Final Process Engineering Course Material-8

SIT Process Engineering
MODULE - VIII
Post Graduate Diploma In
“PROCESS ENGINEERING”
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PREFACE
SIT (Suvidya Institute of Technology) is a leading provider of industrial training to meet the requirements of skilled
manpower in the field of "OIL & GAS". Our aim is to develop skilled manpower in specialized field and to provide
expert engineers to the industry, who are not only confident about their subject but can also handle their job
activities independently & efficiently.
SIT is a team of young, efficient, qualified and hardcore professionals with broad spectrum of consultancy and
industrial background. Our industrial training programmes are based on sound engineering principles &
methodology, applicable code requirements and best industrial practices.
We are aware that, 'Engineer is the key person in the material progress of the world. It is his engineering that
converts the potential value of science into service by translating scientific knowledge into tools, resources and
energy. To make contributions of this kind the Engineer requires three things; the imagination to visualize the
needs of society, an eye to appreciate what is possible, last and most important is the technological and
broad social understanding to bring his vision into reality.
Swift changes in global scenario and market, have transformed the dimensions of professionals in every industry.
The specialist from any field of engineering has to focus more and more narrowly on his specialized topics & work
area rather than broad spectrum of faculty. This has heightened the challenges of young & passionate Engineers.
By realizing, this great obligation to build Technocrat Engineers and well-grounded Indian Work force, to compete
global requirements of industry, young, energetic, qualified, top notch professionals from Software, Consultancy &
Industrial background, we have formed a Consortium and laid the foundation of SIT.
Keeping global competition in mind, SIT has designed professional courses which are a combination of theory,
latest industrial practices and practical sessions. Our institute offers numbers of courses to cover wide spectrum
of industrial aspects, which are recognized by industries.
Syllabus covered in these courses is exactly as per the global standards as well as latest working requirements of
various engineering companies. To develop proficient thinking skills in our participants we have adopted case
study approach.
Course structures are not at all dry accumulations of facts but it has way of thinking about possible difficulties,
ways to find solutions of obviously puzzling problems, which make our students well equipped to be in lead roles.
The overall structure assesses the students against the requirements, which include key skills, knowledge level
and execution power that define competences.
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Our Faculty…
SIT is globally known for its educational values and ethics. Our faculty members are the experienced, leading
professionals from top relevant organizations. These experts have the skill of illustrating highly complex subject
with an engaging combination of clarity & wit. This transforms complex engineering into easy learning states.
Practical sessions have been designed to set to rest all difficulties in classroom learning. These sessions are vital
parts of our courses.
Having attained firm footing, our organization is very keen to be a livewire of Industry and offer consultancy
services on various industrial & development Projects. Our Students have made strong impact & carved niche
difference in the Industry. They are rendering their services to various Industries in India & Abroad. Their every
contribution to Industry has made us proud.
Our Services…
• Industry specific Training in various disciplines of Engineering.

• Corporate Training as per the Company requirement.
• In-plant Training facilities.
• Case Studies to develop rational thinking skill.
• Seminars to update knowledge.
• Industrial visit to develop visualization skills.
• Personality development and Mock Interviews to develop confidence.
• Opportunity to work on Live Projects.
• Guidance to choose a right career.
• Enhancing the non-technical students to build up their Career.
Some of the companies where our students have made strong impact…
• M/s. Petrofac Engineering India Ltd - Mumbai

• M/s. Aker Solutions Pvt. Ltd. – Mumbai
• M/s. Toyo Engineering India Ltd. - Mumbai
• M/s. Tecnimont ICB Pvt. Ltd. – Mumbai
• M/s. Reliance Engineering Associates Pvt. Ltd - Mumbai
• M/s. Bechtel India Pvt. Ltd. – Gurgaon
• M/s. Flour Daniel India Pvt. Ltd. – Gurgaon
• M/s. Mott MacDonald Pvt. Ltd. - Mumbai
• M/s. UHDE India Ltd,
• M/s. Chemtex Engineering India Ltd. - Mumbai
• M/s. Jacobs Engineering India Ltd. - Mumbai
• M/s. Larsen & Turbo Ltd. Faridabad ….. and many more in India and abroad.
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Objectives of these Courses …
• To identify the basic vocabulary and to introduce the major concepts of design.
• To provide & understand the basic requirements for design as per the international codes & standards.
• To understand how to design cost effective new installation.
• To understand how to create cost effective design in trouble shooting as well as while improving existing
system.
SPECIALISED COURSES OFFERED BY US WHO CAN ATTEND:
• Piping Engineering - Mechanical, Chemical & Production Engineers
Advanced Pipe Stress Analysis - Mechanical/Chemical Engineering/ Piping
Engineers
• H.V.A.C - Mechanical & Production Engineers.
• Process Engineering - Chemical Engineers.
• Mechanical Design of Process Equipment - Mechanical / Production Engineers.
• Structural Engineering. - Civil / Structural Engineers.
• Electrical Engineering - Electrical Engineers.
• Instrumentation & Control - Instrumentation / Electronics Engineers.
• Water & Waste Water Engineering. - Engineers, B.Sc & M.sc
• Engineering Design & Drafting. - HSC
• Piping Design & Drafting - ITI - Mechanical Draughtsman.
TOGETHER WE WILL BRING NEW DIMENSIONS TO ENGINEERING
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INDEX
CONTENTS Page Nos.
1. SAFETY VALVE GUIDELINES…………….………………..……………………..……..6
2. SAFETY VALVE SELECTION & SIZING…………...…………………………….….....12
3. SAFETY VALVE – ENGINEERING DESIGN & GUIDELINE .………………....…….33
4. FLARE…………………………………………………………...………………..…..….…..53
5. FLARE AND BLOWDOWN SYSTEM……………………………………....….......……..92
6. OPTIMALLY ECONOMIC DESIGN OF FLARE SYSTEM.…….……………………126
7. FLARE SELECTION AND SIZING (ENGINEERING DESIGN GUIDELINE)……..132
8. EMISSION CALCULATION ……………………………………………………………..143
9. FLARE DESIGN…..…………………………………………………………………….…..151
10. API-TANK VENTING CALCULATIONS..………………………………………………155
11. FIRED HEATER………………………..…………………………………………………..166
12. FIRED HEATER OPTIMIZATION…..…………………………………………………..172
13. CHIMNEY DESIGN………………………………………………………………………..188
14. DESIGN OF JET MIXERS………………………………………………………………...190
15. STEAM TRACING…………………………………………………………………………209
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Safety Valve Guidelines
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Safety Valve Guidelines

Depressuring System - Use in Hydrocarbon Industry
This article highlights various depressurising systems used in hydrocarbon industries such as oil and gas field
development (onshore and offshore), their processing facilities, transportation pipelines, refineries,
petrochemicals, fertilizers and chemicals. Although guidelines are provided by the engineers to understand the
need of a relief valve, deciding its location, capacity calculation and sizing of relief valve, it is very essential to
consult the codes and references mentioned and apply their experience and judgement on a case-to-case basis.
Every process industry has a need for disposal system for disposing of undesirable gases and liquids. The
disposal of gases and liquids may be required during normal operation or emergency. This article is related to the
disposal of only gases and the associated liquids, which are not desirable.
When the quantity of vent gases is higher, the safe disposal of waste gases happens through the combustion or
via elevated flares. On the other hand, when the quantity of vent gases is smaller, the safe disposal of waste
gases happens through the cold vent stacks.
The height of vent stack is calculated on the basis of the concentration of hydrocarbon vapours at ground level
(ground level concentration, GLC). The ground level concentration of hydrocarbon vapours should be lower than
0.1 to 0.5 times the lower flammability limits, LFL. However, if the vented vapour is more toxic then even lower
ground level, concentration of vapour may be required. This may require an even higher vent stack. The vent
stacks can also be supported from a distillation column, chimney or other tall structures in a plant.
A flare system is the safe outlet in a process industry for flaring gases during normal conditions as well as during
emergency conditions. The flare system flares the gases relieved from relief valves or undesirable gases vented
during normal operation.
The relief valves basically provide the protection relief to process plants against over pressure developed in any
part of the plant. The flare handles the vented gases from storage tanks, process, equipment, or pipeline system.
Various Flaring Systems in Hydrocarbon Industry
The various systems compromise venting gases from

pressure vessels, heat exchangers, distillation columns,
pipelines and atmospheric storage tanks.
Firstly, the gases vented from atmospheric hydrocarbon

storage tanks are generally routed to vent stacks located very
near to these tanks because of pressure limitations (Figure 1).
This case is applicable to storage tanks designed in
accordance with API-650 code.
Secondly, the vent gases from slightly positive pressure

atmospheric storage tanks (500 mmwg) can also be
routed to flare stacks provided it is very near to the flare
stack. The examples are C2, C3, C4 and ammonia
storage tanks etc (figure 2). This case is applicable to
storage tanks designed in accordance with API-620 code.
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Thirdly, the gases vented from pressurised systems

such as pressure vessels, columns, exchangers,
pipelines etc are routed to flare systems having k o
drum, seal drum flare stack etc (Figure 3-on page 77).
This case is applicable to pressure vessels designed
in accordance with ASME section VIII division 1.
There is substantial amount of cost associated to flare equipment. These equipment include flare stack header,
k o drum, k o drum liquid transfer pumps, flare stack, tips etc. Sometimes the cost of flare associated equipment
becomes the controlling factor in deciding the process design of system, equipment etc. for example, in oil field
development designs, if we produce and stabilise the well fluid at higher pressure, a small flare system of
approximately 10 to 12 Te/hr is required to cater to the need of a separator safety valve sized on fire exposure.
However, if the process platform is designed for lower pressure, the flare system should be designed to handle
the fluid from safety valve sized on blocked discharge conditions. In this case, the flare system becomes larger.
So, if we design the platform at a higher pressure equivalent to well head pressure, we need not provide big flare
equipment. And if we design the platform at lower pressure, we need to provide bigger flare equipment.
Therefore, an optimisation is required - whether to provide a high-capacity fare equipment with a low-pressure
platform or to provide small flare equipment with a high-pressure platform.
Under abnormal conditions of the plant, it is quite likely that some portions of the plant may undergo a higher
pressure. During normal running of the plant, it is not expected that relief valves will lift and vent the gases. Again
during abnormal conditions of the plant, some parts of the plant undergo excessive pressure and, therefore,
protections are required to relieve these parts against excessive pressure by providing safety valves.
While estimating the quantity of gases relieved, more than one occurrence will not be considered at a time.
For identification of need of a relief valve in process system:
An evaluation of hazard from operation point of view should be made while designing the process
system.
Even after completion of process design activities, one can carry out a study of the process system to find
out if there is any safety valve left out.
In this evaluation, each and every piece of equipment is studied whether it can reach overpressure levels due to
abnormal conditions because of any operational mistake, utility failure, instrumentation failure, failure of any part
of equipment, piping, plant firs etc. or any reason thereof.
If there is any change of overpressurisation on that part of equipment/piping over and above the operating
pressure, that part of equipment/piping can be protected by any of the following means:
By designing that part of equipment/piping to the maximum possible pressure up to which operating
pressure can shoot up
By designing that part of equipment/piping up to an intermediate pressure where the plant is economic
and protecting that part of equipment or piping by a relief valve. The set pressure of safety valve can be
either lower than the design pressure or it can go even up to design pressure, but in no case set pressure
of safety valve can be higher than the design pressure.
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Causes of Overpressure
The portable causes of overpressure of the equipment/piping can be

any one of the following.
Blocked discharge case: This can happen when there is a sudden

closure of valve in any flowing pipeline. In this case, the safety valves
provided on pipeline or equipment need to be designed on full flow rate
(figure 4)
Plant fires: Whenever a pressure vessel is provided in a process flow scheme, it is necessary to check the safety
of vessel when it is enveloped into fire. The vessel may contain liquid, gas or a mixture of both. It is essential to
protect the equipment by a safety valve. Set press of safety valve may be equivalent to design pressure of vessel.
Heat exchanger tube failure: When there is a wide

difference in design pressure between the two exchanger
sides and the low pressure side is designed at a pressure
less than two-third of design pressure of high pressure side,
a relief valve is required at the low pressure side (Figure 5)
Cooling water failure: When there is a sudden failure of

cooling water in overhead condensers of distillation column,
the column pressure starts increasing due to loss of reflux
after 5-10 minutes. To overcome this, a relief valve is
required that can vent the additional quantity of vapour
generated to flare (figure 6 - on page 78)
Abnormal Heat Input from Reboilers
When reboiler temperature controller fails, additional heat input above normal design can occur. This will result in
increase of column pressure. To protect the column, a safety valve is required.
After applying each cause of overpressure to a piece of equipment/piping process, the engineer can identify the
applicable cause of overpressure and, accordingly, he provides the safety valve to protect the system against
overpressure.
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If there is any isolating valve on he pipeline or the equipment the safety valve should be located before the
isolation valve. After identifying the type of relief valve its capacity can be determined.
Capacity Calculation of A Relief Valve
The calculation of capacity in each case is described below:
Blocked discharge case: When the safety valves are provided to protect against blocked discharge case, the
capacity of safety valve should be least equivalent to the quantity of fluid being produced. IN fact, it should be
about 25 percent higher to take care of any surges during production.
Plant fires: When there is a plant fire, liquid-filled vessel as well as gas-filled vessel can be enveloped in fire. The
method of calculation is as follows:
Calculation of relief load when liquid filled vessel is under fire (for example, well fluid launcher, dia=16 in &
length=13.12 ft, 80 percent filled with liquid and 20 percent filled with vapour)
Operating pressure = 21 kg/cm2g

2
Set pressure = 92.7 kg/cm g
Accumulation = 21%
Latent heat of liquid = 50 Btu/lb
Environmental factor, F = 1.0
Surface Area of vessel, 'A' =*D*L = 54.9 ft2
Volume fraction of vessel when vessel is 80% full = Vf = 0.86

2
Wetted surface area of vessel, Aw = Vf*A'=47.12 ft
Heat input to wetted surface, Q = 21000*F*Aw0.82 = 494599 Btu/hr
Weight flow of vapour generated, W1 = Q/λ = 9892 lb/hr
Calculation of relief load when gas-filled vessel is under fire:
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Surface area of vessel, A' =*D*L=54.9 ft
Volume fraction of vessel when vessel is 80% full = Vf = 0.86
Wetted surface area of vessel, Aw =Vf*A '= 47.12 ft2

2
Area of unwetted portion of vessel A" = A'-Aw = 7.78 ft
°
Vessel wall temp = Tw = 1560 R
Relieving press = r = 1627 pisa
Relieving temp = Tr = 1156°R (From Hysis simulations)
0.5 1.25 1.1506

Relieving rate W2 = 0.1406 (M*Pr) (A"(Tw-Tr) /Tr ) = 106.9 lb/hr
Total Relief load of the 80% liquid and 20% vapour vessel = W1+W2 = 9998.9 lb/hr
Heat exchanger tube failure (shell and tube type) : When the low press side of exchanger is operating at a
pressure much lower than high pressure side, the tube of exchanger can fail and the pressure of low pressure
side of exchanger starts increasing. To protect low pressure side of exchanger a safety valve has been provided.
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Under these circumstances, it is assumed that a sharp break has occurred in one tube of shell and tube heat
exchanger. The maximum flow, which is possible from twice the cross-section of tube, should be considered as
capacity of the safety valve.
Cooling water failure in distillation column overhead condensers: Since the surge capacity of reflux drum is
limited to approximately 10 minutes, the capacity of relief valve is considered as the total incoming vapour to the
overhead condenser when there is no reflux. This can be determined by referring column simulation at normal
operating conditions. The capacity of safety valve will be equivalent to the vapours coming out from 2nd tray to
1st tray. However, this can also be done by resimulating column at relieving pressure at no reflux conditions.
Abnormal heat input from reboilers: When reboiler temperature controller fails, additional heat input above
normal design can occur. This will increase column pressure. To overcome this, a safety valve is required on the
top of column. The relief load can be calculated by re-simulating the column at relieving pressure.
Sizing of A relief Valve
After determining the capacity of safety valve, the tentative sizing of safety valve can be carried out by the help of
software Instrucalc or by API-520/API-521 codes which can be further cross-checked by vendors catalogues.
Flare and Relief Analysis
After completing the design of process systems, a final flare and relief analysis of process system should be
done. A comparative study of flare and relief loads should be determined and the worst scenario foreseen. Based
on the worst conditions, flare load should be designed. And based on the controlling flare load, the flare
equipment such as flare k o drum, k o drum liquid transfer pumps and the flare stack are designed.
References
1. API-521, API-520
2. API-14C, API 14E
3. API-650, API-620, API-2000, API-2500, API-2500A
4. ASME SECT. VIII DIV.1, Sec. 125 to 133.
5. IBR
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Safety Valve Selection & Sizing
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Safety Valve – Engineering Design & Guideline :
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Flare
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Flare and Blowdown System
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OPTIMALLY ECONOMIC DESIGN OF FLARE SYSTEM
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FLARE SELECTION AND SIZING

(ENGINEERING DESIGN GUIDELINE)
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Emission Calculations
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Flare Design
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API
Tank Venting Calculations
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Fired Heater
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FIRED HEATER
An industrial furnace or direct fired heater is equipment used to provide heat for a process or can serve as reactor
which provides heats of reaction. Furnace designs vary as to its function, heating duty, type of fuel and method of
introducing combustion air. However, most process furnaces have some common features.
Fuel flows into the burner and is burnt with air provided from an air blower. There can be more than one burner in
a particular furnace which can be arranged in cells which heat a particular set of tubes. Burners can also be floor
mounted, wall mounted or roof mounted depending on design. The flames heat up the tubes, which in turn heat
the fluid inside in the first part of the furnace known as the radiant section or firebox. In this chamber where
combustion takes place, the heat is transferred mainly by radiation to tubes around the fire in the chamber. The
heating fluid passes through the tubes and is thus heated to the desired temperature. The gases from the
combustion are known as flue gas. After the flue gas leaves the firebox, most furnace designs include a
convection section where more heat is recovered before venting to the atmosphere through the flue gas stack.
(HTF=Heat Transfer Fluid. Industries commonly use their furnaces to heat a secondary fluid with special additives
like anti-rust and high heat transfer efficiency. This heated fluid is then circulated round the whole plant to heat
exchangers to be used wherever heat is needed instead of directly heating the product line as the product or
material may be volatile or prone to cracking at the furnace temperature.)
Radiant section
Middle of radiant section
The radiant section is where the tubes receive almost all its heat by radiation from the flame. In a vertical,
cylindrical furnace, the tubes are vertical. Tubes can be vertical or horizontal, placed along the refractory wall, in
the middle, etc., or arranged in cells. Studs are used to hold the insulation together and on the wall of the furnace.
They are placed about 1 ft (300 mm) apart in this picture of the inside of a furnace. The tubes, shown below,
which are reddish brown from corrosion, are carbon steel tubes and run the height of the radiant section. The
tubes are a distance away from the insulation so radiation can be reflected to the back of the tubes to maintain a
uniform tube wall temperature. Tube guides at the top, middle and bottom hold the tubes in place.
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Convection section
Convection section
The convection section is located above the radiant section where it is cooler to recover additional heat. Heat
transfer takes place by convection here, and the tubes are finned to increase heat transfer. The first two tube
rows in the bottom of the convection section and at the top of the radiant section is an area of bare tubes (without
fins) and are known as the shield section, so named because they are still exposed to plenty of radiation from the
firebox and they also act to shield the convection section tubes, which are normally of less resistant material from
the high temperatures in the firebox. The area of the radiant section just before flue gas enters the shield section
and into the convection section called the bridgezone. Crossover is the term used to describe the tube that
connects from the convection section outlet to the radiant section inlet. The crossover piping is normally located
outside so that the temperature can be monitored and the efficiency of the convection section can be calculated.
The sightglass at the top allows personnel to see the flame shape and pattern from above and visually inspect if
flame impingement is occurring. Flame impingement happens when the flame touches the tubes and causes
small isolated spots of very high temperature.
Burner
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Furnace burner
The burner in the vertical, cylindrical furnace as above, is located in the floor and fires upward. Some furnaces
have side fired burners, such as in train locomotives. The burner tile is made of high temperature refractory and is
where the flame is contained in. Air registers located below the burner and at the outlet of the air blower are
devices with movable flaps or vanes that control the shape and pattern of the flame, whether it spreads out or
even swirls around. Flames should not spread out too much, as this will cause flame impingement. Air registers
can be classified as primary, secondary and if applicable, tertiary, depending on when their air is introduced. The
primary air register supplies primary air, which is the first to be introduced in the burner. Secondary air is added to
supplement primary air. Burners may include a premixer to mix the air and fuel for better combustion before
introducing into the burner. Some burners even use steam as premix to preheat the air and create better mixing
of the fuel and heated air. The floor of the furnace is mostly made of a different material from that of the wall,
typically hard castable refractory to allow technicians to walk on its floor during maintenance.
A furnace can be lit by a small pilot flame or in some older models, by hand. Most pilot flames nowadays are lit by
an ignition transformer (much like a car's spark plugs). The pilot flame in turn lights up the main flame. The pilot
flame uses natural gas while the main flame can use both diesel and natural gas. When using liquid fuels, an
atomizer is used, otherwise, the liquid fuel will simply pour onto the furnace floor and become a hazard. Using a
pilot flame for lighting the furnace increases safety and ease compared to using a manual ignition method (like a
match).
Sootblower
Sootblowers are found in the convection section. As this section is above the radiant section and air movement is
slower because of the fins, soot tends to accumulate here. Sootblowing is normally done when the efficiency of
the convection section is decreased. This can be calculated by looking at the temperature change from the
crossover piping and at the convection section exit. Sootblowers utilize flowing media such as water, air or steam
to remove deposits from the tubes. This is typically done during maintenance with the air blower turned on. There
are several different types of sootblowers used. Wall blowers of the rotary type are mounted on furnace walls
protruding between the convection tubes. The lances are connected to a steam source with holes drilled into it at
intervals along its length. When it is turned on, it rotates and blows the soot off the tubes and out through the
stack.
Stack
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Stack damper
The flue gas stack is a cylindrical structure at the top of all the heat transfer chambers. The breeching directly
below it collects the flue gas and brings it up high into the atmosphere where it will not endanger personnel.
The stack damper contained within works like a butterfly valve and regulates draft (pressure difference between
air intake and air exit)in the furnace, which is what pulls the flue gas through the convection section. The stack
damper also regulates the heat lost through the stack. As the damper closes, the amount of heat escaping the
furnace through the stack decreases, but the pressure or draft in the furnace increases which poses risks to those
working around it if there are air leakages in the furnace, the flames can then escape out of the firebox or even
explode if the pressure is too great.
Insulation
Insulation is an important part of the furnace because it prevents excessive heat loss. Refractory materials such
as firebrick, castable refractories and ceramic fibre, are used for insulation. The floor of the furnace are normally
castable type refractories while those on the walls are nailed or glued in place. Ceramic fibre is commonly used
for the roof and wall of the furnace and is graded by its density and then its maximum temperature rating. For
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example, 8# 2,300 °F means 8 lb/ft density with a maximum temperature rating of 2,300 °F. An example of a
castable composition is kastolite.
First fire
The first fire is the moment when a furnace or another heating device (usually for industrial use such as
metallurgy or ceramics) is first lit after its construction. The refractory of the furnace walls should be as dry as
possible and the first fire should be done slowly with a small flame as the refractory of the still unfired furnace has
a minimal amount of moisture. Gradually or during subsequent firings, the flame or heat source (e.g. Kanthal
heating elements) can be turned up higher.
After first fire some adjustments should be done usually to fine-tune the furnace.Despite this, a first fire is always
a moment of great excitement for the people who designed and built the furnace.
Description
An outdoor wood-fired boiler (OWB) also known as a waterstove or outdoor wood furnace or simply a wood
boiler, is a heating technology that has grown in popularity in the Northern United States. OWBs in most cases
look like a small shack with metal siding. They are self-contained, and are only connected to the building they
heat through underground insulated water pipes. OWBs contain a metal combustion chamber for a wood fire,
which is surrounded by a water tank or water jacket. The fire heats the water, which is then circulated through the
insulated water pipes into the heated building. Once the hot water from the boiler reaches the building, the heat
from the hot water can be transferred to most existing heating systems and the building's hot water supply.
A damper and fan on the boiler interacts with a thermostat inside the building. If the building's temperature falls,
the thermostat will trigger the damper to open, letting oxygen enter the combustion chamber, which causes the
fire to burn more intensely. The fire will then raise the temperature of the water which increases the heat supplied
to the home.
Benefits
OWBs have several benefits that increase their popularity. Their large combustion chamber accommodates more
fuel than many other forms of wood heat, decreasing the number of times an owner has to add fuel to the fire.
Home insurance may cost more for people who heat with an indoor form of wood heat than with an OWB. Finally,
for people with a large supply of free wood and willing to invest the time to prepare the wood and stock the OWB,
an OWB can be less expensive than heating with gas, oil, or electricity.
Controversy
OWBs are not without controversy, as their emissions sometimes bother neighbors. Some states and
municipalities have regulated the devices.They are not currently regulated by the United States Environmental
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Protection Agency (EPA), unlike other forms of wood heat. However, recently the EPA has worked with
manufacturers to develop a method for manufacturers to identify OWBs that meet a voluntary emissions
standard. Studies conducted on OWBs suggest that these devices may produce more emissions, most notably
particulate matter under 2.5 micrometers (PM2.5) than other heating technologies, though manufacturers dispute
these assessments. Exposure to elevated levels of PM2.5 has been associated with cardiopulmonary health
effects and premature death.
As of July 2006, the HPBA, along with many of the major OWB manufactures, have requested users of their
products follow the "Outdoor Wood Furnace Best Burn Practices". These guidelines have been set up by the
HPBA to help cut down on problems associated with OWBs.
Early in January 2007, the United States Environmental Protection Agency (EPA) initiated a voluntary program for
manufacturers of outdoor wood furnaces. The EPA's primary intent is to encourage manufacturers to produce
cleaner Outdoor Wood-fired Hydronic Heaters (OWHH) models. The EPA also wants those who buy an OWHH /
OWB to buy the cleanest models available, which are those that meet EPA performance verified levels. To
participate in this program, manufacturers commit their best efforts to develop cleaner models with goals of
distributing their units starting in April 2007.
The EPA now publishes a list of all OWHH / OWB units that pass the new voluntary program. These furnaces
come with either an orange EPA tag, signifying Level 1 certification, or a white EPA tag, signifying Level 2
certification, to notify the customer of the units particular emission level output. (One beneficial aspect of this
process to consumers is that outdoor wood boilers that are EPA-certified are usually more energy efficient than
those that are not, extracting more energy per unit of wood, and thus reducing costs to the owner. Plus,
consumers benefit by knowing that such boilers are far less likely to annoy their neighbors.)
Boilers that do pollute enough to cause a public nuisance (such as by smoke wafting into the house of a
neighbor) can be subject to lawsuits by nearby people who are impacted by the smoke nuisance in question, an
ancient right under the common law for the abatement of nuisance. This is in addition to local and state
regulations, laws, or ordinances that cause restrictions on operation to or even compel removal of excessively
polluting boilers. For example, the Commonwealth of Massachusetts Department of Environmental Protection has
barred the sale, installation, or use of new outdoor wood boilers that are not Level 2 certified by the EPA, though
old boilers remain grandfathered so long as they do not cause a public nuisance or manifestly impact health and
safety.
171
Fired Heater Optimization
172
FIRED HEATER OPTIMIZATION
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187
Chimney Design
188
189
Design of Jet Mixers
190
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Steam Tracing
209
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Final Process Engineering Course Material-8

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Final Process Engineering Course Material-8

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SIT Process Engineering

Post Graduate Diploma In

• Industry specific Training in various disciplines of Engineering.

• M/s. Petrofac Engineering India Ltd - Mumbai

Objectives of these Courses …

SPECIALISED COURSES OFFERED BY US WHO CAN ATTEND:

• Piping Engineering - Mechanical, Chemical & Production Engineers

Advanced Pipe Stress Analysis - Mechanical/Chemical Engineering/ Piping

• H.V.A.C - Mechanical & Production Engineers.

• Process Engineering - Chemical Engineers.

• Mechanical Design of Process Equipment - Mechanical / Production Engineers.

• Structural Engineering. - Civil / Structural Engineers.

• Electrical Engineering - Electrical Engineers.

• Instrumentation & Control - Instrumentation / Electronics Engineers.

• Water & Waste Water Engineering. - Engineers, B.Sc & M.sc

• Engineering Design & Drafting. - HSC

• Piping Design & Drafting - ITI - Mechanical Draughtsman.

TOGETHER WE WILL BRING NEW DIMENSIONS TO ENGINEERING

1. SAFETY VALVE GUIDELINES…………….………………..……………………..……..6

2. SAFETY VALVE SELECTION & SIZING…………...…………………………….….....12

3. SAFETY VALVE – ENGINEERING DESIGN & GUIDELINE .………………....…….33

5. FLARE AND BLOWDOWN SYSTEM……………………………………....….......……..92

6. OPTIMALLY ECONOMIC DESIGN OF FLARE SYSTEM.…….……………………126

7. FLARE SELECTION AND SIZING (ENGINEERING DESIGN GUIDELINE)……..132

8. EMISSION CALCULATION ……………………………………………………………..143

10. API-TANK VENTING CALCULATIONS..………………………………………………155

11. FIRED HEATER………………………..…………………………………………………..166

12. FIRED HEATER OPTIMIZATION…..…………………………………………………..172

13. CHIMNEY DESIGN………………………………………………………………………..188

14. DESIGN OF JET MIXERS………………………………………………………………...190

15. STEAM TRACING…………………………………………………………………………209

Safety Valve Guidelines

Safety Valve Guidelines

Various Flaring Systems in Hydrocarbon Industry

The various systems compromise venting gases from

Firstly, the gases vented from atmospheric hydrocarbon

Secondly, the vent gases from slightly positive pressure

Thirdly, the gases vented from pressurised systems

For identification of need of a relief valve in process system:

The portable causes of overpressure of the equipment/piping can be

Blocked discharge case: This can happen when there is a sudden

Heat exchanger tube failure: When there is a wide

Cooling water failure: When there is a sudden failure of

Abnormal Heat Input from Reboilers

Capacity Calculation of A Relief Valve

The calculation of capacity in each case is described below:

Operating pressure = 21 kg/cm2g

Latent heat of liquid = 50 Btu/lb

Environmental factor, F = 1.0

Surface Area of vessel, 'A' =*D*L = 54.9 ft2

Volume fraction of vessel when vessel is 80% full = Vf = 0.86

Heat input to wetted surface, Q = 21000*F*Aw0.82 = 494599 Btu/hr

Weight flow of vapour generated, W1 = Q/λ = 9892 lb/hr

Calculation of relief load when gas-filled vessel is under fire:

Volume fraction of vessel when vessel is 80% full = Vf = 0.86

Wetted surface area of vessel, Aw =Vf*A '= 47.12 ft2

Relieving press = r = 1627 pisa

Relieving temp = Tr = 1156°R (From Hysis simulations)

0.5 1.25 1.1506

Sizing of A relief Valve

Flare and Relief Analysis

Safety Valve Selection & Sizing

Safety Valve – Engineering Design & Guideline :

Flare and Blowdown System

Surface Area of vessel, 'A' =DL = 54.9 ft2

Heat input to wetted surface, Q = 21000FAw0.82 = 494599 Btu/hr