Polaris

Engineering
Standard
100.2
Rev.: 0
Page: 1 of 9
Date: 07/05/09

DESIGN PHILOSOPHY

TABLE OF CONTENTS PAGE

I. SCOPE 2

II. GENERAL OBJECTIVES 2

III. GENERAL DESIGN PHILOSOPHY
3

A. Process Design 3
B. Design Life 3
C. Abnormal Operation 3
D. Operation During Power Failure 3
E. Off-Test Operation 3

IV. SPARE EQUIPMENT 4

A. Pumps 4
B. Compressors 4

V. SELECTION OF PUMP AND COMPRESSOR DRIVERS 5

VI. SELECTION OF COOLING METHOD 5

VI. PROCESS DESIGN GUIDELINES 5

A. Vessels 5
B. Exchangers 7
C. Pumps 9
D. Line Sizing Criteria 9



Polaris
Engineering
Standard
100.2
Rev.: 0
Page: 2 of 9

DESIGN PHILOSOPHY

I. SCOPE

This Standard outlines the design philosophy to be followed for refinery, chemical, and
production facilities.

Where conflicts exist between this Engineering Standard and other POLARIS
Engineering Standards and/or applicable codes or regulations, the more stringent
requirement shall govern. All conflicts shall be brought to Clients attention for
resolution. Client shall be the sole arbiter of any conflicts.

II. GENERAL OBJECTIVES

It is the Client's objective that all facilities be provided at minimum cost while satisfying
requirements for operability and safety as stated herein. No design, regardless of cost, is
permitted which reduces safety of operation below the Clients or industry standards,
whichever is more stringent.

Quality of materials, equipment and workmanship are not to be sacrificed to obtain lower
investment. Rather, savings shall be obtained by elimination of unnecessary equipment,
compact layout to reduce materials, sound engineering design, and avoidance of
unjustified surplus capacity. Incremental investments above this minimum will be
approved only when they satisfy the economic criteria for the project.

It is the Clients intent to operate all process facilities continuously for a minimum of
three years without shutdown for inspection and maintenance; therefore, the design,
materials, and equipment shall be of proven reliability to provide this objective.

To assist in attaining these general objectives, the following design guidelines shall be
followed by the Contractor unless he can demonstrate to the Client a less costly and more
efficient way to accomplish these same objectives. Contractor must have the Client's
prior approval in writing before proceeding in these cases.

III. GENERAL DESIGN PHILOSOPHY

A. Process Design

In general, the process design shall provide the capacity, product quality and
yields specified by Client. No reserve for future potential capacity or flexibility is
desired unless otherwise specified.

B. Design Life

Except where more stringent requirements are specified by POLARIS or industry
standards, equipment and piping shall be designed for twenty years operating life.


Polaris
Engineering
Standard
100.2
Rev.: 0
Page: 3 of 9

Where corrosion rates are specified by Client, they shall be used to determine
corrosion allowances that are to be built into the equipment. Where corrosion
rates are not specified, corrosion rates generally accepted in the petroleum
industry shall be used, and the Contractor shall specify the corrosion rate or
corrosion allowance he has used for each limiting material on each piece of
equipment. Corrosion allowances specified in these standards shall be considered
the minimum acceptable values.

C. Abnormal Operation

Plant design, including equipment capacities and necessary piping shall provide
for start-up, shutdown, fail safe operation on power or cooling water outage, off-
test operation, and other unusual but inevitable operating conditions or upsets.

D. Operation During Power Failure

It is not intended that the processing facilities will operate during a complete
power failure. However, the facilities shall be designed and supplied with enough
steam drivers, alarms, warning devices, automatic steam cut-ins, and the like so
that in the event of a complete power failure, all processing facilities can be shut
down by a minimum operating staff in an orderly manner without damage to any
facilities or equipment.

E. Off-Test Operation

Process units shall be designed to internally recycle any off-test or slop stocks
whenever practical. If necessary, off-test pumping and control facilities shall be
provided to permit disposal of off-test and other "slop" stocks to tankage. Off-test
connections shall be centralized (preferably at the Battery limit) to form a slop
manifold where possible.

IV. SPARE EQUIPMENT

A. Pumps

In general, all pumps except those considered non-critical to process operations
by Client are to be spared.

1. Where pumping duty is handled by a single pump, the spare pumps shall
be of equivalent (100%) capacity. Where multiple pumps are required for
the design duty, the spare pump shall be equivalent in capacity to one such
pump (50%, 33%, etc.).

2. Common spares will be considered with Clients approval when the
pumping services spared by the common pump are streams of similar
characteristics.


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Engineering
Standard
100.2
Rev.: 0
Page: 4 of 9

3. Pumps in non-critical service, such as basement sump pumps and certain
chemical injection pumps are generally not spared. The Client shall verify
which services are considered non-critical.

4. In critical services the main pump shall be steam turbine driven and the
spare pumps shall have motor drivers. The motor driver shall be provided
with an auto-start system. Critical services, such as lube oil, shall be as
defined by the Client.

B. Compressors

All process compressors shall be spared unless approved by Client. In general, all
utility compressors except those considered non-critical to process operations by
Client are to be spared. Consideration shall be given to providing the required
capacity in two or more machines for a particular service when:

1. Loss of total compressor capacity would endanger operations, poison
catalyst, and the like.

2. Processing can continue at a reduced rate without appreciable affect on
other processing facilities or without reducing the throughput of the entire
refining facility.

3. The incremental cost for the multiple units over the single machine can
reasonably be justified on an insurance basis or by continuation of
operation at a reduced rate.

V. SELECTION OF PUMP AND COMPRESSOR DRIVERS

Pumps and compressors shall generally be motor driven except where specifically stated
otherwise. However, Contractor may utilize steam turbine drivers, with Clients approval,
where required to achieve economic steam balance, and where reduced operating costs
warrant the additional investment within the criteria established by Client for the project.

VI. PROCESS DESIGN GUIDELINES

The following are selected process design guidelines that are to be used by the Contractor
as indicated. These criteria represent Clients minimum requirements, except where
stated in Project Design Specifications or Basic Engineering Design Data and are not
intended to supercede Contractors customary design practices. Other process design
criteria will be per the Contractors standard practices. Contractor will identify any
significant conflicts and bring them to Clients attention for review and approval.
Contractor shall provide Client with access to his standard practices for spot checks to
ensure conformance of the Contractor to these standards.

A. Vessels


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Engineering
Standard
100.2
Rev.: 0
Page: 5 of 9

1. Towers/Drums Design Pressure

a. Non-liquid Full Vessels

1) Operating pressure x 1.10 or + 25 psi (whichever is greater)

2) Unless otherwise specified, all vessels to be designed for
full vacuum at 300F

b. Liquid Full Vessels

Same as above but calculate as shut-in pressure 0.9. Use this for
design if higher than a.1) above. This will avoid lifting of relief
valve on major liquid full vessels when exposed to pump shut-in
conditions.

2. Towers/Drums Design Temperatures

a. Maximum Operating Temperature + 50 F Min.

b. Unless otherwise specified, 300 F @ full vacuum

c. Minimum design temperature = 300F at design pressure.

d. Unless otherwise specifed, use 650 F minimum design
temperature for Carbon Steel unless this requires a higher flange
rating.

3. Trays

a. Maximum percent flood shall be 80% based on using conventional
trays.

b. Design for turndown to 40% of design rates.

c. Trays in foaming and high pressure services are to be sized by
using appropriate system factors. Examples of typical system
factors are:

- Amine Absorber 0.80
- Amine Regenerator 0.85
- Hydrocarbon Absorber 0.75
- Gas Plant Stripper 0.85
- Sour Water Stripper 0.75

For high pressure fractionation, with vapor densities of 1.8 lb/ft
3
or
higher, use the following:

Polaris
Engineering
Standard
100.2
Rev.: 0
Page: 6 of 9


- System factor = 1.21 / d
v
0.32
, where d
v
is vapor density, lb/ft
3


d. Minimum spacing between trays shall be 24 unless approved by
Client.

4. Vessel Sizing

Horizontal Drum
Hydrocarbon residence time
(HLL-LLL)
5 minutes minimum
Low Liquid Level (LLL) Minimum 1-0 above bottom
or as required for water
settling
High Liquid Level (HLL) Maximum 1-0 below top or
as required per vapor / liquid
separation criteria

Water Boot
Water residence time (HLL-LLL) 4 minutes
Low Liquid Level (LLL) Minimum 1-0 above bottom
tangent line
High Liquid Level (HLL) Maximum 1-0 below top
tangent line

Vapor Flow Area
Droplet / particle size for separation 150 500 microns with
demister pad
300 microns maximum without
demister pad
150 microns maximum for
Compressor Suction and
Interstage Drums

Chimney Tray residence time Greater of:
a) 3 minutes on net product
plus reflux.
b) 1 minute on total
liquids(including pumparound)

Steam Generation Quality Remove 100% of all entrained
droplets 8 microns and larger.
Maximum 20 ppb Na in
product steam. Chevron type
separators external to steam
drum are required.


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Engineering
Standard
100.2
Rev.: 0
Page: 7 of 9

B. Exchangers

1. Exchanger Design Pressure

a. Pumped systems:

1) Design pressure = shut-in 0.95

2) When protected by a common relief valve with a vessel
calculate as shut-in pressure 0.9.

b. Reboilers, overhead condensers, feed exchangers, etc. Design
pressure = System PSV setting pressure drop static head
effects. In general, tower overhead condenser and receiver design
pressure = column design pressure. Reboiler design pressure =
column design pressure + the greater of tray pressure drop or 5 psi.

c. In all cases, the design pressure of the lower pressure side should
be set so that the low pressure side test pressure is equal to or
greater than the high pressure side design pressure.

2. Exchanger Design Temperatures

a. Maximum Operating Temperature + 50 F Min.

b. Unless otherwise specified, 300 F @ full vacuum

c. Minimum design temperature = 300F at design pressure.

d. Unless otherwise specifed, use 650 F minimum design
temperature for Carbon Steel unless this requires a higher flange
rating.

3. Fouling Factors

a. In the absence of specific licensor or Client supplied data, the
typical fouling resistances in TEMA shall be used as a guideline.
It is preferable to use job specific fouling resistances approved by
Client.

Unless approved by Client the following minimum fouling factors
shall be used:

1) For process streams:

a) 0.002 ft
2
- hr-F/BTU for Naphtha and lighter.


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Engineering
Standard
100.2
Rev.: 0
Page: 8 of 9

b) 0.003 ft
2
- hr-F/BTU for distillate and heavier.

2) For steam: 0.0005 ft
2
- hr-F/BTU.

3) For temperate water: 0.001 ft
2
- hr-F/BTU

4) For the air side of air coolers: 0.002 ft
2
- hr-F/BTU.

4. Design Margins

In general a minimum design margin (flows and duties) of 1.1 shall be
used for all heat exchange services. For tower overhead condensers and
pump-arounds the margin shall be 1.2.

Good engineering judgement must be used to determine if other services
warrant higher design margins, due to such factors as feedstock
variability, future catalyst improvement, etc.

C. Pumps

1. Datum for NPSHA calculations shall be bottom tangent (vertical vessels)
or bottom invert (horizontal vessels).

2. Unless otherwise specified, NPSHA reported on data sheet shall be NPSH
(calculated) 1 foot.

3. Allow for permanent suction strainer 50% plugged or 0.3 psi delta P,
whichever is greater.

4. Shut-in Pressure: Pump shut in pressure is defined as shut in head plus
maximum suction pressure (assume shut in head is equal to 1.25 times
design head if a pump curve is not available). Maximum suction pressure
is source PSV set pressure static head pressure drop effects.

5. Reflux and pump-around pumps should be designed with 20% excess flow
capability. All other pumps should be designed with 10% excess flow
capability.

D. Line Sizing Criteria

Apply 20% margin to friction factor. Use the following guidelines for pressure
drop and velocity.
Pressure
Drop
PSI / 100 ft
Velocity
Ft / Sec
Boiling liquids (at equilibrium) to pump 0.05 0.25 1 4
Sub-cooled liquids (40 F below bubble point) 0.2 1.0 1 8

Polaris
Engineering
Standard
100.2
Rev.: 0
Page: 9 of 9

Pressure
Drop
PSI / 100 ft
Velocity
Ft / Sec
to pump suction
Cooling water to pump suction 0.2 1.0 1 8
Pump discharge & liquids under pressure
(Note 1)
1.0 2.0 5 10
Cooling water at pump discharge 0.5 2.0 5 12
Differential pressure liquids - 15 Max.
Process Gases
Vacuum (Note 2) 0.02 0.3 300 Max.
Atmospheric +/- (Note 2) 0.1 0.5 150 Max.
Pressure (>50 psig) 0.5 1.0 100 Max.
Steam
50 psig headers & laterals 0.1 0.25 150 Max.
300 / 600 psig - headers 0.5 1.5 250 Max.
- laterals 0.5 2.5 250 Max.
- Vacuum (Note 2) Based on
available
delta P
300 Max.
Two Phase Flow (Notes 3 & 4) 4 Max. 100/SQRT (mix
density) Max.
Lean Amine - 5 Max.
Rich Amine - < 5 Max.
Sour Water - 5 Max.



Notes:
(1) For offsite rundown lines, keep pressure drop around 0.5 1.0 psi/100ft.
(2) For critical services such as turbine exhaust and compressor suction size
line such that available delta P/calculated delta P 1.20.
(3) For thermosyphon reboilers available/calculated pressure drop should be
2/1 when using average mixed phase density.
(4) For two phase systems with straight vertical runs in excess of 5 diameters,
check for slug flow.