PERANCANGAN BEJANA BERTEKANAN & ALAT PENUKAR

PANAS

(Heat Exchanger & Pressure Vessel Design)

Arrange by, Zulnovri, ST, M.Si

Session 1st:

Codes & Standards of Process Design

A GLANCE ABOUT PROCESS DESIGN, CODES, STANDARD

Process Design
Process design establishes the sequence of chemical and physical operations;
operating conditions; the duties, major specifications, and materials of construction
(where critical) of all process equipment (as distinguished from utilities and building
auxiliaries)
the general arrangement of equipment needed to ensure proper functioning of the
plant; line sizes; and principal instrumentation
The process design is summarized by a process flow sheet, a material and energy
balance, and a set of individual equipment specifications
Sometimes only a preliminary design and cost estimate are needed to evaluate the
advisability of further research on a new process or a proposed plant expansion or
detailed design work
A particularly valuable function of preliminary design is that it may reveal lack of
certain data needed for final design

Equipment
Two main categories of
designed

process equipment are proprietary and custom-

Proprietary equipment is designed by the manufacturer to meet

performance specifications made by the user; these specifications may be
regarded as the process design of the equipment. This category includes
equipment with moving parts such as pumps, compressors, and drivers as well
as cooling towers, dryers, filters, mixers, agitators, piping equipment, and
valves, and even the structural aspects of heat exchangers, furnaces, and
other equipment
Custom design is needed for many aspects of chemical reactors, most
vessels, multistage separators such as fractionators, and other special
equipment not amenable to complete standardization.

Categories of Engineering Practice

Although the design of a
complete design and
mechanical, structural,
piping designers; and
prices

chemical process plant is initiated by chemical engineers, its

construction requires the inputs of other specialists:
electrical, and instrumentation engineers; vessel and
purchasing agents who know what may be available at attractive

On large projects all these activities are correlated by a job engineer or project manager; on
individual items of equipment or the process engineer small projects, naturally assumes
this function

Sources of Information for Process Design

For information about chemical manufacturing processes, the main
encyclopedic references are Kirk-Othmer (1978-1984), McKetta and
Cunningham (1976-date)
and Ullmann (1972-1983) (References,
Section 1.2, Part B)
The most comprehensive compilation of physical property data is that of
Landolt-Bornstein (1950-date) (References, Section 1.2, Part C)
Data and methods of estimating properties of hydrocarbons and their
mixtures are in the API Data Book (1971-date) (References, Section
1.2, Part C)

Codes, Standards & Recommended Practices

A large body of rules has been developed over the years to, and materials to ensure
the safe and economical design, fabrication and testing of equipment, structures &
materials
Codification of these rules has been done by associations organized for just such
purposes, by professional societies, trade groups, insurance underwriting companies,
and government agencies
Engineering contractors and large manufacturing companies usually maintain
individual sets of standards so as to maintain continuity of design and to simplify
maintenance of plant
Table 1.1 is a representative table of contents of the mechanical standards of a large
oil company.
A listing of codes and standards bearing directly on process design is in Table 1.2, and
of supplementary codes and standards in Table 1.3

TABLE 1.1. Internal Engineering Standards of a Large

Petroleum Refinery
1 Appropriations of Mechanical Orders
(10)
2 Buildings-architectural (15)
3 Buildings-mechanical (10)
4 Capacities and weights (25)
5 Contracts (10)
6 Cooling towers (10)
7 Correspondence (5)
8 Designation and numbering rules for
equipment and facilities (10)
9 Drainage (25)
10 Electrical (10)
11 Excavating, grading and paving (10)
12 Fire fighting (10)
13 Furnaces and boilers (10)
14 General instructions (20)
15 Handling equipment (5)
16 Heat exchangers (10)

17 Instruments and controls (45)

18 Insulation (10)
19 Machinery (35)
20 Material procurement and disposition
(20)
21 Material selection (5)
22 Miscellaneous process equipment
(25)
23 Personnel protective equipment (5)
24 Piping (150)
25 Piping supports (25)
26 Plant layout (20)
27 Pressure vessels (25)
28 Protective coatings (10)
29 Roads and railroads (25)
30 Storage vessels (45)
31 Structural (35)
32 Symbols and drafting practice (15)
33 Welding (10)

TABLE 1.2. Codes and Standards of Direct Bearing on

Chemical Process Design (a Selection)
A. American Institute of Chemical Engineers, 345 E. 47th St., New York, NY
10017
1. Standard testing procedures; 21 have been published, for example on
centrifuges, filters, mixers, firer heaters
B. American Petroleum Institute, 2001 L St. NW, Washington, DC 20037
2. Recommended practices for refinery inspections
3. Guide for inspection of refinery equipment
4. Manual on disposal of refinery wastes
5. Recommended practice for design and construction of large, low
6. Recommended practice for design and construction of pressure
7. Recommended practices for safety and fire protection pressure storage tanks
relieving devices
C. American Society of Mechanical Engineers, 345 W. 47th St., New York,
NY 10017
8. ASME Boiler and Pressure Vessel Code. Sec. VIII, Unfired
9. Code for pressure piping York, NY 10017 Pressure Vessels
10. Scheme for identification of piping system

TABLE 1.2. Codes and Standards of Direct Bearing on

Chemical Process Design (a Selection).contd
D. American Society for Testing Materials, 1916 Race St., Philadelphia, PA
19103
11. ASTM Standards, 66 volumes in 16 sections, annual, with about 30% revision
each year
E. American National Standards Institute (ANSI), 1430 Broadway, New
York, NY 10018
12. Abbreviations, letter symbols, graphical symbols, drawing and drafting room
practice
F. Chemical Manufacturers' Association, 2501 M St. NW, Washington, DC
20037
13. Manual of standard and recommended practices for containers, tank cars,
pollution of air and water
14. Chemical safety data sheets of individual chemicals
G. Cooling Tower Institute, 19627 Highway 45 N, Spring, TX 77388
15. Acceptance test procedure for water cooling towers of mechanical draft
industrial type
H. Hydraulic Institute, 712 Lakewood Center N, 14600 Detroit Ave.,

TABLE 1.2. Codes and Standards of Direct Bearing on

Chemical Process Design (a Selection) .contd
I. Instrument Society of America (ISA), 67 Alexander Dr., Research Triangle
Park, NC 27709
18. Instrumentation flow plan symbols
19. Specification forms for instruments
20. Dynamic response testing of process control instrumentation
J. Tubular Exchangers Manufacturers' Association, 25 N Broadway,
Tarrytown, NY 10591
21. TEMA standards
K. International Standards Organization (ISO), 1430 Broadway, New
York, NY 10018
22. Many Standard

TABLE 1.3. Codes and Standards Supplementary to

Process
Design (a Selection)
A. American Concrete Institute, 22400 W. 7 Mile Rd., Detroit, MI 48219
1. Reinforced concrete design handbook
2. Manual of standard practice for detailing reinforced concrete structures
B. American Institute of Steel Construction, 400 N. Michigan Ave.,
Chicago, IL 60611
3. Manual of steel construction
4. Standard practice for steel buildings and bridges
C. American Iron and Steel Institute, 1000 16th St. NW, Washington, DC
20036
5. AIS1 standard steel compositions
D. American Society of Heating, Refrigerating and Air Conditioning
Engineers (ASHRE), 1791 Tullie Circle NE, Atlanta, GA 30329
6. Refrigerating data book
E. Institute of Electrical and Electronics Engineers, 345 E. 47th St., New
York, NY 10017
7. Many standards
F. National Bureau of Standards, Washington, DC
8. American standard building code

FLOWSHEETS

BLOCK FLOW SHEET

At an early stage or to provide an overview of a complex process or plant, a
drawing is made with rectangular blocks to represent individual processes or
groups of operations, together with quantities and other pertinent properties of
key streams between the blocks and into and from the process as a whole
Such block flowsheets are made at the beginning of a process design for
orientation purposes or later as a summary of the material balance of the
process.

Example:
the coal carbonization process of Figure 2.1 starts with 100,000Ib/hr of coal and
some process air, involves six main process units, and makes the indicated
quantities of ten different products

BLOCK FLOW SHEET

BLOCK FLOW SHEET

PROCESS FLOW SHEET

Process flowsheets embody the material and energy balances between and
the sizing of the major equipment of the plant.
They include all vessels such as reactors, separators, and drums; special
processing equipment, heat exchangers, pumps, and so on. Numerical data
include flow quantities, compositions, pressures, temperatures, and so on.

FLOW SHEET EQUIPMENT SYMBOL

FLOW SHEET EQUIPMENT SYMBOL (Contd)

FLOW SHEET EQUIPMENT SYMBOL (Contd)

FLOW SHEET EQUIPMENT SYMBOL (Contd)

FLOW SHEET EQUIPMENT SYMBOL (Contd)

FLOW SHEET EQUIPMENT SYMBOL (Contd)

CONTOH FLOW SHEET

CONTOH FLOW SHEET (Contd)

MECHANICAL (P&I) FLOW SHEETS

Mechanical flowsheets also are called piping and instrument (P&I) diagrams to
emphasize two of their major characteristics.
They do not show operating conditions or compositions or flow quantities, but they do
show all major as well as minor equipment more realistically than on the process
flowsheet.
Included are sizes and specification classes of all pipe lines, all valves, and all
instruments.
In fact, every mechanical aspect of the plant regarding the process equipment and
their interconnections
is
represented except for supporting structures and
foundations.
The equipment is shown in greater detail than on the PFS, notably'with regard to
external piping connections, internal details, and resemblance to the actual
appearance

CONTOH P&I FLOW SHEET

CONTOH P&I FLOW SHEET (Contd)

UTILITY FLOW SHEETS

These are P&I diagrams for individual utilities such
as steam, steam
condensate, cooling water, heat transfer media in general, compressed air,
fuel, refrigerants, and inert blanketing gases, and how they are piped up to the
process equipment.
Connections for utility streams are shown on the mechanical flowsheet, and
their conditions and flow quantities usually appear on the process flowsheet
Since every detail of a plant design must be recorded on paper, many other
kinds of drawings also are required: for example, electrical flow, piping
isometrics, instrument lines, plans and elevations, and individual equipment
drawings in all detail.
Models and three-dimensional representations
standard practice in many design offices

by computers also are now

THANK YOU