HowtoPreparea Process Design Basis ‘Anthony Pavone SRI Consulting Take care not to overlook anything when preparing naive ietiaage this document, which is vital for spelling out a well- nteligent — and thorough ~prep- 5 4 aration of proen-dsig bere planned chemical-process project. lcument can make the difference > ae es between a high-quality design for The checklists and tables in this article a chemicalprocess project and & poor | Fs io The. poceesaeobass dee | can serve as reminders ment represents the owner’ instru: | tions tothe design engineering orge- | v Process contrl philosophy cost plant that can meet eapaely and nization about what the owner wants | v'The managementofthe project | product spucifcatons tis important designed, and how the owner wants | v'The project contract forthe proce design organization to the process design to be done. Note | The process design deliverables, and | Ieow the owner's intentions over this that these instructions tothe process | their format capitaloutlay spectrum. design engineering effort are diferent | v How information will ow between | — Also of prisary importance is the from what the owner would provide to | "the parties during the project product slate that the Snsehe plant is the basic designnechanical engineer: | v Preferred vendors, any, to produce. Flow much ofeach product ing ordanization, o tho designeso- | v Condoct of the process design eng | is to bo made (in tonafoas, bottles, struct organization. neers or ther units)? What specifications Nate also the distinction between | v The nature ofthe plantsite host the product aatiafy? Are there a process-dosign-basls document and | vAny unusual economiccriteria | diferent product grades to be made a scope-ctwork document. Tho scope | v’The offi facilities and the infia-| if so, what are the specifications, of work is an integral pars of the de- |" soraeture requirements and how mich of each grade isto be sign basis, but the design basis also | v Brownfelésite compatibility thade! How are the fnal products to contains rauch more. The seope of | vEnviroamental, safety and vessel | be stored, packaged, and then trans- ‘work defines what is to be done, and | and structural-design standards, | posted to customers? ‘what are the limits of that activity | permits and requirements fa particular process technology is ‘The design basis also provides the | Plant operation and mulntenance | to be used, say so in the document. On who, the how, the why, and the when. | ~ philosophy the one band, this might be a particu Furthermore, the seape of work rarely | v Owner's wishes regarding working | Jar, licensed ‘commercial technology. addresses the design philosophy, the | — capital tn the otner hand, the apecifics of the fesign standards, the exceution plan, | v The comeaunteation system for the | process might not be known at this the format of deliverables, or the com: | completed plant basly stage. morsel terme. w'The security of the project, and of | The standards to be used for the the completed plant pocess design are set by the owner, Don’ tleave anything out w Project execution expectations rot the design organization. These A fimdamental attribute of a good Standards inelude the following: ‘rocess-design-basia document is that | Objectives, products, load bearing standards (pling, nothing important. he omitted. The | control, management spread footings) fownor's engincer whois charged with | Some projects are financed with in- | v Structural support standards producing such a doeument accord- | vestment adequate to. encourage a | v Stroctural integrity standards {ingly mast give at least initial, fact | long plant operating-ife, maximum | vPressurewessel desiga standards tailed, attention to all of an exten- | run-time between turnarounds, mini- | (ASME) sive list of projet aspects: tnal labor intensity, ensy switches be- | v Fire protection standards ONFR, ¥ The overall plant objective teen product grades, and minimal | UL) The products thatthe plant will pro- | bottlenacks during operation. At the | vEquipment standards (API, DIN, duce other extreme, the owner's objective | ANSI other) The process technology to be used | is instead to build the lowestcapital- | v Testing standards (e., ASTM) 48° CHEWICAL ENGINEERING WHACHE COM JUNE 2005‘wor seope of work or prososs ‘Souign engineer ‘Owners Ist of project deliverables ‘wnors schedule Tor proiost com= pletion EP eos —_E EE EEE ‘Conduction vehicles, ‘Accounting wears Tien ist Correrpondence ecards Sie layout pion Prieet satus oper ‘Change orders “Agreed-upan tome for folmbureo- iment dump sum, reimbursable cost, Cos! plus fxod feo, percentage of fotoleapitaleosh Feedstock ond product specifeations Inpuifouiaut alageara Sa civ étowings (ia pan, Sonera, seta see reagways, dranese, pining runs above ond below ground fend data highways) Bock tow aiogreme Firewater ard ‘Schedule for pail payments dung term ot contact Location whore design work wil be Process aw alagrems Hectic! supply a Piping &ineumenltion dlograms ‘Safoly shower and eyewesh map Nighiline pleniighting plan ‘incerteken ‘stor contol center map and Terms for subcontracting otha! ‘Onestine elecicol cawings Working captolist andapesiteation [process & uty pina Ka Terms for eancelation our enue z piping Force migjoure provisions ‘Substation map ond specifications Conliol house laysut ond equipment Dispute-resouion/ form endTerum oot and mateiial balances ‘Site-wide seam nofwork crewing Trauienes ‘Conk loop arawings HAZOP reper ‘Confcentially nondisclosure ogfee ment Infellaciual property ciscovery/in= ‘vontons/owmetshin Piping specication lt Processlaboratony specications: ‘One:page process ard uty ‘Scuipment speciiection shoots ‘Acministtion bulling spocmectons ‘one-page insumenianon Spectioahon sheats Muha indemaestion Mainfenance shoo ond equipment ‘vassal crewing Tox leet veniciee Tenkage capeciy wBlectrical standards GHEE, NEO, ub ‘The process control philosophy to be used in the Gnished plant, as well as the type of systom to bo considered for supervisory control and data acquisi- tion (SCADA) system, should he speci- fied in terms of either performance or specifi selection by the owner. The lovel of data communication between the process control function, the onsite engineering and the maintenance fa- tllities is also to be defined. In many cases, an operating company will stan- ddardize on one partieular process-con- trol vendor in order to avoid the need forstaffeross-teaining. fa vendor has been designated by the owner, this should ofcourse be specified in the de- sign basis document. ‘With respect to tho management of the project, the process-design-basis document should identify the owner's ‘authorized person for approving all design activities. The management chains of command on both the own- ees side and the engineering organi- 2ation's side should likewise be spelled ‘out. Approval mechanisms (embodied in, for instance, change orders) for all activities (changes inside scope and changes outside scope) that would {ngur additional cost forthe projet are defined, The nature and format of Ube design deliverables are to be defined (hese two topic are each discussed in more detail below), The frequency of progress reports, and how they are to tbe presented, must be spelled out. The project schedule must be defined. And Tar most projects, the document should {insist on prior approval in waiting be- fore any commitments are made to outside vendors that eould incur fo- ‘ure costs or liabilities to the project. ‘The legal contract between the owner and the process design engi- ‘heer must incorporate all the rela- tionship roquirements fora successful ‘outcome. In addition to ones specified in the preceding paragraph, these in- vyolve details concerning the periodic and end-ofjob payments, as well as, tonversely, the interim and Gal pro- ‘cess engineering deliverables tojustity those payments Several elements that should be aldreseed in a good contract inchude these listed in Table 1. Deliverables: content, format ‘The specifics and tho format of the process design deliverables noed to be ‘explicitly stated in the design basis ‘document, Key elements include those ‘shown in Table 2 ‘As noved in Table 2, one ofthe items among the deliverables should be an, inpuvlootput diagram that defines the ‘ajo inpits to this plant (what feed stocks and their specifications, what utilities, and other production inputs such a additives and catalysts), as ‘well ap the major outputs. In most feasee, the quantification of all ofthese materials is not yet known ut this stage, but the nature of the impute and ‘outputs should be defined to the pro- cose design organization Format: Owners are entitled to eon formance with specific formats for engineering deliverables, in order to satisfy companywide and industrially ‘recognized standards, The format gen- rally addresses such aspects a6. the following eriteria and guidelines ‘7 Units of measure to be used (metric, English) w Standardized enginecring-drawing symbols - Eguipent numbering and tering nomenclature Wlnstrumentation and control syn: hols ‘7 Unita of identifeston for bulks and non-B's (halle oquipment represents simple hardware bought. in large amounts without specific equip. ment numbers, These items often in ‘dude block valves, sample and drain valves, piping, switches, illumination, walloways and rilings, able and its ‘housing. Non-R's, or nonequipment, represent other materials required to he purchased and consumed an a job, such as canerove, asphalt, structural CHEMICALENGINEEAING YOUWCHECOM JUNE Zi06 49Engineering Practice and reinforcing steel, insulstion, coatings, and welding rod) Standardized piping line lists and Hein lists Material balance formats wBquipment and piping one-page process spec sheets w Proseure vessel and tank drawings v Electrical one-line drawings ¥ Control loop drawings wiThe size paper to be used for ro- ports whe size paper to be used for draw- ings w Type-font and letter sive © Requirement and format for vendor cats (paper drawings, pictures, de- seriptive material, dimensions and specifications of specific equipment provided by a specific vender) ‘Owners aro also entitled to demand the use of industry-wide, non-propri- etary computer software for gener ating engineering deliverables. One reason for this standardization is t0 ‘allow computerized translation from ‘one software package to ancther. This ‘entitlement pertains to the software ‘used for planning and scheduling, ‘cost estimating, process design, piping ‘network analysis, process simulation, ‘computer-aided 20 and 3D design, and ‘he preparation of writzen reports. Project communication ‘The process design basis document should include a contract communi- cation specification (CCS), It defines how information will flow and bo shared during project execution ‘The CCS is designed to minimize communication misunderstandings ‘and misinterpretations, and to assure that all members of the project organi- zation aze continuously working ofthe ‘meat current sot of design docurnents ‘The CCS és also intended to optimize the amount oftime and effort expended far eomm:unieation between client and ‘engineer, between members of the de~ sign engineering organization, and ‘with third parties that are involved in the process design. These third parties, typically include governmental regula tors, eubcontractor, elient employees not dizeetly Invalved in the project, finaneial institutions, vendors and suppliors, Key ulements of the CCS include those shown in Table 8. (Com- Eres eon ear eur Sooneuens Documents the goals and abjectves ‘tine prolec! rey aren Gai ‘Subsol choracteriics Tistng facilis tho! may need tobe emai or romevers ‘Specifies he scope ot 12 Idenifes the member of he eam ond fot coordinate Trlsing facilities hot ore fo Be ured/ ‘soba Cina Establishes the formats or hor-copy ‘ond elactonic proect delverobios Dense the ros ahd jesponsibiios ‘ofeach tom membse Defines the foals al cemmunieaion elements, dota ‘Detios whol infomation sjobe Kept ‘ond archived. Weleoriogy Design for stir intenely (usuclly 160- yearbos) ‘Wind design requirements Foodpleindesign equerents | Farthquake design chor Sandetoim piopensily and inlensy Denno binding conirachval rms Formalizes prolect schedule ond Buege! Proximiy to drpors that would affect squipmont howsh ‘Contaminated ss ‘munication involving the plant operat- ing personnel after the plantis up and running is a separate issue also to be addressed in the process design basis document, as discussed below.) ‘Vendors and engineers Owners are entitled to provide to the design enginesring organization a list of preferred or approved vendors, provided that these vendors operate ‘where the plant i to be built and that their products eonform to intornation- ally recognized engineering standards (API, DIN, EU, for instance). The en- ineering organizetion is required to develop its design in 2 manner consistent with the use of such pre ferred vendors; conversely, tho owner is required to provide at least three preferred vendors for each major kind fof equipment, 29 avoid iasues invaly- ing monopoly pricing or proprietary equipment designe ‘Meanwhile, the design basis doca- ment should also address any issues rogarding the conduct that is expected ofthe design organization's personnel Key elements to be addressed include the following buthorizations to visit plantsite Authorizations a visit owner's head quarters site Suitable ative fr vilts to plant and owner's site w Personnel protective equipment for plantste visits wlssues involving any cultural sen- sitivities; non-diserimination stan- dards 7 Ovener's policy on euhies ‘Design-ieam company’s policy on ties 50 CHENCAL ENGINEERING WAMWCHECOM NE 2008 ‘Snow load end inioraliy ‘Cortosive cmbient air 0.9. seawater spray, aeid, chlor/alcol erwionment) Seer nna anos 'Eeonomio’ | Desigh fector” [impact High eos! | Equipment spacing flan aia Insulation ona wosalng ‘imate | citer High water | Dosohina/ water re- cost Cyelesaitcooing High aloo | Fp design pressure ety cost _| sropvatiemnahve divers igh Max. conversion/max. feedsiock/ | recycle/custody hans: proctict cos! | fermetering igh High autemation ior Ieper ees! | slsnign eauipment raliaoity High Materials elections opltal cost | process inensticalion/ Sacign standards Tah envi- | Zero dscharge/onsite fonmental | treatment disposal lebutios Drugs and alcohol policy and stan« dards eControlled-substance policy and standards Policy and reporting requirements for bribery (Business Roundtable standards) Plantsite, offsites, infrastructure ‘The site chosen for the production fae cility is to be defined exactly: Where ig i? Why was it chosen? What are the particular characteristics of this site that have led the owner's man-stores or feedstock, prod US termediate, estives abe ete ‘Aaimnisiation Bulsing Meinfonance bulaing spate pers warehouse, Medica toctilos 7ocess laboratory end equipment Tieng toely Taaing racks ruck ana ra Religious/euturlfocilios TAgLE ret ect ENVIRONMENTAL PROTECTION oa Dietary EYES ‘Wattawatartesatment stoncores Design anders for noise Frocass 908 ctehatges 10 he ai (yout standards for bullet zones “Combustion gos design/emissiens Endangered epecies/habital evalu= fequkemonis 9.9, ow-NOxbumness, | | ston jestoge ee Din) Pont constuction and operation tat- Sold waste keolment/incinewofon/ | | te managernont [onsite cepesal__| | Vgualsiandards theight, calor. fone Foticulatek in ot ing. ote) Noe Emergency plonning,respanso and ‘ovacuation “Automatic sensing ona olaims or “rac Guing conavelion and opeic= ten Frocess flare and fore gos header Vacuum ine do uel gos heads) ‘Marine toca (pers dooks, cranes) ‘eleibomne planisaupparl vessais tone alschargos Harordus chemical storage inven- tory end menagement Spi penton ccuntoonae Taineicad oan | |(AAEeena en nme Dust/ait generation ing construe fon Spl prevention slanccids ‘estewaierfeaimentfeciiy creo Haserdous melaich soege Fiasees asensof eons “Suge arving,roatmen! cha aisposal focatiee Tank broaihing/oating-rootskondorét| [unitary wastewater reatment ONG Planning stangaras ynozara commun | | dlsposa! seat SSeiReay Sess | Ropero one roo seer aoiTaT {moigoney plenning/evacuation ee eS Sosiesaeeal er gan oies ao Lockers/change facilities tor 05M ‘Perladic emissions (loam cirdecok:. | | Nonhazardous solid waste treatment personnel ing, soot blowing, ete.) and disposal Cafeteria Senilory feces and smoking sheds Fencing and plant secur Firehouse, fre water deluge and moniots Eneiganey shows, ove wash Process fetes and flare headers ‘unimes ‘agement team to select it? Is the site fa greenfield one or a brownfield one? Tesues related to brownfield sites are discussed separately, in detail, below. ‘Siteepecific and Unusual charactor istics of the plantsite need to be com- ‘municated to the project organization Rey characteristics of the site that need tobe spelled out include those in Table 4 Unusual eoonomie criteria: Most ‘engineering-design eriteria implicitly contain assumptions dealing with pro wailing economic conditions. These as- sumptions are rarely documented. It's pevticwlay plantsite involves unusu ally high cost elements, these should be identified such that the design or ganization can modify its design eri feria aceardingly, Some eomron ecu nomie factors, and the design criteria, they affect, are listed in Table 5, Offkites: Offsites for utilities aed ac cessory facilities are to be defined by Tneneration requirements the owner in terms of performance {The detgn engineering organization || Hegaiaaus ete waste recent ana well convert this input into engineer- ing design specifications. Typical off site facilites inelude those in Table 6. Infrastructure requirements. 1¢ | [Process gos eeiment pri te venting facilities outside of the main process | [ronk brecihing loss reaiment Batore plant plus its offsite utility facilites | | venting: reas: for footing roots fe required, these need to be speci- | [raya is design steam contol ond | fi othe design organisation Thee | | Late opseireaniemente. oo infrastruclure requirements may well, ie ame include outside docka/perslsiding | [1% mewoterrooyse facilities, transshipment and other recuiving facilities for feedstock and Chemicals, and facilites to ship prod- | nization can design the new plant to tet to the customer, If intermediate | be consistent with existing facilites ‘worehousing facilities are required | A key component of the design basis vey from the plant site, this vequire- | document is a tien list that shows Iuat needs to be defined. Cogeners- | what facilities are available, exactly tion, seawaler-desalting or other facil- | where they are available (ocation ities providing utilities tothe sita are | specific battery limits), and their ea likewise tobe spelled out. Any sboring | pabilitles. Existing-facility availabil: of facilities betwuen indusizial plants | ity should inelude these items: fn a community (fire protection, seeu- | v Spare infrastructure eapacity’ rity, utilities) should also be defined | v Spare ublity capacity and spaciied by the owner. 1 Spare tankage capacity Brownfield site compatibility: 1f | v Firewater availability and pressure the project is to be built at «site with | v Potable-water availability, pressure ‘existing faciitios, such that these ex- | v Procoss-water availabilty, pressure Isting facilities are expected toe used | v Raw-water andior seawater avail or available to the projec the demon- | ability and pressure strated — not design — capabilities | v Boilerfeedwater availablity, pres Of the existing fuclities are lo Ue docu- |” sure, composition (TDS, eonduetiv- ‘mented 30 that the engineoring orga- | ity) ‘Combusion gos low: NOx bumnors ‘and two-s109@ [een bum systems ‘Gooing-walersyslom management CCNEMMCAL ENGINEERING WHAICHECOM LUNE 2000 84TABLES. Preity pons Foimetstalament of management Sctely plosophy Process Safty management system ‘Aecounlabiity Process safety objectives ond goals Proce knowedgo Technical documentation equlre= ments ate Rode uc kclace cet Soe Project schedule preperation ERC contractor selection ‘Consucion management team selsction Basie engineering Detaled mecnaniealdoaon ‘Construction setety ond trining program ‘ongeing moniny poles! coe esimates (capital expand. v op.-cosl expend) Goveinmental permite Envkonmentelimaac siglemen! pieparation ‘Sie layout crewing for constuction phose Eglipinentfecowha, lay down ane worehousing tology. Procurement siciegy and standards (prefered vendors, local Content, other) ‘Operaing plant orachiation char shed count Process ek management HAZOP analyse ‘Operating ergenizcion process haining “Change-order management ‘Operaing organlzeion Eas Feahing Pr6c066 & ocubment intogtty Human fector onginesting inal ena palosle Waning Solely performance auaiing [[Cempany stendords ona codes | Fevaning tegat standards end codes Tpelden! Invesigalion and remedial ‘ion Consitustion punching Woid cefiiceions evewed and approved Hyctotedting end pipoine Blow-out Solely (ely startup (leweter ners, B16) ily fey store re #lorup pfocess eauibinen Testa Insrmanttion, elechieal ond SCADA checkout Ne-load process eaulpment unis [Audis and consctiva coton Colatst loading enatfesasock ti | EMhoncemont of corporate sarony knowlsage & performance: w Flare and flareheader availability ‘and spare capacity wdvailable steam flowrates, pres- ‘sures and dogrees of superbeat v Available capacity and pressure of Inert gas and instrument air wFuelges and fael-oil avaslability and pressure v Electric system availability (sub- station location, eapacity, voltage, phase, frequency] Environment, safety The prevailing legal standards cov- ering environmental protection need to be indicated, These are likely to include some or all of the issues in ‘Table 7. The consequent plant-porfer- riance reqrements and environmen tal-permit requirements must also bbe spelled out by the owner . Likely major requirements to be addressed Inelude some oral of those related to the list in Table 8, ‘With respect to safety, the design standards and the procedures to be utilized to assure inherently safe de Process plan! sige ‘Sion siete operation cchieved Product specications achieved Design and tuindewn capecity ochioved’ Porlomance guarantee achloved ent commissioned ‘Pont domongiraled copabilios daterminod ‘Asi arawings completed ena uined over TPC conltacior dalverables comploed and luined Gver ‘Pant accoptanee ond EPC ceniiaelorprolee! fumover to owner 1 sign, construction and operation aro | Level of automatic instrumentation tobe specified by the owner. Elements |” 10 be provided that is not needed! for neorporated in many design basis | control documents include those in Table 9. | v Redundant online equipment Redundant offline equipment Operation, maintenance Level of equipment sparing that 3s The owner is required to inform the | inline ‘engineering organization of the op- | v Level of equipment sparing that is feration-and-maintenanee (O&M) phi- | warchoused losophy to be refleted by the process | v Equipment-driver selestion and design. Components ofthis philosophy | philosophy include the following wDual drivers for eritieal process Expected ran length between sched- | oquipment sled turnarounds w Fuclities to be provided with un-in wExpected equipment runtime be- |” terraptible power supplies (UFS) tsreen meas failure vy Bquipment-rebwild capabilities onsitewv Bquipment rebuild capabilities tobe sbopped out Turndown capability: Tes plant is designed for a nameplate capac ity Gin, for instanee, metrie tons per year) at 2 particular serviee factor (operating hours per year divided by 8,760 hours per year). Although the plant is designed for optimal opera- tion at a particular throughput cate (etream-day flowrate), business con- ditions may dictate that the plant ran fat substantially lower-than-design rate for an indefinite period of time. ‘This turndown ratio should be spoei- fied by the owner. There may also be short-term periods (days, not weeks) in which tho plant should be capable of running above nameplate capac ity in order to recover from outages, of build inventory in preparation for turnaround. This turnup ratio should also be specified Working capital: The owner must provide inatructions to the enginecr- ing organization as to the design basis philosophy for the working ‘capital to be maintained in the plant, Such working capital includes: the number of days storage for feedstock, intermediate and final products; the additives inventory, in-process and in-storage catalyst quantities and spare-catalyst charge requirements; find the inline equipment spares, rarehoused equipment spares, parts spares, and constructiowmainte- ance equipment. The owner should provide instructions on the choice of purchased equipment versus leased equipment, especially for Meet and onstruction yehielos, distributor held spares and OEM held spares. Communication system: Tae owner should provide guidance as to the preferred system for inplant and ‘x-plant communication for the com pleted and operating facility, inelad- ing both fixed-line and mobile-line capability and capacity. If a sys tem operator is required, the owner should specify the reporting require. ments for that operator (usually part ofplant eceurity), External communi ceations capabilities with the owner's headquarters, and with local law en- Tareement, environmental regulators, eossrguard and marine officials, tnd governmental officials should be specified in terms of who is to be contacted, how, by whom, and under what circumstances, Docamentation neads for explant communications are alzo to be specified, ‘Security, Standards to protect the plant from unauthorized destructive need to be addressed. The primary fequee affect tho following: RUT se ea, aa ee ORT Actions by either local maleontents or . & national or international terrorists 4 oe | 7 Bquipment layout Plant access Bmergency and countermeasure plans Security fencing Security people Personnel hiringlsereening proce dares Security communications network (ox-plant) 7 Coordination with local law enforce- ment Project execution ‘The focus of this article bas been upon process design, But the process design organization is in many in- stangos contracted to provide to the owner a plan for executing the bale ance ofthe project, including mechan feal and structural design, constrac- ton, startup and commissioning. The owner's expectations as to the level of detail required isto be specified to tthe engineer, and guidance should be provided for the planning components in Table 10. . Edited by Nicholas P Chopey Author mee ere pep or Si Corl (4800 Bebo ees ena ete ot speci he pe 10 ars So a alae a peer SF ea Sparoereiaie ey ater a Se oleeeae coke erat ea tes Se eee erin outa Sct deiotay irae ae, Se Lae Gea cae iain Re SE i The Hose Trask Lifecyie ‘Analysis Syst (patent pending) is evolutlonary tracking sytem that Mls you take contol of your hose assembly and process squipment usage. Hose Track tes RFID technology to uniquely Identity each part nd create aud tral, taking hay wear-alated vents Hoge Track is valatable 121 GFR Pan 11 1 Hose Tack ofes an excellent way for manutactring end ‘malnfenanca parsoinel to monitor cleaning and usage, Work wit ‘ctl data to determine replace iment dates, not an ineficient ‘alenoar methoa, Reduce product fie, wasted ie, and undertized eauipment. 1 Contact AvantaPure today. Phone 888-884-6984 ch@advantapure.com www.advantapure.com/ch en, BURY Wi Fin Flow Systus™ p ESOP ‘xcszi Circle 24 on p. 78 or a0 to isrche.comisBa0'2!