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Lead Process Engineer

The lead process engineer (lpe) is responsible for developing the project scope. He or she also manages the process team's costs and schedule. The questions listed below should be answered early in a project.

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400 views7 pages

Lead Process Engineer

The lead process engineer (lpe) is responsible for developing the project scope. He or she also manages the process team's costs and schedule. The questions listed below should be answered early in a project.

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picapic
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© Attribution Non-Commercial (BY-NC)
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fee E&C PROJECTS Clarifying the Role of the Lead Process Engineer The LPE can make or break a project, depending on how well he orshe clarifies the project scope and produces thorough PFDs and P&lDs John Lagace, LeadProcessEngineer.com jor any capital-intensive and labor-intensive eng neering and ‘construction (E&C) project, the lead process engineer (LPE) plays a pivotal role, To maximise the success of these complex projects, companies that hire E&C companies should be aware of the role that the E&C pro- cess engineering team plays in terms of helping to execute these projects. In a nutshell, the LPE is responsible for developing the project scope and managing the process team's costs and schedule When the LPE does this proper! the scope of the project is well- PEMTHATOP preliminary tquioment Zqupment Technica bid evalvalon Management’ | © PSM/HAZOP fnal design {Process signoff for purshore oor (Whi this (Gsapena.” | | st of action toms ‘cont not ciways practices mporion fr highly Mronagement of © MOC process st up Engineered equipment such cs towers com Change (w0G)| + MOG process octnies prstsor ond oo on) reviews Tnvienmerta_| + Environmental revi of procere + Fugliveemisionsestmate ing ine Kat = Oblain lie Ta rom Piping Beplor develop one {Flareemissions estimate toe ooine pas neon ° + Pump-seol requirements (per leak detection + Sze primar nes ‘and vepat. (DAR raqurertent) + Sze minor ines 1 Update process ntomation on tne Bist + itera fevew of nw ist ‘Waste seam atlemote spostion Update tn it lines owned by the piping {ivand water permit ccfa opt) Study report | » Sve (These formats oe bes saved as Company formar Stl ond developed oly once) + Whing Assembly Equipment quipment sng calculations “ranemitel (hers oop” and electronic) sign SEgaBinentanhs te mn = + Equipment zing ealoutation intemal review | Font 7 Sie + Equipment sing clon review loockng (FL) * Wing + Sted equipment ist package tor | Tables + Mettungica consicerotions frat + Figures | Equipment dofe sheets Revision A (iis he + assombiy process dest. information issued to the mechan- 1 intemal review leat dept.for its input) nation « CaulpmtontEngncerbg Design Summary (€D5) + Tansmital (hard copy and electron (explains he sources of date used ond assump: | Font end | ~ Sivle ‘fons behing the eauibment sing) engineering |= Witting + Equipment data soot Revision & lent = | evelopment | «Tables ‘on Geoyoce |S Foues + Equipment dato sheets, Rev. ® Sgetormat” |“ Assombiy “ranemifol othe mechanical ep. fris input * Infernal review fodato thests ‘heviton + Update for endor comments and clrtictions ‘Trensmital (hers copr and electronic) + Process revew ofthe mechanical Sept EDS. Rev. barca Archive a Dioringury and purchase order ‘aronning a {Aching In general, a PFD shows the follow- ing details: * All process piping incuding major bypass or recirculation lines + Flow direction A. preliminary line size based on heat and matcrial balance (H&MB) conditions * Interconnecting lines to other units * Major equipment and —_ item numbers * Primary control instruments By comparison, PFDs typically do not show * Pipe specifications or line numbers + Piping or mechanical specialty items + Process control instrumentation be- yond the primary element and re- lated control valve * Minor process lines sVents and — drains, locks and bleeds + Process safety valves (PSVs) + Other piping and process details of a ‘minor nature In general, PFDs typically follow this familiar format: ‘Streams enter at the top left of the first page and streams leave on the right side of each sheet double + All equipment components are rep resented in sequence and connected by lines representing the piping © Major utilities are indicated in terms of where they are used in the process + Linco are called streams and cach one carries a unique number for reference. A diamond shape is typi- cally used © The stroam numbers correspond to the stream summary in the H&MB in conjunction with the PFD +A H&MB usually accompanies a PFD giving the stream composition, flowrate, physical properties and thermodynamic aroperties, * Each equipment item on the PFD has a unique equipment item num- ber, and a corresponding equipment block summarizing such parameters as dimensions, capacity, horsepower, material of construction, design pressure and design temperature * The equipment symbols identify the piece of equipment within reason and are typically understood by all process engineers # The PFD has a revision number and date to indicate its current status CHEMICAL ENGINEERING WW.CHECOM MARCH 2011 + Normal, minimum and maxi mum stream values are given for defined cases + Each H&MB represents a “case, whether it is normal operation, startof.run conditions, —end-of- run conditions, or a particular product ren Most, but not all of these character- isties are usually found on a PFD. A typical PFDis shown in Figure 2 with all of these attributes Developing the PFD PFDs can be developed using paper and a pencil, or they ean be developed using a process simulator. All major simulators 1ave PFD sereens where the simulation is pieced together in a PFD format. How a PFD is developed isn't critical, but, using a simulator can save the engineering team a lot of time. A PED js used to quickly under- stand a prozess, so it makes sense to minimize the sheets required to de- fine the process. As a first pass, try to use a single sheet to show the entire process. Fifteen to twenty equipment items can oceupy a single sheet. How- a7 fins ever, a complex tower with furnace, pump-arounds and a reheat and cooling train may be easier to un- derstand if broken down onto a few sheets, Try it and see. There is no single answer. Tfind it easy w use Microsoft Bxvel or Visio to develop a quick PFD. I do this whether a simulation will be used or not. It provides a useful template for piecing the process together. Developing the H&MB is a critical aspect of PFD development. Some en- gineers may argue that the H&MB is separate from the PFD, but I believe that a PFD without an H&MB is an complete document and of little ity for further process development. ‘The H&MB must ensble the pro- cess engineer to design the equipment and piping indicated. As such, it must go beyond the normal compositions, flows, temperatures and pressures, and provide useful information for ex: treme conditions that may be possible. ‘To develop a H&MB, map out the pos- sible scenarios to be considered, such as the following: * Normal case + Startup ease * Shutdown case + Startup run ease + End run ease «+ Product A, B through n cases * Runaway case ‘tpn! H&M i showa on the PPD (Figure2). The HMB typicallyislocated on the PFD or as a table following the PED drawings. These scenarios are required to identify materials of construction, extreme design conditions for equip- ment, stress conditions for piping and safety scenarios for PSV sizing. From these cases, the worst-case coincident conditions can be identified that drive the design. Following the principles in this article will give you the knowledge required to quickly develop a PFD. ‘he workhorse P&ID ‘The P&ID is a ubiquitous document in all E&C projeets, although the aero- nym is defined in several ways. Some define P&ID as the process and in- strumentation diagram, thers define it as the piping and instrumentation diagram, and the word drawing can be substituted for diagram. At the end of the day, the P&ID is a pivotal docu- ment for any E&C project. There is ongoing debate over whether a P&ID or a PED is the best document to use, and in general, the particular phase of the project will dictate whieh is best. Bott PFDs and P&IDs are required, each serving a particular need ata particular time. In general, a P&ID is more involved than a PFD and represents a more mature level of project development — therefore it will be more costly to develop. A PFD, with its attendant heat and material balance (H&MB), provides the relevant details about process flows and compositions to sup- port economic decisions made in the early front-end loading (FEL) phases. ‘The P&ID provides a summary of every plant component in sequential order. It contains the information and references necessary to define every en- gzineored piping item, equipment item or specialty item on the P&ID drawing. Ref. 2 provides an excellent summary ‘on how to develop P&1Ds. Because it is so complete, this dccument has become widely used and is considered the gold standard for P&ID development, ‘As shown in Table 2, the project phases are designed to limit the capi- tal commitment until a decision is made to proceed with or to cancel a project. The initial phases (Phases 1 and 2, called FEL 1 and FEL 2 in the table) are driven by process engineers because these are development stages where the question “what if?” is use- ful, In the first two phases, creative brainstorming is used to get all of the ideas out on the table. In Phase 3 (FEL 3), consideration of options is eomp ete and the project must close in on ¢ final solution and nnail down the seope to minimize fu- ture rework. At th's point, other disei- plines, such as piping, mechanical and instrument and electrical have input to the P&IDs to better define their discipline scope of work. The LPE's role must change from development of scope to maintaining the integrity of the approved scope. Bach subsequent phase of an E&C project commits more capital, so com- prehensive information must be gath- ered as inexpensively as possible. This is the key to using P&IDs most effee- 4B CHEMICALENGINEERING WhWW.CHE.COM MARCH 2011 tively. Once the process has been de- fined in the P&D, it is time to fill in the details required to make it work- able in practice, and to identify all components that must be purchased. Unlike PFDs, the P&ID also has a legal Lusis.” Specifically, OSHA 1910.119(eX6) requires updating and revalidation of process hazard analy- sis (PHA), Up-to-date P&IDs are a re. quirement of a PHA. P&IDs are continually upgraded, with more cetails added, as a project proceeds. Each issue is worth some discussion with key stakeholders. The issue shoul always contain all of the details knovin and available, but each issue should have at least a minimum level of detail for it to have value at that point. ‘As noted, Table 2 defines the P&ID revision name at each project phase. The various issues are explained below. ‘The first issue is usually called “Issue for Comment” or “Issue for In- formation.” It generally refleets the in- formation that is known to the process engineer, with only minimal input from other disciplines. Input from other dis- ciplines will come later, after the client has approve the basic process concept that is illustrated by the P&IDs. Once the client comments are in- corporated, further detail is added to provide all major information to the PAID. These will be signed off by the client and are typically called “Issued for Approval PIDs", This is the formal tomplate for the final process push. Process hydrau- lics calculations are used to size lines, pumps and valves. Much more detail is now available, and this set of P&IDs is ready for process to issue to the other disciplines for detailed engineering to begin. They are called “Issue for De- sign P&IDs (FD)? P&IDs developed for the IFD con- tainall ofthe information possible that does not require detailed engineering input, such as actual tie point details, and vendorsupplied equipment de- tails because the equipment is defined but not yet ordered. Piping runs are not yet determined, s0 decisions re- lated to pumps and control valves are not final. Vendor information on most equipment is not yet known either, Phase [Business oppor [Frontend | Frontend Frontend eng | Detailed eng | Consiruction tunity selection | loading? | leading 2 neering develop- | neering mont Major [Block flow [Process flow | PFD preliminar/PEID | PalDsissued or | PAlDa ksuedfor |PRID os bull documents |aiegrams | ctagrams ‘approval constustion Engineers [Process Process Process engineers, | All dscipines involved engineers [engineers _| some input by Ping, instrument, Mocrarical Paid [Owned by [Owned by | Owned by ‘Owned by project [Owned by prof | Owned by he process dept | process dept. | process dept. erpiping dept. Jectorsipng | elent pl Project% [Project — [Proiect% | Project % Project % Project Project = Complete |complele =05 | complete = 1.5 | complete = 5.0 complete =10 [complete =25 | complete = ‘00 Major —_|Pranning ___|Prenning | Panning Beecuting Becutng Executing “activities | Capital [Capital com- | Capital com- [Capital commitment | Capital commit- | Capital commit. | Capital com committed | mitment very | mitment very | smatt ment significant |menticrge | mitment huge smal small Soars Rf Piping and Instrumentation Diagram Documentation Criuria, PIP PICODI, Process dustry Prati April 2008, ‘These “holds” will be filled in when the project staffs up for detailed engineering. The P&IDs now are ready for pro- cess safety management (PSM) re- view. Some companies eall these “Issue for Hazop." Updating the P&IDs with the PSM items will produce the “Issue for Design 2” or Hazop set of P&IDs for use during detailed engineering. In many E&C organizations, cus- tody of the P&IDS moves from process to the project engineer or piping coordinator after the PSM stage. While there is some debate on this, point, my recommendation is that pro- cess engineers shculd remain owners of the P&ID for optimal Management of Change (MOC) results. ‘The amount of information con- tained in a given P&ID differs for dif- ferent client companies. Some P&IDs show a single equipment item and pe- ripherals, waile other P&IDs are more cluttered, sowing, for instance ten to twelve equipment items. Between these two extremes is a wide array of P&ID formats. As noted earlier, Ref 2 provides realistic guidelines for de- veloping P&IDs with an appropriate amount of detail Several items can help to make P&IDs moremanageable. Forinstance, every P&ID is made up of multiple drawing layers, each with a purpose. Resistant to corrosion Meag gear pumps in chemistry Mag Pump Systems A 8158 Oberg, Sutzerons welcomesrraas com: ‘yanutraag com Circle 24 on p. 62 oF go to adlinks.che.com/35063-24 While bearing in mind the particular pplication, the selection of diferent rraterals allows for complete protec- ton against corrosion. The design of the shats is based on many years of experiance with high temperatures ind pressure conditions, Incceased efficiency and dosing precision alow Maag gear pumps to operate more ecourately. Decisively longer opera tng tes are being achieved com. pared to with similar products, maag Boz Systems ‘SEE US AT INTERPHEX IN BOOTH #3070 Circle 13 on p. 62 oF go to adlinks.che.com/35063-13 CHEMICAL ENGINEERING WW.CHECOM MARCH 2011 (FIA = ENN i Programmable, Digital Dispensing & Mete PDS-100 FMI Pumps feature: One Moving Part Ceramic Internals 1% Accuracy Ideal for... Analytical Lab, Process, & Production ‘* Many Dispense & Metering Modes « Intuitive Set-up & Programming # Single, Dual Channel & "Pulseless Flow” * Eesy Integration with Process Controls * Dispense from 500 nL. « @ FLUID wereen, inc. 516-922-6050 / 800-223-3388 fins ‘These typically appear as different colors on a CAD computer screen, but print as black so that they appear to be a single layer. ‘The drawing can also include a hid- den “CAD design intent layer” that does nol print. This hiddeen layer ean be used! to explain the process intent of the P&ID and clarify any non-obvious design details. By way of example, T once designed a forced-feed reboiler. A particular butterfly valve (where the reboiler line entered the column bot- tom) was deleted during detailed en- gineering to save money. The intent was to delay vaporization until after the valve, to prevent fouling of the re- References 1, Lagu, J, Project cope The inundation afc ‘ess Cher, ig, Pebruary 900, p. 30-28. 2. Pipine and Instramentatior Diagram Dosu Insulation Cetera BIB ERGO cess I dustry Practices, Aprit 2008, 3. The Engincrs Tel Box — The Proses How Big (PPD maic Horton of som: assed at perenne ‘Bacompl procenow-ingred S65 boiler. When the design eoncept did not work during startap, I was called by the client and I explained the process necessity of the butterfly valve. A hid- den CAD layer cou'd have been used to convey the importance and intended use oF the valve to sve start up teu. Tam a firm believer in the LPE ap- proving all additions to P&IDs after the IFD issue, in order to control and centralize all revisions. Establishing the LPE as the central gatekeeper for all changes will ensure that con- sisteney is mainteined for all marks mace, and will prevent potentially conflicting and inappropriate design changes from being implemented by 4. Tnformit, 12 Process Flow Diagram (PFD): ‘cceesed at Rtpviwne informa convarteles) frtce appeal asa eseqhumezeriiad 5. Ping "Desens Com "race Flow 1m (PPD; acento inglecgnerscomerosnas 8. Webtgols — Proce Diagrams accesed at isthe dlnear aig comes ‘Shapes 4180306%8 eh pa other project participants. It also pro- vides an audit trail to document who ‘made what mark and for what reason, A log book should also accompany the P&IDs to capture who made a change to the drawing, and to describe vwlieat aud wy it wats tnade, Before the PSM stage, the log book is a simple log book. After the Hazop stage, this docu- ‘ment becomes the MOC log. . Edited by Suzanne Shelley Author dob C. Legaes, Je, PB, fas wore ‘hue 3) years of ‘expeience (imal: jagace EaadProcesEngtncercon) sin polymer cpemical and refi the He holds 2 BSChE. fom ‘The Lowel ‘Technological Im. ‘Sitae (noe the Universty of Maseachurels at Lowel od an MSChE. fom Ponnsyivae ila State University whee he les rate Be Rep Pe extensive caperonce leading te ta large ERC rroets and has worked fr Shell GheniES Co afs as Chemie Gorin the US solo Yar ical ah and Walui at wwwesdProcestingineseton Ultra-Clean The new cGMP-drum offers process reliability by validated cleaning procedures = Santa wooed esa ~ Bogy tase isn stein — FOR apsroed seo dastomer Seat. USP ies = Garp th FEA anc cGMP hc Maller GmbH - 78618 Fwinfeiden (Germany) Industrowea 5 - Phone + 4(0)7623/980-0 - Fax: 4(0)7623/960-60, Reompany of te Maller group Infoemuetler-gmbh.com -wwmullr-gmbh.com Circle 26 on p. 62 oF go to adlinks.che.com/35063-26 50 CHEMICAL ENGINEERING WWWCHE.COM MARCH 2011 SoundPLAN noise modeling software's detailed graphics and comprehensive report capaailities help you: | + Keep organized + Save money + Save time One model far all sizes eliminates hidden costs and expensive upgrades. Now featuring Google Earth interface ‘and full 3-D solid model view, Learn more SoundPLAN advantages. Call or click today. +1360 432 9840 (trang 28 Years as the wor ise mapping seoare. ‘Circle 34 on p. 62 oF go to adinks.cho.com/35063-34

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