Principles and Practice of Engineering PE Chemical Reference Handbook by National Council of Examiners for Engineering and Surveying (NCEES) (z-lib.org)

Chapter 8: Plant Design and Operations

GENERAL PIPING SYMBOLS GENERAL PIPING SYMBOLS
SIGHT GLASS FLANGE
BLIND FLANGE
DT DRAIN TRAP WELDED END CAP
FLAME ARRESTOR SCREWED CAP
SPARK ARRESTOR SPECTACLE BLIND (OPEN)
REDUCER
SPECTACLE BLIND (CLOSED)
CONSERVATION VENT HOSE CONNECTION
QUICK COUPLING
VENT (WITH HOOD)
OPEN VENT WITH GOOSENECK COOLING TOWERS

INDUCED-DRAFT
COOLING TOWER

SIPHON DRAIN FORCED-DRAFT
COOLING TOWER
Y TYPE STRAINER
HYPERBOLIC
BASKET-TYPE STRAINER COOLING TOWER
IN-LINE STATIC MIXER
RO NATURAL-DRAFT
RESTRICTION COOLING TOWER
ORIFICE

RUPTURE DISK

©2020 NCEES 482

Chapter 8: Plant Design and Operations

VALVE AND CONTROL SYMBOLS VALVE AND CONTROL SYMBOLS
GATE VALVE
GLOBE VALVE PRESSURE SAFETY RELIEF VALVE
BALL VALVE
PLUG VALVE VACUUM SAFETY RELIEF VALVE
BUTTERFLY VALVE
NEEDLE VALVE P PILOT-ACTUATED RELIEF OR
DIAPHRAGM VALVE SAFETY VALVE ACTUATOR
PINCH VALVE
SPRING- OR WEIGHT-ACTUATED
CHECK VALVE RELIEF OR SAFETY VALVE
3-WAY VALVE ACTUATOR
4-WAY VALVE RUPTURE DISC,
PRESSURE RELIEF
DAMPER
RUPTURE DISC,
VACUUM RELIEF

©2020 NCEES 483

Chapter 8: Plant Design and Operations

8.5.2.4 Instrumentation Tag Identifiers and Symbols
The following identifiers are used in P&ID instrument tags.

Identification Letters

First 4 Letters Succeeding 3 Letters

Measured or Modifier Readout or Output Function Modifier
Initiating Variable Passive Function

A Analysis Alarm

B Burner, combustion

C Control

D Differential

E Voltage Sensor (primary
element)

F Flow rate Ratio (fraction)

G Glass, viewing device

H Hand High

I Current (electrical) Indicate

J Power Scan

K Time, time schedule Time rate of Control station
change

L Level Light Low

M Momentary Middle, intermediate

O Orifice, restriction

P Pressure, vacuum Point (test) connection

Q Quantity Integrate, totalize

R Radiation Record

S Speed, frequency Safety Switch

T Temperature Transmit

U Multivariable Multifunction Multifunction Multifunction

V Vibration, mechanical Valve, damper,
analysis louver

W Weight, force Well

X Unclassified X axis Unclassified Unclassified Unclassified

Y Event, state, or Y axis Relay, compute,
presence convert

Z Position, dimension Z axis Driver, actuator,
unclassified final
control element

Source: Taken from ANSI/ISA -5.1-2009 - Copyright © 2009, ISA - all rights reserved. Used with permission of ISA.

©2020 NCEES 484

Chapter 8: Plant Design and Operations

General Instrument or Function Symbols

PRIMARY FIELD AUXILIARY
LOCATION MOUNTED LOCATION
**NORMALLY **NORMALLY
ACCESSIBLE TO ACCESSIBLE TO
OPERATOR OPERATOR

DISCRETE *IP1
INSTRUMENTS

SHARED DISPLAY,
SHARED CONTROL

COMPUTER
FUNCTION

PROGRAMMABLE
LOGIC CONTROL

* Abbreviations of the user's choice—such as IP1 (Instrument Panel #1), IC2 (Instrument Console #2), CC3
(Computer Console #3), etc.—may be used when it is necessary to specify instrument or function location.

** Normally inaccessible or behind-the-panel devices or functions may be depicted by using the same symbol
but with dashed horizontal lines, as in:

Additional General Instrument or Function Symbols

PILOT LIGHT DIAPHRAGM SEAL *

INTERLOCK LOGIC

* This diamond is approximately half the size of the larger symbols.

©2020 NCEES 485

Chapter 8: Plant Design and Operations
Actuator Symbols

M

WITH OR WITHOUT PREFERRED FOR DIAPHRAGM ROTARY MOTOR (SHOWN
POSITIONER OR OTHER DIAGRAM ASSEMBLED PRESSURE–BALANCED TYPICALLY WITH ELECTRIC
WITH PILOT*, ASSEMBLY SIGNAL, MAY BE HYDRAULIC OR
PILOT IS ACTUATED BY ONE
PNEUMATIC)
INPUT (SHOWN
TYPICALLY WITH
ELECTRIC INPUT)

DIAPHRAGM
SPRING –OPPOSED OR
UNSPECIFIED ACTUATOR

SPRING-OPPOSED DOUBLE-ACTING PREFERRED FOR ANY CYLINDER
SINGLE-ACTING THAT IS ASSEMBLED WITH A PILOT*
SO THAT ASSEMBLY IS ACTUATED
CYLINDER WITHOUT POSITION OR OR OTHER PILOT
BY ONE CONTROLLED INPUT

IS

S PREFERRED ALTERNATIVE. A
SOLENOID
BUBBLE WITH INSTRUMENT

TAGGING, E.G. TY-I MAY BE

USED INSTEAD OF THE I SINGLE-ACTING CYLINDER
INTERLOCK SYMBOL (IMPLIED I/P)

CYLINDER WITH POSITIONER AND OVERRIDING PILOT VALVE

FOR PRESSURE RELIEF HAND ACTUATOR
OR SAFETY VALVES ONLY. OR HANDWHEEL
SPRING WEIGHT DENOTES A SPRING
WEIGHT OR INTEGRAL PILOT

* Pilot may be positioned solenoid valve signal converter, etc.

©2020 NCEES 486

Chapter 8: Plant Design and Operations

Symbols for Self-Actuated Regulators, Valves, and Other Devices

FICV FCV
XX XX

AUTOMATIC REGULATOR AUTOMATIC REGULATOR
WITH INTEGRAL FLOW WITHOUT INDICATION
INDICATION

FLOW FG
XX
RO
XX FLOW SIGHT GLASS,
PLAIN OR WITH PADDLE
RESTRICTION ORIFICE (ORIFICE PLATE, WHEEL FLAPPER, ETC.
CAPILLARY TUBE OR MULTI-STAGE
TYPE. ETC.) IN PROCESS LINE

HV
XX

HAND

HAND CONTROL VALVE
IN PROCESS LINE

TANK

LCV
XX

LEVEL

LEVEL REGULATOR WITH
MECHANICAL LINKAGE

PCV PSV PSV
XX PCV XX XX
XX

PRESSURE PRESSURE-REDUCING BACKPRESSURE PRESSURE RELIEF OR VACUUM RELIEF VALVE,
REGULATOR, SELF- REGULATOR SAFETY VALVE, GENERAL SYMBOL
CONTAINED, WITH
SELF-CONTAINED GENERAL SYMBOL
HANDWHEEL ADJUST-
ABLE SETPOINT

©2020 NCEES 487

Chapter 8: Plant Design and Operations

PRESSURE (CONTD.) PSE PSE P
XX XX

RUPTURE DISC OR RUPTURE DISC OR PILOT-OPERATED
SAFETY HEAD FOR SAFETY HEAD FOR RELIEF VALVE
PRESSURE RELIEF
VACUUM RELIEF

8.5.3 Layout and Siting Considerations

8.5.3.1 Fixed Facilities
Building Siting Evaluation: The procedures used to evaluate the hazards and establish the design criteria for new buildings and
the suitability of existing buildings at their specific locations.

Facility: The physical location where the management system activity is performed. In early life-cycle stages, a facility may be
the company's central research laboratory or the engineering offices of a technology vendor. In later stages, the facility may be
a typical chemical plant, storage terminal, distribution center, or corporate office. Site is used synonymously with facility when
describing to Risk Management Plan (RMP) audit criteria.

Fixed Facility: A portion of or a complete plant, unit, site, complex, or any combination thereof that is generally not moveable. In
contrast, mobile facilities, such as ships (e.g., transport vessels, floating platform storage and offloading vessels, drilling plat-
forms), trucks, and trains, are designed to be moveable.

Siting: The process of locating a complex, site, plant, or unit.

Guiding Principles for Location of Fixed Facility
API Recommended Practice 752 is based on the following guiding principles:

b. Locate personnel away from process areas consistent with safe and effective operations.
c. Minimize the use of buildings intended for occupancy in close proximity to process areas.
d. Manage the occupancy of buildings in close proximity to process areas.
e. Design, construct, install, modify, and maintain buildings intended for occupancy to protect occupants against
explosion, fire, and toxic material releases.
f. Manage the use of buildings intended for occupancy as an integral part of the design, construction, mainte-
nance, and operation of a facility.

Source: API Recommended Practice 752: Management of Hazards Associated with Location of Process Plant Buildings,
3rd ed.: American Petroleum Institute, 2009, p. 1. Reproduced courtesy of the American Petroleum Institute.

©2020 NCEES 488

Chapter 8: Plant Design and Operations

Overall Building Siting Evaluation Flow Chart

START

IS BUILDING YES IS BUILDING YES IS BUILDING YES CHOOSE BUILDING
WITHIN THE INCLUDED IN IMPACTED BY SITING EVALUATION
SCOPE OF THE SITING EXPLOSION, FIRE APPROACH(ES) AND
VALUATION? OR TOXICS?
API752? CRITERIA

NO NO NO

DESIGN BUILDING

IS IT A NEW (INCLUDING

BUILDING OR YES EXTENSIONS AND
MODIFICATIONS TO
MODIFICATION TO

EXISTING EXISTING BUILDINGS)

BUILDING? TO MEET BUILDING

SITING EVALUATION

NO

CARRY OUT BUILDING ARE BUILDING YES
SITING EVALUATION SITING

EVALUATION
CRITERIA MET?

NO

INCLUDE BUILDING
IN MITIGATION PLAN.

DEVELOP AND
IMPLEMENT

MITIGATION PLAN.

IMPLEMENT
MANAGEMENT OF
BUILDING OCCUPANCY
AND/OR MANAGEMENT

OF CHANGE

STOP

©2020 NCEES 489

Chapter 8: Plant Design and Operations

Building Siting Evaluation for Explosions

START

COULD BUILDING YES IS IT A NEW YES DETERMINE DESIGN BUILDING
BE IMPACTED BUILDING OR BLAST LOADS (INCLUDING EXTENSIONS
MODIFICATION TO ON BUILDING AND MODIFICATIONS TO
BY EXPLOSION? EXISTING BUILDINGS) TO
EXISTING MEET BUILDING SITING
BUILDING?
EVALUATION FOR
NO EXPLOSION
DETERMINE
NO BLAST LOADS
ON BUILDING

COMPLETE A BUILDING
DAMAGE LEVEL
ASSESSMENT OR

A DETAILED STRUCTURAL
ANALYSIS

CARRY OUT MORE YES
DETAILED ANALYSIS?

NO

DOES BUILDING YES
MEET BUILDING SITING
CRITERIA FOR EXPLOSION?

NO
INCLUDE BUILDING AND

MITIGATION PLAN

BUILDING SITING
EVALUATION FOR
EXPLOSION NOT

REQUIRED.

IMPLEMENT MANAGE-
MENT OF THE BUILDING

OCCUPANCY AND/OR
MANAGEMENT OF
CHANGE

STOP

©2020 NCEES 490

Chapter 8: Plant Design and Operations

Building Siting Evaluation for Fire

START

COULD BUILDING YES IS A SPACING YES ARE SEPARATION YES
BE IMPACTED BY TABLE APPROACH DISTANCES MET?

FIRE? USED?

NO NO NO

DETERMINE FIRE
EFFECTS AT BUILDING
AND SELECT THE FIRE
PROTECTION CONCEPT

IS IT A NEW YES DESIGN BUILDING
BUILDING OR TO MEET BUILDING
MODIFICATIONS TO SITING EVALUATION

EXISTING CRITERIA.
BUILDING?

NO

DOES BUILDING YES
MEET BUILDING
SITING EVALUATION

CRITERIA?

NO

BUILDING SITING INCLUDE BUILDING IN CARRY OUT MORE INCLUDE BUILDING AND CARRY OUT MORE
EVALUATION FOR FIRE MITIGATION PLAN DETAILED ANALYSIS. MITIGATION PLAN AN AND DETAILED ANALYSIS
AND IMPLEMENT IF NEEDED, INCLUDE IMPLEMENT MITIGATION IF NEEDED, INCLUDE
NOT REQUIRED. MITIGATION PLAN BUILDING IN MITIGATION BUILDING IN MITIGATION
PLAN AND IMPLEMENT PLAN PLAN AND IMPLEMENT
MITIGATION PLAN
MITIGATION PLAN

IMPLEMENT
MANAGEMENT OF
BUILDING OCCUPANCY
AND/OR MANAGEMENT

OF CHANGE

STOP

©2020 NCEES 491

Chapter 8: Plant Design and Operations

Building Siting Evaluation for Toxic Material Release

START

IS THERE YES IS IT ASSUMED THAT YES
POTENTIAL FOR A TOXIC BUILDING IS
IMPACTED?
RELEASE?

NO NO

PERFORM TOXIC GAS
DISPERSING MODELING.

ARE BUILDING SITING YES SELECT PROTECTION
EVALUATION CRITERIA CONCEPT FOR TOXIC

EXCEEDED? MATERIAL.

NO

IS IT A NEW BUILDING OR YES DESIGN AND BUILDING
MODIFICATION TO EXISTING TO MEET BUILDING

BUILDING? SITING THE EVALUATION
CRITERIA.

NO

BUILDING SITING INCLUDE BUILDING A CARRY OUT MORE
EVALUATION FOR TOXIC MITIGATION PLAN AND DETAILED ANALYSIS . IF
IMPLEMENT MITIGATION
NOT REQUIRED NEEDED, INCLUDE
PLAN BUILDING IN MITIGATION
PLAN AND IMPLEMENT

MITIGATION PLAN.

IMPLEMENT
MANAGEMENT OF
BUILDING OCCUPANCY
AND MANAGEMENT OF

CHANGE.

STOP

©2020 NCEES 492

Chapter 8: Plant Design and Operations

8.5.3.2 Portable Buildings
Portable Building: Any rigid structure that can be moved easily to another location within the facility, regardless of the length of
time it is kept at the site. Examples of portable buildings include wood framed trailers (single- and double-wide), container boxes,
semi-trailers, and portable structures designed to be blast resistant. Lightweight fabric enclosures, such as tents, are excluded.

Guiding Principles for Siting Portable Buildings
API Recommended Practice 753 is based on the following guiding principles:

a. Locate personnel away from covered process areas consistent with safe and effective operations.
b. Minimize the use of occupied portable buildings in close proximity to covered process areas.
c. Manage the occupancy of portable buildings, especially during periods of increased risk including start-up or planned
shut-down operations.
d. Design, construct, install, and maintain occupied portable buildings to protect occupants against potential hazards.
e. Manage the use of portable buildings as an integral part of the design, construction, maintenance, and operation of a facility.

Source: API Recommended Practice 751: Management of Hazards Associated with Location of Process Plant
Portable Buildings: American Petroleum Institute, 2007. Reproduced courtesy of the American Petroleum Institute.

©2020 NCEES 493

©2020 NCEES 8.5.3.3 Building Occupancy

IBC Table 307
Maximum Allowable Quantity per Control Area of Haz

Material Class Group When Solid Storageb (
the Maximum Pounds F
Combustible dust (Cubic Liquid
Combustible Allowable Gallons
liquidc,i Quantity Is Feet) (Pounds)
Exceeded
Combustible fiber
Consumer N/A H-2 q N/A
fireworks
Cryogenics, II H-2 or H-3 120d,e
flammable
Cryogenics, inert IIIA H-2 or H-3 N/A 330d,e
Cryogenics,
oxidizing IIIB N/A 13,200e,f

Explosives Loose H-3 (100) N/A
Baledo (1000)
Flammable gas
1.4G H-3 125d,e,l N/A
Flammable liquidc
494 Flammable liquid, N/A H-2 N/A 45d
combination (1A,
1B, 1C) N/A N/A N/A N/A 1
Flammable solid
Inert gas N/A H-3 N/A 45d

Division 1.1 H-1 1e,g (1)e,g
Division 1.2 H-1 1e,g (1)e,g
Division 1.3 H-1 or H-2 5e,g (5)e,g
Division 1.4 H-3 50e,g (50)e,g
Division 1.4G H-3 125d,e,l N/A
Division 1.5 H-1 1e,g (1)e,g
Division 1.6 H-1 1d,e,g N/A
N/A
Gaseous H-2 N/A (150)d,e
Liquefied 30d,e
H-2 or H-3 N/A 120d,e
1A
1B and 1C

N/A H-2 or H-3 N/A 120d,e,h

N/A H-3 125d,e N/A

Gaseous N/A N/A N/A
Liquefied N/A N/A N/A

7.1 (1)
zardous Materials Posing a Physical Hazarda,j,m,n,p

Used in Closed Systemsb Used in Open Systemsb

Gas Solid Liquid Gas Solid Liquid
(Cubic Pounds Gallons (Cubic Pounds Gallons
Feet at (Cubic (Pounds) Feet at (Cubic (Pounds)
NTP) NTP)
Feet) Feet)

N/A q N/A N/A q N/A

120d 30d

N/A N/A 330d N/A N/A 80d

13,200f 3300f

N/A (100) N/A N/A (20) N/A Chapter 8: Plant Design and Operations
(1000) (200)

N/A N/A N/A N/A N/A N/A

N/A N/A 45d N/A N/A 10d

NL N/A N/A NL N/A N/A

N/A N/A 45d N/A N/A 10d

N/A 0.25g (0.25)g N/A 0.25g (0.25)g
N/A 0.25g (0.25)g N/A 0.25g (0.25)g
N/A N/A
N/A 1g (1)g N/A 1g (1)g
N/A 50g (50)g N/A N/A N/A
N/A N/A N/A N/A N/A N/A
N/A 0.25g (0.25)g N/A 0.25g (0.25)g
1000d,e N/A N/A 1000d,e N/A N/A
N/A N/A N/A
N/A (150)d,e N/A N/A
N/A 30d,e N/A
N/A 120d,e N/A 10d
30d

N/A N/A 120d,h N/A N/A 30d,h

N/A 125d N/A N/A 25d N/A

NL N/A N/A NL N/A N/A
NL N/A N/A NL N/A N/A

©2020 NCEES Maximum Allowable Quantity per Control Area of Hazardous

Group When Storageb

Material Class the Maximum Solid Liquid G
Allowable Pounds Gallons (C
Quantity Is (Cubic (Pounds) Fe
Exceeded NT
Feet)

UD H-1 1e,g (1)e,g N
I
II H-2 5d,e (5)d,e N
III
Organic peroxide IV H-3 50d,e (50)d,e N
V
H-3 125d,e (125)d,e N

N/A NL NL N

N/A NL NL N

4 H-1 1e,g (1)e,g N

Oxidizer 3k H-2 or H-3 10d,e (10)d,e N

2 H-3 250d,e (250)d,e N

1 N/A 4000e.f (4000)e.f N

Oxidizing gas Gaseous H-3 N/A N/A 15
Liquefied
N/A (150)d,e N

495 Pyrophoric N/A H-2 4e,g (4)e,g 5
material

Unstable (reactive) 4 H-1 1e,g (1)e,g 1
material 3 H-1 or H-2 5d,e (5)d,e 5
2 50d,e (50)d,e 25
1 H-3 N
N/A NL NL

Water-reactive 3 H-2 5d.e (5)d.e N
material 2
1 H-3 50d.e (50)d.e N

N/A NL NL N

For SI: 1 cubic foot = 0.028 m3, 1 pound =
NL = not limited; N/A = not applicable;

s Materials Posing a Physical Hazarda,j,m,n,p (cont'd)

Used in Closed Systemsb Used in Open Systemsb

Gas Solid Liquid Gas Solid Liquid
Cubic Pounds Gallons (Cubic Pounds Gallons
eet at (Cubic (Pounds) Feet at (Cubic (Pounds)
NTP)
TP) Feet) Feet)

N/A 0.25g (0.25)g N/A 0.25g (0.25)g Chapter 8: Plant Design and Operations
N/A 1d (1)d N/A 1d (1)d
N/A 50d (50)d N/A 10d (10)d
N/A 125d (125)d N/A 25d (25)d
N/A NL NL N/A NL NL
N/A NL NL N/A NL NL

N/A 0.25g (0.25)g N/A 0.25g (0.25)g
N/A 2d (2)d N/A 2d (2)d
N/A 250d (250)d N/A 50d (50)d
N/A N/A
4000f (4000)f 1000f (1000)f
500d,e 1500d,e
N/A N/A N/A N/A N/A N/A
N/A (150)d,e N/A N/A

50e,g 1g (1)g 10g 0 0

10g 0.25g (0.25)g 2e,g 0.25g (0.25)g
50d,e 1d (1)d 10d,e 1d (1)d
50d,e 50d (50)d 250d,e 10d (10)d
NL NL NL NL NL NL

N/A 5d (5)d N/A 1d (1)d
N/A 50d (50)d N/A 10d (10)d
N/A NL NL N/A NL NL

= 0.454 kg, 1 gallon = 3.7785 L
UD = unclassified detonable

Chapter 8: Plant Design and Operations

a. For use of control areas, see Section 414.2.
b. The aggregate quantity in use and storage shall not exceed the quantity listed for storage.
c. The quantities of alcoholic beverages in retail and wholesale sales occupancies shall not be limited provided the liquids

are packaged in individual containers not exceeding 1.3 gallons. In retail and wholesale sales occupancies, the quantities
of medicines, foodstuffs, consumer or industrial products, and cosmetics containing not more than 50 percent by volume
of water-miscible liquids, with the remainder of the solutions not being flammable, shall not be limited, provided that such
materials are packaged in individual containers not exceeding 1.3 gallons.
d. Maximum allowable quantities shall be increased 100% in buildings equipped throughout with an automatic sprinkler
system in accordance with Section 903.3.1.1. Where Note e also applies, the increase for both notes shall be applied
accumulatively.
e. Maximum allowable quantities shall be increased 100% when stored in approved storage cabinets, day boxes, gas cabinets,
or exhausted enclosures or in listed safety cans in accordance with Section 5003.9.10 of the International Fire Code. Where
Note d also applies, the increase for both notes shall be applied accumulatively.
f. The permitted quantities shall not be limited in a building equipped throughout with an automatic sprinkler system in
accordance with Section 903.3.1.1.
g. Permitted only in buildings equipped throughout with an automatic sprinkler system in accordance with Section 903.3.1.1.
h. Containing not more than the maximum allowable quantity per control area of Class IA, IB, or IC flammable liquids.
i. The maximum allowable quantity shall not apply to fuel oil storage complying with Section 603.3.2 of the International Fire
Code.
j. Quantities in parentheses indicate quantity units in parentheses at the head of each column.
k. A maximum quantity of 200 pounds of solid or 20 gallons of liquid Class 3 oxidizers is allowed when such materials are
necessary for maintenance purposes, operation, or sanitation of equipment. Storage containers and the manner of storage shall
be approved.
l. Net weight of the pyrotechnic composition of the fireworks. Where the net weight of the pyrotechnic composition of the
fireworks is not known, 25% of the gross weight of the fireworks, including packaging, shall be used.
m. For gallons of liquids, divide the amount in pounds by 10 in accordance with Section 5003.1.2 of the International Fire
Code.
n. For storage and display quantities in Group M and storage quantities in Group S occupancies complying with Section 414.2.5,
see Tables 414.2.5(1) and 414.2.5(2).
o. Densely packed baled cotton that complies with the packing requirements of ISO 8115 shall not be included in this material
class.
p. The following shall not be included in determining the maximum allowable quantities:
1. Liquid or gaseous fuel in fuel tanks on vehicles
2. Liquid or gaseous fuel in fuel tanks on motorized equipment operated in accordance with this code
3. Gaseous fuels in piping systems and fixed appliances regulated by the International Fuel Gas Code
4. Liquid fuels in piping systems and fixed appliances regulated by the International Mechanical Code
q. Where manufactured, generated, or used in such a manner that the concentration and conditions create a fire or explosion
hazard based on information prepared in accordance with Section 414.1.3.

Source: 2012 International Building Code, Country Club Hills, Illinois: International Code Council.
All footnote references are to the IBC.

©2020 NCEES 496

©2020 NCEES IBC Table 3
Maximum Allowable Quantity Per Control Area of

Liquefied (150)h Storaged

Material Solid Pounds Liquid Gallons Gas So

Corrosive (Cubic Feet) (Pounds)e,f (Cubic Feet at NTP)e Pou
Highly toxic
Toxic 5000 500 Gaseous 810f 50
Liquefied (150)h

10 (10)h Gaseous 20g 1
Liquefied (4)g,h

500 (500)h Gaseous 810f 50
Liquefied (150)f,h

497 For SI: 1 cubic foot = 0.028 m3, 1 pou

a. For use of control areas, see Section 414.2.
b. In retail and wholesale occupancies, the quantities of medicines, food

not more than 50% by volume of water-miscible liquids—with the rem
provided that such materials are packaged in individual containers no
c. For storage and display quantities in Group M and storage quantities i
414.2.5(1) and 414.2.5(2).
d. The aggregate quantity in use and storage shall not exceed the quantit
e. Maximum allowable quantities shall be increased 100% in buildings e
accordance with Section 903.3.1.1. Where Note f below also applies,
f. Maximum allowable quantities shall be increased 100% when stored
specified in the International Fire Code. Where Note e above also ap
g. Allowed only when stored in approved exhausted gas cabinets or exha
h. Quantities in parentheses indicate quantity units in parentheses at the
i. For gallons of liquids, divide the amount in pounds by 10 in accordan

Source: 2012 International Building Code, Country Club Hills, Illinois

307.1 (2)
Hazardous Material Posing a Health Hazarda,b,c,i

Used in Closed Systemsd Used in Open Systemsd

olid Liquid Gallons Gas Solid Liquid Gallons

undse (Pounds)e (Cubic Feet at NTP)e Poundse (Pounds)e

000 500 Gaseous 810f 1000 100
Liquefied (150)h

10 (10)i Gaseous 20g 3 (3)i
Liquefied (4)g,h

00 (500)i Gaseous 810f 125 (125)
Liquefied (150)f,h

und = 0.454 kg, 1 gallon = 3.785 L Chapter 8: Plant Design and Operations

dstuffs, consumer or industrial products, and cosmetics containing
mainder of the solutions not being flammable—shall not be limited,
ot exceeding 1.3 gallons.
in Group S, occupancies complying with Section 414.2.5, see Tables

ty listed for storage.
equipped throughout with an approved automatic sprinkler system in
the increase for both notes shall be applied accumulatively.
in approved storage cabinets, gas cabinets, or exhausted enclosures as
pplies, the increase for both notes shall be applied accumulatively.
austed enclosures as specified in the International Fire Code.
head of each column.
nce with Section 5003.1.2 of the International Fire Code.

s: International Code Council. All footnote references are to the IBC.

Chapter 8: Plant Design and Operations

International Building Code Area Classification Descriptions

Occupancy Description
Class

A Assembly Group A occupancy includes, among others, the use of a building or structure, or a portion thereof, for
the gathering of persons for purposes such as civic, social or religious functions; recreation, food or drink consump-
tion or awaiting transportation.

B Business Group B occupancy includes, among others, the use of a building or structure, or a portion thereof, for of-
fice, professional or service-type transactions, including storage of records and accounts. Business
occupancies shall include, but not be limited to, the following:

Airport traffic control towers
Ambulatory care facilities
Animal hospitals, kennels, and pounds
Banks
Barber and beauty shops
Car wash
Civic administration
Clinic, outpatient
Dry cleaning and laundries: pick-up and delivery stations and self-service
Educational occupancies for students above the 12th grade
Electronic data processing
Laboratories: testing and research
Motor vehicle showrooms
Post offices
Print shops
Professional services (architects, attorneys, dentists, physicians, engineers, etc.)
Radio and television stations
Telephone exchanges
Training and skill development not within a school or academic program

F Factory Industrial Group F occupancy includes, among others, the use of a building or structure, or a portion there-
of, for assembling, disassembling, fabricating, finishing, manufacturing, packaging, repair, or processing operations
that are not classified as a Group H hazardous or Group S storage occupancy.

©2020 NCEES 498

Chapter 8: Plant Design and Operations

International Building Code Area Classification Descriptions (cont'd)

Occupancy Description
Class

F-1 Factory Industrial uses which are not classified as Factory Industrial F-2 Low Hazard. Examples include:

Aircraft (manufacturing, not to include repair)
Appliances
Athletic equipment
Automobiles and other motor vehicles
Bakeries
Beverages over 16-percent alcohol content
Bicycles
Boats
Brooms or brushes
Business machines
Cameras and photo equipment
Canvas or similar fabric
Carpets and rugs (including cleaning)
Clothing
Construction and agricultural machinery
Disinfectants
Dry cleaning and dyeing
Electric generation plants
Electronics
Engines (including rebuilding)
Food processing and commercial kitchens not associated with restaurants, cafeterias and

similar dining facilities
Furniture
Hemp products
Jute products
Laundries
Leather products
Machinery
Metals
Millwork (sash and door)
Motion pictures and television filming (without spectators)
Musical instruments
Optical goods
Paper mills or products
Photographic film
Plastic products
Printing or publishing
Recreational vehicles
Refuse incineration
Shoes
Soaps and detergents
Textiles
Tobacco
Trailers
Wood: distillation
Woodworking (cabinet)
Upholstering

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Chapter 8: Plant Design and Operations

International Building Code Area Classification Descriptions (cont'd)

Occupancy Description
Class

F-2 Factory industrial uses that involve the fabrication or manufacturing of noncombustible materials which during
finishing, packing or processing do not involve a significant fire hazard. Examples include:

Beverages up to and including 16-percent alcohol content
Brick and masonry
Ceramic products
Foundries
Glass products
Gypsum
Ice
Metal products (fabrication and assembly)

H High-Hazard Group H occupancy includes, among others, the use of a building or structure, or a portion thereof,
that involves the manufacturing, processing, generation or storage of materials that constitute a physical or health
hazard in quantities in excess of those allowed in control areas complying with Section 414, based on the maxi-
mum allowable quantity limits for control areas set forth in Tables 307.1(1) and 307.1(2). Hazardous occupancies
are classified in Groups H-1, H-2, H-3, H-4 and H-5 and shall be in accordance with this section, with the require-
ments of Section 415 and the International Fire Code. Hazardous materials stored, or used on top of roofs or
canopies shall be classified as outdoor storage or use and shall comply with the International Fire Code.

H-1 Buildings and structures containing materials that pose a detonation hazard. Examples include: Deton-able pyro-
phoric materials, explosives, organic peroxides (unclassified detonable), Class 4 oxidizers, Class 3 detonable and
Class 4 unstable (reactive) materials.

H-2 Buildings and structures containing materials that pose a deflagration hazard or a hazard from accelerated burning.
Examples include:

Class I, II, or IIIA flammable or combustible liquids which are used or stored in normally open
containers or systems, or in closed containers or systems pressurized at more than 15 psi
(103.4 kPa) gauge

Combustible dusts where manufactured, generated or used in such a manner that the concentration and
conditions create a fire or explosion hazard based on information prepared in accordance
with Section 414.1.3

Cryogenic fluids, flammable
Flammable gases
Organic peroxides, Class I
Oxidizers, Class 3, that are used or stored in normally open containers or systems or in closed

containers or systems pressurized at more than 15 psi (103.4 kPa) gauge
Pyrophoric liquids, solids, and gases, nondetonable
Unstable (reactive) materials, Class 3, nondetonable
Water-reactive materials, Class 3

©2020 NCEES 500

Chapter 8: Plant Design and Operations

International Building Code Area Classification Descriptions (cont'd)

Occupancy Description
Class

H-3 Buildings and structures containing materials that readily support combustion or that pose a physical hazard. Ex-
amples include:

Class I, II, or IIIA flammable or combustible liquids that are used or stored in normally closed
containers or systems pressurized at 15 pounds psi (103.4 kPa) gauge or less

Combustible fibers, other than densely packed baled cotton
Consumer fireworks, 1.4G (Class C, Common)
Cryogenic fluids, oxidizing
Flammable solids
Organic peroxides, Class II and III
Oxidizers, Class 2
Oxidizers, Class 3, that are used or stored in normally closed containers or systems pressurized

at 15 pounds psi (103.4 kPa) gauge or less
Oxidizing gases
Unstable (reactive) materials, Class 2
Water-reactive materials, Class 2

H-4 Buildings and structures that contain materials that are health hazards. Examples include:

Corrosives
Highly toxic materials
Toxic materials

H-5 Semiconductor fabrication facilities and comparable research and development areas in which hazardous produc-
tion materials (HPM) are used and the aggregate quantity of materials is in excess of those listed in Tables 307.1(1)
and 307.1(2).

I Institutional Group I occupancy includes, among others, the use of a building or structure, or a portion thereof, in
which care or supervision is provided to persons who are or are not capable of self-preservation without physical
assistance or in which persons are detained for penal or correctional purposes or in which the liberty of the occu-
pants is restricted.

M Mercantile Group M occupancy includes, among others, the use of a building or structure, or a portion thereof, for
the display and sale of merchandise and involves stocks of goods, wares, or merchandise incidental to such purpos-
es and accessible to the public. Mercantile occupancy shall include, but not be limited to, the following:

Department stores
Drug stores
Markets
Motor fuel-dispensing facilities
Retail or wholesale stores
Sales rooms

R Residential Group R includes among others, the use of a building or structure, or a portion thereof, for sleeping pur-
poses when not classified as an Institution Group I or when not regulated by the International Residential Code.

S Storage Group S occupancy includes among others, the use of a building or structure, or a portion thereof, for stor-
age that is not classified as a hazardous occupancy.

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Chapter 8: Plant Design and Operations

International Building Code Area Classification Descriptions (cont'd)

Occupancy Description
Class

S-1 Moderate hazard Storage Group S-1. Buildings occupied for storage uses that are not classifies as Group S-2, in-
cluding, but not limited to, storage of the following:

Aerosols, levels 2 and 3
Aircraft hangars (storage and repair)
Bags: cloth, burlap and paper
Bamboos and rattan
Baskets
Belting: canvas and leather
Books and paper in rolls or packs
Boots and shoes
Buttons, including cloth covered, pearl or bone
Cardboard and cardboard boxes
Clothing, woolen wearing apparel
Cordage
Dry boats (indoor)
Furniture
Furs
Glues, mucilage, pastes and size
Grains
Horns and combs, other than celluloid
Leather
Linoleum
Lumber
Motor vehicle repair garages complying with the maximum allowable quantities of hazardous

materials listed in Table 307.1(1) (see Section 406.8)
Photo engravings
Resilient flooring
Silks
Soaps
Sugar
Tires, bulk storage of
Tobacco, cigars, cigarettes and snuff
Upholstery and mattresses
Wax candles

©2020 NCEES 502

Chapter 8: Plant Design and Operations

International Building Code Area Classification Descriptions (cont'd)

Occupancy Description
Class

S-2 Low-hazard storage, Group S-2. Includes among others, buildings used for the storage of noncombustible materials
such as products on wood pallets or in paper cartons with or without single thickness divisions; or in paper wrap-
pings. Such products are permitted to have a negligible amount of plastic trim such as knobs, handles or film wrap-
ping. Group S-2 storage shall include, but not be limited to, storage of the following:

Asbestos
Beverages up to and including 16-percent alcohol in metal, glass or ceramic containers
Cement in bags
Chalk and crayons
Dairy products in nonwaxed coated paper containers
Dry cell batteries
Electrical coils
Electrical motors
Empty cans
Food products
Foods in noncombustible containers
Fresh fruits and vegetables in nonplastic trays or containers
Frozen foods
Glass
Glass bottles, empty or filled with noncombustible liquids
Gypsum board
Inert pigments
Ivory
Meats
Metal cabinets
Metal desks with plastic tops and trim
Metal parts
Metals
Mirrors
Oil-filled and other types of distribution transformers
Parking garages, open or enclosed
Porcelain and pottery
Stoves
Talc and soapstones
Washers and dryers

©2020 NCEES 503

Chapter 8: Plant Design and Operations

International Building Code Area Classification Descriptions (cont'd)

Occupancy Description
Class

U General. Buildings and structures of an accessory character and miscellaneous structures not classified in any
specific occupancy shall be constructed, equipped and maintained to conform to the requirements of this code com-
mensurate with the fire and life hazard incidental to their occupancy. Group U shall include, but not be limited to,
the following:

Agricultural buildings
Aircraft hangars, accessory to a one- or two-family residence (see Section 412.5)
Barns
Carports
Fences more than 6 feet (1829 mm) in height
Grain silos, accessory to a residential occupancy
Greenhouses
Livestock shelters
Private garages
Retaining wall
Sheds
Stables
Tanks
Towers

Source: 2012 International Building Code, Country Club Hills, Illinois: International Code Council.

8.5.3.4 Area Separation Requirements

Required Separation of Occupancies (Hours)

Occupancy A, E I-1, I-3, I-4 I-2 R F-2, B, F-1, H-1 H-2 H-3, H-4 H-5
S-2b, U M, S-1
A, E S NS S NS S NS
I-1, I-3, I-4 S NS S NS S NS S NS S NS S NS S NS 34 23 2 NP
NN 1 2 3 NP 2 NP 2 NP
I-2 —— N N 2 NP 1 2 N 1 1 2 NP NP 3 NP 2 NP 2 NP
R ——— — 3 NP 2 NP 2 NP
F-2, S-2b, U ——— — 2 NP 1 NP 1 2 1 2 NP NP 34 23 2 NP
B, F-1, M, ——— —
S-1 N N 2 NP 2 NP 2 NP NP NP 23 12 1 NP
H-1
H-2 — — N N 1 2 1 2 NP NP NP NP NP NP NP NP
H-3, H-4 N NP 1 NP 1 NP
H-5 — — — — N N 1 2 NP NP —— 1d NP 1 NP
—— —— N NP
——— — — — — — — — N N NP NP

——— — — — — — — — — — N NP
——— — ———————— — —
——— — ———————— — —
——— — ———————— — —

S = Buildings equipped throughout with an automatic sprinkler system installed in accordance with Section 903.3.1.1
NS = Buildings not equipped throughout with an automatic sprinkler system installed in accordance with Section 903.3.1.1
N = No separation requirement
NP = Not permitted

a. See Section 420.
b. The required separation from areas used only for private or pleasure vehicles shall be reduced by 1 hour but to not less than 1 hour.
c. See Section 406.3.4.
d. Separation is not required between occupancies of the same classification.

Source: 2012 International Building Code, Country Club Hills, Illinois: International Code Council. All footnote references are to the IBC.

©2020 NCEES 504

Chapter 8: Plant Design and Operations

8.5.3.5 Wind Direction

Prevailing winds should be considered in both plant siting and layout:

a. For siting, it is undesirable to locate a plant where prevailing winds would carry any fugitive emissions into nearby residen-
tial areas.

b. In laying out a plant, safety considerations dictate that process units be located such that:
1. Prevailing winds would not carry potentially flammable releases to an area of the plant where there could be a
source of ignition.

2. Prevailing winds would not carry potentially hazardous or toxic releases to an area of the plant where workers are in
enclosed areas, e.g., offices, control rooms, or enclosed process buildings.

8.5.3.6 Designs for Preventing Fires and Explosions

Designs for Fire- and Explosion-Prevention

Feature Explanation

Maintenance programs The best way to prevent fires and explosions is to stop the release of flamm­ able materials.
Preventive maintenance programs are designed to upgrade systems before failures occur.

Fireproofing Insulate vessels, pipes, and structures to minimize damage resulting from fires. Add deluge systems
and design to withstand some damage from fires and explosions, e.g., use multiple deluge systems
with separate shutoffs.

Control rooms Design control rooms to withstand explosions.

Water supplies Provide supply for maximum demand. Consider many deluge systems runn­ ing simultaneously.
Diesel-engine pumps are recommended.

Control valves for deluge Place shutoffs well away from process areas.

Manual fire protection Install hydrants, monitors, and deluge systems. Add good drainage.

Separate units Separate (space) plants on a site, and separate units within plants. Provide access from two sides.

Utilities Design steam, water, electricity, and air supplies to be available during emergencies. Place
substations away from process areas.

Personnel areas Locate personnel areas away from hazardous process and storage areas.

Group units Group units in rows. Design for safe operation and maintenance. Create islands of risk by
concentrating hazardous process units in one area. Space units so hot work can be performed on one
group while another is operating.

Isolation valves Install isolation valves for safe shutdowns. Install in safe and accessible locations at edge of unit or
group.

Railroads and flares Process equipment should be separated from flares and railroads.

Compressors Place gas compressors downwind and separated from fired heaters.

Dikes Locate flammable storage vessels at edge of unit. Dike vessels to cont­ain and carry away spills.

Block valves Place automated block valves to stop and/or control flows duri­ng emergencies. Consider the ability
to transfer hazardous materials from one area to another.

Online analyzers Add appropriate online analyzers to (1) monitor the status of the process, (2) detect problems at their
incipient stage, and (3) take appropriate action to minimize effects of problems while still in initial
phase of development.

Fail-safe designs Design all controls to fail safely. Add safeguards for automated and safe shutdowns during
emergencies.

Safety-instrumented Use SIS to automatically bring process to a safe state upon detection of potentially hazardous
systems (SIS) conditions.

Source: Davenport, John A., "Prevent Vapor Cloud Explosions," Hydrocarbon Processing: 1977, pp. 205–214.

©2020 NCEES 505

Chapter 8: Plant Design and Operations

8.5.4 Economics

Abbreviation Nomenclature
A
BV Definition
C Uniform amount per interest period
Dj Book value
F Cost, present worth
G Depreciation in year j
i Future worth, value, or amount
m Uniform gradient amount per interest period
n Interest rate per interest period
P Number of compounding periods per interest period
r Number of interest periods, or the expected life of an asset
Sn Present worth, value, or amount
Nominal annual interest rate
e Expected salvage value in year n
j
n Subscripts
Effective
At time j
At time n

8.5.4.1 Cost Estimation and Project Evaluations

Basic Equations

Factor Name Converts Symbol Formula
Single payment compound amount
Single payment present worth to F given P (F/P, i%, n) F = P (1 + i)n
Uniform series sinking fund
to P given F (P/F, i%, n) P = F (1 + i)-n

to A given F (A/F, i%, n) A = Fe (1 + i n − 1 o
i)

Capital recovery to A given P (A/P, i%, n) A = Pf i (1 + i)n p
Uniform series compound amount to F given A (F/A, i%, n) (1 + i)n − 1
Uniform series present worth to P given A (P/A, i%, n)
F = Ae (1 + i) n − 1 o
i

P = Af (1 + i)n − 1 p
i (1 + i)n

Uniform gradient present worth to P given G (P/G, i%, n) P = Gf (1 + i)n − 1 − i (1 n i) n p
i 2 (1 + i)n +

Uniform gradient* future worth to F given G (F/G, i%, n) F = Gf (1 + i) n − 1 − n p
to A given G (A/G, i%, n) i2 i
to ie given r, m
Uniform gradient uniform series A = G e 1i − (1 + n − 1 o
i) n

Interest rate ie = c1 + r m − 1
m
m

Book value BV = initial cost − RD j

* F = F − n = F # A
G A A G
i

©2020 NCEES 506

Chapter 8: Plant Design and Operations

Depreciation Methods

Method Description Formula Stipulations

Annual d = V − Vs where d = annual depreciation, in $ per year
depreciation cost n V = original value of the property at
start the service-life period,
Straight line Book value Va = V − ad completely installed and ready
for use, in $
Declining balance (or Fixed percentage 1 Vs = salvage value of property at end
fixed percentage) factor (f) dVVs n of service life, in $
Book value f = 1 − n = service life, in years
Sinking fund Uniform annual n Va = asset or book value
depreciation cost a = number of years in actual use
Modified (R) Va = V`1 − f ja i = annual interest rate expressed as
Accelerated Cost Book value a fraction
Recovery System R = `V − Vs j _1 + i − 1 R = uniform annual payments made
MACRS iin at end of each year (annual
depreciation cost), in $
Va = V − `V − Vsj _1 + iia − 1 V – Vs = total amount of the annuity
_1 + iin − 1 accumulated in an estimated
service life of n years (original
value of property minus salvage
value at end of service life), in $

Dj = (factor) C factor—see table

Source: Peters, Max S., and Klaus D. Timmerhaus, Plant Design and Economics for Chemical Engineers, 4th ed.,
New York: McGraw-Hill, Inc., 1991, pp. 278, 280, 283, and 284.

MACRS FACTORS

Recovery Period (Years)

Year 35 7 10

1 Recovery Rate (Percent) 10.00
2 18.00
3 33.33 20.00 14.29 14.40
4 11.52
5 44.45 32.00 24.49 9.22
6 7.37
7 14.81 19.20 17.49 6.55
8 6.55
9 7.41 11.52 12.49 6.56
10 6.55
11 11.52 8.93 3.28

5.76 8.92

8.93

4.46

©2020 NCEES 507

Chapter 8: Plant Design and Operations

8.5.4.2 Cost Indicies

Cost indices are used to update historical cost data to the present. If a purchase cost is available for an item of equipment in year
M, the equivalent current cost can be found using:

Current $ = (Cost in year M)d Current Index n
Index in year M

Cost Index

Year Equipment Index Labor Index Material Index
100
0 341 100 106
112
1 344 107 113
120
2 352 116 127
139
3 360 128 161
174
4 368 139 188
205
5 383 147 228
241
6 401 155 248
251
7 421 164 255

8 432 176

9 444 187

10 503 197

11 552 210

12 579 218

13 514 223

14 554 231

15 569 236

8.5.4.3 Scaling Equipment Costs

The cost of Unit A at one capacity related to the cost of a similar Unit B with X times the capacity of Unit A is

approximately X n times the cost of Unit B, or: n
o
Cost of Unit A = Cost of Unit Be Capacity of Unit A
Capacity of Unit B

Typical Scaling Factors (n) for Equipment Cost vs. Capacity

Equipment Size Range Exponent
0.50
Agitator, propeller 0.30
0.50
Agitator, turbine 0.72
1.72
Boiler, industrial, all sizes 1.00
0.65
Boiler, package 0.77
0.76
Centrifuge, horizontal basket 0.87

Centrifuge, solid bowl 0.69

Conveyor, belt

Conveyor, bucket

Conveyor, screw

Conveyor, vibrating

Compressor, reciprocating, air-cooled, two-stage, 150 psig discharge 10 to 400 ft3
min

©2020 NCEES 508

Chapter 8: Plant Design and Operations

Typical Scaling Factors (n) for Equipment Cost vs. Capacity (cont'd)

Equipment Size Range Exponent

Compressor, rotary, single-stage, sliding vane, 150 psig discharge 100 to 1000 ft3 0.79
min
0.65
Crystallizer, growth 10 to 102 ft2 0.55
Crystallizer, forced circulation 10 to 102 ft2 0.70
Crystallizer, batch 0.76
Dryer, drum, single vacuum 0.40
Dryer, drum, single atmospheric 0.80
0.68
Dust collector, cyclone
0.75
Dust collector, cloth filter
0.70
Dust collector, precipitator
0.53
Evaporator, forced circulation
0.44
Evaporator, vertical and horizontal tube
1.17
Fan, centrifugal 103 to 104 ft3
min 0.58
Fan, centrifugal 0.55
2 x 104 to 7 x 104 ft3 0.60
Filter, plate and press min 0.44
Filter, pressure leaf 0.65
Heat exchanger, shell and tube, floating head, carbon steel 100 to 400 ft2 0.85
Heat exchanger, shell and tube, fixed sheet, carbon steel 100 to 400 ft2 0.69
Mill, ball and roller 0.99
Mill, hammer 5 to 10 hp 0.67
Motor, squirrel cage, induction, 440 volts, explosion proof 20 to 200 hp 0.70
Motor, squirrel cage, induction, 440 volts, explosion proof 0.34
Pump, centrifugal, carbon steel 2 to 100 gpm 0.56
Pump, centrifugal, stainless steel 100 to 1000 gal 0.60
Pump, reciprocating, cast iron, horizontal, including motor 0.50
Reactor, stainless steel, 300 psi 3- to 10-ft diameter 0.68
Tanks and vessels, pressure, carbon steel 3- to 10-ft diameter 1.20
Tanks and vessels, horizontal, carbon steel 0.86
Tanks and vessels, stainless steel
Tray, bubble cap, carbon steel
Tray, sieve, carbon steel

Source: Guthrie, K.M., "Data and Techniques for Preliminary Capital Cost Estimating," Chemical Engineering,
New York: Chemical Engineering, 1969.

©2020 NCEES 509

Chapter 8: Plant Design and Operations

8.5.4.4 Return on Investment (ROI)

Return on Investment

ROI r=ate of return (after taxes) net income per year
total investment

Payout

Payout period (years) = total plant investment less working capital
cash flow

where

cash flow = net yearly income after taxes plus depreciation

Taxation

Income taxes are paid at a specific rate on taxable income. Taxable income is total income less depreciation and ordinary expens-
es. Expenses do not include capital items, which should be depreciated.

Inflation
To account for inflation, the dollars are deflated by the general inflation rate per interest period f, and then they are shifted over
the time scale using the interest rate per interest period i. Use an inflation adjusted interest rate per interest period d for computing
present worth values P.

The formula for d is d = i + f + (i × f)

Capitalized costs

Capitalized costs are present worth values using an assumed perpetual period of time.

Capitalized Costs = P= A
i

Bonds

Bond value equals the present worth of the payments the purchaser (or holder of the bond) receives during the life of the bond at
some interest rate i.

Bond yield equals the computed interest rate of the bond value when compared with the bond cost.

Rate-of-return

The minimum acceptable rate-of-return (MARR) is that interest rate that one is willing to accept, or the rate one desires to earn on
investments. The rate-of-return on an investment is the interest rate that makes the benefits and costs equal.

Benefit-cost analysis
In a benefit-cost analysis, the benefits B of a project should exceed the estimated costs C.

B – C ≥ 0, or B/C ≥ 1

©2020 NCEES 510

©2020 NCEES 8.6 Materials of Construction

8.6.1 Material Selection

8.6.1.1 Thermoplastics

PP Typical Thermop

Property Unit Homo- Copolymer PVC CPVC
polymer H
po
Density g
cm3 0.91 0.88–0.91 1.38 1.5 1.7
— — 16
Melting point °C 160–175 150–175 — — 32

(crystalline) °F 320–347 302–347 Physical P
6.0–7.5 — 4
Break strength; kpsi 4.5–6.0 4.0–5.3
ASTM D 638 ——
— — 16
511 Modulus flex MPa 1135–1550 345–1035
@ 73oF; kpsi 165–225 50–150 — —5
Thermal P
ASTM D 790
57 — 13
Yield strength; kpsi 4.5–5.4 1.6–4.0 135 — 27
ASTM D 638
4.4 3.9 7.
HTD at 0.46 °C 107–121 75–89
MPa (66 psi); °F 225–250 167–192 — — 0.1
ASTM D 648
10 7–9.5 — — 1.1
Linear coeffi- in. # 10 -5
cient of expan- in. -cC 0.1 0.16
sion; ASTM D 0.7 1.1
696

Conductivity; W
ASTM C 177 m -K
Btu
ft2-hr-icnF.

Source: Republished with permission of McGraw-Hill, Inc., from Perry
8th ed., New York, 2008; permission conv

plastic Properties

PVDF ECTFE ETFE FEP TFE PFA

Homo- Copolymer 2.2–2.3 2.12–2.17
olymer 327 310
621 590
75–1.79 1.76–1.79 1.68 1.70 2.12–2.17
2.0–2.7 4.0–4.5
60–170 141–160 220–245 270 275 — — Chapter 8: Plant Design and Operations
20–340 285–320 460 518 527 120
Properties 190–235

4.5–7.0 3.5–6.0 6.6–7.8 6.5 2.7–3.1

— — — — —
65–325 90–180 180–260 200 80–95

5.0–8.0 2.9–5.5 — 7.1 — — —

Properties

32–150 93–110 90 104 70 221 75

70–300 200–230 194 220 158 250 166

.2–14.4 14.0 8 6 8–11 10 12

17–0.19 0.16 —— — — —

18–1.32 1.11 —— — — —

y's Chemical Engineers' Handbook, Robert H. Perry and Don W. Green,
veyed by Copyright Clearance Center, Inc.

Chapter 8: Plant Design and Operations

8.6.1.2 Gasket Materials

Important Properties of Gasket Materials*

Material Max Service Important Properties
Rubber (straight): Temp °F

Natural Good mechanical properties. Impervious to water. Fair to good resistance to
225 acids, alkalies. Poor resistance to oils, gasoline. Poor weathering, aging prop-
Styrene-butadiene (SBR)
erties.
Butyl
250 Better water resistance than natural rubber. Fair to good resistance to acids,
Nitrile alkalies. Unsuitable with gasoline, oils, and solvents.

Polysulfide 300 Very good resistance to water, alkalies, many acids. Poor resistance to oils,
gasoline, most solvents (except oxygenated).
Neoprene
300 Very good resistance to water. Excellent resistance to oils, gasoline. Fair to
Silicone good resistance to acids, alkalies.

Acrylic Excellent resistance to oils, gasoline, aliphatic, and aromatic hydrocarbon
150 solvents. Very good resistance to water. Good resistance to alkalies. Fair acid
Chlorosulfonated polyethylene
(Hypalon) resistance. Poor mechanical properties.
Floroelastomer (Viton,
Fluorel 2141, Kel-F) Excellent mechanical properties. Good resistance to nonaromatic petroleum,
Asbestos: 250 fatty oils, solvents (except aromatic, chlorinated, or

Compressed asbestos-rub- ketone types). Good water and alkali resistance. Fair acid resistance.
ber sheet
Asbestos-rubber woven Excellent heat resistance. Fair water resistance. Poor resistance to steam at
sheet 600 high pressures. Fair to good acid, alkali resistance. Poor (except fluorosilicone
Asbestos-rubber (beater
addition process) rubber) resistance to oils, solvents.
Asbestos composites
Asbestos-TFE 450 Good heat resistance but poor cold resistance. Good resistance to oils, aliphat-
ic and aromatic hydrocarbons. Poor resistance to water, alkalies, some acids.
Cork compositions
Excellent resistance to oxidizing chemicals, ozone, weathering. Relatively
250 good resistance to oils, grease. Poor resistance to aromatic or chlorinated

hydrocarbons. Good mechanical properties.

450 Can be used at high temperatures with many fuels, lubricants, hydraulic fluids,
solvents. Highly resistant to ozone, weathering. Good mechanical properties.

To 700 Large number of combinations available; properties vary widely depending on
To 250 materials used.

Same as above.

400 Same as above.
To 1000
To 500 Same as above.
Combines heat resistance and sealing properties of asbestos with chemical
250 resistance of TFE.
Low cost. Truly compressible materials that permit substantial deflections
with negligible side flow. Conform well to irregular surfaces. High resistance
to oils. Good resistance to water, many chemicals. Should not be used with
inorganic acids, alkalies, oxidizing solutions, live steam.

©2020 NCEES 512

Chapter 8: Plant Design and Operations

Important Properties of Gasket Materials* (cont'd)

Material Max Service Important Properties
Temp °F
Cork rubber
300 Controlled compressibility properties. Good conformability, fatigue resistance.
Plastics: Chemical resistance depends on kind of rubber used.

TFE (solid) (tetrafluoro- 500 Excellent resistance to almost all chemicals and solvents. Good heat resis-
ethylene, Teflon) tance; exceptionally good low-temperature properties. Relatively low com-
To 500 pressibility and resilience.
TFE (filled) To 500
Selectively improved mechanical and physical properties. However, fillers
TFE composite 350 may lower resistance to specific chemicals.
212
CFE (chlorotrifluoro- 150 Chemical and heat resistance comparable with solid TFE. Inner gasket mate-
ethylene, Kel-F) rial provides better resiliency and deformability.

Vinyl Higher cost than TFE. Better chemical resistance than most other gasket mate-
rials, although not quite as good as TFE.
Polyethylene
Plant fiber: Good compressibility, resiliency. Resistant to water, oils, gasoline, and many
acids and alkalies. Relatively narrow temperature range.
Neoprene-impregnated
wood fiber Resists most solvents. Poor heat resistance.
SBR-bonded cotton
Nitrile rubber-cellulose 175 Nonporous; recommended for glycol, oil, and gasoline to 175°F.
fiber 230
Vegetable fiber, glue binder Good water resistance.
212
Vulcanized fiber Resists oil at high temperatures.
To 2200
Inorganic fibers Resists oil and water to 212°F.
Felt: Low cost. Good mechanical properties. Resists gasoline, oils, greases, waxes,
many solvents.
Pure felt Excellent heat resistance. Poor mechanical properties.

TFE-impregnated Resilient, compressible, and strong, but not impermeable. Resists medium-
Petrolatum- or paraffin- strength mineral acids and dilute mineral solutions if not intermittently dried.
impregnated Resists oils, greases, waxes, most solvents. Damaged by alkalies.
300 Good chemical and heat resistance.
Rubber-impregnated
High water repellency.

Many combinations available; properties vary widely depending on
materials used.

©2020 NCEES 513

Chapter 8: Plant Design and Operations

Important Properties of Gasket Materials* (cont'd)

Material Max Service Important Properties
Metal: Temp °F

Lead 500 Good chemical resistance. Best conformability of metal gaskets.
Tin 800 Good resistance to neutral solutions. Attacked by acids and alkalies.
Aluminum 1400 High corrosion resistance. Slightly attacked by strong acids and alkalies.
Copper, brass 1500 Good corrosion resistance at moderate temperatures.
Nickel 2000 High corrosion resistance.
Monel High corrosion resistance. Good against most acids and alkalies, but attacked
Inconel 220 by strong hydrochloric and strong oxidizing acids.
Stainless steel Excellent heat, oxidation resistance.
Metal composites High corrosion resistance. Properties depend on type used.
Many combinations available; properties vary widely depending on materials
Leather used.
Low cost. Limited chemical and heat resistance. Not recommended against
Glass fabric pressurized steam, acid, or alkali solutions.
High strength and heat resistance. Can be impregnated with TFE for high
Material chemical resistance.

Rubber (straight) Important Properties of Packing and Sealing Materials
Rubber composites:
Max Service Important Properties
Cotton-reinforced Temp °F
Asbestos-reinforced
Asbestos: 600 See Gasket Materials for properties. Mainly used for ring-type seals, although
Plain, braided asbestos some types are available as spiral packings.

Impregnated asbestos 350 High strength. Chemical resistance depends on type of rubber used; however,
most types are noted for high resistance to water, aqueous solutions.
Asbestos composites
450 High strength combined with good heat resistance.

500 Heat resistance combined with resistance to water, brine, oil, many chemicals.
To 750 Can be reinforced with wire.
To 1200
Environmental properties vary widely depending on type of asbestos and
impregnant used. Neoprene-cemented type resists hot oils, gasoline, and sol-
vents. Oil-and-wax-impregnated type resists caustics. Wax-impregnated blue
asbestos type has high acid resistance. TFE-impregnated has good all-around
chemical resistance.

End properties vary widely depending on secondary material used.

©2020 NCEES 514

Chapter 8: Plant Design and Operations

Important Properties of Packing and Sealing Materials

Material Max Service Important Properties
Temp °F

Metals:

Copper To 1500 Properties depend on other construction materials and form of copper used.
Packing made of copper foil over asbestos core resists steam and alkalies to
Aluminum To 1000 1000°F. Packing of braided copper tinsel resists water, steam, and gases to
Lead 550 1500°F.
Organic fiber:
Flax Resists hot petroleum derivatives, gases, foodstuffs, many organic acids.
Jute
Ramie Many types are available.
Cotton
Rayon 300 Good water resistance.
Felt 300 Good water resistance.
300 Good resistance to water, brine, cold oil.
Leather 300 Good resistance to water, alcohol, dilute aqueous solutions.
300 Good resistance to water, dilute aqueous solutions.
TFE 300 See Gasket Materials.
Good mechanical properties for sealing. Resistant to alcohol, gasoline, many
Carbon graphite To 210 oils and solvents, synthetic hydraulic fluids, water.
Available in many forms, all of which have high chemical resistance.
To 500 Good bearing and self-lubricating properties. Good resistance to chemicals,
heat.
700

* From Materials in Engineering Design, New York: Reinhold, 1959, p. 11-126.

Source: Republished with permission of McGraw-Hill, Inc., from Perry's Chemical Engineers' Handbook,
R.H. Perry and D. Green, 6th ed., New York, 1984; permission conveyed by Copyright Clearance Center, Inc.

8.6.2 Corrosion

Corrosion is a natural process that converts a refined metal to a more stable form such as its oxide, hydroxide, or sulfide. It is the
gradual destruction of a material by chemical reaction with its environment. Corrosion effects must be taken into account during
the design of any system, unit, facility, or plant.

Use the following corrosion data charts to assist in narrowing the field of choice of materials. Once the choice has been narrowed,
the effects of contaminants, aeration, galvanic coupling, erosion, and so on must be taken into
account. Field testing is best for final suitability decisions.

Source: All corrosion data from Perry, John H., and D. Green, Perry's Chemical Engineers' Handbook, 6th ed.,
New York: McGraw-Hill, 1963, pp. 23-13 to 23-30.

©2020 NCEES 515

Chapter 8: Plant Design and Operations
Detailed Corrosion Data on Construction Materials

KEY TO CHARTSTEMPERATURE, °F

300 ACID,
ACETIC
200 ACID,
BORIC
100 ACID,
CHROMIC
0 ACID,
0 50 100 CITRIC
ACID,
CONCENTRATION, % FORMIC
ACID,
ALUMINUM HYDROCHLORIC
= < 0.005 IN. PER YR. ACID,
= 0.005 - 0.02 IN. PER YR. HYDROFLUORIC
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR. 500 F AIR FREE AIR FREE AIR FREE

ASPHALTIC RESINS AERATED CARBON-FILLED
= SATISFACTORY CEMENT
= SATISFACTORY FOR LIMITED USE
= UNSATISFACTORY 400 F NOTE SYMBOLS ON VERTICAL 450 F
HEAVY LINES REPRESENT 100%
COPPER, AL BRONZE, TIN BRONZE CONCENTRATION. SYMBOLS ON
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR. HORIZONTAL HEAVY LINES
= 0.02 - 0.05 IN. PER YR. REPRESENT 300 F. TEMPERATURE.
= > 0.05 IN. PER YR.
15,50000FF
EPOXY RESINS
= SATISFACTORY AERATED OR
= SATISFACTORY FOR LIMITED USE NON-AERATED
= UNSATISFACTORY
AERATED OR
FURANE RESINS AIR-FREE
= SATISFACTORY
= SATISFACTORY FOR LIMITED USE 12½ 25 37½
= UNSATISFACTORY 12½ 25 37½

GLASS
= < 0.005 IN. PER YR.
= 0.005 - 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

HASTELLOY B
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR..
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

HASTELLOY C
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

HASTELLOY D
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

©2020 NCEES 516

Chapter 8: Plant Design and Operations

Detailed Corrosion Data on Construction Materials (cont'd)

TEMPERATURE, °FKEY TO CHARTS

ACID,300
ACETIC
ACID,200
BORIC
ACID,100
CHROMIC
ACID,0
CITRIC0 50 100
ACID,
FORMICCONCENTRATION, %
ACID,
HYDROCHLORICIRON, CAST
ACID,= < 0.002 IN. PER YR.
HYDROFLUORIC= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR. AERATED AIR FREE AIR FREE AIR FREE AIR FREE
AERATED
MONEL HARD RUBBER AIR FREE AIR FREE AIR FREE AIR FREE
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR. HARD SOFT GR-S
= 0.02 - 0.05 IN. PER YR. RUBBER CANNOT BE USED
= > 0.05 IN. PER YR.
HARD RUBBER
NEOPRENE

= SATISFACTORY
= FOR LIMITED USE ONLY
= UNSATISFACTORY

NICKEL
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

PHENOLIC RESINS
= SATISFACTORY
= SATISFACTORY FOR LIMITED USE
= UNSATISFACTORY

POLYETHYLENE
= COMPLETE RESISTANCE
= SOME ATTACK
= ATTACK OR DECOMPOSITION

RUBBER (NATURAL, GR-S)

= SATISFACTORY
= SATISFACTORY FOR LIMITED USE
= GENERALLY UNSATISFACTORY

RUBBER, BUTYL

= SATISFACTORY
= SATISFACTORY FOR LIMITED USE
= GENERALLY UNSATISFACTORY

©2020 NCEES 517

Chapter 8: Plant Design and Operations

Detailed Corrosion Data on Construction Materials (cont'd)

KEY TO CHARTS

TEMPERATURE, °F

ACID,
ACETIC
ACID,
BORIC
ACID,
CHROMIC
ACID,
CITRIC
ACID,
FORMIC
ACID,
HYDROCHLORIC
ACID,
HYDROFLUORIC
300
STRESS CORROSION
200

100

0
0 50 100

CONCENTRATION, %

STAINLESS STEEL, 18-8
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

STAINLESS STEEL, TYPE 316
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

STAINLESS STEEL, 12% Cr
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

STAINLESS STEEL, 17% Cr
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

STEEL
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

STYRENE COPOLYMERS, HIGH IMPACT
= SATISFACTORY
= SATISFACTORY FOR LIMITED USE
= UNSATISFACTORY

ZIRCONIUM
= < 0.002 IN. PER YR.
= 0.002 - 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

©2020 NCEES 518

Chapter 8: Plant Design and Operations

Detailed Corrosion Data on Construction Materials (cont'd)

KEY TO CHARTS

TEMPERATURE, °F

ACID,
NITRIC
ACID,
OXALIC
ACID,
PHOSPHORIC
ACID,
SULFURIC
ALUMINUM
CHLORIDE
ALUMINUM
POTASSIUM
SULFATE (ALUM)
AMMONIA,
AQUEOUS
300
IN ETHANOL
200
AIR FREE AERATED AERATED, AIR FREE DRY
100 NO VELOCITY 600 F

0 IN ETHANOL
0 50 100
IN ETHANOL
CONCENTRATION, %
300 400 F
ALUMINUM 200
= < 0.005 IN. PER YR.
= 0.005 - 0.02 IN. PER YR. TECH
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR. NOT
RECOMMENDED
ASPHALTIC RESINS
= SATISFACTORY TECH
= SATISFACTORY FOR LIMITED SERVICE
= UNSATISFACTORY SLUDGE-
HCI AND
COPPER, AL BRONZE, TIN BRONZE 250 PSI
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

EPOXY RESINS
= SATISFACTORY
= SATISFACTORY FOR LIMITED USE
= NOT RECOMMENDED

FURANE RESINS
= SATISFACTORY
= SATISFACTORY FOR LIMITED USE
= UNSATISFACTORY

GLASS
= < 0.005 IN. PER YR.
= 0.005 - 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

HASTELLOY B
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

HASTELLOY C
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

HASTELLOY D
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

©2020 NCEES 519

Chapter 8: Plant Design and Operations

Detailed Corrosion Data on Construction Materials (cont'd)

KEY TO CHARTSTEMPERATURE, °F

300 ACID,
NITRIC
200 ACID,
OXALIC
100 ACID,
PHOSPHORIC
0 ACID,
0 50 100 SULFURIC
ALUMINUM
CONCENTRATION, % CHLORIDE
ALUMINUM
IRON, CAST POTASSIUM
= < 0.002 IN. PER YR. SULFATE (ALUM)
= < 0.02 IN. PER YR. AMMONIA,
= 0.02 - 0.05 IN. PER YR. AQUEOUS
= > 0.05 IN. PER YR.
AIR FREE AIR FREE, AIR FREE
MONEL NO VELOCITY
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR. AERATED,
= 0.02 - 0.05 IN. PER YR. NO VELOCITY
= > 0.05 IN. PER YR. AERATED

NEOPRENE AERATED AERATED,
= SATISFACTORY NO VELOCITY
= FOR LIMITED USE
= UNSATISFACTORY IN ETHANOL

NICKEL
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

PHENOLIC RESINS
= SATISFACTORY
= SATISFACTORY FOR LIMITED USE
= UNSATISFACTORY

POLYETHYLENE
= COMPLETE RESISTANCE
= SOME ATTACK
= ATTACK OR DECOMPOSITION

RUBBER (NATURAL, GR-S)
= SATISFACTORY
= SATISFACTORY FOR LIMITED SERVICE
= GENERALLY UNSATISFACTORY

RUBBER, BUTYL
= SATISFACTORY
= SATISFACTORY FOR LIMITED SERVICE
= GENERALLY UNSATISFACTORY

©2020 NCEES 520

Chapter 8: Plant Design and Operations

Detailed Corrosion Data on Construction Materials (cont'd)

KEY TO CHARTS

TEMPERATURE, °F

ACID,
NITRIC
ACID,
OXALIC
ACID,
PHOSPHORIC
ACID,
SULFURIC
ALUMINUM
CHLORIDE
ALUMINUM
POTASSIUM
SULFATE (ALUM)
AMMONIA,
AQUEOUS
300
AIR FREE, STRESS
200 NO VELOCITY CRACKS

100 IN ETHANOL

0
0 50 100

CONCENTRATION, %

STAINLESS STEEL, 18-8
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

STAINLESS STEEL, TYPE 316
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

STAINLESS STEEL, 12% Cr
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

STAINLESS STEEL, 17% Cr
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

STEEL
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

STYRENE COPOLYMERS, HIGH IMPACT
= SATISFACTORY
= SATISFACTORY FOR LIMITED USE
= UNSATISFACTORY

ZIRCONIUM
= < 0.002 IN. PER YR.
= 0.002 - 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

©2020 NCEES 521

TEMPERATURE, °F Chapter 8: Plant Design and Operations

AMMONIUMDetailed Corrosion Data on Construction Materials (cont'd)
CARBONATE
AMMONIUMKEY TO CHARTS
CHLORIDE
CALCIUM300
CHLORIDE
CALCIUM200
HYPOCHLORITE
100

0
0 50 100

CONCENTRATION, %

ALUMINUM
= < 0.005 IN. PER YR.
= 0.005 - 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

ASPHALTIC RESINS
= SATISFACTORY
= SATISFACTORY FOR LIMITED USE
= UNSATISFACTORY

COPPER, AL BRONZE, TIN BRONZE
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

EPOXY RESINS
= SATISFACTORY
= SATISFACTORY FOR LIMITED USE
= NOT RECOMMENDED

FURANE RESINS
= SATISFACTORY
= SATISFACTORY FOR LIMITED USE
= UNSATISFACTORY

GLASS
= < 0.005 IN. PER YR.
= 0.005 - 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

HASTELLOY B
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

HASTELLOY C
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

HASTELLOY D
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

©2020 NCEES 522

Chapter 8: Plant Design and Operations

Detailed Corrosion Data on Construction Materials (cont'd)

KEY TO CHARTSTEMPERATURE, °F

300 AMMONIUM
CARBONATE
200 AMMONIUM
CHLORIDE
100 CALCIUM
CHLORIDE
0 CALCIUM
0 50 100 HYPOCHLORITE

CONCENTRATION, % AVOID HCI
AND Fe, NI IONS
IRON, CAST
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

MONEL
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

NEOPRENE
= SATISFACTORY
= FOR LIMITED USE ONLY
= UNSATISFACTORY

NICKEL
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

PHENOLIC RESINS
= SATISFACTORY
= SATISFACTORY FOR LIMITED USE
= UNSATISFACTORY

POLYETHYLENE
= COMPLETE RESISTANCE
= SOME ATTACK
= ATTACK OR DECOMPOSITION

RUBBER (NATURAL, GR–S)
= SATISFACTORY
= SATISFACTORY FOR LIMITED SERVICE
= GENERALLY UNSATISFACTORY

RUBBER, BUTYL
= SATISFACTORY
= SATISFACTORY FOR LIMITED SERVICE
= GENERALLY UNSATISFACTORY

©2020 NCEES 523

Chapter 8: Plant Design and Operations
Detailed Corrosion Data on Construction Materials (cont'd)

TEMPERATURE, °FKEY TO CHARTS

AMMONIUM300
CARBONATE
AMMONIUM200
CHLORIDE
CALCIUM100
CHLORIDE
CALCIUM0
HYPOCHLORITE0 50 100

CONCENTRATION, % pH > 7 pH > 7

STAINLESS STEEL, 18-8
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

STAINLESS STEEL, TYPE 316
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

STAINLESS STEEL, 12% Cr
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

STAINLESS STEEL, 17% Cr
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

STEEL
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

STYRENE COPOLYMERS, HIGH IMPACT
= SATISFACTORY
= SATISFACTORY FOR LIMITED USE
= UNSATISFACTORY

ZIRCONIUM
= < 0.002 IN. PER YR.
= 0.002 - 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

©2020 NCEES 524

Chapter 8: Plant Design and Operations

Detailed Corrosion Data on Construction Materials (cont'd)

KEY TO CHARTSTEMPERATURE, °F

300 COPPER
SULFATE
200 ETHANOL
ETHYLENE
100 GLYCOL
FERRIC
0 CHLORIDE
0 50 100 FERROUS
CHLORIDE
CONCENTRATION, % FERROUS
SULFATE
ALUMINUM GLYCERINE
= < 0.005 IN. PER YR.
= 0.005 - 0.02 IN. PER YR. AIR FREE
= 0.02 - 0.05 IN. PER YR. 0.09% HCI
= > 0.05 IN. PER YR.

ASPHALTIC RESINS
= SATISFACTORY
= SATISFACTORY FOR LIMITED USE
= UNSATISFACTORY

COPPER, AL BRONZE, TIN BRONZE
= < 0.002 IN. PER YR.
= 0.002 - 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

EPOXY RESINS
= SATISFACTORY
= SATISFACTORY FOR LIMITED USE
= NOT RECOMMENDED

FURANE RESINS
= SATISFACTORY
= SATISFACTORY FOR LIMITED USE
= UNSATISFACTORY

GLASS
= < 0.005 IN. PER YR.
= 0.005 - 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

HASTELLOY B
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

HASTELLOY C
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

HASTELLOY D
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

©2020 NCEES 525

Chapter 8: Plant Design and Operations

Detailed Corrosion Data on Construction Materials (cont'd)

KEY TO CHARTSTEMPERATURE, °F

300 COPPER
SULFATE
200 ETHANOL
ETHYLENE
100 GLYCOL
FERROUS
0 CHLORIDE
0 50 100 FERROUS
SULFATE
CONCENTRATION, % FERRIC
CHLORIDE
IRON, CAST GLYCERINE
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR. PITS
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

MONEL
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

NEOPRENE
= SATISFACTORY
= FOR LIMITED USE ONLY
= UNSATISFACTORY

NICKEL
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

PHENOLIC RESINS
= SATISFACTORY
= SATISFACTORY FOR LIMITED USE
= UNSATISFACTORY

POLYETHYLENE
= COMPLETE RESISTANCE
= SOME ATTACK
= ATTACK OR DECOMPOSITION

RUBBER (NATURAL, GR–S)
= SATISFACTORY
= SATISFACTORY FOR LIMITED SERVICE
= GENERALLY UNSATISFACTORY

RUBBER, BUTYL
= SATISFACTORY
= SATISFACTORY FOR LIMITED SERVICE
= GENERALLY UNSATISFACTORY

©2020 NCEES 526

Chapter 8: Plant Design and Operations

Detailed Corrosion Data on Construction Materials (cont'd)

KEY TO CHARTS

TEMPERATURE, °F

COPPER
SULFATE
ETHANOL
ETHYLENE
GLYCOL
FERRIC
CHLORIDE
FERROUS
CHLORIDE
FERROUS
SULFATE
GLYCERINE
300
DRY DISCOLORS
200

100

0
0 50 100

CONCENTRATION, %

STAINLESS STEEL, 18-8
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

STAINLESS STEEL, TYPE 316
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

STAINLESS STEEL, 12% Cr
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

STAINLESS STEEL, 17% Cr
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

STEEL
= < 0.002 IN. PER YR.
= < 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

STYRENE COPOLYMERS, HIGH IMPACT
= SATISFACTORY
= SATISFACTORY FOR LIMITED USE
= UNSATISFACTORY

ZIRCONIUM
= < 0.002 IN. PER YR.
= 0.002 - 0.02 IN. PER YR.
= 0.02 - 0.05 IN. PER YR.
= > 0.05 IN. PER YR.

©2020 NCEES 527