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

© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy Chemical Engineering Design
 How do companies implement this
design process?

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

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

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

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

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

Towler & Sinnott Chemical Engineering Design only. Do not copy Chemical Engineering Design
 3. The Project Plan

Project must be delivered:

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 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
2/22

incentives into the E&C

19 PFD Review
20 Basic Engineering
21 P&ID review 5/18

contract to ensure that

22 Detailed Engineering
23 Layout Review 8/31

24 Procurement

this happens
25 Fabrication
26 Delivery & Installation
27 Begin Run 12/28

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

Towler & Sinnott Chemical Engineering Design only. Do not copy 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

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

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

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

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

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

Towler & Sinnott Chemical Engineering Design only. Do not copy Chemical Engineering Design
 Process Design Basis
Company Name
Address
Project Name
Project Number
REV DATE BY APVD REV
Sheet
DATE BY
1
APVD
• Documentation of design assumptions
Form XXXXX-YY-ZZ
1 General Information
DESIGN BASIS
and boundary conditions is very important
Owners Name

• For new process plants, most companies

Process Unit Name

Plant Location

Correspondance Contacts
Address

use some sort of design basis form or

Telephone / Fax
E-mail

2 Measurement System

3 Equipment Numbering System

English Metric
questionnaire to serve as a record of the
design basis
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
• This record is also essential in handing
off information between the operating
Production Rate
Tons per year
Tons per day
Other units

Product Purity (wt%)

Product shipment mode

company, technology suppliers and
Additional Specifications

contractors
5 Primary Raw Materials
(Attach additional sheets if needed)
Feedstock name

• There’s a template online at: booksite.

Feedstock grade
MSDS form number

Feedstock availability
Tons per year

Elsevier.com/Towler
Tons per day
Other units

Feedstock price ($/lb)

(Default: open market price)

Known feedstock impurities Name ppmw Name ppmw Name ppmw Name ppmw

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

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

Towler & Sinnott Chemical Engineering Design only. Do not copy Chemical Engineering Design
 What’s 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 aren’t 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
 What’s 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

Telephone / Fax
Low ambient temperature (F)
High ambient temperature (F)
Hight ambient relative humidity (%)
Site elevation (ft)
Maximum wind loading (mph)

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

Towler & Sinnott Chemical Engineering Design only. Do not copy Chemical Engineering Design
 What’s 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
Towler & Sinnott Chemical Engineering Design only. Do not copy Chemical Engineering Design
 What’s 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

English

AC Air cooler
Metric

G Grinder, mill R Reactor

Production Rate
Tons per year
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

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 (%)

Additional Specifications
Site elevation (ft)
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

Towler & Sinnott Chemical Engineering Design only. Do not copy Chemical Engineering Design
 What’s 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

Other units
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

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)

Known feedstock impurities Name ppmw

(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

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

Towler & Sinnott Chemical Engineering Design only. Do not copy Chemical Engineering Design
 What’s 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

Maximum wind loading (mph)

4 Primary Products

Product Name
Product Grade
MSDS Form Number

Production Rate
Tons per year

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

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

Towler & Sinnott Chemical Engineering Design only. Do not copy Chemical Engineering Design
 What’s 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

• Fuel oils
H2S
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

Water feed stream Raw Water Process Water Boiler Feed Water Condensate

• Process Air
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)

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

Towler & Sinnott Chemical Engineering Design only. Do not copy Chemical Engineering Design
 Learning activities 1

Enter the site: booksite.Elsevier.com / Towler ,

download the design basis template; complete the
general information of the study case.

Use the checklist for the Design Basis

© 2007 G.P. Towler / UOP. For educational use in conjunction with

Sinnott & Towler Chemical Engineering Design only. Do not copy 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

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

Towler & Sinnott Chemical Engineering Design only. Do not copy Chemical Engineering Design
 Learning Activities 2

• Read the chapter and answer the quiz.

Pipe Drafting and Design 2nd Edition

Roy A. Parisher, Robert A. Rhea
Chapter 8
Codes and Specifications

© 2007 G.P. Towler / UOP. For educational use in conjunction with

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

© 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
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

© 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
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

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

© 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
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

Towler & Sinnott Chemical Engineering Design only. Do not copy 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 a starting point for the capital
6. A list of major plant cost estimate
equipment
7. Equipment specification sheets
8. A piping and instrumentation
diagram
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
© 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 Equipm ent 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

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

6. A list of major plant equipment

Pressure drop calculated psi
Flow velocity ft/s

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

7. Equipment specification
Fouling coefficient Btu/h.ft2.F
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

© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy Chemical Engineering Design
 What’s 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
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

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 lb/h
Total steam flow lb/h
Fluid vaporized / condensed lb/h
Density 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 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.

© 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 3

• 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 • Material Safety Data Sheets
6. A list of major plant equipment (MSDSs) must be provided to
7. Equipment specification sheets
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
© 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