PROCESS PLANT EQUIPMENT

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3 PROCESS PLANT EQUIPMENT

5 PROCESS PLANT EQUIPMENT Operation, Control, and Reliability Edited by MICHAEL D. HOLLOWAY CHIKEZIE NWAOHA OLIVER A. ONYEWUENYI A JOHN WILEY & SONS, INC., PUBLICATION

6 Cover photography: courtesy of Chikezie Nwaoha Copyright 2012 by John Wiley & Sons. All rights reserved. Published by John Wiley & Sons, Inc., Hoboken, New Jersey Published simultaneously in Canada No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, scanning, or otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without either the prior written permission of the Publisher, or authorization through payment of the appropriate per-copy fee to the Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923, , fax , or on the web at Requests to the Publisher for permission should be addressed to the Permissions Department, John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, , fax , or online at Limit of Liability/Disclaimer of Warranty: While the publisher and author have used their best efforts in preparing this book, they make no representations or warranties with respect to the accuracy or completeness of the contents of this book and specifically disclaim any implied warranties of merchantability or fitness for a particular purpose. No warranty may be created or extended by sales representatives or written sales materials. The advice and strategies contained herein may not be suitable for your situation. You should consult with a professional where appropriate. Neither the publisher nor author shall be liable for any loss of profit or any other commercial damages, including but not limited to special, incidental, consequential, or other damages. For general information on our other products and services or for technical support, please contact our Customer Care Department within the United States at , outside the United States at or fax Wiley also publishes its books in a variety of electronic formats. Some content that appears in print may not be available in electronic formats. For more information about Wiley products, visit our web site at Library of Congress Cataloging-in-Publication Data: Process plant equipment : operation, control, and reliability / edited by Michael D. Holloway, Chikezie Nwaoha, Oliver A. Onyewuenyi. p. cm. Includes index. ISBN (cloth) 1. Pumping machinery Maintenance and repair. 2. Pipelines Maintenance and repair. 3. Valves Maintenance and repair. 4. Compressors Maintenance and repair. 5. Storage tanks Maintenance and repair. 6. Mixing machinery Maintenance and repair. 7. Boilers Maintenance and repair. 8. Filters and filtration. I. Holloway, Michael H., 1963 II. Nwaoha, Chikezie, 1984 III. Onyewuenyi, Oliver A., 1952 TJ900.P dc Printed in the United States of America

7 For the memory of Denton Ward student and friend

9 CONTENTS Contributors Preface xxiii 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, Linear-Motion Control Valves, Rotary-Motion Control Valves, Nonreturn Valves, Relief Valves, Control Valve Actuators, Pneumatic Valve Actuators, Electric Valve Actuators, Hydraulic Valve Actuators, Control Valve Sizing and Selection, Selecting a Valve Type, Sizing and Selection: Letting the Computer Do It All, Common Problems of Control Valves, Control Valve Cavitation, Control Valve Leakage, Control Valve Nonlinearities, Diagnosing Control Valve Problems, Control Valve Reliability and Selection, Control Valve Maintenance, Detecting Control Valve Stiction, 23 vii

10 viii CONTENTS 2.8 Control Valve Troubleshooting, 24 References, 24 3 Pumps 27 Craig Redmond 3.1 Types of Pumps, Positive-Displacement Pumps, Dynamic Pumps, Pump Applications, Flooded Suction Applications, Suction Lift Applications, Staged Pumping, Solids-Handling Applications, Pump Sizing and Selection, System Head Curve, Pump Peformance Curves, Actual Pump Sizing and Selection, Net Positive Suction Head, Net Positive Suction Head Available, Pump Maintenance, Bearing Lubrication, Seal Maintenance, Maintaining Performance, Winterizing and Long-Term Storage, Cold Temperature Installations, Pump Troubleshooting, 44 4 Pipes 45 Shaohui Jia 4.1 Types of Pipes, Seamless Pipe, Welded Pipe, Pipe Selection, Pipe Strength, Pipe Toughness, Pipe Weldability, Piping Material, Pipeline Network Design and Optimization, Pipeline Failure, Pipe External Corrosion, Pipe Internal Corrosion, Stress Corrosion Cracking, Pipeline Inspection and Leak Detection, Pipeline Inspection, Pipeline Inspection Tools, Pipeline Leak Detection, Pipe Maintenance, Pipeline Coatings, Pipeline Repair, Pipe Troubleshooting, 60 References, 61

11 CONTENTS ix 5 Cooling Towers 63 Zaki Yamani Zakaria and Chikezie Nwaoha 5.1 Cooling Tower Operation, Cooling Tower Psychrometrics, Principles of Cooling, Heat Exchange, Components of Cooling Towers, Types of Cooling Towers, Natural-Draft Cooling Towers, Mechanical-Draft Cooling Towers, Common Problems of Cooling Towers, Scale Deposits, Delignification of Wood, Poor Pump Performance, Poor Airflow, Makeup Water, Clogging of Distribution Nozzles, Measuring Cooling Tower Performance, Performance Assessment, Cooling Tower Maintenance, 77 References, 79 6 Filters and Membranes 81 Flora Tong and Chikezie Nwaoha 6.1 Types of Filters, Gas Filters, Liquid Filters, Mechanisms of Filtration, Depth Straining, Surface Straining, Depth Filtration, Cake Filtration, Filter Selection, Chemical Compatibility, Accurate Pore Size, Particle-Size Measurement Techniques, Image Analysis, Direct Mechanical Measurement, Ultrasonics, Laser Scattering Technology, Filter Location, Pressure Line Filters, Suction Line Filters, Return Line Filters, Membrane Filtration, Ultrafiltration, Microfiltration, Reverse Osmosis, Nanofiltration, Filter Maintenance, Preparation for Maintenance, 104 References, 104

12 x CONTENTS 7 Sealing Devices 107 Matt Tones and Jim Drago 7.1 Gaskets, Gasket Materials, Gasket and Seal Construction, Principles of Gasket Operation, Gasket and Metal Seal Applications, Gasket Selection, Compression Packings, Packing Materials, Packing Construction, Packing Selection, Packing Installation, Mechanical Seals, Considerations for Using Mechanical Seals, Types of Mechanical Seals, Mechanical Seal Applications, Environmental Controls, Failure Analysis, Troubleshooting Mechanical Seals, Expansion Joints, Joint Construction, Principles of Joint Operation, Joint Selection, Industrial Use of Expansion Joints, Joint Installation, Joint Troubleshooting, General Sealing Device Selection, Product Selection, Understanding the Forces, STAMPS Criteria, 158 References, Steam Traps 163 Jacob E. Uche and Chikezie Nwaoha 8.1 Steam Trap Operation, Types of Steam Traps, Thermodynamic Steam Traps, Mechanical Steam Traps, Thermostatic Steam Traps, Steam Trap Installation, Outlets of Steam-Using Equipment, On Steam Lines, Steam Trap Checking, Sight Method, Sound Method, Temperature Method, Fluid Conductivity Method, Common Problems of Steam Traps, Air Binding, Dirt, Improper Sizing, 175

13 CONTENTS xi Steam Trap Leakage, Steam Locking, Water Hammer, Erosion of Seat and Valve Sealing Faces, Life Expectancy, Steam Trap Selection, Steam Trap Applications, Protection Service, Process Service, Other Applications, Steam Trap Sizing, Basic Considerations, Steam Trap Maintenance, 181 References, Process Compressors 183 N. Sitaram and Chikezie Nwaoha 9.1 Types of Compressors, Continuous Compression Compressors, Ejectors, Dynamic, Rotodynamic, or Turbocompressors, Intermittent Compression Compressors, Positive-Displacement Compressors (Intermittent Flow), Rotary Compressors (Continuous Flow), Centrifugal Compressors, Major Components of Centrifugal Compressors, Thermodynamics of Centrifugal Compressors, Energy Transfer in Centrifugal Compressors, Slip in Centrifugal Impellers, Losses and Efficiencies, Performance, Stall, and Surge, Drivers, Reciprocating Piston Compressors, Compressor Operation, Thermodynamic Laws, Compression Cycles, Power Requirements, Multistage Compression, Cylinder Clearance and Volumetric Efficiency, Valve Losses, Major Components of Reciprocating Piston Compressors, Drivers, Compressor Troubleshooting, 209 References, 210 Further Reading, Conveyors 213 Okenna Obi-Njoku 10.1 Industrial Use of Conveyors, Types of Conveyors, Belt Conveyors, Bucket Conveyors, 215

14 xii CONTENTS Cart-on-Track Conveyors, Chute Conveyors, Gravity Wheel Conveyors, Monorails, Chain Conveyors, Pneumatic Conveyors, Roller Conveyors, Screw Conveyors, Slat Conveyors, Sortation Conveyors, Vane-Type Throwing Machines, Tow Conveyors, Trolley Conveyors, Vertical Conveyors, Vibrating Conveyors, Troughed Belt Conveyors, Magnetic Belt Conveyors, Power-and-Free Conveyors, Conveyor Selection, Conveyor Safety, Conveyor Maintenance, Summary, 222 References, Storage Tanks 225 Marcello Ferrara and Chikezie Nwaoha 11.1 Types of Storage Tanks, Aboveground Tanks, Underground Tanks, Storage Tank Classification, Aboveground Tanks, Underground Tanks, Construction Materials, Tank Materials, Protective Coatings, Insulation, Common Problems of Storage Tanks, Corrosion, Vapor Losses, Storage Tank Fires, Storage Tank Maintenance, Tank Blanketing, Holiday Detection, Tank Cleaning, Tank Appurtenances, Mixers, Dikes, Insulators, Platforms and Ladders, Gauging Devices, Valves, Manways, Diffusers, 243

15 CONTENTS xiii Water Cannons, Vents, Grounding, Supporting Structures, Storage Tank Maintenance, 243 References, Mixers 245 Jayesh Ramesh Tekchandaney 12.1 Mixing Concepts: Theory and Practice, Batch and Continuous Mixing, Selection of Mixing Equipment, Design of Mixing Equipment, Scale-Up of Mixing Equipment, Fluid Mixing, Fluid Mixing Applications, Mixing Regimes, Power Consumption in Agitated Vessels, Flow Characteristics, Liquid Agitation Equipment, Solid Blending, Properties of Solids Affecting Blending, Types of Blend Structures, Mechanisms of Solid Blending, Segregation Mechanisms, Scale-Up of Solid Mixers, Solid Blending Equipment, Mixing High-Viscosity Materials and Pastes, Dispersive, Distributive, and Convective Mixing, Power for Viscous Mixing, Scale-Up of High-Viscosity Mixers, Heat Transfer, Equipment for Mixing High-Viscosity Materials and Pastes, Mechanical Components in Mixing Equipment, Motors, Mixer Speed Reducers, Couplings, Bearings, Shaft Seals, Variable-Speed Operation Devices, Mixer Installation, Startup, and Maintenance, Mixer Specifications, 295 References, Boilers 297 Celestine C. G. Nwankwo 13.1 Types of Boilers, Water Tube Boilers, Fire Tube Boilers, Pot Boilers, Saddle Boilers, Packaged Boilers, 301

Distribution System Requirements for Fire Protection

Distribution System Requirements for Fire Protection AWWA MANUAL M31 Fourth Edition MANUAL OF WATER SUPPLY PRACTICES M31, Fourth Edition Distribution System Requirements for Fire Protection Copyright 1989,