Basic Definitions of Overall Engineering Phases

8/3/2019 Basic Definitions of Overall Engineering Phases

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BASIC DEFINITIONS OF OVERALL ENGINEERINGPHASES

PROCESS DESIGN PACKAGE (BASIC ENGINEERING)

Process Block Diagram(s) – PBDEach Block can be represented a single piece of equipment or a completestage in the process. The stream flow rates, temperatures andcompositions can be shown on the diagram adjacent to the stream lines.

1.1 Process Flow Diagram - PFD( with material and energy balance )

PFD should indicate the following:

1.1.1 All major equipment1.1.2 Equipment names,1.1.3 Equipment identification number,1.1.4 Major by-pass and recirculation lines,1.1.5 Control valves,1.1.6 Valves required to demonstrate routing for all mode of

operation,1.1.7 Pipe sizes if required by office practice,1.1.8 Interconnections to other systems,1.1.9 Equipment ratings or capacities,

Pumps : Capacity, Head,H / Exch. : Heat duty,Lines : Flow, Temp. Pressure,Reactors : Diam., Catalyst Volume, LHSV

Inlet / Outlet Temp’s and Pressuresa SOR and

EOR conditions.

Towers : Diam., No of trays, Feed / ProductsInlet outlet tray

Numbers /temperatures (andpressures)Heaters : Heat Duty, inlet/outlet temperatureand pressuresDrums & Vessels : Diam., Height, Level or Volume

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1.2 Process Control Flow Diagram - CFD

( on PFD )

CFD should indicate the following:Recommended major instrumentation and control elementsfor all mode of operation on the PFD.

1.3 Detailed Process Description

1.3.1 Basis of Design (The Basis of Design document defines project requirement,

primarily outlined during the conceptual and feasibility stages, in terms of quality,

capacity, utilities and performance)System design basis, (Description of the overall

system)

1.3.2 Description of operating modes,

1.3.2.1 Initial start-up and/ or start-up after majoroverhaul,

1.3.2.2 Normal start-up,1.3.2.3 Min. capacity case,1.3.2.4 Normal shut-down,1.3.2.5 Emergency shut-down (power failure, cooling

water failure, fire or as appropriate )

1.3.3 Description and performance ratings of majorequipment, if necessary for all mode of operation

1.3.4 Control concept,1.3.5 Detail description of catalyst regeneration, catalyst

and/or support material loading / unloading, chemicalcharge, washing drying etc.

1.4 Major equipment list

1.5 Major equipment process data sheets,

1.6 Proposed metallurgy (for equipment, pipes, structural etc.)

1.7 Safety requirements

1.8 Waste disposal requirements,

1.9 Recommended analytical techniques,

1.10 Fire Fighting

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1.0 FRONT – END ENGINEERING PACKAGE

2.1 System Design Basis ( as a part of basic engineering package )

2.2 Basic Engineering Design Data – BEDD

2.2.1.Feed stocks, intermediates and products specifications ( ormaterial data sheets),

2.2.2.General :2.2.3.Measurement Systems,

- Applicable codes and standards,- Utilities & Site Conditions & Pollution Control & Safety:- Steam ( LP, MP, HP, normal/max./min temp and press

levels, mechanical design ranges)- Condensate ( types and pressure levels )

- Electric power (rates)

- Water ( type of water and specifications), sea water,

demin. -water, desalinated water, CCCW, temperedwater,

- Fuel ( Liquid, gas or solid, composition, LHV, HHV,availability)

- Air and Inert Gaso Plant Air ( Press., Temp., Dew Point)o Instrument Air ( Press., Temp., Dew Point)o Inert Gas ( Nitrogen or Fuel Gas composition,

Pressure)

- Flare and Blow Down- Site Conditions;

o Direction of prevailing wind ( throughout a year )

o Design wind pressure

o Temperature ( summer-winter max/min, shade/solar)o Soil Temperature (surface 0.5m, 1.0m & 1.5m depth

in summer & winter)o Dry bulb max/min.o Welt bulb temperature and humidity.o Snow rainfall (mm, p/hour, p/year)

o Earthquakeo Sea Water, River Water ( lowest, max, normal levels)

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o Soil Exploration Data ( Soil Report),

o Geo-hazard report,

- Anti – pollution Measurement and EnvironmentalRegulationso Noise levelso Water disposal ( clean, oily, chemical, domestic)o Waste gaseso Solid / Sludge Waste disposal

- Min. Safety Distances between units/ facilities ( on- siteand off site ), equipment spacing

2.2.4.Operating reliability and flexibility 2.2.5. Delivery and shipping logistics (feed and products),

2.2.6.Equipment design and sizing criteria.

- Min / max velocities- Min / max pressure drops- Dimensions, volumes- Metallurgies,- Recommended sizes,

2.2.7.Philosophy for isolation and decontamination2.2.8.Material construction2.2.9. Winterization requirement (selection of insulation material,

steam vs. electrical tracing vs. hot oil vs. hot process fluid

circulation etc.)2.2.10. Fire protection requirement (fire hydrant, sprinkler system,

CO2 etc.)2.2.11. Waste disposal requirement2.2.12. Safety requirements2.2.13. All required procedures, method statements etc.

2.3Utilities & Effluents

2.3.1 Utility Summary

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2.3.2 Catalyst & Chemicals & Support Materials Summaries2.3.3 Effluent Summary

2.4Equipments

2.4.1 Complete equipment list(s)2.4.2 Equipment data sheet ( with Process and Mechanical

design information )

2.4.2.1 Vessels, Drums, Tanks, Bins etc.2.4.2.2 Heat Exchangers (Tubular, Fin-Fan, Coils etc.)2.4.2.3 Heaters/Furnaces2.4.2.4 Rotary Machinery (pumps, fans, compressors

turbines etc.),2.4.2.5 Vendor package units (nitrogen plant, IA

dryers etc.)2.4.2.6 Others, (PSV data sheets, Process Inst. Data

sheets etc.)

2.5Flare Loading Sheets ( Summary )

2.6 Line List / Schedule ( with Piping Spec’s )

2.7Drawings2.7.1 General Plot Plan ( with elevations )2.7.2 Equipment Layout and Spacing2.7.3 P & ID’ s ( Process, Utilities and Off-site )2.7.4 Material of Construction ( marked on PFD’s )2.7.5 Preliminary piping layout and tie-in.

2.8General Specifications

2.8.1 Piping,2.8.2 Mechanical,2.8.3 Electrical,2.8.4 Instrument,2.8.5 Civil/Arch./Structural,2.8.6 Others ( painting, insulation, fireproofing),

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2.9HAZID and / or HAZOP Review

2.0 PROCUREMENT

4.1 Pre-select vendors,4.2Prepare Inquire and Material Requisition,4.3Receive Bids,4.4Preliminary Evaluation of Bids,4.5Technical & Commercial Evaluation,4.6Pre-award meeting-(Condition Bids)4.7Select Vendor4.8Pre-commitment meeting4.9Award Order

3.0 EXPEDITING PROCEDURE

5.1 Inspection ( Workshop and Field )5.2Acceptance of Equipment

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5.0 DETAILED ENGINEERING CHECK LIST

5.1 Process

Process Flow Diagram (PFD)

Process Control Flow Diagram (CFD)

Process Description (unit by unit)Heat & Material balances (on Process Flow Diagram)

Process lines physical / chemical dataProcess equipment specification / load sheetsProcess equipment sizes /sketches with recommended metallurgy(See Process Design Package for details)

5.2 Systems

Plot Plan Preparation / Equipment LayoutP & I Diagrams, process / utility / auxiliaryHydraulic Profiles of Process and Utilities on Plant Layout

Battery limit conditions for each process blockUtility balance diagramsLine schedule or Line list - Line sizing / wall thickness & line data(metallurgy, operation and design temperatures & pressures)Pump & re-boiler NPSH calculationsRelief valve discharge & flare calculationsRelief valve data sheets

Piping special item data sheetsEnvironmental emissions & permit documentsEquipment lists for all engineering sections(See Process Design Package for details)

5.3 Furnaces & Heaters

Furnace design / purchase specifications

Furnace data sheetsFurnace design calculations

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Furnace general arrangement / detail drawingsFurnace Inquiry / Purchase requisitionsVendor drawings

Test procedures/test reports / performance requirements

Parts lists / recommended spares

Operating & maintenance catalogues

5.4 Vessels (Tanks, Towers, Drums, Bins etc.)

Vessel design / purchasing specificationsVessel outline & detail drawingsVessel design calculationsVessel nozzle sizes / orientations

Vessel inquiry / purchase requisitionsVendor fabrication drawings & design calculationsVessel platforms / ladders & pipe support / guide drawings

5.5 Exchangers

Exchanger design / purchasing specificationsExchanger rating / calculationsExchanger setting plans / tube sheet layoutsExchanger inquiry / purchase requisitionsVendor fabrication drawings & design calculations

5.6 Rotating Machinery / Special & Utility Equipment

Equipment design / purchasing specificationsEquipment detail specifications / data sheetsEquipment Inquiry / purchase requisitionsFloor space and utility summaryVendor arrangement / detail drawings Test procedures / test reports / performance curves Vendor partslist / recommended spares

Vendor operating and maintenance catalogues.

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5.7 Instruments

Instrument Architecture and Design Philosophy

Instrument design / purchasing specifications

Instrument IndexInstrument specifications/data sheetsFunctional process control specificationsControl room & panel layoutsInstrument logic diagramsDCS & PLC configuration codeInstrument vessel / equipment sketchesInstrumentation inquiry / purchase requisitions

Instrument location plansInstrument loop diagramsInstrument tray / conduit / cable / piping layouts

Instrument installation detailsInstrument winterization scheduleInstrument wring/termination lists

5.8 Plant and Piping Layout

Plot plans / Site plans / Piping layout ( 1/ 5000 )

Plant arrangement studiesPlot plan block model (1/8" = 1)Piping design model (3/8" = 1)Battery limits connections plan (tie-in's)Piping design / purchasing specificationsPipe line material specification sheetsU/G piping drains, sewers, layouts drawings

A/G piping key plans / elevation drawingsPiping isometrics

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Piping bills of materialsPiping stress, load & support calculationsPiping support drawings / detailPiping special items data sheetsPiping materials inquiry / purchase requisitions (plain carbon steel,

lined / coated carbon steel, galvanized, stainless steel, alloys, etc. )

5.9 Civil

Civil design / purchasing specifications (incl. blast proof buildings)

Site preparation drawingsFoundation design calculations

Foundation design drawingsA/G concrete structure design calculations

A/G concrete drawingsRebar detail drawingsFoundation location plansSite paving / ditches drawingsCivil material bill of quantitiesCivil material inquiry / purchase requisitions

5.10 Architectural

Building sketches / floor plansPurchased components specifications/data sheetsBuilding layout s/ detail drawingsBuilding inquiry / purchase requisitionsCivil design / purchasing specifications

5.11 Structural Steel

Structural steel design / purchasing specifications

Structural steel design drawings & calculationsStructural steel fabrication detailsStructural steel bills of materialsStructural steel inquiry / purchase requisitions

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5.12 Electrical

Electrical design / purchasing specificationsElectrical loads listSingle-line electrical diagramsElectrical area classification drawingsElectrical equipment specifications/data sheetsElectrical power layouts

Electrical cable sizingElectrical U/G conduit / cable runs

Electrical A/G cable tray / conduit layoutsElectrical schematic & wiring drawingsElectrical grounding layouts / detailsCathodic protection drawingsElectrical wiring / termination listsElectrical material / inquiry / purchase requisitions

5.13 Paint / Insulation – Winterizing – Desert Area –Marine Atmosphere /

Fireproofing

Painting design / purchasing specifications Insulation design /purchasing specifications.

Fireproofing design / purchasing specifications

List of painted / insulated / fireproofed equipment

List of painted / insulated / fireproofed piping

List of painted / fireproofed structural steel

Special Considerations

6.0 HAZOP Study and Safety Inspection Checklist

(Ref. GPA – Safety Insp. Checklist)

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7.0 Applicable Local and International Design and Engineering

Codes, Standards and Recommended Practices

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Basic Definitions of Overall Engineering Phases

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