Equipment Sizing and

Costing Using Petro-SIM

Rodolfo Tellez Schmill
Product Champion - Petro-SIM Simulation
KBC Downstream Technology Day

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 Outline
• Objectives of Equipment Sizing
• Typical Workflow
• New Functionalities for Equipment Sizing in Petro-SIM
• Export simulation information to datasheet templates
• Petro-SIZE® integration with Petro-SIM
• Equipment Costing (Petro-SIM and Cleopatra)
• Future Developments in Petro-SIM
• Conclusions

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 Objectives of Equipment Sizing
• Equipment sizing is a fundamental activity in design engineering.
• The capital expenditure is highly dependent on the results from
equipment sizing.
• Process simulations are an essential tool for equipment sizing.

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 Typical Workflow
• Different design scenarios, flow rate and energy capacities, and physical
properties are part of the information needed to size equipment.

• Once this information is checked and validated, Process, Mechanical

and Instrumentation Engineers apply recognized practices and
construction codes to size equipment.

• Results from engineering calculations are transferred to equipment or

instrumentation data sheets.

• These data sheets are reviewed by different engineering disciplines, and

then submitted to equipment vendors for analysis and construction.

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 New Functionalities for Equipment Sizing and Petro-SIM
• Export simulation results to datasheet templates
• A new feature in Petro-SIM 7.0 is the ability to export data from the process
simulation into data sheet templates in Excel.
• The user can customize these Excel templates, select a specific unit operation
within the simulation, and then export the required information to the Excel
template.
• Petro-SIZE® integration with Petro-SIM
• Petro-SIM will be able to transfer information directly to Petro-SIZE®.
• Petro-SIZE® in turn will perform sizing calculations and report results. This is
the only commercial process simulator in the market that can do this.

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 Export simulation information to datasheet templates
• The unit operation is selected and the with the click of a button, the
information is sent so the datasheet templates.
• Then the Datasheet Template Report is used to initiate the actual
transfer of information from Petro-Sim to Excel.
• The list of sample equipment datasheet templates that will be shipped
with Petro-SIM version 7.0 are:
• Centrifugal Pump
• Reciprocating Pump
• Centrifugal Compressor
• Reciprocating Compressor
• Shell & Tube Heat Exchanger
• Air Cooler

(A sample of a heat and material balance table is also included)

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 Sample equipment datasheet templates in Petro-SIM 7.0

• Centrifugal pump

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 Sample equipment datasheet templates in Petro-SIM 7.0

• Shell & Tube heat exchanger

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 Sample equipment datasheet templates in Petro-SIM 7.0
• Instructions needed to extract the right information from the Petro-SIM
simulation are very easy to set up:

• For example, the shell side outlet fluid is expected to be a two-phase

stream, both vapour and liquid flow rates are required, therefore the
instructions needed to transfer the mass flow rates for each phase are:
• ~Shell Side Product Stream | Phase Mass Flow (Vapour Phase) | IN_UNITS |
lb/hr
• ~Shell Side Product Stream | Phase Mass Flow (Liquid Phase) | IN_UNITS | lb/hr

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 Sample equipment datasheet templates in Petro-SIM 7.0

• The details of the simulation variable tag for the Excel template can be
checked by following these steps:
• Open the material stream view
• Select the simulation variable
• Right-click and select Send Detailed Template Tags to Clipboard
• Look at the tag in the Trace Window

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 Exporting equipment datasheet information to Excel
templates
• An example of this functionality

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 Exporting equipment datasheet information to Excel
templates
• Select the heat exchanger, then right-click and Send to Datasheet
Templates…

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 Exporting equipment datasheet information to Excel
templates
• Excel template selection view:

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 Exporting equipment datasheet information to Excel
templates
• Path: KBC / SIM Suite 7.0 / Petro-SIM / Cases

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 Exporting equipment datasheet information to Excel
templates

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 Exporting equipment datasheet information to Excel
templates

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 Exporting equipment datasheet information to Excel
templates

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 Petro-SIZE® integration with Petro-SIM
• Petro-SIZE® provides a robust tool to meet these unique sizing and
rating needs.
• Petro-SIZE® offers a suite of comprehensive modules that undertakes
various process calculations.
• It is a flexible and reliable tool for assisting process engineers as well as
plant engineers and operators in their day-to-day design,
troubleshooting and debottlenecking activities.
• Petro-SIZE® is also ideal for process review and conceptualisation. It is a
valuable time saving tool that allows engineers to respond to business
needs faster and more efficiently.

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 Petro-SIZE® integration with Petro-SIM
• Petro-SIZE® includes several equipment sizing and rating modules,
most of them being unique and not available elsewhere.
 In-plant line sizing (single and two-
phase)
 Centrifugal pumps and NPSH (net
positive suction head)
 Two and three phase separators
 API separators
 Surge drums
 Heat exchangers (shell and tube and
air-cooled)
 Fired-heaters and boilers
 Crude heater treaters
 Crude oil desalters
 Gas dehydration with solid desiccants
 Compressor suction K.O. drums
 Desuperheaters
 Corrosion rate estimation
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 Pressure safety and relief valves
 Flare K.O. drums
 Filter separators
 Control valves
 Crude production separators (GOSP
traps)
 Slug catchers (finger and vessel type)
 Tray hydraulics
 Packing hydraulics (random and
structured)
 Flow meters
 Compressors and expanders
 Atmospheric storage tanks
 Gas-solid cyclone separators
 Economics (Net Present Value)
 Petro-SIZE® integration with Petro-SIM
• The robust and unique pressure vessel optimisation engine in Petro-
SIZE® allows users to achieve significant savings in capital expenditure
by designing the most optimum equipment for each service.
• It also enables users to improve plant reliability and product quality by
accurately determining the capacity of existing equipment.

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 Petro-SIZE® integration with Petro-SIM
• The following snapshots illustrate the information that has to be
transferred into the Excel template for a typical 3-Phase Separator.
• Items with numbers in red are the ones found in the attached
template.

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 Petro-SIZE® integration with Petro-SIM

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 Petro-SIZE® integration with Petro-SIM

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 Petro-SIZE® integration with Petro-SIM

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 Petro-SIZE® integration with Petro-SIM

Coming soon in Petro-

SIM version 7.1
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 Equipment Costing
• Our new strategic partnership with Cost Engineering will allow
interoperability between Cleopatra Enterprise from Cost
Engineering and Petro-SIM to provide cost estimates at each
Petro-SIM design iteration, improving cost estimating
efficiencies and accuracy.
• Cleopatra Enterprise is a comprehensive project cost
management solution. It offers the tools needed for the full
project life cycle for estimating, budgeting, planning, cost
control, and benchmarking of technical projects and complex,
time-driven, turnarounds.

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 Equipment Costing
• Intended workflow between Petro-SIM and Cleopatra®

• CESK® Process Equipment knowledgebase is a data set for conceptual and feasibility
estimating. The built-in cost models can be used to estimate equipment costs and quickly
build a total installed cost estimate using the integrated factor estimating methodologies.

• CESK® Objects include typical equipment items (objects). The object models allow the user to
specify the main parameters for various equipment types and automatically calculate not
only the equipment supply cost but also all other related costs, including disciplines such as
piping, insulation, painting, installation, electrical, instrumentation and civil.

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 Interface with Cleopatra®

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 Future developments in Petro-SIM
• Complete the full integration of Petro-SIZE® with Petro-SIM
• Provide more Excel templates for process equipment
• Implement the ability to export simulation information to instrument
datasheets
• Complete integration with Cleopatra® to enhance Petro-SIM
functionality and offer major improvements to engineering design, cost
estimation, cost management, debottlenecking, troubleshooting and
optimization.

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 Conclusions
• Petro-SIM 7.0 can seamlessly and reliably transfer information into data
sheet templates prepared in Excel.
• Full integration of Petro-SIZE® with Petro-SIM will provide a robust
capability for equipment sizing and rating.
• Once Petro-SIZE® is fully integrated, the ability of transferring data into
data sheet templates will also be available in Petro-Sim 7.1.
• Plans and activities for the integration with Cleopatra are currently
underway.

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