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The 10 Steps of Piping Design and Process Plant Engineering
Process Engineering

How to Design A Process Plant in 10 Steps

May 14, 2023 No Comments

The process of designing and building a process plant is a complex and multifaceted task that requires a team of professionals with expertise in various areas, including chemical engineering, mechanical engineering, electrical engineering, and construction.  If you are looking to find out the specific process then you have come to the right place.  We look at the various steps and also share the tools which you may use at various stages.  As you may be involved with only a certain step due to your specific engineering discipline we’ve made it easy for you to skip to the section or sections that are most relevant to you with the Table of Contents with brief descriptions:

Table of Contents

  1. FEED (Front-End Engineering Design): This is the initial phase of the project, during which the scope and objectives of the project are defined and a conceptual design is developed.
  2. Design Study Phase: During this phase, the design team studies and assesses the technical and operational requirements of the project, as well as the site conditions and constraints.
  3. Plot Plan: The plot plan is a top-down view of the project site that shows the location of the piping system and other process equipment.
  4. Conceptual Design Phase: During this phase, the design team develops a high-level design for the piping system, including the layout, routing, and sizing of the pipes.
  5. Detailed Design: This phase involves the creation of 3D models of the piping system and the process equipment, as well as the development of detailed design drawings and specifications.
  6. Engineering: During this phase, the design team performs engineering analysis, such as pipe stress analysis and code compliance, and specifies the materials and components to be used in the piping system.
  7. Piping Isometric and Fabrication Drawings: These are detailed drawings that show the layout, routing, and dimensions of the piping system, as well as the fabrication details for the pipes and fittings.
  8. Construction Drawings: These are drawings that show the installation details of the piping system, including the support locations, anchor points, and instrumentation.
  9. Procurement: This is the process of purchasing the materials and components needed for the piping system.
  10. Installation and Commissioning: During this phase, the piping system is installed and tested to ensure that it meets the design specifications and is ready for operation.
  11. Maintenance: Once the piping system is in operation, it will need regular maintenance to ensure its continued reliability and performance. This may include activities such as cleaning, inspection, and repair or replacement of components as needed.

1. Front-End Engineering Design

Front-end engineering design (FEED) is the process of defining and developing the technical and commercial aspects of a project in sufficient detail to allow an accurate assessment of its overall cost, schedule, and risks. FEED typically follows the conceptual design phase and precedes the detailed design phase of a project. It involves the preparation of design documents, such as process flow diagrams, piping and instrumentation diagrams, and equipment specifications, as well as the identification of materials and equipment required for the project. The goal of FEED is to define the project scope, determine the necessary resources, and establish a baseline for the detailed design and construction phases of the project.

Industry Survey for Determining the State of Practice of Front End Engineering Design for Industrial Construction | Practice Periodical on Structural Design and Construction | Vol 25, No 4
Front-End Engineering Design (FEED). Source: ASCE Library

2. Design Study Phase

The design study phase is a critical phase in the process of designing and building a process plant. It follows the conceptual design phase and precedes the detailed design phase. During the design study phase, more detailed information is developed based on the preliminary design. This phase involves more detailed calculations and analysis to determine the size and type of equipment needed, as well as the layout of the plant. The design study phase also includes the preparation of piping and instrumentation diagrams (P&IDs) and process flow diagrams (PFDs), which provide a detailed representation of the process and the flow of materials and energy through the plant. The goal of the design study phase is to refine the design and identify any potential issues or challenges that may need to be addressed in the detailed design phase.

Design Study Phase of a process plant engineering project.
Design Study Phase of a process plant engineering project. Source: Greg Pajak – P. Tech (Eng.), ISA84 SIS Expert, Instrumentation, Functional Safety and FGS Technical Consultant

3. Plot Plan or General Arrangement(GA) Drawing

The design study phase is a critical phase in the process of designing and building a process plant. It follows the conceptual design phase and precedes the detailed design phase. During the design study phase, more detailed information is developed based on the preliminary design. This phase involves more detailed calculations and analysis to determine the size and type of equipment needed, as well as the layout of the plant. The design study phase also includes the preparation of piping and instrumentation diagrams (P&IDs) and process flow diagrams (PFDs), which provide a detailed representation of the process and the flow of materials and energy through the plant. The goal of the design study phase is to refine the design and identify any potential issues or challenges that may need to be addressed in the detailed design phase.

Plot Plan Design: Process Requirements - Chemical Engineering | Page 1
Plot Plan General Arrangement Drawing for a Process Plant. Source: Chem Eng Online.

4. Conceptual Design Phase

The conceptual design phase  starts with the Process Flow Diagram (PFD) and client specifications, and the project scope is defined during this phase. The working documents used during this phase are the PFD and the Conceptual Plot Plan. Based on the PFD, a large chemical plant or offshore production facility is sub-divided into several small, manageable areas. A Plot Plan is then generated for each area, and boundary limits for each area are specified using spatial coordinates, known as match lines. The conceptual design phase results in preliminary sizes and locations of major equipment, which is used to generate the plot plan for use during the design study phase. The goal of the conceptual design phase is to define the overall scope and direction of the project.

Conceptual Design

Conceptual Design is at The Heart of Process Engineering for a Process Plant. Source: Chem Eng Online.

5. Detailed Design

The detailed design phase is where the design team takes the high-level design from the conceptual design phase and creates detailed design drawings, 3D models, and specifications for the piping system and process equipment.  During this phase, the design team uses computer-aided design (CAD) software to create detailed 3D models of the piping system and process equipment. These models include all of the piping, fittings, valves, pumps, and other components of the system. The 3D models are used to ensure that the piping system is designed correctly, with the correct dimensions, and that all components fit together properly.

The design team also creates detailed design drawings that show the layout, routing, and dimensions of the piping system. These drawings include information about the materials to be used, the type of welding to be used, and any special instructions for the installation of the piping system.  The specifications created during the detailed design phase include information about the materials and components to be used in the piping system. These specifications outline the type and grade of materials to be used, the size and rating of pipes and fittings, and any special requirements for valves, pumps, or other components. The specifications also include information about any special welding procedures or testing requirements.

detailed design indiworks
During Detailed Design the Design Team Uses Computer-aided design (CAD) Software . Source: Dalei

6. Engineering

During the Engineering phase, the design team will perform various engineering analyses to ensure that the piping system is safe and meets all necessary codes and standards. This may include pipe stress analysis to ensure that the piping can withstand the forces and pressures it will encounter during operation, as well as flow analysis to ensure that the system will operate efficiently.

In addition to the engineering analysis, the design team will specify the materials and components to be used in the piping system, taking into account factors such as compatibility with the process fluid, corrosion resistance, and cost. They will also determine the sizes and ratings of the pipes, valves, and fittings, and create a bill of materials (BOM) that specifies the quantity and type of each component needed for the project.

Engineering IndiWorks
Engineering. Source: Cade Engineering

7. Piping Isometric and Fabrications Drawings

Piping Isometric and Fabrication Drawings are detailed drawings that show the layout, routing, and dimensions of the piping system, as well as the fabrication details for the pipes and fittings.  The isometric drawing is a 3D representation of the piping system that shows the size and shape of the pipes and fittings, as well as their connections and orientation. Isometric drawings are particularly useful for identifying potential clashes or interference between different components of the piping system.

Fabrication drawings provide detailed information on how the pipes and fittings should be fabricated, including the dimensions, tolerances, and surface finish requirements. These drawings also specify the materials to be used for each component, as well as any special requirements such as welding procedures or non-destructive testing.  The piping isometric and fabrication drawings are important deliverables that are used by the construction team to fabricate and install the piping system. They are also used by the quality control team to ensure that the piping system meets the design specifications and applicable codes and standards.

Piping Isometric IndiWorks
Piping Isometric Piping Isometric and Fabrication Drawings are detailed drawings that show the layout, routing, and dimensions of the piping system. Source: Fitter Training.

8. Construction Drawings

During the Construction Drawings phase, the design team creates detailed drawings that provide the necessary information for the installation of the piping system. These drawings will include information on the location and layout of the piping system, as well as details on how the piping will be supported and anchored to the structure.

Construction drawings may also include information on the instrumentation and control devices that will be used to monitor and control the piping system, such as valves, pumps, and pressure gauges. In addition, construction drawings may specify the materials to be used for piping supports, hangers, and clamps, as well as the type and size of bolts and fasteners needed for installation.  The construction drawings will be used by contractors and skilled laborers during the installation phase of the project. By providing detailed instructions and information on the design, the construction drawings help to ensure that the piping system is installed correctly and meets the required design specifications.

Construction Drawings IndiWorks
The design team creates construction  drawings that provide the necessary information for the installation of the piping system. Source: Cannon Design

9. Procurement

The procurement process typically includes the creation of a detailed bill of materials (BOM) that lists all the materials and components needed for the piping system, along with their quantities, specifications, and expected delivery dates. The BOM is used as a reference throughout the procurement process to ensure that the correct materials are ordered and delivered on time.

Procurement involves identifying suitable vendors and suppliers, obtaining quotes and bids, and negotiating contracts.  Once the materials and components have been procured, they are inspected and verified to ensure that they meet the required specifications and quality standards. Any defective or non-conforming materials are returned to the supplier for replacement or refund.

Procurement IndiWorks
Procurement involves identifying suitable vendors and suppliers, obtaining quotes and bids, and negotiating contracts. Source: OpenBOM

10. Installation and Commissioning

During this Installation and Commissioning, the piping system that has been designed and fabricated is installed in the field, and the final testing and commissioning takes place to ensure that the system is ready for operation.  Installation of the piping system involves a variety of activities, such as excavation and installation of underground piping, above-ground pipe installation, and installation of pipe supports and hangers. The installation process must follow specific procedures to ensure that the system is installed correctly and that the piping is not damaged during the installation process.

Once the piping system is installed, it undergoes testing and commissioning to ensure that it meets the design specifications. The testing may involve hydrostatic testing, where the system is filled with water to check for leaks and pressure integrity, as well as other types of non-destructive testing. Once the testing is complete, the system is commissioned and brought online.

During the commissioning phase, the system is checked to ensure that it operates correctly, and all control systems and instrumentation are working as designed. The commissioning process may also involve simulation of different operating conditions to ensure that the system can operate safely and efficiently under various circumstances.

Installation and Commissionig IndiWorks
Once the installation and commissioning process is complete, the piping system is ready for operation. Source: Deep South Crane

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How-To-Become-A-Plant-Engineer-At-Different-ProcessHow to Become a Plant Engineer at Different Process Plants?
How-To-Become-A-Plant-Engineer-At-Different-Process
Process Engineering

How to Become a Plant Engineer at Different Process Plants?

November 21, 2022 No Comments
Table of Contents

 

So you want to become a Plant Engineer?  Well whether you just finished your engineering diploma or degree or have been in industry for a long time, one thing is for sure; you need to understand what Process Plants are.  Becoming a Plant Engineer is mostly based on the experience you gain throughout your engineering career so it is extremely important you understand where you can gain the experience needed in order to become a Plant Engineer one day.  So, let’s start with understanding – what is a process plant?   Process plants, also referred to as factories, are engineering facilities where raw materials are transformed chemically and physically into completed goods or into intermediate products that require additional processing.

Types of Process Plants

Examples of process plants include the following (click on link to learn more about the process plant you are interested in):

 

Why Do We Need Process Plants?

Though are many more types of process plants, the processing facilities listed above play a vital role in meeting the basic needs of humanity.  This is why it is important for any aspiring Plant Engineer to own a physical copy of the books listed above as these will act as handbooks which you will use throughout your engineering career, a truly valuable resource to have. With the book available on site for reference you will be able to carry out proper design, maintenance and operation of such facilities. This will bring you a step closer to becoming a Plant Engineer as steady, dependable supply of materials and products required for comfortable and productive living in the contemporary modern world will be produced consistently at the facility at which you work. 

Building strength in chemical engineering through process optimization

Engineers design and build process plants in order to meet the most basic needs of humanity [Source: Elsevier]

How Are Process Plants Designed?

Plant Layout and Piping Design involve many activities which can initially seem overwhelming – however once broken down into project phases the tasks to completed become easier to manage, these include:

•Development and the continuous refining of “Plot Plans”. Plot plans are depictions of the exact location of major equipment and their associated infrastructure (foundations, ladders, platforms etc.). These plot plans are created by creating the process, client specification, quality, environmental and health and safety requirements. The coordinates of the process plant used extensively in determining and specifying the locations of the equipment.
• Determining the sizes and locations of nozzles. a nozzle is a cylindrical or round spout at the end of a pipe, hose, or tube used to control a jet of gas or liquid.

• Routing of pipes. The planning of pipeline layout, which includes considerations of neatness, economy, and safety. Pipe routing must consider the effects of vibration, corrosion, and normal service on pipes before deciding where to lay them.
• Designing of accessory components of major equipment. These accessory components include foundations, platforms, and stairways.
• Specifying safety equipment and their locations. In order to comply with health and safety requirements and standards the location of safety equipment has to be indicated based on the specification for the equipment. This equipment includes fire hydrants and safety showers.
• Multi-disciplinary interaction between engineering specialties. Being conscious of the location of instruments, structures, control valves, electrical raceways and other ancillary plant items is critical when carrying out pipe routing.

How are process plants designed?

Steps in the design of process plants [Source: Shikin Aziz ]

 

How Are Process Plants Built?

Process plants consist of various types of equipment, such as; piping systems, instruments, electrical systems, electronics, computers and control systems.  This is what makes the design of process plants such a complex undertaking.  The complexity of process place requires team effort involving different disciplines of engineering: process (chemical), mechanical, piping, electrical, instrumentation, controls, materials and project management. In addition to the team effort, on the individual level, it requires considerable management and coordination skills – skills which are critical for anyone looking to become a Plant Engineer. 

When building a Process Plant the goal is to design, construct and commission the facility in the most cost-efficient way possible.  This must be achieved  while still meeting the process requirements of the facility and within all specifications given by the client.  Th most important part of the entire build process is to ensure that the Plant will operate in a safe and reliable manner. Besides these, there are other factors that need to be taken into consideration when designing process plants, and they are:

  • Designing, engineering and constructing the facility according to the initial project schedule and getting the plant on stream as quickly as possible.
  • Cutting out or minimising field rework, which increases plant construction costs quite significantly.
  • Constructability – construction feasibility review, a process in construction design whereby plans are reviewed by others familiar with construction techniques and materials to assess whether the design is actually buildable.
  • Maintainability –  the probability that a failed component or system will be restored or repaired to a specified condition within a specified period or time when maintenance is performed in accordance with prescribed procedures..
  • Operability – the ability to keep a piece of equipment, a system or a whole industrial installation in a safe and reliable functioning condition, according to pre-defined operational requirements.
  • Compliance to quality, environmental and health and safety requirements – this requires complying to ISO 9001, 14001 and 45001 related standards, respectively.
  • Minimising costs.

Interaction of various engineering disciplines in process plant layout and design

Interactions of various engineering disciplines in plant layout and design. [Source: ]

Skills Needed to Become a Plant Engineer or Piping Engineer

You may have seen them on a job description for that Senior Piping Engineer or that Plant Engineer role you’ve been working towards, well – that’s because they are truly needed.  The list below the skills which you must inherently possess to be a proficient Pipe Design or Plant Engineer.   

  • Full understanding and detailed knowledge of the process that will be used in operation of the plant.  This will allow you to know the function of all equipment in the process plant. You can get this information from the Process Flow Diagrams(PFDs) which are generated the process engineering department.
  • Understanding of the operations of all equipment and their maintenance procedures.
  • Attention to detail and common sense in terms of technical aptitude that allows you to exhibit sound engineering judgement.
  • Being able to think creatively  in order to develop solutions relating to layout problems and challenges.
  • Being able to think and move objects in your mind in order to visualise spatial relationships between plant items in three dimensions.
  • Being proficient with Computer Aided Design (CAD) tools such as 3D modeling software and pipe stress analysis software.  It is advised to develop expertise with the Autodesk Suite of Software, specifically AutoCAD Plant 3D.
  • Brilliant communication skills – this is applicable to both technical and non-technical communication.  Should you wish to develop your communication skills as an Engineer read Communication Skills for Engineers – The Basics.
  • Being able to work well as part of a team.  This is critical in order to function effectively as a member of a multi-disciplinary project team.
  • Being able to communicate issues and problems relating to plant layout effectively to the  project management team.
  • Being able to generate, maintain and update project drawings and documentation as and when needed.
  • Awareness that conscientious, quality effort during the design and engineering phase can shorten project schedules resulting in economic benefits and client goodwill.

Plant Engineer or Piping Engineer Skills

Skills need to become a Plant Engineer or Piping Engineer [Source: Arcelor Mittal]

What Data is Used in Process Plant Design?

Large amounts of data is generated and made use of in the design of process plant.  These are mostly generated by the plant layout and piping design engineering team.  The data generated contributes significantly to the overall quality of the project.  This is why it is necessary to ensure data integrity and accessibility through proper management of project and process plant data.  Plant data can be broadly categories and the 3 categories of Process Plant data are:

 

  1. Project data is made up of information such as the location of the process plant, access roads, applicable standards, regulations and codes or bylaws, climate  data (rainfall, wind speed and wind direction, humidity and pressure, and average temperature), seismic activity, waterways, railways etc.
  2. Design and engineering data is generated internally at the design and engineering phases of the project. Design  and engineering data includes; equipment that’s needed and their respective sizes, service conditions (humidity, temperature, pressure etc.), and mass flow rates.
  3. Vendor data consists of information provided by equipment suppliers and contractors in the form of vendor drawings and data sheets.  

Data generated in piping engineering

Project data, design and engineering data and vendor data are generated in process plant projects. [Source: Enginering360]

 

Rules of Thumb for Plant Layout and Piping Design

The approach to plant layout and piping design can vary depending on the nature of the plant and the project. For example, the design philosophy for an offshore facility is quite different from that for an onshore chemical plant simply because of limited space available on offshore platforms. However, there are a few useful rules of thumb that can be followed.

  • Knowledge and understanding of project requirements and project documents.
  • Conservation of space and resources.
  • Arrangement of equipment in a neat, organised manner taking into account process needs and safety.
  • Attention to detail including adjacent equipment, supports and other items, which can cause potential clashes between piping and equipment/supports.
  • Consideration of constructability, operability and maintainability of the plant.
  • Routing of pipe in a neat, orderly and symmetrical manner keeping in mind the future needs of the plant.
  • Avoiding excessive changes in elevations and directions.
  • Ensuring consistency in design.
  • Avoiding excessive amounts of relocations and revisions by “doing it right the first time”.

Rules of thumb for plant layout and piping design

Rules of thumb for plant layout and piping design. [Source: Amazon]

Common abbreviations used in Process Plant design

Terminology and jargon are always are critical factor of any field or industry.  This is moreso when it comes to Process Plant Design and Layout as it is usually the separating factor between being deemed competent or incompetent. In order to be able prove that you know what you are talking as a Plant Engineer, make sure that you are know the following abbreviations – thing of them as the ABCs of Plant Design and Piping Engineering.

  • N,S,E,W: North, South, East and West
  • CL: Centerline
  • El: Elevation
  • TOS: Top of Steel
  • BOP: Bottom of Pipe
  • POS: Point of Support
  • BBP: Bottom of Baseplate
  • ISBL: Inside Battery Limits
  • OSBL: Outside Battery Limits
  • AG: Above Ground
  • UG: Underground
  • φ: Diameter
  • OD: Outside Diameter of pipe
  • ID: Inside Diameter of pipe

Abbreviations used in piping

Common Abbreviations used in plant layout and piping design [Source: What Is Piping?]

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The 10 Steps of Piping Design and Process Plant EngineeringHow to Design A Process Plant in 10 Steps