellers are opposed to each other, The first stage is on the far left of the pump. The fluid travels to the left for the first four stages. After the fourth stage, the fluid crossed over to the far right and travels to the right for the Sth through 8th stages. This is to balance the axial thrust on the bearings,Horizontally Split Multi-Stageee ey ay tes Six stage, axially split pump. Note the crossover piping internal to the casing.Radially split multi-stage pump. Radially split multi-stage pumps are more expensive and take longer to repair than axially split multi-stage pumps. The axially split multi-stage pump has a large casing split. Therefore, to reduce the possibility of process fluid leakage, API 610 does not allow the use of axially split multi-stage pumps if the pumping temperature is over 400°F, the discharge pressure is over 1450 psig or the specific gravity is under 0.7.| Multi-Stage Pump with Balancing Drum | fa Suction Pressure Suction | Decrgs Baines Line | Thermometer Cooking HO Tae Soal Flush | Sloove Beating, | Eo va Kingsbury | Mochani 7 S | Seal Assembly Assombly Inside a radially split multi-stage pump. Note that the impellers are all facing the same direction. This is because the design of the forged, barrel type casing does not allow for the cross over piping. To balance the axial thrusts, a balance drum. attached to a line at suction pressure is installed on the discharge side. This drum absorbs the axial thrust. Also, this enables both seals to seal against suction pressure.| Radially Split Multi-Stage |Six stage radially split pump. Note the double suction suction first stage for reduced NPSH. Also note the balance piston discharge. 78Model | LMV-311 Sundyne | | Process Power Pump | | Unit | | Cesatiga Separator BD. Mechanical Seal Diffuser Impeller Inducer | Pump Casing Sundyne pump. This is a high speed, integrally geared pump used for low flow, ry high head applications, Sundyne is the only manufacturer having good success with this design of pump. This pump is built to API 610 standards. It can achieve high heads using high speed rather than multiple impellers. a Se a by bnge pope AL keral,Gears | to Increase “E— Speed Tncreaser Box Gear Box and Pump Seals a Cone Impeller Open view of Sundyne speed increasing gear box. Speed | 80SUNDYNE PUMPS | LMV-806 Simple Sundyne with no gear box. ar| SUNDYNE PUMPS | | LMV-322 | Sundyne with single gear between motor shaft and impeller shaft. This type gear box is good to 50 hp.| _-SUNDYNE PUMPS, | LMV311 | Sundyne with idler shaft gear box. This type gear box is good to 200 hp. Note the internal circulating oil system for the bearings and gears. Also, note the internal cyclone separator seal flush system 5 8————— i | Impeller and Inducer | | Without inducer ‘with Inducer Head Pow D required | Inducer 025 3075 10) 125150 | | Percent of Design Flow Many Sundynes have inducers which lower the NPSH required. The inducer is a spiral mechanism which bolts on to the inlet of the impeller. UOP does not recommend the use of inducers for horizontal pumps. There have been mixed results when inducers are applied to horizontal pumps but they work well on Sundynes, apo | Affinity Relationships | € Q = Capacity, gpm N_ = Rotative Speed, rpm | H_ = Head, feet | | HP = Horsepower D_ = Impeller Diameter | Affinity relationships or fan laws, ‘The flow varies proportional to the speed variation and the head varies proportional to the square of the speed. These laws explain why high flows and low heads are achieved with low speed pumps and low flows and high heads are achieved with high speed (Sundyne) pumps.| Horsepower x Head x SP.GR. _ Ib/min x Head _ GPM x PSI | | 3960 x Eff ~ "32000 BR 1714 x Ee | 0 Cycle | Qbo = 1.2 Qey | | Hy = 1.44 Hy NPSH,)= NPSH so | 076 Se ee eee ee oy When using pump curves for 60 cycle and the pumps will be in a county with 50 cycle power, the flow, head, and NPSH required must be corrected before a pump can be selected.10 120 | HeadlCapac}ty / rae 00 100 t 56 (ord | w 5% | 0 Eo =| 59 20 20 2 10 | a 0209 400 600 00 1000 1200 1400 | Capacity gpm For constant speed pumps (motor driven), there is only one characteristic curve, If an off-design case falls below the curve, the excess head must be taken across a control valve. This wastes power, 87o em Speed Variation | 1900} min } ead Feet : [eae 0300400 €OO BH TO60 1200 400 caps | sox | If there is a variable speed driver (steam turbine or variable speed motor), there are many head-capacity curves. The speed can be changed to handle off-design cases. Power consumption is less for these cases than for a single speed driver using a control valve. 88—— _ | 150, - _ 100 : £ se, ; += Combine Curve 2 oy > Le | vuab ) Purl A 5 400 800«1200-=«1600-« 2000-2400 Capacity gpm ‘When pumps are operated in parallel, the combined performance curve is obtained by adding horizontally the capacities of the same heads. It is preferred that the hhead-capacity curves rise to shutoff. If the curves droop and if the second pump comes on-line at low flow, the pump could “hunt” between two flows at the same head.Two Centrifugal Pumps in Series 250 | 1 Car | 150 | 100 | so| | 0 a0 80 1200160020000 Capac gpm o For series operation, the combined performance curve is obtained by adding vertically the heads at the same capacities. Note that the maximum suction pressure of the downstream pump is the shutoff pressure of the upstream pump. 90Typical Motor/Motor Spare Pump ] € Arrangement | Discharge | Suction | ere ee ‘Typically, there are two pumps installed, one operating and one spare. If a pump ry goes out of service, an operator has to come out and start up the spare pump. Pumps are typically started with the discharge valve closed or pinched open. The least amount of starting torque required by the motor to start the pump is with the discharge valve closed. 9| Typical Motor-Auto Cut-In Turbine | Spare Pump Arrangement | Discharge | sow fo | i | | : §/ Conrot | ‘Steam 11.3 Kg/em’g Exhaust Steam 3.5 Kelom'g ———ee wet a Critical service pumps are on automatic start. Examples of critical service pumps are Boiler Feedwater, Surface Condenser Condensate, Compressor Lube Oil, and HF Acid pumps. If a critical service pump goes out of service, equipment, personnel, or catalyst could be damaged before an operator could get the spare pump in operation. Therefore, the spare pump must come on-line automatically when the operating pump goes down,| Reliability and Maintenance | | What is Reliability? | ‘The main objective of reliability is to achieve the | highest plant availability at the lowest possible | cost in order to maximize profit. The goal is to achieve the World Class | target of 95+% plant availability! |MODE RELIABILITY |AINT. $ |1 [Reactive | Low High | Preventative reece High | 3. [Proactive = pre ie iy | _ High Low _ Reactive — Run to failure Preventative - Time-based maintenance Proactive — Condition-based maintenance 4Reliability and Maintenance Reactive - Run to Failure Process Interruption No Opportunity for Diagnosis Frequent Failures Other Parts are Effected Replace Good Parts 95Preventatiy ased Mai No Opportunity for Diagnosis a Replace Good Parts 96Proactive ‘ondition. sed Maintenance | | = Repair Before Pump Fails | | = Replace Only Bad Parts | a | ® Diagnostics and Root Cause Analysis | _ ed 97Best Practices | | = Critical Equipment - Centrifugal Compressors - Unspared | = Continuous Monitoring System | = Pumps, Reciprocating Compressors - Spared « Periodic Monitoring of Vibration Data - Collect | and Analyze | = Root Cause Analysis 98Reliability and Maintenance | Suction Specific Speed < 11000 | L?/D4 < 60 (inches) Design pump for operation at or near BEP | 5 foot NPSH margin Minimum 5 pipe diameters straight pipe on | suction Install API Flush Plan 23 if pumping temperature > 300°F (149°C) | 99| Reliability and Maintenance Best Practices - Pump Operation | 4 Do not start and stop = Do not run pump dry ® Operate at or near BEP | Visual inspec pump often (once per | shift) = Measure and record | vibrations = Check cooling water and seal flush temps Inspect and change bearing oil (2000 hours maximum) * Do not “hose down” pumps = Report problems immediately = Training Amp Rellols kG 100| API 610 | 5-1-3 | | ASME B 73.1 | | 5-21-1 | | _. | Hydrocarbon pumps are designed to API 610. Non-flammable pumps (water, caustic) are typically designed to ASME B73.1 tolASME ys. API | — CO | | Mig aring Life [17,500 HR 25,000 HR | | Is Runour 10.05 MM 025 MM. L 300°E for Cast Iron —| (Cost _130 to 50% of API I een The ASME pump is a light duty pump used for non-hazardous, non-flammable services. It is not a custom engineered pump. UOP accepts ASME pumps for low flow, low pressure water, and caustic services. They cost about 30% of API pumps. Also, dimensional equivalence among manufacturers is obtained as the ASME standard lists dimensions of major parts for the various model sizes. This can reduce spare partsPressure | Lubricating 0 Diaphragm Lubricated | Relief Valve Drive High Speed Worm Stroke Micrometer | ‘Adjysiment | Strainer _ sere Propottioning pump. Proportioning pumps are used for low flow injection type services. They are positive displacement, There is no pump curve. Stroke speed is about 100 strokes.min, The flow rate can be adjusted by changing the stroke length, This can be done manually or automatically, Proportioning pumps can have rates down to 20cc/hr. Relief valves are required because the pump will always try to overcome the discharge pressure. ‘If blocked in, the pump could be damaged 108th== Gland Adjuster Liquid end of a plunger type proportioning pump. Ball valves are free to open and close with differential pressure. Process suction pressure forces the suction valves open and the cavity fills with liquid. The plunger squeezes the liquid to a higher pressure. When the pressure inside the cavity is greater than the discharge pressure, the discharge valves open, discharging the fluid. Most proportioning pumps require pulsation bottles in the discharge piping. The bottles dampen the pulsations caused by the pump. to#Plunger type proportioning pump. 105| Discharge Aulomatic AirBleod Ball Check Vane Valve Relief Valve Diaphragt Pressure | Lubricated | | Diaphragm | Suction patchece "SY Res Valve Magnet’ | Vale 4 # Behind Pisin Stainer | This is a diaphragm type proportioning pump. The plunger type (previous 2 slides) ey is sealed with packing, which leaks. The diaphragm type has no process fluid leakage. 106echnotogy irements | a G | a Diaphragm type proportioning pump. 107L _. | Four proportioning pumps on a single driver. 108wd | Aligned Indvid Hook-Up ‘valve cba Ny fecha Opa Crosshead Pi rripie” Seal Ploneee orgod 8 | ties Ons Eke erate j pone ie | | 5 4 | Suction ta cage wie Jaros ae ining Babi ind ral ston Gut Grating od Type Cruad wae Sime Reciprocating pump. Reciprocating pumps are used for services requiring very high pressures such as ram and test pumps or high pressure wash water pumps. They are positive displacement. The only capacity control is with spillback or variable speed. 109| Pneumatic Chemical Injectors Extremely Low Volume Highly Accurate Pneumatic Chemical Injection pump. These proportioning pumps are air driven. ry There is no driver. They are used for very low flow services. 110rors fee Positive eng ar Thrust «Bearing Screw pump. Used for high viscosity fluid such as lube oil, The oil gets trapped between the driven and idler rotors and gets squeezed to a higher pressure level. The process fluid lubricates the rotors.Variable speed gear type pump. Used for low flow, viscous fluids. The speed can be adjusted in the gear box to adjust the capacity oe,Note the wearing ring and throat bushing flushes. The areas of close clearanc flushed with heavy cycle oil to eliminate any catalyst fines. are 1B—S ‘B Circulating Pump Slurry Pump HCO flush to wearing rings, throat bushing, seals (LCO backup) 4-6 gpm ® Diffusion coating wetted parts 8 Two turbine drivers = Maximum size impellers ® Packing/mech. seal - now two mech. seals u Last 3 years - Lawrence pump alternate'B Product Pump No flush due to product guarantees Normal process pump with diffusion | coating of wetted parts m= Last 3 years Lawrence | u Seals are being flushed (2-3 gpm)Hydrocarbon Processing Industry ‘Slurry Pumps Series 6000 116FT | LPI Fully Lined Pump Technology ‘Mechanical Seal - Bearing Assembly Impelier Pressure Casing &@ | po4PI-610 Fully Lined Piinp Mechanical Seal 19CASING LINER MATERIAL + Casing Liner Material isan tason rexinantiron-niekel-chromium- ‘molybdemaum alloy which has ben specifically developed fer exosive sly applications Liner Hardnes canbe incensed from 350 BHIN twaver 600 BAN by wing v special eat reatment proces (Casings on unlined pumps cant be fardenedo aj for eat) + Surace Finish ofthe Liners ontoled by machining, Final machined surices ote tines opposite the mpeller peo redue the souging ston caused by the vores which form {tbe spit flow fom he volute——— Casing Features Casing drain is located ouside of high velocity ave o the woute so that tis protected frm + Awarm up connection is located 2 the hotom of, the easing to ensute even heating ofthe pump during stu. + A2" anchor pin is provide at the bottom ofthe ¢asing te maintain pump alignment under ll API nozzle loads & process temperature changes. WARM UP & 27 DRAIN > CONNECTION J ancior piv rt| Series 6000 Slurry Pumps | Rotating Element| Vertical Intine Pump | Moto Dive Sha | Maintenance On Pump Shall Sleeve "= Mechanical Seal Discharge _— Suetion = Impeller Balance ‘Wear Ring Hole _ __ Vertical Inline pump. This pump is available in API or ASME models. They are perceived to be more difficult to maintain than a horizontal pump. This is because the motor must be removed to remove the impeller. They take up much less space than a horizontal pump so, if plot space is a concem, vertical pumps could be considered.Ta Fiexible Coupling : Grewe Poin —[ 5 [Stat xing 2-Stage | ir sewing towing Submersible | Stlling Box ae: ctundrotover = Lift Pump | ain | Seating Spider Volute Casing ‘Sleeve Bearing Sump Pump. Sump pumps are on-off services. When the sump level is high, the pump evacuates the sump down to the minimum level and the pump automatically shuts down, ry 14ee | Gear Pump Internal Relief Valve Assembly Heating Steam Inlet | oy | =ONd! L, U | Heating —T== team Outlet Gear pump. Used for high viscosity fluids such as lube oil. This is a positive displacement pump. As in the screw pump, the process fluid provides lubrication for the rotors.PUMPS Introduction Pumps provide # means of adding energy to a fluid in order to have the capability of transporting the fluid from one level of potential and kinetic energy to another. Depending on a multitude of parameters, various means of adding the energy ae employed. Some of the mast promiseatcofsiderins in making a pump selection ave the following: ” + Capacity + Differential Pressure + Fluid Characteristics + Temperature + Pressure + System Analysis Once the specifies are defined, the basic pump type can be selected and then the specific mechanical design ean be developed, including seal types, bearing selection, rotor design, materials requirements, driver selection, control and instrumentation desiga, ete Because centrifugal pumps are the most versatile type of pumps and since in our industry the "process" type pump, which basically conforms to API 610 design criteria, is used so extensively, the major impetus ofthis paper will be in that area, Pumping Terms And Definitions Pumping is the addition of energy to a liquid to move it from one point to another. Reciprocating Pumps use pistons, plungers, diaphragms or other devices to displace 2 given volume of liquid during each stroke of the unit. Liguid Piston or Plunger of a reciprocating pump is the moving member that contacts the liquid and imparts energy to it Simplex reciprocating pumps are those which are equipped with only one liquid piston or plunger. EDS/997 Pumps-1Duplex or Triplex reciprocating pumps are equipped, respectively, with two or three liquid pistons or plungers. C Single-Acting reciprocating pumps produce only one suction and one discharge stroke per cycle. Double-Acting reciprocating pumps produce two suction and two discharge strokes per cycle Surge Chambers are containers built into a reciprocating pump or attached to its adjacent piping to cushion the shock of the reciprocating action and, therefore, smoothing the liquid flow. Centrifugal Pumps employ centrifugal force to develop a pressure rise for moving a fluid. Impeller is the rotating clement in a centrifugal pump through which liquid passes and by means of which energy is imparted to the liquid. Casing of a ceatrifugal pump is the housing surrounding the impeller. It contains the bearings for supporting the shaft on which the impeller mounts. Single-Stage centrifugal pump is one in which total head is developed by one impeller. “Multi-Stage centrifugal pump is one having two or more impellers acting in series in one casing, cri ical Speed of a centrifugal pump is that speed at which the rotating shaft corresponds to its natural frequency. At this speed, any minor imbalance of the shaft is magnified and excessive vibration will occur. Rotary Pumps use gears, vanes, pistons, serews, cams, etc, in a fixed casing to produce positive displacement of a liquid. Packing is any material used to control leakage between a moving and stationary part in the pump. ‘Mechanical Seals are devices mounted on the shaft of centrifugal pumps to seal the liquid in the casing. These are freq ly used in preference to packing because of their longer life and minimized leakage Cavitation is the phenomenon caused by vaporization of a liquid inside a pump. When the pressure at any point drops below the vapor pressure corresponding to the temperature of the liquid being pumped, vaporization of the liquid will occur. Small cavities of vapor thus formed move with the flow through the pump until a region EDS/997 Pumps-2