Search Results for: Heat Transfer Data book

A COMPILATION OF COVER STORIES AND FEATURED REPORTS GUIDEBOOK- 2017

Chemical Engineering’s Feature Reports provide concise, factual information that aids in solving real problems. The practical, how-to orientation of these articles ensures that they can be directly applied to chemical engineers’ daily jobs. Each story applies to a relatively broad section of the chemical process industries as opposed to focusing on just one niche.

Cover Stories provides concise, factual information that aids in solving real problems. The practical, how-to orientation of these articles ensures that they can be directly applied to chemical engineers’ daily jobs. Each article applies to a relatively broad section of the chemical process industries as opposed to focusing on just one niche.

All 2017 articles are compiled into this one convenient location.

Delivered in a PDF format, 239 pages.

Articles include:

Overcoming Corrosive Processes with High-Alloyed Stainless Steels
Advanced high-alloyed stainless steels with austenitic properties can address corrosion concerns in challenging phosphoric and nitric acid processes

What’s Corroding Your Control Room?
Corrosion-induced failures are frequent in the electronics products used in control rooms, but proper environmental assessment, control and monitoring can help abate these concerns

High Purity Chemicals: Processing Equipment Essentials
Some practical tips regarding the design and fabrication of piping systems and equipment for high-purity applications are presented here

Heat Exchanger Standards for Shelland- Tube Equipment
Reliable operation of shell-and-tube heat exchangers begins with an appropriate standard. This article provides an overview of those that are applicable

Special Flange Joints Used in Floating-Head Shell-and-Tube Heat Exchangers
Single-pass, floating-head heat exchangers are common in certain process operations, but they often use flange joints that are not covered in existing design codes. Design details, advantages and disadvantages of the different options are discussed here

A Primer on Compressor Design
From initial conceptualization to final calculation, designing compressors requires not only engineering intuition and robust simulation tools, but also a bit of creativity

Control Engineering for Chemical Engineers
Chemical engineers who are aware of process control requirements and challenges are in a position to improve
process designs

Eye Protection, Part 1- Beyond Basic Eye Safety. How to protect, preserve and enhance workers’ safety

Eye Protection, Part 2- How to Avoid Fogging, A look at the hidden dangers of lens fogging and how to prevent them

Batch Drying With Vacuum Contact Dryers
Drying is a demanding unit operation where solvents need to be removed without altering product chemistry. Vacuum dryers are essential pieces of equipment for accomplishing this task

Optimizing Analysis for Spray-Drying
Precise control over spray-drying processes can be enabled by modern measurement approaches that provide information on particle size and shape in realtime

Crossflow Membrane Filtration Essentials
Several aspects of crossflow membrane filtration , including process design, equipment selection and control, are detailed here

Gas-Phase Filtration Media Properties: What to Know
There are many physical properties that can impact the ultimate performance of adsorbent media in gas-phase filtration applications

Implementing an ‘Integrity Operating Window’ Program
An effective Integrity Operating Window (IOW) program — which establishes safe operating limits and acceptable limits of process variation before an asset begins to degrade — can help operators stay ahead of potential repairs and reduce risk

Storage Tanks: Heating and Cooling System Design
Various heating or cooling options are described here, along with the factors and design parameters that need to be considered. A sample calculation regarding coils is included

Practical Solutions to Modular Project Execution
Follow this guidance to improve results on capital projects

Getting the Most from Severe Service Valves

Severe service valves (SSVs) differ from general purpose valves in important ways. Presented here is guidance on how to increase service life, reduce costs and improve safety and environmental performance of SSVs

Activated Carbon: Fundamentals and New Applications
Activated carbon sorbents are important tools in water purification and air-pollution control. This article provides information on the fundamentals of this diverse sorbent and on new applications for which it is being employed

Rupture Discs: Effectively Minimize Leaks and Emissions
When installing rupture discs, there are several mechanical and operational considerations for reducing the likelihood of leaks and fugitive emissions

Proper Sizing and Installation for Steam System Safety Valves
Successful operation of safety valves in steam systems requires careful adherence to established industry standards for installation and design

Reboiler Circuit Debottleneck with No Hardware Changes
With a thorough investigation and proper problem diagnosis, an entire gas plant limited by a deethanizer reboiler circuit was successfully debottlenecked

Dry-Tray Pressure Drop of Sieve Trays Revisited
Data points from literature are refined into a single correlation defining dry-tray pressure drop in sieve trays

Mixing: Impeller Performance in Stirred Tanks
Characterizing mixer impellers on the basis of power, flow, shear and efficiency

Drones Take to the CPI Skies
Drones are quickly entering the chemical processing space as more companies begin to embrace their use for inspection and monitoring tasks

Odor Issues and Solutions for Wastewater Treatment
Increasingly, wastewater treatment plants must address odors due to volatile contaminants. This guide provides an overview of odor causes and possible remedial actions

Smart Water- Management Strategies: The Time is Now
Considering water-management strategies as a central component of infrastructure design at industrial facilities will unlock cost savings throughout the operation

Feeder Design for Solids Handling
Processes involving the movement of bulk solid materials require careful consideration of the feeder equipment design, including how the feeders work with various bins and hoppers

Choosing Agglomeration Equipment- Part 2
A product’s intended use often dictates what type of agglomeration equipment should be used. Presented here is a discussion of the main types of equipment and methods for forming agglomerates

Valves: Emissions Standards and Current Practices
New industry standards aimed at reducing fugitive emissions have necessitated updates to valve-testing procedures and a renewed focus on high-performance sealing and packing technologies

Minimizing Leakage on Heat- Exchanger Girth Flanges
Thermal distortion in heat-exchanger internal components can lead to leakage, but several design measures can be taken to mitigate these concerns

Confronting Crystallization Issues
Reliable information about industrial crystallization can be difficult to find and to apply to new situations. The work
process outlined here will help engineers approach crystallization challenges

Cooling Towers: Keeping Your Power Plant Cool
General guidelines for selecting the appropriate power-plant cooling system are presented here

Powder and Bulk Solids Handling: Particle Size and Distribution Analysis
The size and size distribution of particles are important determining factors in the design and operation of many process operations involving dry particles and powders. Follow this guidance to understand the impact of these key characteristics

Cost Engineering Integrating Technology and Economics
The Process Synthesis Model presented here is a methodology that integrates technology and economics, thereby improving process design and reducing costs

Decommissioning: Preparing Plants for a Retrofit
As technologies advance and market challenges continue to pose new pressures for operators, the decommissioning and retrofitting of facilities is inevitable. This article provides guidance on how to tackle projects of this nature safely and efficiently

Cost Engineering Time Value of Money
Deciding whether to put a project on the fast track entails risks. Some observations are presented here to help minimize risks and maximize profits

 

Feature Reports Compilation Guidebook – 2018

Chemical Engineering’s Feature Reports provide concise, factual information that aids in solving real problems. The practical, how-to orientation of these articles ensures that they can be directly applied to chemical engineers’ daily jobs. Each story applies to a relatively broad section of the chemical process industries as opposed to focusing on just one niche.

All 2018 articles are compiled into this one convenient location.

Delivered in a PDF format, 194 pages.

Articles include:

Taking Representative Samples in Solids-Handling Processes
Non-representative sampling in solids processes has costly consequences. A better understanding of the mathematical basis for sampling and of acceptable quality levels can help to alleviate potential sampling issues and more closely approximate reality

Preventing Flow Stoppages in Powder Handling Processes
Predicting powder flow behavior is important to successful solids-handling processes. Provided here is a review of shear-cell testing and how the technique can be used to
predict arching, ratholing and other behaviors

Effective Agitator Operation and Maintenance
Agitators play key roles in chemical processing. Their proper operation and maintenance can improve process reliability, leading to reduced downtime and costs

Maintaining heat-transfer-fluid quality

PVDF: A Fluoropolymer for Chemical Challenges
When it comes to selecting materials of construction, keep in mind the favorable properties of fluoropolymers for corrosive service

Integrity of Aging Assets: Using Corrosion Data to Stave Off Extinction
Petroleum refineries built in the 1960s and 1970s have trouble dealing with the corrosive effects of modern feedstocks. Continuous monitoring of corrosion can prevent
process equipment failures

Recent Air Regulations: Impact on Turnaround Vapor Deinventory Strategies
With the onset of new environmental regulations, turnaround teams must look to temporary vapor-control strategies to ensure compliance during non-routine operations

Pitfalls to Avoid When Generating Cost Estimates
The pitfalls in cost estimating that cause project overruns have been well known for decades, yet they continue to plague the CPI

Distillation, Part 1: Experimental Validation of Column Simulations
A practical look at the need for validation, as well as conceptual considerations and a case study

Distillation, Part 2 Bubble-Cap Tray Vapor Turndown
The concept of tray stability can apply to bubble caps and be used as an alternative method to determine the minimum efficient capacity of these devices. A new stability
correlation for bubble-cap trays is proposed and checked against FRI data

Single-Use Gloves: Problems and Solutions
When wearing single-use protective gloves, sweat can create health and safety issues. Presented here is a look at the causes of the problems and possible solutions

Process Commercialization: The Kirkpatrick Chemical Engineering Achievement Award

The Road to Commercialization: Best Practices
Experts share their best practices in process commercialization

Enclosed Combustion Equipment and Technology
A thorough understanding of enclosed combustion technologies will help engineers to select the proper equipment to balance emissions-control performance with
efficiency, costs and complexity

Pump Sizing and Selection Made Easy
Viscosity, power consumption, commercial availability and lifecyle cost analysis are all important considerations in pump sizing. An automated spreadsheet method helps
engineers take those factors into account in centrifugal pump selection

Photochemical Processes in Stirred Tank Reactors
A general overview of industrial photochemistry and the design of large-scale stirred-tank photochemical reactors

Performance Prediction for Industrial Boilers
Understanding boiler performance calculations can allow engineers to improve the operation of their facility’s steam system and better engage with boiler-system vendors

Steam Balancing: The First Step in Steam Optimization
The ability to achieve an optimal steam balance can help to improve the overall thermal cycle efficiency of any steamproduction system

Rotating Machines: Digital Technologies to Enable Predictive Maintenance
Predictive maintenance for rotating machinery is gaining prominence as plant operators embrace analytics and learn how to approach their operating benchmarks

Guidelines for Designing a Compressed Air System
With the proper knowledge, engineers can work alongside compressor manufacturers to ensure that an optimal air compression system is installed

Pressure-Relief System Design: Developments and Deficiencies
Areas of recent activity for pressure-relief systems include new calculation methods and updates to existing codes and standards. Included here is an
overview of recent developments and a look at the results from a recent study of pressure-relief system deficiencies and solutions

Sizing Pressure-Relief Valves for Two-Phases
Several methods are available for sizing two-phase pressurerelief valves (PRVs). Here, the API 520 homogeneous direct integration method is compared to a potentially simpler alternative that does not require integration

Precision Grouting: Setting the Foundation for Equipment Reliability
A clear understanding of grout material properties is important to ensure that equipment is effectively protected against vibration and misalignment

Torque Limiter Technologies for Rotating Machinery
Torque overloads can cause serious problems for rotating machinery, but an understanding of torque limiting technologies can help engineers to enable more reliable
operations

Best Practices in Capital Equipment Commissioning
Ensuring that real-world commissioning tests are properly executed can benefit both equipment end users and suppliers

Commissioning and Startup: Increase Certainty Through Advanced Planning
Taking commissioning and startup into consideration during the early design phase can result in more predictable project schedules and more robust equipment designs

Wireless Monitoring for Pressure Relief Systems
New diagnostic devices can identify when pressure incidents happen, while keeping an eye on the condition of pressure-relief valves and rupture disks

How to Troubleshoot and Maintain Pressure Regulators
Following a five-step process enables better outcomes for fluid system control

Experimental Methodologies to Verify Distillation Simulations
Presented here are practical considerations concerning the equipment and methods used for experimental verifications of simulations

Avoid Common Mistakes When Specifying Burner Management Systems
While some aspects of burner management systems may seem intuitive, overcoming misconceptions in their specification and design will help to elevate overall safety

Reduce Risk and Cost with a Lifecycle Approach to Process Safety
Better upfront planning and management can lead to safer, more productive processes throughout every phase of operation

Treating Boiler Feedwater for Reliable Operation
These key elements of internal boiler feedwater (BFW) treatment will help avoid boiler tubefailures due to scale and pitting

Microbial Control in Cooling Water
Three chlorine-based strategies for controlling microbial load in industrial cooling water are evaluated here

Minimizing Corrosion and Fouling: Volume 2 — Equipment-Specific Best Practices

Volume two of this Chemical Engineering guidebook series addresses corrosion issues pertaining to a range of widely used chemical process equipment.
Articles focus on aboveground and underground piping systems. Guidance is provided on how to assess corrosion non-invasively and how mitigate corrosion damage to reduce the likelihood of system failure or leakage.
The merits of polymer-based piping, and piping made from fiberglass-reinforced polymers are profiled, with focus on strategies for managing corrosion under piping insulation. You will find practical guidance for addressing corrosion-related issues associated with heat exchangers, membrane-based systems used in water treatment, valves, underground and aboveground storage tanks, condensate systems, heaters, and glass-lined reactors. These engineering tutorial-style articles were originally published in Chemical Engineering.
107 pages, delivered as a PDF guidebook.

Table of Contents

Facts at Your Fingertips: Acid Storage
Facts at Your Fingertips: Controlling Membrane Fouling
Facts at Your Fingertips: Wet Scrubbers
Preventing Tank Corrosion: Why a Tank’s Coating Application Process Makes all the Difference
Silo Design and Selection: Materials, Construction Methods, Installation Consideration and Other Design Criteria
Tank Coatings: Covering the Basics of Selection and Specification
Compact Heat Exchangers: Improving Heat Recovery
Controlling SO2 Without Corroding the Bottom Line
Maintenance and Repair of Glass-Lined Equipment
The Shotgun Approach: Removal of Fouling Deposits on Heat Transfer Surfaces in
Coal-Fired Process Heaters & Boilers
Heat Exchangers for Hot Acids: Material Selection
Compact, High-efficiency Heat Exchangers: Understanding Fouling
Corrosion in Flexible Burner Hoses
Don’t Overlook Composite FRP Pipe
Direct-Fired Heaters: Evaluate Thermal Performance and the Effects of Fouling
Valves & Specialty Metal Materials
Industrial Insulation Systems: Material Selection Factors
Strategies for Controlling Membrane Fouling
CPVC Piping In Chemical Environments: Evaluating the Safety Record
Polymer-Based Piping Systems in the CPI
Cracking Down On Corrosion
Improving Pipeline Safety
How Do Your Tanks Measure Up?

FOR YOUR EYES ONLY: Please do not forward the PDF file. It’s against the law to copy, fax, or electronically transmit the newsletter without our permission.

For group subscription information and discount pricing, contact Sarah Garwood at [email protected] or 301-354-1705.

Heat Exchanger Fouling- Mitigation and Cleaning Technologies

This handbook presents, now in the 2nd completely worked over and enlarged edition, the most important technologies concerning the reduction of fouling in heat exchangers beginning with constructional disposition, prevention measures and the appropriate technologies of removal and cleaning. It is an instructive adviser for engineers, maintenance managers and their staff, as well as technical managers.
The authors are experts of involved companies and institutions from the European and American industries.
Delivered in a PDF format.
FOR YOUR EYES ONLY: Please do not forward the PDF. It’s against the law to copy, fax, or electronically transmit without our permission. For group subscription information and discount pricing, contact Sarah Garwood at 301-354-1705.

For inquiries, please contact our Client Services Department at [email protected], (888) 707-5812 inside the United States or 1-301-354-2100 outside of the United States.

Managing Air Pollution — Volume 2: Eye on Combustion and High-Temperature Operations

This Chemical Engineering guidebook contains tutorial-style engineering and “Facts at Your Fingertips” articles. The collection of practical, how-to pieces provides engineering guidance on an array of topics related to monitoring and managing vapor and particulate emissions that can arise during chemical process operations involving high temperatures and combustion.

Several articles provide guidance for reducing or managing fugitive emissions from burners, combustion units, and flares and other process equipment. Others offer support on protective equipment for personnel, and tips for understanding environmental regulations.

The articles were originally published in Chemical Engineering magazine, from 2012 through 2017. This Guidebook is part of a 2-Volume Set; Volume 1 — entitled “Managing Air Pollution: Eye on Fugitive Emissions and Dust Explosions” — is sold separately.

Delivered in a PDF format. 126 pages.

Articles Include:

Flare Selection for the CPI- 4

There are many factors to consider when selecting a flare system for CPI sites that can impact safety, operating costs and environmental performance

Key Considerations for the Use of Portable Gas Detectors- 8

Recent advances in gas-monitoring technologies can greatly increase worker connectivity and safety

Advanced Control Methods for Combustion-11

Advanced control techniques can raise efficiency and lower pollutant emissions in industrial combustion. The capabilities and adoption of several methods are discussed

Engineering for Plant Safety- 17

Early process-hazards analyses can lead to potential cost savings in project and plant operations

Eye on Flare Systems- 26

Proper gas sampling is essential to meet operating and regulatory objectives

Cooling Towers: Estimate Evaporation Loss and Makeup Water Requirements- 30

Applying mass and energy balance calculations yields critical operating insight

Gas Detention-34

Gas Hazard Definitions and Data-35

Wet Scrubbers- 36

Flare Consolidation Considerations- 37

Consolidating multiple flares can help mitigate emissions and maintenance

Enclosed Combustion Equipment and Technology- 40

A thorough understanding of enclosed combustion technologies will help engineers to select the proper equipment to balance emissions-control performance with efficiency, costs and complexity

Cooling Towers: Water-Treatment Options Advance- 44

Water-treatment programs for cooling towers have evolved in recent years, favoring non-phosphorus programs today. This article reviews the impact on water chemistry and operating reliability

Performance Prediction for Industrial Boilers- 50

Understanding boiler performance calculations can allow engineers to improve the operation of their facility’s steam system and better engage with boiler-system vendors

Post-Combustion Carbon Capture Technologies- 58

Several CCS processes hold much promise, and there are challenges yet to be met

Industrial Combustion Products- 62

The Value of Safety Instrumented Systems- 63

A safety instrumented system (SIS) is important to ensure the safe operation of a plant. The SIS requires up-to-date sensors — recent developments in vortex flowmeters are presented here

Flare-Gas Recovery Methods for Olefin Plants- 65

Adding flare-gas recovery units at strategic locations of an olefin plant can not only reduces emissions, but will save money as well

Key Questions to Guide Effective Selection of Personal Protective Equipment- 70

Armed with a proper understanding of chemical exposure risks and available safety solutions, engineers can be confident in selecting the best personal protective equipment to provide reliable barriers to workplace hazards

Burner Inspection and Maintenance- 74

Burners and their components can be quite complex. Establishing maintenance and inspection best practices encourages long-term operational reliability

Process Safety and Functional Safety in Support of Asset Productivity and Integrity-80

Approaches to plant safety continue to evolve based on lessons learned, as well as new automation standards and technology

Considering Fugitive Emissions During the Conceptual Design Stage- 85

The ability to reduce fugitive emissions through the use of strategic design modifications not only protects workers and the environment, but reduces losses of valuable process materials

Best Practices in Capital Equipment Commissioning-92

Ensuring that real-world commissioning tests are properly executed can benefit both equipment end users and suppliers

Commissioning and Startup: Increase Certainty Through Advanced Planning- 100

Taking commissioning and startup into consideration during the early design phase can result in more predictable project schedules and more robust equipment designs

Optimizing Flare Operation Through Proper Design- 105

Flare problems are often caused by the seal systems that are designed to control air ingress. Follow these troubleshooting guidelines to improve design and ensure safe, reliable flare operation

Improve Energy Management to Reduce Your Facility’s Carbon Footprint- 111

This article describes an approach that uses data analytics for finding and addressing root causes of process deviations that reduce energy efficiency in key plant utility systems, and shares three case examples

Avoid Common Mistakes When Specifying Burner Management Systems-115

While some aspects of burner management systems may seem intuitive, overcoming misconceptions in their specification and design will help to elevate overall safety

Reduce Risk and Cost with a Lifecycle Approach to Process Safety- 120

Better upfront planning and management can lead to safer, more productive processes throughout every phase of operation

Co-located Facilities: Untangling Environmental Compliance, Liability and Accountability Issues- 123

When multiple operators, co-owners, co-operators and third party contractors are all managing different engineered systems at the same location, extra care is needed to manage potential environmental issues that may arise

MINIMIZING FOULING AND CORROSION: Improved Processes and Practices- Volume Two

Minimizing Fouling and Corrosion — Volume 2: Improved Processes and Practices
The fight against corrosion and fouling is a never-ending battle for process operators throughout the chemical process industries (CPI). The articles in this Chemical Engineering Guidebook provide a wealth of practical engineering recommendations and best practices for effective corrosion monitoring and prevention in various types of CPI equipment components and systems.
Several topics focus on troubleshooting and inspection as well as provide tips for identifying and rectifying corrosion-related issues during plant revamps.
Articles center on selecting the most appropriate material of construction to withstand exposure to corrosive media. Also provided are tips for proper selection, handling and storage of acids, addressing fouling- and corrosion-related issues in cooling towers, filtration systems, wastewater-treatment plants and more.
This volume shares a wealth of maintenance, risk-reduction and reliability strategies.
238 pages, delivered in a PDF format.
 Articles Include
Cooling Towers: Managing Tighter Water-Discharge Regulations
• Tightening regulations for cooling tower water discharge quality are requiring plant engineers to evaluate enhanced treatment options, sometimes including zero-liquid-discharge systems
Engineering for Plant Safety
• Early process-hazards analyses can lead to potential cost savings in project and plant operations
Cooling Towers: Estimate Evaporation Loss and Makeup Water Requirements
• Applying mass and energy balance calculations yields critical operating insight
Non-chemical Water Treatment
Overcoming Corrosive Processes with High-Alloyed Stainless Steels
• Advanced high-alloyed stainless steels with austenitic properties can address corrosion concerns in challenging phosphoric and nitric acid processes
What’s Corroding Your Control Room?
• Corrosion-induced failures are frequent in the electronics products used in control rooms, but proper environmental assessment, control and monitoring can help abate these concerns
Preventing Tank Corrosion
• Why a tank’s coating-application process makes all the difference
Plant Revamps and Turnarounds: Some Lessons Learned
• Although time is always precious, taking shortcuts and skipping standard procedures can be costly
Common Mistakes When Conducting a HAZOP and How to Avoid Them
• An important part of ensuring the success of a HAZOP study is to understand the errors that can cause the team to lose focus
The Relationship Between Materials Selection and Machining Processes
• An awareness of the impact of materials selection on the machining processes for small, complex components can affect overall end-product quality and costs
Corrosion Resistance Using Rock and Glue
• Low-cost, corrosion-resistant castings are being produced using epoxy and mineral aggregates
Pressure-Vessel Quality Control Requirements
• Understanding what is required for boiler and pressure-vessel manufacturers can help scheduling and cost assessments
Process Hazards Analysis Methods
Internal Corrosion Sampling
• Proper sampling and handling procedures are critical for supporting corrosion-management decision making
A New Approach to Corrosion Monitoring
• The impact of corrosion on assets and processes is great. Advances in technology allow engineers to assess corrosion in a whole new way, with real time monitoring and the ability to link deterioration with process conditions
Filtration and Separation During Chemical Process Operations: Avoid Common Errors
• The seven commonly made mistakes discussed here often lead to poor filtration and separation performance and many associated problems
Materials Selection in The CPI
• An overview of the many factors to be considered when selecting materials of construction
Field Troubleshooting 101 and How to Get the Job Done
• A major part of field work lies in troubleshooting problems: finding out why a system is not operating the way it is intended. This article provides guidelines for effective troubleshooting and contains many practical examples of their successful use
Why Bad Things Happen to Good Steam Equipment
• Accounting for an entire steam-trap population is crucial to avoiding safety incidents and suboptimal production — high-priority consideration must be given to steam-system management
Steel Corrosion
Materials Management — Evolving the Process for an Evolving Marketplace
• The case examples presented here show that proper planning, communication and execution of tasks can add value and reduce unintended negative consequences for many capital-intensive projects
Understanding New PPE Regulations
• The new European Union Personal Protective Equipment (PPE) Regulation explained, and what it means for the chemical process industries
Five Steps to Replacing Aged Heat-Transfer Fluid
• Follow these guidelines to help ensure efficient operation of heat transfer systems, and proper exchange and disposal of aged fluids
Beware of Flow- Accelerated Corrosion
• Operators of steam-generating systems should understand flow-accelerated corrosion and the potential problems it can cause
Corrosion in Flexible Burner Hoses
• Special care must be taken to avoid corrosion in flexible hoses for burners. This failure analysis illustrates the mechanism and provides recommendations
Performance Trends of Top Performers in the CPI
• Focusing on a ‘reliability culture,’ mechanical availability and optimum costs leads to top performance
Integrated Risk-Management Matrices
• An overview of the tools available to reliability professionals for making their organization the best-in-class
Implementing an ‘Integrity Operating Window’ Program
• An effective Integrity Operating Window (IOW) program — which establishes safe operating limits and acceptable limits of process variation before an asset begins to degrade — can help operators stay ahead of potential repairs and reduce risk
Storage Tanks: Heating and Cooling System Design
• Various heating or cooling options are described here, along with the factors and design parameters that need to be considered. A sample calculation regarding coils is included
Burner Inspection and Maintenance
• Burners and their components can be quite complex. Establishing maintenance and inspection best practices encourages long-term operational reliability
Safety in Sulfuric Acid Storage Tanks
• Commonly used in the CPI, sulfuric acid requires many special precautions to ensure its safe handling and storage
Large-Scale Fermentation Systems: Hygienic Design Principles
• Follow these tips to optimize systems that use microbial fermentation to produce biochemicals and biopharmaceuticals
Sampling for Internal Corrosion
Piping Codes: What the CPI Engineer Should Know
• An overview of the codes and standards that are most pertinent to chemical processing facilities
Coupler Technologies for Secure Chemical Handling
• Significant improvement in reducing fluid loss, optimizing flow paths and easing operation are among the advances in next-generation coupler technologies
Treating Wastewater for Industrial Reuse
• Secondary treated wastewater from municipal plants can be a water resource for industry. Important water characteristics and treatment options are discussed
Advantages Gained in Automating Industrial Wastewater Treatment Plants
• Process monitoring and automation can improve efficiencies in wastewater treatment systems. A number of parameters well worth monitoring, as well as tips for implementation are described
Odor Issues and Solutions for Wastewater Treatment
• Increasingly, wastewater treatment plants must address odors due to volatile contaminants. This guide provides an overview of odor causes and possible remedial actions
Strategies for Controlling Membrane Fouling
• In water treatment, the bulk solution, concentration polarization, permeate flux and membrane properties are some of the parameters that can be influenced
Modern Water-Treatment Challenges
• LNG and other facilities that are expanding due to the shale gas boom face specific challenges when it comes to ensuring the purity of the inlet and outlet water
Challenges of Drying Sticky Wastewater Sludge
• In wastewater-sludge drying and dewatering operations, many issues arise from the sticky properties of the sludge. Here are some insights to address them
Troubleshooting Tube-Deterioration Mechanisms in Direct-Fired Heaters
• A practical step-by-step guide for reducing future tube failure

Managing Steam: Volume 1 — Best Practices for Producing and Using Steam

Volume one of this two-part PDF guidebook series contains tutorial-style articles, originally published in Chemical Engineering.
Included are recommendations on how to produce and use steam in the most cost and energy efficient way. Several articles focus on traditional boiler-based systems for producing steam, and best practices for generating steam using integrated cogeneration facilities (which produce both steam and power for the end user).
Guidance is provided on properly interpreting and using ASME pressure vessel code and ASME boiler code to guide each engineers decision making. Also discussed are the requirements and challenges of systems that capture waste heat from fluegas as a key energy source to produce steam for use onsite. Numerous articles cover key operational challenges related to managing steam traps, water hammer and corrosion.

Delivered in a PDF format. 102 pages.

Table of Contents

Section 1- Traditional Steam Production

Facts at Your Fingertips: Steam generator operation and thermodynamics
Applying ASME Boiler Code to Steam Generation Systems
Decoding Pressure Vessel Design
Dynamic Modeling for Steam System Control
Handle Steam More Intelligently
Steam Management: Don’t Send Money Down the Drain
Steam Generation Thermodynamics

Section 2- Producing Steam Via Waste-Heat Recovery and Combined Heat and Power Production

Boosting Energy Efficiency in Chemical Manufacturing: A Look at Cogeneration
Combined Heat and Power for the CPI: Modern Concepts
Waste Heat Recovery Methods and Technologies
Integrating Gas Turbines into CPI Facilities
Get the Most Out of Waste Heat
Recover Waste Heat From Fluegas

Section 3- Operational Issues: Managing Condensate, Corrosion and Steam Traps

Corrosion Control in Condensate Systems
Don’t Leave Steam-Trap Maintenance to Chance
The Number One Problem in Steam System: Water Hammer
Waterhammer in Condensate Return Lines
Wireless Diagnostics for Steam Traps
Beware of Flow-Accelerated Corrosion
The Importance of Intensive Steam Trap Management
Reboiler Condensate Drums: Silencing Hydraulic Hammer

FOR YOUR EYES ONLY: Please do not forward the PDF file. It’s against the law to copy, fax, or electronically transmit the newsletter without our permission.

For group subscription information and discount pricing, contact Sarah Garwood at [email protected].

Fluid Handling

CHAPTERS: Chapter 1. Pumps; Chapter 2. Valves; Chapter 3. Flowmeters and flow measurement; Chapter 4. Problem fluids and flow problems; Chapter 5. Pipeline issues; Chapter 6. Calculations and modeling; Chapter 7. Related topics

CHAPTER 1. PUMPS

Keeping centrifugal pumps battle-ready
Scott Boyson, A.W. Chesterton Co., Mech. Seals Div.

Consider hydraulic factors to reduce pump downtime
Allan Budris and R. Barry Erickson, ITT Industrial Pump Group; Francis Kludt and Craig Small, Celanese Ltd.

Avoid cavitation in centrifugal pumps
Mouafak Zaher, Unitec Applied Technology Institute

The relationship of vibration to problems in centrifugal pumps
William D. Marscher, Mechanical Solutions, Inc.

Keep gear pumps healthy
Hailin Zhu, Jiangsu Institute of Petrochemical Technology

Getting gear pumps up to speed
Al Moze and Mike Stevens, Liquiflo Equipment Co.

Installing and maintaining gear pumps
Kent Whitmire, Roper Pump Co.

Regenerative turbine pumps: Unsung heroes for volatile fluids
Bruce Wright, Roth Pump Co.

Selecting multiphase pumps
Allan J. Prang, Ingersoll-Dresser Pump Canada, Inc.

Pumping liquids loaded with dissolved gas
Daniel Wood, Flowserve Corp ., Robert Hart, and Ernesto Marra, DuPont Co.

Problem solving for high-energy pumps
Paul Cooper and Charles Heald, Ingersoll-Dresser Pump Co.

Determining sealing flowrates in horizontal run pumps
Alejandro Anaya Durand, Instituto Mexicano del Petroleo, and Mauricio Marquez-Lucero, National Autonomous University of Mexico

Choose the right vacuum pump
Joe Aliasso, Graham Manufacturing Co.

Selecting low-flow pumps
Christopher Poe, Tritech Technologies, and Ken Bonnell, Cole-Parmer Instrument Co.

High-pressure diaphragm pumps
Josef Jarosch, LEWA Herbert Ott GmbH

How fluid properties affect hydraulically balanced metering pumps
Donald B. Cameron, Pulsafeeder, Inc.

Pump installation: Penny pinch at your own risk
Perry c. Monroe Jr., Monroe Technical Services, Inc.

Repair grouting to combat pump vibration
Richard Myers, ITW Philadelphia Mixers

Nonmetallic sealless pumps: How to pick a winner
Erich Meyer, Vanton Pump & Equipment Corp.

What makes a pump for high-purity fluids?
Bruce Smith, Fristam Pumps, Inc.

A pump for high-value products
Thomas Heng, KSB Aktiengesellschaft

CHAPTER 2. VALVES

Avoid pitfalls when specifying control valves
R. Michael Bell, Stone & Webster Engineering Corp.

Heavy-duty control valves live long and prosper
Herbert Miller, CCI

Control valves: Match the trim to the selection
Ron Darby, Texas A&M University

Making the most of valves
John Frenck, Consultant

Control valve health certificate
Michel Ruel, TOP Control

Increasing longevity of valves
Nate Paxton, Worcester Controls Corp.

Predict control valve noise
George W. Page, Jr., H.D. Baumann, Inc.

A firm new handle on valve noise
Hans D. Baumann, Fisher Controls International, Inc.

Peering inside the low-noise valve
Hans Baumann, HB Services Partners LLC

Gain proportional control with solenoid valves
Andrew Harris, Burkert USA

How valve performance affects the control loop
Michel Ruel, TOP Control

Flow control with three-way valves
Neculae Baitz, Foxboro/Eckardt AG

Selecting clean valves
Mike Schmidt, Emerson Process Management

Specify the right-sized relief valve
Virginia Carillo, Whesso Varec., Inc.

Control the differential pressure on the PRV inlet line
Wing Y. Wong, WYWong Engineering

Using the ideal-gas specific-heat ratio for relief-valve sizing
Aubry Shackelford, Berwanger

For sampling, match the valve to the task
Edmond Ilg, Strahman Valves

CHAPTER 3. FLOWMETERS AND FLOW MEASUREMENT

Selecting the right flowmeter
James Pomroy, Fischer-Rosemount

Choosing the best flowmeter
Corte Swearingen, Cole-Parmer Instrument Co.

Choose the right flowmeter
Corte Swearingen, Cole-Parmer Instrument Co.

Evaluating flow-measurement choices
Deborah Lanaux, Occidental Chemical Co., and John Landsom, Rosemount

Metering high-purity fluids
Dan Gear and Tom O’Banion, MicroMotion, Inc.

Rotameters: Simplicity = utility
John Scheer, ABB, Inc.

CHAPTER 4. PROBLEM FLUIDS AND FLOW PROBLEMS

Alleviating unsteady-state flow headaches
Terrence Fay and Harold Loiterman, Lockwood Greene Engineers and Constructors

Take the mystery out of non-Newtonian fluids
Ron Darby, Texas A&M Univ.

Pressure drop for non-Newtonian slurries: A wider path
Ron Darby, Texas A&M University

Improved design practices for slurry piping
Stanley Grossel, Process Safety & Design, Inc.

Critical length helps calculate compressible flow
Italo H. Faina, Universidad Nacional de la Plata

Determing settling rates of particles
Ron Darby, Texas A&M University

Dealing with two-phase flows
Lawrence Daniels, AEA Technology

CHAPTER 5. PIPELINE ISSUES

Working the kinks out of piping design
Fred Bandel and Jeff Lawson, ProcessPlus

Approximating equations for pipe sizing
B.B. Gulyani, University of Roorkee

Select the optimum pipe size
Ronald W. Capps, Gulf Coast Consulting Group

Updated rules for pipe sizing
Alejandro Anaya Durand, Jorge Arroyo Boy, Joaquin Lastra Corral, Luis Ojeda Berra, Jose Suarez Trueba, Petro Villalon Brena, UNAM

Pipe design for robust systems
Michael Bussler, Algor, Inc., and Tony Paulin, Paulin Research Group

Correlate pressure drops through fittings – Part 1
Ron Darby, Texas A&M Univ.

Correlate pressure drops through fittings – Part 2
Ron Darby, Texas A&M Univ.

Save pipes from bursting with a compensator
Jack Boteler, Flowguard USA , and David Clucas, Flowguard Ltd.

The use of certified KR for rupture disks
Jeff Scoville, Oseco

Calculate pipeline flow of compressible fluids
T.W. Cochran, BASF Corp.

Keeping pipelines safe from harm
Brian Payne, EDM Services

Improving pipeline safety
Brian Payne, EDM Services

Selecting secondary containment piping
Anthony Palozzolo, Perma-Pipe, Inc.

Picking the best thermoplastic lining
Gary Dennis, Elf Atochem North America, Inc.

The case for flangeless plastic-lined pipe
John M. Kalnins, Dow Chemical Co. , and Nancy L. Lindley, Unistrut Corp.

Proper piping for vacuum systems
Loren Wetzel, Graham Manufacturing Co.

Understanding impedance heating
Fred S. Epstein and Gary L. White, Indeeco

Steam tracing keeps fluids flowing
Joseph Radle, Spirax Sarco, Inc.

Electric heat tracing — A better design path
Mitchell Todd, Nelson Heat Tracing Systems, Robert Ragno, Kvaerner Process

Keep piping insulation dry
Brent Cottingham, Refrigeration Concepts

CHAPTER 6. CALCULATIONS AND MODELING

Spreadsheet calculates critical flow
Sunil Kumar, Worley Engineering

Gas-flow calculations: Don’t choke
Trey Walters, Applied Flow Technology

CFD comes of age in the CPI
Nathalie Hamill, AEA Technology plc

Improve reactors via CFD
Vivek V. Ranade, Natinoal Chemical Laboratory (Pune, India)

Validate CFD results using process tomography
Gary Bolton, Industrial Tomography Systems

Maximizing simulation’s reach
Mark Broussard, Hyprotech Ltd.

CHAPTER 6. RELATED TOPICS

Avoid fatigue failures in reciprocating compressors
Yi Gong and Neville Wright, SVT Engineering Consultants Pty; CCWan, BHP Billiton

Gasket standardization: Why and how
Carl Jones, W.L. Gore & Assoc.

Automatic lubrication saves money
Heinz P. Bloch, Process Machinery Consulting

Minimizing Fire and Explosion Risk — Volume Two: Managing Process Plant Hazards

All chemical process plants that routinely handle fuels, chemicals, other potentially flammable and explosive fluids, and combustible dry powders have a risk of fire and explosions.
The proper identification of potential hazards, the use of proper engineering design strategies, and appropriate instrumentation and control systems can greatly reduce risk and help to minimize the damage in the aftermath of such an occurrence.
This Chemical Engineering Guidebook provides a variety of practical engineering articles to help facilities maximize safety and minimize the risk of fire and related damage to the facility and personnel.  Provided are tips for facilities to assess potential risks and take the necessary engineering steps to protect personnel and plant assets.
Articles focus on handling potentially explosive liquids and dry powders, operating vacuum systems, distillation systems, and more. Also included is proper tank and pipeline design guidelines.
This volume consists of several articles related to proper management of Material Safety Data Sheets (MSDSs) and selecting the right protective gear for plant personnel.
Delivered in a PDF. 200 pages.
Articles Include:
How to Handle Hydrogen inn Process Plants
    • Process-unit layout, piping, instrumentation/control and materials of construction are but a few of the technical issues requiring special attention during the design or retrofitting of process plants that use hydrogen as a raw material
A Checklist for Safer Chemical Batch Reactions
    • A good understanding of the reaction chemistry is needed for a safe process design
Designing Safer Process Plants
    • Several often-overlooked strategies to increase inherent safety are discussed here
Runaway Reactions: Ignore the Chemistry at Your Peril
    • Proper hazards testing is key to ensuring chemical process safety
Preventing Self-Heating and Ignition in Drying Operations
    • Incident investigation reveals that the most common root cause is lack of understanding
Engineering for Plant Safety
    • Early process-hazards analyses can lead to potential cost savings in project and plant operations
Designing Atmospheric Storage Tanks
    • Insights into the basics of process design of atmospheric storage tanks and an example of how to prepare a process datasheet are presented here
Gas Detection
Batch Drying With Vacuum Contact Dryers
    • Drying is a demanding unit operation where solvents need to be removed without altering product chemistry. Vacuum dryers are essential pieces of equipment for accomplishing this task
Dust Hazards
Chemical Protective Clothing
Gas Hazard Definitions and Data
Static Electricity Discharge and Fire Prevention
Clearing the Air About Respiratory Protection
    • Learn the basics about selection and regulatory compliance for these potentially life-saving devices
Eye-and-Face Personal Protective Equipment
    • Protecting the eyes and face in the workplace is imperative to preventing the estimated 10–20% of work-related eye injuries that result in temporary or permanent vision loss
Managing Compliant MSDSs and Labels
    • Compliant MSDS programs depend on inventory management, regulatory knowledge and consistent authoring
Design Safer Solids Processing Plants
    • This approach defines a systematic framework and points toward relevant sources in the public domain
Process Hazards Analysis Methods
Finding the Right Gloves to Fit the Application
    • There is a wide range of gloves available for hand protection on the job. Matching gloves to their chemical-resistance properties is one criterion for selection
Dust Control in the Chemical Processing Industries
    • The prevention of dust hazards in the CPI is integral to process-safety management — widereaching mitigation schemes must be implemented
Cybersecurity Defense for Industrial Process-Control Systems
    • Security techniques widely used in information technology (IT) require special considerations to be useful in operational settings. Here are several that should get closer attention
Piping Design for Hazardous Fluid Service
    • Extra considerations and precautions are needed beyond the requirements of codes and standards
Alarm Management
Prevent Combustible Dust Explosions with N2 Inerting
    • Targeted use of blanketing with inert gas offers an effective strategy for preventing combustible dust explosions in CPI facilities
Industrial Combustion Products
Pressure-Relief System Design: Developments and Deficiencies
    • Areas of recent activity for pressure-relief systems include new calculation methods and updates to existing codes and standards. Included here is an overview of recent developments and a look at the results from a recent study of pressure-relief system deficiencies and solutions
Insulating Heat-Transfer-Fluid Piping
NFPA 652: Standardizing Combustible Dust Standards
    • The latest NFPA standard applies to many industry sectors, and aims to address the fragmented nature of the industry-specific standards currently in place
Managing Material Safety Data Sheets in the Workplace
    • While regulatory agencies outline requirements for communicating chemical hazards, the format of compliance is up to the employer. Software tools can be helpful aids in meeting these requirements
Dust Explosions: Prevention & Protection
    • Understand what causes these disasters and then put these practical measures in place
Piping Design for Potentially Lethal Chemicals
    • Integrity and reliability are critical for piping and equipment that handle chemicals with extreme health hazards
Safety in Sulfuric Acid Storage Tanks
    • Commonly used in the CPI, sulfuric acid requires many special precautions to ensure its safe handling and storage
Dust Management in Bulk-Material-Handling Operations
    • Dust management can be divided into three main categories: prevention, containment and suppression. Understanding the key considerations for each can help bulk solids handlers arrive at an optimal dust control solution
Filter Aids
Preventing Dust Explosions
    • Risk management programs are critical for safe handling and processing of combustible dust as well as for OSHA regulatory compliance
Compressed Gases: Managing Cylinders Safely
    • Follow these recommendations to ensure the safe handling, storage and use of gas cylinders
Reduce Hazards in Process Vacuum Systems
    • Reduce explosion risks, and chemical and physical hazards, to ensure safer operation of vacuum pumps and related systems
Piping Codes: What the CPI Engineer Should Know
    • An overview of the codes and standards that are most pertinent to chemical processing facilities
Cybersecurity: You Cannot Secure What You Cannot See
    • Follow this guidance to understand today’s cybersecurity risk landscape and take the necessary steps to create a sound industrial control system cybersecurity program, including the development of a comprehensive, in-depth cyber-asset inventory
Tolerable Risk
    • While determined risk is generally well understood, tolerable risk can be the missing link to complete risk assessments
Vacuum Systems: Recommendations for Safe Operation
    • Follow this guidance to ensure that steam ejector systems, mechanical vacuum pumps and integrated vacuum systems are designed, operated and maintained to ensure process safety

Instrumentation (Volume 1): Controlling Temperature, Pressure, Level and Flow

Volume 1 of this 2-part guidebook contains useful “Facts at Your Fingertips” guide sheets, and practical, how-to engineering articles, all of which were originally published in Chemical Engineering. 
Proper selection, specification and use of instrumentation is essential for optimal operation of chemical process industries (CPI) facilities. The detailed engineering articles contained in Volume 1 of this 2-volume set provide guidance on monitoring and controlling several key process variables — pressure, temperature, level and flow, and several articles are provided on the appropriate measurement of pH, as well.
The engineering support on pressure monitoring focuses on the accurate measurement of low pressures, high pressures and overpressure, and several articles focus on the proper use of rupture disks and pressure-relief valves to manage high-pressure situations, too.
The guidance on temperature monitoring provides coverage of competing methods, including RTD sensors, remote infrared thermal sensors, thermowells and other analytical options.
Specific articles focus on addressing the challenges of temperature measurement in extremely cold climates. The articles on measuring flow focus on applications handling both fluids and bulk solids or particulate materials. 
Delivered in a PDF, 97 pages.
Table of Contents
Characterize Bulk Solids to Ensure Smooth Flow…………………………………………………………………………………………3To minimize problems associated with handling all types of bulk solids, engineers must adopt a systematic approach tocharacterizing the flow and mechanical properties of the materials under a variety of operating conditions
Stream Selection Assemblies For Analytical Instrumentation……………………………………………………………………….13Intelligent selection and specification help to assure getting representative, uncontaminated samples from multiple processlines to a shared analyzer
Extremely Low-Temperature Systems…………………………………………………………………………………………………………17Understanding the nuances of low-temperature engineering is key to safe and efficient operations
New Measurement Practices for Cold Climates……………………………………………………………………………………24Selecting the right pressure, temperature, flow and level meters and connection systems can help to eliminate the need forheated enclosures and sensing lines
Low-Pressure Measurement…………………………………………………………………………………………………………………….. 29
 
Avoiding Pressure Relief Problems……………………………………………………………………………………………………………. 30
pH Electrodes and Temperature Dependence…………………………………………………………………………………………….. 31
Infrared Temperature Measurement…………………………………………………………………………………………………………… 32
Selecting Two- and Four-wire Magnetic Flowmeters…………………………………………………………………………………… 33
Thermowell Installation……………………………………………………………………………………………………………………………. 34
Level- Measurement Device Selection……………………………………………………………………………………………………….. 35
Flowmeter Selection…………………………………………………………………………………………………………………………………. 36
Liquefied- Industrial-Gas Safety………………………………………………………………………………………………………………… 37
Level Measurement Devices……………………………………………………………………………………………………………………… 38
Fluid Flow………………………………………………………………………………………………………………………………………………… 39
Using Rupture Disks with Pressure Relief Valves………………………………………………………………………………………… 40
Managing Pressure while Pigging an Oil Pipeline………………………………………………………………………………………. 41Pressure control valves can manage pressure in oil pipelines, but pigging the line presents a challenge
Vessel Sizing and Level Instrumentation……………………………………………………………………………………………………..43When sizing process vessels, it is important to consider instrumentation. Consistent, safe and reliable results depend on it
Remote Thermal Sensing……………………………………………………………………………………………………………………………48By making it easy to detect heat anomalies, thermal cameras and infrared thermometers support preventive and predictivemaintenance
Pressure-Vessel Quality Control Requirements……………………………………………………………………………………………53Understanding what is required for boiler and pressure-vessel manufacturers can help scheduling and cost assessments
INFRARED TEMPERATURE MONITORING: Know the Right Questions to Ask………………………………………………..61The infrared approach is especially useful in situations where process temperatures are extremely high, the target is inmotion, and the need to avoid contaminants is significant
Advances in Process Temperature Measurement: Trends and Technologies…………………………………………………..66Process temperature measurement is a constantly evolving field, and new technologies have allowed for more reliablemeasurements to be realized in many applications
Field Troubleshooting 101 and How to Get the Job Done……………………………………………………………………………..70A major part of field work lies in troubleshooting problems: finding out why a system is not operating the way it is intended.This article provides guidelines for effective troubleshooting and contains many practical examples of their successful
Warming up to Accurate Temperature Measurement……………………………………………………………………………………77Proper specification, installation and operation can ensure the accuracy required of your temperature sensor
Optimizing Pressure Relief Systems……………………………………………………………………………………………………………81Alternative designs for pressure relief systems may offer investment cost savings
Pressure Transmitter Basics: Selection Guidelines……………………………………………………………………………………….87Climbing the decision tree to pick the right pressure sensor
pH Measurement in Industrial Waters…………………………………………………………………………………………………………93
Applying CPI Temperature Sensors……………………………………………………………………………………………………………..94Don’t fall back on outdated rules of thumb that may no longer be valid, or ‘plug and play’ solutions that may not be applicable