GUIDE DOCUMENT

loved by Bm'n mpter d RN.

GE I 312 1 1.1.2 1 I 1 0

hpe
-
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
1
PROCESS MANUAL (DATA BOOK) COLUMNS/ DRUMS

CONTENTS

,.,.*.,..:.
.: .........
1 COLUMNS . ,,.. ~:
..,
...... .-... . ..'-.:.
.......
...........
.._.. : ,,-..i,.-..'..,'
c. ,. >-- .
I . . .
1
1. D ~ n i t i & i i ~ t o & used i n tray desfgp- ::. /.::
I.2 .........
Determ~&&&&f ...... .....
column diamet&hfjm:Hays)
I.3 ray [email protected] ...........
. ..... . .
I.4 .. .,;.:;.-.-:;
D e..t w i t i o n of column height.
............. ....
....
. . ... ....'
......... .. ., .... ....
,._ ..
I.........
_.._ ...... .. ., ....:.
2. . . ...: .
DR~JMS: , .
..........
. ............
:,: '._
. .
,.'.....:.:......,
.............
..:'('Xf
_. . ..I$rmulae
-. for the dpdtdiolr of droplets
.-,'.....2i2.i'::'~i~uid-va~our shaW0:
.:. ....: .::
,...,... . . .. .. ..
..
'

..........
, .__I

.
........
. .. . 2.2.1 Critical velh&
' 2.2.2 Vapgur,velocity
2.2.3 ~i~i;id'&?dence time
2.24 veitjtai:~+kse~s
2.2.5 &tiion61 . . vessels
....-..... .:,, ...
................
-.
2.3
;.,..........
Liq4ld:liquid
.. . .. . . . . separation without vapour phase

P'3.1''..~iopletsize
...-
.....&j:?
.--..'. .........
....
;

.IThree Phase separation

... .'.'.........
2...Si.:_ ..Other
. types of separators
..........
.. . . .. ..
 GUIDE DOCUMENT
Cwed DY W d chamere Rsv.

GE I 312 1 1.1.2 1 I 1 0
i
m e
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
COLUMNS/DRUMS 2
PROCESS MANUAL (DATA BOOK)

....... .
:_.-..
,
.......
... . ... ...
1 COLUMNS
...' {
~ .,.
'....... ':
,.. ... ..".. -.:
1.1 DEFINITION OF TERMS USED IN TRAY DESIGN ;...:<.. ."" .''
....................'>
.,. .... .._:
; ..
..I..
~..
.: .,' .-._ -..
,.-.. . . . . -'.;
. ',..:..:
;
, ....... ..:
2..
......
.<

I
- ,

.,
....... ....._
... ..-.. ..._.i
:.; -...,.
.. '
-.I ... >.
.. .:............
. . . .;
: (;.-.; :
:. . ..
. ................
(_

...............
.
.C
.
..__ '..
...........:*.''..
Notation: . -.
...............
...............
&
.-.
, :3 e
.........
., ...........
....
., .,
..'
~ownc$~eihlfhnce HLC Clear liquid height
Ts Tray spacing
j
... - e
~i~uid:&b=.h

- h ,$&height
:... ;2
hl ,_.--. "t;iIj:i
._ .:crest
u
v
Velocity below downwmer
Velocity in downwrner
......
: ' ;1 .......~.+d&rner width
ur
., .... :. .:
..........
. . .
......
............
_-..
- .. ... ..:,. .,..
:
;:.
.. ::
L

,,........
........ .
r"6
E
' , S
*
fi
4
=
. e
.)
9
.. t
e

Y ,
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE

PART 1- SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COLUMNS / DRUMS

1.2 DETERMINATION OF COLUMN DIAMETER (VALVE TRAYS) ,.......

.
I
.,, - .....
: ?

This calculation can be done by using the program BALTRAY (p.&$IirRrR$ house),
G-RATE (Glitsch) or manually (a calculation sheet based on @&@s0hllast Tray
method is attached). Where vapour and liquid rates vary signific&~.$r& the column
height, a diameter calculation should be done for each zoqeII<ge&r$lfy for the tray
where the V load is maximum. ...... :.:,,....
,'._
...
.. '..... .; .
A

..........
...... .:
,.~... : ....
, .
...... :..-..... packing is a more
Where the column di~metef:.is.,f.ess than 1 m, check.-~h~&:&p
;:..:...'::&~t, . '. ".
economical solution than
..............
. . ....
: <..: ,..-..:
-., :.... .
,
...................
..~.
-
For other types of trays;-~m::&thods shall be uq&.7$e.&meter resulting from the
use of sieve trays is y=ualr$:~lo$e
. . to the diameterobtpced:kith valve trays.
.......... 2 . .
... .. .. ..
.. . .. . .. .. . .. '..;'
:..... /.'...:.: ,
;
' ..............
,.. . .'... .
1.2.1 TRAY SPACING '
. .......<,. .
...... ...........
..:..
,.
. . : ..
I..,'

,. .. .__;' , .: .
............
!':.--' .
I: '

A 300 mm t@.$pac$dg
.............: is generally not : ., ;. :,-.
~cd:" . .~........
.
..;' .. :
............... ..............
:_. ,.'
450 m m ~ ~ ~ g be ~ used
c a up
n to,a:'@a.h&m diameter of 2 m for standard columns
r6fm
and :'?.e&ita. ..
+ .
.. ,. .
superfractionat~.&jmn~~
-...:
.: ...
:', .......
. .....
.
~ra:y'spki*s of 600 mm and ..-.. above A d b e used with no diameter limitation.
.
;.; ..........
: ...

1.2.2
.'
NUMBER OF PASSES . :..".........I. .
:;
. '.
. ..' ::
..:..
...................
.... ....
The number of passeg~:cii&&n so as to minimise column diameter, bearing in mind
that a multipass tr@pis.&iqe'expensive than a single pass tray. Avoid use more than
2 passes, except ,fQc~i:)i&h liquid rates (e.g. circulating reflux zones). Multipass trays
have a lower ........
effit$~n&fhan single pass trays which should be taken into account
(particularly trtie-focs~trpemactionation).
...
... .: ...
.......-..
,

For constr(l+ii'and installation reasons, in particular access through manways, it is not

possible-t~~~lpultipasses
tray below certain diameters. The following minimal values
I . y.
shoul@,'benb$l
.......'.
. be followed:
... . :.
A

......
~

I 2:~ass tw'' Diameter > 1400 - 1500

.:: <:
I . :, ..
&&$s:'&ys Diameter > 2800
I
Do not use 3 pass trays.
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE ~ g e

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) COLUMNS/DRUMS 4

f.2.3 MAIN SIZING CRITERIA .......

.........
.'f . ~.
.....
. .,

Liquid seal (j) .$t<timm

- :.. ,'
.... ......
........
.............
..
.........
Downcomer clearance (e) ..,"...?...46:inm
:. .. . '.... "..
Standard value
.., .. ..
Pressure drop ..--..
.
.........
.............
.',.-... .:.
...
......
..........
.
..... Less than twice the dry tray
pressure drop
.. ,.
. .,. .... .
- Efficiency is lower if the FPL
... . . .. ....
Flow path [email protected])..-.:'
, ............ .,.'
decreases

specific liii;idio$i~-.' 100 maximum

(CW~ mzhf
.........
... . . :.,;

These criteria are applicable to both valve trays and sieve trays.
 GUIDE DOCUMENT
~~~

.*%

m e
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
5

I PROCESS MANUAL (DATA BOOK)

TRAY EFFICIENCY
I COLUMNS / DRUMS

.............
:...... . -.
,. /
,
.. ..
Table 3 gives indicative tray efficiency values for the most fregt&$@&&
. . . ......' . .> refining
applications. :. c..: .. .-: .~?.. /.. ,.,.:
.......
.,.. .._..
. ...... ..
.....
DETERMINATION OF COLUMN HEIGHT :..::.:.. .....
..... ....-..: ~.
,. '._ .:
:
.._
...
a. H I Generally betwee"'&~and 1000 mm .. .. '..
...............
-..,;,: ;..........
:.,.-- i ..........
,
-
....'..,
.:..
< ,::
..........
........
:
,5

...................
.. . .._ . yic
.,_.:._ .'.. ..:, <...\
,".... ....,:'. ....:.:
.. .. ...
:

..-.. . . ..:
..........
. . ...........
...
.....
,I ...._.. .._
....... .. ...
;. .:.-.,: ..
:. ;. +
2 .;;,;

-
'.'
:;
M
&j . .,..
___ ..p .......<
.'. .. : ;./,I

>?-....,
11
. -
JI
: ..........

__
b..“.......

... ..... . . 'P :

.............
. . :".: ,.-; - C

... .-,
. ., .. .. ......... ....:,.t
'i.

.
...................
. . .. . . ._. ........:;.....;
:.: :; i

Transiii3n
....,

...
. -.
...............
............... .f 1::.
.,;...........
...............
:.. . . . .
. . . .
-.
-
..,
. . . . . . I

b. H2 ~2 ............
= - (.*..h of actual trays - 1 ) x tray spacing
.-.. . .b&
... ,,

Notes .......... ';

-
,:
'_ .'...:;
;;

~ ~ ? ~ with
] more
~ n than
s one section (see 1.2). the height of the transition
..~,:'.&..&.&
;' n . . be estimated using the formula : ..
.... .:p
'.....%i=
..--.
.......... T(@t - @z)
. .. .:.. ..
:.,,.-.,
:, ...
.......,..<.'..iced
...... trays and manholes : General practice is to allow one manhole every
15 trays andlor at feed tray locations. Extra shell height must be allowed for this
as tray spacing is increased to 900 mm for feed trays and at manhole locations.

h l = (tray spaang) x 2
h2 = to be determined based on the hold up required, allowing for an LLL
at 300 mm above the tangent line.
 GUIDE DOCUMENT

? ,' pa!F
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
6
PROCESS MANUAL (DATA BOOK) COLUMNS / DRUMS

TRAY CALCULATION SHEET - valve tray ,- .

.---..
,.- .
....... .
.,./....... . .
. . 8

.*
Contract number : Date ..;,
:,..:-... 'J.. ,:;
se@&,.- .:;:;:
Column : . I:
.................
Tray : .~t.!inb&..c$'passes
..
:..,;..... . ...... .
:
....... ,' .._ .... ..
Designer : .:._-.
. .. ...... .:
....
, ;:. .,: .
a:.. ,. ..............
..... :..-...
:I :. :
.............
. . ....:
.:~.:~)-'..~..,
1. VAPOR TO TRAY............
......
............... ......: :...
. *. .
-,:.,:
:* 3 Product . Mw . ..... ........>
l',.&x
. . t, PC
..............
. ..__
. . .'._ .. . ... .
:.:-._ ........
.
.._,. . . ._. . . . .'.;:'.. ....:
..........
. . .._'._
............. ......
.._..
. ...... . . . .'. .:. .
............
: 'i

.
._I.,..'
.__ .
., .. . .
,..........
........ . . -.._,..
..\........'
. .....
.,
Total [ (
,,':, ...........
. . :: t : ......, :.-......:
;: ; ..-,
; ..........
................ . .. . ... . . .
t" =,: .: ;:;: ,,.: QC ..........
,. . ~. . . ..
......
P= ATM abs
,*.>...- .<, ,; ..
+ 273 = .<
..I..-......

y;= t;.+.27'3 = .....D,K PC= ATM abs

.'. ...._
. ..._ .....
.. ..
P
:.,'~zk.k+ 273 = + 273.....= -..4 p' = -PC
.
:;:,..-.:.;. . ...... .
.

T = - T"
Tc
:. : ' '...
:.._.:,.........,...; .
';

........... .......
.-, . .
................. Hence Z =
. -
.......... ..:'
..............
V a ~ odens*.. r .............
;: ...........
: , . '.
., ..
D
.L
:: =..,1 & ' f ~ ~ x ~ ( a b-n ) - 1 2X2 x -
-
::.....Y... .. Z x Tu(" K)
........ ..,
......
,
.. f .. ::; --
......... - kglm3
_.-.__ ......
.._ ...
..........
.:'...........
iY v & ~ otl& r rate
. .
...... . . :
............
,..-.
.:.... .'
.,,... :.. :..
.
G=--- kgh - m3/h
.-J :... I; .. 0" -
........
..........
-a
$ 2. LIQUID FROM TRAY
. 9
i d154= dLatt= kg11 then x lo3= kglm3
z=
i
i
,
4
.
1 Liquid flow rate = kglh
1
::9 .,. ~ 1 0 3 ~ x lo3= m31hat t
.i 2
(L
G = d~atkfl
t ~( k g )
 GUIDE DOCUMENT
- - ~ -

A
page
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 :PROCESS EQUIPMENT
7
PROCESS MANUAL (DATA BOOK) COLUMNS / DRUMS

3. DOWNCOMER VELOCITY DVd, ,......... .

.:.......
.. ..,
,<' tf
-
............"':
1 ..
TS = mm ......
................ : :
. , .
:. (..;.'/' "?,. .,
DL-&= Kg/m3 ..............
.......
., .:. :, ;
;.' ...
,
......
DVdago = . ...... m3/hlm2maximum)
m3/Wm2(fig 1),(610 ...._
c..' .......
....._.
':.
. . . ........
. . ':. ......
....
......-..........
Factor K1 = (:.:.:/ :
(table 1) ;.... .......
. . .....
:.-..
...........
........ ?
x.g$.:=.;:>
hWO .' m3/h/m2 ;
,
:,
,
\..
,
-
. ;...... .*:
...-.... '...I'.:.
;

..........
=
Dvdag
.:.,.
.-...--... ;
._..._.._ _.
..............
......"....
;
"]
C:
".: . . y
Where appropriatec..~G'~~~a&aY : ........ . . be increase,.to .........
6vm37h/m2 with the agreement of
. . . . . :_.:;
GLITSCH ....... ........
.;;.......
....... ..; ............
. . .
.-..
... _....
....: .., ... . .,.. .. . ,
..............
..-.. . . . .,_ .. ., ..
. . ,..-.,......... ',.'
4. VAPOR CA;~KCI%VACTOR,
:...
.
;.':. .........
. .;: : . CAF ...........
..;,':-.). :.......
. '

............
. . . . . . .:
TS = .,,, ,: ;:.:; ........ mm .............
: ..; ,. , :.: .........
.:,.-: ) ..;'
........... :.: '

cAFp.Y,. .............. (fig.21... ..:7

. '.. ... . ..
:.; ...... ..... ,':
Factor K;"=' ............
(table 2) '
:: ;' ,. "..
: ; '... ..' .;
CAF = CAF, x K2 = :.._..'.x .......,:
-
................
........
........... :
5. EFFECTIVE VAPORt0AD':Vbad
,.''-\
...........
..
.rj

,v = xJ---'= x s
. ..._
.........
,

-
-
: ._ i
..........
..-..., x '..' - m3h
......: :!
,
......
6 . APPROYI~~~AFDIAMETER 4 Dr= in (fig.3)
..........
.............
....
FPL(now ~ a t lenathl
7 . APP~OXI~ATE
........... h
._.._
..........
\

umbefpf passes NP =
*.:Y',........
'. ,. .
;
....

P ~&'FPL = 0.75 x ?jii-DT - x -- m

-$
s 8. MINIMUM ACTIVE AREA MAA
Flooding factor = = FF generally 0.82
F
0.77 for column under vacuum ...
X
0 0.65 to 0.75 for diameter less than 900 mm. 2
fr I ~~

Vw+(1.36x C,x FPL) - +(l.Mx x ) - m2

MMA= 1108xCAFxFF - 1108x X
s
 GUIDE DOCUMENT

hoe
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COLUMNS / DRUMS 8

9. MINIMUM DOWNCOMER AREA DMA (1) ,........

...........
. ... . ;.
.........
..I...

--
r

- ...........
._- :.
DMAo = FF = m2 :::
;.:..
,
.., ,.
; "",
. , ..... .'.
If the result is less than 11 % of MMA value, the value cor.t$de:ic!d,.,f;i DMA will be the
,,,.
smallest of the two following values : .....
........
, ..
:.,.......
...
.:,........ “.....
M h.1;o
= .l
#.. :: ................
.. .. . .....:.
.......
.~@d;;~= i.2 ,i. .:-..::,.-..
......
.............
(......... ..............
I
, .. .:
........... .> ,. . - .
(1) The tray for which.'@&iirjrjid ... .. load is rnaxim&:dc$e$:;ndt . . . . . necessarily have the greatest
active area. : ..........
.......... ............
.....
.......... .............
... ._. .__
. -..; . .....
.. '.. . ..:
;......

... ... ,r. ..

kIen&..D&l= ............
. .-.:
.. .. .. . .., ........
.. . . .....,: ..:
., . .
lo.. MINIM& .;Z~&UMN
,. ,. SECTION ..... :,;
.
: .,
.
.........
......:
, ....__
j :
_ :. I.....
:.-.
Take@~~rf:.ttte'st of the two follo~i&,$&.ps
, (' ,,: ?
; . .
...:.......
A~~.I.=I&T& + 2 x MDA = +,,?.?',: ......jm 2
.. ... -.......
r .I.
..
.
vw - -
:.: ::
-.........
.......
:"AN..=
:_: .._..
.. :
x W CPFFF - - . .._
i
.. ..
..-.. 2
en& ATM = ............. m
:: ....
:-. '.
,.;..: .::
11. MINIMUM A P P............
~ O ~ M $ " COLUMN DIAMETER
,-,,-M = p
i- ,---
- :., .
'..,
............ m =
0.785 7'. -.:
._. '.
.... mm
..........
External col@.~&&ter DT ext. = rnm (standard diameter)
., :
.......
'..
Shell thicip$$.. .. ... e= mm
..........
lnterna1.mlurnir-diameter DT = DT ext. - 2e = - - mm
. ..--.:
,
.&< .:"
AT ='-4. .x (bT)2 =
- m2
.
..............
........
.. AREA
~Z?~Q~~NCOMER
.- ..
.....&& $t%e greatest of the two following values :
......

If the liquid flow rate is very low and the DA value calculated by the first equation is less
than 0.1 x AT, a DA value so that 0.05 AT < DA < 0.1 AT shall be selected provided that
it is 22 DM&.

The selected DA is then : DA = rn2

 GUIDE DOCUMENT -

tx.-
.......#..
Rge
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
9
PROCESS MANUAL (DATA BOOK) COLUMNS /DRUMS

......
13. FPL (flow path lenqth) ...............
i
. . . .. .
. ... -I :., :
...........
1

. , . .
:.' '.-> ......;
Sinqle pass tray : . ,. ,-:
......... .. ..:..::
: It. ,
:
,
/

.. . .. <.
OA-
- -
- H1 -
; m- (table 4) ,.'<..... ...-"
i...'.....
AT
......
........ .._.
:....._ .;
.
.......... .-... .-.
, C

Ht=nxDT= H1
X J:. .
......
;2 rn' ,.........
:.... ;,..........
DT-2Ht - -
2
.. --.,:
.....‘.....:,....
.'
.-..<,-: ;.-. '
FPL = 7- 7'.....:..... rn ...... : :..:.: ....-/
; -?

.............. ......................
i *.

;............
:. -.:--. .........
-; ...........
............
....... I- :. J
;,. ........ ;.
..
..... ,,.' ;'..,. .?
Two pass tray : :..........
. . . .
.......... . . . ,,.. .:
,
.........."... ..: ,.---. .......
...........
.
:. .......' .........~..
. . . .. ...
. . .
=- - . .. -.
. .. ...?
,
H 3 = DA .......
._.-.. .
. . . . ;'. rn .
,.
. .'.. ,: ,:
,.
:
.:...
. _.-.. .......
'.
DA - && ! - ' '..
:: .. rn2 ...;.-,:' ...........
1- 2 7.............. ...
i:=
.;.,.............
;- -..,
.. ,..
..;
'
>
...

....
........I :...
w,..
-,.
.......
.
-DAi -
AT -
,;;
''
:. ..... , .*
....... ..;.',;
. -*
?'gjT:; '.;
.... '; (Table 4)
:.., . .
. ,". .......
:.
, . ,,-)
. . . ......
...... .-
.I.,
.'". ..,. rn
H, =..~.x,QT = X
., ..-.. .
...........
,
.... -
DT-(2Hl+H3) - :.
FPL = 2 - ;.._ '.
L:'
: 2 <.'
: ........':.
: ;. - rn
.............
....
. : ._ .....
..
Four pass tray : . -.
..............
. .......
.. :
'"
..... .
;., .....:..:
............
t
.....
DA -- rn
, -.
H3= 0.575 = '0:575~:;
.. = 0.575 x
....... ;...
.............
= 0.565 x - rn
H, = 0.565 ---5
?T-. . ;
0.566 x
/ / ::
DA, = 0.21&~=.?.21
..--... . . . x - rn2
................
..,.. ..: .. ..
DA1 - i :.
- . , +-1-
DT -
H (table 4)
AT - .......... ,',:

:.
...............
..--.
;.,
i=
. '
2.
.........
,I ....DT,:? DT = x - rn
...........
ei
E
FPL =
DT-(2Hl + H j + 2 H s )
4
-- - (2 x + +2x 1

E - -
- rn
a
E

i
V
z
- 3
<
3
ks
 GUIDE DOCUMENT

-
paga
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COLUMNS / DRUMS 10

,..-.-..
.... ..,
I........
i :'
... ) f
14. ACTIVE AREA (AA) . . . -..'.:
.....-......
,.'.... ..... .
- ..:... .,:..........
, ;-.
AA=AT-2DA= - - m2 ...............:
..........
.'. -.......
.:.I.; :.......
I.

..
"

.-...
......... /.. ......
...... .......
.' i : : ............
15.PER CENT FLOOD......... ;:. '-.i:':. ....... . .......-.:.
,. . :,.-..
........... .
% M n g - VW+ (1.36 + ~ , , ? f f ~ j+- ,.A.
;,

._
'
-;:..-.-::,:'::
........
.
t
.

., a 100 -

- A=...
11tJ6x GAF..xpD9..... .-
,-- .:. .; x x = .........
.-....
: -..-...........
: . ". -.
...........
.....-....
..............
........
................
. ..:
..........: . ...._
. .'.__....+
.,

% Rooding - ..
:..-,k: .--: , ..........
,.--. .?
...
iw -...+xGZ..xAT. . = x .
, .
y ,; -...-\
.
. :.
' ....... /....:... :. .. ,.!'
Take &..gre&&st of the two v......
a ~-;:... e ~ , " ~ ~ v ashall
l u ebe less than the maximum
alloyabl&?&&ng Factor. . .
..... . . . . .
...../..,-......
,'.I .:,:
: -..,:;, . . ............
.
........
. :::. .....,.:
?.'. ,
,-:,.............:;.' ..,
.,.
,:,..
_ , ...,.I . -::
.......
. . .._
-., .
. .. -.
.
'-'ld:.k.~
P (Flow Path width)
...-..
..
,

;,.:.-. .........
,
:... -
WFP = FA ~A L
-
-
...... . ,:- m
: ............
;
..........
............
..__ '..
......: ....
......-. &
.

..............
.......
..........
'3 &= :.., . , --
.. ... .-...;... :
9 17. ..... normally < 72
i ....:.
The n ~ ~ : ~ : * & s s e swill be selected to minirnise the column diameter. More than two
, ..--.. $idrally
passesshgl to be avoided except if liquid rates are abnormally high.
,
:
:.....,.':,::
.-._'.._
...........
......
...........
.. .. . . .. ..
:',

,. .
-.". ..- :. :
.,.........
......
............
.-.. :-.
:.,...,: .... ...
;

.> \...........
.
..........
r"c'
5
,
-
9
E
5
-
=
.. e
i
1
9
- 5
u
0
 GUIDE DOCUMENT -

me
PROCESS ENGINEERING DESIGN GUIDE
PART 1- SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
11
PROCESS MANUAL (DATA BOOK) COLUMNS /DRUMS
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE we

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COLUMNS / DRUMS 12

.......
'....'.
,,
: ,_.._
,

...... ... ..
':: ,
, ,
:
I.

2
ee3
c -
2 &
5 - m
0

s *
.e .',
!! *
egm ;"x
'3,
;-Y
0
-
x
n
.-
-
-z

w
d
a
s
a
O N 3

-
 GUIDE DOCUMENT

- Rrlr
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COLUMNS / DRUMS 14

.......
.........
, .....
'f
:...... ... ...
.........:
: ;':. . .- ...'
..
........
;.
:

. , :,.:>
1
:
.

;
' t.;.":
TABLE 1
Downcomer system factors K1 . ..................
'
.. . -..: I
,.'.,,:
:.. -...
,-.., -.... .-..
: . .
........
..... i ... ....
Service 2; s!:.
. , .
. . '.-
.,.....$y4erp factorK1
... .... ...'.: 1.00
i.

.
Non foaming, regda!s'$&is
... .
. .-.., .... ..:, 0.90
-.I
~luorinated's$~@i:: ................
e.g. ~m-=.F&'ir>
..... . ..........
:
. . .
Moderate foaming e.g.,~::&&@&ffi,amine and glycob... . I .:
: : . 0.85
r&P'!:h&s
I. ,
.. :._
. .
.
Heavy foaming, '&$&$nesand glycol absorb&:--..:'. ... ..-: 0.73
~ey&,cef~c$l$,e.g. MEK units
........
. .. 0.60
Foam stab$:kyst<h?k., , . :.-..
e.g. caustic regengfiif&.......' 0.30
,;.,:' .>.; . ........
: .: , ,
:.'
.. .:'
._.............
I ,. ,.-.
..
. “. .
. .._ .
........-..'... .:: .:.
: :
. ,
. ........
. .i.,:'. ..;'
.;. .....
.:. . . ...._;
.
L_
.I
,,
;' ..........
i.: .__.._
... ,:
''......%.ABLE 2
Vapqr
,,
;.: ......... capa&i
.-.
system factor K2

.i.. :....<.....;
I
..
.:'I.
&.+:>....,' System factor K2
Non f o a m i ~ , ~ ~ u l h ~ . 6 y s t e m s 1.00
~u6i;'hai:ed.kystems 0.90
eg:'~~3<~reon
Moderate foarn~pg~'$:.oila h , amine and g l y d 0.85
".......~ m t o r s
..
.
. ...
Heavy fo;ijfio$ .
. , e.g.amines and glycol absorbers 0.73
0.60

:
:
, .
. _
~ o & m & @ ~sjstems, e.g. caustic regenerators
,.--. .__.'
............
:
..-.. ..\
.._
..:.
., ..
0.30 - 0.60

:, ...
. ;:'. .
.........
..........
GUIDE DOCUMENT
 GUIDE DOCUMENT

1 Pase
1: :
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1
I
S.S. 1.2 : PROCESS EQUIPMENT
COLUMNS / DRUMS 16 !
PROCESS MANUAL (DATA BOOK) i
i
I
.......
. . I!
2 DRUMS .i :
Z'
... .-.
...-_
..
:.. '-.. ::
.'. .. .'.. . ..., : I';.:
2.1 FORMULAE FOR THE SEPARATION OF DROPLETS
........:......
.
. :>
,
'.. ,.,.
; I-:
...:
I
I
Stokes law For Re < 2 .p&.~~4$$ib
,.
..
;
............
:... ......;.. I
!

D i x b - p c ) ........ ,:. ... ....

.,.:,,_-. . i..
-...I
Vt = 5.45~10-'Ox p,
'
< '......
;....... :
;;
. ........
. . . .
._
....-.:..-.......
;: : .
i
.
.
...........
..... . - : :::
, <.; ;-.. 1..'

Intermediate law .:'.::i&ir.i'.rRe < 500 '.."'._.........

.. "-.::kef : Ludwig
..................I I:
$ ;..............
*,;' ... : ........ ' 2 [ ::
'...;i"$;.:;;)w .......
.. ...:
V1= 2.216 x 1 O?X....;.~+~~ :
........
,..............
. .:. ......
.. - i
.....:..
:....: : ...:
,..--. ....... I
..... .... ; ................
... ... . . 'I I
Newton Re > 500
.,:,.,.. .:. :.. Ref : Ludwig 1
&
.:,ri
. . ....... :
:
:. ..
. . . :: . . .....
.............. j
........... ,,: ;-:.___
;..,.-., ..
_ ...
.... .. ,.-. .....' j
v1=@46;&;6-:i
. -.; ..'
;.......::
d T
DAx(pd-p )
............
,.-,.,-., J. ..(.. .
, --.,
: .,
...... . .._....;:;
: .._
' I.
;.. .__.,.
..
::
.:Re'.L-. V ' " t i 9 ~ " ........< ..-.
:..'
,,
.....
. ..:. . lo*, .....:
..
.,
.........:'.
i
; : <:;-.::
:i

Where : \ ................. ..
.......
........
Subscript c for the ~ ~ n ' t r o phase
::,, "..
us !, .

'1 subscript d for the-d:@ed

................
.......
., ..........
C.
phase
1'.
..

DP ..
?ropletgiimeter
.. (micron) I...' ..
1:
.........
.....
..-::.. t5$iQ (kgIm3)
I
P ,
..-., . j
.'. .. . ::.
: !

p .-:;-..:::'::.~iswsity (cP)
......... ;.
............
.. . ... ..
..
. .......
. I; Terminal velocity (mls) ...
,.---.
......... .
.........
..
:2 Re. Reynolds number
. . .. ..
:, : .
...........
* . .
....... , .
$

4 I
!

a
* !

1
>
B
z !

i.:.
 GUIDE DOCUMENT

--2:
3
pase
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COLUMNS / DRUMS 17

2.2 LIQUID-VAPOUR SEPARATION

.-.-_, ...-.. ...,-::

.'...........
i.

<.. ......,:
. . ,,, : :
'
L_
..............
.:.......
....... :
.............
.. :
;
; .. . .:
...............
'..,..:.' ,.".
;. ...........
.... ........... ..../'./
.'.:..*.: ..... -., ..........
2.2.1 CRITICAL VELOCITY ........ . : ...... . .: .:..:. .......
.:.,._.>..
.. -............ ...............
Subscript L is used fbr-@&ipersed liquid phase. ._.. :..
._..............
........
:...for~e.$ntinuous
Subscript g is used gas phase'.. .........
...
. . .. _ . . .
....... ....................
V, = critical v&j@ty.'(G&) ... ... .. ...., :..,
;'

p = density 4.j h. e 6~ditions , ........... ./

............
.....
~ . ._*
,'] ......... :
............
,.,,
:. "..
................
i ; ,. ;
: . ..............
.....
I . . . . ......
: . . ; .''>.
;.........
., .. . ....... .....
. . . ;:
,. .....'
- ..
.;....... :. ..-....:
.....:.'.'.:': :
...__ .:
2.2.2 LOCITY
VA~&U~E .- .
.\ ,:
...... ,

The allowable gas v e l o c i t y ~ ~on& the ~ service and whether a mist eliminator or
other separation enhancinh,'d&&is used. Allowable gas velocity is expressed as a
percentage of the criticii'I'v=lo&$. This percentage varies in most cases from 80 to
.-
220% of the critical velaci6$:(&e
....I.....:...
Table 1for values of K).
.., '._
............
Vw = maximum at$*s;dblev&pour
.. " velocity (mls)
. . . . . :.
V=
,KV
..
........, ...... . ...
'::.............
.....
: ..
...'.
......
.. :::
.........
. ...
......
..--.__. ..._
.. . ..
:.............
2.2.3
-
[email protected] TIME
........\ ........:
...........
I,

w'hq~w residence time is determined based on considerations of process control and

&'fety,,!,j <
..........
Between HLL and LLL:

The following residence times may be reduced if an advanced process control scheme
is used, in particular of the feed forward type.
1
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE

PART I - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COLUMNS/ DRUMS

a. Reflux drum . .......

............ ,

Liquid distillate directly feeding a column requiring a cons?firit .....fe&$j

The greater of the two following values : ,.,........
......
,..... ,
:
> " .
......
::
,
."
* 5 mins of the reflux flow rate. '... c. -.... ...-.
,,' i

, ..
15 mins based on the product rate (without co&l&:fQ.
i .....
/
."........
...... ._
....-..
Liquid distillate goi.q:to storage : .. .::
..... ;.following values : ..........
C_
.....
The greater of tt@'rjv~
.-._-.. ...................
....... . -.,>
5 mins of t F ~ ~ . ~ & f l o w rate. ,., ...-,:,,.-. . :.
.......... :..".:..'.
2 mins based ......&the product rate. ,;................ ........;
................. ..............
~ a s e o u s ~ & ~: d n l ~ . .....-./
.......
............ ..".......;........
5 iiii;'bf.& r d u x flow rate........ ....... :....
,,.........'.:' .... ,: .. -..
. . . ...............
. . -. I
,
;

b. ~rodw-&-&@ .... a furnace .:... .. .

.:.:.--. ....... ..\....... :'
...........
* i 3 to {Omins
................ ,,.;,..-.: ;.-....
, .............
...............
I . . . . . . : , ?

c. :!PJI~&+ product (pump ~u~tiin.?tu&

.........
. . . . ...,::
. ... :
.........
< ::
: ..:
.:,:
, ..
........
..., 6mins
+ .........,..:.
:_,: ...... ..... ..:
. .
d. " d n pumped product--.;
:
............
3 to 5 mins (bb&&jlg on process control requirements)
.................',/
................
e. Steam drum ,......;::,:....
The greater:bFt@ba
r. .
following values :
............
?/+.a.me:v&me of the boiler and pipework,
2 &hs.
. &.die feed water flow rate.
.........
............... ..
.... ...,,
....... .: VESSEL
VER%$
...._
.__.__.,...,
Me-fiill,'horizontal. cross-sectional area of the drum is used for the vapour velocity

..--. .
.............
![.-.' G.eperal rules to be followed when determining vertical vessel dimensions are given in
:........-..
y$irre 1.
s .

.........
For wire mesh mist eliminators : where the vessel diameter is not fixed by the vapour
velocity, the active cross sectional area of the mesh can be reduced so that the velocity
through the mesh is between 170 to 220 % of the critical velocity .

If the consequential mesh diameter is less than half of the vessel diameter a horizontal
vessel would be probably more economical.
 GUIDE DOCUMENT

\
F a s a d
PROCESS ENGINEERING DESIGN GUIDE I
PART 1- SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
19
PROCESS MANUAL (DATA BOOK) COLUMNS / DRUMS Ii
..--..
. .
.........
. . .....
2.2.5 HORIZONTAL VESSELS ,
. ..i ::
:... ..........
:'
%

... ..:. ...ar'

General rules to be followed when determining vertical vessel dime$s@~s ;e given in

Figure 2. , '
.. ,
.'
,: >
:
. . . :..../;/,
...:..... ...........
.
An economic length (Tn) to diameter ratio is generally in.&&?nge I;' ...... of 2 to 4 and
depends on the vessel design p ;'. ~ w', u r e .
.-.,
......
....
.... .:.
.._
,.. '.,..,? ,.: ........
. .._ . .-.. . .
Sectional area of ~artiallv..fhedhorizontal vessels <..,,'c.:,.-.:
..............
c........
.:,.........
:
...........
. . .
............. - /.
: - ':
i:: :.........
,.,.,-
......
......... .......:
................. ............
............
................ . . . . . .:

D I...
.: .'.
::
.... ..
..
:-;

..... . .. -;:
.
;:
.
:.. .-_
:

A L..' > .4.~ ' x-.: cos

-.._.. (v)
- (9 - x1.-
. . .....
h) h in metre
.;.....'.......
:
;
.
:
. ... ".
<..' . ,:
D-2n
Arc cos ()
7 ............~.
in.&iarw:.,' D in metre
. .

.
;.. ,--.. :.
.
.I
5 .

Heads partial'~ol&e
......... (2 heads)
........
............
..........
.. . .
- . '; ..
/,,,.-..
~~

..
:.
.. .
. ........I. volume of the two heads combined in m3
K Eccentricity: 1 for spherical heads

1.9 for standard elliptical heads

 GUIDE DOCUMENT

\ . 1
#
>' I
Pqe
PROCESS ENGINEERING DESIGN GUIDE I
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
COLUMNS/DRUMS 20
PROCESS MANUAL (DATA BOOK)
i
,........
.............. .
i .'
,

a. Sizinn without a mesh <-.

. .
........... . ...
..'/ .3'.. ....-.: :
:....
/:

.,'
'. , .; ,-.
: , : / .%
.

Choose a diameter Doand a length b (m). ...-::

.. , .........,.
,
,:
. ,.
Fix the liquid level (see 2.2.3. and Figure 2)* :.,:..' ....
.............
... ...... -.. -:
..:
Calculate the,.lii&.area
,, : : &, .......
..._............
-..;I . .
Calculate t&;wp6.ur
..... area Av with :' ,,:>-:;C;.?..''
............ ...... .......J.,.-:,..:
' ::
..... -
8

A - - ............
Q","
..........
" - ?.::.;:.., . . . ...'
: ...............
.. .-.:'---
......... .............
vc ... .....&,&. "elocity mls . .,*.. ......;..../
, .:,... ...
K.,. ':&&ble
6 ..... % Vc (Table I).:'.-.. . <.
......'." apour
. ..-..
....
. . . . ....;,
flow rate m3/sls,.j:..
. . ........ . .. .. ....
. . ...>.."'
8 ,

..:.... :. - ...
:'. "

\.!....~e&&culatethe diametcfc?+adthe length LI

'
............
-. ..': : ....
.,,.:.... ..+ ''lt6kte until convergektc$-is'i'~a'ched.
.......
. ... .._.-.;._
. ..
, I
.; ,
. . .:, r':. ;

........ .. .......,,.'. . ,.
;

.: ,._
. ........
.
/.
.........
....
..._
;
:
.
........
:_.. . . .. ..
,.
~he&'the decantina lens@;.
I;'. ' ;' '..
; :.. <.;-.; .:.
The allowable vapaur..,vek& V, is determined using Newton's formula choosing a
droplet diameter a&&'rd:Ve&cal
......::,... vessel (Table 1).
. ...-.
.:..-..... :
Using the hei&:$.tb.,vapour space, h, (m) :
:...................
'..... . ........
---.
:- .___.._ the separation time in seconds :
&lculath

-._
. '._
..........
..........
, .
_.._.
.:.... -.,.'t. "'~etermineC&, the minimum distance behnreen the inlet and outlet gas
............
... :: nozzles:
......
.,.;...;...........
,.
:: ......
. .. LSmh= Vvix 0 (m).
:. ...
....
,_ .___. :: .
........
V, :true horizontal gas velocity (mls).
 GUIDE DOCUMENT
I
i
.+l
. .
~'..,t
,

PROCESS ENGINEERING DESIGN GUIDE RR

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COLUMNS / DRUMS 21 \
.........
.......
,
, .....
,
. ,.
,'/.. . .
;.' .....
:
b. Sizinq with a mesh .... ..",.:::
. :.> '....; ,.
,:j
<. ...., ...;
;

The cross sectional area of the mesh will be estimated in the sa<e.*.d.s for a vertical I

vessel (gas velocity through the mesh between 80% and 220 Yi'd~criticaivelocity).
;.........
,.,.; ...."...
The minimum values for h l , h~;,f;'$':have to be respected (&&figur&'2) and correspond !
,......:.': ..........
,........
...........
to h, min. i........:
..#

......... :. .
.......
-,,:..I;.
,
, .--
Choose a diamelqr.Di;&d
.._..__
.
I:'-.'.-.'
a length b (m)..'...,..... j
-.. i.

Calculate t!m-G$&.;iia
.:. .-:-.........'
& . :
....:'... ...."..."
.............
......... :.:P
,. , '~
....... area Av based ?n..&:(;:i..,;::
Calculat~tti~.&pour ._ . .
. -. -.: ... C !

..... ....,_.'-.._
~ecalcylai'e'.t$~
. . . . . . . . diameter D. ....... .
..., ._ . ....... -.I

.. _-.. .. is obtained when p

. :. Di is 'kmall.
::.
Converge6W
..;-... . ,,..-..........
..........
....I....-.
'. ',.'
. :.:... ...,
I
Hish Q
.
.....
: .
. . . . . . V,
Check that.g&&dr&&
;.: .,.>.......
:.
~. s. .. 8.kGs:
. ..
d~
< KVc

.........
....
. . ....
...-._
;:........:, !
...............
. ._
f
..
. .‘-...,.;
: ..
....I

.. (..
~oi;&&..&? vessel diameter, a .'cei#ral inlet n o d e and two outlet noules, one !
equipped&th a mesh at each-end .-.... of the drum can be used. The cross sectional area
of each mesh will be calcu@'
divided by two.
:
e$:$tb .,
.. :: half the gas flow rate and the vapour area will be
: ............
.......... .............
..
.......... >:.,. .“..
.. -.:--- ........
............
.__. . . '...
: X !
.._
:.,,......:....
.._ :I
:. .. .-......
. ....,
k.

., .
.........
+.............
...
. . .....
_-..__ !
.
2 :-'\ :
<! .:..:::!
_ ......
. .
. ._
,..._.-.__ . . .,
.............. . I

.,. ... . . .. ...

,
,.. .._ . ,
\

.......... :
,.--..
............ I
!
i....
:: :-.,
., .
i~.\
. ..:.
........
...........
-::

ii5
I

e
S
3
.,
<

3
5
t
 i
GUIDE DOCUMENT
I

II
- i I:.
i.:
m e
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COLUMNS / DRUMS 22 1
2.3 LIQUID-LIQUID SEPARATION WITHOUT VAPOUR PHASE .......
..
............
,
. .
<,'{. ..: :.
2.3.1 DROPLET SIZE
;... '. . '.,'
,
...:....:
I:
;
,, , Ij -..I
.. .
, I-.

...
As the minimum droplet sizes found in usual calculations yg*.%~&ntly, ...,, the following
:..:.........
, . "
:
values are suggested: .... -..;
........ I-..-. ...:
:....... :. C. i
.. Heavv phase .........
........ .:-........... :;1.
,
Liaht phase , .Db minimum
;........
........
: ..... .:
,
.._.. ._
.. .._ ; <.,
. :.: H 2 0 or caustic.)...'
Sp Gr:5 < 0.850 .......I.....
:-.. . . - . (. .,:f27 micron (0.005 inch)
........ .., .... ........".. . i.
...
) ........“-.
..:I; .........‘......... .:I1- :
Sp Gri5 > 0.885
:...........
. ;0 .."
--:<---.... HzO or c a u ~ t i c . . 89 micron (0.0035 inch)
.,.......
. '.: I.
: ........
. . ...... . : ......:
........
The ~ermin&.~e&cityshould
not exceed,.~.$5.h/~ in either phase.
.................
. , ,. .. . .'. .:
..-........... ,
......... .,.
......
. . ..
......... .... ... ... . . ..:. ;
2.3.2 SIZING:
. .~.
<
. . ..:
,.........
. ,i
:
.
......
: ,.--
,
.' .
..........
.....
- -..,
.:. ;'........... . . .............
: :
-. ,, . . the terminal veloci.t;l':in.'e~~h'~hase
..C+@dI@p
-. , . with the formulae from paragraph 2.1.
* ,.;
., . ....... ::
.' .. :: '
.I...
: ..;
': .

,. . . . . . . ........
-i:

.:.._.._
..'*'.-.. ~stimate the diameter : ...........
.... ..-
:_; .._.._
:
........
D = 0.664 d x . j....... (m)
;. ; .,".-...:.:
. ........... .
c .....
light pha$e.h6erence
. .
..........-:,,... 1:
d _ .phase..kference
hea*
.........
J .._-..
I.
:
Q fla:'w&te.~
.. .. . . .-.. . .. m3/s
V ..--.. _____..-.,.... velocity in m/s
;--&&ting
.-..
;
'
:
...-.,..:
.
.... ::,
I
I:
..-.~h&&e.a
.. ._.. value for UD and determine L in m,
...............
.
,
. ,.. ..:
,._ ,. .. .. >

.---. ........ ,,,:

...... ...'*"..
.,-.
.1eallow
i m i n e the approximate height of each phase imposing a minimum 300 mm to
,;.;
:. ~. . .
-
f
-
.. .
.........
'
.:
h =
for the installation of level instruments.

(&) X D height of the d phase in metres

5
-
3
E
H,=D-h, height of the c phase in metres I
I
5
t 1
4,
i

9
3
"
w
- i
 ,.:
GUIDE DOCUMENT
,
i
-. ,.

11
Pqe
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION I S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COLUMNS / DRUMS 23
I

.......
Check that the decanting time is not greater than the residence t
irn . .......:.1
:. d
td=%andt,=<
h
. .
I
'..
...............
....
j .......... .
...,' ,:../.,.....;.,..
::

,. ,..y
: ;,:
,:

.........
....,. .......
t :. decanting time (s) , .
: ...
,,
A
:'./..... k...
....... __ : .._ ....:
...._
2
x L x 3600 ........... ..
<:. . .
Ad ,._
d'l = Qd /:,,.c.:

A, x L x 3600
...,._..:
.._ '...
.,_
I.

lc= ................:
......_......
Qc
........ .. ,
0: residence time-(&).)."::.
...............
... ...
A:
.......
. .
cross [email protected] (mZ) . .., .:.... . ..:
.....:.
:.... ._.
,._ ,;.':."..... ._
; ......' ' ....... ......
.............
.......I
..... ...
.......... . .,.,... . . ... ...
'

0~timise.&.6* in order to obtai~'.. .:-...., I::.

:, .. ,. ..
,, .
..........
.............. ; .'. ......
:.. ,~,:.... -..
< q;2i+/G*d;. ..........
:.
. '.';'"' ....'
..: ..-.:,:,.....;".:;.':
......... .,.....:...
... :. ....:..
,>.

.,:.,.._
.., ... .. ... .' .. ::
........
.
;'. ......... .......
'.._._.-. I'
TH~EEPC~ASE SEPARATION.^ .
..................
,

:: ;.. ':
Three phase separator s@n&' ......
,k+: done by calculating the vapour area as for a
liquid-vapour separation::~$~~Iiquidarea as for a liquid-liquid separation. However
this method is not ap@iikIfqr production separators (crude oil separators) because in
this case the liquifl~liQ~--separationis based only on residence times which are
generally taken *+&.:and
.,. .........
5 minutes.
'. ...
..
If the heavy p@-&hw Ate is low. a boot may be used. Its diameter must be less than
113 of the..-vwseldiarneter unless special agreement with the pressure vessel
..... :
depattmenf<r;i'e.&hanical).
I .. ,.

. . ......". .
sm:;&;% :. dona by vendors.
,. ... .,
:.

I Contad vendors. Check the pressure drop required by this type of device.

& 2.5.2 CYCLONE TYPE SEPARATORS

Contact vendors.
 GUIDE DOCUMENT

l PROCESS ENGINEERING DESIGN GUIDE

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
24
PROCESS MANUAL (DATA BOOK) COLUMNS / DRUMS

TABLE 1 , ........
..-__..'...
Allowable vawur velocity :
,
i ;'
,
..
Coefficient K = %Vc ,,.,. .......
. . .,.':.;
:

'
........ . ,;.-:.. ......
. .,". I
:"

,.*)......
,. ..
....'
'.. ,,...,,..

j
i

i
. .....,.'
.--..
:.
* (with.4&1 ..I:.
intemals guaranteed for a predetermined entrainment level)
f

..... '...
.............
............. .;
.,....... .....,..,..
,., ... ::
Relationshin . . . n the droplet diameter in micron and % Vc bv com~arisonof Newton's formula
. . . hehe-6
......
with : .:,: .:...
-
",= o.'&.x.:$+
........
i:
5 80% VC > 50 microns
9
-
E
-
Z
=
130% VC
170%Vc
220% vc
>
z
>
130 micmns
225 miaons
375 microns
t
?
 GUIDE DOCUMENT
-,
i
j ;

-w
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
25
PROCESS MANUAL (DATA BOOK) COLUMNS/ DRUMS i

FIGURE 1 ....... .
..........
,
fall dimensions in mml
:
,, . ... ..
. .. . ::.:
.
.:;...........
.
: :
-.
., .....
. ,
.
;. . . . . I
<..
.: ......- .: ..:'...
,.,.
..........
.' ,... .,
....
<,;, .......
;

I..
“....:'.;
'..
-.. -.....
C i
........
. ,. ,.--..
, ,
lnlet,nn&k&eter
" ......... I
hl

....
_..:...:
.. .
mf1+~6.j$00
:.._
..
: .:'.
Q '
>
.........

4000
h l = 400
:... -...:..Q,'!+ 1200
h l = 600 (Notel)
h l = 0.15 D
-
,.-.
. -1
-/
,,

.._ ._
e~:):&=
. . . .',; .h2 = 100
..
non d i n g setvice
:. '. . . 150 coking service i
.............
..& [
.....
....... ::...." < mo h3=300+@/2
;
'
. .,. :
.............
. . . h3 = greater of f
0.5D and 450 + @I2
1.

greater of 1.5 and 400 + cp/2

..
i
h5 if HHLApresent, residence time of 1
to 2 min, with a minimum of 200 mm
..............
h6 300 minimum

h7 If LLLA present, residence time of 1

4
\: i:

to 2 min, with a minimum of 200 mm

, , 1

h8 300 minimum. Check if the residence

time k compatiblewith the safety 1
e.g. dosure time of the shutdown
valve on the liquid line.
.:.. ..-.. ... .. i
h9 2 @minimum
.. '......'..
..................
.._ ...-I.. ..,
I
:!':..-- h10 100+@12
.......... ' r .
I

.......... I
P
13 Drum ~ i t h wmesh:
t h l + h2 + h3 = 0.75 D with limits of 900 minimum and $800maximum 1
E For spherical heads h l = 150 minimum !
LLA to LLL or HLA to HLL : 10 % of h6 or 50 minimum i
k
;
z
<
2
"3
1
 GUIDE DOCUMENT

%\

Rge
PROCESS ENGINEERING DESIGN GUIDE
PART 1- SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
COLUMNS/DRUMS 26
PROCESS MANUAL (DATA BOOK)

FIGURE 2 . ......
. .
......... .....
.i.:'. . .: :..
[all dimensions in mml
..............
.. ./,'/*
.;,:/
':.....
.
.' < ' ,.-....
: .. ; ., .,.
....:........
. . .'.;
. . . .....
..

. . . .

..-..
,,.;......',.......
<' ,*.- .':
:::..... ;/
...... ..............
..........
..............
hl 300 min
/ .......> -: ..
:. 7.-..........
h2 h2 el&.:* coking service
;.., . ...........-.
--.
,&+
~ ~

service
........
.-.-. .. .
............
:-
,
h3 ,,..;..-..,..?OO d n
.....
.. :.: a ,
:

h4,. . .f HHLA present, residence time = I - 2 min. 100 minimum

..:.. . .'.. .:. .
,,

qiP:.
_.---I-....-...!,:' 300 minimum (see residence time under 2.2.3)
;.;,..
.........I

;
;:
...
. .
\..
h6.'':.
: I
If LLLA present. residence time =-I
2 min. 100 minimum
........."
. ,
z :

3 7 150 min (Check if the residence time is compatible with the safety
e.g. closure time of the shutdow~~valve on the liquid line.) Note 1.

Drum without mesh hv = hl + h2 + h3 = 0.2 D with 300 min

Note : If nozzle F extends inside the vessel e.g. to avoid sediment, inaease h7
accordingly.
 GUIDE DOCUMENT

'1
r pase
PROCESS ENGINEERING DESIGN GUIDE
PART 1- SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
27
PROCESS MANUAL (DATA BOOK) COLUMNS / DRUMS

CURVE 1
{A, IA,=f(hlD)
 GUIDE DOCUMENT
by Bm* n' Olwler n* ~ov.

GE I 312 1 1.1.2 1 II I 0
 GUIDE DOCUMENT

-P
PROCESS ENGINEERING DESIGN GUIDE
1
PART 1 SECTION 1 - S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) STORAGE TANKS

...... ..
,.I...'"'...,...
,,

< .... .: :.
.........
........J"
:, .. ;-., '. ,'

CONTENTS
'.<..,; ....;. :/,..y
,.; ........
,.: ....
, -..
:
....
;
........ .
......... ..;
:' ..
..-..

..,.._
;.,...-...
.._.
_.
. .:
,...::.':
. ._.....:
:
.._
,. ..
..:.....
... ._..
,......
.i..

.............
. .. .
.................. :
i

........... ......
:
. . . . ..: ,
... :' ::
<. ......
. .'"....“... ......... "
1. TYPES OF X m ' .. .........
:..... ..- ... ...'
....-....
.............. -;
...........
... . .. . .' 2
...........;. .. ..:
.........
1.1 Fixed rod;i:&&::> :...._ ..
..........“.
........... ..,,: ...............
. . . ....;
.............
1.2 ~lo&"&rod,tanks , . ..... .,.,,.,.. ..:~.. :...
. .
i:...-" ...,.. . .................
...........
1.3 , . ~ ~ s u tanks
:;'
;.>. .......
..: U & ~ :...,.'.'.......
.
:.......
..:........
..
:. .... :.;
.;:,
....... ....
,............
.
............
..:.
;
.. .,' .._
.:. /'.'
. ...:... .;;.'..' ; ; .,.:
;
'

......$j .. VOLUME IDIMENSIOE;IS..?.'.: :

::.... .;
...: ..-..
2.1 Working volurnty{iit&rqof and I or floating roof)
i ., '.,' '.
:/' . ........ ':'

2.2 Tank dirnens@n&.--.,.'

....
>- ........
:, ‘..
:. -.:.........;,
..........:. .............
%
;.
...:................
.....
..I....
,, ,.
.........
.--.-._____ ._
,
....... ....,..
. . ..
:.,-., :
...,.,...,:,;
.......
. .. ...._,..
. _.-.._
............ '
.....
,,.. ., . .. ..
<

......
.
'.. ,:..:.
........
............
.i.........
. .~. :.~

......... :.,:.
, :..
\ .

. .........
 GUIDE DOCUMENT
-

...

I PROCESS ENGINEERING DESIGN GUIDE ( RPS

,,
PART 1- SECTION 1
L
S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) STORAGE TANKS

.......
1 TYPES OF TANKS ..............
'i
. ..:.. ,
, .
:: ....,.. ,:::':
.. ... .. .
:...................
i

1.1 FIXED ROOF TANKS <...,:,../ . ;.

. . . .....'. /. .
......
Fixed roof tanks are used for the storage of liquids with @%..va&d pressure, low
volatility and a relatively high flash point. Products stored inihi&t!&e. of tank must have
low potential for loss by ev&&on ... . . and tank breath in&^ miist represent only a
......... ............
limited fire hazard. ..
........ c.. .........
,, , , .......-,
?-..
..... '
............ <,
< ) t
.
-
,
:
,.
-
;

Fixed roof tanks are gen&&uqgd. -. ............... oil.

for gas oil, disti11&$~68fi;el
;.......:'.;. ..
............
When a fixed roof &ik..j~.~sed
-
for the storage
: .........
........
... I.......

of :aplat+@produds it is recommended
and in some cases'.r&d@d by some particul;h..dul&on (e.g. forthcoming European
legislation) to eqc;iip.t(t&m.&h an internal floa.tifi@$di
.. ,. . .
...... '.
............. .. .,. . .. ,..
..-" ,._......
:',
5

...............
:

I.2 FLOATING &OF!$ANKS . , . ..' ........

.... ........
i..
............
. . ,.'
..... '..
;,,.......?
: :
. ..............
,
,:
;.

,.;...... :.. are used in the,'f&$vi$g.pases:

~loatind'hf4anhs
.: .. . /".
, :: , '.,'
:..%&tikflu'/ds: crude oil, gasoke.'e.'.:. .
: ...........
. .._
........
''fluid&& a low flash point.; kerosene, naphtha, light slops
............
., ..
~

All fluids for which con&t&i;bir should be avoided : chemical solvents, lubricating
oil, reformer feed (~~&$!t$e)
.......
.. ....
..-.....
2%.
~

Corrosive produqk,:............
,
, .
........\..

...........
~ressurise@;~b~g'&.~re of cylindrical or spherical shape. They are widely used for the
storage d:a&bient temperature of LPG's such as propane, propylene, butane and
...... are also commonly used for the semi-refrigerated storage of ethylene
butene,.~b;h&q
. , e .........'.."
or e w
. .............:..,.
:
,

me$lohcvirig capacity limits for the most commonly stored produds are given as a
&,jierie :
.,..........
.. .:,. :
* " " ~ & ~ l e n(21
e barg) 1500 m3
Propane 2000 m3to 3000 m3
Butane 3000 m3to 5000 m3

European regulations have lead to the increasing use of semi-buried cylinders in unit
sizes of up to 3000 m3.
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE pq.

3
PART 1 - SECTION 1 S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) STORAGE TANKS

2 VOLUME IDIMENSIONS .......

.........
i I'
.... ..,
i . . . .. ..
.............. '/
2.1 WORKING VOLUME (FIXED ROOF AND IOR FLOATING R d d.. “...
~:'. ..:'
:'
.... .:. ..."
q.:.

There is a dead volume in a storage tank, comprising of.*% v6l&< below the suction
nozzle, or "heel" and the volume equivalent to the m i n & u m " ~ p u r space required to
. ,.,. .'. ;. can be taken, as a.....\........
prevent overfill. This deacJ.,uoI~e fi'igp$&ch,
. . as 15 % of the total
volume. <'.....
<,,.,*:.,-.,
:
......... :. ............. . i.-..:.::
............
.......... ..;
:........... ;.., . . . . .;' .
...........
.
:<

2.2 TANK DIMENSION.^...';....:"

.......... i
..............
.........
......
............. .................
......./
The process d@&&it generally specifi@i..!J$@,.stbragevolume only (total volume or
working volwpe d&$ing on the conte$~$th.&job). Final tank dimensions are fixed by
the vessel '(q$&a&al) department .b*.ph'layout
. constraints andlor contractual
specifi~q&. ,:'.. :, :
, ,*., . ..
-.. ,.......,;
II :

::
:. .: :.
, .........
.........
~he,&j..;bl&e of a tank can be'&fibMpdfrom Table 1, which gives the total volume
as,&f$%$of
........ diameter and ..........
h&&(de&ed:' .... :
from API 650).
............. .
,,.w
;.......:
. . -..__
:_;
..('
.._.
'=
.:. ,:,:
,.,'
.I....
......
......
.._.I
.:

In tanks wem&$t..by weiding of standard steel plates (72" or 96" wide). Thus
the dimensions of ta&s &$ding to API 650 A2 and A4 correspond to an integer
. number of elements.. Nk-&roach, still followed in the USA, has been abandoned by
.-...
European tank conk&$$who
,----:,, ..
do not impose standard dimensions.
. -.
..............
..........
.........
........
. . '.. -.':.
:. . . . .
.,.... . '._
. .:
..
...........
.............
. .
:
..... ....,.'
. ,
;.'.. :
.,;;
... ..
_ ..':;:
..................
......................
. . . .::. ..
,. ..
:.. ' .
% \

..--...............
.
............
:
:
....-.. .~,
,' :
:. .!
i.........." .
..........
 GUIDE DOCUMENT

Rpe
PROCESS ENGINEERING DESIGN GUIDE 4
PART 1 - SECTION 1 S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) STORAGE TANKS

TABLE 1 .......
..--.......
Total volume (m3) of tanks as a function of diameter and h e i d , , ... ., .
...... ,:
(derived from API 650 tables with integer values in mete&-.:.., I:
:
,
: ....,..)“........
.-;
......;,.' ...........
,
:
'
,.....
.
'J
GUIDE DOCUMENT
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE Paos

PART 1- SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
HEAT EXCHANGERS 1
PROCESS MANUAL (DATA BOOK)

.......
.: ._._. '.
.....
,,
: ..
[ . .,
CONTENTS .,........
. . . .-.. . ?;
..........."
:..' .<.....;
/;.' ,..('.
..................
./;' .....
;
' ..... ......
Ir
:;, .........

2.
1.

SHELL AND ,. ..
-
SHELL AND TUBE.-HANGER
'
;'
.. ./:
.<.

TME~QHANGER
.....
;
SELECT~O~~U~DE~':

[email protected]~W@E . .
.............
............
... .:........ . )
......“.... "] I
..................
..
3. BASIC cORl&iis ........... OF AN AES T?IPE ...........
E~XHANGER
............... ,. .........
........... ......I
4. TEMA +Y~ESA;~<T, AJW .......
.*... .:....:..
; .,;: ....... . .......
..
\
., . . ..\'..
...... .. .,
5. TEM;*'ES BEM. AEP, C F_ i ~ '.. .:
!:.. ,...... ..\.......
i !, .. ..
,
....... /
6. ;:.... , , . TERISTICS OF ... TU&&:::;.~."
;
: ... -1....... ....
.:....,.,.. ;,: " .............
,, . . E#T TRANSFER AREA-THE MAXIMUM TUBE COUNT WITHIN A
.......
:'
,< .
-'
N SHELL DlAnn'
I %$d
..........
... '.... ".
f,
: .. ....
8. “..." HEAT TRANSFERAREA CALCULATION
..............
:; .. - ...
9. LOG MEAN & P F ~ T U R E DIFFERENCE (LMTD) CALCULATION
,:. ............"
........
10. LMTD C 6 W ' C...l h N FACTOR CHARTS
.....;.....:'.... -.
.........
11. ESTIMATJW~~FOVERALL HEAT TRANSFER COEFFICIENT
...
....... .; .. . . .
\ :

12. ~S-WATION OF FILM COEFFICIENTS

: . ...
,, ..". !
. .
13.'~':.~lf$ACT OF TOTAL FOULING RESISTANCE ON THE OVERALL HEAT
............
. . . ._ T
. .W .. S F E R COEFFICIENT
.,,.. ..~
,.--.'..$4.......,$0
............. ULING RESISTANCE
i:---.

......... ji'i
, .

.........
;
ALLOWABLE ENTRAINMENT RATIO FOR KETTLE EXCHANGERS
 GUIDE DOCUMENT
-

Pnp
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT -
PROCESS MANUAL (DATA BOOK) HEATEXCHANGERS 2

........
.......
I SHELL AND TUBE EXCHANGER SELECTION GUIDE ,.',,*.
. .
,..,:. ......
,. -.::,:.;
.'.... ,..:. ....
,.
( .
/
Refer to the nomenclature given in paragraph 2, page 4. : ..,.
. ..,.' ,>'
..............
.,.........
.,~ ........
FRONT END STATIONARY HEAD TYPES . . . .
;',..........
; r
........ ... .: I
a. Tvpe A : tubes are easily$&able, since only the r&;wl ova cover is required.
Therefore, in case of f&~J&f .,, .
.......... cleaning, this type m.d.&;selected. Examples of
. <. ; .". .
use :residues, sea water?..........: .
.<:'.. “....
... ? : -
.........
. ..-.'.'
.............
b. Tvw B : less t&@&&' .......
?
&an Type A, b&c$ea@$i of tubes requires piping I
o,ov,dismantling of ,&ht&ted piping, removal,of~~aikek and of integral cover - or
-
bonnet which*i$:kh~&yitem. Therefore rb&hm i.....-..
eb
i ed only for dean services E.
Examples : @ht$$dr&rbons, treated........ @@r>., ...:.
...-.;......
........ .......
.. *.
i :. i . I :

c. Tvw Cdi& T~&''N: the tubesh@is,$ad.r$f the sktionary head. Less expensive
than .~&..A.!fbr low-pressure s'%s-..ihe cost increases significantly with
p+ie$il-c&e .....
of high AP, ~~&k+vnl.t;i! preferred.
~&:Hkt$k
,, are required, . . . .
i.e.,?lae.osk$af
...... experiencing a leakage are reduced.
.:I..........
.. ,. ; . .:: ::

i. ~
. . .~. .r. l ; 'the ~ Type
l l ~ C, with km&able tube bundle is barely used, and is usually -

seleaed only in case of,specific ~ k n t ' srequirement.

..................
:: ;.. .
The Type N is assod&@:;#' rear ends Type L, M or N, and the result is a fixed
tube sheet exchan&?~..~%ii~type of exchanger is economical, but the tube bundle
cannot be disrn~tIe&:d'i a shell expansion bellows may be required because of
thermal expan,s~On~'::.~.--~'''
.........
.......“...“.... 1
:
'
. '.. '.. .'
.-..,.i I

.
,
1.1 SHELL TYPEG-.;;
........... . ...
,.-.._ .._ ..,
a. TVIE most commonly used.
...'.I.../'..:.
b. ~ ~ ~ F . . ~ >an ~ ideal
~ I ocounter-current
w s exchange between hot and cold fluid
&?4TD':$xrection factor F = 1).
....--!hwbf,
, ..__.this Type has the following drawbacks :
.::.--
, ... C'i
:a
. .......
Internal leakage is likely to occur between the shell and the longitudinal baffle.
resulting in a reduction of the heat transfer coefficient
Unbalanced thermal expansion in case of large temperature diierence
between inlet and outlet. This may cause mechanical problems.
Pressure drop shall not exceed - 0.2 bar to avoid damaging the longitudinal
baffle.
As a result, this Type may be used only if it allows a reduction in the number of
Type E shells installed in series.
 GUIDE DOCUMENT

pala
PROCESS ENGINEERING DESIGN GUIDE
PART 1- SECTION 1 S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) HEAT EXCHANGERS 3

c. Tvpe G and T v ~ eH : no support plates are provided, hence I j M h g the maximum

tube length :
...........
, ' .:.:
: . ::
for Type G : tubes 314- (resp. I"),
maximum tube len@ . . .:>d.'ff$esp.
. 12 R)
for Type H : tubes 314", maximum tube length : 20 ff C..'','' .;'.:
......... :. .,'../
Both Types allow temperature cross through the ep&an&r;'r,:~&mmonly used for
., ..: .... 50 g I cm2).
thermosyphon reboileq-andlow pressure drop serv.&i(&~..-
......
......
.,' .. ....
...... .:
d. TyDe : for high floG@@sand AP that cann@';@,ha~@led by Type E and also for
condensers to a " & of vapour-belts. d*,djameter shall be less than half
the shell diamet"~.:>. ..)
.............
................
......... :1;. .... ..................
:. ......... ~>
...............
e. Tme K : con&jnlY ._..
. . . . . . used when propereya&d&engaging with no liquid carryover
required,..(e.@ .am$& regenerator rehire$':::.
... .../.."
,
...... ;',.......... '.._.;
.............
f. T O low pressure s+4ice$.;(few mm Hg), since it entails low pressure
dro@[Allo$i$ femperature cross(~i&al&t to ideal counterwrrent if there are more
~ h . i h r & ~ , ~ ~ s on s tub+gibejI-'fypical applications : steam turbine vacuum
s e the
..@~&hstSk, cracked gas co~w$so& intercoolers.
. .
:' ..,;,.:
...........::
. . . . .
..-:.
. ,.-'.,...,: .: ...;
....,..-..
.'
C

., ..
'
.: %.........
:,..j'&
.& .......
1.2
. &..D....
. ..: TYPES ........;
...
a. Type L. Tme M arl&:?Vm.~ :fixed tube sheet heat exchangers. For clean services
on shell side. S h d l ' e M n s i n bellows required when AT exceeds 50 O F .
Type 1and ~@~$:-&~ recommended for fouling services on tube side, since
dismantling is-e&iXype M is preferred for clean s e ~ c e as s it is more economical.
-.
:..............
...........
b. T v ~ e%.:...mii:$br services which allow the use of packing-box (e.g. water).
d ..
~ r o h i b i f foth'#rocarbons.
.......; ..._
Not commonly used.
............
c. Tvrte:$
.,.......
. . ,.
: ~ m o n l used
y but more expensive than other rear end Types.
..
< ..,/ ;
d:,..$a& : for frequent dismantling (e.g. residue on shell side), or if cleaning is only
on the tube sheet side for accessibility purpose (e.g. column integrated
.,~;.~~-p$s$bIe
.
;. cohdenser). Expensive and also requires a bigger shell diameter than Type S for
same tube count. Barely used.
. .'..'.. .:..'.:.
:'
:. \
.......... ei.:' T v ~ U
e : requires dean service on tube side. Low cost (e.g : steam on tube side).
..........
f. TvDe W : for mild services, never used in refining applications, due to inappropriate
tightness.

CONCLUSION : The most commonly used types of exchangers are : BES, BEU, AES,
divided flow (J), double split flow (H).
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT .-
HEAT EXCHANGERS 4
PROCESS MANUAL (DATA BOOK)

Z 3
I
< STANDABDS OF TUBULAB EXCHANGEB MANUF4CTUBEBS ASSOCIATION
I
 GUIDE DOCUMENT

p.ga
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
HEAT EXCHANGERS 5
PROCESS MANUAL (DATA BOOK)

.......
........
,. 5, ...'..
3 BASIC COMPONENTS OF AN AES TYPE EXCHANGER
:. ..... . ..: .:,
:
1. STATIONARY HEAD - CHANNEL ,;: ..... ..-,';'
2. STATIONARY HEAD - BONNET .:., ;:. ._ ... :
3. STATIONARY HEAD FLANGE - CHANNEL OR BONNET
.. '. ."...>:, :
....
4. CHANNEL COVER ..........
. .. . .<.;' .. ...'.
5. STATIONARY HEAD NOZZLE ,.:r.. -.. I

:..........
.............
6. STATIONARY NBESHEET :,
7. TUBES ...... . .
.. '._ ...: .
,.;,.--: .... '.. . ..
C_
8. SHELL
9. SHELL COVER 8.. (: ..'
:::
)
, ............
.................
lo. SHELL FLANGE -STATION& H E N END . C. ,,: .-.,
- ':
11. SHEW FLANGE - R E ~ ~ H ~ ~ . E N D :
;
. ... . :... . ,.
12. SHEU NOZZLE .................‘
,
;
...........
..........:
........
-.
13. SHELL COVER F~+GE:~~.)..~' : ..- ............
..
14. EXPANSIONJ O l v ............ .. .............I

...............
15. FLOATING TUWHE.m.
16. FLOATING HEAQ ., . . , : ...:......
.
.....
17. FLOATINGHEAP',- ....... ........
18. FLOATIN~I$'*BACKING
SHK@~IW
DEVICE
:
. . ... . . ..
.. .I.............
19. SPLIT
20. SUP&%A~NGFLANGE
::
:
,~ :*
"
"'
'. .
..'-....
21. FLO~BNG HEAD COVER - EXTERNAL ....... ...........
1. ... ,:...--.
. . . .. . .
22. F I , Q ~ ~ ! ~ G . ~ ~ ~ sSKIRT
HEET
23. p M N 6 8 0 %
:: ?.....,.........
z&'~Am~tdc~.. .............
&P&&I~G~LAND , , : ..................
': .I
.:@
' LAN@.@4 RING './,:::,.'.......
:". ..27qlERODS AND SPACERS
<.: %..~RANSVERSE BAFFLES OR SUPP~R~:~LATES
29. IMINGEMENT PLATE .......
30.LONGINDINAL BAF-..:'
31. PASS PARTITION i: * ';
:
...'"...
,.., .-
32. VENT WNNECTKN. .............,.',,:
33. DRAIN CONNECTIW. ..............
34. INSTRUMENT CgNNe9.Y
35. SUPPORT SADPLF..........:.
36.LImNG LUG, .-.............
n.SUPPORT .:-wtg
38.WEIR < ...-......
39. LIQUID,- .
-'I.,..., C O ~ N ~ C T I O N
..............
.. ,.
I..

w.. -3

ST,qNDABDS OF T ~ ~ U =
Lx A
C H~A N G E ~X . A N U T A C T U R Z B S ASsOC'*T1oN
 p.ee
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT -.
6
PROCESS MANUAL (DATA BOOK) HEAT EXCHANGERS

TEMA TYPES AKT, AJW

-Iu-

AJW

0 l 6 STANDARDS O F TUBULAR EXCHANGER MANUFACTURERS ASSOCIATION

I
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE

PART 1 - SECTION 1
PROCESS MANUAL (DATA BOOK)
S.S. 1.2 : PROCESS EQUIPMENT
HEAT EXCHANGERS
-
7

...-.....
5 TEMA TYPES BEM. AEP, CFU

, .

STANDARDS OF TUBULAR EXCHANGER MANUFACTURERS ASSOCIATION *. 5

 GUIDE DOCUMENf '
-

PROCESS ENGINEERING DESIGN GUIDE

we
PART I- SECTION 1 S.S. 1.2 :PROCESS EQUIPMENT -
HEAT EXCHANGERS 8
PROCESS MANUAL (DATA BOOK)

CHARACTERISTICS OF TUBING

Table 1
 GUIDE DOCUMENT

I PROCESS ENGINEERIN1G DESIGN GUIDE

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
Y
PROCESS MANUAL (DATA BOOK) HEAT MCHP LNGERS

.......
HEAT TRANSFER AREA FOR THE MAXIMUM TUBE COUNT W:T W b GIVEN
7
SHELL DIAMETER : . ::
.I
.
............... ;
: . . . . -:
................
The following charts and tables give the maximum tubeleubt' *in a given shell
..
.m'd t[l&$ftch
internal diameter, depending on the external diameter, ... and number of
passes. ,.../........
.. '.-.
..--..
........ ..... '..,.:5
The tables also give the'd&hum area for the sh&&s'dered for 16 R. or 20 R. long
tubes. These values &i"ditive only, since hd t$+
?-$&en established for floating
head(s) exchangewv$th$&i. . nozzle diameter$.in.&l&son to shell diameter.
For different ends'.br:lafg&
-... nozzle diamet&k)&e:."umber of tubes that can be
accommodated d t h i n t ~ s h e lwill
l be diiereh<'..::).::. .
......
;........... <.' ...,..;',. '.'
r. :
'...
...I
:
.._. .._ . ..
. .._
 H ~ ~ ~ R A N ' S AREA
~ E R (m21
.,.fXjR
r
,-
.
\ ThE MAXiMUM TUBE COUNT
, \\..
,I

One pass on tube side

Number of tubes N, depending on the
shell internal diameter
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE

PART 1 - SECTION I S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) HEAT EXCHANGERS

, ....
.........
HEAT TRANSFER AREA (m2) FOR MAXIMUM TUBE COUNT.--.
.,.: ... !.
................
N, : number of tubes. A,, : bundle external surface, L :t~be.@&(&Ij
tube 314" - 1" square pitch ..:' (. ,.;.
. . ,,...
 GUIDE DOCUMEW
-

\--
1
p.os
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
13
PROCESS MANUAL (DATA BOOK) HEAT EXCHANGERS

HEAT TRANSFER AREA (m2) FOR MAXIMUM TUBE COUNT ....

.: :_'..
......,.
8 .
1..
.
;;

Nt :number of tubes, & : bundle external surface, L : tube leng@$~)..>ii

.;: ; '.....,
tube 314" - 15/16" triangular pitch ..... :...,.:: .;....

......-
I I ' ..-..
I..' .-.I ! I I
 GUIDE DOCUMENT

PlOe
PROCESS ENGINEERING DESIGN GUIDE
-
PART 1 SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
14
PROCESS MANUAL (DATA BOOK) HEAT MCHANGERS

,.....-. .
HEAT TRANSFER AREA lm2) FOR MAXIMUM TUBE COUNT--.-..,
i:
::
.... ;,
Nt: number of tubes. & : bundle external surface. L :tube:;. !$&.f.ftf,.;
;.., '...,.;.
tube 314" - 1" triangular pitch ,.' < .;', ' .":
,-.:. ..... :'.'
,.,.
,.
...'I

:
.: ..... .... '
L.
i..
I

" Y ? t : 3 4 P c E ' t 9 9 t P " t c Z t

I 5 " - n
& m o
e o =y Tn n= n ro ~o ~
r cn o ~c rP O
o In i -q : r- r ~~e = .
2qem
S"

4 54
rra E
-- -<-< -< -< -< -<
- " r ^ z z " ; E z f i z C = E X : $ = ;
 GUIDE DOCUMENT
--

Rg.
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT ~.
.
HEAT MCHANGERS 15
PROCESS MANUAL (DATA BOOK)

HEAT TRANSFER AREA (m2)FOR MAXIMUM TUBE COUNT .......

,..':'.....
..,. ..,, ... .,,
..........
Nt : number of tubes, Ao : bundle external surface, L : tube lengw&ti::--,!,i
.....
tube 1" - 1 114" square pitch .:: <.....,/
. ..;/....
.<..... ..
.........
. . . . . . . ......
..
: ,~
 GUIDE DOCUMENT

Rpa
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
HEAT EXCHANGERS 16
PROCESS MANUAL (DATA BOOK)

.... ...
HEAT TRANSFER AREA (mZ)FOR MAXIMUM TUBE COUNT--
.,.'/,.' ....':
. .,
Nt : number of tubes, & : bundle external surface, L : tube.$$f-(ft): . .
,;',,.' ,.-;, ........
tube 1" - 1 114" triangular pitch :.. '..,,.'..; :;..-.
.-...........,,,.
.:. '..... .,,
.. i

-- :. '..

-".' --- " -=

L

- N0

*
..?.,? c 9 7 = 7 4 4. i
' d, n n
y,,?+,m-
. . .::
...
n
: ,' .. -.
c
-
c
C =
c
2r
':
.n

.' k.$.
r g-..-y
n
.,.Ti..=
, ..
-
- *
;
o n o
;d

- .. .:.:......
a

-
4-

0,
=:
.........
......
. i-..
:.. ..-
,?.... .-. d
hh.;;
.. . . , Y , ~
............. N N
G;
w o
-
o..&:k e:r 2 y y
2 ;:.,G..-<.&.,~*;
o c -,.- .-.
...
7..7.,T.t....W
.
::a - - ,
8S.8:
*
-

L
J
-
E ' 1 " " 2 2 ? ' 1 t ' 9 9 t ? ? " ? ? ?
g,"~~?.=D*Cn.DoPncrO
,,,,oOr-oCpg:za ---
=j;i".
: $1- 3
q< * -
C
o ~
-;
~
-< -< -< -
~
-<
;
~ = r - ~ l n c n - n
- N n N n n n - n - - r , , . .
r c = n ~ p -

I
 GUIDE DOCUMENT

w
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 :PROCESS EQUIPMENT
17
..

PROCESS MANUAL (DATA BOOK) HEAT EXCHANGERS

HEAT TRANSFER AREA (m2) FOR MAXIMUM TUBE COUNT ....---.-.,

,.,,,, ..... .:.
p~

.,.I.

. ::
../ .. ..
N, : number of tubes. A. : bundle external surface. L : tube length:.CrtJ.:'..l.i
. ... ....,. ,> ...:
I
tube I 114"- 1 9/16" square pitch .~.

...........'..-.......
,
I
./
;
,,

..' :. ..
. ,.. .... ;
I,.
'
I

: 3~
~..,

E ..

!i
I
C
z< .-
0

4
s
 GUIDE DOCUMENT

1
Paps
PROCESS ENGINEERING DESIGN GUIDE
PART 1- SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
18
PROCESS MANUAL (DATA BOOK) HEAT EXCHANGERS ,
 GUIDE DOCUMEW

pqo
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) HEAT MCHANGERS 19

8 HEAT TRANSFER AREA CALCULATION

8.1 AREA CALCULATION

:i
; .. ......
Area is calculated from the Fourier equation : ..........
.' .._ ._'...:-.5
f'
.....
\
<. ..
.....
,I

Q = U. A. F. LMTD where!;'...
-': .....,: j
#.

.'
.
.........
.........
.... ..........
... :.
........
,,-._ ..:.. ,.,.....
i .:
Q: Heat transferr.;~caN ,...<. .-..,:....,.,:;: .
U: Overall heatt.*.M$r&efficient, ;...
kcaI/h.&$3,:~& includes a clean
coefficien~aRd.fO'ir.Mg resistances. ...... .'.:; ..?.
A: Area, w..?..:)..,
........ .................
. _ .: :
F: LMTO ;-..c&e$ti?h factor from ideal.......
.. ,.: -.:
&b"t&?rrent. Refer to Figure 2 to 8.
..................'...
ln,&;'e&~ shall not be less $Man 03. For single-pass exchangers on the
@ll's@+,'.ihis corresponds to'.ide&l outlet temperatures of the hot and
,..Oqld.fl# ("limit of tempe&$.$dng")
.;: , -
.....;. ,.; ......... .;' .........?
LMTD 2 i'.,,.jpg.+lean ~ e m ~ e r........
a t u r ~ ~ eOC
.*~,
..............
............
. / .: . : : ......
. . ._.._;,.
,:... ......)'.<
( G r n-L ~ D
,.,. ....:.., -..LMTD =
.:'._. GnD ' ..... '.: where :
....:. Ln (m? .,,
..
.; .........
,
, '-

GlTD : ~ r e a t @ ~ & & l Temperature difference,

LlTD :~esser..f&i'rlal Temperature diirence.
...............
>,: “..
. ..'%@.@I:."
Refer to
.........

~.
.... .
Table 2 9.i&:dved~~ heat transfer coefficient values obtained with common petroleum
products t~(ll&id-li~uidexchangers, reboilers and condensers.
,..............
...................
FiguF.9 . . additional data for water-cooled condensers or gas coolers.
. . g%&
.. '....... /
........
Jfj&&iierent fouling resistances are considered, Figure 15 shall be used to correct
@eva@ obtained (see sample calculation is section 8.4).
..........,
-=- 1 + (fouling resistance) (~bbm
+ (fouling resistance) *s
Userviat u cIb m
lmoortant note : on the tube side, the heat transfer coefficient is mainly depending on
the Row reaime (turbulent. streamline, etc..) and subsequently on fluid viscosity. For
viscositiesabovi 50 cP (liminar flow), do not use ~ a b l d
2. also cautious for
viscosities between 1and 50 cP (transient or streamline flow).
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE p.pe

PART 1 - SECTION 1 S.S. 1.2 :PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) HEAT EXCHANGERS 20

.......
.........
: .
i' .....
,/' ..: :.
..."......
.. ... - .
i
,;,:

8.3 MORE ACCURATE CALCULATION OF OVERALL HEAT T.............

~F~R'COEFFICIENT
.... '...../
If the metal resistance for tubes is neglected, the overall:& tr;d'ilsfer coefficient is
calculated as follows : ....... ,..:..,:.......
._
.....:
.;
........
..
. ., ..
.,,;
.I

. . .
....
<. .....
............
- < ,
;
.'..,....:.....
;..-........'
) Rf,+ -
1
U - h ~ + . . . cvhere
h o + pk?.... : .
.
...................
: .I
'.. - : ;.;
:
/
...........I.

ha : Tube side fjIrr~&k&nt .... corrected to e,d&~&&'

.............
< ........" .......>
ha = hi K'+
,. .-?-
“...“...
..........with : Di : tufb.i&iil diameter (see table 1)
.:.................
..... ,. .... Do: ,..tu&~&ide diameter
............
.........
. .
. .'
hi :/:,..?i~&;
., ., &he film coefficient for internal area
., .
:.:.-' .......
h. : %el! sid; film coefficient ;:.:.,
:.. "'
........
"

.......
&.., ,>$Tubei&e
;: fouling resistan@.&?e$@d .
.:'... ".. to external area
:. ......../. ,-: ..-..
..;. ....@;,.A . .R6 . I

..........
. . . . ';

.:....
, wiU~,..:...,.,,: ;G'f tube side fouling resistance for internal area
..'......
L.
........
.....
...
.I........

hell side fouling .&sistan&" .

{':.............
,
Figure 10 through 14&6%~
t' $ coefficient values. In Tables 3. 4 and 5 are shown some
..
typical values of fdM&.&&tances.
._,.-.“..
..........
>,:.
:. -.:.
<.,.....
........I
...........
.,; ........... :
...........
:

8.4 ....__.......
SAMPL+&.~~~TION
A I ~ u t ) @ ~ f i n ~ contract
r$ no 5954 X
~xct&ih$d item E 1001 :
......
........;.....
.........
.. .,.I , .:.; .:*.,.' Service :crude oil (tube side) Ikerosene (shell side)
..
__..-. :. ...........
..............
One pass on shell side, lwo passes on tube side
, .-..
.>: , 0 = 6.2
. ..,.:...,
;
:
i
.lo6 kcah
:, ,,.
..........'
.......... Tubesl",BWG12
Crude oil : di5 = 0.858, i.e. 33 O API
lnlet Ioutlet temperature : 30 OC / 53 O C
Average viscosity :5 CP
Kerosene: Inlet / outlet temperature :200 OC 1 120 OC
Average viscosity :0.3 cP
 GUIDE DOCUMENT

Paw
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
HEAT MCHANGERS 22
PROCESS MANUAL (DATA BOOK)

........
I:., .' ..........
.. .
<...... :
.,;:. .......-,.;'
1
!

. .-., "-.. ; :
'

8.4.2 MORE ACCURATE CALCULATION OF OVERALL HEAT fdn$lSF'$~COEFFICIENT

;. ;:..............:
.. ..
............... ......
:. . . . .
From Figure 10, curve no!,...hi = 120 Btult~.ft~.~F ...... . . . . . ..:'.;
........
.. .. ':. .....
......
::..'..,:; .........
.. . -.
. .;.....
....... ......
..
From Figure 11, cur&&?;.:::bD . . .:...:.,...:
.........: = 310 ~ttJ/h.ft~.~~;.! :. : .!
,, . -_ ., .
;
..............
........ ..........."
: .
........I..........*
.........:'.;. ... ...........

From
,:
.....
: . . ...p-
....
.*:--
'.........
.........
'‘.hx:, .*
. ............

.. lax19.85 + 2 .x..............
19.85 '.=
................
:'
. ~ .n .. .,.
;:
Btu/h.ft2.0F

. .._
...-.:
.:.... .......
.,. ., ..::
:. .. . ,.
..
.........
...
a , .
:'.
......
.,
.
.............
..._..,
..'.....'.... '
-1 z.... 1...... I
+ 0.000786 + 31w.&'..4:88....,
,'..--: i ....4-0.000205 = 261 k~aVh.m~.~C
u .,:-
... <,. .,.,:.,.: ..;.';
.... , .................
.. ~.. ,.......
.. ..
.
..
, .
. . ._
. .
:
I
. :
.. :. ....,,',..
,
......
: L

..........
...I
..........
'..
'.' 6.20 x lo6
......
=.211 mZ
263 x 116 x 0.97 .......:.....
-
;: ... ...;
:. :. ..,'.: .
i
.....................
..............
........
/.........:,,.'...
: -.:............
;
, .....
< ........"...
<.,. :................
.....
. .. . .... .:.
,- ,.
.......
..........._
,. .. ...,,
.--.. .i

;...........,: :!
...... ?

..--..........
.. -
:..:.
,,
..........
,,. ... . ... ..
I,..

:'.-
...... ... ........:
.............
;.:..-.. .'.
'.

.. '.:''
.I
:...
............
a

...........
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE

PART I - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) HEAT EXCHANGERS 23

LMTD CALCULATION .,...... .

'/ . .....
:.....

.
,
,. 'a

Fiaure 1
:
:. ._ .;
...
,., ....... :j
;;
.....................
; , , ....
........I :'
CHART FOR SOLVING LMTD FORMULA .,.? . ................
.....
- LTTD) ..,.:;.._
:*. -._
.,..-.._
...-.5
LMTD = (GITD ........ ..:
.._
......
............
,
Tenninal Ternperat&'~i*~6& .
."......... :..,. ,..
Temperatm.~rtllte.
>.. ......:

Gmater Terminal Tcmpnturr [kffermce

IIOTE-For points nol kr(ud& on mh rhrrt multiply ~ n a t . , ~ n ~ i n Tmoentun
.1 Dltlcnna and Lesser Terminal T.mp.nturr Ditfennu
by am of ro and d i r ~mu^^ WW. of c u d urns 4 u m c nwmd*. ...
STANDARDS O F TUBULAR EXCHANGER MANUFACTURERS ASSOCIATION 145
 GUIDE DOCUMENT

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PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
HEAT =CHANGERS 24
PROCESS MANUAL (DATA BOOK)

I lo
LMTD CORRECTION FACTOR CHARTS

I I
.
P TEYPERANRE EFFICIR(GI
LMTO CORRECTION FACTOR 1
,+, 2 Y l E U PASSES * 4 OR MULTlRE OF 4 TUBE PASSES

I:
' 2 shells in series
 GUIDE DOCUMENT

Pape
PROCESS ENGINEERING DESIGN GUIDE
PART I - SECTION I S.S. 1.2 : PROCESS EQUIPMENT
HEAT EXCHANGERS 25
PROCESS MANUAL (DATA BOOK)
..-...
.. .. .
Fiaure 3 ;'..---.
.. .'
,.' ..
<..'..... ::
8'

, . '.",',,'
m .....: :
m
*Z
-!
. ,.
.I.:

"
r
0
Eos
2'C
m
2 Eon
9 Y
=
s
$
rn
E
e4.7

I;* L
5 I
3
D
I
0s f
E
Z
9 0.5
*
r:
9

2
Z
D

!
s
-, ...' .....

1
I
F
i

c fL
P.lEYPWNRE EFFKlEWGI
LMTD CORRECTION FACTOR
b
0 T
4 i! 4SmLLPASE!3f 6MIWLTIPLEW8TUBE~
t
2 - LILT:
*curl

-
p.
H n . a

* or 4 shells in series
 GUIDE DOCUMENT

7
pap.
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
HEAT EXCHANGERS 26
PROCESS MANUAL (DATA BOOK)

Fiqure 4 ......
.,.:...-._
..., .*,
':

:.' ;.
. . ... ,.',.:.
.. .. ..

t
f

....
* or 5 shells in ,, ..... :.
0
4
>
:. .,. . ..
<~,.

3a
i

'or 6 shells in series

7
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
27
PROCESS MANUAL (DATA BOOK) HEAT EXCHANGERS
......
.
Fiaure 5 ......
,
...........
,.
1
I
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUlPMEl
PROCESS MANUAL (DATA BOOK) HEAT EXCHANGERS

.--...
.
Fiaure 6 .',....._
. '..
.. .. '.;. j.
TEMA X exchanger or single tube pass Air cooler ,./"('
'
,..,. .........":..''
'
 pale
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
HEAT EXCHANGERS 29
PROCESS MANUAL (DATA BOOK)
,.-.-._
.,. ...... ........
,
Fiaure 7
;.,;-...
. -...,::/':
%

TEMA X exchanger or Air cooler with 2 tube passes

. . .. " .
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE

m
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
HEAT MCHANGERS 30
PROCESS MANUAL (DATA BOOK)

Fiaure 8
...--._

CORRECTION FACTOR
 pw
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT -.

HEAT EXCHANGERS 31
PROCESS MANUAL (DATA BOOK)

;, ,.-..
.3.). . .&era11
(......... ,..:
.
heat transfer coefficient U in k~aVh.m~.~C
.......
(2) Fouling resistance in h.m2.DC/kcal

(3) Fouling resistance for water : 0.0004 h.m2.0C/kcal

6
X<
(4) Minus 5 % for water-cooled gas coolers I
O (5) Minus 5 % for heavy gas oil (H)
3 ..
8
 GUIDE DOCUMENT

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PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) HEAT EXCHANGERS 32

,.....
Fiqure 9
,:. :_........~,
.. .... .. .,.
,
Condensers or water-cooled gas coolers :
.-.'-..."..-,,':I
:
... -..-..:.'
...'.,.,:,....
:,:
I'

:' ,:;
.-.."...'........:/..
.,
: /

C)=0.0004 h.m2.'C
PM = MW (molecular weight)
 GUIDE DOCUMENT

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PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
33
PROCESS MANUAL (DATA BOOK) HEAT EXCHANGERS

i
.I

[
,..-..
: . ....
ESTIMATION OF FILM COEFFICIENTS ..
.......
....
..............
,
;

,,. < ,.,.; .,.:'

. . . .
Fiaure 10 -Tube side (internal) film coefficient hi for liquid hydro@t$q,.l',l
GUIDE DOCUMENT
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PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
HEAT EXCHANGERS 36
PROCESS MANUAL (DATA BOOK)

Fiqure 13 ,........
 GUIDE DOCUMENT

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PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
HEAT M C H ANGERS 37
PROCESS MANUAL (DATA BOOK)
......
Fiqure 14 I,,..........
.I

......cO$
Tube side (internal) film coefficient h, for gaseous hydrocarbons containing;..IS('< ...*.:; CO2

Z< x H* in x m ~ l

9
f
Y
 GUIDE DOCUMENT

p.ga
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) HEAT EXCHANGERS 38

,.....
13 IMPACT OF TOTAL FOULING RESISTANCE ON THE OVERAL&E~~.:TRANSFER ..
COEFFICIENT . t' .... ._:::
,..,,,. .':.. --...'..,'- :. :
;.
; <. ..' ',
. .. . .":
Fisure 15 ..-;, ......<...: :..'
.,..,.... ..., :,

.. .,
1, - ...-. . ;
.- . -.......'.:,
......
..<
,'

::
:':,-.I

: ,.
'~bta~iduling resistance = -(fouling resistance /tube side)
+ (fouling resistancelshell side)
 Rps
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
HEAT EXCHANGERS 39
PROCESS MANUAL (DATA BOOK)

14 FOULING RESISTANCES .......

..............
............. .,:,../
Divide fouling resistances in h.ft2.OFIBtu by 4.88 to obtain the number $:rn2:?@ikcal.
Table 3 ..,:,./'<.. ........
.. ,.:.,
::....... ,. ,,.
Water, Industrial fluids, chemical processing streams-.,
(from TEMA - to be used only for shell and tube exchapg..ers]..._
::.:
:..'.,:..........
. -..
FOULING RESISTANCESFOR *A (h.ff..FBTU) ...... ...
...... .:
T m p r d n d r n W
TmnpdUmdW*
<.......
.....
. .I.. ",
.-.._.......
............
................
.;J

.: -
up--
,-.',*.
m(a vslody
i'

.,,.(
;.........
.......
: ...
2 y.:.
...........;. Fuses.
-'*.1007..
.htwF.
:../i:,:Wfr vahxw

-
Twos dWater >:..".; w?.'.... ...,Snd M Ovr3
..-....
....
3 nd-
-we- I......
.... ...........
(.OD&) (.mi, (.ml)
.m
BRc(QnW* ...............
: :; .mz i"'..*f
..... ...I .OM
C'WbmJ am ud y lQ :" .
.; ._..
--Unlratd ...............
SF '
1 ............ SQlS ,002 .002
T d Make UP
*-. .
..... .a/...- .... .pY ,005 .OM
.mc; : ':;: m1 ,002 ,002
c w a W d W?tu
wmwaw:
(*..-*)
::. ...-..
I. \ . . . ..
.
.,m.........-<...'.m1 .an

-
.w3
-Lhmm a03
..'I................
.OM
-* P s w
Awng
' .........,.
, :
.. $a$,: .... ' .Kc?
,002 .m4 .a
,005
.OM .005
Hud (Ow 15.*.),,.>
. w m ~ c $ ,
:&&d...'
7.
. ....
...l
'; ,,--..
q .mi .m1 .OM
,W.' .m05 .a05 .a05
. lmmcdw
d.*~dm# .<......./'-...m
';.m~ .a05
.002
.ml
,002
.mi
.om
B a m. u. ..m
. .. . ....
.I
. - h & 3 ~ 4 u s - r p l - ~ o ( ( h a - n v d u m d ~ ~ ~ ' F . V m ~ ~

- . .IR
(Lnpadn!s~4co-F.ndm * k m r m b s c a b . t h p s ~ ~ b e ~ - .
RsLsm~~rq~fmm0.m1500.0m h.R.'FrnN
5 d
W - * . ~ ~ ( ~ ~ ~ I I S O ..!Yy+
T E M A ~ ..-.. .
...............
FOULING RESISTA~&$&RINDUS~ FLUIDS

FOULING RESISTANCES FOR CHEMICAL PROCESSING STREAMS

OASES AND VAPORS .001
.001
Stable Overhead Produ ,001
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE ps

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) HEAT EXCHANGERS 40

Table 4 .......
Chemistry, Gas processing. refinery streams ....
,. .......-.....
.,
,. ..
:. ...
.. -:., .
,,-:,.......
.,;.:;-.. "-..
.... .<, .......
. ;.:" 2'

LIM~IDS (h. ~ ~ * . ~ F / B T u ) L
..... ....... ,:,';'
. . . .. ...
:. . . .....
MEA & DEA Solutions . . . . . . . . . . . . . . . . . . . .? .,'., :.-.. . . y . . ,002
DEG & TEG Solyiions . . . . . . . . . . . . . . . . . . . . ...'.:' . . :...;..:5 ..' . . - - ,002
Stable Side Drbyfd~ldBottom Product. . . . . . . .,<.>:,. ......... ,001
Caustic Soluyioi\s i; . . . . . . . . . . . . . . . . . . . . . ... . ?. .. ~..:' ..
i . . .. . . . . .002
<
Vegetable pis.,.'< . . . . . . . . . . . . . . . . . . . . !,.: .,.>... :............
...<. ;....... .003
. ~ o u L l N -t~ C ; ' ~ ~ ~ ~.. '.A.A.T?W I A L G A S - G A S....
OL)~ -RE-
.........
..............
~ q . i ~ r t . u ~ r o ~ s
a... : .. -
:...........
:':
~ a t & t . s a s.... . . . . . . . . . . . . . . . . ?.; :.,;.:,I: ............. .W1
~ .~ $.i ? ~ o d u .c. t. .s . . . . . . . : ;..-.:.,.,., :...:5 . . . . . . . . . . . . . . . .001
......: ........
.......
,
-:..1+pf:
( “......
' .........
._.-.. .
...:
'..Lao Oil . . . . . . . . . . . . . . . ,:..:.:-I.:..
.?. , . : . . . . . . . . . . . . . . . . . . .
...--:W Q i l . . . . . . . . . . . . . . . ::. . . .': .;. . . . . . . . . . . . . . . . . . . . .
.002
......... Gases. . . . . . . . . . . . . . .
,001
.:. YaWal Gasoline & Liquefies\%.b+h .........
_.._, . .001
- . E . < ~._ I N ~... . ~ I S ~ W C E S FOR 01pjtepwt7 STREIMS
;:'.: ,..,~.......c
....... RUDE L VACUUM u';rii-$ii'i~ei AND VAPORS
. . .
,.' ...: .........
,. .:>.. ..........
.:. :.;. AtmosphericTower..~lvei~ead.Yaporr.. .....................
. .. : Light Naphthas /'. .:.:j j . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,001
. . .001
.,:. ,... .. Vacuum Overhead..&w!s. .............................. ,002
:..............
. . . .......... .._ ..
.._.'

,.
.--.... ..
.........
:. ....,; ;
.._.. '...
.,
_..--.
..............
...... &%line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
:., ..
.W1
:;' ..:,. . & aLight Distillates.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
......... .:.
~
#
I
~~phth .001
Ke-"e ............................................. .001
........... Li@t Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .002
Heavy Gas Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .003
H-vy Fuel Oils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005
Asphalt & Residuum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .010
 GUIDE DOCUMENT
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'M
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
HEAT MCHANGERS 41
PROCESS MANUAL (DATA BOOK)

Table 5
Refinery streams

..
.... ..
!.;..., . ...... LI&T ENDS PROCESSING~U~E&
.... .Tlvcrhead Vawrs & Gases. . . .>. . .:
. .i
..................... ,001

.......
LUBE OIL @mdb
.-........ STREAMS :
.......................................
Feed St&,::.,>-..: ,002
S0lvent.$~d.&8ix,.i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,002
solve* :..... >,. :.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,001
Extractt .......:.:..: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,003
Rqffinatk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,001
~ ..,,
~ ;;.. . .. ..-.. .. .. .. .. .. ..- .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .005
.Nax.,Slurr~est .003
.......................................
<:'Re6nbd
-..:: Lube Oil. .001
..--.... ...:
'-..?%ylbns
.........
must be " h a to pmcnt wax d e p o l i M n on -Id NM w*lll.

.,. ......
. .. . . ..
#
.. .. i s
I :
::
:
. ...........
.----:
.: :..,_-..
:
.......I

,..
.. . ..:
.......... :.
',:
..........
 GUIDE DOCUMENT

Rcp
PROCESS ENGINEERING DESIGN GUIDE
PART 1- SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
HEAT EXCHANGERS 42
PROCESS MANUAL (DATA BOOK)

.......
15 ALLOWABLE ENTRAINMENT RATIO FOR KEITLE EXCHANGE~S-.:'.:,
.. ..
:.. .... ::
...............
. . . -:
15.1 KETTLE EXCHANGERS FOR WHICH LIQUID ENTRAINM~~<:I$ T#'GAS PHASE
........ <. ..
,...........
,
;
IS ALLOWED
: -..
.. ...:.' ,

P Reboilers, ..... ............

. . .
.. ..
. . ,:...
. ..
.._
..... :
...........
P Steam generators f$ral&l use without superheati&$Vd,not connected to a general
steam header. .:.;:. ..,_
;., .......:
..........: (:............
-
. ........
.-..; .:
....
............
. . ..................... :
: '

.., ..__
;.......A. ..
.._: .... ....".......
..
E = 0.05
.........
i..--:; :. :.,'......
.........
. ']
,'.._..
: .......
I.. ........... '5
.........
i.

15.2 KEITLE ~cH&.&s FOR WHICH LIQU~ENTRAINMENT IS NOT DESIRABLE

EVEN THC&!@+"~~~U AMOUNT MA$:~E.@&~ITTED
.....; ........ . :, ::
\

P ~a&iiferp$I& "wet drum" to c o l l ~ t l w ~andd ensure a good liquid Ivapour

.. _.
?e&tatioA;
.. \ .........
,;;,.-..) j... ...,
....... .................
P ,."'&&m-.generators with doy&@&q...... ;superheating, for local use and not connected
:
. . '.to.;b&neral steam headek:";
.:?'
' , -..
L .r,, .........
. j -.
.......
......... . ....
..
'-" .....g:=0.005 .,
,.....
;,': ......,."
i

..... :, , ........ :
15.2.1 .-..
KETTLE EXCHANGE&.E~~RWHICH LIQUID ENTRAINMENT SHALL BE AVOIDED
...............
P Vaporizers yri#!!d&drumn only equipped with a heating device to re-vaporize any
condensaf+;.Jmapplication
i. : refrigerant compressors ('1
........
.........?
P Steam g~I;'&@~rs with downstream superheating, with connection to a general
header.bhere'dty steam is required.
............
_.-._. ......;
E%~.)IO~
.:,.*.......:
.. '..
m).,?...;:
.....
.. .. \ .
.....'(l). higher
-- .&i ratio (0.002 to 0.005) may be allowed, provided that the
entrainment
...........
. . . .~.: at the machineand
: ./-"
:,. ~.
pressure drop the heat input from environment will lead to a ratio 5 0.001
.......,.
,
,
;
inlet.
.........
 GUIDE DOCUMENT
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 GUIDE DOCUMENT
!s-d by ara*na RY.
GE I 312 1 1.1.2 1 IV I o

I PROCES!5 ENGINEERING DESIGN GUIDE I - - 1-1

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) AIR COOLERS 1

....... .
,. ,.--.
'/ '..: ';.
: .
.'...'..-,
. ,;.:.:
:.',,.'. ,,,..:, .......
2;

._:
:. %..'..' ,".
....... .:. ...:.
CONTENTS
.:.,... ..,....'-.....-,'
...........I
Ii.

........
,. ..... .. : :.I

..I.... <._. ........

? :
.*..'..::::
i
...-.........
..........
...........
...-. i ....>....:
..... I . . . .
. . . . .
(..............“'. . . ;: <. .,: . . .;
,.., .... :..',',,'.:
. .....
.......... : .."..........
i.........;... ................
1. ESTIMATIONOE.WERALL HEAT T m F E R COEFFICIENT U
.........
: ............ .... ". .. ' 5
. ..'.'. '.., :

11 ~q&&&iing service ......................;.

1.2 't&&&ohng service ................ :.
1.3.::::&(&iidensers . :::: .. ..
I ,TM
I............... .
. c a l heat transferpoefii&t values
.......... :,..
..
.....~....“......." ... ......_:
.... ::. ..-,
-
,,
; :, ,/
:: ..:,, .....I .........
. ; ....'::
.............
. .I. .I ,

,
....:$I...........
... .MT TRANSFER A I ~ ~ K ~ N D ' F A
DRIVER
.._
N
.. .,:
POWER CALCULATION
....... .....

........>.:. ....
,
3.1 Des$ri@on/.'
3.2 rtl&
ji +rsus forced draught aimow
3.3 &iivedonal
,. .. . . .
designation
 GUIDE DOCUMENT . ,,
W b Y e n ' DUpUw Re".
GE ( 312 1 1.1.2 1 IV I 0

PROCESS ENGINEERING DESIGN GUIDE

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) AIR COOLERS

......
Whenever it is possible, prefer&&should ........
be given to reu&9.valki determined after
complete thermal rating on ' .. projects. .. .. ,. :............
...... .. .. ..
,
.._.._._'._'.._
._
...........I
. ....
..
. ..::........
.... . ..; .
':

The following methods nla$.al&.& employed :

.........>:.....
..............
.!................
:.._ ..
.............. .............
........:
,:......... .................
..:
I.I LIQUID COOLING S&WCF ::.....
....',,.
... :.......
.................. .................;
......
, ~ .' $ m
Read U from ~ .~(m
.__..' : viscosity
te is at .,&@e&+, .t&nperature)
,
:.. .. .
........ ._._..
. .-.. ......
.:,i ., .. ............ j

.,......
#

12 GAS C O. ~. ~/...I ~....

~'&&~VICE :
. ............
. .;........,,'
.........
. .." ,."?
....:......
.........
, , 2 (note : prewG%
~ead,.@fro@JGiure . . dropk
. between 1 to 3 % of operating pressure).
.. ..
L ....... .....-<.:;
..',......... -..
'.._.....
:.; .......
I
.3 ....>..._
AIR C O ~ ~ D ~ N S E R S ....._..
;. ;, .......
For pure condensation\,#Hdtjt:desuperheating or subcooling and in the absence of
water :read U direct&&&:Ei$ure 3
Examples of U ~ ~ s . . crude
.........'...
... '.....
f ~ f distillation column overhead condensers where
water c o n d e n s $ t i ~ n . ~ r sThese
. values are applicable to each linear section of
. ... . . . . to section 2 below).
the enthalpy &,&.[&r
. >
Ki,.kuk : ;.'"-"' . . IP-145 (4-6% water weight)
............. U=447 k~aVh.m~.~C
..-.. ._
...:
~ a s s. i.~.&. $. & o u:dIP-145 (3.1% water weight) U=388 kcaVh.m2.0C
.......
~~ait:::..:::, IP-145 (13.3% water weight) U=423 kcaVh.m2.0C
,
...........
.
+.!!$I$:
......
IP-147 (5.3% water weight) U=394 kcaVh.rn2.0C
............
:,_-..
,.
:: :....
. :.
:.. ~.
.
............. .
I
 GUIDE DOCUMENT
X
-IJ by We h P u W Rsv.
GE / 312 1 1.1.2 1 IV I o

PROCESS ENGINEERING DESIGN GUIDE ~ g e

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) AIR COOLERS 3

.......
..........
: ..... .,
1.4 TYPICAL HEAT TRANSFER COEFFICIENT VALUES
<.,. .....
'.... .::,::
a

., . -. r.

The following table gives typical values of U for various servieg',

: . ..,.->"'....
.....
........ . ;".' 'I I.;

Light hydmrbons 90120 440-585 510680

Ught naphma 93 440 510
Process water 120-145 585705 680-825
Residuum 10-20 50100 55-1 10
Tar 5-10 WO 27-55

~*e-m-b.n~~~4jn.OD.tub.r*nh4O-*I.fn.lh..lBinNgh.212~~.
 GUIDE DOCUMENT
t lrwsdby ec&nm amerr+ Re". (

PROCESS ENGINEERING DESIGN GUIDE pw

PART 1- SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) AIR COOLERS 4

.......
.........
.....
,

2 HEAT TRANSFER AREA AND FAN DRIVER POWER CALCULATIQN:' ..... : ::

. . .I'::
...... ..
This method is only applicable when the enthalpy curve is linea~:'i~fji$we,ei,it can be
..i,@.&,,.::;.'
used as a first approach when the curve T= f (Q) is close to being::l . . .
-.. ..__
,. I C.
:'.
If not, calculation should be mad.e .. for.. each zone where the,&....
&.@q .: be considered as
.......
linear and the results summed,.' .....: j
:' .....
..
....... : .:.....
..I:
.;..-.>....:
..............
In the case of d e s u p......
e r h ~ f l ~condensing
~.~? + s&&@$ a single approximate
..... as input data :
calculation can be done &;sid&.hg
.-.......2, .
,:!).::....:?."
............
......".......
L. j
The inlet and o u .~ t.t & . ~. r a t u r e s of the conw.&&:&ne . . .
. . .... . . '..I
.....
................ .
;
The total heat{ex&nged ._
. ._.. .,................
. . ... .,,
The condfi'tib;ji..&ne ..
~.~ heat transfer &h=ien?
....... ......
;. i.
~. .
,.. ............
:;,
.
...............
.
. ............ .
. . . ;
...,/;...'-;
. " ,, .._
.......-.....
i.
?

.'. '..,.','
. . : ,:.; .....
....... :'
. '..
.. ..
1) ~n..~wrgi.+;:tkad ... & at the itpd.@e&tidi,'of
....... :
. . .
:' ,... ....
........
....
:.; .-.., -.. . .
*'....U ' estimated in th*%t ...... .... cha$er.
;

The optimum nit$&&:rows (nearest to the dotted line).

;... ..........
.. ,',:
..............
........
where At =,,Aiof:ait;across the air cooler.
Ah.+.e,jqf
.........
..,.,..................
%
.,

...... ..
, .
.........
T,-,-.-=---y..
-..,>
2) From *.?
:: . .
=and &-= x, read & on Figure 5, where:
:
.._
. .....
..: '._.
._
.
. . . . ...
......
..,,'.:.*--...fi."'.. " ~ ofluid
t inlet temperature
i '..*-I.__. . Hot fluid outlet temperature
.. A
...... T Hot fluid temperature drop
;. :.... . * t, Air inlet temperature
:, .. ,
. .. ..,
..........
........
,
t2 Air outlet temperature.

3)At= &*(TI - t , ) - > t ~ = t+At

~

4)~t=+
 GUIDE DOCUMENT
I by m n . ~hqas i w . 1

PROCESS ENGINEERING DESIGN GUIDE mw

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) AIR COOLERS 5

......'..
i
,, ..
i' .,.....
.
. ... .---.
..,. .-.
: # .

5) Aq : Bare tube external area =

a
(m2)where : ................. . ./ i
... .<.....;./
........ . ..,..:..
.........:
...;...,. '........,
:

.......
Q Heat exchanged (kcallh) :,.; ...........
U Heat tra~isr: .
., , .coefficient . . . '..... :
(kcaI/h.~$Y.C)
:.- '....,);'
......... '. ..',..... .>.-.. .......
.............
.......
. . . ."...
\
. ."' ;. .',,..-..: :.:
, . t.
.:"...- 1
..........
6) Facial area (m2) .....- $ube
.........-.*:. ... length x Bay ::"..............::.."
dth.::'..
..............
..... .........
........
C

' .......:... 0 .9 * /b
..... . .
................ of* . . .,,..'
. .. ..,,,:
........ ....
._
....
.'........
.
( : ......: ........ .
,.---.
.............
'.
.,... _.i ,i.
i

..... . '.._.;.
....... ,

.........
. . .',:
7) IP= l$ihimut$ji"stalled
.............
power ( ~ ~ ) - ' ~ ; ~ ~ & ~ . ' ~ a
....... area
c i a(mZ)
l
..;..... .
.
--:i
......: ,.... :;,
~ h.........
.:. : .: '-...;':
, e ~ $ ~ @ l @ - - ~will
w edepend,.6p+%dard
r motor sizes:
...............
...-..: ;
,

.......
:$&so&dpower :rc; 0.9 instakd'k$otor
...._ power. -.,..
;
:.1 ........
i

...I .....
.
,..;.....'....
, ".:
Notes: ::i.. ;:;-.;
I

...................... .;
.............
......:..
1. Figure 5 is v~l~d.fot.~!=l,
i.e. for air coolers comprising more than 3 tube passes
(general case). kisst.@@Aed that the number of tube passes is likely to be less than
3 (low allowabj@.~&byre drop, limit on tube side velocity, for example for low pressure
. . .
gas coolers~'~&~t$e$odolo~~ is identical but :
.:.. . . .
.......
F&musr@ estimated using the charts for single pass air coolers and TEMA type
,.,..Kqxchahgers
. given in the chapter on Heat Exchangers (Figures 6, 7, 8). by
:: :.d$ulating R and P from the four inlet and outlet temperatures.
.......-.......
I..

...*."...w
,./.
...,.... . .~. ~,
. estimated area will be corrected as follows:
.--.. .......... .:.:
...............
;.._.
;;' :.., ..
i

...........
; ,: . :i
..........
2. The maximum cold air temperature is generally given in the client's design basis.

If this temperature has to be determined from meteorological data, the temperature of

cold air used for thermal design shall be the dry bulb temperature which is not exceeded
more than 5% of the time during the 4 hottest months of the year.

If no site data are available, reference can be made to ASHRAE Chapter 33 which gives
meteorological conditions for many sites in many countries.
 GUIDE DOCUMENT
-by -n. aup(an b".
GE I 312 1 1.1.2 1 Iv 1 0

PROCESS ENGINEERING DESIGN GUIDE ~ g e

PART I - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) AIR COOLERS 6

-
FIGURE 1 Air cooler on liquid hydrocarbons sewice ,:I.,-.'.'. .....
,,

... ..
.__.._ .. . ..
.
FIG~J?~E'.~,.-::A~'~
cooler on gaseo&trybt&rbons
,,.-.~..-...~-...' service
i.. :.. .... .. ,
:... :._, --
1. W*out hydrogen : i n t a & t ~ l i ~ & . d e - the iwo a r m ~ ~- $ ; B * M W I ~ O .
2. mth hydrogen : inter+@ llritjerly,in two steps, fvst as in g l . , ~ : a fofuthe
~ MW of the h y d m mixiun (rvimout
, e n a d and the H2arrvebqs+d,?h,i?gqolar hadon.
hydrogen), then beWee,?iIgg'W!?t
.~ , .. . . . .

.. ..
-
\..'FIG$~E 3 Air condenser (pure condensation no water) -
 GUIDE DOCUMENT
Issued bY 0-n* Ch.ptrff &.
GE I 312 1 1.1.2 1 IV I o

~ g e
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) AIR COOLERS 7
 GUIDE DOCUMENT
)Yuedby Bm*na awwu h.
GE I 312 ( 1.1.2 1 IV 10

- - -

pwle
PROCESS ENGINEERING DESIGN GUIDE
PART 1- SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT -
PROCESS MANUAL (DATA BOOK) AIR COOLERS 8

...... :............
;. .....-.....
3.1 DESCRIPTION .:.....
.< .,.,. .. :. ........... .:.:
,....
. .
i.. ; ...-........
Air coolers usually have ,jm.i&;i+ 'l tube bundles. ~@-pii+rj;,s may be found :
inclined tube air coolers ,J~P&'."f;ed in power stations'.'a...$'$ea.rh
vertically mounted tube........... .
bbidle$(&rely
.. ..:-..........
used). ............
. " . turbine condensers) or
..................
..,..%....
.'..., )
.
.....
Horizontal air coole$&&ther ...
be induced (Fiiv@)-&*orced draught (Figure 7).
... .:;... . ...
..........
.. .~
.....
............. .. .>
Figure 8 d i s p ..-..
la~~ ....
& : ~ r i n ccomponents.df
i~al ..
. , an..aq&ioled heat exchanger.
. .., '
.
.._... ,..~..'i ., .
.
. ........
. . :. .
, ..
Air coolers 46
groykd in batteries hq~d$9.m' or more services. A battery contains
several &$
.'@a
tie
l.l Each bay is'@ia&up ... of one or more tube parallel bundles
. .
(gener@f~~];6f.finnedtubes (see ~i~uip.?j...
,.]'...._.:..:::.:. ....,,:
'
....: :. :.:
;
I....

. . . . . .;;'&&lly2 fans per bay;eii:h:.equipped

Tht&&p
......,,': with a plenum for air distribution.
:.; .......
....
The width"bf a bundle varie@&qa minimum of 0.6 m to a maximum of 3.0 3.5 m (11 -
feet). The usual length of ?i<.df,&
. ..~.... ......(..
.......
............
._. '..
.
with 2 fans per bay is 9.14 m (30 feet).

Swcial cases '.. .......':,, ....

. -. :
...:........
A bay may c o n t a i r r : $ k bundle when the heat transfer area is small and the service
cannot be com~:&%$$othem for reasons of process control. In this case, the tube
length is decrpasi5b.andthe bay width increased to allow the use of a single fan.
_.............
..-.......
..,
~heneve~$&e are no problems of process control, it is more economic for several
kioidng
services..... '.. only a small heat transfer area-to be grouped in a single bay with two
.....-...........
fans. ,,. j
., ..
. ..
;:
.~.,
 GUIDE DOCUMEh
I Llludby -no aumr"' Rsv.

PROCESS ENGINEERING DESIGN GUIDE

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) AIR COOLERS 9

,.:..,,...--..
.....
..
::
:
,
. ,::::
........
:
..,,. .......
i..
.....'
3.2 INDUCED VERSUS FORCED DRAUGHT AIRFLOW ,:-.
:. ..,,.,;/. >;,
<........:
%
...:.... ..._ .
.;'.'..."..
-.. ......
I,,
:
.':.
........
FORCED DRAUGHT ,,.':.-:) ... D~UGHT
INLIU~ED
....... :
Lower efficiency: . :. Better efficier?cjl<'i,.-;>..>
-Higher risk of hot air recirculation,'.. ....'....:'...?.. l o w e r risk dhbt'@iF&irwlation.
..............
............... ,.......... -,:.
. ..........'...'I
-Poorer air distribution. .-.........:. .. -Better &id@tsi@uUb;n.
.. .. . . .
................
. .
......... I........

-Efficiency will vary dependh$o;i&~ther less affected by weather

-~ffid&c&&~.l;k
conditiins. C................
........ ‘..... -~ns>.,
.
......... .................
::
. . .. ~,
Easier maintenan&.---" ... .." :". L L h . & & maintenance
-Removal of rows pip$sible,v&hout removing .-Ahy-rndintenance of the tube bundle requires
.....,',: -
,,-I::
plenums and fans: >..::..-:j..' ,> &pryal of plenums and fans.
,.,: ;. > .-.
: .... .. ,". ..............
. . . I

: ;
-Easier mot~,insfallgtionand maintenance,,@@. e
o
&rl diioult motor installationbecause of the long
"

drive shaff.'~tw&hotor and fan. ....::..' drive shaft between motor and fan.
:........ ,
.........
:_,. ...... ".. '.;
-Easy access'b-&n for maintenance and blade''.' -Access to fans for maintenance and blade angle
angle adjustment. Fan located in +a+".-. .. adjustment less good. Fan located in hot air.
: : <.,.-.. :
~. , ,
.............
... : :.
Other advantages: ................... Other advantages:
-Lower theoretical consumed,&.:'-, -More natural convection.
. . -.. .
...............
-No limit to outlet air tem&i:(@n is in cold air). -It is possible to dean the fins of the first row of
i'
.:. ............ tubes without stopping the fans.
-Well adapted to air reci&atik'&hen required in
::.--
winter for example....... ....... ... ."., -Less noisy.
..,.". ,:
:
,
.'......::;'._:
.............
.....
.. ...............
. . ._. .'.
... . . .. :..
..... ........
............
\
...... .; .
:.
::' :'
::
\ .. . . .
I~

..........
..........
 GUIDE DOCUMENT -
by soan. a!amerff nn.
GE ( 312 1 1.1.2 1 IV 10
i

PROCESS ENGINEERING DESIGN GUIDE pw

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT -
PROCESS MANUAL (DATA BOOK) AIR COOLERS 10

....... ..
3.3 CONVENTIONAL DESIGNATION .........
i/ .... .,,
: .
,, . '. . ";.::, :
,.. ........
TECHNIP'Sconventional designation of an air cooler is as follows ;."(,..
,
7
“....:" ~-
,.;'.. .............
" , .' .'
,";

,...._. ..... .....

.......
The first number give the number of bays
,.........:....
........_ ..... .-
......
<, , .,;.
The second number gives tkeTft@c'lengthin feet ,..
I:..,,; . ......
..-............
The third number gives th$ba$yvidth in feet ........ i..........'
....
.......... ? . ..-.:.,..-.
;: I'

:., ,; ,: I
: ..

The fourth number gi&&B.&kber of rows or l&.&af.tyljes.

.........>:.. .... :. .............
.\/
.....: ........"
......I....

....
.......
.......
............... ...::....
, ...(.'..' _:
..;
...........
.. .. ...
:
. ........
...
..I...
Example : 4 - 30 i:'&'r'6 i&ntifies an air cooki:$ith)..'
. . .....
. ....
.......... .. .. \:. :...
::.-" :, *..
.........
4 bays, 3 ~ ! l o n ~ ~wide
\.. , . 22 .
.........
,..... . ,.;
.............. :_.. .' -,.-.-.,
.,,'I
I

8 bun~ds.oftub&s each 11' wide vl;'id:filberows

...,.... ....,.'. . :...:
. 8 f$& ..."....'.:"
;.'
,
; ..
..........
%. ;,
,.
..
..-.,.__..':
,,-... ) .,,
. I . . . . .

.:......./';:
I

.........
:_: .........
i.

.. ...I' '
'
.I
.......
,,.;,.-..;'.' ..
: . :.. '..:
:. :,. '..' .:
............... .. /
.-._
................
. >,: .-.....
.........._
: -.:..........:
.............
..........
. . 1
;.I ..........: i

.. .. . '......:.
, ..
.........
..............
.......
....-....
...... :
......
.'/ : :
.......
......
................
...................
..... . .. ..
.....
............;!
#

.......
............
.......
;:
.~.; :.. .:
.............
:
T..
e .

..........
 GUIDE DOCUMENT
h-d by W n 0 Oup~lw RN.
GE I 312 1 1.1.2 1 IV 1 o

PROCESS ENGINEERING DESIGN GUIDE paw

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) AIR COOLERS 11

...-...
FIGURE 6 .....'.. ..
i
..
...... ./:. :.
i/
'.
.
'
a
Induced draught Air Cooler
.. .
:,.. ,..:, ......,:

:,
.A,

..:.....
. :.;'
.... . I.;
.,.,,, ..._ . ...'I

. ,
 GUIDE DOCUMENT
m b v Wb -n w.
GE I 312 I 1 . . IV 1 0

PROCESS ENGINEERING DESIGN GUIDE Ree

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) AIR COOLERS 12

........
........ ..
FIGURE 7
.,.,:.;. ..'. .,
Forced draught Air Cooler

.
,..
, : .
.......
.;, .............
; ',.',.
... ,. :>'
.- :'
.......
::

,-.,.............
........ ... .........
. ..,
 GUIDE DOCUMENT
k e d by Bm*nS C-ww h.
GE I 312 1 1.1.2 1 IV I o

PROCESS ENGINEERING DESIGN GUIDE RSS

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) AIR COOLERS 13

.......
FIGURE 8 .."............
.
Components of an horizontal aircooled heat exchar& jj .._ . -. , .
...........
..........I
...::
...,..<.,:;.* ,.:
.................
,..., -._:
,.
,:.,. .... -..:
,
L

:,,. ..........
!

.........
... .. ...
.......
............
........ FORCED DRAUGHT
...,............
... ..:
.. .:..,:..
......
;,.,..---:
,.-..'~;.f=&'
.:.._.
,
6. Tube bundle
:
I \ :
. .
'.,'......&;Fan ring 7. Drive assembly
.......
3. Plenum 8. Column support

4. Nozzle 9. Inlet bell

5. Header 10. Outlet bell

 GE (
-by
312 1
-". ]
GUIDE DOCUMENT

1.1.2
ed@ew
IV I
R,

0
.\

I '

PROCESS ENGINEERING DESIGN GUIDE

PART 1 SECTION 1 - S.S. 1.2 : PROCESS EQUIPMENT
~ g e

MANUAL (DATA BOOK)

AIR COOLERS 14

FIGURE 9 ........
,.......
, .:........
.-

General arrangement for air coolare with horkonbl bundled. \;. ;

~,
j ................
..........
..' (. ,.,... >:' '.....'
I
......
-
.-:.".. ,..,.,.,; ..
.,..........
.. ..;.
.......

LBNGTH

r
2EmION.OR BAY .._..
?......:, .....:
:..............
-.-..
..........
. . .
............
................... 2
< . .
. : "... '? UNIT 1

.......; . > .
...........
. .
..: ....,..
:
...--..
.'
,, . ......
_ . .::'..
...... YIrn
, ..........
-:,.:
.. ............
'1
5 .... ........:,..:.:..,.
,
... . . ~.
.........
...........
,, ..-..
::
.~.
#
'. . ....: .:..,
............
..........
GUIDE DOCUMENT
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE ~ g e

1
PART 1 - SECTION I S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COOLING TOWER

..........
,::..I........
f
.... : :
.. .,
\

CONTENTS
...> .....-..-/,i
. . :.:. .....,"
/,.
:, ...'.',... >
% :.
......................
. .. . . . .
.,. ..
.... , ......
:
.........
.......
1 COOLING TOWER TYPE'..: p. . ..:5
<:.'......
,' : :
::
.. ..,
.........
... ;>.-.........
I-

....... . .:.....
1 Natural-Draft to$&>.. ..'..: (. . ,..--:
.
L.-:

1.2 ~echanical-~rpff . . .'t;;*i

.. ......... :........!
.....-...........
........._ :li..“...._. ......... ........
< ..:-...........
..........
...............?
:
.: ........
'..; .:,;"..,'
:.,. ..............
P.

......
. .
'.._ '..
(

2 COOLING.~O~E~:DESIGN ............. .............. ..,..?

......
_..-._.._.-.. ... .., .., ..
2.1 C @ ~ S fl'&ling
& water ........ .',:;:
..............
2.2 ,T*+fures ....... :___
2.3 ,.j&stimetlon of water flow &id---.::::
2.4: '.P'dhty consumption .,,.:-..:>...>.;
z;6 ....T.*r ~ ' ..: ; ..'
,,, :
,. ,. .._.. ~mensions ;.
.:....... ....
.........
....
:............ . .
..
.. .....
'I..
.'I
,
__.: . .._
; ' ' ....
;,*

3 EXTRAPOLATION OF ......... OPERATING CONDITIONS OF AN EXISTING

COOLING T O W.. , .............
>-- -....2%.'....
................
-.
......
............
,i.,

................?..?
....... . .. .......
..
:
....... ; .
...
:..............
.
. . .
.... . ..,,
..;:,,..: ;s
:., .......:
.............
,_.-..'.._ '._
........
.............'-:
... . .....
~.. ..
..-..
............
;. ,.--..
, ,.
:I
i :. :
., ....__.'
,
.I

,.
::
..........
 GUIDE DOCUMENT
by was mwmrrr w.
GE I 312 1 1.1.2 1 J
' l o
'1
PROCESS ENGINEERING DESIGN GUIDE pqa
PART 1 - SECTION 1 S.S. 1.2 :PROCESS EQUIPMENT
2
R?oCESS MANUAL (DATA BOOK) COOUNG TOWER

...-...
1 COOLING TOWER TYPE

In cooling towers, water is cooled

1.1 NATURALDRAFT
2.. -..,,.,:
,A. ..., '...
'
Natural draft towers are ,&li:@y:d4 in
nuclear and thermal ':.-$oL$&> plants
because their therrnaf:@&c$y is very
high for a low ope&g..j)a$.~ater flow ,..
.._ . ) . . .
rates are in the ran~~;o.~lf)0'000
m3/h.
........:.,.:.. '-.:'
,_.._. ... '..
i.2 MECHA$JIC&D&FT ., TOWER
i. .:.. ,
..___:
, .. .
Smaller ,.,':&~h.-.--.ri~turaldrafito
mechanl$&&~ towers can h
coolip$ '&a&,,' flow rates of .'
25g.6JAIJAI pe?unit.
..I ..,....:..: .,.--..
There are several ;;,t&i+.. of
mechanicaldraft towers : ;,.. '.: .>
(..,...\,...'.._.__.I'
.....'.i
-Forceddraft towers..fa$:.:~~?~efan is
mounted laterally at.t&~asase-~f the tower
and air is forced tlp'&2~ti:tl&
, ,, '...
packing.
., > ''....' .'>

.-..._.___.
-~nduceddraft.~-t&~ ': The fan is
mounted at .W.$op tower ,sucking
air up t h ~ g f i : : & packing.
e The airhater
...':.
heat exchaRgP.~susually in counter-flow
basis ,@K::h.'Wbss-flow basis (c), the
powej i;pnshr$ption of the fan is lower but
~ i,a &. j r ' i-.
;,.-.. .:..
::
q..' h o r evoluminous. I
-.
I.
$$et&jtowets : lnduding a dry exchanger (air cooler type) at the top of the tower, the
'hy& or "wetdry" towers limit fogging and plume abatement. More expensive,
voluminous and energy consuming than other types, they s.hould only be installed where
specifically required by the dent or authority to reduce plume (visual impact) or risk of
ice formation in very cold environment.
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE pqo

PART 1 SECTION 1 - S.S. 1.2 :PROCESS EQUIPMENT

3
PROCESS MANUAL (DATA BOOK) COOLING TOWER

2 COOLING TOWER DESIGN .......

.............
.. .
.:. :..
.i /.
The following sections allow to do a preliminary design of the ,&ip.&ajdcteristics of a
cooling tower and its electrical equipment. :..;., ...j ..;;.%
;
.;

...,..................
.' ,. .. ... .
...
...... ....
,
;
2.1 CHOICE OF COOLING
,..-..TOWER .) ...:.........
I.... ...,
.'/":
.I

....... .:
I...

The type of tower can ..I....

&:V&ied ......S:,.-..
in the following t@l8:' e'*ral. solutions can often be
. ........, C. ,: ..... .:
accepted. .........
........:
<, ..............
;
. - '.I: :,.:
. '... ...... ,'

:_:

..............
.. ,: ......
,
:
: i .: ;
.%
,.

2.2 TEMPERAT~PW..-..,:....
..............
.......
...........:
Wet bulb temmi@q.&~ and drv bulb temperature DB of air are fixed by the plant
location and a@ljS$My given in a Project general specification.
,
...........
............
Hot water,&i~e&GA HWT and cold water tem~eratureCWT are usually imposed by
.. -.. .., following initial approach shall be followed:
the clien~~-lf-n&."the
,, -. .
....... .: ;
~'@F"$hall be as high as possible (max. 45 OC) with a reasonable temperature
.,.,;@
. .*&. from the process fluid to be cooled.
.,. ... ..
...... i"..".&shall -
be 10 to 15 OC lower than HVVT (AT= HVVT CWT = 10 to 15 OC)
;.,'...-.. ..........
;
.
., .I>

'.. ':;Take a temperature approach a = CWT - WB = 5 OC (a should not be less than 3 OC

i.......:
r" ........I."for a mechanicaldraft and 8 OC for a naturaldraft tower)
t
C Verify that the efficiency 7 is greater than 65% ;if not increase AT or decrease a
E
e
e HWTCWT=&
"'HWT-\NB AT+a

(Axa= values of (10;5)or (12;6)are commonly used and can be considered in a

s preliminary study.
Y
 GUIDE DOCUMENT
luwaby em*". Oup*r"- m.
GE I 312 1 1.1.2 1 J
' I 0

PROCESS ENGINEERING DESIGN GUIDE I 1 R O ~

PART 1- SECTION 1 S.S. 1.2 :PROCESS EQUIPMENT 4
PROCESS MANUAL (DATA BOOK) COOLING TOWER

2.3 ESTIMATION OF WATER FLOW RATES

,..
.........
:
: ,:
,
. ,.
Water flow rates are based on a concentration rate C = 2 with C beip$tb&&'f'h behnreen
the concentration of dissolved salts in recirculated water and:~f&~,,'&&olved salts
concentration in make-up water. The ratio may vary between yfb.b'8-d&@nding on the
.._,
...... :,. . ....
quality of make-up water (6 to 8 for demineralised make-up w&k&
. ..'.,.. . ......
.~.
.:
... ...
C
.............
.I.....

Flow rate of vawrised wat&> !/

.......... :..., ...;.... . '
i..-........
. . . I ,,
......... <,. . ;
'."I,""-;
Ev(m3/h) = Q.AT 1 5 8 0..“...‘“........ ..... '..;',.'
Q, recirculated watq.ti'&:Iii:ei" m3h ...............
.................
AT, cooling tempe6wzfference. (OC). -..................
:
.....
........
............
.
. . . . .,; .......(.'.:,...,
. .....
.. ,.. ......;
. -.::I;.;..::::
Purqe flow rate.; ....-............
.................
.......
.._ .. ..: .,.
....\
i;
,
p = & I (dl)
.I. n ,

yEx.fw C=2 .........::

.
*'& .......
< . I :

: a #
...........
The aby&.'&\sr,&he also includes losses as droplet carry over.
/,,;
' .: .,..>......... . .............
: ....
... :
:. ....../ ;.. .,.;..........
.... ..:..... .:
MBK&~UQ.:~~&
.,: '... ...,
flow rate : . .
.......
........... ...
X(IT$&]=P+E,= 2Ev=.Q:
, . AT;'&O
{j.............
Filtered water flow rate 5,'.......I;.
. . . ..
,.....
.............
:.......
i:,
.:
.
F (m3Ih) =0.05 Q ,.~&dlie';..k
.. -..:-- ...... provided to remove suspended solids.
.
..... .
.......... .
.' ...........
"., .. '.'
........:.:
Coolina watefr)umb.fiow rate :

Pump fl9,d&if6-.=:d + p+ F
......: ::
.'
:. ..........
'

.. i :

..-power of the recirculation pump

G
. ..........
...-.. .?.
;
.

i...
.I. If &pressure
.
.__.I
drop in the cooling water header is known, the absorbed power can
".be.&lculated as for any centrifugal pump with a pump efficiency taken as 75% ; if
not the power can be estimated from the formulae below :

Small installation : P* (kW) : 0.12 Q

Industrial complex : P h (kW) : 0.24 Q

Fan power consumption :

P (kW) = 0.06 Q
 GUIDE DOCUMENT
M b y -no aup(r* RN

GE I 312 1 1.1.2 1 v 1 0
 GUIDE DOCUMENT
lDwsday mdcw -ns Rn.

GE I 312 1 1.1.2 1 V 1 0
\-

PROCESS ENGINEERING DESIGN GUIDE PW

-
PART 1 SECTION 1 S.S. 1.2:PROCESS EQUIPMENT
6
PROCESS MANUAL (DATA BOOK) COOLING TOWER

,........
..

,. .........
....... .,
' .
'.. '
. . ::
;:
,........
:. . .;'
,.'[
.
..'> ..'
...*.I

"

3 EXTRAPOLATION OF THE OPERATING CONDITIONS OF AI~&&+JF~G . . COOLING

. . . .....I
.....
TOWER .. - .........
.........
..-.. :.I

Based on diagram 1 and knp* that the 'rating facto~&i~v=&ly proportional to

water flow rate for a given t&ei<?t is possible to detep$f&:i& operating conditions
:.;.
,......I....
,..
when one parameter is chahzed ,:....
'
.
i..:
.......
. .
> .

........ i /
........................
:..: I ...
.: ....... . -
..................
-.
:......... ......., .. .............
:
.............
........... .....
:
:................
........ :. ._. .. .....;:
...;.,-
.....
.... ..(,:;. ..;: :
..,............. >
......"\...
2.
..... ........
' . ...:
I

1. A tower is,'der;i~&for
::. ,.:.-,,.. ..'
: : .
........ ..,:
.......
a .
I :

...........
C w , i25.?@.( HWT = 35 OC, h&~;r,
.:
. w- ,..I 10 OC = 18 OF
W=.&G'= 68OF, hence a = = 5OOC = 9 OF
q
I..'

...-$'t.&hi'&
. &m. . indicates a &$Ici'br-7if = 2.15
,.
........... ....: .:.'....,.
..,.t./
:.........
..........
. '.
'..I
5

2. At re;j'il&dload with th++qe water flow rate, AT = 10 OF (5.6OC). What are the
new operating oonditio@[? ,<.:;
'. ..,...'
................
I
I -

WB is always 20 %:=$&OF and RF = 2.15

The diagram i$@t~$.~&proxirnately a = 5 OF = 2.8 OC
Hence, CW=;W@?, a =20 + 2.8 = 22.80C and MVT = 22.8 + 5.6 = 28.4.
,.I................
1
.:.., . .~.
. . I '
... . ...:
......... ~

3. Increment"of-.-l~:%.of omling water flow rate due to a plant expansion with AT

rnaintai,m&;at 10 %. What are the new operating conditions ?
.' .;. :;
....: /
-
PF<:~..&/1.1 = 1.95and WB = 20 OC = 68 OF and AT = 10 O C
..........
* i irhe.di$gkm indicates an approach a = 10 OC = 5.6 OF
..,--:{ .. ~. I.~ ~ &=C
WB a = 20 + 5.6 = 25.6 and HWT = 25.6 + 10 = 35.6 OC.
W+ T
.........
;.._,
-

;
::
i ..
::
...........
I
. .:,::
I

.......... .

I
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE pqa

7
PART 1 - SECTION 1 S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COOLING TOWER

Diagram 4
(source : Equipment Design Handbook)
 GUIDE DOCUMENT
bed by W n * Uupern0 %.
GE I 312 1 1.1.2 1 VI I o

S.S. 1.2 : PROCESS EQUIPMENT

 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE m-

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
FIRED HEATERS AND COMBUSRON 1
PROCESS MANUAL (DATA BOOK)
.......
............
... .
. .
I"/

........... ::
.;
<

.: ,.. '.. '.

.I
........
. -
'....'
,. ,. .;...
......... t. ,

.
...........
..-. . . ....
... . . .....: ,
.....
:
I.,... .....
..... .....:..:
......
.'."-$ONTENTS
.. ......
....
............
.
2
.
.

, .
: '...,,:,:
i
.
.'... ......
, .,:..-.......
.., ..
............?
i
.I . < :;.. ;
<. .',. : :
I..
,

........
................. ...."........
. . .
.......... "'
. .._ . ._'.
........:., ..; ...................
.............
i.................. ...........
. . . :
:............ ... ..
..........:,,:... ...,.:
1. coMBusTlo~~. ... ..::....: .....
:.... ..'.......: ; ..I..... .._
...........
,.', . ..'..;
.._
.:..., .. . ......
I.I ~ ~ t & g " $ l p e
1.2 N ~ ' e x c e s s ............. ...:
...........
1.3 ..&.&l&hs to atmospher~~~-~~'i~SS...
1 . 4 - ~efficiency~ ~ ~ ~,.,-..
.........
:I

...:'l..,_,. .....'
"..
........ .; .....';:
%S.?*~B;~E index
..*:6 '..s&- SO, equilibriuni: '..,.:,:'
...........
. .... '._. '._,
.._....?
: ..........
...:
'
.......
:..'j.........
,: .."...

2. INDUSTRIAL DESIG~~.
............ .........
..':'.,:.:'
........
2.1 Type of fiwtieabrs
2.2 Type +.$.&-,,';
2.3 :. .....
cho&in@s&?d
.. ... . . . .
..
,.
,.......
..........

...... .."..
..:.. .,: :.
....
..-.... .....,. .
.._'.. '..
,
;
............
, .............. ....:
i.

............
a,
... ..: :,..
. ,
,
...... ;
............
.;.;..-..
;. .,
. . ~....,..:.
;
'

..............
.
.........
 GUIDE DOCUMENT
bwmq Bcew wqr"' Re".

GE 1 312 1 1.1.2 1 VI I o
\

PROCESS ENGINEERING DESIGN GUIDE prls

PART 1- SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) FIRED HEATERS AND COMBUSnON 2

.....
.....
..........
I COMBUSTION ,. ... :'.
: . ::
..............
.
,/
'-.. "..';
....':. :'.....'
:.
:

.:......:
The fuels generally used in refineries are :
...
,,.,........
:' ..... ._.
:. :
a) Gases produced by the units :, .........
..:,........ . -
b) Liquid fuels (mixture of residues and fluxants)
,,.i.....::;
',-.,:.
t
........
....'-. ._
..-.. '.. -..
.: .
For a hydrocarbon CnHa+*th@q.&tion of combustion iS.<,.-\
... ;>,..-.-.:"-..,?
. ._
. ._
. .. : ':
<,........: .'........_
.( ,: ,.'
C_

.......".
... > .I..... ..
-i

C.H*z + 3n+1O2 .....'::_.I,$Q + (n+l ) H20 .+:'

. ......:'...........
...
:

2 ................
.......
;...... ..............
........I.......
............- :. ..,/ ...
>.'
.............
This enables cakylatjon'pf the amount of &eh.and hence the air required for the
. . . . . . . . reaction withour$ii'.&&) . ,
combustion (stc~#6het& and the flue gas compositiin :
. . . .:.. . .
......... '
.,.......;
. "
,, ::

For a &.&pud~el of known comp$$@i .......

brti-Table 1 can be used to determine the
s t o.i .c ~....~ m ~ ~ ~ a iofn oxygen
o u n t @&peSf.
., ..........
. . . . .,..;. .....\.I .. '.....
,. . .5
~ & a f u e ~ gwhich
r the C02qhd ~2co"tentsin the Rue gas are known, Table 3 can
.$$$$fe&d to calculate the"f&. . ..H/c
. ratio and the actual amount of oxygen
"."corisu@ed. ...... ..,,
................
i',.... '.:
:::
......
. :
: ..........:
,
.......
.............
...........
C

,-- .....:,. ..
1.1 HEATING VALUE < -.:..........,,'
.I..,...,. .'..
...............
By definition, he&&.$& is the quantity of energy released from the combustion of
one kilogram
.............. eat in^ value can be defined in two ways :
'.. 1
,.,-y...
Hiqh heahrXl val"e .HHV ( also called Gross Calorific Value)
< ..........
.......
~.f.Qel.k.hken at To. Combustion products are at the same temperature, To and
..
.._ &.,&ndensed.
v@er
.,--...\
............
.
...
...
I..

.:... cow...
,6 heatina value. LHV (also called Net Calorific Value)
:, . :
.......... :
'..4t14 fuel is taken at To. Combustion products are at the same temperature, TOand
water is assumed to be at vapour state.

Reference temperatures TOcan be found in the literature as 0 OC, 15.6 'C (60°F) and
25 "C
 GUIDE DOCUMENT
kia*aq

GE ( 312 ( 1.1.2 1 VI Io

PROCESS ENGINEERING DESIGN GUIDE ~ g e

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) FIRED HEATERS AND COMBUSTION 4

...--.....
,.-..
. ...
,.. ..: ':,,
.'
.....
Calculation of LHV
............*,:j,:
.:......
..:
. , ,':. ....
/ :..;.,.: ,.":'
, .
....,1.':
a. Gas fuel ..:.-,,.;.... .'._
.... ,.
*...,.:, ....
LHV of a gas can be calcuIated
........
,
from Tables 2 and 2 i&iat .._ .. &d:$?
or at 25 OC) from
its composition.
.........
:
( .
:
'., '..,.', :.
...'....._........
.......;..-.."....
.. ... .:
:. ‘....'.. ...........
For a gaseous hydrps+~@l~.:i&houtinert commbqk::alid a bit of hydrogen. LHV
can be calculated .-...... :.
b y u * i . & e approximate f o ~ l & (to ~ be
w used only when
LHV cannot be cdcdated.by other methods). ...:. .:'..,'
I. :. “...
'.... <..........
......,:' ..:':.
LHV = 1400 i.:lP&B:
..............: p .: .................-;
................ I..

LHV : k&i&&: ....... . . . .

...,_-..
....... ...,. .. .. .:: ..:
:. ...
.. .
i ~ , & ~ ........
.......... -
.
'......I.

P ;...
..........
, .
.'?
................ -..
.. : :. .....:,.- .....
b. tia&;u&,; ;;.. ...........
..........
. , :..: . ....
,
,.]'. .... 1..I' ..
.....I ..": I
I...
7

,.&e.fo&bdng formula, defina-.@(the French Normalisation Office for heavy fuels

'.(s'&~c gravity between 0.92 to'~,b15)produced by French refineries in 1980, can
be u& (this formula d?if:.be
:2' .........
used for asphalts).
..
.........
LHV = 13258....,- $&Q.,.@ at 15 "C) - 76.5 . (% S)
..............
LHV : ... d
i*! kg
. -..............
:

p at 15 OC ,.':..:'....:;.&nsi
ty
“..“...... in T Im3
%S
............' ' ' ~ . ~ ~ l ~content
"
.
%
,
;
' , h u r in mass %
A ..........
In som@:~".&diments andlor water should be accounted for. When water is
prese&'.i~~as an impact as an inert but it also reduces the heating value because
of yater.&risation.
.,..................
., ...: ...
d&erafforrnula (sulphur content is not taken into account)
.,.-.........
.............
[>.-'Lw:
I.. . . (kcal Ikg) = 17355 + 5112 In (WC) +607 (In WC)Z
.........
%. ' ,.'
''..TI& WC ratio can be calculated from the flue gas composition or from the fuel
characteristics :

See API diagram, Data Book chapter Ill SS 1.1, characterisation of petroleum
fractions.

* Composition of gas fuels.

 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE p.ge

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) FIRED HEATERS AND COMBUSTION 5

.........
.........
,,. ..'. :
. .... . . .:.:.
:
1.2 AIR EXCESS ..;. .......
. -:,:.
...........
. :> ...;
;. c. "' ,>
/

To achieve a complete combustion, (that is, with no ~ ? $ o & k , , i n the flue gas) a
quantity of air greater than the theoretical (stoichiometri~.a'nounf'Shall
; ...
be introduced in
..,
:, ._ .'-
...
the furnaces or the fired heaters.
.... ............... .:
' 5
'-._....
<:'..,:,. ...............
The quantity of excesg&dr? be identified by a&$$$$= flue gas with an analyser
.......
or any mobile devicg&at.$a$measure the oxy$e@a$l$.C%
....... content.
..........>.,".;
.... ........:.
.;... '...::'
<. ............
/
.. ..."'
Air excess (e) p~&c+lculated ......... from the@ o
& gl.......
fn :,. .... fokula :
......... .I '._
&..:..:' .3.96 ..
x 02 4 a&: '
$ $i
. . . :.. .
~ ,
n
. .....
:.
.
vblume %.
.......,. -...(w,.,
2.-3.'6 02) .,:..
. ' .
......-
.I

........ :
I:

. . ._ . .
N2repr&nts$)trAn content in wd$8ue.$as., ,,..> :.-.... calculated from :
>;, .........
......... ::., ............
,
-. .. .
.......
,?

N2:&:1,q$-,,(/o o2 + % C02) ..-. :

... ....... :.' ,,,.',..... .>.....,.:
.
.
;
;

,: ....
. ;.. ...
. .. ......
.
.i;
, .( '
.:... ;
-... c..
lfth&C02 content in flue gas i;'imi'cnown, it can be estimated from the characterisation
I-,'

fact&; "a' . 'a" is f u d ...pf CM. It represents the C02 content in flue gas for
.............'
. . .' '::
stoichiometric combuddr&--;
.......
. .....: ..? ..
a = ,...... :: + 7
.:cy.*r.:.
I'.."...-."..
,,,, .............
i
+2882~
.(61- +
.,...,. .....
::
. ...
..
,-....;.
G = &:j&~....:?(~~~~ %)
.“. i total fuel
:.......'....
_ ......
.:
.............
*.'..-F~p.%plete combustion of gaseous fuel :G = 100 and a = 12.5.
ic..........
...~c$&m~letecombustion of liquid fuel : G = 0 and a = 16
......
............
/.";'-" ~ .&. c eCO2content in flue gas = a 11-(% 02/
I

.....
........
..
I

7% C02and % O2in volume %)

 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE page

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) FIRED HEATERS AND COMBUSTION 7

1.4 THERMAL EFFICIENCY ........ .

.........
:..i i''.. ...' .~

'

The thermal efficiency of a fired heater is the ratio between tty$.h~~a@orbed and the
. . . . %...
heat produced during the combustion of fuel. .:c:,.. . . ,.-j
:
. ..:.....
. . ...'.....;'.:
..
R = Total heat absorbed x 100 ..
.
.........
,, .
Total heat production . . ........;
. :....A.
,

C '.../ :
._-....
Total heat absorbed : su~i$%heat absorbed by radiat&aqd
.._..
d6;lvection
Total heat production,?$&t &xluced by the con&d&5p$f'hel plus heat produced by
... ._ .
combustion air preh.&fi(if;a"y) .._.._'. .
and to a less,e~ent;..&nsible heat of the fuel(s).
.., '..,' ...........
One part of the ~ a...........
t~bssi% occurs
s through fie-:@e&fieaterss walls (about 2 % of total
heat productio?).)'.a~~,gndther part results fm&,.t@e.$ue gas leaving the fired heater at
: '..,.'; '.,
high temperatiire:'..- .......) ..... . .. .
.............
., . 5 . .i

R = 100 - .......
(haiif@ss&sto heater stack,,~.<&t~!&f+es through heater's walls)
.._ i ?, .
*. .. . .
~ .. ..
#

. .. .,
~omm&;&irjeiides are : ._......
........ ,',;
.. ,.........
I

55d...........!.! Inside radiant f&ii:$.+t9rs

....... ;.., ...... . .. . .
.. .-._.
. Inside fired,,,hf@$ts&ith
,. ..
. . ......:% %
............;.... ' 2
,' . .
..;
:
...... :.
.: energy recovery by convection.
: '..
: C

:........
.....
... .:
:." W&E ,.-..
'..I
1.5 INDEX
,.I . .
...... ........A

..........
The Wobbe index (al&.&f@'wobbe number) charaderises the heating value of a gas
in its actual conditii~'of.operationat the inlet of burners. It is defined as :
.._.-..
.:,, ...
W = HHV - . ---....
>--
...............
Ja .... ........
............
....................
w : 8?jobhiiex
HHV : :(:::&&.heating value (') in MJlNm3
d ..........
......... : S+C%C gravity (air = 1)
;.. .....:. :,
('!.4s@il$~araderisation uses the LHV. But this must not be referred to as Wobbe index
. .
..............
1.6 &2-&$ EQUILIBRIUM
.........
....-:: “.........
......
. . .:. . a0.60. ~CIU~UERIUU
::
!. ~,
.
'S

............ . .*
s :

..........
...
.... :......
....
%
-
 I - bY
GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE

-
PART 1 SECTION 1
PROCESS MANUAL (DATA BOOK)
S.S. 1.2 :PROCESS EQUIPMENT
FIRED HEATERS AND COMBUS77ON
-
8
--

......
,. ..,
...-....
. ,. ... .:;.':. :.
,.
,,.] .
.;: .-..- :'
. . , ......
;
,
INDUSTRIAL DESIGN ,,.;
...:... ."<.,.'" ..'
...,., .......,
TYPE OF FIRED HEATERS

i
There are two main types ijf$(ed.h,eaters :
< 8,

..........'..
"'

................
.
......
. .;
..........
: ........
. - '../
,
.. .....
..'/....
:.: ..,......-..
......
.......
...
..-..\........
i..... '..'
.:. .: ..... .:
,;.........
%.
,. :...
. ;
5
;

........:.. ....
. .... ....:'... ........
.....
cabin fired heat.@u&fio&ontal or vertical t&&s.. ...: 2
............ vertical or helicoidgljfod&
cylindrical firedfi~te'i~.with ....
,:.".::.: ....":
..... ..'
................
..... :
.., .........
...... . . ..,. ..
; i

..-.. .._"..
.
The choice &&'&rtical
. ,' .. .. or horizontaj.f&.he$ers
.._._ is mainly based on :
.....:......... :;
..
:
/'
\
..............
I
;....>
const&&&.:..' .... -......... .......
. . :" .....,'
...... .....:-..........
..........
......... .:. ;' : .: .. ,
:
,Fqi.a gi<@ fired heater, the&,k.&$limiktion of heat transfer. Above 60xl0g kcal Ih
{;.of:heqt exchange capacity, hd&ntal fired heaters are selected because at this
ca&& vertical fired heat- can ge difficult to construct.
:I;;--.:,.,.. ....
<.,.-.:;
External dimensions : i.'............. .;
.........
..............
........
Horizontalfired lpte&.equire
.. -............. more ground space than vertical fired heaters.
................
..........
Investment &tr .............
. .. . . ....
. .:
........;..
\

Cabin firtM-.h*rs are more expensive than vertical fired heaters for low to
I . ..
avera~ey$~aci@(up to 30 MMkcal Ih).
:*.
....',:.~
;;
I.._

..
, '
......... are used to mix air and fuel for a complete combustion .
q~~oe$
There are two types of burners :

naturaldraft burners
I
forceddraft burners
 GUIDE DOCUMENT

PW
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
FIRED HEAERS AND COMBUSTION 9
PROCESS MANUAL (DATA BOOK)

,,...... .
,..' ..., ..,.
.........
. . ,::*; :
:
..........
2.2.1. Naturaldraft burners ,.;.,' ...........-:...
.......
:I ../,'.' ..'>
.. .. ...;
They can be used with both liquid and gas fuels. Every by$er.i$e:@ipped with a pilot
fed by a separate fuel line. ,. .-.'..
/".. ..,..-..:
..-.. ..-..
:
.I

Naturaldraft burners ow.;'6f2with air excesses from..@:f0.25% depending on the type

.......
of fuel. Steam c o n s u m (. :
P ~ ' ~ etodatornise the li$j-,&i'[email protected] 300 g Ikg of fuel. %.
.
;
..
.
.-
.

...................
..........
.:...........
.......... . . :
.. ... .. .. ,...;.:
........ ..................
: .........
2.2.2. ~ o r c e d d d ~ J j i i e i s ...........
:
........:.......
........... ..... .......
...:.A. .:
These burne,~ ,.
,. h,a$e.$everal advantages........
&m&redto naturaldraft burners :
;.... ";' ....: .........
.' ,-.-.,'. :.
c e ~.......
Air e &... ~ ' i ~ h n ito
i t e5dto 10%. &te&khe : ..... type of fuel.
i :. ..
, .............
........
;

&+p$ating flexibilii &d 10 of flow rate against 1 to 3 with

.......
; @ t ~ k f f k f tburners), which.a1~~operation
from 10% to 100% of the heater
:; .......; .......:
:
..,..
...->... . .. ......
,

. , ,. "..",.
'..,......
,, '. .....
.
2.3
I.......

:.,"~H&ING
STEAM
..,.:
.....
,, ,
A;
......,
....
;: .'.. .;
In the absence of ~ek$~~&ormation, the first estimate can be based on the vapour
...
quantity required fG".r+I& three times the volume of the combustion chamber in
15 minutes. >-- ......
/ -
.:,,“..
............... . '.
<;.
.............
,...........
........... ;

.~.
::
. ......
....,
.
.........
,,.
..............._
.
....... ...,..,
, ,.-. :
;
<:/....,.':,;:
......
...........
........... ..
..,.... .. .. ... ...
. . I . . . . .

.......... ,.
n .
,.
........
.............
;'

I ;..-" ."-..
:.. (.'. ..~.
#
..
........
....'./
.......
 GUIDE DOCUMENT
I W t y

PROCESS ENGINEERING DESIGN GUIDE RW

PART 1- SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) FIRED HEATERSAND COMBUSVON 10

,.--.._
,.--..
,, .. ...
. ... .,. .,.
'
,'{'
TABLE I .I_
- 4

... ..,..'...-:.
,.:,. . '.".,'..
,..,.I
,.
;
<.
: ... ,. >
2.
Determination of the amount of oxvaen rwuired
.*.,.'
.'/ .... .., .
.-....,.,.
,. ,,
for stoichiomettic combustion of a aas ..
: .. ....I

. , .
. '.....,;.
.. .. ..____.'
I..--..
.*...-In:=
:: .. ,.:Mass flow rate of fuel
. .......,,/
', '.
.....x.= Molecular Row rate of oxygen consumed
x=m' 8
A 100
 GUIDE DOCUMENT

M
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
FIRED HEATERS AND COMBUSTION 11
PROCESS MANUAL (DATA BOOK)

.......
..........
. .... ... ~

TABLE 2 :'i ..
. .. .. . ::
.
1
a
.

DETERMINATION OF LHV OF A GAS AT 60 OF ,.:.' .:..:.'

.. .<. ,. . /..
....................
.... i

% mass x
Composition % Vd. Mdecular
weight
% Vd. x
mass..
LHV
(kcal Mm3)
% ~ dx .
LHV .,..
. ',,'"'...._.
"'..:
LHV
(kml I kg) LHV
.:.:... ....
....
Hyd- 2.0 .;. a. .......
:: 2 576 .......
.........
........ i..........
28 640
. . . ..".,
oxygen 32.0 .......
.........
, .............
'' ,
( .;
,
%.
. . :. .: ...... ..:
I.
. .. . ' ,..:...........
(
'-'
CO 28.0 '............'
.._:.,..;
,---.. 3 015 ........:' 2 412
................
. ... .._: .
q~drogen 34.1 .:.. 'y.-.......“
....... 5 525 ............. 3 633
. ........... ...........
..
?
:
:
Sulphide ....
......... ; .......
................ 11 947
Methane ........,.".....;:
,.,yjy,
,
8 55&
........... . ...
:.
Ethane ....-.m.t...>
..... 15 6 '; j 11 343
......... ;
Ethylene ;. (,.. 2,j),. -" .,I~ :.~.. '.......
......... 9 8 11 264
;
...............
., ,.: :.2f3+ 11 073
Propane ",:' ,
;
44.1
'--
....
:I 5
:.. "-.',( ,.:: 42.1 ......I.'%..* 10 936
PmPYlene '. .-.
., .........
.... I' "..,.:
:' ::
10 886
sobutane ............
.' .
'........
., 58.1 "(. 28 228
.....
:
. ..,',: ''.,128316 10 920
Butane 58.1
. ..
.,..-..
........
Butene 56.1 ,{ :.,. (+.,.. .: 27 090
: ..
10 823

sopentane 72.1 ;... ........

. . :;
........... 34 505 10 720
.....
........ A.: B= C=
Total
. .--
,;..:'...''-...-..___:
........
;..,
..........
........... .. .. .:...:
.. .. ...
..........
\

............. '.:
.........
.--. .: ...
: : .
.:. ........
. :,. LHV = B 1 100 kcal I Nm3
.....
p= Densw=--..>..h
= kg I Nm3
''I@x 22.414
.,.........
: *. ., ::
LHV = B kcal 1 kg = C 1 100
.......
............
;:.--- ,...'.,.
:
,. .. .'
...... ::':
I \

..........
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE RW

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) FIRED HEATERS AND COMBUSTION 12

..........
,.;,. ,.---.
:.. .... .: :.
....
TABLE 2 bis
DETERMINATION OF LHV OF A GAS AT 25 OC
. I
............
..............
,:, ...,...
;'
* .

.' :. ,../ ;
. ... .:.. i,;
.. I.;

Composition % Vd. Mdecular % Vd. x LHV % VOI. x % ,&&. ......~ H V 9/. mass x
weight mass ,Jkcal /Nm3) LHV (
......... ., (kcal Ikg)
........ LHV
.... .:. ..; 2 579
2
.
.
.....
...
Hydrogen 2.0
< '...... ......
.......:.... 28 669
........... :. .....#y........
Oxygen 32.0 ........ ._:.:
/............. .......
......
...'./..!:..,;.'
. ..:.
CO
Hydrogen
28.0
34.1
;-
.......
..............
..., . . 3 016
...........
";
............ 5 529
.:.. .........
.................
......... :
'..........
, :
2413
3 636
a
.....
:.. ....... ...; ..:..... I ..
. ....
.
Sulphiie :..........
. . .I.....

. ..... . ....
Methane 6.0........:!.;, ........''S 8 556 ............... ....:.
............. 11 954
Ethane . .... .:.. ....
.30;a' . 15 226 ( (' '.,. '.: 11 350
.' : ., ::
I...... i..... .
Ethylene [&, < . . j 14 ID7..."......-.'... 11 272
. . ..
, . .
...
Propane
; .. ;.'>..,4;l-<,;.
:..,> Z?.Z@.........: 11 079
Pmpylene ,-.;./ ..........'q
..
._. '.,' : ' . ; ; ..
,.,&&+: 10 942
lsobutane .. ,,
I,.'

.
............
, i. .....58.1 < .._.
"2$:243 10 892
:.,' ...."... 28.h
Butane .; 58.1 ,..-..
.
10 927
Butene 56.1 ;...j. .......27 098 10 826
i :., '.. h.. '
lsopentane 72.1 ...............!,.;' 34 804 10 813
..........
Total A =.,2'......
..-..... 8= c=
.:-.
:. .........
..........
......... : 1
.... ._..,'
..........
: : ..., .
%
;.

...... 5
.....

!.
......... ,
........... .._,..
........: ..,
.....
; . .
:.:.....
._.-.. .... '._
..
LHV = B 1 100 k c a l l Nm3
.........
:', ...........:
-:

p = Density [ ':A 4 = kg 1Nm3

...---.
. . "lil0*,22.414
...... ....
.-.,. LHV = - 6 kcallkg = CIIOO
:. ... .
;;'
'.......... ,':
'
. . P
e ..........
8
.,

t
4
s
 GUIDE DOCUMEM
by mmn. -N ~.v.
GE ( 312 1 1.1.2 ( VI I o

S.S. 1.2 : PROCESS EQUIPMENT

-
: 'a = .....% vol.
01 mrrespond to Nibugen of the sample :x = $[I w -(a
+ a]

To obtain the number of mdes of excess

air.multiply the result by theorelical air

.......... .. .
......... .....
i

p
P f l u e g a s ~ OC Pair= OC

Moles per kg of fuel ~ o l mx A enthalpy Sensible heat of flue gas

(see parag 1.3)
in kcal Ikg of fuel

Excess of air

Heal losses through the stack - LOSS through me sbdc = %

t-
Low heatingvalue
x 11M) = -= % Extemal losses = % (radialion)

Total = %
Efficienoy = %
 GUIDE DOCUMENT

S.S. 1.2 : PROCESS EQUIPMENT

FLUE GAS CONTENT :

ot m r m d to N i i of the sample : $[100-(COz +Oz)]

To obtain the number of moles ofexcess

o? = Oxygen mntqntjn@~e
gas''' air,mulsply the result by thsore(lca1air
co2 = co2 conteAtipnus.&.

PFluegao=ZM)DC Pah=lSOC

Moles per kg of fuel Mdes x Aenthalpy Sensible heat of flue gas

(see parag 1.3) in Kcal Ikg of fuel

75.3 135

372.8 483

H20 v 47.6 72

Excess of air 89.61 .:.117

Heat lodses through the stack = 807 kcal Loss through the stack = 9.3 %
x 100 = = 9.3% Extemal losses = 2 % (radiation)
Low hea5ng value 8700
GUIDE DOCUMENT
 GUIDE DOCUMENT

me
PROCESS ENGINEERING DESIGN GUIDE
PART 1- SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
COMPRESSORS 1
PROCESS MANUAL (DATA BOOK)
.......
CONTENTS ...~..
',/..........
:..
,

....
"
.: :,
1. GENERAL ..
, , ,"..."...'
-
,..> ..........
'.'
;

. <... .....
: . ,. ,. ':
1. -
Theoretical reminders Mollier diagram ..................
...... . .. .-._ I .'.
1.2 Methods of calculation Units - : ,

:.,.
:
......
,:
.......-..:
........
:
2. MPES OF COMPRESSORS.,~~~.;:'.) .....
....
<:'...,,:i .._._. '... . . .
. ..............
........
I

. . i , .. :
2.1 Selection chart '.. ..-...:....:':; .:.<..:.,,.... ::
:' .:
2.2 performance ctiivi+..>:. '. :.....
.........
.:....... :
.................
"

2.3 Main f e a t u r e p - ~ ~ b r s : .. -..

(. .-.:........, . ................
. .
.......
3. ...
CALCU~A~ONU~AD~BATIC EXPONENT ts&i&
......'.....
. . . . . . '.; .._
. . '
I'

.............
.......I......
,
3.1 Estirn&h'&'charts .,... .. . ... .. : ..
3.2 Dqt$6& $ic';rlation : :.
................
.,
.... .. ..
::: I
..................'
4. C E N ~ ;... W ~ A ~ ~ O M P R E S S O... .,R; ::S ??) . ; ....
..:..
.<,.
. . . . . ...-
: ....:... ,'.;
....
............
4,?.'..... mrip&io n c h w *....
fTOm .....
:;
':.r "....,,:.
.4.g betiiled calculation
:.<. ....
..... .:.: .
....
:_; .....
......3.2.1 ~ o l ~ t r o p.fficien&,"
ic
4.2.2 Polytro@$+d.(H,)
4.2.3 Shaft P@pk.."> ; :
4.2.4 Dirch~temjWaturO
4.2.5 ~ u m ' b + $ h l s Icasings required
4.2.6 l~@&~h'~:
4.2.7 , ~ ~ n
4.28 . .~,,~~~~culation
:... .'......:.
5. AXIALCQ~(P&ORS . .
. ...,,
.---.. ,'
5.1 + ,&&pci efficiency
5.2 S .'&
'pin flow
&
~
$
5
:~
.,&
:u
nri pmssure
..,. ... . ... ..
. . :. mTlNG COMPRESSORS
6. ........p
. . . .E .
::.-.. .:. .
::
.:. 6 . Estimationfrom chart
6 Performance calculation
6.2.1 Number of stages and discharge ternpsratum
6.2.2 Adlabgtic pomK
6.2.3 Total shaft power
6.2.4 Sample calculation

7.

8. INSTRUMENT AND SERVICE AIR COMPRESSORS

 GUIDE DOCUMENT

'I

PROCESS ENGINEERING DESIGN GUIDE m

PART I- SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COMPRESSORS 2

......
. . .
,. .........
.. .. .. ..
1

1.1
GENERAL

THEORETICAL REMINDERS MOLLIER DIAGRAM - ,

.

..........
I

..........
,...,>.............
" .i'.i:' ....."
!
.
,.'.,: '... '..-,:i:
?

' . : ...... ;
/.........
a. Adiabatic and oolvtro~iccom~ression .....-.
.... '.. -:
,
.--..
,. . ..... ".'
,......... I

Compression of an ideal g&xf$ be considered a s , < t $ + & + @ ( ~=~ constant and

k=Cp/Cv) or polytropic (~~'I:=.+$bnt).
, '. .
i<.:..... :
.:..........
.......
. ... '1
..........
... * ::,,,:;:
,'.. '.
.......
........... "I

Compressor manufactcners-..Qenerally use the::"x!l&Mc compression model for

reciprocating comprg$sd:&:?nd the polytropic c o p p f i & ~ m o d e l for centrifugal or axial
compressors. ~diabdc-::~:~polytropic effi~ien~~5:~:Iad'applied in the calculation to
..............
account for true &h&ot~t?
... ._
,
..........
................
..... .. . . .. ,..
i

~.. 'I

The wnversi6;-df adiabatic efficiency q,(b;.b$6 polytmpic efficiency q, (or b)for a

given w ~ p ~ ~ j j o o d , ~ s(wmpre*.-qtto
ervi
........ and k=C& are known), may be
obtained,.f@pre 1 below.
,.........
: ,
.......... ?
. , ..".! .....
...:I........... ; ....;:
,.]'. ..: >,.,.
......
.,.. . . ......
... Fisure 1 -!*.sA
........
. . ......
........ :. SI 5.8 1980
.........
I.,'
...; ... .I
' ..-.,
Polytropic effiienq ( q p )

~~
hpnrionro(io
.-
7 Miibmii sfliiknq ( 1- 4 ).
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE psps

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COMPRESSORS 3

.....
b. Mollier diaqram
/,......--...
....
1..
'..'.
.) j #

Whenever a Mollier diagram is available for the gas to be cqmpre3s&; the following
................
simple calculation method may be used. .. (../..: .,..:.. :. '.....'/
... :.. .-.
....
Fiaure 2 - Simplified Mollier Diagram // :..... ......
..... :.,.;.. ........
.., :
: -. -:

. . . . . . '...,,. .
..
<f:'i-::i:~r~m Inlet state point 7 ahd,kection of p, and tl (suction conditions), follow line of
&stant entropy to .&harge -6ressure p2, locating adiabatic discharge state point
;. ,.-..';...
..
2d. ; : /,,-.. .;:
The adiabatic ~I&.&-&!H~ (N.m/kg) = Ah, (kJ1kg) x 1000 with Ahd = h~ - hl (in

.:-
British units :,m&&n.... factor = 778 RLb/Btu with enthalpy in BtulLb)
:'.. ..........'
Using an e'sti~.tqladiabatic efficiency qd (refer to following sections), the actual
discharg$+m'at$y . , hz is :
.. .. . . .
>....A :
Lee&+..$.
h2 =.&.,
..'I.:'. : :
On.~0flier,plot vertically from h2to p2, locate discharge state point 2 and read 12.
................
.....
?I,:'
, , -'h&haft power is :
.........: ':..'
:'.
...... 7 .-.\--P-ti.(kW)= m ( w h )x H& ( ~ m l k g )
lradx*x105 (JMNY,h)
. . \:;1
,,' :""
:, .
...........
%.

...........
The polytropic head is :

hp = -
H d x/IP
pad

See efficiency conversion chart on Figure I.

(Note: 1 kJlkg = 2.326 BNLb)

A
 GUIDE DOCUMENT

i
-

page
PROCESS ENGINEERING DESIGN
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COMPRESSORS 4

METHODS OF CALCULATION UNITS -

. . ....> .........
...
In the following sections, two calculation methods are described .:/'<
..../... .,> ........
...,, ..........
I..

A quick power estimate from charts. .......

0 , ......
2
,.:
..i.. ...
.... -..
A more accurate method,.,med on simple calculatipn..for podver and discharge
temperature. : .'-,,.'...,,i..;: ......
.........
.........
,A. -. :...,
...
..... :
.......
<. .:..-...:.....
. .:.....
The System ~ntemation~l.::(~l~op'unik is generally.~~&.~~oughout the calculation.
Usual units may be [email protected].@$x$V(e.~.pressure in p<~$st$ad'of kPa).
<................
..~
.............
........?
........... . ..:
,. ........
.. . .....:
I._..

,.
TYPES OF COMP~&&<S ............
......
.:' ..-..';;/ "..... ......
...............
........
~.... . . ... . . ... ...
:: '
.

. . .;.
............. ..........-.
The follqvi(ig.)irt'gives typical fie~d$.bf'~~&cation for various typles of compressors.
Note thdt'a&d~imits
.:.... . ma" vary frrn&ie':manufacturer
......... to another. Consider this chart

*
i

as a.guideltqe'b"ly
.. ..; for t h e m o s.i.c. .q i applications.
~
' . .-
:.;. .........
i
.. '.I .....
.............
, . ., .. 1
 GUIDE DOCUMENT

paw
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COMPRESSORS 5
......
\
i :'
,
...... .,
..........
2.2 PERFORMANCE CURVES < .... : :
.............
I ._ ,/:.
The performance curves (polytropic head vs. suction vo~umeti&,ff&$~a& ._ .., . , dierent for
..................
.
each type of compressor. . , ........
:.
;',.. ..... .../'
[ ......
........
AL : Reciprocating.....
......... . .... -......
.:...
Ax: Axial .. ,. I. .:
..< .-..........
........
C: Centrifugal ........
'... '..':r' ........
. :...-.......
, ...,:,,..-: )
;
' .
..........
......... ;
.:"...,:' ........ i. .:
... ...... Figure 4 .................
...........:I..
.:............. " ;.
.-........ -:. ..; :.............
I . ..c............ . .... .. .
')
............
: ......“-.
....
:'. ;.:,.' .....,,:
..........
.. '.._'. '.;
.......... ..............
. :.
........‘....
.........
(
................
. . ..: :

r)
.r(
P
0

..........
.. . . ..
..___.,' I
I

Suction Flow Rate

 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE Rae

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) COMPRESSORS 8

......
Table 2 ,./',
,,
... ..
........
( I... !,:
...".........
,,,./ .......: /
Reference GPSA - SI 4.1. Ed 1980 ;
. .,. .,-
> .....
,. ..,,.'.:.,.';. .,'.:>
M d n S p d S r H& Cqmci~yMC, lU.ol.(in -1. Ulknrl. % ...>... %

(I) omo -: Wrnd % h . I hprti- d ~wr-b- UI b hoirrfl,;'

o d
. '.....
, .": :

....
.I
,.--...
............
;:' :.., "

Example :hbs'ai'.~6
...........I OC intake tem~erature
...............
.. -..
:1:-,..':
,,.---.. Table 3
: ...........
,.,'.. '.-. blculation of k
?

< .............
. .
..................
Examplegas mixture :'. '. ' h l n a t i o n of equhalent DetenninaUonof MCp
........ ..
.............. molecular mass Molar specific heat ~ a ~ a d t y
. .. ..,.
., .-.. I.

Component .....
Mole f&&'iy individual component yx M Individualcomponent Y X MCP
name -._. '._
......... . molecular mass M MC, at 7S°C at 7%
.............
. . . . .
,. .. . . . .
. .
Methane i 'Q.92fq 16.04 14.782 37.870 34.901
Ethane .....
. . .'..o
. . .(p& 30.07 1.467 58.819 2.870
Propane
........
:: .0.0185 44.10 0.816 83.585 1.546
i-Butane :. 1~0039 58.12 0.227 110.408 0.431
kButane ...::::c..:..b.0055 58.12 0.320 110.334 0.607
i-Pentane 0.0017 72.15 0.123 135.581 0.230

Total 1.0000 M mix 17.735 MC,mix 40.585

k = MCJMC. k = 40.585 1 (40.585 - 8.3145) = 1.26

-
Note : Other sources : refer to Chapter VI, S.S 1.I.of the Process Data book.
 GUIDE DOCUMENT
I by mt
v

PROCESS ENGINEERING DESIGN GUIDE "v

PART 1 SECTION 1 - S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COMPRESSORS 7

.........
......... .
.,.,.. .....
: .
.
.;" ........":.::. :
3 CALCULATION OF ADIABATIC EXPONENT K .,:..,' .......
:. ...:
,-.>... :.....,:.:;
'

The adiabatic exponent k that is used in formula is, by,.&:nv&&i ,i taken as C d C ,

(CdG of ideal-gas state) at ..--..
suction temperature. (
'.
.........
I,..

......... .....; ... " ...... ..:

....,: : , ' : : .........
.........
2.
........ ....
..-.......
3.1 ESTIMATION FROM . . . :. <..:......
i .:
.............
.:..._..
..."... '
. . - . ::
.......... ...-,'.,.
If only the molecqlar..W$&tof the gas is kn~$m#$k6carbon mixtures), and not its
composition, an dmx&te value for k cad~$&-&t&mined from the curve given in
. .
. . . .. Process ~atabo@t.(s&dP~~

3.2
Chapter VI, ~.~.::'t.,j;dflhe

...
DETAILE~-C~L~$ULATION
....
...I......
.
....
. ...'. ..::
Fig. 13.8).
. '.
...............
. . . .
.............
.:..
, .,
. ._: :..
.:.:.--, . .'
,/.,
i
...........:::
.......
...........
For a..mb&a&rate calculation, .a~~,h..rpn-hydrocarbongases, k is calculated using
the ,%;?s)'&uation
. . . :,....; ...... .. ., .::
which applle$tq~aRideal gases :
,*)
t
......... .............
:
. ','UxCp ,

.....//
' C '-
..4-.+..g'~.3rxc,-p .....
,.
::
:_; ......
.... : .... ,>
wher6':
......:. ...
.......
:;
; : <..
...;
.-.;
/

MC& : ~onsta ...........

n t . p h & i k o l a rspecific heat capacity (ideal-gas state)
.......
...........:.....
R: ~ni*&.gas&nstant
........ = 8.3145 if M& is in kJ/kmol.OC
:
..........
;..,..............
. )
= 1.986 if M& is in kcaVkmol."C or Btu/Lbm~i.~F
:: ......
'i

Table 2 wodS
$ii&the Values of MCwfor various gases. For multicomponent gas, the
mole wei&'tted$@rage value of molar heat capacity must be determined. See the
sample',.cai$ulation below.
. .....
:
-..:
.... ..
.............
L

............. :

..... ... .. . ..
'
..........
:.:
..--.
.. , ..
...............
\ .
I :

...... .'. .:
:;'
. '......... ,.
:
I :a

. .......
\
. .
.
.

.
I
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE em

PART 1 SECTION 1 - S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COMPRESSORS 6

........
. .,"..
,
.....
2.3 MAIN FEATURES OF COMPRESSORS ::, f... i : \

. . *,/ ::
........
.......
Table 1 ....... ,..> “........
::. ............
..-) . /;/
.:,.. ...........
, '

..........:',.. .... ....:

:
..... .
2.
. ...'.:
"
TYPe Sped Compression,:'&Mntages ~ i s a d v a n t ........
ag~y& u~
type Typical
Capacity Efficiency,..:...... ...?::' .....i..........
. , .....
; applications
.....................? .:. ., :. . .
, ,.:
Compression
ratio ....-. ".-:. .> .............
%.

..
.......... - ,

mtoTxxlorpm .........:I;
w* "qbq'...&hnbirr

-
AUprsuvrrr
:......-......
'._- - )U '-during
.............. h..
.... .......... lonppaiods
.
swwmtbw: o=mwwt%yF=Gas- M MS
nh:UlOmYh : y... pl..zv..",:
ma%:2x1mOo
:......e& b.%. Lowmaintenanoc ....... ..... Ek&kaI~ Csta(y6csraddng
Centrifugal rn , .sw &&
:wboul'W)dp85%of
-&
.... r-T
PofmWhead (I%)?:'..:' '*?5 ,;.: ... % diw tTddWv. -.=&=s
IYXIrntoJoaaoq'l;
... ,.. .,., f-=aW=paS?y;.l+++ng=and -pas
smar
csli"g ...
.: .:
........... ;. mnhol
.-*
j -._, -Ah-
....
*P&

m t o l2qgq.&> .........
vay~&$,~ip~&::.

-
~hMue~imy.nd air
....:.. ... 'opasaon

-
c-nw-sa
m m . :... ':..;" .." ... .ywMe
.I.;

vw& ; (d-.-
min : mYli'....,,' dimacpidn.i&a SiearnWne
........
......ntp:
: ""v...
gWvpasrsused

Axial 75-85% P&amancs.nd Ga5Wna $msstawMiedto

ZEZh,i ,.. l
emmeyam
hcglaoffolding ~lecbia(mdw
=bars

:{' +p-a; ..
i i *-on

-
. .:...'-.-..
. : .........
3 0 0 t o 1 ~ ~
.........>:.,..ttecmww~'
Spareisnqlirsdia
o p e r a f i o n ~ ~ d u s m
-Irlpblmad air
Plurtatr
. -.
...:......... -FU w
swwmflau:
OblJMln'hl ...............
(.,,.............
.............
-.lforlOv -*
~mn(iruaus
sm=
-iwm%l(d
-R60: ....
.': K~rcainlrnms

Reciprocating
rim4.5 persmae. a
-diashsrpe .......
,:

.-..... F:?%
".'.'" up m 3 5 bar
-F-=uw
~ -,, &"",T
bmpasbnt :lBO-l&, PipilpWtok -fWmumnF(ss
F , .'.,-..
.... .
:
.., ~ d f k i c w cammdaion+
&-

....I.:.!
.._/
:; , thsncedrih@fu
hpwr
becauseof-

. '. Nar lubricded

, ._---.
-..".. -:
............
.. . .. . ... ..
N0tdlsdEdbyg.s mnquin
pDprtias trrasnc -Js
: a., ;:
. .
9Q9fQ@3' ~owwmrtthpn ~ilarsrnguindpt - ~ a r air
d

s*,: cafifup.l ruclionldrschrge Mpu

--
BrrmCaicncldnp
.m.m4oGu,M
.......... wlefdfkicw -by *-v-=-
UmncedMupI bnpcnh.sincnsss
&+.&,* Not-*
mm=~cvcler
+=kwd
2 ~ 7 ~ * ~ Not-by-
S- iaa-~~ofrs
,5-&,%
popatiea MvMing
bsa.
Standadbedprts Mwmnholbyaiha
miahspaador
bVpaos

Plbriad
 GUIDE DOCUMENT

paw
PROCESS ENGINEERING DESIGN GUIDE
-
PART 1 SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
9
PROCESS MANUAL (DATA BOOK) COMPRESSORS
.........
,,
/
... ..'

4 CENTRIFUGAL COMPRESSORS . . :
1'

........ ) I
:
.
;/'
. . .
.... ..->......:." ,

4.1 ESTIMATION FROM CHART

:. <..::,,/ ./.:.,.>
...........
-..
, .
..........
. ......
:.
Curves are available which allow easy estimation of requirement for a given
. , . . .....
k value (1.4 in the examQI++low), compression rabpi..suctlan pressure, and suction
volumetric flow.

"-3 . g asserr, a a -;g-c-g-g-s

~.
 GUIDE DOCUMENT -

b d b y Bm*"- auparr Ra
GE 1 312 1 1.1.2 1 VII 1 o
,

PROCESS ENGINEERING DESIGN GUIDE ~ g e

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COMPRESSORS 10

4.2 DETAILED CALCULATION

4.2.1 POLYTROPIC EFFICIENCY

a. For sinale wheel :

.-.

This curve is derived from the following equations :

Qv > 8500 m3/h ( approximately 5000 ACFM)

b = 0.751 + 0.01985 Ln(Qv18500)
 GUIDE DOCUMENT

R9c
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COMPRESSORS 11

,....... .
..........
.. . ... ..,
. . . . ;'.. ..
I :
: ..
........... '
. . ..... -:..
b. For multiple-wheel s t a ~ .:,..: . ..:. _
. . ,
....
.-.
::'
Provided that there is no intermediate intake, the polfi.ii'pic..$~~iency calculated at
stage suction shall apply to the complete stage. Thi~::usual!y
:.,, .., ~.leads to a reasonable
accuracy. .......
..:..-.. .. '._ .... ,:
...._
...... I
.

:< .. ............
In the case of lateral..&<&. depending on the . ~ ~ : ~ o l " flow t n erate compared to
compressed gas vo)u~ifla$~rate, efficiency m .a.t.t .x.w. .b.>be
reviewed.
.............
.........: ...........
.._'.__ :
.......... ':,, ... ........
'

4.2.2 ........ :
POLYTROP~C..I~E&~~~H$
..........
.__
....._: .
.........
. ...I..
.I......
...
. ............
.
._
. __ ._...
. ...:....
:

zm,qr .?.p k '. .

+x..&f(s$* - 1] .. ..... ... ..
............
Hp =
.. ... ... ...
........
......
.:. ..'. ..., ..
<
:... ..... .........'...
.............
where
., .. :,. .1
.........I...
: _._ .
,..,.. . ... .'..,
::. ...".';..."... .'
. I

:,
: ,._
Hp.Aim.........
. kjnc-'-af
;., ".___
.. . . .. .;
.."K.;
._ .I.

.....;
.:
y. ' k ~ . r n l k ~ ................
;'
. ,.' .. ..;. .. ......,:
Adiabatic exponhf .&:cpd&,calculated in section 3.2,
. Gas molecular wei$~;.:'
P : Discharge ..,....
arl&~,uctionabsolute pressures.
R: ~niversal~+s~la$.~onstant = 8.314 kJ Ikmol.OK,
Z.: Average w'inpr+%ibility,
PP ~olytr6pi@e$tlclknc~,calculated in section 4.2.1,
T. : .........
~u@i&j;tih&ierature, OK
.....
...........
..........
H, is often e$~:~&$'in
..~... . ..'. . metre or feet by analogy with pump differential head
.
..........
1 kJlkg'~----kf4:mlkg= 101.97 kgf.m/kg, i.e. 101.97 "metres" or 334.4 "feet" (that is,
appro$G+tely, 30 kJlkg = 10 000 feet)
.,;._
_ ..::'. ..
......
.............
.. . ..... ...'... ,..
..,...-..
.. ..
, .. ..
' ~ e d c i e :r
......
.............
....
.
.-.,
, :.. FO;~ a
given compressor (rotation speed and wheel diameter fixed), a variation in the gas
"........&b perties or in suction conditions will change the compression ratio r = P,I Pawhile the
polytropic head is not affected.
 GUIDE DOCUMENT
!ssmby war* -n. RN

GE I 312 1 1.1.2 1 VII I I

PROCESS ENGINEERING DESIGN GUIDE PI*

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) COMPRESSORS 12

,........
........
....
4.2.3 SHAFT POWER :,. .. .,. :.
.. .. .. ...'-..-..I..:.
. .
2.'

.. / >, -...-...:
The gas horsepower is : .. ''.. -.;::
;
.: >:.
... ...:.................
:
_ .
. . ..... ..
. . . . .,
mxT
P. = -
C? LRT.
x*[(g)* - I]
,.--.
L

{', ......"..
. . . '._ . .:
.. '._
.... ..:
...<.....
. .:. .:
: :
,'
.-......
.. . .'.. .
where : .:. . .:.i
.....
............
. . .
...........
..........
.
. ;. ..."
. i.......
....... .: '.. - : ::
Pu : Gas ~orse~ow6r&.k$V~ ...........
.. . ..../,.:
._ ._.'._:
"

H, : Polytropic h,ead.k~lkL ...............

.. . . . .. .. ..
k: Adiabatic ,e.&$Gfrct-k = CpdC,, . .. ... .. ...
............
, .
M: Gas molee$ac'~e?~ht, . .... .......
:. .._..

P,. Pa: ~ i s c h ~ r g ~ . . ~ d . ~ $ uabsolute

c t i o n pr,essui'b;.:::::
R: Unive&a~.&~law constant = 8.3i4.kJ&+ol.0~,
Q: ~&~fiow,;k~/h, .....
, ,
:............
'.
..
'.
Zm: ~\i&ge~@m~ressibility, ......... .....................
I4 : ...;pdytsij$6
, . .
efficiency (see sectii~4-~:1),
T:. :' i a t i 0 . n temperature, OK. ....... .:.
................ :,.; ..............
.'.
.. , . ... , a,........ ::
;.
.....
P (s&.horse'6;&er) = P. (gas hors&psber) .. .. + bearing and oil seal losses
. . . . .... ...
Losses are'taken as 40 kW a$&ist.approach (80 kW for P. > 8000 kW)
:
.: ... <.;-.... ..
.............. ;

-
Note : .. .....
................
......
......... >:-..,, “..
In case a mechaniql.$@$-vaa"ator is installed, consider 2.5 % of the compressor
power as additiona?io$sd$:.::
.:. .,. '..,. '...
, .. .....
.
......... ,
............
. .
......... . ...1.
.' ,.-. :
4.2.4 DISCHARG:~.T~~.IPERATURE
...... .. '._

... .-......./
.........
........
wfiefe :p.,
: ... .~.
............
..
T: ' - Discharge temperature, OK.
T:. Suction temperature, OK.
P,, Pa: Discharge and suction absolute pressure.
I4: Polytropic efficiency (see section 4.2.1).
 paw
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
COMPRESSORS 13
PROCESS MANUAL (DATA BOOK)
........
;
,
...' ..
I.......

.
a::

.......... i:
.........
. . . I:
;.;i...:. .......
4.2.5 NUMBER OF WHEELS : ...... .-:,
......... <. ,
;,.
.
'
. ....:. . ...;
,
...
.....
The following guidelines may be followed : ;/'. ;. '"-.
.........
The maximum polytropl<head for a single wheel &&! ......th&.&nge of 10000 to 12000
.......>.-............
feet (10 000 feet cor@&$rids to about 30 KJIKg).-, ...:
.......... '.. :'. ': ,.-. *'
A casing may q&in..:irp.' ...to ..
.:.,
8 wheels (or.......
.dv@n.:lO,,:'
.............
_
. if they are small), with the
.-........ ..........:
following guideline& . _.........
. ..I
lnte&mg-fd"e inlet and one o;ifle#).Yilfnecessitateremoval of 1 wheel,
.....
i.e.::$e&t$mg can only contain~&+~=~wheels.
:;.. ". ........
.
. .(&let or outlet) does not modify the
.#he':,+res&nce of a side .sfream.
,..:::m~mum number of whet?&. . .'! .i
;: :.., . ........ ,',:
~he!.&~rokhateminimum nu#@&-wheesl required for a given polybopic head
&.
,, ,
...
&&hdlecular weight ca~'&.&&ined
..............
using the following chart :
. '
.
.. ,.]
, ,, 1
.
.:
.............I. ; ......
';
.I......

.':
. ....
. . ;' .<.... ,
:
:...........
..
:C
:.,. .._. .-.. “... '.;
%,

....... ...... " ' Fiaure 7

;.. ..,.-..',,.'.... GPSA SI 1980
:. .:. <:,.....;
... .................. ,. Wheels required . .
................
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE ~ g a

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) COMPRESSORS 14

........
, ,, '.
.....
4.2.6 INTAKE FLOW
:
ij
. : :. .
,,..> .........-,.;:
For a centrifugal compressor, the maximum volume flow at $qdimp "tdditions is
approximately 170 000 actual m3/h(i.e. -100 000 ACFM). .-..:... .....:/,/
..............
,>
I;
..... .... ;

Should the flow become close f ~ m t h i value,

/. .... .'; s a split flow com~&s6&,may be required.
........ ......
..........
.
;: ; *. .
.........
..-..
, .
I:../:

. :
: ...'.... :..-.......
...........
,
.......... . <. ....:.....; ..:
<.
% *

Suction flow Number o&he$k) Speed for Hp of 3@?.-.:::j'. Notes

per,&.. ':: ............
...............
........... .........
rsrl mah
Q < 800 . ........
.......
.....>....
........
, ..
.
J
wm. .: ,.....
up to 2b.W~'....... Special compressor
800-12000 .:...... .:;,;f?)..,:: l,~Sq'.. ..)
12000-34000 . ........
......
:_-.. .. '4
. . ....9 .4i'&i.'...,
......
i .6~00;;
i: i' . ..::..
34 000- 56 000 ,. ,. .*.a,.
-.
56 000-94 000 8 ;,.,..., .
941)0&136000 ,.> ............. 8 , ..... .. :....
:'*.yo
136 000- 195 000,!;.' ,.;> ........ 8 ........
'... :. $600 Simple or split flow
195 000- 245
245 000 - 340.bop
. ..<.. "
@...:..' . ::'
.........
7
7
..........
.....
I.::
....::
';'"...: 2 8oo
2 500
Split flow
Split flow
. .....
::........
i
'
.
.....':
.......
.'.,..
.....,
:';,.....:.......
....
:: ;.;-.; :
....fic$m.&ufacturers
Source :Catalogues
............... and GPSA 1980.
.I._.-
,. .........:,:....
. -.
...............
>. ......
(. ...............
*;. .............
4.2.7 SPEED VARIATION. "......'
,-....:.
............_
:
01 Mi-.: Pur
z=K
Nt
.
:.'.*...,,:.;
( N
1 BG; =
NI
(N;)
3

......
..........'::
where :/ ................
.,:. ..:
i :

N : &ed:,in rpm,
~:;.V&ure
l flow,
. P&ropic head,
p'..."..@;orbed
u ....... power.
 GUIDE DOCUMENT
IrJluldbY Bool n- ENpU"' Rn.

GE I 312 1 1.1.2 ( VII I 0

Psw
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COMPRESSORS 15

.. .......
4.2.8 SAMPLE CALCULATION
..........
.
,
. ..:
.
.=
: .
: r a.

......... ,:i :.i

Compression of hydrocarbon gas with a molecular weight of 2a$$;.i i&aff;26.5
:. ..:.,..' ,'.> bar ab5
-35 OC to 43.59 bar abs.
..............
.......
. .. .
: ,:
Molar flow
,
: 5 891.7 kmollh ,.
.' .._
.::,::
......
Estimated compressibility factor : z = 0.786 -.....
...... .*=._ .... ...
'-\

.:... ': .
.... -. .:
a. Suction volume flow i:::'..,.:: ...........
.,.-;
......
........
. :...,.:
........... .. . . :..-..'-..'
;,
."
:. .: ..... .:
(PV = nzRT) Q %:~:786&13.314x (
~.=.&&..ji; 103
,
,,, .............
273.16-35
) .... 5;89il~...Pj.
-...:..'
....
:............, .
........
..........
. . . ..,.:
.. :. I..

. .
Type of compreks.@r..:&htrifugal (vertically-ff;ZIik~s'i~ arrangement), or reciprocating
. .
chart in sectipn.3:?y:..I:i ,...........;-......
.. i
.....
.._.___
,. ._
'..,'.. .., . .... ..,
;', .....
,.....
. ..:
.......
~
. :::
........
b. k ca~.c~ati&: ;':,..-: ...........
.-..
.:
,
:. ........'.. : :.. ,
: : .... .-,
/ , ............ ..<......
~rothh!di@? 3.1, with MW = 22,Oi:aR$.~= -35 OC, k = 1.28
. ~.. ~ l k i.~ s l j i t isection
~ , ~from 3.2 f6r:&i-1o;;i composition).
.' -..
::.-....
.......
......
.
i... ........
..'./, ....
....
c. Polvtropic efficiency.:....' . .;. . .......
!
.
..
. .,:
c.:
............
i .I
'.
From section 4.2.1 ,:&i&'.~.s.3.46 x103 m3/h, = 0.716
.>.,: ......
.*-.-....

.. ..
.......
,
: : :;
Hp = 37;9%~lkg that is 37.97 x 101.94 = 3 871 m
w,.j ~ ..J ~ & . ~ f . h e:eprobably
~; Is 2
.: . ...: ::
I

..e:..;-
.'..-
I.

,.-.... .___.
:
/,........
.. p ".:$
,
E;07$3x37.97 = 1912 kW (1700 kW from chart in section 4.1)
........
. .

f. Discharae temoerature :
 GUIDE DOCUMENT
r bswiby sm*W ch.paw RN,

PROCESS ENGINEERING DESIGN GUIDE pqe

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COMPRESSORS 16

......... .
...". .....
::.'.., '.: ::
;
8. ;'
,..>;...... -.*.:,,:
......
5 AXIAL COMPRESSORS .. <.,. .:;,-, ,,.:..I
...I

....
;
...............: .:;'
.'/
The calculation is identical to that of centrifugal compre*., with' the following
exceptions . :.....,-...
..-....
.'..-.. ....:5
:
.......... i.

,':..'.,..,,:..,.'.
, <. -..
........ :. ..............
.....; .i....:..... :
..........
........ .: < .,. : .::
.
: ,..-.
.:..........
:
5.1. POLYTROPIC EFFICIE&+.:'....~;;:. .. .. .........-,,.'
..,,.....
......... h,.'... ............."
.: .............. : . . i

Polytropic efficiency @4ji&ec.Fan

............. : ..... ..-
for centrifugal,cpm&e'ss'&s.
.............
. . ...._'.,
Typical value for c$~jdtidri:
..-.......
..;........
= 80 to 85 Y',.;;::::....:.::
. . ' :. ,i
::
' . '' /.
5 ,

.......
:..... .. ..
:i'.
:.........
.......
:.. ,:.
I \
............. '............
_..
......
; '..,
,
.,.
"
._
.......... :.. .....;.........
'

............
.....
......
5.2. S U C T, I ~ . ~ F ( O Y ~ ~
.. .. .............
..... , :.!:. ....,.
,,.'
..: ......
~his&&hf .,
&kpressor requires a.ihbjmum suction volume flow of about 50 000 m3Ih
to p6rfo~~&tisfactorily. ,......
..........
...........
.... :<. .; ,: :
5.3. '...'......':. .'
MAXIMUM PRESSURE ,?...........I
........
,........5%. ...
Discharge pressure.....
is.'ljmited-to 30 bar abs.
(, .......:....
-
,,.:...............
:. .. ... .. .. ..
......... . .'.
*,s,,
.......... -._
....... ._ ..
:

,,. ,-... : ...

i

.I

::..*...,.:..'
.--..
..... ..... I

....:.-.: :
..........
... .., ...... \
.
.........
.. :: :
...-
...... .
: ...........
.., ...
,
: :
.
...........
:.
~ ... ::,::
..........
3
i
C
i<
2
,"
U
 GUIDE DOCUMENT
I kaved by Brrmlr aup*rw Rn

PROCESS ENGINEERING DESIGN GUIDE ~ g e

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) COMPRESSORS 17

.......
6 RECIPROCATING COMPRESSORS ii/
......,.--.....
:
.'..
.: :,
. .
.... .. .: ... ......-. .
.......... :,:

i
. '
.. ..":, :'

,. . .. <.....:..,:
C.'
6.1 ESTIMATION FROM CHART
......"...
.. .. .......
From the k value calculated in section 3, the following c&$Hays
compression horsepower,.rj5~~irements. .....
....... ......: an easy estimation of
':. '.,....:.:. ...............:,
.............. .
Fiaure 8 - Estimation af.&m&ssion
....... horsepower fdr.&$iCh&ting compressors
.'......
.... "..........(from ~reusot-~oi~).>.~.'.~~,*:..'
..--.....::1.;,'-../
.; .............
...........:
;'..........
................
........ .........
:."..........
.......
.... ..:,..... ',
.../....:
...? ....

.........
,.---. -:
...........
. .....
.,........_'.......... \
:
I :
.. \\
..--. ,'.:
..............
;
:."
.-.. \

:. .'. i ' : w 2

................ . 'Tn,r n
:i
.........
 GUIDE DOCUMENT .
w by wmn dumn ~ v .

GE I 312 1 1.1.2 / VII I 0

PROCESS ENGINEERING DESIGN GUIDE pxp

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) COMPRESSORS 18

6.2 PERFORMANCE CALCULATION

6.2.1 NUMBER OF STAGES AND DISCHARGE TEMPERATUREA..:".-:.

......
.,.",,,..*.., .. ,:....... ..".':
The number of stages is estin?b.bd.l5ased
...... ......y-.. ... :
on the following~okifiYia
<. .....:.... , :...<. .::/ ....: :.: .
..$
.

a. The discharge [email protected]?.:$=ach stage shall fid:sxize* 180 OC. For dry piston
compressors with~Tefldh..segments,the di~ct@r&.*~;i'&tin~ temperature shall be
., ..
limited to 135 1 iAb.*p:,"-.-'
...........
........'-:
.............
. . ..
.......:... :., .............
The dischargFtq&k$ture ......., is calculated;...-. by:.>:) ....
_..-._ . . .,:.
9. .
..t.. ............\:.,:..
Tr = Ta ] .......
............
.. . ... .. ......'.:. ....
:.....: i ...,
'.: ....>.-..o: .. ;...........
, 6.I?:'.',:'. . ....,..
,. &charge and sucti$:&?~petatures, O K
, ......... ~schargeand suc$ii'$bsdlute pressures.
:
........... .....I.. Adiabatic exponen:t;~&lculated in section 3.
..........
:,,. ......... ...:I

:: <;..-..::
This temperature is @e...i* al adiabatic compression temperature, not to be
confused with the .:';iischar& temperature of centrifugal compressors (refer to

.........
........
It does not,.,:jfak&..i:& account frictional losses and the non-reversibility of
compression 'dp&d The actual discharge temperature will be calculated by the
comPressdi:ji!hufacturer.
.. I The temperature increase (T, - T.) will usually raise by
10 to 15.21.: ...
... ._
, . :
..,: : ;

The..tt$eo.dti@l discharge temperature given in Figure 9 is derived from this

&&$. ..“..."
... :::
.,...........:
,

,.---i
.
..........
b'.'he':$otal
a , compression ratio is obtained by multiplying the stage-wise compression
......'..rati%, taking into account pressure drop through intercoolers.
........
 GUIDE DOCUMENT

paps
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COMPRESSORS 19
 GUIDE DOCUMENT --
by B m iN madern RN.

GE I 312 1 1.1.2 1 VII ( o

- -

PROCESS ENGINEERING DESIGN GUIDE a

p e

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) COMPRESSORS 20

.........
,.--...;
......
.I

6.2.2 ADIABATIC POWER ,,; .,

,..,.':'...-..'..-,,.;:.' :
. a

The adiabatic power for each stage is calculated by :

.:. ...> .......
:
.,' ". ,.,., .,-;"
........
. > ....... .:..
Om .!.. ....... ......
P i = m ~ m x ~ x ~ a i x & x [ ( ~ )- 11 ,. .....
:'/-..
........
...... ............
......... :. <....
Pi : Adiabatic power, W,j/ . .......
...-.. ....
..'.....i....:..... >
k: Adiabatic expo@dk;..'..-, ,-. <.-.:.,.--;j
Pd, P, : Stage idischaf&:&e~$udion absolute pK&t&w3i:..:
R: Universal Slas&&it 8.314 ~~lkrno~g,..?.'......~.
..........
Qm : Molar flowi.lcmgb4t;-." ........:
.....................
&: ~vera~e'&$&gsibilit~, :.. .....
Tai : Stag~i.~.~$;&mperature,
.....
.. ........:. .
OK. ................. :..
.............
. .. :/ .....
.:
;':.--' ,.:..., .
. . . . . . I a5 ,

....................
.
1.. ::
ii
. . :: ............
................ ;'.. ....;.-.-..,
6.2.3 TOTAL .&&&P'C~'~ER
'..' '
......
,: : ,
...........
i-.: ".......
......... :;/
.....I.. .; .........
.:. ,: ;.; ......;:
A g!&al.effi'&cy is determined fo~.$w
... .; stage with the following procedure :
.

:
.....I

.......
...

*,.'
An aver$= value of 75 % is,&-Wdered,
:,. ,, .'..
and correction factors added :
:., . C.?.:
.::
a. Ifthe adiabatic DoweF..d...:.......'...
.. .!>....
. .........
>.____
-
Lower than $ 5 . ~.........
- Non applicable method
Between 15 k$4$.$.~ -5%
Between 40 k ~ a d t l kW
b - 3%
Between $b~.&d 220 kW 0
~ g * , ban 2% k~ + 3%
. . ..:
....:
.......5
._---.
;...“...
.......
.:. ,*..; .....:. ...
..
b. ...lf ~ e b $ ~ r e s s i oratio
n for the considered staoe is :
/,.... ; -""
.-.,
::
:. ........:j Lowerthanl.10 Non applicable method
""'-'.Between 1.10 and 120 -5%
Between 1.20 and 1.70 -3 %
Between 1.70 and 2.50 0
Higher than 2.50 +3%
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COMPRESSORS 21

,..........
,..-.... .:
/.... : ::
:.......
' I'

,.>
,:,. ..-:......
,::
c. If the aas molecular weiaht is : ........
.
:
'
. <. .;,.. ,.,>
- -.. . ,.
+ 3 %.:,' ..... ... ,I,
s
Between 2 and 10
Between 10 and 30 w':.;. .:. ..
....
Between 30 and %.-:; -Q.%... .:
..-..
Higher than @..)"( .,.;.-.,4$:..3
i..I.__ ..
;........"... i (, .........-.:. :
...........
............
._........
.. .> .:., ...
...........:.
.-........,;: .. ," .
...:'...'.... ..
..............
.: ..:........... ....
d. If oil traces&$lwed . . . . . in aas : ...........
. ...,./ ......:
......
.........
.............. ..........
I.....
,
. ....': . : ...................
.. . .. ..
Yes .... ....
.. .
.
0
No
I. : ._
:....
. .: ..... ..j
.
, :..
.........'/''
: .
:
-4 %
,<
* , . ,.'
:.. ..........."
:\
..................
. .
,
..;.. . . . . ....
::. ..."...;.....?,.
...................
; .' ' :
: .......... ,-:
,
......... .:. ;, :.
..............
. .... . .
: .: :
.Tfie tdter,Ijower is :
...:'.......
.,..........
P = X.4
,

?!.-. <.: '

. .... ..
: .....;'. ..-.. ,
;:. ,....:........
::
:.
;:;-. .: ';
;

6.2.4 ....I.
SAMPLE CALCU~&#:::~~":
......>:,:'.
,-. .
Compression pf.t)wca&n gas with a given composition (MW = 22.3), from 7 bar abs
and 40 OC tq$i:5$af:abs, using a reciprocating compressor.
Flow : 5915'$?g/ti....:;:
.......____ ._
~verage,&&ssibility fador : 0.975
. .
. .........: ...,,
......
.", ;:
k&l"uIation :
a. ........
. . . . ....:
..............
Ge composition is known. A detailed calculation can be done from the method
.---,bas&
........
...... in section 3.2.
i'
*
.:,
. .--h.'$1.23
I."... ,
........
. .
b. Number of staaes :

If one stage only, the compression ratio is : r = 21.5 17 = 3.07

.*
-
(k I ) l k = 0.187 T, = (273 + 40) (3.07)0.'87
T,= 113OC

Discharge temperature is acceptable. A single-stage compressor can be selected.

 GUIDE DOCUMENT -.
by -6 dup(orW RN.

GE I 312 1 1.1.2 1 VII I o

PROCESS ENGINEERING DESIGN GUIDE p.0~

PART 1 SECTION 1- S.S. 1.2 : PROCESS EQUIPMENT - --

PROCESS MANUAL (DATA BOOK) COMPRESSORS 22

.......... ..
,, .,.-.
~ ~ -.

' 8'. "..:': . a .

c. Adiabatic Dower calculation :
,..>:

/'./. ,..>.......... -
< . :<.
........ . ......
.,-:,
P = SX h x 0 . 9 7 5 x8.314 x * x (273 + 40) x (3.07°.'87 - 1) ,;.( ........
..,/..........: ...,.'
.....
:.......
,.......
-~

P = 234 kW ....: :; 'I....... ....

.',
<.'........
/', %
,..

..............
. ..:>".. .......>
,..,,.'
'-..
..............
,._. ........
<....:
,A. i
. .._..
": [ '.
-'
. : : :; ,-A-.

d. Total shaft ~ o w e~a1cu~on‘l-l r . .

..............
....
.
...........
..........I.

(.............
............I
..
...........
-::
,' 2
i

...... %
.....I.........
Global efficiency : bas&-;..% .......% :... ..:....
.... .../
. '.. .._
................
.........I
.:. .'. . .: .....
P > 220 k w . . . %, . . . ._
...-..> .........
r > 2.5 ;:.-.' ; ...:. $dd +3 %, ..............
I :

.......
.........
..... ::
:: s .
......
: :.-.
MW =,2$.3.. . . ..I::<.: add 0 %. . :... ............
......... - . -..
.
: ....

i.e. a ,.gt&&.&&Qncy
.........
...........
,.. ....
:.. ,":

..... p of: 81 %
..
.......
.
,,
; .
.'.. .:
"..
......: : ......::
i.,.,:.
....: : '..,
;.'..............
....:

e. Com~arisonwith actual&u&$ h m manufacturers :

.............
................ /

........
......... .:,......
Manufacturer ,,4&k$lt;band Worthington Technip estimation .. .)-
Shaft power (w /..'............
. . .:&
. 289 289
Discharge temperature q.,..; : '.'.'I 12 120 113
...............
...--.... .....
. .
.'.....
.., :. :,
;
1

._ :'
'.. '..; .I
............
............:
.:.:......
........
. ":., .
..--.. .........
.............
a. I :

; ,.-.. .
:
::
,. .
,
I .
'.
.

.......... ::,:
\
*

a ..........

i<
0

i
;;
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE hpe

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) COMPRESSORS 23

.......
,......
.....
. .: :.,
,,',
7 BLOWERS . i Z,

;., ........
. -,: /.I
.. ..: ,. .._
Fiaure 10 - Estimation of power and speed for bloyi&&;~'
.3
.....
:.. ........
(from NEU)
i:
..:....
. . ........
..
........
. . ......
:.,. ........

,
,:C
. .-:,
...
...I.....
:.,'

.......
....
......
..........
.........; :
..........
.... . . ... ..
..:.. ::
POWER AND SPEED CALCULATION
,.--. .......... "
,.,;............
......
:: k<?ower Diagram B- Speed Diagram Example, blower no77
i :. :
'.. '..-~$*bmto eslimate the absorbed it a l k s to eslimate the rotating CR:1.68 CR:l.68
.....*.
Pmcedure (0 (dlow :
speedofmeblower.
M u r e to follow :
Po:10332mmHP
Q :49.000 m'lh
To:25*:
N:??
P=103OkW N= W f p m
I.CR: read the ampression ratio on 1. CR: read the compression ratio m
the first diagram the fintd i i m .
2. Po :Suction pressure in mm H a 2. To :Suction temperalure (*:I

3. Q :Suction Row rate in m'lh 3. Blower number (fmm the first

o m )
4. The absorbed power is estimated. 4. The mtating sped is estimated in rpm.
in kW.
 GUIDE DOCUMENT
Irartdby Bmi* mwsr"' Pa".

GE I 312 1 1.1.2 1 VII / o

PROCESS ENGINEERING DESIGN GUIDE

-
PART 1 SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) COMPRESSORS 24

8 INSTRUMENT AND SERVICE AIR COMPRESSORS FIGURE;??-...

..' (,.. .-... .,. I
 GUIDE DOCUMENT
by Bmk no c!wwn" RW.

GE I 312 1 1.1.2 1 Vlll 1 o

PROCESS ENGINEERING DESIGN GUIDE

-
PART 1 SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

8 ,
i

B
j
B
.-
S

$
5
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE

PART 1- SECTION 1
PROCESS MANUAL (DATA BOOK)
S.S. 1.2 : PROCESS EQUIPMENT
PUMPS
-
1

........
..........
,
.....
. *,
( '.
i :'
..
...
.:...
. .
;.I.' .:."..-..;- ;. ;j,;

:.'
.....
(./</ ,>
.....:/.'.
....;.:... .. .:....;'
CONTENTS
.. ,.....-...
:....;.j..
...... ..... ..,,..:..:
.......
'
..........
. ".' :. ;:. . .
..-.............
,,
_ -. .'..:
. . I

...;... :-..-.:.
............
.... (1, ,*:..':,..-: .:,....:
,'..'............... .................. .
%.

1. PUMPSELEC~'~O$.~ .....-. : ..........

.................-
.: ..:.-......... .........
...........
I' I.. .>
1.I ~&:sG!+ion
.
..:..............
.
,..;,.... :
.
1.2 ~lo'&+ti:0l
'..,.,.. '..: ..~,._
........:...
(
...... .. .....................
.
. :.. .:...
2. CENTRIP~@AL PUMPS .
.,,.
.:: :. :. ...........
~

I
\ 3 , ,_.._ .. /
..................
..; 2~2:....l&dence of main *&fig
.......- . . . . . parameters
;
' ,.: :, ,: ........... .L

:: .....',,.' ,.;;;2.1 -1
................ Modif@airdh.@impellefls speed (n, rpm)
,
......
.,:......... ,; 2.1.2 ~od@i'~on of impeller's diameter
:, .._ ..
I_... ........
. . 2.1.3 NPSH'...;: .,
....... .....
2.2 Main feat&*'&cenbifugal : I,...... pumps
.; ,:
2-21 .>..'..&aps
. . operating i n parallel
2.2.2 ....:::::lqting point
2.2h -:::--.---Minimum flow
2$:4::'..:>?
;
Materials of construction
'..'..
'.......
:: . .
2.3-.-&le&&nof centrifugal pumps
. .
?.%:-.~&r estimation
......... ,:
::..'.. ..:.! 2.4.1 Shaft power
......".........
........... 2.42 Pump efficiency
.......
......
,. ..
: :
' 2.4.3 Viscosity correction factor
.. .. , 2.4.4 Eledi~cal motor efficiency
..................
.-.. 2.4.5 Criteria for motor selection
.,' ~.
.
,I

,:
..
......... .'.:.
:: Power at reduced capacity
:, ,. 2.4.6
.......... 2.4.7 Pump suction specfic speed Nss

3. OTHER TYPES OF PUMPS

4. IMPACT OF DISSOLVED GASES ON THE NPSH

 GUIDE DOCUMENT
I b u d by

page
PROCESS ENGINEERING DESIGN GUIDE
PART 1- SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) PUMPS 2

1 PUMP SELECTION

1.I PUMP SELECTION DIAGRAM

.., - .._.
...:.,. -......-.:':.
,i._

Refer to the selection chart enclg~.ed

. . . . overleaf. ' ..
.. .-. ' ......
;:. '..;.:': :
.<
..
,
........ .
.....
The borderlines of the vaibu'S..qieas are conservativ$~:%k$.:ih'by be exceeded after
mechanical department a&f&l.$"based
......... .-/
........
on vendofsba&~.,.~:~:
..................
;.-.....2,... ..........
.......
For reciprocating and &*purhps, also refer to th&~=s.biven on pages 13 8 14.
............
:. . ..........
. . . .....:
.. .......:......
As a general rul=;&tt@gal pumps should &&:be preferred whenever they can be
used, since they.€et;&:@ bk cheaper and mofe"ie'&~le
. ...-..,. .?.-..,...:.
:
;
.:'... '......".,, ..
,

They should'&.ner@& . :.-...

.............~not be considerep:i"fhe-fotlowing cases
.. , ;.. ........-.....:
HiQ~$s&is&-(>400 cSt) .............
. . . . . head at low flgt+rqte?...~:
H@$&&I:B~~~I
..........
; . . ... ......
.,:........
L ....
._ ..........
'.;
: ......
....... ......./'.
.........
1.2 FLOW CONTROL i.::: ..-.::
<..-.:
. .
.............. <

Whatever the type of p&p:i~4h6 flow can always be controlled by adjusting the speed;
At a fixed speed, &&y-'
&-.
't$ten ;
............ adjusted through control valve, throttling valve, etc.
.............
............
; '.
‘............
.,..,.. .'.. ......
.%
.;
:,
,...... , .
..---. _____ .....
....... ....,..
..:..-..: ::I'

:: ....
. .......
.: :
.......:
........
.............
.;.: .....
,:'.5 .
~
.. ..
'.
._._. .........
. ,,:
..............
/;....'
.. ..':, ~
,
..
.........:.
::..
..........
 GUIDE DOCUMENT
W by 80*v -fl ~ev.

GE I 312 1 1.1.2 1 Vlll I 0

PROCESS ENGINEERING DESIGN GUIDE Rs.

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) PUMPS 3

,,.-.._
PUMP SELECTION DIAGRAM ,.'.,.... '....'.
i j ., ,.
. . i;
.,
,2] '..... ..-,'.,..
 GUIDE DOCUMENT
k m d ~ y m n . -n w.
GE I 312 1 1.1.2 ( Vlil I o

PROCESS ENGINEERING DESIGN GUIDE pope

PART 1- SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) PUMPS 4

2 CENTRIFUGAL PUMPS

2.1 INCIDENCE OF MAIN OPERATING PARAMETERS

;
. :...'....
i..........
.......
.......
,,
...... '.. :
...........
,. .: :j ..-...........
.....
2.1.1 ... ..
MODIFICATION OF IMPELLEF?&PEED (n, rpm) >
:.:, ,
.:!
....... : :
.... .............
?
........".'
............
.....
....... .'...,.... . . . ..
..>
................
................. ...........
For a given geometry ::..-,::: ......, .. :........ ...:
:.
...............
.._............ .....
: . : ,. .....
>
: .2,,'.
.......
. .
The flow rate.:~$.&$dt$Pr~portional to n,.,;::::-..>..:::
The head I$~is'&&y proportional to @'{ .: j
The powe@'is&&tly proportionaltg.*.'@t.fbied efficiency)
The eftide:w.:i,.hot affected s i g n * ? & speed modification, excepted for low
s p ~.$. '.~.' .n i f i f s l i g h tdecrease&
ly .....-....{...... ..
.,-..,
,;..,. ..........
: '-.,:'
.
+.:-, :... .......... . .... ...I
, ;
. < .... ,: :.
2.1 1 : .....
MO , € $ J ~ ~ TOF
I~NIMPELLER'S.-.EIER .. -
........
.. .I
.: ....
/",.,.-.
',:.'.
'

At a given speed i. :. ;:....

-. . :?
....... *........
\..........,,,,..
The Impeller shape"ofPe~
- : :..
a constant cross sectional area (exit velocity triangles
<
remain similar) : -.:.............
......
.........
The ROW yke.k4&y proportional to D
........
The head'e.is"didctly proportional to DZ
The p6wer.piq
.... ...... directly proportionalto D1 (at fixed efficiency).
....,..,.-.:.
,' ,,
: *..,..:/
The .....
cixkqzL@onal area through the impeller increases with the diameter.
..- -. ......
...........
.:iTh&~ffpw
.
~ rate is directly proportional to DZ
-.,Thewead H is directly proportionalto DZ
........
:2'
-4 P is directly proportional to D (at fixed efficiency)
, :..
........:?fie efficiency slightly decreases when the impeller's diameter is reduced.
. ........
...
2.1.3 NPSH

It is directly proportional to rP, but does not vary with the diameter of the impeller
I
(provided that the diameter reduction is less than 20 %). The use of inducers allows to
decrease the NPSH required.

n : impeller speed (revolution per minute, rpm)

 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE ~ a e

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) PUMPS 5

.........
.........
2.2 MAIN FEATURES OF CENTRIFUGAL PUMPS
,.'(,' ... .:
. ::
,I?.-...'..it
. 8
:

.. ..........-";,.'
'
. . ; ,,.;
2.2.1 PUMPS OPERATING IN PARALLEL .. .....
.. ...I....:'./.
,,
: r
._.......
The performance curves should be drooping as m u c l ~ $ ~ - ~ ~ . s to
i b lprovide
e a good
operating stability. This @n-+ achieved if the angle!:b+w&n'impeller blades is less
than 180 , which entails 8 W p t reduction in pump effic@ij;:-..
:..... .....
5.. "..
............
................ +
I.
...;.......
.'
. :..... .:
y..
.

2.2.2
....:'.....'... ........
RATING POINT ;.......:I;.....
............._ ..
'.."/,.
...'?.. ...........
I. ............."
. . .........
..................
.......
The pump ratI?g..pqm! shall be l o c a t e & s . l as possible from the maximum
efficiency , k.: ..'
t &autd'iiot
/ -..' go beyond in te&s.of.fjow
..... rate.
... ,................
. ..
...-.:..,.......
'. .:........
,.
. <

2.2.3
MINIM$.gL&.,' 5
'.
.......
,
' .'
i
5 :

................
' :: ;'.............
.... ..i ...,
I,,;

A m~&,J'kfl&wshall always d~&&63ihed in a centrifugal pump. This may require a

rp&&~~~~:~automaticrecira&$~h$pass (restriction orifice, valve or "schroeder
. . .
.'..&e&w&e).
. c.-....,:.,/
'.. ......
.... ...:
%_
:?-..
: ......
.-..;. Gy the pump supplier. It is usually 20 to 30 % of the
~ h e k i n i m u mflow is -.@fied
nominal flow, except& :.;.'..Lfor".Bigh-speed
.. pumps, for which performance curves are
bell-shaped and the m ! n ~ . ~ f l o w can be up to 50% of normal flow.
.....
.........
. ._. .. ,'
....
,,--.....>:,.'-..

2.2.4 ,.
MATERIALS ~.W.NS~RUCTION
...........
........
; . . './
.,
Refer to the\.t8bk.&osed overleaf.
.......> .
:.,.........
._ i
....
..... .....
:..-.
' :.. ;;
:
:
.......
. .. .'.... .
........
.............
......... . .. :.::..:. . .
*
#
,
....... .
,........I.
: .............
:.'.....
:: . ..'
:. ..
....
........
.........
.::
 GUIDE DOCUMENT
'YYadLy w v -v &.
GE I 312 1 1.1.2 1 Vlll ( 0
\

PROCESS ENGINEERING DESIGN GUIDE ~ g a

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT --

PROCESS MANUAL (DATA BOOK) PUMPS 6

.......
2.3 SELECTION OF CENTRIFUGAL PUMPS ,,.......
. ...:
,
.,
. . ",:,.;.
: .._
........
, , ..
The main characteristics of various types of centrifugal pumps ar6~,~1~ih&wi=ed in the
: .........?
following table: .-...............(,,.' ..
.,. ...
I
.....

'1
9

doublestage
pump
250
.,.,. i..+60~j;
...
.,;.: ............
a

35 w-:
.....
i...l@to
.. .. ...
..........
: '-%
75 2 to 5 Valve moderate

.,..,.,. ......
multi-stage 150&.:'. .!..' ,.1 140 .:j+~..,~::l0 to 80 3 to 8 Valve moderate
, ,
pump :.. ...I .: ......:,,:
.....
.............
.., ... ,'.
. ....
. .'-;
.,
..: ...-... ....
.............
::
.'.".... .::
(
;
. ;,, (

.....................
:. .............
'..............
...:., ...
, ..............
-.
..............
,
. ......... .)
.;\.~.. .....:...........
... :
....... .> .. . . .
::........“. ...
........ ....,,
;-. ; ::
.'.'...........
,

I
...... . '....:
....:....
...........
.,.:.:. . ......
~.. .
_--.. ........... ;..
............
\
.......
:: .
.,'.~.
..,:.
:
:.........
: '.
..........

i
e3
s
 GUIDE DOCUMENT
&-d by sxun- uMan. (Uv

GE ( 312 1 1.1.2 ( V~II ( o

PROCESS ENGINEERING DESIGN GUIDE h

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) PUMPS 7

MATERIAL SELECTION TABLE FOR CENTRIFUGAL PUMPS..."\

::: .. ..
 GUIDE DOCUMENT

RSS
PROCESS ENGINEERING DESIGN GUIDE
-
PART 1 SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
8
PROCESS MANUAL (DATA BOOK) PUMPS

..........,
MATERIAL SELECTION TABLE FOR CENTRIFUGAL PUMPS ..........
..
: :i. j.... . .:, .:
a

,.'; .... ".; ;

H-2 API Stvldud 610 (8th E
- . P$ ....../
: ...;.,. : ."?
................ ..,..
.
.' '.. . . . . .
...
.,;'.........
....
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE p.w

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) PUMPS 9

.........
..........
,'/
'... ,.
:
: ...
............ ,:;) I
,:;. ............ " .'
I < , :.
: ,.-:
. . .<. .;.' . ."
.
.
........
..........
.,, .. ........
.....
,

<;,."........-..
'
,.-.. -.:
API Standard 61% .-
.I '.:
<:....,.:/,
(8th Edition - A ~ & . ~ s s ).,'
............
. . . .
.
..;....... . .
. . . ..... . ........ 1,.-..'.....'
.....
/.. ..:..; . .:
....................
:......,.......
... . '..." .
.................
,
....... ...........:.
.........A . ..: : ..........
':..-:: ......... ........ ..,:
.,. . '..; .
-
...........
, .
.............. .. .?'...:..........
:

... :...... ...._',..

'-;

' j ....
...... .. ..,....... . ..............
.:................
-.i

,. ........_...,.._.. . .. .,
:~ . C m m + b U ~ - m U & . * N D ~ * 1 1 . 1 1 0 1 W
. .'.., .::. ...............
.-..
.:,.':............
i .

,._..
3 #

&*iz;;-
.:.-.
I....

,. :..
........... ..;
;
.............. . .
. .
1. ~ ~ . l i d r i s h d c t ~ o ~ ~ i p l i ' 9 ~ ~ ~ ~ 3 0 ~ # 5 . 3 0 ) . 3 1 4 # 1 . r l
pllk++kibiirdche~willd+..:
2~ o l & ; ~ ~ r i m ~ ~ ; : ~ d ~ i . ~ c L o r ~ . ~ t
s h m r ~ ~ ~ s ~ . ~ 7 . ~ + l q d ~ 1 . ~ r m i * w ~ v ~ ~ ) - ~ u c i l h . ~ 1 ~ 4 1
;, ..............
vialiquidwillilbv. ; : <,..*..;
3.lJdasochar~arpsdfis0mc~~brr~~md&rpcdt~~~faadlr(lp~doallr~
~~cbcnndad*.'hrcbibropoPL~mbnbbda(~.r~g*rrrLcda-
rea064)aibcuccd--rrh.rw60dW.ulPrb.tgdepc~dslolltk-
dthaprmpodliqd :. .:.. .........
..............
4. ~ a ~ ~ 4 . m C . b . ~ ~ ~ ~ ~ p & a s 175.CO~aifdforboibhd
b m m c i f ~ ~ d
-(ace Appendix ~i~%&€&!)c.
..
5. ~ ( ~ d r h ~ .l...b
....c ~ . ~ i c h a
mbin. / .,-..;;!
a~ ~ . l i m & j ; , & t ~ u e ~ a ~ p . ~ c n d ~ b b ~ ~ r r v ~
& a s sbp$~&iqh.i'ti~cr o w i d uipblc for mC m*L
......
. .'
..........
7. ~ l - ~ P c l i r i j & ~ r u b r a ~ l r c d f ~ l i q u i d t ~ s ~ i h m 4 ~ ( 1 1 o . ~ ) a l 0 r a b ~ r r ~ o d . l r c r * i a r
a. ~ ~ ~ ~ ~ ~ ~ 1 4 1 ~ d ~ b s l l r d f o r a o l - ~ ~ . I l a r * . d ~
..':
.. '.. .:
::
: I
',
...........
..........

-
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE p.w

PART I- SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) PUMPS 10

,...........
........ ..
,../'... . ,.:.:.
, ,

<
'. ......-,.,;
2.4 POWER ESTIMATION ..',..:, . ;.:,......
:' '...;:.'
I
,..'>.....
...........
,' .
,. . '. ...;.,..'
.
SHAFT POWER
..,. ...........'-....:
,
2.4.1
.i...

..:.:
:;
....... ,..
Q (m31h)x AP (bar) :, ,,.-.. : ....:.C.
.-.
P (kW) = 36 x (pump's e
)- ;.. . .j .:: ..-.\......
a:,
......... :. ,,.
;", ... :..-.....?
.................
,:".. .
. . . . . .? .. r.. /:...,.--.
........ .:
/'...:
I .

PUMP EFFICIENCY .................. . . . . . ......

.
..................... ..
2.42 ..........
.1;. ... : "
. ......... '
a
:
- '., ., '-.. '
. . . the chart [email protected].&&:.14.
It can be estimated @&g:bn. ......
........
. ..: ..... ...
,;..., ........... .........
..... ':.
,...........
. . .,. ...
2.4.3 VISCOSITY C ~ ~ T I OFACTOR
....I....

N .
:::.: .....
/ :. ."., - I.........

............. .......
...:. ...
It can be esti&t&$ased ., .
on the chat?&nc;f&~b;;r page 15.
....,/ ;..> ....... ._.........-..:' ( .,.
, ..
The in&h.@i.&mp .....
efficiency cay~<&jflcant above 5 cSt, especially in the case of
low tjd*
... a~id.l$
.......
pump head. .....
... .< . .:' .
........
...... .....i_

..-.
I....
.. , i

2.4.4 ELECTRICAL MOTOR EFF-NCY

; : ;I.-
. : ::
. .
It can be estimated basqI.4hw.gble enclosed on page 16.
.:.-;....
.._
,.........
The motor eficienCi&-a.re-&en for a 75 % load (from maximum power), which is
(1'' ......'..
,. .... ?
usually the case. ............
. .. . . . . .
For motors e F A n g '15 kW, the efficiency increases by 0.5 % at full load and
decreases by2:%at&hlfload.
a..:
.........".;,..; .
!

2.4.5 ......
CRITEWJ~&.MOTOR SELECTION
.. . . . .
# i .

A sta~ard.,$minal power shall be selected for the motor. The nominal power will be
w::&iidd'id nominal power immediately above the absorbed power at design
4&dii44s.
............
............
API 610 selection criteria shall be followed, i.e. the ratio of motor nominal power and
pump shaft power at rating point shall not be less than :

1.25 if the shaft power at rating point is < 22 kW

1.15 if the shaft power at rating point is from 22 to 55 kW
1.I if the shaft power at rating point is > 55 kW.
 GUIDE DOCUMENT
Urwdby Bmn- -w m.
GE I 312 I I . .1 Vlll 1 o

PROCESS ENGINEERING DESIGN GUIDE ~ L W

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) PUMPS 11
.........
.........
,. .....
. . .;;
(' ..
,'., .. -..,. "
When the pump is specified for open-valve start-up, the a b w w e r at maximum
flow (end of the curve flow Ihead) shall be considered to s&$cftheajhotor,excepted for
high specific velocity pumps for which the maximum a&rt&:#wer corresponds to
,, ..
minimum flow. <.;,' .......-..
Practically, to calculate thg:power at maximum flow @nd of'& curve flow Ihead), the
mechanical department;hi!l,.'k$nsider 125 % of the ~QW;&~.&€.P. (Best Efficiency Point).
.... (...
......... ;',,-., .........."
...... > <.' <.;,..-..:
The standard novi+l..:&$6rs of electric r~)~foc$::at$:given alongside with motor
efficiency values ,in.d@iap$l&
enclosed on paw'::16).~~y'
'....:';;:"....." ..............
........
Generally, lo~~$olf8&-:motors
(380 V) a r < i f & o n g as the nominal power does not
exceed 132.k*.&@ high voltage m o t q ~ - ( s & ; ~for
) higher values. However, the limit
between l&<;id.hiih voltage tends td:.ni'&k+&Iand a limit of 160 or even 200 kW may
be cons~&f@;'~his
.,----:
. . . , is usually defineck.ih.a
...... ~r$jectgeneral specification.
.. . .
:. : . . . ..
...-...
............
....-. ...
,.,..: . ..;'.. ........ .; ;;...
#

:
;.. ............
i......... ;

.. ,....,.'... ....)
: ;,' .,-: .....:'.. . .....,:
............. .,
.,&hi+'
:.... ..,, of calculations,~~< ...._ :.j ./
,
.......
,. .
:.: &&,
.......
. .
j.

'.I

...... .
........';..
:; . :
The shaft power req<i6,.fo;;a pump at design conditions is equal to 7 kW. From the
table given page l&.&:t$ikn :
.._
:,;.,.. ..
........
Motor effi&ficy.:--8~'% for a 7.5 kW motor
... .
Motor ef~&&;:86 % for a I 1 kW motor.
. . '... .'...
::

For the..7:5\& A t o r , the absorbed power is 7 I0.85 = 8.2 kw. This motor is not
accep,&e'fk&se the absorbed power (8.2) exceeds the nominal power (7.5).
;
. "..:-..:;!
I.
3 .

abmotor, the absorbed power is 7 10.86 = 8.1 kW. This motor is acceptable
~or'Ure:%!! kW
@&de
.... .,.. _ ..:
sorbed power (8.1) is lower than the nominal power (11).
' ..: :. .
,.._.
.... 'cti"hna
*
of the API 610 criteria :
.......... .....
..............
: . .
. F Q ~the 11 kW motor, the ratio (motor nominal power Ipump shaft power) equals 11 17
:

'-.----t:e.
1.57 > 1.25. The criteria is met.
 GUIDE DOCUMENT

Page
PROCESS ENGINEERING DESIGN GUIDE
PART 1- SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) PUMPS 12

.......
....
.:,.$.............: :.
a

Example no 2 . ......
, .
. .'..-.;;. ;
/>. ........
.;. .,.; .
The shaft power required for a pump at design conditions is eqy@t&4?&4w. From the
table given page 16, we obtain :
:
;...........
........ ..... L

...... . . ......
..
Motor efficiency : 87 % for.a.%&k~motor ,.........
.-.
.........
Motor efficiency : 88 % f&.$@5
....... kW motor. ......:..:....: ....
..........
.....
-.. "...'
.._.
(,'/%."/ ..
,..-..:.
For the 15 kW motor, w-aabsGrbedpower is 12.2Y:.p:47'?i 14 kW. This motor is ,

acceptable because th6sb3&ed ............ nominal power (15).

. .,..__ power (14) is lov&r.t~a$.the
...........
/ ............ . ..:
..............
,

For the 18.5 kW m&?;@$absorbed power i$..3.2;2 I 6.88 = 13.9 kW. This motor is
......
acceptable beca&eif$abhorbed power ( 1 .3 .a.j ~
. .. l @than
~ & the nominal power (18.5).
......
............
,........ :..... .. .. . . ~ \ :..'........'j.: :
.......
Checkina oft&& APi 010 criteria:
:..I............
. . . . .; .......
. :i.............
.........
\
....
..................
;

For the :?&&$'?30tor, the ratio (rnotqr.~ik!l power Ipump shaft power) equals
.,
15 11~2'=-$2%'< 1.25. The critetj6<f$:rybttin'et.
...... . ...........
,:,... ._ ..
:...... .I....
~ofthe'.l&:5kW motor, the ratio (motGrhominal power 1pump shaft power) equals
18.5 112.2= 1.5 > 1.25. ~h,e:&$eea is met.
:I :
...
.
<;,.-.:;:
...... ,:
........
2.4.6 POWER AT REDUCED.&~I~.C~~V
,
..........
-.
.:., ...
.:........ :

;..,................
The power at redu&j;&j~=it~ will be estimated by the following method :
Calculation of:fbe b d e r Pat design flow Y
For a red&a)& x, the power P'will be :
...... -....,I

.......-:
__--._
..........
........
.. . . .\ . ."
.. ..
2.4.7 P ..---.
UMP~C~O N
SPECIFIC SPEED NSS
............
..-..
: :.
&=
.........b(:i
..........
Q OI(NPSH
~ )' ,

where : N: rotating speed of the pump rPm.

Q: flow by suction intake m3/h
NPSH, NPSH required for the pump m

This criteria is used by the mechanical depariment for pump selection when a maximum
value is imposed by the client ; If nat, it is only used as a guideline.
 GUIDE DOCUMENT
bwadby Bm"= w n - m.
GE ( 312 1 1.1.2 1 vlll ( o

PROCESS ENGINEERING DESIGN GUIDE 1 pnle

PART 1- SECTION 1
PROCESS MANUAL (DATA BOOK) I S.S. 1.2 : PROCESS EQUIPMENT
PUMPS

. '.. '. ' 1

The N , is calculated for the flow giving the best efficiency v&h .$re::j&eller maximum
diameter. This means that for a same service, two pump sG&i:e'&$ll usually provide
, depending on the position of the operating pqfif:
different N '.....'"-..
......~.*
,.
.
..,.'..-~.
;
i.
..
In some particular cases,.,m.increase of the NPSH re&red'&hsequently of the NPSH
available) can be desirjihfG.2~get an acceptable N& ,.' B.Bu~ this case is uncommon
bemuse few suppliersC8np&pose two NPSH for,.*&&Pdmp ....... model (different wheels
for a same pump casifl&..:....' . '............. .,:.,;
.
"......... > .:. '... ...."
.................
.............. -.,
.......I

The Process daf2a$nent.'does not have to \ler&hi$>criteria ; It has to be done by the

mechanical d&adm$r$. ........ .:.
:, ............

... ;,..........
,:,:.. -.; ........
................ .;
.... .' ....~
:....
..... .....
...... ./':...." .....
.: :. ....
............. :.. .., :':
'......'
::' . -.'
,..%
.. ,,
~
...... .
....
:. .................
.:.......
8 ,

::
.............. ...:
~. :
.. ...:..-......
;2:,
........... :
. .:. ,:. ,.: ../
,,;

: ..... .
- ,
..............
. . .
......
: .:
'.. "
, ... ;:
........ .'.........
...,... '... ,
.*,
I
.......
........
......-..
C

:
.......
,
.. . . . . .....I':
....
.I ..-.
. %
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE M

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) PUMPS 14
 GUIDE DOCUMENT
-nu -,,. R,

GE ( 312 1 1.1.2 1 Vlll I o

PROCESS ENGINEERING DESIGN GUIDE

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) PUMPS

Comction chart of viscous liquid- c . .ca

centrifugal-
of '%darI of the Hydmdk Instilute", New York, USA 1955
Exfm~t
GUIDE DOCUMENT
 GUIDE DOCUMENT
I ka*M by

PROCESS ENGINEERING DESIGN GUIDE I 1 - 1

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) PUMPS 17

.,.............
...... ..
,
..
,
.. '....-.,.,..::
'/ ..;,.
3 OTHER TYPES OF PUMPS
../ .....
...............
..' <.';,.' ,,.: "

.-.'... '.I
The main features of reciprocating and rotary pumps ; gf$ s u ' ~ n z e don the tables
enclosed on pages 21 and 22. ..:.,.,,............._ .,
.--..
: '.
...... : ...... ....'::
Unless otherwise spec~&.we maximum flows in+afedFe limit values that may not
be compatible with th&m%itrylm differential head$::.F!L$t;b:rder cases, the mechanical
department shall be&&.@.: . . .
.. - :..-.
........ . :..: '
.....
...-....:A:'- ..... ................:.
...........I

NPSH of reciaii&i*a-d;lm~s
...........
........
:.....
...........
........ ........ ... :.
.*... ..,';..........
For recipropQ&~'&~s, the pumped fluid-&&&ed in the suction line. To produce this
acceleratj~nj'a.:k.rtain amount of en&y'ls'iGuired. This energy, which adds to the
frictiond'Jos's~,,.'i& called "acce~eratio~'h@~@'. The NPSH available for a reciprocating
,.>...........
pump fiaofiaosub~equent~y be c a l c.' ,.u ~: ~ -..
~ . ~ yfollowing
+ h & formula :
..,. ;... ........
,.' : . .
........-...
.. .. . . . .,.' ............
.....'.... ?.',
................ ...:....
.......
., . .. .; ..
. ... .. . : ; ..: ..'
.. .. .....
,a

: ....I
1
.'.. ....;.
..... '.:

Pump

.......
.--.. ...
.....: ;:
.'.
.,.......
::

*.. ........
.:., ..,,.. ..a.:, ..
i
/ ;

1.(jqA-He)+
( P ~ - T v ) - ((AP*)~ + ( H ~ )
gxpx103
2 0.5
(1) (notel)
...........
I :

..-._ ..
..............
.-.. . .
I
.'
......".-&'.* .:and H ~ :
; li
::
8 ' .

...... Height in m
PA Suction pressure in bar abs
Tv : Vapour pressure of the pumped liquid in bar abs
9: Gravity factor in mlsz
P: Density in kg/m3
A PAB: Pressure drop due to friction in m
HAB : Acceleration head
 GUIDE DOCUMENT

'i

PROCESS ENGINEERING DESIGN GUIDE P*P

PART I- SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) PUMPS 18

.......
..........
... :
::./....... ,;::.:
8. s

For centrifugal pumps, Hm is nil and APm does not depend on the p&i<.~h$.N~~~.
. ,.....
is
inde~endentof the selected D U ~ D . .. .....
: . .'. . ',.' ;...
.,.................
.,. . .
...I

For a reciprocating pump, HAs and AP, depend on the pu&;::the. N$SH available is
.; /.'; ..:
dependent on the selected pump':.. .....
.._ .. ....
.........
...... ...
: '. :: ..........
AP:, Pressir&d(op due to friction, is @@&do
f.r the maximum
Iiqui&.;iel+?it$ . '. ,.".,,.''.::.)
. (' '
<........... .> . . ..........
.....
+ HM : (. '..--.
.~*tibn
. .
........' .............. ;
head, dependsO&th.&pdnping rate.
............ ,,., ....:.... ..:
During the preparation'?d:th= process speaficatio.$i:@e 6haracteristics of the pump are
unknown and the:~~&:(hm ........
equation 1) ~rl_rrot.~..galculated.
The NPSH given in the
... NPSH. for a notY+ulsadjflow, i.e. :
process specif@&on.~s.fhe
:'. :.
:.:.--.. ........ .............
...,.I

The ~ ~ ~ ~ , . ~ ~ & b ~ , ~ c a is
l cthe
u l a@e&%ot&ed
ted as for a centrifugal pump, (HABnil
and A ~k..&leu&kid for an average::del@~which
............ corresponds to the average flow
, :. . ...,: .'
indicatqd.h~~e.6pecification). ,.;.........
:.
., . , . . . : '{ .,.......: :::) ...,:
~ n ~ ~ d i j kselection,
. ~ & ~provid&.@& the piping layout at pump suction is defined.
the 'NP&-.&ailable for the Sslf?cted pump can be given. Subsequently, the following
note is written on the proce&8~.~.cation:
..; .;;. .
. .........:
: :\
:
"The mechanical depar@e&-must check with the supplier that the NPSH available
corresponding to the .pump.g'cpmpatible
-. with its NPSH required."
...............
.......... ...... 'x.

A pAacalculatior3.~.
, . ......'. ...
..>.......
\ :
z.....,
. s ...
The pressure:~bb'b.dye to friction is calculated as for a centrifugal pump, but the
maximum liq!ji@.;veloi;ity, corresponding to the maximum instantaneous flow of the liquid
in the suctfoh.$$e, has to be considered. Depending on the type of pump selected, the
maximup.i~st&aneousflow can be calculated by multiplying the average design flow
..
by the+foll~~~gfactor :
*., ,. . :. .
.........
._._.
,
:
..............
,,' ;-.,
I

Sinabactina numn Double-actina vumv

.,:.. ,,.
j* : '.,
, .
a,+&<,.* ,. ,. 3 2
.....
Duplex 2 1.5
Triplex 2 1.3
Quadruplex 1.5 1.3
Others 1.3 1.3

-
Note : If a pulsation dampener is installed on the suction line, the factor to consider is
1.2 whatever the type of pump is.
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE FUW

PART 1- SECTION I S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) PUMPS 19

........
,,........
.
....... . .. .
. .
A. . ... ..,.. ..
.........
:
3.
"
H ~ ~ = o . ~ ~ z x K x ~ ,.,:,.:' ,.,....--.-I.:
eq. 2 (note 2) '. . ,'. "'
;
:...........
... . . . .
'
.',.-.
.,I
.:: .....
....I

Where : /..... .._

.....
.......
.. ,,-.
:
. ,,.-..
. .. .-.. .......
H*s: in m
...
i......,.)., ; ..........
. ..... ..
'...; 1..........
Q:
N:
average d&@floy in Vmin
~umbec<&@@.>
i.'.. ,.'.. \
.. ...,.... '.'.,.,, '.,:; : -
'
D: Pipe $i&d+.@'mm :........................
.....
L: Pipe;[email protected] ..............)
K: ........
~a&ko;&ijPsndin~ on the type q?t~&&~ :
.....".. ..........
, ........‘....'.; .......... . . ...:
............ ..
....
;............
. . . . . . ..) .:::.'. .... ~. .
,

.
:... a , ~

.:',i .,:. ""..::. .. .........

.. :,;
.mi" D
.............
I
s i n a l.e,d a : d-.. Double-actina D U~D
........
;, .
; ......" i
.. - - . . ..?
...........
," ,, ...........
Sim!&< ?I:., ,.,',,--,,'.:?:Q+ 0.50
............ :. .
,Jj&lex",," :. *..:.;o.50
..
:.,~~.i,&;
.....I.
.........
... 0.29
..-... 0.166
...........
, 4.166
Quadruplex ....
..........
: . \.. ': :
:: 0.125 0.10
Others
. *..I
.............
,
I :

0.10 0.10
......
...........
.........
.. '..
,..____
In case the suofiq.liii~.,&mprises several piping diameters, Hw must be calculated for
each s e c t i o n ~ $ i ~ $ ~ ~ u ladded.
ts
;:..........."...
The equ&?.a&e derives from the following assumptions :
..........
Thefmotid&enerat by the pump is assumed to be a harmonica1one,
QkAtiid is assumed to be incompressible.
.. ,.
....... “.... ".;
,$k&$ &sumption is never realised. Usually, the motion generated by the connecting
k b d d d k assembly exceeds the maximum values of the harmonic curve. This excess
I.....'
..-...~d&&s on the ratio r = (length of the connecting rod Ilength of the stroke), which
: :. c$inmonly ranges from 1.5 to 2.
.... .:
..........
aI\

.......
'

h e maximum acceleration head must be increased bv 25 to 35 %.

The second assumption is checked when the suction pressure is close to the
atmospheric pressure, which is usually the case for reciprocating pumps.
-.,
 GUIDE DOCUMENT -

"1

Rw
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PUMPS 20
PROCESS MANUAL (DATA BOOK)

. .. : :
:
. .... ,: :
Remark : When a pulsation dampener is installed on the suction l$,.&.~wleration
head between the pulsation dampener and the pump must be [email protected],.fp;jh equation
2. The acceleration head between the drum and the pu~sation,darii&n&' will be taken
as 10 % of the calculated value from equation 2. The two he$$.ba;eto be added to
:.,' .....-..:
obtain the total acceleration head:-. .. , .
..... .:
........
: ..! <. ....
:. .. .. .. .-..~. .
.........
....... .< '
:....:.....
<. .......I

-
Notes : , . :.
..........
. . . . ..._... ;
.., ....-.',,.":
: I

..:.:... :...;.,.
............ :
..... ...
1. There is a phase sb&&tvji&n
....... the pressure::#.. i d .....
Pm and the t e . , t o friction A
-pressuredrop caused 6yqae1&tion Hm (accelerabqhi$~imumwhen the velocity is
minimum). This phetXom@$&.is
......... taken into accowbj!.4he:$em
...... ((AP,)' + (H,) 2 )a5
in equation 1. . .
...... ... .: ....... ....
.: ..........
..."..
-G, ,

..... ., . . ._
,
. )
.I.........

-
\

.. . ...,
2. Some sour&~:in&Ate equation 2 as b& u$dalistic when the suction line is very
long. ; .. .
., :. ... ......
.....
.. ..........
:
........... ,;',...-'.:i...-..,
a

:;. '.. :
.... ,.\
:
....... .. ...,,
( ..-.
" .....:

4 I M R ~ ~ ~ "DISSOLVED
QF GASES ;~SN;THE NPSH
....
..' ...-...
...........
The occurrence of d i s s o l v @ ' ~ ~the
~ . ~liquids
~ dramatically reduces the NPSH really
......
available at the pump sucti*:.. ..::.,,<.:
..................
...
...........
It is then necessary w@ke:&me margins into account, deriving from past experience.
These mamins shaH.Jkhnsidered in the SPP and shall be dearly indicated to re vent
anv misunderstad~.kith~the mechanical de~artment.
. . '.. :
.
,-. .. . . .
......
The following.-..
~ ~ q m d a t i o can n s be found in the literature :
.. . ..!
..... -..
BFW pi~@ps : divide by 1.25
Othe$u~ps: d i i e by 2 or consider liquid at bubble point.
..........
,..............
.::... :. : !
 GUIDE DOCUMENT

pq.
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION I S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) PUMPS 22

.,.......

MAIN FEATURES OF ROTARY PUMPS

............
. .
Type of Flow (1) Viscosity ~ifferential..l.. usual ... Global NF!@; ........ Remarks
rotary
......j velocity
pressure.(%j' efficiency re&lr+ . .:....:...... ..:'
......
Pump m'lh .........., :..: %
.....
. . a .

cSt bat-.. .....“.... .' rpm ,<. ,+.! ;

Gear 200 10 x lo6 ...
25&-.::-..:;?
..................
0-3000 ...(a:...)@:.'
50-90 ........:. . ax. temperature : 350 oc
....... ........
.. ...,,,:
.. ]
........... ,.., ..........
Screw : I
.......'..'.&jo....... Max. temperature : 300 O
C
-2screws 1000-2000 1x10" . 2000 SO-@:., 3-4
- 3 screws 1000 2 x lot:? .:
. .
. ..."."20i) up to . . . . . 3-4
....-.,:....
.......
:.,."'. ,., ...'.
15000~: "
::.......
,
~.
.' ..
., . . ...... ......
.........
Vanes 400
....;'.xI... , . 25
............
O-l@-> i ......
......:......
Max. temperature : 260 O
C

.........
,, .,,.: ....
...........
. . . . . . . I

;;'
; Hydraulic pumps : 200 bar
,:
.' ...... .: .....:
a';.

..........'
. . ..... , . .,
.,,. ....:'._. '..';' 2 0 d l h , 2000 rpm.
:'
,_.
........
6..

.......
....
Pistons up to 5 0 - ..) (3) up to 7OQ .
. ... ,2000~3600 (3) These pumps are used
I;.,-.d,. . .... in hydraulic systems for
;. : <.,...;. '; which the fluids have a
....................
I.

50011000 Cst viscosity.

...............
.........
........
Deformable 20 20000 . -
............. 200-1800 10 to 30 Max. temperature :80%
rotor i ............
Off centre 200 Ito s:,.:. ...........50 0-1500 50 1-5 Max. temp. :80-90°C
.................
Screw 20Qm
........... Can handle erosive
.'...,-.,
.':
. ..!
.:
partides.
C. '....',.'
.. ,
Lobes ,' 5-20 -= 700 3040 1-5 Max. temperature : 120 OC

Defomable 5.15 0-200 30-50 Max. temperature : 95 OC

stator :
:/
.-.. :. ......
:, :.
:,
\ ..
.........
I
.. Can handle erosive
. .:
. ....... particles.
P
$ Mouvex 120 35 250-1400 4550 Max. temp. :250-300 OC

( I ) The maximum values given may not be compatible.

(2) These efficiencies commonly exceed 70 % when the operating conditions ( d i i n t i a l pressure + fl0w +
$< viscosity) are in the optimal range for the pump selected.

2
 GUIDE DOCUMENT
I h u e d by
 -mlm GE 1
bwd by

312 1
soau
GUIDE DOCUMEKT

1.1.2 1
-*
IX
R.v

( o
.')
PROCESS ENGINEERING DESIGN GUIDE wx
PART 1 - SECTION 1 S.S. 1.2 :PROCESS EQUIPMENT 1
PROCESS MANUAL (DATA BOOK) VACUUM SYSTEM

.......
..-.
. . ......
:
..,..'.
: ..
I'

>., .......
...'. ..*,....::
.
........... ,,.:.....
:
.: .c,. ........
. . . .
....“.......
...... .._ //.
.
. ...
..........
I ;
/...........
;
......
CONTENT
...--.
.: ....
.'.....
,' : : .:. .... .... P
;: '.. :: ..-.. .:....
.I......
. . . . :.:..:
........
..I

...
.
,'
,. .........'
-..
:< ,
;
;.,. ..."......
........... '
. : ,.-.,:
.:
......“...
. . . . .."!.,/.
- 1

.........
....... ..............
..............
.'. > ............
.............
................ .........:
1 STEAM+T:.E$~TOR
............
...,..... ..:
,. ...I.......
............. :
....
........... :.
,: ............. .
: .........
...... :..-..- ......
:,
_.._.
.... ._,. ..I.
,
,'.. > ,
;
;
. . :. :. . .
l.f'(.~h@G of number of s@ .....": : gi:'
. :: ;,',............
.4::2...'Q&u1af ton of d r i v.i ~
............ _~, ~ ._.d f l o wfor a teach
e stage
< :, ,,.: .-.
: , ... ,
,,
.........I.:.. .............
........
,',,'., : .. '
..........
,. ,. .._.. .
.. :; .:
<. . '
:. 2
.. ../,;
i'
:..A. .... . .........
.,_
'"2 "....:VACUUM PUMPS...... ...,,.
/;.. -.::... .
:: . "..
i .,, <..,".. ;:
:
............
.....
............. ,'
. ,)
.. ..
.............
..'...,.....
. -.:-.-........
..
"\ .....
...........
.,/ ,,,. '...........:..: ?
:. . . . . .
..,..* '....,:.
....... ; :
:.........~.
. .
....-.... .....;
:..-,, :
.: ..:/. :
....
i

....
...............
,,:.................
.. ., ... ...
.
......
::
,.
5 .
.. ,::.:
..........
.......... ........
..,'.
:...
,
~.
............ : :
.........
'
-e
B
?
.
P
2

&!
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE p.pe

PART 1 SECTION 1 - S.S. 1.2 :PROCESS EQUIPMENT

3
PROCESS MANUAL (DATA BOOK) VACUUM SYSTEM

,
........
DRIVING STEAM CONSUMPTION PER STAGE ,i < ...:.. .
.....-.‘.
.,.; '..... '..'..,::
: ::
...............
. . '-.,'
:

step : Define the flow rate and the characteristics of different fl&&.t6.&;sucked.
Id
..............
..:............
steam kg/h : ml
..'/.. ....". ....:
. -.........
......:-... '-
air : !.,'!?.'.,
kglh ...
......
%_

,..,' : : .......
noncondensable hydrocart,bri~.,.~'
......... : kglh : .........
, , .....
.........
:..-..
........,: : . : .... .:
.. ..........
...........
.. .. ..... . MW : ......... :: .,:,:
.., .. '-..;' :.. .,. -.." :.
..........
k g , :$..:.
I
. ..: .........;
condensable hydroqaiins.."'? . .....‘...."
,;... .._..
......
...........
. .
._ ........... ww. ..>............. ::
.......
. .
..............
< .......':
.......
'.. . .....
.I.......
...-.......:
. , ~.
.
..
........
.
2d step : ~al*flo(bf:the equivalent =tea$ & b&bcked
.; .... :.
j : ..............
..............
-. ';
1) Detenniri,e $=-&ivalent in air of cii&&$pipction gases by using the graph 1 (divide the
..,.
m a s. s : .o ~ ~ ~ ~coefficient r e.&. &
b$he . .Y.~. &. ) :
....... ....... : .....
~~@n6@@nsables ; : . i .,+r=.' kg& : m3
.......
ljG.&ndenkables
.....,,
'.:
‘&.:% = k g h : m4

2) Transform the equivalent,c$6&tQQequivalentof steam :

; :,, <.:-.; ,:
x = m 2 + m 3 + . . =. .........
. . ..kgh
1.25 ............
.........::,, ...
?:,,
3) ,.'...........
Calculation of eqqidatsnt-&team :
M = ml
. . . ......:..'. .
~. . .. . ..' ~ _ :
.........
~
, ,~k

.
.
..............
3" step : ~i%j~tion'6f
. I. ,
steam s p e c k consumption.
:: &..... ;,/'

Ps = sY&.pisure : mmHg
. pd = ~ c ~ & $ ~ U r e1 mmHg
Pm = @hying:steam pressure : mmHg (I
bar :750 mrnHg)
............
;;;..h
i';.....' .
;. :.. .
.........
. ,:
.......... graph 2
---> ---
c = spec. cons. : kglkg
g :
4w step : Cablation of driving steam consumption

driving steam flowrate : Mx c= kg/h

 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE pw

4
PART 1 - SECTION 1 S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) VACUUM SYSTEM

..
.......

.....
Cany-over M,~:..::::::.'
. 'Mas-sdss
...........::,,-.“.. Y(~lsdair
. -.
............ : GRAPH 2
<. .........
~ra~h.&.s&cif&consum~tion,C

1 2 3 4 5 6 8 H ) 20304050 UH) 20030OUY)U)O MOO 2000 50m

 GUIDE DOCUMENT
I hsAby

PROCESS ENGINEERING DESIGN GUIDE Rss

PART 1 - SECTION 1 S.S. 1.2 :PROCESS EQUIPMENT 5
PROCESS MANUAL (DATA BOOK) VACUUM SYSTEM

......
2 VACUUM PUMPS
/,...I........
....
.:, :.,
:
.
. . . ..:.:
........:.....
:
Main vacuum pumps and scope of application.
.............
... *../.',/'
.:....
. . . . ...;...:
: ;,./

...'.,.....
:L
..'
:: .

.'--......:,. ..
:. -.:............
............
.i

1 torr = 133.,3>.t59.:"...>
: : .......
.,.., ._... :
i...... :
. .
::........“..
....... ._
....-. '
._I'
.< .... .::
/
. :.
. .: '._
........ . .__ '..
... .
..,...............
.. . . . ...
.............
,.
-.,:.
.........
............
,,.,."'
::
. : ..
.*. I...
:. ,,.. . .
..........
..........
 GUIDE DOCUMENT
1 by W o n uumerw rrev. I

S.S. 1.2 :PROCESS EQUIPMENT

z
2
zz
E
s
r
=

<

S
 GUIDE DOCUMEh
luueaby w n * Uuptan. &

GE 1 312 1 1.1.2 1 x I 0

PROCESS ENGINEERING DESIGN GUIDE pw

SECTION 1 - PART 1 1
S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) STEAM TURBINE

.......
,. ,..-.......
. : .
('
,I,
'
. .. ;:..
.
.
........ .".;
CONTENTS -_ ..........
..,.
; :. .
........
. . .:,: . .I.:
.......... /.;.
..'.........
. ..._.'
; '
...........
. ..
." ._. ...-..:
; ,
......
. .: '._.. .:
.(':........
:
. '. C,
.. '..
..............
'...... ..
..,'
._.-._ 5

1 SELECTION OF TUR&E$(PRACTICAL
,
............ . : . .j
ADW~~S);.-: .
................ ..........* ::
I Non API 612-&ii$&&ilisation (Ps 1~4$:{:'.
1.2 U t i l i s a .t i.o. ~. .~.? ; ~ ~ 1turbine
.6i2 (P > 1MVv)..:'..'
' . ...'.. .:,.;,;' .....::
,,-...
. . . .'...
....
1.2.1 !. .....M* ..temperature
1.2.2.:... . Usual max. Pressure ~52b.ba
......_.,
........
.'...
..__ ..;, t -
I&%' ,.llc;'bid water content 8f.th=..ihtlet of the turbine
li2.4 \ ~ncontrolledextr&&&(exf;ad flow rate Itotal flow rate < 0.15)
,..j:l>,$::~,iControlled
.... .... .
extra&16,$(*ct
, flow rate Itotal flow rate > 0.15)
......
....... ;
.....:......
I': .. -._..
2 .C~L:C.@I&-~ION
. .. ,. .........
METHOD O~.:~J,RBINES WITHOUT EXTRACTION
1 . ..
I' L.
.._ .._
.....
..
:,.; k*;:.;Principle .._:
2.2 "~alculationexa,+icj
. . . . .turbines without extraction
; : <..*.: ;
2.2.1 He+vy'd&(j6ck pressure turbines (P > 1kW)
2.2.2 $--$.d.hrbines
Hea'i$:@@ji''condensing turbines
2.2.3 .
.. .. .........
.. .. .. .. .
,i..

................
.. .. . . . .
3 C A L C U ~ ~-.._ &OF'TURBINES WITH EXTRACTION
............
.. ..
3.1 .F!&$iple..'
.. '._
3.2 .:'..&mple
.................. .
,...............
... . .. .,
4 ~TJCI&TION OF REDUCED LOAD TURBINES
,...-:; '.........
:';.--- .".,
._......~ .E C T I O NTABLE
5 i..'...
........,

6 GRAPHS
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE fw

2
SECTION 1 - PART 1 S.S. I.2:PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) STEAM TURBINE

,.......
Preamble : This is a method to estimate a pure back pressure, condensation or,d:&$qn steam
turbine. ," :. ... ':{.
............
......
.........
. .:. ......I :...:. ...:
.........
............. ,.
1 SELECTION OF TURBINES (PRACTICAL ADVICES) : .......
... .....
.', .._
,,

Steam turbine manufacturers can :

..-.. . ..... :
....:........
..'.A,.

..,,-...: .:
either supply a low duty'et$~dard
. ....:..-. turbine but with..&;8;;.hure
.._ and temperature
. ........ ........;..-.:.....
constraints,
.......... .'
/
.. ",: .....
/.:.
::
':

or build a turbine 6*&&:.i .......

;y case. In this @F
~
I&x$~A?I 612 requirement are
followed. .........-. ...
..............
<.....
::...............
........
............
........ .....
............. .:
........... : ............
1.1 Non API 612 turbineujiiahon (P 5 1 MW) ..........
,' .. ....:
.............. 9. ................
.i...:
...I
. . . .::. .._
;,,--

. ._. .._.
............
P&~" p:Gction exhaust..... . . . V. rot extraction Condensation
..w.
.... .
:
,
...... bar g bar g ..........
.......
.-.-.i . . rpm
Back pressure /'&;&a;.. s 41 s 5 2 : . ' < . s0 0 s 6 000 non non
turbines non API 61?;'--..: .........:.
... .._,.
..........,.-
../:
..'...
: : .,,
:

..........
........ .........
....
:.........
. :....
The propk&d methods of c&$afion correspond only to single stage turbines with or
without casing. This type of .$a&&i
. s .: normally cost effective.
..
. . . . . .'.;.
...............
.................
....-......:,, ...
1.2 Utilisation of ~~j.::'-~l.2.--tu.;bines(P>1 MW, condensation, back pressure,
.......
extractioncondepb&o'@&d
.. .. . . . ...,. re-injection)
~

.........._ 612 are more expensive and have to follow some criteria.
Turbines followtng.'i~~.
..
...:. ...
...... i

.....
,
,' ;
1.2.1 Max. tem&iatirie
.......... <.
525 OC,@~.SI&NS, RATEAU, JAPANESE)
510 O C for oh& manufacturers
~ ~, ~
. .?.;.' e. .; ' f o r : ; duty
n ' ~ ~turbines
~ (> 50 MW) power generation allow once until 537 OC.
I. ,.-.,
;:
: :,
......
. ..
1.2.2 ......
l&&x. pressure :120 bar
The same applies for heavy duty turbines for power station (> 50 MW) we can go up to
160 bar.

1.2.3 Liquid water content at the outlet of the turbine

< 8 % to prevent the decrease of turbines stators life span.

 GUIDE DOCUMENT

page
PROCESS ENGINEERING DESIGN GUIDE
3
SECTION 1 - PART 1 S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) STEAM TURBINE

...........
;/
. ..i .'!
Uncontrolled extraction (extract flow rate Itotal flow rate <:.;~%j&.-...:;
. ......
Foi some manufacturers it is possible to foreseen witholff (&si,ir;i6act, interstage
extraction, i.e, modular assembly of turbines (sIEMEN$.),::.\M~@~~~pressure and
flowrate of these turbines is not controlled and deped.:bn. opedings condition of
.......
,.-..
.......:.:: ' ...
; ...: : :..I

'
. . "-.,
........ '.. l'miy
...........
i Vendor
:'
.....: ;:
.. . ..
t..

:. :.........

Po

........
........'. ........... ......... ',,' P
... .. ........
.........
,. . . : :
.............
...........
;'.,. ;,,> ,.'.
, '. ;;
............
..........
. . . ..;'...'
.'. .. ... . ......
L.
P4
...........
:.,, ........ ._:
I....

... ,: ...................
;.; ........ '..
,
....A

:., :. .
. a ;.,...... .,;:
..................
................
...............
..-.':,,....
turbine and prt,,&$~drd~ created by throttle valve(@ (or regulating valves) (1). User
.: .: '.. '..
shall foresee,d&n~,bystem of pressure P3.
... ... . '._
.........,.. . .
:

.....
P,, : ~&@iii.<;Sedin~ pressure
. , '. :
P, : :.@rfiine
._ '._ inlet pressure based on throttle valve (1) opening
. .
~::i j i ..,
: w i i o pressure
n
,, . ~,
....of extraction is determined by vendor so that P2> Pgwhatever
!&tion
I...
:.:::::
,. ":.---ttie
value of P, and P4
.:; . :. . I
',...'.....__.
P&; Constant pressure of users' network
'.__
: Exhaust pressure
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE ~ s r

4
SECTION 1 - PART 1 S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) STEAM TURBINE

. . . ......
........
, ,,
....
... ..; ;.
Controlled extraction (extract flow rate Itotal flowrate r 0.15) ! I
:
Turbines are supplied with necessary equipment to assure the stabikty'&r$re!$&ure and
extiact flowrate is permanently adjusted to match the needs. ~he.s&';tu$ip& are more
expensive than the one mentioned before.
........ < :i..
., .....:
...........
..: C .,

If the & k......

~
o$ axtract flow rate to total flowrate is more than 0.2, supplier will probably
su@tbusb a double cell turbine.
,:.,:
a
.*,.-..:
 GUIDE DOCUMENT
bs- bv Bm*n- auwe h.

GE I 312 I 1.1.2 1 X 1 0

PROCESS ENGINEERING DESIGN GUIDE p w

5
SECTION 1 - PART 1 S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) STEAM TURBINE

........
. .
2 CALCULATION METHOD OF TURBINES WITHOUT EXTRACTI~X-'...
.........
.. ;/:
.."'.
, '.."I
2.1 Principle ....j ,. ........
............ ._
I :. i:
This method consists in calculating turbine flowrate with the,s$i~ietjd~ra~hs.
.... .,..., ......,
Using this method, one has to use : . . .
..............
:./ ........
Mollier diagram or VD!~$$?S to find out thermody&mi~~coifditions of consumed and
(:.'.....;.:.!
produced steams, ......... .............
.......
. >... . ....:%
........... .. <.,: ......
graphs 1 to 6 to de€ei-qxne.the .....
. . . . . .,:.,.:'
............ turbines efficien'oy; :::
.........
.........:I.,....... . . .; ...............
: ......... ..;
................
.....
.......... ......I.
. .
....... .............
..'
.. .
.'
.I......

:
._.......
. .._ ......,
HA ....:....
................... . ..............
..... ;

.... .. .. ..../.........
. . . ..I
MOLLIER DIAGRAM

.,... ...__.';
. . b
. *..____
.....
;., ..-.: " ENTROPY S (KJ1h.T)
:: .: ' .
:
/

..........
, 1
'. :,:
..........

P : Shaft power supplied by turbine.

M I : defined by conditions of inlet steam.
M2 : defined by isentropic expansion of steam (Sl:S2) and exhaust pressure P2.
M2' : defined by real expansion of steam ( by PI. T I .P2, p).
Ah- = H(M1) - H(M2)
Ahred = H(M1) - H(M2')
 GUIDE DOCUMENT
I W by BOO*^. Ch.pno w.
GE I 312 1 1.1.2 1 x 1 0
1
PROCESS ENGINEERING DESIGN GUIDE ploe

SECTION 1 - PART 1 6
S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) STEAM TURBINE
-
......
.......
. .
' I . ......:
/'

< . . . .,:./.
...........
.............-/'.
.......
weal
, : :.;
PtWkz= -
~ ~ 6 a m
read from figures 1, 2, 3.4, 5 d e p e n d:i.:n g . d ~ t u ~ ~ ~ p e .
....:
.:
Hence, steam flowrate =
.....

-
Note .........
For determination
....... 3600 .....
............
"P
' (kglk~~.~''~:'~*'..:;'
... .. . . ........... ?
.,
......
..:.,........
.....>
.,_-...........
(kJ/kg)
.:...............
,
,
,;
.:. .. .... ....
.. ,. ..
.....
~
:. I. ,
.........I

\. ..........
8 .
.,I]....:
. . .j... . .
:,.,..'. . ;..,. .....-..
... .............
2
;
. . . . . .?
2.2 .-:. .........
C~ICUI~~~~II':~'&I~I~
of turbine "i*&t&traction
.. .. . . . . ..' :.' .: ;
.......
2.2.1 .........
~ea&&'b~ck . . 1 kW)
pressure turbiX&s.('P:>
...
./ ..-.. .,

:: .,.:...... .:..... .
; -'. ..
C..' '
j
Turbine has to supply ?.f$~.d.&er with live steam at 41 bar g, 400 "C, and exhaust
.............
..:. :.. ..
pressure at 5 bar g. ........:,.
From the Mollier di&ii.;.--
.<'...'.... ..."
AH isentropic .+..' . . - 2750 = 462 kJ/kg
. .......'. 3212
From the heaq&.lpii. . pressure turbine graph (figure 1) :
....,:
e4Ylb.= 0.70 .; .::..j
..,.::
..... : ;
therefore
....... :<..
f'.-...
....... :
.............
.. . . . .
i,.C-..$I@ = ) 2000 x 3.6 = 22.3 tonnethour
...... ........
.............. 0.70 x 462
:,_-..
:: ...\.
~.
.~.
: .,.
. . : :.
.............
.........
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE RW

7
SECTION 1 - PART 1 S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) STEAM TURBINE

....... .
.........
.' i . .... :...
,

:. .
............';
2.2.2 Heavy-duty condensing turbines ........
,,..,.. ,,.; ........,. I

Turbine has to supply 2 MW of power with live steam at ....... 4f.$ai{g..'a00 OC, and to be
condensed at 55 OC (0.16 bar a). :...
; ........ I
..I:'

;'/ ..."...
AH isentropic = 3121-2190..=.1022 kJlkg ,, .......
.....:.'._ ...
........ ....... ..'
From figure 2 we have :4&.d,&84, therefore ...........
. .....:...
..... .........
.. .,i..-.: . .....:'
Q E..:2600'x3.6 = 10.3 w:.:.":""' ;i
. . . . .."..,'
':...:l).&54:.x 1022 .............
...................
....
.........:I;
Liquid ratio at U & . @ ~ ~ s t ' ~ ohas
.............
determined : /....... ....:
..... ;.. ....
i n tto be............

..
ch~&&therefore the point M2' has to be
: ..' .-.'> .... .:. .';
..............
AH real
.....: ....'..=. AH isent. x p
j..‘....
..... .,.................
... . ,
/.,:..-.,. ..:. .,.=',lo22 x 0.684 = 6gd,kdk&,j ................
w h e..r,..e -.~ & ~ L=j 3212 - 699 = 259q kdlQ '
.............
; .............. /

Thii bpini js on the 0.16 bar a,,is&&f &ich the vapour ratio is, x = 0.965, therefore.
y$ter@$@nt is 3.5% < 8 %..So;'It;is'&irect. ........
'.._ ..... ..._'..
_...........
;
'

... . _.. .._

....,,:
'.._ .._
-
...,'
....
..,.._;i
....
2.2.3 Standard turbines ::: ' : .....
: C..".: :
... . .. .
. . ..........
When calculating &~~@&dard turbine, one has to chose between turbines without gear
reductor with a .bw-&6@encyand turbines with gear reductor that will give a better
.:...... petisive.
efficiency but gdre.&i
.......
This choice d$.thh$i$'depends on turbine driven machine speed.
.. ...
~xam~le,<:.)in~ has to supply power at 750 kW with a speed at 400 rpm with live
steam .*-40
,-..: baig; 400 OC and exhaust pressure at 5 bar a.
.' ; , .
a) wiih'txlt'bear reductor
...............
~ise?t..''=:
477 kJkg
.. ..
$eeoretjl consumption =
...... 3600 = 7.6 kgkWh
............
.:
,,. .......'.
. ,
477
'..
!.......
F&& figure 3, p =
0.31 therefore,
'.--&;I consumption= 7.610.31 = 24.5 kg/kWh hence, 18.4 t/h

b) with aear reductor

From figure 4. p = 0.41 therefore,
real consumption= 7.610.41 = 18.5 kg1kWh hence 13.9 t/h
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE ROO

SECTION 1 - PART 1 8
S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) STEAM TURBINE

.......
3 CALCULATION OF TURBINE WITH EXTRACTION

..-...
............
. ... ....
,

HypothesiS. j. <..-.:. ..:

...........
Mo : ,&+;;wrfi
-.......
MI :..,:-.&ion
M2........:eqrld&nsation
?;
<. ............
...........
: ., ..... .;.
. .. . .
.I"'@ \...: total flowrate of live steam
............
..........
. . .Q' .....'i
imposed extraction flowrate
<._
'
"..; .
: .H I : back pressure enthalpy differential
...'...JH2 : condensation enthalpy differential
...........
........
.. ......
./,,.--
.;
, ..
..--.
. . . .:.
.........'
I

, . .
.-.. , Pi = back pressure power
:.:: ..-..
I
P2 = condensation power
.. ........... .
:...
. ': I
P = total power of turbine
............

Back pressure efficiency AH I

= p1 = AH1 imnt

Condensation efficiency AH2

= p2 = AH2itent
 GUIDE DOCUMENT

'
m e
PROCESS ENGINEERING DESIGN GUIDE 9
SECTION 1 - PART 1 S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) STEAM TURBINE

.......
.......
, ..:.. ...
3.1. Principle '.. .:.
The steps of the calculation are : .......
...........I
../ . . . ..C.:
; ..........
. < :,..
- . ,, .......
1st step : efficiencies p1. p2 are taken equal to 1 and'qis.
. gfulated from the
equation(1)
.
.... .
.' .. ......, ..........
- 2nd step : Calculate the ,=value of back pressure and.&nd&.yion power with Q, that
will give the new value of.$fic<ency (to be read from $ g ~ + Band ~ . 2), and consequently,
......
new value for the flowrat'eQ!T.his iteration shall be.si:&e.u$til:there is no variation for Q.
. p = p1 + p2 .{?.. ."...
........... ...?
.: '.. '... '.
.:......... .. .- ,.., : :.
i

.........
..........."...
/,'
..................
,I * P I =
.........A.
Q P AH.<i*
~ ........,..
3Jj........:..
";
:........
....... .
..........
. .. . .
'.;
: ...;....:
....
(Q -.d;l-i;;..eL-&
P 2 = .; ..: .-..._.......
....
.. .".;
............. ...,
.,::. ...
"'

................... . :.
1

Q.&;AI+.~A; +p , AH2i.ent) - Q>illlrlai&nt

P = :* I . , .
............ ; ;
..... .. ..'. . . . . .
.......I

. . *,-;.
)

........
'

...........
. . . .
2.'
. ._
,:
... ......
:,._..
........
:... . ..... .:
.:
.............
........
;. i'. <,.:-.: . , : (1)

.............
I

.......... .
: ........; .

....-.......':,,.....
._,.
:.. -.:...........
I power in kW .:>.i...::...,
.............
.i
Flowrate in *.,
%
,;,

.
.....
........., ....:'
~nthal~~.'di~epe$il . ... kJlkg
.........
, . ,:
.,....
......:;
::
. . ..
.. -.,-.....:
. . '..
..............
.. . . .. ...,
,.,. ... .
..-.-......... ,'.>
..............
........ .. ..
:,. .... .. :
............j ,
a ..........
5
s<
55
E

e
'i
.i
Y
 GUIDE DOCUMENT

PW
PROCESS ENGINEERING DESIGN GUIDE
10
SECTION 1- PART 1 S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) STEAM TURBINE

...........
,..-._.....
.
: .. . . ......,
,' .,'
........-.../:
3.2 Example .....
.
,...,.. .........
.' , :./ .. :,

Turbine of 13614 kW that use live steam at 120 bar a and 510 OC,..w+:k -.-.I at 40 bar a
. . . ...........
and condensation at 0.16 bar a. Extraction flowrate is at 80 tlh. ;i'.:..
.. ;. ....
:.; ........
....-.
.. ......
........ ....::
... j
..............
1st iteration .......
-., : ....... ..:............
. .
('.:. ,:......
i'
......... .
............. .;
p1=@ = 1 .......
.: ...................:
*,
........- :.....'
........ . .,.,',
"

From Mollier diagram, afte~~~;yit!a'placed

all the ne&s~a~.points,
t...........
............... .... './
AHl irant = 3380 - 30.i::f ::SQ0kJlkg
.......... .*... .......
: -:..
..:,.... '.>
.
.I.....
AH2&,,, = 3080 -21
. .$,'<.950
. . kJ1kg ........... . .i.
................
. .. .. .
-......
. '.,, ';. ,. . . .
. . ::
I . _ ..
..I...... ... ............. :,.;.
(1&14 x 3 6 ) + (80 x Ix 950),,2;t&.fi.,
('1 ,.:> >:, '..(?.~300)
=..... .... + (1 x 950) .,. <... :;.-...-,?
. .'...."
i,
. . . ,:)
.. .,-.. .>.. ........
.. .,/' "..,
..
. . . .......
Theref~..:.. . '...:
.. ,,.
.:.............
... ..... ...... . . i.

i,~'$t-~>loo x 1x 300 = 8333 kw'....- > figure1 = 0.75

.. 3.6 ..-.,
/;.......;....
p2 = (100 80) X 1 X -........ .:. k"&78
?R .. kw -> figure 2 @ = 0.736
...........>:,;. ..
i.,
.............I

2nd iteration ................

-.
.......
.........
.........
p1 = 0.75 ,, . '.
".'../' :.
................
,
.........
fl = 0.736 ...............
:
.
: ..
I

..........
'1--. ': (13614 x 3.6) + (80 X 0.736 X 950) = 13.6 t/h
('1 . ....... (0.75 x 300) + (0.736 x 950)
............... -:
............
There* '.:
.. .....'
.........
_,---. , .':

x 0.75 x 300 = 7100 k w

= '' .-..'I 3.6 ; 3.6 figure1 p~= 0.734
, ~.
.......... :
I .
. .
..........
13.6 - 80) 0'736 950 = 6526 k w
(I
PI= figure 2 ,Q = 0.744
3.6
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE

SECTION 1 - PART 1 S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) STEAM TURBINE

......
...........
.........
.' i ! i

...........
UTlLlSATlON OF REDUCED LOAD TURBINE (Figure 6a and 6b) :....:.......... -!
.
, .
.........
' ,. ,: .'.,'
Graphs to be used for heavy duty turbines when they are used.........
@s.*lly@ss : power P
than the normal power P
W
I :.
.._ .
..... ............
:.,. .......
..... ... ' 5
a. Turbine without extraction .......... , ...
;. ,<:.....
................. ....
<:.*.....:.i
Calculate p r with
figure 6a.
, _ ...:.
~ ~,~./'&t&e?former
............
......... ..' .
formulas, .
~&$,:p/plW
......
...... ...
.
..... :..-.......1,
. . = F(P/P,)
'."...'
and the

........ .................... i
.....a

.........._;
,:::
:... ...........
............. -: load turbine m a._.............
Efficiency, p of t&:i&uced y~~e~.b~~duced.
. . . ... . . ........
b. Turbine with e x t r a m : .
............
.....
... :. ...... ...;
li

i:
- If the e~ctiort.R$wrateis the same a$$he'&mal flowrate, the value of efficiency
calculate@fFj'~no$)i&l
. .......
. . power can beI......
,
.........
m &...,
i
'.".....:/
- If n o l l ,? .& ~ ~ . a h kloo
I,.
d can be .&
. &$ . at& with ,,P, graphs and the calculation
r n.............
e ~ @ ' . d ~ i o3, nthen p,l@i,$.&Jd pzlpz,, with the graphs on figure 6b
. ........
t!-~6t'fodthi?value of and flif2-.';{
%e'.&umption
".. '.:
flowrate,.qt the iiifet can be calculated with the formulas in the
............
. ...
section 3.1. ;,...
: <:;...'>
. ..
..'. ...............
\
.
> ..............
. .
.......
2.. ...
. ....-....
-.
................
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE

13
SECTION 1 - PART 1 S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) STEAM TURBINE

.......
.........
5 SELECTION TABLE I. :.
. ..... ......
..:....:
a

..........
. . ....
.... ,,'
,.. .:.........
(
,:. '..";
Considered cases Data Results - figurqm ....... imitations
.........
.. ..
Heavy duty back pressure Power Figure 1 !'..+. ......I?ower
. ...; > 1 MW
turbine Inlet [email protected]~ efficiency .... ._.
. . .
~xhau$f'&&~ure
'. . ................
, .... .
.:'......
I

....
Heavy duty turbines with
,A. '
power..'.- ...'.....: 2 .
. . : ' Power > 1 MW
Fig. 2 ... <
effic@ha..."-(."
condensation lnlet@?&.$e Liquid water
k.llatMprature
..............
............ content 5 8%
.......... :
............
..E@qsTpressure
: ..... . . ....1.
... ,..:,:..
Heavy duty turbine with ,.. ::&&ei ......'@:.l..+ Fig.2 Power r 1MW
uncontrolled extraction I '=.~dnlkfpressure
......... ..........
. ek+rbdion and . Liquid water
condensation ...... .. :..l$ettemperature jr. *$densation content s 8% at the
<1. .
I.

:::'
. .#
Exhaust ...-..'....:
,:@ciency exhaust
,,..:. ...........
I

.. 2' Extraction pressii$;;::. !..-.. . Extrac. flowrate < %

,;,'.' ........... Extraction flow&$'(: """ Total. flowrate -
: . , ,..; ....... ,,';....; ) .......
Heavy duty tu&h&4i$,.“ Power .( .....,.,.: Fig. 1 + Fig. 2 Power r 1 MW
. .
controlled e#&ti.od'." Inlet pressu&-....'-., extraction and liquid water
condensatian .'...> Inlet tempratu&" condensation content < 8%
Exhay$t-d-ure efficiency Extrac. flowrate %
~xtr@o<p&ssure Total. flowrate
...
mrq&$@5wrate
Small turbine without gear ,,P&'''> -.---
.......: Fig. 3 Power : 300 kW to 1 MW
reductor /.. "lqktpressure efficiency Pm< 41 berg
.2'...::mi$t.kmperature
, . '. Tw* < 400 OC
. :.
* . Exkiaust pressure
......... Pa,, s 5.2 bar g
i......... .
.. ..pesign consumption speed c 6000 rpm.
Small turbine with g6q.'.:
;. ........;
Power Fig 4 Power : 300 kW to 1 MW
reductor ...... -: Inlet pressure efficiency Pwas 41 barg
...........
...... Tm 5 400 'C
............. Inlet temperature
..,.. . ...:. ,..:
.:.. Exhaust pressure P- 5 5.2 bar g
...........-.
~

......... Design consumption more expensive

vety sm&t&jiie Power Fig. 5 Power c 300 kW
...........
\ . :,.: . efficiency PW < 41 bar g
.........I THa 5 400 OC
P- 2 5.2 bar g

Partial load on heavy duty Fig. 6a and 6b

turbine
 GUIDE DOCUMENT

I PROCESS ENGINEERING DESIGN GUIDE I

SECTION 1 - PART 1 S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) STEAM TURBINE

.........
_.._ ..
GRAPHS
:
,,,,',
, .
.....
.. .,
: .
............
.....:. . . ;
.::
Fig 1 , 2 , 3 , 4
Fig 5,6a, 6b
source from WORTHINGTON
Source TECHNIP ,
.
i . >.; .,,.:.......
-. ..
.:. I. ' ,'
%.,/:,.,

...,.. ........
.......I
'
,I ..
...........
: , ..
F a r e No1 ....:'5'-

......
.A.

Efficiency of hea$&fv back oressure turbines .........

. .,
'.. 5
,..@$dr~> IMW) .'.................
. i '... .
 GUIDE DOCUMENT
I lrnued by

PROCESS ENGINEERING DESIGN GUIDE pqs

SECTION 1 - PART 1 S.S. 1.2 :PROCESS EQUIPMENT 15
PROCESS MANUAL (DATA BOOK) STEAM TURBINE

,.-..._
.',,.."...\
Fisure No2 .i :.. /i ..: :.
Efficiency of heavy duty condensina turbines , :.., '....'.."-.
Power > I MW .. . ,... "....J"
:
;'
..:..-.....,.......,,.;,
.'.. ,...~ '... ,.
 GUIDE DOCUMENT -

PROCESS ENGINEERING DESIGN GUIDE pape

16
SECTION 1 - PART 1 S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) STEAM TURBINE

.-..
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE w

SECTION 1 - PART 1 17
S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) STEAM TURBINE

....... .
,.,..--.., '..

I,
 GUIDE DOCUMENT
I b-d by ~m n*

PROCESS ENGINEERING DESIGN GUIDE

SECTION 1 - PART 1 18
S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) STEAM TURBINE

.......
.........
.....
Fiaure No5 ,<.! ... .: :.
Efficiencv of vew small turbines .......... ,;.:
..........
(Power 1300 kW) ...'..'../..........
:........... ,..'.>
......:..........
. . . ...._ .;:
: ,.
.; ........ .,:
'

:.,, ............
.,,.--.
. ...
.:
. ' ,...:::.
..' .... (2..

.......... ...........
I....

...........
<........
'.. '..(..'-.. ..............
" ;:... ...
% . , , ,

! .;
: .I .."...
.......;.:: :
....
I

..........

-
 GUIDE DOCUMENT
I k-d by W V cnlptanm ,a".

PROCESS ENGINEERING DESIGN GUIDE pape

SECTION 1 - PART 1 19
S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) STEAM TURBINE

,,...._
. .'..
...'.....
,' .. .
 GUIDE DOCUMENT
h s d bY Bm*ne Vunans Rev.

GE I 312 1 1.1.2 1 XI1 I 0

PART 1 - SECTION 1 S.S. 1.2 :PROCESS EQUIPMENT

 GUIDE DOCUMENT
LBusdby W n v Oup)anS Rev.

GE I 312 1 1.1.2 1 XI1 I o

PROCESS ENGINEERING DESIGN GUIDE ~ g e

1
PART 1- SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) DIESEL ENGINE

.......
..-. .
,..:
,.'. . .... ...
SPECIFIC CONSUMPTION ESTIMATION OF DIESEL EN&N&.-.,<:
.......
. .,;.. ......~.
,..
...> .......: ...../.
....'..,:.. ..........
.....
.'
The two graphs attached .?!ow. a rapid estimation of .&&$xpnsumption of a diesel
engine. ...'.......' '.,'. .....
........ .:
....
('
......(' .........
.....
......; ;.....".....
I.

........
... . . . .
1) Estimate the engiIle.Sp&pc consumption frorq'~dph~?;
......... ................. .......
.............
,i..

2) Do the correption-a..thz p w e r by taking<lnte.+&"nt site conditions according to

IS0 3046 s&hd:&i*os'kd as reference by tfie,.*$bUctor (graph 2)
:.,:. ....:'.... .'.1 ......;....
., .. . .
. .;.'... ........
... ...;.' .... .I.... .._
........ . '.'..,;
..... ..............
.' . .
,.. . .
I.
.....
:
........
.. .. .. .. . . .,: .
Note : ;;;.-.'
- :. .... .::. ., /.. ... _.._ ............
.
.............
.___,' I
.'..... i....
~dd.%&al.c&ection related to &.&-ir.riibisture can also be added.
: ,. :.. .........~...
......'
;.
,..'., . ... ;';
,"i
..... .....
,., .. ...:
.i
;
'
.';.:'..,/.;,..;: .'::
: ,. .. *
:
.,.' ........
i
'.. .........
.I_. ,:
.'.'. R&.*,'s : .......
/:,.............
Real consumption is f~did'nhfseveral parameters such as, rotational speed, fuel etc.
. . &w
The proposed m.@$bd:::gl to estimate with a good accuracy an indicative
,,:::.I._'......
consumption. ......
. -...
...:........ I

~pecirication<6f &@$.engine has to show the operation conditions such as, continuous
operation, i!~bih@t$nt operation, operating time, operation duration under overload
condition,s-.&bas fo specify also the operationing type, example, automatic starting.
.
These .i.&gnrrat:n are essential to choose an effective device.
.!
.........
,
.:
<............
I.

........;
.............
..............
.:...'.. .. . .'; .j
...........
.....
......
............
; _._. ,-.,
:;
,'. ..:..
..............
:a
..........

....
 GUIDE DOCUMENT
b e d by Boa"* -nq mv.

GE I 312 1 1.1.2 1 XI! I o

PROCESS ENGINEERING DESIGN GUIDE w

PART 1 - SECTION 1 2
S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MAIJUAL (DATA BOOK) DIESEL ENGINE

,.-..._
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE ~ g c

PART 1 - SECTION 1 3
S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) DIESEL ENGINE
,....._
 GUIDE DOCUMENT

RT 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

.S

I
>/

i
2
u
u
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE p.pe

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) UNES SIZING B
.......
,.,,............ '.
... .:.. . . .,.. ,...
CONTENT ..............
.. . . - ,:
...........
: <. ./ ,., ,,.>
;. I . . . . . :

. . . .
. . <. .'..'..
...,.... . . ..._
,/',,......
: ......
..'... . ....'.:
.
. :.
. .

1. TUBES CHARACTERI~~C$
..--..
. .
:....-. , .'.
C. .....
............
. ,;............
I...

........ "..; i

...............
;.............. ..,',..:
.,- :......,:,::
............... ...... .....'
;.'...........
2. ESTIMATION OF;TL&S$HICKNESS ;: . .I:....; ...
;...................
:'...:"... .. .:..........
:... '.;
......... '-; ............
3. CORREC~&&$&RS . . ......... . .. AND FLUID VELOCITY
OF PRESS~R~~&QPS
;<.,.--:
......
........>
,..: ,..,
.. ..
:'. :
,t <
..i
' .i
..'
................ './
...........
4. .........
LINE.,.:.&NG;$RITERIA , . :...
,......
..'/ .........-.. ,..
...........-...?
:' :

4.1j-..fiipid lines within ba@e%ti& '

.t&2>..$a:sr'iines within ba@&~wi '.'

.
<./:.&:% &xed phase lines in&6%.+ery limit .
; -.
.' 4:'4,;3Jtility lines in off-site
.._
'
.;.
4.5. Exchanger tub?$:::: .......
4.6. Sonic velocity i ( l:.';: ,:
:-._:.. ............
...............
I....
.........
.... .:, ...
5. PRESSURE D F~O~:~RKING
............ , . . ._:
............. '.
:: '
. . '..
., .. . . . ...
..
........., ..._
% .

:...........
. ..: ...../
....
....-..
.
: ,
:' ... : ;
..
.._ .::
._'._...
. . ..._
.,_--._
.............. ...
.,.. ..... . . ...: :..,
. . . .
................
............
......
.:..I. .,-.~
:. ~.
~ - .. ..
..........
..........
 GUIDE DOCUMENT

PB=
PROCESS ENGINEERING DESIGN GUIDE
PART 1- SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) LINES SIZING 2

......
,... .'.
... ,... ..,
,,
,:
I I I
Nominal diameter Schedule Nominal diameter Achedul: ...
I. ::
in ' Thickness in ' .,..:.
....:'..,J@kkness
(4. an) A B C an (4. ext m) A 8 .;',C,;.. "...;"
an
- .... '.. .
-.
12 5s 0.396 20 : 0.478
-
-.mi
i
(32.385) 10s 0.457 (50.800) l O . ' , 0.554
20 - - 0.635 10 - .' 0.635
.:.:
,,.,z.'..
30 - 0.838 ,.... 20 <S&.. 0.953
- SM 40s 0 . w,...*..., 30 ,
::'..+ ..L
-
1270
- I.*<., ,:; 4p...'...-'... 1.506
40
- XS BOS ' <.'
I@. &' I. ....:...,: - 2.062
60 - 42427,..'.....> ,:"sp): . ...;. . - 2.619
80 - :"..l,f45 '-..,
‘‘..?: ~p..;
"
.
,.. .$w:.,,,.',:
':.. "a.. .,:'-
3.254
100 - :",.. 3.810
- r,----...*.*o;,> .:-,.a*.. - 4.445
"'.a*'.
'
120 XXS
140 - - ,.. '..,.'.-,2858
...I.._.

, ‘“.. - 4.999
160 - - . . '.....'....?<332 24
< -..,:
'... :. ; ...'
:I.

- 5s 0.554
- (60.9602.---..,'....".10 - 10s 0.635
14
- ....'w.:
~,.~,;"~.,::::0.396
<. . .
......,..'.... ..... 20 SM -
- .. .. .- ... ..'.'. 0.635 0.478
.. ,.
0.953
,I

(=.=) .,. . - -
10
20
30
-!:.
I

.... '

_ ..i
0.792
0.953
.
,~

~.. ....,':
,,...... ....___.." 40
;
: 30
XS
-
-
1.270
1.427
1.745
st$( -:;,
40 ,,.:,-'.,, '.....,',.'
- :;..'xa> .'-...:.'
w' ...,A.; ;.:.,-:--
1.110
1.270
1.506 ,.,-
.
+.
_
,;',:,--. :!,.....,
-..., ......
'-.,.
- . _, '
60
80
100
-
-
-
2.459
3.099
3.889
m;.- ... :, ..,. 1.905 , . ;;. ' : .
. ... .; :
120 - 4.602
.A@ ...-..,:' - 2.380 2.. .... , ;/ 140 - 5.237
.., -.. -
: . 1 4 ....':.--
;',.?@.
- 2.776 '.. '. 160 5.951
..' - 3.175
33 10 - 0.795
160
- - 3,m> .-.. ... (66.04) - SM - 0.952
16 - 5s 20 XS - 1.270
(40.640) - 10s 'q.?.ZE.. . ';' -
10 - ;.;... ..q.635.,.' 28 10
- -
0.792
20 - - ...-.....".:g.792 (7'1.12) SM
- 0.952
30 SM - :' -.-.._.__ 20
30
xs
- 1. n o
1.588
..".:
-,.-.,'-.
. .. c i i o
.; .., ....'...,:1.270
:
40 XS - 5s 0.635
60 - .., . '..'._"..: 1.666 30
10 - 10s 0.792
80 - ,....... ,, '.' 2.141 (7'6.20)
- SM - 0.952
100 - ........
. -... 2.619 > ~
20 XS - 1.270
120
:
,:.... - '.. : 3.094 30 - 1.588
140 ,.'.-.. -- '; 3.650
-
180 <.< '..':; 4.046 32 10
- - 0.792
, - ... .'..5s
, , Std 0.952
(812 8 )
18 2.. 0.419 20 XS - 1.270
(45.720) ,;:;,.. ...........,.'10s
A. 0.478 30 1.588
i10 ,.
.?1 - 0.635 40 1.748
'T ...-..
.. .. -.....SM - "' 0.792
10 - 0.792
0.953 34
(86.36) - S t d - 0.952
20 XS - 1.270
30 1.588
40 1.748
36 10 - 0.792
(91.44) - S M - 0.952
20 XS - 12M
30 1.588
40 1.905

Remark : For the big diameter, attention to

the design thickness of the pipe.
 GUIDE DOCUMENT
I by Bm*w Ch.pua w.1

PROCESS ENGINEERING DESIGN GUIDE RW

PART 1 - SECTION 1 S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) UNES SIZING 1

..-....
,.... .
1 TUBES CHARACTERISTICS .,'.'.... ....:. ..:.
...
,..;,> ..........-,..
. '
,.'/
The characteristics of steel pipes with commonly used diahdte$in%e industries are
shown in the tables below.
:
..,:...
. ....
<...":
.,. ._.. ' ._..
 GUIDE DOCUMENT
!ssmd by Boo*no -.w W.

GE I 312 1 1.1.2 1 Xlll I 0

PROCESS ENGINEERING DESIGN GUIDE

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) LINES SIZING 3

2 ESTIMATION OF TUBES THICKNESS (1)

............... : i . .

The calculation of the minimum required thickness depen&$.-$ . ~standards

' used
(A.N.S.1, SNCT, ...). The following formula, extracted fm,d:'~9E6~:.8.31.3.
.. . .... _ is the most
.,.....
, .
...
I

commonly used :
...... . . . . .'... .5
.....
'.._.-. ..:
..........
, .. ':..
=
PD
2(SE+PY) C .......
, c
' ............
.........
.'.;.:.: ........;
+
.... !........
e
'., ......':...:":
i...:
..

: minimum thi~,[email protected] with (e-~)c~lf3..>--.::....:.

1 .

P : design prtysu@:jp.ljar g
..............
...................
D : external &meter-i6 mm
.........
....... ...;
S : basic a@&jbl&stress in bar e x c l u ~ ~ . & i l i r ; 'joints ~ , or structural-grade quality
factws, t@?t.&nd on type of m?te&l.$nd the design temperature.
E : quaiky:*toibf the welding ;.' ................ ,. '..'
Y :i6&i'cq$ff&ient %...
:0.4 until 482 .......i II:
C : &m,s{oh allowance in mm ...................
...
...................
...........I .;'::-* :.-.-..
..... ...... ,?
5

,/

(1J'Fgr;mgrp . . . information see & .w . .6..3.1'.3(ex. ANSI)

:." .... ....'..:, .' :/"... .) '..'
..'''&=fi"at&ickness will be 12:5.%Ir.bigher
.... than this value e (manufacturing allowance).
...;. ......
...,'> ..... '.:
...............
,

. . . . ES :
MINIMUM THICKNES$'W~
...................
- Carbon steel or.--.
.......:.. ..
k~&t+it&w-~ercenta~e alloy :

.. I.,

,,..:?-.:l.rjlm
.. for 0 < 318" (instrument)
i:
::
,. . ;"!h.6mmfor2wr0>318"
-.
....
..--. .. ..*.:.,'2 mm for 4" 2 0 2 2 112"
: ; ........
.:.......
. '.,,'
: *..
:
.,;. . 2.5 mm for 0 2 6"
,
...........
5 :

..........
E1
P=
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE 1 PW

PART 1 - SECTION 1
PROCESS MANUAL (DATA BOOK) I S.S. 1.2 : PROCESS EQUIPMENT
UNES SIZING I
.......
TYPICAL VALUES OF "E" . . . .. ..
:......
.* .,

.
i <'
: . ::
.........
- Carbon steel or steel with low-percentage alloy : ... ..,.
,.. .':.
. ..._ .,;
..... ..
..
I

. . . . . . .'
, ....
1 f o r 0 s16" .............
,:.; .......:/ / .
for 0 2 18". E = 1 in case of radiography of the ..+rding, E = 0.85 if no
radiography. ...... :.I... ......
...... ..,..
.._
........... ....
:.. .......:;.; .
;..... .-...~. .
..............
- Stainless steel : ,... ......:. :
......... ,.......
, ,
,>.-.. ....:
:.......... :
. ,... ...........
,............. ...........
. . . . . . a .

..............
lforms8". ........ ........:
.:., .. ....'>........
....“....."
for 0 2 10". E..-.~l..h:"case
. of . . welding,
radiography:oftb8 E = 0.85 if no
radiography. :>...:'-...>.,, .........
:_ ;'.... :
.......
.......
._ I ...
In some cases, an?cd;rn&& study shall worbg~rt;i'&&cessity of radiography (or not).
......
..... . .' I
....“...
;.;..-. .......
,,
, ,
:
...., ..: ~,
I .
..............
; :

VALUES OF t&. I N ~ A R ......

(ref. ASME ~3f-$1$90~'i;l
:: ,._ .-: .,.............
................. " . .,.'
T ~ar&..::"'i.:?@ ~r 5% ~r ,..,;:::~~S%MO Stainless steel
O C s t “... A.335 A 335 !. '........:'A 3 k A 312
A:jQp..,
1. . . . .
'"P11 P5 .'.........
'.... P 1 304L 316 316L 321
. '
S38 1379.3 "' 1379.3 1.;339.3. 1262.1 1151.7 1379.3 1151.7 1379.3
...............
93.3 1379.3 1289.7 $............
3 - 1262.1 1151.7 1379.3 1151.7 1379.3
148.9 1379.3 1241.4 .......
.:"'.~$Jo.o,." 1206.9 1151.7 1379.3 1151.7 1379.3
204.4 1379.3 .............
1206.9 ,:"?i?&.2 1165.5 1089.7 1331.0 1069.0 1282.8
. .
260 1303.4 1186.2: ...'.......>97 9.3 1124.1 1020.7 1234.5 993.1 1193.1
;, ..........
. .
315.6 1193.1 115k?., ....... '1 158.6
, .
1082.8 965.5 1172.4 931.0 1131.0
.........
343.3 1172.4 2
..... ...,, 1144.8 1062.1 944.8 1151.7 910.4 1110.3
371.1 1137.9 ,:',;.?935.9 1124.1 1041.4 931.0 1124.1 889.7 1089.7
.: . . .% :;
869.0 1082.8
398.9 896.6.,..- 910.4 951.7 917.2 1110.3
. .:.@
. +.3.3. :
426.7 744:@'-. '-.,'\0&.5 882.8 931.0 896.6 1096.6 855.2 1069.0
.. . .. .
............
454.4 ;iooO.O 834.5 910.3 882.8 1082.8 834.5 1055.2
........
.. -.__
_..,'
.:'/'-" . 813.8 1048.3
482.2
:. :. ~.. 882.8
.:: 751.7 820.7 1069
510 ............ ,,; 758.6 551.7 682.8 1062.1 793.1 1041.4
.......
537.8 537.9 400.0 537.9 1055.2 772.4 951.7

(1)ASME B 31-3 shall be applied to the pipes installed inside the battery limit An other code shall be applied to
the pipelines (ANSI B 31.8 for the gas, B 31.4 for the liquids for instance).
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE we

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) UNES SIZING 5

.........
.............
. ..:j
,' .,'
'..........
' '\s

3 CORRECTION FACTORS OF PRESSURE DROPS AND FLUSD.WOCITY

:. ..........
/
,. ,":
%../,
,,-p... ,;,'.,
.!....

of the pipe
considered is

........ .....'
For laminar flo,$..:<:;.-----.:
: ........
. . .._
. ........ . .-.
. .........
, :/.. '..
:, ..-...'.: ...... ......
........
. '.. '. ... ..:
.............
'i
-... :.
. . .. ..... ..
.......
:.... ,.
: .: ......... :..
......
a .

. @w.chae
I
"
:

)"

_
..........
For tu&henth&w . , .;:.- -....'.. @i&pipe
Apk&-&.j,
.....................
..........
. ." ,,,,:.: (.?.
..... ...............
2.
>:, .....*.... ..:..-..
. . . >. ....
.'.. . . . ....: ..:..:
':
<..*....!!
..I

.. .I__... .'
:...........
, I.

.; ...... ._..
~ 2 . vx ~
2
S k d &rrection fact0r,..:
............
@int *rt
(aim )
::' ;..-...
; :. ,.: ...
:.. ................ .
I r :

...............
...._,.'.
Remark :
......... ::,......
: .
.
.
.
..
.
.
..
.
.
.
.I

-..."...."....
..
If the pipe i,s."~~~in~$aibon steel, an additional correction of roughness is mandatory.
... ... . ...,:.
.
.........
::........"..
~

,. .. ....
.---. ...
.it:';m
.6
Ia
R..
......
................
:?1&4~' calculation charts are valid only for commercial carbon steel pipes without
. . and with roughness at 0.5 mm
(hldi*
. I.
............
,
......
.-.I

: :.
::
..
:.... ., .,.
::
............
.....
.....

(1) AFTP :Association Franwise des Technidens du PBtrde

(French assodation of petrol)
 GUIDE DOCUMENT

1
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) UNES SIZING 6

.......
.
/,........
4 LINE SIZING CRITERIA :.,. :. . . ;...
.......... ., :.,
....... ." .. ',:

4.1 LIQUID LINES WITHIN BAITERY LIMiT ..,... .:....

....:..; ';

<. ./,: .
: -:
.........
............
,. ,
..... , .....
'..,
:.; ......
..'.A,.

-.....
...-.
........;.
,
I ....
..........
. .... !
. .....
. i

Type of line .<aP/'

..........
. (barlkm) (6) .;.....,
..,,.-.:...... . ...:. .Max. velocity
'. - , .
, I . . ;

'.N&&.::.:
.......... Max. ......', :.. ,,':, (MIS)(6)
,
8

. ......
. . . ....:. ............
.a
,,#.

Pump suction ................ ...............:

0.9 '.............. p.6 for 0 s '2
I
Lquid at bubble point or containing :. .,:. .....0.,6 .....
.........
..
dissolved gasses : ..........
........
.... : ..................
. .:;. . . . . .'0.9 for3'<0< 10'
.. I..,. ...
:
.... . 1.2fOr12'sos18'
.,._
................
.
............
., ._
............. .. 1.5for0220'
,. ..
.. . .. . i
. ._.
Liquid far from bubble point,:-::::: ". ...;:. j.
.:, .. ,."..
, .
I:
2.3
......
:*,. ',..
.......
.
....... j. ..........
-. 0.9for0sT
1.2for3'~0<6
.............
._ .,-. ....
. . ; ..., 1.5for8"sP)r;18'
:.:::............ .................
/ ...:.... ,..>
:; ,.-....._ . ...._
....,.:. 1.8for0~20'
centrifugal p u m . .~ ~ i 8 c $ ~ / . ..'........!
...
AP s 50 bar ..:. .:. .....
.,. 3.5 *.., ‘....../
......... 4.5 ) 1.5 for the small diameter to 6 for
AP > 50 bar L..'........... 9
-.....I.: ...I the big lines
......:"..
;'; .-..,,
Kerosene lines . ....
i. :,. c..".:.:: (2)
(JPl.JP4 and kemsene) , '.
................
: ..........."
,

........
......... >:,
Columns withdrawal . - 46 0.9 0.6for0sT
..............
......
..'._.
.. .. . . . .
.........
.........
0.9for0 2 3' (1)
. -3
;':
:. : '.. '..
Gravity flow ,.... . . . '. . 0.25 0.45
....... \ . (8)
........... .._.:
Water line In carbon:::s:*
A) Cooling water (7) : ...... .:
. '.__
..........
-
- Large header e h h , ."..:' 1.5 (3) 1.5to3
pumping room grid
.\'.'.....I..... .
units
:
- Lines ~ ::
: . b t l e r y l i m(4) i 1.5 for the long lines ; 1.5fof0sT
.:. .... .:
.......I .
,
.
.. .
..........
.
~
2.5 to 3.5 for the short lines 2for0=3'
2.5for0=C
3fOr0=6

B) Sea water network 2.5 to 3.5 (2 min.)

i
fi C) Boiler feed water PC50 bar 3.5 4.5 3 to 6
P> 50 bar 7 9 3 to 6
i<
i Reboller feeding (5) 0.2 0.4
s
 GUIDE DOCUMENT
I W b y w n . -no &.i

PROCESS ENGINEERING DESIGN GUIDE R9e

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) LINES SIZING 7

.......
,.--. .
.....
. .:. :,,
.......
,,' :,'
..........
. *....,:
.. ............
:
, .
I
'. /
-. ../...:, , ; :,
(1) Minimum fall of 3 rn before being reduced at the pump suction (St;kf~<h<~is
4.l).
.:;... ,..... .....
(2) Max. 3 mls (average 2 @+.This velocity shall be limited to.~mliat:~ inlet of a tank or a loading
berth (on a 50 to 1%.m tength) in order to decreasA$ia.nsk 'ielated to static elecbicity.
phenomenon which a&&u$,bnly on this product categfi?:.;..;)
.,.........
. . '-..
............ <:.... :.
',..t .,.--.:
.
(3) The allowable pr@$e.@iry to be fixed for each case;.
............
..... .......
...!.::
'
I ;..-.............
...,;: .. , .
(4) Small diamder-f?ipes.&ich are used to cooft$&dne shall be overdesign because the
supplier d+a:ienOttoflen finalised during tpligd,si%q&
.......... ....
... ,/; ........
. . a
...............
(5) lndicatkn%$y, 2.kadvised to make a de'iail@lqladon (the detail calculation of the reboiler circuit
is qade by@j-leat Exchanger ~epa&nt). ':j
..... ,..<,..'
;:'
:: ..
.. . .
..................:
<. ...........
(6) . ~ w . v a @ s do not supersede m . * i = e & b r
,.;,:.:,:. ;..,'......... . .....: ..., requirement.
(7):. ....?aiidyso for the utility water. ....: *
.,-:,..........
..
(.,/'..:
;:.
..... .{ ..../:
.I' ,'
:,.
. . . [ I. ~ o i m avel* l : 0.6 mls. ..... c..
::....
... .._'.. ... .;
...: '
. ..... .
".,'
;.................
:. . . . . .
: . '..' ': . .:
.......: ............
............
..........
%

.................
. -.
...............
................
;.,..........
...............
.......
: .. .. ._....'
..~,
.........
.............
..-._. .._
.'. ,.-.. .!.
..,;
.I
:.' '..,;: :
.....
...........
.......... .......,.::
. . ..:.:.
, 1
,., ,,.
.
, .
.---. . :; :
...............
.___,I

........ .,..~ ..,

::
:*.~.. .
........ ,'.:
..........
 GUIDE DOCUMENT
)raMd by BaoLn. ch.p(anm Rsu
-
GE I 312 1 1.1.2 1 xlll I o
I

PROCESS ENGINEERING DESIGN GUIDE pqe

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) UNES SIZING 8

4.2 GAS LINES WITHIN BATTERY LIMIT . ......

. .
.........
. . .....
,,,,, . *,
Type of lines Max. pv2 Max. velocity Normal . &'..
......... .-.-&x. AP
GAS LINES ... .. ,. . .-:
I . . .

.
. .

>..:, : ...............
... .'
P520 barg 6 000 (3) . . ......
: .._
,.:....
...........
: '. .
20cPc50barg 7 500 (3) ......
.I...... /.._.._ ...: .
....
C_

50<P=80barg 1o owizj.
. . .,.:.
:...... :.
::' sure
:"< @y~?t&
drop shall be
and consistent with
P280barg .....
15 OOQ.@+.>-.::.;
................ ..:..*. '-the.':;AP allocated to the
........... ..".....?..:&&tion
considered
...........
.....-......... ;
.:., ... ............
;._
. . '... './
Compressor suction ~ o n s i s t e n $ ~the @ above .'.. ..',........:
:...;,.-
va~rii?.~''.trefer' to Part 4 - . . .. ... .
s:S:,,ff?Q. ...
;: .............
;.:.............:
Compressor discharge ....:::Gf
.... ,' . .,: .;
:, . . .
*:&part 4 - S.S. 4.1) . 0.45 1.15
. ..-.
.. . . {
.......... /
,
:: .....
...... : ..........
Discontinuous operation . .
.
;
5 .

:....
,,..:, ..........
: :
:;:, ;.., ...-....' 10000 ..I:'.....;.
.. ..:.; >
,.: ,.. .....
Pcsbarg
... ..,:,,, .. '>. .,-..
. . .., .... .
........
,
: .....:
See figure 1 page 9
50 < p 580 baF'$' ......;......... 15 l)OO
. .
.. .. .....
I
L .., 25 OOo “....._
::
(..
max. AP : 5 mm Hg
.....:......
P 2 80 bar g''..:."
...
..' 5
~ d u m head
n I P> latrn) ...
15 opq:i&), ....... 0 E E
: , .'....?
; ',, '." , ,
:.. .. . 3 =8
Vacuum distillation head
Striwer steam recvcle
...............
.............
. .
......
i_ -s x' mg gz 02 0.45
.......',,,...
r-
: -.:............ 02 0.25
,.....
Kettle rebdler outlet
.....:....:.-..
<. 52" 10 15
STEAM LINES H20 (6) :
; ............,.
......... '..$$l)OO (5)
.......*.~....
Ibarg 3'-8" 30 40 0.12 0.24
LOW (2)
Shod .--.. .............
.....:15 000 (5) 0.46 0.92
::-'. ! 210" 40 60
10 .30 barg Long (2) .:"..: ..,:..: 15 000 (5) 0.23 0.92
.....
short ........".. '.:
................
. . . .... 15 000 (5) 1.16 2.30
~. 15OOO (5) 0.35 0.92
40 barg
........:::
~onQi2)
..........
+?*
: .-
~.
15 000 (5) 1.16 2.30
:. ~.
. .
............ . #

..........
(2) These values shall be taken as first basis of calculation.
(3) Indicative value only. Do not exceed 15000 (for new design). For revamping, limit of 25000 could be accepted. These
criteria cannot be applied to the safety valves collector networks (flare and vent).
(4) Column under high pressure.
(5) In case of high pressure drop systems (pressure reducer system, ...) value can be extended to 25 000 and pressure
drop can be relaxed.
(6) A special attention have to be paid to long lines (offside ...) feeding steam turbines in order to set the right pressure at
inlet as forextraction.
 GUIDE DOCUMENT
I Issued by

PROCESS ENGINEERING DESIGN GUIDE

-98
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) LINES SIZING 9

: ,..-.......,.
i ['
:..' .
... ...."...-,::
,, .
::
:
: ,: ,..> '....,..'
,
Figure N ' l : (, ,.' ,
.-...."......'.,."../;,>.''
,

Allowable AP in the column ovehea~;.',.,' ........'

./.. .,...
 GUIDE DOCUMENT
br BOO*@ ~upnrw mv

GE I 312 1 1.1.2 1 Xlll I 0

I

PROCESS ENGINEERING DESIGN GUIDE %X

PART 1- SECTION I S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) LINES SUNG 10

:_._. .
4.3 MIXED PHASE LINES INSIDE BATTERY UMlT .:,..:,,.. .'..:. '.:,
.. - .i
#

;'] ....“....I

a. Step one, use charts of the gas lines by considering the ave&',+e=ifii;: gravity of
. . . . . .:,:'. .
the mixture. Criteria should be fixed as follow : .....:.........
'. . .
:
. .......
.. ,-.. I'

.........
vm:10t023mls : , .. '..
......:
. . . . . I .

p ,.vm2 : 5 000 to 10 0C$.k&hls2 (max. 15000 kg/rn/i;'~..

< ....
.: : ..........\..
:....... ?
Determine from the s&biiic-.~brts the flow patep-ik$Omia~ we try to be in the
range of continuous fl,&;(&ajif;ed, smoottl or \?la*.; W r s e d ; annular ; bubble
for horizontal lines .~.dis$1$6d ; annular or bubhj8.f&&ttical
._........... lines).
- (. ............."
For h ~ r i z o n t @ ' l i & & : ~
For vertical~in'&:;s$
~ 2 rl)
figure
figure 3
..
......
...... .:
;
. . . .
:...........
:,. .......
.:
<- .............. .........
.............
vG and v~.~eth&wperficial
.. ,-.. ..": ..'.. gas and l i h ~ i d $@city respectively in all section of the
;~..........
pipe. :; .,
.. '.. :: ..
.................
....... :,: .............
:.-..
,, . . :.-...
(),
. . . .
.,,:?' *.? ..../. .. :.. .: ..... .>
,.r''..
.g*- nce :G. A GREGORY &~C?:-S.I
. . pse notes forthe design , d . ~ i ' ~ , ~ gas, KA212
f o rliquid mixtures,
.., See
, ,
tea 5 . 6 , 7 UniversityOft$tgbry ALBERTA 1977
- Section 4.4.1?.., ....
..;.......
: ......
......
also GE '....
. .; ,
..-... .,'
I.... :;.
.......
,

b. Return line from reboilet butiet: ?

..........,.,:
Optimal diameter anii:'$&ure drop can be estimated by empirical formulae :
.................

....
....
@=2 * 10-7 * p:*. : v;-x;%
............
............
....... ....>/

4ootkna(:",..-.: ) : in inches
Q" ....'.,.... ..
... . . :volumetric flow rate of vapoui- m3/h
/,"...;.'..............
'.... “.. :'. density of the vapour, kgIm3
.. .~

P L t,~ :; : density of the liquid, kg/m3

,-x .......... .,:.
,,,i,&........ , :vapour mass fraction
. ... . ,
:,..... :pressure drop in bar
.-. .j
.. fm.,! :average density of the mixture kglm3 -
, .,'
'-4m. :average velocity in m/s
L : pipe length in m
D : diameter of the pipe in m,

I for a short calculation, 0.4 to 0.6 barlkm of AP can be considered.

I
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE

PART 1 SECTION 1 - S.S. 1.2 : PROCESS EQUIPMENT
11
PROCESS MANUAL (DATA BOOK) UNES SIZING
.......
........
........
1.~
c. Lines with heat transfer
', .,
: .
.. ;;
.........
........... ::

;. ;:,:<, .;',,......:
" .'./
...... ..,':.; I~_
Furnace outlet (liquid phase) : as per inlet criteria.,.
.j:. ... ..."'....>.. ......./'
.: ,............ .: I.
:, . .
Furnace outlet (mw~hase)
............
... .:
. ....,,!;
%
..
.......
Typical ~ a l u e ~ . ~ . . ~ ~ sdrop
vacuum condti'l&.;:-;'
.....-.......
s u rinside
e a h&ij.tr$h&er
..........
(' ,, ,,.-. :
...... ...
L.

.. :.." .
line at atmospheric and
I~
............. .............
.............. :
-l
ATMOSF+ERT&
...............?:: ..............
........?
Small "&sih'&rbon steel .("...:......
... a
. ......
'.;
barkm
I
~ m a ~ . ~ , ~ ' b . i $ . ~ ksteel ...+...
i n l e ~..........
s barkm
~i~bnit&.it.lskinless steel . .;: . :, 3 barkm 1..
~btdl q$dable pressure drop j
.. '..;..,.)I. 0.5 bar
i' : . .:: .......
...........
,,.],.'.;....i . .
...............
....... .............?
:'.. - ,,
,
,;.....
. .. , 2.> ........
I.; .......:...-...,.....: I~
,..........
.
.,. ...... *:u&cuuM
.. ,:....-:
........;;
.:'.....
q

.:....
.........
:.......-
. . . . . . % sonic velocity .....
.... .. : 80 I-
"..' Total allowable.......... mssure d k p : 0.35 bar
:;. ........
.:...
. C;".; . .
*.. '..........
, I ~

d. Condenser ou&t.lihes..,'
........:'::...'. ..
:.. -.:...........
...........
Apply wsz$i&%teria of pressure drop as for gravity lines (Gas lines chart applieo
to mixe@bha~a$'
..........
._.,
.
.....
...
1 .........
'.. ...: I ~

.......
.:
'
...... ...'
i
, I

.. ,....;
..............
.............. I-
.,.;..,.. '...,'...,
.....
........
::
. ,;
...............
;,. *-.;
;
I
:: ~.:...:
/'

....
I

........,;,;
\

..........
I
L
1
1
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE ege

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT

PROCESS MANUAL (DATA BOOK) LINES SIZING 12

Flow pattern in rnultiphase system for a horizontal pipelines;...

:;:,
' ._.. .._" .. .
, .
::
I' :
;.-:, "-.. :'
,,

:< . . ..
 GUIDE DOCUMENT

GE I
luved by

312 1
~ mn-*

1.1.2 1
ciwterrr

Xlll I
mV
0 ,
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
13
1
PROCESS MANUAL (DATA BOOK) LINES SIZING

< ...
......_
,. '.. .~~,
:
:,.._
I : .
),:
I
Fiqure 3
.',..,
. '...,.'...,",: .,.'
,. < ,., ". :
Flow pattern in multiphase system for a vertical pilwl~nes.......I'
. :.'..,'
J
.,.,,. .... . ..:I

I
I
.'
'I I
I
I
I
I
)I
I
I
I
I~
I.
I.
' I-
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE p.ge

PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) LINES SIZING 14

......
..........
4.4 UTILITY LINES IN OFF-SITE .i ..','. '...: ~,
.
.:..........
. :
;
..
The following typical values shall be used and shall be confirmed th&gka:cbst
:. ...>',.' ,'>
impact
analysis. ........... ,../:.. , . . . . .... ,.
: '..
TYPE AP bar Ikm , .......
!..A..... .. Max. velocity
Max.: ...........
.. ,
rn/s
< '..' : ........
v*,. j...........2
Long carbon steel ......'...? .@.
.... ;. .: ,..; ::
pipe lines for water /'..............
.....
.............. ,
;. '.. - :....;
.......... ..
Bonna pipe .....
........ :., .....; .............: 2.5 to 3 ( m a . )
:.........
condensate return . l...".-:----... @.'2to 0.3 .........
.......... .>

in multiphase ......:..
...........
- . ,, ....
. .
, .'....,'......;:
10 to20
.....
... ,;,... . -..;. .
,: ..............
........ .'.:
...............
'x.,

...... ..
.!'.. '......'..'.:...
::
4.5 EXCHANGE~~JB&;, .
A limit of 6Ct& kg&ls2 for the .... :.-.
sh~'b;;..ge&rally pv2 considered on tube side and on
shell s i d p i . > T h i i criterion
~ ~ ~ appli@s:.:gn..b$(ndle inlet only but then some flexibility is
possibl4 ii9@*lly for debottlenecpn&p@ijqct.
......." i ......
.,..,
:C
.. :.:.,
. ........... ....I .<....;:, ;
...: . ..--.,
,.:.........
For ideal gas, sonic velocity: SIr d
'.,($iW as follow :
( :
,v =
.............
v~m : ~.$cmii\jelodty at T
.
Y
R
T
.
: ..".
,.q$&j.;:
I
, -
......&
-. 79:5 JIK kmole (constant of ideal gas)
.............Y:&lute temperature of flowing fluid
MW ''is''.;. " ' ~ l e c u l a weight
r
......... ..
: . .
.............
5 ,
...*'..,.'.::.
PRE~~U&~DROP'CHECKING

AP = KX..
...p4vp,
, . Qxg95r
,. ..
, . ::
fl . '
:
._....... " .....@ng pressure dmp in bar
\C'...-."
::
'
..,::'--*.fluid
j?,..... .1 :
. velocity mls
....... ,: density of fluid kglm3
K.......?.' 'k" factor for valves and fitting
Equivalent length in km (L) :
w
-
= M",
flm : average pressure drop at correspondent specific gravity, for a given tube
diameter in barlkm
For compressible fluid, the variation of specific gravity shall been taken into account.
GUIDE DOCUMENT
i -
av
GUIDE DOCUMENT
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE

w
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
LINES SIZING 17
PROCESS MANUAL (DATA BOOK)
 GUIDE DOCUMENT
ksvad by Bmb a,,pwc &.
GE I 312 1 1.1.2 1 Xlll I 0
 GUIDE DOCUMENT
w s d by em*"' -w w
GE I 312 1 1.1.2 1 Xlll I o
\
4

Page
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) LINES SIZING 19

9
,I

49-

. .. -
.. 0
- .

. .. ...,.
K - 1.0
X
....__....
Ed
z'-
--
4 Od 0
= P
001
E 01s /; rn.tlfba&w
: Qm w . d i c iri.du.

--- cr-
....-...-....-
E aisL+ 01y
K-ah.v&xq
.t Fun hligh.."ud.mt.rw.
*JhrpaDDd - , , , l c i d . b w&m..duhcr....a
A..oci.d..
D = k m

i K factor
"d
u
 GUIDE DOCUMENT
I b.wd by

PROCESS ENGINEERING DESIGN GUIDE hoa

.
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) UNES SIUNG 20

i
K Factor -
I
 GUIDE DOCUMENT
b e d OY &&no w n . ~sv.

GE I 312 1 1.1.2 ( XIV 1 0

PART 1 - SECTION 1
 GUIDE DOCUMENT
!WedbY B m b Chq)ab R.r

GE ( 312 ( 1.1.2 1 XIV I 0

:
hw
PROCESS ENGINEERING DESIGN GUIDE 1
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) VALVES AND INSTRUMENTS

..
<i .
."....
.......
.;.,,.
.
,.......-
..........
.....
...-,
.; :.
:.,/
.,.> '....: ,'
,
:' .../..' ,,-;
,
CONTENTS
.:. .L
., . . ...<. .1,.,.:
............ .....
.,
......
<..:......
'.. .....:' 5
'.
.....
. . .. .. ......
...,..-. ......
. ..........
,

<: ,.
'...,,;,i .
.... . ... . .'....'.
...... ;... .... I. .... -..>.-..
: ......
......... : i '.-, .' , :
1 ..._,.., .._:
MAIN NPES .&.?~LV~S ,......;>..
....'? :../,.I
....:....... :
: .........
I.I ~loc~~gi!~es~;~ ........: ....
.......... ...
,, ..
.:, :... '.;
I.2 CofitW':vzipes .............
'.._ '._
.......... ".:
........... ............. .;
.. .:,.._ ..:..........
. . . . ...:
., ,.. ..
~.
2
::
, .
CV:L~~~~E&INATION
. . .~. .
...........
,..-.. ,
..
.............
, '

. . .
:2.i:4.iquid .......
. .:.__.
; ..
:............ :' ..
._.............. ?
.:',.'zq',..Gas and steam :.......:.........
: ....... .........
............. ;

,...... . .z.$:;"Two phase flow: .I.......,"''.._

.. .... :
.. .. .
. .. . . . . . .._,
...,. . . .. . .. ..,.:
,
....... .....
3 : . .......
CALCULATION~~F~~E~TR~CT~ON ORIFICES
. . . ..:.
3.1 Liquid ..... \.,:'---.->'
............
3.2 ~as,@&L'*cal
: -.-
.........: expansions)
..,.......;.
.> 4 CORR@T~O$~
;.,.........
.............
'../
OF ORIFICE PLATE FLOWMETER
,.
.........
......
4.$.:---ti&id
..&*.::.)Gas
,'
...
.. ..,...::'..
.. ..
................
............
.
. $4b
.......
,'..
REGULATORS
........
...........
........ .:.
:.... ... ..
:;
*.........,,:'
..........

....
i

s
,"
U
 GUIDE DOCUMENT
I
I GE
M l Y y

I 312 1 1.1.2 1 XIV I o

PROCESS ENGINEERING DESIGN GUIDE w e
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT 2
PROCESS MANUAL (DATA BOOK) VALVES AND INSTRUMENTS

1 MAIN TYPE OF VALVES .......

........
i ;' ., .,
.....
I.I Block Valves :. ..
......
, ,. ..
.
...*,,"..
.
;.:, ;'. “........
. . . .. .'>
...... ,/
.'.. '.. '.. :
. ... . . .... .,.
'
.......
.
:
,
.-. ..
. .::
r
Y
,
X

,. ._.,
........
....A. '-:

'..
,._.I
:_
. .
....:...... .......:
..............
*.,... ...
.: ,'. ..: . L
d
...............'/
............. 3
.;......
. ;:... -
...,Zu
L

:....-.
... :;- ...;
-
.......>. “... . v L
b ,E
-
;,'...--. ........ d
-
C
.-0
ma
..... :
........
._
::
'._
..... '.:
:
Em! -
E
-
.- ..,, -gm 5 =j &
C
5 a
> 5 g .s
=u% =
c sN 3 z
a m % A -
o a 2 - L S
-
-hi?
gm 8E gP.=8
85
= 2
- 33
C -.- .Y m nn
rZ =m l X 3 $ ?5 2
cr)$Od
I , ,
.. ..
..I.....
...
I I

C
0
p....... ; .
.........“...
C .....
.-
0

.--..
..............
.,,.'.-.. :.
X B
I,, :.. ::s :

............
.........

2 -9 *..a
-m>5 -5 ->?m z
-2 %3
9 .
I=
- CD
a d 5: 8

%0 ?
# h 8 %5
m a
9
, of

-
 GUIDE DOCUMENT
I bs&by

I GE ( 312 1 1.1.2 1 XIV I o

PROCESS ENGINEERING DESIGN GUIDE Ros
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT 4
PROCESS MANUAL (DATA BOOK) VALVES AND INSTRUMENTS

CV DETERMINATION .......
..........
BY definition. Cv is the volume of water in US gallon per minute at 6 6 ~ kth&will . flow
through a given element with a pressure drop of 1 psi. ...",,,..
....... ........
.:. ,.>
; i

..' ;..
..>.(', <.:,.'./' ,/ "

Liquid ...............
,. ........
:'...
a. Non critical flow : P i - P2 < Cf APS
:
:...I ,,...........
...
,..
,:.....
.....
...:
with APs = P1-(0.96 - .......... ....
., , .i...........'
........I.. (1. ............ .:
.._._..._ . = P i - pv
or to simplify if Pv < ~.$.$+..-.d~k
........ .: ............. .
........ :.. .
.;.,.
........ .-:::.,..".; ................
......... . . ... .
G = 1.16 Q,/=.~: ......... ............
PI :
7.. ....
~pk@&$essure in bar a .'....:. ..;"', ..... ..:
I.. . '..
P2 : @&tf&m pressure in bapa---.:.... .......
d : . ..d'bq'i&,at
.. conditions (tlm3~';'."". .."."
PV : :':...-Wa&vi pressure of the liqbd4i.&t$id) bar a
Cf ........
: :. Cd$ficient of critic floyjjiS$&bpihe constructor
Q ..... ...:'.-. metric flowrate af 6&$& condition mJ/h
PC : <.:, :;: ,..c .
........... :,.*. ntical pressure bar-a:; .:
:
,,',',.... : ..;'
. .__ .; :
.... ,.. ......,
,,
C_ ....... :
.(.....
;, ........... ......
b. biti&.jbv (cavitation and.....
vapori&d.bn)
.............
P I -P2>CfAPs i::: ,.' ......:'
<..*.:
.................
Cv = 1.16
Cf
- r-'y-.-"
- Ap6- .......>:, ...:
..............
........
................
Gas and steam
.,,..':.... .....
, . '.
..........
I

....,~~i&cal flow Critical flow

........
P1 - P2 c P&-& P l PI - P 2 ~ 0 . 5 c F P 1
.,. * : ........
...... ......
Gas
cv =
Qrn
257 Cf P i
, .-.. .:...
i :'
., ..
...........'::' :
!, ',

v -.i,
& - 724 W Saturated steam 83.7 W
JPI P2) (PI +P2) cv = Cf.P1

72.4 W (1+0.00126 ,T 83.7 W (1+0.00126 ,T

cv= cv =
J(P1-P2) (Pl+W) Cf Pl
- I
 GUIDE DOCUMENT
W e d by Em** 9wpte~b W.

GE 1 312 1 1.1.2 1 XIV 1 0

paw
PROCESS ENGINEERING DESIGN GUIDE 5
PART I- SECTION 1 S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) VALVES AND INSTRUMENTS

......
.......... :
...... .. .
,I

Cf, PI, P2 see paragraph 2.1 <. .. .. .....,... ' I

...I.

G : Sp Gr of gas at 15 OC and 1 atm calculated ;l@$ing-~o air density (*) ;,

T : Upstream fluid temperature, K

." ,,......
:.........
.,.... . . .........
................ I
'

Z : Upstream compressibility factor : .. /

W : Mass flowrate, tlhr ...,,........._
Tos
.. Temperat* of superheated steam, ......... oc
Q : Gas vql.i$.@i
p ,;. ".. '
..I I
......
. c flowrate at 15 OC, l,.z$m'&hg,
, ,
........:.......... G3h
( ) G : - :.. wi*-k,= density of gas at~;~.~~;;:l,@m
Pap...........
..... ...........?pa+ = density of$%
.........>:.,... 7.'&
Jlrfai.......... atm
:. .......... 1
.<
...:
. ..:.-
. ......... .........
. .
..- ......
................
;
.. .....
..................
. . . :.
:..'..........
',".. :. : ..............
.. .. .. .. .>
, .,. :..........
. . .
2.3 ......
Two phase-,fl&.: .. :... ..::..
#

............
,

....... .......
AP is lidked
. . . to
............. . .9.5 c f PI ..:..... .
,.',..........I.
.....
..: .
........... ,?
~ i m. t ..& ,...
- ~ 6 a t i oofnliquid , . - :, . with vaporisation
....... ................'.::
,, ,. . :
' ..'/ . 36.6 W
. ......... .
"
Cv =
'.. : rn
....... ..... '.I

............., ..
:f .....
;
,

W : ........._.I
Total flo&k bib',;
dl : ........ .
densi$oi'~.&$&kure :
L at the upstream, kg/m3

WIL : ..<::~$d.flowmte, kglh

W l v :,..;:-:.: v a w r flowrate, kglh upstream
d l L (:.: ... ;,.:' Liquid density, kg/m3
d l.y...:l........... vapour density, kg/m3
............. I..'

42 '.: mixture density at the downstream kglm3

WzL : liquid flowrate, kgh

WZv : vapour flowrate, kgh downstream
dZL : Liquid density, kg/m3
d2" : vapour density, kg/m3
 GUIDE DOCUMENT
~-
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GE I 312 1 1.1.2 1 XIV I 0

- '
I
.~

PROCESS ENGINEERING DESIGN GUIDE page

6
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) VALVES AND INSTRUMENTS

.......
. ..'\
.:........
:..-..'., ::.::.
,'/ . I

3 CALCULATION OF THE RESTRICTION ORIFICE ,

....... ...'I:
...........
;.;.:
3.1 Liquids ...-. ,.......
,.,
. ((/ :
.......... , .,.'
I
.:. .. :
: ..
,.';.... .....
:.: ......-.>
.i.,

Q = 1.044 d2 , @ for an orifi~$&fioient equal to 1 %_....._.._ . ...

'... .,:./ .........
. .:....." .. '..
............ :.. . ......
I . . .....:
( >.-; ,,.-: ;
. ,

d : orifice diameteg.,'hp+..>..? ;.., .... :. .;,:

.........
.: .......... .. : .........
.............. : ')
AP : in bar .:...-.............
.-..............; .'i ... .
..........
............... ..,./
.: /.. ...;
.
;'
...........
. . .........
p : density,..........at&&$&s, kglm3
:..........
.......'i
... . . ,
.......... : ....."... ...
............
.i ':
......". ,..~.... .
;,.
, ..
.. '..... /,.: .
Q : flow&'&..&pditions m31h : :.
i., :.. .., .. ........
..............
. . . . ..,:. .,..........
../ .-.;:"...
a

............. ' ............

..I: .::..I
:
.... -.. .?
..............
3.2 Gas (nan.k&d~kxpansions) ,,,,':..,* .: .....: :
:.. ....
,. ..
..i: , .
; ....,.: /
:. .............
......\. '-i
....I

i
::... i.; ...... ....:

,. ,.
;... . . . .
...........I

j Q : flowrate inside.w::drifi&?, 1atm, 15 OC, m3/h

. -.
........:,
'- ...
.............
P1 : ~~strea~i?;~pe$sure,
:\ ..............?
bar a )~
P2 : .......,..
~own&&a&~kssure, bar a
A ..........
p : deiisity
:; ', :
at'l'8tm. 15 OC, ks/m3
< ........ :
d : ......<iifi&Qiameter, mm
...............
.........
T ... . - d
.:: w temperature, K
........ \.._.,'
,
- ............
.:. ..
.... : i
i.............
Not;.:.,'
these formulae are applicable if dm 5 115

d :Orifice diameter
~ ~

D : pipe diameter
I
 GUIDE DOCUMENT
1 4 by m o w auc&-r m.
GE I 312 ( 1.1.2 1 XIV I 0

Rge
PROCESS ENGINEERING DESIGN GUIDE
7
PART 1 - SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) VALVES AND INSTRUMENTS

............... .
. . i .:
t:

4 CORRECTIONS OF ORIFICE FLOWMETER ,......

...............
,, .. ...." -.
The purpose of this correction (or compensation) is to take didp
.p$y$t the diierences
between operating mnditions and design conditions of the .fJ&iii~t~.&nceming
, ... :
...
.....
........
the nature of product. ..... .-.......
........
, --
... ~. .....,
........
temperature : ...........
.,..,,I.;:. ............
......
..'..... i..........
pressure (only for &$::'...>::
,:. ......... <..:......: :,:
y'...-.
,.:. '.. ". .',.'
The real flowrate ..............
mhy:%&&tained-; .....:...
by multiply~ng-.t&.:lalue read by the coefficient
named FC. ................ ..........
.........;
............. ..........
Note : This pr&+d;j.k:ican be used for &l~.tybe'dfflowmeter using the method of
....
pressure dii+?xent$t{~uyere, .......).: .:
venturi tube).....
..._..._
...........
. . . .,..... I... . .:,....:... . ...:, ....
4.1 Liquid /;..--. .~, ........... ;

:. :'.
... .,. .......
.............
........i ..
,/ ,. :
4.1.1
.
~ead&Li"k&s
: ,: ./
. . .....
. . . . . .:.:.
........
,,
:
'
:...
...........
........
- : .,?
...........
. . ., * ....;:
,,.
...
... ....;::
........
.........;
......
..'
....
D, : Actual spec#&&avity at operating conditions
:: ;:;-.. ;:
D$, : Operating &c#if:.dravity on the specification sheet of the orifice plate,
meanin&@:~&ecific gravity of the fluid at the operating temperature
... ..:.. ......I the design.
estimgifidtlrihg
...............
.........
4.1.2 .. .. '.. :. referencetemperature
Reading in u~fu@~.bt.*
.. .. . . .

. ..
D....'.......::': True specific gravity at operating conditions.
I :

....
. . . . ..
::':.--'
.: D<.; . .
, .
...........
. M . .. . True fluid specific gravity at the reference temperature (example : 15 OC).
'''.--Q% : Operating specific gravity on the specification sheet of the orifice plate,
meaning that the specific gravity of the fluid at the operating temperature
estimated during the design.

Dd, : Specific gravity at the reference temperature indicated on the specification

of orifice plate, meaning that the specific gravity of the fluid foreseen at the
reference temperature.
 GUIDE DOCUMENT
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bwd by smb aupMlnD RN.

GE ( 312 1 1.1.2 1 XIV I 0

PROCESS ENGINEERING DESIGN GUIDE

-
PART 1 SECTION 1 S.S. 1.2 : PROCESS EQUIPMENT
8

PROCESS MANUAL (DATA BOOK) VALVES AND INSTRUMENTS

.......
. .
............
.' . . .: .,:
< .-. "
............. .
4.2 Gas ........... .
.(.,;.,... . ........- ,..
....
.
.
. . ..( .
..,.,..,,.'
.. ..........
4.2.1 Reading in mass
,
, ':
. ._...... .
:..........
,I.; .
'- . ..
...... ...... . .........
.'..;.--.,.; .....
....\.....
........
: ......... .. ,
.".-.:..........
.

or else

~. . . molecular weight and

. . :,.
.................
;.'.:' ...........
compressibility .*9j..--...
: ........... ,?
Index op: i .I'........
;......... ;:.;
:
;:
refer to ope&$4n$iitions
.'...".. ......
lndex..i!t:
....... . : refer to op&$&
i conditions estimated during the design. The
........
:_.. ..... values that aksbown on the restriction orifice specification.
.. :
.I ..-..
.
..........
:.,i;.
;: ........ ;:
: . . .. .
... .........
4.2.2 . .
Reading in volume ref&&to.feference condiiions
.--....... ..
>,:.

Reference conditions:&rj4e.n'ormal conditions (P = 1 atm, and T = 0 OC), or standard

conditions (P =atd>C{&
l OF).
.... '"
In this condition~..,'~d~sibility factor, z can be considered as equal to 1 and the
formula of FC di(iy.w.written
.. I as :
,...-.... ...

. . ..:: ,.:
or :.\. ......'..
......
............
.....
 GUIDE DOCUMENT
hrwdby nm*a UlnMSsb RN..

GE I 312 1 1.1.2 1 XIV I o

PROCESS ENGINEERING DESIGN GUIDE w e

9
PART 1 - SECTION 1 S.S. 1.2 :PROCESS EQUIPMENT
PROCESS MANUAL (DATA BOOK) VALVES AND INSTRUMENTS

........
. .
,........"..':.
., , ..., -..-,':.,..:.
.
5 PID REGULATORS
.:/. ,.. '.. :
Each of these three controller actions gives their contribution c.!':."' ;.I, <
........ :.. ...
.,... . . . .......
;
, ,
;

Proportional : ..,
... :' .._
:',i.. I.-.

Integral ......... .'

.........
.._
'-
...'.;
.......
. :: . . .
Derivative .:..*..._
....:,::..
,i.._
...I...............
. .:,.-__
:.I
,I.,......
; I
...._.,
.
Practically, it is comrp&@con?bine
..~ these three ........
a b t ~ nj,:!~ .
._.._'..,......._: ...............
.i;

......... .: '.I
;; ........... ..>
....I......

< ......... .........

.
. ..
............. .. ,."..
a
.':

: .., -. -.. : .............

.\ '._
Reaulation by d i ~ r t i d action a~
. .
;
'

. ..../,: ...... ..............

.......
. . .
Action of .&&..&n.troller will provokei$&.'$~&nent of the controller device to be
proporti~&t6t.a, t h e gap between._.... th$:.me.asure
.. and the set point of the regulated
..........
I.......
:.. ,:.-;.
parameiei,.
?., ......... ;
I : . : .-..
.-%

~rO,&~thi$"&$i&~, ., ... . ~.u l l f ' t h eproportionality coefficient is infinite. this is

this gap will onl$.be
d&.@"&&namic
......... stability. ,,
-j ....,i .......'
. ....
,
,: ,.
....; , ;-.....::::
.......
:.,..........
:'
........ . .>
...
Rea'dhition by intearal action
................
The position of the re$GIatbr:device is modified proportionally to the integral of the gap
mesure-set point ipkqk$on:.bf time. It is a way to bring back the controlled parameter to
. ...... : modification of the disturbance parameter.
the value of set pQjnt.dft<he
The response,..;f.t%.-a&on slower than the one for the proportional action but it
eliminate all $e.~a~~&ucedby the proportional action.
:.. . . '.. . ,?
. .....
,~.
.........
..............
~erivativereauta6on
.' ,' '. :
this'^& is to expedite the response time create by the integral action when it is
......
insWe$o+ a system that have a large inertia. Derivative adion will measure every
*riation: of the controlled parameter in time and will give to the regulation device a
p&&$nal
_..--. movement to this variation speed.
............
~f'-"Iw.Rractice,corrective action is more important than a fast modification of the measured
: '. % .

:. .~...vatbe.
...........
 GUIDE DOCUMENT

S.S. 1.3 : MATERIALS - LINES - P&ID

I' j

,,

z
2
5
3
w
E
5

f
'?

2~~.
GUIDE DOCUMENT
 GUIDE DOCUMENT
W b y wn. ChlDteTn. R.V.

GE I 312 1 1.1.3 1 I 1 0

-P
PROCESS ENGINEERING DESIGN GUIDE 1
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS LINES - P81D -
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

......
:..-. ...
.......
..,. .:'.. . ..: :..
I'

CONTENTS
>;;, .........:/'
,. ,. ;:.. '.. :
,..
:. <,.:; >:.
'..I

...."...... ,:.,,
I .. :. ...
STANDARDS, EQUIVALENTS AND COMMERCI~~,~;!~AR~.~~.
. '.
........ '.....:'.;
:
"

2 APPLICATION L :.I M ~ ~ V F
FLANGES ......
C.

..........
..,...'[:: ......;
. ,i..-. :-....
3 STEEL BEHAW$J~+I'~; ....... LOW TEMPERAK$RE..-;
i ...:-. '., ;...._.........
..................
. . ',.'
:
........
3.1 Normal~ciotjdiiin of service .............
3.2 Less$pePequent'and exceptional &~:alldii~ns
;...........
.............. '..........
....:.:....
.
..... ..:
4 ..............
C O R.: W S~~:
....
................
. . . .
. . ..... ...
.:..-...
4.1 ..--&r.i'iion allowance , .., .
4.&..-.i
: . :. ..
.lyd;&en
< . .I. .........
corrosion ,.....
...........
:,,:

.,-:. ........4.$/1 Corrosion at l!i$.d!lnperature

...........
:...";-.:
.....j:. :::$2.2 Hydrogen e g 6 .m .k i .m ~ n t
,, , . ............. ,:
..I:'. “...4;3.;;"Temperature erq*)t,bm&nt
..'..."...
: . ...... ... 414' Corrosion by suifuy:.. ..
5 Corrosion by.H2Swith the presence of hydrogen at elevated
tempe6-(*en- of liquid water)
4.6 Corrosi4 byhM
id
i H2S
.............
4.6.1 Q&&~S~&I corrosion and by pitting
........... I
4.6.r~sb':&rosion
4.6,$C(,lC.corrosion
<. ........I....

4.7 & l y t h i i c acid corrosion

4.8......hht&ic acid corrosion ) HOLD
4,&::~-~x~corrosion
,&lo) Corrosion by chlorides and sea water ) HOLD
. . Tables of corrosion graphs
':.q:~j:'
............ .
................
5 ,.! .. '$$NERAL
!
............
~
.. BASIC INFORMATION
.-.-.'. . . S l Cr Equivalent INi Equivalent
.
:
f '
. 5.2 P i i n g Resistance Equivalent Number (PREN)
:..: . i"? . ,.
......:
\

..&..... DEFINITIONIGLOSSARY IABRMATIONS 1

1
6.1 Definitions IGlossary ) HOLD
6.2 Abreviations 1
 GUIDE DOCUMENT
-

pxle
PROCESS ENGINEERING DESIGN GUIDE
2
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P&ID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

.......
.........
/
.... ..,
:.. .... ,::,::
1.

........
.. .. . . ...
....................
I STANDARDS, EQUIVALENTS AND COMMERCIAL MARKS .;.....c. ",:./...."
, ....
.... .............
Composition of a steel or an alloy according to its standard depfgh@io"&n be identified
in the tables below. Substitubq corresponding to oth.$&ar$+rd.... .. or from oter
manufacturer may also be fout@' by:usi
.'. .... n g these tables. . .
.............
..........: ::.
.- *.
.. .>.-..
I.....
, .....:
For the other undefined ........
~6btleti&:?in these tables, t..................
d & . - y ~ & ~
can~ be~ ~ ~ ~ ~
referred to : ...........>
........... .;.. . . . . .
................
................ :.. ............
. . .
:. .-:............
Table I .-...:......>..A.
...:...,.. . . C, and low-alloy gt.a&.(&<~o~ standard).
. . .
......
:
.
I . . . . . .

.
.... .
Tables I1A I B .I ~ .~.'..'~ : foreign ~ , ~ e q u i v .a l.6.$ .f ~.& c h grades (A. C and
....> ..... . low-alloy). i : :. :.
........
.. . . . . . . I

,..\ .
a :........ . ' j
.
,
., "'
.......
...........
Tables..,. '&.$
. IU ,..] ..'"...', : foreign q!vqlkrts, and its composition of stainless steel
French ghadq:""..,'
:
. .. ...' . ,-.:
I ............
,;. .... "...,':
:
.............. ;;:
Tawe
, . I V ...... : com&sifc& of principal American grades of alloy steel.
........ .......
;'
I,.. ....... '.. f
~ablesd
AIB : prindpal
.-.. cgmmercial American grades of steels and alloys
.... ;
I

. $'.SO&S+ANSI
: 86.5. Ed. 88)
:
..
:. ................
.................
.........._
. >,: '.."..
. . -..
...............
-
Note : .............
..... .. ..".'
.. ..
.? ......
Application limits &.:.fl&&s according to the type of steel as shown in tables VA and VB
are indicated inl@a&r.?ph2.
:
. ...... ....
.......
..,
.,. ,:
.:..... .:;:'..:
'.._
............
.......
,. .............
.., ... .,.
. ... ,..
I

._...........
..--.
\

..............
...... .. ...
.~.,
;;'
I. I.
r ........ ..'
..........
 GUIDE DOCUMENT
I bwdbv W V W V RN.

Pqs
PROCESS ENGINEERING DESIGN GUIDE 3
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P&ID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION
r

Table I
 GUIDE DOCUMENT
~-

PROCESS ENGINEERING DESIGN GUIDE ~ g a

4
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P&ID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION
 GUIDE DOCUMENT

\
pnp
PROCESS ENGINEERING DESIGN GUIDE 5
-
PART I SECTION 1 S.S. 1.3 : MATERIALS - LINES - P&ID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION
 GUIDE DOCUMENT
we
d by em"' Wup*rrc m.
GE I 312 1 1.1.3 1 I 1 0
,-
-F
PROCESS ENGINEERING DESIGN GUIDE
6
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P&ID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION
 GUIDE DOCUMENT

r -#
PROCESS ENGINEERING DESIGN GUIDE 7
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P81D
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

, ... ...
,,'
,' ,'
......
. ..__. . .~
..
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE st

PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - PdlD
8
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

,,.-._.
,..-. .
,:
i /
.... :.
 GUIDE DOCUMENT

Pqe
PROCESS ENGINEERING DESIGN GUIDE 9
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P&ID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION
 2
0
2 0
0 ;
.......
....-......
,,;,.; '..' :, Tableau llH:. ..
...
s-l-
- .
.:.........
,,
:
'..!,:;::>. ._
. .._
.. PtE
....... ; , ::. ,.: ......... ,,..
,

.
,.' ..',:"...::>COMPOBITION
~. ,' :. ':. ......:..
:. :, : .
I
:........'... ' . . . . . . . CHIMIOUC
FRANCE A L L E ~ A W ~ ~ . ~ ~ ~ lRETAONE
?.+A ! ~ ~ ~ .
ORANDI- ............
:'. ,.......... : :
Mn
. ,n%;... cr x MO x Avtrar
:; .
CX
. .,......., r n a x - . . q y ; :
. ,
ZBCNDT 17.12
i
.: ..... .....
L
,"> s 0.08 2 1 '.i~+{3 .: ::i~-1.8 2-2.6 Ti ;r 6 c et s 0.6
X 10 Cr-Ni-Mo-Ti 16.10 ,::.,." :, ,,.' :., '.., 2 1
,
. .. ,:
i 0,lO
................ 2-2.6 Ti T 6 C
lb,3:13,~;.j~6i~.6
I14 6 7 0
'....'@q
; :

...,. .sl?,..">s
$.

0.06 0.6-2 0.2-1 1 1 - 1 4 ld.+id;@ 1,2+3 Ti 2 4 c a t s 0.6

Z 6CNDNb 17.12 ? ,, 2 i 10.6-13 '$%id' i /,..'.~ks . ( ~+ b Ta) r 10 c et s 1
X 10 Cr-Ni-Mo-Nb 18.10 '....,./ ' .b0.1?': 2 1 10.6-13.6 16.6-18.$. ~',;2,11,6,14W.t TI) 2 8 C rn
(14 660) . :. .P....?.' ....., ,: ,.: .. .I-..:'..
2 2 CND 17.13 '.ii6.03 2,,," :...! 11.6-1 3.6 16-18 $.B;$'' ..........
........
X 2 Cr-Ni-Mo 16.12 i Oh3 2 .. .. '
.:? 12.6-16 16.6-16.6 2.6-'&'
(14 436)
I
...............
..
r 0.03 :...2 ...-j. .. :.:.fq-14 16-18 2-3 '9
316 L
316 8 12 + 0.03 0.6-2 0;2-.1:. 11>14... 16.6-18.6 2.26-3
Z6CND 17.12. r 0.07 2 '..I' i - i ' 2.6-3
1 ':J 1,s-,14
X 6 Cr-NI-Mo 18.1 2
(14 4361
b 0.07 2 , . .* .......
. .
jlQ.6-18.6 2.6-3

318 i 0.08 2 1 lb-Iw' ..',i~:.h 2-3 ...

31 6 S 16 S 0.07 0.6-2 0.2-1 10-I%-' ,W,S-.!aS' , Z q 3
Z 2 CND 19.16 r 0.03 2 1 14-10 'i7.6.~o'.y'....".a~+..
X 2 Cr-Ni-Mo 18.16 S 0.03 2 1 16-17 17-1.0 .:
,.'?:?r. '...
I14 4361 .:. .; .......>-.': ,',.:'
317
317 8 12
s 0.08
+ 0.03
2 1
0.6-2 0.2-1
11-16
14-18
18-20
17.6-19.6
<:.$41' , ,.,:.,.' ?..:..
.............
( I / Emm p.mnthlms mnr indiqd8 hs WERKSTOFPNUMMER
:9
..; ...
...: .,;.........
..'/..
....'' ,.... .: ...:......
.........?..".".'..,,"....
..... .,.
:'...
.......
....>,,! .: \
<:. ..: ,.:
;
,'
:.......... 5
. .......
. .
t
D
W
VI
I
0.
0
N sJY
0 1 I I E'L'C I ZCE I 39
hen uPpOng a m ~q -
 GUIDE DOCUMENT

~ g e
PROCESS ENGINEERING DESIGN GUIDE
12
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P&ID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION
 GUIDE DOCUMENT

IJ
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS -LINES - P&ID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

ur
191 e t a - w ka r
1101 rh.anrr-.-vu-.nutnnnpnwnnu.
.OO*.b* lSrY @ c m m
d n e wth A S T U B M1
rh.mrulnun. -. (o*.-
.napnnunnMmnt.YUMlmlomc
tnh. &cn nd marhow. . h l b. n r c o
 GUIDE DOCUMENT

PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P81D 14

PROCESS MANUAL (DATA BOOK) MA TERlALS AND CORROSION

... . ..
..........
..* .;
~

i :/
2 APPLICATION LIMITS OF FLANGES .......... .. ..
. ... . ..:
......
ThGse are defined by ANSI 8-16.5, from which are extracted the fgI$&&j&les of the
principal series (1998 edition). European series (IS0 PN) that &$jDb..fo American
series are stated as follow : . ,.' .-..,,'
.... .
.......
:A,...
i,. ...
-
US ,
.......... Europeans ..........''
I....:...
i ....
......
150 # ;:. ........i
.?......... :....
I S 0 PN 20y.:,j:.:.....>
....
3oo # . . . .. .. Is0 PN &<-,:,,-.;j
600 # <
.?
:.>
:, . . .' Is0 pNl~@..~..,~,.;

It is possible to use tl$2,.$&&an series I S 0 .~...~

.... l ~ ' & d ' (no
1 6 American equivalence)
for the utilities s e ~ & s 'a'iid the characterist&of'tq&& series are attached here after.
(reference : do,@i$eiit&~~~
, . E-29.005. ~ a h & a ~ ) 9 9 1 )
........ . /
.. .. ..":
5
.. .
...........
.........
.
~n~l~~~d.&b&.::::::j' :
...
.,':.............
) :.-.,:

Table VI[~'.-.:;'. ,.
.,.'.i ASTM Grades
.. ........
..,-:. .....;,.: ,, .. ' :
:.
'.
Material d@$&r'ih:for ASME 6-16.5. ED. 98
:..~ .__I $....//

~ .. . 1
a &vl-2.9: Rating for gmusl .Imaterials ASME 516.5, ED. 98
Table VI-2.1.2 ., .
. 1.2 materials
~at&.fbrgroup ASME 516.5, ED. 98
Table VI-2.1.3 .....
~hg:$.f@oup 1.3 materials ASME 516.5, ED. 98
Table VI-2.1.4 'l'&t&~or group 1.4 materials ASME 6-16.5, ED. 98
Table Vl-2.1.5 <.'/:~at&'for
......... group 1.5 materials 1 ASME&~~.~,ED.
98
Table VI-2.1.7 :.*.>...>l.$tahng for group 1.7 materials
.,
I ASME 516.5, ED. 98
Table VI-2.1.9 ....... :;...
...........
I'kating for group 1.9 materials ASME 516.5. ED. 98
Table VI-2.1..lo... -
.. . . .. ....... II Ratina for a- r o.u ~1.I0 materials I ASME 516.5.~.ED. 98
- - -

1
-- - -

Table ~1-2;j!;3/..: I Rating for group 1.I3 materials I ASME 516.5. ED. 98
I Table VC:~.~T:.I~~..;:: I Ratingfor group 1.I4 materials I ASME 516.5, ED. 98 1
I ~able(~1~2.1~55
,.--.. ..........
...............
..... I Rating for gmup 1.I4 materials I ASME 6-16.5. ED. 98
1I I
I
I I
$Able
. ._~li2.2.1
,.
I Rating for group 2.1 materials 1 ASME 6-16.5, ED. 98
~ab&vi-2.2.2 Rating for gmup 2.2 materials ASME 516.5, ED. 98
Table Vl-2.2.3 Rating for group 2.3 materials ASME 6-16.5, ED. 98
Table Vl-2.2.4 Rating for gmup 2.4 materials ASME 6-16.5, ED. 98
Table Vl-2.2.5 Rating for group 2.5 materials ASME 6-16.5, ED. 98
Table Vl-2.2.6 Rating for gmup 2.6 materials ASME 6-16.5. ED. 98
Table Vl-2.2.7 Rating for group 2.7 materials ASME 6-16.5. ED. 98
Table Vl-2.2.8 Rating for group 2.8 materials ASME 6-16.5, ED. 98
 GUIDE DOCUMENT

14-
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P&ID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

(continuation) .......
.
:.. ..-..-,.b
<
Enclosed table .......
... '- urce
" b$M'r.i.d-16.5.
Table VI-2.3.1 Rating for group 3.1 materials :.'<, ' ED. 98
Table Vl-2.3.2 Rating for group 3.2 materials ,.? "'. .&Sf& 516.5. ED. 98
.

..... for gnxlp 3.3 materials :<I. ............ .....ASME B-16.5. ED. 98
~

Table Vl-2.3.3 Rating

.:':
. '.
Table Vl-2.3.4 ...rjfaf@b
. . . for group 3.4 materials ........... .... ' ASME 8-16.5, ED. 98
"

Table Vl-2.3.5 .
.:'-''Rat& for group 3.5 mated#&..> ):-.;.'-.:' ASME 816.5, ED. 98
Table Vl-2.3.6
......
;. "&& for group 3.6 mat&ls
.......... ,
. . . ....'......'
.
. ...... ASME 8-16.5, ED. 98
..........
;: .....;.&ti.:
Table Vl-2.3.7 .
ng for group 3.7 dfer&1~;~" ASME 8-16.5, ED. 98
Table Vl-2.3.8 ::::'
...>.:":.
....... Rating for group 3.~m?&&'
. :
ASME 816.5, ED. 98
......;."....
Table ~1-2.%9. '.1 Rating for group.3.9.&at&als ASME 8-16.5. ED. 98
Table V : I ~ b;'~
. .....":.
.'? ~ ~ Rating for gr&R 3.l$;$aterials ASME 8-16.5, ED. 98
..... ... ,.
.....
Table d!;2.3.1 .....-.
Rating for.@&i~i..'materials ASME 516.5, ED. 98
~qd~i'~i&3.1.?i
........ Ratimg ._..
. &ig&ip&12 materials ASME 816.5, ED. 98
1..&&. ..$17!&3.1 3 I Rati~&fa;'Gi;d'6
.'. :.- . 3.13 materials 1 ASME 816.5, ED. 98
ASME 816.5. ED. 98
. . V'if2.3.14
..::..:w.e
:,;
~ a C i ~ : G . ~ r o3.14
u p materials
T~~W'VI-2.3.15 ..F@ting foi'$roup 3.15 materials
...... ASME 516.5, ED. 98
Table Vl-2.3.16 : ::'E&&Q . . for group 3.16 materials ASME 8-16.5, ED. 98
1 Table Vl-2.3.17 .:>..:$&hig
.... for group 3.17 materials 1 ASME 516.5, ED. 98 1
.........
...:,, ...
'.I

Tables V13.1 &qlt;'3:<:""

:..................
...
?
Classificationof materials for grades
according to ISOINF standards
NF E-29.005, Nov. 91

Tables VU:~$~O Rating for IS0 PN 2.5.6, 10,16,25 and NF E-29.005, Nov. 91
~11-3.136.....
.-.. .. .., 40
,
. .
......
,.' : ;
-
<, ....../,:'.
....
................
+ ~egarding:&fb@isi&, , .. .
options are made, in practically all situations, between materials in groups 1.1 and
.
# .

1.3: :,.........::
:'

pwo&i f t -$b i r@
.
d.
~.~
[f&
.
1x4
.......'.
. .
yalves
1.1 are used when temperature remains higher than 20 'C (limit requirement fuced
and fittings made of A216 WCB).
riks+er&ls in group 1.3 are used when the temperature might ~t as low as 46 'C (value consistent
with cast valves and fittings made of A352 LCB). On the contrary, there are no forged fittings, and no
-
-
flanges in particular, within this group. Then, Ranges made of A350 LF2 are used, if necessary, since
this material withstands at temperature as low as - 46 "C.
+ Group 1.4 is never used.
+ Group 1.2 is very seldom used. Vendors sometimes propose valves made of materials in this group. It
should be noted that there are not either any for@ fittings in this group and that utlkation, whenever
necessary, of flanges made of materials part of group 1.1, restricts then use of group 1.1 to combined P/T
requirements for this group.
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE prps

15
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - PBID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

.......
TABLE VI-I
,/ i'
........ .....
,. .
. . .
.,
.>:
.... ...*.:,:::
.....
;. ..;.'/.' .....
........ .........
ASME BI(L6.-lsls ,........
...-. ... ... ,...,'
:. .
I 1.1
i

;
I

..
::
.. .,.:.'
....
I

..........
. . .
.......
 GUIDE DOCUMENT

I Pxle
PROCESS ENGINEERING DESIGN GUIDE 15-1
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P&ID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

, ..

A m Or. a3~m3
AmO.szMa
A1SIGr.QUII
ASlU.EDUU,
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE e

PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P81D 15-2
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

, ..._ .._,<
TABLE VI-I (cont'd) .. .,.......
:
.......
..'......
....... .....'.. ...: : :

, .
: '
li
(....,:
-.........
.
........;..-..
. .....
C_

ASME BlK5'-lP10
.......... i
...........
.............
I.......
'......“... '>
.......
(.,' .:,.--.
. .
......... :..-,:...,:
...........
.
':
.....
..
1. TABU I+-.&.&~~TwuL --~...-'
.
...*.;-,""& --&&,,&-,
yI.y
c*rs &i. .".......:'
c@".wak.l .
'. .hp.,w.
.
*la. m*r
.......
.. ;.&&:: .“.. . w
t~ mi-zsc.-l~~~'/'.... ? 2.113 B a 1 or. ---....
-............
";
BS~QI.HD~~~

t14
Ni-k-m-Cq'
47~1-Z&ijj5-s;ib..;) 2-Ll4
BW-.

6-1
m
O: NO&
l-
.j j. BfaSW.NPOI1

B 6 m G r . w

a15 ~ i & - 2 1 0 ( ': 1,5

.......
.... B 4Qa GI. NOW10
B W *-NO&
ti6 ~ l & h % S ~ , ~ 2.tle B E.,~u~..+&-., BWGr.NO(m0
.........
1 ....
-. ....; :.:. . ..........
-
t17
-5
--*:
,
.~'&+~&-25~o 2-217
.
.............
: ..':
A '351 Gr. CWM

w ~ ~ . + P . . l ; ma
h NO*.
e in T ~ WL 8: ,:
.*Y*, *.+
I b l ( 1 9 n * 9 * i ~ . n ~ d ~ ~ u r ~ ~ d 1 l n g a 1 ~ ~ 5 . 1 1 . * d d i t i d p l * . ~ ~ * ~ l i d i n ~ B l W
rrih oangadnp .la% air.*
...
Id U l l i * ~ n a i W i n T a * l A m ~ ( o r u b h k a O n ~ B l ( L Y .
NOTE: ...........
tll~~~~nd~aun~wl~&~'~*k*h*romnlk.nqui*nn.dhmlind~~ci-
-"."&b.wd. : i '...-': '
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE

PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P&ID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

.......
TABLE VI-2.1.1 et TABLE VI-2.1.2
i ;'
,
, ...., ..,
..........
. . -.::::
....I.....
...~.......- ...
,
... ..: .. ...>,
'..'
I
8
- ..................
, r.
111811 I....

.: ......;
.. . .‘...
--NIEna=RII '
QPUn 1.t VMOLUl J.17 Y
L-
: . . .....
,
..
......' ,.
100 sow 1.1 Y
L-

........

.....
............ rara-nmm . .:
lr
.".i '
....... ....&.', .
'
*. m .* m 11* w

.,.;:.-,&-.......,.' PI
1.~ ',!

. ,.%, ....'am...;'. i
*is.'.. H. 111 mm
m m Is
*.> m a6
I m .....'*
*.",. ..m.
an
m II m

*,.:.,.
:',/
:' ....*r .'.: w 6 n, m II)

...........
. . . . w !'?.?.'--. ; w,,: m II* I*

.. .. */
. .:'+..,...
-
** U m m
......... YI
6
g.. ...'. .
.: IWn (.10 I 4 a
;' ........ mo
I
.:......... II)
tm m
w
rn
.I **
I*
*(.
I
PD
a
PP
; "
I*
R
I
I
....
&.- .. ,.'..
am, I 6 PI YID

a 6 wm m P*

;..-;s
ID sm I YI
w m I
I
U
I
w
:g,.
. . .,' . ..-..'..'1.
I
*.
sw
(.r
6lS
I)
I
a
.............
...
 GUIDE DOCUMENT
muadby Bmnq m.p~lv w.
GE I 312 1 1.1.3 1 I 1 0

PROCESS ENGINEERING DESIGN GUIDE F-W

17
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P81D
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

TABLE VI-2.1.3 et TABLE VI-2.1.4 ....... .

...-.
.' '.
. .
, : "...:.,
... .'..
'.. :i
I:

...<...,/,...
CetlWOESIWDFuNQEDlrnwGs As+i+Wp.-,,...

! ,.'
;.,
,......................
:
TMLEblJ. R A l ' W S S ~ ~ l s ~ ~
,,' '....:
.w.l ,
............. . ,
aCll kk. r*l*r
.., -..
........ A r a c*. ma .... .......:
w
.........
::
<' '...,,/."
~ r c s ( i r<.. q &
CUcS(
..........
.. '. .':
.......
: ..... :..............
A 5u q.rjiwwW'..

2'M c
................. . ..'; ) ;:
~2?&..4@.
rw ............
-. :. y&icr.Dhr',;,
.............. ................
...........
t n ~ p o n - ..........:
...a,.
mnes: & + + ! ~ . b ~ * . ~ . ~ . d e $ d i i b
--vd+.kmug*
la nr# m by.d qum*.''..:
-"-*\.- . .......
. ._
. -.
m " 0 h. "F;m:,;: ......
.......
!

.
....
4&t:ir
, ....'.;.

Cat-.........
'.. -...
runnuis~

I
o ,~
n

crtr*
o unu-
~ r ~
k

A 616 (ir. m Ill

 GUIDE DOCUMENT
1-bY Bmlb -W W.

GE I 312 1 1.1.3 1 I 1 0

i
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS LINES - P81D -
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

TABLE W - 2 s et TABLE W3.1.7 - ,

.........
...........
.
~1.h;';~ .. '.; j

i : :* .
T
- '3
&ilk*.
FOR QROUP 1.7 MA-
NaW ;:. ........ .
......-;.:,., m8"
m
.-.. .:.. ..
c-wo <..-.::. .....;,' I A ID( G
,. c (11

,,- .....
.
,./,.,tq

... ".'.-.bow
p o l o n p . d a p a u n m ~ . b o n ~ . * * ~ ~ h u d ~
;& . n u m d n u * a - m ~ i * . k m ~ e . b u t . ~ ~ - r o r ~
rnF.
..... '..GI \ ~ y nd ~lnpnd-ah.
,::......... n r W m a w d n r IOOOT.
,. ,. . . .
.:'.., ::
::
..-..'. *'
wmmG-m-r*
.........

-
am Ism zsm
.........
,. p"p..-f 151 am mu Sm

lmo nm rn 050
..........
,
. ,'.: mim
ot&.' m
i8o
160
m lmo
1500
1500 la0 rn
110
860
8016
".......... 210
100
RO
0%
SS
925
1.46
1 s
216
1QO w sm
4m 015 66a
500 1m 4 s lm 1-

1210 1815 3#m 6010

140 6s DI
800
125 ?PO 115 1175 176 m bws
650
m 755 11% 1705 2UO no
700 110
710 1065 16% zsm u30
m % 530
1015 1525 ZYO 4230
800 w 510 615

ns 1480 zu6 408a

850 6 4s 650 3745
40 800 00 llbD 2245
m 51
530 s45 1615 m
' a
-35 a15 UO
WO
no 406 6s 1010 lams
loo0 10 2m 135
lo60 ... 160 210 115 47s RO
 GUIDE DOCUMENT

-W
PROCESS ENGINEERING DESIGN GUIDE
20
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P&ID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

I ,
........
TABLE VI-2.1.13 et TABLE VI-2.1.14 .........
i ,,/ ...::
i..
..
..'.................
,., .. "..;

-
rirnwnnsua-~nrm ...~(.//,*$i&lea' . .
...
....... .:.......:
TAgE M.13 M m FOR QII(IIIP 1.13 H
4- .... ;.'
I*IY .:'/ .. “....
:.; & ....
ac.l*l 9 W b
*iiwm,.)S '..
:...... .:
5Q-*
dfQ.*:h -..............
......... '.
...... : ;..... >.-.. :......
, , ,
A217 0.C810

rn
Ill Ur ~ ...........
. .& .. -.o,
n*,,
;
'
. '+
......
"d
,, ,---:
: ..
../.'
... ../
'..“..
; c.
~ ~
i.. .....
I
...........; ..................
I
h
CII.
. F
:
......b0:.... I*
..;&..... 1
. . . ... no a ..: ':Ilm0 m
-aD 1m
.....
MOD :,do":'
....... ...
"
zzso m
rn
QP
am . .,'.:
.',
'. a;:,,745
...m nus m6 am6
l am ns em .- 2160 160 ~ I I
1 a ..... ...:‘.SO m :. air 6mo
sop.:.....' :., ..4P
106
am 16 ;:.. . 19:
faid,
lDDS =
~ 1 0
ea
...... XI0
I.......

&{ '; ; 1m m6 -
5 . 1175
ms ass OD0
'. M
' 1 s 640 ' m6 106
,
...,,.?n#. ......:..
,.'..' 7ra
110
95
61D
80
:..
,. .*.......... .? 1 1 s
h.' 1066
1m
1-
IUO
IU
m
'UOO
.' .. a*, r; .
, .
. . . . . .
'..* .; .'
. m 510
....... , : ...
1015 1SZs a40 4.m
. . .
. . '.spd /' m ei'
....< '..': :;a'
am U60 2416 4mo
,....',. ...,...\..."m
;
,i.
C. ado'
OD
60
% 0s .......'JL6
4S
sm
740 1110
a
1-
1.w
106
m
6
m am ".,% QO sas 96 m
... ..........
:IT.. 1m 290 40 ZdD lam

llm ...
. . . {. (. :I,;%
136
ID
Sm
125
90
1-
4US
310
m
515
1160
.......

-
lam '...a;.. a n 108 1m m
........
1h.h.~
MmOr W ORoUp 1.14 YIlERlrls
mm,& .':::.. ........

-
. . .. M*
Dr*lyw. crrr
qgil&.'.....'I-.
. :. . .....
A lKD.R I A 117(L. 0 2 111
!
-::
trl-uirS+."d-
.......... . . *.
......
.' .
..... '-.i
--.ICLULLmim
*.
T.+.+i
,: !'
. NI I .* am 10 N*
- ; : m MID lrm P8D 3150 iPBD
': rum
.i..:..-..*.
'
*,,
i.0
j
no
PD
am
760
730
706
1WO
me
OQ
1466
1410
'ma
2116
2115
!3l60
S8a
ar0
QP
lDlO
ma
1. .......
. ..".....y 170 0s nus 1m Inn 3P6 sC*)
t ::.-- .
:i: UD OD0
.,. :"::: PO
m6 105 1210 1816 3015
!: m 1 s m m 1175 17e 2YO QOS
1. . ' 110 em 766 1156 17s IUO m0
.......... m 96 OD 710 la5 18% 28aO UP
ID0 P 510 676 1016 16% 'Ma 4.m
!
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PROCESS ENGINEERING DESIGN GUIDE 21
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P&ID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

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 GUIDE DOCUMENT
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GE I 312 1 1.1.3 1 I 1 0

PROCESS ENGINEERING DESIGN GUIDE FYW

PART I- SECTION 1 22
S.S. 1.3 : MATERIALS - LINES - P&ID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

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PROCESS ENGINEERING DESIGN GUIDE 23
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P&ID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION
 GUIDE DOCUMENT
I luuedby Wlr ChqUn. Rav.

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PROCESS ENGINEERING DESIGN GUIDE ~ g e

PART 1 - SECTION 1 -
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PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

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PROCESS ENGINEERING DESIGN GUIDE me

PART 1 - SECTION 1 S.S. 1.3 : MATERIALS LINES - P&ID - 24-2
PROCESS MANUAL (DATA BOOK) MA TERlALS AND CORROSION

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PART 1 SECTION 1 - S.S. 1.3 : MATERIALS - LINES - P81D
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

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 GUIDE DOCUMENT

-
PROCESS ENGINEERING DESIGN GUIDE pw

PART 1 - SECTION 1 244

S.S. 1.3 : MATERIALS - LINES - P&ID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

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U
6 tm 05 = U

,, .. . . .: .:
e ,
,no IUO
.......... a0 1.0
126
PT
*O
01
m 1m
m5
rn aa QI
.......... 10

111
0
7.
15
I* m
PI
78s
m 'nsr
,116 m
116
nu
I*0
4 m
.01
Ism sm 00

-
I0 eo 610 'n ,01

m 1- **
,
F9

,s
rr
FO
fl
a
m
.
s5
.I0
Q
s,s
9m
m
w
IUO
Zl.5
IW
376
m
wm I0 35 UI m m 1.20
IOD
Is( ... II (ID llD 110 310

13m ... zz m
. us K6 m o s
1u. ... m am TTO 6 T
m am
1'6
... (I 2.1 rn SB PT
la0
,PO
,300
...
... I,.
us
"5
m
215
.a
m
TI5
U ,
ltlD
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE p.ge

PART 1 - SECTION I -
S.S. 1.3 : MATERIALS LINES - P&ID
24-5
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

.......
. ...".
TABLE Vl-2.3.9. et TABLE VI-2.3.10 :i ..
. ..
, .
.;..i
.............
. ".
................
':
.. 2.. ...,.

ml
U )
(OBYP-
-

.,.'......
".,
..
:
....
......
:,
........ :
: TIIE~S.(O M ~ R I I I Q * I Iaiom-
C
..-..........;
...-......
............
*rY
DICL. I hlk Crrr I(...

I asro.rmnr
.....; ...... .
:. . . . .,: :
~
-
4Y I s.RP.-iIIB I
,_.._ .........
.
..............
m.
01 lh---a*.
(I)n,,rhl*ll~irdr*lle4.rrk~hnCC.nrr.nd@'-'-'
.:: . . . . .:..
1. ,'.
.. n*lmrr~ol..*nmk-*.1Y.pld.rrh-R

.......... .. IR-.I-"l~~b.h-r***+rY*=

...........:
.' l0lOl0-nV-d
er
1-7 m am 4 n om *) NI =
-arm m m' mm IUD zla mom 000
0. W IP 10 1- nm am #am
sw 91 m *) - 1 m ILP YI srm
QO 0. Ma s6 1 m MD Ja w
rrn 170 el0 U6 l a 1 u lm rrol

00 uo m m t1m 110 am 410

OD la6 m m 114 1- Y QI
 GUIDE DOCUMENT -
-by w* -* Rn.

GE I 312 1 1.1.3 1 I 1 0

1 PROCESS ENGINEERING DESIGN GUIDE I

PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P&ID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

,,.......
,' ... .',
.........
<. .... . . ..,
., ............. :
..;
..............
. I . .

... ....'.... . .:>. ...'

TABLE VI-2.3.11 et TABLE Vl-2.3.12 , ,

;.. '.. ..........

. ..' '._
..,..~ .._1
,

.
-
+A r
:'*
...',.,.:..
., ,
.........
..,'.'..m
:, .
.>...&."
.'+
- j i w

-
N
.

em
U
L-W-

a
-
.
,.
,,
A
a$,.'
a ,

.. :,!
:::.:..a
,
....(: en
. .
. . . .-.-
.
.: hQ,:;
im
(10
wa -
(

=
m
I
,

PO
ma
."..-.'%. m as rn .... :.,, U M
u
I*
aa
:.,' m...'.: 1 1 Q ma '....: elr us0 =
Y
1D
 GUIDE DOCUMENT

i
Fwae
PROCESS ENGINEERING DESIGN GUIDE 24-7
PART 1 - SECTION I S.S. 1.3 : MATERIALS - LINES - P&ID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

,........
. .
: . ::
............ :;
TABLE W-2.3.13 et TABLE VI-2.3.14 ..i(.'
.....~...“... " .
...,..,... ....>.....
. . . . .:. ,: "
........
i ,' . '..-.,.'
.,il-. /
 I - bY
GUIDE DOCUMENT

PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P&ID

24-9
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

.......
..
...............
TABLE W1-3.1 et TABLE W13.2 .', ; .. .
: .
- 0

,.........
..' . 2..'.,'.*EM '.';:;
..............
. ...... .,?'/......
;
;

Relations pression I temp6rature .,:..>

........ .......
...;....
Relations pression I temp6ratuy.po.ur IS0 PN 2.5, I S 0 PN 6 &O LO, IS0 PN
PN 25, IS0 PN 40 ......
. i: :
?' ....
...... .:
: *...,,:/'
I.. '.. :
........
......
,,..,; ;..-..........
.............
....... <
).,

\.-;.,..-;,:
..............
................ ............ ..";.:.
. . .......
...:.*.........
........__....
.-.-.. ;.. ."....:'... "... "
........
. ....:'./
I
.

3.. "..
:. .....:....
' . T 1 ..............

.:. .............
/.,,..........."...
............r
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE pw

PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P&ID

24-10
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

.......
TABLE W13.3 et TABLE Vll-3.4 .........
,, ,'
, .....
., ,,

...
---'---*: ;.......
"*J;. &# ?.,pi+..; . .......'
. ........
.,,*.,;.--- 16 ..,.‘'&,?
, ::. .
24 m
3.76 ........ "

..........
.... ..'?mAu-.&dmMk
: ( ............
....:........
.. '. .: .: . . 7. bir.
....,,. 26.0
.
..,;',k#~.,~.~
20
110
160
.*.' . .............
.. .. ...
. ,,. ..,...'M
'

.. .,
60 MA
100
,
:.~*y.a ,,:;
-. ......
.......
,_ ..14,A...'
26.0
(40
40.0
: 6.4 r26 m.0
............
j q 9.0
; , . ;'-' ..
a&. ...' !, . !q
......
zoo
260 :: :. 1fi:.......
.,,.,...,..?
...:....
4a
42
'.. ....... 11.9
,?p..:..
. 2ao a.0

.......... !... :.-.. ._: 17.6 aLo

3m.'
: C.
:'
.......p 38 : ,%; 4$/j .' 0.8 16.0. '24.0
.J'
+Y..J.., . . 1.26
._..:'._ Om 3.0 "6.q ......
...
.I'
a0 126 rn
400 3.6 14.0
 GUIDE DOCUMENT
I k%db, Bm*V Ovptad m.

I
paw
PROCESS ENGINEERING DESIGN GUIDE 24-11
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P81D
PROCESS MANUAL (DATA BOOK) MAERIALS AND CORROSION
 GUIDE DOCUMENT .-
w a y Boo*". Pup(r". R.V.

GE I 312 1 1.1.3 1 I 1 0
 GUIDE DOCUMENT

Rs.
PROCESS ENGINEERING DESIGN GUIDE 24-1 3
PART 1 - SECTION 1 -
S.S. 1.3 : MATERIALS - LINES P&ID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

.......
TABLE W13.8a et TABLE V113.8b
i .. . .. .
I.............
 GUIDE DOCUMENT
I -by

PROCESS ENGINEERING DESIGN GUIDE pw

PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - PBlD 24-14

PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

TABLE W13.9a et TABLE Vl13.9b .......

 GUIDE DOCUMENT

Rga
PROCESS ENGINEERING DESIGN GUIDE 24-15
PART 1 SECTION 1 - S.S. 1.3 : MATERIALS - LINES - PBID
PROCESS MANUAL (DATA BOOK) MAERlALS AND CORROSlON

.......
...........
TABLE W13.10a et TABLE Vll-3.10b :., ... .. .
'.
,
.....-.-,.F ' E ' ~
'-., N
..:;>.., . ...........
....
ty.r U : ( r r l L P I O ( * * u n m u l l C I 1 ) -:..(..,,<< ;.:>
.:..

-
.._ ' ..
mom I.......
I
'
......
; i '.. -*.
25 ..6-.., 10
I 16 ..... 26 “....... Q
. ..,/,L#"",

--
i *.
T.nci.~n
'."
.. .nF;;;b.+:.
.t
3l
......
..........
.......
............
...r-:.
,

...#.-.. .? 1 w
I
. ( . : ; t I?
.
. $.33. 6U

................. &:&* -;

:'... ....
20 . . . ....."6 3
,.i2c;::. 0Q
. ".;4,t..:\'
,'...,/'~;~.,.:
p2 368
50 :=$l%.::.. ..:.: 6.1 U . ... '._ . 21.1 SU
.: .
. .... ........... as
?/4..-. ........
100 4.7 14 j* lo#
150 ..-..“...... t
m ;';..-..' ,,..,...1 ; ~' i
.+ 45
~ . . ....:.. 1 1 8 1- 29.1

: .. 41
...........
...
Zp'..
p,s.
,

......"
112 17C 278
250 \ '.... /,.
........
i ;!1.63 3.9 . . , ..-.... 1 0 5 16.3 261

::....
.....I....

;. . . .
151 3.6 '...,.',.aB..,> ' 9.7 15.1 W
: .W
l I;/ ,"i
3 5 ..."...,'.-....y 14.4 23,l
.....;'..... 6Q....,.'
92
.“..
.........
1.44
...-....
3 . 'a2
.-.. .
1.39 6 8 88 1 3 8
.
.:' ...-..
L
"-..-..450
;
......* 1.34
'%
32

..-..3 2
/.,.-..',A
. ,'
"
6.4
63
W
8.5
13.4
1 I I
21s
21.2

~ .
. . ..
b l ~ ( l E~0 lvaleun
12 ~ : ~b-rur
~ Rm1)
.................
............."
.... 180PN
,........>: ....
<=%: .........,' 6 I 10 I 16
25
I 40

Tnui.*w,. ;>...>.'._
.-....
,. ......... Rnd.xd.rihWadw#mnbu.l20.C
'C
:..... . . .
. i'....,
....... + ...
:. 95
I 16.8
I Zli.1 I 392 I 62.7

:..............,
. .-... ,' h.rlolrnaM..dnirlb*..nbr

'..; .j 2.81 63 1OA 16,7 26.1 418

<+i-;; 15.8 24.7 S.6
.5q ,.:* 2.47 59 9.9
...........
.......
......ioo..,“....' 2.31 55 9.2 148 23.1 37A

;~ t?? ! 2.17 5.2 8-7 1- 21,7 34.7

......... *...&
............ 2.06 4.9 k2 132 208 n.9
/ ,.-.' 31.1
;; ;.. .:
:,,...........
1.
:
1
. 250
300
1.94
1.86
4.7
4.5
1.8
1C
12C
113
19.4
185 10.7
"........ 350 1.79 43 72 11.4 178 Us
400 1.73 42 6.9 11.1 17.3 27.7
450 1.m 4.1 08 108 169 2lP

M 265
5w 1g6 4.0 10d 165
-

. ' ~ e s ~ p r e o s l a n t ~ d e s ~ ~ a r ~ i n m y d a b l c s , b a s e e t s u r ~ ~ , . , t i e n n e n t c o m
cslte~telcsquedomdesdanshmnn.NFA36209.'
 GUIDE DOCUMENT

%v
PROCESS ENGINEERING DESIGN GUIDE 24-17
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS LINES - P&ID -
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

........
TABLE Vll-3.12a et TABLE Vll-3.12b
,...............
;' '.: ::
.
:. . . ......"..
:.,. ...:. , NF E

--:.~(lOw.uIIn~IcuI) <..;,,.,: . . :/ ,-;-

.om'
...-> . ;'..
..........
.,..... . . ......
2.5
I ,e . I 10 I 1e :.......... 10
Imp*....
.C .:.';<--* +d . . . . . ..
hq.4..r b.,f. k*....
'.. :..-.'..i
. .-. .'.;
21% ;: , '., '+t
3
.
4 . '.-..y '..;
'
............
w I ..
.......... . . h.r*n-* &,,,&-&&:...' ..
w
:
..... -..;
............. . . . .
..........
...
.....:*5 w
20
q. 0
.
1 1
......:.:
.'
....a
. 4 W
50 1
. . ... . 62 &7 ,; ? 216 HJ
100 .. $97 "
.:.;...'x+ ...:
.
:
I
.
4.7 73 .,.....'... . '._'ly 19.l 31s
7,z .............
'
. . w
150
..-.. ‘‘...l+
4.3
.. .lf$ lep

....'I... :..'.:..(bZ 33 v.. ) j 10s m.3 1

.
m

2 6 0 ;. j . 3.1 .,.-.<t..;-..>"
. . _ _ . 9.7 IS? 24.4
yq. .,..........
. . / 1.41
::
3.4 .;.:-'.@. , :
: ............
9.0 14,l , pl
./&.,..,;"- --. 133
;. ...... . .... ... ....,".@
'
,
213
. ...... . 1.28
32
...... .: ..&
8.6 13.3

.'... . ,.&.........
3.1,,/..-- 8.2 12s 20A
...
....... . ...'.
124 3.&.:..: 6.0 ep 12.4 199
(;
'......." s q 122 26 ...: 49 76 12.2 19C
..-..
~arli,:;.ai>* 14 E o (*n
. ::.
b e a ru;
: . :.".
.................
.-._
. .
.-.
,. laom
. . .
+s .....:1 .“., e 10
I la I 2s U)

.,,..:
. . 2..- ......:
I T-P*N..C ..: ...
....:... h m l m i + r r ( ~ m b r . i ~ ~ ~ ~
- , '.. "..'
a

.
: a........
.
...........
9.6

C
I n
lkl
r *
26.1
n ~ ~
40,l

~ b u
04.1

. ...........
--.. .....
,26.. . ', 267 6.4 10.7 11.1 26.7 427
:. sb ..,.;,:: 2 s 6.1 102 lS.4 26.6 40.0
..-. ......
1 w ... '.: 23.4 315
........ : .... 234 5.6 9.4 15.0
. . 15.p':.. . 2.12 5,l 85 138 212 -24.0
. . 2~:
..--.........
rn 4.7 7.9 12.6 19.1 31.6
"---a6
/',,..... ..' 186 45 1,b 119 10.6 29.7
.: .,~, :. .:
a I 1.13 42 69 11.1 11.3 27.7
........ ..;,: 350
I :

1.67 4.0 6.7 10.7 16.7 26.7

..........
400 160 38 6.4 102 16,O 266
450 1.n 38 6.3 10.0 16.1 25.1
500 1.54 ' 3.7 82 09 16.4 24.7
.

. .
'Les~parsbn/(an~dasbridesmmal$ecsmaciersinmydableo , h a & e s s u r ~ , t k m m t ~ ~
mtk ca&hbqw teMes que domeas dans la mnne NF A 36-209.'
 GUIDE DOCUMENT
I I W b y Bm*,r aqtrv R.V.

.
PROCESS ENGINEERING DESIGN GUIDE Rga

PART 1 - SECTION 1 24-18

S.S. 1.3 : MATERIALS - LINES - P81D
PROCESS MANUAL (DATA BOOK) MATERlALS AND CORROSION

TABLE W1-3.15a 4 TABLE Vll-3.13b ......

.. .. ....
........
i( ..
; .. w;g2&los
....................
 GUIDE DOCUMENT
lpuadby man. au$mn. m".
GE ( 312 1 1.1.3 1 I 1 0

PROCESS ENGINEERING DESIGN GUIDE prp

25
PART 1 - SECTION 1 S.S. 1.3 :MATERIALS LINES - P&ID -
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

........
,..:....-.......
. . :: ., ,
,. .. -.I
..:
%

3 STEEL BEHAVIOR AT LOW TEMPERATURE ,............

:

....................
:,' .... ......
. %'..</.
, .,'
3.1 NORMAL CONDITION OF SERVICE
., ........:
,..>..... i

At low temperature, steels become more fragile and it i$:'&cps's'G to select by taking
this constraint into considemtion.
........ ,
:,..<.,..
. '-..
..........
....
,.:: .. .I'
The normal admissible tC.hp&tature limits are as fol.o.......
w>..:-.,
/.. '.. l...
....... . ?... '..:
......... ?
......... ( <..'.,-..: j o c
,
.........
...'....../
,:.......... .I.:
. . :.. -
..:-
Ordinary carlmn~s&,P-; ..................
............ - 29
......
.............. ........
.. . ..' .5 ;' - 45 (a)
Killed carbqit.sfw:l.. .. : ........
. .. . ..:,A.
........... ._
:.... .....:
'
Steel w i w . q..5.. %:hi ..............
.....;.. - 100 (b)
........ , .: ...
I
..: ...... :.. \.
.i. .l, .gQ/<Ni
Steel.$ith .....
... ,.
and 1818
.......
; ..........
..............
c - 100 (b)
,. .
............... ..I.'-. :.-....
Re$*& . . . . . .
:;;;-.. . :.....;,.;.- .....'
. : "
..............
...... .; ..... .:
(6j
.... %<<Bfe certain dead g@1+1,,6t&fthat can stand down to -50 'C
....... ..... <..
(d.''@).I~een,nickel steel-canbe replgced by 1818 for the the availability reasons.
.... ...-...
...........
........
:i <.-.. ?
32 ._..
LESS FREQUENT:!&&~PTIONAL CONDITIONS
.......
When an equipM@lt&...........
ri:be .
submitted even exceptionally, to a temperature decrease,
(GPL p r e s s u ~ f ~ ~ , . ~ d e p r e s s u r i ~etc
t i o...)
n ,the choice of material have to take into
account thd~~r&ni'stances.This applies to carbon steel at 0.5 % Mo, low alloy
chromium.........
st&l f&.hgh temperature and nickel steel for low temperature.
When ~i$-.fl~&xist, it shall be specfied in process specification the correspondent
minimh: ~ressudtemperature.
<.. .........
........-.,....
.....
'._

................
. :
..,.. ... . . ..: ..:
....... ............
...........
2."' .:..
: ::
.......
........,',..',
..........
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE ROC

PART 1- SECTION 1 26
S.S. 1.3 : MATERIALS - LINES - P&lD
PROCESS MANUAL (DATA BOOK) MATERIALSAND CORROSION

4 CORROSION .......
.........
,. :... '... "*.
4.1 CORROSION ALLOWANCE ...-.....
:,
..........
::
I:
.
,..... ;.;, ........
_..I .
When there is a risk of a specific corrosion, the corrosion allowan&'& &determined
............
from the corrosion tables available at the Documentation Depgqhent,,:Sbme
, . of these
tables are attached in this chapter. ...:,'i ; ..“...
.....
:....". I'
............
.: .
.._ .._
....
This corrosion allowance will bg.&errnined for a minimum:~~~span . ., of the equipment.
..... :...........
generally fixed for 10 years. ,
............
. . . .c.., ;: '........... .:
::
;..................
: I

............. ; . c . .:!
........
In several cases and e&&pUpinrhen it is for a fl&:&&dt to characterise or with
variable quality of fluid (qude.:bil for example), th&.:is.:flo
. . . .
corrosion allowance @dete&ned ...,.
experimentally:..
......
.............
reference table and the
... . .,.
.............
..
In this case noka&:::+&n steel is used.$&ith::~iidsion allowance of 3 mm for the
. $.ds
moderately cor@%ive:fl
.. .., (crude oil, non d~$%lphfi$sedcut, etc...).
.::,. ,
..........I...
.
.............
The corro~io"~~~~lodance
is reduced tf:tj5imm when the risk of corrosion is low (for
.......
examp~e,~kt#~e;.butane, light g a s,~ ~.j ~. ~ f f ~ ~ d e s u l ~ h u r i s a t i o n ) .
. . . :.
............... .',.. , .,: ........:
I....

It is .iriiri+sed.io 6 mm and evetif&afer for the services particularly corrosive (H2S +

wat&"'&..he. condensation), no o t h e r e ~ n ~ m i c aand
l l ~technically acceptable solution
can be p&ljbsed. .........
:;;..-- ..“....
; : <:'.-..;:
To be noted that it is ger(eit$pra&e to take no corrosion allowance when designing a
hydrocarbon storage tank..kl$ss.there is a possibility of water decantation together with
............. for hydrocarbon tanks or hydrocarbon slop tanks).
the presence of H2S(g$ej!&l.$ase
..._
.I
. .'.. .'.._
Finally, dmerent &o>dowance may be specified for a given fluid depending on the
Bquipment maint&"adifi
:-....: For example, for boiler type equipment, the corrosion
allowance is 3.m.&re else 1.5 mm for the line that the maintenance is done or even
changed fre@$*tly,''the operation that is not been normally done on the principal
material. .( :.'...?.
.. .._
.._ ,.
.........."..
e l 1818 is used. the phenomenon of corrosion is not to be
~ h e n , : s t ; ? ~ ~ s s t etype
z& corrosion allowance can be used.
worri@;a........
....--.
. ... .-.
. . . .'
l(&.alsii\possible to limit the corrosion in certain part of an equipment by application of
&,&@:;
..........
synthesis coating : plastic or paint
concrete lining
metallic plating

Precaution shall be taken when using the first two type of coating because they are very
fragile and the basic metal can get corroded very fast. They are not suitable for the
security system in case of coating deterioration. It is advisable in this case to foresee an
admissible corrosion allowance to minimise this risk.
 GUIDE DOCUMEN
W by Bop** ch.pterv w.
GE ( 312 1 1.1.3 ( I 1 0

PROCESS ENGINEERING DESIGN GUIDE pa9

PART I- SECTION 1 27
S.S. 1.3 : MATERIALS - LINES - P&ID
PROCESS MANUAL (DATA BOOK) MATERIALSAND CORROSION

Somehow, when metallic plating is used, this will substitute the -$ion allowance.
However, one has to verify, especially for an equipment with a srp$ff'&kkness, that the
cost of basic metal + plating is cheaper than the cost of having fd&$aSsi~emetal at the
same grade as the plating for the equipment. Nevertheless, cece$i$&+tihg grades might
have welding problems with the basic metal. The faisability ~ftJ$s$bfl[.iiave to be verified
with the Boilermaking Department. .,./.... . . .....
; ..
...
.,' .........
. .-.
...... '....:-:
:
4.2 HYDROGEN C O R R O S I Q ~ ~ ~ . ~ : .........
'.f,:........
::
.,..............
....; .
i ............'
4.2.1 Corrosion at high teni'&Me . .
(,.-,( .....-:j
'.. ...........:..
. . .............. ..
...I ...... ....-.'
Steels are sensitwk&y&ogen corrosion +,..*ht'$ temperature. It is due to the
property of moo.&~ic-hydrogen to diffuse 'ir)i&$eeemetal
........... : and then to react with the
arbon , whcih:!.?.:: ...........
.....
... ..'::.. ......
.... .._'._
.............
........... . .....
. :.
~eduq&ej.~mechanicaI properties";...".... . :
-. :. : .
. .
~ea&;td'th&~iimation of methaneb&.t$t
. . . produce blisters and cracks
. . . ......
.,..-.
..'...; i....
a ,
::
~~d&&.%sion is well know".&bm&non
..........
. that refer to Nelson graphs published in
AF!~&$,?sy figure 1). ..........
I........ .:
.,..................
. .. . ' . . . :
/. '...,{ .
;
: ..
..-'gfiffh
. &ition published in hnuiayy 1997 confirms the deletion of graphs related to
:-"&&p steel 0.5 Mo. ~ t i l i s a t i o n this d steel beyond the limits acceptable for carbon
steel is not advisable. .......
, '.:.''.'
,..'.. :, :
:
On the graphs, zq~,$.:bh@iare delimited by the discontinued lines, correspond to
...... :
hydrogen conos@".'.tl;l$t:&ds to surface decarburisation. (modification from late edition
,i...
::
of April 1990). -.:::--........
..........
.........
The new e&iii.df&i~uary 1997 supersede the graph of 3.0 Cr 0.5 Mo. Utilisation of -
- ..............
3.0 Cr 0.5.Md.\st&l is replaced by the graph 3 Cr 1 or 2.25 Cr - IMo V - -
.. ..
1997,,.&bn specifies that the temperatures indicated on the graphs represent the
ave&&,{hPerating values around which a fluctuation of 2 20 O F 1I0C) is to be
c,~l*i-& User may or may not include this range when selecting the steels.
.,... .'.. ?
,,
,

.....when.fhis range is used, it is applicable only for the operating conditions.

..............
:
:;'
_._.
,. :. T& decarburisation does not lead to cracking but lead to a reduction of allowable
'--.::::$bfistraint, of hardness and to the increase of steel ductility.

Zones which are delimited by the continue lines correspond to an internal

decarburisation in the heart of the metal with the formation of methane that lead to the
formation of cracks and blisters.

Graphs of API 941 are applicable also for the equipment functioning in liquid phase with
dissolved hydrogen, the partial pressure of hydrogen to be considered as the partial
pressure of the vapour at the equilibrium state with the liquid.
 GUIDE DOCUMENT
I hruaaby soo*"' ,aa@r"- Rm. .(

PROCESS ENGINEERING DESIGN GUIDE

PART 1 - SECTION 1 28
S.S. 1.3 : MATERIALS - LINES - P&ID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

,,
Hydrogen corrosion at high temperature will only appear after, aiw;ieriod of ...&
incubation related to the nature of the steel and to the utilisation q@itipri>~l$~h 2 can
be used as refference for actually limited utilisation in time of c&$n.:'$&l, beyond its
normal limit of utilisation. This constraint will be clearly specfie@'& th&.&ued document
.
............
,
(specification, PID, operating manual).
..... : ._...-'.:
.. .. ;
,' '._
:-.. ,. .._. ....
However, it is preferable to .i$hB&noble metal that t@$o.:$nstraint of exposition
>..., ....
.... ...:......
...A.

limitation to hydrogen at hig@teih&wture.

. . . . ..:
..
,._ .., .__
'..'
...............
%.

;..,.,.. ..
....;.../.'.
Finally, the imp~ementatioc[:.~'f~.~ermaltreatment,.&2$e::&bipment limits the risk of
hydrogen corrosion a$-h$$~.tedperature. ~owevei;.$h:i~lementationdoes not allow
the derogate the limif..s&&~
:. ....
by the graphs p&kljed&the
..... API.
,:.....:....
............. ; ........._
........ . .. ..._
........, .........
. , . . . . .'I
........
,.. : . .. .. . . :.. :..
;.. .. :, '..
........
.......... . ... ,.'
' I \ I .

::~.
:: ............,.
......
,. ......
,..............
... .. . . ........
.
....
..;. ::...
;. ... ,: .....Y?
:
,."(' ,.;,':.
.. ..: . :.;.-: . .......... .-. . .
...,......
............ .I

,.-> . .......... ..,:

I

:
.:
. . . ......,
.
C_
. . . ..
.......
.I...

. :.._:
. .._......
:'. ........
:_.. ..... . .'.: .. ,.
 GUIDE DOCUN
ImadbY Bm*@ Chqwn.

GE ( 312 1 1.1.3 ( I 1 0

PROCESS ENGINEERING DESIGN GUIDE -W

29
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P&ID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

..........\
..........
.
,. /. ..:. .:
4.2.2. Hydrogen embrittlement ..........*,:.,:
,',..',,.>
. . . ....../'
This phenomenon is due to the decrease of solubility and.............
~*.b&~s$ity of hydrogen in
steel when the temperature decrease. '.'. . ....",.
.........
: ......
"

In normal operation, steet,,$charged with hydrogem:&& if ..&caution has not been

<'' ':..',./
taken, there will be : .......... .............
....i....:"....:'
.,*;
..........
............ ? < .;.-: .;
. ,
:.x.
. . .
a formation of .$ntf?nat.cracks. blisters pr.,$lq$fa&'detachment during a rapid
depressurisatim-->:..":; ..................
............
:....... ;
'
.............. :
............ ;
' I. '..'./
a rupture &$&be repressuring, d@.&"ttie"drop
.. ' of mechanical properties of
hydrogq*&d steel. . . . . ... .'.._
.._.-._
.............. .
...... .....
'.._ 4
,..,.. ..\
:..
,
~
.':.
.. .....
to :
So, it w~l~$e.&Jdsable
. ,, ........
............:.
....... .
........
(
:: .......
d$&-~khut-down, to rer$~~.~&gressivelyand in stages the temperature to
:.~IOG hydrogen outgassing.......; ...>.:
...............
. . . . . ... .,.
,,
, ,.-..
;'
,
..,. :. :: '.I

j
.
'
:';*?.tq ..-~ :p"ion pressure at a ce'&$"mperature
t hsteel,
e .
during the..start-up:.' ,
in which the hydrogen is dissolved again
,;:..........
4.3 .............
TEMPERATURE EM$RI&ENT
.......
.............
This type of coqs&fi&.me ..... most d i c u l t to be taken into consideration.
. . -..
...............
~tcorre~~on~4~fd~f&:~~0d'fication of temperature of soft/tiagib transition zones for the
equipment h a t bd;2 % Cr and 3 Cr grades and operating at 343OC to 528OC (650 -
1000°F). .&. the equipment is brought down to this transition zones, i.e between
. .
ambient&m&ture and 100 OC, it leads to fragile ruptures.
. .-..: :
' ,' ;

~tee&:@t& contain les than 2 % % of Cr or more than 3% of Cr is not concerned by this

ph$ii~&e&~h.
.....
..
#
,
::
.
......~.>wl&on has been established between this type of corrosion and the
.........
,:',.-.~'mlgr&on/dIffusion of certain impurities from the metal to the grain boundaries.
:*~. .
..
......... . .
': I
'......This relation is shown by the following formula.

J=(%Si+%Mn)(%P+%Sn)104

This factor is about 300 for the steel used in the past and had been brought to 100 in
the steel used actually.

This precaution is not sufficient and generally, it is required to complement with a test
for the steel used fro the consbudion of the equipment. This test is called 'step cooling"
or 'step wise cooling". This test has to be representative for a life span of 20 years.
 GUIDE DOCUMENT

P.PS
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS LINES - P&ID - 30
PROCESS MANUAL (DATA BOOK) MATERIALSAND CORROSION

... ......
............ ..
. .,,; ..
" j ,
4.4 CORROSION BY SULPHUR .....-...
:
. . ....-,.
.: ,:' ......
.' , .' :. '. '
;

Sulphur compounds present in petroleum products generate corrii&,k , . increases

that
rapidly above 260°C.
.-..
.' -.,
. '.... ._ -
.._..,.,,
. I'
.'
. '.., ..I' ;
{ ,' ..
i.

Its wrrosivity depends on the ,qrtype of sulphur compou@$, dii& temperature at

. , ..
. . , of the products of tt&@&mposition.
which they decompose and the.'riafQe
._ :..'.
........... ...,.,;...,.. >..'..
. . ...'.,..
With the absence of hydroge$;.t~.$ffached graphs Ill.3. .S . . .w. .. :a be referred to.
I.._

.........
._ .._-.. ......
;..--....*,:. .. .................
The graph Ill gives thd.femseet(ble corrosion for't~diffeientgrades of steel on the
. .
basis of TEXAS crud4:ai:$:$% sulphur.
........
..",.'.......‘.:
:..,... ...,.
... ,..,,.'
..., .: .......:. .._'...
........ tii' the foreseeable.,&rn$$ii.fbr
The graph IV corr&s'tj.h.d
.. :::: petroleum products containing
0.6% sulphur. ,.,:.-.:' ,.; ...:,
. ... ..
,.. ,..
I
.....
. .
~.
,, ,.
.
. ,.
,.........

.. :...
.;',:........
. . . . . . . . . I

These graplyj'$eo"&
. . . . . . . . indicative. : ...
.: ........ :
:, ,.' ,:,:. . ....
.__ - . ... .
:
. . . .: : .
.......I
.
:-;
2
.' .,-._,
....;...
,
. . :. ...
.. .,:
4.5 . COR.R&SIOR~Y H2SWITH THE ~ ~ E $ E N COF
E HYDROGEN AT HIGH
... ,.
TEMPERATURE (ABSENCE OF L I W @ WATER)
.........
........
In these conditions, graphs i~
ttd.% (COUPER AND GORMAN graphs) are to be used,
which its usage is general, d$ipi;.$l'can also be used, older document.
.:.. ..........
i........
.-.,.:.-..
:, ...

4.6 . ._ ._ .
CORROSION BY l&?l$ii;'~.'
;.',., '... -... .._:
This denominatiod.,'&n&y&e presence of water liquid. It happens at low temperature
with or without:&&@q.. .
.......
.,,.--..:
...
Three form$:&,$s
i type of corrosion is to be known :
......
...........
._....:
~&&ili&.fl '&rrosion and by pitting
~u'dtte.s&ss cracking
,...~$d&& induced cracking. This type of corrosion is due to atomic decomposition of
/ {'H ..".
, ., *S$$ H and HS and not to the presence of molecular hydrogen
~. . .
.......... :
..........
4.6.1 Generalised corrosion and by pitting

The precaution can be taken against this type of corrosion :

By having a sufficient corrosion allowance

By injecting a corrosion inhibitors
By applying an appropriate coating.
 GUIDE DOCUMENT

~g
PROCESS ENGINEERING DESIGN GUIDE
31
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P&ID
PROCESS MANUAL (DATA BOOK) MATERIALSAND CORROSION

.....
.....
........
,,,.,' ..... ..
. ... :. :.
:
4.6.2 Sulfide Stress Cracking ........... ::
, . ;.. ........:
/,...
.,
'L

"

Sulfide stress cracking will affect high elastic limit steel with.@ psfi@ce of water liauid
(water liquid Igas diphasic or liquid Ihydrocarbon liqyiii! g%i::hphasic) at normal
temperature. :.'
,.,....... .
...... .
,.-._. ,..
."'.,..".,.) ..........
....
C...

This type of corrosion, ;i)Walarly studied for up~~m..?nstallations, is subjected to

NACE standard : ~~a~'i.35.. ..%Q know whether thF''(i$i(ijf~:&msion exist, the attached
graphs (graph VII) &&%xn this standar@-*I lk(hsed. If this risk exist a more
.............
..........
.......... ..>
precise standard teqh&y;i"
r' ...........j
.....
:.,.., . ._.
he accept&re:*~@ria~s
..... ,.,: .. ...'.:
: .......
. . .
The acceptgtjk.i$nealing condition ...- .....-.. .>:
,.
The m,a$mala&nissible hardness &f6?de$s&ss treatment
......
.
. . . . . . . . I

!/..-
: '. ..
............ . 0 :

, , .....
...............
.... -. ......j
shall [email protected] ,,,.;,:-: :....

4.6.3 ,
I..,:.: ..............'
. . . .,; .: ,'>
...:
...........:.
..........
..,, .. ,
.....
:<n*o&h
,.. .
:.
.
.<..~..:.:
. . Induced Crackin&-.......
.
.
;

'-...
. .
,.............
.,. .....;
..>
...........I
. -
.., . .i

This ';;ornosion is due,&::h. dissociation of H2S to HS and H, with hydrogen atom

migration in the steel &&n&e,?ewnstitution of molecular hydrogen, source of blisters.
............
,.-.._:............
Eventhough the &j&~qnditions in which this corrosion might occur is not wmpletely
characterised, i(&&rihat it affects particularly carbon steel with the presence of
humid H2S at eibj&t.?emperature.
; ".. '.. '.'
,
:
: . ..... .2
...
In this case,'hlisatibn
.......... ._.I
of this steel is advisable :

~fl&$half dhad steel or dead steel

t&*'lfur steel (e0.003%)
0.'. ::S:t&k&ntaining Cu or rare earth
...
/, :'._~.& , steel.
& i
,.-.. \
.......'.I.

::
...........
; ~.
.
... ..
:j.-.'@$-i"formation is only indicative.
:
..........
 GUIDE DOCUMENT

/ PROCESS ENGINEERING DESIGN GUIDE 1 I?

I
I PART 1- SECTION 1 I S.S. 1.3 : MATERIALS - LINES - P&ID 1"
1 PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION
I
4.7 POLYTHIONIC ACID CORROSION
.,. .. ;. ,
............... '
This corrosion is for grade 300 steel used between 360 and 700 OG...............
;.'--.<."'
.. .. . . .......
,

It is due to the precipitation of chromium carbide at the grain..&hn&aG?~he content of

chrome is reduced that induce.;l-reduction of protection ,&vid&.:by chrome and a
. .,/
possible attack by polythionic$c@i ......
..........
/ -.... . .
........... :.., .. ,,-.,. .....
>...,
:' ( '..... :
This happens normally d,uf$~~~~th$iihut down oper+ibn..W&:there is a presence of
fenrm sulphide, water and:Pqg&i'at
...... : the same time..:..>.: b..:."
(

:. .-:--......... ........:
...........
.
Two palliatives : :<...::...:?...
.. .. .. ... ..
....
......... . ...:.. . ... .
.
........:.......
........... .........
a. Use 321 or &?:j@tin& These stain~ess.&&i$~i'e:stabilised with Ti for the first one
and Nb for.@ se&d. These metals h$Ge the affinity with carbon, that prevent the
....
precipitatiih of.$nromium carbide in.,h"e!$6Gd condiiions. It is said that they are
insensjiiyB.id~t~bhenomenon.
...:........-.
. :.. ..i,.' ;.; :..........
...............
-:
;!-....
; ....
..........
. . . . . of polythionic ac@!by
b. ~e,ufilis~t@ri . .;.'6ari&csolution, during the shut off.
.'. .L.
. . '..I ... .. ....' .

.: .....-
............
4.8 NAPHTENIC ACID CORRQSIW;":;
:.._. ,.
I. ........'....
.............
Hold. '.. '..

..............
Deward and::&li!lian'&"&onogram (see figure XI) will be used. This monogram gives
normally 4 6&iervative value of the corrosion rate because it has not taken into
account,,th&.p&ivation coat at the surface of the metal when COz is associated with
other .&~^il&+rifs
. . . (for example H2S).
.. ..

4.10 $RR&IoN BY CHLORIDES AND SEA WATER

.........
Hold.
 GUIDE DOCUMENT

')
PW
PROCESS ENGINEERING DESIGN GUIDE
33
PART 1 - SECTION 1 S.S. I.3: MATERIALS - LINES - P81D
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

......
,...',.--...
...,.
iC .....
4.11 TABLES OF CORROSION GRAPHS .;',
: .
,.. '.. "-..:: :
............ ... -'
.' (: ,;:.' ,.:.'
Graphs I and II : Hydrogen corrosion. API 941 .JAR@^^ , .._ . 1997
,.
(Nelson graphs) .' ,...... .....;
Y,..,
..... :
.,
,, .........
Graph Ill r'..-.:m. d e oil corrosion at 1.5*qf sulphur, NACE Data.
: .'i
<, .. ,',
..... ...............s
.....: ...........
Graph IV ~:'>..>..$&drocarbon corrosi9tid,D:ljj% of sulphur, NACE Data.
.,.........I.....
.._ .. .:iMac CONOMY g~pl$...)-::.a2 ..................
f .--....... .:. >. ....
..............
Graphs VA to vE;' ....:>::'-:'."' HzScorrosion in p!.@n.& of hydrogen at high
,
,
.............
............. temperature, bab (COUPERIGORMAN graphs)
....:;..............;
....... . ..._
. ....... . . '.._
..........: ..
Graph VI,.....:"....:.....,
, . : HzScorr&ion m'presence of hydrogen at high
;', ..-.. ..... ..,.
:.: .. .. , ._.....
..........I.
ternped@e..&,kosion Data Survey (Ed. 1967)
:~.
............... , ..'......i
Gra,pvV[b-........ : SSC CiQiIo&3n limit by humid HzS.
... i../'. .;.;.
:,,.'
. ..- '
1 .......
~hdE.MR01-75.
. . ..'..,;. .".;'
.
: " ..........
2. ....;: ,:
. ........vl,l
.,:';&ph : C s. ..~.. ~ i by
on caustic solution, Corrosion Data Survey.
j.,'

...:
'

Graph IX . ..,...~ u l ~ h u racid

I.:.....:' i c corrosion,
:
:: 8. (.';&rrosion Data Survey
: ............
........
................
.......
Graph X ..--.......:,,. ... Hydrochloride acid corrosion,
.-< -............. ,' Corrosion Data Survey
...........
. .......
...........
,I Graph XI :.. .. ....., :
,_:
CO2corrosion, DEWARD and MILLIANS.
,.--...: : s

..............
._...:
,.
.-.....
.' ..".
:,. ....,;:
: a .

'.. '..
.......
.,_--._
............. I. ._..
.,......... .~.::::.
.
....... "'
. ......
............
.
,,.,.." :.
:i
:~... ,.'".. .:
.........
#

..........

\,
A'

i
."
u
 GUIDE DOCUMENT
hwad by srmrb oup*rrr m.
GE ( 312 1 1.1.3 1 I 1 0
'I

PROCESS ENGINEERING DESIGN GUIDE PW

PART 1 - SECTION 1 -
S.S. 1.3 : MATERIALS LINES - P&ID
34
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

I GRAPH I - Hydrogen corrosion at high temperature .......

........
I
.. ..
.', ........
: ...
API 941 - Ed. January 1997 (NELSON Graph) . .
.., ........,/,':
:
 GUIDE DOCUMENT

I
Pxp
PROCESS ENGINEERING DESIGN GUIDE 35
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS LINES - P81D -
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

... ..
......... ,

/ .. . 1'

GRAPH II - Hydrogen corrosion at high temperature.,..<..:-.-.,

, . .:/
................ -...
., <. ,;./ .....,,.?
(Incubation period of carbon steel) .; ...... (. ,..
. .,. . .._
,. .. :,
..
...... '

.:;.. ...-....
. .... ..... .:-..
:J
.....
........:..:; ....
,.-..-'.. ..
C.

<:.i
/ ..........
;...... :....;. 1..........
.,.,..#

...... :...,'-.:
...... ..... :...--.
I I. ; .' ;
........... * .'
..................
::
......:
................. .........
.........,;: ... ...................
........
I ..........., "
........... ............>

. ..I...
:. ....;
:,;
:
;

........ '..,5
........
.............
,., .,
....
.: ' . ,.:' .,:,
~

,--.. ......... :'

..............
:.._.
..:. ..
#..............;..
::'
:
%
.........,

!
A
API 941 - Ed.January 1997 (NELSON Graph)

s
s
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE RW

PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P&ID
36
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

Corrosion rates of steels in crude oil containing 1.5

percent sulfur.'

SOURCE : W E
 GUIDE DOCUMENT

-F
PROCESS ENGINEERING DESIGN GUIDE 37
PART 1 - SECTION 1 -
S.S. 1.3 : MATERIALS - LINES P&ID
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

......;
. .
-
. .........
..----:
.;:.._. .I-: .
TEMPERATURE 'F
. :,
...........",.'
'S

"Average" corrosion rates of steels by high-tempera-

l....... ture hydrogen sulfide in hydrogen-free environments.
 GUIDE DOCUMENT
I k%Wb,

PROCESS ENGINEERING DESIGN GUIDE ~ p e

PART 1 - SECTION I S.S. 1.3 : MATERIALS - LINES - P81D 38
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

,....... .
CARBON STEEL - GAS OIL ,.........
,'<-, .. :
..
-
-
-
7

-
-

- --
-
7

-
- -
-
-
-

---
- --
vi
ru --- -
I -
- -
- -
;,.,. ............ .
.. ... . '._...'..: - .
- ,.
~.
.......~,
...........
. . .. ......:
. .... COURBE VA

0.01 -
:
,,';,..., ;
.._ .<.
.:;:: --
-- ...............
.-__.._
. . .
.......
.., ._
. ,.. .,: .:. . .
..,:..
H2S CORROSION
---
- , ,
JT-.. ...
.......',.'
a, IN PRESENCE OF HYDROGEN --
-
............. AT HIGH TEMPERANRE
,' -.
:;
:.
.. ..
: 'I

........::
.. .......
(COUPERIGORMANGraph) -
- -

0.001 I I I I I I -
4 00 600 800 1000
TEMPERATURE, *F
2 NILS = I N C H E S ~ ~ O O O
SOURCE : NACE
i
3

-~
GUIDE DOCUMENT
 GUIDE DOCUMENT
Lsmdby Bm*b Oup(a@ RW

GE 1 312 1 1.1.3 1 I 10
%,
i
PROCESS ENGINEERING DESIGN GUIDE Rg.
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P&ID 40
PROCESS MANUAL (DATA BOOK) MATERIALSAND CORROSION

.......
! 9 % CR STEEL 7 GAS OIL ,...........
. ,. ,
. ,.
'.. '.. ;. :.
!
: ..
.'i
. .
..........
10 -
-
-
1 I I I I .....:........
.......
: :. ....... ;,>'
-
J

-
--
.........
............
.. .. .......
. ". / --
\ - ...... -
- -
- -
........
!
1.0
.......
-
-- .. ,.4
,,

--
-
-
-
...._
...
-
,:
..
s ., ,....-..
:'. .._
. ..__
....
..'
'A
0.1 -
--
---
0

. V)
-
I -
-
-
N
I - ........ -
- . -
" ....... .:,. ...
............... -
- ..............
. . . ._ . ..,.... -
! .......~,
................
: : '.. '.
.. .. . ...I COURBE VC
- .... 3
1 - : :..
....._......
... ...
i
! ...--....:
.........
... H2S CORROSION
IN PRESENCE OF HYDROGEN
......:..:, :,
.__

-
1 AT HIGH EMPERANRE
i .. '._ -
0.01 .............
...........
-.. . . ~. . .. . . ..:.
.: :.
' (COUPERIGORMAN Graph) -
--
- ., .

.-~
-.
'.
. .. ,:.
........ -
........
.j :.....-,:,, - ...:...:, -
7
'

...........' .. -
I ....-...
- -

0.00 1 I I I I I I
4 00 600 800 1000
3
i
/ N I L S = IllCHES11000
TEMPERATURE, * F SOURCE : NACE

-
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iuu(ld by ~ m * b 0up*rnm w.
GE ( 312 1 1.13 1 I ( 0
 GUIDE DOCUMENT
1Bugby em* -,- &.
GE I 312 1 1.1.3 1 I 1 0

PROCESS ENGINEERING DESIGN GUIDE P.P.

PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P&lD 42
PROCESS MANUAL (DATA BOOK) MA TERlALS AND CORROSION

.......
I
I --
i
! --
-
-
-
1.0 - - --
- --
-
-
-
1 -
- : ,. -
$
: -I

,
0
s
0.1-
-
-
5 -
--
x
- . ... .:...........
..........
I.

..........
,.: .............
i,
-
i
: .. '.'._'.
. -
.......,;.... ...
d
~ :

- ..............
,.......
...... '._
..,,' COURBE VE
-
.:' :,/:*
. .a.,'

0.01 - ........ ..... .: -

I

---
....I...

i
. I --- :... ,(................'
./.
.'. .:
. ..
....... : :::
. H2S CORROSION
I
:
..........
7.--;
-.. .-.
.
-.......'/.,. ...
i
. . IN PRESENCE
AT HIGH
OF HYDROGEN
TEMPERATURE --
I ....
% .

(COUPERIGORlllAN G-h)
-
I
2.......
-
I
I - -

J
5
i
i

i
0.00,
4 00
I I
600
I
800
I I I
1000

i 1 IILS = INLHES/1000
TEMPERATURE, 'F
: MACE

; -
 GUIDE DOCUMENT

Rp
PROCESS ENGINEERING DESIGN GUIDE
43
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P81D
PROCESS MANUAL (DATA BOOK) MATERIALSAND CORROSION

G W H VI - H2S Corrosion at high temperature .......

...
.........'
..
in presence of hydrogen ,,. .. '
. : '. .: .:
............
.
.......... -.../
,/

.
:
., < ,:'/ ,,..
: -..:
STEEL CONTAINING 0 TO 10% Cr ........
..........'"/'
...... ..I

i 6*

500

LOO

1!
300

....-..: ........
....... ......
... .. .. ..
I :
.. STEEL ~&%df:

".
< * ' .; -.....'
:...' r "....,.....WAINLESS STEEL 18% Cr- 8% Ni

902 W. 906 w ' 2,

PARTIAL PRESSURE OF HYDROGEN SULFIDE, BAR

WSISTANCE TO CORROSION OF DIFFERENT STEELS

0
IN GEOFH

-
(From CORROSION DATA SURVEY NACE Houston Ed. t967) - -
 PROCESS ENGINEERING DESIGN GUIDE ROO
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - PBID 44
PROCESS MANUAL (DATA BOOK)
MATERIALS AND CORROSION

I GRAPH VII - SSC Corrosion by humid H2S

_..-.._
.; ___.
1
I ... ..'.. .,. I
-I.

Source : NACE MR 01 75 ...f.,.',. :I

 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE 4r

-
PART 1 SECTION 1 S.S. 1.3 : MATERIALS - LINES P&ID - 45
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION

I GRAPH Vlll - Corrosion by Caustic solution

CAUSTIC SODA SERVICE GRAP~?~:::~:?

, .
...-.._
..,.,;,..--.
-.~ . .
....,
\

.. ,. ,.'> ...,.
:' <../..' ...>
..'>"... .:. .,/...'

u
a
d
L
F
2
.A

:
*

20 -

0 10 20 30 40 50
CONCENTRATION NAOH, I 8Y WEIGHT
2

s - : COBBOSIOli DATA S W W
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE

46
PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - PdlD
PROCESS MANUAL (DATA BOOK) MATERIALS AND CORROSION
-
GRAPH IX - Sulphutic acid corrosion ......
. . .
.,.........
,:' .., ,.,
I
!
i
CODE FOR M1 XE D AC 1 DS GRAPH ,............. .:..'..:......! . . 2j
Nlderiak in shaded zones have mpwlsd corrosion rates of <20 mp)! '-.,.:' ,,,>
....... <.. .,:,;.
.,...... . ....: .,
ZONE 1 ZONE 2 ZONE 3 ZONE 4 ,..':,...:'.-...- "ZONE 5
..... ..........
,'.. . 18Cr
M C r 30Ni 18Cr 8Ni : ,I . . 30Ni
:"....*r 18Cr sf&..'....
. -..,:,' ...........
,. ,. .. . ..
Gold 20Cr 30Ni ,:....:>..
.......h d
...........
m$~pyi:'..:
..
.....
<
“.' 20Cr 30Ni
. . '. .(, ,,:,:
Lead Cast Iron '.....
......... L..:'...
'....Platinum .GM;...
........... I;,,: Aluminum
;..:'.,.:: :;....:. Silicon lmn ...............
Platinum ~d :fl&i&k
........... Odd
...........
.. . ... ..I..' I ...........
:

Silicon Iron lead.. ,.;........ . Tantalum

.....
....... ... 'elicon iron Platinum
,: ......... ...,.' ........
,.. .,,.-. :
Sted . . '..' Tmtalum
"
I . . . . . . . .

s i l i i boll

Tamalum Tantalum

CORROSION RESISTANCE OF MATERIALS TO MIXED ACIDS

AT ROOM TEMPERATURE
 GUIDE DOCUMENT

,'
,l
PROCESS ENGINEERING DESIGN GUIDE
PART 1 - SECTION 1
PROCESS MANUAL (DATA BOOK)
S.S. 1.3 : MATERIALS -LINES - P&ID
MATERIALS AND CORROSION
-
47

.......
GRAPH X - HC1 Corrosion .... ..
,............
,

:,'
.....
. . : ,:

-
S-E :~ 1 0 1DATA
1 SWVBY ...... -..,:?
CODE. FOR HYDROCHLORIC ACID .G~P;$# ....,., ....
w.(l in h.m nporcadconodon ra0a. of <Mv!k. ,.,, ....:,.. .
C : ....'
-ZONE 1 ZONE 2
,.-.. '. -
ZONE 3 &;:'-.... '.. 5
.. ZONE 5
.."...-., i 62Ni 28Mos
, 'A.

:.. .......,/..
: 20Cr 30Ni1 62Ni 32Q, &N;.37Cu;;';
........ 62Ni 28Mos
! 86Ni JZCul ~ o l ~ b d a .r u . . . :.... M d y b b u m
..........
~ Platinum
. ...............
;................... ;
. ....
62Ni 28Mo mninum ......... Platinum
................ .. -.
...................... Silvar
Coppar' Silii~!.:..:~' Silva ...........
.... ..gvar Tantalum
............
s,i&;.&.&,, ..........' "'
,...I.....
. . .
I NiM' .._ Tantalum ....... ,. . Tantalum Zirconium
...: .i.... ............ ..;
,
.:qt&,/ ..: ,7ir-'+ .-....'..; “... Tungsten
Platinum
................
. .,:.... .. .,.
; S i r i bronze' ;';.-..Y&um, . .......... :.
i : .. .
Zirconium
., - ......I.
......
! Silicon cast iron?. :. - . - . & n i u m
.........
.............
j... ....
..,.;.:-)-1.- .......... C

....
Tanalum' .! . ...
Timi&.
..........
,
'.., '..
....,':
Tunoren
Zirconium

I.<Tr.,2s('
2. No air
I. No 1'61,
4.<IOXrtUC
5. No &tine
 GUIDE DOCUMENT
(ru*dby Bm*V mp*rw b
GE ( 312 1 1.1.3 1 I ( 0

PROCESS ENGINEERING DESIGN GUIDE ~ p e '

PART 1 - SECTION 1 S.S. 1.3 : MATERIALS - LINES - P81D 48

PROCESS MANUAL (DATA BOOK) MAERIALS AND CORROSION

GRAPH XI

<, ...............
DeWard (1 ~ i ~ i a d - 6 o m o g r afor
m calculations of corrosion
a function of partialC 0 2pressure (bar) and
rates (rnm1.y.ebr1.a~
temperat&e-S];
....
~xampJ&dorrosion rate 0.1 mmlyear with 0.1 bar C02at 7OC.
............
._ C
 GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE m e

49
PART 1 - SECTION 1 S.S.1.3 : MATERIALS - LINES - P81D
PROCESS MANUAL (DATA BOOK) MATERIALSAND CORROSION

.......
.,..-.
5 GENERAL BASIC INFORMATION ,.':
....... \..;
; i l
...............
t..
:;
,
5.1 Cr-EquivalentINi Equivalent .,............
..
,.> ...,. -,..
.,.?.... .:.....
.;:.,/. . ,";

a. Cr Equivalent .,,. ....

.....
..',r......
......
Express equivalence.......
of:alkying
: -......
elements as ferritB.&biliser'property of chromium :
.. '.. :: "....>
% Cr equivalent = % c<+.T& Si) + 1.5 (% Mo) + 5 (%&&.5(.M)+ 1.75 (% Nb) + 1.5 (% Ti) +
..........
0.75 (% W) . .................
.. (, <. , ,.-,. :

.--..-...
:
-..
....:
. ..
.
".
.,
I.__
..*.-
:(. ;:
- ......
..'..
..........-...... "
..
.
1 ;
::.:.........
......... ;.
b. Ni ~ ~ u i v a . l:
.. ;...~ i ...".
e
.I. ......
:. .. .'. . .
.......... . . . . .../
..'. ..../.
:'I.

~x~res~a~k&a@ of~alloying
ce ..._.....
elePe&d:+,austenite stabiliser property of Nickel :
........ :.......
.... Ni + % Co + 30 (% c)$ 25 (96j~)+ 0.5 (%Mn) + 0.3 (% Cu)
... ... ......... .;
% ~i.&akht+%
::
i:
...
, .......
..........I.
': :.-.....
.,.> .......... :.:
,..... ........
.......I
$'

c. :, ,...,:,.$,.c h i e f f l t ~ r ~ i i m . .. .-".... .'

..........
.
...
I

I
............ ,,
. .. &&[&mate
,
metaI~urgi~ljfs&ctu&of Stainless Steel

O R Q Y U l ~W.%
.
............
. . .
5.2. % n.
...........
'G 'beesistance Equivalent Number (PREN)
......... .
...'
> ...
!': ::.--. r f n g Resistence Equivalent Number (PREN) is an index comparing the resistance of
".. 4 d y s to pitting and crevice corrosion :
:.......
..........
PREN = % Cr + 3.3 (% Mo) + 16 (%N)

According to various experimentator's reports. coefficient for (% Mo) might range

between 3.0 and 3.3, coefficient for (% N) might range between 12.8 and 30.

A modified formula has been proposed for use when tungstent is added to an alloy :

PREN = % Cr + 3.3 ((% Mo) + 0.5 (% W))+ 16 (% N).