equipment engineering

Equipment Engineering Training

Welcome to this presentation.

It is part of a suite of Engineering training modules.

It shows the activities and deliverables of the Equipmentdiscipline.

Comments are most welcome (herve.baron@gmail.com),which I will incorporate for the benefit of all.

Hervé

Engineering disciplines: activities and deliverables

� PROCESS

� EQUIPMENT

� SAFETY & ENVIRONMENT

� CIVIL

� PIPING LAYOUT & MATERIAL

� INSTRUMENTATION

� ELECTRICAL

A unique synthesis

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3000 copies sold to date

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Your reference

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Process design

H&M balance

Rotating

Pressure vessels

Fired equipment

Heat exchangers

Packages etc.

Process

data sheet

Equipment specification

Equipment list

Equipment ∕ Mechanical

Which documents are issued to

• Specify

• Inquire

• Select

• Order

Equipment?

Rotating Equipment

Let’s start with rotating

Rotating Equipment

Which documents are produced to specify Rotating Equipment ?

Let’s start with rotating

Process Data sheet / Mechanical Data Sheet

What additional information does the

MDS contain compared to the PDS?

The starting point for the mechanical

engineer is the Process Data Sheet (PDS) it

receives from the Process discipline.

From this, the Equipment Engineer produces

a Mechanical Data Sheet (MDS).

What are the contents of the code ?

• Data sheet template

• The list of information to be

defined by Purchaser, e.g. cooling

medium, hazardous area

classification etc.

• Technical requirements for the

design, accessories, tolerances

Mechanical Data Sheet

Some data is highlighted in green while some data is highlighted in

orange. What is the difference?

How and by whom are the Materials of Construction defined?

Engineering disciplines: activities and deliverables

� PROCESS

� EQUIPMENT

� SAFETY & ENVIRONMENT

� CIVIL

� PIPING LAYOUT & MATERIAL

� INSTRUMENTATION

� ELECTRICAL

Piping discipline

Plant LayoutPiping

installationPiping materials

Materials/corrosion,

insulation, painting

Piping

calculations

& supports

Material selection

Pressure Vessels

Which documents are produced to specify Pressure Vessels ?

Mechanical design

Any other document ?

What additional information is contained in the Mechanical DataSheet that is not contained in the Process Data Sheet? What doesMechanical design entail?

Process Data Sheet:

• design conditions

• skeleton drawings

• material (generic type) and corrosion allowance

• equipment dimensions

• definition of type of internals

• nozzles list

• height from ground

Mechanical Data Sheet:

• design conditions & code

• scaled drawing

• material grades and thickness of all parts

• all dimensions

• drawings of internals

• nozzzles position and elevation

• designed support

• weight

• loads on foundation

• limits of supply

Mechanical design

The vessel wall thickness is calculated so that with all

loadings, i.e.,

• Internal pressure

• External pressure

• Weight

• Seismic

• Wind

• Other external loads, from connected pipes etc.

the maximum stress for the selected material is not

exceeded

Mechanical design

The vessel wall thickness is calculated so that with all

loadings, i.e.,

• Internal pressure

• External pressure

• Weight

• Seismic

• Wind

• Other external loads

Mechanical design

http://www.microprotol.com/demo_viewlet.htm

Mechanical design

Calculation file

Mechanical Design

Mechanical data sheet

Heat Exchangers

Heat Exchanger

The starting point for the Equipment engineer is the Data Sheet received from

Process discipline. Depending on the type of Heat Exchanger, this data sheet

shows the duty only, i.e., flow + inlet/outlet conditions or the size of the heat

exchanger.

Plate & Frame heat

exchangers, Air coolers:

specified only – not sized - by

Process.Shell & tube heat exchangers: sized by Process.

Heat Exchanger

Shell & TubesSizing of Shell & tube heat exchangers by Process

https://www.htri.net/demo/

Heat Exchanger thermal sizing

TEMA Data Sheet

The Data Sheet issued by

Process to Equipment for a

Shell & Tube Heat

Exchanger is a Thermal Data

Sheet, it indicates the size

of the heat exhcnager:

numbers & length of tubes

Heat Exchanger

The data Sheet issued by

Process for other types of

heat Exchangers indicates

the duty only, i.e., flow +

inlet/outlet conditions, no

sizing.

Heat Exchanger

Mechanical Design

The Equipment engineer performs the Mechanical design of Shell & Tube type heat exchangers only.

HLLHLL

Ref[1]: 0

Heat Exchanger

Mechanical Design

Heat Exchanger / Mechanical Data Sheet

The mechanical design results in the issue of the Mechanical Data Sheet

How are heaters specified ?

Heaters Process Data Sheet

What is particularly important while specifying a heater ?

What are the miscellaneousequipment?

What is a package ?

Package = Set of equipment, accessories and services

� contracted or purchased to a single Vendor

� realizing a process function, with associated functional guarantees

� assembled on a single skid or multi skid, or shipped loose (bulk)

What is a package ?

What is, for Engineering, the purposeto order as a package ?

Purpose

� to have a better efficiency (than if it was done by the Engineer)

� to minimize site erection work

� to have ONE single functional guarantee

� to have a party (vendor) who is able to bring a specific know-how

What is a package ?

What is usually ordered as a package ?

Common types of packages

� Turbo-compressor

� Heaters, boilers, incinerators,

� Air/nitrogen generation, chemical injection

� Water/gas treatment

� Solid handling, conveyors, cranes etc.

Packages

Off-shore

Instrument air generation Air dryers skid

Packages

Off-shoreGlycol regeneration

Packages

On-shore

Cold boxStorage tank

(25m high)

Steam bath vaporizer

Nitrogen generation unit

What is a package ?

Which is the responsible discipline ?

� Packages requiring mainly know-how for one Equipment type,designed to ONE particular code: the concerned Equipmentdiscipline

� Turbo-compressor ROTATING

� Heaters, boilers, incinerators FIRED HEATER

� Desalter PRESSURE VESSELS

� Packages involving several Equipment type, the design of which isNOT dictated by ONE particular code: the PACKAGE discipline

� Air/nitrogen generation, chemical injection PACKAGE

� Water/gas treatment PACKAGE

� Solid handling, conveyors, cranes etc. PACKAGE

What is a package ?

Which document is produced to specifya package ? By whom ?

A duty spec rather than a

Data Sheet is issued for

packages.

It is issued by Process

What type of guarantees

are requested?

What type of guarantees

are requested?

� Applicable specifications: Manufacturer standard, a few Projectspecifications or all?

� Automation design: Independent control system or not ?

� Pre-assembly level / extent of site works

� Definition of limits of supply and interfaces in all disciplines, e.g. civil

� Involvement of Engineer: no / partial or full check ?

What are the key to consider whenspecifying a package?

� Applicable specifications: Manufacturer standard, a few Projectspecifications or all?

� Automation design: Independent control system or not ?

� Pre-assembly level / extent of site works

� Definition of limits of supply and interfaces in all disciplines, e.g. civil

� Involvement of Engineer: no / partial or full check ?

Local control Centralized control

Instrumentation Specification for packaged units

What other documents besides the Data Sheet / Duty

specification are issued to specify and order Equipment ?

What other documents besides the Data Sheet / Duty

specification are issued to specify and order Equipment ?

2) THE SPECIFICATION

Data sheet / Specification

What is the scope of each document?

Data sheet / Specification

Two types of specifications are issued. What are the two types?

Specification

EP - 21799_a_A_ppt_01 - Eng. Mangement Part 2 - Engineering disciplines63

General

Specification

General specification:

� It does not apply to a particular equipment (tag) but to all items of this

family of equipment, e.g. fired heaters, S&T HX etc.

� Only lists the amendments to a code

� For standard supplies, it is enough, along with the MDS

� For packages, general specifications for all equipment types within the

package must be included

Equipment codes & Standards

Pressure Vessels

ASME Section VIII, Division 1 Rules for Construction of pressure Vessels

ASME Section VIII, Division 2 Rules for Construction of pressure Vessels

Fired Heaters and Steam Boilers

ASME Section I Power Boilers Code

API 560 Fire heaters for refinery services

Heat Exchangers

API 660 Shell & Tube

API 661 Air-cooled HX

Rotating Equipment

API 610 Centrifugal pumps for Petroleum and Natural Gas Industries

API 617 Centrifugal compressor for general refinery service

API 611 General purpose turbines for refinery service

Atmospheric Storage Tanks

API 650 Welded Tanks For oil Storage

Specification

Particular

Specification

General specification:

� It does not apply to a particular equipment (tag) but to all items of this

family of equipment, e.g. fired heaters, S&T HX etc.

� Only lists the amendments to a code

� For standard supplies, it is enough, along with the MDS

� For packages, general specifications for all equipment types within the

package must be included

Particular specification

� Specific to a particular equipment item (Equipment Tag)

� Issued for complex and extended scope of supply, including several types

of equipment, e.g. machinery auxiliaries, and for packages

� Issued when the supply is not standard, i.e. specific requirements etc. that

the general specification does not cover

� It is fully comprehensive... as shown on the TOC on the next slide

Specification

� Detailed scope of supply

� Scope of services

� Reference documents

� Applicable codes & standards

� Deviations & Exceptions

� Design Requirements

� Packing, marking and shipping

� Shop assembly and delivery conditions

� Inspection & testing

� Guarantees & warranty

� Data required with the bid

Specification

Deviations and exceptions are discussed with

Vendors, and incorporated in the specification

final revision IFP

Specification

In all concerned disciplines (to reduce the

number of other discipline specs

transmitted to the vendor)

Specification

� Documentation

Strongly influences the amount of work on

Specification

During bid stage (before PO)

information is required to Vendor for

Technical analysis. This paragraph is

deleted for IFP revision

Which document, issued to the bidders, summarizes the inquiry?

Which document, issued to the bidders, encapsulates all

requirements for a particular supply?

1) THE MECHANICAL DATA SHEET

2) THE SPECIFICATION

3) THE MATERIAL REQUISITION

Material requisition

� 1 PIM, attendance to all checks and test points (HOLD)

� 2 PIM, optional attendance to checks and test points

� 3 Attendance to final tests only

� 4 Review of documents only

Inspection requirements

Supplier class

Very critical

Critical

Low critical

Non critical

previous experience with this supplier (rating by

Engineering / Inspection / Expediting),

References, audits, NCR etc.

Operating Conditions,

Manufacturing Difficulty, Impact on

Design or overall Project Schedule.

Very good Good Fair Bad

Inspection requirements

Very good Good Fair Bad

Supplier class

Very critical

Critical

Low critical

Non critical

1 PIM, attendance to all checks and test points (HOLD)

2 PIM, optional attendance to checks and test points

3 Attendance to final tests only

4 Review of documents only

qualified

What are thedifferent typesof documentsrequested fromthe vendor ?

Vendor documents

� Design documents, such as mechanical calculation note etc.

� Interface documents, such as loads on foundation, Purchaser's

connections drawing etc.

� Manufacturing documents such as welding and testing procedures,

inspection and test reports,

� Installation documents, such as preservation procedure, lifting

instructions etc.

� Operating and maintenance manual, spare parts list

Vendor documents

� Design documents, such as mechanical calculation note etc.

� Interface documents, such as loads on foundation, Purchaser's

connections drawing etc.

� Manufacturing documents such as welding and testing procedures,

inspection and test reports,

� Installation documents, such as preservation procedure, lifting

instructions etc.

� Operating and maintenance manual, spare parts list

Which type of documents is the most critical for Engineeringdevelopment ?

Vendor Documents Requirements & Schedule (VDRS)

What do you do to ensure these documents will be submitted on-time ?

Vendor Documents Requirements & Schedule (VDRS)

Equipment / Mechanical

WRAP-UP !

Documents issued by Equipment discipline:

� Mechanical Data Sheet

� Specification (General / Particular)

� Material Requisition

Another document is issued by the Equipment discipline, whichone?

Bid technical evaluation

Supplier 1 Supplier 2Requirements

What is the work of the Equipment engineer after the purchase order isplaced?

� Review of vendor documents

Scope of supply: counter

flange to be supplied by

vendor, as per contractual

specification

Decision during a clarification meeting

with vendor, for instance to allow

maintenance

Comments on Instrument

numbering and

installation: Vendor P&ID

shall use the same

nomenclature than

project’s P&ID

Missing information: setting pressure of

PCV shall be indicated on P&ID

� Coordination with other disciplines

� Coordination with other disciplines. There are many interfaces…

Interfaces

Discipline Provider Receiver

Piping Nozzle elevation,orientation, loads

Nozzleexactposition

Plant layout Elevation &position ofmanholes, heightof skirt/support

Civil Platform supports(location and load)

Loads onfoundation

Piping supports Pipe supportlocation

Instrumentation Elevation of levelconnections

Internals vendor Internals supports

Electrical Earthing lug /lightning lug

Which engineering data is exchangedwith the Vendor of a column?

Other Engineering disciplines / Project

functions will also be involved….

Discipline Involvement

Materials/Corrosion Review materials,

coating, insulation

cathodic protection

Inspection Tests, NDE, RBI

Construction Reviews, site assembly,

heavy lifts

A column is vendor is also at interface

with another vendor. Which one?

� That of the column internals…

Illustation courtesy of Sulzer

Wrap-up

Dcouments issued to order various types of equipment

Equipment Process discipline Equipment/Mechanical discipline

PDS Duty

MDS Particular

Specification

General

Specification

Pressure Vessel X X X X

Rotating equipment X X For

extended /

complex

supplies

Heat Exchanger – Shell &

X X X X

Air-coolers X X X

Fired heater X X For

extended /

complex

supplies

Package X X X

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