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Session 1st: Codes & Standards of Process Design

Arrange by, Zulnovri, ST, M.Si(Heat Exchanger & Pressure Vessel Design)NOTE:To change the image on this slide, select the picture and delete it. Then click the Pictures icon in the placeholder to insert your own image.a glance about process design, Codes, StandardProcess DesignProcess design establishes the sequence of chemical and physical operations; operating conditions; the duties, major specifications, and materials of construction (where critical) of all process equipment (as distinguished from utilities and building auxiliaries)the general arrangement of equipment needed to ensure proper functioning of the plant; line sizes; and principal instrumentationThe process design is summarized by a process flow sheet, a material and energy balance, and a set of individual equipment specificationsSometimes only a preliminary design and cost estimate are needed to evaluate the advisability of further research on a new process or a proposed plant expansion or detailed design workA particularly valuable function of preliminary design is that it may reveal lack of certain data needed for final designEquipmentTwo main categories of process equipment are proprietary and custom-designedProprietary equipment is designed by the manufacturer to meet performance specifications made by the user; these specifications may be regarded as the process design of the equipment. This category includes equipment with moving parts such as pumps, compressors, and drivers as well as cooling towers, dryers, filters, mixers, agitators, piping equipment, and valves, and even the structural aspects of heat exchangers, furnaces, and other equipmentCustom design is needed for many aspects of chemical reactors, most vessels, multistage separators such as fractionators, and other special equipment not amenable to complete standardization.Categories of Engineering PracticeAlthough the design of a chemical process plant is initiated by chemical engineers, its complete design and construction requires the inputs of other specialists: mechanical, structural, electrical, and instrumentation engineers; vessel and piping designers; and purchasing agents who know what may be available at attractive pricesOn large projects all these activities are correlated by a job engineer or project manager; on individual items of equipment or the process engineer small projects, naturally assumes this function

Sources of Information for Process DesignFor information about chemical manufacturing processes, the main encyclopedic references are Kirk-Othmer (1978-1984), McKetta and Cunningham (1976-date) and Ullmann (1972-1983) (References, Section 1.2, Part B)The most comprehensive compilation of physical property data is that of Landolt-Bornstein (1950-date) (References, Section 1.2, Part C)Data and methods of estimating properties of hydrocarbons and their mixtures are in the API Data Book (1971-date) (References, Section 1.2, Part C)Codes, Standards & Recommended PracticesA large body of rules has been developed over the years to, and materials to ensure the safe and economical design, fabrication and testing of equipment, structures & materialsCodification of these rules has been done by associations organized for just such purposes, by professional societies, trade groups, insurance underwriting companies, and government agenciesEngineering contractors and large manufacturing companies usually maintain individual sets of standards so as to maintain continuity of design and to simplify maintenance of plantTable 1.1 is a representative table of contents of the mechanical standards of a large oil company.A listing of codes and standards bearing directly on process design is in Table 1.2, and of supplementary codes and standards in Table 1.3TABLE 1.1. Internal Engineering Standards of a Large Petroleum Refinery1 Appropriations of Mechanical Orders (10)2 Buildings-architectural (15) 3 Buildings-mechanical (10) 4 Capacities and weights (25) 5 Contracts (10) 6 Cooling towers (10) 7 Correspondence (5) 8 Designation and numbering rules for equipment and facilities (10) 9 Drainage (25) 10 Electrical (10) 11 Excavating, grading and paving (10)12 Fire fighting (10) 13 Furnaces and boilers (10) 14 General instructions (20) 15 Handling equipment (5) 16 Heat exchangers (10) 17 Instruments and controls (45) 18 Insulation (10) 19 Machinery (35) 20 Material procurement and disposition (20)21 Material selection (5) 22 Miscellaneous process equipment (25) 23 Personnel protective equipment (5) 24 Piping (150) 25 Piping supports (25) 26 Plant layout (20) 27 Pressure vessels (25) 28 Protective coatings (10) 29 Roads and railroads (25) 30 Storage vessels (45) 31 Structural (35) 32 Symbols and drafting practice (15) 33 Welding (10) TABLE 1.2. Codes and Standards of Direct Bearing on Chemical Process Design (a Selection)A. American Institute of Chemical Engineers, 345 E. 47th St., New York, NY 10017 1. Standard testing procedures; 21 have been published, for example on centrifuges, filters, mixers, firer heaters B. American Petroleum Institute, 2001 L St. NW, Washington, DC 20037 2. Recommended practices for refinery inspections 3. Guide for inspection of refinery equipment 4. Manual on disposal of refinery wastes 5. Recommended practice for design and construction of large, low 6. Recommended practice for design and construction of pressure 7. Recommended practices for safety and fire protection pressure storage tanks relieving devices C. American Society of Mechanical Engineers, 345 W. 47th St., New York, NY 100178. ASME Boiler and Pressure Vessel Code. Sec. VIII, Unfired 9. Code for pressure piping York, NY 10017 Pressure Vessels 10. Scheme for identification of piping systemTABLE 1.2. Codes and Standards of Direct Bearing on Chemical Process Design (a Selection).contdD. American Society for Testing Materials, 1916 Race St., Philadelphia, PA 19103 11. ASTM Standards, 66 volumes in 16 sections, annual, with about 30% revision each year E. American National Standards Institute (ANSI), 1430 Broadway, New York, NY 10018 12. Abbreviations, letter symbols, graphical symbols, drawing and drafting room practiceF. Chemical Manufacturers' Association, 2501 M St. NW, Washington, DC 20037 13. Manual of standard and recommended practices for containers, tank cars, pollution of air and water 14. Chemical safety data sheets of individual chemicals G. Cooling Tower Institute, 19627 Highway 45 N, Spring, TX 77388 15. Acceptance test procedure for water cooling towers of mechanical draft industrial type H. Hydraulic Institute, 712 Lakewood Center N, 14600 Detroit Ave., Cleveland, OH 44107 16. Standards for centrifugal, reciprocating, and rotary pumps 17. Pipe friction manual

TABLE 1.2. Codes and Standards of Direct Bearing on Chemical Process Design (a Selection) .contdI. Instrument Society of America (ISA), 67 Alexander Dr., Research Triangle Park, NC 27709 18. Instrumentation flow plan symbols 19. Specification forms for instruments 20. Dynamic response testing of process control instrumentation J. Tubular Exchangers Manufacturers' Association, 25 N Broadway, Tarrytown, NY 10591 21. TEMA standardsK. International Standards Organization (ISO), 1430 Broadway, New York, NY 1001822. Many StandardTABLE 1.3. Codes and Standards Supplementary to Process Design (a Selection)A. American Concrete Institute, 22400 W. 7 Mile Rd., Detroit, MI 48219 1. Reinforced concrete design handbook 2. Manual of standard practice for detailing reinforced concrete structuresB. American Institute of Steel Construction, 400 N. Michigan Ave., Chicago, IL 60611 3. Manual of steel construction 4. Standard practice for steel buildings and bridges C. American Iron and Steel Institute, 1000 16th St. NW, Washington, DC 20036 5. AIS1 standard steel compositions D. American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRE), 1791 Tullie Circle NE, Atlanta, GA 30329 6. Refrigerating data book E. Institute of Electrical and Electronics Engineers, 345 E. 47th St., New York, NY 10017 7. Many standards F. National Bureau of Standards, Washington, DC 8. American standard building code 9. National electrical code G. National Electrical Manufacturers Association, 2101 L St. NW, Washington, DC 20037 10. NEMA standardsflowsheetsBLOCK FLOW SHEETAt an early stage or to provide an overview of a complex process or plant, a drawing is made with rectangular blocks to represent individual processes or groups of operations, together with quantities and other pertinent properties of key streams between the blocks and into and from the process as a wholeSuch block flowsheets are made at the beginning of a process design for orientation purposes or later as a summary of the material balance of the process.

Example: the coal carbonization process of Figure 2.1 starts with 100,000Ib/hr of coal and some process air, involves six main process units, and makes the indicated quantities of ten different productsBLOCK FLOW SHEET

BLOCK FLOW SHEET

PROCESS FLOW SHEETProcess flowsheets embody the material and energy balances between and the sizing of the major equipment of the plant. They include all vessels such as reactors, separators, and drums; special processing equipment, heat exchangers, pumps, and so on. Numerical data include flow quantities, compositions, pressures, temperatures, and so on.

FLOW SHEET EQUIPMENT SYMBOL

FLOW SHEET EQUIPMENT SYMBOL (Contd)

FLOW SHEET EQUIPMENT SYMBOL (Contd)

FLOW SHEET EQUIPMENT SYMBOL (Contd)

FLOW SHEET EQUIPMENT SYMBOL (Contd)

FLOW SHEET EQUIPMENT SYMBOL (Contd)

CONTOH FLOW SHEET

CONTOH FLOW SHEET (Contd)

MECHANICAL (P&I) FLOW SHEETSMechanical flowsheets also are called piping and instrument (P&I) diagrams to emphasize two of their major characteristics. They do not show operating conditions or compositions or flow quantities, but they do show all major as well as minor equipment more realistically than on the process flowsheet. Included are sizes and specification classes of all pipe lines, all valves, and all instruments. In fact, every mechanical aspect of the plant regarding the process equipment and their interconnections is represented except for supporting structures and foundations.The equipment is shown in greater detail than on the PFS, notably'with regard to external piping connections, internal details, and resemblance to the actual appearance

CONTOH P&I FLOW SHEET

CONTOH P&I FLOW SHEET (Contd)

UTILITY FLOW SHEETSThese are P&I diagrams for individual utilities such as steam, steam condensate, cooling water, heat transfer media in general, compressed air, fuel, refrigerants, and inert blanketing gases, and how they are piped up to the process equipment. Connections for utility streams are shown on the mechanical flowsheet, and their conditions and flow quantities usually appear on the process flowsheetSince every detail of a plant design must be recorded on paper, many other kinds of drawings also are required: for example, electrical flow, piping isometrics, instrument lines, plans and elevations, and individual equipment drawings in all detail. Models and three-dimensional representations by computers also are now standard practice in many design officesTHANK YOU