EQUIPMENT CALCULATIONS

1. EQUIPMENT CALCULATIONS SELECTION & SIZING

2. DETAIL REQUIRED FOR A PROJECT • COMPONENTS NEEDED FOR EVALUATION • M & E BALANCE DATA • EQUIPMENT COSTS • OPERATING COSTS • OTHER FACTORS http://ecb.jrc.it/testing-methods/

3. 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 http://www.mcnallyinstitute.com/06-html/6-01.html

4. 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 http://www.geeco.co.uk/storagetanks.php

5. 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 http://highered.mcgraw-hill.com/sites/0072392665/student_view0/cost_estimator.html

6. TYPICAL ESTIMATE FACTORS

7. 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 http://www.heatexchangersonline.com/images/index.jpg

8. 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 http://www.ubh.co.uk/procves.htm

9. VESSEL DESIGNS • TYPICAL LIMITS • PROCESS TANKS - 20% FREEBOARD • STORAGE TANKS - 10% FREEBOARD • PUMP TANKS - 5-10 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

10. 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 http://www.hydrocarbons-technology.com/contractors/compressors/elliott/

11. 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 http://www.arrowengine.com/chemical.htm

12. http://usdidactic.com/refpdf/gunt/04062000%202.pdf. 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

13. COMPRESSORS • FOR LARGER UNITS • VIBRATION MONITORS • ALARMS • SHUTDOWN CIRCUITS • LOCAL CONTROL PANELS http://www.nt.ntnu.no/users/lovland/SIK3035/pictures/compress.htm

14. 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 E-MAIL QUOTE

15. 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

16. 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

17. http://www.iit.edu/~smart/garrear/fuelcells.htm TYPICAL FACTORS IN COST SCALE-UP FOR FACILITIES • MATERIALS OF CONSTRUCTION • SS TYPICALLY THREE TIMES CARBON STEEL • SEE FIGURE 12-41 FOR OTHERS • PRESSURE AND TEMPERATURE • AS PER FIGURE 14-15 • ALSO MAY CHANGE CODE REQUIREMENTS • EXAMPLE FOR SOLID OXIDE FUEL CELL STACK IS ON THE NEXT SLIDE

18. SOFC SCALE-UP EXAMPLE www.netl.doe.gov/publications/proceedings/06/seca/pdf/Thijssen.pdf

19. 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

20. MARSHALL & SWIFT INDEX • CHEMICAL ENGINEERING MAGAZINE, DEC 2006

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

22. CURRENT BUSINESS INDICATORS • CHEMICAL ENGINEERING MAGAZINE, DEC 2006

23. 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

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

25. 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