Engineering Systems in a Food Plant

by Robberts; Theunis Christoffel

• ISBN13: 9781566769693
• ISBN10: 1566769698
• Format: Hardcover
• Copyright: 2002-06-13
• Publisher: CRC Press

Summary

Pumps. Boilers. Power transmission. Water treatment. Waste disposal. Efficient lighting. Maintain them, and you'll experience optimal performance. Ignore them, and the system will collapse. While many texts adequately describe the processing lines used in food manufacturing, none address the importance of the ancillary equipment that allows the plant to operate. Food Plant Engineering Systems fills this gap by focusing on these crucial but frequently forgotten parts of the system.With clear, easy-to-understand language, this book details the bits and pieces that keep systems running and explains how they fit within the bigger picture:· Properties of fluids· Pumps and piping· Electrical systems including motors, starters, electrical heating and lights· Steam generation and heating systems· Cooling and refrigeration systems· Water and waste and material handling systems· Food plant design, including site, foundations, floors, walls roofs, drains, and insulation· Safety and EPA regulationsGetting all the units to work together as a well-orchestrated system is what manufacturing design and management are all about. This book provides the first truly comprehensive look at food plant operation. Food Plant Engineering Systems ensures that all elements of the system are properly balanced to efficiently accomplish the job.

Table of Contents

Units and Dimensions
Introduction	1	(1)
History	1	(1)
Terms	2	(4)
Base Units	2	(1)
Definitions	3	(1)
Supplementary Units	4	(1)
Derived Units	5	(1)
Definitions	5	(1)
Dimensional Analysis	6	(2)
Units for Mechanical Systems	8	(3)
Conversions and Dimensional Analysis	11	(1)
Problems	12	(1)
General Calculations
Introduction	13	(1)
Basic Principles	13	(12)
Conservation of Mass	13	(1)
Mass Balances	13	(12)
Problems	25	(2)
Properties of Fluids
General Description	27	(1)
Physical Properties of Flow	27	(6)
Pressure	27	(1)
Density (P)	28	(1)
Specific Mass (w)	28	(1)
Specific Gravity (SG)	29	(1)
Bulk Modulus (k)	29	(1)
Ideal Fluid	29	(1)
Viscosity	29	(2)
Temperature Effects on Fluid Flow	31	(1)
Shear-Thinning Fluids	32	(1)
Bingham Plastics	32	(1)
Pseudoplastics	32	(1)
Shear-Thickening Materials	33	(1)
Surface Tension and Capillary Action	33	(2)
Vapor Pressure	34	(1)
Atmospheric Pressure	34	(1)
Hydrostatics	35	(2)
Pressure Intensity	35	(2)
Basic Concept of Fluid Motion	37	(2)
Introduction	37	(1)
Conservation of Mass	38	(1)
Types of Flow	39	(4)
Turbulent and Laminar Flow	39	(1)
Reynolds Number	40	(2)
Rotational and Nonrotational Flow	42	(1)
Steady and Unsteady Flow	42	(1)
Uniform and Nonuniform Flow	43	(1)
Conservation of Energy in Liquids	43	(7)
Potential Head	43	(1)
Pressure Head	43	(1)
Velocity Head	44	(1)
Energy Changes and Flow	44	(2)
Frictional Losses	46	(1)
Frictional Losses in Straight Pipes	46	(3)
Fittings in Pipes	49	(1)
Mechanical Energy Requirement	49	(1)
Problems	50	(1)
Pumps
Introduction	51	(1)
General Principles	51	(1)
Pump Efficiency	52	(1)
Centrifugal Pumps	53	(3)
Operation	54	(2)
Net Positive Suction Head	56	(1)
Suction Systems and Sump Design	56	(3)
Positive Displacement Pumps	59	(7)
Rotary Pumps	61	(1)
External Gear and Lobe Pumps	61	(1)
External Gear Pumps	61	(1)
Internal Gear Pumps	62	(1)
Lobe Pumps	63	(1)
Peristaltic Pump	63	(2)
Progressive Cavity Pump	65	(1)
Pipelines in the Industry	66	(4)
Piping Materials	66	(1)
Pipe Assembly	67	(1)
Stainless Steel Pipeline	67	(1)
Welding of Sanitary Pipe	67	(3)
Pipeline Construction	70	(1)
Problems	71	(2)
Thermodynamics
Introduction	73	(1)
Energy of a System	73	(1)
Characteristics of a System	73	(2)
Energy of a System	74	(1)
Gases and Vapors	75	(8)
Ideal Gas Equation	76	(1)
Pressure Expressions	77	(1)
The Perfect Gas Law	78	(2)
Mixtures of Gases	80	(3)
Problems	83	(2)
Electrical Systems
Introduction	85	(1)
Electricity Generation	85	(1)
Definitions	86	(1)
Energy Conversion	87	(1)
Electrical Energy	88	(1)
Electric Motors	88	(2)
Single-Phase Motors	88	(1)
Single-Phase Universal Motor	88	(1)
Single-Phase Split-Phase Motor	88	(1)
Single-Phase Capacitor Motor	89	(1)
Three-Phase Squirrel-Cage Induction Motors	89	(1)
Motor Management	90	(1)
Power Transmission	91	(3)
Flat Belts	91	(1)
V-Belts	92	(1)
Gears	93	(1)
Calculation of Shaft RPM	93	(1)
Management of Drive Systems	94	(1)
Control Equipment for Electrical Apparatus	94	(1)
Illumination of the Processing Facility	95	(4)
Light Intensity and Application	96	(1)
Types of Lamps	96	(3)
Heating Systems for Processing Plants
Heat Transfer	99	(1)
Conductive Heat Transfer	99	(6)
Resistance to Heat Flow	101	(2)
Heat Flow Through Cylindrical Walls	103	(1)
Steady-State Conduction through a Composite Cylinder	103	(2)
Convective Heat Transfer	105	(3)
Heat Transfer by Conduction and Convection	106	(2)
Heat Transfer by Radiation	108	(2)
Stefan's Law	108	(2)
Steam Heating	110	(1)
Energy	110	(1)
Specific Heat Capacity	110	(1)
Specific Latent Heat	111	(1)
Energy Associated with Steam	111	(1)
Heat Pressure Diagram for Water	111	(4)
Properties of Steam	113	(1)
Saturated Liquid	113	(1)
Saturated Vapor	113	(1)
Wet Steam	114	(1)
Superheated Steam	114	(1)
Steam Tables	115	(1)
Boiling Point of Water	116	(1)
Heating with Live Steam	116	(1)
Culinary Steam	116	(1)
Hot Water Systems	117	(2)
Energy Calculations for Water Heating	117	(2)
Piping	119	(1)
Expansion of Pipes	119	(1)
Problems	120	(3)
Steam Generation
Introduction	123	(1)
Boilers	123	(1)
Fire-Tube Boilers	123	(1)
Water-Tube Boilers	124	(1)
Boiler Efficiency	125	(3)
Fuel-to-Steam Efficiency	126	(1)
Combustion Efficiency	126	(1)
Thermal Efficiency	126	(1)
Stack Temperature	127	(1)
Radiation Loss	127	(1)
Boiler Blowdown	127	(1)
Water Treatment	128	(1)
Boiler Selection Criteria	128	(8)
Codes and Standards	129	(1)
Steam Pressure	129	(1)
System Load	129	(1)
Heating Load	130	(1)
Process Load	130	(1)
Combination Load	130	(1)
Load Variations	130	(1)
Load Tracking	131	(1)
Number of Boilers	131	(1)
Downtime Cost	132	(1)
Boiler Turndown	132	(1)
Fuels	132	(1)
Fuel Oil	132	(1)
Gaseous Fuels	133	(1)
Solid Fuels	134	(1)
Combustion of Solid Fuels	134	(1)
Stack Emissions	135	(1)
Nitrogen Oxides	135	(1)
Sulfur Oxides	135	(1)
Carbon Monoxide	135	(1)
Replacement Boilers	136	(1)
Boiler Fittings and Accessories	136	(4)
Pressure Gauge	136	(1)
Steam Pressure Regulating Valve	136	(1)
Steam Trap	137	(1)
Water Columns	137	(1)
Water Injection	138	(1)
Safety Valve	138	(1)
Fusible Plug	138	(2)
Steam Purity	140	(1)
Refrigeration and Freezing
Overview	141	(1)
Natural Refrigeration	142	(1)
Natural Refrigeration to Subzero Temperatures	143	(1)
Solid CO2	143	(1)
Mechanical Refrigeration	143	(10)
Capacity	145	(1)
Evaporating Coil	145	(1)
Removal of Oil	145	(1)
Expansion Valve	146	(1)
Back-Pressure Regulator	147	(1)
Compressors	148	(1)
The Condenser	148	(1)
Automatic Control	148	(1)
Refrigerants	149	(1)
Ammonia	150	(1)
Other Refrigerants	150	(1)
R-134a	150	(3)
R-407	153	(1)
R-32	153	(1)
R-125	153	(1)
Thermodynamics of Vapor Compression	153	(5)
Coefficient of Performance	155	(3)
Secondary Refrigeration	158	(4)
Congealing Tank System	158	(1)
Brine System	159	(3)
Management	162	(1)
Storage Rooms	163	(4)
Insulation	163	(1)
Prefabricated Polyurethane Panels for Cold Room Construction	164	(1)
Cold Room Doors and Devices	165	(1)
Management of Cold Rooms	165	(1)
Defrosting	166	(1)
Water and Waste Systems
Introduction	167	(1)
Water Quality	167	(1)
Potable Water	167	(4)
Water Safety	168	(1)
Health Concerns	168	(1)
Turbidity	169	(1)
Microbiological Concerns	169	(1)
Radioactive Materials	170	(1)
Aesthetic Concerns	170	(1)
Substances in Water	171	(2)
Hardness	171	(1)
Iron	172	(1)
Manganese	172	(1)
Nitrates	172	(1)
Chlorides and Sulfates	172	(1)
Gases	172	(1)
Silica	173	(1)
Treatment of Water Supplies	173	(5)
Treatment to Remove Turbidity	173	(1)
Softening Hard Water	174	(1)
Cold Lime Method	174	(1)
Ion Exchange	175	(1)
Base Exchange	175	(1)
Water Demineralizing	176	(1)
Filtering	177	(1)
Care of Filters and Ion Exchangers	177	(1)
Treatment of Boiler Feedwater	178	(1)
Deaeration	179	(1)
Wastewater Treatment	179	(2)
Water Conservation	180	(1)
Fluming Debris	181	(1)
Treatment Facilities	181	(1)
Aerated Lagoon	181	(1)
Trickling Filters	182	(1)
Activated Sludge	182	(1)
Anaerobic Treatment	182	(1)
Waste Disposal	182	(5)
Prevention of Waste	183	(1)
Solid Wastes	183	(1)
Waste Incineration	184	(1)
Controlled Incineration	184	(1)
Incinerator Emissions	185	(1)
Landfill	185	(1)
Landfill Methods	185	(1)
Public Health and Environment	186	(1)
Materials Handling
Importance of Materials Handling	187	(1)
Increasing Materials Handling Efficiency	188	(4)
Designing a Materials Handling System	189	(1)
Kinds of Systems	189	(1)
Analysis of a Materials Handling System	190	(2)
Materials Handling Equipment	192	(6)
Conveyors	192	(1)
Chutes	192	(2)
Roller Conveyors	194	(1)
Belt Conveyor	195	(1)
Slat Conveyors	195	(1)
Chain Conveyors	196	(1)
Vibratory Conveyors	196	(1)
Screw Conveyors	196	(1)
Bucket Elevator	196	(1)
Trucks	196	(1)
Pallets	197	(1)
Bulk Handling	197	(1)
Plant Layout for Materials Handling	198	(1)
Space Arrangements	198	(1)
Efficient Use of Materials Handling Equipment	199	(2)
Maintenance	199	(2)
Manufacturing Plant Design
Building Design	201	(1)
Legal Aspects	201	(1)
Building Bylaws	201	(1)
Sanitation Codes	201	(1)
OSHA	202	(1)
EPA	202	(1)
Expansion	202	(1)
Plant Location	203	(2)
Planning the Building on the Site	205	(1)
The Structure	206	(7)
Foundations	207	(1)
Supporting Structure	207	(1)
Walls	208	(1)
Floors	209	(1)
Slope of Floors	209	(1)
Kinds of Floors	209	(1)
Concrete	209	(1)
Metal Plate Floor	209	(1)
Monolithic Floor Surfaces	210	(1)
Tile or Paver Floors	210	(1)
Drains	211	(1)
Floor Drains	211	(1)
Gutter Drains	211	(1)
Windows	211	(1)
Doors	212	(1)
Piping	212	(1)
Electrical	212	(1)
Ventilation	213	(1)
Hand-Cleaning Stations	213	(1)
Facilities Layout	213	(1)
Summary	214	(1)
Safety
Workplace Safety	215	(1)
Causes of Accidents	215	(2)
Safety	217	(1)
Hazards in the Food Industry	217	(1)
Handling Materials	217	(1)
Accident Prevention	218	(2)
Color-Coding	218	(1)
Operating Instructions	218	(2)
Pressure Equipment	220	(1)
Grain Handling Equipment	220	(1)
Flammable Material	220	(1)
General Plant Safety	220	(1)
Inspection of Equipment	221	(1)
Power Drives	221	(1)
Fire Protection	221	(4)
Fire Fighting	224	(1)
Portable Extinguishers	225	(1)
Noise Control	225	(3)
Occupational Safety and Health Administration	228	(3)
Appendix 1: Conversion Tables	231	(8)
Appendix 2	239	(14)
A2.1 Some Help with Calculations	239	(1)
A2.2 The Plus/Minus Rule	239	(1)
A2.3 Fractions	239	(3)
A2.3.1 The Diagonal Rule	239	(1)
A2.3.2 Do On Both Sides Rule	240	(1)
A2.3.3 Adding Fractions	241	(1)
A2.3.4 Multiplying Fractions	242	(1)
A2.3.5 Dividing fractions	242	(1)
A2.4 Exponents	242	(3)
A2.5 Quadratic Equations	245	(1)
A2.5.1 Solution by Factorization	245	(1)
A2.5.2 Solution Using the Formula	245	(1)
A2.6 Simultaneous Equations	246	(2)
A2.7 Differentiation	248	(3)
A2.7.1 Rule 1	248	(1)
A2.7.1.1 Repeated Differentiation	249	(1)
A2.7.2 Rule 2	249	(1)
A2.7.3 Rule 3	249	(2)
A2.7.4 Rule 4	251	(1)
A2.8 Applications of Differentiation	251	(2)
Appendix 3: Steam Tables	253	(6)
References	259	(2)
Index	261