xamples of Equipment and Components Designed and Specified while Employed

      in Industrial Operations and Design Engineering

  E

• Safety and overpressure relief valves • rupture discs
  

• overpressure blowout panels
  

• Skimmers, flotation and settling clarifiers
  

• Ground flares and elevated flare stacks for burning hazardous gases and liquid chemicals
  

• Non-burning vent stacks for disposal of non-hazardous gases to meet EPA anti-pollution regulations
  

• Gas blowers • fans
  

• Ejectors
  

• Compressors (for gases, including air and nitrogen) including:
  

     xamples of Systems Designed and Specified while Employed in Industrial Operations and

     Design Engineering 

  E

• Overpressure relief systems
  

     xamples of Facilities Designed while Employed in Industrial Operations and Design Engineering

  E

Safety Design of Equipment and Facilities - including safeguards and warnings

Safety design was a routine, integral part of the engineering design of all industrial and manufacturing equipment and facilities while employed in industrial operations and engineering design.

Air and Water Pollution Control Facilities

• Gas vent stacks for numerous industrial and manufacturing facilities.
  

• Water pollution control design for an acrylonitrile manufacturing.
  

• Water pollution control facility for a high density polyethylene manufacturing facility.
  

Utility System Facilities  (steam, treated water, plant and instrument air, nitrogen, etc.)

• a petrochemical, utilities and storage complex, a large group of industrial, manufacturing, utilities and storage facilities
  

• a lube oil manufacturing facility
  

• a substitute natural gas (SNG) manufacturing and storage facility.
  

• a pharmaceutical manufacturing facility.
  

• a polystyrene manufacturing facility.
  

Industrial and Manufacturing Facilities

• Plastics manufacturing grassroots* facilities including:
  

• low density polyethylene manufacturing facilities
  

• polypropylene manufacturing facilities
  

• a polystyrene (styrene) manufacturing facility
  

• extrusion and compounding facilities (used to knead plastics) for grassroots high density polyethylene manufacturing facilities
  

• Petroleum processing facilities including:
  

• a lube oil manufacturing facility
  

• a crude oil topping facility
  

• a naphtha reforming (reformulation) facility
  

• a gas oil separation facility with stabilization
  

• Chemical production grassroots* facilities including:
  

• herbicide manufacturing facilities
  

• ethyl hexanol manufacturing facilities
  

• a MTBE and paraxylene absorption manufacturing facility
  

• a MTBE and Dimersol manufacturing facility
  

• a benzene hydrofining unit
  

• a fire retardant manufacturing facility
  

* "grassroots" facilities, also known as "greenfield" facilities are facilities which are totally new, starting

    with the grading of the ground • such facilities may or may not be in a manufacturing complex with

    other older completed facilities

• Natural gas processing grassroots* facilities including:
  

• a natural gas processing facility and export terminal
  

• an underground peak shaving natural gas storage facility
  

• a natural gas saturates facility
  

• a natural gas and hydrocarbon liquids processing facility.
  

• Renovation of solvent recovery and refining facilities for a high density polyethylene manufacturing facility
  

• Dry ice expanded tobacco manufacturing facility.
  

• a natural gas separation facility
  

• a natural gasoline facility.
  

• Tank farms (a large number of large tanks and associated equipment, piping and instrumentation in a stand-alone facility) for:
  

• a facility for revaporization of liquefied natural gas
  

• a facility to produce substitute natural gas (SNG).
  

• Downsizing and modernization of:
  

Other Technical Activities Associated with Engineering Design

• Conducted equipment operation testing in manufacturing facilities
  

• Performed industrial operation studies in manufacturing facilities, including studies to develop the data required to design additional similar facilities
  

• Performed drainage studies in industrial and manufacturing facilities to develop the data required for the design of surface facilities and trenches/flumes and sewers for the drainage required
  

• Designed specialized safety and air pollution control systems, including flares, vents, foam fire protection systems and the like
  

• Assisted with construction of industrial and manufacturing facilities, including providing technical assistance to Construction personnel at the construction site and providing construction site engineering design services and supervision of construction
  

• Participated in the commissioning (completing the construction) and startup of manufacturing facilities
  

• Designed and presented courses to Design Engineers covering the design of safety relief devices and safety relief systems
  

• Organized, participated in and supervised the writing of Design Manuals for equipment, machinery, piping, valving and instrumentation to meet safety design requirements and applicable codes, standards and recommended practices
  

• Organized, participated in and supervised the writing of a Design Manual for the design of boiler systems to meet safety design requirements and the ASME Boiler Code and other applicable codes and standards
  

• Assured the technical quality of engineering designs, especially of the safety design of equipment and facilities, design of safety facilities and  warnings; through hands-on reviews and formal technical reviews and approvals of engineering designs of industrial and manufacturing facilities, piping, valving, instrumentation, equipment and machinery
  

• Made use of industry, technical society and government codes, standards and recommended practices extensively during design of industrial and manufacturing facilities, piping, valving, instrumentation equipment and machinery, and advised and instructed others on the proper use of these Codes in their design
  

• Pressure relief systems for numerous industrial and manufacturing facilities.
  

• Gas and liquid burning flare stacks for numerous industrial and manufacturing facilities.
  

• Fire suppressant systems, including water, inert gas and foam systems for several facilities.
  

Specialized Safety Facilities, including those using fire and those for fire suppression

• designing equipment to reduce or eliminate hazards in the use of the equipment, which is usually called designing out the safety hazards
  

• the specification of safeguards (such as barrier guards, light curtains, dual operating buttons, safety instrumentation, etc.) as required
  

• the designing or specification of warnings as required
  

• Human Factors and the analysis of the human - equipment and human - facility interfaces
  

• accepted engineering safety standards and practices
  

• Codes & Standards and Recommended Practices
  

● 

• first, design out the safety hazards in equipment, products and facilities whenever possible
  

• second, use safeguards to protect from those safety hazards which cannot be designed out
  

• third, use warnings for those safety hazards which cannot be designed out and for which safeguards cannot be used to protect from the safety hazard
  

• fourth, use warnings to complement safeguards when safeguards are used to protect from hazards
  

●  Safety design includes:

●  Safety design is based on:

• do NOT use warnings in place of safeguards or designing out a hazard, if these are practical
  

• do NOT use safeguards in place of designing out a hazard, if this is practical
  

●  Design using the Safety Design Hierarchy has prohibitions as follows:

• Control system panel layouts • alarm panel layouts
  

• Fire suppression systems
  

• Piping and tubing ranging from approximately 1/4 inch to 48 inches in diameter, used for:
  

• water
  

• steam
  

• gases
  

• chemicals
  

• pneumatic control and power systems (using air or nitrogen)
  

• hydraulic control and power systems  (using hydraulic fluid), etc.
  

• Valves ranging from approximately 1/4 inch to 48 inches in size including:
  

• hand-operated valves
  

• remote-operated valves (with electrical, hydraulic or pneumatic control and power)
  

• automatically operated valves (with electrical, hydraulic or pneumatic control and power)
  

• gate valves
  

• globe valves
  

• needle valves
  

• butterfly valves
  

• ball valves
  

• rotary valves, etc.
  

• Furnaces, including:
  

• centrifugal compressors
  

• reciprocating compressors
  

• screw compressors
  

• Pumps (for liquids, including water and chemicals) including:
  

• centrifugal pumps
  

• reciprocating positive displacement pumps
  

• screw positive displacement pumps
  

• sump pumps, etc.
  

• Vacuum pumps (for gases - creates and maintains a vacuum)
  

• Turbines, motors, and engines to drive machinery, including:
  

• steam-driven turbines
  

• gas-expansion turbines
  

• electric motors
  

• gas-fired and oil-fueled engines
  

• compressors
  

• pumps
  

• blowers,
  

• conveyors
  

• plastics processing equipment
  

• similar powered equipment
  

machinery driven by turbines, motors, and engines includes:

• Heaters and heat exchangers including:
  

• safety, control, fuel, exhaust and product instrumentation systems
  

• piping and ductwork systems
  

• Dryers for solids, including:
  

• liquid to liquid heat exchangers
  

• liquid to gas* heat exchangers
  

• gas* to gas* heat exchangers
  

• shell and tube heat exchangers
  

• double pipe heat exchangers
  

• multipipe heat exchangers
  

• plate heat exchangers
  

• bayonet heat exchangers
  

• air coolers
  

• tank coils
  

• vessel jacketing
  

• kettle reboilers
  

• thermo-siphon reboilers
  

• vessel and tank heaters, etc.                             
  

     xamples of Engineering Design Activities

      while Employed in Industrial Operations and Design Engineering

  E

Madden Accident Analysis & Forensic Engineering

8803 Brecksville Road, Suite 7-216, Cleveland, Ohio 44141

phone: 440-838-1191    fax: 440-838-1192

email address: maddenforensic@yahoo.com

website: www.maddenforensic.com

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• automatic and manual control systems
  

• local and remote control systems
  

• pneumatic, electrical and hydraulic control systems
  

• including those specifically designed to assure the safety of the operation of equipment and systems
  

• including the associated piping, valves, equipment and instrumentation
  

• Hazardous chemical (liquid and gas) relief systems
  

• Air pollution systems
  

• including the associated piping, valves, equipment and instrumentation
  

• Surface and open subsurface drainage and spill containment systems
  

• including the associated piping, valves, equipment and instrumentation
  

• Gravity and pressure industrial sewer systems
  

• Liquid and solid industrial waste disposal facilities
  

• including the grading, surfacing, trenches and flumes
  

• Control systems including:  
  

• including skimmers, and flotation and settling clarifiers
  

• Steam and electricity co-generation systems (which generate steam and electricity at the same time)
  

• Refrigeration systems
  

• including water, foam and inert gas systems
  

• Utility production systems for the production of:
  

• including machinery (compressors, etc.), controls, safety systems and piping
  

• Utility distribution systems
  

• steam (using boilers)
  

• treated water for industrial purposes
  

• plant and instrument air
  

• nitrogen, etc.
  

• Signage, including warning signs
  

• Equipment and machinery layouts
  

• building and structure specifications
  

• including piping, instrumentation and controls
  

• Utility distribution systems for numerous industrial and manufacturing facilities
  

• including piping, instrumentation and controls
  

• Utility production systems for the production of:
  

• steam (using boilers)
  

• treated water for industrial purposes
  

• plant and instrument air
  

• nitrogen, etc.
  

for use in:

• Direct-fired boilers • waste-heat boilers (including steam generators), including:
  

• safety, control, fuel, exhaust and product instrumentation systems
  

• piping and ductwork systems
  

* gases handled by heat exchangers included air

• Dehumidifiers to remove liquids from gases
  

• Pressure and vacuum vessels and tanks for liquids and gases.
  

• Atmospheric storage tanks for liquids
  

• Storage bins for solids and particulates
  

• Distillation, absorption and solvent extraction columns, including:
  

• rotary dryers
  

• fluidized bed dryers
  

• spray dryers, etc.
  

• Plastics processing equipment, including:
  

• trayed and packed columns.
  

• Conveyors, including:
  

• compounders
  

• extruders
  

• choppers, etc.
  

• Liquid and gas filters and bag houses
  

• Separators, including:
  

• belt conveyors
  

• pneumatic conveyors
  

• screw conveyors
  

• bucket conveyors, etc.
  

• impingement separators
  

• cyclone separators, etc.
  

• Traveling cranes, traveling winches, etc.
  

• Materials of construction for:
  

• piping, equipment, machinery, etc.
  

    Equipment and Components designed and specified conformed to applicable Codes & Standards, were designed

    using Safety Design and Human Factors principles, and included Safeguards and Warnings where required

    Systems designed and specified conformed to applicable Codes & Standards, were designed using Safety Design

    and Human Factors principles, and included Safeguards and Warnings where required

    Facilities designed conformed to applicable Codes & Standards, were designed using Safety Design and Human

    Factors principles, and included Safeguards and Warnings where required

Safety design is performed based on the the Safety Design Hierarchy, which is the accepted system for design of safe equipment, systems, products and facilities. The Safety Design Hierarchy requires designing for safety as follows:

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Engineering Design Activities, and Equipment

and Facilities Designed by James D. Madden, P.E. while

employed in Industrial Operations and Design Engineering

See the      Employment page    for details on specific employers and employment in

Industrial Operations and Design Engineering.

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