Oil & Gas Engineering Training

HERVE BARON

Oil & Gas Engineering Training

HERVE BARON

Dear colleague, I am glad to share with your this educative material on the Engineering of Oil & Gas facilities. I developed it for classroom training sessions which I have been conducting since 2009. This material will give you an overview of the work and deliverables of the different engineering disciplines. I also thrived to produce workflow visuals to help understand the work sequence of each discipline and how they interface. I wish you an enjoyable journey within Engineering…

HERVE BARON

Oil & Gas Engineering Training HSE Moment Intro, scope & objectives Project Engineering The Design Basis Discipline presentations Field engineering Schedule Quality

HERVE BARON

Oil & Gas Engineering Training HSE Moment Intro, scope & objectives Project Engineering The Design Basis Discipline presentations Field engineering Schedule Quality

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Training Objectives • To give a detailed knowledge of what engineering of oil and gas facilities consist of •To describe the activities and show a sample deliverable in the various disciplines •To explain the challenges

Scope

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Oil & Gas Engineering Training HSE Moment Intro, scope & objectives Project Engineering The Design Basis Discipline presentations Field engineering Schedule Quality

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Installation

Procurement

Manufacturing

Construction & erection

Inspection & tests

Shipping

Hand-over

HERVE BARON Home office (Paris) •Project management •Detail Engineering (part) •Procurement

Engineering SubContractor (Delhi) Detail Engineering (part)

Shipyard (Korea) Hull Engineering & Fabrication

Satellite office (Pau) •Detail Engineering (part)

Fabrication yard (Nigeria): Fabrication (part)

Offshore (Nigeria):

Installation, commissioning, start-up

Shipyards (Singapore & Malaysia) Topsides Fabrication & Integration

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Project

Engineering

Procurement

Construction

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Project

Instrumentation & Control

Layout & Piping

Process

Engineering

Procurement

Construction

Electrical

Equipment

Civil

Safety

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Engineering document register Document revision

Discipline code A

Instrumentation & Control

C

Civil engineering

E

Electrical

G

Project general documents

J

Mechanical

K

Safety

M

Piping & Layout

P

Processes

S

Steel Structures

V

Vessels – Heat exchangers

W

Materials – Welding

Document number

Document title

A

1

48104

Service building instrument. rooms cables routing

B

A

2

48102

Trouble shooting diagrams

D

A

3

48134

F&G system architecture drawing

E

A

4

50100

Instrument index

B

A

7

50003

Spec for instrument installation works and service

C

A

8

50960

Instrument Data sheets for temperature switches

B

A

9

50110

Requisition for pressure relief valves

B

M

1

62059

General plot plan

B

M

2

62020

Piping details standard

C

1

Installation drawings

M

2

62070

Piping general arrangement Area 1

D

2

Detail drawings

M

4

60100

Special items list

D

3

Diagrams

M

5

62250

Piping isometrics booklet

C

4

Lists – Bill of Quantities

M

6

60000

Pipes and fittings thickness calculation

A

5

Isometrics

M

6

62351

Calculation note CN1 - piping stress analysis

A

6

Calculation notes

M

7

60001

General piping specification

C

7

Specifications

M

8

60103

Data sheets for station piping material

B

8

Data sheets

M

9

60200

Requisition for pipes

F

9

Requisitions

Document code

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Diagram

Key plan

Drawing

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Drawings common sizes & scales

A0 = 840x1188

A1 = 594x840 A2 = 420x594 A4 = 210x 297

A3 = 297x 420

Scale

1m =

1/1000

1 mm

1/500

2 mm

1/250

4 mm

1/100

1 cm

1/50

2 cm

1/33

3 cm

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Engineering schedule

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Engineering resources

Commissioning 9%

Electrical 9%

Mechanical Equipment 6%

Instrumentation /ICSS/Telecom 10%

Naval 4% Process 2% Others 6%

Structural 23%

~1,000,000 man-hours Piping 31%

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Client Documents submitted to client

Approval/ Comments

Design basis:

Documents for Construction:

- Functional requirements

Construction drawings & specifications

Engineering

- Client specifications

Documents for Purchase: bill of quantity & specification

- Design codes Documents submission

Comments

Vendors

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Oil & Gas Engineering Training HSE Moment Intro, scope & objectives Project Engineering The Design Basis Discipline presentations Field engineering Schedule Quality

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Design Basis Infrastructure:

Feedstock and products flow Feedstock composition Battery limit conditions Equipment Spare

Pressure (bar)

Process facilities: 50

Administrative and technical buildings

45 40

Control room

35

Access road

30

Site fencing, gates, check point

25 20

Performance:

15

Products specifications

10

Energy efficiency, emissions

Design criteria: % of over design

5 0 -85

Utilities: Electric power supply Other utilities

-80

-75

-70

-65

-60

-55

Environment data: Min/max temperature Rain/snow fall Wind Geological conditions

Systems: Process control Fire/gas alarm Public address, LAN, PABX

Applicable codes and standards: International standards Local rules

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Oil & Gas Engineering Training HSE Moment Intro, scope & objectives Project Engineering The Design Basis Discipline presentations Field engineering Schedule Quality

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Engineering disciplines Process Equipment HSE Civil Layout Piping Instrumentation Electrical

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Functional requirements – example of a gas compression station Gas composition

Performance

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TEG

HP Compression & TEG Gas Injection

1200 psig 3000 psig

500 psig

200 psig

IP Compression From Wells 165 - 205 F

HP Separator 500 psig

5500 psig

50 psig

LP Compression

5 psig

Cooler

Emul. Treater 50 psig 150 F

Process Scheme Optimization

Degasser 5 psig

Oil Production

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Process simulations

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Process Flow Diagram (PFD)

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Equipment list

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Thermodynamic calculations

Heat & Material balance

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Equipment sizing

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Process data sheet

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Fluid list

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Piping & Instrumentation Diagram (P&ID)

Line List

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Piping & Instrumentation Diagram (P&ID)

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P&IDs legend & symbols

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Line sizing

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Process automations: Cause & effect chart

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Process control

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Process safety

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ESD logic diagram

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ESD simplified diagram

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Flare Report

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Operating manual

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Quiz: Is this a P&ID? a PFD?

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Engineering Process Equipment HSE Civil Layout Piping Instrumentation Electrical

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Process design PFDs H&M balance

Process data sheet

Equipment specification Rotating Pressure vessels Fired equipment Heat exchangers Packages etc.

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Equipment list

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Rotating machinery

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Pressure vessels

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Heat exchangers

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Packages

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Process data sheet Mechanical data sheet

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Vessel guide drawing

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Material Requisition

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Bid technical evaluation

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Vendor design

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Equipment summary

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Engineering Process Equipment HSE Civil Layout Piping Instrumentation Electrical

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HAZOP Review RISK LEVEL RISK MATRIX

FREQENCY

SEVERITY

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HAZOP Action sheet

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Fire Fighting

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Fire Water demand calculation note

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Fire Water P&IDs

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Deluge system arrangement drawings

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Fire fighting equipment location drawing

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Passive fire protection drawing

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Passive fire protection

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Fire & Gas detection layout

Hazardous HERVE area BARON classification drawing

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Quantitative Risk Analysis (QRA)

Case stuy: Gas leak from random piping component rupture Cause: installation error, corrosion, material defect… Possible consequence: Dispersion without ignition / jet fire / flash fire / explosion Section considered: Compressor building

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Quantitative Risk Analysis (QRA)

Step 1: Identification and characterisation of initiating events

Σ risk components *failure rate (from statistics)

Gas leak inside compressor buidling due to component rupture

Frequency (event/year) Outflow rate (kg/s)

Hole size (% of component section) 5%

20%

Full

1,11E-01

5,06E-04

6,83E-05

5,7

90,8

2270,0

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Quantitative Risk Analysis (QRA) Step 2: Event tree analysis Release Frequency

Probability of immediate ignition for 1-50 kg/s release rate is 7% (from statistical data)

Immediate ESD & Fire Fighting ignition

0,998 0,070

Delayed Ignition

Explosion/ Flash-fire

Consequence Event

Frequency (ev/y)

Gas detectors are provided inside the building, that activate isolation and depressurization. It is Jet fire ESD & FF 7,779E-03 assumed that they operate 95% of the time.

0,002

Jet fire no ESD & FF

1,520E-05

Probability of explosion vs flash fire depends on mass of gas and degree of confinement

1,11E-01 Release/yr 0,949

Dispersion

9,827E-02

0,120

Explosion

1,774E-05

0,880

Flash fire

1,301E-04

Dispersion

5,133E-03

0,930 0,028 0,051 0,972

Frequency (event/year) Jet fire ESD & FF 7,779E-03 Jet fire no ESD & FF 1,520E-05 Explosion 1,774E-05 1,301E-04 Flash Fire Dispersion 1,034E-01

Yes

No B04a/b/c/d

5%

Probability of delayed ignition takes into account equipment explosion protection (Ex)

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Quantitative Risk Analysis (QRA)

Step 3: Consequence evalutation

Overpresssure (bar)

0.2

0.1

0.01

Distance (m)

96

167

1270

CONSEQUENCE CLASS

QUANTITATIVE CRITERIA

EFFECTS

MINOR

≤0.1 bar locally (within 10m)

No effect, no damage

SIGNIFICANT

≤0.1 bar locally (within 50m)

Limited damage to plant and operators

SEVERE

> 0.1 bar within plant

Damage to plant and operators

MAJOR

> 0.1 bar on populated areas

Damage to plant, operators & public

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Quantitative Risk Analysis (QRA)

Unacceptable risk area– Design change necessary

Final step: classification of risk Release Frequency

Immediate ESD & Fire Fighting ignition

Delayed Ignition

Explosion/ Flash-fire

Consequence Event

As Low As Reasonably Practicable – Plant Management measures Acceptable risk area

Frequency (ev/y)

0,998

Jet fire ESD & FF

7,779E-03

0,002

Jet fire no ESD & FF

1,520E-05

0,070

1.0E-02

1,11E-01 Release/yr Dispersion

9,827E-02

0,120

Explosion

1,774E-05

0,880

Flash fire

1,301E-04

Dispersion

5,133E-03

0,949 0,930 0,028 0,051 0,972 Yes

Frequency (event/year) Jet fire ESD & FF 7,779E-03 1,520E-05 Jet fire no ESD & FF Explosion 1,774E-05 1,301E-04 Flash Fire Dispersion 1,034E-01

No B04a/b/c/d

5%

1.0E-03

1.0E-04 Unlikely 1.0E-05 Rare 1.0E-06

Minor

Significant

CONSEQUENCE CLASS

QUANTITATIVE CRITERIA

EFFECTS

MINOR

≤0.1 bar locally (within 10m)

No effect, no damage

SIGNIFICANT

≤0.1 bar locally (within 50m)

Limited damage to plant and operators

SEVERE

> 0.1 bar within plant

Damage to plant and operators

MAJOR

> 0.1 bar on populated areas

Damage to plant, operators & public

Severe

Major

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Environmental Impact Assessment (Air quality dispersion analysis)

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Noise Map

dB(A)

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Engineering Process Equipment HSE Civil Layout Piping Instrumentation Electrical

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Process design PFDs

P&IDs

H&M balance

Piping Instrumentation

Process data sheet

Equipment specification Rotating Pressure vessels Fired equipment Heat exchangers Packages etc.

Vendor drawings

Layout Civil Electrical

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Grading plan

Required finish level

Native soil elevation

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Vendor information

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Foundation Calculation

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Foundation drawing/ re-inforcement

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Foundation drawing/ Formwork

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Civil works specification

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Loading data

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Structural design

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Calculation note

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Structural drawings

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Architectural drawings

Equipment layout drawing

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Heating, Ventilation &Air Conditioning (HVAC)

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Civil Works Installation Drawings

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Standard drawings

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Engineering Process Equipment HSE Civil Layout Piping Instrumentation Electrical

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Process design PFDs

P&IDs

H&M balance

Piping Instrumentation

Process data sheet

Equipment specification Rotating Pressure vessels Fired equipment Heat exchangers Packages etc.

Vendor drawings

Layout Civil Electrical

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Layout/ principles

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Layout/vendor drawings

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Layout/consideration for all networks

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General Plot Plan

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Unit Plot Plan

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3D modelling

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3D model clash check

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3D model review

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Equipment handling

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Engineering Process Equipment HSE Civil Layout Piping Instrumentation Electrical

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Process design PFDs

P&IDs

H&M balance

Piping Instrumentation

Process data sheet

Equipment specification Rotating Pressure vessels Fired equipment Heat exchangers Packages etc.

Vendor drawings

Layout Civil Electrical

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Line Diagram

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Piping Layout drawing

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Isometric drawing

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Piping Pre-fabrication

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Post Weld Heat Treatment

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Piping Inspection and testing

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Piping General Arrangement drawing

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Calculations

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Standard Pipe Support drawings

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Plot Plan

Piping line diagram

Piping installation work process

Piping studies & layout

Piping 3D modelling

Piping stress analysis

Piping isometric drawing

Stress OK?

Process OK?

Piping isometric drawing IFC

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Material Selection

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Material Selection Diagram

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Process Fluids list

Piping material classes

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Piping material classes

Piping material class specification

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Piping material classes specification

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Piping material classes specification

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Piping material classes specification

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Σ

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Piping material requisition

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Engineering Process Equipment HSE Civil Layout Piping Instrumentation Electrical

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Piping & Instrumentation Diagram (P&ID)

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Instrument list

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Level sketch

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Instrument data sheet

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Process Control System

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System Architecture drawing

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Control narrative

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Mechanical Equipment Control

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Emergency shutdown

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The instrument hardware Instrument room Marshalling

Controller

cabinet

cabinet

Control room

VDU

PT

JB

Process line

CPU

LAN Secondary cable Multi cable

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Junction Box drawing

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Instrument location drawing

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Building detail drawing/ Telecom and PAGA layout

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Instrument standard installation drawings

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Junction box wiring

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Cable routing drawings

Cable list

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Instrument bulk Material Take-Off

ITEM

QUANTITY

DESIGNATION

1

195

Gauge adapter – ½” x ½”

2

37

Block manifold 2 valves (Gas) – ½”

3

23

Block manifold 5 valves (Gas) –½”

4

0

Ball valve ½” – 12mm

5

300m

6

200

Reducer – 12mm x ¼”

7

50

Union tee – 12 x 12 x 12mm

8

50

Female connector – 12mm x ½”

9

350

Male connector – 12mm x ½”

10

9

Plug – ½” NPTF

11

8

Plug – ½” NPTM

Tubing – 12mm OD x 1mm

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Cable routing inside technical room

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Instrumentation & control rooms layout

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Screen displays

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Instrument loop diagram

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Engineering Process Equipment HSE Civil Layout Piping Instrumentation Electrical

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Electrical consumer list

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Electrical Load Summary

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General One Line Diagram

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Generators

Switchgear

Transformer

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Equipment data sheet

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Switchboard Single Line Diagram

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Switchgear Typical Diagram

VOLTAGE OF MS-001 (STUDY1)

HERVE 10000 BARON 9900 9800

Bus Volt a ge (Volt s )

9700 9600 9500 9400 9300 9200 9100 9000 8900 8800 0.0

2.5

5.0

7.5

10.0 Time (Seconds)

12.5

15.0

17.5

20.0

FREQUENCY OF MS-001 (STUDY1) 50.0

Bus Frequency (Hz)

49.5

49.0

48.5

Calculations

48.0

47.5

47.0 0.0

2.5

5.0

7.5

10.0 Time (Seconds)

12.5

15.0

17.5

20.0

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routing drawing

Cable schedule

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Typical installation drawings

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Block Diagram

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Trouble shooting diagrams

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Lighting layout

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Lighting illumination level

Iso lux curves

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Electrical equipment layout

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Electrical Control System

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Electrical Control System

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From main power generators

From emergency (diesel) generators

Electrical load shedding

To normal consummers e.g. pumps in process and utility units

To essential consummers e.g. fire water pump

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Oil & Gas Engineering Training HSE Moment Intro, scope & objectives Project Engineering The Design Basis Discipline presentations Field engineering Schedule Quality

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Field Engineering

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Site Query

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Site MASTER set of documents

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Oil & Gas Engineering Training HSE Moment Intro, scope & objectives Project Engineering The Design Basis Discipline presentations Field engineering Schedule Quality

HERVE BARON PROJECT SCHEDULE PLANT START-UP PIPING PRE-FABRICATION & INSTALLATION PIPING MATERIAL & DRAWINGS AT SITE PIPING MATERIAL MANUFACTURING & SHIPPING PURCHASE OF PIPING MATERIAL TECHNICAL & COMMERCIAL CLARIFICATIONS CALL FOR TENDER FOR PIPING MATERIAL PREPARE PIPING MATERIAL TAKE-OFF PIPING ROUTING STUDIES PIPING & INSTRUMENTATION DIAGRAMS (PIDs)

1

MONTH 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

5

4 X X X X X X

1X

2 3X

X X

X X

5

3

4 2

X X X X X X X X X X

5

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simulations Process data sheet Equipment selection & purchase Vendor data

Foundation drawings

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Engineering schedule

Safety valves duty & data sheet (Process)

Size & weight estimates

Safety valves inquiry and purchase (procurement)

Safety valves location & piping routing (piping/layout)

Estimates must be done to meet the schedule

Piping calcs & supports (piping/stress) Steel structure design and drawings (civil)

Supports & loads estimates Purchase steel (manufacturer)

Safety valves sizing & drawings (vendor)

Fabrication (manufacturer) Shipping

Structure at Site

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What the Vendor supplied

What Engineering designed

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Oil & Gas Engineering Training HSE Moment Intro, scope & objectives Project Engineering The Design Basis Discipline presentations Field engineering Schedule Quality

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Engineering Quality Assurance: Engineering document register

Document number

Document title

Document revision

A

1

48104

Service building instrument. rooms cables routing

B

A

2

48102

Trouble shooting diagrams

D

A

3

48134

F&G system architecture drawing

E

A

4

50100

Instrument index

B

A

7

50003

Spec for instrument installation works and service

C

A

8

50960

Instrument Data sheets for temperature switches

B

A

9

50110

Requisition for pressure relief valves

B

M

1

62059

General plot plan

B

M

2

62020

Piping details standard

C

M

2

62070

Piping general arrangement Area 1

D

M

4

60100

Special items list

D

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Engineering Quality Assurance: Document checking and distribution

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Engineering Quality Assurance: Document revision

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Engineering Integrity: Site Query from Construction

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Interface Agreement

Section/Step 1

Section/Step 2

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Interface definition

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The Oil & Gas Engineering Guide 2nd edition

Do you want to know more... Much more?

© 2015 – Hervé Baron

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The Oil & Gas Engineering Guide - 2nd edition Table of Contents

© 2015 – Hervé Baron

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The Oil & Gas Engineering Guide - 2nd edition Table of Contents

Discipline presentation: activities and deliverables

© 2015 – Hervé Baron

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The work of each Engineering discipline is described

© 2015 – Hervé Baron

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Design activities are explained, e.g., Plant Equipment layout

© 2015 – Hervé Baron

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Complex activities, such as QRA, are explained through a practical example.

© 2015 – Hervé Baron

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A sample of all common Engineering documents is included

© 2015 – Hervé Baron

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Difference between Engineering and Shop drawings

© 2015 – Hervé Baron

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Understand the main technical aspects, e.g., DCS vs ESD

© 2015 – Hervé Baron

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The Oil & Gas Engineering Guide - 2nd edition Table of Contents

The overall process © 2015 – Hervé Baron

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The Oil & Gas Engineering Guide - 2nd edition Table of Contents

© 2015 – Hervé Baron

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The Oil & Gas Engineering Guide - 2nd edition Table of Contents

© 2015 – Hervé Baron

HERVE BARON

The Oil & Gas Engineering Guide - 2nd edition Table of Contents

© 2015 – Hervé Baron

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The Oil & Gas Engineering Guide 2nd edition Order direct from the publisher: http://www.editionstechnip.com/en/catal ogue-detail/1111/oil-gas-engineeringguide-the.html

© 2015 – Hervé Baron