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This document provides an overview of the mid and downstream business training module. It discusses the typical design cycle for a plant from feasibility study through to commissioning. It also describes the various stages of engineering including FEED, review, and stage 0. Examples are provided of key deliverables for stage 0 such as updated P&IDs, process datasheets, equipment lists, utility summaries, and more. The purpose is to familiarize trainees with the engineering design process and key documents/outputs for midstream and downstream oil and gas facilities.

Engineering
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Mid & Downstream Business Training Module HYDROCARBON PROCESSING – AN OVERVIEW LNG PRODUCED WATER GAS Upstream Mid and Downstream
Mid & Downstream Business Training Module Plant Design Cycle Detail Engg. Pre-Commissioning & Commissioning Feasibility Study Process Design / Basic Engg. FEED Stable Operation & Performance Testing Trouble Shooting & Revamp
Mid & Downstream Business Training Module Feasibility Study:  Conceptualization  Process Simulation  Development of Process Flow Scheme  Cost Estimation  Techno-Commercial Evaluation Basic Engineering:  Mass and Energy Balance  Process Control Scheme  PFDs and Basic Process P&IDs  Sizing and Basic Spec. for Equipments and Instruments
Mid & Downstream Business Training Module Front End Engineering Design (FEED):  BEP to Project Specific Package (Residual Engineering)  Verification of Process data for Critical items  Preparation of Specifications  Identification of Scope Splits  Identification of applicable Codes & Standards Commissioning:  Pre-Commissioning  Commissioning  Startup and Feed charging  Performance Guarantee test run
Mid & Downstream Business Training Module
Mid & Downstream Business Training Module WORK FLOW DIAGRAM PP CV EL ME EQ IN PE BDEP BDEP TQ TQ EQUIPMENT LIST EQUIPMENT LIST EQUIPMENT LIST EQUIPMENT LIST EQUIPMENT LIST EQ. LIST EQ. LIST UHD UHD UHD UHD UHD UHD UHD UTILITY SUMMARY UTILITY SUMMARY FLARE LOAD SUMMARY FLARE LOAD SUMMARY PROCESS D/S FOR EQUIPMENTS PROCESS D/S FOR EQUIPMENTS PROCESS D/S FOR EQUIPMENTS CHEMICAL SUMMARY CHEMICAL SUMMARY LINE LIST LINE LIST LINE LIST REVISED P&ID REVISED P&ID REVISED P&ID REVISED P&ID REVISED P&ID REVISED P&ID REVISED P&ID UPDATED D/S FOR EQUIPMENTS UPDATED D/S FOR EQUIPMENTS PROCESS D/S FOR MACHINERY ITEMS UPDATED D/S FOR INSTRUMENTS UPDATED D/S FOR INSTRUMENTS UPDATED D/S FOR INSTRUMENTS PRECOMMISIONING MANUAL PRECOMMISIONING MANUAL OPERATING MANUAL OPERATING MANUAL PROCESS D/S FOR EQUIPMENTS HAZARDOUS SOURCE LIST HAZARDOUS SOURCE LIST HAZARDOUS SOURCE LIST PLOT PLAN REVIEW & COMMENTS VENDOR DOCUMENTS REVIEW & COMMENTS FABRICATION DWG. REVIEW & COMMENTS PC EQUIPMENT LIST LINE LIST
Mid & Downstream Business Training Module REVIEW STAGE:  Review of Contract Documents  Preparation of TQs
Mid & Downstream Business Training Module STAGE 0:  P&IDs mark up based on General Specifications, Standards, Amendments etc.  Updation of Process Datasheets based on PFD and other documents  Preparation of UHDs  Sizing of Utility lines  Preparation of Equipment list  Preparation of Utility summary  Preparation of Catalyst and Chemical summary  Preparation of Tie-in summary  Preparation of Line-list  Preparation of Hazardous source list
Mid & Downstream Business Training Module  P&IDs mark up based on General Specifications, Standards, Amendments etc. Licensor P&ID Standard Details
Mid & Downstream Business Training Module Marked up P&ID As per the standards, the control valve assembly with block & bypass and Vent & Drain arrangement is shown in detail
Mid & Downstream Business Training Module  Updation of Process Datasheets based on PFD and other documents
Mid & Downstream Business Training Module Updated Process Datasheets
Mid & Downstream Business Training Module  Preparation of UHDs
Mid & Downstream Business Training Module  Sizing of Utility lines
Mid & Downstream Business Training Module  Preparation of Equipment List MUMBAI EQUIPMENT SERVICE NO. DIMENSIONS INTERNAL EQUIPMENT ERECTION DESIGN CONDITION INSULATION NO. REQD. (ID).X(TL-TL) TYPE THICKNESS WEIGHT PRESSURE TEMP. TYPE THICKNESS (m) (mm) (Tons) (kg/cm2 g) (°C) (mm) TOP BOTTOM TOP BOTTOM COLUMNS LNHT UNIT Top = 2.0 Bottom = 2.8 TL-TL = 27.9 Top = 3.2 Bottom = 4.0 TL-TL = 36.9 PENEX UNIT Top =1.7 Bottom = 3.2 TL-TL=26.2 TITLE : EQUIPMENT LIST OPERATING CONDITION MOC + C.A PRESSURE (kg/cm2 g) TEMP (°C) SHELL & HEAD TRAYS 125 IH 171 Int : 15.82 Ext : FV 91 - - DA-31701 STRIPPER KCS + 3 mm TP410 1 Trays, Distributor Internal baffles, Vortex Breaker, DA-31702 DEPENTANIZER KCS + 3 mm TP410 1 Trays, Distributor Internal baffles, Vortex Breaker, - - 70 119 STABILIZER DA-32810 DA-32811 LPG STRIPPER 57 179 1 1 KCS+3mm TP410 - - - TP410 CS+3mm Int : 4 Ext : FV Int : 13.5 Ext : FV Int : 13.5 Ext : FV 232 171 IH 80 120 60 210 179 147 119 120 - - Trays, Distributor Internal baffles, Vortex Breaker, Trays, Distributor Internal baffles, Vortex Breaker, - 45 60 ISOMERISATION PROJECT 0.75 x 21 IH Equipment list
Mid & Downstream Business Training Module Equipment List contains the information such as • Equipment Number • Service • Dimensions • Internals • Material of Construction • Operating and Design Conditions • Insulation Details • Other Special requirements  Preparation of Equipment List (Continued)
Mid & Downstream Business Training Module Sample view of Equipment list MUMBAI EQUIPMENT SERVICE NO. DIMENSIONS INTERNAL EQUIPMENT ERECTION DESIGN CONDITION INSULATION NO. REQD. (ID).X(TL-TL) TYPE THICKNESS WEIGHT PRESSURE TEMP. TYPE THICKNESS (m) (mm) (Tons) (kg/cm2 g) (°C) (mm) TOP BOTTOM TOP BOTTOM COLUMNS LNHT UNIT Top = 2.0 Bottom = 2.8 TL-TL = 27.9 Top = 3.2 Bottom = 4.0 TL-TL = 36.9 PENEX UNIT Top =1.7 Bottom = 3.2 TL-TL=26.2 TITLE : EQUIPMENT LIST OPERATING CONDITION MOC + C.A PRESSURE (kg/cm2 g) TEMP (°C) SHELL & HEAD TRAYS 125 IH 171 Int : 15.82 Ext : FV 91 - - DA-31701 STRIPPER KCS + 3 mm TP410 1 Trays, Distributor Internal baffles, Vortex Breaker, DA-31702 DEPENTANIZER KCS + 3 mm TP410 1 Trays, Distributor Internal baffles, Vortex Breaker, - - 70 119 STABILIZER DA-32810 DA-32811 LPG STRIPPER 57 179 1 1 KCS+3mm TP410 - - - TP410 CS+3mm Int : 4 Ext : FV Int : 13.5 Ext : FV Int : 13.5 Ext : FV 232 171 IH 80 120 60 210 179 147 119 120 - - Trays, Distributor Internal baffles, Vortex Breaker, Trays, Distributor Internal baffles, Vortex Breaker, - 45 60 ISOMERISATION PROJECT 0.75 x 21 IH
Mid & Downstream Business Training Module  Preparation of Utility summary  Utility Summary summarizes the consumption / generation of utilities in all equipments.  The utility data for consumption to be furnished with “- ve value”. Similarly the utility data for generation to be furnished with “+ve value”.  Following are the Utilities taken into account • Electricity • Steam • Condensate • Boiler Feed Water • Cooling Water • Service Water and Portable Water • Instrument Air, Plant Air and Nitrogen • Fuel Gas and Fuel Oil
Mid & Downstream Business Training Module Sample View of Utility summary
Mid & Downstream Business Training Module  Preparation of Chemical summary TITLE : CHEMICAL SUMMARY Rev.: 0 1 -- 3200 kg MRPL 2 20% Wt 6.5 m3 MRPL 3 100% 200 kg MRPL 4 100% 20 kg MRPL 5 99.9 % Min. 30 m3 MRPL 6 -- 2500 kg MRPL 7 20% Wt 25 m3 MRPL 8 -- 350 kg MRPL Sodium Nitrate (NaNO3) Make-up Caustic (NaOH) for Penex unit Anhydrous Ammonia L&T-CHIYODALIMITED BARODA, INDIA Document No.: A-317-4012 ISOMERISATION PROJECT Required as corrosion inhibitor for LNHT unit First fill quantity required Scope of supply Chemical Identification Required for scrubbing of gases from stabiliser & during catalyst regeneration of naphta hydrotreating reactor. As a sulfiding agent during stat-up % Purity Chemical Service Required during initial start up. Anhydrous Hydrochloric Acid (HCl) Sr. No. For preparing neutralizing solution during regeneration For preparing neutralizing solution during regeneration As a promotor for penex reactor catalyst Required to neutraiize reactor effluent gases Perchloroethylene (C2Cl4) DMDS Caustic for LNHT reactor neutralisation Soda Ash (Na2CO3) This document summarizes the consumption of Chemicals for the process.
Mid & Downstream Business Training Module  Preparation of Catalyst summary TITLE : CATALYST SUMMARY Bed (m3) Contingency 5% (m3) 2500 3200 9240 2900 9240 UOP -- -- Sock 3.62 2600 930 11.2 520 Sock 2480 6.62 Sock UOP 6.8 -- 7 FA-32801A Puraspec 2020 1200 Zinc oxide treater ADS-11 UOP "H-8" Catalyst FA-32802 1800 DC-32801 Reactor Saturation Reactor Sulfur guard bed 2400 3 2 1 Equip. Tag No. Sr.No. Catalyst Sock UOP "S-12" Catalyst 1065 DC-31701 UOP Service Equip ID (mm) Bed Height (mm) Bulk Density (Kg /m3 ) Type Type of Loading 4 DC-32810 Puraspec 2443 1100 Methanator Reactor Sock 7160 UOP 0.34 7.14 -- 5 DC-32811 UOP "I-8" Catalyst 2900 882 Dense 61 UOP 6 DC-32812 UOP "I-8" Catalyst 61 UOP 3720 Manufacturer 19.215 Quantity Total quantity (m3) 0.915 18.3 0.56 11.76 UOP 0.331 6.951 6464.4 Total quantity (kg) 20464.0 64.05 64.05 Penex Reactor Penex Reactor 3.05 3.05 882 Dense 0.181 3.801 6115.2 56492.1 56492.1 This document summarizes the consumption of Catalyst for the process.
Mid & Downstream Business Training Module  Preparation of Tie-in summary Battery Limit Tie-in Summary contains the following information for all ISBL & OSBL lines  Flow rate of all process and utility streams going to B/L.  Operating and Design Conditions  Line Specifications  Main Properties of the Streams (Optional)
Mid & Downstream Business Training Module Sample view of Tie-in summary Sr. Stream Name From To Phase Flowrates No. L/V/M Tons/hr kg/m3 (L) Visc. Normal MW (V) cP Pressure Temperature Pressure kg/cm2 g deg C kg/cm2 g min/nor/max min/nor/max (C) INCOMING UTILITY LINES: 1 MP Steam B/L HEADER V 36066.0 18.0 0.02 14/15/16 255/260/270 22 2 LP Steam B/L HEADER V 33180.0 18.0 0.02 3/3.5/4 160/175/200 10 3 HP Steam B/L HEADER V 2930.0 18.0 0.01 39/40/41 330/390/408 45 4 Instrument Air B/L HEADER V 625.0 29.0 0.02 4.5/6.5/ - - /40/ - 10.5 5 Cooling Water Supply B/L HEADER L 2378207.0 1000.0 0.60 - /4.5/ - - /33/ - 7 6 Fuel Gas B/L HEADER V 1212.0 15.5 0.01 - /4.5/5 - /40/ - 6 7 Fuel Oil B/L HEADER L 2273.0 854.0 11.50 - /13/20 - /170/ - 25 TITLE : BATTERY LIMIT TIE-IN SUMMARY MUMBAI Properties Operating Conditions Design Cond
Mid & Downstream Business Training Module  Preparation of Line-list  Line List contains the data related to process conditions and the data related to mechanical design and test conditions for all the lines.  Line List is the base document utilized for verification of major deliverables of Piping department.  Line List contains the information such as • Line Number • Line Size • Fluid Code and Piping class • From & To Location • State and Nature of the fluid • Operating (Normal&Alternative) and Design Conditions • Steam out requirements • Insulation Details • Test fluid and Test pressure
Mid & Downstream Business Training Module Sample View of Line-list TITLE : LINE LIST FOR LNHT UNIT IDENTIFICATION LOCATION STATE (A) (L/V/M) 1 10-P-3170001-A1A1 606 10 P 317 0001 A1A1 FA-31701 P-3170215 L HC 2 6-P-3170002-A4A1 606 6 P 317 0002 A4A1 GA-31701A P-3170046 L HC 3 10-P-3170003-A1A1 606 10 P 317 0003 A1A1 P-3170001 P-3170216 L HC 4 6-P-3170004-A4A1 606 6 P 317 0004 A4A1 GA-31701B P-3170002 L HC 5 0.75-P-3170005-A1A1 691 0.75 P 317 0005 A1A1 P-3170002 SN-31701 L HC 6 0.75-P-3170006-A1A 691 0.75 P 317 0006 A1A SN-31701 FLARE L HC 7 0.75-P-3170007-A4A1 691 0.75 P 317 0007 A4A1 SN-31701 P-3170001 L HC 8 6-P-3170008-A4A1 606 6 P 317 0008 A4A1 P-3170002 FV-002 L HC 9 6-P-3170009-A1A1 606 6 P 317 0009 A1A1 FV-002 FA-31701 L HC LINE NO. FROM TO NATURE OF FLUID INSULATION TYPE INSULATION THK. (MM) SR. NO. P & ID NO. SIZE (INCH) FLUID CODE UNIT NO. LINE NO. PIPING CLASS MUMBAI
Mid & Downstream Business Training Module  Preparation of Hazardous Source List  Hazardous Source List is the base document utilized for hazardous area classification drawing deliverable of Electrical department.  This document contains the information such as • Inlet and Outlet streams of all equipments • State and Nature of the fluid • Composition • Max. operating temperature • Properties like Density and Molecular weight • Flammability • Flash point • Auto-ignition temperature
Mid & Downstream Business Training Module Sample View of Hazardous Source List
Mid & Downstream Business Training Module STAGE 1:  Hydraulic Check of Process lines  Sizing of Vessels  Thermal rating of Heat exchangers  PSV Sizing & Flare hydraulics  Preparation of Flare Load Summary  Preparation of Equipment datasheets for new items  Scope demarcation for Vendor items  Updation of P&IDs based on Hydraulic results
Mid & Downstream Business Training Module STAGE 1 (Continued):  Updation of Pumps and Instruments datasheets based on Hydraulics  Updation of Equipment list  Development of Control and Safeguarding Narratives
Mid & Downstream Business Training Module  Hydraulic Check of Process lines Loop identification in PFD
Mid & Downstream Business Training Module  Hydraulic Check of Process lines Collecting Inputs required for hydraulic calculations
Mid & Downstream Business Training Module Sample View of Hydraulic Calculation Sheet
Mid & Downstream Business Training Module  Sizing of Vessels  Sizing of vessels is carried out based on Project Design Criteria (Droplet size, Residence time)  Sometimes, Sizing is governed by separation of fine entrained droplets using mesh pad, impact separators, etc.
Mid & Downstream Business Training Module Sample view of Vessel Sizing calculation sheet
Mid & Downstream Business Training Module  Thermal rating of Heat exchangers  Designing / Rating of heat exchangers is carried out with the help of HTRI computer program.  This activity enables the designer to model heat exchangers, allowing the designer to gauge the performance, geometry and inherent limitations of the shell and tube heat exchanger even before its fabrication.  This results in lower risks of damage to the equipment while in service.
Mid & Downstream Business Training Module Sample HTRI Specification Sheet Sample HTRI Tube Layout
Mid & Downstream Business Training Module  PSV Sizing and Flare Hydraulics  The safety of personnel and the protection of equipments due to overpressure are the basis for the design, sizing, and selection of pressure relieving systems.  All systems and pressure relief devices shall be designed based on the applicable codes (API 520, 521, etc.), industry standards and practices.  For Flare header Sizing, first we have to determine the appropriate relief contingencies yielding maximum loads  Flare header size has to be large enough to prevent excessive backpressure on the plant safety valves and to limit gas velocity and noise to acceptable levels.
Mid & Downstream Business Training Module Sample view of Flare Hydraulics calculation sheet
Mid & Downstream Business Training Module  Preparation of Flare Load Summary This document summarizes the relief load of all PSVs for the applicable relieving cases.
Mid & Downstream Business Training Module  Preparation of Equipment datasheets for new items
Mid & Downstream Business Training Module  Scope demarcation for Vendor items Vendor scope of supply has to be identified and to be clearly marked in the P&IDs.
Mid & Downstream Business Training Module  Updation of P&IDs based on Hydraulic results Licensor P&ID
Mid & Downstream Business Training Module Updated P&ID based on Hydraulics Compressor Suction line is increased to 6” from 4” as per hydraulic calculations
Mid & Downstream Business Training Module  Updation of Pumps and Instruments datasheets based on Hydraulics Licensor Datasheet
Mid & Downstream Business Training Module Updated Pumps datasheets based on Hydraulics
Mid & Downstream Business Training Module  Development of Control Narratives  This narrative describes the plant control systems by instrumentation.  The purpose of this document are as follows : (1) To explain control systems to those who may not be familiar with instrumentation symbols or functional logic diagrams. (2) To define purpose and algorithm of each control system.  Pump auto start systems will be also covered in this document.
Mid & Downstream Business Training Module  Development of Safeguarding Narratives The purpose of this narrative is to thoroughly explain the safeguarding scheme and its significance. Based on the same it is possible to understand how safeguarding scheme works and how it will be depicted in “Cause and Effect diagram” or “Safeguarding Matrix”.
Mid & Downstream Business Training Module Sample of Cause and Effect Diagram P-5105B HP STEAM VALVE P-5105A HP BFW PUMP P-51203 HP BFW PUMP P-51402A MP BFW PUMP P-51206A HP BFW PUMP P-51206B HP BFW PUMP P-51206C HP BFW PUMP P-51206D HP BFW PUMP COMMON TRIP ALARM CAUSE CLOSE TRIP TRIP TRIP TRIP TRIP TRIP TRIP ALARM ACTION TAG NO. DESCRIPTION PEFS NO. 51UZA-2103 51UZA-2102 51UZA-2104 51UZA-2100 51UZA-2105 51UZA-2106 51UZA-2107 51UZA-2108 51UZA-2100 TAG NO. 51LZA-2008 D-0098-51-25-0006 X X X X X 51LZA-2008 51LZA-2011 D-1651-51-50-0018 X X X X X 51LZA-2011 51LZA-2008 D-0098-51-25-0006 X X X X X X X X X 51LZA-2008 51LZA-2011 D-1651-51-50-0018 51LZA-2011 51LZA-2008 D-0098-51-25-0006 51LZA-2008 51LZA-2011 D-1651-51-50-0018 X X X X X X X X X 51LZA-2011 V-51203 LEVEL LOW LOW V-51210 LEVEL LOW LOW V-51203 LEVEL LOW LOW V-51210 LEVEL LOW LOW <51HS-2012 is 'V-51203' position> EFFECT 51UZA-2100 V-51203 / V-51201 SGS DESCRIPTION <51HS-2012 is 'BOTH' position> SAFE GUARDING MATRIX UNIT 51 <51HS-2012 is 'V-51210' position> V-51210 LEVEL LOW LOW V-51203 LEVEL LOW LOW Cause Section Effect Section
Mid & Downstream Business Training Module STAGE 2:  Interface Activities  Updation of Control & Safeguarding narratives and issue for HAZOP Study  Updation of Utility summary  Updation of Line list
Mid & Downstream Business Training Module  Interface Activities  Vendor Document Review  Review of Engineering Drawings  Review of Plot Plan  3D-Model Review  Review of DCS Graphics
Mid & Downstream Business Training Module  Vendor Document Review Some of the Critical points to be reviewed in Engineering Drawings are:  Consistency of Process data as per process datasheets such as Operating & Design Conditions, MOC, Special service requirements, etc.  Review of other technical aspects (a) Meeting all Specifications as per requirement. (b) Expected Utility consumption figures. (c) Guarantee figures, if any. (d) Other technical requirements specified in the requisition. (e) Fulfilment of Scope of Supply.
Mid & Downstream Business Training Module  Review of Engineering Drawings Some of the Critical points to be reviewed in Engineering Drawings are:  Consistency of Process data as per process datasheets such as Operating & Design Conditions, MOC, Special service requirements, etc.  Number of Nozzles  Sizes of Nozzles  Checking location and orientation of all nozzles especially nozzles for Temperature, Pressure and Level Instruments as per Project requirements
Mid & Downstream Business Training Module  Review of Plot Plan Some of the Critical points to be reviewed in Plot plan are:  Consistency of equipments shown in plot plan with Equipment List, PFD and P&IDs.  Are the distances between equipment kept minimum with respect to pressure drop?  Are the height of Towers and vessels enough to provide NPSH of pumps?  Are the equipment located symmetrically such as column and reboilers?  Is there enough space around columns, towers and reactors for removal of internals?  Is there enough space to remove tube bundle of heat exchangers?  Are the equipments arranged considering safety aspects especially for Fired heaters, Compressors and Tanks?
Mid & Downstream Business Training Module  3D-Model Review Some of the Critical points to be considered in 3D-model review are:  Is piping arranged to provide straight run requirement such as inlet of tower?  Are CV sets placed as per Project requirements such as closeness to equipment, at high or low level, etc., if any?  Are symmetrical piping considered for AFC’s?  Are the valves located at operable location from the nearest platform or grade?  Is piping arranged to keep special bending radius requirements, if any?
Mid & Downstream Business Training Module  Review of DCS Graphics Review of Control logics as per Control & Safeguarding narratives
Mid & Downstream Business Training Module STAGE 2 (Continued):  Updation of Control & Safeguarding narratives and issue for HAZOP Study  Updation of Utility summary  Updation of Line list
Mid & Downstream Business Training Module STAGE 3:  Safety Studies / Analysis  Updation of P&IDs based on Safety Studies recommendation  Preparation of Precommisioning manual  Preparation of Operating manual
Mid & Downstream Business Training Module  Safety Studies / Analysis  HAZOP Study  SIL Study  FIREPRAN Study
Mid & Downstream Business Training Module HAZard and OPerability study is a technique to examine a system, part by part, in a very systematic manner, to find out the cause and consequence of every conceivable deviation in the normal operation of the system as well as during emergencies, start-ups and shutdowns. The method enables prediction of all possible ways in which a hazard or an operating problem could arise, whether the design takes preventive care of them and if not, recommends changes (Action) as may be necessary. HAZOP Study
Mid & Downstream Business Training Module SIL  Measurement of confidence level for performance of safety function is called the Safety Integrity Level(SIL)  Safety integrity of a system can be defined as “ The probability (likelihood) of a safety-related system performing the required safety function under all the stated conditions within a stated period of time”  SIL is a measure of the reliability of the safety function performing to specification.  The SIL is based on the accepted risk level and ranges from 1 to 4 Probability of Failure Safety Integrity Level (SIL) Mode of Operation – On demand (average probability of failure to perform its design function upon demand) Mode of Operation – continuous (probability of dangerous failure per hour) 4 > 10-5 to < 10-4 > 10-9 to < 10-8 3 > 10-4 to < 10-3 > 10-8 to < 10-7 2 > 10-3 to < 10-2 > 10-7 to < 10-6 1 > 10-2 to < 10-1 > 10-6 to < 10-7
Mid & Downstream Business Training Module FIREPRAN study FIRE PRotection & ANalysis is a new technique employed at the design phase of a facility or installation to achieve the following objectives  Overview the role of the facility and its significance to the overall operation.  Review the facility’s Fire and Explosion Strategy (FES) in the context of the role of the facility and its significance to the overall company.  Analyze threats to loss of containment or other potential sources of combustion events.  Assess release event consequences and explosion scenarios  Review and assess adequacy of threat control measures, mitigation and recovery measures.  Make recommendation for risk reduction measures to achieve levels as low as reasonably practicable (ALARP).
Mid & Downstream Business Training Module Example for Firepran Study Column middle cut pool fire and isopleths is analyzed as shown below in case of possible explosion due to oil leakage above its Auto Ignition Temperature. Heat Flux kW/m2 Effects on Human Effects on Property 4 Sufficient to cause pin to personnel if unable to reach cover within 20 seconds. No damage 12.5 This level of radiation will cause a 30% chance of fatality for a prolonged exposure. Minimum energy required for piloted ignition of wood, melting of plastic tubing 37.5 Sufficient to cause damage to process equipment. Exposure to this level of radiation is assumed to give rise to a 100% chance of fatality Failure of steel structures within 30 minutes
Mid & Downstream Business Training Module Critical Area identification Area in red needs to be given extensive consideration for fire protection systems
Mid & Downstream Business Training Module  Updation of P&IDs based on Safety Studies recommendation  Preparation of Precommisioning manual  Preparation of Operating manual STAGE 3 (Continued):
Mid & Downstream Business Training Module

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320725879-Process-Engineering-Chiyoda.ppt

  • 1. Mid & Downstream Business Training Module HYDROCARBON PROCESSING – AN OVERVIEW LNG PRODUCED WATER GAS Upstream Mid and Downstream
  • 2. Mid & Downstream Business Training Module Plant Design Cycle Detail Engg. Pre-Commissioning & Commissioning Feasibility Study Process Design / Basic Engg. FEED Stable Operation & Performance Testing Trouble Shooting & Revamp
  • 3. Mid & Downstream Business Training Module Feasibility Study:  Conceptualization  Process Simulation  Development of Process Flow Scheme  Cost Estimation  Techno-Commercial Evaluation Basic Engineering:  Mass and Energy Balance  Process Control Scheme  PFDs and Basic Process P&IDs  Sizing and Basic Spec. for Equipments and Instruments
  • 4. Mid & Downstream Business Training Module Front End Engineering Design (FEED):  BEP to Project Specific Package (Residual Engineering)  Verification of Process data for Critical items  Preparation of Specifications  Identification of Scope Splits  Identification of applicable Codes & Standards Commissioning:  Pre-Commissioning  Commissioning  Startup and Feed charging  Performance Guarantee test run
  • 5. Mid & Downstream Business Training Module
  • 6. Mid & Downstream Business Training Module WORK FLOW DIAGRAM PP CV EL ME EQ IN PE BDEP BDEP TQ TQ EQUIPMENT LIST EQUIPMENT LIST EQUIPMENT LIST EQUIPMENT LIST EQUIPMENT LIST EQ. LIST EQ. LIST UHD UHD UHD UHD UHD UHD UHD UTILITY SUMMARY UTILITY SUMMARY FLARE LOAD SUMMARY FLARE LOAD SUMMARY PROCESS D/S FOR EQUIPMENTS PROCESS D/S FOR EQUIPMENTS PROCESS D/S FOR EQUIPMENTS CHEMICAL SUMMARY CHEMICAL SUMMARY LINE LIST LINE LIST LINE LIST REVISED P&ID REVISED P&ID REVISED P&ID REVISED P&ID REVISED P&ID REVISED P&ID REVISED P&ID UPDATED D/S FOR EQUIPMENTS UPDATED D/S FOR EQUIPMENTS PROCESS D/S FOR MACHINERY ITEMS UPDATED D/S FOR INSTRUMENTS UPDATED D/S FOR INSTRUMENTS UPDATED D/S FOR INSTRUMENTS PRECOMMISIONING MANUAL PRECOMMISIONING MANUAL OPERATING MANUAL OPERATING MANUAL PROCESS D/S FOR EQUIPMENTS HAZARDOUS SOURCE LIST HAZARDOUS SOURCE LIST HAZARDOUS SOURCE LIST PLOT PLAN REVIEW & COMMENTS VENDOR DOCUMENTS REVIEW & COMMENTS FABRICATION DWG. REVIEW & COMMENTS PC EQUIPMENT LIST LINE LIST
  • 7. Mid & Downstream Business Training Module REVIEW STAGE:  Review of Contract Documents  Preparation of TQs
  • 8. Mid & Downstream Business Training Module STAGE 0:  P&IDs mark up based on General Specifications, Standards, Amendments etc.  Updation of Process Datasheets based on PFD and other documents  Preparation of UHDs  Sizing of Utility lines  Preparation of Equipment list  Preparation of Utility summary  Preparation of Catalyst and Chemical summary  Preparation of Tie-in summary  Preparation of Line-list  Preparation of Hazardous source list
  • 9. Mid & Downstream Business Training Module  P&IDs mark up based on General Specifications, Standards, Amendments etc. Licensor P&ID Standard Details
  • 10. Mid & Downstream Business Training Module Marked up P&ID As per the standards, the control valve assembly with block & bypass and Vent & Drain arrangement is shown in detail
  • 11. Mid & Downstream Business Training Module  Updation of Process Datasheets based on PFD and other documents
  • 12. Mid & Downstream Business Training Module Updated Process Datasheets
  • 13. Mid & Downstream Business Training Module  Preparation of UHDs
  • 14. Mid & Downstream Business Training Module  Sizing of Utility lines
  • 15. Mid & Downstream Business Training Module  Preparation of Equipment List MUMBAI EQUIPMENT SERVICE NO. DIMENSIONS INTERNAL EQUIPMENT ERECTION DESIGN CONDITION INSULATION NO. REQD. (ID).X(TL-TL) TYPE THICKNESS WEIGHT PRESSURE TEMP. TYPE THICKNESS (m) (mm) (Tons) (kg/cm2 g) (°C) (mm) TOP BOTTOM TOP BOTTOM COLUMNS LNHT UNIT Top = 2.0 Bottom = 2.8 TL-TL = 27.9 Top = 3.2 Bottom = 4.0 TL-TL = 36.9 PENEX UNIT Top =1.7 Bottom = 3.2 TL-TL=26.2 TITLE : EQUIPMENT LIST OPERATING CONDITION MOC + C.A PRESSURE (kg/cm2 g) TEMP (°C) SHELL & HEAD TRAYS 125 IH 171 Int : 15.82 Ext : FV 91 - - DA-31701 STRIPPER KCS + 3 mm TP410 1 Trays, Distributor Internal baffles, Vortex Breaker, DA-31702 DEPENTANIZER KCS + 3 mm TP410 1 Trays, Distributor Internal baffles, Vortex Breaker, - - 70 119 STABILIZER DA-32810 DA-32811 LPG STRIPPER 57 179 1 1 KCS+3mm TP410 - - - TP410 CS+3mm Int : 4 Ext : FV Int : 13.5 Ext : FV Int : 13.5 Ext : FV 232 171 IH 80 120 60 210 179 147 119 120 - - Trays, Distributor Internal baffles, Vortex Breaker, Trays, Distributor Internal baffles, Vortex Breaker, - 45 60 ISOMERISATION PROJECT 0.75 x 21 IH Equipment list
  • 16. Mid & Downstream Business Training Module Equipment List contains the information such as • Equipment Number • Service • Dimensions • Internals • Material of Construction • Operating and Design Conditions • Insulation Details • Other Special requirements  Preparation of Equipment List (Continued)
  • 17. Mid & Downstream Business Training Module Sample view of Equipment list MUMBAI EQUIPMENT SERVICE NO. DIMENSIONS INTERNAL EQUIPMENT ERECTION DESIGN CONDITION INSULATION NO. REQD. (ID).X(TL-TL) TYPE THICKNESS WEIGHT PRESSURE TEMP. TYPE THICKNESS (m) (mm) (Tons) (kg/cm2 g) (°C) (mm) TOP BOTTOM TOP BOTTOM COLUMNS LNHT UNIT Top = 2.0 Bottom = 2.8 TL-TL = 27.9 Top = 3.2 Bottom = 4.0 TL-TL = 36.9 PENEX UNIT Top =1.7 Bottom = 3.2 TL-TL=26.2 TITLE : EQUIPMENT LIST OPERATING CONDITION MOC + C.A PRESSURE (kg/cm2 g) TEMP (°C) SHELL & HEAD TRAYS 125 IH 171 Int : 15.82 Ext : FV 91 - - DA-31701 STRIPPER KCS + 3 mm TP410 1 Trays, Distributor Internal baffles, Vortex Breaker, DA-31702 DEPENTANIZER KCS + 3 mm TP410 1 Trays, Distributor Internal baffles, Vortex Breaker, - - 70 119 STABILIZER DA-32810 DA-32811 LPG STRIPPER 57 179 1 1 KCS+3mm TP410 - - - TP410 CS+3mm Int : 4 Ext : FV Int : 13.5 Ext : FV Int : 13.5 Ext : FV 232 171 IH 80 120 60 210 179 147 119 120 - - Trays, Distributor Internal baffles, Vortex Breaker, Trays, Distributor Internal baffles, Vortex Breaker, - 45 60 ISOMERISATION PROJECT 0.75 x 21 IH
  • 18. Mid & Downstream Business Training Module  Preparation of Utility summary  Utility Summary summarizes the consumption / generation of utilities in all equipments.  The utility data for consumption to be furnished with “- ve value”. Similarly the utility data for generation to be furnished with “+ve value”.  Following are the Utilities taken into account • Electricity • Steam • Condensate • Boiler Feed Water • Cooling Water • Service Water and Portable Water • Instrument Air, Plant Air and Nitrogen • Fuel Gas and Fuel Oil
  • 19. Mid & Downstream Business Training Module Sample View of Utility summary
  • 20. Mid & Downstream Business Training Module  Preparation of Chemical summary TITLE : CHEMICAL SUMMARY Rev.: 0 1 -- 3200 kg MRPL 2 20% Wt 6.5 m3 MRPL 3 100% 200 kg MRPL 4 100% 20 kg MRPL 5 99.9 % Min. 30 m3 MRPL 6 -- 2500 kg MRPL 7 20% Wt 25 m3 MRPL 8 -- 350 kg MRPL Sodium Nitrate (NaNO3) Make-up Caustic (NaOH) for Penex unit Anhydrous Ammonia L&T-CHIYODALIMITED BARODA, INDIA Document No.: A-317-4012 ISOMERISATION PROJECT Required as corrosion inhibitor for LNHT unit First fill quantity required Scope of supply Chemical Identification Required for scrubbing of gases from stabiliser & during catalyst regeneration of naphta hydrotreating reactor. As a sulfiding agent during stat-up % Purity Chemical Service Required during initial start up. Anhydrous Hydrochloric Acid (HCl) Sr. No. For preparing neutralizing solution during regeneration For preparing neutralizing solution during regeneration As a promotor for penex reactor catalyst Required to neutraiize reactor effluent gases Perchloroethylene (C2Cl4) DMDS Caustic for LNHT reactor neutralisation Soda Ash (Na2CO3) This document summarizes the consumption of Chemicals for the process.
  • 21. Mid & Downstream Business Training Module  Preparation of Catalyst summary TITLE : CATALYST SUMMARY Bed (m3) Contingency 5% (m3) 2500 3200 9240 2900 9240 UOP -- -- Sock 3.62 2600 930 11.2 520 Sock 2480 6.62 Sock UOP 6.8 -- 7 FA-32801A Puraspec 2020 1200 Zinc oxide treater ADS-11 UOP "H-8" Catalyst FA-32802 1800 DC-32801 Reactor Saturation Reactor Sulfur guard bed 2400 3 2 1 Equip. Tag No. Sr.No. Catalyst Sock UOP "S-12" Catalyst 1065 DC-31701 UOP Service Equip ID (mm) Bed Height (mm) Bulk Density (Kg /m3 ) Type Type of Loading 4 DC-32810 Puraspec 2443 1100 Methanator Reactor Sock 7160 UOP 0.34 7.14 -- 5 DC-32811 UOP "I-8" Catalyst 2900 882 Dense 61 UOP 6 DC-32812 UOP "I-8" Catalyst 61 UOP 3720 Manufacturer 19.215 Quantity Total quantity (m3) 0.915 18.3 0.56 11.76 UOP 0.331 6.951 6464.4 Total quantity (kg) 20464.0 64.05 64.05 Penex Reactor Penex Reactor 3.05 3.05 882 Dense 0.181 3.801 6115.2 56492.1 56492.1 This document summarizes the consumption of Catalyst for the process.
  • 22. Mid & Downstream Business Training Module  Preparation of Tie-in summary Battery Limit Tie-in Summary contains the following information for all ISBL & OSBL lines  Flow rate of all process and utility streams going to B/L.  Operating and Design Conditions  Line Specifications  Main Properties of the Streams (Optional)
  • 23. Mid & Downstream Business Training Module Sample view of Tie-in summary Sr. Stream Name From To Phase Flowrates No. L/V/M Tons/hr kg/m3 (L) Visc. Normal MW (V) cP Pressure Temperature Pressure kg/cm2 g deg C kg/cm2 g min/nor/max min/nor/max (C) INCOMING UTILITY LINES: 1 MP Steam B/L HEADER V 36066.0 18.0 0.02 14/15/16 255/260/270 22 2 LP Steam B/L HEADER V 33180.0 18.0 0.02 3/3.5/4 160/175/200 10 3 HP Steam B/L HEADER V 2930.0 18.0 0.01 39/40/41 330/390/408 45 4 Instrument Air B/L HEADER V 625.0 29.0 0.02 4.5/6.5/ - - /40/ - 10.5 5 Cooling Water Supply B/L HEADER L 2378207.0 1000.0 0.60 - /4.5/ - - /33/ - 7 6 Fuel Gas B/L HEADER V 1212.0 15.5 0.01 - /4.5/5 - /40/ - 6 7 Fuel Oil B/L HEADER L 2273.0 854.0 11.50 - /13/20 - /170/ - 25 TITLE : BATTERY LIMIT TIE-IN SUMMARY MUMBAI Properties Operating Conditions Design Cond
  • 24. Mid & Downstream Business Training Module  Preparation of Line-list  Line List contains the data related to process conditions and the data related to mechanical design and test conditions for all the lines.  Line List is the base document utilized for verification of major deliverables of Piping department.  Line List contains the information such as • Line Number • Line Size • Fluid Code and Piping class • From & To Location • State and Nature of the fluid • Operating (Normal&Alternative) and Design Conditions • Steam out requirements • Insulation Details • Test fluid and Test pressure
  • 25. Mid & Downstream Business Training Module Sample View of Line-list TITLE : LINE LIST FOR LNHT UNIT IDENTIFICATION LOCATION STATE (A) (L/V/M) 1 10-P-3170001-A1A1 606 10 P 317 0001 A1A1 FA-31701 P-3170215 L HC 2 6-P-3170002-A4A1 606 6 P 317 0002 A4A1 GA-31701A P-3170046 L HC 3 10-P-3170003-A1A1 606 10 P 317 0003 A1A1 P-3170001 P-3170216 L HC 4 6-P-3170004-A4A1 606 6 P 317 0004 A4A1 GA-31701B P-3170002 L HC 5 0.75-P-3170005-A1A1 691 0.75 P 317 0005 A1A1 P-3170002 SN-31701 L HC 6 0.75-P-3170006-A1A 691 0.75 P 317 0006 A1A SN-31701 FLARE L HC 7 0.75-P-3170007-A4A1 691 0.75 P 317 0007 A4A1 SN-31701 P-3170001 L HC 8 6-P-3170008-A4A1 606 6 P 317 0008 A4A1 P-3170002 FV-002 L HC 9 6-P-3170009-A1A1 606 6 P 317 0009 A1A1 FV-002 FA-31701 L HC LINE NO. FROM TO NATURE OF FLUID INSULATION TYPE INSULATION THK. (MM) SR. NO. P & ID NO. SIZE (INCH) FLUID CODE UNIT NO. LINE NO. PIPING CLASS MUMBAI
  • 26. Mid & Downstream Business Training Module  Preparation of Hazardous Source List  Hazardous Source List is the base document utilized for hazardous area classification drawing deliverable of Electrical department.  This document contains the information such as • Inlet and Outlet streams of all equipments • State and Nature of the fluid • Composition • Max. operating temperature • Properties like Density and Molecular weight • Flammability • Flash point • Auto-ignition temperature
  • 27. Mid & Downstream Business Training Module Sample View of Hazardous Source List
  • 28. Mid & Downstream Business Training Module STAGE 1:  Hydraulic Check of Process lines  Sizing of Vessels  Thermal rating of Heat exchangers  PSV Sizing & Flare hydraulics  Preparation of Flare Load Summary  Preparation of Equipment datasheets for new items  Scope demarcation for Vendor items  Updation of P&IDs based on Hydraulic results
  • 29. Mid & Downstream Business Training Module STAGE 1 (Continued):  Updation of Pumps and Instruments datasheets based on Hydraulics  Updation of Equipment list  Development of Control and Safeguarding Narratives
  • 30. Mid & Downstream Business Training Module  Hydraulic Check of Process lines Loop identification in PFD
  • 31. Mid & Downstream Business Training Module  Hydraulic Check of Process lines Collecting Inputs required for hydraulic calculations
  • 32. Mid & Downstream Business Training Module Sample View of Hydraulic Calculation Sheet
  • 33. Mid & Downstream Business Training Module  Sizing of Vessels  Sizing of vessels is carried out based on Project Design Criteria (Droplet size, Residence time)  Sometimes, Sizing is governed by separation of fine entrained droplets using mesh pad, impact separators, etc.
  • 34. Mid & Downstream Business Training Module Sample view of Vessel Sizing calculation sheet
  • 35. Mid & Downstream Business Training Module  Thermal rating of Heat exchangers  Designing / Rating of heat exchangers is carried out with the help of HTRI computer program.  This activity enables the designer to model heat exchangers, allowing the designer to gauge the performance, geometry and inherent limitations of the shell and tube heat exchanger even before its fabrication.  This results in lower risks of damage to the equipment while in service.
  • 36. Mid & Downstream Business Training Module Sample HTRI Specification Sheet Sample HTRI Tube Layout
  • 37. Mid & Downstream Business Training Module  PSV Sizing and Flare Hydraulics  The safety of personnel and the protection of equipments due to overpressure are the basis for the design, sizing, and selection of pressure relieving systems.  All systems and pressure relief devices shall be designed based on the applicable codes (API 520, 521, etc.), industry standards and practices.  For Flare header Sizing, first we have to determine the appropriate relief contingencies yielding maximum loads  Flare header size has to be large enough to prevent excessive backpressure on the plant safety valves and to limit gas velocity and noise to acceptable levels.
  • 38. Mid & Downstream Business Training Module Sample view of Flare Hydraulics calculation sheet
  • 39. Mid & Downstream Business Training Module  Preparation of Flare Load Summary This document summarizes the relief load of all PSVs for the applicable relieving cases.
  • 40. Mid & Downstream Business Training Module  Preparation of Equipment datasheets for new items
  • 41. Mid & Downstream Business Training Module  Scope demarcation for Vendor items Vendor scope of supply has to be identified and to be clearly marked in the P&IDs.
  • 42. Mid & Downstream Business Training Module  Updation of P&IDs based on Hydraulic results Licensor P&ID
  • 43. Mid & Downstream Business Training Module Updated P&ID based on Hydraulics Compressor Suction line is increased to 6” from 4” as per hydraulic calculations
  • 44. Mid & Downstream Business Training Module  Updation of Pumps and Instruments datasheets based on Hydraulics Licensor Datasheet
  • 45. Mid & Downstream Business Training Module Updated Pumps datasheets based on Hydraulics
  • 46. Mid & Downstream Business Training Module  Development of Control Narratives  This narrative describes the plant control systems by instrumentation.  The purpose of this document are as follows : (1) To explain control systems to those who may not be familiar with instrumentation symbols or functional logic diagrams. (2) To define purpose and algorithm of each control system.  Pump auto start systems will be also covered in this document.
  • 47. Mid & Downstream Business Training Module  Development of Safeguarding Narratives The purpose of this narrative is to thoroughly explain the safeguarding scheme and its significance. Based on the same it is possible to understand how safeguarding scheme works and how it will be depicted in “Cause and Effect diagram” or “Safeguarding Matrix”.
  • 48. Mid & Downstream Business Training Module Sample of Cause and Effect Diagram P-5105B HP STEAM VALVE P-5105A HP BFW PUMP P-51203 HP BFW PUMP P-51402A MP BFW PUMP P-51206A HP BFW PUMP P-51206B HP BFW PUMP P-51206C HP BFW PUMP P-51206D HP BFW PUMP COMMON TRIP ALARM CAUSE CLOSE TRIP TRIP TRIP TRIP TRIP TRIP TRIP ALARM ACTION TAG NO. DESCRIPTION PEFS NO. 51UZA-2103 51UZA-2102 51UZA-2104 51UZA-2100 51UZA-2105 51UZA-2106 51UZA-2107 51UZA-2108 51UZA-2100 TAG NO. 51LZA-2008 D-0098-51-25-0006 X X X X X 51LZA-2008 51LZA-2011 D-1651-51-50-0018 X X X X X 51LZA-2011 51LZA-2008 D-0098-51-25-0006 X X X X X X X X X 51LZA-2008 51LZA-2011 D-1651-51-50-0018 51LZA-2011 51LZA-2008 D-0098-51-25-0006 51LZA-2008 51LZA-2011 D-1651-51-50-0018 X X X X X X X X X 51LZA-2011 V-51203 LEVEL LOW LOW V-51210 LEVEL LOW LOW V-51203 LEVEL LOW LOW V-51210 LEVEL LOW LOW <51HS-2012 is 'V-51203' position> EFFECT 51UZA-2100 V-51203 / V-51201 SGS DESCRIPTION <51HS-2012 is 'BOTH' position> SAFE GUARDING MATRIX UNIT 51 <51HS-2012 is 'V-51210' position> V-51210 LEVEL LOW LOW V-51203 LEVEL LOW LOW Cause Section Effect Section
  • 49. Mid & Downstream Business Training Module STAGE 2:  Interface Activities  Updation of Control & Safeguarding narratives and issue for HAZOP Study  Updation of Utility summary  Updation of Line list
  • 50. Mid & Downstream Business Training Module  Interface Activities  Vendor Document Review  Review of Engineering Drawings  Review of Plot Plan  3D-Model Review  Review of DCS Graphics
  • 51. Mid & Downstream Business Training Module  Vendor Document Review Some of the Critical points to be reviewed in Engineering Drawings are:  Consistency of Process data as per process datasheets such as Operating & Design Conditions, MOC, Special service requirements, etc.  Review of other technical aspects (a) Meeting all Specifications as per requirement. (b) Expected Utility consumption figures. (c) Guarantee figures, if any. (d) Other technical requirements specified in the requisition. (e) Fulfilment of Scope of Supply.
  • 52. Mid & Downstream Business Training Module  Review of Engineering Drawings Some of the Critical points to be reviewed in Engineering Drawings are:  Consistency of Process data as per process datasheets such as Operating & Design Conditions, MOC, Special service requirements, etc.  Number of Nozzles  Sizes of Nozzles  Checking location and orientation of all nozzles especially nozzles for Temperature, Pressure and Level Instruments as per Project requirements
  • 53. Mid & Downstream Business Training Module  Review of Plot Plan Some of the Critical points to be reviewed in Plot plan are:  Consistency of equipments shown in plot plan with Equipment List, PFD and P&IDs.  Are the distances between equipment kept minimum with respect to pressure drop?  Are the height of Towers and vessels enough to provide NPSH of pumps?  Are the equipment located symmetrically such as column and reboilers?  Is there enough space around columns, towers and reactors for removal of internals?  Is there enough space to remove tube bundle of heat exchangers?  Are the equipments arranged considering safety aspects especially for Fired heaters, Compressors and Tanks?
  • 54. Mid & Downstream Business Training Module  3D-Model Review Some of the Critical points to be considered in 3D-model review are:  Is piping arranged to provide straight run requirement such as inlet of tower?  Are CV sets placed as per Project requirements such as closeness to equipment, at high or low level, etc., if any?  Are symmetrical piping considered for AFC’s?  Are the valves located at operable location from the nearest platform or grade?  Is piping arranged to keep special bending radius requirements, if any?
  • 55. Mid & Downstream Business Training Module  Review of DCS Graphics Review of Control logics as per Control & Safeguarding narratives
  • 56. Mid & Downstream Business Training Module STAGE 2 (Continued):  Updation of Control & Safeguarding narratives and issue for HAZOP Study  Updation of Utility summary  Updation of Line list
  • 57. Mid & Downstream Business Training Module STAGE 3:  Safety Studies / Analysis  Updation of P&IDs based on Safety Studies recommendation  Preparation of Precommisioning manual  Preparation of Operating manual
  • 58. Mid & Downstream Business Training Module  Safety Studies / Analysis  HAZOP Study  SIL Study  FIREPRAN Study
  • 59. Mid & Downstream Business Training Module HAZard and OPerability study is a technique to examine a system, part by part, in a very systematic manner, to find out the cause and consequence of every conceivable deviation in the normal operation of the system as well as during emergencies, start-ups and shutdowns. The method enables prediction of all possible ways in which a hazard or an operating problem could arise, whether the design takes preventive care of them and if not, recommends changes (Action) as may be necessary. HAZOP Study
  • 60. Mid & Downstream Business Training Module SIL  Measurement of confidence level for performance of safety function is called the Safety Integrity Level(SIL)  Safety integrity of a system can be defined as “ The probability (likelihood) of a safety-related system performing the required safety function under all the stated conditions within a stated period of time”  SIL is a measure of the reliability of the safety function performing to specification.  The SIL is based on the accepted risk level and ranges from 1 to 4 Probability of Failure Safety Integrity Level (SIL) Mode of Operation – On demand (average probability of failure to perform its design function upon demand) Mode of Operation – continuous (probability of dangerous failure per hour) 4 > 10-5 to < 10-4 > 10-9 to < 10-8 3 > 10-4 to < 10-3 > 10-8 to < 10-7 2 > 10-3 to < 10-2 > 10-7 to < 10-6 1 > 10-2 to < 10-1 > 10-6 to < 10-7
  • 61. Mid & Downstream Business Training Module FIREPRAN study FIRE PRotection & ANalysis is a new technique employed at the design phase of a facility or installation to achieve the following objectives  Overview the role of the facility and its significance to the overall operation.  Review the facility’s Fire and Explosion Strategy (FES) in the context of the role of the facility and its significance to the overall company.  Analyze threats to loss of containment or other potential sources of combustion events.  Assess release event consequences and explosion scenarios  Review and assess adequacy of threat control measures, mitigation and recovery measures.  Make recommendation for risk reduction measures to achieve levels as low as reasonably practicable (ALARP).
  • 62. Mid & Downstream Business Training Module Example for Firepran Study Column middle cut pool fire and isopleths is analyzed as shown below in case of possible explosion due to oil leakage above its Auto Ignition Temperature. Heat Flux kW/m2 Effects on Human Effects on Property 4 Sufficient to cause pin to personnel if unable to reach cover within 20 seconds. No damage 12.5 This level of radiation will cause a 30% chance of fatality for a prolonged exposure. Minimum energy required for piloted ignition of wood, melting of plastic tubing 37.5 Sufficient to cause damage to process equipment. Exposure to this level of radiation is assumed to give rise to a 100% chance of fatality Failure of steel structures within 30 minutes
  • 63. Mid & Downstream Business Training Module Critical Area identification Area in red needs to be given extensive consideration for fire protection systems
  • 64. Mid & Downstream Business Training Module  Updation of P&IDs based on Safety Studies recommendation  Preparation of Precommisioning manual  Preparation of Operating manual STAGE 3 (Continued):
  • 65. Mid & Downstream Business Training Module