Description of the Process design of Oil & Gas facilities.
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Engineering disciplines: activities and deliverables
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
Engineering disciplines: activities and deliverables
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
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
Process Design Basis
Presenter
Presentation Notes
Turndown would be representative of end-of-life conditions for an Upstream facility for instance (low flow rate due to depleted reservoir and low pressure)
Engineering disciplines: activities and deliverables
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
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
Scheme including the following information, as a minimum:
Main equipment (all the itemized ones),
Process lines between equipment,
All control loops and main instruments,
For each stream, indication of: • Temperature • Pressure • Composition • Specific gravity • Operating density • Heat content • Flow rate (relevant to each phase)
Design conditions of main equipment.
It shall be drawn-up according to ISA 6.12 regulation as far as symbology is concerning
Engineering disciplines: activities and deliverables
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
Engineering disciplines: activities and deliverables
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
Engineering disciplines: activities and deliverables
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
The Process Data Sheet specifies the duty. It is completed by a trade data sheet: the Mechanical Data Sheet for an Equipment, the Instrument Data Sheet for an Instrument, which specifies all other requirements to ensure long life and reliable service.
Sizing criteria • Separator • KO drum • Distillation/Absorption column • Reactor • Storage tank
Presenter
Presentation Notes
Separator – Size of droplet => velocity // residence time + Surge KO Drum – Size of droplet => velocity // Hold up time Distillation/Absorption column – Diameter based on flow. Number of trays/height of packing based on purity required Reactor – Contact time (space velocity) Tank – Storage capacity
Sizing criteria • 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
Engineering disciplines: activities and deliverables
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
Compare the information shown on the PFD and the P&ID
What are the purposes of P&IDs?
At design stage: • Defines the design basis for Piping & Instrumentation disciplines • Serves to show and agree the operating and maintenance features between
Engineer and Owner or between Engineer and Vendor • Serves to show the interface with equipment/package vendors • Perform HAZOP review
During operation: • Reference drawing for operator, work permit, plant modifications etc.
Compare the information shown on the PFD and the P&ID
What are the purposes of P&IDs?
At design stage: • Defines the design basis for Piping & Instrumentation disciplines • Serves to show and agree the operating and maintenance features between
Engineer and Owner or between Engineer and Vendor • Serves to show the interface with equipment/package vendors • Perform HAZOP review
During operation: • Reference drawing for operator, work permit, plant modifications etc.
Compare the information shown on the PFD and the P&ID
What are the purposes of P&IDs?
At design stage: • Defines the design basis for Piping & Instrumentation disciplines • Serves to show and agree the operating and maintenance features between
Engineer and Owner or between Engineer and Vendor • Serves to show the interface with equipment/package vendors • Perform HAZOP review
During operation: • Reference drawing for operator, work permit, plant modifications etc.
P&ID review
Which are the usual points reviewed during a P&ID review?
2. Item number and service description of each equipment with relevant design condition
3. 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…)
4. Battery limits between Parties, e.g. contractor and vendor
5. All valves for operation, start-up, maintenance with indication of valve type, including isolation valves, check valves etc.
6. 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.),
7. 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
9. Particular data or notes relevant to equipment/instruments installation, such as: • 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,
10. Item number and service description of each equipment with relevant design condition
11. Connecting flags for pipe lines running from one drawing to another
Instruments and controls must be drawn-up according to ISA 6.12 requirements.
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
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
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
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
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
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
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?
Presenter
Presentation Notes
Sample collection Drains Isolation (blinding) of equipment Double/single block isolation Isolation and instrumentation at battery limit PSV
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
Quiz Which revision of P&IDs has the following purpose/contents?
Purpose IFR IFD IFC 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 IFR IFD IFC Comments from all disciplines
Comments from Piping, I&C disciplines
Finalized interfaces with eqt/package
Exercised Contract Option(s)
Size, number of PSVs and CVs Diameter of process lines Diameter of utility lines HAZOP comments incorporated Client comments incorporated
Quiz Which revision of P&IDs has the following purpose/contents?
Purpose IFR IFD IFC Collect Client comments X Perform PID review X Perform HAZOP X Perform Piping MTO for 1st Piping purchase X Freeze Control system I/O list X Issue Piping ISOs X Contents IFR IFD IFC Comments from all disciplines X
Comments from Piping, I&C disciplines X
Finalized interfaces with eqt/package X
Exercised Contract Option(s) X
Size, number of PSVs and CVs X Diameter of process lines X Diameter of utility lines X HAZOP comments incorporated X Client comments incorporated X
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
IFC incorporates HAZOP impacts and information from Vendors. It is a pre-requisite to: • Start production of Piping isometrics
An IFD2 revision is issued in case major change from Vendors/HAZOP to up-date piping material purchases, instrumentation design etc.
Piping routing
Piping 1st material purchases
Instrumenation & Control design
Undeground piping (civil)
Piping Isos
Piping material top-up
IFD2
HAZOP
Up-date
Start
Presenter
Presentation Notes
Notes related to the IFD revision: The IFD Revision is necessary for discipline co-ordination, which cannot wait until everything is finalized (IFC) An additional revision (IFD2) may be issued to: Improve Piping MTO Start partial Isometric production Up-date information for instrumentation, in particular for ordering the ESD system In particular, when major changes to IFD P&IDs resulted from HAZOP, vendors etc.
Engineering disciplines: activities and deliverables
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
Engineering disciplines: activities and deliverables
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
Contents: type of instrument, flowrate, operating pressure and temperature, maximum available differential pressure, physical properties of handled product (including critical P and T, and vapor pressure), material of construction, action of control valves in case of air failure, layout of graphic, tightness requirement, special requirements (fire test, emergency air bottle, etc.)
What is the most important process data for control valves?
Presenter
Presentation Notes
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
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
Engineering disciplines: activities and deliverables
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
Engineering disciplines: activities and deliverables
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
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
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
Engineering disciplines: activities and deliverables
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
• 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
+?%
Presenter
Presentation Notes
The Process Design criteria is the JSD for Process
• 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%
Presenter
Presentation Notes
The Process Design criteria is the JSD for Process
• 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. (c) The lowest temperature that may be caused by auto-refrigeration. (d) The maximum metal temperature that can occur during steam out or decoking operation.
Equipment data sheet Equipment process data sheet: - Operating conditions, - Duty - Diameters of vessels - Size of Nozzles - Pump head + specific info for internals etc.
Equipment Mechanical data sheet
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
Equipment data sheet Equipment process data sheet: - Operating conditions, - Duty - Diameters of vessels - Size of Nozzles - Pump head + specific info for internals etc.
Equipment Mechanical data sheet
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