Equipment sizing and costing using Petro-SIM
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Equipment sizing and costing using Petro-SIM Rodolfo Tellez Schmill Software user conference 2018, USA
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Equipment sizing and costing using Petro-SIM
- 1. Proprietary Information Equipment Sizing and Costing UsingPetro-SIM RodolfoTellezSchmill ProductChampion-Petro-SIMSimulation KBCDownstreamTechnologyDay
- 2. Proprietary Information Outline • Objectives of Equipment Sizing • Typical Workflow • New Functionalities for Equipment Sizing in Petro-SIM • Export simulation information to datasheet templates • Petro-SIZE® integration with Petro-SIM • Equipment Costing (Petro-SIM and Cleopatra) • Future Developments in Petro-SIM • Conclusions
- 3. Proprietary Information ObjectivesofEquipmentSizing • Equipment sizing is a fundamental activity in design engineering. • The capital expenditure is highly dependent on the results from equipment sizing. • Process simulations are an essential tool for equipment sizing.
- 4. Proprietary Information TypicalWorkflow • Different design scenarios, flow rate and energy capacities, and physical properties are part of the information needed to size equipment. • Once this information is checked and validated, Process, Mechanical and Instrumentation Engineers apply recognized practices and construction codes to size equipment. • Results from engineering calculations are transferred to equipment or instrumentation data sheets. • These data sheets are reviewed by different engineering disciplines, and then submitted to equipment vendors for analysis and construction.
- 5. Proprietary Information NewFunctionalitiesforEquipmentSizingandPetro-SIM • Export simulation results to datasheet templates • A new feature in Petro-SIM 7.0 is the ability to export data from the process simulation into data sheet templates in Excel. • The user can customize these Excel templates, select a specific unit operation within the simulation, and then export the required information to the Excel template. • Petro-SIZE® integration with Petro-SIM • Petro-SIM will be able to transfer information directly to Petro-SIZE®. • Petro-SIZE® in turn will perform sizing calculations and report results. This is the only commercial process simulator in the market that can do this.
- 6. Proprietary Information Exportsimulationinformationtodatasheettemplates • The unit operation is selected and the with the click of a button, the information is sent so the datasheet templates. • Then the Datasheet Template Report is used to initiate the actual transfer of information from Petro-Sim to Excel. • The list of sample equipment datasheet templates that will be shipped with Petro-SIM version 7.0 are: • Centrifugal Pump • Reciprocating Pump • Centrifugal Compressor • Reciprocating Compressor • Shell & Tube Heat Exchanger • Air Cooler (A sample of a heat and material balance table is also included)
- 8. Proprietary Information SampleequipmentdatasheettemplatesinPetro-SIM7.0 • Shell & Tube heat exchanger
- 9. Proprietary Information SampleequipmentdatasheettemplatesinPetro-SIM7.0 • Instructions needed to extract the right information from the Petro-SIM simulation are very easy to set up: • For example, the shell side outlet fluid is expected to be a two-phase stream, both vapour and liquid flow rates are required, therefore the instructions needed to transfer the mass flow rates for each phase are: • ~Shell Side Product Stream | Phase Mass Flow (Vapour Phase) | IN_UNITS | lb/hr • ~Shell Side Product Stream | Phase Mass Flow (Liquid Phase) | IN_UNITS | lb/hr
- 10. Proprietary Information SampleequipmentdatasheettemplatesinPetro-SIM7.0 • The details of the simulation variable tag for the Excel template can be checked by following these steps: • Open the material stream view • Select the simulation variable • Right-click and select Send Detailed Template Tags to Clipboard • Look at the tag in the Trace Window
- 11. Proprietary Information ExportingequipmentdatasheetinformationtoExcel templates • An example of this functionality
- 12. Proprietary Information ExportingequipmentdatasheetinformationtoExcel templates • Select the heat exchanger, then right-click and Send to Datasheet Templates…
- 13. Proprietary Information ExportingequipmentdatasheetinformationtoExcel templates • Excel template selection view:
- 14. Proprietary Information ExportingequipmentdatasheetinformationtoExcel templates • Path: KBC / SIM Suite 7.0 / Petro-SIM / Cases
- 18. Proprietary Information Petro-SIZE® integrationwithPetro-SIM • Petro-SIZE® provides a robust tool to meet these unique sizing and rating needs. • Petro-SIZE® offers a suite of comprehensive modules that undertakes various process calculations. • It is a flexible and reliable tool for assisting process engineers as well as plant engineers and operators in their day-to-day design, troubleshooting and debottlenecking activities. • Petro-SIZE® is also ideal for process review and conceptualisation. It is a valuable time saving tool that allows engineers to respond to business needs faster and more efficiently.
- 19. Proprietary Information • Petro-SIZE® includes several equipment sizing and rating modules, most of them being unique and not available elsewhere. Petro-SIZE® integrationwithPetro-SIM In-plant line sizing (single and two- phase) Pressure safety and relief valves Centrifugal pumps and NPSH (net positive suction head) Flare K.O. drums Two and three phase separators Filter separators API separators Control valves Surge drums Crude production separators (GOSP traps) Heat exchangers (shell and tube and air-cooled) Slug catchers (finger and vessel type) Fired-heaters and boilers Tray hydraulics Crude heater treaters Packing hydraulics (random and structured) Crude oil desalters Flow meters Gas dehydration with solid desiccants Compressors and expanders Compressor suction K.O. drums Atmospheric storage tanks Desuperheaters Gas-solid cyclone separators Corrosion rate estimation Economics (Net Present Value)
- 20. Proprietary Information Petro-SIZE® integrationwithPetro-SIM • The robust and unique pressure vessel optimisation engine in Petro- SIZE® allows users to achieve significant savings in capital expenditure by designing the most optimum equipment for each service. • It also enables users to improve plant reliability and product quality by accurately determining the capacity of existing equipment.
- 21. Proprietary Information Petro-SIZE® integrationwithPetro-SIM • The following snapshots illustrate the information that has to be transferred into the Excel template for a typical 3-Phase Separator. • Items with numbers in red are the ones found in the attached template.
- 25. Proprietary Information Petro-SIZE® integrationwithPetro-SIM Coming soon in Petro- SIM version 7.1
- 26. Proprietary Information EquipmentCosting • Our new strategic partnership with Cost Engineering will allow interoperability between Cleopatra Enterprise from Cost Engineering and Petro-SIM to provide cost estimates at each Petro-SIM design iteration, improving cost estimating efficiencies and accuracy. • Cleopatra Enterprise is a comprehensive project cost management solution. It offers the tools needed for the full project life cycle for estimating, budgeting, planning, cost control, and benchmarking of technical projects and complex, time-driven, turnarounds.
- 27. Proprietary Information EquipmentCosting • Intended workflow between Petro-SIM and Cleopatra® • CESK® Process Equipment knowledgebase is a data set for conceptual and feasibility estimating. The built-in cost models can be used to estimate equipment costs and quickly build a total installed cost estimate using the integrated factor estimating methodologies. • CESK® Objects include typical equipment items (objects). The object models allow the user to specify the main parameters for various equipment types and automatically calculate not only the equipment supply cost but also all other related costs, including disciplines such as piping, insulation, painting, installation, electrical, instrumentation and civil.
- 29. Proprietary Information FuturedevelopmentsinPetro-SIM • Complete the full integration of Petro-SIZE® with Petro-SIM • Provide more Excel templates for process equipment • Implement the ability to export simulation information to instrument datasheets • Complete integration with Cleopatra® to enhance Petro-SIM functionality and offer major improvements to engineering design, cost estimation, cost management, debottlenecking, troubleshooting and optimization.
- 30. Proprietary Information Conclusions • Petro-SIM 7.0 can seamlessly and reliably transfer information into data sheet templates prepared in Excel. • Full integration of Petro-SIZE® with Petro-SIM will provide a robust capability for equipment sizing and rating. • Once Petro-SIZE® is fully integrated, the ability of transferring data into data sheet templates will also be available in Petro-Sim 7.1. • Plans and activities for the integration with Cleopatra are currently underway.