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Process Engineering Tutorial

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Description of the Process design of Oil & Gas facilities.

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Process Engineering Tutorial

  1. 1. ©2015–HervéBaron 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 (herve.baron@gmail.com), 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
  2. 2. ©2015–HervéBaron HERVE BARON Engineering disciplines: activities and deliverables  PROCESS  PLANT LAYOUT  EQUIPMENT  SAFETY & ENVIRONMENT  CIVIL  PIPING  PIPELINE  INSTRUMENTATION  ELECTRICAL
  3. 3. ©2015–HervéBaron 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
  4. 4. ©2015–HervéBaron 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
  5. 5. ©2015–HervéBaron HERVE BARON What constitutes the Design Basis of a Process/Utility Unit? Process Design Basis
  6. 6. ©2015–HervéBaron 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
  7. 7. ©2015–HervéBaron HERVE BARON Process design basis Compressor Station
  8. 8. ©2015–HervéBaron 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
  9. 9. ©2015–HervéBaron HERVE BARON Choice of Process Scheme What are the bases of process scheme definition?
  10. 10. ©2015–HervéBaron HERVE BARON Overall Plant Process Design What is the name of this drawing?
  11. 11. ©2015–HervéBaron 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
  12. 12. ©2015–HervéBaron HERVE BARON Unit Process Design
  13. 13. ©2015–HervéBaron HERVE BARON The Process Flow Diagram (PFD)
  14. 14. ©2015–HervéBaron 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?
  15. 15. ©2015–HervéBaron HERVE BARON Process simulations
  16. 16. ©2015–HervéBaron HERVE BARON Process simulations Input - Feed composition and conditions Simulator settings - Flow scheme - Thermodynamic model - Equipment performance Output - Stream flows and composition - Equipment duty
  17. 17. ©2015–HervéBaron HERVE BARON Process simulations Input - Feed composition and conditions Simulator settings - Flow scheme - Thermodynamic model - Equipment performance Output - Stream flows and composition - Equipment duty
  18. 18. ©2015–HervéBaron HERVE BARON Process simulations Input - Feed composition and conditions Simulator settings - Flow scheme - Thermodynamic model - Equipment performance Output - Stream flows and composition - Equipment duty
  19. 19. ©2015–HervéBaron HERVE BARON Process simulations Input - Feed composition and conditions Simulator settings - Flow scheme - Thermodynamic model - Equipment performance Output - Stream flows and composition - Equipment duty
  20. 20. ©2015–HervéBaron HERVE BARON Process simulations Input - Feed composition and conditions Simulator settings - Flow scheme - Thermodynamic model - Equipment performance Output - Stream flows and composition - Equipment duty
  21. 21. ©2015–HervéBaron HERVE BARON Process simulations Input - Feed composition and conditions Simulator settings - Flow scheme - Thermodynamic model - Equipment performance Output - Stream flows and composition - Equipment duty
  22. 22. ©2015–HervéBaron HERVE BARON The Process Flow Diagram (PFD)
  23. 23. ©2015–HervéBaron 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
  24. 24. ©2015–HervéBaron 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)
  25. 25. ©2015–HervéBaron HERVE BARON Heat & Material Balance
  26. 26. ©2015–HervéBaron 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
  27. 27. ©2015–HervéBaron HERVE BARON Process Description
  28. 28. ©2015–HervéBaron 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
  29. 29. ©2015–HervéBaron HERVE BARON Engineering disciplines: activities and deliverables
  30. 30. ©2015–HervéBaron 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
  31. 31. ©2015–HervéBaron HERVE BARON Equipment sizing
  32. 32. ©2015–HervéBaron HERVE BARON 32 Cass study: Equipment Sizing
  33. 33. ©2015–HervéBaron HERVE BARON 33
  34. 34. ©2015–HervéBaron HERVE BARON Case study: Equipment Sizing Production separator Sets the gas cross section Sets the liquid volume Vessel size
  35. 35. ©2015–HervéBaron HERVE BARON Process data sheet Drums
  36. 36. ©2015–HervéBaron 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)
  37. 37. ©2015–HervéBaron HERVE BARON Process Data sheet Column
  38. 38. ©2015–HervéBaron HERVE BARON Columns and Drums Column internals must be specified. These pictures are excerpts from Sulzer douments
  39. 39. ©2015–HervéBaron HERVE BARON Process Data sheet Column
  40. 40. ©2015–HervéBaron HERVE BARON Process Data sheet Rotating equipment
  41. 41. ©2015–HervéBaron HERVE BARON Process Data sheet Rotating equipment
  42. 42. ©2015–HervéBaron HERVE BARON Process Data sheet Heat Exchangers / Shell & Tubes
  43. 43. ©2015–HervéBaron 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
  44. 44. ©2015–HervéBaron HERVE BARON Process Data sheet Heat Exchangers / Other types
  45. 45. ©2015–HervéBaron HERVE BARON Process Data sheet Air Cooled HX
  46. 46. ©2015–HervéBaron HERVE BARON Process Data Sheet Fired heaters
  47. 47. ©2015–HervéBaron HERVE BARON Process Data Sheet Fired heaters What is particularly important while specifying a heater ?
  48. 48. ©2015–HervéBaron HERVE BARON Process Data Sheet Storage tank
  49. 49. ©2015–HervéBaron HERVE BARON Process Sizing Process Equipment Sizing is done on the basis of:  Sizing cases  Over design  Design criteria
  50. 50. ©2015–HervéBaron HERVE BARON Process Sizing Process Equipment Sizing is done on the basis of:  Sizing cases – all operating cases  Over design  Design criteria
  51. 51. ©2015–HervéBaron 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
  52. 52. ©2015–HervéBaron 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?
  53. 53. ©2015–HervéBaron 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
  54. 54. ©2015–HervéBaron 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
  55. 55. ©2015–HervéBaron HERVE BARON Process specification Package What document is issued by Process for packages?
  56. 56. ©2015–HervéBaron HERVE BARON Process specification Package
  57. 57. ©2015–HervéBaron HERVE BARON Process specification Package What type of guarantees are requested?
  58. 58. ©2015–HervéBaron HERVE BARON Process Equipment list
  59. 59. ©2015–HervéBaron HERVE BARON Process Equipment list
  60. 60. ©2015–HervéBaron 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
  61. 61. ©2015–HervéBaron HERVE BARON Piping & Instrumentation Diagram (P&ID) Compare the information shown on the PFD and the P&ID
  62. 62. ©2015–HervéBaron 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
  63. 63. ©2015–HervéBaron 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?
  64. 64. ©2015–HervéBaron 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.
  65. 65. ©2015–HervéBaron 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
  66. 66. ©2015–HervéBaron 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?
  67. 67. ©2015–HervéBaron 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
  68. 68. ©2015–HervéBaron 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?
  69. 69. ©2015–HervéBaron 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?
  70. 70. ©2015–HervéBaron HERVE BARON Isolation philosophy
  71. 71. ©2015–HervéBaron HERVE BARON Isolation philosophy
  72. 72. ©2015–HervéBaron HERVE BARON Isolation philosophy
  73. 73. ©2015–HervéBaron 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
  74. 74. ©2015–HervéBaron 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
  75. 75. ©2015–HervéBaron 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…)
  76. 76. ©2015–HervéBaron 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
  77. 77. ©2015–HervéBaron 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.
  78. 78. ©2015–HervéBaron 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
  79. 79. ©2015–HervéBaron 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
  80. 80. ©2015–HervéBaron HERVE BARON P&IDs legend & symbols
  81. 81. ©2015–HervéBaron 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
  82. 82. ©2015–HervéBaron HERVE BARON Identification and numbering system
  83. 83. ©2015–HervéBaron HERVE BARON Identification and numbering system
  84. 84. ©2015–HervéBaron 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
  85. 85. ©2015–HervéBaron 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
  86. 86. ©2015–HervéBaron 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
  87. 87. ©2015–HervéBaron 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?
  88. 88. ©2015–HervéBaron 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?
  89. 89. ©2015–HervéBaron 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
  90. 90. ©2015–HervéBaron HERVE BARON P&ID work sequence P&IDs are typically issued 3 times, as design progresses
  91. 91. ©2015–HervéBaron HERVE BARON P&ID work sequence IFR IFD IFC P&IDs are typically issued 3 times, as design progresses
  92. 92. ©2015–HervéBaron HERVE BARON P&ID work sequence IFR IFD IFC P&IDs are typically issued 3 times, as design progresses
  93. 93. ©2015–HervéBaron HERVE BARON P&ID work sequence IFR IFD IFC P&ID Review P&IDs are typically issued 3 times, as design progresses
  94. 94. ©2015–HervéBaron HERVE BARON P&ID work sequence IFR IFD IFC P&ID Review HAZOP P&IDs are typically issued 3 times, as design progresses
  95. 95. ©2015–HervéBaron 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
  96. 96. ©2015–HervéBaron 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
  97. 97. ©2015–HervéBaron HERVE BARON P&ID work sequence IFR IFC P&ID Review P&IDs are typically issued 3 times, as design progresses IFD HAZOP
  98. 98. ©2015–HervéBaron 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
  99. 99. ©2015–HervéBaron 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
  100. 100. ©2015–HervéBaron 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
  101. 101. ©2015–HervéBaron 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
  102. 102. ©2015–HervéBaron 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
  103. 103. ©2015–HervéBaron HERVE BARON Fluids list
  104. 104. ©2015–HervéBaron HERVE BARON Line list
  105. 105. ©2015–HervéBaron HERVE BARON Line sizing
  106. 106. ©2015–HervéBaron 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
  107. 107. ©2015–HervéBaron HERVE BARON Instrument process data sheet
  108. 108. ©2015–HervéBaron HERVE BARON Instrument process data sheet What is the most important process data for control valves?
  109. 109. ©2015–HervéBaron 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.
  110. 110. ©2015–HervéBaron 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
  111. 111. ©2015–HervéBaron 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?
  112. 112. ©2015–HervéBaron HERVE BARON ESD logic diagram
  113. 113. ©2015–HervéBaron HERVE BARON Safeguarding narrative & Cause and Effects charts
  114. 114. ©2015–HervéBaron HERVE BARON Process and Safety Diagrams (PSD)
  115. 115. ©2015–HervéBaron 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
  116. 116. ©2015–HervéBaron HERVE BARON Relief load summary
  117. 117. ©2015–HervéBaron HERVE BARON Flare study
  118. 118. ©2015–HervéBaron HERVE BARON Flare study
  119. 119. ©2015–HervéBaron 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
  120. 120. ©2015–HervéBaron HERVE BARON Operating manual
  121. 121. ©2015–HervéBaron HERVE BARON Operating manual What are the most important contents of the operating manual?
  122. 122. ©2015–HervéBaron HERVE BARON Operating Manual Table of Contents (typ.) 1 INTRODUCTION 1.1General presentation 1.2Glossary 1.3Basic data 2 DESCRIPTION OF FACILITIES 2.1General 2.2Process 2.3Utilities 2.4Auxiliaries 3 AUTOMATIC CONTROL SYSTEM 3.1System overview 3.2Operator control interfaces 3.3Telecommunications 3.4Process alarms and trips 3.6Emergency shutdown system 3.7Fire & gas system 4 OPERATION 4.1Start-up 4.2Normal operation 4.4Shutdown 4.5Depressurization 5 SAFETY 5.1Operating philosophy 5.2Escape, evacuation and rescue 5.3Emergency power system 5.4Safety equipment list 5.5Fire protection
  123. 123. ©2015–HervéBaron 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
  124. 124. ©2015–HervéBaron 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
  125. 125. ©2015–HervéBaron HERVE BARON Operating Manual Control loops and Alarms list
  126. 126. ©2015–HervéBaron 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
  127. 127. ©2015–HervéBaron HERVE BARON Process design criteria What are the different Process design criteria?
  128. 128. ©2015–HervéBaron 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
  129. 129. ©2015–HervéBaron HERVE BARON Process design criteria • Design margins • Design Pressure and Temperature criteria • Equipment sizing criteria • Line sizing criteria • Control valve sizing criteria
  130. 130. ©2015–HervéBaron 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 +?%
  131. 131. ©2015–HervéBaron 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%
  132. 132. ©2015–HervéBaron HERVE BARON Process design criteria • Design margins • Design Pressure and Temperature criteria • Equipment sizing criteria • Line sizing criteria • Control valve sizing criteria
  133. 133. ©2015–HervéBaron 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.
  134. 134. ©2015–HervéBaron HERVE BARON Process design criteria • Design margins • Design Pressure and Temperature criteria • Equipment sizing criteria • Line sizing criteria • Control valve sizing criteria
  135. 135. ©2015–HervéBaron HERVE BARON Process design criteria • Design margins • Design Pressure and Temperature criteria • Equipment sizing criteria • Line sizing criteria • Control valve sizing criteria
  136. 136. ©2015–HervéBaron HERVE BARON Licensed vs Open Art Process When one uses a process under license, what are the deliverables issued by the process LICENSOR?
  137. 137. ©2015–HervéBaron 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
  138. 138. ©2015–HervéBaron 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
  139. 139. ©2015–HervéBaron HERVE BARON The Oil & Gas Engineering Guide 2nd edition Do you want to know more... Much more?
  140. 140. ©2015–HervéBaron HERVE BARON The Oil & Gas Engineering Guide - 2nd edition Table of Contents
  141. 141. ©2015–HervéBaron HERVE BARON The Oil & Gas Engineering Guide - 2nd edition Table of Contents This suite of training modules covered the discipline chapters of the book...
  142. 142. ©2015–HervéBaron HERVE BARON The Oil & Gas Engineering Guide - 2nd edition Table of Contents The Guide contains much more: The overall picture, interfaces, methods & tools, etc.
  143. 143. ©2015–HervéBaron HERVE BARON The Oil & Gas Engineering Guide 2nd edition Order direct from the publisher: http://www.editionstechnip.com/en/catalogu e-detail/1111/oil-gas-engineering-guide- the.html

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