Process Design Induction - Introduction to Process Engineering

INTRODUCTION

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PROCESS ENGINEERING / DESIGN

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ORGANOGRAM

Lead Process

Senior Process Engineer

Senior Process Designer

Process Engineers Process Designers

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Process Department

• The department is made up of group of professionally trained chemical engineers & non-chemical engineers who collectively worked together to produce required “deliverables" (output) for a particular process as described or desire by clients.

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Scope of Work

• Process scope of work is usually divided into two;

• Process

• Utility

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Process Design Basis & criterial

• Process design criteria: Standards, rules or test by which process design decisions may be based.

• Process design basis: Fundamental data upon which process design calculations are based.

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Process Design BasisFunctions of the Process Design Basis:• Defines the basic requirements that a design

must meet• Communicates important design information to

the Client• Serves as a key approval point in the

development of the unit• Serves as a key interface point for coordinating

stream operating• conditions between process units• Serves as a kick-off point for licensed unit

designs

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Process Design BasisContent of Process Design Basis:• Plant capacity• Site location• Source of process technology• Units of measurement• Meteorological and other site data• Raw materials• Products / By-products• Tabulation of utility conditions• Battery limit conditions• Materials of construction• Plant on-stream factor

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Process Design Basis

• Plant capacity design margin• Equipment design factors• Startup and shutdown requirements• System reliability requirements• Physical / thermodynamic properties• Reactions• Yields / losses• Storage Requirements• Environmental requirements

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Process Design Basis• The preparation of the Process Design Basis is

the responsibility of the Lead Process Engineer.

• Licensed designs will require close coordination between the Process Engineer, the Client, and the Licensor in developing the Process Design Basis.

• It is the responsibility of the Process Engineer to adhere to the basic design parameters provided in the Process Design Basis, and to be familiar with the Process Design Basis of interconnected units.

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Process Design Criteria

The purpose of the Process Design Criteria is to establish specific guidelines and constraints that govern the following:

• Format and Content of Flow Diagrams• Specification and Design of Equipment• Economic Analysis• Safety• Design and Development of Instrumentation and

Piping Systems

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Process Design Criteria

• Topics covered by Process Design Criteria:• Codes and standards• Environmental regulations• Source for physical property data• Noise level limitations• Naming and numbering of equipment• Drawing numbering• Criteria for flexibility and expansion• Safety considerations• Economic criteria• Utility design information

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Process Design Criteria

• Materials of construction• BFDs (Block Flow Diagrams)• PFDs (Process Flow Diagrams)• P&IDs (Piping and Instrumentation Diagrams)• Equipment datasheets and design basis sheet• Piping and Hydraulics• Instrumentation• Relief System

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Process Design Criteria

The following sources are used for the preparation of the Process Design Criteria:

• Project/Plant Specific Process Design Criteria• Client Standards• Applicable Codes and Standards

It is the responsibility of each Process Engineer to be familiar with the project process Design Criteria and to apply it on the project. Any deviation from the Process Design Criteria requires the approval of the Lead Process Engineer.

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Diagrams

• Block Flow Diagram (BFD) is a simplified drawing of the overall process.

• Major equipment, processes, or unit operations are represented by blocks.

• It serves as a communication tool between the Process Engineer and the Client when the basic concepts of the process are preliminary.

• It provides a simplified starting point for preparing Process Flow

• Diagrams (PFD) and heat and material balances.

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Diagrams

Types of Block Flow Diagram:

• Overall Process Block Flow Diagram

• Utilities Block Flow Diagram / Balance

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Process Description

• It is a detailed narrative describing the activities represented by process document (BFD, PFD, or P&ID).

• It is designed to answer questions relating to what, why, and how.

• The content is generally tailored to the level of design in progress, and can vary significantly from project to project.

• It serves as a tool to communicate design issues within the task force.

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Process Description

A typical Process Description covers the following:

• Description of the overall function of the operations depicted on the flow sheet

• Discussion of feed streams including method of control and conversion to products

• Description of major equipment including its function in the process

• Process controls• Operating conditions

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Process DescriptionThe following documents may be used in the preparation of a process description:

• Process Unit Design Basis• Block Flow Diagrams• Process Flow Diagrams and Material Balances• Equipment List and Datasheets• P&ID’s• Instrument Index• Control and Interlock Descriptions• Utility Summaries• Catalyst and Chemicals Requirements

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Utilities DescriptionThe Utility part /section of major projects includes;• Raw Water treatment• Cooling water• Potable water• Service (Utility water)• Drain system

-oily water, storm water, chemical contaminant water, sanitary water

• Waste treatments• Fuel gas system• Steam/ condensate• Refrigeration• Tank and Storage• Flare

- elevated or ground flare

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Utilities Description

• Incineration

• Air system

-instrument air, service/utility/plant air

• Nitrogen system

• Fire water system

-Main ring, foam, & deluge system

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SoftwareProcess software;• Hysys; For determining heat, energy and material balances• Pipesim;Fluid & multiphase flow modeling, Reservoir, well & completion

modeling• Pipephase;Multiphase modeling• Auto CAD;For drafting/drawing

Utility software;• Pipenet; hydraulic analysis of spray & sprinkler system, Transient &

Fluid network• Flaresim; Modeling of flare radiation and sizing• Flarenet; Modeling of flare network

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Process Equipments

• Separator

• Pumps

• Compressors

• Heat Exchangers

• Tanks

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Safety Equipments

• Pressure Safety Valve (PSV)

• Vent

• SDV/ESD/BDV

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Equipments List

• Equipment List displays the name, item number, and brief information about each piece of process equipment on a project.

• It helps to define the scope of a unit.

• It serves as a communication tool among Process, Mechanical, Controls/Estimating, and the Client.

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Equipments List• The Process Engineer usually initiates the Equipment

List.

• The Equipment List is later transferred to the Mechanical Engineer for maintenance and updating

• Information that is provided in a sized equipment list generally includes equipment size or capacity, design pressure and temperature, insulation, materials of construction, etc.

• It is important that both name and the item number be carried forward to other documents.

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Process Calculations• It is extremely important that process work be accurate

to meet the requirements of the project and the Client. It is the responsibility of engineers to have their work checked for completeness, accuracy, consistency, valid assumptions and references, correct methods, and format.

• Process calculation is one of the deliverable for ISO-9001 compliance.

• Every Calculation requires a calculation cover page

• Format for calculation: electronic or manual is set by Lead Engineer.

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Process Checking & Approver

• Work Instructions identify key activities where accuracy must be verified to ensure a high quality product.

• The ORIGINATOR: self-checking tool.

• The CHECKER : ascertain that all aspects relevant to the satisfactory completion of that document have been considered.

• The APPROVER : establish that both the originator and

checker have performed all the functions for which they are responsible.

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Process Checking & ApproverLevels of checking requirement:

• Checking Level 1

Complete detailed check (100% checklist activity items) of all documents.

• Checking Level 2

Selective check (partial utilization of the checklist activity items) of all documents, or complete check of selective documents.

• Checking Level 3 (discontinued)

Spot check of random selection of documents.• Checking Level 4

Complete "self check" only by the originator.

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Filing

The Lead Engineer is responsible for:

• Setting up the filing system at the start of the project

• Ensuring that each process engineer files information in a consistent manner

• Examining the files for archiving purposes and sort the contents with a view to retention or disposal upon project completion