01a-introduction to process plant design
TRANSCRIPT
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Introduction to
Process Plant
Design
Copyright , 2009
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, 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 the
Portland Process(US CDC)
http://www.cdc.gov/elcosh/docs/d0200/d000279/ilochap93.html
Limestone,
Clay, etc.
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Parties to Plant
Design(The 'PIPING GUIDE')
Client wants a finished
plant Business Case Primary
Concern
Everyone Else is
Temporary
Design Engineers
produce highly quality
assured product
definition data
Construction Realizes
DesignSource:
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 Design
Basis of Plant
Enforces Client
Requirementshttp://www.osha.gov/dcsp/partnerships/regional/region2/453_signing.html
The Project Engineer
Plans and Schedules
Workhttp://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 vendoror supplier
Obtained through a procurement process
Result in a list of vendors and
subcontractors
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Project Organization
Source: The 'PIPING GUIDE'
http://www.pipingguide.com
Project
Design
Groups and
InformationFlow
(Source: The
'PIPING GUIDE')
http://www.pipingguide.com
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 acceptance
methods
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 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
Supplier/Vendor Relationship
Request the required information only
Disclosing only necessary information to
get the right data
Avoid:
Disclosing competition
Telling vendor hell get the order
Gratuities and never demand them (lunch)
Ordering to get information then cancel
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
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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 PlantDecommission
Plant
Maintain Plant
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/
Common Status Terms
As-built: Process plant's actual physical
and functional aspects at a specific point
in timeAs-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 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 operational
through specific
procedures
Confirm Staff
Skills
Verify productdata
Test equipment
Equipment
Commissioning
Procedures - Step-
by-step explanation
of start-up actions
required to
commission
equipmentin the
planthttp://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 the
plant
Preserving it 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
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
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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