PROCESS PLANT DESIGN

Dr. Le Ba Hung
06 Jan 2018
HCM, Viet Nam
 This course

 Helps you understand these processes

 Helps you design these processes
 Helps you prevent…..

10
 OUTLINE
I. OVERVIEW

II. DESIGN BASIS

III. PROCESS FLOW DIAGRAM

IV. PIPING & INSTRUMENTATION DIAGRAM

V. PROCESS DESIGN AND SIMULATION

VI. EQUIPMENT DESIGN

VII.COST ESTIMATION
11
12
13
Process Engineering Design Scope

14
Process Engineering Design Scope

15
Process Engineering Design Scope

16
 Process Engineering Design Scope
The The
COMPANY suppliers
“Client”

PETROVIETNAM
(Dung Quat Refinery)
The EPC
Contractor

Technip The sub-

JGC contractors

PTSC
LILAMA
….
 Process Engineering Design Scope

Conceptual Basic Project Execution

evaluation Engineering By EPC
By COMPANY By ENGINERING CONTRACTOR
 Process Engineering Design Scope
CAPEX estimated at ±30%
Sanction : launch FEED studies EPC Contract Hand-over

CAPEX estimated at ±15% CAPEX estimated at

Techno-Economical Sanction : ITB for EPC phase ±10%
studies

Filing
Flowscheme and Licensor Feedback
Equipment Sizing
selection
Datasheets
Heat & Material Balance Assistance to Project and
P&ID Development
Optimisation studies to Site

Feasibility Detailed Procurement Start-Up

“Basic” “FEED” Operation
Study Design Construction Test runs

Performances
Demonstration

3 MONTHS 6 MONTHS 6-12 MONTHS 12-18 MONTHS 24 MONTHS 6 MONTHS

19
Process Engineering Design Scope

20
Process Engineering Design Scope

21
 Process Engineering Design Scope

Document for
Construction:
Design basis:
Construction
drawings &
1. Functional specifications
requirement
ENGINEERING

2. Client
Specifications Document for
Purchase:
3. Design codes
Bill of quantity &
specification

22
Process Engineering Design Scope

23
Process Engineering Design Scope

24
Process Engineering Design Scope

25
 Process Engineering Design Scope
➢ BFD
➢ Simulation
➢ PFD
➢ UFD
➢ Process Description
➢ Heat & Material Balance(H&M)
➢ P&ID
➢ Process Design Criteria
➢ Utility Consumption
➢ Chemical Consumptions
➢ Line List (For Piping Discipline)
➢ Instrument PROCESS Data Sheet (For Instrument Discipline)
➢ Equipment PROCESS Data Sheet (For mechanic Discipline)
➢ Process Data Sheet For Piping Special Item (For Piping Discipline)
26
Process Engineering Design Scope

27
Process Engineering Design Scope

28
Process Engineering Design Scope

29
Process Engineering Design Scope

30
31
 Role of Process Design Engineer

Importance of Process Design

 In Preliminary Process Design
◦ 98% Operating Costs Committed
◦ 80% Capital Costs Committed
 Less than 10% $ Spent
 Design is Very Important

 But why is this so?

32
 Role of Process Design Engineer

Importance of Process Design

Why ?
 In Preliminary Design
◦ Decide on Raw Materials Operating Costs
◦ Decide Process
 Reactor System Capital Costs
 Separation System Capital Costs
 Recycle System Capital Costs
 Heat Integration Scheme Capital Costs
 Utilities Operating Costs

33
 Role of Process Design Engineer
How is Design Practiced
 Process Conception
 Preliminary Design
◦ Process Concepts
◦ Process Economics
 Management decision to go forward
 Intermediate Design
◦ P&ID’s
◦ Ask vendors for prices major pieces of equipment
 Reactor, Separators, HX, Utilities, tank farms
◦ Process Economics
 Management decision to go forward
 Detailed Design
◦ Mechanical Engineering
 Equipment + Supports
◦ Where are all the nuts and bolts
◦ Piping elevation
◦ Electrical/Power Engineering
◦ Utilities
◦ Process Economics
 Management decision to go forward

34
 Role of Process Design Engineer
Process Creation
 Chemical Reaction Routes
 Preliminary Database
◦ MSDS – (Health and safety info.)
 Raw Materials
 Reaction Products and Intermediates
◦ Thermo/phys properties (Expts and Predictions)
 Heats of Formation
 VLE data, solubilities, etc.
◦ Chemical Prices (Chemical Market Reporter)

35
 Role of Process Design Engineer
Operating costs

 Selection of Raw Materials

 Selection of Reaction Path to Product
 Determine Gross Profitability of Process

 Examples
◦ Vinyl Chloride Manufacture (part of PVC plant)
◦ Octane Manufacture (part of refinery)

36
37
 Process Design Basis

The objective of this document is to

define the Process Basis of design
for selected project

38
 Process Design Basis

Project description
Codes and standards
System of units
Environmental data
Design input
Process design criteria / general requirements

39
40
Role Of Feasibility Studies In Upstream And Downstream Projects

41
 HowBlock
toFlow
develop a P&ID
Diagram (BFD)

A BFD (Block Flow Diagram) is a simple breakdown of a process into blocks

or units of operations which represent major parts of the process being
depicted.
Mixed Gas
Toluene, C7H8 2610 kg/hr
10,000 kg/hr

Reactor Gas Separator Benzene, C6H6

C6H6
8,210 kg/hr
CH4
Hydrogen H2
820 kg/hr C7H8
Mixed Liquid

75% Conversion of
Toluene

Reaction : C7H8 + H2 C6H6 + CH4

Block Flow Diagram for the Production of Benzene 42

 Block Flow Diagram (BFD)

 Is the simplest flowsheet.

 Process engineer begins the process design with a block diagram in

which only the feed and product streams are identified.

 Input-output diagrams are not very detailed and are most useful in
early stages of process development.

 Flow of raw materials and products may be included on a BFD.

 The processes described in the BFD, are then broken down into
basic functional elements such as reaction and separation sections.

 Also identify the recycle streams and additional unit operations to

achieve the desired operating conditions.

43
Block Flow Diagram (BFD)

44
 Process Flow Diagram (PFD)

A PFD (Process Flow Diagram) is a detailed breakdown of a process into symbols

which represent all major equipment and pipelines which are part of a process
as defined by the BFD.

Process Flow Diagram for the Production of Benzene 45

 Process Flow Diagram (PFD)

PFD will contains the following information:

All major pieces of equipment (descriptive name, unique equipment

no.), pumps and valves.

 All the utility streams supplied to major equipment such as steam lines,
compressed air lines, electricity, etc.

Basic Control Loop: showing the control strategy used to operate the
process under normal operations.

46
 Process Flow Diagram (PFD)

PFD stands for “Process Flow Diagram”, It is also called as PFS i.e. “Process Flow Schematic”.
PFD’s are useful to understand,
1. Overall Process flow from start to end in one glance.
2. It shows main areas of Process Plant, related equipments in that area or sub area and its main
connectivity (for exp. Storage Tank, Vessels, Compressors, Pumps etc.)
3. PFD’s are useful to identify critical Instruments and ESDV signal interlock for Plant ESD (Emergency
Shutdown) and PSD (Process Shutdown).
4. PFD’s are used to design detail P&ID (Equipment and Area wise for Overall plant.)
5. Process Department is responsible for DESIGN of PFD’s and Instrument department for proper
representation of Instrument Symbols, Instrument Tags, Interlocks, Open and Closed Loops, System
Symbols (DCS, ESD, PLC and Third Party systems).
6. It is useful to generate graphics for Overall Plant, Area and sub area.
7. It is useful to generate Cause and Effect Diagram for ESD and PSD.
PFD is critical document leads to the Project

47
48
 Piping & Instrumentation Diagram (P&ID)

What are the purpose of P&IDs?

49
 Piping & Instrumentation Diagram (P&ID)

Piping and Instrumentation Diagram (P&ID)

 Piping (P)
 and Instrumentation (&I)
 Diagram (D)

A Piping and Instrumentation Diagram (P&ID) is a schematic illustration

of functional relationship of piping, instrumentation and system
equipment components.

50
 Introduction

❖What Does P&ID Stand For?

❖Why Learn to Read P&IDs?
❖Who Uses P&IDs?
❖How Are P&IDs used?
❖How to Read P&IDs?

51
 Introduction

P&ID Stands For:

➢ Piping
➢ and Instrumentation
➢ Diagram or Drawing

52
 Introduction

➢ Design Review and Feedback: P&IDs reflect overall design and operating
intent. Knowing how to read P&IDs, allows you to better understand the
design intent and provide feedback.
➢ Operation: Aid to understanding of process and process interactions.
Correlation to SCADA. Options for control.
➢ Maintenance: Tag numbers; interlocks with other equipment; valves and
controls; redundancy.

53
Introduction

54
 Introduction

Design:

➢ Integrate different disciplines, including Process, Mechanical, Piping

Electrical, and I&C.
• Show Functional requirements (not Physical)
• Used to develop and check equipment lists
• Used to develop PLC input/output lists
• Describe requirements for PLC and SCADA software

Operation and Maintenance:

➢ Reference Tool
➢ Training Tool
➢ Documentation of Plant Process and Control
55
Introduction

56
It includes:

57
It includes:

58
It includes:

59
60
Legend and Symbols

61
Identifications and Numbering

62
Identifications and Numbering

63
Details and Typical

64
Details and Typical

PSV PSV

LO

MIN
TI TT LO LO
(6)

600 MIN
V V (13) FO

600 MIN
V (3)
(1)
20 20
LO LC

FO
PG
SP (7) TSO
(4)
BDV
(11) (1)
MH
(9)
600

LG LT LIC
(8)

TL
(12) UC
(5)
(10)
(1)

LPT

D (2)

65
Review of basic and specialized symbols
Temperature Process
 Review of basic and specialized symbols
Building the P&ID
The P&ID will use symbols and circles to represent each instrument and how
they are inter-connected in the process.
 Review of basic and specialized symbols
Building the P&ID
Tag “numbers” are letters and numbers placed within or near the instrument to
identify the type and function of the device.
Review of basic and specialized symbols
Building the P&ID
 BASIC INSTRUMENT SYMBOLS

Basic Loop
Process

Sensing Element

Final Control Measuring

Element Element Transmitter

Transmit
Element

Control Element
 BASIC INSTRUMENT SYMBOLS

Basic Loop Set point

Controller

Transmitter

Fluid Fluid

Orifice
(Flow Sensor)
BASIC INSTRUMENT SYMBOLS
BASIC INSTRUMENT SYMBOLS
 BASIC INSTRUMENT SYMBOLS
FC Flow Controller PT Pressure Transmitter
FE Flow Element PTD Pressure Transducer
FI Flow Indicator
FT Flow Transmitter LC Level Controller
FS Flow Switch LG Level Gauge
FIC Flow Indicating Controller LR Level Recorder
FCV Flow Control Valve LT Level Transmitter
FRC Flow Recording Controller LS Level Switch
LIC Level Indicating Controller
PC Pressure Controller LCV Level Control Valve
PG Pressure Gauge LRC Level Recording Controller
PI Pressure Indicator
PR Pressure Recorder TE Temperature Element
 BASIC INSTRUMENT SYMBOLS

PS Pressure Switch TI Temperature Indicator

PIC Pressure Indicating Controller TR Temperature Recorder
PCV Pressure Control Valve TS Temperature Switch
PRC Pressure Recording Controller TC Temperature Controller
PDI Pressure Differential Indicator TT Temperature Transmitter
PDR Pressure Differential Recorder
PDS Pressure Differential Switch
PDT Pressure Differential Transmitter
BASIC INSTRUMENT SYMBOLS
 BASIC INSTRUMENT SYMBOLS
Instrumentation Symbology

Instruments that are field mounted.

-Instruments that are mounted on process plant (i.e sensor that
mounted on pipeline or process equipments.

Field
mounted on
pipeline
 BASIC INSTRUMENT SYMBOLS

Instrumentation Symbology
Instruments that are board mounted
-Instruments that are mounted on control board.
 BASIC INSTRUMENT SYMBOLS
Instrumentation Symbology
Instruments that are board mounted (invisible).
-Instruments that are mounted behind a control panel
board.
 BASIC INSTRUMENT SYMBOLS

Instrumentation Symbology
Instruments that are functioned in Distributed Control System (DCS)
- A distributed control system (DCS) refers to a control
system usually of a manufacturing system, process or any kind
of dynamic system, in which the controller elements are not central
in location (like the brain) but are distributed throughout the system
with each component sub-system controlled by one or more
controllers. The entire system of controllers is connected by
networks for communication and monitoring.
 BASIC INSTRUMENT SYMBOLS

Instrumentation Symbology

SAFETY INSTRUMENTED SYSTEMS (SIS): Systems

composed of sensors, logic solvers, and final control elements
for the purpose of taking the process to a safe state if
predetermined conditions are violated. Other terms commonly
used include Emergency Shutdown System (ESD or ESS),
Safety Shutdown System (SSD), and Safety Interlock System
(SIS).
BASIC INSTRUMENT SYMBOLS
83
84
85
86
87
88
89
Engineering disciplines: activities and deliverables

90
Design basis and criteria

91
 Design basis and criteria

Summary of Production Forecast for Total Production

Associated
Oil Water Total Liquid
Year Gas
(std bbl/d) (std. bbl/d) (std. bbl/d)
(scf/d)
2011 6758 5339532 764 7522
2012 5870 4795923 941 6811
2013 5218 4391937 1080 6298
2014 4597 3996549 1182 5778
2015 4207 3758737 1277 5483
2016 3860 3548457 1348 5208
2017 3545 3337631 1425 4970

92
Process simulation

93
Process simulation

94
Process design basis

95