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97% found this document useful (36 votes)
12K views281 pagesExxon - EXXON PDC VOL I
Uploaded by
Khalid IqbalCopyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
/ 281
PROCESS DESIGN
COURSE
VOLUME I
PRESENTATION
ZS
EXXON ENGINEERING PROCESS DESIGN
COURSE
VOLUMEI
PRESENTATION
EXXON ENGINEERING is
1.
2.
3.
DATA St
Given:
Given:
Given:
05309101. Pom
TRAINING PERFORMANCE OBJECTIVES
EXXON ENGINEERING PROCESS DESIGN COURSE
SOURCES
+ A.gas stream of three defined components
+ The mol. fraction of each component
+ Temperature and pressure of gas stream
Determine the following properties of the stream:
Molecular weight
Weight and mola] average boiling points
Pseudocritical temperature
Pseudocritical pressure
Absolute viscosity
Compressibility factor
Density in pounds/ft3 at conditions.
eteaoce
+ A liquid stream of three defined components
* Volume fraction of each component
+ Temperature and pressure of liquid stream
Determine the following properties of the stream:
Molecular weight
Mean, molal, volume, and weight average boiling points
Characterization factor
True critical temperature
True critical pressure
Density in pounds/ft3 at 60°F
Density in *API at 60°F
eroance
* A liquid stream of three defined components
* The weight fraction of each component.
* Viscosity of each component at 100°F and 210°F
Determine:
a - The viscosity of the mixture at 100°F and 210°F via the Blending
Index procedure.
b - The viscosity of the mixture at 150°F using
viscosity-temperature charts.
c- The difference in enthalpy between the stream as a liquid at
100°F and 30 atmospheres and the stream as a vapor at 600°F and
1 atmosphere.
d- The latent heat of vaporization at 600°F. 4.
5. Given
6. Given:
. Given:
05309101.POM
+ A gas stream of three defined components
+ The mol fraction of each component
+ Temperature and pressure of the gas stream
Flow rate of stream in MegaSCF/SD
Determine:
a
b
- The brake horsepower required to compress the stream
adiabatically to twice the given pressure
- Temperature of the compressed stream
+A stream of three defined components
+ The mol fraction of each component
+ Pressure of the stream
Estimate the following properties of the stream using Vapor
Pressures:
a
b
* A stream of three defined components
- Bubble point temperature
- Dew point temperature
The mol fraction of each component
The equilibrium instants for each component
+ Temperature and pressure of the stream
Determine the following properties of the stream:
a
b
- Mole percent liquid at given conditions
= Liquid and vapor phase compositions
ASTM Distillation of pipestil] gas oil cut
API gravity
Determine:
a
- Specific heat of stream at 200°F, 300°F, and 400°F
(correct for Ky)
- Latent heat of vaporization of stream at 200°F, 300°F, and 400°F
- 15/5 Distillation Curve
- The "names" of an arbitrary number of pseudocomponents that will
define the stream
Cx DISTILLAT! (OLOGY AND TOWER DESIGN
1. Given:
+ Temperature, pressure, and rate of C3-430°F refinery stream
+ Composition of the stream through C5 material
+ Product specifications for Cq in the bottoms and Cs in the
overhead
* ASTM distillation of the C5+ material
Conditions of utilities that are available
Be able to
- Determine a quickie preliminary design using Fenske-Gilliland
procedure
2. Be able to define the following tray design terms:
a - Blowing g - Single Pass Tray m - Downcomer Clearance
b - Dumping h - Bubble Area n - Two Pass Tray
¢ - Jet Flooding i - Hole Area o - Antijump Baffle
d - Liquid Gradient dj - Perforated Area P - Downcomer Seal
e - Weeping k - Waste Area @ - Downcomer Filling
f - Ultimate Capacity 1
Free Area
3. Be able to classify the following types of trays:
- Bubble Cap - det
~ Sieve - Valve
In order of increasing:
a - Capacity c - Fractionation Efficiency
b - Cost per Unit Area d - Flexibility
4. Given:
~ A liquid stream’ s--
+ Flow rate (pounds/hour) and composition
+ Surface tension
* Viscosity
+ Temperature
- A vapor stream’s -~
* Flow rate (pounds/hour) and composition
+ Viscosity
+ Temperature
+ Pressure
- Required flexibility of the service
Be able to design a sieve tray by hand for this service IIL. HEAT TRANSFER FUNDAMENTALS
1. Given:
+ Shell and tube exchangers for concurrent, countercurrent, and
mixed flow
Be able to:
a - Identify each
b - Explain the differences among them
2. Given:
+ Temperature in and out for both sides of S & T exchanger
+ Number of tube and shell side passes
«No change in phase for either fluids
Be able to:
a - Calculate the ATLM
b - Calculate Fn
¢ - State the temperature approach
d - State the temperature cross
e - Explain why one should not design an exchanger that results in
outlet temperatures giving Fy <0.8
3. Given:
* Temperatures in and out for both sides of a water condenser
* 1/Q curve for the HC being condensed
Be able to:
- Calculate the effective temperature driving force (Ate)
4. Given:
« Temperatures in and out for both sides of S & T water cooler
* Rate of HC on the shell side
+ API gravity and MABP of the HC
+ Exchanger geometry (tube sizes, area, etc.)
Be able to:
Calculate the individual film coefficients and the overall
coefficient
- Calculate the total resistance due to fouling
- Calculate tube wall temperature on the water side
Specify which, if either, film coefficient is controlling
- Estimate the effect on the overall coefficient if the rate of HC
is doubled
eane
05309101.POM 5.
\T_EXCHANGER DESIGN CONSIDERATIONS
Given:
Be ab]
Be abl
and wa‘
Given:
Given:
(05309101. POM
* An exchanger design with less than the maximum allowable AP on
both sides
Be able to:
a - Explain why low pressure drop is undesirable
b - List steps that could be taken to increase AP
fe to list two advantages for double-pipe exchangers.
e to list the factors that enter into the choice between air-cooled
ter-cooled exchangers.
+ The total duty of a $ & T exchanger (Btu/h)
+ The characteristics at the two fluids in the exchanger
« The temperatures and pressures of both fluids
+ Type of service
* Tube side and shel] side fouling factors
Be able to:
a - Determine the minimum number of shells and explain reason for
this minimum
b - Determine which fluid should be on the tube side
c - Specify whether a fixed tube sheet, U-tube, or pull-through
floating head design should be used
d - Specify the tube layout
- Specify tube type (bare or low fin)
© The task of designing aS & T exchanger with specified shell side
pressure drop
Be able to:
Specify minimum and maximun baffle spacing
Explain reason for maximum limitation
¢ - Specify the most desirable baffle orientation if the exchanger
has condensing vapor on shell side
List advantages and disadvantages for high pressure drop through
the shell side
a 6. Given:
Shell side hydrocarbon rate (no change of phase)
Shel] side fluid properties
Temperatures and pressures
Allowable pressure drop
Water side inlet temperature
Water side allowable AP
Be able to:
- Estimate the area of the exchanger
5309101 .POM e Vv. FURNACES
1. Given
2. Given
+ The design of a furnace from a furnace supplier
+ The process information and requirements for the furnace
+ Type of fuel and percent excess air
Be able to:
a - Determine radiant heat flux
b - Calculate heat transferred in the radiant section
¢ - Calculate bridgewall temperature
d - Calculate heat transferred in the convection section
e - Calculate the stack temperature
f - Calculate maximum tube metal temperature in radiant section
g - Calculate fin-tip temperature in the convection section
h - Calculate film temperatures
‘* Fuel gas type and rate to a furnace
« Stack temperature
+ Flue gas analysis
+ Anbient air temperature
Be able to:
a - Calculate the percent excess air
b - Calculate the furnace efficiency
3. The following information is given for a 100 M Btu/hour (heat to oi1)
furnace:
05309101. POM
* 75% of heat load is obtained with 15° API fuel oi]
+ 25% of heat load is obtained with 1000 Btu/scf fuel gas
O11 burners operate at 25% excess air
* Gas burners operate at 15% excess air
* 0.6 pounds of atomizing stean (150 psig saturated) is required per
pound of fuel oi] fired
* Stack temperature is 60°F
Determine:
a - Furnace efficiency
b - Pounds per hour of flue gas VL. _FLUID FLOW, PUMPS, COMPRESSORS
1. Given
+ A piping system handling a liquid hydrocarbon stream
+ Stream flowrate and properties
+ Length and size of pipe
«+ Number and type of fittings
Be able to:
a - Estimate equivalent length of pipe
b - Estimate pressure drop
2. Be able to define the term "cavitation"
3. Given the following data for each of four pumping services:
Rate
Specific gravity and viscosity
NPSH available to the pumps
Solids content
Differential head required
Viscosity
Be able to select from the following list the type of pump to be
used in each service
a - Centrifugal
b - Rotary screw
¢ - Reciprocating
4. Given the following data for a pumping service:
Horizontal centrifugal pump with motor driver
Suction drum is an overhead distillate drum
Elevation of drum and pump centerline
Size, length, and number of fittings in the suction line
Rate, specific gravity and viscosity of the liquid being pumped
Be able to determine the NPSH available to the pump
05309101 .POM @ 5. Given the
same data as TPO Number 4 plus
* Pump characteristic, efficiency, and NPSH curves
+ Pump impeller diameter
«© Flow control valve pressure drop
« Piping system downstream of pump
« Downstream controlled pressure
Be able to determine
fo
b-
c-
Brake horsepower required by pump
System resistance curve
Diameter to which impeller should be trimmed to allow for a
control valve pressure drop equal to 20% of the line friction
pressure drop
Be able to list process information required to specify pump and
spare
6. Given, for a centrifugal compressor:
« Composition and rate of gas stream feeding the compressor
+ Discharge pressure
» Suction pressure and temperature
Be able to estimate:
ance
05309101.PON
Temperature rise exponent
Discharge temperature
Polytropic compression exponent
Brake horsepower -10-
WIL. PROCESS CONTROL
1. For Item under Fluid Flow Section, be able to determine the control valve
size.
2. Given
3. Given
4. Given
5. Be abl
05309101. Pom
* A list of services such as feed from tankage to tower,
fractionator reflux, etc.
Be able to:
a - List the four fundamental types of control
b - Select the type or types of control which would be most
frequently used for each service
¢ - Select the control valve action on instrument air failure for
each contro] valve
‘An incomplete process design flowplow for a multipass process
furnace
Properties and operating conditions of process stream
Fuel gas pressure
Pilot gas source is natural gas (pipeline)
Coil outlet temperature control is to be used
Furnace pressure drop
Be able to prepare sketch showing typical instrumentation for
controlling furnace operation
* Compressor suction knockout drum with automatic liquid drawoff to
blowdown drum
Be able to:
~ Sketch drum and compressor showing all instrumentation needed for
the drum, including alarms and compressor shutdown
je to:
a - Define the term rangeability
b - State the maximum rangeability for a control valve (double
seated, globe) and for an orifice meter.
© - Specify when a rotameter, turbine meter and venturi are used ’
e
-u-
DRUM.
Given:
05309101.POM
* Existing P&ID for a tower that is to be expanded
* Detailed Heat and Material Balance for the new conditions
Be able to:
a - Calculate the maximum velocity permitted in the vapor-liquid
distillate separator drum
- Determine the volume required in the drum for the liquid
- Determine the length and diameter of the drum
- Prepare a detailed process design drawing of the drum suitable
for submission to a vendor
aoc -12-
IX. GENERAL PROCESS DESIGN CONSIDERATIONS
1. Be able to define the following terms:
a - Operating temperature
b - Maximum fluid temperature
c - Design temperature
d - Operating pressure
e - Design pressure
f - Short time design basis
2. Be able to explain why it is very important to minimize the difference
betwee
operat:
3. Given
4. Given
Given
05309102. Pom
n operating temperature and design temperature for carbon steel
‘ing above 650°F
* The task of designing a depropanizer, a butane splitter and a
gasoline rerun tower
Be able to
a - List the factors that should be considered in specifying the
design pressures and the minimum design temperatures for the
vessels.
b - Explain how the vendor will know what internal
pressure the bottom of the towers will have to withstand
+ Temperatures and pressures in and out of two exchangers in series
in discharge from pump
+ Pump curves
+ Normal and maximum operating conditions upstream of the pump
* Exchangers have bypasses
Be able to
a - Specify the design temperatures for each exchanger
b - Specify the design pressure for each exchanger
+ A carbon steel piping system with uninsulated flanges
* Design temperature
+ Design pressure
Be able to
a - Determine the flange rating for the pipe
b - Calculate the maximum design pressure for the system using the
selected flanges
c - Calculate the maximum pressure to which the system may be
subjected at the given temperature -B-
e 6. In addition to the onsite process design considerations, be able to list
at least three other systems that need to be considered in the complete
design of a project.
In the preparation of a plot plan layout, be able to specify the desirable
location for:
a - Furnaces with respect to other equipment
b - Cooling towers with respect to the unit
c - Air fin exchangers with respect to fractionating towers and
furnaces
d - Pumps with respect to fractionating towers and furnaces
05309101 POM -u-
X._ SAFETY. CONSIDERATIONS
1, Be able to list the references used in the design of emergency release
systems.
2.
Be able to
Sorusse-heance
3. Given
© The process flow sheet for a unit
Explain the meaning of the following
Autoignition Temperature
Contingency
Emergency
Explosive Limits
Flash Point
- High Flash Stocks
- Light Ends
Low Flash Stocks
Pyrophoric Material
Single Risk
Toxic Material
Fire Zone
Pressure Relief Valve
Spacing standards
Be able to
N&xE
