Oil & gas engineering training suite

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Oil & Gas Engineering Training Suite

Welcome to this Training suite.

It shows the activities and deliverables of the different Engineering discipline.

Comments are most welcome: [email protected]

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Project Control

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Project Control

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Engineering disciplines: activities and deliverables

PROCESS

PLANT LAYOUT

EQUIPMENT/MECHANICAL

SAFETY & ENVIRONMENT

CIVIL

PIPING

PIPELINE

INSTRUMENTATION & CONTROL

ELECTRICAL

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PROCESS Design basis and criteria Process Flow Scheme, PFD, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual

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

Process Design Basis

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

Sizing cases: max capacity /turndown

Other operating cases

Feedstock composition and condition

Product specifications

Battery limit conditions

Process Design Basis

PrsentateurCommentaires de prsentationTurndown would be representative of end-of-life conditions for an Upstream facility for instance (low flow rate due to depleted reservoir and low pressure)

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Process design basis Compressor Station

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PROCESS Design basis and criteria Process simulations, Process Flow Diagram, HMB Process description Process Operating and Control Philosophy Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual

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Choice of Process Scheme

What are the bases of process scheme definition?

PrsentateurCommentaires de prsentationFeedstock composition, Products specifications, environment constraintsCriteria: ability to handle change in feedstockAvailable utilities

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Overall Plant Process Design

What is the name of this drawing?

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The Block Flow Diagram (BFD)

Results from the high level functional requirements of the plant Depicts the various Processes carried out within the facility and their sequence Shows the inputs (feed) and outputs (products) The item of the BFD is the Process Unit

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Unit Process Design

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The Process Flow Diagram (PFD)

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Unit Process Scheme Optimization

HP Separator 500 psig

5500 psig

Emul. Treater 50 psig 150 F

3000 psig

200 psig

Degasser 5 psig

5 psig

50 psig

1200 psig Gas Injection

Oil Production

From Wells 165 - 205 F

500 psig

HP Compression & TEG

LP Compression

TEG

Cooler

IP Compression

What are the elements taken into account in the definition/optimization of the process scheme?

PrsentateurCommentaires de prsentationReduction of equipment countAvailable equioment capacity - Technological limit (equipment size)Flexibility (turndown)Availability, e.g., 2 trainsAbility to handle upsets, e.g., pollutants in feedstockDesign basis, e.g., cooling mediumCAPEXUtility consumption = OPEX

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Process simulations

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Process simulations

Input

- Feed composition and conditions

Simulator settings

- Flow scheme - Thermodynamic model - Equipment performance

Output

- Stream flows and composition

- Equipment duty

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Process simulations

Input


Simulator settings


Output


- Equipment duty

PrsentateurCommentaires de prsentationThe equipment performance (outlet pressure, efficiency) is specifiedFor a heat exchanger: the outlet temperature is specified

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Process simulations

Input


Simulator settings


Output


- Equipment duty

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Results from process simulations

Depicts the various Equipment within a Process (or Utility) Unit and their sequence

Shows the process controls

The individual drawing item of the PFD is the Equipment Item

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Scheme including the following information, as a minimum:

Main equipment (all the itemized ones),

Process lines between equipment,

All control loops and main instruments,

For each stream, indication of: Temperature Pressure Composition Specific gravity Operating density Heat content Flow rate (relevant to each phase)

Design conditions of main equipment.

It shall be drawn-up according to ISA 6.12 regulation as far as symbology is concerning

Heat & Mass Balance (HMB)

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Heat & Material Balance

PrsentateurCommentaires de prsentationThe Heat & Mass Balance is issued for various operating cases, representative of the entire operating conditions envelope

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Process Description

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Equipment sizing

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35

Cass study: Equipment Sizing

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36

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Case study: Equipment Sizing Production separator

Sets the gas cross section

Sets the liquid volume

Vessel size

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Process data sheet Drums

PrsentateurCommentaires de prsentationThe Process Data Sheet specifies the duty. It is completed by a Mechanical data sheet which specifies all other requirements, including materials, design and fabrication code etc. to ensure long life and reliable service.

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Process data sheet

Contents of the Process Data Sheet: Design conditions Overdesign Fluid properties Equipment duty Skeleton drawing & dimensions Material (generic type) and corrosion allowance Specification of internals: demister, distributor, baffle etc. Nozzles list Allowable pressure drop, fouling factor, Cp, Cv, enthalpy curve (for HX, heaters) Available NPSH (for pumps)

PrsentateurCommentaires de prsentationWhat is fouling factor?

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Process Data sheet Column

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Columns and Drums

Column internals must be specified.

These pictures are excerpts from Sulzer douments

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Process Data sheet Column

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Process Data sheet Rotating equipment

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Process Data sheet Heat Exchangers / Shell & Tubes

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Heat Exchanger thermal sizing TEMA Data Sheet

A Thermal data sheet is received from Process for shell & tubes heat exchangers following thermal sizing

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Process Data sheet Heat Exchangers / Other types

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Process Data sheet Air Cooled HX

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Process Data Sheet Fired heaters

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Process Data Sheet Fired heaters

What is particularly important while specifying a heater ?

PrsentateurCommentaires de prsentationOf particular importance is the turn-down, for the burner.

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Process Data Sheet Storage tank

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Process Sizing

Process Equipment Sizing is done on the basis of:

Sizing cases

Over design

Design criteria

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Process Sizing


Sizing cases all operating cases

Over design

Design criteria

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Process Sizing


Sizing cases all operating cases

Over design 10% as a rule

Design criteria

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Process Sizing


Sizing cases all operating case


Sizing criteria On which basis are the following equipment sized?

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Process Sizing

Process Sizing is done on the basis of:



Sizing criteria Separator KO drum Distillation/Absorption column Reactor Storage tank

PrsentateurCommentaires de prsentationSeparator Size of droplet => velocity // residence time + SurgeKO Drum Size of droplet => velocity // Hold up timeDistillation/Absorption column Diameter based on flow. Number of trays/height of packing based on purity requiredReactor Contact time (space velocity)Tank Storage capacity

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Process Sizing




Sizing criteria Separator Size of droplet => velocity, residence time + Surge KO Drum Hold up time Distillation/Absorption column Diameter based on flow. Number

of trays/height of packing based on purity required Reactor Contact time (also called space velocity) Tank Storage capacity

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Process specification Package

What document is issued by Process for packages?

PrsentateurCommentaires de prsentationA duty specification

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What type of guarantees are requested?

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Process Equipment list

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Piping & Instrumentation Diagram (P&ID)

Compare the information shown on the PFD and the P&ID

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What are the purposes of P&IDs?

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At design stage: Defines the design basis for Piping & Instrumentation disciplines Serves to show and agree the operating and maintenance features between

Engineer and Owner or between Engineer and Vendor Serves to show the interface with equipment/package vendors Perform HAZOP review

During operation: Reference drawing for operator, work permit, plant modifications etc.

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P&ID review

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P&ID review

Which are the usual points reviewed during a P&ID review?

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Piping & Instrumentation Diagram (P&ID) P&ID review

Ease of operation and maintenance:

Isolation /bypass of equipment

Isolation/bypass of valves

Vents/drains

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Vents/drains

What do you call each type of isolation?

PrsentateurCommentaires de prsentationSingle vs Double block and bleed

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Vents/drains

Where do you use double block and bleed?

PrsentateurCommentaires de prsentationThere is not general rule.In general above a certain pressure and for toxic fluids.It must be defined in the typical P&IDs.

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Isolation philosophy

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Vents/drains

PrsentateurCommentaires de prsentationHow would you call this type of drainage arrangement? Open drain

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Piping & Instrumentation Diagrams (P&IDs)

Important features Normal operation Redundancy for critical instruments / safety switches Shutdown Check valves Start-up Pressurization warm-up / purge lines Maintenance Equipment isolation & bypass: valves, spectacle/blind Nitrogen injection, vent Drains Control and ON/OFF valves isolation Instrument isolation

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It includes:

1. All itemized equipment,

2. Item number and service description of each equipment with relevant design condition

3. All lines (process , utilities, start-up, maintenance), with indication of Diameter Rating Material Service Line number Piping class Piping class break / change External finishing (such as insulation, personal protection, tracing)

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4. Battery limits between Parties, e.g. contractor and vendor

5. All valves for operation, start-up, maintenance with indication of valve type, including isolation valves, check valves etc.

6. All instruments with detailed control loops: All instruments shall be tagged as per united numbering system, Local instruments or instruments on local panel, Sequences and interlocks (with brief description e.g.: comp. start / stop,

permissive to start, etc.),

7. Control valves, ON/OFF valves,

8. Safety valves (with set point and inlet/outlet size),

9. Electrical controls, such as pump local or remote start/stop, emergency shutdown

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9. Particular data or notes relevant to equipment/instruments installation, such as: Max or mini length of piping (requirement regarding suction / discharge

piping straight length, etc.), Slope of piping Elevation of equipment Pertinent interior arrangement of equipment Safe location requirement Control and monitoring signals for rotating equipment and electrical

motors,

10. Item number and service description of each equipment with relevant design condition

11. Connecting flags for pipe lines running from one drawing to another

Instruments and controls must be drawn-up according to ISA 6.12 requirements.

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Various types of P&IDs Legend and Symbols Identification & Numbering Details and Typicals Process or Utility P&ID Distribution P&ID Interconnection P&ID Pumps auxiliary P&ID Package P&ID

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P&IDs legend & symbols

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Identification and numbering system

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P&ID representation

Details

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What are the different typicals that should be defined?

PrsentateurCommentaires de prsentationSample collectionDrainsIsolation (blinding) of equipmentDouble/single block isolationIsolation and instrumentation at battery limitPSV

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Piping & Instrumentation Diagram (P&ID) - Typicals

How would you call each of these two types of arrangement? For what service(s) would each be used?

PrsentateurCommentaires de prsentationOpen Drain / Open + Closed drainNon hazardous mainly for water / Flammable, e.g. hydrocarbon, or toxic fluids

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P&ID work sequence

P&IDs are typically issued 3 times, as design progresses

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P&ID work sequence

IFR IFD IFC


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P&ID work sequence

IFR IFD IFC

P&ID Review


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P&ID work sequence

IFR IFD IFC

P&ID Review HAZOP


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Quiz Which revision of P&IDs has the following purpose/contents?

Purpose IFR IFD IFC Collect Client comments Perform PID review Perform HAZOP Perform Piping MTO for 1st Piping purchase Freeze Control system I/O list Issue Piping ISOs Contents IFR IFD IFC Comments from all disciplines

Comments from Piping, I&C disciplines

Finalized interfaces with eqt/package

Exercised Contract Option(s)

Size, number of PSVs and CVs Diameter of process lines Diameter of utility lines HAZOP comments incorporated Client comments incorporated

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Quiz Which revision of P&IDs has the following purpose/contents?

Purpose IFR IFD IFC Collect Client comments X Perform PID review X Perform HAZOP X Perform Piping MTO for 1st Piping purchase X Freeze Control system I/O list X Issue Piping ISOs X Contents IFR IFD IFC Comments from all disciplines X

Comments from Piping, I&C disciplines X

Finalized interfaces with eqt/package X

Exercised Contract Option(s) X

Size, number of PSVs and CVs X Diameter of process lines X Diameter of utility lines X HAZOP comments incorporated X Client comments incorporated X

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P&ID work sequence

IFR IFC

P&ID Review


IFD

HAZOP

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P&ID work sequence The different revisions

The prime purpose of the first issue (IFR: Issued for Review) is to obtain COMPANYs comments/APPROVAL this APPROVAL is necessary before progressing the design further to avoid re-work

The IFD revision, which incorporates COMPANY comments, aims at transferring information from Process to other disciplines:

to Piping, to perform routing studies to Piping materials, to perform 1st MTO for purchase To Instrumentation, to perform Instrument list To Civil for routing of Undeground Piping

IFC incorporates HAZOP impacts and information from Vendors. It is a pre-requisite to:

Start production of Piping isometrics

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P&ID work sequence

IFR IFD IFC Piping routing Piping 2nd MTO & 1st material purchases Instrumenation & Control design Undeground piping (civil)

Piping Isometric drawings

Piping material top-ups

P&ID Review HAZOP

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P&ID work sequence

IFR IFD

P&ID Review HAZOP

Sometimes an IFH revision, mark-ups of the P&ID review, is used to anticipate the HAZOP

IFC

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P&ID Review

P&ID work sequence

IFR IFD IFC

An IFD2 revision is issued in case major change from Vendors/HAZOP to up-date piping material purchases, instrumentation design etc.

Piping routing Piping 1st material purchases Instrumenation & Control design Undeground piping (civil)

Piping Isos Piping material

top-up

IFD2

HAZOP

Up-date

Start

PrsentateurCommentaires de prsentationNotes related to the IFD revision:

The IFD Revision is necessary for discipline co-ordination, which cannot wait until everything is finalized (IFC)

An additional revision (IFD2) may be issued to:Improve Piping MTOStart partial Isometric productionUp-date information for instrumentation, in particular for ordering the ESD system

In particular, when major changes to IFD P&IDs resulted from HAZOP, vendors etc.

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Fluids list

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Line list

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Line sizing

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Instrument process data sheet

PrsentateurCommentaires de prsentationContents:type of instrument,flowrate,operating pressure and temperature,maximum available differential pressure,physical properties of handled product (including critical P and T, and vapor pressure),material of construction,action of control valves in case of air failure,layout of graphic,tightness requirement,special requirements (fire test, emergency air bottle, etc.)

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What is the most important process data for control valves?

PrsentateurCommentaires de prsentationMaximum flow rate: 110% of max. operating flow rateMinimum flow rate: 30% of minimum operating flow rate,in order to guarantee correct functioning at the extremes of the operating range.

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Operating range, typ. Maximum flow rate: 110 % of max. operating flow rate Minimum flow rate: 30 % of minimum operating flow

rate, in order to guarantee correct functioning at the extremes of the operating range.

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Process Shut Down

Look at the extracts of these 2 P&IDs. How is the protection against loss of liquid level achieved in each case?

PrsentateurCommentaires de prsentationLeft: segragated control and shutdown functions / Right: combined control and shutdown functions

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ESD logic diagram

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Safeguarding narrative & Cause and Effects charts

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Process and Safety Diagrams (PSD)

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Relief load summary

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Flare study

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Operating manual

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Operating manual

What are the most important contents of the operating manual?

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Operating Manual Table of Contents (typ.)

1 INTRODUCTION 1.1 General presentation 1.2 Glossary 1.3 Basic data

2 DESCRIPTION OF FACILITIES 2.1 General 2.2 Process 2.3 Utilities 2.4 Auxiliaries

3 AUTOMATIC CONTROL SYSTEM 3.1 System overview 3.2 Operator control interfaces 3.3 Telecommunications 3.4 Process alarms and trips 3.6 Emergency shutdown system 3.7 Fire & gas system

4 OPERATION 4.1 Start-up 4.2 Normal operation 4.4 Shutdown 4.5 Depressurization

5 SAFETY 5.1 Operating philosophy 5.2 Escape, evacuation and

rescue 5.3 Emergency power system 5.4 Safety equipment list 5.5 Fire protection

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Operating Manual Annexes (typ.)

EQUIPMENT LIST

PFDs

P&IDs

ESD LOGIC DIAGRAM

EQUIPMENT START/STOP & SHUTDOWN SEQUENCES

GENERAL PLOT PLAN

DCS ARCHITECTURE DRAWING

ELECTRICAL CONTROL SYSTEM ARCHITECTURE DRAWING

SINGLE LINE DIAGRAM

F&G SYSTEM ARCHITECTURE DRAWING

VESSELS MECHANICAL DATA SHEETS

INSTRUMENT DATA SHEETS (PSVs, Level instruments)

ESD SIMPLIFIED DIAGRAM

CONTROL LOOPS AND ALARM LIST

SECURITY SWITCHES LIST

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Operating Manual Control loops and Alarms list

PrsentateurCommentaires de prsentationCalled RAT: Ranges, Alarms and Trips list

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Process design criteria

What are the different Process design criteria?

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What are the different Process design criteria?

Design margins Design Pressure and Temperature criteria Equipment sizing criteria Line sizing criteria Control valve sizing criteria

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Design margins: what is the usual Equipment (rotating, heat exchangers, columns) overdesign (%)? Design Pressure and Temperature criteria Equipment sizing criteria Line sizing criteria Control valve sizing criteria

+?%

PrsentateurCommentaires de prsentationThe Process Design criteria is the JSD for Process

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Design margins: what is the usual Equipment (rotating, heat exchangers, columns) overdesign (%)? Design Pressure and Temperature criteria Equipment sizing criteria Line sizing criteria Control valve sizing criteria

+10%

PrsentateurCommentaires de prsentationThe Process Design criteria is the JSD for Process

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The design temperature should be the highest or lowest temperature to which the equipment is subjected, plus a margin. The following cases must be considered: (a) A maximum temperature which can occur when bypassing a heat exchanger or cooler for cleaning. (b) A high metal temperature on uninsulated equipment due to solar radiation. (c) The lowest temperature that may be caused by auto-refrigeration. (d) The maximum metal temperature that can occur during steam out or decoking operation.

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Licensed vs Open Art Process

When one uses a process under license, what are the deliverables issued by the process LICENSOR?

PrsentateurCommentaires de prsentationIt depends on the AGREEMENT with the PROCESS licensor but it is usually as follows

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Typical PROCESS Licensor / Engineering split

Item Process Licensor Engineer PFD, H&MB X

Equipment data sheet Equipment process data sheet: - Operating conditions, - Duty - Diameters of vessels - Size of Nozzles - Pump head + specific info for internals etc.

Equipment Mechanical data sheet

P&IDs Generic customized (piping class, line and valves size, HAZOP comments, vendor info)

Line sizing Line sizing criteria Sizing (takes into account eqt loc, elevation etc.)

Plot Plan recommendations X Material selection Basic requirement MSD

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The Oil & Gas Engineering Guide 2nd edition

Get all this material wrapped up your desk companion:

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The Oil & Gas Engineering Guide - 2nd edition

Table of Contents

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Table of Contents

This suite of training modules covers the discipline chapters of the book...

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Table of Contents

The Guide contains much more:

The overall picture, interfaces, methods & tools, etc.

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Table of Contents

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Order direct from the publisher:

http://www.editionstechnip.com/en/catalogue-detail/1111/oil-gas-engineering-guide-the.html

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PROCESS

PLANT LAYOUT



CIVIL

PIPING

PIPELINE


ELECTRICAL

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Piping discipline

Plant Layout & Piping discipline

Plant Layout Piping installation Piping

materials Piping stress

analysis

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Plant layout

What has to be considered in the layout of a plant?

PrsentateurCommentaires de prsentationExternal interfaces: pipelines, utilitiesTraffic of plant personnel: parking etc.Prevailing windAccess / Exit

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Layout/principles

From which direction comes the prevailing wind?

PrsentateurCommentaires de prsentationFrom North West

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Layout/principles

The wind rose shows the frequency of winds blowing from particular directions. The length of each "spoke" around the circle is related to the frequency that the wind blows from a particular direction per unit time, emanating from zero at the center to increasing frequencies at the outer circles.

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Plant layout

The first step of Plant layout is to divide the Plant area into separate blocks and units. Why is this done? How?

PrsentateurCommentaires de prsentationto reduce escalation of fire and explosion hazardsit is done by respecting minimum space between units

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The Block Flow Diagram (BFD)

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Plant layout

Minimum distances between Process Units are determined according to GE GAP 2.5.2/2A Classify Units in terms of Fire and

Explosion Hazard into 3 categories:

Moderate Hazard (MH) Intermediate Hazard (IH) High Hazard (HH)

Apply the following minimum distances

between units of various hazard category:

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Plant layout

The first step of Plant layout is to divide the Plant area into separate blocks and units. The second step of Plant layout is to locate Equipment within each unit. Which document are used as starting points by Plant Layout?

PrsentateurCommentaires de prsentationThe PFD and the Equipment list

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Plot Plan

PrsentateurCommentaires de prsentationFunctional sub-systems are identified on the PFD

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Plant layout

What else shall be taken into account to locate equipment?

PrsentateurCommentaires de prsentationAlloy and heavy wall piping whose runs length shall be minimized and minimum safety distances between equipment

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Layout Requirements from Process

REFLUX CONDENSER

REFLUX ACCUMULATOR

REFLUX PUMP

COLUMN

What shall be the respective elevation of these equipment?

PrsentateurCommentaires de prsentationReflux condenser above reflux accumulator above reflux pump. No other constraint (except no pocket in overhead line).

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REFLUX CONDENSER

REFLUX ACCUMULATOR

REFLUX PUMP

COLUMN

What shall be the respective elevation of these equipment?

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On-shore plant: Equipment spacing recommendations as per GE GAP Guidelines .2.5.2

Clear horizontal distance, in meters, between adjacent edges of equipment

PrsentateurCommentaires de prsentationGE GAP: GE Asset Protection GuidelinesTable does not apply to equipment in similar service, e.g. pump and spare./ means provide spacing based on access for operation and maintenance

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What shall be the respective elevation of the column and reboiler?

REBOILER

COLUMN

PrsentateurCommentaires de prsentationIt depends on process requirements: refer to PDS

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REBOILER

COLUMN

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Layout/principles Accesses

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Layout principles: provision for piping flexibility

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Layout principles: typical Unit Layout

PrsentateurCommentaires de prsentationThe Equipment are arranged along a backbone = piperack. Connecting pipes run on the pipe-rack.This grade-mounted horizontal equipment arrangement is suitable when there enough real estate for the Plant. The advantage is ease of access for operation and maintenance as well as safety. The disadvantage is high real estate use and long runs of pipes, cables etc.

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Structured-mounted vertical vs grade-mounted horizontal Equipment arrangement

PrsentateurCommentaires de prsentationAn alternative if the structured-mounted vertical equipment arrangement where equipment are stacked on each other, on a multilevel steel or concrete structure. The advantage is less use of plant area, suitable for housing as required by environmental or process conditions. The disadvantage is less convenient access/egress for operating personnel as well as for maintenance (monorails, drop zones to grade lay down area have to be provided) and less easy, i.e., longer construction.

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PrsentateurCommentaires de prsentationThe Equipment are arranged along a backbone = piperack. Connecting pipes run on the pipe-rack.

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Unit Layout

What type of equipment has a large impact on the layout?

PrsentateurCommentaires de prsentationAir coolers their size must be estimated with the greatest possible accuracy

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Layout / Equipment size by vendors

14 meters

8 meters

Duty spec

Waste Heat

Boiler

PrsentateurCommentaires de prsentationfor the same duty one vendor comes up with a 8 meter long equipment, another with a 14 meters long!

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Layout / package arrangement

PrsentateurCommentaires de prsentationDimensions from Vendors are specially important for packages, that involve auxiliaries etc.

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Layout principles: pipe routing

There are 2 ways to run pipes. Name them.

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B/L(Battery limit)

C/L of Road

R

Min. 7.5 m

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What is the purpose of leaving 3 meters distance between the 2 vessels??

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Layout principles: typical Arrangement of Air-coolers

PrsentateurCommentaires de prsentationThe Equipment are arranged along a backbone = piperack. Connecting pipes run on the pipe-rack.Access are provided to:motor, fan and bearing for maintenance: motors are dismantled and dropped on a four-wheel trolley at service platform level then brought up to a dvait from service platform to grade.Both headers for cleaning and instrument access

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Plant Layout Job specification for design / Plant layout guidelines

Site elevation (s)

Minimum distances between units, equipment, buildings: applicable code + supplementary information

Clearance around equipment

Road width, clearance

Headroom clearance

B/L(Battery limit)

C/L of Road

R

Min. 7.5 m

A

Line Up C/L of Equipment

Pipe Rack of Structure

Min. 3 m

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Interfaces between Engineering disciplines Plot Plan

Plot Plan

Process design & simulations

Process eqt specs

Process Flow diagrams

Process eqt sizing

Eqt sizing by vendors

Equipment dimensions

Piping routing

Fire water network routing

Electrical distribution & cable routing

Instrument JB & cable routing

Sewage sizing & layout

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Overall Site plan

PrsentateurCommentaires de prsentationDefines the location of a complex and of its environment 1:5000 scale

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General plot plan

PrsentateurCommentaires de prsentationShows the entire Plant and the arrangement of the various units (process, utility), storage facilities, buildings and other facilities 1:1000 scale

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Unit plot plan

PrsentateurCommentaires de prsentationShows location of equipment, pipe-racks, structures, with co-ordinates and elevation 1:200 scale

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Unit plot plan Elevation view

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Unit plot plan Plan view

PrsentateurCommentaires de prsentationShows location of equipment, pipe-racks, structures, with co-ordinates and elevation

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3D modelling

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3D model clash check

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3D model review

3 model reviews are usually done

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3D model review

3 model reviews are usually done:

What is the scope of the first model review?

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First model review: Scope: finalize the Plot Plan Content: Equipment + 30% of piping is modelled, i.e. all ines on PFDs Outcome: after incorporation of COMPANYs comments, the Plot plan is released as the base for the design (IFD). Aspects reviewed: Unit location, equipment location, main access and escape routes to facilities, major piping routes indicated on PFDs, arrangement around LLI, location of main manifolds, space around equipment for maintenance, platforms for main operation access

3D model review

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30% model review

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Air-Cooled Heat Exchangers In which case would you install the ACHE at grade vs on pipe-rack?

PrsentateurCommentaires de prsentationInstall on pipe-rack when you lack real estate

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Air-Cooled Heat Exchangers In the case of installation on top of pipe-rack, what extra access shall be provided?

PrsentateurCommentaires de prsentationService platform for maintenance of motor, fan and bearing motors are dismantled and dropped on a four-wheel trolley at service platform level then brought up to a dvait from service platform to grade.

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Piping Layout Modular plants

In which cases is a modular plant preferable vs a stick built?

PrsentateurCommentaires de prsentationConstruction not easy of costly (extreme wetaher: Siberia, Canada, remote area, high labour cost)Revamping: to minimize SIMOPS

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Do you want to know more... Much more?

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Table of Contents

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Table of Contents

This suite of training modules covered the discipline chapters of the book...

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Table of Contents

The Guide contains much more:

The overall picture, interfaces, methods & tools, etc.

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Use this as standard, question deviations.

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Understand the new 3D-model centered engineering process

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Understand what drives

the Project schedule

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Order direct from the publisher:

http://www.editionstechnip.com/en/catalogue-detail/1111/oil-gas-engineering-guide-the.html

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PROCESS

PLANT LAYOUT



CIVIL

PIPING

PIPELINE


ELECTRICAL

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Process design

PFDs

H&M balance

Rotating Pressure vessels Fired equipment Heat exchangers Packages etc.

Process data sheet

Equipment specification

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Heat Exchangers

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Equipment Mechanical

Starting from the Process Equipment list, Equipment discipline issues documents to specify, select and order equipment.

Which documents?

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Starting from the Process Equipment list, Equipment discipline issues documents to specify, select and order equipment.

Which documents?

1) THE MECHANICAL DATA SHEET

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Rotating Equipment

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Mechanical Data Sheet

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Mechanical Data Sheet What additional information to the Process Data Sheet does the Mechanical Data Sheet contain?

PrsentateurCommentaires de prsentationApplicable design and manufacturing codeType of delivery: skid mounted or not,Materials of Construction, Type of auxiliaries,Explosion protection required,Utilities available,Environment data,Location of equipment, e.g., within building or not

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Process Data sheet / Mechanical Data Sheet

PrsentateurCommentaires de prsentationApplicable design and manufacturing codeType of delivery: skid mounted or not,Materials of Construction, Type of auxiliaries,Explosion protection required,Utilities available,Environment data,Location of equipment, e.g., within building or not

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Pumps could be specified as per ANSI or API code.

What are the differences?

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API vs ANSI pumps

ANSI API

Illustration courtesy of Flowserve corporation

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API vs ANSI pumps

ANSI API

Standard dimensions

Casing rating

Casing/ casing back-cover joint

Mounting feet


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API vs ANSI pumps

ANSI API

Standard dimensions YES NO

Casing rating

300 lbs at 300F 750 lbs at 500F


Also holding bearing frame adpator

Independent, with metal/metal joint.

Mounting feet Bottom Center lined


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API vs ANSI pumps

ANSI API


Casing rating

300 lbs at 300F 750 lbs at 500F





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API vs ANSI pumps

Bearing frame adaptor Casing cover

Gasket


PrsentateurCommentaires de prsentationIn the ANSI design shown here, the back cover and gasket is held against the pump casing by the bearing frame adaptor, which is most frequently supplied in cast iron. This usually results in a gap between the mating faces of the frame adaptor and the pump casing that has the potential to permit uneven torquing of the bolts. This may cause a fracture of the adaptor in the event of a higher than normal pressurization of the casing by the process system.

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API vs ANSI pumps

Bearing frame adaptor Casing cover

Gasket


PrsentateurCommentaires de prsentationThe API design bolts the back cover directly to the casing and uses a confined, controlled compression gasket with metal to metal fits. The adaptor is bolted independently to the back cover and does not play a part in the pressure boundary of the pump casing.

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API vs ANSI pumps

ANSI API


Casing rating

300 lbs at 300F 750 lbs at 500F






PrsentateurCommentaires de prsentationAnother difference between the two pump styles is the configuration of the mounting feet. All ANSI pump casings are mounted on feet projecting from the underside of the casing and bolted to the baseplate. If these pumps are used on high temperature applications, the casing will expand upwards from the mounting feet and cause severe thermal stresses in the casing which will detrimentally affect the reliability of the pump. Operation at lower temperatures will not be affected by this feature.On the other hand, API pumps are mounted at the horizontal centerline of the casing on feet projecting from each side of the casing and bolted to pedestals which form part of the baseplate. This arrangement provides the API pump with the advantage of being able to operate with pumpage at elevated temperatures. As the pump comes up to temperature in such cases, any expansion of the metal will be above and below the casing centerline and will exert minimal amounts of stress to the casing, thus contributing to the optimum reliability of the pump.The ability to handle higher temperature services is also evident in the bearing housings of the API pumps, which tend to be much more robust in design and also accommodate cooling jackets with a greater capacity of cooling water. Source: Ross Mackay

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API vs ANSI pumps

ANSI API


Casing rating

300 lbs at 300F 750 lbs at 500F





Conclusion: For which services would you select an API vs an ANSI pump ?


PrsentateurCommentaires de prsentationAPI for hazardous fluid or high pressure or high temperature.Typically API pumps are specified for all hydrocarbon services and ANSI for non-hydrocarbon services. This is probably over the top.

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What are the contents of the code ?

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What are the contents of the code ?

Data sheet template

The list of information to be defined by Purchaser, e.g. cooling medium, hazardous area classification etc.

Technical requirements for the design, accessories, tolerances etc.

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Some data is highlighted in green while some data is highlighted in orange. What is the difference?

PrsentateurCommentaires de prsentationThe data sheet:- Contains a lot of information- Is revised several times during requisition and detailed engineering phases- Shares information issued by several entities

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How and by whom are the Materials of Construction defined?

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PROCESS

EQUIPMENT


CIVIL

PIPING LAYOUT & MATERIAL


ELECTRICAL

Piping discipline

Plant Layout Piping installation Piping materials Materials/corrosion, insulation, painting

Piping calculations & supports

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Material selection

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Material selection

PrsentateurCommentaires de prsentationAPI 610 (centrifugal pump) gives materials class selection guidance for the various Refinery services

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Pumps data sheet

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Pumps data sheet

229

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Pumps data sheet

230

What is the MDMT?

PrsentateurCommentaires de prsentationLower of min amb temp and temp which can be achieved in case of depressurization (by auto-refrigeration)

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Pump data sheet

Who is defining the seal type?

PrsentateurCommentaires de prsentationProcess, based on the hazard of the fluid, in the Process design criteria

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Pump data sheet

PrsentateurCommentaires de prsentationSeal Plan (API Plan 11, 23, 53A, 53B etc.) is selected by Mechanical.

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Mechanical Data Sheet Page 1/5 Page 2/5

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Mechanical Data Sheet Page 3/5 Page 4/5

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Mechanical Data Sheet Page 5/5

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Columns and Drums

Which documents are produced to specify Pressure Vessels ?

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Pressure vessels

Any other document ?

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What does Mechanical design entail?

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Mechanical design

The vessel wall thickness is calculated so that with all loadings, i.e.,

Internal pressure

External pressure

Weight

Seismic

Wind

Other external loads, from connected pipes etc.

Loads during transport, lifting

the maximum stress for the selected material is not exceeded

PrsentateurCommentaires de prsentationThe maximum allowable stress of a material for use in a pressure vessel will be far from its ultimate strength or the strength that will be considered for the use of this material for other purposes, e.g. structural purposes. e.g. for SA 285 C, maximum allowable stress for use in a pressure vessel 13750 psi versus maximum allowable stress for structural purpose 18,000 psi.

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Mechanical design

The vessel wall thickness is calculated so that with all loadings, i.e.,

Internal pressure

External pressure

Weight

Seismic

Wind

Other external loads, from connected pipes etc.

Loads during transport, lifting

the maximum stress for the selected material is not exceeded

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Mechanical design

=

=

Circumferential stress

Longitudinal stress

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Mechanical design

=

=

Circumferential stress

Longitudinal stress

Vessel wall thickness is calculated so that circumferential stress is below admissible material stress

<

PrsentateurCommentaires de prsentationThe maximum allowable stress of a material for use in a pressure vessel will be far from its ultimate strength or the strength that will be considered for the use of this material for other purposes, e.g. structural purposes. e.g. for SA 285 C, maximum allowable stress for use in a pressure vessel 13750 psi versus maximum allowable stress for structural purpose 18,000 psi.

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Design of tall towers

Loadings that create compressive stress:

Internal pressure Wind OR seismic Weight

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Mechanical design

=

Longitudinal stress



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Design of tall towers Wind load

X F

M

D

Wind load F = Pw * X * D

Moment M = F * X/2



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X F

M

D

Wind load F = Pw * X * D

Moment M = F * X/2

Inertia I = R3 t M * R Stress S = I

M Stress S = R2 t

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X F

M

D Loadings that create compressive stress:


M Stress S = R2 t

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Weight W W Stress S = 2 R t

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Total stress: Algebraic Sum P (R-0.4 t) F * X/2 W Stress S = + - 2 Et R2 t 2 R t Total stress must remain below maximum

allowable for the material as specified in the code

X

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Mechanical design

http://www.microprotol.com/demo_viewlet.htm

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Mechanical design Calculation file

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Mechanical Design

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Mechanical data sheet

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Look at the PDS and MDS in your exercise book. What additional information is contained in the MDS? What does Mechanical design entail?

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Process Data Sheet: design conditions skeleton drawings material (generic type) and corrosion allowance equipment dimensions definition of type of internals nozzles list height from ground

Mechanical Data Sheet: design conditions & code scaled drawing material grades and thickness of all parts all dimensions drawings of internals nozzzles position and elevation designed support weight loads on foundation limits of supply

PrsentateurCommentaires de prsentationThe MDS also serves for Piping installation studies

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1) Most frequent type of heat exchangers: shell & tubes

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Heat Exchanger Shell & Tubes

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Heat Exchanger thermal sizing TEMA Data Sheet

A Thermal data sheet is received from Process for shell & tubes heat exchangers following thermal sizing

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Heat Exchanger Mechanical Design

N1B

N2A

N4

N5 N3

N2B

N1A

V

DUC

HLLHLL

Ref[1]: 0

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N1B

N2A

N4

N5 N3

N2B

N1A

V

DUC

HLLHLL

Ref[1]: 0

What additional aspect is taken into account in the mechanical design of heat exchangers compared to that of other pressure vessels (columns, drums)?

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N1B

N2A

N4

N5 N3

N2B

N1A

V

DUC

HLLHLL

Ref[1]: 0

PrsentateurCommentaires de prsentationThe differential thermal expansion between parts,e.g., bewteen tubes and shell. This could impose an expansion joint on the shell side for fixed tubesheet heat exchangers.

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Heat Exchanger Mechanical Data Sheet

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Heat Exchanger

Process Process/heat exchange Equipment

Proces Data Sheet

Thermal sizing

Thermal data sheet


Mechanical design

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Heat Exchanger

Process Process/heat exchange Equipment

Proces Data Sheet

Thermal sizing

Thermal data sheet


Mechanical design

Overall eqipment dimensions, position of nozzles, weight etc.

Heat transfer coefficient, number of shells/passes per shell, heat transfer surface, number of tubes

Thermal exchange duty

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2) Plate & Frame and other proprietary design heat exchangers

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Heat Exchanger Plate and Frame

How are Plate and Frame Heat Exchangers specified ?

PrsentateurCommentaires de prsentationSame as for Air-Coolers:Engineering specifies the duty only + all fluid propertiesSize and number: to be advised by vendor

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What are the advantages of the Plate and Frame HX versus the Shell & Tube?

PrsentateurCommentaires de prsentationRequires less spaceCapacity can be extended by adding plates

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How are Air cooled Heat Exchangers specified?

PrsentateurCommentaires de prsentationBy way of Process Data Sheet only: No mechanical data sheet is issued

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How are heaters specified ?

PrsentateurCommentaires de prsentationHeaters are specified by means of a PDS and also a MDS, that specifies: design code, MOC, efficiency required (on fuel gas, e.g. 92 %), emissions limits, accessories to be supplied (platforms etc).No thermal sizing is done by Engineering. The MDS does not contain any sizing information but only the process duty.

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How are storage tanks specified ?

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Storage tanks

Flat bottom cylindrical atmospheric tanks are designed as per API 650 Welded storage tanks for oil storage

Above a diameter of 6 meters, tanks are not be shop but Site fabricated

PrsentateurCommentaires de prsentationFoundation can be directly on filled material/sand or ringed wall

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Storage tanks Mechanical data sheet

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What are the miscellaneous equipment?

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What is a package ?

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What is a package ?

Package = Set of equipment, accessories and services contracted or purchased to a single Vendor realizing a process function, with associated functional guarantees assembled on a single skid or multi skid, or shipped loose (bulk)

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What is a package ?

What is, for Engineering, the purpose to order as a package ?

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What is a package ?


Purpose to have a better efficiency (than if it was done by the Engineer) to minimize site erection work to have ONE single functional guarantee to have a party (vendor) who is able to bring a specific know-how

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What is a package ?


What is usually ordered as a package ?

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What is a package ?



Common types of packages Compressors Heaters, boilers, incinerators, Air/nitrogen generation, chemical injection Water/gas treatment Solid handling, conveyors, cranes etc.

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Packaged Compressor

Picture courtersy LMF

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Packages Off-shore

Instrument air generation Air dryers skid

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Packages Off-shore Gas Dehydration

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Packages On-shore

Cold box Storage tank

(25m high)

Steam bath vaporizer

Nitrogen generation unit

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What is a package ?



Which is the responsible discipline ?

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Which is the responsible discipline ?

Packages requiring mainly know-how for one Equipment type, designed to ONE particular code: the concerned Equipment discipline Turbo-compressor ROTATING Heaters, boilers, incinerators FIRED HEATER Desalter PRESSURE VESSELS

Packages involving several Equipment type, the design of which is

NOT dictated by ONE particular code: the PACKAGE discipline Air/nitrogen generation, chemical injection PACKAGE Water/gas treatment PACKAGE Solid handling, conveyors, cranes etc. PACKAGE

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What are the key things to consider when specifying a package?

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Applicable specifications: Manufacturer standard, a few Project specifications or all?

Automation design: Independent control system or not ? Pre-assembly level / extent of site works Definition of limits of supply and interfaces in all disciplines, e.g. civil Involvement of Engineer: no / partial or full check ?


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Applicable specifications: Manufacturer standard, a few Project specifications or all?

Automation design: Independent control and safety systems or not ? Pre-assembly level / extent of site works Definition of limits of supply and interfaces in all disciplines, e.g. civil Involvement of Engineer: no / partial or full check ?


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Package instrumentation & control

Package with control loops and protection system integrated with the Plant control and safety systems

The Package with stand alone process control and safety system

PrsentateurCommentaires de prsentationRight side (P3): Package control system included. Cables 2 supplied and installed by Vendor. Cables 3 supplied and installed by Purchaser.

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What could be the drawbacks of ordering something as a package?

PrsentateurCommentaires de prsentationHigher cost: 50% higher cost for thermal reactor package compared to de-packaged as 5 orders (burner/chamber/WHB/refractory/piping & instr), also incinerator depackaged as burner/chamber/WHB/fan/stack/ducts. Cost saving significant on large large duty.Less control of implementation of ones specifications by all sub-vendors.Poor management of sub-vendors by package suppliers

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What other documents besides the Data Sheets are issued to specify and order Equipment ?

PrsentateurCommentaires de prsentationA supply specification

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What other documents besides the Data Sheets are issued to specify and order Equipment ?

2) THE SPECIFICATION

PrsentateurCommentaires de prsentationA supply specification

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Data sheet / Specification

What is the scope of each document?

PrsentateurCommentaires de prsentationThe data sheet indicated standard requirements. The Specification indicates non standard requirements.

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Data sheet / Specification

Two types of specifications are issued. What are the two types?

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Specification

EP - 21799_a_A_ppt_01 - Eng. Mangement Part 2 - Engineering disciplines 298

General

PrsentateurCommentaires de prsentationGeneric to a family of equipment, e.g. fired heaters, S&T HX etc.It features amemdment/supplement to a given standard.No only addition but, waiver as well, for instance API 661 for ai-coolers specifies direct coupling whereas the Engineer will specify with pulley.For standard supplies, it is enough, along with the MDS for the MRCalled JSS in Technip

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Specification

General specification: It does not apply to a particular equipment (tag) but to all items of this

family of equipment, e.g. fired heaters, S&T HX etc. Only lists the amendments to a code For standard supplies, it is enough, along with the MDS For packages, general specifications for all equipment types within the

package must be included

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Equipment codes & Standards

Pressure Vessels ASME Section VIII, Division 1 Rules for Construction of pressure Vessels ASME Section VIII, Division 2 Rules for Construction of pressure Vessels Fired Heaters and Steam Boilers ASME Section I Power Boilers Code API 560 Fired heaters for refinery services Heat Exchangers API 660 Shell & Tube API 661 Air-cooled HX API 662 Plate & Frame Rotating Equipment API 610 Centrifugal pumps for Petroleum and Natural Gas Industries API 617 Centrifugal compressor for general refinery service API 611 General purpose turbines for refinery service Atmospheric Storage Tanks API 650 Welded Tanks For oil Storage

PrsentateurCommentaires de prsentationExample of requirement from API 661 for Air-coolers: 2 fans by bay, minimum heat exchanged if fans are off etc.Note: API codes, e.g., API 661, requires the purchaser to specify the pressure design code. ASME VIII div 1 is usually specified.

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Specification

Particular

PrsentateurCommentaires de prsentationSpecific to a particular eqt item, sometimes called Particular for this reasonIssued when the supply is not standard, otherwise JSS is enough alongside MDS in MRIssued when more than one item in particular for a packagesCalled SP in Technip

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Specification

General specification: It does not apply to a particular equipment (tag) but to all items of this

family of equipment, e.g. fired heaters, S&T HX etc. Only lists the amendments to a code For standard supplies, it is enough, along with the MDS For packages, general specifications for all equipment types within the

package must be included Particular specification Specific to a particular equipment item (Equipment Tag) Issued for complex and extended scope of supply, including several types

of equipment, e.g. machinery auxiliaries, and for packages Issued when the supply is not standard, i.e. specific requirements etc. that

the general specification does not cover It is fully comprehensive... as shown on the TOC on the next slide

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(Particular) Equipment specification

Detailed scope of supply

Scope of services

Reference documents

Applicable codes & standards

Deviations & Exceptions

Design Requirements

Packing, marking and shipping

Shop assembly and delivery conditions

Inspection & testing

Guarantees & warranty

Data required with the bid

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Specification

Detailed scope of supply

Scope of services

Reference documents

Applicable codes & standards

Deviations & Exceptions

Design Requirements

Packing, marking and shipping

Shop assembly and delivery conditions

Inspection & testing

Guarantees & warranty

Data required with the bid

Dev

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