Laboratory and Pilot-Scale Plant Design and Installation

We provide continuously updated and dynamically maintained documentation throughout the entire project lifecycle. From concept design to commissioning, every document—PFDs, P&IDs, equipment specs, and safety analyses—is meticulously prepared and revised. This ensures full traceability, compliance with international standards, and enhanced project reliability.

Precise documentation is the backbone of efficient and optimized process execution. Aligned with EN and ISO standards, we ensure every phase—from concept to execution—meets the highest industry requirements. Continuously updated, our documentation minimizes risks, accelerates commissioning, and enhances long-term operational efficiency.

1. Project Initiation Documentation

Objective: To define the project scope, conduct feasibility analysis, and establish project requirements.

1.1 Project Definition Document
- Project scope and purpose
- Technical requirements
- Delivery schedule and milestones
1.2 Feasibility Studies
- Economic feasibility and ROI analysis
- Risk assessment and mitigation strategies
- Environmental Impact Assessment (EIA) according to EU regulations
1.3 Concept Design Documentation
- Process selection and comparison
- Preliminary design report with mass and energy balances
- Technology assessment and alternative evaluation

2. Process Design Documentation

Objective: To provide detailed process flow and instrumentation designs for the facility.

2.1 Process Flow Diagram (PFD)
- Overview of process steps with key equipment and streams
- Standards: ISO 10628
2.2 Piping and Instrumentation Diagram (P&ID)
- Detailed process connections, control loops, and safety systems
- Standards: ISO 14617, EN 62424
2.3 Mass and Energy Balance Report
- Detailed calculations for mass and energy flow
2.4 3D Facility Layout and Modeling
- Full 3D modeling of process plants, including equipment layout and piping routing
- Tools: AutoCAD Plant 3D, SolidWorks, or similar platforms

3. Equipment Design and Technical Specifications

Objective: To ensure the design of all process equipment meets project requirements and standards.

3.1 Equipment List and Specifications
- Equipment names, capacities, pressure, temperature ratings, and materials of construction
- Standards: ASME BPVC, EN 13445, PED (Pressure Equipment Directive)
3.2 Pressure Vessel Design and Analysis
- Thickness calculations, stress analysis, and compliance with standards
- Standards: ASME VIII, EN 13445
3.3 Tank and Storage System Design
- Capacity and insulation requirements
- Standards: API 650, EN 14015

4. Piping and Connection Documentation

Objective: To provide detailed piping design and connection information.

4.1 Line List
- Pipe sizes, materials, design pressure, and temperature
4.2 Valve List and Specifications
- Valve types (gate, globe, ball), material properties, and connection details
4.3 Insulation and Heating Plans
- Insulation requirements and steam tracing designs

5. Control and Automation Documentation

Objective: To develop control strategies and provide detailed automation documentation.

5.1 Control Philosophy Document
- Control strategies, process variables, and safety functions
- Standards: IEC 61511
5.2 Instrument List and Technical Specifications
- Pressure, temperature, level, and flow sensors; PLC and SCADA systems
5.3 Software and PLC Programming Documentation
- Programming standards, test procedures, and emergency scenarios

6. Safety and Environmental Documentation

Objective: To ensure process safety and environmental compliance.

6.1 Process Safety Analysis (HAZOP, LOPA)
- Identification of hazards and implementation of safety measures
6.2 Emergency Response Plans
- Fire, explosion, and gas leakage scenarios
6.3 Environmental Compliance and Waste Management Plan
- Standards: ISO 14001

7. Testing and Commissioning Documentation

Objective: To verify the correct operation of the system and ensure safety and performance.

7.1 Test Plans and Protocols
- Factory Acceptance Test (FAT), Site Acceptance Test (SAT)
- Standards: EN 10204, IEC 61508
7.2 Calibration and Instrumentation Tests
- Calibration certificates and test reports for pressure, temperature, and flow meters
7.3 Commissioning Procedures
- Functional verification and emergency stop tests

8. Operation and Maintenance Documentation (O&M)

bjective: To provide step-by-step operating and maintenance procedures.

8.1 Standard Operating Procedures (SOPs)
- Startup, shutdown, and emergency procedures
8.2 Preventive Maintenance Plans
- Maintenance schedules for critical equipment
8.3 Spare Parts List
- Inventory management and critical spare parts

9. Training and User Documentation

Objective: To ensure the proper training of operators and maintenance personnel.

9.1 Training Programs and Materials
- Training modules for operators and maintenance staff
9.2 User Manuals and Quick Guides
- Equipment operation and software use instructions

10. Project Closeout and Evaluation Documentation

bjective: To summarize project performance and officially close the project.

10.1 Performance Evaluation Report
- Project goal assessment and capacity analysis
10.2 Final Acceptance Report
- Official project closeout documentation

11. Quality Assurance and Compliance Documentation

Objective: To ensure adherence to quality and regulatory requirements.

11.1 Quality Management Plan (QMP)
- Standards: ISO 9001, ISO 17025
11.2 Compliance and Certification Documents
- CE certification, ATEX certification, PED compliance

12. Emergency and Safety Management Documentation

Objective: To enhance process safety and define emergency procedures.

12.1 Process Safety Management (PSM)
- Standards: OSHA PSM, IEC 61511
12.2 Emergency Response Plans
- Evacuation, firefighting, and gas leak response plans

13. Environmental Management and Sustainability Documentation

Objective: To promote environmentally friendly operations and sustainability.

13.1 Waste Management Plan
- Hazardous waste management and recycling strategies
13.2 Energy Efficiency and Carbon Footprint Report
- Standards: ISO 50001

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