Basic Design and Concepts

of Industrial Plant Systems

and Equipment
Group 1
Asis, Jessalyn
Bolanos, Jameskey
Daradar, Marlyn
Occidental, Mary Jean
Industrial Plant Engineering
We define the term "industrial plant engineering"
as assembling machines, systems, machine and
system parts that are delivered to the end customer.
Furthermore, existing plants are relocated,
extended and adjusted as part of rationalization
projects. If required by the customer, solution
proposals are drawn up for changing existing
systems and plants, for example as part of
company relocations, machine relocations and
repair tasks.
Some Example of Industrial Plants
Textile industry
Footwear industry
Clothing Accessories Industry
Pharmaceutical industry
Plastic industry
industrial equipment
Preserved Food Industry
Industry of processed foods
Electronic Equipment Industry
Beverage industry
Cleaning products industry
Leather industry
Furniture and accessories industry
Industry of machinery and
Metal industry
Primary metallurgical industry
Cosmetic Industry
General Design Considerations
Plant location
Site and plant layout
Plant operation and control
Utilities
Storage
Waste disposal
Health and safety
Materials handling ( will be discussed in the next chapters)
Plant Location and Site Selection
- The geographical location of the final plant can have strong influence on the
success of an industrial venture.

- Considerable care must be exercised in selecting the plant site, and many different
factors must be considered.

- Primarily, the plant should be located where the minimum cost of production and
distribution can be obtained, but other factors, such as room for expansion and safe
living conditions for plant operation as well as the surrounding community, are also
important
The major factors in the selection of most plant
sites are:

Marketing Area
Raw Materials
Transportation Facilities
Availability of Labors
Water supply
Energy Availability (power and fuel)
Climate
Plant Operations

It is the managing and controlling the equipment,

facilities, systems, or plants in industrial and
manufacturing processes to produce desired
products that ensures the effective implementation
and efficient, safety, and reliable process operation
Operation and
Maintenance
Plant Operation is the managing and controlling the equipment, facilities, systems,
or plants in industrial and manufacturing processes to produce desired products that
ensures the effective implementation and efficient, safety, and reliable process
operation.

Maintenance is the process of maintaining or preserving activities that performs

equipment or facilities to minimize the possibility of damage or the lowering of
performance quality because of corrosion, contamination, or deterioration for the
continuous operation.
Turnaround is a process of making a system or plant ready for use again; a scheduled
shutdown period when planned the inspection, testing, and preventive maintenance as
well as corrective maintenance such as the modification, replacement, or repair is
performed; a financial recovery of a company that has been performing poorly.

Deactivation and Decommissioning (D&D) is the planned shut-down or removal of a

plant or facility from the operation or usage that includes the process of safely closing
a plant or facility to retire it from service after its useful life has ended.
Construction Work Completed means that all the works described in the contract
documents have been carried out as specified, all appropriate payments have been
made, there are no defects and an appropriate handover has taken place, and
physically ready to be occupied or to be put into use.

Punch List is a punch items list in which are not conformed to the contract
specifications that needs to be corrected and completed to satisfy the terms of the
contract.
Mechanical Completion Certificate (MCC) is an owner's acceptance certificate
issued to a contractor when the contractor completes or achieves the requirements of
Mechanical Completion (M/C) criteria in accordance with the contract.

Provisional Acceptance Certificate (PAC) is an owner's acceptance certificate to

contractor when the contractor achieves the requirements of provisional acceptance
(PA) criteria in accordance with the contract terms and conditions.
Hand Over (or Turnover) is a responsibility transfer work process, giving of care, custody, and
control (CCC) for project to owner at the final stage of project after the plant is constructed,
inspected, and tested.

Commissioning is the activities performed in getting processes running to establish normal

operation that include the process verification and documentation of the facility and its system
components and assemblies are designed, installed, tested, and operated to meet the project
requirements of individual units and systems.
Start-up is the plant operation activities that is the commencement of an initial
operation after achieved the completion of construction works and commissioning
activities, and continued until the acceptable production capacity and quality are
achieved: successful plant performance test and commercial operation start.
Performance Test is a test or an examination of the plant capacity and quality to
achieve the desired results that is to verify the plant meets the specifications and
contractual requirement.

Final Acceptance Certificate (FAC) is a certification system work process that is

issued by an owner to a contractor after successfully completed the final acceptance
criteria such as a performance test including all the contractual obligations and
requirements
Normal Operation is the phase of process operation between the start-up phase and
shutdown phase that is the day-to-day functions of a process, plant, business or
corporation.

Emergency Sequence is the detailed procedures on how to make plant and process
safe, minimizing risks to operators and facilities at all stages covering the PPE, level
of intervention which is safe and when to evacuate.
Operation
Plant Operation is the managing and controlling the equipment, facilities, systems, or
plants in industrial and manufacturing processes to produce desired products that
ensures the effective implementation and efficient, safety, and reliable process
operation.

Operations Readiness and Assurance (OR&A, Ops Readiness) is a systematic

management approach to safety, health, environment, reliability, and availability, and
an asset efficiency to ensure a smooth handover from the project to operation phase
that is used in the oil and gas, hydrocarbon, and energy industries
Backwash is the backward movement of water caused by passing through that is the
reverse circulation.

Blowdown is a process of discharging that removes a significant portion of

accumulated deposits or other impurities from the aqueous solution
Maintenance
Maintenance is the process of maintaining or preserving activities that performs
equipment or facilities to minimize the possibility of damage or the lowering of
performance quality because of corrosion, contamination, or deterioration for the
continuous operation

Condition Monitoring (CM) is the process of monitoring a parameter of

condition in machinery with respect to some independent parameter to
indicate the current and future ability of a structure, system, or component to
function within acceptance criteria
Condition Based Inspection (CBI) is the ability to calculate the expected wear rate of
equipment or its components to determine the expected life span, which is calculated
based on the information obtained from inspection. The optimal replacement threshold
is often based on minimization of long-run average maintenance costs per unit time
due to preventive and failure replacements
Turnaround
Overhaul is to repair or replace every parts of a plant that should work whole.

Scale-up is the action of increasing in size or number. The Scale-up in the expansion
of process is the steps involved in transferring a manufacturing process or section of
the process from a laboratory scale to level of commercial production
Maintainability is the ease and speed of the system restoring to the normal
operational status that is to prevent unexpected working condition, to maximize a life
cycle of equipment and facilities, and to maximize efficiency, reliability, and safety
operations.

Capital Spare is identified through the Failure Modes and Effects Analysis (FMEA)
that determines the probability of failure through a normal operation and the
scheduled Preventative Maintenance (PM) programme.

Condition Monitoring (CM) is the process of monitoring a parameter of condition in

machinery with respect to some independent parameter to indicate the current and
future ability of a structure, system, or component to function within acceptance
criteria
Condition Based Inspection (CBI) is the ability to calculate the expected wear rate of
equipment or its components to determine the expected life span, which is calculated
based on the information obtained from inspection. The optimal replacement threshold
is often based on minimization of long-run average maintenance costs per unit time
due to preventive and failure replacements
Decommissioning
Deactivation and Decommissioning (D&D) is the planned shut-down or removal of a
plant or facility from the operation or usage that includes the process of safely closing
a plant or facility to retire it from service after its useful life has ended.

Decommissioning is a process of permanently and officially stopping of use and

removing from service or usage.

Nuclear Decommissioning is the safely removing a nuclear facility or site from

service, and reducing residual radioactivity to a level that permits either to release the
property for unrestricted use, or to release the property under restricted conditions.

Decontamination is a process of cleaning to remove of hazardous substances from

objects. (Refer to the DECON (Decontamination
Asset Management
Asset Management is the systematic activities and practices that is the ability of an
asset and asset system to perform its required function effectively and efficiently. The
Asset Management performs the risks and expenditures over a life cycle period for the
purpose of achieving its organisational strategic plan.
Asset Allocation is an investment strategy that is a spread of fund investments among
different investment forms.

Asset Category is a grouping of investments including people, chemicals,

information, environment, equipment, facilities, and activities or operations.

Enterprise Asset Management (EAM) is the management of an organization's entire

value chain of physical assets and infrastructure throughout the entire business
lifecycle.
The major factors in the selection of most plant
sites are:

Marketing Area
Raw Materials
Transportation Facilities
Availability of Labors
Water supply
Energy Availability (power and fuel)
Climate
Marketing Area
RAW MATERIALS: The availability and price of suitable raw materials will often
determine the site location. Plants that produced bulk chemicals are best located close to
the source of the major raw material, as long as the cost of shipping product are not
greater than the cost of shipping feed.

TRANSPORTATION FACILITIES: A lot of money is spent both in transporting the

raw material and the finished goods. Depending upon the size of raw material and
finished goods, a suitable method of transportation like roads, rail, water or air is selected
and accordingly the plant location is decided.

AVAILABILITY OF LABORS: Stable labor force, of right kind, of adequate

size(number), and at a reasonable rates with its proper attitude towards work are a few
factors which govern plant location to a major extent. The purpose of the management is
to face less boycotts, strikes or lockouts and to achieve lower labor cost per unit of
production.
WATER SUPPLY: Water is used for processing, as in paper and chemical industries,
and is also required for drinking and sanitary purposes. Depending upon the nature of
plant, water should also be available in adequate quantity and should be of proper
quality (clean and pure). A chemical industry should not be set up at a location which
is famous for water shortage.

ENERGY AVAILABILITY: Because of the wide spread use of electric power, in

most cases fuel (coal, oil, etc.) has not remained a deciding factor for plant location.
Even then steel industries are located near source of fuel (coal) to cut down the fuel
transportation costs.

CLIMATE: With the developments in the field of heating, ventilating and air-
conditioning, climate of the region does not present much problem. Of course, control
the climate needs money