Lecture -4 &5

CH4317 Project Engineering

Process Design & Development

Dr. Mahendra Chinthala

Assistant Professor
Department of Chemical Engineering
NIT Rourkela
General Design considerations
Emphasis will be on
Health and safety Hazards
Loss prevention
Environmental Protection
Plant location
Plant layout
Plant operation and control
Utility use
Structural design
Materials handling
Storage, and
Patent considerations
LOSS PREVENTION
 The phrase loss prevention in the chemical industry is the financial
loss associated with an accident.
 This loss not only represents the cost of repairing or replacing the
damaged facility, but also includes the loss of earnings from lost
production during the repair period and any associated lost sales
opportunities.
 Loss prevention in process design can be summarized

 Identification and assessment of the major hazards.

 Control of the hazards by the most appropriate means, for example,
containment, substitution, improved maintenance, etc.
 Control of the process, i.e., prevention of hazardous conditions in
process operating variables by utilizing automatic control and relief
systems, interlocks, alarms, etc.
 Limitation of the loss when an incident occurs.
 Safety Analysis Methods
 Generally, the purpose of any safety analysis is to prevent the
occurrence of accidents.
 This can only be achieved if the analysis is conducted by using the
most effective method for a given problem.
 In order to perform an effective analysis, a careful consideration
must be given in selecting a safety analysis tool.

 Hazard and Operability Analysis (HAZOP)

 Fault Tress analysis (FTA)
 Failure Modes and Effect Analysis (FMEA)
 Markov Method
 Job Hazard analysis (JHA)
 Control Charts
HAZOP Study
 The HAZard and OPerability study, commonly
referred to as the HAZOP study, is a systematic
technique for identifying all plant or equipment
hazards and operability problems.
 HAZOP is a process to identify and assess risk.

 In this technique, each segment (pipeline, piece of

equipment, instrument, etc.) is carefully
examined, and all possible deviations from
normal operating conditions are identified.
HAZOP is an identifying technique and not
intended as a means of solving problems
Features of HAZOP study

Subsystems of interest Line, valve, equipment, vessels, etc

Modes of operation Normal operation
Start -up mode
Shutdown mode
Maintenance /construction / inspection
mode
Trigger events Human failure
Equipment/instrument/component failure
Supply failure Emergency environment
event
Effects within plant Changes in chemical conditions
Changes in inventory
Change in chemical physical conditions
Features of HAZOP study

How would During normal operation Upon human

hazardous conditions failure Upon component failure In other
detected ? circumstances
Contingency actions Improve isolation Improve protection
Corrective actions Change of process design
Change of operating limits
Change of system reliability
Improvement of material containment
Change control system Add/remove
materials
When to conduct HAZOP study ?
Documents needed for HAZOP study
GUIDE WORDS

Guide Words Meaning

No, None Negation of Intention (No flow)
More Of Quantitative Increase (e.g., higher Temp).
Less Of Quantitative Decrease (e.g., lower Pressure)
As Well As (More Than)Qualitative Increase (e.g., an impurity)
Part Of Qualitative Decrease (e.g., only one of two
components in a mixture)
Reverse Opposite of Intention (e.g., backflow).
Other Than Complete Substitution (e.g., flow of wrong
material
Process elements

 Flow
 Composition
 pH
 Pressure
 Temperature
 Reaction
 Time
 Stirring Speed
 Maintain Level
 Particle Size
 Viscosity, etc.,
STUDY NODES
The locations (on P&ID or procedures) at which the process
parameters are investigated for deviations.
These nodes are points where the process parameters (P, T, F etc.)
have an identified design intent.
INTENTION
The intention defines how the plant is expected to operate in the
absence of deviations at the study nodes.
DEVIATIONS
A deviation is a way in which the process conditions may depart
from their design/process intent.
Guide-word + Parameter = Deviation
Example: No + Flow = No Flow
 CAUSES: The reason(s) why the deviation could occur.
Several causes may be identified for one deviation.
 It is often recommended to start with the causes that may result in
the worst possible consequence.

 CONSEQUENCES: The results of the deviation, in case it

occurs.
Consequences may both comprise process hazards and operability
problems, like plant shut-down or reduced quality of the product
Several consequences may follow from one cause and, in turn,
one consequence can have several causes.
Safeguards

Facilities that help to reduce the occurrence frequency of

the deviation or to mitigate its consequences.
There are five types of safeguards that:
1.Identify the deviation:
2.Compensate for the deviation:
3.Prevent the deviation from occurring:
4.Prevent further escalation of the deviation:
5.Relieve the process from the hazardous deviation.
 HAZOP procedure

1. Divide the system into sections (i.e., reactor, storage)

2. Choose a study node (i.e., line, vessel, pump, etc.,)
3. Describe the design intent
4. Select a process parameter
5. Apply a guide-word
6. Determine cause(s)
7. Evaluate consequences/problems
8. Recommend action: What? When? Who?
9. Record information
10. Repeat procedure (from step 2)
HAZOP procedure
HAZOP TEAM
Case Study

Shell & Tube Heat Exchanger

HAZOP Study

A flammable liquid reagent

is unloaded from tank trucks
into a storage tank maintained
under a slight positive
pressure until the reagent is
transferred to the reactor in
the process.

Piping and Instrumentation diagram used in HAZOP example

HAZOP Advantages
HAZOP Disadvantages
Fault Tree Analysis (FTA)
• The fault-tree analysis (FTA) is primarily a means of
analyzing hazardous events after they have been
identified by other techniques such as HAZOP.
• The FTA is used to estimate the likelihood of an accident
by breaking it down into its contributing sequences, each
of which is separated into all its necessary events.
• The use of a logic diagram or fault tree then provides a
graphical representation between certain possible events
and an undesired consequence.
Fault Tree Analysis (FTA)

 Fault Tree Analysis was originally developed in 1962 at Bell

Laboratories by H.A. Watson.
 FTA is a deductive analysis approach for resolving an undesired
event into its causes.
 Logic diagrams and Boolean Algebra are used to identify the
cause of the top event
 FTA is widely used in industry to perform reliability analysis of
engineering systems during design and development.
Objectives of FTA

 To identify critical areas

 To recognize cost-effective improvements
 To confirm the ability of a system to meet its imposed safety
requirements
 To confirm system reliability
 To understand the functional relationship of systems failure.
 Fault Tress Analysis (FTA)

 Fault tree is the logical model of the relationship of the

undesired event to more basic events
 FTA begins by identifying an undesirable event, called top event,
associated with a system under consideration.
 The middle events are intermediate events and the basic
events are at the bottom.
 Fault events that can cause the top event are generated and
conducted by logic operators such as OR and AND.
Fault Tress Analysis (FTA)
Fault Tress Analysis (FTA)

Basic Event: A lower most event that can not be further

developed.

Intermediate Event: This can be a intermediate event

(or) a top event. They are a result of logical combination
of lower level events.

Undeveloped Event: An event which has scope for

further development but not done usually because of
insufficient data.

External Event: An event external to the system which

can cause failure
 Fault Tress Analysis (FTA)

OR Gate: Either one of the bottom event results in the occurrence

of the top event.

AND Gate: For the top event to occur all the bottom events should
occur.

Inhibit Gate: The top event occurs only if the bottom

event occurs and the inhibit condition is true.
Procedure for Fault Tree Analysis
Fault Tree analysis
symbols
Example of FTA
Probability evaluation of Fault Trees
Example of FTA
Advantages of FTA

 User could select the top event to be specific to the failure of

interest.
 The minimal cut sets provide enormous inside into the various
failure modes for top event to occur.
 Minimal cut sets with a product of 4 or more independent
failure will increase the reliability of the system.
 Provide a qualitative and quantitative reliability analysis.
 Software are available to construct fault tree, to determine cut
sets and to calculate the failure probabilities.
Disadvantages of FTA

 Can be enormous (thousands gate and intermediate events)

 Not necessarily all failure modes are considered.
 Need experienced engineers
 Assume hardware not to fail partially (such the possibility of
valve leak is not considered).
 Assume failure of one component does not put stress on the
other components (that could change component failure
probabilities).
 External events not correctly treated
General Design considerations
Emphasis will be on
Health and safety Hazards
Loss prevention
Plant operation and control
Environmental Protection
Patent considerations
Plant location
Plant layout
Plant operation and control
 In the design of an industrial plant, the methods which will be
used for plant operation and control help determine many of the
design variables.

 For example, the extent of instrumentation can be a factor in

choosing the type of process and setting the labor requirements.

 Maintenance work will be necessary to keep the installed

equipment and facilities in good operating condition.

 The engineer must recognize the importance of such factors

which are directly related to plant operation and control and
must take them into proper account during the development of a
design project.
Main title

Process Control
Write title here

WriteA process
Discussion herecan
be defined as a series of operations in the
making, handling or treatment of a product.

Process control refers to the methods that are used to

control process variables when manufacturing a product.

Manufacturers control the production process for three

reasons:

Variability.
Increase Efficiency.
Ensure Safety.
Main title

The
Write titleControl
here Loop
WriteADiscussion
control loophere
is a group of instruments that work together to keep a process
variable at its desired value, referred to as set point.

There are four components in a control loop:

Process variable
Sensing/measuring device.
Controller.
Final control device.

Regardless of the process, measuring and control jobs are very similar. But,
the instruments used to perform measuring and control will vary from one
process to another.
Main title

Control
Write title hereLoop Definitions
Write Controlled
Discussion here A controlled variable is sometimes referred to as the process variable. It is the
variable element that is to be controlled, for example, pressure, temperature, level,
flow, chemical composition, etc.
Measured A measured variable is a measurement signal of the controlled variable.
variable
Setpoint The setpoint is the desired value of a process. It is the value of the controlled
variable that the process is required to operate at.
Error An Error is the difference between the measured variable and the set point and
can be either positive or negative.
Offset The Offset is a sustained deviation of the process variable from the set point.
Manipulated A manipulated variable is the actual variable changed by the final control
variable element to obtain the desired effect on the controlled variable.
Disturbances (upsets) are any changes that can occur to the process to cause
Disturbances the controlled variable to change from the setpoint.
Main title

Control
Write Loops and Controller Action
title here

WriteA control system

Discussion here is a mechanical or electronic system that is used to obtain and
maintain the specific result.

Process control can simply be defined as the automated control of a process or

the manipulation of a set of conditions to bring about a desired change in the
output of the process.
Main title

Process
Write variable
title here
A process
Write variable
Discussion hereis a condition of the process fluid that can change
the manufacturing process in some way. Common process variables
include:

Basic Process Measurement

Pressure
Flow
Level
Temperature
Control system for Heating
process
Level control system of a continuous stirred-tank
reactor
Pressure control system
Flow control system
Main title

Sensing/measuring
Write title here device
Primary
Write elements
Discussion here are devices that cause some change in their property with changes
in process fluid conditions that can then be measured.

Orifice Plates
Pitot Tubes
Pressure Sensing Venturi Tubes
Diaphragms, Magnetic Flow
Tubes Coriolis
Strain Gauges, Flow Tubes
Capacitance Ultrasonic
Cells Annubar Vortex
Sheddar

Radar
Resistance Nuclear
Temperature
Detectors (RTDs) Ultrasonic
Thermocouples
Thermometers Capacitive
Displacer
Main title

WriteControl
title here system

Write Discussion here

Controllers also commonly reside in a digital control system such as.

Distributed Control Systems (DCS)

DCSs are controllers that, in addition to performing control functions, provide readings of
the status of the process, maintain databases and advanced man- machine-interface.

Programmable Logic Controllers (PLC)

PLCs are usually computers connected to a set of input/output (I/O) devices. The
computers are programmed to respond to inputs by sending outputs to maintain all
processes at set point.

Supervisory Control and Data Acquisition (SCADA)

SCADA systems are generally used to control dispersed assets using centralized data
acquisition and supervisory control.
Main title

WriteFinal
title here
control device
Write Discussion here
Final control element is the part of the control system
that acts to physically change the manipulated
variable.

The final control element may be Control valve

Electrical motors Pumps
Dampers
Main title

WriteClosed
title hereand Open control loops
Write Discussion here
Closed Loop
A closed control loop exists where a process variable is measured, compared to a
set point, and action is taken to correct any deviation from set point.
Main title
Closed and Open control loops
Write title here
Open Loop
Write Discussion here
An open control loop exists where the process variable is not
compared, and action is not taken in response to feedback on the
condition of the process variable, but is instead taken without regard
to process variable conditions.
Main title

WriteAutomatic
title here and Manual control

WriteAutomatic
DiscussionControl
here
This term came into wide use when people learned to adapt automatic regulatory
procedures to manufacture products or process material more efficiently.

Such procedures are called automatic because no human (manual) intervention is

required to regulate them.
Main title

WriteAutomatic
title here and Manual control
Write Discussion here
Manual Control Loop
Without automatic controllers, all regulation tasks will have to be done manually.

For example: To keep constant the temperature of water discharged from an

industrial gas-fired heater, an operator has to watch a temperature gauge and
adjust a gas control valve accordingly.
Main title

Write title here

Closed Loop Control
Write Discussion here
Main title

Write
Opentitle Loop
here Control

Write Discussion here

Main title

Write title here

Write Discussion here

Instrumentation
Main title

Write title here

Write Discussion here

Pressure Measurement
Basics of Instrumentation and Control
Main title

WriteCommonly
Coursetitle here Used Flow Devices
Contents

WriteDifferential Pressure (Head) Type

Discussion here
Course Topics
Orifice Plate
Venturi Tube
Introduction to measurements and control concepts Pressure measurement
Flow Nozzles
FlowElbow
measurement Level measurement
Pitot Tube,
Temperature measurement
Wedge Meter
Control Valves Process Control Loops
V-Cone
Velocity
Control Type
Systems (PLC, DCS, SCADA)
Magnetic
Doppler Turbine
Vortex
Mass Type
Coriolis Thermal
Variable Area meter
Rotameter
Main title

Write title here

Write Discussion here

Level Measurement
Basics of Instrumentation and Control
Main title

Write title
Course here
Contents
Types of level measurement
Write Discussion here
Course Topics
Introduction
Contacttotype
measurements and control concepts Pressure measurement
instrument
FlowSight-type Instruments
measurement Level measurement
Float-type
Temperature Instruments
measurement
Hydrostatic Pressure-type
Control Valves Process Control Loops
Displacer-type Instrument
Control Systems (PLC, Instruments
Electrical-type DCS, SCADA)

Non-contact type instruments

Sonic-type Instruments Radiation-
type Instruments
Main title

Write title here

Write Discussion here

Temperature Measurement
Classification

1.Glass thermometers
2.Pressure gauge thermometers
3.Differential expansion thermometers
4.Electrical resistance thermometers
5.Thermo couples
6.Optical pyrometers
7.Radiation pyrometers
8.Fusion pyrometers
9.Calorimetric pyrometers
Main title

Write title here

Write Discussion here

Final Control Elements

Control Valves
Basics of Instrumentation and Control
Main title

Final Control Element

Write title
Course here
Contents

Write Discussion here

Course Topics
Basic Valve
Introduction Components
to measurements and control concepts Pressure measurement
Flow measurement Level measurement
Body
Temperature measurement
Control Valves Process Control Loops
Bonnet
Control Systems (PLC, DCS, SCADA)
Trim

Packing Actuator
Basics of Instrumentation and Control
Main title

Control
Write
Coursetitle hereValve
Contents Classification
Write Discussion here
Course Topics
Introduction to measurements and control concepts
ControlPressure measurement
Valve
Flow measurement Level measurement
Linear Rotary
Temperature measurement Motion
Motion
Control Valves Process Control Loops
Globe Diaphragm Gate Ball Butterfly Disk
Control Systems (PLC, DCS, SCADA)

Globe Angle 3 way

Single Double
port port
Main title

Write title here

Write Discussion here

Process Control Loops

Controller Modes

1. ON-OFF controller/two position controller

2. Proportional Action Control
3. Integral/Reset Action Control
4. Derivative/Rate Action Control
5. P+I Control
6. P+D Control
7. P+I+D Control
Basics of Instrumentation and Control
Main title

Write
Course Types
 title here
Contents of Control Schemes
 The control
Write Discussion here scheme of a PID feedback controller is the
CoursemostTopicscommon control scheme used in industry today.
 Other
Introduction control schemes
to measurements have
and control beenPressure
concepts developed to improve
measurement
the response
Flow measurement Level of the process to disturbances, some being:
measurement
 Cascade
Temperature control.
measurement
RatioProcess
 Valves
Control control.
Control Loops
Control Split range.
 Systems (PLC, DCS, SCADA)
 Feedforward control.
 Selectors,
 Overrides, and Interlocks.
 Multivariable control. Adaptive control.
Basics of Instrumentation and Control
Main title

WriteP&ID
Coursetitle Symbols
here
Contents

Write Discussion here

P&IDsTopics
Course provide information about all
equipment, all the instruments used to
monitor ortocontrol
Introduction the process,
measurements andcontrol
and all concepts Pressure measurement
their associated lines or pipelines.
Flow measurement Level measurement
There are standard
Temperature symbols and
measurement
designations for P&IDs. They may use
Control Valves Process
the International Control
Society Loops
of Automation
(ISA) standards, or your facility may
Control
use Systems
their own(PLC, DCS, SCADA)
standards. All drawings
must be done the same way, using the
same symbols and designations for:
Equipment.
Instruments designations and symbols.
Pipeline designations.
Valve and miscellaneous symbols.
Basics of Instrumentation and Control
Main title

WriteInstrument
Course title here
Contents Designations

WriteThere are several

Discussion here different instrument designations for process variable control or
Course TopicsThis table shows some of the most common ones.
monitoring.

Introduction to measurements and control concepts Pressure measurement

Flow measurement Level measurement
Temperature measurement
Control Valves Process Control Loops
Control Systems (PLC, DCS, SCADA)
Basics of Instrumentation and Control
Main title

WriteInstrument
Coursetitle here
Contents Symbols
Write Discussion here
Course Topics
Introduction to measurements and control concepts Pressure measurement
Flow measurement Level measurement
Temperature measurement
Control Valves Process Control Loops
Control Systems (PLC, DCS, SCADA)
Basics of Instrumentation and Control
Main title

Write title
Course here
Contents
Process Variable Symbols
Write Discussion here
Course Topics
Introduction to measurements and control concepts Pressure measurement
Flow measurement Level measurement
Temperature measurement
Control Valves Process Control Loops
Control Systems (PLC, DCS, SCADA)
Basics of Instrumentation and Control
Main title

Write title
Course here
Contents
Process Variable Symbols
Write Discussion here
Course Topics
Introduction to measurements and control concepts Pressure measurement
Flow measurement Level measurement
Temperature measurement
Control Valves Process Control Loops
Control Systems (PLC, DCS, SCADA)
Basics of Instrumentation and Control
Main title

WriteInstrument
Coursetitle here
Contents Line Symbols
Write Discussion here
Course Topics
Introduction to measurements and control concepts Pressure measurement
Flow measurement Level measurement
Temperature measurement
Control Valves Process Control Loops
Control Systems (PLC, DCS, SCADA)
Basics of Instrumentation and Control
Main title

WriteValve
Coursetitle Symbols
here
Contents

Write Discussion here

ThereTopics
Course are several types of valves used in a process and several ways they may
be actuated. Examples of valve types include:
Introduction to measurements and control concepts Pressure measurement
Flow measurement Level measurement
Temperature measurement
Control Valves Process Control Loops
Control Systems (PLC, DCS, SCADA)
Basics of Instrumentation and Control
Main title

Write title
Course here
Contents
Example
Write Discussion here
Course Topics
Introduction to measurements and control concepts Pressure measurement
Flow measurement Level measurement
Temperature measurement
Control Valves Process Control Loops
Control Systems (PLC, DCS, SCADA)
Text books:
1. Peters – Timmerham, Plant Design and Economics for Chemical Engineers, McGraw
Hill Book Co , 2017
2. F. C. Viberandt and C. E. Dryden, Chemical Engineering Plant Design, McGraw Hill
Book Co , 1959

Referernces
1. V.V. Mahajani & S. M. Mokashi, Chemical Project Economics, MacMillan INIDA
2. R. Smith, Chemical Process Design & Integration, John Wiley & Son
3. R.K. Sinnott, Chemical Engineering Design, Vol.6
4. J.M. Dougles, Conceputual Design & Chemical Processes, McGraw –Hill.
Thank
you