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The objective of plant design is to define the equipment, piping, instrumentation and process requirements needed to build and operate a process plant. By equipment, we mean vessels, pumps, heat exchangers, etc. These are the most common type of equipment in chemical and petrochemical plants, where most of the process streams are gases or liquids. Other industries that deal with solids use equipment like conveyors, Cyclones, and others that will not be dealt with here. Vessels can be of many types, such as drums, tanks, reactors, phase separators, and distillation columns.
Heating or cooling stream to a given temperature. Vaporizing a liquid stream partially or totally. Condensing a vapor stream partially or totally. Adiabatically flashing a stream to a given pressure. Exchanging heat between two streams. Pumping a liquid stream. Compressing a vapor stream. Separating a stream into 2 or more streams in a series of vapor- liquid equilibrium (VLE). Reacting certain components of a mixed stream according to a predefined stoichiometry.
PIPING DESIGN
Piping plant design is an essential part of successful plant operation. Many decisions must be made in the design phase to achieve this successful operation, including: Required fluid quantity to or from a process The optimum pressure- temperature for the process Piping material selection Stress and nozzle load determination Pipe support scheme
PROCESS PLANT
Roads Access Units Buildings
PROCESS UNIT
Access Equipment
PROCESS EQUIPMENT
Spacing Arrangement
OVERALL PHILOSOPHY
Arrange units to provide: Economical plant Safe and easy to operate and maintain Compactness in arrangement Integrated in flow sequence Space provided for convenient operation and maintenance access Planed expansion
HOUSED PLANT
Multi level Vertical and horizontal arrangements important Gravity flow possible Mobile crane-use in central aisle Pipe rack locations and main access Piping runs to change elevation on direction change Ability to extend plant Offices and control room
Flares(radiation levels, alternatives) Solids (use gravity flow, Containment) Expensive piping (Run lengths) Reactors (catalyst dump) Maintenance (access, removal)
MODULAR SYSTEMS
Major savings in construction costs( 50%) Require more detailed engineering design Extra structural steel (30%) Transportation costs (1-2% of module cost) Small footprints possible Ideal for small-scale plants
PROCESS UNIT
Access
Equipment
PROCESS EQUIPMENT
Spacing
Arrangement
General terrain
Regulations, Native,
Maintenance, Utilities
Overall Philosophy
Economical plant
Compactness in arrangement
Planed expansion
Housed Plant
Multi level
Instrumentation(CVs accessible)
Piping is the physical elements that interconnect the equipment and in which the process streams flow. Piping comes in different sizes and materials. It is the duty of the process engineer to specify the size and materials of the piping and also the thermal insulation, if required. The term piping also includes accessories such as elbows, tees, valves, flanges, etc.
The most common material is carbon steel. Other materials, such as varies grades of stainless steel, and plastic materials, such as PVC, Teflon, are also used.
Instrumentation are devices used to measure, control, and monitor the process variables.
These variables can be flow, temperature, pressure liquid levels, viscosity, and others. Control valves and relief valves are also an important part of the instrumentation.
Plant design normally stars with a process scheme that is a known series of physic-chemical operations that must be performed to go from the feed stocks to the desired products. These operations are established during the process development stage, normally in pilot plants, which are a small scale versions of the industrial plant.
Separating a stream into 2 or more streams in a series of vapor- liquid equilibrium (VLE).
Piping code
In 1926 the American standards institute initiated Project B31 develop a piping code. ASME was the sole administrative sponsor. A number of separate sections have been prepared, most of which have been published.
B31.4 Liquid Transportation System for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia, and Alcohols.