1. Industrial Process Design
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

2. 1. Design Work Process Common to all design problems in all industries
Determine
Customer Needs
Set Design
Specifications
Build Performance
Models
Generate Design
Concepts
R&D if Needed
Predict Fitness
For Service
Evaluate Economics
& Select Design
Customer
Approval
Detailed Design &
Equipment Selection
Procurement
& Construction
Begin Operation
Common to all design problems in all industries
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

3. How do companies implement this design process?
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

4. 2. The Design Team Project Sponsor Business Input Project Manager
Process
Engineer(s)
Technical
Specialists
Control
Engineer
Cost Engineer
Consultants
R&D
Specialists
Mechanical
Engineer(s)
Civil
Engineers
Contractors
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

5. Specialization and Outsourcing
Operating Companies
Own plants
Produce chemicals
High sales revenue
Margins & return on assets (ROA) vary by sector
Technology Vendors
Own patents
Sell catalysts, enzymes, equipment, licenses
Sales volume low
Margins, ROA usually high
Engineering & Construction Companies
Experienced project managers
Highly competitive & cost effective
Medium sales volume, low margins
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

6. Company Performance by Sector
Notes:
Data from as of
Oil industry is usually not so profitable as during
Technology companies are usually smaller, and are often subsidiaries or privately held. Financial data are often not publicly available.
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

7. Long ago (<1980s) most projects were done “in house”
Operating
Company
Project
Sponsor
Business
Input
Project
Manager
Process
Engineer(s)
Technical
Specialists
Control
Engineer
Cost Engineer
Consultants
R&D
Specialists
Mechanical
Engineer(s)
Civil
Engineers
Contractors
E&C
Company
Technology
Vendor
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

8. Nowadays (For most companies, most sectors)
Project
Sponsor
Business
Input
Operating
Company
Project
Manager
Process
Engineer(s)
Technical
Specialists
Control
Engineer
Cost Engineer
Consultants
R&D
Specialists
Mechanical
Engineer(s)
Civil
Engineers
Contractors
Technology
Vendor
E&C
Company
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

9. Implications
Most major projects involve several companies working together
“OpCo” might itself be a joint venture between several companies
The companies might all be based in different regions of the world
Teamwork, technology transfer and effective communications have high impact and value
Good project management is more important than ever
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

10. 3. The Project Plan Project must be delivered: On-time On-budget
OpCo usually writes incentives into the E&C contract to ensure that this happens
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

11. Design Work Process These steps have to come first
Determine
Customer Needs
Set Design
Specifications
Build Performance
Models
Generate Design
Concepts
R&D if Needed
Predict Fitness
For Service
Evaluate Economics
& Select Design
Customer
Approval
This also needs time
This takes time
Detailed Design &
Equipment Selection
Procurement
& Construction
Begin Operation
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

12. The Project Plan Is developed & implemented by the project manager
Sets deadlines for completion of activities & intermediate deliverables
Allows scheduling of subordinate or dependent tasks
Allows estimation of the required manpower resources at each stage of the project
Determines the procurement schedule & gives an estimate of when cash outlays are expected
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

13. Example: 11-Week Plan for a Process Design Project
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

14. What’s In a Project Plan?
List of tasks
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

15. What’s In a Project Plan?
Durations, start
and end dates
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

16. What’s In a Project Plan?
Predecessor
tasks
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

17. What’s In a Project Plan?
Resource
allocations
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

18. What’s In a Project Plan?
Gantt
chart
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

19. Example: 11-Week Plan for a Process Design Project
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

20. Tools for Project Planning
Specialized software for larger projects
MS Project
SureTrak
Primavera Project Planner
Enterprise PM
Cobra
Small project plans & Gantt charts can be drawn in spreadsheets or using cheap software (<$100)
AceProject (free on-line)
TurboProject
Project Vision
Quick Gantt
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

21. 4. The Design Basis We need to know:
Determine
Customer Needs
Set Design
Specifications
Build Performance
Models
Generate Design
Concepts
R&D if Needed
Predict Fitness
For Service
Evaluate Economics
& Select Design
Customer
Approval
Detailed Design &
Equipment Selection
Procurement
& Construction
Begin Operation
We need to know:
What are we designing? How much of it do we want?
Where will it be built? What are the boundary conditions?
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

22. Process Design Basis
Documentation of design assumptions and boundary conditions is very important
For new process plants, most companies use some sort of design basis form or questionnaire to serve as a record of the design basis
This record is also essential in handing off information between the operating company, technology suppliers and contractors
There’s a template online at: booksite.Elsevier.com/Towler
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

23. What’s in the Design Basis?
Project information and revision tabs
To allow retrieval of documentation
To ensure that revisions are properly documented and make sure that the engineers aren’t working from the wrong version
To document review and approval of the design basis
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

24. What’s in the Design Basis?
Contact information
Company name
Process unit name
Who to contact & where to reach them
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

25. What’s in the Design Basis?
Conventions followed
Units of measurement
Customer specific and may also depend on location
Design engineers have to be able to work with both metric and English units
Equipment labeling convention
Sometimes other conventions and codes, e.g. design codes
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

26. What’s in the Design Basis?
Product information for primary products
Product grades desired
Safety data sheet reference number
Production rate, purity, shipment details
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

27. What’s in the Design Basis?
Information for primary raw materials
Feedstock grades
Safety information
Availability and pricing
Feed impurities and their concentrations
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

28. What’s in the Design Basis?
Site information
Ambient conditions needed for design of insulation, air coolers, etc.
Special conditions such as wind loads, hurricane and earthquake conditions that are needed for mechanical and civil engineering design
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

29. What’s in the Design Basis?
Sheet 2 of the Design Basis has utility information
Fuel gases
Fuel oils
Steam levels
Coolants
Process water
Electricity
Process Air
Conditions, availability, price, etc.
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

30. 5. Design Practices: Codes & Standards
Methods and rules for designing processes and equipment are given in design codes of practice
Codes are set by national or international industry panels (e.g., ISO, ASME, API, ISA)
Codes are reviewed and reissued frequently
Codes specify practices for design, construction, testing and operation of equipment and processes, that are expected to lead to a safe design, based on the experience of the code committee
Design in accordance with code is usually required by the company or by law
Standard sizes for piping & equipment, compositions, etc. are given in standards
Tubing dimensions, valve sizes, exchanger layouts, screw threads, wire gauges, screens, …
The two terms tend to be used interchangeably
Always consult the current (latest) edition of the code. Always make sure that the codes and standards used comply with local legal requirements.
Examples will be given throughout the course
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

31. 5. Design Practices: Design Factors (Design Margins)
Equipment is usually sized for greater than the design throughput
Allows for uncertainty in the design method and data
Leaves some room for expanding output
Ensures the plant can run at design capacity
Companies usually have a policy on design margins
Typically size equipment for 110% of design basis
Be careful to add design margin only once!
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

32. 6. Design Documentation
Determine
Customer Needs
Set Design
Specifications
Build Performance
Models
Generate Design
Concepts
R&D if Needed
Predict Fitness
For Service
Evaluate Economics
& Select Design
Customer
Approval
Detailed Design &
Equipment Selection
Procurement
& Construction
Begin Operation
Design information must be clearly documented to enable:
Fair comparison between competing design alternatives
Transfer of information to E&C company for detailed design
Development of plant manuals
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

33. Design Documentation
The design documentation for a process usually includes a minimum of:
The design basis
A written description of the process
A process flow diagram
At least one mass & energy balance
Product specifications and properties
A list of major plant equipment
Equipment specification sheets
A piping and instrumentation diagram
A cost estimate
HS&E information (e.g., HAZAN, HAZOP, MSDS forms)
Additional information such as techno-economic analysis, market information, analysis of competing technologies or alternative design options may also be included if within the scope of the project
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

34. Design Documentation
The design basis
A written description of the process
Process flow diagram
At least one mass & energy balance
Product specifications and properties
A list of major plant equipment
Equipment specification sheets
A piping and instrumentation diagram
A cost estimate
HS&E information
The PFD or flowsheet identifies all the equipment items and process streams
Usually broken into several separate sheets, defining plant sections
By convention, feeds enter at left, products exit right
Usually also indicates stream temperature & pressure
XYZ Co.
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

35. Design Documentation
The design basis
A written description of the process
Process flow diagram
At least one mass & energy balance
Product specifications and properties
A list of major plant equipment
Equipment specification sheets
A piping and instrumentation diagram
A cost estimate
HS&E information
Mass & energy balances are usually given for each design case (e.g., SOR/EOR, different feeds, winter /summer, etc.)
Usually mass flow, mole flow, wt% and mole% are given for every component in every stream
Often summarized as a table at the bottom of the PFD
XYZ Co.
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

36. Design Documentation The design basis
A written description of the process
Process flow diagram
At least one mass & energy balance
Product specifications and properties
A list of major plant equipment
Equipment specification sheets
A piping and instrumentation diagram
A cost estimate
HS&E information
XYZ Co.
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

37. Design Documentation Defines equipment names
Indicates which equipment is “spared”
Often used to summarize equipment costs and serve as a starting point for the capital cost estimate
The design basis
A written description of the process
Process flow diagram
At least one mass & energy balance
Product specifications and properties
A list of major plant equipment
Equipment specification sheets
A piping and instrumentation diagram
A cost estimate
HS&E information
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

38. Design Documentation
The design basis
A written description of the process
Process flow diagram
At least one mass & energy balance
Product specifications and properties
A list of major plant equipment
Equipment specification sheets
A piping and instrumentation diagram
A cost estimate
HS&E information
Give detailed design information (stream properties, dimensions) for each major piece of equipment
Occasionally include mechanical drawings if the equipment is not standard
Sometimes substituted with vendor specification sheets for sourced items
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

39. What’s in a Spec Sheet? Project info & rev tab
Equipment service and summary information
Stream data needed for design
Calculated design information for the equipment
Dimensions and construction details
Notes
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

40. Standard Templates
Typical templates for spec sheets and calc sheets are available at:
booksite.Elsevier.com/Towler
These can be customized for your design projects
© 2007 G.P. Towler / UOP. For educational use in conjunction with
Sinnott & Towler Chemical Engineering Design only. Do not copy

41. Design Documentation
The design basis
A written description of the process
Process flow diagram
At least one mass & energy balance
Product specifications and properties
A list of major plant equipment
Equipment specification sheets
A piping and instrumentation diagram
A cost estimate
HS&E information
The P&ID is more detailed than the PFD and almost always runs to several sheets
It shows all the plant instruments, control systems, control logic and shutdown systems
It also shows pipe sizes and metallurgy (but not pipe layout)
The P&ID is critical for performing design safety reviews
XYZ Co.
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

42. Design Documentation Variable costs of production
The design basis
A written description of the process
Process flow diagram
At least one mass & energy balance
Product specifications and properties
A list of major plant equipment
Equipment specification sheets
A piping and instrumentation diagram
A cost estimate
HS&E information
Variable costs of production
Raw materials
Utilities
Consumables
Packaging & shipping
Fixed costs of production
Wages
Taxes
Maintenance
Overheads
Capital costs
Working capital
Installed capital cost
Royalty costs
Annual capital charge
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

43. Design Documentation
Information on materials safety is required for hazard analysis, detailed design
Material Safety Data Sheets (MSDSs) must be provided to employees and customers by law in the U.S.A. (OSHA Hazard Communication Standard 29 CFR Part )
Information also needs to be collected to begin applying for emissions permits
The type of information needed and level of detail varies locally
The design basis
A written description of the process
Process flow diagram
At least one mass & energy balance
Product specifications and properties
A list of major plant equipment
Equipment specification sheets
A piping and instrumentation diagram
A cost estimate
HS&E information
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy

44. Conclusion: What Makes a Process Design in Industry
Design work process
Design team
Project plan
Design basis
Standard design procedures & practices
Design documentation
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy