Life Cycle of a Process Plant

1st Edition - December 4, 2021
Editors: Mahdi Nouri, Eberhard Lucke
Language: English
Paperback ISBN:
9 7 8 - 0 - 1 2 - 8 1 3 5 9 8 - 3
eBook ISBN:
9 7 8 - 0 - 1 2 - 8 1 3 5 9 9 - 0

Life Cycle of a Process Plant focuses on workflows, work processes, and interfaces. It is an ideal reference book for engineers of all disciplines, technicians, and business… Read more

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Life Cycle of a Process Plant focuses on workflows, work processes, and interfaces. It is an ideal reference book for engineers of all disciplines, technicians, and business people working in the upstream, midstream, and downstream fields. This book is tailored to the everyday work tasks of the process and project engineer/manager and relates regulations to actions engineers can take in the workplace via case studies. It covers oil, gas, chemical, petrochemical, and carbon capture industries. The content in this book will be interesting for any engineers (from all disciplines) and other project team members who understand the technical principles of their work, but who would like to have a better idea of where their contribution fits into the complete picture of the life cycle of a process plant.

This book shows the basic principles and approaches of process plant lifecycle information management and how they can be applied to generate substantial cost and time savings. Thus, the readers with their own knowledge and experience in plant design and operations can adapt and implement them into their specific plant lifecycle applications.

Cover image
Title page
Table of Contents
Copyright
Contributors
“Begin with the End in Mind.”
Chapter 1. General guidelines and definitions
1.1. Process design
1.2. Gated design process
1.3. Facility siting
1.4. Fabrication and construction terms
1.5. Sustainability
1.6. Lean manufacturing
1.7. CAFE
1.8. NextGen facilities
1.9. Business sectors
1.10. Capital estimate classifications
1.11. Permitting
1.12. Cradle to grave
1.13. Cradle to cradle
1.14. Internet of Things
1.15. Digital Twin
1.16. Other definitions
Chapter 2. Feasibility studies
2.1. Introduction
2.2. The process industries
2.3. The importance of chemistry
2.4. Chemical engineering: an essential skill
2.5. Phase equilibria
2.6. Chemical reactions
2.7. Chemical engineering drawings
2.8. Engineering skills
2.9. Business skills
2.10. Report writing
2.11. Classification of studies
2.12. Project planning studies
2.13. Feasibility
2.14. The feasibility study report
2.15. Pre-FEED work
Chapter 3. Process design
3.1. The role of a FEED package in the definition of the project
3.2. Importance of process design during FEED
3.3. Basis of Design
3.4. Process development
3.5. Role of process engineer during the FEED
Chapter 4. Cost estimating
4.1. Introduction
4.2. Basic concepts for studies
4.3. The engineering stage
4.4. Conceptual design emulation
Appendix A: Estimating gas pipelines and compressor stations
Appendix B: CDE modeling results for a gas plant amine unit
Chapter 5. Fabrication and construction
5.1. Construction management team
5.2. Quality of FEED and work packages
5.3. Procurement and expediting
5.4. Selection of fabrication method
5.5. Selection of construction method
5.6. Mechanical completion
Chapter 6. Commissioning and testing
6.1. Definition of terms
6.2. Testing
Chapter 7. Start-up and performance test
7.1. Readiness for start-up
7.2. Start-up plan and schedule
7.3. Status reporting
7.4. Temporary modifications for start-up
7.5. Material cost control
7.6. Training
7.7. System turnover to operations
7.8. Integrated approach
Chapter 8. Operation, maintenance, and turnarounds
8.1. Operations philosophy
8.2. Operations staffing considerations
8.3. Maintenance philosophy
8.4. Maintenance cost and budgeting
8.5. Turnarounds
Chapter 9. Process plant optimization, debottlenecking, and revamps
9.1. Overall procedure
9.2. Defining the boundaries
9.3. Setting the operating boundaries
9.4. Product values
9.5. Utility costs
9.6. What equipment to choose for initial review?
9.7. Process variables to consider
9.8. Energy optimization
9.9. Flow/capacity optimization
9.10. Financial optimization
9.11. Facilities optimization guideline
Chapter 10. End of plant life
10.1. Plant shutdown
10.2. Tank inventory management
10.3. Environmental considerations
10.4. Disposal or materials
10.5. Reuse
10.6. Repurpose
10.7. Most common mistakes
Chapter 11. Project management in oil and gas
11.1. Introduction
11.2. Project management in oil and gas industry
11.3. Project Management Body of Knowledge (PMBOK)
11.4. Conclusion
Index

Mahdi Nouri

Mr. Mahdi Nouri CEng Fellow of IChemE, Founder & Principal Consultant of Triumph Gas Technology Consulting in Houston, Texas. Mr. Nouri has over 23 years of solid experience in gas processing, cryogenic gas processing (NGL and LNG facilities), and CCUS (carbon capture and utilization including CO2 compression & dehydration, and transmission). Prior to forming Triumph, Mr. Nouri was Vice President of gas processing & LNG sector at Americas Region with Worley Group; Director of Upstream and Midstream with Jacobs Consultancy, and Technical Specialist of Gas Processing & LNG with Technology Division of Bechtel OG&C. Mr. Nouri has led consultancy, design, engineering, project management teams for gas plants and LNG facilities design small to large capacity, gas plants modularization, carbon capture, benchmarking, due diligence, feasibility and conceptual studies, PreFEED, FEED, economic analysis, Owner’s Engineer, operation readiness, technical services (plant optimization, operational excellence, troubleshooting, debottlenecking and operation support). Mr. Nouri holds a Bachelor of Chemical Engineering. He has published various papers in the world of gas processing, and technical reports for GPA Midstream, and has presented the keynote addresses for the AIChE Spring gas utilization conference in 2017 and 2019. He was also honored with the GPA Midstream Committee Volunteer of the Year Award 2018, the F&PD Outstanding Presentation Awards at AIChE/2015 & AIChE/2016. Mr. Nouri is also the Chairman of the Facility Design, Operation and Maintenance Committee, the Chairman of the Facility Forum, and member of the Program Committee since 2017 at GPA Midstream; Director of AIChE Management Division (2019 – 2021) and Director of AIChE F&PD (2017 – 2020), and Chairman of Gas Utilization Conference at AIChE spring meeting (2018 – 2021).

Affiliations and expertise

CEng FIChemE, Founder & Principal Consultant, Triumph Gas Technology Consulting, LLC, Houston, Texas, United States.

Eberhard Lucke

Mr. Lucke is a well-established and recognized expert in the oil refining and gas processing industries with over 30 years of experience as a consultant, engineer, and manager. Starting as process and technology engineer in one of Germany’s leading refinery, Eberhard completed a 2-year assignment in Venezuela before he moved to the USA. Working for several leading engineering and consulting firms in Houston he covered the regions Europe, Caribbean, North and South America in distinct roles like consultant, lead process engineer, owner’s engineer, project manager, department manager and company executive. He led studies and design work in oil refining and petrochemicals, gas monetization, carbon capture, storage and utilization, and biofuels manufacturing. In 2012 Eberhard founded Lucke Consulting Technology Services, LLC to utilize his technical expertise and industry experience in the growth and development of clients across the energy sector. Since then he supported many projects as owner’s engineer and consultant by providing design reviews, due diligence, and technical management. Eberhard serves on the advisory board for the Professional Science Masters Program (Environmental) at Rice University.

Affiliations and expertise

Chief Executive Officer, Lucke Consulting Technology Services, LLC, Houston, Texas, United States.