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MPEC, Inc. MCDANIEL PROCESS ENGINEERING CONSULTANTS, INC.
MPEC, Inc.MCDANIEL PROCESS ENGINEERING CONSULTANTS, INC.
How to Contact Us
MCDANIEL PROCESSENGINEERING CONSULTANTS
William D. (Doug) McDanielChemical Engineering Consultant
MPEC, Inc.1020 Bay Area Blvd.Suite 222Houston, Texas 77058
Office: (281) 280-0363Fax: (281) 280-8468
E-Mail: [email protected]
Introduction to MPEC, Inc.Purpose
MPEC, Inc. is a chemical engineering consulting and design firmWe supply proven and cost-effective design engineering and consulting to the refining and petrochemical industriesOur typical work product ranges from a few hours of consultation through detailed “Schedule A” packages
Introduction to MPEC, Inc.Strengths
MPEC’s strength is process design and optimization of refining unitsWe are specialists in debottlenecking existing units through innovative solutionsWe view ourselves as extensions of yourengineering staff, working for the benefit of your company.
Profile - W. Doug McDanielMPEC, Inc. - Houston, Texas - February, 1988 to Present
Doug McDaniel is the founder and President of MPEC. He is responsible for all of the business activities of MPEC, but more importantly, he directs all of the process engineering design, computer applications, and economic appraisal studies of the company. Doug has worked on numerous projects involving the design and specification of all types of process equipment. In one of his recent assignments, he was the process design leader for a refinery expansion from 25,000 to 55,000 BPSD. This effort involved not only MPEC, but also a supervisory role over the process engineering of several other large engineering and construction firms. At MPEC, Doug has written the computer programs “2PDP” and “MPEC” to solve process hydraulic problems. “2PDP” is used to calculate two-phase pressure drops through piping, heater, and exchanger networks. “MPEC” is a collection of various process calculations for sizing compressors, pumps, orifices, control valves, reactors, etc.
PCI Consultants, Inc. - Houston, Texas - March, 1974 to February, 1988
Doug was a general engineer for PCI from 1974 to 1979, the Manager of Process Design from 1979 to 1987, and then Vice President of Process Design until leaving in 1988.
During his 14 years with PCI, Doug worked on numerous petrochemical and refining design assignments ranging from conceptual process selections through operator training and startup. Doug also worked on writing and implementing linear program (LP) models, economic analyses, plant appraisals and new computer software development. Doug authored PCI-HEXN, a heat exchanger network simulator which was sold through PCI and now through MPEC.
Texas Petrochemicals - Houston, Texas - February, 1970 to March, 1974
At Texas Petrochemicals (formerly Petro-Tex Chemical Corporation), Doug was Technical Services Engineer from February, 1970 to March, 1973 and then the Assistant Production Supervisor of the OXO Unit (oxidative dehydrogenation of butylenes to butadiene) from March, 1973 to March, 1974.
Education: Bachelor of Science in Chemical Engineering, January, 1970University of HoustonHouston, Texas
Personal: Registered Professional Engineer in TexasMarried with three childrenBorn May, 1947
Profile - Howard S. PollicoffMPEC, Inc. – Houston Texas – February, 2000 to Present
Howard Pollicoff is Vice President of MPEC. He is a senior consultant for conceptual process design, technology selection and evaluation, process design (for both new and revamp projects), economic analysis of processing alternatives, market studies, capital project planning, plant economics and appraisals, project management/owner’s engineer, environmental risk assessment, and general management consulting. He has performed client studies in a variety of industries including chemicals, petroleum refining, gas processing, and oil production.
PCI International, Inc and related subsidiaries– August, 1976 to February, 2000
Howard Pollicoff served as Vice President and manager of PCI’s consulting engineering business activities. In addition to his management role, he led client studies involving economic feasibility, plant expansion, process design, computer model development, linear program models of refinery and petrochemical plants, plant startup and operator training, plant appraisal and valuation, gasoline blending models, environmental permit coordination, litigation support services to legal, financial, and insurance companies, and owner’s engineering representative. Industries served included petroleum refining, chemicals, gas processing, and oil production.
TEXACO, INC. – Houston, Texas – May, 1973 to August, 1976
Howard Pollicoff served as a process design engineer in TEXACO’s Houston Engineering Department where he provided process design and technical services to TEXACO client departments worldwide. During this time, he was primarily involved in the design of Distillate Hydrotreating Units.
Education: Master of Science, Chemical Engineering, 1976 Bachelor of Science, Chemical Engineering, 1973University of Texas at Austin Texas A&M UniversityAustin, Texas College Station, Texas
Professional: Registered Professional Engineer - TexasMichiganIllinoisNew Mexico
Member, AIChE
Profile - Charlie JacobsMPEC, Inc. - Houston, Texas – March, 2000 to Present
After taking early retirement from Simpson, Charlie joined MPEC, Inc. where he provides expertise in computer systems, and computer and data methods. He does general engineering work and runs simulation and optimization studies.
Champion International / Simpson Paper Company - Pasadena, Texas - June, 1968 to January, 2000
Charlie joined Champion International as a Process Engineer. Because of his computer background, he was selected to form the new process control department, where he was to conceptualize, design and implement computer process controls. He worked along with IBM who was developing their first process computer. This was some of the first computerized process control developed. He was promoted to Senior Process Engineer and Manager of Process Controls. Under his direction, the roll of computers was expanded from process control to production systems to information systems with true millwide computer control. He instituted predictive controls, self-tuning, advanced feed-forward algorithms and many other high level controls which were not yet commercially available. He also developed the first closed loop color control in the paper industry. This included the development of the prototype color sensor. Through an association with online sensor vendors, the controls he developed have been incorporated into their sensor and control packages. He was recognized by TAPPI for this work. During this time he was a frequent lecturer at TAPPI-ARKLATEX.
In 1989, Simpson purchased the Pasadena Mill from Champion. Charlie’s employment with Simpson began with technology identification and vendor selection for millwide conversion from discrete analog pneumatic instrumentation controlled by process computers to electronic DCS systems and Plantwide Information systems. He has experience with Foxboro and Fisher DCS systems. The new systems incorporated all previously developed higher level controls and was highly integrated into a total millwide control system. All process, quality, production and financial information was presented as a single system to both mill personnel, corporate personnel and the customer base. Both Total Quality and Statistical Methods were incorporated to enhance the overall picture. Personal Computers and plantwide networks provide users with an interactive graphic interface for operations. He has been Chairman of the Managers Quality Council and the Managers Safety Council. He worked as an Evaluator and Change Manager during several different corporate reorganizations. When the Mill sold in January, 1999, Charlie opted for early retirement, but remained an employee with Simpson till January, 2000.
Education: Bachelor of Science in Chemical Engineering, January, 1970University of HoustonHouston, Texas
Personal: Married with four childrenBorn February, 1947
Profile – W. Ross McDanielMPEC, Inc. – Houston, Texas – May, 2005 to Present
Ross McDaniel works as a Process Design Consultant on process optimization and/or expansions typically for refineries and petrochemical plants. His work includes running computer simulations, pump hydraulic calculations, vessel sizing, writing equipment specs, and compiling reports. He has also served as an on-site contractor as general process engineering help and Turnaround process engineering help.
Equistar Chemicals (Now Lyondel-Basell) – Channelview, Texas – June, 2003 to May, 2005
Ross worked as the Utilities Production Engineer at the Channelview North Plant. He oversaw the day to day operations of basic utilities, the plant’s Environment Control Unit (ECU or wastewater treatment plant), waste disposal, and monitoring the emissions on cooling towers, flare, and water outfall. He also worked on several capital project groups to implement future utility units.
Lubrizol Corporation – Deer Park, Texas – (1st term) June, 2000 to August, 2000; (2nd & 3rd Term) January, 2001 to August, 2001
Ross worked 3 Co-Op terms during college with Lubrizol as a Production Engineer Co-Op working on various projects he was given by his supervisors including looking at heater efficiencies, Muratic Acid Recovery Unit (MUA) optimization, and creating the plants first PI Historian “board” pages for observation (to mimic DCS screens).
Education: Bachelor of Science, Chemical Engineering, May, 2003University of LamarBeaumont, Texas
Professional: Registered Professional Engineer - Texas
An Example Experience
In El Paso, Texas, an independent bought an 18 MBPSD refinery from a major. The Crude Unit’s heater was being overfired, the column was flooded, the overhead condensers were overloaded, and the preheat exchangers were being so overpressured that the relief valves were being blocked in. Three months before a turnaround, MPEC was asked if the unit could be revised for higher capacity. The answer, based on previous experience, was yes! Time was short, so MPEC outlined piping changes that were engineered in conjunction with the process design engineering. Three and one-half months later, the turnaround / expansion was completed, and the Crude Unit started up to run at 25 MBPSD (a 40% expansion) without a single new piece of major equipment, and at essentially the same absolute energy consumption!
The secret lay in understanding Crude Unit optimization through use of a pre-flash drum to allow flashing of the light crude to unload the heater, the Crude Column, and its overhead. Based on this success, MPEC was used exclusively for all process evaluations in the refinery for the next 5 years (until it re-changed ownership to a major). This entailed revising all the downstream units to handle the higher Crude Unit capacity, and eventually expanding the refinery to 55 MBPSD.
Reference: Mr. William (Bill) G. MillerInternational Alliance Group (IAG)Houston, Texas
Partial Listing of MPEC's Design Experience -- Page 1/3
Unit Project Scope Client Location
Alkylation -- H2SO4 Expansion El Paso Refining Co., Ltd. (Now Western Refining) El Paso, TX Expansion Chevron Products Co. El Segundo, CA
Alkylation -- HF Debottlenecking Williams Refining, LLC (Now Valero Refining) Memphis, TN Debottlenecking Western Refining Gallup, NM Debottlenecking Navajo Refining Artesia, NM
Alky Splitter Grass Roots Navajo Refining Artesia, NM
Benzene Removal Unit Grass Roots Williams Alaska Petroleum, Inc. (Now Flint Hills Resources) North Pole, AK
Butane Fractionation Process Design Chevron U.S.A. Products Company (Now Western Refining) El Paso, TX
C5/C6 Isomerization Debottlenecking Williams Refining, LLC (Now Valero Refining) Memphis, TN
Chemicals Processing Troubleshooting Texmark Chemicals, Inc. Galena Park, TX
Crude Expansion El Paso Refining Co., Ltd. (Now Western Refining) El Paso, TX Project Engineering Ergon Refining, Inc. Vicksburg, MS Conceptual Process Gulsby Engineering, Inc. Houston, TX Troubleshooting Clark Refining Blue Island, IL Exchanger Optimization Montana Refining Company Great Falls, MT Debottlenecking Williams Alaska Petroleum, Inc. (Now Flint Hills Resources) North Pole, AK Debottlenecking Williams Refining, LLC (Now Valero Refining) Memphis, TN Expansion Universal Refining N.V. (Now Petroplus) Antwerp, Belgium Debottlenecking Frontier Refining El Dorado, KS Debottlenecking Mažeikiu Nafta, AB Mažeikiai, Lithuania Debottlenecking Chevron Products Co. Kapolei, HI Debottlenecking Western Refining Gallup, NM Expansion Coffeyville Resources Coffeyville, KS
Cryogenic Gas Recovery Expansion Williams Refining, LLC (Now Valero) Memphis, TN Grass Roots Valero Refining Memphis, TN
Partial Listing of MPEC's Design Experience -- Page 2/3
Unit Project Scope Client Location
Delayed Coker Expansion Coffeyville Resources Coffeyville, KS Debottlenecking Frontier Refining Cheyenne, WY
Diesel Hydrotreater Debottlenecking Clark Refining Hartford, IL Debottlenecking Western Refining El Paso, TX Debottlenecking Williams Refining, LLC (Now Valero Refining) Memphis, TN
Ethanol Debottlenecking Giant Refining (Now Abengoa Bioenergy) Portales, NM
FCC Gasoline Hydrotreating Grass Roots--Monitor Western Refining El Paso, TX
FCCU M.C. & Gas Plant Debottlenecking El Paso Refining Co., Ltd. (Now Western Refining) El Paso, TX Grass roots El Paso Refining Co., Ltd. (Now Western Refining) El Paso, TX Troubleshooting Clark Refining Blue Island, IL Debottlenecking Clark Refining Hartford, IL Debottlenecking Western Refining Gallup, NM Expansion Coffeyville Resources Coffeyville, KS Debottlenecking Clark Refining (Now Valero Refining) Port Arthur, TX Debottlenecking Williams Refining, LLC (Now Valero Refining) Memphis, TN Optimization Montana Refining Company Great Falls, MT Expansion Chevron Products Co. El Segundo, CA Debottlenecking Mažeikiu Nafta, AB Mažeikiai, Lithuania
Hydroprocessing Startup Troubleshooting Ergon Refining, Inc. Vicksburg, MS Project Engineering Ergon Refining, Inc. Vicksburg, MS Debottlenecking Mažeikiu Nafta, AB Mažeikiai, Lithuania
JP-4 Treating Expansion El Paso Refining Co., Ltd. (Now Western Refining) El Paso, TX
LPG Treating Expansion El Paso Refining Co., Ltd. (Now Western Refining) El Paso, TX
LSR Hydrotreater Grass Roots Western Refining El Paso, TX
Partial Listing of MPEC's Design Experience -- Page 3/3
Unit Project Scope Client Location
Naphtha Hydrotreating Debottlenecking Williams Refining, LLC (Now Valero Refining) Memphis, TN Debottlenecking Western Refining El Paso, TX Debottlenecking Mažeikiu Nafta, AB Mažeikiai, Lithuania
Natural Gas Processing Debottlenecking Endevco Natural Gas Dubach, LA
Oligomerization Unit Debottlenecking Mažeikiu Nafta, AB Mažeikiai, Lithuania
Poly Unit Debottlenecking Williams Refining, LLC (Now Valero Refining) Memphis, TN Process H&MB Montana Refining Company Great Falls, MT
Refinery Reactivation Process Design Triangle Engineering Nederland, TX
Reforming Conceptual Process Gulsby Engineering, Inc. Houston, TX Conceptual Expansion Montana Refining Company Great Falls, MT Debottlenecking Williams Refining, LLC (Now Valero Refining) Memphis, TN Debottlenecking Western Refining El Paso, TX Debottlenecking Mažeikiu Nafta, AB Mažeikiai, Lithuania
SATS Gas Debottlenecking Chevron U.S.A. Products Company Now Western Refining) El Paso, TX Grass Roots Frontier Refining Cheyenne, WY Debottlenecking Universal Refining N.V. (Now Petroplus) Antwerp, Belgium Debottlenecking Mažeikiu Nafta, AB Mažeikiai, Lithuania Debottlenecking Valero Refining Memphis, TN
Transmix Fractionation Process Design Direct Fuels, Inc. Dallas, TX
Vacuum Project Engineering Ergon Refining, Inc. Vicksburg, MS Grass roots El Paso Refining Co., Ltd. (Now Western Refining) El Paso, TX Troubleshooting Clark Refining Blue Island, IL Expansion Coffeyville Resources Coffeyville, KS Expansion Chevron Products Co. Kapolei, HI
Visbreaking Expansion Mažeikiu Nafta, AB Mažeikiai, Lithuania
James Resinger Holly Frontier Corp. Rick Chavez Stancil & Company 2828 N. Harwood #1300 15455 Dallas Parkway, Suite 350 Dallas, TX 75201-1507 Addison, TX 75001 (214) 871-3555 (214) 954-1521
Chris R.Heimbuch Chevron Products Company Robert Haugen CVR Energy 2351 North 1100 West 2277 Plaza Drive, Suite 500 Salt Lake City, UT 84116 Sugar Land, TX 77479 (801) 539-7543 (281) 207-3200
Steve Hunkus Murphy Oil Corp. Ken Jinkerson Murco Petroleum Ltd. 200 Peach Street Milford Haven Refinery El Dorado, AK 71730 PO Box 10 (901) 573-6045 Milford Haven
Pembrokeshire SA73 3JD Tel: 01646 690300
References – Page 1/2
Weldon Lybarger Mustang Engineering, Inc. Shannon Melton TPE, Inc. 16001 Park Ten Place 951 West Main, Suite 200 Houston, TX 77084 Jenks, OK 74037 (713) 215-8000 (918) 296-3391
Ron Murrell Western Refining Jeff Peterson Valero Refining 212 N. Clark St. 543 West Mallory Ave. El Paso, TX 79905 Memphis, TN 38109 (915) 775-3300 (901) 947-8304
Ralph Thompson Chevron Products Company Jeffrey K. Warmann Monroe Energy, LLC 324 West El Segundo Blvd. 4101 Post Road El Segundo, CA 90245 Trainer, PA 19061 (310) 615-4115 (610) 364-8000
References – Page 2/2
Equipment No. 26-13-002 26-13-003 26-13-019 26-13-038 26-13-039 26-13-040Service SS Rx Feed Rx Feed Stripper Btms. NHDS Feed NHDS Feed NHDS Feed TS Rx Eff l. Rx Eff l. CW Stripper Btms. Stripper Btms. Stripper Btms.
Type BEU BEU M.T.D.P. AEU AEU AEU
Shell Side: Design Pressure (PSIG) 550 550 500 514 514 514 Design Temp (°F) 640 550 650 500 500 500 Inner Diam. (In.) 25.0 25.0 21.0 21.0 21.0 Baffle Spc.(In.) In/Norm/Out 17.0 17.0 None 15.5 15.5 15.5 Baffle Cut - % of Shell I.D. Baffle Thickness (In.) Nozzle Size (In.) 8 8 3 6 6 6 Arrangement < - - - - - -2S- - - - - -> N/A <- - - - - - - - - - - - - -3S- - - - - - - - - - - - -> Passes Per Shell 1 1 1 1 1 1 Tube/Baff le Dia. Clear.(in.) 0.01 0.01 0.01 0.01 0.01 Shell/Baff le Dia.Clear.(In.) 0.175 0.175 0.1875 0.1875 0.1875 Bundle/Shell Dia. Clear. (In.) 0.125 0.125 0.4375 0.4375 0.4375 No.Pairs of Sealing Strips No.Internal.Bypass Lanes 1 1 1 1 1 Width of Lanes (In.) 0.625 0.625 2.25 2.25 2.25 Metallurgy 1/2 Mo. C.S. C.S. C.S. C.S. C.S.Tube Side: Design Pressure (PSIG) 500 500 500 659 659 659 Design Temp (°F) 750 640 650 500 500 500 No. Holes Per Tubesheet 356 356 7 (1) 340 340 340 Nom. St. Length (ft., in.) 16 16 20.5 20 20 20 Outer Diam. (In.) 0.75 0.75 0.875 0.75 0.75 0.75 Thickness (In.) 16 BWG 14 BWG 0.083 0.083 0.083 0.083 Pitch (In.) 1.0 Sq. 1.0 Sq. ? 0.9375 Δ 0.9375 Δ 0.9375 Δ Nozzle Size (In.) 8 8 2-1/2 6 6 6 Passes Per Shell 2 2 1 2 2 2 Area Per Shell (f t²) 1,162 1,162 67(b) 262(f) ? 1,319 1,319 1,319 Metallurgy 17 Cr. S.S. 1/2 Mo. C.S. C.S. C.S. C.S.
MPEC
Deliverables
Equipment Data Collection When preparing a process study, MPEC normally first goes to the unit and collects the equipment
data. Summaries of the major equipment data are then prepared such as this exchanger data table.
MPEC Deliverables – PFD Overview
After reviewing plant operations, an up to date PFD of the unit is then drawn and the typical current operating data is shown, including feed and product distillations and/or compositions.
MPEC’s PFD’s contain all the essential information needed by a process engineer. For example, all line sizes, vessel sizes, and number of trays are included. Also, all vessels are drawn to the same scale. All control valves and control schemes are includedas well as all flow meters. Information such as temperature, pressure, vapor flow, and liquid flow are shown in flags connected to the process lines.
MPEC DeliverablesTypical PFD
Stream Reformer Recycle Gas (from SP-202) Ref. Stab. Pre-Flash Drum Offgas (from SP-207) Reformer Stabilizer OH Offgas (from T-202) Reformer Stabilizer OH Offgas (from T-202)Date November 13, 2000 November 6, 2000 November 6, 2000 November 13, 2000Mol. Wt. ? (From Lab) 7.80 (From Below) ? (From Lab) 9.27 (From Below) ? (From Lab) 32.11 (From Below) ? (From Lab) 64.58 (From Below)Comp. Mol% t/d (metric) Lb Mol/h Wt% LV% Mol% t/d (metric) Lb Mol/h Wt% LV% Mol% t/d (metric) Lb Mol/h Wt% LV% Mol% t/d (metric) Lb Mol/h Wt% LV%
H2 78.00 391.89 17856.37 20.17 58.64 73.50 2.16 98.26 15.99 52.01 20.00 1.41 64.10 1.26 7.73 0.00 0.00 0.00 0.00 0.00N2 0.14 9.77 32.05 0.50 0.13 0.00 0.00 0.00 0.00 0.00 0.46 0.45 1.47 0.40 0.21 0.00 0.00 0.00 0.00 0.00C1 9.86 394.22 2257.23 20.29 13.76 10.88 2.54 14.55 18.83 14.29 8.03 4.49 25.74 4.01 5.76 0.00 0.00 0.00 0.00 0.00
C2's 6.75 505.84 1545.26 26.03 14.87 8.52 3.73 11.39 27.64 17.66 29.20 30.64 93.59 27.35 33.06 2.68 5.21 15.92 1.25 2.10H2S 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00C3's 3.72 408.82 851.61 21.04 8.43 5.06 3.25 6.76 24.07 10.80 25.62 39.42 82.11 35.19 29.87 13.74 39.10 81.46 9.38 11.07C4's 1.22 176.72 279.29 9.10 3.23 1.65 1.40 2.21 10.34 4.11 13.11 26.58 42.02 23.73 17.81 30.63 114.93 181.64 27.57 28.63C5's 0.31 55.74 70.97 2.87 0.93 0.33 0.35 0.44 2.57 0.94 3.53 8.89 11.31 7.93 5.47 40.74 189.72 241.54 45.51 43.51C6+ 0.00 0.00 0.00 0.00 0.00 0.06 0.08 0.08 0.56 0.19 0.05 0.15 0.16 0.13 0.09 12.21 67.91 72.39 16.29 14.70
Total 100.00 1943.02 22892.78 100.00 100.00 100.00 13.49 133.69 100.00 100.00 100.00 112.02 320.50 100.00 100.00 100.00 416.88 592.94 100.00 100.00
Stream Hydrotreated Naphtha ReformateAnalysis Date November 11, 2000 November 13, 2000t/m3 (SG 68°F) 0.7320 0.7990
°API (60°F) 60.76 44.71Wt ppm Sulfur 0.2 0
RVP ? ?MON ? 86.5RON ? 97
Distillation D-86 D-86LV% Over °C °F °C °F
0 (IBP) 75 167 72 16210 90 194 85 18550 108 226 114 23790 140 284 154 309
100 (EP) 164 327 188 370% Recovery 98 98% Residue 0.9 0.9
MPEC DeliverablesTypical PFD with Plant Data
TK-315
EDUCTOR
24681012141618202224262830323436384042444648505253
1
54K-304
V12
AO-304
AV-312
S-323
V1
T-305
V2
SP2
V8
V9
TK-325
AO-308-9SEC
AV-307
DEBBTMSPL
V11 2468
101214161820222426283032343638404244464850525456586061
1
62K-306
V14
AO-306
AV-316
V10
AO-308-S1
AV-304
M10
V13
AO-308-2S
AV-306
M17
STABFD
STABBTM
STABFD1
STABBTM2
DEBFLSHOH1
STABFD4
STABOH
TO317
DEPROFD
SDGASOLDR
STAB-H2O
STABOH2
AIR-304
STABOH3
AIRR-304
CWS-312
STABOH4
CWR-312
DEPROFD1
SDGASOLDR1
DEBFLSHOH
SDGASOL
STABBTM6
STABBTM-BP STABBTM-BP-2
STABBTM7
CAUSTIC
STABBTM8
CAUSTIC2
AIR-308-1-2
STABBTM9
AIRR-308-1-2
CWS307
STABBTM10
CWR307
GASOLINE
GASOL-REC1
DEPROPFD4
DEP-OH
TO314
C3PROD
C4PROD1
DEP-OH2 AIR-306
DEP-OH3
AIRR-308
CWS-316
DEP-OH4
CWR-316
SDGASOL1
AIR-308-S1
SDGASOL2
AIRR-308-S1
CWS-304
SDGASOL3
CWR-304
GASOL-PROD
C4PROD2
AIR-308-2S
C4PROD4
AIRR-308-2S
CWS306
C4PROD5
CWR306
STABBTM11
DEP-H2O
23709146338
1024411588
601144262
383022081
6414256217
237098493
188608485
10244---
25592
2522612.78145252
23709086255
116135
116110
5068
4986
38592
220106
220100
22081
5068
5075
21893
21878
5068
4069
87262
87139
146262
8466
5068
5068
8468
4930.1484228
58050.85220204
59
41
53
41
75
41
41
77
51
41
601
1446
22263
545018259
23.0025211341.43
139140
Q = 20.24
Q = -38.09
Q = 33.32
17500
L/D = 1.7083
10050L/D =2.6243
1001 GPM
400 GPM
145252
50160
5075
4069
5068 2874 GPM
25 GPM
RVP = 8.0 psi
316.27 Met T/Day
600.81 Met T/Day
2195.63 Met T/Day
Stabilizer /Depropanizer
310 GPM
801 GPM
770 GPM
0
K-304Stabilizer
K-306Depropanizer
6.8 MM #/Hr
5.1 MM #/Hr
283226 #/Hr
2.5 MM #/Hr
566452 #/Hr
311074.90146223
8486
Trays @ 35 %Flood (per ProII)@ 1.0 SF
Trays @ 40 %Flood (per ProII)@ 1.0 SF
Trays @ 25 %Flood (perProII)@ 1.0 SF
Trays @ 29 %Flood (per ProII)@ 1.0 SF
11588
46172146305
29239256216
86262
Reboiler FeedTo TK-314
102 °F Bubble Point
104 °F Bubble Point
90.49 % Recovery C3=
Q = -15.69
Q = 28.91 A = 22449 U = 18.6 R / 59.1 EFT = 0.977
Q = 9.18 A = 8676 U = 40.9 R / 74.8 EFT = 0.963
Q = 14.26 A = 16837 U = 15.4 R / 86.8 EFT = 0.989
Q = 1.43 A = 6039 U = 14.0 R / 33.5 EFT = 0.926
Q = 4.64 A = 1871 U = 28.9 R / 84.7 EFT = 0.931
Q = 0.48 A = 1690 U = 18.1 R / 58.4 EFT = 0.987
Q = 0.68 A = 935 U = 8.5 R / 30.5 EFT = 0.930
Q = 0.0045 A = 4758 U = 0.87 R / 14.0 EFT = 1.0
Q = 22.00 A = 8418 U = 26.7 R / 67.5 EFT = 0.933
Q = 0.85 A = 6910 U = 5.9 R / 61.4 EFT = 0.998
Q = 1.06 A = 1130 U = 18.6 R / 25.0 EFT = 0.618
Q = 12.05 A = 9903 U = 23.2 R / 53.8 EFT = 0.882
0 #/Hr H2O
Pinched BlockValve
0 #/Hr H2O
Reboiler FeedTo TK-317
Closed Block Valve
Q = MMBTU / Hr A = Ft2 U = BTU / (Ft2 - °F - Hr)FT = Dimensionless (LMTD Correction Factor)
Temperature -Pressure -Vapor Flow -Liquid Flow -
°FPSIGMMSCFD @ 68°FBPSD @ 60°F
MPEC Deliverables – Simulation OverviewNext, a base case simulation of the unit is prepared using either “PRO/II” by Simulation Sciences
or “DS03” by Oleson & Associates. (Typical “PRO/II” Simulation Flowsheet)
PAGE 144DISTILLATION SIMULATION-03 DATE 10-19-98
PROJECT 18-073-94 CUSTOMER MAPCO-M PROBLEM 65ECU2 ENGINEER WBH
IV-B. STREAM SUMMARIESSTREAM NO. 14 - PF OVFL
TEMPERATURE 452.87 DEG. F LIQUID FROM STAGE 7 OF UNIT 4PRESSURE 20.86 PSIG TO STAGE 8 OF UNIT 4
* STREAM PROPERTIES * * LABORATORY DISTILLATION *
DEG API 37.6 VOL TBP D-86 D-1160WATSON K 11.87 PCT F ASTM ASTMMOLEC. WT. 208.1MABP (DEG F) 493. 0. 119. 207. 144.VABP (DEG F) 525. 5. 332. 312.S.G. .8369 10. 350. 379. 368.LB/GAL 6.978 20. 430.LB/BBL 293.09 30. 482. 493. 490.
40. 521.MOL/HR 61.373 50. 550. 542. 550.M-LB/HR 12.774 60. 574.MM-BTU/HR 4.204 70. 596. 575. 596.BPSD 1046. 80. 621.GAL/MOLE 29.8 90. 657. 625. 657.
95. 652. 690.LB/FT3 T,P 42.3 100. 768. 715. 768.
* PROPERTIES AT OTHER TEMPERATURES *DEG F S.G. VISC, CP BTU/FT2/HR BTU/LB MM-BTU/HR GPM
/DEGF/FT453. .6784 .37 .0706 329.10 4.204 37.62450. .6799 .37 .0707 327.15 4.179 37.54400. .7042 .42 .0719 294.02 3.756 36.25350. .7266 .49 .0731 262.29 3.350 35.13300. .7474 .59 .0744 231.96 2.963 34.15250. .7671 .74 .0756 203.03 2.593 33.27200. .7859 .99 .0768 175.50 2.242 32.48150. .8043 1.48 .0780 149.37 1.908 31.74100. .8224 2.61 .0793 124.65 1.592 31.03
* PROCESS LINE SIZES *
NOM. PRES DROP VEL HD VELOC. RE/ FRIC I.D.SIZE PSI/100FT PSI FT/SEC 1000 FACT INCHES1 38.33 1.29 16.8 228.0 .0238 .95701.5 3.75 .21 6.8 145.4 .0220 1.50002 .73 .06 3.6 105.5 .0213 2.06703 .10 .01 1.6 71.1 .0211 3.06804 .03 .00 .9 54.2 .0215 4.0260
MPEC
Deliverables
Typical “DS03” Simulation Stream Summary
MPEC
Deliverables
SIMULATION SCIENCES INC. R PAGE P-30PROJECT DHDS PRO/II VERSION 5.11 386/EMPROBLEM Nap to DHDS OUTPUT PTW
RIGOROUS HEAT EXCHANGER SUMMARY 7 Sep 2000=====================================================================================================================
SHELL AND TUBE EXCHANGER DATA SHEET FOR EXCHANGER 'E-1-2-3-4'I----------------------------------------------------------------------------II EXCHANGER NAME Rx-Fd-Effl UNIT ID E-1-2-3-4 II SIZE 36 - 249 TYPE BEU HORIZONTAL CONNECTED 2 PARALLEL 2 SERIES II AREA/UNIT 12856.FT2 AREA/SHELL 3214.FT2 II----------------------------------------------------------------------------II PERFORMANCE OF ONE UNIT SHELL-SIDE TUBE-SIDE II----------------------------------------------------------------------------II FEED STREAM ID COMB-FD1 EFFL1 II FEED STREAM NAME Rx Feed Rx Effl II TOTAL FLUID LB/DAY 18950509. 18950462. II VAPOR (IN/OUT) LB/DAY 961202. / 2134977. 4172816. / 1647494. II LIQUID LB/DAY 17989224. / 16815533. 14777647. / 17302981. II STEAM LB/DAY / / II WATER LB/DAY / / II NON CONDENSIBLE LB/DAY II TEMPERATURE (IN/OUT) DEG F 408.4 / 561.6 646.0 / 507.8 II PRESSURE (IN/OUT) PSIG 816.00 / 804.53 720.00 / 711.43 II----------------------------------------------------------------------------II SP. GR., LIQ (60F/60F H2O) 0.853 / 0.853 0.846 / 0.846 II VAP (60F/60F AIR) 0.227 / 0.486 0.985 / 0.426 II DENSITY, LIQUID LB/FT3 45.196 / 40.273 36.045 / 41.490 II VAPOR LB/FT3 0.571 / 1.027 1.742 / 0.844 II VISCOSITY, LIQUID CP 0.293 / 0.156 0.104 / 0.188 II VAPOR CP 0.019 / 0.030 0.036 / 0.027 II THRML COND,LIQ BTU/HR-FT-F 0.0508 / 0.0429 0.0384 / 0.0453 II VAP BTU/HR-FT-F 0.1157 / 0.1166 0.1001 / 0.1105 II SPEC.HEAT,LIQUID BTU/LB-F 0.6041 / 0.6710 0.7191 / 0.6515 II VAPOR BTU/LB-F 1.3733 / 0.9630 0.7927 / 0.9885 II LATENT HEAT BTU/LB 101.51 87.37 II VELOCITY FT/SEC 19.09 19.21 II DP/SHELL PSI 5.74 4.28 II FOULING RESIST HR-FT2-F/BTU 0.00200 0.00200 II----------------------------------------------------------------------------II TRANSFER RATE BTU/HR-FT2-F SERVICE 82.89 CLEAN 133.42 II HEAT EXCHANGED MM BTU/HR 86.467 MTD(CORRECTED) 81.1 FT 0.884 II----------------------------------------------------------------------------II CONSTRUCTION OF ONE SHELL SHELL-SIDE TUBE-SIDE II----------------------------------------------------------------------------II DESIGN PRESSURE PSIG 885. 785. II NUMBER OF PASSES 1 2 II MATERIAL CARB MLY 321 S.S. II INLET NOZZLE ID IN 10.0 10.0 II OUTLET NOZZLE ID IN 10.0 10.0 II----------------------------------------------------------------------------II TUBE: NUMBER 832 OD 0.750 IN BWG 14 LENGTH 20.8 FT II TYPE BARE PITCH 1.0 IN PATTERN 90 DEGREES II SHELL: ID 35.75 IN SEALING STRIPS 2 PAIRS II BAFFLE: CUT 0.164 SPACING (IN/CENT/OUT): IN 25.00/ 11.50/ 17.00,DOUBLE II RHO-V2: INLET NOZZLE 4402.3 LB/FT-SEC2 II TOTAL WEIGHT/SHELL,LB 23918.1 FULL OF WATER 47895.3 BUNDLE 16252.6 II----------------------------------------------------------------------------I
MPEC rigorously simulates each piece of major equipment using a variety of programs. “PRO/II” can rigorously do shell and tube exchangers and generate outputs such as this.
MPEC can also rigorously do entire networks of exchangers using our in-house “HEXN” program. “HEXN” also has the capability of calculating air coolers and G-fin exchanger.
Typical “HEXN” Heat Exchanger SummaryCRUDE VS COLD BTMS - 013/014 - (WITH NEW BUNDLES) (EXCH. NO. 2 )
.xXXXXx.DEG.F. XX XX DEG.F.469.79 --> XX /\/\/\/\ XX --> 307.47 348,542.0 #/HR ATM BOTTOMS, API= 21.42, K= 11.86,
FROM EXCH. NO. 14 229.92 <-- XX XX <-- 157.00 843,552.0 #/HR CRUDE CHARGE + 4.44 LV% WATER, (Cp
WAS INPUT), FROM SOURCEXX XX
`^XXXX^'
A = 3,820.186 SQ.FT.U = 47.312 BTU/HR-FT2 (AT 100.00 % OF RIG.U CALC.)Q = 34.183 MMBTU/HR
LMTDc = 189.100 DEG.F Ft = 0.986 (DIM.) (BASED ON 2 SHELL PASS)
RIGOROUS U CALCULATION SUMMARY :EXCHANGER TYPE = SHELL AND TUBESHELLS IN SERIES = 2 , SHELLS IN PARALLEL = 1 , TOTAL SHELLS = 2
Uclean = 77.462 BASED ON BARE TUBE OUTSIDE SURFACE AREAUservice = 47.275 BASED ON BARE TUBE OUTSIDE SURFACE AREAUservice = 47.275 BASED ON FINNED OUTSIDE SURFACE AREA
TOTAL SHELLSIDE PRESSURE DROP = 12.5204 PSI.TOTAL TUBESIDE PRESSURE DROP = 38.7801 PSI.
GEOMETRY DATA FOR ONE SHELLSHELL I.D. = 31.0000 IN. BAFFLE SPC.(IN/NORM/OUT)-IN. = 24.0000 / 21.0000 /
21.0000 NO. OF SHELL PASSES = 1 NO. OF TUBE PASSES = 4
BAFFLE TYPE = SINGLE SEGMENTALBAFFLE CUT = 25.0000 % OF SHELL I.D. BAFFLE THICKNESS = 0.312500 IN.TUBE-TO-BAFFLE DIAMETRICAL CLEARANCE (BAFFLE HOLE I.D. - TUBE O.D.) = 0.031250 IN.SHELL-TO-BAFFLE DIAMETRICAL CLEARANCE (SHELL I.D. - BAFFLE O.D.) = 0.250000 IN.BUNDLE-TO-SHELL DIAMETRICAL CLEARANCE (SHELL I.D. - BUNDLE O.D.) = 0.812500 IN.NO. OF PAIRS OF SEALING STRIPS BETWEEN BAFFLES = 0.000 ( 21.9205 TUBE ROWS CROSSED
BETWEEN BAFFLES)NO. OF BUNDLE INTERNAL PARALLEL BYPASS LANES = 1.000 ( AT 0.6642 INCHES WIDE
EACH.)BUNDLE: DIAMETER 30.1875 IN. TUBES IN CROSSFLOW 379.25
CROSSFLOW AREA 1.6119 FT2 WINDOW AREA 0.6738 FT2WINDOW HYD DIA 1.1606 IN TUBE-BFL LEAK AREA 0.1262 FT2 SHELL-BFL LEAK AREA 0.0564 FT2
TUBE LENGTH = 16.000 FT. TUBE O.D.= 0.7500 IN. TUBE I.D.= 0.5800 IN. TUBE THICKNESS = 0.0850 IN.
NO.OF TUBES = 608 TUBE PITCH = 1.0000 IN. SQR. ROT.TUBE THERMAL CONDUCTIVITY (k) = 26.00 BTU/(HR)(FT2)(DEG.F/FT)BARE TUBE SURFACE AREA = 1910.093 FT2
INTERMEDIATE CALCULATION RESULTS SHELLSIDE (BELL) TUBESIDEFLUID CALORIC TEMP.-DEG.F. 186.80 373.64FLUID VELOCITY - FT./SEC. 2.94 6.79FLUID SG. @ CAL. TEMP. 0.7927481 0.8199199FLUID VIS. @ CAL. TEMP. - CP. 1.89306 2.69489FLUID k @ CAL. TEMP. (OPT) 0.07263(4) 0.06572(4)FLUID Cp @ CAL. TEMP. 0.55208 0.59619CALCULATED WALL TEMP.-DEG.F. 269.26 269.26FLUID VIS. @ WALL TEMP. - CP. 1.03906 6.92910HEAT TRANS.COEF. (BARE,O.D.) 225.113 122.026TOTAL RETURN BEND PRESSURE DROP-PSI -- 4.078FOULING FACTOR 0.0040 0.0040
MPEC
Deliverables
Pumps and their suction and discharge circuit pressure drop profiles are documented on summary sheets such as this. A pump curve, with the
operating point marked, is also included with this sheet.
PUMP Job No.: 18-111-97 Item No: 12-15-025 / 026 Page:CALCULATION SHEET Case: 1
Client: Location: Service: Lean Oil Str. Ovhd.
Case Reflux to FCCU LightSuction Pressure 12-10-036 Gasoline Pumped Fluid
+ Origin Press., psia: 94.70 94.70 Lean Oil Str. Ovhd. Normal+ Static Head, psi: 2.72 2.72 Pumping Temp., F: 106.0
- Exch & Line. Loss, psi: 0.20 0.20 Viscosity, cp @ T&P: 0.24Pump Suct. Press., psia: 97.22 97.22 Vap. Press., psia @ T&P: (3) 94.7
Net Pos. Suction Head S.G. @ T&P: 0.6273+ Origin Press., ft: 348.57 348.57 Normal Flow , bpsd @ 60F: 2450
+ Static Head, ft: 10.00 10.00 Normal Flow , gpm @ T&P: 74.4- Exch & Line. Loss, ft: 0.74 0.74
- Vap. Press., ft: 348.57 348.57Available NPSH, ft: 9.26 9.26 Reference Conditions
Discharge Pressure Barometric Pressure, psia: 14.7Delivery Press., psia: 104.70 150.75 <-------Delivery to CV inlet
Static Head, psi: 14.10 Pump PerformanceLine Loss, psi: 0.45 0.26 Pump NPSHR, ft: 5.0
Control Valve DP, psi: 28.75 Pump max DP, psi: 53.8Exchanger DP, psi: Pump max Suct., psig: 127.6
Furnace DP, psi: Pump max Disch., psig: 181.4Orif ice DP, psi: 3.00Valves DP, psi:
Pump Disch. Press., psia: 151.01 151.01 HorsepowerDifferential Pressure Normal Hydraulic Hp: 2.3
Disch. Press., psia: 151.01 151.01 Normal Efficiency, %: 62.0Suct. Press., psia: 97.22 97.22 Normal Flow BHP: 3.8Total Pump DP, psi: 53.79 53.79 End of Curve BHP: 7.2Total Pump DH, ft: 198.00 198.00 Existing Driver Hp: 10.0
Notes:1) Clean pipe assumed.2) Pipe lengths approximated from P&ID's and Plot Plan3) Fluid is greatly subcooled, but w as assumed to be at BPT for NPSH Calc.
Revision: 0Date: 10/05/2000
By/Review ed: PTW/WDM
12-10-036
12-10-021
12-15-025/026
1250
1200
Δ Elev.51' 11"
Δ Elev.10'
80
90
136
12-13-043
Lt. FCCUGasoline
MPEC
Deliverables
Also attached to each pump calculation sheet is the pump suction and discharge pressure drops using MPEC’s liquid DP spreadsheet as shown here. The liquid pressure drops are rigorously calculated
using the formulas in Crane’s Technical Paper No. 410.
MPEC's Liquid Pressure Drop WorksheetVersion 1.0 By WDM 5/12/98
CLIENT:UNIT: Gas Con
SYSTEM: Lean Oil Str. Ovhd.DATE / BY: 10/05/2000 PTW
CASE: 69000 BPD NormalPUMP: 12-15-025 / 026
REV. NO. 0
INPUT CASE Suction Discharge Product StreamLine LOSLTLQ (GC) LOSLTLQ (GC) LOSLTLQ (GC)From 12-10-021 12-15-025/026 Split
To 12-15-025/026 Split Contrl. VavleInput BPSD60 OR Lb/Hr BPSD60 2,450 2,450 1,200
Lb/HrSp. Gr. @ 60°F 0.6527 0.6527 0.6527Sp. Gr. @ Temp. 0.6273 0.6273 0.6273Temperature °F 106 106 106Visc. @ Temp. cP 0.21 0.21 0.21Pipe I. D. Inches 3.068 3.068 3.068Roughness Feet 0.00015 0.00015 0.00015Straight Feet Of Pipe 20.0 10.0 10.0 Sq. Flush Entrance 1.0 T-Run No. T-Branch No. 1.0 1.0 1.0 45 Welded Elbow No. 90 Welded Elbow No. 4.0 6.0 4.0 180 Welded Elbow No. Gate No. (Full Size) 1.0 1.0 2.0 Butterfly No. (Full Size) St. Globe No.(Full Size) Ang. Globe No. (Full Size) Fl.Check Valve No.(Swing) 1.0 ExitSource of Misc. Fittings K 3X2 Red; 2X1.5 Red Misc Fitttings K 0.915Total Fittings K 3.058 4.114 3.612SOURCE of Misc. DPMisc. Delta P PSI
RESULTS Flowrate: BPSD60 2,450 2,450 1,200Lb/Hr 23,335 23,335 11,429GPMh 74.4 74.4 36.4
Density LB/FT3 39.124 39.124 39.124
Reynolds No. 229,474 229,474 112,394Friction f 0.019051 0.019051 0.020416Total Resistance K 4.549 4.859 4.410Total Equivalent Feet 61.04 65.21 55.23
Velocity Ft/Sec. 3.23 3.23 1.58ΔP / 100 Eq. Ft. PSI 0.3277 0.3277 0.0843ΔP / K PSI 0.0440 0.0440 0.0106
ΔP - Str. Pipe PSI 0.0655 0.0328 0.0084ΔP - Fittings PSI 0.1345 0.1810 0.0381ΔP - Misc. PSI 0.0000 0.0000 0.0000ΔP - TOTAL PSI 0.2001 0.2137 0.0465ΔP - Sect. Tots. PSI 0.2001 0.2137 0.0465
MPEC
Deliverables
Compressors and column tray hydraulics, and many other calculations can be done using MPEC’s in-house “MPEC” program. Presented here is the opening menu of this program. Copies of “MPEC”are typically given to clients upon request, so that their own engineers can calculate these items on
the same basis as MPEC.
***** MPEC-I ** 1 OF 2 MPEC PROCESS ENGR. CALC. PROGRAMS *****(BY W.D.MCDANIEL, MPEC, INC., HOUSTON, TEXAS, OCT 6, 99)
(Phone (281) 280-0363, Fax (281) 280-8468)THIS COMPLIMENTARY PROPRIETARY COPY PROPERTY OF W.D. MCDANIEL
MPEC, Inc. - HOUSTON, TEXAS
(MPEC,INC. IS NOT RESPONSIBLE FOR ANY USE OF THIS PROGRAM BY OTHERS.)
1 - Single Phase Pipe/Duct Delta P 10 - Vapor Orifice2 - Two-Phase Flow Calculations 11 - Liquid Orifice3 - Compressible Vapor Flow 12 - Valve Tray Diameter4 - Flashing Pure Comp. Pipe Delta P 13 - Valve/Sieve Tray Hydraulics5 - K Resistances of Pipe Fittings 14 - Compressor BHP Calculation6 - Control Valve 15 - Centrifugal Compressor7 - Pump BHP Calculation 16 - Reciprocating Compressor8 - Drop Settling D - Exit to DOS9 - Time Value of Money (Type 'EXIT' to return to
calcs)
NOTE: REFER TO MPEC-II FOR THE FOLLOWING CALCULATIONS.- Heat Exchanger - Maxwell's Shortcut Fractionation- Bubble Point, Dew Point & Flash
MPEC
Deliverables
A typical reciprocating compressor output is shown here.
********************* MPEC'S RECIPROCATING COMPRESSOR CALC *****************CYL.NO. | 1 | 2 | 3 | 4 |
1-Cyl. name | CYL # 1 | | | |2*Flow-MMSCF/D | 9.188 | 0.000 | 0.000 | 0.000 |3-Gas mol. wt. | 80.000 | 0.000 | 0.000 | 0.000 |
| | | | |4*Inlet PSIA | 100.000 | 0.000 | 0.000 | 0.000 |5-Inlet temp - F. | 100.000 | 0.000 | 0.000 | 0.000 |6-Inlet Z factor | 0.990 | 0.000 | 0.000 | 0.000 |7-Inlet k (Cp/Cv) | 1.300 | 0.000 | 0.000 | 0.000 |Inlet ACFM | 999.990 | 0.000 | 0.000 | 0.000 |
| | | | |8-Disch PSIA | 350.000 | 0.000 | 0.000 | 0.000 |THEORET.Tout-F. | 287.725 | 0.000 | 0.000 | 0.000 |EST.ACT Tout-F. | 326.097 | 0.000 | 0.000 | 0.000 |
9-Disch Z factor | 0.930 | 0.000 | 0.000 | 0.000 |10-Disch k (Cp/Cv) | 1.300 | 0.000 | 0.000 | 0.000 |
| Note: B/P = By Program; Set@ = Set by User |11-Poly.eff.%(OPT) |B/P 85.244 |B/P 0.000 |B/P 0.000 |B/P 0.000 |
Calc. cly. GHP | 740.195 | 0.000 | 0.000 | 0.000 |12-Mech.Loss-HP(OPT)|B/P 37.010 |B/P 0.000 |B/P 0.000 |B/P 0.000 |
Total Cyl. BHP | 777.205 | 0.000 | 0.000 | 0.000 |TOTAL COMPRESSOR BHP FOR ALL CYLINDERS COMBINED = 777.205
13-Speed-RPM | 500.000 | 0.000 | 0.000 | 0.000 |Speed-FT/MIN | 750.000 | 0.000 | 0.000 | 0.000 |
14*Cyl I.D.-in. | 19.1889 | 0.0000 | 0.0000 | 0.0000 |15-Cyl STROKE-in. | 9.0000 | 0.0000 | 0.0000 | 0.0000 |16-F.E.Rod I.D.-in. | 9.0000 | 0.0000 | 0.0000 | 0.0000 |17-H.E.Rod I.D.-in. | 0.0000 | 0.0000 | 0.0000 | 0.0000 |
Pist. Displ-CFM | 1,340.552 | 0.000 | 0.000 | 0.000 |18*F.E.% CL. Vol. | 10.0000 | 0.0000 | 0.0000 | 0.0000 |19*H.E.% CL. Vol. | 10.0000 | 0.0000 | 0.0000 | 0.0000 |
F.E Vol. Eff. | 74.5960 | 0.0000 | 0.0000 | 0.0000 |H.E.Vol. Eff. | 74.5960 | 0.0000 | 0.0000 | 0.0000 |Comp. Rod Load | 78,660.38 | 0.00 | 0.00 | 0.00 |Tens. Rod Load | 50,032.62 | 0.00 | 0.00 | 0.00 |
20-Solved for... | CYL ID | IDLE | IDLE | IDLE |
MPEC
Deliverables
MPEC DeliverablesA typical tray hydraulics calculation is shown here.
**** MPEC'S GLITSCH VALVE OR TREYBAL SIEVE TRAY HYDRAULICS ****1V-VAP.TO TRAY-LB/HR 30,000.000 1L-LIQ.FR.TRAY-LB/HR 50,000.0002V-VAP.DEN-LB/FT3.......... 0.2500 2L-LIQ.DEN-LB/FT3.......... 45.000
ACFS VAPOR............. 33.333 GPM LIQUID......... 138.5193A-SYSTEM FACTOR 1.000 3B-COL.DIAMETER-FT......... 4.00004A-TRAY SPACING-IN.......... 24.000 4B-NO.LIQ.PASSES............... 15A-FLOW PATH LEN-IN........ 32.00 5B-TOT.TOP DC AREA-FT2... 1.377
5C-TOT.BTM DC AREA-FT2... 1.3776A-WEIR HEIGHT-IN.......... 2.0000 6B-TOT.WEIR LENGTH-IN...... 35.787A-DC CLEARANCE-IN......... 1.5000 7B-TOT.DC BTM.LENGTH-IN.... 35.788A-NO.VALVES/TRAY (OPT)...... 114 8B-TYPE OF VALVES............. V-19A-VALVE MET.DEN-LB/FT3....... 500 9B-VALVE THICKNESS-IN....... 0.074010-ACTIVE AREA-FT2.(OPT). 9.813 11-K2 FACTOR ................. 0.86
DRY TRAY DP-IN.LIQ....... 2.517 % DRY TRAY ALLOW DP======== 52.441TOT.TRAY DP-IN.LIQ....... 4.303 TOT.TRAY DP-PSI............ 0.1121HT.OVER WEIR-IN.LIQ...... 0.986 ACT.DC.VEL-GPM/FT2........ 100.594HT.UNDER DC-IN.LIQ....... 0.446 DSN.DC.VEL-GPM/FT2........ 245.790DC.BACKUP-IN.LIQ........ 7.762 %LIQ.(DC VEL) FLOOD======== 40.927DC.BACKUP-%TS........... 32.341 VLOAD..................... 2.4915MAX.ALLOWED-%TS......... 60.000 CAFo (FIG 5b).............. 0.4545% OF MAX.DC BACKUP====== 53.902 % VAPOR (JET) FLOOD======== 63.513
(NOTE: DC AREA IS LESS THAN MIN. REC. 11% OF COL. AREA)
E-050
Section Number Δ Q (mmbtu/hr) Δ P (psi)
10
9
8
7
6
5 4
3
2
1
Totals
0
0
-22.197
0
0
0
0
-18.321
-42.940
0
-83.458
0.497
0.298
0.403
1.214
0.833
2.3880.100
1.617
0.024
0.325
7.7
30"
20"
OH ACCUM
WBH, MPEC INC, 3/4/98, 100CC0H6.VSDUSED 100CCOH6.SD
100CC0H6.PD
"2PDP" SUMMARY FOR CRUDE COLUMN OHPHASE 3
15.7
8.0PSIG
E-051
E-065 E-067
E-066 E-068
14"
18"
12"
14"
14"
MPEC
Deliverables
Two-phase pressure drops through pipes, heaters, and exchangers can be rigorously calculated using MPEC’s in-house “2PDP” program. Shown here is
a typical “2PDP” summary.
MPEC Deliverables – Typical 2 Phase Output — Page 1/2Shown here are typical pages of “2PDP” output. As shown below, several different exchanger tube vibration analyses are built into the “2PDP” program to help detect the potential for this
problem.PIPE SECTION NAME = E-019 SHELLSIDEPIPE SECT. NO. 2 FLOW/PASS = 339.293 MLBS/HR.
( 1 PASS SECTION) EXIT PRESS. = 42.8671 PSIA.(EXCH SHELLSIDE) EXIT TEMP. = 447.42 DEG.F.
EXIT ENTH. = 118.199 MMBTU/HR.EXIT VEL. = 25.215 FT/SEC.SONIC VEL. = 690.030 FT/SEC.
SHELL PASSES/SHELL = 1.00 TUBE LENGTH = 16.00 FT.TUBE O.D. = 0.75 IN. TUBE ID = 0.5320 IN.TUBE THICKNESS = 0.10900 IN. TUBE PITCH SPACING = 1.0000 IN.TYPE TUBE PITCH = 3 (WHERE 1=SQ., 2=TRI., 3=SQ.ROT., 4=TRI.ROT.)NORMAL BAFFLE SPACING = 20.0000 IN. BAFFLE TYPE = SINGLE SEG.BAF.PASSES/SHELL PASS = 9.00 SHELL I.D. = 31.000 IN.NO. TUBES/SHELL = 608 TOTAL SECTION DUTY = 9.350 MM BTU/HR.SHELLSIDE DELTA P CORR. = BELL TUBESIDE FLUID DENSITY = 47.3100 LB/FT3TUBE-TO-BAFFLE DIA.CLEAR = 0.015625 IN. TUBE-BAF LEAK AREA = 0.05706 FT2.SHELL-TO-BAFFLE DIA. CLEAR. = 0.250000 IN. SHELL-BAF LEAK AREA = 0.05238 FT2.BUNDLE-TO-SHELL DIA. CLEAR. = 0.812500 IN. BUNDLE DIAMETER = 30.18750 IN.No. PAIRS SEALING STRIPS = 0 BAFFLE THICKNESS = 0.375000 IN.BAFFLE CUT - % OF SHELL I.D.= 31.650000 %No. OF PAR. BYPASS LANES = 1 WIDTH PAR BYP LANES = 0.664200 IN.TUBES IN CROSSFLOW = 284.691 CROSSFLOW AREA = 1.529159 FT2.WINDOW AREA = 0.92824 FT2 WINDOW HYD. DIA. = 1.17514 IN.
RUN BASIS: 34.38 % OF THE STREAM DATA FLOWRATE, 100 % OF THE PIPE DATA FLUX RATE.NOTE: BP = BAFFLE PASSES PER SHELL = BAFFLE PASSES PER SHELL PASS x NO. OF SHELL PASSES PER SHELL.SECT AVE INCR AVE AVE AVE AVE AVE FRICT ACCUM VIBRATIONAL ANALYSIS No's.INCR PRESS DELTA P TEMP ENTHALPY VAP MIX DEN VEL DELTA P FR LEN ----------------------------------NO PSIA PSI DEG F MMBTU/HR WT% LBS/FT3 FT/SEC PSI/BP NO. BP V1 V2 V3 V4 V5 V6 V7
---- ------- ------- ------- -------- ------ -------- ------- ------- -------- ---- ---- ---- ---- ---- ---- ----1 43.30 0.86 446.86 117.999 17.72 2.4923 24.73 2.188 0.39 5.4 1.1 0.3 0.1 1.8 0.9 0.62 44.16 0.87 445.68 117.584 17.24 2.5923 23.78 2.104 0.81 5.2 1.1 0.3 0.1 1.7 0.9 0.63 45.04 0.89 444.37 117.139 16.76 2.6995 22.83 2.020 1.25 5.0 1.1 0.3 0.1 1.6 0.8 0.54 45.95 0.91 442.96 116.667 16.26 2.8145 21.90 1.937 1.72 4.8 1.0 0.3 0.1 1.6 0.8 0.55 46.86 0.93 441.43 116.164 15.74 2.9379 20.98 1.856 2.22 4.6 1.0 0.3 0.1 1.5 0.7 0.56 47.80 0.95 439.76 115.629 15.22 3.0708 20.07 1.776 2.75 4.4 1.0 0.3 0.1 1.4 0.7 0.57 48.76 0.97 437.94 115.057 14.68 3.2145 19.17 1.696 3.32 4.2 1.0 0.2 0.1 1.4 0.7 0.58 49.73 0.98 435.97 114.447 14.13 3.3703 18.29 1.618 3.93 4.0 1.0 0.2 0.1 1.3 0.6 0.49 50.73 1.00 433.81 113.794 13.56 3.5400 17.41 1.540 4.58 3.8 0.9 0.2 0.1 1.2 0.6 0.4
10 51.74 1.02 431.46 113.093 12.98 3.7256 16.54 1.464 5.28 3.6 0.9 0.2 0.1 1.2 0.6 0.411 52.78 1.05 428.89 112.341 12.39 3.9298 15.68 1.388 6.03 3.4 0.9 0.2 0.1 1.1 0.5 0.412 53.83 1.07 426.07 111.530 11.77 4.1556 14.83 1.312 6.85 3.2 0.9 0.2 0.1 1.0 0.5 0.313 54.91 1.09 422.97 110.655 11.14 4.4070 13.99 1.237 7.73 3.0 0.8 0.2 0.1 1.0 0.5 0.314 56.01 1.11 419.57 109.707 10.49 4.6892 13.14 1.163 8.68 2.9 0.8 0.2 0.1 0.9 0.4 0.315 56.74 0.35 417.03 109.015 10.04 4.8973 12.59 1.113 9.00 2.7 0.8 0.2 0.1 0.9 0.4 0.3
--------------------------- THE FOLLOWING CONDITIONS ARE AT THIS PIPE SECTION'S INLET --------------------------0 56.91 0.00 416.42 108.849 9.94 4.9488 12.45 1.102 9.00 2.7 0.8 0.2 0.1 0.8 0.4 0.3
^ ^ ^ ^ ^ ^ ^IBRATIONAL ANALYSIS EXPLANATION: | | | | | | |V1 - VORTEX SHEDDING FREQUENCY TO NATURAL TUBE FREQUENCY RATIO - DO NOT EXCEED 5.0 | | | | | |V2 - CROSS FLOW VELOCITY TO CONNOR'S CRITICAL VELOCITY RATIO - DO NOT EXCEED 0.69 --' | | | | |V3 - BAFFLE DAMAGE No. (FOR DOUBLE SPAN TUBES) - DO NOT EXCEED 1.0 --------' | | | |
(DIVIDE BY 4 FOR SINGLE SPAN BAFFLE DAMAGE NO.) | | | | V4 - COLLISION DAMAGE No. (FOR DOUBLE SPAN TUBES) - DO NOT EXCEED 1.0 -------------' | | |
(DIVIDE BY 16 FOR SINGLE SPAN COLLISION DAMAGE NO.) | | |V5 - VORTEX SHEDDING TO ACOUSTICAL FREQUENCY RATIO - 1ST MODE - AVOID 0.8 TO 1.2 (VAPOR ONLY) ------' | |V6 - VORTEX SHEDDING TO ACOUSTICAL FREQUENCY RATIO - 2ND MODE - AVOID 0.8 TO 1.2 (VAPOR ONLY) -----------' |V7 - VORTEX SHEDDING TO ACOUSTICAL FREQUENCY RATIO - 3RD MODE - AVOID 0.8 TO 1.2 (VAPOR ONLY) ----------------'
THE TOTAL THERMAL CRACKING FOR THIS PIPE SECTION IS 0.000000 % THIS IS BASED ON 1.95347 SECONDS RESIDENCE TIME.
MPEC Deliverables – Typical 2 Phase Output — Page 2/2Shown here are typical pages of “2PDP” output. As shown below, a typical “2PDP” heater
analysis.
CASE DESCRIPTION: PHASE 3 CRUDE COL HTRS (FROM RUN 100ECU6.TWR)PIPE SECTION NAME = 24" TRANSFER LINEPIPE SECT. NO. 1 FLOW/PASS = 989.888 MLBS/HR.
( 1 PASS SECTION) EXIT PRESS. = 33.5000 PSIA.(NORMAL PIPE) EXIT TEMP. = 667.80 DEG.F.
EXIT ENTH. = 503.390 MMBTU/HR.EXIT VEL. = 73.780 FT/SEC.SONIC VEL. = 556.064 FT/SEC.STRAIGHT FT = 410.00 FT. (DELTA P IS AFFECTED BY FRICTION FACTOR)TOT.FIT. K = 5.4500 (DELTA P NOT AFFECTED BY FRICTION FACTOR)FLUX LEN. = 410.00 FT.PIPE O.D. = 24.000 IN.PIPE I.D. = 23.250 IN.FLUX RATE = 0.00 BTU/HR-FT2
RUN BASIS: 100 % OF THE STREAM DATA FLOWRATE, 78.727 % OF THE PIPE DATA FLUX RATE.THE ABSOLUTE PIPE ROUGHNESS CHOSEN WAS .00015 ( VS. 0.00015 FOR CLEAN COMMERCIAL STEEL )( NOTE THAT THE ABSOLUTE PIPE ROUGHNESS AFFECTS STRAIGHT FEET DELTA P, BUT NOT FITTING DELTA P.)
THE NORMAL WEIGHTED-DENSITY, LIQUID-VISC PRESSURE CALCULATION WAS CHOSEN FOR THIS RUN.THE INCREMENTAL LENGTHS WERE THEREFORE BASED ON THE 9TH COLUMN PRESSURE DROPS BELOW.SECT AVE INCR AVE AVE AVE AVE AVE ST.PIPE ACCUM BAKER MAP / R. KERN CALCSINCR PRESS DELTA P TEMP ENTHALPY VAP MIX DEN VEL DELTA P ST. FT. ---------------------------------NO PSIA PSI DEG F MMBTU/HR WT% LBS/FT3 FT/SEC PSI/100 + K Bx By REG. PSI/100
---- ------- ------- ------- -------- ------ -------- ------- ------- -------- -------- ---------- ----- -------1 33.83 0.67 668.05 503.390 42.80 1.2812 72.79 0.588 43.45 36.33 63246.14 DISP 0.9232 34.51 0.68 668.54 503.390 42.41 1.3162 70.86 0.573 88.97 37.47 62142.54 DISP 0.9033 35.20 0.70 669.03 503.390 42.02 1.3523 68.96 0.557 136.69 38.67 61049.32 DISP 0.8834 35.91 0.71 669.53 503.390 41.62 1.3896 67.11 0.543 186.69 39.90 59966.45 DISP 0.8645 36.62 0.73 670.02 503.390 41.22 1.4281 65.30 0.528 239.12 41.19 58893.88 DISP 0.8456 37.36 0.74 670.53 503.390 40.82 1.4679 63.54 0.514 294.07 42.53 57831.55 DISP 0.8267 38.10 0.75 671.03 503.390 40.42 1.5089 61.81 0.500 351.70 43.92 56779.41 DISP 0.8078 38.87 0.77 671.53 503.390 40.01 1.5513 60.12 0.486 412.13 45.37 55737.41 DISP 0.7899 39.27 0.04 671.80 503.390 39.80 1.5741 59.25 0.479 415.45 46.15 55195.43 DISP 0.779
--------------------------- THE FOLLOWING CONDITIONS ARE AT THIS PIPE SECTION'S INLET --------------------------0 39.29 0.00 671.81 503.390 39.79 1.5753 59.20 0.479 415.45 46.19 55168.14 DISP 0.779
THE TOTAL THERMAL CRACKING FOR THIS PIPE SECTION IS 0.004102 % THIS IS BASED ON 6.25451 SECONDS RESIDENCE TIME.
Vapor pressure drops can be calculated using MPEC’s vapor DP spreadsheet as shown here. The vapor pressure drops are rigorously calculated using the formulas in Crane’s Technical Paper No. 410.
MPEC VAPOR ΔP SPREADSHEET C.PIPEFLOW, Version 2.0, Jan. 9, 1997CLIENT: Based on C.Pipeflow by J. L. Bravo of S&B December 1981.
UNIT: Revised by W.D.McDaniel of MPEC Jan.,1997. Program uses SYSTEM: Bernoulli equation for isothermal compressible flow in pipes.
DATE / BY: Crane Tech. Paper No. 410, Equation 1-6 & 3-7CASE:
REV. NO.
Barometric Atm. Press in PSIA 14.70 INPUT CASE Example
From Inlet Point ATo Point A Outlet
Given Flow Lb/Hr 177422 177422Or SCFM (60°F, 14.7Psia) SCFM
CALCULATED FLOW Lb/Hr 177422 177422SCFM 10389 10389SCFH 623326 623326
Molecular Wt MW 108.00 108.00Ht Cap Ratio Cp/Cv 1.10 1.10Compress Fac Z 0.850 1.000Temperature °F 420.0 420.0Viscosity cP 0.018 0.018Pipe I Diam Inches 7.981 10.020Roughness Feet 0.00015 0.00015Straight Feet Of Pipe 5.00 40.00 Sq. Flush Entrance 1.0 T-Run No. T-Branch No. 1.0 1.0 45 Welded Elbow No. 90 Welded Elbow No. 5.0 3.0 180 Welded Elbow No. Gate No. (Full Size) 1.0 2.0 Butterfly No. (Full Size) St. Globe No.(Full Size) Ang. Globe No. (Full Size) Fl.Check Valve No.(Swing) 1.0 Exit 1.0 Misc Fitttings K 0.262 0.223 Source of Misc. K 8X6 8X10Total Fittings K 3.122 3.719SOURCE of Misc. DPMisc. Delta P PSIDestination Pr. PSIG 121.000 15.000
RESULTS Reynolds No. 7797451 6210724Friction f 0.01420 0.01362Total Resistance K 3.2285 4.3719Total Equivalent Feet 151.226 267.965
P in PSIG 124.849 25.858Density in Lb/Ft3 1.878 0.464Vel. in Ft/Sec 75.55 194.01Mach No. in 0.113 0.291
P out (in pipe) PSIG 121.000 15.000Density out Lb/Ft3 1.826 0.340Vel. out Ft/Sec 77.69 264.94Mach No. out 0.116 0.397
ΔP - Str. Pipe PSI 0.127 1.621ΔP - Fittings PSI 3.721 9.238ΔP - Misc. PSI 0.000 0.000ΔP - Sonic PSI 0.000 0.000ΔP - TOTAL PSI 3.849 10.858
MPEC
Deliverables
FEED PIPE SPARGER CALCULATION SUMMARY(Vapor, Liquid, or Two-Phase)
Vessel No./ Service: 26-10-035 / NHDS FRACTIONATOR Spreadsheet is by:Nozzle: Feed to Tray # 24 (per Fig 1) WDM of MPEC, Inc.Client / Location Houston,TexasRev. No. / Date / By: 1 / 1-25-99 / PTW (281) 280-0363Case / Comment Intermediate / Run 400INT1 done 11/24/98 Rev. 0, 1/14/99
TOTAL NORMAL FLOW TO SYSTEM OF SPARGERS = Inputs(Remember to do pumparounds at column return conditions.)
Vapor Liquid Mixture Comment Operating Cond. Basis :Wt. Flow - Lbs/Hr 58,869 429,946 488,815 °F Pin, Psig Density (ρ) - Lb/Ft3 (at Cond.) 1.218 36.830 8.146 (Note 1) 345 112Visc. ( µ ) - cP (at Cond.) 0.016 0.140 0.040 (Note 2)Flow as BPSD (at 60°F) 39,815.67 46,018.21 (Optional)Surf. Ten. ( σ ) - dynes/cm 8.60Vol. Flow - Ft3/s (at Cond.) 13.426 3.243 16.668% of Vol. Flow (at Cond.) 80.546 19.454 100.000Flow as GPM (at Cond.) 6,025.45 1,455.33 7,480.79API Gr. - (as 60°F Liq) 59.71 62.88 from Wt & BPSD
Set Actual Number and Size of Spargers and Holes ( Revise, if desired to meet recommendations below.) :2 Number of parallel spargers in system (Total flow above will be divided by this.)
7.981 dp - ID of pipe - in. 8.17 L - length of single sparger pipe - Ft.33 N - Number of holes in single sparger
1.5000 do - Diameter of holes - in.0.00015 ∈ - Pipe Roughness ( Clean Commercial Steel is 0.00015 ) - Ft.1.166 Ratio of total hole area in sparger to its pipe cross sectional area
Calculate Flow Conditions per Sparger ( Use "Mixture" Flows and Properties ) :244,407.5 W - Flow per sparger - lb/hr3,740.4 Q - Flow per sparger - as GPM at Cond.23.990 Vp - Velocity in pipe sparger at inlet - Ft/s
Calculate Intermediate Sizing Results :By = "Y" axis on Baker two-phase map = 396 x w.f. vap x W / dp2 / √(ρG x ρL) = 27,322 (Note 1)Bx = "X" axis on Baker two-phase map = 530.7 x w.f. liq. / w.f. vap. x ρG
1/2 x µL1/3 / ρL
1/6 / σL = 141.6 (Note 1)Re = Reynold's No. = 6.31 x W / dp / µ = 4,816,037RR - Roughness Ratio = ∈ x 12 / dp = 0.000226f - Friction Factor = { -2 x Log [ RR/3.7 - 5.02/Re x Log ( RR/3.7 + 14.5/Re ) ] } -2 = 0.014275 (Note 3)J Head Loss Factor = 0.3335 + 0.4904/N + 0.1891/N2 = 0.349C Orifice Flow Coefficient, If Re > 40,000 = 0.6 / √ [ 1 - (do/dp)4 ], otherwise input here 0.600 (Note 4)α Vel. Corr. Factor ( 1.1 if Re > 4000, 2.0 if Re <= 4000 ) = 1.1b - Coefficient for Y factor below, b = 0.23 if do/dp < 0.2, otherwise b = 0.23 + 0.2 x do/dp = 0.230 (Note 5)Y - Vapor Expansion Factor, Use 1.0 if liquid > 5 vol%, otherwise = 1 - b(above) x ΔPo / (Pin +14.7) = 1.00 (Note 5)Ek - Kinetic Energy Per Unit Vol (psi) = 2.8x10-7 x α x W2 / ρ / dp4 = 0.5567ΔPp - Pressure Drop along pipe sparger length (psi) = [(12 x f x L x J / α / dp ) -1] x Ek = -0.5258
Calculate Recommendations for < 5% Maldistribution :Recommended minimum hole ΔPo = Greater of (10 x Ek) or (10 x ABS(ΔPp) ) or 0.25 psi = 5.57So the max. rec. Ao total hole area ( in2) = 0.000415 x W / C / Y / √ ( ρ x rec. min.ΔPo ) = 25.09Min. prefered do (hole dia.) (in) = 0.15 x dp ( but not less than 0.5" which is the min. permitted ) = 1.1972Maximum recommended do (hole dia.) (in) = 0.2 x dp = 1.5962Max. no. of holes (N) at min. rec. do (hole dia.) = (max. rec. Ao) / [ ( min. rec. do / 2 ) ^ 2 x π ] = 22.3Max. no. of holes (N) at max. rec. do (hole dia.) = (max. rec. Ao) / [ ( max. rec. do / 2 ) ^ 2 x π ] = 12.5More small holes prefered over fewer large holes. Space hole centers at least 2 hole diameters apart.
Calculate Actual ΔP and Maldistribution for Set Actual Holes @ 3 Flowrates : @ 50% @100% @200%Ao - Actual hole area (in2) = N x (do/2)2 x π = 58.32 58.32 58.32Vo - Hole Velocity (Ft/s) = W / ρ / (Ao/144) / 3600 10.29 20.58 41.16ΔPo - Hole ΔP (psi) = [ 0.000415 x W / (act. Ao) / C / Y] 2 / ρ = WANT 0.25 MIN (Note 6) 0.26 1.03 4.12% Maldistribution = ABS ( 100 x { √ [ { ΔPo - ABS (ΔPp) } / ΔPo ] - 1 } ) = 30.02 30.02 30.02
Note 1) Homogeneous (non-slip) flow is assumed (if 2-phase). Size pipe for spray or bubble flow. ( prefer By >30,000 on Baker Map )Note 2) Use Liquid viscosity for mix if vapor is < 5 vol%. Otherwise average mix viscosity on a volume basis.Note 3) If Re <= 2000, then flow is laminer and this cell uses f = 64 / Re instead.Note 4) If Re <40,000 Look up C factor for square-edge orifices on page A-20 of Crane's and put in box provided.Note 5) If ΔPo / Pin(in psia) > 0.5, then vapor systems become sonic and this calculation becomes incorrect.Note 6) Do not design for less than 0.25 psi (ΔP)o @ 100% of flow, and preferably at 50% of flow.
Column feed spargers can be designed or evaluated with the in-house spreadsheet shown here. This spreadsheet is used to calculate the sparger pressure drops and
percent maldistribution for vapor, liquid, or two-phase flows.
MPEC
Deliverables
MPEC DIESEL HYDROTREATING CORRELATIONBased on correlations used with permission of J Y Livingston Consultant of Pasadena, Texas
And PCI Consultants, Inc Of Houston, Texas(As Modified By W.D.M., 10/10/96)
NOTE: = Req. Input DataDIESEL FEED DATA
Name BPSD API SG Lb/Hr UOP K VABP-°F D-86 EP,°F MW Wt% S Wt% N Wt % Olef Anil Pt Calc. C.I.
FCCU LCO 18,480 26.80 0.8939 241,010 10.97 490 713 183.7 0.6000 0.0500 10.00 98.0 32.05WCU DSL(Stg) 635 37.91 0.8353 7,739 11.91 528 713 213.7 0.1100 0.0000 0.00 165.0 53.94WCU DSL(Live) 19,000 37.91 0.8353 231,547 11.91 528 713 213.7 0.1100 0.0000 0.00 165.0 53.94ECU K/D 385 41.14 0.8196 4,604 11.91 478 709 189.3 0.0700 0.0000 0.00 157.0 53.30
TOTAL 38,500 32.43 0.8632 484,900 11.45 509 713 197.4 0.3532 0.0249 4.97 134.8 42.76
NOTE: The Calculations Below Are Based Only on The Total Stream Properties Above.
Input Operating Conditions:
Rx. Inlet Press., PSIG: 755Rx. Exit Press., PSIG 705Ave. Rx. Temp., °F 660Recycle Gas, MMSCFD 23.0Recycle Gas m% H2 70.0Makeup Gas, MMSCFD 10.0Makeup Gas m% H2 78.0Catalyst Vol., Ft3 4524Catalyst Activity 1.25 ( Normally 1.0 for 1/8" extrusion, 1.25 for 1/16" extrusion, 1.5 for 1/16" spheres )Catalyst Type 1.00 ( Input 1.00 for Cobalt Moly or 1.50 for Nickel Moly - Used for Nitrogen Removal activity)
Calculate Reaction Severities Calculate Data Points For Reaction Sensitivity Curves(See Attached Graphs)
Moles/Hr Oil Feed to Rx. = 2456.03 Sulfur:Moles/Hr Gas Feed to Rx. = 3623.19 Product Sulfur at Other LHSV's And TemperaturesMoles/Hr H2 Feed to Rx. = 2624.07 LHSV 1.0 1.5 2.0 2.5 3.0Rx. Inlet H2 Partial Pressure, PSIA = 332.2 Temp-°F % S in Product Oil HDS KtLHSV, 1/Hr = 1.99 600 0.0041 0.0182 0.0382 0.0596 0.0802 1.5451
625 0.0027 0.0138 0.0311 0.0505 0.0698 1.6893HDS Kt = 1.9139 650 0.0017 0.0102 0.0248 0.0421 0.0600 1.8468HDN Kt = 0.4914 675 0.0011 0.0073 0.0193 0.0346 0.0509 2.0190Olefin Sat Kt = 2.2493 700 0.0006 0.0051 0.0147 0.0278 0.0425 2.2074
725 0.0003 0.0034 0.0110 0.0219 0.0349 2.4132Wt.% S in Product Oil 0.0222 750 0.0002 0.0022 0.0079 0.0169 0.0281 2.6383Wt.% DES (% Sul.Removal) 93.71Wt.% N in Product Oil 0.0122 Nitrogen:Wt.% DEN (% Nit. Removal) 50.85 Product Nitrogen at Other LHSV's And TemperaturesWt.% Olefins in Product oil 0.1924 LHSV 1.0 1.5 2.0 2.5 3.0Wt.% DEO (% Olef. Removal) 96.13 Temp-°F % N in Product Oil HDN Kt
600 0.0098 0.0133 0.0156 0.0171 0.0182 0.3242625 0.0082 0.0119 0.0143 0.0159 0.0172 0.3855650 0.0066 0.0103 0.0128 0.0147 0.0160 0.4585675 0.0052 0.0087 0.0113 0.0133 0.0147 0.5452700 0.0038 0.0072 0.0098 0.0118 0.0133 0.6484725 0.0027 0.0057 0.0082 0.0102 0.0119 0.7711750 0.0018 0.0043 0.0066 0.0086 0.0103 0.9170
Olefins:Product Olefin at Other LHSV's And Temperatures
LHSV 1.0 1.5 2.0 2.5 3.0Temp-°F % Olefin in Product Oil Olef Sat Kt
600 0.0424 0.2074 0.4589 0.7390 1.0153 1.6555625 0.0221 0.1345 0.3317 0.5700 0.8178 1.8810650 0.0106 0.0823 0.2294 0.4244 0.6395 2.1373675 0.0046 0.0471 0.1509 0.3035 0.4837 2.4284700 0.0018 0.0249 0.0937 0.2074 0.3521 2.7592725 0.0006 0.0121 0.0546 0.1345 0.2455 3.1350750 0.0002 0.0053 0.0295 0.0823 0.1630 3.5621
Whenever hydrotreating reactors are involved in the process study, they can be calculated using MPEC’s in-house “Hydrotreating” spreadsheet. The spreadsheet (presented here) and the chart on the following page, present 2 of this program’s 8
pages of output.
MPEC
Deliverables
MPEC Deliverables -- CorrelationsChart showing Product Sulfur vs. Temperature & LHSV inside MPEC’s Diesel Hydrotreating Correlation.
Product Sulfur Vs. Temperature & LHSV
0.000
0.005
0.010
0.015
0.020
0.025
0.030
0.035
0.040
0.045
0.050
0.055
0.060
600 610 620 630 640 650 660 670 680 690 700 710 720 730 740 750Average Reactor T emperature - °F
Wt %
Sul
fur i
n Pr
oduc
t
1.0
1.5
2.0
2.5
3.0
LHSV’s
LHSV = 3.0
LHSV = 2.5
LHSV = 2.0
LHSV = 1.5
LHSV = 1.0
MPEC Deliverables – Base Case PFD
After using any or all of these programs as appropriate, MPEC prepares a base case PFD to summarize the calculated plant operations. The PFD can be compared to the actual plant data to identify plant problems and set turnaround priorities.
As mentioned before, MPEC’s PFD’s contain all the essential information needed by a process engineer. Our base case PFD also contains a heat exchanger table which shows the duty, area, heat transfer coeff., LMTD, and pressure drop of each exchanger.
MPEC DeliverablesTypical Base Case PFD
12-10-005 High Pressure Receiver Loadings
Vessel Process Summary Sheet
Basis:Operating Conditions: 106 οF, 200 PSIG
Case Loadings Lbs/Hr. BPSD60 GPMh ACFS Lbs./Ft3 Visc.,cP.Normal Vapor 106429 27.2 1.08 0.01LEP Vapor 106427 27.0 1.09 0.01
HC Liquid
Overhead Vapor: Normal LEPVc = Critical Vel. = 0.157((pL -pv)/pv)0.5 = 0.93 ft./sec 0.92 ft./secActual Vapor Vel. = ACFS / C.S. Area = 0.35 ft./sec 0.34 ft./secActual Vapor Vel. as % of Vc 38 % 37 %
HC Liquid In Bottom of Vessel: (Based on Normal Case)NLL HC Holdup in Vessel = 7931 gal., 3.97 min. (turnover)Assumed Instrument Span = 24 in., 1735 gal.Net HC Prod. or Feed Rate= 65852 BPSD60, 1999 GPMhInstrument Span Holdup = 0.87 min.(total)NLL to HLL = 0.43 min.NLL to LLL = 0.43 min.
Water Decant In Vessel: (Based on Normal Case)Design Water Droplet Diameter 0.005 in.Water Settling Velocity = Vs = 25.60 in./min. (Intermediate Law)( Note that 10 in./ min. is the max. recommended for new designs.)Vertical distance required to Settle = Dv = 60 in.Hor. Liq. (HC + H2O) Vel. in Drum = Vh = 6.82 ft./minRequired Length to settle = Dx X Vh / Vs = 15.98 ft.Required Length as % of Available Length = 85 %
Water Liquid in Boot: (Based on Normal Case)Water Holdup in Boot = 296 gal., 38.09 min.Instrument Span in Boot = 24 in., 170 gal.Net Water Prod. or Feed Rate = 7.77 GPMhInstrument Span Holdup = 5.82 min.
HC Decant in Boot: (Based on Normal Case)Design HC Droplet Diameter = 0.005 in.HC Settling Velocity = Vs = 11.52 in./min. (Stokes Law)(Note that 10 in/min. is the max. recommended for new designs.)Water Velocity in Boot = 1.29 in./min.Water Velocity as % of Allowable Settling Velocity = 11 %
Nozzle Velocities and ΔP's:
Normal Case LEP Naphtha CaseNo. ft./sec. psi/100' No. ft./sec. psi/100'
1 33.15 0.955 1 32.65 0.8782 34.64 0.186 2 34.44 0.1853 0.34 0.009 3 0.37 0.0114 5.76 0.193 4 5.35 0.165
Vessel Process Summary Sheet12-10-005 High Pressure Receiver
SCALE: NTS APPROVED BY: DRAWN BY ERDDATE: 10/04/2000 REVISED
DRAWING NUMBER69,000 BPD Case Loadings
15'-3" 3'-6" 3'-11"
7'-6
"
Elevation to Center Line 25'-0"
10'-0
"
N.L.L.
1'-0
"
1 14" Inlet 212" Vap. Out
4
12" Liq. Out
3" Drain
3
25'-0"
18' - 9"Assumed Water Settling Length
N.L.L. 3"-9"
Vessels are evaluated for adequacy in our base case report and documented on vessel loading summary sheets. Vessel holdups, liquid-vapor separations, and water-
hydrocarbon separations are checked.MPEC
Deliverables
MPEC Deliverables -- Recommendations
Once the unit’s existing capabilities and problems are understood, MPEC can then reuse these same computer tools to improve the unit’s performance and/or expand its capacity without making any unnecessary changes to the unit.
Typically better column internals, better heat exchanger bundles, and more optimized piping can be installed to substantially improve unit capacities with little or no major equipment additions or replacements.
MPEC Deliverables -- RevisionsMPEC will then complete the study by issuing a report of recommendations with revised PFD’s showing all the
suggested revisions and the improved or expanded heat and material balance. Process specifications for all the new or revised equipment will be included so that the client can submit these items to vendors for quotations.
Shown here is a typical vessel specification.
MPEC Deliverables – PFD with RevisionsShown here is a typical PFD with revisions noted in red.
B-6 Refining Horizons THEOILDAILY March 24, 1992
Doug McDaniel Aims to Provide Alternatives for Small RefinersBy Susie T. Parker
William D. “Doug” McDan-iel likes the challenge of hav-ing to come up with real so-lutions to the problems thatmany independent domesticrefiners face today. “People come in with realproblems and you work themout. I enjoy that becausethat’s real engineering,” hetells Refining Horizons. After20 years in the business, hesaid it’s still a “soberingthought” to see a refinery putinto effect changes he’s pro-posed. Somewhat of a refiningtroubleshooter, McDaniel saidhe began his own consultingand process engineering firm,MPEC Inc., in 1988 to focuson a “niche market” that wasnot, and is not, being handledproperly by the larger engi-neering companies. Thatmarket is the process engi-neering requirements of thesmall independent refiners. Major engineering compa-nies “are dedicated to (jobs)that are the biggest and cost-liest,” said McDaniel. As such, he added, theyoften suggest changes thatare not in the best interests ofsmall refiners, many of whomsimply want to maximize the
output of their existing plantsin the least costly mannerpossible.
Not Really Needed In short, McDaniel believesthe major engineering firms,who concentrate on mega-projects, often proposechanges to small refineriesthat aren’t really needed. They “do a bunch of workand run up big bills,” he said.“The smaller refiners’ needsrequire more interest andtime that the majors arewilling and able to give them,”he adds. Houston-basedMPEC tries to fill that void bydoing the work “more effec-tively and cheaper.” In one instance, McDanielsaid El Paso Refining Co. inEl Paso, Texas, sought thehelp of larger engineeringcompanies in boosting thecapacity of its refinery. “The other engineers said(the plant) was bottleneckedout and running at full limit.We suggested some pipingchanges that raised the ca-pacity from 18,000 barrels aday to as high as 27,000b/d,”said McDaniel. The job, which took placein 1988, saved El Paso $1million per month at the re-finery, he noted.
Acts as Advance Team McDaniel said MPECdoesn’t take away businessfrom major engineering firms.Instead, it acts as sort of anadvance team by doing theprocess engineering work forthe small refiners. The largeengineering firms usuallythen follow and perform de-finitive engineering work. “I believe that the majorengineering (companies)would just as soon havesomeone give them the proc-ess designs: so they can focuson definitive engineering,” hesaid. The reason: “Most of themoney is made on the defini-tive design.” McDaniel estimates thatprocess design work accountsfor only 2 percent of the totalcosts of a stand-alone grass-roots facility, while definitiveengineering accounts for 12percent. “We cater to the small re-fineries that don’t have proc-ess expertise,” he noted.
Like an Architect McDaniel likens a processengineer’s job to that of anarchitect. He works on com-puters and doesn’t go near“any of the hard stuff such assteel and concrete.” The “dirtywork” is left up to the defini-tive engineer, whose job islike that of a builder.
For a refinery, the processengineer’s job is to examine“the jillions of questions thatgo into the actual design.There are a lot of little ques-tions that the process engi-neer needs to ask in layingout the game plan. These canonly be answered by the in-terplay between the ownerand the process engineer,”said McDaniel. Because of all the consid-erations, he noted, “there areno two refineries that are thesame. They are almost alwayscustom-designed for the indi-vidual customer.” On the other hand, thedefinitive engineer’s workincludes things such as thefoundation, structural work,column thickness and piping.“All their work amounts tomechanical work,” saidMcDaniel.
Limited Clientele He indicated that histhree-man firm has a limitedclientele, with only five or sixclients: “I’m just known in thebusiness among a few selectrefiners, and that keeps mebusy.” The “hardest thing is to getfinished the work I’ve prom-ised in the time allowed,”observed McDaniel. But, heacknowledged, “I’m in thekind of business where a
busy schedule can quicklyturn into a not-so-busyschedule.” He said his work can be-come “very limited” as inde-pendent refiners close downcapacity due to the high costof implementing federal andstate environmental regula-tions. If that happens, he saidhe may have to go to work fora major engineering com-pany. “That’s just a fact oflife.”
Cites Peter Principle In the meantime, McDan-iel, 45, said he has yet tosuccumb to the Peter Princi-ple, “where guys get promoteduntil they’re incompetent.” He adds that he won’t getrich doing what he does, butrather collects a manage-ment-type salary. He seeshimself as the general practi-tioner rather than the spe-cialized heart surgeon, whomakes the big bucks. McDaniel, who is presidentof MPEC, is joined by partner,Joe Musumeci, and his wife,Sharon, who is secretary andtreasurer. “She allows me to donothing but process designand optimization work.Thanks to her, I can dedicatemy full time to engineering.That’s a valuable partner in asmall business.”
MPEC -- Providing Alternatives
