Process Engineering

Equipment Handbook

Claire Soares

McGraw-Hill
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Library of Congress Cataloging-in-Publication Data

Soares, Claire.
Process engineering equipment handbook / Claire Soares.
p. cm.
Includes index.
ISBN 0-07-059614-X (acid-free paper)
1. Chemical plants—Equipment and supplies. I. Title.

TP157.S658 2002
660¢.283—dc21 2001045228

McGraw-Hill

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ISBN 0-07-059614-X

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Contributors

A
ASME Specifications
ASME: 345 East 47 Street, New York, NY 10017 USA
Abrasives
Abrasive Technology, Inc.: 8400 Green Meadows Drive, Westerville, OH 43081
USA
Sandusky-Chicago Abrasive Wheel Co., Inc.: 1100 W. Barker Avenue, Michigan
City, IN 46360 USA
National Metal Abrasive, Inc.: P.O. Box 341, Wadsworth, OH 44282 USA
Acid Rain
Environment Canada: Environment Canada Enquiry Centre, Ottawa, Ontario
K1A 0H3 Canada
Acoustic Enclosures, Turbine
Altair Filters International Limited: Omega Park, Alton, Hampshire GU34
2QE England
Actuators
J.M. Voith GmbH: P.O. Box 1940, D-89509 Heidenheim, Germany
Voith Turbo GmbH & Co., KG: P.O. Box 1555, D-74555 Crailsheim, Germany
Air Filtration
Altair Filters International Limited: see above
Air Pollution Control
Alstom (formerly ABB Power Generation): Finspong 61282 Sweden;
Hasselstrasse 16, CH-5401 Baden, Switzerland; 5309 Commonwealth Center
Parkway, Midlothian, VA 23112 USA

B
Bearings
Demag Delaval: 840 Nottingham Way, Trenton, NJ 08638 USA
Revolve Magnetic Bearings, Inc.: Calgary, Alberta, Canada
Boilers
Environment Canada: see above
Brakes
J.M. Voith GmbH: see above

xv
xvi Contributors

CFD (Computational Fluid Dynamics)

Fluent Inc.: Lebanon, NH USA
Carbon; Carbon-Graphite Mix Products
Advance Carbon Products: 2036 National Avenue, Hayward, CA 94545 USA
Carbon Dioxide (CO2); CO2 Disposal
Vatenfall: S162 87 Stockholm, Sweden
Cement; Portland Cement
Environment Canada: see above
Centrifuges
Dorr-Oliver Inc.: 612 Wheelers Farm Road, Milford, CT 06460 USA
Chemical Complex; (Petro)Chemical Complex; Chemical Plant
Petrochemcial Company of Singapore: Singapore
Chemicals
ARCO Chemical Company: 3801 West Chester Avenue, Newton Square, PA
19073-2387 USA
Chemicals (Toxic), Handling
ARCO Chemical Company: see above
Chillers; Crystallizers; Chemical Separation Method; Alternative to Distillation/Fractional Distillation
Armstrong Engineering Associates: P.O. Box 566M, West Chester, PA 19381-
0566 USA
Cogeneration
Alstom: Finspong 61282 Sweden
Compressors
Sulzer-Burckhardt: Winterthur, Switzerland
Demag Delaval: see above
Aerzener Maschinenfabrik, GmbH: D2358 Aerzen, Germany
Condensers
Alstom: Hasselstrasse 16, CH-5401 Baden, Switzerland; D6800 Mannheim 1,
Germany
Condition Monitoring (CM); Condition-Monitoring System(s) (CMS); Engine Condition Monitoring (ECM); Engine
Condition–Monitoring System(s) (ECMS)
Claire Soares Inc.: P.O. Box 540213, Dallas, TX 75354 USA
Control Systems; Controls
Sulzer-Burckhardt: see above
Voith Turbo GmbH & Co., KG: P.O. Box 1555, D-74555 Crailsheim, Germany
Voith Safeset A.B.: Ronningev. 6, S-82434 Hudliksvall, Sweden
Controls, Retrofit
Petrotech Inc.: 108 Jarrel Drive, P.O. Box 503, Belle Chase, LA 70037 USA
Demag Delaval: see above
J.M. Voith GmbH: see above
 Contributors xvii

Conveyors
Sandvik Process System, Inc.: USA
Bloch, H., and Soares, C. M., Process Plant Machinery, 2d ed., Butterworth-
Heinemann, 1998.
Coolant; Engine Coolant
ARCO Chemical Company: see above
Cooling; Cool, Products That (Air Conditioners); Liquid-Cooled Air Conditioners
Thermoelectric Cooling America Corporation (TECA): USA
Cooling Towers
The Marley Cooling Tower Company: Marley and Lone Elm Roads, Olathe, KS
66061 USA

D
Drying
ARCO Chemical Company: see above

E
Ecological Parks; Industrial Ecological Parks
Environment Canada: see above
Ecosystem
Environment Canada: see above
Electric Motors; Electric Motor Controls
Reliance Electric Company: Cleveland, OH USA
Emissions; Air Emissions
Environment Canada: see above
Engines, Gas
Cooper-Bessemer Reciprocating: Grove City, PA USA
Environmental Accountability
Kodak: USA
Cultor: Finland
Environmental Economics
AssiDomän: Sweden
Exhausters, Centrifugal Gas
Ansaldo: Milan, Italy
Expansion Joints
Townson Expansion Joints: United Kingdom
Explosion; Explosion Hazard Analysis; Explosion Hazards
Eutech Engineering Solutions Ltd.: Billingham, Cleveland TS23 4YS England
H.M. Principal Specialist Inspector, Health & Safety Executive, Quay House, Quay
Street, Manchester M3 3JB England
xviii Contributors

F
Fans, Centrifugal
Ansaldo: see above
Bloch, H., and Soares, C. M., Process Plant Machinery, 2d ed., Butterworth-
Heinemann, 1998.
Filters
Peerless Manufacturing Company: 2819 Walnut Hill Lane, Dallas, TX 75229
USA
Forest Products
AssiDomän: see above
Fuel Gas Conditioning System(s)
Peerless Manufacturing Company: see above
Fuel Systems; Fuel Flow Control
J.M. Voith GmbH: see above
Whittaker Controls, Inc.: 12838 Saticoy Street, North Hollywood, CA 91605 USA
Fuels, Alternative; Fuels, Gas Turbine
Bechtel Power Corporation: Gaithersburg, MD 20878 USA

G
Generators; Turbogenerators
Alstom: see above

H
Heat Exchangers
Armstrong Engineering Associates: see above
Heat Pumps; Heat Pumps, Geothermal; Heating Systems with a Renewable Energy Source
Enertran: Canada

L
Life-Cycle Assessment (LCA) (of Turbomachinery)
Claire Soares Inc.: P.O. Box 540213, Dallas, TX 75354 USA
Liquid Natural Gas (LNG)
Peerless Manufacturing Company: see above
Lubrication
Demag Delaval: see above

M
Measurement
Demag Delaval: see above
Metallurgy; Metallurgical Repair; Metallurgical Refurbishment
Liburdi Engineering: Hwy. 400, Dundas, Ontario, Canada
 Contributors xix

O
Oil Sands; Synthetic Crude; Tar Sands; Shale
Syncrude Canada Limited: Ft. McMurray, Alberta, Canada
Oxygen Analysis
Rosemount Analytical: Orville, OH USA
Ozone
Environment Canada: see above

P
Pollutants, Chemical; Pollutants, (from) Chemical Processes; Pollutant Indicators; Pollutants, Toxic; Pollutants,
Toxic Chemicals
Environment Canada: see above
Power Transmission
Demag Delaval: see above
MAAG Gear Company: Switzerland
J.M. Voith GmbH: see above
Pulp and Paper
AssiDomän: see above
Pulsation Dampeners
Peerless Manufacturing Company: see above
Pumps
Bloch, H., and Soares, C. M., Process Plant Machinery, 2d ed., Butterworth-
Heinemann, 1998.
Demag Delaval: see above
Sulzer Pumps: USA
Goulds Pumps: USA

R
Refineries, Petroleum
Environment Canada: see above

S
Seals; Gas Seals
Revolve Magnetic Bearing, Inc.: see above
Separators
Peerless Manufacturing Company: see above
Stacks
Altair Filters International Limited: see above

T
Tanks
A.O. Smith Engineered Storage Products Company: 2101 S. 21st Street,
Parsons, KS 67357 USA
Enraf: England
xx Contributors

Turbines, Gas
Alstom: see above
ASME: see above
Turbines, Steam
Demag Delaval: see above
Peerless Manufacturing Company: see above
Turbochargers
Demag Delaval: see above
Turboexpanders
Demag Delaval: see above

U
Ultrasonic Cleaning
Sonics: USA

V
Vaporizers; Vaporizor Applications
Armstrong Engineering Associates: see above

W
Waste Management
Environment Canada: see above
About the Author

A registered professional engineer in Texas and Alberta, Canada, Claire Soares

graduated with a B.Sc.Eng. in 1972 and an M.B.A. in 1993. Her career began in
computational fluid dynamics working for Brian Spalding in Imperial College,
London, on the COBALT project. She then spent about two years working on
developing structural patents for the marine and the power distribution industries
in England and Canada. Her rotating machinery career began in earnest at the oil
sands Syncrude site in Fort McMurray, Alberta, in 1975. Four years later, she
moved to Esso Resources and conventional oil and gas production until the “oil
patch sat on its tail” at the end of 1981. She then accepted a three-year commission
with the Canadian Air Force as Propulsion Systems Manager for all transportation
engines in the Department of Defence Transport Command in Canada. She took
charge of six helicopter engine fleets, as well as projects related to selecting
replacements for two of those fleets. After that, she moved to the United States to
start work as a senior engineer for Ryder Airline Services Division (ASD was also
called Aviall and, before that, CooperAirmotive). At that point ASD was the largest
independent overhaul facility for airline engines in the world, with a shop capacity
of about 1000 engines a year. She ran technical support on second shift for 250
mechanics and their supervisors on the JT8D, JT3D, and CFM 56 engine lines.
Three years later, she was made manager of the V2500 engine repair program, at
that time the first and only designated facility for this engine in the United States.
Two years later, after the engine line was up and running, she left to become an
independent consultant, trainer, and writer. She has now lived and worked on four
continents. Ms. Soares organizes one to two conference sessions annually for the
International Gas Turbine Division of the American Society of Mechanical
Engineers (ASME) and has done so since 1985. In May 2001 she was appointed to
Fellow grade by ASME.
Process Engineering Equipment Handbook is her fourth book. The first, Process
Plant Machinery, Second Edition, was coauthored with Heinz Bloch, P.E. This work
and Environmental Technology and Economics: Sustainable Development in
Industry helped provide the present handbook with its broad perspective.
Turboexpanders and Process Applications, her third book, also coauthored with
Heinz Bloch, was released in 2001. All her books are used when appropriate as
course instruction material for her own and others’ courses. Ms. Soares writes
extensively for technical journals, such as Petroleum Economist, Asian Electricity,
and International Power Generation.
She also writes for more general audiences, with some television screenplays and
articles for various international newspapers and magazines to her credit. A
published photographer, she writes poetry and has staged multimedia performances
of her work for organizations such as the city of Dallas. She is a scuba diver and
licensed commercial pilot, and also enjoys swimming and hiking.

In-30
Preface

If you picked up this book you are probably one of those lucky people who run plants.
Either a thinly spread engineer (branch of specialty is irrelevant), a newly promoted
technical manager, or a harassed technologist or senior mechanic, who just was told:
“See that plant out there? You’re in charge of making it work!” Even if you’ve been
in plants for years, that’s enough to make your innards rumble. If you have just
stepped out of school, into your first plant, or into a totally different plant from the
previous one you were at, your reaction might be more severe, especially if you
belong to one of the numerous organizations with no budget for rotating machinery
specialists (who look after what moves a process through its paces) or
environmental specialists (who make certain you don’t get fined or jailed, good
intentions notwithstanding, as you run your plant). At this point, I should explain
where I fit in with your agenda.
Twenty-some years ago, some heated arguments on the subject of how much I
wanted to be a rotating machinery specialist took place in Canada’s wild and woolly
north. I was fencing with my boss, a process engineer, who was recommending I
join his field. It was what my company needed, he asserted. I thought it needed
both of us doing what we loved best. My career bears witness to the fact that I won
the match, in the short- and long-term.
Time since has brought a few things forcibly home to me. To start with, the more
I dealt with plant machinery in any form, the more I accepted that process
conditions could affect the performance of that machinery at least as much as actual
mechanical characteristics. In operations, repair and overhaul, or retrofit design
and reengineering, what keeps people like me a step ahead of the manufacturer’s
field service representatives is knowledge of the process and familiarity with the
controls that govern the entire system. In turn, the process engineer who gets
handed a plant to run must acquire some basic knowledge of my bread and butter,
the machinery that makes everything move up, down, or around. In large facilities,
such as the ones I was fortunate enough to spend time in, there generally are in-
house rotating machinery specialists. Often, though, the process engineer is not
that lucky and gets everything—process components, machinery, controls, and all.
Life handed me an education (after formal degree acquisition) in rotating
machinery specialization and the environmental technology that goes with it (yes,
we machinery “cranks” run the stuff that turns out arguably 80 percent of the gunk
in the universe). While doing this, I worked with scores of process engineers, control
engineers, and various other specialists on a variety of projects that were among
the most high profile in the world in their own right. It was “arranging to be in the
right place—an operating plant—to get the best education in the best school in the
world.”
After all, curriculum, undergraduate or otherwise, is not necessarily any comfort.
In my day they rarely taught this stuff to process, chemical, or mechanical engineers

xi
xii Preface

at universities. They still don’t. That leaves all the young engineers in the same
boat—without any practical guide for reference.
My editor at McGraw-Hill was keen that they should have one, and one that was
easy to read. We soon found we were on the same page on the subject of readability.
We do not like technical material that sounds more intellectual than it absolutely
has to, and we do like many diagrams, photographs, tables, and figures.
I add two other ingredients to my books and courses: (1) information on items
(such as condition monitoring and specialized controls) that will help the engineer
optimize cost-effective operations and (2) information that will help the engineer
stay out of trouble with legislators, particularly environmental legislators
(regardless of whether the legislation is current or impending). Fines levied for
ignoring emissions or pollutant statutes may not be high enough to be a deterrent
in themselves when weighed against a process plant’s gross production revenue.
They can, however, whittle away at profits while adding to overall costs per
operating hour. Frequently, though, environmental equipment can actually result
in machinery’s attaining longer times between overhauls. Also, the loss of goodwill
—that priceless commodity on annual reports—is immense if environmental
standards are not followed.
In this competitive age, plants do vie for national, state, or provincial quality
control awards. Clever managers can turn those into longer customer lists.
Attaining these awards is not something that many accountants, lawyers, and
MBAs, who run major corporations but may have little or no technical exposure,
can pull off without their engineers. It is the engineers who are likely to be the key
figures in putting together the action framework for what will buy their firm new
or continued goodwill. Environmental accounting plans, holistic management of
resources and waste products, environmental policy, waste and toxic management—
they mean pretty much the same thing and they are not a feature at all in many
other process engineers’ reference books.
It is painfully evident that the emphasis given to waste and toxic management
varies globally. It reaches a high in Sweden and Norway, England is fast developing
an aggressive proactivity in this vein, and Canada has excellent technology, which
may or may not get enforced to the appropriate extent depending on the political
balance of power at any time. The United States has some large loopholes that are
surprising for a country so advanced; shared emissions legislation is one. And yet,
it’s in the area of waste and toxic management that companies receive the most
vocal and widespread media coverage (and loss of business) when exposed. Some of
the world’s youth appear to have a sense of resources running low and therefore a
need to conserve them. In these days of increasing international joint ventures, the
gaps between all these preferences is fast diminishing and the stable point for the
resultant system can tend to reflect the highest standards among the partners.
One could argue that subjects that infringe on environmental and waste
management turf belong in another handbook and with another kind of engineer.
That is not entirely true though this is becoming a specialist field. The reasons for
this statement are rooted in profit margins. If environmental considerations and
waste products can be integrated into production in a way that what might have
been a hazard or waste now contributes to revenue, this is obviously preferable
to that hazard or waste being isolated with its own disposal/neutralization system
that does not contribute revenue. Some examples are biomass waste in pulp and
paper production, formerly disposed of, that can be converted to gaseous fuel for a
turbine (see Pulp and Paper) and chemical by-products in complex downstream
petrochemical plastics production, otherwise waste, that can now also be used as
turbine fuel. The controls and system modifications that assist incorporation of
these profitable adaptions into process plants are given some space.
 Preface xiii

I have also included some basic information on specific controls and monitoring
systems. They are a fact of life on a process engineer’s turf; the ones I have
highlighted have a proven track record for adding profit margins to processes by
minimizing downtime or fluctuations.
Similarly, a process engineer may have to make decisions related to
turbomachinery performance or capacity that are affected by metallurgical
processes. Included is some information on common critical alloys used in today’s
plants.
This book contains information on the major components and basic systems,
including instrumentation and controls, and some optimization techniques that I
wish I had had when I landed, albeit happily, in my first major plant. It also contains
examples, drawn from knowledgeable sources, of action plans that have kept
various process companies in good standing and high esteem with their public and
governments worldwide. Selected extracts of the technology that are the bases of
these policies are also included. These examples and technology extracts are
frequently missing from engineering handbooks; I would be doing users of this
handbook a disservice to leave out this information.
Increasingly process plants are becoming small power producers. Governments
are now beginning to offer incentives to small power producers. The Thai
government, which buys the excess power from Esso’s Sriracha refinery, is just one
such example. The Alberta, Canada, government buys excess power from Syncrude
Canada Limited, which produces 170,000 barrels of crude oil a day. The British
power network buys excess power from Elf Acquitaine’s Flotta terminal, which
collects North Sea petroleum products.
In other words, this book aims to provide a process engineer with:
 Knowledge of the basics the process engineer will meet up with
 Enough knowledge to help the process engineer optimize operation safety,
efficiency, and profit margins
 Information about environmental systems and avoiding trouble with the law
 Tools to integrate the plant’s operation with other services, such as power
production and waste management, to further optimize profits and minimize
losses due to interruptions in services provided by external companies

Claire Soares
claire_soares@compuserve.com
Introduction

The contemporary process engineer has to be an all-around generalist. This

handbook contains basic information on items that cause or assist chemical
reactions, such as chillers. In today’s environment, information on additional
sectors is also required to help the plant engineer function.
To begin with, besides the components in a plant that produce required chemical
and physical state changes, such as fractionating distillation columns and reactors,
the plant engineer needs to know the process plant machinery that transports and
delivers raw material and products. It is this machinery that is very often the bane
of the engineer’s existence. The good news is that with a little knowledge one can
keep most of it running.
When that happens, the process plant engineer may have to troubleshoot
equipment if the plant does not have a rotating machinery engineer. That may be
why so many of the process plant engineers I talked with asked me to include
material on condition monitoring and life-cycle (of machinery components)
assessment. These two items alone can save a plant a huge amount of its costs per
plant operating hour, if properly utilized. I have included some of my notes from
two of my basic courses on these subjects.
Interestingly enough, plant problems are common at system interfaces—at
expansion joints, rather than at what they connect, and at gearboxes, couplings,
and torque measurers, rather than the parent items of machinery they link. Also,
certain accessories can be weak points if improperly applied. Air filtration can
protect a machine from icing and erosive particles or it might build up excessive
pressure drop and penalties on turbine output power. The quantity of information
provided on these items, such as air filtration and power transmission equipment,
reflects this fact.
Environmental technology and economics is another area now integral to a
process engineer’s world. Without this knowledge, the company could be fined and
management imprisoned. Even if this is not an issue, environmental savvy can buy
a corporation an inestimable amount of goodwill and a high profile in proactive
community service. It has resulted in national quality control awards and other
recognition. This may mean that corporation is preferentially selected as a product
or services supplier. Environmentally sound cohabitation of industrial real estate
in what are termed ecological industrial parks can also save utility costs.
Most importantly, however, taken over the life of a plant, environmentally sound
methodology saves in overall operating costs per unit time. What seems like
cleanliness and politically correct “extras” saves in parts longevity. This is not
common knowledge in the engineering world. In fact, one common motivation for
fitting environmental accessories is that operators are aware that if they wait until

xxi
xxii Introduction

use of same is forced upon them, retrofits of items such as flue gas desulphurization
cost as much as 300 percent more than installation with initial construction.
Process plant engineers will probably also have to run their own in-house power
plant at some point. They will have to manage interfaces with the power plant and
their main process facility. The power is primarily for their own needs, but they
frequently sell their excess power to the national grid. Even more interesting is the
fact that process fluids that would otherwise be waste can sometimes be used as
fuel. Examples include flue gas from a mining process used as a heat source and
waste biomass from pulp and paper production gasified to use for steam production
for running a steam turbine. In turn, waste heat from turbines is used for process
purposes. Excess steam from the heat recovery steam generator in the independent
power plant at Kuala Langat, Malaysia, is used in the owner’s neighboring mill.
Heat recovery schemes in Alberta, Canada, are being used to provide heat to
vegetable greenhouses.
This cooperative effort between power generation and process technology is
underlined by three major factors. First, the major oil companies, such as Shell,
Amoco, and Esso, are now actively involved in major independent power production
as a policy—the fuel they produce has a certain market as power production fuel.
Second, the drive toward environmentally economic technology to dampen the
strain on the world’s sagging natural resources has played a major part in
integrating the process engineer’s world with that of power production. Last but
not least, internal power production gives process engineers a much better handle
on avoiding the brownouts, fluctuations, and power cuts that an external utility
supplier can cause. They can also have the flexibility to use products within the
plant for “unusual” fuel when they work with manufacturers who will accommodate
their requirements. The contemporary competitive business environment is making
it much easier for an engineer to negotiate this adaptability from a manufacturer.
With this complex, mobile, and fascinating framework, know that one could never
fit representative information on everything a process engineer might need in one
volume. The compromise I have struck is to cover the basics succinctly and spend
effort on items that the process engineers I talk to and work with have very little
information on, but ask about all the time. Not surprisingly, these items can cost
the most in terms of cost per operating hour. Costs include lost production time,
machinery problems, troubleshooting efforts, useless expense in overdesigned
machinery condition monitoring systems, premature parts replacement, and power
supply problems.
Then there was the matter of highly specialized process sectors, such as pulp and
paper, agriculture, and food processing. This book hits the highlights with these
industries and others, and a specifications and standards section is provided for the
process engineer to use in conjunction with this book. All the common items in any
process industry, such as pumps, motors, couplings, controls, and so forth, are in
this book. As terminology for an item varies so much between industries, it is a
good idea to read through the Contents and the Index a few times to get the most
out of this book.
Last, but not least, although this book might be more for process engineers in
plant operations, I have included some design information where I felt it would
assist logic. Design and specification work gains from operations and maintenance
exposure.
Contents

Preface xi
Contributors xv
Introduction xxi

A A-1
ASME Specifications A-1
Abrasives A-1
Accident Management A-9
Accountability, Environmental (see Environmental Accountability)
Acid Rain A-9
Acoustic Enclosures, Turbine A-10
Actuators A-37
Aerfoils; Airfoils (see Metallurgy; Turbines)
Agitators A-38
Agriculture; Agricultural Product Processing A-48
Air Filtration; Air Inlet Filtration for Gas Turbines A-49
Air Pollution Control A-83
Air Purification; Air Sterilization A-101

B B-1
Balancing; Onspeed Balancing of a Rotor B-1
Balancing Problems, Troubleshooting (Turbomachinery) (see Condition Monitoring)
Batteries (see Cells)
Bearings B-1
Blades and Vanes (for a Turbine) (see Metallurgy; Turbines)
Boilers B-11
Borescopes B-11
Brakes B-11
Brick-Lined Process Equipment B-23
Briquette Machines B-28

C C-1
CAD/CAM C-1
CFD (Computational Fluid Dynamics) C-1
Carbon; Carbon-Graphite Mix Products C-7
Carbon Dioxide (CO2); CO2 Disposal C-13
Castings (see Metallurgy)
Cells C-22
Cement; Portland Cement C-22
Centrifuges C-34
Ceramics C-38

v
vi Contents

Chemical Cleaning C-38

Chemical Complex; (Petro)Chemical Complex; Chemical Plant C-38
Chemicals C-41
Chemicals (Toxic), Handling C-42
Chillers; Crystallizers; Chemical Separation Method; Alternative to Distillation/
Fractional Distillation C-62
Chimneys (see Stacks)
Cleaning C-78
Clutches (see Power Transmission)
Coatings (see Ceramics; Metallurgy)
Cogeneration C-78
Coker (see Oil Sands)
Color Coding C-81
Columns (see Towers and Columns)
Combustor(s); Low NOx Combustor (see Turbines)
Compressors C-81
Condensers C-233
Condition Monitoring (CM); Condition-Monitoring System(s) (CMS); Engine
Condition Monitoring (ECM); Engine Condition–Monitoring System(s) (ECMS) C-253
Control Regulators (see Actuators)
Control Systems; Controls C-331
Controls, Retrofit C-354
Conversion Tables (see Some Commonly Used Specifications, Codes, Standards,
and Texts)
Conveyors C-408
Coolant; Engine Coolant C-408
Coolers, Dairy C-412
Cooling; Cool, Products That (Air Conditioners); Liquid-Cooled Air Conditioners C-413
Cooling Towers C-423
Corrosion; Anticorrosion Coatings C-426
Couplings (see Power Transmission)
Crushers C-426

D D-1
Dampeners (see Pulsation Dampeners)
Desalination D-1
Dialysis; Electrodialysis D-2
Distillation; Fractional Distillation D-2
Diverter; Diverter Damper; Diverter Valve; Flapper Valve D-3
Doctor D-3
Drives D-3
Drum; Knock-Out Drum; Knock-Out Vessel (see Separators)
Drying D-4
Ducting; Ducting and Joints D-18

E E-1
ECM (Engine Condition Monitoring) (see Condition Monitoring)
ECMS (Engine Condition–Monitoring Systems) (see Condition Monitoring)
Ecological Parks; Industrial Ecological Parks E-1
Ecosystem E-1
Ejectors E-2
Electric Motors; Electric Motor Controls E-3
Emergency Power Generation (Packages) (see Engines, Gas)
Emissions; Air Emissions E-36
Engines, Gas E-38
Environmental Accountability E-40
 Contents vii

Environmental Air Monitoring (see Emissions)

Environmental Economics E-49
Evaporative Coolers (see Chillers; Coolers, Dairy)
Exhaust Stacks (see Stacks)
Exhausters, Centrifugal Gas E-56
Expansion Joints E-57
Explosion; Explosion Hazard Analysis; Explosion Hazards E-67
Extraction, Liquid-Solid E-87

F F-1
Fans, Centrifugal F-1
Filters F-5
Flare Stacks F-12
Floating Covers F-12
Fluidized Bed F-12
Forest Products F-12
Fuel Gas Conditioning System(s) F-24
Fuel Systems; Fuel Flow Control F-29
Fuels, Alternative; Fuels, Gas Turbine F-37

G G-1
Gas Turbine Cleaning or Washing (see Turbines)
Gas Turbines (see Turbines)
Gearboxes (see Power Transmission)
Gears (see Power Transmission)
Generators; Turbogenerators G-1
Grinding (see Abrasives; Some Commonly Used Specifications, Codes, Standards,
and Texts)
Grinding Wheels (see Abrasives)

H H-1
Hazards (see Color Coding; Explosion; Some Commonly Used Specifications,
Codes, Standards, and Texts)
Heat Exchangers H-1
Heat Pumps; Heat Pumps, Geothermal; Heating Systems with a Renewable Energy
Source H-1
Heat Treatment (see Metallurgy)
Heaters, Electric H-6
High-Speed Drive Systems (see Power Transmission)
Hot Isostatic Pressing (or HIPing) (see Metallurgy)
Hydraulic Filters (see Filters)

I I-1
Industrial Ecological Park (see Ecological Parks)
Industrial Ecology (see Ecological Parks)
Inlet Ducts and Silencers (see Acoustic Enclosures, Turbine; Air Filtration; Ducting)
Instrumentation (see Condition Monitoring; Measurement)
Insulation (see Some Commonly Used Specifications, Codes, Standards, and Texts)
Irradiation, Food Product I-1

L L-1
LCA (see Life-Cycle Assessment)
LNG (see Liquid Natural Gas)
Laser Cutting, Drilling, Machining, Welding (see Metallurgy)
viii Contents

Life-Cycle Assessment (LCA) (of Turbomachinery) L-1

Liquid Eliminators (see Separators)
Liquid Natural Gas (LNG) L-21
Lubrication L-24

M M-1
Magnetic Bearings (see Bearings)
Measurement M-1
Metallurgy; Metallurgical Repair; Metallurgical Refurbishment M-31
Metering, Fluids; Metering Pumps (see Fuel Systems)
Mist Eliminators (see Separators)
Mixers (see Agitators; Centrifuges)
Monitoring (see Condition Monitoring)
Motors (see Electric Motors)

N N-1
Noise and Noise Measurement (see Acoustic Enclosures, Turbine)
Noise Silencing and Abatement (see Acoustic Enclosures, Turbine)
Nondestructive Testing (FP1, MP1, X Ray) (see Metallurgy)
Nozzles N-1

O O-1
Oil Analysis O-1
Oil Sands; Synthetic Crude; Tar Sands; Shale O-1
Oxygen Analysis O-1
Ozone O-4

P P-1
Packaging P-1
Paper (see Pulp and Paper) P-1
Pipe (see Some Commonly Used Specifications, Codes, Standards, and Texts) P-1
Plastics P-1
Pollutants, Chemical; Pollutants, (from) Chemical Processes; Pollutant Indicators;
Pollutants, Toxic; Pollutants, Toxic Chemicals P-7
Portland Cement (see Cement) P-72
Power Production; Power Production In-House; IPP; SPP P-72
Power Transmission P-73
Pulp and Paper P-204
Pulsation Dampeners P-214
Pumps P-214

R R-1
Reactors; Chemical Reactors R-1
Refineries, Petroleum R-1
Refrigerant(s) R-10
Regenerator R-19

S S-1
Seals; Gas Seals S-1
Separators S-10
Snubbers (see Pulsation Dampeners)
 Contents ix

Stacks S-29
Steam Generator and Steam Supply S-38

T T-1
Tanks T-1
Temperature and Pressure Sensors (see Measurement)
Thermal Insulation (see Some Commonly Used Specifications, Codes, Standards,
and Texts)
Thin-Film Processors (see Chillers)
Torque Converters, Measurements, and Meters (see Power Transmission)
Towers and Columns T-40
Toxic Substances (see Pollutants, Chemical)
Transportation, of Bulk Chemicals, of Large Process Equipment T-40
Triple Redundancy T-41
Turbines, Gas T-43
Turbines, Steam T-76
Turbochargers T-112
Turboexpanders T-114

U U-1
Ultrasonic Cleaning U-1

V V-1
Valves (see Control Systems)
Vanes (see Metallurgy)
Vaporizers; Vaporizer Applications V-1
Vents and Flame Arrestors V-31
Vibration Measurement (see Condition Monitoring)

W W-1
Waste Heat Recovery (see Cogeneration)
Waste Management W-1
Welding (see Metallurgy)

Some Commonly Used Specifications, Codes, Standards, Texts Sp-1

Index In-1
 A
ASME Specifications

A list of specifications available from the American Society of Mechanical Engineers

is available in the section Some Commonly Used Specifications, Codes, Standards,
and Texts at the end of the book before the index. This list provides additional detail
on items that may not be covered in great depth here.

Abrasives

Abrasives is a term given to various materials with different physical formats (such
as aggregate, grains, shot, particles bonded with an adhesive, and so forth) that are
used to wear down surfaces to desired dimensions or surface finishes or for some
other purpose. They may be used in their “raw” state, such as with shot or glass in
shot or glass-bead peening operations. Or they may be used in conjunction with
adhesives and fillers to make belts, wheels, and tool surfaces.
Sometimes peening operations address more than surface finish. Glass-bead
peening has been used to add a compressive stress layer to the surface of gas-
turbine compressor wheels to bring the net tensile stress level down to tolerable
levels. As alloy metallurgy improved, machinery component operation totally under
the stress endurance curve was possible, and such applications were phased out.
They are worth mentioning, however, as they can contribute to puzzling failure
modes if they are wrongly applied during design or repair and overhaul.
Abrasives may also be combined with adhesives to make grinding wheels, belts,
or other components for precision grinding in sophisticated manufacturing or repair
machinery such as a blade-tip grinder. A blade-tip grinder is basically a combination
of a grinder and a computer or some form of computer numerical control (CNC) that
is used to grind airfoil blade tips to arrive at precise turbine-wheel-assembly
dimensions.
Product improvements now have produced superabrasives for high-precision
processes that are generally used in conjunction with CNC and computer-aided
design/computer-aided manufacturing (CAD/CAM) programming and equipment.
Different types of grinding materials allow larger depths of cut (decreased work
time) with less metallurgical workpiece (heat soak) damage. This lowers overall
production costs.
In the continued drive for improved environmental impact in production, some
companies are using water coolants rather than oil coolants.
The applications of abrasives in process technology are too numerous to mention;
however, some basic information on the common facets of abrasives in various states
and process formats follows. Sources are as acknowledged.

CNC Applications*
Precision-plated grinding wheels are now replacing standard wheels (that use
adhesive bonding with abrasive grit) in some applications. These are suitable for

* Source: Abrasive Technology, Inc., USA. Adapted with permission.

A-1