PROCESSDESIGNENGINEERING GUIDELINE
1.GETTING STARTED
1.1 PROCESS ENGINEERING AND ROLE OF PROCESS ENGINEER
Process design is the design of processes for desired physical and or chemical transformation ofmaterials. Process design is central to chemical engineering and it can be considered to be the summit of chemical engineering bringing together all of the ponents of that field.Process Engineering involves design of unit operations & equipment design.
Role of Process Engineer:
asd s ma daap saae auassad saa eauand designing new process plants and equipment or modifying existing ones. The processes thatseaupoad sewauo se pue o o ulue snpod aeaus o pasn ae yrm dn aoo au speciality chemicals to food and drink.
It is a vocation wherein the process engineer is supposed to perform any one or all of the activitiesas mentioned below to provide documentation for a safe reliable and profitable design
Design new equipment/unit/plant as per good and internationally accepted engineeringpractices (Greenfield)●Rate or check adequacy of existing equipment/unit/plant for changed operating conditions (e.g. pressure temperature flow etc.) as per good and internationally accepted engineering practices(Brownfield)
>Principal accountabilities:
●High level design option selection including economics.Optimization/evaluationof existing processes including understanding feedstock position heat/material balance implications.●Troubleshoots existing plant systems.●Understands uses and champions engineering standards and work processes.●Modelling of systems. ●Plant support when needed Process Hazard analysis Documentation of work.
Responsibilities:
● Develops and evaluates plans and criteria for a variety of projects and problem solving activities including scale up design optimization of chemical manufacturing processes and facilities.●Develops/assesses the feasibility soundness and safety of engineering designs and solutions. Provides conceptual design of process equipment systems.● Identify and apply design and simulation tools for design optimization and troubleshooting of●Based on Client's requirements develops Heat & Material Balances using simulation software. processes.●Develops Process Flow diagrams to show operations necessary to convert feedstock into on● Defines and sizes Equipment and Instrumentation to be implemented and issues relevant specification products in the most economical manner.Process Data sheets.● Elaborates Piping and Instrumentation Diagrams.
●Performs hydraulic and thermal calculations on piping systems pipelines flow lines in steadystate and transient operation.●Defines the utilities requirements and designs the associated systems. ●Defines quantities and characteristics of effluents to be disposed to the environment.●Participates to the preparation of Operating Manual under Pre-missioning department● Identify process hazards and participate in process safety review. supervision.
1.2 VARIOUS PACKAGES USED IN INDUSTRY
>Conceptual And Feasibility Studies
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•Is it technically feasible?●What is the best possible chemistry and reaction for the process?●Should it be a batch or continuous production process? ●How much would it cost to set up the unit?●Is there a ready market available for selling the product?●Is the technology environment friendly and safe?
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●Evaluating the various process routes from economic environment and safety view point and selecting the best option.●Develop preliminary process flow or block diagrams● Develop preliminary material and energy balances based on a selected economic plant capacity.•Estimate cost of the project with a deviation of 50% / -30%. ●List of major equipment.●Identify weak areas in process design such as experimental design insufficient laboratory or pilotplant data scale-up from pilot plant design and benchmarking against existing designs.
>Front End Engineering Design (FEED)
Process Engineering Information
●Raw Material SpecificationsuseUtility Specifications
Typical Process Engineering Deliverables:
●Process Design Basis● Process Flow Diagrams (PFDs) including major process control automation ●Extensive Heat & Material Balance generally using process design simulators●Utility Balance and Utility Flow Diagrams (UFDs)●Piping & Instrumentation Diagrams (P&IDs)●Process Safeguarding Diagrams
●Material Selection Diagrams●Line Designation List Equipment List Tie-in List●Hazardous Area Classification Schedule ●Equipment (Static / Rotating) Process Datasheets●Instrument Process Datasheets●Relief Devices Datasheets and Relief Devices Summary Report ●Process Description●Operating Control and Safeguarding Philosophy Process Control Narrative●Hydraulic Calculations and Line Sizing Report●PHA / HAZID / HAZOP Reports ●Trip and Alarm Summary Report●Piping Material Specification●Insulation Specification
Detail Engineering Design
In addition to this many documents and drawings specific to this phase are prepared which involveengineering from other engineering disciplines such as Mechanical Piping Instrumentation Electrical and Civil.
List of Specific Deliverables Prepared during Detail Design
●Pre-missioning and Commissioning Manual ●Operation and Maintenance Manual●Pre-Construction HAZOP Review and Closeout Report●Effluents and Emissions Summary●Instrument Loop Diagrams (ILDs) ●Single Line Diagrams (SLDs)●Material Requisitions (MRs) for Static Equipment (Tanks / Vessels / Columns)●MRs for Electrical Items (Transformers / DG Sets / Switchgear / Cables / UPS System) ●MRs for Rotary Equipment (Pumps / Compressors / Fans / Blowers)●MRs for Instrument Items (Flow / Pressure / Level / Temperature / Control Valves / Shut-down●MRs for Civil/ Structural Valves / DCS / PLC)●Piping Key Plan Piping GA Drawings Piping Isometric Drawings●Piping Bulk Material Take-Off (MTO) (Valves / Pipe fittings / Pipe Supports) ●Instrument Bulk MTO (Tubing & Fittings / Cable Trays / Stanchion / Instrument Cables/ CableGlands / Multi Cable Transit)●Electrical Bulk MTO (Cables / Conduits/ Cable Trays / Cable Ties / Connectors / Lugs)●Civil Bulk MTO (Earthwork Cut/Fill / Piles / Structural Steel / Concrete) ●Bar Bending Schedule (Civil)●Review of Vendor Documents / Drawings (All Disciplines)●Technical Bid Analysis ●Specifications for Active and Passive Fire Protection●Fire Fighting MTO
