China Petrochemical Corporation

The process design package of the Petrochemical Plant

(The whole set of technology for the process package)

SHSG-052-2003

Issued by China Petrochemical Corporation on May 23, 2003 and

Implemented on August 1, 2003

 China Petrochemical Corporation

The process design package of the Petrochemical Plant

(The whole set of technology for the process package)

SHSG-052-2003

Prepared by: Sinopec Engineering Incorporation

Participated by: Shanghai Jinshan Petrochemical Engineering Company under

China Petrochemical Corporation

Nanjing Engineering Institute under China Petrochemical

Corporation

Luoyang Petrochemical Engineering Company under China

Petrochemical Corporation

Approved by: China Petrochemical Corporation

Date for Implementation: August 1, 2003

 1 General Provisions
2 Contents of the Process Design Package of Petrochemical Plant
2.1 Design Basis
2.2 Process Specifications
2.3 Material Balance
2.4 Consumption
2.5 Table of Battery Limit Conditions
2.6 Explanations to Sanitation, Safety and Environmental Protection
2.7 Table of the Analysis and Test Items
2.8 Process Pipe and Instrument Diagram (PID)
2.9 Proposed Layout of Equipments and Related Explanations
2.10 Table of Process Equipments
2.11 Process Equipments
2.12 Automatic Instruments
2.13 Special Pipelines
2.14 Data Sheet of Major Safety Discharging Facilities
2.15 Catalogue of Related Patent Documents
3 Process Manual
3.1 Process Specifications
3.3 Preparation Procedures for Starting
3.4 Starting Procedures
3.5 Normal Shutdown Procedures
3.6 Accident Treatment Principles
3.7 Handling of Catalysts
3.8 Sampling
3.9 Analysis and Control Measures of Process Risk Factors
3.10 Environmental Protection
3.11 Equipment Inspection and Maintenance
4 Analysis and Test Manual

1. General Provisions
1.1 The Process Design Package of the Petrochemical Plant (The whole Set of
Technology for the Process Package) is specially developed to unify the
contents and depth of the process design package documents of
petrochemical plants. It is hereinafter referred to as "this provision".

1.2 This provision is applicable to the development of the process design

package in the petrochemical projects of the subordinate units of China
Petrochemical Corporation and may also be used as the foundation in the
negotiation on the contents and depths of process design package when
purchasing /selling technologies.

1.3 This provision is used for standardizing the contents of process design
package, guarantee the reliable supporting technologies for engineering
design and meet the requirements on proceeding foundation design and
instructing the owners to compile detailed operating manual.

1.4 Chapter 2 "Contents of the Process Design Package of Petrochemical Plant"

in this provision covers the basic contents of process design package. Any
special requirements of the owner may be determined through negotiation
when signing the contract.

1.5 In Chapter 3 "Process Manual" and Chapter 4 "Analysis and Test Manual" of
this provision, whether the schedule requirement and the required cost are
prepared shall be determined as the contract.

1.6 This provision only covers the contents of requirement and may be used as
reference for document editing instead of the interior specialty of design
organizations.

1.7 Provisions related to this provision are "Provisions for the Basic Engineering
Design of Petrochemical Plants" (SHSG-033-2003) and "Provisions for the
Detailed Engineering Design of Petrochemical Plants" (SHSG-053-2003).

2. Contents of the Process Design Package of Petrochemical Plant

2.1 Design Basis

2.1.1 Outline

2.1.1.1 Project Background: Descript the source of project, its relationship with
clients, relevant Units and relevant plants.

2.1.1.2 Design bases: Descript the design bases such as contract, official
approval, technical documentation, etc. List the name, number of
following document, and the name of approval Unit for document.

For example:

Proposal for the project or the feasibility study report and its approval
document;

Technology transfer or technology import contract;

Design contract (including local Geological and meteorological

conditions);

The agreement of relevant meetings;

Appraisal certificate for domestic developed technology;

Any other important document the project based on.

2.1.1.3 Source of technique and authorization: Descript the patents, know-how

and their supplier, the limitation, exclusive requirement of the patents and
know-how, and the scope of the proprietary technology.

2.1.1.4 Scope of design: Descript design scope and split.

2.1.2 Scale of the plant and its composition

Descript the scale of the plant by listing the processing raw material amount in
one year or design production capacity per year or per hour. It is necessary to
indicate the annual operation hours.

The phased project should list the scale of each phase.

If there are multiple products or there are intermediate products or

byproducts, or the units are consist of multiple parts, list the name of each
part, the processing capacity and the yield rate, conversion rate, production of
each product, intermediate product or byproduct per part.

2.1.3 Specification of raw materials, products, intermediate products and

byproducts

List the parameters such as state of raw material, composition, impurities,

color degree, specific gravity, viscosity, coefficient of refraction which must be
 indicated. Meanwhile, for each parameter, list the standard or code to which
the analyzing method conforms, if it is a special one, there should be a
description. If there are several project schemes, they should be indicated
separately.

Descript the Specification of products, intermediate products and byproducts,

the standard or code on which they based. For each parameter, list the
standard number of analyzing method to which they conform.

2.1.4 Specification of catalysts, chemical materials

For each catalyst, list the model, shape, size, composition, life
expectancy and other physical/chemical parameters which should be
indicated respectively.

For each chemical material, list the name of chemistry, molecular formula,
appearance, status, main composition, impurities and other specific
parameters which must meet the process requirements respectively. If
the chemical material is purchased directly, indicate the name of
commodity and its standard number.

2.1.5 Utilities and specification of energies

List the specification of water, steam, pressurized air, nitrogen, electricity, etc.
for example:

Circulation water: temperature (inlet/outlet), pressure (inlet/outlet);

Fresh water, soften water, deoxidized water, demineralized water, steam:

temperature, pressure;

Pressurized air (instrumental air, plant air): temperature, pressure, dew

point, oil demand;

Nitrogen, oxygen: temperature, pressure, purity;

Fuel (fuel gas): temperature, pressure, heat value, composition;

Heating carrier: composition, heat value, boiling point, thermal property;

Cooling carrier: temperature, pressure;

Electricity: voltage, frequency, phase and mode of connection.

2.2 Process Specifications

2.2.1 Process principle and characteristics

Descript physical and chemical principle and characteristics of process, reaction

 equation. If complicated, more steps of the process. It can be illustrate by block
diagram and separately describe the principle.

2.2.2 Main process operation conditions

Describe the main operating conditions of different process such as

temperature, pressure, material balance, etc. For the interval process, further
describe the period and the dozing amount, etc.

2.2.3 Description of process flow

Descript the process for the material going through the equipment,
separation and product outlet;
Descript key operating conditions for main equipment (temperature,
pressure, material ratio, etc.);
Descript main control requirements, include emergency shut down control
philosophy.

2.2.4 Process flow diagram

Diagrammatic represent:
Names and tag numbers of process equipments;
Main process pipes;
Location of special valves;
Tag numbers and operating conditions of materials (temperature, pressure,
flow rate, etc.);
Heat load of industrial furnaces and heat exchangers;
Names, operating conditions, flow rates of utilities;
Main control and interlocking schemes

2.2.5 Material date sheets

List main material data under different process conditions in form of a table:
Including:
Startpoint and endpoint.
Composition.
Total flow rate, liquor flow rate and gas flow rate.
Temperature, pressure, molecular weight.
Density, viscosity and enthalpy of gas, liquid.

2.3 Material Balance

2.3.1 Material balance in the whole plant

List the material balance in the whole plant, including the consumption of each
material per hour, per year and the yield of product.
If there are multiple products or there are intermediate products or byproducts,
or the units are consist of multiple parts, Diagrammatic represent the material
 balance and the relationship of the different parts.
To those materials which would have important influence on the quality of
products or operation of the process, list the balance sheets of those materials
respectively, for example, to sulfite balance or hydrogen balance.

2.3.2 Material balance of utilities

To those materials in complicated conditions such as water which has multiply

usage or steam which to be used progressively, diagrammatic represent the
material balance and the relation of the different consumers.

2.4 Consumption

2.4.1 Consumption of materials

List the annual consumption of material. If there are multiply materials, list them
respectively.

2.4.2 Consumption of catalyst, chemical material

For catalyst, list the name of catalyst, dosing amount at first time, life,
annual consumption, consumption per one ton material.
For chemical material, list the name of chemical material, annual
consumption, consumption per one ton material.
Remark it if the catalyst or chemical material is supplied by a Licensor.

2.4.3 Consumption of utilities and energies

List the normal consumption and max consumption of water, electricity, steam,
nitrogen, pressurized air, ammonia, etc.
Water: list the consumers, temperatures, materials, flow rates of circulating
cooling water, circulating heating water, fresh water.
Electricity: list the consumers, total numbers of units, numbers of operating
units and standby units, voltages and power.
Steam: list the steam pressure classification, consumers and their
consumption, mass of condensate.
Nitrogen, pressurized air: list the consumers and their consumption.
Fuel: list the consumers and their consumption of fuel or fuel gas.
Refrigerating capacity: list the consumers, their consumption and
parameters of usages.

2.5 Table of Battery Limit Conditions

List all the conditions of material going through the battery limits including their
status, temperatures, pressures, flow directions and transferring methods.
2.6 Explanations to Sanitation, Safety and Environmental Protection

2.6.1 Storage and transporting Requirement for hazard material in Plant

List the property of hazard materials in plant which are harmful to human health,
for example, the specific gravity or density, molecular weight, flash point,
explosion limit, spontaneous ignition point, highest concentration permitted by
sanitation, degree of toxicity, cross function of medium. List it If there is specific
storage and transporting requirement.

2.6.2 Key point to Sanitation, Safety and Environmental Protection

Provide the key point to sanitation, safety and environmental protection

according to the characteristics of the process, for example, the deviation of
process conditions, the consequence when it is out of control, proposed
preventive treatment, requirements to the safety instrumental system.

2.6.3 Explanations to safety relief system

Descript the data of safety relief and purge system under different emergent
conditions, provide the conclusion of research on flare system loading and the
suggested loading for flare system.

2.6.4 Explanation to discharge of wastes

List a table to describe the sources, temperatures, pressures, discharging rates,

concentrations of major pollutants, frequency of discharge, suggested treating
methods of waste gas, waste water and waste solid.

2.7 Table of the Analysis and Test Items

List the names of materials, Analysis and Test Items and their frequency
(startup/ normal operation), and the analyzing and testing methods, for the
guaranty of operation and products qualities.

2.8 Process Pipe and Instrument Diagram (PID)

Diagrammatic represent:
Name and tag number of process equipments;
Dominate size of main pipes (including main process pipes, pipes for start-
up or shutdown, pipes for safety relief system, pipes for utilities) ;
Dominate size of valves;
Material degree and specific requirement;
Safety relief valves;
Main control and interlocking loops.
2.9 Proposed Layout of Equipments and Related Explanations

Provide the relationship of major equipments and their suggested sizes,

describe the special requirements and provisions they must be conform to.

2.10 Table of Process Equipments

For process equipments in the PID, List their tag numbers, names, total
numbers (operating units/standby units), temperatures, pressures, technical
specifications, materials.
For proprietary equipments, list the recommended suppliers.

2.11 Process Equipments

2.11.1 Description of process equipments

Descript the characteristics of process equipments in PID, the principle of

equipment selection, requirements for their materials.

2.11.2 Data sheets of process equipments

List the process equipments in PID as a table according to their categories

such as pressure vessels (including column vessels, reactors), heat
exchangers, industrial furnaces, motors and pumps, mechanicals. Attach
brief drawings for those static equipments.
For pressure vessels: list the tag numbers, names, quantities, properties,
operation conditions (temperatures, pressures, flow rates), process and
mechanical design conditions, specifications and sizes, specifications of
major nozzles and tables of nozzles, requirements for internal devices,
normal/highest/lowest liquid level, materials and corrosions allowances of
major parts, key design requirements and the others that should be
described.
For heat exchangers: list the tag numbers, names, quantities, properties of
mediums, heat loadings, operation conditions (temperatures, pressures,
flow rates), design conditions, types, heat transfer area, structures and
materials of major parts, corrosion allowances, fouling coefficient, for those
with phase change, further provide the flow rates, physical properties,
thermodynamic properties or curves at five or more points above the gasify
point or below the condensate point.
For rotating machines: list the tag numbers, names, quantities, properties of
mediums, operation conditions (temperatures, pressures, flow rates),
design conditions, specifications of mechanical and materials, driving mode
and requirements for performance curves.
2.12 Automatic Instruments

2.12.1 Index of instruments

List the tag numbers and names of controlling loops in PID.

2.12.2 Main data sheets of instruments

List the names, tag numbers, process parameters, types or specifications in

PID.

2.12.3 Explanation to interlocking function

Explain main logic relationships of interlocking functions.

2.13 Special Pipelines

2.13.1 Provisions for special piping material classification

Stipulate the material classification for special pipelines, not for those pipelines
for common use or utility.

2.13.2 Index of special pipelines

List the index of special pipelines as tables, the contents include: numbers of
pipelines, dominate diameters, starting points and ending points, names of
materials, status of materials, operation pressures, operation temperatures, etc.

2.13.3 Data sheets of special pipelines accessories

If there is any special pipelines accessory, list its process and mechanical
requirements, attach a brief drawing if necessary.

2.14 Data Sheet of Major Safety Discharging Facilities

List the names, tag numbers, discharging medium, process parameters,

discharging quantities and so on of safety valves, rupture discs, breather valves.

2.15 Catalogue of Related Patent Documents 6

List the patent names, patent numbers and the authorized area.
3. Process Manual

3.1 Process Specifications

3.1.1 Process principle and characteristics

Descript physical and chemical principle and characteristics of process.

3.1.2 Operation variables analysis

Analyze and express clearly the variables influences on the process by text,
graphs or sheets.

3.2 Normal Operation Procedures

Describe the controlling steps and methods in normal operation basing on part.

3.3 Preparation Procedures for Starting

Describe the preparation procedures for starting respectively according to the

different complexity of process, for example: the procedures and key points for
vessel inspection, hydrostatic test, pipelines inspection.

3.4 Starting Procedures

Describe the step and key points for starting in time series basing on parts.

3.5 Normal Shutdown Procedures

Describe the step and key points for shutdown in time series basing on parts.

3.6 Accident Treatment Principles

Describe the emergent treatment methods and key points respectively for
different accidents which may happen.

3.7 Handling of Catalysts

Describe the steps and key points for catalysts loading.

Describe the steps and key points for catalysts unloading
3.8 Sampling

List the location, frequency of sampling under normal operation and describe
the sampling methods.

3.9 Analysis and Control Measures of Process Risk Factors

Describe the controlling figures of safety and sanitation for flammable and
explosive, hazard or harm materials.
Describe the main risks which may happen during the operation and provide the
preventing methods and their principles accordingly.

3.10 Environmental Protection

Describe the source of pollution under normal operation, starting, shutdown or

inspecting, provide methods to reduce the pollution from view of process and
explain their principles.

3.11 Equipment Inspection and Maintenance

For the patented/proprietary equipments/facilities, describe the methods of

inspection and maintenance. For example:
Inspection steps;
Main maintaining point;
Specification for lubrications, hydraulic oil, etc.
Special inspecting and maintaining methods and tools;
Safety precautions and controlling methods;
Testing requirements and parameters for controlling systems of
equipments/facilities.

4. Analysis and Test Manual

If the analysis and test for the material, products, discharging, catalysts or
chemicals must be carried out according to the specified methods or by using
specific instruments rather than base on the state standard, industrial standards,
common international standards, compile these special items into an Analysis
and Test Manual Guide.
Analysis and Test Manual Guide shall list the names of analyzing and testing
methods, sources of standards, number of standards and describe the
installation, adjusting, operating methods, accuracy requirements of instruments
used.