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Industrial Process

Design

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Chemical Engineering Design
1. Design Work Process
Determine Set Design
Customer Needs Specifications
Build Performance
Models
Generate Design
R&D if Needed
Concepts
Predict Fitness
For Service

Evaluate Economics
& Select Design
Customer
Approval
Detailed Design & Procurement
Begin Operation
Equipment Selection & Construction

Common to all design problems in all industries


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How do companies implement this
design process?

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2. The Design Team

Project Business
Sponsor Input

Project
Manager

Process Technical Control


Cost Engineer Consultants
Engineer(s) Specialists Engineer

R&D Mechanical Civil


Contractors
Specialists Engineer(s) Engineers

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Specialization and Outsourcing
Operating Companies
Technology Vendors
Own plants
Own patents
Produce chemicals
Sell catalysts, enzymes,
High sales revenue equipment, licenses
Margins & return on assets Sales volume low
(ROA) vary by sector
Margins, ROA usually high

Engineering & Construction Companies


Experienced project managers
Highly competitive & cost effective
Medium sales volume, low margins

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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

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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

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Chemical Engineering Design
Design Work Process
Determine Set Design
Customer Needs Specifications
Build Performance
Models
These steps Generate Design
have to R&D if Needed
Concepts
come first Predict Fitness
For Service

Evaluate Economics
& Select Design
Customer
Approval
Detailed Design & Procurement
Begin Operation
Equipment Selection & Construction

This also needs time This takes time

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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
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Example: 11-Week Plan for a Process Design Project

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Whats In a Project Plan?

List of tasks

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Whats In a Project Plan?

Durations, start
and end dates

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Whats In a Project Plan?

Predecessor
tasks

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Whats In a Project Plan?

Resource
allocations

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Whats In a Project Plan?

Gantt
chart

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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
4. The Design Basis
Determine Set Design
Customer Needs Specifications
Build Performance
Models
Generate Design
R&D if Needed
Concepts Predict Fitness
For Service
Evaluate Economics
& Select Design
Customer
Approval
Detailed Design & Procurement
Begin Operation
Equipment Selection & Construction

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?

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Process Design Basis
Company Name
Address
Project Name
Project Number
REV DATE BY APVD REV
Sheet
DATE BY
1
APVD
Documentation of design
assumptions and boundary
DESIGN BASIS
Form XXXXX-YY-ZZ
1 General Information

conditions is very important


Owners Name

Process Unit Name

Plant Location

Correspondance Contacts
Address
Telephone / Fax
E-mail

2 Measurement System

3 Equipment Numbering System


English Metric For new process plants, most
Equipment will be identified by alphabetic
prefix as defined here, followed by three-
digit serial number unless otherwise
indicated
AC
B
C
CT
D
Air cooler
Boiler
Compressor, blower, fan
Cooling tower
Dryer
G
H
J
M
ME
Grinder, mill
Heater (fired or electric)
Ejector, jet, turboexpander
Mixer
Miscellaneous equipment
R
SP
T
V
Reactor
Sample point
Storage tank
Vessel (including columns)
companies use some sort of
design basis form or questionnaire
First digit - process section E Exchanger P Pump
Second & third digits - equipment count F Filter, classifier PRV Pressure relief valve

4 Primary Products

Product Name

to serve as a record of the design


Product Grade
MSDS Form Number

Production Rate
Tons per year
Tons per day

basis
Other units

Product Purity (wt%)

Product shipment mode

Additional Specifications

5 Primary Raw Materials


(Attach additional sheets if needed)
Feedstock name
This record is also essential in
handing off information between
Feedstock grade
MSDS form number

Feedstock availability
Tons per year
Tons per day

the operating company, technology


Other units

Feedstock price ($/lb)


(Default: open market price)

Known feedstock impurities Name ppmw Name ppmw Name ppmw Name ppmw

suppliers and contractors


Additional specifications

6 Site Information
Theres a template online at:
booksite. Elsevier.com/Towler
Low ambient temperature (F)
High ambient temperature (F)
Hight ambient relative humidity (%)
Site elevation (ft)
Maximum wind loading (mph)
Other site design requirements

http://booksite.elsevier.com/9780080966595/

2012 G.P. Towler / UOP. For educational use in conjunction with


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Chemical Engineering Design
Whats in the Design Basis?
Project Name
Company Name Project Number Sheet 1
Address REV DATE BY APVD REV DATE BY APVD

DESIGN BASIS
Form XXXXX-YY-ZZ
1 General Information

Owners Name

Process Unit Name

Plant Location

Correspondance Contacts
Address
Telephone / Fax
E-mail

2 Measurement System

English Metric

Project Name
3 Equipment Numbering System

Equipment will be identified by alphabetic AC Air cooler G Grinder, mill R Reactor


prefix as defined here, followed by three- B Boiler H Heater (fired or electric) SP Sample point
digit serial number unless otherwise C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
indicated 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

Project Number Sheet 1


4 Primary Products

Product Name
Product Grade
MSDS Form Number

Production Rate
Tons per year
Tons per day

REV DATE BY APVD REV DATE BY APVD


Other units

Product Purity (wt%)

Product shipment mode

Additional Specifications

5 Primary Raw Materials


(Attach additional sheets if needed)
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 Name ppmw Name ppmw Name ppmw Name ppmw

Additional specifications

6 Site Information

Low ambient temperature (F)


High ambient temperature (F)
Hight ambient relative humidity (%)
Site elevation (ft)
Maximum wind loading (mph)
Other site design requirements

Project information and revision tabs


To allow retrieval of documentation
To ensure that revisions are properly documented and make sure that the
engineers arent working from the wrong version
To document review and approval of the design basis

2012 G.P. Towler / UOP. For educational use in conjunction with


Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Whats in the Design Basis?
Project Name
Company Name Project Number Sheet 1
Address REV DATE BY APVD REV DATE BY APVD

DESIGN BASIS
Form XXXXX-YY-ZZ
1 General Information

Owners Name

Process Unit Name

Plant Location

Correspondance Contacts
Address
Telephone / Fax
E-mail

2 Measurement System

English Metric

3 Equipment Numbering System

Equipment will be identified by alphabetic AC Air cooler G Grinder, mill R Reactor


prefix as defined here, followed by three- B Boiler H Heater (fired or electric) SP Sample point
digit serial number unless otherwise C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
indicated 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 Primary Products

Product Name
Product Grade
MSDS Form Number

Production Rate
Tons per year
Tons per day
Other units

Product Purity (wt%)

Product shipment mode


1 General Information
Additional Specifications

5 Primary Raw Materials


(Attach additional sheets if needed)
Owners Name
Feedstock name
Feedstock grade
MSDS form number

Feedstock availability
Tons per year
Tons per day
Other units Process Unit Name
Feedstock price ($/lb)
(Default: open market price)

Known feedstock impurities Name ppmw Name ppmw Name ppmw Name ppmw
Plant Location

Correspondance Contacts
Additional specifications

6 Site Information Address


Low ambient temperature (F)
High ambient temperature (F)
Hight ambient relative humidity (%)
Site elevation (ft)
Maximum wind loading (mph)
Telephone / Fax
E-mail
Other site design requirements

Contact information
Company name
Process unit name
Who to contact & where to reach them

2012 G.P. Towler / UOP. For educational use in conjunction with


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Chemical Engineering Design
Whats in the Design Basis?
Project Name
Company Name Project Number Sheet 1
Address REV DATE BY APVD REV DATE BY APVD

DESIGN BASIS
Form XXXXX-YY-ZZ
1 General Information

Owners Name

Process Unit Name

Plant Location

Correspondance Contacts
Address
Telephone / Fax
E-mail

2 Measurement System

English Metric

3 Equipment Numbering System

Equipment will be identified by alphabetic AC Air cooler G Grinder, mill R Reactor


prefix as defined here, followed by three- B Boiler H Heater (fired or electric) SP Sample point
digit serial number unless otherwise C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
indicated 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 Primary Products

Product Name
Product Grade

2 Measurement System
MSDS Form Number

Production Rate
Tons per year
Tons per day
Other units

Product Purity (wt%)

Product shipment mode

Additional Specifications

English Metric
5 Primary Raw Materials
(Attach additional sheets if needed)
Feedstock name
Feedstock grade
MSDS form number

3 Equipment Numbering System


Feedstock availability
Tons per year
Tons per day
Other units

Feedstock price ($/lb)


(Default: open market price)

Known feedstock impurities Name ppmw Name ppmw Name ppmw Name ppmw

Equipment will be identified by alphabetic AC Air cooler G Grinder, mill R Reactor


prefix as defined here, followed by three- B Boiler H Heater (fired or electric) SP Sample point
Additional specifications

6 Site Information

Low ambient temperature (F)


High ambient temperature (F)
Hight ambient relative humidity (%)
digit serial number unless otherwise C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
indicated CT Cooling tower M Mixer V Vessel (including columns)
Site elevation (ft)
Maximum wind loading (mph)
Other site design requirements

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

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
2012 G.P. Towler / UOP. For educational use in conjunction with
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Chemical Engineering Design
Whats in the Design Basis?
Company Name
Address
Project Name
Project Number
REV DATE BY APVD REV
Sheet
DATE BY
1
APVD
Product Name
Product Grade
DESIGN BASIS
Form XXXXX-YY-ZZ
1 General Information

MSDS Form Number


Owners Name

Process Unit Name

Plant Location

Correspondance Contacts
Address
Telephone / Fax
E-mail

2 Measurement System

3 Equipment Numbering System

Equipment will be identified by alphabetic


prefix as defined here, followed by three-
English

AC
B
Air cooler
Boiler
Metric

G
H
Grinder, mill
Heater (fired or electric)
R
SP
Reactor
Sample point
Production Rate
Tons per year
digit serial number unless otherwise C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
indicated 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

Tons per day


4 Primary Products

Product Name
Product Grade
MSDS Form Number

Other units
Production Rate
Tons per year
Tons per day
Other units

Product Purity (wt%)

Product shipment mode

Additional Specifications

5 Primary Raw Materials


(Attach additional sheets if needed)
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 Name ppmw Name ppmw Name ppmw Name ppmw
Product Purity (wt%)

Additional specifications

Product shipment mode


6 Site Information

Low ambient temperature (F)


High ambient temperature (F)
Hight ambient relative humidity (%)
Site elevation (ft)

Additional Specifications
Maximum wind loading (mph)
Other site design requirements

Product information for primary products


Product grades desired
Safety data sheet reference number
Production rate, purity, shipment details

2012 G.P. Towler / UOP. For educational use in conjunction with


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Chemical Engineering Design
Whats in the Design Basis?
Feedstock name
Company Name
Project Name
Project Number Sheet 1
Feedstock grade
MSDS form number
Address REV DATE BY APVD REV DATE BY APVD

DESIGN BASIS
Form XXXXX-YY-ZZ
1 General Information

Owners Name

Process Unit Name

Feedstock availability
Plant Location

Correspondance Contacts
Address
Telephone / Fax
E-mail

2 Measurement System

English Metric
Tons per year
Tons per day
3 Equipment Numbering System

Equipment will be identified by alphabetic AC Air cooler G Grinder, mill R Reactor


prefix as defined here, followed by three- B Boiler H Heater (fired or electric) SP Sample point
digit serial number unless otherwise C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
indicated CT Cooling tower M Mixer V Vessel (including columns)

Other units
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 Primary Products

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 Primary Raw Materials


(Attach additional sheets if needed)
Feedstock name
Feedstock price ($/lb)
(Default: open market price)
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 Name ppmw Name ppmw Name ppmw Name ppmw

Known feedstock impurities Name ppmw


Additional specifications

6 Site Information

Low ambient temperature (F)


High ambient temperature (F)
Hight ambient relative humidity (%)
Site elevation (ft)
Maximum wind loading (mph)
Other site design requirements

Information for primary raw materials Additional specifications

Feedstock grades
Safety information
Availability and pricing
Feed impurities and their concentrations
2012 G.P. Towler / UOP. For educational use in conjunction with
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Chemical Engineering Design
Whats in the Design Basis?
Project Name
Company Name Project Number Sheet 1
Address REV DATE BY APVD REV DATE BY APVD

DESIGN BASIS
Form XXXXX-YY-ZZ

Low ambient temperature (F)


1 General Information

Owners Name

Process Unit Name

Plant Location

High ambient temperature (F)


Correspondance Contacts
Address
Telephone / Fax
E-mail

Hight ambient relative humidity (%)


2 Measurement System

English Metric

3 Equipment Numbering System

Equipment will be identified by alphabetic AC Air cooler G Grinder, mill R Reactor

Site elevation (ft)


prefix as defined here, followed by three- B Boiler H Heater (fired or electric) SP Sample point
digit serial number unless otherwise C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
indicated 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 Primary Products

Product Name
Product Grade
MSDS Form Number

Production Rate
Tons per year
Maximum wind loading (mph)
Other site design requirements
Tons per day
Other units

Product Purity (wt%)

Product shipment mode

Additional Specifications

5 Primary Raw Materials


(Attach additional sheets if needed)
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 Name ppmw Name ppmw Name ppmw Name ppmw

Additional specifications

6 Site Information

Low ambient temperature (F)


High ambient temperature (F)
Hight ambient relative humidity (%)
Site elevation (ft)
Maximum wind loading (mph)
Other site design requirements

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

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Chemical Engineering Design
Whats in the Design Basis?
Project Name
Company Name Project Number Sheet 2
Address REV DATE BY APVD REV DATE BY APVD

Form XXXXX-YY-ZZ
DESIGN BASIS
Sheet 2 of the Design Basis has
utility information
7 Utility Information

Fuel Gas
Gas source or operation mode Nat Gas
Supply header temperature (F)
Supply header pressure (psia)
Net calorific value (BTU/lb)
Marginal availability (lb/h)
Marginal fuel cost ($/MMBTU)

Fuel gases
Sulfur content (wppm)
Nitrogen content (wppm)
Chlorine content (wppm)
Gas composition (vol%)
H2O
O2
N2
CO
CO2
H2S

Fuel oils
H2
CH4
C2H4
C2H6
C3H6
C3H8
C4H8
iC4H10
nC4H10

Steam levels
C5H10
C5+

Fuel Oil
Fuel source or operation mode #2 Heating Oil
Supply header temperature (F)
Supply headder pressure (psia)
Net calorific value (BTU/lb)
Marginal availability (lb/h)

Coolants
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

Process water
Steam header classification VHP HP MP LP
Operating pressure (psia)
Operating temperature (F)
Mechanical design pressure (psia)
Mechanical design temperature (F)
Marginal availability (lb/h)
Marginal cost ($/Mlb)

Coolants

Electricity
Coolant classification Cooling Tower Water Once-Through Water Chilled Water
Operating pressure (psia)
Supply temperature (F)
Maximum return temperature (F)
Marginal availability (lb/h)
Marginal cost ($)
Marginal cost units

Process Water Feeds

Process Air
Water feed stream Raw Water Process Water Boiler Feed Water Condensate
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

Conditions, availability, price, etc.


Electric power
Power range (kW)
Voltage (V)
Phase
Frequency (Hz)
Marginal availability (kW)
Marginal cost ($/kWh)

Plant air streams


Air stream Plant Air Instrument Air Plant Nitrogen
Header pressure (psia)
Header temperature (F)
Moisture (ppmw)
Marginal availability (lb/h)
Marginal cost ($/Mscf)

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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.

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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

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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

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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
Determine Set Design
Customer Needs Specifications
Build Performance
Models
Generate Design
R&D if Needed
Concepts Predict Fitness
For Service
Evaluate Economics
& Select Design
Customer
Approval
Detailed Design & Procurement
Begin Operation
Equipment Selection & Construction

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

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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

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Chemical Engineering Design
Design Documentation
1. The design basis
2. A written description of the process The PFD or flowsheet
3. Process flow diagram identifies all the
4. At least one mass & energy balance equipment items and
5. Product specifications and properties process streams
6. A list of major plant equipment
7. Equipment specification sheets
Usually broken into
8. A piping and instrumentation diagram
9. A cost estimate several separate sheets,
10.HS&E information defining plant sections

By convention, feeds
enter at left, products exit
right

Usually also indicates


stream temperature &
pressure
XYZ Co.

2012 G.P. Towler / UOP. For educational use in conjunction with


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Chemical Engineering Design
Design Documentation
1. The design basis
2. A written description of the process Mass & energy balances
3. Process flow diagram are usually given for each
4. At least one mass & energy balance design case .
5. Product specifications and properties
6. A list of major plant equipment Usually mass flow, mole
7. Equipment specification sheets
flow, wt% and mole% are
8. A piping and instrumentation diagram
9. A cost estimate given for every
10.HS&E information component in every
stream

Often summarized as a
table at the bottom of the
PFD

1 2 3 4 5 6 7 8 9 10 11 12
25C 25C 25C 25C 25C 25C 25C 25C 25C 25C 25C 25C
120 kPa 121 kPa 122 kPa 123 kPa 124 kPa 125 kPa 126 kPa 127 kPa 128 kPa 129 kPa 130 kPa 131 kPa
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

XYZ Co.
Nitrogen
Carbon
Nitrogen
Oxygen
Fluorine
Neon
Total

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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 1
5. Product specifications and properties 25C
120 kPa
6. A list of major plant equipment kg/h kmol/h wt% mol%
Hydrogen
7. Equipment specification sheets Methane
8. A piping and instrumentation diagram Ethane
Ethylene
9. A cost estimate Propane
10.HS&E information Propylene
Butanes
n-butylene
i-butylene
Water
Carbon dioxide
Total

1 2 3 4 5 6 7 8 9 10 11 12
25C 25C 25C 25C 25C 25C 25C 25C 25C 25C 25C 25C
120 kPa 121 kPa 122 kPa 123 kPa 124 kPa 125 kPa 126 kPa 127 kPa 128 kPa 129 kPa 130 kPa 131 kPa
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
XYZ Co.
Oxygen
Fluorine
Neon
Total

2012 G.P. Towler / UOP. For educational use in conjunction with


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Chemical Engineering Design
Design Documentation
Defines equipment names
1. The design basis
2. A written description of the process
3. Process flow diagram Often used to summarize
4. At least one mass & energy balance equipment costs and serve as
5. Product specifications and properties
6. A list of major plant a starting point for the capital
equipment cost estimate
7. Equipment specification sheets
8. A piping and instrumentation
diagram
9. A cost estimate
10. HS&E information
No. of Capacity Capacity Equipment Cost per
Plant Section Label Equipment Name Type Metallurgy Items Measure Capacity Units Measure Capacity Units Item (k$)
Air cooler Area m2
Boiler Steam rate kg/h
Column Diameter m No. of trays
Compressor Flow m3/s Power kW
Cooling tower Flow m3/h
Dryer Evap duty kg/h
Ejector Gas flow kg/h
Exchanger Area m2
Heater (fired) Duty MW
Air cooler
Mixer Drive power kW
Air cooler
Motor Power kW
Air cooler
Pump Flow litre/min Power kW
Air cooler
Tank Volume m3
Air cooler
Vessel Volume m3
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
Project Name
Company Name Project Number Sheet 1 of 1
Address REV DATE BY APVD REV DATE BY APVD

SHELL & TUBE HEAT EXCHANGER

1. The design basis


Form XXXXX-YY-ZZ
Owner's Name
Plant Location Units English Metric
Case Description
Equipment label Equipment name

2. A written description of the process


Plant section
Process service
Design code TEMA Exchanger type
Shells per unit Series Parallel
Surface per unit ft2 Surface per shell ft2
DATA PER UNIT

3. Process flow diagram Stream No.


Fluid
IN
SHELL SIDE
OUT IN
TUBE SIDE
OUT

4. At least one mass & energy balance


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

5. Product specifications and properties


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

6. A list of major plant equipment


Normal temperature F
Max temperature F
Min temperature F
Pressure psia
Pressure drop allowed psi
Pressure drop calculated psi

7. Equipment specification
Flow velocity ft/s

Number of passes
Film transfer coefficient Btu/h.ft2.F
Fouling coefficient Btu/h.ft2.F

sheets
Heat duty Btu/h
FT factor
Effective mean temperature difference F
Minimum surface required ft2

CONSTRUCTION & MATERIALS PER SHELL

8. A piping and instrumentation


Tubes
Material
Count Pitch in Square Triangular Welded
Length ft O.D. in Wall thickness in

diagram
Design pressure at max temp psia Test pressure psia Max external pressure psia
Number of tubes blanked

Shell
Material

9. A cost estimate
Length ft I.D. in Wall thickness in
Design pressure at max temp psia Test pressure psia Min internal pressure psia
Baffle material Baffle type Baffle pitch in
Tubesheet material Tubesheet thickness in
Bonnet material Bonnet type

10. HS&E information Branches


Shell side inlet
Tube side inlet

NOTES
in N.B.
in N.B.
Shell side outlet
Tube side outlet
in N.B.
in N.B.

1.
2.
3.
4.
5.

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


2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Whats in a Spec Sheet? Project Name
Company Name Project Number Sheet 1 of 1

Project info & rev tab


Address REV DATE BY APVD REV DATE BY APVD

SHELL & TUBE HEAT EXCHANGER


Form XXXXX-YY-ZZ
Owner's Name
Plant Location Units English Metric
Case Description
Equipment label Equipment name

Equipment service and


Plant section
Process service
Design code TEMA Exchanger type
Shells per unit Series Parallel

summary information
Surface per unit ft2 Surface per shell ft2
DATA PER UNIT

SHELL SIDE TUBE SIDE


IN OUT IN OUT
Stream No.
Fluid
Total fluid flow lb/h
Total vapor flow lb/h

Stream data needed Total liquid flow


Total steam flow
Fluid vaporized / condensed
Density
lb/h
lb/h
lb/h
lb/cu ft

for design
Dynamic viscosity lbm/ft.s
Specific heat capacity Btu/lb.F
Thermal conductivity Btu.ft/h.ft2.F
Latent heat Btu/lb
Normal temperature F
Max temperature F
Min temperature F
Pressure psia

Calculated design
Pressure drop allowed psi
Pressure drop calculated psi
Flow velocity ft/s

Number of passes

information for the


Film transfer coefficient Btu/h.ft2.F
Fouling coefficient Btu/h.ft2.F
Heat duty Btu/h
FT factor

equipment
Effective mean temperature difference F
Minimum surface required ft2

CONSTRUCTION & MATERIALS PER SHELL

Tubes
Material
Count Pitch in Square Triangular Welded

Dimensions and
Length ft O.D. in Wall thickness in
Design pressure at max temp psia Test pressure psia Max external pressure psia
Number of tubes blanked

Shell

construction details
Material
Length ft I.D. in Wall thickness in
Design pressure at max temp psia Test pressure psia Min internal pressure psia
Baffle material Baffle type Baffle pitch in
Tubesheet material Tubesheet thickness in
Bonnet material Bonnet type

Branches

Notes
Shell side inlet in N.B. Shell side outlet in N.B.
Tube side inlet in N.B. Tube side outlet in N.B.

NOTES

1.
2.
3.
4.
5.

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 Documentation
1. The design basis The P&ID is more detailed
2. A written description of the process
3. Process flow diagram than the PFD and almost
4. At least one mass & energy balance always runs to several
5. Product specifications and properties sheets
6. A list of major plant equipment
7. Equipment specification sheets It shows all the plant
8. A piping and instrumentation diagram instruments, control
9. A cost estimate
10.HS&E information 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
XYZ Co.
reviews
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
Variable costs of production
2. A written description of the process
3. Process flow diagram Raw materials
4. At least one mass & energy balance Utilities
5. Product specifications and properties Consumables
6. A list of major plant equipment Packaging & shipping
7. Equipment specification sheets
8. A piping and instrumentation diagram
Fixed costs of production
9. A cost estimate
Wages
10.HS&E information
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
Information on materials safety is
1. The design basis
2. A written description of the process
required for hazard analysis,
3. Process flow diagram detailed design
4. At least one mass & energy balance
5. Product specifications and properties
6. A list of major plant equipment
Material Safety Data Sheets
7. Equipment specification sheets (MSDSs) must be provided to
8. A piping and instrumentation employees and customers by law
diagram
9. A cost estimate in the U.S.A. (OSHA Hazard
10.HS&E information 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
Chemical Engineering Design
Questions ?

2012 G.P. Towler / UOP. For educational use in conjunction with


Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design

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