An Applied Guide to Process and Plant Design.

Front Cover -- An Applied Guide to Process and Plant Design -- Copyright Page -- Contents -- Preface -- Acknowledgments -- 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 -- Variation and selection -- Variation/creativity -- Selection/analysis -- Academic versus professional practice -- Process plants versus castles in the air -- What we design and what we do not -- Standards and specifications -- Design manuals -- Rules of thumb -- Approximations -- Professional judgment -- 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" -- Modeling as "conceptual design" -- Front End Engineering Design (FEED)/basic design -- Detailed design -- Site redesign -- Posthandover redesign -- Unstaged design -- Product engineering -- Fast-tracking -- Conceptual/FEED fast-tracking -- FEED/detailed design fast-tracking -- Design/procurement fast-tracking -- The fast-track to bad design -- Further Reading -- 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 -- Academic approach -- Professional budget pricing -- Professional firm pricing -- Equipment list/schedule -- Datasheets -- Safety documentation -- HAZOP study -- Zoning study/hazardous area classification -- Design calculations -- Isometric piping drawings -- Simulator output -- Further Reading -- 4 Twenty-First Century Process Plant Design Tools.

General -- Use of computers by chemical engineers -- Implications of modern design tools -- Categories of design -- Unit operation sizing and selection -- Hydraulic design -- Mass balance -- Energy balance -- Tools-Hardware -- Mobile devices -- Handheld calculators -- Graphical calculators -- Tools-Software -- Spreadsheets -- MS Excel -- Microsoft Visual Basic -- Other numerical analysis software -- MathWorks MATLAB -- PTC Mathcad -- Simulation programs -- Aspentech Hysys, etc. -- Invensys SimSci Pro/II -- Chemstations CHEMCAD -- COMSOL Multiphysics, etc. -- Other -- Project management/programming tools -- Microsoft Project -- Microsoft Excel -- AMS Realtime -- Oracle Primavera -- Computer-Aided Design (CAD): drawing/drafting -- Autodesk AutoCAD/Inventor, etc. -- Bentley Systems Microstation -- PTC Creo -- Computer-Aided Design (CAD): process design -- Bentley Systems Axsys.Process/PlantWise -- Computer-Aided Design (CAD): hydraulic design -- COMSOL Multiphysics -- Matlab/Simulink -- Autodesk® Simulation CFD -- Other -- Microsoft Visio -- Microsoft Access -- Further Reading -- 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? -- Further Reading -- 2 Professional Practice -- 6 System Level Design -- Introduction -- 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 -- Client documentation -- Design manuals -- Standards -- Manufacturer's catalogues and representatives -- More experienced engineers -- Pilot plant trials/operational data -- Previous designs -- "T'Internet" -- Libraries -- Further Reading -- 7 Professional Design Methodology -- Introduction -- Design methodologies -- The "is" and "ought" of process design -- Right versus wrong design -- Interesting versus boring design -- Continuous versus batch design -- Why use batch processing? -- Apparent simplicity -- Flexibility -- Solids handling -- Batch integrity -- The main batch design requirements -- Nonsteady state -- Batch heat transfer -- Batch distillation -- Batch reaction -- Batch sequencing -- Energy balance and utility requirements -- Simple/robust versus complicated/fragile design -- Lessons from the slide rule -- Estimation/feel -- Setting the design envelope -- Summary statistics -- Implications of new design tools -- Importance of understanding your design -- Manager/engineer tensions in design -- Manager/engineer tensions I: risk aversion -- Manager/engineer tensions II: the Iron Triangle -- Whole-system design methodology -- Design stages in a nutshell -- Conceptual design -- Intermediate design -- Design for construction -- Variations on a theme -- Further Reading -- 8 How to Do a Mass and Energy Balance -- Introduction -- Unsteady state -- Implications of feedstock and product specifications -- Stages of plant life -- Handling recycles -- How to set it out in Excel -- Using Excel for iterative calculations: "Goal Seek" and "Solver" -- 9 How to Do Hydraulic Calculations -- Introduction -- Matching design rigor with stage of design -- Level 1-superficial velocity -- Level 2-nomograms, etc. -- Liquids -- Net positive suction head.

Gases -- Level 3 (now superseded)-Moody diagram -- Level 3 (updated): spreadsheet method -- Liquids -- Gases -- Level 4-CFD -- Hydraulic networks -- Pump curves -- Further Reading -- 3 Low Level Design -- 10 How to Design and Select Plant Components and Materials -- Introduction -- What process engineers design -- Matching design rigor with stage of design -- Materials of construction -- Scaling and corrosion -- Mechanical equipment -- Pumps/blowers/compressors/fans -- Valves -- Heat exchangers -- Electrical and control equipment -- Motor control centers -- Cabling -- Instrumentation -- Control system -- Local controllers -- Programmable logic controllers -- PC -- Supervisory control and data acquisition -- DCS -- Aftermarket systems: supervisory computer, etc. -- Further Reading -- 11 How to Design Unit Operations -- Introduction -- Matching design rigor with stage of design -- Rule of thumb design -- Approaches to design of unit operations -- First principles design -- Design by simulation program -- Design from manufacturers' literature -- Sources of design data -- Scale-up and scale-out -- Neglected unit operations: separation processes -- Further Reading -- 12 How to Cost a Design -- Introduction -- Matching design rigor with stage of design -- The basics -- Academic costing practice -- Capital cost estimation by MPI/factorial method -- Operating cost estimation -- Economic potential -- Payback period, NPV, and so on -- Sensitivity analysis -- Professional costing practice -- Accurate capital cost estimation -- Bought-in mechanical items -- Bought-in electrical items -- Mechanical installation -- Electrical installation -- Software and instrumentation -- Civil and building works -- Design consultants -- Project programming -- Man-hours estimation -- Pricing risk -- Margins -- Competitive design and pricing -- Accurate operating cost estimation.

Further Reading -- 4 High Level Design -- 13 How to Design a Process Control System -- Introduction -- Matching design rigor with stage of design -- Operation and Maintenance manuals -- Specification of operators -- Automatic control -- Specification of instrumentation -- Precision -- Accuracy -- Cost and robustness -- Safety -- Specification of control systems -- Standard control and instrumentation strategies -- Alarms, inhibits, stops, and emergency stops -- Chemical dosing -- Pump speed control -- Pump stroke length control -- Actuated valve control -- Compressors/blowers/fans -- Positive displacement -- Centrifugal -- Distillation -- Filters -- Backwash control -- Chemical cleaning control -- Fired heaters/boilers -- Heat exchangers -- Pumps -- Dry running protection -- No flow protection -- Over-temperature protection -- Pumps: centrifugal -- Pumps: positive displacement -- Pumps: dosing -- Tanks -- Valves -- Rotary actuators-modulating duties -- Linear actuators-open/closed duties -- Valve positioner/limit switch -- Further Reading -- 14 How to Lay Out a Process Plant -- Introduction -- General principles -- Factors affecting layout -- Cost -- Health/safety/environment -- Robustness -- Site selection -- Natural environment -- Man-made environment -- Regulatory environment -- Plant layout and safety -- Plant layout and cost -- Plant layout and aesthetics -- Matching design rigor with stage of design -- Conceptual layout -- In which direction is the prevailing wind? -- Indoor or outdoor? -- Construction, commissioning, and maintenance -- Materials storage and transport -- Emergency provision -- Security -- Central services -- Earthworks -- Conceptual layout methodology -- Detailed layout methodology -- For construction -- Further Reading -- 15 How to Make Sure Your Design Is Reasonably Safe and Sustainable -- Introduction -- Why only reasonably?.

Matching design rigor with stage of design.

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Electronic reproduction. Ann Arbor, Michigan : ProQuest Ebook Central, 2024. Available via World Wide Web. Access may be limited to ProQuest Ebook Central affiliated libraries.