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Introduction toProcess Plant
Design
Copyright ©, 2009William 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 aTypical 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 thePortland Process
(US CDC)
http://www.cdc.gov/elcosh/docs/d0200/d000279/ilochap93.html
Limestone,Clay, etc.
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Parties to PlantDesign
(The 'PIPING GUIDE')
• Client wants a finishedplant– Business Case Primary
Concern
– Everyone Else isTemporary
• Design Engineersproduce highly qualityassured productdefinition data
• Construction RealizesDesign
Source: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
The Project Engineer
• Reviews the DesignBasis of Plant
• Enforces ClientRequirements
http://www.osha.gov/dcsp/partnerships/regional/region2/453_signing.html
The Project Engineer
• Plans and SchedulesWork
http://www.osha.gov/dcsp/partnerships/regional/region2/459_signing.html
Procured Materials and Services
• Items that has been obtained from vendor orsupplier
• Assistance or advice provided by a vendoror supplier
• Obtained through a procurement process
• Result in a list of vendors andsubcontractors
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Project Organization
Source: The 'PIPING GUIDE'http://www.pipingguide.com
ProjectDesign
Groups andInformation
Flow(Source: The
'PIPING GUIDE')
http://www.pipingguide.com
Design Organizational Roles
DesignSupervisor
Designer
Designer
Designer
Designer
Checker
ProjectData
Design supervisor/Group leader
• Manages the documentation of in processand approved engineering data
• Contacts the Project Engineer for anyapprovals required
• Assigns work to designers at the appropriatetime
• Assures all data needed for work isavailable to designers
The Piping Designer
• Responsible for correctness of hiswork
• Inform supervisor if questions arise
• Recognize need for data required tocomplete 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 acceptancemethods
– 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 bythe equipment
–What equipment is supposed to do
Vendor-Proprietary Equipment
• Equipment whose performance isguaranteed by the vendor.
• Specified by equipment datasheet inprocess design specificationspackage.
• Usually designed by first selecting avendor who performs testing andsizing of the item
Supplier/Vendor Relationship
• Request the required information only
• Disclosing only necessary information toget the right data
• Avoid:
–Disclosing competition
–Telling vendor he’ll get the order
–Gratuities and never demand them (lunch)
–Ordering to get information then cancel
Documentation
• All project management, design,contractual, regulatory, and disposaldocuments produced during the lifecycle of a process plant.
• Has versions and releases that mustbe managed.
• Includes all documentation retainedpast the end of the plant life cycle
Operations Documents
• Covers all the many different phases andaspects of plant operation
• Documentation necessary to run theplant safely:
–Procedure to start up and shut down theplant
–Parameters and settings for processequipment and controls
Handover
• Transfer of responsibility for the plant
–Construction team to commissioning team
–Commissioning team to operating team
• Involves transfer of all supportingdocumentation
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Activity Model of the Oil and GasProduction Facility Life-cycle
(ISO 15926)
Produce ConceptualProcess Design
Produce DetailedProcess Design
Produce ConceptualEngineering Design
(Front End)
Produce DetailedEngineering Design
CommissionPlant
Construct PlantPre-Commission
Operate PlantDecommission
Plant
Maintain Plantand Equipment
Demolish Plantand Restore Site
Procure and Control Equipment, Material and ServicesSuppliers andFabricators
http://www.tc184-sc4.org/About_TC184-SC4/About_SC4_Standards/
Common Status Terms
• As-built: Process plant's actual physicaland functional aspects at a specific pointin timeAs-approved: Product data provide toand approved by clientAs-specified: Approved data provide toengineer by clientAs-released: Product data officiallyprovided to anyone
Construction Release
• All data needed to realize the plant– Build,
– Commission,
– Train to operate, maintain
• Approved for release by engineering forconstruction
• Stamped by a registered professionalengineer
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 operationalthrough specificprocedures
– Confirm StaffSkills
– Verify productdata
– Test equipment
• EquipmentCommissioningProcedures - Step-by-step explanationof start-up actionsrequired tocommissionequipment in theplanthttp://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 theplant
• Preserving it forlatercommissioning ordemolition
• May not includesite 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 Taskssuch that if any is latethe 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 scheduleddelivery time, grade, and quantity ofproduct to be produced
Source: EPISTLE Process Industries Data Handover Guide - Part 1http://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