Steps to select process equipments. What are standard and special equipments.

1. NAME : SAKHARELIYA SHUBHAM ATULBHAI
ENROLLMENT NO. : 180470105047
BRANCH : CHEMICAL ENGINEERING
SUBJECT : CHEMICAL PROCESS PLANT DESIGN & ECONOMICS
SELECTION OF PROCESS EQUIPMENTS

2. OUTLINE
• INTRODUCTION
• SPECIFICATION
• STANDARD AND SPECIAL EQUIPMENTS
• SPECIFICATION SHEETS
• PRELIMINARY SPECIFICATIONS FOR EQUIPMENT
• SELECTION OF MATERIAL
• MATERIALS OF CONSTRUCTION
• ECONOMICS IN SELECTION OF MATERIALS

3. INTRODUCTION
• THIS PRESENTATION DEALS WITH SELECTION AND PURCHASE OF
EQUIPMENT WITH ITS DESIRED SPECIFICATIONS.
• AT THIS PHASE, FOLLOWING IS ALREADY KNOWN:
1. NAME OF PRODUCT WITH PRODUCTION RATE
2. MANUFACTURING PROCESS
3. REQUIREMENT OF EQUIPMENTS/INSTRUMENTS WITH ITS
DESIGN DATA/SPECIFICATIONS, UTILITIES, RAW MATERIALS ETC.
4. MATERIALS TO BE HANDLED IN EACH EQUIPMENTS ALONG WITH
ITS MATERIAL SAFETY DATA SHEET (MSDS)
5. HAZARDS IF ANY DUE TO OPERATING CONDITIONS OR
MATERIALS

4. SPECIFICATIONS
• A GENERALIZATION FOR EQUIPMENT DESIGN IS THAT STANDARD EQUIPMENT
SHOULD BE SELECTED WHENEVER POSSIBLE. IF THE EQUIPMENT IS
STANDARD, THE MANUFACTURER MAY HAVE THE DESIRED SIZE IN STOCK.
• IN ANY CASE, THE MANUFACTURER CAN USUALLY QUOTE A LOWER PRICE
AND GIVE BETTER GUARANTEES FOR STANDARD EQUIPMENT THAN FOR
SPECIAL EQUIPMENT.
• THE CHEMICAL ENGINEER CANNOT BE AN EXPERT ON ALL THE TYPES OF
EQUIPMENT USED IN INDUSTRIAL PLANTS AND, THEREFORE, SHOULD MAKE
GOOD USE OF THE EXPERIENCE OF OTHERS. MUCH VALUABLE INFORMATION
CAN BE OBTAINED FROM EQUIPMENT MANUFACTURERS WHO SPECIALIZE IN
PARTICULAR TYPES OF EQUIPMENT.

5. SPECIFICATIONS
• BEFORE A MANUFACTURER IS CONTACTED, THE ENGINEER SHOULD
EVALUATE THE DESIGN NEEDS AND PREPARE A PRELIMINARY
SPECIFICATION SHEET FOR THE EQUIPMENT.
• THIS PRELIMINARY SPECIFICATION SHEET CAN BE USED BY THE
ENGINEER AS A BASIS FOR THE PREPARATION OF THE FINAL
SPECIFICATIONS, OR IT CAN BE SENT TO A MANUFACTURER WITH A
REQUEST FOR SUGGESTIONS AND FABRICATION INFORMATION.

6. STANDARD EQUIPMENTS
• STANDARD EQUIPMENTS MEANS THOSE FEATURES OR EQUIPMENT THAT
ARE AVAILABLE IN MARKET AND PURCHASE CAN NOT PUT THEIR CHOICE ON
THAT.
• THE SPECIFICATION SHEET FOR A SHELL & TUBE HEAT EXCHANGER CAN BE
PREPARED ONLY WHEN ITS PROCESS DESIGN IS FINALIZED AND ALL THE
PROCESS PARAMETERS ARE CAPTURED IN A PROCESS DATASHEET. THIS
PROCESS DATASHEET IS THEN USED ALONG WITH THE TEMA (TUBULAR
EXCHANGER MANUFACTURERS ASSOCIATION) STANDARDS TO CREATE
SPECIFICATION SHEET FOR THE FABRICATION OF THE EXCHANGER.
• WHEN ORDERING FOR MANUFACTURING OF A SHELL & TUBE HEAT
EXCHANGER , THE CLIENT SHALL PROVIDE THE MANUFACTURER A
SPECIFICATION SHEET FOR THAT SHELL & TUBE EXCHANGER.

7. POINTS STANDARD EQUIPMENT SPECIAL EQUIPMENT
USE THEY ARE COMMONLY USED IN
MULTIPLE PROJECTSWITH STANDARD
ORTYPICALTYPE OF OPERATION.
THEY ARE USED FOR SPECIAL
PROJECTSWITH SPECIALTYPE OF
OPERATIONS.
MANUFACTURE THESE COMPONENTSARE EASILY
MANUFACTURED AND EASILYAVAILABLE
FROM DEALERS.
THESEARE MANUFACTURED AS PERTHE
REQUIREMENTAND SPECIAL ORDER ISTO
BE PLACEDTO GET SUCH EQUIPMENT.
AVAILABILITY EASILYAVAILABLEAND FAST
DELIVERY
AVAILABILITY IS DIFFICULT ANDTHE
DELIVERY IS ALSO LATE.
SPARE PARTS SPARE PARTSARE EASILYAVAILABLE SPARE PARTSARE NOT EASILY
AVAILABLE
REPAIRAND
MAINTENANCE
EASY DIFFICULT
COST OFTHE
PRODUCTION
IT IS LESS PER UNIT IT IS HIGH PER UNIT
GUARANTEES PROVIDED FOR NO. OFYEARS BASED ON
PAST EXPERIENCEAS IT HAS BEEN USED
SINCE MANYYEARS AND HAVING
CUSTOMER REVIEWS, FEED BACK
NO

8. SPECIFICATION SHEETS
• STANDARD SPECIFICATION SHEETS ARE NORMALLY USED TO
TRANSMIT THE INFORMATION REQUIRED FOR THE DETAILED
DESIGN, OR PURCHASE, OF EQUIPMENT ITEMS; SUCH AS, HEAT
EXCHANGERS, PUMPS, COLUMNS.
• AS WELL AS ENSURING THAT THE INFORMATION IS CLEARLY
PRESENTED, STANDARD SPECIFICATION SHEETS SERVE AS CHECK
LISTS TO ENSURE THAT ALL THE INFORMATION REQUIRED IS
INCLUDED.

9. PRELIMINARY SPECIFICATIONS FOR EQUIPMENT
• IDENTIFICATION
• FUNCTION
• OPERATION
• MATERIALS HANDLED
• BASIC DESIGN DATA
• ESSENTIAL CONTROLS
• INSULATION REQUIREMENTS
• ALLOWABLE TOLERANCES
• SPECIAL INFORMATION AND DETAILS PERTINENT TO THE PARTICULAR
EQUIPMENT, SUCH AS MATERIALS OF CONSTRUCTION INCLUDING GASKETS,
INSTALLATION, NECESSARY DELIVERY DATE, SUPPORTS, AND SPECIAL DESIGN
DETAILS OR COMMENTS

10. IDENTIFICATION
• NAME OF EQUIPMENT - HEAT EXCHANGER, DISTILLATION COLUMN
• TYPE OF EQUIPMENT - LOW PRESSURE, HIGH PRESSURE, SIEVE TRAY, FINNED
TUBE HE, PLATE AND FRAME TYPE ETC.
• ITEM NO.- AS PER COMPANY POLICY H07, G05 ETC.
• NOS. REQUIRED - _____
• DATE OF MANUFACTURING - _____
• FABRICATED BY_____COMPANY

11. FUNCTION
• COOLING/HEATING - HEAT EXCHANGER
• CONDENSE OVERHEAD VAPORS FROM METHANOL
• FRACTIONATION COLUMN - CONDENSER
• SIZE REDUCTION - CRUSHERS
• GENERATION OF STEAM -BOILER
• AGITATION - MIXER

12. OPERATION
• BATCH OR CONTINUOUS
MATERIALS HANDLED FOR ALL
STREAMS / INPUT AND OUTPUT ANDTHEIR DATA
• NAME OF MATERIALS HANDLED
• NATURE OF MATERIAL - CORROSIVE/HAZARDOUS
• FLUIDS TUBE SIDE/SHELL SIDE
• MATERIAL OF CONSTRUCTION FOR EQUIPMENT

13. BASIC DESIGN DATA
• QUANTITY/FLOW RATE
• COMPOSITION
• TEMPERATURE
• TUBES AND SHELL - DIAMETER AND LENGTH, NO. OF TUBES, NO. OF
PASS, TRANSVERSE BAFFLES FOR TUBE SUPPORT, DIMENSIONS OF
BAFFLES
• FOR DISTILLATION COLUMN - NO. OF TRAYS,TEMPERATURE ON EACH
TRAYS, ALL INPUT/OUTPUT FLOW RATES ETC.

14. CONTROLS
• COOLING - WATER RATE CONTROLLED BY VAPOR
• TEMPERATURE IN VENT LINE - CONDENSER
• LEVEL INDICATOR IN CASE OF STEAM VAPORIZER
• FLOW METERS
• REACTOR - TEMPERATURE SHOULD BE MAINTAINED
• CONSTANT BY COOLANT FLOW

15. INSULATION REQUIREMENT
• INSULATION MATERIAL
• THICKNESS OF INSULATION
• 2-IN. ROCK WOOL/CORK OR EQUIVALENT; WEATHER PROOFED
ALLOWABLETOLERANCES & SPECIAL
INFORMATION
• PRESSURE, TEMPERATURE
• SUPPORTS REQUIRED, VALVE, PUMP TYPE

16. SELECTION OF MATERIALS
• THE CHEMICAL ENGINEER RESPONSIBLE FOR THE SELECTION OF
MATERIALS OF CONSTRUCTION MUST HAVE A THOROUGH
UNDERSTANDING OF ALL THE BASIC PROCESS INFORMATION
AVAILABLE. THIS KNOWLEDGE OF THE PROCESS CAN THEN BE USED
TO SELECT MATERIALS OF CONSTRUCTION IN A LOGICAL MANNER. A
BRIEF PLAN FOR STUDYING MATERIALS OF CONSTRUCTION IS AS
FOLLOWS:
• PRELIMINARY SELECTION
• EXPERIENCE, MANUFACTURER’S DATA, SPECIAL LITERATURE,
GENERAL LITERATURE, AVAILABILITY, SAFETY ASPECTS,
PRELIMINARY LABORATORY TESTS

17. SELECTION OF MATERIALS
• LABORATORY TESTING
• REEVALUATION OF APPARENTLY SUITABLE MATERIALS UNDER
PROCESS CONDITIONS
• INTERPRETATION OF LABORATORY RESULTS AND OTHER DATA
• EFFECT OF POSSIBLE IMPURITIES, EXCESS TEMPERATURE, EXCESS
PRESSURE, AGITATION, AND PRESENCE OF AIR IN EQUIPMENT
AVOIDANCE OF ELECTROLYSIS FABRICATION METHOD
• ECONOMIC COMPARISON OF APPARENTLY SUITABLE MATERIALS
• MATERIAL AND MAINTENANCE COST, PROBABLE LIFE, COST OF
PRODUCT DEGRADATION, LIABILITY TO SPECIAL HAZARDS
• FINAL SELECTION

18. SELECTION OF MATERIALS
• IN MAKING AN ECONOMIC COMPARISON, THE ENGINEER IS OFTEN FACED WITH
THE QUESTION OF WHERE TO USE HIGH-COST CLADDINGS OR COATINGS OVER
RELATIVELY CHEAP BASE MATERIALS SUCH AS STEEL OR WOOD.
• FOR EXAMPLE, A COLUMN REQUIRING AN EXPENSIVE ALLOY-STEEL SURFACE IN
CONTACT WITH THE PROCESS FLUID MAY BE CONSTRUCTED OF THE ALLOY
ITSELF OR WITH A CLADDING OF THE ALLOY ON THE INSIDE OF CARBON-STEEL
STRUCTURAL MATERIAL.
• OTHER EXAMPLES OF COMMERCIAL COATINGS FOR CHEMICAL PROCESS
EQUIPMENT INCLUDE BAKED CERAMIC OR GLASS COATINGS, FLAME SPRAYED
METAL, HARD RUBBER, AND MANY ORGANIC PLASTICS.

19. MATERIALS OF CONSTRUCTION
• THE EFFECTS OF CORROSION AND EROSION MUST BE CONSIDERED IN THE
DESIGN OF CHEMICAL PLANTS AND EQUIPMENT. CHEMICAL RESISTANCE AND
PHYSICAL PROPERTIES OF CONSTRUCTIONAL MATERIAL ARE IMPORTANT
FACTORS IN THE CHOICE AND DESIGN OF EQUIPMENT.
• THE MATERIALS OF CONSTRUCTION MAY BE RESISTANT TO THE CORROSIVE
ACTION OF ANY CHEMICALS THAT MAY CONTACT THE EXPOSED SURFACES.
• POSSIBLE EROSION CAUSED BY FLOWING FLUIDS OR OTHER TYPES OF MOVING
SUBSTANCES MUST BE CONSIDERED, EVEN THOUGH THE MATERIALS OF
CONSTRUCTION MAY HAVE ADEQUATE CHEMICAL RESISTANCE. STRUCTURAL
STRENGTH, RESISTANCE TO PHYSICAL OR THERMAL SHOCK, COST, EASE OF
FABRICATION, NECESSARY MAINTENANCE, AND GENERAL TYPE OF SERVICE
REQUIRED, INCLUDING OPERATING TEMPERATURES AND PRESSURES, ARE
ADDITIONAL FACTORS THAT INFLUENCE THE FINAL CHOICE OF CONSTRUCTIONAL
MATERIALS.

20. MATERIALS OF CONSTRUCTION
• IF THERE IS ANY DOUBT CONCERNING SUITABLE MATERIALS FOR
CONSTRUCTION OF EQUIPMENT, REFERENCE SHOULD BE MADE TO
THE LITERATURE, OR LABORATORY TESTS SHOULD BE CARRIED OUT
UNDER CONDITIONS SIMILAR TO THE FINAL OPERATING
CONDITIONS.
• THE RESULTS FROM THE LABORATORY TESTS INDICATE THE
CORROSION RESISTANCE OF THE MATERIAL AND ALSO THE EFFECTS
ON THE PRODUCT CAUSED BY CONTACT WITH THE PARTICULAR
MATERIAL.
• FURTHER TESTS ON A PILOT-PLANT SCALE MAY BE DESIRABLE IN
ORDER TO DETERMINE THE AMOUNT OF EROSION RESISTANCE OR
THE EFFECTS OF OTHER OPERATIONAL FACTORS.

21. ECONOMICS IN SELECTION OF MATERIALS
• FIRST COST OF EQUIPMENT OR MATERIAL OFTEN IS NOT A GOOD
ECONOMIC CRITERION WHEN COMPARING ALTERNATE MATERIALS
OF CONSTRUCTION FOR CHEMICAL PROCESS EQUIPMENT.
• ANY COST ESTIMATION SHOULD INCLUDE THE FOLLOWING ITEMS:
1. TOTAL EQUIPMENT OR MATERIALS COSTS
2. INSTALLATION COSTS
3. MAINTENANCE COSTS
4. ESTIMATED LIFE
5. REPLACEMENT COSTS

22. THANK YOU