Process Plant Equipment: Operation, Control, and Reliability

695 Pages·2012·8.851 MB·English

PROCESS PLANT EQUIPMENT
PROCESS PLANT EQUIPMENT
Operation, Control, and Reliability
Edited by
MICHAEL D. HOLLOWAY
CHIKEZIE NWAOHA
OLIVER A. ONYEWUENYI
A JOHN WILEY & SONS, INC., PUBLICATION
Coverphotography:courtesyofChikezieNwaoha
Copyright©2012byJohnWiley&Sons.Allrightsreserved.
PublishedbyJohnWiley&Sons,Inc.,Hoboken,NewJersey
PublishedsimultaneouslyinCanada
Nopartofthispublicationmaybereproduced,storedinaretrievalsystem,ortransmittedinanyformorbyanymeans,electronic,mechanical,
photocopying,recording,scanning,orotherwise,exceptaspermittedunderSection107or108ofthe1976UnitedStatesCopyrightAct,withouteither
thepriorwrittenpermissionofthePublisher,orauthorizationthroughpaymentoftheappropriateper-copyfeetotheCopyrightClearanceCenter,Inc.,
222RosewoodDrive,Danvers,MA01923,978-750-8400,fax[phone],oronthewebatwww.copyright.com.RequeststothePublisherfor
permissionshouldbeaddressedtothePermissionsDepartment,JohnWiley&Sons,Inc.,111RiverStreet,Hoboken,NJ07030,201-748-6011,fax
201-748-6008,oronlineathttp://www.wiley.com/go/permission.
LimitofLiability/DisclaimerofWarranty:Whilethepublisherandauthorhaveusedtheirbesteffortsinpreparingthisbook,theymakenorepresentations
orwarrantieswithrespecttotheaccuracyorcompletenessofthecontentsofthisbookandspecificallydisclaimanyimpliedwarrantiesofmerchantability
orfitnessforaparticularpurpose.Nowarrantymaybecreatedorextendedbysalesrepresentativesorwrittensalesmaterials.Theadviceandstrategies
containedhereinmaynotbesuitableforyoursituation.Youshouldconsultwithaprofessionalwhereappropriate.Neitherthepublishernorauthorshall
beliableforanylossofprofitoranyothercommercialdamages,includingbutnotlimitedtospecial,incidental,consequential,orotherdamages.
Forgeneralinformationonourotherproductsandservicesorfortechnicalsupport,pleasecontactourCustomerCareDepartmentwithintheUnited
Statesat877-762-2974,outsidetheUnitedStatesat317-572-3993orfax317-572–4002.
Wileyalsopublishesitsbooksinavarietyofelectronicformats.Somecontentthatappearsinprintmaynotbeavailableinelectronicformats.Formore
informationaboutWileyproducts,visitourwebsiteatwww.wiley.com.
LibraryofCongressCataloging-in-PublicationData:
Processplantequipment:operation,control,andreliability/editedby
MichaelD.Holloway,ChikezieNwaoha,OliverA.Onyewuenyi.
p.cm.
Includesindex.
ISBN978-1-118-02264-1(cloth)
1. Pumpingmachinery–Maintenanceandrepair. 2. Pipelines–Maintenanceandrepair. 3. Valves–Maintenanceandrepair.
4. Compressors–Maintenanceandrepair. 5. Storagetanks–Maintenanceandrepair. 6. Mixingmachinery–Maintenanceandrepair.
7. Boilers–Maintenanceandrepair. 8. Filtersandfiltration. I.Holloway,MichaelH.,1963– II. Nwaoha,Chikezie,1984– III.
Onyewuenyi,OliverA.,1952–
TJ900.P7252012
621.8–dc23
2011028229
PrintedintheUnitedStatesofAmerica
10987654321
Forthememoryof
DentonWard
studentandfriend
CONTENTS
Contributors xxiii
Preface xxiv
SECTION I PROCESS EQUIPMENT OPERATION
1 Introduction 3
MichaelD.Holloway
2 Valves 9
AliAhammadShoukatChoudhury,ChikezieNwaoha,andSharadVishwasrao
2.1 Types of Control Valves, 10
2.1.1 Linear-Motion Control Valves, 10
2.1.2 Rotary-Motion Control Valves, 11
2.1.3 Nonreturn Valves, 12
2.1.4 Relief Valves, 12
2.2 Control Valve Actuators, 12
2.2.1 Pneumatic Valve Actuators, 12
2.2.2 Electric Valve Actuators, 13
2.2.3 Hydraulic Valve Actuators, 13
2.3 Control Valve Sizing and Selection, 13
2.3.1 Selecting a Valve Type, 14
2.3.2 Sizing and Selection: Letting the Computer Do It All, 15
2.4 Common Problems of Control Valves, 15
2.4.1 Control Valve Cavitation, 15
2.4.2 Control Valve Leakage, 16
2.4.3 Control Valve Nonlinearities, 17
2.5 Diagnosing Control Valve Problems, 19
2.6 Control Valve Reliability and Selection, 20
2.7 Control Valve Maintenance, 22
2.7.1 Detecting Control Valve Stiction, 23
vii
viii CONTENTS
2.8 Control Valve Troubleshooting, 24
References, 24
3 Pumps 27
CraigRedmond
3.1 Types of Pumps, 28
3.1.1 Positive-Displacement Pumps, 28
3.1.2 Dynamic Pumps, 30
3.2 Pump Applications, 34
3.2.1 Flooded Suction Applications, 34
3.2.2 Suction Lift Applications, 35
3.2.3 Staged Pumping, 35
3.2.4 Solids-Handling Applications, 36
3.3 Pump Sizing and Selection, 37
3.3.1 System Head Curve, 37
3.3.2 Pump Peformance Curves, 38
3.3.3 Actual Pump Sizing and Selection, 39
3.3.4 Net Positive Suction Head, 40
3.3.5 Net Positive Suction Head Available, 40
3.4 Pump Maintenance, 40
3.4.1 Bearing Lubrication, 41
3.4.2 Seal Maintenance, 41
3.4.3 Maintaining Performance, 43
3.4.4 Winterizing and Long-Term Storage, 43
3.4.5 Cold Temperature Installations, 43
3.5 Pump Troubleshooting, 44
4 Pipes 45
ShaohuiJia
4.1 Types of Pipes, 45
4.1.1 Seamless Pipe, 45
4.1.2 Welded Pipe, 45
4.2 Pipe Selection, 46
4.2.1 Pipe Strength, 46
4.2.2 Pipe Toughness, 46
4.2.3 Pipe Weldability, 48
4.2.4 Piping Material, 48
4.3 Pipeline Network Design and Optimization, 48
4.4 Pipeline Failure, 50
4.4.1 Pipe External Corrosion, 51
4.4.2 Pipe Internal Corrosion, 52
4.4.3 Stress Corrosion Cracking, 53
4.5 Pipeline Inspection and Leak Detection, 54
4.5.1 Pipeline Inspection, 54
4.5.2 Pipeline Inspection Tools, 55
4.5.3 Pipeline Leak Detection, 56
4.6 Pipe Maintenance, 58
4.6.1 Pipeline Coatings, 58
4.6.2 Pipeline Repair, 59
4.7 Pipe Troubleshooting, 60
References, 61
CONTENTS ix
5 Cooling Towers 63
ZakiYamaniZakariaandChikezieNwaoha
5.1 Cooling Tower Operation, 63
5.1.1 Cooling Tower Psychrometrics, 63
5.1.2 Principles of Cooling, 65
5.1.3 Heat Exchange, 67
5.1.4 Components of Cooling Towers, 67
5.2 Types of Cooling Towers, 69
5.2.1 Natural-Draft Cooling Towers, 69
5.2.2 Mechanical-Draft Cooling Towers, 72
5.3 Common Problems of Cooling Towers, 74
5.3.1 Scale Deposits, 74
5.3.2 Delignification of Wood, 74
5.3.3 Poor Pump Performance, 75
5.3.4 Poor Airflow, 75
5.3.5 Makeup Water, 75
5.3.6 Clogging of Distribution Nozzles, 75
5.4 Measuring Cooling Tower Performance, 75
5.4.1 Performance Assessment, 76
5.5 Cooling Tower Maintenance, 77
References, 79
6 Filters and Membranes 81
FloraTongandChikezieNwaoha
6.1 Types of Filters, 81
6.1.1 Gas Filters, 82
6.1.2 Liquid Filters, 83
6.2 Mechanisms of Filtration, 87
6.2.1 Depth Straining, 87
6.2.2 Surface Straining, 87
6.2.3 Depth Filtration, 87
6.2.4 Cake Filtration, 87
6.3 Filter Selection, 87
6.3.1 Chemical Compatibility, 87
6.3.2 Accurate Pore Size, 87
6.4 Particle-Size Measurement Techniques, 88
6.4.1 Image Analysis, 88
6.4.2 Direct Mechanical Measurement, 88
6.4.3 Ultrasonics, 88
6.4.4 Laser Scattering Technology, 88
6.5 Filter Location, 89
6.5.1 Pressure Line Filters, 89
6.5.2 Suction Line Filters, 89
6.5.3 Return Line Filters, 89
6.6 Membrane Filtration, 89
6.6.1 Ultrafiltration, 90
6.6.2 Microfiltration, 94
6.6.3 Reverse Osmosis, 95
6.6.4 Nanofiltration, 102
6.7 Filter Maintenance, 103
6.7.1 Preparation for Maintenance, 104
References, 104
x CONTENTS
7 Sealing Devices 107
MattTonesandJimDrago
7.1 Gaskets, 107
7.1.1 Gasket Materials, 107
7.1.2 Gasket and Seal Construction, 113
7.1.3 Principles of Gasket Operation, 119
7.1.4 Gasket and Metal Seal Applications, 120
7.1.5 Gasket Selection, 123
7.2 Compression Packings, 125
7.2.1 Packing Materials, 126
7.2.2 Packing Construction, 128
7.2.3 Packing Selection, 129
7.2.4 Packing Installation, 130
7.3 Mechanical Seals, 131
7.3.1 Considerations for Using Mechanical Seals, 132
7.3.2 Types of Mechanical Seals, 134
7.3.3 Mechanical Seal Applications, 137
7.3.4 Environmental Controls, 140
7.3.5 Failure Analysis, 142
7.3.6 Troubleshooting Mechanical Seals, 144
7.4 Expansion Joints, 147
7.4.1 Joint Construction, 148
7.4.2 Principles of Joint Operation, 149
7.4.3 Joint Selection, 149
7.4.4 Industrial Use of Expansion Joints, 152
7.4.5 Joint Installation, 155
7.4.6 Joint Troubleshooting, 156
7.5 General Sealing Device Selection, 157
7.5.1 Product Selection, 157
7.5.2 Understanding the Forces, 157
7.5.3 STAMPS Criteria, 158
References, 161
8 Steam Traps 163
JacobE.UcheandChikezieNwaoha
8.1 Steam Trap Operation, 163
8.2 Types of Steam Traps, 164
8.2.1 Thermodynamic Steam Traps, 164
8.2.2 Mechanical Steam Traps, 166
8.2.3 Thermostatic Steam Traps, 169
8.3 Steam Trap Installation, 172
8.3.1 Outlets of Steam-Using Equipment, 172
8.3.2 On Steam Lines, 172
8.4 Steam Trap Checking, 172
8.4.1 Sight Method, 173
8.4.2 Sound Method, 174
8.4.3 Temperature Method, 174
8.4.4 Fluid Conductivity Method, 174
8.5 Common Problems of Steam Traps, 175
8.5.1 Air Binding, 175
8.5.2 Dirt, 175
8.5.3 Improper Sizing, 175
CONTENTS xi
8.5.4 Steam Trap Leakage, 175
8.5.5 Steam Locking, 176
8.5.6 Water Hammer, 176
8.5.7 Erosion of Seat and Valve Sealing Faces, 176
8.5.8 Life Expectancy, 176
8.6 Steam Trap Selection, 176
8.7 Steam Trap Applications, 178
8.7.1 Protection Service, 178
8.7.2 Process Service, 178
8.7.3 Other Applications, 178
8.8 Steam Trap Sizing, 178
8.8.1 Basic Considerations, 179
8.9 Steam Trap Maintenance, 181
References, 181
9 Process Compressors 183
N.SitaramandChikezieNwaoha
9.1 Types of Compressors, 183
9.2 Continuous Compression Compressors, 184
9.2.1 Ejectors, 184
9.2.2 Dynamic, Rotodynamic, or Turbocompressors, 185
9.3 Intermittent Compression Compressors, 186
9.3.1 Positive-Displacement Compressors
(Intermittent Flow), 186
9.3.2 Rotary Compressors (Continuous Flow), 187
9.4 Centrifugal Compressors, 189
9.4.1 Major Components of Centrifugal Compressors, 189
9.4.2 Thermodynamics of Centrifugal Compressors, 195
9.4.3 Energy Transfer in Centrifugal Compressors, 196
9.4.4 Slip in Centrifugal Impellers, 197
9.4.5 Losses and Efficiencies, 198
9.4.6 Performance, Stall, and Surge, 199
9.4.7 Drivers, 201
9.5 Reciprocating Piston Compressors, 202
9.5.1 Compressor Operation, 202
9.5.2 Thermodynamic Laws, 203
9.5.3 Compression Cycles, 203
9.5.4 Power Requirements, 204
9.5.5 Multistage Compression, 204
9.5.6 Cylinder Clearance and Volumetric Efficiency, 205
9.5.7 Valve Losses, 206
9.5.8 Major Components of Reciprocating Piston
Compressors, 206
9.5.9 Drivers, 207
9.6 Compressor Troubleshooting, 209
References, 210
Further Reading, 211
10 Conveyors 213
OkennaObi-Njoku
10.1 Industrial Use of Conveyors, 213
10.2 Types of Conveyors, 214
10.2.1 Belt Conveyors, 214
10.2.2 Bucket Conveyors, 215
xii CONTENTS
10.2.3 Cart-on-Track Conveyors, 215
10.2.4 Chute Conveyors, 216
10.2.5 Gravity Wheel Conveyors, 216
10.2.6 Monorails, 216
10.2.7 Chain Conveyors, 216
10.2.8 Pneumatic Conveyors, 217
10.2.9 Roller Conveyors, 217
10.2.10 Screw Conveyors, 218
10.2.11 Slat Conveyors, 218
10.2.12 Sortation Conveyors, 219
10.2.13 Vane-Type Throwing Machines, 219
10.2.14 Tow Conveyors, 219
10.2.15 Trolley Conveyors, 219
10.2.16 Vertical Conveyors, 220
10.2.17 Vibrating Conveyors, 220
10.2.18 Troughed Belt Conveyors, 220
10.2.19 Magnetic Belt Conveyors, 220
10.2.20 Power-and-Free Conveyors, 220
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
MarcelloFerraraandChikezieNwaoha
11.1 Types of Storage Tanks, 225
11.1.1 Aboveground Tanks, 225
11.1.2 Underground Tanks, 226
11.2 Storage Tank Classification, 227
11.2.1 Aboveground Tanks, 227
11.2.2 Underground Tanks, 227
11.3 Construction Materials, 227
11.3.1 Tank Materials, 227
11.3.2 Protective Coatings, 228
11.3.3 Insulation, 229
11.4 Common Problems of Storage Tanks, 229
11.4.1 Corrosion, 229
11.4.2 Vapor Losses, 230
11.4.3 Storage Tank Fires, 231
11.5 Storage Tank Maintenance, 233
11.5.1 Tank Blanketing, 233
11.5.2 Holiday Detection, 233
11.5.3 Tank Cleaning, 234
11.6 Tank Appurtenances, 241
11.6.1 Mixers, 241
11.6.2 Dikes, 241
11.6.3 Insulators, 241
11.6.4 Platforms and Ladders, 242
11.6.5 Gauging Devices, 242
11.6.6 Valves, 242
11.6.7 Manways, 243
11.6.8 Diffusers, 243