PLANT DESIGN 101

The first step of process design is to define what it is you wish to accomplish. You mentioned an esterification plant. What ester do you propose to produce. Research how that product can be produced and is produced if produced commercially. A process description is a good place to begin. You can leave some things undefined or posed as questions to answer. What is the chemistry to be carried out in this process? You may have more than one route to this product. Write down the chemical equations. Esters can be produced by direct esterification of an organic acid by an alcohol in the presence of a suitable catalyst or esters can be produced by transesterification of another ester or by a Tischenko condensation of two aldehydes, or by a Cannizarro reaction, or by a variety of other processes. Your process description might be the proposal to evaluate the production of the desired product by two different methods. Describe what feedstocks are needed (including catalysts), what assay is needed for each, and potential sources of the raw materials. Once you have the what and the chemistry defined, work on defining what engineering operations might be required. An example might be receipt, storage, and feed equipment for raw materials, a reactor (CSTR, etc.) for the reaction, purification equipment for the product, equipment for any recyles and waste streams, and bulk storage and loading equipment for finished product. At this point you should be able to draw a block diagram of the process. The process description should contain a preliminary block flow diagram that will be built into a full process.

You can spend more time researching how some of the unit operations might be accomplished in your process. For a simple esterification plant producing a product such as butyl butyrate you might need bulk storage for n-butanol and n-butyric acid, a CSTR for a reactor, and distillation columns to purify the product. Distillation could include low boiler removal, high boiler removal, and product purification to a sales spec. There could be a recycle of n-butanol and disposal of waste products as well.

You need to spend more time studying what potential byproducts can be made in the process and in collecting physical properties of all the compounds in the process. Now you begin to develop a more detailed process flow diagram. Bulk storage tanks for raw materials and products need to include purge/vent systems for blanketing and emissions from the storage tanks. The reactor should include any operations to heat and/or cool the reactor or any of its streams and the pumps to feed, circulate, or remove product from the reactor. Distillation columns should include condensers, reboilers, and process tanks as well as pumps. Put together a more detailed process flow diagram.

Next you need to describe how each unit operation will function in the process. This can be data from literature sources, bench scale or larger work, and from process modeling of the process sections with Aspen or Chemcad or other package. This is where the property and VLE data you collected is put to use. You may begin to appreciate other operations that may be needed. In n-

butyl butyrate it may be possible to decant some water from the reactor product and to make an ester/hiboiler split by taking low boilers and the water/ester azeotrope overhead in a distillation column. Low boilers might be separated from the ester in a second distillation column as their water azeotropes with an ester cut as a base vapor takeoff. The required separations, including all known byproducts, have to be defined from some source. At this point one can produce a fairly detailed process flow diagram with a wealth of information on it.

At some point one needs to do a theoretical balance around the process assuming 100% stochiometric yields and the process capacity. This could be done at the block diagram stage.

Once the unit operations have been defined, a detailed mass balance including recyles and waste streams is to be done to show reactor yields and losses across unit operations. This will establish mass flow rates through the process and raw material requirements. An energy balance has to be done next. I will stop for now and complete this later if it appears to be what you are looking for.
You seem to have some parts of the design process in mind since you mention a hazop study. A hazop study is done when you have the process defined well enough for the study to be meaningful and to contribute to the design process. Let's pause a moment and cover something that you know before starting this process; the site where such a plant could or will be built. Is this a grassroots effort? or an extension of an existing plant? or a conversion of an existing plant? The answer will influence several things in the process design. Let's consider that you have a process description, property data for chemicals involved, process chemistry, block flow diagram, semi-detailed process flow diagram, theoretical mass balance, unit operations modeling, and a site. Now a detailed mass and energy balance based on the process flow diagram, the reaction yields, and the unit operations engineering yields has to be built. Process conditions (pressure, temperatures, flows, etc.) should be noted. The mass balance should be by component. List what utilities will be required for the process. Electricity for pumps, instruments, etc. What will be used to heat or cool process streams. Closed loop cooling water system, river water, steam, hot oil, etc. Instrument air and compressed air. Nitrogen for blanketing. Where will these utilities come from? tie-in to existing facilities? new facilities? The process diagram needs to be broken into sections for P&ID's. Moderately detailed P&ID's should be developed for each section. Items from the following considerations will be added to the P&ID's. ENVIRONMENTAL: Will this plant require a permit? Will it be a new permit or a modification of an existing permit? What will be the disposition of vapors from process vents? process wastes? SAFETY: Where will relief valves or rupture disks be required? What will be the bases for sizing the devices? Platforms, ladders, and process flooring must be built to standards. Are there other safety issues? MATERIALS OF CONSTRUCTION: what materials are required for equipment, piping, utilities,

etc. You will need to determine where corrosion can occur and what materials are appropriate for each service. If organic acids are to be used in an esterification plant, one should know that dilute amounts are very corrosive on 316 SS. Typically the service may require something like Sandvik 2205. INSULATION: Where will insulation be used? what type. One needs to be concerned about under insulation corrosion also particularly with mineral wool or Calsil. INSTRUMENTS: What type of control system will be used with this plant? DCS? Single loop controllers? PLC? What instruments will be required with each unit operation for level, flow, temperature, pressure, etc. Pumps: what types and sizes of pumps will be needed for each application. Consider mechanical reliability here in the sealing and flush applications. Equipment Sizing: You should begin to estimate the size of reactors, distillation columns, heat exchangers and other equipment that will be needed in the process. Information from these items should be included on the P&ID's that you are compiling. When the P&ID's are as well defined as one can make them, a hazop study can be done. The question to be asked is, "what are the effects of deviations from design intent" If a heat exchanger loses coolant flow, what is the effect and are there any process alarms or actions needed for this possibility. You are also ready to begin the process of estimating the cost of the process. One can use the module/factor approach and arrive at a budget estimate. It has been my experience that cost estimates, once given, are never forgotten. It has been my practice to try to produce a 10% estimate if possible. You have a wealth of detail at hand by now. Equipment estimates can be obtained from vendors. Knowing the site and the equipment layout, you can begin to estimate lengths of pipe, conduit, etc. The Richardson system is a method that allows one to make a semidetailed capital estimate of the components, labor, and indirect costs associated with a project. I know there are many other details that I have not spoken of. You will need to incorporate them as you come across them. Engineering standards and approved vendor lists for your employer have to be followed. Try to bring some improvement to as many of the unit operations as you can.

PID Piping Guidelines for P&ID Review By: James O. Pennock This document is intended to provide various members of the Piping Department with suggestions of what to look for and what questions to ask during a P&ID (Piping and Instrument Diagram) Review. The three key Piping entities that should be present during a P&ID Review are: Piping Material Engineering Focus on all data and comments that will impact the development and or modification of the Piping Material Line Class Specifications, The need for and the details of SP Items, Insulation Specifications, etc. Piping Design Focus on all data and comments that relate to the actual routing of piping systems, including process requirements, operations, maintenance and safety. Pipe Stress Engineering Focus on all data and comments that relate to factors that impact pipe stress including temperatures for both normal operations and any upset condition that might occur. Each of these individuals (and groups) will have distinct but interrelated duties and responsibilities

during the ongoing Detailed Design Phase of the project that will follow the P&ID Review. The person who will represent each of these groups (or functions) should be provided with (or obtain) ahead of time a copy of all diagrams to be reviewed. These copies should be studied and marked with questions and or comments before the review. To be prepared is to be forearmed. Here is something everyone needs to remember. A P&ID is a schematic drawing of a process plant system. It has no relationship to scale, relative dimensions or true shape or character. It has no relationship to north, south, east or west. It has only a marginal relationship to up and down. However, through the use of standard symbols, line conventions and notes a level of understanding must be achieved and communication must happen so that what is shown on these P&ID drawings in a schematic way is converted to reality. Areas of interest and suggested questions or items of interest: P&ID Lead Sheet: Does the project have a P&ID Lead Sheet? If possible the review should start with the Lead Sheet that lists all the common General Notes and may include a list of all P&IDs and Utility Diagrams for the Unit or Project depending on the project size. It should have project applicable acronyms with definitions. Are all the Notes clear and understandable? Are all the notes applicable to the project? What else is on this sheet and what does it mean to this project? P&ID Symbology Sheet: Does the project have a P&ID Symbology sheet? If there is not a Symbology Sheet, then ask why not? If there is a Symbology Sheet: Are all the symbols consistent with the ISA standard and known to all present? Are there any new symbols required for this project? What are these new symbols and what do they mean? P&ID Standard Detail Sheet: P&IDs on any project contain many situations that are repetitive and very detailed. Many times there are details that are similar but have small differences. These details, if repeated in full detail at every occurrence can cause congestion and confusion to the person reading the P&ID. So a full detail is drawn once and then a smaller and simpler symbol is placed at the use point. These common details might include: High Pressure Steam Trap Station with bypass High Pressure Steam Trap Station without bypass Medium Pressure Steam Trap Station with bypass Medium Pressure Steam Trap Station without bypass Low Pressure Steam Trap Station with bypass Low Pressure Steam Trap Station without bypass Utility Station Requirements for Grade Utility Station Requirements for elevated platforms on Vessels Utility Station Requirements for at Heaters Safety Valve (SRV, PSV, PRV, etc) Manifold with bypass Safety Valve (SRV, PSV, PRV, etc) Manifold without bypass Steam-Out Connection Hard piped, with double block valve, spec blind, check valve and bleed Steam-Out Connection Block valve w/ blind flange, swing ell to valved steam line P&ID Sheet Format: P&ID formats are normally fairly standard and consistent with-in a specific company. However the

Client may ask for special additions, deletions and or modifications that are new and different for a project. Is there anything new and or different about the P&ID Format for this project? If so, what are they and what do they mean? Are there additional Notes for a specific P&ID in addition to the General Notes on the common Lead Sheet? P&ID Equipment Review: The review for each type of equipment and each piece of individual equipment should follow a consistent pattern. If the review does not follow a pattern then things get forgotten. Is each equipment type and piece shown by a standard and recognizable symbol? Is this symbol consistent with what is known about the actual planned equipment? Is the equipment identified? Is there an appropriate Data Box at the top (or bottom) of the P&ID for this type of equipment? Is all the Data Box information completed? If the Data Box information is not completed, when will it be completed? For trayed vessels, are the trays at all side entry nozzles numbered? For Shell & Tube Exchangers, is the correct number of shells shown? For Air Coolers (Fin Fan Coolers) is the correct number of Cells and Cell Nozzles shown? For Air Coolers, does the inlet and/or outlet headers need to be; Balanced Flow? Symmetrical Flow? Other?

Line by Line Piping Review: Piping on a P&ID is, as noted above, schematic. However, there are certain absolutes that rule the interpretation of the pipe lines. These rules apply to the sequence of appearance of the valves or other symbols on any given line. With only a few exceptions what the P&ID shows that is the way the finished physical piping shall be installed. As you review each line you should look for the following: Does the line originate and terminate on the same sheet? If the line originates or terminates on another sheet does it have connectors? Do both connectors for the line match? Is there a Line Identification (Line Number, Line Designation or other) for the line? Is the commodity known? Have the Design Conditions been set? Is the maximum operation pressure known? Is the maximum operating temperature known? Is the line size known and shown? What is the specific function for This line? Are all special process required line conditions (Line Slope, Do Not Pocket, Free Drain, etc) shown or noted? Are all valves shown? Are the valve type symbols consistent with the actual valve type in the Piping Line Class Specification? What is the purpose and function of each valve? Is there a size on each valve? Or are all valves to be assumed to be line size unless noted otherwise? If there are Line Class Spec Breaks are they on the correct side of the valve? Are all Instruments in or on a line shown? If a Pressure instrument and a Temperature instrument are in close proximity (10 pipe diameters

or less) to each other is the temperature instrument downstream (easy way to remember is alphabetical order) of the pressure instrument? When reducers are shown does process really want a reducer or are other common methods of pipe size changes (reducing TEE branches from a common header) acceptable? Is the term or note Min used and what is specifically needed and or to be avoided? Are all Process vents and drains shown? Are there any odd mechanical device requirements that are not in (or will not be in) the normal Line Class Specifications? Are these items identified as SP Items and details available?

Utility Distribution Sheet Review: Utility Distribution Diagrams are also schematic drawings but they differ from a P&ID in that they are somewhat Plot Plan oriented. This is required and done so the supply and return headers can be properly sized. Utility Distribution Diagrams may have all services on one sheet or may have the services grouped by some family breakdown. Steam Utilities may include - High Pressure Steam - Medium Pressure Steam - Low Pressure Steam - Medium Pressure Condensate - Low Pressure Condensate Water Utilities may include: - Cooling Water Supply - Cooling Water Return - Plant Water - Potable (Drinking) Water Air Utilities may include: - Plant Air - Instrument Air Miscellaneous Utilities may include: - Nitrogen - Flare Header - Slops Pump-Out Specific items to question are: Is the Utility Distribution Diagram plot plan oriented? Are all Utilities shown? Are the branches from the Utility headers in the correct sequence? Are the sizes for all the branches all known and indicated? Are the main Utility header sizes correct for the number, size and sequence of the branches? Is the number of Utility Stations correct? Are the Utility Stations numbered? Are the Utility Stations schematically located correctly? For Steam Headers, are steam trap manifolds shown at the correct locations? Do the connectors from the Utility Distribution Diagram match the connector on the P&ID? Is there a Line Identification (Line Number, Line Designation or other) for each line?