Equipment desig dr khalid.pdf
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Ministry of Higher Education
And Scientific Research
University Of Technology Chemical Engineering Department
Equipment Design With The Aid Of Computer
Third Year By
Dr.Khalid A.Sukkar 2008-2009
Equipments Design with the Aid of Computer Programming
Theoretical 2 hr/week Tutorial 1 hr/week Practical 3 hr/week :Using Simulation by HYSYS Program.
References . 1- Ludwig E.E. (1999) Applied Process Design for Chemical and Petrochemical
Plants, Volume 1, Third Edition, Butterworth-Heinemann. 2- Ludwig E.E. (1999) Applied Process Design for Chemical and Petrochemical
Plants, Volume 3, Third Edition, Butterworth-Heinemann. 3- Peters, M. S., and Timmerhaus K. D. (1991). Plant Design and Economics for
Chemical Engineers, 4th edition, McGraw Hill. 4- McCabe, W., Smith, J. and Harriott, P. (2004). Unit Operations of Chemical
Engineering, 7th Edition, McGraw Hill. 5- Perry, Robert H. and Green, Don W. (1984). Perry's Chemical Engineers'
Handbook, 6th Edition, McGraw-Hill. 6- Kister, Henry Z. (1992). Distillation Design, 1st Edition, McGraw-Hill. Part (A) 1. Process Planning:
Scheduling and flow sheet design. Flow sheet types and designation. Block diagram. Process flow sheet. Piping and instruments diagram. Utility flow sheet. Equipment layout and plot plan. Project evaluation. Feasibility studies. Site selection. Project cost estimation. (6hrs) 2. Piping networks and pumps:
Pipe fittings, valves. Steam traps. Piping design standards. Piping material and selection. Pump specifications and data sheets. Optimum diameter. Types of pumps. Hydraulic characteristics for centrifugal pumps. (6hrs)
3. Vessels and Tanks: Types of vessels. Flash drums. LPG tanks. Criteria in vessel design. Stress
considerations. Design of tall vertical vessel. Design of pressure vessels. Supports and foundations (6hrs) 4. Heat transfer equipment:
Types of exchangers and applications. Exchanger ratings. Exchanger design. Exchanger specification sheets. Furnaces. Convection and radiation zones. Types of fuels. Burners and arrangements. Steam boilers, types of boilers. (6hrs) 5. Mass Transfer Equipment:
Types of columns. Plate and packed Types of plates and packing. Design features. Pressure drops in columns. (6hrs) Part (B) : Complete equipment design of each of the following units: 1. Pressure vessels, pumps and compressors:
Flash drum. Gas-liquid separator, LPG storage tanks. Cyclone separators. Gas movers and compressors. Pumps. Piping network. etc. (8hrs) 2. Heat Equipment:
Shell and tube heat exchangers. Plate heat exchanger. Boilers. Furnaces. Vaporizers. Air coolers. Coil type heaters. Condensers. etc. (10hrs) 3.Mass transfer equipment and reactors:
Distillation column. Absorber. Extractor. Dryer. Absorption towers. Leaching equipment. Scrubbers. Stripping towers. Reactors. (12hrs)
DesignsEquipment the Aid of Computer Programming ith w
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Equipment Design
Process design is the design of processes for desired physical and/or chemical transformation of materials. Process design is central to chemical engineering and it can be considered to be the summit of chemical engineering, bringing together all of the components of that field.
Process design can be the design of new facilities or it can be the modification or expansion of existing facilities. The design starts at a conceptual level and ultimately ends in the form of fabrication and construction plans.
in Chemical Engineering Field Transport Processes 1- Momentum Transfer (Fluid Flow)
2- Heat Transfer
3- Mass Transfer
and reaction kinetic and mechanism
:e equipments are classified tothngineering Ehemical C in, nThe
1- Fluid flow equipments (such as: pipes, pumps, storage tanks and vessels…..)
2-Heat transfer equipments ((such as: coolers, heat exchangers, boilers, reboilers,
heaters, condensers, furnaces, …….)
3- Mass transfer equipments (such as: distillation column, absorption column, leaching,
dryer, crystallizer, …….)
4- Reaction units (such as: CSTR, tubular reactor, fixed bed reactor, fluidized bed reactor,
biological reactor (fermenter),
Petroleum refinery
Tray in a distillation column Reboiler
Oil Refinery
Chemical plant near the river
Chemical Engineer (Process Engineer)
He has the following responsibilities:-
1. Prepares studies of process cycles and systems for various product productions.
2. Prepares economic studies associated with process performance.
3. Design and /or specifies items of equipment required to define the process flow sheet
or flow system.
4. Evaluates competitive bids for equipment.
5. Evaluates operating data for existing or test equipment.
6. Guides flow sheet draftsmen in detailed flow sheet preparation.
Flow Sheet –Types There are several types of flow sheets:-
1- Pictorial Flow Diagram
2- Block Diagram
a) Usually used to set for the a preliminary or basic processing concept with
out details,
b) The blocks represent the steps of process without details.
c) Each block represents a manufacturing step in the process.
d) It is used in survey studies to management, research summaries and
process proposals.
3. Process Flow Diagram (PFD)
A. Used to present the heat and mass balances of the process.
B. Show all production steps, starting from raw material to final products.
C. Show the operating conditions of each production step in the process (operating conditions
are: Temperature, Pressure, Flowrate, -----).
D. Show the type and quantities of utilities that required for the process (such as: water,
steam, O2, H2, -----)
E. Shows the process equipments and their conction pipes.
F. Gives some details for the main process equipments (such as: distiallion column: its
diameter, height, type of internals (trays or packing types), material of construction,
thickness, ---)
G. Show the main control system (type of instruments) required for the process.
H. Used as data base for Piping and Instrumentation Diagram (PID ) and for equipment
schedule (equipment summary).
3. Piping and instrument diagram (PID)
1) Prepared by chemical engineer with the aid of mechanical and control
Engineers.
2) Regarded as a data base for mechanical engineer for manufacturing of vessels,
Heat exchangers, Machines and controllers.
3) This diagram flows the PFD configuration.
4) Show piping details (diameter, length, type of flowing material, material of
construction, flow direction, design pressure, type of instillation and pipe position
in the process.
5) Show the position of measurement points for T, P and sample point.
6) Show all equipment in the process with details.
7) Used as data base for preparation of detailed design.
4. Utility Diagram (UD)
A. Utilities are:-cooling water, steam, air, O2, N2, H2, Flue gas, fire
water…….)
B. This diagram shows the quantities of required utilities for each
production step.
C. Show the operating conditions of utilities tat to be supplied
(specification, T, P……)
D. This diagram regarded as a Complementary diagram for ( PID) and
(PFD).
Model
1- It is a small three dimensional sample of the original plant shows all
instruments, pipes and carrying pipes.
2- It has a great advantage in the designing faults correction of instruments
location and pipes; directions and pathways before project establishing.
2- Useful in the training purposes as well as explaining the project to the
visitors after its done.
Three dimensional plant models
Plot Plans (Plant layout)
Actual north Pipe Racks
Control
room
H.E
H.E
H.E
Input of raw material Out put of products
S
W N
S
West north
Horizontal storage tank
Vertical storage tank
Power station
W
E
E
Furnaces
Towers
Symbology and Designation ا������و�� ��� �(�م� �1 ا��Rا��م�ز ا��
Symbology divination
W
Rw
Tw
Sw
S
S150
S400
V
M
A
SA
Water
River water
Treated water
Sea water
Low pressure steam
150 Psi steam
400 Psi steam
Vent
Methan
Air
Sulfuric acid
Data sheet or Schedule or Equipment summary
Pumps
-Section pressure
-Discharge pressure
- Net Position Section Head (NPSH)
-Quality of flow
-Type of fluid
-Type of material of Construction
-Physical properties of fluid (µ, ρ, -----)
Vessel
-Length
-Diameter
-Material of construction
-Operating pressure
-Design pressure
-Test pressure
-Internal (trays or packing, -----------)
*Lines
-size
-Schedule
-Material of construction
-operating pressure
-Design pressure
-Test pressure
-Type of flowing fluid and physical properties
Pressure Types in Design Work - Design pressure
- Operating pressure
- Test pressure
Design pressure = Operating pressure + 20% (Operating pressure)
Test pressure = 2×Design pressure
Activity analysis
Activity analysis Time%
Process design calculations
Conferences and consultion
Supervision
Preparation of chart
Marking, chart and reviewing
Group meeting
Literature
Coffee breaks
others
35-52
13-29
4-15
1-3
9-12
1-3
0.5-2
4-6
5-10
Estimated Equipment Calculation Man-Hours Man–hour: - for a specific calculation vary with process equipment, process system,
physical properties and familiarity of process engineer with design work.
Estimated total Job process Engineering =Estimated equipment Man-hours
0.45
Man –hour patterns
Assignment of Personnel It is important to plan ahead for the proper assignment of qualified engineering to various
projects as they arise.
The consideration selected for engineering works:-
1. Basic ability to understand the process under consideration.
2. Compatibility with the project engineer and other key decision making
representatives with whom they will be in daily contact.
There are two approaches to developing personnel
1. The generalist approached
2. The specialist approach
COST
Pb= Pa ( Cb/ Ca )0.6
Where:-
Pb:- cost of plant or section of plant of new capacity "b"
Pa:- cost of plant or section of plant of original capacity "a"
Cb:- capacity of plant or section of new requirements.
Ca:- capacity of plant or section of original requirements
Design of Drums There are three main types of drums:-
A. Liquid Surge Drums
B. Liquid -Liquid Separators
C. Vapoure-Liquid Separators or Vapour-Two Liquid Separators
Liquid Surge Drums
Surge time (ts)
ts: - depends on a functionality and location of surge drum.
Position of Surge Drum ts
A. Distillation reflux drum
B. Surge drum between two distillation column
C. Feeding a furnaces or reactor
D. Checking drum or drum feeding unite
5 minute
8 minute
12 minute
20 minute
Liquid surge time (ts) :- should be corrected for:-
1. Operators experience = ts×1 for fully experience
= ts ×1.5 for inexperience
2. Correction for the type of instrumentation
= ts×1 for fully instrumented
= ts ×1.5 for poorly instrumented
Design Surge Drum
-Length
-Diameter
-Material of construction (function temperature)
-Thickness
-Nozzle (location and size)
- Length/Diameter ratio (L/D) : it is related to pressure
Three ranges of (L/D)
(L/D)=1.5 for low pressure range (1.5-3) bar
(L/D)= 3 for pressure range (4-42) bar
(L/D)= 5 for pressure greater than 42 bar
Material of Construction it is Depends on Temperature
-For operating temperature -45 to 200 0C we used carbon steel (C.S) where, its
Tensile Strength (F) =950 Kg/cm2
-For operating temperature -45 to -104 0C we used 3(2
1 ) Nickel where, its
Tensile Strength (F) =1150 Kg/cm2
-For operating temperature -104 to -196 0C we used stainless steel where its
Tensile Strength (F) =1400 Kg/cm2
Liquid –liquid Separators (For two immiscible liquids)
Mechanism of Liquid-Liquid Separation
In separation of two liquids of marked densities differences, separation will occur by
settling. Therefore, the droplets of heavy phase (water droplet) will have a tendency to
full down and out of light phase under the influence of gravitational forces. The heavy
droplets accelerate until frictional force balance the gravitation force, at this point the
heavy droplet will continue to full down (phase out ) of the light phase at a constant
velocity which is the (terminal velocity ) until it reach the interface.
An analogy mechanism applies to separation of light phase droplets that may be present
in heavy phase (water) except that in this case the motion is up wards and the drag
frictional forces opposed by bouncy force.
Vapoure-Liquid Separators or Vapour-Two Liquid
Separators
Design of Bubble Cap Trays