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PART I: PRACTICAL PRINCIPLES
1. PROCESS PLANT DESING
What is engineering?
What is design?
Engineering design
Project life cycle
Process plant design
Process plant design versus process design
Academic versus professional practice
State of the art and good engineering practice
The use and abuse of computers
2. STAGE OF PROCESS PLANT DESING
General
Conceptual design of chemical processes
Front-End Engineering Design (FEED)/basic design
Detailed desing
Site redising
Posthandover redesign
Unstaged desig
Product engineering
Fast-tracking
3. PROCESS PLANT DESING DELIVERABLES
Overview
Design basis and philosophies
Specification
Process flow diagram
Piping and instrumentation diagram
Functional design specification
Plot plan/general arrangement/layout drawing
Program
Cost estimate
Equipment list/Schedule
Datasheets
Safety documentation
Design calculations
Isometric piping drawings
Simulator output
4. TWENTY-FIRST CENTURY PROCESS PLANT DESIGN TOLOS
General
Use of computers by chemical engineers
Implications of modern design tools
Categories of design
Tools-hardware
Tools-Software
Further Reading
5. THE FUTURE OF PROCESS PLANT DESIGN
Process porn
Will first-principles design replace heuristic design in future?
Will primary research become the basis of engineering design in future?
Will “chemical process design” replace process plant design in future?
Will network análisis from the coreo f design practice in future?
Will process simulation replace the design process in future?
Will process plant defign never change?
PART II. PROFESSIONAL PRACTICE
6. SYSTEM LEVEL DESIGN
Introduction
How to Put Unit Operations Together
Matching Design Rigor with Stage of Design
Implications for Cost
Implications for Safety
Implications for Robustness
Rule of Thumb Design
First Principles Design
Design by Simulation Program
Sources of Design Data
7. PROFESSIONAL DESIGN METHODOLOGY
Introduction
Design Methodologies
The "is" and "Ought" of Process Design
Right versus Wrong Design
Interesting versus Boring Design
Continuous versus Batch Design
Simple/Robust versus Complicated/Fragile Design
Setting the Design Envelope
Implications of New Design Tools
Importance of Understanding Your Design
Manager/Engineer Tensions in Design
Whole-System Design Methodology
Design Stages in a Nutshell
Variations on a Theme
8. HOW TO DO A MASS AND ENERGY BALANCE
8.1 Introduction
8.2 Handling Recycles
8.3 How to Set it Out in Excel
8.4 Using Excel for Iterative Calculations: "Goal Seek" and "Solver"
9. HOW TO DO HYDRAULIC CALCULATIONS
Introduction
Matching Design Rigor with Stage of Design
Hydraulic Networks
Pump Curves
PART III. LOW LEVEL DESIGN
10. HOW TO DESIGN AND SELECT PLANT COMPONENTS AND MATERIALS
Introduction
What Process Engineers Design
Matching Design Rigor with Stage of Design
Materials of Construction
Mechanical Equipment
Electrical and Control Equipment
11. HOW TO DESIGN UNIT OPERATIONS
Introduction
Matching Design Rigor with Stage of Design
Rule of Thumb Design
Approaches to Design of Unit Operations
Sources of Design Data
Scale-up and Scale-out
Neglected Unit Operations: Separation Processes
12. HOW TO COST A DESIGN
Introduction
Matching Design Rigor with Stage of Design
The Basics
Academic Costing Practice
Professional Costing Practice
PART IV. HIGH LEVEL DESIGN
13. HOW TO DESIGN A PROCESS CONTROL SYSTEM
Introduction
Matching Design Rigor with Stage of Design
Operation and Maintenance Manuals
Specification of Operators
Automatic Control
Standard Control and Instrumentation Strategies
14. HOW TO LAY OUT A PROCESS PLANT
Introduction
General Principles
Factors Affecting Layout
Plant Layout and Safety
Plant Layout and Cost
Plant Layout and Aesthetics
Matching Design Rigor with Stage of Design
15. HOW TO MAKE SURE YOUR DESIGN IS REASONABLY SAFE AND SUSTAINABLE
Introduction
Why Only Reasonably?
Matching Design Rigor with Stage of Design
Conceptual Design Stage
Detailed Design Stage
Formal Methods: Safety
Formal Methods: Sustainability
Specification of Equipment with Safety Implications in Mind
Specification of Safety Devices
Types of Safety Device
PART V. ADVANCED DESIGN
16. PROFESSIONAL PRACTICE
Introduction
General Design Methodology
Informal Design Reviews
Formal Design Reviews
Quality Assurance and Document Control
Informal Data Exchange
17. BEGINNER'S ERRORS TO AVOID
Introduction
Lack of Equipment Knowledge
Lack of Knowledge of Many Types of Unit Operations
Lack of Knowledge of Many Materials of Construction
Lack of Utilities
Layout
Process Control
18. DESIGN OPTIMIZATION
Introduction
Matching Design Rigor with Stage of Design
Indicators of a Need to Integrate Design
How to Integrate Design
When and How Not to Integrate Design
Where's the Harm? The Downside of Academic "Process Integration"
19. DEVELOPING YOUR OWN DESIGN STYLE
Introduction
The Art of Engineering
The Philosophy of Engineering
The Literature of Engineering
The Practice of Engineering
Personal Sota
Appendix 1: Integrated Design Example
Appendix 2: Upset Conditions Table
Appendix 3: Plant Separation Tables
Appendix 4: Checklists for Engineering Flow Diagrams
Appendix 5: Teaching Practical Process Plant Design