Проектирование Технологической Установки

PROCESS PLANT ENGINEERING

Welcome! !

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PROCESS PLANT ENGINEERING DEVELOPMENT -

Welcome to this presentation. It shows the activities and documents of the different engineering disciplines (process, piping, civil etc.) for the engineering of a Process Plant. It covers the 2 common stages of engineering development: BASIC Engineering DETAIL Engineering

. ( , , ..) . 2 - :

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GENERAL / PROCESS / MECHANICAL / SAFETY & ENVIRONMENT / .

CIVIL / PIPING LAYOUT & MATERIAL /

INSTRUMENTATION / ELECTRICAL / SCHEDULE /


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BASIC ENGINEERING

Engineering/

Documents for Inquiry / : Bill of Materials / specifications / /

Documents submitted to client /

Client /

Approval/Comments /

Process Design Package (PDP) /

Vendors / Sub-Contractors /

Quotations /

Inquiries /

Cost Estimate Department /

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DETAIL ENGINEERING

Engineering /

Documents for Purchase / : bill of quantity & specification/ /

Documents for Construction / : Construction drawings & specifications /

Client /

Design basis / : - Functional requirements /

- Client specifications /

- Design codes /

Vendors /

Documents submission /

Comments /

Approval/Comments /

Documents submitted to client /

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ENGINEERING ORGANISATION

Engineering /

Instruments & Control

Layout & Piping

Process

Electrical

Equipment/Mechanical

Civil

Safety

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ENGINEERING DOCUMENT REGISTER

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LIST OF COMMON ENGINEERING DELIVERABLES (1/2) (1/2)

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LIST OF COMMON ENGINEERING DELIVERABLES (2/2) (2/2)

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ENGINEERING DOCUMENT QUALITY REQUIREMENTS: CHECKING :

Discipline self check

Inter-Discipline Check (IDC) ()

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ENGINEERING DOCUMENT REVISION

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ENGINEERING MASTERS

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ENGINEERING REVIEW ACTION ITEMS FOLLOW-UP

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Key plan /

Diagrams /

Drawings /

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18

Plan view /

Elevation view /

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Section /

Plan view /

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GRID SYSTEM

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DETAIL

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DRAWINGS COMMON SIZES & SCALES

Scale 1m =

1/1000 1 mm

1/500 2 mm

1/250 4 mm

1/100 1 cm

1/50 2 cm

1/33 3 cm

A0 = 840x1188

A1 = 594x840

A2 = 420x594

A4 = 210x297

A3 = 297x420

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SPECIFICATIONS /

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BASIC ENGINEERING DESIGN DATA

Process facilities / : Feedstock and products flow / Feedstock composition / Battery limit conditions / Equipment Spare / Performance / : Products specifications / Energy efficiency, emissions / , Utilities / : Electric power supply / Other utilities / Systems / : Process control / Fire/gas alarm / Public address, LAN, PABX / , LAN, PABX

0 5

10 15 20 25 30 35 40 45 50

-85 -80 -75 -70 -65 -60 -55

Pre

ssu

re (

ba

r) Infrastructure / :

Administrative and technical buildings Control room / Access road / Site fencing, gates, check point / . , , - Design criteria / : % of over design / % Environment data / . : Min/max temperature / ./. Rain/snow fall / (/) Wind / Geological conditions / Applicable codes and standards / : International standards / Local rules /

Pressure (bar)

Hydrates Curve

Phase Envelope

Temperature (C)

25

20

15

10

5

0

-5

-10

-15

-20

-25

-30

-35

-40

-45

-50

-55

-60

-65

-70

-75

-80

-85

80

75

70

65

60

55

50

45

40

35

30

25

20

15

10

5

0

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COMMON ENGINEERING DELIVERABLES (1/2) (1/2)

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FUNCTIONAL REQUIREMENTS E.G. GAS COMPRESSOR STATION . .

Gas composition / Performance /

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PROCESS FLOW DIAGRAM (PFD)

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PROCESS SIMULATIONS

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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 / TEG

LP Compression /

TEG

Cooler /

IP Compression /

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EQUIPMENT LIST

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HEAT & MATERIAL BALANCE

Thermodynamic calculations /

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PROCESS DATA SHEET

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EQUIPMENT SIZING

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FLUID LIST

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PIPING & INSTRUMENTATION DIAGRAM (P&ID)

Line List /

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P&IDS LEGEND & SYMBOLS -

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LINE SIZING

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PROCESS CAUSES & EFFECTS CHART -

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PROCESS DESCRIPTION AND OPERATING PHILOSOPHY

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ESD CAUSES & EFFECTS CHARTS -

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ESD SIMPLIFIED DIAGRAM

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FLARE STUDY

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OPERATING MANUAL

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COMMON ENGINEERING DELIVERABLES (1/2)

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PROCESS EQUIPMENT LIST

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ROTATING MACHINERY

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PRESSURE VESSELS

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HEAT EXCHANGERS

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PACKAGES

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DATA SHEET / SPECIFICATION /

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PROCESS DATA SHEET / MECHANICAL DATA SHEET /

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VESSEL GUIDE DRAWING

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MATERIAL REQUISITION /

Western Engineering Company MATERIAL REQUISITION /

Russian Design Institute / TECHNICAL PART OF ORDER

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VENDOR DESIGN

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BID TECHNICAL EVALUATION

Supplier 1 Supplier 2 Requirements

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VENDOR DESIGN DEVELOPMENT

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EQUIPMENT SUMMARY

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Package / Centralized control /

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Package / Local control /

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THE WORK OF THE EQUIPMENT SPECIALIST

Process design /

PFDs / H&M balance

Rotating equipment / Pressure vessels / Fired equipment / Heat exchangers / Packages etc. / ..

Process data sheet /

Equipment specification & Data Sheets /

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HAZOP REVIEW / DEVIATION (HAZOP ) /

Too much, too little, no , ,

Flow, Pressure, Temperature / , ,

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Too much, too little, no , ,

Flow, Pressure, Temperature / , ,

HAZOP REVIEW / DEVIATION (HAZOP ) /

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HAZOP ACTION AND RESPONSE SHEET HAZOP

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SAFETY OF LAYOUT

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FIRE FIGHTING

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FIRE FIGHTING

Nozzle Arrangement /

Piping Arrangement /

/ :

/

/

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FIRE WATER P&IDS

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FIRE FIGHTING EQUIPMENT LOCATION DRAWING

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PASSIVE FIRE PROTECTION

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FIRE & GAS DETECTION LAYOUTS

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FIRE & GAS MATRIX

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Legend /

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Case study: Gas leak from random piping component rupture Cause: installation error, corrosion, material defect Possible consequence: Dispersion without ignition / jet fire / flash fire / explosion Section considered: Compressor building

QUANTITATIVE RISK ANALYSIS (QRA)

: - : , , : / / / :

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Step 1 / 1:

Identification and characterisation of initiating events

Gas leak inside compressor buidling due to component rupture Hole size (% of component section)

5% 20% Full

Frequency (event/year) 1,11E-01 5,06E-04 6,83E-05

Outflow rate (kg/s) 5,7 90,8 2270,0

risk components *failure rate (from statistics) /

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Release Frequency Immediate ignition

ESD & Fire Fighting

Delayed Ignition

Explosion/ Flash-fire

Consequence Event Frequency (ev/y)

0,998 Jet fire ESD & FF 7,779E-030,070

0,002 Jet fire no ESD & FF 1,520E-05

1,11E-01Release/yr

0,949 Dispersion 9,827E-020,930

0,120 Explosion 1,774E-050,028

0,051 0,880 Flash fire 1,301E-04

0,972 Dispersion 5,133E-03

Yes Frequency (event/year)Jet fire ESD & FF 7,779E-03Jet fire no ESD & FF 1,520E-05Explosion 1,774E-05

No Flash Fire 1,301E-04Dispersion 1,034E-01

B04a/b/c/d 5%

Probability of immediate ignition for 1-50 kg/s release rate is 7% (from statistical data).

1-50 / 7% ( ).

Gas detectors are provided inside the building, that activate isolation and depressurization. It is assumed that they operate 95% of the time.

; . , 95% .

Probability of explosion vs flash fire (12%) depends on mass of gas and degree of confinement.

(12%) .

Probability of delayed ignition (2.8%) takes into account equipment explosion protection (Ex).

(2,8%) .

Step 2 / 2: Event tree analysis /

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Step 3 / 3:

Consequence evalutation /

Overpresssure (bar) ()

0.2 0.1 0.01

Distance (m) / ()

96 167 1270

CONSEQUENCE CLASS /

QUANTITATIVE CRITERIA /

EFFECTS /

MINOR / 0.1 bar locally (within 10m) / 0.1 ( 10 )

No effect, no damage /

SIGNIFICANT / 0.1 bar locally (within 50m) 0.1 ( 50 )

Limited damage to plant and operators /

SEVERE / 0.1 bar within plant 0.1

Damage to plant and operators /

MAJOR / 0.1 bar on populated areas 0.1

Damage to plant, operators & public / , .

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Unacceptable risk area Design change necessary

As Low As Reasonably Practicable Plant Management measures

Acceptable risk area

1.0E-02

1.0E-03

1.0E-04 Unlikely 1.0E-05 Rare

1.0E-06 Minor

Significant

Severe

Major

Final step / :

Classification of risk /

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Final step / :

Classification of risk /

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ENVIRONMENTAL IMPACT ASSESSMENT ()

Ground Concentration of NOx (g/m3) / NOx (/3)

Coordinates of sources / Sources definition /

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NOISE STUDY

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COMPLEMENTARY (SOIL) INVESTIGATIONS SPECIFICATION ()

Basic Design / : Typical soil sections/domains and variability / ; Local geohazards if any (liquefiable, expansive or collapsible soils,

underground cavities) / ,

(, , );

Geotechnical parameters for selection of suitable earthworks and foundations options /

.

detail design (complementary investigations) / ( ): To define the limits of geohazards areas, if any / ; To confirm the geotechnical parameters for Geotechnical Basis of Design / ,

; To precise soil conditions underneath specific critical structures / ,

.

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GRADING PLAN

Native soil elevation /

Required finish level /

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EARTHWORKS DRAWINGS

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VENDOR INFORMATION

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(FOUNDATION) CALCULATION NOTES ()

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FOUNDATION DRAWING: REINFORCEMENT . .

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FOUNDATION DRAWING: FORMWORK . .

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CIVIL WORKS SPECIFICATION /

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STEEL STRUCTURES, PIPE RACKS ,

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LOADING DATA

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STRUCTURAL DESIGN

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CALCULATIONS

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STRUCTURAL DESIGN DRAWINGS

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SHOP DRAWINGS & FABRICATION . .

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ERECTION DRAWINGS

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ARCHITECTURAL DRAWINGS

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Discip. DeliverableARCHITECTURAL doors and finishing schedules

ARCHITECTURAL elevation views

ARCHITECTURAL plan views

ARCHITECTURAL section views

ELECTRICAL cable sizing and schedule

ELECTRICAL distribution board schedule

ELECTRICAL distribution diagram

ELECTRICAL grounding layout drawing

ELECTRICAL illumination calculation note

ELECTRICAL lighting equipment layout drawing

ELECTRICAL socket layout drawing

HVAC control logic diagram

HVAC ductwork sizing

HVAC equipment and ducts layour drawings

HVAC equipment list

HVAC equipment sizing

HVAC air flow diagram

PLUMBING water and sewage pipe sizing

PLUMBING water and sewage pipes layout

SAFETY fire alarm logic diagram

SAFETY fire detection and alarm devices layout

SAFETY fire fighting calculations

SAFETY fire fighting equipment layout

STRUCTURAL bill of material for concrete re-inforcement

STRUCTURAL details drawings

STRUCTURAL floor drawings

STRUCTURAL foundation drawings

STRUCTURAL structural design calculation note

TELECOM public address and general alarm devices layout

TELECOM telecom equiment layout

BUILDING DETAIL DESIGN

Sheet1

Discip.Deliverable

ARCHITECTURALdoors and finishing schedules

ARCHITECTURALelevation views

ARCHITECTURALplan views

ARCHITECTURALsection views

ELECTRICALcable sizing and schedule

ELECTRICALdistribution board schedule

ELECTRICALdistribution diagram

ELECTRICALgrounding layout drawing

ELECTRICALillumination calculation note

ELECTRICALlighting equipment layout drawing

ELECTRICALsocket layout drawing

HVACcontrol logic diagram

HVACductwork sizing

HVACequipment and ducts layour drawings

HVACequipment list

HVACequipment sizing

HVACair flow diagram

PLUMBINGwater and sewage pipe sizing

PLUMBINGwater and sewage pipes layout

SAFETYfire alarm logic diagram

SAFETYfire detection and alarm devices layout

SAFETYfire fighting calculations

SAFETYfire fighting equipment layout

STRUCTURALbill of material for concrete re-inforcement

STRUCTURALdetails drawings

STRUCTURALfloor drawings

STRUCTURALfoundation drawings

STRUCTURALstructural design calculation note

TELECOMpublic address and general alarm devices layout

TELECOMtelecom equiment layout

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BUILDING DETAIL DRAWING / TELECOM LAYOUT . .

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HEATING, VENTILATION & AIR CONDITIONING (HVAC) , ()

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CIVIL WORKS INSTALLATION DRAWINGS

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STANDARD DRAWINGS

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PIPING DISCIPLINE

PIPING DISCIPLINE

PLANT LAYOUT

PIPING INSTALLATION

PIPING MATERIAL

PIPING STRESS ANALYSIS

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PLANT LAYOUT

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ON-SHORE PLANT: INTER-UNIT SPACING RECOMMENDATIONS (AS PER GE GAP GUIDELINES .2.5.2) :

( 2.5.2 GE )

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LAYOUT/PRINCIPLES .

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LAYOUT/PRINCIPLES .

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LAYOUT PRINCIPLES: PROVISION FOR PIPING FLEXIBILITY . .

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LAYOUT/VENDOR DRAWINGS . .

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LAYOUT/CONSIDERATION FOR ALL NETWORKS

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GENERAL PLOT PLAN

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UNIT PLOT PLAN

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3D MODELLING 3D

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3D MODEL CLASH CHECK 3D

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3D MODEL REVIEW 3D

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PIPING DISCIPLINE

PIPING DISCIPLINE

PLANT LAYOUT

PIPING INSTALLATION

PIPING MATERIAL


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PIPING LAYOUT DRAWINGS

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PIPING ROUTING/PROVISION FOR FLEXIBILITY . .

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PIPING ROUTING/ERGONOMICS . .

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PIPING MODELLING IN 3D MODEL 3D

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PIPING DRAWING EXTRACTION

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ISOMETRIC DRAWINGS

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PIPING DESIGN ISO VS SHOP ISO ISO ISO

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PIPING PRE-FABRICATION

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POST WELD HEAT TREATMENT

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PIPING INSPECTION AND TESTING

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PIPING GENERAL ARRANGEMENT DRAWING

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PIPING DISCIPLINE

PIPING DISCIPLINE

PLANT LAYOUT

PIPING INSTALLATION

PIPING MATERIAL


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PIPING STRESS ANALYSIS CALCULATION NOTE

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PIPE SUPPORT DRAWINGS

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SPRING SUPPORTS

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PIPING DISCIPLINE

PIPING DISCIPLINE

PLANT LAYOUT

PIPING INSTALLATION

PIPING MATERIAL


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PIPING MATERIAL: LINE PIPE, FITTINGS : ,

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MATERIAL SELECTION

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PIPING MATERIAL CLASSES

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GENERAL PIPING SPECIFICATION

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PIPING MATERIAL CLASS SPECIFICATION

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PIPING MATERIAL TAKE-OFF

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PIPING MATERIAL REQUISITION

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INSTRUMENT LIST

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INSTRUMENT DATA SHEET

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PCS (PROCESS CONTROL SYSTEM) ( . )

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SYSTEM ARCHITECTURE DRAWING

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SYSTEM REQUISITION

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CONTROL NARRATIVE

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PROCESS AUTOMATION

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MECHANICAL EQUIPMENT CONTROL

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EMERGENCY SHUTDOWN (ESD) ( )

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Package / Centralized control /

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Package / Local control /

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FIRE & GAS SYSTEM

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FIELD INSTRUMENTATION

Process line /

PT JB / .

Marshaling Cabinet

DCS Cabinet

Instrument room

Control room

VDU /

CPU /

LAN

Secondary cable / Multi cable /

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MAIN CABLE ROUTINGS AND JUNCTION BOX (JB) LOCATION DRAWING

()

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INSTRUMENT LOCATION & SECONDARY CABLE ROUTING DRAWINGS

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TELECOMMUNICATION EQUIPMENT LAYOUT DRAWING

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TYPICAL INSTALLATION DRAWINGS

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JUNCTION BOX WIRING

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INSTRUMENT LOCATION & SECONDARY CABLE ROUTING DRAWINGS / CABLE LIST .

.

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ITEM QUANTITY DESIGNATION

1 195 Gauge adapter x

2 37 Block manifold 2 valves (Gas)

3 23 Block manifold 5 valves (Gas)

4 0 Ball valve 12mm

5 300m Tubing 12mm OD x 1mm

6 200 Reducer 12mm x

7 50 Union tee 12 x 12 x 12mm

8 50 Female connector 12mm x

9 350 Male connector 12mm x

10 9 Plug NPTF

11 8 Plug NPTM

INSTRUMENT BULK MATERIAL TAKE-OFF

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EQUIPMENT LAYOUT DRAWINGS

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MIMIC DISPLAY DRAWINGS

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INSTRUMENT LOOP DIAGRAM

FIELD

JUNCTION BOX /

FIELD DEVICE

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ELECTRICAL CONSUMER LIST

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ELECTRICAL POWER DISTRIBUTION

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GENERAL ONE LINE DIAGRAM

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Turbogenerator

Switchgear

Transformer

EQUIPMENT SIZING

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EQUIPMENT DATA SHEET

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SWITCHBOARD SINGLE LINE DIAGRAM

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SWITCHGEAR TYPICAL DIAGRAM

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ELECTRICAL CONTROL SYSTEM

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From emergency (diesel) generators / -

From main power generators /

To normal consumers e.g. pumps in process and utility units / . .,

.

To essential consummers e.g. fire water pump . .,

.

ELECTRICAL CONTROL SYSTEM

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EQUIPMENT LAYOUT DRAWING

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CABLE ROUTING DRAWINGS / CABLE LIST . .

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TYPICAL INSTALLATION DRAWINGS

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BLOCK DIAGRAM

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TROUBLE SHOOTING DIAGRAMS

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LIGHTING LAYOUT DRAWINGS

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8800

8900

9000

9100

9200

9300

9400

9500

9600

9700

9800

9900

10000

0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0

VOLTAGE OF MS-001 (STUDY1)Bus V

oltage (Volt

s)

Time (Seconds)

47.0

47.5

48.0

48.5

49.0

49.5

50.0

0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0

FREQUENCY OF MS-001 (STUDY1)

Bus Freque

ncy (Hz)

Time (Seconds)

CALCULATIONS

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SCHEDULE /

PROCESS PLANT ENGINEERING

Good bye! !

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The Oil & Gas Engineering Guide - 2nd edition

Table of Contents

http://www.editionstechnip.com/en/catalogue-detail/1111/oil-gas-engineering-guide-the.html

http://www.editionstechnip.com/en/catalogue-detail/1111/oil-gas-engineering-guide-the.html

Diapositive numro 1Diapositive numro 2Diapositive numro 3Basic Engineering Detail Engineering Diapositive numro 6Diapositive numro 7Diapositive numro 8Diapositive numro 9Diapositive numro 10List of Common Engineering Deliverables (1/2) (1/2) List of Common Engineering Deliverables (2/2) (2/2) Engineering document quality requirements: checking : Engineering document revision Engineering MASTERs Engineering review action items follow-up Diapositive numro 17Diapositive numro 18Diapositive numro 19Grid system Grid system Detail Drawings common sizes & scales Specifications / Basic engineering design data Diapositive numro 26Diapositive numro 27Diapositive numro 28Diapositive numro 29Diapositive numro 30Process Scheme Optimization Diapositive numro 32Diapositive numro 33Diapositive numro 34Diapositive numro 35Diapositive numro 36Diapositive numro 37Diapositive numro 38Diapositive numro 39Diapositive numro 40Diapositive numro 41Diapositive numro 42Diapositive numro 43Diapositive numro 44Diapositive numro 45Diapositive numro 46Diapositive numro 47Diapositive numro 48Diapositive numro 49Diapositive numro 50Diapositive numro 51Diapositive numro 52Diapositive numro 53Diapositive numro 54Diapositive numro 55Diapositive numro 56Diapositive numro 57Diapositive numro 58Bid technical evaluation Vendor design development Equipment summary Diapositive numro 62Diapositive numro 63Diapositive numro 64Diapositive numro 65Diapositive numro 66HAZOP review / Deviation (HAZOP ) / Diapositive numro 68HAZOP action and response sheet HAZOPSafety of Layout Fire Fighting Fire Fighting Fire Fighting Fire Water P&IDs Diapositive numro 75Passive fire protection Passive fire protection Diapositive numro 78Diapositive numro 79Diapositive numro 80Diapositive numro 81Diapositive numro 82Diapositive numro 83Diapositive numro 84Diapositive numro 85Diapositive numro 86Environmental Impact Assessment ()Noise study Diapositive numro 89Diapositive numro 90Diapositive numro 91Diapositive numro 92Diapositive numro 93Earthworks drawings Diapositive numro 95Diapositive numro 96Diapositive numro 97Diapositive numro 98Diapositive numro 99Civil works specification / Diapositive numro 101Loading data Diapositive numro 103Diapositive numro 104Diapositive numro 105Diapositive numro 106Diapositive numro 107Diapositive numro 108Diapositive numro 109Diapositive numro 110Diapositive numro 111Diapositive numro 112Diapositive numro 113Diapositive numro 114Diapositive numro 115Diapositive numro 116Diapositive numro 117Diapositive numro 118Diapositive numro 119Diapositive numro 120Diapositive numro 121Diapositive numro 122Diapositive numro 123Diapositive numro 124Diapositive numro 125Diapositive numro 126Diapositive numro 127Diapositive numro 128Diapositive numro 129Diapositive numro 130Diapositive numro 131Diapositive numro 132Diapositive numro 133Diapositive numro 134Diapositive numro 135Diapositive numro 136Diapositive numro 137Diapositive numro 138Diapositive numro 139Diapositive numro 140Diapositive numro 141Diapositive numro 142Diapositive numro 143Diapositive numro 144Diapositive numro 145Diapositive numro 146Diapositive numro 147Diapositive numro 148Diapositive numro 149Diapositive numro 150Diapositive numro 151Diapositive numro 152Diapositive numro 153Diapositive numro 154Diapositive numro 155Diapositive numro 156Diapositive numro 157Diapositive numro 158Diapositive numro 159Diapositive numro 160Diapositive numro 161Diapositive numro 162Diapositive numro 163Diapositive numro 164Diapositive numro 165Diapositive numro 166Diapositive numro 167Diapositive numro 168Diapositive numro 169Diapositive numro 170Diapositive numro 171Diapositive numro 172Diapositive numro 173Diapositive numro 174Diapositive numro 175Diapositive numro 176Diapositive numro 177Diapositive numro 178Diapositive numro 179Diapositive numro 180Diapositive numro 181Diapositive numro 182Diapositive numro 183Diapositive numro 184Diapositive numro 185Diapositive numro 186Diapositive numro 187Diapositive numro 188Diapositive numro 189Diapositive numro 190Diapositive numro 191Diapositive numro 192Diapositive numro 193Diapositive numro 194Diapositive numro 195Diapositive numro 196Diapositive numro 197Diapositive numro 198Diapositive numro 199Diapositive numro 200Diapositive numro 201Diapositive numro 202Diapositive numro 203Diapositive numro 204Diapositive numro 205Diapositive numro 206Diapositive numro 207Diapositive numro 208Diapositive numro 209Diapositive numro 210Diapositive numro 211Diapositive numro 212Diapositive numro 213Diapositive numro 214The Oil & Gas Engineering Guide - 2nd edition