01b.- Design Phases & Information

7/29/2019 01b.- Design Phases & Information

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Stoichiometry Piping and Instrument Diagram (PID)

Major Equipment Placement Plot Plan (Plant Layout)

Piping LayoutMajor Pipe Routing

Fabrication ISOsPipe Segment PFV Material

Piping Spool SheetsExtracted Pipe Segments

From Turton s et. al. P. 2

Economic Model Process Flow Diagram (PFD)

Plant Design Documents

and Information Flow

Copyright , 2008,

William G. Beazley, PhD

All Rights Reserved

Other Copyrights Apply as Noted

Accumulation of Value Delivered inCapital Projects

ProcessFlow Diag

& ROI

DesignConcept &

ROI

Discount orPremium to

AchieveExpected Valueto Customer Vi

ConceptualDesign

DetailDesign

Construction CommissioningClientCase

ROI withFabricator /

Suppier Bids

Plant Built

Production

ProductionBegins

Contributing Activities

Value Assessments

Premium to Operate (Service Contract)

Premium to Complete (Fixed Bid)

Discount to Purchase (Prudent Buyer)

Front-End Loading Process(The Business Roundtable)

Critical planning phases of the project

Named from commitment of time and resourcesat FEL to dictate future success of project

FEL 1 Business Planning - opportunity is explored

FEL 2 Facility Planning hones broad objectivesinto a particular project at a particular site with aparticular technology configuration and schedule.

FEL 3 Project Planning stage fills in detailsneeded so detailed engineering can execute the

project with little or no change.

http://www.ipainstitute.com/home/publications/pdf/ipa_business_stake.pdf

The IPA Institutes Gatekeeper seminar will arm gatekeepers with the

questions they need to ask to move a project forward or to kill it.

Gate 1

ExecutionPhase

Gate 3Gate 2

ProjectPlanning

FacilityPlanning

BusinessPlanning

Turnover

OperationsPhase

75% of theIdeas Do Not

Pass Gate 1

50% of theRemaining

Ideas DoNot Pass

Gate 2

Only 1% ofthe

RemainingIdeas Do Not

Pass Gate 3

Decision Gates

Idea

Initiation

Recycle

Back

Continue

Cancel/Shelve

Three-Phase Gated Approval System

(IPA Institute)

Engineering Design Phases Conceptual designs

Sketchy or minimal information

Abstract plot plan (equipment & piping layout)

Preliminary, or study phase Unchecked or uncertified data

Design a facility in sufficient detail so that: Confirm purchased equipment costs & delivery

Purchase Long Lead Time Bulk materials.

Detail phase All designs are finalized

Based on such checked data; Steel, concrete, hydraulics drawings,

Certified vendor drawings for equipment, valves, and instruments.

Layout designer impact in conceptual, study phases

Three Major Sources of Project Data

1. Project design data supplied by the clientor project engineering.

Process and process materials

Plant location and environmental features

2. Vendor data pertaining to equipment andspecialty bulk items.

3. Internally generated engineering data.


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The Flow of Information to Pipers

Plant DesignInformation Flow

Economics

Owner

Process

Owner

Controls

and

Stability

Owner

Materials

IntegrityOwner

BFD PFD

P&ID

Matl

SPEC

Equipment

Vendors

Equip Data

Piping

Layout

Owner

Piping

Layout

Feedback

FEED EPC

Structures,

Foundations,

etc.

FabISOs,

Spools, Etc.

Process Information Process description, including reactions,

separations, mixing stages and their stability Operating/Extreme pressures, temperatures Likelihood and consequences of excursions

and loss of control Process flow diagram (PFD) and stream data Required function and performance rate of

each equipment item Physical properties of process materials

Arterial inventories Corrosion data and materials of construction.

http://www.osti.gov/bridge/servlets/purl/788122-TeVDrj/native/788122.pdf

Block Flow Diagram forEarly Entrance Coproduction Plant

(US DoE)

http://www.valero.com/AboutUs/Refineries/TexasCitySchematic.htm

Claus Plant: H2S to Sulphur

http://en.wikipedia.org/w/index.php?title=Image%3AClausPlt.JPG


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Process Flow Diagram(US OSHA)

Block FlowDiagram

(ChevronProducts

Company)

http://www.aqmd.gov/ceqa/documents/2003/nonaqmd/chevron/chvFND.html

Process Flow Diagram Shows Material Flows and Properties

Anchor Point Temperatures and Pressures

Material Balances As Best Known

Shows Equipment that Changes State:

Major Pressure Vessels (Reactors, Columns,Drums)

Major Pumps and Compressors

Column Reboilers and Condensers

Reactors, Furnaces, Heat Exchangers Valves If a Significant Pressure Drop

Typical Project PFD (KBR)

Sample ProcessFlow Diagram

(Source: Bausbacherand Hunt)

Data Normally Included on a Process Flowsheet

Process lines, but including only those bypasses essential to anunderstanding of the process

All process equipment. Spares are indicated by letter symbolsor notes

Major instrumentation essential to process control and to

understanding fIowsheet

Valves essential to an understanding of the flowsheet

Design basis, including stream factor

Temperatures, pressures, flow quantities

Weight and/or mol balance, showing compositions, amounts,and other properties of the principal streams

Utilities requirements summary

Equipment Data


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Operators Viewing Process Details(Chevron Phillips Chemical Company)

http://www.cpchem.com/enu/image_bank.asp

Information Developed from PFD

Piping and Instrumentation

Diagram (P&ID)

Equipment List (then EquipmentData)

Process Material Hazards

Material Specification

P&ID asSchematicfor Layout

P&ID Example(Source: DoE)

Piping and Instrumentation Diagrams

Schematic (connectivity only)

Shows Items Needed to Control ProcessConditions:

All process, utility, and auxiliary equipment

Connecting piping,

Valving,

Specialty items,

Instrumentation and

Insulation, and heat tracing requirements.

Equipment List

Itemized accounting list by class ofall equipment to be used on project

Gives the equipment item numbers

and descriptions

Generally furnished by the client orproject engineering


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PIP P&ID Equipment ClassesCLASS SUBJECT DESCRIPTION

A Mixing Equipment Agitators, Aerators, Mechanical Mixers

B Blowers Centrifugal Blowers, Positive DisplacementBlowers, Fans

C Compressors Centrifugal, Reciprocating, Screw, Vacuum

D Mechanical Drivers Electric and Pneumatic Motors, DieselEngines, Steam and Gas Turbines

E Heat Exchangers Unfired Heat Exchangers, Condensers,Coolers, Reboilers, Vaporizers and HeatingCoils, Double Pipe, Spiral, Plate & Frame, AirCoolers

F Furnaces Fired Heaters, Furnaces, Boilers, Kilns

P Pumps Horizontal and Vertical Centrifugal, PositiveDisplacement, Vertical Canned, Screw, Gear,Sump

R Reactors

T Towers / Columns

TK Tanks API atmospheric and low pressure

U Misc Equipment Filters, Bins, Silos

V Drums Separators, Driers, Ac cumulators

P&ID Data Included for Particular Equipment(James R. Couper)

Compressors SCFM (60F. 14.7 psia, P psi; HHP; number of stages;details of stages if important

Drives type; connected HP; utilities such as kW. lb steam/ hr, or Btu/hr

Drums and tanks- ID or OD. seam to seam length, important internals

Exchangers: Sqft, KBtU/hr, temperatures, and flow quantities in and out,shell side and tube side indicated

Furnaces: KBtU/hr, temperatures in and out, fuel

Pumps: 6PM (60Ft, P psi, HHP, type, drive

Towers Number and type of plates or height arid type of packingidentification of all plates at which streams enter or leave: ID or OD seamto seam length; skirt height

Other equipment: Sufficient data for identification of duty and size

Sample Equipment List(Source: Bausbacher and

Hunt)

Process Materials & Hazards

Hazardous properties, eg Lower Flammability Limit (LFL)

Upper Flammability Limit (UFL)

Immediately Dangerous to Life or HealthConcentrations (IDLH)

Long Term Exposure Limit (LTEL)

Electrical classification practices

Site climatic conditions & impacts

Environmental effects and permitteddischarge & release levels

Pipe Specs

Maximum Hydrostatic Test Pressure:

e.g. 450 psig

Allowed Service Types:

SW Seawater - Raw SH Sodium Hypochlorite

FL Flare

WP Water - Potable

Specified Pipe, Valves, Fittings (PVF)

Specified Flanges, Blinds, etc.

Changing Pipe Pressures in Oil Production(Source: API RP 14E)

As Oil, Gas Moves Down Stream, Pressure, Temperature Changes Changing Pressure, Temperature Requirements Reflected in Pipe Spec

2500 PSIG (Well Head Press)2500 PSIG (Well

Head Press) 1420 PSIG 500 PSIG 125 PSIG


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Pipe Spec Can Change WhenProcess Conditions Change

A FEED Process Document Schedule(Puneet Sharma, Iris LLC)

http://www.irisllc.com/

Typical Deliverables(Puneet Sharma, Iris LLC)

Conceptual Design Estimate

Deterministic @ 30-40%

Risk-Based for Base Case

Facilities (Process)

Heat & Material Balance

Process Flow Sketch

Flowlines & Pipelines

Route Definition

Structural

Design Concept

Front-End Design Class A Package

Completed Pipeline Surveys

Deck Layout with CG

Facility Weights,Lift Plan &Structural Design

Long-Lead Item POs

Process Hazard Analysis

Preliminary P&Ids

Estimate @ 15-20%

Detail Design Equipment & E&I Pos

HAZOP

P&IDs, UFDs

Loop Diagrams, Piping ISOshttp://www.irisllc.com/

Stoichiometry Piping and Instrument Diagram (PID)

Major Equipment Placement Plot Plan (Plant Layout)

Piping LayoutMajor Pipe Routing

Fabrication ISOsPipe Segment PFV Material

Piping Spool SheetsExtracted Pipe SegmentsFrom Turton s et. al. P. 2

Piping Design Documents

Economic Model Process Flow Diagram (PFD)

DESIGN DOCUMENTATIONTYPICAL PER $100MM

FLOWSHEETS /PIDs 100 - 150

PIPING ISOs 2500 - 3000

INSTRUMENT LOOPS 2000 - 3000

VESSEL/EQUIP DWGS 100

ROTATING EQUIP SPECS 150 - 200

Richard B. Pettigrew, Rohm & Haas Co, at EAC Systems 96Richard B. Pettigrew, Rohm & Haas Co, at EAC Systems 96

Piping and

Instrument

Diagram

(PID)

Plot Plan

(Plant

Layout)

Piping Layout

From Turton s et. al. P. 2

Piping Layout Information Flow

Piping

Spec

Equipment,

Item Data

Sheets


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Plant Layout Design

Conceptual and preliminary development

of process unit plot plans Routing of major above and below grade

piping

Layout of equipment and its associatedinfrastructure

Good Layout Design and Engineering

Affects plant cost and economy

Can shorten constructionschedules

Affects operations andmaintenance efficiency

Plot Plan Information

Pipe Racks

Layout of the Equipment in the PFD

Layout of Major Equipment

Tankage

Other areas shown as blocks

Access via roads, rail, waterway

Plant perimeter

Sample Proposal Plot Plan(Source: Bausbacher and Hunt)

ApproxLayout &Grouping

Major interfacesand flows

OverallDimensions

Sample Planning Plot Plan(Source: Bausbacher and Hunt)

DefinedAreas

TaggedEquipment

Critical

Dimensions

Sample Construction Plot Plan(Source: Bausbacher and Hunt)

FinalDimensions

FoundationLocations


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Plant Layout Plan(Axis Point Design) http://www.axispointdesign.com/

Pipe LayoutPlan

(Axis Point Design) http://www.axispointdesign.com/

Pipe Layout

Elevation(Axis Point Design) http://www.axispointdesign.com/

Pipe Fab ISO

& BOM(Axis Point Design)

http://www.axispointdesign.com/

Typical Fabrication ISO Single Line Isometric Spool Drawing


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Spool Bill of Materials

BusinessOpportunity

SelectProcess Route

ProcessDesign

Evaluate:-Safety

Environment

Operabil i ty

Evaluate Costs:-Capital

Operating

PlantLayout

Layout Interactions with Business

Case and Design Baseline

Good Practice guidance from:

Layout standards

Published or company experienceand guidance.

Prior work