Introduction to Process Plant Design

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1

Introduction to

Process Plant

Design

Copyright ©, 2012

William 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 a

Typical 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, CSTRs, etc.

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

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

CSTR – Continuously Stirred

Tank Reactor



2

Product Separation(US DOE)

• Drums, Towers, Filters,

Extraction, 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, Drums, etc.

Waste Capture and 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

• Incinerators, Sequestration, Ash

Precipitators, Chemical Sewers,

etc.

Sales

• Pipelines, Tanker Trucks,Metered OBL Flows, etc.

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

Portland Process for Cement Manufacture(US CDC)

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

Limestone,

Clay, etc.



3

What a Barrel

of Crude Oil

Makes

(Texas Oil &

Gas Association)

Product Gallons per barrel

Gasoline 19.5

distillate fuel oil(Includes home heating oil & diesel fuel)

9.2

kerosene-type jet fuel 4.1

residual fuel oil(Heavy oils used as fuels in industry,marine transportation and forelectric power generation)

2.3

lique fied re finery gasses 1.9

still gas 1.9

coke 1.8

asphalt and road oil 1.3

pe trochemical fe edst ocks 1.2

lubricants 0.5

kerosene 0.2

other 0.3

Figures are based on 1995

average yields for U.S.

refineries. One barrel

contains 42 gallons of

crude oil. The total

volume of products made

is 2.2 gallons greaterthan

the original 42 gallons of

crude oil. This represents

"processing gain."

http://www.txoga.org/articles/308/1/WHAT-A-BARREL-OF-CRUDE-OIL-MAKES

Crack Spread(Wikipedia)

• Hedge against adverse price movements by buying

oil futures and selling futures for its primaryrefined products according to the proportions of its

optimal mix.

• Crack Ratio X:Y:Z and X=Y+Z. Hedging by

buying X barrels of crude oil and selling Y barrels

of gasoline and Z barrels of distillate in the futures

market.

• As the 3:2:1 crack spread is the most popular, i.e.,

the "Gulf Coast 3:2:1" and the "Chicago 3:2:1"

http://en.wikipedia.org/wiki/Crack_spread

CAPEX vs OPEX

• Capital Expenditures (CAPEX)’

– First Costs

– Ends with Production (Commissioning)

– Amortized over the “life” of the plant

• Operational Expenditures (OPEX)

– Ongoing expenditures resulting in revenue (sales)

– Starts with Production – Current expense, matched with revenue

• Main Point: EPC is generally CAPEX

– EPC guys are temporary “rented experts”

– Save your money for rainy days

Life-Cycle Sustainable Development(Sandia)

http://www.sandia.gov/archsur/C33.htm

Parties to Plant

Design(The 'PIPING GUIDE')

• Client wants a finished

plant

– Business Cas e Primary

Concern

– Everyone Else is

Temporary

• Design Engineers

produce highly quality

assured product

definition data

• Construction Realizes

DesignSource:

The 'PIPINGGUIDE'

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



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The Project Engineer

• Formal point of contact with the client

– Voice of the client insi de the engineering organization

– Usually “seals” design as professional engineer

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


• Reviews the Design

Basis of Plant

• Enforces Client

Requirements

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


• Plans and Schedules

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

Procured Materials and Services

• Items that has been obtained from vendor or

supplier

• Assistance or advice provided by a vendor

or supplier

• Obtained through a procurement process• Result in a list of vendors and

subcontractors

Project Organization

Source: The 'PIPING GUIDE'


Project

Design

Groups and

Information

Flow(Source: The

'PIPING GUIDE')




5

Design Organizational Roles

Design

Supervisor

Designer

Designer

Designer

Designer

Checker

Project

Data

Design Supervisor/Group Leader

• Manages the documentation of in process

and approved engineering data

• Contacts the Project Engineer for any

approvals required

• Assigns work to designers at the appropriate

time

• Assures all data needed for work is

available to designers

The Piping Designer

• Responsible for correctness of his

work

• Inform supervisor if questions arise

• Recognize need for data required to

complete 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

Functional Equipment Characteristics

• Describe or specify:

–Functional requirements for the

equipment

–Service provided to the process by

the equipment

–What equipment is supposed to do

Vendor-Proprietary Equipment

• Equipment whose performance is

guaranteed by the vendor.

• Specified by equipment datasheet in

process design specifications

package.

• Usually designed by first selecting a

vendor who performs testing and

sizing of the item



6

Documentation

• All project management, design,

contractual, regulatory, and disposal

documents produced during the life

cycle of a process plant.

• Has versions and releases that must

be managed.

• Includes all documentation retained

past the end of the plant life cycle

Operations Documents

• Covers all the many different phases and

aspects of plant operation

• Documentation necessary to run the

plant safely:

– Procedure to start up and shut down the

plant

– Parameters and settings for process

equipment and controls

Handover

• Transfer of responsibility for the plant

– Construction team to commissioning team

– Commissioning team to operating team

• Involves transfer of all supporting

documentation

Common Status Terms

• As-built: Process plant's actual physical

and functional aspects at a specific point

in time

As-approved: Product data provide to

and approved by client

As-specified: Approved data provide to

engineer by client

As-released: Product data officially

provided to anyone

Construction Release

• All data needed to realize the plant

– Build,

– Commission,

– Train to operate, maintain

• Approved for release by engineering for

construction

• Stamped by a registered professional

engineer

Finalized Construction Documents

• All documentation related to theerection, commissioning and operation

• Includes:

– As-built reports,

– Equipment certification,

– Operating manuals,

– Testing procedures,

– Field changes,

– Nameplate information of installedequipment , and

– Photos of as-built units, modules and plant



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Plant Commissioning• Required before

client handover

• Proven operational

through specific

procedures

– Confirm Staff

Skills

– Verify product

data

– Test equipment

• Equipment

Commissioning

Procedures - Step-

by-step expla nation

of start-up actions

required to

commission

equipment in the

planthttp://www.usaid.gov/iraq/photogallery/gallery_8/capconstr1_06.html

Maintenance

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

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• Shutdown: Ceasing

Operations

• Decommissioning:

– Remove from

active status

– Shutdown &

preserving for later

commissioning or

demolition

– May not include

site 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 Tasks

such that if any is late

the project is late.

– Can be more than one

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

Questions



8

Production Output• Materials or energy to be sold or

traded

• Result of processing raw material(s)

(Production Input)

• Produced according to a scheduled

delivery time, grade, and quantity of

product to be producedSource: EPISTLE Process Industries Data Handover Guide - Part 1

http://www.uspi.nl/projects/Joint_Projects/fr_joint_projects.html

PISTEP Process Plant Engineering Processes

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

Activity Model of the Oil and Gas

Production Facility Life-cycle(ISO 15926)

Produce Conceptual

Process Design

Produce Detailed

Process Design

Produce Conceptual

Engineering Design

(Front End)

Produce Detailed

Engineering Design

Commission

Plant

Construct Plant

Pre-Commission

Operate Plant Decommission

Plant

MaintainPlant

and Equipment

Demolish Plant

and Restore Site

Procure and Control Equipment,Material and ServicesSuppliers and

Fabricators

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

Supplier/Vendor Relationship

• Request the required information only

• Disclosing only necessary information to

get 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

Introduction to Process Plant Design

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