SPD

D0005ERN
N

PR
ROCESS DESIGN
D M
MANUAL

DESIGN PHILOSO
OPHY

REV.: 4
7.09
DATE: 2013.07

SAMSU
UNG ENG
GINEERIN
NG CO., LTD.
L
 PROCESS DESIGN MANUAL SPD0005ERN
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DATE: 2013.07.09 DESIGN PHILOSOPHY
Page i of i

CONTENTS
1.  SCOPE ................................................................................................................................ 1 

2.  PURPOSE AND CONTENTS OF BASIC DESIGN.............................................................. 1 

3.  BASIS OF DESIGN ............................................................................................................. 2 

4.  GRADE OF DESIGN ........................................................................................................... 2 

5.  RESPONSIBILITY ............................................................................................................... 4 

5.1.  Performance.................................................................................................................. 4 

5.2.  Cost ............................................................................................................................... 4 

6.  MINIMUM CAPITAL COST DESIGN ................................................................................... 5 

7.  DESIGN ............................................................................................................................... 5 

7.1.  Continuous Operating Period ........................................................................................ 5 

7.2.  Considerations Required for Alternate Operations ........................................................ 5 

7.3.  Emergency Operation ................................................................................................... 6 

7.4.  Turndown Ratio ............................................................................................................. 6 
7.5.  Design Life .................................................................................................................... 6 

7.6.  Pump and Compressor Spares ..................................................................................... 6 

7.7.  Drivers for Pumps and Compressors ............................................................................ 7 

7.8.  Design Allowances ........................................................................................................ 8 

7.9.  On-stream Maintenance ................................................................................................ 9 

8.  REVISION HISTORY......................................................................................................... 10 

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1. SCOPE
This manual presents an overview of the design philosophy to be employed in the
development of a basic design project, including the purpose, policy, criteria and
contents of a Basic Design Package. For additional details of this philosophy, please
refer to the specific topics as addressed in the supporting "Basic Design Manuals,” in
which minimum requirements have been specified.

Unless otherwise noted in the supporting "Basic Design Manuals", the best design
shall accrue from the basic design philosophy outlined below.

2. PURPOSE AND CONTENTS OF BASIC DESIGN

The Basic Design Package is developed to support the subsequent detailed design
work and plant operation, The Basic Design Package shall include, at a minimum,
the following:

(1) Process Description including Process Design Basis

(2) Basic Engineering Design Data
(3) Process Flow Diagrams
(4) Heat and Material Balance
(5) Equipment List
(6) Equipment Data Sheet
(7) Instrument Process Data Sheet
(8) Conceptual Plot Plan
(9) Piping & Instrument Diagram
(10) Utility Diagram
(11) Material Selection Diagram
(12) Chemical Requirement
(13) Catalyst Requirement
(14) Effluents Data
(15) Laboratory Manual
(16) Standard Analytical Method
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(17) Operating Guide

(18) Operating Manual
(19) Engineering Spec.
(20) Standard Drawing.

For additional details on the contents of the Basic Design Package, please refer to
Basic Design Manual SPD0007ERN,”Basic Design Package”.

3. BASIS OF DESIGN
Basic design work will proceed based on the following requirements:

(1) Design basis, refer to Basic Design Manual SPD0013ERN, “Design Basis”

(2) Basic engineering design data, refer to Basic Design Manual SPD0008ERN,
“Basic Engineering Design Data”

(3) Applicable industry and regulatory codes and standards.

The project requirements as reflected in these basis documents must reflect the
client's project and design philosophy, which must be fully understood by our
engineering staff. If more economical and practical alternatives are found, they shall
be proposed and discussed with the client, before starting the basic design work.

4. GRADE OF DESIGN
The "Basic Design Manuals" specify the design philosophy and basic design
procedures for EPC projects. However, the basic design procedures for proposal or
other study purposes such as planning, evaluation, feasibility studies, etc., are often
different from those for EPC projects.

Hence, the following design content and practices shall be taken as satisfying the
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minimum requirements for study purposes.

Design calculation:

Maximize use of prorating and approximation from “go-by” projects and minimize
process calculations.

Design information:

Prepare the following design information. The minimum necessary for study
purposes is acceptable.

Proposal for Detailed Feasibility Study for Rough

Information
Cost Estimate Cost Estimate

1.Process flow diagram Required Required

2.Utility summary Required Required

3.Catalyst and chemicals Required Required

4.Equipment list Required Required

5.Vessel data sheet Required Not Required

6.Heat exchanger data sheet Required Not Required

7. Fired heater data sheet Required Not Required

8. Pump and compressor data sheet Required Not Required

9. Instrument and PSV data sheet Required Not Required

10. Piping Process Data Required Not Required

11. P & I diagram Required Not Required

12. Conceptual Plot plan Required Not Required

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5. RESPONSIBILITY
Consideration for both facility performance guarantees and plant costs must be
incorporated into the Basic Design Package engineering activities, as successful
project execution depends on a well thought out and evaluated basic design.

5.1. Performance
Usually, the Technology Licensor and the Contractor are responsible for
performance under the contract with the client and must satisfy the following
performance guarantees or incur some penalties.

a) Process performance guarantee

The Technology Licensor and the Contractor are generally responsible for
process performance, such as plant capacity and product specifications,
as defined by the performance test operations defined in the contract.

b) Utility guarantee
As above, the Technology Licensor and the Contractor shall have the
responsibility for maximum utility consumption, except for equipment
designed and guaranteed by vendors.

c) Mechanical and equipment guarantees

Vendors have mechanical responsibility for their equipment. However,
process engineers are responsible for the process information specified in
the basic design package.
5.2. Cost
As the major part of plant erection costs is decided by basic design information,
over-design (beyond the design margins specified in the design basis
documents) is discouraged and minimum cost design encouraged.
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6. MINIMUM CAPITAL COST DESIGN

The plant must satisfy both the client's requirements for performance and safety and
the appropriate industry and regulatory standards. Therefore, plant capital costs
shall not be reduced at the sacrifice of performance or safety. "Minimum capital cost"
is defined as that which satisfies the requirements of performance and safety and is
the objective of the basic design effort.

However, where incremental capital expenditure reduces the total operating cost of a
plant (through reduced utility consumption, etc.), the following design options may be
adopted.

(1) Economic design—lowest capital cost

(2) “Optimum” design—allowing for a tradeoff between capital costs and operating
costs

(3) Energy conservation—minimizing operating costs

As to optimum design, care must be taken that plant cost increases do not affect
client's competitiveness and/or cause target cost overruns. Therefore, this design
policy must have the prior approval of the project manager before implementation.

7. DESIGN
Unless otherwise specified in the client's requirements and standards, the following
design philosophies shall be considered.

7.1. Continuous Operating Period

Process facilities shall be capable of operating continuously for two years or
more without shutdown. Material and equipment selection shall take this
requirement into account.

7.2. Considerations Required for Alternate Operations

In addition to normal operating conditions the plant shall provide the necessary
facilities for startup, shutdown, emergency and other identified alternative
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operations.
Specifically, the following shall be considered: testing, purge and sampling
connections; flushing precautions; vent and drains; circulation lines; plugging
prevention; catalyst regeneration and de-coking facilities, etc.

7.3. Emergency Operation

In the event of a complete utility failure, all processing facilities shall be
capable of an orderly shutdown by a minimum operating staff in a controlled
manner, without damage to facilities or equipment or injury to personnel.
Basically, a plant shall be designed with fail safe consideration for system
failures, providing necessary warning devices, pressure relieving, cooling,
temperature runaway protection and emergency shutdown devices, etc.

7.4. Turndown Ratio

Process facilities shall be capable of operations at 50% of their design
throughput capacities, unless otherwise identified in the design basis
documents. Special caution shall be taken with regard to pump performance
for water circulating operations of the plant.

7.5. Design Life

Major equipment shall be designed for an operating life as listed below, unless
otherwise identified in the design basis documents.
Equipment Life

Heater tubes 10 ~ 20 years

Pressure vessels 20 years

Tankage 20 years

Vessel internals 10 - 20 years

Heat exchanger bundles 20 years

Piping 10 years

7.6. Pump and Compressor Spares

a) Pumps
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The policy for providing spares shall take into consideration the following
kinds and degrees of possible impact in ensuring safe plant operation.
Type of Impact Type of Sparing Required

Minor loss of unit

Common
throughput

Major loss of unit

Full
throughput

Possible venting, flaring

Common
or draining to sewer

Damage to equipment Full

Damage to personnel Full

b) Compressors
Because of their high reliability and expensive cost, centrifugal
compressors need not be provided with spares. In the case of
reciprocating compressors in process service, spares will be necessary, as
compressors require shutdown during maintenance. Often, three 50%
reciprocating compressors are recommended to minimize the cost of
compressors. Spares for instrument air compressors will normally be fully
provided.

7.7. Drivers for Pumps and Compressors

(1) Electric power failure
Pumps specifically required for the safe emergency shutdown of a plant shall
be steam turbine driven.
(2) Economical choice
For large drivers requiring power over 100 KW, type selection shall be made
by comparing the cost of turbines and motors.
(3) Type Selection
Driver selection shall consider plant steam balance and fuel gas and power
costs.
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7.8. Design Allowances

The following design factors are typical for design purposes in equipment
calculation. Design allowances for a particular project should be identified in
the project’s Design Basis documentation.
Equipment Sizing Variable Equipment Sizing Factor

Operating max. range (% of flood) 0.80 -0.85

Operating min. range (% of flood) 0.5

Residence time (minutes) 2 – 10

Vessel/Tower
Number of trays (after application of efficiency) As Calculated

As Calculated Per Each

Packing volume
Bed of Packing

Catalyst volume 1.0

Heat duty 1.1

Heat Exchanger
Surface area 1.1

Heat absorbed 1.1

Fired heater
Heat flux 1.0

Diff. head 1.0

Charge 1.1
Pump
Capacity (Flow) Products 1.1

Reflux 1.2

Diff. head 1.0

Compressor
Capacity 1.1
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7.9. On-stream Maintenance

Facilities will be incorporated to allow on-stream maintenance of the following
equipment.
Equipment Area of Concern

Critical heat exchanger Heavy fouling

Pump and compressor Mechanical failure

Control valve - small size Plugging

Instruments Mechanical failure

Strainer Cleaning

Utility supply system Mechanical failure

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8. REVISION HISTORY

Rev. No. Date Scope Description

First Edition
-Team: Process Engineering
0 1998.04.17 All Pages -Prepared by: J.H.Park, J.E.Lim
-Checked by: B.I.Lee, S.B.Cho, J.C.Noh
-Approved by: S.K.Oh

Partial Revision
-Team: Process Engineering
1 2003.10.20 6,8 -Prepared by: J.S.Yi
-Checked by: J.C.Noh
-Approved by: C.S.Jung

Partial Revision
-Team: Process Engineering
2 2009.05.19 All Pages -Prepared by: L.J.Jeong
-Checked by: H.Sung, E.D.Lee, J.C.Noh
-Approved by: C.S.Jung

Document Numbering Revision

-Team: Process Engineering
-Prepared by: C.H.Yun
3 2010.11.25 All Pages -Checked by: J.H.Park
-Approved by: Y.Y.Koo
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-Team: Process Engineering Department

-Prepared by: I.Hwang
4 2013.07.09 All Pages
-Checked by: P.M. Hur, J.H. Park
-Approved by: S.B.Lee