Design of simple and robust process plant - j.l.a. koolen

Design of Simple and Robust Process Plants. J. L. Koolen Copyright  2002 Wiley-VCH Verlag GmbH & Co. KGaA ISBNs: 3-527-29784-7 (Hardback); 3-527-60047-7 (Electronic)

J. L. A. Koolen Design of Simple and Robust Process Plants

Design of Simple and Robust Process Plants. J. L. Koolen Copyright  2002 Wiley-VCH Verlag GmbH & Co. KGaA ISBNs: 3-527-29784-7 (Hardback); 3-527-60047-7 (Electronic)J. L. A. Koolen

Design of Simple and Robust Process Plants

Weinheim ± New-York ± Chichester ± Brisbane ± Singapore ± Toronto

Design of Simple and Robust Process Plants. J. L. Koolen Copyright  2002 Wiley-VCH Verlag GmbH & Co. KGaA ISBNs: 3-527-29784-7 (Hardback); 3-527-60047-7 (Electronic)

Author J. L. A. Koolen Bertelstraat 3 4535 CH Terneuzen The Netherlands

&

This bookwas carefully produced. Nevertheless, author, and publisher do not warrant the information contained therein to be free of errors. Readers are advised to keep in mind that statements, data, illustrations, procedural details or other items may inadvertently be inaccurate. Library of Congress Card No.: applied for British Library Cataloguing-in-Publication Data A catalogue record for this book isavailable from the British Library. Die Deutsche Bibliothek ± CIP Cataloguingin-Publication Data A catalogue record for this publication is available from Die Deutsche Bibliothek  2001 WILEY-VCH GmbH, Weinheim, Germany All rights reserved (including those of translation in other languages). No part of this book may be reproduced in any form ± by photoprinting, microfilm, or any other means ± nortransmitted or translated into a machine language without written permission from the publisher. Registered names, trademarks, etc. used in this book, even when not specifically marked as such, are not to be considered unprotected by law. Printed in the Federal Republic of Germany Printed on acid-free paper Composition Kühn & Weyh, Freiburg Printing Strauss Offsetdruck, Mörlenbach Bookbinding Osswald& Co., Neustadt (Weinstraûe) ISBN 3-527-29784-7

Design of Simple and Robust Process Plants. J. L. Koolen Copyright  2002 Wiley-VCH Verlag GmbH & Co. KGaA ISBNs: 3-527-29784-7 (Hardback); 3-527-60047-7 (Electronic)

Dedicated to Jans, Yvonne and Harald, Bart and Petra, and my grandchildren Sanne and Eva

ªImagination is more important than knowledgeº Albert Einstein

Design of Simpleand Robust Process Plants. J. L. Koolen Copyright  2002 Wiley-VCH Verlag GmbH & Co. KGaA ISBNs: 3-527-29784-7 (Hardback); 3-527-60047-7 (Electronic)

VII

Contents
Foreword Preface
XIII XV XVII

Acknowledgments 1 1.1 1.2 1.3 1.3.1 1.3.2 Introduction
1

1.3.3 1.3.4 1.3.5 1.3.6 1.3.7 1.3.8 1.3.9 1.3.10 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12
2 2.1

A New Evolutionary Step 1 The ProcessPlant of the 21st Century: Simple and Robust 5 Design Philosophies 8 Minimize Equipment and Piping 8 Design for Single Reliable and Robust Components Unless Justified Economically or from a Safety Viewpoint 8 Optimize Design 9 Clever Process Integration 9 Minimize Human Intervention 9 Operation Optimization Makes Money 9 Just-in-time Production (JIP) 10 Design for Total Quality Control (TQC) 10Inherently Safer Design 12 Environmentally sound design 13 Process Synthesis and Design Optimization 13 Process Simplification and Intensification Techniques 13 Design Based on Reliability 14 Optimization of a Complex, and Evaluation of its Vulnerability 15 Design of Instrumentation, Automation and Control 15 Operation Optimization 16 The Efficient Design and Operation of High-quality Process Plants16 Overall Example of Process Design 17 Summary 20
Simple and Robust Plant Design 23

What is ªSimpleº? 23

VIII

Contents

2.2 2.3 2.4 2.4.1 2.4.2 2.4.3 2.5
3 3.1 3.2 3.2.1 3.3 3.3.1 3.3.2

The Level of Complexity Why Higher Reliability? What is Robustness? 31 Mechanical Robustness Control Robustness 32 Operational Robustness Summary 33
Design Philosophies
35

25 30 32 32...