process engg practices to be used in the refinery industry

7/27/2019 Process Engg Practices to be used in the refinery industry

1/86

FOSTER WHEELER USA CORPORATION PEP No.: 1000PROCESS ENGINEERING PRACTICE Page: 1 of 1

Revision: 8Date: May. 20, 2009

______________________________________________________________________

INDEX

PEP Total Issue or Latest RevisionNumber Title or Subject Pages Revision Date Number

PEP-1000 Index 1 May 20, 2009 8PEP-1001 Sample Process 1 Mar. 06, 2006 4

Engineering Practice (PEP)PEP-1002 Flow & Maintenance of 6 Feb. 24, 2009 5

Distributed MaterialPEP-1003 Process File Numbers 4 Apr. 15, 2009 5PEP-1004 Equipment List 2 Mar. 06, 2006 4PEP-1005 Process Flow Diagrams 5 Mar. 06, 2006 4PEP-1006 Engineering Flow Diagrams 3 Mar. 06, 2006 4PEP-1007 Engineering Flow Diagrams 6 Aug. 09, 2007 5

Piping DetailsPEP-1008 Utility Header Designations 1 Mar. 06, 2006 4PEP-1009 Instrumentation 3 Aug. 09, 2007 5PEP-1010 Vessels 3 Aug. 09, 2007 5PEP-1011 Fired Heaters 3 Mar. 06, 2006 4

PEP-1012 Hydraulics 8 Feb. 11, 2009 6PEP-1013 Exchangers 3 Mar. 06, 2006 4PEP-1014 Pumps and Compressors 4 Mar. 06, 2006 4PEP-1015 Work Plan Preparation and 15 Sep. 12, 2008 0

MaintenancePEP-1016 Process Chiefs Review 17 Feb. 11, 2009 0

All items posted to this Index have been reviewed for current applicability and werefound to be correct and complete.

APPROVED: _____________________________________Director - Process Engineering

DATE: ____May 20, 2009___________________

/var/www/apps/conversion/tmp/scratch_6/160328168.doc


2/86


Revision: 4Date: Mar. 6, 2006Date: Mar. 6, 2006

______________________________________________________________________

PEP - 1001

SAMPLE PROCESS ENGINEERING PRACTICE

This is an example of a Process Engineering Practice. Each of these PEP's will beaimed at a single subject of interest to Process Design engineers working on a project.Sometimes, where appropriate, a common grouping of subjects may be covered.

Comments and corrections, along with changes as time passes, will require revisions.Revision numbers with dates of issue will be indicated underneath the page number.The PEP Table of Contents page will normally show the date of the latest issue.

Specific exceptions may be taken from the PEP's when the rules listed are counter tostandard design practice for specific applications. The engineer should be prepared to

justify his exception.

These PEP's are general for all projects. Job specific PEP's will be issued with a jobspecific reference number where client requirements or other requirements dictate.



3/86

FOSTER WHEELER USA CORPORATION PEP No.: 1002PROCESS ENGINEERING PRACTICES Page: 1 of 6

Revision: 5Date: Feb 24, 2009

______________________________________________________________________

PEP - 1002

FLOW & MAINTENANCE OF DISTRIBUTED MATERIAL

A. FLOW

1. When required, job specific PEP's will be issued to all process engineersassigned to a contract, as well as the FW Project Engineering Managers.

2. Other correspondence of a general nature (i.e., pertaining to more thanone unit) shall be distributed to all concerned process engineers. It shallbe the Lead Process Engineer's responsibility to act on all applicable

material.

3. All process specifications, data sheets etc., to be issued within andoutside the department shall be reviewed by the appropriate ChiefProcess Engineer, or his assigned deputy, prior to transmittal. Atransmittal form (see attached sample) shall be prepared by the LeadProcess Engineer.

Departmental or project-specific policy will apply to letters issued tolicensors, catalyst vendors, etc.

All other Process Design correspondence for the project within FW will beover the signature of the Process Manager or the Lead Engineer asappropriate.

4. All correspondence to the Client shall follow the job specific coordinationprocedure. Unless otherwise indicated, correspondence shall be over thesignature of the Project Manager.

5. All process specifications and vessel sketches shall be prepared onstandard Foster Wheeler forms available in the Process Library or onequivalent computer generated forms. As required by the contract, client

specific forms may also be used.


5

5


4/86



______________________________________________________________________

PEP - 1002 (Cont'd)


B. MAINTENANCE

1. Desk Files

a. Lead Process Engineer

As instructed by the Chief Process Engineer, the Lead ProcessEngineer on each unit must keep some or all of the following books

in separate loose-leaf binders:

Originals Book:

Originals of issued process specifications (including Equipment Listuntil control is released to Project) and PREP data must bemaintained. The originals shall capture the approval signature orinitials of the Chief Process Engineer (or designee) in one of thefollowing two ways:

1. Hand written initials in the approval block of the process

specification, or2. Hand written signature or initials on the Process Transmittal

sheet. The initials of the Chief Process Engineer mustmatch the typed initials shown in the approval box on theprocess specification.

This book shall also note the location (Directory) for the electronicfiles stored on the network. See below regarding use of the originalas the Process Master.

Process Masters Process Specifications

A distributed copy of the as-issued process specification shallbecome a Process Master and shall have the words ProcessMaster stamped or written on the copy of the process specificationthat was issued.

If hard-copy distributions are not being made then a signed originalcopy may be used as the Process Master and retained to show thatthe issued document was approved.


5


5/86



______________________________________________________________________

B. MAINTENANCE

1. Desk Files

a. Lead Process Engineer (Cont'd)

Process comments noted on Process Masters shall be clearlymarked, dated, and initialed by the person making the comment.

All previous issues of the process specifications shall be retained ifdirected by the Chief Process Engineer. Any superseded Process

Masters shall be clearly indicated as such with a red line drawnthrough each page.

Process Masters Requisitions and Vendor Drawings

All issues of project requisitions including DIs (design instructions)issued for nozzle arrangements shall be kept as Process Masters.

Process comments on requisitions received shall be clearlymarked, dated, initialed by the reviewer and transmitted to Project.This transmitted copy shall become the new Process Master.

All superseded issues should be clearly indicated as such with ared line.

Process Masters Drawings

Process Masters of the following drawings shall also be maintainedby the Lead Process Engineer (assuming these drawings arerequired and created for the project):

Process Flow Diagram.

Engineering Flow Diagram.

Design Pressure/Temperature

Materials of Construction Diagram.

Plot Plan.


5


6/86


7/86

PEP - 1002 (Cont'd)


B. MAINTENANCE

2. Process Department File

a. Specifications (Contd)

Upon completion of the contract or customer acceptance of theunit, the Lead Process Engineer, Process Coordinator, and ChiefEngineer have the joint responsibility to assure that final issues ofall specifications, flowsheets, etc., from the Masters and OriginalsBooks, as well as the process calculations, are properly placed inthe Process File.

Appropriate vendor drawings may be filed at the discretion of theChief Engineer (e.g., tray drawings and/or ratings should usually befiled).

b. Correspondence

All correspondence shall be sent to the appropriate section of theProcess File.

c. Chief's Review Flow Diagrams

The originals of the Engineering Flow Diagrams marked up duringthe Chief's Review shall be forwarded to the "Flow Diagrams"section of the Process File. Each flow diagram must be dated andlabeled "Chief's Review". A list of those in attendance must also beindicated on at least the first flow diagram in the series.

5

5


8/86


Revision:5Date: Feb 24, 2009

________________________________________________________________________________

FOSTER WHEELER USA CORPORATIONCLINTON, NEW JERSEY

PROCESS DATA TRANSMITTAL DATE 1995

UNIT NAME: Unit DEF PROJECT: Projec t XYZ

UNIT NO.: XXX Customer ABC

CONTRACT NO.: XX-XXXX Location

DISTRIBUTION COPIES

MEMO ATT'S MATERIAL TRANSMITTED

Process File XX-XXXX 1 1

Process Manager 1 1 Process Flow Diagrams

Chief Process Eng. 1 1 Engineering Flow Diagrams

1 1 Equipment List

Lead Process Eng. 1 1+orig Vessels

Project Manager 1 1 Exchangers

Project Eng. Mngr. 1 1 Instruments

1 1 Compressors

1 1 Fired Heaters

Pumps

Item Revision No. of

Number Number Date Sheets

NOTES:

By

FOR PROJECT ENGINEER USE

FOSTER WHEELER USA CORPORATION

HOUSTON, TEXAS


9/86


Revision:5Date: Feb 24, 2009

________________________________________________________________________________


10/86

PEP - 1003PROCESS FILE NUMBERS

The following is a sample Process File Index. A job specific index is to be prepared by theChief Process Engineer or designee and issued for each project. Refer to EngineeringPractice EP 6-1.

PROJECT XYZ

SAMPLE PROCESS FILE NUMBERS

File Number XX-XXXXX-XX

1.0 PROPOSALS & CONTRACT MATTERS

1.1 Proposal1.2 Contract1.3 Contract Changes

2.0 CLIENT & LICENSOR CORRESPONDENCE

2.1 FW to Client2.2 Client to FW2.3 Standard Engineering Transmittal Letters to Client2.4 Standard Procurement Transmittal Letters to Client2.5 To Licensors and Vendors2.6 From Licensors and Vendors

3.0 NOTES OF MEETING

3.1 Project Notes (Meetings with Client)

3.2 Notes of Meeting (Internal and with Vendors)3.3 Action Item/Needs List

4.0 ESTIMATES, FINANCIAL & COMMERCIAL

4.1 Estimates

5.0 COORDINATION & PERSONNEL

5.1 Project Coordination Procedure (including Filing System Index)5.2 Coordination Memos

5.5Project Execution Plan


11/86

PEP-1003 (Contd)PROCESS FILE NUMBERS

6.0 SCHEDULES & REPORTS

6.1.4 Master Progress Schedule

6.1.5 Detailed Work Schedule6.1.6 Staffing Plan6.1.7 Progress Letter/Report (to Client)6.1.8 Weekly Progress Report (Process Work Plan)6.1.9 Variance Notice Program6.1.11 Labor Reports

7.0 PROCESS DATA

7.00 Utility Data/Utility Summary7.01 Design Basis Document

7.02 Heat and Material Balances7.03 Test Run/Operating Data Report7.05 Technical Specification/Process Package/Study Reports7.06 Process Calculations (Issued Outside FW Process)7.07 Computer Simulation Data (Issued Outside FW Process)7.09 Process Equipment List7.10 Client Design Data7.11 Tower and Tray Load Process Data Sheets7.12 Reactors and Internal Process Data Sheets7.13 Drum Process Data Sheets7.14 Tank Process Data Sheets

7.19 Other Vessel Process Data Sheets7.21 Shell and Tube Exchanger Process Data Sheets7.22 Double Pipe Exchanger Process Data Sheets7.23 Air Cooled Exchanger Process Data Sheets7.24 Fired Heater Process Data Sheets7.27 Vacuum Equipment Process Data Sheets7.31 Pump Process Data Sheets7.32 Compressor Process Data Sheets7.34 Material Handling Equipment Process Data Sheets7.50 Flow Diagrams (PFD/DPT/MOC/EFD)7.51 Process Line List

7.60 Instrument Process Data Sheets7.63 PSV Data Sheets/Flare Summary7.91 Package System Process Data Sheets


12/86


7.0 PROCESS DATA (Cont)

7.92 Utility Thermal Equipment

7.93 Water Treating7.94 Waste Treating7.95 PHA/HAZOP Reviews/Safety/Safeguarding7.96 Catalyst and Chemicals7.97 Miscellaneous7.98 Environmental

8.0 ENGINEERING CORRESPONDENCE

8.00 Basic Engineering Data8.01 Equipment Lists

8.2 Design Pressure / Temperature (By Project)8.3 Process Correspondence and Process Transmittals

Use Section 8 to also file Engineering data sheets, requisitions, vendor drawings,etc. Use same file suffixes as Section 7 (for example Engineering Data on pumpswould be filed under 8.31)

11.0 PROCESS CALCULATIONS

Use Section 11 to file process calculations. Use same file suffixes as Section 7 (forexample drum calculations would be filed under 11.13)

12.0 DESIGN INSTRUCTIONS (DIs)

12.10 Vessels12.20 Exchangers12.30 Machinery12.50 Piping/P&IDs12.60 Instruments

13.0 DRAWINGS

13.1 FWUSA Drawings (See also Section 7.50)13.2 Vendor Drawings (Typically file in Section 8)13.3 Client Drawings


13/86


16.0 PLANT OPERATIONS & START-UP

16.1 Operating Guidelines/Manual

16.2 Field Testing and Reports16.3 Start-up16.4 Personnel16.5 Blind List16.6 Systems Description and Scope16.7 Turnover Forms16.8 Hydrostatic Test Packages16.9 Work Package Description16.10 Punch List16.11 Certification/Handover Documents

17.0 QUALITY ASSURANCE

17.1 QA Activity and Audit Schedule17.2 QA Audit Reports17.3 Non-Conformance Reports17.4 Quality Notices17.5 Corrective Action Reports17.6 Preventive Action Reports17.7 QA Correspondence and Follow-up17.8 Quality System Documents (Project Procedures, Quality Plan)


14/86


Revision: 4Date: Mar. 6, 2006

______________________________________________________________________

PEP - 1004

EQUIPMENT LISTS

l. Equipment lists shall be set up in the following order of principal equipmentdesignations. For a full list of equipment letter designations and a furtherdiscussion of the rules refer to Engineering Practice EP 6-10. The standardprocess Equipment List is on the following page.

Vessels

Towers (T- )Reactors (R- )Drums (D- )

Tanks (TK- )

Heat Transfer Equipment

Heat Exchangers (E- )Furnaces (H- )

Mechanical Equipment

Pumps (P- )Compressors (C- )Miscellaneous (eg. DS, F, M, S, X)

in same order as code of accounts

2. Equipment numbering shall be as follows:

Equipment letter - Unit/Section number + suffix designation beginning with 1unless the customer designates otherwise. The first unit/section shall be 100.

EXAMPLE: First and second drums in Unit 100:

D-101D-102

3. All pump spares will be numbered as follows:

P-101A (Main)P-101B (Spare)


15/86



______________________________________________________________________________________________________________

FOSTER WHEELER USA CORPORATION CONTRACT: EQUIPMENT LIST NAME OF UNITClinton, NJ 08809 SECTION:

CLIENT: REVISION ORIG. 1 2

LOCATION: DATE

CLASS ITEM NO. DESCRIPTION EFD REQ'N. NO. P. O. NO.

Form No. 110-330 17 Feb 1999 NAME: STANDARD FORM (If Modified, rename form)


16/86



______________________________________________________________________

PEP - 1005

PROCESS FLOW DIAGRAMS

Process Flow Diagrams

1. Process Flow Diagrams (PFD's) shall be drawn according to normal FWEngineering practice on drawing size No. 2.

2. The title box shall be in accordance with the enclosed sample.

3. PFD's will not have material balance tables provided on drawings unless requiredfor the project. Material balances will be provided separately on diamond

sheets. A typical sample is attached.

4. Temperatures and pressures (normal operating) shall be provided at vessels andwhere deemed necessary on the drawings, in addition to the diamond sheets.Maximum and minimum data shall be included where important to equipmentdesign.

5. All major items of equipment must be shown on the PFD. Adjacent to each itemshown, the underlined item number must be provided. Underneath the itemnumber, the item name shall appear exactly as indicated on the equipment list.

6. Do not indicate spares for pumps, (e.g. show P-801, not P-801 A/B).

7. Provide normal process duty for exchangers in a "HEATER/EXCHANGERSUMMARY" for the operating case(s) shown on the PFD. For fired heaters,show process heat absorbed and other coil heat absorbed, where applicable.When all other coil heat duties are available, show total heat absorbed. Dutiesshould correspond to normal operating case shown on PFD.

8. Major control loops (automatic or otherwise) and other instrumentation necessaryfor the understanding of the PFD shall be shown. Do not show PI's or TI's. Donot indicate board or local control. Only show mode of control, e.g., FC even if in

reality instrument is FT-FIC-FR. Do not indicate electronic or pneumatic modefor instruments - use only dashed lines connecting instrument to valve operator.The dashed lines are not to be interpreted as electronic instrumentation. Usesolid lines connecting sensor to instrument and operator to valve.



17/86

LC

FI

FC

MTC



______________________________________________________________________

PEP - 1005 (Cont'd)


Flow orifices are not to be shown on the PFD. Examples of instrumentation areshown below.

9. Each PFD must contain an explanatory legend with the information shown below.Additional symbols and notes may be shown as necessary to clarify theflowsheet:



18/86



______________________________________________________________________

PEP - 1005 (Cont'd)


10. Provide battery limit temperatures and pressures for all process streams (in andout) and indicate destination of material, intermediate tankage. Name allstreams.

11. Each PFD must have the following statement.

THESE PROCESS DATA ARE FOR DESIGN PURPOSESONLY. WHILE USEFUL AS A GUIDE TO OPERATION, THEYDO NOT NECESSARILY REPRESENT EXACT OPERATINGCONDITIONS.



19/86



______________________________________________________________________

PEP - 1005 (Cont'd)


12. The initial issue of the PFD is to be Issue A with subsequent issues inalphabetical order. Each issue shall be designated as indicated below:

SAMPLE TITLE BOX

This Drawing is the Property of the


PERRYVILLE CORPORATE PARK, CLINTON, N.J.AND IS LENT WITHOUT CONSIDERATION OTHER THAN THE BORROWER'SAGREEMENT THAT IT SHALL NOT BE REPRODUCED, COPIED OR DISPOSED OFDIRECTLY OR INDIRECTLY, NOR USED FOR ANY PURPOSE OTHER THAN THATFOR WHICH IT IS SPECIFICALLY FURNISHED. THE APPARATUS SHOWN IN THEDRAWING IS COVERED BY PATENTS.

PROCESS FLOW DIAGRAMUNIT DEFUNIT 800PFD GHIPROJECT XYZCustomer ABC Location

EST. NO. DRAWN BY: 04-01-95 SH. X OF Y

REV. A April, 1995 Initial IssueInit. Contract No. XX-XXX Dwg. No. xxxx-x-xx-xx A



20/86


UNIT: UNIT DEF UNIT NO.: PG.NO.:

CUSTOM ER: CUSTOM ER ABC REF. DWG.: REV.:

LOCATION: CONTRACT NO.: DATE:

STREAM NO. 1 2 3 4 5 6

STREAM DESCRIPTION

OPERATING CASE

FLUID STATE

TEM PERATURE, F

PRESSURE, P SIG

TBP CUT RANGE, F

TOTAL BPSD

API

LIQUID, LB/HR

VAP OR, LB/HR

SOLID, LB/HR

TOTAL, LB/HR

LIQUID S.G. @ O.T.

LIQUID VISC. @ O.T., CKS

MW OF VAPOR

COMP ONENTS, LB M OLS/HR

SUBTOTAL (DRY)

H2O

TOTAL



_____________________________________________________________________


21/86



______________________________________________________________________

PEP - 1006

ENGINEERING FLOW DIAGRAMS

1. Engineering flow diagrams (EFD's) shall be drawn on drawing size No. 2, accordingto normal FW engineering practice. The title box shall be in accordance with theenclosed sample (page 3).

On each EFD, a column along the right side, directly above the title box, will be usedfor Notes and Holds.

A chart along the bottom of each EFD will be used to provide the required equipmentdata.

2. The following non-standard pipe sizes shall not be used: 3/8", 1-1/4", 2-1/2", 3-1/2",5" or 7", etc.

In the event that these sizes are required for equipment connections, they shall bechanged as soon as feasible to the connecting pipe size.

Minimum pipe sizes shall be 1" for both process and utility piping, except forconnections to equipment which vendors supply or for sample lines to and fromanalyzers.

3. Unless the process, client or vessel code dictates otherwise, relief valve nozzleconnections shall not be located on vessels but on overhead piping withoutappropriate justification.

4. Silencers for vents, when provided, shall be numbered and shall be included on theequipment list.

5. In general, air coolers are to be provided with louvers, where required forsupplemental (start-up and shutdown) freeze/pour point protection, with control of theair temperature by the forced-draft or induced draft fans. The process outlettemperature from each bay is to be monitored. In general, steam coils will be

provided for air coolers, when required for start-up and shutdown purposes.

6. Turbines shall be provided with full capacity relief valves mounted in the exhauststeam piping and relieving to atmosphere.



22/86



______________________________________________________________________

PEP - 1006 (Cont'd)


7. Insulation

Process piping and equipment operating at temperatures exceeding 150F (65 C)

shall, in general, be insulated for heat conservation unless heat loss is desired. Hot

surfaces, exceeding 150F (65C), not requiring insulation for heat conservation, shall

be insulated for the purpose of protecting personnel in areas adjacent to operatingareas, platforms, etc., or within reach from grade.

8. Relative elevations of vessels, loop seals, exchangers and thermosyphon circuits are

to be indicated on the EFD's. For vessels, show elevation above grade of bottomtangent line on vertical vessels, or bottom on horizontal drums.

9. The following must be shown in detail on the EFD's: number of passes for each coilfor fired heaters, number of shells or bays for exchanger services. These are to beestimated by the process or heat transfer engineers.

10.The initial issue of the EFD's is to be Issue A and designated as shown on theattached Sample Title Box. With the second issue of EFDs (Rev.B) the ProcessEngineer relinquishes control to the Project Department. Therefore, this issue will notbe made until specifically approved by the Chief Engineer.



23/86

PEP - 1006 (Cont'd)


SAMPLE TITLE BOX

THIS COLUMN RESERVED FOR NOTES AND HOLDS FROM THE TOP OF TITLE BOX TOTOP OF DRAWING

This Drawing is the Property of the

FOSTER WHEELER USA CORPORATIONPERRYVILLE CORPORATE PARK, CLINTON, N.J.AND IS LENT WITHOUT CONSIDERATION OTHER THAN THE BORROWER'S AGREEMENT THAT IT SHALL NOT BEREPRODUCED, COPIED OR DISPOSED OF DIRECTLY OR INDIRECTLY, NOR USED FOR ANY PURPOSE OTHER THAN

THAT FOR WHICH IT IS SPECIFICALLY FURNISHED. THE APPARATUS SHOWN IN THE DRAWING IS COVERED BYPATENTS.

ITEMS NOS.THIS

DRAWINGENGINEERING FLOW DIAGRAMSOUR WATER STRIPPING UNITUNIT 600SOUR WATER STRIPPERCUSTOMER ABC

Customer ABC Location

EST NO. DRAWN BY: 04-01-95 SH X OF Y

REV. A April, 1995 PROCESS ISSUEINITIALS Contract No. XX-XXXX DWG. NO. XXXX-2-50-01 A


24/86


Revision: 5Date: Aug. 9, 2007

______________________________________________________________________

PEP - 1007

ENGINEERING FLOW DIAGRAM PIPING DETAILS

Pump Piping

1. A pressure gauge shall be installed between centrifugal pumps and checkvalves, and a 3/4" valved bleed connection shall be provided between the checkvalve and block valve.

2. For all single stage pumps operating above 500F (260 C) and all multistage

pumps operating above 400F (204 C), a 1" warm-up line with globe valve shall

be installed. The warm-up line is to be routed around the check valve only.

3. The casing vents of LPG pumps will be hard-piped to the flare system usingdouble blocks and bleeds.

Compressor Piping

The following piping items shall be provided at each compressor or compressor cylinderfor purging, maintenance, etc.:

- connection to flare from discharge line for flammable gases

- connection to atmosphere from discharge or recycle line

- fittings inside block valves for connections to nitrogen system or cylinders forpurging

Nitrogen Piping

Typically temporary connections, rather than permanent connections, shall be providedfor all intermittent nitrogen requirements. Permanent connections will be provided onlyfor continuous nitrogen requirements. Swing elbows or spool pieces shall be provided,

but not flexible hoses.


25/86

~

5

~

Set @ xx psigPSV -

Size

CoolingWater

Return

3/4"

Vent

CoolingWaterSupply

To Grade at

Safe Location

3/4"

Drain



______________________________________________________________________

PEP - 1007 (Cont'd)


Exchanger Piping

The following detail shall be supplied for water cooled exchangers

Back flushing, chemical cleaning and 1" winterizing line requirements are at the client'soption and are not included in this detail.

Furnace Piping

1. In general, the steam-air decoking piping connections details shall be as shown.

Inlet and outlet piping for heaters which are to be steam air decoked should haveremovable spool pieces on the inlet and the outlet piping. Locate the heater inletPI downstream of the inlet line spool; locate an outlet coil TI upstream of the

outlet line spool.


26/86



______________________________________________________________________

PEP - 1007 (Cont'd)


Furnace Piping (Cont'd)

2. If manually operated globe valves are used to regulate the flow in multiple passfurnaces, such valves shall be located at ground level and each pass shall beprovided with an outlet temperature indicator visible from the valves.

3. The superheated steam piping design temperature from each heater superheatcoil shall be established after heater vendor data is available (by the detailedengineering contractor). A note should be placed on the EFD to indicate this.

4. In general, piping for furnaces equipped with superheat stripping steam coilsshould have:

- Start-up vent with silencer downstream of superheat coil

- Board-mounted TI on main header downstream of superheat coil butupstream of start-up vent

- A PSV sized in accordance with requirements of ASME Boiler CodeSection I, when the superheat coil can be blocked in. PSV should

discharge to atmosphere.

A note is to be included on the heater specification that the superheated steamcoil is to be designed for zero steam flow conditions during otherwise normal(fouled) operation.

5. A local PI should be on the inlet line to each process coil. Locate the PIdownstream of the heater inlet control valve (if any).

5


27/86



______________________________________________________________________

PEP - 1007 (Cont'd)


Vessel Piping(refers to towers and drums only)

1. The gas vent line from drums such as overhead receivers and the productseparators shall have a vent line to the flare.

2. All vessels must be provided with a high point vent, low point drain and steamoutconnection. Vents are to be on the top of the vessel. Drains are to be on thebottom piping. Separate steamout connections are not required for vessels

which already have stripping steam connections or clean water vessels andsteam drums or kettles.

Auxiliary nozzles for all vessels (including towers) are to be sized in accordancewith the Process Standard on drums.

Board mounted PDI's shall be provided on the main sections of the towers.

PI's should be located on piping or on level gages.

Control Valves

For line sizes 2" or less, blocks and by-passes shall be provided around control valves.In addition, blocks and by-passes shall be installed around any critical service controlvalve whose malfunction would cause unit shutdown mode or prevent continuousoperation of unit. Blocks and bypasses will also be provided for erosive services orservices with a pressure drop above 150 psi. For line sizes greater than 2", controlvalves in non-critical services shall be provided with a manually operated hand wheel

jack with valve opening indicator, without by-pass. Upstream control valve bleeds areto be shown on the EFD's. If the control valve size sets a PSV load, the bypass valveCV should be less than or equal to the control valve CV.

Relief Valves

1. Relief valves requiring periodic testing shall be provided with Car Seal Open(CSO) isolation valves and a 3/4" bleed valve. A bypass line with a normallyclosed (NC) valve and a 3/4" PI tap, for use when the valve is being tested, shallbe provided around the relief valve(s) and isolation valves.


28/86



______________________________________________________________________

PEP - 1007 (Cont'd)


Relief Valves (Cont'd)

2. Relief valve discharge lines to atmosphere shall be provided with " weep holes.The weep hole drain lines shall be piped to a "safe location".

Sample Connections

Where sample points are required, they are identified as below.

for sample connection without cooling.

for sample connection with cooling.

Battery Limit Connections

In general, draw B.L. connections as shown below. Battery limits may only be shown attop or bottom of the EFD.

B.L.

PI

B.L.

S

SC


29/86

PEP - 1007 (Cont'd)


LINES ON TWO EFDS

Extensions of lines to adjacent EFDs should be at equal drawing elevation indexnumbers (see the example below). This practice is preferable but not absolutelyrequired for the extension of lines to non-adjacent EFDs within the same unit.

All lines extended from one EFD to another must be labeled and designated by source(if entering) or destination (if leaving) as in the example below.


30/86

FOSTER WHEELER USA CORPORATION PEP No.: 1008PROCESS ENGINEERING PRACTICES Page: 1of 1


______________________________________________________________________

PEP - 1008

UTILITY HEADER DESIGNATIONS

Utility connections on EFDs will be shown by balloons. A set of balloons for thisproject will be included on one of the General Notes and Symbols EFD for each unit.

Under no circumstances should additional balloons be included by an engineer withoutapproval by the project manager.

The purpose of utility balloons is to enable geographic layout of utility flow diagrams(UFDs) for each unit. They are not to be used for injection facilities such as inhibitor,ammonia or similar connections.

EFD#

12

EFD#

01

55

54

53

52

51

50

55

54

53

52

51

50

STRIPPED WATER

FROM TK-1501

SOURWATER

TO D-1501

SOUR WATER

FROM P-1501

STRIPPER BOTTOMS

TO E-1501

EFD #03EFD #02


31/86


32/86



______________________________________________________________________

PEP - 1009 (Cont'd)

INSTRUMENTATION

9. Provisions for oxygen analyzers are required on all heater stacks. Continuousanalyzers are to be provided only where the information will require operators tomake process changes, and not for monitoring only.

10. Primary sensing instrumentation providing inputs to emergency shutdownsystems shall be separate from the process control loop instrumentation.Example: use a dedicated PSLL (Pressure Switch Low-Low) to provide a lowpressure trip input instead of using an alarm switch residing on the loopcontaining the control loop pressure transmitter. Exception: Flow trips may use

a common primary element (orifice plate, venturi, etc.) but separate taps arerequired.

11. Process Instrument Data Sheets

a. In general, do not specify PI's, TI's, LG's, except to indicate specialrequirements, e.g., nonreflex LG's, decoking temperature for heater outletTI's.

b. All alarm points must be specified. Level alarms should be specified aseither a percentage of the level range shown on the process vessel

sketch, e.g., LAH @ 80%, LAL @ 20% or alternatively as the actual LLLand HLL shown on the sketch given in feet and inches above a referencepoint such as BTL (Bottom Tangent Line).

c. Indicate service of instruments not their location.

d. Control valve failure to be indicated by FC, FO, FLO or FLC.FC (Fail Closed)FO (Fail Open)FLO (lock in position on air failure, but 'drifts' open)FLC (lock in position on air failure, but drifts closed)

e. Instrument sheets must be filled out in accordance with Process Standard501.


33/86

PEP - 1009 (Cont'd)

INSTRUMENTATION

12. Relief Valve Process Data Sheets

a. Specify process relief valves. Loads for thermal expansion are to bespecified with calculated loads and conditions.

b. Indicate destination of discharge and EFD number for each relief valve onthe FW relief valve standard form.

c. For PSVs discharging to atmosphere, list atmosphere for superimposedback pressure and less than 10% for built-up back pressure unless thedischarge system is special. For PSVs discharging to flare, list later forsuperimposed and built-up back pressure until the flare system has beenspecified.

13. Flare Load Summary Sheets

Provide the following information for relief valves:

For all PSV's discharging to the flare, loads must be supplied on the flare sheetsfor block, power failure, fire, instrument air failure and cooling water failure. If noload exists for any particular contingency, the word "none" should be listed in theload row.

14. The allowable accumulation to be used for a PSV load due to exposure to fireshall be "per code," 16% for a single relief valve, or 21% for multiple relief valves.

15. If the liquid filled cold side of a shell and tube exchanger requires protectionagainst thermal expansion and against exposure to fire, and if the thermalexpansion load requires a relatively small PSV, whereas the fire load requires arelatively large PSV, then two PSV's shall be provided:

Thermal Relief - Set Pressure = Design Pressure- Accumulated Pressure = 1.10 x Set Pressure

Open Fire - Set Pressure = 1.10 x Design Pressure-Accumulated Pressure = 1.10 x Set Pressure

16. For vacuum protection, the accumulated vacuum relief pressure is often inexcess of 10 or 21% (as typical for Pressure Relief Valves) and sometimes ashigh as 100%. It is important to note that the accumulated vacuum pressure maynot exceed the vacuum rating of the associated vessels.


34/86



______________________________________________________________________

PEP - 1010VESSELS

1. Pressure vessels with relief valves shall be designed for a minimum internalpressure of at least 10% or 25 psi (1.72 Bar); whichever is greater, above themaximum specified operating pressure in psig at the top. Minimum designpressure, at the top, is to be 50 psig (3.45 Barg). Minimum design metaltemperature is to be specified where required by Process (i.e. auto-refrigeration).

2. Vessels without pressure relieving devices shall be provided with an outlet whichcannot be completely blocked off. The minimum outlet opening shall be sized sothat the maximum pressure which can be developed in the vessel is not greaterthan the design pressure.

3. Vessels shall be designed for vacuum conditions as required. Vessels with

steam injection (for example, stripping steam) are typically designed for fullvacuum.

4. The minimum design temperature shall be the maximum operating temperatureplus 50F (28 C).

5. The title box shall be in accordance with the sample shown below. The initialissue of the process vessel specification drawing is to be Revision 0 withsubsequent issues in numerical order. Each issue shall be designated on thevessel sketch (see sample title box below).

REFERENCE DRAWINGS, REQUISITIONS,STANDARDS

DRAWN PEM 01APR95 CONTRACT NUMBERXX-XXXX

CHECKED

APPROVEDREQUISITION NUMBER

1 15APR96 PEM CLIENTCOMMENTS

SPLITTER T-101

UNIT XYZ

CUSTOMER ABC LOCATION

0 01APR96 PEM INITIAL ISSUEP. O. NUMBER

REV. DATE BY DESCRIPTION

REVISIONS DRAWING NUMBERSHEET 1 OF 2

REV.1


35/86



______________________________________________________________________

PEP - 1010 (Cont'd)

VESSELS

6. The following liquid surge capacities are to be used for this project. They aresummarized from the appropriate Foster Wheeler Standards.

Unless otherwise specified, surge capacity is defined as the capacity betweenhigh-liquid level (HLL) and low-liquid level (LLL).

Low - Liquid Level

a. Without Water Settling.- Horizontal Vessels 6" above Bottom- Vertical Vessels 8" above BTL

- Hard-Piped Low-Low Level Switch 1-5" above BTL (Note)on Vertical Vessels

(Note: Use of a level transmitter, if permitted by client standards, can allow theLow, Low Level set-point to be as low as 0-6 above BTL.)

b. With Water Settling.Provide five (5) minutes holdup at the total hydrocarbon rate below thelow-liquid level for the "settling out" of water. If a pot is not employed, five(5) minutes of holdup for the water itself must also be provided in the bottomof the vessel.

Surge Time in Drums

Service Surge Time, Minutes

Feed to Tower or FurnaceDrum Diameter, Ft.Below 4 204 - 6, Inclusive 15

Above 6 10

Reflux to Tower 5

Product to Storage 2

Total draw off pans on towers on Greater of:level or flow control - 2 minutes on products

- 1 minute on pumparoundto

section above- 5 minutes on wash to

sectionbelow

5


36/86



______________________________________________________________________

PEP - 1010 (Cont'd)

VESSELS

In case surge must be provided for both product and reflux, the larger volume isused (not the sum of the two volumes).

Surge Time in Towers

Service Surge Time, Minutes

Bottoms to Subsequent Tower

- on Level Control 5- on Flow Control 15

Bottoms to Heat Exchanger 2 (not applicable toand/or Tankage vacuum towers)

Feed to fired coil reboilers: sum of 5 minutes on vaporized portion and 2 minuteson product. It is normally desirable that 5 minutes on vaporized portion beemployed to establish NLL, the subsequent 2 minutes on product used toestablish the HLL (NLL to HLL, minimum of l ft.).


37/86



______________________________________________________________________

PEP - 1011

FIRED HEATERS

The following notes are generally applicable to fired heaters in conventional services.Some of these notes may not apply to special heaters such as coker heaters orreformers.

1. Fired heater process specification shall be on standard FW process data formsor equivalent computer generated forms. Additional sheets for data and notesmay be added as required for each service.

2. The process engineer should indicate the minimum design pressure, but the

design metal temperature must be left blank.

3. Burner type shall be specified for all heaters. In accordance with the BEDDsheets, burners specified for liquid fuels require pilot burners to be specified.Burner location shall not normally be specified by the process engineer.

4. Furnaces in services classified as "dirty" (or subject to coking) shall be providedwith facilities for steam and air decoking and designed to withstand the metaltemperature and thermal stress of steam air decoking.

5. The following notes should be included in the process specification for each

heater where applicable. Additional notes may be added as required, e.g.:

a. Vendor shall confirm that the superheated steam coil is capable ofwithstanding zero steam flow conditions during normal and fouledoperations.

b. Heater shall be designed for continuous operation and shall be capable ofoperating at turndown as required by Basis of Design.

c. Vendor shall provide information concerning their recommendations forthe proper design and operation of steam air decoking facilities.


38/86



______________________________________________________________________

PEP - 1011 (Cont'd)

FIRED HEATERS

d. Vendor shall provide the following with regard to soot blowers, (appliesonly for fuel oil/combination firing with a convection section.)

- Soot blowing lanes with end bearing and mounting flanges- Shrouds for refractory protection in the soot blower lanes.- Design drawings for soot blower platforms.- Convection coil design that will accommodate fuel oil firing without

rapid fouling.

8. Process data and cost of available fuels will be provided on the BasicEngineering Data sheets.

9. Given below are guidelines to be used in estimating utility line sizes and utilityrequirements for fired heaters (at least until vendor requirements are confirmed).

a. Purge Steam (fire box):

l) 100 to 200 lbs. steam per MMBtu (180 to 360 Kg steam perMMkcal) (liberated)

2) use M.P. steam (150 psig)

3) label header "purge steam" not "snuffing steam"

b. Coil Steamout:

l) use 5 lb/sec. ft2 (24.4 Kg/sec.-m2) for steam mass velocity throughcoil

2) use 2" diameter line for each coil

3) use M.P. steam or higher pressure if necessary (steam supplypressure should be higher than down stream pressure)

4) label header "coil steamout"


39/86



______________________________________________________________________

PEP - 1011 (Cont'd)

FIRED HEATERS

c) Atomizing Steam:

1) 0.5 lb steam per lb of oil consumed

2) use M.P. steam or a steam with at least 30 psi (2.1 Bar) higher thanfuel oil pressure.

3) size steam line for 1.0 lb steam per lb of oil consumed

d) Soot Blowers:

1) must be specified for each heater specified for oil or combinationfiring

2) design consumption is typically 10,000 lbs/hr (4,536 kg/hr)

3) use M.P. steam

10. The following items must be shown on engineering flow diagrams for each firedheater:

- Flue gas analyzer with board indication.

- Draft gage, connections only.

- Skin thermocouple on each pass with board indications.

- TI's for radiant zone, arch, convection section, stack and crossovers.

- Fuel gas flow with board indication.

- Stack damper, manual loading station on board.

- Automatic switch over to natural draft operation on failure of air blower.

11. Air blowers for fired heaters will not be spared.

Fired heaters will be specified for stable operation without the air blower and withautomatic switchover to natural draft. Vendors will be instructed to adviseturndown required for natural draft operation.


40/86


Revision: 6Date: Feb. 11, 2009

______________________________________________________________________

PEP - 1012

HYDRAULICS

1.0 LINE SIZING CRITERIA

Below are some general rules for line sizing. These rules should cover mostnormal situations, but may not be suitable for all cases, especially revamps. Forcritical services or long headers, the process engineer is to carry out a hydraulicstudy of the system to confirm the total pressure drops and the pressure balance,regardless of whether the lines meet the allowable pressure drop and velocitycriteria as given in this PEP.

The process engineer should also refer to Process Standard 201, Fluid FlowSingle Phase, and Standard 202, Fluid Flow Two Phase. In case of any conflictswith the process standards, this Process Engineering Practice shall govern.

1.1 Drawoff Nozzles

Reference the FW Process Standards 103, section 3.0. The minimum drawoffbox depth shall be one and one-half times the nominal drawoff size, but not lessthan 9 inches. In case of any conflicts with the Process Standard 103, thisProcess Engineering Practice shall govern.

1.2 Pump Suction Lines

Pipe Diameters 8" and less Pipe Diameters more than 8"

Approx.Velocity,

ft/sec

Allowable P,psi/100 ft

Approx. Velocity,ft/sec

Allowable P,psi/100 ft

NonboilingLiquid

3 to 5 1.0 to 1.5 12 max 1.0 to 1.5

BoilingLiquid

1 to 3 0.3 to 0.5 6 max 0.3 to 0.5

Note: Gas blanketed liquids are to be considered as boiling liquids for line sizing,pump calculations, specifications, etc.

6

6


41/86



______________________________________________________________________

PEP - 1012 (Cont'd)

HYDRAULICS

1.0 LINE SIZING CRITERIA (Contd)

1.3 Pump Discharge Lines

Allowable Pressure Drop

1.5 to 3 psi/100 feet

0.5 to 1.0 psi/100 feet maximum for long headers (800 equivalent feet andgreater)

Approximate Velocity

Pipe Diameter Approximate Velocity, ft/sec

4" and less 5 to 76" 10 max.8" and more 12 max.

1.4 Reboiler Lines

Reboiler Trap - out

Allowable Pressure Drop 0.15 to 0.3 psi/100 feetApproximate Velocity 3 to 5 feet/second

Reboiler Return

Allowable Pressure Drop 0.3 psi/100 feet(See rules for 2 phase below.)


42/86


43/86


44/86



______________________________________________________________________

PEP - 1012 (Cont'd)

HYDRAULICS


1.10 Sour Water Lines

Allowable VelocityMaximum Allowable

Pipe Material Fluid Velocity, ft/secCarbon Steel Sour Water/Hydrocarbon Mixture 20

Sour Water > 250F 5

Sour Water

250F 10

Stainless Steel Sour Water at all 20temperatures

Pressure drop per Section 1.1 through 1.4 above.

1.11 Amine Solution Lines

Allowable Velocity

Maximum Allowable

Pipe Material Fluid Velocity, ft/sec

Carbon Steel Lean Amine 20Rich Amine 3

Stainless Steelor Alloy 2205 Rich Amine 20

Carbon Steel is the preferred pipe material for amine services.Velocity limits assume fluid remaining as liquid.

Pressure drop per Section 1.1 through 1.4 above.


45/86



______________________________________________________________________

PEP - 1012 (Cont'd)

HYDRAULICS


1.12 PSV Lines

Line sizing shall generally be in accordance with API RP 520, Part I andPart II, and RP-521.

To reduce noise levels during an emergency "blow" to the flare, dischargeline and header velocities shall not exceed ft/sec,/100 Dg or 80% ofsonic velocity, whichever is lower.

Where:

a. sonic = 223 X MkT / where T= R, M= mol. wt.

OR

b. sonic = 68.1 X DgkP/

where k= Cp/Cv, P= psia, Dg= lbs/cu. ft.

Flare headers shall be free draining toward flare drum.

1.13 Condenser Bypass Lines, Balance Lines, and Vent Lines

Both the controlled bypass lines around the condenser and the vent linefrom the accumulator drum are sized for a minimum of 10% of the tower'sgross overhead flow. Refer also to Process Standard 507, Section 4.0 formore conservative sizing criteria.

Open balance lines in total condenser services should be sized for 25% ofthe tower gross overhead flow or shall be sized to pass any relief flows,whichever case controls.

1.14 Thermosyphon Reboiler Circuits

When calculating the skirt height of a tower having a thermosyphonreboiler, Foster Wheeler's normal practice of requiring a driving forceequal to three times the calculated pressure drop in the thermosyphoncircuit shall be employed. For very large units, if approved by theresponsible chief engineer, this driving force may be reduced from three totwo times the calculated pressure drop.

6


46/86


47/86



______________________________________________________________________

PEP - 1012 (Cont'd)

HYDRAULICS

2.0 CONTROL VALVE PRESSURE DROP ALLOWANCE

Unless otherwise dictated by process, control valve pressure drop shall becalculated on the following basis:

2.1 Pumping Services (Discharge side)

Generally, the pressure drop assigned to the control valve for the pump, atnormal operating capacity, shall be equal to either 10% of the systemoperating pressure in psig at pump destination, up to 1000 psig, or 33% of

the frictional loss in the system excluding the pressure drop assigned tothe control valve, whichever is greater. For systems where high frictionallosses are taken, i.e., crude preheat circuits, 10% of the estimated pumpdestination pressure should be adequate; but in no case shall theassigned control valve pressure drop for the pump design case be lessthan 10 psi. For systems operating above 1000 psig, the control valvemay take less than 10% of the system pressure, depending on processand control considerations.

Control valves (including actuators) should be specified as capable ofshutoff and opening with maximum upstream pressure and minimumdownstream pressure. On a pump discharge system, the maximumupstream pressure is the pump shutoff pressure at maximum pumpsuction pressure.

2.2 Other Liquid Services (Gravity flow, cascading from one pressure level toanother, etc.)

Pressure drop is a function of the system under consideration, but as ageneral rule, the pressure drop assigned to the control valve shall not beless than 10% and no greater than 85% of the pressure differentialavailable for frictional loss.

2.3 Gas Services

For compressor services, the engineer should be guided by the pumpcriteria listed above.

Generally, for other gas services, the pressure drop assigned to the gascontrol valve shall not be less than 10% and not greater than 85% of thepressure differential available for frictional loss.


48/86



______________________________________________________________________

PEP - 1013

EXCHANGERS

1. Air cooled exchangers typically are forced draft, usually with a minimum of twofans per bay.

Combined services within one bay are not desired.

2. If both the cold side inlet and outlet of an exchanger require block valves, a reliefvalve shall be provided on the cold side inlet to prevent excessive thermalexpansion. In no case, should this relief valve be set lower than the highestpump shut-off pressure to which it may be subjected, or higher than theexchanger design pressure.

3. The general order of priority to establish the tubeside fluid is listed below. Thislisting is for guidance only and should not be considered inflexible.

(i) Cooling water

(ii) A corrosive fluid or a fluid likely to deposit coke, sediment or other solidssuch as catalyst.

(iii) The higher fouling fluid.

(iv) The less viscous of the two fluids, where large differences exist.

(v) The fluid under higher pressure, where large differences exist.

(vi) The hotter fluid.

Condensing vapors are usually located on the shell side. Also, if the temperaturechange of a fluid in an exchanger is very large, for example, several hundreddegrees, it is often better to pass this fluid through the shell. Otherwise multiplebundles may be required to avoid excessive temperature stresses on thetubesheets.


49/86


50/86


51/86



______________________________________________________________________

PEP - 1014

PUMPS AND COMPRESSORS

1. Overcapacity Factors

The following overcapacity factors shall be used unless otherwise specified bythe chief engineer.

a. Pumps

Charge, product, transfer services 1.1

Reflux, pumparound, reboiler & other

critical services 1.2

b. Compressors

Centrifugal 1.2

2. Pump hydraulic calculations are to be issued together with the pumpspecifications, and are to be included in the Process Technical Specificationbook.

3. For pumps specified for bubble point fluids show "B.P." on the pump specificationsheet rather than the actual vapor pressure. Note that this also applies to fluids

containing dissolved/entrained gas.

4. Calculation of Pump Shutoff Pressure at Maximum Suction Pressure

Pump Maximum Suction Pressure

a. Taking suction from tankage open to the atmosphere.

MSP (Max. Suction Pressure) = static head measured from maximum tankliquid level (zero frictional line loss)

b. Taking suction from a pressure vessel.

MSP = Vessel minimum design pressure at top plus estimated frictionalloss through trays plus static head measured from highest liquid level(zero frictional line loss)


52/86



______________________________________________________________________

PEP - 1014 (Contd)


4. Calculation of Pump Shutoff Pressure at Maximum Suction Pressure (Contd)

Pump Shutoff Pressure for Centrifugal Pumps*

PSP (Pump Shutoff Pressure) = MSP plus 1.2 x (pump differential at maximumspecified specific gravity).

*Pump shutoff as calculated above is used to designate preliminary equipmentdesign pressure; but is to be confirmed by the Project Department on selection offinal pump curves.

5. Minimum flow requirements must be specified for each pump, to cover suchconditions as start-up, shutdown, turndown, regeneration, etc.

6. Pump calculations for NPSH and power consumption are to be made at thedesign flowrate.

7. Static head requirements for a discharge pressure calculation shall be based onactual operating temperature where the static head occurs (not necessarilypumping temperature).

8. The following note is to be affixed to the specification for all equipment having a

design pressure determined by pump shutoff.

DESIGN PRESSURE: Psig*

*But not less than the shutoff pressure of P- (or P- ifcommon spare) at maximum suction conditions.

9. Spare Capacity

a. 100% spare capacity shall be specified for all pumps in critical service.

b. Air blowers serving fired heaters will not be spared.

c. Single speed electric motors are preferred drivers for primary and sparepumps, as well as for compressors. Steam turbine drivers may beselected based on special process, utility or mechanical considerations.


53/86



______________________________________________________________________

PEP - 1014 (Contd)


10. Centrifugal compressors shall be specified when appropriate.

11. Drivers for air blowers shall be designed for cold air operation.


54/86


Revision: 0Date: Sep. 12, 2008

______________________________________________________________________

PEP - 1015

WORK PLAN PREPARATION AND MAINTENANCE

1 SCOPE

This work practice outlines the requirements for preparing and maintaining a ProcessDept Detailed Work Plan, including the Work Plan Summary Sheet (WPSS), covered inEP 8-1, for typical projects. Special considerations may require deviation from thiswork practice with the approval of the Director-Process Engineering.

2 GENERAL

2.1 This PEP is applicable to all projects ranging from Process Design Packages to fullEPCM projects, with the understanding that progress milestones and weightingvalues (percentages) will vary between the types of projects handled.

2.2 The Lead Process Engineer shall prepare the detailed work plan and correspondingWPSS used to track the progress of all equipment items, studies and/or workproducts assigned to the Process Department for the given project. The ChiefProcess Engineer may elect to assign another Process engineer to prepare andmaintain the work plan, however, it shall be the Lead Process Engineersresponsibility to ensure that the plans accuracy as well as the requirements of thisPEP and other practices referenced herein are followed in the preparation and

maintenance of the detailed work plan and WPSS.

2.3 The purpose of the work plan is to plan, execute and report progress by achievingspecific activity milestones for each tagged equipment or, study, activity and/or workproduct. Partial earned credit may be taken, as defined in paragraph 7.3, for thesemilestones. The work plan also reports hours earned as well as total percentcomplete per item or activity.

2.4 A template Workplan and WPSS, Form No. 210901, is located on the Processdepartment webpage of the Foster Wheeler Intranet in the Workplan Templatedirectory. The file is a single Excel Workbook that includes the WPSS and

Workplan. The Process Work Plan Template workbook contains the following tabs:

2.4.1 WPSS is the first tab and is clearly labeled WPSS ROLLUP (typical for alldepartment WPSS practices). The Department WPSS Form containscompany-wide Earned Value and Productivity Calculations that arepassword protected for consistency across the organization.

2.4.2 An overall summary is the second tab. The overall summary is auto-populated from the Progress report sheet (see paragraph 2.4.3).


55/86


56/86



______________________________________________________________________

Milestones progressable levels of completeness with weighting for each activity.PEP - 1015 (Contd)

Earned Value (EV%) is the percent of the hours or units earned for each JobClass. This is summed up to provide the total percent complete for all activities onthe project.

Productivity is a measure of the Earned Hours vs. Expended Hours.

2.6 The Lead Process Engineer or designee shall submit the completed work plan,including the WPSS, to the Chief Process Engineer for review and approval prior todistribution to the Project Manager or as directed by the Project Manager. The ChiefProcess Engineer shall signify approval of the work plan and WPSS by returning a

signed copy of the WPSS to the Lead Process Engineer.

3 INFORMATION REQUIRED FOR SETUP

3.1 The following list defines the information needed by the Lead Process Engineer inorder to prepare the work plan and WPSS.

3.1.1 Equipment List with item tag numbers and descriptions or preliminaryprocess flow diagram.

3.1.2 Project schedule with planned activity dates.

3.1.3 Approved Contract Budget Manhours for the Process Department includingbreakdowns by activity if available.

3.1.4 Scope of Work

3.1.5 Project Execution Plan

4 CREATION OF WORK PLAN

4.1 The work plan must be created by making a copy of the department work plan

template located on the Process Dept. Intranet web page, and saving to the projectfolder. DO NOT copy an existing work plan from another project. The electronic filename for the work plan shall follow the convention given in EP 8-1.

4.2 Modify the work plan by inserting the project item tag numbers, descriptions,activities and budget man hours with scheduled dates for completion. (Refer to

Attachment A and paragraphs 5.1 through 5.5 below)

4.3 Activity milestones not applicable due to the scope of the project may be zeroed outon the WPSS form. However, the milestone activities will still be listed.


57/86



______________________________________________________________________

PEP - 1015 (Contd)

4.4 Additional milestones, not contained within the template, shall not be added withoutprior consultation with the Chief Process Engineer(s) and Director-ProcessEngineering.

4.5 The weighting value associated with each milestone, as given in paragraph 6.2,shall not be modified without prior consultation with the Chief Process Engineerand/or Director-Process Engineering.

4.6 The work plan is divided into several tabs within the electronic file, as described inparagraph 2.4. Typically, one work plan is produced per project, regardless of how

many units are in that project. However, if the client and/or Project Manager requireseparate tracking for each unit, then individual work plans or separate Progressreport tabs linked to a single overall summary and WPSS ROLLUP tabs, may needto be created.

4.7 If the activity and/or milestones do not apply for a particular project, they will be leftblank on the WPSS ROLLUP tab. The activities are fixed and rows cannot beadded or deleted nor can activity names be changed.

4.8 After the set up process, all formulas shall be reviewed to insure that they arefunctioning properly. The template can be used to assist in correcting any cells that

may have been accidently modified during set up.

5 WORK PLAN SUMMARY SHEET SET-UP

5.1 The WPSS shall be set-up based on Job Class/Activity. Job Classes shall consistof the following activities listed below with their respective unit of measure.

JobClass

Activity Unit of Measure

1 Design Basis / Kick-off Meeting # of Documents

2 Yields # of Calculations

3 Simulation Modeling # of Simulations4 Heat and Material Balance # of Documents

5 Process Studies # of Simulations

6 Process Specifications # of Process DesignSpecifications (PDS)

7 Equipment List # of Documents

8 Process Description # of Documents

9 Utility Summary & EffluentEmissions

# of Documents


58/86



______________________________________________________________________

JobClass

Activity Unit of Measure

10 Instrument Process Data # of Process DesignSpecifications (PDS)


59/86



______________________________________________________________________

PEP - 1015 (Contd)

Job Class Activity Unit of Measure11 Interlocks # of Documents12 PSV (includes Flare Summary) # of Process Design

Specifications (PDS)13 Line Sizing # of Systems

14 Hydraulics # of Systems15 PFDs # of Drawings

16 EFDs # of Drawings

17 Materials of Construction (MOC) # of Drawings

18 Design Pressure & Temperature(DPDT)

# of Drawings

19 Process Writeups (PDP) # of Documents

20 Progress Reports / Coordination -21 Operating Guides (with list of

Analytical procedures)# of Documents

22 HAZOP # of Drawings

23 Review of Critical Documents # of Documents

24 Requisition Review # of Process DesignSpecifications (PDS)

25 Vendor Quotes # of Process DesignSpecifications (PDS)

26 Instrument Support # of Drawings

27 Project Support (P&I) # of Drawings

28 Model Review # of Systems

29 Follow up / Coordination # of Weeks

30 Hydraulic Checks (ISOs) # of Systems31 Variances (Approved) # of Variances

5.2 The Unit Count and Budget Hours associated for each Job Class shall bedetermined from the values located in the work plan. During the initial set up, thevalues for the Original Plan, Approved Contract Budget and Current Forecast shallall be the same.

5.3 The Activity Milestones and their Weighting for each Job Class shall be taken fromthe work plan without modification.

5.4 The primary document for forecasting and measuring progress is the Progressreport tab in the work plan workbook. The Progress report is customized to eachproject and will list each activity by drawing number, tag number, study, etc., asshown on the template in Form 210901 on the Process Department Intranet webpage. While certain fields in the Progress report worksheet are protected becausethere is a formula, the number of rows may be increased or decreased as required.


60/86


61/86



______________________________________________________________________

PEP - 1015 (Contd)

6.1.1 Basis of Design The Process department is responsible for preparing theBasis of Design for a project. The Basis of Design incorporates relevantdata from the following: Client requirements; Basic Engineering Data (BED)sheets; contractual requirements; Process Coordination Procedure; andProcess technology requirements.

6.1.2 Basic Heat & Material Balance In accordance with Process DepartmentProcedures, the Process Department is responsible for establishing thematerial balance flows to and from the unit as well as establishing allintermediate stream flows. The material balance then sets the associatedenergy balance. Stream flows are captured on Material Balance Sheets

(also known as Diamond Sheets). Each stream has a number that isreferenced on the Process Flow Diagram of the associated process unit.

6.1.3 Process Equipment List In accordance with Engineering Practices (EPs),the Process Department is responsible for establishing equipment numbersand equipment names for major equipment items and associated spareequipment. The Process Equipment List can be found in the Formsdirectory on the Process home page.

6.1.4 Process Flow Diagrams Process Flow Diagrams (PFDs) are created andmaintained by the Process in accordance with Process Department

Procedures and the Process Engineering Practices (PEPs), and show allequipment, stream numbers, temperatures and pressures that results fromthe design necessary to meet the requirements established in the Basis ofDesign.

6.1.5 Material Balance Summary Sheets This form is used to capture the unitmaterial balance. The Process Flow Diagram reference stream numberswith a diamond symbol. The Material Balance Summary Sheets (alsoknown as Diamond Sheets) list the appropriate stream data for eachreferenced stream. The Material Balance Summary Sheets can be foundin the Forms directory on the Process home page. These sheets are also

linked to the EZ Diamond program to easily populate diamond sheets froma ProII simulation.


62/86


63/86



______________________________________________________________________

PEP - 1015 (Contd)

6.1.10 Catalysts/Chemicals Summary In accordance with Process DepartmentProcedures, the Process Department is responsible for issuing andmaintaining the Catalyst and Chemical Summary throughout the project.The Catalyst and Chemical Summary is a listing of all catalysts andchemicals consumed or required to be present during the operation of theunit or system.

6.1.11 HAZOP Review A HAZOP (Hazardous Operations) review is coordinatedby the Project Department and supported by the Process Department inaccordance with the Engineering Practices. For this review, the ProcessDepartment typically assigns one Process Engineer and one Process

Operator to participate in the HAZOP review. Following the HAZOP reviewthe Process Department also supports the HAZOP resolution phase wherespecific items are addressed to rectify any issues captured during thereview.

6.1.12 Process Technical Specifications Also known as the Tech Spec, SpecBook or PDP Package, this write-up is a compilation of all Projectdeliverables set forth in the contract. The Process Technical Specificationoften includes deliverables developed and issued by other disciplines (suchas the Material of Construction Diagram, Plot Plan, Design Pressure/DesignTemperature Diagram, etc). This is often the final deliverable to the client.

6.1.13 Operating Manuals/Guidelines Operating Guidelines are a set of generaloperating criteria and/or instructions that pertain to a specific unit. Althoughthese guidelines cover all the major systems, they represent only a startingpoint for continued development of Operating Manuals.

An Operating Manual is a valve-by-valve/ line-by-line set of instructions thatgive specific instructions on commissioning, start-up, shutdown, emergencyshutdown and normal operations. Instrumentation set-points, alarm-pointsand trip points are also addressed. Operating Manuals are typicallydeveloped by the owners Operations Group.

6.1.14 Vendor Drawings Squad Check This is a review of vendor information,initiated, controlled and circulated by the Project Department to obtaincomments from all engineering disciplines and capture these commentsonto a single document. The vendor information is to be reviewed againstthe department master of the respective equipment, drawing or instrumentitem.


64/86



______________________________________________________________________

PEP - 1015 (Contd)

6.1.15 Hydraulic Checks In accordance with the PEPs and the ProcessStandards, hydraulic checks are the responsibility of the ProcessDepartment. As required, and depending on the contract deliverables andscope of the project, Process shall request all necessary supportinginformation (such as isometric drawings) to evaluate, confirm and finalizeline sizes, equipment elevations, relief valve set pressures, pipingconfigurations, thermosyphon hydraulics, gravity flow circuits, and othercritical circuits to ensure that the final design, construction and operation ofthe unit or system will achieve its objectives and the contract throughputrate.

6.1.16 Start Up & Commissioning Assistance As requested by the client, theProcess Department shall provide on-site commissioning and start-upassistance for a specific unit or system. A commissioning period is typically8 to 12 weeks in duration. During this time, all punch-lists are cleared, andoperating procedures are reviewed and finalized with the unit operators.Prior to start-up (oil in), the unit is flushed, cleaned and drained per theoperating procedures. At this point the unit is ready for start-up, wherefeedstock is introduced into the unit and the unit is operated as specifiedand designed to make the desired products.


65/86



______________________________________________________________________

PEP - 1015 (Contd)

6.2 The project scope will have a direct effect on the weighing factors applied to eachActivity Milestone. For example, PDPs will have fewer milestones with differentweightings than EPC projects. For full EPC projects, the following weighting factorsshall be used.

EPC Projects

Milestone 1 2 3 4 5 6

Design Basis / Kick-offMeeting

40% 40% 20%

Yields 50% 50%

Simulation Modeling 25% 50% 25%

Heat and Material Balance 25% 50% 25%Process Studies 35% 50% 15%

Process Specifications 25% 25% 35% 10% 5%

Equipment List 50% 50%

Process Description 50% 50%

Utility Summary & EffluentEmissions

50% 50%

Instrument Process Data 25% 25% 25% 15% 10%

Interlocks 25% 25% 25% 15% 10%

PSV (includes Flare Summary) 25% 25% 25% 25%

Line Sizing 30% 30% 30% 10%

Hydraulics 30% 30% 30% 10%

PFDs 25% 25% 25% 10% 10% 5%

EFDs 40% 20% 20% 10% 5% 5%

Materials of Construction(MOC)

50% 50%

Design Pressure &Temperature (DPDT)

50% 50%

Process Writeups (PDP) 33% 33% 34%

Progress Reports /Coordination

100%

Operating Guides (with list ofAnalytical procedures) 33% 33% 34%

HAZOP 100%

Review of Critical Documents 100%

Requisition Review 100%

Vendor Quotes 100%

Instrument Support 100%

Project Support (P&I) 100%

Model Review 100%


66/86


67/86



______________________________________________________________________

PEP - 1015 (Contd)

7.3 Since work plans are to be updated on a weekly basis, and considering the timedurations needed to complete some of the milestones, partial credit shall be claimedfor any milestone meeting the criteria set forth in Attachment A. All othermilestone activities are to be reported on an all or nothing basis.

7.3.1 Partial credit may be claimed for Heat and Material Balances based uponthe number of cases to be presented. For example, if 3 cases are to bepresented and only one has been completed, then 33% credit may beclaimed.

7.3.2 Partial credit may be claimed for Process Studies based upon the number

of studies. For example, if 3 studies are considered part of the scope of theproject and only one has been completed, then 33% credit may be claimed.

7.3.3 Partial credit may be claimed for Process Specifications based upon thenumber of equipment items. For example, if there are 50 pieces ofequipment and only ten have been completed, then 20% credit may beclaimed.

7.3.4 Partial credit may be claimed for Instrument Process Data based upon thenumber of instrument datasheets. For example, if there are 100 taggedinstrument items that require a datasheet, and only 25 have been

completed, then 25% credit may be claimed.

7.3.5 Partial credit may be claimed for PSVs based upon the number of PSVs.For example, if there are 10 relief valves and only 3 have been completed,then 33% credit may be claimed.

7.3.6 Partial credit may be claimed for PFDs based upon the number of drawings.For example, if there are 10 PFDs and only 2 have been completed, then20% credit may be claimed.

7.3.7 Partial credit may be claimed for EFDs based upon the number of drawings.

For example, if there are 50 EFDs and only ten have been completed, then20% credit may be claimed.

7.3.8 Partial credit may be claimed for MOC diagrams based upon the number ofdrawings. For example, if there are 10 MOC drawings and only 2 havebeen completed, then 20% credit may be claimed.

7.3.9 Partial credit may be claimed for DPDP diagrams based upon the numberof drawings. For example, if there are 10 drawings and only 2 have beencompleted, then 20% credit may be claimed.


68/86



______________________________________________________________________

PEP - 1015 (Contd)

7.3.10 Partial credit may be claimed for Review of Critical Documents based uponthe number of documents to be reviewed. For example, if there are 50critical documents and only ten have been completed, then 20% credit maybe claimed. Critical documents will be defined in the project kick-off.

7.3.11 Partial credit may be claimed for Requisition Review based upon thenumber of requisitions. For example, if there are 50 requisitions and onlyten have been completed, then 20% credit may be claimed.

7.3.12 Partial credit may be claimed for Vendor Quotes based upon the number ofdocuments to be reviewed. The total number of documents to be submitted

by the vendor shall be established at the time the equipment has beenawarded to the vendor and this number shall be the basis for determiningpartial credit.

8 UTILIZATION OF WORK PLAN AND WPSS

8.1 The work plan and WPSS are designed to function as the Process Disciplinesprimary progress reporting vehicle and is to be submitted to the designated ProjectControls Manager for the project(s) being reported on. The Chief Process Engineerand Director-Process Engineering shall be copied at every reporting period, asdefined in paragraph 7.1.

8.2 The work plan and WPSS will indicate Productivity and Earned Value (EV) onaccomplished work utilizing a quantity based tracking system. Manhours areearned when progress is recorded against each of the milestone activities.

8.3 Productivity values of 1.0 or less indicate efficient execution of the project.Productivity values exceeding 1.0 indicate too many manhours are being chargedfor the milestone activities reached. If this is the case, the root cause of the highproductivity value shall be determined and addressed in order to avoid exceedingthe budget for the project and maintain overall project schedules.

8.4 If the high productivity values result from an increased scope, or rework due toinfluences outside the Process or Project Management departments, variances shallbe written and submitted to the Project Manager as soon as the change to theoriginal or planned scope of work occurs.


69/86



______________________________________________________________________________________________________

ATTACHMENT A


70/86



_______________________________________________________________