Process 140328151909 Phpapp02 PDF

HERVE Engineering Training
BARON
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 (herve.baron@gmail.com),

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.
© 2015 – Hervé Baron

Hervé
HERVE Engineering disciplines: activities and deliverables
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 PROCESS
 PLANT LAYOUT
 EQUIPMENT
 SAFETY & ENVIRONMENT
 CIVIL
 PIPING
 PIPELINE

 INSTRUMENTATION
 ELECTRICAL
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 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
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 PROCESS
• P&IDs
• Flare study

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

HERVE Process Design Basis
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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

HERVE Process design basis
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Compressor Station

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 PROCESS
• Process simulations, Process Flow Diagram, HMB
• P&IDs
• Flare study

HERVE Choice of Process Scheme
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What are the bases of process scheme definition?
HERVE Overall Plant Process Design
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What is the name of

this drawing?

HERVE The Block Flow Diagram (BFD)
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 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 Unit Process Design
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HERVE The Process Flow Diagram (PFD)
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HERVE Unit Process Scheme Optimization
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TEG HP Compression & TEG
1200 psig Gas Injection
3000 psig 5500 psig
500 psig 200 psig 50 psig
IP Compression LP Compression
From Wells HP Separator

Cooler 5 psig
165 - 205 F 500 psig
Emul. Treater
50 psig 150 F
Degasser
Oil Production
5 psig

What are the elements taken into account in the
definition/optimization of the process scheme?
HERVE Process simulations
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Simulator settings
Output
Input
- Flow scheme
- Stream flows and
- Feed composition and - Thermodynamic model
composition
conditions - Equipment performance
- Equipment duty

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Simulator settings Output

Input
- Flow scheme - Stream flows and
- Feed composition and
- Thermodynamic model composition
conditions
- Equipment performance - Equipment duty

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Simulator settings
Output
Input
- Flow scheme
- Stream flows and
composition
- Equipment duty

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Simulator settings
Output
Input
- Flow scheme
- Stream flows and
composition
- Equipment duty

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Simulator settings
Output
Input
- Flow scheme
- Stream flows and
composition
- Equipment duty

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Simulator settings
Output
Input
- Flow scheme
- Stream flows and
composition
- Equipment duty

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 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

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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 Heat & Mass Balance (HMB)
• 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
HERVE Heat & Material Balance
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 PROCESS
• P&IDs
• Flare study

HERVE Process Description
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 PROCESS
• P&IDs
• Flare study

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 PROCESS
• P&IDs
• Flare study

HERVE Equipment sizing
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HERVE Cass study: Equipment Sizing
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32
33

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HERVE
HERVE Case study: Equipment Sizing
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Production separator
Sets the gas

cross section
Vessel size
Sets the liquid volume

HERVE Process data sheet
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Drums

HERVE Process data sheet
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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)
HERVE Process Data sheet
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Column

HERVE Columns and Drums
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Column internals must be specified.

These pictures are excerpts from Sulzer douments
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Column

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Rotating equipment

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Rotating equipment

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Heat Exchangers / Shell & Tubes

HERVE Heat Exchanger thermal sizing
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TEMA Data Sheet
A Thermal data sheet is
received from Process for
shell & tubes heat
exchangers following
thermal sizing

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Heat Exchangers / Other types

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Air Cooled HX

HERVE Process Data Sheet
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Fired heaters

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Fired heaters

What is particularly important while specifying a heater ?
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Storage tank

HERVE Process Sizing
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Process Equipment Sizing is done on the basis of:
 Sizing cases
 Over design
 Design criteria

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 Sizing cases – all operating cases
 Over design
 Design criteria

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 Sizing cases – all operating cases
 Over design – 10% as a rule
 Design criteria

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 Sizing cases – all operating case
 Sizing criteria On which basis are the following

equipment sized?

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Process Sizing is done on the basis of:
 Sizing criteria
• Separator
• KO drum
• Distillation/Absorption column
• Reactor
• Storage tank

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 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 Process specification
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Package

What document is issued by Process for packages?
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Package

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Package
What type of guarantees

are requested?

HERVE Process Equipment list
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HERVE Process Equipment list
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 PROCESS
• P&IDs
• Flare study

HERVE Piping & Instrumentation Diagram (P&ID)
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Compare the
information shown on

the PFD and the P&ID
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Compare
Comparethe
the
information
informationshown
shownon
on

the
thePFD
PFDand
andthe
theP&ID
P&ID
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What are the

purposes of P&IDs?
Compare the

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What are the

purposes of P&IDs?
At design stage:
• Defines the design basis for Piping & Instrumentation disciplines
Serves to
•Compare theshow 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.
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What are the

purposes of P&IDs?
P&ID
At design stage: review
Serves to

During operation:
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What are the

purposes of P&IDs?
Which are the usual
points reviewed
during a P&ID
review?
P&ID
At design stage: review
Serves to

During operation:
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P&ID review
Ease of operation and maintenance:
• Isolation /bypass of equipment
• Isolation/bypass of valves
• Vents/drains

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P&ID review
• Vents/drains
What do you call each type of

isolation?
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P&ID review
• Vents/drains
Where do you use double block

and bleed?

HERVE Isolation philosophy
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P&ID review
• Vents/drains

HERVE Piping & Instrumentation Diagrams (P&IDs)
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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
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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…)
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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
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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.
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 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

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• Package P&ID

HERVE P&IDs legend & symbols
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• Package P&ID

HERVE Identification and numbering system
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HERVE Identification and numbering system
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• Package P&ID

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P&ID
• Legend and Symbols representation
• Pumps auxiliary P&ID Details
• Package P&ID

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• Package P&ID

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• Package P&ID
What are the different typicals that should be

defined?

HERVE Piping & Instrumentation Diagram (P&ID) - Typicals
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How would you call each of these two types
of arrangement?
For what service(s) would each be used?
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• Package P&ID

HERVE P&ID work sequence
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P&IDs are typically issued 3 times, as design progresses

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IFR IFD IFC

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IFR IFD IFC

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P&ID
Review
IFR IFD IFC

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P&ID
HAZOP
Review
IFR IFD IFC

HERVE Quiz
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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 Quiz
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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
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P&ID
HAZOP
Review
IFR IFD IFC

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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

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P&ID
HAZOP
Review  Piping Isometric
drawings
 Piping material
top-up’s
IFR IFD IFC

 Piping routing

 Piping 2nd MTO & 1st material purchases
 Instrumenation & Control design
 Undeground piping (civil)
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Sometimes an « IFH » revision, mark-up’s of the P&ID review,

is used to anticipate the HAZOP
P&ID
HAZOP
Review
IFR IFD IFC

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An IFD2 revision is issued in case major change from Vendors/HAZOP to

up-date piping material purchases, instrumentation design etc.
P&ID HAZOP
Review  Piping Isos
 Piping material
Start top-up
IFR IFD IFD2 IFC

Up-date

 Piping routing
 Piping 1st material purchases
 Instrumenation & Control design
 Undeground piping (civil)
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 PROCESS
• P&IDs
• Flare study

HERVE Fluids list
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Line list
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HERVE
HERVE Line sizing
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 PROCESS
• P&IDs
• Flare study

HERVE Instrument process data sheet
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What is the most
important process data
for control valves?
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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.
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 PROCESS
• P&IDs
• Flare study

HERVE Process Shut Down
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Look at the extracts of these 2 P&IDs.

How is the protection against loss of
liquid level achieved in each case?

HERVE ESD logic diagram
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HERVE Safeguarding narrative & Cause and Effects charts
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HERVE Process and Safety Diagrams (PSD)
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 PROCESS
• P&IDs
• Flare study

HERVE Relief load summary
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HERVE Flare study
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HERVE Flare study
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 PROCESS
• P&IDs
• Flare study

HERVE Operating manual
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HERVE Operating manual
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What are the most important contents of the

operating manual?

HERVE Operating Manual
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Table of Contents (typ.)
1 INTRODUCTION 4 OPERATION
1.1 General presentation 4.1 Start-up
1.2 Glossary 4.2 Normal operation
1.3 Basic data 4.4 Shutdown
4.5 Depressurization
2 DESCRIPTION OF FACILITIES
2.1 General 5 SAFETY
2.2 Process 5.1 Operating philosophy
2.3 Utilities 5.2 Escape, evacuation and
2.4 Auxiliaries rescue
5.3 Emergency power system
3 AUTOMATIC CONTROL SYSTEM 5.4 Safety equipment list
3.1 System overview 5.5 Fire protection
3.2 Operator control interfaces
3.3 Telecommunications

3.4 Process alarms and trips
3.6 Emergency shutdown system
3.7 Fire & gas system
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Annexes (typ.)
 EQUIPMENT LIST  SINGLE LINE DIAGRAM

 PFDs  F&G SYSTEM ARCHITECTURE
DRAWING
 P&IDs
 VESSELS MECHANICAL DATA
 ESD LOGIC DIAGRAM SHEETS
 EQUIPMENT START/STOP &  INSTRUMENT DATA SHEETS (PSVs,

SHUTDOWN SEQUENCES Level instruments)
 GENERAL PLOT PLAN  ESD SIMPLIFIED DIAGRAM
 DCS ARCHITECTURE DRAWING  CONTROL LOOPS AND ALARM LIST
 ELECTRICAL CONTROL SYSTEM  SECURITY SWITCHES LIST

ARCHITECTURE DRAWING

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Annexes (typ.)
 EQUIPMENT LIST  SINGLE LINE DIAGRAM

 PFDs  F&G SYSTEM ARCHITECTURE
DRAWING
 P&IDs
 VESSELS MECHANICAL DATA
 ESD LOGIC DIAGRAM SHEETS
 EQUIPMENT START/STOP &  INSTRUMENT DATA SHEETS (PSVs,

SHUTDOWN SEQUENCES Level instruments)
 GENERAL PLOT PLAN  ESD SIMPLIFIED DIAGRAM
 DCS ARCHITECTURE DRAWING  CONTROL LOOPS AND ALARM LIST
 ELECTRICAL CONTROL SYSTEM  SECURITY SWITCHES LIST

ARCHITECTURE DRAWING

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Control loops and Alarms list

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 PROCESS
• P&IDs
• Flare study

HERVE Process design criteria
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What are the different Process design criteria?

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What are the different Process design criteria?
• Design margins
• Design Pressure and Temperature criteria
• Equipment sizing criteria
• Line sizing criteria
• Control valve sizing criteria

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• Design margins

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• Design margins: what is the usual Equipment (rotating, heat exchangers, columns) overdesign (%)?
+?%

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• Design margins: what is the usual Equipment (rotating, heat exchangers, columns) overdesign (%)?
+10%

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• Design margins

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• Design margins
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.
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• Design margins

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• Design margins

HERVE Licensed vs Open Art Process
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When one uses a process under license, what are the deliverables
issued by the process LICENSOR?

HERVE Typical PROCESS Licensor / Engineering split
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Item Process Licensor Engineer

PFD, H&MB X
Equipment data sheet Equipment process data sheet: Equipment Mechanical data sheet
- Operating conditions,
- Duty
- Diameters of vessels
- Size of Nozzles
- Pump head
+ specific info for internals etc.
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 Typical PROCESS Licensor / Engineering split
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Item Process Licensor Engineer

PFD, H&MB X
Equipment data sheet Equipment process data sheet: Equipment Mechanical data sheet
- Operating conditions,
- Duty
- Diameters of vessels
- Size of Nozzles
- Pump head
+ specific info for internals etc.
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 The Oil & Gas Engineering Guide
BARON
2nd edition
Do you want to know more... Much more?

HERVE The Oil & Gas Engineering Guide - 2nd edition
BARON
Table of Contents

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Table of Contents
This suite of training modules

covered the discipline
chapters of the book...

BARON
Table of Contents
The Guide contains much more:
The overall picture, interfaces,

methods & tools, etc.

HERVE The Oil & Gas Engineering Guide
BARON
2nd edition
Order direct from the publisher:
http://www.editionstechnip.com/en/catalogu
e-detail/1111/oil-gas-engineering-guide-
the.html

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HERVE 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

Comments are most welcome (herve.baron@gmail.com),

Please download this file so that you can see my trainer’s

© 2015 – Hervé Baron

 SAFETY & ENVIRONMENT

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

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

© 2015 – Hervé Baron

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

• Sizing cases: max capacity /turndown

• Other operating cases

• Feedstock composition and condition

• Battery limit conditions

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

What is the name of

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

TEG HP Compression & TEG

1200 psig Gas Injection

3000 psig 5500 psig

500 psig 200 psig 50 psig

From Wells HP Separator

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

Simulator settings Output

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

 Results from process simulations

© 2015 – Hervé Baron

 Shows the process controls

 The individual drawing item of the PFD is the Equipment Item

Scheme including the following information, as a minimum:

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

Sets the gas

Sets the liquid volume

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron