Design Refinery

Mid & Downstream Business Training
HYDROCARBON PROCESSING – AN OVERVIEW

Module
Upstream Mid and Downstream
LNG
GAS
PRODUCED WATER
Module
Feasibility Study
Trouble Shooting Process Design /

& Revamp Basic Engg.
Plant Design Cycle

Stable Operation
& Performance FEED
Testing
Pre-Commissioning Detail
& Commissioning Engg.
Feasibility Study: Module

 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
Front End Engineering Design (FEED):

Module
 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
Module
WORK FLOW DIAGRAM
Module REVIEW & COMMENTS PLOT PLAN
EQUIPMENT LIST
UHD PP
REVISED P&ID
LINE LIST
TQ TQ
PROCESS D/S FOR
EQ. LIST EQ. LIST EQUIPMENTS
UHD UHD
UTILITY UTILITY
EQUIPMENT LIST CV
SUMMARY SUMMARY
FLARE LOAD FLARE LOAD
EQUIPMENT LIST
SUMMARY SUMMARY
CHEMICAL CHEMICAL
UHD EL
REVISED P&ID
SUMMARY SUMMARY
HAZARDOUS
HAZARDOUS HAZARDOUS
SOURCE LIST
SOURCE LIST SOURCE LIST
REVIEW & COMMENTS VENDOR DOCUMENTS
REVISED P&ID REVISED P&ID
BDEP PE BDEP PC EQUIPMENT LIST

UHD ME
REVISED P&ID
LINE LIST LINE LIST
PROCESS D/S FOR
PROCESS D/S FOR PROCESS D/S FOR MACHINERY ITEMS
EQUIPMENTS EQUIPMENTS REVIEW & COMMENTS FABRICATION DWG.
UPDATED D/S FOR UPDATED D/S FOR
EQUIPMENTS EQUIPMENTS
EQUIPMENT LIST
UPDATED D/S FOR UPDATED D/S FOR
INSTRUMENTS
UHD EQ
INSTRUMENTS REVISED P&ID
PRECOMMISIONING PRECOMMISIONING PROCESS D/S FOR
MANUAL MANUAL EQUIPMENTS
OPERATING OPERATING EQUIPMENT LIST
MANUAL MANUAL UHD IN
REVISED P&ID
LINE LIST
UPDATED D/S FOR
INSTRUMENTS
REVIEW STAGE:
Module
 Review of Contract Documents
 Preparation of TQs
STAGE 0:
Module
 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 of Line-list
 Preparation of Hazardous source list
 P&IDs mark up based on General Specifications,
Module
Standards, Amendments etc.
Standard Details
Licensor P&ID
As per the standards, Module

the control valve assembly with block
& bypass and Vent & Drain arrangement is shown in detail
Marked up P&ID
 Updation of Process Module

Datasheets based on PFD and other
documents
Updated Process Datasheets

Module
 Preparation of UHDsModule
 Sizing of Utility linesModule

 Preparation of Equipment List
Module
Equipment list
ISOMERISATION PROJECT
MUMBAI
TITLE : EQUIPMENT LIST
EQUIPMENT SERVICE NO. DIMENSIONS INTERNAL EQUIPMENT ERECTION MOC + C.A OPERATING CONDITION DESIGN CONDITION INSULATION
NO. REQD. (ID).X(TL-TL) TYPE THICKNESS WEIGHT PRESSURE TEMP PRESSURE TEMP. TYPE THICKNESS
(m) (mm) (Tons) SHELL & (kg/cm2g) (°C) (kg/cm2 g) (°C) (mm)
TRAYS
HEAD TOP BOTTOM TOP BOTTOM
COLUMNS
LNHT UNIT
Top = 2.0
Trays, Distributor
Bott om = 2.8 Internal baff les, Int : 15.82 232
DA-31701 STRIPPER 1 KCS + 3 mm TP 410 - - 91 171 IH 125
TL-TL = 27.9 Vortex Breaker, Ext : FV 171
Top = 3.2
Trays, Distributor
Bott om = 4.0 Int : 4 147
DA-31702 DEPENTANIZER 1 Internal baff les, KCS + 3 mm TP 410 - - 70 119 IH 80
PENEX UNIT
Top =1.7
Trays, Distributor
Bott om = 3.2 Internal baff les, Int : 13.5 210
DA-32810 STABILIZER 1 KCS+3mm TP 410 - - 57 179 IH 120
TL-TL=26.2 Vortex Breaker, Ext : FV 179
Trays, Distributor
Internal baff les, Int : 13.5 120
DA-32811 LPG STRIPPER 1 0.75 x 21 CS+3mm TP 410 - - 45 60 - -
Ext : FV 60
Vortex Breaker,
Module
 Preparation of Equipment List (Continued)
Equipment List contains the information such as
• Equipment Number
• Service
• Dimensions
• Internals
• Material of Construction
• Operating and Design Conditions
• Insulation Details
• Other Special requirements
Module
Sample view of Equipment list
ISOMERISATION PROJECT
MUMBAI
TITLE : EQUIPMENT LIST

EQUIPMENT SERVICE NO. DIMENSIONS INTERNAL EQUIPMENT ERECTION MOC + C.A OPERATING CONDITION DESIGN CONDITION INSULATION
NO. REQD. (ID).X(TL-TL) TYPE THICKNESS WEIGHT PRESSURE TEMP PRESSURE TEMP. TYPE THICKNESS
(m) (mm) (Tons) SHELL & (kg/cm2g) (°C) (kg/cm2g) (°C) (mm)
TRAYS
HEAD TOP BOTTOM TOP BOTTOM
COLUMNS
LNHT UNIT
Top = 2.0
Trays, Distributor
Bottom = 2.8 Internal baffles, Int : 15.82 232
DA-31701 STRIPPER 1 KCS + 3 mm TP 410 - - 91 171 IH 125
Top = 3.2
Trays, Distributor
Bottom = 4.0 Int : 4 147
DA-31702 DEPENTANIZER 1 Internal baffles, KCS + 3 mm TP 410 - - 70 119 IH 80
TL-TL = 36.9 Ext : FV 119
Vortex Breaker,
PENEX UNIT
Top =1.7
Trays, Distributor
Bottom = 3.2 Internal baffles, Int : 13.5 210
DA-32810 STABILIZER 1 KCS+3mm TP 410 - - 57 179 IH 120
TL-TL=26.2 Vortex Breaker, Ext : FV 179
Trays, Distributor
Internal baffles, Int : 13.5 120
DA-32811 LPG STRIPPER 1 0.75 x 21 CS+3mm TP 410 - - 45 60 - -
Vortex Breaker, Ext : FV 60
 Preparation of UtilityModule
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
Module
Sample View of Utility summary
Module
 Preparation of Chemical summary
This document summarizes the consumption of Chemicals for the

process.
ISOMERISATION PROJECT L&T-CHIYODA LIMITED

BARODA, INDIA
TITLE : CHEMICAL SUMMARY Document No.: A-317-4012
Rev.: 0
Chemical Identification
First fill
Scope of
Sr. No. % Purity Chemical Service quantity
supply
required
1 DMDS -- As a sulfiding agent during stat-up 3200 kg MRPL
2 Caustic for LNHT reactor neutralisation 20% Wt Required to neutraiize reactor effluent gases 6.5 m3 MRPL
3 Soda Ash (Na2CO3) 100% For preparing neutralizing solution during regeneration 200 kg MRPL
4 Sodium Nitrate (NaNO3) 100% For preparing neutralizing solution during regeneration 20 kg MRPL
5 Perchloroethylene (C2Cl4) 99.9 % Min. As a promotor for penex reactor catalyst 30 m3 MRPL
6 Anhydrous Hydrochloric Acid (HCl) -- Required during initial start up. 2500 kg MRPL
Required for scrubbing of gases from stabiliser & during catalyst

7 Make-up Caustic (NaOH) for Penex unit 20% Wt 25 m3 MRPL
regeneration of naphta hydrotreating reactor.
8 Anhydrous Ammonia -- Required as corrosion inhibitor for LNHT unit 350 kg MRPL
Module
 Preparation of Catalyst summary
This document summarizes the consumption of Catalyst for the
process.
TITLE : CATALYST SUMMARY
Catalyst
Quantity
Equip. Tag Equip ID Bulk Total Total
Sr.No. Service Bed Height Type of
No. (mm) Type Density Bed Contingency quantity quantity Manufacturer
(mm) Loading
(Kg /m 3) (m3) 5% (m3) (m3) (kg)
2500 UOP "S-12"

1 DC-31701 Reactor 3720 1065 Sock 18.3 0.915 19.215 20464.0 UOP
Catalyst
Sulfur guard
2 FA-32802 1800 ADS-11 2600 930 Sock 6.62 0.331 6.951 6464.4 UOP
bed
Saturation UOP "H-8"

3 DC-32801 2400 2480 520 Sock 11.2 0.56 11.76 6115.2 UOP
Reactor Catalyst
Methanator
4 DC-32810 1100 Puraspec 2443 7160 -- Sock 6.8 0.34 7.14 -- UOP
Reactor
Penex UOP "I-8"

5 DC-32811 2900 9240 882 Dense 61 3.05 64.05 56492.1 UOP
Reactor Catalyst
Penex UOP "I-8"

6 DC-32812 2900 9240 882 Dense 61 3.05 64.05 56492.1 UOP
Reactor Catalyst
Zinc oxide
7 FA-32801A 1200 Puraspec 2020 3200 -- Sock 3.62 0.181 3.801 -- UOP
treater
 Preparation of Tie-inModule
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)

Module
Sample view of Tie-in summary
MUMBAI
TITLE : BATTERY LIMIT TIE-IN SUMMARY
Sr. Stream Name From To Phase Flowrates Properties

No. L/V/M Tons/hr kg/m3 (L) Visc. Operating Conditions Design Cond
Normal MW (V) cP Pressure Temperature Pressure
kg/cm2 g deg C kg/cm2 g
min/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

 Preparation of Line-list
Module
 Line List contains the data related to process conditions
and the data related to mechanical design and test
conditions for all the lines.
 Line List is the base document utilized for verification
of 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
Sample View of Line-list Module
MUMBAI
TITLE : LINE LIST FOR LNHT UNIT
IDENTIFICATION LOCATION STATE
PIPING CLASS
INSULATION
INSULATION
FLUID CODE
(A)
P & ID NO.
THK. (MM)
UNIT NO.
LINE NO.
(INCH)
TYPE
SR. NATURE
SIZE
NO. LINE NO. FROM TO OF
FLUID
(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

Module
 Preparation of Hazardous Source List
 Hazardous Source List is the base document

utilized for hazardous area classification drawing
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 Molecular
weight
• Flammability
• Flash point
• Auto-ignition temperature
Sample View of HazardousModule

Source List
STAGE 1:
Module
 Hydraulic Check of Process lines
 Sizing of Vessels
 Thermal rating of Heat exchangers
 PSV Sizing & Flare hydraulics
 Preparation of Flare Load Summary
 Preparation of Equipment datasheets for new items
 Scope demarcation for Vendor items
 Updation of P&IDs based on Hydraulic results

STAGEModule
1 (Continued):
 Updation of Pumps and Instruments datasheets based

on Hydraulics
 Updation of Equipment list
 Development of Control and Safeguarding Narratives

Module
Loop identification in PFD

Module
Collecting Inputs required for hydraulic calculations

Module
Sample View of Hydraulic Calculation Sheet
 Sizing of Vessels Module
 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.
Module
Sample view of Vessel Sizing calculation sheet
Module
 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.
Sample HTRI Specification Sheet Module
Sample HTRI Tube Layout

 PSV Sizing and FlareModule

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 yielding maximum
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.
Modulecalculation sheet
Sample view of Flare Hydraulics
 Preparation of Flare Load Summary
Module
This document summarizes the relief load of all PSVs for the
applicable relieving cases.
Module
 Preparation of Equipment datasheets for new items
Module
 Scope demarcation for Vendor items
Vendor scope of supply has to be identified

and to be clearly marked in the P&IDs.
Module
 Updation of P&IDs based on Hydraulic results
Licensor P&ID
Module Updated P&ID

based on
Hydraulics
Compressor
Suction line is
increased to 6”
from 4” as per
hydraulic
calculations
 Updation of Pumps and Instruments datasheets based
Module
on Hydraulics
Licensor Datasheet
Updated Pumps datasheets based on Hydraulics
Module
Module
 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 each
control system.
 Pump auto start systems will be also covered in this

document.
Module
 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”.
Sample of Cause and Effect Diagram

Module
EFFECT
51UZA-2100 V-51203 / V-51201 SGS
Effect Section
P-5105B HP STEAM VALVE
DESCRIPTION
P-51402A MP BFW PUMP
P-51206C HP BFW PUMP

P-51206A HP BFW PUMP
P-51206B HP BFW PUMP
P-51206D HP BFW PUMP

P-5105A HP BFW PUMP
P-51203 HP BFW PUMP
COMMON TRIP ALARM

SAFE GUARDING MATRIX UNIT 51
Cause Section
CAUSE CLOSE TRIP TRIP TRIP TRIP TRIP TRIP TRIP ALARM ACTION
51UZA-2102
51UZA-2100
51UZA-2105
51UZA-2107
51UZA-2103
51UZA-2104
51UZA-2106
51UZA-2108
51UZA-2100
PEFS NO.
TAG NO. DESCRIPTION TAG NO.
<51HS-2012 is 'BOTH' position>
51LZA-2008 V-51203 LEVEL LOW LOW D-0098-51-25-0006 X X X X X 51LZA-2008
51LZA-2011 V-51210 LEVEL LOW LOW D-1651-51-50-0018 X X X X X 51LZA-2011
<51HS-2012 is 'V-51203' position>
51LZA-2008 V-51203 LEVEL LOW LOW D-0098-51-25-0006 X X X X X X X X X 51LZA-2008
51LZA-2011 V-51210 LEVEL LOW LOW D-1651-51-50-0018 51LZA-2011
<51HS-2012 is 'V-51210' position>
51LZA-2008 V-51203 LEVEL LOW LOW D-0098-51-25-0006 51LZA-2008
51LZA-2011 V-51210 LEVEL LOW LOW D-1651-51-50-0018 X X X X X X X X X 51LZA-2011

Module
STAGE 2:
 Interface Activities
 Updation of Control & Safeguarding narratives and issue
for HAZOP Study
 Updation of Utility summary
 Updation of Line list

Module
 Interface Activities
 Vendor Document Review
 Review of Engineering Drawings
 Review of Plot Plan
 3D-Model Review
 Review of DCS Graphics

 Vendor Document Review
Module
Some of the Critical points to be reviewed in Engineering
Drawings are:
 Consistency of Process data as per process datasheets

such 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 the
requisition.
(e) Fulfilment of Scope of Supply.
Module
 Review of Engineering Drawings
Some of the Critical points to be reviewed in Engineering

Drawings are:
 Consistency of Process data as per process datasheets

such as Operating & Design Conditions, MOC, Special
service 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
 Review of Plot Plan
Module
Some of the Critical points to be reviewed in Plot plan are:
 Consistency of equipments shown in plot plan with
Equipment List, PFD and P&IDs.
 Are the distances between equipment kept minimum with
respect to pressure drop?
 Are the height of Towers and vessels enough to
provide NPSH of pumps?
 Are the equipment located symmetrically such as column and
reboilers?
 Is there enough space around columns, towers and
reactors for removal of internals?
 Is there enough space to remove tube bundle of heat
exchangers?
 Are the equipments arranged considering safety
aspects especially for Fired heaters, Compressors and Tanks?
 3D-Model Review
Module
Some of the Critical points to be considered in 3D-model

review are:
 Is piping arranged to provide straight run

requirement 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 AFC’s?
 Are the valves located at operable location from the
nearest platform or grade?
 Is piping arranged to keep special bending radius
requirements, if any?
 Review of DCS Graphics
Module
Review of Control logics as per Control & Safeguarding narratives
Module
STAGE 2 (Continued):
 Updation of Control & Safeguarding narratives and issue
for HAZOP Study
 Updation of Utility summary
 Updation of Line list

Module
STAGE 3:
 Safety Studies / Analysis
 Updation of P&IDs based on Safety Studies
recommendation
 Preparation of Precommisioning manual
 Preparation of Operating manual

Module
 Safety Studies / Analysis
 HAZOP Study
 SIL Study
 FIREPRAN Study
HAZOP Study Module
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 the
design takes preventive care of them and if not,
recommends changes (Action) as may be necessary.
SIL
Module
 Measurement of confidence level for performance of safety
function is called the Safety Integrity Level(SIL)
 Safety integrity of a system can be defined as
“ The probability (likelihood) of a safety-related system
performing 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 1
to 4
Probability of Failure
Safety Mode of Operation – On demand Mode of Operation – continuous
Integrity (average probability of failure to perform (probability of dangerous failure per
Level (SIL) its design function upon demand) hour)
-5 -4
4 > 10 to < 10 > 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
FIREPRAN study
Module
FIRE PRotection & ANalysis is a new technique employed at
the design phase of a facility or installation to achieve the
following objectives
 Overview the role of the facility and its significance to the

overall operation.
 Review the facility’s Fire and Explosion Strategy (FES) in the
context of the role of the facility and its significance to the
overall company.
 Analyze threats to loss of containment or other potential
sources 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 to
achieve levels as low as reasonably practicable (ALARP).
Example for FirepranModule
Study
Column middle cut pool fire and isopleths is analyzed as
shown below in case of possible explosion due to oil leakage
above its Auto Ignition Temperature.
Heat Effects on Human Effects on Property

Flux
kW/m2
Sufficient to cause pin to personnel No damage

4 if unable to reach cover within 20
seconds.
This level of radiation will cause a Minimum energy

12.5 30% chance of fatality for a required for piloted
prolonged exposure. ignition of wood,
melting of plastic
tubing
Sufficient to cause damage to Failure of steel

37.5 process equipment. Exposure to structures within 30
this level of radiation is assumed to minutes
give rise to a 100% chance of
fatality
Critical Area identification
Module
Area in red needs to be

given extensive
consideration for fire
protection systems
Module
STAGE 3 (Continued):
 Updation of P&IDs based on Safety Studies
recommendation
 Preparation of Precommisioning manual
 Preparation of Operating manual

Module

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Mid & Downstream Business Training

HYDROCARBON PROCESSING – AN OVERVIEW

Trouble Shooting Process Design /

Plant Design Cycle

Feasibility Study: Module

 Mass and Energy Balance

Front End Engineering Design (FEED):

BDEP PE BDEP PC EQUIPMENT LIST

 Review of Contract Documents

 Preparation of Equipment list

As per the standards, Module

 Updation of Process Module

Updated Process Datasheets

 Sizing of Utility linesModule

Equipment List contains the information such as

TITLE : EQUIPMENT LIST

 Utility Summary summarizes the consumption / generation of utilities in

 The utility data for consumption to be furnished with “- ve value”.

 Following are the Utilities taken into account

This document summarizes the consumption of Chemicals for the

ISOMERISATION PROJECT L&T-CHIYODA LIMITED

1 DMDS -- As a sulfiding agent during stat-up 3200 kg MRPL

Required for scrubbing of gases from stabiliser & during catalyst

TITLE : CATALYST SUMMARY

2500 UOP "S-12"

Saturation UOP "H-8"

Penex UOP "I-8"

Penex UOP "I-8"

Battery Limit Tie-in Summary contains the following

 Flow rate of all process and utility streams

 Operating and Design Conditions

 Main Properties of the Streams (Optional)

TITLE : BATTERY LIMIT TIE-IN SUMMARY

Sr. Stream Name From To Phase Flowrates Properties

(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

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

Sample View of Line-list Module

TITLE : LINE LIST FOR LNHT UNIT

IDENTIFICATION LOCATION STATE

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

 Hazardous Source List is the base document

 This document contains the information such as

Sample View of HazardousModule

 Hydraulic Check of Process lines

 Thermal rating of Heat exchangers

 PSV Sizing & Flare hydraulics

 Preparation of Flare Load Summary

 Preparation of Equipment datasheets for new items

 Scope demarcation for Vendor items

 Updation of P&IDs based on Hydraulic results

 Updation of Pumps and Instruments datasheets based