Process Plant Equipment (eBook, ePUB)

Operation, Control, and Reliability
Redaktion: Holloway, Michael D.; Onyewuenyi, Oliver A.; Nwaoha, Chikezie

• Format: ePub

Produktbeschreibung

"Process Plant Equipment Book is another great publication from Wiley as a reference book for final year students as well as those who will work or are working in chemical production plants and refinery..." -Associate Prof. Dr. Ramli Mat, Deputy Dean (Academic), Faculty of Chemical Engineering, Universiti Teknologi Malaysia "...give[s] readers access to both fundamental information on process plant equipment and to practical ideas, best practices and experiences of highly successful engineers from around the world... The book is illustrated throughout with numerous black & white photos and diagrams and also contains case studies demonstrating how actual process plants have implemented the tools and techniques discussed in the book. An extensive list of references enables readers to explore each individual topic in greater depth..." -Stainless Steel World and Valve World, November 2012 Discover how to optimize process plant equipment, from selection to operation to troubleshooting From energy to pharmaceuticals to food, the world depends on processing plants to manufacture the products that enable people to survive and flourish. With this book as their guide, readers have the information and practical guidelines needed to select, operate, maintain, control, and troubleshoot process plant equipment so that it is efficient, cost-effective, and reliable throughout its lifetime. Following the authors' careful explanations and instructions, readers will find that they are better able to reduce downtime and unscheduled shutdowns, streamline operations, and maximize the service life of processing equipment. Process Plant Equipment: Operation, Control, and Reliability is divided into three sections: * Section One: Process Equipment Operations covers such key equipment as valves, pumps, cooling towers, conveyors, and storage tanks * Section Two: Process Plant Reliability sets forth a variety of tested and proven tools and methods to assess and ensure the reliability and mechanical integrity of process equipment, including failure analysis, Fitness-for-Service assessment, engineering economics for chemical processes, and process component function and performance criteria * Section Three: Process Measurement, Control, and Modeling examines flow meters, process control, and process modeling and simulation Throughout the book, numerous photos and diagrams illustrate the operation and control of key process equipment. There are also case studies demonstrating how actual process plants have implemented the tools and techniques discussed in the book. At the end of each chapter, an extensive list of references enables readers to explore each individual topic in greater depth. In summary, this text offers students, process engineers, and plant managers the expertise and technical support needed to streamline and optimize the operation of process plant equipment, from its initial selection to operations to troubleshooting.

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Produktdetails

• Verlag: John Wiley & Sons
• Seitenzahl: 728
• Erscheinungstermin: 20. August 2012
• Englisch
• ISBN-13: 9781118162545
• Artikelnr.: 37363331

Autorenporträt

Michael D. Holloway, AS, BA, BS, MS, CLS, has over twenty-five years of industrial experience in lab synthesis, pilot scale manufacturing, product development, application engineering, sales and marketing management, and most recently as Director of Technical Development and Reliability for NCH Corporation. A graduate of Salve Regina College and the University of Massachusetts, he has served as a contributing writer for Manufacturing.net, Assembly, and Plant Services and is the author of Spend Analysis and Specification Development Using Failure Interpretation. He resides in North Texas with his wife and two children. Chikezie Nwaoha, AMIMechE, MOSHAN, is a petroleum engineer specializing in process engineering/equipment operations, natural gas processing/distribution, and pipeline integrity. He is a contributing editor to both Control Engineering Asia and PetroMin and a downstream correspondent to Petroleum Africa. He worked with Port Harcourt Refining Company (PHRC) in 2005 and 2007 as an industrial trainee. He is also a guest member of the Subsea Integrity Research Group, University of Aberdeen. OLIVER A. ONYEWUENYI, PE, PhD, is President of MISOL Technology Solutions LLC. He was formerly the program manager of Deepwater Technology/R&D at Shell International and led the award-winning Shell Structural Integrity Analysis Team in Houston. He is the recipient of four industry awards from ASME International and six Shell Special Recognition Awards.

Inhaltsangabe

Contributors xxiii Preface xxiv SECTION I PROCESS EQUIPMENT OPERATION 1 Introduction 3 Michael D. Holloway 2 Valves 9 Ali Ahammad Shoukat Choudhury
Chikezie Nwaoha
and Sharad Vishwasrao 2.1 Types of Control Valves
10 2.2 Control Valve Actuators
12 2.3 Control Valve Sizing and Selection
13 2.4 Common Problems of Control Valves
15 2.5 Diagnosing Control Valve Problems
19 2.6 Control Valve Reliability and Selection
20 2.7 Control Valve Maintenance
22 2.8 Control Valve Troubleshooting
24 References
24 3 Pumps 27 Craig Redmond 3.1 Types of Pumps
28 3.2 Pump Applications
34 3.3 Pump Sizing and Selection
37 3.4 Pump Maintenance
40 3.5 Pump Troubleshooting
44 4 Pipes 45 Shaohui Jia 4.1 Types of Pipes
45 4.2 Pipe Selection
46 4.3 Pipeline Network Design and Optimization
48 4.4 Pipeline Failure
50 4.5 Pipeline Inspection and Leak Detection
54 4.6 Pipe Maintenance
58 4.7 Pipe Troubleshooting
60 References
61 5 Cooling Towers 63 Zaki Yamani Zakaria and Chikezie Nwaoha 5.1 Cooling Tower Operation
63 5.2 Types of Cooling Towers
69 5.3 Common Problems of Cooling Towers
74 5.4 Measuring Cooling Tower Performance
75 5.5 Cooling Tower Maintenance
77 References
79 6 Filters and Membranes 81 Flora Tong and Chikezie Nwaoha 6.1 Types of Filters
81 6.2 Mechanisms of Filtration
87 6.3 Filter Selection
87 6.4 Particle-Size Measurement Techniques
88 6.5 Filter Location
89 6.6 Membrane Filtration
89 6.7 Filter Maintenance
103 References
104 7 Sealing Devices 107 Matt Tones and Jim Drago 7.1 Gaskets
107 7.2 Compression Packings
125 7.3 Mechanical Seals
131 7.4 Expansion Joints
147 7.5 General Sealing Device Selection
157 References
161 8 Steam Traps 163 Jacob E. Uche and Chikezie Nwaoha 8.1 Steam Trap Operation
163 8.2 Types of Steam Traps
164 8.3 Steam Trap Installation
172 8.4 Steam Trap Checking
172 8.5 Common Problems of Steam Traps
175 8.6 Steam Trap Selection
176 8.7 Steam Trap Applications
178 8.8 Steam Trap Sizing
178 8.9 Steam Trap Maintenance
181 References
181 9 Process Compressors 183 N. Sitaram and Chikezie Nwaoha 9.1 Types of Compressors
183 9.2 Continuous Compression Compressors
184 9.3 Intermittent Compression Compressors
186 9.4 Centrifugal Compressors
189 9.5 Reciprocating Piston Compressors
202 9.6 Compressor Troubleshooting
209 References
210 Further Reading
211 10 Conveyors 213 Okenna Obi-Njoku 10.1 Industrial Use of Conveyors
213 10.2 Types of Conveyors
214 10.3 Conveyor Selection
221 10.4 Conveyor Safety
221 10.5 Conveyor Maintenance
222 10.6 Summary
222 References
223 11 Storage Tanks 225 Marcello Ferrara and Chikezie Nwaoha 11.1 Types of Storage Tanks
225 11.2 Storage Tank Classification
227 11.3 Construction Materials
227 11.4 Common Problems of Storage Tanks
229 11.5 Storage Tank Maintenance
233 11.6 Tank Appurtenances
241 11.7 Storage Tank Maintenance
243 References
244 12 Mixers 245 Jayesh Ramesh Tekchandaney 12.1 Mixing Concepts: Theory and Practice
246 12.2 Fluid Mixing
248 12.3 Solid Blending
264 12.4 Mixing High-Viscosity Materials and Pastes
274 12.5 Mechanical Components in Mixing Equipment
284 References
295 13 Boilers 297 Celestine C. G. Nwankwo 13.1 Types of Boilers
298 13.2 Boiler Accessories
303 13.3 Boiler Selection
305 13.4 Common Problems of Boilers
306 13.5 Boiler Failure Analysis and Welding Defects
308 13.6 Boiler Maintenance
313 13.7 Boiler Troubleshooting
319 13.8 Boiler Chemicals
321 13.9 Boiler Efficiency and Combustion
325 References
327 Further Reading
328 SECTION II PROCESS PLANT RELIABILITY 14 Engineering Economics for Chemical Processes 331 Alberto R. Betancourt-Torcat
L. A. Ricardez-Sandoval
and Ali Elkamel 14.1 Time Value of Money
331 14.2 Cash Flow Analysis
333 14.3 Profitability Analysis
336 14.4 Cost Estimation and Project Evaluation
340 References
353 15 Process Component Function and Performance Criteria 355 Robert Free 15.1 Material Classification
355 15.2 General Physical Quantities and Considerations
356 15.3 Material Transfer and Conveyance Equipment
366 15.4 Conveyors
367 15.5 Pumps
394 15.6 Valves
400 15.7 Pipes
405 15.8 Conclusions
410 References
410 Corporation Web Sites
411 16 Failure Analysis and Interpretation of Components 413 Michael D. Holloway 16.1 Assessing the Situation
413 16.2 Failure Defined
414 16.3 Taking Advantage of Failure
415 16.4 Sources of Failure
416 16.5 Failure of Materials and of Machines
416 16.6 Types of Forces
417 16.7 Strength
418 16.8 Creep (Deformation)
419 16.9 Fatigue (Material)
420 16.10 Wear
422 16.11 Property Changes
423 16.12 Temperature
423 16.13 Oxidation: Molecular Transitions and Chemical Influences
425 16.14 Deposit Formation
426 16.15 Factors that Affect Deposit Formation
428 16.16 Documenting Failure
429 References
432 17 Mechanical Integrity of Process Vessels and Piping 435 Oliver A. Onyewuenyi 17.1 Perspectives on Mechanical Integrity
Fitness for Service
and Condition Monitoring
437 17.2 Types of Flaws and Damage Mechanisms
439 17.3 Inspection
Characterization
and Monitoring of Flaws
442 17.4 Fracture Mechanics and Fitness-for-Service Assessment
443 17.5 Control and Prevention of Brittle Fracture
452 17.6 Case Histories and Examples of FFS Applications to Cracks in Process Plant Pressure Vessels
459 References
464 18 Design of Pressure Vessels and Piping 467 Maher Y. A. Younan 18.1 Modes of Failure
467 18.2 Basic Stress Analysis
469 18.3 Design of Pressure Vessels
470 18.4 Design of Piping Systems
481 References
486 19 Process Safety in Chemical Processes 489 Jelenka Savkovic-Stevanovic 19.1 The Hazards
490 19.2 Hazard Analysis
499 19.3 Risk Analysis
503 19.4 Safety Ratings
511 19.5 Development and Design of a Safe Plant
524 19.6 Safety Process Operation
543 19.7 Safety and Reliability Analysis
557 19.8 Summary
581 References
582 SECTION III PROCESS MEASUREMENT
CONTROL
AND MODELING 20 Flowmeters and Measurement 587 Gregory Livelli and Chikezie Nwaoha 20.1 Flow Measurement Techniques
587 20.2 Flow-Rate Meters
592 20.3 Common Problems of Flowmeters
599 20.4 Flowmeter Installation and Maintenance
601 20.5 Calibration and Certification
606 20.6 LACT and Prover Descriptions
607 20.7 Troubleshooting LACT and Prover Systems
614 20.8 Troubleshooting Flowmeters
614 References
617 21 Process Control 619 John A. Shaw 21.1 Control System Components
619 21.2 Control System Requirements
620 21.3 Sensor Response
620 21.4 Control Algorithms
624 21.5 Loop Tuning
625 21.6 Multiloop Control
629 21.7 Final Control Elements
633 21.8 Process Controllers
634 Reference
634 22 Process Modeling and Simulation 635 Mathew Chidiebere Aneke 22.1 Process Modeling
635 22.2 Process Simulation
636 22.3 Process Optimization
636 22.4 Commercial Tools for Process Modeling
Simulation
and Optimization
637 22.5 Process Modeling Case Studies
638 22.6 Concluding Remarks
650 References
650 Appendix I Methods for Measuring Process Temperature 653 Chikezie Nwaoha Appendix II Airflow Troubleshooting 659 Chikezie Nwaoha Appendix III MIG Shielding Gas Control and Optimization 663 Jerry Uttrachi Appendix IV Rupture Disk Selection 665 Chikezie Nwaoha Appendix V Pressure Gauge Selection 669 Chikezie Nwaoha Appendix VI Corrosion and Its Mitigation in the Oil and Gas Industries 673 Krupavaram Nalli Appendix VII Mixers 681 Jayesh Ramesh Tekchandaney Glossary of Processing Terms 685 Garlock Sealing Technologies Index 693

Rezensionen

"Process Plant Equipment Book is another great publication from Wiley as a reference book for final year students as well as those who will work or are working in chemical production plants and refinery..." (Associate Prof. Dr. Ramli Mat, Deputy Dean (Academic), Faculty of Chemical Engineering, Universiti Teknologi Malaysia)
"... give[s] readers access to both fundamental information on process plant equipment and to practical ideas, best practices and experiences of highly successful engineers from around the world." (Stainless Steel World, November 2012)

"The book is illustrated throughout with numerous black & white photos and diagrams and also contains case studies demonstrating how actual process plants have implemented the tools and techniques discussed in the book. An extensive list of references enables readers to explore each individual topic in greater depth." (Valve World, November 2012)