1

Introduction toProcess Plant

Design

Copyright ©, 2009William G. Beazley, PhD

All Rights ReservedPhoto: Air Products

Process Plants• Characterized by Chemical Processes

– Different from power (including nuclear), propulsion,etc.

– Hazards from both energy and substance release

– Substances and their temperature and pressure, etc.,usually drives the selection of piping materials anddesign ratings

• Petrochemical Plants have their own:– Design standards

– Terminology

– Practices and

– Constraints

Basic Components of aTypical Chemical Process

(R. K. SINNOTT)

Tanks,Warehouses,Hoppers,Piles, etc.

Pumps,Compressors,Exchangers,Heaters,Crushers,Mixers, etc.

Reactors,Furnaces,etc.

Drums,Towers,Filters,Dryers, etc.

Reflux,Strippers,Treaters,etc.

Tanks,Warehouses,Baggers,etc.

Raw Material Storage

• Tanks, Hoppers, Piles, etc.

Feed Preparation(US Navy, Nasa, Transportation,

• Pumps, Compressors, Exchangers, Heaters,Crushers, Mixers, etc.

http://www.npt.nuwc.navy.mil/facilities/QuietWater/default.htm

http://www.tfhrc.gov///pubrds/05jan/02.htm

http://www.ih.navy.mil/Departments/ord/che-ext-tec-div/index.asp

Reaction(US Army, DOE, )

• Reactors, Furnaces, etc.

http://www.pmcd.apgea.army.mil/multimediaviewer.aspx?id=585

http://www.netl.doe.gov/technologies/coalpower/cctc/summaries/tampa/tampaedemo.html

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Product Separation(US DOE)

• Drums, Towers,Filters, Dryers, etc.

http://www.nrel.gov/data/pix/searchpix.cgi?

http://www.greensboro-nc.gov/departments/Water/watersystem/treatment.htm

Product Purification(US OSHA, DOT)

• Reflux, Strippers,Treaters, Sorters, etc.

http://iforms.osha-slc.gov/dts/osta/otm/otm_iv/otm_iv_2.html

Product Storage

• Tanks, Warehouses,

• Baggers,

• etc.

Waste Storage(DOE, EPA, USGS)

http://www.fedcenter.gov/_storage/Photos/176.jpg

http://www.tobyhanna.army.mil/about/certifications/environmental/rcra%20cleanup.htm

http://pubs.usgs.gov/gip/gw_ruralhomeowner/gw_ruralhomeowner_new.html

Sales

http://www.msc.navy.mil/sealift/2005/September/katrina.htm

The Manufacture of Cement by thePortland Process

(US CDC)

http://www.cdc.gov/elcosh/docs/d0200/d000279/ilochap93.html

Limestone,Clay, etc.

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Parties to PlantDesign

(The 'PIPING GUIDE')

• Client wants a finishedplant– Business Case Primary

Concern

– Everyone Else isTemporary

• Design Engineersproduce highly qualityassured productdefinition data

• Construction RealizesDesign

Source:The 'PIPING GUIDE'http://www.pipingguide.com

Process Plant Client• Funds the engineering and construction of the plant

• Generally supplies or approves the processes to be used

• Accepts the work performed

The Project Engineer

• Formal point of contact with the client

– Voice of the client inside the engineering organization

– Usually “seals” design as professional engineer

• Responsible for completeness and correctness of workhttp://www.nps.gov/hfc/products/imi/imi-ser-class.htm

The Project Engineer

• Reviews the DesignBasis of Plant

• Enforces ClientRequirements

http://www.osha.gov/dcsp/partnerships/regional/region2/453_signing.html

The Project Engineer

• Plans and SchedulesWork

http://www.osha.gov/dcsp/partnerships/regional/region2/459_signing.html

Procured Materials and Services

• Items that has been obtained from vendor orsupplier

• Assistance or advice provided by a vendoror supplier

• Obtained through a procurement process

• Result in a list of vendors andsubcontractors

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Project Organization

Source: The 'PIPING GUIDE'http://www.pipingguide.com

ProjectDesign

Groups andInformation

Flow(Source: The

'PIPING GUIDE')

http://www.pipingguide.com

Design Organizational Roles

DesignSupervisor

Designer

Designer

Designer

Designer

Checker

ProjectData

Design supervisor/Group leader

• Manages the documentation of in processand approved engineering data

• Contacts the Project Engineer for anyapprovals required

• Assigns work to designers at the appropriatetime

• Assures all data needed for work isavailable to designers

The Piping Designer

• Responsible for correctness of hiswork

• Inform supervisor if questions arise

• Recognize need for data required tocomplete work

• Never contact the client directly

Engineering Design Specifications

• Established basis for final plant design

• Includes:

– start-up procedures,

– initial site selection information,

– general pre-commissioning guidelines,

– equipment testing procedures and acceptancemethods

– final process topology,

– material and energy balance information

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Functional Equipment Characteristics

• Describe or specify:

–Functional requirements for theequipment

–Service provided to the process bythe equipment

–What equipment is supposed to do

Vendor-Proprietary Equipment

• Equipment whose performance isguaranteed by the vendor.

• Specified by equipment datasheet inprocess design specificationspackage.

• Usually designed by first selecting avendor who performs testing andsizing of the item

Supplier/Vendor Relationship

• Request the required information only

• Disclosing only necessary information toget the right data

• Avoid:

–Disclosing competition

–Telling vendor he’ll get the order

–Gratuities and never demand them (lunch)

–Ordering to get information then cancel

Documentation

• All project management, design,contractual, regulatory, and disposaldocuments produced during the lifecycle of a process plant.

• Has versions and releases that mustbe managed.

• Includes all documentation retainedpast the end of the plant life cycle

Operations Documents

• Covers all the many different phases andaspects of plant operation

• Documentation necessary to run theplant safely:

–Procedure to start up and shut down theplant

–Parameters and settings for processequipment and controls

Handover

• Transfer of responsibility for the plant

–Construction team to commissioning team

–Commissioning team to operating team

• Involves transfer of all supportingdocumentation

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Activity Model of the Oil and GasProduction Facility Life-cycle

(ISO 15926)

Produce ConceptualProcess Design

Produce DetailedProcess Design

Produce ConceptualEngineering Design

(Front End)

Produce DetailedEngineering Design

CommissionPlant

Construct PlantPre-Commission

Operate PlantDecommission

Plant

Maintain Plantand Equipment

Demolish Plantand Restore Site

Procure and Control Equipment, Material and ServicesSuppliers andFabricators

http://www.tc184-sc4.org/About_TC184-SC4/About_SC4_Standards/

Common Status Terms

• As-built: Process plant's actual physicaland functional aspects at a specific pointin timeAs-approved: Product data provide toand approved by clientAs-specified: Approved data provide toengineer by clientAs-released: Product data officiallyprovided to anyone

Construction Release

• All data needed to realize the plant– Build,

– Commission,

– Train to operate, maintain

• Approved for release by engineering forconstruction

• Stamped by a registered professionalengineer

Finalized Construction Documents

• All documentation related to the erection,commissioning and operation

• Includes:– As-built reports,

– Equipment certification,

– Nameplate information of installed equipment,

– Operating manuals,

– Testing procedures,

– Field changes, and

– Photos of as-built units, modules and plant

Plant Commissioning• Required before

client handover

• Proven operationalthrough specificprocedures

– Confirm StaffSkills

– Verify productdata

– Test equipment

• EquipmentCommissioningProcedures - Step-by-step explanationof start-up actionsrequired tocommissionequipment in theplanthttp://www.usaid.gov/iraq/photogallery/gallery_8/capconstr1_06.html

Maintenance

http://flickr.com/photos/coolnewspics/244371213/in/dateposted/

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Maintenance

http://www.eere.energy.gov/industry/bestpractices/energymatters/full_issue.cfm/volume=37

http://www.srs.gov/general/busiops/tech-transfer/plant.htm

http://www1.usaid.gov/iraq/photogallery/gallery_39/photo18.html

http://splash.metrokc.gov/wtd/southplant/index.htm

Shutdown/Decommissioning

• Shutting down theplant

• Preserving it forlatercommissioning ordemolition

• May not includesite remediation

http://www-als.lbl.gov/als/als_news/news_archive/vol.240_042804.html

http://www.lm.doe.gov/land/sites/oh/fernald_orig/VImages/PhotoTour/1998/Dec98/Plt6c.htm

http://www.nrc.gov/reading-rm/doc-collections/fact-sheets/decommissioning.html

Project Schedule

• Duration

• Start Date

• Critical Path

– Sequence of Taskssuch that if any is latethe project is late.

– Can be more than one

http://www.coconino.az.gov/cji.aspx?id=383

Questions

Production Output• Materials or energy to be sold or

traded

• Result of processing raw material(s)(Production Input)

• Produced according to a scheduleddelivery time, grade, and quantity ofproduct to be produced

Source: EPISTLE Process Industries Data Handover Guide - Part 1http://www.uspi.nl/projects/Joint_Projects/fr_joint_projects.html

PISTEP Process Plant Engineering Processes

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Course Outline

• Part 1 Pipe Lifecycle

• Part 2 Pipe Fluid Flow & Control

• Part 3 Plant Equipment

• Part 4 Pipe Structural Design

• Part 5 Project Practices & Management

• Part 6 Project