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PROCESS DESIGN

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Process Design and Engineering Services
 
 
 
 
Description: 
Engineering can be defined as the art of an engineer to execute projects by using technical means and implementing the know-how with-in the practical constraints of time, budgets, environmental conditions and safety. The various elements of a conventional engineering project are:
 
 
 
Design Basis: 
The design basis forms the foundation of any project and defines the parameters which need to be considered during the engineering phase. The design basis needs to be filled up by the customer of the project and submitted to the engineering company. USPTM has a standard design basis which comprehensively covers all aspects relevant to the engineering design.
  
 
Process Simulation and H&MBs: 
USPTM has 2 licensed copies of ProMax- process simulation software. ProMax, has a wide application in the refining industry, petrochemicals units and allied industries. It is a market leader in the area of gas processing and gas treatment, particularly H2S removal, SRU-TGTU, Amine treatment, CO2 removal and numerous other process engineering applications.
 
USPTM process engineers will run the process simulations on ProMax and set-up a computer model. Given their vast experience with ProMax and a number of training sessions attended by USPTM engineers, the simulations will be optimized in terms of utilities and various process parameters. The most appropriate thermodynamic property package will be considered.
Once the simulations are frozen, Heat and Materiel Balances (H&MBs) will be developed.
 
 
 
 
                                          Typical Example of a Simple Gas Plant
 
Process Flow Diagrams (PFDs): 
The PFDs will be developed from the process sketch as obtained from the process simulation. The PFDs will show all the major equipments, control loops as well as the safety installations like ESD, safety/relief valves, PLC based interlocks etc.
 

          Typical Example of Process Flow Diagram (PFD)

 

Piping and Instrumentation Diagrams (PIDs):
 The PIDs are engineering documents which form the basis and the foundation for engineering by other disciplines such as piping, mechanical, civil, structural, instrumentation with-in any engineering company. The PIDs depict all aspects of piping and instrumentation in detail, including valves, fittings, all equipments including spares, instruments and their tagging, tagging and dimensions of equipments, all lines including start-up and commissioning.
 
PIDS also undergo a number of revisions during the life of a project and used for the purposes of a HAZOP. The typical issues of PIDs would be: Issued for FEED (IFF), Issued for HAZOP (IFH), Issued for Design (IFD) and Issued for Construction (IFC) and As-built status.
 
 
 

    Typical Example of Piping & Instrumentation Diagram (P&ID)

 

 
 
Equipment Sizing:
Specification sheets for all equipments would be prepared giving the key process parameters such MOC, operating design and test pressures and temperatures, dimensions and utility requirements. The following equipments would be sized and rated:
  • Heat Exchangers – Thermal rating and TEMA data sheets would be provided
  • Reactors - Reactor sizing would be done based on Promax model and considering space velocity as well as catalyst vendor inputs, if available.  Complete data sheet would be given.
  • Columns - Column sizing would be done based on rigorous TSWEET mass transfer model of Promax, vendor inputs for packing/trays would be considered, if available.
  • Compressors
  • Pumps

 

 

 

          Typical Example of Heat Exchanger-Thermal Rating and Sizing

 

 Control valves Safety Relief valves (PSVs) 

 
Vessels:  Data sheets with dimensions as well as nozzle locations would be submitted for 3-phase separators, 2-phase separators, storage tanks, hold-up drums, guard beds, day tanks etc.The vessel data sheet would have the complete information pertaining LLL, NLL and HLL, Where ever the boots are provided, the boot would be shown and its sizing as well would be indicated. 
 

               Typical Example of a Separator

 
Line sizing: Line list would be developed inidicating the size of the piping, the operating, design and test temperatures and pressures. The line list could be further developed to to indicate the line schedule and service.
 
 
                                  Typical Example of Line Sizing

Instrument data sheets:Process Data sheets would be provided for all instruments –Flow Temperature, Pressure, Level, TW, (FE/FT, TE/TT, PE/PT, DPI, LT/LI).

 
Safety interlocks
 
Flare Header / network sizing: The flare header sizing would be done on ProMax using the dynamic mode and considering various scenarios.
 
 
                              Typical Example of Flare Header
 
 
 
 
USPT&M – ENERGY DIVISION - PROCESS ENGINEERING EXPERTISE
 
We are capable of supporting all phases of project work including conceptual design, process simulation, preparation of process flow diagrams, process equipment specifications, piping and instrument diagrams, piping line schedules and process instrument data, We can also provide assistance towards preparation of start-up and operating manuals.
 
Our Chief process engineer has have almost 24 years of experience in process engineering in the upstream and downstream industry, specializing in hydroprocessing, hydrotreating, sulphur recovery catalytic reforming, isomerisation, and other refining processes. This diverse experience profile includes process design and systems engineering, technical services and commissioning activities. He has been called upon to function as a Lead Process Engineer for several leading and prestigious projects. These include the Reliance JERP and DTA projects with Bechtel; HPCL clean fuels projects for Axens, research and development project for Air Liquide, Haldia Petrochemicals project for Lurgi. He has Bachelors in Chemical Engineering from Shivaji University and a Masters from IFP with specialization in Refining, Petrochemicals and Engineering.
 
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