Lecture 1 Unit Outline and Introduction to Design

HB Vuthaluru 2006

302259 / 304767

Process Plant Engineering 322/518

A/Prof Hari Vuthaluru
Chemical Engineering
Curtin Engineering

UNIT OUTLINE
2013

ESSENTIAL ADMINISTRATIVE INFORMATION

TEACHING STAFF
Hari Vuthaluru (Lecturer) Your lecturer or tutor: Asim Saeed (Tutor) Harshini Karunarathna (Tutor)
h.vuthaluru@curtin.edu.au

Email:

Asim.Saeed@curtin.edu.au kahm_harshi@yahoo.com

Phone: Building: Room: Contact Hours:

92664685 204 517A 10.00am - 12.00 noon Friday

UNIT SYLLABUS
Interpretation and creation of PFDs, P&IDs, mechanical drawings, plot plans and equipment specification sheets; Materials Selection & Specification. Fluid Flow, Pipe Friction for Single and Multi-phase Flow. Pipeline & Pumping Design. Valves, Pumps, Seals. Piping System Design. Pressure Vessel Design. Pressurised Systems. Foundation Design. Plant Energy Systems and Utilities etc.

LEARNING RESOURCES

The learning environment is Blackboard which can be accessed at the following link. http://lms.curtin.edu.au/ In case of not having a password, you may have to activate your account through oasis with your date of birth first. Below is the link for OASIS. https://portal.curtin.edu.au/http://smportal.curtin.edu.au:8080/portal/dt For security reasons you may change your password if you wish and later you can access Blackboard with your new password.

LEARNING RESOURCES
Blackboard based material covering only lecture slides will be made available as supplemental material.

This is not a lecture/tutorial (problem-solving) course such as you have come to expect and become familiar.

There is no adequate textbook available that includes the range of topics to be covered, or the topics in relation to practical applications rather than theoretical considerations. For this reason the unit is designed as a library resource-based, reading and self-study module.

Students must be prepared to obtain information from journals and design handbooks, and also to spend a 'reasonable' amount of time reading and assessing/summarizing the best available material. The formal class sessions will only provide a starting point for study - an introduction or overview.

TEXT BOOK
You will need to purchase the following textbook in order to complete this unit: Peters, M. S. and Timmerhaus, K. D., 2003, 'Plant Design and Economics for Chemical th Engineers' 5 Edition, McGraw-Hill, New York.

Recommended Texts:
You do not have to purchase the following textbooks but you may like to refer to them. Walas, S. M., 1988, 'Chemical Process Equipment - Selection and Design', Buttersworths, USA. Sandler, H. J. and Luckiewwicz, E. T., 1987, 'Practical Process Engineering - A Working Approach to Plant Design', McGraw-Hill, New York. Green, D. W., 1984, 'Perry's Chemical Engineers Handbook' 6th Edition, McGraw-Hill, New York. Woods, D. R., 1995, 'Data for Process Design and Engineering Practice', Prentice Hall. Coulson, J. M. et al, 1994, 'Chemical Engineering Volume 6 - Design' 2nd Edition, Pergamon Press, UK. M S Ray & M G Sneesby "Chemical Engineering Design Project: A Case Study Approach"

Important Note: Library materials are essential for Process Plant Engineering 322. Supplementary materials (mainly photocopies scanned) in the Curtin E-Reserve which are also essential for the satisfactory learning of this unit. The following are required in Library Reserve section (or classified as Reference section) for access by all students at all times. Full details of the following can be obtained via the Curtin Library catalogue. Codes and Standards (1 copy of each except AS 1210) Complete Set of American Society for Testing and Materials (ASTM) Standards Australian Standard AS 1210: Unfired Pressure Vessels 3 copies ASME Boiler and Pressure Vessel Code, Section VIII, Divisions 1 and 2 British Standard BS5500: Unfired Pressure Vessel Design Code TEMA: Tubular Exchanger Manufacturers Association Heat Exchanger Design Code (USA) Books (3 copies of each) Walas, S.M., Chemical Process Equipment: Selection and Design, Butterworths USA (1988). Sandier, HJ., and Luckiewicz, E.T., Practical Process Engineering: A Working Approach to Plant Design, McGraw-Hill, New York (1987) Turton, R., et al.. Analysis, Synthesis, and Design of Chemical Processes, Prentice-Hall (1998). Moulijn, J.A., Makkee, M., and Van Diepen, A., Chemical Process Technology, Wiley (2001). Seider, W.D , Seader, J.D., and Lewin, DR., Process Design Principles, Wiley (2001). Felder, R.M., and Rousseau, RW, Eementary Principles of Chemical Processes, 3rd edn, Wiley (2000). Green, D W. (Ed.), Perry's Chemical Engineers' Handbook, 7th Edn, McGraw-Hill. New York (1995).

Woods, DR., Process Design and Engineering Practice, Prentice-Hall (1995). Woods, D.R., Data/or Process Design and Engineering Practice, Prentice-Hall (1995), Peters, M.S., and Timmerhaus, K D , Plant Design and Economics for Chemical Engineers, 4th Edn, McGraw-Hill, New York (1990). nd Coulson, J.M., Richardson, J.F., & Sinnott, R., Chemical Engineering Volume 6: Design, 2 Edn, Pergamon Press, UK (1994). 1 copy of each: Zappe, R.W, Valve Selection Handbook, 2nd Edn, Gulf Publishing, USA (1987). 621.84 ZAP Chuse, R., Pressure Vessels (ASME Code). 681.76041 CHU Nichols, R.W. (Ed.), Pressure Vessel Codes and Standards, Elsevier UK (1987). 681.76041 DEV AlChE, Pump Manual (Equipment Testing Procedures}, AlChE, New York (1960). 621.6 AME Chemical Engineering Deskbook, Pump and Valve Selector, 217 pages, 11 October 1971. 621.6CHE Weaver, R., Process Piping Design, Volume 2. Q665.53 WEA Pipelines: Design, Construction, and Operation. Q621.8672 PIP Process Piping Systems, Chemical Engineering, 120 pages, 17 June 1968. Q621.8672 PRO Chemical Engineering (N. Y.) magazine Reprint Volumes: Process Heat Exchange Q621.4022 PRO Process Energy Conservation Q660.28 PRO Separation Techniques (2 volumes) Q660.2842 SEP Process Technology and Flowsheets (2 volumes) Q660.28 PRO Fluid Movers: Pumps, Compressors, Fans, and Blowers Q621.6 FLU Process Piping Systems Q660.283 PRO Selecting Materials for Process Equipment Q660.282 MAT

Process Plant Engineering 322

Assessment Summary The assessment (continuous individual/group tasks with no final exam) for this unit consists of the following items.

Assessment Tasks

Due in Teaching Week

% marks

Assignment 1 (Individual submission) Wednesday,

11th September, 2013

5 9 12 4 11 TOTAL

7.5% 7.5% 35% 25% 25% 100%

Assignment 2 (Individual submission) - Wednesday, 9th

October, 2013

Project (Group submission maximum of 4 students only)

Monday, 4th November, 2013)

Test 1 (Wednesday, 28th August, 2013) Test 2 (Wednesday, 30th October, 2013)

Process Plant Engineering 518

Assessment Summary The assessment (continuous individual/group tasks with no final exam) for this unit consists of the following items.

Assessment Tasks

Due in Teaching Week 5 9 12 4 11 TOTAL

% marks

Assignment 1 (Individual submission)

Wednesday, 11th September, 2013

7.5% 7.5% 35% 25% 25% 100%

Assignment 2 (Individual submission) Wednesday, 9th October, 2013

Project (Group submission maximum of 4 students

only) Monday, 4th November, 2013

Test 1 (Wednesday, 28th August, 2013) Test 2 (Wednesday, 30th October, 2013)

Note: Assessments for postgraduates will be different in terms of time and complexity. All assignments
are to be submitted on their own except project task.

Process Plant Engineering 322

The tasks required for the project should be divided between all members of the team. Each team member is required to write up their section of the design and all sections combined into the final, composite report. This report should include executive summary, conclusions and recommendations. The project reports are due on Monday, 4th November, 2013.

Process Plant Engineering 518

All postgraduates are required to handle the project tasks in groups. Each team member is required to write up their section of the design and all sections combined into the final, composite report. This report should include executive summary, conclusions and recommendations. The project reports are due on Monday, 4th November, 2013. The University regards very seriously any acts of cheating, or dishonesty by way of plagiarism (claiming the work of others as your own). Penalties will be applied refer to Curtin Handbooks and Calender for further details.

Teaching schedule for PPE 322/518 (Semester 2, 2013)

Week Orientation 1. Begin Date
29 July

Lecture/ Seminar

Pre-readings

Tutorial/Other

Assessment Due

5 August

Introduction to design, block flow diagram P&IDs, Materials of construction Fluid Flow Process piping design

2. 3. 4. 5.

12 August

2 3 and 4 Test 1 Tuition Free Week

19 August 26 August 2 September

6.

9 September

Selection of piping materials, Pipe support design Valves, Pumps Pressure Vessel Design

4 and 5

Assignment 1

7. 8. 9. 10. 11.

16 September

6 7 Tuition Free Week

23 September 30 September 7 October

Pressure Vessel Design Pressure Vessel Design Pressurized Systems, Foundation Design Plant Utilities

8 9

Assignment 2

14 October

12.

21 October

10

13. 14. 15. 16. 17

28 October 4 November 11 November 18 November 25 November

Test 2 Project Study Week Examinations Examinations

Lecture/Tutorial schedules (PPE322/518)

Activity

Class No. 1 1 3 2 1

Day

Start Time End Time 14:00 11:00 14:00 17:00 13:00 16:00 13:00 15:00 18:00 14:00

BuildingRoom 402.220 402.220 202.122 300.217 300.217

Lecture 1 Lecture 2 Tutorial Tutorial Tutorial

Wednesday Monday Tuesday Monday Friday

Assessments and Due Dates

Assignment 1 (Individual submission) Wednesday, 11th September, 2013 Assignment 2 (Individual submission) - Wednesday, 9th October, 2013 Project (Group) max of 4 students only) Monday, 4th November, 2013

Test 1 - 2-4 pm, Wednesday, 28th August, 2013 (402.220)

Test 2 - 2-4 pm, Wednesday, 30th October, 2013 (402.220)

All assignments and project reports are to be submitted in Assignments Office on level 2 in engineering building 204.

Important note

Important note: Chemical Engineering Department will provide an HP10S Scientific Calculator to each student to use for their examinations and for the rest of the course.

 Feedback is any information that is designed to help you gauge your learninghow

What is Feedback?

much you have learned, whether you are learning the right things and the quality or depth of your learning. It is designed to make you think about your learning and what you can do to improve it. the front of your unit outline. Also note the syllabus statement which indicates the content of the unit.

To know what you should be learning, carefully read the Unit Learning Outcomes on

Marks Marks on your work are of limited value only. A 60% on an assignment for example does not necessarily mean that you know 60% of what you should know. It does not tell you whether or not you have achieved a satisfactory standard or have demonstrated a required learning outcome. A 60% on an assignment in one unit does not necessarily mean the same as a 60% on an assignment in another unit. However, a pattern of marks (in units or in components of units) over time does tell you whether your study skills and knowledge-development are improving, holding steady or worsening. Trends in marks give you early-warning signs which are a useful form of feedback.

What is Feedback?
Comments written on your work If you receive written comments on your work, please read them carefully. If you dont understand the comments, talk to your tutor. This is personal feedback designed to help you improve. Ticks on a scoring rubric If you have been given a scoring rubric (table that describes different standards of work) note the descriptors for each grade of work, in particular, where you have not achieved the highest grade. This shows you the shortcomings in your work and, often, in which aspects you can do better next time. When lecturers and tutors talk to the class Often, lecturers or tutors will discuss assignments or tests in general terms in class. This is feedback. Learn what you can from these talks, even if everything does not appear to apply to you.

What is Feedback?
When a tutor or lecturer talks to you personally Sometimes a tutor will comment on your work in class, laboratories or in a casual/chance meeting. Sometimes they will ask you questions. Take note as they are giving you informal feedback. Ask for more information. Anything else? Lecturers may post model solutions, exemplary answers, or particularly bad answers to assignments. This shows you expected standards and is therefore feedback. Some lecturers hand out a short summary of good or bad points in assignments. Do any apply to you? Some lecturers may ask you to mark or assess other students work. This provides great feedback as you learn to judge the standard of work and learning. Finally feedback only has real value if you learn from it by taking the actions necessary to improve your academic performance!

STUDENT FEEDBACK For Semester 1 and Semester 2 eVALUate is open for student feedback in teaching weeks 7-12. For other study periods see

http://evaluate.curtin.edu.au/info/dates
We welcome your feedback as one way to keep improving this unit. Later this semester, you will be encouraged to give unit feedback through eVALUate, Curtins online student feedback system (see http://evaluate.curtin.edu.au).

In Sem 2, 2012 the response rate was around 38% with total enrolments being 177 including postgraduates students. This unit helped me visualize what an engineer does in working life .. It has helped me understand my abilities more. The most helpful aspect were the assignments, which helped me see clearly what design is all about... By doing assignment and project, I think I can understand this subject better. Lots of work constantly meant that this unit got priority over others thus it ended up being second nature to study

Following feedback concerning number of assessments and workload, assignments have been reduced from 4 group submissions to 2 individual submissions.

Introduction to Design
Design
Creative activity one of the most rewarding activities undertaken by an engineer

What is design??
It is a synthesis combining ideas together to achieve a desired purpose

Designer
Starts with an objective in mind develops and evaluates possible designs arrives at the best scenario for achieving the goal for eg. It could be chair, a new bridge or for a chemical engineer, a new chemical product

Introduction to Design (contd.)

Possible designs
designer needs to narrow down the number of possible designs on what basis? Depending on the nature of constraints

Constraints??

Physical laws, government regulations and standards (fixed constraints) Other constraints could be less rigid Constraints that are outside the designers influence (external) Economic constraint ==> a major one in any engineering design
eg. Plants must make a profit.

Time will also be a constraint

Design stages

Design Objective
Design
it is a conversion of an ill-defined requirement into a

satisfied customer

Whats the designer role

Fulfilling a particular need
public need for the product or the commercial opportunity as foreseen by the sales and

marketing organisation

Designer Requirements
Designer requires a complete statement of the requirements as

far as possible

If the requirement (need) arises from outside the design group,

from a client from another department (What to do??)

Designer has to elucidate the real needs through discussion. One has to distinguish between the real needs and the wants Wants are the desirable ones (can be flexible)
for eg. Product specification (sales department may consider it as desirable

but may be difficult and costly to obtain). Hence relaxation is possible.

Data Collection
Before proceeding with a design
the designer must gather all the relevant facts and data required

(What sort of data??) For process design ==> information on possible processes, equipment performance, physical property data This stage can be one of the most time consuming & frustrating aspects of design (Whats the solution??)
Preparation of basic data manual containing all the information (many

companies do this)

Many organisations have design manuals covering preferred methods and data for the more frequently used, routine, design procedures National standards also good sources of design methods and data

Possible Design Solutions

Creative part of the design process involves the generation of possible design solutions designer will largely rely on previous experience of his own or others usually experienced will wisely prefer the tested and tried methods (not the untried novel design methods) Chemical Engineering projects (three types) Modifications and additions to existing plant (handled by plant design group)
New production capacity to meet growing sales demand and the sale of established

processes by contractors (done by repeating existing designs with minor design changes)

New processes (R&D), developed from laboratory research, through pilot plant, to a

commercial process (even here, most of the unit operations, process equipment will use the established designs) done in collaboration with a university or well known scientific institute

Selection Process
Probable designs likely candidates

Selection process will go through the following stages:

Possible designs (credible) within the external constraints Plausible designs (feasible) within the internal constraints Best design (optimum) judged by the best solution to the problem

Selection process will become more detailed and more refined

as the design progresses from the area of possible to probable solutions

Early stages
a coarse screening based on common sense, engineering judgement and rough costing

will usually suffice for eg. it would not take that much time to narrow down the choice of raw materials for NH3 manufacture from possible candidates of say wood, peat, coal, natural gas or oil to a choice of oil and gas (Note: Tutorial 1 - problem 1 is formulated along these lines)

Detailed design and costing is needed

to move from probable to best design

Anatomy of Chemical Process

 Stage 1 ==> Raw material storage

Anatomy of Chemical Process

Why?? To smooth out fluctuations and interruptions in supply Why?? Some purification is essential before it is fed to reaction stage liquid feeds are vaporised before fed to gas-phase reactors solids may need crushing, grinding and screening (coal-fired utilities) some require removal of impurities

Stage 2 ==> Feedstock preparation

Stage 3 ==> Reactor

This is the heart of a chemical manufacturing process this is where the raw materials are brought together under conditions that promote the production of the desired material

Stage 4 ==> Product preparation

to separate unwanted material and recycle

Stage 5 ==> Purification (to meet product specification) Stage 6 ==> Product storage (may be held to match the sales)

 Provisions have to be made for supply of services (utilities)

What are these?? Process water, compressed air, cooling water, steam facilities also needed for maintenance, fire fighting, offices, accommodation and in-house lab facilities

Ancillary Processes

Processes are of two types

Continuous usually be more economical for large scale production > 5 x 106 kg/h situations involving single product, no severe fouling, good catalyst life, proven process design, established market Batch are used where some flexibility in production rate (< 5 x 106 kg/h) or product specification situations involving severe fouling, short catalyst life, new product, uncertain design

Structure of a Chemical Engineering Project

Structure of a Chemical Engineering Project

Organisation of Chemical Engineering project

Project Documentation
This will include
General correspondence within the design group and with

government departments, equipment vendors, site personnel Calculation sheets covering design calculations, costing, computer print-out Drawings covering flow-sheets, P&IDs, layout diagrams, plant/site plans, equipment details, piping diagrams, architectural drawings, design sketches Specification sheets for equipment such as heat exchangers, pumps, valves etc. Purchase orders covering quotations, invoices
All documents will be assigned a code number for easy cross

referencing, filing and retrieval.

Codes and Standards

When did the need arise for standardisation
Early in the evolution of the modern engineering industry

Who introduced the first standard?

Joseph Witworth for a screw thread to give a measure of

interchangeability between different manufacturers in 1841

Proposed to Institution of Civil Engineers universal set of specifications for the

angle and pitch of screw threads

Modern engineering standards

Cover a much wider function than the interchange of parts

What these codes and standards cover for engineering practice??

Materials, properties and compositions Testing procedures for performance, compositions and quality Preferred sizes; for eg. Tubes, plates, sections Design methods, inspection, fabrication Codes of practice, for plant operation and safety

Codes and Standards

Whats the difference between codes and standards??
Codes are used for a code of practice, covering say, a recommended

design or operating procedure Standards are preferred for sizes, compositions etc.
Developed and many developing countries

have national standards organisations responsible for the issue and maintenance of standards for the

manufacturing industries and for the protection of customers

United Kingdom
Preparation and promulgation of national standards are the

responsibility of the BRITISH STANDARDS INSTITUTION (BSI) Comprises of which people??

Persons from appropriate industry, the professional engineering institutions

and other interested organisations

Codes and Standards

United States
NATIONAL BUREAU OF STANDARDS Standards are issued by Federal, State and various commercial organisations

Principal ones of interest to chemical engineers are

American National Standards Institute (ANSI) American Petroleum Institute (API) American Society of Testing Materials (ASTM) American Society of Mechanical Engineers (ASME) Pressure Vessels

International Organisation for Standardisation (ISO)

Coordinates the publication of international standards

Many organisations have their own standards and codes of their own (in-house) Equipment manufacturers also work to standards to generate designs and size ranges

for commonly used items, such as electric motors, pumps, pipes and pipe fittings.

Factors of Safety
Why safety factors??
To absorb errors and uncertainties in the available design data

In mechanical and structural design

Used to allow for uncertainties in material properties, design methods,

fabrication and operating loads. For eg. a factor of 4 on the tensile strength, or about 2.5 on the 0.1% of proof stress, is normally used in structural design
In process design
Used to give some tolerance in design For eg. The process stream average flows calculated from material balances

are usually increased by 10% Why this is done??

to give some flexibility in process operation. This factor will set the maximum flows

for equipment, instrumentation and piping design

Lecture 2-Block-Process-Flow-Diagrams.ppt