Self-directed learning project - 2014/Memo 4

Memo

McMaster Chemical Engineering (McChem Inc.)

1280 Main Street West

Hamilton, Ontario, L8S 4L7

Canada

http://learnche.mcmaster.ca

To	Colleagues in Chemical Engineering 4N04
cc:	Myrto Korogiannaki, Heera Marway, and Tyler Homer
Date:	13 November 2014
From:	Kevin Dunn
Subject:	Final details on the self-directed learning project

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Final details required for project report

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It is typical during engineering design of a new process or system that updated or new information becomes available every day, and sometimes even more frequently. Rather than update you every day, I've collected a variety of updates together that I want to inform you about.

1. . The MARR for our company has been set by the finance department as 12%.
2. . The plant is being added onto our existing site, in Ontario, Canada. We do not need to purchase extra land, and we have utility supplies, office buildings, roadways, security and other aspects already at the site.
3. . The number of years we are considering the new plant to be operating is N=25 years. However your sensitivity analysis is to consider 15, 20, 25, 30 and 35 year plant lifetimes.
4. . The assumption is that capital and operating costs are to be for 2013 (or as close as possible). Ensure that your operating costs are modified appropriately to get it to 2013 values.
5. . Tentatively assume that the life of all equipment is the same, i.e. so no equipment needs to be replaced midway through the life of the plant.
6. . The level of detail in the P&IDs is to be at the level of detail shown in the Woods diagram, used in assignment 6. Also see page 23 in the `free PDF chapter 1 <http://ptgmedia.pearsoncmg.com/images/9780132618120/samplepages/0132618125.pdf>`_ from Turton *et al.* You can omit pipe diameters though. Note that that P&ID was for two distillation columns only, and it filled a complete page. Your P&ID will likely cover 2 pages.
7. . Feel free to submit your P&ID as a separate PDF document; it does not add to your page count, so be generous in the drawing's spacing. It definitely has to be legible (some trial versions of drawing software downgrade the resolution - that's not acceptable for submission; I do not mind if there are watermarks from trial software, but I have to be able to read the drawing). The PDF should preferably be machine searchable so I can quickly locate valves and other references. I will be grading the report with the P&ID open side-by-side, and I have to be able to easily locate the items you are describing in the report.
8. . Differences from the original drawing provided must be described somewhere in your report. Additions of extra valves, control loops, bypasses, duplicated equipment, changes that you make to improve economics and sustainability of the process, *etc*, should be documented in the report.
9. . Note that equipment redundancies should be explained in the operability section; do not assume that it is obvious why certain equipment is duplicated.
10. . Remember to label all the equipment in the drawings (including valves), and refer to these in your reports. These are especially useful when you describe the start-up and shut down procedures, and the choice of control loops.
11. . Please ensure that you use standard symbols in your P&ID. Do not make up your own key.
12. . Indicate on control valves whether they should fail open or closed, and in your report give a brief explanation why, in the safety section, for at least 5 valves.
13. . The fuel gas burned in the fired heater can be considered as a purchased utility stream of natural gas.
14. . The switch condenser is a utility too. The operator will charge us $0.75 per tonne of material entering the condenser (subject to the specifications outlined in memo 1).
15. . For the economics section of the report, you are to have capital cost estimates of the entire plant. Be sure to show comprehensive calculations for these units: (no more than 0.5 page per unit)

* R-701 * E-701 * H-701 * C-701 * E-702 * P-702A * T-701 * V-701

Show the cost estimates for the remaining units in a summary table.

1. . Control loops should have brief explanations of their purpose. Do not assume that control loops provided in memo 1 were all useful; there were several useless loops in the Turton diagram which, once you start to consider operability do not make sense. Remove these, add others, and justify their use.
2. . For the operability section of your report your group is to focus on one main unit. You are free to select one unit from this list:

* H-701 * E-701 * E-703

If you have already considered another unit, you might may write an email to me, to describe the work you have done, and request to continue on with that unit's operability analysis.

1. . Your report requires a HAZOP to be performed on only **one node**. The node for your group is:

* R-701: the molten salt loop pipe leaving the reactor till just before entering the pumps, ``P702A/B``: groups A1, B1, A5, B5, and A10 * R-701: the entering stream 8, starting from the junction of streams 6 and 7, till just before the reactor entrance: groups A2, B2, A6, B6, and B10 * R-701: the exit stream from the reactor till just before entering ``E703``: groups A3, B3, A7, B7, and A9 * E-704: the stream leaving the exchanger and entering the vessel, ``V-701``: groups A4, B4, A8, B8, and B9

Any changes and improvements you make around your node's HAZOP should be reflected in a separate P&ID (start by copying and pasting your original P&ID then modify it) that only shows that node with a bit of context, then add the SIS, alarms, and other features you have added for improvement.

1. . As a reminder, the due date for the project is Friday, 28 November 2014, at 13:30.

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Sincerely,

Kevin Dunn

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