process-project engineering for uic senior design (1)

8/10/2019 Process-Project Engineering for UIC Senior Design (1)

http://slidepdf.com/reader/full/process-project-engineering-for-uic-senior-design-1 1/62

Process / Project Engineering

UIC Senior Design

Process / Project Engineering

UIC Senior Design



• Learning Objectives

• Project Definition

• Basic or Process Engineering

• Systems or Project Engineering

Process/Project Engineering

Agenda



Learning Objectives

• Discuss Best Practices in setting a ProjectDefinition to ensure a successful project

• Understand the roles of the different Partiesinvolved in the overall execution of a Project

• Examine the various steps of Process andProject Engineering



Project Definition

Grass roots refinery installationwith multiple processes andutilities

Addition of a complex of newprocess technologies in anexisting facility

Addition of a single processunit

Addition to or revamp of anexisting process unit

Changes to an existing piece of

equipment

• A “Project Definition” is required for any projectrequiring design and construction



Phases of the Project

Defining Project- Market Research

- Economic Studies

- Finance

- Licensor Selection- +/- 50% TIC

Basic Engineering- Project Defined

- Process Design

- Project Design

- +/- 10% TIC

EPC- Detailed Design

- Procurement

- Construction

Start-up- Commissioning

- Initial Unit Operation

- Performance Test

(Typically 18 – 48 months)

Phase that focuses onProcess / Project Engineering

Conceptual

Planning

Basic

Engineering

Engineering,

Procurement

Construction

Commissioning

& Start-up

Project Definition



• First Step is to Finalized Project Definition

• Second Step is to Complete the Design• End Product is the Basic Engineering Design

Package

At UOP Known as the “Schedule A”

Used as the Basis for the Detailed Design / Procurement /Construction Phases of the Project

• The Basic Engineering Design Work Process is

Split into 2 Phases: The Process Engineering Phase

The Project Engineering Phase

Basic Engineering Phase

Project Definition



Scope Definition

• What Parties are involved?

Licensor: for Licensed Technology and Catalyst

There may not be a Licensor if only Technique andKnow-how (TKH) is required

Project Management Consultant, PMC, to help Refinerexecute a major project

Contractor – Front End Engineering Design (FEED) tocoordinate Licensor information / off-sites / utilities

Contractor – Detailed Design (actual plot, isometrics),equipment requisition, actual construction

Subcontractors Equipment Vendors



So How Do You Go About Setting a Good ProjectDefinition?

Project Definition

Project

Definition

DefineProject

Scope

Set

Design

Basis

Complete

BEDD

Establish

Schedule



Scope Definition

• Engineering Agreements and Contracts defineresponsibilities for:

Engineering deliverable content/detail

Scope boundaries for equipment design

Scope boundaries for supply of equipment

Basis for Design



Setting the Design Basis

• A good Design Basis is a critical part of theProject Definition

•Design Basis is set in:

Design Basis Meeting with various parties

Design Basis Meeting Notes document discussionand decisions from the Design Basis Meeting

Legal Agreements include much of what is defined inthe Design Basis Meeting Notes, and binds the partiesin terms of Scope and Deliverables

Basic Engineering Design Data (BEDD, BEDQ)

Yield Estimates




• Set unit capacity

Based on feed or product

Based on on-stream efficiency (e.g. 330 d/y)

Define turndown requirements or future capacities

• Feed definition

Feed cases (limit the number – ideally 2, at most 4)

Define compositions

Define contaminant limitations

• Product specifications

Recovery

Purity

Contaminant limitations (sulfur)

Other important specifications (octane)




• Identify specific process schemes (process flow)

Desired process flow to be scoped out before designbegins (have preliminary PFD available)

Future capacity

Feed pre-treating methods

Product treating methods

• Identify specific design decisions for major orspecialty equipment, e.g.

Specific compressor types

Specialty exchangers, vertical, welded plate

Specialty fractionator trays



Basic Engineering Design Data

Design Basis• General Information

Units of measurement

Turndown requirement Customer names and addresses

Communication protocol

• Utility Information Steam level identification and condition

Cooling water battery limits

Fuel for fired heaters Fuel oil impurities

Fuel gas pressure and impurities



Basic Engineering Design Data

Design Basis• Specific equipment design requirements

Desired fired heater efficiency

Method of obtaining fired heater efficiency

Tray and packing information

Shell and tube exchanger tube diameter and length

Air cooler design air temperature, air only breaktemperature and air/water break temperature

• Site conditions

Winterizing temperature

Unit elevation

• Battery limit temperatures and pressures



Schedule

• Schedule is critical because time is money

Consider opportunity cost of time on-stream

The schedule needs to be reasonable

The schedule needs to be balanced between licensor,EPC contractor and vendors

Might need to meet schedules for product/feed contracts

• Remember:“the bitterness of poor quality remains long after thesweetness of meeting the schedule has been forgotten”



Project Implementation

Owner’s Influence on Project versus Time

Basic

Engineering

Detail Design, Procurement, Construction Startup

+ A

b i l i t y t o I n f l u e n c e P

r o j e c t

T o t a

l C o s t o

f P r o j e

c tHigh

Low



Process Engineering (Basic Design)

• Heat and Material Balance (Simulation)

Produce stream properties to specify equipment

• Process Flow Diagram

• Major &/or Long Lead Equipment Sizing



Process Engineering Design Steps

Establish Basis of Design

Develop Process Flow Diagram

Major Equipment Selection and Sizing

Modify Mass and Energy Balances

Internal and External Reviews

Produce Process Flow Diagram with Controls

CompressorsReactors FractionatorsHeat Exchangers Other

Produce & Optimize Mass and Energy Balance

Recycle From Any Point May Be Needed For Design Optimization

R i P j D fi i i I f i



Review Project Definition Information

• Yield Estimate

• Legal Agreements

• Design Basis Meeting Notes• Basic Engineering Design Data

• PFD and Simulation Modules

• Standard Specifications

Yi ld E ti t I t



Yield Estimate Importance

Critical definition of:

• Feeds

•Products Total

Individual

• Reactor conditions Temperature and pressure

H2 partial pressure

Wash water rates

Heat of reactions Recycle rates

Cycle times

St d d & S ifi ti



Standards & Specifications

Licensor Standard Specifications may well differfrom the customer’s Standard Specifications -

External specifications need to be reviewed by Skill

specialists

A consolidated list of significant differences betweeninternal and external Standards will help avoidproblems

P d H t & W i ht B l



Produce Heat & Weight Balance

• Choose the appropriate simulator

• Define component list

• Select property packages• Assign hydraulic values

• Produce a model

Connect and define unit operations

• Review product quantities and qualities

• Optimize flow scheme

• This is the Key Output!

Optimize Flow Scheme



Optimize Flow Scheme

• Things that are typically optimized? Equipment Used in the process flow

Divided wall Column vs. Two columns

Heat Exchangers

Feed/Effluent Heat Exchange vs. Fired Heater vs. Air

Cooler Duty

Compressors & Pumps

Is it possible to avoid the use of a compressor or pump?

Determine best compressor type and efficiency

Check that the compression ratio and discharge

temperature are within acceptable range

Fractionators

There are many options in any flowscheme thatcan be optimized (operating vs. capital cost

tradeoffs)

Optimize the Fractionators



Optimize the Fractionators

• Total number of trays

• Feed tray location

• Feed enthalpy• Condenser type and cooling medium

• Reboiler type and heating medium

• Select and design internals (trays vs.packing)

Process Flow Diagram



Process Flow Diagram

• The PFD should provide an easy to understandview of the unit

The major equipment that is needed

The routing of the major flows

The regulatory (functional) control system

Customer PFD Check



Customer PFD Check

• The customer provides needed input basedon the process data

Products streams

Duties

Instrumentation

Operability

Preliminary equipment sizes Preliminary utilities

Preliminary Equipment Size Info




• Fired Heaters Basic heater type

Process duty

Design conditions

Inlet/outlet fluid properties Burner types / requirements

Efficiency requirements

Metallurgy

Fuel Fired

• Vessels Vessel Orientation

Design conditions Diameter / Tangent Length / Elevation

Internals (distributors, trays , packing, etc.)





• Heat Exchangers Basic heat exchanger type (vertical, S&T, hairpin, etc.) Process duty Design conditions Inlet/outlet fluid properties

U value Surface Area Number of shells Tube OD, Length, Pitch

TEMA type Metallurgy

• Pumps Pump type (centrifugal, proportioning, etc) Process conditions / NPSHA Metallurgical requirements Seal Requirements Seal / Flush Plans

Driver Type





• Compressors Compressor type (centrifugal, proportioning, etc)

Process conditions / Estimated BHP

Number of Stages

Number of Compressors Metallurgical requirements

Driver Type

Project Engineering Phase



Project Engineering Phase

• Hydraulics

• Line sizing

• Equipment design

temperatures & pressures• Material selection

• Flange ratings

• Equipment specifications

• Standard Specifications &

drawings

• P&I diagrams

• Plot plan

• Instrument specifications

• Piping specifications

• Relief valve specifications

• Transition work to support

the start of detailed design

Hydraulics



• Hydraulics are the “Heat and Material Balance”of Project Work – define connections betweenequipment

• Hydraulics to size lines, specify pumps,compressors, control valves, set equipmentelevations and design pressures

• Basic engineering hydraulics based onpreliminary unit plot plan (estimated pipinglengths, equipment layout and nozzle elevations)

• EPC Contractor responsible for verifying basicengineering system hydraulics are adequate.Adjusted for final plot layout, pipingarrangement and actual equipment purchased

Hydraulics

Hydraulics



• Set vessel elevations

• Mechanical clearance

• Pump NPSH• Thermosyphon reboilers

• Relative elevations

• Account for static heads• Set/confirm allowable

equipment pressure drops

Hydraulics

• Tabulate hydraulic circuits for normal, design andturndown flows

Line Sizing



Line Sizing

• Size all lines and determine pipeschedules using hand or computertools

Select criteria based on the service

Estimate pipe schedule from the operatingpressure

Consider alternative operations(regeneration)

• Use a PFD quality drawing as ahydraulic flow diagram

• Most line loss is due to fittings notlength, hence the use of “equivalent”length

Design Pressures



• Locate pressure relief valves

• Determine PRV set pressures

• Determine which PRV protectswhat equipment

• Set equipment designpressure based on:

Minimum design pressure

A margin over operating pressure

Pressure at relieving

Pump shutoff/shut-in pressure

Special operating conditions

10/13th rule for exchangers

g

Design Temperatures



• Set equipment designtemperatures based on:

Nominal minimum design temperature

A margin over max operatingtemperature

Failure of upstream equipment

Special operating conditions

g p

• Set minimum design metal temperature

Winterizing Adiabatic flash at 40% of normal operating pressure

Material Selection



• Material selection is generally supported bya skilled metallurgist

• Hydrogen resistance (Nelson Curves)

• Corrosive elements

Hydrogen chloride (HCl)

H2S, sulfur

Water

Caustic

• Extreme operating temperatures

Hot (up to 1010 F)

Cold (down to ambient [min. Design -10

F])

Determine Flange Ratings



• Determine flange ratings forequipment based on allowablestresses for:

• Material selected• Design pressure

• Design temperature

• Use ASME B-16.5 flange tables

• Consider adjusting design

conditions if small changes canreduce the flange class.e.g. Class 600 vs. Class 300

g g

Equipment Specifications



• Where process design is impacted by the typeof equipment, process engineer sets basicparameters

Fired heater summary

Fractionator ID, no. of trays and tray design

Reactor diameter

Compressor discharge temperature

• For highly mechanical equipment, equipmentspecialist are required to generate theequipment specifications




• Major Equipment Designed

Fired heaters

Vessels – Fractionator, Reactor

Heat Exchangers

Pumps

Compressors




• Duty specification – work witha vendor and provide: Basic heater type

Process duty

Design conditions

Inlet/outlet fluid properties Burner types / requirements

Efficiency requirements

Code

requirements/recommendedpractices

Coil metallurgy, connections

Fired Heaters

Equipment Specifications – Vessels



• Reactors

Catalyst volume set by yield estimate

Process technology generally determines

reactor type e.g. downflow, radial Process engineer may set bed dimensions

Diameter set by mass flux or pressure dropcriteria

Pressure drop for packed beds iscalculated by Ergun pressure dropcalculations

Internals designed by skill specialists –mechanical engineers

Equipment Specifications – Vessels



• Vessels Set basic dimensions by:

Residence time

Settling velocities

Clearances/freeboard

Loading of adsorbents/support

Specify elevation

Set design conditions Specify metallurgy and corrosion

allowances

Size & locate nozzles

Specify internals, reference std dwgs

Reference design codes

Specify ancillaries




Specifications include process

data for hot and cold streams todata sheet

Includes heat release curves ifnon-linear

Confirms number of shells andallowable pressure drop

Assigns design conditions foreach side

Heat Exchangers

Checks surface area to confirm maximum bundle size or weighthas not been exceeded

Equipment Specifications – Pumps



• The pump type generally needs to be known in order tocalculate NPSH

• Consultation with a skill specialist or vendor may be

required prior to hydraulics

• Specification indicates:

Pump overage for Rated Flow

Motor Load requirements

If Pump will handle differentfluids at any time

Curve rising to shutoff forparallel operation

If downstream equipmentdesign pressures are set by

pump shutoff pressure



Equipment Specifications – Compressors



• Compressor type determined in the process stage

• Consultation with a skill specialist or vendor/ catalogis prudent during the process work

• Base sparing on the reliabilityof the compressor type

• Use API data sheets• Consider head contingency

with centrifugal compressors

• Indicate regeneration gascomposition for recycle gasservice

EDS/CD-100

Piping and Instrument Diagrams



• Detailed schematic flow diagrams of the unit showing:

All process equipment, including equipment names andidentification numbers, and vessel dimensions

All process pipelines, including sizes, pipe class, by-passes,process vents and drains, sample connections, and lines

required for start-up, shutdown, flushing and regeneration Indication of requirement for insulation, heat tracing or steam

jacketing

Utility connections required for process reasons, such as

steam, cooling water, fuel oil, fuel gas, nitrogen andcompressed air

Relief valves, block and throttling valves, strainers and pipefittings required for process reasons

Minimum acceptable level of regulatory instrumentationsystems for basic measurement and control of the unit.

Piping & Instrument Diagram Review



• Process review of lines and instrumentation

• Review of equipment specifications against PID’s

•Start-up and shutdown procedure review

• Technical input from:

Project Manager – consistency

Process Specialist – design philosophy

Technical Services – operating experience

Instrumentation Skill – control

Equipment Skill – mechanical

R&D/Licensor – process technology

• Document decisions and action items throughmeeting notes

Piping and Instrument Diagrams



• Other Uses Input by Equipment and Instrumentation Specialists

Add Contractor Requirements

Basis for Generating the Detailed P&IDs or MechanicalFlow Diagrams (MFDs)

Pre-Startup Checkout

Operator Training



Equipment Specifications – Instruments



•Instrumentation is used to monitor key variablesthroughout the process

• Primary things to consider for instrumentation designare:

Safe Operation

Provide controls to avoid unsafe operation

Keep process variables within control

Production rate Provide control loops to insure production rate are achieved

Product Quality

Provide composition control / monitoring of feeds / products

Cost

Advanced process control to minimize utilities / maximize product




• Temperature / Pressure Indicators• Flowmeters

Type (orifice, mass, venturi, etc.)

Special requirements (minimum straight length piping distance,etc.)

• Level Gauges / Transmitters

Type (displacement, dP cell, gauge class, magnetic, etc.)

Show connections (pipe columns / directly connected to vessel)

Show vents / drains / connections to relief header

Indicate COF and range




• Control Valves

Bypass

Indicate fail position (if necessary)

Show vents / drains / connections to relief header

• Control Loops

Simple Feedback Control (FIC→ CV)

Cascade Control (LIC→ FIC→ CV)

• Cause and Effect Tables

Emergency ShutDown (ESD) systems

Piping



• Piping expertise is generally with a skillspecialist

• Piping design conditions are determined by

the equipment to which it is connected• Need to consider alternate operations

• Piping classes are best indicated on the PID’s

to show where class breaks occur • Piping line lists are usually done in detailed

design

Piping



• Basic Pipe Class Definition:

Metallurgy

Class - 150, 300, etc.

Flange Facing

Corrosion Allowance

• Additional information included on line lists: Insulation thickness

Post weld heat treating requirements

Steam tracing objective temperature

Fluid in the pipe

Relief Valves



• Relief Valve Design according to:

API Recommended Practice 520

API Recommended Practice 521

• Load Analysis – How much is relieving and atwhat conditions?

Make simplifying assumptions to minimize analysis

time Steady state models

Use of normal HWB information where possible

• Document Assumptions

Relief Valves



• Summarize all Casualties

Loads

Fluid Properties

• Specify PRV orifice for Governing Case

• Size Inlet and Outlet piping

• Specify PRV mechanical requirements basedon the characteristics of the service

• Summarize loads for common casualties sorelief header design can be performed

Use of Project Specifications



•Supports Capital Cost Estimate Based onBudget Quotes

• Serves as Basis for EPC Contractor Biddingand Selection

• Allows for the development of the offsitesrequirements

• Leads to Design and Construction of the

Process Unit

• Used as Reference for an Operating Guide

Transition to Detailed Design



• Transfer of Technology from Licensor to DetailedDesign Contractor

• Typically at Customer PID Review Meeting

• Detailed design finalizes hydraulics based onequipment purchased, actual plot plan and pipingruns

• Application of Local Codes versus US Codes• Resolution of deviations between Licensor

Specifications and “As Built” Unit

In Closing



• Although the tasks of the “Process” and“Systems” Engineer may differ depending onthe organization, the tasks associated with

plant design tend to be the same• Effort placed in setting a good project definition

and design basis will maximize efficiencyduring process and project engineering – andensure the design meets customer needs

process-project engineering for uic senior design (1)

Documents