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Bechtel Confidential– 1 –

LEVEL 1 ORIENTATION Process Systems Engineering

Overview10 April 2006

LEVEL 1 ORIENTATION Process Systems Engineering

Overview10 April 2006

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Bechtel Confidential– 2 –

Process Systems Overview – ObjectivesProcess Systems Overview – Objectives

This module will provide a high level review of the roles of the Process Systems Engineers, the discipline’s organization, processes, procedures, major deliverables, and tools in the OG&C GBU.

When completed, you will have a framework in which to fit the Process Systems activities, work processes, and interfaces.

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Bechtel Confidential– 3 –

Process Systems Overview – ContentsProcess Systems Overview – Contents Process Systems Organization

Process Systems Responsibilities

Process Systems Deliverables

Process Systems Deliverables/Requirements

Purpose/Use of P&IDs

P&ID Development Responsibilities

Development of Other Process Systems Engineering Deliverables

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Bechtel Confidential– 4 –

Process Systems Overview – OrganizationProcess Systems Overview – Organization The Process Systems group on a project is

headed by the Process Systems Engineering Group Supervisor (EGS)

The Process Systems EGS is supported on a project by the Process Systems Engineers

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Bechtel Confidential– 5 –

Process Systems Overview – ResponsibilitiesProcess Systems Overview – Responsibilities

The responsibilities of the Process Systems Engineering Group Supervisor’s are:

Overall design coordination

Know overall design status

Identify problems in execution of design

Budget and schedule design work

Lead other Process Systems Engineers

Responsible for completion of all deliverables

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Bechtel Confidential– 6 –

Process Systems Overview – ResponsibilitiesProcess Systems Overview – Responsibilities

The responsibilities of the Process Systems Engineer are:

Produce assigned deliverables

Participate in HAZOP Reviews

Coordinate with other engineering disciplines

Usually responsible for several systems or units

3D Model driving and coordination

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Bechtel Confidential– 7 –

Process Systems Overview – DeliverablesProcess Systems Overview – Deliverables P&IDs

Line Designation Tables (LDTs)

Project-specific Specifications (i.e., PSV)

PSV Summary List

Equipment List

Specialty Item List

Hydraulic Calculations

Tie-in List (if required)

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Bechtel Confidential– 8 –

Process Systems Engineering Deliverables/ Requirements

PFDs – Process Systems provides CADD support only, in support of Process Engineering

Design Pressure and Temperature Guide (DPDT) – the DPDT guide will be an overlay of the PFDs and will be Issued for Use by Process Systems with input/review by Process

Material Selection Guides (MSGs) – the MSG guide will be an overlay of the PFDs and will be issued for approval/design by MET with CADD support by Process Systems

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Bechtel Confidential– 9 –

Process Systems Engineering Deliverables/ Requirements

P&IDs – to be Issued for Review (IFR), Approval (IFA), HAZOP (IFH), Design (IFD) and Construction (IFC) using project approved CADD format

 LDTs – to be issued along with P&IDs

Equipment List – will be developed by Process Systems with input from Process and Mechanical

Pump and Compressor Calculations –hydraulic calculations will be performed for all rotating equipment

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Bechtel Confidential– 10 –

Process Systems Engineering Deliverables/ Requirements

Hold Lists, DCNs and Management of Change (MOC) – MOC will be implemented after P&IDs are issued for HAZOP; revision lists will be issued with P&IDs after the HAZOP is complete; hold Lists and DCNs will be issued after Issued for Design (IFD)

Specialty and tie-in lists

PSV Summary

Model Driving/Coordination – provide a model driver for model reviews and coordinate models comments

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Bechtel Confidential– 11 –

Types of P&IDsTypes of P&IDs

Process P&IDs

Utilities P&IDs

Auxiliary P&IDs

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Bechtel Confidential– 12 –

Purpose / Use of P&IDsPurpose / Use of P&IDs

The most essential document on the project

Defines the scope of work

Transmits essential information to design groups

Used for planning by construction, startup and operations

Used to prepare preliminary piping and special material take-offs

Used to develop preliminary plot plan

Used to provide the design basis for model work

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Bechtel Confidential– 13 –

Purpose / Use of P&IDs (Cont’d)Purpose / Use of P&IDs (Cont’d)

Used to control changes to the scope of work

Used to help maintain basic job documents

— Line Designation Tables

— Instrument Index

— Insulation and heat tracing requirements

— Piping material classes

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Bechtel Confidential– 14 –

Purpose / Use of P&IDs (Cont’d)Purpose / Use of P&IDs (Cont’d)

Used for constructability reviews

Used with equipment list to make engineering work hour estimates

Provide basis for the client’s operator training and maintenance planning

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Bechtel Confidential– 15 –

P&ID Development ResponsibilitiesP&ID Development ResponsibilitiesProject Engineering Manager PEM ensures that all P&ID guidelines are

followed

Area Project Engineer Verify schedule for issuing P&IDs is consistent

with project requirements Ensures specific requirements are in place for:

— Sparing philosophy

— Winterization

— Insulation/tracing

— Drainage systems.

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Bechtel Confidential– 16 –

P&ID Development Responsibilities (Cont’d)

P&ID Development Responsibilities (Cont’d)

Process Engineering

Provides process design information

— Issues and updates PFDs

— Issues stream data and properties

— Issues initial pump requirements

Provides process design information for equipment

— Vessel design sketches

— Tray data sheets

— Fired heater process data

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Bechtel Confidential– 17 –

P&ID Development Responsibilities (Cont’d)

P&ID Development Responsibilities (Cont’d)

Process Engineering (Cont’d)

Provides process design information for equipment (Cont’d)

— Compressor process data sheets

— Heat exchangers process data sheets

Provides relief valve selection basis including size estimate

Prepares utility balances

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Bechtel Confidential– 18 –

P&ID Development Responsibilities (Cont’d)

P&ID Development Responsibilities (Cont’d)

Process Systems Engineers

Prepare all P&ID drawings

Perform pipe size calculations

— Select line sizes

— Provide control valve and flow element sizing data to control systems

— Assign Line Numbers

— Prepare LDTs

Identify and number all specialty items

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Bechtel Confidential– 19 –

P&ID Development Responsibilities (Cont’d)

P&ID Development Responsibilities (Cont’d)

Process Systems Engineers (Cont’d)

Verify the accuracy of mechanical data sheets and specifications based on the P&ID

Coordinate information between P&IDs of systems and related areas of plant

Ensure system design is suitable for upset conditions

Ensure all applicable environmental and safety codes and practices are followed

Ensure that P&IDs meet maintenance and safety needs

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Bechtel Confidential– 20 –

P&ID Development Responsibilities (Cont’d)

P&ID Development Responsibilities (Cont’d)

Process Systems Engineers (Cont’d)

Make all P&ID issues (IFR, IFA, IFH, IFD, IFC)

— Prepare and issue revision lists (after IFH issue)

Maintain the up-to-date master markup

Conduct P&ID review meeting of client P&ID comments after IFA issue

Conduct 3D Model Reviews

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Bechtel Confidential– 21 –

P&ID Development Responsibilities (Cont’d)

P&ID Development Responsibilities (Cont’d)

Control Systems Engineering

Works with Process Systems in the representation of control systems on the P&ID

Reviews Control Philosophy and ensures conformance to project requirements

Issues uniform criteria for application of control systems and instrumentation

Ensures proper instrumentation numbering and symbology on the P&IDs

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Bechtel Confidential– 22 –

P&ID Development Responsibilities (Cont’d)

P&ID Development Responsibilities (Cont’d)

Control Systems Engineering (Cont’d)

Prepares functional control diagrams

Regularly updates master markup

— Reviews changes in instrumentation that will impact other disciplines with Process Systems and the affected disciplines

Ensures accurate representation of instrumentation supplied with vendor packages

Identifies control systems packages including utility requirements

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Bechtel Confidential– 23 –

P&ID Development Responsibilities (Cont’d)

P&ID Development Responsibilities (Cont’d)

Plant Design and Piping

Issues piping material classification specifications

Provides configuration of the piping on the P&IDs

Updates the project master markup

Advises Process Systems of equipment layout changes that affect the P&IDs

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Bechtel Confidential– 24 –

P&ID Development Responsibilities (Cont’d)

P&ID Development Responsibilities (Cont’d)

Mechanical Engineering

Provides preliminary estimate of number of exchanger shells and air cooler exchanger sections

Coordinate any changes to mechanical equipment that affects the P&IDs

Provides equipment data summary with utility requirements

Provides preliminary vendor data obtained from successful equipment vendor’s quotation

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Bechtel Confidential– 25 –

Development of Other Process Systems DeliverablesDevelopment of Other Process Systems DeliverablesHydraulic Calculations Line Designation Tables (LDT)

— Line Designation Tables provide a listing of all process and utility lines, includes velocity and delta P per km specifications for normally flowing lines

— Includes the upset and design pressure/temperature (at IFH issue)

— Line Designation tables contain pertinent design information for each line to determine wall thickness, insulation, stress analysis, supports

Pump and Compressor Hydraulic Calculations— Determine preliminary system requirements— Determine preliminary power requirements

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Bechtel Confidential– 26 –

Development of Other Process Systems Deliverables (Cont’d)

Development of Other Process Systems Deliverables (Cont’d)

Pump and Compressor Hydraulic Calculations IFQ Phase ─ Level 1

— Level 1 uses preliminary information for pump calculations, Equipment Dp, Estimated Dp for Control Valves, Plot Plan and equipment layout for line loss estimates

IFP Phase ─ Level 2— Level 2 uses quoted pump curves, quoted pump

NPSH (adjust skirt height), quoted equipment Dp, Calculated control valve CV, Piping drawings for line loss calculations

VP Phase ─ Level 3— Level 3 uses final pump curves, pump NPSH,

equipment DP, Control Valve CV, Isometrics

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Bechtel Confidential– 27 –

Process Systems Overview – SummaryProcess Systems Overview – Summary

This module provided a high level review of the roles of the Process Systems Engineers, the discipline’s organization, processes, procedures, major deliverables, and tools in the OG&C GBU

Now you have a framework in which to fit the Process Systems activities, work processes, and interfaces