THE OIL & GAS ENGINEERING GUIDE 3.21 RRR ee é Herv Editions TECHNIPTHE Om & Gas ENGINEERING GUIDE Hervé Baron t Editions TECHNIP 25 rve Ginous, 75015 PARIS, FRANCEDisclaimer: “The author has taken due care to provide complete and accurate information in this work. However, nether the Fditor nor the author guarantees the accuracy or completeness ‘of any information published herein, Neither the Editor nor the author shall be held responsible for any errors, omissions, or damages arising out of use ofthis information, {© 2010, Editions Technip, Paris, All rights reserved, No part of this publication may be reproduced or twansmitted in any form or by aay means, electronic or mechanical, including photocopy, recording, or any information storage and retrieval system, without the prior written permission of the publisher. BN 978-2-7108-0945-6 Preface 2 ‘When the author, an alumni of IFP School, contacted me in 2008 to express his desire to share his experience with students, I readily accepted. Such isthe practice of IFP School: toiavolve working professionals among its faculty, tobridge the gap between the academic and professional worlds. This transfer of living knowledge is the foundation of our curriculum. What [did not expect, though, was that he would fake this opportunity to write a book! What started as a one-day lecture gave rise to a book summarizing 15 years of professional experience In doing so, know thatthe author took a great deal of pleasure. Not only inthe sense that he was producing something useful but also in the consolidation of the various aspects of his experience as well Writing this book was an opportunity for him to stand back from details and derive principles. This resulted ina clear synthesis offering an overall view to the newcomer. | wish this work great success T also wish the author to geow in his teaching ski capturing the audience as he does by covering the subject mattersimply asa recollection of fest hand experiences Jean-Lue Karnik, Dean, IFP SchoolAcknowledgments > The author wishes to address a special thank to + Jean-Luc Karnik, Dean of IFP school, forthe opportunity he offered him to give lectures there, which i how this work originated + Michel Angot, for his review and significant contribution to this work. The author also wishes to thank his many colleagues who helped him put this work together: Luis Marques, Ywonne Parle, Joseph Hubschwerlin, Francoise Penver-L’het, Marie ‘Omon,Biruno Lequime, Frank Sentier, Benoit Le Bart, Claude Baron, Paul Martinez, Didier Salome, Julien Gamelin, Philippe Sainte-Foi, Mirza Sakic, Sonia Ben-Jemia, P. Balasamy Venkatesan, Nedimn Tiric, Jacques Félix, Christophe Antoine, Taha Jemaa, Patrice Bois, ‘Tony Rizk Al Gharib, Xavier Carcaud, Roland Bark, Patrick Valchéra, Philippe Defrenne, Gérard Brunet, Gauthier Hott, Pierre Benard, Erik DuBoullay, Gilles Lumé, Charles Michel, Alain Nicolas, Thierry Lavelle, Séverin Chapuis, Cyndi Cecillon, Christophe Le Cloarec, Yon Jestin, Christophe Pagé, Alain Guillemin, Bruno Le Guhennec, David Gravier, Sebastien Rimbert, Sergio Sarti, Etienne Karmuta, Christophe Alcoutfe, Denis C. Amon, Alexandee Cuénin, Serjun V, Palencia, Bernard Caussanel and Philippe Zuelgaray ‘The engineering documents shown herein come from real projects executed by Saipem land Technip. The author svishes to thank these two companies for their authorization to Publish these documents, Finally the author wishes to thank Groupe H, Labbe (www labbe-france.t), for their authorization to reproduce pictures of equipment manufactured in their premises Reader's feed back: [Not being a specialist fall subject matters described in ths work, the author submitted its various sections to the review of senior engineers in each discipline. This will not have removed all erors oF avoided omissions. The author will be grateful to the reader that ‘will point them out, comment on the book or make any suggestion for improvement, CConrespondence tothe author shal be addressed tr [email protected]. Table of Contents Preface. um Acknowledgments. Usual Engineering Abbreviations Introduction 1 1. Project Engineering, 5 2. Getting started .. B 3. Process 1B 4. Equipment/Mechanical 31 5. Plant layout. 41 6. Health, Safety & Environment (HSE) 51 7. Civil engineering. a 8. Material & Corrosion 93 Piping. 99 10, Plant model. — . 123 11, Instrumentation and Control. 131 12, Electrical 158 13, Field Engineering .w.nmnmnmnnmennne - 173 14, The challenges: matching the construction schedule. 7 15, The challenges: controlling information. 187 Index: Common Engineering Documents. 197 Appendix: Typical engineering schedule 201Usual Engineering Abbreviations > 3D 3 Dimensions ) cwr Civil Works Installation drawing EPC Engineering, Procurement and Construction ESD Emergency Shut Down . Ex Explosion protection Introduction FEED Front End Engineering Design Fire and Gas HAZOP —HAZard and OPerability study j > HVAC Heating, Ventilation and Air Conditioning HSE Health, Safety and Environment TFA Issue For Approval ! FC Issue For Construction The execution of a turn-key Project for an industrial facility consists of three 1D Issue For Design ‘main activities: Engineering, Procurement and Construction, which are followed im ahaa by Commissioning and Start-Up, 180 piping Isometric drawing | = MTO Material Take-Off S PED Process Flow Diagram (Hawes ] Comarion P&ID Piping & Instrumentation Diagram ’ Pcs Process Control System QRA Quantitative Risk Analysis, Engineering designs the facilities, produces the lst, specifications and data sheets, a = Tie construction site specifications prepared by Engineering,2 iroduction Finally, Construction installs all equipment and materials purchased by Progurementas per the erection drawings produced By Engineermg—————— Engineering design is the first, and most critical part, of the execution of a Project. Its indeed engineering that writes the music that will then be played by all project functions: Procurement procures equipmer c Engineering, Construction erects as shown on engineering drawings. Engineering is the task of translating a set of functional requirements into a full set of drawings and specifications depicting every detail of a facility. Engineering involves a variety of specialities, which include Process, Safety, Civil, Electrical, Instrumentation & Control to name a few, and a large number of tasks, from high level conceptual ones to the production of very detailed fabrication and installation drawings Cost pressures in the past decade have resulted in the transfer a number of tasks from high cost countries to low cost centres. This does not make it easy for today’s engineers entering an Engineering and Construction Contractor to get an overall view of Engineering activities. Tntroduction 3 This work's purpose is to meet this need. It describes in a synthetic yet exhaustive way all activities carried out during the Engineering of Oil & Gas facilities, such as refineries, oil platforms, chemical plants, ete The work stays on the level of principles rather than going into detailed practices. In this sense, what is described here is not the practice of a particular Engineering Company but is, to a very large extent, common to all and can be found on any Project. All illustrative documents (drawings, diagrams, text documents) are actual Engineering deliverables which were used on executed Projects.L 403dey9 Project Engineering > Engineering of a facility is done in two different steps, a conceptual one, the Basic Engineering, and an execution one, the Detailed Engineering. These twostepsare almost always done by different contractors. The Basic Engineering is usually done under an engineering services contract while detailed design is normally part of the facility's Engineering, Procurement and Construction (EPC), also called turn-key, contract. ‘Thescope of Basic Engineering, also called Front End Engineering Design (FEED), is to define the facility at conceptual rather than a detailed level. It entails defining the process scheme, the main equipment, the overall plot plan, the architecture of systems, etc. Basic Engineering stops with the issue of the main documents defining the plant, mainly the Piping and Instrumentation Diagrams, the overall layout of the plant (plot plant), the specification of the main equipment, the Electrical distribution diagram and the Process Control system architecture crawing, ‘The basic engineering documents serve as the technical part of the call for tender for turn-key execution of the project, Detailed Engineering takes place during the actual project execution phase. It consists of producing all documents necessary to purchase and erect all plant ‘equipment. Ittherefore entails producing the specification and bill of all quantities for all equipment and materials. Italso entails producing all detailed installation drawings.6 Project Engineering Detailed Engineering integrates vendor information (actual equipment data after design by vendor), as purchasing of equipment actually takes place in this pphase, whereas Basic Engineering takes place ahead of equipment purchasing. “The depth of details required in installation related Engineering activities, such as Civil, Steel Structure, Piping, Electrical and Instrumentation, ete. will depend on the split of responsibility that has been agreed with the construction contractor. Itis very common, for instance, that pipes with a diameter below 2” are excluded from the Engineer's scope. Their routing, the material take-off and the procurement of the associated material are under the responsibility ofthe construction contractor. ‘The Engineering Execution Plan contains a split of responsibility matrix who defines who does what between the Engineer and the Construction Contractor. {CHC cena 7 x = = fea 7 Additionally, Engineering tasks can be distributed between Engineering centres in different parts of the world, Engineering is split into various disciplines, the main ones being shown on the chatt here, ‘& Conta [==] [e=] [me] Project Engineering ' ‘The disciplines are coordinated by the project engineering manager who, like an architect for a building project, ensures consistency between the trades. Engineering activities are of a various nature, Some disciplines, such as Process, are not much concerned by the geographical layout of the plant: They only produce diagrams (representation of a concept) and do not produce drawings (scaled geographical representation of the physical plant). Other disciplines are very much concernend with these physical drawings, as shown on the matrix below. Process | Equipment [Civil [Piping |nstrumenation | Electrical sae contol Diagrams x x [Georapical x | x % i rains architecture x rains Calclaions x x m) x x qipment or x x material specification, datasheet & requisition Site works | x | Xx es x specification ‘Thousands of documents and drawings are issued by Engineering on a typical Project These documents can nevertheless be grouped in categories. For instance, although Piping isstes as many large scale drawings as required to cover the whole plant area, all are of the same type: “Piping General Arrangement Drawing” All commonly issued engineering documents are listed in the Index at the end of this work. An example of each one is included in the corresponding discipline section,‘There are many inter-dependencies between these documents. For instance, piping routing drawings are issued after the process diagram is defined, etc. ‘These inter-cependencies will be described in the schedule section. ‘The typical schedule of issue of engineering documents is shown in Appendix A given document will usually be issued several times, at different stages. ‘Typically, a document is first issued for internal review (IFR) of the other disciplines, then to the client for approval (IFA), then for design (IFD) and ultimately, for construction (IFC). ‘Most ofthe documents will also undergo revisions to incorporate the necessary changes or additional details as the design progresses, A document numbering system is put in place. Document numbers include, besides a serial number, discipline and document type codes. This allows quick identification of the issuing discipline and nature of document. An Engineering Document Register is maintained to show at any time the list and current revision of all documents. Drawings are mainly of 3 types, as follows: + diagrams, such as Piping & Instrumentation Diagrams, which show a concept, ‘© drawings, such as Piping General Arrangements Drawings, which show a scaled geographical representation of the plant. The representation may be plan (top), an elevation (front, side, back) or a cross section view. + key plans, which shows the division of the plant territory in multiple drawings of a particular type, covering all plant areas at high enough a scale. oft Diagram: mt tallation drawings niin downer + lesa = i Se ama cae) i & [2 | 4st02 | Troan wooing dinars 2 = een ; 7 [a [str reine ors | o + fee eae ! [= [se | ncn pero . — Wet [st [ee xn = — 1 [= [eo [Porat z ee | w+ | sr 2 +o ; i= ea [rosie E es : ‘34s the common size for diagrams and A. for drawings (in order to cover the i [es [recs saan — [= eae ! maximum surface area inthe later case). AO is not often used as it doesnot easly [= [sae [a perma] + [a ; unfold at the job Site it [|i eae fe a i Overall drawings, such a8 the overall plot plan are issued with a seale of pr 008 [Ea sews aon pra mat e 1/300 or 1/100, depending on size of plant, while detailed i [= ee Reasen eee F issued by Piping and Civil for each plant are issued with a 1/50 scale.133 [em AO = 840x188 AL = 594x840 201 A2 = 420x594 = a= || a3 = 9 210x|| 297% Wy >» 297° || 420 E RU iit Engineering is the integrator of vendor supplied equipment. Such integeation is highly dependant on information from the vendors (size of equipment, power consumption, etc:- One of the challenges faced by Engineering is the management of such an integration, which requires timely input of vendor information not to delay design development. ‘The plant owner is involved in the Engineering process as they need to review and approve the design and check the compliance to their requirements. ‘The main information flows are depicted in the diagram that follows. u" Gis =] lex ‘inde Tama Cora — Saoaeetaee a —. | i on toc a — | J+ [eam ea Dict ‘iat Sern = Vendors Managing the flow of information at the interfaces (between disciplines and with vendors) is highly critical, as will be explained in the conclusion to this workZ4a3deyo Getting started od Deep of a vr comm ly rvs oS pes comet reguemens, of Ke fancton. In shot, wt te pes be ped veeucton YAMA Gur bop enel silat of cre ol sequied capac th fed ck an productspeistons andthe perormance | (availabilty, thermal efficiency, etc.) typical duty for an oil platform would be: } “The facilities will be designed to handle production rates of 200 kbp. (annual average) of oil production and a peak of 15 Msm3/d of ga production, ‘The full wellstream production from the subsea wells will be separate | into oil, water, and gas phases in a three-stage flash separation process with inter-stage cooling designed to produce a stabilized crude product of i (0.9 bara true vapor pressure, Water will be removed in the flash separation / | stabilization process in order to reach of 0.5 vol-% BS&W oil specification. ‘The produced gas will be compressed, dehydrated and be injected into the reservoir to maintain pressure as well as conserve the gas.” j o On top of thRUREEORAGURERENEED me a number ofGHGALSSECIRCALONSINNNID | === SS j4 instance, design and ‘mechanical requirements will be specified for pumps, so as to limit wear and need for maintenance, to ensure uninterrupted operation over a specified service Sameer a It includes both project specific functional requirements, which include the ‘scope of work and the design basis, and general requirements, such as Client's design standards and specifications. In order for all engineering disciplines to work with a concise document summarizing the main design bases, the Engineering Manager issues the Adieu eta Siting € 4a3dey9 Process > How to process the inlet fluid(s) to produce the required product(s), ie,, the Process, will be defined by performing Process simulations. These simulations ‘use thermodynamic models to simulate fluid behaviours under the different [process operations: phase separation, compression, heat exchange, expansion, etc,The software also calculates the duty of the equipment, For instance, the software will calculate the required capacity of the compressor to bring. gas of such composition from a given inlet pressure to a given discharge pressure. Such calculation is difficult to make manually as petroleum fluids contain a large variety of components. The software incorporates thermodynamic models, which include the properties of all these components, and calculates the differen i] enthalpy between the compressed and non-compressed gas, hence the requil compressor capaci Various schemes are simulated to find the optimum process scheme. This timisation is done to match a few constraints, eg, the ratio of outlet to inlet Running process simulations will allow to try several scenarios and optimize the process, ie., reduce the number of equipment, energy consumption, ete. In the case of crude oll stabilisation for instance, pressure levels will be optimized, in order to reduce the number of separators while keeping pressures at values that allow easy gas re-compression (for injection back into the reservoir) = _vecengenen 166 The Process SHUPMENUNEND he register ofall Process equipment. I ie from the PFDs. quent it ‘ce Seeme _ ‘Optimization "Fpaa |_ot Peston ‘Once the optimum scheme is found, Process displays it on 1ST SSIETSOD GRBEAENEED) that show the process equipment, e4,, separator, heat exchanger, compressor, etc, and their sequence.18 Process, Process simulations are run for all operating cases, such as initial year of ‘operation, plateau level, operating case at field end of life when water to pilatio has increased significantly, etc. ‘The results are tabulated in the heat and material balance, whi flow, composition and condition of each stream, shows the Hea & Materia balance cies beste i ictivahl beet | e e200 i Process then performs the sizing of equipment as per the required process duty, eg, size of gas compressor according to required gas flow and gas geavity, size af cooling water pump as per process fluid cooling requirements and calorific value, etc. and Site conditions, e.g., temperature of available cooling medium (air/sea water) A106 =e 2S OR ‘The process duty ofeach equipment is specified in Process daty sheet p re2 ear] The SEDIANONON ORO EUNEENRG, by indicating the serie amv pms) ipsa G0) aan epee Scheme. Ths is further descrbed by Process in te ii Te unis ent of th san stl be cared at, mannyc satay, by sing ‘ieTeaors ftw uns sntling erect ee lou pu sco ue patra nei) ‘issue am mene oa 2 gett ore) ‘As the process diagram is further detailed, PFDs are translated into Piping and Instrumentation Diagrams (P&IDs). P&IDs show in details the equipment, piping, valves (manual/motorized), instrumentation, process control and emergency shutdown devices. P&IDs do not only include all lines, instruments, valves required during normal operation, but also the ones required for maintenance, plant start-up and all operating cases, They will include, for instance, equipment isolation valves, depressurization and drainage lines. They will also include a secyele line required for operation of the plant at low throughput, etc. ‘The Legend and Symbols P&ID shows the meaning of the graphical elements and symbols used on the P&IDs.2 Gann ‘The P&IDs are developed by Process as per the various Operating, Safety and ‘Maintenance requirements: ‘+ Equipment isolation philosophy: valves and bypass to be provided, + Requirements for start-up and shutdown, ie, additional bypass/ pressurization, drain lines, ete., ‘+ Process controls, which are directly shown on P&IDs by means of dotted. as = s i Mle = Hl vm i el ~ cause sf ‘ + egeee ee i pe oh Process safety automations: sensors initiate process shutdown in case of upset of process parameters. Their detailed logic of operation is shown on the Emergency Shutdown (ESD) Cause & Effect Diagrams.4 "Emergency Shutdown cause eet diagram EFFECT CAUSE — “tess —[ tor Be i Faiet Sa ipment ako called Mechanica, disiline nes various splits, such as passe sess en eangers fis equipment aig equpmee Flags22 xxchangers are designed and sized by Engineering, as they are of a slandard non-proprietary design (shell and tube, ef ttwace used to model the heat transfer for the specified geometry (numberof PoRItIOn oF bales, etc). The input and results of the calculation are recorded on eee ‘Process Data ‘Hot Shelisige ‘Cold Tubeside Gace oe | fhe a, rs oe - cee a ‘ wee ee | ee =. yperature, InOut (Degc) 128.30 98.60 24.40 998 ee cenit ere ea oes |e ice eee ei | ee | oa | ae | sateen ee eae | eeee ea | cee Ree tes eee | ae | es, | as ence . = puts — ce ; es ia Perec c aS = eee ene eg an ce sie nsttcetce pee oe == mance aay ee Eornatamares oe se cee Pressure vessels, on the otherhand.are specified in details ta the manufactuner: nozdles, whieh Core from process requirements. For_a_gas/oil/waisr — Separator for instance, the section of the vessel will be sized to teduce the gas ‘Yolume will be defined s0 as to provide enough residence time to achieve ‘The design and sizing of other equipment, such as compressors, ete. is adequate oil/ water separation, e.g, 3 minutes for light ofl and 8 minutes tor— yoprietary and done by their vendors. haeaei For a distillation column, the distance between trays will be defined by the vomning. Eachanger Fad Wolumes eprviate sels () serzs| oormate Neesise) 125212] ‘The Process data is completed by the Equipment specialist, which produces the Mechanical data sheet. The Mechanical Data Sheet specifies additional requirements besides the process diity, such as codes and standards to be applied, performance, energy efficiency, type and materials of construction, ete, process licensor, which will in turn set the elevation of the column, nozzles, ef The detailed arrangement of the vessel is specified to the manufacturer by means of a vessel guide drawing.M Equipment/ Mechanical 7 - ese ge ding smn | ‘This guide drawing is also issued to Piping for routing of connected pipes. ‘The orientations of nozzles are not defined on the guide drawing, Instead, they are defined by Piping following the piping routing studies 4 supply specification propoeddesrbing then scope and Limits of suppiy-ani fications. The piping specification, for instance, should be referenced if the supply includes piping, the electrical specification should —be— included if —the supply includes — electrical equipment, ete Many pieces of equipment are indeed not purchased on their own, such as a Pressure vessel or a heat exchanger, but as a package. A package is a sot-of ‘equipment, purchased as a functional unit, e.g., a water treatment unit. It comes complete with all equipment, piping, instrumentation, cables, etc, already installed on one or several “skids” (frames). This approach, which consists of purchasing a part of the plant already pre-fabricated, reduces construction time at Site, as assembly is carried out at the vendor's premises instead, Equipment/ Mechanical 38 ‘The scope of supply of the package vendor in all disciplines must be precisely defined. For a package made of several parts, for instance, the party who is supplying the interconnections (pipes, cables) between the parts must be ‘pacified. A detailed matrix, suchas the one shown below for Instrumentation, is the most efficient way to precisely define the split of responsibilities and battery limits ro eas The specification and the data sheet are attached to a document called a Material Requisition, q for Purchasing the equipment. The requisition precisely defines the equipment/ ‘material fo be supplied and the exact scope of supply and services, eg, what requirements, the documentation to be supplied by the vendor and its delivery schedule, The documents tequized from vendors ate of different types: + Study documents, such as P&IDs, calculation notes, general arrangement drawings, ec + Interface documents, showing all connections at the supply’s battery limits ‘nall disciplines: anchor bolts and loads on foundation, piping connections, electrical and-nstrumentation connections, etc. The interface documents and their timely submission are of primary importance to Engineering, for integration ofthe equipment/package into the overall plant, Provision ofthese documents must be synchronised with the engineering schedule. Penalties are specified for late submission of critical documents by the vendor. 1. Documents required at the construction site: preservation procedure, list of components (packing list), lifting instructions, commissioning and start-up instructions.a (mene) ‘+ Documents to be retained by the plant owner: manufacturing records, operating and maintenance manual, lst, references and drawings of spare parts, ‘Seon pecation ‘Material Requstion| Upon receipt of the inquiry tae vendors will perform their cwn design. Fora compressor, for instance, this will entail defining the number and design of the impellers to match all operating cases with maximum efficiency. The vendor will submit such Ferformance data in their proposal. (rion ‘Once the bids are received from vendors, technical appraisal is carried out to both confirm compliance to requirements and to compare the offers from the various vendors, ‘The detailed technical analyses of the bids are shown in the Technical Bid ‘Tabulation document. It covers scope of supply and services, compliance to performance guarantees, design and fabrication codes and standards, inspection and quality requirements, supplier’s references in similar supplies, etc. For each item, the specified requirements are shown together with what is offered by each Sipe?38 Equipment/Mechanical Following this detailed technical analysis, including clarification meetings held with suppliers, the technical acceptability of each bid is advised by Engineering to Procurement. ‘Once the equipment is purchased, and before proceeding with fabrication, the vendor submits its design documents to Engineering for review and approval, Vendor documents are checked by Engineering for compliance with the purchase onder specifications, Comments from the various disciplines are consolidated, The document is returned to the vendor with a code, result of the review, instructing the vendor either to proceed or to revise its design and resubmit it for further review. [/__COAMENT STATIS TRE AESROWA OF TS OGRE ES NOT FELEVE THE SIPRUEROF — See || SE [ oni SS en Vendordocuments provide information on the equipment, suchas dimensions, weight, electrical and other utilities consumption, etc. which Engineering incorporates in the overall plant design. A register is maintained of all equipment: the Equipment Summary, Such register is used, for an on-shore project, by the contractor at Site to know how ‘many equipment will have to be installed for its planning purposes and what is the capacity of the cranes required to lift these equipment in order to mobilize the proper cranes, (Onan Off-Shore project, the equipment summary helps to prepare the weight report A lifting study is also produced, based on the weight derived from the Material Take-Off in each discipline, to estimate the weight and the centre of ‘gravity, It serves to validate or not the lifting feasibility by the selected crane. In the case where the load exceeds the hook capacity, a weight management is, required, to modify the arrangement of the module or to decide to remove a part of the module and reduce the weight for the lifting phase.‘Welakt por Daal tor maae% Center of Gravty g 40}dey9 Plant layout 2 (Once the plant equipment is defined, upon completion of the Process Flow Diagrams (PFDs), Plant layout (also called installation) discipline performs installation studies, which consists of defining the topographical organisation of the facility An industrial facility is usually split into 3 zones: Process, Utilities and Offsite. ‘+ The process units are where the feedstock is processed into products, + Utilities units deal with electrical power generation, production and handling of utility fluids such as steam, heating/cooling medium, water, compressed air, nitrogen, etc. and treatment of the waste fluids, such as sain and oily water, drains, waste gas, etc., ‘+ Offsites consist of product storage, shipping facilities and of buildings. An Off-Shore facility will also include living quarters (LQ) and a helicopter landing pad, located as far as possible from the process units. ‘The site where the plant is to be built will impact its layout. A restricted land plot size will drive a vertical stacking rather than an horizontal spread of the plant equipment, a sloped relief will decide a terraced arrangement to minimize the earthworks, uneven soil geotechnical properties will impose constraints for location of heavy or critical installations (large storage tanks, turbo-machinery, etc.)2 Plant layout ‘The plant layout takes into account the plant envionment: location of access/ exit roads, external connecting networks: pipelines, electrical grid, water supply, etc. It is depicted on the General Plot Plan, which is the base graphical cocument used to locate all items of equipment, structures, buildings, roads and oundaries for the overall plant complex. ‘The location of the various units, and that of equipment within units, is etermined following a number of principles, primarily related to safety Hazardous units, such as gas compression units, are located far units, such as power generation, and manned areas, such as liv ay from vital laters, Plant layoutUnits are classified in terms of risk of releasing flammable materials (leak) or igniting them (explosion, fire). The risk level mainly derives from operating conditions: the higher the pressure and the temperature, the higher the risk. Risk are classified in High (HH), Intermediate (IH) and Moderate Hazard (Me. ama iA HA] Minimum distances between units MH} 15 a0 BO] a¥e specified by codes, as per the iH 30 GO] combination of risks. This will HH 60] ensure, forinstance, that flammable vapour released by oneunit diffuses toa concentration below the explosive limit when it reaches another unit where a source of ignition exists Additionally, units at tisk of releasing flammable substances are located away and downwind of equipment that could be source of ignition, Electrical sub-stations for instance, will be located upwind of gas coolers, Should a leak occur in the gas coolers, the gas cloud will not reach the electrical sub-station which houses spark generating equipment that could ignite the gas cloud, 45 Within units, the positions ofequipment naturally follow their sequence in the process flow to minimize the length |} eam, of inter-connections. Free space is provided around equipment for proper operator access and for maintenance {removal of ppatts, truck crane access). Special attention is given to free space/access for personnel evacuation and fire fighting. Enough space is provided between and around equipment. Acot and leaance for ie Going veils ‘An optimum spacing is found with respect to cost. The size of the plant footprint has indeed a direct impact on the quantities to be purchased and installed: length of pipes, pipe-racks, electrical and instrumentation cables, sewage, fire fighting, roads, paved areas, ete.46 Plant layout Equipment elevations may be dictated by process reasons. Apump, for instance, shall be placed at a lower elevation than the vessel from which it is fed, to ensure proper supply to the pump without cavitation, Another example is that of vessel thatis used to collect drains by gravity, It must be located at a ower elevation than the vessel(s) it . drains from. Equipment dimensions will not be available initially. It will become available fonce the equipment supplier has finalized its design and purchased its sub- equipment. Not only the size of the main equipment should be considered while elaborating the Plot Plan, such as a turbo-compressor unit, but also their auxiliaries, e.g, fuel gas unit, lube oil skid, ete Plant layout 47 Experience is required to account for all equipment, and estimate their size with accuracy before actual information is available from vendors, in order to be able to freeze the plot plan at an early stage. Such freeze of the plot plan is essential as itis a pre-requisite for the start of Site activities48 B Space for routing of all networks (all process and utility pipes, Electrical and Control cables, fire fighting, sewage, pits...) must be duly considered in the Plot Plan. This isthe reason why delining a correct layout requires a lt of experience. One indeed needs to have a vision of the entire plant, including all pipes, networks, accesses, etc, before they appear on the drawing boards, thanks to one’s experience on previous facilities. All such items will indeed come later on as the design develops and will occupy space that must have been reserved. armen aces i] id snl abe pli Eisele dl ‘ndesroun pipe] sre eb dit] ‘The position of equipment is shown on the Unit Plot Plan, coordinates or distance to axis of reference datum point, e.g, inl ‘equipment. ‘Unit Po Pla ewe SAP 1300 x (m_m_ 3m smd Sn 49 by means of let nozzle on. : Is|3 hah ee le Hae Perea9 493dey9 Health, Safety & Environment (HSE) > Health, Safety and Environment (HSE), also called Loss Prevention Engineering or simply "Safety", works at preventing or minimizing the consequences of accidents linked to the operation of the plant. It is also in charge of ensuing that it complies with legal requirements in terms of release to the environment (gaseous emissions, waste water, noise, solid wastes, etc) ‘The first field in which safety is involved is that of the plant process itself. It leads an audit, called a HAZOP Review (HAZard and OPerability Review), which is a systematic review of all possible process upsets, verifying that the design incorporates adequate safeguards to allow the process to come back to normal or to safely shut down, HAZOP reviews are usually carried by Safety with the help of a third party, to avoid conflicts between safety requirements, Contractor and Client's interests. The reviewing team includes Process, Operations, Instrumentation & Control specialists, as many aspects are to be jointly considered, A systematic method is used for the review: at each point of the process (in each line, in each equipment) the causes anel consequences of possible process (pressure/ temperature /flow) upsets are identified and evaluated.82 ‘The likelihood of an undesirable event happening is evaluated, taking into account the safeguards already included in the design, such assafety automations, alarm, operating instructions, ‘The consequence that would result from the undesirable event is determined and its severity is ranked using criteria such as the ones shown in the table below. ‘The risk is then finally evaluated as a combination of the likelihood to happen {frequency) and the severity HAZOF Roien RISK LEVEL, Ui gemnloonimois nae tal pry Ll Se ence ner rusk MarR Glee) acetate lupe a ye fT c Frys na ane 000 mee pete Frequency” Ft eete pete eattcony | seventy High risks (H) are events with severe consequences and high likelihood to happen. High risks are unacceptable. The HAZOP team identifies high risks, for which it records that the design must be improved. Precise tracking ofthe status and expediting ofthese requested improvements will be made throughout the Engineering phase in order to ensure their implementation Atypical example of a reviewed item would be the scenario of overflow of a liquid containing vessel. The team would identify the possible cause (miss operation during filling), consequence (release of product to atmosphere through vessel overflow pipe), ‘existing safeguards (Liquid level indicator, operating instructions, high level alarm). (Heat Satety Environment G3) s ‘The Frequency of occurrence will be estimated considering likelihood of error by operator, malfunction of the level sensor, et ‘The Severity will depend on the type of product released to atmosphere (personnel and/or environmental hazard). Should Frequency * Severity (risk) be found high, the HAZOP team would prescribe an action from the design team (a check to be done, a calculation to be made, a change to the design such as the addition of a safeguard, etc). ‘The form below shows a typical HAZOP worksheet, issued after the review as part of the HAZOP report. The first item does not require any action by the design team. The second item requires an action (addition of a non-return valve), ‘which Engineering has implemented as shown on the P&ID. — ie a oe ee ae ee Bias54 Healthy Safety & Environment (HSE) Early incorporation of additional requirements resulting from the HAZOP is essential to minimize the amount of design reworks they generate Second only to process safety is the safe layout of the facility. Explosion and. fire hazards exist in Oil & Gas facilities due to the flammable and explosive inventories handled. Adequate design considerations, in particular in the field of layout (relative positions of equipment) and spacing (minimum distances between equipment), can reduce the risk or consequence of such events. Explosion and fire damage can indeed be significantly reduced with proper layout as explosion overpressure and fire radiation intensity rapidly decrease with distance. Minimum distances are specified between units and equipment based on the risk levels. Safety will also review the layout of the plant to ensure sufficient space is provided for escape of personnel in case of emergency and for access for fire fighting. Please refer to the Plant Layout section for details of safety considerations in plant layout. ‘The Fire Fighting system of the plant is designed by Safety. Such system comprises both passive and active fire fighting means, Active fire fighting system consist of the fire water system, a pressurized water ring feeding hydrants, fire monitors (for manual fire fighting) and the deluge system (for automatic fie fighting). The deluge system consists of spray nozzles (sprinklers) arranged around the equipment, that will automatically spray water on the equipment upon detection of fire. The detection itself is done by fusible plugs located around the equipment, that melt when subject to heat. ‘The purpose of the water spray is not to extinguish the fire but to cool down, the equipment, for instance a pressure vessel, to prevent the steel from loosing its strength at elevated temperature which could lead to the collapse of the vessel and loss of containment. ‘The quantity of fire fighting water is determined in the fire water demand calculation note. The plant area is first divided into fire zones. Health, Safely & Environment (HSE) 55 i ‘The water demand calculation is then calculated on the basis of a fire in one of the fire zone, with all fire fighting equipment in operation in this fire zone. The deluge water demand is calculated from the number of sprinkler nozzles, itself a function of the the surface areas of the protected vessels.56 Health, Safety & Environment (HSE) The fire water system is depicted by the Safety on the Fire Water Piping & Instrumentation Diagrams (P&IDS). Fie Wier PADS Arrangement of deluge nozzles around equipment is shown on the Deluge system arrangement drawings. Health, Safety & Environment (HSE) 57 ‘The location of the fire fighting equipment is shown on the Fire fighting equipment location drawings.58 Healthy, Safety & Environment (HSE) Passive fire fighting, by means of fireproofing, is applied to structures supporting equipment and pipes. Protection of such structures will prevent/ delay the fall of critical equipment or pipes therefore avoiding the escalation of the incident. In order to define which structures shall be fireproofed, Satey proceeds as follows: It first establishes the list of equipment generating a fire hazard, such as equipment containing a significant volume of flammable liquid, etc. Each such equipment creates a “fire scenario envelope” in its surroundings. ‘The various envelopes are consolidated and structures located inside the overall envelope are identified Not all structures within the envelope shall be fireproofed, but only the ones: supporting equipment and pipe whose collapse could lead to incident escalation or lange damage. This would include for instance a large andl heavy tank, even if merely containing water, located at height. Extent of fireproofing of the structures is defined by means of typical drawings such as the ones shown here. Fire proofing can be done by applying a special coating, or concrete, in which case requirements are addressed to the civil engineer who develops the required standard drawings. 59 a eae) Fire fighting includes a Fire and Gas detection system, which activates alarms and performs automatic actions, such as electrical isolation, in case of fire and ‘gas detection.60 Health, Safety & Environment (HSE) Safety defines the number, location and type of Fire and Gas detectors both in process areas and inside buildings and shows the same on the Fire & Gas detection layout drawings. Legh Safety defines the emergency actions, such as process shutdown, electrical isolation, etc. upon fire or gas detection. These actions and their initiators are shown on the ESD logic diagrams. Health, Safety & Environment (HSE) 6 ‘The detailed logic is shown on the Fire and Gas Matrix. (EAUSES EFFECTS In the example shown above, detection of gas in the air inlet of the building ventilation system will cause the ventilation fan to stop and the damper (shutter of the ventilation duct) to close. Indeed, the equipment located inside buildings is not designed to work in an explosive atmosphere, Safety identifies the areas of the plant where explosive atmospheres could form, This is based on the identification of known sources of release and potential sources of leaks. Sources of release include storage tanks, vents of equipment and instruments, etc. Potential sources of leaks include flanged connections in pipework etc. The extent of the explosive atmosphere around the source is assumed using a set of rules, for instance a radius of 3 meters around an instrument vent, etc Hazardous area classification drawings are prepared showing areas where an explosive atmosphere could be present, along with the likeliness of presence (Zone 0/1/2).a ESTRCTEDAOWO i) enennibytertendenis sete tater mena 2079 Electrical equipment located in hazardous areas must be of a special design 80 that they are nota source of ignition. Such special design provides various degree of protection against the risk of being a source of ignition, The required degree of protection is determined based on the classification (zone 0 > 1 > 2) of the area where the equipment is located. Protection could be achieved by different designs such as * explosion proof, referred to as “d”: the equipment is enclosed inside a heavy. duty enclosure that would contain an explosion and avoid its propagation, ‘+ increased safety, referred to as “e": the equipment is designed not to ‘generate any spark, ‘+ intrinsic safety, referred to as “i”: the amount of energy created by a spark in the equipment is not high enough to ignite the explosive atmosphere, # ete, Besides this level of explosion protection, Safety specifies the composition of the explosive atmosphere to which the equipment could be exposed. The nature of the explosive atmosphere has indeed a direct impact on the minimum ignition energy: An atmosphere of hydrogen, such as the one that could develop in a battery room during charging, requires much less energy to ignite than a natural a8 atmosphere for instance. The nature of the atmosphere is specified by reference to a gas group, e.g. IIC for hydrogen, et. Finally, Safety specifies the maximum temperature authorized on the equipment surface. Indeed, the explosive atmosphere will ignite if it comes in contact with a temperature above its sel-ignition temperature. This again depends on the composition of the explosive atmosphere: methane selt-ignition {temperature is around 600°C whereas that of ethylene is 425°C. The maximum equipment surface temperature is specified by means of a temperature class, e.g., T3 means maximum surface temperature of 200°C. Electrical equipment protected against explosion is clearly marked by means of an international code encompassing the information above: The Quantitative Risk Analysis (QRA) is a systematic way to assess the hazardous situations associated with the operation of the plant. The analysis is related {o release of hazardous materials to atmosphere that can cause damage to people or equipment, e.g,, due to explosion, fire, ete Each accidental event is plotted inside a risk matrix, according to its frequency and severity.Action is required for any event falling in the “Intolerable Risk Area” of the matrix. Its frequency or consequences must be reduced to bring it into the “ALARP (As Low As Reasonably Practicable)” or “Acceptable” risk areas, through risk reduction measures. ‘The first step of the QRA is to perform a hazard identification. In the example that follows, the hazard reviewed is that of an explosion due to leak from piping. The cause could be material detects, construction errors, corrosion, maintenance overlook, et ‘The plant is divided into individual isolable sections of similar hazardous ‘material, process conditions and location. The section considered here is the building housing a compressor. ‘The inventory of each component from which the leak could originate (pipes, flanges, pumps, valves, instruments...) is made. Frequency of leak of individual ‘components is taken from statistical data found in the literature, for various leak size, eg., 5% of component bore size, etc. The sum of the individual component leak frequencies and sizes give the overall plant section leak frequency and size. ‘se sty: Gas ea rondo piping ‘cerpecet pte ‘Cs: nstltion er, corosin, tra sc Dispenion with anton Jee asi exes Ssslon senses Cpr bldg isk components Step I re \ensfcuion and characterisation of) (sisi) Gein oars eases see tae [pat | ame Guew w g 37 [| sx [amo Release of hazardous material to atmosphere can give rise to different effects, such as simple dispersion without harm or on the contrary fire, explosion, etc ‘This depends on a number of factors, such the presence of ignition sources, the degree of confinement, etc. It is the purpose of the second step of the QRA to evaluate the probability of each possible consequence. ‘The various scenarios are shown on event trees. The frequency of each event is factored by the probability of the subsequent one, resulting in the frequency of the various possible ultimate consequences, ‘Ovaatatve Risk ‘Sip 2: ‘Anais (OR) Event re amas ‘hae lnm and eesarton same Sathya ee hime Si te ec aby of apn a oe pe onsen decane ae Pet fe cn ‘The third step of the QRA is to evaluate the effects of each accidental scenario, Consequences are expressed in terms of reference values of overpressure, heat radiation, eteo7 acy 66 ED The Quantitative Risk Assessment results in requirements, such as blast “Sac resistance of buildings, reinforcement of strictures supporting safety critical a elements, etc, which are incorporated inthe design oo The impact of the plant on the envionment is specified and evaluated by the ape mine HSE discipline {An ENVID (ENVironmental aspects IDentifcaton) review is performed to identify all environmental aspects of the plant, Le, all equipment having a Fame oie eee, bosansoy (por [am Daves |i [A Wate [Rew rwia[ was] ewares | Unit | Pattee consumption | eats | "rene | Reliet ] CONSEQUENCE CLASS | QUANTITATIVE CRITERIA | PFFECTS: ane fawn |__| earerisa it [ etd owe ] eosin | [sucwiricane _¥ [<1 tr cally within sm_| ie damage n plat and operes az 1 evens Fottwitinnin [Omar melee comin cr erie eppanaear[oeee ee Frese x toe Coating water | Legionella ‘Water ay" ‘The risk is ranked in a class of consequences and plotted on the Risk Matrix wc x rete ge | coe to check its acceptability mice "oan —- Gane Rk nts a Sue tae ‘Anais (ORA) lesion fk | =68 Health, Safety @ Emironment (HSE) The review covers, for each aspect, the corresponding environmental concerns (noise, NOX emission, energy consumption, waste generation...) and the measures that are implemented in the design to control the environmental impact. ‘The Health and Environment Requirements specification states the requirements for each of the identified environmental aspect: regulatory standards, limits forall emissions (contaminants in discharged water, pollutants in gaseous discharges, etc), design dispositions to limit/monitor pollutants for each type of emission/effluent discharge, ambient air quality, noise limits, Aisposition for disposal of hazardous wastes, etc. Etlvent Guaity Crore for Discharge into Sea Organic Specine Parameter symiot [urns | Momtiy | simarn oa Oneric Catan roe | mat © 75 lest hose ane ea w= ‘The above requirements are fed back into the design (water segregation and treatment system, height of exhauist stacks) and addressed to equipment vendors mits of NOx for gas turbines, etc), Later in the Project, an Environmental Impact Assessment is performed to verify that the design complies with the above requirements, It includes an analysis of the dispersion of atmospheric pollutants released by the plant to evaluate the impact of the plant on the surrounding air quality. It entails an inventory of all sources of atmospheric emissions (machinery exhausts, etc), and the modelling of the atmospheric dispersion according to local meteorological data. It results in the calculation of the levels of ground concentration of atmospheric pollutants at various distances from the plant, eg, within the facility, in nearby populated areas, etc. Health, Safely & Environment (HSE) 9 Ground Concentration of NOx (im?) a mite) | we Aa soo | (ARE g / CE eS ca ONS The scope of the Environmental Impact Assessment covers emissions in normal ‘operation only. Accidental emissions and their impact on the facilities or populations is out of the scope and is covered in the Quantitative Risk Assessment, ‘The environmental impact assessment also includes a Noise study. It starts with, the inventory ofall noise sources. Noise levels are then obtained from reference data base during preliminary studies, then from each equipment vendor after purchase. A computer is used to run a model of the noise dispersion. Both noise sources and bartier elements with noise screen effect such as buildings, are entered in the model ‘The noise level at each location of the plant is evaluated. Verification is done that noise levels in working areas, and at the facility's boundaries, are within the safe/ legal limits ‘The noise study records the bases and results of noise calculations, Equipmentnoiseinsulationrequirements are derived from the noise study. The results of the noise study are shown on the Noise map.0 Health, Safety & Environment (ASE) Finally, the Environmental Impact Assessment includes a waste management study, The wastes generated by the plant are inventoried and the possible options for recycling, treatment or disposal are studied based on existing local waste recycling / treatment disposal facilities. This study allows to size the temporary waste storage area required on site Zaajdeyo engineering > ‘The fist step of civil engineering for an On-Shore plant is to know the Site and the type of soil on which the plant will be built. A survey is required to collect topographical, hydrological, geologicaland geotechnical data. A Soil Investigations Specification is prepared by the Geotechnical Engineer to define the scope ofthis survey. Itwill include soil investigations, by means of geotechnical and geophysical methods, to collect a good understanding ofthe type of soil and its variability over the plant area. The type of soil determines the type of equipment required for excavations (excavators /explosives) and the type of foundations (shallow /deep) required for the plant equipment It will also include the identification of any local geo hazards, such as seismic hazard, collapsible soil, underground cavities, ete. and the definition of the soil {geotechnical parameters to be used for the sizing of the foundations, such as soil bearing capacity. Specific studies are performed underneath critical structures, such as large storage tanks, tall columns, et. ‘The geotechnical engineer will also provide specific recommendations to the engineer with respect to, for instance, reinforcement of slopes to be done in backfilled areas, eten Gi Once the overall layout (General Plot Plan) of the facility is defined, the first Site activities can start, These are the earthworks, which consist of levelling the site up to the required elevation. Earthworks drawings are produced, such as the Grading Plan, showing the natural ground elevation and the final desired elevation (Chil engineering B Earthworks equipment will then excavate/fill in order to teach the required finished level. Once the Site is levelled, local excavation can be done and foundations of main equipment can be cast. Indeed, the main equipment foundations are the deepest undergrounds to be installed hence they have to be installed first. Design of equipment foundation requires Vendor information such as footprint, location of anchor bolts, static and dynamic loads, ete. The vendordetermines these loads, which are the basis for the sizing of the foundation,5 The civil engineer designs the foundation using a computer software. The type (piles, etc.) and size of the foundation depend on soil characteristics (bearing capacity, etc.). The bases of design and results of calculations are recorded in the foundation calculation note,16 Givil engineering From the above design results the size of the foundation, its shape, dimensions, depth, and amount of re-inforcement. Foundation drawings are produced, which show the dimen: ins and depth of the foundation, the position, number and size of re-inforcing bars, and the position of anchor bolts to be cast in the foundation. Reinforcement drawings and Formwork drawings are usually issued as ‘separate drawings.8 Ghil engineering Givil engineering ~ Besides drawings, Civil issues Civil works specifications, for each trade, eg, Civilalso issues Construction standards, such site preparation, concrete works, roads, buildings, ete. which define the materials to as the one shown here for anchor bolts, which be used, how the work shall be cone, the inspections and testing requirements, ete show repet Similarly to foundations for an On-Shore facility, deck structural drawings are produced J foran Off-Shore facility The deck structure is made of the primary structure, which comprises the main girders making the deck frames, and the connection between the decks (legs), the secondary structure, madeof beams supportingequipment, ‘and tertiary structure, made of small beams supporting plating. Layout studies determine the number, size and elevation of deck levels and the main equipment location. Together with equipment weights, it allows the Structure discipline to perform its design, calculations and to issue the Primary Steel Structure drawings. ve arrangements, a Git works speciation re-fabrication is done to the maximum possible extent in order to reduce installation time, Concrete indeed requires around 2 weeks to dry before it can bbe buried. For the ease of a foundation cast in-situ for instance, the excavation, which occupies a lange footprint, needs to remain open for such period of time, which prevents surface works to proceed. Pre-fabrication of the foundation would avoid that and allow immediate backfill after installation, Besicles specific concrete constructions which are one-off and customized to a particular equipment, civil also produces generic concrete items, Civil standard drawings, such as the one showing standardized pipe support foundations here, are issued for that purpose, Such standardisation allows mass production at the pre-fabrication yard80 Civil engineering ‘The primary structure (welded plate girders forming the deck frame, deck legs, ete.) is made out of steel plates that are a long lead item. Indeed, such steel has special properties (high strength, through thickness properties), requires special tests and must come from a mill that has been duly qualified The primary steel structure material take-off is therefore issued early in the project to quantity all necessary steel plates. Secondary structure drawings are issued next, which show the main equipment support beams, and the associated bill of material, which has of a shorter lead time than primary steel In On-Shore facilities, besides equipment supporting structures, long stretches of large steel structures supporting pipes, called pipe-racks, are found. Requirements for these structures (location, width, number and elevation of levels, etc) and input for their design (number of pipes to be supported, weight, ‘operating loads) are defined by Piping, Good communication between Piping and Civil is essential to optimize their design and include contingencies in order to avoid changes ata later stage, when piping studies will have progressed.82 Givil engineering Large piping operating loads, such as loads at piping fixed points, thermal loads from low or high temperature lines (subject to high expansion), etc. are calculated by Piping Stress analysis group and advised to Civil. Other piping loads are estimated by Civil, ‘To these piping loads are added external loads such as seismic and wind loads. ‘Ghil engineering 83 ‘The structure is designed using a 3D modelling and calculation software, Design of the structure includes sizing of main members, selection of connection type (pin/moment) between the members, provision of secondary ‘members, such bracings for stability, etc, It results in a structural calculation note, which shows the design input and results (stress ratios in structure ‘members, deflection of members).1 mene w ‘The civil designer then prepares the steel structure design drawings, which are issued to the manufacturer of steel me Cc a ‘The steel structure manufacturer models the structure in all details, including all connections between steel members, and issues shop drawings, such as the ‘one shown below; to its fabrication shop. 152x152x30UC_- 5960 LG C157.6 X 152.9) VIEW B-B One shop drawing is produced for each structural member, showing all fabrication details, such as exact dimensions, position of gussets, positions and number of holes for bolts, ete. There is also usually a direct transfer of all fabrication data from the design office 3D model software to the numerical control fabrication machinery. ‘The manufacturer issues the Erection drawings, which show the overall view of the structure, together with the arrangement of the various steel members, identified by their piece marks.86 (Givil engineering : x | t Identification is key. A given steel structure may come in as many as one thousand pieces, reaching, the erection Site by several different truck loads, spread during storage before erection in very extencled lay down areas. Givil engineering 87 (On top of equipment and piping supporting structures, civil provides small, platforms for operator access (to equipment, instrument, valves, etc). Corresponding access requirements (location, elevation, dimensions of operating stages) are identified and defined by Piping installation discipline. Civil discipline implements these requirements by designing the corresponding small structures. A standard design is produced, which will be applied to all these repetitive items, and to the associated handrails, stairs, ladders, etc. Sea Seaton standard drawings jon (CWI) drawings show the layoutof al underground objects and networks. These are very detailed drawings showing, for each area, the location and elevation of the numerous underground objects: foundations (of equipment, structures, buildings, pipe supports, etc. networks (process and utility services, cables, sewage, pits, roads, ete). Production of the CWI drawings ensures coordination of all underground objects in order to anticipate and prevent interferences