Detailed process data mapping module. 

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... Corporation’s SmartPlant® 3D (SP3D) are then used in order to build the integrated detailed process engineering solution. Among the process data managed by SPPID, the process data related to instrumentation, piping and mechanical disciplines are automatically transferred into SPI and SP3D by means of the data mapping procedure. Through this automated process, man-hours and human errors will be minimized. A condensate stabilizer unit, part of a typical offshore gas compression system, has been selected for the purpose of verifying the efficiency of the proposed methodology to build an integrated solution to offshore topside process engineering. Fig. 9 shows the integrated basic process engineering solution using AZ. The engineering process data are automatically transferred into the relevant items and are consistently managed through systematic linkages between HYSYS, AZ, and in-house programs. The following steps are the brief explanation of the procedure used to build an integrated basic process engineering solution. Process Simulation Using HYSYS Process modeling and simulation on the condensate stabilizer unit performed using HYSYS is shown in Fig. 9a. The condensate stabilizer system including several unit operations, including heat exchanger, column, pump, compressor, scrubber, and separator is a typical offshore process system. The condensate stabilizer system stabilizes the condensates (consisting of pentane (C5), hexane (C6) and heavier hydrocarbons) separated from a scrubber installed on the suction line of each compressor. PFD Generation Using AZ PFD generation of the condensate stabilizer unit is a core activity in the basic process engineering phase and is performed by the AZ Drawing Editor (Fig. 9b). Importing Process Data from HYSYS The process data for each equipment item and for each stream generated by HYSYS are imported in the AZ database using the AZ Simulation Importer while the AZ Simulation Importer performs data mapping between HYSYS and AZ. In addition, inlet and outlet material ports in AZ are set up to transfer all process data to the AZ database from HYSYS. Imported process data from HYSYS are saved as object attributes in the AZ database. Those data can be observed by using AZ Explorer. Preparation of SHI In-house Programs Fig. 9c shows the calculation, input, and output modules of the horizontal knockout drum performed by in-house programs developed by SHI in order to apply the AZ PFD of the condensate stabilizer unit. SHI in-house programs developed in Microsoft® Excel (Excel) are prepared to allow calculation of the process data from the AZ database. Process data can be imported to Excel from the AZ database as input values. It is also possible for calculated process data to be exported to the AZ database by means of a proprietary SHI in-house program algorithm. Importing/Exporting Process Data between AZ and SHI In-house Program The AZ Bridge function allows process data to be transferred between AZ and SHI in-house programs. The function of AZ Bridge is to import and export process data between AZ database and such external applications as Excel and Microsoft® Word. Before transferring process data between the AZ database and SHI in-house programs, the appropriate input and output data need to be determined. Data transfer is executed after configuring logical link sets between the AZ object attribute and the SHI in-house program data cell. Generation of Customized Process Datasheet in AZ All equipment and instrumentation process datasheets are customized from datasheet templates provided by AZ Datasheet Definer for example, the centrifugal compressor datasheet shown in Fig. 9d. It is possible for these process datasheets to be updated by linking the AZ database and the appropriate AZ datasheet in AZ workspace. In addition, revisions to, and approval management of, the customized process datasheets can be automatically handled in the AZ datasheet. This procedure allows the integrated detailed process engineering solution for the condensate stabilizer unit to be developed while the integrated basic process engineering solution is being built. During building of the integrated basic process engineering solution, all process data generated are automatically transferred to, and generated in, SPPID and SPI. The following steps describe the procedure used to build the integrated detailed process engineering solution for a specific feed surge drum in the condensate stabilizer unit Generation of Graphic and Process Data in SPPID Process data are entered in the property window provided by SPPID after generating a P&ID graphic in SPPID (Fig.10). Process Data Mapping The link between the SPPID and SPI databases is generated by means of an Import Utility and automatically transfers process data from SPPID to SPI (previously called INtools®, InterGraph Corporation) (Fig.11). Detailed Mapping Detailed mapping of attributes between SPPID and SPI is performed on a link map as shown in Fig. 12. It is possible for process data that is required in SPI to be imported from SPPID through this procedure. Generated Index of Mapping Results As a result of these data mapping procedures, indices of mapping results are generated, and all process data related with instrumentation, piping, and mechanical disciplines in the feed surge drum P&ID are successfully transferred and generated (Fig. 13). Process Datasheet from Imported Results The process datasheet, including the item’s general and specific properties and conditions, can be generated after inputting additional instrumentation data in the generated index (Fig. 14). Process data mapping is a procedure that ensures that process data generated and changed from FEED to detailed engineering are automatically transferred between the basic and detailed integrated process engineering solutions. SPF’s Basic Integrator performs process data mapping between these two integrated solutions. Consequently, all process data generated by the integrated basic process engineering solution are automatically transferred into the integrated detailed process engineering solution. To successfully avoid interface customizing problems between two integrated solutions, the integrated database should use SPF developed by InterGraph Corporation and Aspen Technology, Incorporated. The business benefits resulting from building two integrated solutions to offshore topside process engineering proposed by SHI are summarized in Table 2. Firstly, both manpower costs and schedule periods are reduced because of the procedures capacity to rapidly fix process data and systematically manage document revisions. Secondly, human errors, resulting from repeated inputting of process data, are markedly decreased by effectively reusing process data generated in previous engineering phases. Thirdly, vendor claim costs are reduced because the reliability and quality of the engineering data are improved through managing engineering data as a single source concept. Therefore, building a integrated solution to offshore topside process engineering will contribute to improving the engineering work efficiency. This, in turn, will help the oil and gas industry to more efficiently build, operate, and maintain future offshore ...