華東理工大學機械與動力工程學院

ProcessTechnology

─EquipmentandSystem華東理工大學機械與動力工程學院2005年3月7日Introduction雙語教學：

Bilingualeducation1Teachersfortheclass：潘家禎教授博士生導師王正東教授博導學院常務副院長周紹萍副教授系主任在讀博士惠虎副教授博士王學生副教授博士石巖講師在讀博士周先桃博士后2OurTeam：Qualifiedteachers;Bestteam;──Todevoteourbestforstudents;Tofulfillthetaskbetter.Teamwork──Teachingresearch;improvingourteachingquality;Teacherscanlearneachotherfromother’sstrongpointstooffsetone’sweakness.OurobjectiveCooperatewithstudentstofulfillthisclasssatisfactory.Toobtainmoreknowledge,tolearnactively,tobesuccessful.3Threetransforms：Frompassivestudytoactivestudy.Fromforced-feedingmethodofteachingtoheuristiceducation.Frommerelybooklearningtoqualityeducationincludingvariouscomprehensivestudying.─Thistaskshouldbecooperatedbyteachersandstudents.4Weencourage：Everystudentchoosesyourfavoriteteachers.Everyteacherchoosesyourfavoritestudents.─.Acceptfavoritestudentstoteacher’sresearchteam.─.Encouragefavoritestudentstopursuehigherdegree.5

潘家禎HowtoIntroduceyourselfPanJiaZhenWillreplytoMr.PanWesternstyle:JiaZhenPanMaybeconfusedtoMr.ZhenAmericanFormBritishFormFirstNameMiddleNameLastNameGivenNameReligiousNameFamilyNameSurname6JiaZhenPANRecommendCapitalizeorPAN,JiaZhenAuthorIndexstylePANJiazhenJiazhenPanPAN,Jiazhen7K.J.MillerWesternNameKeith.John.MillerKeith.J.MillerMiller,K.J.8石亞文ChineseName－FromSCI,ScienceCitationIndexShiYWWenSYThisiswrong.TenwaystoexpressChineseName:1.ShiYaWen2.YaWenShiSomeproblem,notsurethefamilyname93.ShiYawenTenwaystoexpressChineseName:4.YawenShi5.ShiYa-Wen6.Ya-wenShi10.Y.W.Shi9.ShiY.W.NoproblemEast-AsiaChineseOK.7.YaWenSHI8.SHIYawenWesterncustom10我們們的的專專業(yè)業(yè)稱稱為為““過過程程裝裝備備與與控控制制工工程程””即：：What’’smeans“ProcessEquipment””?ProcessEquipmentandControlEngineering11Background(背景景)教育育部部幾幾次次專專業(yè)業(yè)調(diào)調(diào)整整，，合合并并和和削削減減了了許許多多專專業(yè)業(yè)，，戴戴帽帽的的機機械械專專業(yè)業(yè)全全部部取取消消，，如如：：食食品品機機械械、、輕輕工工機機械械、、紡紡織織機機械械等等，，均均統(tǒng)統(tǒng)稱稱為為““機機械械設設計計與與制制造造””專專業(yè)業(yè)。。只只有有化化工工機機械械專專業(yè)業(yè)由由于于其其不不可可替替代代的的重重要要性性而而予予以以保保留留，，但但是是更更名名為為““過過程程裝裝備備與與控控制制工工程程””專專業(yè)業(yè)。。它它體體現(xiàn)現(xiàn)了了拓拓寬寬專專業(yè)業(yè)面面的的要要求求，，它它的的培培養(yǎng)養(yǎng)對對象象就就不不僅僅僅僅是是化化學學工工業(yè)業(yè)，，而而是是適適用用于于所所有有的的過過程程工工業(yè)業(yè)。。What’’smeans“ProcessEquipment””?12What’’smeans“Process””?Howmanykindsofprocessesarerelatedtous?What’’smeans“ProcessEquipment””?Sixprocessesarecloselyrelatedtoourspecialty:1.Fluiddynamicalprocess:(流體動動力過程程)Itdealswithpump(泵),compressor(壓縮機機),ventilator(風風機),pipesandvalves(管道和和閥門等等).13What’smeans“Process”?Howmanykindsofprocessarerelatedtous?What’smeans““ProcessEquipment”?Sixprocessesarecloselyrelatedtoourspecialty:2.Heattransferprocess:(熱量傳傳遞過程程)Itdealswithheattransferequipment.(它涉及及熱量交交換過程程及設備備，即：：換熱器器，熱交交換器等等)。14What’smeans“Process”?Howmanykindsofprocessarerelatedtous?What’smeans““ProcessEquipment”?Sixprocessesarecloselyrelatedtoourspecialty:3.Masstransferprocess:(質(zhì)量傳傳遞過程程)Itdealswithdry,distillation,condense,extractionprocessandequipment.(它它涉及有有關(guān)干燥燥,蒸蒸餾,濃濃縮,萃取取等過程程及裝備備)。15What’smeans“Process”?Howmanykindsofprocessarerelatedtous?What’smeans““ProcessEquipment”?Sixprocessesarecloselyrelatedtoourspecialty:4.Momentumtransferprocess:(動量傳傳遞過程程)Itdealswithsizereductionandsizeenlargementprocessandequipment.(它它涉及固固體物料料的粉碎碎、造粒粒等過程程及設備備。)16What’smeans“Process”?Howmanykindsofprocessarerelatedtous?What’smeans““ProcessEquipment”?Sixprocessesarecloselyrelatedtoourspecialty:5.Thermodynamicsprocess:(熱力學學過程)Itdealswithrefrigeration,cryogenicrefrigeration,andairseparationetc.(它涉及及冷凍,深度度冷凍,空氣氣分離等等過程及及設備。。)17What’smeans“Process”?Howmanykindsofprocessarerelatedtous?What’smeans““ProcessEquipment”?Sixprocessesarecloselyrelatedtoourspecialty:6.Chemicalprocess:(化學過過程)Itdealswithsynthesize,decompositionprocessandequipment.(它涉及及化學反反應，如如：合成成、分解解等過程程及設備備。)18Including:Thisbook:“ProcessTechnology””Introductiontoprocessequipment;Valves;Pipingandvessels;Pumps;Compressors;Turbinesandmotors;Heatexchangers;Coolingtowers;Steamgenerations(boilers);Firedheaters(furnaces);19Including:Thisbook:“ProcessTechnology”Processinstrumentation;Processdiagrams;Utilitysystems;Reactionsystems;Distillationsystems;Otherseparationsystems;Plasticssystems.20Understandingforthetest:About:“Thetest””Studyisforyourselves,notforteachers,notforparents;Trytounderstandimportantconceptforthiscourse;ThisisnotanEnglishcourse.ItisacoursetouseEnglishtounderstandthespeciality.Testingisawaytocheckyourunderstandingforthecourse.Encouragestudentstojoinustobuildatestingdatabasefortesting.Tochoosethebestquestions,andbestanswers,tohelpyouunderstandingthecourse.答疑及課外外輔導時間間：21ProcessIndustryTheProcessindustryiscomposedofrefineriesandpetrochemical,paperandpulp,powergeneration,andfoodprocessingplants.22ProcessIndustryProcesstechniciansinspectandmaintainequipment,placeandremoveequipmentfromservice,completechecklists,controldocumentation,respondtoemergencies,andtroubleshootsystemproblems.23ProcessIndustryTofulfillthoseresponsibilities,theprocesstechnicianmusthaveathroughunderstandingoftools,equipment,andsystems.24BasicHandTools251.RotaryEquipmentProcessEquipment

canbedividedinto:2.StationaryEquipment261.RotaryEquipmentSafetyNotice:Severeinjuriescanresultwhenlooseclothing,shoelaces,jewelry,orlonghairgetstangledaroundrotatingparts.Tips:awareofprotectingyourselftoavoidanyinjuries,especiallyforyoureyes.Don’’thurtyourself;Don’’thurtotherperson;Don’’tbehurtbyotherperson.271.RotaryEquipment1.1DriversandEquipmentAdriverisadevicedesignedtoproviderotationalenergytoanotherpieceofequipment.ThemostcommondriverMotorsPumpsCompressorsGeneratorsFansConveyorsSolidfeedersCouplings,belts,orchainsconnectdrivesanddrivenequipments.281.RotaryEquipment1.1DriversandEquipmentCouplingsFixed-speedcouplingsRigidcouplingsFlexiblecouplingVariable-speedcouplingsHydrauliccouplingsMagneticcouplings291.RotaryEquipment1.1DriversandEquipmentBeltsBeltsareusedtoconnecttwoparallelshafts.Apulleyismountedontheendofeachshaft.Thesizeofthepulleysallowthedriveranddrivenequipmenttooperateatdifferentspeeds.Beltsfitinthegroovesofthepulley.Beltscomeinavarietyofshapesandsizesandaremadeofdurablematerialdesignedtowithstandoperatingconditions.301.RotaryEquipment1.1DriversandEquipmentBeltsBeltsareusedtoconnecttwoparallelshafts.Beltdrivesrequirelessspacethanfixed-speedorvariable-speedcouplings.Abeltdrivecanmakespeed-to-torqueortorque-to-speedconversions.Processtechniciansfrequentlyinspectbeltsduringroundstoensurethatsafetyguardsareinplace,thatbelttensioniscorrect,andthatthebeltsarestillmountedonthepulleys.Flopping,squealing,orsmokingbeltsindicatewear,tension,ordriven-equipmentproblems.311.RotaryEquipment1.2GearboxesandPowerTransmissionGearboxesOftenusedbetweenthedriverandthedrivenequipment.Thedrivegearmesheswithalargerorsmallergear,thedrivengear.Asthedrivegearrotates,theinterlockedgearsintheboxturn,transmittingpowertothedrivenequipment.Smallgearsizeisassociatedwithspeed.Largegearsizeisassociatedwithtorque.321.RotaryEquipment1.2GearboxesandPowerTransmissionGearboxesPowertransmissioninrotatingequipmentisclassifiedasspeed-to-torqueconversionortorque-to-speedconversion.Speed-to-torqueconversionisaccomplishedwithasmalldrivegearwithalargedrivengear.Torque-to-speedconversionusesalargedrivegearwithasmalldrivengear.331.RotaryEquipment1.3ElectricmotorsTheprocessindustryuseselectricmotorstooperatepumps,generators,compressors,fans,blowersandotherequipment.Electricmotorsareeitherdirectcurrent(DC)oralternatingcurrent(AC).Theoperationofanelectricmotorisbasedonthreeprinciples:Electriccurrentcreatesamagneticfield;Oppositemagneticpolesattracteachother,likemagneticpolesrepeleachother;Currentdirectiondeterminesthemagneticpoles.341.RotaryEquipment1.3ElectricmotorsElectricmotorconsistsof:Stationarymagnet(stator)Movingconduct(rotor)Permanentmagneticfieldisformedbythelinesofforcebetweenthepolesofthemagnet.WhenelectricitypassesthroughtheconductorinaDCmotor,itbecomesanelectromagnetandgeneratesanothermagneticfield.Thetwinfieldsincreaseinintensityandpushagainsttheconductor.351.RotaryEquipment1.3ElectricmotorsTherotorinanACmotorisaslottedironcore.Copperbarsarefittedintotheslots.Twothickringsholdthebarsinplace.Alternatingcurrentflowsintothestator,producingarotatingmagneticfield.Thestatorartificiallycreatesanelectriccurrentintherotor,whichgeneratesthesecondmagneticfield.Whenthetwofieldsinteract,therotorturns.362.StationaryEquipmentStationaryEquipmentconsistsofPipingandstoragetanksGateglobe,andballvalvesFiltersHeatexchangersCoolingtowersfurnacesBoilersReactorsDistillationcolumns372.StationaryEquipmentPipefittings38Chapter2.ValvesValve─adevicetodirectandcontrolthefluidsbystarting,stopping,andthrottling(restricting)flowtomakeprocessingpossible.Valves─aredesignedtowithstandpressure,temperature,andflowandcanbefoundinhomesandindustryacrosstheworld.39Chapter2.ValvesThecommonvalvesfoundinthemanufacturingenvironmentare:GatevalveBallvalveCheckvalveButterflyvalvePlugvalveNeedlevalveThree-wayvalveDiagragmvalveReliefvalveSafetyvalveAnglevalveMultiportvalveglobevalve40Chapter2.ValvesProcessoperatorsclassifyvalvesby:ClassificationofvalveFlow-controlelementfunctionOperatingconditionGatevalveGlobevalveNeedlevalveCheckvalvePlugvalveAdjustingvalveCut-offvalveThree-wayvalveHand-operatingvalveSafetyvalveElectric-operatedvalvePneumatic-operatedvalveConnectingmannerFlangeconnectionThreadedconnectionClampconnectionWeldingconnection41Chapter2.ValvesAdevicethatplacesamovablemetalgateinthepathofaprocessflow.1.GatevalvesBonnet機罩Yoke機架Thetypicalgatevalveconsistsofagate,body,seatingarea,stem,bonnet,packing,stuffingbox,packinggland,andhandwheel.Thegatesaresizedtofittheinsidediameterofapipe.42Chapter2.ValvesVerylittlerestrictionoccurswhenitisintheopenposition.1.GatevalvesSize:from0.125”toseveralfeet.Path:from“wideopen””to“completelyshut””.Shouldnotbeusedtothrottleflow.Thegatecanbewedgeshapedormayconsistofparalleldiscs.Thegateisplaceddirectlyinthepathofaprocessflowwhenitisshutandisliftedcompletelyoutofthewaywhenopen.43Chapter2.ValvesGatevalvesThebodyisthelargestpartofthevalve.Thebodycanbeconnectedtotheprocesspipinginthreeways:flanges,threaded,orwelding.Theseatingconsistsoftwofixedsurfacesorringsinsidethebodyofthevalvethatthegateclosesagainsttostopflow.Theseatingareafallsintotwocategories:replaceableorfixed.Thestemisalong,slendershaftattachedtothegate,bushing,orwheel.Whenthehandwheelisturned,ittransmitsrotationalenergytothestem,causingittorisetoopenorlowertoclose.Thebonnetprovidesahousingforthegateordiscwhenitisliftedoutoftheprocessflow.Itisattachedtothebodypermanentlybyweldingortemporarilybythreadingorbolts.44Chapter2.Valves2.GlobevalvesGlobevalvesarethesecondmostcommonusedinindustry.Aglobevalveplacesamovablemetaldiscinthepathofaprocessflow.Thistypeofvalveismostcommonlyusedforthrottlingservice.Thediscisdesignedtofitsmuglyintotheseatandstopflow.Processfluidenterstheglobevalveandisdirectedthrougha90oturntothebottomofthesealanddisc.45Chapter2.Valves2.GlobevalvesGlobevalvesmustbeinstalledproperlytoworkwell.Ifthevalvesisinstalledbackwarditwilltendtowearunevenlyandpushtheflow-controlelementdown.46Chapter2.Valves2.GlobevalvesThetypicalglobevalveconsistsof:discbodyseatingareastembonnetpackingStuffingboxPackingglandHandwheel47Chapter2.Valves2.GlobevalvesThediscisattachedtothesteminthreeways:SlipjointThreadingOne-piecemanufacturingThedisccanbeclassifiedasplug,ball,composition,orneedleshape.48Chapter2.Valves3.BallvalvesThehollowballrotatesintotheopenorclosedposition.Aballvalvedoesnotlifttheflow-controldeviceoutoftheprocessstream.Ballvalvesprovideverylittlerestrictiontoflowandcanbefullyopenedwithaquarterturnonthevalvehandle.Intheclosedposition,theportisturnedawayfromtheprocessflow.Intheopenposition,itlinesupperfectlywiththeinnerdiameterofthepipe.Ballvalvestaketheirnamefromtheballshaped,movableelementinthecenterofthevalve.49Chapter2.Valves3.BallvalvesBallvalvesarenotdesignedforexcessivetemperatures.Itshouldnotbeusedforthrottlingservice.Ballvalvesdonotgenerallysealaswellasglobevalvesinhigh-pressureservice.Someballvalves(multiportvalves)aredesignedwithmultipleports,soanoperatorcanswitchfluidsourceswithoutstoppingflow.Theballvalvesonlyrequireone-quarterturnonahandle.50Chapter2.Valves4.CheckvalvesFlowliftsthediscandkeepsitlifteduntilflowstopsorreverses.Atypicalcheckvalvedesignistheswingcheck,whichhasahingeddiscthatslamsshutwhenflowreverses.Acheckvalvesisdesignedtopreventreverseflowandtoavoidpossiblecontaminationordamagetoequipment.51Chapter2.Valves4.CheckvalvesLiftchecksareidealforsystemsinwhichflowratesfluctuate.Liketheswingcheck,itisdesignedtoclosewhenflowreverses.Theliftcheckismoredurablethantheswingcheck.Inthehorizontalorverticalliftcheckdesign,apistonorballisliftedupandoutoftheseatbyprocessflow.Anotherdesignistheliftcheck,whichhasadiscrestsontheseatwhenflowisidleandliftswhenflowisactive.Specialguideskeepthediscinplace.52Chapter2.Valves5.ButterflyvalvesDuringathrottlingoperation,abutterflyvalvehandleshouldbecarefullysecured.Theyhavenon-uniformflowcharacteristics.Aone-quarterturnisallittakestofullyopenorclosethevalve.Theyaredesignedtobeoperatedatlowtemperatureandlowpressure.Butterflyvalvesarecommonlyusedforthrottlingandon/offservice.Thebodyofthistypeofvalveisrelativelysmallwhencomparedwithothervalves.Itoccupiesmuchlessspaceinapipeline.53Chapter2.Valves6.PlugvalvesPlugvalvesprovideverylittlerestrictionstoflowandcanbeopened100%withaone-quarterturnonthevalvehandle.Theplugvalvetakesitsnamefromtheplug-shapedflow-controlelementitusestoregulateflow.Plugvalvesdependonalubricantinsidethebodyofthevalve.Thelubricanthelpsthevalveprovidealeak-freeseal.Quick-opening,one-quarterturnplugvalvesareverypopularintheprocessindustry.Theplugvalveisdesignedforfuelgaspipingsystems,low-pressuresituations,slurryandlubrication,on/off,low-temperatureservice.54Chapter2.Valves7.DiaphragmvalvesThestemisattachedtoadevicecalledthecompressor.Diaphragmvalvesuseaflexiblemembraneandseattoregulateflow.Inachemicalplant,avarietyofslurries,corrisiveorstickysubstances,aretransferredfromplacetoplace.Standardvalveswouldhaveadifficulttimewiththistypeofproduct.Diaphragmvalvesarespeciallydesignedforthejob.Thecompressorpushesonaflexiblediaphragm.Theinternalpartsofthevalvenevercomeintocontactwiththeprocessmaterial.Thediaphragmvalveseatsaremadeofchemical-resistantplastic,rubber,orneoprene.Diaphragmvalvecanhandlecorrosivefluids.55Chapter2.Valves8.ReliefandsafetyvalvesInthevalveadiscisheldinplacebyaspringthatdoesnotopenuntilthesystempressureexceedsoperatinglimits.Reliefvalveistorespondautomaticallysuddenincreasesofpressureinliquidservices.Theydonotrespondwellingasservice.Areliefvalveisdesignedtoopenatapredeterminedpressure.Thetwoadvantadgesofreliefvalvesarethattheywillreseatassoonasthepressuredropsbelowthereliefpressureandthespringtensionisadjustable.56Chapter2.Valves8.ReliefandsafetyvalvesWhenasystemoverpressures,safetyvalvesrespondtoallowexcesspressuretobeventedtotheflareheader.Theyaredesignedtorespondquicklytoexcessvapor,orgas,pressure.Safetyvalvesareconsideredtobeaprocesssystem’’slastlineofdefense.Thisventingpreventsdamagetoequipmentandpersonnel.Thethreemajordifferencesbetweenareliefandsafetyare:liquidversusgasservice,pressureresponsetime;largeexhaustport.Reliefvalveisdesignedtoliftslowly;Safetyvalvetendtopopoff.57Chapter2.ValvesSummary1Agatevalveplacesamovablemetalgateinthepathofaprocessflowinapipeline,Gatevalvesareconsideredexcellentdevicesforprocessservicesthatareinfrequentlyused.Processtechniciansclassifyvalvesbyflow-controlelement(thepa