design-refinery.pdf

Mid & Downstream Business Training

ModuleHYDROCARBON PROCESSING AN OVERVIEW

LNG

PRO

DU

CED

WA

TER

GA

S

Upstream Mid and Downstream


Module

Plant Design Cycle

DetailEngg.

Pre-Commissioning& Commissioning

Feasibility Study

Process Design /Basic Engg.

FEEDStable Operation& Performance

Testing

Trouble Shooting& Revamp


ModuleFeasibility Study: Conceptualization

Process Simulation

Development of Process Flow Scheme

Cost Estimation

Techno-Commercial Evaluation

Basic Engineering:

Mass and Energy Balance

Process Control Scheme

PFDs and Basic Process P&IDs

Sizing and Basic Spec. for Equipments and Instruments


ModuleFront End Engineering Design (FEED):

BEP to Project Specific Package (Residual Engineering)

Verification of Process data for Critical items

Preparation of Specifications

Identification of Scope Splits

Identification of applicable Codes & Standards

Commissioning:

Pre-Commissioning

Commissioning

Startup and Feed charging

Performance Guarantee test run


Module


ModuleWORK FLOW DIAGRAM

PP

CV

EL

ME

EQ

IN

PEBDEP BDEP

TQTQ

EQUIPMENT LIST

EQUIPMENT LIST

EQUIPMENT LIST

EQUIPMENT LIST

EQUIPMENT LIST

EQ. LIST EQ. LISTUHD UHD

UHD

UHD

UHD

UHD

UHD

UTILITYSUMMARY

UTILITYSUMMARY

FLARE LOAD SUMMARY

FLARE LOAD SUMMARY

PROCESS D/S FOREQUIPMENTS



CHEMICALSUMMARY

CHEMICALSUMMARY

LINE LIST LINE LIST

LINE LIST

REVISED P&ID REVISED P&ID

REVISED P&ID

REVISED P&ID

REVISED P&ID

REVISED P&ID

REVISED P&ID

UPDATED D/S FOREQUIPMENTS

UPDATED D/S FOREQUIPMENTS

PROCESS D/S FORMACHINERY ITEMS

UPDATED D/S FORINSTRUMENTS



PRECOMMISIONINGMANUAL

PRECOMMISIONINGMANUAL

OPERATINGMANUAL

OPERATINGMANUAL


HAZARDOUSSOURCE LIST



PLOT PLANREVIEW & COMMENTS

VENDOR DOCUMENTSREVIEW & COMMENTS

FABRICATION DWG.REVIEW & COMMENTS

PC

EQUIPMENT LIST

LINE LIST


ModuleREVIEW STAGE:

Review of Contract Documents

Preparation of TQs


ModuleSTAGE 0:

P&IDs mark up based on General Specifications, Standards, Amendments etc.

Updation of Process Datasheets based on PFD and other

documents

Preparation of UHDs

Sizing of Utility lines

Preparation of Equipment list

Preparation of Utility summary

Preparation of Catalyst and Chemical summary

Preparation of Tie-in summary

Preparation of Line-list

Preparation of Hazardous source list


Module P&IDs mark up based on General Specifications, Standards, Amendments etc.

Licensor P&ID

Standard Details


Module

Marked up P&ID

As per the standards, the control valve assembly with block & bypass and Vent & Drain arrangement is shown in detail


Module Updation of Process Datasheets based on PFD and other documents


ModuleUpdated Process Datasheets


Module Preparation of UHDs


Module Sizing of Utility lines


Module Preparation of Equipment List

MUMBAI

EQUIPMENT SERVICE NO. DIMENSIONS INTERNAL EQUIPMENT ERECTION DESIGN CONDITION INSULATIONNO. REQD. (ID).X(TL-TL) TYPE THICKNESS WEIGHT PRESSURE TEMP. TYPE THICKNESS

(m) (mm) (Tons) (kg/cm2g) (C) (mm)TOP BOTTOM TOP BOTTOM

COLUMNSLNHT UNIT

Top = 2.0Bott om = 2.8TL-TL = 27.9

Top = 3.2Bott om = 4.0TL-TL = 36.9

PENEX UNITTop =1.7

Bott om = 3.2TL-TL=26.2

TITLE : EQUIPMENT LISTOPERATING CONDITIONMOC + C.A

PRESSURE (kg/cm2g)

TEMP(C)SHELL &

HEAD TRAYS

125IH171 Int : 15.82Ext : FV91--DA-31701 STRIPPER KCS + 3 mm TP 4101Trays, DistributorInternal baff les, Vortex Breaker,

DA-31702 DEPENTANIZER KCS + 3 mm TP 4101Trays, DistributorInternal baff les, Vortex Breaker,

- - 70 119

STABILIZERDA-32810

DA-32811 LPG STRIPPER

57 179

1

1 KCS+3mm TP 410 - -

-TP 410CS+3mm

Int : 4Ext : FV

Int : 13.5Ext : FV

Int : 13.5Ext : FV

232171

IH

80

12060

210179

147119

120

- -

Trays, DistributorInternal baff les, Vortex Breaker,


- 45 60

ISOMERISATION PROJECT

0.75 x 21

IH

Equipment list


Module

Equipment List contains the information such as

Equipment Number

Service

Dimensions

Internals

Material of Construction

Operating and Design Conditions

Insulation Details

Other Special requirements

Preparation of Equipment List (Continued)


ModuleSample view of Equipment list

MUMBAI

EQUIPMENT SERVICE NO. DIMENSIONS INTERNAL EQUIPMENT ERECTION DESIGN CONDITION INSULATIONNO. REQD. (ID).X(TL-TL) TYPE THICKNESS WEIGHT PRESSURE TEMP. TYPE THICKNESS

(m) (mm) (Tons) (kg/cm2g) (C) (mm)TOP BOTTOM TOP BOTTOM

COLUMNSLNHT UNIT

Top = 2.0Bottom = 2.8TL-TL = 27.9

Top = 3.2Bottom = 4.0TL-TL = 36.9

PENEX UNITTop =1.7

Bottom = 3.2TL-TL=26.2

TITLE : EQUIPMENT LISTOPERATING CONDITIONMOC + C.A

PRESSURE (kg/cm2g)

TEMP(C)SHELL &

HEAD TRAYS

125IH171Int : 15.82Ext : FV91--DA-31701 STRIPPER KCS + 3 mm TP 4101


DA-31702 DEPENTANIZER KCS + 3 mm TP 4101Trays, DistributorInternal baff les, Vortex Breaker,

- - 70 119

STABILIZERDA-32810

DA-32811 LPG STRIPPER

57 179

1

1 KCS+3mm TP 410 - -

-TP 410CS+3mm

Int : 4Ext : FV

Int : 13.5Ext : FV

Int : 13.5Ext : FV

232171

IH

80

12060

210179

147119

120

- -



- 45 60


0.75 x 21

IH


Module Preparation of Utility summary

Utility Summary summarizes the consumption / generation of utilities in

all equipments.

The utility data for consumption to be furnished with - ve value.

Similarly the utility data for generation to be furnished with +ve value.

Following are the Utilities taken into account

Electricity

Steam

Condensate

Boiler Feed Water

Cooling Water

Service Water and Portable Water

Instrument Air, Plant Air and Nitrogen

Fuel Gas and Fuel Oil


ModuleSample View of Utility summary


Module Preparation of Chemical summary

TITLE : CHEMICAL SUMMARY Rev.: 0

1 -- 3200 kg MRPL

2 20% Wt 6.5 m3 MRPL

3 100% 200 kg MRPL

4 100% 20 kg MRPL

5 99.9 % Min. 30 m3 MRPL

6 -- 2500 kg MRPL

7 20% Wt 25 m3 MRPL

8 -- 350 kg MRPL

Sodium Nitrate (NaNO3)

Make-up Caustic (NaOH) for Penex unit

Anhydrous Ammonia

L&T-CHIYODA LIMITED BARODA, INDIADocument No.: A-317-4012


Required as corrosion inhibitor for LNHT unit

First fill quantity required

Scope of supply

Chemical Identification

Required for scrubbing of gases from stabiliser & during catalyst regeneration of naphta hydrotreating reactor.

As a sulfiding agent during stat-up

% Purity Chemical Service

Required during initial start up.Anhydrous Hydrochloric Acid (HCl)

Sr. No.

For preparing neutralizing solution during regeneration

For preparing neutralizing solution during regeneration

As a promotor for penex reactor catalyst

Required to neutraiize reactor effluent gases

Perchloroethylene (C2Cl4)

DMDS

Caustic for LNHT reactor neutralisation

Soda Ash (Na2CO3)

This document summarizes the consumption of Chemicals for the process.


Module Preparation of Catalyst summary

TITLE : CATALYST SUMMARY

Bed (m3)

Contingency 5% (m3)

2500

3200

9240

2900 9240

UOP---- Sock 3.62

2600 930

11.2520 Sock2480

6.62Sock

UOP

6.8--

7 FA-32801A Puraspec 20201200Zinc oxide treater

ADS-11

UOP "H-8" Catalyst

FA-32802 1800

DC-32801

Reactor

Saturation Reactor

Sulfur guard bed

24003

2

1

Equip. Tag No.Sr.No.

Catalyst

SockUOP "S-12" Catalyst 1065DC-31701 UOP

Service Equip ID (mm) Bed Height (mm)

Bulk Density(Kg /m 3)

Type Type of Loading

4 DC-32810 Puraspec 24431100Methanator Reactor Sock7160 UOP0.34 7.14 --

5 DC-32811 UOP "I-8" Catalyst2900 882 Dense 61 UOP

6 DC-32812 UOP "I-8" Catalyst 61 UOP

3720

Manufacturer

19.215

QuantityTotal

quantity (m3)

0.91518.3

0.56 11.76

UOP0.331 6.951 6464.4

Total quantity

(kg)

20464.0

64.05

64.05

Penex Reactor

Penex Reactor

3.05

3.05882 Dense

0.181 3.801

6115.2

56492.1

56492.1

This document summarizes the consumption of Catalyst for the process.


Module Preparation of Tie-in summary

Battery Limit Tie-in Summary contains the following information for all ISBL & OSBL lines

Flow rate of all process and utility streams going to B/L.

Operating and Design Conditions

Line Specifications

Main Properties of the Streams (Optional)


ModuleSample view of Tie-in summary

Sr. Stream Name From To Phase FlowratesNo. L/V/M Tons/hr kg/m3 (L) Visc.

Normal MW (V) cP Pressure Temperature Pressurekg/cm2 g deg C kg/cm2 gmin/nor/max min/nor/max

(C) INCOMING UTILITY LINES:

1 MP Steam B/L HEADER V 36066.0 18.0 0.02 14/15/16 255/260/270 22

2 LP Steam B/L HEADER V 33180.0 18.0 0.02 3/3.5/4 160/175/200 10

3 HP Steam B/L HEADER V 2930.0 18.0 0.01 39/40/41 330/390/408 45

4 Instrument Air B/L HEADER V 625.0 29.0 0.02 4.5/6.5/ - - /40/ - 10.5

5 Cooling Water Supply B/L HEADER L 2378207.0 1000.0 0.60 - /4.5/ - - /33/ - 7

6 Fuel Gas B/L HEADER V 1212.0 15.5 0.01 - /4.5/5 - /40/ - 6

7 Fuel Oil B/L HEADER L 2273.0 854.0 11.50 - /13/20 - /170/ - 25

TITLE : BATTERY LIMIT TIE-IN SUMMARY

MUMBAI

PropertiesOperating Conditions Design Conditions

ISBL


Module Preparation of Line-list Line List contains the data related to process conditions

and the data related to mechanical design and test conditions for all the lines.

Line List is the base document utilized for verification of major deliverables of Piping department.

Line List contains the information such as

Line Number Line Size

Fluid Code and Piping class

From & To Location

State and Nature of the fluid

Operating (Normal&Alternative) and Design Conditions

Steam out requirements Insulation Details Test fluid and Test pressure


ModuleSample View of Line-list

TITLE : LINE LIST FOR LNHT UNIT

IDENTIFICATION LOCATION STATE OPERATING (A)

(L/V/M)

1 10-P-3170001-A1A1 606 10 P 317 0001 A1A1 FA-31701 P-3170215 L HC

2 6-P-3170002-A4A1 606 6 P 317 0002 A4A1 GA-31701A P-3170046 L HC

3 10-P-3170003-A1A1 606 10 P 317 0003 A1A1 P-3170001 P-3170216 L HC

4 6-P-3170004-A4A1 606 6 P 317 0004 A4A1 GA-31701B P-3170002 L HC

5 0.75-P-3170005-A1A1 691 0.75 P 317 0005 A1A1 P-3170002 SN-31701 L HC

6 0.75-P-3170006-A1A 691 0.75 P 317 0006 A1A SN-31701 FLARE L HC

7 0.75-P-3170007-A4A1 691 0.75 P 317 0007 A4A1 SN-31701 P-3170001 L HC

8 6-P-3170008-A4A1 606 6 P 317 0008 A4A1 P-3170002 FV-002 L HC

9 6-P-3170009-A1A1 606 6 P 317 0009 A1A1 FV-002 FA-31701 L HC

LINE NO. FROM TONATURE

OFFLUID

INSU

LATI

ON

TYPE

INSU

LATI

ON

THK

. (M

M)

SR. NO.

P &

ID N

O.

SIZE

(INCH

)

FLU

ID C

OD

E

UNIT

NO

.

LIN

E N

O.

PIPI

NG

CLA

SS

MUMBAI


Module Preparation of Hazardous Source List

Hazardous Source List is the base document utilized for hazardous area classification drawing deliverable of Electrical department.

This document contains the information such as

Inlet and Outlet streams of all equipments State and Nature of the fluid Composition

Max. operating temperature

Properties like Density and Molecular weight

Flammability

Flash point Auto-ignition temperature


ModuleSample View of Hazardous Source List


ModuleSTAGE 1:

Hydraulic Check of Process lines

Sizing of Vessels

Thermal rating of Heat exchangers

PSV Sizing & Flare hydraulics

Preparation of Flare Load Summary

Preparation of Equipment datasheets for new items

Scope demarcation for Vendor items

Updation of P&IDs based on Hydraulic results


ModuleSTAGE 1 (Continued):

Updation of Pumps and Instruments datasheets based on Hydraulics

Updation of Equipment list

Development of Control and Safeguarding Narratives


Module Hydraulic Check of Process linesLoop identification in PFD


Module Hydraulic Check of Process linesCollecting Inputs required for hydraulic calculations


ModuleSample View of Hydraulic Calculation Sheet


Module Sizing of Vessels

Sizing of vessels is carried out based on Project

Design Criteria (Droplet size, Residence time)

Sometimes, Sizing is governed by separation of

fine entrained droplets using mesh pad, impact

separators, etc.


ModuleSample view of Vessel Sizing calculation sheet


Module Thermal rating of Heat exchangers

Designing / Rating of heat exchangers is carried

out with the help of HTRI computer program.

This activity enables the designer to model heat

exchangers, allowing the designer to gauge the

performance, geometry and inherent limitations of

the shell and tube heat exchanger even before its

fabrication.

This results in lower risks of damage to the

equipment while in service.


ModuleSample HTRI Specification Sheet

Sample HTRI Tube Layout


Module PSV Sizing and Flare Hydraulics

The safety of personnel and the protection of equipments due to overpressure are the basis for the design, sizing, and selection of pressure relieving systems.

All systems and pressure relief devices shall be

designed based on the applicable codes (API 520,

521, etc.), industry standards and practices.

For Flare header Sizing, first we have to determine the appropriate relief contingencies yielding maximum loads

Flare header size has to be large enough to prevent excessive backpressure on the plant safety valves and to limit gas velocity and noise to acceptable levels.


ModuleSample view of Flare Hydraulics calculation sheet


Module Preparation of Flare Load SummaryThis document summarizes the relief load of all PSVs for the applicable relieving cases.


Module Preparation of Equipment datasheets for new items


Module Scope demarcation for Vendor items

Vendor scope of supply has to be identified and to be clearly marked in the P&IDs.


Module Updation of P&IDs based on Hydraulic results

Licensor P&ID


Module Updated P&ID based on Hydraulics

Compressor Suction line is increased to 6 from 4 as per hydraulic calculations


Module Updation of Pumps and Instruments datasheets based on Hydraulics

Licensor Datasheet


ModuleUpdated Pumps datasheets based on Hydraulics


Module Development of Control Narratives

This narrative describes the plant control systems by instrumentation.

The purpose of this document are as follows :

(1) To explain control systems to those who may not be familiar with instrumentation symbols or functional logic diagrams.

(2) To define purpose and algorithm of each control system.

Pump auto start systems will be also covered in this

document.


Module Development of Safeguarding Narratives

The purpose of this narrative is to thoroughly

explain the safeguarding scheme and its

significance. Based on the same it is possible to

understand how safeguarding scheme works and

how it will be depicted in Cause and Effect

diagram or Safeguarding Matrix.


ModuleSample of Cause and Effect Diagram

P-5105B HP STEAM VAL

VE

P-5105A HP BFW PUMP

P-51203 HP BFW PUMP

P-51402A MP BFW PUMP

P-51206A HP BFW PUMP

P-51206B HP BFW PUMP

P-51206C HP BFW PUMP

P-51206D HP BFW PUMP

COMMON TRIP ALARM

CAUSE CLOSE TRIP TRIP TRIP TRIP TRIP TRIP TRIP ALARM ACTION

TAG NO. DESCRIPTION PEFS NO.

51UZA-2103

51UZA-2102

51UZA-2104

51UZA-2100

51UZA-2105

51UZA-2106

51UZA-2107

51UZA-2108

51UZA-2100

TAG NO.

51LZA-2008 D-0098-51-25-0006 X X X X X 51LZA-2008

51LZA-2011 D-1651-51-50-0018 X X X X X 51LZA-2011

51LZA-2008 D-0098-51-25-0006 X X X X X X X X X 51LZA-2008

51LZA-2011 D-1651-51-50-0018 51LZA-2011

51LZA-2008 D-0098-51-25-0006 51LZA-2008

51LZA-2011 D-1651-51-50-0018 X X X X X X X X X 51LZA-2011

V-51203 LEVEL LOW LOW




EFFECT 51UZA-2100 V-51203 / V-51201 SGS

DESCRIPTION

SAFE GUARDING MATRIX UNIT 51



Cause Section

Effect Section


ModuleSTAGE 2:

Interface Activities

Updation of Control & Safeguarding narratives and issue

for HAZOP Study

Updation of Utility summary

Updation of Line list


Module Interface Activities

Vendor Document Review

Review of Engineering Drawings

Review of Plot Plan

3D-Model Review

Review of DCS Graphics


Module Vendor Document Review

Some of the Critical points to be reviewed in Engineering Drawings are:

Consistency of Process data as per process datasheets such as Operating & Design Conditions, MOC, Special service requirements, etc.

Review of other technical aspects

(a) Meeting all Specifications as per requirement.

(b) Expected Utility consumption figures.

(c) Guarantee figures, if any.

(d) Other technical requirements specified in the requisition.

(e) Fulfilment of Scope of Supply.


Module Review of Engineering Drawings

Some of the Critical points to be reviewed in Engineering Drawings are:

Consistency of Process data as per process datasheets such as Operating & Design Conditions, MOC, Special service requirements, etc.

Number of Nozzles

Sizes of Nozzles

Checking location and orientation of all nozzles

especially nozzles for Temperature, Pressure and

Level Instruments as per Project requirements


Module Review of Plot PlanSome of the Critical points to be reviewed in Plot plan are:

Consistency of equipments shown in plot plan with Equipment List, PFD and P&IDs.

Are the distances between equipment kept minimum with respect to pressure drop?

Are the height of Towers and vessels enough to provide NPSH of pumps?

Are the equipment located symmetrically such as column and reboilers?

Is there enough space around columns, towers and reactors for removal of internals?

Is there enough space to remove tube bundle of heat exchangers?

Are the equipments arranged considering safety aspects especially for Fired heaters, Compressors and Tanks?


Module 3D-Model Review

Some of the Critical points to be considered in 3D-model review are:

Is piping arranged to provide straight run requirement such as inlet of tower?

Are CV sets placed as per Project requirements such as closeness to equipment, at high or low level, etc., if

any?

Are symmetrical piping considered for AFCs?

Are the valves located at operable location from the nearest platform or grade?

Is piping arranged to keep special bending radius requirements, if any?


Module Review of DCS GraphicsReview of Control logics as per Control & Safeguarding narratives


ModuleSTAGE 2 (Continued):

Updation of Control & Safeguarding narratives and issue

for HAZOP Study

Updation of Utility summary

Updation of Line list


ModuleSTAGE 3:

Safety Studies / Analysis

Updation of P&IDs based on Safety Studies

recommendation

Preparation of Precommisioning manual

Preparation of Operating manual


Module Safety Studies / Analysis

HAZOP Study

SIL Study

FIREPRAN Study


Module

HAZard and OPerability study is a technique to examine a

system, part by part, in a very systematic manner, to find

out the cause and consequence of every conceivable

deviation in the normal operation of the system as well

as during emergencies, start-ups and shutdowns. The

method enables prediction of all possible ways in which a

hazard or an operating problem could arise, whether the

design takes preventive care of them and if not,

recommends changes (Action) as may be necessary.

HAZOP Study


ModuleSIL Measurement of confidence level for performance of safety function is called the Safety Integrity Level(SIL)

Safety integrity of a system can be defined as The probability (likelihood) of a safety-related system

performing the required safety function under all the stated conditions within a stated period of time

SIL is a measure of the reliability of the safety function performing to specification.

The SIL is based on the accepted risk level and ranges from 1 to 4

Probability of Failure Safety

Integrity Level (SIL)

Mode of Operation On demand (average probability of failure to perform

its design function upon demand)

Mode of Operation continuous (probability of dangerous failure per

hour) 4 > 10-5 to < 10-4 > 10-9 to < 10-8 3 > 10-4 to < 10-3 > 10-8 to < 10-7 2 > 10-3 to < 10-2 > 10-7 to < 10-6 1 > 10-2 to < 10-1 > 10-6 to < 10-7


Module FIREPRAN studyFIRE PRotection & ANalysis is a new technique employed at the design phase of a facility or installation to achieve the following objectives

Overview the role of the facility and its significance to the overall operation.

Review the facilitys Fire and Explosion Strategy (FES) in the context of the role of the facility and its significance to the overall company.

Analyze threats to loss of containment or other potential sources of combustion events.

Assess release event consequences and explosion scenarios

Review and assess adequacy of threat control measures, mitigation and recovery measures.

Make recommendation for risk reduction measures to achieve levels as low as reasonably practicable (ALARP).


ModuleExample for Firepran StudyColumn middle cut pool fire and isopleths is analyzed as shown below in case of possible explosion due to oil leakage above its Auto Ignition Temperature.

Heat Flux kW/m2

Effects on Human Effects on Property

4

Sufficient to cause pin to personnel if unable to reach cover within 20 seconds.

No damage

12.5

This level of radiation will cause a 30% chance of fatality for a prolonged exposure.

Minimum energy required for piloted ignition of wood, melting of plastic tubing

37.5

Sufficient to cause damage to process equipment. Exposure to this level of radiation is assumed to give rise to a 100% chance of fatality

Failure of steel structures within 30 minutes


ModuleCritical Area identification

Area in red needs to be given extensive consideration for fire protection systems


Module

Updation of P&IDs based on Safety Studies

recommendation

Preparation of Precommisioning manual

Preparation of Operating manual

STAGE 3 (Continued):


Module

Slide 1Slide 2Slide 3Slide 4Slide 5Slide 6Slide 7Slide 8Slide 9Slide 10Slide 11Slide 12Slide 13Slide 14Slide 15Slide 16Slide 17Slide 18Slide 19Slide 20Slide 21Slide 22Slide 23Slide 24Slide 25Slide 26Slide 27Slide 28Slide 29Slide 30Slide 31Slide 32Slide 33Slide 34Slide 35Slide 36Slide 37Slide 38Slide 39Slide 40Slide 41Slide 42Slide 43Slide 44Slide 45Slide 46Slide 47Slide 48Slide 49Slide 50Slide 51Slide 52Slide 53Slide 54Slide 55Slide 56Slide 57Slide 58Slide 59Slide 60Slide 61Slide 62Slide 63Slide 64Slide 65

design-refinery.pdf

Documents

basic process pids sizing

general specifications

control valve assembly

block bypass