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Process Design Manual Lurgi PDF
Process Design Manual Lurgi PDF
Process Design Manual Lurgi PDF
FOR
Table of Contents
Section
2.0 Utility Battery Limit and Utility Header & Block Valves
Anoop Sharma,
Approval: Name, Date, Signature
Copying of this document, and giving it to others and the use or communication
of the contents thereof, are forbidden without express authority by Lurgi.
Foreword
We are pleased to note that Process Engineering Department is releasing the Process Engineering Design
Basis for use by its engineers.
In the past, it was seen that the engineers had to resort to repetitive use of uncompiled information required by
them in their day to day work. The need was therefore felt to compile all the design guidelines/data in one place.
The exercise carried out by the process engineers was therefore a fruitful one in the generation of this manual.
We are sure the manual will serve as a useful tool for the process engineers in their day to day work.
Pressure drop and velocity criteria for the sizing of lines are outlined below. For revamped units higher
line velocities may be considered for existing lines.
The following non-standard line sizes will not be used unless approved by customer.
, 2 , 3 , 5, 7, 9.
Design margins for two phase flow pressure drop calculations normally are 50% of the pressure drop
calculated at normal flow to allow for inherent inaccuracy in the calculation methodology, manufacturing
tolerances, deterioration of the new pipe with scale, etc.
It is important not to oversize pipe with vertical upward two-phase flow. The flow regime shall be
calculated for design, normal, and turndown. Every effort shall be made to avoid slug flow regime.
These margins are based on experience and range from 0% to 20% plus on the pressure drop at normal
flow, depending on the configuration of the system being designed. For most systems, 20 % pressure
drop margin is applied. However for very low pressure systems, margins are individually assessed, for
example in a tank to vent pipework.
Pipe fitting, contractions and enlargements are taken into account by utilising equivalent lengths as per
normal engineering practices.
Liquids
General
Less than 1.03 bara 0.1 to 0.06
Upto 6.9 bara 250 75 0.06 to 0.13
Upto 69 bara 200 60 0.13 to 0.5
Over 69 bara 150 45 0.2% of
100 30 Pressure
Compressor Suction
- Reciprocating 0.1
- Centrifugal 20 to 40 6 to 12 0.1
40 to 80 12 to 25
Steam General 0.02 to 0.6**
50 d * 15 d *
High Velocity Flow (pressure let down)
0.9 Mach 0.9 Mach
* d is in inches
** Depends if short or long line and steam pressure level
A margin of at least 0.9 m between calculated NPSH and available NPSH has to be applied.
For positive displacement pumps, effect of acceleration head on NPSH will be taken into account.
1.10 Differential Head Calculations
Besides discharge piping loss, other losses taken into account are:
BFW pumps will meet the requirements of ASME code section 1; i.e. be capable of supplying water to
boiler at a pressure of 3% higher than the highest setting of any safety valve on the boiler.
a. Process Vessels
Process vessels (tower and drums) shall have vents, drains and steam-out or purge connections as
shown below:
Provide 1 NB x 300 # (min.) flanged vents and drains at high and low points on Heat Exchangers. All
vents and drains are to be valved and blanked off.
Exchangers in total condensing service require a 2 vent connection at the opposite end of the shell inlet.
Sizes of Multi purpose connections and pressure gauge connections on exchanger nozzle shall be 1 NB
x 300 # (min.) for below 12 nozzles and 2 NB x 300 # (min) for 12 and over nozzles.
1.13 Piping
4 and below
6 to 10 1
12 and over 1 1
On Air Coolers one 2 vent shall be placed at the highest point on the inlet header and one 2 drain at the
lowest point in the outlet header. The exact locations of these vents and drains are dependent on the
actual cooler design. Connections are to be valved and blanked off.
For non-volatile services, casing vents and pumps drains shall be piped into a sewer or closed drain
system.
For volatile services, casing vents and drains are to be piped to the relief header and sewers.
1. Valved and blanked off vent and drain connection shall be furnished on all equipment that is not
self-venting or self-draining. Connection shall be located on equipment, if practical, but may be
located on connected piping when there are no valves or blocks between the vent or drain
connections and the equipment.
2. Hydrostatic vents and drains for piping are to be provided and will not be shown on P&ID.
3. When soda ash neutralisation is required in shell and tube exchangers, standardise on 2 flange
connection.
4. At relief valves, a valve blanked off bleed shall be shown upstream of safety valve.
5. Vents from vessels that may chill and freeze during depressurising shall have double block valves
separated by at least 900 mm.
6. Steam out connections shall be located at minimum distance above the bottom head seam of
vertical vessels and the side or head of horizontal drums.
7. Steam-out connections shall be located at minimum distance above the bottom head seam of
vertical vessels and the side or head of horizontal drums.
8. Blanked off vents shall be located on the top head of towers and vertical vessels. They shall be
located on the top of horizontal drums at the same end as the drain and the end opposite from the
steam out or purge connection.
9. A vessel drain shall be located in the bottom outlet line when the outlet line is located where it can
be used to drain the vessel. Consider adding downstream orifice for vessel drains under pressure
to limit drain velocity.
10. Minimum size vents for vessels having only one personnel access way shall be 4 for horizontal
vessels and 2 for vertical vessels.
11. Minimum manhole size shall be 20 internal diameter.
12. Large size manholes will be specified if required to accommodate internals. For underground
vessels the minimum manhole size is 30 internal diameter.
13. In trayed columns, manholes will be provided above top tray, below the bottom tray, at the feed
tray, at any other tray as identified on process data sheets. Maximum spacing of manholes does
not exceed 10 m. The minimum spacing of trays between manholes shall be 760 mm.
14. In horizontal vessels, equal or longer than 6 m, if an internal baffle is installed, two manholes will
be required, one manhole in every compartment.
2.0 Unit Battery Limit and Utility Header & Block Valve
2.1 General
For new units and / or new storage, two block valves, blind and bleed or vent will be provided at
battery limits. When a second valve is located within the process unit, only one block valve is required.
For steam, fuel gas, steam condensate, boiler feed water & hydrogen, provide double block
valves, blind & bleed. For HP steam, also provide a 1 warm-up bypass.
For instrument/plant air, service water, nitrogen, cooling water etc., provide a single valve, blind
and bleed.
Main Process Pumps viz. Feed Pumps, Product pumps, reflux pumps and transfer pumps
Reciprocating Compressors
All Control Valves shall be provided with manual bypass globe valve unless provided with
handwheel
Filters where duplex is specified or where additional Filter is required owing to process reasons.
Equipment duty margins (between normal and design duties) are specified on the process data sheet.
In case of new equipment, duty margins are allowed as follows as minimum requirement.
A nominal over surface, based on either 10% on flow and / or duty will be used depending on if the
services is critical or non critical, in consultation with the Customer.
Notes:
For fuel fired heaters a maximum of 25% excess air is allowed.
For gas fired furnaces the excess air is 15%.
5.4 Pumps
Centrifugal Pumps : For small process pumps and reflux pumps use 20% margin on
normal flow. For large pumps, use 10% of normal flow.
Reciprocating Pumps : Use 10% of normal flow for both small and large pumps.
5.5 Compressor
For both centrifugal and reciprocating compressors, use 10% margin of normal flow.
For air blower use 10% margin on normal flow.
API 520
API 521
API 526
API 527
API 2000
The size of relief valves are based on either over-pressure condition, fire exposure or vacuum situation
for a particular system.
Blocked Discharge
Inadvertent Valve Opening
Utility Failure
Cooling Water Failure
Electrical / Mechanical Failure
Loss of Air Cooler Fans
Loss of Heat in Fractionation
Loss of Instrument Air or Electric Power
Instrument Failure or Blow-by
Reflux Failure
Abnormal Heat Input From Reboilers
Heat Exchanger Tube Failure
Trapped Liquid Expansion
Balanced bellow will be used for the cases where the built-up backpressure and the variable
superimposed backpressure exceeds 10%, but is below 50% of the set pressure.
Pilot operated relief valves may be used for systems when maximum set point accuracy is required. They
will be installed in equipment, which operate very close to set pressure. All above valves are also limited
by process considerations (i.e. H2S service etc.) and material.
Notes:
1. Valve selection will be based on maximum operating temperature and relief valve set pressure.
2. Where H2S is present, process data sheet will contain a note to indicate its presence.
3. Safety valves on column circuits are preferred to be located at the highest point in the overhead
vapors lines. Alternatively, these safety valves can be located as per below provided that the
pressure drop in the inlet line is within 3% of set pressure.
4. PSV discharge to be free draining to flare header, and join at 45o angle for 2 and larger size and
90o and free draining towards flare header for 1 and higher size.
7. Relief valves, which are susceptible to plugging, shall be steam traced and have a rupture disc
installed under them.
9. For atmospheric relief, the open end of discharge will be located 30m from any source of ignition.
Discharge is usually 3m higher than any equipment or manholes (Ladder, platform etc.) within 15m
radius
NO
POCKETS
FREE DRAINING
COLUMN CONDENSER
REFLUX DRUM
To reduce heat loss, piping, vessels, tanks and the equipment will be insulated where operating
temperature exceeds 70oC.
Table - 1
Insulation Thickness for Personal Protection
Insulation thickness in mm
Surface temperature of insulation less than 60C
Table - 2
Insulation Thickness for Heat Conservation
Insulation thickness in mm
Heat Loss = 150 Kcal/hr-m2 (max)
Notes:
1. Applicability for thermal insulation Temp. range 60 to 550 C For Pipes, Ductwork and
Equipment. NOT applicable for Embedded/Buried lines, buildings and structures.
2. For operating temperatures above 550C, decide material and thickness on case to case basis.
Table - 3
Insulation Thickness for Cold Insulation
Tracing
In piping at all vessels and tanks nozzles, where the nozzle is below liquid level of the vessels and
tanks.
In exchanger inlet and outlet, only if exchanger requires frequent inspection or cleaning.
In suction and discharge piping of pumps, turbines and compressors.
At equipment in auxiliary piping for gland oil, flushing oil, cooling water and for removal of
equipment.
At equipment in steam piping for steam driven equipment.
At fuel oil and fuel gas piping to furnaces or fired heaters. Valve shall be located 15m from the
equipment and accessible for rapid operation in emergency.
For drains to closed drain header. Install a check valve, one pair of flanges and a bleed valve
upstream of block valve. (Note: Flanges and bleed to be provided between check and block
valves.)
In product lines to slop header. Install a check valve and block valves.
For gas stream <100 barg pressure or liquid system of <60 barg pressure. If the operations will be
more frequent than twice per annum, or the system contains gases or liquids, which are potentially
toxic, then a double block and the bleed system will be used.
In lines to flare header
In Process Units
In Off-Sites
Utility stations will be provided near pump stations and chemical injection systems. (Direct
connections from utility header to process vessels must be avoided to stop process fluid entering
into utility system.
On all spared pumps, turbines and compressors on the equipment side of the block valve, where
applicable.
At unit limits either between double blocks or on unit side. (refer Section 2.0).
At equipment, which can be physically entered, provision for temporary blinds.
For vents and drains- provision for temporary blinds.
4 nozzle, 1200mm diameter by 610mm deep-water draw-off sump, internal pipe terminating 100mm
above bottom of sump and drain valve.
Water draw-off nozzles shall be located near shell manholes to facilitate cleaning of sumps.
Design Pressure
The design pressure for pressure vessels shall be as per the following criteria:
a. For operating pressures upto 70 kg/cm2g, the highest of the following to be considered :
c. For vessels operating under vacuum, design pressure to be 1.0 kg/cm2g and full vacuum.
Notes:
1. For equipment connected to flare (e.g, flare knockout drum), design pressure of equipment to be
same as flare design pressure.
2. Equipment in circuits that can be evacuated by an ejector and suction drum on reciprocating
compressor will be designed for full vacuum conditions in addition to operating conditions. Strippers
using steam will be designed to full vacuum conditions.
3. Mal-operation during the steam out of vessels is not to be considered.
4. The vessels open to atmosphere shall be designed for full of water condition.
5. Design pressure mentioned above does not include the liquid head.
Design Temperature
Note: For exchangers, pumps, compressors, filters, etc., use as above pressure vessel design
temperature
Equipment in a pump discharge circuit with a down stream block valve shall have a design pressure
which should be the higher of the two :
- suction vessel operating pressure + normal liquid static head + pump differential shut-off
pressure
- suction vessel design pressure + maximum liquid static head + pump differential pressure (at normal
flow)
For estimates of pump shut off head on motor driven centrifugal pumps at normal operating suction
pressure, use the suction pressure plus 1.25 times the rated differential pressure of pump. The suction
pressure shall be the vessel normal operating pressure plus the normal liquid static head.
For constant speed turbine driven pumps, use the suction pressure 1.35 times rated differential pump
pressure. For variable speed turbine pumps, uses the suction pressure plus 1.5 times rated differential
pump pressure.
For a full liquid system at the discharge of a positive displacement pump, the mechanical design pressure
shall be higher of these two:
The minimum design pressure and design temperature requirements of tanks shall be as below:
Design Pressure
Tank design pressure does not include liquid head. Design pressure is for the top of the tank. Mal-
operation during steam out is not to be considered. A vacuum breaker shall be provided.
Blanketed storage tanks shall have a blanketing pressure of 150 mmwc unless specified by client.
Design Temperature
The minimum design temperature shall be the lowest temperature expected in service.
For equipment in a tower overhead system with a relief valve, the design pressure shall be arrived as
follows:
a) In front of a train of equipment, design pressure to be compatible with the relief valve set pressure
plus liquid static head.
b) In rear of a train of equipment, design pressure to reflect relief valve set pressure, liquid static
together with line and equipment pressure losses, including fouled equipment.
For centrifugal or axial compressor, the design pressure of upstream equipment should be set at a safe
margin above the settle-out pressure. The safe margin is normally at least 10%.
For reciprocating compressors, each stage is fitted with safety valve at a margin above the normal
discharge pressure by the vendor. The piping and equipment downstream will be set at blocked-in
condition. The upstream equipment will be set at in the usual way, above the normal operating pressure
or the settle out pressure and protected by relief valve.
Design pressure for the piping will normally be at least equal to theoretical maximum expected operating
pressure and similar to the connected equipment.
Design temperature for the piping will take into consideration flowing conditions, shut conditions and solar
radiation and will be similar to the connected equipment.
For relief valve inlet pipe, design temperature and pressure will be same that of the connecting
equipment. For discharge pipe, design temperature must be determined separately.
For shell and tube heat exchangers the low-pressure side shall be specified for a mechanical design
pressure at least equal to 2/3rd of high-pressure side mechanical design pressure. If this is not possible, a
relief valve of adequate size must protect the low-pressure side. 2/3rd rule shall necessarily be adhered to
when:
LP fluid is on tube side
Relief discharge cannot be connected to flare header owing to nature of fluid
Relief discharge is two phase and cannot be connected conveniently to a low-pressure destination
with free-draining piping.
Liquid relief cannot be connected to CBD system
When the 2/3rd criteria calls for an increase by less than a factor of 1.5 of the mechanical design
pressure of the LP side as would be calculated from normal estimation procedures.
The surge time shall not be confused with residence time as surge time is hold up time between two level,
usually HLL and LLL, while residence time is hold up time from NLL to empty vessel.
The guidelines for Surge time is given below:
Level transmitters and level gauges shall cover the cut-off point (low-low / high-high) also
* The operating and design conditions are typical and tentative and shall not be used for design purposes.
For actual utility conditions please refer project design basis of the specified project.
All process units should conform to a work area limit of 90 dBA. The maximum eight-hour exposure level
for personnel exposure shall not exceed a continuous sound pressure level of 87dBA. This limit does
neither apply to locations where excessive noise exposure is infrequent, or to non-recurring operating
conditions such as venting.
At no time shall personnel be exposed to sound- levels in excess of 115 dBA. Hearing protection does not
alter this requirement.
The following limits shall apply to all plant areas and buildings.
Executive office, conference rooms 35 dBA
Semi-private offices, small conference rooms 45 dBA
General offices, laboratories 50 dBA
Control rooms 55 dBA
Workshop offices 65 dBA
Personnel shelters 70 dBA
Workshops, machine rooms 75 dBA
Operating areas within 15m of permanent operator's station 85 dBA
or maintenance station
Noise reduction
Plant fence line noise levels shall not exceed the following:
Leq 72dBA
LIO 75dBA
Where Leq is the equivalent continuous equal energy level. LIO is the 10% excess sound level.
During the detailed engineering phase of the project noise shall be further controlled by placing limitations
on the suppliers of new equipment and for the refurbishment of existing equipment where applicable.
Meteorological Conditions
The pertinent data shall be referred from Project Design Basis, to be provided by the client.
All steam users (Heat Exchangers, vessels, condensate pots etc.) where condensate is flashed to
atmospheric pressure i.e. downstream is not connected to IBR system are not under IBR and IBR
specification is done at last isolation valve upstream of equipment.
All steam users where downstream piping is connected to IBR i.e. condensate is flashed to
generate IBR steam are covered under IBR.
Deaerator, BFW pumps are not under IBR and IBR starts from BFW pump discharge.