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Process Engineering

Facts, Fiction, and Fables
By Norman P. Lieberman
Copyright: 2017   |   Status: Published
ISBN: 9781119370277  |  Hardcover  |  
366 pages
Price: $225 USD
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One Line Description
Written in plain and easy-to-understand language in the form of character dialogues and useful technical explanations by one of the world’s most prolific and well-respected process engineers, this is the most unique and helpful book ever written for the practicing process engineer.

Process engineers, chemical engineers, technicians, plant managers, plant operators, plant engineers, petroleum engineers

This is not your average technical book! Using a humorous and easy-to-understand approach to solving common process engineering problems, this unique volume is the go-to guide for any veteran or novice engineer in the plant, office, or classroom. Textbooks are often too theoretical to help the average process engineer solve everyday problems in the plant, and generic handbooks are often out of date and not comprehensive. This guide focuses on the most common problems that every engineer faces and how to solve them. The “characters” walk the reader through every problem and solution step-by-step, through dialogues that literally occur every day in process plants around the world.

With over half a century of experience and many books, videos, and seminars to his credit, Norm Lieberman is well-known all over the world and has helped countless companies and engineers through issues with equipment, processes, and training. This is the first time that this knowledge has appeared in a format like this, quite unlike anything ever published before in books on process engineering. This is a must-have for any engineer working in process engineering.

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Supplementary Data
• Uses real-life examples, illustrated by characters who are trying to solve daily problems in process engineering that are found in real-world situations
• Shows the beginning engineer how to avoid common pitfalls
• Is filled with useful figures and descriptions of the most common problems and solutions found in the plant
• Is a unique take on process engineering, debunking many of the common myths in process engineering and offering the best ways forward
• Is a must-have for any process engineer

Author / Editor Details
Norman P. Lieberman is one of the most well-known and respected process engineers in history. With over 53 years of experience and eight often-quoted and often-used books to his credit, he has left and continues to leave a lasting impression on the energy industry. His contribution to the industry is considerable, and troubleshooting process problems is the single biggest part of his business. With a writing style that is unique to technical books, he brings a no-nonsense and practical approach to his subjects.

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Table of Contents
Other Books By Norman Lieberman xiii
Introduction xv
1 Process Operations & Design 3
Carl & Clare
Increasing Cooling Water Flow Thru An Elevated Condenser
or Cooler 4
Hot Vapor By-Pass Pressure Control 7
Stalling A Thermosyphon Reboiler 10
Optimizing Fractionator Pressure 13
Adjusting Steam Turbine Speed to Minimize
Steam Consumption 16
Steam Condensate Drainage from Reboilers Blowing
Condensate Seal 19
Effect Of Reflux On Fractionator Top Temperature 22
Centrifugal Pump Head Vs. Flow Performance Curves 25
Condensate Back-Up In Condensers The Effect Of Sub-Cooling 27
Distillation Tray Downcomer Back-Up And Liquid Flooding 29
Effect Of Foam On Level Indication In Distillation Towers 32
Split Liquid Levels In Vertical Vapor - Liquid Separators 35
Optimizing Excess Air in A Fired Heater To Minimize Fuel Consumption 37
Distillation Tray Dumping or Weeping With Valve Cap
Tray Decks 41
Fired Heater - Tube Failures 44
Low Air Flow In A Fin Fan Forced Draft Air Cooler 47
Measuring Air Flow For An Aerial Fin Fan Aerial Cooler 50
Measuring Cooling Tower Efficiency Approach To Wet Bulb Temperature 53
Adjusting Heater Stack Damper For Optimum Energy Efficiency 56
Preventing Tray Dumping By Use Of Bubble Cap Trays 59
Demister Fouling In Vapor-Liquid Seperator Vessels
Effect of Temperature on Liquid Level Indication 65
Draw-Off Nozzle Capacity Limits 68
On-Stream Repair of Tube Leaks in Surface Condenser 70
When are Vortex Breakers Required? 73
Naphtha Injection to Centrifugal Compressor 76
Internal Overflow from Total Trap-Out Chimney Tray 80
Vacuum Ejector – Loose Steam Nozzle 83
Effect of Tramp Air Leaks on Heater Efficiency 86
Effect of A Single Fouled Tray 89
Steam Turbine – Surface Condenser Outlet Temperature 92
Water Accumulation in Turbine Case 96
2 Crude Distillation 99
Professor Pot & Kumar
How To Adjust Pumparound Flows 100
How Top Reflux Rate Affects Flooding on Top Trays 103
Desalter - Adjusting Mix Valve Pressure Drop 107
Causes of Tray Deck Fouling 110
Minimizing Flash Zone Pressure 113
How to Adjust Bottoms Stripping Steam Rate 117
Overhead Condenser Corrosion 120
On-Line Spalling of Crude Pre-Heat Exchangers 123
Effect of Reflux on Overhead Accumulator Temperature 127
Removing Trays from Pre-Flash Towers 130
Total Trap-Out Chimney Tray 133
Side Draw-Off Limitations 136
Packed Towers 139
Rules of Thumb for Packed Towers 141
Controlling Ago Draw-Off Rate 143
Filming Amine Plugs Overhead Vapor Line 146
Stripping Tray Pressure Drop Profile 150
Protecting Crude Tower Stripping Trays from Damage Due
to Water In Steam 153
3 Engineering Basics 157
Irene & Norm
Draft in Fired Heaters 158
Turbine Exhaust Surface Condenser Outlet Temperature 162
Adjusting Steam Turbine to Save Steam 166
Distillation Tray Downcomer Seal 170
Bernoulli’s Equation 173
Properties of Steam 176
Measuring Flows 179
Head Loss in Pipelines 182
Irene Explains Horsepower 185
Refrigeration 186
Packed Towers Vs. Trayed Towers 190
Condensing Steam Turbine Exhaust 194
Maximizing Lmtd In Heat Exchangers 198
4 Routine Refinery Operating Problems 203
Dr. Petry & Pat
Pump Bearings Lubrication 204
Pressure Measurement Problems in Vapor Lines 207
Negative Pressure Drops 210
Coked-Up Thermowells 213
Centrifugal Compressor Surging 216
Commisioning Steam Turbine 219
Refrigeration Systems 222
Seal Pan Drain Hole 225
Measuring Steam Flow Without A Steam Meter 228
Air Leak on Suction of Cooling Water Pump 231
5 Refinery Safety 235
Dangerous Dan & Safety Sally
Auto-Ignition of Hydrocarbons 236
Failure of Mechanical Pump Seals 239
Sampling Tar Safely 242
Dangers of Iron Sulfides 244
H2s Fatalities 247
Fired Heater – Positive Pressure 250
Refinery Explosions & Fires 253
Flooding Fire Box with Fuel 256
Routing Relief Valves to the Flare 259
Isolating Equipment with Gate Valves 262
Explosive Limit of Hydrogen 265
Climate Change 268
Danger of Carbon Steel Piping Spool Pieces 271
Screwed Connections 274
Dangers of Steam Deaerators 277
Connecting Steam Hose to Hydrocarbon System 281
Process Vessel Collapse Under Vacuum During Start-Up 284
Acid Gas K.o. Drum 287
Safety Note 290
Value of a Chemical Engineering Degree to the Process
Engineer in a Refinery 291
6 Pitfalls in Computer Modeling 295
Basis for Process Engineering Calculations 296
Underlying Assumptions in Distillation Technology 297
Tray Fractionation Efficiency 298
Heat Exchanger Train Performance 299
Heat Exchanger Pressure Drop 300
Packed Towers 301
Air Coolers 302
Fired Equipment 303
Piping Systems 304
Centrifugal Pumps – NPSH 305
Rotating Equipment 306
Summary 307
References 308
7 Latent Heat Transfer 309
Propane-Butane Splitter Reboiler 311
Heat Flux Limitations 312
8 Hydraulics 315
Fluids other than Water 317
Rotational Energy 318
Pressure Drop Through an Orifice 319
Effect of Fluid Density on Orifice Pressure Drop 320
Head Loss in Piping 321
Factor Affecting Orifice Coefficients 323
Compressible Fluids 324
9 Air Coolers 325
Measuring Air Flow 326
Air Recirculation 327
Vane Tip Clearance Problems 329
Cleaning Tube Bundle 330
Effect of Fouling on Reverse Air Flow 331
Effect of Adding Rows of Tubes 332
Changing Fan Blade Tips & Speed 333
Slipping Belts 334
Air Humidification 335
Induced Draft Fans 336
10 Extracting Work From Steam 337
An Isentropic Expansion 338
Steam Turbines 339
The Potential Energy of Steam 340
Condensing Steam at Low Pressure 342
The Meaning of Entropy 343
Video Library 444
The Norm Lieberman Refinery Troubleshooting Seminar
Video Presentation 347

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TEC031030 : TECHNOLOGY & ENGINEERING / Power Resources / Fossil Fuels
SCI024000 : SCIENCE / Energy
BUS070040 : BUSINESS & ECONOMICS / Industries / Energy
THF: Fossil fuel technologies
TGB: Mechanical engineering
TDCB: Chemical engineering

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