ome Celilo i P DesigJOSHI’s Process Equipment Design Fourth Edition V V Mahajani S B Umarji MACMILLAN 0 A JSHX=P4U-YDBN©M V Joshi, V V Mahajani & S B Umarji, 2009 All rights reserved. No part of this publication may be reproduced or transmitted, in any form or by any means, without permission. Any person who does any unauthorised act in relation to this publication may be liable to criminal prosecution and civil claims for damages. First published, 1976 Reprinted, 1979 Second edition, 198] Reprinted, 1985, 1987, 1991, 1995 Third edition, 1996 Reprinted, 1997-2008 (thirteen times) Fourth edition, 2009 Reprinted, 2010 MACMILLAN PUBLISHERS INDIA LTD Delhi Bangalore Chennai Kolkata Mumbai Ahmedabad Bhopal Chandigarh Coimbatore Cuttack Guwahati Hubli Hyderabad Jaipur Lucknow Madurai Nagpur Patna Pune Thiruvananthapuram Visakhapatnam Companies and representatives throughout the world ISBN 10: 0230-63810-4 ISBN 13: 978-0230-63810-5 Published by Rajiv Beri for Macmillan Publishers India Ltd 2/10, Ansari Road, Daryaganj, New Delhi 110 002 Typeset by Text-o-Graphics B1/36, Arawali Apartment, Sector 34, Noida 201 301, UP Printed at Sanat Printers 312 EPIP, Kundli, Sonipat 131 028 This book is meant for educational and learning purposes. The author(s) of the book havhave tuken all reasonable care to ensure that the contents of the book do not violate any existing copyright or other intellectual property rights of any person in my manner whatscever, In the event the author(s) havhave been enable to track any source and if any copyright has been inadvertently infringed, please nouify the publisher in writing for corrective action,Preface to the Fourth Edition Preface to the Third Edition Preface to the Second Edition Preface to the First Edition Acknowledgements to the Third Edition Acknowledgements to the First Edition Chapter 1 Basic Considerations in Process Equipment Design 1.1 Introduction 1.2. The General Design Procedure 1.3. Computer Aided Design 1.4 Fabrication Techniques 1.5 Equipment Classification 1.6 Power for Rotational Motion 1.7 Drives for Process Equipment Chapter 2. Materials of Construction 2.1 Mechanical Properties 2.2 Materials 2.3. Corrosion 2.4 Corrosion Prevention 2.5 Choice of Material Chapter 3. Design Considerations 3.1 Introduction 3.2 Stresses Created Due to Static and Dynamic Loads Duuwnbtbwe —_ &L8zEss &EE Convriohted materia!Contents Design Stress Elastic Instability Combined Stresses and Theories of Failure Fatigue Brittle Fracture Creep Temperature Effects Radiation Effects Effects of Fabrication Methods Economic Considerations Chapter 4 Design of Machine Elements 4.1 — Introduction 4.2 Shafts 4.3 Keys and Pins 44 Couplings 4.5 Bearings 4.6 Belts and Pulleys 4.7 Chain Drive 4.8 Gear Drives 4.9 Riveted Joints 4.10 Welded Joints 4.11 Threaded Fasteners 4.12 Packing and Gaskets 4.13 Design of Stuffing Box and Gland 4.14 Mechanical Seals 4.15 Zero-Leak Drive Chapter 5 Pressure Vessels 5.1 Introduction 5.2. Operating Conditions 5.3 Pressure Vessel Codes 5.4 Selection of Material 5.5 Vessels Operating at Low Temperatures 5.6 Vessels Operating at Elevated Temperatures 5.7 Design Conditions and Stresses 5.8 Design of a Shell and its Components 5.9 Supports 5.10 Stresses from Local Loads and Thermal Gradient 5.11 Thermal Stresses in Cylindrical Shell 5.12 Fabrication 5.13 Review of Unfired Pressure Vessel Codes (Appendix G) 5.14 Inspection and Tests 143 145 1465.15 Illustration Chapter 6 High Pressure Vessels 6.1 Introduction 6.2 Constructional Features 6.3. Materials for High Pressure Vessels 6.4 Solid Walled Vessel 6.5 Multi-shell Construction 6.6 Vessel Closures 6.7 Jacket for Vessels 6.8 Illustration Chapter 7 Storage Vessels 7.1 ‘Introduction 7.2 Storage of Fluids 7.3 Storage of Non-volatile Liquids 7.4 Storage of Volatile Liquids 7.5 Storage of Gases 7.6 Design of Rectangular Tanks 7.7 Design of Tanks 7.8 Nozzles and Mountings 7.9 Large Capacity Storage Tanks 7.10 Illustration Chapter 8 Reaction Vessels 8.1 Introduction 8.2 Materials of Construction 8.3 Agitation %.4 Classification of Reaction Vessels 8.5 Heating Systems 8.6 Design Considerations 8.7 Illustration Chapter 9 Heat Exchangers 9.1 Introduction 9.2 Types of Heat Exchangers 9.3. Design of Shell and Tube Heat Exchangers 9.4 Illustration Chapter 10 Evaporators and Crystallisers 10.1 Evaporators 10.2 Types of Evaporators 10.3 Entrainment Separators Contents xix 149 159 159 159 161 162 167 170 174 175 178 178 178 178 179 184 185 187 196 198 199 204 204 205 205 205 206 208 216 223 223 252 262 262 270xx Contents 10.4 10.5 10.6 10.7 Materials of Construction Design Consideration Crystallisers Illustration Chapter 11 Distillation and Absorption Towers/Columns 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 Introduction Basic Features of Towers/Columns Process Engineering Data Tower/Column Internals Stresses in Columns Shell Determination of Shell Thickness (at Different Heights) Elastic Stability under Compressive Stresses Allowable Deflection Design and Construction Features of Column Internals 11.10 Supports for Column 11,11 Mlustration Chapter 12 Auxiliary Process Vessels 12.1 12.2 12.3 12.4 12.5 12.6 Introduction Reflux Drum Compressor Knock-Out Drum Liquid-liquid Separators Vapour/Gas Liquid Separators Wire Mesh Mist Eliminators (Entrainment Separators) Chapter 13 Supports for Vessels 13.1 13.2 13.3 13.4 13.5 13.6 Introduction Bracket or Lug Supports Leg Supports Skirt Supports Saddle Supports Illustration Chapter 14 Mixers 14.1 14.2 14.3 14.4 14.5 14.6 14.7 14.8 Introduction Types of Agitators Baffles Power Requirements for Agitation Design of Agitation System Components Drive for Agitators Static Mixers Illustration 274 274 274 279 286 286 286 289 290 311 311 312 319 319 332 332 381 391 395 397Chapter 15 Filters 15.1 15.2 15.3 15.4 15.5 Classification Vacuum Filters Pressure Filters Centrifuges Selection of Filters Chapter 16 Dryers 16.1 16.2 16.3 16.4 Introduction Types of Dryers Batch Type Dryers Continuous Dryers Chapter 17 Process Hazards and Safety Measures in Equipment Design 17.1 17.2 17.3 17.4 17.5 17.6 Introduction Hazards in Process Industries Analysis of Hazards Safety Measures Safety Measures in Equipment Design Pressure Relief Devices Chapter 18 Process Flow Diagrams 18.1 18.2 18.3 18.4 Definition/Meaning Process Block Diagram (PBD) Process Flow Diagram (PFD) Piping and Instrumentation Diagram [P&ID] Annesure 18.1 Some Commonly used Symbols in PFD Annesure 18.2 Some Commonly used Piping Symbols in P&IU Diagrams Appendices Index Plates I: Reaction Vessel ¥V. Horizontal Rotory Filter I; Heat Exchanger Ill: Calendria Evaporator IV: Trough Crystallizer VI: Rubber Lined Basket Centrifuge VII: Typical Drawing of Reactor (Chapter 8) Contents xxi 405 405 406 417 426 436 439 439 439 458 458 458 459 462 465 473 473 473 475 476 480 485 489 519Absorption, 1, 19, 206, 2861, 386 columns, 21, 286-322 AC motors, 6 Accelerating, loads, 6 torque, 5 Acid proof brick lining, 40 Agitated vacuum dryer, 443-4, 443¢ rotary joint in, 443-4, 444f Agitators, bearings in, 387-8 designing of, 381-90 drive systems, 391-5 main parts of, 386-7 mountings, 393, 395 power absorption in vessel fittings, 380 power output of, 381-2 power requirement for, 378— 81, 378f process data sheet, 394 selection chart for, 3781 shaft design, 382-6 on critical speed, 384-5 on torque and bending moment, 383-4 supported on bearings, 385f shaft seals, 388-90 side entering, shaft in, 392, 392/ propeller type, 371 special drives, 392-3 stabilizers for, 388 top-cntering, 371 transmission and gland losses, 381 types of, 371-5 typical drive system for, 382, 382f vertical drives, 392 Alloy, cast iron, 16 steels, 17 Aluminium, 14, 21, 22, 28, 30-6, 57, 69, 74, 78, 82, 85, 92, 9S— 7, 171-3, 205, 234, 264, 336, 419 and its alloys, 14, 21-2, 68, 95-6, 495, 500, 506 American Iron and Steel Institute (AISD, 18-21 numbering system of, 20¢ Anchor, agitators, 371-2, 372f bolt design, 353-4 Angle bearing plate, 353 Anti-friction bearings, 71 API standard-650, 94, 187 Index API storage, 486a ASME code, 59, 92, 98, 145, 148, 156, 157, 511 ASTM codes, 19, 21 Austenitic stainless steels, 18, 30 Auxiliary process vessels, 332-8 Axial stresses, 49, 101, 167, 213, 214, 307, 310, 322, 342, 359, 369 Baffle tank, 376-7 characteristics of, 376-7 Baffles, 243, 376-7 in a screw agitated vessel, 374 longitudinal, 243 segmental, 243 size and shape of, 376 transverse, 243, 243/ Ball, bearings, 71, 72/, 413, 432, 435, 449 valve, 488a Ballast trays, 295 Band dryer, 446 Basic coated electrodes, 144 Basket centrifuge, 427-33, 428 main casting or curb in, 431-2 main components of, 428-9 mesh or screen in, 431 Copyrighted material520 Index sizes of baskets in, 429-30, 4291 Batch centrifuge, 427-33 construction material for shell, 431r minimum thickness of shell for, 43ir with basket, 427-33 Batch pressure filter, 417 types of, 417-19 Batch reactors, 205 Bearings, 67—71, 387-8, 413, 416 dissipation of heat generation in, 70 features of, 413 lubrication to, 70 materials for, 68—9r strength and rigidity of, 70 types of, 67-71 wear in, 70 with rolling contact, 71 Belts, 71-4, 72° Bending moment and deflection of beams, 497-87 Beryllium, 14, 17, 22,24 Bevel gears, 75, 76f Bhattacharyya, B.C., 4 Blower, 1, 8, 30, 87, 454, 455, 485a Bolting chair, 354-6, 355f Bolts, 82, 139-41 and nuts, 82, 82 Bowl centrifuges, 435 Boyson, S., 87 Bracket supports, 343-6 base plate for, 343 column support for, 344-6 size and dimensions of, 345-6, 345f web plates for, 3434 welding of, 341f Breather vents, 197-8 size of, 198 Bnittle fracture, 44, 57, 96, 99, 145 conditions of, $7 Bronze bush, 67 Bronzes, 14, 22, 67-70, 78, 82, 88, 274, 387, 415, 425, 429 BS-1500, 98 BS-1515, 98 BS—3274, 230 BS-3274, 230 BS-5500, 98, 148, 511 Bubble caps, 293-4, 293 Buckling, lobes formed at, 104f pressure, 53, 54, 104-7, 112, 217, 220, 283 Butt weld, 78, 81, 408, 411, 414, 416 Carbon dioxide gas, 143, 462 fire extinguisher, 462 Carbon steels, 16, 18, 36, $7, 58, 96, 97, 100, 234, 511 Cast iron, 14, 15, 57, 69, 92, 234, 389 Cathodic and anodic inhibitors, 35 Cavitation corrosion, 30 Cayard, M.S., 40 Cellulose coated electrodes, 144 Centred chair, 354-5 Centrifuge, 8, 19, 26, 30, 87, 426— 36, 487a discharge filter, 425, 426f machines, types of, 425-46 Chain drive, 74-5, 74f, 432, 444 Channels, 244-5 Check valve (non return) , 489a Chemical plants, 1-5, 44-59 and equipment, classification for, 5 pressure vessel group, 5 rotational motion group, 5 structural group, 5 factors for performance, 2 linings for, 38-40 need for, 1 design considerations, 2, 44-59 fabrication techniques in, 4 classified, 4 general design procedure, 34 material for construction of, 10-43 plant and machinery, | type of chemical engincer- ing in, 2-3 Chemical process industry (CPI), 143 motors used in, 6-7 Chemical project economics, 58 Chrome—molybdenum steel, 95 Chromium and its alloys, 24 Chromium-nickel steels, 17 Cladding, 19, 24, 36, 37, 92, 96, 178, 205 Closed discharge, 421 Cogeneration, 8 Cold-forming operations, 58 Column supported roof, 196 Compressor, 8, 485a Computer-aided designing system, 4 Condenser, defined, 228 Cone roof, 193 stresses in, 193, 193f Cone type agitator, 374, 374f Continuous centrifuges, 434—5 screw conveyor type, 434, 434f spiral scraper type, 434-5 types of, 434-5 Continuous, deformation, effect of tempera ture on, 58 flow reactors, 206 Cooling coils, 207 Copper and its alloys, 22, 96 Corrosion, 27-36, 100 allowance, 100 cathodic protection, 31, 32, 35 control of process environment, 31, 35 measures to control, 31-6 measuring the rate of, 31 unit of, 31 prevention from, 31-6 types of, 28-31 Counter shaft, 60 Couplings, 65, 387 types of, 65-7 Creep, 12, 57-8 resistance steels, 162 Crevice corrosion, 28-9 Cyclone, 487a 335 Cylindrical shell, 101-7buckling pressure for, 104 head and covers of, 107-13 attachment of, 112-13 types of, 107-13 internal pressure to, 101-02 thermal stresses in, 142-3 under combined loading, 102 4 unsupported length of, 105f DC motors, 6 Dealuminification, 29 Deflection, 46, 61, 311-12, 314, 432, 497 Design stress, 52-3, 100 Dezincification, 29 i 246-7 Distillation and absorption towers, 286-321 basic features of, 286-8 determination of shell thickness 307-09 diameter and height, 288 kinds of internals in, 290-305 packed, 288 process engineering data for, 289 stresses in, 305-06 support for, 319 types of, 288 Distortion energy theory, 56 Distribution baffles, 296 Dome roof, 193 Double motion agitator, 375 Double pipe heat exchanger, 224, 224f Downcomers, 291 and weirs, 291 chord type, 292f circular and pipe type, 292/ function of, 291 multiple tray, 292-3 with boot (separator), 487a Dryers, 439-57 batch type, 440-6 classified, 439-57 continuous dryer, 446-57 direct, 439 function of, 439 indirect, 439 Ductility, 12 method, 62 Duplex steels, 18 Dynamic mixers, 370-1 factors for consideration, 371 with heater/cooler, 486a Ejector, 485a Elastic, analysis, 99 buckling, 104 instability, 53-4 limit, 12 stability, 311 under compressive stresses, 311 Elasticity, 12 Electric motor, 6-7 classified, 6 on electric power supply, 6 on starting torque, 7 on type of the power input, 6 rating for application, 7 selection of, 7-8 Electrical supply/signal, 491a Electricals, defined, | Elliptical and hemispherical heads, 108f, 111 Enamel, 38 Endurance limit, 57 Erosion corrosion, 29-30 Euler's buckling, 311 Expander, 485a Expansion bellow, 246, 247/f Extended nozzle with flanged joint, 11sf External chair, 355 Fabricated nozzles, 113 Fabrication methods, effects of, $8 Fatigue, 12, 56-7 corrosion, 29 limit, 56-7 factors influencing, 57 Ferrite stainless steels, 18 Index 521 Ferrous, materials, stresses for, 148¢ metals, 15 Fillet weld, 78, 81, 193, 195, 210, 339, 347 types of, 81 Film drum dryers, 452-4, 452f double drum dryer in, 453, 453f Filter press, 417-18, 418/, 419-21, 424, 425, 436 control of leakage in, 421 dimensions of, 420f filtrate discharge methods in, 421 plates and frames, 419/, 419- 20 drainage surface of, 421 movable head, 422-3 screws and screw standard, 424-5 side bars, 421 stationary head, 423-4 supporting legs, 425 types of arrangement, 420-1 Filters, 1, 6, 19, 405-38, 486a driving force for, 405 function of, 405 selection of, 436 Filter valves, 409 Finned tube heat exchanger, 229, 230f Fire-fighting agents, 462 principles of working, 462 Fire hazard, 460-2 terms associated with, 460-2 Fired heater/furnace, 483a Fixed roof tanks, 179-80, 180/, 188-9 bottom design for, 188-9, 9f categories of, 188 class ‘a’ tanks, 188 class ‘b’ tanks, 188 design of, 187-188 codes for, 188 materials used for, 188 open-top tanks, 188 Fixed tube sheet, 232-3, 240, 245, 251522 Index exchanger, 232-3, 245-7, 251, with bellow, 247/° Flame arrester, 469, 490a Flammability, 460-1 Flange, dimensions, 133f facings, 128-30, 130f male and female face, 129, 130f narrow-face, 128 ring facing, 129, 130f tongue and groove face, 129, 130f wide face, 128 joints, 122-41 design of, 131-9 main considerations for, 131 with tube sheet, 245f thickness, 141 types and sizes of, 122-8 Flanged, and dished heads, 107 nozzles, 198f Flash, dryer, 454, 454f point, 460 Flat heads and covers, 108-09, 110/ attachment of, 110f Flexible coupling, 67, 67f Flexy trays, 295, 295f Floating roof tank, 183—4 accessories of, 183-4 drains for, 184 seals for, 183-4 Fluid, bed dryer, 454-55, 455f viscosity loads, 6 Formed heads, 107, 108f and dished heads, 109-12 Formed nozzles, 118, 118f Fractionating column, 277, 320, 332, 466, 467 self-supported, 287/ Fractionation, 286, 332 Free-roof cylindrical tanks, 179 Fretting corrosion, 30 Friction loads, 6 Fusion welding, 143-4 classified, 143 Galvanic corrosion, 28 Gas welding, 143 Gases, storage of, 184-5 Gaskets, 25, 26, 32, 84, 122, 128, 130-1, 134, 135, 139, 157, 170-2, 204, 229, 233, 244, 245, 266, 421, 465, corrugated, 131 flat ring type, 130 laminated, 131 metallic, 131, 134, 245 materials for, 135-6r reactions to stress, 131-9 elastic reaction, 131 springy reaction, 132 ring, 131 seating width, 137-8r, 139¢ self-sealing, 131 serrated, 130 spinal wound, 131 types of, 130-1 Gate valve, 4882 Gear drives, 75-8 classified, 75 Glass lining methods, 39 hot dust process, 39 spray dust process, 39 wel spray process, 39 Globe valve, 488a Graphite, 15, 25, 29, 38, 87, 131, 223, 229, 234, 300, 444, 468 bushing, 444/ erosion, 29 heat exchangers, 229 seat, 444° Gravity separators, 335 Grey cast iron, 15 Guest theory, 55 Heat, dissipation, 88 exchange, 223 direct or indirect, 223 Heat exchangers, 223-61, 483a as reboiler, 483a bowed tube arrangement for, 249-50 channel and channel cover of, 243-4 classification by TEMA, 230, 232 classified, 223-9 on flow paths, 223, 232 on function, 223 on materials of construc- tion, 223 on mechanical construction, 223 corrosion allowance for, 235 design pressure in, 234 design temperature for, 234 expansion bellow for, 246, 247f expansion provision for, 245— 250 fired, 223 floating head details in, 249f, 250f fluid flow arrangement in, 232 fluid temperature limitations for, 234f internal floating head, 249 materials of construction, 234 nozzles for, 250-51f outside packet floating head, 248 process sheet, 230, 2311 shell of, 235-6 minimum thicknesses of, 235f side passes in, 241-2 special type of, 228-9 supports in, 251, 251f tube sheet, 236-41, 237f, 239f fixing method for, 238f lined fixed, 241 minimum thicknesses of, 241 side passes in, 242 types of tubes for, 236 unfired, 223 u-tube arrangement for, 249 vertical, 251f with cooling water, 483a Heat transfer equipment, 464 precautions in design for, 464 Helical, filter, 425, 427 gears, 75 screw agitator, 374, 376 Hemispherical heads, 107