Process Engineering PDF

HERVE Engineering Training
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Welcome to this presentation.
It is part of a suite of Engineering training modules.
It shows the activities and deliverables of the Process

discipline.
Comments are most welcome (herve.baron@gmail.com),

which I will incorporate for the benefit of all.
Please download this file so that you can see my trainers

notes in the top left corner latest Acrobat Pro feature.
2015 Herv Baron

Herv
HERVE Engineering disciplines: activities and deliverables
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PROCESS
PLANT LAYOUT
EQUIPMENT
SAFETY & ENVIRONMENT
CIVIL
PIPING
PIPELINE
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INSTRUMENTATION
ELECTRICAL
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PROCESS
Design basis and criteria
Process Flow Scheme, PFD, HMB
Process description
Process Operating and Control Philosophy
Equipment sizing
P&IDs
Piping specification and sizing
Instrument process specification
Process and Emergency shutdown
Flare study
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Operating manual
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PROCESS
Process description
Equipment sizing
P&IDs
Flare study
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Operating manual
HERVE Process Design Basis
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What constitutes the Design Basis of a Process/Utility Unit?
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HERVE Process Design Basis
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What constitutes the Design Basis of a Process/Utility Unit?
Sizing cases: max capacity /turndown
Other operating cases
Feedstock composition and condition
Product specifications
Battery limit conditions
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HERVE Process design basis
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Compressor Station
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PROCESS
Process simulations, Process Flow Diagram, HMB
Process description
Equipment sizing
P&IDs
Flare study
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Operating manual
HERVE Choice of Process Scheme
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What are the bases of process scheme definition?
HERVE Overall Plant Process Design
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What is the name of

this drawing?
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HERVE The Block Flow Diagram (BFD)
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Results from the high level functional requirements of the plant
Depicts the various Processes carried out within the facility and their sequence
Shows the inputs (feed) and outputs (products)
The item of the BFD is the Process Unit
HERVE Unit Process Design
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HERVE The Process Flow Diagram (PFD)
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HERVE Unit Process Scheme Optimization
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TEG HP Compression & TEG
1200 psig Gas Injection
3000 psig 5500 psig
500 psig 200 psig 50 psig
IP Compression LP Compression
From Wells HP Separator

Cooler 5 psig
165 - 205 F 500 psig
Emul. Treater
50 psig 150 F
Degasser
Oil Production
5 psig
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What are the elements taken into account in the
definition/optimization of the process scheme?
HERVE Process simulations
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Simulator settings
Output
Input
- Flow scheme
- Stream flows and
- Feed composition and - Thermodynamic model
composition
conditions - Equipment performance
- Equipment duty
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Simulator settings Output

Input
- Flow scheme - Stream flows and
- Feed composition and
- Thermodynamic model composition
conditions
- Equipment performance - Equipment duty
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Simulator settings
Output
Input
- Flow scheme
- Stream flows and
composition
- Equipment duty
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Simulator settings
Output
Input
- Flow scheme
- Stream flows and
composition
- Equipment duty
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Simulator settings
Output
Input
- Flow scheme
- Stream flows and
composition
- Equipment duty
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Simulator settings
Output
Input
- Flow scheme
- Stream flows and
composition
- Equipment duty
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Results from process simulations
Depicts the various Equipment within a Process (or Utility) Unit and their sequence
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Shows the process controls
The individual drawing item of the PFD is the Equipment Item

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Scheme including the following information, as a minimum:

Main equipment (all the itemized ones),
Process lines between equipment,
All control loops and main instruments,
For each stream, indication of:
Temperature
Pressure
Composition Heat & Mass Balance (HMB)
Specific gravity
Operating density
Heat content
Flow rate (relevant to each phase)
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Design conditions of main equipment.
It shall be drawn-up according to ISA 6.12 regulation as far as symbology is
concerning
HERVE Heat & Material Balance
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PROCESS
Process description
Equipment sizing
P&IDs
Flare study
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Operating manual
HERVE Process Description
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PROCESS
Process description
Equipment sizing
P&IDs
Flare study
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Operating manual
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PROCESS
Process description
Equipment sizing
P&IDs
Flare study
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Operating manual
HERVE Equipment sizing
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HERVE Cass study: Equipment Sizing
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32
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HERVE
HERVE Case study: Equipment Sizing
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Production separator
Sets the gas

cross section
Vessel size
Sets the liquid volume
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HERVE Process data sheet
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Drums
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HERVE Process data sheet
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Contents of the Process Data Sheet:
Design conditions
Overdesign
Fluid properties
Equipment duty
Skeleton drawing & dimensions
Material (generic type) and
corrosion allowance
Specification of internals:
demister, distributor, baffle etc.
Nozzles list
Allowable pressure drop, fouling
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factor, Cp, Cv, enthalpy curve (for
HX, heaters)
Available NPSH (for pumps)
HERVE Process Data sheet
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Column
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HERVE Columns and Drums
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Column internals must be specified.
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These pictures are excerpts from Sulzer douments
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Column
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Rotating equipment
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Rotating equipment
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Heat Exchangers / Shell & Tubes
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HERVE Heat Exchanger thermal sizing
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TEMA Data Sheet
A Thermal data sheet is
received from Process for
shell & tubes heat
exchangers following
thermal sizing
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Heat Exchangers / Other types
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Air Cooled HX
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HERVE Process Data Sheet
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Fired heaters
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Fired heaters
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What is particularly important while specifying a heater ?
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Storage tank
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HERVE Process Sizing
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Process Equipment Sizing is done on the basis of:
Sizing cases
Over design
Design criteria
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Sizing cases all operating cases
Over design
Design criteria
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Sizing cases all operating cases
Over design 10% as a rule
Design criteria
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Sizing cases all operating case
Sizing criteria On which basis are the following

equipment sized?
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Process Sizing is done on the basis of:
Sizing criteria
Separator
KO drum
Distillation/Absorption column
Reactor
Storage tank
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Sizing criteria
Separator Size of droplet => velocity, residence time + Surge
KO Drum Hold up time
Distillation/Absorption column Diameter based on flow. Number
of trays/height of packing based on purity required
Reactor Contact time (also called space velocity)
Tank Storage capacity
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HERVE Process specification
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Package
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What document is issued by Process for packages?
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Package
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Package
What type of guarantees

are requested?
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HERVE Process Equipment list
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HERVE Process Equipment list
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PROCESS
Process description
Equipment sizing
P&IDs
Flare study
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Operating manual
HERVE Piping & Instrumentation Diagram (P&ID)
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Compare the
information shown on
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the PFD and the P&ID
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Compare
Comparethe
the
information
informationshown
shownon
on
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the
thePFD
PFDand
andthe
theP&ID
P&ID
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What are the

purposes of P&IDs?
Compare the
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What are the

purposes of P&IDs?
At design stage:
Defines the design basis for Piping & Instrumentation disciplines
Serves to
Compare theshow and agree the operating and maintenance features between
Engineer and Owner or between Engineer and Vendor
Serves to show the interface with equipment/package vendors
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Perform HAZOP review
During operation:
Reference drawing for operator, work permit, plant modifications etc.
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What are the

purposes of P&IDs?
P&ID
At design stage: review
Serves to
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During operation:
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What are the

purposes of P&IDs?
Which are the usual
points reviewed
during a P&ID
review?
P&ID
At design stage: review
Serves to
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During operation:
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P&ID review
Ease of operation and maintenance:
Isolation /bypass of equipment
Isolation/bypass of valves
Vents/drains
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P&ID review
Vents/drains
What do you call each type of
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isolation?
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P&ID review
Vents/drains
Where do you use double block

and bleed?
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HERVE Isolation philosophy
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P&ID review
Vents/drains
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HERVE Piping & Instrumentation Diagrams (P&IDs)
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Important features
Normal operation
Redundancy for critical instruments / safety switches
Shutdown
Check valves
Start-up
Pressurization
warm-up / purge lines
Maintenance
Equipment isolation & bypass: valves, spectacle/blind
Nitrogen injection, vent
Drains
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Control and ON/OFF valves isolation
Instrument isolation
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It includes:
1. All itemized equipment,
2. Item number and service description of each equipment with relevant

design condition
3. All lines (process , utilities, start-up, maintenance), with indication of

Diameter
Rating
Material
Service
Line number
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Piping class
Piping class break / change
External finishing (such as insulation, personal protection, tracing)
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4. Battery limits between Parties, e.g. contractor and vendor
5. All valves for operation, start-up, maintenance with indication of

valve type, including isolation valves, check valves etc.
6. All instruments with detailed control loops:

All instruments shall be tagged as per united numbering system,
Local instruments or instruments on local panel,
Sequences and interlocks (with brief description e.g.: comp. start / stop,
permissive to start, etc.),
7. Control valves, ON/OFF valves,
8. Safety valves (with set point and inlet/outlet size),
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9. Electrical controls, such as pump local or remote start/stop,
emergency shutdown
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9. Particular data or notes relevant to equipment/instruments
installation, such as:
Max or mini length of piping (requirement regarding suction / discharge
piping straight length, etc.),
Slope of piping
Elevation of equipment
Pertinent interior arrangement of equipment
Safe location requirement
Control and monitoring signals for rotating equipment and electrical
motors,
10. Item number and service description of each equipment with relevant
design condition
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11. Connecting flags for pipe lines running from one drawing to another
Instruments and controls must be drawn-up according to ISA 6.12

requirements.
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Various types of P&IDs

Legend and Symbols
Identification & Numbering
Details and Typicals
Process or Utility P&ID
Distribution P&ID
Interconnection P&ID
Pumps auxiliary P&ID
Package P&ID
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Legend and Symbols
Distribution P&ID
Package P&ID
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HERVE P&IDs legend & symbols
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Legend and Symbols
Distribution P&ID
Package P&ID
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HERVE Identification and numbering system
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HERVE Identification and numbering system
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Legend and Symbols
Distribution P&ID
Package P&ID
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P&ID
Legend and Symbols representation
Distribution P&ID
Pumps auxiliary P&ID Details
Package P&ID
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Legend and Symbols
Distribution P&ID
Package P&ID
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Legend and Symbols
Distribution P&ID
Package P&ID
What are the different typicals that should be

defined?
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HERVE Piping & Instrumentation Diagram (P&ID) - Typicals
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How would you call each of these two types
of arrangement?
For what service(s) would each be used?
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Legend and Symbols
Distribution P&ID
Package P&ID
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HERVE P&ID work sequence
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P&IDs are typically issued 3 times, as design progresses
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IFR IFD IFC
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IFR IFD IFC
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P&ID
Review
IFR IFD IFC
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P&ID
HAZOP
Review
IFR IFD IFC
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HERVE Quiz
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Which revision of P&IDs has the following purpose/contents?
Purpose IFR IFD IFC
Collect Client comments
Perform PID review
Perform HAZOP
Perform Piping MTO for 1st Piping purchase
Freeze Control system I/O list
Issue Piping ISOs
Contents IFR IFD IFC
Comments from all disciplines
Comments from Piping, I&C disciplines
Finalized interfaces with eqt/package
Exercised Contract Option(s)
Size, number of PSVs and CVs
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Diameter of process lines
Diameter of utility lines
HAZOP comments incorporated
Client comments incorporated
HERVE Quiz
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Which revision of P&IDs has the following purpose/contents?
Purpose IFR IFD IFC
Collect Client comments X
Perform PID review X
Perform HAZOP X
Perform Piping MTO for 1st Piping purchase X
Freeze Control system I/O list X
Issue Piping ISOs X
Contents IFR IFD IFC
Comments from all disciplines X
Comments from Piping, I&C disciplines X
Finalized interfaces with eqt/package X
Exercised Contract Option(s) X
Size, number of PSVs and CVs X
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Diameter of process lines X
Diameter of utility lines X
HAZOP comments incorporated X
Client comments incorporated X
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P&ID
HAZOP
Review
IFR IFD IFC
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The different revisions
The prime purpose of the first issue (IFR: Issued for Review) is to
obtain COMPANYs comments/APPROVAL this APPROVAL is
necessary before progressing the design further to avoid re-work
The IFD revision, which incorporates COMPANY comments, aims
at transferring information from Process to other disciplines:
to Piping, to perform routing studies
to Piping materials, to perform 1st MTO for purchase
To Instrumentation, to perform Instrument list
To Civil for routing of Undeground Piping
IFC incorporates HAZOP impacts and information from Vendors. It

is a pre-requisite to:
Start production of Piping isometrics
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P&ID
HAZOP
Review Piping Isometric
drawings
Piping material
top-ups
IFR IFD IFC

Piping routing
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Piping 2nd MTO & 1st material purchases
Instrumenation & Control design
Undeground piping (civil)
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Sometimes an IFH revision, mark-ups of the P&ID review,

is used to anticipate the HAZOP
P&ID
HAZOP
Review
IFR IFD IFC
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An IFD2 revision is issued in case major change from Vendors/HAZOP to

up-date piping material purchases, instrumentation design etc.
P&ID HAZOP
Review Piping Isos
Piping material
Start top-up
IFR IFD IFD2 IFC

Up-date
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Piping routing
Piping 1st material purchases
Instrumenation & Control design
Undeground piping (civil)
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PROCESS
Process description
Equipment sizing
P&IDs
Flare study
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Operating manual
HERVE Fluids list
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Line list
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HERVE
HERVE Line sizing
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PROCESS
Process description
Equipment sizing
P&IDs
Flare study
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Operating manual
HERVE Instrument process data sheet
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What is the most
important process data
for control valves?
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Operating range, typ.

Maximum flow rate: 110 % of max. operating flow rate
Minimum flow rate: 30 % of minimum operating flow
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rate,
in order to guarantee correct functioning at the extremes
of the operating range.
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PROCESS
Process description
Equipment sizing
P&IDs
Flare study
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Operating manual
HERVE Process Shut Down
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Look at the extracts of these 2 P&IDs.

How is the protection against loss of
liquid level achieved in each case?
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HERVE ESD logic diagram
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HERVE Safeguarding narrative & Cause and Effects charts
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HERVE Process and Safety Diagrams (PSD)
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PROCESS
Process description
Equipment sizing
P&IDs
Flare study
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Operating manual
HERVE Relief load summary
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HERVE Flare study
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HERVE Flare study
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PROCESS
Process description
Equipment sizing
P&IDs
Flare study
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Operating manual
HERVE Operating manual
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HERVE Operating manual
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What are the most important contents of the

operating manual?
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HERVE Operating Manual
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Table of Contents (typ.)
1 INTRODUCTION 4 OPERATION
1.1 General presentation 4.1 Start-up
1.2 Glossary 4.2 Normal operation
1.3 Basic data 4.4 Shutdown
4.5 Depressurization
2 DESCRIPTION OF FACILITIES
2.1 General 5 SAFETY
2.2 Process 5.1 Operating philosophy
2.3 Utilities 5.2 Escape, evacuation and
2.4 Auxiliaries rescue
5.3 Emergency power system
3 AUTOMATIC CONTROL SYSTEM 5.4 Safety equipment list
3.1 System overview 5.5 Fire protection
3.2 Operator control interfaces
3.3 Telecommunications
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3.4 Process alarms and trips
3.6 Emergency shutdown system
3.7 Fire & gas system
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Annexes (typ.)
EQUIPMENT LIST SINGLE LINE DIAGRAM

PFDs F&G SYSTEM ARCHITECTURE
DRAWING
P&IDs
VESSELS MECHANICAL DATA
ESD LOGIC DIAGRAM SHEETS
EQUIPMENT START/STOP & INSTRUMENT DATA SHEETS (PSVs,

SHUTDOWN SEQUENCES Level instruments)
GENERAL PLOT PLAN ESD SIMPLIFIED DIAGRAM
DCS ARCHITECTURE DRAWING CONTROL LOOPS AND ALARM LIST
ELECTRICAL CONTROL SYSTEM SECURITY SWITCHES LIST

ARCHITECTURE DRAWING
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Annexes (typ.)
EQUIPMENT LIST SINGLE LINE DIAGRAM

PFDs F&G SYSTEM ARCHITECTURE
DRAWING
P&IDs
VESSELS MECHANICAL DATA
ESD LOGIC DIAGRAM SHEETS
EQUIPMENT START/STOP & INSTRUMENT DATA SHEETS (PSVs,

SHUTDOWN SEQUENCES Level instruments)
GENERAL PLOT PLAN ESD SIMPLIFIED DIAGRAM
DCS ARCHITECTURE DRAWING CONTROL LOOPS AND ALARM LIST
ELECTRICAL CONTROL SYSTEM SECURITY SWITCHES LIST

ARCHITECTURE DRAWING
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Control loops and Alarms list
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PROCESS
Process description
Equipment sizing
P&IDs
Flare study
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Operating manual
HERVE Process design criteria
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What are the different Process design criteria?
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What are the different Process design criteria?
Design margins
Design Pressure and Temperature criteria
Equipment sizing criteria
Line sizing criteria
Control valve sizing criteria
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Design margins
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Design margins: what is the usual Equipment (rotating, heat exchangers, columns) overdesign (%)?
+?%
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Design margins: what is the usual Equipment (rotating, heat exchangers, columns) overdesign (%)?
+10%
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Design margins
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Design margins
The design temperature should be the highest or lowest temperature to which the
equipment is subjected, plus a margin.
The following cases must be considered:
(a) A maximum temperature which can occur when bypassing a heat exchanger or
cooler for cleaning.
(b) A high metal temperature on uninsulated equipment due to solar radiation.
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(c) The lowest temperature that may be caused by auto-refrigeration.
(d) The maximum metal temperature that can occur during steam out or decoking
operation.
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Design margins
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Design margins
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HERVE Licensed vs Open Art Process
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When one uses a process under license, what are the deliverables
issued by the process LICENSOR?
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HERVE Typical PROCESS Licensor / Engineering split
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Item Process Licensor Engineer

PFD, H&MB X
Equipment data sheet Equipment process data sheet: Equipment Mechanical data sheet
- Operating conditions,
- Duty
- Diameters of vessels
- Size of Nozzles
- Pump head
+ specific info for internals etc.
P&IDs Generic customized (piping class, line and
valves size, HAZOP comments,
vendor info)
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Line sizing Line sizing criteria Sizing (takes into account eqt loc,
elevation etc.)
Plot Plan recommendations X
Material selection Basic requirement MSD
HERVE Typical PROCESS Licensor / Engineering split
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Item Process Licensor Engineer

PFD, H&MB X
Equipment data sheet Equipment process data sheet: Equipment Mechanical data sheet
- Operating conditions,
- Duty
- Diameters of vessels
- Size of Nozzles
- Pump head
+ specific info for internals etc.
P&IDs Generic customized (piping class, line and
valves size, HAZOP comments,
vendor info)
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Line sizing Line sizing criteria Sizing (takes into account eqt loc,
elevation etc.)
Plot Plan recommendations X
Material selection Basic requirement MSD
HERVE The Oil & Gas Engineering Guide
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2nd edition
Do you want to know more... Much more?
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HERVE The Oil & Gas Engineering Guide - 2nd edition
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Table of Contents
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Table of Contents
This suite of training modules

covered the discipline
chapters of the book...
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Table of Contents
The Guide contains much more:
The overall picture, interfaces,

methods & tools, etc.
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HERVE The Oil & Gas Engineering Guide
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2nd edition
Order direct from the publisher:
http://www.editionstechnip.com/en/catalogu
e-detail/1111/oil-gas-engineering-guide-
the.html
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HERVE Engineering Training

Welcome to this presentation.

It is part of a suite of Engineering training modules.

It shows the activities and deliverables of the Process

Comments are most welcome (herve.baron@gmail.com),

Please download this file so that you can see my trainers

2015 Herv Baron

SAFETY & ENVIRONMENT

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What constitutes the Design Basis of a Process/Utility Unit?

2015 Herv Baron

What constitutes the Design Basis of a Process/Utility Unit?

Sizing cases: max capacity /turndown

Other operating cases

Feedstock composition and condition

Battery limit conditions

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What is the name of

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TEG HP Compression & TEG

1200 psig Gas Injection

3000 psig 5500 psig

500 psig 200 psig 50 psig

From Wells HP Separator

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Simulator settings Output

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Results from process simulations

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Shows the process controls

The individual drawing item of the PFD is the Equipment Item

Scheme including the following information, as a minimum:

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Sets the gas

Sets the liquid volume

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