1 General provisions
1.1 The Provisions is formulated to organize the plant design of large-scale construction projects in petrochemical industry, determine the engineering design criteria, design principle and specification, optimize the general layout of the plant and the design schemes of utility systems, realize the control targets in general process flow, general layout, total staffing, overall schedule and total investment of the construction projects, ensure that the requirements of laws and regulations on environmental protection, safety and occupational health are met, and coordinate and unify the contents and depth of the overall design document.
1.2 The Provisions are applicable to the overall design of newly-built large-scale construction projects in petrochemical industry with three or more process plants. For the construction projects in which several production plants or supporting facilities need to be renovated and expanded, the Provisions may be referred to.
1.3 The overall design document shall be prepared according to the approved project application report or feasibility study report. The overall design shall be started after the production technology route of the process has been basically determined, the project application report or the feasibility study has been approved, and delivered after the design documents of each process package or equivalent process package have been completed. If the overall design document contains any major changes with respect to the approved feasibility study report, the reasons and base for such changes shall be given.
1.4 In the overall design document, the design scope shall be explicit and all the individual works to be constructed shall be taken into consideration; after being reviewed and approved, the overall design document may be used as the basis of basic engineering design for each individual works together with the Unified provisions on overall design.
The following work contents must be completed in the overall design:
One decision: decide the major items of design and design division.
Two balances: overall material balance;
Overall fuel and energy balance.
Three unifies: unify design principles (such as plant design level, plant management system, information management level, utilities setting, energy saving and emission reduction, environmental protection, safety and occupational health, etc.);
Unify technical standards and applicable laws and regulations;
Unify design bases (such as meteorological conditions, geological conditions, design parameters of utilities, specifications of raw and auxiliary materials, etc.).
Four coordination: coordinate the design contents and depth and engineering-related regulations;
coordinate the design schemes for environmental protection, safety facilities, occupational health, energy conservation and emission reduction and fire protection;
coordinate the design scale for utility& auxiliary facility;
coordinate administrative and living facilities.
Five determinations: determine the general process flow;
determine the general layout;
determine the total staffing;
determine the total investment;
determine the overall schedule.
1.5 The Provisions shall not serve as the basis for internal division of labor and discipline of design organizations, but may serve as the basis for the arrangement of design documents in terms of volumes, parts and chapters. The items of each project may be determined according to its specific conditions, but all the designs must reach and conform to the depth requirements of the Provisions.
2 General description
2.1 General
2.1.1 Overview of construction projects
The following main contents shall be included:
a) project name and construction site;
b) project contents; State the names and construction scales of the production plants in the construction projects and brief supporting utilities and auxiliary facilities;
c) management system and fund sources of construction projects.
2.1.2 Design bases
List the documents related to the design bases (including their name, number and date. Important ones should be taken as the attachment of the overall design):
a) Project application report, feasibility study report and documents on their approval and modification;
b) For large-scale newly-built refining-chemical integration projects, the plant site selection report and corresponding approval documents shall also be listed;
c) Decisions on major issues of the overall design made by the competent department and the development organization (such as important meeting minutes and approval documents).;
d) Planning data of the area in which the construction project is located;
e) Agreement of intent on off-plant works;
f) Relevant agreements signed with the relevant parties for the project which is dependent on society and existing enterprise projects;
g) The import contracts, meeting minutes, etc., signed with foreign companies for each imported project (process plant);
h) Documents related to financial resources, mode of loan, agreements, etc.;
i) Design contract(s);
j) Main principles proposed by the development organization on plant management system, organization and staffing;
k) Design bases provided by the development organization (including the standards and specifications adopted for the project; see Annex B);
l) Process package design documents;
m) Approved environmental impact report;
n) Safety pre-evaluation report;
o) Occupational health pre-evaluation report;
p) Seismic safety evaluation report of the construction site;
q) Other important documents related to the project.
2.1.3 Design principles and main provisions
State some major design principles to which the project should be adhered in accordance with the relevant national guidelines and policies and with combination of specific conditions of the construction project, with emphasis on the following contents:
a) Principles on integration of production plants, systematization of overall process and systematization of in-plant utility systems;
b) Principles on centralized and socialized supply of utilities;
c) Principles on selection of process technology route, determination of engineering technology standards, degree of introducing foreign technology and localization, etc.;
d) Principles on automation level of production plant, utilities and auxiliary facilities and type selection of instrument and control system, requirements on the design of instrument power supply and gas supply, etc.;
e) Design principles of the scale, standard, layout and other data for utility & auxiliary facility, non-production facilities, etc.;
f) Principles on setting up machine repair, electrical repair and general warehouse;
g) Principle on setting storage and transportation facilities;
h) Principles on the design of administrative and living facilities;
i) Design principles of environmental protection, safety, occupational health, fire protection, energy saving and water saving;
j) Unified requirements for overall design;
k) Requirements for selection of engineering design standards;
l) Principle on work division in the area for battery limit of process plant design and overall design.
Foreword i
1 General provisions
2 General description
2.1 General
2.2 Plant site and plant construction conditions
2.3 Production scale and product scheme
2.4 Brief descriptions of the plant-wide overall process flow and utility system balance
2.5 Supply of raw materials, fuel and auxiliary materials
2.6 List of main items and design division
2.7 Overall management system and total staffing
2.8 Situations about the dependence on the society and enterprises
2.9 Major modifications on feasibility study report
2.10 Main technical and economical indexes
2.11 Existing problems and suggestions
3 Production plant (state them separately by process plant)
3.1 General
3.2 Technical specifications of products, by-products, raw materials, catalysts, chemicals and utility supplies
3.3 Consumption (or output) quota and consumption (or output) quantity
3.4 Battery limit conditions
3.5 Automatic control
3.6 Equipment
3.7 Packaging and finished product warehouse
3.8 Architecture and structure
3.9 Environmental protection
3.10 Safety facilities
3.11 Fire fighting
3.12 Occupational health
3.13 Energy saving
3.14 Others
3.15 Technical and economic indexes of the process plant
4 Overall general layout & transportation
4.1 General layout of plant area
4.2 Vertical layout of plant area
4.3 Overall transportation
4.4 Main technical and economic indexes of general layout
5 Logistics system
5.1 Storage and transport of liquid materials
5.2 Gas storage and transport system and facilities Note
5.3 Overall process and outdoor heating pipe
5.4 Overall fuel oil and fuel gas systems
5.5 Overall sump oil system
5.6 Storage and transport of solid materials
5.7 Existing problems and suggestions
6 Utility work and auxiliary facilities
6.1 Water supply and drainage
6.2 Heat supply
6.3 Power supply and distribution
6.4 Telecommunication
6.5 Whole-plant control system and central control room
6.6 Enterprise information management system
6.7 Central laboratory
6.8 Fire station and gas protection station
6.9 Air separation station
6.10 Air compression station
6.11 Refrigeration station
6.12 Heat exchange station
6.13 Heating, ventilation and air conditioning
6.14 Flare and flare gas recovery system
6.15 Sewage treatment plant
6.16 Waste residue landfill
6.17 Waste incineration facility
6.18 Environmental monitoring station
6.19 Servicing
6.20 Administrative and living facilities
6.21 Buildings and structures
7 Off-plant facilities
7.1 Basic requirements for design of off-site facilities
8 Environmental protection
8.1 General
8.2 Status of existing environmental protection facilities
8.3 Design basis
8.4 Main pollution sources and pollutants
8.5 Environmental protection measures and greening
8.6 Environmental management and monitoring
8.7 Environmental protection investment
8.8 Implementation of environmental impact report and approval opinions
8.9 Existing problems and suggestions
9 Safety facilities
9.1 Project overview
9.2 Analysis of hazardous and harmful factors in production process
9.3 Main safety facilities and measures adopted
9.4 Accident prevention and emergency rescue measures
9.5 Description of implementation of safety evaluation report opinions
9.6 Arrangement and staffing of safety management institution
9.7 Investment estimation of safety facilities
9.8 Expected effects
9.9 Existing problems and suggestions
10 Fire fighting
10.1 Project overview
10.2 Analysis of hazard factors
10.3 Safety measures for fire prevention
10.4 Fire fighting design
10.5 Estimation of special investment
11 Occupational health
11.1 Design basis and standards
11.2 Analysis of occupational disease hazard factors
11.3 Occupational health protection measures and facilities
11.4 Organization and management of occupational disease prevention and control
11.5 Occupational disease prevention and control investment estimation
11.6 Description of implementation of occupational disease evaluation report opinions
11.7 Existing problems and suggestions
12 Energy saving and water saving
12.1 Principle of comprehensive utilization of heat energy in the whole plant
12.2 Utilization measures of the electrical energy in the whole plant
12.3 Water saving measures
13 Preliminary schedule of project construction progress
14 Budgetary estimate for overall design
15 Supplementary provisions
Annex A - Table of overall design conditions
Annex B - Data sheet of design foundation