Lecture 2

Chemical Process Engineering

Engineering 14 – July – 2022
In
Oil & Gas Ahmed Mohamed Shafik Ali Attia

Industry Process & Operations Engineering Expert

[email protected]
 Safety Moment
Thursday 14th of July 2022
 • Introduction.
• Process Engineering Documents.
• Process Engineering Activities.
Objective • Process Engineering Tools.
• Roles and Responsibilities
• Process Performance & Efficiency Monitoring
• Process Design & MOC – Management of Change.
• Process Optimization
 • In chemical engineering, process engineering is an assessment of
the choice and sequence of units that will allow a material to
undergo a desired physical and/or chemical transformation.

• Process engineering is the central focus of chemical engineering,

and there is no doubt that it can provide a very high level of
integration between all the components of that field.
Introduction
• The design of a process is not limited to the design of new
facilities but may also include modifying or expanding facilities
that already exist.

• There are many stages to the design process, from

conceptualization (the idea) to eventual realization (a live
industry).
Process Engineering Documents
Process Engineering Documents
Aim of Process design documents:

• Define clearly the design.

• Ensure that the design components fit together.
• Communicate ideas and plans to other engineers involved with the
design, external regulatory agencies, equipment vendors, and
construction contractors.
 Process Engineering Documents
Key Process design documents include:
• Design Basis / Specifications.
• Drawings: Block flow diagrams (BFD), Utility flow diagram (UFD), Process flow diagrams (PFD), Piping and instrumentation
diagrams (P&ID).
• Process Description.
• Sizing calculation reports.
• Process Control Narrative.
• Process Safeguarding philosophy.
• Alarm Management philosophy.
• Process simulation report.
• Chemicals summary and consumption report.
• Pressure transient analysis report.
• Process Safety Studies.

Note: There are many other process documents that are derived from the above key documents.
 Process Engineering Documents
Design Basis / Specifications:

• The "Process Design Basis" is a structured document and is developed sequentially for ease of developing other process engineering
deliverables for the project.

• It includes:
• PROCESS DESCRIPTION
• PROJECT SCOPE
• DESIGN PHILOSOPHY
• DESIGN CRITERIA
• CODES & STANDARDS
 Process Engineering Documents
PROCESS DESIGN BASIS MAY INCLUDE BASIS FOR, BUT NOT BE LIMITED TO:

• DESIGN PRESSURE • DRAIN PHILOSOPHY

• DESIGN TEMPERATURE • MATERIAL & CORROSION PHILOSOPHY
• DESIGN OR MAXIMUM VELOCITIES FOR PIPING / PIPELINES • UTILITY REQUIREMENT & BATTERY LIMIT
CONDITIONS FOR ISBL
• NPSHA (PUMP HYDRAULICS)
• FOULING FACTORS (HEAT EXCHANGERS) • CHEMICAL DOSING REQUIREMENT

• NOZZLE MOMENTUM VALUES (VESSELS / SEPARATORS) • FIRE, SMOKE & GAS DETECTION PHILOSOPHY

• PIPING ROUGHNESS VALUES • INSULATION REQUIREMENT.

• OPERATION, CONTROL & SAFEGUARDING PHILOSOPHY

• ISOLATION PHILOSOPHY
Rotating

Process Engineering Documents

Symbolog y
Before we touch the drawings, we
need to understand some of the
main items which will be plotted
on the process drawings:
Process Engineering Documents

Symbolog y
Process Engineering Documents

Symbolog y
Vessels & Tanks

Process Engineering Documents

Symbolog y
Process Engineering Documents
Block Flow Diagrams (BFD):

• Those are Very simple diagrams composed of Blocks and lines indicating major
material or energy flows.
• To make clear, easy to understand, and unambiguous block flow diagrams - several
rules should be followed:

1. Unit operations such as mixers, separators, reactors, distillation columns and

heat exchangers are usually denoted by a simple block or rectangle.
2. Groups of unit operations may be noted by a single block or rectangle.
Process Engineering Documents
Block Flow Diagrams (BFD):

• Process flow streams flowing into and out of the blocks are
represented by neatly drawn straight lines. These lines should
either be horizontal or vertical.
• The direction of flow of each of the process flow streams
must be clearly indicated by arrows.
• Flow streams should be numbered sequentially in a logical
order.
• Unit operations (i.e., blocks) should be labeled.
 Process Engineering Documents
BFD Sample

Acrylic Acid Production - BFD

 Process Engineering
Documents
Process Flow Diag rams (PFD):

• Typically, more complex diagrams of major unit operations as well as flow

lines.
• They usually include:
1. Material / Energy balance (HMB).
2. Stream compositions, and stream and equipment pressures and temperatures.
3. Piping Information (class, line numbers).
4. Minor bypass lines
5. Isolation and shutoff valves
6. Maintenance vents and drains
7. Relief and safety valve
8. Code class information
Process Engineering Documents
Process Flow
Diag rams (PFD)
Process Engineering Documents
Piping and Instrumentation Diag rams (P&ID):
• Instrumentation • Interconnections references
• Mechanical equipment with names • Control inputs and outputs, interlocks
and numbers • Interfaces for class changes
• All valves • Seismic category
• Process piping, sizes • Quality level
• Miscellaneous - vents, drains, special • Annunciation inputs
fittings, sampling lines, reducers, • Computer control system input
increasers and swaggers • Vendor and contractor interfaces
• Permanent start-up and flush lines • Identification of components and subsystems
• Flow directions delivered by others
• Intended physical sequence of the equipment
Process Engineering Documents
Piping and
Instrumentation
Diagrams (P&ID)
Process Engineering Documents

Process Control Narrative:

• Control narratives can be a subset of a design specification. For smaller

systems sometimes supplying just a control narrative will provide all the
information required to configure the control system.
• Typically Control Narratives contain definitions of all control loops with
important details like range, description, alarms, graphic depiction, interlocks,
automated logic, etc.
• It tailors our deliverables to match the size and scope of the project thus
saving you money.
Process Engineering Activities
 Process engineering activities can be divided into the
following disciplines:
1- Process design:
Process • Synthesis of energy recovery networks
• Synthesis of distillation systems
Engineering • Synthesis of reactor networks

Activities • Hierarchical decomposition flow sheets

• Superstructure optimization
• Design multiproduct plants.
 2- Process control:

• Model predictive control.

Process • Robust control.

Engineering • Nonlinear control.

• Statistical process control.
Activities • Process monitoring.
• Thermodynamics-based control.
 3- Process operations:

Process • Scheduling process networks.

• Planning and optimization.
Engineering • Data reconciliation & analysis.

Activities • Real-time optimization.

• Troubleshooting/fault diagnosis.
Process Engineering Tools
 • Process engineering involves utilization of multiple
tools and methods.
• Depending on the exact nature of the system,
processes need to be simulated and modeled using
mathematics and computer science.
• Processes where phase change and phase equilibrium
Process are relevant require analysis using the principles and
laws of thermodynamics to quantify changes in energy
Engineering and efficiency.
• In contrast, processes that focus on the flow of
material and energy as they approach equilibrium are
best analyzed using the disciplines of fluid mechanics
and transport phenomena.
 • Operations Daily reports.
• Process Data Analytics using simulation software
such as ASPEN to find out the break-even point.
• Lab analysis for all streams.
• Optimization tools such as
• Linear Programming.
Process • Nonlinear programming (NLP).

Engineering • Optimization of differential-algebraic equations

(DAEs).

Key Tools • Mixed-integer nonlinear programming (MINLP).

• Sequential Quadrant Programming (SQP).
• Net present value, marginal sales, marginal cost,
return on investment of the industrial plant after
the analysis of the heat and mass transfer of the
plant.
Process Performance & Efficiency Monitoring
 Why are Plant Performance and Efficiency of such
importance?
• It should be remembered that most chemical products
sold in the commercial sector do not have faces (e.g.,
polyethylene, propane, LPG, etc.) and therefore
Process customers are only concerned with their quality, price,
and availability whenever making a selection.
Engineering • When it comes to being competitive in the hydrocarbon
Activities industry, ultimately what it boils down to is offering
what the competitor cannot offer cheaper AND
better, AND faster than what the company can supply.
• From raw materials to refined chemicals and final
consumer products, the "Product Family Tree of the
Chemical Industry" shows the production process.
 Process Units Classification
Any Process Plant Consists of

• Unit Operations:
This is the type of activities and equipment that are required in the plant to produce the specific products
as designed (i.e. mechanical unit operations, fluid flow, heat transfer, mass transfer, etc…)
NO REACTION
• Unit Processes:
This is the specific chemical processes involved in the unit operations to produce the specific products as
designed (i.e. oxidation, hydrogenation, desulphurization,…etc.)
REACTION
Basic Requirements to Monitor Plant Performance

• Have detailed knowledge of the various operations and processes

involved
• Know the design conditions and specifications
• Have a reliable and up-to-date monitoring system
• Have the ability to diagnose the root causes of performance degradation
• Anticipate the need for performance maintenance
• Determine the economic impact of performance degradation
 What Triggers the need for Monitoring?

• Due to significant changes in the recent past due to increased cost of energy
and increasingly stringent environmental regulations, the Oil & Gas
industry is forced to look seriously at modifications to:

1. Plant design.
2. Plant operating conditions.
• This will enable the improvement of efficiency and profitability.
 Aim of Performance Monitoring

• Although consumer final products (Y) change or are being replaced by better ones in the course of time, still, raw materials
(X), basic and intermediate products do not change.

• The only real variable is availability which is a mirror image of plant performance & efficiency.

• This highlight the need for better utilization of existing feedstocks and increased R&D efforts to improve the efficiency of
current operations and processes.

• It worth to mention that not only the products are subjected to change by time, also the production processes have a
lifetime and that’s why brainstorming should be continuously done.
What is the value-added by Plant Surveillance?
 Components of the Process Plant
• Any chemical plant started with a vision (“bright idea”).

• This initial idea was then tested and proven through R&D in the laboratory, and further tested on pilot plant modeling before actual implementation on
an industrial scale for actual economical production of the desired product.

• At the center of an HC processing plant is the chemical reaction that produces the desired product.

• This reaction takes place on the surface of a suitable catalyst which enhances the quality and the rate of production.

• This reaction determines the reactor (type, shape, size. Etc..) that is required to hold the catalyst and provide the space and environment for the chemical
reaction to take place on the active surface.

• The reactor and catalyst properties determine the qualities of the required feedstock (pre-treatment, filtration, mixing,…etc.) as well as the product workup
(rectification, crystallization, drying, etc…), waste disposal, tank farms, energy supplies, safety, and environmental systems,..etc.

• Finally, the chemical industrial process that can run through its whole production cycle without the involvement of people, is still to be discovered. (Thanks
To The Great Merciful Allah to secure our jobs )
 Performance Monitoring

• Performance Monitoring is a management tool to evaluate the basic Operating Objective of any
process, namely: To maximize the profitable production of the specified products.

• Performance monitoring can be applied to any discipline or area of the process including:

1. Personnel and working procedures.

2. Processes and Operating procedures.

3. Equipment and maintenance procedures.

4. Strategies and research procedures.

 Operating Procedures

• Operating procedures are compiled during design and start up of the plant for which the
process yields maximum profits, within the constraints of products quality, constitute the
best set of operator objectives.

• However, the plant operators often cannot specify precise operating objectives, particularly
economic ones.

• Important that management, once they have decided to do performance monitoring or

optimization, include the complete process and not only the individual parts or equipment.
 What Influences the Operating Objectives?

Operating objectives may change due to:

1. Change in feedstock quality or quantity

2. Debottlenecking of existing processes

3. New technology that becomes available

4. Change in the final product range

5. Economic survival of the company

6. Other market requirements.

 Performance Monitoring Building Blocks

Performance monitoring involves the following activities:

1. Define the critical process variables.

2. Assign priority to each of these variables based on the impact on production.

3. Identify key performance indices to meet the plant objectives.

4. Set values of baseline (operating envelope) and thresholds (Alarms & Trips) on each of these variables to be monitored.

5. Define the frequency of monitoring, hourly/weekly/monthly…, based on the priority of the variable.

6. Assess the gathered data and compile a list of bad actors / worst-performing activities which need immediate action to rectify.

7. Ensure the precision of the applied control systems.

8. Ensure the precision of the process constraints.

9. Ensure optimum knowledge of the processing system to enable linking possible causes of disturbance/failures.
Plant Surveillance Framework
Plant Surveillance - Process Overview
 Plant Surveillance – COP’s
Critical Operating Parameters
• When you develop a surveillance plan, you have to list the key process conditions that will have an
impact on the process.
• Moreover, you will refine the list of process conditions and identify what are called COPs – Critical
Operating Parameters.
• A process Condition is qualified to be a COP if:
1. It is a Process condition (e.g., flow rate, temperature) that if limits are exceeded can lead to a serious equipment
failure leading to fatality.
2. There is no Automatic protection system, and the Operator’s manual intervention is the final control to prevent
serious consequences.
• COPs are required to have alarms, with procedures clearly listing the operator actions in response to
the alarms and handed over to Operations for close observation.
• COPs are sometimes called CPP (Critical Process Parameters).
Process Design
 • In chemical engineering, process design is the
choice and sequencing of units for desired physical
and/or chemical transformation of materials.

Introduction • Once again, please keep in mind that the design

starts at a conceptual level and ultimately ends in the
form of fabrication and construction plans.
 Career Definition of a Process Design Engineer

• Specialize in directing and implementing capital projects for companies.

• Design processes to meet budgets and project goals.
• Oversee continuous improvement efforts for companies.
• Examining and approving design orders, evaluating changes, and drawing releases.
• Collaborating with operations on design and packaging specification; and creating
front-end packages designed to control project expenses.
• Evaluate vendor bids, services, and equipment bid requirements, and generate
procurement recommendations.
• They may also devise methods to reduce costs, implement lean manufacturing practices,
and determine root causes of issues by utilizing statistical analyses.
 Key Tools for Process Design Engineer

1. Knowledge.
2. Experience.
3. Codes, standards, and specifications.
4. Simulation.
5. Flexibility.
6. Communication Skills.
7. Willing To Learn.
 Standards
General Vessels - Tanks
AGS     American Gas Society API     American Petroleum Institute
ANSI     American National Standards Institute ASME     American Society of Mechanical Engineers
BSI     British Standards Institute AWWA     American Water Works Association
CGSB     Canadian General Standards Board NBBI     National Bureau of Boiler & Pressure Vessel Inspectors
CSA     Canadian Standards Association
Heat Transfer Equipment
ISO    International Organization for Standardization
NBS     National Bureau of Standards API     American Petroleum Institute
ISA     Instrument Society of America CTI     Cooling Tower Institute
TEMA     Tubular Exchanger Manufacturers Association
Safety
ANSI     American National Standard Institute Rotating Equipment
EPA     Environment Protection Agency ANSI     American National Standard Institute
NBFU     National Board of Fire Underwriters API     American Petroleum Institute
NFPA     National Fire Protection Association AWWA     American Water Works Association
OSHA     Occupational Safety and Health Administration DEMA     Diesel Engine Manufacturers Association
CCPS Center of Chemicals and Process Safety MPTA     Mechanical Power Transmission Association
 Standards
Process Equipment
AWWA     American Water Works Association
GPSA     Gas Processor Suppliers Association
API     American Petroleum Institute
ASME     American Society of Mechanical Engineers
ASTM     American Society for Testing and Materials
ANSI     American National Standards Institute
NBBI     National Bureau of Boiler and Pressure Vessel Inspectors
CMAA     Crane Equipment Manufacturers Association of America

Material Handling
CEMA     Conveyor Equipment Manufacturers Association
CMAA    Crane Equipment Manufacturers Association of America
CSA     Canadian Standards Association
FEM     Fédération Européenne de la Manutention (Rules for the Design of Hoisting Appliances)
MHI     Material Handling Institute
RMA     Rubber Manufacturers Association
 Standards - API
API
Publ. 941    Steel for Hydrogen Service at Elevated Temperature and Pressures in Petroleum Refineries and Petrochemical Plants
Publ. 2009    Safe Welding and Cutting Practices in Refineries
Publ. 2015    Safe Entry and Cleaning of Petroleum Storage Tanks
Publ. 2021    Fighting Fires In and Around Flammable and Combustible Liquid Atmosphere Storage Tanks
Publ. 2030    Guidelines for Applications of Water Spray Systems for Fire Protection in the Petroleum Industry
Publ. 2517    Evaporation Loss from External Floating-Roof Tanks
Publ. 2557    Vapour Collection and Control Options for Storage and Transfer Operations in the Petroleum Industry
RP 14C    Analysis, Design, Installation and Testing of Basic Surface Safety Systems on Offshore Platforms
RP 14F    Design and Installation of Offshore Platforms
RP 14G    Fire Prevention and Control on Open Type Offshore Production Platforms
RP  30    Calculation for Heater Tube Thickness in Petroleum Refineries
RP 500    Recommended Practice for Classification of Locations for Electrical Installations at Petroleum Facilities
 Standards - API
RP 520    Sizing, Selection, and Installation of Pressure Delivery Devices in Refineries.  Parts 1 and 2
RP 521    Guide for Pressure Delivery and Depressuring Systems
RP 526    Flanged Steel Safety Relief Valves
RP 551    Process Measurement Instrumentation
RP 560    Fired Heater for General Refinery Services
RP 651    Cathodic Protection of Aboveground Petroleum Storage Tanks
RP 652    Lining of Aboveground Storage Tank Bottoms
RP 682    Shaft Sealing System for Centrifugal and Rotary Pumps
RP 1110    Pressure Testing of Liquid Petroleum Pipelines
RP 2001    Fire Protection in Refineries
RP 2003    Protection Against Ignitions Arising out of Static, Lighting and Stray Currents
Spec. 5L    Line Pipe
Spec. 6D    Pipeline Valves
Spec. 6FA    Fire Test for Valves
Spec. 12D    Field Welded Tanks for Storage of Production Liquids
Spec. 12F    Shop Welded Tanks for Storage of Production Liquids
Spec. 12J    Oil and Gas Separators
Spec. 12K    Indirect Type Oil Field Heaters
Spec. 12L    Specification for Vertical and Horizontal Emulsion Treaters
Spec. 12P    Specification for Fibreglass Reinforced Plastic Tanks
 Standards - API
Std. 510    Pressure Vessel Inspection Code
Std. 526    Flanged Steel Safety - Relief Valves
Std. 527    Seat Tightness of Pressure Relief Valves
Std. 594    Wafer and Wafer-Lug Check Valves
Std. 598    Valve Inspection and Testing
Std. 599    Metal Plug Valves - Flanged and Butt-Welding Ends
Std. 600    Steel Gate Valves - Flanged and Butt-Welding Ends
Std. 602    Compact Steel Gate Valves - Flanged Threaded, Welding, and Extended-Body Ends
Std. 603    Class 150, Cast, Corrosion-Resistant, Flanged-End Gate Valves
Std. 607    Fire Test for Soft-Seated Quarter-Turn Valves
Std. 608    Metal Ball Valves - Flanged and Butt-Welding Ends
Std. 609    Lug - and Wafer - Type Butterfly Valves
Std. 610    Centrifugal Pumps For Petroleum, Heavy Duty Chemical and Gas Industry Services
Std. 611    General Purpose Steam Turbines for Refinery Services
Std. 612    Special Purpose Steam Turbines for Refinery Services
Std. 613    Special Purpose Gear Units for Refinery Services
Std. 614    Lubrication, Shaft-Sealing and Control Oil Systems for Special Purpose Application
Std. 615    Sound Control of Mechanical Equipment for Refinery Services
Std. 616    Gas Turbines for Refinery Services
Std. 617    Centrifugal Compressors for General Refinery Services
Std. 618    Reciprocating Compressors for General Refinery Services
Std. 619    Rotary-Type Positive Displacement Compressors for General Refinery Services
Std. 620    Design and Construction of Large, Welded, Low Pressure Storage Tanks
Std. 630    Tube and Header Dimensions for Fired Heaters for Refinery Service
Std. 650    Welded Steel Tanks for Oil Storage
Std. 660    Heat Exchangers for General Refinery Service
Std. 661    Air-Cooled Heat Exchangers for General Refinery Service
Std. 670    Vibrations, Axial Position, and Bearing-Temperature Monitoring System
Std. 671    Special Purpose Coupling for Refinery Service
Std. 674    Positive Displacement Pumps - Reciprocating
Std. 675    Positive Displacement Pumps - Controlled Volume
Std. 676    Positive Displacement Pumps - Rotary
Std. 677    General Purpose Gear Units for Refineries Services
Std. 678    Accelerometer-Base Vibration Monitoring System
Std. 1104    Welding Pipelines and Related Facilities
Std. 2000    Venting Atmospheric and Low-Pressure Storage Tanks - Non-Refrigerated and Refrigerated
Std. 2530    Measurement Standard Chapter 14, Natural Gas
 Standards - ANSI
ANSI American National Standards Institute
A1 Liquefied Petroleum Gas System
A13.1     Scheme for Identification of Piping Systems
B.16.1     Cast Iron Pipe Flanges and Flanged Fittings, Class 25, 125, 250, and 800
B.16.5     Pipe Flanges and Fittings
B16.9     Steel Buttwelding Fittings
B31     Corrosion Control for B31.1
B31.1     Power Piping
B31.2     Fuel Gas Piping
B31.3     Chemical Plant and Petroleum Refinery Piping
B31.4     Liquid Petroleum Transportation Piping Systems
B31.5     Refrigeration Piping
B31.8     Gas Transmission and Distribution Systems (1982)
B31.11     Slurry Transportation Piping Systems
B36.10     Welded and Seamless Wrought Pipe
B36.19     Stainless Steel Pipe
B73.1M     Horizontal, End Suction Centrifugal Pumps
B73.2M    Vertical In-line Centrifugal Pumps
B133.2     Basic Gas Turbine
B133.4     Gas Turbine Control and Protection Systems
LOS4C1     Flushing and Cleaning Gas Turbine Gen. Lube Systems
58     Standard for the Storage and Hauling of Liquefied Petroleum Gas
MC96.1     Temperature Measurement Thermocouples
 Standards - ASME &NFPA
ASME NFPA
Boiler and Pressure Vessel Code 11     Low Expansion Foam Systems
11A     Medium and High Expansion Foam Systems
Section  I     Power Boilers
12     Carbon Dioxide Extinguishing Systems
Section  II     Materials Specifications
12A     Halon 1301 Fire Extinguishing Systems
Part A      Ferrous Materials 12B     Halon 1211 Fire Extinguishing Systems
Part B     Non-Ferrous Materials 13     Installation of Sprinkler Systems
Part C     Welding Rods, Electrodes and Filler Metal 14     Stand Pipe and Hose Systems
Part D     Properties 15     Water Spray Fixed Systems
Section  IV     Heating Boilers 16     Deluge Foam-Water Sprinkler and Spray Systems
Section  V     Non-Destructive Examination 17     Dry Chemical Extinguishing Systems
20     Centrifugal Fire Pumps
Section  VIII         Pressure Vessels -     Division 1 / Division 2
22     Water Tanks for Private Fire Protection
Section  IX     Welding and Brazing Qualifications 24     Installation of Private Fire Service Mains and Their Appurtenances
Section  X     Fibreglass-Reinforced Plastic Pressure Vessels 25     Water Based Fire Protection Systems
Std.  120     Gas Turbine Generator Lube Oil Systems 37     Stationary Combustion Engines and Gas Turbines
Performance Test Codes 51     Oxygen-Fuel Gas Systems for Welding
PTC  1     General Instructions 54     National Fuel Gas Code
PTC  2     Definitions and Values CUA 58    LP Gas Storage, Use
59     LP Gases at Utility Gas Plants
PTC  4.1     Steam Generating Units
59A     Storage and Handling of Liquefied Natural Gas
PTC  8.2     Centrifugal Pumps
82     Incinerators, Waste and Linen Handling Systems and Equipment
PTC  9     Displacement Compressors, Vacuum Pumps and Blowers 214     Water Cooling Towers
PTC  10     Compressors and Exhausters 291     Fire Flow Testing and Marking of Hydrants
PTC  22     Gas Turbine Power Plants 655     Prevention of Sulphur Fires and Explosions
Steps of Process Design
 I have an idea, It’s reasonable and will get us a great benefit. Let’s
GO AHEAD & IMPLEMENT IT NOW!!!!!!!!!!!!!!!!!!!!!!!!
Be Patient!!!!!!!!!!!!!!!!

Yes, we need to implement opportunities that will enable us to

gain more benefits, but we need to do it properly. Therefore, let’s
see how to do it properly.
 MOC – Management of Change
• Management of Change (MOC) is the proper pathway to study thoroughly
any potential opportunity in order to make sure that the idea is qualified to be:

1. Technically feasible
2. Costly effective.
3. Safely to be implemented and has no hazardous consequences to the
facility.
4. Concurred by management.
5. Lined up with the company vision.
 Supporting Calls for MOC
• OHSAS 18001: Explicit requirements for management of change were added into section
4.3.1 of OHSAS 18001 in the 2007 revision of the standard.
• Occupational Health & Safety Series - UK

• ANSI/AIHA: U.S. Occupational Health and Safety Management System standard —

ANSI/AIHA Z10-2005.
• ANSI – American National Standards Institute - US
• AIHA – American Industrial Hygiene Association - US

• EU Council Directive: MOC is an explicit requirement for safety management systems

implemented to comply with the Seveso II Directive (see Annex III of EU Council
Directive 96/82/EC).
 What are MOC applications?

For purposes of MOC, the changes that need to be addressed include:

1. Organizational changes (e.g., personnel or staffing changes)

2. Activity changes (e.g., changes to processes, equipment,
infrastructure, software)
3. Material changes (e.g., new chemicals, packaging)
4. Changes to the management system (e.g., procedures)
 Why is the management of change so important?

• To quote the U.S. Chemical Safety and Hazard Investigation Board (CSB), “In
industry, as elsewhere, change often brings prog ress. But it can also
increase risks that, if not properly managed, create conditions that may
lead to injuries, property damage or even death .” (from CSB press release
announcing its 8/28/2001 Safety Bulletin concerning “Management of
Change”).

• Ineffective management of change is one of the major contributing factors in

many of the incident investigations conducted by the CSB. To check it out, go
to the CSB website at http://www.csb.gov and enter “management of
change” as your search term at the link.
 Where / When MOC is required?

• MOC reviews are conventionally done in operating plants and

increasingly done throughout the process life cycle at company offices
that are involved with capital project design and planning.

• MOC reviews should be done for “changes” – not for replacements-in-

kind (RIKs) or in other terms Like to Like replacement.
 Who is responsible to do the MOC?
1. First of all, anyone in the organization who got an idea should be able to generate a
change request.
2. Then a Qualified engineer, normally independent of the MOC originator, reviews
the request to determine if any potentially adverse risk impacts could result from the
change, and may suggest additional measures to manage risk.
3. Based on the review, the change is either authorized for execution, amended, or
rejected.
• Often, final approval for implementing the change comes from another designated individual,
independent of the review team.
• A wide variety of personnel are normally involved in making the change, notifying or training
potentially affected employees, and updating documents affected by the change.
 What are the types of MOCs?
1. Temporary MOCs: This type is covering the temporary changes which are required to be in place
for a limited period of time (up to 6 months and subjected to extension with management approval
for 1 more time then if further extension is still required and the implemented solution has proven
as a safe option so it will be converted into a permanent MOC.

2. Permanent MOCs: Changes that are required to be in place permanently.

3. Emergency MOCs: Changes that are required to be implemented within a very short period of
time (48 hours) to avoid severe impact on health, environment, business, or reputation. After
implementation, they should be furtherly studied to ensure their adequacy to be kept permanently.
MOC Life Cycle
 MOC Report Ingredients
• Organizations usually have written procedures detailing how MOC will be implemented.
• The MOC feasibility report will include the following sections:
Process Optimization
Vision of Optimization in Chemical Engineering

• The optimization involves the application of mathematical techniques & tools to find
out the best possible solution from several available alternatives.
• Maximum ROI – Return On Investment
• Higher productivity @ lowest applicable cost.
• Eliminate losses
• Utilize lower-cost feedstock @ acceptable quality.
• Maximize the operating capacity of process equipment
• Design & operate the plant @ the most optimum condition - max production rate
• Max profit, min waste generation & impact on environment
 Optimization – Definition

• Origin: Latin word “ Optimus” means “best”.

• Optimization: is the science of making the best possible decisions

• By performing optimization, we aim to obtain the best result

under given circumstances
Why do we need to run Optimization studies?

1) Improve the process to realize optimum system potential.

2) Attain new or most efficient designs, maximize profits, reduce the cost of production, minimize losses & impact
to an event.

3) Utilize feedstock, and energy, utilizing in the most efficient way (e.g., Heat Integration).

4) Reduce waste generation and minimize the environmental impact.

5) Determine the most desirable operating conditions and safe operation.

6) Meet product specification and max profit.

 Optimization Benefits
• Improved plant performance such as
• Yield
• Availability
• Reduce energy consumption
• Reduce maintenance cost
• Reduce failure in equipment
• Minimize the unplanned shutdown

• Example: To Optimize a distillation column performance, we will consider Feed

tray location, Reflux ratio, and Reboiler duty.
 Optimization – Examples
• Design of HEX network (Heat Integration).

• Real time optimization of a distillation column.

• Model predictive control.

• Operations planning & scheduling.

• Pipeline sizing, Reactor sizing, Distillation column (CAPEX/OPEX).

• Predictive Maintenance (Machine Learning Applications).

 Optimization Framework
• All optimization problems are stated in some standard form.

• You have to identify the essential elements of a given problem and translate them into a prescribed mathematical form.

• Requirements for application of optimization problem:

1. The design variables.

2. The constraints.

3. The objective (Target) function (Max / Min).

4. The process model.

Optimization Framework – Design Variables

You need to know the design variables that affect the system.

• Example: reactor temp, feed rate, No. of trays In the column, reflux ratio, Batch time and reactor yield.

• A practical problem may involve many design variables

• Some of these may be highly sensitive and heavily influence the process being optimized. Choose these as design variables
and others (not so sensitive variables) may be kept constant.

Note: If all the design variables are fixed, there is No scope for optimization.

Thus, one or more variables must be relaxed so that the system becomes an Under Determined System which has at least principle
infinite no. of SOLUTIONS.
 Optimization Framework – Objective Function

A suitable objective function (cost function) is defined in terms of design variables and often price parameters.

The objective function may be technical or economic, which needs to be either maximum or minimum

 Examples of economic objectives:-

1. Max profit.
2. Minimize the cost of production.
 Examples of technical objectives:-
1. Maximize reactor yield.
2. Minimize the size of equipment.
3. Minimize environmental impact
Note:- technical objectives (Target) are ultimately related to economics

In a practical process plant, there would be multi-objective functions to be optimized in one case only, therefore, there are more than one
objective functions.
Optimization Framework – Constraints
The constraints request some additional relationships among the design variables and process parameters.

The constraints originate because design variables must satisfy certain physical phenomena & certain resource
limitations.

Constraints are such as production limitations, raw material limitations, safety restrictions, product specifications,
and design limitations.

Example: Variable bounds: 0<x<1 (Don’t exceed the range in any direction) (Max / Min)
• Equality constraints: The sum of mole fraction should be unity such as for component balance equation in a
distillation column.
• In equality constraints: In the packed reactor, process temp should be less than the catalyst deactivation
temp/acidic conditions PH<7, stress developed anywhere in a component should be less than the maximum
allowable stress
Optimization Framework – Process Model

• A process model (HYSYS) is required to describe the manner in which the design
variables are related. The process model also tells us how the objective function is
affected by the design variables.

• A model is a mathematical equation or is a collection of several equations that define

how the design variables are related and the acceptable values these variables can take.

• Optimization studies are carried out using a simplified (but reasonably accurate)
model of a real system.

• Note:- working with a real system (life) is time-consuming , expensive , and risky &
that’s why you need to work on a model rather than a life case.
Classification of Optimization Methods
Based on the presence/absence of constraints:
1. Optimization problems that are subject to one or more constraints.

2. Unconstrained optimization problem- No constraints exist (Not Practical).

Based on the nature of the equation involved:-

1. Linear Programming (LP)

2. Non–Linear Programming (NLP)

3. Sequential Quadratic Programming (SQP)

Classification of Optimization Methods
• Based on the nature of design variables:-
1. Continues optimization (Linear Programming )
2. Integer programming (IP) (integer values)
3. MILP mixed-integer (Linear & Integer Programming)
4. MINLP (Non-Linear & Integer Programming)

• Based on local search methods or global search methods

• Based on the number of object functions:

1. Single
2. Multi
 Optimization Problem Formulation
• In order to be able to perform optimization on any process, firstly you will need to formulate the
optimization problem.

• In order to formulate a proper optimization problem, you will need to digest the following
expressions:

1. Process Models for optimization

2. Degrees of freedom analysis

3. Optimization problems in chemical engineering

 Process Models for Optimization
• Optimization requires the use of mathematical techniques for maximization or
minimization of an objective function (Variable required to be approached
– Target).

• Note: With the advent of computers, optimization has become part of

computer-aided design

• In order to use optimization algorithms on computers, we must have a

quantitative model available to compute the responses of the objective
function.
 Process Models for Optimization
• A process model is a set of equations that imitates reality and cannot incorporate all features the
real process. However, a reasonably accurate model saves us time and money as we can avoid
repetitive experience & measurements.

• Classification of process models:-

1. Theoretical Model.
2. Database Models (Practical).

• Other classifications:-
1. Linear vs nonlinear models
2. Steady-state vs non-steady-state
 Degrees of Freedom Analysis
• The degrees of freedom analysis gives us the number of design variables that can
be changed during the optimization process to obtain the optimal solution

• Degrees of freedom, DOF = No. of variables – No. of linearly independent

equations (As in Algebra)

1. If DOF = 0, unique solution exists – no optimization is possible

2. If DOF> 0, under determined system - Infinite solution exist &
optimization is possible
3. DOF< 0, over determined system - No solution exists
 Net Present Value - NPV
• At any point you are planning to do a modification to optimize the plant,
you have to calculate the Net Present Value.

• In simple Words, NPV is to weigh the future benefit as of Today. the total
gain in the process after implementing the selected solution (optimized) –
total cost of implementing the solution = Positive Cash Flow – Negative
Cash Flow

• It provides a method for evaluating and comparing capital projects or

financial products with cash flows spread over time
 Net Present Value - NPV

• Given the (period, cash flow) pairs (t, Rt) where N is the total number of periods,
the net present value NPV is given by:

Where,
• T, is the time of the cash flow
• I, is the discount rate, i.e. the return that could be earned per unit of time on investment with a similar risk
• Rt is the net cash flow i.e. cash inflow – cash outflow, at time t.
 Examples of Optimization Application in Engineering

Chemical reactor design:

• Target: Achieve design Conversion @ optimum cost
• Possible Solutions:
• Increase Reactor Size at same separation capabilities
(energy) – (CAPEX).
• Increase Separation requirements @ same reactor size
– (CAPEX).
• Optimize both, reactor size and the separation energy
requirements – (CAPEX / OPEX) - (Optimization
Path).
Other Examples of Optimization Application in Engineering

 Design of Pipeline
1. Size
2. Price of material (CAPEX).
3. Cost of infrastructure (CAPEX).
4. Energy Cost (OPEX).
 Optimization of CDU
1. Feedstock cost (OPEX).
2. Refined product cost (OPEX).
3. Profit Margin (OPEX).
 Application Example for Optimization –
Heat Exchanger
• If we wish to maximize heat transfer from a fin, we must be able to calculate
the amount of heat transfer for different designs of fin.

• During heat exchanger design, if pressure drop can't exceed 10 psi, we must be
able to compute pressure drop has given shell/tube passes, no. of baffles,
etc.....

• Getting a valid & accurate model of the process is an important step in

optimization
 Case Study - Hydrocarbon Pipeline Optimization
Using Simulation

Objective
• Optimally determine the best-suited pipeline size considering the material cost of the pipe, pump (CAPEX), and the
associated running cost of the pumping system (OPEX).

Constraints:
1. Pipeline ANSI rating 300# and 600#.
2. Pipeline Length 125 km.
3. Diesel design flow of 725 m³/hr.
4. Operational hours of 16 hrs.
5. Potential pipe sizes (X), of 16”, 18”, and 20”.
6. ACCE (Aspen Capital Cost Estimator) for a pipeline cost estimate.
7. APEA (Aspen Process Economic Evaluation) for pump fixed and running cost.
Case Study - Hydrocarbon Pipeline Optimization
Using Simulation

• Case 1- Base Case:

1. Design Flow 725 m³/hr.

2. ANSI rating 600#.
3. Operational hours: 16 hrs.
4. Pipe ID: 16”.
Case Study - Hydrocarbon Pipeline Optimization
Using Simulation

• Case 2:

1. Design Flow 725 m³/hr.

2. ANSI rating 300#.
3. Operational hours: 16 hrs.
4. Pipe ID: 18’’.
Case Study - Hydrocarbon Pipeline Optimization
Using Simulation

• Case 3:

1. Design Flow 725 m³/hr.

2. ANSI rating 300#.
3. Operational hours: 16 hrs.
4. Pipe ID: 20”.
 Case Study - Hydrocarbon Pipeline Optimization
Using Simulation

Key Results:
 Case Study - Hydrocarbon Pipeline Optimization
Using Simulation
Final Conclusion:
Case 2 can be disqualified where the shut off pressure of the export pump will exceed the
design pressure of 47.7 barg.
• Case 1 and Case 3 are technically viable where them meet the flow requirements and the
design pressure of 300# and 600# respectively.
• Case 1 (16” pipeline - ANSI 600#) has reported a lower CAPEX to Case 3 (20” - ANSI 300#),
however the pump cost and electricity cost of Case 1 is higher.
• Although Case 1 has reported lower pipeline CAPEX, however, it can be dismissed for the
following reasons:
• Pump OPEX is nearly three times the value of Case 3.
• Maximum operating pressure under case 1 is 2.8 times of Case 3. As a result, the expected peak surge
and relieving volume would result in a bigger SRV size and more relieving volume.
 Case Study - Hydrocarbon Pipeline Optimization
Using Simulation

Recommendation:
Considering the outcomes from techno-economic analysis, it is
recommended to:
• Case 3 is deemed more favorable and technically viable to cater
to the operational requirements (design flow rate and less
surge demand) and more economic compared to Case 1 and
Case 2.
THANK YOU