A Working Guide to Process Equipment, Fourth Edition

The latest methods for troubleshooting and maintaining process equipment

Applicable to a broad range of technicians and industries and fully updated throughout, A Working Guide to Process Equipment, Fourth Edition, explains how to diagnose, troubleshoot, and correct problems with chemical and petroleum refining process equipment. Nine new chapters cover:

• Tray design details
• Shell-and-tube heat exchanger design details
• Relief valve system design
• Vapor lock and exchanger flooding in steam systems
• Steam generation operating and design details
• Wastewater strippers
• Thermodynamics -- how it applies to process equipment
• Centrifugal pumps -- reducing seal and bearing failures
• Hand calculations for distillation towers
• Vapor -- liquid equilibrium, absorption, and stripping calculations

Filled with examples and illustrations, this practical resource demonstrates how theory applies to solving real-world plant operation problems. Selected hand calculation methods are also provided.

Foreword
Preface to the Fourth Edition
Preface to the Third Edition
Preface to the Second Edition
Preface to the First Edition
Introduction
Acknowledgments

Chapter 1 : Process Equipment Fundamentals
Chapter 2 : Basic Terms and Conditions
Chapter 3 : How Trays Work : Flooding
Chapter 4 : How Trays Work : Dumping (Weeping through Tray Decks)
Chapter 5 : Notes on Tray Design Details
Chapter 6 : Why Control Tower Pressure (Options for Optimizing Tower Operating Pressure)
Chapter 7 : What Drives Distillation Towers (Reboiler Function)
Chapter 8 : How Reboilers Work (Thermosyphon, Gravity Feed, and Forced)
Chapter 9 : Inspecting Tower Internals
Chapter 10 : How Instruments Work (Levels, Pressures, Flows, and Temperatures)
Chapter 11 : Packed Towers : Better Than Trays? (Packed-Bed Vapor and Liquid Distribution)
Chapter 12 : Steam and Condensate Systems (Water Hammer and Condensate Backup Steam-Side Reboiler Control)
Chapter 13 : Vapor Lock and Exchanger Flooding in Steam Systems
Chapter 14 : Bubble Point and Dew Point (Equilibrium Concepts in Vapor-Liquid Mixtures)
Chapter 15 : Steam Strippers (Source of Latent Heat of Vaporization)
Chapter 16 : Draw-Off Nozzle Hydraulics (Nozzle Cavitation Due to Lack of Hydrostatic Head)
Chapter 17 : Pumparounds and Tower Heat Flows (Closing the Tower Enthalpy Balance)
Chapter 18 : Condensers and Tower Pressure Control (Hot-Vapor Bypass : Flooded Condenser Control)
Chapter 19 : Air Coolers (Fin-Fan Coolers)
Chapter 20 : Thermodynamcis (How It Applies to Process Equipment)
Chapter 21 : Deaerators and Steam Systems (Generating Steam in Boilers and BFW Preparation)
Chapter 22 : Stream Generation
Chapter 23 : Vacuum Systems : Steam Jet Ejectors
Chapter 24 : Steam Turbines (Use to Horsepower Valves and Correct Speed Control)
Chapter 25 : Surface Condensers (The Condensing Steam Turbine)
Chapter 26 : Shell-and-Tube Heat Exchangers : Heat-Transfer Fouling Resistance
Chapter 27 : Heat Exchanger Innovations
Chapter 28 : Shell-and-Tube Heat Exchangers : Design Details
Chapter 29 : Fired Heaters : Fire-and Flue-Gas Side (Draft and Afterburn, Optimizing Excess Air)
Chapter 30 : Fired Heaters  Process Side (Coking Furnace Tubes and Tube Failures)
Chapter 31 : Refrigeration Systems (An Introduction to Centrifugal Compressors)
Chapter 32 : Cooling Water Systems
Chapter 33 : Catalytic Effects : Equilibrium and Kinetics
Chapter 34 : Centrifugal Pumps : Fundamentals of Operation (Head, Flow, and Pressure)
Chapter 35 : Centrifugal Pumps : Driver Limits Electric Motors and Steam Turbines
Chapter 36 : Centrifugal Pumps : Suction Pressure Limits Cavitation and Net Positive Suction Head
Chapter 37 : Centrifugal Pumps : Reducing Seal and Bearing Failures
Chapter 38 : Control Valves
Chapter 39 : Separators : Vapor-Hydrocarbon-Water (Liquid Settling Rates)
Chapter 40 : Gas Compression : The Basic Idea (The Second Law of Thermodynamics Made Easy)
Chapter 41 : Centrifugal Compressors and Surge (Overamping the Motor Driver)
Chapter 42 : Reciprocoating Compressors (The Carnot Cycle, Use of Indicator Card)
Chapter 43 : Compressor Efficiency (Effect on Driver Load)
Chapter 44 : Safety Concerns (Relief Valves, Corrosion, and Safety Trips)
Chapter 45 : Relief Valve System Design
Chapter 46 : Corrosion - Process Units
Chapter 47 : Waste Water Strippers
Chapter 48 : Fluid Flow in Pipes (Basic Ideas to Evaluate Newtonian and Non-Newtonian Flow)
Chapter 49 : Super-Fractionation Separation Stage
Chapter 50 : Hand Calculations for Distillation Towers (Vapor-Liquid Equilibrium, Absorption, and Stripping Calculations)
Chapter 51 : Computer Modeling and Control
Chapter 52 : Field Troubleshooting Process Problems

Glossary
Index
The Norm Lieberman Video Library of Troubleshooting Process Operations

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