THE UNIVERSITY OF MELBOURNE

DEPARTMENT OF CHEMICAL AND BIOMOLECULAR ENGINEERING

CHEN90022 and BIEN90002 DESIGN PROJECT 2017

DESIGN NOTICE 6
Design Assessment Tasks

Detailed Design Report

The Detailed Design Report is an individual submission. The last two tasks in this report (items 8 and 9)
require team collaboration, but the write-up of these sections will remain an individual responsibility. So, for
example, for a team containing five members, five reports, Volumes 3(a), 3(b), 3(c), 3(d) and 3(e) will be
submitted.

5 Major Equipment Design

5(a) Major Process Design

Each member of the group is to undertake the detailed process design of a different item within the plant.
For example
Acid Gas Removal
Methanol Reactor
Methanol Purification
Methanol Dehydrator
DME Purification
H2 Purification

Your process design will depend upon the item you have been allocated. For example, in designing the reactor,
you might look at reaction kinetics and optimise the residence time.

The work you do in this part will undoubtedly result in you wanting to adjust the material and energy balances
determined in the Process Development Report. In this case, simply make a note that the two reports are
inconsistent and explain why.

Indicate why you have selected particular details of your process design in light of other alternatives provide
justification for your preferences. Discuss any utility requirements and/or safety considerations that have
influenced your choices. Your report should include a process data sheet for the equipment item outlining key
process parameters such as size, process environment, operating conditions, safety features, instrumentation
requirements and any other aspect important to document the design. An Appendix is to be provided detailing
calculations of the design.

5(b) Major Mechanical Design

Complete the mechanical design of one equipment item. This work should take all the process design
information and convert it into a detailed dimensioned drawing and mechanical data sheet containing detailed
mechanical information eg. wall thickness of pipe or vessel, materials of construction, design pressure and
temperature. This section should include the details of internal structures in a reactor. Calculate the capital cost
of your item based on your mechanical and process design.

The mechanical design should be of a single equipment item. For example, a student undertaking the heat
exchanger integration for their major process design, might complete their mechanical design on a single heat
exchanger, or the steam supply deaerator. A student working on acid gas removal needs only to do the
mechanical design on either the absorber or the stripper.
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6 Minor Equipment - Preliminary Design
The minor equipment design this year departs from previous years.

Perform preliminary sizing and costing of one minor item of equipment in your section. This could be a storage
vessel, heat exchanger or pump. The sizing should be sufficient to cost the equipment and to define its
approximate physical size (e.g. diameter and length of a kiln or rotary filter; height, diameter and number of
trays in a tower). In many cases, only short cut or "rule of thumb" methods need to be used. You should also
specify the construction material of each item.

You should also provide a list of all equipment items in your design.

7 Piping and Instrumentation Diagrams

a) The P&ID
Provide a detailed Piping and Instrumentation Diagram (P&ID) for the single item you designed in detail
above. You may wish to also include on this P&ID ancillary equipment immediately surrounding this item. For
instance, if your detailed design item was a distillation column it would make sense to include the condenser
and reboiler on the P&ID. However, you do not need to provide the P&ID for your entire section. Think quality
not quantity.

The P&ID represents a key project document and acts as the focal point for communicating information to
other engineering disciplines on the project team. Consequently, you should ensure that you mark all
instrumentation, all pipes and all valves. This will require preliminary pipe sizing, key materials of construction
and designers notes to be included in the diagram. Liberal use of notes is common. All the necessary detail of
control loops, startup lines, drains etc should be represented on the P&ID.

As you develop the P&ID you should be envisaging potential safety issues and design in appropriate protective
measures e.g. should valves fail open or fail closed? Do you need pressure relief valves? What bunding is
needed? Drain diversions? Safe operating procedures? Many of these features will have been raised in your
original safety considerations! Apply this knowledge. It will make for better designs and reduce rework in the
HAZOP Study.

An Appendix should provide the calculations supporting the pipe sizing provided on the P&ID.

b) Process Control Description

Your report should outline the process control philosophy for your detailed equipment item, referring to the
P&ID. Discuss any specific safety issues and how your control system has been designed to deal with these
concerns. Describe any extra control systems that will be required for safe startup and shutdown.

c) Process Operation
Your report should outline a basic operating procedure for your detailed equipment item, referring to the P&ID.
The procedure should be more of a Work Aid than a full procedure. Include safety aspects such as relevant
personal protective equipment. Discuss how your section of the plant will operate on a day-to-day basis, how it
will start up and shut down and any extra control systems that will be required for these times.

Section 7 will not only explain the plant operations but will also form the preamble to the HAZOP study.

8 HAZOP Analysis
The HAZOP technique is a team-based approach for the identification of potential plant hazard and
operability problems. As a team, you should perform a HAZOP on each of the detailed design items.

In each case, you should take it in turns to act as chairperson and designer as follows:

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 Person 1 Person 2 Person 3 Person 4
Round 1 Chair Designer Team member Team member
Round 2 Team member Chair Designer Team member
Round 3 Team member Team member Chair Designer
Round 4 Designer Team member Team member Chair

Each individual will present their design to the HAZOP team as the designer and subject it to the relevant
process. Once agreement is gained on the design, the chairperson will mark up any issues on a copy of the
P&ID and record Meeting Minutes, including a list of attendees and a list of actions for improving the safety
and operability of the design. Include in your report the marked up P&ID and Minutes for the section where
you acted as Chairperson (i.e. not your own section). Do not modify the design simply explain how the
improvements would be made.

9 Economic Analysis
This task will require team collaboration, but will be marked as an individual contribution.
You should first compile all the relevant data that your team will need for the economic evaluation of the
project e.g:

Capital costs: Equipment items, using the equipment list as a focal document

Operating Costs: Raw materials consumption

Utility consumption (steam, cooling water etc.)
Staff and other fixed costs
Other costs appropriate to the facility

Using this data, develop estimates of your total plant capital cost and operating expenses. Calculate and report
the overall cost for the project. Perform an economic analysis of the viability of your plant using DCF and/or
break-even point calculations. Indicate the assumptions you have made with respect to government charges,
inflation, raw material and utility costs, and plant life. Perform a sensitivity analysis on your results.

For this final section, Tables, data and graphs prepared by the team may be shared (with authorship clearly
indicated), but the individual must write their own report.

10 Conclusions, Recommendations and Overall Appearance

Your Detailed Design report should contain a Title Page, Executive Summary, Table of Contents,
Recommendations and Conclusions. References must be cited in full, either at the end of each Chapter, or in an
Appendix at the end of the report.