Process auxiliaries, control systems piping

In this approach accident cases and design recommendations can be analysed level by level. In the database the knowledge of known processes is divided into categories of process, subprocess, system, subsystem, equipment and detail (Fig. 6). Process is an independent processing unit (e.g. hydrogenation unit). Subprocess is an independent part of a process such as reactor or separation section. System is an independent part of a subprocess such as a distillation column with its all auxiliary systems. Subsystem is a functional part of a system such as a reactor heat recovery system or a column overhead system including their control systems. Equipment is an unit operation or an unit process such as a heat exchanger, a reactor or a distillation column. Detail is an item in a pipe or a piece of equipment (e.g. a tray in a column, a control valve in a pipe). 

Normally where it is necessary, fireproofing is preferred over water spray for several reasons. The fireproofing is a passive inherent safety feature, while the water spray is a vulnerable active system that requires auxiliary control to be activated. Additionally the water spray relies on supplemental support systems that may be vulnerable to failures, i.e., pumps, distribution network, valves, etc. The integrity of fireproofing system is generally considered superior to explosion incidents compared to water spray piping systems. The typical application of water sprays in place of fireproofing is for process vessel protection. 

Estimation of column costs for preliminary process evaluations requires consideration not only of the basic type of internals but also of their effect on overall system cost. For a distillation system, for example, the overall system can include the vessel (column), attendant structures, supports, and foundations auxiliaries such as reboiler, condenser, feed neater, and control instruments and connecting piping. The choice of internals influences all these costs, but other factors influence them as well. A complete optimization of the system requires a full-process simulation model that can cover all pertinent variables influencing economics. 

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