Process Engineering Tutorial

© 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


HERVE BARON

Engineering disciplines: activities and deliverables

PROCESS

PLANT LAYOUT

EQUIPMENT

SAFETY & ENVIRONMENT

CIVIL

PIPING

PIPELINE

INSTRUMENTATION

ELECTRICAL


HERVE BARON


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


HERVE BARON




HERVE BARON

What constitutes the Design Basis of a Process/Utility Unit?

Process Design Basis


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

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)


HERVE BARON

Process design basis Compressor Station


HERVE BARON


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


HERVE BARON

Choice of Process Scheme

What are the bases of process scheme definition?

Presenter

Presentation Notes

Feedstock composition, Products specifications, environment constraints Criteria: ability to handle change in feedstock Available utilities


HERVE BARON

Overall Plant Process Design

What is the name of this drawing?


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


HERVE BARON

Unit Process Design


HERVE BARON

The Process Flow Diagram (PFD)


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?

Presenter

Presentation Notes

Reduction of equipment count Available equioment capacity - Technological limit (equipment size) Flexibility (turndown) Availability, e.g., 2 trains Ability to handle upsets, e.g., pollutants in feedstock Design basis, e.g., cooling medium CAPEX Utility consumption = OPEX


HERVE BARON

Process simulations


HERVE BARON

Process simulations

Input

- Feed composition and conditions

Simulator settings

- Flow scheme - Thermodynamic model - Equipment performance

Output

- Stream flows and composition

- Equipment duty


HERVE BARON

Process simulations

Input


Simulator settings


Output


- Equipment duty


HERVE BARON

Process simulations

Input


Simulator settings


Output


- Equipment duty


HERVE BARON

Process simulations

Input


Simulator settings


Output


- Equipment duty


HERVE BARON

Process simulations

Input


Simulator settings


Output


- Equipment duty

Presenter

Presentation Notes

The equipment performance (outlet pressure, efficiency) is specified For a heat exchanger: the outlet temperature is specified


HERVE BARON

Process simulations

Input


Simulator settings


Output


- Equipment duty


HERVE BARON



HERVE BARON


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


HERVE BARON


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)


HERVE BARON

Heat & Material Balance

Presenter

Presentation Notes

The Heat & Mass Balance is issued for various operating cases, representative of the entire operating conditions envelope


HERVE BARON




HERVE BARON

Process Description


HERVE BARON




HERVE BARON



HERVE BARON




HERVE BARON

Equipment sizing


HERVE BARON

32

Cass study: Equipment Sizing


HERVE BARON

33


HERVE BARON

Case study: Equipment Sizing Production separator

Sets the gas cross section

Sets the liquid volume

Vessel size


HERVE BARON

Process data sheet Drums

Presenter

Presentation Notes

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.


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)

Presenter

Presentation Notes

What is fouling factor?


HERVE BARON

Process Data sheet Column


HERVE BARON

Columns and Drums

Column internals must be specified.

These pictures are excerpts from Sulzer douments


HERVE BARON

Process Data sheet Column


HERVE BARON

Process Data sheet Rotating equipment


HERVE BARON

Process Data sheet Rotating equipment


HERVE BARON

Process Data sheet Heat Exchangers / Shell & Tubes


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


HERVE BARON

Process Data sheet Heat Exchangers / Other types


HERVE BARON

Process Data sheet Air Cooled HX


HERVE BARON

Process Data Sheet Fired heaters

Presenter

Presentation Notes

Of particular importance is the turn-down, for the burner.


HERVE BARON

Process Data Sheet Fired heaters

What is particularly important while specifying a heater ?

Presenter

Presentation Notes

Of particular importance is the turn-down, for the burner.


HERVE BARON

Process Data Sheet Storage tank


HERVE BARON

Process Sizing

Process Equipment Sizing is done on the basis of:

Sizing cases

Over design

Design criteria


HERVE BARON

Process Sizing


Sizing cases – all operating cases

Over design

Design criteria


HERVE BARON

Process Sizing


Sizing cases – all operating cases

Over design – 10% as a rule

Design criteria


HERVE BARON

Process Sizing


Sizing cases – all operating case


Sizing criteria On which basis are the following equipment sized?


HERVE BARON

Process Sizing

Process Sizing is done on the basis of:



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


HERVE BARON

Process Sizing




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


HERVE BARON

Process specification Package

What document is issued by Process for packages?

Presenter

Presentation Notes

A duty specification


HERVE BARON



HERVE BARON


What type of guarantees are requested?


HERVE BARON

Process Equipment list


HERVE BARON

Process Equipment list


HERVE BARON




HERVE BARON

Piping & Instrumentation Diagram (P&ID)

Compare the information shown on the PFD and the P&ID


HERVE BARON





HERVE BARON



What are the purposes of P&IDs?


HERVE BARON




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.


HERVE BARON







P&ID review


HERVE BARON







P&ID review

Which are the usual points reviewed during a P&ID review?


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

Presenter

Presentation Notes

Where do you provide DBB? High pressure, Toxic – It is defined Project wise, in the Process Design Criteria


HERVE BARON





• Vents/drains

What do you call each type of isolation?

Presenter

Presentation Notes

Single vs Double block and bleed


HERVE BARON





• Vents/drains

Where do you use double block and bleed?

Presenter

Presentation Notes

There is not general rule. In general above a certain pressure and for toxic fluids. It must be defined in the typical P&IDs.


HERVE BARON

Isolation philosophy


HERVE BARON



HERVE BARON



HERVE BARON





• Vents/drains

Presenter

Presentation Notes

How would you call this type of drainage arrangement? Open drain only


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


HERVE BARON


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…)


HERVE BARON


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


HERVE BARON


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.


HERVE BARON


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


HERVE BARON




HERVE BARON

P&IDs legend & symbols


HERVE BARON




HERVE BARON

Identification and numbering system


HERVE BARON

Identification and numbering system


HERVE BARON




HERVE BARON



P&ID representation

Details


HERVE BARON




HERVE BARON



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


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?

Presenter

Presentation Notes

Open Drain / Open + Closed drain Non hazardous – mainly for water / Flammable, e.g. hydrocarbon, or toxic fluids


HERVE BARON




HERVE BARON

P&ID work sequence

P&IDs are typically issued 3 times, as design progresses


HERVE BARON

P&ID work sequence

IFR IFD IFC



HERVE BARON

P&ID work sequence

IFR IFD IFC



HERVE BARON

P&ID work sequence

IFR IFD IFC

P&ID Review



HERVE BARON

P&ID work sequence

IFR IFD IFC

P&ID Review HAZOP



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


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


HERVE BARON

P&ID work sequence

IFR IFC

P&ID Review


IFD

HAZOP


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


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


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


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

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.


HERVE BARON




HERVE BARON

Fluids list


HERVE BARON

Line list


HERVE BARON

Line sizing


HERVE BARON




HERVE BARON

Instrument process data sheet

Presenter

Presentation Notes

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.)


HERVE BARON


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.


HERVE BARON


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.


HERVE 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?

Presenter

Presentation Notes

Left: segragted control and shutdown functions / Right: combined control and shutdown functions


HERVE BARON

ESD logic diagram


HERVE BARON

Safeguarding narrative & Cause and Effects charts


HERVE BARON

Process and Safety Diagrams (PSD)


HERVE BARON




HERVE BARON

Relief load summary


HERVE BARON

Flare study


HERVE BARON

Flare study


HERVE BARON




HERVE BARON

Operating manual


HERVE BARON

Operating manual

What are the most important contents of the operating manual?


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


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


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


HERVE BARON

Operating Manual Control loops and Alarms list

Presenter

Presentation Notes

RAT: ranges, alarms and trips list


HERVE BARON




HERVE BARON

Process design criteria

What are the different Process design criteria?

Presenter

Presentation Notes

The Process Design criteria is the JSD for Process


HERVE BARON


What are the different Process design criteria?

• Design margins • Design Pressure and Temperature criteria • Equipment sizing criteria • Line sizing criteria • Control valve sizing criteria

Presenter

Presentation Notes



HERVE BARON



Presenter

Presentation Notes



HERVE BARON


• 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



HERVE BARON


• 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



HERVE BARON




HERVE BARON



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.


HERVE BARON




HERVE BARON




HERVE BARON

Licensed vs Open Art Process

When one uses a process under license, what are the deliverables issued by the process LICENSOR?

Presenter

Presentation Notes

It depends on the AGREEMENT with the PROCESS licensor but it is usually as follows…


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


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


HERVE BARON

The Oil & Gas Engineering Guide 2nd edition

Do you want to know more... Much more?


HERVE BARON

The Oil & Gas Engineering Guide - 2nd edition

Table of Contents


HERVE BARON


Table of Contents

This suite of training modules covered the discipline chapters of the book...


HERVE BARON


Table of Contents

The Guide contains much more:

The overall picture, interfaces, methods & tools, etc.


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




Education

Process Engineering Tutorial