Integrated Management System

PROCESS DESIGN CRITERIA - GUIDELINE

Document No: IMS-OG-GL-ENG.PRO-GDL-0003

1 OF 51

Revision : 00 Date : 15-JAN-2018

This document is part of a set of Integrated Management System documentation developed to meet the
requirements of ISO 9001, ISO 14001 & OHSAS 18001.

00 15-JAN-2018 ISSUED FOR USE R. SHAIKH S. MAITI J. HOWARD B. GALA

ISSUED FOR COMPLIANCE /
B1 21-DEC-2017 R. SHAIKH S. MAITI J. HOWARD B. GALA
CONSISTENCY REVIEW
A1 14-DEC-2017 ISSUED FOR INTERNAL REVIEW R. SHAIKH S. MAITI T. MANDAL B. GALA

REV DATE ISSUE DESCRIPTION AUTHOR CHECKER HSSE / Q APPROVER

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TABLE OF CONTENTS

1.0 INTRODUCTION .......................................................................................................... 4

1.1 Purpose .............................................................................................................. 4
1.2 Scope ................................................................................................................. 4
1.3 Responsibility .................................................................................................... 4
2.0 GUIDELINE .................................................................................................................. 4
2.1 Design Pressure ................................................................................................ 4
2.2 Design Temperature .......................................................................................... 5
2.3 Design Margin .................................................................................................... 6
2.4 Equipment Sizing .............................................................................................. 7
2.4.1 Vessel Sizing ............................................................................................ 7
2.4.2 Reactors .................................................................................................. 16
2.4.3 Tanks ....................................................................................................... 16
2.4.4 Heat Exchangers .................................................................................... 19
2.4.5 Fired Heaters .......................................................................................... 27
2.4.6 Pumps ..................................................................................................... 27
2.4.7 Compressors .......................................................................................... 31
2.5 Line Sizing and Hydraulic Calculation ........................................................... 34
2.5.1 Pump Suction Lines ............................................................................... 34
2.5.2 Compressor Suction Lines .................................................................... 34
2.5.3 Pump/Compressor Discharge Lines and Other Applications ............. 35
2.5.4 Reboiler Lines......................................................................................... 36
2.5.5 Cooling Water Lines ............................................................................... 37
2.5.6 Steam Condensate Lines ....................................................................... 37
2.5.7 Steam Lines ............................................................................................ 37
2.5.8 Two-Phase Flows ................................................................................... 38
2.5.9 Tower Draw-Off Line Sizing ................................................................... 38
2.5.10 Amine Lines ............................................................................................ 39
2.5.11 Control Valve .......................................................................................... 39
2.5.12 Piping at Control Valves ........................................................................ 40
2.6 Flare & Relief System Design ......................................................................... 41
2.6.1 Simultaneous Cases for Maximum Relief Discharge ........................... 41
2.6.2 Relief Valve Set Pressure....................................................................... 42
2.6.3 Relief Valve Sizing .................................................................................. 42
2.6.4 Relief Valve Locations ........................................................................... 42
2.6.5 Piping at Relief Valves ........................................................................... 43
2.6.6 Slope of the Relief Header ..................................................................... 43
2.6.7 Thermal Relief......................................................................................... 44
2.7 Valve and Isolation Selection ......................................................................... 44
2.7.1 Valve Selection Criteria .......................................................................... 44
2.7.2 Valve Operator Selection ....................................................................... 44
2.7.3 Control Valve Stations ........................................................................... 45
2.7.4 Vents and Drains .................................................................................... 45
2.8 Insulation & Heat Tracing ............................................................................... 45
2.8.1 Personnel Protection ............................................................................. 46
2.8.2 Heat Conservation .................................................................................. 46

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2.8.3 Cold Medium Conservation ................................................................... 46

2.8.4 Noise attenuation ................................................................................... 46
2.8.5 Heat Tracing............................................................................................ 46
2.9 Corrosion Allowance ....................................................................................... 47
3.0 DEFINITIONS ............................................................................................................. 48
4.0 ABBREVIATIONS ...................................................................................................... 48
5.0 REFERENCE DOCUMENTS ...................................................................................... 49
6.0 CODES AND STANDARDS ....................................................................................... 49
7.0 REVISION HISTORY.................................................................................................. 50
8.0 RECORDS ................................................................................................................. 50
APPENDIX 1 – PROJECT DELIVERY APPLICABILITY ............................................................. 51

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1.0 INTRODUCTION

This guideline describes the preparation of Process Design Criteria specific to a particular project.
This provides the basis to perform process design calculations for a project.

1.1 Purpose

The Process Design Criteria will define the technical design approach to be applied to a specific
project for a specific client. This document along with relevant project documents covers the basis to
be used in design of the equipments, critical instruments, lines etc. for a project.

1.2 Scope

This guideline is applicable to all projects where SNC-Lavalin Oil & Gas provides either full or partial
services. This document shall be modified to reflect project specific basis. Delete sections which do
not apply. The document number for Design Criteria template is IMS-OG-GL-ENG.PRO-TMP-0057-
01.

1.3 Responsibility

The Process Engineering Department Manager is responsible to administer, maintain and ensure
adherence to this guideline.

2.0 GUIDELINE

The process design criteria shall contain the following.

2.1 Design Pressure

The design pressure of the equipment will be based on following criteria:

Table 2.1-1 Design Pressure Selection
Maximum Operating Pressure (MOP) Design Pressure
0.0 - 49.0 kPag 100 kPag *
50.0 - 999 kPag MOP + 100 kPag *
1000 kPag - 6895 kPag 1.1 x MOP
6900 kPag - 13780 kPag MOP + 690 kPag
Above 13780 kPag 1.05 x MOP

* Maximum Design Pressure for vessels without ASME code stamping. For vessels with pressure
relieving system to flare, consider 350 kPag as minimum design pressure to reduce flare header
size requirements.

Notes:
1. Operating pressure is defined as maximum normal operating pressure at top of vessel.

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2. Allowances for pressure drop across internals, hydrostatic head and weight of catalyst or
packing must be added to the operating pressure to arrive at the design pressure for the lower
sections of the vessel.
3. Where there is a possibility that vacuum conditions might be experienced during operations,
vessels should be designed accordingly. If steam-out is a frequent occurrence or is part of the
process cycle, the external design pressure will be 50 kPa. The possibility of a closed vent
during steam-out for shutdown or hydrostatic test will not be considered reasons for designing
vessels for vacuum.
4. The most severe coincident conditions of temperature and pressure should also be stated and
considered in the design.
5. This table does not apply to atmospheric storage tanks.

Equipment in a pump discharge circuit with a downstream block valve and no relief valve will have a
design pressure at least as high as the shutoff or minimum flow pressure of the pump at normal
operating suction pressure. This is to be checked after equipment design.

For estimates of pump shutoff head on motor-driven centrifugal pumps, use the greater of the
suction pressure, plus 125% of the rated differential pressure of the pump or the maximum suction
pressure plus the normal differential head. The normal suction pressure will be the vessel operating
pressure plus the normal liquid static head. The maximum suction pressure should be the maximum
liquid head plus the maximum vessel pressure (consider relieving condition). For turbine driven
pumps, use the suction pressure plus 1.25 x (1.05)² x the rated differential pressure, which allows
for turbine overspeed. If a blocked outlet at pump discharge causes a relieving condition in the
suction vessel then the pump shutoff head will be the maximum suction pressure (relieving
condition) plus 125% of the rated differential head for motor driven pumps. A factor of 138% should
be used for turbine driven equipment.

For Shell and Tube Exchangers, the design pressure of the LP side will follow API STD 521.

Vacuum design conditions will be specified for:

 Equipment that normally operates under vacuum conditions or is subjected to vacuum
conditions during start-up, shutdown, ejector operation, commissioning, regeneration etc.
 Suction drums on reciprocating compressors (vacuum conditions to be considered in addition
to operating conditions)
 Vessels/exchangers that normally operate liquid full and can be blocked in and cooled down
 Columns and associated equipment (e.g. condenser etc.) that can be subjected to vacuum
condition on loss of heat input.

2.2 Design Temperature

 For operating temperatures above 15°C, the design temperature will be the operating
temperature plus 30°C.
 The operating temperature is defined as the maximum temperature encountered during
normal operation, start-up or shutdown. An alternate operating temperature and pressure
should be specified for situations such as catalyst regeneration.
 For equipments operating at ambient conditions and located outdoor & installed under shade,
the maximum design temperature shall be 50°C. For equipments operating outdoor and

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susceptible to direct solar radiation the maximum design temperature shall be 65 °C.
 Both top and bottom operating temperatures should be specified for columns. Normally,
design temperature will be based on bottoms temperature. However, two or more design
temperature zones should be specified if economic considerations dictate (i.e. alloy material,
stress values).
 Low temperature operating conditions should be taken into consideration for the design. For
operating temperatures of 15°C or lower, the minimum design temperature should be 5°C
below the operating temperature. Operating temperature for low temperature service should
be taken as the minimum temperature encountered during normal operation, start-up, or
shutdown. Minimum design temperature of equipment and piping will be based on lowest one-
day mean temperature, winterizing temperature and/or depressurization temperature, as
applicable.
 The most severe conditions of temperature and pressure will be stated and considered in the
design.
 Vessels subject to changes in operating temperatures such as catalyst regeneration will have
the frequency shown on the process data sheet.
 The design temperature of vessel internals (e.g. packing) should take into consideration
steam-out conditions.

2.3 Design Margin

The overdesign margins of different equipment are listed below:

Table 2.3-1 Design Margins for Equipment

Item Margin Remarks

Pumps Rated flow will be For pumps with continuous minimum flow through
110% of normal flow RO and open valve, calculate minimum flow and
add to pump flow.
Reflux / Reboiler / 20% on material
Pump around Pumps balance flows
Loading / Transfer 20% on material This margin is kept to facilitate accelerated
Pumps balance flows loading / export, if required.
Hydraulics Design for 100% on For early phase of engineering (when plot plan
material balance flow development is in progress), consider margin on
and check for 110% on equivalent length. Higher margin on flow will not
material balance flow be considered to take care of this uncertainty.
Exchangers/ Coolers NIL Except for Condenser / Reboiler, as stated
separately. For all exchangers / coolers /
condensers / reboilers etc., fouling factor to be
considered based on EOR operation and
turnaround period of the plant.

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Item Margin Remarks

Condensers/ Reboilers 10% on material

balance flow and duty
Fired Heater 10% - 15% on duty
Compressors Rated flow will be Consider additional 10% (to be corrected on
110% on material available Supplier data) for spillback of
balance flow reciprocating compressor.

2.4 Equipment Sizing

2.4.1 Vessel Sizing

The general guidelines for vessel design are presented in the following sections and effort has been
made to cover normal operations for different services. Consult Lead Engineer if the service will be
different than specified below.

The guidelines for liquid holdup are shown in the table below:
Table 2.4-1 Holdup Time (t h ) / Surge Time (t s ) for Vessels
Holdup Time (t h ) Surge Time (t s )
Service (NLL - LLL) (NLL - HLL)
min. min.
A. Unit Feed Drum 10 5
B. Separators
1. Feed to Column 5 3
2. Feed to Other Drum or Tankage
a) With Pump or Through Exchanger 5 2
b) Without Pump 5 1
3. Feed to Fired Heater 10 3
C. Reflux or Product Accumulator
1. Reflux Only 3 2
2. Reflux and Product
a) Based on reflux (3 minutes) + appropriate holdup
time (t h ) of overhead product (as per B-1,B-2, B- 3+(t h ) 2+(t h )
3)
D. Column Bottoms
1. Feed to another column 5 2
2. Feed to other drum or tankage
a) With pump or through exchanger 5 2
b) Without pump 2 1+
3. Feed to fired reboiler
a) Based on reboiler vapour expressed as liquid (3
minutes) + appropriate holdup time (t h ) for the 3+(t h ) 2+(t h )
bottom product (per D-1, D-2)
E. Compressor Suction / Inter-stage Scrubber
1. Between HLL (HLA) and HHLL 3 N/A
From bottom tangent to HLL (HLA) (Note 1) 10 N/A

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Holdup Time (t h ) Surge Time (t s )

Service (NLL - LLL) (NLL - HLL)
min. min.
F. Fuel Gas Knock-out Drum
Volume = 6 m
1. From NLL to HHLL
slug in feed line
G. Flare Knock-Out Drum
1. From LLL to HLL(Note 2) 20-30
Notes:
1. The following criterion shall be used for sizing of Compressor suction and interstage
Scrubbers / knockout drums.
 The drum shall be designed to remove liquid droplets greater than 300 microns in the gas
stream.
 The gas outlet nozzle shall be sized for allowable ρV² of 1250
 The liquid outlet nozzle velocity shall be limited to 1.0 m/s
2. The flare knock out drum shall be designed to remove liquid droplets bigger than 300 microns
from the gas stream. The liquid hold-up time in the drum shall be minimum 30 minutes.

When the discharge rate is unimportant, a nominal hold-up time of approximately two (2) minutes is
provided. Level control should span between the high and low levels. Where high and low level trips
are required, these should be located at a reasonable elevation above and below the high and low
levels respectively, to allow operator intervention before a trip occurs. Low liquid level shall be at
least 200 mm above the bottom (for horizontal vessels) or bottom tangent line (for vertical vessels).

For water settling the above applies but this may need to be increased. Where there may be solids
in the drum, which are not to be drawn off, the liquid outlet may be raised and the low liquid level
shall be increased accordingly

For horizontal vessels, the highest liquid level shall be at least either 300 mm or 20% of the drum
diameter below the top, whichever is the greater. Note: if a crinkled wire mesh pad is present then
highest liquid level shall be at least 300 mm below the bottom of the pad.

For vertical vessels, if vapour flow is present the highest liquid level shall be at least 300mm below
the bottom of the inlet arrangement. If little or no vapour is present, the highest liquid level shall be
at least 300 mm or 15% of the drum diameter below the top tangent line, whichever is the greater.

The minimum time between a HLL alarm and trip and between a LLL alarm and trip shall be no less
than 2 minutes.

2.4.1.1 Piping at Vessel

Safety relief valves may be located on the vessel nozzle or overhead piping. Location of PSVs on
the vessel or vessel nozzle is preferred. Major factors affecting pressure safety valve nozzle
location, are discharge destination, accessibility to the valve, and structural support.

All process vessels will be provided with process vent, process drain and vessel purging
connections as follows:

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 The vessel drain will be sized according to vessel volume as indicated in section 2.4.1.2. The
drain line may originate from a bottom liquid draw-off line. It should terminate with a line size
block valve and blind flange in case of localized drain.
 The process vent will be sized according to vessel volume as indicated in section 2.4.1.3. It
will be located, at the high point of the overhead vapor line or on the top head whichever is
higher. Process vent lines will be provided with a line size block valve and the valve will be
readily accessible from an operating platform.
 Drains, including level gauges and level controllers for butane or lighter compounds will be
piped to the flare header.
 Vents for light hydrocarbon service or materials above their flash points will be piped to the
flare system.
 Steam out connections, if required, will be 2” on all vessels and will be located 200 mm above
the bottom tangent line on towers and vertical drums and 300 mm above the bottom of
horizontal drums. The connections will be provided with a block valve and blind flange.

2.4.1.2 Drain Sizes

The guidelines for sizing drains are provided in the following table:
Table 2.4-2 Vessel Drain Sizes
Vessel Volume (m³) Drain Size (in)
1.4 and under 1
1.4 to 5.7 1½
5.7 to 17.0 2
17.0 to 70.8 3
Over 70.8 4

2.4.1.3 Vent Sizes

Once the drain size has been determined, the size of the vent can be obtained from the table below
for drums operating at essentially atmospheric pressure.
Table 2.4-3 Vent Sizes for Atmospheric Drums
Drain Size (in) Vent Size (in)
1 ¾
1½ 1
2 1½
3 2
4 3

For drums operating at above atmospheric pressure, the vent size may be calculated from the
following equation, d = C As

Where d = vent diameter, inches

As = shell + heads surface area of the drum, m²

C = a coefficient related to the operating pressure as follows:

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Table 2.4-4 Factors for Vent Sizing

Operating Pressure (kPag) C
103 - 414 2.476
414 - 1380 1.722
1380 - 4828 1.292

2.4.1.4 Steam-Out and Blowdown Sizes

The guidelines for sizing steam-out and blowdown connection are provided in the following table
Table 2.4-5 Steam-Out and Blowdown Sizes
Vessel Volume (m³) Steam-Out (in) Blowdown (in)
1.4 and under 1 2
1.4 to 5.7 1 3
5.7 to 17.0 1 3
17.0 to 70.8 2 4
Over 70.8 3 4

2.4.1.5 L/D Ratio and Vessel Positioning

The selection of an appropriate L/D ratio for a particular design is affected by the following factors:
 Process considerations are the primary factor over cost considerations. The shape of a drum
may be somewhat limited by requirements for liquid surge and holdup times, minimum vapor
areas, settling velocities, etc. In some cases, plot plan limitations will also fix the L/D ratio.
 Drums with diameters less than 610 mm may be difficult to construct and operate
(maintenance problems), particularly if they have internals such as wire-mesh pads, baffles, or
special level-controllers. These would normally be formed from appropriately scheduled pipe.
 Optimum L/D ratios are not as relevant in the case of drums with complex internals as with
simpler drums.

The following criteria will, in most cases, lead to near minimum cost designs.
 The L/D ratio for all process vessels should be within the range: 1.5 ≤ L/D ≤ 6, except in the
case of surge vessels operating at atmospheric conditions; in such cases, it may be cheaper
to use smaller L/D ratios.
 For design pressures between 100 and 1900 kPag, the optimum L/D ratio is approximately
between 1.5 and 3.0.
 For vessels at design pressures between 1900 and 3800 kPag, the recommended L/D is
between 3.0 and 4.0.
 For design pressures above 3800 kPag, the recommended L/D ratio is between 4.0 and 6.0.
 To keep engineering costs low, the standard manufacturer vessel sizes should be selected.
 Tower with L/D greater than 25 shall be avoided, if possible, due to support problem.

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To reduce vessel dimension, split flow can be considered for horizontal drums; especially when
dealing with large gas flow. Crinkled wire mesh screens will be considered where vapour-liquid
disengagement is important and it will reduce vessel diameter.

Following guidelines can be considered for positioning the vessel:

 Small knockout vessels and flash drums should be vertical.
 Horizontal vessels should be used when water or another liquid phase is being settled out.

Vertical drums should not be used for oil / water separation except in water boot applications.

2.4.1.6 Dimensioning Procedure

Vessel / column inside diameters will be specified in increments of 5 mm. Tangent - to - tangent
lengths will be specified in increments of 5 mm.

Maximum and normal liquid levels and alarm and shutdown levels will be specified from bottom
tangent line for columns and vertical vessels, and above the bottom for horizontal vessels.

Height of bottom tray above bottom tangent line will be given for columns.

Minimum tray spacing will be as follows:

Table 2.4-6 Minimum Tray Spacing

Tower ID (mm) Max No. of Tray Passes Min Tray Spacing (mm)
750 to 1800 1 500
1800 to 2700 2 500
2700 to 3300 2 600
3300 to 4800 4 600
4800 to 6000 4 600
> 6000 4 750

Tray spacing should be greater than the minimum shown above where required for access to
column internals, vapour disengaging, nozzle interference or other reasons.

Vessels with trays will be provided with the following number of manways:
Table 2.4-7 Number of Manways
Number of Trays Number of Manways
1 - 25 2
26 - 41 3
42 - 61 4
62 - 80 5

Manways are preferred at drawoffs and chimney trays.

In services in which frequent cleaning is anticipated, the number of manways will be increased in
accordance with severity of service, to a maximum of one for each three trays.

The minimum tray spacing at manway locations will be 760 mm.

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Minimum distance from top of tray to top tangent will be 915 mm or as required to accommodate
manway, internals or nozzles.

Column trays will be numbered from top to bottom.

Packed vertical vessels will have a manway at the top and bottom of each packed bed for filling and
emptying. A manway will also be provided below the packing support of the lowest bed when the
distance from the bottom tangent line to the packing support ring is 915 mm or greater.

Vessels will be provided with a minimum of one manway in each pressure compartment or two 8”
diameter hand-holes or inspection openings when the vessel diameter is less than 915 mm, except
that when such vessels contain internals, one end-flange and one 8” diameter hand-hole or
inspection opening will be provided.

2.4.1.7 Selection of Vessel Heads

 Consider 2:1 elliptical heads if the inside diameter D < 4.57m and the design pressure, P >
690 kPag.
 Hemispherical heads are typically used when D > 4.57m regardless of design pressure.
 Dished heads with knuckle radius of 0.06 D are typically used if D < 4.57m and design
pressure < 690 kPag.

2.4.1.8 Distillation Columns and Internals

The guidelines for preliminary sizing of distillation towers are indicated in the following sections.
Final design of the internals and accordingly of tower will be decided by internals Supplier.

Many applications will require either sieve or valve trays while sieve trays are preferred due to easy
maintenance and lower cost. Valve trays are preferred if column turndown is more than 3:1.

If tower diameter is less than 915 mm then packing is to be considered. Packing will also be
considered where low pressure drop is required or in corrosive, non-fouling service.

For towers the following percent flood and system derating factors are to be considered:
Table 2.4-8 System Derating Factor and Flood%
Service Maximum % Flood System Derating Factor
Hydrocarbon Fractionators (no
80 1.00
foam)
Amine Contactors 80 0.60
Amine Regenerators 80 0.75
Sour Water Strippers 80 0.60 (with reboiler)
Sour Water Strippers 80 0.70 (with steam stripping)

The below specified theoretical tray efficiencies are indicative and will be further confirmed based on
Licensor or Tray / Packing Supplier recommendation.

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Table 2.4-9 Theoretical Stage Efficiency

Service Theoretical Stage Efficiency %
Crude Fractionators (Naphtha Section) 60%
Crude Fractionators (Distillate / AGO / GO) 50%
Crude Fractionator (P/A) 40%
Side Strippers 40%
Depropaniser 70%
Debutanizer 70%
Steam Stripper (General) 65%
Sour Water Stripper 30%

For preliminary design purposes consider the following:

 Allowable Pressure drop per tray
Table 2.4-10 Allowable Pressure Drop per Tray
For: Pressure Service For: Vacuum Service
Tray Type
kPa per tray kPa per tray
Sieve 0.7 - 1.4 0.13 - 0.26
Valve 0.7 - 1.4 0.46 - 0.6
Bubble Cap 0.7 - 1.4 0.46 - 0.6

 Chimney tray pressure drop will be 1.25 kPa minimum

 Minimum tray pressure drop for structural design will be 1.7 kPa. Wherever deposits on tray
are possible, consider higher figure.
 Downcomer backup will be limited to 50% of tray spacing.

Columns which are generally proprietary design by Licensors will be governed by Licensor’s design
/ datasheet.

2.4.1.9 Skirt Height

Required skirt heights above grade will be set by process conditions (e.g. pump NPSH). When skirt
height is not influenced by process factors, it will be specified as “Minimum”.

2.4.1.10 Nozzles, Boots and Manways

Process Nozzles

Process nozzles on vessels will be identified as N1, N2, N3 etc.; manways will be identified as M1,
M2, M3 etc. and instrument nozzles on vessels as J1, J2, J3, etc.

All connections will be flanged, with a 1” minimum size. The minimum flange rating for 3” and
smaller connections is 300 #. Minimum nozzle size for connected process piping is 2”.

Nozzles shall be sized by limiting velocities in accordance with below Table.

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Table 2.4-11 Maximum Nozzle Velocities

Nozzle Max Velocity (m/s)
Column Bottom Outlet
2" 1
3" 1.4
4" 1.5
6" 1.8
8" 2
10" 2.3
12" 2.4
Column Feed (Note-1) 122/(ρ)0.5
Column Drawoff to Pumps (Note-2)
Suction box velocity
- Liquid falling from above 0.3
- From Quiet Zone 0.6
Column Drawoff to Pumps (Note-2)
Minimum liquid height above top of draw-off nozzle, mm
- Liquid falling from above
900 1.2
760 0.9
600 0.6
300 0.3
150 0.2
- From quiet zone
600 1.2
450 0.9
300 0.6
150 0.3
0 0.2

Notes:
1. ρ = average density of mixture at flowing conditions, kg/m³. Column feed inlet line to be a
minimum of 10 pipe diameters at this velocity. No bends in the vertical plane over this length.
2. This limitation is set to prevent trapped vapors from getting into the pump. From a point 3m
below the draw-off nozzle, the connecting line can be reduced to its regular calculated size. All
column side draws must turn down immediately for a minimum of 3m. A note to this effect
should appear on Piping and Instrumentation diagrams when required.
3. Other nozzles shall match calculated line size.

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Boots
Boots will be furnished on horizontal vessels in hydrocarbon service which have continuous water
drains. Low and high interface level transmitters with board mounted alarms will be provided on all
boots. Boots will be sized for at least 7 minutes water flow with 5 minutes residence time below the
hydrocarbon / water interface. For elevated vessels, water drawoff pots located at grade will be
used instead of vessel boots. The drawoff pot should be connected to the vessel with an oversized
line to permit 2-way flow. The connection line shall be sized with 0.2 m/s maximum.

Raised vortex breakers, or liquid outlets projecting into the vessel are not preferred. If raised liquid
outlets are required, outlets will be taken from the side of the vessel at the required elevation.

Manways

The preferred manway size for vessels will be 24”. The minimum manway size to be used is 18”.
Manways will be sized at either 18” or 24” and intermediate sizes shall not be used with the
exception of high pressure vessels and reactors.

For determining manway sizes, the following general guidelines will be used:
Table 2.4-12 Manways on Shell

Vessel Diameter (mm) Manway Size (in)

≤ 760 No Manway (see below)
760 - 1675 18
≥ 1830 24

Table 2.4-13 Manways on Heads

Vessel Diameter (mm) Manway Size (in)
≤ 760 No Manway (see below)
760 - 1070 18
≥ 1220 24

Consideration will be given to using flanged heads or handholes for smaller diameter vessels (≤
760) where appropriate.

Sizes of manways on reactors will be considered on an individual basis. For vessels in high
pressure service (6200 kPag or higher), the manway size will be 22” I.D.

All vessel internals will be specified to fit through 20” manways in Narrative Specifications and other
pertinent documentation.

Mist Eliminators

Mist eliminators separate mist from a gas stream to recover valuable products, improve emissions,
protect downstream equipment, and improve product purity.

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In order for a mist eliminator to work properly, it must be designed to collect and capture the
droplets present in the system. Therefore, it is imperative to define the size of the droplets present.
After the droplets have been captured, the mist eliminator must be able to remove the droplets from
the system by draining effectively. Through the initial selection process, the most appropriate mist
eliminator media must be selected so that liquid hold-up in the pad does not become an issue after
the mist eliminator is installed. When designing a mist eliminator, engineers are also responsible for
defining the environment the mist eliminator will operate in so that maintenance requirements are
minimized.

Wire-mesh mist eliminators are the most common. Knitted wire mesh pads remove entrained liquid
droplets down to 3mm in diameter from gas streams with velocities above 1 ft/s. Wire-mesh mist
eliminators are made of knitted metal mesh. Wire-mesh pads are most often used in vertical flows,
but may also be used horizontally. The wire-mesh mist eliminators have better efficiency, modest
pressure drop, and low capital and operating costs.

Fiber-bed mist eliminators consist of columns of fibrous material that remove very fine droplets of
liquid entrained in a gas stream. They are extremely efficient for large liquid flowrates and to remove
droplets smaller than 3mm in diameter. Fiber-bed mist eliminators are designed for horizontal,
concurrent gas stream flow though the bed, never for upward gas flow.

Baffle-type, also known as chevron or vane, mist eliminators change the direction of the gas flow in
an attempt to force liquid droplets to collect on the baffle surface. Baffle-type mist eliminators are
useful for both vertical and horizontal gas flows. Little pressure drop occurs from baffle-type mist
eliminators, which pressure loss kept to a minimum. However, baffle-type mist eliminators are only
effective for droplets larger than 3 micrometers in diameter and for velocities above 2.54 m/s.

2.4.2 Reactors

Reactors are generally proprietary design by Licensors and will be governed by Licensor’s design /
datasheet.

2.4.3 Tanks

Tank design will preferably follow API STD 650 or API STD 620 standard, as applicable. API STD
12F and API STD 12P shall be used for small volume shop built tanks and shop built FRP tanks
respectively.

2.4.3.1 Selection

The criteria for deciding the type of roof for petroleum liquid storage tank roofs is based on the True
Vapour Pressure of the liquid. Following guidelines may be generally followed.
Table 2.4-14 Selection of Tank Roof
True Vapor Pressure Type of Tank
< 10 kPa Fixed or Conical Roof Tank
10 kPa - 76 kPa. External Floating Roof Tank
10 kPa - 76 kPa. Internal Floating Roof Tank

Fixed Roof Tank is not recommended beyond 40 meter Diameter

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Internal floating roof tanks shall be used in following scenario:

 Protection, by the fixed roof, from severe weather conditions, particularly rain, snow, and ice.
 No product contamination from rain water and melting snow.
 Carcinogenic product

Storage tank selection and design needs to be reviewed by the process engineer for:
 Material losses due to evaporation
 Optimized cost of tank
 Safety and reliability of the system
 Minimum environmental impact due to vapor or liquid release

As a rule, storage temperature will be at least 28°C more than pour point of the liquid stored.
Viscosity of liquid (for pumping out) will also be considered for setting the storage temperature.

In / out breathing requirements of tanks will be based on API STD 2000.

2.4.3.2 Design Pressure and Temperature

A design pressure of “ATM” can be stated for external floating roof tank, uncovered tank or tank with
loose cover.

For most hydrocarbons and commonly used chemicals, the following design pressure criterion is
applicable.
Table 2.4-15 Tank Design Pressure
Type of Tank Design Pressure
Conical roof tanks with goose neck only + 25 / - 10 mm WC

Conical roof tank with Pressure Vacuum Breather valve and Flame Arrestor +200 / - 65 mm WC

Conical roof tank with Pressure Vacuum Breather valve and Flame Arrestor with inert
+250 / - 65 mm WC
gas blanketing

For External Floating roof tank Design pressure shall be Atmospheric / - (These tanks have no
negative design pressure).

For Internal Floating roof tank Design pressures shall be as per the type of outer tank.

The design temperature will be determined in accordance with section 2.2: Design Temperature.

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2.4.3.3 Nozzles, Sumps and Manways

Preferred alternative is that the liquid can enter at the bottom of the tank as this eliminates the static
electricity hazard. For top entry into the tank, dip pipes are used for eliminating the static electricity
hazard. For nozzles having dip pipes appropriate size for the outer nozzle to be specified.
Removable dip pipes are used for corrosive services as these can be replaced externally. For non
corrosive services, welded dip pipes may be used.

General Criteria for providing number of tank side drains is as follows.

Table 2.4-16 Tank Draw-off

Tank Diameter (m) Minimum Water Drain Size (in) Total Number of Drains

Up to15 3 1
15 to 30 4 1
30 to 45 4 (or 6) 2 (or 1)
45 to 60 4 3
> 60 4 (or 6) 4 (or 2)

Larger tanks are built with draw-off sump and the tank floor slopes to low point sump. General
Criteria for the sizes of sumps is as follows.
Table 2.4-17 Tank Sump Size

Nominal Pipe Sizes (in) Diameter of Sump (in) Depth of Sump (in)

2" 24 12
3" 36 18
4" 48 24
6" 60 36

To drain rainwater from the deck of the floating roof, flexible armoured PVC hose or swing type pipe
roof drain is used which is connected to shell and kept open to atmosphere during monsoon
season. A non return valve is provided near the roof end to prevent backflow of stored product onto
the roof in case the drain pipe gets punctured. The number and size of roof drain shall be
determined in accordance with the maximum local rainfall. General guideline for deciding the size of
floating roof drain nozzle for external floating roof tanks is as follows.
Table 2.4-18 Tank Roof Drain
Tank Diameter (m) Floating roof drain size (in)
< 20 3
20 > D < 60 4
D > 60 6

Provision of floating roof drain nozzles is not applicable to internal floating roof tanks.

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Emergency floating roof drains shall be provided for external floating roof tanks to prevent the roof
from sinking due to accumulation of rain water during heavy rains or by chance the roof drain valve
is closed during monsoon. These drains are not to be installed on single deck floating roof tanks.
The design of these drains shall be as per API 650 guidelines Water seal is to be maintained
regularly to prevent escape of vapours through this arrangement.

Internal access shall be via a number of manways as outlined below. Multiple manways shall be
approximately equally spaced and a manway shall be positioned adjacent to the water draw-off.
Table 2.4-19 Number of Manways for Tank
Manways in Fixed Roof Manways in Floating Roof
Tank Diameter (m) Manways in Shell (in)
(in) (in)
<6 1 No. x 24 1 No. x 24 1 No. x 30
6 > D <18 2 Nos. x 24 1 No. x 24 1 No. x 30
18 > D < 36 3 Nos. x 24 1 No. x 24 2 Nos. x 30
2 Nos. x 24
> 36 2 Nos. x 24 2 Nos. x 30
1 No. x 30

2.4.3.4 Tank Heating and Heat Conservation

Storage tanks produce wax in service shall be equipped with an internal heating coil to maintain the
process liquid temperature at least 10 ºC above the liquid pour point or melting point. Heating coils
or fin tube bundle heaters are the preferred options when tanks require protective heating. For small
heat duties, removable electric heaters should be considered.

Tank insulation may also be required for heat conservation or winterisation in other services (e.g.
when the pour point, freeze point or congealing point of the fluid is above the average ambient
temperature). An economic analysis should dictate whether heating will be required in conjunction
with isolation.

It is normally sufficient to insulate up to 10%-20% above normal liquid level when storing liquids with
low pour points or in extreme cold climates. Tank roofs are normally not insulated.

2.4.3.5 General Criteria

Automatic Bleeder vents shall be provided on floating roof to vent the air from under the roof when
the tank is being filled initially.

Fixed roof tanks are blanketed or purged with inert gas to prevent the formation of flammable
mixtures in the vapour space.

Mixing can be done using a propeller type mixer or a jet mixer.

When frequent cleaning is anticipated, cleanout nozzles shall be provided.

2.4.4 Heat Exchangers

Heat exchangers will be designed in accordance with the appropriate standards listed below in
conjunction with appropriate job narrative specification.
 TEMA Standards

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 ASME Boiler and Pressure Vessel Code, Section VIII, Division 1

 API STD 660
 API STD 661
 API STD 662

2.4.4.1 Rating of Exchangers

All shell and tube heat exchangers will be thermally sized prior to request for quotation. Thermal
guarantees of performance in accordance with the Contractor’s specifications will be obtained from
the selected exchanger Supplier.

Information to be supplied with the thermal rating will include but not be limited to the following:
 Total effective heat transfer surface
 Tube outside diameter
 Tube wall thickness
 Tube pitch
 Tube length
 Number of tubes
 Number of passes
 Shell pass configuration
 Baffle details (orientation and percentage cut)
 Central baffle spacing
 Number and location of shell side nozzle connections
 Number and location of tube side nozzle connections.

Heat release curves are required for condensers and vaporizers if the curve is not linear. The plot
should also show the vapour or liquid rates, vapour molecular weight, and liquid gravity based on
Hysys output.

2.4.4.2 Design Pressure and Temperature

All parts of the tube bundle including floating head will be designed for either full tube side internal
pressure or full shell side external pressure, whichever condition is controlling. Differential pressure
will be used as design basis for certain high-pressure services, but these will be submitted to the
Company for approval on an individual basis.

Consideration will be given to setting the differential pressure so that water will not leak to
hydrocarbon or feed will not leak to product.

The exchanger tube side and shell side design pressure will be set at the highest of the following
conditions as applicable:
 Shutoff pressure of an upstream pump if the exchanger can be shut-in
 In accordance with section 2.1: Design Pressure

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 In accordance with the design pressure of other ASME Section VIII equipment that is
associated with the exchanger and that is protected by the same common pressure safety
system.

The design temperature will be determined in accordance with section 2.2: Design Temperature.

For water coolers, the design temperature on the cooling water side will be 120°C within the cooling
water block valves to allow for steam out.

2.4.4.3 General Criteria

Selection of TEMA front and rear head types will be in accordance with the following table:

Table 2.4-20 Exchanger Head Selection

TEMA Type Heads (Front / Rear)
Shell Side Fouling Designation
Clean Fouled
Tube Side Tube Side
Clean Fouled Clean Fouled
Non-removable bundle F / M,U A,C / L,N
Removable bundle B/U A / S or T B/U A / S or T

High pressure or other design requirements may justify deviation from the guidelines above.

U-tube exchangers are preferred when tightness is essential and the tube side service is considered
as non-fouling, e.g. hydrogen service. For fouling services and cooling water services in the tube
side, floating head construction will normally be specified.

Unless otherwise specified, exchangers will be designed to have cooling water on the tube side.

Kettle type reboilers and U-tube units will be provided with fixed shell covers. All other exchangers
will be provided with removable shell covers.

Packed floating heads will not be used.

Fixed tube sheet exchangers are not considered desirable. The Company’s approval is required for
this type of exchanger. The use of shell side expansion joints is not acceptable. The differential
expansion between shell and tubes of a fixed tube sheet exchanger, where approved, will be based
on the controlling metal temperatures, either clean or one side fouled. The maximum controlling
differential temperature between the tube and shell side during operation, start-up, shut down or
steam out will be stated on the data sheet and used to determine the requirement for an expansion
joint and tube sheet thickness on a fixed tube sheet heat exchanger.

The use of TEMA Type F (i.e. removable long baffles) is discouraged. As a general guideline, shell
side pressure drop will be limited to 7 kPa and temperature differential to 120°C if TEMA Type F
design is proposed.

Maximum shell and tube exchanger sizes will be as shown below. The thermal designer may
consider larger sizes to realize economic or design advantages.

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 Preferred maximum tube length for straight tubes will be 6100 mm.
 Preferred maximum bundle diameter for removable bundle exchangers will be 1525 mm.
 Preferred maximum removable bundle weight will be 18,140 kg.

Preferred tube size and layout selection will be as specified below.

Table 2.4-21 Exchanger Tube Size and Layout
Wall Thickness
Tube OD Tube Pitch (Preferred Minimum)
Layout
(in) (in)
Inches BWG
Nonferrous
1 1.25 Square (1) 0.083 14
(Admiralty, Cu Ni etc.)
Carbon Steel / Low Alloy (up to
1 1.25 Square (1) 0.109 12
and including 5 Cr ½ Mo)
High Alloy
1 1.25 Square (1) 0.109 12
(Above 5 Cr ½ Mo)

Notes:

1. Layout may be square or rotated square. Triangular pitch is not permitted.

Based on the fluids to be handled, following fouling factors shall be used for heat exchanger design.
Table 2.4-22 Fouling Factors
Commodity Fouling Factor (m².°C/W)
Air 0.00035
Reformed Gas 0.00018
Steam (non-oil bearing) 0.00009
Boiler Feed Water/Condensate (Treated) 0.00018
Non-condensing 0.00176
Condensing 0.00176
Tail Gas 0.00018
LPG 0.00018
Gasoline 0.00018
Fuel Gas 0.00018
Cooling Water (treated) 0.0006
Tri Ethylene Glycol (TEG) 0.00035

All factors in this table are recommendations only. The respective Process Licensors are
responsible for the Fouling Factors used in their areas of concern.

2.4.4.4 Allowable Velocities and Pressure Drops

As a guideline, the recommended allowable pressure drop per shell for shell and tube exchangers in
pumped liquid service will be as follows:

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Table 2.4-23 Allowable Pressure Drop-Pumped Exchangers

Viscosity (cP) Shell Side Press. Drop (kPa) Tube Side Press. Drop (kPa)
< 1.0 21 35
1.0 - 5.0 35 48
5.0 - 15.0 48 69
15.0 - 25.0 69 103
25.0 - 50.0 103 172

The allowable pressure drop for shell and tube condensers will be as follows:
Table 2.4-24 Allowable Pressure Drop-S&T Condensers
System Pressure (kPag) Allowable Pressure Drop Shell Side (kPa)
< 350 10 per shell
350 - 1380 20 per shell
> 1380 35 per shell

The allowable pressure drop for multiple exchanger services in series may be specified for the
entire train, instead of item by item.

The allowable pressure drop for air coolers in pumped liquid services will be as follows:
Table 2.4-25 Allowable Pressure Drop-Air Coolers
Viscosity (cP) Tube Side Press. Drop (kPa)
< 1.0 35
1.0 - 10.0 69
10.0 - 50.0 172

The allowable pressure drop for water coolers will be 69 kPa maximum on the cooling water side.
For cooling system design, allow an additional 69 kPa for throttling and balancing.

The allowable pressure drop for air cooled condensers will be as follows:
Table 2.4-26 Allowable Pressure Drop-Air Cooled Condensers
Operating
Service Allowable Pressure Drop (kPa)
Pressure (kPaa)
Liquid Cooling All 69 Not valid for viscous fluids
202- 441 6.9
Gas Cooling 441- 1785 20
1785 - 10200 35
For multi-pass air coolers, high pressure drops assure
Total Atmospheric & proper flow distribution. The higher pressure drop will
3 Min.
Condensation above also assure good flow distribution at lower than design
throughput
Partial Atmospheric &
14 -35
Condensation above
Selection of an allowable pressure drop should be from
Condensation Vacuum 0.4 - 0.66
the results of an economic study

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For condensers where total isothermal condensation takes place, the pressure drop is usually low or
negligible.

For surface condensers allow 0.4 - 0.66 kPa for operating pressures about 4 kPag.

For kettle type reboilers the shell side pressure drop is generally termed ‘negligible’.

For thermosyphon type reboilers the exchanger pressure drop must be low and is normally in the
region of 1.7 to 3.5 kPa.

2.4.4.5 Cooling Water Velocities

Water velocities for coolers and condensers will preferably be within the ranges specified below
except when pressure drop limitations govern.

Table 2.4-27 Allowable Velocities-Cooling Water

Tube Material Allowable Velocities (m/s) Maximum Velocity (m/s)
Carbon Steel 1.8 - 2.5 3.0
316 Stainless Steel 1.5 - 3.7 3.7
Titanium 3.0 4.6
Monel 1.5 - 3.7 3.7
Admiralty 1.8 - 2.5 3.0
Cupro-Nickel (70-30 & 90-l0) 2.1 - 2.5 3.0
Aluminium Brass 1.8 - 2.5 2.5

Carbon steel will normally be specified for cooling water service.

2.4.4.6 Reboiler Selection

Reboiler selection will be made from the following types:

 Kettle
 Vertical thermosyphon (not preferred)
 Horizontal thermosyphon.

For thermosyphon reboilers, 75% of the calculated available hydrostatic head will be used for the
process side available pressure drop.

Reboiler selection will be made to satisfy as many of the points in below table as possible.
Additional considerations will include:
 Equipment arrangement
 Maintenance facilities.

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Table 2.4-28 Reboiler Selection

Horizontal Horizontal Vertical
Selection Criteria Kettle
Once-Thru Thermosyphon Thermosyphon
Maximum % Unlimited
60% 25% 25%
vaporized (30 to 90% Normal)
Bottoms require Kettle and column Column only Column only Column only
pumping must be elevated elevated elevated elevated
Neither column nor Neither column nor Neither column nor
Bottoms do not Column usually
reboiler need to be reboiler need to be reboiler need to be
require pumping must be elevated
elevated elevated elevated
MTD Highest Highest Lowest Lowest
Within kettle and
Surge capacity Within column Within column Within column
column
Typical pressure
5 kPa 10 kPa 10 kPa 10 kPa
drop
Column internals Simplest Simplest Require baffling Require baffling
Space requirement Highest In-between In-between Lowest

Surge time is a factor to consider when there is a level controlled flow from a kettle type reboiler. A
minimum of 2 minutes surge in the level control range beyond the weir is usually necessary for
stable control. More surge time may be necessary depending on destination and required stability
of output flow.

If the required surge volume cannot be economically accommodated in the exchanger, provisions
should be made in an external surge drum. For kettle reboilers, the column bottom can often be
used for this purpose.

Horizontal thermosyphon reboiler will have more than one inlet and outlet nozzle if the bundle length
to diameter ratio is greater than five. Even with multiple nozzles, very long tube lengths with small
shell diameters are not recommended because of potential maldistribution and excessive piping
cost. Maximum tube length will be in accordance with the following:
Table 2.4-29 Reboiler Tube Length
Shell Diameter (mm) Maximum Tube Length (mm)
305 - 460 2440
480 - 740 3660
>760 4880

2.4.4.7 Shell Side versus Tube Side Service

Shell side / Tube side selection will be made to satisfy as many as possible of the following points:
Table 2.4-30 Service Selection
Service Shell Side Tube Side
Sea Water / Cooling Water X
Condensing Vapours X
Lower Allowable Press Drop X
Larger Flow with Similar Properties X
High Pressure Fluids X

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Corrosive Fluids/Alloy Construction X

High Fouling Factors X
Very Viscous Fluids X
Slurry Service X
High Temperature X

The above principles may conflict in some instances and alternative designs shall be investigated.
In these cases the most economical design shall be selected.

Traditionally high fouling fluids are placed on the tube side, particularly where mechanical cleaning
or highly effective hydroblasting is required. However, where the high fouling stream or stream with
suspended solids also has a high viscosity, it is preferable to place that stream on the shell side to
reduce the surface area or number of shells required. A higher wall shear stress and U value can be
achieved with the higher viscosity stream on the shell side, potentially reducing fouling tendency
with a proper design. Attention to baffle design and maintaining low leakage stream flow fractions is
critical in these situations.

2.4.4.8 Air Cooled Exchangers

Tube side fouling factors will be the same as specified for shell and tube exchangers.

Air side fouling factors will be assumed negligible.

The maximum ambient temperature of 45°C will be considered for air coolers. A temperature
approach of 10°C will be considered in the design. Allowable pressure drop shall be 50 kPa.

Air cooler tubes will be 1” O.D. with square or rotated square pitch layout. There are times when
different tube diameters might be preferred.

The preferred tube length for Air Cooled Exchangers is 7315 mm. Alternate lengths may be
proposed based upon pipe rack width and economic considerations. The maximum tube length shall
be 12200 mm.

Air-cooling shall be maximised for which the cut-off temperature of process streams shall be 45 ºC.
Further trim-cooling will be by water as necessary. The dry bulb temperature specified in the Basis
of Design shall be considered for cooler sizing. However, these criteria can be relaxed to avoid
small trim cooler or air cooler.

2.4.4.9 Piping at Exchangers

Heat exchangers, coolers, condensers, and reboilers that can be removed from service without a
unit shutdown will generally have block valves provided on, or immediately adjacent to, all inlets and
outlets. Bypasses will be provided if required to remove the exchanger from service. Heat
exchangers, coolers, condensers, and reboilers that require a unit shutdown for isolation need not
have block valves. Air coolers will also have isolation block valves only if a unit shutdown is not
required for isolation. For multiple bay services, the use of isolation valves for each tube bundle
section will be reviewed with the Company on a service-by-service basis.

Unless venting and draining can be done via other equipment, shell and channel side piping will be
provided with a vent and drain connection. Vent and drain valves will be ¾” minimum.

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2.4.4.10 Heat Exchanger Instrumentation and Control

Provision for temperature / pressure measurement at inlet / outlet of both fluids will be provided.
Connections for pressure measurement and thermowell are only necessary; mounted instruments
need not be shown. Temperature control valve with by-pass will be preferably provided with the
stream for which temperature control is required. In some cases, it is incorporated in less fouling
service.

2.4.5 Fired Heaters

Fired Heater design will confirm to API STD 560 and relevant standards. Design of the fired heaters
will be done by Supplier as per the process data provided. The Process Engineer needs to define
some important parameters that will be used by Supplier; namely, maximum allowable film
temperature and pressure drop.

2.4.6 Pumps

Process centrifugal pumps will be specified and designed in accordance with API STD 610,
“Centrifugal Pumps for General Refinery Services”, and appropriate job narrative specifications.

2.4.6.1 Rated Capacity

The rated pump capacity will be determined in accordance with section 2.3: Design Margin

For pumps in intermittent service (i.e. product shipment), only the rated capacity need be specified.

All pumps in continuous service will be either 100% spared or common-spared. Common-spares
will be specified only if design conditions, fluid characteristics, capacity, and power requirements are
similar. In large capacity services where parallel operating pumps are required, a common spare
will also be specified.

Once pump curves are available, consideration will be given on to optimisation of design flowrates.

2.4.6.2 NPSH Calculation

The calculation of NPSH will be based on the following:

For subcooled liquids, the source pressure will be the minimum operating pressure and the vapour
pressure will be at the maximum operating temperature. Fluids in gas-padded drums will be
assumed to be at their bubble point.

The suction line losses will be based on rated flow capacity of the pump. A pressure drop
allowance of 7 kPa will be taken for temporary or permanent suction strainers.

Static head will be measured from the bottom of the horizontal drums and from the bottom tangent
line of columns or vessels with bottom drawoffs, and from the elevation of the outlet nozzle for side
drawoffs, to the centreline of horizontal pumps, or the outlet nozzle of vertical pumps.

For NPSHA calculations, the pump centreline for horizontal pumps will be assumed if no pump
vendor details are available. The reference point to be used in determining the NPSH required for
double case vertical pumps will be the suction nozzle horizontal centreline.

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Table 2.4-31 Pump Centre Line Elevation

Pump Capacity (m³/hr) Centre Line Elevation (m)

Up to 45 0.76
45 - 225 0.91
225 - 2270 1.07
2270 - 4540 1.37

No contingency will be added to the calculated NPSH available.

2.4.6.3 Design Pressure

The design pressure of centrifugal pumps will be determined in accordance with section 2.1: Design
Pressure

Positive displacement pumps and associated piping will be designed to withstand either the stalling
pressure or will be provided with a discharge relief valve which will not be set higher than the casing
design pressure.

The Contractor will confirm adequate casing design pressure based upon the actual shut-in heads
of purchased equipment.

2.4.6.4 Minimum and Maximum Flow

Normally all pumps will be suitable for continuous operation for a flow of 30% of rated capacity. If
process conditions necessitate flow at below the Supplier’s stated minimum, then minimum flow
provisions for centrifugal pumps will consist of a line from the pump discharge to the suction source.
The minimum flow required for a specific pump will be based on the manufacturer’s
recommendations. Minimum flow bypasses will be used in the following services:
 Multistage Pumps
 Boiler Feed water Pumps
 Where there is a possibility of a no-flow condition occurring in a pump discharge system and
where pump characteristics would rapidly cause mechanical damage or hazard as the result of
shut-in
 High speed in-line pumps (Sundyne).

2.4.6.5 Injection Pumps

Injection pumps in acid, chemical and caustic service will be capable of flow control by adjusting the
stroke while the pump is in operation.

2.4.6.6 Materials of Construction

The material class designation of pumps will normally be in accordance with API 610.

Cast iron will not be used for casings of any pumps in hydrocarbon service, hazardous services, or
rated discharge pressures above 690 kPag.

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2.4.6.7 Drivers

Drivers will be either electric motors, gas turbines or back pressure steam turbines. Condensing
turbines will be preferred except large steam turbine application.

Depending on Technology selection, process gas expanders might be used. Gas or Diesel engines
for reciprocating machines, Fire Water Pumps, etc. may be preferred over electric motors.

Consideration will be given, on an individual basis, to pump runout conditions in sizing of the driver.

Electric Motors

Electric motors for centrifugal pumps should have ratings as follows:

Table 2.4-32 Motor Design Rating
Motor Rating (kW) % of Pump (kW)
Up to 22 kW 125
>22 kW to 55 kW 115
>55 kW and over 110

Steam Turbines

Unless otherwise stated, all steam turbines should comply with the requirements of API STD 611 as
applicable.

Steam turbines in sizes above approximately 5000 kW or unspared are to be considered “Special
Purpose” API STD 612 type and should be of multi-valve design having all valves under governor
control.

“Special Purpose” steam turbines should be fitted with a variable speed governor. The governor will
be readily accessible and operable.

All turbines will be equipped with an overspeed safety trip mechanism mounted directly on the
turbine shaft.

Where turbine casings on exhaust piping are not designed to withstand the design pressure of the
steam main, they should be protected by relief valves capable of passing the full flow of steam
which can pass through the turbine.

2.4.6.8 Seals

Pump mechanical seals will be specified as per API Seal Schematics. e.g. For specific services
such as high temperature, dirty service or environmentally hazardous service, single mechanical
seals shall not be used.

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2.4.6.9 Selection

Wherever conditions will allow, horizontal centrifugal pumps will be the preferred installation.
Vertical pumps will be limited to services where NPSH or head / capacity make a horizontal pump
impractical, or for services less than 150 °C and 37 kW driver size where a vertical pump may result
in considerable piping savings.

2.4.6.10 Piping at Pumps

Each centrifugal pump will have a suction block valve, and at least one discharge check valve and
one discharge block valve, all of which will be located as close to the pump nozzle as possible.
Consideration will be given to providing two discharge check valves and two discharge block valves
for high pressure pumps (greater than 6900 kPag discharge pressure).

All pumps will have strainers installed on the pump side of the suction valve. Permanent strainers
with a flanged side entry for screen removal (i.e. constructed such that the screen can be removed
for cleaning without disturbing the suction piping or removing a spool) will be installed in the suction
lines of dirty service pumps, process solvent circulating pumps, pumps with a suction temperature
greater than 150°C, cold insulated pumps, and pumps with RTJ flanges. When steam turbines are
used, inlet piping to the turbine will contain permanent strainers.

The design pressure of the piping and equipment not protected by relief valves on the discharge
side of a centrifugal pump will be specified as per criteria defined in section 2.1.

The pump suction block valve and any pipe or fittings between the block valve and the pump will
have a continuous service pressure rating equal to at least 75% of the rated discharge pressure. If
the pump suction casing or suction nozzle does not meet this criterion, the suction system will be
protected by a pressure relief valve rated at 20% of normal pump flow. The requirements of this
paragraph apply only to spare pump services.

For positive displacement pumps, the discharge piping will be designed for either the downstream
relief valve setting or the casing design pressure.

Additional process requirements for vent and drain connections of pumps are as follows:
 Casing vents and drains for pumps in non-volatile services will be piped to the closed drain
system.
 Casing vents for pumps in services handling materials near the auto ignition point will be
discharged to a closed system or flare.
 Casing vents for pumps in hydrocarbon services handling C4 fractions and lighter will
discharge to a closed system or flare.
 Vents and drains in services releasing lethal vapours will discharge to a closed system or
flare.
 In abrasive services, valve vent and drain connections will be located in adjacent piping and
not in pump casings and liquid end cylinders.
 Vent and drain connections will be ¾” nominal pipe size minimum.
 In vacuum service, pump vent connections will be permanently piped to the vapor space of the
suction vessel.

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 Single stage overhung centrifugal pumps are generally self venting.

Sight flow indicators will be provided on cooling water lines to pump jackets. Open drains are
preferred, however, conservation of cooling water should be considered.

¾” minimum warm-up bypasses will be provided on all pumps that operate above 150°C or are in
high viscosity service.

¾” minimum warm-up bypasses will be considered for increasing the temperature of pump casings
and associated piping prior to starting a spare pump during cold ambient conditions.

2.4.7 Compressors

Process centrifugal compressors will be specified and designed in accordance with API 6l7, “Axial
and Centrifugal Compressors and Expander-compressors for Petroleum, Chemical, and Gas
Industry Services”. Process reciprocating compressors will be specified and designed in accordance
with API 618, “Reciprocating Compressors for Petroleum, Chemical, and Gas Industry Services”.
Both API 6l7 and API 6l8 will be used in conjunction with the appropriate job narrative specifications.
In addition, this section covers the general process criteria for the different types of compressors like
API 619 for Rotary Type Positive Displacement Compressors for Petroleum, Petrochemical and
Natural Gas Industries and API 672 for Packaged, Integrally Geared Centrifugal Air Compressors
for Petroleum, Chemical & Gas Industry Service.

2.4.7.1 Compressors Selection and Rating

Preliminary compressor calculations will be performed by the Contractor for each compressor.
Primary objectives of these calculations are:
 Estimation of power requirement
 Estimation of temperature rise
 Approximate number of stages
 Estimation of utility requirements
 Establishment of control requirements.

Centrifugal compressors will be specified for high reliability and, in general, will not be spared.

Large reciprocating compressors may be either 100% spared (two 100% machines), or 50% spared
(three 50% machines). The choice will depend on the particular service and the economics
involved.

2.4.7.2 Mode of Control

Centrifugal Compressors

Turbine driven compressors may be flowrate controlled by:

 Adjusting turbine speed within limits allowed by the Supplier
 Suction throttling
 Spillback of flow as required.

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Motor driven compressors may be rate controlled by:

 Suction throttling
 Spillback flow as required
 Combination of spillback and suction throttling.
 Variable frequency drive within limits allowed by Supplier

If required, provisions will be made for compressor unloading at start-up.

Provision will be made for surge protection.

Spillback coolers will be capable of maintaining rated suction temperature under sustained
operation near the surge point.

Reciprocating Compressors

Turbine driven reciprocating compressors are not preferred.

For constant speed machines, spillback control may be used for less than rated compressor output.
The spillback cooler system will be rated for 100% of rated compressor flow.

Inlet valve unloaders may be used for control to avoid wastage of power. Modern flow controllers
use stepless unloading for seamless flow modulation / control compressor throughput. Spillback
control, stepless unloading and inlet valve unloaders may be used in combinations for various
capacity changes.

Small compressors in service such as air supply, where sufficient receiver capacity is provided, may
be controlled by automatic start-stop or constant speed unloading.

Provisions will be made for compressor unloading at start-up.

Suction throttling is not to be used.

Shutdown

Remote manual trip switches for emergency shutdown of each compressor will be provided both at
the compressor and in the central control house. These devices, as well as any automatic
emergency shutdown instrumentation, will be specified in the individual design specifications.

2.4.7.3 Performance Curves (Centrifugal Compressors)

The following process information will be provided by compressor Suppliers during detailed
engineering:
 Calculated power
 Accurate statement of discharge temperature
 Speed of compressor at design point
 Performance curves showing discharge pressure and temperature, brake kW, polytropic head
and efficiency as a function of inlet volume. This will include curves at 80, 90, 95, 100 and 105

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percent of rated speed. Estimated surge points will be shown at each speed. The variable
speed data does not pertain to units on electric motor drive.
 Quadrant curves are required on all variable Mol. Wt. processes
 For variable speed drivers, characteristics will be given at 80, 90, 95, 100 and 105 percent of
rated speed
 Identification of harmonic modes.

2.4.7.4 Drivers

Refer to Section 2.4.6.7 for discussion of drivers.

2.4.7.5 Compressor Suction K.O. Drum

All compressors will be provided with K.O. drums in the suction lines as close as possible to the
compressor. Discharge K.O. drums will be provided only when required by the process. K.O. drums
will be sized to retain the calculated condensation and entrainment that will occur during four hours
of operation. Inlet lines are to be heat traced with no low pockets. Demister pads are to be
reinforced for pulsation protection.

With vertical K.O. drums, compressors will be controlled to shutoff if the K.O. drum liquid level
reaches 90% of the height of the bottom of the inlet nozzle. A pre-alarm will be located as close as
practical to the normal liquid level.

With horizontal K.O. drums, compressors will be controlled to shut off if the K.O. drum liquid level
reaches 50% of the vessel diameter. A pre-alarm will be located as close as practical to the normal
liquid level.

2.4.7.6 Compressor Cooling Water

Compressor lube oil water coolers will have a higher pressure on the lube oil side than on cooling
water side.

Water side fouling factors will be 0.00052 m².°C/W and oil side fouling factors will be 0.00018
m².°C/W.

Cylinder cooling water inlet temperature will be at least 10 °C above the inlet gas dew point.

2.4.7.7 Piping at Compressors

Compressor suction lines between suction knockout drum and compressor will be heat traced to
avoid any condensation likely at cool down. A suction heater or steam jacketing is preferred. Traps
in the suction lines should be avoided.

All compressor suction piping including pulsation bottles will have the same pressure rating as the
discharge piping back to and including the first suction block valve.

All compressors will have valve drains piped to a safe disposal area.

Compressors will have inlet suction strainers located as close as practical (not to interfere with flow)
with breakout flanges and differential pressure alarms and indicators.

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Compressor isolation valves and ESD philosophy will be established and confirmed with the
Company and equipment Suppliers during the engineering design phase of the Project.

If the material being handled is toxic, flammable, or otherwise hazardous, proper purge facilities will
be provided.

2.5 Line Sizing and Hydraulic Calculation

The general guidelines for hydraulic calculations are presented in the following sections and an
effort has been made to cover normal operations for different services. Should the service be
different from those specified below, Process Engineers are advised to consult the Lead Process
Engineer.

Generally, for single phase calculation, KORF software may be considered as back up for the
Process department’s validated spreadsheet template (both developed based on Darcy correlation).
For different services, the allowable velocities and pressure drops for line sizing are indicated in the
following tables Special caution should be exercised for two-phase flow and each pipe segment flow
regime must be checked for different applicable turndown conditions. In each case, besides
following the pressure drop / velocity guidelines, process / operating requirements must be met e.g.
low pressure applications.

2.5.1 Pump Suction Lines

Pump suction line sizing shall be based maximum allowable velocities and pressure drop as per
criteria indicated below:
Table 2.5-1 Pump Suction Lines
Service Condition Pipe Diameter < 8” (NPS) Pipe Diameter > 8” (NPS)
Max Press. Drop, Max Velocity Max Press. Drop
Max Velocity (m/s)
(kPa/100 m) (m/s) (kPa/100 m)
Non-boiling Liquid 1.5 34 1.8 34
Boiling Liquid (Pump
0.9 11 1.8 11
NPSH A > 10 m)
Boiling Liquid (Pump
NPSH A < 10 m) 0.9 11 0.9 11

For pump suction lines, consider suction strainer pressure (150% of clean service pressure drop for
the suction line size). For reciprocating pump, consider acceleration head losses in conjunction with
distance from buffer vessel (dampener), wherever provided.

2.5.2 Compressor Suction Lines

Compressor suction lines will follow the sizing criteria as indicated below:
Table 2.5-2 Compressor Suction Lines
Friction Drop Velocity (m/s)
(kPa/100 m) Normal Maximum
Reciprocating 0.3% OP 6.0 - 12.0 7% Sonic

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Centrifugal 0.6% OP 12.0 - 24.0 13% Sonic

In the above table, OP needs to be considered in kPaa. For large diameter inlet suction line (> 30”
NPS), maldistribution of vapour is possible and this may have a negative impact on aerodynamic
performance of centrifugal compressor. For such cases, the compressor inlet line sizing to be
checked with Supplier.

2.5.3 Pump/Compressor Discharge Lines and Other Applications

In the following table, velocity and pressure drop criteria for pump / compressor discharge services
and general liquid / vapour lines are indicated. Velocity and pressure drop criteria for some specific
applications (e.g. amine, sour water and utilities etc.) are also indicated.
Table 2.5-3 Velocity and Pressure Criteria
Allowable Pressure Total line Pressure
Allowable Velocity
Service Drop Drop
(m/s)
(kPa/100 m) (kPa)
Liquid Lines
Pump Discharge (hydrocarbons and non-specialty services)
< NPS 4” 1.5 - 2.1 23 - 68
NPS 6” 3.0 Max 23 - 68
NPS > 8” 3.7 Max 23 - 68
Specialty Services
Sulphuric Acid (except as noted
1.2
below)
93 wt% - 99.6 wt% (CI pipe), 8”
1.8
or larger (> 82°C)
Weak acid (< 30 wt%) in plastic
1.8
or plastic lined pipe
Sodium Hydroxide (< 30 wt%) 1.8
Sodium Hydroxide (30 wt% - 50
1.5
wt%)
Sodium Hydroxide (50 wt% - 73
1.2
wt%)
Sulphur, pumped 3.0 11 - 67
Lean Amine Follow the guidelines for hydrocarbons
Cold Rich Amine(CS) 1.0
Cold Rich Amine (Alloy Steel) 5.5
Hot Rich Amine (CS) Due to high corrosive nature of hot rich amine (temp. > 66°C), review with
project metallurgist the sour gas content of the rich amine and also review
Hot Rich Amine (Alloy Steel) selected line velocity.
Sour Water < 0.5 wt% (H2S +
1.8
NH3)
Sour Water > 0.5 wt% (H2S +
1.0
NH3)
TEG (Tri Ethylene Glycol) Follow the guidelines for hydrocarbons
Vapor Lines
Allowable Velocity Allowable Pressure Maximum Velocity,
(m/s) Drop (m/s)

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Allowable Pressure Total line Pressure

Allowable Velocity
Service Drop Drop
(m/s)
(kPa/100 m) (kPa)
(kPa/100 m)
Hydrocarbon gases/vapours
Vacuum (0 - 100 kPa) 61 - 76 1.1 - 5.5 50% of sonic
122
Low Pressure (0 - 345kPag) 5.7 - 11.0
�ρg

Medium Pressure (345 - 1035 122

11.0 - 34.0
kPag) �ρg

High Pressure (1035 - 3450 122

34.0 - 68.0
kPag) �ρg
122
> 3450 kPag 1.6% of OP
�ρg
Other gases / vapours
Vacuum
61 - 76 1.1 - 5.5 50% of sonic
(0 - 100 kPa)
0 - 690 kPag 46 - 61 5.7 - 11.0 50% of sonic
690 - 6900 kPag 30 - 46 11.0 - 45.0 50% of sonic
> 6900 kPag 30 0.7% of OP 50% of sonic
SO 2 and SO 3 process gas 15 - 27
Utilities
Instrument Air 9.1 - 30.0 11.0 - 45.0
Utility Air 9.1 - 30.0 11.0 - 45.0
Natural Gas 6.1 - 18.0 16.0 - 45.0
Fuel Gas 6.1 - 18.0 16.0 - 45.0
Nitrogen 0.63 - 3.2

Notes:

1. In above table, ρg is gas density in kg/m3.

2. OP is operating pressure in kPaa.

2.5.4 Reboiler Lines

Reboiler lines will follow the sizing criteria as indicated below:

Table 2.5-4 Reboiler Lines
Service Allowable Pressure Drop Allowable Velocity (m/s)
(kPa/100 m)
Reboiler Trap out 3.4 - 6.8 0.9 - 1.5
Reboiler Return 6.8 4.6 -9.1

For reboiler trap-out lines, preferably use 0.9 m/s velocity and 3.4 kPa/100m pressure drop criteria.

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For reboiler return lines, two-phase flow will be encountered. To calculate the flow regime, use
Baker chart or equivalent. Depending on vapour %, either annular or dispersed flow is preferred i.e.
slug flow to be avoided. The following guidelines can be considered for minimum velocity (based on
mixed phase homogenous density):
Table 2.5-5 Minimum Velocity (Reboiler Lines)
Operating pressure (kPag) Minimum Velocity (m/s)
0 - 100 12.2
>100 - 275 9.1
>275 - 2070 4.6 - 6.1
> 2070 4.6

2.5.5 Cooling Water Lines

Cooling water main headers and branch lines will follow the sizing criteria as indicated below:
Table 2.5-6 Cooling Water Main Header
Pipe Diameter (NPS) Allowable Velocity (m/s) Allowable Pressure Drop
(kPa/100 m)
< 4” 1.5 - 2.1 23 - 34
6” 3.0 max 23 - 34
> 8” 3.7 max 23 - 34

Table 2.5-7 Cooling Water Branch Lines

Pipe Diameter (NPS) Allowable Velocity (m/s) Allowable Pressure Drop
(kPa/100 m)
< 4” 1.5 - 2.1 23 - 68
6” 3.0 23 - 68
> 8” 3.7 23 - 68

2.5.6 Steam Condensate Lines

Assuming all condensate remains as liquid, the allowable velocity is 0.3 - 0.6 m/s. Where
condensate flashing will cause two-phase flow, due consideration for presence of steam will be
applied. The maximum velocity of flashed condensate should be 20 - 25 m/s using mixed phase
density at actual conditions. The maximum velocity upstream of the steam trap should be below 0.3
m/s to allow for vapour disengagement.

2.5.7 Steam Lines

The following pressure and velocity guidelines will be considered for steam lines:
Table 2.5-8 Steam Lines
Steam Pressure Level, Pressure Drop Velocity (m/s)
kPag kPa/100m Normal Maximum

< 345 5.7 - 11.0 50√D 100√D

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Steam Pressure Level, Pressure Drop Velocity (m/s)

kPag kPa/100m Normal Maximum

345 - 1035 11 - 34 40√D 100√D

1035 - 3450 34 - 68 30√D 100√D

> 3450 1.6% of pressure level 30√D 100√D

Superheated Steam
1.6% of pressure level 50√D 100√D
> 1725

In above table, D is the nominal pipe diameter (NPS) in inches.

2.5.8 Two-Phase Flows

For all two-phase flow applications, the pressure drop, flow regime, and velocity criteria are to be
checked (This can be done by KORF software). If slug flow cannot be avoided for a particular case,
specify in the P&I Diagram and Line List that slug flow is possible or that slug flow can exist. For
critical applications, KORF output must be checked with manual calculation using Dukler method
(constant slip model) for pressure drop calculations. It is preferred that the line be divided into a
minimum of 10 segments, each with 10% of the total pressure drop. Consider initial and terminal
conditions of each segment and calculate pressure drop based on the average mixed density. A
detailed calculation must be carried out for critical applications. Check flow regime for each case
(e.g. Griffith / Wallis chart or Baker chart).

2.5.9 Tower Draw-Off Line Sizing

Liquid from a tower tray is aerated to some extent depending on the foaminess of the gas-liquid
mixture.

The recommended method for sizing drawoffs employs the following criteria:

1. The depth of the drawoff pan to be 1-1½ times the nozzle diameter. The minimum allowable
depth is 200 mm.

2. Allowable velocity may vary from 0.7 m/s to 1.2 m/s depending on the nozzle size (see following
tables -‘Capacities of Side-Pan Drawoff Nozzles’ and ‘Capacities of Bottom-Pan Drawoff
Nozzles’).

3. The nozzle is to be swaged down to a line size which will not exceed 10 kPa/100m pressure
drop. The swage is to occur at a point in elevation 1.2 m below the nozzle drawoff. Only lines
0.2 m and larger are to be swaged down, small lines will be maintained at nozzle size to the
pump or first exchanger

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Table 2.5-9 Capacities of Side-Pan Drawoff Nozzles

Nominal Line Size (mm) Allowable Velocity (m/s) Flowrate, m³/hr

80 0.7 12.5
100 0.7 21.6
150 0.7 50.4
200 0.8 88.1

Table 2.5-10 Capacities of Bottom-Pan Drawoff Nozzles

Nominal Line Size (mm) Allowable Velocity (m/s) Flowrate, m³/hr

80 0.7 12.5
100 0.7 21.6
150 0.8 52.5
200 0.85 97.4

2.5.10 Amine Lines

Velocities in equipment and piping shall be limited as follows:

 Lean Amine: 2.0 m/s for carbon steel
 Rich Amine: 0.9 m/s for carbon steel
 4.0 m/s for 300 series Stainless Steel and higher alloys.

2.5.11 Control Valve

Sufficient pressure drop must be allowed for control valves to obtain good regulation, maintain flow
characteristics, and obtain desired maximum capacity. It is important that a valve pressure drop
allowance be made in specifying pumps, blowers, compressors and reboilers. The following
minimum control valve pressure drops are for normal applications.

At normal operating rate, 50% of the variable system pressure drop exclusive of the control valve, or
one-third of the total variable system drop including the control valve, should be allowed. For large
variable system pressure drops, 1035 kPa or more, such as may be encountered with heaters or
furnaces, the minimum allowable pressure drop shall be 15% of the variable system pressure drop,
exclusive of the control valve. On light hydrocarbon products to storage that are stored under
product vapour pressure, the valve pressure drop will be based on downstream vapour pressure at
maximum ambient temperature of 38°C.

In general, the minimum pressure drop at design flow will include the following allowances to
account for circuit static pressure differentials:
 10% of static differential up to a static differential pressure of 1380 kPa
 140 kPa for static differentials from 1380 kPa to 2760 kPa
 5% of static differential for static differential pressures above 2760 kPa.

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For reflux, charge and recycle pumps, 100 kPa minimum or one-third of the total variable system
pressure drop, whichever is greater, should be allowed. The pump curve (when available) should
be reviewed to make sure that enough pressure drop has been built into the pump head for the
control valve to operate at the maximum pump design rate. The pressure drop that has been
allowed should be equal to a minimum of 15% of the variable system drop at the maximum pump
design rate or 70 kPa, whichever is greater.

For control valves in the steam line to reboilers, the allowable pressure drop will be 5 to 10% of the
initial absolute steam pressure.

For automatic pump start-up, where the control valve is in the steam line to the pump driver, the
control valve will be line size. The resulting pressure drop is not a factor for sizing and should be 35
kPa or less.

Control valves will be sized for a maximum capacity of 1.3 times the normal flow or 1.1 times the
maximum design flow, whichever is greater.

2.5.12 Piping at Control Valves

The following criteria will generally be used in the piping and valving of control valves.

Control valves in flashing service will be placed as close as practical to the destination of the
stream. Consideration will be given to avoiding traps in the piping downstream of flashing control
valves. Where possible, angle valves discharging directly into a vessel vapour space should be
used. If it is not possible to use an angle valve discharging directly into a vessel, the downstream
piping will be sized such that cavitation does not take place.

The use of blocks and bypass valves around a control valve must be justified in terms of safe
operability. If control valve operation is sufficiently critical, consideration should be given to a
parallel, standby control valve. Control valves which do not have bypasses will normally be
equipped with hand-jacks.

Bypass valves will have at least the same Cv as the control valve. Maximum Cv for the bypass
valve will be twice the Cv of the control valve.

Expansion of piping size immediately downstream of control valves in flashing service or high
letdown pressure drops will be considered in order to prevent sonic velocity limitations through the
control valve manifold. Consideration will be given to increased sizing of the block valve
downstream of the control valve and expansion of piping size immediately downstream of the
bypass valve.

Spools will be provided between control valves and block valves. Valved ¾” drains will be provided
on the isolatable spool upstream of control valves with “FO” Fail safe position, for control valve with
FC fail safe position ¾” drains will be provided on the isolatable spool upstream and downstream of
control valves.

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2.6 Flare & Relief System Design

Relief systems will be designed in accordance with ASME Pressure Vessel Code, Section VIII,
Division I, ANSI B3l.3, API STD 520 (Part 1) and API STD 52l. Advantages of diaphragm valves in
low pressure services will be considered. Consideration will also be given to the economics and job
impact of raising the design pressure of limiting low pressure equipment. Heat and material balance
calculations will be the basis for the determination of the required relief loads at individual relief
valves. A relief valve design data sheet will be prepared for each major PSV. The use of rupture
disks will be considered in conjunction with relief valves for corrosive, fouling, or coking services.

2.6.1 Simultaneous Cases for Maximum Relief Discharge

The maximum discharge rate to the relief system will be considered from the following cases
evaluated on a single-order basis.

Operator Error:
 Blocked discharge
 Inadvertent opening of valves.
 Utilities failure:
o Cooling water failure
o Electric power failure
o Steam / boiler feed water failure
o Loss of fuel
o Instrument air failure (general)
 Local equipment/operation failure:
o Reflux failure
o Reboiler - abnormal heat input
o Heat exchanger tube failure
o Failure of controller or control valve.
 Fire:

The safety facilities will be designed to handle the largest load resulting from any possible single
contingency. No emergency that arises because two or more unrelated contingencies occur
simultaneously need be considered in the sizing. Contingencies, including fire, are considered as
unrelated if there is no process, mechanical, or electrical relationship between them. However,
when analyzing any single contingency (such as cooling water failure), all directly related effects on
other equipment resulting from that contingency should be considered.

The relief valves on the discharge of positive displacement pumps may discharge to the pump
suction or to the suction source.

Thermal relief valves will discharge to a safe location.

Cold liquid relief valves may discharge to a large accumulator.

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2.6.2 Relief Valve Set Pressure

Relief valves will be set to open at or below the design pressure of the system or equipment to be
protected.

2.6.3 Relief Valve Sizing

The pressure relief valves will be estimated by the Process Engineer in accordance with API STD
520, however sizing must be confirmed by the Contractor based upon actual Suppliers selected.

Unless otherwise noted, the maximum allowable total back pressure is the maximum permissible
back pressure while that valve is blowing. Built up back pressures will be assumed for sizing of
PSVs and these back pressures must be confirmed by the Contractor when the definitive piping
layout is established.

2.6.4 Relief Valve Locations

Equipment that is connected together by a system of piping not containing valves which could
isolate any item may be considered as one unit in applying a relief valve or valves. If the equipment
can be isolated from one another by valves in the connecting piping, then each system will be
considered as a unit with its own relief valve or valves. Car-sealing or padlocking of block valves
may be used, with the Company’s and regulatory approval, to circumvent the need for additional
relief valves.

Thermal relief, or if required, vapour relief valves, will be supplied between block valves on the cold
side of heat exchangers which can be blocked in.

Relief valves will be provided for the discharge of all reciprocating compressors on the compressor
side of block valve.

Relief valves will be provided for the discharge of positive displacement pumps on pump side of
block valve, unless internal relief valve is provided.

Where required by safety considerations, relief valves will be provided between the block valves on
the low pressure side of heat exchangers, or other equipment subject to internal leaks or tube
failures.

Piping systems for pumps, compressors, and blowers will be provided with relief valves or an
automatic shutdown device when the casing design pressure may be exceeded. The automatic
shutdown device may be used to minimize the total volume of relieved fluids, but should not obviate
the need for a PSV or reduce the maximum relieving rate. Over pressure by fire will not be
considered.

If a non-condensing turbine is installed to start automatically, full relief capacity is required and will
be sized in accordance with NEMA Recommended Standards Publication No. SM23.

For vessels in vapour service, relief valves installed on the vessels are preferred.

The pressure drop in the inlet piping to the relief valve will not exceed 3% of the set pressure of the
relief valve at design relief capacity.

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For vessels in vapour and/or liquid service, relief valves will be located to avoid two-phase flow.
Where two - phase flow exists; relief valves will be located at the highest elevation.

For relief protection from a single source requiring multiple valves, one of the valves will be set at or
below the design pressure and the remainder may be staggered up to a maximum of 105% of
design pressure.

2.6.5 Piping at Relief Valves

Relief valve inlet and outlet line sizing will be shown on the Piping and Instrumentation Diagrams
(P&IDs). Discharge line sizing is to be confirmed during detailed design based upon allowable built
up back pressures and final establishment of flare system piping layouts. The inlet lines to relief
valves must be at least the size of the safety valve inlet. When multiple safety valves are
manifolded, the cross sectional areas of the manifold piping must be equal or greater than the sum
of all the inlet area of valves opens to the manifold. Relief valve inlet line size must be checked
independently of sizing the relief valve. The maximum allowable frictional pressure drop between
the vessel being protected and the relief valve will be 3% of the relief valve set pressure.

If pressure relief valves are fitted with block valves at both upstream and downstream sides or at the
upstream side only, these block valves will be car sealed in an open position. Block valves will be
full ported and the same size as the adjacent relief valve inlet or outlet. If spare pressure relief
valves are provided, block valves will be supplied at both the relief valves. These block valves will
be car-sealed in an open position, except when removed for testing or repairs. If spare pressure
relief valves are not supplied and the primary relief valve can be blocked in, a full size bypass valve
with an inlet pressure indicator must be supplied.

Relief valves will not discharge flammable fluids to the atmosphere.

Relief valves should be located as close as possible to the equipment being protected to minimize
the inlet piping pressure loss. However, the requirement that the relief valve outlet piping be free-
draining to the flare header will often necessitate that the relief valve be mounted some distance
from the equipment being protected. In such cases, the inlet line to the relief valve may have to be
one or two sizes larger than the valve inlet nozzle in order to have acceptable inlet pressure losses.

2.6.6 Slope of the Relief Header

Relief system piping will be self - draining toward the discharge end. Where pocketing of discharge
lines cannot be avoided, piping will be traced and provided with suitable drip legs, condensate pots
and drains.

A slope of 0.2% of run is desirable for all laterals and headers, taking into account piping deflections
between supports. Laterals will enter the header from above with 45° connections.

Headers receiving two phase or liquid relief, or having the possibility of condensation, will be
equipped with a knockout drum with a liquid hold-up time of 10 to 30 minutes. This should be
equipped with a gauge glass, alarm, and drain. Traps or other devices with operating mechanisms
will not be used.

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2.6.7 Thermal Relief

These criteria should be considered as general rather than specific in regard to both location and
application. Certain situations will arise that may require deviation from these norms.

Protection against over pressure will be provided when low boiling liquids can be blocked in and the
pressure can be increased due to vaporization.

Heat sources may be any of the following:

 Solar radiation
 Tracing
 Process heat.

Thermal relief valve set pressure will be the design pressure of the weakest component in the
system being protected.

Thermal relief valves will discharge to a safe location.

Thermal relief valves will be ¾” x 1” in size, except for the following applications (for which valve
sizes will be calculated in accordance with API STD 521.
 Long pipelines of large diameter
 Large vessels or exchangers operating liquid full
 Where vaporization of the liquid occurs at the relieving pressure and temperature (e.g. blocked
in cold side of heat exchanger which may experience vaporization at the relieving pressure).

If the liquid being relieved is expected to flash or form solids while passing through the relief device,
the procedure in API STD 521 will be used.

Heat exchangers will be protected by thermal relief valves set to initiate relief at 100% of design
pressure when the cause of the pressure is one of the following:
 Thermal expansion of liquid when the closure of a single valve isolates contents
 Light hydrocarbon service blocked inlet and outlet when the vapor pressure at 35°C exceeds
the design pressure.

2.7 Valve and Isolation Selection

2.7.1 Valve Selection Criteria

Piping spec should be used as primary reference for valve selection based on the line spec the
valve will be located.

2.7.2 Valve Operator Selection

Powered versus Manual Operation

 Valves that modulate to control process conditions will have pneumatic or power operators /
actuators, if manual control is not practical.

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 Operating block valves (other than check valves) that are required to change position in order
to perform a safety-related function will be either power or air operated if: (1) sufficient time is
unavailable for manual operation, (2) lack of available personnel to perform manual operation,
or (3) lack of access due to environmental conditions. Fast acting valves, required to fail in the
“open” or “close” position, will be air actuated. Valves that have to continue operating following
loss of air, shall be motor operated.

2.7.3 Control Valve Stations

 Block valves upstream and downstream a control valve will be equal to the line size. This
allows flexibility for future expansion.

2.7.4 Vents and Drains

Drains at low points and vents at high points are required for proper system operation and
maintenance. All process drains and vents should be fitted with valve/s and blind.
 Vents, drains and purge connections for vessels shall be sized as follows.
Table 2.7-1 Vents and Drains Sizes

Vessel size (m³) Vent Size Drain Size Purge Size

1.5 and under 2’’ 1’’ 1’’

1.5 to 6 2’’ 1-1/2’’ 1-1/2’’

6 to 17 2’’ 2’’ 2’’

17 to 71 2’’ 3’’ 2’’

71 to 141 2’’ 3’’ 2’’

141 to 283 3’’ 4’’ 3’’

283 to 708 4’’ 4’’ 3’’

Above 708 6’’ 6’’ 2-3’’ (opp. Side)

2.8 Insulation & Heat Tracing

Due to corrosion under insulation being a general problem on insulated equipment, the philosophy
shall be to avoid insulation where possible. Appropriate coating systems shall be selected to
minimize the above problem when insulation is required.

The insulation and heat tracing requirements shall be determined with due consideration to safety
aspects as well as to process aspects. All operating modes shall be considered. Insulation and heat
tracing shall be avoided on spectacle blinds and flanges.

Insulation shall be provided as required to perform the following functions:-

 Personnel protection
 Heat Conservation

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 Cold Medium Conservation

 Noise attenuation

Design requirements and criteria for the respective insulation classes are specified in the following
sections

2.8.1 Personnel Protection

Personnel protection insulation shall be required whenever exposed surfaces reach a temperature
of 60°C or greater. Exposed surfaces are defined as those that may be within reach while operating
or maintenance personnel are undertaking normal duties.

2.8.2 Heat Conservation

The heat conservation insulation shall be used where heat losses from the piping and equipment to
the surroundings to be minimized for the following reasons:-
 Maintain a proper heat balance for optimum operation of the process and utility systems.
 Limit heat losses in heater systems to minimize required heat input and thereby reduce
equipment size and weight.
 To avoid internal condensation in gas systems (e.g. fuel gas system).
 To maintain sufficient liquid / water temperature and avoid increased liquid viscosities.

If sufficient (waste) heat is available, consideration shall be given to possibly avoid insulation.

Heat Conservation requirements shall be determined by unit process requirements and the need to
optimize energy usage. These requirements shall be indicated on the line list and on the Piping and
Instrument Diagrams. In addition, all aboveground piping to safety showers and eyewash stations
shall be thermally insulated.

2.8.3 Cold Medium Conservation

This insulation type shall be used for piping and equipment including valves and instruments which
normally operate below ambient temperature and where heat transfer from the surroundings shall
be minimized for the following reasons:-
 Maintain a proper heat balance and low temperature in the process system.
 Limit heat input to piping, and thereby reduce equipment size and weight.

2.8.4 Noise attenuation

Noise attenuation insulation may be necessary in order to comply with the requirement of the
project. Where required, enclosures or insulation shall be provided for noise control. The target
sound level shall be 85 dBA at 1 meter from equipment to area where operating personnel
available.

2.8.5 Heat Tracing

Heat tracing shall be provided to compensate heat losses and to maintain a minimum temperature.
Heat tracing to equipment and piping should be protected for below purposes

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 To avoid freezing
 To avoid fluid depositions, i.e. hydrate, wax, asphaltenes, etc.
 To avoid formation of ice crystals or hydrates in gas streams
 To protect instruments against maloperation.

Steam tracing shall be considered for tracing as Steam is available in the Refinery. Where steam is
not available or feasible, electric heat tracing shall be provided.

2.9 Corrosion Allowance

Corrosion allowance shall be in accordance with the Material Selection Diagram (MSD) and Material
Selection Report (MSR).

Internal corrosion allowances for carbon steel pipeline, piping, vessels and equipment should be
selected from the following values in accordance with ISO 21457:
 1.5 mm (low corrosivity systems, minimum corrosion allowance)
 3 mm (standard corrosion allowance if no specific corrosion calculations have been
performed)
 4.5 mm (If indicated by metal loss calculations)
 6 mm (If indicated by metal loss calculations)

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3.0 DEFINITIONS

Company

Shall mean the Client for which services are being rendered by the Contractor.

Contractor

Shall mean any person or persons, firm, partnership, corporation or combination thereof (including
its Subcontractors) employed for the performance of services by Client.

Licensor

A licensed technology holder that provides a licensed package for the use of the technology.

Subcontractor

Shall mean any company providing services, materials or equipment on behalf of Company and/or
Contractor, e.g. Surveyor. The Surveyor shall be qualified to practice land surveying under the laws
of the area in which the property is located.

Vendor

Shall mean any person, firm or company having a purchase order with the Contractor for the
performance of any item of work.

4.0 ABBREVIATIONS

Abbreviation Description
AGO Atmospheric Gas Oil
BWG Birmingham Wire Gauge
Cv Valve Coefficient
EOR End of Run
FC Fail Close
FO Fail Open
HLA High Liquid Alarm
HLL High Liquid Level
HHLL High High Liquid Level
I.D. Inside Diameter
ISO International Organisation for Standardization
K.O. Knock Out
LP Low Pressure
LPG Liquefied Petroleum Gas

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Abbreviation Description
LLL Low Liquid Level
LLLL Low Low Liquid Level
Max Maximum
Min Minimum
MOP Maximum Operating Pressure
MSD Material Selection Diagram
NPS Nominal Pipe Size
NPSH Net Positive Suction Head
NEMA National Electrical Manufacturers Association
NLL Normal Liquid Level
O.D. Outside Diameter
OP Operating Pressure
P/A Pump Around
PSV Pressure Safety Valve
RO Restriction Orifice
RTJ Ring Type Joint
TEMA Tubular Exchanger Manufacturing Association
WC Water Column

5.0 REFERENCE DOCUMENTS

Document Number Document Title

IMS-OG-GL-ENG.PRO-GDL-0005 Guidelines for Flare, Vent and Blowdown
IMS-OG-GL-ENG.PRO-PRO-0009 Relief Valve & Rupture Disc Sizing

6.0 CODES AND STANDARDS

Document Number Document Title

NA NA

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7.0 REVISION HISTORY

REVISION COMMENTS/NOTES

A1 ISSUED FOR INTERNAL REVIEW

B1 ISSUED FOR COMPLIANCE / CONSISTENCY REVIEW
00 ISSUED FOR USE

8.0 RECORDS

Records will be maintained throughout the project as indicated in this document and the MS
Records process. When the project is complete, all records will be archived as per the applicable
project instructions, MS Records process and O&G Document Management processes and
procedures.

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APPENDIX 1 – PROJECT DELIVERY APPLICABILITY

Proposals EPC Construction

Studies Project Management Commissioning
Preliminary Engineering Technical Services Site Services
FEED Procurement Ops and Maintenance
Detailed Design Construction Management

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