HAZOP and LOPA studies for ADNOC (Hail and GHASHA Development Project)
Process Design and Systems Engineering
Process Simulation
PROCESS SIMULATION and H&MBS: We have experience and knowledge of almost all the commercially available softwares and can be deployed based on customer specs; our preferred process simulation software is PROMAX® from BR&E. PROMAX® represents the best in class with validated results; It is an industry leader in the field of Oil & Gas, petroleum refining and petrochemicals. It is especially known for it's capabilities 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 and set-up a computer model. Given their extensive experience, 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.
process design
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, SIS etc.
systems engineering
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
equipment sizing and rating
Specifications and Process Data Sheets
Specification sheets for all equipments would be prepared giving the key process parameters such as 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, 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.
LINE SIZING: Line list would be developed indicating 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.
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.