EQUIPMENT CALCULATIONS SELECTION & SIZING

DETAIL REQUIRED FOR A PROJECT COMPONENTS NEEDED FOR EVALUATION M & E BALANCE DATA EQUIPMENT COSTS OPERATING COSTS OTHER FACTORS

SIMULATION DATA ENERGY CONSUMPTION FOR ROTATING EQUIPMENT –MECHANICAL EFFICIENCY DATA –THERMODYNAMIC EFFICIENCY DATA HEAT TRANSFER DATA –APPROACH TEMPERATURES –TRANSFER COEFFICIENTS MASS TRANSFER DATA –STAGE EFFICIENCIES –CAPACITIES MOMENTUM TRANSFER –MINIMUM/MAXIMUM FLOW VELOCITIES AND/OR PRESSURE DROPS –TOTAL HEAD LOSS ESTIMATES m/06-html/6-01.html

CAPITAL EQUIPMENT TO ESTIMATE EQUIPMENT CAPITAL COSTS (REFER TO APPENDIX E – HUERISTICS FOR PROCESS EQUIPMENT DESIGN DIMENSIONAL DATA –MASS –AREA TYPES OF EQUIPMENT –HEAT EXCHANGE –PUMPS –REACTION –INVENTORY PROCESS DATA –DESIGN PROCESS CONDITIONS –UTILITY REQUIREMENTS –MATERIALS OF CONSTRUCTION DATA tanks.php

INSTALLATION COSTS SEE DETAILS IN CHAPTER 6 RANGE OF COSTS TYPICALLY RUN FROM 4.7 TO 5.9 TIME EQUIPMENT (SEE TABLE 6- 9) –COSTS DEPEND ON: TYPE OF PROCESS, FLUID, SOLID OR MIX MATERIALS OF CONSTRUCTION LOCATION OF FACILITIES SIZE OF PLANT SEE COST ESTIMATOR AT PAGE xvi IN TEXT AND hill.com/sites/ /student_view0/cost_e stimator.htmlhttp://highered.mcgraw- hill.com/sites/ /student_view0/cost_e stimator.html

TYPICAL ESTIMATE FACTORS

CODES AND STANDARDS HEAT EXCHANGER STANDARDS –THERMAL EXCHANGER MANUFACTURERS ASSOCIATION (TEMA) –TYPES R, B & C SEE CHAPTER 14 FOR DETAILS –CONFIGURATION OF HEADS AND TUBES –NDE AND TESTING REQUIREMENTS –SUPPORT & INSULATION DATA –NOZZLE SIZES & LOCATIONS –ASME CODE REQUIREMENTS ndex.jpg

VESSEL DESIGNS SEE CHAPTER 12 FOR DETAILS NOZZLE DIMENSIONS & LOCATIONS DESCRIPTION OF INTERNALS SURFACE FINISHES INSULATION REQUIREMENTS CODE REQUIREMENTS - ASME OR API FABRICATION & TESTING DATA s.htm

VESSEL DESIGNS TYPICAL LIMITS PROCESS TANKS - 20% FREEBOARD STORAGE TANKS - 10% FREEBOARD PUMP TANKS MIN. SURGE ACCESS NOZZLES FOR ALL INTERNALS MINIMUM NUMBER OF WELDED SEAMS MAXIMUM DIAMETER - 4 m FOR SHOP FABRICATION HOLD POINTS AT FAB DRAWINGS, INSPECTION OF SHOP FAB STANDARDS, REVIEW OF NDE, PRESSURE TEST PRIOR TO PAINTING

ROTATING EQUIPMENT MOTOR OR TURBINE DRIVEN –CHAP. 12 TOTAL PACKAGE - DRIVEN UNIT, DRIVERS, GEARS, COUPLINGS, SHAFTS, BELTS, BASES & SUPPORTS GUARANTEE PERFORMANCE POINT - TO BE TESTED IN SHOP PRIOR TO SHIPMENT TYPES OF BEARINGS & LUBRICATION TYPES OF SEALS NOISE LIMITS technology.com/contractors/compress ors/elliott/

PUMPS LOW HEAD/HIGH FLOW - RADIAL, CENTRIFUGAL, NOT SELF-PRIMING HIGH HEAD/LOW FLOW - TURBINE, POSITIVE DISPLACEMENT INSTALLATION CONFIGURATION - HORIZONTAL, VERTICAL, INLINE, SUBMERGED, JACKETED, SINGLE OR MULTI-STAGE –MINIMUM NPSH –NORMAL DISCHARGE P –STANDARD CASINGS –MACHINED IMPELLERS

COMPRESSORS SMALL UNITS ARE TREATED LIKE PUMPS DYNAMIC AND TORSIONAL ANALYSES FOR THE TRAIN –1ST CRITICAL - SEVERE STRESS –2ND CRITICAL - NOT AS BAD –3RD CRITICAL - RELATED TO 1ST BUT NOT AS BAD –HIGHER VALUES - NOT NORMALLY CONSIDERED unt/ %202.pdfhttp://usdidactic.com/refpdf/g unt/ %202.pdf.

COMPRESSORS FOR LARGER UNITS VIBRATION MONITORS ALARMS SHUTDOWN CIRCUITS LOCAL CONTROL PANELS /SIK3035/pictures/compress.htm

COST CALCULATIONS DETAIL AND SOURCE DEPEND ON LEVEL OF ESTIMATE REQUIRED (FIGURE 6-4) –FEASIBILITY - OUTLINE SPECIFICATION –QUOTATION - COMPLETE SPECIFICATION –BUDGET - AWARDED CONTRACT COSTS IN TEXT ARE BASED ON 2002 DATA COST ESTIMATES ON WEB SITE MAY BE MORE CURRENT COSTS IN SUPERPRO ARE MORE CURRENT VENDOR DATA IS CURRENT BUT MUST BE VERIFIED – WRITTEN OR QUOTE

COST ADJUSTMENTS SCALE-UP FACTORS DEPEND ON –TYPE OF EQUIPMENT –SIZE OF EQUIPMENT –CATALOG VERSUS CUSTOM EQUIPMENT SEE TABLE 6-4 FOR TYPICAL EXPONENT VALUES MATERIALS OF CONSTRUCTION

COST SCALE-UP DUE TO TYPE OF EQUIPMENT FLUID FLOW EQUIPMENT SCALES UP BY 0.67 WHICH IS THE RATE THE AREA OF THE PIPE INCREASES WITH VOLUME EQUIPMENT LIKE HEAT EXCHANGERS –HAVE FIXED COSTS FOR HEADS –VARIABLE COSTS FOR TUBES (AREA) ROTATING EQUIPMENT DRIVE MOTORS COSTS VARY BY VOLTAGE

TYPICAL FACTORS IN COST SCALE-UP FOR FACILITIES MATERIALS OF CONSTRUCTION –SS TYPICALLY THREE TIMES CARBON STEEL –SEE FIGURE FOR OTHERS PRESSURE AND TEMPERATURE –AS PER FIGURE –ALSO MAY CHANGE CODE REQUIREMENTS EXAMPLE FOR SOLID OXIDE FUEL CELL STACK IS ON THE NEXT SLIDE smart/garrear/fuelcells.htm

SOFC SCALE-UP EXAMPLE

SCALE-UP FOR INFLATION INFLATION - USE M&S OR CHEMICAL ENGINEERING INDICES VALUES ARE AVAILABLE IN CHEMICAL ENGINEERING MAGAZINE SEE TABLE 6-2 FOR INDICES THROUGH 2002

MARSHALL & SWIFT INDEX CHEMICAL ENGINEERING MAGAZINE, DEC 2006

CHE PLANT COST INDEX (CEPCI) CHEMICAL ENGINEERING MAGAZINE, DEC 2006

CURRENT BUSINESS INDICATORS CHEMICAL ENGINEERING MAGAZINE, DEC 2006

DATA SOURCES – VENDOR INFORMATION EQUIPMENT VENDORS CAN BE VALUABLE SOURCES OF DATA FEASIBILITY PROJECTS –RECOMMEND TYPES OF EQUIPMENT BASED ON PROCESS REQUIREMENT –PROVIDE DATA FOR OUTLINE SPECIFICATIONS –PROVIDE COST & SCHEDULE DATA –PROVIDE OUTLINE DIMENSIONAL & UTILITY DATA

VENDOR SUPPORT PROJECT EVALUATION –EXAMPLES OF SIMILAR EQUIPMENT INSTALLATIONS –ACCURATE COST DATA FOR ESTIMATE –ACCURATE UTILITY DATA FOR DESIGN –ACCURATE OUTLINE DRAWINGS

VENDORS AS CLIENTS PROJECT AUTHORIZATION AND FINANCING –HARD MONEY QUOTATION WITH AWARD –ALL DESIGN DATA NEEDED FOR INSTALLATION –ALL INTERFACE DATA –DETAILED FABRICATION, TESTING & DELIVERY SCHEDULE –DETAILED CASH FLOW SCHEDULE –QUALITY CONTROL DATA