Introduction to Process Plants

Process Plant • Characterized by Chemical Processes

– Different from power (including nuclear), propulsion,
Design etc.
– Hazards from both energy and substance release
– Substances and their temperature and pressure, etc.,
usually drives the selection of piping materials and
design ratings
• Petrochemical Plants have their own:
– Design standards
– Terminology
– Practices and
Copyright ©, 2009
William G. Beazley, PhD – Constraints
Photo: Air Products All Rights Reserved

Basic Components of a Raw Material Storage

Typical Chemical Process
(R. K. SINNOTT)
• Tanks, Hoppers, Piles, etc.

Tanks, Pumps,
Compressors, Reactors, Drums, Reflux, Tanks,
Warehouses, Furnaces, Towers, Strippers, Warehouses,
Hoppers, Exchangers,
Heaters, etc. Filters, Treaters, Baggers,
Piles, etc. Dryers, etc. etc. etc.
Crushers,
Mixers, etc.

Feed Preparation Reaction

(US Navy, Nasa, Transportation, (US Army, DOE, )
• Pumps, Compressors, Exchangers, Heaters, • Reactors, Furnaces, etc.
Crushers, Mixers, etc.

http://www.ih.navy.mil/Departments/ord/che-ext-tec-div/index.asp
http://www.tfhrc.gov///pubrds/05jan/02.htm
http://www.netl.doe.gov/technologies/coalpower/cctc/summaries/tampa/tampaedemo.html
http://www.npt.nuwc.navy.mil/facilities/QuietWater/default.htm http://www.pmcd.apgea.army.mil/multimediaviewer.aspx?id=585

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 Product Separation Product Purification
(US DOE) (US OSHA, DOT)
• Drums, Towers,
• Reflux, Strippers,
Filters, Dryers, etc.
Treaters, Sorters, etc.

http://www.nrel.gov/data/pix/searchpix.cgi?
http://www.greensboro-nc.gov/departments/Water/watersystem/treatment.htm http://iforms.osha-slc.gov/dts/osta/otm/otm_iv/otm_iv_2.html

Product Storage Waste Storage

(DOE, EPA, USGS)
• Tanks, Warehouses,
• Baggers,
• etc.

http://pubs.usgs.gov/gip/gw_ruralhomeowner/gw_ruralhomeowner_new.html
http://www.fedcenter.gov/_storage/Photos/176.jpg

http://www.tobyhanna.army.mil/about/certifications/environmental/rcra%20cleanup.htm

The Manufacture of Cement by the

Sales Portland Process
(US CDC)

Limestone,
Clay, etc.

http://www.msc.navy.mil/sealift/2005/September/katrina.htm http://www.cdc.gov/elcosh/docs/d0200/d000279/ilochap93.html

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 Parties to Plant Process Plant Client
Design • Funds the engineering and construction of the plant
(The 'PIPING GUIDE') • Generally supplies or approves the processes to be used
• Client wants a finished • Accepts the work performed
plant
– Business Case Primary
Concern
– Everyone Else is
Temporary
• Design Engineers
produce highly quality
assured product
definition data
• Construction Realizes
Design
Source:
The 'PIPING GUIDE'
http://www.pipingguide.com

The Project Engineer The Project Engineer

• Reviews the Design

• Formal point of contact with the client Basis of Plant
– Voice of the client inside the engineering organization • Enforces Client
– Usually “seals” design as professional engineer Requirements
•http://www.nps.gov/hfc/products/imi/imi-ser-class.htm
Responsible for completeness and correctness of work http://www.osha.gov/dcsp/partnerships/regional/region2/453_signing.html

The Project Engineer

Procured Materials and Services
• Items that has been obtained from vendor or
supplier
• Assistance or advice provided by a vendor
or supplier
• Obtained through a procurement process
• Result in a list of vendors and
subcontractors
• Plans and Schedules
Work
http://www.osha.gov/dcsp/partnerships/regional/region2/459_signing.html

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 Project Organization Project
Design
Groups and
Information
Flow
(Source: The
'PIPING GUIDE')

Source: The 'PIPING GUIDE'

http://www.pipingguide.com
http://www.pipingguide.com

Design Organizational Roles Design supervisor/Group leader

Project • Manages the documentation of in process
Data and approved engineering data
• Contacts the Project Engineer for any
Design approvals required
Checker
Supervisor
• Assigns work to designers at the appropriate
Designer time
Designer • Assures all data needed for work is
Designer available to designers
Designer

The Piping Designer Engineering Design Specifications

• Established basis for final plant design
• Responsible for correctness of his • Includes:
work – start-up procedures,
• Inform supervisor if questions arise – initial site selection information,
– general pre-commissioning guidelines,
• Recognize need for data required to – equipment testing procedures and acceptance
complete work methods
• Never contact the client directly – final process topology,
– material and energy balance information

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 Functional Equipment Characteristics Vendor-Proprietary Equipment
• Describe or specify: • Equipment whose performance is
guaranteed by the vendor.
–Functional requirements for the
equipment • Specified by equipment datasheet in
process design specifications
–Service provided to the process by
package.
the equipment
• Usually designed by first selecting a
–What equipment is supposed to do
vendor who performs testing and
sizing of the item

Supplier/Vendor Relationship Documentation

• Request the required information only
• All project management, design,
• Disclosing only necessary information to contractual, regulatory, and disposal
get the right data documents produced during the life
• Avoid: cycle of a process plant.
– Disclosing competition • Has versions and releases that must
– Telling vendor he’ll get the order be managed.
– Gratuities and never demand them (lunch) • Includes all documentation retained
– Ordering to get information then cancel past the end of the plant life cycle

Operations Documents Handover

• Covers all the many different phases and
• Transfer of responsibility for the plant
aspects of plant operation
– Construction team to commissioning team
• Documentation necessary to run the
– Commissioning team to operating team
plant safely:
• Involves transfer of all supporting
– Procedure to start up and shut down the
plant documentation
– Parameters and settings for process
equipment and controls

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 Activity Model of the Oil and Gas Common Status Terms
Production Facility Life-cycle
(ISO 15926) • As-built: Process plant's actual physical
and functional aspects at a specific point
Produce Conceptual
Process Design
Produce Detailed
Process Design
Commission
Plant
Operate Plant
Decommission
Plant
in time
As-approved: Product data provide to
Produce Conceptual
Produce Detailed Construct Plant Maintain Plant Demolish Plant
and approved by client
Engineering Design
(Front End)
Engineering Design Pre-Commission and Equipment and Restore Site
As-specified: Approved data provide to
engineer by client
Suppliers and
Fabricators
Procure and Control Equipment, Material and Services
As-released: Product data officially
provided to anyone
http://www.tc184-sc4.org/About_TC184-SC4/About_SC4_Standards/

Construction Release Finalized Construction Documents

• All documentation related to the erection,
• All data needed to realize the plant commissioning and operation
– Build, • Includes:
– Commission, – As-built reports,
– Train to operate, maintain – Equipment certification,
– Nameplate information of installed equipment,
• Approved for release by engineering for
– Operating manuals,
construction – Testing procedures,
• Stamped by a registered professional – Field changes, and
engineer – Photos of as-built units, modules and plant

Plant Commissioning Maintenance

• Required before
client handover
• Proven operational
through specific
procedures
– Confirm Staff
Skills
– Verify product
data
– Test equipment
• Equipment
Commissioning
Procedures - Step-
by-step explanation
of start-up actions
required to
commission
equipment in the
http://www.usaid.gov/iraq/photogallery/gallery_8/capconstr1_06.html plant http://flickr.com/photos/coolnewspics/244371213/in/dateposted/

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 Maintenance Shutdown/Decommissioning
• Shutting down the
plant
• Preserving it for
later
commissioning or
demolition
• May not include
site remediation
http://splash.metrokc.gov/wtd/southplant/index.htm

http://www1.usaid.gov/iraq/photogallery/gallery_39/photo18.html http://www.nrc.gov/reading-rm/doc-collections/fact-sheets/decommissioning.html
http://www.srs.gov/general/busiops/tech-transfer/plant.htm http://www.lm.doe.gov/land/sites/oh/fernald_orig/VImages/PhotoTour/1998/Dec98/Plt6c.htm
http://www.eere.energy.gov/industry/bestpractices/energymatters/full_issue.cfm/volume=37 http://www-als.lbl.gov/als/als_news/news_archive/vol.240_042804.html

Project Schedule
• Duration
• Start Date
• Critical Path Questions
– Sequence of Tasks
such that if any is late
the project is late.
– Can be more than one

http://www.coconino.az.gov/cji.aspx?id=383

PISTEP Process Plant Engineering Processes

Production Output
• Materials or energy to be sold or
traded
• Result of processing raw material(s)
(Production Input)
• Produced according to a scheduled
delivery time, grade, and quantity of
product to be produced
Source: EPISTLE Process Industries Data Handover Guide - Part 1
http://www.uspi.nl/projects/Joint_Projects/fr_joint_projects.html

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 Course Outline
• Part 1 Pipe Lifecycle
• Part 2 Pipe Fluid Flow & Control
• Part 3 Plant Equipment
• Part 4 Pipe Structural Design
• Part 5 Project Practices & Management
• Part 6 Project