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Life Cycle of a Process Plant - 1st Edition - ISBN: 9780128135983

Life Cycle of a Process Plant

1st Edition

Authors: Mahdi Nouri Eberhard Lucke
Paperback ISBN: 9780128135983
Imprint: Elsevier
Published Date: 1st November 2021
Page Count: 250
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Life Cycle of a Process Plant focuses on workflows, work processes and interfaces. It is an ideal reference for process engineers working in the chemical, petrochemical and O&G industries. This book is tailored to the everyday work tasks of the process and project engineer, and relates regulations to actions engineers can take in the workplace via case studies. It is covers upstream, midstream and downstream fields. The content in this book will be interesting for any engineers (from all disciplines) that 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.

Key Features

  • EPA and OSHA regulations which relate to process plants are discussed
  • Covers the entire workflow process of a process plant from project initiation and design through to the commissioning stage
  • Authors bring their practical, hands on industry expertise to this book


Process engineers, project engineers, technical safety engineers, equipment engineers, instrument engineers, engineers who are interested in process design at oil and gas companies and engineering companies. This book can also be used as a reference text for senior plant design courses

Table of Contents

1. Introduction

Purpose of the book
Target audience
How to use the information

2. General Guidelines and Definitions

Design philosophies
Gate process vs continuous process
Project and process development phases – definitions
Energy Industry Sectors and differences in approach

3. Initial Evaluation: Pre-project Studies

Define the need/demand
Market studies
Process Ideas and Options that fit the demand/need
Licensed process vs Open Art
Size and pricing process options
Sites assessment and selection
Class 5 cost estimates
Preliminary economic analysis leading to identifying the preferred process route
Feedstocks identified with possible sources
Products and by-products and their use/disposal identified
Establishing a goal for plant capacity
Understanding the commercial opportunity and how to realize it
Options for project financing and which one to chose

4. Feasibility Study

Determine how a project is to be realized
Scope and method of construction
Setting the design basis including design case, feedstock, utilities, and site conditions (BEDD)
Technical feasibility:
Development of a feasible process scheme (with or without process licensor assistance)
Preliminary PFD, utility balances, sized equipment lists for process, utilities and off sites
Economic feasibility:
Class 4 cost estimate
Updated project economics
Environmental feasibility:
Permit requirements
Cost and schedule impact
Other regulatory requirements
Other considerations:
Project risks identified in design and construction
Understanding the technical basis for the project
Confirming the financial needs.

5. Process Design

The importance of the design basis (BEDD)
Licensor selection
Contingency and the importance of clear and accurate drawings
Process modelling techniques – selecting the best software for the job
Equipment design and the sizing: equipment list
Consulting with mechanical engineers over equipment type and maintenance needs
Preliminary vendor data
Reliability and maintenance considerations
Material selection
Significance of piping class
Finalizing operating and design conditions
Process data sheets
Utility balances
Storage needs
Process control concept
Start-up and shutdown, emergency operations
Health, safety and environment
Effluent summary
Process Licensor package and limitations to its scope
Process Design Package.

6. Engineering Design (FEED)

The significance of the contract, its scope and the basis for design
Integrating the process licensor package with 'Open Art' design
Process engineer involvement during FEED
Layout development, process safety, P&ID development, PHA (HAZID, HAZOP, other methodologies)
Consulting with instrument/control specialists over process control
Sizing of process control and pressure relief systems
Operating manual
Engineering design and what is produced
Roles of the various engineering groups and interfaces
When to freeze the scope of work and why
Reimbursable or fixed price construction?
Material take-offs and Class 3 vs. 2 cost estimates
Difference in time frame, accuracy of cost estimate.

7. EPC

Type of contract – EPC, EPCM, EPFC and more….
Engineering - where does it stop?
The procurement process
The supply chain
Handling of vendor data (drawings, specifications etc…)
Construction activities and planning processes
Modular vs stick-built

8. Commissioning/Start-up/Test Run

Commissioning planning – systems and start-up sequencing
Start-up considerations
Performance Test
Lender Reliability Test
Care and Custody transfer

9. Plant Operations

Maintenance – reactive, preventative and predictive
Planning turnarounds/revamps
Construction/maintenance work in an operating plant

10. End of life
Equipment conservation plans
Environmental considerations


No. of pages:
© Elsevier 2021
1st November 2021
Paperback ISBN:

About the Authors

Mahdi Nouri

Mahdi Nouri, CEng, FIChemE Leader of Midstream Operations, OG&C, CH2M Vice chair GPA Technical Committee Section A – Facility Design and Optimization AIChE, Technical Advisory IChemE, Member of Technical Commitee

Affiliations and Expertise

Leader of Midstream Operations, OG&C, CH2M

Eberhard Lucke

Eberhard Lucke Technology Director, OG&C, CH2M AIChE, Technical Advisory AFPM 2-time Q&A panel member Rice University Houston Professional Master’s Program Advisory Board Member

Affiliations and Expertise

Technology Director, OG&C, CH2M

Ratings and Reviews