Plant Design and Operations provides practical guidance to do with the design, operation and maintenance of process facilities. The book is based on years of hands-on experience gathered during the design and operation of a wide range of facilities in many different types of industry including chemicals, refining, offshore oil and gas, and pipelines. The material in the book will help managers, engineers, operators and maintenance specialists with advice and guidance that can be used right away in working situations.

The contents of each chapter provide information and guidance that can be used immediately. For example, the chapter on Energy Control Procedures describes seven levels of positive isolation — ranging from a closed block valve all the way to double block and bleed with line break. The Safety in Design chapter describes topics such as area classification, fire protection, stairways and platforms, fixed ladders, emergency showers, lighting and alarms.

Other areas covered in detail by the book include security, equipment and transportation. A logical, practical guide to maintenance task organization is provided, from conducting a Job Hazards Analysis to the issue of a work permit, and to the shutdown and isolation of equipment. Common hazards are covered in detail, including flow problems, high pressure, corrosion, power failure, and many more.


Key Features

• Provides information to managers, engineers, operators and maintenance personnel which is immediately applicable to their operations.
• Supported by useful, real-world examples and experience from a wide range of facilities and industries.
• Includes guidance on occupational health and safety, industrial hygiene and personal protective equipment.



Managers, engineers, operators and maintenance specialists working in the process industries, including refineries, chemical plants, offshore oil and gas installations and pipelines.

Table of Contents

1. Design and Operations
2. Operations
3. Maintenance
4. Energy Control Procedures
5. Occupational Safety
6. Personal Protective Equipment
7. Health and Industrial Hygiene
8. Contractors
9. Human Factors
10. Security
11. Safety in Design
12. Equipment, Piping and Valves,
13. Transportation
14. Layout
15. Common Hazards
16. Project Management


No. of pages:
© 2015
Gulf Publishing Company
Print ISBN:
Electronic ISBN:

About the author

Ian Sutton

Ian Sutton is a chemical engineer with over thirty years of experience in the process industries. He has worked on the design and operation of chemical plants, offshore platforms, refineries, pipelines and mineral processing facilities. He has extensive experience in the development and implementation of process safety management and operational excellence programs.