Solutions Manual for Analysis, Synthesis, and Design of Chemical Processes, 3rd Edition

,
, Chapter 1 x




1.1 Block Flow Diagram (BFD)
x x x



Process Flow Diagram (PFD)
x x x x



Piping and Instrument Diagrams (P&ID)
x x x x




(a) PFD
(b) BFD
(c) PFD or P&ID x x



(d) P&ID
(e) P&ID


1.2 P&ID


1.3 It is important for a process engineer to be able to review a 3-dimensional model prior to
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the construction phase to check for clearance, accessibility, and layout of equipment,
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piping, and instrumentation.
x x x




1.4 (1) Clearance for tube bundle removal on a heat exchanger.
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(2) NPSH on a pump – affects the vertical separation of feed vessel and pump inlet.
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(3) Accessibility of an instrument for an operator – must be able to read a PI or x x x x x x x x x x x x x x x



change/move a valve.
x x x



(4) Separation between equipment for safety reasons – reactors and compressors.
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(5) Crane access for removing equipment. x x x x



(6) Vertical positioning of equipment to allow for gravity flow of liquid.
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(7) Hydrostatic head for thermosiphon reboiler – affects height of column skirt. x x x x x x x x x x




1.5 Plastic models are no longer made because they are too expensive and difficult to
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change/revise. These models have been replaced with virtual/E-model using 3-D CAD.
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Both types of model allow revision of critical equipment and instrument placement to
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ensure access, operability, and safety.
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1.6 Another reason to elevate the bottom of a tower is to provide enough hydrostatic head
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driving force to operate a thermosiphon reboiler.
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1-1

, 1.7 (a) x PFD or P&ID
x x x



(b) PFD
(c) PFD
(d) P&ID
(e) BFD (or all PFDs) x x x




1.8 A pipe rack provides a clear path for piping within and between processes. It keeps piping
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off the ground to eliminate tripping hazards and elevates it above roads to allow vehicle
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access.
x




1.9 x A structure – mounted vertical plant layout is preferred when land is at a premium and the
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x process must have a small foot print. The disadvantage is that it is more costly because of
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x the additional structural steel.
x x x




1.10 (a) x BFD – No change
x x x x



PFD – Efficiency changed on fired heater, resize any heat exchanger used to extract
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heat from the flue gas (economizer) x x x x x x



P&ID – Resize fuel and combustion air lines and instrumentation for utilities to fired
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heater. Changes for design changed of economizer (if present) x x x x x x x x x



(b) BFD – Change flow of waste stream in overall material balance x x x x x x x x x



PFD – Change stream table
x x x x x



P&ID – Change pipe size and any instrumentation for this process line
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(c) BFD – No change x x



PFD – Add a spare drive, e.g. D-301  D-301 A/B x x x x x x x x x



P&ID – Add parallel drive
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(d) BFD – No change x x



PFD – No change
x x x



P&ID – Note changes of valves on diagram x x x x x x x




1.11 x (a) A new vessel number need not be used, but it would be good practice to add a letter
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to donate a new vessel, e.g. V-203  V-203N. This will enable an engineer to locate
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the new process vessel sheet and vendor information.
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(b) P&ID definitely
x x



PFD change/add the identifying letter. x x x x




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