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Description of the Process design of Oil & Gas facilities. Download the file to see my trainer's notes!
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© 2015 – Hervé Baron
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.
Please download this file so that you can see my trainer’s notes in the top left corner – latest Acrobat Pro feature.
Hervé
© 2015 – Hervé Baron
HERVE BARON
Engineering disciplines: activities and deliverables
PROCESS
PLANT LAYOUT
EQUIPMENT
SAFETY & ENVIRONMENT
CIVIL
PIPING
PIPELINE
INSTRUMENTATION
ELECTRICAL
© 2015 – Hervé Baron
HERVE BARON
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
© 2015 – Hervé Baron
HERVE BARON
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
© 2015 – Hervé Baron
HERVE BARON
What constitutes the Design Basis of a Process/Utility Unit?
Process Design Basis
© 2015 – Hervé Baron
HERVE BARON
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
© 2015 – Hervé Baron
HERVE BARON
Process design basis Compressor Station
© 2015 – Hervé Baron
HERVE BARON
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
© 2015 – Hervé Baron
HERVE BARON
Choice of Process Scheme
What are the bases of process scheme definition?
© 2015 – Hervé Baron
HERVE BARON
Overall Plant Process Design
What is the name of this drawing?
© 2015 – Hervé Baron
HERVE BARON
The Block Flow Diagram (BFD)
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
HERVE BARON
Unit Process Design
© 2015 – Hervé Baron
HERVE BARON
The Process Flow Diagram (PFD)
© 2015 – Hervé Baron
HERVE BARON
Unit Process Scheme Optimization
HP Separator 500 psig
5500 psig
Emul. Treater 50 psig 150 F
3000 psig
200 psig
Degasser 5 psig
5 psig
50 psig
1200 psig Gas Injection
Oil Production
From Wells 165 - 205 F
500 psig
HP Compression & TEG
LP Compression
TEG
Cooler
IP Compression
What are the elements taken into account in the definition/optimization of the process scheme?
© 2015 – Hervé Baron
HERVE BARON
Process simulations
© 2015 – Hervé Baron
HERVE BARON
Process simulations
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
Process simulations
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
Process simulations
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
Process simulations
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
Process simulations
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
Process simulations
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,
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
Heat & Mass Balance (HMB)
© 2015 – Hervé Baron
HERVE BARON
Heat & Material Balance
© 2015 – Hervé Baron
HERVE BARON
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
© 2015 – Hervé Baron
HERVE BARON
Process Description
© 2015 – Hervé Baron
HERVE BARON
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
© 2015 – Hervé Baron
HERVE BARON
Engineering disciplines: activities and deliverables
© 2015 – Hervé Baron
HERVE BARON
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
© 2015 – Hervé Baron
HERVE BARON
Equipment sizing
© 2015 – Hervé Baron
HERVE BARON
32
Cass study: Equipment Sizing
© 2015 – Hervé Baron
HERVE BARON
33
© 2015 – Hervé Baron
HERVE BARON
Case study: Equipment Sizing Production separator
Sets the gas cross section
Sets the liquid volume
Vessel size
© 2015 – Hervé Baron
HERVE BARON
Process data sheet Drums
© 2015 – Hervé Baron
HERVE BARON
Process data sheet
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)
© 2015 – Hervé Baron
HERVE BARON
Process Data sheet Column
© 2015 – Hervé Baron
HERVE BARON
Columns and Drums
Column internals must be specified.
These pictures are excerpts from Sulzer douments
© 2015 – Hervé Baron
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
What is particularly important while specifying a heater ?
© 2015 – Hervé Baron
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
HERVE BARON
Process Sizing
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
HERVE BARON
Process Sizing
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
HERVE BARON
Process Sizing
Process Equipment Sizing is done on the basis of:
Sizing cases – all operating case
Over design – 10% as a rule
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
© 2015 – Hervé Baron
HERVE BARON
Process specification Package
What document is issued by Process for packages?
© 2015 – Hervé Baron
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
HERVE BARON
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
© 2015 – Hervé Baron
HERVE BARON
Piping & Instrumentation Diagram (P&ID)
Compare the information shown on the PFD and the P&ID
© 2015 – Hervé Baron
HERVE BARON
Piping & Instrumentation Diagram (P&ID)
Compare the information shown on the PFD and the P&ID
Compare the information shown on the PFD and the P&ID
© 2015 – Hervé Baron
HERVE BARON
Piping & Instrumentation Diagram (P&ID)
Compare the information shown on the PFD and the P&ID
What are the purposes of P&IDs?
© 2015 – Hervé Baron
HERVE BARON
Piping & Instrumentation Diagram (P&ID)
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.
© 2015 – Hervé Baron
HERVE BARON
Piping & Instrumentation Diagram (P&ID)
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
© 2015 – Hervé Baron
HERVE BARON
Piping & Instrumentation Diagram (P&ID)
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?
© 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
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
What do you call each type of isolation?
© 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
Where do you use double block and bleed?
© 2015 – Hervé Baron
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
HERVE BARON
Piping & Instrumentation Diagrams (P&IDs)
Important features 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
© 2015 – Hervé Baron
HERVE BARON
Piping & Instrumentation Diagrams (P&IDs)
It includes:
1. All itemized equipment,
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…)
© 2015 – Hervé Baron
HERVE BARON
Piping & Instrumentation Diagrams (P&IDs)
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
© 2015 – Hervé Baron
HERVE BARON
Piping & Instrumentation Diagrams (P&IDs)
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.
© 2015 – Hervé Baron
HERVE BARON
Piping & Instrumentation Diagrams (P&IDs)
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
Piping & Instrumentation Diagrams (P&IDs)
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
HERVE BARON
Piping & Instrumentation Diagrams (P&IDs)
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
HERVE BARON
Piping & Instrumentation Diagrams (P&IDs)
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
Piping & Instrumentation Diagrams (P&IDs)
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
HERVE BARON
Piping & Instrumentation Diagrams (P&IDs)
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
Piping & Instrumentation Diagrams (P&IDs)
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
How would you call each of these two types of arrangement? For what service(s) would each be used?
© 2015 – Hervé Baron
HERVE BARON
Piping & Instrumentation Diagrams (P&IDs)
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
HERVE BARON
P&ID work sequence
IFR IFD IFC
P&IDs are typically issued 3 times, as design progresses
© 2015 – Hervé Baron
HERVE BARON
P&ID work sequence
IFR IFD IFC
P&IDs are typically issued 3 times, as design progresses
© 2015 – Hervé Baron
HERVE BARON
P&ID work sequence
IFR IFD IFC
P&ID Review
P&IDs are typically issued 3 times, as design progresses
© 2015 – Hervé Baron
HERVE BARON
P&ID work sequence
IFR IFD IFC
P&ID Review HAZOP
P&IDs are typically issued 3 times, as design progresses
© 2015 – Hervé Baron
HERVE BARON
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
© 2015 – Hervé Baron
HERVE BARON
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
© 2015 – Hervé Baron
HERVE BARON
P&ID work sequence
IFR IFC
P&ID Review
P&IDs are typically issued 3 times, as design progresses
IFD
HAZOP
© 2015 – Hervé Baron
HERVE BARON
P&ID work sequence The different revisions
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
© 2015 – Hervé Baron
HERVE BARON
P&ID work sequence
IFR IFD IFC Piping routing
Piping 2nd MTO & 1st material purchases
Instrumenation & Control design
Undeground piping (civil)
Piping Isometric drawings
Piping material top-up’s
P&ID Review HAZOP
© 2015 – Hervé Baron
HERVE BARON
P&ID work sequence
IFR IFD
P&ID Review HAZOP
Sometimes an « IFH » revision, mark-up’s of the P&ID review, is used to anticipate the HAZOP
IFC
© 2015 – Hervé Baron
HERVE BARON
P&ID Review
P&ID work sequence
IFR IFD IFC
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
© 2015 – Hervé Baron
HERVE BARON
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
© 2015 – Hervé Baron
HERVE BARON
Fluids list
© 2015 – Hervé Baron
HERVE BARON
Line list
© 2015 – Hervé Baron
HERVE BARON
Line sizing
© 2015 – Hervé Baron
HERVE BARON
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
© 2015 – Hervé Baron
HERVE BARON
Instrument process data sheet
© 2015 – Hervé Baron
HERVE BARON
Instrument process data sheet
What is the most important process data for control valves?
© 2015 – Hervé Baron
HERVE BARON
Instrument process data sheet
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.
© 2015 – Hervé Baron
HERVE BARON
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
© 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
HERVE BARON
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
© 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
HERVE BARON
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
© 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
Operating Manual Table of Contents (typ.)
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
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
HERVE BARON
Operating Manual Annexes (typ.)
EQUIPMENT LIST
PFDs
P&IDs
ESD LOGIC DIAGRAM
EQUIPMENT START/STOP & SHUTDOWN SEQUENCES
GENERAL PLOT PLAN
DCS ARCHITECTURE DRAWING
ELECTRICAL CONTROL SYSTEM ARCHITECTURE DRAWING
SINGLE LINE DIAGRAM
F&G SYSTEM ARCHITECTURE DRAWING
VESSELS MECHANICAL DATA SHEETS
INSTRUMENT DATA SHEETS (PSVs, Level instruments)
ESD SIMPLIFIED DIAGRAM
CONTROL LOOPS AND ALARM LIST
SECURITY SWITCHES LIST
© 2015 – Hervé Baron
HERVE BARON
Operating Manual Annexes (typ.)
EQUIPMENT LIST
PFDs
P&IDs
ESD LOGIC DIAGRAM
EQUIPMENT START/STOP & SHUTDOWN SEQUENCES
GENERAL PLOT PLAN
DCS ARCHITECTURE DRAWING
ELECTRICAL CONTROL SYSTEM ARCHITECTURE DRAWING
SINGLE LINE DIAGRAM
F&G SYSTEM ARCHITECTURE DRAWING
VESSELS MECHANICAL DATA SHEETS
INSTRUMENT DATA SHEETS (PSVs, Level instruments)
ESD SIMPLIFIED DIAGRAM
CONTROL LOOPS AND ALARM LIST
SECURITY SWITCHES LIST
© 2015 – Hervé Baron
HERVE BARON
Operating Manual Control loops and Alarms list
© 2015 – Hervé Baron
HERVE BARON
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
© 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
HERVE BARON
Process design criteria
• 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
HERVE BARON
Process design criteria
• 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
HERVE BARON
Process design criteria
• 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.
© 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
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
HERVE BARON
Typical PROCESS Licensor / Engineering split
Item Process Licensor Engineer PFD, H&MB X
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
© 2015 – Hervé Baron
HERVE BARON
Typical PROCESS Licensor / Engineering split
Item Process Licensor Engineer PFD, H&MB X
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
© 2015 – Hervé Baron
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/catalogue-detail/1111/oil-gas-engineering-guide-the.html