01a-Introduction to Process Plant Design

8/8/2019 01a-Introduction to Process Plant Design

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Introduction to

Process Plant

Design

Copyright , 2009

William G. Beazley, PhD

All Rights ReservedPhoto:Air Products

Process Plants

Characterized by Chemical Processes

Different from power (including nuclear), propulsion,etc.

Hazards from both energy and substance release Substances and their temperature and pressure, etc.,

usually drives the selection of piping materials anddesign ratings

Petrochemical Plants have their own:

Design standards

Terminology

Practices and

Constraints

Basic Components of a

Typical Chemical Process(R. K. SINNOTT)

Tanks,

Warehouses,

Hoppers,

Piles, etc.

Pumps,

Compressors,

Exchangers,

Heaters,

Crushers,

Mixers, etc.

Reactors,

Furnaces,

etc.

Drums,

Towers,

Filters,

Dryers, etc.

Reflux,

Strippers,

Treaters,

etc.

Tanks,

Warehouses,

Baggers,

etc.

Raw Material Storage

Tanks, Hoppers, Piles, etc.

Feed Preparation

(US Navy, Nasa, Transportation, Pumps, Compressors, Exchangers, Heaters,

Crushers, Mixers, etc.

http://www.npt.nuwc.navy.mil/facilities/QuietWater/default.htm

http://www.tfhrc.gov///pubrds/05jan/02.htm

http://www.ih.navy.mil/Departments/ord/che-ext-tec-div/index.asp

Reaction

(US Army, DOE, ) Reactors, Furnaces, etc.

http://www.pmcd.apgea.army.mil/multimediaviewer.aspx?id=585

http://www.netl.doe.gov/technologies/coalpower/cctc/summaries/tampa/tampaedemo.html


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Product Separation(US DOE)

Drums, Towers,

Filters, Dryers, etc.

http://www.nrel.gov/data/pix/searchpix.cgi?

http://www.greensboro-nc.gov/departments/Water/watersystem/treatment.htm

Product Purification(US OSHA, DOT)

Reflux, Strippers,

Treaters, Sorters, etc.

http://iforms.osha-slc.gov/dts/osta/otm/otm_iv/otm_iv_2.html

Product Storage

Tanks, Warehouses,

Baggers,

etc.

Waste Storage(DOE, EPA, USGS)

http://www.fedcenter.gov/_storage/Photos/176.jpg

http://www.tobyhanna.army.mil/about/certifications/environmental/rcra%20cleanup.htm

http://pubs.usgs.gov/gip/gw_ruralhomeowner/gw_ruralhomeowner_new.html

Sales

http://www.msc.navy.mil/sealift/2005/September/katrina.htm

The Manufacture of Cement by the

Portland Process(US CDC)

http://www.cdc.gov/elcosh/docs/d0200/d000279/ilochap93.html

Limestone,

Clay, etc.


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Parties to Plant

Design(The 'PIPING GUIDE')

Client wants a finished

plant Business Case Primary

Concern

Everyone Else is

Temporary

Design Engineers

produce highly quality

assured product

definition data

Construction Realizes

DesignSource:

The 'PIPING GUIDE'

http://www.pipingguide.com

Process Plant Client Funds the engineering and construction of the plant

Generally supplies or approves the processes to be used

Accepts the work performed

The Project Engineer

Formal point of contact with the client

Voice of the client inside the engineering organization

Usually seals design as professional engineer

Responsible for completeness and correctness of workhttp://www.nps.gov/hfc/products/imi/imi-ser-class.htm


Reviews the Design

Basis of Plant

Enforces Client

Requirementshttp://www.osha.gov/dcsp/partnerships/regional/region2/453_signing.html


Plans and Schedules

Workhttp://www.osha.gov/dcsp/partnerships/regional/region2/459_signing.html

Procured Materials and Services

Items that has been obtained from vendor or

supplier

Assistance or advice provided by a vendoror supplier

Obtained through a procurement process

Result in a list of vendors and

subcontractors


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Project Organization

Source: The 'PIPING GUIDE'


Project

Design

Groups and

InformationFlow

(Source: The

'PIPING GUIDE')


Design Organizational Roles

Design

Supervisor

Designer

Designer

Designer

Designer

Checker

Project

Data

Design supervisor/Group leader

Manages the documentation of in process

and approved engineering data

Contacts the Project Engineer for any

approvals required

Assigns work to designers at the appropriate

time

Assures all data needed for work is

available to designers

The Piping Designer

Responsible for correctness of his

work

Inform supervisor if questions arise Recognize need for data required to

complete work

Never contact the client directly

Engineering Design Specifications

Established basis for final plant design

Includes:

start-up procedures,

initial site selection information, general pre-commissioning guidelines,

equipment testing procedures and acceptance

methods

final process topology,

material and energy balance information


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Functional Equipment Characteristics

Describe or specify:

Functional requirements for theequipment

Service provided to the process by

the equipment

What equipment is supposed to do

Vendor-Proprietary Equipment

Equipment whose performance is

guaranteed by the vendor.

Specified by equipment datasheet in

process design specifications

package.

Usually designed by first selecting a

vendor who performs testing and

sizing of the item

Supplier/Vendor Relationship

Request the required information only

Disclosing only necessary information to

get the right data

Avoid:

Disclosing competition

Telling vendor hell get the order

Gratuities and never demand them (lunch)

Ordering to get information then cancel

Documentation

All project management, design,

contractual, regulatory, and disposal

documents produced during the life

cycle of a process plant.

Has versions and releases that must

be managed.

Includes all documentation retained

past the end of the plant life cycle

Operations Documents

Covers all the many different phases and

aspects of plant operation

Documentation necessary to run the

plant safely:

Procedure to start up and shut down the

plant

Parameters and settings for process

equipment and controls

Handover

Transfer of responsibility for the plant

Construction team to commissioning team

Commissioning team to operating team

Involves transfer of all supporting

documentation


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Activity Model of the Oil and Gas

Production Facility Life-cycle(ISO 15926)

Produce Conceptual

Process Design

Produce Detailed

Process Design

Produce Conceptual

Engineering Design

(Front End)

Produce Detailed

Engineering Design

Commission

Plant

Construct Plant

Pre-Commission

Operate PlantDecommission

Plant

Maintain Plant

and Equipment

Demolish Plant

and Restore Site

Procure and Control Equipment, Material and ServicesSuppliers and

Fabricators

http://www.tc184-sc4.org/About_TC184-SC4/About_SC4_Standards/

Common Status Terms

As-built: Process plant's actual physical

and functional aspects at a specific point

in timeAs-approved: Product data provide to

and approved by client

As-specified: Approved data provide to

engineer by client

As-released: Product data officially

provided to anyone

Construction Release

All data needed to realize the plant

Build,

Commission,

Train to operate, maintain

Approved for release by engineering for

construction

Stamped by a registered professional

engineer

Finalized Construction Documents

All documentation related to the erection,commissioning and operation

Includes:

As-built reports,

Equipment certification,

Nameplate information of installed equipment,

Operating manuals,

Testing procedures,

Field changes, and

Photos of as-built units, modules and plant

Plant Commissioning Required before

client handover

Proven operational

through specific

procedures

Confirm Staff

Skills

Verify productdata

Test equipment

Equipment

Commissioning

Procedures - Step-

by-step explanation

of start-up actions

required to

commission

equipmentin the

planthttp://www.usaid.gov/iraq/photogallery/gallery_8/capconstr1_06.html

Maintenance

http://flickr.com/photos/coolnewspics/244371213/in/dateposted/


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Maintenance

http://www.eere.energy.gov/industry/bestpractices/energymatters/full_issue.cfm/volume=37

http://www.srs.gov/general/busiops/tech-transfer/plant.htm

http://www1.usaid.gov/iraq/photogallery/gallery_39/photo18.html

http://splash.metrokc.gov/wtd/southplant/index.htm

Shutdown/Decommissioning

Shutting down the

plant

Preserving it for

later

commissioning or

demolition

May not include

site remediation

http://www-als.lbl.gov/als/als_news/news_archive/vol.240_042804.html

http://www.lm.doe.gov/land/sites/oh/fernald_orig/VImages/PhotoTour/1998/Dec98/Plt6c.htm

http://www.nrc.gov/reading-rm/doc-collections/fact-sheets/decommissioning.html

Project Schedule

Duration

Start Date

Critical Path

Sequence of Tasks

such that if any is late

the project is late.

Can be more than one

http://www.coconino.az.gov/cji.aspx?id=383

Questions

Production Output Materials or energy to be sold or

traded

Result of processing raw material(s)

(Production Input)

Produced according to a scheduled

delivery time, grade, and quantity of

product to be producedSource: EPISTLE Process Industries Data Handover Guide - Part 1

http://www.uspi.nl/projects/Joint_Projects/fr_joint_projects.html

PISTEP Process Plant Engineering Processes


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Course Outline

Part 1 Pipe Lifecycle

Part 2 Pipe Fluid Flow & Control Part 3 Plant Equipment

Part 4 Pipe Structural Design

Part 5 Project Practices & Management

Part 6 Project