Process Engg Practices To Be Used in The Refinery Industry

FOSTER WHEELER USA CORPORATION PEP No.
: 1000
PROCESS ENGINEERING PRACTICE Page: 1 of 1
Revision: 8
Date: May. 20, 2009
______________________________________________________________________
INDEX
PEP Total Issue or Latest Revision

Number Title or Subject Pages Revision Date Number
PEP-1000 Index 1 May 20, 2009 8

PEP-1001 Sample Process 1 Mar. 06, 2006 4
Engineering Practice (PEP)
PEP-1002 Flow & Maintenance of 6 Feb. 24, 2009 5
Distributed Material
PEP-1003 Process File Numbers 4 Apr. 15, 2009 5
PEP-1004 Equipment List 2 Mar. 06, 2006 4
PEP-1005 Process Flow Diagrams 5 Mar. 06, 2006 4
PEP-1006 Engineering Flow Diagrams 3 Mar. 06, 2006 4
PEP-1007 Engineering Flow Diagrams 6 Aug. 09, 2007 5
Piping Details
PEP-1008 Utility Header Designations 1 Mar. 06, 2006 4
PEP-1009 Instrumentation 3 Aug. 09, 2007 5
PEP-1010 Vessels 3 Aug. 09, 2007 5
PEP-1011 Fired Heaters 3 Mar. 06, 2006 4
PEP-1012 Hydraulics 8 Feb. 11, 2009 6
PEP-1013 Exchangers 3 Mar. 06, 2006 4
PEP-1014 Pumps and Compressors 4 Mar. 06, 2006 4
PEP-1015 Work Plan Preparation and 15 Sep. 12, 2008 0
Maintenance
PEP-1016 Process Chiefs Review 17 Feb. 11, 2009 0
All items posted to this Index have been reviewed for current applicability and were
found to be correct and complete.
APPROVED: _____________________________________
Director - Process Engineering
DATE: ____May 20, 2009___________________
/var/www/apps/conversion/tmp/scratch_3/348497161.doc
FOSTER WHEELER USA CORPORATION PEP No.: 1001
Revision: 4
Date: Mar. 6, 2006
Date: Mar. 6, 2006
______________________________________________________________________
PEP-1001
SAMPLE PROCESS ENGINEERING PRACTICE
This is an example of a Process Engineering Practice. Each of these PEP's will be

aimed at a single subject of interest to Process Design engineers working on a project.
Sometimes, where appropriate, a common grouping of subjects may be covered.
Comments and corrections, along with changes as time passes, will require revisions.
Revision numbers with dates of issue will be indicated underneath the page number.
The PEP Table of Contents page will normally show the date of the latest issue.
Specific exceptions may be taken from the PEP's when the rules listed are counter to
standard design practice for specific applications. The engineer should be prepared to
justify his exception.
These PEP's are general for all projects. Job specific PEP's will be issued with a job
specific reference number where client requirements or other requirements dictate.
PROCESS ENGINEERING PRACTICES Page: 1 of 6
Revision: 5
Date: Feb 24, 2009
______________________________________________________________________
PEP-1002
FLOW & MAINTENANCE OF DISTRIBUTED MATERIAL
A. FLOW
1. When required, job specific PEP's will be issued to all process engineers
assigned to a contract, as well as the FW Project Engineering Managers.
2. Other correspondence of a general nature (i.e., pertaining to more than

one unit) shall be distributed to all concerned process engineers. It shall
be the Lead Process Engineer's responsibility to act on all applicable
material.
3. All process specifications, data sheets etc., to be issued within and

outside the department shall be reviewed by the appropriate Chief
Process Engineer, or his assigned deputy, prior to transmittal. A
transmittal form (see attached sample) shall be prepared by the Lead
Process Engineer.
5 Departmental or project-specific policy will apply to letters issued to

licensors, catalyst vendors, etc.
All other Process Design correspondence for the project within FW will be
over the signature of the Process Manager or the Lead Engineer as
appropriate.
4. All correspondence to the Client shall follow the job specific coordination
procedure. Unless otherwise indicated, correspondence shall be over the
signature of the Project Manager.
5. All process specifications and vessel sketches shall be prepared on

5 standard Foster Wheeler forms available in the Process Library or on
equivalent computer generated forms. As required by the contract, client
specific forms may also be used.
Revision: 5
Date: Feb 24, 2009
______________________________________________________________________
PEP-1002 (Cont'd)
B. MAINTENANCE
1. Desk Files
a. Lead Process Engineer
As instructed by the Chief Process Engineer, the Lead Process

5 Engineer on each unit must keep some or all of the following books
in separate loose-leaf binders:
Originals Book:
Originals of issued process specifications (including Equipment List

until control is released to Project) and PREP data must be
maintained. The originals shall capture the approval signature or
initials of the Chief Process Engineer (or designee) in one of the
following two ways:
1. Hand written initials in the approval block of the process

specification, or
2. Hand written signature or initials on the Process Transmittal

sheet. The initials of the Chief Process Engineer must
match the typed initials shown in the approval box on the
process specification.
This book shall also note the location (Directory) for the electronic
files stored on the network. See below regarding use of the original
as the Process Master.
Process Masters Process Specifications
A distributed copy of the as-issued process specification shall

become a Process Master and shall have the words Process
Master stamped or written on the copy of the process specification
that was issued.
If hard-copy distributions are not being made then a signed original

copy may be used as the Process Master and retained to show that
the issued document was approved.
Revision: 5
Date: Feb 24, 2009
______________________________________________________________________
B. MAINTENANCE
1. Desk Files
a. Lead Process Engineer (Cont'd)
Process comments noted on Process Masters shall be clearly

5 marked, dated, and initialed by the person making the comment.
All previous issues of the process specifications shall be retained if

directed by the Chief Process Engineer. Any superseded Process
Masters shall be clearly indicated as such with a red line drawn
through each page.
Process Masters Requisitions and Vendor Drawings
All issues of project requisitions including DIs (design instructions)

issued for nozzle arrangements shall be kept as Process Masters.
Process comments on requisitions received shall be clearly

marked, dated, initialed by the reviewer and transmitted to Project.
This transmitted copy shall become the new Process Master.
All superseded issues should be clearly indicated as such with a

red line.
Process Masters Drawings
Process Masters of the following drawings shall also be maintained

by the Lead Process Engineer (assuming these drawings are
required and created for the project):
Process Flow Diagram.
Engineering Flow Diagram.
Design Pressure/Temperature
Materials of Construction Diagram.
Plot Plan.
Revision: 5
Date: Feb 24, 2009
______________________________________________________________________
PEP-1002 (Cont'd)
B. MAINTENANCE
1. Desk Files
a. Lead Process Engineer (Cont'd)
It is the responsibility of the Lead Process Engineer to maintain the

5 "Process Master" of the above drawings and keep them up to date.
All "Process Master" drawings must be stamped with a Process
Master stamp and dated. Hand-writing the equivalent information
in red ink is also acceptable
The Lead Process Engineer shall keep a copy of all issues of the
flow diagrams listed above in his office. These may be discarded
when the contract is completed.
b. Calculations (dated with page number and title)
Process calculations are to be kept by the Lead Process Engineer

in an organized binder. Calculations must be organized in a
5
manner that mirrors the project filing procedure. All calculations,
whether hand calculations or electronic calculations (such as Excel)
must be included in the binder and also stored in the project
network directory.
Upon completion of the process work, the originals of the process

calculations should be edited, numbered, indexed, bound and sent
to the Process File in accord with department procedure.
2. Process Department File
a. Specifications
No preliminary issues of Process Specification Sheets, Material

Requisitions, Process Flow Diagrams, Engineering Flow Diagrams,
etc., are to be sent to Process File.
PEP-1002 (Cont'd)
B. MAINTENANCE
2. Process Department File
a. Specifications (Contd)
Upon completion of the contract or customer acceptance of the

5 unit, the Lead Process Engineer, Process Coordinator, and Chief
Engineer have the joint responsibility to assure that final issues of
all specifications, flowsheets, etc., from the Masters and Originals
Books, as well as the process calculations, are properly placed in
the Process File.
Appropriate vendor drawings may be filed at the discretion of the

Chief Engineer (e.g., tray drawings and/or ratings should usually be
filed).
b. Correspondence
All correspondence shall be sent to the appropriate section of the

Process File.
c. Chief's Review Flow Diagrams
The originals of the Engineering Flow Diagrams marked up during

the Chief's Review shall be forwarded to the "Flow Diagrams"
5 section of the Process File. Each flow diagram must be dated and
labeled "Chief's Review". A list of those in attendance must also be
indicated on at least the first flow diagram in the series.
Revision:
5
Date: Feb 24, 2009
________________________________________________________________________________
FOSTERWHEELER
FOSTER WHEELERUSA
USACORPORATION
CORPORATION
HOUSTON, TEXAS
CLINTON, NEW JERSEY
PROCESS DATA TRANSMITTAL DATE 1995
UNIT NAME: Unit DEF PROJECT: Project XYZ

UNIT NO.: XXX Customer ABC
CONTRACT NO.: XX-XXXX Location
DISTRIBUTION COPIES
MEMO ATT'S MATERIAL TRANSMITTED
Process File XX-XXXX 1 1
Process Manager 1 1 Process Flow Diagrams
Chief Process Eng. 1 1 Engineering Flow Diagrams
1 1 Equipment List
Lead Process Eng. 1 1+orig Vessels
Project Manager 1 1 Exchangers
Project Eng. Mngr. 1 1 Instruments
1 1 Compressors
1 1 Fired Heaters
Pumps
Item Revision No. of

Number Number Date Sheets
NOTES:
By
FOR PROJECT ENGINEER USE

Revision:
5
Date: Feb 24, 2009
________________________________________________________________________________
PEP-1003
PROCESS FILE NUMBERS
The following is a sample Process File Index. A job specific index is to be prepared by the
Chief Process Engineer or designee and issued for each project. Refer to Engineering
Practice EP 6-1.
PROJECT XYZ
SAMPLE PROCESS FILE NUMBERS
File Number XX-XXXXX-XX
1.0 PROPOSALS & CONTRACT MATTERS
1.1 Proposal
1.2 Contract
1.3 Contract Changes
2.0 CLIENT & LICENSOR CORRESPONDENCE
2.1 FW to Client
2.2 Client to FW
2.3 Standard Engineering Transmittal Letters to Client
2.4 Standard Procurement Transmittal Letters to Client
2.5 To Licensors and Vendors
2.6 From Licensors and Vendors
3.0 NOTES OF MEETING
3.1 Project Notes (Meetings with Client)

3.2 Notes of Meeting (Internal and with Vendors)
3.3 Action Item/Needs List
4.0 ESTIMATES, FINANCIAL & COMMERCIAL
4.1 Estimates
5.0 COORDINATION & PERSONNEL
5.1 Project Coordination Procedure (including Filing System Index)

5.2 Coordination Memos
5.5 Project Execution Plan
PEP-1003 (Contd)
6.0 SCHEDULES & REPORTS
6.1.4 Master Progress Schedule

6.1.5 Detailed Work Schedule
6.1.6 Staffing Plan
6.1.7 Progress Letter/Report (to Client)
6.1.8 Weekly Progress Report (Process Work Plan)
6.1.9 Variance Notice Program
6.1.11 Labor Reports
7.0 PROCESS DATA
7.00 Utility Data/Utility Summary

7.01 Design Basis Document
7.02 Heat and Material Balances
7.03 Test Run/Operating Data Report
7.05 Technical Specification/Process Package/Study Reports
7.06 Process Calculations (Issued Outside FW Process)
7.07 Computer Simulation Data (Issued Outside FW Process)
7.09 Process Equipment List
7.10 Client Design Data
7.11 Tower and Tray Load Process Data Sheets
7.12 Reactors and Internal Process Data Sheets
7.13 Drum Process Data Sheets
7.14 Tank Process Data Sheets
7.19 Other Vessel Process Data Sheets
7.21 Shell and Tube Exchanger Process Data Sheets
7.22 Double Pipe Exchanger Process Data Sheets
7.23 Air Cooled Exchanger Process Data Sheets
7.24 Fired Heater Process Data Sheets
7.27 Vacuum Equipment Process Data Sheets
7.31 Pump Process Data Sheets
7.32 Compressor Process Data Sheets
7.34 Material Handling Equipment Process Data Sheets
7.50 Flow Diagrams (PFD/DPT/MOC/EFD)
7.51 Process Line List
7.60 Instrument Process Data Sheets
7.63 PSV Data Sheets/Flare Summary
7.91 Package System Process Data Sheets
PEP-1003 (Contd)
7.0 PROCESS DATA (Cont)
7.92 Utility Thermal Equipment

7.93 Water Treating
7.94 Waste Treating
7.95 PHA/HAZOP Reviews/Safety/Safeguarding
7.96 Catalyst and Chemicals
7.97 Miscellaneous
7.98 Environmental
8.0 ENGINEERING CORRESPONDENCE
8.00 Basic Engineering Data

8.01 Equipment Lists
8.2 Design Pressure / Temperature (By Project)
8.3 Process Correspondence and Process Transmittals
Use Section 8 to also file Engineering data sheets, requisitions, vendor drawings,
etc. Use same file suffixes as Section 7 (for example Engineering Data on pumps
would be filed under 8.31)
11.0 PROCESS CALCULATIONS
Use Section 11 to file process calculations. Use same file suffixes as Section 7 (for
example drum calculations would be filed under 11.13)
12.0 DESIGN INSTRUCTIONS (DIs)
12.10 Vessels
12.20 Exchangers
12.30 Machinery
12.50 Piping/P&IDs
12.60 Instruments
13.0 DRAWINGS
13.1 FWUSA Drawings (See also Section 7.50)

13.2 Vendor Drawings (Typically file in Section 8)
13.3 Client Drawings
PEP-1003 (Contd)
16.0 PLANT OPERATIONS & START-UP
16.1 Operating Guidelines/Manual

16.2 Field Testing and Reports
16.3 Start-up
16.4 Personnel
16.5 Blind List
16.6 Systems Description and Scope
16.7 Turnover Forms
16.8 Hydrostatic Test Packages
16.9 Work Package Description
16.10 Punch List
16.11 Certification/Handover Documents
17.0 QUALITY ASSURANCE
17.1 QA Activity and Audit Schedule

17.2 QA Audit Reports
17.3 Non-Conformance Reports
17.4 Quality Notices
17.5 Corrective Action Reports
17.6 Preventive Action Reports
17.7 QA Correspondence and Follow-up
17.8 Quality System Documents (Project Procedures, Quality Plan)
Revision: 4
Date: Mar. 6, 2006
______________________________________________________________________
PEP-1004
EQUIPMENT LISTS
l. Equipment lists shall be set up in the following order of principal equipment

designations. For a full list of equipment letter designations and a further
discussion of the rules refer to Engineering Practice EP 6-10. The standard
process Equipment List is on the following page.
Vessels
Towers (T- )
Reactors (R- )
Drums (D- )
Tanks (TK- )
Heat Transfer Equipment
Heat Exchangers (E- )

Furnaces (H- )
Mechanical Equipment
Pumps (P- )
Compressors (C- )
Miscellaneous (eg. DS, F, M, S, X)
in same order as code of accounts
2. Equipment numbering shall be as follows:
Equipment letter - Unit/Section number + suffix designation beginning with 1

unless the customer designates otherwise. The first unit/section shall be 100.
EXAMPLE: First and second drums in Unit 100:
D-101
D-102
3. All pump spares will be numbered as follows:
P-101A (Main)
P-101B (Spare)
Revision: 4
Date: Mar. 6, 2006
___________________________________________________________________________________________________________
____
FOSTER WHEELER USA CORPORATION CONTRACT: EQUIPMENT LIST NAME OF UNIT

Clinton, NJ 08809 SECTION:
CLIENT: REVISION ORIG. 1 2
LOCATION: DATE
CLASS ITEM NO. DESCRIPTION EFD REQ'N. NO. P. O. NO.
Form No. 110-330 17 Feb 1999 NAME: STANDARD FORM (If Modified, rename form)
Revision: 4
Date: Mar. 6, 2006
______________________________________________________________________
PEP-1005
PROCESS FLOW DIAGRAMS
Process Flow Diagrams
1. Process Flow Diagrams (PFD's) shall be drawn according to normal FW

Engineering practice on drawing size No. 2.
2. The title box shall be in accordance with the enclosed sample.
3. PFD's will not have material balance tables provided on drawings unless required
for the project. Material balances will be provided separately on diamond
sheets. A typical sample is attached.
4. Temperatures and pressures (normal operating) shall be provided at vessels and

where deemed necessary on the drawings, in addition to the diamond sheets.
Maximum and minimum data shall be included where important to equipment
design.
5. All major items of equipment must be shown on the PFD. Adjacent to each item
shown, the underlined item number must be provided. Underneath the item
number, the item name shall appear exactly as indicated on the equipment list.
6. Do not indicate spares for pumps, (e.g. show P-801, not P-801 A/B).
7. Provide normal process duty for exchangers in a "HEATER/EXCHANGER

SUMMARY" for the operating case(s) shown on the PFD. For fired heaters,
show process heat absorbed and other coil heat absorbed, where applicable.
When all other coil heat duties are available, show total heat absorbed. Duties
should correspond to normal operating case shown on PFD.
8. Major control loops (automatic or otherwise) and other instrumentation necessary

for the understanding of the PFD shall be shown. Do not show PI's or TI's. Do
not indicate board or local control. Only show mode of control, e.g., FC even if in
reality instrument is FT-FIC-FR. Do not indicate electronic or pneumatic mode
for instruments - use only dashed lines connecting instrument to valve operator.
The dashed lines are not to be interpreted as electronic instrumentation. Use
solid lines connecting sensor to instrument and operator to valve.
Revision: 4
Date: Mar. 6, 2006
______________________________________________________________________
PEP-1005 (Cont'd)
Flow orifices are not to be shown on the PFD. Examples of instrumentation are
shown below.
FC
M TC
LC
FI
9. Each PFD must contain an explanatory legend with the information shown below.
Additional symbols and notes may be shown as necessary to clarify the
flowsheet:
Revision: 4
Date: Mar. 6, 2006
______________________________________________________________________
PEP-1005 (Cont'd)
10. Provide battery limit temperatures and pressures for all process streams (in and
out) and indicate destination of material, intermediate tankage. Name all
streams.
11. Each PFD must have the following statement.
THESE PROCESS DATA ARE FOR DESIGN PURPOSES ONLY.

WHILE USEFUL AS A GUIDE TO OPERATION, THEY DO NOT
NECESSARILY REPRESENT EXACT OPERATING
CONDITIONS.
Revision: 4
Date: Mar. 6, 2006
______________________________________________________________________
PEP-1005 (Cont'd)
12. The initial issue of the PFD is to be Issue A with subsequent issues in
alphabetical order. Each issue shall be designated as indicated below:
SAMPLE TITLE BOX
This Drawing is the Property of the

FOSTER WHEELER USA CORPORATION
PERRYVILLE CORPORATE PARK, CLINTON, N.J.
AND IS LENT WITHOUT CONSIDERATION OTHER THAN THE BORROWER'S
AGREEMENT THAT IT SHALL NOT BE REPRODUCED, COPIED OR DISPOSED OF
DIRECTLY OR INDIRECTLY, NOR USED FOR ANY PURPOSE OTHER THAN THAT FOR
WHICH IT IS SPECIFICALLY FURNISHED. THE APPARATUS SHOWN IN THE
DRAWING IS COVERED BY PATENTS.
PROCESS FLOW DIAGRAM

UNIT DEF
UNIT 800
PFD GHI
PROJECT XYZ
Customer ABC Location
EST. NO. DRAWN BY: 04-01-95 SH. X OF Y
REV. A April, 1995 Initial IssueInit. Contract No. XX-XXX Dwg. No. xxxx-x-xx-xx A
Revision: 4
Date: Mar. 6, 2006
_____________________________________________________________________

UNIT: UNIT DEF UNIT NO.: P G.NO.:
CUSTOM ER: CUSTOM ER A B C REF. DWG.: REV.:
LOCA TION: CONTRA CT NO.: DA TE:
STREAM NO. 1 2 3 4 5 6
STREA M DESCRIP TION
OP ERA TING CA SE
FLUID STA TE
TEM P ERA TURE, F
P RESSURE, P SIG
TB P CUT RA NGE, F
TOTA L B P SD
A P I
LIQUID, LB /HR
VA P OR, LB /HR
SOLID, LB /HR
TOTA L, LB /HR
LIQUID S.G. @ O.T.
LIQUID VISC. @ O.T., CKS

M W OF VA P OR
COM P ONENTS, LB M OLS/HR
SUB TOTA L (DRY)
H 2O
TOTA L
Revision: 4
Date: Mar. 6, 2006
______________________________________________________________________
PEP-1006
ENGINEERING FLOW DIAGRAMS
1. Engineering flow diagrams (EFD's) shall be drawn on drawing size No. 2, according
to normal FW engineering practice. The title box shall be in accordance with the
enclosed sample (page 3).
On each EFD, a column along the right side, directly above the title box, will be used
for Notes and Holds.
A chart along the bottom of each EFD will be used to provide the required equipment
data.
2. The following non-standard pipe sizes shall not be used: 3/8", 1-1/4", 2-1/2", 3-1/2",
5" or 7", etc.
In the event that these sizes are required for equipment connections, they shall be
changed as soon as feasible to the connecting pipe size.
Minimum pipe sizes shall be 1" for both process and utility piping, except for
connections to equipment which vendors supply or for sample lines to and from
analyzers.
3. Unless the process, client or vessel code dictates otherwise, relief valve nozzle
connections shall not be located on vessels but on overhead piping without
appropriate justification.
4. Silencers for vents, when provided, shall be numbered and shall be included on the
equipment list.
5. In general, air coolers are to be provided with louvers, where required for
supplemental (start-up and shutdown) freeze/pour point protection, with control of the
air temperature by the forced-draft or induced draft fans. The process outlet
temperature from each bay is to be monitored. In general, steam coils will be
provided for air coolers, when required for start-up and shutdown purposes.
6. Turbines shall be provided with full capacity relief valves mounted in the exhaust
steam piping and relieving to atmosphere.
Revision: 4
Date: Mar. 6, 2006
______________________________________________________________________
PEP-1006 (Cont'd)
7. Insulation
Process piping and equipment operating at temperatures exceeding 150F (65 C)

shall, in general, be insulated for heat conservation unless heat loss is desired. Hot
surfaces, exceeding 150F (65C), not requiring insulation for heat conservation, shall
be insulated for the purpose of protecting personnel in areas adjacent to operating
areas, platforms, etc., or within reach from grade.
8. Relative elevations of vessels, loop seals, exchangers and thermosyphon circuits are
to be indicated on the EFD's. For vessels, show elevation above grade of bottom
tangent line on vertical vessels, or bottom on horizontal drums.
9. The following must be shown in detail on the EFD's: number of passes for each coil
for fired heaters, number of shells or bays for exchanger services. These are to be
estimated by the process or heat transfer engineers.
10. The initial issue of the EFD's is to be Issue A and designated as shown on the
attached Sample Title Box. With the second issue of EFDs (Rev.B) the Process
Engineer relinquishes control to the Project Department. Therefore, this issue will not
be made until specifically approved by the Chief Engineer.
PEP-1006 (Cont'd)
SAMPLE TITLE BOX
THIS COLUMN RESERVED FOR NOTES AND HOLDS FROM THE TOP OF TITLE BOX TO
TOP OF DRAWING
This Drawing is the Property of the

PERRYVILLE CORPORATE PARK, CLINTON, N.J.
AND IS LENT WITHOUT CONSIDERATION OTHER THAN THE BORROWER'S AGREEMENT THAT IT SHALL NOT BE
REPRODUCED, COPIED OR DISPOSED OF DIRECTLY OR INDIRECTLY, NOR USED FOR ANY PURPOSE OTHER THAN THAT
FOR WHICH IT IS SPECIFICALLY FURNISHED. THE APPARATUS SHOWN IN THE DRAWING IS COVERED BY PATENTS.
ITEMS NOS.
THIS ENGINEERING FLOW DIAGRAM
DRAWING SOUR WATER STRIPPING UNIT
UNIT 600
SOUR WATER STRIPPER
CUSTOMER ABC
Customer ABC Location
EST NO. DRAWN BY: 04-01-95 SH X OF Y
REV. A April, 1995 PROCESS ISSUEINITIALS Contract No. XX-XXXX DWG. NO. XXXX-2-50-01 A
Revision: 5
Date: Aug. 9, 2007
______________________________________________________________________
PEP-1007
ENGINEERING FLOW DIAGRAM PIPING DETAILS
Pump Piping
1. A pressure gauge shall be installed between centrifugal pumps and check valves,
and a 3/4" valved bleed connection shall be provided between the check valve
and block valve.
2. For all single stage pumps operating above 500F (260 C) and all multistage
pumps operating above 400F (204 C), a 1" warm-up line with globe valve shall
be installed. The warm-up line is to be routed around the check valve only.
3. The casing vents of LPG pumps will be hard-piped to the flare system using
double blocks and bleeds.
Compressor Piping
The following piping items shall be provided at each compressor or compressor cylinder
for purging, maintenance, etc.:
- connection to flare from discharge line for flammable gases
- connection to atmosphere from discharge or recycle line
- fittings inside block valves for connections to nitrogen system or cylinders for
purging
Nitrogen Piping
Typically temporary connections, rather than permanent connections, shall be provided

for all intermittent nitrogen requirements. Permanent connections will be provided only
for continuous nitrogen requirements. Swing elbows or spool pieces shall be provided,
but not flexible hoses.
Revision: 5
Date: Aug. 9, 2007
______________________________________________________________________
PEP-1007 (Cont'd)
Exchanger Piping
The following detail shall be supplied for water cooled exchangers
Cooling
gWater
Return
PSV -
XXX
Set @ xx psig 3/4"
Size Vent
Cooling
Water ~
Supply ~
3/4"
To Grade at
Drain
Safe Location
Back flushing, chemical cleaning and 1" winterizing line requirements are at the client's
option and are not included in this detail.
Furnace Piping
1. In general, the steam-air decoking piping connections details shall be as shown.
Inlet and outlet piping for heaters which are to be steam air decoked should have
removable spool pieces on the inlet and the outlet piping. Locate the heater inlet
PI downstream of the inlet line spool; locate an outlet coil TI upstream of the
outlet line spool.
Revision: 5
Date: Aug. 9, 2007
______________________________________________________________________
PEP-1007 (Cont'd)
Furnace Piping (Cont'd)
2. If manually operated globe valves are used to regulate the flow in multiple pass
furnaces, such valves shall be located at ground level and each pass shall be
provided with an outlet temperature indicator visible from the valves.
3. The superheated steam piping design temperature from each heater superheat
5 coil shall be established after heater vendor data is available (by the detailed
engineering contractor). A note should be placed on the EFD to indicate this.
4. In general, piping for furnaces equipped with superheat stripping steam coils
should have:
- Start-up vent with silencer downstream of superheat coil
- Board-mounted TI on main header downstream of superheat coil but

upstream of start-up vent
- A PSV sized in accordance with requirements of ASME Boiler Code

Section I, when the superheat coil can be blocked in. PSV should
discharge to atmosphere.
A note is to be included on the heater specification that the superheated steam

coil is to be designed for zero steam flow conditions during otherwise normal
(fouled) operation.
5. A local PI should be on the inlet line to each process coil. Locate the PI
downstream of the heater inlet control valve (if any).
Revision: 5
Date: Aug. 9, 2007
______________________________________________________________________
PEP-1007 (Cont'd)
Vessel Piping
(refers to towers and drums only)
1. The gas vent line from drums such as overhead receivers and the product
separators shall have a vent line to the flare.
2. All vessels must be provided with a high point vent, low point drain and steamout
connection. Vents are to be on the top of the vessel. Drains are to be on the
bottom piping. Separate steamout connections are not required for vessels
which already have stripping steam connections or clean water vessels and
steam drums or kettles.
Auxiliary nozzles for all vessels (including towers) are to be sized in accordance
with the Process Standard on drums.
Board mounted PDI's shall be provided on the main sections of the towers.
PI's should be located on piping or on level gages.
Control Valves
For line sizes 2" or less, blocks and by-passes shall be provided around control valves.
In addition, blocks and by-passes shall be installed around any critical service control
valve whose malfunction would cause unit shutdown mode or prevent continuous
operation of unit. Blocks and bypasses will also be provided for erosive services or
services with a pressure drop above 150 psi. For line sizes greater than 2", control
valves in non-critical services shall be provided with a manually operated hand wheel
jack with valve opening indicator, without by-pass. Upstream control valve bleeds are
to be shown on the EFD's. If the control valve size sets a PSV load, the bypass valve
CV should be less than or equal to the control valve C V.
Relief Valves
1. Relief valves requiring periodic testing shall be provided with Car Seal Open
(CSO) isolation valves and a 3/4" bleed valve. A bypass line with a normally
closed (NC) valve and a 3/4" PI tap, for use when the valve is being tested, shall
be provided around the relief valve(s) and isolation valves.
Revision: 5
Date: Aug. 9, 2007
______________________________________________________________________
PEP-1007 (Cont'd)
Relief Valves (Cont'd)
2. Relief valve discharge lines to atmosphere shall be provided with " weep holes.
The weep hole drain lines shall be piped to a "safe location".
Sample Connections
Where sample points are required, they are identified as below.
SC
for sample connection without cooling.
for sample connection with cooling.
Battery Limit Connections
In general, draw B.L. connections as shown below. Battery limits may only be shown at
top or bottom of the EFD.
PI
B.L.
B.L.
PEP-1007 (Cont'd)
LINES ON TWO EFDS
Extensions of lines to adjacent EFDs should be at equal drawing elevation index

numbers (see the example below). This practice is preferable but not absolutely
required for the extension of lines to non-adjacent EFDs within the same unit.
All lines extended from one EFD to another must be labeled and designated by source
(if entering) or destination (if leaving) as in the example below.
PROCESS ENGINEERING PRACTICES Page: 1of 1
Revision: 4
Date: Mar. 6, 2006
______________________________________________________________________
PEP-100
8 EFD #02 EFD #03
55 55
54 54
SOUR WAT ER SOUR WAT ER
53 53
TO D-1501 FROM P-1501
52 52
51 51
50 50
ST RIPPED WAT ER ST RIPPER BOT TOMS

FROM TK-1501 TO E-1501
EFD #12
UTILITY HEADER DESIGNATIONSEFD #01
Utility connections on EFDs will be shown by balloons. A set of balloons for this
project will be included on one of the General Notes and Symbols EFD for each unit.
Under no circumstances should additional balloons be included by an engineer without
approval by the project manager.
The purpose of utility balloons is to enable geographic layout of utility flow diagrams
(UFDs) for each unit. They are not to be used for injection facilities such as inhibitor,
ammonia or similar connections.
Revision: 5
Date: Aug. 9, 2007
______________________________________________________________________
PEP-1009
INSTRUMENTATION
1. In general, all vessels containing vapor and liquid shall be equipped with high
and low level alarms.
2. As required by stream properties, instruments shall be protected from adverse

conditions by protective heating, sealing, housing, insulating and/or flushing.
3. A temperature sensing element in a control loop shall be checked by a separate

thermocouple.
4. As a minimum, fractionating tower top and bottom tray temperatures shall be

monitored, as well as all furnace inlet and outlet points.
5. To indicate overheating and possible coking of heater tubes during operation, a

sufficient number of thermocouples shall be provided on the outside skin of
heater tubes when appropriate. The location for each skin TI shall be at the
expected high temperature portion of each coil.
6. In general, all level instruments shall be mounted separately. Standpipes will not
be used. The process engineer will define the normal operating range by setting
approximate High and Low Liquid Levels (HLL & LLL) in vessels. These values
set the end points for both visible level indications (gauge glasses) and
transmitter range. Extreme high or low level shut-down points or alarms may be
set beyond these range limits, using level switches. For such extreme levels,
either a separate gauge glass or an extension of coverage by the full range glass
5 shall be provided. The minimum setting for hard piped low- low level switch on
vertical vessels is 1'-5" above vessel bottom tangent line or consult with the
Automation and Controls Group. (See also PEP 1010).
7. Instrumentation shall be provided to indicate the pressure of each tower and

vessel protected by a safety valve.
8. In general, relief valves for liquid thermal expansion shall be provided on the
water side of water-cooled exchangers. Thermal relief valves shall also be
provided on the cold side of all exchangers that can be blocked in. Blocked in
circuits in LPG, where atmospheric conditions are a problem, also require a PSV.
Liquid C2, C3 and C4 circuits, which can expand and/or vaporize when heated by
ambient conditions, also require a PSV.
Revision: 5
Date: Aug. 9, 2007
______________________________________________________________________
PEP-1009 (Cont'd)
INSTRUMENTATION
9. Provisions for oxygen analyzers are required on all heater stacks. Continuous
analyzers are to be provided only where the information will require operators to
make process changes, and not for monitoring only.
10. Primary sensing instrumentation providing inputs to emergency shutdown

systems shall be separate from the process control loop instrumentation.
Example: use a dedicated PSLL (Pressure Switch Low-Low) to provide a low
pressure trip input instead of using an alarm switch residing on the loop
containing the control loop pressure transmitter. Exception: Flow trips may use
a common primary element (orifice plate, venturi, etc.) but separate taps are
required.
11. Process Instrument Data Sheets
a. In general, do not specify PI's, TI's, LG's, except to indicate special

requirements, e.g., nonreflex LG's, decoking temperature for heater outlet
TI's.
b. All alarm points must be specified. Level alarms should be specified as

either a percentage of the level range shown on the process vessel
sketch, e.g., LAH @ 80%, LAL @ 20% or alternatively as the actual LLL
and HLL shown on the sketch given in feet and inches above a reference
point such as BTL (Bottom Tangent Line).
c. Indicate service of instruments not their location.
d. Control valve failure to be indicated by FC, FO, FLO or FLC.

FC (Fail Closed)
FO (Fail Open)
FLO (lock in position on air failure, but 'drifts' open)
FLC (lock in position on air failure, but drifts closed)
e. Instrument sheets must be filled out in accordance with Process Standard

501.
PEP-1009 (Cont'd)
INSTRUMENTATION
12. Relief Valve Process Data Sheets
a. Specify process relief valves. Loads for thermal expansion are to be

specified with calculated loads and conditions.
b. Indicate destination of discharge and EFD number for each relief valve on
the FW relief valve standard form.
c. For PSVs discharging to atmosphere, list atmosphere for superimposed

back pressure and less than 10% for built-up back pressure unless the
discharge system is special. For PSVs discharging to flare, list later for
superimposed and built-up back pressure until the flare system has been
specified.
13. Flare Load Summary Sheets
Provide the following information for relief valves:
For all PSV's discharging to the flare, loads must be supplied on the flare sheets
for block, power failure, fire, instrument air failure and cooling water failure. If no
load exists for any particular contingency, the word "none" should be listed in the
load row.
14. The allowable accumulation to be used for a PSV load due to exposure to fire
shall be "per code," 16% for a single relief valve, or 21% for multiple relief valves.
15. If the liquid filled cold side of a shell and tube exchanger requires protection
against thermal expansion and against exposure to fire, and if the thermal
expansion load requires a relatively small PSV, whereas the fire load requires a
relatively large PSV, then two PSV's shall be provided:
Thermal Relief - Set Pressure = Design Pressure

- Accumulated Pressure = 1.10 x Set Pressure
Open Fire - Set Pressure = 1.10 x Design Pressure

- Accumulated Pressure = 1.10 x Set Pressure
16. For vacuum protection, the accumulated vacuum relief pressure is often in
excess of 10 or 21% (as typical for Pressure Relief Valves) and sometimes as
high as 100%. It is important to note that the accumulated vacuum pressure may
not exceed the vacuum rating of the associated vessels.
Revision: 5
Date: Aug. 9, 2007
______________________________________________________________________
PEP-1010
VESSELS
1. Pressure vessels with relief valves shall be designed for a minimum internal
pressure of at least 10% or 25 psi (1.72 Bar); whichever is greater, above the
maximum specified operating pressure in psig at the top. Minimum design
pressure, at the top, is to be 50 psig (3.45 Barg). Minimum design metal
temperature is to be specified where required by Process (i.e. auto-refrigeration).
2. Vessels without pressure relieving devices shall be provided with an outlet which
cannot be completely blocked off. The minimum outlet opening shall be sized so
that the maximum pressure which can be developed in the vessel is not greater
than the design pressure.
3. Vessels shall be designed for vacuum conditions as required. Vessels with

steam injection (for example, stripping steam) are typically designed for full
vacuum.
4. The minimum design temperature shall be the maximum operating temperature

plus 50F (28 C).
5. The title box shall be in accordance with the sample shown below. The initial
issue of the process vessel specification drawing is to be Revision 0 with
subsequent issues in numerical order. Each issue shall be designated on the
vessel sketch (see sample title box below).
REFERENCE DRAWINGS, REQUISITIONS, DRAWN PEM 01APR95 CONTRACT NUMBER

STANDARDS XX-XXXX
CHECKED
APPROVED
REQUISITION NUMBER
1 15APR96 PEM CLIENT SPLITTER T-101
COMMENTS
0 01APR96 PEM INITIAL ISSUE UNIT XYZ P. O. NUMBER

REV. DATE BY DESCRIPTION
REVISIONS CUSTOMER ABC LOCATION DRAWING NUMBER REV.

SHEET 1 OF 2 1
Revision: 5
Date: Aug. 9, 2007
______________________________________________________________________
PEP-1010 (Cont'd)
VESSELS
6. The following liquid surge capacities are to be used for this project. They are
summarized from the appropriate Foster Wheeler Standards.
Unless otherwise specified, surge capacity is defined as the capacity between

high-liquid level (HLL) and low-liquid level (LLL).
Low-Liquid Level
a. Without Water Settling.

- Horizontal Vessels 6" above Bottom
- Vertical Vessels 8" above BTL
5 - Hard-Piped Low-Low Level Switch 1-5" above BTL (Note)
on Vertical Vessels
(Note: Use of a level transmitter, if permitted by client standards, can allow the
Low, Low Level set-point to be as low as 0-6 above BTL.)
b. With Water Settling.

Provide five (5) minutes holdup at the total hydrocarbon rate below the
low-liquid level for the "settling out" of water. If a pot is not employed, five
(5) minutes of holdup for the water itself must also be provided in the bottom
of the vessel.
Surge Time in Drums
Service Surge Time, Minutes
Feed to Tower or Furnace

Drum Diameter, Ft.
Below 4 20
4 - 6, Inclusive 15
Above 6 10
Reflux to Tower 5
Product to Storage 2
Total draw off pans on towers on Greater of:

level or flow control - 2 minutes on products
- 1 minute on pumparound
to
section above
- 5 minutes on wash to
section
below
Revision: 5
Date: Aug. 9, 2007
______________________________________________________________________
PEP-1010 (Cont'd)
VESSELS
In case surge must be provided for both product and reflux, the larger volume is
used (not the sum of the two volumes).
Surge Time in Towers
Service Surge Time, Minutes
Bottoms to Subsequent Tower
- on Level Control 5
- on Flow Control 15
Bottoms to Heat Exchanger 2 (not applicable to

and/or Tankage vacuum towers)
Feed to fired coil reboilers: sum of 5 minutes on vaporized portion and 2 minutes
on product. It is normally desirable that 5 minutes on vaporized portion be
employed to establish NLL, the subsequent 2 minutes on product used to
establish the HLL (NLL to HLL, minimum of l ft.).
Revision: 4
Date: Mar. 6, 2006
______________________________________________________________________
PEP-1011
FIRED HEATERS
The following notes are generally applicable to fired heaters in conventional services.
Some of these notes may not apply to special heaters such as coker heaters or
reformers.
1. Fired heater process specification shall be on standard FW process data forms

or equivalent computer generated forms. Additional sheets for data and notes
may be added as required for each service.
2. The process engineer should indicate the minimum design pressure, but the
design metal temperature must be left blank.
3. Burner type shall be specified for all heaters. In accordance with the BEDD
sheets, burners specified for liquid fuels require pilot burners to be specified.
Burner location shall not normally be specified by the process engineer.
4. Furnaces in services classified as "dirty" (or subject to coking) shall be provided

with facilities for steam and air decoking and designed to withstand the metal
temperature and thermal stress of steam air decoking.
5. The following notes should be included in the process specification for each
heater where applicable. Additional notes may be added as required, e.g.:
a. Vendor shall confirm that the superheated steam coil is capable of

withstanding zero steam flow conditions during normal and fouled
operations.
b. Heater shall be designed for continuous operation and shall be capable of

operating at turndown as required by Basis of Design.
c. Vendor shall provide information concerning their recommendations for

the proper design and operation of steam air decoking facilities.
Revision: 4
Date: Mar. 6, 2006
______________________________________________________________________
PEP-1011 (Cont'd)
FIRED HEATERS
d. Vendor shall provide the following with regard to soot blowers, (applies
only for fuel oil/combination firing with a convection section.)
- Soot blowing lanes with end bearing and mounting flanges

- Shrouds for refractory protection in the soot blower lanes.
- Design drawings for soot blower platforms.
- Convection coil design that will accommodate fuel oil firing without
rapid fouling.
8. Process data and cost of available fuels will be provided on the Basic
Engineering Data sheets.
9. Given below are guidelines to be used in estimating utility line sizes and utility
requirements for fired heaters (at least until vendor requirements are confirmed).
a. Purge Steam (fire box):
l) 100 to 200 lbs. steam per MMBtu (180 to 360 Kg steam per
MMkcal) (liberated)
2) use M.P. steam (150 psig)
3) label header "purge steam" not "snuffing steam"
b. Coil Steamout:
l) use 5 lb/sec. ft2 (24.4 Kg/sec.-m2) for steam mass velocity through
coil
2) use 2" diameter line for each coil
3) use M.P. steam or higher pressure if necessary (steam supply

pressure should be higher than down stream pressure)
4) label header "coil steamout"

Revision: 4
Date: Mar. 6, 2006
______________________________________________________________________
PEP-1011 (Cont'd)
FIRED HEATERS
c) Atomizing Steam:
1) 0.5 lb steam per lb of oil consumed
2) use M.P. steam or a steam with at least 30 psi (2.1 Bar) higher than
fuel oil pressure.
3) size steam line for 1.0 lb steam per lb of oil consumed
d) Soot Blowers:
1) must be specified for each heater specified for oil or combination

firing
2) design consumption is typically 10,000 lbs/hr (4,536 kg/hr)
3) use M.P. steam
10. The following items must be shown on engineering flow diagrams for each fired
heater:
- Flue gas analyzer with board indication.
- Draft gage, connections only.
- Skin thermocouple on each pass with board indications.
- TI's for radiant zone, arch, convection section, stack and crossovers.
- Fuel gas flow with board indication.
- Stack damper, manual loading station on board.
- Automatic switch over to natural draft operation on failure of air blower.
11. Air blowers for fired heaters will not be spared.
Fired heaters will be specified for stable operation without the air blower and with
automatic switchover to natural draft. Vendors will be instructed to advise
turndown required for natural draft operation.
Revision: 6
Date: Feb. 11, 2009
______________________________________________________________________
PEP-1012
HYDRAULICS
1.0 LINE SIZING CRITERIA
Below are some general rules for line sizing. These rules should cover most
normal situations, but may not be suitable for all cases, especially revamps. For
critical services or long headers, the process engineer is to carry out a hydraulic
study of the system to confirm the total pressure drops and the pressure balance,
regardless of whether the lines meet the allowable pressure drop and velocity
criteria as given in this PEP.
The process engineer should also refer to Process Standard 201, Fluid Flow
6
Single Phase, and Standard 202, Fluid Flow Two Phase. In case of any conflicts
with the process standards, this Process Engineering Practice shall govern.
1.1 Drawoff Nozzles
Reference the FW Process Standards 103, section 3.0. The minimum drawoff
box depth shall be one and one-half times the nominal drawoff size, but not less
6 than 9 inches. In case of any conflicts with the Process Standard 103, this
Process Engineering Practice shall govern.
1.2 Pump Suction Lines
Pipe Diameters 8" and less Pipe Diameters more than 8"
Approx. Allowable P, Approx. Velocity, Allowable P,

Velocity, psi/100 ft ft/sec psi/100 ft
ft/sec
Nonboiling 3 to 5 1.0 to 1.5 12 max 1.0 to 1.5
Liquid
Boiling 1 to 3 0.3 to 0.5 6 max 0.3 to 0.5
Liquid
Note: Gas blanketed liquids are to be considered as boiling liquids for line sizing,
pump calculations, specifications, etc.
Revision: 6
Date: Feb. 11, 2009
______________________________________________________________________
PEP-1012 (Cont'd)
HYDRAULICS
1.0 LINE SIZING CRITERIA (Contd)
1.3 Pump Discharge Lines
Allowable Pressure Drop
1.5 to 3 psi/100 feet
0.5 to 1.0 psi/100 feet maximum for long headers (800 equivalent feet and
greater)
Approximate Velocity
Pipe Diameter Approximate Velocity, ft/sec
4" and less 5 to 7

6" 10 max.
8" and more 12 max.
1.4 Reboiler Lines
Reboiler Trap-out
Allowable Pressure Drop 0.15 to 0.3 psi/100 feet

Approximate Velocity 3 to 5 feet/second
Reboiler Return
Allowable Pressure Drop 0.3 psi/100 feet

(See rules for 2 phase below.)
Revision: 6
Date: Feb. 11, 2009
______________________________________________________________________
PEP-1012 (Cont'd)
HYDRAULICS
1.5 Cooling Water Lines
Reference for Sizing
Use FW charts 5-107-B-1 to 6 but add an additional 20 percent to the

pressure drop values given in the chart to allow for aging. Cameron, with
C=100 is not acceptable.
1 to 1.5 psi/100 feet for main headers

1.5 to 3 psi/100 feet for branch lines
Approximate Velocity
Same as for pump discharge lines (Item 1.3 above).
1.6 HC Vapor Lines
For lines not exceeding 300 feet in length
Pressure Level Pressure Drop, psi/100 feet
28" Vacuum (1 psia) 0.0625

15" Vacuum (7 psia) 0.15
0 psig to 50 psig 0.25 to 0.5
150 psig to 500 psig 1.5 to 3.0
Over 500 psig (0.5% of pressure level)
Allowable Velocities
Maximum for gas = 100/ Dg ft./sec, where Dg is density of gas in lb/cu. ft.
Revision: 6
Date: Feb. 11, 2009
______________________________________________________________________
PEP-1012 (Cont'd)
HYDRAULICS
1.7 Two-Phase Process Lines

100
Maximum for two-phase flow = Dmix
, ft/sec
60
Minimum for two-phase flow = Dmix
, ft/sec
Where Dmix is the density of the mixture in lb/cu. ft.
Velocity may be less than 60 / Dmix , ft . / sec at vessel inlet or for

horizontal runs where separation of the two phases is desirable.
For critical two-phase lines, detailed calculations must be made for pressure
drop and flow required.
1.8 Steam Condensate
Onsite lines only.
Allowable Velocity
1 to 2 feet/second, as if all condensate remained as liquid.
1.9 Steam Lines
For lines not exceeding 300 feet in length
Pressure Level Pressure Drop, psi/100 feet
28" Vacuum (1 psia) 0.0625

15" Vacuum (7 psia) 0.20
150 psig to 500 psig 1.5 to 3.0
Over 500 psig (0.5% of pressure level)
Revision: 6
Date: Feb. 11, 2009
______________________________________________________________________
PEP-1012 (Cont'd)
HYDRAULICS
1.10 Sour Water Lines
Allowable Velocity
Maximum Allowable
Pipe Material Fluid Velocity, ft/sec
Carbon Steel Sour Water/Hydrocarbon Mixture 20
Sour Water > 250F 5
Sour Water 250F 10
Stainless Steel Sour Water at all 20
temperatures
Pressure drop per Section 1.1 through 1.4 above.
1.11 Amine Solution Lines
Allowable Velocity
Maximum Allowable
Pipe Material Fluid Velocity, ft/sec
Carbon Steel Lean Amine 20

Rich Amine 3
Stainless Steel
or Alloy 2205 Rich Amine 20
Carbon Steel is the preferred pipe material for amine services.

Velocity limits assume fluid remaining as liquid.
Pressure drop per Section 1.1 through 1.4 above.

Revision: 6
Date: Feb. 11, 2009
______________________________________________________________________
PEP-1012 (Cont'd)
HYDRAULICS
1.12 PSV Lines
Line sizing shall generally be in accordance with API RP 520, Part I and
Part II, and RP-521.
To reduce noise levels during an emergency "blow" to the flare, discharge

line and header velocities shall not exceed 100 / Dg , ft/sec or 80% of
sonic velocity, whichever is lower.
Where:
a. sonic = 223 X kT / M where T = R, M = mol. wt.

OR
b. sonic = 68.1 X kP / Dg
where k = Cp/Cv, P = psia, Dg = lbs/cu. ft.

Flare headers shall be free draining toward flare drum.
6 1.13 Condenser Bypass Lines, Balance Lines, and Vent Lines
Both the controlled bypass lines around the condenser and the vent line
from the accumulator drum are sized for a minimum of 10% of the tower's
gross overhead flow. Refer also to Process Standard 507, Section 4.0 for
more conservative sizing criteria.
Open balance lines in total condenser services should be sized for 25% of
the tower gross overhead flow or shall be sized to pass any relief flows,
whichever case controls.
1.14 Thermosyphon Reboiler Circuits
When calculating the skirt height of a tower having a thermosyphon

reboiler, Foster Wheeler's normal practice of requiring a driving force
equal to three times the calculated pressure drop in the thermosyphon
circuit shall be employed. For very large units, if approved by the
responsible chief engineer, this driving force may be reduced from three to
two times the calculated pressure drop.
Revision: 6
Date: Feb. 11, 2009
______________________________________________________________________
PEP-1012 (Cont'd)
HYDRAULICS
1.15 Slurry Service
a) Velocity criteria for line sizing: To avoid settling in lines, design for a
minimum allowable velocity of 3 ft/sec in normal operation. To
avoid abrasion and excessive wear in the lines, design for
maximum normal velocity of 7 ft/sec.
b) Do not use a common suction line to spare slurry pumps. Provide

one line to each pump to prevent losing spare capacity due to
plugging on suction side.
c) Normally connect steam generators in slurry service in parallel.

Design is often for two 50% exchangers. This facilitates cleaning
the exchangers without having to shutdown the unit. It also
decreases problems encountered during turndown operation.
d) Exchangers in slurry service should be designed for 5 - 7 ft/sec

velocity at normal operating conditions.
Revision: 6
Date: Feb. 11, 2009
______________________________________________________________________
PEP-1012 (Cont'd)
HYDRAULICS
2.0 CONTROL VALVE PRESSURE DROP ALLOWANCE
Unless otherwise dictated by process, control valve pressure drop shall be

calculated on the following basis:
2.1 Pumping Services (Discharge side)
Generally, the pressure drop assigned to the control valve for the pump, at
normal operating capacity, shall be equal to either 10% of the system
operating pressure in psig at pump destination, up to 1000 psig, or 33% of
the frictional loss in the system excluding the pressure drop assigned to
the control valve, whichever is greater. For systems where high frictional
losses are taken, i.e., crude preheat circuits, 10% of the estimated pump
destination pressure should be adequate; but in no case shall the
assigned control valve pressure drop for the pump design case be less
than 10 psi. For systems operating above 1000 psig, the control valve
may take less than 10% of the system pressure, depending on process
and control considerations.
Control valves (including actuators) should be specified as capable of

shutoff and opening with maximum upstream pressure and minimum
downstream pressure. On a pump discharge system, the maximum
upstream pressure is the pump shutoff pressure at maximum pump
suction pressure.
2.2 Other Liquid Services (Gravity flow, cascading from one pressure level to
another, etc.)
Pressure drop is a function of the system under consideration, but as a

general rule, the pressure drop assigned to the control valve shall not be
less than 10% and no greater than 85% of the pressure differential
available for frictional loss.
2.3 Gas Services
For compressor services, the engineer should be guided by the pump

criteria listed above.
Generally, for other gas services, the pressure drop assigned to the gas
control valve shall not be less than 10% and not greater than 85% of the
pressure differential available for frictional loss.
Revision: 4
Date: Mar. 6, 2006
______________________________________________________________________
PEP-1013
EXCHANGERS
1. Air cooled exchangers typically are forced draft, usually with a minimum of two
fans per bay.
Combined services within one bay are not desired.
2. If both the cold side inlet and outlet of an exchanger require block valves, a relief
valve shall be provided on the cold side inlet to prevent excessive thermal
expansion. In no case, should this relief valve be set lower than the highest
pump shut-off pressure to which it may be subjected, or higher than the
exchanger design pressure.
3. The general order of priority to establish the tubeside fluid is listed below. This
listing is for guidance only and should not be considered inflexible.
(i) Cooling water
(ii) A corrosive fluid or a fluid likely to deposit coke, sediment or other solids
such as catalyst.
(iii) The higher fouling fluid.
(iv) The less viscous of the two fluids, where large differences exist.
(v) The fluid under higher pressure, where large differences exist.
(vi) The hotter fluid.
Condensing vapors are usually located on the shell side. Also, if the temperature
change of a fluid in an exchanger is very large, for example, several hundred
degrees, it is often better to pass this fluid through the shell. Otherwise multiple
bundles may be required to avoid excessive temperature stresses on the
tubesheets.
Revision: 4
Date: Mar. 6, 2006
______________________________________________________________________
PEP-1013 (Contd)
EXCHANGERS
4. In general, air cooled exchangers shall be provided with:
- Process side temperature indication and low alarms (as required) in

control room for each outlet nozzle.
- Variable speed fan motors, as required (depending on desired degree of

outlet process temperature control), with temperature controller, unless
otherwise specified.
The following additional provisions are required for freeze protection, where
applicable, during start-up and shutdown:
- Self draining, steam coils and louvers shall be provided on air cooled
exchangers handling high pour materials, water or hydrocarbon/water
mixtures.
- Self draining and louvers shall be provided on air cooled exchangers

handling hydrocarbon/water mixtures containing less than 10 wt% water.
- If louvers are provided for supplemental freeze protection during start-up

and shutdown, they will be controlled only via manual loading stations.
5. The specified fouling resistance shall be in accordance with the latest TEMA
standards. The following fouling resistances shall be specified for utility streams
regardless of velocity or temperature:
Utility Fouling Factor (Ft2 hr F/BTU)
Steam 0.0005
Boiler Feedwater 0.001
Condensate 0.001
Cooling Water 0.002
Lean Amine 0.002
Rich Amine 0.002
Revision: 4
Date: Mar. 6, 2006
______________________________________________________________________
PEP-1013 (Cont'd)
EXCHANGERS
6. The suggested minimum design pressure for shellside and tubeside shall be
specified by the process engineer. This value shall be the greater of:
- Maximum pump shutoff pressure, when exchanger can be blocked off and
exposed to pump shutoff.
- 25 psi or 10% greater than maximum operating pressure. Where

exchanger is protected by relief valve, a pressure balance for relieving
conditions must be made to determine design pressure.
- 50 psig
9. Suggested minimum design temperature for shellside and tubeside fluids shall be
specified by the process engineer. This value shall be the greater of:
- maximum normal operating temperature plus 50F
- other based on air or bypass or turn-down
10. Where applicable, limiting transfer rates and exchanger type shall be indicated.
Revision: 4
Date: Mar. 6, 2006
______________________________________________________________________
PEP-1014
PUMPS AND COMPRESSORS
1. Overcapacity Factors
The following overcapacity factors shall be used unless otherwise specified by

the chief engineer.
a. Pumps
Charge, product, transfer services 1.1
Reflux, pumparound, reboiler & other

critical services 1.2
b. Compressors
Centrifugal 1.2
2. Pump hydraulic calculations are to be issued together with the pump

specifications, and are to be included in the Process Technical Specification
book.
3. For pumps specified for bubble point fluids show "B.P." on the pump specification
sheet rather than the actual vapor pressure. Note that this also applies to fluids
containing dissolved/entrained gas.
4. Calculation of Pump Shutoff Pressure at Maximum Suction Pressure
Pump Maximum Suction Pressure
a. Taking suction from tankage open to the atmosphere.
MSP (Max. Suction Pressure) = static head measured from maximum tank
liquid level (zero frictional line loss)
b. Taking suction from a pressure vessel.
MSP = Vessel minimum design pressure at top plus estimated frictional

loss through trays plus static head measured from highest liquid level
(zero frictional line loss)
Revision: 4
Date: Mar. 6, 2006
______________________________________________________________________
PEP-1014 (Contd)
4. Calculation of Pump Shutoff Pressure at Maximum Suction Pressure (Contd)
Pump Shutoff Pressure for Centrifugal Pumps*
PSP (Pump Shutoff Pressure) = MSP plus 1.2 x (pump differential at maximum
specified specific gravity).
*Pump shutoff as calculated above is used to designate preliminary equipment

design pressure; but is to be confirmed by the Project Department on selection of
final pump curves.
5. Minimum flow requirements must be specified for each pump, to cover such
conditions as start-up, shutdown, turndown, regeneration, etc.
6. Pump calculations for NPSH and power consumption are to be made at the
design flowrate.
7. Static head requirements for a discharge pressure calculation shall be based on

actual operating temperature where the static head occurs (not necessarily
pumping temperature).
8. The following note is to be affixed to the specification for all equipment having a
design pressure determined by pump shutoff.
DESIGN PRESSURE: Psig*
*But not less than the shutoff pressure of P- (or P- if

common spare) at maximum suction conditions.
9. Spare Capacity
a. 100% spare capacity shall be specified for all pumps in critical service.
b. Air blowers serving fired heaters will not be spared.
c. Single speed electric motors are preferred drivers for primary and spare
pumps, as well as for compressors. Steam turbine drivers may be
selected based on special process, utility or mechanical considerations.
Revision: 4
Date: Mar. 6, 2006
______________________________________________________________________
PEP-1014 (Contd)
10. Centrifugal compressors shall be specified when appropriate.
11. Drivers for air blowers shall be designed for cold air operation.
Revision: 0
Date: Sep. 12, 2008
______________________________________________________________________
PEP-1015
WORK PLAN PREPARATION AND MAINTENANCE
1 SCOPE
This work practice outlines the requirements for preparing and maintaining a Process
Dept Detailed Work Plan, including the Work Plan Summary Sheet (WPSS), covered in
EP 8-1, for typical projects. Special considerations may require deviation from this
work practice with the approval of the Director-Process Engineering.
2 GENERAL
2.1 This PEP is applicable to all projects ranging from Process Design Packages to full
EPCM projects, with the understanding that progress milestones and weighting
values (percentages) will vary between the types of projects handled.
2.2 The Lead Process Engineer shall prepare the detailed work plan and corresponding
WPSS used to track the progress of all equipment items, studies and/or work
products assigned to the Process Department for the given project. The Chief
Process Engineer may elect to assign another Process engineer to prepare and
maintain the work plan, however, it shall be the Lead Process Engineers
responsibility to ensure that the plans accuracy as well as the requirements of this
PEP and other practices referenced herein are followed in the preparation and
maintenance of the detailed work plan and WPSS.
2.3 The purpose of the work plan is to plan, execute and report progress by achieving
specific activity milestones for each tagged equipment or, study, activity and/or work
product. Partial earned credit may be taken, as defined in paragraph 7.3, for these
milestones. The work plan also reports hours earned as well as total percent
complete per item or activity.
2.4 A template Workplan and WPSS, Form No. 210901, is located on the Process
department webpage of the Foster Wheeler Intranet in the Workplan Template
directory. The file is a single Excel Workbook that includes the WPSS and
Workplan. The Process Work Plan Template workbook contains the following tabs:
2.4.1 WPSS is the first tab and is clearly labeled WPSS ROLLUP (typical for all
department WPSS practices). The Department WPSS Form contains
company-wide Earned Value and Productivity Calculations that are
password protected for consistency across the organization.
2.4.2 An overall summary is the second tab. The overall summary is auto-
populated from the Progress report sheet (see paragraph 2.4.3).
Revision: 0
Date: Sep. 12, 2008
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PEP-1015 (Contd)
2.4.3 The detailed work plan is provided in the third tab, labeled Progress report.
The detailed work plan lists all of the activities defined in the WPSS with a
further detailed breakdown. For example, the WPSS has an activity,
Process Specifications (job class 6) while the work plan lists each major
piece of equipment by tag number.
2.4.4 Variances are summarized in the fourth tab, labeled Variances. Variances
are further discussed in paragraph 7.2.
2.4.5 Password protection: Milestone weightings and earned value calculation

cells of the WPSS shall remain password protected. Control of the
password is the responsibility of the Director-Process Engineering (EP 8-1).
2.5 The WPSS includes the following information:
Job Class the Job Classes are the standard Job Classes for the Process
department.
Activity Name this is a short description of the Job Class.
Unit of Measure these are the units that are used to provide more objective
measuring tools in determining the earned value of the project.
Unit Counts (Original, Approved and Forecast) this is a value for the number of
items (see Unit of Measure) that are required for each Job Class. The Original
number is the initial number from the original estimate for the project. The
Approved number would include the Original number plus all approved quantities
due to client approved Change Orders. The Forecast number includes the
Approved number plus submitted variances that have not been approved or
detected variances that have not been submitted.
Budget Hours (Original, Approved and Forecast) this is a value for the number of
hours that are required for each Job Class. The Original number is the initial
number of hours from the original estimate for the project. The Approved number
would include the Original Number of hours plus all approved hours due to client
approved Change Orders. The Forecast number includes the Approved hours
plus submitted variances that have not been approved or detected variances that
have not been submitted.
Earned Hours a calculation of the earned hours for effective hours for each Job
Class.
Revision: 0
Date: Sep. 12, 2008
______________________________________________________________________
Milestones progressable levels of completeness with weighting for each activity.

PEP-1015 (Contd)
Earned Value (EV%) is the percent of the hours or units earned for each Job
Class. This is summed up to provide the total percent complete for all activities on
the project.
Productivity is a measure of the Earned Hours vs. Expended Hours.
2.6 The Lead Process Engineer or designee shall submit the completed work plan,
including the WPSS, to the Chief Process Engineer for review and approval prior to
distribution to the Project Manager or as directed by the Project Manager. The Chief
Process Engineer shall signify approval of the work plan and WPSS by returning a
signed copy of the WPSS to the Lead Process Engineer.
3 INFORMATION REQUIRED FOR SETUP
3.1 The following list defines the information needed by the Lead Process Engineer in
order to prepare the work plan and WPSS.
3.1.1 Equipment List with item tag numbers and descriptions or preliminary
process flow diagram.
3.1.2 Project schedule with planned activity dates.
3.1.3 Approved Contract Budget Manhours for the Process Department including
breakdowns by activity if available.
3.1.4 Scope of Work
3.1.5 Project Execution Plan
4 CREATION OF WORK PLAN
4.1 The work plan must be created by making a copy of the department work plan
template located on the Process Dept. Intranet web page, and saving to the project
folder. DO NOT copy an existing work plan from another project. The electronic file
name for the work plan shall follow the convention given in EP 8-1.
4.2 Modify the work plan by inserting the project item tag numbers, descriptions,
activities and budget man hours with scheduled dates for completion. (Refer to
Attachment A and paragraphs 5.1 through 5.5 below)
4.3 Activity milestones not applicable due to the scope of the project may be zeroed out
on the WPSS form. However, the milestone activities will still be listed.
Revision: 0
Date: Sep. 12, 2008
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PEP-1015 (Contd)
4.4 Additional milestones, not contained within the template, shall not be added without
prior consultation with the Chief Process Engineer(s) and Director-Process
Engineering.
4.5 The weighting value associated with each milestone, as given in paragraph 6.2,
shall not be modified without prior consultation with the Chief Process Engineer
and/or Director-Process Engineering.
4.6 The work plan is divided into several tabs within the electronic file, as described in
paragraph 2.4. Typically, one work plan is produced per project, regardless of how
many units are in that project. However, if the client and/or Project Manager require
separate tracking for each unit, then individual work plans or separate Progress
report tabs linked to a single overall summary and WPSS ROLLUP tabs, may need
to be created.
4.7 If the activity and/or milestones do not apply for a particular project, they will be left
blank on the WPSS ROLLUP tab. The activities are fixed and rows cannot be
added or deleted nor can activity names be changed.
4.8 After the set up process, all formulas shall be reviewed to insure that they are
functioning properly. The template can be used to assist in correcting any cells that
may have been accidently modified during set up.
5 WORK PLAN SUMMARY SHEET SET-UP
5.1 The WPSS shall be set-up based on Job Class/Activity. Job Classes shall consist of
the following activities listed below with their respective unit of measure.
Job Activity Unit of Measure

Class
1 Design Basis / Kick-off Meeting # of Documents
2 Yields # of Calculations
3 Simulation Modeling # of Simulations
4 Heat and Material Balance # of Documents
5 Process Studies # of Simulations
6 Process Specifications # of Process Design
Specifications (PDS)
7 Equipment List # of Documents
8 Process Description # of Documents
9 Utility Summary & Effluent # of Documents
Emissions
Revision: 0
Date: Sep. 12, 2008
______________________________________________________________________
Job Activity Unit of Measure

Class
10 Instrument Process Data # of Process Design
Revision: 0
Date: Sep. 12, 2008
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PEP-1015 (Contd)
Job Class Activity Unit of Measure

11 Interlocks # of Documents
12 PSV (includes Flare Summary) # of Process Design
13 Line Sizing # of Systems
14 Hydraulics # of Systems
15 PFDs # of Drawings
16 EFDs # of Drawings
17 Materials of Construction (MOC) # of Drawings
18 Design Pressure & Temperature # of Drawings
(DPDT)
19 Process Writeups (PDP) # of Documents
20 Progress Reports / Coordination -
21 Operating Guides (with list of Analytical # of Documents
procedures)
22 HAZOP # of Drawings
23 Review of Critical Documents # of Documents
24 Requisition Review # of Process Design
25 Vendor Quotes # of Process Design
26 Instrument Support # of Drawings
27 Project Support (P&I) # of Drawings
28 Model Review # of Systems
29 Follow up / Coordination # of Weeks
30 Hydraulic Checks (ISOs) # of Systems
31 Variances (Approved) # of Variances
5.2 The Unit Count and Budget Hours associated for each Job Class shall be
determined from the values located in the work plan. During the initial set up, the
values for the Original Plan, Approved Contract Budget and Current Forecast shall
all be the same.
5.3 The Activity Milestones and their Weighting for each Job Class shall be taken from
the work plan without modification.
5.4 The primary document for forecasting and measuring progress is the Progress
report tab in the work plan workbook. The Progress report is customized to each
project and will list each activity by drawing number, tag number, study, etc., as
shown on the template in Form 210901 on the Process Department Intranet web
page. While certain fields in the Progress report worksheet are protected because
there is a formula, the number of rows may be increased or decreased as required.
Revision: 0
Date: Sep. 12, 2008
______________________________________________________________________
PEP-1015 (Contd)
5.5 The overall summary tab of the workbook will be automatically populated with the
data from the Progress report tab. The cells in this worksheet are protected to
prevent an individual from writing over the formulas.
5.6 The WPSS ROLLUP tab has some fields auto-populated from the overall summary
worksheet but the following fields must be input by the Lead Process Engineer:
5.6.1 Unit Count, Original plan the number of units for each activity is input.
Currently, this is a manual function where the Lead Process Engineer has
to count the number of units from the Progress report summary. Units are
defined in paragraph 5.1.
5.6.2 Budget Hours, Current forecast typically this will be equal to the Approved
Budget Hours; however, if there were any variances that have not been
approved or submitted for approval, these hours would be reflected in this
column.
5.6.3 Milestone weightings in general, the milestone weightings are fixed,

however depending on the scope of the project (PDP, FEED, EPC, etc.),
there may be a need to change the weightings, as discussed in paragraph
6.3. Once the initial milestones and milestone weightings are determined
for a particular project, these shall remain unchanged throughout the project
duration.
5.6.4 Milestone units the number of units for each activity completed for each
milestone is manually entered. In some categories, for example, process
specifications, this number may have to be adjusted from the actual number
in order to match the number of manhours completed from the Progress
report worksheet. This is because for this category, different equipment
types (towers, exchangers, pumps, etc.) have different manhours per item
assigned and when the unit totals are combined, the result may differ from
the Progress report summary. If this occurs, the Lead Process Engineer
has to manually adjust the unit number until the earned manhours agree
with the manhours on the Progress report worksheet.
5.5 After the set up process, the formulas shall be reviewed to insure that they are
functioning properly. The template can be used to assist in correcting any cells that
may have been accidentally modified during set up.
6 ACTIVITY MILESTONES
6.1 The primary Activity Milestones to be used on the work plan and WPSS, and their
definitions, are given below:
Revision: 0
Date: Sep. 12, 2008
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PEP-1015 (Contd)
6.1.1 Basis of Design The Process department is responsible for preparing the
Basis of Design for a project. The Basis of Design incorporates relevant
data from the following: Client requirements; Basic Engineering Data (BED)
sheets; contractual requirements; Process Coordination Procedure; and
Process technology requirements.
6.1.2 Basic Heat & Material Balance In accordance with Process Department
Procedures, the Process Department is responsible for establishing the
material balance flows to and from the unit as well as establishing all
intermediate stream flows. The material balance then sets the associated
energy balance. Stream flows are captured on Material Balance Sheets
(also known as Diamond Sheets). Each stream has a number that is
referenced on the Process Flow Diagram of the associated process unit.
6.1.3 Process Equipment List In accordance with Engineering Practices (EPs),

the Process Department is responsible for establishing equipment numbers
and equipment names for major equipment items and associated spare
equipment. The Process Equipment List can be found in the Forms
directory on the Process home page.
6.1.4 Process Flow Diagrams Process Flow Diagrams (PFDs) are created and
maintained by the Process in accordance with Process Department
Procedures and the Process Engineering Practices (PEPs), and show all
equipment, stream numbers, temperatures and pressures that results from
the design necessary to meet the requirements established in the Basis of
Design.
6.1.5 Material Balance Summary Sheets This form is used to capture the unit
material balance. The Process Flow Diagram reference stream numbers
with a diamond symbol. The Material Balance Summary Sheets (also
known as Diamond Sheets) list the appropriate stream data for each
referenced stream. The Material Balance Summary Sheets can be found
in the Forms directory on the Process home page. These sheets are also
linked to the EZ Diamond program to easily populate diamond sheets from
a ProII simulation.
Revision: 0
Date: Sep. 12, 2008
______________________________________________________________________
PEP-1015 (Contd)
6.1.6 Process Data Sheets Equipment The Process Department is

responsible for issuing and maintaining Process equipment data sheets for
all equipment or vendor packages throughout the project. In accordance
with Process Department Procedures and the Process Standards, Process
Data Sheets contain all dimensions, operating flow rates, temperatures,
pressures, transient conditions, and design pressure necessary for other
engineering disciplines to develop detailed equipment requisitions suitable
for equipment purchase. The Process Department maintains the Process
Data Sheets throughout the project. All equipment data sheets can be
found in the Forms directory on the Process home page.
6.1.7 Engineering Flow Diagrams All equipment, line sizes, valves, relief valves,
elevation requirements and all other specific information necessary to
design a specific unit or system is reflected on the Engineering Flow
Diagrams (EFDs). Content and ownership of the EFDs is outlined in the
Engineering Practices (EPs). In general, the Process Department
originates the EFDs and controls them up to the B issue, where Process
releases control of the EFDs to the Project Department and all subsequent
issues are by the Project Department. EFDs are often referred to as P&IDs
(Piping and Instrument Diagrams).
6.1.8 Process Data Sheets Instruments In accordance with Process

Department Procedures, PEPs and the Process Standard Design Bulletins,
the Process Department is responsible for issuing and maintaining Process
Instrument Data Sheets throughout the project. The specific valves,
transmitters, indicators, etc., to be included on the data sheets are
established in the deliverables section of the project contract. The process
data to be included for each type of instrument can be found in the
Standard Design Bulletins directory of the Process home page.
6.1.9 Utility Summary In accordance with Process Department Procedures, the

Process Department is responsible for issuing and maintaining the Utility
Summary throughout the project. The Utility Summary is a listing of each
piece of equipment that consumes or produces a utility (such as cooling
water or steam) and the associated utility flow rate. As this is a balance, it
is not suitable to list all equipment in a single system that consume or
produce a utility in a series arrangement (for example, if BFW is preheated
in two consecutive exchangers then only list the first consumer).
Revision: 0
Date: Sep. 12, 2008
______________________________________________________________________
PEP-1015 (Contd)
6.1.10 Catalysts/Chemicals Summary In accordance with Process Department

Procedures, the Process Department is responsible for issuing and
maintaining the Catalyst and Chemical Summary throughout the project.
The Catalyst and Chemical Summary is a listing of all catalysts and
chemicals consumed or required to be present during the operation of the
unit or system.
6.1.11 HAZOP Review A HAZOP (Hazardous Operations) review is coordinated

by the Project Department and supported by the Process Department in
accordance with the Engineering Practices. For this review, the Process
Department typically assigns one Process Engineer and one Process
Operator to participate in the HAZOP review. Following the HAZOP review
the Process Department also supports the HAZOP resolution phase where
specific items are addressed to rectify any issues captured during the
review.
6.1.12 Process Technical Specifications Also known as the Tech Spec, Spec
Book or PDP Package, this write-up is a compilation of all Project
deliverables set forth in the contract. The Process Technical Specification
often includes deliverables developed and issued by other disciplines (such
as the Material of Construction Diagram, Plot Plan, Design Pressure/Design
Temperature Diagram, etc). This is often the final deliverable to the client.
6.1.13 Operating Manuals/Guidelines Operating Guidelines are a set of general

operating criteria and/or instructions that pertain to a specific unit. Although
these guidelines cover all the major systems, they represent only a starting
point for continued development of Operating Manuals.
An Operating Manual is a valve-by-valve/ line-by-line set of instructions that

give specific instructions on commissioning, start-up, shutdown, emergency
shutdown and normal operations. Instrumentation set-points, alarm-points
and trip points are also addressed. Operating Manuals are typically
developed by the owners Operations Group.
6.1.14 Vendor Drawings Squad Check This is a review of vendor information,

initiated, controlled and circulated by the Project Department to obtain
comments from all engineering disciplines and capture these comments
onto a single document. The vendor information is to be reviewed against
the department master of the respective equipment, drawing or instrument
item.
Revision: 0
Date: Sep. 12, 2008
______________________________________________________________________
PEP-1015 (Contd)
6.1.15 Hydraulic Checks In accordance with the PEPs and the Process
Standards, hydraulic checks are the responsibility of the Process
Department. As required, and depending on the contract deliverables and
scope of the project, Process shall request all necessary supporting
information (such as isometric drawings) to evaluate, confirm and finalize
line sizes, equipment elevations, relief valve set pressures, piping
configurations, thermosyphon hydraulics, gravity flow circuits, and other
critical circuits to ensure that the final design, construction and operation of
the unit or system will achieve its objectives and the contract throughput
rate.
6.1.16 Start Up & Commissioning Assistance As requested by the client, the

Process Department shall provide on-site commissioning and start-up
assistance for a specific unit or system. A commissioning period is typically
8 to 12 weeks in duration. During this time, all punch-lists are cleared, and
operating procedures are reviewed and finalized with the unit operators.
Prior to start-up (oil in), the unit is flushed, cleaned and drained per the
operating procedures. At this point the unit is ready for start-up, where
feedstock is introduced into the unit and the unit is operated as specified
and designed to make the desired products.
Revision: 0
Date: Sep. 12, 2008
______________________________________________________________________
PEP-1015 (Contd)
6.2 The project scope will have a direct effect on the weighing factors applied to each
Activity Milestone. For example, PDPs will have fewer milestones with different
weightings than EPC projects. For full EPC projects, the following weighting factors
shall be used.
EPC Projects
Milestone 1 2 3 4 5 6
Design Basis / Kick-off 40% 40% 20%
Meeting
Yields 50% 50%
Simulation Modeling 25% 50% 25%
Heat and Material Balance 25% 50% 25%
Process Studies 35% 50% 15%
Process Specifications 25% 25% 35% 10% 5%
Equipment List 50% 50%
Process Description 50% 50%
Utility Summary & Effluent 50% 50%
Emissions
Instrument Process Data 25% 25% 25% 15% 10%
Interlocks 25% 25% 25% 15% 10%
PSV (includes Flare Summary) 25% 25% 25% 25%
Line Sizing 30% 30% 30% 10%
Hydraulics 30% 30% 30% 10%
PFDs 25% 25% 25% 10% 10% 5%
EFDs 40% 20% 20% 10% 5% 5%
Materials of Construction 50% 50%
(MOC)
Design Pressure & 50% 50%
Temperature (DPDT)
Process Writeups (PDP) 33% 33% 34%
Progress Reports / 100%
Coordination
Operating Guides (with list of 33% 33% 34%
Analytical procedures)
HAZOP 100%
Review of Critical Documents 100%
Requisition Review 100%
Vendor Quotes 100%
Instrument Support 100%
Project Support (P&I) 100%
Model Review 100%
Revision: 0
Date: Sep. 12, 2008
______________________________________________________________________
PEP-1015 (Contd)
EPC Projects
Milestone 1 2 3 4 5 6
Follow up / Coordination 100%
Hydraulic Checks (ISOs) 100%
Variances (Approved) 100%
6.3 For those projects whose scope is less than full EPC or for projects for which the
milestones do not apply, the appropriate milestones and the weighing factors will be
modified from those given in paragraph 6.2. The Lead Process Engineer shall
consult with the Chief Process Engineer and/or Director of Process Engineering and
assign the weighing factors to the milestones in the work plan and WPSS.
7 MAINTENANCE OF WORK PLAN AND WPSS
7.1 In order for the work plan and WPSS to be most effective, they must be updated
frequently and diligently. The frequency of update shall be not longer than once per
week. The Lead Process Engineer shall submit the approved Workplan and WPSS
to meet Project Controls Reporting Period Requirements, which is normally twice
monthly.
7.2 Variances shall be reported immediately and recorded on the detailed work plan
along with the requested manhours.
7.2.1 The variance associated with the tagged item shall be listed below the tag
number on the work plan. The hours in the variance assigned to that tag
number shall be input in the Forecast column. (See Attachment A)
7.2.2 After Project Controls has issued the notification that the variance has been
approved, the hours shall be added to the Client Approved Budget Hours.
Revision: 0
Date: Sep. 12, 2008
______________________________________________________________________
PEP-1015 (Contd)
7.3 Since work plans are to be updated on a weekly basis, and considering the time
durations needed to complete some of the milestones, partial credit shall be claimed
for any milestone meeting the criteria set forth in Attachment A. All other milestone
activities are to be reported on an all or nothing basis.
7.3.1 Partial credit may be claimed for Heat and Material Balances based upon
the number of cases to be presented. For example, if 3 cases are to be
presented and only one has been completed, then 33% credit may be
claimed.
7.3.2 Partial credit may be claimed for Process Studies based upon the number
of studies. For example, if 3 studies are considered part of the scope of the
project and only one has been completed, then 33% credit may be claimed.
7.3.3 Partial credit may be claimed for Process Specifications based upon the
number of equipment items. For example, if there are 50 pieces of
equipment and only ten have been completed, then 20% credit may be
claimed.
7.3.4 Partial credit may be claimed for Instrument Process Data based upon the
number of instrument datasheets. For example, if there are 100 tagged
instrument items that require a datasheet, and only 25 have been
completed, then 25% credit may be claimed.
7.3.5 Partial credit may be claimed for PSVs based upon the number of PSVs.
For example, if there are 10 relief valves and only 3 have been completed,
then 33% credit may be claimed.
7.3.6 Partial credit may be claimed for PFDs based upon the number of drawings.
For example, if there are 10 PFDs and only 2 have been completed, then
20% credit may be claimed.
7.3.7 Partial credit may be claimed for EFDs based upon the number of drawings.
For example, if there are 50 EFDs and only ten have been completed, then
20% credit may be claimed.
7.3.8 Partial credit may be claimed for MOC diagrams based upon the number of
drawings. For example, if there are 10 MOC drawings and only 2 have
been completed, then 20% credit may be claimed.
7.3.9 Partial credit may be claimed for DPDP diagrams based upon the number
of drawings. For example, if there are 10 drawings and only 2 have been
completed, then 20% credit may be claimed.
Revision: 0
Date: Sep. 12, 2008
______________________________________________________________________
PEP-1015 (Contd)
7.3.10 Partial credit may be claimed for Review of Critical Documents based upon
the number of documents to be reviewed. For example, if there are 50
critical documents and only ten have been completed, then 20% credit may
be claimed. Critical documents will be defined in the project kick-off.
7.3.11 Partial credit may be claimed for Requisition Review based upon the
number of requisitions. For example, if there are 50 requisitions and only
ten have been completed, then 20% credit may be claimed.
7.3.12 Partial credit may be claimed for Vendor Quotes based upon the number of
documents to be reviewed. The total number of documents to be submitted
by the vendor shall be established at the time the equipment has been
awarded to the vendor and this number shall be the basis for determining
partial credit.
8 UTILIZATION OF WORK PLAN AND WPSS
8.1 The work plan and WPSS are designed to function as the Process Disciplines
primary progress reporting vehicle and is to be submitted to the designated Project
Controls Manager for the project(s) being reported on. The Chief Process Engineer
and Director-Process Engineering shall be copied at every reporting period, as
defined in paragraph 7.1.
8.2 The work plan and WPSS will indicate Productivity and Earned Value (EV) on
accomplished work utilizing a quantity based tracking system. Manhours are
earned when progress is recorded against each of the milestone activities.
8.3 Productivity values of 1.0 or less indicate efficient execution of the project.
Productivity values exceeding 1.0 indicate too many manhours are being charged
for the milestone activities reached. If this is the case, the root cause of the high
productivity value shall be determined and addressed in order to avoid exceeding
the budget for the project and maintain overall project schedules.
8.4 If the high productivity values result from an increased scope, or rework due to
influences outside the Process or Project Management departments, variances shall
be written and submitted to the Project Manager as soon as the change to the
original or planned scope of work occurs.
Revision: 0
Date: Sep. 12, 2008
______________________________________________________________________________________________________
ATTACHMENT A
Revision: 0
Date: Feb. 11, 2009
______________________________________________________________________
PEP -1016
Purpose:
A Process Chiefs Review (Chiefs Review) is a systematic, structured review of the

Engineering Flow Diagrams, Design Basis Document, Project Correspondence,
Process Specifications, Process Flow Diagrams, Heat and Material Balances, and Utility
Balances associated with a unit, system or package by the responsible Chief Process
Engineer prior to release of the Engineering Flow Diagrams to Project Engineering for
further development.
This review is organized and conducted by the Chief Process Engineer or designee. A
Chiefs Review conducted by a designee of the Chief Process Engineer requires the
approval of the Director-Process Engineering.
Documentation Required
The revision A issue of the EFDs typically occurs approximately 2 weeks prior to the
Chiefs Review in accordance with Engineering Practice EP 9-1. It is this set of EFDs
that will be reviewed during the Chiefs Review. Early issue of the revision A EFDs
allows time for the other disciplines to review the EFDs and bring their comments to the
Chiefs Review in an organized manner.
In addition to the EFDs, the Process Masters for all equipment shall be available in the
meeting room. By the time of the Chiefs Review, Process Specifications for all
equipment shall have been issued. Only in extenuating circumstances is it permitted to
release the initial issue of Process Specifications during or after the Chiefs Review.
Process Calculation Books (Line Sizing, etc.) shall also be available in the meeting
room, as requested by the Chief Process Engineer.
Scheduling:
The Chief Process Engineer or designee shall send out notification of an upcoming
Chiefs Review to the engineers assigned to the positions listed below. It is expected
that the non full-time invitees visit the Chiefs Review room during the first half-day of
the review to assess their overall involvement and when and if they may be needed
during the review.
The Director Process Engineering shall be informed of all upcoming Chiefs Reviews.
Revision: 0
Date: Feb. 11, 2009
______________________________________________________________________
PEP -1016 (Contd)
Attendees:
The Chief Process Engineer shall notify the following assigned engineering positions to
the Chiefs Review. Attendance for all disciplines other than Process shall be
coordinated and set by the Project Manager, Project Engineering Manager, or designee.
Process attendees:
Process Operations Engineer

Lead Process Engineer
Chief Process Engineer Safety
Process Engineers on call
Other disciplines in attendance:
Project Manager - on call

Project Engineering Manager - on call
Project Engineer - full-time
Instrument Engineer - full-time
Mechanical Engineer - on call
Other disciplines (piping, civil, electrical, drafting) on call
Items to be Reviewed / Checklist:
The attached Chiefs Review Checklist, Table 1016-1, shall be used by the Chief
Process Engineer and attendees as a guide during the Chiefs Review to ensure that
each and every item on the checklist has been fully addressed or deemed to be not
applicable.
The full name and initials of all participants shall be captured on the Chiefs Review
Checklist.
It is understood that each and every necessary review required for a specific project
may not be listed on the Chiefs Review Checklist. It is, however, the responsibility of
the Chief Process Engineer to ensure that all documents listed above under Purpose
are fully addressed for completeness, continuity, and consistency and that the design of
the unit is safe, environmentally sound, fully operable and will ultimately lead to a
successful start-up and operation of the respective operating unit or system.
Revision: 0
Date: Feb. 11, 2009
______________________________________________________________________
PEP -1016 (Contd)
Chiefs Review Protocol:
At the start of the Chiefs Review, the Process Master set of the EFDs shall be put up
on the wall for review. In addition to the Process Master Stamp the following
information shall be included on the EFDs:
Chiefs Review Stamp

Start date of the Chiefs Review
Attendees (Process and non-Process attendees (first few drawings only))
A copy of the Chiefs Review Checklist shall also be posted in the conference room
where the Chiefs Review is being held. The initials of the Process Engineer assigned
the responsibility to review a specific item on the checklist shall be entered on the
checklist once the Chief Process Engineer has reviewed for completeness and
accuracy.
Items that are the responsibility of other departments shall be reviewed in accordance
with their department practices and procedures. Engineers assigned to the Chiefs
Review from other departments that have a responsibility to complete specific checklist
items shall also put their initials next to the checklist items completed. To ensure
consistency in design, the Process Flow Diagrams (PFDs) for the unit must also be
marked up simultaneously with the EFDs.
The color system to be applied to all mark-ups is as follows:
Yellow Items covered

Red Items added
Green Items deleted
Blue Instruction to CAD or Design Group.
At the completion of the Chiefs Review, the marked-up set of Revision A EFDs will be
sent to CAD Drafting. A log of drawings submitted to CAD shall be kept, indicating
dates submitted and dates received back from CAD.
Post Chiefs Review Actions:
The Chief Process Engineer, or designee, shall back-check the EFDs as they come
back from drafting to ensure the accuracy of the drafting. This is not the time to make
additional improvements to the EFDs. Any errors noticed during the back-checking of
the EFDs shall be brought to the attention of the Chief Process Engineer for resolution.
Revision: 0
Date: Feb. 11, 2009
______________________________________________________________________
PEP -1016 (Contd)
Changes made during back-checking shall be recorded on the Chiefs Review master
copy in a separate color, and/or back-circled and dated to indicate that these specific
changes were post-Chiefs Review comments.
The Chiefs Review Checklist shall be scanned for electronic storage within the Process
Files. The hard copy shall be filed along with the Chiefs Review copy of the EFDs in
the Process Library.
The Chiefs Review EFDs must not be discarded as they too shall be scanned for
electronic storage. It is not required that intermediate CAD copies of the EFDs be
saved. Once all EFDs have been accurately drafted, Process shall notify the Project
Manager that the Revision B EFDs are ready for issue per the Document Distribution
Matrix.
The Revision B issue of the EFDs releases control of the EFDs to Project Engineering
for further development. The Lead Process Engineer shall maintain a Process Master
set of EFDs at all times, regardless of the EFD revision.
Following the Chiefs Review, the Process group shall also update and issue any
modified Process Specifications that changed as a result of the Chiefs Review.
Revision: 0
Date: Feb. 11, 2009
______________________________________________________________________
Table 1016-1: CHIEFS REVIEW CHECKLIST

[Scan and file in Process file 13- , 7.50 when complete]
Description Process Operations Comments
1.0 Equipment
1.1 Vessels
- Dimensions
- Design (P,T) details
- Nozzle check
- Internals
- Vortex breaker
- Vent
- Drain
- Exhauster
- Steam out
- Pumpout
- Insulation / tracing
- Elevation details
- Overpressure Protection (PSV) verified
- Frieze Data
1.2 Pumps
- Rated capacity & head
- Estimated shut-off pressure
- Number of pumps / sparing philosophy
- EIV / MOV
- Provision of temporary suction strainer (TS)
- Flushing oil connection and details
- Suction pressure instruments
- Discharge pressure instruments and check valve
- Power
- Insulation / Tracing
- Warm up provisions
- Coke Crushing Impeller noted (as required)
- Vent
- Drain
- Steam Turbine Assembly (Lines, Control, PSV.)
- Overpressure Protection (PSV) at discharge -
Positive Displacement Pumps
- Frieze Data
Revision: 0
Date: Feb. 11, 2009
______________________________________________________________________

1.3 Columns
- Dimensions
- Identify whether trays and/or packing
- Number of trays / beds
- Tray numbering
- Internals such as chimney tray, sheds, etc.
- Partition baffle or hot well for reboiler liquid draw
- Nozzle check
- Internals
- Vortex breaker
- Vent
- Drain
- Exhauster
- Steamout
- Pumpout
- Elevation
- Details of liquid re-distribution trough
- Vortex breaker at each liquid draw
- Tower draw nozzle size vs. Tower Standard
- Flushing oil connection details
- Frieze Data
1.4 Miscellaneous Equipment (Filters, Silencers)

- Nozzle check
- Internals
- Vent/ Drain/ Exhauster/ Steamout (by Detail
Engineering)
- Inlet & outlet size
- Insulation/ tracing
- Flushing oil connection
- Frieze Data
1.5 Exchangers
Revision: 0
Date: Feb. 11, 2009
______________________________________________________________________

- Duty
- TEMA type
- Arrangement (series/parallel)
- Number of shells
- Nozzle check
- Vent connection
- Drain connection
- Flushing oil connections
- Backflush connections
- Chemical Cleaning connection
- TI / TW instruments
- Block Valves and By-Pass lines
- Reboiler Elevations (Driving Force)
- Frieze Data
1.6 Air coolers

- Duty
- Number of bays, bundles, fans
- Louver controls (manual or pneumatic)
- Fan Controls / VFD
- No of fixed speed fans and no of variable speed
- Nozzle check
- Header vents / drains
- Steam coils (freeze or pour point control)
- Flushing oil connections
- TI/TW Instruments
- Inlet/Outlet Distribution Headers ( Maldistribution)
- Frieze Data
1.7 Reactors
Revision: 0
Date: Feb. 11, 2009
______________________________________________________________________

- Catalyst loading & unloading details
- Regeneration/ reactivation provisions
- Reaction control and protection safeguards
- Nozzle check
- Internals
- Vortex breaker
- Vent/ Drain/ Exhauster/ Steamout per FW
standard
(based on volume)
- Exhauster nozzle details
- Elevation details
- TI/TW Instruments
- Temperature runaway protection verified
- Frieze Data
2.0 Packages
Revision: 0
Date: Feb. 11, 2009
______________________________________________________________________

2.1 Compressors
- Capacity, Design (P,T) details
- Discharge pressure & diff. head
- Type of compressor (centrifugal, reciprocating etc)
- No. of stages
- Anti-surge control valve and surge protection for
centrifugal compressor
- Safety relief device on compressor discharge
- Nozzle check
- Driver details (turbine or motor)
- Steam supply for turbine driven compressor
- Control Loops (Throttling valves, Driver speed,..)
- Loop seal heights
- Overpressure Protection (PSV) - Reciprocating
- Frieze Data
2.2 Vacuum Ejectors

- No of ejectors
- Steam supply detail
- Nozzle check
- Liquid sealing and hotwell elevation
- Pressure balance and Off-gas send-out provision
- Frieze Data
2.3 Heaters
- Duty
Revision: 0
Date: Feb. 11, 2009
______________________________________________________________________

- Type of heater (Natural or Forced draft)
- No. passes per section (radiation & convection)
- Type of fuel firing (fuel gas or dual firing)
- Provision of ID/ FD fans
- Combustion air pre-conditioning
- Coil skin temperature monitoring
- Firebox TI's
- Nozzle check
- Atomizing steam (When Firing Liquid Fuels)
- Emergency steam supply provision to heater coils
- Purge steam connections
- Soot Blowers (When Firing Liquid Fuels)
- Velocity Steam / Condensate Injection to Coils
- Provisions for Steam-Air decoking, Pigging and
/or
On-line spalling.
- Firing system control
- Provisions for burning off-gas and waste streams
- Stack provision
- Flue gas monitoring (flow measurement,
Temperature, SOX, NOX and CO analyzers etc.)
- Pollution monitoring nozzles
- Insulation
- Draft Gauges
- Frieze Data
3.0 Hydraulics/Line Sizing

- Identification of gravity flow lines
Revision: 0
Date: Feb. 11, 2009
______________________________________________________________________

- Sloping requirements on overhead vapor lines,
flare relief lines
- Flare purge details
- Flare header and sub-header sizes
- Relief valve outlet size
- Steam generation and supply header (LP, MP or
HP) size
- Condensate recovery and sendout
- Cooling water supply and return header
- Instrument air header
- Plant air header
- Nitrogen supply header and back-up
- Fuel gas supply header and backup
- Unit Blowdown collection and recovery scheme
- Flushing oil supply & provisions
- Startup oil (cold & hot) circulation
- Overpressure Protection (PSV) for specific lines
- Process conditions shown on lines
- Other Provisions (Catalyst Regeneration,
Pump-out, etc.)
4.0 Miscellaneous items

Revision: 0
Date: Feb. 11, 2009
______________________________________________________________________

- Passivation connection (in case of Austenitic
stainless steels)
- Insulation/ tracing for Piping
- Control valve action, drain connections,
- Unit Tie-in breaks
- Future connection provisions
- Sour water collection & sendout
- Anti-corrosion injection
- Corrosion coupons/probes
- Anti-foam injection
- Gas leak detection (Hydrogen, C3, C4, SO2 etc)
- Steamout connection provision (hose or a hard
pipe)
- EIVs (with volumes and criteria per calc.)
- Sample connections/Details as required
- Line connectors between EFDs
- Notes and Holds
- Control loops on each system
- Interlocks
- B.L.Pressure and Temperatures (Process)
- Verify make-up and purge streams are in place for
recycle systems/loops.
5.0 Material balances [Also note meter Tag numbers and PFD stream numbers]
Revision: 0
Date: Feb. 11, 2009
______________________________________________________________________
5.1 Feed streams
5.2 Main Product streams
5.3 Intermittent Feed streams
5.4 By-product streams
5.5 Off-spec streams

Revision: 0
Date: Feb. 11, 2009
______________________________________________________________________
5.6 Flushing oil
5.7 Off-gas
5.8 Residue dump (tar, coke etc)
5.9 Sour water
5.10 Amine (Lean/Rich)

Revision: 0
Date: Feb. 11, 2009
______________________________________________________________________

5.11 Other
6.0 Utility Balances

6.1 Steam
6.2 Cooling water
6.3 Plant Air to process
6.4 Condensate
Revision: 0
Date: Feb. 11, 2009
______________________________________________________________________

6.5 Natural Gas
Process Operations
6.6 Fuel Gas
Revision: 0
Date: Feb. 11, 2009
______________________________________________________________________
Table 1016-2: CHIEFS REVIEW PARTICIPANTS

[Scan and file in Process file 13- , 7.50 when complete]
Full Name Department / Position Part / Full Time Initials

(PT / FT)

Process Engg Practices To Be Used in The Refinery Industry

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FOSTER WHEELER USA CORPORATION PEP No.

PEP Total Issue or Latest Revision

PEP-1000 Index 1 May 20, 2009 8

DATE: ____May 20, 2009___________________

SAMPLE PROCESS ENGINEERING PRACTICE

This is an example of a Process Engineering Practice. Each of these PEP's will be

FLOW & MAINTENANCE OF DISTRIBUTED MATERIAL

2. Other correspondence of a general nature (i.e., pertaining to more than

3. All process specifications, data sheets etc., to be issued within and

5 Departmental or project-specific policy will apply to letters issued to

5. All process specifications and vessel sketches shall be prepared on

FLOW & MAINTENANCE OF DISTRIBUTED MATERIAL

a. Lead Process Engineer

As instructed by the Chief Process Engineer, the Lead Process

Originals of issued process specifications (including Equipment List

1. Hand written initials in the approval block of the process

2. Hand written signature or initials on the Process Transmittal

Process Masters Process Specifications

A distributed copy of the as-issued process specification shall

If hard-copy distributions are not being made then a signed original

a. Lead Process Engineer (Cont'd)

Process comments noted on Process Masters shall be clearly

All previous issues of the process specifications shall be retained if

Process Masters Requisitions and Vendor Drawings

All issues of project requisitions including DIs (design instructions)

Process comments on requisitions received shall be clearly

All superseded issues should be clearly indicated as such with a

Process Masters Drawings

Process Masters of the following drawings shall also be maintained

Process Flow Diagram.

Engineering Flow Diagram.

Materials of Construction Diagram.

FLOW & MAINTENANCE OF DISTRIBUTED MATERIAL

a. Lead Process Engineer (Cont'd)

It is the responsibility of the Lead Process Engineer to maintain the

b. Calculations (dated with page number and title)

Process calculations are to be kept by the Lead Process Engineer

Upon completion of the process work, the originals of the process

2. Process Department File

No preliminary issues of Process Specification Sheets, Material

FLOW & MAINTENANCE OF DISTRIBUTED MATERIAL

2. Process Department File

Upon completion of the contract or customer acceptance of the

Appropriate vendor drawings may be filed at the discretion of the

All correspondence shall be sent to the appropriate section of the

c. Chief's Review Flow Diagrams

The originals of the Engineering Flow Diagrams marked up during

PROCESS DATA TRANSMITTAL DATE 1995

UNIT NAME: Unit DEF PROJECT: Project XYZ

Item Revision No. of

FOR PROJECT ENGINEER USE

SAMPLE PROCESS FILE NUMBERS

File Number XX-XXXXX-XX

1.0 PROPOSALS & CONTRACT MATTERS

2.0 CLIENT & LICENSOR CORRESPONDENCE

3.0 NOTES OF MEETING

3.1 Project Notes (Meetings with Client)

4.0 ESTIMATES, FINANCIAL & COMMERCIAL

5.0 COORDINATION & PERSONNEL

5.1 Project Coordination Procedure (including Filing System Index)

6.0 SCHEDULES & REPORTS

6.1.4 Master Progress Schedule

7.0 PROCESS DATA

DATE: May 20, 2009_______________