An Applied Guide to Process and Plant Design

DedicationPrefaceAcknowledgmentsPart 1: Practical Principles Introduction1. Process Plant Design IntroductionWhat is engineering?What is design?Engineering designProject life cycleProcess plant designProcess plant versus process designAcademic versus professional practiceState of the art and best engineering practiceThe use and abuse of computersFurther reading2. Stages of Process Plant Design GeneralConceptual design“Conceptual design of chemical processes”Front end engineering design (FEED)/basic designDetailed designSite redesignPosthandover redesignUnstaged designProduct engineeringFast-trackingFurther reading3. Process Plant Design Deliverables OverviewDesign basis and philosophiesSpecificationProcess flow diagram (PFD)Piping and instrumentation diagramFunctional design specification (FDS)Plot plan/general arrangement/layout drawingProgramCost estimateEquipment list/scheduleDatasheetsSafety documentationDesign calculationsIsometric piping drawingsSimulator outputFurther reading4. Twenty-First Century Process Plant Design Tools GeneralUse of computers by chemical engineersImplications of modern design toolsCategories of designTools—hardwareTools—softwareFurther reading5. The Future of Process Plant Design Process pornWill 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?Further readingPart 2: Professional Practice 6. System Level Design IntroductionHow to put unit operations togetherMatching design rigor with stage of designImplications for costImplications for safetyImplications for robustnessRule of thumb designFirst principles designDesign by simulation programSources of design dataFurther reading7. Professional Design Methodology IntroductionDesign methodologiesThe “is” and “ought” of process designRight versus wrong designInteresting versus boring designContinuous versus batch designSimple/robust versus complicated/fragile designSetting the design envelopeImplications of new design toolsImportance of understanding your designManager/engineer tensions in designWhole-system design methodologyDesign stages in a nutshellVariations on a themeFurther reading8. How to Do a Mass and Energy Balance IntroductionHandling recyclesHow to set it out in ExcelUsing Excel for iterative calculations: “Goal Seek” and “Solver”9. How to Do Hydraulic Calculations IntroductionMatching design rigor with stage of designHydraulic networksPump curvesFurther readingPart 3. Low Level Design10. How to Design and Select Plant Components and Materials IntroductionWhat process engineers designMatching design rigor with stage of designMaterials of constructionMechanical equipmentElectrical and control equipmentFurther reading11. How to Design Unit Operations IntroductionMatching design rigor with stage of designRule of thumb designApproaches to design of unit operationsSources of design dataScale-up and scale-outNeglected unit operations: separation processesFurther reading12. How to Cost a Design IntroductionMatching design rigor with stage of designThe basicsAcademic costing practiceProfessional costing practiceFurther readingPart 4. High Level Design13. How to Design a Process Control System IntroductionMatching design rigor with stage of designOperation and Maintenance manualsSpecification of operatorsAutomatic controlStandard control and instrumentation strategiesFurther reading14. How to Lay Out a Process Plant IntroductionGeneral principlesFactors affecting layoutPlant layout and safetyPlant layout and costPlant layout and aestheticsMatching design rigor with stage of designFurther reading15. How to Make Sure Your Design Is Reasonably Safe and Sustainable IntroductionWhy only reasonably?Matching design rigor with stage of designConceptual design stageDetailed design stageFormal methods: safetyFormal methods: sustainabilitySpecification of equipment with safety implications in mindSpecification of safety devicesTypes of safety deviceFurther readingSourcesPart 5. Advanced Design16. Professional Practice IntroductionGeneral design methodologyInformal design reviewsFormal design reviewsQuality assurance and document controlInformal data exchangeFurther reading17. Beginner’s Errors to Avoid IntroductionLack of equipment knowledgeLack of knowledge of many types of unit operationsLack of knowledge of many materials of constructionLack of utilitiesLayoutProcess controlFurther reading18. Design Optimization IntroductionMatching design rigor with stage of designIndicators of a need to integrate designHow to integrate designWhen and how not to integrate designWhere’s the harm? The downside of academic “process integration”Further reading19. Developing Your Own Design Style IntroductionThe art of engineeringThe philosophy of engineeringThe literature of engineeringThe practice of engineeringPersonal SotaFurther readingAppendix 1. Integrated Design Example Integrated process control and design exampleAppendix 2. Upset Conditions Table Specific Upset ConditionsAppendix 3. Plant Separation Tables Preliminary spacings for tank farm layoutPreliminary electrical area classification distancesSize of storage pilesAppendix 4. Checklists for Engineering Flow DiagramsAppendix 5. Teaching Practical Process Plant Design IntroductionPedagogyMethodologyExercisesFurther readingGlossaryIndex