CHEMICAL ENGINEERING PLANT DESIGN

By G. BEORE

CONTENTS PART 1 PRACTICAL PRINCIPLES INTRODUCTION 1 PROCESS PLANT DESIGN INTRODUCTION WHAT IS ENGINEERING? WHAT IS DESIGN? ENGINEERING DESIGN PROJECT LIFE CYCLE PROCESS PLANT DESIGN PROCESS PLANT VERSUS PROCESS DESIGN ACADEMIC VERSUS PROFESSIONAL PRACTICE STATE OF THE ART AND BEST ENGINEERING PRACTICE THE USE AND ABUSE OF COMPUTERS FURTHER READING 2 STAGES OF PROCESS PLANT DESIGN GENERAL CONCEPTUAL DESIGN “CONCEPTUAL DESIGN OF CHEMICAL PROCESSES” FRONT END ENGINEERING DESIGN (FEED)/BASIC DESIGN DETAILED DESIGN SITE REDESIGN POSTHANDOVER REDESIGN UNSTAGED DESIGN PRODUCT ENGINEERING FAST-TRACKING 3 PROCESS PLANT DESIGN DELIVERABLES OVERVIEW DESIGN BASIS AND PHILOSOPHIES SPECIFICATION PROCESS FLOW DIAGRAM (PFD) PIPING AND INSTRUMENTATION DIAGRAM FUNCTIONAL DESIGN SPECIFICATION (FDS) PLOT PLAN/GENERAL ARRANGEMENT/LAYOUT DRAWING PROGRAM COST ESTIMATE EQUIPMENT LIST/SCHEDULE DATASHEETS SAFETY DOCUMENTATION DESIGN CALCULATIONS ISOMETRIC PIPING DRAWINGS SIMULATOR OUTPUT 4 TWENTY-FIRST CENTURY PROCESS PLANT DESIGN TOOLS USE OF COMPUTERS BY CHEMICAL ENGINEERS IMPLICATIONS OF MODERN DESIGN TOOLS CATEGORIES OF DESIGN TOOLS—HARDWARE TOOLS—SOFTWARE 5 THE FUTURE OF PROCESS PLANT DESIGN PROCESS PORN WILL FIRST PRINCIPLES DESIGN REPLACE HEURISTIC DESIGN IN FUTURE? WILL PROCESS DESIGN BECOME A FORM OF APPLIED MATHEMATICS IN FUTURE? WILL PRIMARY RESEARCH BECOME THE BASIS OF ENGINEERING DESIGN IN FUTURE? WILL “CHEMICAL PROCESS DESIGN” REPLACE PROCESS PLANT DESIGN IN FUTURE? WILL NETWORK ANALYSIS FORM THE CORE OF DESIGN PRACTICE IN FUTURE? WILL PROCESS SIMULATION REPLACE THE DESIGN PROCESS IN FUTURE? WILL PROCESS PLANT DESIGN NEVER CHANGE? PART 2 PROFESSIONAL PRACTICE 6 SYSTEM LEVEL DESIGN HOW TO PUT UNIT OPERATIONS TOGETHER MATCHING DESIGN RIGOR WITH STAGE OF DESIGN IMPLICATIONS FOR COST IMPLICATIONS FOR SAFETY IMPLICATIONS FOR ROBUSTNESS RULE OF THUMB DESIGN FIRST PRINCIPLES DESIGN DESIGN BY SIMULATION PROGRAM SOURCES OF DESIGN DATA 7 PROFESSIONAL DESIGN METHODOLOGY DESIGN METHODOLOGIES THE “IS” AND “OUGHT” OF PROCESS DESIGN RIGHT VERSUS WRONG DESIGN INTERESTING VERSUS BORING DESIGN CONTINUOUS VERSUS BATCH DESIGN SIMPLE/ROBUST VERSUS COMPLICATED/FRAGILE DESIGN SETTING THE DESIGN ENVELOPE IMPLICATIONS OF NEW DESIGN TOOLS IMPORTANCE OF UNDERSTANDING YOUR DESIGN MANAGER/ENGINEER TENSIONS IN DESIGN WHOLE-SYSTEM DESIGN METHODOLOGY DESIGN STAGES IN A NUTSHELL VARIATIONS ON A THEME 8 HOW TO DO A MASS AND ENERGY BALANCE HANDLING RECYCLES HOW TO SET IT OUT IN EXCEL USING EXCEL FOR ITERATIVE CALCULATIONS: “GOAL SEEK” AND “SOLVER” 9 HOW TO DO HYDRAULIC CALCULATIONS HYDRAULIC NETWORKS PUMP CURVES PART 3 LOW LEVEL DESIGN 10 HOW TO DESIGN AND SELECT PLANT COMPONENTS AND MATERIALS WHAT PROCESS ENGINEERS DESIGN MATERIALS OF CONSTRUCTION MECHANICAL EQUIPMENT ELECTRICAL AND CONTROL EQUIPMENT 11 HOW TO DESIGN UNIT OPERATIONS APPROACHES TO DESIGN OF UNIT OPERATIONS SCALE-UP AND SCALE-OUT NEGLECTED UNIT OPERATIONS: SEPARATION PROCESSES 12 HOW TO COST A DESIGN THE BASICS ACADEMIC COSTING PRACTICE PROFESSIONAL COSTING PRACTICE PART 4 HIGH LEVEL DESIGN 13 HOW TO DESIGN A PROCESS CONTROL SYSTEM OPERATION AND MAINTENANCE MANUALS SPECIFICATION OF OPERATORS AUTOMATIC CONTROL STANDARD CONTROL AND INSTRUMENTATION STRATEGIES 14 HOW TO LAY OUT A PROCESS PLANT GENERAL PRINCIPLES FACTORS AFFECTING LAYOUT PLANT LAYOUT AND SAFETY PLANT LAYOUT AND COST PLANT LAYOUT AND AESTHETICS 15 HOW TO MAKE SURE YOUR DESIGN IS REASONABLY SAFE AND SUSTAINABLE WHY ONLY REASONABLY? CONCEPTUAL DESIGN STAGE DETAILED DESIGN STAGE FORMAL METHODS: SAFETY FORMAL METHODS: SUSTAINABILITY SPECIFICATION OF EQUIPMENT WITH SAFETY IMPLICATIONS IN MIND SPECIFICATION OF SAFETY DEVICES TYPES OF SAFETY DEVICE SOURCES PART 5 ADVANCED DESIGN 16 PROFESSIONAL PRACTICE GENERAL DESIGN METHODOLOGY INFORMAL DESIGN REVIEWS FORMAL DESIGN REVIEWS QUALITY ASSURANCE AND DOCUMENT CONTROL INFORMAL DATA EXCHANGE 17 BEGINNER’S ERRORS TO AVOID LACK OF EQUIPMENT KNOWLEDGE LACK OF KNOWLEDGE OF MANY TYPES OF UNIT OPERATIONS LACK OF KNOWLEDGE OF MANY MATERIALS OF CONSTRUCTION LACK OF UTILITIES LAYOUT PROCESS CONTROL 18 DESIGN OPTIMIZATION INDICATORS OF A NEED TO INTEGRATE DESIGN HOW TO INTEGRATE DESIGN WHEN AND HOW NOT TO INTEGRATE DESIGN WHERE’S THE HARM? THE DOWNSIDE OF ACADEMIC “PROCESS INTEGRATION” 19 DEVELOPING YOUR OWN DESIGN STYLE THE ART OF ENGINEERING THE PHILOSOPHY OF ENGINEERING THE LITERATURE OF ENGINEERING THE PRACTICE OF ENGINEERING PERSONAL SOTA PART