EQUIPMENT DESIGN REPORT 1

CHAPTER 3: DESIGN OF FLUIDS-HANDLING EQUIPMENT

SUBMITTED BY: CAMARO, FRANZ PATRICK

201020019@my.xu.edu.ph

CO-MEMBERS: AGOYLO, REINA NIÑA GRACE

201014355@my.xu.edu.ph

LAPUZ, JURGEN JOSEPH

20150008898@my.xu.edu.ph

NAVARRO, JENNY

20150007935@my.xu.edu.ph

TIMBANG, ALEXANDRIA

20150007673@my.xu.edu.ph

SUBMITTED TO: Dr. Hercules R. Cascon

Instructor
Problem 7.1 Sinnott & Towler
A pipeline constructed of carbon steel failed after 3 years operation. On examination it was found
that the wall thickness had been reduced by corrosion to about half the original value. The pipeline
was constructed of nominal 100 mm (4 in) schedule 40, pipe, inside diameter 102.3 mm (4.026
in), outside diameter 114.3 mm (4.5 in). Estimate the rate of corrosion in ipy and mm per year.
GIVEN:
• Pipeline constructed of 100 mm (4 in) Schedule 40
• Inside diameter, Di = 102.3 mm = 4.026 in
ri = 51.15 mm = 2.013 in
• Outside Diameter, Do = 114.3 mm= 4.5 in
ro = 57.15 mm = 2.25 in

REQUIRED:

• Rate of corrosion in inches per year and mm per year

SOLUTION:
Thickness of pipe, t = Do – Di

Case 1:

Thickness "t" in inches, t = 4.5 – 4.026 = 0.474 inches

Given that wall thickness reduced to half after 3 years,

New thickness of pipe, tnew = t/2 = 0.474/2 = 0.237 inches

Rate of corrosion, r = (t- tnew)/number of years

r = (0.474-0.237)/3 = 0.237/3 = 0.079 inches per year

Case 2:

Thickness "t" in mm, t = 114.3 – 102.3 = 12 mm

Given that wall thickness reduced to half after 3 years,

New thickness of pipe, tnew = t/2 = 12/2 = 6 mm

Rate of corrosion, r = (t- tnew)/number of years

r = (12-6)/3 = 6/3 = 2 mm per year

FINAL ANSWER:
In summary, the rate of corrosion for 3 operating years is 0.079 inches per year and 2
millimeter per year.
 SPECIFICATION SHEET

Specification Sheet for Pipeline

Identification: Item: Pipe
Item No: 4”-(SVC)
Type: Cylindrical

4.5” 4.026”
4” Schedule 40

Standard Steel Pipe

Function: Fluid flow

Design Properties:
Material of Construction Carbon Steel
Schedule SCH 40
Nominal Size 4”
Inside Diameter 4.026in
Outside Diameter 4.5in
Corrosion Rate 0.079 ipy

Problem 7.2 Sinnott & Towler

The pipeline described in question 7.1 was used to carry wastewater to a hold-up
tank. The effluent is not hazardous. A decision has to be made on what material
to use to replace the pipe. Three suggestion have been made:

1. Replace with the same schedule carbon steel pipe and accept renewal at 3-year
intervals
2. Replace with a thicker pipe, schedule 80, outside diameter 114.3 mm (4.5 in),
inside diameter 97.2 mm (3.826 in).
3. Use stainless steel pipe, which will not corrode.

The estimated cost of the pipes, per unit length is: schedule 40 carbon steel £3 ($5),
schedule 80 carbon steel £5 ($8.3), stainless steel (304) schedule 40 £15 ($24.8).
Installation and fittings for all the materials adds £10 ($16.5) per unit length.
The downtime required to replace the pipe does not result in a loss of production.
If the expected future life of the plant is 7 years, recommend which pipe to use
GIVEN:

Cost per unit

Suggestion Material Pipe Schedule Other
length
Renewal at 3-
Option 1 Carbon Steel Schedule 40 £3.00
year intervals
Do = 114.3 mm
Option 2 Carbon Steel Schedule 80 £5.00
Di = 97.2 mm
Option 3 Stainless Steel Schedule 40 £15.00 Will not corrode

Additional £10.00 per unit length for installing and fitting of all materials
Downtime to replace does not result in loss of production.
Expected future life of the plant is 7 years.

REQUIRED:

Recommend which pipe to use.

SOLUTION:

In order to determine which material should be used for the pipe replacement, we need to
calculate the total cost for the replacements throughout the expected future life of the plant (7
years).

Total Cost = [L*(CL + £10)]*R

Where,
L = pipe length.
CL = material cost per unit length
R = number of replacements needed
£10 = additional for installation and fittings per unit length

Option 1: Same Carbon Steel initially used.

The carbon steel initially used needs to be replaced every 3 years. Given that the expected
future life of the plant is 7 years, a total of 3 replacements is needed.

Total Cost = [L*(CL + £10)]*R

CL = £3.00 per unit length

R = 3 times

Total Cost = [L*(£3 + £10)]*3

 Total Cost = £39L

Option 2: Thicker Carbon Steel Pipe

Option 2 explores on the use of thicker carbon steel than the carbon steel initially used. It
is proposed to use a Schedule 80 Carbon Steel pipe.

Total Cost = [L*(CL + £10)]*R

CL = £5.00 per unit length

R = 2 times*

Total Cost = [L*(£5 + £10)]*2

Total Cost = £30L

*Solving for number of replacements needed (Data from Geankoplis Appendix A.5-1)
Schedule 80 Carbon Steel
Do = 114.3 mm
Di = 97.2 mm
Wall thickness = 0.5*(114.3 mm – 97.2 mm)
Wall thickness = 8.55 mm

From these values, we can determine the nominal pipe size of the carbon steel used
which is 4 in.

Schedule 40 Carbon Steel

Do = 114.3 mm
Di = 102.3 mm
Wall thickness = 0.5*(114.3 mm – 102.3 mm)
Wall thickness = 6.00 mm

By ratio and proportion to determine how long the schedule 80 will last before it needs
replacing,
𝑛 8.55 𝑚𝑚
=
3 𝑦𝑒𝑎𝑟𝑠 6.00 𝑚𝑚

8.55
𝑛= ∗ 3 𝑦𝑒𝑎𝑟𝑠
6.00

n = 4.275 years
 It takes 4.275 years for the schedule 80 carbon steel before it needs replacing.
Therefore, it will need to be replaced 2 times throughout the expected future life of the
plant.

Option 3: Stainless Steel Pipe

The use of stainless steel, which will not corrode, is proposed. Since the stainless steel
will not corrode, no additional replacements are needed after the initial replacement.

Total Cost = [L*(CL + £10)]*R

CL = £15.00 per unit length

R = 1 time

Total Cost = [L*(£15 + £10)]*1

Total Cost = £25L

FINAL ANSWER:

Stainless steel pipe is recommended for the replacement. Although it costs the most per
unit length, since the material will not corrode, less replacements are needed. This reduces the
cost when purchasing the material and installation and fittings for the pipe.
SPECIFICATION SHEET

Specification Sheet for Pipeline

Identification: Item: Pipe
Item No: 4”-WWR
Type: Cylindrical

4.5” 4.026”
4” Schedule 40

Stainless Steel Pipe

Function: Carry wastewater

Design Properties:
Material of Construction Stainless Steel
Schedule SCH 40
Nominal Size 4”
Inside Diameter 4.026in
Outside Diameter 4.5in
Problem 5.3 Sinnott & Towler
A liquid is contained in a reactor vessel at 115 bar absolute pressure. It is transferred to a storage
vessel through a 50 mm internal diameter commercial steel pipe. The storage vessel is nitrogen
blanketed and pressure above the liquid surface is kept constant at 1500 N/m 2 gauge. The total
run of pipe between the two vessels is 200 m. The miscellaneous losses due to entry and exit
losses, fittings, valves, etc., amount to 800 equivalent pipe diameters. The liquid level in the
storage vessel is at an elevation 20 m below the level in the reactor. A turbine is fitted in the
pipeline to recover the excess energy that is available, over that required to transfer the liquid
from one vessel to the other. Estimate the power that can be taken from the turbine, when the
liquid transfer rate is 5000 kg/h. Take the efficiency of the turbine as 70%. The properties of the
fluid are: density 895 kg/m3, viscosity 0.76 mNm2s.
GIVEN:
𝑁
𝑎𝑏𝑠𝑜𝑙𝑢𝑡𝑒 𝑟𝑒𝑎𝑐𝑡𝑜𝑟 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒, 𝑃1 = 115 𝑏𝑎𝑟 = 115 × 105
𝑚2
𝑁
𝑔𝑎𝑢𝑔𝑒 𝑠𝑡𝑜𝑟𝑎𝑔𝑒 𝑡𝑎𝑛𝑘 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒, 𝑃2 = 1500
𝑚2
𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑒𝑙𝑒𝑣𝑎𝑡𝑖𝑜𝑛 𝑑𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒, ∆𝑧 = −20𝑚

𝑝𝑖𝑝𝑒 𝑖𝑛𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝐷𝑖𝑛 = 0.05𝑚

𝑝𝑖𝑝𝑒 𝑙𝑒𝑛𝑔𝑡ℎ, 𝐿 = 200𝑚

𝑒𝑥𝑡𝑟𝑎 𝑝𝑖𝑝𝑒 𝑙𝑒𝑛𝑔𝑡ℎ = 800 × 𝐷𝑖𝑛

𝑘𝑔
𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑓𝑙𝑢𝑖𝑑, 𝑚̇ = 5000
ℎ
𝑘𝑔
𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑓𝑙𝑢𝑖𝑑, 𝜌 = 895
𝑚3
𝑘𝑔
𝑣𝑖𝑠𝑐𝑜𝑠𝑖𝑡𝑦 𝑜𝑓 𝑓𝑙𝑢𝑖𝑑, 𝜇 = 0.76 × 10−3
𝑚𝑠
𝑡𝑢𝑟𝑏𝑖𝑛𝑒 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦, 𝜂 = 0.70

REQUIRED:

𝑝𝑜𝑤𝑒𝑟 𝑜𝑓 𝑡𝑢𝑟𝑏𝑖𝑛𝑒

SOLUTION:

1) Calculate the cross-sectional area of the pipeline:

𝜋 𝜋
𝐴 = (𝐷𝑖𝑛 )2 = (0.05𝑚)2
4 4
𝐴 = 0.00196𝑚2
2) Calculate fluid velocity inside the pipeline:
𝑘𝑔 ℎ
𝑚̇ 5000 (3600𝑠)
𝑣= = ℎ
𝜌𝐴 895 𝑘𝑔 (0.00196𝑚2 )
𝑚3
𝑚
𝑣 = 0.792
𝑠
3) Calculate the Reynold’s Number:
𝑚 𝑘𝑔
𝐷𝑖𝑛 𝑣𝜌 (0.05𝑚) (0.792 𝑠 ) (895 𝑚3 )
𝑁𝑅𝑒 = =
𝜇 𝑘𝑔
0.76 × 10−3 𝑚𝑠

𝑁𝑅𝑒 = 46634

4) The equivalent roughness and fanning friction factor can be obtained from Figure 2.10-3
of Geankoplis (2003). For a commercial steel pipe,

𝜀 = 4.6 × 10−5 𝑚

The relative roughness of the pipe is calculated as

𝜀 4.6 × 10−5 𝑚
= = 9.2 × 10−4
𝐷 0.05𝑚
At the obtained relative roughness and Reynold’s number, the friction factor is

𝑓 = 0.007

5) To obtain the friction losses, we first obtain the total pipe length including extra pipe length
to consider miscellaneous losses:
∆𝐿 = 𝐿 + 800(𝐷𝑖𝑛 ) = 200𝑚 + (800)(0.05𝑚)
∆𝐿 = 240𝑚
The friction losses in the pipeline is calculated using Equation 2.10-5 of Geankoplis:
𝑚 2
∆𝐿 𝑣 2 𝑘𝑔 240𝑚 (0.792 𝑠 )
∆𝑃𝑓 = 4𝑓𝜌 = (4)(0.007) (895 3 ) ( )( )
𝐷 2 𝑚 0.05𝑚 2
𝑁
∆𝑃𝑓 = 37, 726
𝑚2
6) The absolute pressure drop is obtained as
𝑁 𝑁 𝑁
∆𝑃 = 𝑃1 − 𝑃2 = [(115 × 105 2
) − (1500 2 + 101325 2 )]
𝑚 𝑚 𝑚
𝑁
∆𝑃 = 11,397,175
𝑚2
 7) Finally, the power requirement of the turbine is obtained through an energy balance:
∆𝑃 ∆𝑃𝑓
𝑔∆𝑧 + − − 𝑊𝑠 = 0
𝜌 𝜌
𝑁 𝑁
𝑚 11397175 2 37726 2
(9.81 2 ) (−20𝑚) + 𝑚 − 𝑚 = 𝑊𝑠
𝑠 𝑘𝑔 𝑘𝑔
875 3 875 3
𝑚 𝑚
𝑘𝐽
𝑊𝑠 = 12.786
𝑘𝑔

Using Equation 2.7-30 of Geankoplis,

𝑊𝑠 = 𝜂𝑊𝑝

𝑘𝐽
12.786 = 0.7𝑊𝑝
𝑘𝑔
𝑘𝐽
𝑊𝑝 = 18.266
𝑘𝑔
𝑘𝑔
5000
𝑃𝑡𝑢𝑟𝑏𝑖𝑛𝑒 = 𝑚̇𝑊𝑝 = ( ℎ ) (18.266 𝑘𝐽 )
3600𝑠 𝑘𝑔
ℎ
∴ 𝑷𝒕𝒖𝒓𝒃𝒊𝒏𝒆 = 𝟐𝟓. 𝟑𝟕𝒌𝑾

FINAL ANSWER:

The power that can be taken from the turbine for the given conditions has been
calculated to be about 25.37kW.

SPECIFICATION SHEET

Specification Sheet for Turbine

Identification: Item: Turbine
Item No: P-101
Type: Turbine
Function: Pump fluid from reactor vessel to storage vessel
Design Properties
Flowrate 5000kg/h
Efficiency 70%
Power Requirement 25.37kW
Problem 10.2 Timmerhaus

A process for sulfonation of phenol requires the use of 11.4 m3 storage vessel. It is desired
to determine the most suitable material of construction for this vessel. Interest will be charged on
the installed cost at a rate of 10 percent/year.
The life of the storage vessel is calculated by dividing the corrosion allowance of the
3.175mm by the estimated corrosion rate. The equipment is assumed to have a salvage value of
10 percent of its original cost at the end of its useful life.
For the case in question, corrosion data indicate that only a few corrosion resistance alloys
will be suitable:

Determine which material of construction should be used with the appropriate justification for the
selection.
GIVEN:

𝑉 = 11.4𝑚3
𝐴𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 = 0.003175𝑚
REQUIRED:
Determine the most suitable material for construction.
SOLUTION:
Sample calculations of relevant costs to be considered using Nickel-clad vessel:
𝐼𝑛𝑠𝑡𝑎𝑙𝑙𝑒𝑑 𝐶𝑜𝑠𝑡 = $𝟖𝟖, 𝟎𝟎𝟎
𝐴𝑑𝑑𝑖𝑡𝑖𝑜𝑛𝑎𝑙 𝐶𝑜𝑠𝑡 (𝑟𝑒𝑙𝑎𝑡𝑖𝑣𝑒 𝑡𝑜 𝑐ℎ𝑒𝑎𝑝𝑒𝑠𝑡 𝑜𝑝𝑡𝑖𝑜𝑛) = $0 (because Nickel-clad is cheapest to install)
𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 3.175𝑚𝑚
𝐸𝑠𝑡𝑖𝑚𝑎𝑡𝑒𝑑 𝐿𝑖𝑓𝑒 = = = 𝟔. 𝟑𝟓 𝒚𝒆𝒂𝒓𝒔
𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑟𝑎𝑡𝑒 0.5𝑚𝑚/𝑦𝑟
𝑆𝑎𝑙𝑣𝑎𝑔𝑒 𝑉𝑎𝑙𝑢𝑒 = $88,000 × 10% = $𝟖, 𝟖𝟎𝟎
𝑅𝑒𝑝𝑙𝑎𝑐𝑒𝑚𝑒𝑛𝑡 𝐶𝑜𝑠𝑡 = 𝐼𝑛𝑠𝑡𝑎𝑙𝑙𝑒𝑑 𝐶𝑜𝑠𝑡 − 𝑆𝑎𝑙𝑣𝑎𝑔𝑒 𝑉𝑎𝑙𝑢𝑒 = $ (88,000 − 8800) = $𝟕𝟗, 𝟐𝟎𝟎
𝑅𝑒𝑝𝑙𝑎𝑐𝑒𝑚𝑒𝑛𝑡 𝐶𝑜𝑠𝑡 $79,200
𝐴𝑛𝑛𝑢𝑎𝑙 𝑅𝑒𝑝𝑙𝑎𝑐𝑒𝑚𝑒𝑛𝑡 𝐶𝑜𝑠𝑡 = = = $𝟏𝟐, 𝟒𝟕𝟐 𝒑𝒆𝒓 𝒚𝒆𝒂𝒓
𝐸𝑠𝑡𝑖𝑚𝑎𝑡𝑒𝑑 𝐿𝑖𝑓𝑒 6.35𝑦𝑟
𝐴𝑛𝑛𝑢𝑎𝑙 𝐼𝑛𝑡𝑒𝑟𝑒𝑠𝑡 𝐶𝑜𝑠𝑡 = $88,000 × 10% = $𝟖, 𝟖𝟎𝟎
𝑇𝑜𝑡𝑎𝑙 𝐴𝑛𝑛𝑢𝑎𝑙 𝐶𝑜𝑠𝑡 = $12,472 + $8,800 = $𝟐𝟏, 𝟐𝟕𝟐
𝐴𝑛𝑛𝑢𝑎𝑙 𝑆𝑎𝑣𝑖𝑛𝑔𝑠 (𝑟𝑒𝑙𝑎𝑡𝑖𝑣𝑒 𝑡𝑜 𝑐ℎ𝑒𝑎𝑝𝑒𝑠𝑡 𝑜𝑝𝑡𝑖𝑜𝑛) = $0
Cost/Investment Comparison:

Nickel-clad Monel-clad Hastelloy B

Installed Cost ($) 88000 105000 198000
Additional Cost (vs Nickel-clad) ($) 0 17000 110000
Estimated Life (Years) 6.5 12.7 27.85
Salvage Value ($) 8800 10500 19800
Replacement Cost ($) 79200 94500 178200
Annual Replacement Cost ($/year) 12472 7441 6399
Annual Interest Cost ($/year) 8800 10500 19800
Total Annual Cost ($/year) 21272 17941 26199
Annual Savings (vs Nickel-clad) ($/year) 0 +3331 -4927
Return on Investment 0 19.59% -

Return on Investment is calculated as:

𝐴𝑛𝑛𝑢𝑎𝑙 𝑆𝑎𝑣𝑖𝑛𝑔𝑠
𝑅𝑂𝐼 = × 100%
𝐴𝑑𝑑𝑖𝑡𝑖𝑜𝑛𝑎𝑙 𝐶𝑜𝑠𝑡
FINAL ANSWER:
The most suitable material of construction for this vessel, based on the table given in the
problem is Monel-clad. Using a monel-clad vessel offers about 19.6% percent return on
investment compared to the option with the cheapest installation option which is nickel-clad.

SPECIFICATION SHEET

Specification Sheet for Tank

Identification: Item: Tank
Item No: TK-101
Type: Reactor tank
 Function: Sulphonation of phenol
Design Properties
Material of Construction Monel-clad
Capacity 11.4m3
Estimated Life 12.7 years

Problem 10.4 Timmerhaus

A manhole plate for a reactor is to be 0.05m thick and 0.5m in diameter. It has been proven
that the entire plate be made of stainless-steel type 316 (SS 316). The plate will have 18 bolt-
holes, and part of the face will need to be machined for close gasket contact. If the base price for
the SS 316 in the form of industrial plates is $10.00 per kilogram, estimate the purchased cost for
the manhole plate.
GIVEN:
𝑘𝑔
𝜌𝑆𝑆316 = 8000 𝑚3 (AZO Materials, 2001; accessed via https://www.azom.com/article.aspx?ArticleID=863)

𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 0.05𝑚
𝐷 = 0.5𝑚
𝑈𝑛𝑖𝑡 𝑐𝑜𝑠𝑡 = $10.00 𝑝𝑒𝑟 𝑘𝑔
REQUIRED:
Total Purchase Cost =?

SOLUTION:
ASTM A240 SS 316 is available for purchase as circular plates up to a thickness of 0.1m
and a diameter of 2.0m (Nandishwar Steel, 2010). Information here has been accessed via
https://www.nandishwarsteel.com/stainless-steel-316-316l-circles.html.
Solving for total mass SS 316 needed,

𝑉 = 𝐴𝑐𝑖𝑟𝑐𝑙𝑒 × 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = (0.5𝑚)2 × 0.05𝑚 = 0.0125𝑚3

𝑘𝑔
𝑡𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 = 𝑉 × 𝜌𝑆𝑆316 = 0.0125𝑚3 × 8000 = 100 𝑘𝑔 𝑆𝑆 316
𝑚3
Solving for base purchase cost,
$10.00
𝐵𝑎𝑠𝑒 𝑃𝑢𝑟𝑐ℎ𝑎𝑠𝑒 𝐶𝑜𝑠𝑡 = 𝑡𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 × 𝑢𝑛𝑖𝑡 𝑐𝑜𝑠𝑡 = 100𝑘𝑔 ×
𝑘𝑔
𝐵𝑎𝑠𝑒 𝑃𝑢𝑟𝑐ℎ𝑎𝑠𝑒 𝐶𝑜𝑠𝑡 = $1000
Solving for total purchase cost from machining assuming machining cost is 50% of the total
purchase cost,
𝑇𝑜𝑡𝑎𝑙 𝑃𝑢𝑟𝑐ℎ𝑎𝑠𝑒 𝐶𝑜𝑠𝑡 = 𝐵𝑎𝑠𝑒 𝑃𝑢𝑟𝑐ℎ𝑎𝑠𝑒 𝐶𝑜𝑠𝑡 + 𝑀𝑎𝑐ℎ𝑖𝑛𝑖𝑛𝑔 𝐶𝑜𝑠𝑡
where machining cost is roughly assumed to be equal to the base purchase cost,
𝑇𝑜𝑡𝑎𝑙 𝑃𝑢𝑟𝑐ℎ𝑎𝑠𝑒 𝐶𝑜𝑠𝑡 = $10000 × 2 = $20,000
FINAL ANSWER:
The total purchase cost for manufacturing the manhole plate for the reactor is estimated
to be about $20,000. However, it should be noted that the machining cost, in this solution, isn’t an
accurate assumption and is just a rough assumption.
SPECIFICATION SHEET

Specification Sheet for Plate on Reactor

Identification: Item: Plate
Type: Manhole Cover

Function: Cover manhole for reactor tank

Design Properties
Material of Construction Stainless Steel 316
Diameter 0.5m
Thickness 0.05m
Number of Bolt-holes 18