The complete design process for a chemical engineering design project

Let’s check the standard instead; it states it clearly in SHSG-053-2011

The implementation of a project requires coordination among four parties: ① the design team, ② the construction team, ③ the project owner, and ④ the supervision team. Each party has different responsibilities, and the specific tasks at various stages of a project vary depending on which party is involved. It’s impossible to talk about it in general terms

Provisions on the Content of the Process Design Package for Petrochemical Plants (Comprehensive Technical Process Package) 1 General Provisions 1.1 These Provisions on the Content of the Process Design Package for Petrochemical Plants (Comprehensive Technical Process Package) are formulated in order to standardize the content and level of detail in the documents related to the process design of such plants. Hereinafter referred to as these Provisions. 1.2 These provisions apply to the preparation of the process design packages for petrochemical projects in the units affiliated with the group company ； It can also serve as a basis for in-depth negotiations regarding the content of the process design package when purchasing/selling technology. 1.3 These provisions are intended to standardize the content of the process design package, ensuring that the engineering design has a solid technical foundation, and meeting the requirements for carrying out preliminary design as well as guiding the owner in preparing detailed operation manuals. 1.4 Chapter 2, “Contents of the Process Design Package for Petrochemical Plants,” of these regulations lists the basic contents of the process design package. If the owner has special requirements, they can be agreed upon upon signing the contract. 1.5 Chapters 3 “Process Manual” and 4 “Analysis and Testing Manual” of these regulations may have their preparation determined in accordance with contract requirements, as well as the timing requirements and associated fees. 1.6 These regulations only specify the required contents and can be used as a reference for document compilation; they shall not serve as a basis for the internal professional structure or division of labor within the design unit. 1.7 The relevant regulations for these provisions are the \"Regulations on the Design Content of Foundations for Petrochemical Plants\" (SHSG-033-2003) and the \"Regulations on the Design Content of Detailed Designs for Petrochemical Plants\" (SHSG-053-2003). 2 Contents of the Process Design Package for Petrochemical Plants 2.1 Design Basis 2.1.1 General Overview 2.1.1.1 Project Background Explain the origin of the project, the relationship with the owner and related parties, as well as the relationship with other related facilities. 2.1.1.2 Design Basis: Describe the contracts, approvals, technical documents, etc., on which it is based. The file name, number, and issuing unit must be provided. Such as: approval documents for project proposals or feasibility study reports, contracts for technology transfer or introduction, design commission contracts (including information on local geological and natural conditions), minutes of relevant meetings, certification documents for domestically developed technologies, and other important documents that serve as a basis. 2.1.1.3 Source of Technology and Authorization: Describe the patents, proprietary technologies used in the process technology, as well as the providers of such technology. It outlines the restrictions on patent use and licensing, as well as the exclusivity requirements. Describe the scope of the proprietary technology. 2.1.1.4 Scope of Design: Describe the scope covered by the process design package and the division of interfaces. 2.1.2 Plant scale and composition The plant scale can be expressed in terms of the annual or hourly processing volume of raw materials, or the annual or hourly output of main products. It is necessary to specify the annual operating hours on which the scale is based. If there are different operating conditions, the capacity of the device under each condition should be specified separately. If there are multiple products, intermediate products, by-products, or if a device is composed of multiple parts, the names of each part should be listed ； The processing volume of each section, as well as the yields, conversion rates, and production volumes of products, by-products, and intermediate products. 2.1.3 Specifications for raw materials, products, intermediates, and by-products: Describe all the parameters that must be specified, such as the state of the raw materials, their composition, impurity content, boiling range, color, specific gravity, viscosity, refractive index, etc. Also list the standard number for the analysis method of each parameter. Special analysis methods need to be explained. If different raw materials are used for different operating conditions, they should be listed separately. Specify the specifications of products, intermediate products, and by-products, as well as the standards they are based on; meanwhile, list the standard numbers for the analysis methods of each parameter according to those standards. 2.1.4 For catalysts and chemicals, the specifications shall list all necessary physical and chemical properties and parameters such as catalyst model, shape, size, composition, and expected lifespan. List separately the characteristic parameters that must meet the process requirements, such as the chemical name, molecular formula, appearance, state, main components, and impurity content of the chemicals. For chemicals that are available for direct purchase, their trade names and product standard numbers should also be listed. 2.1.5 Specifications for utility materials and energy: List the specifications for water, steam, compressed air, nitrogen, electricity, etc. For example: Circulating water – temperature (inlet/outlet), pressure (inlet/outlet); Fresh water, softened water, deoxygenated water, demineralized water; Steam – temperature, pressure; Compressed air (instrument air, plant air) – temperature, pressure, dew point, oil content requirements; Nitrogen, oxygen – temperature, pressure, purity; Fuel oil (fuel gas) – temperature, pressure, calorific value, composition; Heat carriers – composition, calorific value, boiling point, thermodynamic properties; Cooling media – temperature, pressure; Electricity – supply voltage, frequency, phase/wiring configuration. 2.1.6 Performance indicators The expected values and guaranteed values of performance indicators should be listed separately, such as product output, yield, conversion rate, product quality, and key consumption metrics. 2.1.7 Software and Version Information: List the software and its versions used in the design of the process design package as specified in the contract. 2.1.8 Recommended Standards and Specifications – Lists the international standards, **standards, industry standards, or standards specified by patent holders, etc., that are required to be followed in engineering design. 2.2 Process Description 2.2.1 Process Principle and Characteristics Explain the physical and chemical principles as well as the characteristics of the designed process. The reaction equation can be listed. Complex, multi-step processes can be represented using block diagrams to show the interrelationships and explain the principles of each component separately. 2.2.2 Main Process Operating Conditions Describe the main operating conditions of the process: temperature, pressure, material ratios, etc. The conditions for different process operating scenarios should be specified separately. For batch processes, the operation cycle and the amount of material added at one time must also be specified. 2.2.3 Process flow description: It explains in sequence the process by which materials pass through the process equipment, as well as the fate of the separated or produced materials. It describes the key operating conditions of the main process equipment, such as temperature, pressure, and material ratios. For intermittent operation, it is necessary to specify the amount of material fed per operation and the time period. It explains the main process control requirements during operation, including the control principles for emergency shutdowns. 2.2.4 The Process Flow Diagram (PFD) shows the process equipment along with its tag numbers and names ； Main process pipelines ； Special valve location ； Logistics numbering, operating conditions (temperature, pressure, flow rate) ； Thermal load of industrial furnaces and heat exchangers ； Name of utility materials, operating conditions, flow rate ； Main control and interlock scheme. 2.2.5 Logistics Data Table lists various key logistics data, including the start and end points of each logistics flow, phase state, composition, total flow rate, gas-phase flow rate, liquid-phase flow rate, temperature, pressure, molecular weight, gas-phase density, liquid-phase density, gas-phase viscosity, liquid-phase viscosity, gas-phase enthalpy, liquid-phase enthalpy, etc. Data for different operating conditions should be provided. 2.3 Material Balance 2.3.1 Overall Process Material Balance: This presents the overall material balance for all product streams generated by the plant, including the hourly and annual amounts of various materials as well as their yields. For devices composed of multiple products, intermediate products, by-products, and various components, a material balance diagram is used to represent the amounts of materials and the relationships between these different components. For some materials that have a significant impact on the operation of the process or on product quality, their balances should be provided separately, such as the sulfur balance and the hydrogen balance. 2.3.2 Material balance diagrams: For complex situations such as the multiple reuse of water or the step-by-step utilization of steam, balance diagrams can be used to illustrate the amounts of materials and the relationships between various users. 2.4 Consumption 2.4.1 Raw material consumption The annual consumption of raw materials. If there are multiple raw materials, they should be listed separately. 2.4.2 Catalyst and chemical consumption: Catalyst consumption includes the catalyst name, initial loading amount, service life, annual consumption, and consumption per ton of raw material. Chemical consumption includes the chemical name, annual consumption amount, and consumption per ton of raw material. Catalysts and chemicals provided by the patent holder must be indicated. 2.4.3 The normal and maximum consumption amounts for utility materials and energy, such as water, electricity, steam, nitrogen, and compressed air, are listed separately. Water volume — includes the user names, temperature, pressure, and flow rate of circulating cooling water, circulating hot water, fresh water, softened water, deoxygenated water, demineralized water, etc. Power capacity — includes user name, number of devices, number of operation consoles, number of backup consoles, voltage, and calculated shaft power. Steam volume — includes steam pressure rating, user name, usage amount, and condensate volume. Nitrogen, compressed air volume — including user name and usage amount. Fuel quantity — includes fuel oil, fuel gas, user name, and consumption amount. Frozen volume – includes the user’s name, usage parameters, and consumption amounts; for materials and energies generated during the process as shown in the utility and energy tables, such as steam, condensate water, or electricity, a “-” value is assigned. 2.5 The boundary condition table lists the conditions for all materials—including raw materials, products, by-products, intermediate products, chemicals, utilities, and defective items—to enter or leave the boundary zone: status, temperature, pressure (at the entry and exit points), flow direction, flow rate, transportation method, etc. 2.6 Health, Safety, and Environmental Protection Instructions 2.6.1 Properties of Hazardous Materials in the Device and Special Storage and Transportation Requirements List the properties of hazardous materials (including catalysts) present in the device that can affect human health and safety, such as specific gravity or density, molecular weight, flash point, explosion limits, auto-ignition temperature, the maximum allowable concentration for health reasons, the level of toxicity, and any interactions between these substances. Any special storage and transportation requirements should also be mentioned. 2.6.2 Explanation of key health, safety, and environmental protection aspects: Based on the characteristics of the process, key points related to health, safety, and environmental protection are identified, such as the consequences of deviations or loss of control in the process conditions, recommended preventive measures, and requirements for safety instrumented systems. 2.6.3 Description of the safety relief system: It explains the data related to safety relief and purging under different accident scenarios, presents the results of studies on the load of the flare system, and proposes recommended loads for the flare system. 2.6.4 List of explanations for waste emissions: This lists the sources of exhaust gases, wastewater, and solid waste, as well as their temperature, pressure, emission volumes, levels of major pollutants, frequency of emission, and recommended treatment methods. 2.7 The analysis and testing items table lists the names of materials that need to be analyzed to meet operational requirements and product quality standards, along with the analysis items, analysis frequency (during startup/normal operation), and analysis methods. 2.8 The Process Piping and Instrumentation Diagram (PID) shows the process equipment in the PID along with its tag numbers and names ； Nominal diameter, material grade, and special requirements for the main pipelines (including main process pipelines, start-up and shutdown pipelines, safety relief system pipelines, and utility material pipelines) as well as valves ； Safety relief valve ； Main control and interlock circuits. 2.9 The recommended equipment layout diagram and accompanying instructions provide the relative positions of the main equipment as well as the suggested relative dimensions, and outline any special requirements and regulations that must be complied with. 2.10 The process equipment table lists the tag numbers, names, quantities (operational/standby) of the equipment in the PID, operating temperature, operating pressure, technical specifications, material, etc. Patented equipment lists recommended suppliers. 2.11 Process Equipment 2.11.1 Description of Process Equipment: Explains the characteristics of process equipment in PID, the principles for selecting it, and the requirements for material selection. 2.11.2 The process equipment data sheet lists each piece of process equipment in the PID in detail, categorizing them into vessels (including towers and reactors), heat exchangers, industrial furnaces, pumps, machinery, etc. Simplified diagrams should be attached for the main static equipment. Container – tag number, name, quantity, properties of the medium, operating conditions (temperature, pressure, flow rate, etc.), process design and mechanical design requirements, specification dimensions and minimum elevation requirements, specifications for major interfaces and pipe connections, requirements for internal components, normal and maximum/minimum liquid levels, material of major components and corrosion allowance, key design requirements, and information that must be specified regarding the process. Heat exchangers (industrial furnaces) – Tag numbers, names, quantity, properties of the fluid, heat load, operating conditions (temperature, pressure, flow rate, etc.), design conditions, type, heat transfer area, structure and material of key components, corrosion margin, fouling coefficient. For heat exchange equipment involving phase changes, data or curves for more than 5 points regarding the vaporization or condensation side should be provided, including flow rate, fluid properties, and thermodynamic properties. Rotating machinery —— tag numbers, names, quantity, properties of the medium, operating conditions (temperature, pressure, flow rate, etc.), design conditions, mechanical and material specifications, type of drive, requirements for performance curves. 2.12 Automatic Control Instruments 2.12.1 The instrument index table lists the numbers and names of the control loops in the PID. 2.12.2 The main instrument data sheet lists the name, number, process parameters, type, or main specifications of the control instruments in the PID. 2.12.3 Interlock Instructions: Explain the main interlock logic relationships. 2.13 Special Piping 2.13.1 Specifications for Material Grades of Special Piping – These specifications define the material grades required for special piping as well as the requirements for related accessories. Pipes for general, common materials are not included. 2.13.2 Special Pipe Index Table: The special pipe table should generally include items such as pipe number, nominal diameter, PID diagram number, start and end points of the pipe, flow name, flow status, operating pressure, operating temperature, etc. 2.13.3 Data sheet for special pipe fittings: If there are special pipe fittings, the process and mechanical requirements shall be specified for each one, and schematic diagrams shall be attached if necessary. 2.14 The table of main safety relief equipment lists the names, tag numbers, media to be relieved, process parameters, and relief capacity of safety valves, rupture discs, breather valves, etc. 2.15 The patent document catalog lists the relevant patent titles, patent numbers, and grant regions. 3 Process Manual 3.1 Process Description 3.1.1 Explanation of the process principle and characteristics: Describes the physicochemical principles behind the process as well as its characteristics. 3.1.2 Operating variable analysis: Analyzes the impact of operating variables related to the process. All forms that facilitate clear expression can be used, such as text, graphics, tables, etc. 3.2 The normal operating procedures describe the control steps and methods for normal operation in sections. 3.3 The procedures for preparing the vehicle are described separately according to different levels of process complexity, outlining the steps and key points for tasks such as container inspection, hydrostatic testing, and pipeline inspection. 3.4 The driving procedure outlines the steps in sequence along with some key explanations for each step. 3.5 The normal parking procedure outlines the steps in sequence and provides brief explanations of the key points for each step. 3.6 The accident handling principles outline the emergency response methods and key steps to be taken in potential accidents. 3.7 Instructions for Catalyst Loading and Unloading: Steps and key points for catalyst loading. Explain the catalyst unloading steps and key points. 3.8 Sampling shall specify the sampling location, frequency during normal operation, sampling method, etc. 3.9 Analysis of process hazard factors and description of control measures: Safety and hygiene control parameters for flammable, explosive, and toxic materials in the facility. Analyze the main hazards that may occur during the operation of the analysis device, and propose corresponding protective principles or methods. 3.10 Environmental protection guidelines: Identify pollution sources during normal operation, startup and shutdown, as well as maintenance, and propose control methods or principles from a process perspective to reduce pollution. 3.11 Equipment inspection and maintenance: For patented or proprietary equipment and facilities in the plant, the methods for their inspection and maintenance shall be specified. For example: inspection procedures, main maintenance points, specifications required for lubricants, hydraulic fluids, and other fluids used, special maintenance methods and tools, safety precautions and measures during maintenance, debugging requirements and parameters for the control systems of equipment and facilities. 4. Analysis and testing manuals: For those cases where it is necessary to analyze raw materials, products, emissions, catalysts, chemicals, etc., using methods specified by the process provider and specific instruments, and where standard analytical methods such as industry standards or internationally recognized standards (such as ASTM standards) cannot be applied, analysis and testing guidance manuals should be prepared. The analysis and testing manual should specify the name of the analysis and testing methods, the source of the standards, the standard numbers, the instruments and equipment used along with their installation and calibration procedures, the operating procedures, and the accuracy requirements. Additional provisions: 1 Article 1.3 Regarding the scope, for those parts of the process plant that are relatively simple and do not present many process-related issues, such as tank areas and warehouses, it is not necessary to prepare a process design package if this does not affect the completion of the basic design. The scope covered by the process design package for a specific process is variable and should be in accordance with the terms of the contract. If the owner can request only the patent holder to provide the process design package for the regeneration section of the continuous reforming unit. 2 The contents of Article 2.1 “Design Basis” and Article 3.5 “In the Boundary Condition Table” (except for flow rate) shall be determined during the technical negotiations of the contract. 3 Article 2.1.1.3 Technical Source and Licensing: “Specify the restrictions on patent use, licensing, and exclusive requirements.” ”It is necessary to clarify the scope of use of the patent-related contents in the process design package, the restrictions preventing third parties from using them, and whether there are any restrictions on engineering companies; for example, stipulating that an engineering company, after undertaking the design for this process, shall not take on the design work for other processes that produce similar products ； “\"Specify the scope of proprietary technology\" requires indicating which elements in the process design package constitute proprietary technology, such as certain operating parameters, design parameters, as well as the structure, internal components, and materials of the equipment. 4 Article 2.1.2 states that “the scale of a plant can be expressed in terms of the annual or hourly processing capacity of raw materials, or the annual or hourly output of main products.” This takes into account the fact that different plants have different *common ways of expression; for example, in chemical plants and lubricant production plants, the output of the main products is commonly used as an indicator ； Most refining units* use the normal feed rate as a representation ； For hydrogen production units, it is acceptable to express them in terms of hydrogen production rate per hour, etc. 5 Some of the utilities and energies listed in Article 2.1.5 \"Utilities and Energy Specifications\" that have not yet been determined at this stage may be omitted. However, for parameters with specific requirements regarding the process – such as when a certain process demands that the nitrogen purity be no less than 99.99% – these must definitely be listed. 6 Article 2.1.7 “Software and Version Description” sets out the requirements for the providers of the process design package. As design integration becomes increasingly advanced, the software for process design has interfaces with engineering design software (such as layout, piping, heat exchangers, vessel fabrication drawings, etc.). This clause is proposed to facilitate coordination with subsequent work. If the owner does not request it, it can be omitted. 7 Article 2.2.3 “Source of the specified conditions”: For example, pilot plant data from XXX research institution is used ； Production data from XXX factory, etc., are used. 8 Article 2.2.3: “The conditions for various operating scenarios must be specified separately,” such as the conditions at the beginning and end of the reaction, the conditions when using raw material A or raw material B, the conditions for producing product M and product N, etc. 9 Article 2.2.6: Logistics data “should provide data for different operating conditions”, such as the early stage of the reaction and the late stage of the reaction ； Normal operation, regeneration, drying, activation ； Use Material A and Material B ； Producing M products, N products... etc. 10 Article 2.10: The “technical specifications” in the process equipment table are not model numbers. Different content can be written for different types of devices. For structures such as towers and containers, the external dimensions can be specified ； For industrial furnaces and heat exchangers, the heat load or heat exchange area can be used ； For pumps, things like shaft power can be specified. 11 Article 2.11.2: The “all contents that must be specified regarding the design of pressure vessels” refer to the requirements related to the characteristics of the process. For example, when the process involves high temperatures and pressures, or when the medium is corrosive, prone to decomposition, prone to precipitation, or has an extremely high viscosity, there are specific requirements regarding equipment selection, structure, and materials. 12 Articles 2.12 and 2.13: “Critical and main control circuits and control instruments” refer to those control circuits or instruments of certain types or specifications that are necessary for a particular process. For example, the outlet valve on a certain high-pressure separator must be a special control valve designed for high pressures and high pressure drops; this circuit as well as this control valve must be specified in the instrument index sheet and the instrument data sheet. On the contrary, for ordinary circuits that can be regulated using a variety of different types of control valves, these two need not be listed. 13 In renovation and expansion projects, Chapters 3 \"Process Manual\" and 4 \"Analysis and Testing Guide Manual\" should focus on describing the changes in the process route, as well as other modifications related to the equipment composition. The content of the original parts of the device is omitted.

Just follow this directory order mainly

Last year (or the year before), a distinguished gentleman in our group gave a series of lectures.

Someone upstairs also explained in detail that it’s impossible to handle everything when working on a project; it mainly depends on your role – whether you are part of the project owner, design team, construction team, supervision team, or surveying team.

Someone upstairs also explained in detail that it’s impossible to handle everything when working on a project; it mainly depends on your role – whether you are part of the project owner, design team, construction team, supervision team, or surveying team.