1

Stoichiometry Piping and Instrument Diagram (PID)

Major Equipment Placement Plot Plan (Plant Layout)

Piping LayoutMajor Pipe Routing

Fabrication ISO’sPipe Segment PFV Material

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

Economic Model Process Flow Diagram (PFD)

Plant Design Documentsand Information Flow

Copyright ©, 2012,

William G. Beazley, PhD

All Rights Reserved

Other Copyrights Apply as Noted

Accumulation of Elaboration ValueDelivered in Capital Projects

ProcessFlow Diag

& ROI

DesignConcept &

ROI

Discount orPremium to

AchieveExpected Valueto Customer Vi

ConceptualDesign

DetailDesign

Construction CommissioningClientCase

ROI withFabricator /

Suppier Bids

Plant Built

Production

ProductionBegins

Contributing Activities

Value Assessments

Premium to Operate (Service Contract)

Premium to Complete (Fixed Bid)

Discount to Purchase (Prudent Buyer)

Front-End Loading Process(The Business Roundtable)

• Critical planning phases of the project

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

– FEL 1 Business Planning - opportunity is explored

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

– FEL 3 Project Planning stage fills in detailsneeded so detailed engineering can execute theproject with little or no change.

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

The IPA Institute’s Gatekeeper seminar will arm gatekeepers with thequestions they need to ask to move a project forward or to kill it.

Gate 1

ExecutionPhase

Gate 3Gate 2

ProjectPlanning

FacilityPlanning

BusinessPlanning

Turnover

OperationsPhase

75% of theIdeas Do NotPass Gate 1

50% of theRemainingIdeas DoNot PassGate 2

Only 1% oftheRemainingIdeas Do NotPass Gate 3

Decision Gates

IdeaInitiation

RecycleBack

Continue

Cancel/Shelve

Three-Phase Gated Approval System(IPA Institute)

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

http://www.irisllc.com/

Engineering Design Phases• Conceptual designs

– Sketchy or minimal information

– Abstract plot plan (equipment & piping layout)

• Preliminary, or study phase– Unchecked or uncertified data

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

• Purchase Long Lead Time Bulk materials.

• Detail phase– All designs are finalized

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

• Certified vendor drawings for equipment, valves, and instruments.

• Layout designer impact in conceptual, study phases

2

Three Major Sources of Project Data

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

• Process and process materials

• Plant location and environmental features

2. Vendor data pertaining to equipment andspecialty bulk items.

3. Internally generated engineering data.

The Flow of Information to Pipers

Plant DesignInformation Flow

EconomicsOwner

ProcessOwner

Controlsand

StabilityOwner

MaterialsIntegrityOwner

BFD PFD

P&ID

MatlSPEC

EquipmentVendors

Equip Data

PipingLayoutOwner

PipingLayout

Feedback

FEED EPC

Structures,Foundations,

etc.

Fab ISOs,Spools, Etc.

Block Flow Diagram

• Explains the business case for the plant

• Business:

– Finance

– Processes

– Sales

– Input/Output Logistics

• Only major elements, i.e., “blocks”

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

Block Flow Diagram forEarly Entrance Coproduction Plant

(US DoE)

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

3

Claus Plant: H2S to Sulphur

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

Process Flow Diagram(US OSHA)

Block FlowDiagram(ChevronProducts

Company)

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

Process Information• Process description, including reactions,

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

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

equipment item• Physical properties of process materials

– Arterial inventories– Corrosion data and materials of construction.

• Main Point: Know what’s in Pipes & Vessels

Process Flow Diagram• Shows Material Flows and Properties

–Anchor Point Temperatures and Pressures

–Material Balances As Best Known

• Shows Equipment that Changes State:

–Major Pressure Vessels (Reactors, Columns,Drums)

–Major Pumps and Compressors

–Column Reboilers and Condensers

–Reactors, Furnaces, Heat Exchangers

–Valves If a Significant Pressure Drop

Typical Project PFD (KBR)

4

Sample ProcessFlow Diagram

(Source: Bausbacherand Hunt)

Data Normally Included on a Process Flowsheet

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

• All process equipment. Spares are indicated by letter symbolsor notes

• Major instrumentation essential to process control and tounderstanding fIowsheet

• Valves essential to an understanding of the flowsheet

• Design basis, including stream factor

• Temperatures, pressures, flow quantities

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

• Utilities requirements summary

• Equipment Data

Information Developed from PFD

• Piping and InstrumentationDiagram (P&ID)

• Equipment List (then EquipmentData)

• Process Material Hazards

• Material Specification

Operators Viewing Process Details(Chevron Phillips Chemical Company)

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

P&ID asSchematicfor Layout

P&ID Example(Source: DoE)

5

Piping and Instrumentation Diagrams

• Schematic (connectivity only)

• Shows Items Needed to Control ProcessConditions:

–All process, utility, and auxiliary equipment

–Connecting piping,

–Valving,

–Specialty items,

– Instrumentation and

– Insulation, and heat tracing requirements.

Equipment List

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

• Gives the equipment item numbersand descriptions

• Generally furnished by the client orproject engineering

PIP P&ID Equipment ClassesCLASS SUBJECT DESCRIPTION

A Mixing Equipment Agitators, Aerators, Mechanical Mixers

B Blowers Centrifugal Blowers, Positive DisplacementBlowers, Fans

C Compressors Centrifugal, Reciprocating, Screw, Vacuum

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

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

F Furnaces Fired Heaters, Furnaces, Boilers, Kilns

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

R Reactors

T Towers / Columns

TK Tanks API atmospheric and low pressure

U Misc Equipment Filters, Bins, Silos

V Drums Separators, Driers, Accumulators

Sample Equipment List(Source: Bausbacher and

Hunt)

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

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

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

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

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

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

• Pumps: 6PM (60’Ft, ΔP psi, HHP, type, drive

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

• Other equipment: Sufficient data for identification of duty and size

Process Materials & Hazards

• Hazardous properties, eg–Lower Flammability Limit (LFL)

–Upper Flammability Limit (UFL)

– Immediately Dangerous to Life or HealthConcentrations (IDLH)

–Long Term Exposure Limit (LTEL)

• Electrical classification practices

• Site climatic conditions & impacts

• Environmental effects and permitteddischarge & release levels

6

Pipe Specs

• Maximum Hydrostatic Test Pressure:

– e.g. 450 psig

• Allowed Service Types:

– SW Seawater - Raw

– SH Sodium Hypochlorite

– FL Flare

– WP Water - Potable

• Specified Pipe, Valves, Fittings (PVF)

• Specified Flanges, Blinds, etc.

Pipe Spec Can Change WhenProcess Conditions Change

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

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

2500 PSIG (Well Head Press)2500 PSIG (Well

Head Press) 1420 PSIG 500 PSIG 125 PSIG

DESIGN DOCUMENTATIONTYPICAL PER $100MM

FLOWSHEETS /PID’s 100 - 150

PIPING ISO’s 2500 - 3000

INSTRUMENT LOOPS 2000 - 3000

VESSEL/EQUIP DWGS 100

ROTATING EQUIP SPECS 150 - 200

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

Design Execution in Sequence

Typical Deliverables(Puneet Sharma, Iris LLC)

• Conceptual Design– Estimate

• Deterministic @ ± 30-40%

• Risk-Based for Base Case

– Facilities (Process)

• Heat & Material Balance

• Process Flow Sketch

– Flowlines & Pipelines

• Route Definition

– Structural

• Design Concept

• Front-End Design– Class A Package

• Completed Pipeline Surveys

• Deck Layout with CG

• Facility Weights, Lift Plan &Structural Design

• Long-Lead Item PO’s

• Process Hazard Analysis

• Preliminary P&Ids

– Estimate @ ± 15-20%

• Detail Design– Equipment & E&I Pos

– HAZOP

– P&IDs, UFDs

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

7

Stoichiometry Piping and Instrument Diagram (P&ID)

Major Equipment Placement Plot Plan (Plant Layout)

Piping LayoutMajor Pipe Routing

Fabrication ISO’sPipe Segment PVF Material

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

Piping Design Documents

Economic Model Process Flow Diagram (PFD)

Piping andInstrumentDiagram

(PID)

Plot Plan(Plant

Layout)

Piping Layout

From Turton´s et. al. P. 2

Piping Layout Information Flow

PipingSpec

Equipment,Item Data

Sheets

Plant Layout Design

• Conceptual and preliminary developmentof process unit plot plans

• Routing of major above and below gradepiping

• Layout of equipment and its associatedinfrastructure

Good Layout Design and Engineering

• Affects plant cost and economy

• Can shorten constructionschedules

• Affects operations andmaintenance efficiency

Plot Plan Information

• Pipe Racks

• Layout of the Equipment in the PFD

• Layout of Major Equipment

– Tankage

– Other areas shown as blocks

– Access via roads, rail, waterway

– Plant perimeter

Preliminary Information Sketches(Source: Bausbacher and Hunt)

8

Sample Proposal Plot Plan(Source: Bausbacher and Hunt)

• ApproxLayout &Grouping

• Majorinterfacesand flows

• OverallDimensions

Sample Planning Plot Plan(Source: Bausbacher and Hunt)

• DefinedAreas

• TaggedEquipment

• CriticalDimensions

Sample Construction Plot Plan(Source: Bausbacher and Hunt)

• FinalDimensions

• FoundationLocations

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

Pipe LayoutPlan

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

Pipe LayoutElevation

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

9

Pipe Fab ISO& BOM

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

FabricationISO’s

• Single pipeline

• Materialtakeoff

• Field welds• Pressure testresults

• Constructionaid

Source:Bentley Systems Inc.

Typical Fabrication ISO Single Line Isometric Spool Drawing

Spool Bill of Materials

Operations Phase

10

Operations

• Procedures:

– Specified actions

– Expected outcomes (plant states)

– Contingent procedures

• Startup

• Production

• Assessment & Assurance

• Shutdown

• Restart

Maintenance

• Actions taken to keep the plant and itscomponents in good repair

• Governed by maintenance procedures

• Performed to keep or restore it processplant to an operable mode in a safemanner

Repair

• Actions taken to restore the plant and itscomponents to an operable mode in a safemanner

• Governed by maintenance procedures

• Equipment is down or out of specClosing Ideas

“Good Practice” guidance from:

• Layout standards

• Published or company experienceand guidance.

• Prior work

BusinessOpportunity

SelectProcess Route

ProcessDesign

Evaluate:-Safety

EnvironmentOperability

Evaluate Costs:-Capital

Operating

PlantLayout

Layout Interactions with BusinessCase and Design Baseline