Process Technology
─Equipment and System
华东理工大学机械与动力工程学院
2005年3月7日
Introduction
双语教学： Bilingual education
1
Teachers for the class：
潘家祯潘家祯 教授教授 博士生导师博士生导师
王正东王正东 教授教授 博导博导 学院常务副院长学院常务副院长
周绍萍周绍萍 副教授副教授 系主任系主任 在读博士在读博士
惠惠 虎虎 副教授副教授 博士博士
王学生王学生 副教授副教授 博士博士
石石 岩岩 讲师讲师 在读博士在读博士
周先桃周先桃 博士后博士后
2
Our Team：
Qualified teachers; Best team; ── Qualified teachers; Best team; ──
To devote our best for students; To devote our best for students;
To fulfill the task better. To fulfill the task better.
Team work Team work ── ──
Teaching research; improving our teaching quality; Teaching research; improving our teaching quality;
Teachers can learn each other from other’s strong points Teachers can learn each other from other’s strong points
to offset one’s weakness. to offset one’s weakness.
Our objective Our objective
Cooperate with students to fulfill this class satisfactory. Cooperate with students to fulfill this class satisfactory.
To obtain more knowledge, to learn actively, to be To obtain more knowledge, to learn actively, to be
.
3
Three transforms：
From passive study to active passive study to active study.
From forced-feeding method of teaching to From forced-feeding method of teaching to
heuristic education.
From merely book learning to quality education From merely book learning to quality education
including various comprehensive various comprehensive studying.
─ ─ This task should be cooperated by teachers and This task should be cooperated by teachers and
students. students.
4
We encourage：
Every student chooses your favorite student chooses your favorite teachers.
Every teacher chooses your favorite teacher chooses your favorite students.
─. Accept favorite students to teacher’s research Accept favorite students to teacher’s research
.
─. Encourage favorite students to pursue higher Encourage favorite students to pursue higher
.
5
潘 家 祯
How to Introduce yourself
Pan Jia Zhen
Will reply to Will reply to
Mr. PanMr. PanWestern
style:
Jia Zhen Pan
May be May be
confused to confused to
Mr. ZhenMr. Zhen
American
Form
British
Form
First
Name
Middle
Name
Last
Name
Given
Name
Religious
Name
Family
Name
Surname
6
Jia Zhen PAN
Recommend
CapitalizeCapitalize
or PAN, Jia Zhen
Author Author
Index Index
stylestylePAN Jiazhen
Jiazhen Pan
PAN, Jiazhen
7
K. J. Miller
Western Name
Keith. John. Miller
Keith. J. Miller
Miller, K. J.
8
石亚文
Chinese Name－From SCI, Science Citation Index
Shi YW
Wen SY
This is wrongThis is wrong..
Ten ways to express Chinese Name:
1. Shi Ya Wen
2. Ya Wen Shi
Some problem,
not sure the
family name
9
3. Shi Yawen
Ten ways to express Chinese Name:
4. Yawen Shi
5. Shi Ya-Wen
6. Ya-wen Shi
10. Y. W. Shi
9. Shi Y. W.
No problem
East-Asia Chinese
OK.
7. Ya Wen SHI
8. SHI Yawen
Western custom
10
我们的专业称为“过程装备与控制工程”
即：
What’s means “Process Equipment”?
Process Equipment and
Control Engineering
11
Background (背景)
教育部几次专业调整，合并和削减了许多专业，戴帽的
机械专业全部取消，如：食品机械、轻工机械、纺织机械等，
均统称为“机械设计与制造”专业。只有化工机械专业由于
其不可替代的重要性而予以保留，但是更名为“过程装备与
控制工程”专业。它体现了拓宽专业面的要求，它的培养对
象就不仅仅是化学工业，而是适用于所有的过程工业。
What’s means “Process Equipment”?
12
What’s means “Process” ?
How many kinds of processes are related to us?
What’s means “Process Equipment”?
Six processes are closely related to our specialty:
1. Fluid dynamical process: (流体动力过程)
It deals with pump(泵), compressor(压缩机),
ventilator(风机), pipes and valves(管道和阀门等
).
13
What’s means “Process” ?
How many kinds of process are related to us?
What’s means“ Process Equipment”?
Six processes are closely related to our specialty:
2. Heat transfer process: (热量传递过程)
It deals with heat transfer equipment. (它涉及
热量交换过程及设备，即：换热器，热交换器等)。
14
What’s means “Process” ?
How many kinds of process are related to us?
What’s means“ Process Equipment”?
Six processes are closely related to our specialty:
3. Mass transfer process: (质量传递过程)
It deals with dry, distillation, condense,
extraction process and equipment. (它涉及有关
干燥, 蒸馏, 浓缩, 萃取等过程及装备)。
15
What’ s means“ Process” ?
How many kinds of process are related to us?
What’s means“ Process Equipment”?
Six processes are closely related to our specialty:
4. Momentum transfer process: (动量传递过程)
It deals with size reduction and size
enlargement process and equipment. (它涉及固
体物料的粉碎、造粒等过程及设备。)
16
What’ s means“ Process” ?
How many kinds of process are related to us?
What’s means“ Process Equipment”?
Six processes are closely related to our specialty:
5. Thermodynamics process: (热力学过程)
It deals with refrigeration, cryogenic
refrigeration, and air separation etc. (它涉及冷冻,
深度冷冻, 空气分离等过程及设备。)
17
What’ s means“ Process” ?
How many kinds of process are related to us?
What’s means“ Process Equipment”?
Six processes are closely related to our specialty:
6. Chemical process: (化学过程)
It deals with synthesize, decomposition
process and equipment. (它涉及化学反应，如：
合成、分解等过程及设备。)
18
Including:
This book: “Process Technology”
Introduction to process equipment;
Valves; Piping and vessels;
Pumps; Compressors; Turbines and motors;
Heat exchangers; Cooling towers;
Steam generations (boilers);
Fired heaters (furnaces);
19
Including:
This book: “Process Technology”
Process instrumentation;
Process diagrams;
Utility systems;
Reaction systems;
Distillation systems;
Other separation systems;
Plastics systems.
20
Understanding for the test: About: “The test”
Study is for yourselves, not for teachers, not for parents;
Try to understand important concept for this course;
This is not an English course. It is a course to use
English to understand the speciality.
Testing is a way to check your understanding for the
course.
Encourage students to join us to build a testing
database for testing.
To choose the best questions, and best answers, to help
you understanding the course.
答疑及课外辅导时间： 21
Process Industry
The Process industry is composed of refineries
and petrochemical, paper and pulp, power
generation, and food processing plants.
22
Process Industry
Process technicians
inspect and maintain
equipment , place and
remove equipment from
service, complete
checklists, control
documentation, respond
to emergencies, and
troubleshoot system
problems.
23
Process Industry
To fulfill those
responsibilities,
the process
technician must
have a through
understanding of
tools,
equipment, and
systems.
24
Basic Hand Tools
25
1. Rotary Equipment
Process Equipment
can be divided into:
2. Stationary Equipment
26
1. Rotary Equipment
Safety Notice: Severe injuries can result when loose
clothing, shoelaces, jewelry, or long hair gets tangled
around rotating parts.
Tips:Tips: aware of protecting your self toaware of protecting your self to avoid any injuries, avoid any injuries,
especially for your eyes. especially for your eyes.
Don’t hurt yourself;
Don’t hurt other person;
Don’t be hurt by other person.
27
1. Rotary Equipment1. Rotary Equipment Drivers and Equipment
A driver is a device designed to provide rotational
energy to another piece of equipment.
The most common driver
MotorsPumps
Compressors
Generators Fans
Conveyors
Solid feeders
Couplings, belts, or chains connect drives and driven Couplings, belts, or chains connect drives and driven
equipments. equipments.
28
1. Rotary Equipment1. Rotary Equipment Drivers and Equipment
Couplings Fixed-speed couplings
Rigid couplings Flexible coupling
Variable-
speed
couplings
Hydraulic
couplings
Magnetic
couplings
29
1. Rotary Equipment1. Rotary Equipment Drivers and Equipment
BeltsBelts Belts are used to connect two parallel shafts.
A pulley is mounted on the
end of each shaft.
The size of the pulleys allow the driver and driven equipment
to operate at different speeds.
Belts fit in the grooves of the
pulley.
Belts come in a variety of shapes and sizes and are made of
durable material designed to withstand operating conditions.
30
1. Rotary Equipment1. Rotary Equipment Drivers and Equipment
BeltsBelts Belts are used to connect two parallel shafts.
Belt drives require less space than fixed-speed or variable-
speed couplings.
A belt drive can make speed-to-torque or torque-to-speed
conversions.
Process technicians frequently inspect belts during rounds
to ensure that safety guards are in place, that belt tension is
correct, and that the belts are still mounted on the pulleys.
Flopping, squealing, or smoking belts indicate wear,
tension, or driven-equipment problems.
31
1. Rotary Equipment1. Rotary Equipment Gearboxes and Power Transmission
GearboxesGearboxes
Often used between the driver
and the driven equipment.
The drive gear meshes with a
larger or smaller gear, the
driven gear.
As the drive gear rotates, the interlocked gears in the box
turn, transmitting power to the driven equipment.
Small gear size is associated with speed. Large gear size is
associated with torque. 32
1. Rotary Equipment1. Rotary Equipment Gearboxes and Power Transmission
GearboxesGearboxes
Power transmission in rotating
equipment is classified as
speed-to-torque conversion or
torque-to-speed conversion.
Speed-to-torque conversion is accomplished with a small
drive gear with a large driven gear.
Torque-to-speed conversion uses a large drive gear with a
small driven gear. 33
1. Rotary Equipment1. Rotary Equipment Electric motors
The process industry uses electric motors to operate
pumps, generators, compressors, fans, blowers and other
equipment.
Electric motors are either direct current (DC) or alternating
current (AC).
The operation of an electric motor is based on three principles:
Electric current creates a magnetic field;
Opposite magnetic poles attract each other, like magnetic
poles repel each other;
Current direction determines the magnetic poles.
34
1. Rotary Equipment1. Rotary Equipment Electric motors
Electric motor consists of: Stationary
magnet
(stator)
Moving
conduct
(rotor)
Permanent
magnetic field
is formed by
the lines of
force
between the
poles of the
magnet.
When electricity passes through the conductor in a
DC motor, it becomes an electromagnet and
generates another magnetic field.
The twin fields
increase in
intensity and
push against
the conductor.
35
1. Rotary Equipment1. Rotary Equipment Electric motors
The rotor in
an AC motor
is a slotted
iron core.
Copper bars are
fitted into the slots.
Two thick rings
hold the bars in
place.
Alternating
current flows
into the stator,
producing a
rotating
magnetic
field.
The stator
artificially
creates an
electric
current in
the rotor,
which
generates
the second
magnetic
field.
When the two fields interact,
the rotor turns.
36
2. Stationary Equipment
Stationary Equipment Stationary Equipment
consists ofconsists of
Piping and
storage tanks
Gate globe,
and ball valves
Filters
Heat
exchangers
Cooling
towers
furnaces
Boilers
Reactors
Distillation
columns
37
2. Stationary Equipment2. Stationary Equipment
Pipe fittings
38
Chapter 2. ValvesChapter 2. Valves
Valve─ a device to direct and control the fluids by starting,
stopping, and throttling (restricting) flow to make processing
possible.
Valves─are designed to withstand pressure, temperature,
and flow and can be found in homes and industry across
the world.
39
Chapter 2. ValvesChapter 2. Valves
The common valves found in the manufacturing environment
are:
Gate valve Ball valve Check valve Butterfly valve
Plug valve
Needle valve Three-way valve
Diagragm valve
Relief valve Safety valve
Angle valve Multiport valve
globe valve
40
Chapter 2. ValvesChapter 2. Valves
Process operators classify valves by:
Classification of valve
Flow-control element function Operating condition
Gate valve
Globe valve
Needle valve Check valve
Plug valve
Adjusting valve
Cut-off valve
Three-way valve
Hand-operating valve
Safety valve
Electric-operated valve
Pneumatic-operated
valve
Connecting manner Flange connection
Threaded connection
Clamp connection
Welding connection
41
Chapter 2. ValvesChapter 2. Valves
A device that places a movable metal gate in the path of a
process flow.
1. Gate valves
Bonnet 机罩Yoke 机架
The typical gate
valve consists of a
gate, body, seating
area, stem, bonnet,
packing, stuffing
box, packing gland,
and hand wheel.
The gates are sized
to fit the inside
diameter of a pipe.
42
Chapter 2. ValvesChapter 2. Valves
Very little restriction occurs when it is in the open position.
1. Gate valves
Size: from ” to several feet.
Path: from “wide open” to “completely shut”.
Should not be used to throttle flow.
The gate can be wedge shaped
or may consist of parallel discs.
The gate is placed directly in the
path of a process flow when it is
shut and is lifted completely out
of the way when open.
43
Chapter 2. ValvesChapter 2. Valves Gate valves
The body is the largest
part of the valve. The body
can be connected to the
process piping in three
ways: flanges, threaded,
or welding.
The seating consists of
two fixed surfaces or rings
inside the body of the
valve that the gate closes
against to stop flow. The
seating area falls into two
categories: replaceable or
fixed.
The stem is a long, slender
shaft attached to the gate,
bushing, or wheel.
When the hand wheel is turned,
it transmits rotational energy to
the stem, causing it to rise to
open or lower to close.
The bonnet provides a housing
for the gate or disc when it is
lifted out of the process flow.
It is attached to the body
permanently by welding or
temporarily by threading or
bolts.
44
Chapter 2. ValvesChapter 2. Valves 2. Globe valves
Globe valves are the second most common
used in industry.
A globe valve places a movable metal disc
in the path of a process flow.
This type of valve is most commonly used
for throttling service.
The disc is designed to fit smugly into the
seat and stop flow.
Process fluid enters the globe valve and is
directed through a 90o turn to the bottom of
the seal and disc.
45
Chapter 2. ValvesChapter 2. Valves 2. Globe valves
Globe valves must be installed properly to work well.
If the valves is installed backward it will tend to wear unevenly and
push the flow-control element down.
46
Chapter 2. ValvesChapter 2. Valves 2. Globe valves
The typical globe valve consists of:
disc
body
seating
area
stem
bonnet
packing
Stuffing
box
Packing
gland
Hand
wheel
47
Chapter 2. ValvesChapter 2. Valves 2. Globe valves
The disc is attached to the stem in three ways:
Slip joint
Threading
One-piece
manufacturing
The disc can be classified as plug, ball, composition, or needle shape.
48
Chapter 2. ValvesChapter 2. Valves 3. Ball valves
The hollow ball
rotates into the open
or closed position.
A ball valve does not
lift the flow-control
device out of the
process stream.
Ball valves provide very little restriction to flow and can be fully opened
with a quarter turn on the valve handle.
In the closed position, the port is turned away from the process flow. In
the open position, it lines up perfectly with the inner diameter of the pipe.
Ball valves take their name from the ball shaped, movable element in
the center of the valve.
49
Chapter 2. ValvesChapter 2. Valves 3. Ball valves
Ball valves are
not designed for
excessive
temperatures.
It should not be
used for
throttling service.
Ball valves do not generally seal as well as globe valves in high-
pressure service.
Some ball valves (multiport valves) are designed with multiple ports, so
an operator can switch fluid sources without stopping flow.
The ball valves only require one-quarter turn on a handle.
50
Chapter 2. ValvesChapter 2. Valves 4. Check valves
Flow lifts the disc
and keeps it lifted
until flow stops or
reverses.
A typical check
valve design is the
swing check, which
has a hinged disc
that slams shut
when flow reverses.
A check valves is designed to prevent reverse flow and to avoid possible
contamination or damage to equipment.
51
Chapter 2. ValvesChapter 2. Valves 4. Check valves
Lift checks are ideal for systems in which flow rates fluctuate.
Like the swing check, it is designed to close when flow reverses.
The lift check is more durable than the swing check.
In the horizontal or vertical lift check design, a piston or ball is lifted up
and out of the seat by process flow.
Another design is the lift check, which has a
disc rests on the seat when flow is idle and lifts
when flow is active. Special guides keep the
disc in place.
52
Chapter 2. ValvesChapter 2. Valves 5. Butterfly valves
During a throttling operation, a butterfly valve handle should be carefully
secured. They have non-uniform flow characteristics.
A one-quarter turn is all it takes to fully open or close the valve.
They are designed to be operated at low temperature and low pressure.
Butterfly valves are commonly used for throttling and on/off service. The
body of this type of valve is relatively small when compared with other
valves. It occupies much less space in a pipeline.
53
Chapter 2. ValvesChapter 2. Valves 6. Plug valves
Plug valves provide very little
restrictions to flow and can be
opened 100% with a one-quarter
turn on the valve handle.
The plug valve takes its name
from the plug-shaped flow-control
element it uses to regulate flow.
Plug valves depend on a lubricant inside the body of the valve. The
lubricant helps the valve provide a leak-free seal.
Quick-opening, one-quarter turn plug valves are very popular in the
process industry.
The plug valve is designed for fuel gas piping systems, low-pressure
situations, slurry and lubrication, on/off, low-temperature service.
54
Chapter 2. ValvesChapter 2. Valves 7. Diaphragm valves
The stem is attached to a device called the
compressor.
Diaphragm valves use a flexible membrane and seat to regulate flow.
In a chemical plant, a variety of slurries, corrisive or sticky substances,
are transferred from place to place.
Standard valves would have a difficult time with this type of product.
Diaphragm valves are specially designed for the job.
The compressor pushes on a flexible
diaphragm.
The internal parts of the valve never come
into contact with the process material.
The diaphragm valve seats are made of
chemical-resistant plastic, rubber, or
neoprene.
Diaphragm valve can handle
corrosive fluids. 55
Chapter 2. ValvesChapter 2. Valves 8. Relief and safety valves
In the valve a disc is held in
place by a spring that does not
open until the system pressure
exceeds operating limits.
Relief valve is to respond automatically sudden increases of pressure in
liquid services. They do not respond well in gas service.
A relief valve is designed to open at a predetermined pressure.
The two advantadges of relief
valves are that they will reseat
as soon as the pressure drops
below the relief pressure and
the spring tension is
adjustable.
56
Chapter 2. ValvesChapter 2. Valves 8. Relief and safety valves
When a system overpressures, safety valves
respond to allow excess pressure to be
vented to the flare header.
They are designed to respond quickly to
excess vapor, or gas, pressure.
Safety valves are considered to be a process system’s last line of defense.
This venting prevents damage to equipment
and personnel.
The three major differences between a relief
and safety are:
liquid versus gas service,
pressure response time;
large exhaust port.
Relief valve is designed to
lift slowly;
Safety valve tend to pop off.
57
Chapter 2. ValvesChapter 2. Valves Summary 1
A gate valve places a movable metal gate in the path of a process flow in
a pipeline, Gate valves are considered excellent devices for process
services that are infrequently used.
Process technicians classify valves by flow-control element (the part of
the valve that regulates or controls), function and operating conditions
(such as pressure, flow, or temperature).
A valve is a device used to control (stop, start, or restrict or direct) the
flow of fluids.
A globe valve places a movable metal disc in the path of a process flow.
This type of valve is the most common one used for throttling service.
Ball valves and plug valves have a hollow ball- or plug-shaped movable
element in the center of the valve that rotates into the open or closed
position. These valves provide very little restriction to flow; they should
not be used for throttling service or in high-temperature or high-pressure
service.
58
Chapter 2. ValvesChapter 2. Valves Summary 2
Diaphragm valves use a flexible membrane to throttle sticky, viscous, or
corrosive materials.
A butterfly valve has a pivoting flow-control element shaped like a flat disc.
Check valves are used to control flow direction and to prevent
contamination of or damage to equipment.
Relief valves automatically respond to sudden increases in pressure in
liquid services.
Safety valves do the same thing in gas services. The three major differ-
ence between a relief valve and a safety valve are liquid versus gas
service, the pressure response time, and the larger exhaust port of the
safety valve. Relief valves are designed to lift slowly, whereas safety
valves tend to pop off.
Actuators are devices in a control loop that automatically adjust the
position of the valve stem on a control valve.
59
Chapter 2. ValvesChapter 2. Valves Summary 3
The packing should be inspected, and the gland nuts tightened evenly if
a leak is found.
On gate valves, stem threads exposed to weather need to be lubricated.
Maintaining equipment is an important part of an operator’s job.
Valve stems should not be painted, and every effort should be made to
keep them free of dirt and dust.
Process technicians should not overtighten a gate valve to avoid damag-
ing the seats.
When the gate is on the bottom, a wrench should never be used to
wedge ir closed.
60
完
Thank you for listening
61
谢 谢 ！
62
