Snow Plant Engineer's Reference Book

1. Auflage 2013
ISBN: 978-1-4832-9200-7
Verlag: Elsevier Science & Techn.
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, 672 Seiten, Web PDF

* Useful to engineers in any industry * Extensive references provided throughout * Comprehensive range of topics covered * Written with practical situations in mind A plant engineer is responsible for a wide range of industrial activities, and may workin any industry. The breadth of knowledge required by such professionals is so wide that previous books addressing plant engineering have either been limited to certain subjects or cursory in their treatment of topics. The Plant Engineer's Reference Bookis the first volume to offer complete coverage of subjects of interest to the plant engineer. This reference work provides a primary source of information for the plant engineer. Subjects include selection of a suitable site for a factory and provisionof basic facilities (including boilers, electrical systems, water, HVAC systems, pumping systems and floors and finishes). Detailed chapters deal with basic issues such as lubrication, corrosion, energy conservation, maintenance and materials handling aswell as environmental considerations, insurance matters and financial concerns. The authors chosen to contribute to the book are experts in their various fields. The Editor has experience of a wide range of operations in the UK, other Europeancountries, the USA, and elsewhere in the world. Produced with the backing of the Institution of Plant Engineers, this work is the primary source of information for plant engineers in any industry worldwide.

Autoren/Hrsg.

Snow, Dennis A

Inhaltsverzeichnis

1;Front Cover;1
2;Plant Engineer's Reference Book;4
3;Copyright Page;5
4;Table of Contents;10
5;Forword;6
6;Preface;8
7;List of Contributors;9
8;Physical Considerations in Site Selection;14
8.1;1A.1 Environmental considerations of valley or hillside sites;16
8.2;1A.2 Road, rail, sea and air access to industrial sites;17
8.3;1A.3 Discharge of effluent and general site drainage;19
8.4;1A.4 Natural water supplies, water authority supplies and the appropriate negotiating methods and contracts;21
8.5;1A.5 Water storage, settling wells and draw-off regulations;27
8.6;1A.6 Problem areas associated with on-site sewage treatment for isolated areas;29
8.7;1A.7 Landscaping on industrial and reclaimed land;30
9;Plant Location;36
9.1;1B.1 Selecting the location;38
9.2;1B. 2 Services;39
9.3;1B.3 Ecology and pollution;41
9.4;References;43
10;Industrial Buildings;44
10.1;2.1 Introduction;46
10.2;2.2 Specifying an industrial building;48
10.3;2.3 Security;50
10.4;2.4 Leases;52
10.5;2.5 Obtaining approval to build;53
10.6;2.6 Extending existing buildings;54
10.7;2.7 Fire detection and suppression;55
10.8;2.8 Cost comparisons and contract procedure;56
10.9;2.9 Structural and services supports;57
10.10;2.10 Natural ventilation;58
10.11;2.11 Building durability;60
10.12;2.12 Building maintenance;61
10.13;2.13 Building repairs;62
10.14;2.14 Domestic facilities;63
10.15;2.15 Lifts;64
10.16;2.16 Site health and safety;65
10.17;2.17 Sub-ground pits and basements;66
10.18;2.18 Internal and external decoration;66
10.19;2.19 Industrial ground floors;68
10.20;2.20 Ground considerations;69
10.21;References;69
11;Industrial

Flooring;72
11.1;3.1 Introduction;74
11.2;3.2 Thin applied hardener /sealers;75
11.3;3.3 Floor paints;76
11.4;3.4 Self-levelling epoxy, polyester or reactive acrylic resin systems
;76
11.5;3.5 Heavy-duty flooring;77
11.6;3.6 Comparative applied costs;79
11.7;3.7 Conclusion;80
11.8;References;80
12;Planning and Plant Layout;82
12.1;4.1 Introduction;84
12.2;4.2 Technological development and its effect upon plant layout;84
12.3;4.3 Layout planning concepts;84
12.4;4.4 Plant data;85
12.5;4.5 Process /site layout modelling;87
12.6;4.6 Design synthesis;90
12.7;4.7 Site layout realization;93
12.8;4.8 Internal layouts of buildings;96
12.9;4.9 Selling the concept;97
12.10;4.10 Implementation;97
12.11;4.11 Consultants;98
12.12;References;99
13;Contracts and Specifications;100
13.1;5.1 Contracts;102
13.2;5.2 Approaching the contract;102
13.3;5.3 Types and forms of contract;102
13.4;5.4 The specification and drawings;102
13.5;5.5 Estimates and bills of quantities

and estimates;103
13.6;5.6 Specific sums stated in tender documents;104
13.7;5.7 Tender documents;104
13.8;5.8 Direct and bulk purchasing contracts;105
13.9;5.9 Programme of works;106
13.10;5.10 Selection of tenderers;106
13.11;5.11 Inviting tenders;107
13.12;5.12 Analysing tenders;107
13.13;5.13 Selection of the contractor;108
13.14;5.14 Making a contract;108
13.15;5.15 Relationships between contractor and other parties;109
13.16;5.16 Site meetings;109
13.17;5.17 Progress and control;110
13.18;5.18 Quality control;111
13.19;5.19 Interim payments;111
13.20;5.20 Budget control and variations;112
13.21;5.21 Safety on site;112
13.22;5.22 Supply of Goods and Services Act 1982;112
13.23;5.23 Delays and determination;113
13.24;5.24 Liquidated damages and loss and/or expense;114
13.25;5.25 Practical and final certificates;114
13.26;5.27 Common problems and solutions;115
14;Finance for the Plant Engineer;118
14.1;6.1 Accounting;120
14.2;6.2 Types of organization;120
14.3;6.3 Definitions;121
14.4;6.4 Budgetary control;123
14.5;6.5 Capital expenditure – appraisal methods
;125
14.6;6.6 Control of capital expenditure;126
14.7;6.7 Standards and standard costing;127
14.8;6.8 Capital;130
14.9;6.9 Value Added Tax;131
14.10;6.10 Break-even charts;131
14.11;6.11 Supply of steam, power, water,etc. to other departments;132
14.12;6.12 Charges for effluent and environmental services
;133
15;Industrial Boilers;134
15.1;7.1 Terminology;136
15.2;7.2 Heat transfer in industrial boilers;137
15.3;7.3 Types of boiler;140
15.4;7.4 Application and selection;144
15.5;7.5 Superheaters;145
15.6;7.6 Economizers;146
15.7;7.7 Water-level control;147
15.8;7.8 Efficiency;148
15.9;7.9 Boiler installation;148
15.10;7.10 Boiler house pipework;149
15.11;7.11 Feedwater requirements;149
15.12;7.12 Feedwater supply and tanks;151
15.13;7.13 Blowdown requirements, control and tanks;152
15.14;7.14 Clean Air Act requirement for chimneys and flue designs;153
15.15;7.15 Steam storage;154
15.16;7.16 Automatic controls on boilers;155
15.17;7.17 Automatic boiler start;156
15.18;7.18 The automatic boiler house;156
15.19;7.19 Safe operation of automatic boiler plant
;156
15.20;7.20 Energy conservation;158
15.21;7.21 Noise and the boiler house;158
15.22;7.22 Running costs;160
15.23;7.23 Management and operation;160
16;Combustion Equipment;162
16.1;8.1 Introduction;164
16.2;8.2 Oil burners;164
16.3;8.3 Gas burners;166
16.4;8.4 Burner design considerations;168
16.5;8.5 Future developments;169
16.6;8.6 Coal burners;171
16.7;8.7 Dual- and triple-fuel firing;173
17;Oil;176
17.1;9.1 Distribution and delivery;178
17.2;9.2 Storage tanks;178
17.3;9.3 Location of tanks;183
17.4;9.4 Pipework systems;184
18;Gas;188
18.1;10.1 Selection and use of gas as a fuel;190
18.2;10.2 Theoretical and practical burning and heat transfer;191
18.3;10.3 Pressure available to user;192
18.4;10.4 Energy conservation;192
18.5;10.5 Clean Air Acts associated with gas burning;195
18.6;10.6 Chimney requirements: codes of practice and environmental considerations;196
18.7;10.7 Health and safety in the use of gas;200
18.8;10.8 Pressure control;202
18.9;10.9 Gas specification and analysis;203
18.10;10.10 Control of efficiency;205
18.11;10.11 Automation;208
18.12;10.12 Fire and explosion hazards;210
18.13;10.13 Maintenance;211
18.14;10.14 Statutory requirements;212
18.15;10.15 Testing;212
18.16;10.16 The gas grid system anddistribution networks;214
18.17;10.17 Emergency procedures;216
18.18;10.18 Pipework;216
18.19;10.19 Flow charts for use with gas;219
18.20;10.20 Conversion factors;222
19;Liquefied Petroleum Gas;224
19.1;11.1 Introduction;226
19.2;11.2 Composition;226
19.3;11.3 Requirements;226
19.4;11.4 Typical properties of LPG;227
19.5;11.5 Transport and storage;229
19.6;11.6 Cylinder storage;232
19.7;11.7 Safety in storage;233
19.8;11.8 Uses of gaseous fuels;234
19.9;11.9 Safety and legislation;235
19.10;11.10 British Standards;236
19.11;11.11 Codes of Practice and Guidance Notes;236
20;Coal and Ash;238
20.1;12.1 Introduction;240
20.2;12.2 Characteristics of coal;240
20.3;12.3 Delivery;240
20.4;12.4 Coal reception;241
20.5;12.5 Coal storage;244
20.6;12.6 Coal conveying;246
20.7;12.7 Ash handling;251
20.8;Acknowledgement;253
20.9;References;253
21;Steam Utilization
;254
21.1;13.1 Introduction;256
21.2;13.2 What is steam?;256
21.3;13.3 The steam load;259
21.4;13.4 Draining steam lines;261
21.5;13.5 Low-pressure systems;265
21.6;13.6 Flash steam;271
21.7;13.7 Condensate return systems;275
21.8;13.8 Proposed Pressure Systems and Transportable Gas Containers Regulations;286
22;Heating;290
22.1;14.1 Introduction;292
22.2;14.2 Statutory regulations;292
22.3;14.3 Building regulations;292
22.4;14.4 Estimation of heat losses from buildings;294
22.5;14.5 Allowance for height of space;294
22.6;14.6 Characteristics of heat emitters;294
22.7;14.7 Central plant size;295
22.8;14.8 Selective systems;295
22.9;14.9 Multiple-boiler installations;295
22.10;14.10 Heating systems;296
22.11;14.11 Heating equipment – attributes

and applications;301
23;Ventilation;306
23.1;15.1 Introduction;308
23.2;15.2 Ventilation systems and controls;308
23.3;15.3 Powered ventilation equipment;311
23.4;15.4 Natural ventilation equipment;314
23.5;15.5 System design;315
23.6;15.6 Legislation and codes of practice;320
23.7;15.7 After installation;321
23.8;References;322
24;Air Conditioning;324
24.1;16.1 Basic principles and terms;326
24.2;16.2 The air quantity required;331
24.3;16.3 Heat losses and gains;332
24.4;16.4 Air conditioning for computers;334
24.5;16.5 Air distribution and system resistance;335
24.6;16.6 Fans;339
24.7;16.7 Dust control and filtration;341
24.8;16.8 Humidification;342
24.9;16.9 Test procedure for air-conditioning systems;343
25;Water and Effluents
;348
25.1;17.1 Introductory warning;350
25.2;17.2 Requirements for water;350
25.3;17.3 Water chemistry;350
25.4;17.4 Building services;352
25.5;17.5 Boilers;354
25.6;17.6 Specified purities for process use;356
25.7;17.7 Water-purification processes;356
25.8;17.8 Membrane processes;360
25.9;17.9 Effluents;362
26;Pumps andPumping;364
26.1;18.1 Pump functions and duties;366
26.2;18.2 Pump principles;366
26.3;18.3 Effects of fluid properties on pump behaviour
;372
26.4;18.4 Flow losses in systems;376
26.5;18.5 Interaction of pump and system;378
26.6;18.6 Cavitation;381
26.7;18.7 Priming systems;386
26.8;18.8 Seals: selection and care;387
26.9;18.9 Pump and drive selection;388
26.10;18.10 Pump testing;395
26.11;References;395
27;Cooling Towers;396
27.1;19.1 Background;398
27.2;19.2 Theory;398
27.3;19.3 Design techniques (see
Appendix 19.1 );398
27.4;19.4 Design requirements;399
27.5;19.5 Materials and structure design;399
27.6;19.6 Specification;399
27.7;19.7 Water quality and treatment;402
27.8;19.8 Operation;402
27.9;19.9 Modifications – retro-fits;404
27.10;19.10 Consultation;404
27.11;19.11 Environmental considerations;404
27.12;19.12 Problem areas;408
27.13;19.13 Summary;409
27.14;Appendix 19.1 Theoretical calculations;409
27.15;Appendix 19.2 Evaluation of the MDF;411
27.16;Appendix 19.3 Technical requirements;411
28;Electricity Generation
;412
28.1;20.1 Introduction;414
28.2;20.2 Generation of electrical power;414
28.3;20.3 Combined heat and power (CHP);420
28.4;20.4 Factors influencing choice;424
28.5;20.5 The selection;430
28.6;20.6 Plant and installation;434
29;Electrical Distribution and Installation;446
29.1;21.1 Introduction;448
29.2;21.2 Bulk supply;448
29.3;21.3 Distribution systems;449
29.4;21.4 Switchgear;450
29.5;21.5 Transformers;452
29.6;21.6 Protection systems;454
29.7;21.7 Power factor correction;456
29.8;21.8 Motors and motor control;461
29.9;21.9 Standby supplies;463
29.10;21.10 Earthing;465
29.11;21.11 Cables;466
30;Electrical Instrumentation;468
30.1;22.1 Introduction;470
30.2;22.2 Electricity supply metering;470
30.3;22.3 Power factor correction;472
30.4;22.4 Voltage and current transformers;473
30.5;22.5 Voltmeters and ammeters;474
30.6;22.6 Frequency measurement;476
30.7;22.7 Electronic instrumentation;477
30.8;22.8 Instrument selection;478
30.9;22.9 Cathode ray oscilloscopes;478
30.10;22.10 Transducers;480
30.11;22.11 Spectrum analysers;483
30.12;22.12 Bridge measurements;483
30.13;22.13 Data recording;484
30.14;22.14 Acoustic measurements;484
30.15;22.15 Centralized control;484
31;Lighting;486
31.1;23.1 Lighting theory;488
31.2;23.2 Electric lamps;488
31.3;23.3 Luminaires;495
31.4;23.4 Control gear;500
31.5;23.5 Emergency lighting;501
31.6;23.6 Lighting design;503
32;Compressed Air Systems
;506
32.1;24.1 Assessment of a plant's air consumption
;508
32.2;24.2 Compressor installation;509
32.3;24.3 Overpressure protection;515
32.4;24.4 Selection of compressor plant;515
33;Noise and Vibration;520
33.1;25.1 Introduction: basic acoustics;522
33.2;25.2 Measurement of noise;525
33.3;25.3 Vibration;525
33.4;25.4 Noise and vibration control;526
33.5;25.5 Avoiding physical injuryto workers;528
33.6;25.6 Avoidance of damage to plant/machinery/building structures;528
33.7;25.7 Noise-control engineering;528
33.8;25.8 Practical applications;530
34;Air Pollution;534
34.1;26.1 Introduction;536
34.2;26.2 Effects on plants, vegetation,materials and buildings;536
34.3;26.3 Effects on weather/environment;536
34.4;26.4 Legislation on air pollution of concern to the plant engineer;536
35;Dust and Fume Control;544
35.1;27.1 Introduction;546
35.2;27.2 The nature of dusts and fumes;546
35.3;27.3 Control of dusts and fumes;546
35.4;27.4 System design and application;552
35.5;27.5 Testing and inspections;553
35.6;27.6 Legislation;553
36;Insulation;558
36.1;28.1 Introduction;560
36.2;28.2 Principles of insulation;560
36.3;28.3 Calculation of heat loss;561
36.4;28.4 Standards of insulation;564
36.5;28.5 Product selection;567
36.6;28.6 Thermal conductivity;568
36.7;28.7 Physical forms;569
36.8;28.8 Facings;570
36.9;28.9 Insulation types;570
37;Economizers;576
37.1;29A.1 Introduction;578
37.2;29A.2 Oil and coal applications;578
37.3;29A.3 Gas-fired economizers;578
37.4;29A.4 Design;579
37.5;29A.5 Installation;579
37.6;29A.6 Condensing economizers;579
38;Heat Exchangers;584
38.1;29B.1 The APV Paraflow;586
38.2;29B.2 Comparing plate and tubular exchangers
;588
38.3;29B.3 Duties other than turbulent liquid flow
;589
38.4;29B.4 The problem of fouling;591
39;Corrosion;594
39.1;30.1 Corrosion basics;596
39.2;30.2 The implications of corrosion;602
39.3;30.3 Materials selection;603
39.4;30.4 Design and corrosion;610
39.5;30.5 Uses and limitations ofconstructional materials;612
39.6;30.6 Specifying materials;614
39.7;30.7 Corrosion-control techniques;615
39.8;30.8 Corrosion monitoring;617
40;Paint Coatings for the Plant Engineer
;620
40.1;31.1 Definition and function of coatings
;622
40.2;31.2 The constituents of paint;622
40.3;31.3 Types of coating and their uses;623
40.4;31.4 Surface preparation and priming;630
40.5;31.5 Specifications;631
40.6;31.6 Economics;631
40.7;31.7 Painting inspection;631
40.8;31.8 Factors influencing the selection of coating systems
;632
40.9;31.9 Sources of advice;633
41;Maintenance;634
41.1;32.1 Introduction;636
41.2;32.2 A 'planned' maintenance programme;636
41.3;32.3 A manual planned maintenance system
;637
41.4;32.4 Computer systems;641
41.5;32.5 Life-cycle costing;643
41.6;32.6 Condition monitoring;644
41.7;32.7 Training;644
41.8;32.8 Health and safety;644
41.9;32.9 Information;645
41.10;32.10 Conclusion;645
41.11;Appendix: Elements of a planned maintenance system;645
42;Energy Conservation
;650
42.1;33.1 The need for energy conservation;652
42.2;33.2 Energy purchasing;653
42.3;33.3 The energy audit;654
42.4;33.4 Energy management;655
42.5;33.5 Energy monitoring;655
42.6;33.6 Energy targeting;656
42.7;33.7 Major areas for energy conservation
;657
42.8;33.8 The justification for energy conservation measures;661
42.9;33.9 The mathematics of the presentation;661
42.10;33.10 Third-party energy management and finance;663
42.11;33.11 Motivation;663
42.12;33.12 Training;663
42.13;Reference;664
43;Insurance: Plant and Equipment;666
43.1;34.1 History;668
43.2;34.2 Legislation;668
43.3;34.3 The role of the inspection authority;668
43.4;34.4 Types of plant inspected;671
43.5;34.5 Insurance covers on inspected plant;671
43.6;34.6 Engineer surveyors;672
43.7;34.7 Technical services;675
43.8;34.8 Claims;677
43.9;34.9 Sources of information;677
43.10;Appendix 1: Glossary;678
43.11;Appendix 2: Statutory report forms;680
44;Insurance: Buildings and Risks;690
44.1;35.1 Insurance;692
44.2;35.2 Fire insurance;692
44.3;35.3 Business interruption insurance;692
44.4;35.4 Insurance surveys;692
44.5;35.5 Fire legislation;693
44.6;35.6 Fire protection;693
44.7;35.7 Extinguishers;693
44.8;35.8 Auto-sprinkler installations;694
44.9;35.9 Automatic fire alarms;694
44.10;35.10 Trade hazards;694
44.11;35.11 Recommended references;695
44.12;35.12 Fire Protection Association Compendium of fire

safety data;695
44.13;35.13 Security insurance;697
44.14;35.14 Theft insurance policy terms and conditions
;697
44.15;35.15 Risk assessment;698
44.16;35.16 Planning for security;698
44.17;35.17 Security objectives;698
44.18;35.18 Location;699
44.19;35.19 Site perimeter security;699
44.20;35.20 Building fabric;700
44.21;35.21 Doors and shutters;700
44.22;35.22 Windows;700
44.23;35.23 Intruder alarms;700
44.24;35.24 Closed-circuit television (CCTV);701
44.25;35.25 Access control;701
44.26;35.26 Recommended references;701
44.27;35.27 Liability and liability insurance;702
44.28;35.28 Employer's liability;702
44.29;35.29 Third-party liability;702
44.30;35.30 Liability insurance;702
44.31;35.31 The cover provided by liability insurance
;703
44.32;35.32 Points to be considered;703
44.33;35.33 Employee safety and employer's liability;704
44.34;35.34 Safety of the public and public liability (third party)
;706
45;Health and Safety;708
45.1;36.1 Introduction;710
45.2;36.2 Legislation;710
45.3;36.3 Administration of the Health and Safety at Work

Act;710
45.4;36.4 General duties;711
45.5;36.5 Safety policy;712
45.6;36.6 Information;713
45.7;36.7 HSE Inspectorates;713
45.8;36.8 The Employment Medical Advisory Service (EMAS);713
45.9;36.9 HSE area offices;713
45.10;36.10 Health and Safety procedures;715
45.11;36.11 Fire and first-aid instructions;715
45.12;36.12. Good housekeeping;715
45.13;36.13 Protective clothing and equipment
;715
45.14;36.14 Safe working areas;716
45.15;36.15 Materials handling;716
45.16;36.16 Portable tools and equipment;716
45.17;36.17 Confined spaces;717
45.18;36.18 Electricity;717
45.19;36.19 Plant and equipment;717
45.20;36.20 Safety signs and pipeline identification
;718
45.21;36.21 Asbestos;719
45.22;36.22 COSHH;719
45.23;36.23 Lead;719
45.24;36.24 Other information;719
45.25;36.25 Assessment of potential hazards;719
45.26;36.26 Alternative method of assessing hazards;720
45.27;36.27 Permits to work;721
45.28;36.28 Working alone;721
45.29;36.29 Safety policy for lone workers;722
45.30;36.30 Contractor's conditions and safe working

practices;723
45.31;36.31 Safe working practices and procedures
;724
45.32;36.32 Emergency procedures;725
45.33;36.33 Contractor's Guide;725
45.34;36.34 Addresses for health and safety information
;726
46;Education and Training
;730
46.1;37.1 The professional plant engineer;732
46.2;37.2 The Institution of Plant Engineers;732
46.3;37.3 Aims of the Institution;732
46.4;37.4 Organization;733
46.5;37.5 Membership;733
46.6;37.6 Registration with The Engineering Council;734
46.7;37.7 Registration as a European Engineer;734
46.8;37.8 Professional engineering development
;734
46.9;37.9 Addresses for further information;734
47;38 Lubrication;736
47.1;38.1 Introduction;738
47.2;38.2 Lubrication – the added value;738
47.3;38.3 Why a lubricant;738
47.4;38.4 Physical characteristics of oils and greases;739
47.5;38.5 Additives;741
47.6;38.6 Lubricating-oil applications;742
47.7;38.7 General machinery oils;742
47.8;38.8 Engine lubricants;742
47.9;38.9 Gear lubricants;746
47.10;38.10 Hydraulic fluids;755
47.11;38.11 Machine tools;758
47.12;38.12 Cutting fluids;761
47.13;38.13 Compressors;767
47.14;38.14 Turbines;770
47.15;38.15 Transformers and switchgear;771
47.16;38.16 Greases;771
47.17;38.17 Corrosion prevention;774
47.18;38.18 Spray lubricants;774
47.19;38.19 Degreasants;775
47.20;38.20 Filtration;775
47.21;38.21 Centrifuging;776
47.22;38.22 Shaft seals;776
47.23;38.23 Centralized lubrication;777
47.24;38.24 Storage of lubricants;778
47.25;38.25 Reconditioning of oil;778
47.26;38.26 Planned lubrication andmaintenance management;779
47.27;38.27 Condition monitoring;779
47.28;38.28 Health, safety and the environment
;779
47.29;Acknowledgements;780
47.30;Further reading;780
48;Index;782