Process Engineering Guide
This document was uploaded by user and they confirmed that they have the permission to share it. If you are author or own the copyright of this book, please report to us by using this DMCA report form. Report DMCA
Overview
Download & View Process Engineering Guide as PDF for free.
More details
- Words: 5,260
- Pages: 143
Loading documents preview...
HERVE BARON
Engineering Training
Welcome to this presentation. It is part of a suite of Engineering training modules. It shows the activities and deliverables of the Process discipline. Comments are most welcome ([email protected]), which I will incorporate for the benefit of all.
Hervé
© 2015 – Hervé Baron
Please download this file so that you can see my trainer’s notes in the top left corner – latest Acrobat Pro feature.
HERVE BARON
Engineering disciplines: activities and deliverables
PROCESS
PLANT LAYOUT
EQUIPMENT
SAFETY & ENVIRONMENT
CIVIL
PIPING
PIPELINE
INSTRUMENTATION
ELECTRICAL
© 2015 – Hervé Baron
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
Process Design Basis
What constitutes the Design Basis of a Process/Utility Unit?
© 2015 – Hervé Baron
HERVE BARON
Process Design Basis
What constitutes the Design Basis of a Process/Utility Unit? •
Sizing cases: max capacity /turndown
•
Other operating cases
•
Feedstock composition and condition
•
Product specifications
•
Battery limit conditions
© 2015 – Hervé Baron
HERVE BARON
Process design basis Compressor Station
© 2015 – Hervé Baron
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process simulations, Process Flow Diagram, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
Choice of Process Scheme
© 2015 – Hervé Baron
What are the bases of process scheme definition?
HERVE BARON
Overall Plant Process Design
What is the name of this drawing?
© 2015 – Hervé Baron
HERVE BARON
Results from the high level functional requirements of the plant Depicts the various Processes carried out within the facility and their sequence Shows the inputs (feed) and outputs (products) The item of the BFD is the Process Unit
© 2015 – Hervé Baron
The Block Flow Diagram (BFD)
HERVE BARON
Unit Process Design
© 2015 – Hervé Baron
HERVE BARON
The Process Flow Diagram (PFD)
© 2015 – Hervé Baron
Unit Process Scheme Optimization
HERVE BARON TEG
HP Compression & TEG Gas Injection
1200 psig 3000 psig
500 psig
200 psig
50 psig
LP Compression
IP Compression From Wells 165 - 205 F
HP Separator 500 psig
5500 psig
5 psig
Cooler
Emul. Treater 50 psig 150 F
What are the elements taken into account in the definition/optimization of the process scheme?
Oil Production
© 2015 – Hervé Baron
Degasser 5 psig
HERVE BARON
Process simulations
© 2015 – Hervé Baron
Process simulations
HERVE BARON
Input - Feed composition and conditions
Simulator settings - Flow scheme - Thermodynamic model - Equipment performance
Output - Stream flows and composition - Equipment duty
© 2015 – Hervé Baron
Process simulations
HERVE BARON
Input - Feed composition and conditions
Simulator settings - Flow scheme - Thermodynamic model - Equipment performance
Output - Stream flows and composition - Equipment duty
© 2015 – Hervé Baron
Process simulations
HERVE BARON
Input - Feed composition and conditions
Simulator settings - Flow scheme - Thermodynamic model - Equipment performance
Output - Stream flows and composition - Equipment duty
© 2015 – Hervé Baron
Process simulations
HERVE BARON
Input - Feed composition and conditions
Simulator settings - Flow scheme - Thermodynamic model - Equipment performance
Output - Stream flows and composition - Equipment duty
© 2015 – Hervé Baron
Process simulations
HERVE BARON
Input - Feed composition and conditions
Simulator settings - Flow scheme - Thermodynamic model - Equipment performance
Output - Stream flows and composition - Equipment duty
© 2015 – Hervé Baron
Process simulations
HERVE BARON
Input - Feed composition and conditions
Simulator settings - Flow scheme - Thermodynamic model - Equipment performance
Output - Stream flows and composition - Equipment duty
© 2015 – Hervé Baron
HERVE BARON
The Process Flow Diagram (PFD)
© 2015 – Hervé Baron
HERVE BARON
The Process Flow Diagram (PFD)
Results from process simulations
Depicts the various Equipment within a Process (or Utility) Unit and their sequence
Shows the process controls
The individual drawing item of the PFD is the Equipment Item
© 2015 – Hervé Baron
HERVE BARON
The Process Flow Diagram (PFD)
Scheme including the following information, as a minimum:
Main equipment (all the itemized ones),
Process lines between equipment,
All control loops and main instruments,
Heat & Mass Balance (HMB)
Design conditions of main equipment. It shall be drawn-up according to ISA 6.12 regulation as far as symbology is concerning
© 2015 – Hervé Baron
For each stream, indication of: • Temperature • Pressure • Composition • Specific gravity • Operating density • Heat content • Flow rate (relevant to each phase)
HERVE BARON
Heat & Material Balance
© 2015 – Hervé Baron
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
Process Description
© 2015 – Hervé Baron
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
Engineering disciplines: activities and deliverables
© 2015 – Hervé Baron
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
Equipment sizing
© 2015 – Hervé Baron
HERVE BARON
Cass study: Equipment Sizing
© 2015 – Hervé Baron
32
HERVE BARON
© 2015 – Hervé Baron
33
HERVE BARON
Case study: Equipment Sizing Production separator Sets the gas cross section
Vessel size
Sets the liquid volume
© 2015 – Hervé Baron
HERVE BARON
Process data sheet Drums
© 2015 – Hervé Baron
HERVE BARON
Process data sheet
© 2015 – Hervé Baron
Contents of the Process Data Sheet: • Design conditions • Overdesign • Fluid properties • Equipment duty • Skeleton drawing & dimensions • Material (generic type) and corrosion allowance • Specification of internals: demister, distributor, baffle etc. • Nozzles list • Allowable pressure drop, fouling factor, Cp, Cv, enthalpy curve (for HX, heaters) •Available NPSH (for pumps)
HERVE BARON
Process Data sheet Column
© 2015 – Hervé Baron
Columns and Drums
HERVE BARON Column internals must be specified.
© 2015 – Hervé Baron
These pictures are excerpts from Sulzer douments
HERVE BARON
Process Data sheet Column
© 2015 – Hervé Baron
HERVE BARON
Process Data sheet Rotating equipment
© 2015 – Hervé Baron
HERVE BARON
Process Data sheet Rotating equipment
© 2015 – Hervé Baron
HERVE BARON
Process Data sheet Heat Exchangers / Shell & Tubes
© 2015 – Hervé Baron
HERVE BARON
Heat Exchanger thermal sizing TEMA Data Sheet A Thermal data sheet is received from Process for shell & tubes heat exchangers following thermal sizing
© 2015 – Hervé Baron
HERVE BARON
Process Data sheet Heat Exchangers / Other types
© 2015 – Hervé Baron
HERVE BARON
Process Data sheet Air Cooled HX
© 2015 – Hervé Baron
HERVE BARON
Process Data Sheet Fired heaters
© 2015 – Hervé Baron
HERVE BARON
Process Data Sheet Fired heaters
© 2015 – Hervé Baron
What is particularly important while specifying a heater ?
HERVE BARON
Process Data Sheet Storage tank
© 2015 – Hervé Baron
HERVE BARON
Process Sizing
Process Equipment Sizing is done on the basis of:
Sizing cases
Over design
Design criteria
© 2015 – Hervé Baron
HERVE BARON
Process Sizing
Process Equipment Sizing is done on the basis of:
Sizing cases – all operating cases
Over design
Design criteria
© 2015 – Hervé Baron
HERVE BARON
Process Sizing
Process Equipment Sizing is done on the basis of:
Sizing cases – all operating cases
Over design – 10% as a rule
Design criteria
© 2015 – Hervé Baron
Process Sizing
HERVE BARON
Process Equipment Sizing is done on the basis of:
Sizing cases – all operating case
Over design – 10% as a rule
Sizing criteria
On which basis are the following equipment sized?
© 2015 – Hervé Baron
Process Sizing
HERVE BARON
Process Sizing is done on the basis of:
Sizing cases – all operating case
Over design – 10% as a rule
Sizing criteria Separator KO drum Distillation/Absorption column Reactor Storage tank
© 2015 – Hervé Baron
• • • • •
Process Sizing
HERVE BARON
Process Equipment Sizing is done on the basis of:
Sizing cases – all operating case
Over design – 10% as a rule
Sizing criteria
© 2015 – Hervé Baron
• Separator – Size of droplet => velocity, residence time + Surge • KO Drum – Hold up time • Distillation/Absorption column – Diameter based on flow. Number of trays/height of packing based on purity required • Reactor – Contact time (also called space velocity) • Tank – Storage capacity
HERVE BARON
Process specification Package
© 2015 – Hervé Baron
What document is issued by Process for packages?
HERVE BARON
Process specification Package
© 2015 – Hervé Baron
HERVE BARON
Process specification Package What type of guarantees are requested?
© 2015 – Hervé Baron
HERVE BARON
Process Equipment list
© 2015 – Hervé Baron
HERVE BARON
Process Equipment list
© 2015 – Hervé Baron
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
© 2015 – Hervé Baron
Compare the information shown on the PFD and the P&ID
Piping & Instrumentation Diagram (P&ID)
HERVE BARON
© 2015 – Hervé Baron
Compare Comparethe the information informationshown shownon on the thePFD PFDand andthe theP&ID P&ID
Piping & Instrumentation Diagram (P&ID)
HERVE BARON
Piping & Instrumentation Diagram (P&ID)
What are the purposes of P&IDs?
© 2015 – Hervé Baron
Compare the information shown on the PFD and the P&ID
HERVE BARON
Piping & Instrumentation Diagram (P&ID)
What are the purposes of P&IDs?
During operation: • Reference drawing for operator, work permit, plant modifications etc.
© 2015 – Hervé Baron
At design stage: • Defines the design basis for Piping & Instrumentation disciplines •Compare Serves to theshow and agree the operating and maintenance features between Engineer and Owner or between Engineer and Vendor information shown on • Serves to show the interface with equipment/package vendors the PFD and the P&ID • Perform HAZOP review
HERVE BARON
Piping & Instrumentation Diagram (P&ID)
What are the purposes of P&IDs?
P&ID
During operation: • Reference drawing for operator, work permit, plant modifications etc.
© 2015 – Hervé Baron
At design stage: review • Defines the design basis for Piping & Instrumentation disciplines •Compare Serves to theshow and agree the operating and maintenance features between Engineer and Owner or between Engineer and Vendor information shown on • Serves to show the interface with equipment/package vendors the PFD and the P&ID • Perform HAZOP review
HERVE BARON
Piping & Instrumentation Diagram (P&ID)
What are the purposes of P&IDs? Which are the usual points reviewed during a P&ID review?
P&ID
During operation: • Reference drawing for operator, work permit, plant modifications etc.
© 2015 – Hervé Baron
At design stage: review • Defines the design basis for Piping & Instrumentation disciplines •Compare Serves to theshow and agree the operating and maintenance features between Engineer and Owner or between Engineer and Vendor information shown on • Serves to show the interface with equipment/package vendors the PFD and the P&ID • Perform HAZOP review
HERVE BARON
Piping & Instrumentation Diagram (P&ID) P&ID review
Ease of operation and maintenance: •
Isolation /bypass of equipment
•
Isolation/bypass of valves
•
Vents/drains
© 2015 – Hervé Baron
HERVE BARON
Piping & Instrumentation Diagram (P&ID) P&ID review
Ease of operation and maintenance: •
Isolation /bypass of equipment
•
Isolation/bypass of valves
•
Vents/drains
© 2015 – Hervé Baron
What do you call each type of isolation?
HERVE BARON
Piping & Instrumentation Diagram (P&ID) P&ID review
Ease of operation and maintenance: •
Isolation /bypass of equipment
•
Isolation/bypass of valves
•
Vents/drains
© 2015 – Hervé Baron
Where do you use double block and bleed?
HERVE BARON
Isolation philosophy
© 2015 – Hervé Baron
HERVE BARON
Isolation philosophy
© 2015 – Hervé Baron
HERVE BARON
Isolation philosophy
© 2015 – Hervé Baron
HERVE BARON
Piping & Instrumentation Diagram (P&ID) P&ID review
Ease of operation and maintenance: •
Isolation /bypass of equipment
•
Isolation/bypass of valves
•
Vents/drains
© 2015 – Hervé Baron
Piping & Instrumentation Diagrams (P&IDs)
HERVE BARON
Important features
© 2015 – Hervé Baron
Normal operation • Redundancy for critical instruments / safety switches Shutdown • Check valves Start-up • Pressurization • warm-up / purge lines Maintenance • Equipment isolation & bypass: valves, spectacle/blind • Nitrogen injection, vent • Drains • Control and ON/OFF valves isolation • Instrument isolation
HERVE BARON
Piping & Instrumentation Diagrams (P&IDs)
It includes: 1. 2.
3.
All itemized equipment, Item number and service description of each equipment with relevant design condition All lines (process , utilities, start-up, maintenance), with indication of Diameter Rating Material Service Line number Piping class Piping class break / change External finishing (such as insulation, personal protection, tracing…)
© 2015 – Hervé Baron
• • • • • • • •
HERVE BARON 4. 5.
6.
Piping & Instrumentation Diagrams (P&IDs)
Battery limits between Parties, e.g. contractor and vendor All valves for operation, start-up, maintenance with indication of valve type, including isolation valves, check valves etc. All instruments with detailed control loops: • • •
All instruments shall be tagged as per united numbering system, Local instruments or instruments on local panel, Sequences and interlocks (with brief description e.g.: comp. start / stop, permissive to start, etc.),
Control valves, ON/OFF valves,
8.
Safety valves (with set point and inlet/outlet size),
9.
Electrical controls, such as pump local or remote start/stop, emergency shutdown
© 2015 – Hervé Baron
7.
HERVE BARON 9.
Particular data or notes installation, such as: • • • • • •
10.
relevant to
equipment/instruments
Max or mini length of piping (requirement regarding suction / discharge piping straight length, etc.), Slope of piping Elevation of equipment Pertinent interior arrangement of equipment Safe location requirement Control and monitoring signals for rotating equipment and electrical motors,
Item number and service description of each equipment with relevant design condition Connecting flags for pipe lines running from one drawing to another
© 2015 – Hervé Baron
11.
Piping & Instrumentation Diagrams (P&IDs)
Instruments and controls must be drawn-up according to ISA 6.12 requirements.
Piping & Instrumentation Diagrams (P&IDs)
HERVE BARON
Various types of P&IDs • • • • • • • •
Legend and Symbols Identification & Numbering Details and Typicals Process or Utility P&ID Distribution P&ID Interconnection P&ID Pumps auxiliary P&ID Package P&ID
© 2015 – Hervé Baron
Piping & Instrumentation Diagrams (P&IDs)
HERVE BARON
Various types of P&IDs • • • • • • • •
Legend and Symbols Identification & Numbering Details and Typicals Process or Utility P&ID Distribution P&ID Interconnection P&ID Pumps auxiliary P&ID Package P&ID
© 2015 – Hervé Baron
HERVE BARON
P&IDs legend & symbols
© 2015 – Hervé Baron
Piping & Instrumentation Diagrams (P&IDs)
HERVE BARON
Various types of P&IDs • • • • • • • •
Legend and Symbols Identification & Numbering Details and Typicals Process or Utility P&ID Distribution P&ID Interconnection P&ID Pumps auxiliary P&ID Package P&ID
© 2015 – Hervé Baron
HERVE BARON
Identification and numbering system
© 2015 – Hervé Baron
HERVE BARON
Identification and numbering system
© 2015 – Hervé Baron
Piping & Instrumentation Diagrams (P&IDs)
HERVE BARON
Various types of P&IDs • • • • • • • •
Legend and Symbols Identification & Numbering Details and Typicals Process or Utility P&ID Distribution P&ID Interconnection P&ID Pumps auxiliary P&ID Package P&ID
© 2015 – Hervé Baron
Piping & Instrumentation Diagrams (P&IDs)
HERVE BARON
Various types of P&IDs • • • • • • • •
Legend and Symbols Identification & Numbering Details and Typicals Process or Utility P&ID Distribution P&ID Interconnection P&ID Pumps auxiliary P&ID Package P&ID
P&ID representation
Details
© 2015 – Hervé Baron
Piping & Instrumentation Diagrams (P&IDs)
HERVE BARON
Various types of P&IDs • • • • • • • •
Legend and Symbols Identification & Numbering Details and Typicals Process or Utility P&ID Distribution P&ID Interconnection P&ID Pumps auxiliary P&ID Package P&ID
© 2015 – Hervé Baron
Piping & Instrumentation Diagrams (P&IDs)
HERVE BARON
Various types of P&IDs • • • • • • • •
Legend and Symbols Identification & Numbering Details and Typicals Process or Utility P&ID Distribution P&ID Interconnection P&ID Pumps auxiliary P&ID Package P&ID
What are the different typicals that should be defined? © 2015 – Hervé Baron
HERVE BARON
Piping & Instrumentation Diagram (P&ID) - Typicals
© 2015 – Hervé Baron
How would you call each of these two types of arrangement? For what service(s) would each be used?
Piping & Instrumentation Diagrams (P&IDs)
HERVE BARON
Various types of P&IDs • • • • • • • •
Legend and Symbols Identification & Numbering Details and Typicals Process or Utility P&ID Distribution P&ID Interconnection P&ID Pumps auxiliary P&ID Package P&ID
© 2015 – Hervé Baron
HERVE BARON
P&ID work sequence
P&IDs are typically issued 3 times, as design progresses
© 2015 – Hervé Baron
P&ID work sequence
HERVE BARON
P&IDs are typically issued 3 times, as design progresses
IFD
IFC
© 2015 – Hervé Baron
IFR
P&ID work sequence
HERVE BARON
P&IDs are typically issued 3 times, as design progresses
IFD
IFC
© 2015 – Hervé Baron
IFR
P&ID work sequence
HERVE BARON
P&IDs are typically issued 3 times, as design progresses
P&ID Review
IFD
IFC
© 2015 – Hervé Baron
IFR
P&ID work sequence
HERVE BARON
P&IDs are typically issued 3 times, as design progresses
P&ID Review
IFD
IFC
© 2015 – Hervé Baron
IFR
HAZOP
HERVE BARON
Quiz Which revision of P&IDs has the following purpose/contents?
Purpose Collect Client comments Perform PID review Perform HAZOP Perform Piping MTO for 1st Piping purchase Freeze Control system I/O list Issue Piping ISOs Contents Comments from all disciplines
IFR
IFD
IFC
IFR
IFD
IFC
Comments from Piping, I&C disciplines Finalized interfaces with eqt/package Exercised Contract Option(s) © 2015 – Hervé Baron
Size, number of PSVs and CVs Diameter of process lines Diameter of utility lines HAZOP comments incorporated Client comments incorporated
HERVE BARON
Quiz Which revision of P&IDs has the following purpose/contents?
Purpose Collect Client comments Perform PID review Perform HAZOP Perform Piping MTO for 1st Piping purchase Freeze Control system I/O list Issue Piping ISOs Contents Comments from all disciplines
IFR X X
IFD
X X
IFR
Comments from Piping, I&C disciplines
IFD
X X X X X X X
© 2015 – Hervé Baron
Size, number of PSVs and CVs Diameter of process lines Diameter of utility lines HAZOP comments incorporated Client comments incorporated
X X IFC X
X
Finalized interfaces with eqt/package Exercised Contract Option(s)
IFC
P&ID work sequence
HERVE BARON
P&IDs are typically issued 3 times, as design progresses
P&ID Review
IFD
IFC
© 2015 – Hervé Baron
IFR
HAZOP
P&ID work sequence The different revisions
HERVE BARON
The prime purpose of the first issue (IFR: Issued for Review) is to obtain COMPANY’s comments/APPROVAL – this APPROVAL is necessary before progressing the design further to avoid re-work The IFD revision, which incorporates COMPANY comments, aims at transferring information from Process to other disciplines: • • • •
to Piping, to perform routing studies to Piping materials, to perform 1st MTO for purchase To Instrumentation, to perform Instrument list To Civil for routing of Undeground Piping
© 2015 – Hervé Baron
IFC incorporates HAZOP impacts and information from Vendors. It is a pre-requisite to: • Start production of Piping isometrics
P&ID work sequence
HERVE BARON
P&ID Review
HAZOP
Piping Isometric drawings Piping material top-up’s
IFR
IFD
IFC Piping 2nd MTO & 1st material purchases Instrumenation & Control design Undeground piping (civil)
© 2015 – Hervé Baron
Piping routing
P&ID work sequence
HERVE BARON
Sometimes an « IFH » revision, mark-up’s of the P&ID review, is used to anticipate the HAZOP
P&ID Review
IFD
IFC
© 2015 – Hervé Baron
IFR
HAZOP
P&ID work sequence
HERVE BARON
An IFD2 revision is issued in case major change from Vendors/HAZOP to up-date piping material purchases, instrumentation design etc.
P&ID Review
HAZOP
Piping Isos Piping material top-up
Start
IFR
IFD IFD2
IFC
Piping routing Piping 1st material purchases Instrumenation & Control design Undeground piping (civil)
© 2015 – Hervé Baron
Up-date
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
Fluids list
© 2015 – Hervé Baron
Line list HERVE BARON
© 2015 – Hervé Baron
HERVE BARON
Line sizing
© 2015 – Hervé Baron
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
Instrument process data sheet
© 2015 – Hervé Baron
HERVE BARON
© 2015 – Hervé Baron
What is the most important process data for control valves?
Instrument process data sheet
HERVE BARON
Instrument process data sheet
© 2015 – Hervé Baron
Operating range, typ. Maximum flow rate: 110 % of max. operating flow rate Minimum flow rate: 30 % of minimum operating flow rate, in order to guarantee correct functioning at the extremes of the operating range.
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
Process Shut Down
Look at the extracts of these 2 P&IDs. How is the protection against loss of liquid level achieved in each case? © 2015 – Hervé Baron
HERVE BARON
ESD logic diagram
© 2015 – Hervé Baron
HERVE BARON
Safeguarding narrative & Cause and Effects charts
© 2015 – Hervé Baron
HERVE BARON
Process and Safety Diagrams (PSD)
© 2015 – Hervé Baron
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
Relief load summary
© 2015 – Hervé Baron
HERVE BARON
Flare study
© 2015 – Hervé Baron
HERVE BARON
Flare study
© 2015 – Hervé Baron
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
Operating manual
© 2015 – Hervé Baron
HERVE BARON
Operating manual What are the most important contents of the operating manual?
© 2015 – Hervé Baron
HERVE BARON
1 INTRODUCTION 1.1 General presentation 1.2 Glossary 1.3 Basic data 2 DESCRIPTION OF FACILITIES 2.1 General 2.2 Process 2.3 Utilities 2.4 Auxiliaries
4 OPERATION 4.1 Start-up 4.2 Normal operation 4.4 Shutdown 4.5 Depressurization 5 SAFETY 5.1 Operating philosophy 5.2 Escape, evacuation and rescue 5.3 Emergency power system 5.4 Safety equipment list 5.5 Fire protection © 2015 – Hervé Baron
3 AUTOMATIC CONTROL SYSTEM 3.1 System overview 3.2 Operator control interfaces 3.3 Telecommunications 3.4 Process alarms and trips 3.6 Emergency shutdown system 3.7 Fire & gas system
Operating Manual Table of Contents (typ.)
Operating Manual Annexes (typ.)
HERVE BARON
EQUIPMENT LIST
SINGLE LINE DIAGRAM
PFDs
P&IDs
F&G SYSTEM DRAWING
VESSELS SHEETS
INSTRUMENT DATA SHEETS (PSVs, Level instruments)
ARCHITECTURE
MECHANICAL
DATA
ESD LOGIC DIAGRAM
EQUIPMENT START/STOP SHUTDOWN SEQUENCES
GENERAL PLOT PLAN
ESD SIMPLIFIED DIAGRAM
DCS ARCHITECTURE DRAWING
CONTROL LOOPS AND ALARM LIST
ELECTRICAL CONTROL SYSTEM ARCHITECTURE DRAWING
SECURITY SWITCHES LIST
&
© 2015 – Hervé Baron
Operating Manual Annexes (typ.)
HERVE BARON
EQUIPMENT LIST
SINGLE LINE DIAGRAM
PFDs
P&IDs
F&G SYSTEM DRAWING
VESSELS SHEETS
INSTRUMENT DATA SHEETS (PSVs, Level instruments)
ARCHITECTURE
MECHANICAL
DATA
ESD LOGIC DIAGRAM
EQUIPMENT START/STOP SHUTDOWN SEQUENCES
GENERAL PLOT PLAN
ESD SIMPLIFIED DIAGRAM
DCS ARCHITECTURE DRAWING
CONTROL LOOPS AND ALARM LIST
ELECTRICAL CONTROL SYSTEM ARCHITECTURE DRAWING
SECURITY SWITCHES LIST
&
© 2015 – Hervé Baron
HERVE BARON
Operating Manual Control loops and Alarms list
© 2015 – Hervé Baron
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
Process design criteria
What are the different Process design criteria?
© 2015 – Hervé Baron
HERVE BARON
Process design criteria
What are the different Process design criteria? • • • • •
Design margins Design Pressure and Temperature criteria Equipment sizing criteria Line sizing criteria Control valve sizing criteria
© 2015 – Hervé Baron
HERVE BARON
• • • • •
Process design criteria
Design margins Design Pressure and Temperature criteria Equipment sizing criteria Line sizing criteria Control valve sizing criteria
© 2015 – Hervé Baron
Process design criteria
HERVE BARON
• • • • •
Design margins: what is the usual Equipment (rotating, heat exchangers, columns) overdesign (%)? Design Pressure and Temperature criteria Equipment sizing criteria Line sizing criteria Control valve sizing criteria
+?% © 2015 – Hervé Baron
Process design criteria
HERVE BARON
• • • • •
Design margins: what is the usual Equipment (rotating, heat exchangers, columns) overdesign (%)? Design Pressure and Temperature criteria Equipment sizing criteria Line sizing criteria Control valve sizing criteria
+10% © 2015 – Hervé Baron
HERVE BARON
• • • • •
Process design criteria
Design margins Design Pressure and Temperature criteria Equipment sizing criteria Line sizing criteria Control valve sizing criteria
© 2015 – Hervé Baron
Process design criteria
HERVE BARON
• • • • •
Design margins Design Pressure and Temperature criteria Equipment sizing criteria Line sizing criteria Control valve sizing criteria The design temperature should be the highest or lowest temperature to which the equipment is subjected, plus a margin. The following cases must be considered: (a) A maximum temperature which can occur when bypassing a heat exchanger or cooler for cleaning. (b) A high metal temperature on uninsulated equipment due to solar radiation.
(d) The maximum metal temperature that can occur during steam out or decoking operation.
© 2015 – Hervé Baron
(c) The lowest temperature that may be caused by auto-refrigeration.
HERVE BARON
• • • • •
Process design criteria
Design margins Design Pressure and Temperature criteria Equipment sizing criteria Line sizing criteria Control valve sizing criteria
© 2015 – Hervé Baron
HERVE BARON
• • • • •
Process design criteria
Design margins Design Pressure and Temperature criteria Equipment sizing criteria Line sizing criteria Control valve sizing criteria
© 2015 – Hervé Baron
HERVE BARON
Licensed vs Open Art Process
When one uses a process under license, what are the deliverables issued by the process LICENSOR?
© 2015 – Hervé Baron
Typical PROCESS Licensor / Engineering split
HERVE BARON
Process Licensor
Engineer
PFD, H&MB
X
Equipment data sheet
Equipment process data sheet: Equipment Mechanical data sheet - Operating conditions, - Duty - Diameters of vessels - Size of Nozzles - Pump head + specific info for internals etc.
P&IDs
Generic
customized (piping class, line and valves size, HAZOP comments, vendor info)
Line sizing
Line sizing criteria
Sizing (takes into account eqt loc, elevation etc.)
Plot Plan
recommendations
X
Material selection
Basic requirement
MSD
© 2015 – Hervé Baron
Item
Typical PROCESS Licensor / Engineering split
HERVE BARON
Process Licensor
Engineer
PFD, H&MB
X
Equipment data sheet
Equipment process data sheet: Equipment Mechanical data sheet - Operating conditions, - Duty - Diameters of vessels - Size of Nozzles - Pump head + specific info for internals etc.
P&IDs
Generic
customized (piping class, line and valves size, HAZOP comments, vendor info)
Line sizing
Line sizing criteria
Sizing (takes into account eqt loc, elevation etc.)
Plot Plan
recommendations
X
Material selection
Basic requirement
MSD
© 2015 – Hervé Baron
Item
HERVE BARON
The Oil & Gas Engineering Guide 2nd edition
Do you want to know more... Much more?
© 2015 – Hervé Baron
HERVE BARON
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
This suite of training modules covered the discipline chapters of the book...
© 2015 – Hervé Baron
HERVE BARON
The Oil & Gas Engineering Guide - 2nd edition Table of Contents
The Guide contains much more: The overall picture, interfaces, methods & tools, etc. © 2015 – Hervé Baron
HERVE BARON
The Oil & Gas Engineering Guide 2nd edition Order direct from the publisher: http://www.editionstechnip.com/en/catalogu e-detail/1111/oil-gas-engineering-guidethe.html
© 2015 – Hervé Baron
Engineering Training
Welcome to this presentation. It is part of a suite of Engineering training modules. It shows the activities and deliverables of the Process discipline. Comments are most welcome ([email protected]), which I will incorporate for the benefit of all.
Hervé
© 2015 – Hervé Baron
Please download this file so that you can see my trainer’s notes in the top left corner – latest Acrobat Pro feature.
HERVE BARON
Engineering disciplines: activities and deliverables
PROCESS
PLANT LAYOUT
EQUIPMENT
SAFETY & ENVIRONMENT
CIVIL
PIPING
PIPELINE
INSTRUMENTATION
ELECTRICAL
© 2015 – Hervé Baron
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
Process Design Basis
What constitutes the Design Basis of a Process/Utility Unit?
© 2015 – Hervé Baron
HERVE BARON
Process Design Basis
What constitutes the Design Basis of a Process/Utility Unit? •
Sizing cases: max capacity /turndown
•
Other operating cases
•
Feedstock composition and condition
•
Product specifications
•
Battery limit conditions
© 2015 – Hervé Baron
HERVE BARON
Process design basis Compressor Station
© 2015 – Hervé Baron
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process simulations, Process Flow Diagram, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
Choice of Process Scheme
© 2015 – Hervé Baron
What are the bases of process scheme definition?
HERVE BARON
Overall Plant Process Design
What is the name of this drawing?
© 2015 – Hervé Baron
HERVE BARON
Results from the high level functional requirements of the plant Depicts the various Processes carried out within the facility and their sequence Shows the inputs (feed) and outputs (products) The item of the BFD is the Process Unit
© 2015 – Hervé Baron
The Block Flow Diagram (BFD)
HERVE BARON
Unit Process Design
© 2015 – Hervé Baron
HERVE BARON
The Process Flow Diagram (PFD)
© 2015 – Hervé Baron
Unit Process Scheme Optimization
HERVE BARON TEG
HP Compression & TEG Gas Injection
1200 psig 3000 psig
500 psig
200 psig
50 psig
LP Compression
IP Compression From Wells 165 - 205 F
HP Separator 500 psig
5500 psig
5 psig
Cooler
Emul. Treater 50 psig 150 F
What are the elements taken into account in the definition/optimization of the process scheme?
Oil Production
© 2015 – Hervé Baron
Degasser 5 psig
HERVE BARON
Process simulations
© 2015 – Hervé Baron
Process simulations
HERVE BARON
Input - Feed composition and conditions
Simulator settings - Flow scheme - Thermodynamic model - Equipment performance
Output - Stream flows and composition - Equipment duty
© 2015 – Hervé Baron
Process simulations
HERVE BARON
Input - Feed composition and conditions
Simulator settings - Flow scheme - Thermodynamic model - Equipment performance
Output - Stream flows and composition - Equipment duty
© 2015 – Hervé Baron
Process simulations
HERVE BARON
Input - Feed composition and conditions
Simulator settings - Flow scheme - Thermodynamic model - Equipment performance
Output - Stream flows and composition - Equipment duty
© 2015 – Hervé Baron
Process simulations
HERVE BARON
Input - Feed composition and conditions
Simulator settings - Flow scheme - Thermodynamic model - Equipment performance
Output - Stream flows and composition - Equipment duty
© 2015 – Hervé Baron
Process simulations
HERVE BARON
Input - Feed composition and conditions
Simulator settings - Flow scheme - Thermodynamic model - Equipment performance
Output - Stream flows and composition - Equipment duty
© 2015 – Hervé Baron
Process simulations
HERVE BARON
Input - Feed composition and conditions
Simulator settings - Flow scheme - Thermodynamic model - Equipment performance
Output - Stream flows and composition - Equipment duty
© 2015 – Hervé Baron
HERVE BARON
The Process Flow Diagram (PFD)
© 2015 – Hervé Baron
HERVE BARON
The Process Flow Diagram (PFD)
Results from process simulations
Depicts the various Equipment within a Process (or Utility) Unit and their sequence
Shows the process controls
The individual drawing item of the PFD is the Equipment Item
© 2015 – Hervé Baron
HERVE BARON
The Process Flow Diagram (PFD)
Scheme including the following information, as a minimum:
Main equipment (all the itemized ones),
Process lines between equipment,
All control loops and main instruments,
Heat & Mass Balance (HMB)
Design conditions of main equipment. It shall be drawn-up according to ISA 6.12 regulation as far as symbology is concerning
© 2015 – Hervé Baron
For each stream, indication of: • Temperature • Pressure • Composition • Specific gravity • Operating density • Heat content • Flow rate (relevant to each phase)
HERVE BARON
Heat & Material Balance
© 2015 – Hervé Baron
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
Process Description
© 2015 – Hervé Baron
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
Engineering disciplines: activities and deliverables
© 2015 – Hervé Baron
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
Equipment sizing
© 2015 – Hervé Baron
HERVE BARON
Cass study: Equipment Sizing
© 2015 – Hervé Baron
32
HERVE BARON
© 2015 – Hervé Baron
33
HERVE BARON
Case study: Equipment Sizing Production separator Sets the gas cross section
Vessel size
Sets the liquid volume
© 2015 – Hervé Baron
HERVE BARON
Process data sheet Drums
© 2015 – Hervé Baron
HERVE BARON
Process data sheet
© 2015 – Hervé Baron
Contents of the Process Data Sheet: • Design conditions • Overdesign • Fluid properties • Equipment duty • Skeleton drawing & dimensions • Material (generic type) and corrosion allowance • Specification of internals: demister, distributor, baffle etc. • Nozzles list • Allowable pressure drop, fouling factor, Cp, Cv, enthalpy curve (for HX, heaters) •Available NPSH (for pumps)
HERVE BARON
Process Data sheet Column
© 2015 – Hervé Baron
Columns and Drums
HERVE BARON Column internals must be specified.
© 2015 – Hervé Baron
These pictures are excerpts from Sulzer douments
HERVE BARON
Process Data sheet Column
© 2015 – Hervé Baron
HERVE BARON
Process Data sheet Rotating equipment
© 2015 – Hervé Baron
HERVE BARON
Process Data sheet Rotating equipment
© 2015 – Hervé Baron
HERVE BARON
Process Data sheet Heat Exchangers / Shell & Tubes
© 2015 – Hervé Baron
HERVE BARON
Heat Exchanger thermal sizing TEMA Data Sheet A Thermal data sheet is received from Process for shell & tubes heat exchangers following thermal sizing
© 2015 – Hervé Baron
HERVE BARON
Process Data sheet Heat Exchangers / Other types
© 2015 – Hervé Baron
HERVE BARON
Process Data sheet Air Cooled HX
© 2015 – Hervé Baron
HERVE BARON
Process Data Sheet Fired heaters
© 2015 – Hervé Baron
HERVE BARON
Process Data Sheet Fired heaters
© 2015 – Hervé Baron
What is particularly important while specifying a heater ?
HERVE BARON
Process Data Sheet Storage tank
© 2015 – Hervé Baron
HERVE BARON
Process Sizing
Process Equipment Sizing is done on the basis of:
Sizing cases
Over design
Design criteria
© 2015 – Hervé Baron
HERVE BARON
Process Sizing
Process Equipment Sizing is done on the basis of:
Sizing cases – all operating cases
Over design
Design criteria
© 2015 – Hervé Baron
HERVE BARON
Process Sizing
Process Equipment Sizing is done on the basis of:
Sizing cases – all operating cases
Over design – 10% as a rule
Design criteria
© 2015 – Hervé Baron
Process Sizing
HERVE BARON
Process Equipment Sizing is done on the basis of:
Sizing cases – all operating case
Over design – 10% as a rule
Sizing criteria
On which basis are the following equipment sized?
© 2015 – Hervé Baron
Process Sizing
HERVE BARON
Process Sizing is done on the basis of:
Sizing cases – all operating case
Over design – 10% as a rule
Sizing criteria Separator KO drum Distillation/Absorption column Reactor Storage tank
© 2015 – Hervé Baron
• • • • •
Process Sizing
HERVE BARON
Process Equipment Sizing is done on the basis of:
Sizing cases – all operating case
Over design – 10% as a rule
Sizing criteria
© 2015 – Hervé Baron
• Separator – Size of droplet => velocity, residence time + Surge • KO Drum – Hold up time • Distillation/Absorption column – Diameter based on flow. Number of trays/height of packing based on purity required • Reactor – Contact time (also called space velocity) • Tank – Storage capacity
HERVE BARON
Process specification Package
© 2015 – Hervé Baron
What document is issued by Process for packages?
HERVE BARON
Process specification Package
© 2015 – Hervé Baron
HERVE BARON
Process specification Package What type of guarantees are requested?
© 2015 – Hervé Baron
HERVE BARON
Process Equipment list
© 2015 – Hervé Baron
HERVE BARON
Process Equipment list
© 2015 – Hervé Baron
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
© 2015 – Hervé Baron
Compare the information shown on the PFD and the P&ID
Piping & Instrumentation Diagram (P&ID)
HERVE BARON
© 2015 – Hervé Baron
Compare Comparethe the information informationshown shownon on the thePFD PFDand andthe theP&ID P&ID
Piping & Instrumentation Diagram (P&ID)
HERVE BARON
Piping & Instrumentation Diagram (P&ID)
What are the purposes of P&IDs?
© 2015 – Hervé Baron
Compare the information shown on the PFD and the P&ID
HERVE BARON
Piping & Instrumentation Diagram (P&ID)
What are the purposes of P&IDs?
During operation: • Reference drawing for operator, work permit, plant modifications etc.
© 2015 – Hervé Baron
At design stage: • Defines the design basis for Piping & Instrumentation disciplines •Compare Serves to theshow and agree the operating and maintenance features between Engineer and Owner or between Engineer and Vendor information shown on • Serves to show the interface with equipment/package vendors the PFD and the P&ID • Perform HAZOP review
HERVE BARON
Piping & Instrumentation Diagram (P&ID)
What are the purposes of P&IDs?
P&ID
During operation: • Reference drawing for operator, work permit, plant modifications etc.
© 2015 – Hervé Baron
At design stage: review • Defines the design basis for Piping & Instrumentation disciplines •Compare Serves to theshow and agree the operating and maintenance features between Engineer and Owner or between Engineer and Vendor information shown on • Serves to show the interface with equipment/package vendors the PFD and the P&ID • Perform HAZOP review
HERVE BARON
Piping & Instrumentation Diagram (P&ID)
What are the purposes of P&IDs? Which are the usual points reviewed during a P&ID review?
P&ID
During operation: • Reference drawing for operator, work permit, plant modifications etc.
© 2015 – Hervé Baron
At design stage: review • Defines the design basis for Piping & Instrumentation disciplines •Compare Serves to theshow and agree the operating and maintenance features between Engineer and Owner or between Engineer and Vendor information shown on • Serves to show the interface with equipment/package vendors the PFD and the P&ID • Perform HAZOP review
HERVE BARON
Piping & Instrumentation Diagram (P&ID) P&ID review
Ease of operation and maintenance: •
Isolation /bypass of equipment
•
Isolation/bypass of valves
•
Vents/drains
© 2015 – Hervé Baron
HERVE BARON
Piping & Instrumentation Diagram (P&ID) P&ID review
Ease of operation and maintenance: •
Isolation /bypass of equipment
•
Isolation/bypass of valves
•
Vents/drains
© 2015 – Hervé Baron
What do you call each type of isolation?
HERVE BARON
Piping & Instrumentation Diagram (P&ID) P&ID review
Ease of operation and maintenance: •
Isolation /bypass of equipment
•
Isolation/bypass of valves
•
Vents/drains
© 2015 – Hervé Baron
Where do you use double block and bleed?
HERVE BARON
Isolation philosophy
© 2015 – Hervé Baron
HERVE BARON
Isolation philosophy
© 2015 – Hervé Baron
HERVE BARON
Isolation philosophy
© 2015 – Hervé Baron
HERVE BARON
Piping & Instrumentation Diagram (P&ID) P&ID review
Ease of operation and maintenance: •
Isolation /bypass of equipment
•
Isolation/bypass of valves
•
Vents/drains
© 2015 – Hervé Baron
Piping & Instrumentation Diagrams (P&IDs)
HERVE BARON
Important features
© 2015 – Hervé Baron
Normal operation • Redundancy for critical instruments / safety switches Shutdown • Check valves Start-up • Pressurization • warm-up / purge lines Maintenance • Equipment isolation & bypass: valves, spectacle/blind • Nitrogen injection, vent • Drains • Control and ON/OFF valves isolation • Instrument isolation
HERVE BARON
Piping & Instrumentation Diagrams (P&IDs)
It includes: 1. 2.
3.
All itemized equipment, Item number and service description of each equipment with relevant design condition All lines (process , utilities, start-up, maintenance), with indication of Diameter Rating Material Service Line number Piping class Piping class break / change External finishing (such as insulation, personal protection, tracing…)
© 2015 – Hervé Baron
• • • • • • • •
HERVE BARON 4. 5.
6.
Piping & Instrumentation Diagrams (P&IDs)
Battery limits between Parties, e.g. contractor and vendor All valves for operation, start-up, maintenance with indication of valve type, including isolation valves, check valves etc. All instruments with detailed control loops: • • •
All instruments shall be tagged as per united numbering system, Local instruments or instruments on local panel, Sequences and interlocks (with brief description e.g.: comp. start / stop, permissive to start, etc.),
Control valves, ON/OFF valves,
8.
Safety valves (with set point and inlet/outlet size),
9.
Electrical controls, such as pump local or remote start/stop, emergency shutdown
© 2015 – Hervé Baron
7.
HERVE BARON 9.
Particular data or notes installation, such as: • • • • • •
10.
relevant to
equipment/instruments
Max or mini length of piping (requirement regarding suction / discharge piping straight length, etc.), Slope of piping Elevation of equipment Pertinent interior arrangement of equipment Safe location requirement Control and monitoring signals for rotating equipment and electrical motors,
Item number and service description of each equipment with relevant design condition Connecting flags for pipe lines running from one drawing to another
© 2015 – Hervé Baron
11.
Piping & Instrumentation Diagrams (P&IDs)
Instruments and controls must be drawn-up according to ISA 6.12 requirements.
Piping & Instrumentation Diagrams (P&IDs)
HERVE BARON
Various types of P&IDs • • • • • • • •
Legend and Symbols Identification & Numbering Details and Typicals Process or Utility P&ID Distribution P&ID Interconnection P&ID Pumps auxiliary P&ID Package P&ID
© 2015 – Hervé Baron
Piping & Instrumentation Diagrams (P&IDs)
HERVE BARON
Various types of P&IDs • • • • • • • •
Legend and Symbols Identification & Numbering Details and Typicals Process or Utility P&ID Distribution P&ID Interconnection P&ID Pumps auxiliary P&ID Package P&ID
© 2015 – Hervé Baron
HERVE BARON
P&IDs legend & symbols
© 2015 – Hervé Baron
Piping & Instrumentation Diagrams (P&IDs)
HERVE BARON
Various types of P&IDs • • • • • • • •
Legend and Symbols Identification & Numbering Details and Typicals Process or Utility P&ID Distribution P&ID Interconnection P&ID Pumps auxiliary P&ID Package P&ID
© 2015 – Hervé Baron
HERVE BARON
Identification and numbering system
© 2015 – Hervé Baron
HERVE BARON
Identification and numbering system
© 2015 – Hervé Baron
Piping & Instrumentation Diagrams (P&IDs)
HERVE BARON
Various types of P&IDs • • • • • • • •
Legend and Symbols Identification & Numbering Details and Typicals Process or Utility P&ID Distribution P&ID Interconnection P&ID Pumps auxiliary P&ID Package P&ID
© 2015 – Hervé Baron
Piping & Instrumentation Diagrams (P&IDs)
HERVE BARON
Various types of P&IDs • • • • • • • •
Legend and Symbols Identification & Numbering Details and Typicals Process or Utility P&ID Distribution P&ID Interconnection P&ID Pumps auxiliary P&ID Package P&ID
P&ID representation
Details
© 2015 – Hervé Baron
Piping & Instrumentation Diagrams (P&IDs)
HERVE BARON
Various types of P&IDs • • • • • • • •
Legend and Symbols Identification & Numbering Details and Typicals Process or Utility P&ID Distribution P&ID Interconnection P&ID Pumps auxiliary P&ID Package P&ID
© 2015 – Hervé Baron
Piping & Instrumentation Diagrams (P&IDs)
HERVE BARON
Various types of P&IDs • • • • • • • •
Legend and Symbols Identification & Numbering Details and Typicals Process or Utility P&ID Distribution P&ID Interconnection P&ID Pumps auxiliary P&ID Package P&ID
What are the different typicals that should be defined? © 2015 – Hervé Baron
HERVE BARON
Piping & Instrumentation Diagram (P&ID) - Typicals
© 2015 – Hervé Baron
How would you call each of these two types of arrangement? For what service(s) would each be used?
Piping & Instrumentation Diagrams (P&IDs)
HERVE BARON
Various types of P&IDs • • • • • • • •
Legend and Symbols Identification & Numbering Details and Typicals Process or Utility P&ID Distribution P&ID Interconnection P&ID Pumps auxiliary P&ID Package P&ID
© 2015 – Hervé Baron
HERVE BARON
P&ID work sequence
P&IDs are typically issued 3 times, as design progresses
© 2015 – Hervé Baron
P&ID work sequence
HERVE BARON
P&IDs are typically issued 3 times, as design progresses
IFD
IFC
© 2015 – Hervé Baron
IFR
P&ID work sequence
HERVE BARON
P&IDs are typically issued 3 times, as design progresses
IFD
IFC
© 2015 – Hervé Baron
IFR
P&ID work sequence
HERVE BARON
P&IDs are typically issued 3 times, as design progresses
P&ID Review
IFD
IFC
© 2015 – Hervé Baron
IFR
P&ID work sequence
HERVE BARON
P&IDs are typically issued 3 times, as design progresses
P&ID Review
IFD
IFC
© 2015 – Hervé Baron
IFR
HAZOP
HERVE BARON
Quiz Which revision of P&IDs has the following purpose/contents?
Purpose Collect Client comments Perform PID review Perform HAZOP Perform Piping MTO for 1st Piping purchase Freeze Control system I/O list Issue Piping ISOs Contents Comments from all disciplines
IFR
IFD
IFC
IFR
IFD
IFC
Comments from Piping, I&C disciplines Finalized interfaces with eqt/package Exercised Contract Option(s) © 2015 – Hervé Baron
Size, number of PSVs and CVs Diameter of process lines Diameter of utility lines HAZOP comments incorporated Client comments incorporated
HERVE BARON
Quiz Which revision of P&IDs has the following purpose/contents?
Purpose Collect Client comments Perform PID review Perform HAZOP Perform Piping MTO for 1st Piping purchase Freeze Control system I/O list Issue Piping ISOs Contents Comments from all disciplines
IFR X X
IFD
X X
IFR
Comments from Piping, I&C disciplines
IFD
X X X X X X X
© 2015 – Hervé Baron
Size, number of PSVs and CVs Diameter of process lines Diameter of utility lines HAZOP comments incorporated Client comments incorporated
X X IFC X
X
Finalized interfaces with eqt/package Exercised Contract Option(s)
IFC
P&ID work sequence
HERVE BARON
P&IDs are typically issued 3 times, as design progresses
P&ID Review
IFD
IFC
© 2015 – Hervé Baron
IFR
HAZOP
P&ID work sequence The different revisions
HERVE BARON
The prime purpose of the first issue (IFR: Issued for Review) is to obtain COMPANY’s comments/APPROVAL – this APPROVAL is necessary before progressing the design further to avoid re-work The IFD revision, which incorporates COMPANY comments, aims at transferring information from Process to other disciplines: • • • •
to Piping, to perform routing studies to Piping materials, to perform 1st MTO for purchase To Instrumentation, to perform Instrument list To Civil for routing of Undeground Piping
© 2015 – Hervé Baron
IFC incorporates HAZOP impacts and information from Vendors. It is a pre-requisite to: • Start production of Piping isometrics
P&ID work sequence
HERVE BARON
P&ID Review
HAZOP
Piping Isometric drawings Piping material top-up’s
IFR
IFD
IFC Piping 2nd MTO & 1st material purchases Instrumenation & Control design Undeground piping (civil)
© 2015 – Hervé Baron
Piping routing
P&ID work sequence
HERVE BARON
Sometimes an « IFH » revision, mark-up’s of the P&ID review, is used to anticipate the HAZOP
P&ID Review
IFD
IFC
© 2015 – Hervé Baron
IFR
HAZOP
P&ID work sequence
HERVE BARON
An IFD2 revision is issued in case major change from Vendors/HAZOP to up-date piping material purchases, instrumentation design etc.
P&ID Review
HAZOP
Piping Isos Piping material top-up
Start
IFR
IFD IFD2
IFC
Piping routing Piping 1st material purchases Instrumenation & Control design Undeground piping (civil)
© 2015 – Hervé Baron
Up-date
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
Fluids list
© 2015 – Hervé Baron
Line list HERVE BARON
© 2015 – Hervé Baron
HERVE BARON
Line sizing
© 2015 – Hervé Baron
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
Instrument process data sheet
© 2015 – Hervé Baron
HERVE BARON
© 2015 – Hervé Baron
What is the most important process data for control valves?
Instrument process data sheet
HERVE BARON
Instrument process data sheet
© 2015 – Hervé Baron
Operating range, typ. Maximum flow rate: 110 % of max. operating flow rate Minimum flow rate: 30 % of minimum operating flow rate, in order to guarantee correct functioning at the extremes of the operating range.
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
Process Shut Down
Look at the extracts of these 2 P&IDs. How is the protection against loss of liquid level achieved in each case? © 2015 – Hervé Baron
HERVE BARON
ESD logic diagram
© 2015 – Hervé Baron
HERVE BARON
Safeguarding narrative & Cause and Effects charts
© 2015 – Hervé Baron
HERVE BARON
Process and Safety Diagrams (PSD)
© 2015 – Hervé Baron
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
Relief load summary
© 2015 – Hervé Baron
HERVE BARON
Flare study
© 2015 – Hervé Baron
HERVE BARON
Flare study
© 2015 – Hervé Baron
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
Operating manual
© 2015 – Hervé Baron
HERVE BARON
Operating manual What are the most important contents of the operating manual?
© 2015 – Hervé Baron
HERVE BARON
1 INTRODUCTION 1.1 General presentation 1.2 Glossary 1.3 Basic data 2 DESCRIPTION OF FACILITIES 2.1 General 2.2 Process 2.3 Utilities 2.4 Auxiliaries
4 OPERATION 4.1 Start-up 4.2 Normal operation 4.4 Shutdown 4.5 Depressurization 5 SAFETY 5.1 Operating philosophy 5.2 Escape, evacuation and rescue 5.3 Emergency power system 5.4 Safety equipment list 5.5 Fire protection © 2015 – Hervé Baron
3 AUTOMATIC CONTROL SYSTEM 3.1 System overview 3.2 Operator control interfaces 3.3 Telecommunications 3.4 Process alarms and trips 3.6 Emergency shutdown system 3.7 Fire & gas system
Operating Manual Table of Contents (typ.)
Operating Manual Annexes (typ.)
HERVE BARON
EQUIPMENT LIST
SINGLE LINE DIAGRAM
PFDs
P&IDs
F&G SYSTEM DRAWING
VESSELS SHEETS
INSTRUMENT DATA SHEETS (PSVs, Level instruments)
ARCHITECTURE
MECHANICAL
DATA
ESD LOGIC DIAGRAM
EQUIPMENT START/STOP SHUTDOWN SEQUENCES
GENERAL PLOT PLAN
ESD SIMPLIFIED DIAGRAM
DCS ARCHITECTURE DRAWING
CONTROL LOOPS AND ALARM LIST
ELECTRICAL CONTROL SYSTEM ARCHITECTURE DRAWING
SECURITY SWITCHES LIST
&
© 2015 – Hervé Baron
Operating Manual Annexes (typ.)
HERVE BARON
EQUIPMENT LIST
SINGLE LINE DIAGRAM
PFDs
P&IDs
F&G SYSTEM DRAWING
VESSELS SHEETS
INSTRUMENT DATA SHEETS (PSVs, Level instruments)
ARCHITECTURE
MECHANICAL
DATA
ESD LOGIC DIAGRAM
EQUIPMENT START/STOP SHUTDOWN SEQUENCES
GENERAL PLOT PLAN
ESD SIMPLIFIED DIAGRAM
DCS ARCHITECTURE DRAWING
CONTROL LOOPS AND ALARM LIST
ELECTRICAL CONTROL SYSTEM ARCHITECTURE DRAWING
SECURITY SWITCHES LIST
&
© 2015 – Hervé Baron
HERVE BARON
Operating Manual Control loops and Alarms list
© 2015 – Hervé Baron
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2015 – Hervé Baron
• • • • • • • • • • •
HERVE BARON
Process design criteria
What are the different Process design criteria?
© 2015 – Hervé Baron
HERVE BARON
Process design criteria
What are the different Process design criteria? • • • • •
Design margins Design Pressure and Temperature criteria Equipment sizing criteria Line sizing criteria Control valve sizing criteria
© 2015 – Hervé Baron
HERVE BARON
• • • • •
Process design criteria
Design margins Design Pressure and Temperature criteria Equipment sizing criteria Line sizing criteria Control valve sizing criteria
© 2015 – Hervé Baron
Process design criteria
HERVE BARON
• • • • •
Design margins: what is the usual Equipment (rotating, heat exchangers, columns) overdesign (%)? Design Pressure and Temperature criteria Equipment sizing criteria Line sizing criteria Control valve sizing criteria
+?% © 2015 – Hervé Baron
Process design criteria
HERVE BARON
• • • • •
Design margins: what is the usual Equipment (rotating, heat exchangers, columns) overdesign (%)? Design Pressure and Temperature criteria Equipment sizing criteria Line sizing criteria Control valve sizing criteria
+10% © 2015 – Hervé Baron
HERVE BARON
• • • • •
Process design criteria
Design margins Design Pressure and Temperature criteria Equipment sizing criteria Line sizing criteria Control valve sizing criteria
© 2015 – Hervé Baron
Process design criteria
HERVE BARON
• • • • •
Design margins Design Pressure and Temperature criteria Equipment sizing criteria Line sizing criteria Control valve sizing criteria The design temperature should be the highest or lowest temperature to which the equipment is subjected, plus a margin. The following cases must be considered: (a) A maximum temperature which can occur when bypassing a heat exchanger or cooler for cleaning. (b) A high metal temperature on uninsulated equipment due to solar radiation.
(d) The maximum metal temperature that can occur during steam out or decoking operation.
© 2015 – Hervé Baron
(c) The lowest temperature that may be caused by auto-refrigeration.
HERVE BARON
• • • • •
Process design criteria
Design margins Design Pressure and Temperature criteria Equipment sizing criteria Line sizing criteria Control valve sizing criteria
© 2015 – Hervé Baron
HERVE BARON
• • • • •
Process design criteria
Design margins Design Pressure and Temperature criteria Equipment sizing criteria Line sizing criteria Control valve sizing criteria
© 2015 – Hervé Baron
HERVE BARON
Licensed vs Open Art Process
When one uses a process under license, what are the deliverables issued by the process LICENSOR?
© 2015 – Hervé Baron
Typical PROCESS Licensor / Engineering split
HERVE BARON
Process Licensor
Engineer
PFD, H&MB
X
Equipment data sheet
Equipment process data sheet: Equipment Mechanical data sheet - Operating conditions, - Duty - Diameters of vessels - Size of Nozzles - Pump head + specific info for internals etc.
P&IDs
Generic
customized (piping class, line and valves size, HAZOP comments, vendor info)
Line sizing
Line sizing criteria
Sizing (takes into account eqt loc, elevation etc.)
Plot Plan
recommendations
X
Material selection
Basic requirement
MSD
© 2015 – Hervé Baron
Item
Typical PROCESS Licensor / Engineering split
HERVE BARON
Process Licensor
Engineer
PFD, H&MB
X
Equipment data sheet
Equipment process data sheet: Equipment Mechanical data sheet - Operating conditions, - Duty - Diameters of vessels - Size of Nozzles - Pump head + specific info for internals etc.
P&IDs
Generic
customized (piping class, line and valves size, HAZOP comments, vendor info)
Line sizing
Line sizing criteria
Sizing (takes into account eqt loc, elevation etc.)
Plot Plan
recommendations
X
Material selection
Basic requirement
MSD
© 2015 – Hervé Baron
Item
HERVE BARON
The Oil & Gas Engineering Guide 2nd edition
Do you want to know more... Much more?
© 2015 – Hervé Baron
HERVE BARON
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
This suite of training modules covered the discipline chapters of the book...
© 2015 – Hervé Baron
HERVE BARON
The Oil & Gas Engineering Guide - 2nd edition Table of Contents
The Guide contains much more: The overall picture, interfaces, methods & tools, etc. © 2015 – Hervé Baron
HERVE BARON
The Oil & Gas Engineering Guide 2nd edition Order direct from the publisher: http://www.editionstechnip.com/en/catalogu e-detail/1111/oil-gas-engineering-guidethe.html
© 2015 – Hervé Baron
Related Documents
Process Engineering Guide
January 2021 1
Process Engineering Economics
January 2021 1
Process Engineering Chiyoda
January 2021 1
Total Process Engineering Manual
March 2021 0
Process: Guide 4
January 2021 1More Documents from "ahmedm"