Welcome

Plant Design & Chemical Engineering

Department of IAC, Lean Institute of Technology
Course: PGDIAC-1909
Instructor: Jamal Safdar
https://www.lit.leanautomation.com/Courses/PGDIAC

22/12/2019© Lean Institute of Technology BAT-01 PGDIAC-1909

What we`ll cover this morning
• Design Introduction
• Objective
• Design Procedure
• Data collection
• Possible design solutions
• Anatomy of Process
• Organization of project
• Project Documentation
• Codes and Standards
Introduction to Design
Design is the synthesis, the putting together of ideas to achieve a
desired purpose.
Design Objective
According to Chaddock (1975), design is

“ the conversion of an ill-defined requirement into a satisfied

customer”.
Data Collection
• Civil data
• Data for possible process
• Equipment needed
• Equipment Performance
• Physical and chemical property
• Industrial automation
• Sales
Possible Design Solution
Aim is to generate possible solutions to the problems for analysis,
evaluation and selection.

Usually the tried and tested methods are preferred. Keeping that in
mind, design project is divided in three steps,
1. Modification and Addition to existing design
2. New Production capacity to meet growing sales demand.
3. New process, developed in laboratory research to a commercial
process.
Anatomy of Chemical Process
Organization of Project
Project Documentation
• General Correspondence with design group and
• Government departments
• Equipment vendors
• Site personnel
• The client
• Calculation sheets
• Design calculations
• Costing
• Computer print-outs
Contd.
• Drawings
• Flow sheets
• P&IDs
• Layout diagrams
• Plot/site plans
• Equipment Details
• Piping diagrams
• Architectural drawings
• Design Sketches
Contd.
• Specification Sheets
• For all equipment like heat exchanger, pumps etc

• Purchase Orders
• Quotations
• Invoices
Codes and Standards
• Material , properties and composition
• Testing procedure for performance, composition, quality
• Preferred sizes ; for example tubes, plates, sections
• Design methods, inspections, fabrication
• Codes of practice, for plant operation and safety
Optimization

• Design is the optimization

• Selection of design is based on the most optimized techniques.
Flow Sheeting

• It is the basis for a design.

• Includes piping, instrumentation, equipment design and plant layout.
• Material balance and energy balance calculations are also used in
flow sheet design.
Flow Sheet Presentation
• Block Diagrams
• Pictorial Representation
• Presentation of Stream Flow Rates
Flow sheet Presentation
• Information to be included
• Stream composition (Flow rate or weight fraction)
• Total stream flow
• Stream temperature
• Operating pressure
• Optional Information
• Molar percentages
• Physical property data
• Stream name
• Stream enthalpy
Flow sheet Presentation
• Layout
• Precision of data
• Basis of calculation
• Batch Process
• Services/Utilities
• Equipment Identification
Piping and Instrumentation Diagram
P&ID shows the engineering details of the equipment, instrument,
piping, valves and fittings; and their arrangement.
It should include
• All process equipment identified by equipment number.
• All piper identified by line number.
• All valves, control and block valves with identification numbers.
• Ancillary fittings (inline sight glasses, strainers, steam traps)
• Pumps identified by suitable code number.
• All control loops and instruments with identification number.
Identification Letters and symbols (ISA 5.1)
Sample P&ID
Costing and Project Evaluation
• Accuracy and Purpose of cost estimates
• Fixed and working capital
• Operating Cost
• Economic evaluation of Project
Materials of constructions
Material Properties
• Mechanical Properties
• Strength – tensile strength
• Stiffness – elastic module
• Toughness – Fracture resistance
• Hardness – wear resistance
• Fatigue resistance
• Creep resistance
• Effect of temperature
• Corrosion resistance
• Special properties (thermal conductivity, electrical resistance,
magnetic properties)
• Ease of fabrication – Forming, welding, casting
• Availability
• Cost
Corrosion Resistance
Classification of corrosion
• Uniform corrosion
• Galvanic corrosion
• Pitting
• Intergranular corrosion
• Stress Corrosion
• Erosion
• Fatigue
• High temperature oxidation
• Hydrogen embrittlement
Design Information and Data
Sources of Information on Manufacturing Process
• World Wide Web
• Internet Sources
• Heriot Watt University
• Edinburg UK
• Karlsruhe
• Useful Gateways
• EEVL (Edinburg Engineering virtual Library)
• WWW virtual Library
Safety and Loss Prevention

• Intrinsic Safety
• Extrinsic Safety
• The Hazards
• Toxicity
• Flammability
• Explosions
• Sources of Ignition
• Ionising Radiation
• Pressure
• Temperature Deviation
• Noise
General Preventive and Protective Measures
• Adequate and secure water supplies for fire fighting
• Correct structural design of vessels, piping, steel work
• Pressure relief devices
• Corrosion resistant material
• Segregation of reactive material
• Earthing of electrical equipment
• Safe location of auxiliary electrical equipment, transformers etc
• Provision of backup utility supplies and services
• Compliance with national code and standards
• Fail safe instrumentation
• Provision of access of emergency vehicle and evacuation of personnel.
• Adequate drainage for spills and fire fighting water.
• Insulation of hot surfaces.
• No glass equipment used for flammable or hazardous material.
• Adequate separation for hazardous equipment.
• Protection of pipe racks and cable trays from fire.
• Provision of block valves on line to main processing areas.
• Protection of fired equipment against accidental explosion and fire.
• Safe design and location of control rooms