Process Engg Practices to be used in the refinery industry

FOSTER WHEELER USA CORPORATION PROCESS ENGINEERING PRACTICE

PEP No.: Page: Revision: Date:

1000 1 of 1 8 May. 20, 2009

______________________________________________________________________

INDEX PEP Number PEP-1000 PEP-1001 PEP-1002 PEP-1003 PEP-1004 PEP-1005 PEP-1006 PEP-1007 PEP-1008 PEP-1009 PEP-1010 PEP-1011 PEP-1012 PEP-1013 PEP-1014 PEP-1015 PEP-1016

Title or Subject Index Sample Process Engineering Practice (PEP) Flow & Maintenance of Distributed Material Process File Numbers Equipment List Process Flow Diagrams Engineering Flow Diagrams Engineering Flow Diagrams Piping Details Utility Header Designations Instrumentation Vessels Fired Heaters Hydraulics Exchangers Pumps and Compressors Work Plan Preparation and Maintenance Process Chief’s Review

Total Pages

Issue or Latest Revision Date

Revision Number

1 1

May 20, 2009 Mar. 06, 2006

8 4

6

Feb. 24, 2009

5

4 2 5 3 6

Apr. 15, 2009 Mar. 06, 2006 Mar. 06, 2006 Mar. 06, 2006 Aug. 09, 2007

5 4 4 4 5

1 3 3 3 8 3 4 15

Mar. 06, 2006 Aug. 09, 2007 Aug. 09, 2007 Mar. 06, 2006 Feb. 11, 2009 Mar. 06, 2006 Mar. 06, 2006 Sep. 12, 2008

4 5 5 4 6 4 4 0

17

Feb. 11, 2009

0

All items posted to this Index have been reviewed for current applicability and were found to be correct and complete. APPROVED:

_____________________________________ Director - Process Engineering

DATE:

____May 20, 2009___________________

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PEP No.: 1001 Page: 1 of 1 Revision: 4 Date: Mar. 6, 2006 Date: Mar. 6, 2006 ______________________________________________________________________ PEP-1001 SAMPLE PROCESS ENGINEERING PRACTICE This is an example of a Process Engineering Practice. Each of these PEP's will be aimed at a single subject of interest to Process Design engineers working on a project. Sometimes, where appropriate, a common grouping of subjects may be covered. Comments and corrections, along with changes as time passes, will require revisions. Revision numbers with dates of issue will be indicated underneath the page number. The PEP Table of Contents page will normally show the date of the latest issue. Specific exceptions may be taken from the PEP's when the rules listed are counter to standard design practice for specific applications. The engineer should be prepared to justify his exception. These PEP's are general for all projects. Job specific PEP's will be issued with a job specific reference number where client requirements or other requirements dictate.


FOSTER WHEELER USA CORPORATION PROCESS ENGINEERING PRACTICES

PEP No.: 1002 Page: 1 of 6 Revision: 5 Date: Feb 24, 2009 ______________________________________________________________________ PEP-1002 FLOW & MAINTENANCE OF DISTRIBUTED MATERIAL A.

FLOW 1.

When required, job specific PEP's will be issued to all process engineers assigned to a contract, as well as the FW Project Engineering Managers.

2.

Other correspondence of a general nature (i.e., pertaining to more than one unit) shall be distributed to all concerned process engineers. It shall be the Lead Process Engineer's responsibility to act on all applicable material.

3.

All process specifications, data sheets etc., to be issued within and outside the department shall be reviewed by the appropriate Chief Process Engineer, or his assigned deputy, prior to transmittal. A transmittal form (see attached sample) shall be prepared by the Lead Process Engineer. Departmental or project-specific policy will apply to letters issued to licensors, catalyst vendors, etc.

5

All other Process Design correspondence for the project within FW will be over the signature of the Process Manager or the Lead Engineer as appropriate.

5

4.

All correspondence to the Client shall follow the job specific coordination procedure. Unless otherwise indicated, correspondence shall be over the signature of the Project Manager.

5.

All process specifications and vessel sketches shall be prepared on standard Foster Wheeler forms available in the Process Library or on equivalent computer generated forms. As required by the contract, client specific forms may also be used.



PEP No.: 1002 Page: 2 of 6 Revision: 5 Date: Feb 24, 2009 ______________________________________________________________________ PEP-1002 (Cont'd) FLOW & MAINTENANCE OF DISTRIBUTED MATERIAL B.

MAINTENANCE 1.

Desk Files a.

5

Lead Process Engineer As instructed by the Chief Process Engineer, the Lead Process Engineer on each unit must keep some or all of the following books in separate loose-leaf binders: Originals Book: Originals of issued process specifications (including Equipment List until control is released to Project) and PREP data must be maintained. The originals shall capture the approval signature or initials of the Chief Process Engineer (or designee) in one of the following two ways: 1.

Hand written initials in the approval block of the process specification, or

2.

Hand written signature or initials on the Process Transmittal sheet. The initials of the Chief Process Engineer must match the typed initials shown in the approval box on the process specification.

This book shall also note the location (Directory) for the electronic files stored on the network. See below regarding use of the original as the Process Master. Process Masters – Process Specifications A distributed copy of the as-issued process specification shall become a “Process Master” and shall have the words “Process Master” stamped or written on the copy of the process specification that was issued. If hard-copy distributions are not being made then a signed original copy may be used as the Process Master and retained to show that the issued document was approved. /var/www/apps/conversion/tmp/scratch_6/160328168.doc


PEP No.: 1002 Page: 3 of 6 Revision: 5 Date: Feb 24, 2009 ______________________________________________________________________

B.

MAINTENANCE 1.

Desk Files a.

5

Lead Process Engineer (Cont'd) Process comments noted on Process Masters shall be clearly marked, dated, and initialed by the person making the comment. All previous issues of the process specifications shall be retained if directed by the Chief Process Engineer. Any superseded Process Masters shall be clearly indicated as such with a red line drawn through each page. Process Masters – Requisitions and Vendor Drawings All issues of project requisitions including DIs (design instructions) issued for nozzle arrangements shall be kept as Process Masters. Process comments on requisitions received shall be clearly marked, dated, initialed by the reviewer and transmitted to Project. This transmitted copy shall become the new Process Master. All superseded issues should be clearly indicated as such with a red line. Process Masters – Drawings Process Masters of the following drawings shall also be maintained by the Lead Process Engineer (assuming these drawings are required and created for the project): •

Process Flow Diagram.

•

Engineering Flow Diagram.

•

Design Pressure/Temperature

•

Materials of Construction Diagram.

•

Plot Plan.



PEP No.: 1002 Page: 4 of 6 Revision: 5 Date: Feb 24, 2009 ______________________________________________________________________ PEP-1002 (Cont'd) FLOW & MAINTENANCE OF DISTRIBUTED MATERIAL B.

MAINTENANCE 1.

Desk Files a.

Lead Process Engineer (Cont'd) It is the responsibility of the Lead Process Engineer to maintain the "Process Master" of the above drawings and keep them up to date. All "Process Master" drawings must be stamped with a Process Master stamp and dated. Hand-writing the equivalent information in red ink is also acceptable

5

The Lead Process Engineer shall keep a copy of all issues of the flow diagrams listed above in his office. These may be discarded when the contract is completed. b.

Calculations (dated with page number and title) Process calculations are to be kept by the Lead Process Engineer in an organized binder. Calculations must be organized in a manner that mirrors the project filing procedure. All calculations, whether hand calculations or electronic calculations (such as Excel) must be included in the binder and also stored in the project network directory.

5

Upon completion of the process work, the originals of the process calculations should be edited, numbered, indexed, bound and sent to the Process File in accord with department procedure. 2.

Process Department File a.

Specifications No preliminary issues of Process Specification Sheets, Material Requisitions, Process Flow Diagrams, Engineering Flow Diagrams, etc., are to be sent to Process File.


PEP-1002 (Cont'd) FLOW & MAINTENANCE OF DISTRIBUTED MATERIAL B.

MAINTENANCE 2.

Process Department File a.

Specifications (Cont’d) Upon completion of the contract or customer acceptance of the unit, the Lead Process Engineer, Process Coordinator, and Chief Engineer have the joint responsibility to assure that final issues of all specifications, flowsheets, etc., from the Masters and Originals Books, as well as the process calculations, are properly placed in the Process File.

5

Appropriate vendor drawings may be filed at the discretion of the Chief Engineer (e.g., tray drawings and/or ratings should usually be filed). b.

Correspondence All correspondence shall be sent to the appropriate section of the Process File.

c.

5

Chief's Review Flow Diagrams The originals of the Engineering Flow Diagrams marked up during the Chief's Review shall be forwarded to the "Flow Diagrams" section of the Process File. Each flow diagram must be dated and labeled "Chief's Review". A list of those in attendance must also be indicated on at least the first flow diagram in the series.


PEP No.: 1002 Page: 6 of 6 Revision:

5 Date: Feb 24, 2009 ________________________________________________________________________________ FOSTERWHEELER WHEELERUSA USACORPORATION CORPORATION FOSTER HOUSTON, TEXAS CLINTON, NEW JERSEY

PROCESS DATA TRANSMITTAL UNIT NAME: UNIT NO.: CONTRACT NO.:

DATE

PROJECT:

Unit DEF

XXX XX-XXXX

DISTRIBUTION Process File Process Manager Chief Process Eng.

XX-XXXX

Lead Process Eng. Project Manager Project Eng. Mngr.

MEMO 1 1 1

COPIES ATT'S 1 1 1

1 1 1

1 1+orig 1

1 1 1

1 1 1

1995

Project XYZ Customer ABC Location

MATERIAL TRANSMITTED Process Flow Diagrams Engineering Flow Diagrams Equipment List Vessels Exchangers Instruments Compressors Fired Heaters Pumps

Item Number

NOTES:

By

FOR PROJECT ENGINEER USE

Revision Number

Date

No. of Sheets


PEP No.: 1002 Page: 6 of 6 Revision:

5 Date: Feb 24, 2009 ________________________________________________________________________________

PEP-1003 PROCESS FILE NUMBERS The following is a sample Process File Index. A job specific index is to be prepared by the Chief Process Engineer or designee and issued for each project. Refer to Engineering Practice EP 6-1. PROJECT XYZ

SAMPLE PROCESS FILE NUMBERS File Number

1.0

PROPOSALS & CONTRACT MATTERS 1.1 1.2 1.3

2.0

Project Notes (Meetings with Client) Notes of Meeting (Internal and with Vendors) Action Item/Needs List

ESTIMATES, FINANCIAL & COMMERCIAL 4.1

5.0

FW to Client Client to FW Standard Engineering Transmittal Letters to Client Standard Procurement Transmittal Letters to Client To Licensors and Vendors From Licensors and Vendors

NOTES OF MEETING 3.1 3.2 3.3

4.0

Proposal Contract Contract Changes

CLIENT & LICENSOR CORRESPONDENCE 2.1 2.2 2.3 2.4 2.5 2.6

3.0

XX-XXXXX-XX

Estimates

COORDINATION & PERSONNEL 5.1 Project Coordination Procedure (including Filing System Index) 5.2 Coordination Memos 5.5 Project Execution Plan

PEP-1003 (Cont’d) PROCESS FILE NUMBERS 6.0

SCHEDULES & REPORTS 6.1.4 Master Progress Schedule 6.1.5 Detailed Work Schedule 6.1.6 Staffing Plan 6.1.7 Progress Letter/Report (to Client) 6.1.8 Weekly Progress Report (Process Work Plan) 6.1.9 Variance Notice Program 6.1.11 Labor Reports

7.0

PROCESS DATA 7.00 7.01 7.02 7.03 7.05 7.06 7.07 7.09 7.10 7.11 7.12 7.13 7.14 7.19 7.21 7.22 7.23 7.24 7.27 7.31 7.32 7.34 7.50 7.51 7.60 7.63 7.91

Utility Data/Utility Summary Design Basis Document Heat and Material Balances Test Run/Operating Data Report Technical Specification/Process Package/Study Reports Process Calculations (Issued Outside FW Process) Computer Simulation Data (Issued Outside FW Process) Process Equipment List Client Design Data Tower and Tray Load Process Data Sheets Reactors and Internal Process Data Sheets Drum Process Data Sheets Tank Process Data Sheets Other Vessel Process Data Sheets Shell and Tube Exchanger Process Data Sheets Double Pipe Exchanger Process Data Sheets Air Cooled Exchanger Process Data Sheets Fired Heater Process Data Sheets Vacuum Equipment Process Data Sheets Pump Process Data Sheets Compressor Process Data Sheets Material Handling Equipment Process Data Sheets Flow Diagrams (PFD/DPT/MOC/EFD) Process Line List Instrument Process Data Sheets PSV Data Sheets/Flare Summary Package System Process Data Sheets


PROCESS DATA (Cont) 7.92 7.93 7.94 7.95 7.96 7.97 7.98

8.0

Utility Thermal Equipment Water Treating Waste Treating PHA/HAZOP Reviews/Safety/Safeguarding Catalyst and Chemicals Miscellaneous Environmental

ENGINEERING CORRESPONDENCE 8.00 8.01 8.2 8.3

Basic Engineering Data Equipment Lists Design Pressure / Temperature (By Project) Process Correspondence and Process Transmittals

Use Section 8 to also file Engineering data sheets, requisitions, vendor drawings, etc. Use same file suffixes as Section 7 (for example Engineering Data on pumps would be filed under 8.31) 11.0

PROCESS CALCULATIONS Use Section 11 to file process calculations. Use same file suffixes as Section 7 (for example drum calculations would be filed under 11.13)

12.0

DESIGN INSTRUCTIONS (DIs) 12.10 12.20 12.30 12.50 12.60

13.0

Vessels Exchangers Machinery Piping/P&IDs Instruments

DRAWINGS 13.1 13.2 13.3

FWUSA Drawings (See also Section 7.50) Vendor Drawings (Typically file in Section 8) Client Drawings


PLANT OPERATIONS & START-UP 16.1 16.2 16.3 16.4 16.5 16.6 16.7 16.8 16.9 16.10 16.11

17.0

Operating Guidelines/Manual Field Testing and Reports Start-up Personnel Blind List Systems Description and Scope Turnover Forms Hydrostatic Test Packages Work Package Description Punch List Certification/Handover Documents

QUALITY ASSURANCE 17.1 17.2 17.3 17.4 17.5 17.6 17.7 17.8

QA Activity and Audit Schedule QA Audit Reports Non-Conformance Reports Quality Notices Corrective Action Reports Preventive Action Reports QA Correspondence and Follow-up Quality System Documents (Project Procedures, Quality Plan)


PEP No.: 1004 Page: 1 of 2 Revision: 4 Date: Mar. 6, 2006 ______________________________________________________________________ PEP-1004 EQUIPMENT LISTS l.

Equipment lists shall be set up in the following order of principal equipment designations. For a full list of equipment letter designations and a further discussion of the rules refer to Engineering Practice EP 6-10. The standard process Equipment List is on the following page. Vessels Towers Reactors Drums Tanks

(T- ) (R- ) (D- ) (TK- )

Heat Transfer Equipment Heat Exchangers Furnaces

(E- ) (H- )

Mechanical Equipment Pumps Compressors Miscellaneous 2.

(P- ) (C- ) (eg. DS, F, M, S, X) in same order as code of accounts

Equipment numbering shall be as follows: Equipment letter - Unit/Section number + suffix designation beginning with 1 unless the customer designates otherwise. The first “unit/section” shall be 100. EXAMPLE: First and second drums in Unit 100: D-101 D-102

3.

All pump spares will be numbered as follows: P-101A (Main) P-101B (Spare)


PEP No.: 1004 Page: 2 of 2 Revision: 4 Date: Mar. 6, 2006 ___________________________________________________________________________________________________________ ____ EQUIPMENT LIST

FOSTER WHEELER USA CORPORATION CONTRACT: Clinton, NJ 08809 SECTION: CLIENT: LOCATION: CLASS

ITEM NO.

Form No. 110-330

REVISION DATE

DESCRIPTION

17 Feb 1999

NAME:

EFD

REQ'N. NO.

NAME OF UNIT ORIG.

P. O. NO.

STANDARD FORM (If Modified, rename form)

1

2


PEP No.: 1005 Page: 1 of 5 Revision: 4 Date: Mar. 6, 2006 ______________________________________________________________________ PEP-1005 PROCESS FLOW DIAGRAMS Process Flow Diagrams 1.

Process Flow Diagrams (PFD's) shall be drawn according to normal FW Engineering practice on drawing size No. 2.

2.

The title box shall be in accordance with the enclosed sample.

3.

PFD's will not have material balance tables provided on drawings unless required for the project. Material balances will be provided separately on “diamond” sheets. A typical sample is attached.

4.

Temperatures and pressures (normal operating) shall be provided at vessels and where deemed necessary on the drawings, in addition to the diamond sheets. Maximum and minimum data shall be included where important to equipment design.

5.

All major items of equipment must be shown on the PFD. Adjacent to each item shown, the underlined item number must be provided. Underneath the item number, the item name shall appear exactly as indicated on the equipment list.

6.

Do not indicate spares for pumps, (e.g. show P-801, not P-801 A/B).

7.

Provide normal process duty for exchangers in a "HEATER/EXCHANGER SUMMARY" for the operating case(s) shown on the PFD. For fired heaters, show process heat absorbed and other coil heat absorbed, where applicable. When all other coil heat duties are available, show total heat absorbed. Duties should correspond to normal operating case shown on PFD.

8.

Major control loops (automatic or otherwise) and other instrumentation necessary for the understanding of the PFD shall be shown. Do not show PI's or TI's. Do not indicate board or local control. Only show mode of control, e.g., FC even if in reality instrument is FT-FIC-FR. Do not indicate electronic or pneumatic mode for instruments - use only dashed lines connecting instrument to valve operator. The dashed lines are not to be interpreted as electronic instrumentation. Use solid lines connecting sensor to instrument and operator to valve.



PEP No.: 1005 Page: 2 of 5 Revision: 4 Date: Mar. 6, 2006 ______________________________________________________________________ PEP-1005 (Cont'd) PROCESS FLOW DIAGRAMS

FI

LC

MTC

FC

Flow orifices are not to be shown on the PFD. Examples of instrumentation are shown below.

9.

Each PFD must contain an explanatory legend with the information shown below. Additional symbols and notes may be shown as necessary to clarify the flowsheet:



PEP No.: 1005 Page: 3 of 5 Revision: 4 Date: Mar. 6, 2006 ______________________________________________________________________ PEP-1005 (Cont'd) PROCESS FLOW DIAGRAMS 10.

Provide battery limit temperatures and pressures for all process streams (in and out) and indicate destination of material, intermediate tankage. Name all streams.

11.

Each PFD must have the following statement. THESE PROCESS DATA ARE FOR DESIGN PURPOSES ONLY. WHILE USEFUL AS A GUIDE TO OPERATION, THEY DO NOT NECESSARILY REPRESENT EXACT OPERATING CONDITIONS.



PEP No.: 1005 Page: 4 of 5 Revision: 4 Date: Mar. 6, 2006 ______________________________________________________________________ PEP-1005 (Cont'd) PROCESS FLOW DIAGRAMS 12.

The initial issue of the PFD is to be Issue A with subsequent issues in alphabetical order. Each issue shall be designated as indicated below: SAMPLE TITLE BOX

This Drawing is the Property of the

FOSTER WHEELER USA CORPORATION PERRYVILLE CORPORATE PARK, CLINTON, N.J. AND IS LENT WITHOUT CONSIDERATION OTHER THAN THE BORROWER'S AGREEMENT THAT IT SHALL NOT BE REPRODUCED, COPIED OR DISPOSED OF DIRECTLY OR INDIRECTLY, NOR USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS SPECIFICALLY FURNISHED. THE APPARATUS SHOWN IN THE DRAWING IS COVERED BY PATENTS.

PROCESS FLOW DIAGRAM UNIT DEF UNIT 800 PFD GHI PROJECT XYZ

Customer ABC

Location

EST. NO. REV. A

April, 1995

Initial IssueInit.

Contract No.


DRAWN BY: XX-XXX

Dwg. No. xxxx-x-xx-xx

04-01-95

SH. X OF Y

A


PEP No.: 1005 Page: 5 of 5 Revision: 4 Date: Mar. 6, 2006 _____________________________________________________________________ FOSTER WHEELER USA CORPORATION UNIT:

UNIT DEF

UNIT NO.:

P G.NO.:

CUSTOM ER:

CUSTOM ER A B C

REF. DWG.:

REV.:

CONTRA CT NO.:

DA TE:

LOCA TION:

STREAM NO. STREA M DESCRIP TION

OP ERA TING CA SE FLUID STA TE TEM P ERA TURE, °F P RESSURE, P SIG TB P CUT RA NGE, °F TOTA L B P SD °A P I LIQUID, LB /HR VA P OR, LB /HR SOLID, LB /HR TOTA L, LB /HR LIQUID S.G. @ O.T. LIQUID VISC. @ O.T., CKS M W OF VA P OR COM P ONENTS, LB M OLS/HR

SUB TOTA L (DRY) H 2O

TOTA L

1

2

3

4

5

6


PEP No.: 1006 Page: 1 of 3 Revision: 4 Date: Mar. 6, 2006 ______________________________________________________________________ PEP-1006 ENGINEERING FLOW DIAGRAMS 1. Engineering flow diagrams (EFD's) shall be drawn on drawing size No. 2, according to normal FW engineering practice. The title box shall be in accordance with the enclosed sample (page 3). On each EFD, a column along the right side, directly above the title box, will be used for Notes and Holds. A chart along the bottom of each EFD will be used to provide the required equipment data. 2. The following non-standard pipe sizes shall not be used: 3/8", 1-1/4", 2-1/2", 3-1/2", 5" or 7", etc. In the event that these sizes are required for equipment connections, they shall be changed as soon as feasible to the connecting pipe size. Minimum pipe sizes shall be 1" for both process and utility piping, except for connections to equipment which vendors supply or for sample lines to and from analyzers. 3. Unless the process, client or vessel code dictates otherwise, relief valve nozzle connections shall not be located on vessels but on overhead piping without appropriate justification. 4. Silencers for vents, when provided, shall be numbered and shall be included on the equipment list. 5. In general, air coolers are to be provided with louvers, where required for supplemental (start-up and shutdown) freeze/pour point protection, with control of the air temperature by the forced-draft or induced draft fans. The process outlet temperature from each bay is to be monitored. In general, steam coils will be provided for air coolers, when required for start-up and shutdown purposes. 6. Turbines shall be provided with full capacity relief valves mounted in the exhaust steam piping and relieving to atmosphere.



PEP No.: 1006 Page: 2 of 3 Revision: 4 Date: Mar. 6, 2006 ______________________________________________________________________ PEP-1006 (Cont'd) ENGINEERING FLOW DIAGRAMS 7. Insulation Process piping and equipment operating at temperatures exceeding 150°F (65 °C) shall, in general, be insulated for heat conservation unless heat loss is desired. Hot surfaces, exceeding 150°F (65°C), not requiring insulation for heat conservation, shall be insulated for the purpose of protecting personnel in areas adjacent to operating areas, platforms, etc., or within reach from grade. 8. Relative elevations of vessels, loop seals, exchangers and thermosyphon circuits are to be indicated on the EFD's. For vessels, show elevation above grade of bottom tangent line on vertical vessels, or bottom on horizontal drums. 9. The following must be shown in detail on the EFD's: number of passes for each coil for fired heaters, number of shells or bays for exchanger services. These are to be estimated by the process or heat transfer engineers. 10. The initial issue of the EFD's is to be Issue A and designated as shown on the attached Sample Title Box. With the second issue of EFD’s (Rev.B) the Process Engineer relinquishes control to the Project Department. Therefore, this issue will not be made until specifically approved by the Chief Engineer.


PEP-1006 (Cont'd) ENGINEERING FLOW DIAGRAMS

SAMPLE TITLE BOX

THIS COLUMN RESERVED FOR NOTES AND HOLDS FROM THE TOP OF TITLE BOX TO TOP OF DRAWING This Drawing is the Property of the

FOSTER WHEELER USA CORPORATION PERRYVILLE CORPORATE PARK, CLINTON, N.J. AND IS LENT WITHOUT CONSIDERATION OTHER THAN THE BORROWER'S AGREEMENT THAT IT SHALL NOT BE REPRODUCED, COPIED OR DISPOSED OF DIRECTLY OR INDIRECTLY, NOR USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS SPECIFICALLY FURNISHED. THE APPARATUS SHOWN IN THE DRAWING IS COVERED BY PATENTS.

ITEMS NOS. THIS DRAWING

ENGINEERING FLOW DIAGRAM SOUR WATER STRIPPING UNIT UNIT 600 SOUR WATER STRIPPER CUSTOMER ABC Customer ABC Location EST NO.

REV. A

April, 1995

PROCESS ISSUEINITIALS

Contract No.

DRAWN BY: XX-XXXX

04-01-95

DWG. NO. XXXX-2-50-01

SH X OF Y A


PEP No.: 1007 Page: 1 of 6 Revision: 5 Date: Aug. 9, 2007 ______________________________________________________________________ PEP-1007 ENGINEERING FLOW DIAGRAM PIPING DETAILS Pump Piping 1.

A pressure gauge shall be installed between centrifugal pumps and check valves, and a 3/4" valved bleed connection shall be provided between the check valve and block valve.

2.

For all single stage pumps operating above 500°F (260 °C) and all multistage pumps operating above 400°F (204 °C), a 1" warm-up line with globe valve shall be installed. The warm-up line is to be routed around the check valve only.

3.

The casing vents of LPG pumps will be hard-piped to the flare system using double blocks and bleeds.

Compressor Piping The following piping items shall be provided at each compressor or compressor cylinder for purging, maintenance, etc.: -

connection to flare from discharge line for flammable gases

-

connection to atmosphere from discharge or recycle line

-

fittings inside block valves for connections to nitrogen system or cylinders for purging

Nitrogen Piping Typically temporary connections, rather than permanent connections, shall be provided for all intermittent nitrogen requirements. Permanent connections will be provided only for continuous nitrogen requirements. Swing elbows or spool pieces shall be provided, but not flexible hoses.


PEP No.: 1007 Page: 2 of 6 Revision: 5 Date: Aug. 9, 2007 ______________________________________________________________________ PEP-1007 (Cont'd) ENGINEERING FLOW DIAGRAM PIPING DETAILS Exchanger Piping The following detail shall be supplied for water cooled exchangers Cooling gWater Return

PSV Set @ xx psig XXX Size

3/4"

Vent

5 Cooling Water Supply

~ ~

3/4" To Grade at Drain Safe Location Back flushing, chemical cleaning and 1" winterizing line requirements are at the client's option and are not included in this detail.

Furnace Piping 1.

In general, the steam-air decoking piping connections details shall be as shown. Inlet and outlet piping for heaters which are to be steam air decoked should have removable spool pieces on the inlet and the outlet piping. Locate the heater inlet PI downstream of the inlet line spool; locate an outlet coil TI upstream of the outlet line spool.


PEP No.: 1007 Page: 3 of 6 Revision: 5 Date: Aug. 9, 2007 ______________________________________________________________________ PEP-1007 (Cont'd) ENGINEERING FLOW DIAGRAM PIPING DETAILS Furnace Piping (Cont'd) 2.

If manually operated globe valves are used to regulate the flow in multiple pass furnaces, such valves shall be located at ground level and each pass shall be provided with an outlet temperature indicator visible from the valves.

3.

The superheated steam piping design temperature from each heater superheat coil shall be established after heater vendor data is available (by the detailed engineering contractor). A note should be placed on the EFD to indicate this.

4.

In general, piping for furnaces equipped with superheat stripping steam coils should have:

5

-

Start-up vent with silencer downstream of superheat coil

-

Board-mounted TI on main header downstream of superheat coil but upstream of start-up vent

-

A PSV sized in accordance with requirements of ASME Boiler Code Section I, when the superheat coil can be blocked in. PSV should discharge to atmosphere.

A note is to be included on the heater specification that the superheated steam coil is to be designed for zero steam flow conditions during otherwise normal (fouled) operation. 5.

A local PI should be on the inlet line to each process coil. downstream of the heater inlet control valve (if any).

Locate the PI


PEP No.: 1007 Page: 4 of 6 Revision: 5 Date: Aug. 9, 2007 ______________________________________________________________________ PEP-1007 (Cont'd) ENGINEERING FLOW DIAGRAM PIPING DETAILS Vessel Piping (refers to towers and drums only) 1.

The gas vent line from drums such as overhead receivers and the product separators shall have a vent line to the flare.

2.

All vessels must be provided with a high point vent, low point drain and steamout connection. Vents are to be on the top of the vessel. Drains are to be on the bottom piping. Separate steamout connections are not required for vessels which already have stripping steam connections or clean water vessels and steam drums or kettles. Auxiliary nozzles for all vessels (including towers) are to be sized in accordance with the Process Standard on drums. Board mounted PDI's shall be provided on the main sections of the towers. PI's should be located on piping or on level gages.

Control Valves For line sizes 2" or less, blocks and by-passes shall be provided around control valves. In addition, blocks and by-passes shall be installed around any critical service control valve whose malfunction would cause unit shutdown mode or prevent continuous operation of unit. Blocks and bypasses will also be provided for erosive services or services with a pressure drop above 150 psi. For line sizes greater than 2", control valves in non-critical services shall be provided with a manually operated hand wheel jack with valve opening indicator, without by-pass. Upstream control valve bleeds are to be shown on the EFD's. If the control valve size sets a PSV load, the bypass valve CV should be less than or equal to the control valve C V. Relief Valves 1.

Relief valves requiring periodic testing shall be provided with Car Seal Open (CSO) isolation valves and a 3/4" bleed valve. A bypass line with a normally closed (NC) valve and a 3/4" PI tap, for use when the valve is being tested, shall be provided around the relief valve(s) and isolation valves.


PEP No.: 1007 Page: 5 of 6 Revision: 5 Date: Aug. 9, 2007 ______________________________________________________________________ PEP-1007 (Cont'd) ENGINEERING FLOW DIAGRAM PIPING DETAILS Relief Valves (Cont'd) 2.

Relief valve discharge lines to atmosphere shall be provided with ½" weep holes. The weep hole drain lines shall be piped to a "safe location".

Sample Connections Where sample points are required, they are identified as below.

S SC for sample connection without cooling. for sample connection with cooling. Battery Limit Connections In general, draw B.L. connections as shown below. Battery limits may only be shown at top or bottom of the EFD.

PI

B.L. B.L.

PEP-1007 (Cont'd) ENGINEERING FLOW DIAGRAM PIPING DETAILS LINES ON TWO EFD’S Extensions of lines to adjacent EFD’s should be at equal drawing elevation index numbers (see the example below). This practice is preferable but not absolutely required for the extension of lines to non-adjacent EFD’s within the same unit. All lines extended from one EFD to another must be labeled and designated by source (if entering) or destination (if leaving) as in the example below.


PEP No.: 1008 Page: 1of 1 Revision: 4 Date: Mar. 6, 2006 ______________________________________________________________________

EFD #02

EFD #03 55

54 53

54 53

52 51 50

52 51 50

SOUR WATER FROM P-1501

EFD #01

STRIPPED WATER FROM TK-1501

EFD #12

SOUR WATER TO D-1501

55

STRIPPER BOTTOMS TO E-1501

PEP-1008 UTILITY HEADER DESIGNATIONS Utility connections on EFD’s will be shown by “balloons.” A set of “balloons” for this project will be included on one of the General Notes and Symbols EFD for each unit. Under no circumstances should additional “balloons” be included by an engineer without approval by the project manager. The purpose of utility “balloons” is to enable geographic layout of utility flow diagrams (UFD’s) for each unit. They are not to be used for injection facilities such as inhibitor, ammonia or similar connections.


PEP No.: 1009 Page: 1 of 3 Revision: 5 Date: Aug. 9, 2007 ______________________________________________________________________ PEP-1009 INSTRUMENTATION 1.

In general, all vessels containing vapor and liquid shall be equipped with high and low level alarms.

2.

As required by stream properties, instruments shall be protected from adverse conditions by protective heating, sealing, housing, insulating and/or flushing.

3.

A temperature sensing element in a control loop shall be checked by a separate thermocouple.

4.

As a minimum, fractionating tower top and bottom tray temperatures shall be monitored, as well as all furnace inlet and outlet points.

5.

To indicate overheating and possible coking of heater tubes during operation, a sufficient number of thermocouples shall be provided on the outside skin of heater tubes when appropriate. The location for each skin TI shall be at the expected high temperature portion of each coil.

6.

In general, all level instruments shall be mounted separately. Standpipes will not be used. The process engineer will define the normal operating range by setting approximate High and Low Liquid Levels (HLL & LLL) in vessels. These values set the end points for both visible level indications (gauge glasses) and transmitter range. Extreme high or low level shut-down points or alarms may be set beyond these range limits, using level switches. For such extreme levels, either a separate gauge glass or an extension of coverage by the full range glass shall be provided. The minimum setting for hard piped low- low level switch on vertical vessels is 1'-5" above vessel bottom tangent line or consult with the Automation and Controls Group. (See also PEP 1010).

5

7.

Instrumentation shall be provided to indicate the pressure of each tower and vessel protected by a safety valve.

8.

In general, relief valves for liquid thermal expansion shall be provided on the water side of water-cooled exchangers. Thermal relief valves shall also be provided on the cold side of all exchangers that can be blocked in. Blocked in circuits in LPG, where atmospheric conditions are a problem, also require a PSV. Liquid C2, C3 and C4 circuits, which can expand and/or vaporize when heated by ambient conditions, also require a PSV.


PEP No.: 1009 Page: 2 of 3 Revision: 5 Date: Aug. 9, 2007 ______________________________________________________________________ PEP-1009 (Cont'd) INSTRUMENTATION 9.

Provisions for oxygen analyzers are required on all heater stacks. Continuous analyzers are to be provided only where the information will require operators to make process changes, and not for monitoring only.

10.

Primary sensing instrumentation providing inputs to emergency shutdown systems shall be separate from the process control loop instrumentation. Example: use a dedicated PSLL (Pressure Switch Low-Low) to provide a low pressure trip input instead of using an alarm switch residing on the loop containing the control loop pressure transmitter. Exception: Flow trips may use a common primary element (orifice plate, venturi, etc.) but separate taps are required.

11.

Process Instrument Data Sheets a.

In general, do not specify PI's, TI's, LG's, except to indicate special requirements, e.g., nonreflex LG's, decoking temperature for heater outlet TI's.

b.

All alarm points must be specified. Level alarms should be specified as either a percentage of the level range shown on the process vessel sketch, e.g., LAH @ 80%, LAL @ 20% or alternatively as the actual LLL and HLL shown on the sketch given in feet and inches above a reference point such as BTL (Bottom Tangent Line).

c.

Indicate service of instruments not their location.

d.

Control valve failure to be indicated by FC, FO, FLO or FLC. FC (Fail Closed) FO (Fail Open) FLO (lock in position on air failure, but 'drifts' open) FLC (lock in position on air failure, but “drifts” closed)

e.

Instrument sheets must be filled out in accordance with Process Standard 501.

PEP-1009 (Cont'd) INSTRUMENTATION 12.

13.

Relief Valve Process Data Sheets a.

Specify process relief valves. Loads for thermal expansion are to be specified with calculated loads and conditions.

b.

Indicate destination of discharge and EFD number for each relief valve on the FW relief valve standard form.

c.

For PSV’s discharging to atmosphere, list “atmosphere” for superimposed back pressure and “less than 10%” for built-up back pressure unless the discharge system is special. For PSV’s discharging to flare, list “later” for superimposed and built-up back pressure until the flare system has been specified.

Flare Load Summary Sheets Provide the following information for relief valves: For all PSV's discharging to the flare, loads must be supplied on the flare sheets for block, power failure, fire, instrument air failure and cooling water failure. If no load exists for any particular contingency, the word "none" should be listed in the load row.

14.

The allowable accumulation to be used for a PSV load due to exposure to fire shall be "per code," 16% for a single relief valve, or 21% for multiple relief valves.

15.

If the liquid filled cold side of a shell and tube exchanger requires protection against thermal expansion and against exposure to fire, and if the thermal expansion load requires a relatively small PSV, whereas the fire load requires a relatively large PSV, then two PSV's shall be provided:

16.

Thermal Relief

- Set Pressure = Design Pressure - Accumulated Pressure = 1.10 x Set Pressure

Open Fire

- Set Pressure = 1.10 x Design Pressure - Accumulated Pressure = 1.10 x Set Pressure

For vacuum protection, the accumulated vacuum relief pressure is often in excess of 10 or 21% (as typical for Pressure Relief Valves) and sometimes as high as 100%. It is important to note that the accumulated vacuum pressure may not exceed the vacuum rating of the associated vessels.


PEP No.: 1010 Page: 1 of 3 Revision: 5 Date: Aug. 9, 2007 ______________________________________________________________________ PEP-1010 VESSELS 1.

Pressure vessels with relief valves shall be designed for a minimum internal pressure of at least 10% or 25 psi (1.72 Bar); whichever is greater, above the maximum specified operating pressure in psig at the top. Minimum design pressure, at the top, is to be 50 psig (3.45 Barg). Minimum design metal temperature is to be specified where required by Process (i.e. auto-refrigeration).

2.

Vessels without pressure relieving devices shall be provided with an outlet which cannot be completely blocked off. The minimum outlet opening shall be sized so that the maximum pressure which can be developed in the vessel is not greater than the design pressure.

3.

Vessels shall be designed for vacuum conditions as required. Vessels with steam injection (for example, stripping steam) are typically designed for full vacuum.

4.

The minimum design temperature shall be the maximum operating temperature plus 50°F (28 °C).

5.

The title box shall be in accordance with the sample shown below. The initial issue of the process vessel specification drawing is to be Revision 0 with subsequent issues in numerical order. Each issue shall be designated on the vessel sketch (see sample title box below).

REFERENCE DRAWINGS, REQUISITIONS, STANDARDS

DRAWN

PEM 01APR95

CONTRACT NUMBER XX-XXXX

CHECKED APPROVED 1

15APR96 PEM

0

01APR96 PEM INITIAL ISSUE

REV.

DATE

REVISIONS

BY

CLIENT COMMENTS

SPLITTER

REQUISITION NUMBER

T-101

UNIT XYZ

P. O. NUMBER

DESCRIPTION CUSTOMER ABC

LOCATION

DRAWING NUMBER SHEET 1 OF 2

REV.

1


PEP No.: 1010 Page: 2 of 3 Revision: 5 Date: Aug. 9, 2007 ______________________________________________________________________ PEP-1010 (Cont'd) VESSELS 6.

The following liquid surge capacities are to be used for this project. They are summarized from the appropriate Foster Wheeler Standards. Unless otherwise specified, surge capacity is defined as the capacity between high-liquid level (HLL) and low-liquid level (LLL). Low-Liquid Level a.

5

Without Water Settling. - Horizontal Vessels - Vertical Vessels - “Hard-Piped” Low-Low Level Switch on Vertical Vessels

6" above Bottom 8" above BTL 1’-5" above BTL (Note)

(Note: Use of a level transmitter, if permitted by client standards, can allow the Low, Low Level set-point to be as low as 0’-6” above BTL.) b.

With Water Settling. Provide five (5) minutes holdup at the total hydrocarbon rate below the low-liquid level for the "settling out" of water. If a pot is not employed, five (5) minutes of holdup for the water itself must also be provided in the bottom of the vessel.

Surge Time in Drums Service

Surge Time, Minutes

Feed to Tower or Furnace Drum Diameter, Ft. Below 4 4 - 6, Inclusive Above 6

20 15 10

Reflux to Tower

5

Product to Storage

2

Total draw off pans on towers on level or flow control to section

Greater of: - 2 minutes on products - 1 minute on pumparound -

section above 5 minutes on wash to below


PEP No.: 1010 Page: 3 of 3 Revision: 5 Date: Aug. 9, 2007 ______________________________________________________________________ PEP-1010 (Cont'd) VESSELS In case surge must be provided for both product and reflux, the larger volume is used (not the sum of the two volumes). Surge Time in Towers Service

Surge Time, Minutes

Bottoms to Subsequent Tower - on Level Control - on Flow Control Bottoms to Heat Exchanger and/or Tankage

5 15 2 (not applicable to vacuum towers)

Feed to fired coil reboilers: sum of 5 minutes on vaporized portion and 2 minutes on product. It is normally desirable that 5 minutes on vaporized portion be employed to establish NLL, the subsequent 2 minutes on product used to establish the HLL (NLL to HLL, minimum of l ft.).


PEP No.: 1011 Page: 1 of 3 Revision: 4 Date: Mar. 6, 2006 ______________________________________________________________________ PEP-1011 FIRED HEATERS The following notes are generally applicable to fired heaters in conventional services. Some of these notes may not apply to special heaters such as coker heaters or reformers. 1.

Fired heater process specification shall be on standard FW process data forms or equivalent computer generated forms. Additional sheets for data and notes may be added as required for each service.

2.

The process engineer should indicate the minimum design pressure, but the design metal temperature must be left blank.

3.

Burner type shall be specified for all heaters. In accordance with the BEDD sheets, burners specified for liquid fuels require pilot burners to be specified. Burner location shall not normally be specified by the process engineer.

4.

Furnaces in services classified as "dirty" (or subject to coking) shall be provided with facilities for steam and air decoking and designed to withstand the metal temperature and thermal stress of steam air decoking.

5.

The following notes should be included in the process specification for each heater where applicable. Additional notes may be added as required, e.g.: a.

Vendor shall confirm that the superheated steam coil is capable of withstanding zero steam flow conditions during normal and fouled operations.

b.

Heater shall be designed for continuous operation and shall be capable of operating at turndown as required by Basis of Design.

c.

Vendor shall provide information concerning their recommendations for the proper design and operation of steam air decoking facilities.


PEP No.: 1011 Page: 2 of 3 Revision: 4 Date: Mar. 6, 2006 ______________________________________________________________________ PEP-1011 (Cont'd) FIRED HEATERS d.

Vendor shall provide the following with regard to soot blowers, (applies only for fuel oil/combination firing with a convection section.) -

Soot blowing lanes with end bearing and mounting flanges Shrouds for refractory protection in the soot blower lanes. Design drawings for soot blower platforms. Convection coil design that will accommodate fuel oil firing without rapid fouling.

8.

Process data and cost of available fuels will be provided on the Basic Engineering Data sheets.

9.

Given below are guidelines to be used in estimating utility line sizes and utility requirements for fired heaters (at least until vendor requirements are confirmed). a.

b.

Purge Steam (fire box): l)

100 to 200 lbs. steam per MMBtu (180 to 360 Kg steam per MMkcal) (liberated)

2)

use M.P. steam (150 psig)

3)

label header "purge steam" not "snuffing steam"

Coil Steamout: l)

use 5 lb/sec. ft2 (24.4 Kg/sec.-m2) for steam mass velocity through coil

2)

use 2" diameter line for each coil

3)

use M.P. steam or higher pressure if necessary (steam supply pressure should be higher than down stream pressure)

4)

label header "coil steamout"


PEP No.: 1011 Page: 3 of 3 Revision: 4 Date: Mar. 6, 2006 ______________________________________________________________________ PEP-1011 (Cont'd) FIRED HEATERS c)

d)

10.

11.

Atomizing Steam: 1)

0.5 lb steam per lb of oil consumed

2)

use M.P. steam or a steam with at least 30 psi (2.1 Bar) higher than fuel oil pressure.

3)

size steam line for 1.0 lb steam per lb of oil consumed

Soot Blowers: 1)

must be specified for each heater specified for oil or combination firing

2)

design consumption is typically 10,000 lbs/hr (4,536 kg/hr)

3)

use M.P. steam

The following items must be shown on engineering flow diagrams for each fired heater: -

Flue gas analyzer with board indication.

-

Draft gage, connections only.

-

Skin thermocouple on each pass with board indications.

-

TI's for radiant zone, arch, convection section, stack and crossovers.

-

Fuel gas flow with board indication.

-

Stack damper, manual loading station on board.

-

Automatic switch over to natural draft operation on failure of air blower.

Air blowers for fired heaters will not be spared. Fired heaters will be specified for stable operation without the air blower and with automatic switchover to natural draft. Vendors will be instructed to advise turndown required for natural draft operation.


PEP No.: 1012 Page: 1 of 8 Revision: 6 Date: Feb. 11, 2009 ______________________________________________________________________ PEP-1012 HYDRAULICS 1.0

LINE SIZING CRITERIA Below are some general rules for line sizing. These rules should cover most normal situations, but may not be suitable for all cases, especially revamps. For critical services or long headers, the process engineer is to carry out a hydraulic study of the system to confirm the total pressure drops and the pressure balance, regardless of whether the lines meet the allowable pressure drop and velocity criteria as given in this PEP. The process engineer should also refer to Process Standard 201, Fluid Flow Single Phase, and Standard 202, Fluid Flow Two Phase. In case of any conflicts with the process standards, this Process Engineering Practice shall govern.

6

1.1

Drawoff Nozzles Reference the FW Process Standards 103, section 3.0. The minimum drawoff box depth shall be one and one-half times the nominal drawoff size, but not less than 9 inches. In case of any conflicts with the Process Standard 103, this Process Engineering Practice shall govern.

6 1.2

Pump Suction Lines Pipe Diameters 8" and less

Pipe Diameters more than 8"

Approx. Velocity, ft/sec

Allowable ∆P, psi/100 ft

Approx. Velocity, ft/sec

Allowable ∆P, psi/100 ft

Nonboiling Liquid

3 to 5

1.0 to 1.5

12 max

1.0 to 1.5

Boiling Liquid

1 to 3

0.3 to 0.5

6 max

0.3 to 0.5

Note:

Gas blanketed liquids are to be considered as boiling liquids for line sizing, pump calculations, specifications, etc.


PEP No.: 1012 Page: 2 of 8 Revision: 6 Date: Feb. 11, 2009 ______________________________________________________________________ PEP-1012 (Cont'd) HYDRAULICS 1.0

LINE SIZING CRITERIA (Cont’d) 1.3 Pump Discharge Lines Allowable Pressure Drop 1.5 to 3 psi/100 feet 0.5 to 1.0 psi/100 feet maximum for long headers (800 equivalent feet and greater) Approximate Velocity Pipe Diameter 4" and less 6" 8" and more

Approximate Velocity, ft/sec 5 to 7 10 max. 12 max.

1.4 Reboiler Lines Reboiler Trap-out Allowable Pressure Drop Approximate Velocity

0.15 to 0.3 psi/100 feet 3 to 5 feet/second

Reboiler Return Allowable Pressure Drop (See rules for 2 phase below.)

0.3 psi/100 feet



LINE SIZING CRITERIA (Cont’d) 1.5 Cooling Water Lines Reference for Sizing Use FW charts 5-107-B-1 to 6 but add an additional 20 percent to the pressure drop values given in the chart to allow for aging. Cameron, with C=100 is not acceptable. Allowable Pressure Drop 1 to 1.5 psi/100 feet for main headers 1.5 to 3 psi/100 feet for branch lines Approximate Velocity Same as for pump discharge lines (Item 1.3 above). 1.6 HC Vapor Lines Allowable Pressure Drop For lines not exceeding 300 feet in length Pressure Level

Pressure Drop, psi/100 feet

28" Vacuum (1 psia) 15" Vacuum (7 psia) 0 psig to 50 psig 50 psig to 150 psig 150 psig to 500 psig Over 500 psig

0.0625 0.15 0.25 to 0.5 0.5 to 1.5 1.5 to 3.0 (0.5% of pressure level)

Allowable Velocities Maximum for gas =

100/

Dg ft./sec,

where Dg is density of gas in lb/cu. ft.



LINE SIZING CRITERIA (Cont’d) 1.7 Two-Phase Process Lines Maximum for two-phase flow = Minimum for two-phase flow =

100 Dmix 60 Dmix

, ft/sec , ft/sec

Where Dmix is the density of the mixture in lb/cu. ft. Velocity may be less than 60 / Dmix , ft . / sec at vessel inlet or for horizontal runs where separation of the two phases is desirable. For critical two-phase lines, detailed calculations must be made for pressure drop and flow required. 1.8 Steam Condensate Onsite lines only. Allowable Velocity 1 to 2 feet/second, as if all condensate remained as liquid. 1.9 Steam Lines Allowable Pressure Drop For lines not exceeding 300 feet in length Pressure Level 28" Vacuum (1 psia) 15" Vacuum (7 psia) 0 psig to 50 psig 50 psig to 150 psig 150 psig to 500 psig Over 500 psig

Pressure Drop, psi/100 feet 0.0625 0.20 0.25 to 0.5 0.5 to 1.5 1.5 to 3.0 (0.5% of pressure level)



LINE SIZING CRITERIA (Cont’d) 1.10

Sour Water Lines Allowable Velocity Pipe Material Carbon Steel

Stainless Steel

Fluid Sour Water/Hydrocarbon Mixture Sour Water > 250°F Sour Water ≤ 250°F Sour Water at all temperatures

Maximum Allowable Velocity, ft/sec 20 5 10 20

Pressure drop per Section 1.1 through 1.4 above. 1.11

Amine Solution Lines Allowable Velocity Maximum Allowable Velocity, ft/sec

Pipe Material

Fluid

Carbon Steel

Lean Amine Rich Amine

20 3

Rich Amine

20

Stainless Steel or Alloy 2205

Carbon Steel is the preferred pipe material for amine services. Velocity limits assume fluid remaining as liquid. Pressure drop per Section 1.1 through 1.4 above.




PSV Lines Line sizing shall generally be in accordance with API RP 520, Part I and Part II, and RP-521. To reduce noise levels during an emergency "blow" to the flare, discharge line and header velocities shall not exceed 100 / Dg , ft/sec or 80% of sonic velocity, whichever is lower. Where: a. sonic = 223 X

where T = °R, M = mol. wt.

kT / M

OR b. sonic = 68.1 X

kP / Dg

where k = Cp/Cv, P = psia, Dg = lbs/cu. ft. Flare headers shall be free draining toward flare drum. 6

1.13

Condenser Bypass Lines, Balance Lines, and Vent Lines Both the controlled bypass lines around the condenser and the vent line from the accumulator drum are sized for a minimum of 10% of the tower's gross overhead flow. Refer also to Process Standard 507, Section 4.0 for more conservative sizing criteria. Open balance lines in total condenser services should be sized for 25% of the tower gross overhead flow or shall be sized to pass any relief flows, whichever case controls.

1.14

Thermosyphon Reboiler Circuits When calculating the skirt height of a tower having a thermosyphon reboiler, Foster Wheeler's normal practice of requiring a driving force equal to three times the calculated pressure drop in the thermosyphon circuit shall be employed. For very large units, if approved by the responsible chief engineer, this driving force may be reduced from three to two times the calculated pressure drop.




Slurry Service a)

Velocity criteria for line sizing: To avoid settling in lines, design for a minimum allowable velocity of 3 ft/sec in normal operation. To avoid abrasion and excessive wear in the lines, design for maximum normal velocity of 7 ft/sec.

b)

Do not use a common suction line to spare slurry pumps. Provide one line to each pump to prevent losing spare capacity due to plugging on suction side.

c)

Normally connect steam generators in slurry service in parallel. Design is often for two 50% exchangers. This facilitates cleaning the exchangers without having to shutdown the unit. It also decreases problems encountered during turndown operation.

d)

Exchangers in slurry service should be designed for 5 - 7 ft/sec velocity at normal operating conditions.



CONTROL VALVE PRESSURE DROP ALLOWANCE Unless otherwise dictated by process, control valve pressure drop shall be calculated on the following basis: 2.1

Pumping Services (Discharge side) Generally, the pressure drop assigned to the control valve for the pump, at normal operating capacity, shall be equal to either 10% of the system operating pressure in psig at pump destination, up to 1000 psig, or 33% of the frictional loss in the system excluding the pressure drop assigned to the control valve, whichever is greater. For systems where high frictional losses are taken, i.e., crude preheat circuits, 10% of the estimated pump destination pressure should be adequate; but in no case shall the assigned control valve pressure drop for the pump design case be less than 10 psi. For systems operating above 1000 psig, the control valve may take less than 10% of the system pressure, depending on process and control considerations. Control valves (including actuators) should be specified as capable of shutoff and opening with maximum upstream pressure and minimum downstream pressure. On a pump discharge system, the maximum upstream pressure is the pump shutoff pressure at maximum pump suction pressure.

2.2

Other Liquid Services (Gravity flow, cascading from one pressure level to another, etc.) Pressure drop is a function of the system under consideration, but as a general rule, the pressure drop assigned to the control valve shall not be less than 10% and no greater than 85% of the pressure differential available for frictional loss.

2.3

Gas Services For compressor services, the engineer should be guided by the pump criteria listed above. Generally, for other gas services, the pressure drop assigned to the gas control valve shall not be less than 10% and not greater than 85% of the pressure differential available for frictional loss.


PEP No.: 1013 Page: 1 of 3 Revision: 4 Date: Mar. 6, 2006 ______________________________________________________________________ PEP-1013 EXCHANGERS 1.

Air cooled exchangers typically are forced draft, usually with a minimum of two fans per bay. Combined services within one bay are not desired.

2.

If both the cold side inlet and outlet of an exchanger require block valves, a relief valve shall be provided on the cold side inlet to prevent excessive thermal expansion. In no case, should this relief valve be set lower than the highest pump shut-off pressure to which it may be subjected, or higher than the exchanger design pressure.

3.

The general order of priority to establish the tubeside fluid is listed below. This listing is for guidance only and should not be considered inflexible. (i)

Cooling water

(ii) A corrosive fluid or a fluid likely to deposit coke, sediment or other solids such as catalyst. (iii) The higher fouling fluid. (iv) The less viscous of the two fluids, where large differences exist. (v) The fluid under higher pressure, where large differences exist. (vi) The hotter fluid. Condensing vapors are usually located on the shell side. Also, if the temperature change of a fluid in an exchanger is very large, for example, several hundred degrees, it is often better to pass this fluid through the shell. Otherwise multiple bundles may be required to avoid excessive temperature stresses on the tubesheets.


PEP No.: 1013 Page: 2 of 3 Revision: 4 Date: Mar. 6, 2006 ______________________________________________________________________ PEP-1013 (Cont’d) EXCHANGERS 4.

In general, air cooled exchangers shall be provided with: -

Process side temperature indication and low alarms (as required) in control room for each outlet nozzle.

-

Variable speed fan motors, as required (depending on desired degree of outlet process temperature control), with temperature controller, unless otherwise specified.

The following additional provisions are required for freeze protection, where applicable, during start-up and shutdown:

5.

-

Self draining, steam coils and louvers shall be provided on air cooled exchangers handling high pour materials, water or hydrocarbon/water mixtures.

-

Self draining and louvers shall be provided on air cooled exchangers handling hydrocarbon/water mixtures containing less than 10 wt% water.

-

If louvers are provided for supplemental freeze protection during start-up and shutdown, they will be controlled only via manual loading stations.

The specified fouling resistance shall be in accordance with the latest TEMA standards. The following fouling resistances shall be specified for utility streams regardless of velocity or temperature: Utility Steam Boiler Feedwater Condensate Cooling Water Lean Amine Rich Amine

Fouling Factor (Ft2 hr °F/BTU) 0.0005 0.001 0.001 0.002 0.002 0.002


PEP No.: 1013 Page: 3 of 3 Revision: 4 Date: Mar. 6, 2006 ______________________________________________________________________ PEP-1013 (Cont'd) EXCHANGERS 6.

9.

10.

The suggested minimum design pressure for shellside and tubeside shall be specified by the process engineer. This value shall be the greater of: -

Maximum pump shutoff pressure, when exchanger can be blocked off and exposed to pump shutoff.

-

25 psi or 10% greater than maximum operating pressure. Where exchanger is protected by relief valve, a pressure balance for relieving conditions must be made to determine design pressure.

-

50 psig

Suggested minimum design temperature for shellside and tubeside fluids shall be specified by the process engineer. This value shall be the greater of: -

maximum normal operating temperature plus 50°F

-

other based on air or bypass or turn-down

Where applicable, limiting transfer rates and exchanger type shall be indicated.


PEP No.: 1014 Page: 1 of 3 Revision: 4 Date: Mar. 6, 2006 ______________________________________________________________________ PEP-1014 PUMPS AND COMPRESSORS 1.

Overcapacity Factors The following overcapacity factors shall be used unless otherwise specified by the chief engineer. a.

b.

Pumps Charge, product, transfer services

1.1

Reflux, pumparound, reboiler & other critical services

1.2

Compressors Centrifugal

1.2

2.

Pump hydraulic calculations are to be issued together with the pump specifications, and are to be included in the Process Technical Specification book.

3.

For pumps specified for bubble point fluids show "B.P." on the pump specification sheet rather than the actual vapor pressure. Note that this also applies to fluids containing dissolved/entrained gas.

4.

Calculation of Pump Shutoff Pressure at Maximum Suction Pressure Pump Maximum Suction Pressure a.

Taking suction from tankage open to the atmosphere. MSP (Max. Suction Pressure) = static head measured from maximum tank liquid level (zero frictional line loss)

b.

Taking suction from a pressure vessel. MSP = Vessel minimum design pressure at top plus estimated frictional loss through trays plus static head measured from highest liquid level (zero frictional line loss)


PEP No.: 1014 Page: 2 of 3 Revision: 4 Date: Mar. 6, 2006 ______________________________________________________________________ PEP-1014 (Cont’d) PUMPS AND COMPRESSORS 4.

Calculation of Pump Shutoff Pressure at Maximum Suction Pressure (Cont’d) Pump Shutoff Pressure for Centrifugal Pumps* PSP (Pump Shutoff Pressure) = MSP plus 1.2 x (pump differential at maximum specified specific gravity). *Pump shutoff as calculated above is used to designate preliminary equipment design pressure; but is to be confirmed by the Project Department on selection of final pump curves.

5.

Minimum flow requirements must be specified for each pump, to cover such conditions as start-up, shutdown, turndown, regeneration, etc.

6.

Pump calculations for NPSH and power consumption are to be made at the design flowrate.

7.

Static head requirements for a discharge pressure calculation shall be based on actual operating temperature where the static head occurs (not necessarily pumping temperature).

8.

The following note is to be affixed to the specification for all equipment having a design pressure determined by pump shutoff. DESIGN PRESSURE:

Psig*

*But not less than the shutoff pressure of Pcommon spare) at maximum suction conditions. 9.

(or P-

if

Spare Capacity a.

100% spare capacity shall be specified for all pumps in critical service.

b.

Air blowers serving fired heaters will not be spared.

c.

Single speed electric motors are preferred drivers for primary and spare pumps, as well as for compressors. Steam turbine drivers may be selected based on special process, utility or mechanical considerations.


PEP No.: 1014 Page: 3 of 3 Revision: 4 Date: Mar. 6, 2006 ______________________________________________________________________ PEP-1014 (Cont’d) PUMPS AND COMPRESSORS 10.

Centrifugal compressors shall be specified when appropriate.

11.

Drivers for air blowers shall be designed for cold air operation.


PEP No.: 1015 Page: 1 of 15 Revision: 0 Date: Sep. 12, 2008 ______________________________________________________________________ PEP-1015 WORK PLAN PREPARATION AND MAINTENANCE 1 SCOPE This work practice outlines the requirements for preparing and maintaining a Process Dept Detailed Work Plan, including the Work Plan Summary Sheet (WPSS), covered in EP 8-1, for typical projects. Special considerations may require deviation from this work practice with the approval of the Director-Process Engineering. 2 GENERAL 2.1 This PEP is applicable to all projects ranging from Process Design Packages to full EPCM projects, with the understanding that progress milestones and weighting values (percentages) will vary between the types of projects handled. 2.2 The Lead Process Engineer shall prepare the detailed work plan and corresponding WPSS used to track the progress of all equipment items, studies and/or work products assigned to the Process Department for the given project. The Chief Process Engineer may elect to assign another Process engineer to prepare and maintain the work plan, however, it shall be the Lead Process Engineer’s responsibility to ensure that the plan’s accuracy as well as the requirements of this PEP and other practices referenced herein are followed in the preparation and maintenance of the detailed work plan and WPSS. 2.3 The purpose of the work plan is to plan, execute and report progress by achieving specific activity milestones for each tagged equipment or, study, activity and/or work product. Partial earned credit may be taken, as defined in paragraph 7.3, for these milestones. The work plan also reports hours earned as well as total percent complete per item or activity. 2.4 A template Workplan and WPSS, Form No. 210901, is located on the Process department webpage of the Foster Wheeler Intranet in the Workplan Template directory. The file is a single Excel Workbook that includes the WPSS and Workplan. The Process Work Plan Template workbook contains the following tabs: 2.4.1 WPSS is the first tab and is clearly labeled WPSS ROLLUP (typical for all department WPSS practices). The Department WPSS Form contains company-wide Earned Value and Productivity Calculations that are password protected for consistency across the organization. 2.4.2 An overall summary is the second tab. The overall summary is autopopulated from the Progress report sheet (see paragraph 2.4.3).


PEP No.: 1015 Page: 2 of 15 Revision: 0 Date: Sep. 12, 2008 ______________________________________________________________________ PEP-1015 (Cont’d) 2.4.3 The detailed work plan is provided in the third tab, labeled Progress report. The detailed work plan lists all of the activities defined in the WPSS with a further detailed breakdown. For example, the WPSS has an activity, Process Specifications (job class 6) while the work plan lists each major piece of equipment by tag number. 2.4.4 Variances are summarized in the fourth tab, labeled Variances. Variances are further discussed in paragraph 7.2. 2.4.5 Password protection: Milestone weightings and earned value calculation cells of the WPSS shall remain password protected. Control of the password is the responsibility of the Director-Process Engineering (EP 8-1). 2.5 The WPSS includes the following information: 

Job Class – the Job Classes are the standard Job Classes for the Process department.



Activity Name – this is a short description of the Job Class.



Unit of Measure – these are the units that are used to provide more objective measuring tools in determining the earned value of the project.



Unit Counts (Original, Approved and Forecast) – this is a value for the number of items (see Unit of Measure) that are required for each Job Class. The Original number is the initial number from the original estimate for the project. The Approved number would include the Original number plus all approved quantities due to client approved Change Orders. The Forecast number includes the Approved number plus submitted variances that have not been approved or detected variances that have not been submitted.



Budget Hours (Original, Approved and Forecast) – this is a value for the number of hours that are required for each Job Class. The Original number is the initial number of hours from the original estimate for the project. The Approved number would include the Original Number of hours plus all approved hours due to client approved Change Orders. The Forecast number includes the Approved hours plus submitted variances that have not been approved or detected variances that have not been submitted.



Earned Hours – a calculation of the earned hours for effective hours for each Job Class.


PEP No.: 1015 Page: 3 of 15 Revision: 0 Date: Sep. 12, 2008 ______________________________________________________________________  Milestones – progressable levels of completeness with weighting for each activity. PEP-1015 (Cont’d) 

Earned Value (EV%) – is the percent of the hours or units earned for each Job Class. This is summed up to provide the total percent complete for all activities on the project.



Productivity – is a measure of the Earned Hours vs. Expended Hours.

2.6 The Lead Process Engineer or designee shall submit the completed work plan, including the WPSS, to the Chief Process Engineer for review and approval prior to distribution to the Project Manager or as directed by the Project Manager. The Chief Process Engineer shall signify approval of the work plan and WPSS by returning a signed copy of the WPSS to the Lead Process Engineer. 3 INFORMATION REQUIRED FOR SETUP 3.1 The following list defines the information needed by the Lead Process Engineer in order to prepare the work plan and WPSS. 3.1.1 Equipment List with item tag numbers and descriptions or preliminary process flow diagram. 3.1.2 Project schedule with planned activity dates. 3.1.3 Approved Contract Budget Manhours for the Process Department including breakdowns by activity if available. 3.1.4 Scope of Work 3.1.5 Project Execution Plan 4 CREATION OF WORK PLAN 4.1 The work plan must be created by making a copy of the department work plan template located on the Process Dept. Intranet web page, and saving to the project folder. DO NOT copy an existing work plan from another project. The electronic file name for the work plan shall follow the convention given in EP 8-1. 4.2 Modify the work plan by inserting the project item tag numbers, descriptions, activities and budget man hours with scheduled dates for completion. (Refer to Attachment “A” and paragraphs 5.1 through 5.5 below) 4.3 Activity milestones not applicable due to the scope of the project may be zeroed out on the WPSS form. However, the milestone activities will still be listed.


PEP No.: 1015 Page: 4 of 15 Revision: 0 Date: Sep. 12, 2008 ______________________________________________________________________ PEP-1015 (Cont’d) 4.4 Additional milestones, not contained within the template, shall not be added without prior consultation with the Chief Process Engineer(s) and Director-Process Engineering. 4.5 The weighting value associated with each milestone, as given in paragraph 6.2, shall not be modified without prior consultation with the Chief Process Engineer and/or Director-Process Engineering. 4.6 The work plan is divided into several tabs within the electronic file, as described in paragraph 2.4. Typically, one work plan is produced per project, regardless of how many units are in that project. However, if the client and/or Project Manager require separate tracking for each unit, then individual work plans or separate Progress report tabs linked to a single overall summary and WPSS ROLLUP tabs, may need to be created. 4.7 If the activity and/or milestones do not apply for a particular project, they will be left blank on the WPSS ROLLUP tab. The activities are fixed and rows cannot be added or deleted nor can activity names be changed. 4.8 After the set up process, all formulas shall be reviewed to insure that they are functioning properly. The template can be used to assist in correcting any cells that may have been accidently modified during set up. 5 WORK PLAN SUMMARY SHEET SET-UP 5.1 The WPSS shall be set-up based on Job Class/Activity. Job Classes shall consist of the following activities listed below with their respective unit of measure. Job Class 1 2 3 4 5 6 7 8 9

Activity Design Basis / Kick-off Meeting Yields Simulation Modeling Heat and Material Balance Process Studies Process Specifications Equipment List Process Description Utility Summary & Effluent Emissions

Unit of Measure # of Documents # of Calculations # of Simulations # of Documents # of Simulations # of Process Design Specifications (PDS) # of Documents # of Documents # of Documents


PEP No.: 1015 Page: 5 of 15 Revision: 0 Date: Sep. 12, 2008 ______________________________________________________________________ Job Class 10

Activity Instrument Process Data

Unit of Measure # of Process Design Specifications (PDS)


PEP No.: 1015 Page: 6 of 15 Revision: 0 Date: Sep. 12, 2008 ______________________________________________________________________ PEP-1015 (Cont’d) Job Class 11 12 13 14 15 16 17 18

Activity Interlocks PSV (includes Flare Summary)

22 23 24

Line Sizing Hydraulics PFDs EFDs Materials of Construction (MOC) Design Pressure & Temperature (DPDT) Process Writeups (PDP) Progress Reports / Coordination Operating Guides (with list of Analytical procedures) HAZOP Review of Critical Documents Requisition Review

25

Vendor Quotes

26 27 28 29 30 31

Instrument Support Project Support (P&I) Model Review Follow up / Coordination Hydraulic Checks (ISO’s) Variances (Approved)

19 20 21

Unit of Measure # of Documents # of Process Design Specifications (PDS) # of Systems # of Systems # of Drawings # of Drawings # of Drawings # of Drawings # of Documents # of Documents # of Drawings # of Documents # of Process Design Specifications (PDS) # of Process Design Specifications (PDS) # of Drawings # of Drawings # of Systems # of Weeks # of Systems # of Variances

5.2 The Unit Count and Budget Hours associated for each Job Class shall be determined from the values located in the work plan. During the initial set up, the values for the Original Plan, Approved Contract Budget and Current Forecast shall all be the same. 5.3 The Activity Milestones and their Weighting for each Job Class shall be taken from the work plan without modification. 5.4 The primary document for forecasting and measuring progress is the “Progress report” tab in the work plan workbook. The Progress report is customized to each project and will list each activity by drawing number, tag number, study, etc., as shown on the template in Form 210901 on the Process Department Intranet web page. While certain fields in the Progress report worksheet are protected because there is a formula, the number of rows may be increased or decreased as required.


PEP No.: 1015 Page: 7 of 15 Revision: 0 Date: Sep. 12, 2008 ______________________________________________________________________ PEP-1015 (Cont’d) 5.5 The overall summary tab of the workbook will be automatically populated with the data from the Progress report tab. The cells in this worksheet are protected to prevent an individual from writing over the formulas. 5.6 The WPSS ROLLUP tab has some fields auto-populated from the overall summary worksheet but the following fields must be input by the Lead Process Engineer: 5.6.1 Unit Count, Original plan – the number of units for each activity is input. Currently, this is a manual function where the Lead Process Engineer has to count the number of units from the Progress report summary. Units are defined in paragraph 5.1. 5.6.2 Budget Hours, Current forecast – typically this will be equal to the Approved Budget Hours; however, if there were any variances that have not been approved or submitted for approval, these hours would be reflected in this column. 5.6.3 Milestone weightings – in general, the milestone weightings are fixed, however depending on the scope of the project (PDP, FEED, EPC, etc.), there may be a need to change the weightings, as discussed in paragraph 6.3. Once the initial milestones and milestone weightings are determined for a particular project, these shall remain unchanged throughout the project duration. 5.6.4 Milestone units – the number of units for each activity completed for each milestone is manually entered. In some categories, for example, process specifications, this number may have to be adjusted from the actual number in order to match the number of manhours completed from the Progress report worksheet. This is because for this category, different equipment types (towers, exchangers, pumps, etc.) have different manhours per item assigned and when the unit totals are combined, the result may differ from the Progress report summary. If this occurs, the Lead Process Engineer has to manually adjust the unit number until the earned manhours agree with the manhours on the Progress report worksheet. 5.5 After the set up process, the formulas shall be reviewed to insure that they are functioning properly. The template can be used to assist in correcting any cells that may have been accidentally modified during set up. 6 ACTIVITY MILESTONES 6.1 The primary Activity Milestones to be used on the work plan and WPSS, and their definitions, are given below:


PEP No.: 1015 Page: 8 of 15 Revision: 0 Date: Sep. 12, 2008 ______________________________________________________________________ PEP-1015 (Cont’d) 6.1.1 Basis of Design – The Process department is responsible for preparing the Basis of Design for a project. The Basis of Design incorporates relevant data from the following: Client requirements; Basic Engineering Data (BED) sheets; contractual requirements; Process Coordination Procedure; and Process technology requirements. 6.1.2 Basic Heat & Material Balance – In accordance with Process Department Procedures, the Process Department is responsible for establishing the material balance flows to and from the unit as well as establishing all intermediate stream flows. The material balance then sets the associated energy balance. Stream flows are captured on Material Balance Sheets (also known as Diamond Sheets). Each stream has a number that is referenced on the Process Flow Diagram of the associated process unit. 6.1.3 Process Equipment List – In accordance with Engineering Practices (EPs), the Process Department is responsible for establishing equipment numbers and equipment names for major equipment items and associated spare equipment. The Process Equipment List can be found in the Forms directory on the Process home page. 6.1.4 Process Flow Diagrams – Process Flow Diagrams (PFDs) are created and maintained by the Process in accordance with Process Department Procedures and the Process Engineering Practices (PEPs), and show all equipment, stream numbers, temperatures and pressures that results from the design necessary to meet the requirements established in the Basis of Design. 6.1.5 Material Balance Summary Sheets – This form is used to capture the unit material balance. The Process Flow Diagram reference stream numbers with a diamond symbol. The Material Balance Summary Sheets (also known as “Diamond Sheets”) list the appropriate stream data for each referenced stream. The Material Balance Summary Sheets can be found in the Forms directory on the Process home page. These sheets are also linked to the EZ Diamond program to easily populate diamond sheets from a ProII simulation.


PEP No.: 1015 Page: 9 of 15 Revision: 0 Date: Sep. 12, 2008 ______________________________________________________________________ PEP-1015 (Cont’d) 6.1.6 Process Data Sheets – Equipment – The Process Department is responsible for issuing and maintaining Process equipment data sheets for all equipment or vendor packages throughout the project. In accordance with Process Department Procedures and the Process Standards, Process Data Sheets contain all dimensions, operating flow rates, temperatures, pressures, transient conditions, and design pressure necessary for other engineering disciplines to develop detailed equipment requisitions suitable for equipment purchase. The Process Department maintains the Process Data Sheets throughout the project. All equipment data sheets can be found in the Forms directory on the Process home page. 6.1.7 Engineering Flow Diagrams – All equipment, line sizes, valves, relief valves, elevation requirements and all other specific information necessary to design a specific unit or system is reflected on the Engineering Flow Diagrams (EFDs). Content and ownership of the EFDs is outlined in the Engineering Practices (EPs). In general, the Process Department originates the EFDs and controls them up to the “B” issue, where Process releases control of the EFDs to the Project Department and all subsequent issues are by the Project Department. EFDs are often referred to as P&IDs (Piping and Instrument Diagrams). 6.1.8 Process Data Sheets – Instruments – In accordance with Process Department Procedures, PEPs and the Process Standard Design Bulletins, the Process Department is responsible for issuing and maintaining Process Instrument Data Sheets throughout the project. The specific valves, transmitters, indicators, etc., to be included on the data sheets are established in the deliverables section of the project contract. The process data to be included for each type of instrument can be found in the Standard Design Bulletins directory of the Process home page. 6.1.9 Utility Summary – In accordance with Process Department Procedures, the Process Department is responsible for issuing and maintaining the Utility Summary throughout the project. The Utility Summary is a listing of each piece of equipment that consumes or produces a utility (such as cooling water or steam) and the associated utility flow rate. As this is a balance, it is not suitable to list all equipment in a single system that consume or produce a utility in a series arrangement (for example, if BFW is preheated in two consecutive exchangers then only list the first “consumer”).


PEP No.: 1015 Page: 10 of 15 Revision: 0 Date: Sep. 12, 2008 ______________________________________________________________________ PEP-1015 (Cont’d) 6.1.10 Catalysts/Chemicals Summary – In accordance with Process Department Procedures, the Process Department is responsible for issuing and maintaining the Catalyst and Chemical Summary throughout the project. The Catalyst and Chemical Summary is a listing of all catalysts and chemicals consumed or required to be present during the operation of the unit or system. 6.1.11 HAZOP Review – A HAZOP (Hazardous Operations) review is coordinated by the Project Department and supported by the Process Department in accordance with the Engineering Practices. For this review, the Process Department typically assigns one Process Engineer and one Process Operator to participate in the HAZOP review. Following the HAZOP review the Process Department also supports the HAZOP resolution phase where specific items are addressed to rectify any issues captured during the review. 6.1.12 Process Technical Specifications – Also known as the “Tech Spec”, “Spec Book” or “PDP Package”, this write-up is a compilation of all Project deliverables set forth in the contract. The Process Technical Specification often includes deliverables developed and issued by other disciplines (such as the Material of Construction Diagram, Plot Plan, Design Pressure/Design Temperature Diagram, etc). This is often the final deliverable to the client. 6.1.13 Operating Manuals/Guidelines – Operating Guidelines are a set of general operating criteria and/or instructions that pertain to a specific unit. Although these guidelines cover all the major systems, they represent only a starting point for continued development of Operating Manuals. An Operating Manual is a valve-by-valve/ line-by-line set of instructions that give specific instructions on commissioning, start-up, shutdown, emergency shutdown and normal operations. Instrumentation set-points, alarm-points and trip points are also addressed. Operating Manuals are typically developed by the owner’s Operations Group. 6.1.14 Vendor Drawings Squad Check – This is a review of vendor information, initiated, controlled and circulated by the Project Department to obtain comments from all engineering disciplines and capture these comments onto a single document. The vendor information is to be reviewed against the department master of the respective equipment, drawing or instrument item.


PEP No.: 1015 Page: 11 of 15 Revision: 0 Date: Sep. 12, 2008 ______________________________________________________________________ PEP-1015 (Cont’d) 6.1.15 Hydraulic Checks – In accordance with the PEPs and the Process Standards, hydraulic checks are the responsibility of the Process Department. As required, and depending on the contract deliverables and scope of the project, Process shall request all necessary supporting information (such as isometric drawings) to evaluate, confirm and finalize line sizes, equipment elevations, relief valve set pressures, piping configurations, thermosyphon hydraulics, gravity flow circuits, and other critical circuits to ensure that the final design, construction and operation of the unit or system will achieve it’s objectives and the contract throughput rate. 6.1.16 Start Up & Commissioning Assistance – As requested by the client, the Process Department shall provide on-site commissioning and start-up assistance for a specific unit or system. A commissioning period is typically 8 to 12 weeks in duration. During this time, all punch-lists are cleared, and operating procedures are reviewed and finalized with the unit operators. Prior to start-up (“oil in”), the unit is flushed, cleaned and drained per the operating procedures. At this point the unit is ready for start-up, where feedstock is introduced into the unit and the unit is operated as specified and designed to make the desired products.


PEP No.: 1015 Page: 12 of 15 Revision: 0 Date: Sep. 12, 2008 ______________________________________________________________________ PEP-1015 (Cont’d) 6.2 The project scope will have a direct effect on the weighing factors applied to each Activity Milestone. For example, PDP’s will have fewer milestones with different weightings than EPC projects. For full EPC projects, the following weighting factors shall be used. Milestone Design Basis / Kick-off Meeting Yields Simulation Modeling Heat and Material Balance Process Studies Process Specifications Equipment List Process Description Utility Summary & Effluent Emissions Instrument Process Data Interlocks PSV (includes Flare Summary) Line Sizing Hydraulics PFDs EFDs Materials of Construction (MOC) Design Pressure & Temperature (DPDT) Process Writeups (PDP) Progress Reports / Coordination Operating Guides (with list of Analytical procedures) HAZOP Review of Critical Documents Requisition Review Vendor Quotes Instrument Support Project Support (P&I) Model Review

EPC Projects 3 4 20%

1 40%

2 40%

50% 25% 25% 35% 25% 50% 50% 50%

50% 50% 50% 50% 25% 50% 50% 50%

25% 25% 25% 30% 30% 25% 40% 50%

25% 25% 25% 30% 30% 25% 20% 50%

50%

50%

33% 100%

33%

34%

33%

33%

34%

100% 100% 100% 100% 100% 100% 100%

5

25% 25% 15% 35%

10%

5%

25% 25% 25% 30% 30% 25% 20%

15% 15% 25% 10% 10% 10% 10%

10% 10%

10% 5%

6

5% 5%


PEP No.: 1015 Page: 13 of 15 Revision: 0 Date: Sep. 12, 2008 ______________________________________________________________________ PEP-1015 (Cont’d) Milestone Follow up / Coordination Hydraulic Checks (ISO’s) Variances (Approved)

1 100% 100% 100%

2

EPC Projects 3 4

5

6

6.3 For those projects whose scope is less than full EPC or for projects for which the milestones do not apply, the appropriate milestones and the weighing factors will be modified from those given in paragraph 6.2. The Lead Process Engineer shall consult with the Chief Process Engineer and/or Director of Process Engineering and assign the weighing factors to the milestones in the work plan and WPSS. 7 MAINTENANCE OF WORK PLAN AND WPSS 7.1 In order for the work plan and WPSS to be most effective, they must be updated frequently and diligently. The frequency of update shall be not longer than once per week. The Lead Process Engineer shall submit the approved Workplan and WPSS to meet Project Controls Reporting Period Requirements, which is normally twice monthly. 7.2 Variances shall be reported immediately and recorded on the detailed work plan along with the requested manhours. 7.2.1 The variance associated with the tagged item shall be listed below the tag number on the work plan. The hours in the variance assigned to that tag number shall be input in the “Forecast” column. (See Attachment “A”) 7.2.2 After Project Controls has issued the notification that the variance has been approved, the hours shall be added to the Client Approved Budget Hours.


PEP No.: 1015 Page: 14 of 15 Revision: 0 Date: Sep. 12, 2008 ______________________________________________________________________ PEP-1015 (Cont’d) 7.3 Since work plans are to be updated on a weekly basis, and considering the time durations needed to complete some of the milestones, partial credit shall be claimed for any milestone meeting the criteria set forth in Attachment “A”. All other milestone activities are to be reported on an “all or nothing” basis. 7.3.1 Partial credit may be claimed for Heat and Material Balances based upon the number of cases to be presented. For example, if 3 cases are to be presented and only one has been completed, then 33% credit may be claimed. 7.3.2 Partial credit may be claimed for Process Studies based upon the number of studies. For example, if 3 studies are considered part of the scope of the project and only one has been completed, then 33% credit may be claimed. 7.3.3 Partial credit may be claimed for Process Specifications based upon the number of equipment items. For example, if there are 50 pieces of equipment and only ten have been completed, then 20% credit may be claimed. 7.3.4 Partial credit may be claimed for Instrument Process Data based upon the number of instrument datasheets. For example, if there are 100 tagged instrument items that require a datasheet, and only 25 have been completed, then 25% credit may be claimed. 7.3.5 Partial credit may be claimed for PSVs based upon the number of PSVs. For example, if there are 10 relief valves and only 3 have been completed, then 33% credit may be claimed. 7.3.6 Partial credit may be claimed for PFDs based upon the number of drawings. For example, if there are 10 PFDs and only 2 have been completed, then 20% credit may be claimed. 7.3.7 Partial credit may be claimed for EFDs based upon the number of drawings. For example, if there are 50 EFDs and only ten have been completed, then 20% credit may be claimed. 7.3.8 Partial credit may be claimed for MOC diagrams based upon the number of drawings. For example, if there are 10 MOC drawings and only 2 have been completed, then 20% credit may be claimed. 7.3.9 Partial credit may be claimed for DPDP diagrams based upon the number of drawings. For example, if there are 10 drawings and only 2 have been completed, then 20% credit may be claimed.


PEP No.: 1015 Page: 15 of 15 Revision: 0 Date: Sep. 12, 2008 ______________________________________________________________________ PEP-1015 (Cont’d) 7.3.10 Partial credit may be claimed for Review of Critical Documents based upon the number of documents to be reviewed. For example, if there are 50 critical documents and only ten have been completed, then 20% credit may be claimed. Critical documents will be defined in the project kick-off. 7.3.11 Partial credit may be claimed for Requisition Review based upon the number of requisitions. For example, if there are 50 requisitions and only ten have been completed, then 20% credit may be claimed. 7.3.12 Partial credit may be claimed for Vendor Quotes based upon the number of documents to be reviewed. The total number of documents to be submitted by the vendor shall be established at the time the equipment has been awarded to the vendor and this number shall be the basis for determining partial credit. 8 UTILIZATION OF WORK PLAN AND WPSS 8.1 The work plan and WPSS are designed to function as the Process Discipline’s primary progress reporting vehicle and is to be submitted to the designated Project Controls Manager for the project(s) being reported on. The Chief Process Engineer and Director-Process Engineering shall be copied at every reporting period, as defined in paragraph 7.1. 8.2 The work plan and WPSS will indicate Productivity and Earned Value (EV) on accomplished work utilizing a quantity based tracking system. Manhours are “earned” when progress is recorded against each of the milestone activities. 8.3 Productivity values of 1.0 or less indicate efficient execution of the project. Productivity values exceeding 1.0 indicate too many manhours are being charged for the milestone activities reached. If this is the case, the root cause of the high productivity value shall be determined and addressed in order to avoid exceeding the budget for the project and maintain overall project schedules. 8.4 If the high productivity values result from an increased scope, or rework due to influences outside the Process or Project Management departments, variances shall be written and submitted to the Project Manager as soon as the change to the original or planned scope of work occurs.


PEP No.: 1015 Page: 16 of 15 Revision: 0 Date: Sep. 12, 2008 ______________________________________________________________________________________________________ ATTACHMENT “A”


PEP No.: 1016 Page: 1 of 17 Revision: 0 Date: Feb. 11, 2009 ______________________________________________________________________ PEP -1016 Purpose: A Process Chief’s Review (“Chief’s Review”) is a systematic, structured review of the Engineering Flow Diagrams, Design Basis Document, Project Correspondence, Process Specifications, Process Flow Diagrams, Heat and Material Balances, and Utility Balances associated with a unit, system or package by the responsible Chief Process Engineer prior to release of the Engineering Flow Diagrams to Project Engineering for further development. This review is organized and conducted by the Chief Process Engineer or designee. A Chief’s Review conducted by a designee of the Chief Process Engineer requires the approval of the Director-Process Engineering. Documentation Required The revision “A” issue of the EFDs typically occurs approximately 2 weeks prior to the Chief’s Review in accordance with Engineering Practice EP 9-1. It is this set of EFD’s that will be reviewed during the Chief’s Review. Early issue of the revision “A” EFDs allows time for the other disciplines to review the EFDs and bring their comments to the Chief’s Review in an organized manner. In addition to the EFDs, the Process Masters for all equipment shall be available in the meeting room. By the time of the Chief’s Review, Process Specifications for all equipment shall have been issued. Only in extenuating circumstances is it permitted to release the initial issue of Process Specifications during or after the Chief’s Review. Process Calculation Books (Line Sizing, etc.) shall also be available in the meeting room, as requested by the Chief Process Engineer. Scheduling: The Chief Process Engineer or designee shall send out notification of an upcoming Chief’s Review to the engineers assigned to the positions listed below. It is expected that the non full-time invitees visit the Chief’s Review room during the first half-day of the review to assess their overall involvement and when and if they may be needed during the review. The Director – Process Engineering shall be informed of all upcoming Chief’s Reviews.


PEP No.: 1016 Page: 2 of 17 Revision: 0 Date: Feb. 11, 2009 ______________________________________________________________________ PEP -1016 (Cont’d) Attendees: The Chief Process Engineer shall notify the following assigned engineering positions to the Chief’s Review. Attendance for all disciplines other than Process shall be coordinated and set by the Project Manager, Project Engineering Manager, or designee. Process attendees: • • • •

Process Operations Engineer Lead Process Engineer Chief Process Engineer – Safety Process Engineers – on call

Other disciplines in attendance: • • • • • •

Project Manager - on call Project Engineering Manager - on call Project Engineer - full-time Instrument Engineer - full-time Mechanical Engineer - on call Other disciplines (piping, civil, electrical, drafting) – on call

Items to be Reviewed / Checklist: The attached Chief’s Review Checklist, Table 1016-1, shall be used by the Chief Process Engineer and attendees as a guide during the Chief’s Review to ensure that each and every item on the checklist has been fully addressed or deemed to be not applicable. The full name and initials of all participants shall be captured on the Chief’s Review Checklist. It is understood that each and every necessary review required for a specific project may not be listed on the Chief’s Review Checklist. It is, however, the responsibility of the Chief Process Engineer to ensure that all documents listed above under “Purpose” are fully addressed for completeness, continuity, and consistency and that the design of the unit is safe, environmentally sound, fully operable and will ultimately lead to a successful start-up and operation of the respective operating unit or system.


PEP No.: 1016 Page: 3 of 17 Revision: 0 Date: Feb. 11, 2009 ______________________________________________________________________ PEP -1016 (Cont’d) Chief’s Review Protocol: At the start of the Chief’s Review, the Process Master set of the EFD’s shall be put up on the wall for review. In addition to the Process Master Stamp the following information shall be included on the EFDs: • • •

Chief’s Review Stamp Start date of the Chief’s Review Attendees (Process and non-Process attendees (first few drawings only))

A copy of the Chief’s Review Checklist shall also be posted in the conference room where the Chief’s Review is being held. The initials of the Process Engineer assigned the responsibility to review a specific item on the checklist shall be entered on the checklist once the Chief Process Engineer has reviewed for completeness and accuracy. Items that are the responsibility of other departments shall be reviewed in accordance with their department practices and procedures. Engineers assigned to the Chief’s Review from other departments that have a responsibility to complete specific checklist items shall also put their initials next to the checklist items completed. To ensure consistency in design, the Process Flow Diagrams (PFD’s) for the unit must also be marked up simultaneously with the EFD’s. The color system to be applied to all mark-ups is as follows: • • • •

Yellow – Items covered Red – Items added Green – Items deleted Blue – Instruction to CAD or Design Group.

At the completion of the Chief’s Review, the marked-up set of Revision “A” EFDs will be sent to CAD Drafting. A log of drawings submitted to CAD shall be kept, indicating dates submitted and dates received back from CAD. Post Chief’s Review Actions: The Chief Process Engineer, or designee, shall back-check the EFDs as they come back from drafting to ensure the accuracy of the drafting. This is not the time to make additional “improvements” to the EFDs. Any errors noticed during the back-checking of the EFDs shall be brought to the attention of the Chief Process Engineer for resolution.


PEP No.: 1016 Page: 4 of 17 Revision: 0 Date: Feb. 11, 2009 ______________________________________________________________________ PEP -1016 (Cont’d) Changes made during back-checking shall be recorded on the Chief’s Review master copy in a separate color, and/or back-circled and dated to indicate that these specific changes were post-Chief’s Review comments. The Chief’s Review Checklist shall be scanned for electronic storage within the Process Files. The hard copy shall be filed along with the Chief’s Review copy of the EFDs in the Process Library. The Chief’s Review EFDs must not be discarded as they too shall be scanned for electronic storage. It is not required that intermediate CAD copies of the EFDs be saved. Once all EFDs have been accurately drafted, Process shall notify the Project Manager that the Revision “B” EFDs are ready for issue per the Document Distribution Matrix. The Revision “B” issue of the EFDs releases control of the EFDs to Project Engineering for further development. The Lead Process Engineer shall maintain a Process Master set of EFDs at all times, regardless of the EFD revision. Following the Chief’s Review, the Process group shall also update and issue any modified Process Specifications that changed as a result of the Chief’s Review.


PEP No.: 1016 Page: 5 of 17 Revision: 0 Date: Feb. 11, 2009 ______________________________________________________________________ Table 1016-1: CHIEF’S REVIEW CHECKLIST [Scan and file in Process file 13Description 1.0 1.1

Equipment Vessels - Dimensions - Design (P,T) details - Nozzle check - Internals - Vortex breaker - Vent - Drain - Exhauster - Steam out - Pumpout - Insulation / tracing - Elevation details - Overpressure Protection (PSV) verified - Frieze Data

1.2

Pumps - Rated capacity & head - Estimated shut-off pressure - Number of pumps / sparing philosophy - EIV / MOV - Provision of temporary suction strainer (TS) - Flushing oil connection and details - Suction pressure instruments - Discharge pressure instruments and check valve - Power - Insulation / Tracing - Warm up provisions - Coke Crushing Impeller noted (as required) - Vent - Drain - Steam Turbine Assembly (Lines, Control, PSV.) - Overpressure Protection (PSV) at discharge Positive Displacement Pumps - Frieze Data

, 7.50 when complete] Process

Operations

Comments


PEP No.: 1016 Page: 6 of 17 Revision: 0 Date: Feb. 11, 2009 ______________________________________________________________________ Description 1.3

Columns - Dimensions - Design (P,T) details - Identify whether trays and/or packing - Number of trays / beds - Tray numbering - Internals such as chimney tray, sheds, etc. - Partition baffle or hot well for reboiler liquid draw - Nozzle check - Internals - Vortex breaker - Vent - Drain - Exhauster - Steamout - Pumpout - Elevation - Details of liquid re-distribution trough - Vortex breaker at each liquid draw - Tower draw nozzle size vs. Tower Standard - Flushing oil connection details - Insulation / tracing - Overpressure Protection (PSV) verified - Frieze Data

1.4

Miscellaneous Equipment (Filters, Silencers) - Design (P,T) details - Nozzle check - Internals - Vent/ Drain/ Exhauster/ Steamout (by Detail Engineering) - Inlet & outlet size - Insulation/ tracing - Flushing oil connection - Overpressure Protection (PSV) verified - Frieze Data

1.5

Exchangers

Process

Operations

Comments


PEP No.: 1016 Page: 7 of 17 Revision: 0 Date: Feb. 11, 2009 ______________________________________________________________________ Description - Duty - Design (P,T) details - TEMA type - Arrangement (series/parallel) - Number of shells - Nozzle check - Vent connection - Drain connection - Flushing oil connections - Backflush connections - Chemical Cleaning connection - TI / TW instruments - Block Valves and By-Pass lines - Reboiler Elevations (Driving Force) - Overpressure Protection (PSV) verified - Frieze Data

1.6

Air coolers - Duty - Design (P,T) details - Number of bays, bundles, fans - Louver controls (manual or pneumatic) - Fan Controls / VFD - No of fixed speed fans and no of variable speed - Nozzle check - Header vents / drains - Steam coils (freeze or pour point control) - Flushing oil connections - TI/TW Instruments - Inlet/Outlet Distribution Headers ( Maldistribution) - Overpressure Protection (PSV) verified - Frieze Data

1.7

Reactors

Process

Operations

Comments


PEP No.: 1016 Page: 8 of 17 Revision: 0 Date: Feb. 11, 2009 ______________________________________________________________________ Description - Design (P,T) details - Catalyst loading & unloading details - Regeneration/ reactivation provisions - Reaction control and protection safeguards - Nozzle check - Internals - Vortex breaker - Vent/ Drain/ Exhauster/ Steamout per FW standard (based on volume) - Exhauster nozzle details - Insulation / tracing - Elevation details - TI/TW Instruments - Temperature runaway protection verified - Overpressure Protection (PSV) verified - Frieze Data

2.0

Packages

Process

Operations

Comments



Compressors - Capacity, Design (P,T) details - Discharge pressure & diff. head - Type of compressor (centrifugal, reciprocating etc) - No. of stages - Anti-surge control valve and surge protection for centrifugal compressor - Safety relief device on compressor discharge - Nozzle check - Driver details (turbine or motor) - Steam supply for turbine driven compressor - Control Loops (Throttling valves, Driver speed,..) - Loop seal heights - Overpressure Protection (PSV) - Reciprocating - Frieze Data

2.2

Vacuum Ejectors - No of ejectors - Steam supply detail - Nozzle check - Liquid sealing and hotwell elevation - Pressure balance and Off-gas send-out provision - Frieze Data

2.3

Heaters - Duty

Process

Operations

Comments


PEP No.: 1016 Page: 10 of 17 Revision: 0 Date: Feb. 11, 2009 ______________________________________________________________________ Description - Type of heater (Natural or Forced draft) - No. passes per section (radiation & convection) - Type of fuel firing (fuel gas or dual firing) - Provision of ID/ FD fans - Combustion air pre-conditioning - Design (P,T) details - Coil skin temperature monitoring - Firebox TI's - Nozzle check - Atomizing steam (When Firing Liquid Fuels) - Emergency steam supply provision to heater coils - Purge steam connections - Soot Blowers (When Firing Liquid Fuels) - Velocity Steam / Condensate Injection to Coils - Provisions for Steam-Air decoking, Pigging and /or On-line spalling. - Firing system control - Provisions for burning off-gas and waste streams - Stack provision - Flue gas monitoring (flow measurement, Temperature, SOX, NOX and CO analyzers etc.) - Pollution monitoring nozzles - Insulation - Draft Gauges - Overpressure Protection (PSV) verified - Frieze Data

3.0

Hydraulics/Line Sizing - Identification of gravity flow lines

Process

Operations

Comments


PEP No.: 1016 Page: 11 of 17 Revision: 0 Date: Feb. 11, 2009 ______________________________________________________________________ Description - Sloping requirements on overhead vapor lines, flare relief lines - Flare purge details - Flare header and sub-header sizes - Relief valve outlet size - Steam generation and supply header (LP, MP or HP) size - Condensate recovery and sendout - Cooling water supply and return header - Instrument air header - Plant air header - Nitrogen supply header and back-up - Fuel gas supply header and backup - Unit Blowdown collection and recovery scheme - Flushing oil supply & provisions - Startup oil (cold & hot) circulation - Overpressure Protection (PSV) for specific lines - Process conditions shown on lines - Other Provisions (Catalyst Regeneration, Pump-out, etc.)

4.0

Miscellaneous items

Process

Operations

Comments


PEP No.: 1016 Page: 12 of 17 Revision: 0 Date: Feb. 11, 2009 ______________________________________________________________________ Description

Process

Operations

- Passivation connection (in case of Austenitic stainless steels) - Insulation/ tracing for Piping - Control valve action, drain connections, - Unit Tie-in breaks - Future connection provisions - Sour water collection & sendout - Anti-corrosion injection - Corrosion coupons/probes - Anti-foam injection - Gas leak detection (Hydrogen, C3, C4, SO2 etc) - Steamout connection provision (hose or a hard pipe) - EIVs (with volumes and criteria per calc.) - Sample connections/Details as required - Line connectors between EFDs - Notes and Holds - Control loops on each system - Interlocks - B.L.Pressure and Temperatures (Process) - Verify make-up and purge streams are in place for recycle systems/loops.

5.0 Material balances

[Also note meter Tag numbers and PFD stream numbers]

Comments



5.1

Feed streams

5.2

Main Product streams

5.3

Intermittent Feed streams

5.4

By-product streams

5.5

Off-spec streams

Process

Operations

Comments



5.6

Flushing oil

5.7

Off-gas

5.8

Residue dump (tar, coke etc)

5.9

Sour water

5.10

Amine (Lean/Rich)

Process

Operations

Comments



Other

6.0

Utility Balances

6.1

Steam

6.2

Cooling water

6.3

Plant Air to process

6.4

Condensate

Process

Operations

Comments



Natural Gas

6.6

Fuel Gas

Process

Operations

Comments

Process

Operations


PEP No.: 1016 Page: 17 of 17 Revision: 0 Date: Feb. 11, 2009 ______________________________________________________________________ Table 1016-2: CHIEF’S REVIEW PARTICIPANTS [Scan and file in Process file 13Full Name

, 7.50 when complete]

Department / Position

Part / Full Time (PT / FT)

Initials

Process Engg Practices to be used in the refinery industry

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