Industrial Process Design

Industrial Process
Design
© 2012 G.P. Towler / UOP. For educational use in conjunction with

Towler & Sinnott Chemical Engineering Design only. Do not copy
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

How do companies implement this
design process?

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

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

Company Performance by Sector
Company Symbol Market Cap Revenue Profit Margin ROA
($ billion) ($ billion) % %
ExxonMobil XOM 472.5 365.5 10.8 18.1
Valero Energy VLO 40.55 91.8 5.9 15.1
Dow DOW 42.7 49.1 7.6 7.6
DuPont DD 47.3 27.4 13.5 10.1
Pfizer PFE 179.5 48.4 40 16.9
Merck MRK 107.9 22.6 19.6 10.7
Shaw Group SGR 3.8 4.8 1.1 NA
Fluor FLR 9.8 14.1 1.9 5.1
Notes:
• Data from www.CNN.money.com as of 7.2.07
• Oil industry is usually not so profitable as during 2005-2007
• Technology companies are usually smaller, and are often subsidiaries or
privately held. Financial data are often not publicly available.

Long ago (<1980s) most projects were done “in
house”
Operating
Company Project Business
Sponsor Input
Project
Manager


Contractors
E&C
Technology Company
Vendor

Nowadays
(For most companies, most sectors)
Project Business
Operating Sponsor Input
Company
Project
Manager


Contractors
Technology E&C
Vendor Company

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

3. The Project Plan
ID Task Name
Project must be delivered:

M-1 M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13 M14 M15 M16 M17 M18 M19 M20 M21 M22 M23
1 Project KO Meeting 3/31
2 Process Commercialization 74 days
3 Verify Operating Conditions

4 Process Design - Flowsheet
• On-time
5 Verify Full Design Criteria
6 Process Design/Optimization
7 Cold Flow Modeling 206 days
8 Design Sparger
9 Approve Sparger Design 7/15
10 Construction of Wedge
11
12
13
PP design/construction/shakedown
Cold Flow Testing
Catalyst Scale-up 150 days
• On-budget
14 Catalyst Scale-up
15 Demonstration Plant 251 days
• OpCo usually writes

16 Commercialization Team Formed 1/12
17 Demo Plant Design Basis
18 Process Engineering
19 PFD Review 2/22
20
21
22
Basic Engineering
P&ID review 5/18 incentives into the E&C
Detailed Engineering
23
24
25
Layout Review
Procurement
8/31
contract to ensure that
Fabrication
26
27
Delivery & Installation
Begin Run 12/28 this happens

Design Work Process
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
Begin Operation
This also needs time This takes time

The Project Plan
• Is developed & implemented by
the project manager
ID Task Name M-1 M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13 M14 M15 M16 M17 M18 M19 M20 M21 M22 M23
1 Project KO Mee ting 3/31
• Sets deadlines for completion

2 Process Commercialization 74 days
3 Verify Operating Conditions

4 Process Design - Flowsheet
of activities & intermediate

5 Verify Full Design Criteria
6 Process Design/Optimization
7 Cold Flow Modeling 206 days
deliverables
8 Design Sparger
9 Approve Sparger Design 7/15
10 Constru ction of Wedge
11 PP design/construction/shakedown
12 Cold Flow Testing
13 Catalyst Scale-up 150 days
• Allows scheduling of
14 Catalyst Scale-up
15 Demons tration Plant 251 days
16 Commercialization Team Formed 1/12
subordinate or dependent tasks

17 Demo Plant Design Basis
18 Process Engineering
19 PFD Review 2/22
20 Basic Engineering
21 P&ID re view 5/18
22 Detailed Eng ineering
• Allows estimation of the

23 Layout Review 8/31
24 Procurement
25 Fabrication
required manpower resources

26 Delivery & Installation
27 Begin Run 12/28
at each stage of the project

• Determines the procurement
schedule & gives an estimate of
when cash outlays are
expected

Example: 11-Week Plan for a Process Design Project

What’s In a Project Plan?
List of tasks

Durations, start
and end dates

Predecessor
tasks

Resource
allocations

Gantt
chart

Example: 11-Week Plan for a Process Design Project

Tools for Project Planning
• Specialized software for larger projects
– MS Project
– SureTrak
– Primavera Project Planner
– Enterprise PM
– Cobra
• Small project plans & Gantt charts can be drawn in spreadsheets

or using cheap software (<$100)
– AceProject (free on-line)
– TurboProject
– Project Vision
– Quick Gantt

4. The Design Basis
Build Performance
Models
Generate Design
R&D if Needed
Concepts Predict Fitness
For Service
Evaluate Economics
& Select Design
Customer
Approval
Begin Operation
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?

Process Design Basis
Project Name
• Documentation of design
Company Name Project Number Sheet 1
Address REV DATE BY APVD REV DATE BY APVD
DESIGN BASIS
assumptions and boundary conditions

Form XXXXX-YY-ZZ
1 General Information
Owners Name
Process Unit Name
Plant Location
Correspondance Contacts
Address
is very important
Telephone / Fax
E-mail
• For new process plants, most

2 Measurement System
English Metric
3 Equipment Numbering System
companies use some sort of design

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
basis form or questionnaire to serve

Second & third digits - equipment count F Filter, classifier PRV Pressure relief valve
4 Primary Products
Product Name
as a record of the design basis

Product Grade
MSDS Form Number
Production Rate
Tons per year
Tons per day
Other units
• This record is also essential in

Product Purity (wt%)
Product shipment mode
Additional Specifications
5 Primary Raw Materials

(Attach additional sheets if needed)
handing off information between the
operating company, technology
Feedstock name
Feedstock grade
MSDS form number
Feedstock availability
Tons per year
suppliers and contractors

Tons per day
Other units
Feedstock price ($/lb)

(Default: open market price)
Known feedstock impurities Name ppmw Name ppmw Name ppmw Name ppmw
• There’s a template online at:

booksite.Elsevier.com/Towler
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

What’s in the Design Basis?
Project Name
DESIGN BASIS
Form XXXXX-YY-ZZ
Owners Name
Process Unit Name
Plant Location
Address
Telephone / Fax
E-mail
English Metric
Project Name

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

Feedstock name
Feedstock grade
MSDS form number
Tons per year
Tons per day
Other units

6 Site Information

Site elevation (ft)
Project information and revision tabs

• To allow retrieval of documentation
• To ensure that revisions are properly documented and make sure that the
engineers aren’t working from the wrong version
• To document review and approval of the design basis

Project Name
DESIGN BASIS
Form XXXXX-YY-ZZ
Owners Name
Process Unit Name
Plant Location
Address
Telephone / Fax
E-mail
English Metric

4 Primary Products
Product Name
Product Grade
MSDS Form Number
Production Rate
Tons per year
Tons per day
Other units


Owners Name
Feedstock name
Feedstock grade
MSDS form number
Tons per year
Tons per day
Other units
Process Unit Name
Plant Location
6 Site Information Address

Site elevation (ft)
Telephone / Fax
E-mail
Contact information
• Company name
• Process unit name
• Who to contact & where to reach them

Project Name
DESIGN BASIS
Form XXXXX-YY-ZZ
Owners Name
Process Unit Name
Plant Location
Address
Telephone / Fax
E-mail
English Metric

4 Primary Products
Product Name
Product Grade
MSDS Form Number
Production Rate
Tons per year
Tons per day
Other units
English Metric
Feedstock name
Feedstock grade
MSDS form number

Tons per year
Tons per day
Other units


6 Site Information

Site elevation (ft)

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
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
MSDS Form Number

Owners Name
Process Unit Name
Plant Location
Address
Telephone / Fax
E-mail
Equipment will be identified by alphabetic

English
AC Air cooler
Metric
G Grinder, mill R Reactor

Production Rate
Tons per year
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

Feedstock name
Feedstock grade
MSDS form number
Tons per year
Tons per day
Other units


6 Site Information

Site elevation (ft)
Product information for primary products

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

Feedstock name
Company Name
Project Name
Project Number Sheet 1
Feedstock grade
MSDS form number
DESIGN BASIS
Form XXXXX-YY-ZZ
Owners Name
Process Unit Name
Plant Location
Address
Telephone / Fax
E-mail
English Metric
Tons per year
Tons per day

Other units
4 Primary Products
Product Name
Product Grade
MSDS Form Number
Production Rate
Tons per year
Tons per day
Other units

Feedstock name
Feedstock grade
MSDS form number
Tons per year
Tons per day
Other units

Known feedstock impurities Name ppmw

6 Site Information

Site elevation (ft)
Information for primary raw materials Additional specifications
• Feedstock grades
• Safety information
• Availability and pricing
• Feed impurities and their concentrations

Project Name
DESIGN BASIS
Form XXXXX-YY-ZZ

Owners Name
Process Unit Name
Plant Location

Address
Telephone / Fax
E-mail

English Metric
Site elevation (ft)

4 Primary Products
Product Name
Product Grade
MSDS Form Number
Production Rate
Tons per year
Tons per day
Other units

Feedstock name
Feedstock grade
MSDS form number
Tons per year
Tons per day
Other units

6 Site Information

Site elevation (ft)
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

Project Name
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 ($/MMBTU)
• Fuel gases
Sulfur content (wppm)
Nitrogen content (wppm)
Chlorine content (wppm)
Gas composition (vol%)
H2O
O2
N2
CO
CO2
H2S
• Fuel oils
H2
CH4
C2H4
C2H6
C3H6
C3H8
C4H8
iC4H10
nC4H10
• Steam levels
C5H10
C5+
Fuel Oil
Fuel source or operation mode #2 Heating Oil
Supply header temperature (F)
Supply headder pressure (psia)
Net calorific value (BTU/lb)
• Coolants
Marginal fuel cost ($/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 cost ($/Mlb)
Coolants
• Electricity
Coolant classification Cooling Tower Water Once-Through Water Chilled Water
Operating pressure (psia)
Supply temperature (F)
Maximum return temperature (F)
Marginal cost ($)
Marginal cost units
Process Water Feeds

Water feed stream Raw Water Process Water Boiler Feed Water Condensate
• Process Air
Supply pressure (psia)
Supply temperature (F)
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 cost ($/Mscf)

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

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!

6. Design Documentation
Build Performance
Models
Generate Design
R&D if Needed
Concepts Predict Fitness
For Service
Evaluate Economics
& Select Design
Customer
Approval
Begin Operation
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

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

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
• Usually broken into
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.

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 (e.g.,
5. Product specifications and properties SOR/EOR, different
feeds, winter /summer,
8. A piping and instrumentation diagram etc.)
9. A cost estimate
10.HS&E information • Usually mass flow, mole
flow, wt% and mole% are
given for every
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
T otal

1. The design basis
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

• Defines equipment names
1. The design basis
3. Process flow diagram • Indicates which equipment is
4. At least one mass & energy balance “spared”
5. Product specifications and
properties
6. A list of major plant • Often used to summarize
equipment equipment costs and serve as
8. A piping and instrumentation a starting point for the capital
diagram cost estimate
9. A cost estimate
10. HS&E information No. of Capa city Capacity Equipment Cost pe r
Plant Section La bel Equipment Na me Type Metallurgy Ite ms Mea sure Ca pacity Units Measure Ca pa city Units Ite m (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
Project Name
Company Name Project Number Sheet 1 of 1
SHELL & TUBE HEAT EXCHANGER
1. The design basis

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

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
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
properties
Normal temperature ºF
Max temperature ºF
Min temperature ºF
Pressure psia
Pressure drop allowed psi

Pressure drop calculated psi
Flow velocity ft/s
Number of passes
Film transfer coefficient Btu/h.ft2.F
Fouling coefficient Btu/h.ft2.F
7. Equipment specification
Heat duty Btu/h
FT factor
Effective mean temperature difference ºF
Minimum surface required ft2
sheets
CONSTRUCTION & MATERIALS PER SHELL
Tubes
Material
Count Pitch in Square Triangular Welded
Length ft O.D. in Wall thickness in
8. A piping and instrumentation

Design pressure at max temp psia Test pressure psia Max external pressure psia
Number of tubes blanked
Shell
diagram
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
9. A cost estimate Branches

Shell side inlet
Tube side inlet
in N.B.
in N.B.
Shell side outlet
Tube side outlet
in N.B.
in N.B.
10. HS&E information

NOTES
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

What’s in a Spec Sheet? Project Name
Company Name Project Number Sheet 1 of 1
• Project info & rev tab

SHELL & TUBE HEAT EXCHANGER

Form XXXXX-YY-ZZ
Owner's Name
Plant Location Units English Metric
Case Description
Equipme nt la bel Equipme nt na me
• Equipment service and

Plant section
Process service
Design code TEMA Exchanger type
Shells per unit Series Parallel
Surface per unit ft2 Surface per shell ft2
summary information DATA PER UNIT
IN
SHELL SIDE
OUT IN
TUBE SIDE
OUT
Stream No.
Fluid
Total fluid flow lb/h
Total vapor flow lb/h
• Stream data needed

Total liquid flow lb/h
Total steam flow lb/h
Fluid vaporized / condensed lb/h
Density lb/cu ft
Dynamic viscosity lbm/ft.s
for design Specific heat capacity

Thermal conductivity
Latent heat
Normal temperature
Btu/lb.F
Btu.ft/h.ft2.F
Btu/lb
ºF
Max temperature ºF
Min temperature ºF
Pressure psia
Pressure drop allowed psi
• Calculated design
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
Effective mean temperature difference ºF
equipment
Minimum surface required ft2
CONSTRUCTION & MATERIALS PER SHELL
Tubes
Material
Count Pitch in Square Triangular Welded
Length ft O.D. in Wall thickness in
• Dimensions and
Design pressure at max temp psia Test pressure psia Max external pressure psia
Number of tubes blanked
Shell
Material
construction details
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
Shell side inlet in N.B. Shell side outlet in N.B.
• Notes
Tube side inlet in N.B. Tube side outlet in N.B.
NOTES
1.
2.
3.
4.
5.

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

Sinnott & Towler Chemical Engineering Design only. Do not copy
1. The design basis • The P&ID is more detailed
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
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
1. The design basis • Variable costs of production
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
• 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

• Information on materials safety is
1. The design basis
required for hazard analysis,
3. Process flow diagram detailed design
properties • Material Safety Data Sheets
6. A list of major plant equipment (MSDSs) must be provided to
8. A piping and instrumentation employees and customers by law
diagram in the U.S.A. (OSHA Hazard
9. A cost estimate
Communication Standard 29 CFR
10.HS&E information
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
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


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Industrial Process Design

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What are the main steps in a design process?

What are the main steps in a design process?

What roles are involved in a design team?

What roles are involved in a design team?

Industrial Process

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

Common to all design problems in all industries

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

Process Technical Control

R&D Mechanical Civil

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

Engineering & Construction Companies

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

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

Process Technical Control

R&D Mechanical Civil

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

Process Technical Control

R&D Mechanical Civil

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

• “OpCo” might itself be a joint venture between several

• The companies might all be based in different regions of

• Teamwork, technology transfer and effective

• Good project management is more important than ever

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

Project must be delivered:

3 Verify Operating Conditions

• OpCo usually writes

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

This also needs time This takes time

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

• Sets deadlines for completion

3 Verify Operating Conditions

of activities & intermediate

16 Commercialization Team Formed 1/12

subordinate or dependent tasks

22 Detailed Eng ineering

• Allows estimation of the

required manpower resources

at each stage of the project

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

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

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

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

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

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

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

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

• Small project plans & Gantt charts can be drawn in spreadsheets

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

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

assumptions and boundary conditions

Process Unit Name

• For new process plants, most

3 Equipment Numbering System

companies use some sort of design

basis form or questionnaire to serve

as a record of the design basis

• This record is also essential in