SCHOOL OF CHEMICAL ENGINEERING
School of Chemical Engineering
Universiti Sains Malaysia
Engineering Campus
EKC 453 – Plant Design & Economics
Weightage: 360 marks Due Date: 23 May 2021
Design Task # 2
(To be submitted by the group)
1. Planning and execution of the project
Gantt Chart, minutes of meeting, work distribution and execution of the task
A. Piping & Instrumentation Diagram (P & I) Diagram Marks
1. P & I Diagram should include instruments which will monitor the 40
important process variables such as temperature, pressure, flow rate,
composition etc. during plant operations. Equipment identified in PDF with
detail.
2. Identify and draw the control loops needed on each piece of equipment for
steady state operation. These loops are:-
[i] Level Controls
[ii] Flow Controls
[iii] Pressure Controls
[iv] Temperature Controls
[v] Others
The control design in each equipment’s should include:
• Objective of the loop
• Measurements for pairing (MV)
• Manipulated variables (CV)
• Constraints if any
• Disturbances (measured)
• Control structures (single loops etc)
• Additional considerations (safety, shut up and shutdown, etc.).
3. Summary of the control loop for each equipment in the Table form 40
including the safety features (P, PI, PID, PD, Cascade).
4. Draw plant layout at the whole complex (ISBC/OSBC). Should be 40
following the Risk assessment analysis.
5. List up all the sensor selection for each variable/control loops in the 40
P&ID. The possible specification and constraints of each sensor should
be highlighted. Basic maintenance/calibration for each sensor should be
provided.
EKC 453 Plant Design & Economics - 1 -
SCHOOL OF CHEMICAL ENGINEERING
Develop and analyse the proposed control structure in your P&ID in 40
dynamics condition using Aspen Dynamics.
6. Draw the P&ID diagram. The P&ID diagram should be drawn as a 40
professional drawing using proper software ( Visio, AUTOCAD etc ) and
printed on A3 size paper. Use only standard symbols ( TEMA, ISA
standard).
B. Engineering Ethics in Plant Design Marks
[a] Did you face any ethical problem while making the decision on
the design of any unit when data were limited. How you 10
overcome this ethical problem?
[b] What are code of ethics adopted by Malaysian Institute of 10
Chemical Engineers (IEM) and Boards of Engineers Malaysia
(BEM). How these codes affect the Chemical Engineer while
undertaking plant design exercise. ( you may consider from API
etc as well)
[c] What are ethical issues involved in your plant design while 10
addressing environmental safety and health problems in the
operation of designed plant? Would you put public safety above
the cost of plant to make profit ignoring these issues?
[d] In meeting the deadline for submission of design project report, 10
did you break any ethic codes to meet the deadline without
following proper design procedure knowing that the design could
be wrong and unsuccessful? What should be correct practice in
plant design without breaking ethical codes?
C. Plant Risk Assessment Analysis Marks
1. • List hazardous substance utilized and produced together with their 40
chemical, physical and toxic properties
• List equipment used that contain high inventory of the hazardous
substances together with the operating conditions
• Identify the possible hazard derived from the plant
• Perform Probability Analysis and Consequence Analysis of each
identified hazard
• Evaluate the risk of each identified hazard
• Recommend the mitigation strategies to minimize the risk of each
hazard
2. List clearly the steps involves in start up and shut down of the major 40
unit operation in your plant and also the alarm system.
1. Reactor
2. Distillation column
EKC 453 Plant Design & Economics - 2 -
