plant engineer's handbook [electronic resource]

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- ing of their various employers, especially where company contributions have been made, bringing together a wealth of professional knowledge and expertise. An acknowledgement such as this can only scratch the 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 contributions to this Plant Engineering Handbook. Plant engineering is such a broad subject incorporating a multitude of disciplines and a wide variety of solutions to virtually every problem or situation, unlike some sub- jects that have clear-cut methods. In compiling the initial suggested guidelines for each of the contributions, I posed the questions to myself what information and assistance had I found difficult to locate during over 30 years as a plant engineer responsible for plants throughout the world and how could it be best pre- sented to assist others in their profession. I would therefore like to take this opportunity to thank each of the contributing authors for their patience and assistance in helping me to structure this publication. R. Keith Mobley President and CEO The Plant Performance Group Knoxville, Tennessee, USA Contents Foreword vii Preface ix List of Contributors xi 1 Definition and Organization of the Plant Engineering Function 1 2 Plant Engineering in Britain 7 3 The Role of the Plant Engineer 13 4 Physical Considerations in Site Selection 17 5 Plant Location 35 6 Industrial Buildings 43 7 Planning and Plant Layout 67 8 Contracts and Specifications 85 9 Industrial Flooring 101 10 Lighting 111 11 Insulation 131 12 Paint Coatings for the Plant Engineer 147 13 Insurance: Plant and Equipment 161 14 Insurance: Buildings and Risks 185 15 Electricity Generation 199 16 Electrical Distribution and Installation 233 17 Electrical Instrumentation 255 18 Oil 273 19 Gas 285 20 Liquefied Petroleum Gas 321 21 Coal and Ash 335 22 Steam Utilization 353 23 Industrial Boilers 387 24 Combustion Equipment 415 25 Economizers 429 26 Heat Exchangers 437 27 Heating 447 28 Ventilation 465 29 Air Conditioning 481 30 Energy Conservation 503 31 Water and Effluents 517 32 Pumps and Pumping 533 33 Centrifugal Pump Installation 565 34 Cooling Towers 571 35 Compressed Air Systems 587 36 Compressors 601 37 Fans and Blowers 615 38 Mixers and Agitators 623 39 Gears and Gearboxes 629 40 Hydraulic Fundamentals 639 41 Pneumatic Fundamentals 687 42 Noise and Vibration 707 43 Vibration Fundamentals 721 44 Vibration Monitoring and Analysis 757 45 Air Pollution 813 46 Dust and Fume Control 823 47 Dust Collection Systems 837 48 Maintenance Management in UK 845 49 Effective Maintenance Management 857 50 Predictive Maintenance 867 51 Planning and Scheduling Outages 889 52 Lubrication 915 53 Corrosion 961 54 Shaft Alignment 987 55 Rotor Balancing 1009 56 Packing and Seals 1017 57 Gears and Gear Drives 1029 58 Flexible Intermediate Drives 1043 59 Couplings and Clutches 1065 60 Bearings 1081 61 Finance for the Plant Engineer 1101 62 Statistical Approaches in Machinery Problem Solving 1117 63 Health and Safety in the UK 1131 64 Regulatory Compliance Issues in the US 1151 Index 1159 List of Contributors A Armer Spirax Sarco Ltd B Augur, IEng, FIPlantE, MBES J B Augur (Midlands) Ltd HBarber,BSc Loughborough University of Technology DABayliss, FICorrST, FTSC J Bevan, IEng, MIPlantE RJBlaen Senior Green Limited British Compressed Air Society G Burbage-Atter, BSc, CEng, FInstE, HonFIPlantE, FCIBSE Heaton Energy Services PDCompton, BSc, CEng, MCIBSE Colt International Ltd IGCrow, BEng, PhD, CEng, FIMechE, FIMarE, MemASME Davy McKee (Stockton) Ltd R. Dunn Editor, Plant Engineering Magazine PFleming, Bsc(Eng), ARSM, CEng, MInstE British Gas plc CFoster British Coal CFrench, CENg, FInstE, FBIM Saacke Ltd F T Gallyer Pilkington Insulation Ltd RRGibson, BTech, MSc, CEng, FIMechE, FIMarE, FRSA W S Atkins Consultants Ltd BHolmes, BSc(Tech), PhD, CEng, FIChemE, FInstE W S Atkins Consultants Ltd APHyde National Vulcan Engineering Insurance Group Ltd HKing Thorn Lighting BRLamb, CEng, MIChemE APV Baker Ltd S McGrory BH Oil UK Ltd R Keith Mobley International Consultant R J Neller Film Cooling Towers Ltd Ove Arup & Partners, Industrial Division GPitblado,IEng,MIPlantE,DipSM Support Services RSPratt, ALU, CEng, MIMfgE, MBIM, MSAE Secretary-General, The Institution of Plant Engineers GEPritchard, CEng, FCIBSE, FInstE, FIPlantE, MASHRAE Risk Control Unit Royal Insurance (UK) Ltd RRobinson, BSc, CEng, FIEE The Boots Co. plc M J Schofield,BSc,MSc,PhD,MICorrT Cortest Laboratories Ltd J D N Shaw,MA SBD Construction Products Ltd R H Shipman, MIMechE, MIGasE, MInstE Liquefied Petroleum Gas Industry Association K Shippen, BSc, CEng, MIMechE ABB Power Ltd RSmith Life Cycle Engineering, Inc. xii List of Contributors GSolt,FIChemE,FRSC Cranfield Institute of Technology K Taylor, CEng, FCIBSE, FIPlantE, FIHospE, FSE, FIOP, MASHRAE, FBIM, ACIArb Taylor Associates Ltd L W Turrell,FCA KTurton, BSc(Eng), CEng, MIMechE Loughborough University of Technology EWalker, BSc, CEng, MIMechE Senior Green Limited RCWebster,BSc,MIEH Environmental Consultant D Whittleton, MA, CEng, MIMechE, MHKIE Ove Arup & Partners, Industrial Division Copyright  2001 by Butterworth-Heinemann All right reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of this publisher. Recognizing the importance of preserving what has been written, Butterworth-Heinemann prints its books on acid-free paper whenever possible. Butterworth-Heinemann supports the efforts of American Forests and the Global ReLeaf program in its compaign for the betterment of trees, forests, and our environment. Library of Congress Cataloging-in-Publication Data Plant engineer’s handbook/edited by R. Keith Mobley. – [Rev. ed.]. p.cm Rev. ed. of: Plant engineer’s reference book. c1991. Includes index. ISBN 0 7506 7328 1 1 Plant engineering – Handbooks, manuals, etc. I. Mobley, R. Keith, 1943-II, Title: Plant engineer’s reference book. TS184 .P58 2000 696 – dc21 00-049366 British Library Cataloguing-in-Publication Data Plant engineer’s handbook 1 Plant engineering – Handbooks, manuals, etc. 1 Mobley, R. Keith, 1943 – 658.2 The Publisher offers special discounts on bulk orders of this book. For information, please contact: Manager of Special Sales Butterworth-Heinemann 225 Wildwood Avenue Woburn, MA 01801 – 2041 Tel: 781-904-2500 Fax: 781-904-2620 For information on all Butterworth-Heinemann publications available, contact our World Wide Web home page at: http://www.bh.com 10987654321 Typeset by Laser Words, Madras, India Printed in the United States of America 1/1 1 Definition and Organization of the Plant Engineering Function Richard Dunn Editor, Plant Engineering Magazine Contents 1.1 Introduction 1/3 1.2 Basic definition 1/3 1.3 Responsibilities 1/3 1.3.1 Activities 1/3 1.3.2 Knowledge areas 1/4 1.4 Organization 1/4 Responsibilities 1/3 1.1 Introduction The concept of the plant engineering function has changed little over the years. Yet, the ways in which that func- tion is accomplished have changed significantly, primarily because of changing technologies and business models. More than ever before, for example, the plant engineer must learn to manage from the perspective of a business participant, relating his responsibilities and activities to the mission and goals of the enterprise. Moreover, the invasion of electronics and computerization into nearly every facet of engineering and business operation has fos- tered the integration of plant engineering into both the operations and the business plan of the enterprise. Changes in enterprise organization models have also impacted plant engineering. In many industrial plants, for example, the title of ‘plant engineer’ has disappeared, being replaced with such titles as ‘facilities manager’ or ‘asset productivity manager’. Yet, the essential services provided by these people and their departments remains essentially unchanged, and every enterprise with physical facilities must have a plant engineering function, regard- less of the name by which it is labeled and the organiza- tion through which it is accomplished. 1.2 Basic definition Plant engineering is that branch of engineering which embraces the installation, operation, maintenance, modifi- cation, modernization, and protection of physical facilities and equipment used to produce a product or provide a service. It is easier to describe plant engineering than to define it. Yet, the descriptions will vary from facility to facil- ity and over time. Every successful plant is continuously changing, improving, expanding, and evolving. And the activities of the plant engineer must reflect this envi- ronment. Each plant engineer is likely to have his own, unique job description, and that description is likely to be different from the one he had five years earlier. By definition, the plant engineering function is multi- disciplinary. It routinely incorporates the disciplines of mechanical engineering, electrical engineering, and civil engineering. Other disciplines, such as chemical engineer- ing for example, may also be needed, depending on the type of industry or service involved. In addition, skills in business/financial management, personnel supervision, project management, contracting, and training are necessary to the successful fulfillment of plant engineering responsibilities. The function is fun- damentally a technical one, requiring a thorough tech- nical/engineering background through education and/or experience. But beyond it’s most basic level, a broad range of skills is needed. If the plant engineer is a specialist in anything, it is in his/her own plant or facility. Plant engineers must learn to know their own plants thoroughly, from the geology underlying its foundations and the topology of the rainwater runoff to the distribution of its electricity and the eccentricities of its production machinery. They must ensure the quality of the environment both inside and outside the facility as well as the safety and health of the employees and the reliability of its systems and equipment. And they are expected to do all of this in a cost-effective manner. A few phrases from a 1999 classified ad for a plant engineer provide some real-world insight on the scope of responsibilities: ž Support ongoing operations, troubleshoot, resolve emer- gencies, implement shutdowns ž Organize and maintain information on plant sys- tems/equipment and improvement programs ž Implement plant projects and maintain proper docu- mentation ž Deal effectively with multiple activities, requests, and emergencies ž Manage scope, design, specification, procurement, installation, startup, debugging, validation, training, and maintenance. To this list, most plant engineers would quickly add compliance with all applicable laws and regulations as well as accepted industry standards and practices. 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 function: ‘The primary mission of the plant engineer is to pro- vide optimum plant and equipment facilities to meet the established objective of the business. This can be broken down into these four fundamental activities: (1) ensure the reliability of plant and equipment oper- ation; (2) optimize maintenance and operating costs; (3) satisfy all safety, environmental, and other regu- lations; and (4) provide a strong element of both short- term and long-range facilities and equipment planning.’ The description still rings true today. 1.3 Responsibilities There are two ways of analyzing the plant engineering function. One is through the activities plant engineers must perform. The other is through the facilities, systems, and equipment they must be knowledgeable about. For a complete understanding of the function, both must be considered. 1.3.1 Activities The activities that plant engineers must perform generally fall under the responsibilities of middle-to-upper manage- ment. Like all managers, they plan, organize, administer, and control. But more specifically, plant engineers are involved in or in charge of the following activities: ž Design of facilities and systems ž Construction of facilities and systems ž Installation of facilities, systems, and equipment ž Operation of utilities and services ž Maintenance of facilities, systems, and equipment 1/4 Definition and Organization of the Plant Engineering Function ž Improvement, retrofit, and redesign of facilities, sys- tems, and equipment ž Planning to meet business needs ž Contracting for equipment, materials, and services ž Project management, including planning, estimating, and execution ž Administration of the plant engineering organization and personnel as well as related financial consider- ations (budgeting, forecasting, cost control), training, and record keeping ž Regulatory compliance with a wide variety of govern- mental laws and standards ž Coordination of plant engineering activities and responsibilities with all other functions and departments in the organization ž Purchasing of requisite tools, equipment, parts, and materials. These activities are nearly universal throughout the plant engineering function, although they may be described differently in specific companies or facilities. Also, other activities might be added to the list. 1.3.2 Knowledge areas While most plant engineers are, in fact, engineers by edu- cation and training, there is no single, traditional engineer- ing discipline that comprises all areas of plant engineering responsibilities. A combination of mechanical and electri- cal engineering education and experience is essential, and some knowledge in the areas of civil, structural, envi- ronmental, safety, chemical, and electronic engineering is useful and important. Mere education is not enough, however. Plant engineer- ing demands a level of experience in applied knowledge and problem solving that is more intense than in most other engineering functions. In fact, plant engineers are often described as ‘jacks of all trades’ or ‘firefighters’ because of their abilities to respond to a wide variety of needs on short notice, to fix almost anything that breaks, and to implement solutions to emerging problems. Nevertheless, a major portion of every plant engineer’s efforts is devoted to the prevention of problems and emer- gencies, as exemplified by their intense involvement in the maintenance of virtually all structures, systems, and equipment in their facilities. Thus, to be successful, plant engineers must be knowl- edgeable in the design, installation, operation, and main- tenance of the following: ž Electrical power systems ž Electrical machinery ž Lighting ž Fluid power transmission ž Mechanical power transmission ž Instrumentation and controls ž Heating and ventilating ž Air conditioning and refrigeration ž Pumps, piping, and valving ž Material handling and storage ž Paints, coatings, and corrosion prevention ž Fire protection ž Engines ž Lubricants and lubrication systems ž Environmental control systems and compliance ž Compressed air systems ž Buildings and construction ž Tools ž Welding and joining ž Safety and health equipment and practices ž Security. Each of the above categories could easily be broken into numerous subcategories, and more could be added. But these are the generally accepted areas of expertise that plant engineers are expected to know. 1.4 Organization Organizational structures and reporting relationships within the plant engineering function and in relation to other functions are as unique as each business enterprise and individual plant. Yet, some common structures can be identified. To be most effective, the plant engineering function should report directly to top plant or facility manage- ment. In smaller enterprises, it should report directly to the owner or to top corporate management. In any case, Accounting manager Personnel manager Quality supervisor Plant engineer Production manager Material manager Plant manager Maintenance manager Figure 1.1 Typical organization of a small plant illustrates that plant engineering is one of the essential functions in any plant. Maintenance is normally a subfunction of plant engineering Organization 1/5 the plant engineer should have direct access to whoever makes the final decisions on any project, capital expen- diture, legal concern, or enterprise policy decision. In multi-site companies with a corporate engineering depart- ment, each site plant engineer should report directly to the site manager with a secondary reporting relationship to the director of corporate engineering. It is worth noting that a few very large industrial com- panies have divided the plant engineering function into multiple departments. The most common division in these cases is the separation of ‘landlord’ responsibilities (that is, real estate, buildings and grounds, and utilities) from ‘production’ responsibilities (that is, manufacturing and process equipment and systems). Within the plant engineering function, there are typi- cally two primary subfunctions, best described as engi- neering and maintenance. The engineering subfunction is responsible for such matters as design, construction, Plant manager Plant controller Production manager Purchasing manager Quality manager Industrial relations manager Plant engine- ering & main- tenance manager Industrial engineering & distribution manager Plant engineer Electrical supervisor Shops Planning Process A maintenance manager Process B maintenance manager Process C maintenance manager Plant superintendent Figure 1.2 In larger plants, the plant engineering function is often divided into departments to serve particular needs Executive vice president Plant A plant manager Plant B plant manager Plant C plant manager Plant D Director of operations Vice president manufacturing engineering Industrial engineering manager Quality director Vice president quality Tooling & maintenance services MGR Plant superintendent Master mechanic Production manager Maintenance supervisor Maintenance supervisor Maintenance mechanics Maintenance superintendent Maintenance mechanics Maintenance mechanics Maintenance mechanics Plant engineering manager Manufacturing engineering manager Purchasing director Traffic manager Figure 1.3 Multisite enterprises are often organized with a central engineering department providing plant engineering services to all plants and separate maintenance departments within each site 1/6 Definition and Organization of the Plant Engineering Function Director of facilities Executive secretary Manager facilities Clerk Facilities engineer Project manager Tactical planner architect 1st shift supervisor electrical & mechanical repair 2nd shift supervisor electrical & mechanical repair Manager facilities maintenance Manager strategic planning Tactical planner Maintenance technicians Building & grounds technicians Custodial Maintenance technicians Building & grounds technicians Custodial Maintenance technicians Building & grounds technicians Custodial Designer 3rd shift supervisor electrical & mechanical repair Supervisor planning & scheduling Clerk Planners Figure 1.4 Large, complex industrial plants and other facilities require an extensive plant engineering organization to meet constantly changing demands modification, and modernization of the facility, its utili- ties, and operating equipment. The maintenance subfunc- tion provides all maintenance services and carries out many of the changes specified by engineering. Some plant engineering organizations also identify a third subfunc- tion, operations. This group is responsible for running the utility systems, such as electrical control and distri- bution; steam; heating, ventilating, and air conditioning; compressed air; water treatment; etc. The organization charts in Figures 1.1–1.4, adopted from real plant organizations of various sizes and in a variety of industries, illustrate some typical structures. [...]... membership requirements Class of membership Minimum age (years) Student Member 16 Graduate Member 18 Associate – Associate Member (AMIPlantE) 21 Member (MIPlantE) (i) 23 Member (MIPlantE) (ii) 35 Member (MIPlantE) (iii) 26 Fellow (FIPlantE) (i) 25 Fellow (FIPlantE) (ii) 35 Fellow (FIPlantE) (iii) 35 Minimum academic qualifications Engaged in engineering studies and training BTEC NC/ND or HNC/HND or degrees in... The Role of the Plant Engineer R Keith Mobley The Plant Performance Group Contents 3.1 Responsibilities of the plant engineer 3/15 3.1.1 Design and modification of production systems and auxiliary equipment 3/15 3.1.2 Production system specification and selection 3/15 3.1.3 Installation and commissioning of plant systems 3/15 3.1.4 Operation and maintenance of plant services 3/15 3.1.5 Plant safety, energy...2/7 2 Plant Engineering in Britain Roger S Pratt Secretary-General, The Institution of Plant Engineers Contents 2.1 The professional plant engineer 2/9 2.2 The Institution of Plant Engineers 2.3 Aims of the Institution 2.4 Organization 2/9 2/9 2/10 2.5 Membership 2/10 2.5.1 Membership requirements 2/10 2.5.2 Courses leading to a career in plant engineering 2.6 Registration... part, a plant engineer is responsible for: ž Design and modification of production systems and auxiliary equipment ž Production system specification and selection ž Installation and commissioning of plant systems ž Operation and maintenance of plant services ž Plant safety, energy conservation, pollution control and environmental compliance ž Process troubleshooting and optimization systems The plant engineering... outside sources, the plant engineering function is responsible for the internal distribution of electricity, steam and other services and the supervision of the outside service provider 3.1.5 Plant safety, energy conservation, pollution control and environmental compliance Generally, the plant engineering function is responsible for overall plant safety, as well as all compliance issues The plant engineer... organization, the plant engineer is the single source of design knowledge Therefore, he or she is responsible for all design or redesign of plant systems With the increasing complexity of plant systems, the plant engineer must have a thorough knowledge of machine design practices (i.e mechanical, electrical, electronic and microprocessors) 3.1.2 Production system specification and selection Plant engineering... engineering function has had a severe, negative impact on overall plant performance and corporate profitability In today’s plant, the plant engineering function has been reduced to project management, coordination of contractors that provide design, construction, operations and maintenance of plant facilities This trend has seriously diluted the plant s ability to design, install, operate and maintain critical... troubleshooting and optimization 3/15 Responsibilities of the plant engineer 3/15 3.1 Responsibilities of the plant engineer The increasing mechanization of industrial installations has resulted in the use of more complex and costly equipment and this has greatly increased the responsibilities of the plant engineer In today’s environment, the plant engineer must have a practical, well-rounded knowledge... of these grades is shown in Table 2.1 Table 2.1 2.5.2 Courses leading to a career in plant engineering The main courses leading to a career in plant engineering are the Business and Technician Education Council’s (BTEC) Technician Certificate or Diploma in Plant Engineering and Higher National Certificate or Diploma in Plant Engineering In Scotland, the equivalents are the Scottish Technician and Vocational... proper installation criteria is followed In addition, the plant engineer is responsible for testing newly installed systems to assure that they comply with procurement and performance specifications 3.1.4 Operation and maintenance of plant services In traditional organizations, the plant engineer is responsible for the operation and maintenance of all plant services (i.e electric and steam generation, water . plants, the plant engineering function is often divided into departments to serve particular needs Executive vice president Plant A plant manager Plant B plant manager Plant C plant manager Plant D Director. 1943-II, Title: Plant engineer’s reference book. TS184 .P58 2000 696 – dc21 00-049366 British Library Cataloguing-in-Publication Data Plant engineer’s handbook 1 Plant engineering – Handbooks, manuals,. Data Plant engineer’s handbook/ edited by R. Keith Mobley. – [Rev. ed.]. p.cm Rev. ed. of: Plant engineer’s reference book. c1991. Includes index. ISBN 0 7506 7328 1 1 Plant engineering – Handbooks,