An applied guide to process and plant design
An Applied Guide to Process and Plant Design is a guide to process plant design for both students and professional engineers. The book covers plant layout and the use of spreadsheet programmes and key drawings produced by professional engineers as aids to design; subjects which are usually learned o...
| Other Authors: | , |
|---|---|
| Format: | eBook |
| Language: | Inglés |
| Published: |
Amsterdam, [Netherlands] :
Butterworth-Heinemann
2015.
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| Edition: | 1st edition |
| Subjects: | |
| See on Biblioteca Universitat Ramon Llull: | https://discovery.url.edu/permalink/34CSUC_URL/1im36ta/alma991009628929906719 |
Table of Contents:
- 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.
