Project Synopsis

Develop a detailed process design package for a new batch chemical plant for the production of oil field chemicals.

Project Summary


Process Engineering Associates, LLC (PROCESS) was contracted by the client, a multinational energy services and production company, to provide a detailed process design (FEL-3) package for the proposed U.S. plant.  This plant is a batch chemical blend facility that includes two batch blenders.  The two batch units are used to produce a variety oil-field chemicals.  Due to the many potential products scheduled for production, the plant requires several raw material storage tanks and charge pumps along with ancillary utilities (steam, reverse osmosis (RO) quality water, nitrogen, compressed air, etc.)

A process flow diagram (PFD) was produced for the blenders showing the range of potential raw material connections.  However, heat and material balances (HMBs) for a few selected products were produced.  These products were used as the basis for preliminary sizing and cost estimations.

PROCESS worked with the client to establish a process design basis that represented a range of potential products that establishes equipment sizing for a cost estimate.  PROCESS utilized commercial process simulation software to prepare the heat and material balances (HMBs) for a typical blend product.  Preliminary equipment sizing was based on the most stringent duties from the three HMBs.

PFDs and HMBs were also completed for each raw material storage tank or vessel.  These included the raw material charge pump and any required heating units for a given raw material.  In addition, process data sheets were produced for all heat exchangers, tanks, and pumps.  The energy balance portion of the HMB was used to calculate utility usage quantities for heating requirements and relief scenarios.  All storage tanks were designed in accordance with API-650 standards.

Piping and instrumentation diagrams (P&IDs) for the process including utilities (nitrogen, steam, plant air, and RO water) were also constructed by PROCESS.  From the P&IDs, line lists and instrument lists were generated. Instrument data sheets were completed for all instruments associated with the PLC control system.

A cost estimate was prepared based on the preliminary equipment sizes.

PROCESS also produced preliminary plot plans and equipment layout diagrams with assistance from the client.

A complete Front End Loaded Stage 3 (FEL-3) package that included the above-mentioned documentation was issued to the client for the purpose of issuing for bids to construct.

In addition to the traditional FEL-3 design package, PROCESS facilitated the Process Hazard Analysis (PHA) based on the issued P&IDs. PROCESS also constructed a complete set of Operating Procedures for the plant.

Industry Type

  • Oil Field Chemicals Manufacturing

Utilized Skills

  • Detailed process design

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