Engineering Data Book Published as a service to the natural gas processing and related process industries by the Natural Gas Processors Suppliers ™ Association 808 Home Federal Building Tulso, Oklchoma 74103 Compiled and edited in co-operation with the ® Natural Gas Processors Association Ninth Edition 1972Natural Gas Processors Suppliers Association Officers and Directors President: W, First Vice President: John Biegel, Fluor Corp} Houston ‘Second Vice President: A.B. Richert, Dresser Engineer- ing Co, Tulsa Kenneth W. Andrews, Byron Jackson Pumps |Ine. Houston Louis Barnett, Vinson Supply, Tulsa Babe parsers Sette DaP Se EH, San Diego W. L. Davis, Engineers & Fabricators, Ine, Houston Harold F. Dawe, Steans-Koger Corp, Derive 2,8, Deer, Drester-Clark Diy» Dresset, Industies, Tulsa GN: Bonachy, American Meter Co, Tulsa Vineent J. Dove, Hudson Engineering Cork, Houston Harvie Furrh, Panhandle Equipment Co, Paippo, ‘Tex. WA. Griffin, Daniel Indastties, Ine, Houstel BE Hams, Honeywell, Inc, Houston 6. F Hunter, Bowden Consituction Co., Ine ‘Odessa, Tex. George E, Koutelas, 5. F, Pritchard & Co, Kdnsas City 1971-1972 Donachy, American Meter Co., Tulsa ‘Treasurer: Ben K, Rector, Fisher Controls Co, "Marshalltown, Ta. Secretary: R, E. Cannon, NGPA & NGPSA, Tulsa Directors Brock Mott, The Mott Co,, Bellaire, Tex. Raloh Nickle, iaid-Continent Supply Co Fort Worth James C. Norvis, Brown & Root, Inc. Houston Ben K. Rector, Fisher Controls’ Co., ‘Marshalltown, Te. ALB, Richer, Dresser Engineering Co, Tulsa Pranic M. Satlerwhite, Delta Engineering Corp., Houston Walter 8. Smith, Process Equipment Co,, Tul Herman Urech, Krueger Engineering & Mfg. Co, Houston Gary Utter, Nutter Engineering Co, Tulsa Harold Warnick, Ford, Bacon & Davis Texas, Ine, Dallas R. C. Hartman, Atlantic Richfield Co., Dallas Advisor to the Board: W. W. Sentell, AMP. Beaird, Tine, Shreveport Editorinl Committee - Ninth Edition 4. C, Norris, General Chairman, Brown & Root, Inc. MA. Alblght, Phillips Petroleum Co, Gienn Allaredge, ‘Tne’ Rainey, Corp Keith Askins, Stearns Roger Corp. Sam Aubrey? Myers-Aubrey Co. Ken Bacon, Warren Petroleum Corp. Bon Baliara, Coastal Chemical Co HCW. Barber, Phillips Petroleum Co B.C. Barnes, ‘Barnes & Click, Ine Robert G. Holling, Mobil On Corp. B°E Buxton, Union Carbige Corp. E, E Cannon, NGPA, NODSA M._O, Clark Pallips Petroleum Co, °F Connolly, Fluce Cor. 3. F. Cooper, aso. Purppa, Inc Tack, Ne Corbin, NALCO. Chemical Co Web. Cummings, Davison Chemical Div. W. IR, ‘Grace de Co. WoL. Davis, Engineers & Fabricators, Ine Jack Dingman, Jefferson Chemical Co. W>N. Donachy, American Meter Co, Gic Eilts, Matsdor Chemical Co, Homer English, Marathon Oi Co. ohn Erbat, Oklahoma State University Donald N. Bwan, ‘The Ortiott Corp. Ay. Flynn, Shell Oil Co, Giegory’ BHtales, Union ‘Carbide Corp. Charlez Hammack, Engineers & Fabricators, | Ine RoW. Hankinson, Phillips Petroleum Co. Bugeie A. Hanlcher, Continental” Oi Reearch & evelopment Amol Hegwer, Fish Engineering & Construktion, Tee HUB Berin Coatl Sates Gar Producing Co ike Higgins, Ingersoll-Rand Co. TE, Hillourn, Phillips Petroleum Co. George: Holmes, Atlantic Richlicld Co, GAN frouston, The Ortlott Corp. $05" Huppler’ Bato Procuction esearch Co, RH. Jacoby, Gult Research & Development Co. Hon Jones, Peny B Bass, ine D.C: dest; Phillips Petroleum Co, Ki Riliren, Chevron Oil Field Research Ci George Lesehinan, Leachman Engineering. Ce. Ine Re Me Ligon, Brown & Root, Tac. ‘Tom C, Madden, AMF Beaird, Ine. KN. Maddox, Oklahoma State University RZ, Mason, Amoco Production Co. RL H, Meyer, ARCO Pipeline Co, Ray Miller, Foster Wheeler Corp. Virgil Moote, Daniel Industsig D.F. Morris, Dresser Engineering Co. Ross McAlpine, Maloney Crawford Tank Corp. dim’ McGill‘ Myers-Aubrey Co. Forrest, McLane, Flow Control Inc. ‘TE McLarty, Delta P Inc. Dave Parnell, Ford, Bacon & Davis Texas, Inc, Louis Phannensticl, Air Products & Chemicals, ine. EA. Poyhonen, Oklahoma Natural Gas Co. Bil Randall, B.'R. Randall Ben Rector, Fisher Controls Co. Ken H, Rhoads, Shell Oil Co, Glen Rice, Fisher Controls Co, Jack H. Hidde, Betz Laboratories, Inc Raymond . Schneider, Elliott Co, Hubert Sehutz, Mobil Oil Corp. Arnol 1. Sellars, Crest Engineering Tne. BE Shen, Mobil Research and Bevelopment Corp. Joseph Schutz, Humble Oil & Refining Co. Norman F. Sitnmons, Texas Eastern ‘Transmission Corp. HG, Smith, Solar - Div. THC, KE Starling, University of Oklahoma Carl Springer, Continental Oil Co. Gort Sutton, Ne Will Swerdlofi, Mobil Oil Corp. Gordon W. Swinney, Phillips Petroleum Co. BOJ"Thompson, Warren Petroleum Corp. John Thompson, Hunt Oil Ce, Richard Thompson, University of Tulsa EL. Upp, Daniel Industries Herman Urech, Krueger Engineering & Mfg. Co. Gary Unter, Nutter Enaineorng Co, A. R, Valdes, Fish Engineering & Construction, Inc. Bob ‘Vickery, Sun Oil Co. 32M, Ware, United Centrifugal Pumps Wally Westervelt, Warren Petroleum Corp. Robert T, Walliamson, Stearns-Roger Corp. Steve Worley, Production Systems International Lyman Yarborough, Amoco Production Co. Meee eS eee era a See eeePreface to the Ninth Edition ‘The Natural Gas Processors Suppliers Association is an organization of companies with specialized knowledge of and interest in the supply and service needs of the natural gas processing industry. One of its historical and principal contributions to the in- dustry is to provide cooperative, organized diversion it meetings of the Natural Gas Processors Associa~ tion, ‘This activity eliminates the competitive expen- sive, and distracting entertainment by individual companies, which is common to many industry ‘meetings. “The organization operates under rigid rules to assure an atmosphere conducive to pro- ductive technical meetings of the NGPA; these rules also assure equal opportunity to all supply and ser- vice companies in contacting customer personnel at NGPA meetings. A second major service to the gas processing and related process industries is embodied in the Engi- neering Data Book, which was first published in 1935. Over 150,000 copies of prior editions have been used throughout the world by engineers, operating personnel, and students. Over 90% of these have been distributed free of charge by NGPSA member companies as a service to their eustomer-clients. ‘The first edition contained much advertising and a little technical information. In subsequent editions, technical and design information was expanded t ‘the point where the Data Book became the accepted engineering reference work for the gas processing industry. In addition, the Data Book has found wide acceptance in the refining, gas transmission, and petrochemical industries. ‘This edition is an attempt to assemble, in a single volume, basic design information together with data and procedures that can be used by field and plant engineers to determine operating and design param- eters. It is also intended as an aid to design engi- neers who, in spite of increasing availability of com- puter routines and other sophisticated design me- thods, require general reference work as a guide to accepted engineering practice for estimating, feasibility studies, and preliminary design. ‘To meet these dual needs, every attempt has been made to present material and data in simplified, easily used form to allow rapid estimations and cal” culations with a slide rule or desk calculator. Ex- ample problems are included where necessary for clatification, and documentation has been provided for users who wish additional detail In recognition of the rapidly changing technology of the process industries, the Ninth Edition has been published in a loose-leaf format, which will permit periodic up-dating in response to new data, im- proved methods, and industry needs. ‘Acknowledgement NGPSA wishes to acknowledge the work of these individuals who contributed their talents and literally thousands of hours of time to the writing, editing, reviewing, and assembling of the information in this revised edition, Many, though not all, of those in dividuals are listed in the rester of ‘the Editorial Committee. NGPSA also is indebted to processing and service companies that made available both personnel and valuable technical information for this edition, some of which has not been published previously, It would be futile to try to recognize all indi- viduals and companies who made extraordinary contributions to this book, However, at the risk of omitting some deserved recognition, certain con- tributions must be acknowledged James C. Norris, Brown & Root, Inc, who organized the overall effort as Chairman’ of the Ed torial Committee. —Harold F, Dawe, Stearns-Roger Corp, who undertook the thankless but essential, job of Sched~ uuling the many individual committee chores into an orderly and coherent flow of editorial material, ~The Editorial Review Board, which reviewed in detail all editoriai material for accuracy, convenience of use, and consistency with the objectives of the Book; ‘each member, in addition, contributed con- siderably to virtually every section. Review Board ‘members: ‘* Warren White, Chairman, Hudson Engineer ing Corp. Earl Kirk, Union Texas Petroleum Corp. ‘© Manning Ligon, Brown & Root, Inc. * Jay MeGranahan, Delta Engineering Corp. © RN, Maddox, Oklahoma State University * Merle Rahmes, Amoco Produetion Co. In addition, special acknowledgment is due G. L. Farrar, The Oi] and Gas Journal, who served as Editor for the Ninth Edition,Table of Contents Measurement Section| 1 Centrifugal Compressors Section 5 Tank measurement and gaging 1-1 per nanee. Sh ss Postve deplocement and turing Icalednonian cebebeaee 7 Motor proving 12 eee Orifice meter measurement 1319 Mola heat capacity one Volume correction factors 14 (Coeur pelea te iad ene i Refrigeration compressors 513 Orilice meter equations 19—[-l Pumps Section 6 Flow nozzles and venturis ri Centrifugal pumps 6 Mase measurement Lia ~sizing and selection 61 New types of flow measurement 1-12-1113 -nel positive suctionhead Vapor pressures of hydrocarbon conversion factors and mixtures hid formulas 62, 64 Meter factors 116 + 1-28 trouble shooting 63 Reciprocating pumpe 62 [Control Valves Section] 2 + power requirements 65 sapeneengeseeerngteerenars - net positive suction head 6S instructions 21,28 ~ plunger displacement 66 Liquid capacity chart and -piping 86,67 instructions 21,25 trouble sheoting 66,69 Steam capacity chart and aie instructions 1, 2 oe Satheg fade og Capacities of conductors 72 Neloe seolclien’ 28 Transformer connections 72 Motor torque and horsepower 7-4 Relief Valves Section! 3 Motor enclosures 78 , Temperature ratings 7 Laser bs Protective devices 78 Types of pressure relief valves 32 Lightios oan Sane les a Grounding ie Sizing for mixed phase reli! 3.5, eee Sizing for flashing liquids 35 SS Sizing for gas or vapor 36 Shell-and-Tube Heat Transfer Section 8 Fie sizing, liquid systems 36 Basic heat transfer equations @1 Fire sizing, gas systems 37 Log mean temperature difierence 81, 82 Storage systems 37 Film resistances, pressure drop @1 Codes, standards, and recom- Heat transfor coefficients 85 monded practices 38 Sensible heat transfer, problems 85 — 612 an 7 Condensers or Reciprocating Compressors Section! 4 Finned tubes Bla Heat capacity ratios, molal Robollers and chillers eis heat copacity 41 Characteristics of tubing 816 Estimating compressor horse Thermal conductivity of metals 817 bower | HirCooled Exchangers ‘Section 9 Power requirements, estimaled 43 Capacity, volumetricelliciency 44 Arrangement and mechanical Values of re 4s Aide contol 81 Discharge temperature 46,44 berbetedeyisiat na Rod loading ae Estimation surface area, plot Horse power calculations 46—[e4 «area, and horsepower 93,9714Fluid Flow and Piping Section 10 Permissible expansion of natural as 192154 Flow of gas throush pire lines, Vapor-selid equiltbeic 155158 e Flow of gas through pipe lines, aes of water in ea eae noe Dew point of natural gas 1510 “ines, Dorey formula, 10s Gas dehydration 15-11 — 15-19 srg eraes ide rauiareae et cio7 Glycol dehydration 15.11 — 1514 Pisehie ibe oct ines Soliddesiccant dehydration 1514 1516 Fritzsche's formula "199 Glycol infection ae Pressure drop for flowing water 10-10 es ett aad Prossure drop for hydrocarbon ‘asoline and LP-gas treating Tegal toll Processes 18-28 — 15-32, Tobie of elfective fire streams 10.12 Natural gasoline specifications 15.33 — 1534 Pressure drop through values ie oae ecee oan 1535 e cand fittings los Absorption and stripping factors 15-28 Design properties for pipe 10-14 — 10.17 Physical Properties Section 16 Water Treatin tion 11 7 Compressibility of gases 1641, 167 — 16:7 Definitions na Physical constants 16.2 186 Common impurities re Fluid densities 16-18, 16:19, Solubility of chemical otis! compounds 13 Bolling point, distillation 16-25 Boiler water treatment 114 Specific aravity of petroleum : Cooling water treatment ne eats 1620, 1621 Waste disposer i Critical temperatures, pressures 16-28, 16-27 we ‘ : Surface tension 16.27, 1633 — ‘ater analysis 112 lead ieaeioes 5 Vapor pressures 1629, 16:30 Cooling Towers Section 12 , e@ poling Viscosity of liquids. leah Prediction of operating variables 12-1 Viscosity of gasee 1632— 1694 Performance characteristics 123 Thermal conductivity of liquids 16-85, 16-98 Wet and dry bulb temperatures 124 Heating value of natural gases 16-34, 16:37 — — ‘Thermal conductivity of gases 16-37 Storage losses 131 Thermodynamics Section 17 Liquid equivalent of tank ve 1 fee eer Enthalpy corrsiations wns — 1 a Sete cial Entropy correlation 1720, 1724— Vapor pressures of gasolines 138 tet ereetctise 172175 ee Mollier diagrams, me! @ _[Gervession Fectors Seaton 14 athe, one iene, propylone, nitrogen, carbon Velocty le dioxide 17$—17-12 length, Sea eect aaa Ideal gas state enthalpies 17-13 — 17-14 pressure eee ae Total enthalpy charts 17-26 —17-34 APland Baume’ gravity 143 = Circumference, crea, end volume Fquilibrium Ratios Gentenaiaa of circles and cylinders 144 Partial volumes, cylindical tomks 14.6 Description and use of the Partial volumes, ellissolds o quai ae ake 149 The convergence pressure concept 183 @ — etyarction and Treating aT Critical locus chart 185 K-charts, Py: 800; 1000; 1500; 2000 Hydrates in natural gas systems: 15-1 — 158 3000; S000; 10,000 psic 1e9— leuErrata for the First Printing, Engineering Data Book, Ninth Edition Page Wo. 15 “Liquid specific gravity at 60°E", at Equation (4) should read: pp = (Stroke) (zpn) (7D?) 4(4728) Equation (5) should read: pp = (Stroke) (epm) TY (0?-) Supercompressibility, Tables TS-s61, ‘TS- 461, Western Gas Processors and Oil Refiners Asso- ciation, (c) Liquid Hydrocarbon Compressibility API Monograph Standard 1101 (Table No. 3) American Petroleum Institute. (A) Liquid - Volume reduction to 60°F, Tables — ASTM-IP petroleum measurement Tables—(American Society of ‘Testing Material) pp. 1-16 through 1-28 for various meter factors, tables, con- versions, etc.) 1-15F.,— Manometer factors bce This ols fr as wth esr ye ec oe hth on ots th th my sf, hn whee ae set pe gets | tpt [Te [see] naoe | nano] | nace Jaen s:0 ct, |ro0s0 | voor | rove | so | aera | soto | 9951 vs *racao |} roots} sooee | 92 | ese | ‘seu | ‘sm40 450 * [soso |} coir | see | oar | oso | ‘seas | “oos0 700 -— frons0 | ro0is | sam | esr | sear | ovas | s720 759 »—fracse | roo | sree | a0 | eas | seis | ore 30 wooao [van | over | aves | onan | conse | omer soo vanae |) 000 | oem | sor | ose | “sous | apar 450 » rove |} rao0e | 9990 | sees | sear | ovae | oar 700 + Jiecae |} rover | aves | sesr | eas | ‘asa | 9917 750 ~ fro |} o008 | ‘see | ase | eae | apie | se0r c= cor [seore | vance [ene | oor | eae | oan | wre 600 ~~ |roore |} 9958 sas | 9972 | 9956 | 9943 | 9933 oso ~ —Jroote |} sve8 | vvee | es | aver | oman | apne 700 » —fraoto |} see | sree | a2sr | anne | aman | sais 730 + frooie |} ome | ‘se | seu | amas | apte | sp02 0 vaio | son | veo | over | ova | sone | oma 600 tonne || 950 | vere | ozs | osr | oman | sone 6:0 + ]r0000 | aver | vv15 | nose | ansa | apar | ane 700 -—froooe | ares | pore | cosa | pon | sete | anon 750 franco [| ozer | see | soca | 900s | apo | ap00 0 sow | vo00 | vee | var | aes | oso | ooo | oom 600 "| ge00 | s2a0 | apee | esr | seas | oeaa | onze 650 = 9990 || 9979 9967 9953 9938 9925 9915 700 » [5600 | o2r8 | apse | soee | onn0 | opie | anos 70 ~ | 500 | err | over | sour | aear_| 0s | 9ers 350 voor | ao | ore | nea | mos | oom | oma | vas «oo aoa0 ff sor | npe0 | ora | onan | 26 | soir 650 » | 5980 | er | sean | 904s | oeaa | ante | opae 700 » | se80 |} “ove | sese | omer | oma | sor | opm 730 - | s980 |} aren | ars | eas | amir | osoa | sare 9 Tee [aero | eae] ants [ae | as | one | om 600 «| sr | oer | 5981 | see | aea0 | e20 | san 450 ~ | aero aeuo | area | vosr | 9005 | apr | ovoe 700 gor || ase | aver | onan | s020 | ator | sens 780 ~ | gore | ose | pees | ona | oat | anor | ane eaeF,—Gage location factors Gravitation correction factors for manometer factor adjustment (osed on elevation & latitude, opplicable to unadjusted factors in preceding table) \Gope elevation gbave seg level neal fet ae ie 2.000 000" 000" 00 10,000" 0 (Equator! 9987 9986 9985, 9984 9983 9982 5 9987 9986 9985, 9984 9983 9982 10 9988 9987 9986 998s 9984 9983 15 9989 9988 9987 9986 9985 9984 20 9990 9989 9988 9987 9986 9985 25 9991 9990 9989 9988 9987 9986 30 9993, 9992 9991 9990 9989 9908 35 9995, 9994 9993 9992 9991 9990 40 9998 9997 9996 9995: 9994 9993 45 1.0000 9999 9998 9997 9996 9995 50 1.0002 1.0001 1.0000 9999 9998 9997 55 1.9004 1.0003 1.0002 1.0001 1.0000 9999 60 1.0007 1.0006 1.0005 1.0004 1.0003 1.0002 6s 1.0008 1.0007 1.0006 1.0005 1.0004 1.0003 70 1.0010 1.0009 1.0008 1.0007 1.0006 1.0005 75 | 1.9071 1.0010 1.0009 1.0008 1.0007 1.0006 80 1.0012 L011 3.0010 1.0009 1.0008 1.0007 85 | 1.0013 1.0012 19011 1.0010 1.0009 1.0008 90 ole) | 1.0013 1.0012 1.0011 1.0010 1.0009 1.0008 NOTE~While F, values are strictly manomeer factors to account for gage being gpersted under grsitatonal forces that depare from sandard cations ie is suggested that ie be combined with other flow coniante. Iq. which instance, Fy becomes a Location Fattor constant and Fay the Mancmetee Fictor agrcable wich standard gravity remains 4 vatisble factor, subjece to change with epecific gravity, ambient temperate snd Matic rere METER CAPACITY FACTORS ‘These values multiplied by the constant give the moximum hourly copaeity of erifice Tonrrinate arene pena mae, Siterentat [__ Inches vacua Pounds 920 irate 20 oD ° [| 2 * o 700 200 300 2 eee | Eee eee eee een (eed eee 0 7 | w | 2] wil w | a2 | —} —| —| —] 22 20 w } uw fw | a | «2 | a | — | —~ | —] - | 4s 30 — | — |» | fia | os2 |e | ve | 106 7 100 — | — | x | # | 5 | vm | a6 | 10 | 150 10.0 pete eee eee Ta find aprosnat san of ccs to we te Ye maxima bony vate cnbe fort Yor ar wok gn, fount fr seam ond gallons for and lgids(waliply verde by 22 for seam ‘ocficint equal to or areater thon the resilt ligus) by values from above table” The rult is the approximate orifice cofficient for a, 2p ence fr ar) then lok nthe tbe of cificen ond an orice ving 1-7FLANGE TAPS—BASIC ORIFICE FACTORS—/y, FLANGE TAPS—BASIC ORIFICE FACTORS—F, er-1 a3 SEES GEHSESNS BEE 2 8 SEE i L Heens FLANGE TAPS—BASIC ORIFICE FACTORS—Fy FLANGE TAPS—PIPE DIAMETER FACTORS. rie A i a =e = Fe SH [FRG |B 198 8 1 ad a Bre ee EE Pear Ee ee BS Bea He etc Ree Reset 38) (RES Ba $i 1B i i a | ae a 35S 1B i 1B | ie ee 2 oa |e aie a ie a 1am) va 8 PBS SRB IRR IRE) |i iB) ey 1 | 3 5B oe a (a | F4 o 13 38 1a8) Se a Be Se Ba 0 a aga 38 1.0 ona] sco] aon) 2208 once 1.208 caer fe 1 ye oe ae | ES eas Vis ieee a ES 2) ‘2a vx ved | oxo mn. a as Se Ye) ae a ae a a Sa Pe 8B Ei) oi ia a ae ta) | Pe ae ope eau a 10) ae ey 1a a a a |ae ie| |tae 3B RS ae es) a tas) ia) |S 2 1B ah tm 1 1 iia) |B # 4a tS i 1a La ieee be Be ie (oa ial i 8 Bete eS @ 1p ge a a gp om ga oR ee ue 8 1 Sa 3s Bs] (SERFLANGE TAPS—PIPE DIAMETER FACTORS—F, FLANGE TAPS—PIPE DIAMETER FACTORS—/', secre ene ieee Toca Cae eee rea co ae ees 3 ee ase a a ass sea alse ewe : 338 9a Ea i 8 | Et a es 3 Estes 2 s ra a a i (lige ‘| = 2 BLE ge lia = Pa ‘igh ae ae ae Seeds eee vod rl ae a 1B le ia ag VU 2 EE) Ses es ae os [a Fee eee eee eee eee oe [ve sare ae va a ete 93 | aed 1a tal alae 9 | a) ac a vay ‘aa ee a a1) VS] es S| S| aS 13 lag Re la Poe 3s || om) {Zona #005] 1.9009 1.0008 e004 1004) 008 29 |) 0009 1.5000) 1007 Yes) ‘uon] 18803 : bes He eoio dere es ene om [aa sel apa al ae ss ea a ae ete 2 ey eas ae ete Bates 52 Se a ae SSS) is | a ae oe peal Ee te atte 2a | aed ge sve ae ae a sao a an ay H 2 Re Ee ee ee te ee eee 2 Ee ee se tae eae ee & oe [ose ee eee scan ose a oe a faa sa op ae es att at |g cam gon oa oes Re oe ee oe aes A ees ae Se Pa arn apcapeatesy ee ee a $e ee) oe Ss ta Sse 2 | AS Se S| ee Re Sa as a eae ee 5s | Sa oe Ss Stes 2g [aaa a eel a ae) sae og oz ogme aoe te eee sg see ea oo 2 See a ee te ae ee Papen bones oes i eal ee 2 | eS Se Sa ea as a) ae i es feet eater a 8 Bie Hess pes aR apap iar ita 35 |e Sl see eat 3 SBA eae Bag Se te Sn tel) fee Sn te A a eet eee a ou osm ote ow a ox oan oar era ee 32 Rg See ee ee ee Cer a ee apt iB ee SI a tS as Se ea ae Be (Re oe eae Seed oh ste 28 SS EEE SE ce ier Sates St 8 AE) SS SS SEU) GE os [ssc aael sol er so eo 2 [sam emul sam ere ave] oel sel oom or one 9 [sae ome ooo] ex siz) ay sala 9 | a Se oe 2 So Pace Eee iis ig | tt cae ea Sa a oe 38 | HENS 28 So Sh SESE ® oe eae aue oan aun az oa eara Sa | Seat am aaa ga Sis SB aa ee i Se eee See See ie So Be |e Se se Hee Sea ae ah 2335 3 Sash) 8 spn] aa rd 8S sa 8 Si 0s | Sir er Sen esetert “bY VALUES FOR REYNOLDS NUMBER FACTOR, FLANGE TAPS FLANGE TAPS—VALUES OF F, 7] TTT BY i sa ae] a ia 2 is | 18 3) i i je 38 | i 3 8s te | a ae | a haze | irae | swe peal ‘ot | cov a Sear | ago | rat m Sus | oe i #3 | BiVALUES FOR REYNOLDS NUMBER FACTOR, /,,—FLANGE TAPS F wae Puig eee Fe ore Ties HE es 7 & ee =o He oe iB i i iB = se iB ik a Fy No 1B es a 2B 58 2 i 8 333 FA & HS te ae ae Ba ae i 3 is a R . iB ish a8 39 2 i 2 ae ae id Fe ae i 3 8 | | gs ee a is Soe | Se] es os ae Spe taza i} om | “tase | oss om iB Be | ae | ee | i “ He 7 8 ve | 93) 83 oe 3 HE BB | a8 | ga | oe iS Fe Be | oa | oe | set a Sea a ee 10.000 18.500, eS 10.280 a fee He ag aa | a | ss ne Se | osEXPANSION FACTORS — FLANGE TAPS— J; EXPANSION FACTORS — FLANGE TAPS — Y, ea-1 ‘Static Prete Te fom Ute Tape ‘Stale Prose Taken fom Upstream Tape Rallol| EJ wo a a 4 oy ee & 8 2 88 ee 8s ae os sod rel a os on 88 aur saul 8 an 8 3 z 8 Ed 8 3) 82] S # Ey u 2] 2g oe B ES a Q 2 a u x Se 8 3 = a a 53 8 8 = u as # g z a Be a B a 8 a 3 i 2 23) = Ba Ed 8 a z 2) S Hi Q se) = 8 3 8 se 3 2 # a se 7 # sl 3 g i EH EY # z = se 3 8 3 = B 8 32 2 Ea # 8 i Bt 7 H 2 s ea g q E 8 x # sa 3B fH # 3 a 8 # EC 381 2 < 8 z 3 1 4 g ° 2 S = z 8 3 z < = g EXPANSION FACTORS — FLANGE TAPS — V2 State Preme, Taken from Dowratonm Ta 3585S FESS | eag52 Poese 1-24He ee-1 CHECK READINGS FOR L-10 CHARTS PRESSURE BASE FACTORS—/,, Fb = 1479 + tan promis, pie Feet Be ay heh «A en te Premio ne of [Dike age ata Pala g Be 8) HB) 818 mt Pie | 8] ae] el a) ee BE URE Joo] # |] 8/12) 3) a2) 8) ie] 18 ge lie ard | [ig] Be) a] ] if ig OR BSE |B ER) Bee eB BE |i) Be] 88) 8] 2) 8 ose fa |i | as | ie] Bal as] se] MBE |B) BB & Bae |B || el) as rd eo| = a lis |= |aie |e 8B jm lig | te i 2 le 2 |B/B 2 |B | |2|s |e READING OF PRESSURE PEN AT ATMOSPHERIC PRESSUI we | 3S Be | 38 | 30 2 | 28 ee | | a8 | HE) Ae | ag Peewee te, ple Pronnstne |S ery Sets.) 3% ne Ghee Ea TEMPERATURE BASE FACTORS—F, SPECIFIC GRAVITY FACTORS—P, |e [EE |e ae al [ee | ie Ge ae | os le Sas | ise | See | ie | GB | ee | ie | ae a0 | 1 3a88 oss | tims || 0870. vat] a8 oar Pee ee if | & HS | UE | aa | a | ae | ee | | a ce ee ee gee fie | ae | tae | oom | te | oe | cae 35 | Be | S| Ga | SBS | IRE | 1B | SBF SS [RE | SR | | SS | ie |e | ae gee | tae | ame | uae | age | tame | oe | ame Seb] ize |e | | | ie) Boe Se ize | HE | ae | a | ae) ge [ue [am | ime | ig | eee |e9-1 METER FACTORS, 1-10 CHARTS—I VARIATION OF SAYBOLT VISCOSITY WITH TEMPERATURE Sas Nrier Foor vith gh pre amants fx B | Be) 1B S| Bs | He | 3g] ae fetes aco $8 | ie | 8 & | 38) Bi | 68) as FLOWING TEMPERATURE FACTORS—f, | a £18 /8| 8/8 "0° Narain z/ 3 # | aa] ie] ie] ee = [roel i | aol ss | te | ox TTT ST e Eazy ih ie jie | 2 i e iiaR |e i i 3 ] iat | { z i) igo 8 e/ 318 188 | 8 ise 8/883 SBR E 2 #/8e |S Tai ig) rage | 3 793 | gam | Be Toe fie ae bas ie 18 | {2508 | 55 | Zao By peg [ag Lae HBTS 1 12/2 iy id |e SRG |8 3 | EEUU SearirActons HEE TAE] HBTs | i | ia He] Hk | a | at | at =) ime | a | ae a | ta | jae | a | sae | ts | igs | ee | ee 1B | 1 | a8 | | tae | 1B | iB | ie | es | ae 1] AB | 138 | 8s | a) 168 | ta | 188 | 1B iB | ie | ie | se Ba | Hi | tae | ies | da | ee | ae | ta | ae B | i | ie | aS tag | tag | tan | a | ae | | a | ta] ae | ie | a | MESURE) 128 | Bs) |S Sere eee tees YE BE) 18) | ge |S) a | a a | GU | BU 2/18/88) ee 2) eB ee Pee eae ere aoe | 1.003 Vo0g | Voce | 3001 } 1.01 | 1.001 | 4.000 SS 88 |e VE | 8 | 8s | as iwt OILS, SPECIFIC GRAVITY—TEMPERATURE FACTORS—F,, MERCURY TYPE METERS fee 8 REE BR: sudg eaNeE E is G5 BEGG REEE SOLE SS S8288 FERSE SEEKS BES 3 % ' fe i ia 1S) | & a & 2 25) ie 38 fee & i aie 1p | 09 [ested 33851330 Satay aati aml Cass 1B | = |Raies seas sae nal te OILS, SPECIFIC _GRAVITY—TEMPERATURE FACTORS—F, BELLOWS TYPE METERS Foto a 38) 1 ey ta 30) ae ea ES LR ee UR ee : ‘ge aes ter tas a i ERR HV a EB | 38 ‘ee ie a SE | Be) eh | | ab elie SB | 2 | ae te a te alta $5 | 23 gmt ah) vane ea ee goat Gn im | e/g 3 aot ae oo one onan iB) Bae ese reripaes es pre Beebeee-t 8 SR888 32 STEAM COEFFICIENT FACTORS — SATURATED STEAM 88288 & STEAM COEFFICIENT FACTORS—F, SUPERHEATED STEAM OBI War Afrury-Type Meters Hated SE SH SHS RE SES ts Se BES See Gia ge | eas] gaa |ooaey 88 82888 B8EEs ow: oe Helier T3pe Meters ges |e | a | sa [eum t $e | et | 2 Ot HBS | RB | is |S | | |B, ake | Sola | Sah | asa | ian | Sie | hae kt |S | 2a |e ||| scm) ooa| $8 | Set |g aust | $8 ls 35 28588 2EGa PEE EE gSection 2 Control Valves Air or gas capacity chart To determine the size of valve body when the known values are inlet pressure, outlet pressure, rate of flow, specific gravity, and flowing temperature, use alignment chart, Fig. 2-1, and: 1. If the specific gravity of the gas being con sidered is not 1.0, correct the rate of flow by (a) Lay a straight edge on the flow rate on scale “D" and specific gravity of gas on scale “G”. Mark intersection point with line “E”, (b) Pivot straight edge at the point of intersec- tion on line “E” to a specific gravity of 1.0 on line “G." Read corrected flow on scale “D”. 2. If temperature of the gas at the inlet of the valve body is not 60°F, make an additional flow rate correction: (a) Lay a straight edge on the flow rate (cor rected for specific gravity if necessary) on scale "D” and the inlet temperature on scale “7”, Mark Intersection point with line “E”. (b) Pivot straight edge to the point of intersec- tion on line “E” to 60°F on scale “T", Read corrected flow on scale “D”, Noteit the ene being comeidered hag flowing vompersture of £0°F Sten ely tet tut Stop Bae ata the ate fg forested for'apecife sravky'if necemary) directly on ‘eae “D™ 8. Determine the valve size by: (a) Lay a straight edge on the differential pres- sure (inlet minus outlet) on seale “A” and inlet pres— sure on scale “C”. Mark intersection point with seale “BM. (b) If the point of intersection on scale “B” cor- rected inlet pressure is lower than the inlet pressure, lay tho straight edge from this “B” intersecting point, through the flow (corrected for specific gravity and/ or temperature) on scale “D”, to the intersection point on scale “F", This will give the valve size. (c) If the intersection point on scale “BY (cor- rected pressure) is higher than the inlet pressure, position the inlet pressure directly on seale “B" and lay the straight edge from this point, through the flow (corrected) on scale “D”, to the intersection point on seale “F", This will give the valve size ‘To determine the pressure drop when the known values are rate of flow, valve size and lift, and inlet pressure’ 1. Proceed as in steps 1 and 2 above if the gas being considered has a specific gravity other than 1.0 and/or a temperature other than 60°F, 2. Lay the straight edge from the valve side on seale “F” through the corrected flow rate on scale "D”. Read pressure on scale “B”. 3. Lay the straight edge on the point on scale “B” and given inlet pressure on seale “C". Read pressure drop on scale “A”. Liq To determine the size of valve body when the known values are inlet pressure, outlet pressure, #lovr rate, specific gravity, and viscosity, use alignment chart, Fig. 2-2, and: 1. If the specific gravity of the liquid is not 1.0, correct the given rate of flow to the equivalent water flow by: capacity chart (a) Lay a straight edge on the flow rate on scale “BY and the specific gravity of the liquid on scale “GY. “Mark intersection point with line “C”. (b) Pivot straight edge at intersection point on line “C* to specific gravity 1.0 on seale “G". Read corrected flow rate on scale “B”, 2. Lay the straight edge on the pressure drop (inlet minus outlet) on scale “A” and the corrected flow rate on scale “B”. Read the standard valve size on seale “D’. Steam capacity chart ‘To determine the size of valve body when the known values are inlet pressure, outlet pressure, rate of flow, and steam quality or superheat tem- perature, use alignment chart, Fig. 2-3, and proceed as follows: 1. If the steam is superheated or has a quality less ‘than 1.0, correct the given flow rate to the equivalent saturated steam flow by the following method: (a) Lay a straight edge on the flow on scale “DY and superheat temperature or quality on scale “G”. Mark intersection point with line “E”. (b) Pivot straight edge at the point of inter section on line “E” to the saturated steam point (1.0) fon scale “G”, Read corrected flow on sale “D”. 2. Determine the valve size by the following method: (a) Lay a straight edge on the differential pres- sure (inlet minus outlet) on scale “A” and inlet pressure on seale “C", Mark intersection point with seale "B", (b) If the point of intersection on scale “B” (corrected inlet pressure) is lower than the inlet pressure, lay the straight edge from this “B” inter- secting point, through the flow (corrected for super- heat or quality) on scale “D", to the intersection with seale “F”, (ext cont'd. p 2-5)FIG. 2-1 Air or gas copacity Courtesy Fisher Com ® = vo F ws soe 3.3 scope PL? = ae | I Ps <7 »- * | 4" a 1's This chart may be used for estimating maximum air and gas capacities for conventional single and double ported valves with equal-percentage style vatve plugs, and is based on air with a specifie gravity of 1.0 at 147 Ibs. per sq. inch at 60°F. When assembling data for use with thie chart, the units of pressure, vacuum, volume, time, and temperature must correspond. to those shown on the chart.3 Presiere FIG. 2-2 Liquid capacity Courteny Fisher Con * | j 3 Dovble-port valves This chart may be used for estimating iquid capacities for conventional, single and double ported valves with equal-percentage style valve plugs and is based on the flow of water at 60°F. When assembling data for use with this chart, the units of pressure, vacuum, volume, and time must correspond to those shown on the chart.FIG, 2-3 Steam capac s : : Couttesy Fther Co 2S SF 3 ie iE sae SS§ sas 2 | foots: Be i :gt Tew 7 $ 74! ao, S veogad £ 4 : ‘2: | — 7 . eet : we ct = ‘a 4 wt 7 Biel : , This chart may be used for estimating steam capacities for conventional, single and double ported valves with equal percentage style valve plugs and is based on saturated steam. When assembling data for use with this chart, the units of pressure, vacuwn, weight, time, and tem= perature must correspond 10 those shown on the chart.(c) If the point of intersection (corrected pres- sure) on scale “B” is higher than the inlet pressure, position the inlet pressure directly on scale “B” and lay the straight edge from this point through the flow (corrected) on scale “D", to the point of in~ tersection on seale “F”. 3. From the steam sizing coefficient table for the desired valve plus style and bedy type, locate the nearest higher steam sizing coefficient, (C) from the tabulation. This will give the valve size and the percent of total valve travel required to pass the given flow. Cavitating and flashing liquids The procedure used to size control valves for liquid service should consider the possibility of cavitation and fleshing since they can limit the capacity and produce physical damage to the valve. ‘This recommendation introduces a eritical pressure ratio factor, r,, that not only broadens the scope of valve sizing techniques but also increases the sizing accuracy. When used in Equation 1, r, will help to deter- mine more accurately the maximaum allowable pres- sure drop for sizing purposes. In order to under- stand the problems more thoroughly, brief outlines of the cavitation and flashing processes are presented. Cavitation In a control valve, the fluid stream is accelerated as it flows through the restricted area of the orifice, reaching maximum velocity at the vena contracta*, Simultaneously, as the velocity increases, an inter= change of energy between the velocity and pressure heads forces a reduction in the pressure. If the velocity increases sufficiently, the pressure at the vena contracta will be reduced’ to the vapor pressure of the liquid. At this point, voids or cavities, the first stage in cavitation, appear in the fluid stream. Downstream from the vena contracta, the fluid stream undergoes a deceleration process result- ing in a reversal of the energy interchange and rais- ing the pressure above the liquid vapor pressure, ‘The vapor cavities cannot exist at the increased pressure and are forced to collapse or implode, These mplosions, the final stage in the cavitation process, produce noise, vibration and physical damage, In order to avoid cavitation completely, the pressure at the vena contracta must remain above the vapor pressure of the liquid. Flashing ‘The first stages of cavitation and flashing are identical, ile, vapor forms as the vena contracta pressure is reduced to the vapor pressure of the liquid. In the second stage of the flashing process, 4 portion of the vapor formed at the vena contracta remains in the vapor state because the downstream pressure is equal to or less than the vapor pressure of the liquid. Sizing information After the first vapor eavities are formed, the in- crease in flow rate will no longer be proportional to an inerease in the square root of the body differen- tial pressure. When sufficient vapor has been formed, the flow will become completely choked 30 that there will be no increase in flow as AP is increased, ‘The following equation should be used to deter- mine the maximum allowable pressure drop that is effective in producing flow. It should be noted, how- ever, that this limitation on the sizing pressure drop, AP Goon), does not imply that this is the maximum, drop that may be handled by the valve. AP (ase) = Ky (Ps ~ Py) te) After AP(,yo«) has been calculated, it is used in the standard liquid sizing equation, Q = C, \/ APJ to determine cither Q or C,. If the actual AP is less than AP(,y¢), then the actual AP should be used in the liquid”sizing equation, Equation 1 should also be used to calculate the body pressure drop at which significant cavitation can occur. It is recognized that minor cavitation will occur at a pressure drop slightly less than that predicted by Equation 1. However, any cavitation under that pressure drop condition’ should produce igible damage. NOMENCLATURE & liquid sizing coefficient Q = flow rate, gpm AP body differential pressure, psi PCat) maximum allowable differential pressure for sizing purposes, psi FIG, 2-4 Critical pressure ratios for wate 1 + er | oe er ow asl 0 #00 10081300 a0 2300 3000 3300 Use this curve for woter. Enter on the abscissa ot the water vapor pressure at the veive inlet. Proceed vertically to inter- sect the curve, Move horizontally to the left to read the crtieel pressure ratio, fon the ordinate,body inlet pressure, psia Pp vapor pressure of liquid at body inlet temperature, psia *K, = valve recovery coefficient] = 0.7 for globe valves; = 0.50 for Hall valves t critical pressure ratio. figures 4 and 2-5 FIG. 2-5 ical pressure ratios for liquids other than water 10 os os 07 n 08 cei a ° 10 20 30 40 Givicol presi ‘30 60 70 |.20 90 100 Uso this curve for liquids other than water, Getermine the vopor pressure/cvitical pressure ratio by dividifg the liquid ‘vapor pressure ot the vaive inlet by the critical plassure of the liquid. Enter on the abscissa at the ratio just eflculoted ond proceed vertically fo intersect the curve. Move Hprizontally 42 the left and read the critical pressure ratio, r,, onthe ordinate, Noise prediction technique Graphical solution of the following equption, pro~ vides a very expeditious and accurate technique for predicting ambient noise levels resulting, from the Flow of compressible fluids thru control walves SPL = SPLay + ASPlgg + ASPLy/m + |SPLy Where: SPL = overall noise Jevel in db at a predetermined point (48 in, downstream of the vilve outlet and 29 in, from the pipe surface)| SPLay = base SPL in db, determined asla function of aP ASPLy_ = correction in db for C, ASPLAy/m1 = correction in db for valve| style and pressure ratio ASPL = correction in db for acoustical jtreatment; ie, heavy wall pipe, insulation, inline silencers, ete. Example: The following example serves as a guide for using the noise prediction technique. G = specific gravity (water at 60°F = 10) ‘tg low throyeh an otfce, the fold steeamlnes, onverse. before Critical pressure of various fluids, psia’ Ammonia. a 1686 ‘Argon oo 708.6 Butane a 550.4 Corton dioxide 7 1071.6 Carbon monoxide Sie 507.5 87 468 s 708 Ethylene 735 Fluorine 808.5 Helium, 33.2) Hydrogen - oS 1a82 Hydrogen chloride 1198 Isobutane. 529.2 Isobutylene 580 Methane a Hs IT 673.3 Nitrogen 7 ai : 492.4 Nitrous oxide — 1047.6 Oxygen. 7365 Phosgene. See : 823.2 Propane... 6174 Propylene 6703 Refrigerant 635 Refrigerant 12 596.9, Refrigerant 22 716 Water 3206.2 "For values not listed, consult an appropriate reference book, Given: 4 in,, 300 Ib ANSI, cage style globe body, installed in an 8 in, Sch 40 pipe line P, = 615 psia AP = 348 psi Cg = 32Cv = 3(Q@ \/G7SP) Calculated required C, = 4000 From Fig, 28 SPLay = 103.5 db From Fig. 2-7 ASPLigg = —2 db From Fig. 2-11 aSPLap/m) = +85 db From Fig. 2-14 ASPLy = 0 db (103.5 + (—2) + 85 + 0] ab FIG, 2-14 A SPLy correction for pipe-wall attenuation Sehedule number 0 120 160 sto xs OS 9-6 —-12 0 ~6 ~16 0-7 -10-13 0 ~7 ~16 Oo 8 12-15 0 8 —18 0-9 «14-18 0 ~9 ~16 0-9 -4-19 0 6 — 0-10 --2 0 -5 —asp a ase ‘ob FIG. 2-6 FIG. 2-7 Base SPL-all valve styles ASPLc gcorrection - all valve styles 130 A » 120 » 10 10 we 100 ° 70 -0 20 -2 » 20 ry LH ih woo CLL 01 62 0408 102 4 6 10 20 40 60 100 1 02 0406 1-2-4 6 1 20 40.40 100 1° In hundreds Ps Required Co in thovsonds FIGS. 2-8 and 2-9 ASPL p/p, correction - cage- style globe- valves Line size equals body size 2 in. and 3 in. valves 4 in. through 12 in. valves 8. 2 » 20 aaa s ete 6 le 0 Sith asm on ; A Aye My de il yi : ‘rata ay | ° ° : -10 1 Ut o 2 02 04 06 10 OY 02 04.05 01 02 04 06 10 anf,FIGS. 2-10 and 2-11 ASPLap/pcorrection-cage-style globe valves Swaged 24in, through 6-in, valves 2s - 2 1s SPL a tt bs 23th | stent int te aint os - -10 10 Or? as 6 OF or ae 19 ‘or er a as ar a2 on 04 10 ah, ayn, ' FIG. 2-12 F1G.2=13 ASPLan/o, correction — ASPLAp/p,correction - standard ball valves top and bottom-guided globe valves All tine te bedy size ratios All valve sizes All line-to-body-size ratios All valve as 2 Ta 20 2» 1s bine wi re 19] ase ig * ase eee ° ° | 5 10 Ji Lit} 02 OF an OA OS 10 0 arin, ‘ora? 4 06-0) 0a ed ge 10 ar/>, 2-8Section 3 Relief Valves Introduction Pressure relief valves are used for protection against excessive over-pressure on most plant oquip- ment, Because of new codes and laws, their selection and maintenance has hecome extremely important ‘This section will cover the various valve types and the procedures to be used in selection of the correct orifice size, depending on the application. ‘The designer should use the references to various codes, standards, and recommended practices to sup- plement the material contained in this section. DEFINITIONS A glossary of terms used in pressure-relieving sys- tems follows. Each term is defined as it relates to pressure relief. The terms and definitions are taken from API RP521 and do not conflict in any way with any other standard new in common usage. For a more complete glossary of terms, the de- signer is referred to API RP52i; API RP520; Part 1, ANSI Proposed Standard, “Terminology For Pressure Relief Devices"; and ASME PTC25.2. Aceumulation—Accumulation is the pressure in- crease over the maximum allowable working pres- sure of the vessel during discharge through the pressure relief valve expressed as a percent of that pressure, or in psi. Atmospheric discharge—Atmospherie discharge is the release of vapors and gases from pressure relict and depressuring devices to the atmosphere. Back pressure—Back pressure is the pressure existing at the outlet of the pressure relief device due to pressure in the discharge system, Balanced safety relief valves—A balanced safety relief valve incorporates means for minimizing the effect of back pressure on the performance charac- teristics-opening pressure, closing pressure, lift and relieving capacity. Blowdown—Blowdown is the difference between the set pressure and the resealing pressure of a pressure relief valve, expressed as a percent of the set pressure, or in pounds per square inch. Burst_pressure—Burst pressure is the velue of inlet static pressure at which a rupture disk device functions. Conventional safety relief valve—A conventional safety relief valve is a closed bonnet pressure relief valve that has the bonnet vented to the discharge side of the valve. The performance characteristics~ opening pressure, closing pressure, lift and relieving eapacity—are directly affected by changes of the back pressure on the valve. Design pressure—Design pressure is the pressure ‘used in the design of a vessel to determine the mini- mum permissible thickness or physical characteris- ties of the different parts of a vessel Flare—A flare is a means for safe disposal of waste gases by combustion. With an elevated flare the combustion is carried out at the top of a pipe or stack where the burner and igniter are located. A ground flare is similarly equipped except that com- bustion is carried out at or near ground level. A burn pit differs from a flare in that it is normally designed to handle both liquids and vapors. LiftLitt is the actual travel of the disk away from closed position when the valve is relieving. Overpressure—Overpressure is the pressure in- crease over the set pressure of the primary relieving device; it would be termed accumulation when the relieving device is set at the maximum allowable working pressure of the vessel, Note: When the set pressure of the first (pri- mary) pressure relief valve to open is less than the maximum allowable working pressure of the vessel, the overpressure may be greater than 10% of the set pressure of the valve. Pilot-operated pressure relief valve—A pilot-op- erated pressure-relief valve is one that has the major flow device combined with and controlled by a self- actuated auxiliary pressure relief valve. This type valve does not utilize an external source of energy. Pressure relief valve—Pressure relief valve is a generic term applied to relief valves, safety valves, or safety relief valves, Relieving conditions— Relieving conditions per- tain to pressure relief device inlet pressure and tem- perature at a specfie overpressure, The relieving pressure is equal to the valve sot pressure (or rup- ture disk burst pressure) plus the overpressure. The temperature of the flowing fluid at relieving con- ditions may be higher or lower than the operating temperature, Set _pressure—Set pressure in psig is the inlet pressure at which the pressure relief valve is adjust- ed to open under service conditions. In a safety or safety relief valve in gas, vapor, or steam service, the set pressure is the inlet pressure at which the valve pops under service conditions. In a relict or safety relief valve in liquid service, the set pressure is the inlet pressure at which the valve starts to discharge under service conditions, Superimposed back pressure—Superimposed back pressure Is statie pressure existing at the outlet of a pressure relief device at the time the device is re quired to operate, Tt is the result of pressure in the discharge system’ from other sources. This type of back pressure may be constant or variable; it may govern whether a conventional or balanced-type pressute relief valve should be used in specific ap- plications. Vapor depressuring system—A vapor depressur- ing system is a protective arrangement of valves and piping intended to provide for rapid reduction of pressure in equipment by release of vapors. Actua-tion of the system may be automatic or manual. Vent stack—A vent stack is the elevattd vertical termination of a disposal system which [discharges vapors into the atmosphere without compustion or conversion of the relieved fluid, Types of pressure relief valves GENERAL Several designs of pressure-relief devites can be certified and approved under Section VIII of the ASME Boiler and Pressure Vessel Code covering un- fired pressure vessels, These include spring loaded direct acting, pilot operated, and rupture disks. When, ‘the governing code is ANSI B31.8, USA| Standard Code for pressure piping, gas transmission and dis- tribution piping systems, many types of pressure em- iting devices are permitied, such as monitoFing regu- ators, series regulators, weight-loaded relief valves, liquid seals, ete. ‘The discussion below is|limited to ASME Section VIII types of devices. CONVENTIONAL SAFETY RELIEF VALVE! In a conventional safety relief valve the inlet pressure to the valve is directly opposed by a spring closing the valve, and back pressure on |the outlet of the valve changes the inlet pressure at|which the valve will open, BALANCED SAFETY RELIEF VALVES Balanced safety relief valves are thos# in which the back pressure has very little or no influence on the set pressure. The most widely used mefins of bal- aneing a safety relief valve is through the use of a bellows. In the balanced bellows valve, thee effective area of the bellows is the same as the qozzle seat area and back pressure is prevented from] acting on the top side of the disk. ‘Thus the valve ogens at the same inlet pressure even though the back pressure may vary, PILOT OPERATED SAFETY RELIEF VALVES A pilot-operated safety relief valve it a device consisting of two principal parts, a main[valve and fa pilot. Inlet pressure is directed to the jtop of the main valve piston, and with more area bxposed to pressure on the top of the piston than on the bottom; pressure, not a spring, holds the main valve closed. At the set pressure the pilot opens reducing the Pressure on top of the piston and the thain valve goes fully open, At extremely low set pressures, pildt-operated safety relief valves are available in frictior weight diaphragm construction in place| pistons, RESILIENT SEATED SAFETY RELIEF|VALVES ‘When metal-to-metal seated conventiopal or bel- lows type safety relief valves are used jwhere the operating pressure is close to the set presbure, some Teakage can be expected through the sdats of the valve (Refer to API Standard 527, “Commbreial Seat Tightness of Safety Relief Valves with] Metal-to- ‘Metal Seats"). Resilient seated safety relief valves with either ‘O-Ring seat seal or plastic seat such ag Teflon pro- vide seat tightness better than API Standard 527 Limitations of temperature and chemical compatibil- ity of the resilient material must be considered when using these valves. RUPTURE DISK A rupture disk consists of a thin metal diaphragm held between flanges. The disk is designed to rup- ture and relieve pressure Within tolerances estab— lished by ASME Code. Sizing of required orifice areas GENERAL It is not the purpose of this section to discuss de- termination of individual relieving rates of safety relief valves. An excellent reference for determining individual relieving rates is contained in Section 3 of API RP321, “Guide for Pressure Relief and De- pressuring Systems”. After the required relief ca- pacity of a safety relief valve has been determined, it is necessary {0 calculate the minimum orifice area that the relief valve must contain. Methods of per~ forming these calculations are outlined in this section, The safety relief valve manufacturers have standards for orifice designation and area and the valve body sizes which contain these orifices (API Standard 326, “Flanged Steel Safety Relief Valves for Use in Petroleum Refineries). The standard oti- fices available, by letter designation and area -re: D Orifice 0.110 sq in, E Orifice 0.196 sq in. F Orifice 0.307 sq in. G Orifice 0.503 sq in, H Orifice 0.785 sq in. 4 Orifice 1.287 sq in. K Orifice 1.838 sq in. L Orifice 2.853 sq in. M Orifice 3.60 sq in, N Orifice 434 sqin P Orifice 638 sq in. Q Orifice 11.05 sq in. R Orifice 16.0 sq in. T Orifice 26.0 sq. in. However, many small safety relief valves are manufactured with orifice areas smaller than "D", and many pilot-operated types contain’ orifice areas larger than “T”, SIZING FOR GAS OR VAPOR RELIEF, SONIC OR CRITICAL FLOW Safety relief valves in gas or vapor service may be sized by use of one of these equations: wVTVe ——= en CKPK, V1 VVTVNVE = ~ 2 632 CK P, KyVVTVEVE 175 CK P, K, W = flow through valve, lb/hr V = flow through valve, scfm 3) C = coettivient determined by the ratio of the ka c 041 219.28 042 221.59 043 223.86 044 226.10 04s 22830 0.46 23047 047 232.61 048 234.71 0.49 236.78 050 238.83, 051 260.84 052 242.82 053 244.78 oS4 246.72 055 248.62 056 250.50 057 252.36 058 254.19 0.59 256.00 0.60 257.79 0.61 259.55 0.62 261.29 0.63 263.01 0.64 264.72 0.65 26640 0.65 268.06 0.67 269.70 0.48 271.33, 069 272.93 907027452 he on 0.72 078 074 075 076 077 o7e 079 0.80 og! 0.82 0.83 oss 085 0.86. oa7 0.88, 0.89 0.90 091 092 0.93 0.94 095, 096 097 098 099) 1.00 276.09 277.64 279.18 280.70 282.20 283.69 285.16 286.62 288.07 289.49 290.91 292381 293.70 295.07 296.43 297.78 299.11 300.43 301.74 303.04 304.33 305.60 306.86 308.11 309.35 31058 311.80 313.01 314.19" 315.38" ke 191 102 1.03 10 105, 1.06 07 1.08, hos 110 Mn 12 13 114 nas 116 17 re 19 120 121 122 123 24 125 1.26 127 128 129 specific heats of the gas or vapor at standard condi. tions. This can be obtained from Fig. 3-1 or Fig. 3-2 K = coefficient of discharge, obtainable from the valve manufacturer A = effective discharge area of the valve, sq in, P, = upstream pressure, psia. sure plus overpressure plus ihe atmospheric pressure © 347.91 348.84 249.77 350.68 351.60 352.50 353.40 354.29 355.18 356.06 356.94 357.81 358.67 359.53 360.38 361.23 362.07 362.91 363.74 368.56 365.39 366.20 367.01 367.82 368.62 369.41 370.21 370.99 371.77 FIG. 3-1 Values of Coefficient C © ke 31656" 1.31 N74 132 31890 1.33 32005 134 32119138. 3232 1.36 323.44 a7 32455138 32565 1.39 32675 1.40 327.83 1.41 32891142 32998143, 310d ag 33209 1.45, 33314 1.46 33417147, 335200 1.48 33622149) 33724 150 33824 151 339.24 182, 34023153, 34122154 3azt9 155, 343.16 1.56 34413157 34508 1.58. 34603159 346.98 1.60, 130 372.55 hen han 1.62 162 hea 165, 166 167 168 169) 170 un 172 173 174 175 176 7 178 179 1.80 an 182 183, 184 185, has 187 188 a9 1.90 “Interpolated volues, since C becomes indeterminate es either n or k opproaches 1.00. Acetylene Air ‘Ammonia ‘Argon Benzene Corton disulphide Corton dioxide ‘Carbon manoxide Chlorine Cyclohexone Ethane Ethylene Helium Hoxane Mot wt n/t 26 1.28 29140 7 133 4 166 731.10 7% 121 44128 2140 136 41.08 30122 28 120 4 166 861.08 FIG. 3 +2 Values of C for goses 345, 356 351 377 327 338 345, 356 352 324 339 337 377 324 eps 969 1.000 986 1.059 a9 949 969 000 989 310 982 947 ¥059 910 3-3 Hydeochlorie. cid Hydrogen Hydrogen sulphide Iso-butone Methone Methyl ol leahol ‘Methyl chloride Nebutone Natural gas Nitrogen Oxygen Pentone Propene Sulphur dioxide 373.32 374.09 374.85 375.61 378.37 377.42 377.86 378.61 379.34 380.08, 380,80 381.53 382.25 382.97 383.68, 384.39 385.09 385.79 386.49 387.18 387.87 388.56 389.24 389.92 390.59 391.26 391.93, 392.59 393.25, 393.91 Mot wt ener 3651.40 2 34 58 16 2 505 1.20 58 Vir 127 28140 32140) 72 109 4 Mla 126 This is set pres- kan 191 192 193 194 195 1.96 197 198 199 2.00 201 202 2.03 204 205 2.06 2.07 2.08 209 210 2n 212 213 214 215 2.16 217 21a 219 220 356 356 yr 328 346 337 337 328 345, 356 356 325 331 342 294.56 395.21 395.86 396.50 397.14 297.78 398.41 399.05, 399.67 400.30 400.92 401.53, 402.15, 402.76 403.37 403.97 404.58 405.18 405.77 406.37 406.96 407.55 408.13 408.71 409.29 409.87 41044 41101 41158 412.15 cpss 1.000 1.000 978 921 972 947 947 921 969 1.000 1.000 313 930 981K,, = capacity correction factor due to back pres- sure." This can be obtained from Fig. 3-8 for con- ventional valves or pilot operated valves] and from Fig. 3-4 for balanced bellows valves M = molecular weight of gas or vapo ‘T = absolute temperature of the inlet] vapor, °F + 460 Z = compressibility factor for the dqviation of the actual gas from a perfect gas. This dan be ob- tained from Fig. 16-3 G = specific gravity of gas referred| to air 1.00 at 60°F and 14.7 psia SIZING FOR LIQUID RELIEF| Conventional and balanced bellows safety relief valves in liquid service may be sized by usp of Equa- tion 3.4. Pilot-operated relief valves should be used in liquid service only after determining] from the manufacturer that they are suitable for the service. wom VT As | ay MAK, KK, VPP Where: gpm = flow rate at the selected perfentage of overpressure, in U. S. gpm, A = cffective discharge area, s9. in. FIG. 3-3 Constont back pressure sizing factor} K by for conventional safety relief valves|vaporsiand gases) her beck pe Ser pressure 100 psi 80 asig (ene Boney 00 = 1004104147 i thous Constant back pressure 1% absolute back pressure Fellow dotted line, CCopacity with bock pressure boc pressure) 0.89 (rom curve! (0.89) (ated capacity Note: This chart is typlcat and suitable for be ony sahen the moke of valve of the actual eitcal flow pressure Point for the vapor oF gos is unknown; etherwisa, the valve Ironutocturer should be eonauted tor specific dota K,, = capacity correction factor due to overpres- sure. For 25 % overpressure K, = 1.00. The factor for other pereentages of overpressure ean be obtained from Fig. 3-5. K, = capacity correction factor due to back pres- sure “and is required only when balanced bellows valves are used. Ky can be obtained from Fig. 3-6 K, = capacity correction factor due to viscosity. For most applications, viscosity may not be signifi- cant, in whieh ease K, = 1.00. When viscous liquid is being relieved sea method of determining K, as described below. P = set pressure at which relief valve is to begin opening, psig P,, = back pressure, psig G = specific gravity of the liquid at flowing temperature referred to water = 1.00 at 70°F. When a relief valve is sized for viscous liquid service, it is suggested that it be sized first as for non- viscous-type application in order to obtain a prelimi- nary required discharge area, A. From manufactur- ers" standard orifice sizes, the next larger orifice size should be used in determining the Reynold’s number, R, from either of these relationships: pm (2,800 G) (35) Ve FIG. 3-4 Variable or constant back pressure sizing factor,K,for balanced bellows os oS 2 as as eas 80 Note: These curve: represen! a compromise of the values recommended by a number of rele velve. manufoc: turers end may be used when the meke of velve or the ota ctical ow pressure point for the vapor or gos is unknown, ‘When the make ts kaown, the monufocturer should be con sulted for the correction factor ‘These curves ofe ‘or set pressues of SO peig ond above: for set presures lower thon 80 989, the monutecturer shoul bbe consulted tor the valuse of12,700 gpm R= ——__ 7 eons (8.8) Ue where: gpm = flow rate at the flowing temperature, in U.S. gpm G = specific gravity of the liquid at the flow- ing temperature referred to water = 1.00 at 70°F. '# = absolute viscosity at the following tempera ture, in centipoises A = effective discharge area, in sq in. manufacturers’ standard orifice areas) U = viscosity at the flowing temperature, in Saybolt Universal seconds After the value of R is determined, the factor K, is obtained from Fig. 3-7. Factor K, is applied to correct the “preliminary required discharge area”, If the corrected area exceeds the “chosen standard orifice area,” the above calculations should be re- peated using the next larger standard orifice size, (from SIZING FOR MIXED-PHASE RELIEF When a safety relief valve must relieve both liquid and gas or vapor it may be sized by: FIG. 3-5 Capacity correction factors due to overpressure for relief and sofety relief valves in liquid service ° Jt oS 10 15 70 a5 30 95 40 «5 30 Fo Overpressre ‘The above curve shows that up to ond including 25% overpressure, copority is flected by the chonge in lif, the change in orifice dischorge coefficient, ond the change in overpressure, Above 25%, capocity is affected ‘only by the change in overpressure Note Voives opereting ot low overpressures tend to "chatter: therefore, oversressures of less thon 10% should be avorded. 1. Determine the volume of gas or vapor and the volume of liquid that must be relieved. 2 Calculate the orifice area required to relieve the gas of vapor as previously outlined 3. Calculate the orifice area required to relieve the liquid as previously outlined. 4, The total required orifice area is the sum of the areas calculated for liquid and vapor. SIZING FOR FLASHING LIQUIDS ‘There is little authoritative data available related to calculating the required orifice in a safety relief valve under the condition of liquid flashing in the valve when it relieves. The most reasonable approach, is to determine the percent flashing from a Mollier diagram or from the enthalpy values. Then consider the liquid portion and vapor portion separately as in mixed phase flow. A method to calculate the per- ‘cent flashing is shown in Equation 3.7 bp) — be (2) Percent flashing = —— x 100 (3.7) Ingg (2) Where: h, (1) = Enthalpy in BTU/Ib of saturated liquid at upstream temperature by (2) = Enthalpy in BTU/Ib of saturated liquid at downstream pressure hy, (2) = Enthalpy of evaporation in BTU/Ib at downstream pressure FIG. 3-0 Variable or constant back pressure sizing factor, Kw, for 25% overpressure on balanced bellows safety relief valves(liquids only) swith variable beck pressure 5 ost_L_ ° 10 20 30 “80 Fe Gage bock pressere Bee Ser preven Note: The above curve represents o comparison of the volues recommended by a number of lief valve manuloc turers, This curve may be used when the meke of the valve is not known, When the make is known, the menu: Fecturer should be consulted for the correction foctor. 3-5SIZING FOR GAS OR VAPOR ON LOW PRESSURE SUB-SONIC FLO\ When the set pressure of a safety religf valve is very low, such as near atmospheric presstire, the Ky, values obtainable from Fig 3-3 are not| accurate. Safety relief valve orifice areas for this low pressure range may be calculated: ieee ee cee on 863 KF VP, PLY Ps Where: A = effective discharge area of the valve, sq in. Q, = flow through valve, scfm G = specific gravity of gas referred tolair = 1.00 at 60°F and 14.7 psia T = absolute temperature of the inlet or + 460 K = coefficient of discharge, is avail the valve manufacturer vapor in ‘ble from F = correction faction based on the ratio of specific heats. This can be obtained from Fig. 3-8. P, = upstream pressure in psia = se} pressure plus overpressure plus atmospheric pressure downstream pressure at the valve outlet in psia Fire sizing GENERAL CONSIDERATIONS ‘The selection of a relief valve for any i requires frst of all a determination of the be relieved through the valve. The calc: fire capacity must be based on the heat en stallation lapacity to lation tor rey input FIG. 3-7 Capacity correction factor due 10 viscosity 0 100 1000 eye 09% J+ number 100,000 to the system by a fire to be relieved. ‘The exact method of making this calculation must be established from the appropriate codes which apply, API RP-520, Part I, API Standard 2510, NEPA No. 58, or local codes which may apply. Each of the isted codes or standards approach the problem in a slightly different manner. LIQUID SYSTEMS A majority of the systems that are encountered will contain liquids or liquids in equilibrium with vapor. Fire relief capacity in this situation is ealeu- Jated on the basis of heat energy from the fire in terms of vapor generated in the boiling liquid, NFPA 58 applies to LP-gas (propane and butane) systems, It has been greatly simplified In that it presents in tabular form capacity requirements in terms of cfm of air related to total external surface area of the vessel up to 2000 sq ft. If a larger vessel total area is involved it utilizes the equation: Qa = 53,632A°% | —.(3.9) Qu = cfm air at standard conditions (14.7 psia & 60°F) A = Total area of vessel, sa ft ‘This capacity Is allowable a: 120% of maximum per- missible start to discharge pressure. API Standard 2510 applies to LP-gas (propane & butane) in the design of marine and pipeline termi- nals. This standard expresses relieving requirements in terms of cubic feet of alr per minute determined at 120% of maximum permissible start to discharge pressure, Qa = cfm air = 32.FA"% nn (3-10) Qa = cu ft min air at standard conditions (14.7 sia & 60°F.) FIG, 3-8 Flow correction based on specific heat ratio 104 voz 100) % o a jen fecter boted on Cp/Cy Ure venie tow eavation ‘Wows wis wo We absolute 1 20 21 Inte Ourter presture ebsolateA = Area in sq ft of wetted surface of the vessel up to 26 ft. above grade. Wetted surface is calculated at the maximum fill level. Grade is the ground level under the vessel. F = Fireproof factor due to insulation becoming 1.0 for a bare vessel. API RP-520, Part I, applies to refineries and process plants. It expresses requirements in terms of heat input. Q = 21,000FA0s Q = BTU/hr heat input A = Area in sq ft of wetted surface of the ves~ sel up to 25 ft above grade, Wetted surface is caleu- lated at the maximum fill level, Grade is the ground evel under the vessel. (any F = Fireproof factor due to insulation becoming 10 for a bare vessel. ‘The amount of vapor generated with this thon is calculated from the latent heat of the material at the relieving pressuze of the valve, For fire relief only this may be ealculated at 120% of maximum allow- able working pressure. All other conditions must be caleulated at 110% of maximum allowable working pressure. at, = Ww Q = BYU/hr heat input to the vessel H,, = BTU/Ab latent heat of the material being relieved. w (a2) Ib/nr of vapor to be relieved by the relief ‘The value W is used to size the relief valve ori- fice area in the formula listed in Section C. ‘The latent heat of pure and some mixed paraffin hydrocarbons materials may be estimated using the Fig. 11 of API RP-820. A more accurate latent heat evaluation for mixed hydrocarbons will be found by utilizing vapor-liquid equilibrium K data and mek- ing e flash calculation. Mixed hydrocarbons will frac~ tionate, beginning with the lowest temperature boil- ing mixture and progress to the highest temperature mixture; therefore, consideration must be given to the condition which will cause the largest vapor gen- eration requirements from the heat input of a fire, Latent heat will approach a minimum value near critical conditions; however, the effect does not go to zero. An arbitrary minimum value that may be used is 50 BTU/Ib. . GAS-FILLED SYSTEMS When the metal wall of a vessel is subjected to a condition of fire temperatures (1600°F) on the ‘outside and a gas or hydrocarbon vapor on the inside, it may reach a metal temperature that will greatly reduce the pressure rating of the vessel. In this situation consideration of a depressuring system may be desirable. Refer to APTRP-520, Part I, Appen- dix A. SIZING FOR NORMAL OPERATION Previous paragraphs cover the sizing of pressure relieving devices for fire exposure conditions. Certain additional guidelines must be followed to protect a tank or pressure vessel for conditions of normal operation and for upsets, short of fire exposure, that may affect the pressure or vacuum in the tank. NON-REFRIGERATED STORAGE, Atmospheric tanks for petroleum, chemical and other related usage are generally designed in accor« ance with API Std, 650, Welded Steel Tanks for Oil Storage. These tanks are usually equipped with con- servation vents having pressure and vacuum settings of 0.8 o7./sq. in. (0.87 in. of water). Unless the design of @ tank Is specially checked, the vent capacity, for either pressure or vacuum, should ke taken at a maximum of 15 in of water Appendix F of API Std. 650 gives rules for higher internal pressures. The tank designer should be con- sulted before imposing a higher internal vacuum, Tanks for pressures substantially above atmo pherie and not exceeding 15 psig are generally de- signed in accordance with API Sta, 620: Recommend~ ed Rules for Design and Construction of Large, Weld- ed, Low-Prossure Tanks. These are designed for a definite maximum allowable working pressure. At least one pressure relief valve shall be set to operate at no more than the maximum allowable working pressure. For normal operation the re- quired flow capacity should be available at 110% and for fire exposure, at 120% of the maximum allowable working pressure. Appendixes Q and R of API Std 620 contain additional requirements for refrigerated storage tanks. Vacuum vents, which admit air, should be installed on all API Std. 620 tanks even if a separate gas re- pressuring system is used to prevent normal entry of air, Such vacuum vents should be set at 0.5 02/59 in, (0.87 in, of water), unless the tank designer certifies that a higher setting is permissible. Rules for sizing and installing vents for API Std, 650 and API Std. 620 tanks are given in API Std, 2000, Venting Atmospheric and Low-Pressure Stor= age ‘Tanks (Non-refrigerated and Refrigerated) These rules are for normal operating conditions in a temperate climate. In the scope, the user Is cautioned that there may be abnormal variables such as tanks which are heated or subjected to surges. These con- ditions warrant special engineering studies and con- sideration of vent capacities other than standard. Vessels for processing or storage at maximum’ allowable working pressures greater than 15 psig are designed in accordance with the ASME Boiler and Pressure Vessel Code, Section VIII. Rules for sizing and installing pressure-relieving devices are given in API RP 521, Guide for Pressure Relief and De- pressuring Systems, For reftigerated storage tanks additional rules have been developed for specific stored products, These standards contain information on sizing and installing relief valves:Liquefied petroleum gas—NFPA No. 53|LP Gases at Utility Gas Plants. API Std, 2510, Design and Construction of Liquefied Petroleum Gas! Installa~ tions at Marine and Pipeline Terminals, Ntural Gas Processing Plants, Refineries and Tank Farms. iquefied natural _gas—NFPA No. 59h, Lique- fied Natural Gas at Utility Gas Plants, [API Sid 2510A, Design and Construction of LNG| Installa- tions at Petroleum Terminals, Natural Gds Proces- sing Plants, Refineries and Other Industrid! Plants, Applicable codes, standards, and recommended practices ‘The designer's attention is called to ing documents related to pressure relief process plants and natural-gas systems. Al seription of the contents of these codes is| however, they should be obtained and read} the information contained in them. le follow- lvalves in brief de- included: to get all ASME BOILER AND PRESSURE VESSEL ‘CODE SECTION VIII Paragraph UG-125 through UG-134, In the “Scope” certain vessels are excl ASME requirements, including all vessels psig operating pressure. ded from under 15 ASME CODE ANSI B318—GAS TRAN! & DISTRIBUTION SYSTEMS MISSION The portions of this large document peitaining to pressure relief and limitation are: 843.44-—Compressor-station overpressu tion—#43.44 states that MAWP of station equipment may not be exceeded by more and that protective devices (or pressure "4 be provided for this purpose 843.442 states thet a pressure relief v be ised. on the aikeharge' of each_posii ment transmission comprestor. Capacity or greater than the compressor. 815—Limiling of gos presture, genera — This states generally that everything that cam be acei- dentally averpressured ean be protected bp pressure relief oF limiting devices, Any of these if connected to a compres gas source where failure of any equipment overpressure, must be protected: pipeline, tribution system, customer's meter snd cor cilities, compressor station, pipe-type hold type holder, ete 845.2—Overpressure protection—For gi pipelines, and all facilities that might af bottle tight, 845.21 says such facilities shi tected by suitable type of device inclu valves meeting ASME and pilot-loaded sure regulators used as relief valves. 845.3—Protection of high-pressure dj systems — 845,32, permissible devices: (4) spring~ loaded relief valves meeting Section 8 of {Code, (b) back-prossure regulators, (c) dead-weight loaded valves, (d) series regulator, (e) monitoridg regula- tor, and (f) automatic shut-off. fe protec- iping and han 10%, ef) must Ive must displace- Lequal to jor or toa Inain, dis- pected fa r, bottle- Is holders, times be I be pro- ting relief jack pres- jstribution 845.4 —Protection of low-pressure distribution systems—845.42, permissible devices: (a) liquid seal, (b) weight-loaded valves, (c) automatic shut-off, (4) plot-loaded back-pressure regulator, (e) moni toring reyulator, and (f) series regulator 845.43 (b) seems to define 2 psig as the absolute maximum pressure for low-pressure distribution sys- tems. 845.6—Design requirements of pressure-relief in- stallations—This covers: (a) materials that won't corrode, (b) non-sticking valves and seats, (e) in- stalled so that they can be tested for opening and for Teakage, and locking of stop valve under pressure relief valves Several other requirements of design are also covered, 845.7—Required capacity of pressure relief or imiting stations—845.71, sufficient capacity to pre vent pressure going above 10% over maximum allowable; 845.72, covers taking credit for relief ca~ pacity of all relief valves when more than one relief valve is involved. 845.8—Covers proof of adequate eapacity—845.81 covers periodie actual checking of monitor or series regulators. 845.82 covers periodic check of pressure relief devices. 855—Maintenance of pressure. 1g stations— 855.1 calls for periodic inspections and tests to de- termine: (a) valves in good condition, (b) have ade~ quate capacity, (c) open at correct pressure, (a) properly installed with respect to dirt, liquids, ete, 855.3 suggests testing of pressure relief valves in place 10 see that they have adequate capacity, but permits mathematical review of capacity require- ments. Various API API RP520 Part 1, Design—This API design man- ual widely used for fire sizing of relief valves on both liquid and gas filled vessels: (a) liquid vessels ~paragraphs 5 and 6; (1b) gas-filled vessels—Appen- dix D-3, This RP covers only vessels above 15 psig, API RP520 Part II, Installation—This includes: (a) recommended piping practices, (b) calculation formula for reactive force on valve (2.4), and (ec) precautions on preinstallation handiing and ir, API RP521—Guide for pressure relief and de- pressuring systems-—An excellent. document on everything from causes of overpressure through flare stacks, API Gulde for inspection of refinery equipment— Chapter XVI pressure-relieving devices—Gives (a) guide for inspection and record keeping, and (b) frequency of inspection, Paragraph 1602.03, API Std. 527—-Commercial seat tightness of safe- ty-relief valves with metal-to-metal seats—Permis. sible leakage rate of conventional and bellows valves and testing procedure. API Std. 526—Flanged steel safety relief valves for vse in petroleum refineries—Gives industry standards as fo dimensions, pressure-temperature ratings, maximum set pressures, body materials.API Std. 528—Standard for safety relief valve nameplate nomenclature—Standard covering infor- ‘mation that should go on the nameplate of a safely relief valve. API Std. 620—Recommended rules for design and construction of large welded low-pressure storage tanks—Covers tanks at less than 15 psig. Section 6 of this document gives recommendations on relief valve types. API Std. 2000—Venting atmospheric and low- pressure storage tanks (non-refrigerated and re- frigerated)—Covers tanks at less than 15 psig. Ca- pacity requirement calculations for both pressure and vacuum, Also fire-sizing method for low pres- sure tanks, API Bulletin 2521—Use of pressure-vacuum vent valves for atmospheric-pressure tanks to reduce ‘evaporation loss—Includes use of PV valves on very Iow pressure tanks, usually atmosphere to 12 in, water-column pressure. API Std, 2510—Design and construction of LPG installations at marine and pipeline terminals, na- tural-gas-processing plants, refineries, and tank farms—Section 7 covers pressure relief valves and covers refrigerated and non-refrigerated LP-gas vessels. NFPA 58 and 30 ‘This covers storage and handling of liquefied pe- troleum gases. Section B.10 covers safety deviees, in- stallation and testing.Section 4 Reciprocating Compressors Reciprocating compressors are widespread in the natural-gas industry. They vary in size from small units suitable for use on the lease or in the field to large integral units for pipeline use. The engineer in the field is frequently required to: (1) determine the approximate horsepower required to handle a certain volume of gas at some intake conditions to a given discharge pressure and (2) estimate the ca- pacity of a certain existing compressor under speci~ fied suction and discharge conditions, ‘The following pages outline procedures for mak- ing these calculations from the standpoint. of quick estimates and also more detailed calculations. For specific information on a given compressor the best source of complete information is always the manu Tacturer of that unit. Heat capacity (specific heat) ratio ‘There are two ways in which the thermodynamic calculations for compression can be carried out: assuming an adiabatic reversible (isentropic) com- pression path or assuming a polytropic reversible path, In the former case a “k” value is used which is the ratio of the molar heat capacities of the gas. In the second case a polytropie coefficient n” is used General practice is to use k and n as being inter- changeable. This is not correct. There is no specified relationship between the polytropie exponent n and the adiabatie coefficient k: n may be larger or smaller than Equation 1 which applies to all ideal gases is FIG. 4.1 Molal heat capacity MC,” (ideal-gas state), BTU/Ib mol/°R (11 Date source: Selected Volues of Properties of Hydrocarbon, API Research Procct 44 os Sermaia Meer, soe, oF, 0,18 n0OHF OER, Methane cH, 16.042 82334568657 8947 9:277 9.638100 Eyre (Actyiens) —GHz_—«26.096.««9.483—«1023 1033107) 113 ASA 1.881222 Ethene Eylone) —C,_——«28.082««9.324 «10021016 -«1072«sM14D«1208 «1275 13.14 ethene GH, 30068 14s 121712321295 137714631549 1834 Propane (Propylene) CH «4207813691469 «1490 «157516801785 taay 198 Propane Cm, 44074 1564 ©1688 «1713. 1817_—«19'829ay 22.25 23.56 I.Butone (tylene) GH S6NOL 796 = «19ST BT 24-25-2570 27.18 cie2 Butene Che Sétoe ese 104 eae tse 2804 © 2053 2400 25.47 frone-2-Botene cla Sei0e 1884 20022080 261 2299 243725722706 ‘o-Butone 5120 2040 2215 2250 2395577789 29.39 LN rbutone 38.120 2080 7238 «2271-2407 «7581 2754 2923-3090 iso Pentane 72.146 2493 7.16 77.61 -79.42—«31.66 «93.87 «3603 98.14 snPentone 72148 2564 ©2761 -2801-28-70«31.86 33993607 38.12 anzone 78.108 1641 18981875 2046-2246 2446-2708 29.71 stHenane Chi, 86172 30.17 3278 33.30 35.36 3791 04s 4291 45,36 -Heprane EMS voo.198 3496 3700 a6) 4014? 4599.49.77 52.60 Ammonis NH, 17022 8516 e518 «8.519521 as29 8.528 sar a.530, air 28966 6.944 6951 6952 6.960 6973 4990 7.009 7.033 Water Ho 18.018 7983 8.006 «8.010 8033 BOTS 811617) 8.226, Onsen ©, 32.000 6970 6997-7002 7030:« 7078 7120«7.178 «7.232 Nitegen NE 2801669516954 6954 6956 69636970 6 9Bk 6998 Hydrogen Hi 2016 6782-4855 5A71 69056929 6953 59655977 Hycropen sulfide —«HUS-==«94076 «BD «BOM] 1091827836 BaSS BSS Caroon monoxide CO_—«=«28.01«6 952 «695769585963 «8975 6986 7007 7.028 Cerbon dioxide CO, 44010 «8.380 8698-8762 -9.004 9.282 «9.557 10.31 1005 (1 Everton: Air, Keenan and Keen, Thrmalsnamic Probert of Air, Wis. tl Printing 147. Ammonia, Ela Re Grab, Thermo- Upnamic Properticn of Ammonia at Tigh Temperaares and Preaares, Pel, Proctning, Apri 195! Bae Bregretaeot7, (iat Hydrogen Sulfle, JR West Chemused to calculate k. MMefd = Compressor vapacity referred to 14.4 psla and intake temperature Mc, - MC, = 1.99 a) rae is an allowance for interstage pressure drop oo 1.0 for single-stage compression ae molecules -weeiebtlot shel ae F = 1.08 for two-stage compression C,, = heat capacity of the gas at constant pres- foci ope ltatotda tastes sure, BTU/Ib - °F. Equation 3 provides a close estimate of horse- Cy = heat capacity of the gas at constant volume, Sewer requirements for gases with specific gravity BTU/Ib - °F. ‘of 0.65 and stage compression ratios above 2.5. For By rearrangement and substitution we bbtain: gases with specific gravity in the 0.8 to 1.0 range, : Mc, ; FIG, 4-3, Mc,-199 acer Approximate heat-capacity ratios of hydrocarbon gases Th order to calculate K for a gas we peed only Know the molar heat capacity (MC,) fod the gas. Fig. 4-1 gives velues of molecular weight] and heat ‘capacity for various gases. The heat capatity varies considerably with temperature. Since the] tempera ture of the gat inereases as it passes from|suction to discharge in the compressor the Kk, is nommally de- termined at the average of suction and] discharge temperatures. For @ mixture of gases, such as natural gas gen- erally i, the weighted valve of molar hed enpacity must be determined. A sample calculetioh for this determination is illustrated in Fig. 4-2 When the gas analysis is not known thp value of molar heat capacity cannot be calculated |as shown in Fig. 4-2. If the specifie gravity of the gas is known, an approximate value for K ean [be deter~ mined from the curves in Fig. 4-3 Estimating compressor horsepower Equation 3 is useful for obtaining a [quick but reasonable estimate of compressor horsepower: Brake horsepower = (22 bhp) (Ratiq/Staze) (Stages) (MMefa) (F) ae eB) Wher FIG. 4-2 Colculation of k Determination of ME, © om, Smarty “hates cogmee eta «Sate | More gate seed there cows 2007 fuer rome 018s 4 Gals Nutone 0008558120 st oes tonane 00017 7RIS as 08 ata Tord = 10000 Wotie = 1f.795 Pom = 6721 Tymin = 3646 k = 9577/9577 -1.99) = 1.26 For velues of MC,* et other thon 1SO°F. Refer|to Fig. 4-)the multiplication factor will be approximately 20, For compression ratios between 1.5 and 2.0 the fac- tor may be as low as 16 to 18. When using low ratios and/or for high-gravity gases the estimated horsepower from Equation 3 will tend to be on the high side. Curves are available which permit easy estima tion of approiximate compression-horsepower re~ quirements. Fig 4-4 is typical of these curves. The horsepower required is determined by entering the x-axis at the total compression ratio and going ver- tically to the appropriate curve, and then horizontally fo the y-axis to determine the brake horsepower requirement per MMcfd. ILLUSTRATIVE PROBLEM Consider the problem of compressing 2 MMefa of gas at 144 psia and intake temperature through a compression ratio of 9 in a 2-stage compressor. What, will be the horsepower? Solution—From Equation 3 we find the brake horsepower to be: (22) (3) (2) (2) (2.08) = 285 hp. From Fig. 4-4, using a k-value of 1.15, we find the horsepower requirement to be 132 hp/MMofd or 264 bhp. For a k-value of 1.4, the horsepower re- quirement would be 145 hp/MMefd or 290 total horsepower. The two procedures give reasonable agreement, particularly considering the simplifying assumptions necessary in reducing compressor horsepower calcu- Iations to such a simple procedure. Detailed calculations ‘There are many variables which enter into the precise calculation of compressor performance. Gen- eralized data as given in this section are based upon averaging of many criteria, The results obtained from these calculations, therefore, must be consid- ered as close approximations to true compressor performance. Approximate ps ‘ond section temper Overall compression ra FIG. 44 fer required to compress gases ‘ioronie gover LoverCAPACITY Compressor capacity may be expressed|in many. ways. The only independent measure of capacity is intake volume of gas expressed in cubic feet per unit time at suction conditions of temperature and pres- sure. This volume may be calculated as the piston displacement (generally in cu ft/min) multiplied by ‘the volumetric efficiency. ‘The piston displacement is equal to the het piston area multiplied by the length of piston sweep in a given period of time. This displacement mpy be ex- pressed: For a single-acting piston compressing on the outer end only, (stroke) (rpm) (D*) PD = ——_____ wf A) (4) (1,728) 4.98 (104) (stroke) (rpm) (D4 For a single-acting piston compressing on the frame end only, (stroke) (rpm) (D?—d2) PD = ————____— ©) (4) (1,728) = 4.55 (10-4) (stroke) (rpm) (D?—#2) For a double-acting piston (other thah tail rod type), PD = (stroke) (rpm) [2 D*~a]) | (6) = 4.55(104) (stroke) (rpm) [2 Df—d*) Where: PD = piston displacement, eu ft/min stroke = piston stroke, in. D = cylinder diameter, in, d= piston rod diameter, in. rpm = number of revolutions of crankshaft /min VOLUMETRIC EFFICIENCY In a reciprocating compressor the piston, does not travel completely to the end of the cylinder at the end of the discharge stroke. Some “clearance vol ume” is necessary from a purely mechanidal stand- point. ‘The effect of gas contained in this |clearance volume on compressor capacity can be represented by Equation 7. ze VE=96—r—C(— (nM) ~ 1) ~@ Za Where: VE= volumetric efficiency expressed 4s a per- centage the ratio of compression, discharge pressure psia ) suction pressure psia Z, = the compressibility factor at suction tem- perature and pressure Z, = the compressibility factor at discharge tem- perature and pressure © = cylinder clearance as a percent of cylinder volume = ratio of heat capacity of gas at average cylin der temperature 96 = 100s, less an arbitrary factor to provide an adjustment closely reflecting certain actual field test. (Factor courtesy of Amoco Production Co.). When a non-lubricated compressor is used, the olumetrie effieiency should be corrected by ‘sub- ‘acting an additional 5% for slippage of gas. This is a capacity correction only and should nat be con- sidered when calculating compressor horsepower, The energy of compression is used by the gas even though the gas slips by the ring and is not discharged from the cylinder. If the compressor is in propane service an addi- tional 4% should be subtracted from the volumetric efficiency. These deductions for non-Iubrieated and propane performance are both approximate and, if, both appiy, cumulative. Hig. 4-5 is a chart providing the solution to the function, 1/*, Values for compression ratios not shawn may be obtained by interpolation. The closest ke value column may be safely used without a second interpolation. Volumetric efficiencies for “high speed” separable compressors tend to be slightly lower than estimated from Equation 7. This can be allowed for by modi- itying Equation 7 as follows: z, 9 -2r-c( GM) —1) Za Compressibility factors for gas mixtures ean be determined. from charts inthe physical properties section of this Data Book. For pure components such as propane, compressibility factors can be determined from the Moller diagrams. VE (a) EQUIVALENT CAPACITY ‘The net capacity of the compressor in cubic feet per minute may be determined as the product of the piston displacement and the volumetric efficiency. Since compressor capacity is usually considered in. millions of cubic feet per day the net capacity must be converted. To convert to MMcfd referred to at 144 psi and inlet temperature, use Equation 8. cfm MMefd = —— P, 104 8) 2 Where: P, = suction pressure in psia For example, a compressor with 200-cfm capacity, ‘a compressibility of 0. and a suction pressure of 75 Psia would have a capacity of 1.67 MMefd. If com-pressibility is not used as a divisor in calculating tion will specify some other measurement standard ‘cfm, then the statement “not corrected for compr for gas volume. To convert volumes from 14.4 psia sibility” should be added, 144 psia is used in Equa- and intake temperature, Equation 9 would be used. tion 8 because this is the common base pressure for FIG. 4-5 Values of r'*pressure base used in the contract or regu- ration psia T,, = temperature base used in the contract or regulation, * Rankine CF + 460) T, = intake temperature, ° Rankine (“F, + 460) DISCHARGE TEMPERATURE ‘The temperature of the gas discharged from the eylinder ean be computed from Equation 10. Ty = Ty (remy 1. (20) Where: Ty and T, are in °R. Fig. 4-6 a nomograph which can be used to salve Equation 10. The discharge temperature determined from elther Equation 10 or Fig. 4-6 is the theoretical Value, While it neglects heat from friction] itreversi- bility ettects, etey and may be somewhat low, the values obtained from this equation will be feasonable field estimates, True discharge temperatues usually can be clovely estimated by the menufaclurer of a ziven compressor. ROD LOADING Every compressor manufacturer has available a number of standard compressor frames.| Each of these has definite limitations as to maxinjum speed and load-carrying capacity. The load-catrying ca- pacity of a compressor frame involves twp primary considerations: horsepower and rod loading, frame is ability of jwithstand the bear- The horsepower rating of a compressot the measure the manufacturer makes of the the supporting structure and crankshaft to| torque, or turning effort, and the ability of ing to dissipate frictional heat. Rod loads pre estab- lished to limit the static and inertial loalls on the crankshaft, connecting rod, frame, piston rad, bolting, and projected bearing surface. Good design dictates a reversal of 1: during cach stroke. Non-reversal of results in failure to allow bearing surfa and permit entrance of sufficient lubrie} terial. The result will be premature beari failure, Occasionally, rod-load reversals provided, In these cases the compressor mal can furnish special bearings capable of reasonably well without reversal of the lo loading je loading to part tion ma- Ig wear or wnnot_ be vifacturer operating, a. Rod loadings may be calculated by the use of Equations 11 and 12, Load in compression (Py = Pa) Ay + Pe Ae Direction of Ad = ay Ay ~ Ps (Ay —_.-_—> % 7 Load in tension (Pe =P.) Ap — Po, Py (A, Direction of motion <— ta £ 2 " the discharge pressure, psia rn ", = suction pressure, psia A, = cross sectional area of the piston rod in sq in. Ay A loading reversal will be shown by a change in direction of net forces acting on the rod. ‘The true rod loads would be those calculated using internal cylinder pressures after allowance for valve losses. Normally the operator will know only line pressures and because of this manufacturers gen= erally rate their compressors based on Jine-pressure calculations. sr088 sectional area of piston in sq in. A further refinement if the rod-loading caleula- tion would be to include inertial forces. While the manufacturer will consider inertial forees when rat- ing compressors, useful data on this point is seldom available in the field. Except in special cases, inertial forces are ignored. A tail-rod cylinder would require consideration of rod cross-sectional area on both sides of the pis- ton instead of on only one side of the piston, as shown, in Equations 11 and 12. Horsepower Detailed compressor horsepower calculations can be made through the use of Figs, 4-7 through 4-10. For ease of calculations, these figures provide net horsepower, including mechanical efficiency and ges losses. Figs. 4-11 and 4-12 are included for modify- ing the horsepower numbers for special conditions. ‘The proper use of these charts should provide the user with reasonably correct horsepower require- ments that will compare favorably with those caleu- lated by the compressor manufacturer. For more detailed design, the engineer should consult with the several compressor manufacturers. When using the horsepower charts, each stage of compression must be calculated separately and the totals added together to obtain the total brake horse- power requirement. Volumes to be handled in each stage must be cor~ rected to the actual temperature and moisture eon- tent at the inlet to that stage, (Text cont'd. p. 4-12)F1G.4-6 Theoretical discharge temperatures Single-stage compression Read F to k to T, to Ty Yo "timioi2dusy s6s04381p [821220941 i i aan slicherge ss made toe ‘nino90s pumped /24hr day : 2 i ‘ond intoke emp.) BHP per million curve Mechanical efficioncy-95% Gos velocity through valve=3000 ft/min(APi equation) st 2 1 4s nal x ror conselt the rmonufoctorar for bett dete {oe ee ee a as aad ads Ratio of compression Courtesy lagerselt-Rand Coley (Referred to 14.4 pria and intoke temp.) oof a 3 sf a sof as a a 26 FIG. 4-8 BHP per million curve Mechanical efficiency-95% Gas velocity through valve~3000 ft/min (AP | equation) eT OT a eC Courtesy Ingersoll-Rand Cotho /MM cu ft gas pomped/24 he doy ita ape ane mrcasitomer ee 1304 12s} 20} ns no} ro 95 so 6 ao} nf 7 70) “eat FIG. 4-9 BHP per million curve, \echanical efficiency-95% Gas velocity through velve-2000 ft/min API equat hz fas ha pas hs has hz his fu pag ad as 47 an 493051 BSS 8S Courteny lngersell-Rond Co 4-10Bh6/M co ges pumped / 24h doy "ond fnteke tom (neferred to 14.4 150 uw v9] nas] a 15 129} ns} no} 10 100 36 ‘37 BHP per mi FIG. 4-10 jon curve Mechanical efficiency-95% Gos velocity through valve-3000 Ft/min(AP! equation) ‘$06 co 4-u aad 35 38 8768 Courtesy IngerWhen intercoolers are used, allowance| must be ‘This procedure gives the absolute discharge pres- made for interstage pressure drop. Calculated inter- sure of this stage and the calculated absolute intake stage pressures may be obtained by: pressure to the next stage. The calculated upper ‘i stage intake pressure can be corrected for intercooler 1. Obtain the overall compression ratio, r. Sage de drop ‘by reducing the pressure by 39% 2. Obtain the calculated ratio per stage, by taking a 7 Hl a“ jorsepower for compression is caleulsted by the § root of r, where s is the number of compression ging Figo, dc? through 4-10 and Equation 13: stages. Pte 3. Multiply r by the absolute intake pressure of Bhp = Bhp/MM_ — Zage MMsef (13) the stage being considered. 144 FIG. 4-11 Correction) factor for low intake pressure 1 K} rr ua a0 5 tos 106 108 104 103 Ht vor cease eee EEE EEE 1.01 4-12where: Bhp/MM is read from Figs, 4~7 through 4-10 14.4 = Pressure base, psia, for Figs. 4-7 through 4-10 P, = Pressure base used in the contract or regulation, psia T, = Intake temperature, “Rankine T,, = Temperature base used in the contract or regulation, ° Rankine MMsct = Millions of standard cubie feet of ges (rate per day) measured at Py, and T,, Zyye = Average compressibility factor in the (+ Zn) ‘compressor cylinder = ————— 2 Figs, 4-7 through 4-10 are for standard valved cylinders. Caution should be used in applying con- ventional cylinders to low-compression-ratio pipeline compressors. For low ratio pipeline compressors a high clearance type cylinder permits valve designs with higher efficiency, The compressor manufac turer should be consulted for bhp curves on this type cylinder, Fig. 4-11 provides a correction for intake pressure, ‘The corzeetion factor, as read from the curve, is used as a multiplier in Equation 13 to obtain the corrected brake horsepower, Fig. 4-12 provides a correction factor for gas spe- cific gravity. ‘The correction factor is used as a mul- tiplier in the right-hand side of Equation 13 to ob- tain the corrected horsepower, Data presented in Figs. 4-7 through 4-10 are for slow speed integral or process unit compressors rather than the high speed separable compressors, To adjust the horsepower for the high speed unit, the values obtained from Figs. 4-7 through 4-10 should be increased by these percentages: Gas specific gravity Percent horsepower increase 0.05 - 0.80 4 0.90 5 10 6 41 a 1.5 and propane refrigeration units 10 Because of variations by different manufacturers in specifying valve velocities for high speed as op- Posed to slow speed compressors, a given unit may differ from the horsepower corrections shown. Ex- perience with compressors from a specific manufac turer will serve to guide the user and give him con- fidence in utilization of the correction factors shown. Example for Equation 13, Consider the problem of compressing 2MMsefd of gas measured at 14.65 psia and 60°F. Intake pres- sure is 100 psia, and intake temperature is 100°F, Discharge pressure is 900 psia. The gas has a spe- cific gravity of 0.80. What is the required horse- power? 900 psia 1. Compressor ratio is =o 100 psia ‘This would be a two-stage compressor; therefore, the ratio per stage ie /9 or 3. FIG. 4-12 Correction factor for specitic gravity 0 1 | : feo Lo —— 3 se st 7 6 ww AZ 1 vy 7 20 2 22 23 Courtesy of tngers2. 100 psia x 3 pressure) 300 psia x 979% stage) 300 psia (Ist stage disenarge 291 psia (suction to 2nd 900 psia for 2nd ——— = 3.09 (ratio of compression 291 psia stage) (While you may wish to recalculate |the inter- stage pressure to belance the ratios, for this sample problem, the first ratios determined will be used.) 3. From Fig, 4-3 a gas with specific \gravity of 0.8 at 150°F, would have an approximate kc value of 1,21, (For most compression applications, the 150°F, curve will be adequate. This should be back-checked, after determining the average cylinder temperature to see if the assumption was correct.) 4. Discharge temperature for the Ist stage may be obtained by using Fig. 4-6, solving Equation 10. For 2 compression ratio of 3, discharge temperature ‘approximately 20°F, 5. In the same manner, discharge temperature for the second stage (with r= 3.09 and asfuming in- terstage cooling to 120°F.) equals appfoximately 246°F. 6. From the physical properties sect book, you may estimate the compressibill n of this ity factors at suction and discharge pressure and temperature of each stage. Ist stage: Z, = 0.98 Z = 097 Zave = 0975 2nd stage: Z, = 0.99 Zy = 0.98 Zore = 0.94 7. From Fig. 4-8, bhp/MM at 3 ratios and a k value of 1.21 is 63.5 (ist stage). From Fig, 4-8, Dhp/MM at 3.09 ratios and a kk value of 1.21 is 65.2 (2nd stage). 8. ‘There are no corrections to be applied from Fig. 4-11 or 4-12, gs all factors read unity. 9. Substituting in Equation 13: ae we yi =a (2) (3) do an (ss want = oa (5) (i) 004 ‘Total bhp for this application = 135.6 + 138.0 274.6 (See discussion for Equation 3 for correlation) Engine power considerations Limits to compression ratios per stage—The max- imum ratio of compression permissible in one stage is usually limited by the discharge temperature. When handling gases conta ning oxygen, which could support combustion, there is always a possibility of fire and explosion because of the oil vapors present ‘To reduce carbonization of the oil and the danger of fires, @ safe operating limit may be considered to be approximately 300°F, Where no oxygen is present in the gas stream, temperatures of 350°F. to 400°F, may be considered as the maximum, even ‘though mechanical or process requirements usually dictate a somewhat lower figure. Packing life may be significantly shortened by the dual requirement to seal both high pressure and high temperature gases. For this reason, at higher discharge pressures, a temperature closer to 250°F. or 275°F, may be the practical limit. In summary, and for most oil field applications, the use of 30°F, maximum would be a good average, Recognition of the above variables is, however, still useful. Economie considerations are also involved be- cause a high ratio of compression will mean a low volumetric efficiency and require a larger cylinder to produce the same capacity. For this reason a high rod loading may result and require a heavier and more expensive frame. Where multi-stage operation is involved, equal ratios of compression per stage are used (plus an allowance for piping and cooler losses if necessary) unless otherwise required by process design. For ‘two stages of compression the ratio per stage would he approximately equal to the square root of the total compression ratio; for three stages, the cube root; ete. In practice, especially in high-pressure work, decreasing the ratio of compression in the higher stages and thus reducing excessive rod load~ Ing may prove to be advantageous. Engine deration for altitude and ambient tem- perature—Manufacturers of high speed non-turbo- charged and turbocharged engines generally rate their equipment at sea level only. For each 1,000 ft above sea level, the deration is 3% for non-turdo- charged and 2% for turbocharged engines. An addi tional 1% deration for each 10°F. above 60°F. am- bient temperature is also normally used. Such en- gines use the standards of the Internal Combustion Engine Institute. Most manufacturers of the integral engine-com- pressor units make no change in the ratings of their naturally aspirated, blower or pump-scavenging en- gines up to altitudes varying from 1,500 to 2,500 ft above sea level. Beyond these points deration pro- gresses at approximately 3% for each additional 1,000 ft altitude. Normally, no deration is considered for ambient temperature changes.Large integral type turbocharged ongines can be used without deration between 1,800 and #000 ft elevation above sea level. Beyond these points, con- sult the engine manufacturer for deration factor. Engines rated such as the integrals above use the Diesel Engine Manufacturers Association standards and allow an additional 10% overload for 2 hours out of every 24 hours of operation Engine-compressor cosling-water requirements— Jacket water requirements vary with the heat-re~ jection rate from the power eylinder jackets, the oil cooler, the exhaust manifold, the turbo ait after- cooler (for turbocharged units), the compressor cylinder jackets, and with the rise'in the temperature of the water from inlet to outlet Normally, manufacturers recommend a 10°F, to 15°F, rise through the engine jackets; from 5°F, to 10°F. through the turbo air after cooler(s); 10°F. to 15°F. through the oil cooler; and from 5°F. to 20°F. through the compressor cylinder jackets. All of these may be varied at times to obtain a proper heat dissipation balance for the particular distribu- tion system used. Consult the manufacturer for more specific data. Heat-rejection rates are shown in Fig. 4-13 for typical engines used for oil field and process applications. BMEP - definition and implication BMEP is known as brake mean effective pressure and is defined as: 4A-eycle engines: BMEP = FIG. 4-13 Heat rejection /requirements for various gas engines (All figures in BTU/bhp-hr, LHV) Note: Figures moy be opproximote due to, variations in engine services, ond ore reprosentative of new ‘engines nly. Refer to manufacturer for exact rates Head come no sate ib'eetenegsed “win'dpemmest © etter on Paget Engine Pisa Smoonts” cxhowst manifolds" manioles fooler cooler ier Clark HMA, High 9000 2300 1700 — 85 500" Med 9600 = 1900 er) HMB High 8900 = 1700 = as Med 9500 = 1900 — 680 T™B. High 8400 = 1400 220 © 500 Med 3000 1600 220 © 350 HRA, High 8000 1700 — 400 Med 3000 1950 — 495 Low 10000 — 380 HBA, High 8000 1700 — 550 Med 9000 1950 = 40 Low 19000 2300 - 60 HLA High 8000 1700 = 40 Med 9000 1950 — 550 tow 10000 2300 — 600 TA High 7000 1100 285 400 Med 7600 1300 285 450 Tev High 6850 =~ 1050 285 © 350 Cooper Bessemer GMVH a 7600 1450 — 45 GMVA mas 1200 — 500 Gmve ~ 7500 i 1200 180450 GMvH - 7000 _ T0900 205335 GMWK = 7000 ~ Noo 218365 MWe = 6950 a 1000 260 © 320 sve - 8500 3375 2675 — 265 KvG/R = 8100 2700 — — 500 TVR = 7400 7 1720 Included 475 6/8 KvS = 7400 - 2100 Included 350 10/12 KS. = 7300 7 2100 Included 375 6/8 KVSR = 7400 7 2100 125350 10) KVSR as 7300 7 2000 125375 KVR = 6550 950 = 350-350, *Soparable high-speed compressors reject approximately 500 8TU/obp-he.Horsepower x 10° ‘Wo. of power cyls) (power ey. Gia) | (cpm) \strokey as) 2-eyele engines: BMEP Horsepower x 108 (No. of power eyis) (power cyl. dia.) (rpm)(2) Where: BMEP = psia Power cylinder diameter |(etrokey as) inches Stroke = inches ‘To compare the BMEP of one engine with another thas meaning only ia relation to the specific design of each engine. After beating sizes, frame frois et tions, heat rejection capabilities of the ol aga water cooling. passages, ete, have een considered, such comparisons can be wieful. ‘They aléo allow # judg~ ment of suitability for any specific engide at be- {ieee one application and another. From ‘the period of the first World Wg the BMEP on all engines, both power and dj nected compressor type, has steadily risen| was about 72 psi for a 4-eyele engine an: Ir to now irect-con. "Then it 45 to 47 psi for 2-eycle designs. Naturally-aspirated 4-cycle engines have a basic absolute combustion limit of around 105 psi, so they have not moved much above the earlier 72-psi design ‘Something in the 74 to 85-psi range would prob- ably represent the current design. Current design on ‘4 4-eyele (turbocharged) will run from 100 te 185 psi. 1970 BMEP's of 2-cycle engines tend to be about the same range (100 to 180 psi) as turbocharged 4- cycle equipment, These figures are for heavy-duty Diesel Engine Manufacturers Association rated en- gines, Somewhat lower valuas give improved life and maintenance cost for the Internal Combustion En- gine Institute rated engine. There is no reason why BMEP cannot be as high ‘as 200 psi (or higher) if the running gear is built sufficiently strong to take the impact forces, if the ‘engine can remove the heat so that it will not score the power cylinders or freeze the bearings, and if you ean operate without detonation in the combustion spaces. GAS-PULSATION CONTROL Several industry mothods were tried in an effort to come up with a reasonable rule-of-thumb for sizing compressor suetion and discharge non-baffied volume (pulsation) bottles. FIG 4-13 Cont'd. Heat rejection/requirements for various gas engines (All figures in BTU/bhp-hr, LHV) ximote dus 10, va tions in_engine services, ond ore “epresentative of new chines only. Refer to manulacturer for exact rales Regine Pion Worthington SLHC = 7000 ute = 8500 Matnlines-PT = 7000 ‘Mainliner-Iline = 6750 ‘Matnliner-Vee = 6750 Waukesho £28956 = 7800 F35216 = 7800 F3521G51 = 8050, Lars = 8550 L5108s = 8150 510868! = 8200 57906 = 7950 15790681 = 3150 L70426 = 7950 7042681 i 8050 White Supe 6/8 G-510/825 — 8700 6/8 GT-510/825 a 7600 12/16 6-825 = 8700 12/16 GT-825 = 7600 De bev Hv.6/12/16 - 6700 Powerendlockete Fowarendjgckate Sor coterie Meme ihe, 1400 i 135380 2180 = — 500 + 1400 = 265-400 1000 = 300-360, 1000 = 420-360 2940 ~ a 420 2650 = a 445 2560 = 108365 2780 = = 310 2860 = = 445 2700 = a 445 2630 = 10s (365 2650 ~ — 445 2600 = 108-370 3600 = ast 2460 = 300 a 2400 aa am 1600 300 Included 175 — 350380 4-16No two methods gave the same answer. Still, it seems useful to have some short-cut method to judge the adequacy of proposed sizes. With these qualifi- ations, the “middle-of-the-road” chart, Fig. 4-14, is included. It shows a multiplier for cylinder swept volume vs, line pressure. Here is an example of its use: Indicated suction pressure = 600 psi Indicated discharge pressure = 1,400 psi Cylinder bore = 6 in, Cylinder stroke = 15 in, * (6)"/4) (15) ‘Swept volume 424 cu. in, From the chart: At 600 psi inlet pressure, the suction bottle multiplier is approximately 7.5. Or, suction-bottle volume = (7.5) (424) — 3,180 At 1,400 psi discharge pressure, the discharge bottle multiplier is approximately 85. Or, discharge-bottle volume = (8.5) (424) 3,600 cu in. Note: Whew mare than one cslinder it connected to ¢ ott im" perallel, the. sem of the indivaal wept olumet ithe se required for the common bette For more accurate calculations, engineering de- partments of the compressor manufacturers can be consulted. Commercial firms which provide designs and equipment for gas-pulsation control are also available. Having determined the necessary volume of the bottle, the proportioning of diemeter and length to provide this volume requires some ingenuity and judgment. It is desirable that manifolds be as short and of as large diameter as is consistent with pres- sure conditions, space limitations, and appearance. A good general rule is to make the manifold diameter 114 times the inside diameter of the largest cylinder connected to it, but this is not always prac- tieable, particularly where large cylinders are in- volved. Inside diameters of pipe or casing must be used in figuring manifolds. This is particularly important in high-pressure work and in small sizes where wall, thickness may be a considerable percentage of the cross sectional area. Minimum manifold length is determined from eylinder center distances and con- necting pipe diameters: Some additions must be made to the ‘minimum thus determined to allow for saddle reinforeements and for welding on caps. It is customary to close the ends of manifolds with welding caps which add both volume and length, ‘This table gives approximate volume and length of standard caps: * Welding cops Stondard wight fre stone im, ts ve tena, Yetume, Pie sca ‘atm mm aa % wie “ 242 212 200 zn 15 “ m3 312 657 312 48 e” 148.5 anne 1223 41s 120 10” 2956 53/4 2644 aay 12 5170 67/8 475.0 67/8 4 484.6 7136 640.0 713/16 16" 967.6 ° si10. ° 1” 1432.6 101/16 1363.0 woe 20” 2026.4 iA 1938.0 ns 2a” 3451.0 137/16 3313.0 137/16 FIG. 4-14 the sizing eh 7 T Suction bor a x t H Discharge bole sires ° 200 400400 ~—«600-—«900~=«200~—«00~=«40~=«WOD.~«CkOOD a0 2000 Inlet presser. os! aeSection 5 Centrifugal Compressors In the dynamic natural gas industry, the old criteria for applying equipment are rapidly chang- ing. The basic concept of centrifugal compressors lends itself to the new design criteria that have been brought about by new concepts of plant design. ‘There are many configurations of centrifugal com- pressors available. Gas gathering, gas boosting, gas pipeline, refrigeration, ete, are’ services where centrifugals’ have found ‘application, As the gas industry continues to grow, new designs will be made available to suit the specialized requirements, This section is intended to supply information sufficiently accurate to determine whether a centri (gal compressor should be considered for a specific job. The secondazy objective is to present information for evaluating compressor performance. With expanding technology in this rapidly chang- ing field, a compressor manufacturer should be con- sulted before a final decision is reached as to the practicality of a centrifugal compressor-in a new ap- plication, Fig. 5-1 gives an approximate idea as to the flow range that a centrifugal compressor will handle. A multistage centrifugal compressor is normally con~ sidered for inlet volumes between 500 and 200,000 inlet cfm. A single-stage compressor would normally have application between 500 and 150,000 inlet ef ‘A multistage compressor can be thought of as a series ‘of single stage compressors contained in a single casing. There is an overlap with reciproceting compres- sors on the low end of the flow range, On the higher end of the flow range an overlap with the axial compressor exists, The absolute value of this overlap depends on a number of things. Before a technical decision could be reached as to the type of compressor that would be installed, the service, operational re- quirements, and econamic evaluation would have to be determined, FIG. 5-1 Centrifugal compressor flow range Nonina tow aveeee red Frome life Fn) eieleney oor 1 500-7,500 074 2 7,500:20,000 07 3 20,000:33,000 077 4 3,000-55,000 077 5 55,000-80,000 om 6 80,000-115,000 0.77 7 118,000-148,000 0.77 8 — 148,000-200,000 0.77 Performance ‘The operating characteristics must be deter- mined before an evaluation of compressor suitability for the application can be made. Fig. 5-2 gives a centrifugal, and reciprocating compressor. | rough comparison of the characteristics of the axial, / Line A denotes head for the centrifugal curve, line B for the reciprocating curve, and line C for the axial curve. The concept of quantity and head in a power equation is well understood in centrifugal Hquid pump practice. It also applies to dynamic ‘compressors handling compressible fluids. ‘The centrifugal compressor approximates the con stant head-variable volume machine, while the reeip- rocating is thought of as a constant volume-variable head machine. The axial compressor falls somewhere in-between, A compressor is a part of the system, and its performance is dictated by the system resist- ance. The desired system capability or objective must be determined before a compressor can be selected. Fig. 5-3 is a performance map which shows the basie slope of the curve for a variable-speed centrif- ugal compressor. The actual value of the curve is, affected by many variables, such as desired compres- sion ratio, type of gas, number of stages, sizing of compressor, ete, can deliver constant capacity at variable pressure, With variable speed, the centrifugal compressor | variable capacity at constant pressure, or a combina- tion variable capacity and variable pressure. FIG. 5-2 Compressor head I I Line A Centrifugal Line ® Resiproceting I I 1 I / Line © Asie Tole cmBasically, the performance of the centriftgal com- p pressor, at speeds other than design, is duch that the capacity will vary directly as the speed the head 2 developed as the square of the speed, fang! the ro: quired horsepower as the cube of the speed. As the speed deviates from the design speed, the| error of these rules, known as the affinity laws, or fan laws, Fan laws: Quo Qi Qo 1 Qe nie —— a Pao Broo 2h ant; fe, = — Bhpy, Bhp, 3. Bap c n°: ie, By varying speed, the centrifugal comprpssor will meet any load and pressure condition demanded by the process within the operating limits of [the com- pressor and the driver. It normally accomplishes this, FIG. 5-3 Compressor performance, low compression ratio fas efficiently as possible, since only that head re- quired by the process is developed by the compressor. ‘This compares to the essentially constant head devel- oped by the constant speed compressor. Fig. 5-3 predicts a typical gas compressor with ‘a small compression ratio. ‘The system resistance has been superimposed on the performance: Line A rep- resents typleal system resistance of a closed cycle, such as a refrigeration unit, Line B is an open-end system, such as pipeline applications. Fig, 5-4 shows a higher compression ratio with a gas suchas propane. The stability range is reduced ise of the larger Patio 9 performance 8-6, 5-7, 5-8, 5-9, and 5-10 are to be used for estimating compressor performance, These curves are suitable for estimating only and are not intended to take the place of a “wheel-by-wheel” se- lection by the compressor manufacturer. Fig. 5-5 is, (Text cont'd. p. 5-6) HIG, $~4 Compressor performance, higher compression ratio ae 150 - T f na 8 Mo vs ! se 300 100% ; v0 £ [ 3 uo : iH ‘ : “L a) 0 5 wo 70 6 * 0 ob Wo 100 190 i ” 170 EB a0 no 3 7 roe ' E 0 z v0 30 ad ” 70 ” “ 2» i ee en en) ent teh fm500-1000. 2900 Example: Given “Stondord, etm = 60,000 Prevsute(@) 190 ps Nemperature (h)=i00°F, Tey che 9.700 «Cem $200 10.000 20000 30,000 100,600 709,000 100,000 ‘0.000 0,000 40,000 20000 10.000 5900 2.000 1.900 FIG, 5-5 Inlet cubic feet per minuteSe seo 00 ~ 400 600-100 ~ 2000 Ef ea, "78000 ICM oppreximately) “4900 4000 19000, 100.00 80,000 0.000 40000 f 20000 10.000 ‘8.000 6,000 4.000 2,000 11000 Inlet cub FIG. 5-6 feet per minuteisa 3 45 10 Comression sat Molecsar weight 42 "39000 {1 16/ Ib (epproximets) 20 3040-50 Too 100000 89000 Y 60,000 10200 5,900 FIG.5-7 Headoe Man, | used to convert scfm to icfm. All centrifugal com- pressors are based on flows that are converted to inlet or actual cubic feet per minute, ‘This is done Since the centrifugal wheel” is-Fensitive to iplet vol- ume, compression ratio (ie, head), and specific speed. (actual) “Actual Fig, 5-6 is a useful curve to find inlet ‘cfm when the weight flow in Ib/min is know cfm and inlet cfm both denote the suction conditions, These terms are quite offen usd inter- changeably. This curve can be used in rdverse to determine mass flow. Fig, 5-7 is used to find the head required by the desired pressure ratio. If i, the adiabatic exponent, is used, the resulting head is adiabatie head. However, if the polytropic exponent, n, is used, the fesulting head is polytropie, Whichever exponent is|used on Fig, 5-8 should also be used on Fig, 5-9. Fig. 5-8 predicts the approximate number of compressor stages required 10 produce the head. If the humber of stages is not » whole number! use the next highest number Fig. 5-9 is used to determine the appfoximate discharge temperature that is produced by he com- pression ratio. Discharge temperature alfove the 40°F, range should be checked since mqchanical problems as well as safety problems may eyist. This curve includes compressor efficiences in te range of 60 t0. 15% Example Given: r = 100; Q, = 10,000 ietm; k= 1.15; T, = 0° F, Find: Discharge temperature Answer: T, = 230° P. (approximately) Fig. 5-10 gives the approximate horsepqwer re- quired for the compression. It includes compressor efficiencies in the range, 60 to 70%, FIG. 5-8 Stages required vires Aeerorimote avinimue of stages 3040, 30 Head, tt-1b/1b {msliny by 1000) 6070 Example Given: Weight flow, w, = 1,000 1b/min; head 7,000 ft-Ib/tt Find: Horsepower Answer: hp = 3,000 Calculation procedures When a more accurate calculation procedure is required for compressor head, gas horsepower, and discharge temperature, the equations in this section will be used. This method applies to a gas mixture for which a mollier chart is not available. To cal- culate the properties of this gas, see Figs. 4-1 and 4-2. All values for pressure and temperature in this calculation procedures are the absolute values. Use this equation to calculate the inlet volume: fw) (1,845) (Ts) (Zr) aw) (P,) (44) If we assume the compression to be insentropie (reversible adiabatic, constant entropy), then: ae | — 1 Definition of terms specific heat at con- Tq reduced tempera stant pressure ture (T/1.) ey specific heat at con- temperature (°F) Btant volume specific volume (eu Head (# 1b/tb) iby h Enthalpy (BTU/Ib) yoyo Adiabatic expanant eight tlow (Ib/ (e/e0) femperature rise Me, molal specific heat ™ femPer** at constant pressure ee tae MW molecular weight tere cree 1 polytropie exponent cp He Py reduced pressure | OPP 688 horsepo on Bhp brake or shaft : horsepower pressure (psa) r= P. critical pressure 7 _—ffieleney (sia) Subseripts @ capacity (ietm) ad adiabatic process R gas constant ) (i544/MW) P_ polytropie process compression ratio Gt) P,P.) S_ standard conditions— 5 entropy (BTU/b/ tisually 147 pei, Rankine G0°F., dry (Q,) absolute tempera-._ inlet conditions ture("Rankine =F (py) (Q) Ct) $450.8) T, critical temperature 2 discharge conditions (Rankine) @) () (a)wa? a4 s 10 20 Compression tetio, Examples Givens ‘Compression ratio, r=10 a 10,000 ct k as Intet temperature % = 0% Find Discharge temperatore T= 230° E(approninately) FIG.5-9 Discharge temperature 30 40 30 ¢ u p00 600 ace 200 1.000 ‘00 400 ‘500 400 300FIG. 5-10 Horsepower determination to0__200_300 500 1900 _2.000 3.000 5000 1a000 20,900 30,000 50,000 r 100 "300300 500 ‘0002000 3000 5000 flow, welb/min pa.000" Cxomate: Given ia Annee Horsepower He =2,000 ft FIG, 5-11 « ncy conversion Polytropie elficieney 46 6970 72 7% 76 78 50 82 M4 6 o0 PoP ee ON AT TREPTORE He eGSince this calculation will not be a wheel-by- wheel, the head will be calculated across the entire machine. For this calculation use the average com- pressibility factor: Z inlet + Z discharge Lag = 2 This value for compressibility should be substi- tuted in the head equation. Note that all other values are for inlet conditions. Zug RT ( Py yen Bas -1 h (eI /ic P, 1544 Zag T [(P2) (oety/e _ | MW (k-i)/k[\ Pr ‘The gas horsepower can now be ealeulated from the equation below: : WX Hayy Ghp “aa * 33,000 ‘The brake horsepower includes bearing and seal losses which can be estimated at 50 hp. To calculate the brake horsepower: Bhp = Ghp + 50 For the number of stages and approximate speed required, see Fig. 5-1. ‘The speed can be calculated Speed = frame speed x ses Ye ped @ 2 feamtersisagen Gomme head required To determine the exact speed and number of stages required, the compressor manufacturer should bbe consulted. ‘The approximate theoretical discharge tempera- ture can be ealeulated from: ( Py , (eo) fle Ton = Ts |(—— -1 Py T= Ts + ATs The actual discharge temperature can be ap- proximated: Ty + Aaa P2) Geny/k #) fn ] Tea AT scant Ty Sometimes compressor manufacturers use a poly- tropic (reversible) path instead of isentropic. ‘This is usoful, in that the polytropic efficiency (»,) is by definition independent of gas properties or wheel performance with respect to pressure ratio, Poly- tropie efficiency is defined by: nfo-t) = [k/{k-1)] 9» (See Fig. 5-11 for conversion of iy, 10%) ay The equations for head and horsepower based upon polytropie compression are: = 2ukE [(B) mm.) 8, = ene [(R) ie Bd ZT (PL) O12 _, Mw Gh [(% we xhy chp = 3p 58000 Bhp = Ghp + 50 hp Polytropic and adiabatic head are related by a, x”™ When a mnller chart is available for the gas to ve womprassedy the following prowedure shold be used. Fig. 3-12 represents a section of a typical mollier chart. » With the given inlet conditions the enthalpy can be shown as Point 1 on the mollier. Starting from Point 1 follow the line of constant entropy to the required discharge pressure (P.), locating the adia~ Batic discharge state point (2,4). With these two points located the differential adiabatic enthalpy can be calculated from the following equation. Ahyy = haya — hy, BIU/Ib ‘To convert to adiabatic head, the equation is: yy = A yg x 778 fl-b/BTU FIG. 5-12 Mollier chart construction Presare‘To find the discharge enthalpy: Shy +h et ‘The actual discharge temperature can now be ob- tained from the mollier diagram. The gas horse- power now can be calculated again: wi Hag Ghp = ———— Yay X 33,000 ‘The bearing and seal losses can be ebtimated at 50 hp: Bhp = Ghp + 50 hp From Fig. 5:1, the speed_can_be estimated /no, wheels x 10, Speed frame speed To convert to poytropic head it will be necessary to assume a polyttopie efficiency. See Fig.|$-1 for an, _sifisiency. corresponding to the inlet flow | Fis. ‘vill give a corresponding adiabatic cfficieney. ‘The polytropic head will now be: HyaX 7% 5 When a mollier diagram is available, it is the fastest and most accurate method of détermining ‘compressor horsepower and discharge teinpereture. Controls—Centrifugal - compressor coftrols can vary from the very base manual recycle|control to elaborate ratio controllers. The driver characteris- ties, process response, and compressor | operating range must be determined before the right type of controls can be selected. For example, motor drive applications would require a much differdat type of control system than would a variable speed turbine application. I jeisldaaaad (cuit tne |e ltt: ante ey nary Touty- ae ae ne inlmum cotfl system Fea ee Poperalon, uch as Fat aa ar et eTeornal rin, shuld See eae ere wohabie ae. A cael Field performanee—Once the compressdr has been installed, quite often the performance of the system is to be tested. It must be realized that the same information is required for evaluation af was sup- plied for the initial selection. This information is essential: 1. Inlet conditions a. Flow (scfm, iefm, or Ib) b, Gas analysis ©. Pressure, psia 4d, Temperature, °F. 2. Intermediate conditions a, Pressure at intermediate nozzles, psia b. Temperature at intermediate nozzles, °F. 3. Discharge conditions a, Pressure, psia b, Temperature, °F. 4. Compressor speed, rpm. 5. Power requirement from driver if available (steam flow, amperes, ete.) If all these conditions were given except flow, it would not be possible to determine the compressor operating point, The system resistance curve im- posed on the typical performance is not always con stant, Discharge temperature of the compressor is a food indication as to the operation of the compressor. How- ever, such items as recycle (internal or external), different gas anslysis, different suction conditions, and different flow can affect the values. The effi ciency at part load or overload will normally be lower than the design conditions. Test procedures should be agreed upon between the manufacturer and user before a performance test is run. Tt is recommended that a test point be run several times to see if the results can be dupli- cated, and it is very important that calibrated in struments be used to improve the accuracy of the test data, General ‘Two conditions associated with centrifugal com- pressors are surge (pumping) and stonewall (choked flow). The surge condition occurs when the compres- sor does not have the capability to produce enough head to overcome the resistance imposed. When the ‘compressor reaches this point, the gas in the discharge piping back flows into the compressor momentarily. ‘This can also be eaused by lack of flow available to the compressor, causing the wheels to be unstable. This should be avoided since it can be detrimental to the compressor. Surging can cause the compressor to overheat to the point the maximum allowable temperature of the unit is exceeded. Also, prolonged surging can cause damage to the thrust bearing due to the rotor shifting back and forth from active to (the inactive side. ‘The stonewall or choking condition is a point ot which the flow to the compressor cannot be inereased., When the compressor reaches the choking condition, * it cannot produce head. Centrifugal compressors can be driven by a wide variety of drivers, Gas engines, gas-fired turbines, motors, steam turbines, and gas-expander turbines fare some of them, Many of the drivers present Unique design parameters, A motor drive for an ‘example is limited by its constant speed. ‘There are ways to minimize this restriction by suction or dis- charge throttling. The single-shaft gas-fired turbine has a limited- speed operating range due to the characteristics of horsepower output at a redjiced speed. In many cases, the compressor ean be direct connected to the driver. ‘Once the decision has been made as to the type of driver required for the plant, a compressor manu- facturer should be consulted to determine if the compressar can be direct~driven.FIG. 5-13, Motal heat capacity mcp° (ideal gas state), BTU/ tb mol/°R. (2) Data Source: Selected Values of Properties of Hydrocarbons, API Research Project #4 e Chemis] Mot al Gas Formula| we. | o°F | s0°F | coer | 100% | 1s0°F | 200°F | 50°F | 200%F Methane cx, [1e042 | 25a | aais | ease | asi | 2947 | 9277 | 9.30 | 10.01 Bthyne (Acetylene) 26.036 | 9.688] 10.23 | 1033 | 071 | itis | 1154 | ne8 | 1222 Ethene (Ethylene) zsos2 | 9524 1002 | 1016 | 1072 | asao | 1208 | 1273 | asa Ethane goose | 1n4¢ | xzi7 | 1232 | zs | ia77 | a46s | i549 | 16:34 Propene (Propylene) aor | 1363 | 1800 | 1490 | 19:75 | 1680 | izes | 1287 | 19.09 Propane asoo | 15.64 | 16a8 | i719 | 1817 | 1952 | 2000 | 2225 | 20.56 1-Butene (Butylene) |se.104 | 1x06 | 1959 | 19.01 | 21a7 jaar | ana | 2570 | vas Cis-2-Butene seioa | 1654 | 1804 | t8a4 | 19.04 | 21.08 | 2283 | 2400 | 25.47 ‘Trans-2-Butene s6.104 | 184 | 2022 | 2050 | are | 2299 | 2637 | 2572 | 2706 @ iscBitane 50320 | 9.40 | 2215 | 2250 | 2305 | asrr | arse | 2oa9 | anit N-Butane sa120 | 2080 | 2238 | 2271 | 2ao7 | 2501 | 2758 | 2020 | 30.90 Is0-Pentane raase | 2499 | 2716 242 | ste | 307 | 603 | 20.14 N-Pentane | 72,146 | 25.64 27.61 29.70 31.86 33,99 36.07 38.12 Benzene | 78.108 | 16.41 18.38 20.46 22.46 24.46 27.08 29.71 N-Hexane as172 | 307 | sete ssa [azar | 4045 | azer | 45.06 N-Heptane 00.198 | 3496 | 37.00 aor | 4347 | 4593 | aa77 | 52.60 Ammonia 17932 | sie | asi6 8.521 8525 | 8527 | sso Air za966 | 5944 | 6901 6.960 6.990 7.033 Water 3,0 |isor6 | 7983 | 3.006 8033 a6 Oxygen 0, {32.000 | 6970} 607 7.030 730 7302 Nitrogen nx, [2e016 | 5951 | 6.954 6956 6970 5.988 @ vvarogen H, | 2016 | 6.782 | 6.856 6.905 6.953 6oi7 Hydrogen-Suide HS | 34076 | 2.00 | 8001 si8 ane 3.55 Carbon Monoxide CO 28.010 | 952 | 8957 6.963 e986 7028 Carbon Dioxide Co, _| 44010 | a.sa0 | 8.608 9.005 9398 1005 (0) Exceptions: Air, Keenan and Keyes, Thermodynamic Properties of Ais, Wiley, Pressures, Petr. Processing, April 1953 /), Hydrogen-Sutfide, J. R, West, Chom. Eng, Progress 44, 287, (1948) rd Printing 194, y Ammonia, Edw. R, Grahl, Thermodynamic Properties of Ammonia at High Temperatures and Calculation of molal heat copacity of mixtures Gas Mixture Determination of Equiv, Mol. Weight Determination of MC; Molal Heat Capacity Determination of Psuedo Critical Pressure PP,, and Temperature PT, @ Individual Individual | Component Component Mol. | Component Component | y x MC} | Critical Critical Component [Fraction Mol, Weight MC; @ G_"| Pressure Temperature Name Y Mo fyxm| 10°F | 00°F | Pa. psia_|y xP, TOR | yxt Methane | 0.9216 1608 | 14.782 865 | 7.873 673 | 620.2 aaa] 317.0 Ethane | oes] 3007 | ras7} izes | oes2 | io | a4 550 268 Propane | 00185| 44.09 | ogis| 187 osse | nize ees 123, LButane | 0.0039] 58.12 | 0.227| 2395 | 0093 | 529 21 735 29 N-Butane | 0.0055] 58.12 | 0320] 24.07 o132 | 551 $0 766 42 F-Pentane | 0.0017] 7215 | 023 | 29.42 0.050 | 483 oa 329 1M TOTAL = 1.0000] MW. MIX = 17.735 | MC, MIX. = 9.216 [P, MIX. = 6721 To MIX. = $64.8 MC; = MC, — 1545/778 = MG; — 1906. k = MG/MC: = 9216/(9.216 — 1.986) = 1.275 1545 = Universal Gas Constant, Ft Lbs, per Mol, Lb. Per 778 = Fi, Lbs, per BTU. 5-1Comparison of common ref fn 6. 5-14 Raye »>» »[~|f| «| =[~[»l»]»| ||] « ‘Ammonis hoa | waa | ea | aaa | aoa | os | wo | wi | 0 | wee Seagoatr | propyiene | 729] 850 lor | 20 | saa | as0 | aso | 80 | 200 | aes | ooo | us Presse [Promne | 939/799) lea | aos | ass | ara | sai | ass | ase | ora | oo | o41 rreone | 2es| 397 ta | 120 | 150 | sez | ase | maa | ass | aon | siz | ora Fossa of | Ammonia aad of aa) ada] at a] ada a Dertinate | Propyiene| 2071 201 set] uss] 179] 76] ara] 169] ree] tea) eo} 1s7 154 Fertomol” |propane | 226! 238 sas use| vss| ae] 19) am] ist] en] use| ase ca see Ceo | san son) ano) arr [eas] ase aaz| cae] aan) aaa| 405] 905] aoe] er ane GMa Tamnonie | mea) ie |fint | em] em | G00] a96) as] 200] 20e] te9| ae feteerant ippyiene| ata | a2 | isa | igo || sae| 220) sas} eve] aes] aus] asa} 202] ran] ast 12 Ferfonot |propane | ara | a4 | 200 | 158 |hi2e | oor] 220) s79[ aan] ag] are] 290] ans] um 150 fuses lreont2 | s99 | s32 | 2u7 | m7 | fieo | 19 | soe | ase| 670 sar aga] a00| 250 200 Brake [armors | vai|_sze|]aas| oa] au] 200] 176] 150 ed ssrteowsr | Propviene| 900] aa7] sae] ssi || 310) 260] 239] 206] a4) 14s] a0) 2a0] ai) ero] aan Pewee! irepane | 49s] a30] as7{ 943|| sea] aor) 2sa] aen| rz] ran] sel ror] ooo] ez) ase ton Freonte | aao| sae ea] ars[[amn| ace] 2er] or] cas [ use| so] ioe] omg 0) 0 ‘onomsto gu YuurenaTunt 257, CONDENSER EGURE 4 in Pounds of [Ammonis ve] ao] ae] ard) ard soo) aed aa] eyo fettigerett propyiene | 267| 258 za0| 242 || 25] 226] 220] 216] 211) cos] 2 rat] 13] 40] 16 ERE peo | ave] exe) soe] soo| [ser] sas san] si| soo) cor) azo] soc] aon] eas | aso CEN at Armonia io [ver [hae | v0] sar] sao] ane) aan) ana) ane| m2] aa cae fetiatrant Propien | 982 | 260 | 200 [ase | fins | sao] ase] ses] 472) sa] 308] 2m0| zis] iat] se Pertone’ propane | $00 | axe | ase | io |fisa | ue | sas] z20| sos| aza| sz0| ox] 2@| 210] 40 Tore" promt [760 | sao | ane | ona [fer | ase | 129 | 101 | aos) eas] sm] sas] aso] 290] ear rake __| Armonia Ser] ase | [eae] sar| am] 202] as ei] 190] v@] ise] vie] os horsepower |propykene | 149] ex2| sae | sae au] 300] zs] ere] za] ces) ase] 255] rar] sae periene! tprepane | 747 | 660] sas] s1s|| seo] 4o6| aso] ais] 201] 24x] 207] tat] iso] 125] 103 toe reonte | eo | ri] sas] o4e|[4ae| sae] gz] sao) eae] on] zor] uz] va] rae] soe sores me from, BLLIOTE COMPARY fain BN, WSL, on From 12 BASIS OF COMPARISON 0) Gane considered saturated ot competi inlet Heat of (@) Horueyauert are average” gales SERS atthe? kontsng (2) Bropertes of ammeter Butcon of Stara, propel 5-12 Fm Dar Pont ook Sopp fis monte Gc coer (8S conenting) oF HY ant colder CSF "Trermospramic Propet’ of Freon 12FIG. 5-15, Centrifugal refrigeration - compressor riesmromene-| ountaas- | Menscrtarea- | richiros |oudinaen ‘These machines employ drivers of various types In- mvwseme gee: ante meoa asin are audines conieewe cane [eet hws ESE 1. Steam turbine usually direct coupled. TH Wan [eae ble_and constant speed motors usually ey 88 | eS thru a Speed inereesing gear cng rent oom “2, To, 3. Gas turbine driving thru speed reduction gears, Sa an ce ce 4. Gas engine thru speed inereasing gear. See . tae (epee He ™ | am Centvitugals are designed for speed ranges of 9,000 soereiae : iat Ee ia ee tip fo 18,000 RPM ond stort with fuction CPM. around ae so a eS 1800. om refvigerants Number (ARI Designation) 1, _ 7 - 12 and 114 and a single unit can be obtained to handle fa a 7 ie ie wy suction CFM up to 15,000 CFM on Number 11, 6,000 CFM on Number 12 and 4500 CFM on Number 114, ia Minimum discharge CFM will be in the order of 200 7 CFM on Number 12 o 2 Compression ratio per wheel will vary on the order 7 an tums 4 of 15 to 2.75 per wheel with changes in refrigerants 5 Wheto! ws and speeds, Gagan eva em fy Due to the ease of applying side loads to each stage, it is quite common to flash cool refrigerants from the condenser in route to the evaporator and/or to accept side loads from product being cooled at higher than low stage evaporator levels. Since such interstaging is the practice rather than, the exception, it is best to determine evaporator tem- perature level, refrigeration load required in BTU/Hr. heat rejection’ medium (air or water) and source of power then let centrifugal refrigeration manufacturer obtain for you the desired performance charaeteristies, Table I shows the comparative data on refrigerants commonly used in centrifugal compressors followed by pressure enthalpy diagrams on commonly used ve- frigerants. bere ore | are om | om oe —Conrtesy Carrier Corboration Eon Cempored ih = i a a aaSection 6 Pumps Centrifugal Pumps Centrifugal pumps are standard for almost all services other than those characterized by extremely Tow flow rates combined with very high differential pressures. In order to properly select and size a pump, this information is required by the manufacturer: A. Characteristies of the Liquid 1, What it is 2, Pumping temperature 3. Specific gravity (water = 1.0) at pump- ing temperature 4, Are there corrosive elements present and what they are 5. Vapor pressure at pumping temperature B. Desired pumping rate, at pumping tempera- ture, in gallons per minute, barrels per hour, barrels per day, etc, Whether a future or al- ternate capacity is contemplated for the pump C. Pressure conditions required 1. Discharge pressure (Pa) 2. Suetion pressure (Ps) 3, Differential pressure in psi or in ft of head. Ft of head = 2.31 SP/Sp gr 4. Whether a future or alternate head con- dition Is contemplated for the pump 5. Will pump operate in series or parallel with other units? D. NPSH available NPSH) E. Type of pump desired if there is a preference; ie. horizontal, vertical in-line, ete. (See later discussion on F. Flange ratings required if other than standerd for the pressure and temperature GIs a mechanical seal required, and if so pre- ferred manufacturer, if any H. Is cooling water available? I. Preferred metallurgy of major parts J. ‘Type of driver, whether or not manufacturer to furnish, and characteristies of electrical power, steam or fuel. K. Whether pump must conform to API Standard 610 L. Depth of sump if submerged cooling tower or sump service M. Space Limitations, if any ‘This information fs self-explanatory, with the ex- ception of NPSH (net positive suction head). Each pump-impeller design has a characteristic suction head requirement over and above vapor pressure of the fluid, expressed in {1 of head, This characteristic, termed net positive suction head required (NPSHR) is shown on manufacturers’ performance curves for each pump for the range of capacity of the impeller. In some instances, manufacturer's published NPSHR curves may be lowered somewhat for light hydrocar- bon service. These corrections should be done by the manufacturer with full knowledge of the pump application, In order to avoid cavitation, possible vapor lock, and damage to the pump, net positive suction head available (NPSHA) at the suction flange must. meet ‘or exceed the NPSHR for the particular pump at the desired flow rate. NPSHA (in ft of head) can be calculated by NPSHA (Psv_+ Pa — Vp — Pf) 231 + (Hsv — Hp) Spar Where: Psv = Suction vessel pressure, psig Pa = Atmospheric pressure, psia Vp = True vapor pressure of liquid at pumping temperature psia Pf = Friction losses in pipe and fittings between suction vessel and pump suction flange, psi Sper perature (Water Specific gravity of fuid at pumping tem- 1.0) Hsv = Elevation of fluid level in suction vessel during pumping operation, ft Hp flange, ft Elevation of centerline of pump suction Example; Propane service 0.508 sp gr, from pressure vessel at 190 psia. Liquid is at bubble point. Elevation of Hquid level in tank 698 ft; elevation of pump suction nozzle 682 ft. Friction loss in suction line and fittings is LD psi at desired pumping rate, Atmospheric pressure = 14.6 psia,Determine NPSH available at pump syetion: NPSHA (175.4 + 14.6 — 190 — 1.5) 2.31 + (698-682) 508 = 16 - 68 9.2 tt Crude oil service, 0.82 sp gr, pumping| mospherie (open) storage. Vapor pressyre of oil 4.5 psia, Must be able to pump suction tank down to liquid level of 2,176 ft, with pump suctjon nozzle elevation of 2,175 ft. Atmospheric pressure js 14.3 psi. Friction loss in suction piping 2.6 psi. NPSHA = (0 + 143 — 45 — 26) 231 + (2,7 0a = 203 41 213 ft MATERIALS OF CONSTRUCTI ‘The American Petroleum Institute has established a Standard 610 covering “Centrifugal Pumps for General Refinery Services.” This standard contains a table of recommended materials for petroleum services. from at~ -2,175) CONVERSION FACTORS AND FORMULAS Here are the most common conversibn factors and pump formulas. Of particular note are the affinity laws. ‘These relationships are sufficiently accurate |for field ‘changing pumps by altering either impellet diameter ‘or pump rpm or both. Tf an increase is contemplated, particular attention should be given to bhp so that drivers will not be overloaded. ‘These affinity laws may be simply stated: A. If impeller diameter remains constant and speed is changed, a curve for the new rpm can be prepared by taking individual points - hedd capacity and horsepower from the existing pump turve and: pump curve and: 1. Multiplying original capacity by (xpme/rpm,) 2, Multiplying original rpm)? head By (pry MP 3, Multiplying original hp. by (rpm./rom,)* B, If rpm remains constant and impeller diameter is changed: 1, Multiply original capacity by (4,/4)) 2, Multiply original head by (d./d,)* 3, Multiply original HLP. by (do/4,)" HEAD 31 ft water 1 psi =42.04 in, mereury 0.0703 eg/sq in 1 ft of water = 0.433 psi Lin, of mercury = 1182 ft of water 1 kg/sq em = 14.22 pst 14.7 psi 1 atmosphere =4340 ft of water 1035 meters of water BIBLIOGRAPHY 1, Hydraulic Institute Standards, 12th ed. 2. API Standard 610— Centrifugal Pumps for General Refinery Services 3. Ingersoll-Rand book (3rd ed.) 4, Fairbanks-Morse Hydraulic Handbook (3rd ed.) Economy Pumps, Inc., Dats.” Re “Cameron Hydraulic Hand- “Pump Engineering rocating Pumps ‘Types — The single - acting reciprocating pump usuaily fills on the backward stroke and exhausts on the forward stroke. This usually is a plunger-type pump in which the fluid is sealed from the atmos- phere by packing around the plunger, commonly called an “outside packed” pump. These pumps are manufactured with from one to nine plungers, and are either vertically or horizontally operating types. Double-acting pumps fill and exhaust on the same stroke, one side of the piston filling one end of a cylinder and the other side of the piston exhausting the other end of the same cylinder. This type of (Text cont'd. p. 6-5) ATH IMPELLER DIAMETER AND/OR SPEED CHANGE -ERFORMANCE, Qi. hy, Bhps, 4, and ny = initigl capacity, head, brake horsepower, diameter, and speed hs, bhp., D; and n, = new| lcapacity, head, brake horsepower, diameter, and speed. Diameter change only ‘Speed change only ‘Diameter & speed change Qs = @& (da/dy) @ hy (@a/ay)* hy = bhp, (4:/d;)* bap: bhp, @ (a:/ay) 1g = hy (2/1)? bhp, (n/n)? Q (aa/ay x ny/ny) hy (@s/ay X ng/0,)# bhp, = bhp; (da/dy x n./m)*Centrifugal Pump Trouble Shooting Pump nor primed Aveloble NPSH not sufficient ‘it or vopor pocket in suction ine Ar oF gosses in tquid Liquid : e Pump not up to rated speed ‘Wrong rotation Impeller oF passeges clogged Misalignment Worn beerings tae elver eapocty Available NPSH not sufficient Pump not up to rated speed Wrong eototion Impeller or possoges pertcly clogged Weer rings worn or impeller damaged Damaged rotating clement Foundotion not rigid Pumo operating below minimum recommended capacity Impeller clogged Air oF gosses in liquid Viscosity or specific gravity not ae specified Packing too tight Packing not lubricated Air oF vapor pocket in suction line box Incorrect type pecking Air leak in stuffing box Total heed greater than heod for which pump) Gland cocked cosigned Injection of low vapor pessure il im lantern Resta hats Incorrect oil level Air leak in suction line Misolignment or piping strains [Air leak tn stuffing box Insufficient cooling woter Air of gasses in quid Speed to high Bearings too tight or preloaded Bearings Specific gravity or viscosity 100 high * (i rings not functioning Packing too tight ‘Misalignment ‘Total heed lower than rated head Low voltoge oF athor electrical rouble ‘Trouble with engine, turbine, gear or other allied equipment Suction pressure oppreciably different than Specitied Improper lubrication Vibration Dist or woter in beeringsCONVERS! JON FACTORS AND FORMULAS apm 07 x boiler hp Qxhxsper whp = pm 449 x ofs aa60 gpm = 0.0292 x bbl/day Qxhxsper gpm = 0.7 x bbl/hr bhp gpm = 44 x cu meters/hr 960 x © Lb/he QxP gpm ——. bhp = 500 x sp gr 1,115 x P x 231 bhp x 5,250 hb T = sp ar B Qx 321 ct rnV@ VV ax VQ A cay hy Diameter (in.) xn _ ve rprJrn x Ve 229 (hy) 1 vg : hoe -) eee 780 x € n speed in rpm fs cubic feet/second nm specific speed in rpm bbl = barrel (42 gallons) s suction specific speed in rpm. © = specific heat @ capacity in gpm Sp gr = specific gravity P pressure in psi psi pounds/square inch h total head in ft gpm = galions/minute hy, head per stage in it e pump efficiency in decimal Bee het positive suction head in f a Impeller diameter, in. hy Velocity head in ft v velocity in ft/see whp = Water horsepower T jorque in ft-Ib bhp = Brake horsepower {= temperature in °F. u peripheral velocity in ft/sec t, = temperature rise in °F. « 92,16 ft/see/see (Acceleration of gravity) | A = area in sq in. mgd = million gallons/daypump is commonly called an “inside packed” pump, Where the “packing” is a set of piston rings which stops leakage from one side of the piston to the other, ‘The actuating piston rod is relatively small compared to the size of the piston and is easily packed to avoid leakage. This type of pump is universally horizontal- ly operating. Where used—Reciprocating pumps are used for all applications requiring a combination of high differential pressure and relatively low capacities, ranging to a maximum displacement of 1,300 bbl/hr (910 gpm) at 1,050 psia, Much higher pressures an, be achieved at extremely low capacities. Single-acting pumps are selected for high ca pacities and high pressures at high rpm. Initial cost is low, and these pumps have relatively short life. Double-acting pumps provide high capacities at moderate pressures and at low rpm. Initial cost is moderate, and these pumps have extremely long life, Power requirement—Displacement of I gpm of Hguid of any specific gravity against 1 psi requires 0,0005833 theoretical hp. Since the mechanism is approximately 90% mechanically efficient, this fac- tor can be corrected to 0.000848, to reflect this efficiency loss. Therefore: hp = (0.000648) (psi) (gpm displaced) ‘Where: gpm displaced efficiency) (gpm delivered) /(volumeteric Find the horsepower required to pump 100 gpm against a discharge pressure of 1,000 psia. hp = (0.000648) (1,000) (100) = 68.2 hp Pee eaneeee Note: Displacement is the actual volume swept, by the plunger or piston on the discharge stroke during any selected time period. Observe that since the pump is less than 100% efficient volumetrically, it must necessarily run at a higher rpm in order to displace enough volume to deliver the required amount of fluid. Efficieney, compressible fluids—The calculation of volumetric efficiency for compressible fluids de- pends on the internal configuration of each indivi- dual pump, the piston size, and the fluid being pumped. Given full particulars regarding pressure differential, mixture of fluids being pumped, and ‘expected temperature rise on the compression stroke, the pump man&facturer can calculate this efficiency. Horsepower calculations are slightly more com- plex than with an incompressible fluid, but the mag- nitude of the horsepower required will be slightly Jess than if calculated for the full displacement. DISPLACEMENT TABLE Use of the displacement table (Fig. 6-1) can de~ is being termine whether the proper efficiency obtained from the pump. Example: Find the displacement in bbI/hr of a single-acting 3%-in, x 4-in. triplex plunger pump running et 350 rpm. From Fig. 6-1, a 3%-in. plunger with a 4-in, sttoke will displace 0.187 gal/stroke, As this type of pump has 3 discharge strokes/revolution, it will displace 0.167 x 3 = 0.501 gal/revolution. Or, at 350 rpm, 0.501 x 350 = 179.35 gpm. Divide by’ 0.7 (42 bb1/gal divided by 60 ‘min/hr) to give 2504 bbl/hr displacement. At 95% volumetric efficiency, pump will deliver 250.4 x 0.95 = 237.9 bbi/hr. Example: Find pump displacement for a 4-in. x 10-in doubie-acting duplex piston pump operating at 60 rpm. Pump has 1%-in, diameter piston rods, and has 4 discharge strokes per revolution. The two backward strokes displace ess fluid than the for- ward strokes by the volume of the piston rod, Let pump displacement/stroke in general terms Vu of 2 forward strokes = 0.544 x 2 = 1.088 gal V, of 2 backward strokes is: 0.544 gal less Vy of 1%-in. rod is: —0.077 gat Net Vy of backward stroke: 0.467 gal x2 = 0.934 gal ‘Total displacement/revolution = 1.088 + 0.934 2.022 gal ‘Total displacement/revolution x 60 = 121.3 gpm. 121.8/0.7 = 1733 bbl/he Volumetric efficieney (B,) of the pump can then be determined by comparing the calculated displace- ment of the pump with the actual metered deliver rate: E, = Metered delivery rate/Vy NPSH NPSH available for a reciprocating pump is cal culated in the same manner as for a centrifugal pump, except some additional allowance must be made Tor the requirements of the reciprocating action. of the pump. ‘The additional requirement is termed acceleration head. This is the head required to accele- rate the fluid column on each suction stroke so that this column will, at a minimum, catch up with the receding face of ‘the piston during its filling stroke. If this minimum condition is met, the pump will experience a fluid knock, caused when the fluid column, which has a vapor space between it and the piston, overtakes the deceleration piston, ‘This knock occurs approximately two-thirds of the way through the suction stroke. If sufficient acceleration head is provided for the fluid to completely follow the mo- tion of the receding face of the piston, this knock will disappear. In either case, the pump will operate at full efficiency. If there is insufficient head to meet the minimum acceleration requirements, the pump will experience cavitation, caused by incomplete filling of the cylinder, and resulting in loss of volumetricFIG. 6-1 Plunger Displacements 2 > ” “ 6 ‘002 ] 003 o10 | 012 | ov 003 | 004 os | 019 | 021 00s | 006 023 | 027 | 031 008 | 008 oni | 036 | 042 007 | 010 os1 | 048 | 054 ” 99 | coe | 013 ] or ox | 026 | ose | 063 | 052 | 060 | .069 ™ u2a7 | 011 | ore | 02} | 027 | 032 | 043 | 053 | 064 | cova | 08s ™% vgs | 013 | 019 | 02k | 032 | 039 | 051 | 068 | 077 | 089 | 103 1s 1767 | 15 | 023 | 03} | 038 | o4@ | 061 | 077 | 092 | 107 | 122 1% 240s | 021 | 031 | o4p | 052 | 063 | 083 | toa | 125 | tus | 170 2 aiaz | 27 | 041 | 05g | 068 | 082 | 09 | 136 | 163 | 190 | 21a 2% 3976 | 034 | 052 | osp | ose | 103 | 138 | 172 | 206 | 241 | 275 2% 499 | 043 | 064 | 9 ros | 128 | 170 | 219 | 255 | 298 | 340 2% seo | si | o77 | 10) vv | ise | 206 | 257 | 309 | 340 | att 3 7069 | 061 | 092 | 12 rsa | tga | 245 | 306 | 367 | ze | aa aM 296 | 072 | 108 | 14 179 | 21s | 207 | 359 | aan | sos | 7s 3% 9621 | oss | 125 | 16 | 208) 249 | 333 | “a7 | “499 | 503 | 66 3% | ri04 | oss | 14s | igh | 239 | 287 | 302 | 478 | 574 | bor | 765 4 12566 | 109 | 163 | a1 272 | 326 | 435 | sae | 653 | 762 | 270 ay | rags | 423 | tee | 24 307 | 368 | avr | ore | 737 | 860 | 982 4% | 15904 | asa | 207 | 275 | sae | ars | 551 | eae | 02e | 964 | 1.102 5 teas | aro | ass | agp | as | io | o00 | -ts0 | 1020 | 190 | 260 ‘ zazza | 24s | 367 | agp | 62 | 736 | 979 | 1.226 | 1469 ] zie | 1.958 7 sess | asa | ase | cep | ats [sve | vans | sss | vse | ana | ace 8 50266 | as | 52 | ev | 1.088 | 1.306 | 1.741 | 2176 | 2611 | 3.04 | 3.482, ° ea.6i7 | ss | 826 | r2op | 1.377 | 1.682 | 2203 | 2754 | 3305 | 3.856 | 4406 10 | 7as40 | 480 [1.020 | 1.367 | 1.700 | 2040 | 2720 | 2400 | 2.080 | 4.760 | 5.240 12 | 113098 | 979 | 1.468 | 1.95p | 24ae | 2928 | 3.017 | 46 | 5.875 | 6954 | 7.833 efficiency. ‘The noise of cavitation is heaiff on the pump manufacturers for a “safe” or sufficient head discharge side of the pump and can cause ifrmediate usually consider the minimum acceleration head re~ damage to plungers, pistons, valves, and parking due quirement. and not the ideal requirement, and do not to the forces released in collapsing the gas|or vapor take into consideration the installation of pulsation bubbles in the high-pressure discharge strole dampeners on the suction Hine. However, there will probably be some Ipng-term damage done to pistons or plungers, valves, and DESIGN OF PIPING seats, etc., even under minimum conditions jwhere no Here are factors to be considered in the design of eavitation occurs. Full protection of the pump Te- suction piping {eefes to Fins, 6-2 and 6- quires providing enough head to meet the [condition gree rene etree nee er eestier where the fluid follows the receding face of fhe piston 1, Pump should be as close to the fluid supply as throughout the pumping cycle. Recommendations by possible 6-6