Index 391
hydro, geo-thermal, tidal, 372
natural gas, 372
nuclear, 371
ocean waves, 372
switch-grass, 372
wind and solar, 371
CO2 emission suppression, 382–383
centrifugal compressors fixed speed, 386
coal-fueled power plants, alternates to,
371–372
distillation towers, pressure optimisation,
383–384
fired heaters, 385
heat exchangers
shell side, 384
tube side, 384
motor-driven centrifugal pumps, 386
picket/notched weirs, 383
reciprocating compressors, 386–387
steam condensate recovery, 387
steam turbines
condensing, 385–386
topping, 385
tray deck levelness, 383
Coker fractionators, 41
Compression ratio, 241
Compressor fire stage rotor, 253, 254f
Compressors
air-cooled, 260
axial, 241
vs. centrifugal compressors, 242
butane and ethane percent, 260
Carnot cycle, 248–249, 248f
centrifugal, 241, 260
antisurge valve, 246–247
vs. axial compressors, 242
discharge pressure, 243
performance curve, 243–244, 244f, 246
rotating assembly, 242–243, 243f
spill-back valve, 244, 245f
suction throttling of, 245–246, 245f
surge, 244, 245f
confusion index, 241
discharge pressure, 241–243, 261, 263
reciprocating, 241, 247–248, 248f
rod loading, 249–250
suction drum, 260, 264–265
suction pressure, 241–242, 245–246
suction temperature, 261–263
temperature profile, 249
Computer modeling, 135
distillation tower
effective design methods, 150–151
fired heater limitations, 149, 150f
fractionators, 145–146, 146f
heat exchanger efficiency, 147–149, 148f
oil-water settling velocity, 146–147, 147f
pressure drops in pipes, 149
overhead piping system, 140, 140f
of splitter, 139
of vacuum tower, 143
Condensate back-up, 199
steam reboilers, 114–115
Condensate drain valve, 343
Condensate seal, 72–75, 73–74f, 119
blowing, 115, 199
Condenser
distillation column, 23
limitations, 263–264, 264f
surface (see Surface condenser)
vacuum, 179–180, 193–194, 194f
Condensers and reboilers, heat exchange in
carbon dioxide accumulation, 121–122
cooling water inlet location, 122–124
depropanizer reboiler tube leak, 120–121,
120f
de-superheating vapors, 124–125
smooth reboiler tubes, 124
surface condenser air baffle, 122, 123f
surface condensers, air leaks in, 122
vapor binding, 119, 120f
vertical thermosyphon reboiler, venting
from, 121, 121f
Condensing, 103
Confusion index (CI), 241
Control valve, 4
vibrations, 285
Convective section, 161
Converging-diverging steam ejector/jet, 170,
171f, 187–188, 188f, 201, 202f
392 INDEX

Cooling water circuits Delayed coker wash oil, 41–42, 42f

air leaks in suction, 90 Delta P dry, 11–12
cooling towers, 85, 86f and Delta P hydraulic balancing, 13–14
frictional loss in water piping, 88 pressure drop, 11–12
hardness deposits, 88–89 Delta P hydraulic, 11
localized restriction, 89, 90f calculation, 12
pressure drop survey, 87–88, 87f crest height, 12–13
time, temperature, and pH, 86–87 and Delta P dry balancing, 13–14
water pH control, 89 “FrancisWeir” formula, 13
water pressure, 86 liquid droplets, 12
wet bulb tray deck weeping, 12
approach to, 90–91 weight of liquid, 13
temperature, 85–86 weir loading, 12–13
Corrosion, 356 Density difference
hydrogen ion, 357 draft, 95–96
iron sulfide, 357 partial vaporization, 100
Crank-end, 275 Depropanizer, 338–339
Creole Queen, excursion steam boat, 209 alkylation unit, corrosion in, 337–338
Critical flow, 171 design error, 338
Crude flash zones, 41 propane, refrigerant, 337
Crude oil preflash towers, 35 reflux drum, 339
Crude preheat exchanger start-up procedure, 338
network, 142–143 Depropanizer reboiler tube leak, 120–121, 120f
on-line spalling, 131, 132f De-superheater, 203, 204f
Crude tower preflash drum, 135, 136f De-superheating vapors, 124–125
Crude unit Dew point temperature, 85
channel head pass partition baffle, 127, 128f, Diesel freeze point, 153
129 Aspen computer model simulation, 153
crude placement, 127–128 freeze, smoke, cloud point limitations, 155b
heat transfer, effect on, 129 haze point limitation, 155b
number of tube side passes, 130–131, 131f lab analysis, 154–155
on-line spalling, 131–132, 132f post script, 155
plugged tubes, 127, 128f Diesel production
shell side cross-flow velocity, 132 capital investment, 153
surface roughness, 129–130 freeze point (see Diesel freeze point)
tubes fouling factors, 128–129 Differential pressure (DP), 253, 255
Discharge check valve function, 255
D Discharge-to-suction recycle valve, 251
Dark gray deposit, 304 Displacement pump, 219
De-acceleration effect, 290–291 Distillation column, 4, 145, 146f
Debutanizer, 50 Distillation tower
in Aruba, 47 cleaning, 297
flooding, 47 packed distillation columns, 297–298
Deep-water horizon blow-out, BP, 353–354, trayed towers, 298–299
354f computer modeling
 Index 393

effective design methods, 150–151 motive steam, 170, 177–179

fired heater limitations, 149, 150f nonlinear performance of, 171
fractionators, 145–146, 146f primary, 172
heat exchanger efficiency, 147–149, 148f seal drum, 170, 172
oil-water settling velocity, 146–147, 147f secondary, 171
pressure drops in pipes, 149 second stage, 171
modeling, 137–138 third stage, 170
pressure, 374, 374f two-stage ejectors, 172, 173f
pressure optimisation, 383–384 wet steam, 179
reflux function in El Dorado refinery, 259–261
ancient still, 20, 21f Electric motors, 4
bubble cap trays, 23 Energy conservation projects, 367–368
condenser, 23 Engineering function
feed preheater, 23 energy saving projects, 363
light naphtha, 19, 20f in global warming era
naphtha’s tail removal, 23–24, 24f atmospheric oxygen, 365–366
origin of, 23 CO2 atmospheric concentrations, 366
Pisco, 20–21 CO2 distribution, 367
reboiler, 19, 23, 25 CO2 production, 368
two-stage distillation process, 22–23, 22f DNA oxidation, 365
vapor pressure limitations, 21–22 energy conservation projects, 367–368
tray efficiency, 375, 375f exothermic reactions, 364
Distillation trays, 7, 8f oxygen concentration, 365
bubble cap, 9, 10f, 17 photosynthesis, 364
bubble cap trays, 30–31 positive feedback loop, 368–369
downcomer back-up, 29–30 problem of time, 369
foam effect, 28, 29f refinery management personnel,
fractionation efficiency (see Tray explanation to, 364
fractionation efficiency) source of energy, 364
incremental reboiler steam, effect of, 7 U-235 heat release, reduction
perforations, 11 of, 366–367
reflux benefits, 28–29 longer term objectives, 363
valve tray, 9–10, 10f operation objectives, 363
Diverging jet, 186, 186f Enthalpy, 202, 204–205
DNA oxidation, 365 Entropy, 204–205
Double-mechanical seal, 239 Entry permit, 332, 335
Downcomer, 8, 14, 16 Equation of state, 139, 145–146
back-up, 29–30 Erosion, 128
DP. See Differential pressure (DP) Erratic toilet water level, 306
Draft, 95–96 Ethane, refrigerant, 262
driving force, 95–96 Evaporation, 110
Evaporator, 264–265
E Excessive coker grid height, 42–43, 42f
Ejectors Exothermic reactions, 364
first stage, 170f, 176, 178f Explosive region, 164
394 INDEX

F Fouling
FCU. See Fluid catalytic cracking unit (FCU) with carbonate, 91
Feed distributor, 55, 55f refrigerant, 265
Fiber glass, 56 tubes, 128–129, 131
Fin-fan air coolers, 379–380 Fouling factor, 142–143, 148–149
Firebox, 163–165 crude tube side, 143
Fired heater Fractionation efficiency, 155. See also Tray
adjusting excess oxygen, 377, 377f fractionation efficiency
cleaning, 297 Fractionator flooding
convective tubes, 302 crude debutanizer, 47
heater tubes’ exterior, 303–304 pressure measurements, 48, 49–50f
radiant tubes, coke removal tower internal inspection, 49–50, 50f
from, 302–303 tower pressure drop survey, 47–48
spalling and hydroblasting, 303 Fractionator wash oil grids. See Wash oil grids
CO2 emission suppression, 385 Frictional loss, 96
combustion air preheat in drain line, 114
air-to-fuel mixing efficiency, 161 in furnace, 99–100
effect of, 162 thermosyphon circulation, 101
excess air, 161 water circulation, 98–99
flame temperature, 160–161 in water piping, 88
radiant tube wall failure, 162b Friction factor, 149
rate of coke formation, 159, 160f inside process piping, 142
limitations, 149, 150f Furnace draft losses, 99–100
tube failure, 163
box steam installation, 165 G
corrective action, 165–166, 166f Gas compressors, 4
snuffing steam, 164–165, 164f Gas density, 253–255
upper explosive limit, 163–164 Gas oil hydrotreater, 41
Flame temperature, 160–161 GHR Energy, Norco, Louisiana
Flash zone, 19 hot water, 332
Flash zone temperature, 175–176, 178f steam leak, 332
Flooding distillation tower, 47–48 sulfur deposits, 333
Flow measurement, plant safety, 323–324 Global warming, 371
Fluid catalytic cracking unit (FCU) Governor valve, 214
air blower horsepower, 195f, 197–198 Gravity settling de-entrainment, 44
depropanizer, 357 Greenhouse gas, 365
Fluid properties, 142
Fluid velocity, 142 H
Flux, 23 Hardness deposits, 88–89
Flux limitations, 103 steam radiator, 93
Flux limited situation, 105, 124 Haze point limitation, 155b
Foam/froth, vapor-liquid mixture, Head-end, 275
38, 38f Head pressure
Foaming, surfactants effects on, 111 feet of head conversion, 65
Forced circulation, 265 vs. height, 63–64, 64f
Forced refrigerant, 265 velocity conversion, 64–65
 Index 395

Heat content. See Enthalpy pressure recovery, 78

Heater tubes, 162 vapor lock in emulsion line, 78–79, 79f
Heat exchanger, 4 relationship, 63
cleaning, 297 seal flush pressure, 63
acid cleaning, 300 velocity to pressure conversion, 67–68
hydroblasting “U” tube bundles, 300 water pressure in bathrooms, 63–64
shell side cleaning, 301 Hydraulic surge, 69–70
tube side cleaning, 299, 299f Hydroblasting
CO2 emission suppression spalling and, 303
shell side, 384 “U” tube bundles, 300
tube side, 384 Hydrocarbon, 371
design, 376, 376f liquid phase, settling water of, 36, 37f
helical tube support baffles, 376, 376f residual, 53
settling rate, 146–147, 147f Hydrofluoric acid (HF), 341, 343
Heat flux, 306 stripper, 341–342
Heat–kinetic energy conversion, 108–109 vapors, 343
Heat transfer Hydrogen expansion, 109
crude unit, 129 Hydrogen sulfide (H2S), 334–335
rates, 103 American Oil, Texas City, 331–332
Heat Transfer Research Institute (HTRI) Coastal, Aruba, 331
computer program, 309
Heavy vacuum gas oil, 154 I
Hextran computer program, 147–148 Impeller, 65, 68, 229–230
HF. See Hydrofluoric acid (HF) Improper process controls
High temperature creep, 162 alkylation unit HF stripper, 341–342
Hogging jet, 186f, 187 boiler feed water, carbonates in, 342
Hold-time, 53, 58 condensate drain valve, 343
Hot water reboiler channel head pressure,
Beaumont, 333 342–343
GHR Energy, Norco, Louisiana, 332 retrofit design, 343–344
Humidity, cooling towers, 85 steam trap, 344
Hydraulics tube leak, consequences of, 343
centrifugal pumps, 65–66, 66f Incipient Flood Point, 15–16
head pressure Induced draft cooling tower, 85, 86f
feet of head conversion, 65 Installation error, fractionator flooding, 47
vs. height, 63–64, 64f crude debutanizer, 47
velocity conversion, 64–65 pressure measurements, 48, 49–50f
orifice coefficients, 66–67, 67f tower internal inspection, 49–50, 50f
pressure balancing holes, 68 tower pressure drop survey, 47–48
for process problems Intercondensers, 180
chimney tray pressure drop, 82, 82f Interface level control, 293, 294f
cooling water piping pressure drop, 79–81, Ionic hydrogen, 357
80f Isenthalpic expansion, 205
fractionation tray efficiency, 81–82, Isentropic expansion, 170, 185,
81f 204–205, 215
pressure drop, 77–78 Iso-propyl-chloride, 259