Process Engineering and Plant Design

Cover
Half Title
Title Page
Copyright Page
Dedication
Table of Contents
Preface
Acknowledgments
About the Author
List of Abbreviations
Chapter 1: Executing a Process Plant: In a Nutshell
	1.1 Introduction
	1.2 Feasibility Study
		1.2.1 Pre-feasibility Study
		1.2.2 Detailed Feasibility Study
	1.3 Appointment of the Project Management Consultant
	1.4 Preparing the Process Specifications
	1.5 Licensed Technologies and Selection of the Process Licensor
	1.6 Types of Execution Strategies
	1.7 Basic Engineering
		1.7.1 Process Simulation
		1.7.2 Process Flow Diagram
		1.7.3 Piping and Instrumentation Diagram
		1.7.4 Equipment Process Data Sheets
		1.7.5 Equipment Layout
		1.7.6 Piping Material Specifications
		1.7.7 Other Documents
	1.8 Award of Project to Engineering Contractor
	1.9 Execution of the Project
		1.9.1 Project Kick-off Meeting
		1.9.2 Project Schedule
		1.9.3 Detail Engineering
		1.9.4 Procurement Services
		1.9.5 Construction
	1.10 Pre-commissioning and Commissioning
	1.11 Performance Guarantee Test Run
	1.12 Plant Acceptance and Handover
	References
Chapter 2: Flow Sheets, Equipment Lists and Line Lists
	2.1 Introduction
	2.2 Block Flow Diagram
	2.3 Flowsheet
	2.4 Process Flow Diagram
	2.5 Piping and Instrumentation Diagram
		2.5.1 Basic Engineering P&ID
		2.5.2 Detailed Engineering P&ID
	2.6 Utility P&ID
	2.7 Material Selection Diagram
	2.8 Line List
	2.9 Equipment List
	References
Chapter 3: Plot Plan and Equipment Layout
	3.1 Introduction
	3.2 Overall Plot Plan
	3.3 Overall Plot Plan Development
	3.4 Equipment Layout
	3.5 Equipment Setting Guidelines
	3.6 Preparing Equipment Layout
	References
Chapter 4: Piping and Mechanical Considerations
	4.1 Introduction
	4.2 Piping Material specification
	4.3 Insulation of Piping Systems
	4.4 Piping Considerations for Equipment and Accessories
		4.4.1 Pipe Rack
		4.4.2 Centrifugal Pumps
		4.4.3 Vessels and Columns
		4.4.4 Heat Exchangers
		4.4.5 Air Coolers
		4.4.6 Steam Tracing of Piping
		4.4.7 Relief System Piping
		4.4.8 Utility Stations
	4.5 Mechanical Considerations
		4.5.1 Design Pressure, Design Temperature and MAWP
	References
Chapter 5: Flow of Fluids
	5.1 Introduction
	5.2 Flow of Fluids
		5.2.1 General Equations
		5.2.2 Liquid and Gas Pipe Sizing Criteria
	5.3 Pumps
		5.3.1 Selection of Pump Type
		5.3.2 Definition of Terms
		5.3.3 Suction Conditions and NPSH
	5.4 Centrifugal Pumps
		5.4.1 Centrifugal Pump Characteristics
		5.4.2 Centrifugal Pump Head Calculations
		5.4.3 Choosing the Pump Model
		5.4.4 Analysis of the Data
		5.4.5 Analysis of NPSH
		5.4.6 Minimum Flow Requirements of Centrifugal Pumps
	5.5 Reciprocating Pumps
	5.6 Power Consumption for Pumps
	5.7 Choice of Driver for Pumps
	5.8 Piping and Instrumentation Diagrams for Pumps
	5.9 Compressors
		5.9.1 Types of Compressors
		5.9.2 Capacity Control of Compressors
		5.9.3 Antisurge Control and Choking in Centrifugal Compressors
		5.9.4 Power Consumption in Compressors
		5.9.5 Choice of Drives for Compressors
		5.9.6 Piping and Instrumentation Diagrams for Compressors
			Symbols
	References
Chapter 6: Vessels and Tanks
	6.1 Introduction
	6.2 Atmospheric Storage Tanks
		6.2.1 Classification of Stored Liquids
		6.2.2 Definitions
			6.2.2.1 Fixed Roof Design
			6.2.2.2 External Floating Roof Design
			6.2.2.3 Internal Floating Roof Design
		6.2.3 Design and Engineering Aspects
		6.2.4 Tank Blanketing
		6.2.5 Tank Layout, Remote Impounding and Diking
		6.2.6 Tank Data Sheet
	6.3 Pressure Storage Vessels
	6.4 Miscellaneous Process Vessels
		6.4.1 Reflux Drums
		6.4.2 Vapor-Liquid Separators
			Symbols
	References
Chapter 7: Heat Exchangers
	7.1 Introduction
	7.2 Shell-and-Tube Heat Exchangers
		7.2.1 Classification of Shell-and-Tube Heat Exchangers
		7.2.2 Selecting Shellside and Tubeside Fluids
		7.2.3 Choosing the TEMA Type
			7.2.3.1 Front End Stationary Head
			7.2.3.2 Shell Type
			7.2.3.3 Rear End Head Type
		7.2.4 Tubeside Design
		7.2.5 Shellside Design
		7.2.6 Heat Exchanger Configurations
			7.2.6.1 Multiple Shells in Series
			7.2.6.2 Multiple Shells in Parallel
		7.2.7 Heat Exchanger Over-design
		7.2.8 Fouling
		7.2.9 Pressure Drop
		7.2.10 Reboilers
	7.3 Enhanced Heat Transfer
		7.3.1 Modifications on Tubeside
		7.3.2 Modifications on Shellside
		7.3.3 Other Enhancements
	7.4 Plate and Frame Heat Exchangers
	7.5 Double Pipe Heat Exchangers
	References
Chapter 8: Air Coolers and Fired Heaters
	8.1 Introduction
	8.2 Air Coolers
		8.2.1 Reasons for Using Air Coolers
		8.2.2 Construction Features
	8.3 Fired Heaters
		8.3.1 Applications of Fired Heaters
		8.3.2 Combustion
		8.3.3 Types of Heater Construction
		8.3.4 Draft Configurations
		8.3.5 Design Guidelines and Formulae
		8.3.6 Thermal Design of Fired Heaters
			Symbols
	References
Chapter 9: Mass Transfer Equipment
	9.1 Introduction
	9.2 Tray Columns
		9.2.1 Types of Trays
		9.2.2 When to Use Tray Columns
		9.2.3 Design Guidelines for Tray Columns
		9.2.4 Process Data Sheets for Tray Sections
		9.2.5 Miscellaneous Details of Tray Columns
		9.2.6 High Performance Trays
	9.3 Packed Columns
		9.3.1 When to Use Packed Columns
		Packed columns are recommended for use under the following circumstances:
		9.3.2 Design Guidelines for Packed Columns
		9.3.3 Process Data Sheet of a Packed Section
	9.4 Other Aspects of Column Design
		9.4.1 Column Bottom Arrangements
		9.4.2 Miscellaneous Details
			Symbols
	References
Chapter 10: Hazardous Area Classification
	10.1 Introduction
	10.2 Definitions
	10.3 Systems for Classification of Hazardous Areas
		10.3.1 Class/Division System
		10.3.2 Zone System
	10.4 Area Classification Methodology
	10.5 Temperature Class
	10.6 Extent of Hazardous Area
		10.6.1 Gases and Vapors Lighter Than Air
		10.6.2 Gases and Vapors Heavier Than Air
	10.7 Selection of Electrical Equipment for Hazardous Atmospheres
	References
Chapter 11: Instrumentation and Controls
	11.1 Introduction
	11.2 Flow Measurement
		11.2.1 Differential Pressure Type – Orifice Flowmeters
		11.2.2 Differential Pressure Type – Venturi Flowmeters
		11.2.3 Rotameters
		11.2.4 Electromagnetic Flowmeters
		11.2.5 Ultrasonic Flowmeters
		11.2.6 Coriolis Flowmeters
		11.2.7 Vortex Flowmeter
		11.2.8 Turndown of Flowmeters
		11.2.9 Flow meter Selection and Accuracy
	11.3 Level Measurement
		11.3.1 Direct Measurement
		11.3.2 Indirect Measurement
	11.4 Control Valves
	11.5 Controls in a Process Plant
		11.5.1 Controls in a Distillation Column
		11.5.2 Controls in a Reactor System
		11.5.3 Dynamics in a Distillation Column
	11.6 Control Configuration and Hardware
		11.6.1 Distributed Control System
		11.6.2 Emergency Shutdown System
		11.6.3 Cause and Effect Diagram
			Symbols
	References
Chapter 12: Safety and Relief System Design in Process Plants
	12.1 Need for Pressure Relief Systems
	12.2 Definition of Terms
	12.3 Causes of Over-pressure
	12.4 Pressure Relief Systems
	12.5 Components of a Closed Disposal (Flare) System
	12.6 Over-pressure and Relieving Rates
		12.6.1 Blocked Outlet
		12.6.2 Failure of Control Valve
		12.6.3 External Fire
		12.6.4 Heat Exchanger Tube Failure
		12.6.5 Cooling Water Failure
		12.6.6 Power Failure
		12.6.7 Instrument Air Failure
	12.7 Grouping of Relieving Loads
	12.8 Piping Considerations
	12.9 Sizing of Pressure Relief Valves
	12.10 Blowdown Systems
	12.11 Handling Blowdown Streams
		Symbols
	References
Chapter 13: Hazard and Operability Study
	13.1 Introduction
	13.2 Definitions and Methodology
	13.3 Preparatory Work
	13.4 Sample HAZOP
	13.5 HAZOP Study Closeout
	References
Chapter 14: Revamp Engineering and Capacity Augmentation
	14.1 Introduction
	14.2 Line Hydraulics and Pumps
	14.3 Columns
	14.4 Control Valves and Instrumentation
		Symbols
	References
Chapter 15: Interaction and Coordination with Detail Engineering Disciplines
	15.1 Introduction
	15.2 Heat Exchangers
		15.2.1 Case Study
	15.3 Column Trays
		15.3.1 Case Study
	15.4 Column Bottoms
	15.5 Instrumentation
	15.6 3D Model Review
	15.7 Miscellaneous
		Symbols
	References
Chapter 16: Pre-commissioning, Commissioning and Start-up
	16.1 Introduction
	16.2 Pre-commissioning Planning and Manpower Requirement
	16.3 Plant Checkout
	16.4 Putting Utilities into Operation
	16.5 Cleaning Equipment and Process Lines
	16.6 Final Inspection of Equipment
	16.7 Trails for Rotating Equipment
	16.8 Drying of Process Loops
	16.9 Drying of Fired Heaters
	16.10 Catalyst Loading
	16.11 Plant Checkout and Handover
	16.12 Tightness Test
	16.13 Inertization
	16.14 Start-up Activities
	References
Chapter 17: Execution of Large Process Plants
	17.1 Introduction
	17.2 Execution Strategies
		17.2.1 EPC Mode of Execution
		17.2.2 L-EPC Mode of Execution
	17.3 Project Schedule
	17.4 Responsibilities of the PMC
	17.5 Execution of Basic Engineering
	17.6 EPC Execution
	References
Chapter 18: Cost Estimation
	18.1 Introduction
	18.2 Capital Cost Estimates
	18.3 Cost Estimates of Major Equipment
		18.3.1 Estimating Vessels
		18.3.2 Heat Exchangers
		18.3.3 Pumps and Drivers
		18.3.4 Storage Tanks
		18.3.5 Effect of Capacity on Equipment Cost
		18.3.6 Effect of Time on Equipment Cost
		18.3.7 Effect of Location on Equipment Cost
		18.3.8 Effect of Material of Construction on Equipment Cost
	18.4 Utilities and Offsites
	18.5 Capital Cost Estimates
		18.5.1 Order-of-Magnitude Estimates
		18.5.2 Study (Factored) Estimates
		18.5.3 Preliminary Design Estimates
		18.5.4 Definitive Estimates
		18.5.5 Detailed Estimates
			Symbols
	References
Appendix 1: Process Specification
	A1.1 General Project Data
	A1.2 Block Flow Diagram
	A1.3 Plant Capacity and Turndown
	A1.4 On-Stream Factors
	A1.5 Feed Specifications
	A1.6 Product Specifications
Appendix 2: Basic Design Data
	A2.1 General Project Data
	A2.2 Meteorological and Geological Data
	A2.3 Battery Limit Conditions
	A2.4 Utility Specifications
	A2.5 Units of Measurement
	A2.6 Transport Limitations
Appendix 3: Frequently Used Conversion Factors
Appendix 4: List of YouTube Links
Index