Economic Model

Process Flow Diagram (PFD)

Stoichiometry

Plant Design Documents Piping and Instrument Diagram (PID) and Information Flow
Plot Plan (Plant Layout)

Accumulation of Value Delivered in Capital Projects

Contributing Activities
Client Case Conceptual Design Detail Design Construction Commissioning Production

Major Equipment Placement

Premium to Operate (Service Contract) Premium to Complete (Fixed Bid)

Major Pipe Routing

Piping Layout

Discount or Premium to Achieve Expected Value to Customer V i

Discount to Purchase (Prudent Buyer)

Copyright , 2008, William G. Beazley, PhD Fabrication ISOs Pipe Segment PFV Material All Rights Reserved Other Copyrights Apply as Noted Extracted Pipe Segments Piping Spool Sheets
From Turtons et. al. P. 2

Process Flow Diag & ROI

Design Concept & ROI

ROI with Fabricator / Suppier Bids

Plant Built

Production Begins

Value Assessments

Front-End Loading Process

(The Business Roundtable) Critical planning phases of the project Named from commitment of time and resources at FEL to dictate future success of project
FEL 1 Business Planning - opportunity is explored FEL 2 Facility Planning hones broad objectives into a particular project at a particular site with a particular technology configuration and schedule. FEL 3 Project Planning stage fills in details needed so detailed engineering can execute the project with little or no change.
http://www.ipainstitute.com/home/publications/pdf/ipa_business_stake.pdf

Three-Phase Gated Approval System (IPA Institute)

Idea Initiation
Business Planning

Gate 1

Gate 2

Gate 3

Turnover

Facility Planning

Project Planning

Execution Phase

Operations Phase

75% of the Ideas Do Not Pass Gate 1

50% of the Remaining Ideas Do Not Pass Gate 2

Only 1% of the Remaining Ideas Do Not Pass Gate 3

Decision Gates
Recycle Back Continue

Cancel/Shelve

The IPA Institutes Gatekeeper seminar will arm gatekeepers with the questions they need to ask to move a project forward or to kill it.

Engineering Design Phases

Conceptual designs
Sketchy or minimal information Abstract plot plan (equipment & piping layout)

Three Major Sources of Project Data

1. Project design data supplied by the client or project engineering.
Process and process materials Plant location and environmental features

Preliminary, or study phase

Unchecked or uncertified data Design a facility in sufficient detail so that:
Confirm purchased equipment costs & delivery Purchase Long Lead Time Bulk materials.

Detail phase
All designs are finalized Based on such checked data;
Steel, concrete, hydraulics drawings, Certified vendor drawings for equipment, valves, and instruments.

2. Vendor data pertaining to equipment and specialty bulk items. 3. Internally generated engineering data.

Layout designer impact in conceptual, study phases

FEED

EPC

Plant Design Information Flow

Economics Owner Process Owner Materials Integrity Owner

The Flow of Information to Pipers

BFD

PFD

Matl SPEC

Piping Layout Owner

Piping Layout
Controls and Stability Owner

Equipment Vendors

Feedback
Equip Data

Fab ISOs, Spools, Etc. Structures, Foundations, etc.

P&ID

Process Information
Process description, including reactions, separations, mixing stages and their stability Operating/Extreme pressures, temperatures Likelihood and consequences of excursions and loss of control Process flow diagram (PFD) and stream data Required function and performance rate of each equipment item Physical properties of process materials
Arterial inventories Corrosion data and materials of construction.

Block Flow Diagram for Early Entrance Coproduction Plant

(US DoE)

http://www.osti.gov/bridge/servlets/purl/788122-TeVDrj/native/788122.pdf

Claus Plant: H2S to Sulphur

http://www.valero.com/AboutUs/Refineries/TexasCitySchematic.htm

http://en.wikipedia.org/w/index.php?title=Image%3AClausPlt.JPG

Block Flow Diagram

(Chevron Products Company)

Process Flow Diagram

(US OSHA)
http://www.aqmd.gov/ceqa/documents/2003/nonaqmd/chevron/chvFND.html

Process Flow Diagram

Shows Material Flows and Properties
Anchor Point Temperatures and Pressures Material Balances As Best Known

Typical Project PFD (KBR)

Shows Equipment that Changes State:

Major Pressure Vessels (Reactors, Columns, Drums) Major Pumps and Compressors Column Reboilers and Condensers Reactors, Furnaces, Heat Exchangers Valves If a Significant Pressure Drop

Sample Process Flow Diagram

(Source: Bausbacher and Hunt)

Data Normally Included on a Process Flowsheet

Process lines, but including only those bypasses essential to an understanding of the process All process equipment. Spares are indicated by letter symbols or notes Major instrumentation essential to process control and to understanding fIowsheet Valves essential to an understanding of the flowsheet Design basis, including stream factor Temperatures, pressures, flow quantities Weight and/or mol balance, showing compositions, amounts, and other properties of the principal streams Utilities requirements summary Equipment Data

Operators Viewing Process Details

(Chevron Phillips Chemical Company)

Information Developed from PFD

Piping and Instrumentation Diagram (P&ID) Equipment List (then Equipment Data) Process Material Hazards Material Specification

http://www.cpchem.com/enu/image_bank.asp

P&ID Example
(Source: DoE)

P&ID as Schematic for Layout

Piping and Instrumentation Diagrams

Schematic (connectivity only) Shows Items Needed to Control Process Conditions:
All process, utility, and auxiliary equipment Connecting piping, Valving, Specialty items, Instrumentation and Insulation, and heat tracing requirements.

Equipment List
Itemized accounting list by class of all equipment to be used on project Gives the equipment item numbers and descriptions Generally furnished by the client or project engineering

PIP P&ID Equipment Classes

CLASS A B C D E SUBJECT
Mixing Equipment Blowers Compressors Mechanical Drivers Heat Exchangers

P&ID Data Included for Particular Equipment

(James R. Couper)
Compressors SCFM (60F. 14.7 psia, P psi; HHP; number of stages; details of stages if important Drives type; connected HP; utilities such as kW. lb steam/ hr, or Btu/hr Drums and tanks- ID or OD. seam to seam length, important internals Exchangers: Sqft, KBtU/hr, temperatures, and flow quantities in and out, shell side and tube side indicated Furnaces: KBtU/hr, temperatures in and out, fuel Pumps: 6PM (60Ft, P psi, HHP, type, drive Towers Number and type of plates or height arid type of packing identification of all plates at which streams enter or leave: ID or OD seam to seam length; skirt height Other equipment: Sufficient data for identification of duty and size

DESCRIPTION
Agitators, Aerators, Mechanical Mixers Centrifugal Blowers, Positive Displacement Blowers, Fans Centrifugal, Reciprocating, Screw, Vacuum Electric and Pneumatic Motors, Diesel Engines, Steam and Gas Turbines Unfired Heat Exchangers, Condensers, Coolers, Reboilers, Vaporizers and Heating Coils, Double Pipe, Spiral, Plate & Frame, Air Coolers Fired Heaters, Furnaces, Boilers, Kilns Horizontal and Vertical Centrifugal, Positive Displacement, Vertical Canned, Screw, Gear, Sump

F P R T TK U V

Furnaces Pumps

Reactors Towers / Columns Tanks Misc Equipment Drums

API atmospheric and low pressure Filters, Bins, Silos Separators, Driers, Accumulators

Sample Equipment List

(Source: Bausbacher and Hunt)

Process Materials & Hazards

Hazardous properties, eg
Lower Flammability Limit (LFL) Upper Flammability Limit (UFL) Immediately Dangerous to Life or Health Concentrations (IDLH) Long Term Exposure Limit (LTEL)

Electrical classification practices Site climatic conditions & impacts Environmental effects and permitted discharge & release levels

Pipe Specs
Maximum Hydrostatic Test Pressure:
e.g. 450 psig

Changing Pipe Pressures in Oil Production

(Source: API RP 14E)
As Oil, Gas Moves Down Stream, Pressure, Temperature Changes Changing Pressure, Temperature Requirements Reflected in Pipe Spec
2500 PSIG (Well Head Press) 1420 PSIG 500 PSIG 125 PSIG

2500 PSIG (Well Head Press)

Allowed Service Types:

SW Seawater - Raw SH Sodium Hypochlorite FL Flare WP Water - Potable

Specified Pipe, Valves, Fittings (PVF) Specified Flanges, Blinds, etc.

Pipe Spec Can Change When Process Conditions Change

A FEED Process Document Schedule

(Puneet Sharma, Iris LLC)

http://www.irisllc.com/

Typical Deliverables
(Puneet Sharma, Iris LLC)
Conceptual Design
Estimate
Deterministic @ 30-40% Risk-Based for Base Case

Piping Design Documents

Economic Model Process Flow Diagram (PFD)

Front-End Design
Class A Package
Completed Pipeline Surveys Deck Layout with CG Facility Weights, Lift Plan & Structural Design Long-Lead Item POs Process Hazard Analysis Preliminary P&Ids

Stoichiometry

Piping and Instrument Diagram (PID)

Facilities (Process)
Heat & Material Balance Process Flow Sketch

Major Equipment Placement

Plot Plan (Plant Layout)

Flowlines & Pipelines

Route Definition

Structural
Design Concept

Estimate @ 15-20%

Major Pipe Routing

Piping Layout

Detail Design
Equipment & E&I Pos HAZOP P&IDs, UFDs Loop Diagrams, Piping ISOs Pipe Segment PFV Material Fabrication ISOs

Extracted Pipe Segments

Piping Spool Sheets

From Turtons et. al. P. 2

http://www.irisllc.com/

DESIGN DOCUMENTATION TYPICAL PER $100MM

FLOWSHEETS /PIDs PIPING ISOs INSTRUMENT LOOPS VESSEL/EQUIP DWGS 100 - 150 2500 - 3000 2000 - 3000 100

Piping Layout Information Flow

Plot Plan (Plant Layout) Piping and Instrument Diagram (PID) Equipment, Item Data Sheets Piping Spec

ROTATING EQUIP SPECS 150 - 200

Richard B. Pettigrew, Rohm & Haas Co, at EAC Systems 96

Piping Layout
From Turtons et. al. P. 2

Plant Layout Design

Conceptual and preliminary development of process unit plot plans Routing of major above and below grade piping Layout of equipment and its associated infrastructure

Good Layout Design and Engineering Affects plant cost and economy Can shorten construction schedules Affects operations and maintenance efficiency

Plot Plan Information

Pipe Racks Layout of the Equipment in the PFD Layout of Major Equipment
Tankage Other areas shown as blocks Access via roads, rail, waterway Plant perimeter

Sample Proposal Plot Plan

(Source: Bausbacher and Hunt)
Approx Layout & Grouping Major interfaces and flows Overall Dimensions

Sample Planning Plot Plan

(Source: Bausbacher and Hunt)
Defined Areas Tagged Equipment Critical Dimensions

Sample Construction Plot Plan

(Source: Bausbacher and Hunt)
Final Dimensions Foundation Locations

Plant Layout Plan

(Axis Point Design)
http://www.axispointdesign.com/

Pipe Layout Plan

(Axis Point Design)
http://www.axispointdesign.com/

Pipe Layout Elevation

(Axis Point Design)
http://www.axispointdesign.com/

Pipe Fab ISO & BOM

(Axis Point Design)
http://www.axispointdesign.com/

Typical Fabrication ISO

Single Line Isometric Spool Drawing

Spool Bill of Materials

Layout Interactions with Business Case and Design Baseline

Business Opportunity

Select Process Route

Process Design

Evaluate:Safety Environment Operability

Plant Layout

Evaluate Costs:Capital Operating

Good Practice guidance from:

Layout standards Published or company experience and guidance. Prior work