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Optimized Methodology to Build an Integrated Solution to Offshore Topside

Process Engineering

Article · July 2008

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Proceedings of the Eighteenth (2008) International Offshore and Polar Engineering Conference
Vancouver, BC, Canada, July 6-11, 2008
Copyright © 2008 by The International Society of Offshore and Polar Engineers (ISOPE)
ISBN 978-1-880653-70-8 (Set); ISBN 1-880653-68-0 (Set)
Optimized Methodology to Build an Integrated Solution to Offshore Topside Process Engineering
Jihyun Hwang1),4), Joonho Min1), Youngjoo Ahn1), Heechang Kim1), Hakjin Kim2), Myungil Roh3), Kyuyeul Lee4)
1) Samsung Heavy Industries Co., Ltd., 2) Woo-Byung Engineering Co., Ltd., 3) University of Ulsan, 4) Seoul National University
Seoul, Korea
ABSTRACT
An optimized methodology to build integrated solutions to offshore
topside process engineering is described. The method relies on the
concepts and procedures of FEED (Front-End Engineering Design), as
well as those of basic and detailed process engineering. For the purpose
of verifying the efficiency of the proposed methodology, which changes
process data processing from manual to automated and integrated, was
applied to a condensate stabilizer unit. That simulation indicated that
offshore business would benefit from the increase in engineering
efficiency as costs, schedule periods, and errors would be reduced. This
optimized methodology proposed by Samsung Heavy Industries (SHI)
would contribute to performing successful offshore projects in the
future.
KEYWORDS: Optimized methodology; Integrated solution;
Offshore topside process engineering; FEED; Basic process
engineering; Detailed process engineering; Automated and integrated
data processing
INTRODUCTION
Offshore oil and gas field development is increasing relative to onshore
field developments. Production from offshore fields now exceeds that of
onshore fields. Recent production percentages are 60% offshore and
40% onshore, whereas the percentages in the 1990’s were 30% offshore
and 70% onshore. The demand for floating or semi-submersible
offshore platforms (floaters) when developing deep sea oil and gas
fields, located off West Africa, Central and South America, the United
States, and in the Gulf of Mexico, is expected to increase. In particular,
the demand for FPSO (Floating, Production, Storage and Offloading)
projects will grow with the greater demand for natural gas. Therefore,
offshore market prospects are bright in the medium and long term.
(International Maritime Associates Inc., 2005)
With such a bullish outlook on the offshore market, the method of
contract completion of an offshore project has changed to EPIC
(Engineering, Procurement, Installation and Commissioning) from the
more traditional AFC (Approved for Construction) contract type. That
has meant that the contractor must assume responsibility for all
controversial points, from the engineering phase through to the
construction phase. What is more, the application of Engineering
Management (EM) as a part of the Project Management (PM) is being
233
requested by many major oil companies because the concept of life
cycle management, connected to Enterprise Resource Planning (ERP),
is widely used when contractors prepare bids for offshore projects.
(Infield Co., 2005 and Mather, 2002)
Based on the increase in offshore projects and the increase in the use of
EPIC, conventional engineering methods have limited use when
efficiently undertaking engineering projects. Accordingly, the
introduction of an EM system, which automatically processes an
enormous amount of process data without the human errors, is
necessary. EM systems can fundamentally prevent exorbitant costs and
reduce unnecessary man-hours by applying systematic work execution
during the FEED (Front End Engineering Design) stage, basic and
detailed process engineering stage. This paper describes an inherently
optimized methodology in order to prepare the trend of the future
offshore market, using commercially available engineering tools
OFFSHORE TOPSIDE PROCESS ENGINEERING
The general sequence of phases in offshore project development
consists of FEED, basic and detailed engineering, procurement,
installation, commissioning, and operation and maintenance (Fig.1).
The main engineering fields in offshore project development phases can
be divided into two disciplines: offshore topside system engineering and
offshore structure and naval engineering. This study focuses on offshore
topside system engineering, which consists of offshore process, piping,
mechanical, instrumentation, electrical and outfitting engineering.
Among the mentioned engineering areas, the concepts and the
procedure of offshore process engineering phases, one of the highest
priority phases, are presented in the following section.
Figure 1. Offshore project phases.
Offshore Process Engineering
Offshore process engineering ensures that topside systems shall be
economically configured and sized, and considers the reliability,
availability, economic feasibility, and safety of the system in order to
comply with the functional needs of the offshore plant in the specific
offshore field. The duties of the offshore process engineer include:
- reviewing output using economic and feasibility criteria, including
equipment cost;
- defining the project outline and work scope as requested by other
disciplines;
- defining process data;
- preparing heat and material balances using process simulators;
- performing process calculations using in-house or commercial
programs;
- selecting process and utility equipment, and configuring all systems by
considering reliability, availability, economic feasibility, and safety, and
- following up on process engineering works.
Offshore FEED Process Engineering Technical Scheme
In general, the final FEED outputs include determination and
optimization of:
- process system capacity, including separation, crude oil metering, oil
offloading, oil storage and handling, oily water, crude oil loading and
offloading, compressor gas export and injection, gas dehydration, and
produced water treatment systems;
- utility system capacity, including nitrogen, inert gas generation,
instrument and service air, hot and cooling water, methanol injection,
flare, fuel gas, chemical injection, water injection, and gas turbine
generator systems; and
- overall system line size (Fig.2).
In order to achieve the above mentioned final outputs, the following
engineering criteria need to be determined:
- required daily consumption of oil, gas, and water production;
- well components and physical data;
- well capacity;
- environmental and geographical factors;
- product specifications; and
- utility design considerations (Fig.2).
Execution of FEED on the topside process and utility systems, based on
project specification for the particular field and on the above criteria, is
performed using the following procedures.
Figure 2. Offshore FEED process engineering technical scheme.
FEED for the Topside Process System
* Process Simulation
Process simulation is performed in order to obtain product
specifications and to determine temperature, pressure, flow rate and
concentration in each stream using well data for the specific field area
234
that was collected during initial well investigation and drilling. As a
result of this process simulation, the heat and material balance is
calculated and the initial data (capacity, size, etc.) on the major
equipment (separator, heat exchanger, vessel, tower, pump, etc.) are
determined on the basis of the calculated heat and material balance.
Physical properties and thermodynamic data for multiple components
on each stream, and operational conditions are determined on the basis
of the calculated heat and material balance.
* Mathematical Model on Phase Equilibrium
The Peng-Robinson equation is widely used as a mathematical model in
order to calculate a fluid phase equilibrium. The compressibility factor,
fugacity coefficient, and density of a pure component for both liquid
and vapor phase can be calculated by means of the Peng-Robinson
Equation of State (PREOS) which considers parameters such as
temperature, pressure, and molar weight, as well as the supercritical
properties of the selected components.
* Heat and Material Balance
The heat and material balance in overall topside process systems may be
calculated using commercial process simulation software. Overall line
size, capacities of major equipment and the process data for
instrumentation are determined on the basis of the calculated heat and
material balance. A core activity in the execution of FEED for the
offshore topside process systems is the calculation of the heat and
material balance.
* Process Calculation
For the purpose of process optimization, based on the calculated heat
and material balance, several parameters are determined. These include
hydraulic line and separator sizing; compressor and pump rating; and
calculation of Pressure drop, relief load, flare radiation, dew and bubble
points, pressure safety valve (PSV), control valve (CV), orifice sizing,
and physical properties. In order to perform all of the above calculations,
in-house programs, based on industrial standards, may be developed.
* Process Flow Diagram (PFD)
PFD is a drawing used in process engineering to indicate the process
conditions of each stream and piece of equipment. The process systems
diagram and the heat and material table are based on simulation results
from both commercial process simulator software and in-house
programs.
* Process Equipment and Instrument Datasheet
Process equipment and instrument datasheets, including the equipment
and instrument data needed for procurement, construction, and
operation of these items, are prepared on the basis of the heat and
material balance and other process calculations.
FEED for Topside Utility Systems
* Utility Design Consideration
The design specifications and lessons learned from similar projects are
reviewed in this stage of FEED. Ideally, topside utility systems should
be precisely defined after determining all data for the topside process
system. Generally, however, the engineering of topside utility systems
is simultaneously performed with the topside process system because of
time limitations. Utility design data may be changed when process data
is not available.
* Utility Consumption Calculation
The consumption of each utility system is based on the utility design
consideration.
* Utility Balance
A core FEED activity in the design of offshore utility systems is the
calculation of the utility balance, which represents the utility condition
of each utility system.
* Utility Calculation
In order to optimize the calculation of the utility balance, in-house
programs, based on industrial standards, may be developed.
* Utility Flow Diagram (UFD)
The UFD indicates utility system consumptions and conditions for the
utility equipment items that use air, cooling water, nitrogen, or other
consumables. The diagram showing the utility systems, consumptions,
and conditions is based on utility design considerations and utility
consumptions that are often determined by in-house programs.
*Utility Equipment and Instrument Datasheet
The utility equipment and instrument datasheets, including the
equipment and instrument data necessary for procurement, construction,
and operation are prepared on the basis of the utility balance and the
utility calculation.
Procedures and Activities in Offshore Basic and Detailed
Process Engineering (Hwang et al., 2007)
Fig. 4 shows the engineering procedures for offshore plant systems and
the main activities during the basic and detailed design phase. The core
of this engineering phase is preparing P&IDs (Piping and
Instrumentation Diagrams) for each system or facility.

Offshore Basic and Detailed Process Engineering Technical

Scheme
Fig. 3 represents an engineering technical scheme for offshore process
engineering. In general, the final outputs of an engineering technical
scheme, as determined by both basic and detailed offshore process
engineering, are:
- system standardization, which includes FPSO topside systems, FPSO
hull systems, equipment and instrument datasheets, and system
descriptions.
- establishment of safety, including the preparation of a process hazards
Figure 4. Procedures and activities in offshore basic and detailed
analysis check list, development of a HAZOP (Hazard and Operability
process engineering.
Analysis) tracking program, standardization of the SAFE (Safety
Analysis Function Evaluation) chart, emergency shutdown diagram, and
There are four types of P&ID prepared during this engineering stage.
standardization of safety study reports;
- preparation of a checklist for vendor data incorporation, including both
stationary and rotating equipment; and IFR (Issued for Review) P&ID
Based on the initial data from FEED, the engineering of the process and
- development of in-house programs for hydraulic line and separator
utility systems is performed. At this time, an IFR P&ID is prepared for
sizing, compressor and pump rating, pressure drop, load and flare
submission to the client. The three main activities are:
radiation calculations, dew and bubble point estimation, physical
property estimation, and valve sizing (Fig.3). * Specification incorporation
Client requirements are largely divided into project specifications and
The following engineering criteria are needed in order to achieve these
company specifications. These are incorporated into the P&ID through
final outputs:
a technical review. If specific requirements are not technically or
- design basis;
commercially acceptable, clarification is performed to remove
- company specifications;
specification’s deviation from standard.
- rules and regulations;
- vendor data review; * FEED Verification
Among the FEED data, verification of items that are uncertain, based on
- systems design; and
scope of work or a technical issue, is submitted to the client.
- technical review (Fig.3)
Engineering work is performed using those items that have been
The main activities during execution of basic and detailed engineering
reviewed by the client.
on each process and utility system are: FEED verification; HAZOP
tracking; safety study; in-house program calculation of hydraulic * Incorporation of lessons learned
Potential risk elements, which can be broken out, are removed in
balance, and incorporation of vendor data (Fig.3).
advance so that lessons learned from previous experience may be
incorporated at an early stage of the project..

IFA (Issued for Approved) P&ID

During the move from IFR P&ID to IFA P&ID, the main activity is the
design of various systems. Initially, the data for the interface between
the topside and the hull of the offshore plant is incorporated. Secondly,
the heat and material balance and the utility balance, which were
determined at the FEED stage, are verified. After that, the system
design, using an in-house program and based on the updated process
and utility balances, is determined. During this procedure, preparation
of equipment and instrument datasheets and calculation of overall line
size are important activities in order to achieve a balance within the
overall process systems.

IFC (Issued for Construction) P&ID

As the project progresses from IFA P&ID to IFC P&ID, the P&ID
should include actual construction information. At this stage, the main
activities are incorporation of safety factors, client and class comments.
Figure 3. Offshore basic and detailed process engineering technical Line and equipment lists, important items at the construction stage, are
scheme. updated to reflect the IFC P&ID. System engineering should consider

235
fire zone and hazardous area safety factors. In particular, the HAZOP
study may be performed more than once in order to remove potential
risks during the site operation of FPSO. Moreover, client and class
comments on safety, operation, and maintenance of each system are
incorporated in the IFC P&ID through a technical review. The interface
data and associated rules and codes for each vendor are also
incorporated in the IFC P&ID.
As-built P&ID
To prepare an as-built P&ID, incorporation of all modeling or
construction changes must be incorporated. Moreover, items relating to
operation and maintenance, as well as safety are also important
activities. In addition, preparing a system description, SAFE chart,
shutdown philosophy, emergency shutdown diagram, alarm and set
point table, and operation and maintenance manuals should be included
at this stage.
INTEGRATED SOLUTION FOR OFFSHORE TOPSIDE
PROCESS ENGINEERING
Problems with Conventional Process Engineering
Fig. 5 shows a conventional procedure for process engineering.
Following process simulation, the heat and material balance and the
PFD are generated and calculations are performed on the basis of design
criteria and well data. Subsequently, engineering works, such as the
preparation of P&ID, equipment and instrumentation sizing, preparation
of datasheets, incorporation of vendor data, and a HAZOP study, are
performed. These form the final outputs of the basic and detailed
process engineering phase and are based on the heat and material
balance, safety study, control logic, and other related items.
Engineering errors may occur due to the absence of integrated
management of the process data, especially if engineering works were
performed using conventional procedures to obtain data on related
activities. The conventional procedure includes manual processing of
data within the above mentioned activities. Manual data processing is
typically accompanied with serious revision problems on the numerous
drawings and documentations whenever an engineering change occurs.
Thus, the conventional procedure for process engineering using manual
data processing was deemed inefficient due to its requirement for large
amounts of time for the management of the process data. Therefore, an
integrated solution, based on the automated and integrated data
processing, was needed.
Figure 5. Conventional procedure used in process engineering.
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The Proposed New Procedure for Process Engineering
Fig. 6 shows the proposed new process engineering procedure. The
purpose of the new procedure is to increase the efficiency of performing
process engineering activities through automated and integrated data
processing at the FEED, basic, and detailed process engineering stages.
As a result of the proposed new procedure, costs and man-hours are
lowered and an enormous amount of process data is promptly executed
by a few process engineers, thereby reducing the occurrence of human
errors. Furthermore, potentially enormous cost and schedule impacts
may be minimized by rapidly fixing process data at an early engineering
stage and engineering management (EM) which is the requirement in
the future offshore project will be prepared. Therefore, the proposed
new process engineering procedure should greatly contribute to the
success of offshore projects.
Figure 6. Proposed integrated procedure for process engineering.
The Optimized Methodology to Build an Integrated Solution
to Offshore Topside Process Engineering
Introduction to engineering tools
* Aspen HYSYS®
Aspen HYSYS® (HYSYS) from Aspen Technology Inc. is the basic
process engineering tool used to calculate all process data, simulate the
overall process, and configure process systems such as PFD. Generally,
the initial data (capacity, size, etc.) for major process equipment items
are calculated using HYSYS.
* Aspen ZYQAD®™
Aspen ZYQAD®™ (AZ) from Aspen Technology Inc. is a basic
process database management program for the process and control
engineer and is used to import the process data calculated by Aspen
HYSYS. It is also used to configure PFDs, generate equipment
datasheets and lists, link process data with in-house programs, drawings,
and documents, as well as to manage revisions of engineering activities.
* In-house Program
Table 1 shows a list of in-house programs for basic process engineering
developed by Samsung Heavy Industries (SHI). The table of in-house
programs consists of three categories; one is for sizing equipment,
another is for sizing pipes, valves, and instruments, and the third is for
linking the program with other process activities.
Table 1. In-house program list with reference.
In-house Program Reference
Gas/liquid, gas/liquid/liquid separator SHELL DEP and GPSA
sizing chapter. 7
Pump and compressor rating GPSA chapters. 12 and 13
Flare radiation design API RP 521
Hydraulic calculation (line sizing and SHI standard, crane the integrated detailed process engineering solution. Among the process
pressure drop technical handbook among data managed by SPPID, the process data related to instrumentation,
others. piping and mechanical disciplines are automatically transferred into SPI
Relief load calculation API RP 521 and SP3D by means of the data mapping procedure. Through this
Valve sizing (relief, control and other API RP 520, crane automated process, man-hours and human errors will be minimized.
valves) technical handbook among
others.
Physical property and phase equilibrium Gases and liquids, 5th
estimation edition
* SmartPlant P&ID®
InterGraph Corporation’s SmartPlant P&ID® (SPPID) is a detailed
database management program for the process, mechanical and piping
engineer and is used to prepare P&ID and to manage the detailed data
related to mechanical, piping, and other processes on the prepared
P&ID.
* SmartPlant Instrumentation®
SmartPlant Instrumentation® (SPI) from InterGraph Corporation is a
detailed database management program for the instrumentation and
process engineer and is used to manage the detailed data related to
project instrumentation.
* SmartPlant Foundation®
SmartPlant Foundation® (SPF) from InterGraph Corporation plays a
core role in building an integrated solution to offshore topside process
engineering. It is used to manage and link all process data among the Figure 8. Optimized methodology to build an integrated basic process
above mentioned tools based on web. engineering solution.
* Basic Integrator
Basic Integrator is a part of SPF that is used to link process data APPLICATION TO A SPECIFIC OFFSHORE PROCESS
between the integrated basic process engineering solution and the SYSTEMS
integrated detailed process engineering solution by mapping procedures
between those solutions. A condensate stabilizer unit, part of a typical offshore gas compression
system, has been selected for the purpose of verifying the efficiency of
Operation Schematic of the Proposed Methodology the proposed methodology to build an integrated solution to offshore
Fig. 7 shows an operation schematic of the integrated solution to topside process engineering.
offshore topside process engineering using the above mentioned tools.
The proposed methodology makes it possible to automatically generate
Building the Integrated Basic Process Engineering Solution
and consistently manage process data from the FEED stage through to
Fig. 9 shows the integrated basic process engineering solution using AZ.
the detailed design stage. Cost and schedule impacts will be minimized
The engineering process data are automatically transferred into the
because process data is rapidly tabulated, calculated, and transferred
relevant items and are consistently managed through systematic
into the relevant item, even if simulation results or vendor data are
linkages between HYSYS, AZ, and in-house programs. The following
changed.
steps are the brief explanation of the procedure used to build an
integrated basic process engineering solution.

Process Simulation Using HYSYS

Process modeling and simulation on the condensate stabilizer unit
performed using HYSYS is shown in Fig. 9a. The condensate stabilizer
system including several unit operations, including heat exchanger,
column, pump, compressor, scrubber, and separator is a typical offshore
process system. The condensate stabilizer system stabilizes the
condensates (consisting of pentane (C5), hexane (C6) and heavier
hydrocarbons) separated from a scrubber installed on the suction line of
each compressor.

PFD Generation Using AZ

Figure 7. Operation schematic of the proposed integrated solution.
Fig. 8 shows an optimized methodology to build an integrated basic
process engineering solution using HYSYS, AZ and in-house programs.
All activities related with piping, mechanical, electrical and
instrumentation disciplines are simultaneously performed using AZ
database created by the process discipline. SPPID, SPI and InterGraph
Corporation’s SmartPlant® 3D (SP3D) are then used in order to build
PFD generation of the condensate stabilizer unit is a core activity in the
basic process engineering phase and is performed by the AZ Drawing
Editor (Fig. 9b).
Importing Process Data from HYSYS
The process data for each equipment item and for each stream generated
by HYSYS are imported in the AZ database using the AZ Simulation
Importer while the AZ Simulation Importer performs data mapping
between HYSYS and AZ. In addition, inlet and outlet material ports in
AZ are set up to transfer all process data to the AZ database from

237
HYSYS. Imported process data from HYSYS are saved as object
attributes in the AZ database. Those data can be observed by using AZ
Explorer.
Preparation of SHI In-house Programs
Fig. 9c shows the calculation, input, and output modules of the
horizontal knockout drum performed by in-house programs developed
by SHI in order to apply the AZ PFD of the condensate stabilizer unit.
SHI in-house programs developed in Microsoft® Excel (Excel) are
prepared to allow calculation of the process data from the AZ database.
Process data can be imported to Excel from the AZ database as input
values. It is also possible for calculated process data to be exported to
the AZ database by means of a proprietary SHI in-house program
algorithm.
Importing/Exporting Process Data between AZ and SHI In-house
Program
Figure 9. Integrated basic process engineering solution.
238
The AZ Bridge function allows process data to be transferred between
AZ and SHI in-house programs. The function of AZ Bridge is to import
and export process data between AZ database and such external
applications as Excel and Microsoft® Word. Before transferring process
data between the AZ database and SHI in-house programs, the
appropriate input and output data need to be determined. Data transfer is
executed after configuring logical link sets between the AZ object
attribute and the SHI in-house program data cell.
Generation of Customized Process Datasheet in AZ
All equipment and instrumentation process datasheets are customized
from datasheet templates provided by AZ Datasheet Definer for
example, the centrifugal compressor datasheet shown in Fig. 9d. It is
possible for these process datasheets to be updated by linking the AZ
database and the appropriate AZ datasheet in AZ workspace. In addition,
revisions to, and approval management of, the customized process
datasheets can be automatically handled in the AZ datasheet.
Building the Integrated Detailed Process Engineering
Solution
This procedure allows the integrated detailed process engineering
solution for the condensate stabilizer unit to be developed while the
integrated basic process engineering solution is being built. During
building of the integrated basic process engineering solution, all
process data generated are automatically transferred to, and generated
in, SPPID and SPI. The following steps describe the procedure used to
build the integrated detailed process engineering solution for a specific
feed surge drum in the condensate stabilizer unit

Generation of Graphic and Process Data in SPPID

Process data are entered in the property window provided by SPPID
after generating a P&ID graphic in SPPID (Fig.10).

Figure 12. Detailed process data mapping module.

Generated Index of Mapping Results

As a result of these data mapping procedures, indices of mapping
results are generated, and all process data related with instrumentation,
piping, and mechanical disciplines in the feed surge drum P&ID are
successfully transferred and generated (Fig. 13).

Figure 10. Graphic user interface of SPPID.

Process Data Mapping

The link between the SPPID and SPI databases is generated by means
of an Import Utility and automatically transfers process data from
SPPID to SPI (previously called INtools®, InterGraph Corporation)
(Fig.11).

Figure 13. Generated index screen of mapping results.

Process Datasheet from Imported Results

The process datasheet, including the item’s general and specific
properties and conditions, can be generated after inputting additional
instrumentation data in the generated index (Fig. 14).

Figure 11. Database link module between SPPID and SPI.

Detailed Mapping
Detailed mapping of attributes between SPPID and SPI is performed on
a link map as shown in Fig. 12. It is possible for process data that is
required in SPI to be imported from SPPID through this procedure.
Figure 14. Process datasheet screen from imported results.

239
 Building an Interface between Two Integrated Solutions
Process data mapping is a procedure that ensures that process data
generated and changed from FEED to detailed engineering are
automatically transferred between the basic and detailed integrated
process engineering solutions. SPF’s Basic Integrator performs process
data mapping between these two integrated solutions. Consequently, all
process data generated by the integrated basic process engineering
solution are automatically transferred into the integrated detailed
process engineering solution. To successfully avoid interface
customizing problems between two integrated solutions, the integrated
database should use SPF developed by InterGraph Corporation and
Aspen Technology, Incorporated.
Potential Effects on Future Offshore Projects
The business benefits resulting from building two integrated solutions
to offshore topside process engineering proposed by SHI are
summarized in Table 2. Firstly, both manpower costs and schedule
periods are reduced because of the procedures capacity to rapidly fix
process data and systematically manage document revisions. Secondly,
human errors, resulting from repeated inputting of process data, are
markedly decreased by effectively reusing process data generated in
previous engineering phases. Thirdly, vendor claim costs are reduced
because the reliability and quality of the engineering data are improved
through managing engineering data as a single source concept.
Therefore, building a integrated solution to offshore topside process
engineering will contribute to improving the engineering work
efficiency. This, in turn, will help the oil and gas industry to more
efficiently build, operate, and maintain future offshore projects.
Table 2. Potential positive effects of the proposed integrated solution.
Business Benefits Potential Effects in Process Engineering
Increased Approximately 50 % reduction in engineering
productivity man-hours
Reduced cycle time Approximately 15 % reduction in engineering
period
Improved quality Approximately 80 % reduction in human errors
Prevention of Approximately 10 % reduction in vendor
process data change claim cost
CONCLUSION
An integrated solution to offshore topside process engineering has been
created using the following engineering concepts and activities.
1) The concept of using FEED, as well as basic and detailed process
engineering, is seen as the foundation of developing integrated topside
process engineering.
2) A process engineering procedure using automated and integrated
data processing at each FEED, basic, and detailed process engineering
stage is used in order to increase the efficiency of process engineering
activities.
3) The optimized methodology to build integrated solutions for
offshore topside process engineering uses several commercial and in-
house software programs.
4) PFD generation is performed using AZ after executing the process
simulation and configuration using HYSYS.
5) The integrated basic process engineering solution for a typical
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offshore system is built by customizing the process datasheets and
linking the process data among HYSYS, in-house programs, and AZ.
This is based on integrating a single AZ database.
6) The integrated detailed process engineering solution for a specific
item or items is automatically built from the integrated basic process
engineering solution.
7) The interface of the specific system among the integrated basic
process engineering solution, SPPID, and SPI allows the automatic
transfer of process data. Generating the final instrument datasheets is
accomplished through linkages to each database.
It is deemed mandatory for this proposed integrated solution to offshore
topside process engineering to utilize commercially available
engineering tools in order to prepare engineers and the oil and gas
industry to be consistent in the move toward increased efficiency in
future offshore project developments. Our proposed methodology,
which changes engineering methods from manual data processing to
automated and integrated data processing, means that an enormous
amount of process data can be promptly executed by only a few process
engineers. This will result in fewer opportunities for human errors. This
methodology will also reduce costs and man-hours during the
fundamental FEED, basic and detailed process engineering stages. In
addition, process engineering techniques and output quality would be
improved. Finally, EM, which may be seen as a requirement in the
future of offshore projects, is facilitated by the use of this methodology.
In particular, management costs and schedule impacts are minimized
because of the ability to rapidly fix process data at the early
engineering stage of an offshore project. Therefore, this optimized
methodology should greatly contribute to performing successful
offshore projects in the future.
ACKNOWLEDGEMENTS
The writers thank all persons in the engineering solution companies-
particularly at Aspen Technology Incorporation and Intergraph
Corporation that have contributed with information, observations,
suggestions, ideas and analysis of various matters of this paper.
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Mather, A. (2002), “Offshore Engineering – An Introduction”,
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