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Chemical Engineering Design
Industrial Process
Design
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
1. Design Work Process
Determine
Customer Needs
Set Design
Specifications
R&D if Needed
Evaluate Economics
& Select Design
Predict Fitness
For Service
Build Performance
Models
Generate Design
Concepts
Procurement
& ConstructionBegin Operation
Customer
Approval
Detailed Design &
Equipment Selection
Common to all design problems in all industries© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
How do companies implement this
design process?
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
2. The Design Team
Project
Sponsor
ContractorsCivil
Engineers
Business
Input
R&D
Specialists
Technical
SpecialistsCost Engineer
Control
EngineerConsultants
Mechanical
Engineer(s)
Process
Engineer(s)
Project
Manager
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Specialization and Outsourcing
Operating Companies
• Own plants
• Produce chemicals
• High sales revenue
• Margins & return on assets (ROA) vary by sector
Technology Vendors
• Own patents
• Sell catalysts, enzymes, equipment, licenses
• Sales volume low
• Margins, ROA usually high
Engineering & Construction Companies
• Experienced project managers
• Highly competitive & cost effective
• Medium sales volume, low margins
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Company Performance by Sector
Notes:
• Data from www.CNN.money.com as of 7.2.07
• Oil industry is usually not so profitable as during 2005-2007
• Technology companies are usually smaller, and are often subsidiaries or privately held. Financial data are often not publicly available.
Company Symbol Market Cap Revenue Profit Margin ROA
($ billion) ($ billion) % %
ExxonMobil XOM 472.5 365.5 10.8 18.1
Valero Energy VLO 40.55 91.8 5.9 15.1
Dow DOW 42.7 49.1 7.6 7.6
DuPont DD 47.3 27.4 13.5 10.1
Pfizer PFE 179.5 48.4 40 16.9
Merck MRK 107.9 22.6 19.6 10.7
Shaw Group SGR 3.8 4.8 1.1 NA
Fluor FLR 9.8 14.1 1.9 5.1
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Long ago (<1980s) most projects were done “in
house”
Project
Sponsor
ContractorsCivil
Engineers
Business
Input
R&D
Specialists
Technical
SpecialistsCost Engineer
Control
EngineerConsultants
Mechanical
Engineer(s)
Process
Engineer(s)
Project
Manager
E&C
CompanyTechnology
Vendor
Operating
Company
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Nowadays(For most companies, most sectors)
Project
Sponsor
ContractorsCivil
Engineers
Business
Input
R&D
Specialists
Technical
SpecialistsCost Engineer
Control
EngineerConsultants
Mechanical
Engineer(s)
Process
Engineer(s)
Project
Manager
E&C
Company
Technology
Vendor
Operating
Company
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Implications
• Most major projects involve several companies working together
• “OpCo” might itself be a joint venture between several companies
• The companies might all be based in different regions of the world
• Teamwork, technology transfer and effective communications have high impact and value
• Good project management is more important than ever
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
3. The Project Plan
Project must be delivered:
• On-time
• On-budget
• OpCo usually writes
incentives into the E&C
contract to ensure that
this happens
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Design Work Process
Determine
Customer Needs
Set Design
Specifications
R&D if Needed
Evaluate Economics
& Select Design
Predict Fitness
For Service
Build Performance
Models
Generate Design
Concepts
Procurement
& ConstructionBegin Operation
Customer
Approval
Detailed Design &
Equipment Selection
This takes timeThis also needs time
These steps
have to
come first
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
The Project Plan
• Is developed & implemented by the project manager
• Sets deadlines for completion of activities & intermediate deliverables
• Allows scheduling of subordinate or dependent tasks
• Allows estimation of the required manpower resources at each stage of the project
• Determines the procurement schedule & gives an estimate of when cash outlays are expected
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Example: 11-Week Plan for a Process Design Project
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
What’s In a Project Plan?
List of tasks
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
What’s In a Project Plan?
Durations, start
and end dates
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
What’s In a Project Plan?
Predecessor
tasks
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
What’s In a Project Plan?
Resource
allocations
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
What’s In a Project Plan?
Gantt
chart
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Example: 11-Week Plan for a Process Design Project
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Tools for Project Planning
• Specialized software for larger projects
– MS Project
– SureTrak
– Primavera Project Planner
– Enterprise PM
– Cobra
• Small project plans & Gantt charts can be drawn in spreadsheets or using cheap software (<$100)
– AceProject (free on-line)
– TurboProject
– Project Vision
– Quick Gantt
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
4. The Design Basis
We need to know:
• What are we designing? How much of it do we want?
• Where will it be built? What are the boundary conditions?
Determine
Customer Needs
Set Design
Specifications
R&D if Needed
Evaluate Economics
& Select Design
Predict Fitness
For Service
Build Performance
ModelsGenerate Design
Concepts
Procurement
& ConstructionBegin Operation
Customer
Approval
Detailed Design &
Equipment Selection
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Process Design Basis• Documentation of design
assumptions and boundary
conditions is very important
• For new process plants, most
companies use some sort of
design basis form or questionnaire
to serve as a record of the design
basis
• This record is also essential in
handing off information between
the operating company, technology
suppliers and contractors
• There’s a template online at:
booksite. Elsevier.com/Towler
http://booksite.elsevier.com/9780080966595/
Sheet
REV DATE BY APVD REV DATE BY APVD
Correspondance Contacts
Address
Telephone / Fax
English Metric
3
AC Air cooler G Grinder, mill R Reactor
B Boiler H Heater (fired or electric) SP Sample point
C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
CT Cooling tower M Mixer V Vessel (including columns)
D Dryer ME Miscellaneous equipment
First digit - process section E Exchanger P Pump
Second & third digits - equipment count F Filter, classifier PRV Pressure relief valve
4
Product Name
Product Grade
MSDS Form Number
Production Rate
Tons per year
Tons per day
Other units
Product Purity (wt%)
Product shipment mode
Additional Specifications
5
Feedstock name
Feedstock grade
MSDS form number
Feedstock availability
Tons per year
Tons per day
Other units
Feedstock price ($/lb)
(Default: open market price)
Known feedstock impurities ppmw ppmw ppmw ppmw
Additional specifications
DESIGN BASIS
Form XXXXX-YY-ZZ
6
Maximum wind loading (mph)
Other site design requirements
Low ambient temperature (F)
High ambient temperature (F)
Site elevation (ft)
Hight ambient relative humidity (%)
NameNameNameName
Primary Raw Materials
(Attach additional sheets if needed)
2
1
Owners Name
Process Unit Name
Plant Location
Site Information
Equipment Numbering System
Primary Products
General Information
Measurement System
Equipment will be identified by alphabetic
prefix as defined here, followed by three-
digit serial number unless otherwise
indicated
1Company Name
Project Name
Project Number
Address
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
What’s in the Design Basis?
Project information and revision tabs
• To allow retrieval of documentation
• To ensure that revisions are properly documented and make sure that the engineers aren’t working from the wrong version
• To document review and approval of the design basis
Sheet
REV DATE BY APVD REV DATE BY APVD
Correspondance Contacts
Address
Telephone / Fax
English Metric
3
AC Air cooler G Grinder, mill R Reactor
B Boiler H Heater (fired or electric) SP Sample point
C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
CT Cooling tower M Mixer V Vessel (including columns)
D Dryer ME Miscellaneous equipment
First digit - process section E Exchanger P Pump
Second & third digits - equipment count F Filter, classifier PRV Pressure relief valve
4
Product Name
Product Grade
MSDS Form Number
Production Rate
Tons per year
Tons per day
Other units
Product Purity (wt%)
Product shipment mode
Additional Specifications
5
Feedstock name
Feedstock grade
MSDS form number
Feedstock availability
Tons per year
Tons per day
Other units
Feedstock price ($/lb)
(Default: open market price)
Known feedstock impurities ppmw ppmw ppmw ppmw
Additional specifications
DESIGN BASIS
Form XXXXX-YY-ZZ
6
Maximum wind loading (mph)
Other site design requirements
Low ambient temperature (F)
High ambient temperature (F)
Site elevation (ft)
Hight ambient relative humidity (%)
NameNameNameName
Primary Raw Materials
(Attach additional sheets if needed)
2
1
Owners Name
Process Unit Name
Plant Location
Site Information
Equipment Numbering System
Primary Products
General Information
Measurement System
Equipment will be identified by alphabetic
prefix as defined here, followed by three-
digit serial number unless otherwise
indicated
1Company Name
Project Name
Project Number
Address
Sheet
REV DATE BY APVD REV DATE BY APVD
1
Project Name
Project Number
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
What’s in the Design Basis?
Contact information
• Company name
• Process unit name
• Who to contact & where to reach them
Sheet
REV DATE BY APVD REV DATE BY APVD
Correspondance Contacts
Address
Telephone / Fax
English Metric
3
AC Air cooler G Grinder, mill R Reactor
B Boiler H Heater (fired or electric) SP Sample point
C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
CT Cooling tower M Mixer V Vessel (including columns)
D Dryer ME Miscellaneous equipment
First digit - process section E Exchanger P Pump
Second & third digits - equipment count F Filter, classifier PRV Pressure relief valve
4
Product Name
Product Grade
MSDS Form Number
Production Rate
Tons per year
Tons per day
Other units
Product Purity (wt%)
Product shipment mode
Additional Specifications
5
Feedstock name
Feedstock grade
MSDS form number
Feedstock availability
Tons per year
Tons per day
Other units
Feedstock price ($/lb)
(Default: open market price)
Known feedstock impurities ppmw ppmw ppmw ppmw
Additional specifications
DESIGN BASIS
Form XXXXX-YY-ZZ
6
Maximum wind loading (mph)
Other site design requirements
Low ambient temperature (F)
High ambient temperature (F)
Site elevation (ft)
Hight ambient relative humidity (%)
NameNameNameName
Primary Raw Materials
(Attach additional sheets if needed)
2
1
Owners Name
Process Unit Name
Plant Location
Site Information
Equipment Numbering System
Primary Products
General Information
Measurement System
Equipment will be identified by alphabetic
prefix as defined here, followed by three-
digit serial number unless otherwise
indicated
1Company Name
Project Name
Project Number
Address
Correspondance Contacts
Address
Telephone / Fax
1
Owners Name
Process Unit Name
Plant Location
General Information
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
What’s in the Design Basis?
Conventions followed
• Units of measurement– Customer specific and may also depend on location
– Design engineers have to be able to work with both metric and English units
• Equipment labeling convention
• Sometimes other conventions and codes, e.g. design codes
Sheet
REV DATE BY APVD REV DATE BY APVD
Correspondance Contacts
Address
Telephone / Fax
English Metric
3
AC Air cooler G Grinder, mill R Reactor
B Boiler H Heater (fired or electric) SP Sample point
C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
CT Cooling tower M Mixer V Vessel (including columns)
D Dryer ME Miscellaneous equipment
First digit - process section E Exchanger P Pump
Second & third digits - equipment count F Filter, classifier PRV Pressure relief valve
4
Product Name
Product Grade
MSDS Form Number
Production Rate
Tons per year
Tons per day
Other units
Product Purity (wt%)
Product shipment mode
Additional Specifications
5
Feedstock name
Feedstock grade
MSDS form number
Feedstock availability
Tons per year
Tons per day
Other units
Feedstock price ($/lb)
(Default: open market price)
Known feedstock impurities ppmw ppmw ppmw ppmw
Additional specifications
DESIGN BASIS
Form XXXXX-YY-ZZ
6
Maximum wind loading (mph)
Other site design requirements
Low ambient temperature (F)
High ambient temperature (F)
Site elevation (ft)
Hight ambient relative humidity (%)
NameNameNameName
Primary Raw Materials
(Attach additional sheets if needed)
2
1
Owners Name
Process Unit Name
Plant Location
Site Information
Equipment Numbering System
Primary Products
General Information
Measurement System
Equipment will be identified by alphabetic
prefix as defined here, followed by three-
digit serial number unless otherwise
indicated
1Company Name
Project Name
Project Number
Address
English Metric
3
AC Air cooler G Grinder, mill R Reactor
B Boiler H Heater (fired or electric) SP Sample point
C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
CT Cooling tower M Mixer V Vessel (including columns)
D Dryer ME Miscellaneous equipment
First digit - process section E Exchanger P Pump
Second & third digits - equipment count F Filter, classifier PRV Pressure relief valve
2
Equipment Numbering System
Measurement System
Equipment will be identified by alphabetic
prefix as defined here, followed by three-
digit serial number unless otherwise
indicated
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
What’s in the Design Basis?
Product information for primary products
• Product grades desired
• Safety data sheet reference number
• Production rate, purity, shipment details
Sheet
REV DATE BY APVD REV DATE BY APVD
Correspondance Contacts
Address
Telephone / Fax
English Metric
3
AC Air cooler G Grinder, mill R Reactor
B Boiler H Heater (fired or electric) SP Sample point
C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
CT Cooling tower M Mixer V Vessel (including columns)
D Dryer ME Miscellaneous equipment
First digit - process section E Exchanger P Pump
Second & third digits - equipment count F Filter, classifier PRV Pressure relief valve
4
Product Name
Product Grade
MSDS Form Number
Production Rate
Tons per year
Tons per day
Other units
Product Purity (wt%)
Product shipment mode
Additional Specifications
5
Feedstock name
Feedstock grade
MSDS form number
Feedstock availability
Tons per year
Tons per day
Other units
Feedstock price ($/lb)
(Default: open market price)
Known feedstock impurities ppmw ppmw ppmw ppmw
Additional specifications
DESIGN BASIS
Form XXXXX-YY-ZZ
6
Maximum wind loading (mph)
Other site design requirements
Low ambient temperature (F)
High ambient temperature (F)
Site elevation (ft)
Hight ambient relative humidity (%)
NameNameNameName
Primary Raw Materials
(Attach additional sheets if needed)
2
1
Owners Name
Process Unit Name
Plant Location
Site Information
Equipment Numbering System
Primary Products
General Information
Measurement System
Equipment will be identified by alphabetic
prefix as defined here, followed by three-
digit serial number unless otherwise
indicated
1Company Name
Project Name
Project Number
Address
Product Name
Product Grade
MSDS Form Number
Production Rate
Tons per year
Tons per day
Other units
Product Purity (wt%)
Product shipment mode
Additional Specifications
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
What’s in the Design Basis?
Information for primary raw materials
• Feedstock grades
• Safety information
• Availability and pricing
• Feed impurities and their concentrations
Sheet
REV DATE BY APVD REV DATE BY APVD
Correspondance Contacts
Address
Telephone / Fax
English Metric
3
AC Air cooler G Grinder, mill R Reactor
B Boiler H Heater (fired or electric) SP Sample point
C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
CT Cooling tower M Mixer V Vessel (including columns)
D Dryer ME Miscellaneous equipment
First digit - process section E Exchanger P Pump
Second & third digits - equipment count F Filter, classifier PRV Pressure relief valve
4
Product Name
Product Grade
MSDS Form Number
Production Rate
Tons per year
Tons per day
Other units
Product Purity (wt%)
Product shipment mode
Additional Specifications
5
Feedstock name
Feedstock grade
MSDS form number
Feedstock availability
Tons per year
Tons per day
Other units
Feedstock price ($/lb)
(Default: open market price)
Known feedstock impurities ppmw ppmw ppmw ppmw
Additional specifications
DESIGN BASIS
Form XXXXX-YY-ZZ
6
Maximum wind loading (mph)
Other site design requirements
Low ambient temperature (F)
High ambient temperature (F)
Site elevation (ft)
Hight ambient relative humidity (%)
NameNameNameName
Primary Raw Materials
(Attach additional sheets if needed)
2
1
Owners Name
Process Unit Name
Plant Location
Site Information
Equipment Numbering System
Primary Products
General Information
Measurement System
Equipment will be identified by alphabetic
prefix as defined here, followed by three-
digit serial number unless otherwise
indicated
1Company Name
Project Name
Project Number
Address
Feedstock name
Feedstock grade
MSDS form number
Feedstock availability
Tons per year
Tons per day
Other units
Feedstock price ($/lb)
(Default: open market price)
Known feedstock impurities ppmw
Additional specifications
Name
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
What’s in the Design Basis?
Site information
• Ambient conditions needed for design of insulation, air coolers, etc.
• Special conditions such as wind loads, hurricane and earthquake conditions that are needed for mechanical and civil engineering design
Sheet
REV DATE BY APVD REV DATE BY APVD
Correspondance Contacts
Address
Telephone / Fax
English Metric
3
AC Air cooler G Grinder, mill R Reactor
B Boiler H Heater (fired or electric) SP Sample point
C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
CT Cooling tower M Mixer V Vessel (including columns)
D Dryer ME Miscellaneous equipment
First digit - process section E Exchanger P Pump
Second & third digits - equipment count F Filter, classifier PRV Pressure relief valve
4
Product Name
Product Grade
MSDS Form Number
Production Rate
Tons per year
Tons per day
Other units
Product Purity (wt%)
Product shipment mode
Additional Specifications
5
Feedstock name
Feedstock grade
MSDS form number
Feedstock availability
Tons per year
Tons per day
Other units
Feedstock price ($/lb)
(Default: open market price)
Known feedstock impurities ppmw ppmw ppmw ppmw
Additional specifications
DESIGN BASIS
Form XXXXX-YY-ZZ
6
Maximum wind loading (mph)
Other site design requirements
Low ambient temperature (F)
High ambient temperature (F)
Site elevation (ft)
Hight ambient relative humidity (%)
NameNameNameName
Primary Raw Materials
(Attach additional sheets if needed)
2
1
Owners Name
Process Unit Name
Plant Location
Site Information
Equipment Numbering System
Primary Products
General Information
Measurement System
Equipment will be identified by alphabetic
prefix as defined here, followed by three-
digit serial number unless otherwise
indicated
1Company Name
Project Name
Project Number
Address
Maximum wind loading (mph)
Other site design requirements
Low ambient temperature (F)
High ambient temperature (F)
Site elevation (ft)
Hight ambient relative humidity (%)
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
What’s in the Design Basis?
Sheet 2 of the Design Basis has utility information
• Fuel gases
• Fuel oils
• Steam levels
• Coolants
• Process water
• Electricity
• Process Air
Conditions, availability, price, etc.
Sheet
REV DATE BY APVD REV DATE BY APVD
7
Gas source or operation mode
Supply header temperature (F)
Supply header pressure (psia)
Net calorific value (BTU/lb)
Marginal availability (lb/h)
Marginal fuel cost ($/MMBTU)
Sulfur content (wppm)
Nitrogen content (wppm)
Chlorine content (wppm)
Gas composition (vol%)
H2O
O2
N2
CO
CO2
H2S
H2
CH4
C2H4
C2H6
C3H6
C3H8
C4H8
iC4H10
nC4H10
C5H10
C5+
Fuel source or operation mode
Supply header temperature (F)
Supply headder pressure (psia)
Net calorific value (BTU/lb)
Marginal availability (lb/h)
Marginal fuel cost ($/MMBTU)
Fuel viscosity at F
Fuel viscosity at F
Flash point (F)
Pour point (F)
Sulfur content (wppm)
Nitrogen content (wppm)
Ash content (wt %)
Steam header classification
Operating pressure (psia)
Operating temperature (F)
Mechanical design pressure (psia)
Mechanical design temperature (F)
Marginal availability (lb/h)
Marginal cost ($/Mlb)
Coolant classification
Operating pressure (psia)
Supply temperature (F)
Maximum return temperature (F)
Marginal availability (lb/h)
Marginal cost ($)
Marginal cost units
Water feed stream
Supply pressure (psia)
Supply temperature (F)
Marginal availability (lb/h)
Marginal cost ($/1000 gal)
Total dissolved solids (wt%)
Hardness as CaCO3 (ppmw)
Chloride as Cl (ppmw)
Metallurgy
Power range (kW)
Voltage (V)
Phase
Frequency (Hz)
Marginal availability (kW)
Marginal cost ($/kWh)
Air stream
Header pressure (psia)
Header temperature (F)
Moisture (ppmw)
Marginal availability (lb/h)
Marginal cost ($/Mscf)
Fuel Gas
Fuel Oil
Steam
Coolants
Process Water Feeds
Electric power
Plant air streams
DESIGN BASIS
Form XXXXX-YY-ZZ
Condensate
LP
Plant Nitrogen
Boiler Feed Water
Chilled Water
MP
Instrument Air
Process Water
Once-Through Water
Plant Air
Raw Water
Nat Gas
#2 Heating Oil
VHP
Cooling Tower Water
HP
Utility Information
Project Name
Project Number 2Company NameAddress
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Learning activities
Enter the site: booksite.Elsevier.com / Towler ,
download the design basis template; complete the
general information of the study case.
© 2007 G.P. Towler / UOP. For educational use in conjunction with
Sinnott & Towler Chemical Engineering Design only. Do not copy
Chemical Engineering Design
5. Design Practices: Codes & Standards
• Methods and rules for designing processes and equipment are given in design codes of practice
• Codes are set by national or international industry panels (e.g., ISO, ASME, API, ISA)
• Codes are reviewed and reissued frequently
• Codes specify practices for design, construction, testing and operation of equipment and processes, that are expected to lead to a safe design, based on the experience of the code committee
• Design in accordance with code is usually required by the company or by law
• Standard sizes for piping & equipment, compositions, etc. are given in standards
• Tubing dimensions, valve sizes, exchanger layouts, screw threads, wire gauges, screens, …
• The two terms tend to be used interchangeably
• Always consult the current (latest) edition of the code. Always make sure that the codes and standards used comply with local legal requirements.
• Examples will be given throughout the course
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Learning Activities
• Read the chapter and answer the quiz.
Pipe Drafting and Design 2nd Edition
Roy A. Parisher, Robert A. Rhea
Chapter 8
Codes and Specifications
© 2007 G.P. Towler / UOP. For educational use in conjunction with
Sinnott & Towler Chemical Engineering Design only. Do not copy
Chemical Engineering Design
5. Design Practices: Design Factors
(Design Margins)
• Equipment is usually sized for greater than the
design throughput
– Allows for uncertainty in the design method and data
– Leaves some room for expanding output
– Ensures the plant can run at design capacity
• Companies usually have a policy on design
margins
– Typically size equipment for 110% of design basis
– Be careful to add design margin only once!
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
6. Design Documentation
Design information must be clearly documented to enable:
• Fair comparison between competing design alternatives
• Transfer of information to E&C company for detailed design
• Development of plant manuals
Determine
Customer Needs
Set Design
Specifications
R&D if Needed
Evaluate Economics
& Select Design
Predict Fitness
For Service
Build Performance
ModelsGenerate Design
Concepts
Procurement
& ConstructionBegin Operation
Customer
Approval
Detailed Design &
Equipment Selection
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Design Documentation
The design documentation for a process usually includes a minimum of:
1. The design basis
2. A written description of the process
3. A process flow diagram
4. At least one mass & energy balance
5. Product specifications and properties
6. A list of major plant equipment
7. Equipment specification sheets
8. A piping and instrumentation diagram
9. A cost estimate
10.HS&E information (e.g., HAZAN, HAZOP, MSDS forms)
Additional information such as techno-economic analysis, market information, analysis of competing technologies or alternative design options may also be included if within the scope of the project
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Design Documentation1. The design basis
2. A written description of the process
3. Process flow diagram4. At least one mass & energy balance
5. Product specifications and properties
6. A list of major plant equipment
7. Equipment specification sheets
8. A piping and instrumentation diagram
9. A cost estimate
10.HS&E information
XYZ Co.
• The PFD or flowsheet
identifies all the
equipment items and
process streams
• Usually broken into
several separate sheets,
defining plant sections
• By convention, feeds
enter at left, products exit
right
• Usually also indicates
stream temperature &
pressure
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Design Documentation1. The design basis
2. A written description of the process
3. Process flow diagram
4. At least one mass & energy balance5. Product specifications and properties
6. A list of major plant equipment
7. Equipment specification sheets
8. A piping and instrumentation diagram
9. A cost estimate
10.HS&E information
XYZ Co.
• Mass & energy balances
are usually given for each
design case .
• Usually mass flow, mole
flow, wt% and mole% are
given for every
component in every
stream
• Often summarized as a
table at the bottom of the
PFD
kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol%
Hydrogen
Helium
Lithium
Beryllium
Boron
Nitrogen
Carbon
Nitrogen
Oxygen
Fluorine
Neon
Total
128 kPa 129 kPa 130 kPa 131 kPa
25C 25C 25C 25C
9 10 11 12
124 kPa 125 kPa 126 kPa 127 kPa
25C 25C 25C 25C
5 6 7 83
25C
122 kPa
4
25C
123 kPa120 kPa
2
25C
121 kPa
25C
1
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Design Documentation1. The design basis
2. A written description of the process
3. Process flow diagram
4. At least one mass & energy balance5. Product specifications and properties
6. A list of major plant equipment
7. Equipment specification sheets
8. A piping and instrumentation diagram
9. A cost estimate
10.HS&E information
kg/h kmol/h wt% mol%
Hydrogen
Methane
Ethane
Ethylene
Propane
Propylene
Butanes
n-butylene
i-butylene
Water
Carbon dioxide
Total
120 kPa
25C
1
XYZ Co.
kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol%
Hydrogen
Helium
Lithium
Beryllium
Boron
Nitrogen
Carbon
Nitrogen
Oxygen
Fluorine
Neon
Total
128 kPa 129 kPa 130 kPa 131 kPa
25C 25C 25C 25C
9 10 11 12
124 kPa 125 kPa 126 kPa 127 kPa
25C 25C 25C 25C
5 6 7 83
25C
122 kPa
4
25C
123 kPa120 kPa
2
25C
121 kPa
25C
1
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Design Documentation
1. The design basis
2. A written description of the process
3. Process flow diagram
4. At least one mass & energy balance
5. Product specifications and properties
6. A list of major plant equipment
7. Equipment specification sheets
8. A piping and instrumentation diagram
9. A cost estimate
10. HS&E information
• Defines equipment names
• Often used to summarize
equipment costs and serve as
a starting point for the capital
cost estimate
Plant Section Label Equipment Name Metallurgy
No. of
Items
Capacity
Measure Capacity Units
Capacity
Measure Capacity Units
Area m2
Steam rate kg/h
Diameter m No. of trays
Flow m3/s Power kW
Flow m3/h
Evap duty kg/h
Gas flow kg/h
Area m2
Duty MW
Drive power kW
Power kW
Flow litre/min Power kW
Volume m3
Volume m3
Type
Equipment Cost per
Item (k$)
Air cooler
Boiler
Column
Compressor
Cooling tower
Dryer
Ejector
Exchanger
Heater (fired)
Air cooler
Air cooler
Air cooler
Air cooler
Air cooler
Mixer
Motor
Pump
Tank
Vessel
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Design Documentation
1. The design basis
2. A written description of the process
3. Process flow diagram
4. At least one mass & energy balance
5. Product specifications and properties
6. A list of major plant equipment
7. Equipment specification sheets
8. A piping and instrumentation diagram
9. A cost estimate
10. HS&E information
• Give detailed design information (stream properties, dimensions) for each
major piece of equipment
• Occasionally include mechanical drawings if the equipment is not standard
• Sometimes substituted with vendor specification sheets for sourced items
Project Name
Project Number Sheet 1 of 1REV DATE BY APVD REV DATE BY APVD
Owner's Name
Plant Location Units English Metric
Case Description
Equipment label
Plant section
Process service
Design code Exchanger type
Shells per unit Series Parallel
Surface per unit ft2 Surface per shell ft2
Stream No.
Fluid
Total fluid flow lb/h
Total vapor flow lb/h
Total liquid flow lb/h
Total steam flow lb/h
Fluid vaporized / condensed lb/h
Density lb/cu ft
Dynamic viscosity lbm/ft.s
Specific heat capacity Btu/lb.F
Thermal conductivity Btu.ft/h.ft2.F
Latent heat Btu/lb
Normal temperature ºF
Max temperature ºF
Min temperature ºF
Pressure psia
Pressure drop allowed psi
Pressure drop calculated psi
Flow velocity ft/s
Number of passes
Film transfer coefficient Btu/h.ft2.F
Fouling coefficient Btu/h.ft2.F
Heat duty Btu/h
FT factor
Effective mean temperature difference ºF
Minimum surface required ft2
Material
Count in Square Triangular Welded
Length ft in in
Design pressure at max temp psia psia psia
Number of tubes blanked
Material
Length ft in in
Design pressure at max temp psia psia psia
Baffle material in
Tubesheet material in
Bonnet material Bonnet type
Shell side inlet in N.B. in N.B.
Tube side inlet in N.B. in N.B.
1.
2.
3.
4.
5.
DATA PER UNIT
CONSTRUCTION & MATERIALS PER SHELL
NOTES
Equipment name
Address
Company Name
Form XXXXX-YY-ZZ
SHELL & TUBE HEAT EXCHANGER
TEMA
SHELL SIDE
IN OUT IN OUT
TUBE SIDE
Tubes
Shell
Pitch
O.D.
Test pressure
Wall thickness
Max external pressure
I.D.
Branches
Shell side outlet
Tube side outlet
Test pressure
Baffle type
Wall thickness
Baffle pitch
Min internal pressure
Tubesheet thickness
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
What’s in a Spec Sheet?• Project info & rev tab
• Equipment service and
summary information
• Stream data needed
for design
• Calculated design
information for the
equipment
• Dimensions and
construction details
• Notes
Project Name
Project Number Sheet 1 of 1REV DATE BY APVD REV DATE BY APVD
Owner's Name
Plant Location Units English Metric
Case Description
Equipment label
Plant section
Process service
Design code Exchanger type
Shells per unit Series Parallel
Surface per unit ft2 Surface per shell ft2
Stream No.
Fluid
Total fluid flow lb/h
Total vapor flow lb/h
Total liquid flow lb/h
Total steam flow lb/h
Fluid vaporized / condensed lb/h
Density lb/cu ft
Dynamic viscosity lbm/ft.s
Specific heat capacity Btu/lb.F
Thermal conductivity Btu.ft/h.ft2.F
Latent heat Btu/lb
Normal temperature ºF
Max temperature ºF
Min temperature ºF
Pressure psia
Pressure drop allowed psi
Pressure drop calculated psi
Flow velocity ft/s
Number of passes
Film transfer coefficient Btu/h.ft2.F
Fouling coefficient Btu/h.ft2.F
Heat duty Btu/h
FT factor
Effective mean temperature difference ºF
Minimum surface required ft2
Material
Count in Square Triangular Welded
Length ft in in
Design pressure at max temp psia psia psia
Number of tubes blanked
Material
Length ft in in
Design pressure at max temp psia psia psia
Baffle material in
Tubesheet material in
Bonnet material Bonnet type
Shell side inlet in N.B. in N.B.
Tube side inlet in N.B. in N.B.
1.
2.
3.
4.
5.
DATA PER UNIT
CONSTRUCTION & MATERIALS PER SHELL
NOTES
Equipment name
Address
Company Name
Form XXXXX-YY-ZZ
SHELL & TUBE HEAT EXCHANGER
TEMA
SHELL SIDE
IN OUT IN OUT
TUBE SIDE
Tubes
Shell
Pitch
O.D.
Test pressure
Wall thickness
Max external pressure
I.D.
Branches
Shell side outlet
Tube side outlet
Test pressure
Baffle type
Wall thickness
Baffle pitch
Min internal pressure
Tubesheet thickness
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Standard Templates
• Typical templates for spec sheets and calc
sheets are available at:
booksite.Elsevier.com/Towler
• These can be customized for your design
projects
© 2007 G.P. Towler / UOP. For educational use in conjunction with
Sinnott & Towler Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Learning Activities
• Download the specification sheets for the major
equipment in the study case.
• http://booksite.elsevier.com/9780080966595/
© 2007 G.P. Towler / UOP. For educational use in conjunction with
Sinnott & Towler Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Design Documentation1. The design basis
2. A written description of the process
3. Process flow diagram
4. At least one mass & energy balance
5. Product specifications and properties
6. A list of major plant equipment
7. Equipment specification sheets
8. A piping and instrumentation diagram9. A cost estimate
10.HS&E information
• The P&ID is more detailed
than the PFD and almost
always runs to several
sheets
• It shows all the plant
instruments, control
systems, control logic and
shutdown systems
• It also shows pipe sizes
and metallurgy (but not
pipe layout)
• The P&ID is critical for
performing design safety
reviewsXYZ Co.
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Design Documentation1. The design basis
2. A written description of the process
3. Process flow diagram
4. At least one mass & energy balance
5. Product specifications and properties
6. A list of major plant equipment
7. Equipment specification sheets
8. A piping and instrumentation diagram
9. A cost estimate10.HS&E information
• Variable costs of production
– Raw materials
– Utilities
– Consumables
– Packaging & shipping
• Fixed costs of production
– Wages
– Taxes
– Maintenance
– Overheads
• Capital costs
– Working capital
– Installed capital cost
– Royalty costs
– Annual capital charge
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Design Documentation
1. The design basis
2. A written description of the process
3. Process flow diagram
4. At least one mass & energy balance
5. Product specifications and properties
6. A list of major plant equipment
7. Equipment specification sheets
8. A piping and instrumentation diagram
9. A cost estimate
10.HS&E information
• Information on materials safety is
required for hazard analysis,
detailed design
• Material Safety Data Sheets
(MSDSs) must be provided to
employees and customers by law
in the U.S.A. (OSHA Hazard
Communication Standard 29 CFR
Part 1910.1200)
• Information also needs to be
collected to begin applying for
emissions permits
• The type of information needed
and level of detail varies locally
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Conclusion: What Makes a Process
Design in Industry
1. Design work process
2. Design team
3. Project plan
4. Design basis
5. Standard design procedures & practices
6. Design documentation
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy