01b.- design phases & information
TRANSCRIPT
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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