Plant Engineer's

Reference Book
Second edition
Edited by

Eur Ing DeiHliS A. SlIOW

CEng, MIMechE, HonFSOE, HonFIPIantE, HonFIIPE

Engineering Consultant

Former Teaching Fellow, Loughborough

University of Technology, UK

Senior Lecturer and

European Research Project Manager,
De Montfort University,
Leicester, UK

OXFORD AUCKLAND BOSTON JOHANNESBURG

MELBOURNE NEW DELHI
Butterworth-Heinemann
Linacre House, Jordan Hill, Oxford OX2 8DP
225 Wildwood Avenue, Woburn, MA 01801-2041
A division of Reed Educational and Professional Publishing Ltd

A member of the Reed Elsevier pic group

First published 1991

Reprinted 1993, 1996, 1997, 1998, 1999, 2000
Second edition 2002

© Reed Educational and Professional Publishing Ltd 1991, 2002

All rights reserved. No part of this publication may be reproduced in any material
form (including photocopying or storing in any medium by electronic means and
whether or not transiently or incidentall to some other use of this publication)
without the written permission of the copyright holder except in accordance with
the provisions of the Copyright, Designs and Patents Act 1988 or under the terms
of a licence issued by the Copyright Licensing Agency Ltd, 90 Tottenham Court
Road, London, England WlP OLP. Applications for the copyright holder's
written permission to reproduce any part of this publication should be
addressed to the publishers

British Library Cataloguing in Publication Data

A catalogue record for this book is available from the British Library

Library of Congress Cataloguing in Publication Data

A catalogue record for this book is available from the Library of Congress

ISBN O 7506 4452 4

For information on all Butterworth-Heinemann publications visit our website at www.bh.com

Typeset in 10/12pt Times Roman by Laserwords Pvt. Ltd., Chennai, India

Printed and bound in Great Britain by The Bath Press, Bath
Forewords
A quick glance at the contents of this reference book,
immediately gives the reader an idea as to how much
thought has been put into the structuring of this publica-
tion.
This work has been brought together by a very widely
experienced engineer who has 'been there' and experi-
enced so many of the problems and difficulties that a
plant or operations engineer is likely to encounter during
his day to day activities.
This thought process has been directed meticulously
through to all the contributors, and is detectable in the
structure of each chapter.
Although based on the setting up of a new static instal-
lation, the thought processes are similar and applicable to
the efficient running, profitability and care of both mobile
and existing installations.
This book follows a successful decade of the first
edition, and has, where possible, incorporated the many
ongoing updates, brought about by the changing times that
we are now living in, and having to comply with.
This book has been a large part of Dennis' life over the
last few years. His efforts will enable future generations of
Plant and Operations Engineers to benefit from his own
wealth of experience and that of his many contributing
colleagues. Well done Dennis, you have given us all a
valuable legacy!
Eur Ing Mark Hansford BSc(Eng), CEng, HonFSOE,
HonFIPlantE
President Emeritus: Society of Operations Engineers
Past President: Institution of Plant Engineers
Recently the formation of the Society of Operations Engi-
neers, which incorporates the Institution of Plant Engi-
neers as one of the founder Professional Sectors, is an
indication of how the industrial roles of the engineering
professions are changing.
The plant engineering profession, in itself, has not
changed, nor has the responsibilities or importance: but
what has changed is the management terminology. You
will now find terms like asset management, facilities
management and others coming to the fore, and these
find a focus in the generic description of 'Operations
Engineering.' It is this description which is now attributed
to those with responsibility for many and varied areas of
engineering and is included in the title of our new body.
It is encouraging to see that the editor, and his very
experienced colleagues, have continued the theme of the
first edition, in guiding the engineer through the labour
pains of bringing the eventual goal, a total project, to
fruition. Obviously, changes have taken place since the
first edition, with tracks of legislation and many new
'Codes of Practice' introduced, through the European
Community, which have been dealt with as appropriate.
Dennis Snow has been involved in many successful
industrial operations on both sides of the Atlantic. It is
with this experience, coupled to his personal knowledge
of so many of the authors who have helped him to put
this reference book together, that should make the second
edition even more successful than the first.
David Cox JP
MIMechE, HonFSOE, HonFIRTE, HonFIPlantE
First President: Society of Operations Engineers

As with the first edition of this reference book, it would
not have been possible, without the total co-operation
of so many experienced individual authors and their
colleagues, coupled with the backing of many well-known
companies. What a wealth of professional knowledge and
expertise. An acknowledgement such as this can only
scratch the surface and cannot convey my very grateful
thanks that are due to those people who have spent many
hours of their valuable time putting together so many
pages of knowledge, for the benefit of others. Those
who will be seeking assistance in tackling their day-
to-day problems and seeking advice, and in particular
the budding plant engineering students starting out on a
multidisciplinary career, will be extremely grateful.
Over the years I have put together many processing
plants and it was this in mind that I have structured this
book. I was very fortunate to have been in at the begin-
ning of so many projects, from the basic decision stage,
the budgeting, planning, design, specification, tendering,
installation, commissioning to the eventual efficient run-
ning and the maintenance.
Plant engineering is such a broad subject incorporating
a multitude of disciplines, many problems, and a wide
variety of solutions to many situations, unlike some dis-
ciplines that have clear cut methods. I have spent many
Preface to the
second edition
hours trying to obtain information to assist me in my work
and hence the theory behind the structuring of this refer-
ence book.
As a long standing active member of the Institution
of Plant Engineers, I have been to many local branch
meetings, attended conferences and had the opportunity of
discussing problems and new techniques with colleagues.
In turn I hope that I have been able to be of assistance to
them with their problems.
Plant engineering sees no boundary and has brought
together many engineers from competitive companies, all
of who are interested in safety and the development of
new techniques leading to improving efficiency and the
working environment.
I would therefore like to take this opportunity to thank
those members of the Institution for their patience and
assistance in helping me to structure this publication,
many who have contributed.
My wife Betty suffered considerably whilst the first
edition was being put together and did not deserve to
have a second edition thrust upon her. She has been more
than tolerant again, for which she deserves more than my
thanks and appreciation.
Dennis A Snow
 Preface to the first
edition
The preparation of a reference book such as this could not APV Baker Ltd
possibly be acheived without the total cooperation of so The Boots Company pic
many individual authors and the backing of their various BP Oil (UK) Ltd
employers, especially where company contributions have British Coal
been made, bringing together a wealth of professional British Gas
knowledge and experience. British Compressed Air Society
An acknowledgement such as this can only scratch the Colt International Ltd
surface and cannot really portray the grateful thanks I wish Cortest Laboratories Ltd
to acknowledge to all these people and concerns who have Davy McKee (Stockton) Ltd
devoted so much time and effort to place their ideas and Film Cooling Towers Limited
contributions on paper. Heaton Energy Services
Plant Engineering is such a broad subject incorporating
The Institution of Plant Engineers
a multitude of disciplines and a wide variety of solutions
I T I Anti-Corrosion Ltd
to virtually every problem or situation, unlike some sub-
jects that have clear cut methods. Liquefied Petroleum Gas Industry Technical Association
In compiling the initial suggested guidelines for each Loughborough University of Technology
of the contributions, I posed the questions to myself for National Vulcan Engineering Insurance Group Ltd
what information and assistance had I found difficult to Ove Arup & Partners, Industrial Division
locate during over 30 years in industry as a Plant Engineer Pilkington Insulation Ltd
responsible for plant in the UK and abroad and how could Royal Insurance (UK) Ltd
it be best presented to assist others in their profession. SBD Construction Products Limited
As an active member of the Institution of Plant Engi- Saacke Ltd
neers for many years I have been able to seek the knowl- Senior Green Limited
edge of my colleagues when problems have occurred and Spirax-Sarco Limited
I hope that I have been able to help them on occasions. Support Services
I would therefore like to take this opportunity to thank Taylor Associates
those members of the Institution for their patience and Thorn Lighting
assistance in helping me to structure this publication,
and in particular, members of the Publication Committee,
together with the following companies: I would also like to include my wife Betty, who has been
extremely tolerant whilst I have spent many hours word
ABB Power Ltd processing.
W S Atkins Consultants Ltd
J B Auger (Midlands) Ltd Dennis A Snow
 Contributors
Thomas L Adam Peter F Fleming, BSc(Eng), ARSM CEng, MInstE
Financial consultant British Gas pic
M Ahmed Colin French, CEng, FInstE, FIMgt
APV Systems Consultant
W S Atkins Consultants Ltd Eur Ing Roland R Gibson, BTech, MSc, CEng, FIMechE,
FIMarE, FRSA, MAE
Brian Auger, IEng, HonFSOE, HonFIPlantE, MBES Roland Gibson Associates
J B Auger (Midlands) Ltd
Mark Hammonds
H Barber, BSc B P Solar Ltd
Loughborough University of Technology
Hugh King
D A Bayliss, FICorrT, FTSC Thorn Lighting
The Steel Protection Consultancy
B. Lamb
R J Blaen APV Systems
Tony Book Paul Mayoh
Riomay Ltd Spirax Sarco Ltd
BP Oil UK Ltd Andy Neave, BSc(Hons), MBA, AMIMechE,
The British Compressed Air Society Calorex Heat Pumps Ltd, Maldon, Essex
London John Neller
British Gas pic Film Cooling Towers Ltd
Ove Arup & Partners
Jon Brooking, CEng, FIChemE, MCIWEM, MWMSoc
General Waters (UK) Ltd Pilkington Insulation Ltd
Eur Ing M G Burbage-Atter, BSc, CEng, FInstE, HonFSOE, George Pitblado, IEng, MSOE, MIPlantE, DipSM, MIIRSM,
HonFIPlantE, FCIBSE MMWSoc
Heaton Energy Services Support Services
John Childs, IEng, FSOE, FIPlantE G E Pritchard, CEng, FCIBSE, FInstE, FSOE, FIPlantE
Allianz Cornhill Engineering Chartered Engineer
Barrie J Church R Robinson, BSc, CEng, FIEE,
Global Energy Associates Ltd The Boots Co. pic
P D Compton, BSc, CEng, MCIBSE, Royal Insurance
Colt International Ltd
Michael J Schofield, BSc, MSc, PhD, MIM, CEng
Professor I G Crow, BEng, PhD, CEng, FIMechE, FIMarE, Independent Consultant
MemASME
B M & T Consulting Ltd J D N Shaw, MA
Evan Davies, MA, MIEH, Diplnst Ac, DMS R H Shipman, MBE, MIMechE, MIGasE, MInstE
Leicester City Council Liquefied Petroleum Gas Association
Michael Farrell, CEng, FCIBSE, FIMechE K Shippen, BSc, MBA, CEng, MIMechE
Consultant Chieftain Power Services
Eric SIoman Leon Turrell, FCA
Consultant Financial Consultant
Eur Ing Dennis A Snow, CEng, MIMechE, Dr P Urwin, BSc, PhD, CEng, MIEE
HonFSOE, HonFIPlantE, HonFIIPE De Montfort University, Leicester
Past President of the Institution of Plant Engineers
Peter F Tye, IEng, HonFSOE, HonFIPlantE
De Montfort University, Leicester Former Secretary Institution of Plant Engineers
George SoIt, CEng, FIChemE Dave Whittleton, MA, CEng, MIMechE, MHKIE
Consultant
John Willoughby
Eur Ing K Taylor, JP, CEng, FCIBSE, FSOE, FIPlantE, Energy & Environmental Design Consultant
FIHEEM, FSE, PEng, FIOP, RP, MASHRAE, MIOSH, FIMgt,
FRSA, ACIOB, MAE, Member of the Society of Construction Michael A Wood, BSc, MBEng
Law Leicester City Building Control Services
Taylor Associates Ltd C S Yates
Transco Fire Protection Consultant

Keith lhrton, BSc (Eng), CEng, MIMechE

Cranfield University