process-project engineering for uic senior design (1)
TRANSCRIPT
8/10/2019 Process-Project Engineering for UIC Senior Design (1)
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Process / Project Engineering
UIC Senior Design
Process / Project Engineering
UIC Senior Design
8/10/2019 Process-Project Engineering for UIC Senior Design (1)
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• Learning Objectives
• Project Definition
• Basic or Process Engineering
• Systems or Project Engineering
Process/Project Engineering
Agenda
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Learning Objectives
• Discuss Best Practices in setting a ProjectDefinition to ensure a successful project
• Understand the roles of the different Partiesinvolved in the overall execution of a Project
• Examine the various steps of Process andProject Engineering
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Project Definition
Grass roots refinery installationwith multiple processes andutilities
Addition of a complex of newprocess technologies in anexisting facility
Addition of a single processunit
Addition to or revamp of anexisting process unit
Changes to an existing piece of
equipment
• A “Project Definition” is required for any projectrequiring design and construction
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Phases of the Project
Defining Project- Market Research
- Economic Studies
- Finance
- Licensor Selection- +/- 50% TIC
Basic Engineering- Project Defined
- Process Design
- Project Design
- +/- 10% TIC
EPC- Detailed Design
- Procurement
- Construction
Start-up- Commissioning
- Initial Unit Operation
- Performance Test
(Typically 18 – 48 months)
Phase that focuses onProcess / Project Engineering
Conceptual
Planning
Basic
Engineering
Engineering,
Procurement
Construction
Commissioning
& Start-up
Project Definition
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• First Step is to Finalized Project Definition
• Second Step is to Complete the Design• End Product is the Basic Engineering Design
Package
At UOP Known as the “Schedule A”
Used as the Basis for the Detailed Design / Procurement /Construction Phases of the Project
• The Basic Engineering Design Work Process is
Split into 2 Phases: The Process Engineering Phase
The Project Engineering Phase
Basic Engineering Phase
Project Definition
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Scope Definition
• What Parties are involved?
Licensor: for Licensed Technology and Catalyst
There may not be a Licensor if only Technique andKnow-how (TKH) is required
Project Management Consultant, PMC, to help Refinerexecute a major project
Contractor – Front End Engineering Design (FEED) tocoordinate Licensor information / off-sites / utilities
Contractor – Detailed Design (actual plot, isometrics),equipment requisition, actual construction
Subcontractors Equipment Vendors
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So How Do You Go About Setting a Good ProjectDefinition?
Project Definition
Project
Definition
DefineProject
Scope
Set
Design
Basis
Complete
BEDD
Establish
Schedule
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Scope Definition
• Engineering Agreements and Contracts defineresponsibilities for:
Engineering deliverable content/detail
Scope boundaries for equipment design
Scope boundaries for supply of equipment
Basis for Design
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Setting the Design Basis
• A good Design Basis is a critical part of theProject Definition
•Design Basis is set in:
Design Basis Meeting with various parties
Design Basis Meeting Notes document discussionand decisions from the Design Basis Meeting
Legal Agreements include much of what is defined inthe Design Basis Meeting Notes, and binds the partiesin terms of Scope and Deliverables
Basic Engineering Design Data (BEDD, BEDQ)
Yield Estimates
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Setting the Design Basis
• Set unit capacity
Based on feed or product
Based on on-stream efficiency (e.g. 330 d/y)
Define turndown requirements or future capacities
• Feed definition
Feed cases (limit the number – ideally 2, at most 4)
Define compositions
Define contaminant limitations
• Product specifications
Recovery
Purity
Contaminant limitations (sulfur)
Other important specifications (octane)
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Setting the Design Basis
• Identify specific process schemes (process flow)
Desired process flow to be scoped out before designbegins (have preliminary PFD available)
Future capacity
Feed pre-treating methods
Product treating methods
• Identify specific design decisions for major orspecialty equipment, e.g.
Specific compressor types
Specialty exchangers, vertical, welded plate
Specialty fractionator trays
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Basic Engineering Design Data
Design Basis• General Information
Units of measurement
Turndown requirement Customer names and addresses
Communication protocol
• Utility Information Steam level identification and condition
Cooling water battery limits
Fuel for fired heaters Fuel oil impurities
Fuel gas pressure and impurities
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Basic Engineering Design Data
Design Basis• Specific equipment design requirements
Desired fired heater efficiency
Method of obtaining fired heater efficiency
Tray and packing information
Shell and tube exchanger tube diameter and length
Air cooler design air temperature, air only breaktemperature and air/water break temperature
• Site conditions
Winterizing temperature
Unit elevation
• Battery limit temperatures and pressures
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Schedule
• Schedule is critical because time is money
Consider opportunity cost of time on-stream
The schedule needs to be reasonable
The schedule needs to be balanced between licensor,EPC contractor and vendors
Might need to meet schedules for product/feed contracts
• Remember:“the bitterness of poor quality remains long after thesweetness of meeting the schedule has been forgotten”
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Project Implementation
Owner’s Influence on Project versus Time
Basic
Engineering
Detail Design, Procurement, Construction Startup
+ A
b i l i t y t o I n f l u e n c e P
r o j e c t
T o t a
l C o s t o
f P r o j e
c tHigh
Low
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Process Engineering (Basic Design)
• Heat and Material Balance (Simulation)
Produce stream properties to specify equipment
• Process Flow Diagram
• Major &/or Long Lead Equipment Sizing
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Process Engineering Design Steps
Establish Basis of Design
Develop Process Flow Diagram
Major Equipment Selection and Sizing
Modify Mass and Energy Balances
Internal and External Reviews
Produce Process Flow Diagram with Controls
CompressorsReactors FractionatorsHeat Exchangers Other
Produce & Optimize Mass and Energy Balance
Recycle From Any Point May Be Needed For Design Optimization
R i P j D fi i i I f i
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Review Project Definition Information
• Yield Estimate
• Legal Agreements
• Design Basis Meeting Notes• Basic Engineering Design Data
• PFD and Simulation Modules
• Standard Specifications
Yi ld E ti t I t
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Yield Estimate Importance
Critical definition of:
• Feeds
•Products Total
Individual
• Reactor conditions Temperature and pressure
H2 partial pressure
Wash water rates
Heat of reactions Recycle rates
Cycle times
St d d & S ifi ti
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Standards & Specifications
Licensor Standard Specifications may well differfrom the customer’s Standard Specifications -
External specifications need to be reviewed by Skill
specialists
A consolidated list of significant differences betweeninternal and external Standards will help avoidproblems
P d H t & W i ht B l
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Produce Heat & Weight Balance
• Choose the appropriate simulator
• Define component list
• Select property packages• Assign hydraulic values
• Produce a model
Connect and define unit operations
• Review product quantities and qualities
• Optimize flow scheme
• This is the Key Output!
Optimize Flow Scheme
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Optimize Flow Scheme
• Things that are typically optimized? Equipment Used in the process flow
Divided wall Column vs. Two columns
Heat Exchangers
Feed/Effluent Heat Exchange vs. Fired Heater vs. Air
Cooler Duty
Compressors & Pumps
Is it possible to avoid the use of a compressor or pump?
Determine best compressor type and efficiency
Check that the compression ratio and discharge
temperature are within acceptable range
Fractionators
There are many options in any flowscheme thatcan be optimized (operating vs. capital cost
tradeoffs)
Optimize the Fractionators
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Optimize the Fractionators
• Total number of trays
• Feed tray location
• Feed enthalpy• Condenser type and cooling medium
• Reboiler type and heating medium
• Select and design internals (trays vs.packing)
Process Flow Diagram
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Process Flow Diagram
• The PFD should provide an easy to understandview of the unit
The major equipment that is needed
The routing of the major flows
The regulatory (functional) control system
Customer PFD Check
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Customer PFD Check
• The customer provides needed input basedon the process data
Products streams
Duties
Instrumentation
Operability
Preliminary equipment sizes Preliminary utilities
Preliminary Equipment Size Info
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Preliminary Equipment Size Info
• Fired Heaters Basic heater type
Process duty
Design conditions
Inlet/outlet fluid properties Burner types / requirements
Efficiency requirements
Metallurgy
Fuel Fired
• Vessels Vessel Orientation
Design conditions Diameter / Tangent Length / Elevation
Internals (distributors, trays , packing, etc.)
Preliminary Equipment Size Info
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Preliminary Equipment Size Info
• Heat Exchangers Basic heat exchanger type (vertical, S&T, hairpin, etc.) Process duty Design conditions Inlet/outlet fluid properties
U value Surface Area Number of shells Tube OD, Length, Pitch
TEMA type Metallurgy
• Pumps Pump type (centrifugal, proportioning, etc) Process conditions / NPSHA Metallurgical requirements Seal Requirements Seal / Flush Plans
Driver Type
Preliminary Equipment Size Info
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Preliminary Equipment Size Info
• Compressors Compressor type (centrifugal, proportioning, etc)
Process conditions / Estimated BHP
Number of Stages
Number of Compressors Metallurgical requirements
Driver Type
Project Engineering Phase
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Project Engineering Phase
• Hydraulics
• Line sizing
• Equipment design
temperatures & pressures• Material selection
• Flange ratings
• Equipment specifications
• Standard Specifications &
drawings
• P&I diagrams
• Plot plan
• Instrument specifications
• Piping specifications
• Relief valve specifications
• Transition work to support
the start of detailed design
Hydraulics
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• Hydraulics are the “Heat and Material Balance”of Project Work – define connections betweenequipment
• Hydraulics to size lines, specify pumps,compressors, control valves, set equipmentelevations and design pressures
• Basic engineering hydraulics based onpreliminary unit plot plan (estimated pipinglengths, equipment layout and nozzle elevations)
• EPC Contractor responsible for verifying basicengineering system hydraulics are adequate.Adjusted for final plot layout, pipingarrangement and actual equipment purchased
Hydraulics
Hydraulics
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• Set vessel elevations
• Mechanical clearance
• Pump NPSH• Thermosyphon reboilers
• Relative elevations
• Account for static heads• Set/confirm allowable
equipment pressure drops
Hydraulics
• Tabulate hydraulic circuits for normal, design andturndown flows
Line Sizing
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Line Sizing
• Size all lines and determine pipeschedules using hand or computertools
Select criteria based on the service
Estimate pipe schedule from the operatingpressure
Consider alternative operations(regeneration)
• Use a PFD quality drawing as ahydraulic flow diagram
• Most line loss is due to fittings notlength, hence the use of “equivalent”length
Design Pressures
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• Locate pressure relief valves
• Determine PRV set pressures
• Determine which PRV protectswhat equipment
• Set equipment designpressure based on:
Minimum design pressure
A margin over operating pressure
Pressure at relieving
Pump shutoff/shut-in pressure
Special operating conditions
10/13th rule for exchangers
g
Design Temperatures
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• Set equipment designtemperatures based on:
Nominal minimum design temperature
A margin over max operatingtemperature
Failure of upstream equipment
Special operating conditions
g p
• Set minimum design metal temperature
Winterizing Adiabatic flash at 40% of normal operating pressure
Material Selection
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• Material selection is generally supported bya skilled metallurgist
• Hydrogen resistance (Nelson Curves)
• Corrosive elements
Hydrogen chloride (HCl)
H2S, sulfur
Water
Caustic
• Extreme operating temperatures
Hot (up to 1010 F)
Cold (down to ambient [min. Design -10
F])
Determine Flange Ratings
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• Determine flange ratings forequipment based on allowablestresses for:
• Material selected• Design pressure
• Design temperature
• Use ASME B-16.5 flange tables
• Consider adjusting design
conditions if small changes canreduce the flange class.e.g. Class 600 vs. Class 300
g g
Equipment Specifications
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• Where process design is impacted by the typeof equipment, process engineer sets basicparameters
Fired heater summary
Fractionator ID, no. of trays and tray design
Reactor diameter
Compressor discharge temperature
• For highly mechanical equipment, equipmentspecialist are required to generate theequipment specifications
Equipment Specifications
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• Major Equipment Designed
Fired heaters
Vessels – Fractionator, Reactor
Heat Exchangers
Pumps
Compressors
Equipment Specifications
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• Duty specification – work witha vendor and provide: Basic heater type
Process duty
Design conditions
Inlet/outlet fluid properties Burner types / requirements
Efficiency requirements
Code
requirements/recommendedpractices
Coil metallurgy, connections
Fired Heaters
Equipment Specifications – Vessels
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• Reactors
Catalyst volume set by yield estimate
Process technology generally determines
reactor type e.g. downflow, radial Process engineer may set bed dimensions
Diameter set by mass flux or pressure dropcriteria
Pressure drop for packed beds iscalculated by Ergun pressure dropcalculations
Internals designed by skill specialists –mechanical engineers
Equipment Specifications – Vessels
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• Vessels Set basic dimensions by:
Residence time
Settling velocities
Clearances/freeboard
Loading of adsorbents/support
Specify elevation
Set design conditions Specify metallurgy and corrosion
allowances
Size & locate nozzles
Specify internals, reference std dwgs
Reference design codes
Specify ancillaries
Equipment Specifications
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Specifications include process
data for hot and cold streams todata sheet
Includes heat release curves ifnon-linear
Confirms number of shells andallowable pressure drop
Assigns design conditions foreach side
Heat Exchangers
Checks surface area to confirm maximum bundle size or weighthas not been exceeded
Equipment Specifications – Pumps
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• The pump type generally needs to be known in order tocalculate NPSH
• Consultation with a skill specialist or vendor may be
required prior to hydraulics
• Specification indicates:
Pump overage for Rated Flow
Motor Load requirements
If Pump will handle differentfluids at any time
Curve rising to shutoff forparallel operation
If downstream equipmentdesign pressures are set by
pump shutoff pressure
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Equipment Specifications – Compressors
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• Compressor type determined in the process stage
• Consultation with a skill specialist or vendor/ catalogis prudent during the process work
• Base sparing on the reliabilityof the compressor type
• Use API data sheets• Consider head contingency
with centrifugal compressors
• Indicate regeneration gascomposition for recycle gasservice
EDS/CD-100
Piping and Instrument Diagrams
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• Detailed schematic flow diagrams of the unit showing:
All process equipment, including equipment names andidentification numbers, and vessel dimensions
All process pipelines, including sizes, pipe class, by-passes,process vents and drains, sample connections, and lines
required for start-up, shutdown, flushing and regeneration Indication of requirement for insulation, heat tracing or steam
jacketing
Utility connections required for process reasons, such as
steam, cooling water, fuel oil, fuel gas, nitrogen andcompressed air
Relief valves, block and throttling valves, strainers and pipefittings required for process reasons
Minimum acceptable level of regulatory instrumentationsystems for basic measurement and control of the unit.
Piping & Instrument Diagram Review
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• Process review of lines and instrumentation
• Review of equipment specifications against PID’s
•Start-up and shutdown procedure review
• Technical input from:
Project Manager – consistency
Process Specialist – design philosophy
Technical Services – operating experience
Instrumentation Skill – control
Equipment Skill – mechanical
R&D/Licensor – process technology
• Document decisions and action items throughmeeting notes
Piping and Instrument Diagrams
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• Other Uses Input by Equipment and Instrumentation Specialists
Add Contractor Requirements
Basis for Generating the Detailed P&IDs or MechanicalFlow Diagrams (MFDs)
Pre-Startup Checkout
Operator Training
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Equipment Specifications – Instruments
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•Instrumentation is used to monitor key variablesthroughout the process
• Primary things to consider for instrumentation designare:
Safe Operation
Provide controls to avoid unsafe operation
Keep process variables within control
Production rate Provide control loops to insure production rate are achieved
Product Quality
Provide composition control / monitoring of feeds / products
Cost
Advanced process control to minimize utilities / maximize product
Equipment Specifications – Instruments
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• Temperature / Pressure Indicators• Flowmeters
Type (orifice, mass, venturi, etc.)
Special requirements (minimum straight length piping distance,etc.)
• Level Gauges / Transmitters
Type (displacement, dP cell, gauge class, magnetic, etc.)
Show connections (pipe columns / directly connected to vessel)
Show vents / drains / connections to relief header
Indicate COF and range
Equipment Specifications – Instruments
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• Control Valves
Bypass
Indicate fail position (if necessary)
Show vents / drains / connections to relief header
• Control Loops
Simple Feedback Control (FIC→ CV)
Cascade Control (LIC→ FIC→ CV)
• Cause and Effect Tables
Emergency ShutDown (ESD) systems
Piping
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• Piping expertise is generally with a skillspecialist
• Piping design conditions are determined by
the equipment to which it is connected• Need to consider alternate operations
• Piping classes are best indicated on the PID’s
to show where class breaks occur • Piping line lists are usually done in detailed
design
Piping
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• Basic Pipe Class Definition:
Metallurgy
Class - 150, 300, etc.
Flange Facing
Corrosion Allowance
• Additional information included on line lists: Insulation thickness
Post weld heat treating requirements
Steam tracing objective temperature
Fluid in the pipe
Relief Valves
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• Relief Valve Design according to:
API Recommended Practice 520
API Recommended Practice 521
• Load Analysis – How much is relieving and atwhat conditions?
Make simplifying assumptions to minimize analysis
time Steady state models
Use of normal HWB information where possible
• Document Assumptions
Relief Valves
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• Summarize all Casualties
Loads
Fluid Properties
• Specify PRV orifice for Governing Case
• Size Inlet and Outlet piping
• Specify PRV mechanical requirements basedon the characteristics of the service
• Summarize loads for common casualties sorelief header design can be performed
Use of Project Specifications
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•Supports Capital Cost Estimate Based onBudget Quotes
• Serves as Basis for EPC Contractor Biddingand Selection
• Allows for the development of the offsitesrequirements
• Leads to Design and Construction of the
Process Unit
• Used as Reference for an Operating Guide
Transition to Detailed Design
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• Transfer of Technology from Licensor to DetailedDesign Contractor
• Typically at Customer PID Review Meeting
• Detailed design finalizes hydraulics based onequipment purchased, actual plot plan and pipingruns
• Application of Local Codes versus US Codes• Resolution of deviations between Licensor
Specifications and “As Built” Unit
In Closing
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• Although the tasks of the “Process” and“Systems” Engineer may differ depending onthe organization, the tasks associated with
plant design tend to be the same• Effort placed in setting a good project definition
and design basis will maximize efficiencyduring process and project engineering – andensure the design meets customer needs
8/10/2019 Process-Project Engineering for UIC Senior Design (1)
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