Table Of Content

Preface The preparation of an international reference book such as this could not possibly be achieved without the total cooperation of so many individual authors and the back- ingoftheirvariousemployers,especiallywherecompany contributionshavebeenmade,bringingtogetherawealth of professional knowledgeand expertise. Anacknowledgementsuchasthiscanonlyscratchthe surface and cannot really portray the grateful thanks I wish to express to all these people concerned that have devoted so much time and effort to place their ideas and contributionsto thisPlantEngineeringHandbook. Plantengineeringissuchabroadsubjectincorporating amultitudeofdisciplinesandawidevarietyofsolutions to virtually every problem or situation, unlike some sub- jects that have clear-cut methods. In compiling the initial suggested guidelines for each ofthecontributions,Iposedthequestionstomyselfwhat information and assistance had I found difficult to locate during over 30 years as a plant engineer responsible for plantsthroughouttheworldandhowcoulditbebestpre- sented to assist others in theirprofession. Iwouldthereforeliketotakethisopportunitytothank each of the contributing authors for their patience and assistancein helping me to structurethis publication. R. Keith Mobley PresidentandCEO ThePlantPerformanceGroup Knoxville,Tennessee,USA Contents Foreword vii 32 PumpsandPumping 533 33 CentrifugalPumpInstallation 565 Preface ix 34 CoolingTowers 571 ListofContributors xi 35 CompressedAirSystems 587 36 Compressors 601 1 DefinitionandOrganizationofthe 1 37 FansandBlowers 615 PlantEngineeringFunction 38 MixersandAgitators 623 2 PlantEngineeringinBritain 7 39 GearsandGearboxes 629 3 TheRoleofthePlantEngineer 13 40 HydraulicFundamentals 639 4 PhysicalConsiderationsinSite 17 41 PneumaticFundamentals 687 Selection 42 NoiseandVibration 707 5 PlantLocation 35 43 VibrationFundamentals 721 6 IndustrialBuildings 43 44 VibrationMonitoringandAnalysis 757 7 PlanningandPlantLayout 67 45 AirPollution 813 8 ContractsandSpecifications 85 46 DustandFumeControl 823 9 IndustrialFlooring 101 47 DustCollectionSystems 837 10 Lighting 111 48 MaintenanceManagementinUK 845 11 Insulation 131 49 EffectiveMaintenance 857 12 PaintCoatingsforthePlant 147 Management Engineer 50 PredictiveMaintenance 867 13 Insurance:PlantandEquipment 161 51 PlanningandSchedulingOutages 889 14 Insurance:BuildingsandRisks 185 52 Lubrication 915 15 ElectricityGeneration 199 53 Corrosion 961 16 ElectricalDistributionand 233 54 ShaftAlignment 987 Installation 55 RotorBalancing 1009 17 ElectricalInstrumentation 255 56 PackingandSeals 1017 18 Oil 273 57 GearsandGearDrives 1029 19 Gas 285 58 FlexibleIntermediateDrives 1043 20 LiquefiedPetroleumGas 321 59 CouplingsandClutches 1065 21 CoalandAsh 335 60 Bearings 1081 22 SteamUtilization 353 61 FinanceforthePlantEngineer 1101 23 IndustrialBoilers 387 62 StatisticalApproachesin 1117 24 CombustionEquipment 415 MachineryProblemSolving 25 Economizers 429 63 HealthandSafetyintheUK 1131 26 HeatExchangers 437 64 RegulatoryComplianceIssuesin 1151 27 Heating 447 theUS 28 Ventilation 465 29 AirConditioning 481 Index 1159 30 EnergyConservation 503 31 WaterandEffluents 517 List of Contributors A Armer A P Hyde Spirax Sarco Ltd National Vulcan Engineering Insurance Group Ltd B Augur, IEng, FIPlantE, MBES H King J B Augur(Midlands)Ltd Thorn Lighting H Barber, BSc B R Lamb, CEng, MIChemE LoughboroughUniversity of Technology APV Baker Ltd D A Bayliss, FICorrST, FTSC S McGrory BH Oil UK Ltd J Bevan, IEng, MIPlantE R Keith Mobley R J Blaen International Consultant Senior Green Limited R J Neller British Compressed Air Society Film Cooling Towers Ltd G Burbage-Atter, BSc, CEng, FInstE, Ove Arup & Partners, Industrial Division HonFIPlantE, FCIBSE Heaton Energy Services G Pitblado, IEng, MIPlantE, DipSM Support Services P D Compton, BSc, CEng, MCIBSE Colt International Ltd R S Pratt, ALU, CEng, MIMfgE,MBIM, MSAE Secretary-General, The Institutionof Plant I G Crow, BEng, PhD, CEng, FIMechE, Engineers FIMarE, MemASME Davy McKee (Stockton) Ltd G E Pritchard, CEng, FCIBSE, FInstE, FIPlantE, MASHRAE R. Dunn Editor, Plant EngineeringMagazine Risk Control Unit Royal Insurance (UK) Ltd P Fleming, Bsc(Eng), ARSM, CEng, MInstE British Gas plc R Robinson, BSc, CEng, FIEE The Boots Co. plc C Foster British Coal M J Schofield, BSc, MSc, PhD, MICorrT Cortest Laboratories Ltd C French, CENg, FInstE, FBIM Saacke Ltd J D N Shaw, MA SBD Construction Products Ltd F T Gallyer PilkingtonInsulation Ltd R H Shipman, MIMechE, MIGasE, MInstE Liquefied Petroleum Gas Industry Association R R Gibson, BTech, MSc, CEng, FIMechE, FIMarE, FRSA K Shippen, BSc, CEng, MIMechE W S Atkins ConsultantsLtd ABB Power Ltd B Holmes, BSc(Tech), PhD, CEng, FIChemE, FInstE R Smith W S Atkins ConsultantsLtd Life Cycle Engineering,Inc. xiiListofContributors G Solt, FIChemE, FRSC E Walker, BSc, CEng, MIMechE Cranfield Instituteof Technology Senior Green Limited K Taylor, CEng, FCIBSE, FIPlantE, FIHospE, R C Webster, BSc, MIEH FSE, FIOP, MASHRAE, FBIM, ACIArb Environmental Consultant Taylor Associates Ltd D Whittleton, MA, CEng, MIMechE, MHKIE L W Turrell, FCA Ove Arup & Partners, Industrial Division K Turton, BSc(Eng), CEng, MIMechE LoughboroughUniversity of Technology Copyright2001byButterworth-Heinemann Allrightreserved. Nopartofthispublicationmaybereproduced,storedinaretrieval system,ortransmittedinanyformorbyanymeans,electronic,mechanical, photocopying,recording,orotherwise,withoutthepriorwrittenpermission ofthispublisher. Recognizingtheimportanceofpreservingwhathasbeenwritten, Butterworth-Heinemannprintsitsbooksonacid-freepaper wheneverpossible. Butterworth-HeinemannsupportstheeffortsofAmericanForests andtheGlobalReLeafprograminitscompaignforthebetterment oftrees,forests,andourenvironment. LibraryofCongressCataloging-in-PublicationData Plantengineer’shandbook/editedbyR.KeithMobley.–[Rev.ed.]. p.cm Rev.ed.of:Plantengineer’sreferencebook.c1991. Includesindex. ISBN0750673281 1 Plantengineering–Handbooks,manuals,etc. I. Mobley,R.Keith,1943-II, Title:Plantengineer’sreferencebook. TS184.P582000 696–dc21 00-049366 BritishLibraryCataloguing-in-PublicationData Plantengineer’shandbook 1 Plantengineering–Handbooks,manuals,etc. 1 Mobley,R.Keith,1943– 658.2 ThePublisheroffersspecialdiscountsonbulkordersofthisbook. Forinformation,pleasecontact: ManagerofSpecialSales Butterworth-Heinemann 225WildwoodAvenue Woburn,MA01801–2041 Tel:781-904-2500 Fax:781-904-2620 ForinformationonallButterworth-Heinemannpublicationsavailable, contactourWorldWideWebhomepageat:http://www.bh.com 10987654321 TypesetbyLaserWords,Madras,India PrintedintheUnitedStatesofAmerica 1/1 Definition and Organization of the Plant 1 Engineering Function Richard Dunn Editor,PlantEngineeringMagazine Contents 1.1 Introduction 1/3 1.2 Basicdefinition 1/3 1.3 Responsibilities 1/3 1.3.1 Activities 1/3 1.3.2 Knowledgeareas 1/4 1.4 Organization 1/4 Responsibilities1/3 1.1 Introduction and outside the facility as well as the safety and health of the employees and the reliability of its systems and Theconceptoftheplantengineeringfunctionhaschanged equipment. And they are expected to do all of this in a little over the years. Yet, the ways in which that func- cost-effective manner. tionisaccomplishedhavechangedsignificantly,primarily A few phrases from a 1999 classified ad for a plant because of changing technologies and business models. engineerprovidesomereal-worldinsightonthescopeof More than ever before, for example, the plant engineer responsibilities: must learn to manage from the perspective of a business participant, relating his responsibilities and activities to ž Supportongoingoperations,troubleshoot,resolveemer- the mission and goals of the enterprise. Moreover, the gencies, implement shutdowns invasion of electronics and computerization into nearly ž Organize and maintain information on plant sys- everyfacetofengineeringandbusinessoperationhasfos- tems/equipment and improvement programs tered the integration of plant engineering into both the ž Implement plant projects and maintain proper docu- operations and the business plan of the enterprise. mentation Changes in enterprise organization models have also ž Deal effectively with multiple activities, requests, and impactedplantengineering.Inmanyindustrialplants,for emergencies example, the title of ‘plant engineer’ has disappeared, ž Manage scope, design, specification, procurement, being replaced with such titles as ‘facilities manager’ or installation,startup,debugging,validation,training,and ‘asset productivity manager’. Yet, the essential services maintenance. provided by these people and their departments remains To this list, most plant engineers would quickly add essentiallyunchanged,andeveryenterprisewithphysical compliance with all applicable laws and regulations as facilities must have a plant engineering function, regard- well as accepted industrystandards and practices. less of the name by which it is labeled and theorganiza- tion through which it is accomplished. More than 25 years ago, Edgar S. Weaver, then manager of Real Estate and Construction Operations for General Electric, provided a succinct description of the 1.2 Basic definition function: Plant engineering is that branch of engineering which ‘Theprimarymissionoftheplantengineeristopro- embracestheinstallation,operation,maintenance,modifi- vide optimum plant and equipment facilities to meet cation,modernization,andprotectionofphysicalfacilities the established objective of the business. This can be and equipment used to produce a product or provide a broken down into these four fundamental activities: service. (1) ensure the reliability of plant and equipment oper- It is easier to describeplant engineering than to define ation; (2) optimize maintenance and operating costs; it. Yet, the descriptions will vary from facility to facil- (3) satisfy all safety, environmental, and other regu- ity and over time. Every successful plant is continuously lations;and(4) provideastrongelementofbothshort- changing, improving, expanding, and evolving. And the termandlong-rangefacilitiesandequipmentplanning.’ activities of the plant engineer must reflect this envi- The description still rings true today. ronment. Each plant engineer is likely to have his own, uniquejobdescription,andthatdescriptionislikelytobe different from the one he had five years earlier. 1.3 Responsibilities By definition, the plant engineering function is multi- disciplinary. It routinely incorporates the disciplines of There are two ways of analyzing the plant engineering mechanical engineering, electrical engineering, and civil function. One is through the activities plant engineers engineering.Otherdisciplines,suchaschemicalengineer- mustperform.Theotheristhroughthefacilities,systems, ing for example, may also be needed, depending on the and equipment they must be knowledgeable about. For type of industryor service involved. a complete understanding of the function, both must be In addition, skills in business/financial management, considered. personnel supervision, project management, contracting, and training are necessary to the successful fulfillment 1.3.1 Activities ofplantengineeringresponsibilities.Thefunctionis fun- damentally a technical one, requiring a thorough tech- Theactivitiesthatplantengineersmustperformgenerally nical/engineering background through education and/or fallundertheresponsibilitiesofmiddle-to-uppermanage- experience. But beyond it’s most basic level, a broad ment. Like all managers, they plan, organize, administer, range of skills is needed. and control. But more specifically, plant engineers are If the plant engineer is a specialist in anything, it is involved in or in charge of thefollowing activities: in his/her own plant or facility. Plant engineers must learn to know their own plants thoroughly, from the ž Design of facilities and systems geology underlying its foundations and the topology of ž Construction of facilities and systems the rainwater runoff to the distribution of its electricity ž Installationof facilities, systems, and equipment and the eccentricities of its production machinery. They ž Operation of utilities and services must ensure the quality of the environment both inside ž Maintenance of facilities,systems, and equipment 1/4DefinitionandOrganizationofthePlantEngineeringFunction ž Improvement,retrofit,andredesignoffacilities,sys- the maintenance of virtually all structures, systems, and tems, and equipment equipment in theirfacilities. ž Planning to meet business needs Thus,tobesuccessful,plantengineersmustbeknowl- ž Contracting for equipment, materials, and services edgeable in the design, installation, operation, and main- ž Project management, including planning, estimating, tenance of the following: and execution ž Administration of the plant engineering organization ž Electrical power systems and personnel as well as related financial consider- ž Electrical machinery ations (budgeting, forecasting, cost control), training, ž Lighting and record keeping ž Fluid power transmission ž Regulatorycompliancewithawidevarietyofgovern- ž Mechanical power transmission mental laws and standards ž Instrumentation and controls ž Coordination of plant engineering activities and ž Heating and ventilating responsibilitieswithallotherfunctionsanddepartments ž Air conditioningand refrigeration in the organization ž Pumps, piping,and valving ž Purchasing of requisite tools, equipment, parts, and ž Material handlingand storage materials. ž Paints, coatings, and corrosion prevention ž Fire protection These activities are nearly universal throughout the ž Engines plant engineering function, although they may be ž Lubricants and lubrication systems described differently in specific companies or facilities. ž Environmental control systems and compliance Also, other activitiesmight be added to the list. ž Compressed air systems ž Buildings and construction ž Tools 1.3.2 Knowledge areas ž Welding and joining Whilemostplantengineersare,infact,engineersbyedu- ž Safety and health equipment and practices cationandtraining,thereisnosingle,traditionalengineer- ž Security. ingdisciplinethatcomprisesallareasofplantengineering Each of the above categories could easily be broken responsibilities.Acombinationofmechanicalandelectri- into numerous subcategories, and more could be added. calengineeringeducationandexperienceisessential,and But these are the generally accepted areas of expertise some knowledge in the areas of civil, structural, envi- that plant engineers are expected to know. ronmental,safety,chemical,andelectronicengineeringis useful and important. Mereeducationisnotenough,however.Plantengineer- 1.4 Organization ing demands a level of experience in applied knowledge and problem solving that is more intense than in most Organizational structures and reporting relationships other engineering functions. In fact, plant engineers are within the plant engineering function and in relation to often described as ‘jacks of all trades’ or ‘firefighters’ other functions are as unique as each business enterprise because of their abilities to respond to a wide variety of andindividualplant.Yet,somecommonstructurescanbe needs on short notice, to fix almost anything that breaks, identified. and to implement solutionsto emerging problems. To be most effective, the plant engineering function Nevertheless,amajorportionofeveryplantengineer’s should report directly to top plant or facility manage- effortsisdevotedtotheprevention ofproblemsandemer- ment. In smaller enterprises, it should report directly to gencies, as exemplified by their intense involvement in the owner or to top corporate management. In any case, Plant manager Accounting Personnel Quality Plant Production Material manager manager supervisor engineer manager manager Maintenance manager Figure1.1 Typicalorganizationofasmallplantillustratesthatplantengineeringisoneoftheessentialfunctionsinanyplant.Maintenance isnormallyasubfunctionofplantengineering Organization1/5 the plant engineer should have direct access to whoever multipledepartments.Themostcommondivisioninthese makes the final decisions on any project, capital expen- cases is the separation of ‘landlord’ responsibilities (that diture, legal concern, or enterprise policy decision. In is, real estate, buildings and grounds, and utilities) from multi-sitecompanieswithacorporateengineeringdepart- ‘production’ responsibilities (that is, manufacturing and ment, each site plant engineer should report directly to process equipment and systems). the site manager with a secondary reporting relationship Within the plant engineering function, there are typi- to the directorof corporate engineering. cally two primary subfunctions, best described as engi- Itisworthnotingthatafewverylargeindustrialcom- neering and maintenance. The engineering subfunction panies have divided the plant engineering function into is responsible for such matters as design, construction, Plant manager Plant superintendent Industrial Plant engine- Industrial Plant engineering & ering & main- Production Purchasing Quality relations controller distribution tenance manager manager manager manager manager manager Process A Process B Process C Plant Electrical maintenance maintenance maintenance Shops Planning engineer supervisor manager manager manager Figure1.2 Inlargerplants,theplantengineeringfunctionisoftendividedintodepartmentstoserveparticularneeds Executive vice president Plant A Plant B Plant C Plant D Vice president plant plant plant Director of manufacturing Vice president manager manager manager operations engineering quality Tooling & Plant Manufacturing Plant Master Production Purchasing Traffic maintenance engineering engineering superintendent mechanic manager director manager services MGR manager manager Industrial Quality engineering director manager Maintenance Maintenance Maintenance Maintenance supervisor supervisor mechanics superintendent Maintenance Maintenance Maintenance mechanics mechanics mechanics Figure1.3 Multisiteenterprisesareoftenorganizedwithacentralengineeringdepartmentprovidingplantengineeringservicestoall plantsandseparatemaintenancedepartmentswithineachsite