Preface xi
Part I Introduction to EPCC Industry 1
1 Introduction 3
1.1 What Is EPCC Industry 3
1.2 Types of Projects 4
1.3 Function of Different Disciplines 9
1.4 Different Phases of the Project 11
1.5 Importance of Chemical Process Engineers 14
1.6 Interaction with Operating Industry or Customers 15
1.7 Interaction with Vendors 15
1.8 Workshare with Multiple Offices 17
Part II Roles of Chemical Engineers in Different Phases of the Project 21
2 Phase 1 (Scope Planning) 23
2.1 Perform Feasibility Studies 23
2.2 Interaction with Customer, Recommendations, and Meetings 24
2.3 Preparation of Preliminary Scope Reports 25
2.4 Technology Selection 28
3 Phase 2 (Scope Definition) 31
3.1 Develop a Block-Flow Diagram 31
3.2 Develop a Process-Flow Diagram 32
3.3 Prepare IFE Quality P&IDs 36
3.4 Identify Major Pieces of Equipment, Instruments, and Electrical 38
3.5 Estimate Preliminary Sizing of Major Equipment and Instruments 40
3.6 Metallurgy Selection of Major Equipment 42
3.7 Complete Simulations for Different Cases and Prepare IFE Quality HMB 45
3.8 Complete Studies 47
3.9 Preliminary Estimate of Utility Summary 47
3.10 Participation in LOPA 49
3.11 Prepare IFE Quality Design Basis 50
4 Phase 3 (Scope Development) 51
4.1 Perform Detailed Hydraulics 51
4.2 Detail Design of Other Equipment 54
4.3 Input to Line List and the Process 57
4.4 Create Change Orders and Report Any Changes to Project 63
4.5 Process Data for Inline Instruments 64
4.6 Prepare Preliminary Safety Valve Evaluations 66
4.7 Prepare and Issue Equipment Datasheets 68
4.8 Communication with Other Disciplines, Projects, and the Customer 70
4.9 Participate in HAZOP 70
4.10 Follow Up and Implementation of HAZOP Items 71
4.11 Issue and Prepare IFR/IFH/IFA/IFD Quality P&IDs/PFDs/MSDs (Including Tie-in/Demo P&IDs) 72
4.12 Complete and Lead Line-by-Line Reviews of P&IDs 73
4.13 Prepare IFD Quality Design Basis 74
4.14 Issue IFDHMBs 74
4.15 Utility Summary IFD 75
4.16 Prepare DPDT Diagrams 75
4.17 Prepare Material Selection Diagram 76
4.18 Drafting of the Drawings and Backchecking 77
4.19 Input to 30% Model Reviews and Plot Plan Development 79
4.20 Input to Cost Estimate 80
4.21 Budget Estimate, Schedule, and Staffing Plan 80
4.22 Lead Workshare Meetings 87
4.23 Input to Internal Meetings with Project and Discipline Teams 88
4.24 Plant Visits 89
4.25 Input to Preparation of Demolition and Tie-in P&IDs 89
4.26 Preparation of Pipe Service Index 90
4.27 Process Audit 91
5 Phase 4 (Detailed Design) 95
5.1 Participate in the Final HAZOP 95
5.2 HAZOP Action Item Closeout and Hold Items 95
5.3 Project Support as Needed 96
5.4 Provide Offline Instrument Data 96
5.5 Squad Check of Process and Vendor Data 98
5.6 Finalize Safety Valves Design and Issue IFD Datasheets 99
5.7 Closeout of Documents 101
5.8 Input to 60% and 90% Model Reviews 101
5.9 Lead Workshare Meeting 102
5.10 IFC and IFC-RP&IDs 102
5.11 Line List Updates and Input to New Lines 103
5.12 Leading MOC Meetings 103
5.13 Cause-and-Effect Table 105
5.14 Input to SP Items and Tie-in Forms 106
6 Phase 5 (Construction and Support) 109
6.1 Preparation of Procedures and Manuals 109
6.2 Tie-in Execution 109
6.3 Provide Answers to the Construction Team 109
6.4 Updating P&IDs as Needed 111
7 Phase 6 (Commissioning and Startup) 113
7.1 Perform General Process Activities 113
7.2 Prepare and Complete Pre-startup and Safety Checklists 114
7.3 Check Performance Test of All the Equipment 116
7.4 Participate in Control System Loop Testing 116
7.5 Leak Testing 117
7.6 Drying-Out and Oxygen Freeing 118
7.7 Startup Assistance 118
Part III The Process Engineer 119
8 Role by Process Engineer's Position 121
8.1 Entry-Level Process Engineer - 0 Years Experience 121
8.2 Junior Process Engineer - 1-2 Years Experience 121
8.3 Mid-Level Process Engineer - 3-6 Years Experience 121
8.4 Lead Process Engineers - 7-10 Years Experience 122
8.5 Senior Process Engineers -10-15 Years Experience 122
8.6 Process Managers - 15+ Years Experience 122
8.7 Competency Guide for Process Engineers 122
9 Interaction of Process Engineers with Others 137
9.1 Project Tree 137
9.2 Customer 138
9.3 Mechanical Engineer 139
9.4 Projects 140
9.5 Piping Design 140
9.6 Piping Engineering 141
9.7 Control System Engineer 141
9.8 Electrical Engineer 142
9.9 Civil Engineer 142
9.10 Construction Team 143
9.11 Cost Estimating 143
9.12 Project Controls 144
9.13 Licensor 144
9.14 Other EPCC Engineer 145
9.15 CAD and Drafting Coordinator 145
9.16 Document Control 146
Questions 147
Answers 149
Acronyms 153
Appendix 155
Appendix A Project Conceptual Diagram 157
A.1 Explanation of Figure A.1 157
A.2 Explanation of Figure A.2 158
A.3 Explanation of Figure A.3 158
A.4 Explanation of Figure A.4 159
A.5 Explanation of Figure A.5 160
A.6 Explanation of Figure A.6 161
A.7 Explanation of Figure A.7 162
Appendix B Project Schedule Diagrams 163
B.1 Explanation of Figure B.1 163
Appendix C Project 3D Model and Plot Diagrams 165
C.1 Explanation of Figure C.1 165
C.2 Explanation of Figure C.2 166
C.3 Explanation of Figure C.3 167
C.4 Explanation of Figure C.4 167
C.5 Explanation of Figure C.5 168
Appendix D Process Engineering Diagrams 171
D.1 Explanation of Figure D.1 171
D.2 Explanation of Figure D.2 171
D.3 Explanation of Figure D.3 171
References 175
Index 177
