Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
OPITO
Contents
Page
BOOK1
Training Targets
Introduction
Visual Cues
training targets for you to
achieve by the end of the unit
18
activities for you to apply your
new knowledge
Contents (contd)
Page
21
Introduction
Wells
Manifolds
Test Separators
Pig Launcher
Crude Oil Process Flow
Crude Oil Pumps
Gas Compression
Mass Balance
33
Visual Cues
46
2
Contents (contd)
Page
BOOK 2
* Section 1
* Section 2
* Section 3
Visual Cues
training targets for you to
achieve by the end of the unit
3
40
44
Training Targets
When you have completed this unit on Process Engineering Drawings, you will be able to:
Interpret symbols, codes and other information detailed on process flow diagrams (PFDs) and piping and
instrument diagrams (P&IDs).
Demonstrate an understanding of the basic engineering standards utilised in PFDs and P&IDs.
Identify equipment and valves by the symbols utilised on PFDs and P&IDs.
Draw a simple process flow schematic using relevant symbols and codes.
Detail the design criteria and objectives expected, from the information provided on a PFD.
Describe the equipment used to achieve the design objectives from the information provided on a P&ID.
Interpret the control process of equipment from the information provided on a P&ID.
Tick the box when you have met each target.
Introduction
Note: For ease of reference, all Figures and Illustrations referred to are contained in Book 2
Figure 1
The design and construction of an oil production
facility requires the use of many and varied types
of drawings. In this Unit we will look at the three
main types of drawing which will be of use to you in
understanding and operating an oil and gas
production facility,
For the purposes of the Unit, I have used drawings
for one oil production platform located in the UK
Sector of the North Sea.
Book 2
Contains all the drawings that we will use in
this unit. It also contains drawings of symbols,
as specified by British Standards, with an
explanation of what the symbol means, what
the item of equipment is meant to do, and
where the item of equipment may be used.
I have chosen to lay out the Unit in this way
so that you may study the individual sections
of the Unit and refer to Book 2 as and when
required in the text.
I recommend that you read Section 1 and then
take a few hours to study the symbols and
explanations contained in Book 2. After that you
can use Book 2 to look at the various drawings
which we will use throughout the unit, and also
as a reference document as required.
Summary
The whole purpose of this Unit is to
explain how to use the main types of
drawings which you may encounter in
the Oil and Gas Industry. One of the best
methods when learning a new process
is to start by studying the drawings to
discover what the process is meant to do
and what equipment will be used.
If you know what the symbols mean, and
you know how to interpret the drawings,
looking at a process drawing can be
as interesting as reading a good novel.
This especially applies if you are going
to operate or work on the process in the
future.
Before moving on, take a few minutes to
look at Figures 9 and 10 in Book 2. They
may seem extremely complicated but,
by the end of this Unit, you will be able to
read them like a book.
requirements
BS 5070 :
engineering
Symbol
Project
Originator
AA
Area/Mod
Discipline
Type
General symbols
System numbers
Abbreviations
Equipment identification numbering
Vessel trim designation numbering
Instrument symbols
Meanings of instrument identification letters
Equipment symbols
Product designation codes
Insulation class
Primary equipment classification
Line designation numbering
Instrument identification numbering
Valve symbols
Sheet No
Rev
10
minor changes
11
12
NOTES:
An item common to all drawings is a small section
which is commonly titled Notes. The Notes are
items of information which the design engineer has
identified as being important. They may explain a
small aspect of the drawing on which they are written,
or refer the reader to another drawing or manual.
The Notes should be studied with care as they can
be a useful source of essential information.
13
14
NOTE:
All Figure numbers referred to from here onwards
are contained at the back of the Book 2.
Equipment Lists
Many drawings incorporate EQUIPMENT LISTS
to indicate the equipment which will be found on
the drawing. In Figure 7 the equipment list is from
a Plot Plan. We will look at Plot Plans in Section
Two, but for the moment you should note that in this
drawing:
NOTE :
You may find that the prefix letter E is used in some
cases instead of H for heaters, exchangers and
coolers.
Figure 6
15
Summary of Section 1
In this Section we looked at the various British Standards that provide specifications and
practices to be adopted for all Process Engineering Drawings.
We looked at the definitions of drawings and diagrams as described in BS 5070.
We have seen that all drawings :
have a unique identification number
have an identification title
are subject to a revision process
We have seen how the engineers and draughtsmen
responsible for producing the drawing are identified,
and how a document progresses through the
revision process.
We have seen how changes may occur to the
process itself, WITHOUT all of the drawings in
circulation being amended to show the changes.
16
Test Yourself 1
1. What type of equipment would you expect V-1601 to be ?
2. What British Standard would you refer to for graphic symbols for piping systems and plant ?
3 Describe the difference between the THREE types of drawings by completing the following statements.
a)
b)
c)
You will find the correct answer in Check Yourself 1 on Page 47.
17
Modules
To simplify the mechanism of locating items of
equipment most process systems are split into
MODULES. A Module is usually a physical area in
which a certain process or processes are carried
out. In the case of offshore platforms, individual
Modules will probably have been constructed
by different manufacturers, and even in different
countries, before being assembled on-site.
If you refer back to Figure 5 you will see the module
layout of an installation. It indicates that:
D1 & D2 are drilling Modules
P1 & P2 are process Modules
P3 is the flare ( part of the process system )
B1 & B2 are the interconnecting Bridges
L1 & L2 are the accommodation modules
(living quarters)
Scales
Elevation Drawings and Plot Plans are DRAWN TO
SCALE. This means that there is a definite
relationship between the sizes and distances shown
on the drawing, and the sizes and distances which
will be present in the real location.
The scale of a drawing will depend upon the
expected use. In the case of Plot Plans and Elevation
Drawings a scale ratio of 1:150 is normal.
The main thing to remember is to ALWAYS check
the scale of the drawing.
Elevations
Figure 8 is an Elevation Drawing for an offshore
platform.
In Elevation Drawings the platform is viewed from
the four cardinal points of the compass (North,
South, West and East) and where appropriate each
Module is often identified.
Elevation drawings are utilised to provide a scaled
view of the installation, which can be utilised in
conjunction with Plot Plans for identifying hazardous
areas ( zone classification ), escape routes, and
location of emergency equipment and facilities
(lifeboats, life rafts etc.).
18
Plot Plans
Test Yourself 2
By studying Figure 7, describe two alternative
routes, using platform cardinal points, from the inboard end of the HP Flare Drum to the Main Closed
Drain Vessel, naming all equipment passed on each
route.
19
Summary of Section 2
In this section we have taken a brief look at how complex process systems are
separated into Modules so that their location can be more easily identified. We
have seen that they are normally arranged in a logical sequence and that they are
arranged on different levels. We have also seen that specific locations within a
module are given by reference to Platform North.
We have seen how Elevation Drawings and Plot Plans are drawn to scale and that
they are oriented to Platform North.
We have discussed some of the uses to which Plot Plans and Elevation Drawings
are put, such as escape route identification, location of emergency and safety
equipment etc.
You should note that whereas Elevation Drawings and Plot Plans are drawn to
scale, Process Flow Diagrams and Piping and Instrument Diagrams are NOT
drawn to scale.
20
the Separators
21
Activity 1
Manifolds
The next items of equipment we come to are
the TEST MANIFOLD and the PRODUCTION
MANIFOLD.
Test Separators
Wells
The wellheads are not depicted on this diagram, however we will be looking at wellheads later when we look
at P&IDs. The well flowline choke valve and divertor
valves are indicated on this diagram.
22
Test Yourself 3
Take a moment or two to jot down some information about the Test Separator operation
from the information on the PFD.
1. Where is the gas from the test separator normally routed to ?
2 Where is the oil normally routed to ?
3. What type of pump is P-0201 Test Separator Oil Pump and what purpose does it serve ?
4. What type of pump is P-0202 Test Separator Water Pump and what purpose does it serve ?
5. Assuming you have figured out the reason for the pumps, what will we do with the gas in
these circumstances ?
6. What can you glean from the information given about the start-up fuel gas line ?
7. How is the separator pressure normally controlled ?
8. The normal operating pressure is ............... bara. How did you obtain this information ?
9. How is the oil level controlled ?
10. How is the interface level controlled ?
23
Test Yourself 4
The main production system is very similar to the Test Separator System. This Test Yourself will actually teach you the workings of the
Separation and Oil Export Systems.
1. How many stages of separation are there, and what is
the operating pressure for each stage ?
You will find the correct answers in Check Yourself 4 on Page 50.
24
Pig Launcher
We can see that the crude oil pipeline is fitted with PIG
LAUNCHER MO-0301. Pigs are items of equipment
which are pushed through the pipeline to keep the
pipeline clean. Crude oil often contains wax which
will tend to stick to the walls of the pipeline where
it is coolest. Pigs are therefore launched into the
pipeline on a regular basis to clean the pipeline.
Test
Yourself 5
25
Gas Compression
We know, in this instance, that we have a large
amount of gas because of the gas / oil ratio of the
crude oil leaving the reservoir.
If it were only a small amount of gas it would not be
cost effective to provide gas treatment and
compression facilities to export the gas, especially
if it can be used within the process as a source of
fuel gas.
The gas from the Production Separators and the Test
Separator, as we saw earlier, join together before
entering the HP Compressor Suction Coolers.
You should now lay out Figure 10 which is the
PFD for Gas Treatment and Compression.
26
Test Yourself 6
1.
The PFD indicates that there are four HP Compressor Suction Coolers (H-1103A-D),
yet there are only two HP Compressor Suction Drums (V-1103A/B) and two HP
Compressors C-1103A/B. What do you deduce from this information ?
2.
What type of heat exchanger are the coolers on the gas treatment and
compression system ?
3.
4.
What process is carried out in the gas treatment system ( System -13) ?
5.
Can you spot anything unusual regarding the export compressor suction cooling facility ?
You will find the correct answers in Check Yourself 6 on Page 51.
27
Satisfaction
Mass Balance
The table on the PFD appears to be just a mass
of numbers. However, when you have cracked the
code, you will find that it is actually packed full of
useful information. The table represents the Mass
Balance ( often called the Material Balance ) of
the process.
The Mass Balance sheet accounts for the flow of
fluids as it passes through the process. In other
words it is a chart which shows us the BALANCE
between what comes into the process and what
leaves the process.
We will take a look at the column on the left hand
side before we go any further. I will give you a brief
explanation of what each title means. They are :
STREAM NUMBER - if you look at the flow diagram
you will see small diamond shapes with numbers
inside. These are the Stream Numbers to show
you at what point in the process the mass balance
data refers to.
28
COMPOSITION MOL%
NOTE :
C1 is an abbreviated form of C1H4 which is the chemical formula
for methane.
The remaining hydrocarbon composition is as follows :
C2H6 - ethane
C3H8 - propane
iC4H10 - iso-butane
nC4H10 - normal-butane
iC5H12 - iso-pentane
nC5H12 - normal-pentane
nC6H14 - normal-hexane
C7+ - this section refers to all crude oil components which are
heavier than heptane.
29
30
Test Yourself 7
1. (a) What are the temperatures at Stream
number 11 and Stream number 13?
31
Summary of Section 3
Spend some time looking at Figures 9 and 10 until you are familiar with them and their relationship with each other. If you can understand Mass Balance
Data, you are well on the way to an overall understanding of the Process to which it refers.
In this Section we have seen that Process Flow Diagrams can reveal a wealth of information.
From this information we could work out WHY the designer chose to design the process system as depicted on the Process Flow Diagram, and HOW
the process should operate.
The process fluid from the wells is a known factor, and to meet the known specification for oil and gas export into the pipelines are the process
objectives. The designer then has to design the process and equipment required to meet these objectives.
We looked at the crude oil side of the process and identified the main items of equipment. We then identified the gas processing equipment.
I then asked you to bring the drawing alive by highlighting the various flows. This helped you to readily identify the gas, oil, and water systems.
We used a Test Yourself approach to learn how to read a process flow diagram, by answering various questions regarding the operation of the test
and production separator systems.
I then went on to explain the Mass Balance sheet, to give you an insight into how to use the information provided, to help you to understand better how
the process is expected to operate.
In the next section we will look at Piping and Instrument Diagrams. We will be asking a lot of WHY ? questions, and trying to find out the answers from
the drawings.
32
8 LV by-pass line
a butterfly valve
a pipe reducer (12 x 8)
3/4 drain tapping
33
Wellheads
We will start by looking at the title of Figure 11 which
is in the bottom right hand corner. The drawing is
PIPING AND INSTRUMENT DIAGRAM - TOPSIDE
PRODUCTION WELLHEAD TYPICAL
If you look at Note 1 you will see that this drawing
is typical of 28 production wells. We already know
from the Process Flow Diagram that our installation
has 28 Wellheads. This tells us that what we are now
looking at is one of the 28 production wellheads.
Before we look at this P&ID in some detail, I would
like you to note that the Wellhead Control Panel
JP-0101 is identified as a seller system and that
reference must be made to the relevant seller
drawing. This often happens on P&IDs as the
manufacturers of certain self-contained items of
equipment will supply their own P&IDs. As a general
rule they are held in a separate file with all of the
other information on the equipment.
A prime example of such a system is where a
wellhead control panel is purchased and provided
on site as a skid mounted package. The wellheads
P&ID shows the wellhead control panel as a box
and refers the reader to See Seller Drg No. P0176D0002.
I will now explain some of the detail provided in this
P&ID, and then we will revert to a Teach Yourself
method once again.
34
NOTE :
The instrument tag numbering system used in
this P&ID, taking PI T0102B as an example, is as
follows:
PI Pressure Indicator
T
Topsides well
01 System number 01
02 Unique identification number for this
instrument
B Used to indicate that there is at least one
other PI with the same number indicating
this pressure
The letter T for topsides infers that there must be
subsea wells routed to this installation. The letter
S would be used instead of T for subsea well tag
numbers.
If you locate the hydraulic line to the master valve
(MV T0103), you should note that this also has a
wireline control connection point (414 barg). These
connection points are used by the wireline crew
to allow them to maintain control of the hydraulic
supply to the DHV and master valve, whilst carrying
out wireline operations in the well. This prevents
ESD signals closing the valves, resulting in the wire
being cut. Obviously if there is a real emergency
situation, then the wireline crew would be instructed
to close the valves regardless.
35
HIPS
DCS
36
The right hand take-off is the main flow line from the
wellhead. The well fluids flow through the hydraulically operated production wing valve PWV T0109
which is fitted with open and closed indicators similar to the ones fitted to the hydraulic master valve.
37
NOTE :
PSHH T0114 and PSLL T0115 are fitted at this
location so that they can measure the pressure of
the flow line downstream of the flowline choke valve.
If the pressure rises too high at this point (e.g. 205
barg ) or too low ( e.g. 5 barg ) this would indicate
that there is a major problem with the flowline.
Temperature indicating alarm switch TIA T0116
which will indicate a high temperature alarm
signal in the CCR.
Flowline isolation valve PT 003.
Please take the time to make sure that you are fully
familiar with Figure 11, and my explanations, as we
will now change back to the Test Yourself method
once again.
Using Figures 12,13,14 and 15, I will ask a number
of questions and you should use your knowledge
and experience to work out the answers. You also
have the information contained within Book 2 to
refer to as necessary.
Separation
38
Test Yourself 8
1. V-0101 is a
. phase separator
3. What does the line number and the piping symbol tell you about
the line from the fuel gas knock-out drum V-1501 ?
4. There are three PSVs on top of V-0101. Why has one of them
(PSV 01007C) got the upstream valve closed ?
(c) How will the operators in the CCR know that it is open ?
continued...
39
12. What level is LICA 01013 controlling, and where would you expect to
find LCV 01013?
14. What type of meter is used to measure the oil flow from the separator ?
15. What type of instrument is DT 01189 which is located on the oil outlet
line, and what purpose does it serve ?
continued...
40
Test Yourself 9
1. List the types of valves that are used for the booster pump suction and suction valve
bypass line.
Suction Valves
Bypass Valves
2. What is the piece of equipment on the pump suction line downstream of the suction
valves ?
3. What instrumentation protects the pump from pumping against a closed discharge valve ?
continued...
41
continued...
42
Gas Compression
Figures 14 & 15 are P&IDs of a LP Gas Compression
train. As with the previous Test Yourself exercises,
you should take some time to study the general
layout and familiarise yourself with the main flows.
Test Yourself 10
1. Using the information provided on Figures 14 &15, give a brief description of the gas flow
from the 3rd stage separator V-0103 to the IP compressor suction cooler H-102A.
2. With reference to suction cooler H-1101 A, which of the following statements is correct:
(a) If there was a tube rupture the gas would pass into the shell side of the cooler
and contaminate the cooling medium system.
(b) If there was a tube rupture the cooling medium would pass into the tube side of
the cooler and contaminate the gas compression system.
continued...
43
You will find the correct answer in Check Yourself 10 on Page 55.
44
Summary of Section 4
In this Section we have seen how Piping and Instrument Diagrams can be interpreted
to reveal a wealth of information about the process and plant utilised for a specific
operation.
We can see how the design engineer expects to achieve his objectives by looking at
the equipment, plant and control systems he has incorporated within the process.
Understanding what the design objectives are goes a long way to understanding how
the process operates.
We must however, never forget the importance of the hands on approach to learning
the process and remember that reading and gaining knowledge from the P&IDs plays
a major part in the learning process, but only if used in conjunction with the practical
application.
Book 2 contains several P&IDs, some of which we have not used in this unit. I
recommend that you take time to study and make yourself familiar with the detailed
information provided on all the P&IDs contained in this unit, as they are all potential
sources for future examination questions.
You should pay particular attention to the symbols and abbreviations illustrated in
Section 1 and practice identifying them and drawing the symbols. Another useful
exercise would be to practice drawing simplified sketches, using the appropriate
symbols. There will be a requirement in the exam paper for you to demonstrate your
ability to use the correct symbols in reproducing some simplified diagrams.
Test yourself 11 gives you some exercises to help you practice using symbols.
45
Test Yourself 11
1. Identify prefix letters that are normally used, and any common
alternatives, for tag number identification of the following equipment
pump............
heat exchanger...............
filter...........
compressor............
separator..............
electric motor........
2. Identify the products / systems that are normally identified by the following
product designation codes for line designation.
SW or WS
PL or PO
FG
PW
Al or lA
CM or CW
PG
LO
FO
FW or WF
3. Identify the type of valve from the following typical P&ID abbreviations:
(a) ESDV
(b) UHMV
(c) PSV
(d) SSSV
(e) SSIV
(f) BDV
4. Draw the correct symbol for the following different types of valves.
hand operated choke valve
fail open control valve
wedge gate valve
butterfly valve
plug valve
pressure vacuum breaker
check valve
4 way valve
3 way valve
diaphragm actuated pneumatic valve
46
Check Yourself 1
1.
Separator Vessel.
2.
BS1553 Part 1.
3.
4.
These drawings indicate the actual situation of the process as it has actually been built. The As Built drawings remain
subject to the amendment and revision process.
5.
Revision changes are normally identified by a cloud drawn around each alteration.
47
Check Yourself 2
Go to the North walkway and then turn right and walk to the East side of the module. Turn
right again and head South passing on the East side, the escape chute, the east stairs,
Dehydration KO Drum and the Glycol Regeneration Package. On the west side of the
walkway you will pass the Oil Export Pumps P-0301A/B/C. After you have passed the Export
Pumps turn right down the next walkway and head West. You will pass LP Condensate
Pumps P-1101A/B on the south side of the walkway, and Oil Coolers H-00101 A/B on the
north side. At the point that the walkway turns North, you will find the Main Closed Drain
Vessel V-2801 on your left hand side.
OR
Go to the North walkway and then turn left and walk to the West side of the module passing
Produced Water Coolers H-2701 A/B and LP Flare Drum V 1602 on the South side of the
walkway. At the West end of the walkway turn left again and head South passing on the East
side, Third Stage Water Pumps P-2701 A/B and Oil Booster Pumps P-0101 A/B/C. On the
west side of the walkway you will pass a laydown area, hose loading area, the North Bridge
and the North Stairs. After you pass the North Stairs, you will find the Main Closed Drain
Vessel V-2801 on the East side of the walkway.
48
Check Yourself 3
1. HP compressor suction cooler.
2. Second stage separator V-0102.
3. Centrifugal pump. It appears that it will only be
required if the test separator operates at lower
than normal pressures when the oil would not be
able to flow into V-0102.
4. Screw pump. Again it appears that it will only be
required if the test separator operates at lower
than normal pressures when the produced water
would not be able to flow to the produced water
system.
5. Pressure control will be maintained via the
pressure control valve to the flare.
8. The
for stream 1 on the inlet line to the first
stage separator points you to the appropriate
column in the mass balance data table where
the pressure is given.
49
Check Yourself 4
1. Three Stages.
1st stage pressure 26.58 barg.
2nd stage pressure 14.51 barg.
3rd stage pressure 8.65 barg.
2. 1st stage pressure to HP compressor.
2nd stage pressure to IP compressor.
3rd stage pressure to LP compressor.
3. Plate cooler using sea water.
4. Three, P-0101A/B/C.
5. One for each pump, H-0301A/B/C.
50
Check Yourself 5
The test separator can be used for limited 1st
stage separation, although the facility to test
wells during this period would be lost.
Check Yourself 6
1. There are two suction coolers for each compressor due to the large
volume of gas and the high cooling duty requirement.
2. Shell/tube.
3. Centrifugal.
4. Dehydration,
5. There is only one to serve both compressors which means that there will
only ever be one compressor on line at any one time and that the cooling
duty is very low.
51
Check Yourself 7
1. (a) Stream number 11 is 88.5C.
Stream number 13 is 32.2C.
(b) Cooling the gas through suction cooler H-1102A/B.
2. Gas compression through C-1101 A/B.
3. The gas from the compressor discharge (Stream 10) is commingled in
Stream 11 with the warmer gas from V-0102 (Stream 5).
Temperature
Vapour MW
Liquid density
Liquid flowrate
Standard vapour f/rate
Z factor
Comp MOL %
PPM (MOL) H2S
Free water flowrate kg/h
4. The pressure drop across the LCV from 68 bara to 27.58 bara has
created a proportional temperature drop of the NGL.
5 (a) From the export compressor suction scrubber V-1105A/B.
(b) The higher pressure of 68 bara at this stage in the process
combined with the 10.5C temperature drop created across H-1106
and the PCV on the inlet to V-1105A/B make the ideal conditions to
maximise the removal of propane by liquefying it.
52
Check Yourself 8
2. It requires to be reset locally.
53
Check Yourself 9
1.
7.
PR-PD-0086-01.
8.
2.
Suction strainer.
p 3.2 barg.
3.
Temperature -10C/110C.
4.
Parallel.
9.
P ( personnel protection )
5.
6.
PEA01172LL
10.
The recycle line valves are locked open and the FV is fail open.
This means that there will always be a flowpath back to the
3rd stage separator.
54
Check Yourself 10
1.
The gas from the suction drum is routed forward to the suction of LP
compressor C-1101 A. The gas from the discharge side of C-1101A
is routed to the IP compressor suction cooler H-1102A. An anti
surge/ recycle line is incorporated in the compressor discharge to
maintain a flow through the compressor and back to upstream of
the suction cooler H-1101 A.
2.
(b)
3.
continued...
55
8.
9. No.
56
Check Yourself 11
4. You will find the correct symbols in Book 2 on Pages 12-19.
Flow meter Q
Heat exchanger H, E, X
Filter F
Compressor C, K
Separator S, V
Electric motor M
SW or WS
PL or PO
FG
PW
Al or IA
Seawater
Process liquid/oil
Fuel gas
Produced water
Instrument air
(a) ESDV
(b) UHMV
(c) PSV
(d) SSSV
(e) SSIV
(f) BDV
CM or CW Cooling medium/water
PG
Process Gas
LO
Lube oil
FO
Fuel oil/diesel
FW or WF
Fire water
57