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Engineering Calculation Process

The document provides guidance on preparing process engineering calculations, including layout, format, accuracy, and checking. It recommends that calculations include sections for the summary, introduction, main body, conclusions, and references. Calculations should be prepared logically and clearly to communicate to future engineers. Spreadsheets, word processors, and specialist packages can be used, with each having advantages and disadvantages. Assumptions, margins of error, and independent checking help ensure calculation accuracy.

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Mafe Salazar
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684 views

Engineering Calculation Process

The document provides guidance on preparing process engineering calculations, including layout, format, accuracy, and checking. It recommends that calculations include sections for the summary, introduction, main body, conclusions, and references. Calculations should be prepared logically and clearly to communicate to future engineers. Spreadsheets, word processors, and specialist packages can be used, with each having advantages and disadvantages. Assumptions, margins of error, and independent checking help ensure calculation accuracy.

Uploaded by

Mafe Salazar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Preparing Calculations

February 14, 2013 mycheme

Introduction
All chemical engineers have to prepare calculations during process design. These ranging from
scoping estimates to detailed chemical engineering calculations to size equipment. Whilst style is a
matter of personal taste, this article gives a few pointers on how to prepare process engineering
calculations.

Layout
Many calculations are kept for years often for the lifespan of the plant. It may be read by others long
after the author has moved on. Thus, any calculation should be written as a standalone document
which can be understood by engineers in the future without the need for further explanation. The
layout of a calculation should be clear, taking the reader through to its conclusions in a logical order.
Whilst the level of explanation will depend on its complexity, the following sections are typical.
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Summary
The summary is usually found on the front page of the calculation and should repeat key information
given in the rest of the document. Its aim is to give the reader a clear idea of what the calculation is
about without having to read the rest of the document. It should give a statement of the problem, a
description of the calculation method and present the main conclusions.

Introduction
The introduction should put the calculation in context. It should present a statement of the problem and
explain why it is being addressed.

Main Body of the Calculation


The main body should take the reader through the calculation in a logical manner. The calculation
method should be explained and assumptions justified. Consider using sketches, photos or graphs to
explain key points. Any data used should be referenced. It is advisable to break larger calculations
down into subsections.

Conclusions
The conclusions reached should be presented at the end of the calculation. These should be linked to

the statement of the problem given in the introduction. The conclusions should identify the documents
and parts of the plant affected. It is the responsibility of author to ensure that any implications of the
calculation are acted upon.

References
In the event of a future query, the references can be used to confirm the basis of the calculation. To
support the checking process, data and design methods used in the calculation should be referenced.
Care should be taken when using the internet as a source of data, as websites can be transitory. The
reference should give the date that the site was accessed and ideally a screen dump of the webpage
should be posted into the calculation.

Format
Not that many years ago, calculations were hand written. Nowadays most calculations prepared on
computer packages. These make them easier to draft out and to correct mistakes. The main packages
used to produce calculations are discussed below.

Spreadsheets (e.g. Excel)


Spreadsheets, such as Excel, are arguably the most popular package for preparing calculations. They
are widely available and were developed specifically for calculations. They are powerful mathematical
tools which can be extended by the use of Macros. Their main disadvantage is that the formulas are
hidden within the spreadsheet, making them difficult to check. For this reason, some engineering
companies discourage the use of spreadsheets for formal calculations.

Word Processors (e.g. Word)


Word processors, such as Word, is ideal for formatting formal documents as they allow text, pictures
and graphs to be easy presented on the page. Like spreadsheets, they are widely available. Word has
an add-in function which allows the user to write equations into a document.
However, most word processors (including Word) do not have a calculator function. This means that
calculations have to be done outside of the package and the results typed in manually.
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Specialist Packages
There are a number of specialist packages on the market which have been developed specifically to
present and solve calculations examples include MATLAB and MathCAD. These allow the user to

write out the equations and solve them. They can even keep track of units. Unfortunately, as they are
specialist packages, they are not always readily available.

Accuracy
All engineering calculations are approximate, to a greater or lesser extent. Inaccuracies can occur from
a number of sources:
Use of approximate physical properties or other data, such as plant measurements.
Assumptions used in the calculation.
Use of approximate calculation methods.
The level of accuracy required will depend on the use to which the results will be put.
Often engineers will get round the problem of inaccuracies by using conservative assumptions or by
applying design margins. This ensures that the design errs on the safe side but can mean that it is overengineered. The magnitude of the design margin or level of conservatism applied is a judgement to
balance the safety, technical and financial implications.

Checking
Invariably, calculations are checked by a second engineer to minimise the chance of a mistake. The
level of checking will depend on the complexity of the calculation and the use of the results. Some
hints on how to check are listed below:
1. References are the references used correct and appropriate? Ideally, critical information
should be checked with an independent source.
2. Units Incorrect units are probably the biggest source of error in calculations. Units within a
formula should be correct and consistent. Conversion factors should be checked with a
reputable source.
3. Check basic arithmetic this is especially important in spreadsheets where cell references
should be checked.
4. If possible, use approximate calculation methods and rules of thumb to confirm that the results
are in the right ballpark. Check results against other similar calculations or other data such as
vendor information.
5. Perform a sensitivity analysis. Consider the implications if some of the assumptions or design
margins are relaxed.

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