Business Trading Module

8/3/2019 Business Trading Module

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Mid & Downstream Business Training Module

HYDROCARBON PROCESSING AN OVERVIEW

LNG

PRODU

CEDWATER

G

AS

Upstream Mid and Downstream


2/65


Plant Design Cycle

Detail

Engg.

Pre-Commissioning

& Commissioning

Feasibility Study

Process Design /

Basic Engg.

FEEDStable Operation

& Performance

Testing

Trouble Shooting

& Revamp


3/65


Feasibility 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


4/65


Front 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


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6/65


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REVIEW STAGE:

Review of Contract Documents

Preparation of TQs


8/65


STAGE 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 ofLine-list

Preparation of Hazardous source list


9/65


P&IDs mark up based on General Specifications,

Standards, Amendments etc.

Licensor P&ID

Standard Details


10/65


Marked up P&ID

As per the standards, the control valve assembly with block

& bypass and Vent & Drain arrangement is shown in detail


11/65


Updation of Process Datasheets based on PFD and other

documents


12/65


Updated Process Datasheets


13/65


Preparation of UHDs


14/65


Sizing of Utility lines


15/65


Preparation of Equipment List

MUMBAI

EQ UI PM EN T S ER VI CE N O. D IM EN SI ON S I NT ER NA L EQ UI PM EN T E RE CT IO N D ES IG N CO ND IT ION I NS UL AT IO N

NO. REQD. (ID).X(TL-TL) TY PE T HICKNESS WEIGHT PRESSURE TEMP. TY PE THICKNESS

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

TOPBOTTOMTOP BOTTOM

COLUMNS

LNHTUNIT

To p =2 .0

Bottom= 2.8

TL-TL = 27.9

To p =3 .2

Bottom= 4.0

TL-TL = 36.9

PENEXUNIT

Top=1.7

Bottom= 3.2

TL-TL=26.2

TITLE : EQUIPMENT LIST

OPERATING CONDITIONMOC+C.A

PRESSURE

(kg/cm2g)

TEMP

(C)SHELL&

HEADTRAYS

125IH171Int : 15.82

Ext: FV91--DA-31701 S TRIPPER KCS + 3 mm T P 4 101

Trays,Distributor

Internalbaffles,

Vortex Breaker,

DA-31702 D EPENTA NIZER KCS + 3 mm TP 4 101

Trays,Distributor

Internalbaffles,

Vortex Breaker,

- - 70 119

STABILIZERDA-32810

DA-32811 LPGSTRIPPER

5 7 1 79

1

1 KCS+3 mm TP 4 10 - -

-TP410CS+3mm

Int : 4

Ext: FV

Int : 13.5

Ext: FV

Int : 13.5

Ext: FV

232

171

IH

80

120

60

210

179

147

119

120

- -

Trays,Distributor

Internalbaffles,

Vortex Breaker,

Trays,Distributor

Internalbaffles,

Vortex Breaker,- 45 60

ISOMERISATION PROJECT

0.75 x 21

IH

Equipment list


16/65


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)


17/65


Sample view of Equipment list

MUMBAI

EQUIPMENT SERVICE NO. DIMENSIONS INTERNAL EQUIPMENT ERECTION DESIGN CONDITION INSULATION

NO. REQD. (ID).X(TL-TL) TYPE THICKNESS WEIGHT PRESSURE TEMP. TYPE THICKNESS(m) (mm) (Tons) (kg/cm2g) (C) (mm)

TOP BOTTOM TOP BOTTOM

COLUMNS

LNHT UNIT

Top = 2.0

Bottom = 2.8

TL-TL = 27.9

Top = 3.2

Bottom = 4.0

TL-TL = 36.9

PENEX UNIT

Top =1.7

Bottom = 3.2

TL-TL=26.2

TITLE : EQUIPMENT LIST

OPERATING CONDITIONMOC + C.A

PRESSURE(kg/cm2g)

TEMP(C)SHELL &

HEADTRAYS

125IH171Int : 15.82

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

Trays, Distributor

Internal baffles ,

Vortex Breaker,

DA-31702 DEPENTANIZER KCS + 3 mm TP 4101

Trays, Distributor

Internal baffles ,

Vortex Breaker,

- - 70 119

STABILIZERDA-32810

DA-32811 LPG STRIPPER

57 179

1

1 KCS+3mm TP 410 - -

-TP 410CS+3mm

Int : 4

Ext : FV

Int : 13.5

Ext : FV

Int : 13.5

Ext : FV

232

171

IH

80

120

60

210

179

147

119

120

- -

Trays, Distributor

Internal baffles ,

Vortex Breaker,

Trays, Distributor

Internal baffles ,

Vortex Breaker,- 45 60


0.75 x 21

IH


18/65


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


19/65


Sample View of Utility summary


20/65


Preparation of Chemical summary

TITLE : CHEMICAL SUMMARYRev.: 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-CHIYOD BARODA, INDIA

Document No.: A-


Required as corrosion inhibitor for LNHT un it

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 theprocess.


21/65


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"

Catalyst1065DC-31701 UOP

ServiceEquip ID

(mm)Bed Height

(mm)

Bulk

Density

(Kg /m3)

TypeType of

Loading

4 DC-32810 Puraspec 24431100Methanator

ReactorSock7160 UOP0.34 7.14 --

5 DC-32811UOP "I-8"

Catalyst2900 882 Dense 61 UOP

6 DC-32812UOP "I-8"

Catalyst61 UOP

3720

Manufacturer

19.215

Quantity

Total

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 theprocess.


22/65


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)


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Sample view of Tie-in summary

Sr. Stream Name From To Phase Flowrates

No. L/V/M Tons/hr kg/m3 (L) Visc.Normal MW (V) cP Pressure Temperature Pressure

kg/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

Properties

Operating Conditions Design


24/65


Preparation ofLine-list

Line List contains the data related to process conditionsand the data related to mechanical design and testconditions for all the lines.

Line List is the base document utilized for verificationof 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


25/65


Sample View ofLine-list

TITLE : LINE LIST FOR LNHT UNIT

IDENTIFICATION LOCATION STATE

(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 TO

NATURE

OFFLUID

INSUL

ATION

TYPE

INSUL

ATION

THK.(MM)

SR.

NO.P&IDNO.

S

IZE

(IN

CH)

FLUID

CODE

UNITNO.

LINENO.

PIPING

CLASS

MUMBAI


26/65


Preparation of Hazardous Source List

Hazardous Source List is the base documentutilized for hazardous area classificationdrawing 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 Molecularweight

Flammability

Flash point

Auto-ignition temperature


27/65


Sample View of Hazardous Source List


28/65


STAGE 1:

Hydraulic Check of Process lines

Sizing of Vessels

Thermal rating of Heat exchangers

PSV Sizing &Flare hydraulics

Preparation ofFlare Load Summary

Preparation of Equipment datasheets for new items

Scope demarcation for Vendor items

Updation of P&IDs based on Hydraulic results


29/65


STAGE 1 (Continued):

Updation of Pumps and Instruments datasheets based

on Hydraulics

Updation of Equipment list

Development of Control and Safeguarding Narratives


30/65



Loop identification in PFD


31/65



Collecting Inputs required for hydraulic calculations


32/65


Sample View of Hydraulic Calculation Sheet


33/65


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.


34/65


Sample view of Vessel Sizing calculation sheet


35/65


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.


36/65


Sample HTRI Specification Sheet

Sample HTRI Tube Layout


37/65


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 yieldingmaximum 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.


38/65


Sample view ofFlare Hydraulics calculation sheet


39/65


Preparation ofFlare Load Summary

This document summarizes the relief load of all PSVs for theapplicable relieving cases.


40/65


Preparation of Equipment datasheets for new items

OWNER : MANGALORE REFINERY AND PETROCHEMICALS LTD.

PROJECT : LIGHT NAPHTHA ISOMERISATION BLOCK

JOB NO. : DL-4126

: A-328-30006

: 3 OF 4

Rev.

1.

2.

3.

4.

5.6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

30.

32.

33.

34.

35.

36.37.

38.

39.

40.

41.

APVD.DOC. NO.

SHEET DATE

L&T-CHIYODALIMITED,Baroda

VESSEL DATASHEET

MATERIAL

kg/cm2g @

IBR IS APPLICABLE

mm

225 (NOTE-1)

NO

100

YES

%

FA-32850

HOT COLD PP THICKNESS : 120

YES

HEMISPHERICAL

ITEM NO.

SERVICE

NO. REQD.

POSITION

OTHER

NO YES

IF YES THEN STEAM PRESS. / TEMP.

VESSEL TRIM A2A

kg/cm2g

C

mm

YES

2:1 ELLIPSE

NO YES

REFER UOP STD. DRG. 3-122

3

C

TORISPHERICAL

mm

C

915.4

kg/cm2g

kg/m3

mm

mm

mm

min

TL-TL LENGTH OF BOOT

NO

NO

1400

4100

N.A.

N.A.

@ 153

STEAM CONDENSATE

kg/h

kg/m3

kg/h

C

GAS/

VAPOR

LIQ.

TEMPERATURE

PRESSURE

MW

QUANTITY

DENSITY

QUANTITY

STEAM OUT CONDITION

VORTEX BREAKER

IF YES THEN TYPE

DESIGN TEMPERATURE

VACUUM CONDITION

DEMISTER

IF YES THEN TYPE

IF YES THEN

INSULATION

CORROSION ALLOWANCE

SPECIAL SERVICE

INSIDE DIAMETER

RJB

12/4/2004

IF YES THEN TYPE

HEAD TYPE

INSIDE DIAMETER OF BOOT

FLUID

REV.

MADE

NORMAL HOLD UP TIME

OPERATING CONDITIONS

4

18

40861 (Note-4)

RHDCHKD.

NO

5

VERTICAL

CLEAN MP CONDENSATE FLASH VESSEL

1

151.6

4605 (Note-4)

2.63

DESIGN PRESSURE 10

TL-TL LENGTH

YES

DESIGN CONDITIONS

CODE / REGULATION

DENSITY

0

NPK


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42/65


Updation of P&IDs based on Hydraulic results

Licensor P&ID


43/65


44/65


Updation of Pumps and Instruments datasheets based

on Hydraulics

Licensor Datasheet


45/65


Updated Pumps datasheets based on Hydraulics


46/65


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 eachcontrol system.

Pump auto start systems will be also covered in this

document.


47/65


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.


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Sample of Cause and Effect Diagram

P-5105BHPSTEAMVALVE

P-5105AHPBFWPUMP

P-51203HPBFWPUMP

P-51402AMPBFWPUMP

P-51206AHPBFWPUMP

P-51206BHPBFWPUMP

P-51206CHPBFWPUMP

P-51206DHPBFWPUMP

COMMONTRIPALARM

CAUSE CLOSE TRIP TRIP TRIP TRIP TRIP TRIP TRIP ALARM ACTION

TAG NO. DESCRIPTIONPEFS 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


49/65


STAGE 2:

Interface Activities

Updation of Control & Safeguarding narratives and issue

for HAZOP Study

Updation of Utility summary

Updation ofLine list


50/65


Interface Activities

Vendor Document Review

Review of Engineering Drawings

Review of Plot Plan

3D-Model Review

Review of DCS Graphics


51/65


Vendor Document Review

Some of the Critical points to be reviewed in EngineeringDrawings are:

Consistency of Process data as per process datasheetssuch 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 therequisition.

(e) Fulfilment of Scope of Supply.


52/65


Review of Engineering Drawings

Some of the Critical points to be reviewed in EngineeringDrawings are:

Consistency of Process data as per process datasheetssuch as Operating & Design Conditions, MOC, Specialservice 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


53/65


Review of Plot Plan

Some of the Critical points to be reviewed in Plot plan are:

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

Are the distances between equipment kept minimum withrespect to pressure drop?

Are the height of Towers and vessels enough toprovide NPSH of pumps?

Are the equipment located symmetrically such as column andreboilers?

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

Is there enough space to remove tube bundle of heatexchangers?

Are the equipments arranged considering safetyaspects especially for Fired heaters, Compressors andTanks?


54/65


3D-Model Review

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

Is piping arranged to provide straight runrequirement 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?


55/65


56/65



Updation of Control & Safeguarding narratives and issue

for HAZOP Study

Updation of Utility summary

Updation ofLine list


57/65


STAGE 3:

Safety Studies / Analysis

Updation of P&IDs based on Safety Studies

recommendation

Preparation of Precommisioning manual

Preparation of Operating manual


58/65


Safety Studies / Analysis

HAZOP Study

SIL Study

FIREPRAN Study


59/65


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 thedesign takes preventive care of them and if not,

recommends changes (Action) as may be necessary.

HAZOP Study


60/65


SIL

Measurement of confidence level for performance of safetyfunction is called the Safety Integrity Level(SIL)

Safety integrity of a system can be defined as The probability (likelihood) of a safety-related systemperforming 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 1to 4

Probability of FailureSafety

IntegrityLevel (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


61/65


FIREPRAN study

FIRE PRotection &ANalysis is a new technique employed atthe design phase of a facility or installation to achieve thefollowing 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 theoverall company.

Analyze threats to loss of containment or other potentialsources 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 toachieve levels as low as reasonably practicable (ALARP).


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Critical Area identification

Area in red needs tobe given extensive

consideration for fireprotection systems


64/65


Updation of P&IDs based on Safety Studies

recommendation

Preparation of Precommisioning manual

Preparation of Operating manual



65/65


Business Trading Module

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