Key Milestones in Oil & Gas Plants Engineering

ABC in Oil and Gas Plants Engineering:

What`s FEED ?
FEED: Front End Engineering & Design

This the first stage of Engineering for any Project (Chemical / Petrochemical / Oil & Gas / Refinery etc) where the following discussed & decided.

1. Technical / Process Wise:
a. Material Balance (Mass & Heat)
b. Process Flow - How the various raw materials flow from start to end & in what form
c. Major equipment of the process - pumps, vessels, heat exchanges, filters, etc
d. Safety Systems requirement for process " Basic HAZOP,HAZID,QRA, FIRE CASE,..."

2. Engineering Wise:

1. Approximate Load List - for motors, transformers, drives, High Voltage Switchgear, UPS size, Diesel Generator requirements etc
2. Utilities required for the process - Air compressors, Nitrogen Plant, Fire Fighting systems, Hot Oil Heating Systems requirement, Air Dryers etc
3. Major Instrumentation Systems - PLC / SCADA / DCS system (which one or combination of the above etc)
4. Approximate Instrument List - Kind of Networks used, kind of Instruments used, system architecture (rough sketch / drawing showing the different networks connectivity between them)

3. Management Wise:

a. The total cost of the project - around X 20% approximation (within the accuracy of /- 20% accuracy)
b. The total manpower requirement for the plant
c. Total List of Raw Materials requirement & their quantities
d. Approximate time required for completion of the project

4. Philosophies wise:

1. Plant Operating Philosophies / Plant Design Philosophy & design Basis
2. Instrumentation Engineering philosophy - Design & selection basis documentation
3. Control Systems Philosophies - Hierarchies being implemented, design basis for selection of PLC / SCADA / DCS Systems, Third Party Interfaces, OPC Interfaces, Serial Interfaces between systems, Interfaces between DCS, ESD, F&G systems
4. Safety Shutdown Systems philosophy - LOPA Studies / HAZOP studies etc including SIL calculations.

Now apart from the above, the following are the deliverable at the end of the FEED.

1. Mass & Heat Balance Calculations
2. Process Flow Diagrams
3. Process & Instrumentation Diagrams (only 70 - 75% accurate)
4. Load list for electrical
5. Major Equipments & their Sizing (Major Equipments 100% accurate, however, there might be an addition of a one or two pumps / motors / blowers that might get added during the detail engineering stages but not vessels / heat exchanges or tanks).
6. Instrument list - which is 80% to 90% accurate.

However, please do remember the following:

1. Instrumentation Datasheets / Process Datasheets / Mechanical Datasheets are not the deliverable of FEED. They are prepared during the Detail Engineering Phase
2. Instruments Selection, Sizing Calculations are finalized / done during the detail engineering phase only.

What `s Detailed Engineering Design " DED"

Preparation for commencement of detail design. To evaluate FEED deliverables to ensure engineering is sufficiently mature for detail design to progress in a controlled and minimal change environment. To confirm Engineering Execution Plan.
Detail Engineering Design Package generally contains the following:

Process:
1) Process Flow Diagram (PFD) & Process Simulation Report
2) Material Balance for Process & Utility
3) Process Calculation report - line sizing, equipment sizing, and etc
4) Process Design Basis
5) Process Sketch/Basic Engineering Flow Scheme (PEFS)
6) Equipment List & Process Equipment Data Sheet,
7) Instrument Process Data Sheet
8) Line Schedule, Piping Process Data & Tie in List
9) Operating Instruction/ Process Control Philosophy Report
10) Process Safety Design e.g.: Hazardous Area Classification Report & Drawing,
Fire Fighting Facilities

Mechanical:
1) Strength Calculation
2) Mechanical Engineering Drawings
3) Calculation of Rotating Machinery
4) Requisition
5) Review & Check Vendor Drawing
6) Identify & propose platform or attachment on equipment
7) Loading Data
8) Insulation & Painting Information

Piping:
1) Piping Routine Study
2) Structure & Pipe Rack Information
3) Piping Flexibility & Nozzle Orientation Analysis
4) Pipe Support Information
5) Piping General Arrangement & Isometric Drawing
6) Piping Bill of Quantity
7) Requisition of Piping Component & Piping Specialty

Instrument:
1) Instrument Schedule
2) Planning of Control Room
3) Instrument Utility Requirement
4) Layout of Instrument
5) Control Basis & Interlock Diagram
6) Instrument Cable & Duct Routing
7) Panel Instrument Arrangement
8) Instrument Piping Hook-Up & Loop-Up
9) Wiring, Tubing & Utility Piping Layout
10) Instrument Bill of Quantity
11) Instrument Requisition
12) Review & Check vendor Drawing

Electrical:
1) Interlock Diagram
2) Loading Data
3) Planning of Switch Room
4) Cable Routing
5) Cable Duct or Trench Plan
6) Communication System Design
7) Lighting Plan
8) Lightning Design
9) Bill of Quantities
10) Requisition
11) Review & Check Vendor Drawing
12) Calculation Report e.g.: Load Flow Analysis Fault Level Load Study / Schedule Calculation

Civil and Structural:
1) Grade Levelling Plan
2) Road, Paving & Planning Design
3) Sewer, Planning & Design
4) Piling Design
5) Foundation Design
6) Structure Design
7) Building Design
8) Ventilation, Air Conditioning, Plan & Design
9) Bill of Quantities
10) Civil Material Requisition