Plant Engineer's Reference Book (eBook)

Cover 1
Plant Engineer’s Reference Book 4
Copyright Page 5
Contents 12
Foreword 6
Preface to the Second edition 7
Preface to the First edition 8
Contributors 9
Chapter 1. Physical considerations in site selection 19
1.1 Environmental considerations of valley or hillside sites 21
1.2 Road, rail, sea and air access to industrial sites 22
1.3 Discharge of effluent and general site drainage 24
1.4 Natural water supplies, water authority supplies and the appropriate negotiating methods and contracts 26
1.5 Water storage, settling wells and draw-off regulations 28
1.6 Problem areas associated with on-site sewage treatment for isolated areas 31
1.7 Landscaping on industrial and reclaimed land 33
1.8 Legislation on contaminated land of concern to the plant engineer 35
Further reading 41
Chapter 2. Plant location 42
2.1 Selecting the location 44
2.2 Services 45
2.3 Ecology and pollution 48
Chapter 3. Industrial buildings 50
3.1 Introduction 52
3.2 Specifying an industrial building 54
3.3 Security 56
3.4 Leases 58
3.5 Obtaining approval to build 59
3.6 Extending existing buildings 60
3.7 Fire protection, detection and suppression 61
3.8 Cost comparisons and contract procedure 61
3.9 Structural and services supports 62
3.10 Natural ventilation 63
3.11 Building durability 65
3.12 Building maintenance 66
3.13 Building repairs 66
3.14 Domestic facilities 67
3.15 Lifts 69
3.16 Site health and safety 70
3.17 Sub-ground pits and basements 71
3.18 Internal and external decoration 71
3.19 Industrial ground floors 72
3.20 Ground considerations 73
References 74
Chapter 4. Industrial flooring 75
4.1 Introduction 77
4.2 Selection of appropriate flooring material 77
4.3 Requirements of concrete substrate 77
4.4 Special finishes 78
4.5 Comparative applied costs 83
4.6 Conclusion 83
Chapter 5. Planning and plant layout 84
5.1 Introduction 86
5.2 Technological development and its effect upon plant layout 86
5.3 Layout planning concepts 86
5.4 Plant data 87
5.5 Process/site layout modelling 89
5.6 Design synthesis 93
5.7 Site layout realization 96
5.8 Internal layouts of buildings 98
5.9 Selling the concept 100
5.10 Implementation 100
5.11 Consultants 100
References 101
Chapter 6. Contract management 102
6.1 Contracts 104
6.2 Approaching the contract 104
6.3 Types and forms of contract 104
6.4 The specification and drawings 105
6.5 Estimates and bills of quantities and estimates 105
6.6 Specific sums stated in tender documents 106
6.7 Tender documents 106
6.8 Direct and bulk purchasing contracts 107
6.9 Programme of works 107
6.10 Selection of tenderers 107
6.11 Inviting tenders 109
6.12 Analysing tenders 109
6.13 Selection of the contractor 110
6.14 Making a contract 111
6.15 Relationships between contractor and other parties 111
6.16 Site meetings 112
6.17 Progress and control 112
6.18 Quality control 113
6.19 Interim payments 113
6.20 Budget control and variations 114
6.21 The Construction (Design and Management) Regulations 1974 114
6.22 Safety on site and legal action 114
6.23 Delays and determination 115
6.24 Liquidated damages and loss and/or expense 116
6.25 Practical and final certificates 116
6.26 Disputes and arbitration 117
6.27 Hearings 117
6.28 Mediation 117
6.29 Common problems and solutions 117
Chapter 7. Finance for the plant engineer 119
7.1 Accounting 121
7.2 Types of organization 121
7.3 Definitions 122
7.4 Budgetary control 124
7.5 Capital expenditure – appraisal methods 126
7.6 Control of capital expenditure 127
7.7 Standards and standard costing 127
7.8 Capital 131
7.9 Value added tax 132
7.10 Break-even charts 132
7.11 Supply of steam, power, water, etc. to other departments 133
7.12 Charges for effluent and environmental services 134
Chapter 8. Fire safety 135
8.1 Introduction 137
8.2 Means of escape in case of fire 137
8.3 The legal requirement 137
8.4 To summarise 137
8.5 Risk assessment 138
8.6 How does a fire start? 140
8.7 What should happen if a fire starts? Who can be harmed? 141
8.8 How does a fire spread? 141
8.9 Reducing sources of ignition 141
8.10 Minimizing the potential fuel for a fire 142
8.11 Reducing sources of oxygen 142
8.12 Provide detection and warning system 142
8.13 Means of escape in case of fire 142
8.14 Escape checklist 143
8.15 Fire fighting 143
8.16 Maintenance and testing of fire-fighting equipment and systems 143
8.17 Fire training and operating procedures 143
8.18 Making provision for disabled people 145
8.19 Management considerations 145
8.20 Housekeeping 145
8.21 Security 145
8.22 Fire safety checks 146
8.23 Plant emergency plan 146
8.24 Training the employees 147
8.25 Maintenance of plant and equipment 148
8.26 Storage and use of flammable materials 148
8.27 Storage of flammable liquids 148
8.28 Hot working activities in areas near flammable liquids 150
8.29 Electrical equipment 150
8.30 Heating appliances 150
8.31 Smoking and the provision for smokers 150
8.32 Building and maintenance work 151
8.33 Fire detection and fire warning 151
8.34 Number and width of doorways 151
8.35 Corridors and passageways 152
8.36 Stairways 152
8.37 Items prohibited on an escape route 152
8.38 Fire fighting equipment 152
8.39 Types of portable fire extinguishers 153
8.40 Installation, maintenance and testing of fire precautions and equipment 153
8.41 Recommended further reading and reference on fire safety Acknowledgements 154
Chapter 9. Fire sprinkler systems 156
9.1 Sprinkler systems 158
9.2 Why are sprinklers installed? 158
9.3 Insurance premium costs 159
9.4 Safety 159
9.5 Statutory requirements 159
9.6 The risks 159
9.7 Types of installation 160
9.8 Specifying a sprinkler installation 162
9.9 Making the decision 163
9.10 Materials 163
9.11 Storage of materials 163
9.12 Pumping systems and control 163
9.13 Maintenance of a sprinkler system 164
9.14 The fire service 165
9.15 Seeking advice 165
9.16 Codes of practice for contractors 166
9.17 Recognition and acceptability 166
9.18 Value for money 166
Chapter 10. Industrial boilers 167
10.1 Terminology 169
10.2 Heat transfer in industrial boilers 170
10.3 Types of boiler 173
10.4 Application and selection 177
10.5 Superheaters 178
10.6 Economizers 179
10.7 Water-level control 180
10.8 Efficiency 181
10.9 Boiler installation 181
10.10 Boiler house pipework 182
10.11 Feedwater requirements 182
10.12 Feedwater supply and tanks 183
10.13 Blowdown requirements, control and tanks 184
10.14 Clean Air Act requirement for chimneys and flue designs 186
10.15 Steam storage 187
10.16 Automatic controls on boilers 187
10.17 Automatic boiler start 188
10.18 The automatic boiler house 189
10.19 Safe operation of automatic boiler plant 190
10.20 Energy conservation 190
10.21 Noise and the boiler house 191
10.22 Running costs 193
10.23 Management and operation 193
10.24 Fuel conversion of boilers 194
Chapter 11. Combustion equipment 195
11.1 Introduction 197
11.2 Aspects of selection 197
11.3 Air pollution and emissions 198
11.4 Gas burners 200
11.5 Oil burners 202
11.6 Supplementary and auxiliary firing systems 205
11.7 Controls 208
11.8 Fuel handling systems 210
11.9 Solid fuel firing 212
Chapter 12. Oil 213
12.1 Distribution and delivery 215
12.2 Storage tanks 215
12.3 Location of tanks 220
12.4 Pipework systems 221
Chapter 13. Gas 225
13.1 Selection and use of gas as a fuel 227
13.2 Theoretical and practical burning and heat transfer 228
13.3 Pressure available to user 229
13.4 Energy conservation 229
13.5 Emissions 233
13.6 Chimney requirements: codes of practice and environmental considerations 233
13.7 Health and safety in the use of gas 237
13.8 Pressure control 239
13.9 Gas specifification and analysis 240
13.10 Control of efficiency 242
13.11 Automation 245
13.12 Fire and explosion hazards 247
13.13 Maintenance 248
13.14 Statutory requirements 249
13.15 Testing 249
13.16 The gas grid system and distribution networks 251
13.17 Emergency procedures 253
13.18 Pipework 254
13.19 Flow charts for use with gas 256
13.20 Conversion factors 258
Chapter 14. Liquefied petroleum gas 260
14.1 Introduction 262
14.2 Composition 262
14.3 Requirements 262
14.4 Typical properties of commercial LPG 263
14.5 Transport and storage 265
14.6 Cylinder storage 269
14.7 Safety in storage 269
14.8 Uses of gaseous fuels 270
14.9 Safety and legislation 272
14.10 British standards 272
14.11 Codes of practice and guidance notes 272
Chapter 15. Steam utilization 274
15.1 Introduction 276
15.2 What is steam? 276
15.3 The steam load 279
15.4 Draining steam lines 281
15.5 Low-pressure systems 285
15.6 Flash steam 296
15.7 Condensate return systems 299
15.8 Proposed pressure systems and transportable gas containers regulations 311
Chapter 16. Heating 314
16.1 Introduction 316
16.2 Statutory regulations 316
16.3 Building regulations 316
16.4 Estimation of heat losses from buildings 318
16.5 Allowance for height of space 318
16.6 Characteristics of heat emitters 318
16.7 Central plant size 319
16.8 Selective systems 319
16.9 Multiple-boiler installations 319
16.10 Heating systems 320
16.11 Heating equipment – attributes and applications Acknowledgement 325
Acknowledgement 329
Chapter 17. Ventilation 330
17.1 Introduction 332
17.2 Ventilation systems and controls 332
17.3 Powered ventilation equipment 335
17.4 Natural ventilation equipment 338
17.5 System design 340
17.6 Legislation and codes of practice 344
17.7 After installation 345
References 346
Chapter 18. Air conditioning 348
18.1 Basic principles and terms 350
18.2 The air quantity required 355
18.3 Heat losses and gains 356
18.4 Air conditioning for computers 357
18.5 Air distribution and system resistance 359
18.6 Fans 361
18.7 Dust control and filtration 364
18.8 Humidification 365
18.9 Test procedure for air-conditioning systems 366
Chapter 19. Water and effluents 371
19.1 Introductory warning 373
19.2 Requirements for water 373
19.3 Water chemistry 373
19.4 Building services 375
19.5 Boilers 377
19.6 Specified purities for process use 379
19.7 Water-purification processes 379
19.8 Membrane processes 384
19.9 Effluents 385
Acknowledgement 386
Chapter 20. Pumps and pumping 387
20.1 Pump functions and duties 389
20.2 Pump principles 389
20.3 Effects of fluid properties on pump behaviour 396
20.4 Flow losses in systems 399
20.5 Interaction of pump and system 401
20.6 Cavitation 406
20.7 Priming systems 409
20.8 Seals: selection and care 410
20.9 Pump and drive selection 412
20.10 Pump testing 415
References 418
Chapter 21. Cooling towers 419
21.1 Background 421
21.2 Theory 421
21.3 Design techniques 421
21.4 Design requirements 422
21.5 Materials and structure design 422
21.6 Specification 423
21.7 Water quality and treatment 424
21.8 Operation 425
21.9 Modifications – retro-fits 426
21.10 Consultation 426
21.11 Environmental considerations 426
21.12 Problem areas 430
21.13 Summary 432
Appendix 21.1 Theoretical calculations 432
Appendix 21.2 Evaluation of the MDF 433
Appendix 21.3 Technical requirements 433
Acknowledgements 434
Chapter 22. Electricity generation 435
22.1 Introduction 437
22.2 Generation of electrical power 437
22.3 Combined heat and power (CHP) 443
22.4 Factors influencing choice 446
22.5 The selection 452
22.6 Plant and installation 456
Chapter 23. Electrical distribution and installation 468
23.1 Introduction 470
23.2 Bulk supply 470
23.3 Distribution systems 471
23.4 Switchgear 471
23.5 Transformers 474
23.6 Protection systems 476
23.7 Power factor correction 478
23.8 Motors and motor control 481
23.9 Standby supplies 484
23.10 Earthing 486
23.11 Cables 487
Chapter 24. Electrical instrumentation 489
24.1 Introduction 491
24.2 The role of computers in plant engineering 491
24.3 Data logging 491
24.4 Supervisory control 491
24.5 Distributed systems 492
24.6 Display of data 492
24.7 Transducers 492
24.8 Electricity supply metering 495
24.9 Power factor correction 497
24.10 Voltage and current transformers 498
Further reading 500
Chapter 25. Lighting 501
25.1 Lighting theory 503
25.2 Electric lamps 503
25.3 Luminaires 511
25.4 Control gear 515
25.5 Emergency lighting 517
25.6 Lighting design 519
Chapter 26. Compressed air systems 524
26.1 Assessment of a plant’s air consumption 526
26.2 Compressor installation 527
26.3 Overpressure protection 533
26.4 Selection of compressor plant 533
Chapter 27. Noise and vibration 537
27.1 Introduction to basic acoustics 539
27.2 Measurement of noise 541
27.3 Vibration 542
27.4 Avoiding physical injury to workers 543
27.5 Avoidance of damage to plant/machinery/building structures 543
27.6 Noise control engineering 543
27.7 Practical applications 545
27.8 Legislation on noise and vibration of concern to the plant engineer 547
Chapter 28. Air pollution 553
28.1 Effects of air pollution 555
28.2 Dispersion, atmospheric stability and meteorological effects 558
28.3 Calculation of flue heights and dispersion modelling 563
28.4 Legislation on air pollution of concern to the plant engineer 571
Chapter 29. Dust and fume control 585
29.1 Introduction 587
29.2 The nature of dusts and fumes 588
29.3 Control of dusts and fumes 588
29.4 System design and application 595
29.5 Testing and inspections 596
29.6 Inspection and testing procedures 596
Chapter 30. Insulation 601
30.1 Introduction 603
30.2 Principles of insulation 603
30.3 Calculation of heat loss 604
30.4 Standards of insulation 607
30.5 Product selection 609
30.6 Thermal conductivity 610
30.7 Physical forms 611
30.8 Facings 612
30.9 Insulation types 613
Chapter 31. Economizers 619
31.1 Introduction 621
31.2 Oil and coal applications 621
31.3 Gas-fired economizers 621
31.4 Design 622
31.5 Installation 622
31.6 Condensing economizers 622
Chapter 32. Heat exchangers 626
32.1 The APV Paraflow heat exchanger 628
32.2 Comparing plate and tubular exchangers 630
32.3 Duties other than turbulent liquid flow 631
32.4 The problem of fouling 632
Chapter 33. Corrosion 635
33.1 Corrosion basics 637
33.2 The implications of corrosion 643
33.3 Materials selection 644
33.4 Design and corrosion 650
33.5 Uses and limitations of constructional materials 652
33.6 Specifying materials 655
33.7 Corrosion-control techniques 656
33.8 Corrosion monitoring 658
Further reading 659
Chapter 34. Paint coatings for the plant engineer 660
34.1 Definition and function of coatings 662
34.2 The constituents of paint 662
34.3 Types of coating and their uses 663
Waterborne coatings 666
34.4 Surface preparation and priming 670
34.5 Specifications 671
34.6 Economics 671
34.7 Painting inspection 672
34.8 Factors influencing the selection of coating systems 672
34.9 Sources of advice 673
34.10 Further reading 673
Chapter 35. Maintenance 674
35.1 Introduction 676
35.2 A ‘planned’ maintenance programme 676
35.3 A manual planned maintenance system 677
35.4 Computer systems 681
35.5 Life-cycle costing 683
35.6 Condition monitoring 683
35.7 Training 684
35.8 Health and safety 684
35.9 Information 684
35.10 Conclusion 685
Chapter 36. Energy conservation 690
36.1 The need for energy conservation 692
36.2 Energy purchasing 692
36.3 The energy audit 694
36.4 Energy management 695
36.5 Energy monitoring 696
36.6 Energy targeting 696
36.7 Major areas for energy conservation 697
36.8 The justification for energy-conservation measures 702
36.9 The mathematics of the presentation 702
36.10 Third-party energy management and finance 704
36.11 Motivation 704
36.12 Training 704
References 705
Chapter 37. Inspection of plant and equipment 706
37.1 Historical background 708
37.2 The ‘fundamental laws’ 708
37.3 Evolution of legislation 708
37.4 The Health & Safety Executive
37.5 Evolution of inspection authorities 709
37.6 Trade associations 710
37.7 The Engineer Surveyor 710
37.8 Training the Engineer Surveyor 710
37.9 The report 711
37.10 Recognition of defects 711
37.11 The examination 712
37.12 Repairs and renewals 712
37.13 Plant classification 713
37.14 Risk assessment 713
37.15 Specific aspects of regulations 713
37.16 Consultancy services 714
Appendix 1 716
Appendix 2 721
Chapter 38. Insurance: buildings and risks 725
38.1 Insurance 727
38.2 Fire insurance 727
38.3 Business interruption insurance 727
38.4 Insurance surveys 727
38.5 The legal requirement 727
To summarize 728
38.6 Fire legislation 729
38.7 Fire protection 729
38.8 Extinguishers 729
38.9 Auto-sprinkler installations 729
38.10 Automatic fire alarms 730
38.11 Trade hazards 730
38.12 Recommended references 730
38.13 Security insurance 732
38.14 Theft insurance policy terms and conditions 733
38.15 Risk assessment 733
38.16 Planning for security 733
38.17 Security objectives 733
38.18 Location 734
38.19 Site perimeter security 734
38.20 Building fabric 735
38.21 Doors and shutters 735
38.22 Windows 735
38.23 Intruder alarms 736
38.24 Closed-circuit television (CCTV) 736
38.25 Access control 736
38.26 Recommended references 736
38.27 Liability and liability insurance 737
38.28 Employer’s liability 737
38.29 Third-party liability 737
38.30 Liability insurance 738
38.31 The cover provided by liability insurance 738
38.32 Points to be considered 739
38.33 Employee safety and employer’s liability 739
38.34 Safety of the public and public liability (third party) 741
Further Reading 742
Chapter 39. Health and safety 743
39.1 Introduction 745
39.2 Legislation 745
39.3 Administration of the Health and Safety at Work etc Act 745
39.4 General duties 746
39.5 Safety policy 747
39.6 Information 748
39.7 HSE inspectorates 748
39.8 The employment medical advisory service (EMAS) 748
39.9 HSE area offices 748
39.10 Health and safety procedures 749
39.11 Fire and first-aid instructions 749
39.12 Good housekeeping 749
39.13 Protective clothing and equipment 749
39.14 Safe working areas 750
39.15 Materials handling 750
39.16 Portable tools and equipment 751
39.17 Confined spaces 751
39.18 Electricity 751
39.19 Plant and equipment 752
39.20 Safety signs and pipeline identification 752
39.21 Asbestos 753
39.22 COSHH 753
39.23 Lead 753
39.24 Other information 753
39.25 Assessment of potential hazards 753
39.26 Alternative method of assessing hazards 754
39.27 Permits to work 755
39.28 Working alone 755
39.29 Safety policy for lone workers 755
39.30 Contractor’s conditions and safe working practices 759
39.31 Safe working practices and procedures 759
39.32 Emergency procedures 760
39.33 Contractor’s Guide 760
39.34 Health & Safety Information
Chapter 40. Lubrication 763
40.1 Introduction 765
40.2 Lubrication–the added value 765
40.3 Why a lubricant? 765
40.4 Physical characteristics of oils and greases 766
40.5 Additives 767
40.6 Lubricating-oil applications 768
40.7 General machinery oils 769
40.8 Engine lubricants 769
40.9 Gear lubricants 773
40.10 Hydraulic fluids 782
40.11 Machine tools 785
40.12 Cutting fluids 788
40.13 Compressors 794
40.14 Turbines 797
40.15 Transformers and switchgear 798
40.16 Greases 799
40.17 Corrosion prevention 801
40.18 Spray lubricants 802
40.19 Degreasants 802
40.20 Filtration 802
40.21 Centrifuging 803
40.22 Shaft seals 804
40.23 Centralized lubrication 804
40.24 Storage of lubricants 805
40.25 Reconditioning of oil 806
40.26 Planned lubrication and maintenance management 806
40.27 Condition monitoring 806
40.28 Health, safety and the environment 806
Acknowledgements 807
Further reading 808
Chapter 41. Heat pumps and their applications 809
41.1 What is a heat pump? 811
41.2 Types of heat pumps 811
41.3 Coefficient of performance 811
41.4 Thermodynamic cycles 812
41.5 Climate change levy 813
41.6 Industrial applications 814
41.7 Sources of further information 817
Chapter 42. Solar water heating and the plant engineer 818
Introduction 820
42.1 Solar radiation and energy flows on earth 820
42.2 Spectral distribution of solar radiation 820
42.3 Distribution of solar power around the world 822
42.4 Seasonal variation in the UK 822
42.5 Background to basic collector circuits 823
42.6 The benefits of solar heating 824
42.7 How a solar collector works 825
42.8 Swimming pool or large volume water heating 826
Chapter 43. Solar electricity: photovoltaics 827
43.1 Solar electricity 829
43.2 The past and present 829
43.3 How does it work 829
43.4 The benefits 829
43.5 Uses 830
43.6 The future 830
43.7 How can plant engineers make use of photovoltaics? 830
43.8 The plant engineer – the user 831
43.9 Conclusion 831
43.10 The whole idea sounds good to me but how do I exploit it? 832
References 832
Further information 832
Chapter 44. Wind energy and the plant engineer 833
44.1 Introduction 835
44.4 Wind structure above terrain 837
44.5 Technology 837
44.6 Principle of electronical diagram for connection to grid 839
44.7 Special applications 839
44.8 Layout 839
Chapter 45. The engineer as an expert witness and the new civil procedure rules 840
45.1 Introduction 842
45.2 Classifying expertise 842
45.3 Establishing credibility 843
45.4 The Woolf Report and the future 843
45.5 Conclusion 846
References 846
Chapter 46. Education and training 847
46.1 The professional plant engineer 849
46.2 The Institution of Plant Engineers 849
46.3 The Society of Operations Engineers 849
46.4 Aims of the Society 849
46.5 Organization 850
46.6 Membership 850
46.7 Registration with the Engineering Council 850
46.8 Registration as a European Engineer 851
46.9 Professional engineering development 851
46.10 Addresses for further information 851
Chapter 47. Waste management 852
47.1 Identification of waste 854
47.2 What is classed as waste? 854
47.3 Purchasing waste 854
47.4 Why should we worry? 854
47.5 Where do we start with the waste problem? 855
47.6 The Waste Audit 855
47.7 Audit assessment evaluation 855
47.8 Waste identified 855
47.9 The sectors 857
47.10 History and the predicted targets 857
47.11 Your programme 858
Index 859