INTRODUCTION

TO
PROCESS ENGINEERING / DESIGN

ORGANOGRAM
Lead Process

Senior Process Engineer

Senior Process Designer

Process Engineers

Process Designers
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Process Department
The department is made up of group of professionally trained chemical engineers & non-chemical engineers who collectively worked together to produce required deliverables" (output) for a particular process as described or desire by clients.

Scope of Work
Process scope of work is usually divided into two; Process Utility

Process Design Basis & criterial

Process design criteria: Standards, rules or test by which process design decisions may be based. Process design basis: Fundamental data upon which process design calculations are based.

Process Design Basis

Functions of the Process Design Basis: Defines the basic requirements that a design must meet Communicates important design information to the Client Serves as a key approval point in the development of the unit Serves as a key interface point for coordinating stream operating conditions between process units Serves as a kick-off point for licensed unit designs
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Process Design Basis

Content of Process Design Basis: Plant capacity Site location Source of process technology Units of measurement Meteorological and other site data Raw materials Products / By-products Tabulation of utility conditions Battery limit conditions Materials of construction Plant on-stream factor
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Process Design Basis

Plant capacity design margin Equipment design factors Startup and shutdown requirements System reliability requirements Physical / thermodynamic properties Reactions Yields / losses Storage Requirements Environmental requirements
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Process Design Basis

The preparation of the Process Design Basis is the responsibility of the Lead Process Engineer. Licensed designs will require close coordination between the Process Engineer, the Client, and the Licensor in developing the Process Design Basis. It is the responsibility of the Process Engineer to adhere to the basic design parameters provided in the Process Design Basis, and to be familiar with the Process Design Basis of interconnected units.
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Process Design Criteria

The purpose of the Process Design Criteria is to establish specific guidelines and constraints that govern the following: Format and Content of Flow Diagrams Specification and Design of Equipment Economic Analysis Safety Design and Development of Instrumentation and Piping Systems
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Process Design Criteria

Topics covered by Process Design Criteria: Codes and standards Environmental regulations Source for physical property data Noise level limitations Naming and numbering of equipment Drawing numbering Criteria for flexibility and expansion Safety considerations Economic criteria Utility design information
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Process Design Criteria

Materials of construction BFDs (Block Flow Diagrams) PFDs (Process Flow Diagrams) P&IDs (Piping and Instrumentation Diagrams) Equipment datasheets and design basis sheet Piping and Hydraulics Instrumentation Relief System
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Process Design Criteria

The following sources are used for the preparation of the Process Design Criteria:

Project/Plant Specific Process Design Criteria Client Standards Applicable Codes and Standards It is the responsibility of each Process Engineer to be familiar with the project process Design Criteria and to apply it on the project. Any deviation from the Process Design Criteria requires the approval of the Lead Process Engineer.
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Diagrams
Block Flow Diagram (BFD) is a simplified drawing of the overall process.

Major equipment, processes, or unit operations are represented by blocks.

It serves as a communication tool between the Process Engineer and the Client when the basic concepts of the process are preliminary. It provides a simplified starting point for preparing Process Flow Diagrams (PFD) and heat and material balances.
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Diagrams
Types of Block Flow Diagram: Overall Process Block Flow Diagram Utilities Block Flow Diagram / Balance

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Process Description
It is a detailed narrative describing the activities represented by process document (BFD, PFD, or P&ID). It is designed to answer questions relating to what, why, and how. The content is generally tailored to the level of design in progress, and can vary significantly from project to project. It serves as a tool to communicate design issues within the task force.
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Process Description
A typical Process Description covers the following:

Description of the overall function of the operations depicted on the flow sheet Discussion of feed streams including method of control and conversion to products Description of major equipment including its function in the process Process controls Operating conditions
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Process Description
The following documents may be used in the preparation of a process description:

Process Unit Design Basis Block Flow Diagrams Process Flow Diagrams and Material Balances Equipment List and Datasheets P&IDs Instrument Index Control and Interlock Descriptions Utility Summaries Catalyst and Chemicals Requirements
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Utilities Description
The Utility part /section of major projects includes; Raw Water treatment Cooling water Potable water Service (Utility water) Drain system -oily water, storm water, chemical contaminant water, sanitary water Waste treatments Fuel gas system Steam/ condensate Refrigeration Tank and Storage Flare - elevated or ground flare 18

Utilities Description
Incineration Air system -instrument air, service/utility/plant air Nitrogen system Fire water system -Main ring, foam, & deluge system

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Software
Process software; Hysys; For determining heat, energy and material balances Pipesim;Fluid & multiphase flow modeling, Reservoir, well & completion modeling Pipephase;Multiphase modeling Auto CAD;For drafting/drawing Utility software; Pipenet; hydraulic analysis of spray & sprinkler system, Transient & Fluid network Flaresim; Modeling of flare radiation and sizing Flarenet; Modeling of flare network
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Process Equipments
Separator Pumps Compressors Heat Exchangers Tanks

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Safety Equipments
Pressure Safety Valve (PSV) Vent SDV/ESD/BDV

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Equipments List
Equipment List displays the name, item number, and brief information about each piece of process equipment on a project. It helps to define the scope of a unit. It serves as a communication tool among Process, Mechanical, Controls/Estimating, and the Client.
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Equipments List
The Process Engineer usually initiates the Equipment List. The Equipment List is later transferred to the Mechanical Engineer for maintenance and updating Information that is provided in a sized equipment list generally includes equipment size or capacity, design pressure and temperature, insulation, materials of construction, etc. It is important that both name and the item number be carried forward to other documents.
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Process Calculations
It is extremely important that process work be accurate to meet the requirements of the project and the Client. It is the responsibility of engineers to have their work checked for completeness, accuracy, consistency, valid assumptions and references, correct methods, and format. Process calculation is one of the deliverable for ISO9001 compliance. Every Calculation requires a calculation cover page

Format for calculation: electronic or manual is set by Lead Engineer.

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Process Checking & Approver

Work Instructions identify key activities where accuracy must be verified to ensure a high quality product. The ORIGINATOR: self-checking tool. The CHECKER : ascertain that all aspects relevant to the satisfactory completion of that document have been considered. The APPROVER : establish that both the originator and checker have performed all the functions for which they are responsible.
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Process Checking & Approver

Levels of checking requirement:

Checking Level 1 Complete detailed check (100% checklist activity items) of all documents. Checking Level 2 Selective check (partial utilization of the checklist activity items) of all documents, or complete check of selective documents. Checking Level 3 (discontinued) Spot check of random selection of documents. Checking Level 4 Complete "self check" only by the originator.
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Filing
The Lead Engineer is responsible for:

Setting up the filing system at the start of the project Ensuring that each process engineer files information in a consistent manner Examining the files for archiving purposes and sort the contents with a view to retention or disposal upon project completion

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