Professor Robin Smith is Professor of Chemical Engineering at the University of Manchester. Before joining the University of Manchester he gained extensive industrial experience with different companies in process investigation, production, process design, process modelling and process integration. He has co-founded three spin-out companies from the University of Manchester and has acted extensively as a consultant to industry. He is a Fellow of the Royal Academy of Engineering, a Fellow of the Institution of Chemical Engineers in the UK and a Chartered Engineer. He has published widely in the field of process integration and is author of “Chemical Process Design and Integration”, published by Wiley. He was awarded the Hanson Medal of the Institution of Chemical Engineers, UK for his work on waste minimization, and the Sargent Medal for his work on process integration.

• Preface xiAcknowledgments xiiiNomenclature xvAbout the Companion Website xix1 Chemical Process Projects 11.1 The Process Plant Design Problem 11.2 Continuous and Batch Processes 21.3 New Design and Retrofit 31.4 Hazard Management in Process Plant Design 41.5 Project Phases 41.6 Chemical Process Projects – Summary 5References 62 Process Economics 72.1 Capital Cost Estimates 72.2 Class 5 Capital Cost Estimates 82.3 Class 4 Capital Cost Estimates 92.4 Class 3 to Class 1 Capital Cost Estimates 152.5 Capital Cost of Retrofit 152.6 Annualized Capital Cost 162.7 Operating Cost 172.8 Economic Evaluation 202.9 Investment Criteria 232.10 Process Economics − Summary 23Exercises 24References 253 Development of Process Design Concepts 273.1 Formulation of Design Problems 273.2 Evaluation of Performance 273.3 Optimization of Performance 283.4 Approaches to the Development of Design Concepts 293.5 Screening Design Options 323.6 Influencing the Design as the Project Progresses 333.7 Development of Process Design Concepts – Summary 34References 354 Heating Utilities 374.1 Process Heating and Cooling 384.2 Steam Heating 394.3 Water Treatment for Steam Generation 444.4 Steam Generation from the Combustion of Fuels 454.5 Steam Generation from Electrical Energy 484.6 Gas Turbines 504.7 Steam Turbines 514.8 Steam Distribution 554.9 Steam Heating Limits 644.10 Fired Heaters 644.11 Other Heat Carriers 684.12 Heating Utilities – Summary 74Exercises 74References 765 Cooling Utilities 775.1 Waste Heat Steam Generation 775.2 Once-Through Cooling Water Systems 775.3 Recirculating Cooling Water Systems 785.4 Air Coolers 805.5 Refrigeration 825.6 Choice of a Single Component Refrigerant for Compression Refrigeration 885.7 Mixed Refrigerants for Compression Refrigeration 895.8 Absorption Refrigeration 935.9 Indirect Refrigeration 935.10 Cooling Utilities − Summary 94Exercises 95References 966 Waste Treatment 976.1 Aqueous Emissions 976.2 Primary Wastewater Treatment Processes 1016.3 Biological Wastewater Treatment Processes 1046.4 Tertiary Wastewater Treatment Processes 1096.5 Atmospheric Emissions 1096.6 Treatment of Solid Particulate Emissions to Atmosphere 1116.7 Treatment of VOC Emissions to Atmosphere 1146.8 Treatment of Sulfur Emissions to Atmosphere 1206.9 Treatment of Oxides of Nitrogen Emissions to Atmosphere 1236.10 Treatment of Combustion Emissions to Atmosphere 1246.11 Atmospheric Dispersion 1276.12 Waste Treatment − Summary 128Exercises 128References 1297 Reliability, Maintainability, and Availability Concepts 1317.1 Reliability, Maintainability, and Availability 1317.2 Reliability 1337.3 Repairable and Non-repairable Systems 1367.4 Reliability Data 1397.5 Maintainability 1417.6 Availability 1437.7 Process Shut-down for Maintenance 1447.8 Reliability, Maintainability, and Availability Concepts − Summary 145Exercises 145References 1468 Reliability, Maintainability, and Availability of Systems 1478.1 System Representation 1478.2 Reliability of Series Systems 1478.3 Reliability of Parallel Systems 1498.4 Availability of Parallel Systems 1538.5 Availability of Series Systems 1538.6 Redundancy 1568.7 k-out-of-n Systems 1598.8 Common Mode Failure 1618.9 Capacity 1668.10 Reliability, Availability, and Capacity 1698.11 Monte Carlo Simulation 1698.12 Reliability, Maintainability, and Availability of Systems − Summary 172Exercises 172References 1749 Storage Tanks 1759.1 Feed, Product, and Intermediate Storage 1759.2 Intermediate (Buffer) Storage and Process Availability 1779.3 Optimization of Intermediate Storage 1819.4 Storage Tanks − Summary 182Exercise 182References 18310 Process Control Concepts 18510.1 Control Objectives 18510.2 The Control Loop 18510.3 Measurement 18610.4 Control Signals 18710.5 The Controller 18710.6 Final Control Element 19110.7 Feedback Control 19510.8 Cascade Control 19710.9 Split Range Control 19810.10 Limit and Selector Control 20010.11 Feedforward Control 20110.12 Ratio Control 20410.13 Computer Control Systems 20510.14 Digital Control 20710.15 Safety Instrumented Systems 21010.16 Alarms and Trips 21110.17 Representation of Control Systems 21110.18 Process Control Concepts – Summary 215Exercise 215References 21611 Process Control – Flowrate and Inventory Control 21711.1 Flowrate Control 21711.2 Inventory Control of Individual Operations 21711.3 Inventory Control of Series Systems 22311.4 Inventory Control of Recycle Systems 22611.5 Flowrate and Inventory Control – Summary 227References 22812 Process Control – Degrees of Freedom 22912.1 Degrees of Freedom and Process Control 22912.2 Degrees of Freedom for Process Streams 23112.3 Individual Single-Phase Operations 23312.4 Heat Transfer Operations with No Phase Change 23712.5 Pumps and Compressors 24112.6 Equilibrated Multiphase Operations 24312.7 Control Degrees of Freedom for Overall Processes 24612.8 Degrees of Freedom – Summary 256Exercises 256References 25713 Process Control – Control of Process Operations 25913.1 Pump Control 25913.2 Compressor Control 26213.3 Heat Exchange Control 26713.4 Furnace Control 27113.5 Flash Drum Control 27413.6 Absorber and Stripper Control 27413.7 Distillation Control 27813.8 Reactor Control 29113.9 Control of Process Operations – Summary 301Exercises 301References 30214 Process Control – Overall Process Control 30314.1 Illustrative Example of Overall Process Control Systems 30314.2 Synthesis of Overall Process Control Schemes 31014.3 Procedure for the Synthesis of Overall Process Control Schemes 31114.4 Evolution of the Control Design 32314.5 Process Dynamics 32414.6 Overall Process Control – Summary 325Exercises 325References 32815 Piping and Instrumentation Diagrams – Piping and Pressure Relief 32915.1 Piping and Instrumentation Diagrams 32915.2 Piping Systems 33015.3 Pressure Relief 33515.4 Relief Device Arrangements 33815.5 Reliability of Pressure Relief Devices 34115.6 Location of Relief Devices 34515.7 P&ID Piping and Pressure Relief – Summary 346Exercises 346References 34816 Piping and Instrumentation Diagrams – Process Operations 34916.1 Pumps 34916.2 Compressors 35516.3 Heat Exchangers 35916.4 Distillation 36116.5 Liquid Storage 36616.6 P&ID Process Operations – Summary 373Exercises 373References 37417 Piping and Instrumentation Diagrams – Construction 37517.1 Development of Piping and Instrumentation Diagrams 37517.2 A Case Study 37617.3 P&ID Construction – Summary 387References 38718 Materials of Construction 38918.1 Mechanical Properties 38918.2 Corrosion 39218.3 Corrosion Allowance 39318.4 Commonly Used Materials of Construction 39318.5 Criteria for Selection of Materials of Construction 39718.6 Materials of Construction – Summary 398References 39819 Mechanical Design 39919.1 Stress, Strain, and Deformation 39919.2 Combined Stresses 42319.3 Spherical Vessels Under Internal Pressure 42619.4 Cylindrical Vessels Under Internal Pressure 42819.5 Design of Heads for Cylindrical Vessels Under Internal Pressure 43119.6 Design of Vertical Cylindrical Pressure Vessels Under Internal Pressure 43419.7 Design of Horizontal Cylindrical Pressure Vessels Under Internal Pressure 43919.8 Buckling of Cylindrical Vessels Due to External Pressure and Axial Compression 44519.9 Welded and Bolted Joints 44819.10 Opening Reinforcements 45119.11 Vessel Supports 45319.12 Design of Flat-bottomed Cylindrical Vessels 46219.13 Shell-and-Tube Heat Exchangers 46319.14 Mechanical Design – Summary 464Exercises 465References 46720 Process Plant Layout − Site Layout 46920.1 Site, Process, and Equipment Layout 46920.2 Separation Distances 47020.3 Separation for Vapor Cloud Explosions 47220.4 Separation for Toxic Emissions 47720.5 Site Access 47720.6 Site Topology, Groundwater, and Drainage 47920.7 Geotechnical Engineering 48120.8 Atmospheric Discharges 48120.9 Wind Direction 48220.10 Utilities 48320.11 Process Units 48320.12 Control Room 48320.13 Ancillary Buildings 48520.14 Pipe Racks 48520.15 Constraints on Site Layout 48720.16 The Final Site Layout 48720.17 Site Layout − Summary 487References 48721 Process Plant Layout − Process Layout 48921.1 Process Access 48921.2 Process Structures 48921.3 Hazards 49221.4 Preliminary Process Layout 49221.5 Example – Preliminary Process Layout 49321.6 Process Layout – Summary 498References 498Appendix A Weibull Reliability Function 499Appendix B MTTF for the Weibull Distribution 501Appendix C Reliability of Cold Standby Systems 503Reference 504Appendix D Corrosion Resistance Table 505Appendix E Moment of Inertia and Bending Stress for Common Beam Cross-Sections 509E.1 Solid Rectangular Cross-Section 509E.2 Hollow Rectangular Cross-Section 509E.3 Solid Circular Cylinder 510E.4 Hollow Circular Cross-Section 511E.5 Approximate Expressions for Thin-Walled Cylinders 511Appendix F First Moment of Area and Shear Stress for Common Beam Cross-Sections 513F.1 Solid Rectangular Cross-Section 513F.2 Hollow Rectangular Cross-Section 513F.3 Solid Circular Cross-Section 514F.4 Hollow Circular Cross-Sections 515Reference 515Appendix G Principal Stresses 517Appendix H Dimensions and Weights of Carbon Steel Pipes 521Appendix I Bending Moment on Horizontal Cylindrical Vessels Resulting from a Liquid Hydraulic Head 525References 526Appendix J Equivalent Cylinder Approximation 527Index 529

Professor Robin Smith is Professor of Chemical Engineering at the University of Manchester. Before joining the University of Manchester he gained extensive industrial experience with different companies in process investigation, production, process design, process modelling and process integration. He has co-founded three spin-out companies from the University of Manchester and has acted extensively as a consultant to industry. He is a Fellow of the Royal Academy of Engineering, a Fellow of the Institution of Chemical Engineers in the UK and a Chartered Engineer. He has published widely in the field of process integration and is author of “Chemical Process Design and Integration”, published by Wiley. He was awarded the Hanson Medal of the Institution of Chemical Engineers, UK for his work on waste minimization, and the Sargent Medal for his work on process integration.

• Preface xiAcknowledgments xiiiNomenclature xvAbout the Companion Website xix1 Chemical Process Projects 11.1 The Process Plant Design Problem 11.2 Continuous and Batch Processes 21.3 New Design and Retrofit 31.4 Hazard Management in Process Plant Design 41.5 Project Phases 41.6 Chemical Process Projects – Summary 5References 62 Process Economics 72.1 Capital Cost Estimates 72.2 Class 5 Capital Cost Estimates 82.3 Class 4 Capital Cost Estimates 92.4 Class 3 to Class 1 Capital Cost Estimates 152.5 Capital Cost of Retrofit 152.6 Annualized Capital Cost 162.7 Operating Cost 172.8 Economic Evaluation 202.9 Investment Criteria 232.10 Process Economics − Summary 23Exercises 24References 253 Development of Process Design Concepts 273.1 Formulation of Design Problems 273.2 Evaluation of Performance 273.3 Optimization of Performance 283.4 Approaches to the Development of Design Concepts 293.5 Screening Design Options 323.6 Influencing the Design as the Project Progresses 333.7 Development of Process Design Concepts – Summary 34References 354 Heating Utilities 374.1 Process Heating and Cooling 384.2 Steam Heating 394.3 Water Treatment for Steam Generation 444.4 Steam Generation from the Combustion of Fuels 454.5 Steam Generation from Electrical Energy 484.6 Gas Turbines 504.7 Steam Turbines 514.8 Steam Distribution 554.9 Steam Heating Limits 644.10 Fired Heaters 644.11 Other Heat Carriers 684.12 Heating Utilities – Summary 74Exercises 74References 765 Cooling Utilities 775.1 Waste Heat Steam Generation 775.2 Once-Through Cooling Water Systems 775.3 Recirculating Cooling Water Systems 785.4 Air Coolers 805.5 Refrigeration 825.6 Choice of a Single Component Refrigerant for Compression Refrigeration 885.7 Mixed Refrigerants for Compression Refrigeration 895.8 Absorption Refrigeration 935.9 Indirect Refrigeration 935.10 Cooling Utilities − Summary 94Exercises 95References 966 Waste Treatment 976.1 Aqueous Emissions 976.2 Primary Wastewater Treatment Processes 1016.3 Biological Wastewater Treatment Processes 1046.4 Tertiary Wastewater Treatment Processes 1096.5 Atmospheric Emissions 1096.6 Treatment of Solid Particulate Emissions to Atmosphere 1116.7 Treatment of VOC Emissions to Atmosphere 1146.8 Treatment of Sulfur Emissions to Atmosphere 1206.9 Treatment of Oxides of Nitrogen Emissions to Atmosphere 1236.10 Treatment of Combustion Emissions to Atmosphere 1246.11 Atmospheric Dispersion 1276.12 Waste Treatment − Summary 128Exercises 128References 1297 Reliability, Maintainability, and Availability Concepts 1317.1 Reliability, Maintainability, and Availability 1317.2 Reliability 1337.3 Repairable and Non-repairable Systems 1367.4 Reliability Data 1397.5 Maintainability 1417.6 Availability 1437.7 Process Shut-down for Maintenance 1447.8 Reliability, Maintainability, and Availability Concepts − Summary 145Exercises 145References 1468 Reliability, Maintainability, and Availability of Systems 1478.1 System Representation 1478.2 Reliability of Series Systems 1478.3 Reliability of Parallel Systems 1498.4 Availability of Parallel Systems 1538.5 Availability of Series Systems 1538.6 Redundancy 1568.7 k-out-of-n Systems 1598.8 Common Mode Failure 1618.9 Capacity 1668.10 Reliability, Availability, and Capacity 1698.11 Monte Carlo Simulation 1698.12 Reliability, Maintainability, and Availability of Systems − Summary 172Exercises 172References 1749 Storage Tanks 1759.1 Feed, Product, and Intermediate Storage 1759.2 Intermediate (Buffer) Storage and Process Availability 1779.3 Optimization of Intermediate Storage 1819.4 Storage Tanks − Summary 182Exercise 182References 18310 Process Control Concepts 18510.1 Control Objectives 18510.2 The Control Loop 18510.3 Measurement 18610.4 Control Signals 18710.5 The Controller 18710.6 Final Control Element 19110.7 Feedback Control 19510.8 Cascade Control 19710.9 Split Range Control 19810.10 Limit and Selector Control 20010.11 Feedforward Control 20110.12 Ratio Control 20410.13 Computer Control Systems 20510.14 Digital Control 20710.15 Safety Instrumented Systems 21010.16 Alarms and Trips 21110.17 Representation of Control Systems 21110.18 Process Control Concepts – Summary 215Exercise 215References 21611 Process Control – Flowrate and Inventory Control 21711.1 Flowrate Control 21711.2 Inventory Control of Individual Operations 21711.3 Inventory Control of Series Systems 22311.4 Inventory Control of Recycle Systems 22611.5 Flowrate and Inventory Control – Summary 227References 22812 Process Control – Degrees of Freedom 22912.1 Degrees of Freedom and Process Control 22912.2 Degrees of Freedom for Process Streams 23112.3 Individual Single-Phase Operations 23312.4 Heat Transfer Operations with No Phase Change 23712.5 Pumps and Compressors 24112.6 Equilibrated Multiphase Operations 24312.7 Control Degrees of Freedom for Overall Processes 24612.8 Degrees of Freedom – Summary 256Exercises 256References 25713 Process Control – Control of Process Operations 25913.1 Pump Control 25913.2 Compressor Control 26213.3 Heat Exchange Control 26713.4 Furnace Control 27113.5 Flash Drum Control 27413.6 Absorber and Stripper Control 27413.7 Distillation Control 27813.8 Reactor Control 29113.9 Control of Process Operations – Summary 301Exercises 301References 30214 Process Control – Overall Process Control 30314.1 Illustrative Example of Overall Process Control Systems 30314.2 Synthesis of Overall Process Control Schemes 31014.3 Procedure for the Synthesis of Overall Process Control Schemes 31114.4 Evolution of the Control Design 32314.5 Process Dynamics 32414.6 Overall Process Control – Summary 325Exercises 325References 32815 Piping and Instrumentation Diagrams – Piping and Pressure Relief 32915.1 Piping and Instrumentation Diagrams 32915.2 Piping Systems 33015.3 Pressure Relief 33515.4 Relief Device Arrangements 33815.5 Reliability of Pressure Relief Devices 34115.6 Location of Relief Devices 34515.7 P&ID Piping and Pressure Relief – Summary 346Exercises 346References 34816 Piping and Instrumentation Diagrams – Process Operations 34916.1 Pumps 34916.2 Compressors 35516.3 Heat Exchangers 35916.4 Distillation 36116.5 Liquid Storage 36616.6 P&ID Process Operations – Summary 373Exercises 373References 37417 Piping and Instrumentation Diagrams – Construction 37517.1 Development of Piping and Instrumentation Diagrams 37517.2 A Case Study 37617.3 P&ID Construction – Summary 387References 38718 Materials of Construction 38918.1 Mechanical Properties 38918.2 Corrosion 39218.3 Corrosion Allowance 39318.4 Commonly Used Materials of Construction 39318.5 Criteria for Selection of Materials of Construction 39718.6 Materials of Construction – Summary 398References 39819 Mechanical Design 39919.1 Stress, Strain, and Deformation 39919.2 Combined Stresses 42319.3 Spherical Vessels Under Internal Pressure 42619.4 Cylindrical Vessels Under Internal Pressure 42819.5 Design of Heads for Cylindrical Vessels Under Internal Pressure 43119.6 Design of Vertical Cylindrical Pressure Vessels Under Internal Pressure 43419.7 Design of Horizontal Cylindrical Pressure Vessels Under Internal Pressure 43919.8 Buckling of Cylindrical Vessels Due to External Pressure and Axial Compression 44519.9 Welded and Bolted Joints 44819.10 Opening Reinforcements 45119.11 Vessel Supports 45319.12 Design of Flat-bottomed Cylindrical Vessels 46219.13 Shell-and-Tube Heat Exchangers 46319.14 Mechanical Design – Summary 464Exercises 465References 46720 Process Plant Layout − Site Layout 46920.1 Site, Process, and Equipment Layout 46920.2 Separation Distances 47020.3 Separation for Vapor Cloud Explosions 47220.4 Separation for Toxic Emissions 47720.5 Site Access 47720.6 Site Topology, Groundwater, and Drainage 47920.7 Geotechnical Engineering 48120.8 Atmospheric Discharges 48120.9 Wind Direction 48220.10 Utilities 48320.11 Process Units 48320.12 Control Room 48320.13 Ancillary Buildings 48520.14 Pipe Racks 48520.15 Constraints on Site Layout 48720.16 The Final Site Layout 48720.17 Site Layout − Summary 487References 48721 Process Plant Layout − Process Layout 48921.1 Process Access 48921.2 Process Structures 48921.3 Hazards 49221.4 Preliminary Process Layout 49221.5 Example – Preliminary Process Layout 49321.6 Process Layout – Summary 498References 498Appendix A Weibull Reliability Function 499Appendix B MTTF for the Weibull Distribution 501Appendix C Reliability of Cold Standby Systems 503Reference 504Appendix D Corrosion Resistance Table 505Appendix E Moment of Inertia and Bending Stress for Common Beam Cross-Sections 509E.1 Solid Rectangular Cross-Section 509E.2 Hollow Rectangular Cross-Section 509E.3 Solid Circular Cylinder 510E.4 Hollow Circular Cross-Section 511E.5 Approximate Expressions for Thin-Walled Cylinders 511Appendix F First Moment of Area and Shear Stress for Common Beam Cross-Sections 513F.1 Solid Rectangular Cross-Section 513F.2 Hollow Rectangular Cross-Section 513F.3 Solid Circular Cross-Section 514F.4 Hollow Circular Cross-Sections 515Reference 515Appendix G Principal Stresses 517Appendix H Dimensions and Weights of Carbon Steel Pipes 521Appendix I Bending Moment on Horizontal Cylindrical Vessels Resulting from a Liquid Hydraulic Head 525References 526Appendix J Equivalent Cylinder Approximation 527Index 529

Professor Robin Smith is Professor of Chemical Engineering at the University of Manchester. Before joining the University of Manchester he gained extensive industrial experience with different companies in process investigation, production, process design, process modelling and process integration. He has co-founded three spin-out companies from the University of Manchester and has acted extensively as a consultant to industry. He is a Fellow of the Royal Academy of Engineering, a Fellow of the Institution of Chemical Engineers in the UK and a Chartered Engineer. He has published widely in the field of process integration and is author of “Chemical Process Design and Integration”, published by Wiley. He was awarded the Hanson Medal of the Institution of Chemical Engineers, UK for his work on waste minimization, and the Sargent Medal for his work on process integration.

• Preface xiAcknowledgments xiiiNomenclature xvAbout the Companion Website xix1 Chemical Process Projects 11.1 The Process Plant Design Problem 11.2 Continuous and Batch Processes 21.3 New Design and Retrofit 31.4 Hazard Management in Process Plant Design 41.5 Project Phases 41.6 Chemical Process Projects – Summary 5References 62 Process Economics 72.1 Capital Cost Estimates 72.2 Class 5 Capital Cost Estimates 82.3 Class 4 Capital Cost Estimates 92.4 Class 3 to Class 1 Capital Cost Estimates 152.5 Capital Cost of Retrofit 152.6 Annualized Capital Cost 162.7 Operating Cost 172.8 Economic Evaluation 202.9 Investment Criteria 232.10 Process Economics − Summary 23Exercises 24References 253 Development of Process Design Concepts 273.1 Formulation of Design Problems 273.2 Evaluation of Performance 273.3 Optimization of Performance 283.4 Approaches to the Development of Design Concepts 293.5 Screening Design Options 323.6 Influencing the Design as the Project Progresses 333.7 Development of Process Design Concepts – Summary 34References 354 Heating Utilities 374.1 Process Heating and Cooling 384.2 Steam Heating 394.3 Water Treatment for Steam Generation 444.4 Steam Generation from the Combustion of Fuels 454.5 Steam Generation from Electrical Energy 484.6 Gas Turbines 504.7 Steam Turbines 514.8 Steam Distribution 554.9 Steam Heating Limits 644.10 Fired Heaters 644.11 Other Heat Carriers 684.12 Heating Utilities – Summary 74Exercises 74References 765 Cooling Utilities 775.1 Waste Heat Steam Generation 775.2 Once-Through Cooling Water Systems 775.3 Recirculating Cooling Water Systems 785.4 Air Coolers 805.5 Refrigeration 825.6 Choice of a Single Component Refrigerant for Compression Refrigeration 885.7 Mixed Refrigerants for Compression Refrigeration 895.8 Absorption Refrigeration 935.9 Indirect Refrigeration 935.10 Cooling Utilities − Summary 94Exercises 95References 966 Waste Treatment 976.1 Aqueous Emissions 976.2 Primary Wastewater Treatment Processes 1016.3 Biological Wastewater Treatment Processes 1046.4 Tertiary Wastewater Treatment Processes 1096.5 Atmospheric Emissions 1096.6 Treatment of Solid Particulate Emissions to Atmosphere 1116.7 Treatment of VOC Emissions to Atmosphere 1146.8 Treatment of Sulfur Emissions to Atmosphere 1206.9 Treatment of Oxides of Nitrogen Emissions to Atmosphere 1236.10 Treatment of Combustion Emissions to Atmosphere 1246.11 Atmospheric Dispersion 1276.12 Waste Treatment − Summary 128Exercises 128References 1297 Reliability, Maintainability, and Availability Concepts 1317.1 Reliability, Maintainability, and Availability 1317.2 Reliability 1337.3 Repairable and Non-repairable Systems 1367.4 Reliability Data 1397.5 Maintainability 1417.6 Availability 1437.7 Process Shut-down for Maintenance 1447.8 Reliability, Maintainability, and Availability Concepts − Summary 145Exercises 145References 1468 Reliability, Maintainability, and Availability of Systems 1478.1 System Representation 1478.2 Reliability of Series Systems 1478.3 Reliability of Parallel Systems 1498.4 Availability of Parallel Systems 1538.5 Availability of Series Systems 1538.6 Redundancy 1568.7 k-out-of-n Systems 1598.8 Common Mode Failure 1618.9 Capacity 1668.10 Reliability, Availability, and Capacity 1698.11 Monte Carlo Simulation 1698.12 Reliability, Maintainability, and Availability of Systems − Summary 172Exercises 172References 1749 Storage Tanks 1759.1 Feed, Product, and Intermediate Storage 1759.2 Intermediate (Buffer) Storage and Process Availability 1779.3 Optimization of Intermediate Storage 1819.4 Storage Tanks − Summary 182Exercise 182References 18310 Process Control Concepts 18510.1 Control Objectives 18510.2 The Control Loop 18510.3 Measurement 18610.4 Control Signals 18710.5 The Controller 18710.6 Final Control Element 19110.7 Feedback Control 19510.8 Cascade Control 19710.9 Split Range Control 19810.10 Limit and Selector Control 20010.11 Feedforward Control 20110.12 Ratio Control 20410.13 Computer Control Systems 20510.14 Digital Control 20710.15 Safety Instrumented Systems 21010.16 Alarms and Trips 21110.17 Representation of Control Systems 21110.18 Process Control Concepts – Summary 215Exercise 215References 21611 Process Control – Flowrate and Inventory Control 21711.1 Flowrate Control 21711.2 Inventory Control of Individual Operations 21711.3 Inventory Control of Series Systems 22311.4 Inventory Control of Recycle Systems 22611.5 Flowrate and Inventory Control – Summary 227References 22812 Process Control – Degrees of Freedom 22912.1 Degrees of Freedom and Process Control 22912.2 Degrees of Freedom for Process Streams 23112.3 Individual Single-Phase Operations 23312.4 Heat Transfer Operations with No Phase Change 23712.5 Pumps and Compressors 24112.6 Equilibrated Multiphase Operations 24312.7 Control Degrees of Freedom for Overall Processes 24612.8 Degrees of Freedom – Summary 256Exercises 256References 25713 Process Control – Control of Process Operations 25913.1 Pump Control 25913.2 Compressor Control 26213.3 Heat Exchange Control 26713.4 Furnace Control 27113.5 Flash Drum Control 27413.6 Absorber and Stripper Control 27413.7 Distillation Control 27813.8 Reactor Control 29113.9 Control of Process Operations – Summary 301Exercises 301References 30214 Process Control – Overall Process Control 30314.1 Illustrative Example of Overall Process Control Systems 30314.2 Synthesis of Overall Process Control Schemes 31014.3 Procedure for the Synthesis of Overall Process Control Schemes 31114.4 Evolution of the Control Design 32314.5 Process Dynamics 32414.6 Overall Process Control – Summary 325Exercises 325References 32815 Piping and Instrumentation Diagrams – Piping and Pressure Relief 32915.1 Piping and Instrumentation Diagrams 32915.2 Piping Systems 33015.3 Pressure Relief 33515.4 Relief Device Arrangements 33815.5 Reliability of Pressure Relief Devices 34115.6 Location of Relief Devices 34515.7 P&ID Piping and Pressure Relief – Summary 346Exercises 346References 34816 Piping and Instrumentation Diagrams – Process Operations 34916.1 Pumps 34916.2 Compressors 35516.3 Heat Exchangers 35916.4 Distillation 36116.5 Liquid Storage 36616.6 P&ID Process Operations – Summary 373Exercises 373References 37417 Piping and Instrumentation Diagrams – Construction 37517.1 Development of Piping and Instrumentation Diagrams 37517.2 A Case Study 37617.3 P&ID Construction – Summary 387References 38718 Materials of Construction 38918.1 Mechanical Properties 38918.2 Corrosion 39218.3 Corrosion Allowance 39318.4 Commonly Used Materials of Construction 39318.5 Criteria for Selection of Materials of Construction 39718.6 Materials of Construction – Summary 398References 39819 Mechanical Design 39919.1 Stress, Strain, and Deformation 39919.2 Combined Stresses 42319.3 Spherical Vessels Under Internal Pressure 42619.4 Cylindrical Vessels Under Internal Pressure 42819.5 Design of Heads for Cylindrical Vessels Under Internal Pressure 43119.6 Design of Vertical Cylindrical Pressure Vessels Under Internal Pressure 43419.7 Design of Horizontal Cylindrical Pressure Vessels Under Internal Pressure 43919.8 Buckling of Cylindrical Vessels Due to External Pressure and Axial Compression 44519.9 Welded and Bolted Joints 44819.10 Opening Reinforcements 45119.11 Vessel Supports 45319.12 Design of Flat-bottomed Cylindrical Vessels 46219.13 Shell-and-Tube Heat Exchangers 46319.14 Mechanical Design – Summary 464Exercises 465References 46720 Process Plant Layout − Site Layout 46920.1 Site, Process, and Equipment Layout 46920.2 Separation Distances 47020.3 Separation for Vapor Cloud Explosions 47220.4 Separation for Toxic Emissions 47720.5 Site Access 47720.6 Site Topology, Groundwater, and Drainage 47920.7 Geotechnical Engineering 48120.8 Atmospheric Discharges 48120.9 Wind Direction 48220.10 Utilities 48320.11 Process Units 48320.12 Control Room 48320.13 Ancillary Buildings 48520.14 Pipe Racks 48520.15 Constraints on Site Layout 48720.16 The Final Site Layout 48720.17 Site Layout − Summary 487References 48721 Process Plant Layout − Process Layout 48921.1 Process Access 48921.2 Process Structures 48921.3 Hazards 49221.4 Preliminary Process Layout 49221.5 Example – Preliminary Process Layout 49321.6 Process Layout – Summary 498References 498Appendix A Weibull Reliability Function 499Appendix B MTTF for the Weibull Distribution 501Appendix C Reliability of Cold Standby Systems 503Reference 504Appendix D Corrosion Resistance Table 505Appendix E Moment of Inertia and Bending Stress for Common Beam Cross-Sections 509E.1 Solid Rectangular Cross-Section 509E.2 Hollow Rectangular Cross-Section 509E.3 Solid Circular Cylinder 510E.4 Hollow Circular Cross-Section 511E.5 Approximate Expressions for Thin-Walled Cylinders 511Appendix F First Moment of Area and Shear Stress for Common Beam Cross-Sections 513F.1 Solid Rectangular Cross-Section 513F.2 Hollow Rectangular Cross-Section 513F.3 Solid Circular Cross-Section 514F.4 Hollow Circular Cross-Sections 515Reference 515Appendix G Principal Stresses 517Appendix H Dimensions and Weights of Carbon Steel Pipes 521Appendix I Bending Moment on Horizontal Cylindrical Vessels Resulting from a Liquid Hydraulic Head 525References 526Appendix J Equivalent Cylinder Approximation 527Index 529