equipment engineering
DESCRIPTION
Presentation of the work of the Equipment Engineering disciplineTRANSCRIPT
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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 ([email protected]),which I will incorporate for the benefit of all.
Hervé
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Engineering disciplines: activities and deliverables
� PROCESS
� EQUIPMENT
� SAFETY & ENVIRONMENT
� CIVIL
� PIPING LAYOUT & MATERIAL
� INSTRUMENTATION
� ELECTRICAL
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A unique synthesis
200 pages, 250 illustrations
3000 copies sold to date
Order your copy on-line today:
Your reference
http://www.editionstechnip.com/U/baron_oil_gas_engineering_guide_the_1695.asp
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Process design
PFDs
H&M balance
Rotating
Pressure vessels
Fired equipment
Heat exchangers
Packages etc.
Process
data sheet
Equipment specification
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Equipment list
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Equipment ∕ Mechanical
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Equipment ∕ Mechanical
Which documents are issued to
• Specify
• Inquire
• Select
• Order
Equipment?
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Rotating Equipment
Let’s start with rotating
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Rotating Equipment
Which documents are produced to specify Rotating Equipment ?
Let’s start with rotating
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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).
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Process Data sheet / Mechanical Data Sheet
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Process Data sheet / Mechanical Data Sheet
What are the contents of the code ?
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Process Data sheet / Mechanical Data Sheet
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
etc.
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Mechanical Data Sheet
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Mechanical Data Sheet
Some data is highlighted in green while some data is highlighted in
orange. What is the difference?
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Mechanical Data Sheet
How and by whom are the Materials of Construction defined?
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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
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Material selection
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Material selection
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Pressure Vessels
Which documents are produced to specify Pressure Vessels ?
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Mechanical design
Any other document ?
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Mechanical Data Sheet
What additional information is contained in the Mechanical DataSheet that is not contained in the Process Data Sheet? What doesMechanical design entail?
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Mechanical Data Sheet
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
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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
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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
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Mechanical design
http://www.microprotol.com/demo_viewlet.htm
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Mechanical design
Calculation file
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Mechanical Design
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Mechanical Design
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Mechanical Design
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Mechanical data sheet
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Equipment ∕ Mechanical
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Heat Exchangers
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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.
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Heat Exchanger
Shell & TubesSizing of Shell & tube heat exchangers by Process
https://www.htri.net/demo/
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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
etc.
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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.
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Heat Exchanger
Mechanical Design
The Equipment engineer performs the Mechanical design of Shell & Tube type heat exchangers only.
N1B
N2A
N4
N5 N3
N2B
N1A
V
DUC
HLLHLL
Ref[1]: 0
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Heat Exchanger
Mechanical Design
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Heat Exchanger / Mechanical Data Sheet
The mechanical design results in the issue of the Mechanical Data Sheet
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Equipment ∕ Mechanical
How are heaters specified ?
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Equipment ∕ Mechanical
Heaters Process Data Sheet
What is particularly important while specifying a heater ?
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Equipment ∕ Mechanical
What are the miscellaneousequipment?
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Equipment ∕ Mechanical
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)
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Equipment ∕ Mechanical
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
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Equipment ∕ Mechanical
What is a package ?
What is, for Engineering, the purposeto order as 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.
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Packages
Off-shore
Instrument air generation Air dryers skid
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Packages
Off-shoreGlycol regeneration
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Packages
On-shore
Cold boxStorage tank
(25m high)
Steam bath vaporizer
Nitrogen generation unit
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Equipment ∕ Mechanical
What is a package ?
What is, for Engineering, the purposeto order as a package ?
What is usually ordered as a package ?
Which is the responsible discipline ?
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Equipment ∕ Mechanical
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
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Equipment ∕ Mechanical
What is a package ?
What is, for Engineering, the purposeto order as a package ?
What is usually ordered as a package ?
Which is the responsible discipline ?
Which document is produced to specifya package ? By whom ?
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Equipment ∕ Mechanical
A duty spec rather than a
Data Sheet is issued for
packages.
It is issued by Process
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Equipment ∕ Mechanical
What type of guarantees
are requested?
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Equipment ∕ Mechanical
What type of guarantees
are requested?
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Equipment ∕ Mechanical
� 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?
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Equipment ∕ Mechanical
� 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 ?
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Local control Centralized control
Instrumentation Specification for packaged units
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Equipment ∕ Mechanical
What other documents besides the Data Sheet / Duty
specification are issued to specify and order Equipment ?
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Equipment ∕ Mechanical
What other documents besides the Data Sheet / Duty
specification are issued to specify and order Equipment ?
2) THE SPECIFICATION
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Data sheet / Specification
What is the scope of each document?
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Data sheet / Specification
Two types of specifications are issued. What are the two types?
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Specification
EP - 21799_a_A_ppt_01 - Eng. Mangement Part 2 - Engineering disciplines63
General
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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
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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
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Specification
Particular
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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
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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
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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
Deviations and exceptions are discussed with
Vendors, and incorporated in the specification
final revision IFP
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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
In all concerned disciplines (to reduce the
number of other discipline specs
transmitted to the vendor)
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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
� Documentation
Strongly influences the amount of work on
site
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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
During bid stage (before PO)
information is required to Vendor for
Technical analysis. This paragraph is
deleted for IFP revision
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Equipment ∕ Mechanical
Which document, issued to the bidders, summarizes the inquiry?
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Equipment ∕ Mechanical
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
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Material requisition
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Material requisition
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Material requisition
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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
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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
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Inspection requirements
Supplier class
Very critical
Critical
Low critical
Non critical
Eq
uip
me
nt
Cri
tica
lity
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
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Inspection requirements
Very good Good Fair Bad
Supplier class
Very critical
Critical
Low critical
Non critical
Eq
uip
me
nt
Cri
tica
lity
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
2
not
qualified
1
3
1
3
4
4
22
2
333
not
qualified
not
qualified
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Material requisition
What are thedifferent typesof documentsrequested fromthe vendor ?
� 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
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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
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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 ?
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Vendor Documents Requirements & Schedule (VDRS)
What do you do to ensure these documents will be submitted on-time ?
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Vendor Documents Requirements & Schedule (VDRS)
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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?
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Bid technical evaluation
Supplier 1 Supplier 2Requirements
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Equipment / Mechanical
What is the work of the Equipment engineer after the purchase order isplaced?
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Equipment / Mechanical
What is the work of the Equipment engineer after the purchase order isplaced?
� Review of vendor documents
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Equipment / Mechanical
What is the work of the Equipment engineer after the purchase order isplaced?
� Review of vendor documents
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Equipment / Mechanical
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
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Equipment / Mechanical
What is the work of the Equipment engineer after the purchase order isplaced?
� Review of vendor documents
� Coordination with other disciplines
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Equipment / Mechanical
What is the work of the Equipment engineer after the purchase order isplaced?
� Review of vendor documents
� Coordination with other disciplines. There are many interfaces…
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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?
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Equipment / Mechanical
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
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Equipment / Mechanical
A column is vendor is also at interface
with another vendor. Which one?
� That of the column internals…
Illustation courtesy of Sulzer
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Wrap-up
Dcouments issued to order various types of equipment
Equipment Process discipline Equipment/Mechanical discipline
PDS Duty
spec
MDS Particular
Specification
General
Specification
MR
Pressure Vessel X X X X
Rotating equipment X X For
extended /
complex
supplies
X X
Heat Exchanger – Shell &
Tube
X X X X
Air-coolers X X X
Fired heater X X For
extended /
complex
supplies
X X
Package X X X
HERVE
BARON
© 2
01
4 –
He
rvé
Ba
ron
http://www.toblog.fr/en/baron.html
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