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Doc. Ref. No. : UTP-ACA-PROG-PDP-2 Issue Version : 1 Date : January, 2011

GUIDELINES CAB 4023: Plant Design Project (FYDP/PDP) II FOR SUPERVISORS AND STUDENTS January 2011 Semester
CHEMICAL ENGINEERING PROGRAMME UNIVERSITI TEKNOLOGI PETRONAS Bandar Sri Iskandar, 31750 Tronoh, Perak Darul Ridzuan Tel: (05) 3687565 Fax: (05) 3656176

TABLE OF CONTENTS
1.0 2.0 3.0 4.0 5.0 6.0 INTRODUCTION OBJECTIVES OUTCOMES SCOPES DURATION RESPONSIBILITIES 6.1 6.2 6.3 7.0 8.0 Students Plant Design Project Coordinator (PDPC) Committee of Supervisors 1 1 1 2 2 3 3 3 4 4 6 6 9 19 19 20 20 21 21 21 21 22 22 22 23 24 25 26 28 29

PROCESS FLOW OF PDP II FINAL REPORT 8.1 8.2 Format Contents Final Oral Presentation

9.0 10.0 11.0 12.0

PRESENTATIONS 9.1 RESOURCES AND SERVICE REQUIREMENTS ASSESSMENT TECHNIQUE GRADING SCHEME 12.2 12.3 12.4 12.5 12.5 12.6 Final Report Final Oral Presentation Individual Progress Performance Peer Review C-Factor UTP Grading Scheme

13.0 14.0

REFERENCES APPENDICES : Guntt Chart of PDP II : Sample title page

Appendix I Appendix II

Appendix III : Sample certification of approval Appendix IV : Form PDP II-1 Requisition form

Form PDP II-2 C-Factor Form PDP II-3 Final Oral Presentation (Group) Form PDP II-4 Final Oral Presentation (Individual) Form PDP II-5 Group Report Form PDP II-6 Individual Progress Performance Form PDP II-7 Peer Review

30 31 32 33 34 35

ii

1.0

INTRODUCTION
As a continuation from Plant Design Project (PDP) I, the students need to complete PDP II which carries 3 credit hours. This guideline specifically addresses the necessary information for students/supervisors in carrying out their duties for PDP II in UTP.

2.0

OBJECTIVES
The main objective of PDP II is to train/develop students in the application of all the elements of knowledge and skills that have been accumulated throughout the undergraduate program for solving design related problems for typical process industrial plant. The second objective of the course is to develop the skills of working in a team and to nurture leadership qualities. Written and oral communication skills as well as the capability in decision making are also nurtured by the project.

3.0

OUTCOMES
At the end of this course, students should be able to: Integrate their chemical engineering skills and knowledge in a detailed design of a chemical plant. Apply appropriate design codes in a detailed design work Present a piping and instrumentation diagram (P&ID) and control strategy packages Perform detailed economic evaluation of the proposed chemical plant Generate cost effective process options while maintaining operability, safety and environment friendliness of the design.

4.0

SCOPES OF WORK
The scopes of work for FYDP II are as follows: Making the necessary decisions, judgements and assumptions in design Performing the instrumentation and control study Performing the process design of the major process units. Performing the mechanical design of the major process units. Performing the economic evaluation including capital cost estimation Considering the environmental and safety issues related to the plant. problems.

and manufacturing cost estimation. Material safety data sheet (MSDS) for all the chemicals involved must be part of the safety and environmental discussion. Utilising the blend of hand calculations, spreadsheets, mathematical Preparing the group and individual reports as per standard format and computer packages, and process simulators to design a process conducting the oral presentations.

5.0

DURATION
PDP II carries 3 credit hours and students are expected to accomplish their project in 14 weeks during the second semester of their final year. A proposed Gantt chart of PDP II can be found in Appendix I.

6.0

RESPONSIBILITIES
6.1 Students Students must make their own initiative and able to work in a team in bringing the project to completion. Students will also be required to exercise teamwork spirit and job co-ordination during undertaking the

design project. The students may elect one of their team members as the group leader. Among the expected responsibilities are as listed below: Obtaining information and material rightfully and honestly. Seeking advice and guidance from supervisors when necessary. Maintaining good discipline and personal conduct when Preparing themselves against any failure such as work lost due to Preparing a logbook for each member and maintain a good Undertaking the detailed design of at least one unit operation per Submitting all reports on time as specified by plant design Giving/putting significant individual contribution or effort Plagiarism will cause serious consequences.

searching for relevant information especially when out of campus. computer crashes. record of individual activity and progress. person. project coordinator. towards the completion of the group task. Failure to take the above responsibility/responsibilities may lead to failing the course. 6.2 Plant Design Project Coordinator (PDPC) Head of Department will appoint a Plant Design Coordinator (PDPC) and his/her assistants to coordinate PDP II. The responsibilities of PDPC and his/her assistants include: Identifying and selecting design project title. Dividing students into respective groups. Assigning students to respective supervisors. Planning and managing the schedule for PDP II course Providing briefing on PDP II course requirements to lecturers

implementation. and students.

Arranging special seminars in selected topics related to the Coordinating students' oral presentation Arranging external examiners from industry to participate in the Compiling and finalizing students' final scores for submission to The assistants of PDPC will assist him/her in all the above

project to give additional skills to the students to complete the project.

assessment of students' report and oral presentation. examination committee. activities.

6.3

Committee of Supervisors The committee consists of a main and with not more than two assistant supervisors. The responsibilities of the committee can be summarized as below: Advising the students on the preparation of their design projects. Arranging meeting with students periodically. The supervisors Monitoring students progress from time to time. Assisting students in defining the problem involved accordingly. Assigning the students to undertake individual detailed Reviewing and assessing the individual student progress. Assessing reports and commenting on the work. Delivering seminar lectures on some special topics if requested

are expected to meet their students once a week.

calculation of mass and energy balance

by the PDPC

7.0

PROCESS FLOW OF PDP II

The first stage of PDP II is to design the best control systems for the entire plant proposed in PDP I. At this stage, the students need to consider the safety aspects and provide the MSDS for all the chemicals handled in the plant. The HAZOP

analysis of major equipment together with its associated piping and minor units must also be performed. In addition, the students are also required to specify the waste treatment facilities and utility systems, as well as perform the equipment sizing and costing study for the plant before presenting their work in both the final oral presentation. After making the necessary corrections based on the comments provided during the final oral presentation, the students are required to submit their group report using the ring file ABBA Lever Arch Folders (404 Standard). (This submission format is made as a strict requirement to ensure uniformity and ease of document identification and handling as well as to facilitate the later task of storing the design reports.). The final stage is the detailed design of equipment. Each student is expected to perform a detailed equipment design for one major equipment including the mechanical design and to provide the specification sheets for two minor equipment. All the individual works have to be compiled and submit in another ABBA Lever Arch Folders (404 Standard). The process flow diagram of PDP II is shown in Figure 1 and the corresponding Gantt chart can be found in Appendix I. FYPDPII

Instrumentation and Control Safety and Loss Prevention Waste Treatment Process Design of Major Units Process Economics & Cost Estimation Oral Presentation Group Report Submission Mechanical Design of Major Units 5 Specification of Minor Units Individual Report Submission

8.0
8.1

FINAL REPORT 1: Process flow diagram of FYDP II Figure

Format 8.1.1 Language

The report must be written in English Language. 8.1.2 Font and spacing

All text should be one and half spacing (Times New Roman regular font style, size 12) written on a white A4 paper on one side of each sheet. The following however should be single spaced: 8.1.3 Foot notes Tables and figures Length

The length of report should be not less than 50 and not more than 100 pages of (excluding appendices). Students are strongly encouraged to use brief and straightforward expressions and to avoid the use of jargons as far as possible. The number of pages for the appendices is unlimited. 8.1.4 Numbering

All pages should be numbered in proper sequence from introduction to the end of the report. Page number must be positioned at the bottom and centered. 8.1.5 Heading and Margin

Major headings, such as INTRODUCTION, should be capitals, bold and font size 14. Secondary headings such as Example should be in bold. The top, bottom, and right margins are 1 inch except for the left margin, which is 1.3 inch.

8.1.6

Mathematical Text

Mathematical text must be spaced out; superscript and subscript must be clearly shown. All equations, terms and symbols must be written in italic. 8.1.7 Tables and Figures Tables and figures less than a page in size should be inserted into the text near the point of reference. Tables should not be carried over to the next page. Margin limits are the same as text full-page. All tables and figures should be numbered and captioned consecutively. Table heading should be positioned at the top middle of each table. The figure heading should be positioned at the bottom middle of each figure. 8.1.8 Bindings The report must be properly presented in ABBA Lever Arch Folders (404 Standard). Each group is required to submit two folders, i.e. group work folder and individual work folder. Format of both group work and individual work folders are as follows: i) Group Report 1) 2) 3) 4) Title page Certification approval by main supervisor after he/she satisfied with the correction or amendment done by students Acknowledgements Executive summary max of 4 pages + PFD. Contents should include: a) Project summary: Briefly describe the project with information
Annual capacity/requirement Main product By product if any Raw material 1 Raw material 2

such as:

b) Simple PFD in A3 size with major stream values c) Material & energy balance highlights d) Major equipment highlights with main dimensions displayed e.g. Distillation column, Liquid extractor, reactor e) Minor equipment highlights with brief specifications stipulated, e.g., heat exchangers & pumps f) Highlights of: 5) 6) 7) Utilities Waste treatment Economic evaluation & costs Plant location Plant layout

Table of contents List of tables, figures and appendixes The report must be arranged according to: problem statement, objectives, scope of work

CHAPTER 1 INTRODUCTION: background of design project, CHAPTER 2 LITERATURE REVIEW CHAPTER 3 - PRELIMINARY HAZARDS ANALYSIS CHAPTER 4 CONCEPTUAL DESIGN AND SYNTHESIS CHAPTER 5 HEAT INTEGRATION CHAPTER 6 PROCESS FLOWSHEETING CHAPTER 7 INSTRUMENTATION & CONTROL CHAPTER 8 SAFETY & LOST PREVENTION CHAPTER 9 WASTE TREATMENT CHAPTER 10 PROCESS ECONOMICS & COST ESTIMATION 8) 9) 10) Conclusion & Recommendation References Appendices

11) 12) 13)

PFD size A1 PID size A1 Plant Layout size A3

ii) Individual Report Every member of a group needs to perform: 1) 1 detailed design of major equipment 2) TWO (2) minor equipment in specification sheets *each group is also required to submit the final design report (both group and individual work folders) in soft copy preferably in compact disc (CD). *segregate each chapter with a divider. *use punch hole protection (reinforcing ring) for every page that you wish to submit. * Always refer to the guidelines for details

8.2

Contents of Group Report 8.2.1 Title Page

The title page should be set out in accordance with the attached specimen sheet in Appendix II. The project title should be clearly and precisely defined as has been assigned by the PDPC. 8.2.2 Certification

This section should be approved by supervisor after he/she has satisfied with the correction or amendment done by the student. See Appendix III for specimen sheet.

8.2.3

Acknowledgements

Most design teams obtain considerable assistance and advice from supervisors, industrial consultants, librarians, faculty and fellow students. This section provides an opportunity to acknowledge their contributions with an expression of appreciation and thanks. 8.2.4 Table of Contents

All sections in the report should be listed, including the page numbers on which they begin. Hence, all pages in the report, without exception, must be numbered. Each main section must begin with a new page. 8.2.5 Executive Summary

The students should highlight all the important features of the report from the technical reasons for undertaking the study to the conclusion. Remember that most readers only read the summaries of reports and every word counts. Avoid padding phrases and phrases that refer to the reports. 8.2.6 Main Body

The main body of the report must be composed of the following chapters:
Detailed equipment design using acceptable design codes Detailed cost estimates Plant control strategy (plantwide control) Detailed HAZOP study Detailed PFD and P&ID drawings (as per build drawing) Utility systems requirement (furnace, steam, refrigeration, cooling water, electricity) Waste treatment facility design (atmospheric and aqueous emissions) Economic Evaluation of the project (DCFROR, NPV, Cash flow analysis)

Chapter 1: Introduction Background of the design project, problem statement, objectives, scopes of work. Chapter 2: Literature Review Carry out research to uncover the latest information on feed and product properties, product price, market and possible site locations that may lead to a more profitable design. Literature resources include encyclopedias, handbooks,

10

journals, reports, indexes and even World Wide Web (Internet). Standard method for quoting must be implemented and standardize throughout the report. Chapter 3: Preliminary Hazards Analysis The preliminary hazard analysis should be carried out during feasibility study to define/determine safety-related aspects that influence the design. The study should cover the following points: Summary of previous accidents on similar type of plants. Identification of material and chemical hazards in the flammability data, toxicity data, chemical

process such as feed, intermediates, products and byproducts, interactions etc. Compile all MSDS in the appendix session. Discussion on the possibility to reduce potential consequences of an accident by considering inherent safety aspects such as substitute hazardous chemicals, reduce inventories, lower pressure and temperatures, safe location, siting, plant layout and transportation. Identification of any requirement/compliance by local safety regulations and design guidelines Chapter 4: Conceptual Process Design and Synthesis This chapter should be prepared in consultation of or based on either Douglas hierarchical decomposition approach or the Onion Model or a combination of both. 1. Level 1: Process Operating Mode: Batch vs. Continuous 2. Level 2: InputOutput Structure of the Flowsheet

input refers to the raw material of the process and the feedstock that contains the input raw material output refers to the desired products Decision 1. Reactor performance:

3. Level 3: Reactor Design and Reactor Network Synthesis

11

(a) reaction scheme for the chosen process routes (b) reactor type (flow pattern model, i.e., whether batch reactor (BR)/plug-flow reactor (PFR) or CSTR) and (c) reactor network (selecting conversion that maximizes selectivity (also check the economic potential))

Decision 2. Reactor operating conditions: (1) concentration, (2) temperature, (3) pressure, (4) phase, (5) catalyst (inert (e.g., N2)) Decision 3. Reactor configuration: reactor volume (capacity of reactor i.e., input and output flowrates, orientation, and configuration; some of the more common types of reactor configuration are: tubular reactors shell-and-tube reactors stirred-tank reactors fixed-bed catalytic reactors (uses catalyst) fixed-bed noncatalytic reactors (does not use catalyst) moving-bed catalytic reactors fluidized-bed catalytic reactors fluidized-bed noncatalytic reactors kilns (e.g., used in the cement industry) fermentor

4. Level 4: Separation System Synthesis

Decision 1. Types of separators: what type of suitable separators? (e.g., distillation, absorption, membrane) Decision 2. Sequencing of separators (for homogeneous mixtures): how are the separators arranged? (here in this course, we are interested in sequencing of distillation columns) Decision 3. Operating conditions: (a) temperature, (b) pressure, (c) concentration, and (d) addition of extra components (although undesirable)

5. Level 5: Heat Integration (Heat Exchanger Network; Heating and Cooling Utilities):

12

Students are highly encouraged to use the software package SPRINT (Process Integration Software Version 2.2 by Centre for Process Integration, University of Manchester) to assist in the development of the heat exchanger network. Chapter 7: Instrumentation & Control A basic control strategy should be performed for each stage of the process. In the report, a summary of control requirements, possible controlled and manipulated variables must be presented in table form. A production flowrate control strategy must be properly mentioned. No tuning or calculation is required. In a Piping and Instrumentation Diagram (P&ID), draw all control loops (transmitter, controller and final elements) for the control requirements discussed in the report. No advanced control strategy is required unless the control requirement cannot be achieved with basic feedback control. Appropriate description must be given if advanced control strategy to be used. All process equipment should be drawn roughly in proportion and identified by equipment number. All pipes must be properly numbered. Block valve must be drawn in small size for equipment isolation. Symbols in all drawings must follow the Petronas Technical Standard (PTS). A complete Piping and Instrumentation Diagram must be generated by using software such Microsoft Visio (well-recommended) or AUTOCAD (lessrecommended). Chapter 8: Safety & Loss Prevention 8.1 Hazard and Operability Studies (HAZOP) Carry out HAZOP assessment of the specific plant area in group as specified by supervisors. The selection should be based on the process nodes that contain highly hazardous materials and critical process conditions identified during PHA study. Demonstrate the HAZOP study at least for THREE (3) study nodes, in which the nodes must connect to 13

ONE (1) major equipment. An appropriate HAZOP worksheet and report must be produced. 8.2 Plant Layout A simple but scaled plant layout arrangement for the plant should be drawn up indicating access routes and safety appliances as well as storage / stock tanks, silos etc. The siting criteria and layout of the plant should follow any Codes of Practice and Industry Guidance. Students are required to provide relevant justification/statement on the safety aspects of the plant layout. Chapter 9: Waste Treatment To ensure ethical and statutory requirements are fulfilled, pollution control and waste disposal or treatment should be taken into account by referring to the process flowsheet. All major waste must be properly identified and their flowrate and nature (i.e., phase, characteristics, and compositions) must be defined. Appropriate regulation limit must be stated and proposed the treatment strategy. Explanation supported with basic flow diagram (or block flow diagram) that shows the major equipment would be enough, without the need to include the auxiliary equipment such as pumps. In other words, specific design is not required except for sizing of the major equipment for the purpose of costing. Chapter 10: Process Economics & Cost Estimation Estimate capital items, operating costs and economic potential of the plant. Finally, report the estimated return together with some recommendation as to the commercial implications of the study. The Detailed Factorial Method with approximately 25% accuracy must be used for detailed economic evaluation. Plant lifetime is fixed at 15 years. (Note: Discussion needs to be included for every section starting from Chapter 4 to Chapter 10. Explain the significance of the results, include comments and indicate further developments.)

14

Conclusion & Recommendation This section is important as it reflects the essence of the report. Hence, the highlights from Introduction and Theory sections should be included. Do not repeat what has been mentioned in the Discussion section. References All references including sources of physical data should be listed. The following method of referencing must be followed. In the text refer to the work by the last name of the author followed by the year in brackets. If there are 2 authors give the last name of both the authors. If there are more than 2 authors give the last name of the first author followed by et.al. In the bibliography list all the references in the alphabetical order of the last name of the first author. All the authors must be listed as shown in the examples below, followed by year in bracket, the name of the article or book, Name of the Journal, Volume, No and page No. In the case of books the name of the book, edition and publisher should follow the name of the author and year. For example: Nozhevnikova et.al (1997) has discussed the methanogenesis reactions taking place in natural environments. Abu-Absi and Actis (1999) give a detailed description of different reactions taking place in an anaerobic reactor. Metcalf and Eddy (1991) discusses the operational aspects of anaerobic reactions. Otton(1998) has presented results on anaerobic digestion in fluidised bed reactors. Adam (2000) gives some interesting insights into the natural anaerobic processes. Listing of these references is as shown below.
Abu-Absi N.R., and L.A.Actis (1999), Encyclopaedia of Bioprocess Technology:

Fermentation, Bio Catalysis and Bio Separation, Vol 1, John Wiley and Sons, New York. Adam, D. (2000), Where there is muck there is gas, http://www.nature.com/nsu_pf/0004201.html (excess date) Metcalf. C and R. Eddy (1991), Wastewater Engineering: Treatment, disposal and Reuse, 3 rd Ed. Mc-Graw Hill Inc, New York.

15

Nozhevnikova, A.N., C.Hollinger, A.Amman and A.J.B Zehnder (1997), Methanogenesis in Sediments from Deep lakes at Different Temperatures (2-70oC), Water Science and Technology, Vol 36, No 3, pp 384-396. Otton, V. (1998), Anaerobic Digestion in Fluidised Bed Reactor, Thesis, Institute National Polytechnik, Grenoble.

Appendices Lengthy calculations, figures, results from programming, derivation of design data, etc. should be enclosed in the appendices. Students must provide a clear explanation and the author name for each calculation. All drawings must be drawn on the specific paper size as follows: a) Process Flow Diagram c) Individual equipment d) Plant Layout : : : A1 A1 A3 A3 b) Process and Instrumentation Diagram :

Drawings (a), (b) and (d) should be included in the group work folder, whereas drawing (c) in the individual work folder. All A1 and A3 drawings should be folded and inserted in A4 sized plastic wallets, as part of the report. 8.3 Contents of Individual Report

Based on the specified input and output, each student is required to design one major and two minor equipment. The equipment selection must follow the guideline below: 1. All groups must have a detailed design for the following equipment if present in the flowsheet. major equipment: reactor distillation column absorption column 16

furnace

2. Only one student is allowed to undertake the detailed design for each equipment. 3. The rest of the group members must be assigned to conduct two of the following equipment if available. The supervisor may propose to PDPC if there is other major equipment that is not listed below for detailed design. minor equipment: Extraction columns Evaporator Membrane Units Cyclone Filter Cooling tower Sedimentation tanks 4. If minor equipment is not available, students can conduct the detailed design of major equipment provided it is not the same unit. 5. The individual detailed design should cater for thermal design and proper material selection, and mechanical design in such that appropriate dimensional drawing and complete specification sheet can be generated. 6. The rest of the equipment in the process flowsheet must be properly sized by the group such that appropriate capital cost can be estimated. No drawing is required for these items. However specification sheets must be provided for such units, each student to prepare the specification sheets for two minor equipment units. The minor units may include the following. a. Pumps b. Heat exchangers c. Stirrers d. Material conveying equipment e. Size reduction equipment f. Size separation equipment g. Pollution control equipment like bag filters, electrostatic precipitators etc. h. Waste water treatment equipment like, Sedimentation tanks, filters, ion exchangers etc. 7. Groups may propose the responsibility of individual design. The proposal must be approved by the supervisor.

There are four important requirements that must be fulfilled: a) Process Design

17

From fundamental governing equations, carry out the process calculations to optimize the design within specified constraints. If the design involves any assumptions, they should be clearly stated and justified. Critical evaluation and limitations of the design calculations, including computer methods should be included. Complete process design calculations must be included. b) Specification sheet All design parameters and material selection must be properly presented in appropriate specification sheet. c) Mechanical design of the equipment The mechanical design of the equipment should include thickness of the vessel from pressure considerations, thickness of tall vertical vessels by combined load calculations, design of flanges, specification of nozzles, skirts, and supports. d) Dimensional drawing Appropriate dimensional drawing must be generated to visualize the orientation and configuration of the unit operation. All critical parameters that directly affect the process must be properly shown. For example, tube pitch and arrangement for heat exchangers must be shown. All nozzles orientation must be clearly depicted. e) Operating procedure A basic operating procedure on how to start-up, operate and shut down the unit operation. The shutdown procedure must include the safety aspect for carrying out major maintenance work for the equipment. (f) Equipment costing You may consider making use of the graphs in the excellent process economics textbook by Peters, Timmerhaus, and West (2004) for equipment costing. Note that this section should be duplicated in the separate chapter on the economic evaluation and profitability analysis of your complete plant design.

This section will contribute 20% of the final report and will be counted as individual mark. In this section work load distribution among group members and equipment summary must properly presented. For each equipment, the sizing calculation, specification sheet, drawings and operating procedure must be compiled together in one A4 sized plastic wallet and appropriately attached as appendix. If there 18

are four group members, there shall be four separate plastic wallets that contain the complete design documents (sizing calculations, spec-sheet, drawings, and procedures) for the respective equipment. Evaluation will be conducted as per score sheet in Appendix XIV.

9.0
9.1

PRESENTATIONS
Final Oral Presentation This is the crucial part where students need to convince the panel on the effectiveness and the workability/practicability of their proposed design. Students are advised to complete their reports two weeks before the deadline and concentrate on the presentation that is scheduled on 18 March 2009. Presentation will be held in front of a panel that consists of selected representatives from various fields of expertise. Each group will be given 30 minutes for oral presentation and 15 minutes for question & answer session. This provides sufficient time to: introduce the design problem; provide an overview of the proposed process (emphasising alternative discuss major sections of the proposed design by emphasising the

designs that were rejected); strengths of the design through: (a) the complete heat-integrated process flow diagram (PFD) of the plant; (b) the complete piping and instrumentation diagram (P&ID) of the plant; (c) the HAZOP analysis; (d) the design of the waste treatment facilities; and other relevant aspects of the proposed design; present the results of the economic analysis and discuss other summarize the design and make recommendations. considerations;

A student who miss oral presentation will be given Grade F.

10.0 RESOURCES AND SERVICES REQUIREMENTS

19

Students are allowed to seek information or any sort of material needed for the project at any institutions or other places. Application letters to Head of Programme should be written by the students through the main supervisor. The main supervisor must fill-up Form PDP-1 (Appendix IV) and submit to PDPC together with the application letter. All requisitions are subjected to approval of Head of Programme.

11.0 ASSESSMENT TECHNIQUE

At the end of the semester, all student works will be assessed and final grade will be given. Table 1 summarizes the overall technique of assessment. The internal examiners will be selected among the supervisors to assess the interim oral presentation and report. TABLE 1 Assessment Scheme Assessment Stage Supervisor Final Report Group Contribution Final Report Individual Contribution Final Presentation Group Assessment Final Presentation Individual Assessment Individual Progress C-Factor Total 10 10 Examined by and % Contribution Internal External Group Examiner Examiner Mark 20 10 10 10 10 0 1.0 60% 40% 20 30 10 10 30 20 Individual Mark

12.0 GRADING SCHEME

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12.1 Final Report Main Supervisor and Internal examiner will evaluate the final reports (both group and individual work folders). The percentage accounted for is shown in Table 1. 12.2 Final Oral Presentation There are two types of assessment in the final oral presentation, namely group and individual assessments. The percentages accounted for both are shown in Table 1. Score sheets of Form PDP-6 and PDP-7 (Appendix IV) will be used. 12.3 Individual Progress Performance Each group is required to conduct an official meeting once in every two weeks. The first official meeting must be held in the first lecture week of the semester. The last official meeting will be held on week 13th, which will constitute a total of seven (7) official meetings. Minutes of meeting (MOM) must be submitted to the main supervisor within one (1) week after the meeting. Supervisors have to evaluate the individual progress performance by filling up the Form PDP-8 (Appendix IV). Individual progress performance will contribute 10% of the overall individual marks. Students and supervisor may conduct additional meetings as frequent as required. 12.4 C-Factor C-factor is introduced to assess students on their contribution to the group work by the supervisors. Supervisors can take the results from the peer review as a reference in assessing the C-factor. The amount of the group mark that can be obtained by individual is depending on the C-factor value that he/she gets. See Form PDP-9 (Appendix IV). 12.5 Peer Review Students get to evaluate among themselves through the peer review session by filling up Form PDP-10 (Appendix IV) and return it to Plant design project coordinator.

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12.6

UTP Grading Scheme The overall marks for PDP II will be finalized by PDPC after all the forms have been completed by the examiners. The final grades will be given according to Table 2 below: Table 2: UTP Grading Scheme Score 85 100 80 84.9 75 79.9 65 74.9 55 64.9 50 54.9 45 49.9 40 44.9 0 39.9 Grade A AB+ B C+ C D+ D F Point 4.00 3.75 3.50 3.00 2.50 2.00 1.50 1.00 0

13. REFERENCES Peters, Max S., Klaus D. Timmerhaus, and Ronald E. West. Plant Design and Economics for Chemical Engineers. 5th Ed. New York: McGraw-Hill, 2004.

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APPENDICES

23

Proposed Gantt Chart

P NTDE NII (C 4013): January 2011 S ester: Prod LA SIG AB em uction of Poly Ethylene T erephthalate AC IV T ITY 1 In strum entation and Control Strategy P& ID 2 S afety and L Prevention oss H ZO stu - 3 stu notes w A P dy dy hich include 1 m ajor equ ent ipm 3 W aste T reatm t en O block diagramsh nly owing m ajor equipm t is needed en (detailed and proper PF is NO required) D T Draft Report Submission Mid-semester break 4 P tL lan ayout Payattentionto the flare stack location, scaled layout (check PE TRO S Technical Standards) NA 5 D etailed E quipm D ent esign (Individual) each stu dent: detailed m echanical design for one m ajor equ ent and specificationsheets for tw m ipm o inor G reference for m ood echanical design: Tow G ler, avin and Sin nott, R K. C ical En eering V m 6, . hem gin olu e M ajor equ ent: reactors, separators (distillation, ipm absorption, stripping, cy clones) M inor equipm ent: heat exchangers, pum com ps, pressors 6 E conom Evaluation: Cost Accoun ics ting and Cap ital C Estim ost ation Equ ent sizing and costing ipm C apital investm costs ent ent Total capital investm 7 A al C nnu osts, E arnings, and P rofitability A nalysis ash sing DC FRO , NPV IR ) R , R C flowanalysis (u 8 F alised D m in ocu entation an Presentation d Final Report Submission Final Oral Presentation W K EE D E AT 1
24-Jan

2
31-Jan

3
7-F eb

4
14-Feb

5
21-Feb

6
28-Feb

7
7-M ar

8
14-M ar

9
21-M ar

10
28-M ar

11
4-A pr

12
11-A pr

13
18-A pr

14
25-A pr

15
2-M ay

16
9-M ay

A ctivities Im portan D t ates: D eadlin for D e raft R eport Subm ission: 1st A pril D for F ate inal O P ral resen tation: 0 - 08th A 4th pril (W 11) eek D eadlin of F l R e ina eport Subm ission: 22th A pril N otes: M details available in the "M ual for Supervisors and S den ore an tu ts" R efer to PETR NA Techn Standards (PTS) O S ical P& to be prepared in tandemw H ZO ID ith A P R eferen ces E ple of specification sheet (pressu vessel) xam re

24

Final Examinations

Study Week

CAB 4023 PLANT DESIGN PROJECT II

Production of 100,000 Metric Tons per Year Cumene Production Facility

GROUP 1 ZAINAL ABIDIN HASSAN 10001 CHEAH SOON KIT 10002 GOVINDARAJOO SHANTI 10003 MICHEAL BALLACK 10004 NATASHA ZVEREVA 10005

CHEMICAL ENGINEERING PROGRAMME UNIVERSITI TEKNOLOGI PETRONAS

January 2009

25

Side labeling: Group Report

Plant Design Project II (Jan 2011 Semester)

Group Report

Individual Report

Plant Design Project II (Jan 2011 Semester)

CAB4023 (Plant Design II) 26

PLANT DESIGN PROJECT JANUARY SEMESTER (2011)

PRODUCTION OF Poly Ethylene Terephthalate GROUP 1

ZAINAL ABIDIN HASSAN 10001 CHEAH SOON KIT 10002 GOVINDARAJOO SHANTI 10003 MICHEAL BALLACK 10004 NATASHA ZVEREVA 10005

APPROVED BY,

____________________ (DR. ROSMAN ALWI) DATE :

CHEMICAL ENGINEERING PROGRAMME UNIVERSITI TEKNOLOGI PETRONAS

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Doc. Ref. No. UTP-ACA-PROG-FYPDP-01.01

Issue Version

Date January 2010

Form PDP II-1 REQUISITION FORM

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Form PDP II-2

C-FACTOR: Assessment of Individual Group Members by Supervisors (To be completed by Supervisor Group No./Name: Project Title: C-factor (Awarded)

ID

Name

Note: C-Factor Assessment Scheme C-Factor Awarded Scale 1.0 Average 0.7 0 Below Average Poor

Criteria show contribution to the group work satisfactory progress on the group work attend the official meeting no/very little contribution to the group work no/ very little progress on the group work attend the official meeting no contribution to the group work no progress on the group work not attending the meeting without valid reason

(signature) Supervisors name:

Date:

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Form PDP II-3

FINAL ORAL PRESENTATION: Group Assessment (To be completed by External /Internal Examiner) Group No./Name: Project Title:
Marks Allocated Marks Awarded

Aspects of Evaluation 1 2 3 4 5

Process Design and Detailed Mechanical Design Instrumentation and control strategy Safety and loss prevention Waste treatment Process economics and cost estimation

40 15 15 15 15

TOTAL

100

Comments:

.. (Signature)

External /Internal Examiner: Designation:

Date:

UTP GRADING SCHEME Score Range Grade 85 100 A 80 84.9 A75 79.9 B+ 65 74.9 B 55 64.9 C+ 50 54.9 C 45 49.9 D+ 40 44.9 D 0 39.9 F

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Form PDP II-4

Form PDP II-4

FINAL ORAL PRESENTATION: Individual Assessment (To be completed by Internal Examiner) Group No./Name: Project Title: Students Names: 1. 4. 2. 5. Marks Allocated Student no. 1. 2. 3. 4. Appearance and gestures (body language) Creativity, continuity, and cohesiveness Clarity, grammar, and pace of delivery Response to questions-and-answers session TOTAL Comments: 20 30 30 20 100 1 2 3. 6. Marks Awarded 3 4 5 6

Aspect of Evaluation

Internal Examiner: Designation:

.. (Signature) Date:

UTP GRADING SCHEME Score Range Grade 85 100 A 80 84.9 A75 79.9 B+ 65 74.9 B 55 64.9 C+ 50 54.9 C 45 49.9 D+ 40 44.9 D 0 39.9 F

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Form PDP II-5

FINAL GROUP REPORT ASSESSMENT (To be completed by Supervisor /Internal Examiner) Group No./Name: Project Title: Aspects of Evaluation Instrumentation and control strategy Safety and loss prevention Waste treatment Process economics and cost analysis 25 25 25 100 TOTAL Comments: Marks Allocated 25 Marks Awarded

1. 2. 3. 4.

Examiner: Designation:

(signature) Date: Supervisor/Internal examiner

UTP GRADING SCHEME Score Range Grade 85 100 A 80 84.9 A75 79.9 B+ 65 74.9 B 55 64.9 C+ 50 54.9 C 45 49.9 D+ 40 44.9 D 0 39.9 F

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Form PDP II-6

FINAL INDIVIDUAL REPORT ASSESSMENT:

(To be completed by Supervisor /Internal Examiner) Name: Student no. Group no. Major equipment: Minor equipment I: Minor equipment II: Marks Allocated 30 Marks Awarded

Aspects of Evaluation 1. Process design of major equipment Design methodology Basis of selection Sample calculation Startup and shutdown procedures Mechanical design of major equipment Material selection Pressure vessel thickness calculations Combined stress for tall columns Flanges, nozzles, skirts and supports Drawing of major equipment: standards, dimensioning and neatness Specification sheet for minor equipment I Specification sheet for minor equipment II TOTAL Comments:

2.

30

3. 4. 5.

20 10 10 100

Internal Examiner/ Supervisor: (signature)

Date:

UTP GRADING SCHEME Score Range Grade 85 100 A 80 84.9 A75 79.9 B+ 65 74.9 B 55 64.9 C+ 50 54.9 C 45 49.9 D+ 40 44.9 D 0 39.9 F

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Form PDP II-7

PEER REVIEW

CONFIDENTIAL: To be completed by the students and submitted to theSupervisorr Name: Student ID: Group No.: Name of Team Member 1. 2. 3. 4. 5. *Criteria for evaluation: C1: Attendance at group meetings C2: Team work and cooperation C3: Knowledge input to project C4: Timely and correct completion of project C5: Overall contribution to successfulcompletion of project Assessment scheme: Average Score 7 10 4 6 13 Signature and name: .. Date: Scale Above expectation s Meet expectations Below expectations Evaluation* (maximum score: 10) C1 C2 C3 C4 C5 Overall Evaluation (C1 + C2 + C3 + C4 + C5 )/5

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