I. Process Design Concept: Fabregar, N.C.M
I. Process Design Concept: Fabregar, N.C.M
Design is a creative activity, and as such can be one of the most example, a particular product specification may be considered
rewarding and satisfying activities undertaken by an engineer. It is desirable by the sales department, but may be difficult and costly to
the synthesis, the putting together, of ideas to achieve a desired obtain, and some relaxation of the specification may be possible,
purpose. The designer starts with a specific objective in mind, a producing a saleable but cheaper product. Whenever he is in a
need, and by developing and evaluating possible designs, arrives at position to do so, the designer should always question the design
what he considers the best way of achieving that objective; be it a requirements (the project and equipment specifications) and keep
better chair, a new bridge, or for the chemical engineer, a new them under review as the design progresses. Where he writes
chemical product or a stage in the design of a production process. specifications for others, such as for the mechanical design or
When considering possible ways of achieving the objective the purchase of a piece of equipment, he should be aware of the
designer will be constrained by many factors, which will narrow down restrictions (constraints) he is placing on other designers. A tight,
the number of possible designs; but, there will rarely be just one well-thought-out, comprehensive, specification of the requirements
possible solution to the problem, just one design. Several alternative defines the external constraints within which the other designers
ways of meeting the objective will normally be possible, even several must work.
best designs, depending on the nature of the constraints. This can be
clearly illustrated in Figure 1. (DESIGN CONSTRAINTS) Design Collection. To proceed with a design, the designer must first
assemble all the relevant facts and data required. For process design
this will include information on possible processes, equipment
performance, and physical property data. This stage can be one of
the most time consuming, and frustrating, aspects of design. Many
design organizations will prepare a basic data manual, containing all
the process know-how on which the design is to be based. Most
organizations will have design manuals covering preferred methods
and data for the more frequently used, routine, design procedures.
The national standards are also sources of design methods and data;
they are also design constraints.
EQUIPMENT DESIGN
Only those characteristics of equipment are specified by Ulrich and Vasudevan (2006) pointed out that it may be too
process design that is significant from the process point of view. On a late to consider safety once a project has reached the equipment
pump, for instance, process design will specify the operating specification and PID stage. Examples of common safe practices are
conditions, capacity and pressure differential, NPSH, materials of pressure relief valves, vent systems, flare stacks, snuffing steam and
construction in contact with process liquid, and a few other items, but fire water, escape hatches in explosive areas, dikes around tanks
not such details as the wall thickness of the casing or the type of storing hazardous materials, turbine drives as spares for electrical
stuffing box or the nozzle sizes and the foundation dimensions motors in case of power failure, and others. Safety considerations
although most of these omitted items eventually must be known are paramount in the layout of the plant, particularly isolation of
before a plant is ready for construction. Standard specification forms especially hazardous operations and accessibility for corrective
are available for most proprietary kinds of equipment. action when necessary.
Proprietary equipment is provided off the shelf in limited Continual monitoring of equipment and plant is standard
sizes and capacities. Special sizes that would fit particular practice in chemical process plants. Equipment deteriorates and
applications more closely often are more expensive than a larger operating conditions may change. Repairs are sometimes made with
standard size that incindentally may provide a worthwhile safety materials or equipment whose ultimate effects on operations may not
factor. Even largely custom-designed equipment, such as vessels, is have been taken into account. During start-up and shutdown, stream
subject to standardization such as discrete ranges of head compositions and operating conditions are much different from those
diameters, pressure ratings of nozzles, sizes of manways, and kinds under normal operation, and their possible effect on safety must be
of trays and packings. Many codes and standards are established by considered.
government agencies, insurance companies, and organizations
sponsored by engineering societies. This can be seen in the following Because of the importance of safety and its complexity,
tables. Some standardization within individual plant are arbitrary safety engineering is a speciality in itself. In chemical processing
choices from comparable methods, made to simplify construction, plants of any significant size, loss prevention reviews are held
maintenance, and repair: for example, restriction to instrumentation periodically by groups that always include a representative of the
of a particular manufacturer or to a limited number of sizes of heat safety department. Other personnel, as needed by the particular
exchanger tubing or a particular method of installing liquid level gage situation, are from manufacturing, maintenance, technical service,
glasses. All such restrictions must be borne in mind by the process and possibly research, engineering, and medical groups. The review
designer. considers any changes made since the last review in equipment,
repairs, feedstocks and products, and operating conditions (Walas,
SPECIFICATIONS 2010).
10. Electrical power: Voltages allowed for instruments, lighting and The International Organization for Standardization (ISO)
various driver sizes, transformer capacities, need for emergency coordinates the publication of international standards.
generator, unit costs.
All the published British standards are listed, and their
11. Compressed air: capacities and pressures of plant and instrument scope and application described, in the British Standards Institute
air, instrument air dryer. Catalogue; which the designer should consult. The catalogue is
available online, go to the BSI group home page, www.bsi-
12. Plant site elevation. global.com.
13. Soil bearing value, frost depth, ground water depth, piling As well as the various national standards and codes, the
requirements, available soil test data. larger design organisations will have their own (in-house) standards.
14. Climatic data. Winter and summer temperature extremes, cooling Much of the detail in engineering design work is routine and
tower dry-bulb temperature, air cooler design temperature, strength repetitious, and it saves time and money, and ensures conformity
and direction of prevailing winds, rain and snowfall maxima in 1 hr between projects, if standard designs are used whenever practicable.
and in 12 hr, earthquake and hurricane provision. Equipment manufacturers also work to standards to
15. Blowdown and flare: What may or may not be vented to the produce standardised designs and size ranges for commonly used
atmosphere or to ponds or to natural waters, nature of required items; such as electric motors, pumps, pipes and pipe fittings. They
liquid, and vapor relief systems. will conform to national standards, where they exist, or to those
issued by trade associations. It is clearly more economic to produce
16. Drainage and sewers: rainwater, oil, sanitary. a limited range of standard sizes than to have to treat each order as
a special job.
17. Buildings: process, pump, control instruments, special
equipment. For the designer, the use of a standardised component size
allows for the easy integration of a piece of equipment into the rest of
18. Paving types required in different areas. the plant. For example, if a standard range of centrifugal pumps is
19. Pipe racks: elevations, grouping, coding. specified the pump dimensions will be known, and this facilitates the
design of the foundations plates, pipe connections and the selection
20. Battery limit pressures and temperatures of individual feed stocks of the drive motors: standard electric motors would be used.
and products.
For an operating company, the standardisation of
21. Codes: those governing pressure vessels, other equipment, equipment designs and sizes increases interchange-ability and
buildings, electrical, safety, sanitation, and others. reduces the stock of spares that have to be held in maintenance
stores.
22. Miscellaneous: includes heater stacks, winterizing, insulation,
steam or electrical tracing of lines, heat exchanger tubing size Though there are clearly considerable advantages to be
standardization, instrument locations. gained from the use of standards in design, there are also some
disadvantages. Standards impose constraints on the designer. The
23. Environmental regulations. nearest standard size will normally be selected on completing a
24. Safety and health requirements (Walas, 2010). design calculation (rounding-up) but this will not necessarily be the
optimum size; though as the standard size will be cheaper than a
CODES AND STANDARDS special size, it will usually be the best choice from the point of view of
initial capital cost. Standard design methods must, of their nature, be
The need for standardisation arose early in the evolution of historical, and do not necessarily incorporate the latest techniques
the modern engineering industry; Whitworth introduced the first (Sinnot, Coulson and Richardson, Vol.6, 2005)
standard screw thread to give a measure of interchange-ability
between different manufacturers in 1841. Modern engineering LABORATORY AND PILOT PLANT WORK
standards cover a much wider function than the interchange of parts.
In engineering practice they cover: Vendors Questionnaire
DOLE and other government agencies have issued hazard-specific guidelines, departmental orders and implementing rules.
Employers and workers organizations have developed OSH guidelines for their respective membership. Individual firms have made
their specific OSH programs an integral part of their respective health programs. ILO Conventions provide general guidelines on OSH
policy
Chapter I Policy
The State shall promote and develop a tax-exempt employees compensation program whereby employees and their dependents, in
the event of work-connected disability or death, may promptly secure adequate income benefits, and medical or related benefits.
Contributions
Employers from both private and public sector contribute to the State Insurance Fund, which in turn pays the benefits to
covered employees.
Administration of Benefits
The Employees Compensation Commission (ECC) initiates, rationalizes and coordinates the policies of the EC program,
chaired by the Secretary of Labor and Employment. The Commission has a status of a government corporation.
Medical Benefits
Employees who contract sickness or sustain injuries shall be provided by the System during the period of disability with, as
well as cash income benefit or pension.
Under Article 162 of the Philippine Labor Code, the OSHS was promulgated for the guidance and compliance of those
covered. The DOLE administers and enforces the provisions of the Standards. Safety and Health rules may be promulgated, modified
or revoked covering 26 rules and 144 subrules, among which are on:
Reference: http://oshc.dole.gov.ph/UserFiles/oshc2010/file/National-OSH-Profile.pdf
ETHICS1
FUNDAMENTALS OF ETHICS
I. ORIGIN AND NATURE OF ETHICS
It is derived from the Greek word ethos meaning character.
(The greeks believed that developing character would lead one not only to knowing the right thing to do, but to
actually doing the right thing or living the right way of life.)
Or Moral Philosophy It is when man begin to wonder about things to do or how he should live his existence
A personal and life-long commitment